02-03 Honda Civic Si Service Manual

Transcription

INTRODUCTION
How to Use This Manual This manualis dividedinto 23 sections.The first pageof each
seclionis markedwith a blacktab that linesup with its
corresponding
thumb indextab on this pageand the backcover.
You can quicklyfind the first pageof eachsectionwithout
lookingthrougha full tableof contents.The symbolsprintedat
the top cornerof each pagecan also be used as a quick
re{erencesystem.
S p e c i fi c a ti o n s
1)ll:{l+'
M a i n te n a n c e
Eachsectionincludes:
1. A tableof contents,or an explodedview index showingl
. Partsdisassemblysequence.
. Bolttorquesand threadsizes.
. Pagereferencesto descriptionsin text.
proceduresand tools.
2. Disassembly/assembly
3 . Inspefiron.
g.
4. Testing/troubleshootin
5. Repair.
6. Adjustments.
Safety
Your safety,and the satetyof others,is very important.To help
you makeinformeddecisions,we have providedsafety
messages,and othersafetyinformationthroughoutthis manual.
Of course,it is not practicalor possibleto warn you aboutall the
hazardsassociated
with servicingthis vehicle.You must use
your own good judgment.
Emissions
You will find impoftantsafetyinformationin a varietyof forms
including:
. SatetyLabels- on the vehicle.
. Satetv Messages preceded by a salety alert symbol A and
one of threesignalwords, DANGEF,WARNING,or CAUTION.
Thesesignalwords mean:
tmEnEErily;,:H,ll i":5*i5"?;rsERIousLYHuBrir
HURT
ir
E$EEEE ys,:
f#,ff ,:hl:3,:JjERrousLY
tlGtltT]llilll
YoucAN b€ HUBTif vou don'tfollow
. lnstructions
- howto service
thisvehiclecorrectlv
andsafelv.
All informationcontainedin this manualis basedon the latest
productinformationavailableat the time of printing.We reserve
the right to makechangesat any time without notice.No part of
this Oublication
maVbe reDrodLrced,
or storedin a retrieval
system,or transmitted,in any form by any means,electronic,
photocopying,recording,or otherwise,without the
mechanical,
priorwritten permissiono{ the publisher.This includestext,
figures,and tablesAs vou readthis manual,vou will tind informationthat is
precededby a @
symbol.The purposeof this messageis
to help preventdamageto your vehicle,other property,or the
environment,
*Body
z-tl!
^ t
FirstEdition8/2002 1,168pages
HONDAMOTORCO..LTD.
All RightsReserved
ServicePublicationOffice
Specifications
applyto U.S.A.and Canada
As seclion3 with *inclode SRS comoonentsi
special precautionsare required when servicing.
*Restraints
l
GeneralInformation
Ghassisand PaintCodes
- 2 0 0 2M o d e l
. . . . . . . . . . . . . 1. .-.2.
Chassisand PaintCodes
- 2 0 0 3M o d e l
. . . . . . . . . . . . .1. .-.3.
ldentification
NumberLocations ........1-4
Warning/Caution
LabelLocations......1-5
)
Under-hoodEmission
ControlLabel ...........
.... 1-7
L i f ta n dS u p p o r P
t o i n t s. . . . . . . . . , . . . . , . . .1. .-.8. , .
Towing
......1-9
PaftsMarkingLocations......................
1-10
GeneralInformation
Model
Chassisand PaintCodes- 2OO2
VehicleldentfficationNumber
S H H E P 33 5 ' 2
U 300001
[[tttrtF
c d e f g h
a. Manufacturer, Make and Type of Vehicle
S H H ; H O N D A O F T H EU . K .M F G . ,L T D .U . K .
H O N D AP a s s e n g evre h i c l e
b. Line, Body and EngineType
EP3: CIVIC/K20A3
c. Body Type and Transmission Type
Manual
3: 2-door HatchbacUs-speed
d. VehicleGrade lSeries)
5:Si {U.S.}
5 ; S i R( C a n a d a )
6: Si with side airbagsystem (U,S.)
6: SiR with side airbagsystem (Canada)
e. CheckDigit
l. ModelYear
2i 2002
g. Factory Code
U : H o n d ao f U . K .M a n u f a c t u r i nign S w i n d o n ,
En gl a n d
h. Serial Number
U . S , :3 0 0 0 0 1
1-
EngineNumber
K2OA3 1700001
a
a. EngineType
K20A3: 2.0 0 DOHCVTECSequentialMultiport
Fuel-injectedengine
b. Serial Number
Transmission
Number
NBH3
1000001
I
a
TransmissionType
N R H 3 ; s - s D e eM
danual
0
t
PaintCode
Code
B-92P
NH-578
NH-623M
R-81
Y-62P
Color
Niqhthawk
BlackPearl
TaffetaWhite
Satin Silver lvletallic
M i l a n oR e d
E u r oY e l i o wP e a r l
u.s.
Canada
V€hicle ldentif ication Numbo.
and Federal Motor Vehicle
Safety Standard Certification/
Color Label.
I
1-2
Chassisand PaintCodes- 2003Model
VehicleldentificationNumber
S H H E P 33 5 * 3
U 400001
[--t-rlF
c d e fg h
Manufacturer, Make and Type of Vehicle
S H H : H O N D A O F T H EU . K .M F G . ,L T D .U . K .
HONDAPassengervehicle
Line. Body and EngineType
EP3: CIVIC/K20A3
G . Body Type and Transmission Type
Manual
3: 2-door HatchbacldS-speed
d . Vehicle Grade (Series)
5:Si (U.S.)
5 : S i R( C a n a d a )
6: Si with side airbagsystem (U.S.)
6: SiRwith side airbagsystem (Canada)
Check Digir
f. Model Year
3: 2003
Factory Code
U: Hondaof U.K. Manufacturingin Swindon,
England
SerialNumber
U.S.:400001
:700001
EngineNumber
K2OA3 2700001
I
a
a. EngineType
K20A3: 2.0 0 DOHCVTECSequentialMultiport
Fuel-injectedengine
b. SerialNumber
Transmission
Number
NRH3 - 2000001
I
a
TransmissionType
N R H 3 : 5 - s p e eM
d anual
SerialNumber
PaintCode
Code
B-92P
B-520P
NH-578
NH-623M
R-81
Y-62P
Color
Niohthawk
BlackPearl
V i v i d B l u eP e a r l
Taffeta White
Satin Silver N4etallic
M i l a n oR e d
EuroYellow Pearl
U , S . Canada
VehicleldentificationNumber
and FederalMotor Vehicle
Saletv Standard Certif ication/
Color Label.
)_.
1-3
GeneralInformation
ldentificationNumber Locations
Vehicle ldentif ication
Number {vlN}
(
Vehicle ldentificalion
Numbe.lvlN)
0
I
EngineNumber
t)
1-4
, I
O
warning/cautionLabelLocations
NOTE:FRONTPASSENGER
AIRBAG
WARNING
TAG
(CHILD
SEAT)is installedon the glovebox on the U.S.
mooet.
Passenger's
Compartment:
SRSINFORMATION
U.Sm
. odel
Steering Wheel:
DRIVERMODULE
DANGER
CABLEREEL
CAUTION
SRS WARNING
INFORMATION
FRONTPASSENGER
MODULE DANGER
MONITOR
NOTICE
!
,/
FRONT
SEATBELT
TENSIONER
CAUTION
SIDEMODULE
DANGER
SIDEAIRBAG CAUTION
Located on driver's
ano passen9ers
doorjamb(not shown)
..r'
(cont'd)
1-5
GeneralInformation
Warning/CautionLabelLocations(cont'dl
SRSWARNING
LABEL
SERVICEINFORMATIONLABEL
(Undor-hood Emission Control
Informationlab€l)and ENGINE
COOLANTINFORMATION
TIREINFORMATION
RADIATOR
CAPCAUTION
BATTERY
CAUTION
c
t
1-6
Under-hoodEmissionControlLabel
EmissionGroupldentification
Families:
Engineand Evaporative
Example:2002model
EngineFamily:
2 HNX V O2.O VBP
rr-tt--[
t
t
l
a b
. P AT I E R2 B I N5
T H I SV E H I C LCEO N F O R MTSO U . S E
APPLICABLE
TO 2002
LEV
REGULATIONS
AND NLEV
CARSAND
MODELYEARNEWPASSENGER
TO 2OO2
APPLICABLE
REGULATIONS
CALIFORNIA
CARS.
MODELYEARNEWLEVIi LEVPASSENGER
c.
d.
e.
Example:2003model
c d
e
ModelYear
2:2002
3: 2003
ManulacturerSubcode
H N X :H O N D A
FamilyType
V: LDV
Displacement
SequenceCharacters
V B P2: 0 0 2
X K C 2: 0 0 3
Evaporative Family:
rH/
@
THISVEHICLECONFORMSTO U.S. EPATIER2 BIN 5
TO 2O03
APPLICABLE
AND NLEVLEVREGULATIONS
CARSAND
MODELYEARNEWPASSENGER
TO2OO3
APPLICABLE
REGULATIONS
CALIFORNIA
CARS,
MODELYEARNEWLEVII LEVPASSENGER
2 HNX R OO99 AAH
t[-l=[
a b
c d
Model Year
2t 2002
3: 2003
Manufacturer Subcode
H N X :H O N D A
c. Family Type
R: EVAP/ORVR
d . Canister Work Capacity
e . Sequence Charactets
AAH: 2002
AAA: 2003
1-7
GeneralInformation
Lift and Support Points
NOTE:If you are going to remove heavycomponents
such as suspensionor the fuel tank from the rear of the
vehicle,first supportthe front ofthe vehiclewith tall
safetystands.When substantialweightis removed
from the rear of the vehicle,the centerof gravity can
changeand causethe vehicleto tip forward on the hoist.
FrameHoist
1. Positionthe hoist lift blocks(A),or safetystands,
under the vehicle'sfront support points (B)and rear
support points (C).
FloorJack
1. Set the parkingbrake.
2. Blockthe wheels that are not being lifted.
3. When liftingthe rear of the vehicle.put the
gearshiftIever in reverse.
4. Positionthe floor jack underthe front jacking
bracket(A) or rearjackingbracket(B),centerthe
jacking bracketin the jack lift ptatform(C),and jack
up the vehiclehigh enoughto fit the safetystands
u n d e ri t .
0
2. Raisethe hoist a few inches,and rock the vehicle
gentlyto be sure it is firmly supported.
3. Raisethe hoistto full height,and inspectthe lift
pointsfor solid contactwith the lift blocks.
Safety Stands
c
Positionthe safetystandsunderthe support points
and adjustthem so the vehiclewill tevet.
Lower the vehicleonto the stands.
To supportthe vehicleon safetystands.use the same
suppon points (B and C) as for a frame hoist,Always
use satetystandswhen working on or under any
vehiclethat is supportedonly by a jack.
J
1- 8
t
Towing
lf the vehicleneedsto be towed, call a professional
towing service.Nevertow the vehiclebehind another
vehiclewith just a rope or chain.lt is very dangerous.
EmergencyTowing
T h e r ea r et h r e ep o p u l a rm e t h o d so f t o w i n g a v e h i c l e .
Flat-bedEquipment The operatorloadsthe vehicle
on the backof a truck.This is the bestway of
transportingthe vehicle.
To accommodateflat-bedequipment.the vehicleis
equippedwith towing hooks(A)and tie down hooks{B).
The towing hook can be usedwith a winch to pull the
vehicleonto the truck, and the tie down hooks slotscan
be used to securethe vehicleto truck.
Wheel Lift Equipment The tow truck usestwo
pivoting arms that go underthe tires (front or rear)and
lifts them off the ground.The other two wheels remain
on the ground.This is an acceptableway of towing the
vehicle.
Sling-typeEquipment The tow truck uses metal
c a b l e sw i t h h o o k so n t h e e n d s .T h e s eh o o k sg o a r o u n d
parts of the frame or suspensionand the cableslift that
e n d o f t h e v e h i c l eo f f t h e g r o u n d .T h e v e h i c l e ' s
suspensioa
n n d b o d y c a n b e s e r i o u s l yd a m a g e di f t h i s
method of towing is attemPted.
lf the vehiclecannot be transportedby flat-bed,it
should be towed with the front wheels off the ground lf
due to damage,the vehiclemust be towed with the
front wheels on the ground, do the following:
. Releasethe parkingbrake.
. s h i f t t h e t r a n s m i s s i o inn N e u t r a l .
It is bestto tow the vehicleno farther than 50 miles (80
km), and keepthe speed below 35 mph (55 km/h).
. l m p r o p e rt o w i n g p r e p a r a t i ow
n i l l d a m a g et h e
transmission.Follow the above procedureexactly.lf
you cannot shift the transmission,the vehicle must
be transDortedon a flat-bed.
. Trying to lift or tow the vehicle by the bumperswill
, h e b u m p e r sa r e n o t
c a u s es e r i o u sd a m a g e T
designedto supportthe vehicle'sweight.
1-9
GeneralInformation
PartsMarking
To deter vehicletheft, certainmajor componentsare markedwith the vehicleidentificationnumber (VlN).Original
partshave self-adhesivelabels.Replacementbody parts have genericself-adhesivelabels.The originalengrneor
transmissionVIN plate is transferredlo a replacementengine or transmissionand attachedwith break-offbolts.
NOTE:Be careful not to damagethe parts marking labelsduring body repair.Maskthe labelsbefore repairingthe part.
r a
1-10
ra
Specifications
L
Standardsand ServiceLimits
Enqine
ne Electrical
I
Item
Measurement
lgnitioncoil
Rated voltage
Sparkplug
Type
Oualification
F i r i n go r d e r
Gap
l g n i t i o nt i m i n g
Alternator
A t i d l e ( c h e c kr h e
Output
Coillrotor)resistance
5|lp flng u.u.
Starter
Brushlength
Brushspringtension
Output
Commutator
micadepth
Commutator
tunout
Commutator
O.D.
Brushlength
Standard or New
12V
1 3-4 2
N G K t: Z F B 6 K 1 1
DENSO:
SKJ20DR-M11
1 . 0 1 . 1 m m ( 0 . 0 3 90 . 0 4 3
in.)
in neutral:8t2' ETDCat 650150rpm
Service Limit
(
1 . 3 m m ( O . OiSn 1. )
At 13.5V and
80A
normalengine
temperature
At 68.F(20'C)
2.2 3.0 A
14.4mm {0_57
in.)
14.0mm (0.55in.)
10.5mm (0.41in.l
1.5mm {0.06in.)
2.9 3.5N (0.30 0.36kgf,0.7-0.8tbs)
0.50 0.80mm (0.020-0.031
in.)
0.20mm 1O.OO8
in.)
o:BlalqryL4i) max
o.o5mm(0.002
in.)
2 8 . 0m m ( 1 . 1 0
in.)
14.0 14.5mm {0.55 0.57in.)
2 7 . 0m m ( 1 . 0 6
in.)
9.0mm {0.35in.)
Enqtne
Item
Measurement
Compression Pressurecheckat 250rpm with wide
openthroftle. (SeeDesignSpecsfor
rato,
Oualification
Minimum
Maximum
vanatton
Standard or New
Service Limit
930kPa(9.5kgflcmr,135psi)
200kPa{2.0kgf/cm',28psi)
e_
.l
2-2
a
nder Head
Item
Head
Camshaft
Measur6ment
Oualification
'103.95104.05
mm
(4.093 4.096in.)
0.05 0.20mm (0.002 0.008in.)
Endplay
No.l journal
N o . 2 , 3 ,4 , 5
journals
Totalrunout
Cam lobe height
Intake,primary
Intake,
Exhaust
(cold)
clearance
lntake
Exhaust
StemO.D-
lnlaKe
Exhaust
L
o
S t e m - t o - g L r i d cel e a r a n c e
lntake
height
stem installed
Exhaust
lntake
Exhaust
lntake
Exhaust
lntake
Exhaust
Valvesprings
Freelength
Valveguides
LD.
Intake
Exhaust
I n s t a l l e dh e i g h t
lntaKe
Exhaust
Rockerarms
Arm-to-shaftclearance
lntaKe
Exhaust
v
Service Limit
0.05mm {0.002in.)
Warpage
Height
C a m s h a f tt o h o l d e r o i l c l e a r a n c e
Standard or New
0.030 0.069mm
{0.001 0.003in.)
0.060 0.099mm
(0.002-0.004in.)
0.03mrn (0.001in.)max.
in.)
33.925mm (1.3356
in.)
2 9 . 6 3m
8 m (l.1668
in.)
34.092mm (1.3422
0.21 0.2smm 10.0080.010in.)
0.28 0.32mm (0.011 0.013in.)
5.475 5.485mm 10.21560.2159in.)
5.450 5.460mm (0.2146 0.2150in )
0.030 0.055mm (0.0012 0.0022in.|
0.055 0.080mm (0.0022 0.0031in )
1.25 1.55mm (0.049 0.061in.)
1.25 1.55mm (0.049 0.061in.)
4 0 . 8 -4 1 . 0m m ( 1 . 6 0 6 1 . 6 1 4 i n . )
in.)
5 4 . 6 5 4 . 8m m ( 2 . 1 5 02 . 1 5 7
(1.874
in.)
47.61mm
49.64mm (1.954in.)
0.4mm (0.02in.)
0 . 1 5m m { 0 . 0 0i6n . )
0.15mm (0.006in.)
0.04mm {0.002in.)
5.445mm (0.214in.)
5 . 4 2m m ( 0 . 2 1i3n . )
0.08mm (0.003in.)
0.11mm (0.004in.)
2.00mm {0.079in.)
2.00mm {0.079in.)
5.515 5.530mm
|.0.21710.21174n.1
mm
5.515 5.530
\0.2111 0.2177in.l
1 5 . 2" 1 6 . 2m m ( 0 . 5 9 80 . 6 3 8 i n . )
15.5 16.5mm (0.610 0.650in.)
5.55mm (0.219in.)
0.025 0.052mm
(0.00'100.0020in.)
0.018 0.056mm
(0.0007 0.0022in.)
0.08mm (0.003in.)
5 . 5 5m m { 0 . 2 1i9n . )
0.08mm (0.003in.)
lo
2-3
Enqine
n q t n e Block
Item
Block
Measurement
I Warpageof deck
tsorediameter
Oualification
Aori
Borll
Standardor New
0.07mm (0.003in.)max.
86.010 86.020mm
(3.3862 3.3866in.)
ServiceLimir
foro.. (ulur^^-"1
_
f
86.070mm (3.3886
in.)
86.000 86.010mm
(3.3858 3.3862in.)
86.070mm (3.3886
in.)
0 . 0 5m m ( 0 . 0 0 2I n . J
R e b o r i n gl r m i t
Piston
Pistonring
SkirtO.D.at 11mm (0.4in.)from
bottom of skirt
",";"*
lFis,.€-"'"
L-
Ringend gap
0 . 2 5m m ( 00 l i n . )
85.980 85.990mm (3.3850 3.3854in.) 85.930mm (3.383'l
in.)
F"
LetterB
€s.980 r"i33846
85.920mm (3.3827
l-il?0
in.)
0.020 0.040mm (0 0008 0.0016in.) 0.05mm {0.002in.)
Top
1.220 1.230mm (0.0481 0.0484in.) 1.25mm 10.049
rn )
Second
1 . 2 2 0 1 . 2 3 0m m ( 0 . 0 4 8 1 0 0 a 8 4 I n . ) 1.25mm 10.049
in.)
i 2.005 2.025mm (0.0789 0.0797in.) ?.09rrl9.091lt
)
i.'.f 0.13mm (0.005in )
fo.o:s o.oto.rnlo.oorao.ooza
i") 0 . 1 3m m ( 0 . 0 0i5n . )
EO3t 0 056rn. {OJ01rOOO2
Second(FEDEHAL 0.025 0.060mm (0.0010 0.0024in.) 0.13mm (0.005in )
I\4OGUL)
Top
0.20 0.35mm (0.008 0.014in.)
0.60mm (0.024in.)
btt"' "' A
Second
OiI(REKEN)
OiI(FEDERAL
I\4OG
UL)
Pistonpin
o.D.
0.40 0.55mm {0.016 0.022in.)
0.25 0.65mm (0.010 0.026in.)
0 20 0.70mm i0.008 0.028in.)
0.70mm (0.028in.)
0.75mm (0.030in.)
0.80mm 10.031
in.)
21.961 21.965mm {0.8646 0.8648in.) 2 1 . 9 5 3m m l 0 8 6 4 3 i n
0.005-*0.002
mm( 0.00020+
0.005mm (0.0002
in.)
Pin'to-piston
clearance
0.00008
in.)
Connecting
rod
Pin to-rod clearance
Small end bore diameler
L a r g e - e n db o r e d i a m e t e r ( N o r m a l )
Endplayinslalledon crankshaft
Crankshaft
Main journal diameter
No. l journal
No.2 journal
N o .4 j o u r n a l
No.5 journal
No.3 journal
0.005 0.015mm (0.0002 0.0006in.) 0 . 0 2 m m l O 0 O O 8i n I
21.970 21.976mm (0.8650 0.8652in.)
4 8 . 0m m ( 1 . 8 9
in.)
0.15 0.30mm (0.006 0.012in.)
0 . 4 0m m ( 0 . 0 1i6n . )
s4.e84 s5.008mm (2.1648=16illl
5 4 . 9 7 65 5 . 0 0 m
0 m ( 2 . 1 6 4 42 - 1 6 5 4 i n )
Rodjournal diameter
4 4 . 9 7 6 4 5 . 0 0 0m m ( 1 . 1 7 0 7 1 . 1 7 1 7i n . l
Rod/main
0.005mm 10.0002
in.)max.
0.005mm (0.0002
in.)max.
0.10 0.35mm (0.004 0.0'14
in.)
0.03mm (0.0012
in.)max.
0.017 0.041
m m ( 0 . 0 0 0 70 . 0 0 1i6n . )
Rod/mainiournalout of,round
E n dp l a y
Runout
. . - ' . : - - ' +
M a r n o e a r , n 9 - t o J o u r n ao
t t t c t e a r a n c e No. l journal
Deaflngs
c_
0.010mm (0.0004
in.)
0.010mm (0.0004
in.)
0 . 4 5m m 1 0 . 0 1i 8
n.)
0.04mm {0.0016
in.)
0.050mm (0.0020
in.)
No.2 journal
No.4 journal
No.5
No.3 journa/
Bodbearingclearance
q0rr034, -rn {O'o010
0-o01r|"tl 0.055mm (0.0022in.)
0.021 0.049mm (0.0008 0.0019in.)
0.060mm (0.0024
in.)
-
2-4
o i
nqlne
Lubrication
|tem
Measurement
Engineoil
Capacity
Oilpump
lnner-toouterrotorclearance
Pumphousingto outerrotor
clearance
axial
Pumphousing-to-rotor
clearance
Balancer
shafts,journaldiameter
Oualificalion
ServiceLimil
Standerdor New
5.30 (5.6US qt)for engineoverhaul
4.20 (4.4US qt)for oil change,includingfilter
4.00 (4.2US qt)for oil change,withoutfilter
0.20mm (0.008in.)
0.02 0.16mm {0.001 0.006in.)
in.)
0.23mm (0.009in.)
0-15 0.21mm {0.006-0.008
0.02 0.07mm (0.001 0.003in.)
No.1 journal,front
shaft
0.12mm (0.005in.)
19.938 19.950mm 10.78500.7854in.) 19.92mm (0.784in.)
23.938 23.950mm (0.9424 0.9429in.) 23.92mm (0.942in.)
in.l 32.93mm (1.296in.)
No.2 journal,frontand 32.949 32.961mm 11.29121.2911
rearshaft
in.)max.
0.005rnm (0.0002
0.070 0.135mm (0.0028 0.0053in.) 0.15mm (0.006in.)
Front
0.070 0.135mm (0.0028 0.0053in.) 0.15mm (0.006in.)
Rear
0.050 0.082mm (0.0020 0.0032in.) 0 . 1 0m m ( 0 . 0 0i4n . )
No. 1 iournal,front
No 1 journal,rearshaft
Ealancer
shafts,journaltaper
shafts,end play
Balancer
Balancershatts,shaft-to'bear;ng
clearance
shaft
N o . 1 J o u r n a l ,r e a r s h a f t
N o . 2 j o u r n a l ,f r o n t a n d
0.050 0.082mm (0.0020 0.0032in.)
0.060-0.120mm (0.0024 0.0047in.)
0.10mm (0.004in.i
0.15mm (0.006in.)
rear shafl
L
a
LD.
shaftbearings,
Balancer
20.000 20.020mm (0.1814 0.7442in.l 20.03mm (0.789in.)
No. 1 journal,front
shaft
ZI.OZO
m- tOSa+e-OSa57ir'.) 24.03mm (0.946in.)
No. 1 iournal,rearshaft Z+.OOO
in.) 33.09mm {1.303in.)
No.2 journal,frontand 33.021 33.069mm (1.3000 1.3019
rearshaft
R e l i e f v a l v e ,o i l p r e s s u r ew i t h o i l
t e m p e r a t u r ea t 1 7 6 ' F ( 8 0 " C )
At idle
7 0 k P a ( 0 . 7k q ? c m , 1 0 p s r )m i n .
At 3,000rpm
300kPa{3.1ksf/cm',44psi)min.
Standardor New
6 . 7L ( 7 . 1U S
engine,
Coolantcapacity
{includes
heater,hoses,and reservoir)
Thermostat
ServiceLimit
0.53L (0.56US
93 123kPa(0.95 1.25kqtcm , 14 18psi)
't69 176'F(76 80'C)
OPeningtemPerature
8.0mm {0.31in.)min.
TurnsOFF
v
Subtract5 15'F(3 8"C)fromactualON
a
2-5
Fueland Emissions
Item
Fuelpressure
regulator
Fueltank
Engineidle
Measulement
Oualification
Pressurewith fuel pressuregauge
connected
Capacity
ldlespeedwith headlights
and radiator Neutral
fan off
F a s ti d l e
Neutral
Standardor New
ServiceLimit
320-370kPa13.3-'3.8
kgtcm',47 52psi)
f
.
\
5 04 ( 1 3 . 2U Sg a l i
750 50 rpm
1,600150rpm
Clutch
Item
Clutchpedal
Mea3urem€nl
Heightfromthe floor
Stroke
Oualification
D i s e n g a g e m e n th e i g h t f r o m t h e f l o o r
Clutchdisc
Pressureplate
Bunouton clutchmatingsurface
Bivetheaddepth
Ihickness
Warpage
Heightof diaphragm spring fingers
Measured
with
specialtooland
feelergauge
Slandardor New
193mm (7.60in.)
1 3 0 1 4 0m m 1 5 . 1 5 . 5 i n . )
10 16mm (0.39 0.63in.)
1'15
mm (4.53
i n . )m i n .
0.05mm 10.002
in.)max.
1.65 2.25mm (0.065 0.089in.)
8.3 8.9mm (0.33 0.35in.)
0.03mm (0.001in.)max.
0.6mm (0.02in.)max.
ServiceLimit
0.15mm (0.006in.)
0.7mm {0.03in.)
6.0mm (0.24in.)
0 . 1 5m m ( 0 . 0 0i1n . )
0.8mm (0-03in.)
r a
\ < c
2-6
nualTransmissionand M/T Differential
O E
Adiust
20.75mm 10.817
in.)
3 ' 1 . 9m
3 m ( 1 . 2 5i7n . )
27.92
m m ( 1 . 0 9i9n . )
'1.5354
in.)
38.93mm (1.5334n.)
27.987 28.000mm (1.10'191.1024in.)
2 7 . 9 3m m { 1 . 1 0i0n . )
0.02mm (0.001in.)max.
in.)
44.009 44.025mm 11.73261.7333
0.06 0.16mm {0.002 0.006;n.)
23.92 23.97mm (0.94'10.944in.)
in.)
mm (1.3780 '1.3785
35.000-35.015
0.05mm (0.002in.)
44.08mm (1.735in.)
0 . 2 5m m ( 0 . 0 1i0n . )
23.80mm (0.937in.)
34.95mm (1.376in.)
39.937 39 950mm (1.5723 1.512ain.|
39.88mm (1.570in.)
D i a m e t e ro f b a l l b e a r i n gc o n t a c t a r e a
( t r a n s m i s s i o nh o u s i n g s i d e )
30.020-30.0m
3 3m ( 1 . 1 8 1 91- . 1 8 2i4n . )
29.97
m m ( 1 . 1 8i0n . )
Runout
innerrace
35 mm shim-to'bearing
0.02mm {0.001in.)max.
0.04 0.10mm (0.0016 0.0039in.)
0.05mm (0.002in.)
Adjust
in.i
52.010 52.029mm (2.0476-2.0484
0.06 0.16mm (0.002 0.006in.)
-0.904in.)
22.92 22.91$m 10.902
52.010 52.029mm (2.0476 2.0484in.)
0.06 0.16mm (0.002 0.006in.)
21.92 27.91mtn \1.099 1.101in.)
39.95 39.96mm (1.572a 1.5132in.)
in.)
46.989-47.000mm (1.8499-1.8504
in.i
23.03 23.08mm (0.907-0.909
in.l
39.95 39.96mm {1.5728'-1.5732
in.)
46.989 47.000mm (1.8499 1.8504
mm (l.104 1.106in.)
28.03 28.08
52.08mm (2.050in.)
n.)
0 . 2 5m m 1 0 . 0 1i 0
22.87mm (0.900in.)
52.08mm {2.050in.}
4n.)
0.25mm 10.010
in.)
27.87mm 11.097
39.97mm (1.574in.)
46.94mm (l.848in.)
Transmission Capacity
fluid
Endplav
Mainshaft
Diameter
of bushingsurface
D i a m e t e ro f d i s t a n c ec o l l a r
Diameter
of ballbearingcontactarea
(clutchhousingside)
Diameter
of needlebearingcontact
area
Diameter
of ballbearingcontactarea
(transmission
housingside)
Runout
Mainshaft
3rd, t.D.
4th and sth
Endplay
gears
Thickness
Countershaft Diameterof needlebearingcontact
area(clutchhousingside)
of distance
collarcontact
Diameter
alea
L
a
Countershaft
clearance
LD.
End play
Thickness
Countershaft
2ndgear
Countershaft
'lst gear
t.D.
Endplay
Thickness
LD.
o.D.
collar Length
distance
Countersha{l l . D .
o.o.
2ndgear
distance
coliar L e n g t h
v
Se.viceLimit
Standardor New
Forfluidchange:1.50 (1.6US qt)
F o ro v e r h a u1l :. 70 1 1 . 8
U Sq t )
'
l
0
.
1
7
(
0
.
0
0
4
mm
0.007in.)
0.1
20.80 20.85mm {0.819 0.821in.)
mm (1.2594 1.2598
in.)
31.984-32.000
2 7 . 9 7 72 7 s 9 0m m \ 1 . 1 0 1 -51 . 1 0 2i0n . )
M€asurement
Item
Oualification
38.984 39.000mm (1.5348
39.97mm (1.574in.)
46.94mm (1.848in.)
o
2-7
?
Manual
anuatTransmission
I ransm
and Differentialcont'
Measutemenl
Item
Nlainshaft4th
and5thgears
Oualification
LD.
o.D.
distance
collar L e n g t h
B
MBSdistance LD.
Len9th
t.D.
Reverseidler
gear
G e a r l o r e v e r s eg e a r s h a f i c l e a r a n c e
Synchroring
Bingto'gearclearance
Triplecone
Outersynchroring-tosynchrocone
clearance
Synchrocone-to-gear
clearance
Shift fork
Reverseshift
fork
Shiftarm
Outersynchroring-to-gear
cone
clearance
Fingerthickness
Forkto-synchro
sleeveclearance
Fingerthinkness
Fork-to-reverse
idlergear clearance
t.D.
S h i f t f o r k d i a m e t e ra t c o n l a c ta r e a
S h i f t a r m ' t o - s h i f t l e v e rc l e a r a n c e
Selectlever
Shiftlever
Mfi
differential
carrier
Mfi
differential
pinionqear
80 mm shim
Fingerwidth
Shaft-to-selectleverclearance
Groove{to selectlever)
Shaftto shiftarm clearance
Pinionshaftcontactareal.D.
C a r r i e r - t o - p i n i o ns h a f t c l e a r a n c e
DriveshaftcontactareaLD.
Backlash
t.D.
P i n i o ng e a r t o p i n i o n s h a f t c l e a r a n c e
80 mm shim to-bearing
outerrace
clearance
in transmission
housing
Ringpushed
againstgear
Ringpushed
againstqear
Ringpushed
againstgear
Ringpushed
againstgear
Standardor New
32.00-32.01mm (1.2598 1.2602
in.)
38.989 39.000mm (1.5350 1.5354
in.)
51.95 52.05mm (2.045 2.049in.)
24.03 24.08mm (0.946-0.947
in.)
ServiccLimit
3 2 . 0 2m m ( 1 . 2 6i1n . )
38.94mm (1.533in.)
28.00 28.01mm(1.102 1.103in.)
23.95 24.05mm (0.943 0.947in.)
20.016 20.043mm (0.7880 0.7891in.)
0.036 0.08amm (0.0014 0.0033in.)
0.70 1.49mm (0.028 0 059in )
2 8 . 0 2m m ( 1 . 1 0i3n . )
20.90mm (0.832in.)
0 . 1 6m m { 0 . 0 0i6n . )
0.4mm (0.0164n.)
0.70- '1.19
mm {0.028 0.047in.)
0.3mm (0.012in.)
0.50 1.04mm (0.020 0.041in.)
0.3mm (0.012in.)
0.95 1.68mm (0.037 0.066in.)
0.6mm (0.024in.)
7.4 7.6mm 10.29 0.30in.)
0.35 0.65mm (0.014 0.026in.i
13.4 13.7mm (0.527 0.539in.)
0.20 0.59mm (0.007 0.024in.)
13.973 '14.000
mm (0.5501 0.5512in.)
16.9 '17.0
mm (0.665 0.669in.)
0.2 0.5mm (0.008 0.020in.)
14.85 '14.95
mm (0.585 0.589in.)
0.05 0.25mm (0.002 0.010in.)
15.00 15.10mm {0.591 0.594in.)
0.013 0.07mm (0.0005 0.003in.)
18.010 18.028
mm (0.7091 0.7098in.)
0.027 0.057mm (0.0011 0.0022in.)
28.025 28.045mm (1.1033 1.1041
in.)
0.05 0.15mm {0.002 0.006in.)
1 8 . 0 4 21 8 . 0 6m
6 m ( 0 . 7 1 0 30 . 7 1 1 3 i n . )
0.059 0.095mm (0.0023 0.0037in.)
0 0.10mm (0 0.0039in.)
1.0mm (0.039in.)
1.3mm (0.051in.)
0 . 6 2m m ( 0 . 0 2i4n . )
L O
0.50mm (0.020in.)
0.1mm {0.004in.)
0.1mm (0.004in.l
0.15mm (0.006in.)
Adjust
-
2-8
o
Rotational
at outside
olavmeasured
0 10mm (0 0.39in.)
at outside
Startingloadmeasured
2 9 N ( 3 . 0k g f . 6 . 6 l b s )
A n g l e o f r a c kg u i d e s c r e w l o o s e n e d
n
Item
W h e e l a l i g n m e nCamber
t
Measurement
Caster
TotalToe
Oualitication
Front
Rear
Front
lrytt
Rear
Frontwheelturningangle
l n s i d ew h e e l
Aluminumwheelrunout
Axial
Outsidewheel
Radial
Wheelbearing
Endplay
Front
Rear
Standardor New
0'00' 45'
0'45'- 45
ServiceLimit
1"33' 11"
in.)
0-3 mm(0::0.12
lN 2 ' , mm (0.08"' ,, in.)
37'40'-2'
29'50'(Reference)
0 0.7mm (0 0.03in.)
0 - 0 . 7m m ( 0 0 . 0 3 i n . )
0 0.05mm (0 0.002in.)
0 0.05mm (0 0.002in.)
2.0mm (0.08in.)
l.5mm{0.06in.)
o
Y
a
2-9
Brakes
Item
Parkingbrake
lever
Brakepedal
Mastercylinder
Erakedisc
M€asurement
Distance
traveledwhen leverpulled
with 196N (20kgf, 44 lbs) ol force
Pedalheight(carpetremoved)
Freeplay
Piston-to-pushrod
clearance
Thickness
Standardor New
7 8 clicks
ServiceLimit
a
1 8 4m m ( 7 4 / 1 6i n . )
Parallelism
Front
Rear
Front
Rear
Frontand rear
Thickness
Front
Runout
Brakepads
Oualification
llear
0 . 4 3 . 0m m ( 00 1 6 0 ' 1 1 8
in.)
0 0.4mm (0 0.02in.)
2 1 . 0m m ( 0 . 8 3
in.)
9.0mm {0.35in.)
10.0mm (0.39in.)
9.0mm {0.35in.)
19.0m
0 m (0.75
in.)
8-0mm (0.31in.i
0.10mm (0.004in.)
0.10mm (0.004in.)
0.015mm (0.0006
in.)
1 . 6m m ( 0 . 0 6
in.)
1 . 6m m ( 0 . 0 6
in.)
Air Gonditionin
Item
Refrige.ant
Tvpe
Refrigerant
oil
Capacityof system
Type
Moasurement
Capacity
ofcomponents
Oualilication
Condenser
Evaporator
Eachline and
Standard or New
Service Limit
H F C1 3 4a ( B - 1 3a4)
500 550g 117.6 19.4oz)
S P1 O
(P/N38897-P13-A01AH
or 38899-P13-A01
)
25 m0,15/6fl ozl
45 mA111/2fl ozt
10m0 (1/3fl or)
hose
Compressor
Drivebelt
Startercoil resistance
plateclearance
Pulley-to-pressure
Compressor
At 68"F(20"C)
1 3 0 1 5 0m 0 1 41 / 3 5 f l o z )
3.05 3.350
0.35 0.6mm (0.014 0.024in.)
Autotensioner
lneedsno adjustment)
e-
q
2-10
DesignSpecifications
O
Measurement
|tem
DIMENSIONS
Overallwidth
Overallheight
Track
rront
Rear
Groundclearance
G r o s s V e h i c l eW e i g h t R a t i n g
(GVWR)
WEIGHT
(CANADA)
GrossVehicleWeightRating
ENGINE
1,660kg
{GVWR)
Tvpe
Cylinderarrangement
Boreand stroke
Displacement
ratio
Compression
Valvetrain
system
Lubrication
Oil pumpdisplacement
Waterpumpdisplacement
At 6,000engine
rpm
At 3,400engine
L
o
82 0 (87US qt)/minute
Tvpe
Normaloutput
12V
30 seconds
Nominalvoltage
Hourrating
Directionof rotation
CLUTCH
C l o c k w i s ea s v i e w e c lf r o m g e a r e n d
S i n q l e p l a t ed r y , d i a p h r a g m s p r i n g
C l u t c ht v p e
Clutchfrictionmaterialsurfacearea
Tvpe
I\,1AN
UAL
TRANSMISSIONPrimarvreduction
Gearratio
lst
2nd
3rd
4th
Finalreduction
v
Watercooled.4 strokeDOHCV-ECengin(
transverse
Inline4'cylinder,
86 x 86 mm (3.39x 3.39in.)
cuin.)
1 , 9 9 c8 m ' ( 1 2 2
9.8
Chaindrive.DOHCVTEC4 valvespercylinder
Forced,
wet sump,withtrochoidpumP
(57.4
54.30
US qo/minute
gasolinewith 86 pumpoctanenumberor higher
UNLEADED
Gearreduction
F!el required
STARTER
4 , 2 1 0m m { 1 6 5 .i8n . )
in.)
1,695mm 166.7
in.)
1,44m
0 m (56.7
m m ( 1 0 1 .i2n . )
2,570
1,470mm (57.9in.)
'1,470
mm (57.9in.i
152mm (5.98in.)
four {4)
3,660rbs
S e a t i n gc a p a c i t y
wEtGt-iT
{u.s.A.)
Specilication
Oualification
Overalllength
5th
Reverse
Type
Gearratio
1 7 4c m ' { 2 6 . 9s7q i n . )
forward,1 reverse
s-speed
Svnchronized,
D i r e c1t : 1
3.062
1.769
1.212
0.921
0.738
3.583
Sinolehelicalgear
4.164
o
2-11
DesignSpecifications
cont'
Item
Measuremeni
Type
Overallratio
Turns,lockto-lock
Steeringwheeldiameter
Type
STEERING
SUSPENSION
Shockabsorber
WHEEL
ALIGNMENT
Camber
BRAKES
AIR
I n d e p e n d e n ts r r u l w i t h s t a b i l i T e rc. o i l s p r i n g
Rear
Front
Rear
Caster
Totaltoe
Front
Typeof servicebrake
Rear
Front
Bear
Sizeoffront and reartires
Sizeo{ sparetire
Compressor
CONDITIONING
Front
Rear
Type
Numberof
cylinders
Capacity
Maximumspeed
D o u b l ew i s h b o n e
Telescopic,
hydraulic.
nitrogengas-frlled
Telescopic,
hydraulic,
nitrogengas,filled
0"00'
0.45'
1'33'
0 mm (0 in.)
I n 2 m m ( 1 / 1 6i n . )
P o w e r a s s i s t e ds e l f - a d j u s l i n gv e n t i l a t e dd i s c
Power-assisted
self-adjusting
soliddisc
Mechanical
actuating,
rearwheels
4 5c m ' ( 7 . 0s q i n . ) x 2
2 8c m ' ( 4 . 3s q i n . )x 2
Pl95/6081588V
T125r0 D1595M
Scroll
Type
Motor type
85.7m015.23
cu in.)/rev.
12,000rpm
130m0 {4 1/3floz)
SP-10(P/N38897'P13-A01AH
or38899-P13
A01)
Corrugated
fin
Corrugatedfin
Siroccofan
220 Wl12 V
Speed control
4 Speeo
L u b r i c a n tc a p a c i t y
Condenser
Evaporator
Blower
C
Specilication
Electric,
Powerassisted
rackand pinion
15.1
3 6 0m m ( 1 4 . 2
in)
Front
Bear
Front
Typeof parkingbrake
Padfriction surfacearea
TIRES
Oualification
Lubricanttype
Type
Tvpe
L
a
M a x i m u m c a p a c i t y 480m" 116.900
cu ft)/h
T e m p e r a t u r ec o n t r o l
Compressor
clutch
Tvpe
Refrigerant
Electricalpower
cons!mptronat
68"F(20.C)
Type
Capacity
Airmixtype
Dry,singleplate,poly-Vbeltdrive
42W maximumat 12V
HFC134a(R-134a)
500 550g (17.6 19.4oz)
../a
2-12
o
Item
ELECTRICAL
RATINGS
Measurement
Under-hood
fuse
Specitication
1 2 V 3 6A H / 5h o u r s
1 2V - . 1 . 1k W ,1 . 2k W
12V 95A,90A
80A, 60A, 50A, 40A, 30A, 20A, 15A, 10A, 7.5A
Under'dash
Iuse
3 04 , 2 0 a , 1 5A , 1 0A , 7 . 5A
Oualilication
Battery
Starter
Alternator
Fuses
Light bulbs
Headlight
high
beam
Headlight
low
beam
Frontturnsignal
liqhts
Front parlinq lights
Bearturn signal
lights
FronVrear
side
markerlights
Brale/taillighls
H i g h m o L r n tb r a k e
'12v.' 60w
12V 55W
12V 21W
12V 5W
1 2 V" 2 1 W
12V 5W
12V 21/5W
12V 5W
light
t
o
v
a
Backup lights
platelight
License
Ceilinglight
12V 21W
12V 5W
Cargoarea light
12V 5W
12V 5W
Spotlights
'12v'.8 w
Gauge lights
I n d i c a t o rl i g h t s
Sideturn signal
light
LED
12V 5W
2-13
Body Specifications
Unit: mm {in.)
1.555{61.6)
1,i140(56.71
2-14
I
Maintenance
Lubricantsand Fluids
MaintenanceSchedulefor Normal
Conditions
Listed by Distance/Time
MaintenanceSchedulefor Severe
Gonditions
Listedby Distance/Time
t
\.4
MaintenanceSchedule
Listedby Maintenance
ltemfor Normal
Conditions
...................
3-8
Listedby Maintenance
ltem for Severe
Conditions
...................3-9
Lubricantsand Fluids
For detailsof lubricationpoints and type of lubricantsto be applied,referto the illustratedindex and variouswork
o v e r h a u l .l n s t a l l a t i o ne.t c . )c o n t a i n e di n e a c hs e c t i o n .
ures{suchasAssem
LUBBICANT
LUBBICATION
POINTS
NO.
1
Eng ine
The oil container
Honda Motor Oil (P/N08798-9023).
must disolavthe API Cenificationseal shown below.
" AE
M a k es u r ei t s a y s" F o r G a s o l i n eE n g i n e s . S
Viscositv:See chart below.
2
3
Transmission
HondaMTF*'(P/N08798-9016)
Brakesvstem (includesABS line)
C l u t c hl i n e
Release
f o r k ( m a n u a tl r a n s m i s s i o n l
Throftlecableend (throttleIink)
Shift and selectcable ends (manual
transmission)
Throttlecable end (dashboardlower panel hole)
Brakeboosterclevis
CIutchboosterclevis
Shift lever pivot
Pedalinkage
Batteryterminals
F u e lf i l l d o o r
H o o dh i n g e sa n d h o o d l a t c h
H a t c hh i n g e s
, o D e ra n d l o w e r
D o o rh i n o e s u
Caliperpiston boot, caliperpins and boots
A i r c o n d i t i o n i n cg o m p r e s s o r
HondaDOT 3 BrakeFluid*' (P/N08798-9008)
4
5
6
7
I
9
10
11
1'
14
16
17
18
19
S u p e rH i g hT e m p U r e aG r e a s e{ P / N0 8 7 9 8 - 9 0 0 2 )
S i l i c o n eg r e a s e
grease
Multi-purpose
HondaCaliDerGrease(P/N08C30-80234lvl)
o rH
C o m p r e s s o r o iS
l : P - 1 0( P / N3 8 8 9 7 - P 1 3 - A 0 1 A
38899-P'13-A01)
a ( R - 1 3 4a )
F o rr e f r i q e r a nH
t;FC'134
Recommond6dEngineOil
fanges
E n g i n eo i l v i s c o s i l yf o r a m b e n t t e m p e r a l u r e
-30 -20
-10
0
t0
20
* 1 : Always use HondaManualTransmissionFluid (MTF).Using motor oii can causestiffershifting becauseit does
not containthe Drooeradditives.
" 2 : Always use HondaDOT 3 BrakeFluid.Using a non-Hondabrakefluid can causecorrosionand decreasethe life of
the system.
3-2
I
t
o o o o
o
o@@
a9
Y
3-3
MaintenanceSchedule
Listedby Distance/Timefor Normal Conditions
Thistwo pagel/lanitenance
Schedule
outlinesthe minimunrequiredmaintenance.
Serviceat the indicated
distance
or time,whichevercomes
if the vehiclemeetsanyof the qualifiers
in the SevereConditions
first.use the lvlaintenance
Schedule
for Severeconditions
schedule
or if the
vehicleis normallydrivenin Canada.
(cold)(seepage6-321r
Intake:
0.21-0.25mm (0.008 0.010in.)Exhaust:
0.28 0.32mm (0.011 0.013in.)
Inspectvalveclearance.
(NGK)or SKJ20DR-M11
(DENSO).
Replace
sparkplugs.UseIZFR6K'11
1 . 0 1 . 1m m
km/6 years
120,000
mi/ 192,000
fluid.UseHondaMTF(seepage13-3).
I Replace
transmission
! Do items in A,B,alqq.,
/
/ Y vcdrs
120,000
mil 192,000
Type2.
5.00 (5.3US qt).UseHondaAll SeasonAntifreeze/Coolant
Beplace
coolant(seepage106).Capacity:
tailureto do the maintenance
itemsmarkedwith an asterisk
According
to stateandlederalregulations,
{*) will not voidthe customer's
intervalto ensurelong-term
warranties,
However,Hondarecommends
thatall maintenance
services
be doneat the recommended
emissions
reliability.
3-4
I
Dothe itemsin partsA, B, C, D, andE as requiredfor mileage/time
intervallisted.
A
Replace
engineoillseepage8-5i. Capacity
withoutlilterchange:4.0S (4.2US qt, 3.5lmp qt)
Rotatetires.Followthe patternshownin the Owner'sManual Checktireinformationandcondition.
B
Replace
engineoil filterlseepage8-6). Capacity
with filterchange:4.20(4.4US qt,3.7lmp qt)
Inspect
frontandrearbrakes(seepage19 3i.
. Checkpadsand djscsfor wear(thickness),
damage,andcracks.
' Checkcalipers
tor damage,leaks,andtjghtnessot mountbolts.
Checkparkingbrakeadjustment.
ShouldbeIullyappliedwithin7 to I clicks.
Inspect
tie rod ends,steeringgearbox,and boots{seepage17 5).
. Checkrackgreaseandsteeringlinkage.
. Checkbootsfor damageand leakinggrease
. Chackfluidline{or damageand leaks.
lnspectsuspensioncomponents.
. Chockboltsfor tightness.
. Checkconditionof balliointbootslor deterioration
and damage.
Inspectdriveshaftboots.Checkbootsfor cracksand boot bandsfor tightness(seepage16-3).
proponioning
Insp€ctbrakehosesandlines{including
ABS). Checkthemastercylinder,
controlvalve,andABSmodulator{ordamage
andleakage.
Checkall fluidlevelsandconditionot tluids;checkfor leaks.lf necessary,
add MTFlseepage13'3),engioecoolant,brakefluid,and
windshield
washerfluid.
system*.Checkcatalytic
L lnspectexhaust
converterheatshield,
exhaustpipeand mufflerfordamage,leaks,
andtightness{soepage9,8).
lnspect{uellinesandconnections*.
Checkfor looseconnections,
cracksand deterioration;
retightenlooseconnoctions
and replace
damagedparts(s€epage11 146).
andadiustdrivebelt.
l InsDect
. Lookfor cracksanddamage,andinspectautotensioner(needsno adjustment).
Replace
the dustandpollenlilter(seepage21 39).
. Replacethe
dustandpollenfilterwheneverairflow lrom the heatingandcoolingsystemis lessthannormal.
D
Replace
air cleanerelementevery30,000miles(48,000
km)(independent
of time).
E
i I Replace
brakefluidevery3 years(independent
oI mileage).
* ) will not voidcustomer's
According
to stateandfederalregulations,
failureto do the maintenance
itemsmarkedwith asterisk(
emissions
warranties.
thatall maintsnance
servicebe doneat the recommended
intervalto ensurelongterm reliability.
Y
3-5
MaintenanceSchedule
Listedby Distance/Timefor SevereConditions
or time,whichevercomesfirst.Usethisscheduleif the vehicleis drivenMAINLYin Canadaor in anyof the
distance
(seepage3-4).
il onlyOCCASIONALLY
tollowingconditions;
drivenin theseconditions,
usethe NormalConditions
schedule
SevereDrivingConditions
. Drivinglessthan5 miles{8 km) pertrip or, in freezingtemperatures,
drivinglessthan 10miles(16km)pertrip
. Drivingin extremelyhot (over90"F/32"C)
conditions
. Extensive
deliveryvehicle.
idl;ngor longperiodsof stopand go driving,suchasa taxior a commercial
. Trailertowing,drivingwith a car-topcarrier,or drivingin mountainous
conditions.
. Drivingon muddy,dusty,or de'icedroads
R e p l a c et r a n s m i s s i o nf l u i d . U s e H o n d a M T F { s e e p a g e 1 3 3 ) .
(cold)(seepage6 32):lntake:0.21 0.25mm (0.008 0.010in.)Exhaust:
0.28 0.32mm (0.011 0.013in.)
Inspectvalveclearance.
11 (NGK)or SKJ20DR'M
11 {DENSO)
Replace
sparkplugs.Use
IZFR6K
km/ 6 years
R e p l a c et r a n s m i s s i o nf l u i d . U s e H o n d a M T F ( s e ep a g e 1 3 3 ) .
mil 192,000
km/ 10years,thenevery60,000mi/ 96,000km/5 years
5.0015.3US qt) UseHondaAll SeasonAntifreeze/coo
lantType2.
Replace
coolant(seepage10-6).Capacity:
3-6
Dothe itemsin partsA, B, C,D, E,F,and G as requiredfor mileage/time
intervallisted.
A
q (4.2US qt,3.5lmpqt)
Feplaceengineoil(seepageS5). Capacity
withoutlilterchange:4.0
I
Replace
engjneoil filter(seepageI 6). Capacity
with filterchange:4.20 14.4US qt,3.7lmp qt)
Insoectfrontand rearbrakes,
. Checkpadsanddiscsforwearlthickness),
damage,andcracks.
. Checkcalipers
for damage,leaks,andtightnessof mountbolts.
Lubricate
doorlocks,latchesand hingeswith Hondawhitelithiumgrease.
Rotatetires,if the vehiclehasbeendriventhe distancelisted.Followthe patternshownin the Owner'sManual-Checktire inflaronaoo
condition,
Inspecttierod ends,steeringgearbox,and boots(seepage17,5).
. Checkrackgreaseandsteeringlinkage.
. Checkbootsfor damageand leakinggrease.
. Checklluidlinefordamageandleaks.
L Inspectsuspensron
components
. Checkboltsfor tightness.
. Checkconditionof balljointbootsfor deterioration
anddamage.
Inspectdriveshaft
boots.Checkbootsfor cracksand bootbandsfor tightness(seepage16-3).
Checkparkingbrakeadjustment.
Shouldbe fullyappliedwithin7 to 9 clicks.
Insp€ctbrakehosesandlioes.(including
ABS). Checkthe mastercylinder,proportioning
controlvalve,andABSmodulatorfor damage
(seepage19-24).
and leakage
(see
page13 3),enginecoolant,brakefluid,and
Checkall fluidlevelsandconditionot lluids;checkfor leaks.lf necessary,
add MTF
windshield
washerf luid.
Inspectexhaustsystem*.Checkcatalytic
converterheatshield,exhaustpipeand mufflerfor damage,leaks,andtightness(seepage9 8).
Inspect
fuel linesandconnections*.
Checkfor looseconnections,
cracksand deterioration;
retightenlooseconnections
and replace
damagedpans(seopage11'146).
(seepage22-68).
Checkalllights.Checkfunction
otallinteriorandexteriorlights,andthepositionofthe headlights
Inspect
the v€hicleunderbody.
Checkthe paintfor damage,scratches,
stonechippin0,anddents.
L
D
InsDectand adiustdrive belt.
. Looktor cracksanddamage,and inspectautotensioner
{needsno adjustment).
Reolace
dustand oollenfilter.
E
Replace
aircleanerelementevery15,000
miles124,000
km) in dustvcondition{independent
ol timei otherwiseuseNormalConditions
(seepage11-162).
scredule
F
lReplaceaircleanerelementevery30,000miles(48,000km)(independento{timei(seepagell-162).
Replace
brakefluidevery3 years(independent
oJmileagei.
H
Replacethe
dustandpollenIilterevery15,000
milesifvehicleis drivenmostlywhereair hashighconcentration
olsootfrom industryand
dieselpoweredvehiclesj
alsoreplace
the dustand pollenfilteranytimeaarflowis lessthanussal(seepags21-39).
A c c o r d i n gt o s t a t e a n d f e d e r a l r e g u l a t i o n s ,f a i l u r e t o d o t h e m a i n t e n a n c ei t e m s m a r k e d w i t h a s t e r i s k( * ) w i l l n o t v o i d c u s t o m e r ' s e m i s s i o n s
w a r r a n t i e s .H o w e v e r , H o n d a r e c o m m e n d s t h a t a l l m a i n t e n a n c es e r v i c e sb e d o n e a t t h e r e c o m m e n d e d i n t e r v a lt o e n s u r e l o n g - t e r m r e l i a b i l i t y ,
3-7
MaintenanceSchedule
c
Listedby Maintenanceltem for NormalConditions
on the nextpagedo
for SevereConditions
in the lMaintenance
Schedule
if the severedrivingconditions
specified
Followthe NormalSchedule
drivenin severedrivingconditions.
not apply,and if onlyOCCASIONALLY
scheduleif the vehicleis drivenMAINLYin Canada.
Followthe SevereConditions
ortime,
distance
Serviceatthe indicated
whichevercomesfirst.
milesx 1,000
t0
20
30
40
50
km x 1,000
16
32
48
64
80
12
months
Replace
engineoil
o
24
o
o
96
70
80
90
100
112
128
144
160
48
3
o
a
o
o
110
192
12
60
a
a
r20
o
O
a
R o t a t et i r e s
{ C h e c kt i r e i n t l a t i o na n d c o n d i t i o n a t l e a s t o n c e p e r m o n t h )
Replace
engineoil filter
o
o
a
a
a
a
Inspect
frontand rearbrakes
C h e c kp a r k i n g b r a k e a d j u s t m e n t
Visuallyinspectthefollowingitems:
. Tie-rodends,steeringgearboxand boots
. Suspension
components
. Driveshaftboots
. Brakehosesand lines(including
ABSi
. Allfluidlevelsandconditionof{luids
. Exhaust
system*
. Fuellinesandconnections*
a
Inspectandadjustdrivebelt
a
a
a
Replace
dustand pollenfilter
a
fluid
Reolace
transmission
Servicethefollowing items at the recommendedintervals
R e p l a c ea i r c l e a n e re l e m e n t
km)
Every
30,000
miles(48,000
Replace
sparkplugs
Lm)
Every
110,000
miles(176,000
Inspectvalveclearance
km),otherwise
adiusl
onlyif noisy.
Inspect
miles{176,000
every110,000
I n s p e c ti d l e s p e e d *
km)or8 years
Every
160.000
mres1256,000
R e p l a c ee n g i n e c o o l a n t
km)or5
miles(96,000
km)or 10years,
thenevery60,000
At 120,000
miles(192,000
brakefluid
Replace
Every3 years
(*) will not voidcustomer's
emissions
* : According
itemsmarkedwith asterisk
failureto do the maintenance
to stateandlederalregulations,
intervalto ensurelong-termreliabilityservicebe doneat the recommended
thatall maintenance
warranties.
3-8
Listedby Maintenanceltem for SevereConditions
Usethisschedule
if the vehicleis drivenMAINLYin Canadaor in anvof thefollowinaconditions.
NOTE:it onlyOCCASIONALLY
drivenin these
conditions,
usethe NormalConditions
schedute.
SovereDrivingConditions
. Drivinglessthan5 miles(8 km)pertrip or, in lreezingtemperatures,
drivinglessthan 10miles(16km)pertrip.
. Drivingin extremely
hot over90 "F 132'C)conditions.
. Extensive
idling,or longperiodsot stop-and-go-driving,
suchas a taxior a commercial
deliveryvehicle.
. Trailertowing,drivingwith a cartop carrier,or drivingin mountainous
conditions.
. Drivingon muddy,dusty,or de icedroads.
distance
or time,
whichevercomesfirst.
milesx 1,000
10
km x 1,000
16
months
Replace
engineoil
Rotatetires
intlationandconditionat leastonceper monthi
{Checktire
20
30
40
50
60
70
80
90
100
110
120
48
64
80
96
112
128
144
160
176
192
12
24
36
60
48
72
Replace
every
5,000
miies18,000
km)or6 months
a
o
a
a
o
a
a
o
a
a
a
o
R e p l a c ee n g i n e o i l f i h e r
Inspectfrontand rearbrakes
L u b r i c a t ea l l l o c k s ,h i n g e s ,a n d l a t c h e s
Visuallyinspectthe followingitems:
. Tie rod ends,steeringgearboxand boots
. Suspension
components
' Driveshaftboots
Checlparkingbraleadjuslment
a
a
O
a
o
a
Visuallyinspectthefollowingitems:
. Brakehosesand lines{including
ABSi
. Allfluidlevelsandconditionoflluids
. Exhaust
system*
. Fuellinesandconnections*
. Lightsandcontrols,
vehicleunderbody
o
Inspectand adjustdrivebeh
a
o
a
R e p l a c ed u s t a n d p o l l e n f i l t e r " o ' t '
a
Replace
transmission
lluid
a
Servicethe following items atthe recommendedinteruals
Replace
aircleanerelement
Every15,000
miies(24,000
km)in dustyconditions,
otheMiseusenormalschedule.
Replace
sparkplugs
Every
110,000
miles(176,000
km)
Inspectvalveclearance
Inspect
every110,000
miles(176,000
km),otheMise
adiust
onlyif noisy.
I n s p e c ti d l e s p e e d '
Every
160,000
miles(256,000
km)or8vears
Replace
enginecoolant
At 120,000
miles(192,000
km)of 10years,lhen
every
miles(96,000
60,000
km)or5
Replace
brakefluid
Every3 years
* : A c c o r d i n gt o s t a t e a n d f e d e r a l r e g u l a t i o n s ,f a i l u r e t o d o t h e m a i n t e n a n c ei t e m s m a r k e d w i t h a s t e r i s k1 * ) w i l l n o t v o i d c u s t o m e r ' s e m i s s i o n s
w a r r a n t i e s .H o w e v e r , H o n d a r e c o m m e n d st h a t a l l m a i n t e n a n c es e r v i c eb e d o n e a t t h e r e c o m m e n d e d i n t e r v a lt o e n s u r e l o n g { e r m r e l i a b i l i t v .
N O T E 1 : R e p l a c et h e d u s t a n d p o l l e n f i l t e r a t 1 5 , 0 0 0m i l e s / 2 4 , 0 0 0k m i f t h e v e h i c l e i s d r i v e n m o s t l y i n u r b a n a r e a st h a t h a v e h i g h c o n c e n t r a t i o n s
o f s o o t i n t h e a i r f r o m i n d u s t r v a n d d i e s e l - D o w e r e dv e h i c l e s .
t,
3-9
EngineElectrical
EngineElectrical
SpecialTools
4-2
StartingSystem
Comoonent
Location
Index ...............
CircuitDiagram
StarterCircuit Troubleshooting
ClutchInterlockSwitchTest
StarterSolenoid
Test ..............
StarterPerformance
Test
StarterReolacement
...............
StarterOverhaul.......................
4-J
4-4
4-5
4-6
4-7
4-8
4-9
4-10
lgnition System
Component
LocationIndex ...............
4-15
CircuitDiagram
4-16
lgnitionTimingInspection
4-17
lgnitionCoilRemoval/1nsta11ation
.......................
4-18
SparkPlugInspection
4-19
ChargingSystem
Component
LocationIndex ..................................
4-2O
CircuitDiagram
...........................
4-21
Charging
.......................
4-22
CircuitTroubleshooting
DriveBeltInspection
...................
4-26
DriveBeftReplacement
..............
4-26
DriveBeftAuto-tensioner
Inspection..................
4-27
DriveBeftAuto-tensioner
Replacement
..............
4-28
Alternator
Reolacement
.............
4-29
Alternator
................
....
4-30
Overhaul
CruiseControl
Component
Location
Index ..................................
4-36
CircuitDiagram
...........................
4-37
Index .......................
4-38
SymptomTroubleshooting
CruiseControlUnitlnDutTest .............................
4-40
MainSwitchTesVReolacement
...........................
4-42
.. 4-42
SeVResume/Cancel
SwitchTesVReplacement
CruiseControlActuatorTest
......4-43
CruiseControlActuator/Cable
Replacement
......4-44
ActuatorCableAdjustment..................................
4-45
ClutchPedalPositionSwitchTest .......................
4-45
\.
-
+
ENGINE
EngineElectrical
\ C
SpecialTools
Number
o
@
Tool Number
07746-0010400
07749-0010000
Description
Attachment,52 x 55 mm
Driver
otv
1
1
I
\(a
4-2
Starting System
ComponentLocationIndex
UNDER-DASH
FUSE/RELAYBOX
- l - ar]]]ll
-i
I
-_rt_.1
-.
_-- _. /
Itti:
: - l t . i t -i t! -t
!t:!|-
CLUTCH INTERLOCKSWITCH
Test,page4-6
STARTERCUTRELAY
Test,page22-51
\ r \ ' l
\'\l I
\r\, l,
, . \ \
\ \ /
/
'....",r.v
\-
\:,...)
\ /'\
t l
\
STARTER
page4 5
StanerCircuitTroubleshoot,ng,
SolenoidTest,page 4-7
PerformanceTest,page4-8
Replacement,page
4-9
'10
Overhaul,page4
4-3
Starting System
CircuitDiagram
-
ilo.20lOA) :USAmotkl
No.2!l50A) : C.nid. model
UiIOENH@DfUSE/REI.IY
BOX
STHOTin STA8Tilll
UNDEiOASTI
FUST/ifLAY
80x
Y.
cLuTot
[{Tr8LocK
swtlcH
a
4-4
StarterCircuitTroubleshooting
NOTE:
. Airtemperaturemust be between59'and 100'F(15'
and 38'C) during this procedure.
. After this test, or any subsequentrepair,resetthe
enginecontrolemodule (ECM)to clear any diagnostlc
trouble codes (DTCS){seepage 11-4).
. The batterymust be in good conditionand fully
charged.
. lf you disconnectthe baftery,do the ECM idle learn
p r o c e d u r e( s e ep a g e1 1 - 1 3 9 ) .
RecommendedProcedure:
. Use a startersystemtester.
. Connectand operatethe equipmentin accordance
with the manufacturer'sinstructions.
Alternate Procedure
1. Hook up the following equipment:
. Ammeter,0 400A
. Voltmeter,0 20 V (accuratewithin 0.1 volt)
. Tachometer,0 1200rpm
4. Checkthe batterycondition.Checkelectrical
connectionsat the battery,the negativebaftery
cableto body, the engine ground cablesand the
starterfor loosenessand corrosion.Then try
startingthe engine again.
Did the statter crank the engine?
YES Repairingthe looseconnectionfixed the
problem.The startingsystem is now OK.!
N O l f s t a r t e r w i l ln o t c r a n k t h e e n g i n ea t a l l ,g o t o
step 5. lf it cranksthe engine erraticallyor too
slowly, go to step 7. lf it won't disengagefrom the
flywheel ring gear when you releasethe key, check
for the following until you find the cause.
. Solenoidplungerand switch malfunction
. Dirty drive gear or damagedoverrunningclutch
5. Make sure the transmissionis in neutral,then
disconnectthe startersubharness1Pconnector(A)
'lP
from the enginewire harness connector(B).
Connecta jumper wire from the batterypositive
'l
terminalto the startersubharness P connector.
2 . Removethe No. 17 (15A)fuse from the under-dash
fuse/relaybox.
3 . With the clutch pedal pressed,turn the ignition
switchto start (lll).
Did the starter crank the enginenormally?
Did the starter crank the engine?
YES-The startingsystem is OK.I
YES-Go to step 6.
NO-Go to step 4.
wire betweenthe starter
NO Checkthe BLK,ANHT
subharness1Pconnectorand the starter.lf wire is
OK, removethe starter,and repairor replaceas
necessary.
L
(cont'd)
4-5
StartingSystem
StarterCircuitTroubleshooting
(cont'dl
ClutchInterlockSwitch Test
6. Checkthe following items in the order listeduntil
you find the open circuit.
. Checkthe BLIVWHTwire and connectors
betweenthe under-dashfuse/relaybox and the
ignition switch,and betweenthe under-dash
fuse/relaybox and the starter.
. Checkthe ignition switch {seepage 22-53).
. Checkthe clutch interlockswitch and connector.
. Checkthe startercut relay (seepage 22-51).
. CheckLT GRNwire betweenthe startercut relayl
under-dashfuse/relaybox and the clutch
interlockswitch.
. Checkthe BLKwire betweenthe clutch interlock
switch and G501.
1. Disconnect
the clutchinterlockswitch2Pconnector.
7, Checkthe crankingvoltageand currentdraw.
ls ctanking voltagegreatet than or equal to 8.7 V
and current draw less than or equal to 230 A?
YES-Go to step8.
NO Replacethe starter.or remove and
disassembleit, and checkthese items until you find
thecause.
. Starterarmaturedragging
. Shortedarmature winding
. E x c e s s i vder a g i n e n g i n e
8 . C h e c kt h e e n g i n es p e e dw h i l ec r a n k i n gt h e e n g i n e .
2. Removethe clutch interlockswitch (A).
Checkfor continuitybetweenthe terminals
accordingto the table.
. lf the continuityis not as specified,replacethe
clutch interlockswitch.
. lf OK, installclutch interlockswitch and adjust
the pedal height (seepage 12-4l..
ls the engine speed above 100 tpm?
YES Go to step 9.
NO-Replace the starter,or remove and
disassembleit, and checkfor the following until
y o u f i n dt h e c a u s e .
. Excessivelyworn starterbrushes
. Open circuit in commutator brushes
. Open circuit in starterarmaturecommutator
segments
. D i r t yo r d a m a g e dh e l i c asl p l i n e so r d r i v eg e a r
. Faultydrive gear clutch
9. Removethe starter,and inspectits drive gear and
the flywheel ring gear for damage.Replaceany
d a m a g e dp a n s . I
4-6
Terminal
\
Cl","f ri"t.tf ."tS""*Jrl
PRESSED
RELEASED
2
o--
- --o
StarterSolenoidTest
from thestarter
1. Disconnect
the S andlvlconnectors
solenoid.
2. Checkthe hold-incoil for continuitybetweenthe S
terminal and the armaturehousing(ground).There
should be continuity.
. lf there is continuity,goto step 3.
. lf there is no continuity,replacethe solenoid,
et
3. Checkthe pull-incoil for continuitybetween the S
. h e r es h o u l db e
terminaa
l n d M t e r m i n a lT
continuity,
. lf there is continuity,the solenoidis OK.
. lf there is no continuity,replacethe solenoid,
4-7
StartingSystem
Starter PerformanceTest
1 , Disconnectthe wires from the S terminal and the M
termrnal.
5. Disconnectthe batteryfrom the starterbody. lfthe
pinion retractsimmediately,it is working properly.
Make a connectionas describedbelow using as
heavya wire as possible(preterablyequivalentto
the wire used for the vehicle).To avoid damaging
the starter,never leavethe batteryconnectedfor
more than 10 seconds,
Connectthe batteryas shown. Be sure to
disconnectthe startermotor wire from the solenoid.
lf the starterpinion moves out, it is working
propefly.
6 . Clampthe starterfirmly in a vise.
7 . Connectthe starterto the batteryas describedin
the diagram below,and confirm that the motor
starts and keepsrotating.
Disconnectthe batteryfrom the M terminal.lf the
pinion does not retract,the hold-incoil of the
solenoidis working properly.
lf the eiectriccurrent and motor speedmeet the
specificationswhen the batteryvoltage is at 11.5V,
the staner is working properly,
Specifications:
1.1 kw
90 A or less (Electriccurrent),
ot more
L
4-8
Starter Replacement
1. Make sure you havethe anti-theftcode for the radio.
then write down the frequenciesfor the radio's
presetbuttons.
2. Disconnectthe negativecablefrom the batteryfirst,
then disconnectthe positivecable.
5. Disconnectthe startercable (A)from the B terminal
wire
on the solenoid,then disconnectthe BLK,/WHT
{ B )f r o mt h eS t e r m i n a l .
10x 1.25mm
44N.m{a.5kgf.m,33lblft)
3. Disconnectthe knocksensorconnector.
4. Removethe bolt (A) securingthe harnessbracket,
then removethe intakemanifold bracket(B).
A
6x1,0mm
12 N.m {1.2kgf.m,
8.7 tbt.ft)
2
8 x 1 . 2 5m m
9Nm
10.9kgf.m,7 lbl ft)
S'-12x12smm
6ilNm
{ 6 . 5k g l m , 4 7 l b f f t )
Removethe two bolts holdingthe starter,then
removethe starter.
8 x 1.25mm
22 N,m 12.2kgt.m,
16rbf.ftl
7 . lnstallthe starterin the reverseorder of removal.
Make sure the crimped side of the ring terminal (A)
is facing out.
I
Connectthe positivecable and negativecableto
the batterY.
9 . Start the engineto make sure the starteroperates
propeny.
'10.Enterthe anti-theftcode for the radio,then enter
the customer'sradio stationpresets.
1 1 .Set the clock.
L
' t 2 .Performthe enginecontrol module (EcM) idle learn
procedure(seepage 1'1-139).
4-9
StartingSystem
f
Starter Overhaul
Disassembly/Reassembly
STARTERSOLENOID
@
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q
SOLENOIDLEVER
- @-A
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OVERRUNNING
CLUTCHASSEMBLY
o*"lu*.
7:- o
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END COVER
'!4/
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BRUSHHOLDER
\ r
4-10
\
Armature Inspection and Test
5. Checkthe commutatordiameter.lf the diameteris
below the servicelimit, replacethe armature.
1. Removethe starter(seepage 4-9).
2 . D i s a s s e m b lteh e s t a r t e ra s s h o w na t t h e b e g i n n i n g
of this procedure.
Commutator Diameter
Standard(Newl: 28.0mm (1.10in.l
ServiceLimit: 27.0 mm (1.06in.)
3. Inspectthe armaturefor wear or damagefrom
contactwith the permanentmagnet.lf there is wear
or damage,replacethe armature.
6 . Measurethe commutator (A) runout.
?.-
Checkthe commutator(A) surface.lf the surfaceis
dirty or burnt, resurfacewith emery cloth or a lathe
within the specificationsin step 5, or recondition
with # 500 or # 600 sandpaper(B).
. lf the commutator runout is within the service
limit, checkthe commutatorfor carbondust or
brasschips betweenthe segments.
. lf the commutator runout is not within the service
limit, reolacethe armature.
Commutator Runout
StandardlNew): 0.02mm 10.001in.) max.
ServiceLimit: 0.05mm (0.002in.)
(cont'd)
4-11
StartingSystem
StarterOverhaul(cont'dl
7. Checkthe mica depth (A).lf the mica is too high {B),
undercutthe mica with a hacksawbladeto the
properdepth.Cut away allthe mica (C)between
the commutatorsegments.The undercutshould
not be too shallow,too narrow,or V-shaped(D).
9. Placethe armature(A) on an armaturetester (B).
Hold a hacksawblade (C)on the armaturecore. lf
the blade is attractedto the core or vibrateswhile
t h e c o r ei s t u r n e d ,t h e a r m a t u r ei s s h o n e d .R e p l a c e
thearmature.
Commutator Mica Depth
Standard(New):0.50-0.80 mm {0.020-0.031in.)
1 0 ,Checkwith an ohmmeterthat no continuityexists
Checkfor continuitybetweenthe segmentsof the
commutator.lf an open circuitexists betweenany
segments,replacethe armature.
betweenthe commutator(A) and armaturecoll
core (B),and betweenthe commutatorand
armatureshaft (C).lf continuityexists,replacethe
armature.
M
\
4-12
Starter Brush Inspection
Starter Brush Holder Test
11. lvleasurethe brush length.lf it is not within the
servicelimit, replacethe brush holder assembly.
14, Checkthat there is no continuitybetweenthe (+ )
b r u s hh o l d e r{ A )a n d ( ) b r u s hh o l d e r( B } .l f t h e r e
is continuity,replacethe brush holder assembly.
Brush Length
Standard{New): 14.0-14.5 mm (0.55-0.57 in.)
9.0 mm {0.35 in.)
Service Limit:
Brush Spring Inspection
Starter Field Winding Test
12. Checkfor continuitybetweenthe brushes(A).lf
there is no continuity.replacethe armature
h o u s i n g( B ) .
15. Insen the brush (A) into the brush holder,and bring
the brush into contactwith the commutator,then
attacha spring scale(B)to the spring (C).Measure
the spring tensionat the moment the spring lifts off
the brush.lf the springtension is not within
specification,replacethe spring.
Spring Tension: 13.7-17.7 N {1.40-1.80 kgf,
3.09 3.97lbf)
1 3 .Checkfor continuitybetweeneach brush (A) and
the armaturehousing(B).li there is continuity,
replacethe armaturehousing.
(cont'd)
4-13
StartingSystem
StarterOverhaul(cont'dl
Planetary Gear Inspection
Starter Reassembly
1 6 . C h e c kt h e p l a n e t a r yg e a r s( A )a n d r i n g g e a r{ B ) .
Replacethem if they are worn or damaged.
20, Pry backeach brush spring with a screwdriver,then
positionthe brush about halfwayout of its holder,
a n d r e l e a s et h e s p r i n gt o h o l d i t t h e r e .
NOTE:To seatthe new brushes.slip a strip of #5OO
or # 600 sandpaper.with the grit side out, be&veen
the commutatorand each brush,and smoothly
rotatethe armature.The contactsurfaceof the
brusheswill be sandedto the same contouras the
commutator.
OverrunningCluich Inspection
17. Slidethe overrunningclutchalong the shaft.
Replaceit if it does not slide smoothly.
18. Rotatethe overrunningclutch(A) both ways.
Doesit lock in one directionand rotatesmoothly in
reverse?lf it does not lock in eitherdirectionor it
locksin both directions,replaceit.
21 l n s t a l l t h ea r m a t u r ei n t h e h o u s i n ga, n d i n s t a l l t h e
brush holder.Next, pry backeach brush spring
a g a i n ,a n d p u s ht h e b r u s hd o w n u n t i li t s e a t s
againstthe commutator,then releasethe spring
againstthe end of the brush.
s
1 9 .lf the starterdrive gear (B) is worn or damaged,
replacethe overrunningclutch assembly;the gear
is not availableseparately.
Checkthe conditionof the flywheel ring gear.
Replaceit if the starterdrive gear teeth are
oamageo.
Installthe starterend cover to retainthe brush
holder.
i.-
4-14
lgnition System
SPARK
PLUG
page4-'19
Inspection,
IGNITION
COIL
page4-17
lgnitionTimingInspection,
page4-18
Removal/lnstallation,
4-15
lgnition System
(
GircuitDiagram
'No.20lOA)
:USAmo&l
No.Al50A):Cmrda
model
UNDEBHOOD
FUST/8TIAY
M)(
lG1tioT in 0N {ll)
rd SIARIilll)
4-16
lgnition Timing Inspection
1 . Connectthe Honda PGM Testerto the data link
connector(DTC),and checkfor DTC'S.lf a DTCis
present,diagnoseand repairthe causebefore
i n s p e c t i n tgh e i g n i t i o nt i m i n g .
Startthe engine.Holdthe engine at 3,000rpm with
no load (in Neutral)until the radiatorfan comes on,
then let it idle.
C h e c kt h e i d l es p e e d( s e ep a g e1 1 - 1 3 8 ) .
4. Follow the tester'sprompts in the
"SCS" menu
6. Pointthe light toward the pointer (A) on the cam
c h a i nc a s e .C h e c kt h e i g n i t i o nt i m i n g u n d e rn o l o a d
conditions:headlights,blower fan. rearwindow
defogger,and air conditionerare not operaling.lf
the ignitiontiming differsfrom the specification,
and there are no enginecontrol module {ECM)DTcs,
r e p l a c et h e E C M( s e ep a g e1 1 - 4 )
lgnition Timing:
8"+2" BTDC{REDmark {B))during idling in neutral
A
{seethe testeroperator'smanual),
5 . Connectthe timing light to the serviceloop.
o
7. Turn the ignition switch OFF.
D i s c o n n e c t t hH
e o n d aP G MT e s t e ra n dt h e t i m i n g
light.
4-17
lgnition System
lgnitionCoilRemoval/lnstallation
1. Removethe ignition coil cover (A),then removethe
i g n i t i o nc o i l s( B ) .
6x1.0mm
9.8 N.m (1.0kgf.m,7.2lbf ftl
2. Installthe ignition coils in the reverseorder of
removal.
4-18
---a
SparkPlug Inspection
1 . Inspectthe electrodesand ceramicinsulator.
Burned or worn electrodes may be caused by:
. Advancedignitiontiming
. Loosespark plug
. Plug heat rangetoo hot
.Insufficientcooling
3. Replacethe plug at the specifiedinterval,or if the
centerelectrodeis rounded{A). Use onlVthe spark
plugs listedbelow.
Spark Plugs: lZFR6Kl1(NGK)
(DENSO)
SKJ2ODR-M11
Fouledplug may be causedby:
. Retardedignitiontiming
. O i l i n c o m b u s t i o nc h a m b e r
. Incorrectspark plug gap
. Plug heat rangetoo cold
. Excessiveidling/lowspeed running
. C l o g g e da i r c l e a n e re l e m e n t
. Deterioratedignitioncoils
Worn or deformed
electrodes
f .lmpropergap
I
J.Oil-touling
. Cs6on deposits
'r- 1I . Crackedcenter
\ electrodeinsulator
4 . Apply a small quantityof anti-seizecompoundto
the plug threads,and screwthe plugs into the
cylinder headfinger-tight.Then torque them to
1 8 N m ( 1 . 8k g f . m ,1 3 l b f f t ) .
L
Do not adjustthe gap of iridium tip plugs (A);
replacethe spark plug if the gap is out of
specification.
Electrode Gap:
Standard(New):
ServiceLimit:
1.0 1.1 mm
{0.039-0.0€ in.)
1.3 mm {0.051in.l
4-19
GhargingSystem
CHARGING
SYSTEMINDICATOR
(ln the gaugeassembly)
q*o
BATTERY
Test,page22-50
DRIVEBELT
page4 26
Inspection,
page4 26
Replacement,
4-20
ALTEBNATOR
page4-22
Troubleshooting,
page4-29
Replacement,
page4-30
Overhaul,
\
CircuitDiagram
'flo.
{l0Al :uSAhod.l
ilo.20l50Al:C.n.d.mod.l
UNDTRXOOD
FUSI/RILAY
MX
+--,
I fmlil*t"t'
T-
L
+ilt
= l
4-21
GhargingSystem
ChargingCircuitTroubleshooting
lf the chargingsystem indicatordoes not come on or
does not go off, or the batteryis dead or low, test these
items in the order listedbelow:
Battery(seepage 22-50)
Chargingsystem indicator
Alternatorand regulatorcircuit
Alternatorcontrol system
6. Measurethe voltageat the No. 3 terminal of the
e n g i n ew i r e h a r n e s s6 P c o n n e c t ow
r iththe ignition
s w i t c hO N {l l ) .
ENGINEWIREHARNESS6P CONNECTOR
IBLK/YEL}
ChargingSystemIndicatorTest
1 . T u r nt h e i g n i t i o ns w i t c hO N { l l ) .
Does the chatging system indicator come on?
YES Go to step 2.
Wiresideof femaleterminals
NO Go to step 3.
ls there battery voltage?
2. Startthe engine.
YES-Go to step 7.
Does the charging system indicator go off?
YES-Charging system indicatorcircuitis OK. Go
to the Alternatorand RegulatorcircuitTest.t
N O - C h e c k f o r a b l o w nN o . 4{ 1 0 A )f u s e i n t h e
under-dashfuse/relaybox. lf the fuse is OK, repair
open in the wire betweenthe alternatorand the
under-dashfuse/relaybox.I
NO-Go to step 3.
?
7 . Turn the ignition switch OFF.
3. Turn the ignitionswitch OFF.
4. Troubleshootthe multiplexcontrol system (see
page 22 172).
8 . Disconnectenginecontrol module (ECM)connector
B (24P).
9 . Checkcontinuitybetweenthe ECMconnector
ls the multiplex control system OK?
YES Go to step 5.
t e r m i n a lB ' 1 0a n d e n g i n ew i r e h a r n e s s6 Pc o n n e c t o r
t e r m i n a lN o . 6 .
ECM CONNECTOB A (24P)
NO Checkthe multiplexcontrol system as
indicatedby the diagnostictrouble code (DTC) (see
s t e p8 o n p a g e2 2 - 1 7 2 ) . 1
A C G L{ W H T / B L U )
5. Disconnectthe enginewire harness6P connector
from the startersub harness6P connector.
E N G I N EW I B E
HARNESS
6P
L (WHT/BLUI
W i r e s i d eo f f e m a l e t e r m i n as
ls there continuity?
YES Go to step 10.
NO-Repair open in the wire betweenthe
a l t e r n a t oar n dt h e E C N 4 . I
4-22
\"4
'10.
Checkcontinuitybetweenthe ECMconnector
t e r m i n a l8 1 0 a n d b o d y g r o u n d .
ECMCONNECTOR
S I24PI
2 3 t 4t 5
8 I 10 ,/1,/ 3
1 1 8 ,N nt,/ 21
6 7
15
23
ACGL(WHT/BLUI
t1'
Alternator and RegulatorCircuitTest
1. Be sure the batteryis sufficientlychargedand in
good condition{seepage 22-50),and the
connectionsat the fuse box and alternatorare
clean and tight.
2. Raisethe hoist to full height.
3. Hook up the ammeter,0
subharness.
400 A, to the starter
Wire side ol femaleterminals
YES- Repairshort to ground in the wire between
the ECMand the enginewire harness6P connector.
t
NO-Go to alternatorand regulatortest.
Lower the hoist.
Hook up the voltmeter,0
0.1V),toT101.
20 V (accuratewithin
(cont'd)
4-23
GhargingSystem
(cont'd)
ChargingCircuitTroubleshooting
6. Startthe engine.Hold the engineat 3,000rpm with
no load (in Neutral)until the radiatorfan comes on,
then let it idle.
7. Raisethe engine speedto 2,000rpm, and hold it
there.
8. Turn the headlights(high beam)on, and measure
voltageat the under-hoodfuse/relaybox terminal.
ls the voltagebetween 13.9and 15.1v?
YES-Go to step 9.
NOTE:After troubleshooting,performthe engine
control module (ECM)idle learn procedure(seepage
11-139).
1. Checkfor proper operationof the electricalload
detector(ELD)by checkingthe malfunction
i n d i c a t o lra m p ( M l L ) ( s e ep a g e1l - 3 ) .l f a D T Ci s
present,diagnoseand repairthe causebefore
continuingwith this test.
2. Disconnectthe enginewire harness6P connector
from the startersub harness6P connector.
NO Repairor replacethe alternatorcomponents
(seepage 4-30).1
9. Readthe amperageat
Alternator Control SystemTest
'13.5V.
NOTE:Adjust the voltage by turning the blower
motor, rearwindow defogger,brakelights.etc.ON.
3. Start the engine,and turn the headlights(high
b e a m )O N ,
4. Measurevoltage betweenthe enginewire harness
6P connectorterminal No. 2 and the positive
terminal of lhe battery.
ls the amperage604 ot morc?
BATTERY
YES-Alternator/regulatoroperationis OK.I
NO Repairor replacethe alternatorcomponents
(seepage 4-30).1
C {WHT/GRN)
ENGINE
WIREHARNESS
6PCONNECTOR
ls there 1 V or less?
YES Go to step 8.
N O - G o t o s t e p5 .
5 . T u r nt h e h e a d l i g h t a
s n d i g n i t i o ns w i t c hO F F .
6 . DisconnectECMconnectorB (24P).
\,
4-24
\
7, Checkfor continuitybetweenECMconnector
ECM CONNECTORB {24PI
1 2 3 t 4t 5
8 9 10 ,/1,/ 3
nt,/21
11o
6 1
5
23
ACGC{WHT/GRN}
o
10. Checkfor continuitybetweenECMconnector
t e r m i n a l8 1 8 a n d e n g i n ew i r e h a r n e s s6 Pc o n n e c t o r
ECM CONNECTORB l2,lPI
1 2 3 1 4 l 5 l l6l 7
8 9 10
15
t.)
11o
21 23
n
ACGC(WHT/GRN)
o
Wire side ot femaleterminals
C (WHT/GRN)
2
3
5
6
ENGINEWIREHARNESS6P CONNECTOR
Wire side oI lemale terminals
ls therc continuity?
YES-Repair short to ground in the wire between
the alternatorand the ECM.I
L
NO-Check that the terminalsare firmly seatedat
the ECMconnectorB. lf OK, substitutea knowngood ECM,and recheck(seepage 11-6).
lf prescribedvoltage is now available.replacethe
o r i g i n aE
l CM,I
YES Repairor replacethe startersubharnessor
the alternator(seepage 4-30).I
NO Repairopen in the wire betweenthe
a l t e r n a t oar n d t h e E C M . I
Turn the headlightsand ignition switch OFF.
4-25
ChargingSystem
DriveBelt Inspection
indicator(A)is withinthe
Checkthatthe auto-tensioner
(B)
range
as
shown.
lf
it is out of thestandard
standard
range,replacethedrivebelt(seepage4-26).
DriveBelt Replacement
1, Move the auto-tensioner(A) to relievetensionfrom
the drive belt (B).and removethe drive belt.
2. Installthe new belt in the reverseorder of removal.
4-26
\
DriveBelt Auto-tensionerInspection
1 . Checkwhether there is a changein the positionof
the auto-tensionerindicatorbeforestartingthe
engineand after startingthe engine.lf there is a
c h a n g ei n t h e p o s i t i o nr, e p l a c et h e a u t o - t e n s i o n e r .
Removethe auto-tensioner(seepage 4-28).
I n s t a ltlh e t e n s i o n e p
r ulley.
7 . Clampthe auto-tensioner(A) by using two 8 mm
bolts (B)and a vise (C)as shown. Do not clamp the
auto-tensioneritself.
C h e c kf o r a b n o r m a n
l o i s ef r o m t h e t e n s i o n e p
r ulley.
lf abnorman
l o i s ei s h e a r d ,r e p l a c et h e t e n s i o n e r
pulley.
3 . Removethe drive belt (seepage 4-26).
8 . Set the torque wrench (D)on the pulley bolt.
lMovethe auto-tensionerwithin its limit with the
belt tension releasetool in the directionshown.
Checkthat the tensionermoves smoothly and
without any abnormal noise.lf the tensionerdoes
not move smoothly or there is abnormal noise,
replacethe auto-tensioner.
9 . Align the indicator{E)on the tensionerbasewith
c e n t e rm a r k( F )o n t h e t e n s i o n e ar r m b y u s i n gt h e
torque wrench, and measurethe torque. lf the
torque value is out of specification,replacethe
auto-tensioner,
NOTE;lf the indicatorexceedsthe centermark,
recheckthe torque.
Auto-tensioner spring torque:
26.5-36.3 N.m 12.7-3.7 kg.m, 19.5-26.8lbt.ft)
4-27
ChargingSystem
DriveBelt Auto-tensionerReplacement
1. Removethe drive belt (seepage 4'26).
4. Removethe auto-tensioner,
2 . R e m o v et h e i d l e rp u l l e y .
6xl.0mm
9.8 N.m
(1,0kgl.m,
7.2 tbf.ft)
d
I
6x1,0mm
12 N.m
('1.2kgt.m.8.7lbt.ft)
x 1.25mm
22 N.m
{2.2 kgt m, 16 lbf ft}
3. Removethe tensionerpulley.
8 x 1.25mm
22 N.m (2.2kgf.m, 16lbt.ft)
5. lnstall in the reverse order of removal.
4-28
\-a
l\-
AlternatorReplacement
1. Make sure you havethe anti-theftcode for the radio,
preset buttons,
9 . Removethe alternator.
1 0 . Installthe alternatorand drive belt in the reverse
order of removal.
'I
1 . Connectthe positivecable and negativecableto
the battery.
3. Removethe front bumper (seepage 20-85).
tt.
4. Removethe right side headlight(seepage 22-79).
Enterthe anti-theftcode for the radio,then enter
the customer'sradio station presets.
5. Removethe reservetank from the bracket.
1 3 .Set the clock.
6. Removethe drive belt (seepage 4-26).
1 4 . Performthe enginecontrol module {ECM)idle learn
7. Removethe three bolts securingthe alternator.
8 x 1 . 2 5m m
22 N.n 12.2kgl.m,
Disconnectthe alternatorconnector(A) and BLK
wire (B)from the alternator.
8 N.m
10.8kgf.m,6lbf.ft)
\
6
4-29
ChargingSystem
AlternatorOverhaul
ExplodedView
ROTOR
W|UF.,.oy." REARBEARING /
\
\
\
/
,/
FRoNrB
BEARING
./
@b.J.y{=RE+LN'"'
I/
vVFko"-% \
qtr*njlv
V ("rV) ,
BRUSH
HOLOER
TNSULATOR
\
\-
BRUSH
HOLDER
\
\
VOLTAGE
REGULATOR
\11
-\\
\l
}
(-
@*F,-\:
\
PULLEY
/
\
PULLEY
LOCKNUT
/
/@
v_re*î
\gP^@'I
*ffilw9
TERMINAL
INSULATOR
REARHOUSING
ASSEMBLY
INSULATOR
BUSHING
4-30
\-a
L
Special Tools Required
. Driver07749-0010000
. Attachment,52x 55 mm 07746-0010400
5 . R e m o v et h e e n d c o v e r( A )a n d d u s t s e a l{ B ) .
NOTE:Referto the ExplodedView as neededduring
this procedure.
1, Testthe alternatorand regulatorbeforeyou
remove them (see page 4-22l,.
2. Removethe alternator(seepage 4-29).
3. lf the front bearingneedsreplacing,removethe
pulley locknutwith a 10 mm wrench (A) and a
22 mm wrench (B).lf necessary,use an impact
wrencn.
6 . Removethe brush holder (A),voltage regulator(B),
a n dt h e r u b b e rs e a l{ C } .
, (( , t tI
; r _l L t
L1i.21---^
tqLJ
Removethe harnessbracket(A),insulator(B).three
flange nuts (C),and the screw (D),then removethe
p l a t et e r m i n a l( E ) .
B-"--|.
1!q[-dr,:l
(cont'd)
4-31
ChargingSystem
AlternatorOverhaul(cont'dl
7. Removethe four screws,then removethe rectifier
( A )a n d f o u r i n s u l a t o r (sB ) .
the frontbearingand/or
9. lf you arenot replacing
'16.
rearbearing,go to step Removethe rotorfrom
the statordriveendhousing.
1 0 .Inspectthe rotor shaftfor scoring,and inspectthe
bearingjournal surfacein the statorhousingfor
s e t z u r em a r k s .
Removethe four flange nuts,then removethe rear
h o u s i n g( A )a n dw a s h e r( B ) .
o\
. l f e i t h e r t h er o t o r o r s t a t o r h o u s i n g
isdamaged,
replacethe alternator,
. lf both the rotor and the stator housingare OK,
g o t o s t e p1 1 .
'l
\"
1 . R e m o v et h e r e a rb e a r i n gu s i n ga p u l l e ra s s h o w n .
f.r,e
4-32
\1 2 . W i t h a h a m m e ra n d c o m m e r c i a l l a
yvailable
tools
shown, installa new rear bearingon the rotor shaft.
NOTE:Installthe bearingusing the inner race.
14. Supportthe stator housingin a vise, and drive out
the front bearingwith a brassdrift and hammer.
1 5 . W i t h a h a m m e ra n d t h e s p e c i a l t o o l si ,n s t a l a
l new
front bearingin the stator housing.
13. Removethe front bearingretainerplate.
sH
6
u
qE
e
s
07749-0010000
f-\
\r-:1
\s---'^/
07746-0010400
( c o n t ' d)
4-33
ChargingSystem
AlternatorOverhaul(cont'd)
Rectitier Test
Alternator Brush Inspection
16. Checkfor continuityin each direction,betweenthe
B terminal and P terminals,and betweenthe E
terminaa
l n d P t e r m i n a l so f e a c hd i o d ep a i r .
A l l d i o d e ss h o u l dh a v ec o n t i n u i t yi n o n l y o n e
direction.Becausethe rectifierdiodes are designed
to allow currentto pass in one direction,and the
rectifieris made up of eight diodes (four pairs).you
musttest each diode in both directionsfor
continuitywith an ohmmeterthat has diode
checkingcapability:a total of 16 checks.
1 7 . M e a s u r et h e l e n g t ho f b o t h b r u s h e s( A ) w i t ha
v e r n i e rc a l i p e r{ B ) .
. l f e i t h e rb r u s hi s s h o r t e r t h a n t h es e r v i c el i m i t ,
r e p l a c et h e b r u s ha s s e m b l y .
. lf brush length is OK, go to step '18.
Alternator Brush Length:
Standard(New): 10.5mm (0.41in.)
. lf any diode is faulty. replacethe rectifier
assembly.{Diodesare not availableseparately.)
' lf all the diodes are OK, go to step 17.
-
/--:',t-L
-o \--
. -l'-=
\"
Rotor Slip Bing Test
18. Checkthat there is continuitybetweenthe slip rings
{A).
. lf there is continuity,go to step 19.
. lf there is no continuity,replacethealternator.
B P "
P,
P.
P,
P.
1 9 . Checkthat there is no continuitybetweeneach slip
ring and the rotor (B) and the rotor shaft (C).
. lf there is no continuity,goto step 20.
. lf there is continuity,replacethe alternator.
4-34
\r'a
Stator Test
20. Checkthatthereis continuitybetweeneach pair of
leads(A).
lf there is continuity,go to step 21.
lf there is no continuity,replacethe alternator.
'--l-- --i
2 1 .Checkfor no continuitybetweeneach lead and the
coil core (B).
. lf there is no continuity,goto step 22.
. lfthere is continuity,replacethe alternator.
22. Assemblethe alternatorin reverseorder of
disassembly,and note these items:
. Be carefulnot to get any greaseor oil on lhe slip
nn g s .
. lf you removedlhe pulley,tighten its locknutto
1 1 1N . m ( 1 1 . 3k g f m , 8 1 . 7l b f . f t ) w h e n y o ui n s t a l l
it.
4-35
GruiseControl
CRUISECONTROLINDICATOR
(Builtinto gaug6assembly)
CLUTCH
PEDALPOSITION
swtTcH
Test,page4-45
ClutchPedalAdjustment,
page12-4
CRUISECONTROLUNIT
lnputTest,page4-40
BRAKEPEDALPOSITION
SWITCH
Test,page22-84
page'19-6
PedalHeightAdjustment,
t.-
CRUISE
CONTROL
ACTUATOR
Test,page4'43
page4-44
Replacement,
4-36
_,-
_
-
l
l
ACTUATORCABLE
Adjustment,page4-45
\-a
CircuitDiagram
'
fUS'/iILAY IOX
UISEF NOOD
-to
ots
No.aloAl
No.20itoAl
USAnod.l
C.md! modrl
BU/YIL
lcl H0Tii0llilll
mdSTARTlllll
1 Honilsffroi
2
6
1
uNtT
cnu6EcoNTnoL
1
1
3
l0
CTuICIIPEDAL
P0sm0swtrct
4-37
CruiseControl
Symptom TroubleshootingIndex
NOTE:
' The numbersin the table showthetroubleshootingsequence.
. Beforetroubleshooting.
- checkthe No, 10 (7.5A)and No. 4 (10A)fuses in the under-dashfuse/relaybox. and the No. 7 (15A)
fuse in the
under-hoodfuse/relaybox,
- checkthat the horn sounds.
- checkthe tachometerto see if it works properly.
- checkthe speedometerlo see if it works properly.
Symptom
Cruisecontrol cannot be
set
Diagnostic procedure
1. Checkmain switch (seepage 4-42)
2. CheckSET/RESUME/CANCEL
switch (seepage 4-42)
3. Test brakepedal positionswitch (seepage 22-84)and check
its adjustment{seepage 19,6)
4. Test clutch pedal positionswitch (seepage 4-45)and check
its adjustment(seepage 12-41
5. Checkcruisecontrol unit {seepage 4-40}
6. Checkvehiclespeed sensor(VSS)(seepage 22-65)
Cruisecontrol can be set
but indicatorlight does
not go on
1. Checkcruisecontrolindicatorbulbin gaugeassembly{see
page 22-631
2. Checkcruisecontrolunit(seepage4-40)
ar, 'i.a
1. Checkvehiclespeed sensor(VSS){seepage 22-65)
Checkcruisecontrol actuator{seepage 4-43)
2. Checkcruisecontrol unit (seepage 4-40)
câa.l
ic
noticeablh
y i g h e ro r
lower than what was set
Excessiveovershooting
or undershootingwhen
trying to set speed
Speedfluctuationon a
flat road with cruise
control set
Vehicledoes not
decelerateor accelerate
accordinglywhen SET/
RESUME/CANCEL
button
is pushed
Set speed does not
cancel(enginerpm stays
h i g h )w h e n c l u t c hp e d a l
is pushed
Set speeddoes not
cancelwhen brakepedal
is pushed
4-38
Also check for
. Poorground:
G501
. Opencircuit,
looseor
disconnected
t e r mi n a l s :
L TG R N ,
BLI(ORN.
GRY/RED,
BLU.
LTBLU,
BLUAA/HT
. Poor ground:
G501
. Open circuit,
looseor
disconnected
termrnats:
YEL,BLUA/EL
1. Checkcruisecontrol actuator(seepage 4-43)
2. Checkvehiclespeed sensor(VSS)(seepage 22-65)
Checkcruisecontrol unit (seepage 4-40)
3.
1. Checkvehiclespeedsensor(VSS)(seepage22-65)
Checkcruisecontrol actuator(seepage 4-43)
1. CheckSET/RESU
ME/CANCELswitch (seepage 4-42)
2. Checkcruisecontrol unit {seepage 4-40)
Open circuit,loose
or disconnected
terminals:
GRY/RED,
LT GRN/BLK
1. Testclutch pedal positionswitch (seepage 4-45)and check
its adjustment(see page 12-4)
Shortto groundin
the LTBLUwire
'1.
2.
Test brakepedal positionswitch (seepage 22-84)and check Open circuit,loose
its adjustment(seepage 19-6)
or disconnected
Checkcruisecontrol unit (seepage 4-40)
terminals:
WHT/BLK
g ,
svmptom
Set speeddoes not
cancelwhen main switch
i s o u s h e dO F F
Set speeddoes not
c a n c ew
l henCANCEL
button is pushed
Set speedwill not
r e s u m ew h e n R E S U M E
button is pushed(with
main switch on, and set
speedtemporarily
cancelledby pressingthe
brakeDedal)
Diagnosticprocedure
1. Checkmain switch (seepage 4-42)
Also check for
Short to power in
the LT GRNwire.
1. CheckSET/RESU
Opencircuit,loose
or disconnected
terminals:
GRYiRED,
LTGRN/BLK
1. CheckSET/RESU
2. Checkcruisecontrol unit {seepage 4-40)
Open circuit,loose
or disconnected
terminals:
L TG R N / B L K
4-39
CruiseGontrol
CruiseControl Unit Input Test
SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations(seepage 23-'13)and precautionsand
procedures(seepage 23-14)in the SRSsectionbefore performingrepairsor service.
1. Disconnectthe 14Pconnectorfrom the control unit.
2. Inspectthe connectorand socketterminalsto be sure they are all makinggood contact.
. lf the terminalsare bent, loose,orcorroded, repairthem as necessary,and recheckthesystem.
. lf the terminalslook OK, go to step 3.
Wire sideof
femaleterminals
3. With the 14Pconnectordisconnected,make these inDuttests.
Cavity
Wire
Test condition
BRN/WHT Connectbattery
power
2
BLU
3
BLK
5
4-40
lgnitionswitch ON
(ll),main swltch ON
and brakepedal
pressed,then
reteaseo
Test:Desiredresult
Checkthe operationof the
magneticclutch:Clutch
s h o u l dc l i c ka n d o u t p u tl i n k
should be locked.
Checkfor voltageto ground;
There should be 0 V with lhe
pedal pressedand battery
voltagewith the pedal
released.
U n d e ra l l c o n d i t i o n s Checkfor continuityto
grouno:
There should be continuitv
BLIVORN l g n i t i o ns w i t c hO N
Checkfor voltageto ground:
Thereshould be battery
flr)
vottaqe.
WHT/BLK Brakepedal pressed, Checkfor voltageto ground:
then released
There should be battery
voltagewith the pedal
pressed,and 0 V with the
pedal released.
Possiblecause
ifresuhis notobtained
Faultyactuator
P o o rg r o u n d( G 3 0 1 )
An open in the wire
Shon to ground (arcswhen
Doweris connected)
. Faultybrakepedal position
switch
. A n o p e ni n t h e w i r e
. Open in cruisecontrol main
swrtcn
. B l o w nN o . 4 ( 1 0A ) f u s e i n t h e
under/dashfuse/relavbox
. P o o rg r o u n d( G 5 0 1 )
. An open in the wire
'
.
.
.
B l o w nN o . 4 ( 1 0A ) f u s e i n t h e
under-dashf use/relaybox
An oDenin the wire
B l o w nN o . 7 { 1 5A ) f u s ei n t h e
under-hoodfuse/relaybox
Faultybrakepedal position
SWIICN
A n o D e ni n t h e w i r e
Cavity
6
7
11
10
Test condition
Wire
GRYiRED Setbuttonpushed
LT GRN/
BLK
Resumebutton
pusneo
BRN
Connectbattery
BRNI/EL power to the BRN
BLUIVEL
t e r m i n a la n d g r o u n d
to the BRNIVEL
termrnal
lgnitionswitch ON
0r)
12
BLU/VVHT lgnitionswitch ON
(ll) and main switch
ON; raisethe front of
the vehicle,and
rotateone wheel
s l o w l yw h i l e h o l d i n g
the other wheel
Test:Desiredresult
voltage,
W h e nt e s t i n gt e r m i n a lN o . 6 ,
there should be no voltageon
voltage.
W h e nt e s t i n gt e r m i n a lN o . 7 ,
there should be no voltageon
Checkthe operationof the
actuatormotor: You should
be ableto hear the motor.
Possible
cause
il resultis notobtained
Faultyhorn relay
Faultysevresume/cancel
swrtch
Faultycable reel
An open in the wire
Shon to ground (horn sounds
when button is pressed)
. Faultyactuator
Attachto groundi
C r u i s ei n d i c a t o lri g h ti n t h e
g a u g ea s s e m b l ys h o u l dc o m e
on.
Blown No. 10 (7.5A) fuse in
the under-dashfuse/relaybox
Blown cruise indicatorbulfl
F a u l t yg a u g ea s s e m b l y
An open in the wire
Checkfor voltage between
(+) ANdBLK
thE BLU/VVHT
( )terminals:
T h e r e s h o u l d b e 05 V o r
more repeatedly.
FaultyVSS
An openin thewire
Shortto ground
under-dashfuse/relaybox
Faultymain switch
An oDenin the wire
Faultyclutch pedal position
swtlcn
P o o rg r o u n d( G 5 0 1 )
Incorrectclutchswitch
adjustment
An open in the wire
13
LTGRN
lgnitionswitchoN
{ l l )a n dm a i ns w i t c h
ON
Thereshouldbe battery
voltage.
14
LT BLU
C l u t c hp e d a l
reteaseo
Checkfor continuityto
grouno:
T h e r es h o u l db e c o n t i n u i t y .
N O T E : T h e r se h o u l db e n o
continuitywhen the clutch
oedal is Dressed.
lf any test indicatesa problem,find and correctthe cause,then recheckthe system.lf all the input tests prove OK,
the cruisecontrol unit may be faulty. Substitutea known-goodcruisecontrol unit and retest.lf the system works
properly,replacethe cruisecontrol unit.
4-41
CruiseControl
Main Switch Test/Replacement
Set/Resume/Cancel
Switch Test/
Replacement
1 . Removethe driver's dashboardlower cover (see
page 20-59).
1. Removethe two screws.then removethe switch.
Releasethe clips of the main switch and push the
main switch 1A)out of the panel,then disconnect
the 5P connector(B)from the main switch.
Checkfor continuitybetweenthe terminalsin each
switch positionaccordingto the table.
switch positionaccordingto the table. lf the
continuityis not as specified,replaceillumination
bulbs (C)or the switch.
\-------11v1
ON
Terminal
'\
\
1
Position
OFF
. lfthere is continuity,and it matchesthe table, but
switchfailure occurredon the cruisecontrol unit
input test, checkand repairthe switch circult.
. lf there is no continuityin one or both positions,
replacethe switch.
(9
o @ o \J
4
@
o
2
;"itl*
sET(ONt
CF
RESUME
ION)
o
o
CANCEL{ON}
--o
--o
r\--
4-42
CruiseControlActuatorTest
1. Disconnectthe 4P connector(A) from the cruise
control actuator(B).
6. Checkthe operationof the actuatormotor in each
output linkagepositionaccordingto the table.You
should be able to hear the motor.
Batterypower
Dolarities
Output linkageposition
FULt MIDDLEFUtL
OPEN
CLOSE PO$TION
The
The
The
No.3
No,4
Terminal Terminal motor motor motor
runs. runs. stoDs,
The
The
The
No.3
N o .4
Terminal Terminal motor motor motor
sIoos. runs. runs.
OUTPUTLINKAGE
2. Removethe cover (A),and checkthe output linkage
(B)for smooth movement.
,to
FULLCLOSE
1 . lf the actuatormotor does not operateas specified,
replacethe cruisecontrol actuatorassembly,
Connectbatterypower to the No, 2 terminal and
g r o u n dt o t h e N o . 1 t e r m i n a l .
C h e c kf o r a c l i c k i n gs o u n df r o m t h e m a g n e t i cc l u t c h .
The output linkageshould be locked.
5 . lf the output linkageis not locked,replacethe
cruisecontrol actuatorassembly,
4-43
CruiseControl
CruiseControlActuator/CableReplacement
1 . Fully open the cruisecontrol link by hand,then
removethe cruisecontrol cable{A) from link.
Loosenthe locknut(B),and removethe cablefrom
the bracket.
2 . Disconnectthe 4P connector,and removethe three
3 . Removethe actuatorcover (A),then removethe
actuatorcable (B)from the cruisecontrol actuator.
4 . Installin the reverseorder of removal,and adjust
the free play at the throttle linkageafter connecting
the actuatorcable.
bolts securingthe cruisecontrol actuator.
6x1,0mm
12 N.m (1.2kgf.m,8.7lbf.ft)
\rla
4-44
ActuatorCableAdiustment
1. Checkthat the actuatorcable{A) moves smoothly
with no binding or sticking.
ClutchPedalPositionSwitch Test
1. Disconnectthe 2P connectorfrom the clutch pedal
positionswitch (A),
SWITCH2PCONNECTOR
CLUTCHPEOALPOSITION
T e r m i n a l s i do
ef
m a l et e r m i n a l s
2. Startthe engine.
3. Measurethe amount of movementof the output
linkage(B) until the engine speedstartsto increase.
At first, the output linkageshould be locatedat the
fully closedposition(C).The free play (D)should be
3 . 7 5 1 0 . 5m m ( 0 . 1 5 1 0 . 0 2i n , ) .
4. lf the free play is not within specs,loosenthe
locknut(E).and turn the adjustingnut (F)untilthe
free play is as specified,then retightenthe locknut
Removethe clutch pedal positionswitch.
Checkfor continuitybetweenthe terminals
accordingto the table.
. lf the continuityis not as specified,replacethe
clutch pedal positionswitch.
. lf OK, installtheclutch pedal positionswitch and
adjustthe pedal height (seepage 12-4).
Terminal
Cl"t"h P"d"l I
PositionSwitch
1
2
o
o
PRESSED
RELEASED
4-45
EngineAssembly
EngineRemoval
FrontsubframeadapterEOS02C00001
1
I
NOTE:
. Usefender coversto avoid damagingpainted
surfaces.
. To avoid damage,unplug the wiring connectors
carefullywhile holdingthe connectorportion.
. Mark all wiring and hosesto avoid misconnection.
Also, be sure that they do not contactother wiring or
hoses,or interferewith other parts.
\,
6. Disconnecttheintakeairtemperature(lAT)sensor
connector(A),removethe breatherhose (B)and
v a c u u mh o s e( C ) ,t h e n r e m o v et h e a i r c l e a n e r
housingcover/intakeair duct assemblv(D).
1. Securethe hood in the wide open position(support
rod in the lower hole).
2. Make sure you have the anti-theftcode for the radio,
presetbuttons.
4. Removethe battery.
5. Removethe intakemanifoldcover.
II
5-2
A
C
7 . R e m o v e t h e a i r c l e a n e rh o u s i n g .
8. Removethe intakeair duct.
10. Fullv ooen the throttle link and cruisecontrol link
by hand,then removethe throttlecable (A) and
c r u i s ec o n t r o lc a b l e( B ) f r o mt h e l i n k s .L o o s e nt h e
locknuts{C),and removethe cablesfrom the
bracket.
9. Removethe batterycables{A) fromthe under-hood
fuse/relaybox. then removethe harnessclamp (B)
a n d g r o u n dc a b l e( C ) .
1 1 . R e l i e v e f u epl r e s s u r e( s e ep a g e1 1 - 1 4 4 ) .
1 2 . R e m o v et h ef u e ll i n e ( s e e p a g e l l - 1 4 9 ) .
13. Removethe evaporativeemission(EVAP)canister
hose {A) and brakeboostervacuum hose (B).
(cont'd)
5-3
EngineAssembly
..4,
EngineRemoval(cont'dl
1 4 . R e m o v et h e c l u t c hs l a v ec y l i n d e r{ A )a n d c l u t c h l i n e
bracketmounting bolt (B).
16. Disconnectthe engine control module (ECM)
connectors(A) and main wire harnessconnector
(B).
15. Removethe shift cable (A) and selectcable (B).
't7. Remove
the harnessclamps (A) and grommet (B),
t h e n p u l l t h ee n g i n ew i r e h a r n e s st h r o u g ht h e
bulkhead.
\l,
5-4
1 8 .Removethe drive belt (seepage 4-26).
30. Disconnectthe air fuel ratio {4,/F)sensorconnector
(A) and secondaryheatedoxygen sensor
(secondaryHO2S)connector(B),then removethe
three way catalyticconverter{TWC)assembly{C).
1 9 .R e m o v et h e l v C l i n e m o u n t i n gb o l t .
20. Removethe radiatorcap.
2 1 . R a i s et h e h o i s tt o f u l l h e i g h t .
22. Removethe front tires/wheels.
3 1 . R e m o v et h e l o w e rh o s e .
23. Removethe splashshield.
o@
2 4 . L o o s e nt h e d r a i np l u g i n t h e r a d i a t o r t od r a i nt h e
enginecoolant(seepage 10-6).
2 5 . D r a i nt h e t r a n s m i s s i ofnl u i d ( s e ep a g e1 3 ' 3 ) .
26. Drainthe engineoil {seepage8-5).
2 7 . D i s c o n n e ct h
t e s t a b i l i z el ri n k s( s e ep a g e1 8 - 1 8 ) .
28. Disconnectthe suspensionlower arm ball joints
( s e es t e p3 o n p a g e1 8 - 1 9 ) .
29. Removethe driveshafts{seepage 16-3).Coat all
precision
f i n i s h e ds u r f a c e sw i t h c l e a ne n g i n eo i l .
Tie plasticbags over the driveshaftends.
(cont'd)
5-5
EngineAssembly
EngineRemoval(cont'd)
32. Lowerthe hoist.
33. Removethe upperhose(A)andheaterhoses(B).
34. Bemovethe radiator(seepage 10-10).
35. Attachthe chain hoist to the engine as shown.
5-6
36. Removethetransmission
mountbracketsupport
boltandnuts.
37. Removethe upperbracketmountingboltandnut.
(.g
\a
Make sure the hoist bracketsare positioned
properly.Raisethe hoist to full height.
41. Attachthe subframeadaptertofrontofthe
subframe,
thentightenthe knurledknob.
39. Removethe rear mount mounting bolts.
Raisethe jack. Line up the slots in the arms with the
bolt holeson the corner of the jack base,then
attachthe adaDterto the iack basewith the bolts.
40. Removethefrontmountbracketmountinqbolt.
(cont'd)
5-7
EngineAssembly
EngineRemoval(cont'd)
43. Use a markerto make alignmentmarks on the
referencelines(A) that align with the centersof the
r e a rs u b f r a m em o u n t i n gb o l t s( B ) .
,
!:_- _l.=
:r
--
---.-','-
45. Disconnectthe compressorclutchconnector(A),
then removethe Ay'Ccompressor(B)without
disconnectingthe A'./Choses.
-
ffi4
ffit'"
46. Checkthat the engine/transmission
is completely
free of vacuum hoses,fuel and coolanthoses,and
e l e c t r i c awl i r i n g .
4 7 . S l o w l yl o w e rt h e e n g i n ea b o u t1 5 0m m ( 6 i n . ) .
C h e c ko n c ea g a i nt h a t a l l h o s e sa n d w i r e sa r e
disconnectedtrom the engine/transmission.
48. Lowerthe engineall the way. Removethe chain
hoistfrom the engine.
4 9 . Removethe enginefrom under the vehicle.
44. Removethe front subframe(C).
5-8
Enginelnstallation
FrontsubframeadapterEOS02C00001
1
1. lnstallthe accessorybrackets,and tighten their bolts and nuts to the specifiedtorques.
ENGINEMOUNTBRACKET
1 0x 1 . 2 5m m
il4 N.m {4.5kgf.m,33lbl.ft)
A/C COMPRESSOR
BRACKET
10 x 1,25mm
44 N.m {4.5kgf.m,33lbt.ft)
(cont'dl
5-9
EngineAssembly
EngineInstallation(cont'd)
Positionlhe engine under the vehicle.Attachthe
chain hoistto the engine,then lift the engine into
p o s i t i o ni n t h e v e h i c l e .
5. Installthe subframe(A).Alignthe reference
marks
(B)on the subframewiththe centerof the bolt
h e a d st ,h e nt i g h t e nt h eb o l t s .
Reinstallthe
m o u n t i n gb o l t s / s u p p o rntu t si n
the sequencegiven. Failureto follow this
sequencemay causeexcessivenoiseand
vibration,and reducebushinglife.
- - -.'.: -
--=---=--
.-€..'tt-
---:- -
3. Installthe A,/Ccompressor(A),and connectthe
compressorclutchconnector{B).
6r"
F
1 4 x 1 . 5m m
103Nm
{ 1 0 , 5k g f m .
76 rbt.ftl
Replace.
I
6-_-'-
6. Tightenthe rear mount mounting bolts.
8 x 1.25mm
22 N.m 12.2kgf m. 16 lbf.ft)
4. Supportthe subframewith the subframeadapter
a n da j a c k .
l 0 x 1 . 2 5m m
59 N.m (6.0 kgf.m, 4:] lbI.ft)
5- 10
7. Looselytightenthe front mount bracketmounting
bolt.
10. Tightenthe transmissionmount bracketsupport
bolt and nuts.
1 2x 1 . 2 5m m
54 N m {5.5kgt m, 40 lbf.ft}
8 . Lower the hoist.
9 . Tightenthe upper bracketmounting bolt and nut.
'l '1.
Raisethe hoistto full height.
' t 2 . Tighten
the front engine mount bracketmounting
bolt.
12x 1.25rnrn
64 N.m{6.5kgf.m,
47 tbt.ftl
:l
13. Lower the hoist.
1 4 . R e m o v et h e c h a i nh o i s tf r o m t h e e n g i n e .
'15.
I n s t a l l t h er a d i a t o r( s e ep a g e1 0 - 1 0 ) .
'16.
R a i s et h e h o i s tt o f u l l h e i g h t .
17. Installa new set ring on the end of each driveshaft,
then installthe driveshafts.Make sure each ring
"clicks" into place in the differentialand
intermediateshaft.
(cont'd)
5-11
EngineAssembly
EngineInstallation{cont'dl
1 8 . Connectthe suspensionlower arm ball joints (see
s t e p6 o n p a g e1 8 - 1 9 ) .
1 9 . Connectthe stabilizerlinks (seepage 18-18).
2 3 . I n s t a l l t h es p l a s hs h i e l d .
.
-t-
-- -
-- --r
20. Installthe three way catalyticconverter(TWC)
assembly(A);use new gaskets(B) and new selflockingnuts {C).
10x 1.25mm
33 N.m{3.i1kgf.m,
25 tbt.ftl
24. Lowerthe hoist.
25. I n s t a l l t hder i v eb e l t .
26. InstalltheA,/Clinemountingbolt.
6 x '!.0mm
9.8 N.m (1.0kgf.m,
7.2 tbt.ftl
-d
,ry
6\
\
8 x 1.25mm
22N.m |.2.2kglm,
16tbt.ft)
D
2 1 . Connectthe air fuel ratio (4,/F)sensorconnector(D)
and secondaryheatedoxygen sensor(secondary
HO2S)connector(E).
Installthe lower radiatorhose.
v
5-12
a
27. lnstallthe upper radiatorhose {A) and heaterhoses
(B).
30. Connectthe ECI\4connectors(A) and main wire
harnessconnector(B).
Pushthe enginecontrolmodule(ECM)connectors
through
t h eb u l k h e a tdh, e ni n s t a l l t hger o m m e(tA ) .
3 1 .Installthe throttlecable (seepage 11-164),then
a d j u s t t h ec a b l e{ s e ep a g e1 1 - ' 1 6 3 ) .
3 2 . Installthecruisecontrol cable (seepage 4-44),then
adjustthe cable (seepage 4-45),
33. Installthe brakeboostervacuum hose (A) and the
evaporativeemission(EVAP)canisterhose (B).
2 9 . I n s t a l l t h eh a r n e s sc l a m p s( B ) .
3 4 . I n s t a l l t h ef u e l l i n e ( s e ep a g e1 1 - 1 5 0 ) .
(cont'd)
5-13
EngineAssembly
EngineInstallation{cont'dl
\"
Installthe selectcable (A) and shift cable(B) using
the plasticwashers(C),washers(D),and new cotter
p i n s( E ) .
6x1.0mm
9.8N.m(1.0kgf.m,
7.2tbl.ftl
37. Installthe batterycables(A) on the under-hood
fuse/relaybox, then installthe harnessclamp (B).
6x1.0mm
12Nm{1.2kgt.m,
8.7rbf.ft)
"-.----->)
"------'6
I n s t a l l t h eg r o u n dc a b l e( C ) .
3 9 . I n s t a l l t h ei n t a k ea i r d u c t .
6x1.0mm
12Nm{1.2kgf.m,
8.7 tbf.ft)
I n s t a ltlh e c l u t c hs l a v ec y l i n d e r( A )a n d c l u t c hl i n e
bracketmounting bolt (B).
8 x '1.25mm
24 N.m (2.4kgl.m,
5-14
6x1.0mm
9.8 N.m
{1.0kgf.m,
7.2 tbt.ft)
a
\-
4 0 . I n s t a ltlh e a i r c l e a n e rh o u s i n q .
4 3 . I n s t a l l t h ei n t a k em a n i f o l dc o v e r .
6x1.0mm
12 N m (1.2kgf.m,8.7lbt.ft)
6x1.0mm
12Nm11.2kgf.m.
8.7 tbf.ft)
E
4 1 . I n s t a ltl h e a i r c l e a n e rh o u s i n gc o v e r( A )a n d
connectthe intakeair temperature(lAT)sensor
connector(B),
Y
44. Installthe battery.Cleanthe batterypostsand
c a b l et e r m i n a l sw i t h s a n d p a p e rt ,h e n a s s e m b l e
them and apply greaseto preventcorrosion.
]tE
Checkthat the transmissionshifts into gear
smoothly.
46. Inspectfor fuel leaks.Turn the ignition switch ON
(ll) {do not operatethe starter)so that the fuel pump
runs for about 2 secondsand pressurizesthe fuel
line. Repeatthis operationtwo or three times, then
checkfor fuel leakageat any point in the fuel line.
41. R e f i l l t h ee n g i n ew i t h e n g i n eo i l ( s e ep a g e8 - 5 ) .
48. R e f i l tl h e t r a n s m i s s i ow
n i t h f l u i d ( s e ep a g e1 3 - 3 ) .
4 9 . Refillthe radiatorwith enginecoolant,and bleed
air from the cooling system with the heatervalve
o p e n ( s e ep a g e1 0 - 6 ) .
4 2 . I n s t a l l t h eb r e a t h e hr o s e( C )a n d v a c u u mh o s e1 D ) .
5 0 . P e r f o r mt h e e n g i n ec o n t r o lm o d u l e( E C M )i d l el e a r n
5 1 . Inspectthe idle speed (seepage 11-138).
52. I n s p e ctth e i g n i t i o nt i m i n g ( s e ep a g e4 - 1 7 ) .
5 3 . C h e c kt h e w h e e la l i g n m e n {t s e ep a g e1 8 - 4 ) .
54. Enterthe anti-theftcode for the radio,then enter
55. Set the clock.
5-15
\
EngineMechanical
CylinderHead
SpecialTools
6-2
Comoonent
LocationIndex
6-3
EngineCompression
Inspection
b-t'
VTECRocker
Arm Test ...........
............
6-7
VTCActuatorInspection
....................
6-8
ValveClearance
Adjustment
.............
6-9
Crankshaft
PulleyRemovaland Installation..............
6-11
C a mC h a i nR e m o v a l
. . . . . . . . . . . . . . . . . . .6. -. 1
. .2. . . .
C a mC h a i nI n s t a l l a t i o n
. . . . . . . . . . . . . . . .6. .-.1. .5. .
Auto-Tensioner
Removal/1nsta11ation
.........................
6-19
ChainCaseOil SealInstallation
........6-21
CyfinderHeadCoverRemoval
..........
6-22
CylinderHeadRemoval
.....................
6-23
WC Actuator.ExhaustCamshaftSorocket
R e paf c e m e n t
.........6-24
Head
Cylinder
Inspection
for Warpage......................
6-25
Rocker
Arm AssemblyRemoval.................................
6-26
Rocker
ArmsandShafts
..............
6-27
Rocker
ArmsandShaftsInspection............................
6-28
Camshaft
Inspection
..........................
6-29
Valves,Springs,andValveSealsRemoval................
6-31
ValveInsoection......................
...........
6-32
ValveStem-to-Guide
Clearance
Insoection...............
6-32
ValveGuideReolacement
.................
6-33
ValveSeatReconditioning
................
6-35
Valves,Springs,
andValveSealsInstallation............
6-37
Rocker
Arm AssemblvInstallation
.... 6-38
C v l i n d eHr e a dI n s t a l l a t i o.n. . . . . . . . . . . . . . . . . . . . . . . . . . . .6. -. 3
. .9. . . . . . . . . .
CylinderHeadCoverInstallation
......6-41
CylinderHead
a
SpecialTools
O
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o
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O
tro
@
(D
I
ozoa
I oz..rae-oot
07JAB-0010204
07NAB-0010404
07VAE-001010A
OTZAJ.PNAAlOO
OTZAJ-PNAA2OO
I 07ZAJ-PNAA300
07742-0010100
07746-001o4oo
07749-0010000
-
l-:
,.
''
,.-/
a:-t'"
,)
r--\
Lq-,
',..)-)--'
-
o
- 1jr-
r-
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..'.,i2
.<:'':'v''
5'r'
a
o
..#
..a:-"
- -- -i
'a- ti--
@
,-
1
1
1
1
1
1
2
1
1
Regulator
Air Pressure
V a l v eG u i d eR e a m e r5, . 5m m
Socket,19 mm
H o l d e rH a n d l e
HolderAttachment,50 mm
Valve Spring CompressorAttachment
VTECAir Adapter
VTECAlr Stopper
Air Joint Adapter
V a l v eGu i d eD r i v e r , 5 . 5m m
Driver
OTAAJ.PNAA'IOO
OTHAH-PJ7O1OB
--
Oty
Description
Tool Number
Ref. No.
/":
l?
-- -'''
't'tY-,l
a,/'/'
@
6-2
OD
@
ComponentLocationlndex
IGNITIONCOIL
COVER
CYLINDER
HEAD
COVER
page6-22
Removal,
page6-41
lnstallation,
CAM CHAIN
Bemoval,page6-'12
Installation,page6-15
frn
"p
CAM CHAINGUIDEB
| ] t J,
CAM CHAINGUIDEA
VALVE
VARIABLE
TIMINGCONTROL
twc) olL soLENotD
VALVE
PULLEY
CRANKSHAFT
R e p l a c e m e npt a
, g e6 1 1
TENSIONER
ARM
AUTO.TENSIONER
page6-'lI
Replacement,
O-RING
(cont'd)
6-3
CylinderHead
ComponentLocationIndex(cont'd)
CAMSHAFT
HOLDER
Fg
Y f\
R
LI T
fr
F]
CAMSHAFTPOSITION
ICMP}SENSOR
EEI
g-----
CAMCHAIN
GUIDEB
/
-"-oowetew
TOPDEADCENTER
(TDC)SENSOR
EXHAUSTCAMSHAFT
SPROCKET
Removal,page6 24
page6-25
Installation,
EXHAUSTCAMSHAFT
ROCKER
ARM
ASSEMBLY
Overhaul,page6 27
Inspection,page 6-28
6-4
.\
ll"
--€.i
SPRING
RETAINER
vALvE
EXHAUSTVALVE
SEAL
/
.""or", uo.u,
v
,H
>il(
d:l.\
aFl
T1
l l
l* I / uo.ur.r","o l l
H
\ l gg
| |
II
vALVE
-/ TNTAKE
^-'--
I I
U-
tl
Y
EI 1.U
spntruc
.--
G\-r_
9E4L
Replacement,
Page6-31
H e ,
|NTAKEVALVE
GUIDE
page6-33
Replacement,
_-/
i
,p
2bw
9)
\*""'RArNERcovER
wcsrRArNER
\
HEATSHIELD
HEAD
CYLINDER
Removal,page6'23
Inspection,page6-25
EXHAUSTVALVE
Removal,page6-31
INTAKEVALVE
Removal,page6 31
Installation,page6 37
CYLINDER
HEAD
GASKET
6-5
CylinderHead
EngineCompressionInspection
1 . W a r m u p t h e e n g i n et o n o r m a lo p e r a t i n g
temperature(coolingfan comes on).
\
9 . Open the throttlefully, then crankthe enginewith
the startermotor and measurethe compression.
3. Removethe intakemanifoldcover (seestep 1 on
page6-22).
Compression Pressure
Above 930 kpa (9.5 kgf/cm', 135 psi)
1 0 .Measurethe compressionon the remaining
cylinders,
4, Disconnectall four injectorconnectors.
Maximum vadation
Within 200 kPa (2.0 kgf/cm', 28 psi)
5. Startthe engine,and let it run until it stalls.
6 . R e m o v et h e i o u r i g n i t i o nc o i l s( s e ep a g e4 - 1 8 ) .
7. Removethe four spark plugs.
8. Attachthe compressiongaugeto the spark plug
note.
1 1 .lf the compressionis not within specifications,
checkthese items,then remeasurethe
compressron.
.
.
.
.
Damagedorworn valvesand seats
Damagedcylinder head gasket
Damagedor worn piston rings
Damagedorworn piston and cylinderbore
\-
V,
6-6
WEC RockerArmsTest
. Air pressureregulator07AAJ-PNAA100
. VTECair adaoter07ZAJ-PNAA100
. WEC air stoDoer07ZAJ-PNAA200
. Air joint adapter07ZAJ-PNAA300
1. Removethe cylinder headcover (seepage 6-22).
2. Set the No. 1 pistonat top dead center(TDC)(see
step 1 on page6-12).
3. Verify that the intakeprimary rockerarm (A) moves
independentlyof the intakesecondaryrockerarm
(B).
Repeatstep 3 on the remainingintakeprimary
rockerarms with each piston at TDC.When all the
primary rockerarms passthe test, go to step 5.
Checkthat the air pressureon the shop air
compressorgauge indicatesover 400 kPa
(4 kgflcm',57 psi).
6 . Inspectthe valve clearance(seepage 6-9).
7 . Removethe sealingbolt (A)from the relief hole,
and installthe VTECair stopper(B).
OTAAJ.PNAAlOO
D
OTZAJ-PNAA3OO
. lf the intakeprimary rockerarm does not move,
removethe primary and secondaryrockerarms
as an assemblyand checkthat the pistonsin the
secondaryand primary rockerarms move
smoothly.lf any rockerarm needs replacing,
replacethe primary and secondaryrockerarms
as an assemblv,and test.
. lfthe intakeprimary rockerarm moves freely,go
to step 4.
OTZAJ.PNAAlOO
Removethe No. 2 and No. 3 camshaftholder bolts,
and installthe VTECair adapters(C)finger-tight.
Connectthe air joint adapter(D),and air pressure
regulatorwith a 0-100psi gauge (E).
(cont'd)
6-7
CylinderHead
WEC RockerArms Test (cont'dl
'10.
Loosenthe valve on the regulator,and apply the
specifiedair pressure.
Specified air pressure:
290 kPa 13.0kgt/cm', 42 psi)
NOTE:lf the synchronizingpiston does not move
after applyingair pressure;move the primary or
secondaryrockerarm up and down manuallyby
rotatingthe crankshaftclockwise.
1 1 . W i t h t h e s p e c i f i e da i r p r e s s u r ea p p l i e d m
, o v et h e
i n t a k ep r i m a r yr o c k e ra r m ( A ) f o r t h e N o , 1 c y l i n d e r .
The primary rockerarm and secondaryrockerarm
( B )s h o u l dm o v e t o g e t h e r .
lf the intakesecondaryrockerarm does not move,
removethe primary and secondaryrockerarms as
an assembly,and checkthat the pistonsin the
primary and secondaryrockerarms move
smoothly.lf any rockerarm needsreplacing,
replacethe primary and secondaryrockerarms as
an assembly,and test.
VTGActuator Inspection
'11.
Removethe cylinder headcover (seepage 6-22lr.
2. Removethe auto-tensioner(seepage6-19).
3. Loosenthe rockerarm adjustingscrewslsee step 2
on page6-26).
4. Removethe camshaftholder (seestep 3 on page 6-
26t.
5. Removethe intakecamshaft.
6, Checkthat the variablevalve timing control (VTC)
actuatoris lockedby turning the VTCactuator
clockwiseand counterclockwise.
lf the VTC actuator
is not locked,replacethe VTCactuator.
7 . S e a lt h e a d v a n c eh o l e s( A ) a n dr e t a r dh o l e s( B )i n
the No. 1 camshaftjournal with tape.
Puncha hole through the tape over one of the
advanceholes.
1 2 .Removethe specialtools.
1 3 .Tightenthe camshaftholder mounting boltslo
22N m 12.2kgf.m, 16 lbf.ft).
1 4 . T i g h t e nt h e s e a l i n gb o l t t o 2 0 N . m ( 2 . 0k g f . m ,
14 tbf.ft).
t5.
6-8
I n s t a l l t h ec y l i n d e rh e a dc o v e r( s e ep a g e6 - 4 1 ) .
ValveGlearanceAdiustment
9. Apply air to the advancehole to releasethe lock.
NOTE:Adjust the valvesonly when the cylinder head
temperatureis lessthan 100'F (38'C).
1. Removethe cylinderhead cover (seepage6-22).
2. Set the No. 1 piston at top dead center(TDC).The
punch mark (A) on the variablevalve timing control
(VTC)actuatorand the punch mark (B)on the
exhaustcamshaftsprocketshould be at the top.
Align the TDC marks (C)on the VTC actuatorand
exhaustcamshaftsprocket.
1 0 .Checkthat the VTCactuatormoves smoothly.lf the
VTC actuatordoes not move smoothly, replacethe
VTC acluator.
{cont'd)
6-9
GylinderHead
ValveClearanceAdjustment (cont'd)
3. Selectthe correctthickness
feelergaugefor the
valvesyou'regoingto check.
Intake: 0.21 0.25mm (0.008-0.010
in.)
Exhaust; 0.28 0.32mm (0.011 0.013in.)
\.
5 . l f y o u f e e lt o o m u c h o r t o o l i t t l e d r a g ,l o o s e n t h e
locknut(A),and turn the adjustingscrew {B) until
the drag on the feelergauge is correct..
Adiustingscrew locations:
EXHAUST
No. 1
No. 1
N o .2
No.3
N o .4
No.4
Tightenthe locknut,and recheckthe clearance.
Repeatthe adjustmentif necessary
7 . Rotatethe crankshaft180"clockwise(camshaft
p u l l e yt u r n s9 0 ' ) .
4. Insertthe feeler gauge {A) betweenthe adjusting
s c r e w( B )a n d t h e e n d o f t h e v a l v es t e m ,a n d s l i d ei t
backand forth; you should feel a slight amount of
d rag.
t.
\-
8. Checkand, if necessary,adjustthe valve clearance
o n N o .3 c y l i n d e r .
6-10
I
CrankshaftPulleyRemovaland
Installation
9. Rotatethe crankshaft180"clockwise(camshaft
pullevturns 90').
. Holder handle07JAB-001020A
. Holderattachment,50 mm 07NAB-001040A
. Socket,19 mm 07JAA-001020,4
or a commercially
a v a i l a b l e1 9 m m s o c k e t
Removal
1. Removefront tires/wheels.
2. Removethe splashshield (seestep 23 on page 5-5).
3 . H o l dt h e p u l l e yw i t h h o l d e rh a n d l e( A )a n d h o l d e r
attachment(B).
B
07NAB-001040A
1 0 .Checkand, if necessary,adjustthe valve clearance
on No.4 cylinder.
1 1 .Rotatethe crankshaft180"clockwise(camshaft
p u l l e yt u r n s9 0 " ) .
el
/
f
/ Srroo.oo,oroo
(or
commercially
available)
/
Removethe bolt with a 19 mm socket(C)and
breakerbar.
1 2 .Checkand, if necessary,adjustthe valve clearance
o n N o .2 c y l i n d e r .
Installthe cylinder headcover (seepage 6-41).
(cont'd)
6-11
CylinderHead
CrankshaftPulleyRemovaland
Installation(cont'dl
CamChainRemoval
a
NOTE:Keepthe cam chain away from magneticfields.
Installation
1. Cleanthe crankshaftpulley (A),crankshaft(B),bolt
(C).and washer (D).Lubricateas shown below.
1. Turn the crankshaftpulley so ils top dead center
( T D C )m a r k( A )l i n e su p w i t h t h e p o i n r e r( B ) .
. .: Clean
O; Lubricate
ll
ll
t[] rL
-'....-----=a
(-,
,
5U-1J
It
t -
2 . Removethe front tires/wheels.
I n s t a l l t h ec r a n k s h a fpt u l l e y ,a n d h o l dt h e p u l l e y
with holder handle(A) and holder attachment{B).
3 . R e m o v et h e s p l a s hs h i e l d .
- , , - - . = . - - - - - _ _ - - _
B
07NAB-0010iroA
\
A
07JAB-001020A
Tightenthe bolt to 245 N.m (25.0kgf.m, 181 tbf.ft)
with a torque wrench and 19 mm socket(C).Do not
use an impactwrench.
5. Removethe cylinder headcover (see page6-22).
6 . R e m o v et h e c r a n k s h a fpt u l l e y( s e ep a g e6 - 1 1 ) .
I n s t a ltl h e s p l a s hs h i e l d( s e es t e p2 0 o n p a g e5 - 1 2 ) .
5 . Install front tires/wheels.
\-
6-12
7. Disconnectthecrankshaftposition(CKP)sensor
connector{A) and variablevalvetiming control
{VTC)oil control solenoidvalve connector(B).
1 1 . R e m o v et h e s i d ee n g i n em o u n tb r a c k e t .
1 2 . R e m o v et h e c h a i nc a s e .
Removethe VTC oil control solenoidvalve (see
s t e p1 o n p a g e1 1 - 1 2 7 ) .
9 . Supportthe enginewith a iack and wood block
u n d e rt h e o i l p a n .
1 0 .Removethe ground cable (A).and removethe
upper bracket(B).
(cont'd)
6-13
CylinderHead
CamChainRemoval(cont'd)
Looselyinstallthe crankshaftpulley.
(
\
16. Removethe auto-tensioner.
1 4 . Turn the crankshaftcounterclockwiseto compress
the auto-lensioner,
1 7 . R e m o v et h e c a m c h a i ng u i d eB .
gffi
llll
t5.
Align the holes on the lock (A) and the autot e n s i o n e (r B ) ,t h e n i n s e na 1 . 5m m ( 0 . 0 6i n . )
diameterpin (C)into the holes.Turn the crankshaft
clockwiseto securethe Din.
U U
a
\-
6 -14
CamChainInstallation
1 8 . R e m o v et h e c a m c h a i ng u i d eA ( A )a n d t e n s i o n e r
a r m( B ) .
t./6. | \
{n$1J;
,o
NOTE:Keepthe cam chain away from magneticfields.
1. Set the crankshaftto top dead center(TDC).Align
the TDC mark {A) on the crankshaftsprocketwith
t h e p o i n t e r( B )o n t h e c y l i n d e rb l o c k .
g"'1 9 . R e m o v et h e c a m c h a i n .
t
Setthe camshaftsto TDC.The punch mark (A) on
the variablevalve timing control {VTC)actuatorand
t h e p u n c hm a r k( B )o n t h e e x h a u s ct a m s h a f t
sprocketshould be at the top. Align the TDC marks
(C)on the VTC actuatorand exhaustcamshaft
sprocKet.
(cont'd)
6-15
GylinderHead
CamChainInstallation(cont'dl
3. Installthecamchainon the crankshaft
sprocket
with thecoloredpiece(A)alignedwiththe punch
mark(B)on the crankshaft
sprocket.
\
{
5 . I n s t a l l t h ec a m c h a i ng u i d eA ( A )a n d t e n s i o n ear r m
(B).
6x1.0mm
1 2N . m
{1,2kgf.m,
8.7 tbf.ftt
'6I
8 x 1 . 2 5m m
22 N.m
12.2kgt.m,
16tbf.ft)
Installthecam chain on the VTCactuatorand
exhaustcamshaftsprocketwith the punch marks
(A) alignedwith the two colored pieces(B).
B
6. Installthe auto-tensi
a
6x1,0mm
12Nm
(1.2kgt.m,8.7 lbf ti)
a
6-16
1 0 .Removeold liquid gasketfrom the chain case
7 , I n s t a ltlh e c a m c h a i ng u i d eB .
8 x 1.25mm
22 N.m
(2.2kgf.m,16lbt.ft)
H4
\ilt
H g
mating surfaces,bolts,and bolt holes.
1 1 .Cleanand dry the chain case mating surfaces.
evenlyto the
Apply liquid gasket.P/N 08718-0009,
cylinder block mating surfaceofthe chain caseand
t o t h e i n n e rt h r e a d so f t h e h o l e s .
q
8. Removethe Dinfrom the auto-tensioner,
Apply liquid gasket
alongthe brokenline.
Apply liquid gasketto the cylinder blockupper
surfacecontactareas(A) on the chaincase.
evenlyto the
1 4 . Apply liquid gasket,PiN 08718-0009,
oil pan mating surfaceof the chain caseand to the
innerthreadsof the holes.
9 . Checkthe chain caseoil sealfor damage.lf the oil
seal is damaged,replacethe chain case oil seal
( s e ep a g e6 - 2 1 ) .
NOTE:Do not installthe parts it 5 minutesor more
have elapsedsinceapplying liquid gasket.lnstead,
reapplyliquid gasketafter removing old residue.
Apply liquid gasket
(cont'd)
6-17
GylinderHead
CamChainInstallation(cont'd)
'15.
Installthe new O-ring(A) on the chain case.Set the
edge of the chain case (B)to the edge of the oil pan
( C ) ,t h e n i n s t a ltl h e c h a i nc a s eo n t h e c v l i n d e rb l o c k
(D).
t
{
I
a
1 6 . l n s t a l l t h es i d ee n g i n em o u n t . b r a c k e t .
NOTE:When installingthe chain case,do not slide
the bottom surfaceon the oil pan mounting surface.
rbf.ft)
',.9
17. Installthe upper bracket(A),then tightenthe bolv
nuts in the numberedseouenceshown.
6 x 1 . 0m m
12 N.m
{1.2kgl m, 8.7 lbf ft}
6x1.0mm
1 2N . m
(1.2kgt.m.8.7lbf.ft)
6x1.0mm
12Nm
(1.2kgf.m,8.7lbf.ft)
1 2 x 1 . 2m
5m
54 N.m
(5.5 kgt m, 40 lbf.ft)
\
1 8 . I n s t a ltl h e g r o u n dc a b l e( B ) .
\-
6-18
Auto-TensionerRemovaU
lnstallation
1 9 . lnstallthe variablevalve timing control (VTC)oil
c o n t r o ls o l e n o i dv a l v e( s e es t e p 1 o n p a g e1 1 ' 1 2 7 ) .
Removal:
20. Connectthe crankshaftposition(CKP)sensor
connector{A) and VTC oil control solenoidvalve
connector(B).
21. Installthe crankshaftpulley (seepage 6-12).
1 . R e m o v et h e c h a i nc a s ec o v e r .
Turn the crankshaftcounterclockwiseto compress
the auto-tensroner.
2 2 . I n s t a l l t h ec y l i n d e rh e a dc o v e r( s e ep a g e6 - 4 1 ) .
2 3 . I n s t a l l t h ed r i v eb e l t .
2 4 . I n s t a l l t h es p l a s hs h i e l d .
€D@
{cont'd)
6-19
GylinderHead
Auto-TensionerRemoval/lnstallation(cont'dl
3. Align the holes on the lock (A) and the autot e n s i o n e (r B ) ,t h e n i n s e r ta 1 . 5m m ( 0 . 0 6i n . )
diameterpin (C)into the holes.Turn the crankshaft
clockwiseto securethe oin.
4. Removethe auto-tensioner.
\
Installation:
1. Installthe auto-tensioner.
6x1.0mm
12 N.m {1.2kgt.m,8.7 lbt.tt)
Remove the pin from the auto-tensioner.
a
\
\-
6-20
ChainCaseOil SealInstallation
Removeold liquid gasketfrom the chain casecover
mating surfaces,bolts,and bolt holes.
SpecialToolsRequired
. Driver07749-0010000
. Attachment,52 x 55 mm 07746-0010400
4 . Cleanand dry the chain casecover mating surfaces.
Apply liquid gasket,P/N 08718-0009,
evenlyto the
chain case mating surfaceof the chain casecover
and to the innerthreadsof the holes.
NOTE:Do not installthe parts if 5 minutesor more
have elapsedsinceapplyingliquid gasket.Instead,
Apply liquid gasket
a l o n gt h e b r o k e nl i n e .
1 . U s et h e s p e c i atl o o l st o d r i v ea n e w o l l s e a l
squarelyinto the chain caseto the specified
i n s t a l l e dh e i g h t .
07749-0010000
2. Measurethe distancebetweenthe chain case
s u r f a c e( A )a n d o i l s e a l1 B ) .
6 . I n s t a l l t h ec h a i nc a s ec o v e r .
Oil Seal InstalledHeight:
3 3 . 0 - 3 3 . 7m m ( 1 . 3 0 -1 . 3 3i n . )
6x1.0mm
1 2N . m
{1.2kgt.m,
8.7 tbf.ft)
33.0 33.7mm
{ 1 . 3 0 1 . 3 3i n . l
6-21
GylinderHead
CylinderHeadCoverRemoval
1. Removethe intakemanifoldcover.
(
\
4, Removethe cylinder headcover
V:t :;t 1
|,'.i/
2. Removethe four ignition coils (seepage 4-'18).
3. Removethe dipstick(A) and breatherhose (B).
(
\-
6-22
GylinderHeadRemoval
NOTE:
. Usefendercoversto avoiddamagingpainted
surfaces.
To avoid damage,unplug the wiring connectors
carefullywhlle holdingthe connectorportion.
To avoid damagingthe cylinderhead,wait until the
enginecoolanttemperaturedrops below 100'F(38"C)
betore looseningthe cylinder head bolts.
Mark all wiring and hosesto avoid misconnection.
Also, be sure that they do not contactother wiring or
hoses,or interferewith other parts.
' 1 .Drainthe
8. Removethe enginewire harnessconnectorsand
wire harnessclampsfrom the cylinder head.
. Enginecoolanttemperature(ECT)sensor
conneclor
. Camshaftposition(Cl\4P)(top dead center(TDC))
sensor B connector
. Camshaftposilion (CMP)sensorA connector
9. Removethe upper radiatorhose (A) and heater
h o s e( B ) .
enginecoolant(seepage 10-6).
2 . Removethe drive belt (seepage 4-26).
3 . Removethe intakemanifold {seepage 9-3).
Removethe air cleanerhousing(seestep 7 on page
5-2t.
5. Removethe water bypasshose (A).
'10.
Removethe harnessholder (A)from the bracket,
then removethe connectingpipe mounting boh {B)
and brakeboostervacuum line mounting bolts {C).
6 . Removethe exhaustmanifold (seepage9-7) .
7 . Removethe cam chain (seepage 6-12).
11. Removethe water bvpasshose (D).
(cont'd)
6-23
CylinderHead
CylinderHeadRemoval(cont'd)
VTCActuator,ExhaustCamshaft
\
SprocketReplacement
Removethe rockerarm assembly(seepage 6-26).
tJ.
Removethe cylinderhead bolts.To prevent
warpage,unscrewthe bolts in sequence1/3turn at
a t i m e ; r e p e a t h e s e q u e n c eu n t i la l l b o l t sa r e
loosened.
CYLINDERHEADBOLTSLOOSENINGSEQUENGE:
Removal:
1 . R e m o v et h e c a m c h a i n( s e ep a g e6 - 1 2 ) .
2. Hold the camshaftwith an open-endwrench,then
loosenthe variablevalve timing control (VTC)
actuatormounting bolt and exhaustcamshaft
sprocketmounting bolt.
1 4 . R e m o v et h e c y l i n d e rh e a d .
I
\
(
Removethe VTC actuatorand exhaustcamshaft
sprocket.
I
6-24
Installation:
1. Installthe VTC actuatorand exhaustcamshaft
sprocket.
CylinderHeadInspectionfor
Warpage
1 , Removethe cylinder head{see page 6-23).
Inspectthe camshaft(seepage 6-29).
2. Apply engineoil to the th readsof the VTC actuator
mounting bolt and exhaustcamshaftmounting bolt,
then installthem.
3. Hold the camshaftwith an open-endwrench,then
tighten the bolts.
Specified torque:
VTC actuator mounting bolt:
1 1 3N . m ( 1 1 . 5k g l . m , 8 3l b l . f t )
Exhaust camshaft sprocket mounting bolt:
72 N m (7.3 kgf.m, 53 lbf.ft)
Checkthe cylinder headfor warpage.Measure
along the edges,and three ways acrossthe center.
. lf warpage is lessthan 0.05mm (0.002in.)
cylinder head resurfacingis not required.
. lf warpage is between0.05 mm (0.002in.) and
0.2 mm (0.008in.),resurfacethe cylinder head.
. Maximum resurfacelimit is 0.2 mm (0.008in,)
basedon a height of 104mm (4.09in.).
Cylinder Head Height;
Standard{New}: 103.95 104.05mm
{4.093 4.096in.}
4 . I n s t a ltl h e c a m c h a i n{ s e ep a g e6 - 1 5 ) .
6-25
CylinderHead
RockerArm AssemblyRemoval
'1.
Removethe cam chain (seepage 6-12).
4 . Removethe cam chain guide B, camshaftholders,
and camshafts.
2 . Loosenthe rockerarm adjustingscrews (A),
A
5 . Insertthe bolts (A) Into the rockershaft holder,then
removethe rockerarm assembly(B).
3. Removethe camshaftholder bolts.To Drevent
damagingthe camshafts,unscrewthe bolts two
turns at a time, in a crisscrosspattern.
CAMSHAFTHOLDERBOLTS LOOSENING
SEOUENCE:
\-
6-26
{
RockerArms and ShaftsDisassembly/Reassembly
NOTE:
ldentifypartsas they are removedto ensurereinstallationin original location.
Inspectthe rockershaftsand rockerarms (seepage 6-28).
The rockerarms must be installedin the same positionsif reused.
When removing or installingthe rockerarm assembly,do not removethe camshaftholder bolts.The bolts will keep
the holders,springsand rockerarms on the shaft.
Priorto reassembling,cleanall the parts in solvent,dry them, and apply lubricantto any contactpoints.
Bundlethe rockerarms with rubber bandsto keeDthem tooetheras a set.
EXHAUSTROCKER
SHAFT
EXHAUSTROCKER
ARM
wASHEB
Yr
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Y
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INTAKE ROCKER
ARM ASSEMBLY
INTAKEROCKERSHAFT
6-27
CylinderHead
RockerArms and ShaftsInspection
1 . Removethe rockerarm assembly(seepage 6-26).
2 . Measurethe diameterof the shaft at the first rocker
location.
\
4. Measurethe insidediameterofthe rockerarm, and
checkit for an out-of-roundcondition.
Rocker Arm-to-Shaflt Clearance:
Standard lNew):
0.025 0.052 mm
lntake:
(0.0010 0.0020in.)
Exhaust:
0.018 0.056mm
(0.0007 0.0022in.)
0.08 mm (0.003in.)
Service Limit:
3. Zero the gauge (A)to the shaft diameter.
5. Repeatfor all rockerarms and both shafts.lfthe
clearanceis over the Ilmit. replacethe rockershaft
and all overtolerancerockerarms. lf any VTEC
rockerarm needs replacement,replacethe rocker
arms (primaryand secondary)as a set.
(
\.
6. Inspectthe rockerarm pistons{A}.Pusheach
p i s t o nm a n u a l l y .
lf it does not move smoothly,replacethe rocker
arm set.
NOTE:Apply oil to the pistonswhen reassembling.
,,,@@
(
6-28
GamshaftInspection
NOTE:Do not rotatethe camshaftduring inspection.
1. Removethe rockerarm assembly(seepage 6-26).
and disassembleit (seepage6-27).
2. Putthe rockershaft holders,camshaft,and
camshaftholderson the cylinderhead,then tighten
the bolts to the specifiedtorque.
Specified torque:
I mm bolis:
22 N.m {2.2kgt m, 16lbf.ft}
6 mm bolts:
12 N.m {1.2kgf.m,8.7 tbf.ftl
6 mm bolts: @, €0, @
3. Seatthe camshaftby pushing it away from the
camshafp
t u l l e ye n d o f t h e c y l i n d e rh e a d .
4. Zero the dial indicatoragainstthe end of the
camshaft,then push the camshaftbackand forth
and read the end play. lf the end play is beyondthe
servicelimit, replacethe camshafthead and
recheck.lf it is still beyondthe servicelimit, replace
thecylinder.
CamshaftEnd Play:
Standard{New}:0.05 0.20 mm
(0.002 0.008in.l
I
I
(cont'd)
6-29
CylinderHead
CamshaftInspection(cont'dl
Unscrewthe camshaftholder boltstwo turns at a
time, in a crisscrosspattern.Then removethe
camshaftholdersfrom the cylinder head.
Lift the camshaftsout of the cylinder head,wipe
them clean.then inspectthe lift ramps.Replacethe
camshaftif any lobes are pitted,scored,or
excessivelyworn,
1 . C l e a nt h e c a m s h a fjto u r n a ls u r f a c e si n t h e c y l i n d e r
head,then set the camshaftsbackin place.Placea
plastigagestrip acrosseachjournal.
Installthe camshaftholders,then tighten the bolts
to the specifiedtorque as shown in step 2.
\
{
\,
I
10. Checkthe total runoutwith the camshaftsupported
on V-blocks,
. l f t h e t o t a l r u n o u to f t h e c a m s h a f its w i t h i nt h e
servicelimit, replacethe cylinder head.
. lf the total runout is beyondthe servicelimit,
replacethe camshaftand recheckthe camshaftto-holderoil clearance.lf the oil clearanceis still
beyondthe servicelimit, replacethe cylinder
neao.
Camshaft Total Runout:
Standard(New):0.03mm (0.001in.) max.
ServiceLimit: 0.04mm {0.002in.)
9 . Removethe camshaftholders.Measurethe widest
portionof plastigageon eachjournal.
. lf the camshaft-to-holder
clearanceis within
l i m i t s ,g o t o s t e p 11 .
clearanceis beyondthe
servicelimit and the camshafthas been replaced,
replacethe cylinder head.
clearanceis beyondthe
servicelimit and the camshafthas not been
replaced,go to step 10.
Camshaft-to-Holder Oil Clearance:
Standard (New):
No. 1 Journal:
0.030 0.069mm
No.2,3,4,5 Journals:
ServiceLimit:
{0.001 0.003in-)
0.060*0.099mm
{0.002 0.004in.)
0 . 1 5m m { 0 . 0 0i6n . )
1 1 . M e a s u r ec a m l o b eh e i g h t .
Cam Lobe HeiohtStandard(New
INTAKE
PRI
3 3 . 9 2 5m m
(1.3356
in.)
2 9 . 6 3m
8m
( 1 . 1 6 6i n8 . )
P R IP
: rimary
C/C:CamChain
EXHAUST
34.092mm
\1.3422in.l
SEC
SEC:Secondary
\-
6-30
Valves,Springs,and ValveSealsRemoval
Special Tools Bequired
Valvespring compressorattachment07VAE-001010A
4 . I n s t a l l t h ev a l v eg u i d es e a lr e m o v e r .
ldentifythe valvesand valve springsas they are
removedso that each item can be reinstalledin its
original position.
1. Removethe cylinder head (seepage 6-23).
2. Using an appropriate-sized
socket(A) and plastic
mallet {B),lightly tap the valve retainerto loosen
the valve keepers.
5 . Removet h e v a l v es e a l .
\
Installthe spring compressor.Compressthe spring,
and removelhe valve keepers.
6-31
GylinderHead
ValveInspection
ValveStem-to-GuideClearance
Inspection
\
1 . R e m o v et h e v a l v e s( s e ep a g e6 - 3 1 ) ,
2 . Measurethe valve in these areas.
lntake Valve Dimensions
A StandardlNewl: 34.85 35.15mm
{ 1 . 3 7 2 1 . 3 8 4i n . l
B Standard{Newl: 108.7- 109.5mm
14.280-4.311in.)
C StandardlNew): 5.475 5.485 mm
1 0 . 2 1 5 6 - 0 . 2 1 5i n9 . )
C ServiceLimit:
5.445mm {0.214in.l
ExhaustValve Dimensions
A Standard(New):29.85-30.15 mm
( 1 . 1 7 5 -1 . 1 8 7i n . )
B Standard(New):108.3 109.1mm
(4.264- 4.295 in.l
C Standard(New):5.450 5.460mm
(0.2146 0.2150in.)
C ServiceLimit: 5.42mm (0.213in.)
1 . Removethe valves (seepage6-3'1).
S l i d et h e v a l v eo u t o f i t s g u i d ea b o u t1 0 m m . t h e n
measurethe guide-to-stemclearancewith a dial
indicatorwhile rockingthe stem in the directionof
normal thrust (wobble method).
. l f t h e m e a s u r e m e net x c e e d s t h es e r v i c el i m i t ,
recheckit using a new valve.
. lf the measurementis nowwithin the service
limit, reassembleusing a new valve.
. l f t h e m e a s u r e m e n t w i ta
h n e w v a l v es t i l l
exceedsthe servicelimit, go to step 3.
lntake Valve Stem-to-Guide Clearance:
StandardlNew): 0.06 0.11 mm
{0.002 0.004in.}
ServiceLimil: 0.16mm {0.006in.)
Exhaust Valve Stem-to-Guide Clearance:
S t a n d a r dl N e w l : 0 . 1 1- 0 . 1 6 m m
10.004 0.006in.)
ServiceLimit: 0.22 mm 10.009in.)
.<
4,.
(
3 . Subtractthe O.D.of the valve stem. measuredwith
a micrometer,from the LD. of the valve guide,
m e a s u r e dw i t h a n i n s i d em i c r o m e t eor r b a l lg a u g e .
Takethe measurementsin three placesalong the
v a l v es t e m a n dt h r e ep l a c e si n s i d et h e v a l v eg u i d e .
The differencebetweenthe largestguide
m e a s u r e m e nat n dt h e s m a l l e s st t e m m e a s u r e m e n t
should not exceedthe servicelimit
lntake Valve Stem-to-GuideClearance:
Standard(New):0.030 0.055mm
{0.0012 0.0022in.)
ServiceLimit; 0.08mm (0.003in.l
ExhaustValve Stem-to-GuideClearance:
Standard{Newl: 0.055 0.080mm
(0.0022-0.003rin.l
6-32
t-
I
ValveGuideReplacement
. Valveguidedriver,5.5mm 07742-0010100
. Valveguidereamer,5.5mm 07HAH-PJ7o108
1 . Inspectvalve stem-to-guideclearance(seepage 6-
32t.
As illustratedbelow, use a commerciallyavailable
air-impactvalve guide driver (A) modifiedto fit the
diameterof the valve guides.In most cases,the
same procedurecan be done usingthe specialtool
and a conventionalhammer.
Working from the camshaftside. usethe driver and
an aarhammerto drive the guide about 2 mm (0.1
in.)towardsthe combustionchamber.This will
knockoff some of the carbon and make removal
easier.Hold the air hammer directlyin line with the
valve guide to preventdamagingthe driver.
Turn lhe head over, and drive the guide out toward
the camshaftside of the head.
tT
-_|Jfillr-.-4fi'11.,
10.8mm
{0.,|2in.)
3. Selectthe proper replacementguides,and chill
lhem in the freezersectionof a refriqeratorfor
about an hour.
4. Use a hot plate or oven to evenly heatthe cylinder
headto 300'F (150"C).Monitor the temperature
with a cookingthermometer.Do not getthe head
hotterthan 300'F (150"C);excessiveheat may
loosenthe valve seats.
7 . lf a valve guide won't move, drill it out with a I mm
( 5 / 1 6i n c h )b i t .t h e nt r y a g a i n .D r i l lg u i d e so n l y i n
extremecases;youcould damagethe cylinder
head if the guide breaks.
Removethe new guide(s)from the freezer,one at a
time, as vou needthem.
(cont'd)
6-33
CylinderHead
ValveGuideReplacement(cont'dl
Apply a thin coat of clean engineoil to the outside
of the new valve guide. Installthe guide from the
camshaftside of the head;usethe specialtool to
drive the guide in to the specifiedinstalledheight
( A )o { t h e g u i d e( B ) .l f y o u h a v ea l l 1 6 g u i d e s t od o ,
you may have to reheatthe head.
\
1 0 .Coat both reamerand valve guide with cutting oil.
1 1 .Rotatethe reamerclockwisethe full length of the
v a l v eg u i d eb o r e .
O7HAH.PJ7O1OB
Valve Guide Installed Height:
15.2 16.2mm (0.598-0.638in.)
Intake:
Exhaust: 15.5 16.5mm (0.610-0.650in.)
' - \
Continueto rotatethe reamerclockwisewhile
removing it from the bore.
Thoroughlywash the guide in detergentand water
to remove any cutting residue.
1 4 . C h e c kt h e c l e a r a n c ew
s i t h a v a l v e( s e ep a g e6 3 2 ) .
Verifythat a valve slidesin the intakeand exhaust
valve guideswithout exening pressure.
6-34
ValveSeat Reconditioning
1. Inspectvalve stem-to-guideclearance(seepage 632).lf the valve guidesare worn, replacethem (see
page6-33)beforecuttingthe valve seats.
2 . R e n e wt h e v a l v es e a t si n t h e c y l i n d e rh e a du s i n ga
valve seat cutter.
5. Make one more very light passwith the 45" cutter
to removeany possibleburrs causedby the other
cutters.
Valve Seat Width:
Standard(New): 1.25 1.55mm {0.049 0.061in.)
6. After resurfacingthe seat,inspectfor even valve
s e a t i n gA: p p l y P r u s s i a nB l u ec o m p o u n d( A )t o t h e
v a l v ef a c e .I n s e r t h e v a l v ei n i t s o r i g i n a l o c a t i o ni n
the head,then lift it and snap it closedagainstthe
seat severaltrmes.
3 , C a r e f u l l yc u t a 4 5 ' s e a t ,r e m o v i n go n l y e n o u g h
materialto ensurea smooth and concentricseat.
4 . Bevelthe upper and lower edgesat the angles
shown in the illustration.
Checkthe width of the seat and adjustaccordingly.
INTAKE:35"
EXHAUST:30'
- 45'
, { 67.5'
1 . The actualvalve seatingsurface(B),as shown by
the blue compound,should be centeredon the seat.
. lf it is too high (closerto the valve stem),you
must make a secondcut with the 67.5' cutterto
move it down, then one more cut with the 45"
cutterto restoreseatwidth.
. lf it is too low (closeto the valve edge),you must
make a secondcut with the 35'cutter (intake
sidel or the 30" cutter (exhaustside)to move it up,
then make one more cut with the 45" cutterto
restoreseatwidth.
N O T ET
: h e f i n a lc u t s h o u l da l w a y sb e m a d ew i t h
the 45'cutter.
(cont'd)
6-35
CylinderHead
ValveSeat Reconditioning(cont'dl
(
\
8 . Insen the intakeand exhaustvalves in the head,
and measurevalve stem installedheight (A).
Intake Valve Stem Installed Height:
Standard{New):40.8 41.0mm
( 1 . 6 0 6 1 . 6 1 4i n . )
Exhaust Valve Stem Installed Height:
Standard(New):54.6-54.8 mm
|'2.150-2.157 in.l
L lf valve stem installedheight is over the standard,
replacethe valve and recheck.lf it is still over the
standard,replacethe cylinder head;the valve seat
in the head is too deeD.
\-
\-
6-36
Valves,Springs,and Valve SealsInstallation
Valve spring compressorattachment07VAE-00101
0A
1. Coatthe valve stemswith engine oil. lnstallthe
valves in the valve guides.
2. Checkthat the valves move up and down smoothly.
Installthespring seatson the cylinder head.
l n s t a l l t h ev a l v es p r i n g .P l a c et h e e n d o f t h e v a l v e
spring with closelywound coils toward the cylinder
ne a o .
6 . Installthe valve retainer.
7 . Installthevalve spring compressor,Compressthe
spring, and installthe valve keepers.Removethe
valve spring compressor.
Installthe new valve seals(A) usingthe valve guide
s e a li n s t a l l e(rB ) .
NOTE:The exhaustvalve seal (C)has a blackspring
(D),and the intakevalve seal (E)has a white spring
(F).They are not interchangeable.
Lightlytap the end of each valve stem two or three
times with a plasticmallet (A)to ensureproper
seatingof the valve and valve keepers.Tap the
valve stem only along its axis so you do not bend
the stem.
6-37
CylinderHead
RockerArm AssemblyInstallation
:,ean and dry the No. 5 rockershaft holder mating
surfaces.
\
5 . Removethe bolts from the rockershaft holder.
6 . M a k es u r et h e D U n c hm a r k so n t h e v a r i a b l ev a l v e
eeassemblethe rockerarm assembly(seepage 62 1t .
Apply liquid gasket,P/N 08718-0009,
evenlyto the
:ylinder head mating surfaceofthe No. 5 rocker
shaft holder.
\OTE: Do not lnstallthe partsif 5 minutesor more
r a v e e l a p s e ds i n c ea p p l y i n gl i q u i dg a s k e tI.n s t e a d ,
'eapply liquid gasketafter removingold residue.
timing control (VTC)actuatorand exhaustcamshaft
sprocketare facing up. then set the camshafts(A) in
the holder.
fl
c
I
Apply liquid gasket
Insertthe bolts (A) into the rockershaft holder,then
installthe rockerarm assembly(B)on the cylinder
head.
a
\7 . Set the camshaftholders(B) and cam chain guide B
( C )i n p l a c e .
Tightenthe bolts to the specifiedtorque.
Specified torque:
8 mm bolts: 22 N.m (2.2 kgf.m, 16 lbl.ft)
6 mm bolts: 12 N.m {1.2kgf.m,8.7 lbf.fil
6 mm bolts: @),@.@
lnstallthe cam chain (seepage 6-15).and adjustthe
valve clearance(seepage 6-9).
6-38
l-
{
CylinderHeadInstallation
Installthe cylinder head in the reverseorder of
removat:
5. Measurethe diameterof each cylinder head bolt at
ooint A and DointB.
a 50mm (2.0in.l
1. Cleanthe cylinderhead and blocksurface.
f.f
2. Installthe new cylinder headgasket(A) anddowel
pins (B)on the cylinderblock.Always use a new
cylinder headgasket.
)>-
A '15mm {'1.8in.)
" < > .
l f e i t h e rd i a m e t e ri s l e s st h a n 1 0 . 6m m { 0 . 4 2i n . ) ,
replacethe cvlinder head bolt.
Set the crankshaftto top dead center{TDC).Align
the TDC mark (A) on the crankshaftsprocketwith
the pointer(B)on the cylinderblock.
4. Installthe cylinderhead on the block.
( c o n td )
6-39
CylinderHead
CylinderHeadlnstallation(cont'd)
7 . Apply engine oil to the bolt threadsand under the
b o l t h e a d so f a l l t h e c y l i n d e rh e a db o l t s .
8 . Tightenthe cylinder head bolts in sequenceto 39
\
{
10. Installthe rockerarm assembly{seepage6-38).
1 ' .t Installthe water bypasshose (A).
N.m {4.0 kgf.m,29 lbf.ft).Use a beam-typetorque
wrench.When using a preset-typetorque wrench,
be sure to tighten slowly and do not overtighten.lf
a bolt makesany noisewhile you are torquing it,
loosenthe bolt and retightenit from the first step.
---l.-.
B
6
x1.0mm
'r2
N.m
c
(1.2kgl.m,8.7lbf.ftl
6
x
l
.
0
m
m
'12N,m(1.2kgt.m,8.7
lbf.ft)
9 . After torquing,tighten all cylinderhead bolts in two
steps(90" per step).lf you are using a new cylinder
head bolt,tighten the bolt an extra 90..
1 2 .Tightenthe connectingpipe mounting bolt (B)and
brakeboostervacuum line mounting bolts (C),then
i n s t a l l t h eh a r n e s sh o l d e r( D )o n t h e b r a c k e t .
't3. Installthe
(B).
upper radiatorhose {A) and heaterhose
FIRSTSTEP
SECOND
STEP
v
6-40
GylinderHeadCoverlnstallation
1 4 . I n s t a l l t h ew a t e rb v p a s sh o s e .
1. Thoroughlycleanthe headcover gasketand the
groove.
2. Installthe head cover gasket(A) in the groove of
t h e c y l i n d e rh e a dc o v e r( B ) .
1 5 . I n s t a l l t h ea i r c l e a n e rh o u s i n g( s e es t e p3 7 o n p a g e
5-15).
1 6 . I n s t a l l t h ei n t a k em a n i f o l d( s e ep a g e9 - 5 ) .
1 7 . I n s t a l l t h ee x h a u s tm a n i f o l d( s e ep a g e9 - 7 ) .
Checkthat the mating surfacesare clean and dry.
'18.
I n s t a l l t h ec a m c h a i n ( s e ep a g e6 - 1 5 ) .
on the chain
Apply liquid gasket.P/N 08718-0009,
caseand the No.5 rockershaft holder mating areas.
1 9 . A d j u s tt h e v a l v ec l e a r a n c e( s e e p a g e 6 - 9 ) .
2 0 . I n s t a l l t h ed r i v eb e l t( s e ep a g e4 - 2 6 ) .
have elapsedsinceapplying liquid gasket.Instead,
21. Cleanthe batterypostsand cableterminalswith
s a n d p a p e rt h
, e n a s s e m b l et h e m a n d a p p l yg r e a s e
to preventcorrosion.
2 2 . A f t e ri n s t a l l a t i o nc ,h e c k t h a t a ltl u b e s ,h o s e s a n d
connectorsare installedcorrectly.
. u r nt h e i g n i t i o ns w i t c hO N
2 3 . I n s p e c t f o r f u elle a k sT
{ll) {do not operatethe starter)so that the fuel pump
line. Repeatthls operationtwo or three times, then
c h e c kf o r f u e l l e a k a g ea t a n y p o i n ti n t h e f u e l l i n e .
24. Refillthe radiatorwith enginecoolant,and bleed
air from the cooling systemwith the heatervalve
open (seepage 10-6).
2 5 . I n s p e ctth e i d l es p e e d( s e ep a g e1 1 - ' 1 3 8 ) .
2 6 . I n s p e ctth e i g n i t i o nt i m i n g ( s e ep a g e4 - 1 7 ) .
(cont'd)
6-41
GylinderHead
CylinderHeadGoverInstallation(cont'd)
Set the spark plug seals(A) on the spark plug tubes.
O n c et h e c y l i n d e rh e a dc o v e r( B )i s o n t h e c y l i n d e r
head,slide the cover slightly backand forth to seat
the head cover gasket.
7. Tightenthe bolts in two or three steps.In the final
s t e p ,t i g h t e na l l b o l t s ,i n s e q u e n c et ,o 9 . 8 N . m ( 1 . 0
kgf.m,7.2 lbf.ft).
8 . I n s t a ltlh e d i p s t i c k( A )a n d b r e a t h e hr o s ei B ) .
Inspectthe cover washers(C).Replaceany washer
that is damagedor deteriorated.
\
\l
6-42
9 . Installthe four ignition coils (seepage 4-'18).
1 0 . Checkthat all tubes, hoses,and connectorsare
installedcorrectly.
1 1 .lnstallthe intakemanifoldcover.
6
x 1 , 0m m
'12
N.m{1.2kgf m.
8.7tbf.ftl
12. After assemblv,wait at least30 minutesbefore
f i l l i n gt h e e n g i n ew i t h o i l .
6-43
EngineMechanical
EngineBlock
. . . . . . . . . .7.-.2.
S o e c i aTl o o l s
C o m o o n e nLto c a t i oInn d e x . . . . . . . . . . . . . . . . . . . . . . . . . . .7. .-.3. . . . . . . . . . .
EndPlay
RodandCrankshaft
Connecting
7-5
..............
InsDection
7-6
......................
Replacement
Main
Bearing
Crankshaft
7-8
RodBearingReplacement......................
Connecting
. . . . . . . .7. .- 1 1
O i lP a nR e m o v a .l . . . . . . . . . . . . . . . . . . . . . .
........7-12
Piston
Removal
and
Crankshaft
7-14
........................
Inspection
Crankshaft
. . . . . . . . . . . . . . . . . . . . . . . . . . .7.-. 1. .5. . . . . . . . .
B l o c ka n dP i s t o nI n s o e c t i o n
. " . . . . . . . . . . . . .7. -. .' 1. .7. .
C y f i n d eHr o n i n g. . . . . . . . . . . .
7-18
..........
RodReplacement
Piston,PinandConnecting
7 -21
...................
PistonRingReplacement
7-23
...........
Pistonlnstallation....................
7 -24
.......'
Inspection
Rod
Bolt
Connecting
7-24
.....................'.
lnstallation
Crankshaft
. . . . . . . . .7.-.2 7
O i lP a nl n s t a l l a t i o .n. . . . . . . . . . . . . . . . .
Seal
EndCrankshaft
Transmission
........'7-28
Car ...................
lnstallation-ln
EngineBlock
SpecialTools
Ref.No.
6
@
Tool Number
OTZAD-PNAAlOO
07746-0010700
07749,0010000
Description
Oil Seal DriverAttachment96
Driver
\
{
\
{
Oty
1
1
1
I
o
{
7-2
BAFFLEPLATE
LOWERBLOCK
fr
"
fi E
8
-4
MAINBEARINGS
O i l c l e a r a n cpea,g e7 - 6
page7-6
Selection,
I
FLYWHEEL
CRANKSHAFT
OILSEAL.
END
TRANSMISSION
Installation,
step21on page7-26
THRUSTWASHERS
CRANKSHAFT
End play,page7-5
R u n o u t p, a g e7 - 1 4
page7-14
Out-of-Round,
Removal,page7-12
lnstallation,page7-24
(cont'd)
7-3
EngineBlock
/^.,
D-><
Y1
rkrej,
ffil
\
|
l-"t
nrrucs
_,-ersroru
Benlacement. 7-21
rG\ AalQ
[=l
ôJ
PISTON
Removal,page7-'12
Measurement,page7-15
CONNECTINGROD
End play, page7-5
Small end measurement,page7-19
Page
I
f,
\
PISTONPIN
Removal,page7-18
I n s p e c t i o np ,a g e7 - 1 9
Installation,page7,20
6
\
ENGINEBLOCK
Cylinderbore inspection,page7-'15
Warpageinspection,page7-15
C y l i n d e br o r eh o n i n g ,p a g e1 - 1 1
Ridgeremovai,step 13 on page7-13
CONNECTINGROD
CONNECTINGROD BOLT
page7 24
lnspectaon,
7-4
(
ConnectingRod and CrankshaftEnd PlayInspection
1 . Remove
the oil pump(seepage8-9).
Removethe baffleplates(seestep6 on page1 -12).
3. Measurethe connectingrod end play with a feeler
gauge betweenthe connectingrod and crankshaft.
ConnectingRod End Play
Standard{New):0.15 0.30mm
(0.006-0.012in.l
0.40mm (0.016in.l
ServiceLimit
4 . lf the connectingrod end play is out-of-tolerance,
installa new connectingrod, and recheck.lf it is
replacethe crankshaft(see
still out-of-tolerance,
page 7 -12],.
5. lnstalla dial indicatoras shown. Pushthe
crankshaftfirmly away from the dial indicator,and
zerothe dial againstthe end of the crankshaft.Then
pull the crankshaftfirmly backtoward the indicator;
the dial readingshould not exceedthe servicelimit.
Crankshaft End Plav
StandardlNew): 0.10-0.35 mm
{ 0 . 0 0 4 - 0 . 0 1 4i n . l
replacethe thrust
lf the end play is out-of-tolerance,
washersand recheck.lf it is still out-of-tolerance,
replacethe crankshaft.
7-5
EngineBlock
CrankshaftMain BearingReplacement
MainBearingClearance
Inspection
1. To checkmain bearing-to-journaI oil clearance.
removethe lower block and bearinghalves(see
page 1 -12)..
2 , C l e a ne a c hm a i nj o u r n a la n d b e a r i n gh a l fw i t h a
cleanshop towel.
3. Placeone strip of plastigageacrosseach main
l o ur n a l .
4. Reinstallthe
b e a r i n g sa n d l o w e rb l o c k t, h e nt o r q u e
the bolts to 29 N.m {3.0kgf.m,22 lbf.ft) + 56'.
6. lf the plastigagemeasurestoo wide or too narrow,
removethe crankshaft.and removethe upper half
ofthe bearing.Installa new, completebearingwith
the same color code{s),and recheckthe clearance.
Do not file, shim, or scrapethe bearingsor the caps
to adjustclearance.
7. lf the plastigageshows the clearanceis still
incorrect,try the next largeror smaller bearing(the
color listedabove or below that one),and check
again.lf the proper clearancecannot be obtained
b y u s i n gt h e a p p r o p r i a t e
l a r g e ro r s m a l l e rb e a r i n g s ,
replacethe crankshaftand start over.
NOTE:Do not rotatethe crankshaftduring
Inspeclton.
5 . R e m o v et h e l o w e rb l o c ka n d b e a r i n g sa g a i n ,a n d
measurethe widest part of the plastigage.
Main Bearing-to-Journal
Oil Clearance
N o . 1 , 2 ,4 , 5 J o u r n a l s :
Service Limit:
No.3 Journal:
10.0007 0.0016in.l
0.050mm {0.0020
in.)
Standard{Newl:0.025- 0.049mm
(0.0010 0.0019in.)
ServiceLimit: 0.055mm (0.0022
in.l
\.
7-6
Main BearingSelection
Main Journal Code Location
2. The main journal codesa{e stampedon the
cran kshaft.
Crankshaft Bore Code Location
1. Numbersor lettersor bars have been stampedon
the end of the block as a code for the sizeof each of
the five main journal bores.Write down the crank
bore codes.lf you can't readthe codes becauseof
accumulateddirt and dust, do not scrub them with
a wire brush or scraper.Cleanthem only with
solventor detergent.
No. 5 JOURNAL
END)
{FLYWHEEL
No. 1 JOURNAL
IPULLEYEND}
No. 1 JOURNAL
No. 5 JOURNAL
(cont'd)
7-7
EngineBlock
CrankshaftMain Bearing
Replacement(cont'd)
ConnectingRodBearing
Replacement
3. Usethe crank bore codes and crankjournal codes
to selectthe appropriatereplacementbearings
from the following table.
NOTE:
. Color code is on the edge of the bearing.
. When using bearinghalvesof differentcolors.it
does not matterwhich color is used in the top or
bottom.
Main
iournsl
cooe
1
Crank ---=->
bore | 1or
code IAorl
--
2ot
Borll
Lalgercrankbore
3or
c oi__-l
C o r l l l D o r t t t It
--> Smaller bearing
{Thickerl
Pink f!1f;* v"rro* c,""n
l
2
l
v"no*c,""" $;;fl
f111f;,,"
cr""n $ffi
ero-n
ffi#Tr,.*"
i.,""*
'---l-'o"*,
4
Creen ; g=jiff;i Brown Black
5
;;lT]*Brown
Black 6il;
Brack !l;kr
\
RodBearingClearance
lnspection
1 . R e m o v et h e o i l p u m p ( s e ep a g e8 - 9 ) .
2. Bemovethe baffle plates(seestep 6 on page7-12).
3. Removethe connectingrod cap and bearinghalf.
4 . C l e a nt h e c r a n k s h a frto d j o u r n a la n d b e a r i n g h a l f
with a clean shop towel.
5. Placeplastigageacrossthe rod journal.
6 . R e i n s t a l l t hb
e e a r i n gh a l fa n d c a p ,a n dt o r q u et h e
b o l t st o 2 0 N . m ( 2 . 0k g f . m ,1 4 l b f . f t )- l 9 0 " .
NOTE:Do not rotatethe crankshaftduring
inspection.
7 . R e m o v et h e r o d c a pa n d b e a r i n gh a l f ,a n d m e a s u r e
the widest part of the plastigage.
ConnectingRod Bearing-to-Journal
Oil
Clearance:
(0.0008--0.0020in.l
ServiceLimit:
0.060mm (0.0024in.)
\-
ar*
(Thicker)
{
7-8
8 . lf the plastigagemeasurestoo wide or too narrow,
removethe upper half of the bearing,installa new,
completebearingwith the same color code(s),and
recheckthe clearance.Do not file. shim, or scrape
the bearingsor the capsto adjustclearance.
RodBearingSelection
1. Inspecteach connectingrod for cracksand heat
damage.
Connecting Rod Big End Eore Code Locations
9 . lf the plastigageshows the clearanceis still
incorrect,try the next largeror smaller bearing(the
color listedabove or below that one),and check
clearanceagaln.lf the properclearancecannot be
obtainedby usingthe appropriatelarger or smaller
bearing,replacethe crankshaftand stan over.
2 . E a c hr o d h a sa t o l e r a n c er a n g ef r o m 0 0 . 0 2 4m m
(0.0009in.),in 0.006mm (0.0002in.) increments,
dependingon the sizeof its big end bore. lt's then
s t a m p e dw i t h a n u m b e ro r b a r ( 1 ,2 , 3 o r 4 / 1 l,l , l l l ,o l
l l l l )i n d i c a t i n g
t h e r a n g e .Y o u m a y f i n d a n y
c o m b i n a t i o no f n u m b e r sa n d b a r si n a n y e n g i n e .
( H a l ft h e n u m b e ro r b a r i s s t a m p e do n t h e b e a r i n g
cap,the other half on the rod.)
lf you can't readthe code becauseof an
accumulationof oil and varnish.do not scrub it
with a wire brush or scraper.Cleanit only with
solventor detergent.
Normal Bore Size: 48.0 mm 11.89in.l
(cont'd)
7-9
EngineBlock
ConnectingRod BearingReplacement(cont'dl
Connecting Rod Journal Code Location
3. The connectingrod journalcodesare stampedon
the crankshaft.
Connecting Rod Journal Code Location (Letters or
Bars)
\
{
\
{
4. Use the big end bore codes and rod journalcodes
to selectappropriatereplacementbearingsfrom
the followingtable.
NOTE:
. Color code is on the edge of the bearing.
. When using bearinghalvesof differentcolors,it
does not matter which color is used in the top or
bottom.
Big end ---------->
bore
codo
lorl
Rod
Largerbig end bore
2oJll
3 ol lll
4 orllll
---------> Smallsrb.aring {Thickerl
Pink
Pink/ Yollow/
Yellow Grecn
Green
Green/ Brown
Brown
B
Yellow Yellow/
Green
c
Green
Green/ Erown/
Brown Black
Black
D
Brown
Brown/
Black
Blue
Black/
Blue
(Thicker)
No.l JOURNAL No.4 JOURNAL
{
7-10
OilPanRemoval
1 . Drainthe engineoil (seepage8-5).
5 . C u tt h eo i l p a n s e abl y s t r i k i n g t h e s i d e o f t h e c u t t e r
to slidethecutteralongthe oil pan.
lf the engine is still in the vehicle,removethe
subframe.
-1 Attachthe chain hoistto the engine (seestep
35 on page 5-6).
-2 Disconnectthesuspensionlower arm ball
joints (seestep 3 on page 18-19).
-3 Removethe rear mounl mounting bolts (see
step 39 on page 5-7).
-4 Removethe front mount mounting bolt (see
step 40 on page 5-7).
-5 Use a markerto make alignmentmarks on the
referencelinesthat align with the centersof
the rear subframemounting bolts.Removethe
front subframe(seestep 43 on page 5-8).
6 . R e m o v et h e o i l p a n .
Removethe bolts/nutssecuringthe oil pan.
Drivean oil pan seal cutter betweenthe oil pan and
cylinderblock.
7-11
EngineBlock
Crankshaftand PistonRemoval
1 . R e m o v et h e e n g i n ea s s e m b l y( s e ep a g e5 - 2 ) .
2 . R e m o v et h e t r a n s m i s s i o (ns e ep a g e1 3 - 4 ) .
8. Removethe bearingcap bolts.To preventwarpage,
unscrewthe bolts in sequence1/3turn at a time:
repeatthe sequenceuntil all bolts are loosened.
3 . R e m o v et h e o i l p a n ( s e ep a g e7 - 11 ) .
4. Removethe oil pump {seepage8-9).
5. Removethe cylinderhead (seepage 6-23).
6. Removethe baffle plates.
E
7. Removethe 8 mm bolts.
L Removethe lower blockand bearings,Keepall
bearingsin order.
\
(
7-12
1 0 .Removethe rod caps/bearings.Keepall caps/
b e a r i n g si n o r d e r .
14. Use the wooden handleof a hammer (A)to drive
out the pistons(B).
1 1 .Liftthe crankshaftout ofthe engine,being careful
n o t t o d a m a g et h e j o u r n a l s .
1 5 . Reinstallthe lower block and bearingson the
engine in the proper order,
to.
R e i n s t a l l t h ce o n n e c t i n gr o d b e a r i n g sa n d c a p s
after removingeach piston/connectingrod
assembly.
1 7 .To avoid mixup on reassembly.mark each piston/
connectingrod assemblywith its cylinder number.
Removethe upper bearinghalvesfrom the
connectingrods.and set them asidewith their
respectivecaps.
t.J.
NOTE:The existingnumber on the connectingrod
does not indicateits positionin the engine,it
indicatesthe rod bore size.
lf you can feel a ridge of metal or hard carbon
aroundthe top of eachcylinder,remove it with a
r i d g er e a m e r{ A ) .F o l l o w t h er e a m e rm a n u f a c t u r e r ' s
instructions.lf the ridge is not removed,it may
damagethe pistonsas they are pushedout.
7-13
EngineBlock
Crankshaftlnspection
\
Out-ol-Round and Taper
Straightness
1. Removethe crankshaftfrom the cylinder block(see
page7-121.
2. Cleanthe crankshaftoil passageswith pipe
c l e a n e r so r a s u i t a b l eb r u s h .
6. Placethe cylinder blockon the surfaceplate.
7 . C l e a na n d i n s t a l l t h eb e a r i g n so n t h e N o . 1a n d N o . 5
j o u r n a lo f t h e c y l i n d e rb l o c k .
8. Lowerthe crankshaftinto the block.
3. Cleanthe keywayand threads.
4. Measureout-of round at the middle of each rod and
main journal in two places.The differencebetween
measurementson each journal must not be more
than the serviceIimit.
Journal Out-ot-Round
Standard(New):0.005mm (0.0002in.) max.
ServiceLimit; 0.010mm (0.0004in.)
. o t a t et h e
9 . M e a s u r er u n o u to n a l l m a i nj o u r n a l sR
crankshafttwo completerevolutlons.The
differencebetweenmeasurementson eachjournal
must not be more than the servicelimit.
Crankshaft Total Runout
Standard(New):0.03mm 10.0012
in.l max.
ServiceLimit: 0.04mm (0.0016in.l
(
L
I_JJ
fl
5. Measuretaper at the edgesof each rod and main
journal.The differencebetweenmeasurementson
eachjournal must not be more than the service
limit.
JournalTaper
StandardlNewl: 0.005mm (0.0002in.) max.
{
7- 14
Blockand PistonInspection
1 . Removethe crankshaftand pistons(see pageT -121.
Checkthe pistonfor distortionor cracks,
M e a s u r et h e p i s t o nd i a m e t e ra t a p o i n t I 1 m m { 0 . 4
in.)from the bottom of the skirt.There are two
pistons(No Letteror A, and B).The
standard-size
letteris stampedon the top of the piston.Letters
are also stampedon the blockas cylinder bore
stzes.
Piston Diameter:
Standard(Newl:
No Letter {or A): 85.980 85.990 mm
(3.3850 3.3854in.)
B:
85.970-85.980mm
(3.3846-3.3850in.)
4. Measurewear and taper in directionX and Y at
t h r e el e v e l si n e a c hc y l i n d e ra s s h o w n .l f
measurementsin any cylinder are beyondthe
oversizebore servicelimit. replacethe block.lf the
block is to be rebored,referto step 7 after reboring.
CylinderBore Size
Standard(New):
A or l:
86.010 86.020mm
13.3862 3.3866in.)
B or ll:
86.000 86.010mm
(3.3858 3.3862in.)
Service Limit: 86.070 mm (3.3886in.)
Oversize:
O.25t 96.250 86.260 mm (3.3957 3.3961 in.)
Reboringlimit: 0.25mm (0.01in.l max.
Service Limit:
No Lefter lor A): 85.930mm (3.3831in.)
B:
85.920mm 13.3827in.)
Bore Taper:
Limit: (Differencebetween first and third
measurement)0.05mm (0.002in.)
6 mm {0.2in.}
First
Measurement
Second
Measutement
Third
Measurement
6 mm {0.2in.}
Oversize Piston Diameter:
0.25: 86.230-85.240mm (3.3949-3.3953 in.l
(cont'd)
7-15
EngineBlock
Blockand PistonInspection(cont'd)
Scoredor scratchedcylinderbores must be honed.
Checkthe top of the blockfor warpage.Measure
along the edgesand acrossthe centeras shown.
Engine Block Warpage
StandardlNew): 0.07mm (0.003in.) max.
\
7. Calculatethe differencebetweenthe cylinder bore
diameterand the plstondiameter.lf the clearance
is near or exceedsthe servicelimit, inspectthe
pistonand cvlinder blockfor excessivewear.
Piston-to-Cylinder Clearance
StandardlNew): 0.020 0.040mm
{0.0008 0.0016in.)
++
PISTON-TO-CYLINDER
CLEARANCE
PRECISION
STRAIGHT
EDGE
\
(
7-16
CylinderHoning
Only a scoredor scratchedcylinderbore should be
noneo.
'L
M e a s u r et h e c y l i n d e rb o r e s{ s e ep a g e7 - 1 5 ) .
lf the block is to be reused,hone the cylindersand
remeasurethe bores.
H o n et h e c y l i n d e rb o r e sw i t h h o n i n go i l a n d a f i n e
(400grit) stone in a 60 degreecross-hatchpattern
(A).Use only a rigid hone with 400 grit or finer
stone such as Sunnen,Ammco, or equivalent.Do
not use stonesthat are worn or broken.
3 . W h e n h o n i n gi s c o m p l e t et,h o r o u g h l yc l e a nt h e
engine blockof all metal particles.Wash the
cylinder boreswith hot soapywater,then dry and
oil them immediatelyto preventrusting.Never use
solvent,it will only redistributethe grit on the
c y l i n d e rw a l l s .
lf scoringor scratchesare still presentin the
cylinderboresafter honing to the servicelimit,
reborethe cylinder block.Some light vertical
scoringand scratchingis acceptableif it is not deep
enoughto catchyour fingernailand does not run
the full length of the bore.
7-17
EngineBlock
Piston,Pin,and ConnectingRod Replacement
Disassembly
4 . Heatthe piston and connectingrod assemblyto
about 158'F(70"C),then removethe piston pin.
1. Removethe pistonfrom the cylinderblock (see
page7 -12).
2 . A p p l ye n g i n eo i l t o t h e p i s t o np i n s n a p r i n g s( A ) ,
and turn them in the ring grooves until the end
gaps are lined up with the cutoutsin the piston pin
b o r e s( B ) .
NOTE;Takecare not to damagethe ring grooves.
\
Removeboth snap rings (A).Start at the cutout in
t h e p i s t o np i n b o r e .R e m o v et h e s n a pr i n g s
carefullyso they do not go flying or get lost.Wear
eve protection.
\"
7-18
(
Inspection
NOTE:Inspectthe piston,piston pin, and connecting
rod when they are at room temperature.
1. Measurethe diameterof the piston pin.
3. Checkthe differencebetweenthe DistonDin
d i a m e t e ra n d p i s t o np i n h o l ed i a m e t e ri n t h e p i s t o n .
Piston Pin-to-Piston Clearance
Standard(Newl: -0.005 to +0.002 mm
(-0.00020 to +0.00008 in.)
Piston Pin Diameter
(0.8646-0.8648in.)
ServiceLimit: 21.953mm 10.8643
in.l
4 . Measurethe piston pin-to-connecting
rod clearance.
2. Zerc the dial indicatorto the piston pin diameter.
Piston Pin.to-Connecting Rod Clearance
{0.0002 0.0006in.}
ServiceLimil: 0.02mm (0.0008in.l
v
(cont'd)
7-19
EngineBlock
(cont'd)
Piston,Pin,and ConnectingRodReplacement
Reassembly
1 . I n s t a l al p i s t o np i n s n a pr i n g ( A ) .
\
4. Installthe piston pin (A).Assemblethe piston (B)
and connectingrod (C)with the arrow (D)and the
e m b o s s e dm a r k ( E )o n t h e s a m es i d e . -
Coatthe piston pin bore in the piston,the bore in
the connectingrod, and the piston pin with engine
oil.
3 . Heatthe pistonto about 158"F(70'C).
(
5 . I n s t a ltlh e r e m a i n i n gs n a pr i n g ( F ) .
6 . T u r nt h e s n a pr i n g si n t h e r i n gg r o o v e su n t i l t h e
end gaps are positionedat the bottom of the piston.
I
7 -20
PistonRing Replacement
1. Removethe piston{rom the cylinder block(see
page 7 -121.
4. Using a piston,push a new ring (A) into the
c y l i n d e rb o r e 1 5 - 2 0 m m { 0 . 6 - 0 . 8 i n . )f r o m t h e
bottom.
2. Using a ring expander(A),removethe old piston
r i n g s( B ) .
15 20 mm (0.6 0.8 in.)
I
B
3. Cleanall ring groovesthoroughlywith a squaredoff brokenring or ring groovecleanerwith a blade
to fit the pislon grooves.The top and 2nd ring
g r o o v e sa r e 1 . 2m m ( 0 . 0 5i n , ) w i d e T
. h eo i l r i n g
groove is 2.0 mm (0.08in.) wide. Filedown a blade
lf necessary.Do not use a wire brush to cleanthe
ring grooves,or cut the ring groovesdeeperwith
t h e c l e a n i n gt o o l s .
NOTE:lf the piston is to be separatedfrom the
connectingrod, do not installnew rings yet.
Measurethe piston ring end-gap(B)with a feeler
g au g e :
. l f t h e g a p i s t o o s m a l l ,c h e c k t os e ei f y o u h a v e
t h e p r o p e rr i n g sf o r y o u r e n g i n e .
. l f t h e g a p i s t o o l a r g e ,r e c h e c k t h e c y l i n d ebro r e
diameteragainstthe wear limits (seeslep 4 on
p a g e7 - 1 5 ) .
. l f t h e b o r e i s o v e r t h es e r v i c el i m i t ,t h e c y l i n d e r
block must be rebored.
PistonRing End-Gap
Top Fing
Standard(Newl: 0.20 0.35 mm
(0.008 0.014in.l
ServiceLimit: 0.60mm (0.024in..
SecondRing
Standard(New):0.40-0.55 mm
{0.016 0.022in.)
Oil Ring
REKENmanufacturedring
Standard(Newl: 0.25 0.65 mm
(0.010 0.026in.l
FEDERALMOGUL manufacturedrino
{0.008 0.028in.}
(cont'd)
7-21
EngineBlock
PistonRing Replacement(cont'd)
6. Installthe top ring and secondring as shown.The
t o p r i n g ( A )h a sa 1 R m a r ko r n o m a r ka n dt h e
s e c o n dr i n g ( B )h a sa 2 R m a r ko r 2 N D m a r k .T h e
marks must be facing upward.
\
{
8. Positionthe ring end gaps as shown:
OIL RINGGAP
About 90'
SECONDRINGGAP
About 45"
TOP RINGGAP
and SPACER
RINGGAP
\
\5
=:-=2
V"
12-)
V
P'ffi+a
\aq*-pogd
.ZR,
V
PistonRingoimensions:
|
|
|
|
A-
t
J
o
-
ToPRing{Standardl:
A :3 . 1m m { 0 . 1 2
in.l
in.)
B : 1 . 2m m { 0 . 0 5
SocondRing{Standard):
A : 3 . 4m m { 0 . 1 3
in.}
B:'1.2mm (0.05in.i
7, Rotatethe rings in their groovesto make sure they
do notbind.
7-22
PISTONPIN
9. After installinga new set of rings,measurethe
ring-to-grooveclearances:
o\,"16.
s
OIL RINGGAP
Top RingClearance
Standard {New}:
mm {0.0014-0.0024
in.)
0.035-0.060
ServiceLimit:
0.13mm (0.005in.)
SecondRing Clearance
StandardlNew):
REKENmanutactured ring
in.)
0.030-0.055
mm (0.0012-0.0022
FEDERALMOGUL manulactured ring
0.025-0.060mm (0.0010-0.0024in.)
0.13 mm (0.005in.)
ServiceLimit:
{
PistonInstallation
lf the crankshaftis alreadyinstalled
1. Setthe crankshafttobottom dead center(BDC)for
e a c hc y l i n d e r .
2. Removethe connectingrod caps,then installthe
ring compressor,and checkthat the bearingis
securelyin place,
lf the crankshaftis not installed
1 . Removethe connectingrod caps.then installthe
r i n g c o m p r e s s o ra, n d c h e c kt h a tt h e b e a r i n gi s
s e c u r e l yi n p l a c e .
2. P o s i t i o nt h e a r r o w( A ) f a c i n gt h e c a m c h a i ns i d eo f
Ineengrne.
3. Positionthe arrow {A) facingthe cam chain side of
r n ee n g t n e .
\--lno
\
Positionthe piston in the cylinder,and tap it in
u s i n gt h e w o o d e nh a n d l eo f a h a m m e r( A ) .
N4aintain
downward force on the ring compressor
(B)to preventthe rings from expandingbefore
enteringthe cylinder bore.
^ un\-.--l.
t
Positionthe piston in the cylinder,and tap it in
u s i n gt h e w o o d e nh a n d l eo f a h a m m e r( A ) ,
Maintaindownward force on the ring compressor
(B)to preventthe rings from expandingbefore
enteringthe cylinder bore.
>-*/zi
.,.'_\pf{
wr
(( 'V,/:
Stop afterthe ring compressorpops free, and
checkthe connectingrod-to-crankjournal
alignmentbeforepushingthe piston into place.
4. Positionall pistonsattop dead center.
6 . Checkthe connectingrod bearingclearancewith
plastigage(seepage7-8).
7 . lnspectthe connectingrod bolts (seepage 7 241.
Apply engine oil to the bolt threads,then installthe
rod capswith bearings.Torquethe bolts to 20 N.m
{2.0kgf m, 14 lbf ft) + 90'.
7-23
EngineBlock
ConnectingRod Bolt Inspection
1 . Measurethe diameterof each connectinqrod bolt
at DointA and ooint B.
35 mm
mm
CrankshaftInstallation
(
. Driver07749-0010000
. Attachment,24 x 26 mm 07746-0010700
. Oil seal driver attachment96 o7ZAD-PNAAl00
1 . I n s t a ltl h e c r a n k s h a fet n d b u s h i n gw i t h t h e s p e c i a l
tools when replacingthe crankshaft.Drive in the
c r a n k s h a fet n d b u s h i n gu n t i lt h e s p e c i atl o o l s
bottom aqainstthe crankshaft.
07749-0010000
07746-00'l
Calculatethe differencein diameterbetweenpoint
A a n d p o i n tB .
Point A-Point B = Difference in Diameter
Diflerence in Diameter:
Specification:0 0.1 mm (0 0.004in.)
I
\-
(
3 , lf the differencein diameteris out of tolerance,
replacethe connectingrod bolt.
e ith
C h e c kt h e c o n n e c t i n gr o d b e a r i n gc l e a r a n c w
plastigage{seepage7-8).
C h e c kt h e m a i n b e a r i n gc l e a r a n c w
e ith plastigage
( s e ep a g e7 - 6 ) .
4 . lnspecttheconnectingrod bolts (seepageT-241.
\-
7-24
a
5 . I n s t a l l t h eb e a r i n gh a l v e si n t h e c y l i n d e rb l o c ka n d
conneclrngrods.
12. Tightenthe connectingrod bolts to 20 N.m
(2.0kgf.m, 14 lbf.ft).
6 . A p p l ya c o a to f e n g i n eo i l t o t h e m a i n b e a r i n g sa n d
rod bearings.
13. Tightenthe connectingrod bolts an additional90".
7 . H o l dt h e c r a n k s h a fsto r o d j o u r n a lN o . 2 a n d r o d
journal No. 3 are straightup, and lower the
crankshaftinto the block.
8 . l n s t a l l t h et h r u s tw a s h e r s( A )i n t h e N o . 4 j o u r n a lo f
the cylinder block.
14. Removeold liquid gasketfrom the lower block
mating surfaces,bolts and bolt holes.
15. Cleanand dry the lower block mating surfaces.
16. Apply liquid gasket,P/N 08718-0009,
evenlyto the
cylinderblock mating surfaceof the lower block
a n dt o t h e i n n e r t h r e a d o
s f t h e b o l th o l e s .
.\
,i,
\-1
Apply liquid gasket
alongthe broken line.
9 . Apply engine oil to the threadsot the connecting
rod bolts,
1 0 .Seatthe rod journals into connectingrod No. 1 and
connectingrod No. 4. Line up the mark (B)on the
connectingrod and cap,then installthe caps and
bolts finger-tight.
'11. Rotate
the crankshaftclockwise,and seatthe
j o u r n a l si n t oc o n n e c t i n g
r o d N o . 2 a n dc o n n e c t i n g
rod No. 3. Line up the mark on the connectingrod
and cap, then installthe caps and bolts finger-tight.
(cont'd)
7-25
EngineBlock
CrankshaftInstallation(cont'd)
'17
. Putthe lower blockon lhe cylinderblock.
1 8 . Tightenthe bearingcap bolts in sequenceto
29 N.m (3.0kgf m, 22 lbf.ft).
{
2'1. Use the specialtoolsto drive a new oil seal
squarelyinto the blockto the specifiedinstalled
height.
07749-0010000
07zAo-PNAA100
Measurethe distancebetweenthe crankshaft(A)
a n d o i l s e a l( B ) .
Oil Seal InsialledHeight:
1 9 . Tightenthe bearingcap bolts an additional56".
20. Tightenthe I mm bolts in sequenceto 22 N.m 12.2
kgf m, 16 lbf.ft).
7-26
5.5 6.5 mm
|10.22 0.26 in.l
5.5-6.5 mm
{0.22 0.26in.l
\
{
OilPanlnstallation
23. Installthe baffle plates.
6x1.0mm
1 2N . m
(1.2ksf m, 8.7lbf ft)
1 . Removeold liquid gasketfrom the oil pan mating
surfaces,bolts,and bolt holes.
2 . Cleanand dry the oil pan mating surfaces.
3 . Apply liquid gasket,P/N 08718-0009,
evenlyto the
cylinderblock mating surfaceof the oil pan and to
the innerthreadsof the bolt holes.
2 4 . I n s t a l l t h eo i l p u m p ( s e ep a g e8 - 1 4 ) .
25. Installtheoil pan (seepage7-27).
Apply liquid gasket
26. Installthecylinderhead (seepage 6-39).
27. Installthetransmission(seepage 13-8).
4. I n s t a l l t h eo i l p a n .
28. Installtheengine assembly(seepage 5-9).
5. Tightenthe bolts in two or three steps.In the final
s t e p ,t i g h t e na l l b o l t s ,i n s e q u e n c et ,o 1 2 N . m ( 1 . 2
kgf m, 8.7 lbf.ft).
( } @
(cont'd)
7-27
EngineBlock
Oil PanInstallation(cont'dl
I
TransmissionEndGrankshaftSeal
Installation- In Car
6 . l f t h e e n g i n ei s s t i l l i n t h e v e h i c l e i,n s t a l tl h e
subframe,
- 1 I n s t a l l t h es u b f r a m eA. l i g nt h e r e f e r e n c e
lines
on the subframewith the bolt head center,then
tighten the bolts (seestep 5 on page 5-10).
-2 Tightenthe front mounting bolt (seestep 6 on
p a g e5 - 1 0 ) .
-3 Tightenthe rear mount mounting bolts (see
s t e p7 o n p a g e5 - 1 1 ) .
-4 Connectthe suspensionlower arm ball joints
(seestep 6 on page 18-19).
7. After assembly,wait at least30 minutes before
. Driver07749-0010000
. Oil seal driver attachment 96 07ZAD-PNAA100
'1.
D r y t h e c r a n k s h a fot i l s e a lh o u s i n g .
2. Use the specialtools to drive a new oil seal
squarelyinto the blockto the specifiedinstalled
height.
07749-0010000
/$rRfr4T
tr*W(r
-]t fl\
OTZAD.PNAAlOO
Measurethe distancebetweenthe crankshaft(A)
a n d o i l s e a l( B ) .
Oil Seal InstalledHeight:
5.5 6.5 mm 10.22-0.26in.l
5.5 6.5 mm
l0.22- O.26in .l
v
7-28
a
EngineMechanical
t--l
r_::::-l
EngineLubrication
SpecialTools
Ref. No.
o
Tool Number
07HAA-PJ70100
\
Descriotion
Otv
Oil FilterWrench
I
\-
8-2
WASHER
DRAINBOLT
OILPAN
R e m o v apl ,a g e7 1 1
page7-27
Installataon,
OILPUMP
page8-8
OverhaLrl,
HL]
BAFFLEPLATE
OILPUMP
CHAINTENSIONER
OILCONTROL
ORIFICE
-&\JrI
--t
ksrarr
cKEr
OIL FILTERFEEDPIPE
Replacement,page8-7
N\
lN-?
dczt$)
# 1
\
OIL PUMP
CHAINGUIDE
OILFILTER
page8-6
Replacement,
OIL PRESSURESWITCH
SwitchTest,page8 4
Oil Pressuretest, page8'4
R e p l a c e m e npt a, g e8 1 6
8-3
EngineLubrication
Oil PressureSwitch Test
1 . R e m o v et h e Y E U R E Dw i r e ( A ) f r o mt h e e n g i n eo i l
pressureswitch (B).
Oil PressureTest
{
lf the oil pressureindicatorstayson with the engine
r u n n i n g c. h e c kt h e e n g i n eo i l l e v e l .l f t h e o i l l e v e li s
correct:
'1.
Connecta tachometer.
Removethe engine oil pressureswitch,and install
a n o i l p r e s s u r eg a u g e{ A ) .
2. Checkfor continuitybetweenthe positiveterminal
( C )a n d t h e e n g i n e( g r o u n d )T. h e r es h o u l db e
continuitywith the engine stopped.There should
be no continuitywith the engine running.
lf the switch fails to operate,checkthe engineoil
l e v e l .l f t h e e n g i n eo i l l e v e li s O K .c h e c kt h e e n g i n e
oil pressure.lf the oil pressureis OK, replacelhe oil
Dressureswitch.
\.
(
Start the engine.Shut it off immediatelyif the
gauge registersno oil pressure.Repairlhe problem
beforecontinuing.
4. Allow the engineto reachoperatingtemperature
(fan comes on at leasttwice),The pressureshould
be:
EngineOil Temperature: 176'F (80'Cl
EngineOil Pressure:
At ldle:
70 kPa (0.7kgf/cm', 10 psi)
mtntmum
At 3,000rpm: 300 kPa (3.1kgf/cm',44 psi)
minimum
lf the oil pressureis NOT within specifications,
inspectthese items:
. C h e c kt h e o i l s c r e e n f o r c l o g g i n g .
. Checkthe oil pump (seepage8-8).
. Checkcrankshaftand connectingrod bearing
clearances.
I
8-4
EngineOil Replacement
1 . Warm up the engine.
2 . R e m o v et h e d r a i nb o l t ( A ) ,a n d d r a i nt h e e n g i n eo i l .
n
A
44 N.m {i1.5kgf.m,33lbf.ft)
Donotovertighten.
3 . Reinstallthe drain bolt with a new washer (B).
R e f i l l w i t ht h e r e c o m m e n d e o
d i l ( s e ep a g e3 - 2 ) .
Capacity
4.0 0 (4.2US qt) at oilchange.
4.2 014.4US qt) at oilchange includingfilter.
5.3 015.6US $) after engineoverhaul.
5 . Run the enginefor more than 3 minutes.then check
for oil leakage.
8-5
EngineLubrication
EngineOil FilterReplacement
Special Tool Fequired
Oil filter wrench 07HAA-PJ70100
EngineOil Filter(3/4-turntype)
1 . R e m o v et h e o i l f i l t e r w i t h t h e s D e c i at ol o l .
2. Inspectthe threads{A) and rubber seal (B)on the
new filter. Wipe off the seat on the engine block,
then apply a light coat of oil to the filter rubber seal.
Use only filterswith a built-inbypasssystem.
5. lf 4 numbersor marks (1 to 4 or V to VVVV) are
printedaroundthe outsideof the filter, usethe
following procedureto tighten the filter.
. Spin the filter on until its seal lightly seatsagainst
t h e b l o c k ,a n d n o t ew h i c h n u m b e ro r m a r ki s a t
the bottom.
. Tightenthe filter by turning it clockwise3
numbersor marksfrom the one you noted.For
example,if number 2 is at the bottom when the
seal is seated,tightenthe filter until the number 1
comes around the bottom.
Number when rubber
seal is seated.
Number aftertightening.
\..
I n s t a l l t h eo i l f i l t e rb y h a n d .
After the rubberseal seats,tightenthe oil filter
clockwisewith the specialtool.
Tighten:
Tighteningtorque:
3/4 turn clockwise.
12 N.m (r.2 kgf.m,8.7 lbf.ft)
N u m b eor r
M a r kw h e n
r u b b esr e a li s
1
or
V
N u m b e ro r
Mark after
tightening
2
or
VV
3
or
VVV
4
or
VVVV
4
1
or
or
2
or
VV
3
or
VVV
vvvv. v
6 . A f t e ri n s t a l l a t i o nf i,l l t h e e n g i n e w i t ho i l u p t o t h e
specifiedlevel,run the enginefor more than 3
m i n u t e st,h e n c h e c kf o r o i l l e a k a g e .
07HAA-PJ70100
\,
8-6
(
Oil FilterFeedPipeReplacement
1 . Removethe oilfilter (seepage8-6).
Removethe oil filter feed pipe.
3 . l n s t a l l t h e t w o 2 x0 1 . 5 m m n u t s ( Ao) n t o t h e n e w
oil filter feed pipe. Holdthe nut with a wrench,then
tighten the other nut.
4 . T i g h t e n t hoei lf i l t e r f e e p
d i p e t o t h eb l o c k t o4 9N .
m {5.0kgf.m,36 lbf ft),thenremovethe nutsfrom
the oil filterfeedoiDe.
8-7
EngineLubrication
OilPumpOverhaul
ExplodedView
6x1.0mm
1 2N . m
{1.2kgfm,8.7lbf.ft)
BAFFLEPLATE
x 1 . 2 5m m
27 N.m
6x1.0mm
12 N.m
11.2kgf.m,8.7 lbt ft)
(2.8kst m, 20 lbt ft)
A p p l ye n g i n o
eilto
the boltthreads.
Ptr
P UI" I
EU
UPPERBALANCER
SHAFTHOLDER
$--."Dowetem
BALANCERSHAFT
BEARINGS
DOWELPIN
\
REAR
BALANCER
SHAFT
-
/=.---'n
fs/
t w
SEALINGBOLT
39 N.m
{4.0kgf.m,29lbf.ftl
FRONT
BALANCER
SHAFT
LOWERBALANCER
SHAFTHOLDER
\-
8-8
Oil PumpRemoval
6. Removethe oil pump sprocket(A),then removethe
oil pump(B).
1. Setthe No. 1 piston attop deadcenter{TDC){see
s t e p1 o n p a g e6 - 1 2 ) .
2 . R e m o v et h e o i l p a n ( s e e p a g e T - 1 1 ) .
3 . R e m o v ea n d d i s c a r dt h e o i l p u m p c h a i n t e n s i o n e r .
4. To hold the rear balancershaft,inserta 6 mm pin
driver (A) into the maintenancehole in the lower
balancershaft holderand through the rear balancer
shaft.
5. Loosenthe oil pump sprocketmounting bolt.
(cont'd)
8-9
EngineLubrication
Oil PumpOverhaul{cont'dl
Oil PumpInspection
1 . R e m o v et h e p u m p h o u s i n g .
{
3. Checkth e h ousing-to-roto
r axiaI clearancebetween
t h e r o t o r( A )a n d p u m p h o u s i n g( B ) .l f t h e h o u s i n g to-rotoraxial clearanceexceedsthe servicelimit.
r e p l a c et h e o i l p u m p .
Housing"to-Rotor Axial Clearance
Standard(New):0.02 0.07 mm (0.001-0.003 in.l
Checkthe inner-to-outerrotor radialclearance
betweenthe inner rotor (A) and outer rotor {B).lf
the inner-to-outerrotor radialclearanceexceeds
the servicelimit, replacethe oil pump.
Inner Rotor-to-Outer Botor Radial Clearance
Standard{New):0.02 0.16mm (0.001-0.006 in.)
ServiceLimit: 0.20mm (0.008in.,
4 . Checkthe housing-to-outer
rotor radialclearance
betweenthe outer rotor (A) and pump housing(B).
lf the housing-to-outerrotor radialclearance
exceedsthe servicelimit, replacethe oil pump.
\,
Housing-to-Outer Rotor Radial Clearance
StandardlNewl: 0.15 0.21mm (0.006-0.008in.l
1'[1e-\1.-,-2
1
'a :.:
,-'r'
Inspectboth rotors and the pump housingfor
scoringor other damage.Replaceparts if
necessary.
\-
8- 10
BalancerShaft Inspection
1 . Seatthe balancershaft by pushingit away from the
o i l p u m p s p r o c k eet n d o f t h e o i l p u m p .
3. Removethe baffle plate (A) and upper balancer
shaft holder {with bearings)(B),then removethe
front balancershaft (C)and rear balancershaft (D).
9
2 . Zero the dial indicatoragainstthe end of the
balancershaft,then push the balancershaft back
and forth and readthe end olav.
Balancer Shaft End Play:
Fronl Balancer Shaft:
{0.0028 0.0053in.}
Rear Balancer Shaft:
Standard{New):0.070-0.135 mm
(0.0028 0.0053in.l
.r
H
.
''/
j/
L=]
A
R
r
Rfl|]
3B eI ]U U
+-
(cont'd)
8-11
EngineLubrication
Oil PumpOverhaul(cont'dl
4. Measure
the innerdiameterof the No. 1 bearingfor
thefrontbalancer
shaftholeandthe rearbalancer
shafthole.
BearingInnerDiameier:
Front:
Standard(New):20.000-20.020
mm
(0.7874 0.7882in.)
Rear:
Standard(New):24.000-24.020mm
in.)
10.9/t49-0.9457
(
5 . Measurethe diametersof the No. 1 journalson the
front balancershaft and rear balancershaft.
NO.1Journal Diameter:
Front:
(0.7850 0.7854in.)
Rear:
StandardlNewl: 23.938 23.950mm
in.)
{0.9424-0.9/129
Front:
Front:
a
Rear:
\
8-12
6. Cleanboth balancershaft No. 2 journalsand
bearinghalveswith a cleanshop towel.
7. Placeone strip of plastigageacrosseach No.2
journal.
1 0 . A l i g nt h e p u n c hm a r ko n t h e r e a rb a l a n c esr h a f t
with the centerof the two punch marks on the front
balancershaft,then install'thebalancershaftsin
the lower balancershaft holder
8 . Reinstallthe bearingsand upper balancershaft
holder,then torque the bolts.
NOTE;Do not rotatethe balancershaft durinq
insDection.
9 . Removethe uooer balancershaft holder and
bearingsagain,and measurethe widest part of the
plastigage.lf the balancershaft No. 2 journal oil
installthe new
clearanceis out-of-tolerance.
bearings,and recheck.lf it is still out-of-tolerance,
replacethe balancershafts.
No. 2 Journal Oil Clearance:
StandardlNewl; 0.060 0.120mm
ServiceLimit:
(0.0024 0.0047in.l
0.15mm {0.006in.)
1 1 .Apply engine oil to the threads of the 8 mm bolts
(A).
6
x1.0mm
'12
N.m
(1.2kgt.m,8.7 lbt ft)
1 2 . I n s t a l l t h eu p p e rb a l a n c esr h a f th o l d e r( B )a n d
bafile plate (C).
(cont'd)
8-13
EngineLubrication
Oil PumpOverhaul(cont'd)
1 3 . l n s t a l l t h ep u m p h o u s i n g .
Oil PumpInstallation
1. Make sure the No. 1 piston is at TDC (seestep 1 on
p a g e6 - 1 2 ) .
2. Align the dowel pin{A} on the rear balancershaft
with the mark (B)on the oil pump.
9%ttrc
6x1,0mm
1 2N . m
(1.2kgt.m,8.7lbf.ft)
+:.:4.4
/
o/.-lY\
t\
\
To hold the rear balancershaft, inserta 6 mm pin
driver {A) into the maintenancehole in the lower
balancershaft holder and through the rear balancer
shaft.
\,-
-rrdv
:aa:'
f,o-;
!
8- 14
4. Apply engine oil to the threadsof the oil pump
sprocketmounting bolt (A).
8. Squeezethe new oil pump chain tensioner(A),then
installthe set clip (B)on it as shown.
N O T ET
: h e s e tc l i p i s s u p p l i e dw i t h t h e o i l p u m p
chain tensioner.
A
10x 1.25mm
{4 N.m
(a.5kg{ m,
33 rbf.ftl
I
B
9. Installthe oil DumD chain tensioner.
6x1.0mm
12N.m(1.2kgf.m,
8.7rbf.ft)
1 0 x1 . 2 5m m
,l,t N.m {4.5kgf.m,
33 tbt.ftl
8 x 1 , 2 5m m
22N m l2.2kot m.
r6 tbt.fti
5 . L o o s e l yi n s t a l l t h eo i l p u m p( B ) t, h e ni n s t a l l t hoei l
pump sprocket(C).
Removethe pin driver (D).
7 . Tightenlhe oil pump mounting bolts.
(cont'd)
8-15
I
EngineLubrication
Oil PumpOverhaul(cont'dl
I
Oif PressureSwitch Replacement
1 0 . R e m o v et h e s e tc l i pf r o m t h e o i l p u m p c h a i n
tensioner.
1. Disconnectthe oil pressureswitchconnector,then
removethe oil pressureswitch.
1 1 . I n s t a ltl h e o i l p a n ( s e ep a g e T - 2 7 ) .
2. Apply liquid gasketto the oil pressureswitch
threads,then installthe oil pressureswitch.
(
(
\
8-16
EngineMechanical
IntakeManifoldand ExhaustSystem
lntakeManifoldRemovaland Installation.................
9-2
ExhaustManifoldRemovalandInstallation..............
9-7
ExhaustPipeand MufflerReplacement
.....................
9-8
r
r-!i!1
lntakeManifoldRemovaland Installation
\
Exploded View:
8 x 1 , 2 5m m
22 N.m {2.2kgf.m, 16 lbf ft}
I
INTAKEMANIFOLD
Replaceif crackedor
if mating surfaceis
GASKET
Replace.
k
'e)
w)
k
INTAKE MANIFOLDPLATE
Replaceif crackedor
if matingsurfaceis
damaged.
\
'!
(
\-
(
t9
\
8 xx1.25
. 2 5mm
222 N' mm
2
kgf.m, 1 6
12.2ksf
6x1.0mm
1 2N . m
{1.2kgf.m,8.7lbf.ft)
8 x 1 . 2 5m m
22 N.m
(2.2kgf m. 16 lbt.ft)
9-2
Removal:
'1.
Removethe intakemanifoldcover.
3. Disconnecttheintakeairtemperature(lAT)sensor
connector(A),and removethe breatherhose (B),
then removethe air cleanerhousingcover/intake
a i r d u c ta s s e m b l y( C ) .
2 . Removethe evaporativeemission(EVAP)canister
hose (A),brakeboostervacuum hose (B),and
vacuum hoses{C).
4. Fully open the throttle link and cruisecontrol link
by hand,then removethe throttlecable (A) and
cruisecontrol cable(B)from the links.Loosenthe
locknuts{C).and removethe cablesfrom the
bracket.
(
(cont'd)
9-3
IntakeManifoldRemovaland Installation(cont'dl
5. Be preparedto catch and clean up spilledcoolant.
Removethe water bypasshoses,then plug the
water bypasshoses.
(
9 . Removethe enginewire harnessconnectorsand
w i r e h a r n e s sc l a m p sf r o m t h e i n t a k em a n i f o l d .
.
.
.
.
Four injectorconnectors
ldle air control (lAC)valve connector
Throttleposition(TP)sensorconnector
fvlanifoldabsolutepressure{lvlAP)sensor
connector
. Evaporativeemission(EVAP)canister
purge
valve connector
'10. Removethe bolt securingthe intakemanifoldand
bracket.
6 . R e l i e v e f u epl r e s s u r e( s e ep a g e1 1 - ' 1 4 4 ) .
7 . R e m o v et h e f u e l l i n e ( s e e p a g e l l - 1 4 9 ) .
8. Removethe positivecrankcaseventilation(PCV)
hose (A),harnessholder mounting bolt (B)and
h a r n e s sc l a m pm o u n t i n gb o l t ( C ) .
1 1 .Removeallthe intakemanifold mounting bolts/
nuts.
1'>
Removethe two stud bolts (A),then removethe
i n t a k em a n i f o l d( B ) .
\-
9-4
1. Installthe intakemanifold (A)with a new gasket(B),
then installand tighten the two stud bolts (C).
w
4 . Installthe PCVhose {A), harnessholder mounting
b o l t ( B ) ,a n d h a r n e s sc l a m pm o u n t i n gb o l t( C ) .
e-li*h,r
*&
\
8 x 1.25mm
22 N.m
|.2.2k91.m.
16 tbt.ft)
8 x 1.25mm
22 N.rn
(2.2kgf m. 16 lbf.ttl
2. Tightenall intakemanifold mountlng bolts/nutsin a
crisscrosspatternin two or three steps,beginning
with the inner bolt.
?
Tightenthe bolt securingthe intakemanifold and
bracket.
8 x 1.25mm
22 N.m (2.2ksf m, 16lbf.ft)
6x1.0mm
12N.m(1.2kgf.m,8.7lbf.ft)
5 . I n s t a l l t h ef u e l l i n e ( s e ep a g e1 1 - 1 5 0 ) .
6 . Installthewater bypasshoses.
7 . I n s t a ltl h e t h r o t t l ec a b l e( s e ep a g e11 - 1 6 4 )t ,h e n
a d j u s t h e c a b l e( s e ep a g e1 1 - 1 6 3 ) .
8 . Installthe cruisecontrol cable (seepage 4-44).then
adjustthe cable (seepage 4-45).
(cont'd)
9-5
lntake Manifoldand ExhaustSystem
IntakeManifoldRemovaland Installation(cont'd)
9 . l n s t a l l t h ea i r c l e a n e rh o u s i n gc o v e r( A ) ,a n d
connectthe IAT sensorconnector(B).
B
1 2 . I n s t a l l t h ei n t a k em a n i f o l dc o v e r .
6x1.0mm
1 2N . m
l.1.2k91.m,
8.7 tbf.ftl
C
C l e a nu p a n y s p i l l e de n g i n ec o o l a n t .
1 0 .Installthebreatherhose(C).
After installation,checkthat all tubes,hoses,and
connectorsare installedcorrectly.
1 1 .lnstalltheEVAPcanisterhose(A),brakebooster
, n dv a c u u mh o s e s{ C ) .
v a c u u mh o s e( B ) a
Inspectfor fuel leaks.Turn the ignition switch ON
(ll) (do not operatethe starter)so that the fuel pump
line. Repeatthis operationtwo or three times,then
checkfor fuel leakageat any point in the fuel line.
to.
\-
Refillthe radiatorwith enginecoolant,and bleed
air from the cooling systemwith the heatervalve
open (seepage 10-6).
\
9-6
ExhaustManifoldRemovaland Installation
1 . Removethe VTECsolenoidvalve (seepage 1'1-128).
2 . Removethe driveshaftheat shield(seepage 16-19).
3 . Removethe cover and exhaustmanifold bracket,then removethe exhaustmanifold.
8 x 1 . 2 5m m
22 N.m
(2.2kgf.m, 16lbt.ftl
SELF-LOCKING
NUT
10x 1.25mm
44 N.m {4.5ksf.m, 33lbt.ftl
Beplace.
#'-.-
1 0x 1 . 2 5m m
44 N.m
(4.5kgt.m, 33 lbl ftl
Replace.
GASKET
Replace.
WASHEB
10x 1.25mm
14 N.m
{4.5kgl.rn, 33lbf.ft)
8 x 1-25mm
22 N.m (2.2kgI m, 16lbf.ft)
Replace.
Tightenthe boltsin steps,
alternating
sideto side.
Installthe exhaustmanifoldand tighten the bolts/nutsin a crisscrosspatternin two or three steps,beginningwith
the inner bolt.
5 . Installtheother parts in the reverseorder of removal.
9-7
lntake Manifoldand ExhaustSystem
ExhaustPipeand Muffler Replacement
\
NOTE:Use new gasketsand self-lockingnuts when reassembling.
8 x 1 . 2 5m m
22 N.m (2.2kst.m. 16lbf.ftl
Replace.
Tightenthe bolts in steps,
alternatingside'to side.
EXHAUSTPIPEB
HEATSHIELD
\,
6x1.0mm
9.8 N.m
{1.0kgt.m,7.2 lbf ft}
GASKET
Replace.
SECONDARY
HEATED
OXYGEN
SENSOR
HO2SI
{SECONDARY
NUT
SELF-LOCKING
1 0x 1 . 2 5m m
33N.m{3.4kgf.m,
25 rbf.ft)
Beplace.
8 x 1.25mm
22 N.m {2.2kgf m, 16lbf.ft)
Replace.
Tightenthe bolts in steps,
alternatingside to-side.
il4Nm
(4.5 ksf.m,33 lbf.ftl
AIR FUELRATIO {A/F)
SENSOR
44 N.m (it.s kgf.m, 33 lbf ftl
\-.
9-8
EngineCooling
CoolingSystem
Component
Location
Index .........................................
10-2
Radiator
CapTest .....................
..........
10-3
RadiatorTest
.............
10-3
FanMotorTest
..........l0-4
Thermostat
Test ......................
...........
10-4
WaterPumpInspection
.....................
10-5
WaterPumpReplacement
.................
10-5
C o o l a nCt h e c k. . . . . . . . . . . . . .
. . . . . . . . . . . . . . . .1. .0. .- .6. .
CoolantReplacement
.........................
10-6
Thermostat
Replacement
..................
10-8
WaterPassage
Installation
................
10-9
WaterOutletInstallation
....................
10-9
Radiator
andFanReplacement
...................................
10-10
FanControls
C o m p o n e nLto c a t i oInn d e x . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. .0. .-.1. .1. . . . . . .
Index ...............................
10-12
CircuitDiagram
.........10-13
Radiator
FanCircuitTroubleshooting
........................
10-14
Radiator
FanSwitchCircuitTroubleshooting
( O p e n ). . . . . . . . . . . .
. . . . . . .1. 0 - 1 6
Radiator
FanSwitchCircuitTroubleshooting
( S h o r t ). . . . . . . . . . . .
. . . . . . .1. 0 - 1 6
Radiator
FanSwitchTest
...................
10-17
Radiator
FanSwitchReolacement
..............................
10-17
CoolingSystem
\
WATER
OUTLET,
I n s t a l l a t i opna,g e ' 1 0 - g
\\f
WATERPUMP
page10-5
Inspection,
page10-5
Replacement.
PIPE
CONNECTING
RESERVE
TANK
WATERPASSAGE
page10-9
Installation,
THERMOSTAT
Test,page10 4
page108
Replacement,
RADIATOR
CAP
RAOIATORFAN SWITCH
Test,page 10-17
page 10'17
Replacement,
RADIATOR
page 10-'l0
Replacement,
A/C CONDENSER
FAN ASSEMBLY
Replacement,page 10'10-4
10
Fan Motor Test,page
RADIATORFAN
ASSEMgLY
R e p l a c e m e npta, g e1 0 - 1 0
Fan MotorTest,page 10 4
\J
10-2
RadiatorCapTest
RadiatorTest
1. Removethe radiatorcap {A),wet its sealwith
engine coolant,then installit on the pressuretester
( B )( c o m m e r c i a l layv a i l a b l e ) .
1 . Wait untilthe engine is cool, then carefullyremove
the radiatorcap and fill the radiatorwith engine
coolantto the top of the filler neck.
Attachthe pressuretester (A) (commercially
a v a i l a b l et)o t h e r a d i a t o r .
Apply a pressureof 93
kgf/cm', l4 18 psi).
'123
kPa{0.95 1.25
3 . Checkfor a drop in pressure.
4 . lf the pressuredrops, replacethe cap.
3 . Apply a pressureot 93 '123kPa(0.95 1.25
kgf/cm',
'14
18 psi).
4 . I n s p e cfto r e n g i n ec o o l a n tl e a k sa n d a d r o p i n
pressure.
Removethe tester,and reinstallthe radiatorcap.
10-3
CoolingSystem
FanMotor Test
1. Disconnectthe 2P connectorsfrom the radiatorfan
motor and condenserfan motor.
ThermostatTest
\
Replacethe thermostatif it is open at room
remperalure.
To test a closedthermostatl
1. Suspendthe thermostat(A) in a containerof water.
Do not let the thermometer{B)touch the bottom of
t h e h o tc o n t a i n e r .
Testthe motor by connectingbatterypower to the
B terminaa
l n d g r o u n dt o t h e A t e r m i n a l .
lf the motor fails to run or does not run smoothly,
r e p t a c er L
2. Heatthe water, and checkthe temDeraturewith a
thermometer.Checkthe temperatureat which the
thermostatfirst opens,and at which it is fully open.
\.
3 . Measurethe lift height of the thermostatwhen it is
f u l l vo o e n .
STANDARDTHERMOSTAT
Lift height;
above 8.0 mm (0.31in.)
Starts opening: 169 176"F(76 80"C)
Fullyopen:
194"F{90'Cl
\
10- 4
(
Water Pump Inspection
Water Pump Replacement
1 . Removethe drive belt (seepage 4-26),
2 . Turn the water pump pulleycounterclockwise.
Checkthat it turns freely.
2 . D r a i nt h e e n g i n ec o o l a n t{ s e ep a g e1 0 - 6 ) .
3 . R e m o v et h e c r a n k s h a fpt u l l e y( s e ep a g e6 - 1 1 ) .
Checkfor signs of seal leakage.A small amount of
"weeping" from
the bleed holes(A) is normal.
4. Removethe six bolts securingthe water pump,
then removethe water pump (A).
6x1.0mm
1 2 N m { 1 . 2k g t m ,
8.7 rbf.ft)
Inspectand cleanthe O-ring groove and mating
surfacewith the water passage.
I n s t a l l t h ew a t e r p u m pw i t h n e w O r i n g si n t h e
reverseorder of removal.
7 . C l e a nu p a n y s p i l l e de n g i n ec o o l a n t .
8 . I n s t a l l t h ec r a n k s h a fpt u l l e y( s e ep a g e6 - 1 2 ) .
L R e f i l tl h e r a d i a t o w
r i t h e n g i n ec o o l a n t a, n d b l e e d
air from the cooling system with the heatervalve
o p e n{ s e ep a g e1 0 - 6 } .
10-5
CoolingSystem
GoolantCheck
1. Look at the coolantlevel in the reservetank. Make
sure it is betweenthe MAX mark (A) and MIN mark
(B),
CoolantReplacement
\
1 . Startthe engine.Set the heatertemperaturecontrol
dial to maximum heat.then turn off the ignition
switch.Make surethe engine and radiatorare cool
to the touch.
Removethe radiatorcap.
Removethe splashshield(seestep 23 on page5-5).
Loosenthe drain plug (A),and drain the coolant.
lf the coolantlevel in the reservetank is at or below
the MIN mark, add coolantto bring it up to the l\4AX
mark, and inspectthe cooling system for leaks.
\
Removethe reservetank drain cap (A),and drain
the coolant.
\-
10-6
After the coolanthas drained,tighten the radiator
drain plug securely.and installthe reservetank
drain cap securely.
Type 2
8. Pour HondaAll SeasonAntifreeze/Coolant
into the radiatorup to the baseof the filler neck.
NOTE:
. Always use HondaAll SeasonAntifreeze/Coolant
Type 2 {P/N01999-9001).Using a non-Honda
c o o l a n tc a n r e s u l ti n c o r r o s i o nc, a u s i n gt h e
cooling systemto malfunctionor fail.
. HondaAll SeasonAntifreeze/Coolant
Type 2 is a
mixture of 50% antifreezeand 507owater. Prem i x i n gi s n o t r e q u i r e d .
1 . Fillthe reservetank to the MAX mark (A) with
Tvpe 2
HondaAll SeasonAntifreeze/Coolant
(P/NO1999-9001).
EngineCoolant RefillCapacity includingthe
reserve tank capacity of 0.53 4 (0.56 US gtl :
5.0 0 (s.3US qt)
L I n s t a l l t h er a d i a t o cr a p l o o s e l y .
1 0 .Startthe engine,and let it run until it warms up (the
radiatorfan comes on at leasttwice).
1 1 .Turn off the engine.Checkthe level in the radiator,
Type
and add HondaAll SeasonAntifreeze/Coolant
2 if needed.
P u tt h e r a d i a t o cr a p o n t i g h t l y ,t h e n r u n t h e e n g i n e
a g a i na n d c h e c kf o r l e a k s .
tJ.
lnstallthe splashshield(seestep 22 on page 5-12).
10-7
GoolingSystem
a
ThermostatReplacement
1 . D r a i nt h e e n g i n ec o o l a n t( s e ep a g e1 0 - 6 ) .
2. Removethe splashshield (seestep 23 on page 5-5).
3. Removethe lower hose,then removethe thermostat.
6 x 1 . 0m m
9.8N.m
( 1 . 0k g f . m , 7 . 2 l bf ft )
u
i*
-
THERMOSTAT
LOWERHOSE
4. Installthethermostatwith a new O-ring,then installthe lower hose.
5 . I n s t a l l t h es p l a s hs h i e l d( s e es t e p2 2 o n p a g e5 - 1 2 ) .
6. Refillthe radiatorwith engine coolant,and bleed air from the cooling systemwith the heatervalve open (seepage
10_6).
\_
10-8
Water PassageInstallation
Water Outlet lnstallation
1 . Cleanand dry the water passagemating surfaces.
I n s t a l l t hw
e a t e ro u t l e (t A ) w i t ha n e wO - r i n g{ B ) ,
Apply liquid gasketP/N 08718-0009,
evenlyto the
c y l i n d e rb l o c km a t i n gs u r f a c eo f t h e w a t e r p a s s a g e
and to the inner threadsof the bolt holes.
h a v ee l a p s e ds i n c ea p p l y i n gl i q u i dg a s k e t I. n s t e a d ,
1 2 N m ( 1 . 2k g t m , 8 , 7 l b ff t )
3 . I n s t a l l t h ew a t e rp a s s a g e( A ) w i t ha n e w O - r i n g( B ) .
.t':.:
1 0x 1 . 2 5m m
44N m {4.5kgtm.33 lbf.ft}
4. After assembly,wait at least30 minutes before
10-9
CoolingSystem
Radiatorand FansReplacement
{
1. Drainthe enginecoolant(seepage 10-6).
2. Removethe front bumper {seepage 20,85).
3. Removethe bulkhead.
4. Removethe upper radiatorhose and lower radiatorhose.
DRAINPLUG
O.RING
RADIATOR
CAP
UPPERBADIATORHOSE
BADIATOB
BAOIATOAFAN
ASSEMBLY
\LOWERCUSHION
RADIATOR FAN
swtTcH
24Nm
{ 2 . 1kt g l m . 1 7 l b l h l
LOWERFADIATOR
HOSE
RESERVETANK
A/C CONDENSER
FANASSEMBLY
9 . 8N m { 1 . 0k g f m , 7 . 2l b ff t )
CONNECTORS
RADIATOBFANSWITCH
CONNECTOB
5. Disconnectthe fan motor connectorsand radiatorfan switch connector,then pull the radiatorup and out.
6. Removethe fan shroud assembliesand other partsfrom the radiator.
7 . I n s t a l l t h er a d i a t o ri n t h e r e v e r s eo r d e ro f r e m o v a l M
. a k es u r et h e u p p e ra n d l o w e rc u s h i o n sa r e s e t s e c u r e l V .
8 . I n s t a ltlh e b u l k h e a di n t h e r e v e r s eo r d e ro f r e m o v a l A
. p p l y b o d y p a i n tt o t h e b u l k h e a dm o u n t i n gb o l t s .
9 . F i l lt h e r a d i a t o w
r i t h e n g i n ec o o l a n ta n d b l e e dt h e a i r ( s e ep a g e1 0 - 6 ) .
10-10
\.
FanControls
UNDER.HOOD
FUSE/RELAY
BOX
RADIATORFAN RELAY
RADIATOBFAN SWITCH
Test,page 10'17
R e p l a c e m e npt a, g e ' 1 0 - 1 7
RADIATORFAN ASSEMBLY
Motor Test,page 10 4
CONDENSER
FAN ASSEMBLY
Motor Test,page 10-4
10-11
FanControls
\
{
Beforeperformingany troubleshootingprocedurescheck:
. Fuses
. Grounds
. Cleanlinessand tightnessof all connectors
SYMPTOM
PROCEDURE
Radiatorfan does not run at all
RadiatorFanCircuilTroubleshooting(seepage 1O-14).
Radiatorfan does not run for enginecooling, but it runs
with A,/CON
RadiatorFan Switch CircuitTroubleshooting(Open)
( s e ep a g e1 0 - 1 6 ) .
Radiatorfan runs with ignition switch ON (ll),Ay'COFF,
and enginetemperaturebelow 199"F(93"C)
RadiatorFan Switch CircuitTroubleshooting(Short)
(seepage 10-'16).
\ , 4
\-
10-12
o
CircuitDiagram
'
No.20loA): USA
modd
: Cm.de
mod.l
No.20l50A)
UNDEN
DASX
FUSE/RELAY
BOX
BOX
UIIDEFHOOD
FJSE/NILAY
lG2H0TiiAClill,
0N{lllrndSTABI
llll)
10-13
FanGontrols
RadiatorFanCircuitTroubleshooting
1. Checkthe No. 4 (20A)fuse in the under-hood
fuse/relaybox, and the No. 14 (10A)fuse in the
under-dashfuse/relaybox.
ls the tuse (s) OK?
(
4 . C o n n e ct th e N o . l a n d N o . 2 t e r m i n a l s o f t h e
radiatorfan relay 4P socketwith a jumper wire.
RADIATORFAN RELAY4P SOCKET
YES-Go to step 2.
NO- Replacethe fuse (s) and recheck.l
JUMPER
WIRE
2. Removethe radiatorfan relayfrom the under-hood
fuse/relaybox, and test it (seepage 22-51).
ls the relay OK?
YES Go to step 3.
T e r m i n asli d eo f I e m a l tee r m i n a l s
NO Replacethe radiatorfan relay.t
Does the radiatot fan run?
3. Measurethe voltage betweenthe No. 2 terminal of
the radiatorfan relay 4P socketand body ground.
YES Go to step 5.
NO Go to step 6.
RADIATORFAN RELAY4PSOCKET
Disconnectthe jumper, and turn the ignition switch
ON {ll}. Checkfor voltage betweenthe No. 3
terminal of the radiatorfan relay 4P socketand
b o d yg r o u n d .
\-
BADIATOB
FANRELAY4PSOCKET
Terminalside of femaleterminals
ls therebatteryvoltage?
YES Goto step4.
NO Replace
the under-hood
fuse/relay
box.I
Termlnalsideof femaleterminals
ls there battety voltage?
YES-Go to step 9.
NO Checkfor an open in the wire betweenthe
under-hoodfuse/relaybox and under-dashfuse/
relay box.l
\-
10-14
Disconnectthe radiatorfan motor 2P connector.
7 . Checkfor continuitybetweenthe No. 1 terminal of
the radiatorfan relay 4P socketand the No. 2
terminal of the radiatorfan motor 2P connector.
RAOIATOR
FANREI-AY
4PSOCKET
9 . Reinstallthe radiatorfan relay.
1 0 .Disconnectthe radiatorfan switch 2P connector.
1 1 .Connectthe No. 1 and No. 2 terminals,of the
radiatorfan switch 2P connectorwith a jumper wire.
RAOIATOR
FANSWITCH
2P CONNECTOR
5\-'fl \
\r--
Terminalsideof
femaleterminals
f-;
IJUMPER
I wrRE
RADIATORFAN MOTOR2P CONNECTOR
Does the radiator fan run?
ls thete continuity?
YES- Replacethe radiatorfan switch.l
YES-Go to step8.
N O - G o t o s t e p1 2 .
NO Repairopenin the wire betweenthe underhoodfuse/relay
boxandthe radiatorfan motor2P
terminalNo.2,I
connector
8. Checkfor continuitybetweenthe No, 1terminal of
the radiatorfan motor 2P connectorand bodv
g round.
Removethe jumper wire, and measurethe voltage
betweenthe No, 2 terminal of the radiatorfan
switch connectorand body ground,
RADIATOR
FANSWITCH
2P CONNECTOR
RADIATORFAN MOTOR2P CONNECTOR
rftr
T-
Y
Wire side of femaleterminals
YES Replacethe radiatorfan motor.l
NO Checkfor an open in the wire between
radiatorfan motor 2P connectorterminal No. 1 and
body ground. lf the wire is OK, checkfor a poor
g r o u n da t G 3 0 1 . 1
YES Checkfor an open in the wire between
radiatorfan switch 2P connectorterminal No. 1 and
g r o u n da t G 3 0 1 . 1
NO Repairopen in the wire betweenthe radiator
fan switchterminal No. 2 and the under-hood
fuse/relaybox.l
10-15
FanControls
RadiatorFanSwitch Circuit
Troubleshooting(Openl
1. Disconnectthe radiatorfan switch 2P connector.
2 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
3 . M e a s u r ev o l t a g eb e t w e e nt h e N o . 2 t e r m i n a lo f t h e
radiatorfan switch 2P connectorand body ground.
RADIATORFAN SWITCH2P
CONNECTOR
RadiatorFanSwitch Circuit
Troubleshooting(Short)
\
NOTE:After troubleshooting,perform the engine
c o n t r o lm o d u l e( E C M ) i d l el e a r np r o c e d u r e( s e ep a g e
11 , 1 3 9 ) .
1 . R e m o v et h e r a d i a t o fra n r e l a yf r o m t h e u n d e r - h o o d
fuse/relaybox, and test it (seepage 22-51).
ls the relay OK?
YES Go to step 2.
NO
Replacethe radiatorfan relay.I
2. Removethe radiatorfan switch,and test it (see
p a g e1 0 - 1 7
).
Is the radiatot tan switch OK?
YES Go to step 3.
NO
YES-Go to step 4.
Disconnectthe batterynegativecablefrom the
battery.
NO- Repairopen in the wire betweenthe radiator
fan switch 2P connectorterminal No. 2 and underhood fuse/relaybox.l
Turn the ignition switch OFF,and checkfor
continuitybetweenthe No. '1terminal of the
radiatorfan switch 2P connectorand body ground.
RADIATOBFAN SWITCX2P
CONNECTOR
Replacethe radiatorfan switch.I
4 . Disconnectenginecontrol module {ECM)connector
) n d t h e u n d e r h o o df u s er e l a yb o x 1 4 P
B ( 2 4 Pa
connector.
Checkfor continuitybetweenthe No. 2 terminal of
the radiatorfan switch 2P connectorand body
grouno.
RADIATORFAN SWITCH
2P CONNECTOR
lstnere continuity?
YES Replacethe radiatorfan switch.t
YES Repairshort in the wire betweenthe radiator
f a n s w i t c h2 P c o n n e c t otre r m i n a lN o . 2 a n d u n d e r hood fuse/relaybox.l
radiatorfan switch 2P connectorterminal No. 1 and
g r o u n da t G 3 0 1 . 1
10-16
\
NO Replacethe under-hoodfuse/relaybox.t
\-
I
RadiatorFanSwitch Test
RadiatorFanSwitch Replacement
NOTE:Bleedair from the cooling system after installing
the radiatorfan switch (seepage 10-6).
1, Removethe radiatorfan switchfrom the radiator
( s e ep a g e1 0 - 1 7 ) .
1 . Disconnectthe radiatorfan switch connector,then
removethe radiatorfan switch (A).
A
24 N m (2.4kgt.m,17lbt.ftl
2 . S u s p e n dt h e r a d i a t ofra n s w i t c h( A )i n a c o n t a i n e r
of water as shown.
2. Installthe radiatorfan switchwith a new O-ring(B).
3. Heatthe water, and checkthe temperaturewith a
thermometer.Do not let the thermometer(B)touch
the bottom of the hot conlainer.
4. Measurethe continuitybetweenterminal No. 1 and
terminal No. 2 accordingto the table.
Termina
\
Operation
lTemperature
203'F
ON 196"
(91" gs"C)
swtTcH
5' 15'F {3' 8'C) lowel
OFF than the temoerature
when it goes on
1
10-17
Fueland Emissions
Fueland EmissionsSystems
SpecialTools
1't-2
General
Troubleshooting
Information
I I-J
DTCTroubleshooting
lndex .... 11-7
1ndex...............
11 - 1 0
SystemDescriptions
................
11-12
Howto SetReadiness
Codes.. 11-46
PGM-FlSystem
Component
Location
Index .... 11-49
D T CT r o u b l e s h o o t i n. .g. . . . . . . . .11-52
...
MILCircuitTroubleshooting
... 11-97
DLCCircuitTroubleshooting
.. 1 1 - 1 0 9
InjectorReplacement
...............
11-111
A,/FSensorReplacement
.........1 1 - 1 1 3
HO2S
Secondary
Replacement
11-113
ECTSensorReolacement.......1 1 - 1 1 4
CMPSensorB {TDCSensor)
Replacement
11-114
I A TS e n s oR
r e p l a c e m e.n. t. . . . . 1. .1 - 1 1 5
KnockSensorReplacement
.... 1 1 - 1 1 5
CKPSensorReolacement
.......1 1 - 1 1 6
VTEC/VTC
LocationIndex .... 11-117
Comoonent
D T CT r o u b l e s h o o t i n. .g. . . . . . . . .1.1. .- 11 8
VTCOil ControlSolenoid
ValveRemoval/Test
.............
11-127
CMPSensorA Replacement
... 11-128
VTECSolenoid
Valve
R e m o v a l / l n s o e c t.i .o. n. . . . . . .11-128
...
ldle ControlSystem
Location
Index
Component
11-129
. . . . . . . . . . .1. .I.- 1 3 0
D T CT r o u b l e s h o o t i n g
A,/CSignalCircuit
T r o u b l e s h o o t i n.S. . . . . . . . . . . . . .I .t.-. t.5 5
AlternatorFRSignalCircuit
T r o u b l e s h o o t i n.S. . . . . . . . . . . . . .1. 1. .-. 1 3 4
EPSSignalCircuit
T r o u b l e s h o o t i n.S. . . . . . . . . . . . . .1.1. .-1. 3 5
Brake
PedalPosition
SwitchSignal
Troubleshooting
.............
Circuit
11 - 1 3 7
ldle SpeedInspection
11 - 1 3 8
E C Ml d l el e a r nP r o c e d u r e. . . . . . .11 - 1 3 9
FuelSupplySystem
11 - 1 4 0
FuelPump
Circuit
Troubleshooting 1 1 - 1 4 1
F u e lP r e s s rue R e l i e v i n g. . . . . . . . .1. .1 - 1 4 4
F u eP
l r e s s u r e T e s. .t. . . . . . . . . . . .1. 1. .-.1. 4 5
FueL
l i n e sI n s p e c t i o.n. . . . . . . . . .1. .1. .- 1 4 6
FuelLine/Ouick-Connect
FittingsPrecautions.............
11-148
FuelLine/Ou
ick-Con
nect
F i t t i n gR
s e m o v a l. . . . . . . . . . . . .1. 1. .-.1. 4 9
FuelLine/Ou
ick-Con
nect
F i t t i n glsn s t a l l a t i o.n. . . . . . . . . .1. .1. .- 1 5 0
FuelPressure
Regulator
R e p l a c e m e .n.t. . . . . . . . . . . . . . . 1
. .1. .-.1. .5. 2
FuelFifterReplacement
...........
11-152
FuelPump/Fuel
GaugeSending
. .1. .-.1 5 3
U n i t R e D l a c e m e. .n. t. . . . . . . . . 1
F u eP
l u l s a t i oDna m o e r
R e p 1 a c e m e. n
. .t. . . . . . . . . . . . . . 1
. .1. .-.1. .5. 4
F u eT
l a n kR e o l a c e m e n
. .t. . . . . . .1. 1. - 1 5 5
F u eGl a u g e S e n dUi n igt T e s. .t . . . .1. 1 - 1 5 6
11-158
LowFuellndicatorTest
.................
IntakeAir System
C o m o o n e nLt o c a t i o nI n d e x . . . . 1 1 - 1 5 9
T h r o t t l eB o d y T e s t . . . . . . . . . . . . . . 1
. .1. .-.1 6 0
IntakeAir BypassControl
T h e r m aV
l a l v eT e s t . . . . . . . . . . .1. .1. - 1 6 1
A i r C l e a n eR
r e o l a c e m e n .t . . . . . .1. 1 - 1 6 2
A i r C l e a n eE
r lement
R e o l a c e m e n.t. . . . . . . . . . . . . . . . . 1
. .1. .-.1. .6 2
ThrottleCableAdjustment ...... 11-163
ThrottleCable
Removal/lnstallation
............
11-164
Th rottleBody Removal/
Installation
.. 11-165
Th rottleBody Disassembly/
R e a s s e m b l v. . . . . . . . . . . . . . . . . . .1. .1. .- .1. 6. 6
CatalyticConverterSystem
D T CT r o u b l e s h o o t i n. .g. . . . . . . . .1.1. .- 1 6 7
PCVSystem
D T CT r o u b l e s h o o t i n g. . . . . . . . . . .1. .1.- 1 6 8
PCVValveInsDection
a n dT e s t
. . . . . .11 -1 6 9
P C VV a l v eR e o l a c e m e n.t. . . . . . . .1.1 - 1 6 9
EVAPSystem
C o m p o n e nLt o c a t i o nI n d e x . . . . 1 1 - 1 7 0
D T C T r o u b l e s h o o t i n.g. . . . . . . . . .1. .1. - 1 7 1
EVAPTwo Way ValveTest ......11-186
FuelTank VaoorControl
ValveTest
... 11-187
E V A PC a n i s t eR
r e p l a c e m e n.t. . 1 1 - 1 8 9
FuelTank VaoorControl
V a l v eR e o l a c e m e n.t. . . . . . . . . .1. .1.- 1 8 9
SpecialTools
Rel. No.
(L)
@
o
@
@
@
o
@-t
@-2
O-3
@-4
@
(iD
Tool Number
ffi
W
I
o
1
1
1
/6\
l\r
)l
\-,/
\7
@
-'-,---=---1,-'.
ut/t
'jt'
o
@
(i)
I
2
/'r';-:'-;--'
At-''
UtB
o
\-
1
1
--1
a=:t=' (F
(
otv
Description
V a c u u mP u m p / G a u g e0, 3 0 i n . H g
Vacuum/Pressure
Gauge.0 4 in.Hg
BackprobeSet
Fuel PressureGaugeAdapter
PressureGaugeAdapter
FuelSenderWrench
Hose,Oil Pressure
A,/TPressureHose
A,/TLow PressureGaugeW/Panel
A,/TPressureHose,2,210 mm
A,/TPressureHoseAdapter
F u e lP r e s s u r eG a u g e
FuelPressureGauoeSet
A973X-041-XXXXX
07JAZ-0010008
07sAz-001000A
07vAJ-0040100
07NAJ-P07010A
07xAA-001010A
07zAJ-S5AA200
07406-0020201
07406-0070300
OTMAJ-PY4O11A
07MAJ-PY40120
07406-004000A
07zAJ-S5A0100
\,
)
i-==.€
*==-.2'l
-1,40-2, -3,@-4
\\h
*.'l€)
\\:
\\d
o
@
\-
11-2
a
GeneralTroubleshooting
Information
IntermittentFailures
The term "intermittentfailure" means a svstem mav
have had a failure.but it checksOK now. lf the
MalfunctionIndicatorLamp (MlL)on the dash does not
come on, checkfor Doorconnectionsor looseterminals
at all connectorsrelatedto the circuitthat Vou are
troubleshooting.
2. lf the MIL stayson, connectthe HondaPGM Tester
(A) or an OBD ll scantool to the Data Link
Connector{DLC)(B) locatedunderthe driver'sside
o f t h ed a s h b o a r d .
Opensand Shorts
"Ooen" and "Short" are common
electricalterms.An
open is a breakin a wire or at a connection.A short is
an accidentalconnectionof a wire to ground or to
anotherwire. In simple electronics,this usuallymeans
somethingwon't work at all. With complex electronics
( s u c ha s E C M s ) t h i sc a n s o m e t i m e sm e a ns o m e t h i n g
works, but not the way it's supposedto.
How to Usethe PGMTesteror a ScanTool
lf the MIL {Malfunction Indicator Lamp} has come on
'1.
S t a r tt h e e n g i n ea n d c h e c kt h e M I L { A ) .
N O T E l: f t h e i g n i t i o ns w i t c hi s t u r n e dO N ( l l ) ,a n d
the engine is not started,the MIL will stay on for
1 5 2 0 s e c o n d s( s e ep a g e1 1 - 4 6 ) .
K->;"PN/.- -:::--d V-: !
w:ix&K#
Checkthe DiagnosticTroubleCode (DTC)and note
it. Also checkthe freezedata.Referto the DTC
T r o u b l e s h o o t i nIgn d e x ,a n d b e g i nt h e a p p r o p r i a t e
troubleshootingprocedure.
5 . lf you do not find any DTCS,go to MIL circuit
t r o u b l e s h o o t i n(gs e ep a g e1 1 - 9 7 ) .
NOTE:
. Freezedata indicatesthe engineconditionswhen the
first malfunction,misfire,or fuel trim malfunction
was detected.
. The scantool and the Honda PGM Testercan readthe
DTC,freezedata,currentdata,and other Engine
Controll\4odule{EClvl)data.
. For specificoperations,referto the user's manual
that came with the scantool or HondaPGl\4Tester.
lf the MIL did not stay
lf the MIL did not come on but there is a driveability
problem,referto the Symptom TroubleshootingIndex
i n t h i ss e c t i o n .
lf you can't duplicate the DTC
Some of the troubleshootingin this sectionrequires
you to resetthe ECM and try to duplicatethe DTC.lf rhe
problem is intermittentand you can't duplicatethe code,
d o n o t c o n t i n u et h r o u g ht h e p r o c e d u r eT. o d o s o w i l l
o n l y r e s u l ti n c o n f u s i o na n d ,p o s s i b l ya, n e e d l e s s l y
r e p l a c e dE C M .
(cont'd)
11-3
J
GeneralTroubleshootingInformation(cont'dl
How to Resetthe ECM
You can resetthe ECM in eitherof two ways:
. U s et h e O B Dl l s c a n t o o lo r H o n d aP G M T e s t e r t o
resetthe ECM memory.
Seethe OBD ll scantool or HondaPGI\4Testeruser's
manualsfor specificinstructions.
' Turn the ignition switch OFF,and removethe No. 6
ECU{ECM}(15A)fuse (A)from the under-hoodfuse/
r e l a vb o x ( B l f o r 1 0 s e c o n d s .
How to Removethe ECMfor Testing
1. Removethe passenger'sdashboardlower cover
{seepage 20-63),the passenger'skick panel (see
page 20-63),and the glove box (seepage 20-63).
2. Removethe ECM mounting bolts (B)and the ECM
(c),
9.8 N.m
{1.0kgf.m,7.2lbt.ft}
3 . R e m o v et h e E C M ( B ) .
How to Enda TroubleshootingSession
(requiredafterany troubleshootingl
L
4. Installthe ECM in the reverseorder of removal.
1. Resetthe ECM as describedabove.
2 . D o t h e E C Mi d l e l e a r np r o c e d u r e( s e ep a g e1 1 - 1 3 9 )
4. DisconnecttheOBD ll scantool or Honda PGM
Testerfrom the DLC.
NOTE:The ECM is part of the immobilizersystem.
lf vou replacethe ECM,it will have a different
immobilizercode. In order for the engineto start,
you must rewritethe immobilizercode with the
Honda PGM Tester.
\- ta
11-4
How to TroubleshootCircuitsat the ECM
. DigitalMultimeterKS-AHM-32-003
(1) or a
commerciallyavailabledigital multimeter
. BackprobeSet 07SAZ-0010004
(2)
1. Connectthe backprobeadapters(A) to the stacking
patchcords (B),and connectthe cords to a digital
m u l t i m e t e (r C ) .
2 . U s i n gt h e w i r e i n s u l a t i o n
a s a g u i d ef o r t h e
contouredtip ofthe backprobeadapter,gently slide
the tip into the connectorfrom the wire side until it
touchesthe end of the wire terminal.
3. lf you cannot get to the wire side of the connector
or the wire side is sealed(A),disconnectthe
connectorand probe the terminals(B)from the
terminal side. Do not force the Drobeinto the
connector.
Do not puncturethe insulationon a wire.
Puncturescan causeDooror intermittent
electricalconnections.
07sAz-001000A
(cont'd)
11-5
Information(cont'd)
ECMUpdatingand Substitutionfor Testing
HondaInterfaceModule (HlM) EOS05435570
(
How to Substitute the ECM
'1.
Removethe ECMf rom the vehicle.
2. Installa known-goodECM in the vehicle.
Usethis procedurewhen you haveto substitute a
known-goodECM in a troubleshootingprocedure.
does not alreadyhave
U pdatethe ECMonly if the ECN4
the latestsoftwareloaded,
NOTE;
. lMakesure the batteryis fully chargedbeforeyou
updatethe ECN4.
. To preventECMdamageduring the update,do not
turn the ignition switch OFF,and do not use any of
the vehicle'selectricaldevices(light,horn, radio,etc. ).
3 . R e w r i t et h e i m m o b i l i z ecr o d ew i t h t h e E C M
replacementprocedurefrom the Honda PGM
Tester.lt allows you to startthe engine.
4. After completingyour tests,reinstallthe original
E C Ma n d r e w r i t et h e i m m o b i l i z ecr o d ew i t h t h e
E C Mr e p l a c e m e nptr o c e d u r e
o n t h e H o n d aP G M
T e s t e ra g a i n .
How to Update the ECM
1. Turn the ignition switch ON (ll).Do not startthe
e n gI n e .
2. Connectthe HondalnterfaceModule (HlM)to the
Data Link Connector{DLC)(A) locatedunderthe
d r i v e r ' ss i d eo f d a s h b o a r d .
L
EOS05A35570
Do the ECM updateprocedureas describedon the
HlN4label and in the ECM updatesystem.
\-
11-6
I
DTCTroubleshootingIndex
DTC
Temporary
DTC
Detection ltem
{MlLindication*)
P 0 0 1 (05 6 )
VariableValveTiming Control{VTC)Oil Control
P 0 0 1 (15 6 )
P0011
P 0 1 0 (73 )
P 0 1 0 (83 )
P 0 1 1 2( 1 0 )
(10)
P01r3
P 0 1 1 6{ 8 6 )
P0116
S o l e n o i dV a l v eM a l f u n c t i o n
VariableValveTiming Control(WC) System
Malfunction
Note
{ s e ep a g e11 ' 11 8 )
( s e ep a g e1 1 -11 9 )
(MAP)SensorCircuit
ManifoldAbsolutePressure
LowVoltaqe
(MAP)SensorCircuit
ManifoldAbsolutePressure
HiqhVoltaqe
( s e ep a g e1 ' l - 5 2 1
IntakeAir Temperature(lAT)SensorCircuitLow
Voltaoe
IntakeAir Temperature(lAT)SensorCircuitHigh
Voltaoe
EnglneCoolantTemperature(ECT)Sensor Range/
PerformanceProblem
(seepage 11-55)
( s e ep a g e1 1 - 5 3 )
(seepage '11-56)
{ s e ep a g e1 1 - 5 7 )
P0117
{6)
(ECT)SensorCircuit
EngineCoolantTemperature
LowVoltaqe
( s e ep a g e1 1 - 5 8 )
P 0 1 1{86 )
EngineCoolantTemperature(ECT)SensorCircuit
Hiqh Voltaqe
Throttle Position(TP)SensorCircuitLow Voltaqe
Throttle Posltion(TP)SensorCircuitHiqh Voltaoe
CoolinqSVStemMalfunction
Air Fuel Ratio(Ay'F)
Sensor(Sensor1) No Activity
Detected
SecondaryHeatedOxygen Sensor (SecondaryHO2S)
(Sensor2) CircuitLow Voltaqe
SecondaryHeatedOxygen Sensor (SecondaryHO2S)
( S e n s o2
r ) C i r c u i tH i q hV o l t a q e
SecondaryHeatedOxygen Sensor (SecondaryH02S)
( S e n s o2
r )SlowResDonse
SecondaryHeatedOxygen Sensor(SecondaryH02S)
(Sensor2) HeaterCircuitMalfunction
{ s e ep a g e1 1 - 5 9 )
P 0 1 2 t27 \
P 0 1 2 {37 )
P 0 1 2 8( 8 7 )
P 0 1 3 4( 4 1 )
P0128
P 0 1 3 (76 3 )
P0137
P 0 1 3 8( 6 3 )
P0138
P 0 1 3 (96 3 )
P0139
P 0 1 4 1( 6 5 )
P 0 1 7 1( 4 5 )
PO112l'45)
PO\11
PO\l2
P0300andany
of
P 0 3 0 (17 1 )
(721
PO302
P0303(73)
P0304(74)
P0301(7'1)
P0300andany
of
P0301
P0302
P0303
P0304
P0301
No. 1 Cyl n d e rM i s f i r e
P0302
No.2 Cvl n d e rM i s f i r e
P0303
N o . 3 C v l nder Misfire
FuelSvstemToo Lean
FuelSystemToo Rich
R a n d o mM i s f i r e
( s e eD a q e1 1 - 6 0 )
( s e ep a q e1 1 - 6 2 )
( s e eD a q e1 1 - 6 4 )
( s e ep a g e1 1 - 6 5 )
( s e ep a g e1 1 - 6 5 )
( s e ep a g e1 1 - 6 6 )
( s e ep a g e1 1 - 6 7 )
( s e ep a g e1 1 - 6 8 )
( s e ep a q e1 1 - 7 0 )
( s e eo a o e1 1 - 7 0 )
( s e ep a g e1 1 - 7 1 )
{ s e ep a g e1 1 - 7 2 )
{ s e ep a q e11 - 7 2 )
( s e eo a q e1 1 - 7 2 )
P0303(73)
P0304{74)
P0304
N o . 4 C v l nder Misfire
{seeDaqe11-72)
" ; T h e s e D T C sa r e i n d i c a t e db y a b l i n k i n gm a l f u n c t i o ni n d i c a t o lra m p ( M l L ) w h e nt h e S C Ss e r v i c es i g n a l i n e i s
jumped with the Honda PGM Tester.
P0302(721
{cont'd)
11-7
DTCTroubleshootingIndex(cont'd)
(
\
KnockSensorCircuitN4alfunction
PO4i{
P 0 4 5 1( 9 1 )
TU45I
P0452
CrankshaftPosition(CKP)SensorIntermittent
( s e ep a g e1 1 - 7 8 )
CamshaftPosition(CMP)SensorA No
CamshaftPosition(CMP)SensorA Intermiftent
( s e eo a q e1 1 - 1 2 1
i s e ep a g e1 1 - 1 2 1 )
Phqse
G
Yetrgb-le
VelyeTiTing_controlll/T!)
s e eo a o e1 1 - 1 2 2
CqJalystSystemElficie-ncy
Below Threshold
s e eo a q e11 -1 6 7
( F T PS
) e n s o rR a n g e / P e r f o r m a n c e( s e e p a g e l l 1 7 1 )
F u e lT a n kP r e s s u r e
SensorCircuitLow V
FuelTank Pressure(FTP)SensorCircuitHigh V
V e h i c l eS D e e dS e n s o r
C i r c u i tM a l fu n c t i o n
E n g i n eC o n t r o M
l o d u l e( E C N 4P)o w e rS o u r c eC i r c u i l
11-172
s e eD a q e1 1 - 1 3 0 )
( s e ep a g e11 - 8 1 )
SeriaC
l o m m u n i c a t i o Ln i n kM a l f u n c t i o n
Referto the l\4ultiplex
ControlSystem
T r o u b l e s h o o t i n{gs e e
P 1 1 0(61 3 )
(BARO)
Barometric
Pressure
SensorRange/
PerformanP
c er o b l e m
( s e ep a g e11 - 8 3 )
P 1 1 0(?1 3
( B A R OS
) e n s o rC i r c u i tL o w
BarometriP
c ressure
( s e ep a S e11 ' 8 3 )
P 11 0 8( t s '
( B A R OS
) e n s o rC i r c u i tH i g h
BarometriP
c ressure
{ s e ep a g e1 1 - 8 3 )
P112111)
P't121
T h r o t t l eP o s i t i o n{ T P iS e n s o rS i g n a lL o w e rT h a n
( s e ep a g e1 1 - 6 3 )
P1122ll J
Pl122
T h r o t t l eP o s i t i o n( T P )S e n s o rS i g n a lH i g h e rT h a n
tsee page I r-oJ,
i j 1 1 2 8( 5 )
P11f,.8
Pr 158 (48)
(l\,4AP
M a n i { o l dA b s o l u t eP r e s s u r e
S }e n s o rS i g n a l
G;tp"s" 1154)
Loqer Than Expected
( * " p a S e11 5 4 )
ManifoldAbsolutePreisure (MAP)SeiiioiSgnul
H i q h e rT h a nE x
( s e ep a g e1 1 - 8 4 )
A i r F u e lR a t i o( A V FS) e n s o r( S e n s o r1 ) R a n g e /
R e r f o r m a n cP
eroblem
A i r F u e lR a t i o { A " FS) e n s o r{ S e n s o 1
r ) A F S T e r m i n a l ( s e ep a g e11 - 8 5 )
P 11 5 9( 4 8 )
'l)
A i r F u e lR a t i o1 A V FS)e n s o ri s e n s o r A F S+ T e r m i n a l ( s e ep a g e11 - 8 6 )
P 1 1 6 3( 6 1
P 1 1 6 4( 6 1 )
Air FuelRatio{A,/F)Sensor{SensorI ) Slow Response
( s e ep a g e 11 - 8 8 )
A i r F u e lR a t i o( A / F )S e n s o r( S e n s o r1 ) R a n g e /
P 11 2 9( 5 )
P 1 1 5 7( 4 8 )
l\."
-
P 11 6 6( 4 1 )
( s e ep a g e1 1 - 8 9 )
Air Fuel Ratio(4,/F)Sensor(Sensor1) HeaterCircuit
Malfunction
Air Fuel Ratio(A,/F)Sensor(Sensor1) HeaterSystem ( s e ep a g e1 1 - 9 1 )
P 11 6 7( 4 1 )'
Malfunction
" : T h e s eD T C Sa r e i n d i c a t e db y a b l i n k i n gM I L w h e n t h e S C Ss e r v l c es i g n a l i n e i s j u m p e dw i t h t h e H o n d aP G M
Tester.
* 1 r' 0 2 m o d e l
\.
11-8
a
DTC
Temporary
DTC
Detectionltem
{MlLindication*l
P1259t22J
VTECSystem l\4alfunction
P1291t20\
ElectricalLoad Detector(ELD)CircuitLow Voltaqe
P1298(20)
ElectricalLoad Detector(ELD)CircuitHiqh Voltaqe
P 1 3 6 1( 8 )
P 1 3 6 (28 )
P'r456(90)
P1456
(90)
P14s7
P1457
P 1 5 0 (51 0 9 )
P1505
(14)
P1519
P 1 6 0 7( )
CamshaftPosition(CMP)SensorB (Top DeadCenter
(TDC)Sensor)IntermittentSional InterruDtion
CamshaftPosition(CMP)Sensor B (Top DeadCenter
( T D C )S e n s o r N
) o Siqnal
EvaporativeEmissions(EVAP)ControlSystem
Leakaqe(FuelTank Svstem)
EvaporativeEmissions(EVAP)ControlSystem
Leakaqe(EVAPCanisterSvstem)
PositiveCrankcaseVentilation(PCV)Air Leakaqe
ldle Air Control(lAC)ValveCircuitMalfunction
EnginC
e o n t r oM
l o d u l e( E C MI)n t e r n aCl i r c u i t
Malfunction
Page
( s e eD a q e1 1 - 1 2 3 )
( s e eD a q el 1 - 9 2 )
( s e eo a o e1 1 - 9 3 )
( s e ep a g e1 1 - 9 5 )
( s e ep a g e1 1 - 9 5 )
( s e ep a g e1 1 - 1 7 5 )
( s e ep a g e1 ' l - 1 8 0 )
( s e eo a q e1 1 - 1 6 8 1
{ s e ep a q e1 1 - 1 3 1 )
( s e ep a g e11 - 9 6 )
" : TheseDTCSare indicatedby a blinking MIL when the SCSservicesignal line is jumped with the Honda PGM
Tester.
11-9
\
When the vehiclehas one of these symptoms,checkthe diagnostictrouble code (DTC)with the scantool. lf there is no
DTC,do the diagnosticprocedurefor the symptom, in the sequencelisted,until you find the cause.
Svmotom
E n g i n ew i l l n o t s t ar t
(MlL works OK, no DTCSset)
Diaqnostic procedure
1. Testthe battery{seepage 22-50).
2. Testthe starter(seepage 4-8).
3. Troubleshootthe fuel pump circult(seepage 11
141).
E n g i n ew i l l n o t s t a r t( M l L
comes on and stayson, or
n e v e rc o m e so n a t a l l ,n o
DTCSset)
Enginewill not start
(immobilizerindicatorstays
on or flashs)
Troubleshootthe l\4lLcircuit(seepage 1
Hardstarting
(MlLworksOK,no DTCS
set)
1. Testthe battery(seepage22-50).
2 . C h e c k t h ef u e l p r e s s u r e( s e ep a g e1 1 - 1 4 5 ) .
Coldfast idle too low
(MlL works OK. no DTCSset)
Coldfast idle too high
1 . D o t h e E C Mi d l e l e a r np r o c e d u r e( s e ep a g e1 1 - 1 3 9 ) .
2 . C h e c k t h ei d l e s D e e d( s e ep a q e1 1 - 1 3 8 ) .
' ] D o t h e E C I \ 4i d l e l e a r np r o c e d u r e( s e ep a g e11 -1 3 9 ) .
2. C h e c k t h ei d l es p e e d{ s e ep a g e1 1 - 1 3 8 ) .
'1-'163).
the throttlecable (seepage 1
3 . Inspect/adjust
Inspectand test the throttle body {seepage 11-160}.
( s e ep a g e1 1 - ' 1 3 9 ) .I n t a k ea i r l e a k s
1 . D o t h e E C Mi d l e l e a r np r o c e d u r e
2 . C h e c kt h e i d l es p e e d( s e ep a g e1 1 - 1 3 8 ) .
3, Inspecvadjustth e throttlecable (seepage 11''163).
4. Insoectand test the throttle bodv (seepaqe 11-160)
1 . D o t h e E C I Vi d
I l e l e a r np r o c e d u r e( s e ep a g e11 -1 3 9 ) . Vacuum hose clogged/
cracked/poor
2. TroubleshootthealternatorFRsignalcircuit (see
p a g e1 1 - ' 1 3 4 ) .
connectron
3. InsDectand test the throttle bodv {seepaqe 11-160).
1 . D o t h e E C Mi d l e l e a r np r o c e d u r e
{ s e ep a g e1 ' j - 1 3 9 ) .
t e a l t e r n a t oFr Rs i g n a lc i r c u i t ( s e e
2 . T r o u b l e s h o ot h
p a g e1 1 - 1 3 4 ) .
ldle speedfluctuates
After warming up, idle speed
is below specificationswith
no load
{MlL works OK, no DTCSset)
After warming up, idle speed
is above specificationswith
no toao
Low power
E n g i n es t a l l s
'1-97).
Also check lor
Low compressron
N o i g n i t i o ns p a r k
l n t a k ea i r l e a k s
L o c k e du p e n g i n e
B r o k e nt i m i n gc h a i n
Contaminatedfuel
Troubleshootthe immobilizersystem (seepage 22-165).
1 . C h e c kt h e f u e l p r e s s u r e ( s e e p a g e l l - 1 4 5 ) .
2. Inspectand test the th roftle body (seepage 11-160).
3 . I n s p e c v a d j u tsht e t h r o t t l ec a b l e( s e ep a g e1 1 - ' 1 6 3 ) .
1.
2.
3.
4.
D o t h e E C Mi d l el e a r np r o c e d u r e( s e ep a g e1 ' l ' 1 3 9 ) .
C h e c kt h e f u e l p r e s s u r e { s e e p a g e l l - 1 4 5 ) .
C h e c kt h e i d l es p e e d( s e ep a g eI 1 - 1 3 8 ) .
Troubleshootthebrakepedal positionswitch signal
c i r c u i t( s e ep a q e1 1 - 1 3 7 ) .
Low compression
I n t a k ea i r l e a k s
Contaminatedfuel
\-
Low compressron
C a m s h a ftti m i n g
problem
E n g i n eo i l l e v e l
prootem
l n t a k ea i r l e a k s
F a u l t yh a r n e s sa n d
sensorconnections
\-
11-10
Symptom
Difficultto refuel
Fueloverflowsduring
refueling
(No DTCSset)
Diagnosticprocedure
1 . T e s t t h e f u e lt a n kv a p o rc o n t r o lv a l v e { s e e p a g e1 ' l 2. 1471.
I n s p e ctth e f u e lt a n kv a p o rc o n t r o ls i g n a lt u b e
3. betweenthe fuel pipe and the fuel tank vapor
control valve.
4. Inspectthe fuel tank vapor vent tube betweenthe
EVAPcanisterand the fuel tank vapor control valve.
Checkthe EVAPcanister.
Replacethe fuel tank vapor control valve (seepage '11
189).
Also checktor
M a l f u n c t i o n i ngga s
s t a t i o nf i l l i n gn o z z l e .
Malfunctioninggas
stationfilling nozzle.
11-11
SystemDescriptions
\
{
ElectronicControl System
The functionsof the fuel and emlssioncontrol systemsare managedby the enginecontrol module (ECM).
Fail-safeFunction
When an abnormalityoccursin the signalfrom a sensor,the ECI\4ignoresthat signaland assumesa pre-programmed
value for that sensorthat allowsthe enqineto continueto run.
Back-up Function
When an abnormalityoccursin the ECM,the injectorsare controlledby a back-upcircuitindependentof the systemto
p e r m i tm i n i m a ld r i v i n g .
Self-diagnosis
When an abnormalityoccursin the signalfrom a sensor,the ECM suppliesground for the malfunctionindicatorlamp
{MlL) and storesthe diagnostictrouble code {DTC)in erasablememory.When the ignition is first turned on, the EClvl
suppliesground to the l\4lLfor 15 to 20 secondsto checkthe M lL bulb condition.
Two Driving Cycle Detection Method
"two driving cycle detectionmethod" is usedfor some self-diagnostic
functions.
To preventfalse indications,the
When an abnormalityoccurs,the ECM storesit in its memory. When the same abnormalityrecursafterthe ignition
s w i t c hi s t u r n e dO F Fa n d O N ( l l )a g a i n ,t h e E C Mt u r n so n t h e M l L .
\
\.
11-12
ECMData
You can retrievedata from the ECI\4by connectingthe OBD ll scantool or the Honda PGM Testerto the data link
connector(DLC).The items listedin the table below conform to SAE recommendedpractice.The HondaPGM Tester
also readsdata beyondthat recommendedby SAEto help you find the causesof intermittentproblems.
The "operatingvalues" listedare approximateand may vary dependingon the environmentand the individual
vehicle.
Unlessnoted otherwise,"at idle speed" means idling with the enginecompletelywarmed up in the neutralposition,
and the A,/Cand all
Diagnostic
Trouble Code
(DTC}
lf the ECM delectsa problem, it will store it as a code
consistingof one letterand four numbers.Dependingon
the problem,an SAE-definedcode (Poxxx)or a Honda,
definedcode {P1xxx)will be output to the tester.
l f n o p r o b l e mi s
detected,there is no
ourpul.
YES
TheECI\4
computesenginespeedfromthe signalssent
N e a r l yt h e s a m ea s
position(CKP)sensor.Thisdatais
fromthe crankshaft
tachometerindication
usedfor determining
thetimeandamountof injectedfuel. At idle speed;
Manifold
Absolute
Pressure
(MAP)
The ECMconvertspulsesignalsfrom the vehiclespeed
sensor(VSS).
N e a r l yt h e s a m ea s
speedometer
indication
The absolutepressurecausedin the intakemanifold by
e n g i n el o a da n d s p e e d .
Withenginestopped:
YES
Nearlythe same as
almospnencpressure.
At idle speed:about
20 4'1kPa
( 1 5 0 3 1 0m m H g ,
6 - 1 2 i n . H q ) . 0 . 71 . 3V
The ECTsensorconvertscoolanttemperatureinto voltage W i t h c o l d e n g i n e :
and signalsthe ECM.The sensor is a thermistorwhose
S a m ea s a m b i e n t
internalresistancechangeswith coolanttempetature.The temperatureand IAT
ECM usesthe voltagesignalsfrom the ECTsensorto
With enginewarmed
determinethe amount of injectedfuel.
u p ; a b o u t1 1 6 2 ' 1 2 " F
1 0 0 ' c ) . 0 . 5 - 0 .v8
Air Fuel Ratio
( A y ' FS)e n s o r .
(Sensor1)
Secondary
Heated
Oxygen
Sensor
(Secondary
H02S,
Sensor2)
The A,/Fsensordetectsthe oxygen content in the exhaust 0.0- 1.25 V
g a s a n d s e n d sv o l t a g es i g n a l st o t h e E c l v l ,B a s e d o n t h e s e 8 . 0 1 1 . 0 m A ( P G M
signals,the ECMcontrolsthe airlfuel ratio.When the
I Tester)
oxygen contentis high (that is, when the ratio is leaner
At idle speed:
than the stoichiometricratio),the voltagesignal is Iower. about 0.1 0.9 V
When the oxygencontent is low (that is, when the ralio is
richerthan the stoichiometricratio).the voltagesignal is
higher.The A'lFsensorsignalsare electricalcurrentthat
are indicatedas voltaqe on the
The HO2Sdetectsthe oxygen contentin the exhaustgas
0 . 0 1 . 2 5V
a n d s e n d sv o l t a g es i g n a l st o t h e E C M .B a s e do n t h e s e
At idle speed:
signals,the ECMcontrolsthe airlfuel ratio.When the
a b o u t0 . 1 0 . 9V
oxygen contentis high (that is, when the ratio is leaner
than the stoichiometricratio),the voltagesignal is lower.
When the oxygen content is low (that is, when the ratio is
r i c h e rt h a nt h e s t o i c h i o m e t r irca t i o ) t, h e v o l t a g es i g n a li s
NO
(cont'd)
11-13
r a
SystemDescriptions(cont'd)
ECMData(cont'd)
Description
"open" or "closed".
Fuelsystem statusis indicatedas
Closed:Basedon the A,/FSensoroutput,the ECM
determinesthe airlfuel ratio and controlsthe amount of
injectedfuel.
Open: lgnoringAy'FSensoroutput,the ECM refersto
signalsfrom the throttle position{TP),manifoldabsolute
pressure(MAP),intakeair temperature(lAT),barometric
pressure(BARO),and enginecoolanttemperature(ECT))
sensorsto controlthe amount of iniectedfuel.
The airlfuel ratio correctioncoefficientfor correctingthe
Short Term
amount of injectedfuel when the fuel system status
FuelTrim
is "closed." When the ratio is leanerthan the
sloichiometricratio,the ECM increasesshort term fuel
trim gradually,and the amount of iniectedfuel increases.
The airlfuel ratio graduallygets richer,causinga lower
oxygen content in the exhaustgas. Consequently,the
short term fuel trim is lowered,and the ECM reducesthe
amount of injectedfuel.
This cvcle keepsthe airlfuelratio closeto the
stoichiometricratio when in closedloop status.
Long term fuel trim is computedfrom short term fuel trim
LongTerm
and indicateschangesoccurringin the fuel supply system
F u eT
l rim
over a long period.
l f l o n gt e r m f u e lt r l m i s h i g h e rt h a n 1 . 0 0t,h e a m o u n lo f
injectedfuel must be increased.lf it is lower than 1.00,the
amount of injectedfuel must be reduced.
The IAT sensorconvertsintakeair temperatureinto
IntakeAir
Temperature v o l t a g ea n d s i g n a l st h e E C M .W h e n i n t a k ea i r
temperatureis low, the internalresistanceofthe sensor
{IAT)
increases,and the voltagesignal is higher.
Basedon the acceleratorpedal position,the opening
Throttle
anole of the throttlevalve is indicated.
Position
lgnitiontiming is the ignition advanceangle set by the
lgnition
ECM.The ECM matchesignitiontiming to driving
Timing
conditions.
Data
FuelSystem
Status
Calculated
L o a dV a l u e
(cLV)
cLV is the enoine load calculatedfrom IMAPdata.
Opera'tingValue
At idle speed:closed
FreezeData
YES
o.7 1.5
YES
0.8 1.2
YES
w
W i t h c o l de n g i n e :
S a m ea s a m b i e n t
a n dE C T
temperature
YES
At idle speed:
a b o u t1 0%
At idle speed:8" t 5"
| ' t u L w n e nr n e > L )
s e r v i c es i g n a l i n e i s
jumped with the Honda
PGM Tester
At idle speed:
12 34%
At 2.500rpm with no
toao:
't4- 34%
YES
NO
YES
\.,
11-14
J/-\
-1\_/
BEIAY2
A/C CLUTCHRELAY
I
)
RAOIATOR
T
UNDER.HOOD
FUSE/RELAY
BOX:
(8oA)
ONo. 19BATTERY
ONo.6 ECU(ECM)(15A1
(3)No.20lG
{40A1
{Canada:50A}
ONo.l4 OPTION
{40A1
€)No.9 BACKuP (7.5A1
lo)No.7 HORN,STOP{15A}
UNDER.DASH
FUSE/RELAY
BOX:
ONo. 17FUELPUMP
{15A}
@No.,t ACG{10A)
ONo.1 IGNCOIL(1sA)
q)No.10METER
(7.5A)
0)No.14A/C CLUTCH
RELAY
IlOA)
@No.2+B LAF(A/F)
(2OA)
HEATER
(cont'd)
11-15
SystemDescriptions(cont'dl
a
\
ECMElectricalConnections
MAPSENSON
No. INJECTOR
No,2INJECTOR
TPSENSOR
No.3 INJEC]OB
No./tINJECTOF
IATSENSOR
ECTSENSOB
\'
CMP SENSORB
(TDCSENSOSJ
CKPSENSOR
F€VERSELOCK
SOLENOIDVAIVE
\-
11-16
A/FSENSOR
EVAPCANISTE6
PURGEVAIVE
EVAPCANISTER
VENTSHUTVATVE
A/FSENSOR
(sENSOn 1)
sotENotovAtvE
CMP SENSOFA
VIC OIL CONTROL
SO!ENOIDVALVE
No. 1 IGNITIONCOIL
wEcorl
N o . 2 l G N l l l O NC O I L
No. 3 IGNITIONCOIL
PRESSUSESWTICH
VTEC SOLENOID
No. a IGNITIONCOIL
{cont'd)
11-17
\
ECMElectricalConnections
ARAKEPEDAL
POStTtONSWTTCH
GAUGEASSEMBLY
IMMOBILPENUN|T
\
EPSCONTROTUNIT
TERMINALLOCATIONS
\-
11-18
ECMInputsand Outputsat ConnectorA (31P)
2
1
AFS]TC ]GP2
'10
SG2
t1
3
IGPl
^:^ I -:,
12
ACV
22
23
HTC+ LG2
6
AFS+
15 T6
TPS AFS_
26
25 CMPB
CMPA(rDc)
I
KS
1
CKP
18
1 9 2A
V S S IVAP vcc2
21
vccl
27
28
29
30
tGPts,lrcPts3tGPts2GPLS
1
NOTE:Standardbatteryvoltageis 12V.
Terminal Who color
numb€r
ELKAVHT
forminal name
2
YEUBLK
AFSHTC(AIRFUELRATIO
(4./F)SENSOR
HEATER
CONTROL}
IGP2(POWEB
SOURCE)
3
YEUBLK
IGPl {POWER
SOURCE)
4
5
6
1
9
10
12
18
PG2(POWER
GROUND
PG1(POWER
GROUND
AFS+ (AIRFUELRATIO
(A,/F}SENSOR,
SENSOR1
+ stDE)
8LU
CKP(CRANKSHAFT
POSITION
SENSOR)
BED/BLU
) KS E N S O B )
YEL
2 {SENSOR; R O U N D )
G 1{ S E N S O R
;ROUND)
BLIVRED IACV(IDLEAIRCONTROL
(IAC)VALVE)
RED/BLK TPS(THROTTLE
POSITION
SENSOR)
REDI/EL AFS (AIRFUELRATIO
(4,/F)SENSOR,
SENSOB1
SIDE)
WHT/GRN V S S ( V E H I C L ES P E E D
BLK
BLK
RED
SENSOR)
Description
Signal
DrivesAy'Fsensorheater
Withignit'onswitchON {ll):batteryvoltage
Withfullywarmedup enginerunnang:
0V
Powersourcefor the ECM
circuit
Powersourcefor the ECM
Withthe ignitionswitchON 1ll):batteryvoltage
Withthe ionitionswitchOFF:about0 V
Withthe ignitionswatch
ON {ll):batteryvoltage
Withthe ionitionswitchOFF:about0 V
Lessthan 1.0V at all times
Groundforthe ECMcircuit
Groundforthe ECMcircuit
DetectsAy'Fsensor
{sensor1)signal
Detects
CKPsensorsignal
Withenginerunning:pulses
Detectsknocksensorsiqnal
Sensorqrounr
Sensorqroun(
DrivesIACvalve
pulses
Withenqineknocking:
Lessthan1.0Vat elltimes
L e s s t h a 1n . 0 Va t a l l t i m e s
Withenginerunningrdutycontrolled
Detects
TPsensorsignal
Withthrottlefullyopen:about4.8V
Withthronlefullvclosed:ahout0-5V
Detects!y'Fsensor
( s e n s o1r) s i g n a l
Detects
VSSsignal
WathignitionswitchON (lli andfrontwheels
rotating:
cyclesfrom about0 V to about5 V or
(cont'd)
11-19
\. il
SystemDescriptions{cont'd)
ECMInputsand Outputsat ConnectorA (31P)
1
AFS]TC
2
GP2
3
IGPl
4
PG2
12
10
11
SG2 sG1 IACV
22
23
AFS LG2
HTC+
5
6
PG.1 AFS+
'15 1 6
TPS AFS_
26
25 CMPB
Ct\.4PA
(rDc)
I
KS
1
CKP
18
1 9 20
V S S IVAP vcc2
21
vccl
29
30
27
28
IGPLS,I
IGPLS4
IGPLS3
IGPLS2
NOTE:Standard
batteryvoltageis 12V.
[€rminal namo
Description
Jorminal Wirecolor
number
19
DetectsMAPsensorsignal
GRN/RED MAP(MANIFOLD
PRESSURE
ABSOLUTE
SENSOR)
YEUBLU VCC2(SENSOR
VOLTAGE) P r o v i d e ss e n s o r v o l t a g e
20
21
YEURED VCC](SENSOB
VOLTAGE) Provides
sensorvoltage
22
AFSHTC- (AIRFUEL
Detectsa,/Fsensorheater
RATIO(A"iFiSENSOR
voltage
+ SIDE)
HEATER
CONTROL
BRN?ryE
L
LG2(LOGIC
GROUND
roundfor the ECMcircu
1(L
roundfor the ECMcircu
BRN?ryE
L
D e t e c t sC M P s e n s o r A
BLU,^/VHT CMPA (CAMSHAFT
A)
stonal
POSITION
SENSOR
Detects
GRN
CMPB CAMSHAFT
CMPsensor8 (TDc
(CMP)SENSOB sensor)
POSITION
B (TDC(TOPDEADCENTER
SENSORi)
I G P L S 4{ N o .4 I G N I T I O N
DrivesNo, 4 ignitioncoi
BRN
23
24
25
26
27
COILPULSE)
I G P L S 3{ N o . 3 I G N I T I O N
COILPULSE)
28
WHT/BLU
29
GNITION
BLU/RED l G P L S 2 l N o .I 2
COILPTJLSE)
YEUGRN IGPLSI(No.1 IGNITION
co PlltsF)
30
Signal
With ignitionswitchON (ll):about3 V
A t i d l e : a b o u t 1 . 0V ( d e p e n d i n go n e n g i n e s p e e d )
With ignitionswitchON {ll):about5 V
WithionitionswitchOFF:about0V
WithignitionswitchON {ll):about5 V
With ionitionswitchOFF:about0V
W i t h i g n ; t i o ns w i t c h O N l l l ) : b a n e r y v o l t a g e
\.
Lessthan1.0V at alltimes
L e s st h a n
'1.0
V at alltimes
WithignitionswitchON (ll)rabout0 v
O r i v e s N o . 3 r g n i t i o nc o i
DrivesNo.2 ignitioncoil
DrivesNo. I ignitioncoil
\.
11-20
a
a
Wire side o{ femaleterminals
NOTE:Standardbafteryvoltageis 12V.
Terminal
numo€t
Wirecolor
[erminal name
Description
BLUAvHT VTC+ lVTCOILCONTBOL DrivesVTCoilcontrol
2
3
4
5
6
7
8
9
10
'17
18
21
23
VALVE+SIDE)
SOLENOID
lNJa{No.4INJECTOR)
Jo.3INJECTORI
BL
)TOR)
R1
lNJl 1No.I INJECTOR)
BRN
FAN
FANC(RAOIATOR
GRN
CONTROL)
LOCK
GRN/vVHT RVS(REVERSE
VALVE)
SOLENOID
Drives o. 4 iniector
Drives o.3 iniector
Drives o . 2 i n i e c t o r
DrivesNo. 1 iniector
Drivesradiatorfan relay
Signal
WithignitionswitchON (ll):0 V
At idle:dutycontrolled
With radiatorfan running:about0 V
With radiatorfan stopped:battervvoltaoe
Drivesreverselocksolenoid Withvehiclespeedbelow9.4mph (15km/h):
batteryvoltage
Withvehiclespeedabove12.5mph (20km/h):0 V
Withthe ignitionswitchON (ll):about0.1 4.8V
DetectsECTsensorsignal
COOLANT
REDAVHT ECT(ENGINE
ideoendino
on enoinecoolanttemDerature)
TFMPFRATURE
SENSOR)
VTEcoil pressure Withengineat low enginespeed:about0 .
Detects
BLU/BLK VTPSW(VTECOIL
Wirhenoineat hiohenoinesoeed:battervvoltaqe
PRFSSTIRF
SWITCH)
switch sional
L signal With ignitionswit'chON (ll):about0 V
L
Detects
alternator
WHT/BLU ALTL(ALTEBNATOR
Whh enoinerunnino:battervvoltaqe
SIGNAII
FBsignal Withenginerunning:about0 V- 5 V
FR
Deteclsalternator
WHT/RED ALTF(ALTERNATOR
load)
on electrical
S I GN A L I
{deoendinq
DrivesVIECsolenoidvalve A t i d l e : a b o u t 0 V
GRN/YEL VTS {VTECSOLENOID
With ignitionswitchON {ll):about0.1V 4.8v
l.lcnen.iino
on intakeairtemoerature)
Withenginerunning:about0 V 5 V
control
Sendsalternator
(.lcocn.lino
on electrical
ioad)
purge Withenginerunning,enginecoolantbelow149'F
DrivesEVAPcanister
batteryvoltage
valve
165'C):
Withenginerunning,enginecoolantabove149'F
165"C):
dutvcontrolled
W i t h t h e i g n i t i o n s w i t c h O N ( l l ) :0 V
BLK/Vr'HT VTC (VTCOILCONTROL DrivesVTCoilcontrol
SOIFNOIDVALVE SIDE)
IAT(INTAKE
AIR
TEMPERATURE
SENSOR)
WHT/GRN ALTC(ALTERNATOR
CONTROL)
YEUBLU PCS{EVAPORATIVE
EMISSION
CANISTER
PURGE
VALVE)
REDI/EL
DetectsIATsensorsignal
(confd)
11-21
L
ECMlnputsand Outputsat ConnectorE (31P}
1
iMo
FPR
2
3
sr-{]zsLG3
22
23
24
BKSWK-LINESEFMJ
6
1
$1025 MRLY
HTC
16
14
15
18
FTP ELD EPS
ACC
LD
21
26
rMo
NEP
CD
8
AFS
HTCR
4
SG3
I
20
21
Z/VBS VSV
29
scs
30
31
WEN MIL
NOTE:Standardbatteryvoltageis '12V.
Terminal Wire color
number
GRNI/EL
2
3
4
5
6
1
(SECONDARY Drivessecondary
BLKATr'HT SO25HTC
HO2S
HEATED
OXYGENSENSOR heater
(SECONDARY
H02S)
HEATER
CONTROL)
REDA/EL MRLY(PGM.FI
MAIN
DrivesPGM-Flmain
relay1
RELAY}
Powersourceforthe DTC
ORN
I
YEUBLK
'18
Description
IMOFPR(IMMOBILIZER D r i v e s P G M F l m a i n r e l a y 2
FLJEL
PUMPRELAYI
WHT/RED SHO2S(SECONDARY
DetectssecondaryHO2S
HEATED
OXYGENSENSOR {sensor2) signal
(SECONDARY
HO2S),
SENSOR
2r
BRN/YEL LG3(LOGIC
GROUND)
cround forthe ECM/PCM
controlcircuit
PNK
SG3{SENSOR
GBOUND) Sensororound
YEUELU VCC3{SENSOR
VOLTAGE) Providessensorvoltage
I
't4
ferminal name
LT GRN
0Vfor2 secondsafterturningignitionswitchON
{ll).then battervvoltaoe
WiththrottleJullyopenedfrom idlewith fully
warmedup engine:above0.6V
Withthrottlequicklyclosed:below0.4V
Lessthan1.0V at all times
With ionitionswitchOFF:about0 V
With ignitionswitch ON (ll):bafteryvoltage
Wilh fullvwarmedup enginerunning:dul,
controlled
WithignitionswirchON {ll):0 V
IGl (IGNITION
SIGNAL)
With ignition switch ON (ll): battery voltage
With iqnition switch OFF: about 0 V
D e t e c r si g n i t i o n s i g n a l
u
WithignitionswitchON (ll):about0 V
With ignitionswitchOFF:batteryvoltage
AFSHTCR
{AIRFUELBATIO Drivesairfuel ratiosensor
(Iy'F)SENSOR
HEATER
heaterrelay
CONTROLRELAY)
FIP lFUELTANK
(FTP)SENSOR)
PRESSURE
GRN/RED ELD(ELECTRICAL
LOAD
DETECTOF)
LTGRN/8LK EPSLD(ELECIRICAL
POWEBSTEEBING
LOAD
DETECT)
RED
Signal
WithignitionswitchON (ll)andfuelfill capopen:
about2.5V
DetectsELDsignal
WithignitionswjtchON itt):aOoutO.t
V l-gV
(deDendino
on electrical
load)
DetectsPowersteeringload At idlewith steeringwheelin straightahead
srgnal
position:about0 V
At idlewith steeringwheelatfulllock:momentary
DetectsFTPsensorsignal
ACC(Ay'C
CLUTCH
RELAY) DrivesP,/Cclutch relay
Withcompressor
ON:about0 V
With comoressorOFF:battervvoltaoe
\-
11-22
ECMInputsand Outputsat ConnectorE (31P)
l
2
t M o $.c2s
FPR
14
FTP
22
23
24
BKSWK LINESEFMJ
I
AFS
HTCR
6
1
SFIO2S
IV
RLY
HTC
i
15
ELD
16
EPS
LD
26
NEP
21
20
2,4/BS VSV
t8
21
lvo
CD
9
tGl
29
scs
30
31
WEN MIL
NOTE:Standardbatteryvoltageis 12V.
Terminal Wire color
20
21
22
23
21
29
Description
BLU/RED 2WBS(EVAPORATIVE
DrivesEVAPbypass
(EVAP)BYPASSsolenoidvalve
EMISSION
SOLENOID
VALVE)
DrivesEVAPcanistervent
LT GRN/RED VSV (EVAPORATIVE
shutvalve
EI\4ISSION
iEVAP)
VENTSHUT
CANISTEB
VALVE)
Detects brake pedal
WHT/BLK BKSWlBRAKEPEDAL
POSITION
SWITCH)
o o s i t i o ns w i t c h s i o n a l
scan
LT BLU
K-LIN E
Sendsand receives
YEL
26
Terminalname
SEFMJ
N E P( E N G I NSEP E E D
PULSE)
RED/BLU \40CDfl\4MOBTLTZER
CODE)
BRN
S C S ( S E R V I C EC H E C K
BLU
ENABLE
RED,A/VHT WEN(WRITE
SIGNALi
GRN/ORN MIL(MALFUNCTION
LAMP)
INDICATOR
WithignitionswitchON (ll):bafteryvoltage
W i t h i g n i l i o n s w i t c h O N ( l l ) :b a t t e r y v o l t a g e
With brakepedalreleased:
about0 V
With hrake nedal nresse.l: batterv voltaoe
With ignitionswitchON (li)rpulsesor battery
Withenoinerunninounderload:DUlses
Outputsenginespeedpulse Withenginerunning:pulses
C o m m u n i c a t e sw i t h
mrltinleYeontrolunit
D e t e c t si m r n o b i l i z e rs i g n a l
checksignalshortedwith the PGM
O e t e c t ss e r v i c ec h e c k s i g n a l Withthe service
Tester:about0 V
Wiih rheservicechecksionalooened:about5 V
SIGNAL)
30
Signal
D e t e c t sw r i t e e n a b l e s i g n a l
W i t h i g n i t i o n s w i t c h O N ( l l ) :a b o u t 0 V
DrivesN4lL
WithMILturnedON:about0 V
WithMILturnedOFF:battervvoltaqe
(cont'd)
11-23
!
VacuumHoseRouting
INTAKEAIR
BYPASSCONTROL
THERMALVALVE
\*
FRONTOF
VEHICLE
EVAPORATIVEEMISSION
{EVAP}CANISTERPURGEVALVE
\,
11-24
VacuumHoseRouting
I
1}
{SENSOR
O AIRFUELRATIOIA/F)SENSOR
HEATED
OXYGENSENSOR
O SECONDARY
2}
HO2S}{SENSOR
ISECONDARY
(MAPISENSOR
PRESSURE
ABSOLUTE
O MANIFOLD
{ECT)SENSOR
O ENGINECOOLANTTEMPERATURE
(IAT)SENSOR
O INTAKEAIRTEMPERATURE
(CKP)SENSOR
POSITION
O CRANKSHAFT
O KNOCKSENSOR
(CMPISENSOR
B
POSITION
O CAMSHAFT
ITDC)SENSOR)
ITOPDEADCENTER
A
POSITION
O CAMSHAFT
ICMPISENSOR
(IACIVALVE
@ IDLEAIRCONTROL
O THRONLEBODY
.OINJECTOR
OAMPER
@ FUELPULSATION
[I FUELFILTER
REGULATOR
@ FUELPRESSURE
@ FUELPUMP
@ FUELTANK
@ RESONATOR
(9 AIRCLEANER
VENTILATION{PCVIVALVE
@ POSITIVECRANKCASE
CONVERTER
WAYCATALYTIC
@ THREE
EMISSION
{EVAPICANISTER
@ EVAPORATIVE
EMISSION
{EVAP)CANISTER
@ EVAPORATIVE
PURGE
VALVE
(EVAPICANISTER
EMISSION
{} EVAPORATIVE
VENTSHUTVALVE
EMISSION
{EVAP)TWOWAYVALVE
{' EVAPORATIVE
EMISSION
IEVAPIBYPASS
@ EVAPORATIVE
VALVE
SOLENOID
(FTP)SENSOR
@ FUELTANKPRESSURE
EMISSION
IEVAP}VALVE
@ EVAPORATIVE
VALVE
@ FUELTANKVAPORCONTROL
VALVE
60)FUELTANKVAPORRECIRCULATION
VALVE
THERMAL
CONTROL
O INTAKEAIRBYPASS
(cont'd)
11-25
PGM-FISystem
The ProgrammedFuel Injection(PGM-Fl)system is a
sequentialmultiport fuel injectionsystem.
CamshaftPosition(CMPISensorB (TopDeadCenter
(TDCISensor)
TheCMPsensorB (TDCsensor)detectsthe positionof
the No.1 cylinderasa reference
for sequential
fuel
injectionto eachcylinder.
Air Conditioning {A/C) Compressor Glutch Relay
When the ECfMreceivesa demandfor coolingfrom the
Ay'Csystem,it delaysthe compressorfrom being
energized,and enrichesthe mixture to assuresmooth
transitionto the AVCmode.
Air Fuel Ratio lA/Fl Sensor
The Ay'FSensoroperatesover a wide airlfuel range.The
Ay'FSensoris installedupstreamof the TWC, and sends
signalsto the ECMwhich variesthe durationof fuel
injectionaccordingly.
ztRcoNta
ELEMENT
HEATER
MAGNET
SENSOR
TERMINALS
Crankshaft Position (CKPISensor
The CKPsensordetectscrankshaftsoeedand
determinesignitiontiming and timing for fuel injection
of each cylinderas well as detectingengine misfire.
HEATER
TERMINALS
Barometric Pressure {BAROI Sensor
The BAROsensoris insidethe ECM.lt convens
atmosphericpressureinto a voltagesignalthat the ECM
usesto modify the basicdurationof the fuel injection
discharge.
Engine Coolant Temperature (ECT)Sensor
The ECTsensoris a temperaturedependentresistor
(thermistor).The resistanceof the thermistordecreases
as the enginecoolanttemperatureincreases.
TERMINAL
\,
11-26
lgnition Timing Control
The ECMcontainsthe memory for basicignitiontiming
at variousengine speedsand manifold absolute
pressure.lt also adjuststhe timing accordingto engine
coolanttemperature.
Iniector Timing and Duration
The ECM containsthe memory for basicdischarge
d u r a t i o na t v a r i o u se n g i n es p e e d sa n d m a n i f o l d
pressures.The basicdischargeduration,after being
read out from the memory, is further modified by
signalssent from varioussensorsto obtain the final
d i s c h a r g ed u r a t i o n .
By monitoring long term fuel trim, the ECMdetectslong
term malfunctionsin the fuel systemand sets a
DiagnosticTrouble Code{DTC).
Intake Air Temperature (lAT) Sensor
The IAT sensoris a temperaturedependentresistor
{thermistor).The resistanceof the thermistor decreases
as the intakeair temDeratureincreases.
MalfunctionIndicatorLamp lMlLl Indication{ln relation
to ReadinessCodes)
"readinesscodes" that are part
The vehiclehas certain
of the on-boarddiagnosticsfor the emissionssystems.
lf the vehicle'sbafteryhas been disconnectedor gone
dead.if the DTCShave been cleared,or if the ECM has
been reset.these codesare set to incomplete.In some
states,part of the emissionstesting is to make sure
these codes are set to comDlete.lf all of them are not
set to complete,the vehiclemay fail the test and the
test cannot be finished.
To checkif the readinesscodes are set to complete,
turn the ignition switch ON (ll). but do not startthe
e n g i n e . T h e M I L w ci lol m e o n f o r l S 2 0 s e c o n d sl f. i t
then goes off, the readinesscodesare set to complete,
lf it blinksseveraltimes,one or more readinesscodes
are not set to comolete.To set each code, drive the
v e h i c l eo r r u n t h e e n g i n ea s d e s c r i b e di n t h e
proceduresto set them in this section(seepage 11-46).
Manifold Absolute Pressure {MAP) Senso]
The MAP sensorconvertsmanifoldabsolutepressure
i n t oe l e c t r i c asl i g n a l st o t h e E C M .
SENSOR
UNIT
Knock Sensor
The knockcontrol system adjuststhe ignitiontiming to
minimizeknock.
PIEZO
CERAMIC
(cont'd)
11-27
Secondary Heated Oxygen Sensor (Secondary HO2S)
The secondaryHO2Sdetectsthe oxygen content in the
exhaustgas downstreamof the three way catalytic
converter(TWC)and sendssignalsto the ECMwhich
checksthe efficiencyof the TWC.To stabilizeits output,
the sensorhas an internalheater.The secondarvHO2S
i s i n s t a l l e di n t h e T W C .
(
Vehicle Speed Sensor (VSS)
The VSS is driven by the differential.lt generatesa
pulsedsignalfrom an input of 5 volts.The number of
pulsesper minute increases/decreases
with the speed
of the vehicle.
BEARING
SENSOR
TERMINALS
ztRcoNta
ELEMENT
HEATER
TERMINALS
Starting Control
When the engine is started,the ECM providesa rich
mixture by increasinginjectorduration.
(
Throttle Position ITP)Sensor
The TP sensoris a potentiometerconnectedto the
throttlevalve shaft.As the throttle positionchanges,the
sensorvariesthe signalvoltageto the ECM.The TP
sensoris not replaceableapart from the throftle body.
ELEMENT
BRUSHHOLDER
gRUSH
(
11-28
wEc/wc
The i-WEC has a VTC (VariableValveTiming Control)mechanismon the intakecamshaftin additionto the usual
VTEC.
This mechanismimprovesfuel efficiencyand reducesexhaustemissionsat all Ievelsof engine speed,vehiclespeed.
a n d e n g i n el o a d .
The VTECmechanismchangesthe valve lift and timing by using more than one cam profile.
The VTCchangesthe phaseof the intakecamshaftvia oil pressure.lt changesthe intakevalve timing continuously.
HIGH
i
LOW<-
ENGINESPEED
DrivinoCondition
Qr Light-load
VTC Control
B a s eP o s i t i o n
?l M edium/high-load
AdvanceControl
€) High speed
Advance-BasePosition
DescriDtion
Cam angle is retardedto reducethe entry of exhaust
gas into the intakeport and to achievestablefuel
c o n s u m D t i o dn u r i n ql e a nb ur n .
Cam angle is advancedfor EGReffectand to reduce
this pumping loss.The intakevalve is closedquickly
to help reducethe entry of airlfuel mixture into the
intakeport and improve the chargingeffect.
C a m p h a s ea n g l ei s c o n t r o l l e df o r o p t i m u mv a l v e
t i m i n qa n d m a x i m u me n o i n eo o w e r .
{cont'd)
11-29
(
VTC system
. The VTC system makescontinuousintakevalvetiming changesbasedon operatingconditions.
. Intakevalve timing is optimizedto allow the engineto producemaximum power.
'CamangleisadvancedtoobtaintheEGReffectandreducethepumpingloss.Theintakevalveisclosedquicklyto
reducethe entry of the airlfuel mixture into the intakeport and improvethe chargingeffect.
. Cam angle is reducedat idle to stabilizecombustionand reducesenginespeed.
' l f a m a l f u n c t i o n o c c u r s , t h e V T C s y s t e m c o n t r iosl d i s a b l e da n dt h e v a l v et i m i n g i s f i x e da t t h e f u l l y r e t a r d e dp o s i t i o n .
TDC
MAXIMUM VTCADVANCE50'
MAXIMUM VTC ADVANCE50'
i
l(-4
'+-|l
sHoRToVERLAP
LoNGoVERLAP
VTEC system
' The VTECsystemchangesthe cam profileto correspondto enginespeed.lt maximizestorque at low enginespeed
and output at high engine speed.
. The low lift cam is used at low engine speeds,and the high lift cam is used at high enginespeeds.
LOWSPEEDVALVETIMING
11-30
HIGHSPEEDVALVETIMING
System Diagram
CMPSENSORA
From No. il
ACC{10A)fuse
INTAKE
CAMSHAFT
BRN/YEL
-:-
BLU/WHT
BLU/WHT
VARIOUS
SENSORS
BLK/WHT
GRN/YEL
BLU/BLK
BLK
It
:5i.T,""
Camshaft Position {CMP}Sensor
The CMP sensordetectscamshaftangle positionfor the VTC system.
{cont'd}
11-31
(
ldle Control System
FuelSupply System
When the engine is cold, the Ay'Ccompressoris on, the
transmissionis in gear,the brakepedal is pressed.the
power steeringload is high, or the alternatoris
charging,the ECIMcontrolscurrentto the ldle Air
Control(lAC)valveto maintainthe correctidle speed.
Referto the System Diagramto seethe functional
layout of the system.
Fuel Cut-off Control
Duringdecelerationwith the throttle valve closed,
currentto the injectorsis cut off to improve fuel
economy at enginespeedsover 1,030rpm. Fuelcut-off
actionalso occurswhen enginespeedexceeds
6,900rpm, regardlessof the positionof the throttle
valve,to protectthe enginefrom over-rewing. When
the vehicleis stopped.the ECMcuts the fuel at engine
speedsover 6,500rpm.
Brake Pedal Position Switch
The brakepedal positionswitch signalsthe ECMwhen
the brakepedal is oressed.
Electrical Power Steering (EPS)Senser
The EPSsensorsignalsthe ECMwhen the power
s t e e r i n gl o a di s h i g h .
ldle Air Control llACl Valve
To maintainthe proper idle speed,the IACvalve
changesthe amount of air bypassingthe throttle body
in responseto an electricalsignalfrom the ECM.
From AIR
CLEANER
IAC VALVE
11-32
To INTAKE
MANIFOLD
Fuel Pump Control
When the ignition is turned on, the ECMgroundsthe
PGM-Flmain relay which feeds currentto the fuel pump
for 2 secondsto pressurizethe fuel system,With the
e n g i n er u n n i n gt.h e E C Mg r o u n d st h e P G M - Fm
l ain
relay and feeds currentto the fuel pump. When the
engine is not running and the ignition is on, the ECI\4
cuts ground to the PGM-Flmain relaywhich cuts
currentto the fuel pump.
PGM-FIMain Relay1 and 2
The PGM-Flmain relay consistsof two separaterelays.
Relay1 is energizedwheneverthe ignition switch is ON
(ll)to supply batteryvoltageto the ECM power to the
injectors,and power for relay,Relay2 is energizedto
supply power to the fuel pump for 2 secondswhen the
i g n i t i o ns w i t c hi s t u r n e dO N ( l l ) ,a n d w h e n t h e e n g i n ei s
runnrng.
{
IntakeAir System
Referto the SystemDiagramto seethe functional
Throttle Body
The throttle body is a single-barrelside draft type. lt
housesthe TP senserand the IACvalve.The lower
portion of the IAC valve is heatedby enginecoolant
f r o m t h e c y l i n d e rh e a d .
Intake Air Bypass Control Thermal Valve
W h e nt h e e n g i n ei s r u n n i n g t, h e i n t a k ea i r b y p a s s
controlthermal valve sendsair to the iniectors,
IACVALVE
INJECTOR
{cont'd)
11-33
{
GatalyticConverterSystem
PositiveCrankcaseVentilation (PCVISystem
ThreeWay CatalyticConverter(TWC)
(HC),carbon
TheTWCconvertshydrocarbons
monoxide{CO),andoxidesof nitrogen(NOx)in the
exhaustgasto carbondioxide(C02),dinitrogen(N2),
andwatervaDor.
The PCVvalve preventsblow-by gassesfrom escaping
into the atmosphereby ventingthem into the intake
manifold.
BREATHERPIPE
THREEWAY
CATALYST
FRONTOF
VEHICLE
::
€:
BLOW-BY
VAPOR
FRESH
AIR
\
11-34
Evaporative
Emission(EVAPIControl
System
Referto the SystemDiagramto see the functional
EVAPCanister
The EVAPcanistertemporarilystoresfuel vapor from
the fuel tank until it can be purged back into the engine
a n db u r n e d .
EVAP Canister Purge Valve
When the enginecoolanttemperature is below 149'F
(65'C),the ECMturns off the EVAPcanisterpurge valve
which cuts vacuum to the EVAPcanister.
EVAP Two Way Valve and EVAP Eyp8s Solenoid
Valve
The EVAPtwo way valve is installedbetweenthe fuel
tank and the EVAPcanisterline.
The EVAPtwo way valve sendsfuel vapor to the EVAP
canistercorrespondingto the pressureinsidethe tuel
tank. lt also relievesexcessvacuum in the tank by
allowingfresh air to be drawn into the tank through the
EVAPcanister.
The EVAPbypasssolenoidvalve opensto bypassthe
two way valve during the EVAPleakcheck.
EVAP BYPASS
SOLENOID VALVE
FuelTank Pressure (FTP)Sensor
The FTPsensorconvertsfueltank absolutepressure
into an electricalinputto the ECMduring the EVAPleak
cnecK.
VALVE
SENSOR
UNIT
To FUELTANK
(cont'd)
11-35
\
ldle Control System Diagram
The idle speedof the engine is controlledby the ldle Air Control(lAC)varve:
'Aftertheenginestarts,theIACvalveopensforacertainamountoftime.Theamountofairisincreasedtoraisethe
i d l es D e e d .
. When the engine coolanttemperatureis low, the IACvalve is openedto obtain the properfast idle speed.The
amount of bypassedair is controlledin relationto enginecoolanttemperature.
INTAKE MANIFOLD
IACVALVE
AKEAIR DUCT
CLEANER
YEL/BLK ---<
From
PGM.FI
MAIN
RELAY
BLK/
REO
THROTTLEAODY
VARIOUS
SENSOnS
BLK
IntakeAir SystemDiagram
This systemsuppliesair for engine needs.A resonatorin the intakeair pipe providesadditionalsilencingas air is
drawn into the svstem.
THROTTLEAODY
VARIOUS
SENSORS
BLK
I
11-36
{
Evaporative
Emission(EVAPIControlDiagram
The EVAPcontrolsminimizethe amount of fuel vapor escapingto the atmosphere.Vapor from the fuel tanKrs
temporarilystoredin the EVAPcanisteruntil it can be purgedfrom the canisterinto the engine and burneo.
. The EVAPcanisteris purged by drawing fresh air through it and into a port on the intakemanifold.
The purgingvacuum is controlledby the EVAPcanisterpurge valve,which operateswheneverengine cootant
temperatureis above 149'F(65"C).
'WhenvaporpressureinthefueltankishigherthanthesetvalueoftheEVAPtwowayvalve,thevalveopensan
regulatesthe flow of fuel vapor to the EVAPcanister.
' D u r i n g r e f u e l i n g , t h e f u e l t a n k v a p o r c o n t rvoal l v eo p e n sw i t h t h e p r e s s u r ei n t h e f u e lt a n k ,a n d f e e d st h e f u e lv a D o r
to the EVAPcanister.
FUELTANK
VAPOR
RECIRCULATION
VALVE
FUELTANK
VAPOR
SIGNAL
TUBE
BLU/RED
BLK
FUELFILLCAP
FUELTANK
VAPOR
RECIRCULATION
TUBE
EVAP
+
CANISTER
VENTSHUT
VALVE
From
BLK/YEL --<No. 4 Acc
FUELTANK
{ 1 0A } f u s e
EVAP
CANISTER
EVAPTWOWAY
VALVE
(cont'd)
11-37
I
ECM Circuit Diagram
CONNECTOi
mrrrrn
a
CMP SENSORB
(TDCSENSOn)
I-BRN/YEr-
\,
11-38
a
wEc solENorD
_YEL/aLU
-RED/aLK
|-GFN/YEL
I
__f
-----l
_l
F=-1
Hi
I
t_r
I
I?SCNSOn
+
L!l
I
I
I
Y
croz
ff:l_l
*'*"_-ll-t
-KnocK
lSENSOn
l
I
-l-
Ll]
wcoLcoNTnoL
SoLENO|OVAIVE
(cont'd)
11-39
\
ECMCircuitDiagram{cont'd)
-{ffi]
---1t-|
IATSENSOR
-{El
------l
ECTSENSOS
T_""",,..
I-BFN/YEL
CMPSENSOAA
L-
IJUNCTION
I CONNECTOR
-
ft^--l
, " , " . , J | t -' :
I
I
I
+
t!j]]
11-40
REVERSE
LocK
soleloto
vaLvE
_1ffi1
-'----1 | |Fahdl
G8N
t
'--r-
I
,
'8r-K-L-|
|
T
l -r l
l
HcoNNEcroR
BLU/
-l
J.L9l
|
.lurcrroru
F
EVAPCANISTEB
ALK/YEL
WHT/ALU
WHT/NED
WHI/GRN
JUNCTION
CONNECTOR
rrrn
tcM
PLUG
N o . 2 I G N I T I O NC O l t
PLUG
No.3IGNITION COIL
(cont'd)
11-41
a
ECMCircuitDiagramlcont'dl
YEI/BLK
IGP2
VET/BLK
---rF-rl
-lF-forl
--JliD\l
--t-l
a
MAIN BETAV2
t_,",
:t
l-,r'l r,
-,u-
f-"'*'o""
I SENSOS
tr
IMMOAIL|zERUNIT
a
11-42
SECONDAFY
H02S
(s€NsoR2l
m
tlil
TPS€NSOR
'--{=l
-{r
I
CANISTERVEAIT
SHUTVALVE
t-_]
--lti l
EVAP EYPASS
solENorD
To€PS
CONTROLUNIT
CPU
GAUGE ASSEMBTY
(cont'd)
11-43
L
ECMCircuitDiagram(cont'd)
UNDER.HOOD
FUSE/RELAY9OX
!
CONN€CTOF
CONNECTOi
WHI/NED
BLK/YET
lalLREllY_ _l
a
11-44
CONNECTOR
E
""rr"a*J
r''lHr/cnN
1
I
CONNECTOiK
IGNITIONSWITCH
lG2
' I
CONNECTOFJ
/GRN
TEST
TACHOMETER
CONNECTO8
UNDER.HOOD
UNDER.DASH
FUSE/FELAYBOX
UNDER.DASH
FUSE/RELAY
BOX:
4 ACG (1oAt
1 tGN CO|Lt15A)
2 A/F HEATER{2OA)
17 FUELPUMPI15A}
1OMETER{7.5AI
14 A/C CLUTCHRELAY{1OA}
POStTtONSWTTCH
,or"-9J3{51
"_.rl
re* _{F
Brake pedal pressed: closed
Brake pedal releasedropen
11-45
How to Set ReadinessCodes
L
MalfunctionlndicatorLamp(MlL)Indication
(ln relationto Readiness
Codesl
CatalyticConverterMonitorand Readiness
Code
The vehiclehas certain"readinesscodes" that are part
of the on-boarddiagnosticsfor the emissionssystems.
lf the vehicle'sbatteryhas beendisconnectedor gone
dead,if the DTCShave beencleared,or if the ECM has
been reset,these codesare set to incomplete.In some
states,part of the emissiontesting is to make sure these
codesare set to complete.lf all of them are not set to
complete,the vehiclemay fail the emissiontest, or the
test cannot be finished.
NOTE:
. Do not turn the ignition switch off during the
procedure.
. All readinesscodes are clearedwhen the batteryis
disconnectedor when the ECM is clearedwith the
OBD ll scantool or HondaPGlvlTester.
. Low ambienttemperaturesor excessiveslop-and-go
traffic may increasethe drive time neededto switch
the readinesscode from incompleteto complete.
' The readinesscode will not switchto com Dleteuntil
a l l t h e e n a b l ec r i t e r i aa r e m e t .
. lf a fault in the secondaryHO2Ssystemcausedthe
MIL to come on. the readinesscode cannot be set to
comDleteuntil vou correctthe fault.
To checkifthe readinesscodesare complete,turn the
ignitionswitch ON (ll), but do not startthe engine.The
MIL will come on for 15 20 seconds.lf it then goes off,
the readinesscodesare complete.lf it blinksseveral
times, one or more readinesscodes are not complete.
To set readlnesscodesfrom incompleteto complete.
do the procedurefor the appropriatecode.
EnableCriteria
. E C Ta t 1 5 8 " F( 7 0 ' C )o r h i g h e r .
. I n t a k ea i r t e m p e r a t u r e
( l A T )a t 2 0 " F( - 7 ' C ) o r h i g h e r .
. Vehiclespeed is steady,and vehiclespeedsensor
( V S S )r e a d sm o r et h e n 2 5 m p h ( 1 3 k m / h ) .
Procedure
1 . C o n n e ctth e s c a nt o o l t o t h e v e h i c l e ' sd a t al i n k
c o n n e c t o(rD L C i a, n d b r i n gu p t h e t o o l ' sg e n e r i c
O B Dl l m o d e .
2 . Startthe engine.
3 . Test-drivethe vehicleunder stop-and-goconditions
with short periodsof steadycruise.After about
5 miles (3 km),the readinesscode should switch
from incompleteto complete.
lf the readinesscode is still set to incomplete,check
for a temporary DTC.lf there is no DTC,one or
more of the enablecrlteriawere probablynot met;
11-46
\
\"
EvaporativeEmissions(EVAP)Control
SystemMonitor and Readinesscode
Air FuelRatio(A/FlSensorMonitorand
Readiness
Code
NOTE:
NOTE:
. Do not turn the ignitionswitch off during the
orocedure.
. All readinesscodesare clearedwhen the bafteryis
OBD ll scantool or Honda PGM Tester.
All readinesscode are clearedwhen the batterVis
OBD ll scantool or HondaPGM Tester.
The enablecriteriamust be repeatedif the intakeair
temperature(lAT)drops lower than 36'F (20"C)from
i t s v a l u ea t e n g i n e$ a n u p .
EnableCriteria
At enginestart up, ECTand IAT are higherthan 32'F
(0"C), but lower than 95'F (35"C).
At enginestart up, the ECTand IAT are within 12'F
(7'C)of each other.
Procedure
1. Connectthe scantool to the vehicle'sdata link
connector(DLC),and bring up the tool's generic
O B Dl l m o d e .
2. Startthe engine.
3. Test-drivethe vehicleunder stop-and-goconditions
with short periodsof steadycruise.After about
2 . 5m i l e s( 1 . 6k m ) ,t h e r e a d i n e scso d es h o u l d
switchf rom incompleteto complete.
4. lf the readinesscodeisstill setto incomplete,check
for a temporaryDTC.lf there is no DTC,one or
more of the enablecriteriawere probably not met;
repeatthe procedure.
EnableCriteria
ECTat 140'F(60"C)or higher.
Procedure
1. Connectthe scantoolto the vehicle'sdata link
connector(DLC),and bring up the tool's generic
O B Dl l m o d e .
2. Start the engine.
3. Test-drivethe vehicle under stop-and-goconditions
with short periodsof steadycruise.Duringthe
drive, decelerate(wirh the throttlefully closed)for
5 seconds.After about 3.5 miles (2.2km).the
readinesscode should switch from incomDleteto
complete.
4 . l f t h e r e a d i n e s s c o d e i s s t isl le tt o i n c o m p l e t ec,h e c k
for a temporary DTC.lfthere is no DTC,the enable
criteriawas probablynot meU repeatthe procedure.
Air/FuelRatio(A/FlSensorHeaterMonitor
Readiness
Code
NOTE;All readinesscodes are clearedwhen the battery
is disconnectedor when the ECM is clearedwith the
OBD ll scantool or HondaPGM Tester,
Procedure
'1.
Connectthe scantool to the vehicle'sdata link
connector{DLC),and bring up the tool's generic
O B Dl l m o d e .
2. Startthe engine,and let it idle for 1 minute.The
readinesscode should switch from incompleteto
comDlete.
3. lf the readinesscode is still set to incomplete,check
for a temporary DTC.lf there is no DTC,repeatthe
proceoure.
(cont'd)
11-47
How to Set ReadinessCodes(cont'd)
\-
Code
MisfireMonitorand Readiness
. This readinesscode is alwaysset to available
becausemisfiring is continuouslymonitored.
. l\4onitoringpauses,and the misfirecounterresets,if
the vehicleis driven over a rough road.
. Monitoringalso pauses,and the misfire counter
holds at its currentvalue.if the throttle position
changesmore than a predeterminedvalue,or if
driving conditionsfall outsidethe rangeof any
relatedenablecriteria,
Code
FuelSystemMonitorand Readiness
. This readinesscode is always setto available
becausethe fuel system is continuouslymonitored
during closedloop operation.
. Monitoringpauseswhen the catalyticconverter,
EVAPcontrol system,and Ay'Fsensor monitorsare
active.
. Monitoringalso pauseswhen any relatedenable
criteriaare not being met. Monitoring resumeswhen
lhe enablecriteriais again being met.
ComponentMonitorand
Comprehensive
Readiness
Code
This readinesscode is always set to availablebecause
the comprehensivecomponentmonitor is continuously
r u n n i n gw h e n e v e tr h e e n g i n ei s c r a n k i n go r r u n n i n g .
L
a
a
11-48
PGM-FISystem
CAMSHAFTPOS]TION{CMP)SENSORB
(TOPDEAD CENTER(TDC}
SENSORI
Troubleshootina.
oaoe 11-95
p;ge 1-1.1
Replacement,
14
ii'- r'1
ELECTRICAL
LOAD
DETECTOR
{ELDI
Troubleshooting,
page1'l-92
.I11---:,I
''.!,i(..,.?:fir-J-
.....,..:--.
INTAKEAIRTEMPERATURE
{IATISENSOR
Troubleshooting,
page'l'l-55
page11-'l15
Replacement,
f -
r
\
l
ENGINECOOLANTTEMPERATURE
(ECTISENSOR
page11-57
Troubleshooting,
R e p l a c e m epnat ,g e1 11 1 4
MANIFOLD
ABSOLUTE
PRESSURE
(MAP)SENSOR
page11-52
Troubleshooting,
CRANKSHAFTPOSITION
ICKPISENSOR
page'l1-78
Troubleshooting,
page 11-'l16
Beplacement,
THROTTLE
POSITION
ITP}SENSOR
page11-60
Troubleshooting,
KNOCKSENSOR
page11-77
Troubleshooting,
B e p l a c e m epnat ,g e1 11 1 5
AIR FUELRATIO{A/F)
SENSORISENSOR1}
page 11-84
Trorrbleshooting,
page 11-113
Replacement,
{cont'd)
11-49
PGM-FlSystem
\
\.,
v
11-50
'}
DATALINKCONNECTOR
IDLCI
Information,page 1l 3
PGM.FIMAINRELAY1
page11-97
Troubleshooting,
ENGINECONTROLMODULE
g Information,
GeneralTroubleshootin
p a g e1 1 3
page I 1-96
Troubleshooting,
11-51
PGM-FISystem
DTCTroubleshooting
\
DTCP0107:
MAPSensorCircuitLowVoltage
1 . T u r nt h e i g n i t i o ns w i t c hO N ( l l i .
(
ls there about 5 V?
YES-Repair open in the wire betweenthe Eclvl
( A 2 1 ) a n dt h e M A P s e n s o r . l
2. Checkthe MAP with the scantool.
ls about 101kPa (760 mmHg,30 in.Hg)or 2.9 V
indicated?
YES Intermittentfailure, system is OK at this time.
Checkfor poor connectionsor looseterminalsat
t h e M A P s e n s o ra n d a t t h e E C M . I
NO Updatethe ECMif it does not havethe latest
software,or substitulea known-goodECM,then
recheck(seepage 'l1-6).lf the symptom/indication
goes away with a known-goodECfvl,replacethe
originaE
l CM.I
8 . Checkthe MAP with the scantool.
ls 2 kPa (15 mmHg,0.6 in.Hg) ot lessor 0 V
indicated?
YES-Go to step 9.
4. Disconnectthe MAP sensor3P connector.
NO Replacethe lvlAPsensor.l
5 . T u r nt h e i g n i t i o ns w i t c hO N ( l l l .
9 . Turn the ignitionswitch OFF.
6. lvleasurevoltage betweenMAP sensor3P
c o n n e c l o tre r m i n a l sN o . 1 a n d N o . 3 .
'10.Disconnect
ECMconnectorA (31P).
1 1 .Checkfor continuitybetweenMAP sensor
MAP SENSOR3P CONNECTOF
connectorterminal No. 2 and body ground.
\
(
MAP SENSON3P CONNECTOA
sGl
{GRN/WHTI
Wires de of femaleterminais
ls there about 5 V?
YES Go to step8.
1 . Measurevoltage betweenEClvlconnector
t e r m i n a l s4 1 1 a n d 4 2 ' 1 .
ECM CONNECTOR
A 13'IP}
vccr
{YEL/BED)
YES-Repair short in the wire betweenthe ECM
( A 1 9 )a n d t h e M A P s e n s o r . l
NO Updatethe ECM if it does not have the latest
software,or substitutea known-goodECM,then
recheck(seepage 11-6).lf the symptom/indication
goes away with a known-goodECM,replacethe
o r i g i n aE
l CM.I
sGr
{GRN/WHT}
Wire side of female terminals
11-52
(
DTCP0108:MAPSensorCircuitHighVoltage
'1.
Startthe engine.Holdthe engine at 3,000rpm with
no load (in neutral)until the radiatorfan comes on,
then let it idle.
le about 101kPa (780 nmHg, 30 in.Hg)ot highet,
or about2.9 V or higher indicated?
9. Measure
voltagebetweenMAPsensor3P
connector
terminalsNo.1 andNo.3.
MAP SENSOR3PCONNECTOF
vccl
{ Y E L / Rl E
, lD
o)
cl
l . l . r l
I
lsct
d)
l{GRN/wHrr
Y
I
l
l
i
YES Go to step 3.
l
W i r es i d eo f f e m a l el e r m i n a l s
NO-lntermittent failure,system is OK at this time.
the MAP sensorand at the ECM.I
ls there about 5 V?
YES Go to step 10.
4. DisconnecttheMAP sensor3P connector.
NO Repairopen in the wire betweenthe ECM
(A11) and the MAP sensor.I
5, ConnectMAP sensor3P connectorterminalsNo. 2
and No. 3 with a jumper wire.
MAP S€NSOR3P CONNECTOR
1 0 .Turn the ignitionswitch OFF.
1 1 .C o n n e c E
t C Mc o n n e c t otre r m i n a l sA 1 1 a n d A 1 9
with a jumper wire.
1 2 3
MAP
{GRN/REO}
A {31PI
ECMCONNECTOR
SG1(GRN/WHTI
JUMPER
WIRE
J U M P E RW I A E
Wire side of fema e te.minals
6. Turn the ignition switch ON (ll).
T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
Checkthe MAP with the scantool.
ls about 101kPa (760 mmHg,30 in.Hg) ot higher,
or about2.9 V or higher indicated?
ls about 101kPa (760 mmHg,30 in.Hg)or higher,
or about2.9 V ot higher indicated?
YES-Go to step 8.
NO Replacethe MAP sensor.I
8 . R e m o v et h e j u m p e rw i r e .
YES Updatethe ECM if it does not have the lalest
software,or substitutea known-goodECM,lhen
goes away with a known good ECM,replacethe
originaE
l CM.I
NO-Repair open in the wire betlveenthe ECI\il
( A 1 9 )a n dt h e M A P s e n s o r . I
11-53
PGM-FISystem
DTCTroubleshooting(cont'dl
DTCPl128:MAPSensorSignalLowerThan
Expected
ls 54.1 kPa(406mmHg, 16.0in.Hg),1.6 V, or
higher indicated?
YES- Intermittentfailure.system is OK at this
time.I
NO Replacethe MAP sensor.l
\
DTCPl129:MAPSensorSignalHigherThan
Expected
then Iet it idle.
2. Checkthe MAP with the scantoot.
ls 36.9 kPa (277 mmHg, 10.9 in.Hg),1.1 V , or less
indicated?
YES- lntermittentfailure,system is OK at this
time.l
NO Replacethe MAP sensor.l
\
\
11-54
a
DTCP0112:
IATSensorCircuitLowVoltage
2. Checkthe IAT with the scantool.
ls 302'F (150'C) or highet (or H-Limit in Honda
node of PGM Tester),ot 0 V indicated?
8. Checkthe temperaturereadingon the scantool.
Be aware that if the engine is warm, the reading
w i l l b e h i g h e rt h a n a m b i e n t e m p e r a t u r el I. t h e
engine is cold, the IAT and ECTwill have the same
v al u e .
ls the correct ambient temperatureindicated?
YES lntermittentfailure,system is OK at this time
t h e I A Ts e n s o ra n d a t t h e E C M . I
VES-Go to step 3.
NO Go to step 8.
NO Replacethe IAT sensor.l
Disconnectthe IAT sensor2P connector.
4 . Checkthe IAT with the scantool.
ls 302'F(150'C)or higher (or H-Limit in Honda
mode of PGM Testet),ot 0 V indicated?
YES-Go to step 5.
NO- Replacethe IAT sensor.I
7 . Checkfor continuitybetweenIAT sensor2P
c o n n e c t otre r m i n a lN o . 2 a n d b o d y g r o u n d ,
IAT SENSOR2PCONNECTOR
,^\
,
l r 2 l
t
-----Tr---
-
l
IAT
_t{RED/YELI
II
W i r es i d eo f f e m a l et e r m i n a i s
YES Repairshon in the wire betweenthe ECM
( B ' 1 7a) n d t h e I A Ts e n s o r . l
originaE
l CM.I
11-55
PGM-FISystem
DTCP0113:
IATSensorCircuitHighVoltage
1. Turnthe ignitionswitchON (ll).
\
I
\"
{
ls - 4"F ( 20'C) or less(or L-Limitin Honda
mode ot PGM Tester) or 5 V indicated?
2. Checkthe IATwith the scantool.
YES Go to step 8.
ls 4'F (-20'C) or less(or L-Limitin Honda
modeot PGM Tester)or 5 V indicated?
NO - Replacethe IAT sensor.l
YES-Go to step 3.
NO Intermitentfailure,system is OK at this time.
the IAT sensorand at the ECM.I
1 0 . C o n n e cE
t C Mc o n n e c t otre r m i n a l sA 1 0 a n d 8 1 7
w i t h a j u m p e rw i r e .
ECM CONNECTORS
4. Disconnectthe IAT sensor2P connector.
ConnectIAT sensor2P connectorterminalsNo. 1
a n d N o . 2 w i t h a j u m p e rw i r e .
A (31 P)
B {24 P)
IATSENSOR
2PCONNECTOR
rJ--
:---
JUMPERWIRE
l ' l L l
-'_-l--_----r--_
sG2
rAT
I
{GRN/YEL)
IRED/YEL)
I
L ]
WIRE
JUMPER
1 1 .T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
ls - 4"F ( 20"C) or less (or L-Limitin Honda
mode of PGM Tester) or 5 V indicated?
YES Updatethe ECMif it does not have the latest
software,or substitutea known-goodECI\4then
goes away with a known-goodECM.replacethe
originaE
l C M !.
( A 1 0 ,8 1 7 )a n dt h e I A Ts e n s o r . I
\
11-56
(
DTCP0116:ECTSensorRange/Performance
Problem
NOTE:lf DTCP0117and/or P0118are storedat the
same time as DTCP0116,troubleshootthose DTCSfirst,
then recheckfor DTCP0116,
1. Stanthe engine.Hold the engineat 3,000rpm with
no load {in neutral)until the radiatorfan comes on,
then let it idle.
2. Checkthe ECTwith the scantool.
ls 176- 212'F (80
indicated?
100"C)or0.5 0.8V
YES Intermittentfailure.system is OK at this time.
Checkthe thermostatand the cooling system.l
NO-Checkthe thermostatand the cooling system.
lf they are OK, replacethe ECTsensor.l
11-57
PGM-FISystem
DTCP0117:ECTSensorCircuitLow Voltage
\
(
7. Checkfor continuitybetweenthe ECTsensor2P
connectorterminal No. 1 and bodv oround.
ECTSENSOR2PCONNECTOR
ls 150'C (302'F)or higher (ot H-Limit in Honda
YES Go to step 3.
NO Intermittentfailure,system is OK at this time.
the ECTsensorand at the ECM.t
3. Disconnectthe ECTsensor2P connector.
ls 150'C (302"F)or higher (ot H-Limit in Honda
( B 8 )a n d t h e E C Ts e n s o r . l
YES-Go to step 5.
NO-Update the ECMif it does not havethe latest
software,orsubstitutea known-goodECM,then
recheck{seepage 11-6).lf the symptom/indication
goes away with a known-goodEClvl,replacethe
originaE
l CM.I
NO
Replacethe ECTsensor.!
(
6. DisconnectECMconnectorB (24P).
(
11-58
DTCP0118:
ECTSensorCircuitHighVoltage
1 . Checkthe ECTwith the scantool.
ls 20"C ( 4"F)or less (or L-Limitin Honda
YES-Go to step 8.
ls 20'C ( 4'F)or less(or L-Limitin Honda
?
NO Replace
t h e E C Ts e n s o r . I
YES Go to step 3.
NO lntermittentfailure,system is OK at this time.
the ECTsensorand at the ECM.I
Turn the ignitionswitch OFF.
1 0 . ConnectECMconnectorterminalsA10 and Bg with
a j u m p e rw i r e .
ECM CONNECTORS
Disconnectthe ECTsensor2P connector.
5 . Connectthe ECTsensor2P connectorterminals
N o . 1 a n d N o . 2 w i t h a j u m p e rw i r e .
a {31P}
B {24P)
ECTSENSOR2P CONNECTOR
JUMPERWIRE
\
lt tt .l t l l
-I-l*,
Ecr
(RED/WHT)
{GRN/YEL)
t
l
WIRE
JUMPER
1 2 . Checkthe ECTwith the scantool.
wire sideoI Iemaleterminals
ls 20"C ( 4"F) or less (or L-Limitin Honda
mode of PGM Tester) ot 5 V indicated?
6 . T u r nt h e l g n i t i o ns w i t c hO N ( l l ) .
YES- Updatethe ECM if it does not havethe latest
then
software,or substitutea known-goodECI\4,
recheck(seepage 11-6).If the symptom/indication
o r i g i n aE
l CM.I
( A 1 0 ,8 8 ) a n d t h e E C Ts e n s o r . l
11-59
PGM-FISystem
DTCP0122:TP SensorCircuitLowVoltage
1 . T u r nt h e i g n i t i o ns w i t c ho N ( 1 1 1 .
2. Checkthe throttle positionwith the scantool.
8. At the sensorside, measureresistancebetweenthe
TP sensor3P connectorterminalsNo. 1 and No. 2
with the throttlefully closed.
TP SENSOR3P CONNECTOR
ls there about 10./.or 0.5 V when the thrcttle is
fully closed and about 90% or 4.5 V when the
throttle is fully opened?
YES Intermittentfailure,system is OK at this time.
the TP sensorand at the ECM.t
NO Go to step 3.
3. Turn the ignition switch OFF,
T e r m i n as li d eo f m a l et e r m i n a l s
4. Disconnectthe TP sensor3P connector.
Is there about 0.5 0.9 kQ ?
YES Go to step 9.
6. Measurevoltagebetweenthe TP sensor3P
connectorterminals No. 1 and No. 3.
NO Replacethe throttle body (theTP sensoris not
a v a i l a b l es e p a r a t e l yI) .
9 . Measureresistancebetweenthe TP sensor3P
connectorterminalsNo. 2 and No. 3 with the
throttlefully closed.
TPSENSOR
3PCONNECTOB
ls thereabout5 V?
Terminalsideof maleterminals
YES-Go to step7.
N O G ot o s t e p1 4 .
1 . Turnthe ignitionswitchOFF.
ls there about 4.5k{l ?
YES Go to step 10.
NO Replacethe throttle body (theTP sensoris not
a v a i l a b l es e p a r a t e l yI) .
1 0 . D i s c o n n e cEt C Mc o n n e c t oA
r (31P).
11-60
\
11. At thewire harnessside,checkfor continuity
terminalNo,2
betweenTPsensor3Pconnector
a n db o d yg r o u n d .
11 2 1 3
13. At thewire harnessside,checkfor continuity
terminalNo.2
betweenTPsensor3Pconnector
a n db o d yg r o u n d .
TP SENSOR3PCONNECTOR
1 2 3
TPS
(RED/BLX}
'PS
REO/BLKI
Wire sideof female terminals
Wire side ot Iemaleterminals
ls thetecontinuity?
YES-Repairshortin the wire betweenthe ECM
{ A 1 5a) n dt h eT Ps e n s o r . l l
N O - G o t o s t e p1 2 .
terminalA15to body
12. ConnectECMconnector
groundwith a jumperwire.
A 131P)
ECMCONNECTOR
9
1 1 2 1 34 5 6 7
19
t
c
6
10 1 1 1 1 2
8 t2021
23124
YES-Update the ECM if it does not have the latest
originaE
l CM.I
NO- Repairopen in the wire betweenthe ECM
( A 1 5 )a n d t h e T P s e n s o r . l
14. lvleasurevoltage betweenECMconnector
t e r m i n a l s4 1 0 a n d A 2 0 .
A 131P}
ECMCONNECTOB
28129130
wrne
,tf$,rr*, ];uueen
vcc2
(YEL/8LU)
Wire side oJ.femaleterminals
ls there about 5 V?
YES Repairopen in the wire betlveenthe ECM
( A 2 0 )a n d t h e T P s e n s o r . I
NO Updatethe ECM if it does nor have the latest
software,or substilutea known-goodECM,then
r e c h e c k( s e ep a g e11 - 6 ) l.f t h e s y m p l o m i n d i c a t i o n
goes away with a known-goodECM.replacelhe
originaE
l CM.I
11-61
PGM-FISystem
DTCTroubleshooting(cont'd)
DTCP0123:
TPSensorCircuitHighVoltage
1 . T u r nt h e i g n i t i o ns w i t c ho N ( l l )
(
7. Measurevoltage betweenECMconnector
terminalsA10 and A20.
ECMCONNECTOR
A 131PI
ls there about 10%or 0.5 V when the throttle is
fully closed and about 90% or 4.5 V when the
throttle is f ully opened?
YES lntermittentfailure.system is OK at this time.
t h e T P s e n s o ra n d a t t h e E C M I,
NO Go to step 3.
Is there about 5 V?
4. Disconnectthe TP sensor3P connector.
6. At the wire harnessside, measurevoltage between
the TP sensor3P connectorterminalsNo. 1 and
No.3.
W;resideof femaleterminals
ls thete about 5 V?
YES-Replace the throttle body (theTP sensor is
not availableseparately).
I
NO Go to step 7.
11-62
YES- Repairopen in the wire betweenthe ECM
(A10)and the TP sensor.t
NO Updatethe ECMif it does not havethe latest
soflware,or substitutea known-goodECM,then
o r i g i n aE
l CM.I
(
DTCPl121:TPSensorSignalLowerThan
Expected
DTCP1122:.fP
SensorSignalHigherThan
Expected
ls 12.9'/.,0.6 V, or higher indicated when the
throttle is tully opened?
ls 12.9%,0.6 V, or lessindicated when the throttle
is f ully closed?
YES- Intermittentfailure,system is OK at this
time.I
YES Intermittentfailure,system is OK at this
time.l
NO-Replace the TP sensor(the TP sensor is not
availableseparately).
I
NO Replacethe TP sensor(theTP sensoris not
availableseparately).
I
11-63
PGM-FISystem
(cont'dl
DTGTroubleshootang
DTCP0128:CoolingSystemMalfunction
\
3. Checkthe radiatorfan.
Does the tadiator fan keep running?
NOTE;lf the DTCSlistedbelow are stored at the same
time as DTCP0128.troubleshootthose DTCSfirst, then
recheckfor P0128.
P 0 1 0 7P, 0 1 0 8P, 1 1 2 8P
, 1 1 2 9N
: 4 a n i f o ladb s o l u t e
pressure(MAP)sensor
P] I06, P1107,P1108:Barometricpressure(BARO)
sensor
P1259:VTECsystem
P0116,P0117, P0118:Enginecoolanttemperature(ECT)
sensor
P0112,P0113: Intakeair temperature(lAT)sensor
P0500:Vehiclespeedsensor{VSS)
P0335,P0336:Crankshaftposition(CKP)sensor
P0300:Randommisfire
P 0 3 0 1P
, 0 3 0 2P, 0 3 0 3P
, 0 3 0 4N
: o . 1 ,N o .2 , N o . 3 o r N o . 4
cylinder misfire
P0505:ldle control system malfunction
P 1 5 1 9l:d l ea i r c o n t r o l( l A C ) v a l v e
DTCP0128can occasionallyset when the hood is
o p e n e dw h i l e t h e e n g i n ei s r u n n i n g .
1. Checkthe enginecoolant level
Is the engine coolantlevel low?
VES Refillthe enginecoolant.lf necessary,repair
t h e c o o l a n tl e a k a g e . l
NO Go to step 2.
2 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d m a k es u r et h e
A,/Cis off.
11-64
YES Checkthe radiator fan circuit(seepage 1014),the radiatorfan switch circuit(Short)(seepage
10-'16),
and the radiatorfan switch (seepage 10-17).
Also, inspectthe ECTand IAT circuitsand terminal
connections.lf the circuits,the switch,and the
connectionsare OK, updatethe ECI\4if it does not
have the latestsoftware.or substitutea knowngood ECM,then recheck(seepage 11-6).lf the
symptom/indicationgoes away with a known-good
E C M ,r e p l a c et h e o r i g i n a E
l CM.I
NO Replacethe thermostat(seepage 10-8).1
a
DTCP0134:Ay'FSensor(Sensor1) No Activity
Detected
1. Checkthe attachmentstateof the A,/Fsensor
( S e n s o r1 ) .
DTCP0137:
Secondary
HO2S(Sensor
2)
CircuitLowVoltage
1 . R e s e t h e E C M( s e ep a g eI 1 - 4 )
ls it slacked f rom the exhaust pipe?
2. Start the engine.Holdthe engine at 3,000rpm wilh
no load (in neutral)until the radiatorfan comes on.
YES- Reinstallthe Ay'Fsensor(Seneor1) (seepage
11-113).t
3. Checkthe secondaryHO2S(Sensor2) output
voltageat 3,000rpm with the scantool.
NO-Go to step 2.
ls there 0.3 V or less?
2 . R e s e t h e E C M( s e ep a g e11 - 4 ) .
YES Go to step 4.
3 . S t a nt h e e n g i n e H
. o l dt h e e n g i n es p e e da t
3,000rpmwith no load (in neutral)until the radiator
fan comes on, then let it idle for 2 minute.
the secondaryHO2S(Sensor2) and at the ECM.I
ls DTC PO134 indicated?
4. T u r nt h e i g n i t i o ns w i t c hO F F .
YES-Replacethe Ay'Fsensor{Seneor1) (seepage
11-113).t
5 . Disconnectthe secondaryHO2S(Sensor2) 4P
NO - Intermittentfailure, sistem is OK at this time.
the Ay'Fsensor(Seneor1) and the ECM.I
6 . Turn the ignition switch ON (ll).
connector.
7 . Checkthe secondaryHO2S(Sensor2) output
voltagewith the scantool.
ls there 0.3 V or less?
YES Go to step 8.
r ).1
NO Replace
t h e s e c o n d a r yH O 2 S( S e n s o 2
r (31P).
9 . D i s c o n n e cEt C Mc o n n e c t oE
icont'd)
11-65
PGM-FISystem
a
10. Checkfor continuitybetweenthe secondaryHO2S
(Sensor2) 4P connectorterminal No. 2 and body
ground.
SECONDARY
H02S
2) 4PCONNECTOR
ISENSOR
DTCP0138:
Secondary
HO2S(Sensor
2)
CircuitHighVoltage
1 . R e s e t t h eE C M{ s e ep a g e ' 1 1 - 4 ) .
3. Checkthe secondaryHO2S(Sensor2) output
ls thete 1.0 V or morc?
YES Go to step 4.
Terminalside of male terminals
YES-Repair shon in the wire betweenthe ECM
(E2)and the secondaryHO2S(Sensor2).t
originaE
l CM.I|
5. Disconnectthe secondaryHO2S(Sensor2) 4P
connector.
ConnectsecondaryH02S (Sensor2) 4P connector
t e r m i n a l sN o . 1 a n d N o . 2 w i t h a j u m p e rw i r e .
SECONDARY
HO2S
{SENSOR2) 4P CONNECTOR
JUMPERWIRE
SG3 (PNKI
SHO25(WHT/RED)
T e r m i n asl i d eo Jm a l et e r m i n a l s
7. Turn the ignitionswitch ON (ll).
11-66
8 . Checkthe secondaryH02S (Sensor2) output
voltagewith the scantool,
ls there 1.0 V ot mote?
YES-Go to step 9.
DTCP0139:SecondaryHO2S(Sensor2l Slow
Response
1 . R e s e t t h eE C M( s e ep a g e1 1 - 4 ) .
Start the engine.Holdthe engine at 3,000rpm with
NO Replacethe secondaryHO2S(Sensor2).1
3 . Checkthe secondaryHO2S(Sensor2) output
1 0 . ConnectECMconnectorterminalsE2 and E4 with a
J U m p ew
r rre.
E 131PI
ECMCONNECTOR
JUMPERWIRE
ls thete 0.3- 0.8 V, fot 2 minutes?
YES Replacethe secondaryHO2S(Sensor2).!
NO- lntermittentfailure,system is OK at this time.
Checkfor poor connectionsor looseterminaisat
1 1 .Turn the ignition switch ON (ll).
1 2 . Checkthe secondaryHO2S(Sensor2) output
voltagewith the scantool.
ls there 1.0 V or more?
YES Updatethe ECM if it does not have the latest
originaE
l CM.I
NO Repairopen in the wire betweenthe ECM (E2,
E4)and the secondaryHO2S{Sensor2).I
11-67
PGM-FISystem
DTCP0141:
Secondary
HO2S(Sensor
2l
HeaterCircuitMalfunction
1. Resetthe ECM(seepage 1 l-4)
6. Checkfor continuitybetweenbody ground and
secondaryH02S (Sensor2) 4P connectorterminals
N o . 3 a n d N o .4 i n d i v i d u a l l y .
SECONDARY
HO2S{SENSOR
214PCONNECTOR
2. Startthe engine.
ls DTC P0141indicated?
YES-Go to step 3.
Disconnectthe secondaryH02S (Sensor2) 4P
connecror.
ls therecontinuity?
YES- Replace
the secondary
HO2S(Sensor2).1
5 . At the secondaryHO2S(Sensor2) side, measure
resistancebetweenH02S 4P connectorterminals
N o . 3 a n d N o .4 .
NO-Go to step7.
7 . Turnthe ignitionswitchON (ll).
HO2S(SENSOR
SECONDARY
214PCONNECTOR
8 . Measure
voltagebetweensecondary
H02S4P
connector
terminalsNo.3 andNo.4,
SECONDARYHO2S (SENSOR2l ilP CONNECTOR
s02sHTc
{BLK/WHTI
IG1(BLK/ORN}
Wire side ol lemale terminals
ls thereabout3.3 Q ?
T e r m i n asli d eo f m a l et e r m i n a l s
YES Goto step6.
NO- Replace
the secondary
HO2S(Sensor
2).t
YES Go to step 9.
NO Go to step 12.
1 0 . DisconnectECMconnectorE {31P)
11-68
t
terminalE6andbodyground.
ECM CONNECTORE {31PI
1 4 . Reconnectthe secondaryHO2S(Sensor2) 4P
connector.
t5.
DisconnectECMconnectorE (31P).
to.
Turn the ignition switch ON (ll).
1 7 . Measurevoltage betweenECMconnectorterminal
E 6a n d A 5 .
ECMCONNECTORS
Wire side o{fIemaleterminals
A (31 P)
r ).1
( E 6 )a n d t h e s e c o n d a r yH O 2 S( S e n s o 2
NO-Update the ECM if it does not have the latest
o r i g i n aE
l CM.I
MeasurevoltagebetweensecondaryHO2S
(Sensor2) 4P connectorterminal No. 4 and body
g round.
HO2S{SENSOR
2I 4PCONNECTOR
SECONDARY
tFff I
E {31P}
Is there 0-1 V or less?
YES-Repair open in the wire betweenthe ECM
(E6)and the secondaryHO2S(Sensor2).!
NO Updatethe ECM if it does not havethe latest
.
o r i g i n aE
l CMa
l[faJl--ro'
14
|
IBLK/OFN)
Y
I
Terminal
sideof maleterminals
YES Go to step 13.
N O - C h e c k t h e N o . 4 A C G ( 1 0 A )f u s ei n t h e u n d e r dash fuse/relaybox. lf the fuse is OK, repair open in
the wire betweenthe secondaryHO2S(Sensor2)
a n d N o . 4 A C G ( 1 0 A )f u s e . l
11-69
PGM-FISystem
FuelSystemToo Lean
DTCP0171:
DTCP0172:FuelSystemToo Rich
4. With a vacuum pump, apply vacuum to the
evaporativeemission(EVAP)canisterpurge valve
(A) from the evaporativeemission(EVAP)canister
side.
NOTE:lf some of the DTCSlistedbelow are storedat
the same time as DfC PO17'land/ot PO172,
troubleshootthose DTCSfirst, then recheckfor P0171
andlot P0112.
P 0 1 0 7P, 0 1 0 8P. 11 2 8 .P 11 2 9 :M a n i f o l da b s o l u t e
p r e s s u r e( M A P )s e n s o r
P1162.P1166,P 1167:4,,/Fsensor(Sensor1) heater
r)
P 0 1 3 7P, 0 1 3 8S: e c o n d a r yH O 2 S( S e n s o 2
P014'l:SecondaryHO2S(Sensor2) heater
P1259:VTECsystem
1 . C h e c kt h e f u e l p r e s s u r e( s e ep a g e1 1 - ' 1 4 5 ) .
'
ls luel pressure OK?
A973AX-041-XXXXX
YES Go to step 2.
Does it hold vacuum?
NO Checkthese items:
. lf the pressureis too high, replacethe fuel
p r e s s u r er e g u l a t o(rs e ep a g e1 1 - 1 5 2 ) . 1
. l f t h e p r e s s u r ei s t o o l o w . c h e c k t h e f u epl u m p ,
the fuel feed pipe,the fuel filter, and replacethe
f u e l p r e s s u r er e g u l a t o (r s e ep a g e1 1 - 1 5 2 ) . I
11-70
YES-Check the enginevalve clearancesand adjust
if necessary,lf the valve clearancesare OK, replace
t h e i n j e c t o r s( s e ep a g e11 - 111 ) . 1
NO-Replace the EVAPcanisterpurge valve.l
DTCP0300:
RandomMisfireandAny Combination
of the Following:
DTCP0301:
No.1 CylinderMisfire
DTCP0302:No.2 CvlinderMisfire
DTCP0303:
No,3 CvlinderMisfire
DTCP0304:No. 4 CvlinderMisfire
NOTE:
. lfthe misfiring is frequentenoughto trigger detectionof increasedemissionsduring two consecutivedriving cycles.
the MIL will come on, and DTCP0300(and some comlrinationof P0301through P0304)will be stored.
. lf the misfiring is frequentenoughto damagethe catalyst,the MIL will blink wheneverthe misfiring occurs,and OTC
P0300(and some combinationof P0301through P0304)will be stored.When the misfirlng stops,the MIL will remain
on.
1. Troubleshootthe following DTCsfirst if any of them were stored along with the random misfire DTC(s):
P 0 ' 1 0 7P,0 1 0 8P, 1 1 2 8P
, 1 1 2 9N
r 4 a n i f o ladb s o l u t ep r e s s u r e( M A P )s e n s o r
P0111.P0'172t
Fuelsvstem
P0335.P0336:Crankshaftposition(CKP)sensor
P0505:ldle control system
sensor
P1149,Pl 162,P1163,P1164,P 1165:Air fuel ratio (Ay'F)
P1259:VTECsystem
P1361,P1362:Camshaftposition(CMP)sensorB {Top dead center(TDC)sensor)
P 1 5 1 9l:d l ea i r c o n t r o l( l A C )v a l v e
2. Test-drivethe vehicleto verify the symptom.
3. Findthesymptom inthechart below, and dothe relatedproceduresin the order listeduntil you find the cause.
Symptom
R a n d o mm i s f i r eo n l y
at low RPMand
under load
R a n d o mm i s f i r eo n l y
du ring acceleration
Randommisfire at
h i g h R P M ,u n d e r
l o a d ,o r u n d e r
random conditions
Procedure(sl
Also check foi:
Checkfuel pressure(seepage 11-145).
. Lowcompressron.
. Lowqualityfuel.
Checkfuel pressure(seepage 11-145).
in the
Malfunction
VTECsystem(seepage
1' t-123).
C h e c kf u e l p r e s s u r e( s e ep a g e1 1 - 1 4 5 ) .
Correctenginevalve
clearances(seepage 691.
11-71
PGM-FISystem
I
No.1 CylinderMisfire
DTCP0301:
1 . Determinewhich cylinder(s)had the misfire.
DTCP0302:No.2 CylinderMisfire
Does the misf ire occur in the cylinder where the
ignition coil was exchanged?
DTCP0303:No.3 CylinderMisfire
YES Replacethe faulty ignitioncoil.!
DTCP0304:No. 4 CylinderMisfire
NO-Go to step 8.
1. After checkingand recordingthe freezedata,reset
the ECM (seepage 11-4).lf there is no freezedata of
the misfire,just clearthe DTC.
2. Startthe engine,and listenfor a clickingsound
from the injectorat the problemcylinder.
9 . Exchangethe spark plug from the problemcylinder
with one from anothercylinder.
1 0 .Test-drivethe vehiclefor severalminutes in the
rangeof the freezedata or under various
conditionsif there was no freezedata.
Does the injector click?
YES-Go to step 3.
1 1 .Checkfor a DTCor TemporaryDTCwith the scan
Tool.
ls DTC ot Tempotary DTC P0301, P0302, P0303
or P0304indicated?
NO-Go to step 30.
YES Go to step 12.
4. Exchangethe ignition coil from the problem
cylinderwith one from anothercylinder,
NO Intermittentmisfiredue to spark plug fouling,
e t c .( n o m i s f i r ea t t h i st i m e ) . 1
5. Test-drivethe vehiclefor severalminutesin the
range of the freezedata or under va rious
Determine
w h i c h c y l i n d e r ( sh)a dt h e m i s f i r e .
Does the misl ire occur in the cylinder where the
spark plug was exchanged?
6. Checkfor a DTCor a TemporaryDTCwith the scan
root.
YES Replace
t h e f a u l t ys p a r kp l u g . l
ls DTC or Tempotaty DTC P0301, P0302, P0303
or P0304 ind icated?
NO Go to step 13.
YES Go to step7.
Turn the ignition switch OFF.
NO Intermittentmisfire due to poor contactat the
i g n i t i o nc o i l c o n n e c t o r {sn o m i s f i r ea t t h i st i m e ) .
Make sure the coil connectionsare secure.l
1 4 . Exchangethe lnjectorfrom the problemcylinder
w i t h o n ef r o m a n o t h e rc y l i n d e r .
t5.
11-72
L e tt h e e n g i n ei d l ef o r 2 m i n u t e s .
1 6 .Test-drivethe vehiclefor severalminutesin the
rangeof the freezedata or under various
't7.
Checkfor a DTCor a TemporaryDTCwith the scan
22. Measurevoltage betweenignition coil 3P
IGNITIONCOIL3P CONNECTOR
Tool.
ls DTC or TemporaryDTC P0301,P0302, P0303
or P0304 indicated?
YES Go to step 18.
NO lntermittentmisfire due to bad contactat the
injectorconnector(no misfireat this time). Make
surethe injectorconnectionis secure.Checkfor
poor connectionsor looseterminalsat the
injector.l
1 8 .Determinewhich cylinder(s)had the misfire.
YES-Go to step 23.
Does the misf ire occur in the cylinder where the
i njector w as exchanged ?
NO Repairopen in the wire betweenthe No. 1
I G NC O I L( 1 5 A ) f u s ea n dt h e i g n i t i o nc o i l . I
YES- Replacethe faulty injector.I
2 3 . Turn the ignitionswitch OFF.
NO-Go to step19.
24. Checkfor continuitybetweenignitioncoil 3P
20. Disconnectthe ignitioncoil 3P connectorfrom the
IGNITIONCOIL3PCONNECTOR
problemcylinder.
YES Go to step 25.
NO Repairopen in the wire betweenthe ignition
c o i l a n dG 1 0 1 . 1
DisconnectECMconnectorA {31P)
(cont'd)
11-73
PGM-FISystem
a
ECMconnectorterminal (seetable).
ECMCONNECTOR
A {31PI
PROBLEIVI
CYLINDER
DTC
ECM
WIRE
TERMINAL COLOR
N o .1
No.2
No.3
No,4
P0301
P0302
P0303
P0304
430
A.29
428
421
YEUGRN
BLU/RED
WHT/BLU
BRN
ECMCONNECTOR
A {31P}
PROBLEM
CYLINDER
No.1
N o .2
N o .3
N o .4
DTC
P0301
P0302
P0303
P0304
YES Repairshon in the wire betweenthe EClvl
a n dt h e i g n i t i o nc o i l . l
YES-Go to step 29.
ECM
WIRE
TERI\4INAL COLOR
A30
YEL/GRN
429
BLU/RED
A.28
WHT/BLU
A.21
BRN
NO Repairopen in the wire betweenthe ECMand
t h e i g n i t i o nc o i l . l
NO-Go to step 27.
2 7 . C o n n e c itg n i t i o nc o i l 3 P c o nn e c t o rt e r mi n a l N o . 1 t o
body ground with a jumper wire (seetable).
IGNITIONCOII 3PCONNECTOR
29. Checkthe engine compression
ls the compression OK?
originaE
l CI\4.I
N O - R e p a i tr h e e n g i n e . l
Wire s de of femaleterminals
3 0 . DisconnectECMconnectorB (24P).
PROBLEM
CYLINDER
No.1
N o .2
N o .3
N o .4
11-74
DTC
WIRECOLOR
P0301
P0302
P0303
P0304
YEUGRN
BLU/RED
WHT/BLU
BRN
32. fvleasure
voltagebetweenbodygroundandECM
connector
terminal(seetable).
ECMCONNECTOR
B (24P)
36. Exchangethe injectorfrom the problemcylinder
w i t h o n e f r o m a n o t h e rc y l i n d e r .
3 7 . L e t t h ee n g i n ei d l ef o r 2 m i n u t e s .
3 8 . Test-drivethe vehiclefor severalminutes in the
r a n g eo I t h e l r e e z ed a t ao r u n d e rv a r i o u s
condilionsif there was no freezedata.
39. Checkfor a DTCor TemporaryDTCwith the scan
tool.
ls DTC or TemporaryDTC P0301,P0302, P0303,
or P0304 indicated?
W i r e s i d e o f f e m a l et e r m r n a l s
YES Go to step 40.
PROBLEM
CYLINDER
No. 1
No.2
No.3
No.4
DTC
P0301
P0302
P0303
P0304
ECt\4
TERMINAL
B5
B4
B3
WIRE
COLOR
BRN
RED
BLU
YEL
NO Intermittentmisfiredue to injector
malfunction,etc. Make sure the injector
connectionsare secure.Checkfor poor connections
or looseterminalsat the injectorconnector.l
D e t e r m i n ew h i c hc y l i n d e r { sh}a d t h e m i s f i r e .
YES-Go to step 33,
Does the mislirc occur in the cylinder whete the
i nj ector w as exchanged ?
N O G o t o s t e p4 1 .
YES Replacethe faulty injector.l
33. Turn the ignitionswitch OFF,and removethe
engine cover.
34. Disconnectthe injector2P connectorfrom the
p r o b l e mc y l i n d e r .
3 5 , Measurethe resistancebetweeninjector2P
software,or substitutea known-goodECM.then
recheck(seepage 1'l-6).lf the symptom/indication
originaE
l CM.I
4 1 .Turn the ignition switch OFF.
c o n n e c t otre r m i n a l sN o . 1 a n d N o . 2 .
42. Removethe enginecover.
INJECTOB2P CONNECTOR
43. Disconnectthe injector2P connectorfrom the
p r o b l e mc y l i n d e r .
4 4 . T u r nt h e i g n i t i o ns w i t c hO N ( l l )
Terminal side of male terminals
l s t h e r e 1 0Q
13A?
YES-Go to step 36.
NO Replace
t h e i n j e c t o r( s e ep a g e11 -1 1I ) .t
(cont'd)
11-75
PGM-FISystem
45. Measure
voltagebetweeninjector2Pconnector
t e r m i n aNl o .1 a n db o d yg r o u n d .
48. Connectinjector2PconnectorterminalNo.2to
bodygroundwith a jumperwire {seetable).
INJECTOR
2P CONNECTOR
INJECTOR2P CONNECTOR
tll-z]
-lt,o,,"=rrrr*,
oI
tll-Z-l
-]_r-l_rNJ
IJUMPER
IwrBE
Wire side of {emaleterminals
YES-Go to step 46.
NO-Repair open in the wire betweenthe injector
l a i n r e l a yl . l
a n d t h e P G M - Fm
PROBLEM
CYLINDER
No.1
No.2
N o .3
N o .4
DTC
WIRECOLOR
P0301
P0302
P0303
P0304
BRN
RED
BLU
YEL
4 7 .Checkfor continuitybetweenbody ground and
ECM CONNECTORB I24P)
a
B {24P)
ECMCONNECTOR
Wire side oJtemaleterminals
W i r es i d eo f f e m a l et e r m i n a l s
PROBLEM
CYLINDER
N o .1
No.2
No.3
N o .4
ECM
TERMINAL
P030'1
B5
B4
P0302
P0303
B3
P0304
82
DTC
WIRE
COLOR
BRN
RED
BLU
YEL
PROBLEM
CYLINDER
No.1
N o .2
N o .3
N o .4
DTC
P0301
P0302
P0303
P0304
ECM
TERMINAL
B5
B4
B3
82
WIRE
COLOR
BRN
RED
BLU
YEL
YES Replacethe injector,then recheck.l
a n dt h e ; n j e c t o r . I
N O - G o t o s t e p4 8 .
11-76
NO Repairopen in the wire betweenthe ECM and
the injector.I
I
DTGP0325:Malfunctionin KnockSensor
Circuit
1 . R e s e t h e E C M( s e ep a g e1 1 - 4 ) .
7. Connectstanersubharness
6Pconnector
terminal
r ire.
N o .5 t o b o d yg r o u n dw i t ha j u m p e w
STARTER
SUAHARNESS
6P CONNECTOR
then let it idle.
3. Holdthe engineat 3,000-4,000 rpm for at least
60 seconds.
l1l213l
l._, / l 5 l 6 l
KS
IJUMPER
|RED/BLU)
IW|RE
I
ls DTC P0325 indicated?
YES-Go to step 4.
the knocksensorand at the ECM.I
8 . Checkfor continuitybetweenbodygroundand
ECMconnector
terminalA9.
ECMCONNECTOR
A {31PI
5. Disconnectthe startersubharness6P connector.
terminalAg and body ground.
ECMCONNECTOR
A 131P)
YES-Go to step 9.
NO Repairopen in the wire betweenthe ECM (A9)
and the startersubharness6P connector.l
Wire side of lemaleterminals
9 . Checkthe startersubharnessbetweenthe 6P
ls therecontinuity?
YES-Repairshortin thewire betweenthe ECM
(A9)andthe startersubharness
6Pconnector.l
NO Goto step7.
connectorand the knocksensorfor an open or
short. lf it's OK, substitutea known-goodknock
sensorand recheck.
software.or substitutea known-goodECM,then
recheck{seepage '11-6).
lf the sym ptomlindication
goes away with a known good ECM,replacethe
originaE
l CM.I
NO Replace
t h e o r i g i n a kl n o c ks e n s o ra n d / o r
starter subharness.l
11-77
PGM-FISystem
DTCP0335:CKPSensorNo Signal
DTCP0336:CKPSensorIntermittent
Interruption
7. Measurevoltage betweenCKPsensor3P connector
t e r m i n a lN o , 1 a n d b o d y g r o u n d
CKPSENSOR3P CONNECTOR
'1-4).
'1. Reset
the ECM (seepage 1
ls DTC P0335 and/or P0336 indicated?
YES Go to step 3.
Wire side of female tefminals
t h e C K Ps e n s o ra n d a t t h e E C M . I
ls thereabout5 V?
YES Goto stepL
4. Disconnectthe CKPsensor3P connector.
N O G ot o s t e p1 0 .
5. Turn the ignitionswitch ON {ll).
6. Measurevoltage betweenCKPsensor3P connector
t e r m i n a lN o . 3 a n d b o d y g r o u n d .
voltagebetweenCKPsensor3Pconnector
8. Measure
t e r m i n a lN
s o . 2a n dN o .3 .
CKPSENSOR3PCONNECTOR
CKPSENSOR3PCONNECTOF
,llYtL
IGP
1 2 3
(YEL/BLK}
a
L " l
LGl
{BRN/YELI
(
W i r e s i d eo f f e m a l et e r m i n a l s
Wiresadeof femaleterminals
YES Go to step 9.
Is therebattery voltage?
YES- Goto step7.
NO Repairopenln thewire betweenPGM-Flmain
r e l a y1 a n dt h eC K Ps e n s o r . !
NO Repairopen in the wire betweenthe CKP
s e n s o ra n d G 1 0 1. I
9. Substitutea known-goodCKPsensorand recheck.
ls DTC P0335 and/or P0336 indicated?
software.or substitutea known good ECM,then
originaE
l CM.I
t h e o r i g i n aC
l K Ps e n s o r . l
NO Replace
11-78
a
'10.l\4easure
voltagebetweenECMconnector
terminal
A7 andbodyground,
ECMCONNECTOR
A 13lPI
Wiresideot femaleterminals
ls there about 5 V?
(A7)and the CKPsensor.t
N O - G o t o s t e p1 1 .
DisconnectECMconnectorA (31P)
1 3 . Checkfor continuitybetweenECMconnector
terminal 47 and body ground.
ECMCONNEfiORA (31P)
(A7)and the CKPsensor.t
software.or substitutea known-goodECI\4,then
originaE
l CM.t
11-79
PGM-FlSystem
DTCP0500:VSSCircuitMalfunction
1. Test-drivethe vehicle.
10. DisconnectECMconnectorA (3'1P).
2. Checkthe vehiclespeedwith the scantool.
11 . T u r nt h e i g n i t i o ns w i t c hO N { l l } .
ls the correct speed indicated?
YES-lntermiftent failure,system is OK at this time.
t h e V S Sa n d a t t h e E C M . I
NO Go to step 3.
12. Blockthe right front wheel. and slowly rotatethe
left front wheel.
'!3.
lMeasurevoltage betweenECMconnector
t e r m i n a l sA 1 8 a n d A 2 4 .
A I31PI
ECMCONNECTOR
4. Blockthe rearwheels,and set the parkingbrake.
5. Raisethe front ofthe vehicle,and make sure it is
securelysupported,
1 . Blockthe right front wheel, and slowly rotatethe
left front wheel.
8. Measurevoltage betweenECMconnector
t e r m i n a l sA 1 8 a n d A 2 4 .
A {31P)
ECMCONNECTOR
Does the voltage pulse between 0 V and 5 V ol
between0V and battety voltage?
origlnaE
l CM.I
NO Checkthese items:
. A short or an open in the wire betweenthe ECM
( A 1 8 )a n d t h e V S S . I
. l f t h e w i r e i s O K , t e s t t h e V S S( s e ep a g e2 2 7 1 ) . 1
Does the voltage pulse between 0 V and 5 V or
between 0V and battery voltage?
YES-Update the ECM if it does not havethe latest
originaE
l CN4.l
NO Go to step 9.
11-80
DTCP0563:ECMPowerSourceCircuit
Unexpected
Voltage
9 . Removethe glove box (seepage20-63).
1 0 .Removethe PGM-FImain relay 1 (A7.
1 . R e s e t h e E C I \ {4s e ep a g el 1 - 4 } .
3. Wait 5 seconds.
4 . T u r nt h e i g n i t i o ns w i t c hO N { l l l .
YES Go to step 5.
NO-lntermiltent failure,system is OK at this time.
t h e N o . 6 E C U( E C M ){ 1 5A ) f u s ei n t h e u n d e r - h o o d
fuse/relaybox and at the ECM.I
1 1 .Checkfor continuitybetweenECMconnector
terminal E7 and body ground.
ECMCONNECTOR
E 131P)
6 . DisconnectECI\4connectorE {31P).
MRLY
{RED/YEL)
8 . lvleasurevoltagebetweenECMconnectorterminal
E7 and body ground.
ECMCONNECTOR
E {31P}
MRLY
Wiresideof {emaleterminals
l a i n r e l a y1, I
{ E 7 )a n d t h e P G M - Fm
Wiresideol remaleterminals
NO Replace
t h e P G M - Fm
l a i n r e l a y1 . 1
tt.
Turn the ignition suitchOFF.
'13.R e c o n n e cEt C M
c o n n e c t oE
r (31P).
YES Go to step 12.
NO Go to step 9.
(conl'd)
11-81
PGM-FISystem
14. Measurevoltage betweenECMconnectorterminal
E7 and body ground.
1 8 .Removethe glove box (seepage 20-63).
1 9 .Removethe PGM-FImain relay '1{A).
ECMCONNECTORE 13lPI
MRLY
IBEO/YEL)
YES Go to step 15.
software,or substitutea known-goodEClvl,then
o r i g i n aE
l CM.I
1 5 . DisconnectECI\4connectorA (31P).
to.
20. Measure voltage
between body ground and ECM
connector terminals A3 and A2 individually.
ECMCONNECTOR
A {31PI
IGP2
(YEL/BLK)
IGP1
(YEL/BLK)
1 7 . Measurevoltage betweenbody ground and ECIM
c o n n e c t otre r m i n a l s4 3 a n d4 2 i n d i v i d u a l l y .
ECMCONNECTOR
A {3.IP)
IGP2
(YEI./BLX)
IGP1
(YEL/BLKI
I s there battery v oltage?
YES Repairshortto power in the wire between
( A 2 . A 3a) n d t h e P G M - Fm
the ECI\4
W i r es i d eo f f e m a l el e r m i n a l s
YES-Go to step 18.
originalECM/PCl\4.1
11-82
N O R e p l a c e t h eP G M F l m a i n r e l a y1 . !
DTGPl106:BAROSensorRange/Perfomance
Problem
2. Startthe engine.Holdthe engineat 3,000rpm with
then let it idle.
DTCPl107:BAROSensorCircuitLowVoltage
DTCPl108:BAROSensorCircuitHigh
Voltage
1 . R e s e t h e E C M{ s e ep a g e11 - 4 ) .
Test-drivewith the transmissionin 4th gear.
l s D T C P 1 1 0 7o r P 1 1 0 8i n d i c a t e d ?
Acceleratefor 5 secondsusingwide open throttle.
YES-Update the ECM if it does not havethe iatest
then
originaE
l CI\4.I
Checkfor a TemporaryDTCwith the scantool.
Is TemporaryDTC Pl106 indicated?
o r i g i n aE
l C M !.
NO- Intermittentfailure,system is OK at this
trme.l
NO Intermittentfailure,system is OK at this
time.I
11-83
PGM-FISystem
DTGTroubleshooting(cont'dl
DTCPl157:Ay'F
Sensor(Sensor1)Range/
Performance
Problem
1 . R e s e t t h eE C I M( s e ep a g e1 1 - 4 ) .
L
t e r m i n a l4s6 a n dA 1 6 .
ECMCONNECTOR
A {3IP)
2. Startthe engine.
ls DTC Pl157 indicated?
YES-Go to step 3.
the Ay'Fsensor(Sensor1) and at the ECN4.I
Disconnectthe Ay'Fsensor(Sensor1) 4P connector
a n d E C Mc o n n e c t oA
r (31P).
ConnectA,/Fsensor(Sensor1) 4P connector
ls therecontinuity?
YES Goto step9.
NO Goto step7.
(SENSOR
A/F SENSOR
1) 4PCONNECTOR
7 . Connect
A/Fsensor(Sensor1)4Pconnecror
r ire.
t e r m i n aNl o .1 t o b o d yg r o u n dw i t ha j u m p e w
AFS+ {BLU)
(
A/F SENSOR{SENSOR1I 4P CONNECTOR
JUMPERWIRE
(
11-84
terminals46 andbodyground.
A 131P}
ECMCONNECTOR
DTCPl158:Ay'F
Sensor(Sensor1)AFSTerminalLowVoltage
2. Startthe engine.
YES Go to step 3.
NO-lntermittent failure,system is OK at this time
Checkfor poor connectionsor loosetermanalsat
the Ay'Fsensor(Sensor1) and at the ECIMI
Wire side ol lemaleterminals
YES-Repair open in the wire betweenthe Ay'F
sensor(Sensor1) and the ECM(416).1
NO-Repair open in the wire betweenthe Ay'F
sensor(Sensor1) and the ECM (46).1
4, DisconnecttheAy'Fsensor(Sensor1) 4P connector,
r (31P).
a n d E C Mc o n n e c t oA
termina4
l 1 6 a n d b o d yg r o u n d .
A (31P)
ECMCONNECTOR
9 . Substitutea known-goodAy'Fsensor(Sensor1) and
recheck.
YES- Updatethe ECM if it does not have the latest
recheck(seepage 11-6).if the symptom/indication
original ECM.!
Wire side oJfemaleterminals
NO- Replacethe Ay'Fsensor{Sensor1).!
YES-Repair shon in the wire betweenthe A,/F
s e n s o r( S e n s o r1 ) a n dt h e E C M( A 1 6 ) . 1
NO Go to step 6.
' c o n td )
11-85
PGM-FISystem
6. Substitutea known-goodAy'Fsensor(Sensor1)and
recheck.
(
DTCPl159:A,/FSensor(Sensor1)AFS +
TerminalLowVoltage
Is DTC P1158 indicated?
originaE
l CM.I
NO- Replacethe Ay'Fsensor(Sensor1).t
YES-Go to step 3.
NO-lntermiftent failure.system is OK at this time.
Checkfor poor connectionsor looseterminaisat
the A,/Fsensor(Sensor1) and at the ECM.I
4. Disconnectthe Ay'Fsensor(Sensor1) 4P connector
a n d E c M c o n n e c t oA
r (31P).
terminal 46 and body ground.
ECMCONNECTOR
A {31PI
ls therecontinuity?
YES-Repairshortin thewire between
the Ay'F
s e n s o(rS e n s o1r )a n dt h eE C M( A O ) . I
NO Goto step6.
11-86
a
6. Substitutea known-goodAy'Fsensor(Sensor1i and
recnecK.
l s D T C P 1 1 5 9i n d i c a t e d ?
goes away with a known-goodECN4,
replacethe
o r i g i n aE
l CM.I
NO Replace
t h e A y ' Fs e n s o r( S e n s o r1 ) . 1
11-87
PGM-FISystem
DTCPl163:Ay'FSensor(Sensor1) Slow
Response
NOTE:lf DTCP1162is storedat the same time as DTC
P1163.troubleshootDTCP1162first, then recheckfor
D T CP 1 1 6 3 .
1 . R e s e t h e E C M( s e ep a g e11 - 4 ) .
2. Startthe engine.Hold the engine at 3,000rpm with
3. Test-driveunderthe following conditions:
. 55 mph (89 km/h) steadyspeed
' Transmissionin sth gear
' Until the Ay'Fsensorreadinesscode or
TemporaryDTCPl163 comes on
4. Checkfor a TemporaryDTCwith the scantool.
ls Temporary DTC P 1163indicated?
YES Replacethe Ay'Fsensor(Sensor1).I
NO Intermittentfailure, system is OK at this time.
the A'lFsensor (Sensor1) and at the ECM.t
11-88
DTCPl164:A,/FSensor(Sensor1)Circuit
Range/Performance
Problem
( s e ep a g e1 t - 4 ) .
1 . R e s e t t h eE C I \ 4
2 . S t a r tt h e e n g i n e .H o l d t h e e n g i n e a t 3 , 0 0r0p m w i t h
3. Test-drivein 3rd gear.Startingat 1,600rpm,
accelerateusing wide open throttlefor at least
5 seconds.Then deceleratefor at least5 seconds
with the throttle completelycloseduntil the A,/F
sensorreadinesscode is set to completeor
TemporaryDTCP1164comes on.
4. Checkfor a TemporaryDTCwith the scantool.
ls TemporaryDTC P1164indicated?
YES- Replacethe A,,/F
sensor(Sensor1).I
the Ay'Fsensor relay,at the Ay'Fsensor(Sensor1),
a n da t t h e E c M . l
Sensor(Sensor1)Heater
DTCPl166:Ay'F
CircuitMalfunction
2. Startthe engine.
Is therc battery voltage?
soflware,or substitutea known-goodECM.then
o r i g i n aE
l CM.I
NO-Go to step 5.
YES-Go to step 3.
NO-lntermittent failure,system is OK at this lime.
the Ay'Fsensorrelay,the A,/Fsensor(Sensor1),and
t h e E c M .!
5. MeasurevoltagebetweenECMconnector
terminalsA22 and A24.
A {31P}
ECMCONNECTOR
3. Checkthe following fuse:
. No. 14 OPTION(30A)fusein under-hoodfuse/
rerayDox.
. No. 2*B LAF (Ay'F)
HEATER(20A)fuse in underdash fuse/relaybox.
. No. 4 ACG (10A)in underdash fuse/relaybox.
Are any of the fuses blown?
YES Repairshort in the wire betweenthe Ay'F
sensorrelay and the fuses.I
ls therebattery voltage?
NO Go to step 4.
YES Goto step6.
terminalsA1 and A24. 30 secondsafter the ignition
s w i t c hi s t u r n e dO N ( l l ) .
A I31P)
ECMCONNECTOR
N O - G o t o s t e p1 0 .
6. Turnthe ignitionswitchOFF.
E (31P).
7. Disconnect
ECMconnector
s w i t c hO N{ l l ) .
8 . T u r nt h ei g n i t i o n
W i r es r d eo f l e m a l et e r m i n a l s
(cont'd)
11-89
PGM-FISystem
9. ConnectECMconnectorterminal EStobody
ground with a jumper wire, then measurevoltage
betweenECMconnectorterminalsA1 and 424.
YES Repairshort in the wire betweenthe A|/F
sensorrelay,A,/Fsensor{Sensor1) and ECM
lA22J.a
ECMCONNECTORS
NO Go to step 13.
t5.
1 4 . Measurevoltage betweenECMconnector
terminalsE8 and A24.
ECM CONNECTORS
E {31P)
YES- Updatethe ECM if it does not have the latest
originaE
l C M t.
a {31P)
NO Repairopen in the wire betweenthe Ay'F
r ) a n d E C M( A 1 ) t.
s e n s o r( S e n s o 1
1 1 .Disconneclthe ECfMconnectorA (31P)and the Ay'F
sensor(Sensor1) 4P connector.
1 2 . Checkfor continuitybetweenthe Ay'Fsensor
( S e n s o r1 ) 4 Pc o n n e c t otre r m i n a lN o . 3 a n d b o d y
ground.
(A22)and the IVF sensor(Sensor1).I
N O - G o t o s t e p1 5 .
Checkfor continuityin the wires betweenthe Ay'F
sensorand the fuses.
(SENSOR
A/F SENSOR
1)4PCONNECTOR
YES-The wires are OK. Replacethe A,/Fsensor
relay.l
NO Repairopen in the wire betweenthe Ay'F
sensorrelay and the fuses.l
11-90
Sensor(Sensor1)Heater
DTCPl167:Ay'F
CircuitMalfunction
NOTE:lf DTCP1162is storedat the same time as DTC
P1167,troubleshootDTCP1162first, then troubleshoot
D T CP 1 1 6 7 .
1 . R e s e t t h eE C I \ (4s e ep a g e1 1 - 4 )
t e r m i n a l s, 4 6a n d 4 1 6 .
A {31P)
ECMCONNECTOR
AFS- {RED)
trTzTil,ilsl l t
t8
9
2C21
l?rlzsIels
2. Startthe engine.Wait for at least80 seconds.
AFS
IRED/YEL)
YES Go to step 3.
Wire side of lemale terminals
the Ay'Fsensorrelay,at the Ay'Fsensor(Sensor1),
a n da t t h e E C M . I
?
Disconnectthe A,/Fsensor4P connectorand ECM
connectorA (31P).
ls thetecontinuity?
h eA / Fs e n s o(rS e n s o1r ) . 1
Y E S - R e p l a ct e
NO-Repairopenin thewire betweenthe Ay'F
s e n s o(rS e n s o1r) a n dt h eE C M( 4 6o r A 1 6 ) . I
5 . Connectthe Ay'Fsensor(Sensor1) 4P connector
A/F SENSOR(SENSOR1)
4P CONNECTOR
JUMPERWIRE
Wire side of
f e m a l et e r m i n a l s
11-91
PGM-FISystem
I
DTCPl297:ELDCircuitLowVoltage
1 . R e s e t h e E C M{ s e ep a g e1 1 - 4 ) .
2. Startthe engine.
9. DisconnectECMconnectorE {31P).
E C Mc o n n e c t otre r m i n a lE 1 5 .
3 . T u r no n t h e h e a d l i g h t s .
ECMCONNECTOR
E 131PI
I l 2 l 34 5 6 1 7
YES Go to step 4.
to
t h e E L Da n d a t t h e E C M . I
,2 2al2/
tA
7\'
td
8 I
/ 12021
31
ELD
(GRN/RED}
4. Turn the ignition switch and the headlightsOFF.
5. DisconnecttheELD3P connector.
6. Turn the ignition switch ON {ll).
7. Measurevoltage betweenbody ground and ELD3P
connectorterminal No. 3.
ELO3P CONNECTOB
Z
3
ELD{GRN/REDI
ls thereabout5 V?
YES Replace
the ELD.t
11-92
( E1 5 )a n d t h e E L D r.
NO- U pdatethe ECM if it does not havethe latest
o r i g i n aE
l CM.I
a
DTCPl298:ELDCircuitHighVoltage
1 . R e s e t t h eE C M( s e ep a g e1 1 - 4 )
9 . ConnectELD3P connectorterminal No. 3 to body
g r o u n dw i t h a j u m p e rw i r e .
2. Stan the engine.
ELD3P CONNECTOR
3. Turn on the headlights.
---F-------
l 1 l 2: r l
ELD
(GRN/RED)
YES-Go to step 4.
wrRE
IJUMPER
NO- Intermittentfailure.system is OK at this time.
t h e E L Da n d a t t h e E C M . I
4. Turn the ignition switch and headlightsOFF.
5. DisconnecttheELD3P connector.
I
I
Wire side of temaleterminals
1 0 .DisconnectECMconnectorE (31P).
7. Measurevoltagebetweenbody ground and ELD3P
ELD3PCONNECTOR
ECMconnectorterminal E15.
E 131PI
ECMCONNECTOR
1 2 1 34 5
IG1IBLK/ORNI
14
L C
22123
24
I I
6 l / 1 8 2C 21
21./ 2Q 30 J
o t /
ELD
i1' IGRN/RED)
Wire side ot {emaleterminals
Is thetecontinuity?
Y E S - G ot o s t e p1 2 .
YES-Go to step 8.
N O - C h e c k t h e N o . 4 A C G ( 1 0 A ) f u s ei n t h e u n d e r dash fuse/relaybox. lf the fuse is OK, repairopen in
the wire betweenthe No. 4 ACG (10A)fuse and the
ELD.I
NO Repairopenin thewire betweenthe ECM
( E 1 5a) n dt h eE L D .
(cont'd)
11-93
PGM-FISystem
12, Checkfor continuitybetweenELD3P connector
t e r m i n a lN o . 2 a n d b o d y g r o u n d .
E L D 3 PC O N N E C T O R
YES Go to step 13.
NO- Repairopen in the wire betweenthe ELDand
G 2 0 1I.
Reconnectthe ELD3P connectorand ECM
connectorE (31P).
1 4 . Startthe engineand let it idle.
t5_
While measuringvoltage betweenECMconnector
t e r m i n a l s4 2 4 a n d E 1 5 ,t u r n t h e h e a d l i g h t os n
t hi g h ) .
ECM CONNECTORS
W i . e s i d eo f f e m a l et e r m i n a l s
Does the voltage drop?
originaE
l CM.I
NO Replace
the ELD.I
11-94
DTCPl361:CamshaftPosition(CMP)Sensor
B (TDCSensor)Intermittent
Interruption
DTCPl362:CamshaftPosition(CMP)Sensor
B (TDCSensor)No Signal
7. l\4easure
voltage betweenCMP sensorB {TDC
sensor)3P connectorterminal No. 1 and body
ground.
CMP S€NSOR 8 ITDCSENSOR)3P CONNECTOR
2. Startthe engine.
ls DTC P1361and/or P1362 indicated?
YES Go to step 3.
Wlres de ollemaleterminals
NO- Intermittentfailure.system is OK at this time.
t h e C M Ps e n s o rB ( T D Cs e n s o r a
) n da tt h e E C M . I
ls thereabout5 V?
YES-Go to step8.
N O - G o t o s t e p1 0 .
4 . DisconnecttheCMP sensorB (TDCsensor)3P
voltagebetweenCl\ilPsensorB (TDC
8. Measure
s e n s o r3)Pc o n n e c t ot er r m i n a lN
s o .2 a n dN o ,3 .
connector.
5 . Turn the ignitionswitch ON (ll).
CMPSENSON
B llOC SENSOfi)3P CONNECTOF
6 . Measurevoltage betweenCMP sensorB (TDC
sensor)3P connectorterminal No. 3 and body
grouno.
B {TDCSENSOR)
CMPSENSOR
3PCONNECTOR
IGP
1 2 3
{YEL/BLK}
Wire s de olfema etefminals
Y E S - G o t o s t e p9 .
NO Repairopen in the wire betweenthe CMP
) n dG 1 0 1 . 1
s e n s o rB ( T D Cs e n s o r a
Wiresideol temaleterminals
9. Substitutea known-goodCMP sensorB (TDC
sensor)and recheck.
ls DTC P1361and/or P1362 indicated?
YES Go to step 7.
YES Updatethe ECMif it does not have the latest
originaE
l CM.I
NO-Repair open in the wire betweenthe PGM-Fl
m a i n r e l a y1 a n dt h e C M Ps e n s o rI ( T D Cs e n s o r ) . I
NO Replace
theoriginaC
l MPsensorB(TDC
sensor).1
(cont'd)
11-95
PGM-FISystem
(cont'd)
DTCTroubleshooting
10. MeasurevoltagebetweenECI\4
connectorterminal
A26andbodyground.
ECMCONNECTOR
A (31P)
1 2 3 4 5 6 1 7
I
0 1 11 2 1 . /
61,/18 I 2C2l
2324
21m 30
TDC {GRN}
Wire side oI temaleterminals
ls thereabout5 V ?
YES- Repairopenin thewire betweenthe ECM
(426)and CMPsensorB (TDCsensor).1
DTCPl607:Malfunction
in ECMInternal
Circuit
1. ResettheEC|\illsee page 11-4).
2 , T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d w a i t f o r
40 seconds.
ls DTC P 1607 indicated?
recheck(seepage 11 6). lf the symptom/indication
o r i g i n aE
l CM.I
A low batterycan causethis problem . Ask the
customerif there has been any recenttrouble
s t a r t i n gt h e e n g i n e . l
N O - G o t o s t e p1 1 .
1 1 .Turnthe ignitionswitchOFF.
1 2 . Disconnect
ECIM
A (31P)
connector
Checkfor continuitybetweenECMconnector
terminal426 andbodyground.
ECMCONNECTOR
A {31PI
YES Repairshort in the wire betweenthe ECM
(426)and the CMP sensor B (TDCsensor).1
originaE
l CM.I
11-96
\
MIL CircuitTroubleshooting
1. Connectan OBD ll scantool/HondaPGM Tester
( s e ep a g e1 1 - 3 ) .
2. Turn the ignition switch ON (ll) and readthe OBD ll
scantool/HondaPGM Tester.
Does the OBD ll scan tool/Honda PGM Tester
communicatewith the ECM?
YES Go to step 3.
"
NO Go to troubleshooting DLCCircuit
T r o u b l e s h o o t i n g (" s e ep a g e1 1 - 1 0 9 ) .
. A l o o s eN o . 1 7 F U E LP U M P( 1 5 A ) f u s ei n t h e
. A p o o rc o n n e c t i o n
l 31.
a t E C Mt e r m i n a E
. An intermittentopen in the GRN/ORNwire
) n d t h e g a u g ea s s e m b l y .
b e t w e e nt h e E C M( E 3 1 a
. An intermittentshort in the wire betweenthe
ECM(A21)and the manifold absolutepressure
( M A P )s e n s o r .
ECI\4(A20)and the throttle posilion (TPisensor.
ECM (E5)and the fuel tank pressure(FTP)sensor.
3. Checkthe OBD ll scantool/HondaPGM Testerfor
DTCs.
Are any DTCs indicated?
ls the low oil pressure light on?
YES Go to the DTCTroubleshootingIndex.
YES Go to step 10.
NO-Go to step 4.
5 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) a n dw a t c ht h e
l M a l f u n c t i oIn d i c a t oLr a m p( M l L ) .
8 . I n s p e c t t h eN o . 1 0 l \ 4 E T E(R7 . 5 A ) f u s ei n t h e u n d e r dash fuse/relaybox.
ls the luse OK?
Does the MIL come on and stay on for more than
20 secondsaftet turning the ignition switch
YES Go to step L
oN (tr)?
N O R e p a i rs h o n i n t h e w i r e b e t w e e nN o . 1 0
M E T E R( 7 . 5 A ) f u s e
a n d t h e g a u g ea s s e m b l yA. l s o
r e p l a c e t h eN o . 1 0 M E T E R{ 7 . 5 A f) u s e . l
YES lf the MIL alwayscomes on and stayson, go
to step 76. But if the lMlLsometimesworks
normally,first checkfor these problems.
) n dt h e d a t al i n kc o n n e c t o(rD L C ) .
E C I M( E 2 9 a
) n dt h e g a u g ea s s e m b l y .
E C M( E 3 1 a
NO lf the MIL is alwaysoff, go to step 6. But if the
lvllLsometimesworks normally,first checkfor
these problems.
. A l o o s eN o . 1 0 M E T E R( 7 . 5 A f)u s ei n t h e u n d e r
dash fuse/relaybox.
. A l o o s eN o . 2 0 l G ( 4 0 A )( C a n a d a5: 0 A ) I u s ei n t h e
under-hoodfuse/relaybox.
. A i o o s eN o . 6 E C U( E C M )( 1 5 A )f u s ei n t h e u n d e r hood fuse/relaybox.
9. Inspectthe No. 20 lG1 (40A)(Canada:50A)fuse in
the under-hoodfuse/relaybox.
ls the f use OK?
YES Repairopen in the wire betweenthe No. 20
l G ( 4 0 A ){ C a n a d a5r0 A ) f u s ea n d t h e g a u g e
assembly.lf the wire is OK, test the ignition switch
{seepage 22 53).
N O R e p a i rs h o r ti n t h e w i r e b e t w e e nN o . 2 0 l G
( 4 0 A )l C a n a d a5: 0 A ) f u s ea n d t h e u n d e r ' d a s h
fusel
r e l a yb o x .A l s o r e p l a c et h e N o . 2 0 l G ( 4 0 A i
( C a n a d a5: 0 A )f u s e . I
(conr'd)
11-97
PGM-FISystem
MIL CircuitTroubleshooting(cont'dl
1 0 .Tryto startthe engine.
to.
Removethe blown No. 6 ECU{ECfU)(154)fuse
from the under-hoodfuse/relaybox.
Doesthe enginestart?
1 7 . Removethe glove box (seepage 20-63)and the
P G M ' F Im a i n r e l a y1 .
N O - G o t o s t e p1 4 .
1 1 .Turnthe ignitionswitchOFF.
12. ConnectECMconnector
terminalE31to body
groundwith a jumperwire.
ECMCONNECTOR
E 13lPI
l l 2 l 34 5 6 1 7 l1 8I
4 1 5161,/118 2( 2t
2' 23 24
z7l/ 129 31
JUMPER MIL
(GRN/ORN}
WIRE
1 8 . Checkfor continuitybetweenbody ground and
P G M - Fm
l a i n r e l a y1 4 P c o n n e c t otre r m i n a l sN o . 2
a n d N o .4 i n d i v i d u a l l v .
PGM-FIMAIN RELAY1
4P CONNECTOR
ls the M lL on?
goes away with a known-goodECIM,replacethe
o r i g i n aE
l CM.I
NO-Check for an open in the wire betweenthe
) n d t h e g a u g ea s s e m b l yA. l s o c h e c kf o r
E C M( E 3 1 a
a b l o w nM I L b u l b .l f t h e w i r e sa n d t h e b u l ba r e O K ,
replacethe gauge assembly.l
't4. Turn
the ignltion switch OFF,
f V (wHr/
B
v)
BLK)(
IA
W r r es r d eo l l e m a l et e r m r n a l s
Y E S - R e p a i rs h o r ti n t h e w i r e b e t w e e nt h e N o . 6
) 5 A )f u s ea n d t h e P G M - Fm
E C U( E C l \ 4( 1
l a i n r e l a y1 .
A l s o r e p l a c et h e N o . 6 E C U( E C M )( 1 5 A )f u s e . l
N O - G o t o s t e p1 9 .
(15A)fuse in the
1 5 . Inspectthe No. 6 ECU (ECIM)
ls the f use OK?
YES-Go to step 22.
N O - G o t o s t e p1 6 .
11-98
19. Disconnecteach of the componentsor the
connectorsbelow, one at a time, and checkfor
continuitybetweenPGM-FImain relay 1 4P
21. Checkfor continuitybetweenPGM-FImain relay 1
4P connectortermlnal No. 1 and body ground.
PGM-FIMAIN RELAY1
4P CONNECTOR
.
.
.
.
.
PGfvl-Flmain relay 2
ECMconnectorA (31P)
Eachinjector2P connector
ldle air control (lAC)valve3P connector
CamshaftPosition(CMP)sensorB (Topdead
center(TDC)sensor)3P connector
. Crankshaftposition(CKP)sensor3P connector
PGM-FIMAIN RELAY1
4PCONNECTOR
YES Repairshort in the wire betweenthe PGM-Fl
main relay 1 and each item. Also replacethe No. 6
E C U{ E C M )( 1 5 A )f u s e . l
l a i n r e l a y1 .A l s o r e p l a c e
N O - R e p l a c et h e P G M - Fm
t h e N o 6 E C U{ E C I M()1 5 A )f u s e .I
( 1 5 A ) f u s ei n t h e
22. I n s p e c t t h eN o . 1 7 F U E LP U I \ 4 P
under-dashf use/relaybox.
YES Go to step 20.
ls the tuse OK?
NO- Replacethe componentthat made continuity
to body ground go away when disconnected.lf the
item is the ECM,updatethe ECM if it does not have
the latestsoftware.or substitutea known-good
ECM,then recheck(seepage 11-6).lf the symptom/
indicationgoes away with a known'good ECM,
r e p l a c et h e o r i g i n a E
l CM.
Also replacethe No. 6 ECU(ECM)(15 A) fuse,
YES Go to step 34.
NO Go to step 23.
23. R e m o v et h e b l o w nN o , 1 7 F UE LP U M P( 1 5 A )f u s e
from the under-dashfuse/relaybox.
2 4 . DisconnectECfvlconnectorE (31P).
20. Disconnectthe connectorsof all these components.
.
.
.
.
.
P G M - Fm
l a i n r e l a y2
E C Mc o n n e c t oA
r (31P)
lnjectors
l d l ea i r c o n t r o l( l A C ) v a l v e
CamshaftPosition{CMP)sensorB (Top dead
center(TDC)sensor)
. Crankshaftposition(CKP)sensor
(conr'd)
11-99
PGM-FISystem
terminal E9 and body ground.
27. Checkfor continuitybetweenECIVI
connector
terminalEgandbodyground.
ECMCONNECTOR
E (31P)
ECMCONNECTOR
E 131P)
Wire side o{ {emaleterminals
Wire side oI Jemaleterminals
YES-Go to step 26.
YES Repairshort in the wire betweenthe No. 17
,r
F UE LP U M P( 1 5 A ) f u s ea n d t h e E C M( E 9 ) o
betweenthe No. 17 FUELPUMP (15A) fuse and the
P G M - Fm
I a i n r e l a y2 . A l s o r e p l a c et h e N o . 1 7 F U E L
P U M P( 1 5 A ) f u s e . l
N O R e p l a cteh e N o . l T F U E L P U M P ( 1 5 A ) f u s e ,
and updatethe ECM if it does not have the latest
originaE
l CM.I
NO Go to step 28.
28. Removethe rear seatcushion (seepage 20-80).
26. Removethe PGM-Flmain relay 2 (A).
29. Removethe accesspanelfrom the floor.
30. Disconnectthe fuel pump 5P connector.
11-100
\
31. Checkfor continuitybetweenfuel pump5P
connector
terminalNo.5 andbodyground.
FUELPUMP5PCONNECTOR
33. Checkfor continuitybetweenfuel pump5P
connector
FUELPUMP5P CONNECTOR
=
Wire side ol lemal€ rerminals
YES Repairshortin thewire betweenthefuel
p u m pa n dt h eP G M - Fml a i nr e l a y2 .A l s or e p l a c e
t h EN O .1 7F U E LP U M P( 1 5 Af)U S E . T
YES Replacethe PGM-Flmain relay 2. Also
r e p l a c et h e N o . 1 7 F U E LP U M P( 1 5 A )f u s e . l
NO Checkthe iuel pump, and replaceil if
necessary.Also replacethe No. 17 FUELPUMP
( 1 5 A )f u s e . !
NO-Go to step32.
32. Reinstallthe
PGM-Flmainrelay2 (A).
34. DisconnectECMconnectorE (31P).
3 5 . T u r nt h e i g n i t i o ns w i r c hO N { 1 1 1 .
E9 and body ground.
ECfl CON|{CCIORE (3rPt
Wire side ol female lerminals
YES Go to step 37.
F U E LP U M P( 1 5 A ) f u s ea n d t h e E C M( E 9 ) . 1
(cont'd)
11-101
PGM-FISystem
(cont'dl
MIL CircuitTroubleshooting
37. lvleasure
voltagebetweenECM/PCM
connector
t e r m i n aEl 7a n db o d yg r o u n d .
40. lvleasurevoltage betweenPGN4-Fl
main relay 1 4P
c o n n e c t otre r m i n a lN o . 4 a n d b o d vq r o u n d .
PGM-FIMAIN RELAY1
ilP CONNECTOR
ECM CONNECTORE {31PI
MRLY
Wire side ot lemale terminals
YES Go to step 42.
Y E S - G o t o s t e p4 1 .
NO Go to step38.
E C U( E C M )( 1 5 A )f u s ea n d t h e P G f M - Fml a i n r e l a y1 .
I
3 9 . Removethe PGM-FImain relay 1 {A}
-A
4 1 . Checkfor continuitybetweenPGM-FImain relay 1
4P connectorterminal No. 3 and ECMconnector
t e r m i n a lE 7 .
PGM.FIMAIN RELAY1
4P CONNECTOR
MRLY(RED/YEL)
ECMCONNECTOR
E 131PI
MRLY(RED/YEL)
YES-Testthe PGM-Flmain relay 1 (seepage2251). lf the relay is OK, updatethe ECM if it does not
have the latestsoftware,or substitutea knowngood ECM,then recheck{seepage 11'6).lf the
symptom/indicationgoes away with a known-good
E C M ,r e p l a c et h e o r i g i n a E
l CM.I
NO*Repair open in the wire betweenthe PGM-FI
m a i n r e l a y1 a n d t h e E C M( E 7 ) . 1
11-102
\
42. ReconnectECI\4connectorE {31P).
48. MeasurevoltagebetweenPGM-FI
mainrelay1 4P
connector
4 3 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
PGM.FIMAIN RELAY1
4PCONNECTOR
44. Measurevoltage betweenbody ground and ECM
connectorterminals42 and 43 individually.
ECMCONNECTOR
A {31PI
YES Go to step 49.
N O R e p a i ro p e ni n t h e w i r e b e t w e e nt h e N o . 6
E C U{ E C M )( 1 5 A } f u s ea n d t h e P G M - Fm
l ain
r e l a y1. !
YES Go to step 51.
NO Go to step 45.
4 9 . T u r nt h e i g n i t i o ns w i t c hO F F .
46. R e m o v et h e P G M ' F m
l a i n r e l a y1 {A)
5 0 . Checkfor continuitybetweenPGM-Flmain relay 1
t e r m i n a l s4 2 a n d 4 3 i n d i v i d u a l l y .
,A
PGM.FI MAIN RELAYI
ilP CONNECTOR
IGPl (YEL/BLK)
YES Replace
t h e P G M - Fm
NO Repairopen in the wire betweenthe PGM-FI
'1
m a i n r e l a y a n d t h e E C M( A 2 ,A 3 ) . 1
{cont'd}
11-103
PGM-FISystem
51. MeasurevoltagebetweenbodygroundandECM
connector
terminals44, A5,423,and424
individuallv.
ECMCONNECTOR
A 131P)
PG2(BLK)
PG1IBLKI
54. Disconnectthe manifoldabsolutepressure(MAP)
sensor3P connector.
55. T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
c o n n e c t otre r m i n a A
l 21.
ECMCONNECTOR
A {31P)
ls there morc than 1.0 V ?
YES Go to step 52.
N O - R e p a i r o p e ni n t h e w i r e ( s )t h a t h a d m o r et h a n
1.0V betweenG 10'l and the ECM (A4,A5, A23,
A24l.a
Measurevoltagebetweenbody ground and ECM
c o n n e c t otre r m i n a 4
l 21.
ECMCONNECTOR
A 131P)
ls there about 5 V?
YES Replacethe MAP sensor.l
NO Go to step 57.
5 7 . Turn the ignition switch OFF.
5 8 . D i s c o n n e cEt C Mc o n n e c t oA
r (31P).
ls there about 5 V?
YES-Go to step 60.
N O - G o t o s t e p5 3 .
11-104
\
59. Checkfor continuitvbetweenECIM
connector
t e r m i n a4l 2 1a n db o d yg r o u n d .
t t,
o z , Disconnectthe throttle position(TP)sensor3P
connector.
ECM CONNECTORA {3,IPI
connectorterminal 420,
ECMCONNECTOR
A 131P)
YES*Repair short in the wire betweenthe ECM
( 4 2 1 )a n d t h e M A P s e n s o r . l
NO Updatethe ECM it it does not have the latest
recheck(seepage 1'l-6).lf the symptom/indication
originaE
l CM.I
ls there about 5 V?
YES Replacethe thronle body (theTP sensoris
not availableseparately).
I
6 0 . Measurevoltagebetweenbody ground and ECM
connectorterminal 420.
NO Go to step 65.
ECMCONNECTOR
A {3TP}
65. Turn the ignition switch oFF.
66. DisconnectECMconnectorA (31P).
1 1 2 1 43 5 o t /
I
1 0 11112
5 6 / 1189 2t 21
2' 231?4 ? q
Tln 29
vcc2
IYEL/
BLU)
W i r es i d eo t f e m a l tee r m i n a l s
ls there about 5 V?
YES-Go to step 68.
N O - G o t o s t e p6 1 .
conlo
11-105
PGM-FISystem
MIL CircuitTroubleshooting(cont'd)
6 7 . Checkfor continuitybetweenECIM
connector
t e r m i n aAl 2 0a n db o d yg r o u n d .
c o n n e c t otre r m i n a lE 5 .
ECMCONNECTOR
A (31P)
r l 2 l 3 1 54
9
o t /
10 t1 121,/1,/ 1516
22 '3 241 12526
ECMCONNECTOR
E (31PI
ta,
n
9 2A21
vcc2
o
{YEL/
BLU}
Is there about 5 V?
YES Repairshon in the wire betweenthe ECN4
{A20)and the TP sensor,or repairshort in the wire
betweenthe ECM (A8) and the knocksensor.t
YES U pdatethe ECM if it does not have the latest
o r i g i n aE
l CM.t
recheck(seepage l1-6).lf the symptom/indication
originaE
l CM.t
NO-Go to step 69.
6 9 . Turn the ignition switchOFF.
7 0 . Disconnectthe fuel tank pressure(FTP)sensor3P
connector.
11-106
72. MeasurevoltagebetweenbodygroundandECM
connector
terminalE5.
ECMCONNECTOR
E 131P}
7 8 . Measurevoltage betweenECMconnectorterminal
E 2 9a n d b o d y g r o u n d .
ECMCONNECTOR
E (31P)
r l 2 l 3 1 4
5 6 1
15 6
,/1,/114
22
23 241 l,/
8 9
2A21
2930
scstBRN)
ls there about 5 V?
YES Replacethe FTPsensor.t
NO Go to step 73.
ls there about 5 V (or battery voltage)?
YES-Go to step 82.
7 4 . DisconnectECMconnectorE (3'lP).
NO Go to step 79.
t e r m i n a lE 5 a n d b o d y g r o u n d .
8 0 . DisconnectECMconnectorE (31P).
ECMCONNECTOR
E {31PI
Is there continuity?
( E 5 )a n dt h e F T Ps e n s o r . l
originaE
l CM.I
(cont'd)
11-107
PGM-FISystem
MIL GircuitTroubleshooting(cont'd)
t e r m i n a lE 2 9a n d b o d y g r o u n d .
ECMCONNECTOR
E 131P}
r l 2 l 34 5
14 t c
22123124
8
I
61,/118 2A21
271./ 3031
scs(BRN)
o
YES-Repair short in the wire betweenthe data link
connector(DLC)and the ECM(E29).1
o r i g i n aE
l CI\4,I
DisconnectECMconnectorE (31P).
Does the MIL stay on?
YES-Repair short in the wire betweenthe gauge
a s s e m b l ya n dt h e E C M( E 3 1) . l f t h e w i r e i s O K ,
r e p l a c et h e g a u g ea s s e m b l y . l
originaE
l CM.I
11-108
lf the ECMdoes not communicatewith the OBD ll scan
tool, HondaPGfMTester,or l/M test equipment,do this
troubleshootingprocedure.
1. Measurevoltage betweenDLCterminal No. 16 and
body ground.
3. Measurevoltage betweenDLCterminalsNo. 5 and
No. 16.
DATALINKCONNECTOR
{DLC)
DATALINKCONNECTOR
{DLCI
(WHT/RED)
Terminal
sideof lemaleterminals
YES Go to step 4.
ls therc battery voltage?
NO- Repairopen in the wire betweenDLCterminal
N o . 5 a n dt h e E C M( E 3 )t.
YES-Go to step 2.
NO-Repair open in the wire betweenDLCterminal
N o . 1 6 a n d t h e N o . 9 B A C KU P ( 7 . 5A ) f u s ei n t h e
under-hoodf use/relaybox.I
Measurevoltage betweenDLCterminalsNo. 4 and
No.16.
5 . M e a s u r ev o l t a g eb e t w e e nD L Ct e r m i n a l sN o . 5 a n d
No.7.
DATA LINKCONNECTOR
{DLCI
DATA LINK CONNECTOR(DLCI
T e r m i n asli d eo f l e m a l et e r m i n a l s
Terminalsideof Jemale
terminals
ls there 8.5 V or more?
YES Go to step 10.
Is there battery voltage?
NO Go to step 6.
YES Go to step 3.
NO Repairopen in the wire betweenDLCterminal
N o . 4 a n d b o d yg r o u n d . l
(cont'd)
11-109
PGM-FISystem
{cont'dl
7. DisconnectEClvlconnectorE (31P).Make sure the
O B Dl l s c a nt o o l o r H o n d aP G MT e s t e ri s
disconnectedfrom the DLC.
YES U pdatethe ECMif it does not have the latest
originaE
l CI\4.I
8. Checkfor continuitybetweenDLCterminal No. 7
a n d b o d yg r o u n d .
DATALINKCONNECTOR
IDLC)
NO Repairopen in the wire betweenDLCterminal
N o . 7 a n dt h e E C M{ E 2 3 )A. f t e rr e p a i r i n gt h e w i r e ,
checkthe DTCwith the OBD ll scantool/Honda
PGl\4Tester,and go to the DTCTroubleshooting
Index.l
1 0 .T u r nt h e i g n i t i o ns w i t c hO F F .
1
' I.
Ierminal side of femaleterminals
DisconnectECI\4connectorE (31P).l\4akesure the
O B Dl l s c a nt o o l o r H o n d aP G MT e s t e ri s
disconnectedfrom the DLC.
tJ.
YES-Repair short to ground in the wire between
DLCterminal No. 7 and the ECM {E23).After
r e p a i r i n gt h e w i r e ,c h e c kt h e D T Cw i t h t h e O B Dl l
scantool/HondaPGM Tester,and go to the DTC
Troubleshootingindex.I
Measurevoltage betweenDLCterminalsNo. 5 and
No.7.
DATALINKCONNECTOR
{DLC}
NO Go to step 9.
9 . Checkfor continuitybetweenDLCterminal No. 7
a n d E C Mt e r m i n a lE 2 3 ,
ECMCONNECTOR
E {31PI
K-LINE{LTBLU)
DATA LINK CONNECTOR
Is there 0 V?
YES Updatethe ECMif it does not havethe latest
then
originaE
l CM.I
NO Repairshort to power in the wire betweenthe
D L Ct e r m i n a lN o . 7 a n d t h e E C M( E 2 3 )A. f t e r
repairingthe wire, checkthe DTCwith the OBD ll
scantool/HondaPGMTester,and go to the DTC
T r o u b l e s h o o t i ni g
n d e x I.
11-110
t
InjectorReplacement
(seepage1l-144).
1 . Relieve
fuel pressure
2 . Disconnect
the connectors
fromthe injectors(A),disconnect
the groundcable(B),andremovethe bracket(C).
(2.2 kgf.m, l6 lbf.ftl
ffi\t\
*\
o
3. Disconnectthe quick-connectfittings (D).
4 . R e m o v e t h e f u erl a i lm o u n t i n g n u t s ( Ef)r o m t h e f u e l r a i l( F ) t h e nr e m o v e t h e f u e rl a i la n d i n j e c t o r sa s a n a s s e m b l y .
5. Removethe injectorclip (G)from the injector.
6. Removethe injectorfrom the fuel rail.
(cont'd)
11-111
PGM-FISystem
InjectorReplacement(cont'd)
7 . C o a t t h e n e w o - r i n g s ( A ) w i t h c l e a n e n g i n e o l l , a n d i n s e r t t h e i n j e c t o risn(tBo)t h e f u e lr a i l( C ) .
\
8 , l n s t a ltl h e i n j e c t o cr l i p { D ) .
9. Coatthe injectoro-rings(E)with cleanengine oil.
1 0 . I n s t a l l t h ei n j e c t o r si n t o t h e f u e lr a i l ,t h e n i n s t a l tl h e f u e l r a i li n t o t h e i n t a k e m a n i f o l d ( G ) .
1'1. Installthe fuel rail mounting nuts,ground cable.and bracket.
12. Connectthe connectorsto the injectors.
13. Connectthe quick-connectfittings.
1 4 . T u r n t h ei g n i t i o ns w i t c hO N ( l l ) ,b u t d o n o t o p e r a t e t h es t a r t e rA. f t e r t h e f u e lp u m p r u n sf o r a b o u t2 s e c o n d st,h e
fuel pressurein the fuel line rises.Repeatthis two or three times. then checkfor fuel leakage.
11-112
A/F SensorReplacement
SecondaryHO2SReplacement
O2 sensorwrench,Snap-onYA8875.SPTools 93750,
o r e q u i v a l e n ct ,o m m e r c i a l l a
yvailabre
Special Tools Fequired
02 sensorwrench,Snap-onYA8875,SP Tools 93750,
o r e q u i v a l e n tc,o m m e r c i a l l a
Vv a i l a b l e
1. Disconnectthe A,/Fsensor4P connector(A),then
removethe A,/Fsensor{B).
\I
ffi
1. Disconnectthe secondaryHO2S4P connector(A),
then removethe secondaryH02S (B).
B
44N.m
InstalltheIVF sensorin the reverseorder of
removal.
2 . InstallthesecondaryHO2Sin the reverseorder of
removal.
11-113
PGM-FlSystem
ECTSensorReplacement
'1.
CMPSensorB (TDCSensorl
Replacement
R e m o v et h e a i r c l e a n e r{ s e ep a g e1 1 - 1 6 2 ) .
2. Disconnectthe ECTsensor2P connector.
' t . R e m o v et h e a i r c l e a n e r( s e ep a g e1 1 - 1 6 2 ) .
3. Removethe ECTsensor(A).
2. Disconnectthe CN4PsensorB (TDCsensor)3P
conneclor.
Removethe CMP sensorB (TDCsensor)(A).
{1.2kgt m.8.7 lbt.ft}
l n s t a l l t h es e n s o ri n t h e reverse order of removal
with a new o-ring {B).
11-114
---r, ".- ,',',.,*nr...
8.7tbf.ftl
4 . lnstallthe sensorin the reverseorder of removal
with a new o-ring {B).
IAT SensorReplacement
1, Dlsconnectthe IAT sensor2P connector.
KnockSensorReplacement
1. Removethe intakemanifold bracket(A).
2. Removethe clip (A) and the IAT sensor(B).
3. lnstallthe sensorin the reverseorder of removal.
24Nm
(2.4kgt.m,17lbt.ftl
2. Disconnectthe knocksensor 1Pconnector.
3 . R e m o v et h e k n o c ks e n s o r( B ) .
4 . Installthesensorin the reverseorder of removal.
11-115
PGM-FISystem
GKPSensorReplacement
1. Disconnect
the CKPsensor3Pconnector.
2. RemovetheCKPsensor{A).
12 N.m (1.2kgt m.
8.7 tbf.ftl
3. lnstallthe sensorin the reverseorder of removal
with a new o-ring (B).
11-116
VTEC/VTC
-gl
:1
i-
ia
r-:
@'-;'
--tl
;'l--i
-
lt i..,,
€)
',..
.
VTCOILCONTROL
VALVE
SOLENOID
page11-118
Troubleshooting,
11-'l27
Test,page
-'
tt
'--'-
/
CAMSHAFTPOSITION
ICMPISENSORA
Troubleshooting,page 11-121
Replacement,
Pagel'!-128
VALVE
VTCSOLENOID
page11-123
Troubleshooting,
page11-128
Removal/lnspection,
11-117
VTEC/VTC
DTGTroubleshooting
DTCP0010:WC Oil ControlSolenoidValve
Malfunction
8. MeasureresistancebetweenVTCoil control
s o l e n o i dv a l v e2 Pt e r m i n a l sN o . 1 a n d N o . 2 .
VTC OIL CONTAOLSOLENOID
VAI"VE2P CONNECTOB
2. Start the engine.Hold the engineat 3,000rpm with
t h e nl e t i t i d l e .
3. Test-driveat a steadyspeed between20-40mph
(30-60km/h)for 10 minutes.
T e r m i n a s i d 6 o t m a t e t e r m i n as
YES Go to step 4.
ls there 6.75 8.25 Q ?
NO- Intermittentfailure,system is OK at this time.
the VTC oil control solenoidvalve and at the
ECM.I
YES-Go to step L
5. Disconnectthe ECMconnectorB {24P).
6. MeasureresistancebetweenECrUconnector
t e r m i n a l sB 1 a n d 8 2 3 .
NO-Replace the VTC oil control solenoidvalve
(seepage 11-1271.a
9 . C o n n e cV
t T Co i l c o n t r o ls o l e n o i d v a l v e 2 P
connectorterminalsNo. 1 and No. 2 to body
g r o u n dw i t h a j u m p e r w i r ei n d i v i d u a l l y .
wc otl coNTBoL
sotENoto
VALVE 2P CONNECTOR
-4t 1 t
ECMCONNECTOR
B I24P)
wc
I
2 l
lwc*
tBr-K/wHT) |
liELU/WHT)
JUMPER
WTREI IJUMPEnW|RE
W i r e s i d eo f 1 6 m a l et e . m i n a t s
t e r m i n a l sB 1 a n d 8 2 3 a n d b o d y g r o u n di n d i v i d u a l l y .
ls there 6.75 8.25 Q ?
YES Go to step 11.
NO Go to step7.
7. Disconnectthe VTC oil control solenoidvalve2P
connector.
Y E S G o t o s t e p1 1 .
NO- Repairopen in the wire betweenthe ECM (B1,
B23)and the VTCoil control solenoidvalve.I
11-118
\
t e r m i n a l sB 1 a n d B 2 3a n d b o d y g r o u n di n d i v i d u a l l y .
DTCP0011:VTCSystemMalfunction
1. Resetthe EClvl(seepage 11-4).
2 . S t a r tt h e e n g i n e .H o l dt h e e n g i n ea t 3 , 0 0 0r p m w i t h
n o l o a d ( i n n e u t r a l u) n t i lt h e r a d i a t o fra n c o m e so n .
VTC
(BtK/WHT)
3. Test-driveat a steadyspeed between20 40 mph
(30 60 km/h)for 10 minutes.
4 . Checkfor TemporaryDTCP0011with the scantool
ls Tempotaty DTC P0011indicated?
YES-Go to step 5.
YES Go to step 12.
NO- Intermittentfailure, system is OK at this time.
Checkfor poor connectionsor loosewires at the
V T Co i l c o n t r o ls o l e n o i dv a l v ea n d a t t h e E C M . I
original EClvl.!
Watch the low oil pressurelight with the engine
r un n i n g .
ls the low oil pressute light on?
12. Disconnectthe VTC oil control solenoidvalve 2P
connector.
YES- Checkthe oil pressure(seepage 8-4).I
t e r m i n a l sB 1 a n d 8 2 3 a n d b o d y g r o u n di n d i v i d u a l l y .
7 . Removethe auto-tensioner(seepage 4-28).
vfc
(8LK/WHT)
W i r e s i d eo f f e m a l er e r m i n as
Y E S - R e p a i rs h o r ti n t h e w i r e b e t w e e nt h e E C M( B 1 ,
B23)and the VTCoil control solenoidvalve.l
NO Replacethe VTC oil control solenoidvalve
(seepage 11-1211.a
(cont'd)
11-119
VTEC/VTC
Removethe VTC strainer(A).Checkthe WC
s t r a i n e fro r c l o g g i n g .
13. ConnectECM connectorterminalsA3 and 81 witha
j u m p e rw i r e m o m e n t a r i l y .
NOTE:Do not jump for more than 1 minute,
ECM CONNECTORS
ls the strainet OK?
YES Go to step g.
NO-Clean the VTC strainer,then replacethe
e n g i n eo i l f i l t e ra n d t h e e n g i n eo i l . l
9. Checkthe VTCoil control solenoidvalve{seepage
11-127
).
ls the VTC oilcontrol solenoid valve OK?
YES Go to step 10.
NO Cleanthe ports of the WC oil control solenoid
valve,or replacethe VTCoil control solenoidvalve
{seepage 11-127).a
1 0 .InstalltheVTCoil control solenoidvalve.
1 1 .Startthe engine.Hold the engine at 700 1,000rpm.
1 2 . C o n n e cE
t C Mc o n n e c t otre r m i n a lB 2 3 t o b o d v
g r o u n dw i t h a j u m p e rw i r e .
ECMCONNECTOR
B {24PI
213415
8
1
e l1a,/1,/
6 7
15
181./l l./ 21
23
vTc
JUMPER
(BLK/WHT} WIRE
11-120
Did the engine stall or run rough?
YES Test-driveat a steadyspeedbetween
20 40 mph (30 60 km/h)for 10 minutes.
lf temporaryDTCP00'l1 is indicated,updatethe
ECIVIif it does not have the latestsoftware,or
substitutea known-goodECM,then recheck(see
page 11-6).lf the symptom/indicationgoes away
with a known-goodECM,replacethe original
E C M !.
NO Go to step 14.
1 4 . Checkthe VTC actuator(seepage6,8).
ls the VTC actuatot OK?
YES Removethe auto-tensioner(see page 4-281,
and clean or replacethe VTC oil strainer.Update
the ECI\4if it does not have the latestsoftware,or
substitutea known-goodECM,then recheck(see
page 11-6).lf the symptom/indicationgoes away
with a known-goodECM,replacethe original ECM.
T
NO Replacethe VTC actuator.t
\
DTCP0340:
CMPSensorA No Signal
DTGP0344:CMPSensorA Intermittent
Interruption
7. MeasurevoltagebetweenCMPsensorA 3P
terminalNo. 1 andbodyground.
connector
CMP SENSORA 3P CONNECTOR
'11-4).
1 . R e s e t h e E C M( s e ep a g e
2. Startthe engine.
ls DTC P0340and/or P0344indicated?
YES-Go to step 3.
W i r e s i d eo l f e m a l e t e r m i n as
t h e C M Ps e n s o rA a n d a t t h e E C M . I
ls thercabout5 V?
YES-Go to step8.
NO-Go to step10.
4. Disconnectthe CMPsensorA 3P connector.
6. Measurevoltage betweenCMPsensorA 3P
CMPSENSORA 3P CONNECTOR
tG1
1 2 3
voltagebetweenCMPsensorA 3P
8. Measure
s o .2 a n dN o .3 .
c o n n e c t ot er r m i n a lN
CMP SENSORA 3P CONNECTOF
;f-;-1 J ,o,,r.*,"r.,
I l1
l-t
,-or---T--I
{8RN/YEL)
ni-
(BLK/YEL}
YES Go to step 9.
NO-Repair open in the wire betweenthe Cl\4P
s e n s oA
r a n dG 1 0 1 . 1
YES Go to step 7.
N O C h e c kt h e N o . 4 A C G { 1 0 A )f u s ei n t h e u n d e r dash fuse/relaybox. lf the fuse is OK, repairopen in
the wire betweenthe CN4PsensorA and No. 4 ACG
( 1 0 A )f u s e . I
9. Substitutea known-goodCMPsensorA and
recheck.
ls DTC P0340and/ot P0344indicated?
o r i g i n aE
l CM.I
t h e o r i g i n aC
l M Ps e n s o rA { s e ep a g e
NO Replace
11-128).t
(cont'd)
11-121
VTEC/VTC
1 0 .Measurevoltage betweenECMconnectorterminal
A25 and body ground.
ECMCONNECTORA 131P)
DTCP0341:WC PhaseGap
1 . R e s e t t h eE C M{ s e ep a g e1 1 - 4 ) .
2. Startthe engine.
YES Go to step 3.
t h e C M Ps e n s o rA a n d a t t h e E C M . I
Wiresideof femalete.minals
3. Checkthe VTC oil control solenoidvalve (seepage
11_127]-.
ls there about 5 V?
( A 2 5 )a n d C M Ps e n s o rA . I
N O - G o t o s t e p1 1 .
Isthe VTC oil control solenoid valve OK?
YES-Go to step 4.
NO-CIean the VTCoil control solenoidvalve,or
r e p l a c ei t ( s e ep a g e1 1 - ' l 2 7 l . a
't2.
DisconnectECMconnectorA (31P)
Checkfor continuitybetweenECMconnecror
terminal A25 and body ground.
ECMCONNECTONA 131P}
4. Removethe head cover,and checkthe cam chain
{seepage 6-12).
ls the cam chain OK?
YES Go to slep 5.
NO Replace
t h e c a m c h a i n( s e ep a g e6 - 1 2 ) . 1
5. Checkthe VTC actuator(seepage 6-8).
ls the VTC actuator OK?
ls tnere continuity?
(A25)and the CMP sensorA. t
NO Updatethe ECt\4if it does not have the latest
originaE
l CM.I
11-122
YES- U pdatethe ECM if it does not have the tatest
soflware,or substitutea known-goodECI\4,
then
originaE
l CM.I
NO- Replacethe VTC actuator.l
DTCPl259:WEC SystemMalfunction
. Pressuregaugeadapter07NAJ P07010A
. A/T low pressuregaugew/panel 07406-0070300
. A/T pressurehose 07406-0020201
. Av/Tpressurehose,2,210mm 07IMAJ-PY4o11A
. l"/T pressureadapter07MAJ-PY40120
. Oil pressurehose 07ZAJ-S54,4200
6. Disconnectthe VTECoil pressureswitch2P
connector.
7. Checkfor continuitybetweenVTECoil pressure
switch 2P connectorterminals No. 1 and No. 2
SWITCH
VTECOILPRESSURE
2PCONNECTOR
2 . C h e c kt h e e n g i n eo i l l e v e l ,a n d r e f i l li f n e c e s s a r y .
no load {in neutral)until the radiatorfan comes on.
4. Roadtestthe vehicle:
Acceleratein the 1stgear to an engine speedover
4.000rpm. Holdthe speedfor at least2 seconds.lf
DTCP1259is not repeatedduring the first road test,
repeatthe test two more times.
YES Go to step 5.
NO-lntermittent failure,system is OK at this time
Checkthe oil consumptionif oil was added in step
2. Checkfor poor connectionsor looseterminalsat
the VTECsolenoidvalve,the VTECoil pressure
I
switch,and at the ECI\4.
5, Turn the ignitjon switch OFF.
T e r m i n asl i d eo f m a l et e r m i n a l s
Is therecontinuity?
YES-Go to step8.
switch.l
theVTECoil pressure
NO Replace
s w i t c hO N( l l ) .
switch
voltagebetweenVTECoil pressure
9. Measure
terminalNo.1 andbodyground
2Pconnector
SWITCH
VTECOILPRESSURE
2PCONNECTOR
VTPSW
/T\ {BLU/BLK}
{.--rr-l'--.l
\rJ
II
oI
Y E S G o t o s t e P1 4 .
NO-Go to step 10.
(cont'd)
11-123
VTEC/VTC
89 and body ground.
14. fMeasure
voltagebetweenVTECoil pressure
switch
2 Pc o n n e c t ot er r m i n a lN
s o .1 a n dN o .2 ,
ECMCONNECTOR
B (24P)
VTECOILPRESSURE
SWITCH
2P CONNECTOR
VTPSW
(BLU/BLK)
213415
o 1
8 I a t / t / n 3 15
(BRN/YELI
WPSW {BLU/BLK}
WiresideofIemale
terminals
Wire side of Iemaleterminals
YES Repairopen in the wire betweenthe VTECoil
pressureswitch and the ECM(89).t
Y E S - G o t o s t e p1 5 .
N O - G o t o s t e p1 1 .
NO Repairopen in the wire betweenthe VTECoil
p r e s s u r es w i t c ha n d G 1 0 1 . 1
DisconnectECMconnectorB {24P).
to.
t e r m i n a lB g a n d b o d y g r o u n d .
ECMCONNECTOR
B {24P)
2 3 415
I 9 ol./ ./ 13
6 7
15
Disconnectthe VTECsolenoidvalve 2P connector.
1 7 . Checkfor resistancebetweenVTECsolenoidvalve
2 Pc o n n e c t otre r m i n a l sN o , 1 a n d N o . 2 .
VTECSOLENOIDVALVE
2PCONNECTOR
VTPSW{BLU/BLK}
Wrre side of femaleterminals
T e r m i n as li d eo f m a l et e r m i n a l s
YES Repairshort in the wire betweenthe VTECoil
pressureswitch and the ECM (89).I
ls there 14- 30 Sl ?
YES Go to step 18.
originaE
l C N 4! .
11-124
NO Replacethe VTECsolenoidvalve (seepage
11-128).t
1 8 . Removethe VTECoil pressureswitch (A) and
i n s t a l l t h es p e c i a l t o o l a
s s s h o w n ,t h e n r e i n s t a ltlh e
VTECoil pressureswitch.
07406-0070300
07406-0020201
ot
07MAJ-PY,lo11A
and
07MAJ-PY40120
\lsl
24. Disconnectthe VTECsolenoidvalve 2P connector.
25. Aftachthe batterypositiveterminalto VTEC
s o l e n o i dv a l v e2 P c o n n e c t otre r m i n a lN o . 2 .
26. Startthe engine,then connectthe batterynegative
t:={
R
A
22 N.m
l2.2kgt.m,
16rbf.ft)
07NAJ-P07010A
t e r m i n a l t oV T E Cs o l e n o i dv a l v e2 P c o n n e c t o r
t e r m i n a lN o . 1 , a n d c h e c kt h e o i l p r e s s u r ea t a n
engine speedof 3,000rpm.
ls the oil pressure above 390 kPa (4.0 kgt/crtf ,
57 psi)?
YES Go to step 27.
NO InspecttheVTECsolenoidvalve (seepage I112Al.a
1 9 .Reconnectthe VTECsolenoidvalve 2P connector
and VTECoil pressureswitch 2P connector.
20. Connecta tachometeror OBD ll scantool/Honda
PGM Testerto the DLC.
2 1 . Startthe engine.Holdthe engine at 3,000rpm with
27. With the batteryterminalsstill connectedtothe
VTECsolenoidvalve connector,measurevoltage
betweenECMconnectorterminal 89 and bodv
oround.
B {24P)
ECMCONNECTOR
22. Checktheoil pressureat enginespeedsof 1,000
and 2.000rpm. Keepthe measuringtime as shon
a s p o s s i b l e{ l e s st h a n 1 m i n u t e )b e c a u s et h e e n g i n e
i s r u n n i n gw i t h n o l o a d .
ls the oil ptessure below 49 kPa (0.5 kgf/cnf,
7 psi)?
YES Go to step 23.
NO Inspectthe VTECsolenoidvalve (seepage 11't28l.a
ls there battery voltageabove 4,000 tpm?
YES Go to step 28.
NO-Replace the VTECoil pressureswitch (see
p a g e1 1 ' 1 2 8 ) . 1
29. Disconnectthe batteryterminalsfrom the VTEC
solenoidvalve terminal connector.
(cont'd)
11-125
WEC/VTC
30. DisconnectECMconnector B (24P)
ECM CONNECTORB {24P)
32. ConnectVTECsolenoidvalve 2P connector
terminal No. 2 to body ground with a jumper wire.
VTEC SOLENOIDVALVL
2P CONNECTOR
r-.'-r.---.1
t 1 t 2 l
+
JUMPERI VtS
WIRE I IGRN/YEL)
I
ls therecontinuity?
ECM CONNECTORB {24PI
YES-Repairshortin thewire betweentheVTEC
s o l e n o ivda l v ea n dt h eE C M( 8 1 5 ) . 1
NO Goto step32.
originaE
l CM.I
NO Repairopen in the wire betweenthe VTEC
s o l e n o i dv a l v ea n dt h e E C M( 8 1 5 ) . I
11-126
WC OilControlSolenoidValveRemoval/Test
1 . R e m o v et h e W C o i l c o n t r o ls o l e n o i dv a l v e( A ) .
NOTE:lnstallthe valve in the reverseorder of
removalwith a new o-ring (B),then checkthese
tlems:
Connectthe batterypositiveterminal to VTC oil
control solenoidvalve 2P connectorterminal No. 2.
VTCOILCONTROLSOLENOID
VALVE2PCONNECTOR
Cleanand dry the VTCoil control solenoidvalve
mating surface.
Coatthe O-ringwith engineoil.
Do not installthe VTC oilcontrol solenoidvalve
while wearingfibrous gloves,
Be carefulnot to contaminatethe cylinder head
openrng.
Terminalside oJ
BATTERY
Connectthe batterynegativeterminalto VTC oil
c o n t r o ls o l e n o i dv a l v e2 Pc o n n e c t otre r m i n a lN o . 1 ,
t h e n m a k es u r et h e v a l v e( A )o p e n sf u l l y .
Checkthe VTC oil control solenoidvalve filter for
clogging.lf it is clogged,replacethe VTC oil control
solenoidvalve.
Checkthe clearancebetweenthe port (advance
side)and the valve.The clearance(A) should be at
l e a s t2 . 8m m ( 1 / 8i n . ) .
11-127
VTEC/WC
CMPSensorA Replacement
WEC SolenoidValveRemoval/
Inspection
1 . R e m o v et h e a i r c l e a n e r( s e ep a g e11 - 1 6 2 ) .
Disconnectthe CMP sensorA 3P connector.
1 . Disconnectthe VTECsolenoidvalve 2P connector.
Removethe CMPsensorA (A).
MeasureresistancebetweenVTECsolenoidvalve
c o n n e c t otre r m i n a l sN o . 1 a n d N o . 2 .
Resistance:14-30 Q
B-'-----'-l:,",14*
Installthe sensorin the reverseorder of removal
with a new o-ring (B).
3. lf the resistanceis within specifications,removethe
VTECsolenoidvalve assemblv(A)from the
cylinder head,and checkthe VTECsolenoidvalve
f i l t e r( B ) f o rc l o g g i n g l.f i t i s c l o g g e d r, e p l a c et h e
solenoidvalve filter,the engine oilfilter, and the
e n g i n eo i l .
6x1.0mm
9.8 N.m (1.0kgf.m, 7,2 lbf.ftl
11-128
L
ldleGontrolSystem
TE'
IDLEAIRCONTROL{IAC)VALVE
page11-'131
Troubleshooting,
11-129
ldle ControlSystem
(
DTCTroubleshooting
DTCP0505:ldle ControlSystemMalfunction
7 . P u ty o u r f i n g e r so n t h e l o w e rp o n ( A )i n t h e t h r o t t l e
oooy.
NOTE:lf DTCP1519is storedatthe same time as DTC
P0505,troubleshootDTCP1519first, then recheckfor
DTCP0505.
then let it idle,
2. Checktheengine speedat idle with no,load
conditions:headlights,blower fan, rear defogger,
radiatorfan, and air conditioneroff.
Is the engine running at 750t50 rpm?
YES- Intermittentfailure,system is OK at this
trme.I
Does the enginestall?
NO lf the idle speed is lessthan 700 rpm, go to
step 3; if it's 800 rpm or higher,go to step 4.
Y E S C h e c k t h ei d l es p e e d( s e ep a g e1 1 - 1 3 8 )l f. i t ' s
out of specification,replacethe IACvalve.l
3 . D i s c o n n e ct h
t e i d l e a i r c o n t r o l{ l A C )v a l v e 3 P
connector.
Does the engine speed increase or fluctuate?
YES- Checkthe idle speed{seepage 1 1-138).lf the
idle will not adjust properly,cleanthe passagein
the throttle body, and then adjustthe idle.I
NO- Replace
t h e I A Cv a l v e . I
5. Removethe intakeair duct from the throttle body.
6. Startthe engine,and let it idle.
11-130
NO With the throttlevalve completelyclosed,
c h e c kf o r v a c u u ml e a k sa, n d r e p a i ra s n e c e s s a r y . l
DTCPl519:IACValveCircuitMalfunction
8, Checkfor continuitybetweenbody ground and IAC
v a l v e3 Pc o n n e c t otre r m i n a lN o . 1 .
IACVALVE3PCONNECTOR
2. Turn the ignition switch ON (ll)
ls DTC P 1519indicated?
2
1
YES Go to step 3.
3
PG1{BLK}
the IACvalve and at the ECM.I
a.
4. Disconnectthe IACvalve 3P connector.
6. Measurevoltage betlveenIACvalve 3P connector
terminal No. 2 and body ground.
IACVALVE3PCONNECTOR
NO Repairopen in the wire betweenthe IACvalve
a n dG ' 1 0 1 . 1
9 . DisconnectECMconnectorA (31P)
1
2
3
IGP{YEL/BLK)
1 0 . Checkfor continuitybetweenbody ground and
l 12.
E C Mc o n n e c t otre r m i n a A
ECM CONNECTORA 131P)
s
r l 2 l 3 l 45 6 1 7
/ 115 6 ./118192C21
da 25126 l27ln2930
r0 1l 12./
IACV{BLK/RED}
1,)
YES Goto step7.
NO-Repairopenin thewire betweenthe IACvalve
a n dt h eP G M - Fml a i nr e l a y1 . 1
terminals
WiresideoJJemale
7 . Turnthe ignitionswitchOFF.
YES-Repair short in the wire betweenthe IAC
v a l v ea n dt h e E C M( A 1 2 ) . 1
N O G o t o s t e p 11 .
LCOnIOl
11-131
ldle ControlSystem
(
11. ConnectIACvalve3Pconnector
terminalNo.3to
bodygroundwith a jumperwire.
15. Measurevoltagebetweenbody ground and ECM
c o n n e c t otre r m i n a A
l 12.
IACVALVE3PCONN€CTOR
ECMCONNECTOR
A 131P}
r l 2 l 3 1 54 6 1 7
IACVIBLK/REO}
JUMPERWIRE
t 0 1tl12l,/l/
22
tc
231?4l|
12.
9
6 ,/ 118 2C21
zil28 30
IACVIBLK/RED)
t e r m i n a l A l 2 a n d b o d yg r o u n d .
ECMCONNECTOR
A 131P)
I s there battery voltage?
YES-Update the ECI\4if it does not have the latest
o r i g i n aE
l CI\4.1
N O - R e p l a c et h e I A Cv a l v e . I
ls therecontinuity?
YES Goto step13.
NO-Repairopenin thewire betweenthe IACvalve
a n dr h eE c M( A 1 2 ) . r
1 3 .Reconnect
the IACvalve3Pconnector.
1 4 .Turnthe ignitionswitchON (ll).
11-132
!
A/G SignalCircuitTroubleshooting
2 . MomentarilyconnectECMconnectorterminals424
and E18with a jumper wire severaltimes.
6. Momentarilyconnectunder-hoodtuse/relaybox
14Pconnectorterminal No. 10 to body ground with
a jumper wire severaltimes.
UNDER.HOOD
FUSE/RELAY
BOX
I4P CONNECTOR
1 2 3
1 8 9 10 11
5 6
I J
14
ACC (RED)
JUMPERWIRE
ls there a clicking noise I rom the NC compressor
clutch?
ls there a clicking noise f rom the NC compressor
clutch?
YES Go to step 3.
YES- Repairopen in the wire betweenthe ECM
(E'18)and the Ay'Cclutch relay.l
NO-Go to step 6.
NO- Checkthe A/C systemfor other symptoms.l
Start the engine.
Turn the blower switch ON.
5. Turn the Ay'Cswitch ON.
Does the NC operate?
Y E S - T h e a i r c o n d i t i o n i n sg i g n a li s O K . I
o r i g i n a€
l CM.l
11-133
ldle GontrolSystem
AlternatorFRSignalCircuitTroubleshooting
' t . Disconnectthe alternator4P
connectorfrom the
alternalor.
2. T u r nt h e i g n i t i o ns w i t c hO N { l l ) .
'11.
Connectalternator4P connector term inal No.4 to
body ground with a jumper wire.
ALTERNATOR4P CONNECTOR
3 . Measurevoltage betweenECMconnector
t e r m i n a l s4 2 4 a n d 8 1 3 .
ECM CONNECTORS
A l31Pl
1
2
3
4
ALTFIWHT/RED)
1 2 1 3 4 5 6 1 1| 1 . , 'I
10 1 1 1 1 2 , / 5 6 , / r8119l2C21
23124
28129130
L
JUMPERWIRE
(BRN/Y EL)
ALTF
(WHT/REDI
213 4t5
8
9ltal,/l/
6 1
15
EClvlconnectorterminal 813.
ECMCONNECTOB
B (24PI
ls there about 5 V?
YES Go to step 4.
\
N O - G o t o s t e p1 3 .
5. Reconnectthe alternator4P connector.
6. Slan the engine.Hold the engineat 3,000rpm with
then let it idle.
7. lvleasurevoltagebetweenECMconnector
t e r m i n a l sA 2 4 a n d B 1 3 .
Does the voltage decrease when the headlights
and rear window defogger arc tutned on?
YES-Testthe alternator(seepage 4-22).1
( B1 3 )a n dt h e a l t e r n a t o r . l
Y E S T h e a l t e r n a t oFr Rs i g n a li s O K . l
9. DisconnectECMconnectorB (24P).
10. Disconnectthe alternator4P connector.
11-134
't4. DisconnectECMconnectorB (24P).
ElectricalPowerSteering(EPSI
SignalCircuitTroubleshooting
ECIMconnectorterminal 813.
ECM CONNECTORB I24P}
2 . l\4easure
voltage betweenECMconnector
t e r m i n a l s4 2 4 a n d E 1 6 .
( 8 1 3 )a n dt h e a l t e r n a t o r . l
rechecklsee page 11-6).lf the symptom/indication
o r i g i n aE
l CM.I
YES Go to step 6.
NO Go to step 3.
3 . Startthe engine.
4 . Turn the steeringwheel lo the full lock position.
5 . l\4easurevoltage betweenECMconnector
t e r m i n a l sA 2 4 a n d E 1 6 .
ls there momentatybattery voltage?
Y E S T h e E P Ss i g n a li s O K . t
6 . T u r nt h e i g n i t i o ns w i t c hO F F .
7. Disconnectthe EPScontrol unit 20Pconnector.
(cont'd)
11-135
ldle ControlSystem
ElectricalPowerSteering(EPSISignalCircuitTroubleshooting(cont'd)
9. Measure
voltagebetweenEPScontrolunitterminal
N o . l 7a n db o d yg r o u n d .
'13.
l\4easure
voltagebetweenEPScontrol unitterminal
N o . 1 7a n d t h e b o d y g r o u n d .
EPSCONTROLUNIT2OPCONNECTOR
EPSCONTROLUNIT2OPCONNECTOR
YES Substitutea known-goodEPScontrol unit
andrecheck.l
YES-Substitute a known-goodEPScontrol unit
a n dr e c h e c k . I
NO- Repairopen in the wire betweenthe ECM
( E1 6 )a n d t h e E P Sc o n t r o lu n i t . l
N O - G o t o s t e p1 4 ,
t5_
I ' I. Disconnectthe EPScontrol unit 20Pconnector.
D i s c o n n e c t t hE
e C Mc o n n e c t oE
r {31P).
E C I \ c4o n n e c t otre r m i n a E
l 16.
ECMCONNECTOR
E {31PI
1 2 3 4 5 6 1 7 l1 89
5 6 . / 1 8 2A21
22 23
zi ./ 2930 o l
EPSLD
{LTGRN/BLK)
a,
Wiresideot Iemaleterminals
lsthere continuity?
YES Repairshort in the wire betweenthe ECN4
( E1 6 )a n d t h e E P Sc o n t r o lu n i t . l
originaE
l CM.I
11-136
BrakePedalPositionSwitch SignalCircuitTroubleshooting
1. Checkthe brakelights.
Are the brake lights on without pressing the brake
pedal?
YES Inspectthebrakepedal positionswitch
( s e ep a g e1 9 - 6 ) . I
NO Go to step 2.
2. Pressthe brakepedal.
Do the brake lights come on?
4 . I n s p e ctth e N o . 7 H O R N S
, T O P( 1 5 A )f u s el n t h e
ls the tuse OK?
YES- Repairopen in the wire betweenthe brake
pedal positionswitch and the No.7 HORN,STOP
( l5A) fuse, Inspectthe brakepedal positionswitch
( s e ep a g e1 9 - 1 0 ) . 1
NO Repairshort in the wire betweenthe ECM
( E 2 2 )a n dt h e N o . 7 H O R N ,S T O P( 1 5 A ) f u s e .
Replace
the No.7 HORNS
, T O P( 1 5 A ) f u s e . t
YES-Go to step 3.
NO Go to step 4.
terminalsA24 and E22with the brakepedal
presseo.
YES-The brakepedal positionswitch signal is
oK,I
NO Repairopen in the wire betweenthe Eclvl
(E22)and the brakepedal positionswitch.l
11-137
ldle ControlSystem
ldle Speedlnspection
NOTE:
' Leavethe idle air control (lAC)valve connecled.
. Beforecheckingthe idle speed,checkthese items:
- T h em a l f u n c t i o n
i n d i c a t o lra m p ( M l L )h a s n o t b e e n
reportedon.
- l g n i t i o nt i m i n g
- S p a r kp l u g s
- Aircleaner
- PCVsystem
. P u l l t h ep a r k i n gb r a k el e v e ru p . S t a r tt h e e n g i n e a
, nd
make sure the headlightsare off.
1. Disconnectthe evaporativeemission(EVAP)
canisterpurge valve 2P connector.
3 . Startthe engine.Holdthe engineat 3,000rpm with
n o l o a d ( i n n e u t r a l u) n t i lt h e r a d i a t ofra n c o m e so n ,
t h e nl e t i t i d l e .
4 . Checkthe idle speedwith no-loadconditions;
headlights,blower fan, radiatorfan, and air
conditioneroff.
ldle speedshould be: 750 t 50 rpm
5 . Let the engine idle for 1 minute with the heaterfan
switch on Hl and air conditioneron, then checkthe
i d l es p e e d .
ldle speedshould be: 750 t 50 rpm
2. Connecta tachometer(A)to the test tachometer
connector(B),or connectthe HondaPGM Tester(C)
or an OBD ll scantool to the data link connector
(DLC)(D) locatedunder the driver'sside of the
dashboard.
11-138
NOTE:lf the idle speed is not wilhin specification,
go to the Symptom TroubleshootingIndex,
6 . Reconnectthe EVAPcanisterpurgevalve 2P
connector.
ECMldle LearnProcedure
The idle learn proceduremust be done so the ECMcan
learnthe engine idle characteristics.
Do the idle learn procedurewheneveryou do any of
these actions:
. Disconnectthe battery.
Replacethe ECMor disconnectits connector.
Resetthe ECM.
NOTE:ErasingDTCSwith the HondaPGM Tester
does not requireyou to do the idle learn procedure.
Removethe No.6 ECU{ECM)( 15A)fuse from the
Removethe No.19baftery(80A)fuse from the underhood fuse/relaybox.
R e m o v eP G M - Fm
I a i n r e l a y1 .
Removeany of the wires from the under-hoodfuse/
retayDox.
Disconnectany of the connectorsfrom the under
hood fuse/relaybox.
Disconnectthe connectorbetweenthe engine
compartmentwire harnessand ECMwire harness.
Disconnectthe G2 terminal from the transmission
h ous r n g .
DisconnecttheG'l terminal from the body.
D i s c o n n e c t t hG
e 1 0 1t e r m i n a fl r o m t h e c y l i n d e rh e a d
cover.
Procedure:
To completethe idle learn procedure,do this:
1. Make sure all electricalitems (Ay'C,
audio, rear
defogger,l:ghts,etc.,)are off.
2. Startthe engine,and hold it at 3,000rpm with no
l o a d{ i n n e u t r a l u) n t i lt h e r a d i a t o fra n c o m e so n , o r
u n t i lt h e e n g i n ec o o l a n t t e m p e r a t u r e a c h e s1 9 4 " F
(90'c).
3. Let the engine idle for about 5 minuteswith the
NOTE:lf the radiatorfan comes on, do not includeits
r u n n i n gt i m e i n t h e 5 m i n u t e s .
11-139
FuelSupplySystem
{
PUMP
T e s t ,p a g e1 1 - 1 4 1
page 11'153
Fleplacement,
FUELFILTER
page 11-152
Replacement,
FUELGAUGESENDINGUNIT
T e s t ,p a g e1 1 - 1 5 6
page 11-153
Replacement,
FUELPRESSUN
REGULATOR
page'11-'152
Replacement,
FUELFILLCAP
FUELTANK
R e p l a c e m epnat ,g e '1l - 1 5 5
FUELTUBE/OUICK.CONNECT
FITTINGS
page 11-148
Precautions,
p
a
g
e
Removal,
11-'149
Installation,page 11-'l50
FUELFEEDLINE
FUELVAPORLINE
a
FUELPULSATIONDAMPER
page11'154
Replacement,
i
.
.
/
PGM.FIMAIN RELAY1
PGM.FIMAINRELAY2
T r o u b l e s h o o t ipnagg, e ' l ' l - 1 4 1
11-140
FuelPumpCircuitTroubleshooting
lf you suspecta problemwith the fuel pump, checkthat
the fuel pump actuallyruns;when it is on, you will hear
some noise if you listento the fuel fill port with the fuel
fill cap removed.The fuel pump should run for 2
secondswhen the ignition switch is first turned on. lf
the fuel pump does not make noise,checkas follows:
5. N4easure
voltage betweenPGM-Flmain relay 2 5P
PGM.FI MAIN RELAY2
5P CONNECTOR
2. Removethe glove box {seepage 20-63),then
removethe PGM-FImain relay 2 (A).
Wire side oJfemaleterminals
YES Go to step 6.
NO Repairopen in the wire betweenthe underd a s hf u s e / r e l a yb o x a n d P G M - Fm
3 . Turn the ignitionswitch ON {ll).
Measurevoltage betweenPGM-Flmain relay 2 5P
connectorlerminal No. 5 and body ground.
PGM.FIMAIN RELAY2
5P CONNECTOR
8. Checkfor continuitybetweenPGM-FImainrelay2
t e r m i n a lE 1 .
PGM-FIMAIN RELAY2 5PCONNECTOB
E
t 2
l
Ftxm
IGPl
(YEL/BLK}
7 -
z
IMOFPR
(GBN/
YEL)
ECMCONNECTOR
E 131P}
ls therecontinuity?
YES-Go to step 5.
YES-Go to step9.
NO Repairopen in the wire betweenthe PGM'Fl
m a i n r e l a y1 a n dt h e P G M - Fm
l a i n r e l a y2 . t
NO-Repairopenin thewire betweenthe PGMFl
m a i nr e l a y2 a n dt h eE C M( E 1 ) . 1
(cont'd)
11-141
FuelSupplySystem
FuelPumpCircuitTroubleshooting(cont'dl
L R e i n s t a l l t hP
e G M - Fm
(
YES U pdatethe ECM if it does not havethe latest
so{1ware,or substitutea known-goodECM.then
o r i g i n aE
l CM.I
1 ' ] .Measurevoltage betweenECI\4/PCM
connector
t e r m i n a lE 1a n d b o d y g r o u n d .
ECMCONNECTOB
E {31P)
NO Go to step 15.
t5.
to.
Removethe rear seat cushion (seepage 20-80).
1 1 . Removethe accesspanelfrom the floor.
1 8 . Measurevoltage betweenfuel pump 5P connector
terminal No. 5 and body ground within the first 2
secondsafter the ignition switchwas turned ON (ll).
YES Go to step 12.
N O - R e p l a c et h e P G M - Fm
(
1 3 .ReconneclECMconnectorE (31P).
1 4 .Turn the ignitionswitch ON (ll),and measure
voltagebetweenECMconnectorterminal E1 and
body ground within the first 2 secondsafterthe
i g n i t i o ns w i t c hw a s t u r n e dO N ( l l ) .
wire sideoI femaleterminals
E (31PI
ECMCONNECTOR
YES Go to step 24.
N O - G o t o s t e p1 9 .
20. R e m o v et h e P G M - Fm
11-142
21. ConnectPGM-Flmain relay 2 5P connector
terminalsNo. 1 and No. 2 with a iumDerwire.
PGM.FIMAIN RELAY2
5P CONNECTOR
FUEL
PUMP
(YEL/
GRN)
JUMPER
WIRE
FNI
tri
rcr
fv
{YEL/BLK)
A
25. Checkfor continuitybetweenfuel pump 5P
E
dffi
Wiresideof {emaleterminals
ls therecontinuity?
23. Measurevoltagebetweenfuel pump 5P connector
Y E S R e p l a cteh ef u e lp u m p . l
terminal No. 5 and body ground.
FUELPUMP5PCONNECTOR
NO-Repairopenin thewire betweenthefuel
p u m p5 Pc o n n e c t oarn dG 5 5 1 . 1
Wiresideol femaleterminals
Y E S R e p l a c e t h eP G M - Fm
l a i nr e l a y 2 . t
NO-Repair open in the wire betweenthe PGM-Fl
main relay 2 and the fuel pump 5P connector.l
11-143
FuelSupplySystem
FuelPressureRelieving
Beforedisconnectingfuel lines or hoses,relieve
pressurefrom the system by disconnectingthe fuel
tube/quickconnectfitting in the enginecompartment.
9. Placea rag or shop towel over the quick-connect
fitting (A).
1 . T u r nt h e i g n i t i o ns w i t c hO F F ,
2 . R e m o v et h e P G M - Fm
l a i n r e l a y2 ( A ) .
1 0 .Disconnectthe quick-connectfifting (A):Hold the
connector(B)with one hand and squeezethe
retainertabs (C)with the other handto release
them from the lockingpawls {D).Pullthe connector
off.
3 . S t a r t t h ee n g i n e a, n d l e t i t i d l e u n t i li t i s s t a l l s .
NOTE:The DTCSor TemporaryDTCSP0301.P0302,
P0303,P0304may come on during this procedure.
lf any DTCSare stored,ignorethem.
Removethe fuel fill cap, and relievefuel pressure
inthefueltank.
6 . Removethe enginecover.
NOTE:
. P r e v e ntth e r e m a i n i n gf u e l i n t h e f u e lf e e d l i n e o r
hosefrom flowing out with a rag or shop towel.
. Be carefulnotto damagethe line (E)or other
parts.
. Do not use tools.
. l f t h e c o n n e c t o r d o e ns o t m o v e ,k e e p t h er e t a i n e r
tabs presseddown, and alternatelypull and push
the connectoruntil it comes off easily.
. Do not removethe retainerfrom the line; once
removed,the retainermust be replacedwith a
new one.
7 . Disconnectthe negativecablefrom the battery.
8 . Checkthe fuel quick-connectfitting for dirt, and
cleanit if necessary.
1 1 After disconnectingthe quick-connectfifting, check
i t f o r d i r t o r d a m a g e( s e ep a g e11 - 1 4 9 ) .
11-144
FuelPressureTest
. Fuel pressuregauge 07406-0040004
. Fuel pressuregaugesel 07ZAJ-S5A0100
1 . R e l i e v et h e f u e l p r e s s u r e( s e ep a g e1 ' 1 - 1 4 4 ) .
2. Disconnectthe quick-connectfitting (A).Aftachthe
fuel pressuregaugeset and fuel pressuregauge.
Startthe engineand let it idle.
. lf the enginestarts,goto step 5.
. lf the enginedoes not start,goto step 4.
Checkto see if the fuel pump is running:listento
the fuel fill port with the fuel fill cap removed.The
fuel pump should run for 2 secondswhen the
ignitionswitch is first turned on.
. lf the pump runs,go to step 5.
. l f t h e p u m p d o e sn o t r u n ,d o t h e f u e l p u m pc i r c u i t
t r o u b l e s h o o t i n(gs e ep a g e11 - 14 1) .
5 . Readthe pressuregauge.The pressureshould be
320-370 kpa (3.3-3.8 kgf/cm',a7-52 psi)
. lf the pressureis OK, the test is complete.
. lf the pressureis out of specification,replacethe
fuel pressureregulatorand the fuel filter (see
p a g e1 1 - 1 5 2 t) h, e n r e c h e c kt h e f u e l p r e s s u r e .
11-145
FuelSupply System
FuelLineInspection
Checkthe fuel system lines,hoses,and fuel filter for damage,leaks,and deterioration.Replaceany damagedparts.
\
Makesurethe connectionis
secureand the quick-connect
fitting cover is firmly lockedinto place.
11-146
Checkall clampsandretightenif necessary.
A: Do notdisconnect
the hosefromthe lineat theseioints.
Settheboltflange
T h e r es h o u l d b e n o
W.W
C l a m pi n t h e m i d d l e .
Setthispart
C l a m pi n t h e m i d d l e .
t h e f u e l { i l lt u b e ,
a l i g nt h e m a r k s
on the tubeand
t h el i n e .
11-147
FuelSupply System
FittingsPrecaution
The fuel tube/quick-connect
fittings connectthe fuel rail
(A)to fuel feed hose (B),the fuel feed hose (B)to the
f u e l l i n e( C ) ,a n dt h e f u e l t u b e( D )t o t h e f u e l p u m p
a s s e m b l y( E ) .W h e n r e m o v i n go r i n s t a l l i n g
t h ef u e l f e e d
hose,fuel pump assembly,or fuel tank, it is necessary
to disconnector connectthe quick-connectfittings.
Pay attentionto the following:
. T h e f u e lf e e dh o s e( B ) ,f u e lt u b e ( D ) ,a n d q u i c k connectfittings (F)are not heat-resistanU
be careful
not to damagethem during welding or other heatgeneralrngproceoures.
. T h ef u e l f e e dh o s e( B ) ,f u e l t u b e( D )a n d q u i c k connectfittings (F)are not acid-proof;do not touch
them with a shop towel which was used for wiping
batteryelectrolyte.Replacethem if they came into
contactwith electrolyteor somethingsimilar.
. When connectingor disconnectingthe fuel feed hose
(B),fuel tube (D),and quick'connectfittings (F).be
carefulnot to bend or twist them excessivelv.ReDlace
them it they are damaged.
A disconnectedquick-connectfitting can be
reconnected,but the retaineron the mating line cannot
be reusedonce it has been removedfrom the line.
Replacethe retainerwhen
.
.
.
.
.
.
.
replacingthe fuel rail.
replacing
t h ef u e ll i n e .
replacingthe fuel pump.
replacingthe fuel filter,
replacingthe fuel gaugesendingunit.
it has been removedfrom the line.
it isdamaged.
PART
I\4ANUFACTUREB RETAINER
COLOR
EN GI N E
TOKAI
GREEN
COI\4PARTMENT
( F U EF
LEED
H O S EF; UE L
L I N ES I D E )
E NGI N E
TOKAI
BLU
COIVIPARTMENT
( F U EF
LEED
H O S EF: U E L
R A I LS I D E )
FUELTANK
WHITE
SANOH
UNIT
11-148
I
FittingsRemoval
FuelLine/Ouick-Gonnect
1 . R e l i e v ef u e l p r e s s u r e( s e ep a g e1 ' l - 1 4 4 ) .
2 . Checkthe fuel quick-connectfiftingsfor din, and
clean if necessary.
Hold the connector(A) with one hand and squeeze
the retainertabs(B)with the other hand to release
them from the lockingpaws (C).Pullthe connector
off.
NOTE:
. B e c a r e f u ln o t t o d a m a g et h e l i n ei D ) o r o t h e r
parts.Do not usetools.
. lf the connectordoesnot move, keepthe retainer
tabs presseddown, and alternatelypull and push
the connectoruntil it comes off easily.
. Do not removethe retainerfrom the line; once
removed,the retainermust be replacedwith a
new one.
4. Checkthe contactarea (A) of the line (B)for dirt and
d am a g e .
. lf the surfaceis dirty, clean it.
. if the surfaceis rusty or damaged,replacethe
f u e l p u m p ,f u e l f i l t e r f, u e l f e e dl i n e .
=k
To preventdamagedand keepforeign matter out,
cover the disconnectedconnectorand line end with
plasticbags (A).
NOTE:
. The retainercannot be reusedonce it has been
r e m o v e df r o m t h e l i n e .
Replacedthe retainerwhen
- replacing
t h e f u e lr a i l .
- r e p l a c i n gt h e f u e lf e e dI i n e .
- r e p l a c i n gt h e f u e l p u m P .
- replacingthe fuel filter.
- replacing
t h e f u e l g a u g es e n d i n gu n i t
- it has been removedfrom the line.
- it is damaged.
11-149
FuelSupply System
Fittingslnstallation
1. Checkthe contacta rea (A) of the line (B)for dirt and
damage,and clean if necessary.
Inserta new retainer(A) into the connector(B) if the
retaineris damaged,or after
. r e p l a c i n gt h e f u e l r a i l .
. replacingthe fuelfeed line.
. replacingthe fuel pump.
. replacingthe fuel filter.
. r e p l a c i n gt h e f u e l g a u g es e n d i n gu n i t
. removingthe retainerfrom the line.
11-150
3. Beforeconnectinga new fueltube/quick-connect
fitting assembly(A),removethe old retainerfrom
t h e m a t i n ol i n e ,
4. Align the quick-connectfittingswith the line (A).
a n d a l i g nt h e r e t a i n e (r B )l o c k i n gp a w l sw i t h t h e
connector{C)grooves.Then pressthe quickconnectfittings onto the line until both retainer
p a w l sl o c kw i t h a c l i c k i n gs o u n d .
5. lvlakesure the connectionis secureand that the
p a w l sa r ef i r m l y l o c k e di n t o p l a c e c; h e c kv i s u a l l y
and by pullingthe connector.
N O T E ;l f i t i s h a r dt o c o n n e c tp, u t a s m a l la m o u n to f
n e w e n g i n eo i l o n t h e l i n ee n d .
Connectionwith new retainer:
6. Reconnectthenegativecableto the battery,and
t u r n t h e i g n i t i o ns w i t c hO N ( l l ) .T h e f u e l p u m p w i l l
run for about 2 seconds,and fuel pressurewill rise
Repeat2 or 3 times, and checkthat there are no
fuel leaks.
Reconnectionto existing retainer:
11-151
FuelSupply System
FuelPressureRegulator
Replacement
1 . R e m o v et h e f u e l p u m p ( s e ep a g e11 - 1 5 3 ) .
2 . Removethe fuel pressureregulator(A).
FuelFilterReplacement
The fuel filter should be replacedwheneverthe fuel
pressuredrops belowthe specifiedvalue {270 320 kpa,
2.8 3.3 kgflcm', 40 47 psi),after makingsure that the
fuel pump and the fuel pressureregulatorare OK.
1 . R e m o v et h e f u e l p u m p ( s e e p a g e l l - ' 1 5 3 ) .
2. Removethe fuel filter (A).
@-to
Re
IJ
e"^
ê
g s
AR
...\
@n-)
s g
Installthe part in the reverseorder of removalwith
a n e w o - r i n g( B ) .
Installin the reverseorder of removalwith a new
basegasket(B)and a new o-ring (C),then check
these items:
' When connectingthe wire harness,make sure
the connectionis secureand the terminal (D) is
firmly lockedinto place.
. W h e ni n s t a l l i n g
t h e f u e l g a u g es e n d i n gu n i ti E ) ,
make sure the connectionis secureand the
connectoris firmly lockedinto place.Be careful
not to bend or twist it excessively.
11-152
\
{
FuelPump/FuelGaugeSendingUnit Replacement
F u e ls e n d e rw r e n c h0 7 X A A - 0 0 1 0 1 0 A
8 . R e m o v et h e l o c k n u (t A )a n d t h e f u e lt a n k u n i t .
1 . R e l i e v et h e f u e l p r e s s u r e( s e ep a g e1 1 - 1 4 4 ) .
Removethe fuel fill cap.
Removethe seat cushion(seepage 20-80).
Removethe accesspanel (A)from the floor.
t e f u e l p u m p 5 Pc o n n e c t o(rB ) .
Disconnectthe quick-connectfitting {C)from the
f u e lt a n ku n i t .
7 . U s i n gt h e s p e c i atlo o l ,l o o s e nt h e f u e lt a n ku n i t
locknut(A).
t h e h o o k ( P )a n d
9 . R e m o v et h e s t o p p e r{ O ) .R e l e a s e
r e m o v et h e f u e lf i l t e r( B ) ,t h e f u e l g a u g es e n d i n g
u n i t ( C ) .t h e c a s e( D ) ,t h e w i r e h a r n e s s( E ) ,a n d t h e
fuel pressureregulator(F).
t h e f u e lt a n k u n i t ,m a k es u r et h e
1 0 . W h e nc o n n e c t i n g
i s s e c u r ea n d t h e s u c t i o nf i l t e r( G )i s
connection
t o t h e f u e lp u m p ( H ) .
f i r m l yc o n n e c t e d
1 1 . I n s t a ltl h e f u e lt a n ku n i t i n t h e r e v e r s eo r d e ro f
r e m o v aw
l i t h a n e w b a s eg a s k e t( l ) a n dn e w o - r i n g s
( J ) ,t h e nc h e c kt h e s ei t e m s :
93 N.m
19.5kgf.m,69 lbf.ftl
. W h e nc o n n e c t i n tgh e w i r e h a r n e s sm
, a k es u r e
t h e c o n n e c t i o ni s s e c u r ea n d t h e c o n n e c t o(rK )i s
f i r m l y l o c k e di n t ot h e p l a c e .
. W h e n i n s t a l l i n gt h e f u e l g a u g es e n d i n gu n i t ,
make sure the connectionis secureand the
c o n n e c t oirs f i r m l y l o c k e di n t o p l a c e .B e c a r e f u l
not to bend or twist the connectorexcessively.
t h e f u e l t a n ku n i t ,a l i g nt h e m a r k s
( L )o n t h e f u e lt a n k( M ) a n d t h e f u e lt a n k u n i t( N i
11-153
FuelSupply System
FuelPulsationDamperReplacement
1 . R e l i e v et h e f u e l p r e s s u r e ( s e e p a g e l l - 1 4 4 ) .
2. Removethe enginecover.
3. Removethe fuel rail mounting nuts from the fuel
rail.
4 . R e m o v et h e g r o u n dc a b l e( G1 0 1 .
5 . R a i s et h e f u e l r a i l .
6 . P l a c ea w r e n c h( A )o n t h e f u e l r a i l( B ) .
7 . P l a c ea w r e n c h( C )o n t h e f u e l p u l s a t i o nd a m p e r( D ) .
8. Removethe pulsationdamper.
9. Installthefuel pulsationdamper in lhe reverse
order of removalwith new washers.
NOTE:
. Replaceall washerswhenever the fuel pulsation
damper is loosenedor removed,
. l f t h e d r a i nh o l e( A )o f t h e f u e l p u l s a t i o n d a m p e r
cover does not face bottom, reinstallit as shown.
11-154
FuelTank Replacement
1 . R e l i e v e t h e f u epl r e s s u r e( s e ep a g e1 1 - 1 4 4 ) .
2 . D r a i nt h e f u e lt a n k :R e m o v et h e f u e l p u m p ( s e ep a g e11 - 1 5 3 )U. s i n ga h a n dp u m p ,h o s e ,a n d c o n t a i n esr u i t a b l ef o r
gasoline.draw the fuel from the fuel tank.
3 . Jack up the vehicle,and suppon it with safetystands.
Removethe fuel pipe cover (A).Disconnectthe fuel vapor hose and quick-connectfittings.
Disconnectthe hoses.Slide backthe clamps (B),then twist the hosesas you pull to avoid damagingthem.
(}
A
\
38N.m
(3.9ksf.m,28lbfft)
5. Placea jack or other supportunder the tank.
6 . R e m o v e t h es t r a pb o l t s ,a n d l e t t h e s t r a p( C )h a n g f r e e .
7 . R e m o v et h e f u e lt a n k ( D ) .l f i t s t i c k s t o t h eu n d e r c o a t o ni t s m o u n t ,c a r e f u l l yp r y i t o f f t h e m o u n t
8. Installthe parts in the reverseorder of removal.
11-155
FuelSupply System
FuelGaugeSendingUnit Test
Fuelsenderwrench 07XAA-001010A
NOTE;For the fuel gauge system circuitdiagram,refer
to the GaugesCircuitDiagram(see page 22-58||.
1 . C h e c k t h eN o . 1 0 f U E T E R
{ 7 . 5 A ) f u s ei n t h e u n d e r dash fuse/relaybox beforetesting.
7. Measurevoltage betweenfuel pump 5P connector
terminalsNo. 1 and No. 2 with the ignition switch
ON (ll).There should be batteryvoltage.
. lf the voltage is as specified,go to step 8.
. l f t h e v o l t a g ei s n o t a s s p e c i f i e d , c h e c k f o r :
- a n o p e n i n t h e Y E U B L Ko r B L Kw i r e .
- p o o r g r o u n d( G 5 5 1 ) .
2. Do the gauge drive circuitcheck(see page 22-56|l.
' lf the fuel gauge needlesweepsfrom minimuni
to maximum positionand then returnsto the
m i n i m u mp o s i t i o nt.h e g a u g ei s O K .G o t o s t e p3 .
. lf the fuel gauge needle does not sweep from
m i n i m u mt o m a x i m u mp o s i t i o np o s i t i o na n d
then returnto the minimum position,replacethe
gauge assemblyand retest.
FUELPUMP5PCONNECTOR
3 . T u r nt h e i g n i t i o ns w i t c hO F F .
4. Removethe rear seat cushion{seepage 20-80).
5. Removethe accesspanel (A)from the floor.
-ztr
Turn the ignition switch OFF.Removethe No. 9
BACKUP (7.5A)fusefrom the under-hoodfuse/
relay box for at least 10 seconds,lhen reinstallit.
Installa 2 Q resistorbetweenfuel pump 5P
connectorlerminals No. 1 and No. 2, then turn the
i g n i t i o ns w i t c hO N ( l l ) .
-VVV{Y
{YEL/BLK)
2 9 RESISTOR,
=-a
\
(elrt \
\ 4
//,
5 /
6. Disconnectthe fuel pump 5P connector{B).
11-156
1 0 . C h e c k t h a t t h ep o i n t e r o ft h e f u e lg a u g ei n d i c a t e s
"F".
. lf the pointerdoes not indicate"F", replacethe
g au g e .
. lf the pointerindicates"F", inspectthe fuel
gauge sendingunit.
NOTE:The pointerof the fuel gauge returns to the
bottom of the gaugedial when the ignition switch
is OFF,regardlessof the fuel level.11. Relievethe fuel pressure(seepage 11-144\.
1 2 . R e m o v et h e f u e l f i l l c a p .
1 5 . M e a s u r er e s i s t a n cbee t w e e nt h e N o . 1 a n d N o . 2
'l12
terminalswith the float at E (EN4PTY), \HALF
F U L L )a, n d F { F U L L p
) ositions.
lf you do not get the following readings,replacethe
f u e l g a u g es e n d i n gu n i t{ s e ep a g e1 ' 1 - 1 6 3 ) .
F
Float
Position
Resistance 1 1
{0)
to 13
'U2
68,5
to 74.5
LOW
E
114.4
130
to 126.6 to 132
NOTE:Removethe No. 9 BACKUP (7.5A)fuse from
the under-hoodfuse/relaybox for at least 10
secondsafter completingtroubleshooting,
otherwiseit may take up to 20 minutesfor the fuel
gaugeto indicatethe correctfuel level.
13. Disconnectthe quick-connectfittingsfrom the fuel
pump.
1 4 . U s i n gt h e s p e c i atlo o l ,l o o s e nt h e f u e lt a n ku n i t
locknut(A).
A
93Nm
{9.5ksf.m,69 lbf.ft}
11-157
FuelSupply System
Low FuelIndicatorTest
1 . Do the fuel gauge sendingunit test (seepage 11,
rcol.
. lf the system is OK, go to step 2.
. lf the system has any malfunction,repair it.
Turn the ignition switch OFF.Removethe No. 9
BACKUP (10A)fuse from the under-hoodfuse/
relay box for at least30 seconds,then reinstallit.
Turn the ignition switch ON (ll)with the float at the
E (EMPry) position.
. lf the low fuel indicatoris on, go to step 4.
. lf the low fuel indicatoris not on, referto the low
fuel indicatorCircuitDiagram(seepage 22-58)
and checkthe circuit.
4, Turn the ignition switch OFF.Removethe No. 9
BACKUP (10A)fuse from the under-hoodfuse/
relay box for at least30 seconds,then reinstallit.
Lift the float above the LOW position.
. l f t h e l o w f u e li n d i c a t o r g o eo
s f f , t h es y s t e mi s O K .
. lf the low fuel indicatoris still on, referto the low
fuel indicatorCircuitDiagram{seepage 22-58),
and checkthe circuit.
11-158
\,
IntakeAir System
i
INTAKE AIR BYPASSCONTROL
THERMALVALVE
Test,page 1'1-161
THROTTLEBODY
Test,page l'l-160
page 11-165
page 11 166
Disassembly/Reassembly,
l .
AIR CLEANER
R e p l a c e m e npt a, g e11 ' 1 6 2
AIR CLEANERELEMENT
R e p l a c e m e npta, g e11 - 1 6 2
THROTTLE
CABLE
page11-163
Adjustment,
R e m o v a l / l n s t a l l apt a
i ogne1, 1 - 1 6 4
11-159
IntakeAir System
Throttle BodyTest
NOTE:
. Do not adjustthe throttlestop screw. lt is presetat the
factory.
. lfthe malfunction
i n d i c a t o lra m p ( M l L )h a sb e e n
reportedon, checkfor diagnostictrouble codes
( D L C S()s e ep a g e1 1 3 ) .
1. With the engine off, checkthe throttle cable
movement.The cableshould move without binding
or sticking.
. lf lhe cable moves OK, goto step 2.
. lf the cable binds or sticks,checkit and its routing.
. l f t h e c a b l ei s f a u l t y ,r e r o u t ei t o r r e p l a c ei t a n d
a d j u s ti t ( s e ep a g e1 1 - 1 6 3 )t h
, e ng o t o s t e p2 .
2. l\4ovethe throttle lever by hand to see if the throftle
valve and/or shaft are too looseor too tight.
. lf there is excessiveplay in the throttlevalve
shaft,or any binding in the throttlevalve at the
fully closedposition,replacethe throttle body.
. l f t h e t h r o t t l e v a l v ea n d s h a f ta r e O K ,g o t o s t e p 3 .
3. Connectthe scantoolto the DLC.
5 . Checkthe throttle positionwith the scantool. The
readingshould be about 10%when the throttle is
fully closedand about 90% when the throttle is fully
openeo.
. lf the throttle positionis correct,the throttle body
is OK.
. lf thethrottle positionis notcorrect,replacethe
throttle body.
11-160
!
Test
IntakeAir BypassGontrolThermalValve
Vacuum Pump/Gauge,0 30 in. Hg A973X-041-XXXXX
, n d m a k es u r e
5 . R a i s ea n d l o w e rt h e e n g i n es p e e d a
the vacuum gauge readingdoes not changeas the
rpm cnanges.
1 . S t a nt h e e n g i n e T
. h e nl e t i t i d l € .
NOTE:The enginecoolanttemperaturemust be
b e l o w1 4 9 ' F ( 6 5 ' C ) .
2 . R e m o v et h e v a c u u mh o s e( A ) f r o mt h e i n t a k ea i r
duct, and connecta vacuum pump/gaugeto the
nose.
lf the vacuum readingchanges,checkfor these
proorems:
. l\4isrouted,
leaking,broken,or cloggedintakeair
bypasscontrol systemvacuum lines.
. A crackedor damagedintakeair bypasscontrol
t h e r m a lv a l v e .
. n d m a k es u r e
3 . R a i s ea n d l o w e r t h ee n g i n es p e e d a
t h e v a c u u mg a u g er e a d i n gc h a n g e sa s t h e e n g i n e
speeocnanges.
lf the vacuum readingdoes not change,checkfor
these problems:
. M i s r o u t e dl,e a k i n gb, r o k e n o, r c l o g g e di n t a k ea i r
bypasscontrol system vacuum lines.
. A crackedor damagedintakeair bypasscontrol
t h e r m a lv a l v e .
4 . H o l dt h e e n g i n ea t 3 , 0 0 0r p m w i t h n o l o a d( i n
neutral)until the radiatorfan comes on, then let it
i dl e .
11-161
IntakeAir System
Air CleanerReplacement
1. Removethe nuts (A) and the stud (B).
Air CleanerElementReplacement
t e P C Vh o s e1 A ) .
{0.3kgf m,2lbf.ft)
2. Removethe air cleaner(C).
2 . O p e nt h e a i r c l e a n e rh o u s i n gc o v e r( B ) .
3 . Installin the reverseorder of removal.
3 . R e m o v et h e a i r c l e a n e r( C )f r o m t h e a i r c l e a n e r
h o u s i n g( D ) .
4 . Installin the reverseorder of removal.
11-162
\,
Throttle CableAdjustment
1 . Checkcablefree play at the throttle linkage.Cable
f r e e p fa v ( A )s h o u l db e 1 0 1 2 m m ( 3 / 8 1 / 2i n . ) .
lf the free play is not within spec (10- 12 mm,
3 1 8 - 1 1 2 l n . l , l o o s etnh e l o c k n u (t B ) ,t u r n t h e
adjustingnut (C)untilthe free play is as specified,
then retightenthe locknut.
With the cable properlyadjusted,checkthe throttle
valve to be sure it opens fully when you push the
acceleratorpedalto the floor. Also checkthe
throttlevalve to be sure it returnsto the idle
positionwheneveryou releasethe accelerator
peoar.
11-163
IntakeAir System
Throttle CableRemoval/lnstallation
1. Fully open the throttlevalve,then removethe
throttle cable (A)from the throttle link (B).
Installin the reverseorder of removal.
5 . After installing,startthe engine.Holdthe engine at
3,000rpm with no load (in neutral)untilthe radiator
fan comes on, then let it idle.
H o l dt h e c a b l e ,r e m o v i n ga l l s l a c kf r o m i t .
7 . Set the locknuton the cable bracket{A).
Turn the adjustingnut (B)so that its free play is
0 mm.
T h e s h o u l db e
no crearance.
(P/N08?98-9002)
2 . R e m o v et h e c a b l eh o u s i n g( C ) f r o mt h e c a b l e
bracket(D).
('1.0kgf.m,
7.2 tbf.ftl
!
3 . Removethe throttlecable (A)from the accelerator
p e d a l( B ) .
8 . Removethe cablefrom the cable bracket(A).Set
the adjustingnut on the other side of the throttle
bracket,then tightenthe locknut{C}.
9 . With the cable properlyadjusted,checkthe throttle
valve to be sure it opensfully when you push the
acceleratorpedalto the floor. Also checkthe
throttlevalveto be sure it returnsto the idle
positionwheneveryou releasethe accelerator
Deoat.
SILICONE
GREASE B
(P/N08798-9002)
11-164
Throttle Body Removal/lnstallation
NOTE:
' Do not adjustthe throttle stop screw.
. A f t e r r e a s s e m b l y , a d j u s t t h e t h r o t t l e c a b l e { s e e p a g e l l - 1a6n3d)t h e c r u i s ec o n t r o lc a b l e( s e ep a g e4 - 4 5 ) .
. The throttle position(TP)sensoris not removable.
THROTTLE
LEVER
Thereshould be
noclearance
THROTTLECABLE
MANIFOLD
ABSOLUTEPRESSURE
{MAP}SENSOR
22Nm
(2.2 kgt.m, 16 lbf.ft)
EVAPORATIVEEMISSION{EVAPI
CANISTERPURGEVALVE
IDLEAIR CONTROL
{IACI VALVE
11-165
IntakeAir System
Throttle Body Disassembly/Reassembly
2 N.m
{0.2 kgt m, 1 lbf.ft)
A
V
MAPSENSOR
EMISSION
EVAPORATIVE
{EVAP)
PURGE
VALVE
CANISTER
L
TPSENSOR
THROTTLEBODY
3.5 N.m
(0.35kgf m.2.5lbf ft)
11-166
CatalyticConverterSystem
DTCTroubleshooting
DTCP0420:CatalyticSystemEfficiency
BelowThreshold
NOTE:lf some of the DTCSlistedbelow are storedat
the same time as DTCP0420,troubleshootthose DTCS
first, then recheckfor DTCP0420.
P 0 1 3 7P, 0 1 3 8S: e c o n d a r yH e a t e dO x y g e nS e n s o r
(secondaryHO2S)(Sensor2)
r )heater
P 0 1 4 1S: e c o n d a r yH O 2 S( S e n s o 2
1 . R e s e t h e E C M{ s e ep a g e1 ' l - 4 }t,h e nc o n t i n u et o
step 2 through 5 to resetthe readinesscode.
n o l o a d( i n n e u t r a lu) n t i l t h er a d i a t o fr a n c o m e so n .
D r i v ef o r a b o u t l 0 m i n u t e sw i t h o u ts t o p p i n gY. o u r
speeocan vary.
4 . With the transmissionin 4th gear,drive at a steady
speed between50 62 mph (80-'100 km/h)for
30 seconds.
Repeatstep 4 three times. Betweeneach repetition,
closethe throttlecompletelyfor 1 2 seconds.lf
the engine is stoppedduring this part of the
procedure,repeatsteps3, 4 and 5.
Checkfor a TemporaryDTCwith the scantool.
Does the scan tool indicate Temporaty DTC
P0420?
YES Checkthe TWC. lf necessary,replacethe
TWC.I
N O C h e c kf o r r e a d i n e s cs o d ec o m p l e t i o nl.f t h e
readinessis complete,it was a interminentfailure,
and the system is OK at this time. lf the readiness
code is incomplete,repeatsteps2 through 5.1
11-167
PCVSystem
DTCTroubleshooting
DTCP1505:PCVAir Leakage
n o l o a d( i n n e u t r a l u) n t i lt h e r a d i a t o fra n c o m e so n
3. Letthe engineidle tor al least40 secondswith the
4. Checkfor a DTCP1505with the scantool
YES-Check these partsfor vacuum leaks l
.
.
.
.
.
PCVvalve
PCVhose
EVAPcanisterpurge valve
Throttlebody
Brakeboosterhose
NO - Intermittentfailure,system is OK at this
time.l
11-168
PCVValve Inspectionand Test
1. Checkthe PCVvalve (A),hoses{B),and
connectionsfor leaksor restrictions.
PCVValve Replacement
'L
Disconnectthe PCVhose.
Removethe PCVvalve (A).
2 . At idle, make sure there is a clickingsound from the
PCVvalve when the hose betweenthe PCVvalve
a n d i n t a k em a n i f o l di s l i g h t l yp i n c h e d{ A ) w i t hy o u r
f i n g e r so r p l i e r s .
lf there is no clickingsound,checkthe PCVvalve
grommet for cracksor damage.lf the grommet is
OK. reDlacethe PCVvalve and recheck.
(4.5kgf.m,33lbf.ft)
l parts in the reverseorder of removal
3 . I n s t a lthe
with a n e w g a s k e t( B ) .
11-169
EVAPSystem
EVAPORATIVEEMISSIONIEVAPI
CANISTERPURGEVALVE
Troubleshooting,
'l1-175,
step 3 on page
s t e p1 o n p a g e1 1 - 1 8 0
FUELTANK VAPORCONTROLVALVE
Test,page 11'187
R e p l a c e m e npt a, g e1 1 1 8 9
EVAPORATIVEEMISSION{EVAPI
CANISTER
Troubleshooting,
step 28 on page 11'183
page 11-189
Replacement,
SENSOR
FUELTANKPRESSURE
T r o u b l e s h o o t ipnagg, e11 - 1 7 1
EVAPORATIVEEMISSION{EVAP}
BYPASSSOLENOIDVALVE
Troubleshooting,
p a g e' 1 1 ' 1 7 6 ,
s t e p1
' 120o n
s t e p o n p a g e1 1 1 8 1
EVAPORATIVEEMISSION{EVAP)
CANISTERVENT SHUT VALVE
Troubleshooting,
step 23 on page 1'l 178,
s t e p1 go n p a g el 1 - 1 8 2
11-170
EVAPOBATIVEEMISSON{EVAP)
VALVE
TWO WAY 'l1-'186
Test,page
DTCTroubleshooting
DTCP0451:FTPSensorRange/Performa
nce
Problem
6. Connecta vacuum pump to the open end of the
hose.
SpecialTools Required
Vacuum Pump/Gauge,0-30 in. Hg A973X-041-XXXXX
1 . R e m o v et h e f u e lf i l l c a p .
3. l\4onitorfuel tank pressure(FTP)sensorvoltage
with the HondaPGM Tester,or medsurevoltage
betweenECMconnectorterminalsE4 and E14.
ECMCONNECTOR
E 131P)
7 . Turn the ignition switch ON {ll).
8 . l\4onitorFTPsensorvoltagewith the Honds PGM
Tester,or measurevoltage betweenECM
c o n n e c t otre r m i n a l sE 4 a n d E 1 4 ,a n d c a r e f u l l y
s q u e e z et h e v a c u u mp u m p a l i t t l e .
ECMCONNECTOR
E 13lPI
W i r es i d eo f f e m a l tee r m i n a l s
ls there about 2.5V?
YES-Go to step 4.
NO Replacethe FTPsensor.I
Wiresideof lemaleterminals
5 . Disconnectthe hose betweenthe EVAPtwo way
valve and the FTPsensorat the EVAPtwo way
valve end.
9 . The voltageshould smoothly drop from about 2.5 V
t o a b o u t1 . 5V . S t o pa p p l y i n gv a c u u mw h e n t h e
voltagedrops to about 1.5V or damageto the FTP
sensormay occur.
Does the voltage drop to about 1.5 V and hold?
YES Checkfor misrouted,leaking,or brokenFTP
s e n s o rv a c u u ml i n e s .l f t h e v a c u u ml i n e sa r e O K ,
updatethe ECM if it does not havethe latest
originaE
l CM.I
NO
Replacethe FTPsensor.!
11-171
EVAPSystem
DTCP0452:FTPSensorCircuitLow Voltage
1. Checkthe vacuum lines at the FTPsensorfor
misrouting,leakage.breakage,or clogging.
7 . R e i n s t a l l t h feu e lf i l l c a p .
8. Disconnectthe FTPsensor3P connector.
Are the vacuumlines OK?
YES Go to step 2.
NO Repairor replacevacuum lines as
necessary.I
10. Measurevoltage betweenFTPsensor3P connector
t e r m i n a l sN o . 1 a n d N o . 2 .
3PCONNECTOR
FUELTANKPRESSURE
SENSOR
3 . R e m o v et h e f u e l f i l lc a p .
VCgl {YEL/BLU}
5. Monitor FTPsensorvoltagewith the HondaPGM
Tester,or measurevoltage betweenbody ground
and ECMconnectorterminal E14.
E 131PI
ECMCONNECTOR
1 2 t 3 t 45
././114
22123241 t
tc
26
o
/
8 9
61./18 2C 21
271/ 29
31
TP (LTGRN)
ls there about 5 V?
'1.
YES Go to step 1
NO-Repair open in the wire betweenthe FTP
s e n s o ra n dt h e E C M{ E 5 ) . 1
ls thete about2.5 V?
YES- Intermittentfailure,system is OK at this time.
the FTPsensorand at the ECrM.l
NO Go to step 6.
11-172
11. MeasurevoltagebetweenFTPsensor3P connector
FUELTANKPRESSUBE
SENSOR3P CONNECTOR
FTP(LT GBN)
DTCP0453:FTPSensorCircuitHighVoltage
1. Checkthe vacuum lines at the FTPsensorfor
misrouting,leakage,breakage,or clogging.
Are the vacuumlines OK?
N O R e p a i ro r r e p l a c ev a c u u ml i n e sa s
necessary.I
W i r e s i d eo f f e m a l e t e r m i n a l s
2 . R e s e t h e E C M{ s e ep a g e1 1 ' 4 ) .
3. Removethe fuel fill cap.
ls there about 5 V?
YES- Replacethe FTPsensor.t
N O - G o t o s t e p1 2 .
' t 2 .Turn
5. lvlonitorFTPsensorvoltagewith the Honda PGM
Tester,or measurevoltage betweenbody ground
a n d E C Mc o n n e c t otre r m i n a lE ' 1 4 .
the ignitionswitch OFF.
1 3 .DisconnectECMconnectorE (31P),
1 4 .Checkfor continuitybetweenFTPsensor3P
ECMCONNECTOR
E 131PI
1 1 2 1 34 5 6 7
I 9
5 6 / t18 2C 21
24
2il./ 29 30 31
TP {LTGRN}
FTPSENSOR3P CONNECTOB
FTP (LT GRNI
Is there about 2.5 V?
W i r es i d eo f f e m a l e l e r m i n a t s
YES Intermittentfailure,system is OK at this time.
t h e F T Ps e n s o ra n d a t t h e E C M . I
NO Go to step 6.
YES Repairshort in the wire betweenthe FTP
s e n s o ra n d t h e E C I \ {4E 1 4 ) . I
originaE
l CM.I
{cont'd)
11-173
EVAPSystem
7 . R e i n s t al h
l e f u e lf i l l c a p .
11, Measurevoltage betweenFTPsensor3P connector
t e r m i n a lN
s o . 2 a n dN o . 3 .
FTPSENSOR3P CONNECTOR
8. Disconnectthe FTPsensor3P connector.
FTPILT GRN}
'10.
l\4easure
voltage betweenFTPsensor3P connector
FTPSENSOR3P CONNECTOR
VCC3(YEL/BLU)
ls there about 5 V?
YES Replacethe FTPsensor.l
NO Go to step 12.
l\4easure
voltage betweenECMconnector
t e r m i n a l sE 4 a n d E1 4 ,
ls there about 5 V?
Y E S G o t o s t e p1 1 .
ECMCONNECTOR
E (31P)
NO-Repair open in the wire betweenthe FTP
sensorand the ECM (E4).!
W i r es i d eo f f e m a l tee r m i n a l s
ls there about 5 V?
YES Repairopen in the wire betweenthe FTP
s e n s o ra n d t h e E C M( E 1 4 ) . I
then
software,or substitutea known-goodECN4.
originaE
l CM.I
11-174
\
DTCPl456:EVAPControlSystemLeakage
(FuelTankSvstem)
The fuel system is designedto allow specified
maximum vacuum and pressureconditions.Do not
deviatefrom the vacuum and pressuretests as
indicatedin these procedures.Excessivepressure/
vacuum would damagethe EVAPcomponentsor cause
eventualfuel tank failure.
EVAP Canister Purge Valve Test
3. Disconnectthe vacuum hose from the EVAP
canisterpurge valve (A),and connecta vacuum
oumo to the hose.
Vacuum Pump/Gauge,0-30 in. Hg A973X-041-XXXXX
This is a two-trip code. Oncecleared,it cannot be
reproducedin one trip. Also, cenain specificdriving
and ambientconditionsmust occur beforethe ECMwill
completethe systemchecks.Additionaltest drives may
still not meet the specificconditionsneededto
reproducethe code.
A973X-041-XXXXX
Follow thesetroubleshootingprocedurescarefullyto
ensurethe integrityof the system and to confirm the
causeof the problemor code.
5 . Apply vacuum to the hose.
Does the valve hold vacuum?
NOTE:Freshfuel has a highervolatilitythat creates
greaterpressure/vacuum.
The optimum condltlonfor
testing is fresh fuel, and must be lessthan a full tank. lf
possible,to assistin leakdetection,add 1 gallon of
fresh fuel to the tank (as long as it will not fill the tank).
just beforestartingthese procedures.
YES-The EVAPcanisterpurge valve is OK. Go to
s t e p1 1 .
NO-Go to step 6.
Fuel Fill Cap Check
1. Checkthe fuel fill cap (the cap must say "lf not
tightened3 clickscheckengine light may come
o n ") .
7 . Disconnectthe EVAPcanisterpurge valve 2P
connecror.
ls the proper luel till cap installed and properly
tightened?
YES Go to step 2.
NO- Replaceor tightenthe cap.I
2. Checkthe fuel fill cap seal.
ls the tuel fill cap seal missing or damaged?
YES- Replace
t h e f u e lf i l l c a p . I
N O T h e f u e l f i l lc a p i s O K .G o t o s t e p3 .
{cont'd)
11-175
EVAPSystem
8. Checkfor continuitybetweenEVAPcanisterpurge
valve2Pconnenctor
terminalNo.2 andbody
grouno.
EVAP CANISTERPURGE
VALVE 2P CONNECTOR
EVAP Bypass Solenoid Valve Test
11, Disconnectboth vacuum hosesfrom the EVAPtwo
way valve (A),and connecta vacuum pump to the
canisterport on the EVAPtwo way valve.
F-
A973X-041-XXXXX
ls therecontinuity?
YES Goto step9.
NO Replace
the EVAPcanisterpurgevalve.l
B (24P).
ECMconnector
9 . Disconnect
1 0 . Checkfor continuitybetweenEVAPcanisterpurge
valve2Pconnector
EVAPCANISTERPURGE
VALVE2PCONNECTOR
Turn the EVAPbypasssolenoidvalve on with the
Honda PGM Tester,or connectECMconnecter
terminal E20to body ground with a jumper wire.
E 131P)
ECMCONNECTOR
1 2 3 4 5 6 1 7 l1 8 9
4 5 6 / 118 2C21
2 2 t 2 ? 24
z7l./29
2WBS
(BLU/RED}
JUMPER
WIRE
1 2
PCS
{YEL/BLU)
'.\'
1 3 .Turn the ignitionswitch ON (ll).
1 4 .Apply vacuum to the hose.
Y E S - G o t o s t e p1 5 ,
YES Repairshort in the wire betweenthe EVAP
canistep
r u r g ev a l v ea n dt h e E C I \ {48 2 1 ) . 1
originaE
l CM.I
11-176
NO Go to step 20.
v
to.
Disconnectthe EVAPbypasssolenoidvalve 2P
connecror.
'19.
Measurevoltage betweenEVAPbypasssolenoid
valve 2P connectorterminal No. 1 and body ground.
EVAPBYPASSSOLENOID
VALVE2PCONNECTOR
1 7 . Checkfor continuitybetweenEVAPbypass
solenoidvalve 2P connectorterminal No. 2 and
body ground.
EVAP BYPASSSOLENOID
VALVE 2P CONNECTOR
2
tG'l
{BLK/ORN)
Wire side oI Iemaleterminals
YES Go to step 18.
NO-Repair open in the wire bet\iveen
the EVAP
bypasssolenoidvalve and the ECM (E20).1
'18.T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
YES Replacethe EVAPtwo way/bypasssolenoid
v a l v e( A ) . 1
NO-Repair open in the wire betweenthe EVAP
bypasssolenoidvalve and the No. 4 ACG (10A)
fuse.l
{cont'd)
11-177
EVAPSystem
(cont'dl
DTCTroubleshooting
2 0 . P l u gt h e f u e l t a n kp o r t ( A )o f t h e E V A P t w o w a y
valve,
EVAP Canister Vent Shut Valve Test
22. Disconnectthe vacuum hosefrom the EVAP
canistervent filter (A),and connecta vacuum pump
to the hose.
While monitoring FTPsensorvoltagewith the
HondaPGM Tester,or measuringthe voltage
b e t w e e nE C Mc o n n e c t otre r m i n a l sE 4a n d E1 4 ,
slowly pump the vacuum pump until the voitage
droDSto about 1.5volts.
ECMCONNECTOR
E {31PI
T u r nt h e i g n i t l o ns w i t c hO N ( l l ) .
Apply vacuum to the hosewith five strokesof the
pump.
\
YES Go to step 25.
NO The EVAPcanistervent shut valve is OK. Go
to step 30.
26. Disconnectthe EVAPcanistervent shut valve 2P
Does the voltagedtop to 1.5 V and hold fot at
Ieast 20 seconds?
YES-The EVAPbypasssolenoidvalve/EVAPtwo
way valve is OK. Go to step 22.
conneclor.
2 1 . Checkfor continuitybetweenEVAPcanistervent
s h u tv a l v e2 Pc o n n e c t otre r m i n a lN o . 2 a n d b o d y
ground.
EVAPCANISTEBVENTSHUT
VALVE2PCONNECTOR
N O R e p a i rt h e l e a kf r o m t h e E V A Pb y p a s s
solenoidvalve, EVAPtwo way valve.or
F T Ps e n s o r . l
{LTGRN/REOI
11-178
VacuumHosesand ConnectionsTest
3 0 . Do the fuel tank vapor control valve test (seepage
11 - 1 8 7 ) .
ls the fuel tank vapot control valve OK?
Y E S - G o t o s t e p3 1 .
NO Replace
t h e f u e l t a n kv a p o rc o n t r o lv a l v e . l
5 t .
Tightenthe fuel cap 3 "clicks", then monitorthe
FTPsensor readingswith the Honda PGM Tester.
Startthe engine.and let it idle for 5 minutes.
Checkthe FTPsensor readings.
YES-Go to step 28.
NO-Replace the EVAPcanistervent shut valve (A)
a n d o - r i n g( B ) . 1
29. Checkfor continuitybetweenEVAPcanistervent
s o l e n o i dv a l v e2 P c o n n e c t otre r m i n a lN o . 2 a n d
body ground.
EVAPCANISTERVENTSHUT
VALVE2PCONNECTOR
ls the reading above 0.5 kpa (4 mm Hg, 0.16 in.
Hg) pressure, or about 3 V?
Wire side o{ femaleterminals
goes away with a known-goodECfvl,replacethe
originaE
l CM.t
NO Checkthe following partsfor leaks:l
YES-Repair short in the wire betweenthe EVAP
c a n i s t e vr e n ts h u tv a l v ea n dt h e E C M( E 2 1 ) . 1
o r i g i n aE
l CM.I
.
.
.
.
.
.
.
.
.
F u e l t a n k( A )
F u e lf i l l c a p ( B )
F u e lf i l l p i p e ( C )
F u e l t a n kv a p o rc o n t r o lv a l v e ( D )
F u e l t a n kv a p o rr e c i r c u l a t i ovna l v e( E )
F u e l t a n kv a p o rr e c i r c u l a t i otnu b e ( F )
F u e l t a n kv a p o rs i g n a l t u b e( G )
F u e l t a n kv a p o rc o n t r o lv e n t t u b e ( H )
FTPsensor(J)
- R e p a i ro r r e p l a c ea n y l e a k i n gp a r t s .
11-179
EVAPSystem
DTCPl457:EVAPControlSystemLeakage
(EVAPCanisterSystem)
2. Turn the EVAPcanisterpurge valve on with the
HondaPGM Tester,or connectECMconnector
terminal 821 to body ground with a jumper wire.
The fuel system is designedto allow specified
maximum vacuum and pressureconditions.Do not
deviatefrom the vacuum and pressuretests as
indicatedin these procedures.Excessivepressure/
vacuum would damagethe EVAPcomponentsor
causeeventualfuel tank systemfailure.
ECMCONNECTOR
A I24P'
Vacuum pump/gauge,0-30 in.HgA973X-041-XXXXX
W i r e s i d eo f l e m a l et e r m i n a l s
This is a two-trip code.Once cleared,it cannot be
reproducedin one trip. Also, certainspecificdriving
and ambientconditionsmust occur beforethe ECfMwill
completethe system checks,Additionaltest drives may
still not meet the specificconditionsneededto
16^r^.1'
'^6
rh6
4 . Apply vacuum to the hose.
^^.16
Followthesetroubleshootingprocedurescarefullyto
ensurethe integrityof the system and to confirm the
causeof the problem or code.
NOTE:Freshfuel has a highervolatilitylhat creates
greaterpressure/vacuum.
The optimum conditionfor
testing is fresh fuel, and there must be lessthan a full
tank. lf possible,to assistin leakdetection,add I gallon
of fresh fuel to the tank (as long as it will not fill the
tank),just beforestartingthese procedures.
YES-Go to step 5.
NO-The EVAPcanisterpurge valve is OK. Go to
step 10.
b.
Disconnectthe EVAPcanisterpurge valve 2P
conneclor,
7 . Checkfor continuitybetweenEVAPcanisterpurge
valve 2P connectorterminal No. 2 and body ground.
EVAPCanister Purge Valve Test
1. Disconnectthe vacuum hose from the EVAP
canisterpurge valve (A),and connecta vacuum
pump to the hose.
EVAPCANISTEN
PURG€
VALVE2PCONNECTOR
-4l-fircs
ll2l
IYEL/8Lu)
(f])
I
W i r e s i d eo f f e m a l e l e r m i n a l s
ls therecontinuity?
YES-Goto step8.
4973X-041-XXXXX
NO Repairopenin thewire betweenthe EVAP
821).I
c a n i s t epru r g ev a l v ea n dt h eE C M / P C(M
s w i t c hO N( l l ) .
11-180
t
voltagebetweenEVAPcanisterpurge
9. Measure
terminalNo. 1 andbodyground.
valve2Pconnector
EVAPCANISTERPURGE
VALVE2PCONNECTOR
EVAP Bypass Solenoid Valve Test
10. Disconnectboth vacuum hosesfrom the EVAPtwo
way valve {A),and connecta vacuum pump to the
canisterport on the two way valve.
Wire side oI lemaleterminals
ls thetebatteryvoltage?
the EVAPcanisterpurgevalve.l
YES- Replace
NO Repairopenin thewire betweenthe EVAP
canisterpurgevalveandthe No.4 ACG(10A)
fuse.I
'It
Apply vacuum to the hose.
YES The EVAPtwo way/bypasssolenoid valveis
O K . G o t o s t e p1 8 .
N O - G o t o s t e p1 3 .
1 4 . Disconnectthe EVAPbypasssolenoidvalve 2P
connector.
Checkfor continuitybetweenEVAPbypass
s o l e n o i dv a l v e2 P c o n n e c t otre r m i n a lN o . 2 a n d
EVAPBYPASSSOLENOID
VALVE2P CONNECTOR
Wire sideof female terminals
(cont'd)
11-181
EVAPSystem
EVAP Canisler Vent Shut Valve Test
18. Disconnectthe vacuum hosefrom the EVAP
canistervent filter (A),and connecta vacuum pump
to the hose.
YES Go to step 16.
NO- Replacethe EVAPtwo waylbypasssolenoid
valve (A).1
DisconnectECMconnectorE {31P).
to.
't7.
Checkfor continuitybetweenEVAPbypass
solenoidvalve 2P connectorterminal No. 2 and
body ground.
EVAPBYPASSSOLENOID
VALVE2P CONNECTOR
\ ,
lI l tl - 2l l
19. Turn the EVAPcanistervent shut valve on with the
HondaPGM Tester,or connectECMconnector
terminal E21to body ground with a jumper wire.
ECMCONNECTOR
E (3TP)
1 1 2 1 34 5
1/
1 5tal/la
z3lz4
zil./
2WBS
JUMPER
WIRE
-[BLU/REo)
())
I
8 9 vsv(
{LTGBN/RED)
2A21
m 31
Wiresideol lemaleterminals
20. Turn the ignitionswitch ON (ll)
2 1 .Apply vacuum to the hose.
YES Repairthe short in the wire betweenthe
EVAPbypasssolenoidvalve and the ECM{E20).f
NO Updatethe ECI\4if it does not havethe latest
software.or substitutea known-goodEClvl,then
recheck(seepage 11-6).lf the symptom/indlcation
o r i g i n aE
l CM.I
YES-The EVAPcanistervent shut valve is OK. Go
to step 27.
NO Go to step 22.
2 3 . Disconnectthe EVAPcanistervent shut valve 2P
connector.
11-182
24. Checkfor continuitybetweenEVAPcanistervent
Nlo . 2 a n d b o d y
s h u t v a l v e2 P c o n n e c t o r t e r m i n a
ground.
VATVE2P CONNECTOR
-4l-T_*u
r 2l
Canister System Leak Test
27. Turn the ignition switch oFF.
2 8 , C o n n e c t t w ot,h r e e - w a yT - f i t t i n g s( A )i n t o t h e h o s e
from the EVAPcanisterto the EVAPtwo way valve.
Connectthe FTPsensorto one of the T-fittingsand
t h e v a c u u mp u m p t o t h e o t h e l
ILTGFN/REDI
@
wn€ s de ol l€ma1e terminals
YES Go to step 25.
NO Repairopen in the wire betweenthe EVAP
c a n i s t e vr e n ts h u tv a l v ea n dt h e E C I V(IE 2 1 ) . 1
25. T u r nt h e i g n i t i o ns w i t c ho N ( l l ) .
26. Measurevoltage betweenEVAPcanistervent shut
v a l v e2 P c o n n e c t otre r m i n a lN o . 1 a n d b o d yg r o u n d .
VENTSHUT
EVAPCANISTER
VALVE2PCONNECTOR
29. Removethe vent hosefrom the EVAPcanistervent
shut valve (A),and cap the port (B)to sealthe fresh
air vent of the EVAPcanister.
Wlreside oflem. € rerm na s
YES Replacethe EVAPcanistervent shut valve
( A )a n d t h e o - r i n g( B ) . I
NO Repairopen in the wire betweenthe EVAP
c a n i s t e vr e n ts h u tv a l v ea n dt h e N o . 4 A C G ( 1 0 A )
fuse.I
(cont'd)
11-183
EVAPSystem
I
31. While monitoring FTPsensorvoltagewith the
Honda PGM Tester,or measuringvoltage between
ECMconnectorterminalsE4 and E14,slowly pump
the vacuum oumD.
ECMCONNECTOR
E 13lPI
37. While monitoringFTPsensorvoltagewith the
E C Mc o n n e c t otre r m i n a l sE 4a n d E1 4 ,s l o w l yp u m p
t h e v a c u u mp u m p .
ECMCONNECTOR
E {31PI
32. Continueto pump vacuum until the voltagedrops
to about 1.5V. Make sure the enginecoolant
temperatureis still above 95'F 135.C)and your
v a c u u mp u m p h a s n o l e a k .
38. Continueto pump vacuum until the voltagedrops
33. Monitor the voltagefor 20 seconds.
39. Monitor the voltagefor 20 seconds
Does the voltage drop 1.5V and hold for at least
20 seconds?
YES Inspectthe EVAPcanistervent shut valve
l i n ea n d c o n n e c t i o n s . l
to about 1.5V.Make sure the enginecoolant
temperatureis still above95"F (35"C)and your
vacuum pump has no leak.
Does the voltage hold for at least 20 seconds?
YES Inspeclthe fuel tank vapor control lineand
connections.I
NO Go to step 40.
NO-Go to step 34.
35. Disconnectthe quick-connectfitting (A) fromthe
EVAPcanister,and plug the canisterport {B).
11-184
4 1 .Disconnectthe purge line hose {A) from the
c a n i s t e ar t t h e m e t a ll i n e a n d p l u gt h e h o s e( B ) .
43. While monitoringFTPsensorvoltagewith the
ECMconnectorterminalsE4 and E14,slowly pump
t h e v a c u u mp u m p .
E {31P)
ECMCONNECTOR
4 4 . Continueto pump vacuum until the voltagedrops
to about 1.5V.Make sure the enginecoolant
temperatureis still above 95'F (35'C)and your
v a c u u mp u m p h a sn o l e a k .
45. Monitor the voltagecontinuouslyfor 20 seconds.
Does the voltage drop to 1.5 V and hold f or at
least 20 seconds?
YES Inspectthe EVAPcanisterpurge valve line
and connections.lf they are OK, perform the EVAP
two way valvetest (seepage 11-186)and the fuel
tank vapor controlvalve test (seepage 1'l-187)l
NO-Replace the EVAP canister
( s e ep a g e1 1 - 1 8 9 ) . 1
11-185
EVAPSystem
EVAPTwo Way ValveTest
. V a c u u mp u m p / G a u g e , 0 - 3 0i n . H g
A973X-041-XXXXX
. Vacuum/Pressure
cauge.0-4 in. Hg 07JAZ-0010008
4. Move the vacuum pump hosefrom the vacuum
fitting to the pressurefitting,and move the vacuum
gauge hosefrom the vacuum side to the pressure
side (A) as shown.
1 . R e m o v et h e f u e l f i l l c a p .
2. Disconnectthe vapor line from the EVAPtwo way
valve (A).Connectit to a T-fitting(B)from the
v a c u u mg a u g ea n d t h e v a c u u mp u m p a s s h o w n ,
07JAZ-0010008
Slowly pressurizethe vapor line while watchingthe
gauge.The pressureshould stabilizemomentarilV
a b o v e1 . 0k P a( 8 m m H g ,0 . 3i n . H g ) .
Apply vacuum slowly and continuouslywhile
watchingthe gauge.The vacuum should stabilize
m o m e n t a r i l ya t 0 . 8 2 . 1 k P a( 6 1 6 m m H g ,
0 , 2 0 . 6i n . H g ) .
lf the vacuum stabilizes{valveopens)below 0.8 kpa
( 6 m m H g , 0 . 2i n . H g )o r a b o v e2 . 1k P a( 1 6m m H g ,
0.6 in.Hg),installa new valve and retest.
11-186
. lfthe pressuremomentarilystabilizes(valve
o p e n s )a b o v e1 . 0k P a( 8 m m H g , 0 . 3i n . H g )t,h e
v a l v ei s O K .
. lf the pressurestabilizesbelow 1.0 kPa(8 mmHg,
0.3 in.Hg),installa new valve and retest.
FuelTankVaporControlValveTest
0-30 in. HgA973X-041-XXXXX
VacuumPump/Gauge,
FloatTest
1 . M a k es u r et h e f u e lt a n ki s l e s st h a n h a l ff u l l .
ValveTest
1 . N 4 a kseu r et h e f u e lt a n ki s l e s st h a n h a l ff u l l
2 . R e m o v et h e f u e l f i l l c a p .
3. Disconnectthe fuel tank vapor signaltube (A).
2. Removethe fuel fill cap to relievefuel tank
pressure,then reinstallthe cap.
3. Disconnectthe fuel tank vapor recirculationtube
t v a c u u mP u m Pt o i t .
{ A ) ,a n d c o n n e c a
4 . Disconnectthe vacuum hoses(A) from the EVAP
canister(B),then plug the ports with plugs (C)
A973X-041-XXXXX
P l u gt h e l i n e( B ) .
5 . Apply vacuum to the fuel tank vapor recirculation
tuDe.
lf the vacuum holds, replacethe fuel tank vapor
c o n t r o lv a l v e( s e ep a g e1 1 - 1 8 9 ) .
lf the vacuum does not hold, the float is OK. Do
the valve test.
A973X-O41-XXXXX
5. Disconnectthe vacuum hose (D)from the EVAP
canistervent shut valve (E),and connecta vacuum
pump to the vacuum hose.
6 . P u m pt h e v a c u u mp u m p 8 0 t i m e s .
. l f t h e v a c u u mh o l d s ,g o t o s t e P7 .
. l f t h e v a c u u md o e sn o 1h o l d ,g o t o s t e p 1 0 .
(cont'd)
11-187
EVAPSystem
FuelTankVaporControlValveTest (cont'd)
7. Connecta secondvacuum pump to the fuel tank
v a p o rs i g n a l t u b e( A ) .
Fill the fuel tank with fuel, then checkfor fuel in the
EVAPtwo way valve (A),and fuel tank vapor
recirculationhose (B).
NOTE:At either location,tiny dropletsof fuel are
normal.
. lf fuel runs out of th e hosesat either location,
replacethe fuel tank vapor control valve.
. l f t h e f u e l d o e sn o t r u n o u t o f t h e h o s e s t, h e f u e l
tank vapor systemfunction is normal.
8. Apply vacuum (1 pump) to the fuel tank vapor
signaltube (A).then checkthe vacuum on the
pump in step 6.
. lf the vacuum holds,replacethe fueltank vapor
c o n t r o lv a l v e{ s e ep a g e1 1 - 1 8 9 ) .
. If the vacuum is released,goto step 9.
Checkfor fuel rirnningout.
Checkfor fuel runningout.
1 0 .Disconnectthe fuel tank vapor quickdisconnect
from the EVAPcanister,then plug lhe port on the
canister.Reapplyvacuum (80 pumps).
. lf the vacuum holds,replacethe fuel tank control
v a l v e( s e ep a g e11 - 1 8 9 ) .
. lf the vacuum does not hold, insDectthe EVAP
canistervent shut valve o-ring.lf the o-ring is OK,
replacethe EVAPcanister,and repeatstep 4.
11-188
EVAPCanisterReplacement
FuelTankVapor ControlValve
Replacement
l. Removethe vacuum hoses(A).
1 . R e m o v et h e f u e lt a n k ( s e e p a g e l l - 1 5 5 ) .
2 . R e m o v et h e f u e l t a n kv a p o rc o n t r o lv a l v e ( A )f r o m
t h e f u e lt a n k( B ) .
2. Removethe boit (B).
3. Removethe EVAPcanister(C).
3 . Installthe fuel tank vapor control valve.
4. Installin the reverseorder of removal.
'l
4 , Installthe fuel tank (seepage 1 -155).
11-189
Clutch
.........12-2
Tools
Special
I
n
d
e
x
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
. . . . . , .1. .2.-. 3
........
L
o
c
a
t
i
o
n
Comoonent
Switch,and
ClutchPedal,ClutchPedalPosition
12-4
SwitchAdiustment....................
ClutchInterlock
12-5
.....................
CfutchMasterCylinderRep|acement
12-7
.'........
SlaveCylinderReplacement
.....12-9
...................
ClutchReplacement
Clutch
a
SpecialTools
Ref. No.
(1,
@
o
@
Tool Number
OTJAF-PM7O11A
07LAB-PV001
00 or 07924-PD20003
07zAF-PR8A100
07936-3710100
Description
C l u t c hA l i g n m e n tD i s c
R i n gG e a rH o l d e r
C l u t c hA l i g n m e n tS h a f t
R e m o v e rH a n d l e
Oty
,l
1
1
1
l .
l _ l
'l-r
o
o
.{\
.tt./
'\-'/
o
I
12-2
a
""*--/
\,L_.Ei
/i
(,'.'
_,___-,-s\
SWITCH
CLUTCHINTERLOCK
page12-4
Adjustment,
PEDAL
CLUTCH
POSTTTON
SWITCH
A d j u s t m e npta, g e ' 1 2 - 4
RETAININGCLIP
Replace.
UTCHPEDAL
A d j u s t m e n tP, a g e1 2 4
O-RING
Replace.
CLUTCHMASTERCYLINDER
pagel2-5
Replacement,
CLUTCHDISC
Bemoval,page 12-9
I n s t a l l a t i op
na
, ge'12-12
PRESSURE
PLATE
page'12-9
Removal,
l n s t a l l a t i opna,g e1 2 - 1 2
RELEASE
BEARING
B e p l a c e m epnat ,g e1 2 - 1 3
FLYWHEEL
page'12-1
1
Inspection,
page12-11
Replacement,
CLUTCHHOSE
CLIP
SLAVECYLINDER
page 12-7
Replacement,
\".rr"*"o*
12-3
Clutch
ClutchPedal,ClutchPedalPositionSwitch, and ClutchInterlockSwitch
Adjustment
NOTE:
. To checkthe clutch pedal positionswitch
(seepage 4-45).
. To checkthe clutch interlockswitch (seepage 4-6).
. Removethe driver's side floor mat beforeadjusting
the clutch pedal.
. The clutch is self-adjustingto compensatefor wear.
. lf there is no clearancebetweenthe mastercylinder
pistonand push rod, the releasebearingwill be held
againstthe diaphragmspring.which can resultin
clutchslippageor other clutch problems.
1. Loosenthe clutch pedal positionswitch locknut(A),
and backoff the clutch pedal positionswitch (B)
until it no longertouchesthe clutch pedal (C).
J
9.8 N.m
A
9.8 N.m
11.0kgf.m,7.2 lbf.ft)
o
18 N.m
{1.8kgf.m,
13 tbf.ftl
Loosenthe clutch push-rodlocknut(D).and turn
the push rod (E)in or out to get the specifiedheight
(F),stroke(G).free play (H)and disengagement
h e i g h t( l ) a t t h e c l u t c hp e d a l .
Clutch PedalStroke:
130 140 mm
( 5 . 1 2 5 . 5 1i n . l
Clutch PedalFreePlay: l0 16 mm (0.39-0.63 in.)
Clutch PedalHeight: 193 mm (7.60in.)
Disengagement
Height:
115 mm (4.53in.)
Between Floor And
Carpet Height
(ApproximateValuel: 38 mm {1.50in.l
12-4
3. Tightenthe clutch push-rodlocknut(D).
4. With the clutch pedal released.turn the clutch
pedal positionswitch (B) in until it contactsthe
clutch pedal (C).
5. Turn the clutch pedal positionswitch {B) in an
additional3/4 to 1 turn.
6. Tightenthe clutch pedal positionswitch locknut(A).
7. Loosenlocknut(J)and the clutch interlockswitch
(K).
8. Pressthe clutch pedalto the floor.
9 . R e l e a s teh e c l u t c hp e d a l1 0 ' l 6 m m ( 0 , 3 9 0 . 6 3 i n . )
from the fully pressedposition,and hold it there.
Adjust the positionof the clutchinterlockswitch (K)
so that the enginewill startwith the clutch pedal in
thls position.
10. Tightenthe clutch interlockswitch locknut(J).
ClutchMasterCylinderReplacement
NOTE:Do not spill brakefluid on the vehicle;it may
damagethe paint; if brakefluid does contactthe paint,
wash it off immediatelVwith water.
1 . P r yo u t t h e l o c kp i n ( A ) ,a n d p u l l t h e p e d a lp i n ( B )
out of the yoke. Removethe mastercylinder
mounting nuts (C).
6. Disconnectthe reservoirhose (D)fromtheclutch
mastercylinder reservoir.Plugthe end of the
reservoirhose with a shop towel to preventbrake
fluid from coming out.
7. Removethe O-ring(E)and the clutch master
cylinderseal (F)from the mastercylinder.
8. Installtheclutch mastercylinder in the reverse
order of removal.Installa new O-ring.
9. Make sure the hose clamps (A) are positionedon
the mastercylinder (B)and reservoir(C)as shown.
UP
i
R e m o v et h e a i r c l e a n e rh o u s i n gc o v e ra n dt h e a i r
cleanerhousing (seestep 6 on page 5-2).
3 . Removethe brakefluid from the clutch master
cylinder reservoirwith a syringe.
Removethe clutchline bracketfrom the frame rail,
and removethe clutch line clip.
Removethe clutch mastercylinder(A),and pull it
toward the middle of the enginecompartment.
Removethe retainingclip (B).Disconnectthe clutch
line (C).Plugthe end of the clutch line with a shop
towelto preventbrakefluid from coming out.
g-E
(cont'd)
12-5
Clutch
ClutchMasterCylinderReplacement(cont'd)
10. To preventthe retainingclip (A)from coming off,
pry open the tip of the retainingclip (B)with a
screwdriver,
1 1 .Tightenthe mastercylindermounting nuts to 13 N
m ( 1 . 3k g f m , 9 . 4 l b f . f t ) .
Bleedthe clutch masterhydraulicsystem (seestep
11 o n p a g e 1 2 - 8 ) .
N O T ET
: h e r e s e r v o ifri l l i n gi s c o v e r e di n t h e
bleedingprocedure.
l n s t a l l t h ea i r c l e a n e rh o u s i n g( s e es t e p3 7 o n p a g e
5-15).
12-6
I
SlaveCylinderReplacement
NOTE:
. U s ef e n d e rc o v e r st o a v o i dd a m a g i n gp a i n t e d
surfaces.
. D o n o t s p i l lb r a k ef l u i d o n t h e v e h i c l e i; t m a y d a m a g e
the paint; if brakefluid does contactthe paint,wash it
off immediatelywith water.
6. Removethe mounting bolts (A) andtheslave
c y l i n d e r( B ) .
1. Write down the frequenciesfor the radio's preset
buttons.Disconnectthe negative( ) cablefirst,
then the positive(+)cable from the battery.
Removethe battery.
2. Removethe batterytray.
a
7 . Removethe roll pins (C).Disconnectthe clutch line
( D ) ,a n d r e m o v et h e O - r i n g( E ) .P l u gt h e e n d o f t h e
clutch line with a shop towel to preventbrakefluid
f rom coming out.
Installtheslavecylinder in the reverseorder of
removal.Installa new O-ring (A).
R e m o v et h e a i r c l e a n e rh o u s i n gc o v e ra n dt h e a i r
c l e a n e rh o u s i n g( s e es t e p6 o n p a g e5 - 2 ) .
4 . Removethe intakeair duct (seestep 8 on page 5-3).
5 . Removethe clutch line bracket(A).
,,6NJ'
=-#.q!4sEn
(P/N08798-90021
(Brak6Assembly
Lube)
9 . P u l l t h eb o o t ( B )b a c k ,a n d a p p l yb r a k ea s s e m b l y
l u b et o t h e b o o ta n d s l a v ec y l i n d e r o d ( C ) .R e i n s t a l l
the boot.
1 0 .Apply super high temp urea grease(P/N087989 0 0 2 )t o t h e p u s h r o d o f t h e s l a v ec y l i n d e rT. i g h t e n
t h e s l a v ec y l i n d e rm o u n t i n gb o l t st o 2 2 N m ( 2 . 2
kgfm, 16lbf.ft).
(cont'd)
12-7
Clutch
SlaveCylinderReplacement(cont'd)
11. Bleedthe clutch hydraulicsystem.
. Aftach a hoseto the bleederscrew (A),and
suspendthe hose in a containerof brakefluid.
. M a k es u r et h e r ei s a n a d e q u a t es u p p l yo f f l u i d i n
the clutch mastercylinder,then slowly pump the
clutch pedal until no more bubblesappearatthe
bleederhose.
. lt may be necessaryto llmit the movement of the
releasefork (B)with a blockof wood to remove
all the air from the system.
. Tightenthe bleedscrewto I N.m (0.8kgf.m,6 lbf
ft); do not ovenightenit,
. Refillthe clutch mastercylinderwith fluid when
done.
. Always use only Honda DOT3 brakefluid.
L
12. Installthe intakeair duct (seestep 36 on page 5-14).
1 3 .I n s t a l l t h ea i r c l e a n e rh o u s i n g( s e es t e p3 7 o n p a g e
5-15).
1 4 . Installthe batterytray.
t5.
Installthe battery,connectthe positive(+) cable
first, then the negative(- ) cable.
1 6 . Resetthe frequenciesfor the radio stationpreset
buttons,
12-8
ClutchReplacement
Spscial Tools Required
. Clutchalignmentdisc 07JAF-PM701
1A
. Ringgear holder07LAB-PV00100
or
07924-PD20003
. Clutchalignmentshaft 07ZAF-PR8A100
. Removerhandle07936-3710100
2 . I n s t a l l t h es p e c i atl o o l s .
A
\-
PressurePlateand GlutchDiscRemoval
1 . C h e c kt h e d i a p h r a g ms p r i n gf i n g e r sf o r h e i g h t
using lhe speciallool and feelergauge.lf the height
is more than the servicelimit, replacethe pressure
ptate.
A-.-
nl I
\ffim
9fra-I
StandardlNewl:
ServiceLimit:
0.6 mm (0.02in.) max.
0.8 mm {0.03in.)
07zAF-PR8A100
07936-3710100
OTJAF-PM7O11A
|-
tP
07LAB-PV00100
or
07924-PD20003
plate
To preventwarping,unscrewthe pressure
patternin several
mountingbolts(A)in a crisscross
plate(B).
steps,then removethe pressure
Inspectthefingersof the diaphragmspring(A)for
wearat the releasebearingcontactarea.
5. Inspectthe pressureplate 1A)surfaceforwear,
cracks.and burning.
(cont'd)
12-9
Clutch
ClutchReplacement(cont'd)
6. Inspeclfor warpage using a straightedge (A) and
feeler gauge (B).l\4easureacrossthe pressureplate
(C).lf the warpage is more than the servicelimit,
replacethe pressureplate.
Standard{New):
ServiceLimit:
0.03mm (0.001in.) max.
0.15mm (0.006in.)
9. lvleasure th e clutchd isc th ickness.lfthethickness
is lessthan the servicelimit, replacethe clutchdisc.
StandardlNew):
ServiceLimit:
8.3 8.9 mm
(0.33 0.35in.)
6.0 mm {0.24in.)
1 0 .Measurethe rivet depthfrom the clutchdisc lining
7 . R e m o v et h e c l u t c hd i s ca n d s D e c i a l t o o l s .
1 d
surface(A) to the rivets(B)on both sides.lf the
rivet depth is lessthan the servicelimit, replacethe
c l u t c hd i s c .
Standard(New):
ServiceLimit:
I n s p e c t t h el i n i n go f t h e c l u t c hd i s cf o r s i g n so f
s l i p p i n go r o i l . l f t h e c l u t c hd i s ci s b u r n e db l a c ko r
oil soaked.reolaceit.
12-10
1.65 2.25 mm
(0.065 0.089in.)
0.7 mm (0.03in.)
L
FlywheelInspection
1. Inspectthe ring gear teeth for wear and damage.
FlywheelReplacement
1 . I n s t a l l t h es p e c i atlo o l .
2. Inspectthe clutchdisc mating surfaceon the
flywheel for wear, cracks,and burning.
3. Measurethe flywheel (A) runout using a dial
indicator(B)through at leasttwo full turns. Push
againstthe flywheel eachtime you turn it to take up
the crankshaft th rust washerclearance.lf the
runout is more than the servicelimit, replacethe
flywheel and recheckthe runout.Resurfacingthe
flywheel is not recommended.
Standard(New): 0.05mm (0.002in.) max.
ServiceLimit:
0.15mm (0.006in.)
2 . Removethe flywheel mounting bolts in a crisscross
patternin severalsteps,then removethe tlywheel.
3 . Installtheflywheel on the crankshaft,and install
the mounting bolts fingertight.
4 . I n s t a l l t h es p e c i a l t o o lt,h e nt o r q u et h e f l y w h e e l
mounting bolts in a crisscrosspatternin several
sreps.
1 2 x 1 . 0m m
103 N.m
(10,skst.m. 76 lbf ftl
(cont'd)
12-11
Glutch
ClutchReplacement(cont'dl
ClutchDiscand PressurePlateInstallation
'L
T e m p o r a r i l yi n s t a ltl h e c l u t c hd i s co n t o t h e s p l i n e s
of the transmissionmainshaft,Make sure the clutch
disc slidesfreely on the mainshaft.
2 . l n s t a l l t h er i n g g e a rh o l d e r .
pattern,
5. Torquethe mountingboltsin a crisscross
Tightenthe boltsin severalstepsto prevent
warping
spring.
t h ed i a p h r a g m
PRESSURE
PLATE
MOUNTING
BOLTTOROUE:
25 N.m{2.6kgt.m,19lbt.ft)
o
O?ZAF.PRSAIOO
\---,
/v
07936-3710100
{P/N08798-9002)
07LAB-PVo0'100
or
0792,1-PD20003
3 . Apply super high temp urea grease(P/N087989002)to lhe splines(A) of the clutch disc (B),then
installthe clutchdisc usingthe specialtools.
Removethe specialtools.
Installthe pressureplate (A) and the mounting
bolts (B)finger-tight.
12-12
1 . Make sure the diaphragmspringfingers are all the
s a m eh e i g h t .
ReleaseBearingReplacement
'L
Removethe releasefork boot (A)from the clutch
4 . Apply super high temp urea grease{P/N087989002)to the releasefork (A),the releasefork bolt
( B ) ,t h e r e l e a s eb e a r i n g( C ) ,a n d t h e r e l e a s eb e a r i n g
g ui d e ( D )i n t h e s h a d e da r e a s .
1 . 0 1 . 6g
10.04 0.06oz)
l-'..\
\\
\\
!ac
\ ) ) /
/-/
Xrl-Rl
It\'1
f-l\-._
-A
{re\
I L!),l-*E
0 . 4 1 . 0g
10.01 0.04o
"
0.t 1.09 (0.01 0.04oz)
2 . Removethe releasefork (C)from the clutch
h o u s i n g( B )b y s q u e e z i n tgh e r e l e a s ef o r k s e ts p r i n g
( D ) w i t hp l i e r s R
. e m o v et h e r e l e a s eb e a r i n g( E ) .
3 . Checkthe releasebearingfor play and noise by
p l a yo r
s p i n n i n gi t b y h a n d .l f t h e r ei s e x c e s s i v e
n o i s e ,r e p l a c et h e r e l e a s eb e a r i n gw i t h a n e w o n e .
NOTE:The releasebearingis packedwith grease.
Do not wash it in solvent.
With the releasefork slid betweenthe release
b e a r i n gp a w l s .i n s t a l l t h er e l e a s eb e a r i n go n t h e
m a i n s h a fw
t h i l e i n s e r t i n gt h e r e l e a s ef o r kt h r o u g h
t h e h o l ei n t h e c l u t c hh o u s i n g .
6 . Align the detentof the releasefork with the release
fork bolt,lhen pressthe releasefork over the
r e l e a s ef o r k b o l ts q u a r e l yM
. a k es u r et h e r e l e a s e
f o r k s e t s p r i n g( F )i s p r o p e r l ys e t .
7 . I n s t a l l t h er e l e a s ef o r k b o o t{ E ) .M a k es u r et h e b o o t
s e a l sa r o u n dt h e r e l e a s ef o r k a n d c l u t c hh o u s i n g .
8 . Move the releasefork (A) right and left to make
s u r et h a t i t f i t s p r o p e r l ya g a i n s t h e r e l e a s eb e a r i n g
( B )a n d t h a tt h e r e l e a s eb e a r i n gs l i d e ss m o o t h l y .
12-13
ManualTransmission
SpecialTools
13-2
Transmission
FluidInspection
a n dR e o 1 a c e m e. n. .t. . . . . . . . . . . .|.5-J
...-.
Back-Up
LightSwitchTest ..........t J - 5
Transmission
Removal
13-4
Transmission
Installation...........
I J-at
Transmission
Disassemblv........1 3 - 1 4
Reverse
ShiftForkClearance
lnsoection
13-19
ChangeLeverClearance
lnsoection
13-19
ChangeLeverAssembly
.......13-20
ShiftForksClearance
Inspection
13-21
ShiftForks
.......13-22
Mainshaft
Assemblv
Clearance
Inspection
13-23
't3-25
Mainshaft
Disassembly
Mainshaft
lnsoection
13-26
Mainshaft
Reassembly
| 5-2.5
Countershaft
Assemblv
Clearance
Inspection
13-31
Disassembly
Countershaft
.........13-32
Inspection.............
Countershaft
13-33
Reassembly..........
Countershaft
13-34
SynchroSleeveand Hub
Inspection
andReassembly
.... 13-39
SynchroRingandGear
Insoection
.......13-39
Mainshaft
BearingandOilSeal
R e p l a c e m e n. .t. . . . . . . . . . . . . . . . .1. .3. .-.4, .1. .
Countershaft
Bearing
ReDlacement
.. 13-42
Mainshaft
ThrustClearance
Adiustment
.....13-43
Transmission
Reassemblv.........13-46
Gearshift
Mechanism
R e p l a c e m e n. .t. . . . . . . . . . . . . . . . .1. .3. .-.5. .1. .
M/T Differential
Comoonent
LocationIndex ........13-52
Backlash
Inspection.....................
13-53
FinalDrivenGear/Carrier
Replacement
.. 13-53
... 13-54
CarrierBearings
Replacement
Oil SealReplacement
13-55
..................
Differential
ThrustClearance
Adiustment
.....13-56
ManualTransmission
SpecialTools
ToolNumber
Ref.No.
Description
E n g i n eH a n g e rA d a p t e r ,2 . 0t o 2 . 4 L i t e r
E n g i n eH a n g e r
ral
M a i n s h a fH
t older
07GAJ-PG20' ]10
07GAJ-PG20130
M a i n s h a fB
t ase
@
07JAD-P190100
O i l S e a lD r i v e r
07NAD-P20A100
Oil Seal DriverAftachment
AdjustableBearingPuller,20-40mm
07736-A01000B
ri)
07746-0010300
Driver,40 mm LD.
07746-0030100
@
Driver,30 mm LD.
07746-0030300
@
Driver
07749-0010000
@
of Mainshaft Inspection
on T
o o lS
e t .0 7 G A J - P G 2 0 1 0 2 .
Tool
Set,
'16
S l i d eH a m m e r .
M u s t b e u s e dw i t h c o m m e r c i a l lay v a i l a b l e3 / 8 "
(!l
ar\
o
o
Z-'
-4
U
@
I
o
I
rS'D
A nDr f ;
\".,i'i
\'---''
IN
@
@
-4
-a ,/
Q)-''
o
13-2
Oty
vs802c000015
vs802c000018
@
l
l
,l
Transmission
FluidInspectionand
Replacement
Back-UpLight Switch Test
1. Disconnecttheback-uplight switch (A) connector.
'1.
Parkthe vehicleon level ground,and turn the
e n g i n eO F F .
2 . R e m o v et h e o i l f i l l e rp l u g ( A )a n d w a s h e r( B ) ,c h e c k
the conditionof the fluid, and make sure the fluid is
at the proper level (C).
2 . Checkfor continuitybetweenthe back up light
s w i l c h2 P c o n n e c t o N
r o.1 andNo.2 terminals.
There should be continuitywhen the shift lever is in
reverse.
l f t h e t r a n s m i s s i ofnl u i d i s d i n y , r e m o v et h e d r a i n
p l u g( D )a n d d r a i nt h e f l u i d .
3 . lf necessary,replacethe back-uplight switch.
A p p l y l i q u i dg a s k e t( P / N0 8 7 1 8 - 0 0 0 1a)n, d i n s t a l il t
o n t h et r a n s m i s s i oh
nousing.
A
44 N.m{4.5kgt.m,
33rbr.ftl
R e i n s t a tl lh e d r a i np l u gw i t h a n e w w a s h e r ,a n d
refillthe transmissionfluid to the proper level.
Oil Capacity
1.50 (1.6US (F) at tluid change
1.70 {1.8US qt) at overhaul
Always use Honda ManualTransmissionFluid
(MTF).Using motor oil can causestiffer shifting
and noise becauseit does not containthe proper
additives.
5 . R e i n s t a tl lh e o i l f i l l e rp l u gw i t h a n e w w a s h e r .
13-3
ManualTransmission
Transmission
Removal
. E n g i n eh a n g e ra d a p t e r . 2 . t0o 2 . 4l i t e rV S B 0 2 C 0 0 0 0 1 5
. E n g i n eh a n g e rV S B 0 2 C 0 0 0 0 1 8
. Enginesupport hanger,A & RedsAAR'T 12566'
'
. SubframeadaDterEOS02C000011
* A v a i l a b l et h r o u g ht h e H o n d aT o o l a n d E q u i p m e n t
Program888-424-6857
8. Removethe cable bracket(A).then disconnectthe
c a b l e s( B )f r o m t h e t o p o f t h e t r a n s m i s s i o h
nousing.
Carefullyremove both cablesand the bracket
togetherso as not to bend the cables.
H
A
i
@
l
B
NOTE:Use fender coversto avoid damaging painted
surfaces.
1 . Write down the frequenciesfor the radio'spreset
buttons.Disconnectthe negative( ) cablefirst,
then the positive( )cable from the battery.
Removethe battery.
Removethe intakemanifoldcover {seepageg-3).
R e m o v et h e a i r c l e a n e rh o u s i n g( s e ep a g e11 - 1 6 2 ) .
4 . Removethe intakeair duct {seestep 8 on page 5-3).
Removethe batterytray (A).
9 . R e m o v et h e h a r n e s sc l i p .
I
D i s c o n n e ct h
t e t r a n s m i s s i o gn r o u n dc a b l e( B ) .
7 . Disconnectthe back-uplight switch connector(A)
a n dv e h i c l es p e e ds e n s o r( V S S )c o n n e c t o(rB ) .
13-4
10. Carefullyremovethe slavecylinderand clutchline
bracketso as not to bend the clutch line. Do not
operatethe clutch pedalonce the slavecylinder has
been removed,
12. Attach the specialtool to the threaded hole in the
c y l i n d e rh e a d .
vsB02c00001s
tJ.
1 1 .Removethe enginewire harnesscover (A) by
lifting up on the locktab (B),then slidethe harness
f o r w a r do f f t h e a i r c l e a n e rh o u s i n gm o u n t i n g
bracket{C).
I n s t a l l t h ee n g i n eh a n g e r( A ) a n d t h e e n g i n es u p p o r t
hanger {B) to the vehicle,then attachthe hook to the
sDeciaitool.
vs802c000015
1 4 . Removethe two upper transmissionmounting
bolts.
(cont'd)
13-5
ManualTransmission
Removal(cont'd)
Transmission
15. Removethe transmissionmount bracket(A) and
t r a n s m i s s i om
n o u n t i n gb o l t ( B ) .
20. Removethe three way catalyticconverter(TWC)
assembly(seestep 30 on page 5-5)
2 1 . Removethe driveshafts(seepage 16-3).
22. Removethe intermediateshaft {seepage 16-19).
23. Removethe front enginemount bracketmounting
bolt.
to.
R e m o v et h e a i r c l e a n e rb r a c k e {t C ) .
1 7 . R a i s et h e v e h i c l e a, n d m a k es u r ei t i s s e c u r e l y
supponed.
1 8 . D r a i nt h e t r a n s m i s s i o fnl u i d .R e i n s t a tl lh e d r a i nb o l t
w i t h a n e w w a s h e r( s e ep a g e1 3 - 3 ) .
24. Removethe three bolts securingthe transmission
1 9 . R e m o v et h e s p l a s hs h i e l d .
r e a rm o u n I .
db-qF
€Ds
1 3- 6
and a jack.
27. Removethe clutchcover.
---
EOS02C000011
2 8 . R e m o v et h e f r o n t e n g i n em o u n t .
26. Make referencemarks (A) on the front suspension
subframe(B)and mounting bolts (C).then remove
the front suspensionsubframe.
29. P l a c et h e t r a n s m i s s i oina c ku n d e rt h e t r a n s m i s s i o n ,
and removethe transmissionmounting bolts.
(cont'd)
13-7
ManualTransmission
TransmissionRemoval(cont'd)
TransmissionInstallation
30. Pullthe transmissionaway from the engine until
. Enginehangeradapter,2.0to 2.4 liter VS802C000015
. En g i n eh a n g e rV S 8 0 2 C 0 0 0 0 1 8
. Enginesupport hanger,A & RedsAAR-T-12566"
. subframe adaDterEoS02c000011
* Availablethrough the HondaTool and Equipment
Program888-424-6857
the transmissionmainshaftclearsthe clutch
pressureplate,then lower the transmissionon the
transmissionjack.
Removethe transmissionrear mount (A) and the
transmissionrear mount bracket{B).
\
1. Checkthe two dowel pins are installedin the clutch
h o u s nr g .
Apply super high temp urea grease(P/N087989002)to the releasefork (A) and the releasebearing
(B).Installthe releasefork and the releasebearing.
1 . 0 ' 1 . 6g
{0.04 0.06oz)
3 2 . Removethe boot (A),the releasefork {B).and the
r e l e a s eb e a r i n g( C )f r o m t h e t r a n s m i s s i o (nD ) .
0.4 1.0g {0.01 0.04ozl
3 . I n s t a l l t h et r a n s m i s s i o rne a rm o u n tb r a c k e (t A ) a n d
t h e t r a n s m i s s i o rne a rm o u n t( B ) .
't2x 1 . 2 5m m
64 N m {6.5kgf.m,
47
1 2 x 1 . 2 5m m
64 N.m
{6.5 ksf.m,
47 tbf.ft)
P l a c et h e t r a n s m i s s i o o
n n t h e t r a n s m i s s i o ina c k .
and raiseit to the engine level.
13-8
5 . I n s t a l lt h e t r a n s m i s s i o nm o u n t i n g bolts.
1 2 x 1 . 2 5m m
64 N.m 16.5kgf m.47 lbt ft)
a n da j a c k .
1 2 x 1 . 2 5m m
64 N.m (6.5kgf.m,47 lbf.ft)
6 . I n s t a l l t h ef r o n t e n g i n e m o u n t .
9 . I n s t a l l t h ef r o n t s u s p e n s i o sn u b f r a m e( A )i n i t s
originap
l o s i t i o nb y a l i g n i n gt h e m a r k s( B )y o u
made in the removal procedure,
12 x 1.25ftrn
64 N.m
(6.5 kgf m. 47 lbf.ft)
12x 1.25mm
64 N.m
(6.5kst.m,47 lbf ft)
7 . l n s t a l l t h e c l u t c hc o v e r .
1 4x 1 . 5m m
6x1.0mm
12 N.m {1.2kgI.m,9 lbf ftl
(cont'd)
13-9
ManualTransmission
Transmission
'10.
Installthethree rear mounting bolls for the
transmissionrear mount.
1 5 .Installthe transmissionmount bracket(A) and the
transmissiom
n o u n t i n gb o l t{ B ) .
6x1.0mm
12Nm
1 2 x 1 . 2 5m m
54 N.m {5.5ksf.m, 40lbf.ft)
12x 1.25nn
54 N.m
(5.5kgf.m,
40 tbt.ft)
/t':::=
-)
12 x 1.25 mm
54 N.m
(5.5kgf.m,
40 tbf.ftl
1 6 . Installthe air cleanerbracket(C).
10 x 1.25mm
59 N.m(6.0kgf.m,43tbf.ft)
1 7 . Installthe two uppertransmissionmounting bolts.
1 1 .Looselytighten the front engine mount bracket
mounting bolt.
12x 1.25mrn
64 N.m(6.5kgt.m,47lbf.ftl
12. Installthe intermediateshaft (seepage 16-24).
t5.
Installthedrivershafts(seepage 16-17).
1 4 . lnstallthe three way catalyticconverter(TWC)
assembly(seestep 17 on page 5-12).
13-10
1 8 . R e m o v et h e e n g i n eh a n g e ra n d s p e c i atlo o l f r o m
engrne.
19. Tightenthe front engine mount bracketmounting
bolt.
'12x 1.25mm
64 N.m 16.5kgf.m,
il7 lbf.ft)
21. lnstallthe brakeboosterand EVAPline bracket
mounting bolts (A).and air cleanerhousing bracket
m o u n t i n gb o l t ( B ) .T i g h t e nt h e a i r c l e a n e rh o u s i n g
bracketmounting bolt (C),and installthe water
pipe mounting bolt (D).
A
9.8N.m
( 1 , 0k q f
2 0 . I n s t a ltl h e s p l a s hs h i e l d .
22N.m
l2.2kglm,
16rbt.ft)
%,
9.8Nm
(1.0kgf m.
'B
7.2tbl{rl
22Nm
{2.2kgf m, 16 lbf ft)
22. I n s t a l l t h ee n g i n eh a r n e s sc o v e r .
(cont'd)
13-11
ManualTransmission
Transmission
Applysuperhightemp ureagrease(P/N087989002)to the endof the slavecylinderrod.Installthe
slavecylinderandthe clutchlinebracket.
Takecare
2 5 . I n s t a l l t h ec a b l eb r a c k e (t A )a n d c a b l e s( B ) .
BWZ[i:i'u'T!'*n'-'
not to bend the clutch line.
8 x 1.25mm
22 N.m (2.2 kgf.m, 16 lbf ft)
a^_
#._gEEa9En
(P/N08798-9002)
6x1.0mm
9.8 N.m
(1.0kgf.m,
7.2 tbt.ftl
lPlN 08798-9002)
2 4 . I n s t a l l t h eh a r n e s sc l i p .
26. Apply a light coat of super high temp urea grease
(P/N08798- 9002)to the cable ends.
t1
13-12
Connectthe back-uplight switch connector(A) and
t h e v e h i c l es p e e ds e n s o r{ V S S ) c o n n e c t o( B
r ).
28. Connectthe transmissionground cable (A).
8 x 1.25mm
22 N.m (2.2kgf.m, 16lbf.ft)
B
[---.-.---e
e
6x1,0mm
9.8 N.m
{1.0kgl m. 7 lbf ftl
8x125mm
22Nm
12.2kgt m, 16lbf ft)
29. lnstallthe batterytray (B).
30. Installthe intakeair duct (seestep 36 on page 5-14).
I n s t a l l t h ea i r c l e a n e rh o u s i n g( s e es t e p3 9 o n p a g e
5-15).
3 2 . Installthe intakemanifoldcover (seestep 41 on
p a g e5 - 1 5 ) .
33. Installthe battery.Connectthepositive(+) cable
first, then the negative(-)cable to the battery.
34. R e f l l l t h et r a n s m i s s i ofnl u i d ( s e ep a g e1 3 - 3 ) .
36. Checkthe clutchoperation.
3 1 .Checkthe front wheel alignment(seepage 18-4).
39. D o t h e e n g i n ec o n t r o lm o d u l e( E C M )i d l e l e a r n
13-13
ManualTransmission
Transmission
Disassembly
ExplodedView-ClutchHousing
,.Y
:
/ ,, tl
' r'<__J'.@t
j=-X ri ,1.-6
'-==-Yh,_-9
n""
-',ot/u
,tA'
v
i6
\?
q'/V^
R
-1
t3l
t€4
.!) DIFFERENTTAL
ASSEMBLY
r2lSHIFTFORKASSEMBLY
a9l6 mm FLANGEBOLT
1 2 N . m ( 1 . 2k g f m , 9 l b f f t l
..4]BEARINGsET PLATE
G, COUNTERSHAFTASSEMBLY
O NEEDLEBEARING
3 OIL GUIDEPLATEC
e 14 x 20 mm DOWELPIN
.9-iMAGNET
i.!! MAINSHAFTASSEMBLY
U 28 mm WASHER
13-14
i[, 28 mm SPRINGWASHER
iO BALLBEARING
(l 28 x 43 x 7 mm OIL SEAL
Replace.
.D REVERSE
GEARSHAFT
IDLERGEAR
1' REVERSE
f lr 6 mm SPECIALBOLT
15 N.m (1.5kgt.m, 11 lbf.ft)
(!I REVERSESHIFTFORK
.4' REVERSELOCKCAM
Q-t35 x 58 x 8 mm OIL SEAL
Replace.
?]] BACK-UPLIGHTSWITCH
29 N m (3.0kgf.m,22 lbf ftl
.?1O.RING
Replace.
(Vss)
SPEEo
sENsoR
1!)VEHICLE
.O 8 mm FLANGEBOLT
22 N.m (2.2kgf m, 16lbf.ftl
.' CLUTCHHOUSING
iI6)TRANSMISSIONHANGER
tl 10 mm FLANGEBOLT
44 N.m {4.5kgt.m,33 lbf.ft}
Housing
ExplodedView-Transmission
tt-P
@
"=-@
'\b e
P \ Bo,.
@\
rai
\€:/
z-W €:
iq
{
f /
"
O=-rl
o
dd
@------
\
o
F,z
@
,-1 _\
(g/----------__"^\
\-/r*---------..-,
HOUSING
O TRANSMISSION
O 10 mm WASHER
Replace.
@ 10 mm FLANGEBOLT
44 N.m {4.5kgf.m,33lbf.ft)
O 8 mm FLANGEBOLT
27 N.m 12.8kgf m,20lbl.ft)
.' TRANSMISSIONHANGERA
O INTERLOCKBOLT
39N m (4.0ksf.m,29lbf.ft)
O OILGUIOEPLATEM
€.172 mm SHIM
.' OIL GUTTEBPLATE
{i) 80 mm SHIM
PIN
0 8 x 14mm DOWEL
[A CHANGELEVERASSEMBLY
a06 mm FLANGEBOLT
12N m {1.2kgf.m,9lbfft}
BOLT
O DETENT
22 N.m{2.2kgf.m,16lbf.ft)
O 12mm waSHER
ReDlace.
(D SPRING
[I STEELBALL
(D TRANSMISSION
HANGERB
(9 CLUTCHLINE CLIPBRACKET
@)20 mm WASHER
Replace.
q,]FILLERPLUG
44 N m {4.5kgf.m,33 lbf.ft)
@ 40 x 56 x 8 mm OILSEAL
Replace.
qO14 mm WASHER
Replace.
q' DRAIN PLUG
39 N.m (4.0kgf.m,29 lbf.ftl
@ 32 mm SEALINGCAP
34 N m (3.5 kgf.m, 25 lbf.ft)
(cont'd)
13-15
ManualTransmission
TransmissionDisassembly(cont'd)
NOTE:Placethe clutch housingon two piecesof wood
thick enoughto keepthe mainshaftfrom hittingthe
workbench.
3, Removethe interlockbolt (A),the changelever
a s s e m b l y( B ) ,8 x 1 4 m m d o w e lp i n s( C ) ,a n d t h e
c l u t c hl i n ec l i p b r a c k e{t D ) .
1. Removethe detent bolts (A),springs,steel balls,
and back-uplight switch (B).
€
R e m o v et h e d r a i np l u g( A ) ,f i l l e rp l u g( B ) ,a n d
1 0 m m f l a n g eb o l t ( C ) .
Removethe vehiclespeedsensor(VSS)(A) and
O - r i n g( B ) .
13-16
5. Removethe 8 mm flange bolts in a crisscross
Datternin severalsteos.
10. Removethe reverselock cam.
g
t.l
(,
6 . Removethe transmissionhangerA, and
transmissioh
n a n g e rB .
Y
g
Â
1 1 .Removethe reverseidler gear {A) and reversegear
s h a f t{ B ) .
7 . R e m o v et h e 3 2 m m s e a l i n gc a p ( A ) .
E x p a n dt h e 7 2 m m s n a pr i n g ( B )o n t h e
countershaftball bearing,and remove it from the
groove using a pair of snap ring pliers.
L R e m o v et h e t r a n s m i s s i o h
n o u s i n g( C )a n d
1 4 x 2 0 m m d o w e l p i n s( D ) .
(cont'd)
13-17
ManualTransmission
TransmissionDisassembly(cont'd)
15. Removethe differentialassembly(A) and magnet
( B) .
12. Removethe reverseshift fork.
t7
t1
I
Apply vinyl tape to the mainshaftsplinesto protect
the seal,then removethe mainshaftassembly(A)
and countershaftassembly(B)with the shift forks
{ C ) f r o mt h e c l u t c hh o u s i n g( D ) .
1 4 . R e m o v et h e 2 8 m m s p r i n gw a s h e r( E )a n d 2 8 m m
w a s h e r( F ) .
13-18
1 6 . Removethe oil gutter plate (A),72mm shim (B),
a n d o i l g u i d ep l a t eM .
ReverseShift ForkClearance
Inspection
1. Measurethe clearancebetweenthe reverseidler
gear {A) and the reverseshift fork (B)with a feeler
gauge (C).lf the clearanceis more than the service
limit, go to step 2.
ChangeLeverClearanceInspection
1 . Measurethe clearancebetweenchangelever (Al
and the selectlever (B)with a feelergauge (Cf.lf
i s m o r et h a nt h e s e r v i c el i m i t ,g o r o
theclearance
step 2.
0.05 0.25 mm (0.002-0.010in.)
Standard:
0.20-0.59 mm (o.oo7 0.024 in.l
Standard:
ServiceLimit: r.3 mm {0.051in.)
2. Measurethe groove of the changelever'
Measure the width of the reverseshift fork.
. l f d i s t a n c ei s n o t w i t h i n t h e s t a n d a r dr ,e p l a c e t h e
reverseshift fork with a new one.
. lf distanceis within the standard,replacethe
reversegear wrln a new one.
Standard: 13.4 13.7mm (0.527 0.539in.l
I
. lf distanceis not within the standard,replacethe
c h a n g el e v e rw i t h a n e w o n e .
. l f d i s t a n c ei s w i t h i n t h es t a n d a r dr,e p l a c e t h e
selectlever with a new one.
Standard: 1 5 . 0 0 1 5 . 1 0m m ( 0 . 5 9 1 - 0 . 5 9 4i n . )
,tl
qI
I
13-19
ManualTransmission
ChangeLeverAssemblyDisassembly/Reassembly
Priorto reassembling,clean all the parts in solvent,dry them, and apply lubricantto any contactsurface.
@).1
l L
r rrl
BREATHER
CAP
Turnthe arrowtowardthe{ront
andinstallit.
o{thevehicle,
LEVER
SELECT
Becarefulnotto damagethedustseal
w h e ni n s t a l l i ni tg.
I
l
DUSTCOVEB
I
a^^
7 Fr"irr6-rooa
SHIFTARM COVER
ROLLER
(P/N 08798-9002)
6x1.0mm
12 N.m
(1.2kgl.m,8.7 lbf.ft)
\op
(g)'
WASHER
\r'
'^
E-='1sr/2No
!-d
Fl
q
)-=^l
€2
i
-z:-=:l-':
r
tr7
-, OILSEAL
ReDlace.
sELEcr
sPntruc
(A)
,.*
tace.ix#,,l
H\
lV
/-r,s
\__/
,/
INTERLOCK
SHIFTARM
srx
SELECT
SPRING
\
,/u
/
SELECTSTOP
PLATE
9.8Nm
{1.0kgf.m,7.2 lbf.ft)
LOCKCAM
REVERSE
STRIKER
13-20
Shift ForksGlearanceInspection
NOTE:The synchrosleeveand synchrohub should be
replacedas a set.
1. Measure the clearancebetweeneach shift fork (A)
and its matchingsynchrosleeve(B).lf the
clearanceexceedsthe servicelimit, go to step 2.
3. Measurethe clearancebetweenthe shift fork (A)
and the shift arm (B).lf the clearanceexceedsthe
servicelimit, go to slep 4.
0.2-0.5 mm (0.007 0.020in.)
Standard:
Standard:
0.35 0.65 mm {0.014 0.026in.1
ServiceLimit: 1.0 mm 10.039in.l
4 . Measurethe width of the shift arm.
A
2 . l\4easurethe thicknessof the shift fork fingers.
. l f t h e t h i c k n e s s otfh e s h i f tf o r k f i n g e ri s n o t
within the standard,replacethe shift fork with a
new one.
. l f t h e t h i c k n e s s otfh e s h i f tf o r k f i n g e ri s w i t h i n
the standard,replacethe synchrosleevewith a
new one.
. l f t h e w i d t h o f t h e s h i f t a r mi s n o t w i t h i n t h e
standard,replacethe shift arm with a new one.
. l f t h e w i d t h o f t h e s h i f ta r m i s w i t h i n t h es t a n d a r d ,
replacethe shift fork and shift piecewith a new
one.
Standard: 16.9-17.0 mm (0.665-0.669in.)
Standard:7.4 7.6 mm (0.29-0.30 in.)
13-21
ManualTransmission
Shift ForksDisassembly/Reassembly
Priorto reassembling,clean all the parts in solvent,dry them, and apply lubricantto any contactparts.
sTH SHIFTFORK
PINDRIVER,
5 mm
13-22
MainshaftAssemblyClearanceInspection
NOTE:lf replacementis required,always replacethe
synchrosleeveand hub as a set.
1. Supportthe bearinginner racewith an appropriate
sizedsocket(A).and push down on the mainshaft
(B).
4. Measurethe clearancebetween4th gear (A) and
t h e d i s t a n c ec o l l a r( B )w i t h a d i a l i n d i c a t o (r C ) .
. lf the clearanceis more than the servicelimit, go
to step 5.
. lf the clearanceis within the servicelimit, go to
step 7.
Standard:
ServiceLimit:
0.06 0.16 mnl
(0.002 0.006in.)
0.25mm {0.010in.)
Measurethe clearancebet\iveen2nd (C)and 3rd (D)
gearswith a feelergauge {E).
. l f t h e c l e a r a n c ies m o r et h a nt h e s e r v i c el i m i t .g o
to step 3.
. lf the clearanceis within the servicelimit, go to
step 4.
MeasuredistanceO on the distanceco[ar.
Standard:
ServiceLimit:
0.06 0.16mm
{0.002 0.006in.l
0.25 mm (0.010in.l
. lf distance't is notwithin the standard,replace
the distancecollarwith a new one.
. lf distancee is within the standard,go to step 6.
Measurethe thicknessof 3rd gear.
Standard:
. lf thethickneso
s f 3 r d g e a r i s l e s s t h a n t h es e r v i c e
l i m i t ,r e p l a c e3 r d g e a r w i t ha n e w o n e .
. lf thethickneso
s f 3 r dg e a r i s w i t h i n t h e s e r v i c e
limit, replacethe 3rd/4thsynchrohub with a new
one.
Standard:
ServiceLimit:
24.03 24.08mm
{0.946-0.9/uin.}
23.92-23.97 mm
(0.941 0.944in.)
23.80mm (0.937in.)
(cont'd)
13-23
ManualTransmission
MainshaftAssemblyClearanceInspection(cont'd)
6. Measurethe thlcknessof 4th gear.
. lf thethickneso
s f 4 t h g e a ri s l e s s t h a n t h e s e r v i c e
limit, replace4th gear with a new one.
. l f t h e t h i c k n e s s o4f t h g e a r i s w i t h i nt h e s e r v i c e
limit. replacethe 3rd/4thsynchrohub with a new
one.
Standard:
ServiceLimit:
8. MeasuredistanceO on the distancecollar.
. l f d i s t a n c eO i s n o t w i t h i n t h e s t a n d a r dr ,e p l a c e
the distancecollar with a new one.
' l f d i s t a n c e Oi s w i t h i n t h es t a n d a r dg, o t o s t e p 9 .
Standard:
24.03 24.08mm
(0.946 0.947in.)
23.92 23.97mm
(0.941 0.944in.)
23.80mm (0.937in.)
9. Measurethe thicknessof 5th gear.
7. l\4easure
the clearancebetweenthe distancecollar
( A )a n d s t h g e a r( B )w i t h a d i a l i n d i c a t o (r C ) .l f t h e
clearanceis more than the servicelimit. go to step
i s w i t hi n t h e s e r v i c el i m i t ,g o t o
8.lf theclearance
steD10.
Standard:
ServiceLimit:
13-24
0.06 0.16mm
(0.002-0.006in.)
0.25 mm (0.010in.)
. l f t h e t h i c k n e s s o5f t h g e a r i s l e s s t h a n t h e s e r v i c e
limit, replace5th gear with a new one.
. lf the thicknessof sth gear iswithin the service
limit. replacethe 5th synchrohub with a new one.
Standard:
Service Limit:
23-92 23.97mm
10.9410.944in.l
23.80mm (0.937in.l
MainshaftDisassembly
'10.
M e a s u r et h e t h i c k n e s so f t h e M B S d i s t a n c ec o l l a r .
. l f t h et h i c k n e so
s f M B S d i s t a n c ec o l l a ri s l e s s
than the standard,replacethe MBS distance
c o l l a rw i t h a n e w o n e .
Standard:
1 . R e m o v et h e a n g u l a rb a l l b e a r i n g( A )a n d t h e
taperedcone ring using a commerciallyavailable
b e a r i n gs e p a r a t o{rB )a n d a c o m m e r c i a l l a
yvailable
b e a r i n gp u l l e r{ C ) .B e s u r et h e b e a r i n gs e p a r a t oirs
u n d e rt h e t a p e r e dc o n er i n g .
23.95 24.05mm
{0.9(3 0.947in.)
E-f
Support5th gear (A) on steel blocks,and pressthe
mainshaftout of the sth synchrohub (B).Use of a
jaw-typepuller can damagethe gear teeth.
(cont'd)
13-25
ManualTransmission
MainshaftDisassembly(cont'dl
3. Supportthe 3rd gear (A) on steel blocks,and press
the mainshaftout of the 3rd/4thsynchrohub (B).
Use of a jaw-type puller can damagethe gear teeth.
MainshaftInspection
1. Inspectthe gear surfaceand bearingsurfacefor
w e a r a n d d a m a g et,h e n m e a s u r et h e m a i n s h a fat t
pointsA, B, C, D, and E. lf any part of the mainshaft
is lessthan the servicelimit, reDlaceit with a new
on e .
Standard:
A Ball bearingsurface(transmissionhousingside):
2 7 . 9 8 7 2 8 . 0 0 0m m ( 1 . 1 0 1 9 1 . 1 0 2 4 i n . )
B Distance collar surtace:
31.984 32.000mm {1.2594 1.2598in.)
C Needle bearing surlace:
38.984-39.000mm (1.53/t8 1.5354in.)
D Ball bearingsurface(clutchhousingside):
2 7. 9 7 7- 2 7 . 9 9 0m m ( 1 . 1 0 1 5 1 . 1 0 2 0 i n . )
E Bushing surface:
20.80 20.85mm (0.819 0.821in.)
ServiceLimit;
A : 2 7 . 9 3m m 1 1 . 1 0 i0n . l
B: 31.93 mm |.1.257in.l
C: 38.93mm 11.533in.l
Di 27.92mm {1.099in.l
E: 20.75mm 10.817in.l
{
13-26
2. Inspectthe runout by supponing both ends of the
mainshaft.Rotatethe mainshafttwo complete
revolutionswhen measuringthe runout. lf the
runout is more than the servicelimit. reolacethe
mainshaftwith a new one.
Standard:
0.02mm (0.001in.) max.
13-27
ManualTransmission
MainshaftReassembly
ExplodedView
A
QJ'
frfl
Y7
3RD/4TH
SYNCHRO
SLEEVE
3RD/4TH
SYNCHROHUB
ANGULAB BALL BEARING
Checkfor wear and operation.
Note the directionof
installation.
TAPEBEDCONERING
MBS DISTANCECOLLAR
SYNCHRO
SPRING
SYNCHROSLEEVE
SYNCHRORING
NEEDLE
BEARING
Checkfor wearandoperation.
MAINSHAFT
NEEDLEBEARING
Checkfor wear and operation.
\
(
GEAR
4TH/5TH GEAB DISTANCECOLLAR
SYNCHRORING
SYNCHROSPRING
a
13-28
SpecialTools Required
. D r i v e r , 4 0m m 1 . D . 0 7 7 4 6 - 0 0 3 0 1 0 0
. Attachment,30mm l.D.07746-0030300
6. Installthe3rd/4thsynchrosleeve(A) by aligning
the stops (B)with the 3rd/4thsynchrosleeveand
hub. After installing,checkthe operationof the 3rd/
4th synchrohub set.
this procedure.
'1.
Cleanall the parts in solvent,dry them, and apply
lubricantto all contactsurfacesexceptthe 3rd/4th
and 5th synchrohubs.
@--
2. I n s t a l l t h en e e d l eb e a r i n ga n d 3 r d g e a ro n t h e
mainshaft.
I n s t a l l t h es y n c h r or i n g a n dt h e s y n c h r os p r i n g .
4 . I n s t a l l t h e3 r d / 4 t hs y n c h r oh u b ( A ) b y a l i g n i n gt h e
synchroring fingers (B)with 3rd/4thsynchrohub
grooves(C).
-A
lnstallthe 3rd/4thsynchrohub {A) usingthe special
tool.
7 . I n s t a l l t h es y n c h r os p r i n g( A ) .
I n s t a l l t h es y n c h r or i n g ( B )b y a l i g i n gt h e s y n c h r o
cone fingers (C)with 3rd/4thsynchrohub grooves
(D).
9 . I n s t a l l t h e4 t h g e a r ,n e e d l eb e a r i n gd, i s t a n c ec o l l a r ,
n e e d l eb e a r i n ga, n d s t h g e a r .
07746-0030100
(cont'd)
13-29
ManualTransmission
MainshaftReassembly(cont'dl
1 0 . I n s t a l l t h es y n c h r or i n g a n d t h e s y n c h r os p r i n g .
1
\
1 4 . I n s t a l l t h es y n c h r os p r i n g( A ) .
'1.
I n s t a l l t h es t h s y n c h r oh u b ( A )b y a l i g n i n gt h e
synchrocone fingers (B)with sth synchrohub
grooves(C).
t5.
12. I n s t a l l t h e5 t h s y n c h r oh u b ( A )u s i n gt h e s p e c i a l
tools.
I n s t a l l t h es y n c h r or i n g ( B )b y a l i g n i n gt h e s y n c h r o
cone fingers (C)with sth synchrohub grooves(D).
1 6 . I n s t a l l t h eM B S d i s t a n c ec o l l a ra n dt h e t a p e r e d
c o n er i n g .
1 1 . I n s t a l l t h en e w b a l l b e a r i n g{ A ) u s i n gt h e s p e c i a l
t o o l sa n d a p r e s s( B ) .
U
07746-0030100
07746-0030300
07746-0030100
1 3 . I n s t a l l t h e5 t h s y n c h r os l e e v e .
\.
13-30
1
CountershaftAssemblyClearancelnspection
1 . Measurethe clearancebetweenthe 1st gear (A)
a n dt h e d i s t a n c ec o l l a r( B ) w i t ha f e e l e rg a u g e( C ) .
3. Measure the thicknessof the 1st oear.
. lftheclearance
i s m o r et h a nt h e s e r v i c el i m i t ,g o
to step 2.
. lftheclearance
i s w i t h i nt h e s e r v i c el i m i t .g o t o
step 4.
. l f t h e t h i c k n e s s o lfs t g e a r i s l e s s t h a n t h es e r v i c e
l i m i t ,r e p l a c el s t g e a r w i t h a n e w o n e .
. lf the thicknessof '1stgear is within the service
limit, replacethe lst/2nd synchro hub with a new
one.
Standard:
0.06 0.16mm 10.002 0.006in.l
ServiceLimit: 0.25 mm (0.010in.l
22-92 22.97 mm 10.902 0.904 in.l
Standard:
ServiceLimit; 22.87mm {0.900in.)
2. fvleasurethe thicknessof the distancecollar.
. l f t h e t h i c k n e s iss n o t w i t h i nt h e s t a n d a r dr,e p l a c e
t h e d i s t a n c ec o l l a rw i t h a n e w o n e .
' lf the thicknessis within the standard,go to
Standard:
23.03 23.08mm (0.907 0.909in.l
4. Measurethe clearancebetweenthe 2nd gear (A)
a n d 3 r d g e a r( B )w i t h a f e e l e rg a u g e( C ) .l f t h e
clearanceis more than the servicelimit, go to
steD5.
Standard:
0.06 0.16 mm (0.002 0.006in.)
ServiceLimit: 0.25mm {0.010in.l
(cont'd)
13-31
ManualTransmission
CountershaftAssemblyClearance
Inspection(cont'd)
CountershaftDisassembly
1 . Securelyclamp the countershaftassemblyin a
benchvlse with wood blocks.
5. Measurethe th icknessof the distancecollar.
. l f t h e t h i c k n e s si s n o t w i t h i nt h e s t a n d a r dr,e p l a c e
the distancecollar with a new one.
. l f t h e t h i c k n e s si s w i t h i n t h es t a n d a r dg, o t o
step 6.
Standard:
28.03 28.08mm {1.104-1.106in.)
Removethe specialbolt (left-handthreads).
Supportthe ball bearing(A) on steel blocks,then
use a press (B)and an attachment(C)to pressthe
countershaftout of the ball bearing.
6. Measurethe thicknessof the 2nd qear.
. lf thethickneso
s f 2 n d g e a r i s l e s s t h a nt h e
servicelimit, replace2nd gear with a new one.
. l f t h e t h i c k n e s s o2f n d g e a r i s w i t h i n t h e s e r v i c e
limit, replacelhe 1sV2ndsynchro hub with a new
one.
27-92-21.97 mm|.1.099 1.r01 in.l
Standard:
ServiceLimit: 27.87mm 11.097in.)
4 . R e m o v et h e 3 5 m m s h i m a n d d i s t a n c ec o l l a r .
I
13-32
Countershaftlnspection
5. Support4thgear(A)on steelblocks,thenusea
(B)to pressthe
pressandan attachment
(C)
countershaft out ofthe 5thgear.
1. Inspectthe gear surfaceand bearingsurfacefor
w e a r a n d d a m a g e t, h e n m e a s u r et h e c o u n t e r s h a f t
at pointsA, B, and C. lf any part of the countershaft
is lessthan the servicelimit, replaceit with a new
one.
Standard:
A Ballbearingsurfaceltransmissionhousingsidel:
3 0 . 0 2 0- 3 0 . 0 3 3m m { 1 . 1 8 1 9 1 . 1 8 2 4 i n . )
B Distancecollar surface;
39.937- 39.950mm 11.5723 1.572Ain.l
C Needlebearingsurface(clutchhousingside):
3 5 . 0 0 0 3 5 . 0 1 5m m { r . 3 7 8 0 - 1 . 3 7 8 5i n . )
Service Limit:
A : 2 9 . 9 7m m { 1 . 1 8 0i n . )
B: 39.88mm {1.570in.l
C: 34.95mm {1.376in.)
6 . Support2nd gear (A) on steel blocks,then use a
Dressand an attachment{B}to pressthe
countershaft(C)out of the 3rd gear.
2 . lnspectthe runout by supportingboth ends of lhe
countershaft.Rotatethe countershafttwo complete
revolutionswhen measuringthe runout. lf the
runout exceedsthe serviceIimit, replacethe
countershaftwith a new one.
Standard:
ServiceLimit:
0.02mm (0.001in.) max.
0.05mm (0.002in.)
13-33
ManualTransmission
CountershaftReassembly
ExplodedView
SPECIAL
BOLT
Eeplace.
(
1 1 8N . m 1 2k g fm ,8 7l b ff t )
REVERSE
GEAR
BALL BEARING
Checkfor wear and
operation.
Note the directionof installation.
1ST/2ND
SYNCHRO
HUB
35 mm SHIM
SPRING
TRIPLECONESYNCHRO
ANCE COLLAR
GEAR
4THGEAR
1STGEAR
NEEDLE
BEARING
Checkfor wear
anoopera!on.
DISTANCECOLLAR
Checkfor wear and
operation.
DISTANCECOLLAR
FRICTIONDAMPER
Checkfor wear and damage.
(
COUNTERSHAFT
TRIPLECONESYNCHRO
SYNCHROSPRING
(
13-34
. Driver,40 mm l.D.07746-0030100
. Aftachment.30
mm 07746-0030300
6 . I n s t a l l t h es y n c h r os p r i n g( A ) .
NOTE:Referto the Exploded
Viewas neededduring
lhis procedure.
1. Cleanall partsin solvent,dry them,andapply
lubricanttoall contactsurfaces.
I n s t a l l t h ed i s l a n c ec o l l a r ,n e e d l eb e a r i n ga, n d 1 s t
gear onto the countershaft.
3 . Installthe triple cone synchroassembly(A) by
'lst gear
aligningthe synchrocone fingers (B)with
grooves(C),then installthe synchrospring {D).
1 . lnstallthe triple cone synchroassembly(B) by
aligningthe synchrocone fingers (C)with the
1sv2ndsynchro hub grooves(D).
8 . Installthedistancecollar (A) and friction damper
(B) by aligningthe friction damper fingers (C)with
the 1sv2ndsynchro hub grooves(D).
'1st/2nd
Installthe
s y n c h r oh u b ( A ) b y a l i g n i n gt h e
synchrocone fingers (B)with 1sV2ndsynchrohub
grooves(C).
5 . I n s t a l l t h er e v e r s eg e a r .
(cont'd)
13-35
ManualTransmission
L,
CountershaftReassembly(cont'dl
1 2 . I n s t a ltlh e 4 t h g e a r( A )u s i n gt h e s p e c i a l t o oal n d a
press(B).Do not exceedthe maximum pressure.
9 . I n s t a ltl h e n e e d l eb e a r i n g .
1 0 .I n s t a l l t h e2 n d g e a r( A )b y a l i g n i n gt h e s y n c h r o
cone fingers (B)with znd gear grooves(C).
B
14,700
N {1,500
kgt,
3,307lbf) max.
07746-0030100
'l
1 . Supoortthe countershaft(A) on the steel blocks,
t h e n i n s t a ltl h e 3 r d g e a r( B )u s i n gt h e s p e c i atlo o l
and a press(C).Do not exceedthe maximum
Dressure.
14,700N (1,500kgf,
3,307lbflmax.
07746-0030100
13-36
I n s t a l l t h e5 t h g e a r( A )u s i n gt h e s p e c i atl o o l a n d a
press(B).Do not exceedthe maximum pressure.
14,700N (1.500kgl,
3.307lbf) max.
07746-0030100
I
1 4 . I n s t a ltlh e d i s t a n c ec o l l a r( A ) ,3 5 m m s h i m ,a n d o l d
ball bearing(B)using the specialtools and a press
(c).
16. lf the clearanceis more than the standard,selecta
new shim from the following table. lf the clearance
measuredin step 15 is within the standard,replace
o n l yt h e b a l lb e a r i n g .
35 mm Shim
B
c
D
E
F
11
J
K
L
M
N
P
o
R
t5.
Measurethe clearancebetweenthe old bearing(A)
a n dt h e 3 5 m m s h i m ( B )w i t h a f e e l e rg a u g e( C ) .
T
U
Standard: 0.04 0.10mm 10.002 0.004in.)
X
PartNumber
Thickness
23981-PPP-0000.87mm (0.0343n .
23981-PPP-9000 . 9 1m m { 0 . 0 3 5 8
n,
23982-PPP-0000 . 9 5m m ( 0 . 0 3 7 4
n.
23982-PPP-9000.99mm (0.0390n ,
23983-PPP-0001 . 0 3m m 1 0 . 0 4 0n6,
23983-PPP-9001 . 0 7m m ( 0 . 0 4 2 1n .
23984-PPP-0001 . 11 m m ( 0 . 0 4 3 7
n.
23984-PPP-9001 . 1 5m m ( 0 . 0 4 5 3
n.
23985-PPP-0001 . ' 1 9m m ( 0 . 0 4 6 9n .
n
23985-PPP-9001 . 2 3m m ( 0 . 0 4 8 4
n.
23986-PPP-0001 . 2 7m m ( 0 . 0 5 0 0
23986-PPP-9001 . 3 1m m ( 0 . 0 5 1 6i n .
23987-PPP-0001 . 3 5m m ( 0 . 0 5 3 1i n .
23987-PPP-9001 . 3 9m m ( 0 . 0 5 4 7n .
23988-PPP-0001 . 4 3m m ( 0 . 0 5 6 3i n .
23988-PPP-9001 . 4 7m m ( 0 . 0 5 7 9i n
in
23989-PPP-000 1 . 5 1m m ( 0 . 0 5 9 4
in
23989-PPP-900 1 . 5 5m m ( 0 . 0 6 1 0
23990-PPP-0001 . 5 9m m { 0 . 0 6 2i6n .
23990-PPP-9001 . 6 3m m { 0 , 0 6 4i2n .
23991-PPP-0001 . 6 7m m ( 0 , 0 6 5 7i n
Y
23991-PPP-900 1 . 7 1m m { 0 . 0 6 7 3i n
23992-PPP-0001 . 7 5m m ( 0 . 0 6 8 9i n
23992-PPP-9001 . 7 9m m ( 0 . 0 7 0 5i n
AB
23993-PPP-0001 . 8 3m m ( 0 . 0 7 2i0n
23993-PPP-9001 . 8 7m m ( 0 . 0 7 3 6i n
23994-PPP-000' 1 . 9 1m m ( 0 . 0 7 5 2i n
z
AC
AD
AE
AF
in.
23994'PPP-900 1 . 9 5m m ( 0 . 0 7 6 8
in.
23995PPP-000 1 . 9 9m m ( 0 . 0 7 8 3
{cont'd)
13-37
ManualTransmission
CountershaftReassembly(cont'd)
1 1 . Supportballbearing(A)on steelblocks(B),then
(D)to pressthe
usea press(C)andan attachment
(E)out of the ballbearing.
countershaft
20. Tightenthe new specialbolt (A) (left-handthreads).
'l18 N.m (12kgf.m,
87 tbf.ftl
1 8 . l f n e c e s s a r yi n, s t a l l t h e3 5 m m s h i m s e l e c t e di n
step 16,then recheckthe clearance,
1 9 . Installthe distancecollar (A).35 mm shim, and new
b a l l b e a r i n g( B )u s i n gt h e s p e c i a l t o o l a
s n da p r e s s
(c).
46-0030r00
13-38
SynchroSleeveand Hub Inspection
and Reassembly
1. lnspectthegearteeth on ali synchro hubs and
synchrosleevesfor roundedoff corners,which
indicatewear.
SynchroRingand GearInspection
1 . Inspectthe insideof each synchroring (A) for wear.
Inspectthe teeth (Bi on each synchro ring for wear
(roundedoff).
2. Installeach synchrohub (A) in its mating synchro
sleeve(B),and checkfor freedom of movement.Be
sure to match the three sets of longerteeth (C)(120
degreesapart)on the synchrosleevewith the three
sets of deepergrooves(D) in the synchrohub. Do
not installthe synchrosleevewith its longerteeth
in the 1sv2ndsynchrohub slots (E)becauseit will
d a m a g et h e s p r i n gr i n g .
NOTE;lf replacementis required,always replace
the svnchrosleeveand svnchrohub as a set.
Exampleof synchroring teeth
I
I
/
\
I
l
WORN
GOOD
Inspectthe teeth (C)on each synchrosleeveand
matchingteeth on each gear for wear (roundedoff).
Exampleof synchro sleeve teeth and gearteeth
t
GOOD
l
WORN
\
(cont'd)
13-39
ManualTransmission
SynchroRing and GearInspection(cont'dl
3. Inspectthe thrust surface{D)on each gear hub for
wear.
\
{
7. Measurethe clearancebetweeneach gear (A) and
i t s s y n c h r or i n g ( B )a l l t h ew a y a r o u n d .H o l dt h e
synchroring againstthe gear evenlywhile
measuringthe clearance.lf the clearanceis less
than the servicelimit, replacethe synchro ring and
gear.
Synchro Ring.to.Gear Clearance
Standard:
0.70 1.49mm 10.028 0.059in.)
ServiceLimit: 0.4 mm {0.016in.)
Inspectthe cone surface(E)on each gear hub for
wear ano rougnness.
Inspectthe teeth on all gears(F)for unevenwear,
, n dc r a c k s .
s c o r i n gg, a l l i n g a
Coatthe cone surfaceof each gear (E)with oil, and
placeits synchro ring on it. Rotatethe synchroring,
m a k i n gs u r et h a t i t d o e sn o t s l i p .
13-40
Triple Cone Synchro-to-Gear Clearance
Slandard:
O: Outer Synchro Ring {B}to SynchroCone (Cl
0-70 1.19mm (0.028-0.047in.)
@: Synchro Cone lC) to cear (A)
0.50- 1.04mm (0.020-0.041in.)
O: Outer Synchro Ring (B) to Gear (Al
0.95 1.68mm 10.037 0.066in.)
ServiceLimit:
O: 0.3 mm (0.012in.)
: 0.3 mm (0.012in.)
O; 0.6 mm 10.024in.l
\
MainshaftBearingand Oil SealReplacement
. O i l s e a ld r i v e r0 7 J A D - P 1 9 0 1 0 0
. A d j u s t a b l eb e a r i n gp u l l e r , 2 0 4 0 m m
07736-4010008
. Driver07749-0010000
. Attachment,42x 47 mm 07746-0010300
. S l i d eh a m m e r ,c o m m e r c i a l l a
yvailable
4 . Drive the new oil seal in from the transmissionside
using the specialtools.
07749-0010000
07746-0010300
1. Removethe differentialassembly,
2 . R e m o v et h e b a l l b e a r i n g( A ) f r o mt h e c l u t c h
h o u s i n g( B )u s i n gt h e s p e c i a l t o oal n d a
c o m m e r c i a l lay v a i l a b l e3 / 8 " - l 6 s l i d eh a m m e r( C ) .
Drivethe new ball bearing(A) in from the
t r a n s m i s s i o sni d eu s i n gt h e s p e c i a l t o o l .
Removethe oil seal (A) from the clutch side. Be
carefulwhen removingthe seal so the clutch
h o u s i n gi s n o t d a m a g e d .
13-41
ManualTransmission
CountershaftBearingReplacement
. Adiustablebearingpuller,20-40 mm 07736-A0tOOOB
. Oil seal driver 07JAD-AP190100
yvailable
3. Positionthe oil guide plate C and new needle
bearing(A) in the bore of the clutchhousing(B).
1. Removethe bearingset plate (A)from the clutch
I n s t a l l t h en e e d l eb e a r i n gu s i n gt h e s p e c i a l t o o l .
Installthe bearingset plate (A)wirh bolts (B).
Removethe needlebearing(A) usingthe special
tool and a commerciallyavailable3/8" - 16 slide
hammer (B),then removethe oil guide plate C.
B
6 x 1 . 0n n
12N.m{1.2kgt m,
8.7 tbf.ft)
(
07736-A010008
13-42
MainshaftThrust ClearanceAdiustment
. Mainshaftbase07GAJ-PG20130
. M a i n s h a fht o l d e r0 7 G A J - P G 2 0 1 1 0
5 . Measuredistance@ betweenthe end of the clutch
h o u s i n g( A )a n d t h e b e a r i n gi n n e rr a c e( B ) w i t ha
straightedge and depth gauge.Measureat three
locationsand averagethe readings.
1 . R e m o v et h e 7 2 m m s h i m ( A )a n d o i l g u i d ep l a t eM
from the transmissionhousing(B).
A
,5---o
v/
Shim Selection Formula:
Installthe3rd/4thsynchrohub (A),the distance
c o l l a r( B ) ,t h e 5 t h s y n c h r oh u b { C ) .d i s t a n c ec o l l a r
( D ) ,a n d b a l l b e a r i n g( E )o n t h e m a i n s h a f(t F ) ,t h e n
i n s t a l l t h ea s s e m b l e dm a i n s h a fitn t h e t r a n s m i s s i o n
h o u s i n g( G ) .
6, Selectthe proper 72 mm shim from the chan.
Follow the examplebelow, and use the
measurementsyou made in steps4 and 5:
( B a s i cF o r m u l a )
( 0 . 8* 0 . 1 1 )= s h i m t h i c k n e s s( m a x i m u m )
O+@
( 0 . 8+ 0 . 1 7 )= s h i m t h i c k n e s s( m i n i m u m )
+
O
O
. Add distanceO (step5) to distanceO (step4)
. 0 . 8m m ( 0 . 0 3 1i n ) :S p r i n gw a s h e r ,a d i m e n s i o ni n
the installation.
. 0 . 1 1m m ( 0 . 0 0 4i n ) :l v l i n i m u mt h r u s tc l e a r a n c e
. 0 . 1 7m m ( 0 . 0 0 7i n ) :M a x i m u mt h r u s tc l e a r a n c e .
( F o re x a m p l e )
2 . 3 2+ 0 . 1 5- ( 0 . 8+ 0 . 1 1 ) =1 . 5 6m m ( 0 . 0 6 1i n . )
2 . 3 2+ 0 . 1 5- ( 0 . 8+ 0 . 1 7 ) =1 . 5 0m m ( 0 . 0 5 9i n . )
lnstallthe washer (H) on the mainshaft.
T a k et h e m i d d l ev a l u eo f t h e m i n i m u mv a l u ea n d
t h e m a x i m u mv a l u e ,a n d s e l e c t h e 1 . 5 3m m
( 0 . 0 6 0i n . )s h i m .
MeasuredistanceO betweenthe end of the
transmissionhousingand washerwith a straight
edge and verniercaliper.Measureat three
locationsand averagethe reading.
{cont'd)
13-/li|
ManualTransmission
MainshaftThrust ClearanceAdjustment (cont'dl
72 mm Shim
AN
PartNumber
Thickness
2 3 9 3 1 - P 2 1 - 0 0 00 . 6 0m m { 0 . 0 2 3i6n . )
23932-P21-000 0.63mm (0.0248
in.
2 3 9 3 3 - P 2 1 - 0 0 00 . 6 6m m ( 0 . 0 2 6i0n .
2 3 9 3 4 - P 2 1 - 0 0 00 . 6 9m m ( 0 . 0 2 7 1i n .
23935-P21-000 0 . 7 2m m ( 0 . 0 2 8i3n .
23936-P21-000 0 . 7 5m m ( 0 . 0 2 9i5n .
23931-P21-000 0 . 7 8m m ( 0 . 0 3 0i7n .
23938-P2'l-000 0 . 8 1m m ( 0 . 0 3 1i9n
23939-P21-000 0 . 8 4m m ( 0 . 0 3 3i1n
23940-P21-000 0 . 8 7m m { 0 . 0 3 4 3i n ,
23941-P21-000 0.90 mm (0.0354in.
23942.P21-000 0.93mm (0.0366in.
23943-P21-000 0 . 9 6m m ( 0 . 0 3 7i8n .
23944-P21.000
0 . 9 9m m ( 0 . 0 3 9i0n .
23945-P21-000 1 . 0 2m m ( 0 . 0 4 0i2n .
23946-P21-000 1 . 0 5m m ( 0 . 0 4 1 3i n .
23941-P2't-000 'l.08mm (0.0425
in
23948-P2'l-000 ' 1. 11 m m { 0 . 0 4 3i7n
23949-P21-000 ' 1 . 1 4m m ( 0 . 0 4 4 9i n
23950-P21-000 1 . 1 7m m { 0 . 0 4 6 1n .
23951-P21-000 1.20mm 10.0472
n.
23952-P21-000 1.23mm (0.0484n .
23953-P21-000 1 . 2 6m m { 0 . 0 4 9 6
n.
23954-P21-000 1 . 2 9m m ( 0 . 0 5 0 8n .
23955-P21-000 1 . 3 2m m ( 0 . 0 5 2 0
n.
23956-P21,000 1 . 3 5m m ( 0 . 0 5 3i1n
23957-P21-000 1 . 3 8m m ( 0 . 0 5 4i3n
23958-P21-000 1 . 4 1m m ( 0 . 0 5 5 5n
23959-P21-000 1 . 4 4m m ( 0 . 0 5 6 7
n.
23960-P21-000 1.47mm (0.0579n .
2 3 9 6 1 - P 2 1 - 0 0 01 . 5 0m m ( 0 . 0 5 9 1n .
23962-P21-OOO 1 . 5 3m m ( 0 . 0 6 0 2
n.
23963-P21-000 1 5 6 m m ( 0 . 0 6 1 4n .
23964-P21-000 1 . 5 9m m ( 0 . 0 6 2 6n .
23965-P21-000 1 . 6 2m m ( 0 . 0 6 3 8i n
23966-P21-000 1 . 6 5m m ( 0 . 0 6 5i0n
23967-P21-000 1 . 6 8m m ( 0 . 0 6 6i1n
-000 1 . 7 1m m ( 0 . 0 6 7i3n .
23968-P2r
23969-P21-000 1 . 7 4m m ( 0 . 0 6 8i5n .
23970-P21-000 1 . 7 7m m ( 0 . 0 6 9i7n .
AO
2 3 9 7 1 - P 2 ' t - O O O1 . 8 0m m ( 0 . 0 7 0 9
in.
B
c
D
E
F
J
L
M
N
o
P
o
R
T
U
X
z
AB
AC
AD
AE
AF
AG
AH
AI
AJ
AK
AL
AM
7 . I n s t a l l t h e7 2 m m s h i m ( A )s e l e c t e da n d o i l g u i d e
p l a t eM i n t h e t r a n s m i s s i o h
n o u s i n g( B ) .
,6,,-o
V
8 . Thoroughlycleanthe spring washer (A) and
washer (B) before installingthem on the clutch
h o u s i n gs i d eb a l l b e a r i n g{ C ) .N o t et h e i n s t a l l a t i o n
directionof the spring washer.
{
9 . l n s t a l l t h em a i n s h a fitn t h e c l u t c hh o u s i n g .
1 0 .Placethe transmissionhousingover the mainshaft
and onto the clutchhousing.
1 1 .Tightenthe clutchand transmissionhousingswith
several8 mm bolts.
NOTE:lt is not necessaryto use sealingagent
betweenthe housings.
12. Tap the mainshaftwith a plastichammer.
13-44
13. Attachthe specialtool to the mainshaftas follows:
1 6 . Z e r oa d i a l g a u g e{ A )o n t h e e n d o f t h e m a i n s h a f t .
. B a c k - o ut th e m a i n s h a fht o l d e rb o l t{ A )a n d l o o s e n
the two hex bolts (B).
. Fit the holderover the mainshaftso its lip is
towards the transmission.
. Align the mainshaftholder'slip aroundthe
groove at the insideof the mainshaftsplines,
then tightenthe hex bolts.
07GAJ-PG20130
07GAJ-PG20130
1 4 . Seatthe mainshaftfully by tapping its end with a
p l a s t i ch a m m e r .
1 7 . Turn the mainshaftholder bolt (B)clockwise;stop
turning when the dial gauge (A) has reachedits
maximum movement.The readingon the dial
gauge is the amount of mainshaftend play
NOTE:Do not turn the mainshaftholder bolt more
than 60 degreesafter the needleof the dial gauge
stops moving,this may damagethe transmission.
1 8 .lf the readingis within the standard,the clearance
Threadthe mainshaftholder bolt in until it just
contactsthe wide surfaceof the mainshaftbase.
is correct.lf the readingis not within the standard,
recheckthe shim thickness.
Standard:0.11-0.17 mm (0.004 0.007in.)
13-45
ManualTransmission
Transmission
Reassembly
N O T E :P r i o r t or e a s s e m b l i n gc ,l e a na l l t h e p a r t si n
solvent,dry them, and apply lubricantto any contact
surfaces.
\
4. Installthe reverseshift fork.
6x1.0mm
15 N.m (1.5kgf.m,11 lbf.ft)
1. Installthe magnet (A) and differentialassembly(B).
n-",-o
l;-D
f.)
Installthe reverseidler gear (A) and reversegear
s h a f t( B )b y a l i g n i n gt h e m a r k{ C ) w i t ht h e r e v e r s e
g e a rs h a f th o l e( D ) .
Installthe 28 mm spring washer (A) and 28 mm
washer (B) over the ball bearing(C).Note the
installationdirectionof the spring washer {A).
Apply vinyl tape to the mainshaftsplines(D)to
p r o t e c t t h es e a l .I n s t a l l t h em a i n s h a fat n d
countershaft(E)into the shift forks {F}.and install
themas an assembly.
13-46
(
6 , l n s t a l l t h er e v e r s el o c kc a m .
z/
--'
€t
- 2 6 x 1 , 0m m
/ 15 N.m
/ {1 5 kgf m,
11 tbf.ft)
I
Fl g
E
8. Removethe dirt and oil f rom the tramsmission
h o u s i n gs e a l i n gs u r f a c eA. p p l y l i q u i dg a s k e t( P / N
to the sealingsurface.Be sure to seai
08718-0001)
the entirecircumferenceof the bolt holesto
preventoil leakage.
NOTE:lf 5 minuteshave passedafter applying
liquid gasket,reapplyit and assemblethe housings.
Allow it to cure at least20 minutesafter assembly
beforefilling the transmissionwith oil.
7 . Selectthe proper size72 mm shim (A) accordingto
the measurementsmade during the Mainshaft
'13-43),
Thrust ClearanceAdjustment(seepage
, nd
I n s t a l l t h eo i l g u t t e rp l a t e( B ) ,o i l g u i d e p l a t el \ 4 a
n o u s i n g( C ) .
7 2 m m s h i m i n t ot h e t r a n s m i s s i o h
- -
-Liquid gasket
{cont'd)
13-47
ManualTransmission
TransmissionReassembly(cont'dl
9 . I n s t a ltlh e 1 4x 2 0 m m d o w e lp i n s( A ) .
34 N.m
(3.5 kgf.m,
25 rbf.ft)
(
11. Lowerthe transmissionhousingthe rest of the way
as you expandthe 72 mm snap ring {C).Release
the snap ring so it seatsin the groove of the
countershaftbearing.
12. Checkthat the 52 mm snap ring is securelyseated
in the groove of the countershaftbearing.
DimensionO as instalted: 3.3 6.0 mm
{ 0 . 1 3 0 . 2 4i n . l
1 3 .Apply liquid gasket(P/N08718-0001)
to the threads
o f t h e 3 2 m m s e a l i n gc a p { D ) ,a n d i n s t a l il t o n t h e
transmissioh
nousing,
't4.
I n s t a ltl h e t r a n s m i s s i o h
n a n g e r sA . a n d B , a n d t h e
8 mm flange bolts finger-tight.
\A
e./
./
1 5 . Tightenthe 8 mm flange bolts in a crisscross
PatternIn severalsteDs.
8 x 1.25mm
27 N.m
(2.8kgf.m.
20 rbf.ft)
1 0 .Set the taperedcone ring (B)as shown. Placethe
transmissionhousingover the clutch housing,
being carefulto line up the shafts.
(t
13-48
16. Removethe dirt and oil from the shift iever cover
s e a l i n gs u r f a c eA. p p l y l i q u i dg a s k e t( P / N0 8 7 1 8 0001)to the sealingsurface.
1 9 . I n s t a l l t h ed r a i np l u g( A ) ,f i l l e rp l u g ( B ) ,a n d 1 0 m m
f l a n g eb o l t ( C )w i t h n e w w a s h e r s .
/..l-.=,'-B
g
^
44N.m
@ Ut !?iJl'.'l,''
NOTE:lf 5 minuteshave passedafter applylng
liquid gasket.reapplyit and assemblethe housings.
Allow it to cure at least20 minutesafter assembly
b e f o r ef i l l i n gt h e t r a n s m i s s i ow
n ithoil.
R\-: \
-.-t
A
39Nm
(4.0 kgf m,
33 tbl.ft)
?0,,.ru^
44 N m {4.5kgt m,33lbf.ft}
20. Installthedetent bolts (A),spring,and steel balls
with new washers.
- -
-Liquidgasket
1 7 . I n s t a l l t h e8 x 1 4 m m d o w e lp i n s( A ) .c l u t c hl i n ec l i p
b r a c k e (t B ) ,a n d c h a n g el e v e ra s s e m b l y( C ) .
{3.0kgf.m.22lbf.ft)
2 1 . A p p l y l i q u i dg a s k e t{ P / N0 8 7 1 8 - 0 0 0 1 } t oh e t h r e a d s
o i t h e b a c k - u pl i g h ts w i t c h( B ) ,a n d i n s t a l il t i n t h e
transmissioh
nousing.
6x1.0mm
12N.m(1.2kgf.m,9lbtft)
1 8 . A p p l y l i q u i dg a s k e t( P iN 0 8 7 1 8 - 0 0 0 t1o) t h e t h r e a d s
of the interlockbolt (D),and installit on the
transmissioh
nousing.
(cont'd)
13-49
ManualTransmission
TransmissionReassembly(cont'dl
(
22. Installthevehiclespeedsensor(VSS){A)and
O - r i n g( B ) .
22 N.m (2.2kgf.m,r6 lbf.ft)
{
13-50
GearshiftMechanismReplacement
\
8 x 1.25mm
22 N.m (2.2 kgf.m, 16 lbt ftl
/
,.-,'-'
KNOB
--SHIFT LEVER
8 N m {0.8ksr.m.5.8lbf.ft}
l'/
SHIFTLEVERHOUSING
{P/N 08798-9002}
SHIFTCABLECLIP
Replace.
r-LlRotatethe shift cable
t o w a r dt h e o p e n i n g .
6x1.0mm
9.8Nm
(1.0kgf.m,
7.2 tbf.fr)
COTTERPINS
{P/N 08798-9002)
qrBemovethe shift cable
from the shift leverbracket.
13-51
M/T Differential
(
\
DRIVENGEAR
Beplacement,page 13-53
\
BacklashInsoection.oaoe 13-53
Feplacemeni,paoe I 3-5-3
,<-=/
I \c1
\
13-52
=
\
/
l/
,/
,/BALL BEARING
Beplacemenl,page 13-54
I
Backlashlnspection
FinalDrivenGear/Carrier
Replacement
1 . Placethe differentialassemblyon V-blocks(A),and
installboth axles.
1. Removethe bolts (left-handthreads)in a crisscross
patternin severalsteps,then removethe final
driven gear (A)from the differentialcarrier{B).
\tt
x t . om m { t o )
1 2 1N m
(12.3kgf m,
89 rbt.ft)
M e a s u r et h e b a c k l a s h
o f b o t h p i n i o ng e a r s( B )w i t h
a dial indicator(C).lf the backlashis not within the
standard,replacethe differentialcarrier.
Standard(New):0.05 0.15mm (0.002 0.006in.)
Installthe final driven gear with the chamferon the
i n s i d ed i a m e t e fra c i n gt h e c a r r i e rA
. l i g nt h e m a r k s
o n t h e f i n a ld r i v e ng e a ra n d t h e c a r r i e rT. i g h t e nt h e
bolts in a crisscrosspatternin severalsteps.
\
13-53
M/T Differential
CarrierBearingsReplacement
Special Tool Bequired
Driver,40 mm l.D.07746-0030100
1. Checkthe carrierbearingsfor wear and rough
rotation.lf they rotatesmoothly and their rollers
show no signs of wear, the bearingsare OK,
\
3. Installthe new bearings(A)with the specialtool
and a press.Presseach bearingon until it bottoms.
There should be no clearancebetweenthe bearinos
and the carrier.
NOTE:Turn the sealed(B)side of the bearingaway
from the differentialtoinstallit.
2. Removethe carrierbearing(A) with a
c o m m e r c i a l l y - a v a i l a bbleea r i n gp u l l e r( B ) .
077i16-0030100
6
13-54
07746-0030100
{
Oil SealReplacement
. Driver07749-0010000
. Oil seal driver attachment07NAD-P20A100
4 . I n s t a l l t h en e w o i l s e a li n t h e t r a n s m i s s i o hn o u s i n q
with the specialtools.
1. Removethe differentialassembly.
2. Removethe oil seal (A) from the transmission
5 . I n s t a l l t h en e w o i l s e a li n t h e c l u t c hh o u s i n gw i t h
the specialtools.
3 . R e m o v e t h e o i sl e a l( A )f r o m t h e c l u t c hh o u s i n g( B ) .
13-55
M/T Differential
DifferentialThrust ClearanceAdjustment
SpecialToolRequired
Driver.40 mm LD.07746-0030100
1 . I n s t a lal n 8 0 m m s h i m t h a t ' st h e s a m es i z ea s t h e
one you removeo.
Installthe transmissionhousingonto the clutch
housing,then tightenthe 8 mm flange bolts in a
crisscrosspatternin severalsteps(seestep 15 on
page 13-48).
8 x 1 . 2 5m m
27 N m (2.8 kgf'm, 20 lbf.ft)
Use the specialtoolto bottom the differential
a s s e m b l yi n t h e c l u t c hh o u s i n g .
00746-0030100
2 . Installthe differentialassemblyinto the clutch
housing.
5 . Measurethe clearancebetweenthe 80 mm shim
a n d b e a r i n go u t e rr a c ei n t h e t r a n s m i s s i o h
nousing.
Standard:0
0.10mm l0 0.004in.)
-i.
w
.t
-- --
13-56
..1
:,- -=.
6. lf the clearanceis more than the standard,selecta
n e w s h i m f r o m t h e f o l l o w i n gt a b l e .l f t h e c l e a r a n c e
m e a s u r e di n s t e p5 i s w i t h i nt h e s t a n d a r dg, o t o
step 9.
80 mm Shim
Part Number
B
c
D
E
F
rt
J
tvl
N
P
o
R
Thickness
4 1 4 4 1P L 3 - 8 0 0 1 1 . 0m m ( 0 . 0 3 9 4
n.
41442-PL3-B001 1 mm (0.0433
n.
4 1 4 4 3 - P L 3 - 8 0 0 1 1 . 2m m ( 0 . 0 4 7 2
n.
4 1 4 4 4 - P L 3 - B 0 0 1 1 . 3m m { 0 . 0 5 1 2n .
4 1 4 4 5 - P L 3 - 8 10 0 1 . 4m m 1 0 . 0 5 5 1n .
4 1 4 4 6 - P L 3 - 8 0 0 1 1 . 5m m { 0 . 0 5 9 1n .
41447-PL3-8
1 0 0 1 . 6m m ( 0 . 0 6 3 0n .
4 1 4 4 8 - P L 3 - B 0 0 1 1 . 7m m { 0 . 0 6 6 9n .
4 1 4 4 9 - P L 3 - 8 0 0 1 . 8m m ( 0 . 0 7 0 9n .
41450-PL3-80001. 0 5m m ( 0 . 0 4 1 3n . )
4 1 4 5 1 - P L 3 - 8 0 0 01. 1 5m m ( 0 . 0 4 5 3n . l
41452-PL3-80001 . 2 5m m ( 0 . 0 4 9 2n . l
41453-PL3-8000 1 . 3 5m m ( 0 . 0 5 3 ' ln . )
41454-PL3-80001. 4 5m m ( 0 . 0 5 7 1n . l
41455-PL3-80001 . 5 5m m ( 0 . 0 6 1 0n . )
5 m ( 0 . 0 6 5i0n . )
41456-PL3-8000' 1 . 6m
41457-PL3-8000 1 . 7 5m m ( 0 . 0 6 8 9i n . )
7 . R e m o v et h e b o l t sa n dt r a n s m i s s i o h
nousing.
8 . Replacethe thrust shim selectedin step 6, then
recheckthe clearance.
9 . R e i n s t a tl h
l et r a n s m i s s i o n .
13-57
Driveline/Axle
.............
16-2
SpecialTools
.........................
16-3
Driveshaft
Inspection
Driveshafts
Removal
..........................
16-3
...................
16-5
Driveshafts
Disassembly
DynamicDamperReplacement
........16-8
....................
16-9
Driveshafts
Reassembly
......................
16-17
Driveshafts
lnstallation
..............
16-19
lntermediate
ShaftRemoval
Intermediate
.................................
16-20
ShaftDisassembly
lntermediate
..................................
16-22
ShaftReassembly
16-24
lntermediate
Shaftlnstallation....................................
Driveline/Axle
L
SpecialTools
Ref. No.
n]
@
o
@
t9
6)
o
(D
ToolNumber
07GAD-PH70201
07MAC-S100200
0 7N A F - S R 3 0 1 0 1
07xAc-001010A
07746-0010400
07746-0030400
07749-0010000
07947-S800100
o
t g[]
Orv
DescriDtion
B a l l J o i n tR e m o v e r2, 8 m m
Half Shaft Base
ThreadedAdapter,22 x 1.5mm
u f l v e r ,J 5 m m L U .
Driver
1
1
1
1
1
1
1
1
@
r\J ? )
\*
,0)
16-2
a
DriveshaftInspection
1. Checkthe inboardboot (A) andthe outboardboot
(B)on the driveshaft(C)for cracks,damage,leaking
grease,and loose boot bands (D).lf any damageis
found, reDlacethe boot and boot bands.
DriveshaftsRemoval
Special Tool Required
B a l l j o i n tr e m o v e r 2, 8 m m 0 7 M A C - S 1 0 0 2 0 0
1. Loosenthe wheel nuts slightly
2. Raisethe front of the vehicle,and support it with
safetystandsin the proper locations(seepage 1-8).
3. Removethe wheel nuts and front wheels.
Turn the driveshaftby hand,and make sure the
splines(E)and joint are not excessivelyloose.
Make sure the driveshaftis not twisted or cracked;
if it is, replaceit.
4 . Lift up the lockingtab (A) on the spindle nut (B),
then removethe nut.
lf the !eft driveshaftor the intermediateshaft is to
be removed,drain the transmissionfluid. Reinstall
t h e d r a i np l u g u s i n ga n e w w a s h e r( s e ep a g e1 3 - 3 ) .
H o l dt h e s t a b i l i z ebr a l l j o i n tp i n ( A )w i t h a h e x
wrench {B),and removethe flange nut (C).
Separatethe front stabilizerlink (D)from the lower
ar m .
(cont'd)
16-3
Driveline/Axle
DriveshaftsRemoval(cont'd)
7 . R e m o v et h e l o c kp i n { A ) f r o mt h e l o w e ra r m b a l l
joint castlenut (B),and removethe nut.
NOTE:
. T o a v o i dd a m a g i n gt h e b a l l j o i n t ,i n s t a l a
l hexnut
on to the threadsof the ball joint,
. Be carefulnot to damagethe balljoint boot when
installingthe remover.
\
10. Left driveshaft:Pry the inboardjoint (A)from the
differentialcasewith a prybar.Rightdriveshaft:
Drivethe inboardjoint (A) off of the intermediate
shaft with a drift and hammer. Removethe
driveshaftas an assembly.Do not pull on the
driveshaft(B),becausethe inboardjoint may come
apart.Draw the driveshaftstraightout to avoid
d a m a g i n gt h e o i l s e a l .
Left driveshaft:
a
t
07MAC-S100200
.."8
w^
'e
Separatethe ball joint from the lower arm (C)with
the specialtool (seestep 3 on page 18-19).
Be carefulnot to dislodgethe lower ball joint from
the knuckle.
9 . Pullthe knuckleoutward,and removethe
driveshaftoutboardjoint from the front wheel hub
u s i n ga p l a s t i ch a m m e r .
16-4
Right driveshaft:
Driveshafts
Disassembly
. T h r e a d e da d a D t e r . 2 x2 1 . 5m m 0 7 X A C - 0 0 1 0 1 0 A
yvailable
. Boot band pincers,commerciallyavailable
Inboard Joint Side:
1. Removethe set rlng from the inboardjoint.
Low Profile Type
Removethe boot bands.Be carefulnot to damage
the boot and dynamic damper.
. lf the boot band is a welded type (A),cut the boot
b a n d( B ) .
. lf the boot band is a double loop type (C),lift up
t h e b a n db e n d( D ) ,a n d p u s hi t i n t ot h e c l i p ( E ) .
. lf the boot band is a low profiletype (F),pinch the
b o o t b a n du s i n ga c o m m e r c i a l l a
y v a i l a b l eb o o t
b a n dp i n c e r s( G ) .
Welded Type
(cont'd)
16-5
Driveline/Axle
DriveshaftsDisassembly{cont'd)
M a k ea m a r k( A )o n e a c hr o l l e r( B )a n d i n b o a r dj o i n t
(C)to identifythe locationsof rollersand grooves
i n t h e i n b o a r dj o i n t .T h e n r e m o v et h e l n b o a r dj o i n t
on the shop towel (D).Be carefulnot to drop the
rollerswhen separatingthem from the inboard
Jornt.
8. Wrap the splineson the driveshaftwith vinyl tape
(A)to preventdamageto the boot.
9 . R e m o v et h e i n b o a r db o o t .B e c a r e f u n
l ottodamaoe
the boot.
10. Removethe vinyl tape.
N4akea mark (A) on the rollers(B) and spider (C)to
identifythe locationsof rollerson the spider,then
removethe rollers.
\
R e m o v et h e c i r c l i p{ D ) .
6 . Mark the spider (C)and driveshaft(E)to identifythe
positionof the spider on the shaft,
7 . R e m o v et h e s p i d e r( C ) .
16-6
OutboardJoint Side:
1 . R e m o v et h e b o o t b a n d s .B e c a r e f u n
l ottodamage
t h e b o o ta n d d y n a m i cd a m p e r .
. l f t h e b o o t b a n di s a n e a r c l a m p t y p e( A ) ,l i f t u p
the three tabs (B)with a screwdriver.
Wipe off the greaseto exposethe driveshaftand
t h e o u t b o a r dj o i n t i n n e rr a c e .
4 . Make a mark (A) on the driveshaft(B) at the same
positionof the outboardjoint end {C).
Ear Clamp Type
5. Carefullvclamp the driveshaftin a vise.
2 . Slidethe outboardboot (A)to the inboard ioint side.
Be carefulnot to damaoethe boot.
Removethe outboardjoint (A) usingthe special
t o o l a n da c o m m e r c i a l la
y v a i l a b l e5 / 8 " x 1 8s l i d e
h a m m e r( B ) .
7 . Removethe driveshaftfrom the vise.
(cont'd)
16-7
Driveline/Axle
DriveshaftsDisassembly(cont'dl
8. Removethe stopringtromthe driveshaft.
DynamicDamperReplacement
1 . R e m o v et h e i n b o a r dj o i n t ( s e ep a g e1 6 - 5 ) .
2, Removethe dynamic damper bands.Be carefulnot
to damagethe dynamic damper (seepage 16-5).
. l f t h e b o o l b a n di s a w e l d e d t y p e . c u t t h eb o o t
band.
. l f t h e b o o t b a n di s a d o u b l el o o p t y p e ,l i f t u p t h e
band bend, and push it into the clip.
. lfthe boot band is a low profiletype, pinch the
b o o t b a n du s i n ga c o m m e r c i a l l a
y v a i l a b l eb o o t
band pincers.
3. Wrap the splineson the driveshaftwith vinyl tape
(A)to preventdamageto the dynamic damper.
9 . Wrap the splineson the driveshaftwith vinyl tape
(A) to preventdamageto the boot.
Removethe dynamic damper. Be carefulnot to
d a m a g et h e d y n a m i cd a m p e r .
5 . Adjust the positionof the new dynamic damper to
the figure below.
1 0 . Removethe outboardboot. Be careful not to
damagethe boot.
1 1 .Removethe vinyl tape.
Left driveshaft{Directionall:
296 300mm
( 1 1 . 6 -1 1 . 8i n . )
Right driveshaft(Directionall: 301 305 mm
( 1 1 . 9- 1 2 . 0i n . l
6 . I n s t a l l t h ed y n a m i cd a m p e rb a n d( s e es t e pI o n
p a g e1 6 ' 1 2 ) .
7 . I n s t a ltlh e i n b o a r dj o i n t ( s e ep a g e1 6 - 11 ) .
16-8
DriveshaftsReassembly
ExplodedView
'02 model
SETRING
Replace.
/
0e
//ROLLER
\)
/''"oH?"'
6)
#'g!!a$il
/
YJ
.?-//
"\
,I
rr
in the
Use the greaseIncluded
inboardboot
inboard
boot set.
set
/
// /,/7\
II t,//>\
Usethe greaseincludedin the
inboardboot set.
-
l>/
I
I
.''
.'(9
{\
--.-
-<
OOUBLELOOPBAND
Replace.
/'..-:'\
.-\
|
\\1lg n
r.
.^-.1
//^\l
, \ V L/ A
r\
y
DYNAMTC
DAMPER
,/
//
DOUBLE
LOOPBAND
Replace.
STOPRING
Replace.
EAR CLAMP BANDS
JOINT
OUTBOARD
outboardboot set,
(cont'd)
16-9
Driveline/Axle
I
DriveshaftsReassembly(cont'dl
ExplodedView
'03 model
,
SET RING
/ Replace.
DOUBLE
LOOPBAND
Replace.
(Bootbandreplacement
only.)
INBOAROJOINT
ROLLEB
CIRCLIP
s l
E.
-"-,,,
@(
Usethe greaseincluded
in the nboard boot set.
(^Y \
\_,/
>
LOWPROFILE
BAND
Beplace.
Usethe greaseincluded
in the inboardboot set.
DOUBLELOOPBAND
Replace.
(Boot band replacementonly.)
DYNAMICDAMPER
OUTBOARDJOINT
at-
BOOTITPI
OUTBOARD
outboardboot set.
16-10
. Boot band tool, KD-3191or equivalent,commercially
available
. Boot band pincers,Kent-MooreJ-359'10or equivalent,
commerclallyavailable
. Boot band pincers,commercially
available
3. Installthe spider (A) onto the driveshaftby aligning
the marks (B)on the spider and the end of the
driveshaft.
this procedure.
lnboardJoint Side:
1. Wrap the splineswith vinyl tape (A)to prevent
damageto the inboardboot.
4 . Fit the circlip (C)into the driveshaftgroove.Always
rotatethe circlip in its groove to make sure it is fully
seated.
5
Installthe inboardboot onto the driveshaft,then
removethe vinyl tape, Be carefulnot to damageI n e
inboardboot.
Fit the rollers (A) onto the spider {B)with their high
shouldersfacing outward,and note these items:
' Reinstalltherollers in their original positionson
the spider by aligningthe marks (C).
. Holdthe driveshaftpointed up to preventthe
rollersfrom falling off.
(u
@\
(cont'd)
16-11
Driveline/Axle
I
DriveshaftsReassembly(cont'd)
6 . Packthe inboardjointwith thejointgrease
includedin the newdriveshaft
set.
Greasequantity
Inboardioint: 130 140g (4.6-4.9oz)
inboardboot set.
8 . Make sure the ends of the boot are sealedin the
groovesin the driveshaftand joint, then installthe
boot bands.
. For the double loop type, go to step 12.
(Replacementboot bands only)
. For the low profiletype, go to step 9.
9 . Installthe new low profile band {A) onto the boot
{B).then hook the tab (C)of the band,
7 . Fit the inboardjoint onto the driveshaft,and note
these items:
. Reinstallthe inboardjoint onto the driveshaftby
a l i g n i n gt h e m a r k s( A )o n t h e i n b o a r dj o i n ta n d
the rollers.
. Hold the driveshaftso the inboardjoint is
pointing up to preventit trom falling off.
1 0 .Closethe hook portionof the band (A) with a
commerciallyavailableboot band pincers(B),then
hook the tabs of the band.
1 1 .Installthe boot band on the other end of the boot,
and reoeatsteos9 and 10.
16-12
\
Fit the boot ends onto the driveshaftand the
inboardjoint, then installthe new double loop band
{A) onto the boot.
15. Threadthe free end ofthe band through the nose
sectionof the commerciallyavailableboot band
tool KD-3191or equivalent(A),and into the slot on
t h e w i n d i n gm a n d r e l( B ) .
P u l lu p t h e s l a c ki n t h e b a n db y h a n d
M a r ka p o s i t i o n( A )o n t h e b a n d 1 0 - 1 4 m m ( 0 . 4 0 . 6i n . )f r o m t h e c l i p { B ) .
1 6 . Placea wrench on the winding mandrelof the boot
band tool, and tightenthe band until the marked
spot (C)on the band meetsthe edge of the clip
1 7 . L i f tu Dt h e b o o t b a n dt o o l t o b e n d t h e f r e e e n d o f
the band 90 degreesto the clip. Center-punchthe
c l i o ,t h e nf o l d o v e rt h e r e m a i n i n gt a i l o n t ot h e c l i p .
(cont'd)
16-13
Driveline/Axle
DriveshaftsReassembly(cont'dl
18. Unwind the boot band tool, and cut off the excess
free end of the bandto leavea 5- 10 mm (0.2-0.4
in.) tail protrudingfrom the clip
19. Bendthe band end (A) by tapping it down with a
nammer.
NOTE;
. Make sure the band and clip do not interferewith
anythingand the band does not move.
. Removeany greaseremainingon the
surroundingsurfaces
20. Repeatsteps 12through 19 for the band on the
other end of the boot.
16-14
{
2 ' 1 .I n s t a l l t h en e w s e t r i n g .
OutboardJoint Side:
4. Insertthe driveshaft(A) into the outboardjoint (B)
until the stop ring (C)is closeto the joint.
1. Wrap the splineswith vinyl tape (A) to prevent
damageto the outboardboot.
I n s t a l l t h en e w e a r c l a m pb a n d s( B )a n d o u t b o a r d
boot,then removethe vinyl tape. Be carefulnot to
damagethe outboardboot.
t
3 . Installthe new stop ring into the driveshaftgroove
(A).
5 . To completelyseatthe outboardjoint, pick up the
driveshaftand joint, and drop them from about 10
cm (4 in.) onto a hard surface.Do not use a
hammer as excessiveforce may damagethe
driveshaft.Be carefulnot to damagethe threaded
section(A) of the outboardjoint.
1 0c m
( 4i n . )
- ..,..,1;,t,:-,;
{cont'd)
16-15
Driveline/Axle
DriveshaftsReassembly(cont'd)
Checkthe alignmentof the paint mark (A)with the
o u t b o a r dj o i n t e n d ( B ) .
{
8. Adjust the length of the driveshaftsto the figure
below,then adjustthe boots to halfwaybetween
full compressionand full extension.Make sure the
ends of the boots seat in the groovesof the
driveshaftand joint.
Leftdriveshaft:497502mm (19.6 19.8in.)
t
-tTfi'.D.ilTD
Rightdriveshaft:475 480 mm {18.7 1 8 . 9i n . l
7. Packthe outboardjoint (A)with the joint grease
includedin the new ioint boot set.
Grease quantity
Outboardioint: 105 115g (3.7 4.1 ozl
/llt,)r
-*>
\{(
'.,o"o
:;,"0'A?g.fff
:l:f
16-16
9 . Fit the boot (A) ends onto the driveshaft(B)and
o u t b o a r dj o i n l ( C ) .
DriveshaftsInstallataon
10. Closethe ear portion (A) of the band with a
commerciallyavailableboot band pincersKentMoore J-35910or equivalent(B).
1 1 .Checkthe clearancebetweenthe closedear portlon
of the bands.lf the clearanceis not within the
standard,closethe ear podion of the bandsfarther.
1. Installa new set ring onto the set ring groove of the
driveshaft{left driveshaft).
Apply 0.5 1.0g {0.02 0.04oz) of specifiedgrease
t o t h e w h o l e s p l i n e ds u r f a c e( A )o f t h e r i g h t
driveshaft.After applyinggrease,removethe
greasefrom the splinedgroovesat intervalsof 23 s p l i n e sa n d f r o m t h e s e t r i n gg r o o v e( B )s o t h a t
air can bleedfrom the intermediateshaft.
in.)MAX
6.0mm 10.24
3.0 mm {0.12in.} MAX
12. R e p e ast t e p s1 0 a n d 1 1 f o r t h e b a n do n t h e o t h e r
end of the boot.
(cont'd)
16-17
Driveline/Axle
DriveshaftsInstallation(cont'd)
Cleanthe areaswhere the driveshaftcontactsthe
differentialthoroughlywith solvent,and dry with
compressea
d i r .I n s e n t h ei n b o a r de n d { A )o f t h e
driveshaftinto the differential(B)or intermediate
shaft {C) until the set ring (D)locks in the groove (E).
{
5 . W i p e o f f t h e g r e a s ef r o m t h e b a l l i o i n ta n d l o w e r
arm taperedsurfaces.Installtheknuckle(A) onto
the lower arm {B).Be careful not to damagethe ball
joint boot.Wipe off the greasebeforetightening
the nut at the ball joint. Torquethe new castlenut
(C)to the lower torque specification,then tighten it
o n l y f a r e n o u g ht o a l i g nt h e s l o tw i t h t h e b a l lj o i n t
p i n h o l e .D o n o t a l i g nt h e n u t b y l o o s e n i n gi t .
NOTE:Make sure the ball joint boot is not damage
or cracks.
"-'t-
4. Installthe outboardjoint (A) into the front hub (B).
1 2 x 1 . 2 5m m
59 69 N.m
(6.0-7.0 kgf m,
43 51 tbt.ftl
I n s t a l l t h en e w l o c kp i n { D )i n t ot h e b a l l j o i n tp i n
hole from the insideto the outsideof the vehicle.
7 . Connectthe front stabilizerlink {A)to the lower arm.
H o l dt h e s t a b i l i z elri n kb a l l j o i n tp i n ( B )w i t h a h e x
w r e n c h{ C ) ,a n d t i g h t e nt h e n e w f l a n g en u t { D ) .
'10x 1.25mm
39 N.m
{4.0kgf.m,29 lbf.ft)
16-18
lntermediateShaft Removal
8. Installa newspindlenut{A),thentightenthe nut.
usea driftto stakethe spindlenut
Aftertightening,
shoulder{B)againstthe driveshaft.
1 . Removethe right driveshaft(seepage 16-3).
2 . R e m o v et h e h e a ts h i e l d .
108N.m
(11.0kgf.m,
80 tbt.ft)
/
o
oo
e
3 . R e m o v et h e f l a n g eb o l t{ A )a n d t w o d o w e l b o l t s ( B ) .
22x 1.5 mm
1 8 1N . m
{18.5kgf.m,134lbt.ft)
9. Cleanthe mating surfacesofthe brakedisc and the
front wheel, then installthe front wheel with the
wheel nuts.
€.---2"
E
J
/
€
w
10. Turn the front wheel by hand,and make sure the
clearancebetweenthe driveshaftand
circumferenceparts.
1l. Refillthe transmissionwith recommended
transmissionfluid (seepage 13-3).
12. Checkthe front wheel alignment,and adjust it if
necessary(seepage 18-4).
(cont'd)
16-19
Driveline/Axle
IntermediateShaft Removal
(cont'dl
4. Removethe intermediateshaft (A) from the
differential.Hold the intermediateshaft horizontal
until it is clear of the differentialto preventdamage
to the differentialoil seal (B).
IntermediateShaft Disassembly
{
. Oil seal driver 07947-5800100
. Half shaft base07NAF-SR30101
1 . R e m o v e t h e s e rt i n g ( A ) ,o u t e r s e a (l B ) ,a n d e x t e r n a l
s n a pr i n g ( C ) .
Pressthe intermediateshaft (A) out of the
intermediateshaft bearing(B) using a press.Be
carefulnot to damagethe metal rings (C)on the
intermediateshaft during disassembly.
PRESS
16-20
L
3. Removethe internalsnap ring.
4. Pressthe intermediateshaft bearing(A) out of the
b e a r i n gs u p p o r t( B )u s i n gt h e s p e c i atl o o l sa n d a
oress.
07947-s800100
07NAF-SR30101
16-21
Driveline/Axle
IntermediateShaft Reassembly
ExplodedView
INTERMEDIATE
SHAFTRING
FLANGEBOLT
10 x '1.25mm
39IVm
{4.0kgf.m,29lbt.ftl
\^
,tto", *,"o p
\--'+7\ E
BEARING
SUPPOBT
Packthe interiorof the outer seal.
16-22
. Driver07749-0010000
. Attachment,52x 55 mm 07746-0010400
. Attachment,35 mm 1.D.07746-0030400
. Oil seal driver 07GAD-PH70201
4. Pressthe intermediateshaft (A) intotheshaft
b e a r i n g( B )u s i n gt h e s p e c i atl o o l a n d a p r e s s .
PRESS
I
this procedure.
1 . C l e a nt h e d i s a s s e m b l epda r t sw i t h s o l v e n t a, n d d r y
them with compressedair. Do not wash the rubber
partswith solvent.
2. Pressthe intermediateshaft bearing(A) intothe
b e a r i n gs u p p o r t( B )u s i n gt h e s p e c i atl o o l sa n d a
press.
PRES
I
07746-0030400
I n s t a l lt,h e n s e a tt h e e x t e r n asl n a pr i n g { A ) i n t ot h e
groove of the intermediateshaft (B).
07746-0010400
3 . I n s t a l lt,h e n s e a tt h e i n t e r n asl n a pr i n g i n t ot h e
groove ofthe bearingsupPort.
(cont'd)
16-23
Driveline/Axle
IntermediateShaft Reassembly
(cont'd)
6 . l n s t a l l t h eo u t e rs e a l( A )i n t o t h e b e a r i n g s u p p o r t ( B )
usingthe specialtool and a press.
PRESS
I
IntermediateShaft Installation
1 . U s es o l v e n to r b r a k ec l e a n e tr o t h o r o u g h l yc l e a n
the areaswhere the intermediateshaft {A) contacts
the transmission(differential),and dry with
compressedair. Insertthe intermediateshaft
assemblyinto the differential.Hold the
intermediateshaft horizontalto preventdamageto
the differentialoil seal (B).
Packthe interior
ofthe outer seal.
7 . I n s t a l l t h es e t r i n g .
2 . I n s t a l l t h el l a n g eb o l t( A )a n d t w o d o w e lb o l t s( B l .
A
10 x 1.25mm
39Nm
(4.0kgf.m,29lbf.ft)
16-24
B
l 0 x 1 . 2 5m m
39 N.m
(4.0kgf.m,
29 tbf.ftl
(
3. Installthe heat shield,and tightenthe three bolts.
8 x 1.25mm
22Nm
12.2
4 . I n s t a l l t h er i g h td r i v e s h a f(ts e ep a g e1 6 - 1 7 ) ,
16-25
Steering
Steering
. . . . . . . . . .1. .7.- 2
S p e c i aTl o o l s
. .7. .-.3. . . . . . . . .
C o m o o n e nLto c a t i oInn d e x . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
17-4
PlayCheck.....................".
WheelRotational
Steering
17-4
..........
PowerAssistCheck..................
17-5
.................
andGearboxInspection
SteeringLinkage
...........
l e m o v a.l . . . . . . . . . . . . . . . . . . . . . . . . , . . . .1. .7. -. 6
S t e e r i nW
g h e eR
17-7
................
WheelDisassembly/Reassembly
Steering
17-8
...............
WheelInstallation
Steering
17-9
Steering
ColumnRemovalandInstallation...........'...
17-11
..............
ColumnInspection
Steering
17-'12
.......................................'.
Replacement
SteeringLock
. . . . . " . . . . . . . . '1. .7' .- .1 3
R a c kG u i d eA d i u s t m e n t
ElectricalPowerSteering(EPS)
17-15
Steering
(
SpecialTools
Ref.No.
o
Tool Number
07MAA-S100200
Description
LocknulWrench.43 mm
E
-.tt)-
---<,/
L\2 r
6Y
.Vo
I
1 7-2
Oty
DRIVER'S
AIRBAG
ASSEMBLY
p a g e2 3 - 1 1 3
STEERINGWHEEL
Removal,page 17-6
Disassembly/Reassembly,
page 17-7
Installation,page 17-8
STEERING
COLUMN
SteeringColumnRemovaland Installation,
p a g e1 7 ' 9
SteeringColumn Inspection,
p a g e1 7 - 1 ' l
SteeringLockReplacement,
page 11-12
STEERING
GEARBOX
page'17-13
RackGuideAdjustment,
17-3
Steering
SteeringWheelRotationalPlay
Check
PowerAssistCheck
1 . Startthe engine,and let it idle.
1. Turn the front wheelsto the straightaheadposition.
2. Measurehow far you can turn the steeringwheel
left and right without moving the front wheels.
Attach a commerciallyavailablespring scaleto the
s t e e r i n gw h e e l .W i t h t h e e n g i n ei d l i n ga n d t h e
v e h i c l eo n a c l e a n ,d r y f l o o r ,p u l lt h e s c a l ea s
shown, and read it as soon as the tires begin to turn.
. lf the play is within the limit, the gearboxand
l i n k a g ea r e O K .
. lfthe playexceedsthe
l i m i t ,a d j u s t t h er a c kg u i d e
'17-13).
lf the play is still excessiveafter
{seepage
rackguide adjustment,inspectthe steering
l i n k a g ea n d g e a r b o x{ s e ep a g e1 7 - 5 ) .
BOTATIONAL
PLAY:0 10mm (0-0.39in.l
+ :
3 . l f t h e s c a l er e a d sn o m o r e t h a n2 9 N ( 3 . 0k g f , 6 . 6l b f ) ,
the power assistis OK. lf it readsmore, checkthese
items:
.
.
.
.
17-4
Fronttire pressure
Steeringlinkage(seepage 17-5)
Rackgulde adjustment(seepage 17-13)
EPSsystem (seepage 17-18)
\
SteeringLinkageand GearboxInspection
BOOT
Inspect
Ior damageanddeterioration.
Checkfor looseness,
a n db i n d i n g .
12 mm BOLTS
Inspectfor looseness.
I
STEERING
COLUMN
Inspect
for loosecolumn
mountinghardware
STEERING
JOINTS
Checkfor looseioint bolts,
andlooseor bindingioints.
TIE.RODLOCKNUTS
Checkfor looseness.
STEERING
GEARBOX
Inspectfor loosemounting hardware.
GEARBOXMOUNTING CUSHIONS
Inspectfor deterioration.
TIE.RODENOBALLJOINT
lnsoect
tor looseness,
b i n d i n ga,n dd a m a g e .
BALLJOINT
BOOT
Inspect
for damageanddeterioration.
17-5
Steering
SteeringWheelRemoval
SRScomponentsare locatedin this area.Reviewthe
SRScomponentlocations(seepage 23-13),and
precautionsand procedures(seepage 23-14)in the SRS
sectionbeforeperformingrepairsor service.
1. Align the front wheels straightahead,then remove
the driver'sairbagfrom the steeringwheel (see
p a g e2 3 - 1 1 3 ) .
2. Disconnectthe cruisecontrol sevresumeswitch
connector(A),and loosenthe steeringwheel nut
{B).
{
3. Installa commerciallyavailablesteeringwheel
puller {A) on the steeringwheel (B).Freethe
steeringwheel from the steeringcolumn shaft by
t u r n i n gt h e p r e s s u r eb o l t( C )o f t h e p u l l e r .
Note these items when removing the steering
wheel:
. Do not tap on the steeringwheel orthesteering
column shaft when removingthe steeringwheel.
. l f y o u t h r e a dt h e p u l l e rb o l t s( D )i n t o t h e w h e e l
hub more than 5 threads,the bolts will hit the
cable reel and damageit. To preventthis, install
a p a i ro f j a m n u t s5 t h r e a d su p o n e a c hp u l l e rb o l t .
D
i
Bemovethe steeringwheel puller,then removethe
steeringwheel nut and steeringwheel from the
sleerinocolumn.
17-6
SteeringWheelDisassembly/Reassembly
WHEEL
STEERING
ACCESSPANELA
CONTACTPLATE
75*-=offi
CONNECTORHOLDERS
ffi)Y
MOOULESETBRACKET
-f
STEERING
WHEELREABCOVER
b
/
,/*
accEss
PANEL
B
CRUISECONTROLSWITCH
17-7
Steering
SteeringWheelInstallation
1 . B e f o r ei n s t a l l i n g
t h e s t e e r i n gw h e e l ,m a k es u r et h e
front wheels are alignedstraightahead,then center
the cable reel (A).Do this by first rotatingthe cable
reel clockwiseuntil it stops.Then rotate it
counterclockwiseabout two and a half turns.The
a r r o w m a r k( B )o n t h e c a b l er e e ll a b e ls h o u l dp o i n t
straightup.
3. Installthe steeringwheel nut (A),and tighten it to
the specifiedtorgue.
A
39 N.m(4.0kgf m.29lbt ftl
_
B
lr,',,t
;. _,:!
'' '1i::..'.'l
Connectthe cruisecontrol set/resumeswitch
connector(B).fvlakesure the wire harnessis routed
and fastenedproperly.
Positionthe two tabs (A) of the turn signal
canceling
s l e e v e( B )a s s h o w n .I n s t a l l t h es t e e r i n g
wheel onto the steeringcolumn shaft, makingsure
the steerlngwheel hub (C)engagesthe pins (D) of
the cable reel and tabs of the cancelingsleeve.Do
not tap on the steeringwheel or steeringcolumn
shaft when installingthe steeringwheel.
I n s t a ltlh e d r i v e r ' sa i r b a g a
, n d c o n f i r mt h a tt h e
system is operatingproperly{seepage 23-113).
C h e c kt h e h o r n ,t u r n s i g n a lc a n c e l i n g
a n dc r u i s e
control switchesfor proper operation.
7 . Reconnectthe batteryand do the following:
. D o t h e e n g i n ec o n t r o lm o d u l e( E C M )i d l e l e a r n
p r o c e d u r e( s e ep a g e1 l - 1 3 9 ) ,
. Powerwindow control unit resettingprocedure
\see page 22-1281.
. Enterthe anti-theftcord for the radio,then enter
the custmer'sradio stationpresets.
. Set the clock.
17-8
{
SteeringColumnRemovaland Installation
SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations(seepage 23-13)and precautionsand
procedures(seepage 23-14)in the SRSsectionbefore performingrepairsor service.
Removal
1, Recordthe radio stationpresets,and disconnectthe battery.
2 . R e m o v e t h e d r i v e r ' s a i r b a g a s s e m b l y ( s e e p a g e 2 3 -a1n1d3t)h e s t e e r i n gw h e e l( s e ep a g e1 7 - 6 ) .
p a g e2 0 - 6 0 ) .
3 . R e m o v e t h ed r i v e r ' sd a s h b o a r dl o w e r c o v e r ( s e ep a g e2 0 - 5 9 a) n d u n d e r c o v e r ( s e e
4. Removethe column covers(A:
T
I x 1.25mm
16 N.m (1.6kgf.m,
12 lbl.fr)
b
5 . Disconnectthe wire harnessconnectorsfrom the combinationswitch assembly{B).
6 . Removethe combinationswitch assemblyfrom the steeringcolumn shaft by removingthe screw (C)on the top of
the combinationswitch.
7. Disconnectthe connectorsfrom the ignition switch,and releasethe wire harnessclips from the steeringcolumn.
8. Disconnectthe steeringjoint (D),and remove it from the column shaft.
9. Removethe steeringcolumn {E)by removingthe attachingnuts and bolts.
\
(cont'd)
17-9
Steering
SteeringColumnRemovaland Installation(cont'd)
lnstallation
1 . I n s t a ltl h e s t e e r i n gc o l u m n ,a n d m a k es u r et h e
wires are not caught or pinchedby any parts.
Insertthe upper end ofthe steeringjoint onto the
steeringshaft {A) (line up the bolt hole (B)with the
flat portion (C)on the shaft).
8 x 1 , 2 5m m
28 N.m
{2.9 kgf m,
21rbr.ft)
A
Slip the lower end of the steeringjoint onto the
pinion shaft {D) (line up the bolt hole with the
g r o o v e( E )a r o u n dt h e s h a f t )a, n d l o o s e l yl n s t a l l t h e
lower joint bolt. Be sure that the lower joint bolt is
securelyin the groove in the pinion shaft.
4 . Pull on the steeringjoint to make sure that the
s t e e r i n gj o i n t i s f u l l y s e a t e dT. h e n i n s t a l l t h eu p p e r
joint bolt, and tighten it to the specifiedtorque.
Tightenthe lower joint bolt to the specifiedtorque.
Finishthe installation,and note these items:
. Make surethe wire harnessis routed and
fastenedproperly.
. Make sure the connectorsare properlyconnected.
. R e i n s t a l l t h se t e e r i n gw h e e l( s e ep a g e1 7 - 8 ) .
. Reconnectthe battery.
- Do the power window control unitreset
procedure{seepage 22-128).
- Enterthe anti-theftcode for the radio,then
enterthe custmer'sradio stationpresets.
- Set the clock.
. Verify horn, turn signalswitch,and cruisecontrol
switch operation.
. Checkwheel alignment,if necessary(seepage
18-4).
. D o t h e e n g i n ec o n t r o lm o d u l e( E C M )i d l el e a r n
p r o c e d ur e { s e ep a g e' 1 1 - 1 3 9 ) .
17-10
{
SteeringColumnInspection
. C h e c kt h e s t e e r i n gc o l u m nb a l l b e a r i n g ( A a
) n d t h e s t e e r i n g j o i n t b e a r i n g s ( B ) f o r p l a y a n d p r o p e r m o v e m el fnatn. y
bearingis noisy or has excessiveplay, replacethe steeringcolumn as an assembly,
' C h e c k t h e a b s o r b i n g p l a t e s ( C ) , a b s o r b i n g p l a t e g u i d e s ( D ) , s t o p ( E ) , a n d c o a t i n g p l af o
t er sd(i F
s t)o r t i o na n d
breakage.lf there is distortionor breakage,replacethe steeringcolumn as an assembly.
17-11
Steering
SteeringLockReplacement
NOTE:Do not try to re-keya replacementsteeringlock.
lf necessary,re-keythe other locks.
1 . R e m o v et h e s t e e r i n gc o l u m n( s e ep a g e1 7 - 9 ) .
2. Centerpunch each ofthe two shear bolts (A),and
drill their headsoff with a 5 mm (3i16 in.) drill bit.
Be carefulnot to damagethe switch body when
removingthe shear bolts,
7. Tightenthe shearbolts (A) untilthe hex heads(B)
twist off.
A
I
:..'-":'
3. Removethe shear bolts from the switch body.
4. Installtheswitch body without the key inserted.
5. Looselytighten the new shear bolts.
6. Insertthe ignition key,and checkfor proper
operationof the steeringwheel lock and that the
ignition key turns freely.
17-12
I
RackGuideAdjustment
Locknutwrench, 43 mm 07MAA-S100200
6. Tightenthe rackguidescrew(A)ro25 N.m (2.5
kgf.m,18lbf.ft).thenloosenit.
5" Max.
1. Set the wheels in the straightaheadposition.
j
i-rrrr-,
2. Removethe heat shield(A).
'-.i. ''
'
9 . 8N . m ( r . 0 k g f . m , 7 . 2 l b t f t )
I
32 on page 13-8).
4il N.m
{a.5kgf.m,33lbt.ft)
3 . Removethe transmissionmount bracket(seestep
7 . Retightenthe rack guide screw to 6 N.m (0.6kgf m,
4 lbf.ft),then back it off to the specifiedangle.
Loosenthe rackguide screw locknut(A)with the
specialtool, then removethe rack guide screw (B).
07MAA-S100200
Specified Return Angle: 5' Max.
Hold the rack guide screw stationarywith a wrench,
and tighten the locknutby hand until it's fully
seated.
9 . I n s t a l l t h es p e c i atl o o l o n t h e l o c k n u (t B ) ,a n d h o l d
the rackguide screw (A) stationarywith a wrench,
Tightenthe locknutan additional30" with the
specialtool.
1 0 .Reinstallthe transmissionmount bracketand heat
s hi el d ,
Removethe old sealantfrom rackguide screw,and
apply new sealantto the middle of the threads(A).
Looselyinstallthe rackguide screw on the steering
gearDox.
1 1 .Checkfor unusualsteeringeffort through the
c o m p l e t et u r n i n gt r a v e l .
12. Checkthe steeringwheel rotationplay (seepage
17-4)and the power assist(seepage 17-4).
17-13
ElectricalPowerSteering(EPSI
SpecialTools
. . . . . . . . . .1. .7-. 1 6
C o m p o n e nLto c a t i oInn d e x . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.7. .-.1. .7. . . . . . .
Troubleshooting
General
Information.......................
17-18
DTCTroubleshooting
Index
..............
17-22
Index ...............................
17-23
SystemDescription.................
...........
17-24
CircuitDiagram
.........17-26
DTCTroubleshooting
...............
..........
17-28
EPSlndicator
.......................
17-47
MotorRemoval/lnstallation
...............
17-49
Steering
GearboxRemoval
...............
17-51
Steering
GearboxOverhaul
...............
17-55
Steering
GearboxInstallation
...........
17-63
EPSControlUnitRemova
l/lnsta
llation.......................
17-67
Tie-rodBallJointBootReplacement
..........................
17-67
EPSComponents
SpecialTools
Rel.No.
Tool Number
(!)
07MAC-S100200
at'
070AD-P0A0100
o
07zAA-S5A0100
\
otv
Description
'1
B a l lJ o i n t R e m o v e r2, 8 m m
Attachment,42 mm
LocknutWrench
1
'l
-)
,.^G) C\
_---1t
h5--d-'
)
u_r-.c_t t )
\L-,
t
I
a
17-16
GAUGE
ASSEMBLY
UNDER.DASH
FUSE/RELAY
BOX
UNDER.HOOD
FUSE/RELAY
BOX
-,'/.,....
'.,i,
X \ ]
DATA LINK CONNECTORI16P)
TOROUE
SENSOR
STEERINGGEARBOX
SteeringGearboxRemoval,page 17-51
SteeringGearboxOverhaul,page 17-55
SteeringGearboxInstallation,page 17-63
EPSCONTROL
UNIT
EPSControlUnitRemoval/lnstallation,
page17-67
MOTOR
page l7-49
17-17
EPSComponents
a
Information
EPSIndicator
Undernormalconditions,
the EPSindicator
comeson when
the ignitlonswitchis turnedto theON(ll)position,
thengoes
Thisindicates
off afterthe engineis started.
thatthebulband
itscircuitareoperating
correctly.
lf thereis anytroublein thesystemaftertheengineis started,
will stayon,andthe powerassistis turned
theEPSindicator
off.
WhenEPSindicator
lightcomeson,thecontrolunit
memorizes
the DTC.In thiscase,thecontrolunitwill not
activate
the EPSsystemaftertheenginestartsagain,but it
keepsthe EPSindicator
on.
WhenDTC12,16,17,18or 67 is storedin thecontrolunit,the
EPSindicator
will stayon untiltheDTCis erased.
Whena
problemis detected
andthe EPSindicator
comeson,thereare
stayson untiltheignitionswitchis
caseswhenthe indicator
goesoff
turned0FF,andcaseswhenthe indicator
whenthesystemreturnsto normal.Eventhough
automatically
thesystemis operating
normally,
the EPSindicator
will come
on underthefollowingconditions:
'1:
Condition
. Thevehiclewastraveling
at least12.4mph(20km/h),then
. A rapid changein vehiclespeedwas detected,then
. Thevehicle(orthevehiclespeedsensorsignal)stoppedfor
at least5 seconds
'l,640rpmorhigherforatleastS
. T h ee n g i n se p e e d
w a ss t i l l
seconds
C o n d i t i o n2 :
Afterthevehicle(orthevehiclespeedsensorsignal)has
yettheenginespeedwasstill
for at least10seconds,
stopped
1,640rpmor higherforat least20seconds.
C o n d i t i o n3 :
When
is280rpmor less,
andthevehicle
istraveling
theengine
speed
at
a speed
of6,2mph(10km/h)
or morefor3 seconds.
To determine
theactualcauseofthe problem,question
the
duringwhichthe problem
customer
abouttheconditions
takingtheaboveconditions
intoconsideration.
occured,
DiagnosticTroubleCode(DTCI
. lf theCPUcannotbeactivated,
or itfails,theEPSindicator
comeson,butthe DTCis notmemorized.
. Thememorycanholdanynumberof DTCS.
However,
when
thesameDTCis detected
morethanonce,the mostrecent
onlyone
DTCis writtenoverthe priorDTC,therefore
occurrence
is memorized.
. TheDTCS
areindicated
repeatedly
untiltheignitionswitchis
turnedOFF.
. lf theDTCis not memorized,the
EPSindicator
blinks.
17-18
. TheDTCS
arememorized
in theEEPRO|(non-volatile
memory)therefore
the memorized
DTCS
cannotbe erased
by disconnecting
the battery.
Perform
thespecified
procedures
to clearDTCS.
Self-diagnosis
Self-diagnosiscan be classifiedinto two categories:
. I n i t i a l d i a g n o s i sp: e r f o r m e dr i g h ta f t e rt h e e n g i n e
startsand until the EPSindicatorgoes off.
. Regulardiagnosis:performedright after the initial
d i a g n o s i su n t i lt h e i g n i t i o ns w i t c hi s t u r n e dO F F .
The EPScontrol unit performsthe following functions
when a problem is detectedby self-diagnosis;
'1.
T u r n so n t h e E P Si n d i c a t o r .
2. Memorizesthe DTC.
3. Stops power assistand manual steeringoperation
begrns.
NOTE:
. When DTC23 (a problemwith the circuitfor
enginespeedsignal)is detected,the power
a s s i sw
t i l l r e t u r nt o n o r m a lw h e n t h e v e h i c l e
s p e e di s 0 . 6 2m p h ( 1 k m / h )o r a b o v e .
. Fot DfCs 22,23, 64, or 66 the EPSindicatorgoes
off automaticallywhen the system relurnsto
n o r m a l .F o ra l l o t h e rc o d e s t, h e E P Si n d i c a t o r
goes off when the system is OK afterthe ignition
switch is turned from OFFto ON (ll).
Restrictionon PowerAssistOperation
Repeatedextremesteeringforce.such as turning the
steeringwheel continuouslyback-and-forth
with the
vehiclestopped,causesan increaseof power
consumptionin the EPSmotor. The increaseof electric
t h i sh e a t
c u r r e n tc a u s e st h e m o t o rt o h e a tu p . B e c a u s e
adverselyaffectsthe system,the control unit monitors
the electriccurrent of the motor.
When the control unit detectsheat build-upin the motor,
it reducesthe electriccurrentto the motor graduallyto
protectthe system,and it restrictsthe power assist
o p e r a t i o nT. h e E P Si n d i c a t o dr o e sn o t c o m e o n d u r i n g
t h i sf u n c t i o n .
When steeringtorque is not appliedto the steering
wheel, or when the ignition is turned off, and the motor
cools,the control unit will restorethe power assist
graduallyuntil it's fully restored(afterapproximately15
m i n u t e sm a x i m u m ) .
How to TroubleshootEPSDTCs
The troubleshootingflowchart proceduresassumethat
the causeof the problem is still presentand the EPS
indicatoris still on, Followingthe flowchartwhen the
EPSindicatordoes not come on can result in incorrect
diagnosis.
The connectoriliustrationsshow the female terminal
c o n n e c t o rw
s i t h a s i n g l eo u t l i n ea n d t h e m a l et e r m i n a l
connectorswith a double outline.
1. Ouestionthe customeraboutthe conditionswhen
the problem occured,and try to reproducethe
same conditionsfor troubleshooting.Find out
when the EPSindicatorcame on, such as while
t u r n i n g .a f t e r t u r n i n gw, h e n t h e v e h i c l ew a s a t a
certain speed,etc.
2 . T u r nt h e i g n i t i o nO N ( l l ) ,a n d f o l l o wt h e p r o m p t so n
the PGM Testerto displaythe DTC(s)on the screen.
After determiningthe DTC,referto the DTC
TroubleshootingIndex.
NOTE:See the HondaPGM Testeruser's manual
for specificinstructions.
ServiceCheckSignalCircuit Method:
1 . W i t h t h e i g n i t i o ns w i t c hO F F ,c o n n e c t h e H o n d a
P G MT e s t e r( A ) t o t h e 1 6 Pd a t al i n kc o n n e c t o(rD L C )
(B) locatedunderthe dash on the driver'sside of
the vehicle.
2. When the EPSindicatordoes not come on during
the test drive, but troubleshootingis done basedon
the DTC,checkfor looseconnectors,poor terminal
contact.etc in the affectedcircuit,beforeyou start
troubleshooting.
3. After troubleshooting,clearthe DTCand test-drive
the vehicle.Be sure the EPSindicatordoes not
c o m eo n .
How to RetrieveEPSDTCs
Honda PGM Tester Method:
1, With the ignition switch OFF,connectthe Honda
PGM Tester(A)to the 16Pdata link connector(DLC)
thevehicle.
Short the SCScircuitto body ground using the
HondaPGN4Tester.
T u r nt h e i g n i t i o ns w i t c hO N { l l ) .
Recordthe DTC.
(cont'd)
17-19
EPSComponents
5. The blinkingfrequencyindicatesthe DTC.DTCSare
indicatedby a seriesof long and short blinks.One
l o n g b l i n ke q u a l s1 0 s h o r tb l i n k s A
. d d t h e l o n ga n d
short blinkstogetherto determinethe DTC.After
determiningthe DTC,referto the DTC
TroubleshootingIndex.
The system will not indicatethe DTCunlessthese
conditionsare met:
. Set the front wheels in the straightaheaddriving
position.
. The ignition switch is turned ON (ll).
. The engine is stopped.
. The SCScircuit is shortedto body ground before
the ignition switch is turned ON (ll).
How to ClearEPSDTCs
Honda PGM Tesler Method:
1. With the ignition switch OFF,connectthe Honda
( B )l o c a t e du n d e rt h e d a s ho n t h e d r i v e r ' ss i d eo f
the vehicle.
Exampleof DTC23
Long blinks Short blinks
(two times) (three timesl
Turn the ignition switch ON (ll),and clearthe
DTC{s)by following the screenpromptson the
PGM Tester.
NOTE:Seethe Honda PGMTesteruser'smanual
7 . Disconnectthe Honda PGM Testerfrom the DLC.
17-20
Service Check Signal Circuit Method:
NOTE:Use this procedurewhen the PGM Tester
softwaredoes not matchthe yearlmodelvehicleyou
are working on.
1. With the ignitionswitch OFF,connectthe Honda
PGM Tester(A)to the 16Pdata link connector{DLC)
the vehicle.
1 . Within 4 secondsafter the EPSindicatorgoes off,
returnthe steeringwheel to the straightahead
driving positionagain and releasethe steering
wheel.The EPSindicatorblinkstwice 4 seconds
after releasingthe steeringwheel, indicatingthat
the DTCwas erased.
NOTE:If the EPSindicatordoes not blinktwice, an
error was made in the procedureand the DTCwas
not erased.Turn the ignition switch OFF,and
repeatthe operationfrom step 3.
Turn the ignition switch OFFafterthe EPSindicator
blinkstwice.
9. Disconnectthe Honda PGM Testerfrom the DLC.
10. Performthe DTCcode output operation,and be
sure that the code has been erased.
With the vehicleon the ground,set the front wheels
in the straightaheaddriving position.
Short the SCScircuitto body ground using the
HondaPGM Tester.
4. Turn the ignition switch ON (ll).The EPSindicator
comes on for about 6 seconds.Within 4 secondsof
turning the switch ON, while the EPSindicatoris on,
turn the steeringwheel 45 degreesto the left from
the straightaheaddriving position,and hold the
steeringwheel in that positionuntil the EPS
indicatorgoes off.
Within 4 secondsafterthe EPSindicatorgoes off,
returnthe steeringwheel to the straightahead
driving positionand releasethe steeringwheel.
The EPSindicatorcomes on again 4 secondsafter
releasingthe steeringwheel,
Within 4 secondsafter the EPSindicatorcomes on,
turn the steeringwheel 45 degreesto the left again
and hold it in that position.
The EPSindicatorgoes off after 4 seconds.
17-21
EPSComponents
DTC
Detection ltem
Note
DTC;12
A problem with voltagefor torque sensorT/SlG
(seepage 17-28)
D T C1: 6
A problemwith averageof voltagefor torque sensorVT3 and VT6
(seepage 17-29)
DTC:17
A problemwith thevoltagefor torquesensor12V powersourceVcc1
( s e ep a g e1 7 - 3 1 )
DTC:18
A problemwith the voltagefor torque sensor5 V power sourceVcc 2
( s e ep a g e1 7 - 3 1 )
DfC:22
A problemwith the averagefor vehiclespeedand enginespeed
( s e ep a g e1 7 - 3 3 )
Excessivechangeof the vehiclespeed sensorsignal
{seepage 17-33)
DTC:23
A problemwith the engine speedsignal circuit
( s e ep a g e1 7 - 3 3 )
DTC:37
A problemwith the circuitfor input motor voltage in the EPScontrol unit
(seepage 17-35)
DTC:41
A problemwith the motor voltage
( s e ep a g e1 7 3 6 )
DfC: 42
A problemwith the motor driven current (opencircuitor short to grounol
(seepage '17-38)
DTC:43
A problem with the motor driven current (shortto power)
( s e ep a g e1 7 - 4 1 )
DTC:45
A problemwith the motor driven current (opencircuitor short to grounol
(seepage 17-38)
DfC: 47
A problemwith the motor relav in the EPScontrol unit
{ s e ep a g e1 7 - 4 2 )
DTC:50
A problem with the CPU in the EPScontrol unit
( s e ep a g e1 7 - 4 3 )
D T C :5 1
A problemwith EEPROM
in the EPScontrolunlt
(seepage 17-43)
DTC:62
Fail-saferelay stuckON
( s e ep a g e1 7 - 4 4 )
DTC:64
A problem with low batteryvoltage
(seepage 17-44)
Fail-saferelay contactfailure
(seepage 17-44)
DTC:66
A problem with the motor driven voltage
{seepage 17 45)
DTC:67
A problemwith the torque sensorl/F circuit
( s e ep a g e1 7 ' 4 5 )
DTC:68
A problemwith the interlockcircuit (torque)
{seepage 17-45)
DTC:69
A p r o b l e mw i t h t h e i n t e r l o c kc i r c u i t( c u r r e n t )
( s e ep a g e1 7 - 4 6 )
17-22
Symptom
EPSindicatordoes not
come on
EPSlndicatorCircuitTroubleshooting(seepage 17-47)
EPSindicatordoes not go
off and no DTC is stored
EPSIndicatorCircuitTroubleshooting(seepage 17-47)
EPSindicatordoes not stay
on, no DTCis stored,and
there is no power assist
1. Checkthe motor wires betweenthe EPScontrol unit and the
motor for a short to ground. Repairas needed.
2. lf the motor wires are OK, replacethe steeringgearbox
{short in the motor).
Also check fo]
17-23
EPSGomponents
SystemDescription
EPSGontrolUnit Inputsand Outputsat ConnectorA (2pl
EPSCONTROLUNIT CONNECTORA {2P)
Termanal Wire color
numbol
Terminalsign
(Terminalnamel
Description
WHT/BLU -' BAT
(Plus
bafterv)
2
8LK
Measurement
Conditions
lqnitiqr switch ON (lll
l Ground Constant
Terminals
Powersourcefor the
actuatormotor
Groundforthe actuator
PG
Voltage
Battery voltage
2-Ground
EPSControlUnit Inputsand Outputsat ConnectorB (2P)
EPSCONTROLUNITCONNECTOB
B {2P}
Terminal Wire colol
numDer
Terminalsign
{Te.mioalname)
Description
Terminals
1
RED
M1
(Motor 1
Driveslhe actuatormotor
1-Ground
2
GRN
M2
Drives the actuator motor
2'Ground
17-24
Measuremenl
Conditions
lqnition switch ON llll
Voltage
EPSGontrolUnit Inputsand Outputsat ConnestorC (20P1
EPSCONTROLUNITCONNECTOR
C (2OP)
Terminal
Wire color
numbel
2
5
7
Terminalsign
{Terminelname}
Descriplion
Terminals
Measuremeni
Conditions
{lqnitionswitch ON {lll)
T/SGND
Groundfor the torque
(Torquesensorqround)
3-Ground tarttheenqrne
Powersourcefortorque
ORN
vccl
(Voltaqe
common1
Detectstorque sensor
5 Ground Starttheengineand
YEUBED VT6
(Voltaqe
turnthe steerinowheel
stonal
torque6)
ON
Drivesthe EPSindicator
6 Ground E P S
YEUBLU
(Warninqlamp)
lidhr
uTltnotcatol
Raisethe vehicleoff the
Detectsthe vehiclespeed
BLUAVHT VSP
( V e h i c l es p e e d p u l s e i
groundandspinthe
inputsignalfor the speed
sensoror the ECM(4 pulse/
Voltage
PNK
BRN
10
YEL
11
GRN//EL
SCS
checksiqnal)
{Servjco
IG1
llqnition1
vcc2
Detectsservicecheck
Drivesthetorquesensor
Batteryvoltage
on switchON (ll)
on switchOFF
1'l-Ground tan the enoine
Battervvoltaqe
About5V
on switch OFF
8LU/ORN VT3
YEUBLK T/SIG
(TorquesensorF/S
srgnal
(Voltaoe
toroue3)
OV
Banervvoltaqe
Alternating
voltageabout
OV 5V OV-5V
8-Ground SCSnot grounded
Powersourcefor activating 10-Ground
(Voltaqe
common2)
Ba$ervvoltaqe
OV
About
1'l
LT GRN/
B IK
19
BLU
Providespower steering
PSW
iPowersteerinoswitch) switchsional
Detectsthe enginepulse
NEP
20
GRY
DIAG-H
with
Communications
HondaPGNITester
About
13-GroundStarttheengineand
trrrnthe steerinowheel 5 - 0 v
Momentarily
5V
15-GroundStarttheengine
0-12V
l7-Ground Starttheengineand
nrrnthe steerinowheel
19-GroundStarttheengine,and let
;t idte
5V
20-Ground PGMTesternot
17-25
EPSComponents
CircuitDiagram
\
\
SPE€DSENSOR
3P CONNECTOR
@
GAUGEASSEMATY22PCONNECTOR
TOFOUESENSOR
6P CONNECTOR
lli2l3F
r;T;T-I
(=J_:_LvJ
Wn. !ide ot f.m.l€ r.fmin.ls
17-26
GAUGEASSEMBLY22PCONNECTON
a
OATA !IN( CONN€CTOA(T6P)
EPSCOI{IFOIUNIT
cou{EcToR A (2P)
F-l
vTTrvaEvnrv
A
EPSCONTNOLUNIT
co|lNEcTofi 8 {2P}
| l l
wwzna
MOTOF
CONNECTOR
riTt
t2)
T.rmin.l.id.
oll.m.l.r.rmin.l.
Wir. !.le ol l.m.l. t.tman.r.
17-27
EPSComponents
DTCTroubleshooting
DTC12: TorqueSensorT/SIG
1 . C l e a rt h e D T C .
8 . Measurethe voltage betweenEPScontrol unit
c o n n e c t oC
r ( 2 0 P ) t e r m i n aNl o . 1 5 a n d b o d y g r o u n d .
2 . S t a nt h e e n g i n e .
3. Wait at least 10 seconds.
Does the EPS indicatot come on?
EPSCONTROL
UNITCONNECTOR
C (2OP)
2 3
YES Go to step 4.
5 6 1 8
0
T/SIG
{YEL/BLK)
NO Checkfor loosewires or poor connections.lf
the connectionsare good, the system is OK at this
time.l
4 . Stop the engine,and verify the DTC.
Wire side ot lemaleterminals
ls DTC12 indicated?
I s there battery v oltage?
YES Go to slep 5.
NO-Perform the appropriatetroubleshootingfor
the code indicated.t
YES-Repair short to power in the + circuitwire
betweenthe torque sensorand EPScontrol unit.l
NO Go to step 9.
5 . Make sure the ignitionswitch is OFF,then
disconnectEPScontrol unit connectorC (20P)and
the torque sensor6P connector.
Checkfor continuitybetweenEPScontrol unit
c o n n e c t oC
EPSCONTROL
UNITCONNECTOR
C {2OP)
\
1 0 . Checkfor continuitybetweenEPScontrol unit
connectorC (20P)terminal No. 15 and the torque
sensor6P connectorterminal No. 4.
EPSCONTROL
UNITCONNECTOR
C (2OPI
T/SIG
(YEL/BLK)
TOROUE
SENSOR
6PCONNECTOR
T/SIG
(YEL/BLK)
ls therecontinuity?
YES- Repairshortto bodygroundin thewire
betweenthetorquesensorandEPScontrolunit.l
YES Go to step 1'1,
NO Go to step7.
NO Repairopen in the wire betweenthe torque
sensorand the EPScontrol unit.I
17-28
'I
1 . Substitutea known-goodEPScontrol unit, and
connectthe all disconnectedconnectors.
1 2 .Start the engine.
DTC16:TorqueSensorVT3andW6
2. Startthe engine.
3 . W a i t a t l e a s t1 0 s e c o n d s .
Does the EPS indicator come on?
YES Go to step 13.
YES Go to step 4.
NO Checkfor loose EPScontrol unitconnectors.lf
necessary,replacethe EPScontrol unit and
retest.l
NO Checkfor loosewires or poor connnections.lf
the connectionsare good,the system is OK at this
time.l
1 3 .Stop the engine,and verify the DTC.
4. Stop the engine,and verify the DTC.
ls DTCl2 indicated?
ls DTC16 indicated?
YES Checkfor loosetorque sensorconnectors.
lf necessary,substitutea known-goodsteering
gearboxand recheck.l
the code indicated.!
YES-Go to step 5.
NO Performthe appropriatetroubleshootingfor
5. Make sure the ignition switch is OFF,then
6, Checkfor continuitybetweenthe appropriateEPS
control unit connectorC (20P)terminal and body
ground (seetable).
Terminalname
C
EPScontrolunitconnector
terminalNo.
Vccl
3
Vcc2
VT3
VT6
11
13
T/S GND
5
2
EPSCONINOTUNITCONNECIOR
C (2OP)
W re s d€ oltemalelermi.als
YES- Repairshort to body ground in the
appropriatesensorcircuit betweenthe torque
sensorand EPScontrol unit,!
NO Go to step7.
{cont'd)
17-29
EPSComponents
I
8 . Measurethe voltage betweenthe appropriateEPS
control unit connectorC (20P)terminal and body
ground (seetable).
Terminalname
Vccl
EPScontrol
unitconnector
C
t e r m i nN
a lo .
3
Vcc2
VT3
VT6
11
T/S GND
2
13
5
C {2OP}
1 0 . Checkfor continuitybetweenthe appropriateEPS
control unit connectorC {20P)terminal and the
torque sensorterminal (seetable).
T e r m i n a l TorqueSensor EPScontrol
name
t e r m i n aNl o , unitconnector
C t e r m i n aNl o .
Vccl
2
3
Vcc2
3
11
'l
't3
VT3
VT6
6
5
6
T/S GND
2
TOROUESENSOR6PCONNECTOR
Vccz
(GRN/YELI
Wire side of
VT6 {YEL/RED)
T/S GND {PNK)
EPSCONTROLUNIT
CONNECTOR
C I2OP)
VT6{YEL/RED}
\
ls thete battery voltage?
YES Repairshon to power in the + circuitwire
betweenthe EPScontrol unit and torque sensor.l
NO Go to step 9.
ls therecontinuty?
Y E S G ot o s t e p1 1 .
NO Repairopenin the appropriate
torquesensor
wirecircuitbetweenthe EPScontrolunitandthe
t o r q u es e n s o r . l
\
17-30
1 1 .Substitutea known-goodEPScontrol unit, and
reconnectthe disconnectedconnectors.
't2.
DTC17: TorqueSensorVccl
DTC18:TorqueSensorVcc2
Start the engine.
2 . S t a r tt h e e n g i n e .
YES Go to step 13.
3. Wait at least 10 seconds.
NO Checkfor looseor poor connectionsat the
EPScontrol unit and the torque sensorconneclors.
lf the connectionsare good, replacethe EPScontrol
u n i ta n d r e c h e c k . I
1 3 .Stop the engine,and verify the DTC.
ls DTC16 indicated?
YES Go to step 4.
time.I
YES Replacethe steeringgearboxand recheck.l
4 . Stop the engine,and verify the DTC.
the code indicated.l
Is DTCl7 or DTCl8 indicated?
YES Go to step 5.
NO Do the troubleshootingfor the DTc
indicated.I
Make sure the ignition switch is OFF,then
c o n n e c t oC
r ( 2 0 P ) t e r m i n aNl o . 3 a n d b o d y g r o u n d .
UNITCONNECTOR
C (2OP)
EPSCONTROL
Wiresideo{ femaleterminals
Y E S R e p a i rs h o n t o b o d y g r o u n di n t h e w i r e
betweenthe torque sensorand EPScontrol unit.I
NO Go to step 7.
(cont'd)
17-31
EPSComponents
7. Checkfor continultybetweenEPScontrol unit
c o n n e c t oC
r ( 2 0 P t)e r m i n a lN o . 3 a n d t h e t o r q u e
EPSCONTROL
UNITCONNECTOR
C I2OP)
\
9. Checkfor continuitybetweenEPScontrol unit
connectorC {20P)terminal No. 11 and the torque
EPSCONTROL
UNITCONNECTOR
C (2OP}
Vcc2(GRN/YEL)
YES Go to step 8.
YES-Go to step 10.
s e n s o ra n d E P Sc o n t r o lu n i t . I
sensorand EPScontrol unit.l
8 . Checkfor continuitybetweenEPScontrol unit
c o n n e c t oC
r ( 2 0 P t)e r m i n a lN o . 1 1 a n d b o d y g r o u n d .
EPSCONTROL
UNITCONNECTOR
C (2OP)
connectall the disconnectedconnectors.
1 1 .Start the engine.
2 3
lvcc2
5 6 1 8
0
{GRN/YEL)
YES Go to step 12.
NO Checkfor looseor poor connectionsat the
EPScontrol unit and the torque sensorconnectors.
lf the connectionsare good, replacethe EPScontrol
u n i ta n d r e c h e c k . l
12. Stop the engine,and verity the DTC.
ls DTC17 or DTC18 indicated?
ls therecontinuity?
YES-Replace the steeringgearboxand recheck.l
YES Repairshortto bodygroundin thewire
betweenthetorquesensorandEPScontrolunit.t
NO Goto step9.
17-32
DTC22: VehicleSpeedSensorSignal
3 . Blockthe rearwheels and raisethe vehicle,and
make sure it is securelysupported.
DTC23: EngineSpeedSignal
NOTE:
. lf the MIL indicatoris ON, troubleshootthe PGIVI-Fl
systemfirst.
. Eventhough the system is operatingnormally,the
EPSindicatorwill come on underthe following
conditions.
- C o n d i t i o n1 :
. The vehiclewas travelingat least '12.4mph
(20 km/h),then
. A rapld changein vehiclespeedwas detected,
then
. T h e v e h i c l e( o rt h e v e h i c l es p e e ds e n s o rs i g n a l )
stoppedfor at least5 seconds,and
. The engine speedwas still 1,640rpm or higherfor
at least5 seconds
- Condition2:
After the vehicle(or the vehiclespeedsensor
signal)has stoppedfor at least10 seconds,yetthe
e n g i n es p e e dw a s s t i l l 1 , 6 4 0r p m o r h i g h e rf o r a t
least20 seconds.
- Condition3:
W h e nt h e v e h i c l es p e e di s 1 0 k m / h ( 6 . 2m p h )o r
a b o v ea n d t h e e n g i n ei s r u n n i n ga t 2 8 0 r p m o r
below for 3 seconds.
1. Startthe engineand checkthe tachometer.
ls the tachometer working correctly?
5 . Blockthe right front wheel, and slowly rotatethe
left front wheel, and measurethe voltage between
E P Sc o n t r o lu n i tc o n n e c t oC
r ( 2 0 P ) t e r m i n aNl o . 7
EPSCONTROL
UNITCONNECTOR
C {2OP)
Does the voltagepulse 0 V and 5 V?
YES Go to step 6.
NO Repairopen in the wire betweenthe EPS
control unit and the VSS. lf the wire is OK,checkfor
a loose or poor connectionsat the EPScontrol unit.
lf necessary,substitutea known-goodEPScontrol
u n i t ,a n d r e c h e c k . l
YES- Go to step 2.
2. Test-drivethe vehicleabove 15 km/h {9.3mph).
ls the speedometerworking correctly?
YES Go to step 3.
NO-Perform the speedometersystem
troubleshooting{see page22-651.a
(conr'd)
17-33
EPSGomponents
Turn the ignition switch OFF,and disconnectEPS
control unit connectorC (20P).
7 . Startthe engine,and let it idle.
11. Measurethe voltage betweenEPScontrol unit
c o n n e c t oC
C {2OPI
8 . Measurethe voltage betweenEPScontrol unit
c o n n e c t oC
r { 2 0 P t) e r m i n a lN o . 1 9a n d b o d y g r o u n d .
EPSCONTROL
UNITCONNECTOR
C {2OP)
ls there about 6 V at idle? (With the metet set tor
trequency, is therc 33 Hz per 1,000 engine rpn?)
ls there about 6 V at idle? (With the meter set lol
t requency,is there 33 Hz per 1,000engine rpm?)
YES Checkfor loose EPScontrol unitconnectors.
NO Go to step
YES Checkfor loose EPScontrol unit connectors.
'12.
1 3 .Disconnectthe ECMconnectorE (31P)connector.
NO Repairopen in the wire betweenthe EPS
c o n t r o lu n i ta n d t h e E C M . I
9 . Turn the ignition switch OFF,and disconnectEPS
control unit connectorC (20P).
1 0 .Startthe engine,and let it idle.
!
17-34
'14.
Checkfor continultvbetweenEPScontrol unit
c o n n e c t oC
r ( 2 0 P ) t e r m i n aNl o . 1 9 a n d E C M
connectorE (31P)terminal No. 26.
ECMCONNECTOR
E {31PI
DTC37: EPSControlUnitInternal
Circuit
(lnputCircuitForMotorVoltage)
2. Startthe engine.
3. Turn the steeringwheel from lock-to-lockseveral
times, and wait 10 secondsor more.
YES Go to step 4.
trme.l
YES-Go to step 15.
ls DTC 37 indicated?
N O - R e p a i r o p e n i n t h e w i r e b e t w e e nt h e E P S
c o n t r o lu n i ta n d E C M . I
Y€S Checkfor loose EPScontrol unit conneclors.
1 5 . Disconnectthe gauge assembly22Pconnector.
c o n n e c t oC
r ( 2 0 P ) t e r m i n aNl o . 1 9 a n d b o d y g r o u n d ,
EPSCONTROL
UNITCONNECTOR
C (2OP}
Y E S R e p a i rs h o r t t ob o d y g r o u n di n t h e w i r e
betweenthe EPScontrol unit, the test tachometer
connector,the gaugeassembly,and the ECM.I
NO Checkfor loose ECMcontrol unit connectors.
lf necessary,substitutea known-goodECMcontrol
17-35
EPSComponents
.l
DTC41: VoltageForMotor
c o n n e c t oB
r ( 2 P ) t e r m i n aNl o . 2 a n d b o d y g r o u n d .
B I2P)
times, and wait 10 secondsor more,
Tit
M2 {GRN)FJ
-r
o)
YES-Go to step 4.
I
T
time.l
Y E S - R e p a i rs h o r tt o b o d y g r o u n di n t h e G R Nw i r e
betweenthe EPScontrol unit and the motor,l
YES Go to step 5.
NO Go to step 8.
t h e c o d ei n d i c a t e d . l
disconnectEPScontrol unit connectorB (2P)and
the motor 2P conneclor.
c o n n e c t oB
r ( 2 P ) t e r m i n aNl o . 1 a n d N o . 2 .
B {2P)
EPSCONTROL
UNITCONNECTOR
c o n n e c t oB
r ( 2 P )t e r m i n a lN o . 1 a n d b o d y g r o u n d .
B {2P}
EPSCONTROLUNIT CONNECTOR
M2 (GRNI
M1 (RED}H
F---t||
Itr
(f))
T
,L
YES Repairshort to body ground in the REDwire
betweenthe EPScontrol unit and the motor.!
17-36
YES Repairshort betweenthe REDand GRN
wires in the motor circuit betweenthe EPScontrol
u n i t a n dt h e m o t o r . l
NO Go to step 9.
\
9. Turn the ignition switch ON (ll),and measurethe
voltagebetweenEPScontrol unit connectorB (2P)
terminal No. 1 and body ground
B (2P)
1 1 .T urn the ignition switch is OFF.
Substitutea known-goodEPScontrol unit, and
1 3 .Start the engine,and turn the steeringwheel from
lockto lock severaltimes.
M1 IREDI
H
r-_-1 ||
,<.)\
uL,/
Y
tr
I
WiresideoI femaleterminals
Y E S - G o t o s t e p1 4 .
NO-Check for loose or poor connectionsatthe
EPScontrol unit and the motor connections.lfthe
connectionsare good, replacethe EPScontrol unit
andrecheck.l
1 4 . S t o pt h e e n g i n e a
, n d v e r i t yt h e D T C .
Is there battety voltage?
YES Repairshort to power in the + circuitwire
betweenthe EPScontrol unit and the motor.I
YES Replacethe steeringgearboxmotor and
recheck.l
N O - G o t o s t e p1 0 .
1 0 .Measurethe voltagebetweenEPScontrol unit
t h e c o d ei n d i c a t e d . l
c o n n e c t oB
EPSCONTROL
B (2P)
UNITCONNECTOR
razrcnrrrr
l{. I
l-t
I
(v)
Y
I
YES-Repair shortto power in the - circuitwire
betweenthe EPScontrol unit and the motor.!
17-37
EPSComponents
DTC42,45: MotorDrivenCurrent
{
c o n n e c t oB
r ( 2 P l t e r m i n aNl o . 2 a n d b o d y g r o u n d .
1. Clearthe DTC.
B I2PI
t i m e s ,a n d w a i t 1 0 s e c o n d so r m o r e .
r',rz
tcnnrt
ll
-](o)
T
YES- Go to step 4.
I
NO-Check for loosewires or poor connections.lf
time.I
Stop the engine,and verify the DTC.
lsthere continuity?
ls DTC 42 or 45 indicated?
YES Repairshort to body ground in the GRNwire
betweenthe EPScontrol unit and the motor.l
YES-Go to step 5.
NO Go to step 8.
NO- Performthe appropriatetroubleshootingfor
t h e c o d ei n d i c a t e d . I
M a k es u r et h e i g n i t i o ns w i t c hi s O F F ,t h e n
disconnectEPScontrol unit B connector(2P)and
the motor 2P connector.
c o n n e c t oB
r ( 2 P )t e r m i n a lN o . 1 a n d N o . 2 .
EPSCONTROL
UNITCONNECTOR
B {2P)
6 . Checkfor continuitybetweenEPScontrol unit
c o n n e c t oB
EPSCONTROL
UNITCONNECTOR
B I2P)
M2 {GRN)
M1 IRED}H
I
f2-l
(C))
T
I
YES Repairshort to body ground in the REDwire
betweenthe EPScontrol unit and the motor,I
17-38
YES Repairshort betweenthe REDand GRN
wires in the motor circuit betweenthe EPScontrol
u n i ta n d t h e m o t o r . l
NO Go to step 9.
9. Turn the ignition switch ON (ll),and measurethe
voltage betweenEPScontrol unit connectorB (2P)
t e r m i n a lN o . I a n d b o d y g r o u n d .
B (2PI
M1{RED}H
T-----l | |
(v)
connectorB (2P)terminal No. 1 and the motor 2P
EPSCONTROLUNIT
B 12P)
CONNECTOR
MOTORCONNECTOR
{2PI
M1 IRED)
lil
M1 (RED}
I
I
Wiresideo{ Iemaleterminals
YES-Repair short to power in the + circuitwire
betweenthe EPScontrol unit and motor.l
ls therecontinuity?
YES-Go to step'12.
NO-Repairopenin the REDwire betweenthe EPS
controlunitandthe motor.l
NO Go to step 10.
1 0 .Measurethe voltage betweenEPScontrol unit
c o n n e c t oB
r { 2 P } t e r m i n aNl o . 2 a n d b o d y g r o u n d .
EPSCONTROL
UNITCONNECTOR
B (2P}
mzrcnrur
ll-l
A
(v)
Y
I
Y E S R e p a i rs h o r tt o p o w e ri n t h e + c i r c u i t w i r e
betweenthe EPScontrol unit and the motor.a
N O - G o t o s t e p1 1 .
(cont'd)
17-39
EPSGomponents
L
DTGTroubleshooting(cont'd)
c o n n e c t oB
r ( 2 P ) t e r m i n aNl o . 2 a n dt h e m o t o r2 P
c o n n e c t otre r m i n a lN o . 1 .
EPSCONTROLUNIT
CONNECTORB I2PI
MOTORCONNECTOR
{2P)
YES Replacethe steeringgearboxmotor and
recheck.l
M2 IGRN)
Y E S - G o t o s t e p1 3 .
NO-Repair open in the GRNwire betweenthe EPS
control unit and the motor.l
Checkfor loosewires or poor connections,if the
connectionsare good. substitutea known-good
EPScontrol unit, and connectallthe disconnected
connectors.
1 4 . Startthe engine,and turn the steeringwheel from
YES Go to step 15.
NO Checkfor loose EPScontrol unitconnectors.lf
necessary,replacethe EPScontrol unit and
recheck.a
17-40
(
DTCtli|: MotorDrivenCurrentis Excessively
Hish
8. Measurethe voltagebetweenEPScontrol unit
c o n n e c t oB
EPSCONTROL
UNITCONNECTOR
B I2PI
2. Startthe engine.
'10
times, and wait
secondsor more.
Til
M2tcRNl F-l
f---1 z I
(v)
Y
I
YES Go to step 4.
ttme.I
YES- Repairshort to power in the - circuitwire
betweenthe EPScontorl unit and the motor.!
YES Go to step 5.
NO-Go to step 9.
the code indicated.I
disconnectEPScontrol unit connectorB (2P)and
the motor 2P connector.
1 0 . Checkfor continuitybetweenEPScontrol unit
c o n n e c t oB
r ( 2 P )t e r m i n a l sN o . 1 a n d N o . 2 .
EPSCONTROL
UNITCONNECTOR
B {2P)
'1
c o n n e c t oB
r ( 2 P ) t e r m i n aNl o . a n d b o d y g r o u n d .
B {2P}
M2 {GBN)
M 1 { R E o )H
T------t
I I
Itr
(v)
T
-L
Wiresideot Iemaleterminals
YES Repairshort betweenthe GRN and RED
wires in the motor circuitbetweenthe EPScontrol
u n i ta n d t h e m o t o r . l
ls therc battery voltage?
YES Repairshort to power in the + circuitwire
betweenEPScontrol unit and motor.l
( c o n td )
17-41
EPSComponents
1 2 .Start the engine,and turn the steeringwheel from
(
DTC47: EPSControlUnitlnternalCircuit
(PowerRelay)
1. Clearthe DTC.
2. Startthe engine.
YES Go to step 13.
NO -Check for loose or poor connectionsat the
EPScontrol unit and the motor connections.lf the
connectionsare good, replacethe EPScontrol unit
and recheck.l
1 3 .Stop the engine,and verity the DTC.
YES-Go to step 3,
NO-Check for loosewires or poor connections,lf
time.I
YES-Replacethe steeringgearboxmotor and
recheck.tl
YES Checkfor loose EPScontrol unit connectors.
17-42
DTC50: EPSControlUnit InternalCircuit
(CPUor Microcomputer)
DTC51: EPSControlUnitInternalCircuit
(EEPROM)
1. Clearthe DTC.
YES Go to step 3.
YES-Go to step 3.
the connectionsare good. the system is OK at this
t i m e .t
time.I
YES-Check for looseor poor connectionsat the
EPScontrol unit connections.lf the connectionsare
good, substitutea known-goodEPScontrol unit. lf
the symptom/indicationgoes away, replacethe
original EPScontrol unit.l
EPScontrol unit connections.lf the connectionsare
good. substitutea known-goodEPScontrol unit. lf
original EPScontrol unit.!
17-43
EPSComponents
(cont'dl
DTCTroubleshootang
(Fail-safe
RelayStuckON)
'1.
(
Low
DTC64: BatteryVoltageis Excessively
(Fail-safe
RelayContactFailureandMotor
VoltageFallOff)
Clearthe DTC.
2. Startthe engine.
2. Startthe engine.
YES-Go to step 3.
YES Go to step 3.
time.I
trme.l
YES-Check for loose or poor connectionsat the
EPScontrol unit. lf the connectionsare good,
substitutea known-goodEPScontrol unit. lf the
symptom/indicationgoes away, replacethe
originalEPScontrol unit and recheck.l
YES Go to step 4.
the code indicated.
'18(604)
4. Checkthe No.
fuse in the under-hoodfuse/
relay box, and reinstallthefuse if it is OK.
Is the f use OK?
YES Go to step 5.
NO Replacethe fuse and recheck.l
5. DisconnectEPScontrol unit connectorA (2P).
c o n n e c t oA
r ( 2 P )t e r m i n a lN o . 1 a n d b o d y g r o u n d .
-Blwt{r/Bl.urH
l
\9
I
YES- Checkfor loose or poor connectionsat the
EPScontrol unit connectors,and checkfor a poor
ground at G 151. lf necessary,substitutea knowngood EPScontrol unit and recheck.l
NO Repairopen in the WHT/BLUwire between
t h e N o . 1 8 ( 6 0 , 4 ) f u saen d E P Sc o n t r o lu n i t . l
17-44
DTC66,68: EPSControlUnitlnternalCircuit
DTC67: TorqueSensorl/FCircuit
1. Clearthe DTC.
3. Turn the steeringwheelfrom lock-to-lockseveral
YES-Go to step 4.
YES-Go to step 4.
the connectionsare good.the system is OK at this
time.l
NO Checkfor loose wires or poor connections.lf the
connectionsare good, the system is OK at this time. !
4. Stop the engine.and verify the DTC.
EPScontrol unit. lf the conneclionsare good,
original EPScontrol unit and recheck.I
YES Checkfor looseor poor connectionsat the
original EPScontrol unit and recheck.!
17-45
EPSComponents
2. Startthe engine.
times, and wait 10 secondsor more,
YES Go to step 4.
time.l
YES-Check for loose or poor connectionsat the
original EPScontrol unit and recheck.l
NO- Performthe appropriatetroubleshootingfor
17-46
EPSIndicatorCircuitTroubleshooting
1 . Turn the ignitionswitch ON (ll),startthe engine,
and watch the EPSindicator.
6. DisconnectEPScontrol u n it connectorC (20P).
YES lf the EPSindicatorcomes on and goes off, it's
OK. lf the EPSindicatorstayson or blinks.go to
s t e p1 2 .
8. ConnectEPScontrol unit connectorC (20P)
terminal No. 6 to body ground with a jumper wire.
NO Go to step 2.
EPSCONTBOLUNIT CONNECTOBC {2OP)
Turn the ignition switch OFF,then ON (ll) again,
and watch the brakesystem indicator,
Does the brake system indicator come on?
YES-Go to step 3.
W i r e s d € o f l e m a l e 1 6 r m i n as
NO Repairopen in the indicatorpower source
circuit.l
. B l o w nN o . 1 0 ( 7 . 5 A ) f u s e .
. Open in the wire betweenthe No. 10 (7.5A)fuse
and gaugeassembly.
. Open circuitinsidethe under-dashfuse/relaybox,
. Faultygauge assembly.
YES Go to step 9.
NO Repairopen in the wire betweenthe gauge
assemblyand the EPScontrol unit.l
3 . Turn the ignitionswitch OFF,
4 . Connecta jumper wire betweenthe gauge
assembly22Pconnectorterminal No. 13 and body
g r o u n d ,t h e nt u r n t h e i g n i t i o ns w i t c hO N ( l l ) .
(Blueconnector)
22PCONNECTOR
GAUGEASSEMBLY
1 0 .DisconnectEPScontrol unit connectorA (2P),
' l1 .
connectorA terminal No. 2 and body ground.
A I2PI
EPSCONTROL
UNITCONNECTOA
w i r e s d e o f t e m a l et e r m i n a l s
YES-Go to step 5.
N O I n s p e ctth e E P Si n d i c a t o b
r u l b ,i f t h e b u l b i s
O K , r e p l a c et h e b u l bc i r c u i tb o a r di n t h e g a u g e
assembly.l
YES Checkfor loose or poor connectionsat the
E P Sc o n t r o lu n i t .l f t h e c o n n e c t i o nasr e g o o d ,
originaE
l P Sc o n t r o lu n i ta n d r e c h e c k . I
N O R e p a i ro p e ni n t h e w i r e o r a b a d g r o u n da t
G151,t
(cont'd)
17-47
EPSComponents
I
EPSIndicatorCircuitTroubleshooting(cont'dl
16. Measurethe voltagebetweenEPScontrol unit
'1
connectorA (2P)terminalNo. and body ground.
1 3 .DisconnectEPScontrol unit connectorC (20P).
1 4 .Turn the ignitionswitch ON (ll).
YES-Repair short to ground in the YEUBLUwire
betweenthe gaugeassemblyand the EPScontrol
unit,or replacethe bulb circuit board in the gauge
assembly.l
NO-Go to step 15.
Measurethe voltagebetweenEPScontrol unit
c o n n e c t oC
EPSCONTROL
UNITCONNECTOR
C I2OP)
EPSCONTROL
UNITCONNECTON
A (2P}
+B (WHT/BLUIH
Itr
v
-L
YES-Go to step 17.
NO-Check for a blown No. 18 (604)fuse in the
under-hoodfuse/relaybox or open/shortin the
WHT/BLUwire betweenthe under-hoodfuse/relay
box and the EPScontrol unit.l
1 8 , ReconnectEPScontrol unit connectorA (2P).
connectorC (20P)terminalNo. 8 and body ground.
ls therebatteryvoltage?
EPSCONTROL
UNITCONNECTOR
C (2OP)
NO-Repairopenin thewire betweenEPScontrol
unitconnector
C (20P)andthe No, 10(7.5A)fuse.t
ls therc about 10 V?
YES Checkfor looseor poor connectionsat the
originalEPScontrol unit and recheck.l
NO Repairshort to ground in the BRNwire
betweenthe data link connectorand the EPS
c o n t r o lu n i t . I
17-48
Motor Removal/lnstallation
Bemoval
then write down the frequenciesfor the preset
buttons.
4. Removethe connectorbracket(A) onthegearbox
housing,and disconnectthe motor 2P connector
(B).
9.8 N.m {1.0kgf.m,
2. Disconnectthe negativecablefrom the battery,and
wait 3 minutesbefore beginningwork.
3. Removethe air cleanerassembly(A).
5. Removethe motor {A) from the gearboxhousing.
6. Removethe O-ring (B)and discardit.
(cont'd)
17-49
EPSComponents
(cont'dl
Motor RemovaUlnstallation
(
r 0 .Installthe motor on the gearboxby engagingthe
lnsiallation
7. Cleanthe mating surfaceof the motor (A) and
gearbox.
q
8 x '1.25
mm
20 N.m
12.0kgt.m,7.2lbl ftl
E
motor shaft and worm shaft (D).Note the motor
installationposition{directionof motor wires).
1 1 .Beforetighteningthe bolts,turn the motor two or
three times right and left about 45 degrees.lvlake
sure the motor is evenlyseatedon the steering
gearboxand that the O-ring is not pinchedbetlveen
the mating surfaces.
1 2 .Installthe removedDartsin the reverseorder of
removal.and note these items:
L==-
c].E@
Apply a thin coat of siliconegrease(P/N087338070E)tothe new O-ring(B),and carefullyfit it on
the motor.
9 . Apply grease{Nippon GreaseWR-S or equivalent
steeringgear grease)into the motor shaft (C).
17- 5 0
lvlakesure the motor 2P connectoris properly
connected.
lvlakesurethe motor and EPSwires are not
caughtor pinchedby any parts.
Reconnectthe negativecableto the battery.
D o t h e e n g i n ec o n t r o lm o d u l e( E C M )i d l e l e a r n
Enterthe anti-theftcode for the radio station
Dresets.Resetthe clock,
Do the oower window control unit reset
procedure(seepage 22-1241.
1 3 .After installation,startthe engine,and let it idle.
Turn the steeringwheel from lock-to-lockseveral
times. Checkthat the EPSindicatordoes not come
on.
SteeringGearboxRemoval
Ball ioint remover,2Smm 0TlvlAC-S100200
8. Removethe cotter pin (A)from the tie-rod balljoint
nut {B),and loosenthe nut.
_t\
1. Raisethe front of vehicle,and make sure it is
securelysupponed.
2. Removethe front wheels.
R e m o v et h e d r i v e r ' sa i r b a g ( s e e p a g e 2 3 - 1 1 3 ) .
4 . Removethe steeringwheel (seepage 17-6).
5 . Removethe motor on the steeringgearbox (see
p a g el T - 4 9 ) .
6 . Removethe driver'sdashboardlower cover (see
page20-59)and under cover {seepage20-60).
7 . Removethe steeringjoint bolts (A),and disconnect
the steeringjoint by moving the steeringjoint (B)
toward the column.
l,a.:
'/
--L-
r0 mm HEXNUT
07MAC-S100200
9 . Separatethe tie-rod balljoint and damper steering
arm usingthe specialtool (seepage 18-10).Repeat
on the other side of the vehicle.
1 0 .G r a s pt h e r i g h ts i d et i e - r o d a, n d p u l lt h e r a c ka l l t h e
way to the passenger'sside,
1 1 . Removethe heat shield (A) mounting bolts from
the body stiffener,and let the heat shield lay
againstthe exhaust.
'
i
l
(cont'd)
17-51
EPSComponents
SteeringGearboxRemoval(cont'd)
12. Disconnect
the EPSwire harness6Pconnector
(A),
andremovethe EPSwire harness(B)andmountino
bracket(C).
1 4 . R e m o v et h e e n g i n ew i r e h a r n e s sc l a m p s{ A ) f r o m
the three mounting brackets.
-a--zi
i
F--_1
t5.
1 3 . Removethe groundcableterminal(A)fromthe
steeringgearboxhousing.
..(
.,/
a
bH \
ry T,-.lt'^ \
'"
_ - 1 . . 1 . - '
17-52
\--
Removethe heaterhose {B)from the bracket.
1 6 . Open the heatervalve cableclamp (A),and
disconnectthe heatervalve cable(B).Removethe
heatervalve (C)from the bulkhead,and move jt
aside.
I
17. Removethe bodv stiffener(A).
19. Removethe steeringstiffenerB from the right side
of the steeringgearbox.
i t1-:: .,
1 8 .Removelhe steeringstiffenerA from the left side
of the steeringgearbox.
20. Lower the steeringgearbox,and rotateit so the
pinion shaft points upward.
21. Removethe pinion shaft grommet (A)from the top
of the torque sensor.
(cont'd)
17-53
EPSComponents
SteeringGearboxRemoval{cont'd)
22. Move the steeringgearboxand tie-rod ends as an
assemblyto the wheelwellopening on the
passenger'sside.
23. Carefullyraisethe driver'sside (pinionside)ofthe
steeringgearbox(A) and tie-rod (B) until clearsthe
mastercylinderand under-hoodfuse relay box,
then removethe steeringgearbox.Be careful not to
damagethe hoses,linesand wtre narnesses.
17-51
SteeringGearboxOverhaul
ExplodedView
mm
I x '1.25
ftl
20 N.m(2.0kgf.m,7.2lbt
O.RING
Replace.
CONNECTOR
PINION
SHAFT
GROMMET
RACKGUIDE
-@
.
. DISCWASHEB @'--g
-sPRrNG
SCREW
L)-RACKGUIDE
6
' v---\
\.oc**u.
v
\ >-*\{i#rî
--.
i
6^:,;
BOOT BAND
Beplace.
''
-'t
'"''/
s(./t' J
-l
.
GUIDE \
SLTDER
SRACKET
{îl
\J"
\
@
II
\
\
\
\
BOOTBAND
- Replace.
LOCKWASHER
Replace.
\
stot *,tttc
Renrace
\
LocK
'162 scREw
N.m
l t o . sr g f m , 1 1 9 l bfft )
Beqtace.
TIE.RODEND
rtE-ROD
54 N m {5.5kgf.m,40lbf ft)
44 N m {4.5 kgf.m, 33 tbt.ft)
(cont'd)
17-55
EPSComponents
SteeringGearboxOverhaul(cont'dl
. Locknutwrench 07ZAA-S5A0100
. Pincers,Oetiker1098or equivalent,commercially
available.
4. Removethe stop plate (A).the 12 mm flange bolts
(B),the O-rings(C),and the bracket(D)from the
sleeringgearbox.
NOTE:
. Referto the ExplodedView as neededduring this
procedure.
. Do not allow dust, dirt, or other foreign materialsto
enter into the steeringgearbox.
Eemoval
1, Removethe steeringgearbox(seepage 17-b1).
Disassembly
2. Unbendthe lock washer (A).
-,'i.
. Loosenthe locknut(A),then removethe rack guide
screw (B),sprlng (C),disc washer (D),and rack
g u i d e( E )f r o m t h e s t e e r i n gg e a r b o x .
- -.i::..:4,.-,
Holdthe bracket(A) with one wrencn, anq unscrew
both tie-rod ends (B)with anotherwrench. Remove
the lockwashers.
1 7-56
-
:.--. '
6. Removethe two boot bands (A)from boot (B).
Compressthe boot by hand,and apply vinyl tape
(C)so the boot ends stay collapsedand pulled back
8. Installthespecialtool (A) on the lock screw (B)
securely.then loosenand removethe lock screw
from the steeringgearboxhousing.
07zAA-S5A0r00
1 . Attachthe yoke (A) of a universalpullerto the
steeringgearboxmounts with bolts.Securely
clamp the yoke in a vise as shown. Do not clamp
the steeringgearboxhousingin the vise.
Removethe specialtool.
1 0 .Pull on the rackhousing(A)to remove it from the
steeringgearboxhousing,Removethe boot {B) and
s l i d e rg u i d e( C )f r o m t h e c y l i n d e r .
(cont'd)
17-57
EPSComponents
SteeringGearboxOverhaul(cont'd)
'll.
Checkthe slider guide for damageand cracks.
Using verniercalipersto measurethe thicknessof
the slider guide. lf the thicknessis lessthan service
l i m i t ,r e p l a c et h e s l i d e rg u i d e ,
-.---(fr--',
Il i l ( t t
f
Z,-----:-r-.--------.t.t'E-r
i @ r
25.3mm
{0.925in.}
12
,
/i\
,)))
15. Applymultipurpose
greaseto the indicated
part
part)
of
the
{shaded
outersurfaceof the rack
housing.Do not applyto the dentsandgrooves.
I
|
25.3 mm
{0.925in.l
Removeanddiscardthestopring{A)onthe
cylinderby expanding
it with snapringpliers.
Removeanddiscardthe lockscrew{B}.
\
13. Installthe new lock screw on the rack housing.
1 4 . I n s t a l l t h en e w s t o p r i n g i n t h e g r o o v e( C ) o nt h e
cylinderby expandingit with a snap ring pliers.Be
carefulnot to scratchor damagethe housing
surfacewith the stop ring edges.
I
17-58
16. Set the new boot bands (A) on the band installation
groovesof the boot (B) by aligningthe tabs (C)with
the holes (D)of the band.Do not closethe ear of the
boot band in this step.
1 1 . Compressthe boot by hand,and apply vinyl tape
(E)to the bellowsso the boot ends stay collapsed
and pulled back.
Passthe boot over the rack housingso the smaller
diameterend of the boot facesthe steering
gearboxhousing.
'19. Pushthe rack housing(A) into the steeringgearbox
housing(B) so the notch (C)is alignedwith the pin
(D)on the bottom of the gearboxhousinginside
20. Tightenthe lock screw {A) by hand first, then install
the specialtool (B)on the lock screw. Lightly
tighten the lock screw.Do not tighten the lock
screwto the specifiedtorque Yet.
1 8 .Attachthe yoke (A) of a universalpuller to the
gearboxhousingmounts with bolts.then securely
clamp the yoke in a vise as shown. Do not clamp
the steeringgearboxhousingin a vise.
21. Removethe specialtool.
(cont'd)
17-59
EPSComponents
22. Apply multipurposegreaseto the sliding surface
and circumferenceofthe rackguide (A),and install
it onto the gearboxhousing.Wipe the greaseoff
the threadedsectionofthe housrno.
'1
{
25. Centerthesteeringrackwithin its stroke,and align
t h e s l i d e rg u i d e( A ) w i t ht h e h o t e s( B )i n t h e b o o t ( C ) .
Fit the slider guide to the boot by pressingaround
the edgesof the holessecurely
- .- =-1,...'.
,. ,l
.j
2 3 . I n s t a l l t h ed i s cw a s h e r( B ) w i t hi t s c o n v e xs i d e
f a c i n gt h e r a c kg u i d e .I n s t a l l t h es p r i n g( C ) .A p p t y
sealantto the middle of the threadson the rack
guide screw (D),then installand tighten it to 25
N m (2.5kgf.m, 18 lbf.ft).Looselyinstatlrhetocknut
(E).
24. Apply multipurposegreaseto the sliding surfaceof
the slider guide (A).Keepgreaseoff of the rack-toslider guide mating surfacesand the boot-to-slider
guide mating surfaces.
Slidethe steeringrack all the way to left, and place
t h e s l i d e rg u i d eo n t h e s t e e r i n gr a c kb y a l i g n i n gt h e
bolt holes (B).
E
25 N.m 12.5kgt.m,18tbt.ft)
26. Beforeinstallingthe bracket(D),cleanthe mating
surfaceofthe 12 mm flange bolts (E)and the
bracket.Coatthe new O-rings{F)with multipurpose
g r e a s ea, n d i n s t a l l t h e mo n t h e ' 1 2m m f l a n g eb o l t s .
27. Looselyinstallthe bracketon the steeringrack by
tighteningthe 12 mm flange boltsto 25 N.m (2.5
kgf.m, 18lbf.ft).
28. Hold the gearboxhousingusing a yoke,then install
the specialtoolon the lock screw (A).Retightenthe
lock screwto the specifiedtorque values.
A
{ 1 6 . 5k g t . m , 1 1 9 l b f . f t }
29. Removethe specialtool.
17-60
30, Retightenthe 12 mm flange bolts (A) to the
soecifiedtoroue value.
3 4 . C l o s et h e e a r p o r t i o n( A )o f t h e b a n d s( B ) w i t h
, e t i k e r1 0 9 8o r
c o m m e r c i a l la
v v a i l a b l ep i n c e r sO
e q u i v a l e n(tC ) .
74 N.m (7.5kgf.m,5irlbf.ft)
5 t .
After tighteningthe 12 mm flange bolts, installa
new stop plate (B)over one of the bolt heads.Be
surethe tabs (C)of the stop plate are alignedwith
the flat surfacesof the bolt head.
32,
Cleanoff any greaseor contaminationfrom the
b o o t i n s t a l l a t i ognr o o v e so n t h e h o u s i n g .
Expandthe boot (A) by removingthe vinyltape,
and fit the boot ends (B) in the installationgrooves
o n t h e c y l i n d e rh o u s i n g .
3 5 . I n s t a l l t h en e w l o c kw a s h e r( A )w i t h i t s r a d i u s e d
side facing (B)the tie-rod (C),and screwthe tie-rod
on the bracket(D).Repeatthis stepfor the other
side of the tie-rod.Hold the bracketwith one
wrench,and tightenthe tie-rodsto the specified
torque with anotherwrench.
. .,,";=-.
, . ,
*=,,',
(cont'd)
17-61
EPSComponents
36. Bendthe lock washer againstthe flat spots on the
bracketwitha Iarge pair of pliers.
37. Adjust the rackguide screw {seepage 17-13).
17-62
SteeringGearboxInstallation
'1.
Beforeinstallingthe steeringgearbox,slidethe
rack all the way to the passenger'sside (right
direction).
4. Insertthe pinion shaft up through the bulkhead,
then slip the right side of the steeringgearbox
housing(A) over the mounting stud (C)on the
gearboxmounting bracket.
2 . Passthe right side of the steeringgearboxtogether
with the tie-rodsthrough the wheelwell openingon
the passenger'sside.Continuemoving the steering
gearboxtoward the passenger'sside untilthe
driver'sside tie-rodend and gearboxclearsthe
mastercylinderand under-hoodfuse Ielay box.
Lower the steeringgearbox.and move it toward
t h e d r i v e r ' ss i d eu n t i l t h es t e e r i n gg e a r b o xi s l n
Dosition.
\-
--'
'.'',
i
:-1
. . . .
Be carefulnot to damagethe hoses,lines
and wire harnesses.
10 x '1.25mm
61 N.m
{62 kgl m, 45 lb{ ftl
Installthe steeringstiffenerB, and lightlytighten
the steeringgearboxmounting nuts.
Installthe steeringstiffenerA with the gearbox
m o u n t i n gb o l t s .T h e nt i g h t e na l l t h e s t e e r i n g
gearboxmounting hardwareto the specifiedtorque.
1 0x 1 . 2 5m m
6l N.m
(6.2 kgt.m, 45 lbt.ft)
3 . I n s t a l l t h ep i n i o ns h a f tg r o m m e t( A ) .
.: --.-{
.
( c o n t ' d)
17-63
EPSComponents
SteeringGearboxInstallation(cont'd)
7. Installthebodystiffener(A),andtorquethe
mountingboltsto the specified
torque.
9. Reinstallthe heaterhose (A) on the hose bracket.
8 x 1.25mm
29 N.m {3.0kgf.m,22lbf.ftl
1 0 .Installthe enginewire harnessclamps (B)to the
three harnessbrackets.
L Installthe heatervalve (A) on the bulkhead,and
connectthe heatervalve cableend (B)to the heater
valve arm (C).Readjustthe heatervalve cable{see
page21-46).
L-t
:.i.t'
,
9.8N.m
(1.0kgf m,
7.2tbf.ftl
17-64
' It . Under
the steeringgearbox,installthe ground
cableterminal (A) on the steeringgearboxhousing.
9 . 8N . m
12. lnstalltheEPSwire harnessbracket(A)on the
(B)
gearboxhousing,andconnectthe 6Pconnector
propefly.
9.8 N.m
{1.0kgt m,7.2 lbt.ftl
1 4 . Centerthe steeringrackwithin its stroke.
1 5 . Wipe off any greasecontaminationfrom lhe ball
joint taperedsectionand threads.Then reconnect
the tie-rod ends 1A)tothe damper steeringarms.
lnstallthe ball joint nut (B) and tighten them.
,-', ''l
:
1
)
B
10x 1.25mm
i€ N.m
{4.4 kgf.m.
32 tbt.ftl
1 3 . I n s t a l l t h eh e a ts h i e l d( A ) .
to.
,.!,..
''6
Installthe new cotter pins (C),and bend them as
shown.
f
(cont'd)
17-65
EPSComponents
4
SteeringGearboxInstallation(cont'dl
1 7 . Installthe motor on the steeringgearbox(seepage
17-49).
1 8 . lnstallthe steeringjoint (A).and reconnectthe
steeringshaft (B) and pinion shaft (C).Make sure
the steeringjoint is connectedas follows:
. I n s e r t t h eu p p e r e n do f t h e s t e e r i n gj o i n t o n t o t h e
steeringshaft (line up the bolt hole (D)with the
flat portion (E)on the shaft).
. Slip the lower end of the steeringjoint onto the
pinion shaft (line up the bolt hole with the groove
(F)around the shaft),and looselyinstallthe lower
joint bolt. Be sure that the lower joint bolt is
securelyin the groove in the pinion shaft.
. Pull on the steeringjoint to make surethat the
steeringjoint is fully seated.Then installthe
upper joint bolt, and tighten it to the specified
torque.Tightenthe lower joint bolt to the
specifiedtorque.
22. After installation,performthe following checks.
. Performthe front toe inspection.
. C h e c kt h e s t e e r i n gw h e e ls p o k e a n g l el.f s t e e r i n g
spokeanglesto the right and left are not equal
(steeringwheel and rackare not centered),
correctthe engagementof the joinvpinion shaft
serrations,then adjustthe front toe by turning
the tie-rods,if necessarv.
\
8 x '1.25mm
28 N.m
{2.9kgf.m,
21 tbt.ft)
1 9 .Installthedriver's dashboardlower cover (see
page 20-59)and under cover (seepage 20-60).
20. lf the steeringwheel was turned,centerthe cable
reel by first rotatingit clockwiseuntil it stops.Then
rotateit counterclockwise(abouttwo and half
turns) untilthe arrow mark on the label points
straightup. Reinstallthe steeringwheel (seepage
17-8).
)1
Installthe front wheels.
17-66
EPSControlUnit Removal/
Installation
Tie-rodBallJoint Boot Replacement
Attachment,42 mm 07OAD-P0A0100
1. Removethe passenger'sunder panel.
2. Turn up the floor carpel,removelhe EPScontrol
untr.
l. Removethe boot from the tie-rod end, and wipe the
old greaseoff the ball pin.
2 . P a c kt h e l o w e ra r e ao f t h e b a l l p i n ( A ) w i l h f r e s h
mulr purposegrease.
*-4
r/\-,
d______i.l+_D
-6rA
3 . Disconnectthe EPScontrol unit connectors.
lnstallthe EPScontrol unit in the reverseorder of
removal.
E
After installation,startthe engine,and let it idle.
Turn the steeringwheelfrom lock-to-lockseveral
times. Checkthat the EPSindicatordoes not come
on.
3. Packthe interiorof the new boot (B) and lip (C)with
fresh multipurposegrease.
Note these items when installingnew grease;
. Keepgreaseoffthe boot installationsection(D)
and the taperedsection(E)of the ball pin.
. Do not allow dust, dirt, or other foreign materials
to enterthe boot.
4. Installthe new boot (A) usingthe specialtool.The
boot must not have a gap at the boot installation
sections(B).After installingthe boot.checkthe ball
pin taperedsectionfor greasecontamination,and
wipe it if necessary.
07(lAD-P0A0100
17-67
Suspension
Frontand RearSuspension
SpecialTools
.............
18-2
Component
LocationIndex .........................................
18-3
W h e eA
l l i g n m e n .t . . . . . . . . . . . . . . . . . . . .
. . . . . . . . .1. 8. - 4
18-8
WheelBearingEndPlayInspection............................
18-9
WheelRunoutInspection
..................
... 18-10
B a l Jl o i n tR e m o v a l
FrontSuspension
Knuckle/Hu bAVheelBearingReplacement
BallJoint Boot Reolacement..................
StabilizerBar Rep|acement....................
StabilizerLink Removal/lnstallation
LowerArm Removal/lnstallation
...............
Damper/Spring
Replacement
18-1
18-16
18-17
18-18
18-19
18-20
RearSuspension
H u bB e a r i n U
g n i tR e p l a c e m e .n. t. . . . . . . . . . . . . . . . . . . 18-26
18-28
KnuckleReolacement
18-30
Stabilizer
BarReplacement
....................
Link Removal/lnstallation
18-31
Stabilizer
..........................
18-32
UpperArm Removal/lnstallation
...............
TrailingArm Removal/lnstallation
18-33
Damper/Spring
Replacement
18-34
SpecialTools
Ref.No.
o
@
o
G)
Tool Number
07GAF-SE00100
07MAC-S100200
07746-0010500
07749-0010000
07965-SA50500
07965-SD90100
otv
Description
Hub Dis/AssemblyTool
B a l lJ o i n t R e m o v e r2, 8 m m
Driver
Front Hub Dis/AssemblyTool
Support Base
o
o
[]
I
@
18-2
o
a6,l
FrontSuspension:
DAMPER/SPRING
page18-20
Replacement,
STABILIZER
BAR
page18-17
Replacement,
STABILIZER
LINK
page18 18
KNUCKLE/HU8/WHEELBEARING
page 18-11
Replacement,
Ball Joint Boot
page'18-16
Replacement,
LOWEBARM
page 18 19
RearSuspension:
STABILIZER
BAR
page18-30
Replacement.
UPPERARM
page'18-32
DAMPER/SPRING
page'18-34
Replacement,
UNIT
HUBBEARING
page18'26
Replacement,
KNUCKLE
page18-28
Replacement,
TRAILINGARM
page 18 33
18-3
WheelAlignment
The suspensioncan be adjustedfor front camber,front
toe, and reartoe. However,each of these adjustments
are interrelatedto each other. For example,when you
adjustthe toe, the camberchanges.Therefore,you
must adjustthe front wheel alignmentwheneveryou
adjustthe camberor toe.
Front Casterlnspection
Pre-Alignment
Checks
Checkthe casterangle.lf the casterangle is not within
the specification,checkfor bent or damaged
susoensroncomoonents.
For proper inspectionand adjustmentof the wheel
alignment,do these checks:
o u rw h e e l
U s ec o m m e r c i a l l a
vvailable
c o m D u t e r i z ef d
a l i g n m e net q u i p m e ntto m e a s u r ew h e e la l i g n m e n t
(caster,camber,toe, and turning angle).Follow the
eouiomentmanufacturer'sinstructions.
Front casterangle: 1'40't
1"
1. Releasethe parkingbraketo avoid an incorrect
measurement.
2 . Make sure the suspensionis not modified.
3 . C h e c kt h e t i r e s i z ea n d t i r e p r e s s u r e
Tire size:
Front/rear: 195/60R15
Tire pressure:
230 kPa {2.3kgf/cm',33 psil
Front:
Rear:
210 kPa |'2.1kgf/cm', 30 psi)
Checkthe runout of the wheels and tires.
Checkthe suspensionball joints. (Holda wheel
with your hands,and move it up and down and
right and left to checkfor wobbling),
Bouncethe vehicleup and down severaltimes to
stabilizethe suspension.
18-4
\
Front CamberInspection
Front CamberAdjustment
Use commerciallyavailablecomputerizedfour wheel
alignmentequipmentto measurewheel alignment
(caster,camber,toe, and turning angle).Follow the
equipmentmanufacturer'sinstructions.
The front cambercan be adjustedby exchangingone or
both of the damDerDinchbolts with the smaller
diameteradjustingbolt(s).The differencebetweenthe
adjustingbolt diameterand the pinch bolt hole
d i a m e t e ra l l o w sa s m a l lr a n g eo f a d j u s t m e n t .
Checkthe camberangle.lf the camberangle is not
within the specification,adjustthe camber.
Front camber angle:
0"30' t 45'
DamDerPinchBolt:
AdiustingBoh:
P/N 90188-55A-000
1 . Raisethe front of the vehicle,and support it with
safetystandsin the proper location(seepage 1-8).
Removethe front wheels.
L o o s e nt h e d a m p e rp i n c h n u t sa n d b o l t s( A ) ,a n d
adjustthe camber by moving the bottom of the
d a m p e rw i t h i nt h e r a n g eo f t h e d a m p e rp i n c hb o l t
free play.
-+
+t
A
1 6 x 1 . 5m m
157 N.m
(16.0kgf.m,
116 tbf.ftl
3 . Tightenthe boltsto the specifiedtorque.
4 . Reinstallthe front wheels.Lower the front of the
v e hi c l et o t h e g r o u n d ,a n d b o u n c et h e v e h i c l e
s e v e r atl i m e st o s t a b i l i z teh e s u s p e n s i o n .
5 . C h e c kt h e c a m b e ra n g l e .l f i t i s w i t h i nt h e
specification,checkthe front toe. lf it is not within
the specification,go to step 6.
(cont'dl
18-5
WheelAlignment (cont'd)
Raisethe front of the vehicle,and support it with
7 . Replacethe damper pinch boltswith the adjusting
bolts (A),and adjustthe camber angle.
NOTE:The camberangle can be adjustedup to t
15' (centerof tolerance)by replacingone damper
pinch bolt with the adjustingbolt. The camber
angle can be adjustedup to a 30' by replacingboth
upper and lower damper pinch bolts with the
adjustingbolts.
RearCamberInspection
Use commercially-available
computerizedfour wheel
alignmentequipmentto measurewheel alignment
(caster,camber,toe, and turning angle).Followthe
eouiDmentmanufacturer'sinstructions.
C h e c kt h e c a m b e ra n g l e .l f l h e c a m b e ra n g l ei s n o t
within the specification,checkfor bent or damaged
susDenstoncomoonenrs.
Rearcamberangle:
0"55' t 45'
0
NOn-dEl
Do not loosenthe specialb o l t so n t h e t r a i l i n ga r m .
'rntr
1 5 x 1 . 5m m
157N.m
{16.0kgt.m,
116tbf.ft)
i,iY.a
.:r,//
8 . Tightenthe boltsto the specifiedtorque.
Reinstallthe front wheels.Lower the front of the
vehicleto the ground, and bouncethe vehicle
severaltimes to stabilizethe suspension.
1 0 .Checkthe camber angle.lf it is within the
specification,checkthe front toe. and adjust it if
necessary.lf it is not within the specification,
readjust,and recheck.lJthe camber anglecannot
be adjustedto the specification,checkfor bent or
damagedsuspensioncomponents.
\
18-6
Front Toe Inspection/Adjustment
RearToe Inspection/Adiustment
equipmentmanufacturer'sinstructions,
1. Centerthe steeringwheel spokes.
1, Release
t h e p a r k i n gb r a k e .
2. Checkthetoe.lf it is not with in the specification,go
to step 3.
2. Checkthetoe. lf it is not within the specification.go
to step 3.
Front toe-in: 0 t 3 mm {0 t 0.12in.)
3. Loosenthe locknut(A) while holdingthe tie-rod end
( B) .
1,;
A
1 4 x 1 . 5m m
,14N.m
(a.5 kgt m,33 lbt.ftl
Reartoe-in {inspection):
1 1 3 mm (0.04a 0.12 in.)
3. Loosenthe self-lockingnut (A)while holdingthe
adjustingbolt (B).
Do not loosenlhe specialbolts (C)on the
lower arm to adjustthe alignment.
Turn the tie-rod(C)untilthe toe is correct.
5 . After adjusting,tighten the locknutwhile holding
the tie-rodend. Make sure the toe settingdoes not
change.
4. Replacethe self-lockingnut with a new one, and
l i g h t l yt i g h t e n .
NOTE:Always use a new self-lockingnut whenever
it has been loosened.
Turn the adjustingbolt until the toe is correct.
Rear toe.in (adiustment):
2 ' , mm {0.08 "' ,. in.}
Tightenthe self-lockingnut to the specifiedtorque
w h i l e h o l d i n gt h e a d j u s t i n gb o l t .
( c o n t ' d)
18-7
WheelAlignment (cont'dl
TurningAngleInspection
(caster.camber,toe, and turning angle).Followthe
equiDmentmanufacturer'sinstructions.
1 . T u r nt h e s t e e r i n gw h e e lf u l l y t o t h e r i g h t a n d l e f t
while applyingthe brake,and checkthe turning
anglesof both front wheels, lf the turning angle is
not within the specificationor the inward turning
anglesdiffer betweenthe right and left side,go to
steD2.
WheelBearingEnd PlayInspec'tion
1. Raiselhe vehicle,and support it with safetystands
in the proper location(seepage 1-8).Removethe
wheels.
2. Installsuitable f lat washers (A) and wheel nuts,and
tighten the nuts to the specifiedtorque to hold the
b r a k ed i s cs e c u r e l ya g a i n s t h e h u b .
Front:
Turning angle:
lnward: 34'00'+ 2'
Outward: 28'00' {reference)
108N.m
(11.0kgf.m,
80 rbf.ft)
Rear:
\
Checkthe toe. lf it is correct,but the turning angle
is not within the specification,checkior bent or
damagedsuspensioncomponents,
108N.m
(11.0kgf.m,80 lbf.ft)
3 . S e t u p t h e d i a lg a u g ea g a i n s t h e h u b f l a n g ea s
shown, and measurethe bearingend play moving
the brakedisc inward and outward.
Bearing end play:
Standard:
Front/rear: 0 0.05 mm {0 0.002in.}
4. lf the bearingend play is more than the standard,
replacethe wheel bearing.
18-8
WheelRunoutInspection
1 . Raisethe vehicle,and supportit with safetystands
in the proper location(seepage 1-5,.
Checkfor a bent or deformedwheel.
Set up the dial gauge as shown, and measurethe
axial runout by turning the wheel.
4 . R e s e t h e d i a l g a u g e t o t h ep o s i t i o ns h o w n ,a n d
measurethe radial runout.
Front and rear wheel radial runout:
Standard:
Aluminum wheel: 0 0.7 mm (0 0.03io.)
1.5 mm {0.06in.}
Servicelimit:
Front and rear wheel axial runout:
Standard:
Aluminum wheel: 0-0.7 mm (0-0.03 in.)
Servicelimit:
2.0 mm {0.08in.l
lf the wheel runout is not within the specification,
checkthe wheel bearingend play (seepage 18-8),
and make sure the mating surfaceson the brake
disc and the insideof the wheel are clean.
lf the bearingend play is within the specification
but the wheel runout is more than the servicelimit.
replacethe wheel.
18-9
BallJointRemoval
Ball ioint remover.2Smm 07MAC-SL00200
Always use a ball joint removerto disconnecta ball
joint. Do not strikethe housingor any other part of
the ball joint connectionto disconnectit.
3. Loosenthe pressurebolt (A),and installthe special
tool as shown. Insen the jaws carefully,making
sure not to damagethe ball joint boot. Adjustthe
jaw spacingby turning the adjustingbolt (B).
10 mm HEXNUT
'1,
I n s t a lal h e x n u t ( A )o n t o t h e t h r e a d s o f t h e b a l l j o i n t
{ B ) .M a k es u r et h e n u t i s f l u s hw i t h t h e b a l l j o i n tp i n
end to preventdamageto the threadedend of the
b a l l i o i n to i n .
07MAC-S100200
After adjustingthe adjustingbolt, make sure the
head (C)of the adjustingbolt is in the position
shown to allow the jaw to pivot.
5 . With a wrench,tighten the pressurebolt until the
b a l li o i n t p i n p o p sl o o s ef r o m t h e s t e e r i n ga r m o r
knuckle.lf necessary.apply penetratingtype
lubricantto loosenthe ball joint pin
2 . Apply greaseto the specialtool on the areasshown
(A).This will easeinstallationof the tool and
preventdamageto the pressurebolt {B)threads.
NOTE:Do not use pneumaticor electrictools on
the pressurebolt.
6 . Removethe tool, then removethe nut from the end
o f t h e b a l l j o i n tp i n ,a n d p u l l t h eb a l l j o i n to u t o f t h e
s t e e r i n ga r m o r k n u c k l eI.n s p e c t t h eb a l l j o i n tb o o t ,
and replaceit if damaged.
18-10
FrontSuspension
Knuckle/Hub/WheelBearingReplacement
ExplodedView
WHEELBEARING
Replace.
SNAPRING
5 mm SCREWS
Replace.
FLATSCREWS
6x1.0mm
9.8Nm
KNUCKLE
Checkfor delormation
a n oo a m a g e .
SPLASHGUARD
Checkfor corrosion.delormation.
and damage.
Replaceif rusted.
BRAKEDISC
SPINDLENUT
22 x 1.5mm
1 8 1N m
(18.5kgf.m, 134 lbt.ft)
Replace.
'--7.l
'tq
I
A p p ya s m a lal m o u not f e n g i n o
eil
to theseatingsurface.
lcont'd)
18-11
FrontSuspension
Knuckle/Hub/WheelBearingReplacement{cont'dl
. Hub dis/assemblytool 07GAF-SE00100
. Balljoint remover,2Smm 0TlvlAC-S100200
. Attachment62 x 68 mm 07746-0010500
. Driver07749-0010000
. SuDDortbase07965-5D90'100
5. Raisethe stake(A),and removethe spindle nut (B).
'
,
B
22x1.5mm
1 8 1N . m
('18.s
kgf.m,
134tbt.ft)
2. Removethe wheel cap,wheel nuts, and front wheel.
1 0 8N . m
(11.0kgf m,
80 rbf.ftl
6. Removethe brakedisc retainingflat screws(A).
3. Removethe brakehose bracketmounting bolt (A).
A
8 x 1.25mm
22N.m
12.2ksl.m,
26 tbf.ftl
B
12 x 1.25mm
108N.m
{11.0kgf.m,
80 rbf.ftl
A
6x1.0mm
9.8 N.m
{1.0kgt.m,
7.2 tbl.ttl
\
7. Screwtwo 8 x 1.25mm bolts (B)into the discto
oush it awav from the hub. Turn each bolt two turns
at a time to preventcockingthe disc excessively,
4 . Removethe caliperbracketmounting bolts (B),and
removethe caliperassembly(C)from the knuckle.
To preventdamageto the caliperassemblyor
brakehose,use a short pieceof wire to hang the
caliperassemblyfrom the undercarriage.Do not
twist the brakehose with force.
\
18-12
8. Removethe flange bolt {A) andwheel sensor(B)
from the knuckle.Do not disconnectthe wheel
sensorconneclor.
A
5x1.0mm
9.8 N.m
(1.0kgl.m,
7.2 tbt.ftl
10. Removethe lock pin (A)from the lower arm ball
joint, and removethe castlenut (B).
NOTE:During installation,insertthe lock pin into
t h e b a l l j o i n tp i n f r o m t h e l n s i d et o t h e o u t s i d eo f
the vehicle.The closedend of the lock Din must be
i n t h e r a n g es h o w n .
07MAC-SL00200
€--....-"
'R.
9 . Removethe flange nut (A) while holdingthe joint
pin (B)with a hex wrench (C),and disconnectthe
s t a b i l i z el ri n k{ D )f r o m t h e l o w e ra r m ( E ) .
12x 1.25mm
59 69N m
(6.0 7.0 kgl m,
43 -51 lbf tt)
1 1 .Disconnectthe lower arm from the knuckleusing
the specialtool (seepage l8-10).
12. Loosenthe damper pinch bolts (A) while holding
the nuts (B),and removethe bolts and nuts.
10 x 1.25mm
39 N.m (,1.0kgf.m,29lbf.ft)
'13.Removethe driveshaftoutboardjoint
{C)fromthe
knuckle(D) by tappingthe driveshaftend (E)with a
plastichammer while drawing the knuckleoutward,
then removethe knuckle.
NOTE:Do not Dullthe driveshaftend outward.The
driveshaftjoint may come off.
(cont'd)
18-13
FrontSuspension
(cont'd)
Knuckle/Hub/Wheel
BearingReplacement
14. Separatethe hub (A)from the knuckle(B) usingthe
specialtool and a hydraulicpress.Be carefulnotto
deform the splashguard. Hold onto the hub to keep
it from falling when pressedclear.
1 6 . R e m o v et h e s n a pr i n g ( A )a n dt h e s p l a s hg u a r d( B )
f r o m t h e k n u c k l e( C ) .
07GAF-SE00100
./
.-''-
.|
a'\s
1 1 . Pressthe wheel bearing(A) out of the knuckle(B
usingthe specialtool and a press.
1 5 . Pressthe wheel bearinginner race(A) off of the
h u b ( B )u s i n gt h e s p e i i a l t o o l ,a c o m m e r c i a l l y
a v a i l a b l eb e a r i n gs e p a r a t o(rC ) ,a n d a p r e s s .
07GAF-SE00100
\
18-14
\r
Press
+
Pross
\
1 8 . W a s ht h e k n u c k l ea n d h u b t h o r o u g h l yi n h l g hf l a s h
point solventbefore reassembly.
2 2 . P r e s sa n e w h u b b e a r i n gu n i t{ A )o n t o t h e h u b ( B )
usingthe specialtools and a press.
1 9 . Pressa new wheel bearing(A) into the knuckle(B)
usingthe old bearing(C),a steel plate {D).the
specialtool, and a press.Placethe wheel bearing
on the knucklewith the packseal side facing (metal
color)toward the inside.Be careful not to damage
the sleeveof the packseal.
"-t-_"*,,''
_,.' . . a-.)
../
..-.
23. I n s t a l l t h ek n u c k l e / h u b / h ubbe a r i n gu n i t i n t h e
reverseorder of removal,and notethese items:
2 0 . I n s t a ltlh e s n a pr i n g ( A )s e c u r e l yi n t h e k n u c k l e( B ) .
D
6 N.m10.6kgf.m,4lbfft)
lnstallthe splashguard (C),and tighten the screws
(D)to the specifiedtorque.
. B ec a r e f u n
l o t t o d a m a g e t h eb a l l j o i n tb o o t w h e n
installing
the knuckle.
. Tightenall mounting hardwareto the specified
l O r q u ev a l u e s .
. Torquethe castlenut to the lower torque
specification,then tighten it only far enoughto
a l i g nt h e s l o tw i t h t h e b a l lj o i n t p i n h o l e .D o n o t
align the castlenut by looseningit.
. Installa new look pin on the castlenut after
torquing.
. U s ea n e w s p i n d l en u t o n r e a s s e m b l y .
. B e f o r ei n s t a l l i n g
t h e s p i n d l en u t ,a p p l ya s m a l l
amount of engine oil to the seatingsurfaceof the
nut. After tightening,use a drift to stakethe
s p i n d l en u t s h o u l d e ra g a i n s t h e d r i v e s h a f t .
. B e f o r ei n s t a l l l n gt h e b r a k ed i s c ,c l e a nt h e m a t i n g
surfaceof the front hub and the insideof the
b r a k ed i s c .
t h e w h e e l ,c l e a nt h e m a t i n g
surfaceof the brakedisc and the insideof the
wneet.
. Checkthe front wheel alignment,and adjustit if
18-15
FrontSuspension
BallJoint Boot Replacement
Front hub dis/assemblytool 07965-5450500
Inst€llthe boot onto the ball joint pin, then squeeze
it gentlyto force out any air. Do not let dlrt or other
foreign materialsget into the boot.
1. Removethe boot.
2. Packthe interiorand lip (A) of a new boot with fresh
grease.Keepthe greaseoff of the boot-to-knuckle
mating surfaces(B).
Pressthe boot with the specialtool until the bottom
seatson the knuckle(A) evenly around.
pross
07965-SA50500
-6r
rffi
€l
-
-
B
t
I
6 . After installinga boot,wipe any greaseoff the
exposedportion of the ball joint pin.
Wipe the greaseoff the taperedsectionof the pin
(C),and packfresh greaseonto the base (D).
18-16
i
StabilizerBar Replacement
Removethe self-lockingnuts (A)while holdingthe
joint pin (B)with a hex wrench (C),and disconnect
t h e s t a b i l i z el ri n k s( D ) f r o mt h e s t a b i l i z ebr a r ( E )o n
the right and left.
D
''i]
4. lnstallthe stabilizerbar in the reverseorder of
removal.and note these itemsl
. Use new self-lockingnuts on reassembly.
. Note the right and left directionof the stabilizer
oar.
. A l i g nt h e e n d so f t h e p a i n tm a r k s( A )o n t h e
stabilizerbar with each end of the bushings(8).
. Note the forelaft directionofthe bushing holders.
. Referto stabilizerLink Replacementto connect
t h e s t a b i l i z ebr a r t o t h e l i n k s( s e ep a g e1 8 - 1 8 ) .
,.'i i
.
i.',.:-l
,'
\'r'j--,r'r-'1
i-ii::;i
I
_:
i :..
i'
;4-llt,-'j--;
1 0x 1 . 2 5m m
39Nm
(4.0 kgf m,
29 tbl,ft)
Removethe flange bolts {A) and bushingholders
{B),then removethe bushings(C)and the stabilizer
b a r( D ) .
FORWARD
A
1 0x 1 . 2 5m m
39Nm
(4.0ksf.m, 29lbl.ftl
18-17
Front Suspension
Removethe self-lockingnut (A) and flange nut {B)
while holdingthe respectivejoint pin (C)with a hex
wrench (D),and removethe stabilizerlink (E).
4. Installthe self-lockingnut and flange nut, and
lightlytighten them.
NOTE:Use a new self-lockingnut on reassembly.
5. Placethe floor jack under the lower arm balljoint,
and raisethe suspensionto load it with the vehicle's
weaght.
mri-dEl
Do not placethe jack againstthe lower arm
balljoint.
6. Tightenthe self-lockingnut (A) and flange nut (B)to
the specifiedtorque valueswhile holdingthe
respectivejoint pins (C)with a hex wrench (D).
A
10 x 1.25mm
38 N.m
(3.9kgf m,28 lbf.ft)
\
3 . l n s t a l l t h es t a b i l i z el ri n k( A )o n t h e s t a b i l i z ebr a r { B )
and lower arm (C)with the joint pins (D)set at the
centerof their rangeof movement.
..,
B
10 x 1.25mm
39 N.m
{4.0kgf.m,29lbf.ft}
1 . After 5 minutesof driving, re-tightenthe self,
lockingnut again to the specifiedtorque.
18-18
Lower Arm Removal/lnstallation
Balljoint remover,2Smm 07|MAC-S100200
5. Removethe flange bolts (A),and removethe lower
arm {B}.
1. Raisethe front of the vehicle,and supportit with
Removethe flange nut (A) while holdingthe joint
pin {B)with a hex wrench (C),and disconnectthe
s t a b i l i z el ri n k( D ) f r o mt h e l o w e ra r m ( E ) .
1 4x 1 . 5m m
83 N.m(8.5kgf.m,61lbf.ft)
6. Installthe lower arm in the reverseorder of
removal,and note these items:
10x 1.25mm
39 N.m
{4.0kgf m, 29 lbt.ft)
3 . Removethe lock pin (A) from the lower arm ball
joint, and removethe castlenut (B).
NOTE:During installation,insertthe lock pin into
the ball joint pin from the insideto the outsideof
the vehicle.The closed end of the lock pin must be
i n t h e r a n g es h o w n .
6--__
@a
. Be carefulnot to damagethe ball joint boot when
connectingthe lower arm to the knuckle.
' Tightenall mounting hardwareto the specified
torque values,
. F i r s t i n s t a lal l l t h e c o m p o n e n t sa n d l i g h t l y t i g h t e n
the bolts and nuts.then raisethe suspensionto
load it with the vehicle'sweight beforefully
tighteningit to the specifiedtorques.
. Torque the castlenut to the lower torque
then tighten it only far enoughto
specification,
align the slot with the ball joint pin hole. Do not
allgn the castlenut by looseningit.
. Installa new lock pin on the castlenut after
torquing.
. Beforeinstallingthe wheel, cleanthe mating
wneet.
. C h e c kt h e w h e e la l i g n m e n ta, n d a d j u s t i t i f
'18-4).
necessary(seepage
oTMAc-sloo2oo
1 2x 1 . 2 5m m
59 69Nm
16.0-7.0kgt-m,
43 51 lbf.ft)
4 . Disconnectthe lower arm from the knuckleusing
t h e s p e c i atl o o l ( s e ep a g e1 8 - 1 0 ) .
18-19
Front Suspension
Damper/SpringReplacement
ExplodedView
/.'
â
ta
,/
,,/
./ SELF-LOCK|NGNUT
12 x 1.25inm
44 N.m {4.5kgt.m,33lbf.ftl
neDtace.
e9
-€.-
1, @-:'\--""'
lF \-:-./
- ,
MOUNTINGBASE
- DAMPER
checkfor delormation
E9-
DAMPERMOUNTING
BEARING
UPPER
SPRINGMOUNTING
CUSHION
Checkfor deterioration
anooamage,
\
DAMPER
SPRING
Checkfor lreelength.
DAMPERUNIT
Checkfor oil leaks,
gas leaks,and smooth
operatron.
18-20
Balljoint remover,28mm 07MAC-S100200
5. Removethe damper pinch bolts (A)while holding
t h e n u t s( B ) .
Removal
Removethe cotterpin (A) from the tie-rod end ball
ioint, and removethe nut (B).
6. Removethe flange nuts (A)from the top ofthe
damper,
A 'l.25
mm
10x
10 mm HEXNUT
07MAC-S1002000
Disconnectthetie-rodend from the steeringarm
o n t h e d a m p e ru s i n gt h e s p e c i a l t o o(l s e ep a g e1 8 1 0) .
4. Removethe bolts,and removethe wheel sensor
harnessbracket{A) and brakehose bracket(B)
from the damper.Do not disconnectthe wheel
sensorconnector.
A
6x1.0mm
7. Lower the lower arm, and removethe damper
a s s e m b l y( B ) .
x 1.25nm
q
/.8
(cont'd)
18-21
FrontSuspension
(cont'd)
Damper/Spring
Replacement
Disassembly/lnspection
1 . C o m p r e s st h e d a m p e rs p r i n gw i t h a c o m m e r c i a l l y
availablestrut spring compressor(A) accordingto
the manufacturer'sinstructions.then removethe
s e l f - l o c k i nngu t ( B ) w h i l eh o l d i n gt h e d a m p e rs h a f t
(C)with a hex wrench (D).Do not compressthe
spring more than necessaryto removethe nut,
Reassembleall the pans, exceptfor the upper
s p r i n gs e a ta n d s p r i n g .
4. Compressthe damper assemblyby hand,and
checkfor smooth operationthrough a full stroke.
both compressionand extension.The damper
should extend smoothly and constantlywhen
compressionis released.lf it does not, the gas is
leakingand the damper should be replaced.
Releasethe pressurefrom the strut spring
compressor,then disassemblethe damper as
shown in the ExplodedView.
\
C h e c kf o r o i l l e a k s a
, bnorman
l o i s e sa, n d b i n d i n g
during thesetests.
18-22
FrontSuspension
(cont'dl
Damper/Spring
Replacement
Installation
Right side:
1. Lower the lower arm, and positionthe damper
assemblyin the body, Turn the damper mounting
baseso the "AL" or "AR" mark (A)facestoward
the outsideof the vehicle.
B
10x 1.25mm
,14N.m
{4.5kgt.m,33lbf.ft)
Hold the bottom of the damper with your hand,and
compressthe spring. Do not compressthe spring
excessively.
9 . I n s t a l l t h e1 2 m m n u t ( A )o n t h e d a m p e rs h a f t( B ) .
Hold the damper shaft with a hex wrench (C),and
tighten the 12 mm nut to the specifiedtorque.
,1,6
Looselyinstallthe flange nuts (A) onto the top of
the damper.
(4.5 kgt.m, 33 lbf ft)
1 0 .Removethe damperassembly
fromthe strutspring
compressor.
18-24
L
3 . P o s i t i o nt h e d a m p e ro n t h e k n u c k l ea, n d i n s t a l l t h e
new damper pinch bolts (A) and nuts (B),and
lightlytighten the nuts.
8. Connectthe tie-rod end to the steeringarm, and
tightenthe nut (A)to the specifiedtorque. Install
the cotterpin (B)after tightening,and bend lts end
asshown.
B
1 6 x 1 , 5m m
157N.m
(16.0kgt m,
116tbt.ftl
4 . P l a c et h e f l o o rj a c ku n d e rt h e l o w e ra r m b a l l j o i n t ,
and raisethe suspensionto load it with the vehicle's
weight.
Do not placethe jack againstthe lower arm
balljoint.
5 . Tightenthe flange nuts on the top of the damperto
the specifiedtorque.
9. Cleanthe mating surfaceofthe brakedisc and the
insideof the wheel,then installthe front wheels.
1 0 . C h e c kt h e w h e e la l i g n m e n ta, n d a d j u s t i t i f
necessary{seepage 18-4).
Tightenthe damper pinch nuts to the specified
torque.
1 . Installthe brakehose bracket(A) and the wheel
sensorharnessbracket(B)onto the damper,and
tighten the bolt to the specifiedtorque.
9.8N.m
11.0kgf.m,7.2lbf.ftl
22N|rl.
12.2kgI m,
16rbr,ftl
q
18-25
RearSuspension
Hub BearingUnit Replacement
ExplodedView
SPLASHGUARD
Checkfor deformation.
x 1.0 mm
9.8 N.m (1.0kgf.m,?1 lbf ftl
Checkfor wear and damage.
',[ ',, / -o\ ' 0
un
KNUCKLE
Y
Checkfor delormation.
HUBBEARING
UNIT
Checkfor faultymovement
andwear.
6x1.0mm
9,8 N.m
{1.0kgf.m,7 lbf.ft}
HUB CAP
Replace.
SPINDLENUT
22 x 1.5mm
181 N.m {18.5kgt.m, 134lbf.ft}
Beplace.
-A
T
Appy a small amount oI engineoil
to the seatingsurface.
18-26
1 . Raisethe rear of the vehicle,and support it with
'l-8).
safetystandsin the proper location(seepage
Releasethe parkingbrakelever.
5 . Removethe brakehose mounting bolt (A).
Removethe wheel cap. wheel nuts, and rearwheel.
C
B
1 0x 1 . 2 5m m
55Nm
{5.6kgf m.41lbf.ft}
108N.m(11.0kgf.m,80lbfftl
Removethe hub cap (A), raisethe stake(B),and
r e m o v et h e s p i n d l en u t ( C ) .
(2.2kgtm, 16lbt.ftl
Removethe caliperbracketmounting bolts (B),and
hang the caliper(C)to one side.To preventdamage
to the caliperor brakehose,use a short pieceof
w i r e t o h a n gt h e c a l i p e rf r o m t h e u n d e r c a r r i a g e .
7 . Removethe brakedisc retainingscrews(A).
O
\
A
ap
2 2 x 1 , 5m m
1 8 1N . m
(18.5kgf.m, 134lbf.ftl
t
\
I
A
6x1.0mm
9 . 8N . m
(1.0kgf.m,?.2lbf.ftl
Screwtwo 8 x 1.25mm bolts (B) into the disc {C)to
oush it awav from the hub. Turn each bolt two turns
at a time to preventcockingthe disc excessively.
Removethe brakedisc.
(cont'd)
18-27
RearSuspension
Hub BearingUnit Replacement
(cont'd)
9. Removethe hub bearingunit (A) from the spindle.
KnuckleReplacement
1 . Raisethe rear of the vehicle,and suppon it with
Removethe rear wheels.
R e m o v et h e b r a k ed i s ca n d h u b b e a r i n gu n i t( s e e
s t e p 1 o n p a g e1 8 - 2 7 ) .
Removethe flange bolts (A) and splashguard (B)
from the knuckle.
,=,,,
1 0 .Installthe hub bearingunit in the reverseorder of
. Tightenall mounting hardwareto the specified
torque values,
. Beforeinstallingthe brakedisc,cleanthe mating
surfaceot the hub and the insideof the brake
disc.
. Use a new spindle nut on reassembly.
. After tightening,use a drift to stakethe spindle
n u t s h o u l d e ra g a i n s t h e s p i n d l e .
. Use a new hub cap on reassembly.
wneel.
kgf.m,7.2lbf ft)
11.0
4. Removethe wheel sensor(A),braKenose
m o u n t i n gb r a c k e (t B ) ,a n d p a r k i n gc a b l em o u n t i n g
bracket(C)from the knuckle.Do not disconnectthe
wheel sensorconnector.
8 x 1.25mm
22 N.m
{2.2kgfm, 16lbf ftl
6x1.0mm
9.8 N,m
{I.0 kgt.m,7.2lbf ft)
18-28
tt
5. Placethe floor jack underthe trailing arm {A),to
support it.
Do not placethe jack againstthe plate
sectionof the lower arm, Be carefulnot to
damageany suspensioncomponents.
12x 1.25mm
59 N.m
{6.0ksf.m.43lbf.ft)
Removethe flange bolt (B),and disconnectthe
upper arm {C)from the knuckle.
1 . Mark the cam positionsof the adjustingbolt (A) and
adjustingcam (B),the removethe self-lockingnut
{C},adjustingcam, and adjustingbolt. Discardthe
self-lockingnut.
12x 1.25mm
59 N.m {6.0kgf m,43lbl.ft)
9 . I n s t a l l t h ek n u c k l ei n t h e r e v e r s eo r d e ro f r e m o v a l ,
and note these items:
. F i r s ti n s t a l a
l l l t h e s u s p e n s i o cno m p o n e n t sa, n d
lightlytighten the bolts and nuls,then placea
floor jack under the lower a rm, and raisethe
suspensionto load it with the vehicle'sweight
beforefully tighteningthe bolts and nutsto the
specifiedtorque values.
. Align the cam positionsof the adjustingbolt (A)
and adjustingcam (B)with the markedpositions
w h e nt i g h t e n i n g .
. Use a new self-lockingnut on reassembly.
. T i g h t e na l l t h e m o u n t i n gh a r d w a r et o t h e
. U s ea n e w s p i n d l en u t o n r e a s s e m b l y .
t h e s p i n d l en u t ,a p p l ya s m a l l
amount of engine oil to the seatingsurfaceof the
nut. After tightening,use a drift to stakethe
s p i n d l en u t s h o u l d e ra g a i n s t h e d r i v e s h a f t .
. Beforeinstallingthe brakedisc,cleanthe mating
surfaceof the hub and the insideof the brake
drsc.
. U s ea n e w h u b c a po n r e a s s e m b l y .
wheel.
. Checkthe wheel alignment,and adjust it if
necessary{seepage 18-4).
12x 1.25mm
59Nm(6.0kgf.m,
43 tbI.ftl
8. Remove the flange bolt (D), and remove the
k n u c k l e{ E ) .
18-29
RearSuspension
StabilizerBar Replacement
1 . Raisethe rear of the vehicle,and supportit with
Removethe rearwheels.
Removethe self-lockingnuts (A)while holdingthe
joint pins (B)with a hex wrench (C),and disconnect
t h e s t a b i l i z el ri n k s( D )f r o m t h e s t a b i l i z ebr a r { E )o n
the right and left.
A
1 0 x 1 . 2 5m m
38 N.m
(3.9 kgf.m,28 lbf.ft)
4. Inslallthestabilizerbar in the reverseorder of
removal,and notethese items:
. Use new self-lockingnuts on reassembly.
. lMakesure the right and left ends of the stabilizer
bar are installedon their respectivesidesof the
vehicle.
. Align the ends of the paint marks (A) on the
s t a b i l i z ebr a r w i t h t h e b u s h i n g s( B ) .
. Referto StabilizerLink ReDlacement
to connect
t h e s t a b i l i z ebr a rt o t h e l i n k s{ s e ep a g e1 8 - 3 1 ) .
\....'..: .
Al
.----'';-r'--\---r-
-tt'.,'t),
(
Removethe flange bolts (A) and bushing holders
(B),then removethe bushings{C)and the stabilizer
bar(D).
18-30
1. Raisethe rear of the vehicle,and support it with
4. lnstallthe self-lockingnut and flange nut, and
lightlytighten them.
NOTE:Use a new self-lockingnut on reassembly.
2. Removethe self-lockingnut (A) and flange nut (B)
while holdingthe respectivejoint pin {C)wilh a hex
wrench (D),and removethe stabilizerlink (E).
Placea jack under the trailing arm at the knuckle
side end. and raisethe suspensionlo load it with
the vehicle'sweight.
Tightenthe selflocking nut (A) and flange nut {B)to
the specifiedtorque valueswhile holdingthe
respectivejoint pins (C)with a hex wrench (D).
A
1 0 x 1 . 2 5m m
38 N.m 13.9kgf.m,28lbf.ftl
\,1 i
i'-r d
*l'',:
3 . I n s t a l l t h es t a b i l i z el ri n k( A )o n t h e s t a b i l i z ebr a r { B )
a n dt r a i l i n ga r m ( C )w i t h t h e j o i n t p i n s( D )s e ta t t h e
centerof each moving range,
7. After 5 minutesof driving, re-tightenthe selflockingnut again to the specifiedtorque.
18-31
RearSuspension
UpperArm Removal/lnstallation
1 . Raisethe rear of the vehicle,and supportlt with
P l a c ea f l o o rj a c ku n d e rt h e t r a i l i n ga r m , a n d
supportthe suspensron.
Removethe flange bolt (A) and wheel sensor
h a r n e s sb r a c k e (t B ) .
8 x 1 . 2 5m m
22 N.m(2.2kgf.m,
16rbf.ft)
Removethe flange bolts (A),and removethe upper
arm{B).
1 2 x 1 . 2 5m m
59 N.m {6.0kgf.m,
ir3 lbf.ft)
18-32
1 2 x 1 . 2 5m m
59 N.m 16.0kgf m,
43 tbf.ft)
5. Installthe upper arm in the reverseorder of
renloval,and note these items:
l l l t h e s u s p e n s i o cno m p o n e n t sa n d
lightlytighten the bolts and nuts,then placea
j a c ku n d e rt h e t r a i l i n ga r m , a n d r a i s et h e
beforefully tighteningthe bolts and nuts to the
. T i g h t e na l l t h e m o u n t i n gh a r d w a r et o t h e
' B e f o r ei n s t a l l i n g
t h e w h e e l ,c l e a nt h e m a t i n g
wheel.
. Checkthe wheel alignment,and adjustit if
TrailingArm Removal/lnstallation
1 . Raisethe rear of the vehicle,and suppon it with
safetystandsin the proper location(seepage 1,8).
Removethe knuckle(seepage 18-28).
7. Removethe trailing arm rear mounting bolt (A).
Do not loosenthe specialbolts (B)on the
t r a i l i n ga r m .
A
12 x 1.25mm
3 . P l a c et h e f l o o rj a c ku n d e rt h e t r a i l i n ga r m ( A )t o
support it.
59 N.m
-----\':,'.ttg
'.,--1..-r.':1
B
1 0x 1 . 2 5m m
38Nm
(3.9kgl.m,
28 tbf.ftl
A
1 2x 1 . 2 5m m
61N m (6.2kgt m.
4s tbf,ft)
8 . Lower the jack,and removethe trailing arm.
9 . Installthe trailing arm in the reverseorder of
Removethe flange nut (B),and disconnectthe
s t a b i l i z el ri n k( C )f r o m t h e t r a i l i n ga r m .
Removethe flange bolt {D),and disconnectthe
d a m p e r( E )f r o m t h e t r a i l i n ga r m .
Removethe trailing arm front mounting bolts (A).
l l l t h e s u s p e n s i o cn o m p o n e n t sa n d
lightly tlghtenthe bolts and nuts,then placea
j a c ku n d e rt h e t r a i l i n ga r m , a n d r a i s et h e
beforefully tighteningthe bolts and nuts to the
. Tightenallthe mounting hardwareto the
specified torque values.
wneei.
. Checkthe wheel alignment,and adjust it if
necessary(seepage'18-4).
, ' a ' : -r
A
12 x 1.25Jnm
108N.m {11.0kgt.m,
80 tbf.ft)
18-33
RearSuspension
I
Replacement
Damper/Spring
ExplodedView
9-----.---.-.
-=\
I€tI
t=J
SELF-LoCK|NGNUT
10 x 1.25mm
29 N m {3.0kgf.m,22 lbf.ft}
Replace.
DAMPER
MOUNlING
COLLAR
DUSTCOVER
-tr€)
qnJ/ \
9...
E
\
Z
n \
lt
/t
\
\
\
BUMP
sroP PLArE
\ BUMPSTOP
tor weakness
Check
and damage.
DAMPERSPRING
Checkfor weakened
compressionand damage.
OAMPERUNIT
Checkfor oil leaks,
gas leaks,and smooth
operation,
18-34
Removal
5. Removethe damper assemblyfrom the body.
1. Raisethe rear of the vehicle.and support it with
i
2. Removethe flange bolt {A) from the bottom of the
damper.
3 . Removethe rear bulkheadcover (seepage 20-51).
Removethe flange nuts (A) from the top of the
damper in the trunk.
( c o n td )
18-35
RearSuspension
(cont'dl
Damper/Spring
Replacement
Disassembly/lnspection
1 . C o m p r e s st h e d a m p e rs p r i n gw i t h a c o m m e r c i a l l y
availablestrut compressor(A) accordingto the
manufacturer'sinstructions.then removethe selfl o c k i n gn u t ( B ) w h i l eh o l d i n gt h e d a m p e rs h a f t( C )
with a hex wrench (D).Do not compressthe spring
more than necessarvto removethe nut.
Reassembly
1 . I n s t a lal l l t h e p a r t s e x c e p t t h e
s e l f - l o c k i nngu t o n t o
the damper unit by referringto the ExplodedView.
Align the bottom of the spring {A} and the stepped
part of the lower spring seat (B),and align the
d a m p e rm o u n t i n gb a s ea s s h o w n ,
,, '161\
7fi)1,,
\3P qY/
Releasethe pressurefrom the strut spring
compressor,then disassemblethe damper as
shown ln the ExplodedView.
?
Reassembleall the pans, exceptfor the spring.
4 . Compressthe damper assemblyby hand,and
checkfor smooth operationthrough a full stroke,
both compressionand extension.The damper
should extend smoothly and constantlywhen
compressionis released.lf it does not, the gas is
leakingand the damper should be replaced.
"
I n s t a l l t h ed a m p e ra s s e m b l yo n a c o m m e r c i a l l y
availablestrut spring compressor(C).
C o m p r e s tsh e d a m p e rs p r i n gw i t h t h e s p r i n g
compressor.
Installthenew self'lockingnut (A) on the damper
shaft.
10 x 1.25mm
29Nm
(3.0kgt m,22 lbt.ft)
5. Hold the damper shaft {B)with a hex wrench (C),
and tighten the self-lockingnut to the specified
torque.
Checkfor oil leaks,abnormal noises,or binding
during thesetests.
18-36
Installation
3. Looselyinstallthe flange bolt (A) on the bottom of
thedamper.
1. Positionthe damper assemblyin the body. Note
the directionof the damper mounting base so that
the small hole dot on it is toward the front and
insideof the vehicle.
1 2 x1 . 2 5m m
61N m {6.2kgf.m.45lbf.ft)
Looselyinstallthe flange nuts (A) onto the top of
the damper,
D
A
1 0 x 1 . 2 5m m
59 N.m
16.0kgt.m, ia lbt ft)
Raisethe suspensionwith a floor jack to load the
vehicleweight, and tighten the nuts and bolt to the
C l e a nt h e m a t i n gs u r f a c eo f t h e b r a k ed i s ca n d t h e
i n s i d eo f t h e w h e e l ,t h e n i n s t a ltl h e r e a rw h e e l .
Checkthe wheel alignment,and adjust it if
18-37
Brakes
ConventionalBrakeComponents
Tools
Special
........... l9-2
C o m p o n e nLto c a t i oInn d e x . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. .9. .-.3. . . . . . . . .
BrakeSystemInspectionand
Tests...............
..........
19-4
BrakePedaland BrakePedalPositionSwitch
Adjustment
..............
19-6
ParkingBrakeCheckand
Adjustment
..............
19-7
BrakeSystemBleeding
......................
19-8
BrakeSystemIndicatorCircuit
Diagram
. . . . . . . . . . . . . .1. 9. .-.9.
ParkingBrakeSwitchTest
.................
19-10
BrakeFluidLevelSwitchTest ......................................
19-10
FrontBrakePadslnsoection
and
Replacement
...........
19-11
FrontBrakeDiscInspection
...............
19-13
FrontBrakeCalioerOverhaul......................................
19-14
MasterCylinderReplacement
...........
19-15
MasterCylinderInspection
................
19-16
BrakeBooster
PushrodClearance
Adjustment................................
19-16
BrakeBoosterTest...................
..........
19-18
BrakeBoosterReolacement
..............
19-19
RearBrakePadsInspection
and
Reolacement
...........
19-20
RearBrakeDiscInspection
................
19-22
RearBrakeCaliperOverhaul.......................................
19-23
BrakeHosesand LinesInsoection
.... 19-24
BrakeHoseReolacement
...................
19-25
ParkingBrakeCableReplacement
..............................
19-26
ABS (Anti-lockBrakeSystem)
Gomponents
... 19-29
SpecialTools
Ref.No.
o
I
19-2
Tool Number
07JAG-SD40100
DescriDtion
PushrodAdiustmentGauoe
Qty
1
INDICATOR
BrakeSystemIndicatorCircuit
D i a g r a mp, a g e1 9 - 9
ParkingBrakeSwitch
Test,page 19 10
BrakeFluidLevelSwitch
Test,page 19-10
BRAKECABLE
P a r k i n gB r a k eC a b l e
Replacement,page 19 26
REARDISCBRAKE
RearBrakePads Inspectionand
Replacement,page l9-20
RearBrakeDisc
Inspection,page 19'22
R e a rB r a k eC a l i p e O
r verhaul,
page 19'23
FRONTBRAKES
FrontBrakePads,Inspectionand
page 19-11
Replacement,
FrontBrakeDisc
Inspection,page 19'13
FrontBrakeCaliper
O v e r h a u lp, a g e1 9 - 1 4
BRAKEBOOSTER
BrakeBooster
Test,page 19-18
BrakeEooster
page 19 19
Replacement,
PARKING
BRAKE
LEVER
Parkino
Brake
page19-7
CheckandAdjustment,
BRAKEPEDAL
BrakePedalandErakePedalPosition
Switch
pagel9-6
Adjustment,
BRAKEHOSESand LINES
BrakeHosesand Lines
Inspection,page 19 24
BrakeHoses
page 19 25
Replacement,
MASTERCYLINDER
MasterCylinder
Fl6^1.^6m6nr
^2ô
1O-18
M a s t e rC y l i n d eIrn s p e c t i o np ,a g e1 9 - 1 6
BrakeBoosterPushrodClearance
A d j u s t m e n tp, a g e ' 1 9 - 1 6
BrakeSystemBleeding,page 19-8
19-3
BrakeComponents
Gonventional
BrakeSystemInspectionand Tests
Component
l\4asterCylinder
BrakeHoses
Caliper
ABS l\ilodulator
Procedure
Look for damageor signs of fluid leakageat;
. Reservoiror reservoirgrommets
. L i n ej o i n t s
. Betweenmastercvlinderand booster
Look for damageor signs of fluid leakageat:
. Line joints and banjo bolt connections
. Hosesand lines.also inspectfor twisting or
damaqe
Lookfor damageor signs of fluid leakageat:
. Pistonseal
. Banjo bolt connections
. Bleederscrew
Lookfor damageor signs of fluid leakageat:
. Linejoints
. Modulator
Also check for:
Bulging,twisted or bent lines.
S e i z e do r s t i c k i n gc a l i p e rp i n s .
BrakeSystemTest
Brake pedal sinks/fades when braking
1. Startthe engine,and let it warm up to operatingtemperature.
2. Attacha 2-inchpieceof maskingtape along the bottom of the steeringwheel, and draw a horizontalreference
mark acrossit.
3 . With the transmissionin Neutral,pressand hold the brakepedal lightly,then releasethe parkingbrake.
While still holdingthe brakepedal,hook the end of the tape measurebehind it. Then pull the tape up to the
steeringwheel, noting where the tape measurelines up with the referencemark you made on the maskingtape.
5 . Apply steadypressureto the brakepedalfor 3 minutes.
6 . Watch the tape measure.
. if it moves lessthan 10 mm, the mastercylinderis OK.
. if it moves more than 10 mm replacethe mastercylinder.
19-4
t-
Rapid brake pad wear. Vehicle vibration {after a long
drivel, or High, hard brake pedal
1 . D r i v et h e v e h i c l eu n t i lt h e b r a k e sd r a go r u n t i l t h e
pedal is high and hard.This can take 20 or more
brakepedal applicationsduring an extendedtest
drive.
5. Loosenthe hydrauliclines at the mastercylinder,
then spin the wheelsto checkfor brakedrag.
ls there brake drag at any of the wheels?
YES Go to step 6.
NO- Replacethe mastercylinder.l
2 . W i t h t h e e n g i n er u n n i n g r, a i s et h e v e h i c l eo n a l i f t ,
a n d s p i n a l l f o u r w h e e l sb y h a n d .
6. Loosenthe bleederscrewsat each caliper,then
spin the wheels to checkfor brakedrag.
ls there btake drag at any of the wheels?
Is there brake drag at any of the wheels?
YES Go to step 3.
NO Lookfor other causesof the pad wear, high
p e d a l ,o r v e h i c l ev i b r a t i o n . I
YES Disassembleand repairthe caliperon the
w h e e l ( sw
) i t h b r a k ed r a g . l
NO Inspectbrakehose (s)/line(s).
3. Turn the engineoff, pump the brakepedalto
depletethe vacuum in the brakebooster,and then
spin the wheels againto checkfor brakedrag.
ls therc brake dtag at any ot the wheels?
YES-Go to step 4.
NO Replacethe brakebooster.I
4. Without removingthe brakelines,unbolt and
separatethe mastercylinderfrom the booster,then
spin the wheelslo checkfor brakedrag.
ls there btake drag at any of the wheels?
YES Go to step 5,
NO-Check the brakepedal positionswitch
adjustmentand pedalfree play.I
19-5
BrakePedalandBrakePedalPosition
SwitchAdjustment
PedalHeight
1 . Disconnectthe brakepedal positionswitch
connector,turn the brakepedal positionswitch (A)
c o u n t e r c l o c k w i saen, d p u l l i t b a c ku n t i li t i s n o
l o n g e rt o u c h i n gt h e b r a k ep e d a l .
PedalFreePlay
4. With the engineoff, inspectthe play (A) on the
p e d a lp a d ( B )b y p u s h i n gt h e p e d a lb y h a n d .
F r e eP l a y :0 . 4 - 3 . 0 m m { 0 . 0 1 6 0 . ' l 1 8 i n . )
Lift up the carpetand the insulatorcutout (B).
l\4easure
the pedal height (C)from the middle of
the left side of the pedal pad (D).
StandardPedalHeight (with carpet removed):
184 mm (7 4/16in.)
lf the pedalfree play is out of specification,adjust
the brakepedal positionswitch (C).lf the pedalfree
p l a yi s i n s u f f i c i e n itt, m a y r e s u l ti n b r a k ed r a g .
Loosenthe pushrodlocknut(A),and screwthe
pushrodin or out with pliers until the standard
pedal heightfrom the floor is reached.After
adjustment,tighten the locknutfirmly. Do not
adjustthe pedal heightwith the pushrodpressed.
1 5N . m
(1.5kgl m. 11lbl ft)
19-6
6 . Pushin the brakeoedal oositionswitch until its
dnd(A)touching
p l u n g e ri s f u l l y p r e s s e d( t h r e a d e e
the pad (B)on the pedal arm).Then,turn the switch
45" clockwiseto lock it. The gap betweenthe brake
pedal positionswitch and the pad is automatically
a d j u s t e dt o 0 . 4t o 3 . 0m m ( 0 . 0 1 6 0 . 1 1 8i n . )b y
l o c k i n gt h e s w i t c h .M a k es u r et h e b r a k el i g h t sg o
otf when the pedal is released.
7 . C h e c kt h e b r a k ep e d a lf r e e p l a ya s d e s c r i b e db e l o w .
t
ParkingBrakeCheckand Adiustment
Check
Removethe rear console{seepage 20-57).
1. Pullthe parkingbrakelever {A) with 196 N (20 kgf,
44 lbf) of forceto fully apply the parkingbrake.The
parkingbrakelever should be lockedwithin the
specifiednumber of clicks(B).
Pull the parkingbrakelever up one click,
Leverlockedclicks: 7-8
-
l2okqf,a4lbl)
2. Adjustthe parkingbrakeif the leverclicksarenot
withinthe specification.
7, Tightenthe adjustingnut {A} until the parking
brakesdrag slightlywhen the rear wheels are
t ur n e d .
A
/
Adjustment
1. Releasethe parkingbrakeleverfully.
Loosenthe parkingbrakeadjustingnut, startthe
engine,and pressthe brakepedal severaltimes to
set the self-adjustingbrakebeforeadjustingthe
parkingbrake.
Blockthe front wheels,then raisethe rear of the
vehicle,and supportit with safetystandsin the
proper location(seepage 1-8).
Make sure the parkingbrakearm (A) on the rear
brakecalipercontactsthe brakecaliperpin (B),
NOTE:The parkingbrakearm will only contactthe
brakecaliperpin when the parkingbrakeadjusting
nut is loosened.
8 . Releasethe parkingbrakelever fully, and check
that the parkingbrakesdo not drag when the rear
wheels are turned. Readjustif necessary.
9 . Make surethe parkingbrakesare fully applied
when the parkingbrakelever is pulled up fully.
1 0 . Reinstallthe rear console.
19-7
BrakeSystemBleeding
NOTE:
. Do not spill brakefluid on the vehicle;it may damage
the painUif brakefluid does contactthe paint.wash it
off immediatelywith water.
. The reservoiron the mastercylindermust be at the
MAX (upper)level mark at the start of the bleeding
procedureand checkedafter bleedingeach brake
c a l i p e rA
. d d f l u i da s r e q u i r e d .
. Do not reusethe drainedfluid.
. Always use Honda DOT3 brakefluid. Non-Honda
brakefluid can causecorrosionand shortenthe life of
the system.
. Make sure no din or other foreign matter is allowed
to contaminatethe brakefluid.
5. ReDeattheprocedurefor eachwheel in the
sequenceshown below until air bubblesno longer
a p p e a ri n t h e f l u i d .
BLEEDING
SEOUENCE:
OFront Right
ORe.r Right
O Front Left
ORoar Loft
1 . M a k es u r et h e b r a k ef l u i d l e v e li n t h e r e s e r v o i irs a t
t h e M A X ( u p p e r )l e v e ll i n e( A ) .
Refillthe mastercylinder reservoirto the MAX
{upper)level line.
FRONTBRAKE:
9 N.m 10.9kgf.m,7 lbl.ft)
t-
2 . Slide a pieceof clear plastichoseover the flrst
bleed screw,and submergethe other end in a
containerof new brakefluid.
Havesomeoneslowly pump the brakepedal
severaltimes,then apply steadypressure.
Startingat the left-front,loosenthe brakebleed
screwto allow air to escapefrom the system.Then
tighten the bleedscrew securely.
19-8
REARBRAKE:
9 N m 10.9kgf.m, 7 lbf ft)
BrakeSystemIndicatorCircuitDiagram
UNDER.OASH
FUSE/FELAYBOX
I
A
Y
EBAK€FLUID
IEVELSwlICH
BtK
+
GRN/ORN
,tk
,o"","o ""o*.
(b, 3s1E8,.""",,"
oPEN,Leve,down
I
I
-=:
csor
19-9
Conventional
BrakeComponents
ParkingBrakeSwitch Test
1. Removethe rear console,and disconnectthe
connector(A)from the switch (B).
R
'dFu
!UF-
BrakeFluidLevelSwitch Test
Checkfor continuitybetweenthe terminals(A) with the
float in the down positionand the up position.
. Removethe brakefluid completelyfrom the reservoir.
With the float down, there should be continuity.
. F j l l t h er e s e r v o iw
r i t h b r a k e f l u i d t oM A X ( u p p e r )l e v e l
(B).With the float up, there should be no continuity.
\!E
Y
Checkfor continuitybetweenthe switchterminal
a n d b o d yg r o u n d :
. With the brakelever up, there should be
continuity.
. With the brakelever down, there should be no
continuity.
19-10
\
Front BrakePadsInspectionand Replacement
Replacement
F r e q u e nitn h a l a t i o no f b r a k ep a d d u s t ,r e g a r d l e sos f
m a t e r i acl o m p o s i t i o nc,o u l db e h a z a r d o utso y o u r
1 . R e m o v et h e b o l t( A ) ,a n d p i v o tt h e c a l i p e r( B )u p o u t
of the way. Checkthe hose and pin boots for
d a m a g ea n d d e t e r i o r a t i o n .
. Avoid breathingdust particles.
. N e v e ru s ea n a i r h o s eo r b r u s ht o c l e a nb r a k e
a s s e m b l i e sU. s ea n O S H A - a p p r o v evda c u u m
cleaner.
lnspection
safetystandsin the proper location{seepage 1'8).
2. Checkthe thicknessof the inner pad iA) and outer
p a d { B ) .D o n o t i n c l u d et h e t h i c k n e s so f t h e b r a k e
pad backingplate.
&
\
Brakepad thickness:
9.5 10.5mm (0.37 0.41 in.l
Standard:
Servicelimit: 1.6 mm (0.06in.)
A
2 . R e m o v et h e p a d s h i m i A ) a n d p a d s { B ) .
Innerpad:
' . . '
,
.a
Outer pad:
.^hv/
lf the brakeDadthicknessis lessthan the service
l i m i t ,r e p l a c ea l l t h e p a d sa s a s e t .
\v \ \."r------B
tJ I
(cont'd)
19-11
ConventionalBrakeGomponents
Front BrakePadsInspectionand Replacement(cont'dl
3. Removethe pad retainers(A),and checkthe caliper
pins for free movement.
10. Push in the piston (A) so the caliperwill fitoverthe
pads.Checkthe brakefluid level.The brakefluid
may overflow if the reservoiris too full. lvlakesure
the piston boot is in positionto preventdamagingit
when pivotingthe caliperdown
/:-."
t-..
. .,.';i.:
i '1='
r
r
..a.-
8x1.0mm
34 N.m
3.5 kgt m.
25 tbf.ft)
4. Cleanthe caliperthoroughly;remove any rust,and
checkfor groovesand cracks.
5. Checkthebrakedisc for damageand cracks.
6. Apply Dow CorningMolykoteM77 greaseto the
retainerson their mating surfacesagainstthe
caliperbracket.
7. Installthe pad retainers.Wipe excessgreaseoffthe
retainers.Contaminatedbrakediscsand pads
reducestoppingability.Keepgreaseoff the discs
andpads.
8. Apply Molykote l\477greaseto both sidesof the
p a d s h i m { A ) ,t h e b a c ko f t h e p a d s( B ) ,a n d t h e o t h e r
areasindicatedby the arrows.
Wipe excessgreaseoff the shim. Contaminated
brakediscsand pads reducestoppingability.Keep
greaseoff the discs and pads.
, a .).
Installthe brakepads and pad shim correctly.
Installthe padswith the wear indicators(C)on the
inside.
lf you are reusingthe pads,always reinstallthe
brakepads in their original positionsto preventa
momentary loss of brakingefficiency.
19-12
11. Pivotthe caliperdown into position.Beingcareful
not to damagethe pin boots,installthe bolt (B),and
tighten it to the specifiedtorque.
1 2 . P r e s st h e b r a k ep e d a ls e v e r atli m e s t o m a k e s u r e
the brakeworks,then test drive.
NOTEE
: n g a g e m e not f t h e b r a k em a y r e q u i r ea
greaterpedal strokeimmediatelyafter the brake
pads have been replacedas a set.Several
applicationsof lhe brakepedalwill restorethe
normal pedalstroke.
13. After installation,checkfor leaksat hose and line
joantsor connections,and retightenif necessary.
\
Front BrakeDisclnspection
Runout
Thicknessand Parallelism
2 . R e m o v et h e b r a k ep a d s( s e ep a g e1 9 - 1 1 ) .
2. Removethe brakepads (seepage 19-11).
3. Inspectthe disc surfacefor damageand cracks.
Cleanthe discthoroughly,and removeall rust
3. Using a micrometer,measurediscthicknessat
eight points,approximately45" apart and 10 mm
{0.4 in.) in from the outer edge of the disc.
4. lnstallsuitable flat washers(A) andwheel nuts,and
tightenthe nuts to the specifiedtorque to hold the
brakedisc securelyagainstthe hub.
Brake Oisc Thickness:
Standard:20.9 21.8mm {0.82-0.86 in.}
Max. RefinishingLimit: 19.0mm 10.75in.)
in.)
Brake Disc Parallelism: 0.015 mm 10.0(X)6
max.
NOTE:This is the maximum allowabledifference
betweenthe thicknessmeasurements
10 mm lo.itin.l
': . --'t-'"'t , .
Set up the dial gaugeagainstthe brakedisc as
shown, and measurethe runout at 10 mm (0 4 in.)
from the outer edge of the disc.
BrakeDiscRunout:
ServiceLimit: 0.10mm (0.00ttin.l
lf the disc is beyondthe servicelimit, refinishthe
brakedisc.
Max. RetinishLimit: 19.0mm (0.75in.)
NOTE:
. l f t h e b r a k e d i s ci s b e y o n d t h e s e r v i c lei m i t f o r
r e f i n i s h i n gr ,e p l a c ei t ( s e ep a g e1 8 - 11 ) .
. A new disc should be refinishedif its runout is
g r e a t e rt h a n0 . 1 0m m ( 0 . 0 0 4i n . ) .
4 . l f t h e s m a l l e sm
t e a s u r e m e ni ts l e s st h a nt h e m a x .
refinishinglimit, replacethe brakedisc (seepage
18-11).
lf the disc is beyondthe servicelimit for parallelism,
refinishthe brakedisc with an on-carbrakelathe.
The Kwik-Latheproducedby Kwik-way
"Front BrakeDisc
ManufacturingCo. and the
Lathe" offered by Snap-onTools Co. are approved
for this operation.
19-13
Front BrakeCaliperOverhaul
{
Frequentinhalationof brakepad dust, regardlessof materialcomposition,could be hazardousto your health.
' N e v e ru s ea n a i r h o s eo r b r u s ht o c l e a nb r a k ea s s e m b l i e su.s e a n o s H A - a p p r o v e d
v a c u u mc l e a n e r .
Remove,disassemble,inspect,reassemble,and installthe caliper,and note these items:
' D o n o t s p i l lb r a k ef l u i d o n t h e v e h i c l e i;t m a y d a m a g et h e p a i n t ;i f b r a k e f l u i d g e t s o n t h e p a i n t , w a s h i t o f f
immediatelywith water.
. To preventdripping,cover disconnectedhose joints with rags or shop towels.
. C l e a n a l lp a r t s i n b r a k e f l u i d a n d a i r d r y ; b l o w o u t a lpl a s s a g e s w i t ch o m p r e s s e d
air.
. Beforereassembling,checkthat all parts are free of dust and other foreign particles.
. Replacepartswith new ones as specifiedin the illustration.
. Make sure no dirt or other foreign matter is allowedto contaminatethe brakefluid,
' When reusingpads,always reinstallthemin their original positions to preventloss of
brakingefficiency.
. Do not reusedrainedbrakefluid.
'AlwaysuseHondaDOT3brakefluid.Non'Hondabrakefluidcancausecorrosionandshortenthelifeofthesvstem.
. Do not mix differentbrandsof brakefluid as they may not be compatible.
. C o a t t h ep i s t o n ,p i s t o ns e a lg r o o v e ,a n d c a l i p e rb o r e w i t h c l e a nb r a k e f l u i d .
. Make sure no greaseor oil gets on the brakediscs or pads.
. Replaceall rubber partswith new ones wheneverdisassembled.
. After installingthe caliper,checkthe brakehose and line for leaks,interference,and twistinq.
>:@:Honda
caliper sreaso tplN 08C30-80234M)
Boors
3i,l'1.'"
-ffiFA
/paq\
t l
l l
/
,\L,.'iE/
"=;lGoXu";;;lqEty'
3.4N.m
{3.5kef m,
/
/
\
25 lbf ft)
/
/
t
)/)
II
t9..-\
-
---=-?
.===?
/ ,,'
isli\ii ^ zswttt
SCREW
/8LEEO
/eNm
(o.s
kgr'm.
/
| itbt.ftl
1
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/7\
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*d':ffi
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,-o/
vlJ
Es,lry:' E*,e,a
["fif:i#l1t*"_,,.
\
.==f@
tz x t.zsmm
1 0 8N . m 1 1 1 . 0k g f . m ,
80 tbt.ft)
19-14
/caLl
>vr
//'
SEAL|NG
WASHEaS
WAStrtXS
RepracF
#.'@
PADRETATNERS
\
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(hA
\t/
,
^
*fL-f
(}',
[
-ffi
-ffi
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CALIPER
PINA
\
BRAKE
HOSE/
/
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ourEBpaDsHrM
MasterCylinderReplacement
NOTE:Do not spill brakefluid on the vehicle;it may
damagethe paint;if brakefluid does contactthe paint,
wash it off immediatelywith water,
r s s e m b l y( A ) .
1 , R e m o v et h e a i r c l e a n e a
3 . R e m o v et h e c l u t c hr e s e r v o i (r B )a n d e n g i n e w i r e
harnessclip (C)from the mastercylindermounting
b a s e( D ) .
4. Removethe reservoircap and brakefuid from the
reservoir.
5. Removethe reservoir(E)on the mastercylinder
m o u n t r n gD a s e .
6, Disconnectthe brakelines (F)from the master
cylinder (G).To preventspills,cover the hosejoints
with rags or shop towels.
7. Removethe mastercylinder mounting nuts {H)and
washers.
8. Removethe mastercylinderfrom the brakebooster.
Be carefulnot to bend or damagethe brakelines
when removingthe mastercylinder.
2, Disconnectthe brakefluid level sensorconnector
(A).
9. Removethe rod seal (l) from the mastercylinder.
10. Installthe mastercylinder in the reverseorder of
1 5N . m
{1.5kgt.m,11 lbt.ft)
. Replaceall the rubber partswith new ones
wheneverthe mastercylinder is removed.
. Checkthe pushrodclearancebeforeinstallingthe
mastercylinder.and adjust it if necessary(see
p a g e1 9 - 1 6 ) .
. Use a new rod seal on reassemblY
. Coatthe inner bore lip and outer circumference
of the new rod seal {A) with the recommended
seal greasein the mastercylinderset.
. I n s t a l l t h er o d s e a lo n t o t h e m a s t e rc y l i n d e rw i t h
its groovedside (B)towardthe mastercylinder.
. Checkthe brakepedal height and free play after
t h e m a s t e rc y l i n d e ra, n d a d j u s ti t i f
installing
19-15
MasterCylinderInspection
NOTE:
. Beforereassembling,checkthat alI partsare f ree of
dust and other foreign particles.
. D o n o t t r y t o d i s a s s e m b l e t hm
e astercylinder
assembly.Replacethe mastercylinder assemblywith
a new part if necessary.
. Do not allow dirt or foreign matterto contaminatethe
b r a k ef l u i d .
RESERVOIB
CAP
unecKIor otocKage
I
of vent holes.
,--l
RESERVOIR
r ' , , . J \ +
v
RESERvOIRSEAL
Checklor damaoe
and deterioration.
BrakeBoosterPushrodClearance
Adjustment
Pushrodadjustmentgauge07JAG-SD40100
NOTE:Brakeboosterpushrod-to-piston
clearancemust
be checkedand adjustmentsmade, if necessarV,before
installingthe mastercylinder.
1 . S e t t h e s p e c i atlo o l ( A )o n t h e m a s t e r c y l i n d ebr o d v
(B),push in the centershaft (C)until the top of it
contactsthe end of the secondarypiston {D) by
t u r n i n gt h e a d j u s t i n gn u t ( E ) .
STRAINER
Removeaccumulated
seotment.
RESERVOIR
HOSES
Inspecthosesfor
damage,leaks,and
deterioration.
MASTER
CYLINDER
Checkfor leaks,rust,anddamage
Without disturbingthe centershaft'sposition,
installthe specialtool(A) backwardson the booster.
1 5N m { r . 5
11tbf.ftl
Installthe mastercylinder nuts (B),and tighten
them to the specifiedtorque.
Conneclthe boosterin line with a vacuum gauge
{ C )0 - 1 0 1 k P a{ 0 ' - 7 6 0m m H g ,3 0 i n . H g )t o t h e
booster'senginevacuum supply,and maintainan
e n g i n es p e e dt h a tw i l l d e l i v e r6 6 k P a( 5 0 0m m H g ,
2 0 i n . H g )v a c u u m .
19-16
5. With a feelergauge (A),measurethe clearance
betweenthe gauge body and the adjustingnut (B)
as snown,
lf the clearancebetweenthe gauge body and the
adjustingnut is 0.4 mm (0.02in.),the pushrod-topistonclearanceis 0 mm. However.if the clearance
betweenthe gauge body and the adjustingnut is
clearanceis 0 4 mm
0 mm, the pushrod-to-piston
{0.02in.) or more. Thereforeit must be adjusted
and rechecked.
9 . C h e c kt h e p u s h r o dl e n g t h( A )a s s h o w n i f t h e
boosteris removed,lf the length is incorrect,
loosenthe pushrodlocknut(B),and turn the clevis
(C)in or out to adjust.
A
1 1 6m m { 4 . 6i n . )
Clearance: 0-0./t mm (0-0.02 in.)
1 0 x 1 . 0m m
1.5 N'm
11.5kgf.m,11 lbf.ftl
1 0 . I n s t a l l t h em a s t e rc y l i n d e r( s e ep a g el 9 - 1 5 )
lf the clearanceis incorrect,loosenthe star locknut
(A).and turn the adjuster(B)in or out to adjust.
. Adjustthe clearancewhile the specifiedvacuum
is appiiedto the booster.
. Holdthe clevis(C)while adjusting.
A
22N.n
0 0.4mm l0 -0.02in.)
07JAG-SO40100
7. Tightenthe star locknutsecurely.
8. Removethe specialtool (D).
19-17
Gonventional
BrakeComponents
I
BrakeBoosterTest
FunctionalTest
1. With the enginestopped,pressthe brakepedal
severaltimes to depletethe vacuum reservoir,then
pressthe pedal hard, and hold itfor 15 seconds.lf
the pedalsinks,eitherthe mastercylinderis
bypassinginternally,or the brakesystem (master
c y l i n d e rl,i n e s .m o d u l a t o ro, r c a l i p e r si)s l e a k i n g .
3. Disconnectthe brakeboostervacuum hose (check
valve built-in)(A) at the boosterside.
2. Startthe enginewith the brakepedal pressed.lf the
pedal sinksslightly,the vacuum boosteris working
properly.lf the pedal heightdoes not vary, the
boosteror checkvalve is faulty.
3. With the engine running,pressthe brakepedal
l i g h t l y .l f t h e b r a k ep e d a ls i n k sm o r e t h a n 1 Om m
{3/8 in,) in 3 minutes,the mastercylinder is faulty.
A slight changein pedal heightwhen the Ay'C
compressorcycleson and off is normal.(TheA,/C
compressorload changesthe vacuum availableto
the booster.)
LeakTest
1. Pressthe brakepedalwith the engine running,then
stop the engine.lf the pedal height does not vary
while pressedfor 30 seconds,the vacuum booster
is OK. lf the pedal rises,the boosteris faulty.
2. With the engine stopped,pressthe brakepedal
severaltimes using normal pressure.When the
pedal is first pressed,it should oe row.
On consecutiveapplications,the pedal height
s h o u l dg r a d u a l l yr i s e .l f t h e p e d a lp o s i t i o nd o e s n o t
varv, checkthe boostercheckvalve.
4 . Startthe engine,and let it idle.Thereshould be
v a c u u ma v a i l a b l el .f n o v a c u u mi s a v a i l a b l et ,h e
checkvalve is not working properly.Repiacethe
brakeboostervacuum hose and checkvalve,and
relesI.
5 . Reconnectthe brakeboostervacuum nose.
Startthe engine,and then pinch the brakebooster
vacuum hose betweenthe checkvalve and the
booster,
Turn the ignition switch OFF,and wait 30 seconds,
Pressthe brakepedal severaltimes using normal
pressure,
When the pedal is first pressed,it should be low.
On consecutiveapplications,the pedal height
s h o u l dg r a d u a l l yr i s e .
. lf the pedal positiondoes notvary, replacethe
brakebooster.
. lf the pedal positionvaries,replacethe brake
boostervacuum hose/checkvalve assembly.
19-18
BrakeBoosterReplacement
1 . R e m o v et h e m a s t e rc y l i n d e r( s e ep a g e1 9 - 1 5 ) .
5 . R e m o v et h e c l i p ( A )a n dt h e j o i n t p i n ( B ) .a n d
disconnecttheyoke from the brakepedal.
Removethe mastercylinder brakelines {A) from
t h e b r a k el i n ec l i p .
.,.,....
alu
i
' - /
'..
c
6x1.0mm
9.8 N.m
(1.0kgf.m,
7.2 tbf.ft)
Removethe vacuum hose mounting bracket(B).
Disconnectthe vacuum hose {C)from the brake
booster.
{'l.3kgf.m,9lbf.ftl
Removethe brakeboostermounting nuts (C).
7 . Removethe brakebooster(A)from the engine
comparlmenr.
INdAdEI
. Be carefulnot to damagethe booster
surfacesand threadsof the boosterstud
bolts.
. Be carefulnot to bend or damagethe
b r a k el i n e s .
lnstallthe brakeboosterin the reverseorder of
. Adjustthe pushrodclearancebeforeinstalling
the brakebooster(seepage 19-16).
. U s ea n e w c l i pw h e n e v e ri n s t a l l i n g .
. After installingthe brakeboosterand master
cylinder,fill the reservoirwith new brakefluid,
bleedthe brakesystem (seepage 19-8),and
adjustthe brakepedal height and free play (see
p a g e1 9 - 6 ) ,
19-19
Conventional
BrakeComponents
RearBrakePadsInspectionand Replacement
Replacement
Frequentinhalationof brakepad dust, regardlessof
materialcomposition,could be hazardousto your
h e ah h .
. Never use an air hose or brushto clean brake
assemblies,Use an OSHA-approvedvacuum
cleaner.
1. Removethe bolt (A) and brakehose {B}from the
mounting bracket.
Inspection
'1.
Raisethe rear of the vehicle,and supportjt with
Removethe rearwheels,
2. Checkthe thicknessof the inner pad (A) andouter
pad (B).Do not includethe thicknessof the brake
pad backingplate.
Brakepad thickness:
Standard:
8.5 9.5 mm {0.33-0.37 in.}
Servicelimit: 1.6 mm (0.06in.)
Removethe caliperbolts (C),and removethe
caliper(D)from the caliperbracket.
3 . R e m o v et h e p a d s h i m s( A )a n d p a d s( B ) .
A
t {
B
\
-::--
3 . lf the brakepad thicknessis lessthan the service
l i m i t ,r e p l a c ea l l t h e p a d sa s a s e t .
A
\
r\
)
\
19-20
)
tI
A
4. Removethe pad retainers(A).and checkthe caliper
pins for free movement.
:.i _ _l
11. Rotatethe caliperpiston clockwiseinto the cylinder,
then align the cutout (A) in the pistonwith the tab
{B) on the inner pad by turning the piston backso
t h e c a l i p e rc a n b e i n s t a l l e do n t h e p a d .L u b r i c a t e
the boot with rubbergreaseto avoid twisting the
Distonboot. lf the piston boot is twisted,back it out
so it is positionedproperly.
8 x 1 . 2 5m m
22 N.m
l2.2kgt m,
16rbl.ttl
5. Cleanthe caliperthoroughly;remove any rust.and
checkfor groovesand cracks.
6, Checkthe brakedisc for damageand cracks.
7 . Apply Dow CorningMolykoteM77 greaseto the
retainerson their mating surfacesagainstthe
caliperbracket,
.ar
8 . Installthe pad retainers.Wipe excessgreaseoffthe
retainers.Contaminatedbrakediscs and pads
reducestoppingability.Keepgreaseoff the discs
a n dp a d s .
9 . Apply Dow CorningMolykotelvl77greaseto both
sidesof the pad shims {A),the backof the pads (B),
and the other areasindicatedby the arrows.Wipe
excessgreaseoff the shim. Contaminatedbrake
discs and pads reducestoppingability.Keep
greaseoff the discsand pads.
.
.-.
D
8 x 1.25mm
23Nm
{2.3kgf.m,
17rbf.ft)
I n s t a l l t h eb r a k ec a l i p e r( C )a n d c a l i p e rb o l t s( D ) .
and tighten the boltsto the specifiedtorque.
1 3 .I n s t a l l t h eb r a k eh o s e( E ) .
1 4 . Pressthe brakepedal severaltimes to make sure
the brakeworks, then test-drive.
NOTE:Engagementof the brakemay requirea
greeterpedal strokeimmediatelyafterthe brake
pads have been replacedas a set. Several
applicationsof the brakepedalwill restorethe
n o r m a lp e d a ls t r o k e ,
1 5 . C h e c kt h e p a r k i n gb r a k ea d j u s t m e n{ts e ep a g e1 9 - 7 ) .
1 0 . I n s t a l l t h eb r a k ep a d sa n d p a d s h i m sc o r r e c t l y .
I n s t a l l t h ep a d sw i r h t h e w e a r i n d i c a t o r {sC )o n t h e
inside.
lf you are reusingthe pads,always reinstallthe
brakepads in their originalpositionsto preventa
momentaryloss of brakingefficiency.
1 6 . A f t e ri n s t a l l a t i o nc ,h e c kf o r l e a k sa t h o s ea n d l i n e
joints or connections,and retightenif necessarY.
19-21
Conventional
BrakeComponents
RearBrakeDiscInspection
Runout
Thicknessand Parallelism
1. Raisethe rear of the vehicle,and support it with
Removethe rear wheels,
1. Raisethe rear of the vehicle,and supportwith
safetystandsin the proper location(seepage l-g).
2. Removethe brakepads (seepage 19-20).
2. Removethe brakepads {seepage 19 20).
3. Inspectthe disc surfacefor damageand cracks.
Cleanthe discthoroughly,and remove all rust,
3, Using a micrometer,measurediscthicknessat
, p p r o x i m a t e l4y5 ' a p a r ta n d 1 0 m m
e i g h tp o i n t s a
{0.4 in.)from the outer edge of the disc.
4. lnstallsuitable f lat washers(A) and wheel nuts, and
tighten the nuts to the specifiedtorque to hold the
brakedisc securelyagainstthe hub.
BrakeDiscThickness:
Standard:9.9-10.1 mm (0.389 0.397in.l
Max. RetinishingLimit: 9.0 mm (0.35in.)
BrakeDiscParallelism: 0.016mm 10.0006in.)
max.
108N.m (11.0kgf.m,80lbf.ft)
Set up the dial gauge againstthe brakedisc as
shown. and measurethe runout at 10 mm (0.4in.)
from the outer edge of the disc.
Brake Disc Runout;
lf the disc is beyondthe servicelimit, refinishthe
brakedisc.
Max. RefinishLimit: 9.0 mm (0.35in.)
NOTE:
. l f t h e b r a k ed i s ci s b e y o n d t h e s e r v i c lei m i t f o r
refinishing,replaceit (seepage 18-26).
. A new disc should be refinishedif its runout is
g r e a t e rt h a n0 . 1 0m m ( 0 . 0 0 4i n . ) .
19-22
4 . lf the smallestmeasurementis lessthan the max.
refinishinglimit, replacethe brakedisc (seepage
18-26).
lf the disc is beyondthe servicelimit for parallelism,
refinishthe brakedisc with an on-carbrakelathe.
RearBrakeCaliperOverhaul
Frequentinhalationof brakepad dust, regardlessof materialcomposition,could be hazardousto your health.
' Avoid breathingdust particles.
. Never use an air hose or brushto clean brakeassemblies.Use an OSHA-approvedvacuum cleaner'
Remove,disassemble,inspect,reassemble,and installthe caliper,and note these items:
. D o n o t s p i l lb r a k ef l u i d o n t h e v e h i c l e i;t m a y d a m a g et h e p a i n t ;i f b r a k ef l u i d g e t so n t h e p a i n t ,w a s h i t o f f
. To preventdripping.cover disconnectedhosejoints with rags or shop towels.
. C l e a n a l lp a r t s i n b r a k e f l u i d a n d a i r d r y ; b l o w o u t a lpl a s s a g e s w i t ch o m p r e s s e a
dir'
. Beforereassembling,checkthat all parts are free of dust and other foreign particles
. Replacepans with new ones as specifiedin the illustration.
. Make sure no dirt or other foreign matter contaminatesthe brakefluid.
. When reusingpads,always reinstallthemin their originalpositionsto preventloss of b raking efficiency.
. Do not reusedrainedbrakefluid.
. U s eo n l y c l e a nH o n d aD O T3 b r a k ef l u i d .N o n - H o n d a
b r a k ef l u i d c a nc a u s ec o r r o s i o na n d s h o r t e nt h e l i f eo f t h e
system.
. Do not mix differentbrandsot brakefluid as they may not be compatible.
. C o a t t h ep i s t o n ,p i s t o ns e a lg r o o v e ,a n d c a l i p e rb o r ew i t h c l e a nb r a k ef l u i d .
. Make sure no greaseor oil gets on the brakediscsor pads.
. R e p l a c e a lrlu b b e rp a r t sw i t h n e w o n e sw h e n e v e rd i s a s s e m b l e d .
. After installingthe caliper,checkthe brakehose and line for leaks,interference.and twisting.
oG
BOLT
3 4 N . m( 3 . 5k g f m , 2 5 l b t f t )
WASHERS
, nonau."rip6r qreas€lP/N 08c30-aoa4Ml
BRAKEHOSE
",1 ;[.,.JF
/;;;;---
ADJUSTINGBOLT
\-"o, V((rA
t H\a \l / t,i*t'*"
?,,.t/*"^.,,.:,"",
l, /"V4#
,/
a
i,,'IltE"
/ !!;,ff
olT-J,.o"c.
lii.'i rz.rrgr..
.ARKING
NUr
2 7 N m { 2 . 8 k g ft .mm, ,
20 tbf.ftr
Gd
ffi
PADSPRING
A,n
Na
--t\)(*ff
'(
INNEBPA'SHIM
/
CUP
Beplace.
O.RING
Beplace.
7lfl,lif,loffi',,0,n, \ ,,:,o"\
":;*" *dF
.r.:._U
i*E
fr.x{_>@
,,.-"iV
:
.:r=,9!q!q}l
''"'t!1'ry#'
l^7k
,.2>a>-
fftt **-->**^'"
,/q &'"o.,"."""o"^.,
10 MM FLANGE BOLTS
55 N m (5.6 lgf-m, 4r lbt ft)
19-23
BrakeHosesand LinesInspection
{
1. Inspectthe brakehosesfordamage,deterioration,leaks,interference,andtwisting.
2. Checkthe brakelinesfor damage,rusting.and leakage.Also checkfor bent brakelines.
3. Checkfor leaksat hose and line joints or connections,and retightenif necessary.
4. Checkthe mastercylinderand ABS modulator unit for damageand leakage.
NOTE:Replacethe brakehose clip wheneverthe brakehose is serviced.
BRAKELINE-to-BRAKE
HOSE
15 N.m (1.5kgf.m, 11 lbf.ftl
BRAKEHOSE-to-CALIPER
lBANJOBOLTI
3il N.m {3.5kgf.m.25lbt'ft)
BLEEO
SCREW
9 N.m{0.9kgf.m,7lbf.ftl
ABS MODULATORUNIT-Io-BRAKELINE
15N.m{1.5kgf m.11lbf.ftl
t''
/,i'i'
,/ ,l
t
t,..
-)
L
MASTERCYLINDEB-to-BRAKE
LINE
15 N m {1.5kgt.m,ll lbf.ft)
BRAKEHOSE.tO-CALIPER
{BANJO BOLTI
34 N.m {3.5kgf.m,25 lbl.ft)
BLEEDSCBEW
9 N.m
10.9kgf.m, 7 lbf ft)
19-24
CONTROLVALVE-to-
BRAKELINE
15N.m11.5kgf m, 11lbf.ft)
BRAKELINE-Io-BRAKEHOSE
15 N.m (1.5kgf.m,11lbf.ftl
BrakeHoseReplacement
NOTE:
. Do not spill brakefluid on the vehicle;it may damage
the paint;if brakefluid gets on the paint,wash it off
. To preventdripping,cover disconnectedline joints
with rags or shop towels.
. Beforereassembling,checkthat all parts are free of
dust and other foreign particles.
. Replacepartswith new ones wheneverspecifiedto
do so.
6. Installthe brakehose bracket(A)on the damper
with the flange bolt (B)first, then connectthe brake
hose (C)to the caliperwith the banjo bolt {D) and
n e w s e a l i n gw a s h e r s( E ) .
1. Replacethe brakehose (A) if the hose is twisted,
cracked,or if it leaks.
7. lnstallthe hose onto the hose bracketon the bodv
with a new hose clip (A).
i
!
1 0 x 1 . 0m m
15 N.m
(1.5kgf.m,
1t tbt.ftl
Disconnectthe brakehosefrom the brakeline (B)
using a 10 mm flare nut wrench {C)
Removethe flange bolt (A),and removethe brake
hose bracketsfrom the damper.
Connectthe brakeline to the brakehose.
9 . After installingthe brakehose,bleedthe brake
system (seepage l9-8).
1 0 .Do the following checks:
I x 1 . 2 5m m
. Checkthe brakehose and line joint for leaks,and
tighten if necessary.
. Checkthe brakehosesfor interferenceand
twisting.
4. R e m o v ea n d d i s c a r dt h e h o s ec l i p ( B ) .
Removethe banjo bolt (C),and removethe brake
h o s e( D ){ r o m t h e c a l i p e r .
19-25
1
ParkingBrakeCableReplacement
ExplodedView
ADJUSTING
NUT
PARKINGBRAKE
swtTcH
L
e
PARKING
BRAKECABLE
for stiffness,
Check
binding,anddamage.
19-26
8 x 1.25
22 N.m
12.2kgl
NOTE:
. The parkingbrakecablesmust not be bent or
distorted.This will leadto stiff operationand
prematurefailure.
. Referto the ExplodedView as neededduring this
proceoure.
1 . R e l e a s teh e p a r k i n gb r a k el e v e rf u l l y .
7 . l n s t a l l t h en e w c a b l ei n t h e r e v e r s eo r d e ro f
removal.and note these items:
. Be careful not to bend or distortthe cable.
. M a k es u r et h e p a r k i n gb r a k ec a b l ec l i p i s f u l l y
seatedon the cable housing.
. Do the parkingbrakecable adjuslment(seepage
1 9 - 7) .
2. Removethe rearconsole(seepage 20-57).
4 . Removethe parkingbrakecableclip (A) from the
b r a k ec a b l e( B ) .
Disconnecttheparkingbrakecablefrom the lever
{c).
6 . Removethe parkingbrakecable mounting
hardware,then removethe cable.
19-27
Brakes
BrakeComponents................
19-1
Conventional
ABS (Anti-lockBrakeSystem)Components
C o m o o n e nLto c a t i olnn d e x . . . . . . . . . . . . . , . . . . . . . . . . . . . 1
. .9. .-.3. .0. . . . . . .
Troubleshooting
Information.......................
19-31
General
..............
19-34
DTCTroubleshooting
Index
19-35
Index ...,...........................
.................
...........
19-36
SystemDescription
.........19-42
CircuitDiagram
..........
19-45
DTCTroubleshooting
...............
19-52
ABSIndicator
......................
BrakeSystemIndicator
Circuit
T r o u b l e s h o o t i n. .g. . . . . . . . . . . . . . . . . . . .
. . . . . .1. 9 - 5 5
ABSModulator-Control
UnitRemovaland
.............
19-57
lnstallation
19-59
WheelSensorInsoection
...................
..............
19-59
WheelSensorReolacement
ABSGomponents
(
RIGHT-REAR
WHEELSENSOR
page19-59
Inspection,
page19-59
Replacement,
UNDER.OASH
FUSE/RELAY
BOX
UNDER.HOOD
FUSE/RELAY
BOX
\L
LEFT.REAR
WHEELSENSOR
page 19-59
Replacement,
DATA LINKCONNECTOR
I16PI
RIGHT.FRONT
WHEELSENSOR
page 19-59
Replacement,
ABSMODULATOR.CONTROL
UNIT
page19'57
Removal
andInstallation,
19-30
LEFT-FRONT
WHEELSENSOR
page19-59
Inspection,
page1959
Replacement,
GeneralTroubleshootingInformation
ABS Indicator
DiagnosticTroubleCode{DTCI
. lf the system is OK,theABS indicatorgoes off 2
secondsafter turning the ignition switch ON (ll)
without startingthe engine,and then comes on again
and goes off 2 secondslater after startingthe engine.
This occursbecausethe ABS control unitisturned
on by the lG2 power source.
. The ABS indicatorcomes on when the ABS control
unit detectsa problem in the system.However,even
though the system is operatingproperly,the indicator
will come on underthese conditions:
- Only the drive wheels rotate
- One drive wheel is stuck
- The vehiclegoes into a spin
- The ABS continuesto operatefor a long time.
- The vehicleis subjectedto an electricalsignal
disturbance
. The memory can hold three DTCS.However,when
the same DTCis detectedmore than once,the more
recentDTCis written over the earlierone.
Therefore,when the same problem is detected
repeatedly,it is memorizedas a single DTC.
. The DTCsare in the order they occurred,beginning
with the most recent.
. The DTCSare memorizedin the EEPROM(nonvolatile memory).Therefore.the memorizedDTCs
are not clearedwhen the batteryis disconnected,the
ignition switch is turned off, or the system returnsto
normal. Do the specifiedproceduresto clearthe
DTCs.
To determinethe actualcauseof the problem,question
the customeraboutthe problem.taking the above
condilionsinto consideration.
. When a Droblemis detectedand lhe ABS indicator
comes on, there are caseswhen the indicatorstays
on until the ignition switch is turned OFF,and cases
when the indicatorgoes off automaticallywhen the
sYstemreturnsto normal.
- DTC61: The ABS indicatorgoes off automatically
when the system returnsto normal.
- D T C1 1 ,1 3 , 1 5 , 1 7, 3 1 , 3 2 , 3 3 ,3 4 ,3 5 ,3 6 ,3 7 ,3 8 ,5 4 ,
or 81: The ABS indicatorstayson until the ignition
switch is turned OFFwhether or not the system
returnsto normal.
- D f C 1 2 ,1 4 ,1 6 ,1 a , 2 1 , 5 1 , 5 2o, r 5 3 ;T h e A B S
indicatorgoes off when the vehicleis driven again
and the system is OK afterthe ignition switch is
t u r n e df r o m O F Ft o O N { l l } .
Self-diagnosis
. Self-diagnosiscan be classifiedinto two categories:
- I n i t i ad
l iagnosis:
Done right after the enginestarts and until the ABS
indicatorgoes off
- R e g u l ad
r iagnosis:
D o n er i g h t a f t e r t h ei n i t i a d
l i a g n o s i su n t i lt h e
ignition switch is turned OFF
. When a problem is detectedby self-diagnosis,
the
system does the following:
- Turnsthe ABS indicatoron
- Memorizesthe DTC
- StopsABS control
Kickback
The pump motor operateswhen the ABS is functioning,
and the fluid in the reservoiris forced out to the master
k t t h e b r a k ep e d a l .
c y l i n d e rc, a u s i n gk i c k b a c a
PumpMotor
. The pump motor operateswhen the ABS is
functioning.
. The ABS control unit checksthe pump motor
operationwhen the vehicleis startedthe first time
after the ignition switch is turned ON (ll).You may
hearthe motor operateat this time, but it is normal.
(cont'd)
19-31
ABSComponents
GeneralTroubleshootingInformation(cont'd)
How to TroubleshootABS DTCs
The troubleshootingflowchartproceduresassumethat
the causeof the oroblem is still Dresentand the ABS
indicatoris still on. Followingthe flowchartwhen the
ABS indicatordoes not come on can resultin incorrect
diagnosis.
The connectorillustrationsshow the female terminal
connectorswith a singleoutline and the male terminal
connectorswith a double outline.
1. Ouestionthe customeraboutthe conditionswhen
the problem occured,and try to reproducethe
same conditionsfor troubleshooting.Find out
when the ABS indicatorcame on, such as during
ABS control,after ABS control,when the vehicle
was at a certainspeed,etc.
2 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n df o l l o wt h e
prompts on the PGM Testerto displaythe DTC{S)
on the screen.After determiningthe DTC,referto
the DTCTroubleshootingIndex.
NOTE:Seethe HondaPGM Testeruser'smanual
Service Check Signal (SCS)Circuit Method:
(BI underthe driver'sside of the dashboard.
2. When the ABS indicatordoes not come on during
the test-drive,but troubleshootingis done basedon
the DTC,checkfor looseconnectors.poor terminal
contact,etc.,beforeyou starttroubleshooting.
3. After troubleshooting,clearthe DTC,disconnect
the
HondaPGM Tester.and test-drivethe vehicle.
Make sure the ABS indicatordoes not come on.
How to RetrieveABS DTCs
1, Wjth the ignition switch OFF,connectthe Honda
PGMTester(A)to the 16Pdata link connector(DLC)
(B) under the driver'sside of the dashboard.
19-32
2. Short the SCScircuitto body ground usingthe
HondaPGM Tester.
4. The blinkingfrequencyindicatesthe DTC.DTCSare
indicatedby a seriesof long and short blinks.One
l o n gb l i n ke q u a l s1 0 s h o n b l i n k s A
. d d t h e l o n ga n d
short blinkstogetherto determinethe DTC.After
determiningthe DTC,referto the DTC
T r o u b l e s h o o t i nI gn d e x .
How to ClearABS DTCs
P G MT e s t e r( A ) t o t h e l 6 P d a t a l i n kc o n n e c t o (r D L C )
{ B }u n d e rt h e d r i v e r ' ss i d eo f t h e d a s h b o a r d .
NOTE:
. lf the DTCis not memorized,the ABS indicator
will go off for 3.6 seconds,and then come back
on.
. lf the ABS indicatorstayson, troubleshootfor
"ABS indicator
does not go off" (seestep 1 on
page 19-53).
Th€ system will not indicate the DTC unless these
conditions are met:
. The brakepedal is not pressed.
. The ignitionswitch is turned ON {ll).
. The SCScircuitis shortedto body ground before
t h e i g n i t i o ns w i t c hi s t u r n e dO N ( l l ) .
Example
ot DTC15
Long blink
Short blinks
{five timesl
T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d c l e a r t h e
DTC(s)by following the screenprompts on the
PGM Tester.
NOTE:Seethe HondaPGl\4Testeruser's manual
for sDeclfic instructions.
Examole of DTC 22
Long blinks (two times)
Cycling the lgnition Switch Method:
C l e a rt h e D T Cb y t u r n i n gt h e i g n i t i o ns w i t c hO N ( l l )t h e n
O F Fa t l e a s t2 0 t i m e s .
5 . Turn the ignition swltch OFF,
Disconnectthe HondaPGM Testerfrom the DLC.
19-33
ABSGomponents
DTC
DTC:11
DTC:12
DTC:13
DTC:14
DTC;15
DTC:16
DTC:17
DTC:18
Drc:2l
DTC:3'l
DTC:32
DTC:33
DTC:34
DTC:35
DTC;36
DTC:37
DTC:38
DTC:51
DTC:52
DTC:53
DTC:54
DTC:61
DTC:81
19-34
Detection ltem
Rioht-frontwheel sensor{ooen/shortto bodv qround/shortto power)
Faultv riqht-frontwheel sensoroulse siqnal
Left-frontwheel sensor{oDen/shortto bodv qround/shortto power)
Faultvleft-frontwheel sensorDulsesrqnal
Riqht-rearwheel sensor(oDen/shortto bodv qround/shortto power)
F a u l t vr i q h t - r e awr h e e ls e n s o ro u l s es i q n a l
Left-rearwheel sensor (open/shortto bodv qround/shortto power)
Faultvleft-rearwheel sensorDulsesiqnal
d ulser)
C o n t i n u o uo
s D e r a t i o (nc h i o D e D
Solenoid
Solenoid
Solenoid
Solenoid
Solenoid
S ol en oi d
S ol en o i d
S o l en oi d
lvlotor Iocked
lvlotor stuck off
lMotorstuckon
Main relav stuckoff
lG2 voltaqe
cPU (CentralProcessinqUnit)
Note
(seeoaoe 19-45)
{seeoaoe 19-46)
(seeoaqe 19-45)
(seepaqe 19-46)
(seeDaqe19-45)
(seepaqe 19-46)
(seeDaoe'19-45)
(seeDaqe'19-46)
(seepaqe 19-47)
(seeDaoe19-48)
{ s e eD a q e1 9 - 4 8 )
{seeDaoe19'48)
lsee oaqe 19-48)
(seepaqe 19-48)
(seeDaqe19-48)
(seeDaqe19-48)
(seeDaoe19-48)
( s e eD a q e1 9 - 4 8 )
(seeDaoe19-49)
(seeDaoe19-50)
( s e ep a q e1 9 - 5 1
{ s e eo a q e1 9 - 5 ' l
{seepaqe 19-52)
Symptom Troubleshooting Index
Symptom
ABS indicatordoes nol come on
ABS indicatordoes not go off and no
ABS DTCis stored
Brakesystem indicatordoes nol come
on
Brakesystem indicatordoes not go off
and no ABS DTCis stored
ABS IndicatorCircuitTroubleshooting(seepage
19-52)
ABS IndicatorCircuitTroubleshooting{seestep 1
on Daqe19-53)
BrakeSystem lndicatorCircuitTroubleshooting
(seepaqe 19-55)
Also check for
BrakeSystemIndicator
(seesteo1 on Daqe19-55)
19-35
ABS Gomponents
SystemDescription
ABSControlUnit Inputsand Outputsfor 31PConnector
1 2
4 5 6 7 B I
1 6 1 1 1B 1 9
1112
1 41 5
20 ?1/t/t/l/t/
Terminal
number
Wire
color
Terminal
sign
Description
Measurement
Terminals Conditionsllgnition
Voltage
switch ON (ll))
BLU/
YEL
GRN/
YEL
BLU
RRS
5
GRN/
BLK
F R S( + )
6
BRN/
WHT
BLU/
ORN
F L S( _ )
8
GRY/
RED
R L SH
9
11
YEU
RED
LT BLU
DIAG K
12
BRN
DIAG L
7
19-36
(+)
RRS
F R S( - )
F L S{ + )
R L S( + )
Detects
righfrear
wneetsensor
srgnal
Detectsright-front
wneetsensor
srgnal
;a-_-l
S p i nw h e e l a t AC:0.053V or
I turn/second
above
Wheel
Detectsleft-front
wneet
sensor
srgnal
6-7
Detectsleft-rear
wneetsensor
srgnal
8 9
Communications
with HondaPGM
rester
DTCindication
Oscilloscope
0 . 1 5V p - po r
above
Terminal
number
Wire
color
Terminalsign
WHT/
BLK
BLV
ORN
STOP
16
BLK
M-GND
+ B-MR
18
WHT/
RED
WHT/
GRN
BLK
14
t5
'19
20
BLU/
RED
BRN/
YEL
rG2
+ B-FSR
GND
ABS
Description
Measurement
Terminals Conditions {lgnition
Detectsbrake
switchsiqnal
I 4 - GN D
Powersource
for
activating
the
svstem
Ground
forthe
motor
0umD
15-GND
Powersourcefor
the oumDmotor
Powersourcefor
thevalverelav
Groundfor the
modulator
assemDtv
17-GND
DrivesABS
indicator
20-GND
EBD
Drivesbrake
(Electronic
brake systemindicator
distribution)
switch oN lll))
Brakepedal Pressed
Released
16-GND
,18-GND
Voltage
Eattery
voltaoe
Baftery
voltage
Below
0.3V
Atalltimes
Battery
voltaoe
Atalltimes
Battery
voltaoe
19.GND
ABS
indicator
2 1 - G N D Brakesystem
indicator
Below
0.3V
ON
OFF
OFF
ONfor
bulb
cnecK
A b o u t1 1V
Below 1 V
Below
0.3V
8attery
voltage
( c o n t ' d)
19-37
ABS Gomponents
SystemDescription(cont'd)
Features
When the brakepedal is pressedduring driving,the wheels can lock beforethe vehiclecomesto a stop. In such an
event.the maneuverabilityof the vehicleis reducedif the front wheels are locked,and the stabilityof the vehicleis
reducedif the rearwheels are locked,creatingan extremelyunstablecondition.The ABS preciselycontrolsthe slip
rate of the wheelsto ensuremaximum grip force from the tires,therebyensuringthe maneuverabilityand stabilityof
thevehicle.
The ABS calculatesthe slip rate of the wheels basedon the vehiclespeedand the wheel speed,then it controlsthe
brakefluid pressureto reachthe target slip rate.
Grip Force of Tire and Road Surface
TARGETSLIPRATE
OF
COEFFICIENT
FRICTION
SLIPRATE
19-38
ABSControlUnit
Main Control
The ABS control unit detectsthe wheel speed basedon the wheel sensorsignal it received,then it calculatesthe
vehiclespeed basedon the detectedwheel speed.The control unit detectsthe vehiclespeedduring deceleration
basedon the rate of deceleration.
The ABS control unit calculatesthe slip rate of eachwheel and transmitsthe control signalto the modulatorunit
solenoidvalve when the slip rate is high.
The pressurereductioncontrol hasthree modes: pressurereducing,pressureretaining,and pressureintensifying.
T---
Self-diagnosisFunction
1 . T h e A B S c o n t r ou ln i t i s e q u i p p e d w i t h a m a i n C P U a n d a s u b - C P U . E a c h C P U c h e c k s t h e o t h e r f o r p r o b l e m s .
2. The CPUScheckthe circuitof the system.
3 . T h e A B S c o n t r oul n i t t u r n so n t h e A B S i n di c a t o rw h e n t h e u n i t d e t e c t s ap r o b l e ma n d t h e u n i ts t o p st h e s y s t e m .
4. The self-diagnosiscan be classifiedinto thesetwo categories:
. l n i t i a ld i a g n o s i s
. R e g u l ad
r iagnosis
On-boardDiagnosisFunction
The ABS can be diagnosedwith the Honda PGM Tester.
The ALB Checkercannot be usedwith this system.For air bleedingand checkingwheel sensorsignals.usethe Honda
PGM Tester.Seethe Honda PGMTesteruser's manualfor specificoperatinginstructions.
(cont'd)
19-39
ABSComponents
SystemDescription(cont'd)
ABSModulator
The ABS modulatorconsistsof the inlet solenoidvalves,outlet solenoidvalves,reservoir,pump, pump motor, and the
damping chamber.The modulator reducesthe caliperfluid pressuredirectly.lt is a circulating-typemodulator
b e c a u s e t h eb r a k e f l u i d c i r c u l a t e s t h r o u g h t h e c a l i p e r , r e s e r v o i r , a n d t h e m a s t e r c y l i n d e r . T h e h y d r a u l i ch caos n t r o l
three modes:pressureintensifying,pressureretaining,and pressurereducing.The hydrauliccircuitis an independent
four-channeltype
o ,n e c h a n n efl o r e a c hw h e e l .
Pressureintensifyingmode: Inletvalveopen,outlel valve closed
M a s t e rc y l i n d e fr l u i d i s p u m p e do u t t o t h e c a l i p e r .
Pressureretainingmode:
lnlet valve closed,outlet valve closed
Caliperfluid is retainedby the inlet valve and outlet valve.
Pressurereducingmode:
Inletvalve closed,outlet valve open
Caliperfluid flows through the outlet valveto the reservoir.
lvlotoroperationmode:
When startingthe pressurereducingmode,the pump motor is ON.
When stoppingABS operation,the pump motor is OFF.
T h e c a l i p e rf l u i d i s p u m p e do u t b y t h e p u m p ,t h r o u g ht h e d a m p i n gc h a m b e rt,o t h e
m a s t e rc v l i n d e r .
19-40
t
WheelSensors
The wheel sensorsare the magneticcontactlesstype. As the gear pulserteeth rotate pastthe wheel sensor'smagnetic
coil, AC current is generated.The AC frequencychangesin accordancewith the wheel speed.The ABS control unit
detectsthe wheel sensorsignalfrequencyand therebydetectsthe wheel speed.
GEARPULSER
.r HIGXSPEED
WHEELS€NSOR
!t LOW SPEED
5
Wheel Speed and Modulator Control
VEJ!q!ESPEEq
8E!EEETqE
PRESSURE
OUTLET
VALVE 9p
OFF
INLET
VALVE oN
OFF
MoroR
-,.
I
l
t
l
OFF
When the wheel speeddrops sharplybelow the vehiclespeed,the inlet valve closesand il necessary,the outlet valve
opens momentarilyto reducethe caliperfluid pressure.The pump motor startsat this time. As the wheel speed is
restored,and the outlet valve closes,the inlet valve opens momentarilyto increasethe caliperfluid pressure.
19-41
ABSGomponents
CircuitDiagram
"'----G50l
L "*'*" lJ5 Il
rI * *r +' tl ? l
I
^
Gu
csl
19-42
lo+-sN
LqF**,
*- :ffrre, *riq.r.srbm
r.l
I
q_
L
md/Y4
7--:::
19-43
ABSComponents
CircuitDiagram(cont'd)
UNDER-HOOD
FUSE/RELAY
BOXCONNECTORS
CONNECTOR
CONNECTOR
A {12P)
{12P)
CONNECTOR
B {2P}
BRAKEPEDALPOSITION
SWITCH4PCONNECTOR
UNDER.DASH
FUSE/RELAY
BOXCONNECTORS
CONNECTOR
I {5P)
CONNECTOR
K I17P)
MULTIPLEX
CONTROL
UNIT13PCONNECTOR
5 67
1011121 31 415 1 1
1l2l3l,/15 1 2 3 4
8
GAUGEASSEMBLY
CONNECTORS
CONNECTOR
A I22P)
1 2 3
CONNECTOR
B I22PI
q,
ABSCONTROL
UNIT3IP CONNECTOR
1 2
4 5 6 7 8 I
16 1 1 1 8 1 9
1112 1 415
20 21/1,/1,/vl,/l
/t,/t/t,/t/
OATA LINK CONNECTOR{16P)
WHEELSENSOR2PCONNECTORS
FRONT
J --T:-l
L
q t t / ) l
'lt L_.:-:J
r
\-r-----Tr'
e:l
RIGHT.REAR
LEFT-REAR
tslTt?t
I
tL |
/J 1T-1\
\t rlziJ
T e r m i n asl i d eo f m a l el e r m i n a l s
19-44
,/ ,/
6 7 8 9 10 11n213
DTCTroubleshooting
DTC11,13,15,17:WheelSensor
(Open/Short
to Power)
to BodyGround/Short
5. Checkfor continuitybetweenthe appropriate
wheelsensor(+ ) circuitterminalandbodyground
{ s e et a b l e ) .
1. Disconnectthe ABS control unit 31Pconnector.
DTC
3. Measurethe voltagebetweenthe appropriate
w h e e ls e n s o r( * ) c i r c u i t t e r m i n a lo f t h e A B S
control unit 31Pconnectorand body ground (see
table).
DTC
11(Rioht-front)
13(Left-front)
Appropriate Terminal
11 (Riqht-front)
N o .5 : F R S( + )
13(Left-front)
1 5( R i o h t - r e a r )
17(Left-rear)
N o . 7 : F L S( * )
No.2R
: R S( * )
N o . 9R L S( + l
ABS CONTROLUNIT31PCONNECTOR
ADpropriate Terminal
N o . 5 :F R S( t )
N o , 7 : F L S( * )
15 {Riqht-rear}
17 (Left-rear)
N o .2 : R R S( * )
N o . 9R t S( f )
ABS CONTROLUNIT 31P CONNECTOR
F R S{ + I I G N R / B L K } F L SI + I ( B L U
R R S{ + )
(GNR/YEL)
W i r eside
Wire
s i d eof femaleterminals
ls therecontinuity?
\
YES Goto step6.
NO-Go to step7.
YES Repairshort to power in the (+) circuitwire
betweenthe ABS modulator-controlunit and the
appropriatewheel sensor.I
NO Go to step 4.
Disconnectthe harness2P connectorfrom the
appropriatewheel sensor,then checkfor continuity
b e t w e e nt h e 1 + ) a n d ( ) t e r m i n a l so f t h e h a r n e s s
and body ground.
Y E S - R e p a i rs h o r t t o b o d y g r o u n di n t h e ( + ) o r { )
circuitwire betweenthe ABS modulator-control
unit and the wheel sensor.l
NO Repiacethe wheel sensor.l
(cont'd)
19-45
ABS Components
7. Checkthe resistancebetweenthe appropriate
w h e e ls e n s o r( + ) a n d ( ) c i r c u i t e r m i n a l s{ s e e
ta ble).
DTC
11 {Riqht-front)
'13
{Left-front)
1 5( R i o h t - r e a r )
17 (Left-rear)
*lSide
l+) Side
N o . 5 :F R S( * ) N o . 4 : F R1S- )
N o .7 : F L S{ + i N o . 6F: L S( (-)
No.2:RBS
{+) N o .1 : R B S
N o . 9 :R L S1 - N o . 8B
: L S( -
DTC12,14,
16,18:WheelSensorPutse
Signal
NOTE:lf the ABS indicatorcomes on for the reasons
describedbelow,the indicatorgoes off when you testd r i v et h e v e h i c l ea t 3 1 m p h ( 5 0k m / n l .
. Only the drive wheel rotated
. T h e v e h i c l es p u n
. Electricalnoise
1 . V i s u a l l yc h e c kf o r a p p r o p r i a t w
e h e e ls e n s o r a n d
pulserinstallationand condition(seetable).
DTC
12
14
18
Appropriate Wheel Sensor
Riqht-front
Left-front
Riqht-rear
Left-rear
Ate they installed correctly and not damaged?
YES-Go to step 2,
NO Reinstallor replacethe appropriatewheel
s e n s o ro r p u l s e r , I
Is the rcsistance between 450
2,000 A ?
YES Checkfor a looseABS control unit3lP
connector.lf necessary.substitutea known-good
ABS modulator-controlunit, and recheck.l
3 . Measurethe resistancebetweenthe appropriate
w h e e ls e n s o r( f ) a n d ( ) c i r c u i t e r m i n a l s( s e e
table).
NO Go to step 8.
DTC
appropriatewheel sensor,and checkthe resistance
b e t w e e nt h e ( + ) a n d { ) t e r m i n a l s o ft h e w h e e l
sensor.
12 {Rioht-front)
14 (Left-front)
1 6( R i q h t . r e a r )
18 (Left-read
ls the resistance between 450- 2,000 Q ?
l*) Side
) Side
N o . 5 : F (B*S
No.4:FBS
N o . 7 ; F Ll *S
No,6:FLS
N o . 2R: R(S*
N o1
. :BRS
N o . 9B: L S
1No.8:RLS
Y E S - R e p a i ro p e ni n t h e ( + ) o r ( - ) c i r c u i tw i r e ,o r
short betweenthe (+) circuitwire and the { )
circuitwire betweenthe ABS modulator-control
u n i ta n d t h e w h e e ls e n s o r . l
NO Replace
t h e w h e e ls e n s o r . l
ls therc less than 450 Q ?
YES Go to step 1.
19-46
\\|D
4. Checkfor continuitybetweenthe appropriate
w h e e ls e n s o r( + ) c i r c u i t t e r m l n aal n d o t h e r w h e e l
s e n s o r( + ) c i r c u i t e r m i n a l s( s e et a b l e ) .
DTC Appropiate
Terminal
12
No.5:
F R W( * i
'14
No.7:
FLWIT.)
to
No.2;
RRW(T-)
No.9:
18
R L W( * )
Other Terminal
(Chipped
Operation
DTC21:Continuous
pulser)
1. Clearthe DTC,then disconnectthe HondaPGM
tesler.
No.7
No.2
No.9
2. Test-drivethe vehicleat 19 mph (30 km/h)or more.
No.5
No.2
No.9
Doesthe ABS indicator come on and is DTC 21
indicated?
No.5
No.7
No.9
No.5
N o .7
No.2
YES Go to step 3.
YES Repairshort in the wires betweenthe
appropriatewheel sensorand the other wheel
s e n s o rh a r n e s s e s . l
NO Clearthe DTC,disconnectthe Honda PGM
Tester,and test-drivethe vehicle.lf the ABS
indicatorcomes on and the same DTCis indicated,
replacethe ABS modulator-controlunit.l
NO The system is OK at this time.l
3. Checkthe pulsergear for a chippedtooth.
ls the pulser OK?
YES Checkfor a looseABS control unit 31P
connector.lf necessary,substitutea known-good
ABS modulator-controlunit, and recheck.l
NO Replacethe driveshaftor hub unit (chipped
p u l s e rg e a r ) . 1
appropriatewheel sensorand checkthe resistance
b e t w e e nt h e ( + ) s i d ea n dt h e ( - ) s i d eo f t h e w h e e l
sensor.
ls there lessthan 450 Q ?
YES Replacethe wheel sensor.
NO- Repairshort to wire betweenthe appropriate
w h e e ls e n s o r( + ) a n d ( - ) c i r c u i t s . l
1g-47
ABSComponents
DTC31,32.33,34,35,36,37,38:Solenoid
1. Clearthe DTC,thendisconnect
the HondaPGN4
Tester.
2. Test-drive
thevehicle.
Doesthe ABSindicator comeon and are DTCs 31,
32, 33, 34, 35, 36, 37, 38 indicated?
YES Replace
theABSmodulator-control
unit.t
NO Thesystemis OKat thistime.t
DTC51:Motor Locked
'1.
C h e c kt h e N o . 1 0 ( 4 0 A ) f u s ei n t h e u n d e r - h o o d f u s e /
retayDox.
ls the tuse OK?
YES-Reinstall the fuse, and go to step 2.
NO- Replacethe fuse, and recheck.l
3. Measurethe voltagebetweenthe ABS control unit
3 1 Pc o n n e c t otre r m i n a lN o . 1 7a n d b o d y g r o u n d .
I
YES Go to step 4.
NO Repairopen in the wire betweenthe N o . 1 0
(40A)fuse and the ABS control unit.l
19-48
4. Checkfor continuitybetweenthe ABS control unit
31P connectorterminal No. 16 and body ground.
DTG52:MotorStuckOFF
1 . C h e c tkh eN o .1 0 ( 4 0 Af )u s ei n t h eu n d e r - h o o d
box.
fuse/relay
ls thef useOK?
YES-Reinstall the fuse, and go to step 2.
NO-Replace the fuse, and recheck.l|
3 . Measurethe voltage betweenthe ABS control unit
3 1 Pc o n n e c t otre r m i n a lN o . 1 7 a n d b o d y g r o u n d
UNIT31PCONNECTOR
ABSCONTROL
YES-Go to step 5.
NO Repairopen in the wire betweenthe ABS
control unit and body ground (G202).1
Reconnectthe ABS control unit 31Pconnector.
tester.
7 . Test-drivethe vehicleat 6 mph (10 km/h) or more.
Doesthe ABSindicator come on, and is DTC 51
indicated?
YES-Go to step 4.
YES Replacethe ABS modulator-controlunit.l
NO Repairopen in the wire betweenthe N o . 1 0
(cont'di
19-49
ABS Components
4. Checkfor continuitvbetweenthe ABS control unit
3 1 Pc o n n e c t otre r m i n a lN o . 1 6 a n db o d y g r o u n d .
ABSCONTROL
UNIT31PCONNECTOR
DTC53:MotorStuckON
1 . C l e a rt h e D T C t, h e n d i s c o n n e ct th e H o n d ap GM
Tester.
Does the ABS indicatot come on and is DTC 53
indicated?
YES -Go to step 3.
NO- lntermittentfailure,the system is OK at this
trme.l
3 . Disconnectthe ABS control unit 31Pconnector.
YES-Check for looseterminalsin the ABS control
unit 31Pconnector.lf necessary,substitutea
known-goodABS modulator-controlunit, and
recheck.l
Checkfor continuitybetweenthe ABS control unit
3 1 Pc o n n e c t otre r m i n a lN o , 1 6 a n d b o d y g r o u n d .
ABSCONTROL
UNIT3,IPCONNECTOR
NO Repairopen in the wire betweenthe ABS
c o n t r o lu n i ta n d b o d y g r o u n d( G 2 0 2 ) . 1
YES-Replacethe ABS modulator-controlunit.t
NO-Repair open in the wire betweenthe ABS
c o n t r o lu n i ta n d b o d y g r o u n d( G 2 0 2 ) . I
19-50
DTC54:MainRelayStuckOFF
1 . C h e c k t h eN o . 8 ( 2 0 A )f u s e i n t h e u n d e r - h o o fdu s e /
f u s ei f i t i s O K .
r e l a yb o x ,a n d r e i n s t a l l t h e
ls the f use OK?
DTC61:lG2Voltage
N O T EC
: h e c kt h e N o . 1 1 ( 7 . 5 A f)u s e i n t h e u n d e r - d a s h
fuse/relaybox beforetroubleshooting.
1 . C l e a rt h e D T C ,t h e n d i s c o n n e ct th e H o n d aP G M
tesler.
YES-Go to step 2.
2. Test drive the vehicle.
NO Replacethe fuse, and recheck.l
the voltagebetweenthe ABS control unit
3. l\4easure
c o n n e c t otre r m i n a lN o . 1 8 a n d b o d y g r o u n d .
Doesthe ABS indicator come on and is DTC 61
indicated?
YES Go to step 3.
ABSCONTROL
UNIT31PCONNECIOR
t e A B S c o n t r o lu n i t 3 l P c o n n e c t o r .
5. Measurethe voltage betweenthe ABS control unit
3 1 Pc o n n e c t o r t e r m i n aNl o . 1 5 a n d b o d y g r o u n d .
ABSCONTROL
UNIT31PCONNECTOR
control unit and the under-hoodfuse/relaybox.I
NO - Repairopen in the wire betweenthe ABS
control unit and the under-hood{use/relaybox.l
19-51
ABSComponents
DTC81:CPU(Central
Processing
Unit)
Tester.
Does the ABS indicator come on and is DTC 81
indicated?
ABS IndicatorGircuit
Troubleshooting
ABS indicator does not come on
1 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d w a t c ht h e A B S
indicator.
Does the ABS indicator come on?
YES The system is OK at this time.I
NO Go to step 2,
NO-The system is OK at this time. t
Pull up the parkingbrakelever.
Does the btake system indicator come on?
YES Go to step 3.
NO Repairopen in the indicatorpower source
circuit.lf necassary,substitutea known-goodABS
modulator-controlunit, and recheck.I
. Blown No, 10 (7.5A)fuse.
. O p e ni n t h e w i r e b e t w e e nt h e N o . 1 0 ( 7 . 5 A ) f u s e
a n dl h e g a u g ea s s e m b l y ,
. Open circuitinsidethe fuse box.
Disconnectthe ABS control unit 31Pconnector.
5. T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
Does the ABS indicator come on?
unit 31Pconnector.lf necessary,substitutea
recheck.l
NO Go to step 6.
7 . Removethe gauge assembly(seepage 22-64).
19-52
8 . Disconnectthe gaugeassemblyconnectorA (22P).
9 . Checkfor continuitybetweengauge assembly
connectorA {22P)terminal No, 12 and body ground.
A (22P)
CONNECTOR
GAUGEASSEMBLY
ABS indicator does not go off
fuse/
1. ChecktheNo.8 (20Alfusein the under-hood
relaybox,andreinstallthefuseif it is OK.
ls the fuse OK?
YES Goto step2.
lf thefuseis
NO-Replacethefuse,andrecheck.
blown,checkfor a shonto bodygroundin thisfuse
circuit.ll thecircuitis OK,replacetheABS
modulator-control
unit.I
Checkthe No. 11 (7.5A)fuse in the under-dash
fuse/relaybox, and reinstallthe fuse if it is OK.
ls the f use OK?
YES Go to step 3.
YES- Repairshon to body ground in the wire
betweenthe gaugeassemblyand the ABS control
unit.l
NO Replacethe fuse, and recheck.If the fuse is
blown, checkfor a shortto body ground in this fuse
circuit.lf the circuit is OK, replacethe ABS
modulator-controlunit.I
NO Go to step 10.
'10.Disconnectthe gaugeassemblyconnectorB (22P).
1 1 .Checkfor continuitybetweengauge assembly
3 . Disconnectthe ABS control unit 31Pconnector.
Measurethe voltage betweenterminal No. l8 and
body ground.
connectorB (22P)terminal No. 12 and body ground.
UNIT3lP CONNECTOR
A8S CONTROL
B (22PI
GAUGEASSEMBLY
CONNECTOR
Wiresideol Iemaleterminals
YES-Go to step 5.
YES Checkfor looseterminalsin the gauge
assemblyconnectors.lf the connectorsare OK,
replacethe gaugeassembly.l
NO Repairopen in the wire betweenthe gauge
a s s e m b l ya n d b o d y g r o u n d( G 5 0 1 ) . 1
(cont'd)
19-53
ABSComponents
ABS IndicatorCircuitTroubleshooting(cont'dl
6 . Measurethe voltage betweenthe ABS control unit
10. Connectthe ABS control unit3lPconnector
t e r m i n a lN o . 2 0 a n d b o d y g r o u n dw i t h a j u m p e r
wire.
31PconnectorterminaI No. 15 and body ground.
ABSCONTROLUNIT31PCONNECTOR
ABSCONTROL
UNIT3IP CONNECTOR
Wire side of femaleterminats
Does the ABS indicator go off?
unil 31Pconnector.lf necessary,substitutea
recheck.I
YES-Go to step 7.
NO-Repair open in the wire betweenthe No. 11
(7.5A)fuse and the ABS control unit.I
8 . Checkfor continuitybetweenthe ABS control unit
31Pconnectorterminal No. 19 and body ground.
ABSCONTROL
UNIT31PCONNECTOB
NO Go to step 11.
'l '1.
Removethe gaugeassembly,and leavethe
connectorsconnected.Connectthe gauge
a s s e m b l yc o n n e c t oA
r ( 2 2 P t)e r m i n a lN o . ' 1 2a n d
body ground with a jumper wire.
GAUGEASSEMBLY
CONNECTOR
A (22P)
Does the ABS indicator go off?
YES Go to step 9.
YES-Repair open in the wire betweenthe gauge
a s s e m b l ya n d t h e A B S c o n t r o lu n i t . I
control unit and body ground (G202).t
19-54
NO-Check for loosegauge assemblyconnectors.
lf the connectorsare OK, replacethe printedcircuit
b o a r di n t h e g a u g ea s s e m b l y . l
\
BrakeSystemIndicatorGircuitTroubleshooting
Brakesystem indicator does not come on
'1.
Disconnectthe m ultiplexcontroI unit l3Pconnector
and the ABS control unit 31Pconnector.
Brakesystem indicatordoes not go off
t h e p a r k i n gb r a k e .
2. Release
2. Checkfor continuitybetweenthe ABS control unit
3 l P c o n n e c t otre r m i n a lN o , 2 1 a n d b o d y g r o u n d .
Does the brake system indicatot go ofl after
several seconds?
YES The system is OK at this time.l
NO Go to step 3.
3. Checkthe brakefluid level.
ls the level OK?
YES Go to step 4.
NO Refillthe brakefluid, and recheck.l
4. Checkthe ABS indicator.
Does the ABS indicator stay on?
YES Repairshort to body ground in the wire
betweenthe multiplexcontrol unit and the ABS
c o n t r o lu n i t . l
NO Go to multiplexcontrol system
trou bleshootinglsee page 22''172).a
YES Readthe ABS DTC(seestep 1 on page 19-32).
and do the applicabletroubleshootingfor the DTC
NO Go to step 5.
t e A B S c o n t r o lu n i t 3 l P c o n n e c t o r .
7 . C o n n e ctth e A B S c o n t r o lu n i t3 1 Pc o n n e c t o r
t e r m i n a lN o . 2 1 a n d b o d y g r o u n dw i t h a j u m p e r
W i r es r d eo f l e m a l el e r m i n a l s
(cont'd)
19-55
ABSComponents
BrakeSystemIndicatorGircuitTroubleshooting(cont'd)
8 . Turn the ignititonswitch ON (ll).
9 . Checkthe brakesystem indicator.
Does the brake system indicatot go off?
YES-Replace the ABS modulator-controlunit.l
NO-Go to step 10.
1 1 .Connectthe multiplexcontrol unit 13Pconnector
'l
t e r m i n a lN o . a n d b o d y g r o u n dw i t h a j u m p e rw i r e .
MULTIPLEX
CONTROL
UNIT13PCONNECTOR
JUMPER
WIRE
\
1 3 .Checkthe brakesystem indicator.
Does the btake system indicatot go off?
YES Repairopen in the wire betweenthe
multiplexcontrol unit and the ABS control unit.l
NO Go to multiplexcontrol system
troubleshooting (seepage22-172).a
19-56
ABS Modulator-ControlUnit Removaland lnstallation
NOTE:
. D o n o t s p i l lb r a k ef l u i d o n t h e v e h i c l e i;t m a y d a m a g et h e p a i n Ui f b r a k e f l u i d g e t s o n t h e p a i n t , w a s h i t o f f
. Becarefulnot to damageor deform the brakelines during removal and installation.
. To preventthe brakefluid from flowing, plug and cover the hose ends and joints with a shop towel orequivalent
malenal.
Removal
'1.
2 . P u l lu p t h e l o c k ( A )o f t h e A B S c o n t r o u
l nit3lPconnector(B),thendisconnecttheconnector.
FLARENUT
l5 N.m (1.5kgt.m,11lbt.ftl
6)o
CI
--/Q
\.
I mm NUT
8.8N.m {0.9kgl m.6.5lbfft)
\,
\---'
6 mm BOLT
9.8N.m
11.0ksf.m,7.2lbf.ft)
(cont'd)
19-57
ABS Gomponents
ABS Modulator-ControlUnit Removaland Installation{cont'dl
3. Disconnectthesix brakelines.
4. Removethe two I mm nuts.
5. Removethe ABS modulator-controlunit (C).
Installation
'1.
I n s t a l l t h e A B Sm o d u l a t o r c o n t r oul n i t ,t h e nt i g h t e nt h e t w o 8 m m n u t s .
2. Align the connectingsurfaceofthe ABS control unit 3'lP connector.
3 . P u s h i n t h e l o c k o f t h e A B S c o n t r oul n i t3 1 Pc o n n e c t o ur n t i ly o u h e a ri t c l i c ki n t o p l a c e t. h e nc o n n e c t h e c o n n e c t o r .
4. Connectthe six brakeIines.
5. Bleedthe brakesystem,startingwith the front wheels.
6. Connectthe PGMTester,and do the solenoidfunctiontest for each wheel.
7. Bleedthe brakesystem again,staning with the front wheels.
8. Startthe engine,and checkthat the ABS indicatorand brakesystem indicatorgo off.
9. Disconnectthe Honda PGMTester.Test-drivethe vehicle,and checkthat the ABS indicatorand brakeqvqtem
i n d i c a t odr o n o t c o m e o n .
19-58
WheelSensorInspection
WheelSensorReplacement
1 . Inspectthe front and rear pulsersfor chippedor
damagedteeth.
NOTE:Inslallthe sensorscarefullyto avoid twisting the
wtres.
2. Measurethe air gap betweenthe wheel sensorand
Front:
the pulserall the way around while rotatingthe
pulser.Removethe rear brakedisc to measurethe
gap on the rearwheel sensor.lf the gap exceeds
1 . 0m m ( 0 . 0 4i n . ) ,c h e c kf o r a b e n ts u s p e n s i o a
nrm.
6 mm BOLT
9.8 N.m
{1.0kgf.m,7.2lbf.ftl
Standard:
Front;
0.4- 1.0mm (0.02-0.04 in.)
Rear:
0.2 1.0mm (0.01 0.04 in.l
Front:
0.4 '1.0mm
10.02 0.0'l in.l
I
t
6 mm BOLT
9.8 N.m
{1.0kgf.m,7.2lbf.ftl
WHEELSENSOR
Rear:
6 mmBOLT
9.8 N.m
11.0kgf.m,7.2lbf.ft)
6 mm BOLT
9.8 N.m
(1.0kgf'm,
7.2rbr.ft)
Bear:
0.2 1.0mm
{0.01 0.04in.}
19-59
Body
Doors
C o m p o n e nLto c a t i oInn d e x . . . . . . . . . . .
20-2
D o o rP a n eR
l e m o v a l / l n s t a l l a t i o. .n. . . , . . . . . .20,4
....
DoorOuterHandleReplacement
20-6
DoorLatchReplacement
20-7
DoorGlassand Regulator
Replacement
20-9
D o o rS a s hT r i mR e p l a c e m e n. .t. . . . . . . . . . . . . . 2. .0. .t.0. .
DoorGlassOuterWeatherstrip
Replacement
20- 10
Beplacement
DoorWeatherstrip
20-11
D o o rG l a s sA d j u s t m e n t. . . . . . . . . . . . . . . . . . . . . . .20-11
..........
D o o rP o s i t i oA
n d j u s t m e n .t . . . . . . . . . . . . . . . . . . .20-12
.........
D o o rS t r i k eA
r d i u s t m e n.t. . . . . . . . . . . . . . . . . . . . .2. .0. .1. 3. . . . .
Mirrors
........
C o m p o n e nLto c a t i o Inn d e x . . . . . . . . . . . . . . . . . . .20-14
P o w e rM i r r o rR e p l a c e m e n. .t . . . . . . . . . . . . . . . . .2. 0
. .-. 1. .5. .
M i r r o rH o l d e R
r e p l a c e m e n. .t. . . . . . . . . . . . . . . . .20-15
........
Rearview
M i r r o rR e p 1 a c e m e.n. t. . . . . . . . . . . . . .2. 0. .-.1. .6
Glass
C o m p o n e nLto c a t i o Inn d e x . . . . . . . . . . . . . . . . . . .2. 0
. .1
. .1. . .
W i n d s h i e lR
deplacement
20-19
........
B e a rW i n d o wR e p 1 a c e m e.n. .t . . . . . . . . . . . . . . . .20-25
........
O u a r t eG
r l a s sR e p l a c e m e n. .t . . . . . . . . . . . . . . . . 20-29
Moonroof
C o m p o n e nLto c a t i o Inn d e x . . . . . . . . . . . . . . . . . . .20,35
........
Index
20-36
t d j u s t m e n.t. . . . . . . . . . . . . . . . . . . . 20-37
..........
G l a s sH e i g hA
20-31
G l a s sR e p l a c e m e n t
W i n dD e fl e c t o r8 e p 1 a c e m e n. .t. . . . . . . . . . . . . . .20-38
.......
D r a i nC h a n n eRl e p 1 a c e m e.n. .t. . . . . . . . . . . . . . .20
. . . .39
....
..........
S u n s h a dR
e e p l a c e m e n. .t. . . . . . . . . . . . . . . . . . . . .20-40
Motor Replacement
20-41
Frameand DrainTubeReplacement............
20,42
D r a i nC h a n n eSl l i d e a
r n dC a b l eA s s e m b l y
Replacement
20 44
L i m i tS w i t c hA d j u s t m e n .t . . . . . . . . . . . . . . . . . . . . 20-46
..........
ClosinoForceand ODeninaDraqCheck ......20,44
lnterioiTrim
........
C o m p o n e nLto c a t i oInn d e x . . . . . . . . . . . . . . . . . . .20-49
Trim Removal/lnstallation
DoorArea ..........
20 50
-RearSideArea
20-51
-CargoFloorArea
20-52
Trim Removal/lnstallation-Hatch
Area .........20-53
HeadlinerRemoval/lnstallation
20-54
* C a r p eR
............
t e p 1 a c e m e.n. .t. . . . . . . . . . . . . . . . . . . . . . . .20-55
Consoles
Frontand Rear
Consoles,
20-57
FrontConsoleDisassembly/Reassembly
.....20-58
Dashboard
InstrumentPanelRemoval/lnstallation
........20-59
Driver'sDashboardLowerCover
RemovatInstallation
20-59
Driver'sDashboardUnderCover
Removat Installation
20-60
Oriver'sPocketRemoval/lnstallation
............
20,60
ShiftLeverTrim Removal/lnstallation
..........2 0 6 1
C e n t eP
r a n eR
l e m o v a l / l n s t a l l a t i. o. .n. . . . . . . .20-62
....
Passenger's
DashboardLowerCover
20-63
x GloveBox Removal/lnstallation
20-63
Dashboard
SideVent
R e m o v a l / l n s t a l l a t i. o. .n. . . . . . . . . . . . . . . . . . . . 2
. .0. .-.6. .4. . . .
BeverageHolderRemoval/lnstallation
........20-64
Driver'sTrayRemoval/lnstallation
...............
20-65
Passenger's
Tray Removal/lnstallation
........20 65
* DashboardRemoval/lnstallation
..................
20-66
S t e e r i"n H
q a n q eB
r e a mR e o l a c e m e n. .t. . . . . . .2. 0. - 6 8
Seats
ComponentLocationIndex ...........................
20-10
* FrontSeatRemoval/lnstallation
...................
20-11
* FrontSeatDisassembly/
R e a s s e m b l y - D r i v e. .r .' s. . . . . . . . . . . . . . . . . . . . 2. .0. .-.7. .3. . . .
* FrontSeatDisassembly/
R e a s s e m b l y - P a s s e n g. .e.r. '.s. . . . . . . . . . . . . .2. 0
. .-. 7. .4. .
* F r o n tS e a tC o v e rR e p l a c e m e n. .t . . . . . . . . . . . . .2. .O. .-.7. 5
R e a rS e a tR e m o v a l / 1 n s t a 1 1.a. t. i. o. .n. . . . . . . . .2. .0. -. .8.0
RearSeat-back
LatchReplacement..............
20-81
RearSeat-backStriker
Replacement............
20-81
RearSeat-back
CoverReplacement.............
20-82
R e a rS e a tC u s h i o n
C o v e rR e p l a c e m e n. .t . . . .2. 0 . 8 4
Bumpers
F r o n tB u m p e R
r e m o v a l / l n s t a l l a t .i o
. .n. . . . . . .20,85
...
R e a rB u m o e R
r e m o v a l / l n s t a l l a t.i.o. .n. . . . . . .20-86
....
Hood
Adjustment
20-47
H o o dS e a lR e p l a c e m e n t
20,88
H o o dI n s u l a t oRr e p 1 a c e m e.n. .t. . . . . . . . . . . . . . .20,89
.......
Hatch
Adjustment
. . . . . . . . . . . . . .2. 0
. .-. 9. 0
H a t c hS u p p o nS t r u tR e p l a c e m e n. .t. . . . . . . . . .2. .0.-. 9 1
HatchWeatherstriD
Reo1acement
.................
20-92
FuelFill Door
Adiustment
ExteriorTrim
. . . . . . . . . . . . . .2. 0
. .-. 9. 3
F r o n tG r i l l eR e p l a c e m e n. .t. . . . . . . . . . . .
20-94
CowlCoversReplac"rn""t .. . .....................
20-95
A p i l l a rC o r n eTr r i mR e p l a c e m e n. .t. . . . . . . . . .20-96
....
R o o fl M o l d i nR
g e p l a c e m e n. .t. . . . . . . . . . . . . . . . .20-97
........
RearLicenseTrim Replacement
20,98
H a t c hS p o i l e8r e p 1 a c e m e .n.t. . . . . . . . . . . . . . . . .20-99
........
E m b l e mR e p 1 a c e m e.n. .t. . . . . . . . . . . . . . . . . . . . . .2 0 - 1 0 0
Fenderwell
FrontInnerFenderReplacement
20-102
F r o n tF e n d eFr a i r i n gR e p l a c e m e n. .t . . . . . . . . .2. .0. .- 1 0 3
FuelPipeProtectorReplacement
20-104
R e a rA i r O u t l e R
t e p 1 a c e m e.n. .t. . . . . . . . . . . . . . .20-'to4
.......
Openers
C o m p o n e nLto c a t i oInn d e x . . . . . . . . . . . . . . . . . . .2. .0. -. 1
. .0. .5
H o o dO p e n eC
r a b l eR e p l a c e m e n. .t . . . . . . . . . .2. .0.-. 1 0 6
* FueF
l i l lD o o rO p e n eC
r able
Replacement
20 107
H o o dL a t c hR e p 1 a c e m e .n. t. . . . . . . . . . . . . . . . . . .2. 0
. .-.1. .0. .8.
FueF
l i l lD o o rO p e n eR
r e p l a c e m e n. .t. . . . . . . . .2.0. .- 1 0 9
H a t c hH a n d l eR e p l a c e m e n. .t. . . . . . . . . . . . . . . . .2. .0. -. 1
.1. .0.
H a t c hL a t c hR e p l a c e m e n. .t. . . . . . . . . . . . . . . . . . .2. .0.-. 1. .1. .0.
H a t c hL o c kC y l i n d eRr e p l a c e m e n. .t. . . . . . . . . .20-111
....
Frame
SubframeReplacement.................................
20-112
FrameStiffener,Brace,and Gusset
Replacement
.............
20-113
r Fremp RFnrir Chrrr
. . . . . . . . . . . . . .2. 0
. -114
Doors
a
DOOROUTERTRIM
DOORSASHTRIM
page20-10
Replacement,
DOORGLASSOUTER
WEATHERSTRIP
page20-10
Replacement,
DOOR
Adiustment,
Position
page20-12
K-p
IJ
A'A
dq
W2"'
Ya
\J
aita.
t
DOORWEATHERSTRIP
page20-'l'l
Replacement,
POWERWINDOW
swtTcH
\
POWERDOORLOCKSWITCH
(Driver's)
20-2
GLASS
page20-9
Replacement,
Adjustment,page20-11
IMMOBILIZER
LABEL
@
REGULATOR
page20-9
Replacement,
RETAINERCLIP
LOCK
CYLINDER
\
\
LOCKKNOB O
OUTERHANDLE
PROTECTOR
CYLINDERROO
PROTECTOR
,-\
tt
\
v4,,(,
E ) i l
- /6X@
W (
STRIKER
Adjustment,page20-13
LATCH
page20-7
Replacement,
POWERDOOR
LOCKACTUATOR
20-3
Doors
Door PanelRemoval/lnstallation
Trim pad remover,Snap-onA 177Aor equivalent,
yvailable.
NOTE:When prying with a flat-tipscrewdriver,wrap it
with protectivetape, and apply protectivetape around
the relatedparts.to preventdamage.
3. Removethe armrestcover (A).Takecare not to
scratchthe door panel.
-1 Pry out the front edge of the cover to release
the hooks(B).
-2 Pry out the bottom and rear edge of the cover
to releasethe hooks(C).
-3 Pry out along the top to releasethe tabs (D).
1. Removethe mirror mount cover (seepage 20-15).
2. Inserta hex wrench through the hole (A) in the door
grip base(B),Pushthe door grip cover (C)out to
r e l e a s et h e h o o k( D )a n d t a b ( E ) ,a n d p u l l o u t t h e
cover to releasethe tabs (F)and hook (G) by hand,
then removethe cover.
4 . Removethe screws(A, B), and releasethe tabs (C),
then removethe door grip base(D).Removethe
screw (A) securingthe door panelfrom the armrest
portion.
FastgngrLocations
A> : Screw,3 B > : Screw,5
20-4
5. Pull out the switch panel (A)to releasethe hook (B),
then removethe panelfrom the door panel.
Disconnectthe power window switch connector(C).
7. Disconnectthe inner handlecable {A) from the
i n n e rh a n d l e( B ) ,a n d d i s c o n n e c t t h p
e o w e rd o o r
lock switch connector(C){driver's).Takecare not to
bend the cable.
8. Detachthe harnessclip (A)from the door panel (B).
B
Releasethe clipsthat hold the door panel (A) with a
commerciallyavailabletrim pad remover (B),then
removethe door panel by pulling it upward.
Removethe door panelwith as little bendingas
possibleto avoid creasingor breakingit,
FastenerLocations
> : Clip,9
ffi
EtA
95 mm (3.74in.l
12 mm r q---------i.0.17in.l r <_--'rlmm
{0.04in.l
45 mm {1.77in.l
9 . Installthe door panel in the reverseorder of
. Replaceany damagedclips.
. Make sure the cable is connectedsecurely,and
the connectoris plugged in properly.
. Checkthe window and power door lock
operatrons,
20-5
Doors
Door Outer HandleReplacement
NOTE:Puton glovesto protectyour hands.
4. Disconnectthe cylinder rod (A),and releasethe
retainerclip (B).then removethe lock cylinder(C).
1, Removetheseitems:
. Door panel (seepage 20-4)
. Plasticcover,as necessary(seepage 20-2)
2 . R a i s et h e g l a s sf u l l y .
5.
Removethe lock rod protector(A).
-l Removethe screw.
-2 Releasethe protectorfrom the latch protector
(B).
-3 Pullthe protectordown to releasethe hook (C)
from the door.
FastenerLocation
) : Screw,1
Disconnectthe outer handle rod (A).
FastenorLocations
> : Bolt,2
6x1.0mm
9.8 N.m
{1.0kgf.m,
7.2 tbt.ft')
6 . Removethe maintenancecap (B),and removethe
b o l t ss e c u r i n gt h e o u t e rh a n d l e( C )w h i l e h o l d i n g
the handlefrom outside.Releasethe hook (D).then
removethe outer handleprotector(E).
20-6
Door LatchReplacement
7. Pull out the outer handle(A),then remove it.
NOTE:Put on glovesto protectyour hands.
1. Removethese items:
. Plasticcover,as necessary(seepage 20-2)
Raisethe glassfully.
3 . Removethe lock rod protector(seestep 3 on page
20-6).
4 . Pullthe glass run channel(A) away as necessary,
and removethe bolt, then removethe centerlower
channel(B) by pulling il downward
Installthe handlein the reverseorder of removal,
. Make sure each rod is connectedsecurelv.
. Make sure the door locksand opens properly.
. W h e n i n s t a l l i n tgh e l o c kc y l i n d e rl.e a v e t h e o u t e r
door handlebolts looseso the inner protector
does not interferewith the lock cylinder
installation,then tighten the handle bolts.
. Installthe lockcylinder retainingclip on the
handle,then installthe lockcylinder.Be sure the
c l i p i s f u l l y s e a t e di n t h e s l o to n t h e l o c kc y l i n d e r .
. W h e n r e i n s t a l l i ntgh e d o o r p a n e l ,m a k es u r et h e
plasticcover is installedproperly,and is sealed
aroundthe coversDerimeter.
q
FastenorLocation
> : Bolt,1
IIilE
6x1.0mm
8 N.m
{0.8 kgf.m, 6 lbf.ftl
(cont'd)
20-7
Doors
Door LatchReplacement(cont'dl
5 . Disconnectthe cylinder rod (seestep 4 on page 206).
6 . Disconnectthe outer handle rod (seestep 5 on
page 20-6).
7 . Disconnectthe actuatorconnectors(A),and release
t h e i n n e rh a n d l ec a b l e( B ) f r o mt h e d o o r b y
d e t a c h i n gt h e c a b l ec l i p ( C i .
8 . Removethe screws,then removethe latch{A)
through the hole in the door. Takecare not to bend
the outer handle rod (B),cylinderrod (C),lock rod
( D ) ,a n d i n n e rh a n d l ec a b l e( E ) .
FastenerLocations
) : Screw
U.#
6x1.0mm
5Nm
{0.5kgf.m,
4 tbf.ft)
20-8
9. Installthe latch in the reverseorder of removal,and
notethese rtems:
. [Vlakesure the actuatorconneclorsare pluggedin
properly,and that each rod and cable are
connectedsecurely.
plasticcover is installedproperly,and is sealed
aroundthe coversperimeter.
. M a k es u r et h e d o o r l o c k sa n d o p e n sp r o p e r l y .
Door Glassand RegulatorReplacement
. Plasticcover.as necessary(seepage 20-2)
2 . C a r e f u l l yr a i s et h e g l a s s( A )u n t i ly o u c a n s e e t h e
bolts,then removethem. Carefullypull the glass
out through the window slot.Takecare not to drop
the glass insidethe door.
FastenerLocations
):Boh,2
3. Disconnectand detachthe connector(A) and
h a r n e s sc l i p ( B )f r o m t h e d o o r .
FastonorLocations
C>: Bolt.1 D>: Bolt,5
6x1.0mm
8 N.m
(0.8kgf.m,
6 rbf.ftl
@
Removethe bolts(C),andloosenthe bolts(D),then
removethe regulator(E)throughthe holein the
door,
greaseto allthe sliding
Applymultipurpose
surfaces
of the regulator(A)whereshown.
6x1.0mm
9.8 N m {1.0kgl.m, 7.2 lbf.ftl
Installtheglassand regulatorin the reverseorder
of removal,and note these items:
. R o l l t h eg l a s su p a n d d o w n t o s e ei f i t m o v e s
freely without binding.
. Make sure that there is no clearancebetweenthe
g l a s sa n d g l a s sr u n c h a n n e w
l h e n t h e g l a s si s
ctoseo.
. Adjust the positionof the glassas necessary(see
p a g e2 0 - 11 ) .
. Checkfor water leaks(seestep 7 on page20-121.
. Test-driveand checkfor wind noiseand rattles.
plasticcover is installedproperlyand sealed
around its perimeter.
20-9
Doors
Door SashTrim Replacement
Door GlassOuterWeatherstrip
Replacement
NOTE:Takecare not to scratchthe door.
1. Removethe door glassouter weatherstrip.
2. Pull backthe door weatherstrip(A) at the rear
upper corner,and removethe screw.
Fasten6r Location
) : Screw, I
NOTE:
. Put on glovesto protectyour hands.
. Takecare not to scratchthe door
1 . R e m o v et h e p o w e rm i r r o r( s e ep a g e2 0 - 1 5 ) .
2. Startingat the front, pry the door glassouter
weatherstrip(A) up to detachthe clips (B),and
releasethe weatherstripfrom the door sashtrim
(C),then removethe weatherstrip.
Fastener Locations
B>:Clip,s
3 . Lift up the door sashtrim {B)to releasethe hooks
(C),then removethe trim.
lnstallthe trim in the reverseorder of removal.
3 . Installthe weatherstripin the reverseorder ot
removal,and replaceany damagedclips.
20-10
I
Door WeatherstripReplacement
Door GlassAdjustment
NOTE:
. Takecare not to scratchthe door.
. Use a clip removerto removethe clips.
NOTE:
. Checkthe weatherstripsand glassrun channelfor
damageor deterioration,and replacethem if
necessary.
. Wipe the run channelcleanwith a shop towel.
. Lubricatethe run channelwith Shin-Etsugrease
P/N 08798-9013.
1. At the A-pillar,removethe door stop mounting bolt
(A).
FastenerLocations
A > : B o t t ,1
B>:Clip,1
C > : C l i p ,1 8
1. Placethe vehicleon a firm, level surface.
. Plasticcover {see page20'2)
3. Carefullymove the glass (A) until you can seethe
glass mounting bolts (B),then loosenthem.
'
14.----'
'r,
.,'o-,,tL' .
.rrt
B
6x1.0mm
9.8N.m(1.0kgf.m,7.2lbf.ft)
Pushthe glassagainstthe channel(C),then tighten
the glass mounting bolts.
Detachthe clips (8, C),then removethe door
weatherstrip(D).
Checkthat the glassmoves smoothly.
Installthe weatherstripin the reverseorder of
removaland note these items:
. Make sure the weatherstripis installedln the
h o l d e r( E )s e c u r e l y .
. A p p l y l i q u i dt h r e a dl o c kt o d o o r s t o p m o u n t i n g
bolt beforeinstallation.
. Checkfor water leaks(seestep 7 on page20-'121.
. Test-driveand checkfor wind noase.
(cont'd)
20-11
Doors
DoorGlassAdiustment{cont'd)
6. Raisethe glassfully, and checkfor gaps.Checkthat
the glass(A) contactsthe glass run channel(B)
evenrv.
Door PositionAdiustment
\
NOTE;Checkfor equal gaps betweenthe front, rear,
and bottom door edgesand the body. Checkthat the
door and body edges are parallel.
1. Placethe vehicleon a firm, levelsurfacewhen
adjustingthe door.
2. Adjust at the hinges{A):
. Removethe front innerfender (seepage 20-102)
and front fenderfairing (seepage 20-103).
Loosenthe hinge mounting bolts (B) slightly,and
move the door backwardor forward, uD or down
as necessaryto equalizethe gaps.
. Placea shop towel (C)on the jack (D)to prevent
damageto the door when adjustingthe door.
7 . Checkfor water leaks.Run water over the roof and
on the sealingarea as shown, and note these items:
.
.
.
.
U s ea 1 2 m m ( 1 / 2i n . )d i a m e t e rh o s e( A ) .
Adjust the rate of water flow as shown {B).
Do not use a nozzle.
H o l dt h e h o s ea b o u t3 0 0 m m ( 1 2i n . )a w a y f r o m
the door (C).
\
t,
12mm1112in,l
!
\e
300mm {12in.l
Attachthe plasticcover,and installthe door panel
(seepage 20-4).
9. Test-driveand checkfor wind noise.
20-12
8x1.25mm
29 N.m (3.0kgf.m,
22 tbt.trl
Door StrikerAdjustment
3. Checkthat the door and body edges are parallel.lf
necessary,adjustthe door cushions(A)to make the
rear of the door flush with the bodv.
M a k es u r et h e d o o r l a t c h e s e c u r e l yw i t h o u ts l a m m i n g
it. lf necessary,adjustthe striker(A):The strikernuts
a r ef i x e d ,b u t t h e s t r i k e rc a n b e a d j u s t e ds l i g h t l yu p o r
d o w n ,a n d i n o r o u t .
1. Loosenthe screws(B),rhen inserta shop towel (C)
betweenthe body and striker.
Apply body paintto the hinge mounting bolts and
a r o u n dt h e h i n g e s .
5 . Checkfor water leaks(seestep 7 on page 20-12).
Test-driveand checkfor wind noise.
8 x 1 . 2 5m m
18 N.m 11.8kgf m, 13 lbf.ft)
Lightlytlghten the screws.
Wrap the strikerwith a shop towel, then adjustthe
s t r i k e rb y t a p p i n gi t w i t h a p l a s t i ch a m m e r( D ) .D o
not tap the strikertoo hard.
Loosenthe screws,and removethe shop towel.
5 . Lightlytighten the screws.
6 . Hold the outer handleout, and push the door
againstthe body to be sure the strikerallows a
flush fit, lf the door latchesproperly,tighten the
screwsand recheck.
20-13
Mirrors
POWERMIRRORACTUATOR
page22-1'18
Replacement,
.a\
b\.\
|
\ \-r<,,/
\.J
\.4
1
\\
\
TWEETER
\
TWEETER
MIRRORMOUNTCOVER
POWERMIRROR
page20-15
Replacement,
MIRRORHOLDER
Replacement,page20 '15
__.Q
-'-'
MOUNT
/
/
REARVIEW
MIRROR
page20 16
Replacement,
20-14
PowerMirror Replacement
1 . Lower the door glassfully.
2. Carefullypry out the mirror mount cover (A) by
Mirror HolderReplacement
1 . C a r e f u l l yp u l l o u t t h eb o t t o me d g eo f t h e m i r r o r
holder (A) by hand.Takecare not to scratchthe
mrrror.
hand in the sequenceshown. Disconnectthe
tweeterconnector(B),and releasethe wire harness
(C)from the hook (D).
FastenerLocation
) : Clip,1
3 . R e m o v et h e d o o r p a n e l( s e e p a g e 2 0 - 4 ) .
4. Disconnecttheconnector(A),and detachthe
h a r n e s sc l i p ( B ) .W h i l eh o l d i n gt h e m i r r o r{ C ) ,
removethe nuts,then removethe mirror. Takecare
not to scratchthe door.
FastenerLocrtions
O: Nut.3
Separatethe mirror holderfrom the actuator(B) by
slowly pullingthem apart while detachingthe clips
(C).lf equipped,disconnectthe mirror defogger
from the heaterpad terminals.
connectors{D)
lf equipped,reconnectthe mirror defogger
connectors.
Reattachthe clips of the mirror holderto the
actuator,then positionthe mirror holderon the
actuator.Carefullypush on the clip portionsof the
m i r r o rh o l d e ru n t i l t h em i r r o rh o l d e rl o c k si n t o
prace.
5 . Checkthe operationof the actuator
5 . lnstallthe mirror in the reverseorder of removal,
. Make sure the connectoris plugged in properly.
. Attachthe harnessclip.
20-15
Mirrors
RearviewMirror Replacement
1. Turnthe mirrorbase(A)90.in eitherdirection.
2. Slide the rearviewmirror (A) down toward the
bottom of the windshield,then detachit from the
spring (B) in the mount (C),and removethe
rearviewmirror. Takecare notto scratchthe mirror
Dase.
3. lf necessary,removethe spring from the mount.
20-16
4, Fit the mirror base over the mount, and securethe
mirror by turning the base90".
Glass
PASSENGER'SAIRSAG
CAUTION LABEL
FASTENER,2
glassside)
{Self-adhesive-type,
SIDERUBBERDAM
WINDSHIELDSIDETRIM
4
',
m-_-==}lny'
S{|---..------'RErA'NER,6
f..N\
;\tJ
e
N8*?'
CLIP,4
Blue
WINDSHIELD
page20-19
Beplacement,
CLIP
DAM
LOWERRUBBER
DAM,4
UPPER
RUBBER
SPOILER
FASTENER,2
(Selt-adhesive-type)
'9>
LOWERRUBBERDAM
(cont'd)
20-17
Glass
OUARTER
GLASS
FRONTSEAL
- UPPER
CLIP
tsetl adhesive-typel
..,////
\n iT-
\
l/ / Pll
-
/nJ l"
vI
/
LowERcLrp
.--"..---.-_
b
(Self-adhesive-type)
-.,-''
LEVEMBLEM
('03model)
page20-100
Replacement.
20-18
\
OUARTER
GLASS
page20-29
Beplacement,
I
R €AR CLIP
(Self-adhesive-type)
WindshieldReplacement
NOTE:
. Puton glovesto protectyour hands,
. Weareyeprotection
whilecuttingthe glassadhesive
with pianowire.
. Useseatcoversto avoiddamaging
the seats.
Removethe cowl covers(seepage 20-95).
4. Removethe molding (A) from the upper edge of the
windshield(B).lf necessary,cut the molding with a
utility knife.
1. Removetheseitems:
. Rearview
mirror(seepage20-16)
. Windshield
wiperarms(seepage22-145)
2. Pullup the sidetrim (A)to release
the clips(B)from
(C),andpullthetrim rearwardto
the retainers
releaseit fromthecliD(D)thenremovethetrim
from eachsideof thewindshield.
lf the old windshieldis to be reinstalled,make
alignmentmarks acrossthe glassand body with a
greasepencil.
Pull down the front portionof the headliner(see
page 20-54).Takecare not to bend the headliner
excessively,or you may creaseor breakit.
7 . Apply protectivetape along the edge of the
dashboardand body. Using an awl, make a hole
through the rubber dam, adhesive.and dashboard
sealfrom insidethe vehicleat the corner ponion ot
the windshield.Pusha pieceof piano wire through
the hole, and wrap each end around a pieceof
wood.
(cont'd)
20-19
Glass
WindshieldReplacement(cont'd)
W i t h a h e l p e ro n t h e o u t s i d e p, u l l t h e p i a n ow i r e { A )
backand forth in a sawing motion. Hold the piano
wire as closeto the windshield(B)as possibleto
preventdamageto the body and dashboard.
Carefullycut through the rubber dam and adhesive
( C )a r o u n dt h e e n t i r ew i n d s h i e l d .
\,
,.-
-A
10. With a knife,scrapethe old adhesivesmooth to a
thicknessof about 2 mm (0.08in.) on the bonding
surfacearoundthe entirewindshieldopening
flange:
. Do not scrapedown to the paintedsurfaceofthe
body; damagedpaint will interferewith proper
bonding.
. Removethe rubber dam and fastenersfrom the
oooy.
11. Cleanthe body bonding surfacewith a sponge
dampenedin alcohol.After cleaning,keepoil,
greaseand water from getting on the cleansurface.
,,t""""""""',-\
i-..
-1:-,
-
-= -.--
12. lf the old windshieldis to be reinstalled,use a puttv
knifeto scrapeoff all of the old adhesive,the
fastenersand the rubber dam from the windshield.
Cleanthe insideface and the edge of the
windshieldwith alcoholwhere new adhesiveis to
be applied.Make sure the bondingsurfaceis kept
free of water, oil, and grease.
\
20-20
t5.
Glue the side rubber dams (A) and lower rubber
dam (B)with adhesivetape (NITTO501M,or
equivalent).Glue the fasteners(C)with adhesive
tape (3M 4215,or equivalent)to the insideface of
t h e w i n d s h i e l d{ D )a s s h o w n :
1 4 . G l u et h e m o l d i n g( A ) w i t ha d h e s i v et a p e{ B )
( 3 M 4 2 1 2 ,o r e q u i v a l e n t ) t toh e u p p e re d g eo f t h e
w i n d s h i e l d( C ) ;
. B e s u r et h e a l i g n m e n m
t a r k( D )o f t h e m o l d i n g
l i n e su p w i t h t h e a l i g n m e n m
t a r k( E )o f t h e
windshield.
. Be carefulnot to touch the windshieldwhere
a d h e s i v ew i l l b e a p p l i e d .
. Be sure the rubber dams and fastenersline uD
withthealignmenm
t a r k s( E ) .
. Be carefulnot to touch the windshieldwhere
a d h e s i v ew i l l b e a o o l i e d .
t3.
Installthe fasteners(A),retalners(B, C),and clips
(D)to lhe body.
FastenerLocations
A>:Fastener.2 B>:Retainer,2
q\
C > : R e t a i n e r , 6O> : C l i p , 2
(cont'd)
20-21
Glass
WindshieldReplacement(cont'dl
t o . Set the windshieldin the opening,and centerit.
Make alignmentmarks (A) acrossthe windshield
and body with a greasepencilat the four points
shown. Be careful not to touch the windshield
w h e r ea d h e s i v ew i l l b e a p p l i e d .
18. With a sponge,apply a light coat of glassprimer
aroundthe edge of the windshield(A) betweenthe
d a m s ( B )a n d m o l d i n g{ C )a s s h o w n ,t h e n l i g h t l y
wipe it off with gauzeor cheesecloth:
. A p p l yg l a s sp r i m e rt o t h e m o l d i n g .
. Do not apply body primer to the windshield,and
do not get body and glassprimer spongesmixed
up.
. Nevertouch the primed surfaceswith your hands.
lf you do, the adhesivemay not bond to the
w i n d s h i e l dp r o p e r l yc. a u s i n ga l e a ka f t e r t h e
w i n d s h i e l di s i n s t a l l e d .
. Keepwater. dust, and abrasivematerialsaway
from the primed surface.
'l',,1rr Applyglassprimerhere.
) - '
G1)'r'
1 7 . R e m o v et h e w i n d s h i e l d .
l l
ol
,,/ ll\
tl
B
lnside
20-22
-A
19. With a sponge,apply a light coat of body primer to
the originaladhesiveremainingaroundthe
windshieldopeningflange, Letthe body primer dry
for at least 10 minutes:
. Do not apply glassprimer to the body, and be
carefulnot to mix up glassand body primer
sponges.
. l\4askoff the dashboardbefore paintingthe
flange.
21. Packadhesiveinto the cartridgewithout air pockets
to ensurecontinuousdelivery.Putthe cartridgein a
caulkinggun, and run a bead of adhesive(A)
aroundthe edge of the windshield(B) betweenthe
d a m s ( C )a n d m o l d i n g( D )a s s h o w n .A p p l yt h e
adhesivewithin 30 minutesafter applyingthe glass
primer. Make a slightlythickerbead at each corner.
l'1fifr.,1:
?mm
n
,..-
in.l
10.28
A..
20 mm
(0.79in.l
)t
$?I.",x1"u.80.".,
trl
.,r []\"
Inside
- '
20. Beforefilling a cartridge,cut a
"V"
in the end of the
n o z z l e( A )a s s h o w n .
c.. N
\F1
2 m m I 'Zn l
in.}I
{0.08
l
A
12 mm (0.47in.)
./"
U s es u c t i o nc u p st o h o l dt h e w i n d s h i e l do v e rt h e
t a r k sm a d ei n
o p e n i n ga
, l i g ni t w i t h t h e a l i g n m e n m
step 16,and set it down on the adhesive.Lightly
p u s ho n t h e w i n d s h i e l du n t i li t s e d g e sa r ef u l l y
s e a t e do n t h e a d h e s i v ea l l t h e w a y a r o u n d .D o n o t
open or closethe doors until the adhesiveis dry.
7 mm {0.27in.)
(cont'd)
20-23
Glass
WindshieldReplacement(cont'd)
23. Scrapeor wipe the excessadhesiveoff with a putty
knife or towel. To remove adhesivefrom a painted
surfaceor the windshield,wipe with a soft shop
towel dampensdwith alcohol.
24. Let the adhesivedry for at least t hour, then spray
27. On both sidesofthe windshield,installthe side
trim (Alto the clip (B),then set the bottom edge of
the side trim over the cowl cover (C),and align the
c l i p s( D ) w i t ht h e r e t a i n e r (sE ) ,a n d p u s ho n t h e c l i p
portionsof the trim until the trim is fully seatedon
thewindshield.
water over the windshieldand checkfor leaks.
Mark Ieakingareas,and let the windshielddry, then
seal with sealant:
. Let the vehiclestand for at least4 hours after
windshieldinstallation.lf the vehiclehas to be
usedwithin the first 4 hours,it must be driven
slowly.
. Keepthe windshielddry for the first hour after
installation.
Reinstallthecowl covers(seepage 20-95).
NOTE:Thecowl cover clips may not set properlyif
the windshieldadhesiveis too wet.
Installthe clips (A, B) on both side trim {C).lf the
clip (D) is damaged,replacethe side trim and clips
as an assembly.
A: Grey
B :B l u e
28. R e i n s t a al l l l r e m a i n i n gr e m o v e dp a r t s .I n s t a l l t h e
rearviewmirror afterthe adhesivehas dried
thoroughly.
NOTE:Advise the customernot to do the following
things for 2 to 3 days:
. S l a mt h e d o o r sw i t h a l l t h e w i n d o w sr o l l e du p .
. Twist the body excessively(suchas when going
i n a n d o u t o f d r i v e w a y sa t a n a n g l eo r d r i v i n g
over rough, unevenroads).
20-24
RearWindow Replacement
NOTE:
. Wear eye protectionwhile cuttingthe glassadhesive
w i t h p i a n ow i r e .
. Use seatcoversto avoid damagingany surfaces.
. Do not damagethe rearwindow defoggergrid lines
a n dt e r m i n a l s .
6. With a helperon the outside,pull the piano wire (A)
backand Jorthin a sawing motion. Holdthe piano
wire as closeto the rearwindow (B)as possibleto
preventdamageto the hatch,and carefullycut
t h r o u g ht h e a d h e s i v e{ C }a r o u n dt h e e n t i r er e a r
1 . Removethese items:
. Hatchlower trim panel (seepage 20-53)
. Hatchspoiler(seepage 20-99)
Removethese items:
. High mount brakelight {seepage 22-821
. Rearwindow wiper motor {see page22-1461
Disconnectthe rearwindow defoggerconnectors
(A).
Cutting positions:
4 . lf the old rear window is to be reinstalled,make
alignmentmarksacrossthe glassand body with a
g r e a s ep e n c r l ,
7 . C a r e f u l l yr e m o v et h e r e a rw i n d o w .
Apply protectivetape along the insideand outside
e d g e so f t h e h a t c h .U s i n ga n a w l , m a k ea h o l e
t h r o u g ht h e a d h e s i v ef r o m i n s i d et h e v e h i c l ea t t h e
corner portionof the rearwindow. Pushthe piano
w i r e t h r o u g ht h e h o l e ,a n d w r a p e a c he n d a r o u n da
pieceof wood,
(cont'd)
20-25
Glass
RearWindow Replacement(cont'd)
With a putty kniie. scrapethe old adhesivesmooth
to a thicknessof about 2 mm (0.08in.) on the
bonding surfacearoundthe entire rear window
openingflange:
. Do not scraDedown to the Daintedsurfaceof the
bonding
. Removethe fastenersfrom the tailqate.
Cleanthe hatch bonding surfacewith a sponge
dampenedin alcohol.After cleaning,keepoil,
greaseand water from getting on the surface,
1 0 .lf the old rearwindow is to be reinstalled,use a
putty knifeto scrapeoff all of the old adhesive,the
fastenersand the rubberdams from the rear
window. Cleanthe insideface and the edge oi the
rear window with alcoholwhere new adhesiveis to
be applied.Make sure the bonding surfaceis kept
free of water, oil and grease.
1 1 . G l u et h e s i d eu p p e rf a s t e n e r s( A )a n d s i d e l o w e r
fasteners{B)with adhesivetape {3M 5312,or
e q u i v a l e n tG
) . l u et h e u p p e rr u b b e rd a m s ( C ) w i t h
adhesivetape (NITTO501fM,or equivalent)and
glue the lower rubberdam (D)with adhesivetape
(3M 4216,or equivalent)to the insideface of the
rearwindow (E)as shown. Beforeinstallingthe
lower rubber dam, apply primer (3M N-200,or
equivalent)to the areasbetweenthe alignment
marks {F),then glue the rubber dam on. lf
necessary,glue the spoilerfasteners(G)with
adhesivetape (3M 5671,or equivalent)to the
outsideface of the rearwindow:
. Be sure the side upper fasteners,and upper
r u b b e rd a m s l i n e u p w i t h a l i g n m e n m
t a r k s{ H ,l ) .
. Be sure both ends of the lower rubber dam line
up with the edge of the glass,
. Be sure the spoilerfastenersline up with
a l i g n m e nm
t a r k s{ J ) .
. Be carefulnot to touch the rearwindow where
a d h e s i v ew i l l b e a D o l i e d .
1,1,.,1,'
: Applyprimerhere.
G
E
"6'J1r-,
20-26
12. Glue the side upperfasteners(A) andsidelower
fasteners(B)with adhesivetape (3M 5312,or
equivalent)tothe hatch as shown.
FastonerLocations
A>: Fastener,
2
T-8.
2
B >: Fastener,
cl
ar\\
itf,
1 5 . W i t h a s p o n g ea
, p p l ya l i g h tc o a to f g l a s sp r i m e r
along the edge of the rear window (A),upper
rubber dams (B),and lower rubberdam (C)as
shown, then lightly wipe it off with gauzeor
cheesecloth:
. With the printeddots (D) on the rearwindow as a
guide, apply the glassprimer to both side
portionsof the rearwindow.
. Do not apply body primer to the rearwindow,
and do not get hatchand glass primer sponges
m i x e du p .
lf you do, the adhesivemay not bond to the rear
window properly.causinga leak afterthe rear
w i n d o wi s i n s t a l l e d .
. Keepwater, dust, and abrasivematerialsaway
..
t5.
: Applyglasspiimer here.
Set the rearwindow in the opening,and centerit.
Align the clips (A) of the rearwindow with the holes
i n t h e o p e n i n gf l a n g e .M a k ea l i g n m e n m
t a r k s( B )
acrossthe rearwindow, hatch,and body with a
greasepencilat the four pointsshown. Be careful
not to touch the rearwindow where adhesivewill
beapplied.
1 4 . R e m o v et h e r e a rw i n d o w .
(cont'd)
20-27
Glass
I
RearWindow Replacement(cont'd)
1 6 .With a sponge,apply a light coat of body primer to
t h e o r i g i n aa
l d h e s i v er e m a i n i n ga r o u n dt h e r e a r
window openingflange. Letthe body primer dry for
at least 10 minutes;
. Do not apply glassprimer to the body, and be
sponges.
',,,,,': Applybodyprimerhe.e.
aroundthe edge of the rearwindow (B)as shown.
With the glassprimer (C)you appliedin step 15 as
a guide,apply the adhesiveto both side portionsof
the rearwindow.
Apply the adhesivewithin 30 minutesafter
applyingthe glassprimer. fMakea slightlythicker
bead at each corner.
12 mm r,
10.47in.) ,\
A
ii'(0.28
in.l
20 mm
in.l
10.79
2mm
{0.08in.)
1 7 . Beforefilling a cartridge,cut a
nozzle{A} as shown.
"V" in the end ofthe
7 mm (0.27in.)
20-28
\
aru'.1{-----"
OuarterGlassReplacement
19. Use suctioncups to hold the rearwindow over the
opening.align it with the alignmentmarks you
'13,
made in step
and set it down on the adhesive.
Lightlypush on the rearwindow until its edgesare
fully seatedon the adhesiveall the way around.Do
not open or closethe doors until the adhesiveis dry.
knife or towel. To removeadhesivefrom a painted
surfaceor the rearwindow, use a soft shop towel
dampenedwith alcohol.
21. Letthe adhesivedry for at least 'l hour,thenspray
water over the rear window and checkfor leaks.
Mark the leakingareas,let the rear window dry,
then sealwith sealant.Let the vehiclestandfor at
least4 hours after rearwindow installation,lf the
vehiclehas to be used within the first 4 hours,it
must be driven slowly.
NOTE:
. Wear eye protectionwhile cuftingthe glassadhesive
with piano wire,
. Use seatcoversto avoid damagingany surfaces.
1 . R e m o v et h e C - p i l l atrr i m ( s e ep a g e2 0 - 5 1 ) .
lf necessary,removethe rear side trim panel (see
page 20-51) and B-pillarupper trim (seepage 2050).
2. Removethe front seal {A) from the front edge of the
glass (B).lf necessary,cut the seal with a utility
knife.
2 2 . R e i n s t a l l a lrle m a i n i n gr e m o v e dp a r t s .
NOTE:Advise the customernot to do the following
. S l a mt h e d o o r sw i t h a l l t h e w i n d o w sr o l l e du p .
i n a n d o u t o f d r i v e w a y sa t a n a n g l eo r d r i v i n g
(cont'd)
20-29
Glass
OuarterGlassReplacement(cont'dl
3 . Apply protectivetape to along the insideand
outsideedgesof the body. Using an awl, make a
hole through the adhesivefrom insidethe vehicle.
Pusha pieceof piano wire through the hole, and
wrap each end around a pieceof wood.
With a helperon the outside,pull the piano wire (A)
backand forth in a sawing motion. Holdthe piano
wire as closeto the quarterglass(B) as possibleto
preventdamageto the body, and carefullycut
through the adhesive(C)aroundthe entirequarter
grass.
6 . With a putty knife,scrapethe old adhesivesmooth
to a thicknessof about 2 mm (0.08in.) on the
bonding surfacearoundthe entirequaner glass
o p e n i n gf l a n g e :
. Do not scrapedown to the paintedsurfaceof the
bonding
. Removethe clips from the body.
7 . Cleanthe body bondingsurfacewith a sponge
d a m p e n e di n a l c o h o lA
. f t e rc l e a n i n gk. e e po i l ,
greaseand water from getting on the surface.
lf the old quarter glassis to be reinstalled,use a
putty knifeto scrapeoff all of the old adhesiveand
the rubberdam from the glass.Cleanthe inside
face and the edge of the glasswith alcoholwhere
new adhesiveis to be applied.Make sure the
bonding surfaceis keptfree of water, oil, and
grease.
Cuttingpositions:
5. Carefullyremovethe quarterglass.
20-30
9. Set the quarterglass(A) in the opening,and center
i t . F r o mi n s i d et h e v e h i c l e m
, a k ea n a l i g n m e n m
t ark
(B)to the quarterglasswhere the rear clip will be
installedwith a greasepencil.Be careful not to
l o u c ht h e g l a s sw h e r ea d h e s i v ew i l l b e a p p l i e d .
11 . A l i g nt h e u p p e rc l i p { A )a n d l o w e rc l i p ( B )w i t h t h e
edge of the quarter glass(C),then anachthem with
adhesivetape (NITTO571,or equivalent)to the
insideface of the quarter glass,and align the center
of the rearclip (D)with the alignmentmark (E)you
made in step 9, and attach it with adhesivetape (3
M 4215,or equivalent)to the insideface of the
quarterglassas shown. Be carefulnot to touch the
glasswhere the adhesivetape will be applied.
25.5mm
{ 1 . 0i n . )
10. Removethe quarterglass.
(cont'd)
20-31
Glass
OuarterGlassReplacement(cont'dl
Firstglue the front seal (A)with adhesivetape {31\4
4 2 1 3 ,o r e q u i v a l e n t a
) .n d g l u et h e r u b b e rd a m ( B )
with adhesivetape (NITTO501M,or equivalent)to
the insldeface of the quarterglass(C)as shown.
Beforeinstallingthe front seal and rubber dam,
a p p l yp r i m e r( 3 M N - 2 0 0 o, r e q u i v a l e n t ) t toh e i n s i d e
tace of the glass.then glue the seal on:
. Be sure the front seal lines upwiththe bottom
and front edgesof the glass.
. Be careful not to touch the glasswhere adhesive
will beaoolied.
.,1.,,/:/| Apply prlJnerhete.
30 mm
1 1 . 1i8n . l
-"-c
'13.
With a sponge,apply a light coat of glassprimer
along the edge of the rubber dam (A) and front seal
(B)as shown, then lightly wipe it off with gauzeor
cheesecloth:
With the printeddots (C)on the quarterglass(D)
as a guide, apply the glass primer to the upper
and lower corner ponions of the quarterglass.
Do not apply body primer to the quaner glass,
and do not get body and glassprimer sponges
m r x e du p .
Nevertouch the primed surfaceswith your hands.
lf you do, the adhesivemay not bond to the
quarterglassproperly,causinga leak afterthe
quarterglassis inslalled.
Keepwater, dust, and abrasivematerialsaway
50 mm
I
{1.97in.1
/
\ t
nL
v - -
i--l
'100mm
{3.9i1in.)
45 mm
{ 1 . 7 7i n . }
6 mm (0.24in.) 3.5 mm
{0.r4 in.l
1 1m m
lo.i(} in.)
20-32
14, With a sponge.apply a light coat of body primer to
t h e o r i g i n aa
l d h e s i v er e m a i n i n ga r o u n dt h e q u a r t e r
glassopeningflange.Let the body primer dry for at
least 10 minutes:
. Do not apply glass primer to the body, and be
sponges.
)'/ii,/ii. I Apply bodv prime. here,
20 mm
(0.79in.)
mm
(0.08in.l
around the edge of the rubber dam (B) as shown.
W i t h t h e g l a s sp r i m e r( C ) y o ua p p l i e di n s t e p 1 3 o n
the quarterglass (D)as a guide. apply the adhesive
to the upper and lower corner portionsof the
quarterglass.Apply the adhesivewithin 30
minutesafter applyingthe glass primer. lvlakea
slightlythickerbead at each corner.
l.:J611,
;\
2mm
{0.08in.)
7mm
{0.28in.)
3mm
{ 0 . ' 1 2i n . }
I
I
A
20 mm
{0.79in.)
t5.
Beforefilling a cartridge,cut a "V" in the end ofthe
nozzle(A) as shown.
'10mm (0.39in.)
7 mm 10.27in.)
( c o n l ' d)
20-33
Glass
OuarterGlassReplacement(cont'd)
17. Use suctioncups (A)to hold the quarterglassover
the opening.align it with the clips (B)and set it
down on the adhesive.Lightly push on the quarter
glass until its edges are fully seatedon the
adhesiveall the way around.Do not open or close
the doors untilthe adhesiveis drv.
knife or towel. To remove adhesivefrom a painted
surfaceor the quarterglass,use a soft shop towel
dampenedwith alcohol.
19. Let the adhesivedry for at least t hour,thenspray
water over the quarterglassand checkfor leaks,
Mark the leakingareas,let the quarterglassdry,
then sealwith sealant.Let the vehiclestand for at
least4 hours after quarterglassinstallation.lf the
vehiclehasto be usedwithin the first 4 hours.it
must be driven slowlv.
20. Reinstallall remainingremoved parts.
NOTE:Advisethe customernot to do the following
. Slam the doors with all the windows rolled up.
in and out of drivewaysat an angle or driving
20-34
Moonroof
GLASS
HeightAdjustment,page 20 37
paqe 20-37
Replacement,
C l o s i n oF o r c ea n d O o e n i n" oD r a o
Check;page20-48
DRAINCHANNEL
page20-39
Replacement,
COVER
/,BR^CKEI
,5
_-""-\\q @?a<&,
..t'- ?
.@
-@c
I
LIMITSWITCH
(AUTO.STOP
SWITCH)
page20-46
Adjustment,
E R
@
_a
WIND DEFLECTOR
page20-38
Replacement,
CABLETUBE
REARBRACKET
E
@
E STOP
.a'
CABLEASSEMBLY
Beplacement,page20-44
page20'41
Replacement,
gJ
-.- REARDRA'N TUBE
*\
MOONROOF
CONTROLUNIT
)
REARDRAIN VAI-VE
FRAME
page 20-42
Replacement,
20-35
Moonroof
Diagnosticprocedure
Symptom
'1.
Also check for
Gl a s sh e i g h t
adJustment
Water leaks
Checkfor a cloggeddrain tube.
2. Checkfor a gap betweenthe glassweatherstripand the roof
panel.
3. Checkfor a defectiveor an improperlyinstalledglass
w e a t h e r s t r io
p r d r a i nc h a n n e l .
4. Checkfor a gap betweenthe drain seal and the roof panel.
W i n dn o l s e
1. Checkfor excessiveclearancebetweenthe glassweatherstrip G l a s sh e i g h t
adjustment
and the root panel.
Deflectornoise
1. Checkfor a imDrooerclearancebetweendeflectorseal and
roof panel.
2, Checkfor a insufficientdeflectorextension.
3. Checkfor a deformeddeflector.
Motor noise
1. Checkfor a loose motor.
2 . C h e c kf o r a w o r n g e a ro r b e a r i n g .
3. Checkfor a deformedcable assembly.
Glassdoes not move, 1 . C h e c kf o r a d e f e c t i v eg e a ro r i n n e rc a b l e .
2. Checkfor foreign matter stuck betweenthe guide rail and the
but motor turns
s l i d er .
3 . C h e c kf o r a l o o s ei n n e rc a b l e .
4. l\,4ake
sure the cableassemblyis attachedproperly.
Glassdoes not move
and motor does nol
t u r n ( g l a s sc a n b e
moved with
moonroofwrench)
20-36
1.
2.
3.
4.
5.
6.
Checkfor a blown fuse.
Checkfor a faulty moonroof switch.
Checkthe limit switch.
Checkfor a run down battery.
Checkfor a defectivemotor.
Checkfor a faulty relay.
Checkclosingforce
GlassHeightAdjustment
The roof panel (A) should be even with the glass
weatherstrip(B).to within 2*0.5/ 1 mm (0.08+0.02l
0.04 in.) all the way around.lf not, make the following
adjustment:
GlassReplacement
'L
C l o s et h e g l a s sf u l l y .
S l i d et h e s u n s h a d ea l l t h e w a y b a c k .
Removethe screws (A),then remove both bracket
covers (B).Removethe nuts (C)and shims {D)from
both glassbrackets(E).
B
2 + 0.5/ 1mm
{0.08+ 0.02/-0.0i1in.}
FastengrLocations
A } : Screw, 2
c O ,Nut.
il
@
E
\o
1 , Removethe bracketcover from each side.
2. L o o s e nt h e n u t s{ A ) ,a n d i n s t a l l t h es h i m s( B )
betweenthe glassframe (C)and glass bracket(D)
on each side.
Shim ihickness: Front and rear max. 2 mm 10.08in.l
6x1.0mm
9 N.m {0.9kgf.m,7 lbf.ft}
4. Removethe glass{A) by lifting it up. Do not
damagethe roof panel.
B
\
Forward
A
6x1.0mm
I N.m(0.9kgf.m,7lbt.ft)
3. lf necessary,repeaton the oppositeside.
5. Installthe glassin the reverseorder of the removal,
a n d a d j u s t h e g l a s sh e i g h ta l i g n m e n t .
6. Checkfor water leaks.Use free-flowingwater from
a hose without a nozzle.Do not use high-pressure
water.
20-37
Moonroof
Wind DeflectorReplacement
1 . O p e nt h e g l a s sf u l l y .
2 . Removethe screws(A, B), and releasethe hooks
(C),then removethe wind deflector(D).
Fastener Locations
A>:Screw,2B>:
Screw, 2
3. Installthedeflector(A) in the reverseorder of
removal,and checkthat lhe deflectorarm base (B)
and deflectorlink pivot base (C)line up with the
s a m ea l i g n m e n lti n e s( D ) .l f n e c e s s a r ya,d j u s t h e m
forward or backwardso the edge of the deflector
seal (E)touchesthe roof panel (F)evenly.Each
base must be moved the same amount for
adjustment.lf the deflectorseal and roof panel
make a rubbing sound, move the deflector
backwardas necessaryto positionit properly.
4il mm
( 1 . 7i n . )
_
-
l
' a -- ' -
\
20-38
DrainChannelReplacement
1 . Removethe moonroof glass(seepage 20-37).
4 . R e m o v et h e d r a i nc h a n n e (l A ) .
2 . With the moonroofwrench,move both glass
brackets(A) to the positionwhere the moonroof
normally pivots down, and removethe screws
s e c u r i n gt h e d r a i nc h a n n e (l B ) .
FastenerLocations
) : Screw,2
@
I n s t a l l t h ec h a n n e il n t h e r e v e r s eo r d e ro f r e m o v a l ,
and notethese items:
Releasethe drain channel(A)from both hooks{B)
o f t h e d r a i nc h a n n e sl l i d e rb y p u l l i n gt h e d r a i n
channelforward,
P u s ht h e d r a i nc h a n n e o
l n t ot h e h o o k su n t i la
faint click is heard.
Checkthe glass height adjustment(seepage 2031).
Checkfor water leaks.Letthe water run freely from
a hose without a nozzle.Do not use a high-pressure
spray.
20-39
Moonroof
SunshadeReplacement
1 . R e m o v et h e d r a i nc h a n n e l .
Slidethe sunshade(A) until you can see both
s u n s h a d es l i d e rs p a c e r s( B ) .
4. While liftingthe front portionofthe sunshade(A),
move the sunshadeforward until you can see both
s u n s h a d er e a rh o o k s( B ) .D o n o t d a m a g et h e
s u n s h a d ea n d h o o k s .
FastenerLocations
FastenerLocations
> : Screw,4
) : Screw,4
tF
(F
\
3. Removethe screws,then remove both spacers.
20-40
5. Removethe screws,then remove both hooks.
Motor Replacement
6. Removethe sunshade(A),
1 . Removethe headliner(seepage 20-54).
Put on glovesto protectyour hands.Disconneclthe
connector(A),and removethe bolts,then remove
the motor (B).
::lll'
=r'"'------.-..
--.,
FastenerLocations
>:Bolt,2
'l'i
\
?
A
@@
,
..
7 . Removeboth front sunshadebasesliders (A) and
b o t h r e a rs u n s h a d eb a s es l i d e r s( B )
{0.9kgf.m.
7 rbf.ftl
t'-^'
' a {
Installthe motor in the reverseorder of removal,
. lvlakesurethe connectoris plugged in properly.
. Checkthe motor operation.
8 . I n s t a l l t h es u n s h a d ei n t h e r e v e r s eo r d e ro f r e m o v a l ,
and checkthe glassheight adjustment(seepage
20-37).
9 . Checkfor water leaks.Let the water run freely from
a hose without a nozzle.Do not use a high-pressure
spray.
20-41
Moonroof
Frameand DrainTubeReplacement
. Headliner(seepage 20-54)
. Moonroof glass(seepage20-37)
2. Put on glovesto protectyou r hands.Disconnectthe motor connector(A),open/close-tilt/close
switch connector
{B),moonroof control unit connector{C),auto-stopswitch connector(D),and the drain tubes (Ei,and removethe
moonroofrelays(F).
FastenorLocations
> : Bolt,10
{um
irl
/^
@
6x1.0mm
9.8N.m
(1.0kgf.m,7.2lbfft)
Removethe interiorharness(G) by detachingthe harnessclips (H).
4 . With an assistantholdingthe frame (l). removethe bolts,startingat the rear,and releasethe rear hooks (J) by
moving the f rame forward,then removethe frame.
5 . With the help of an assistant,carefullyremovethe frame through the passenger'sdoor opening.Takecare not to
scratchthe interiortrim and body, or tear the seat covers.
20-42
6. To removea front drain valve (A)from the body,
removethe kick panel,left or right (seepage 20-50).
Tie a string to the end of the drain tube, then pull
the front drain tube (B)down out of the front pillar.
1 . To remove a rear drain valve (A)from the cargo
compartment,removethe rear side trim panel (see
p a g e2 0 - 5 1 ) . D e t a tchhe c l i p s( B ) ,t h e n r e m o v et h e
d r a i nt u b e ( C ) ,
B
8 . I n s t a l l t h ef r a m ea n d d r a i nt u b e i n t h e r e v e r s eo r d e r
of removal,and note these items:
t h e f r a m e ,c l e a rt h e d r a i nt u b e s
and drain valves using compressedair.
. Checkthe frame seal.
. C l e a nt h e s u r f a c eo f t h e f r a m e .
. When installingthe frame, first attachthe rear
hooks into the body holes.
. Make sure the connectorsare plugged in
properly.
. When connectingthe drain tube, slide it overthe
f r a m en o z z l ea t l e a s t1 0 m m ( 0 . 3 9i n . ) .
.Installthetubeclip(A
o )n t h e d r a i nt u b e( B )a s
shown.
Upward
tI I
B
9 . Checkfor water leaks.Let the water run freely from
a hosewithout a nozzle.Do not use a high-pressure
spray.
20-43
Moonroof
DrainChannelSliderand CableAssemblyReplacement
1. Removethe frame (seepage 20-42).
2. Removethese partsfrom the frame:
5 . P i v o t t h eg l a s sb r a c k e (t A )d o w n b y s l i d i n gt h e l i n k
lifter (B) back,then slide both glassbracketsback
with the link lifter.
. Sunshade(seepage 20-40)
. Moonroof motor (seepage 20-41)
3. Put on glovesto protectyour hands,Removethe
screws(A, B),then removethe slide stops (C)and
cabletube rear brackets(D).Removethe bolts (E)
from the cabletube side bracket(F)and the cable
tube mounting screws(G)from both sidesof the
f r a m e( H ) .
FastenerLocations
A> rScrew.2 B): Screw,2 E > : B o l t , 2
@
r):
@
S l i d et h e c a b l ea s s e m b l y( A )a n d b o t hg l a s s
brackets(B) back,then removethem from the
f r a m e( C ) .
Screw
6\-'1
Position switch side:
6x1.0mm
g , aN . m
c
A
No switch sidel
o
B
V
6x1.0mm
9.8 N.m
11.0kgf.m,7.2 lbf.ft)
C
Detachthe onen switch connectorclip {l)from the
frame.
20-44
7 . R e m o v et h e d r a i nc h a n n e sl l i d e r ( A )f r o m t h e g l a s s
bracket(B).
8 . I n s t a l l t h es l i d e ra n d c a b l ea s s e m b l yi n t h e r e v e r s e
o r d e ro f r e m o v a l a, n d n o t et h e s ei t e m s ;
. D a m a g e dp a r t ss h o u l db e r e p l a c e d .
' Apply multipurposegreaseto the glassbracket
( A )a n d g u i d er a i lp o r t i o no f t h e f r a m e ( B )
indicatedby the arrows.
. Beforereinstallingthe motor, make sure both
l i n kl i f t e r sa r e p a r a l l e la, n d i n t h e f u l l y c l o s e d
position.
. Beforereinstallingthe motor, installtheframe
a n d g l a s s t, h e nc h e c kt h e o p e n i n gd r a g ( s e ep a g e
20-481.
B
\
\
----lll
---':rdrt'Irrt
fl
u,t La/J'
I ll
l$=-r:-
20-45
Moonroof
Limit Switch Adjustment
1. Removethe headliner(seepage 20-54).
Fullyclosedpositionadiustment
2. With the moonroof wrench,closethe glass(A) fully:
. Make sure both link lifters(B)are parallel,and in the positionshown.
. Checkthe g lassfit to the roof panel and the glass height (seepage 20-37).
5x0.8mm
5 N.m {0.5kgf.m,4lbf.ft)
3 . W i t h a n o p e n - e n dw r e n c h ,l o o s e nt h e l i m i ts w i t c hm o u n t i n gb o l t s( C ) .
4. Adjust the limit switch (D):
' Move the switch plate (E)a little at a time, then secureit atthe positionwhere you hear a faint clickwhen
the
switch cam (F) pushesthe positionswitch (open/close).
. Checkthat the switch plate contactsthe switch bracket(G).
20-46
Auto-stop position adiustment
5. With the moonroofwrench.operatethe glass(A)to the auto-stopposition.
/--:.!Jtr+rtl
.
,
G
\_-_:_t+#1 <F
/
\
/
\
i!
..
I
5 N.m {0.5kgt.m,4 lbt ft)
With an open-endwrench, loosenthe auto-stopswitch m o u n t i n g b o l t s ( C ) .
7 . Adjustthe auto-stopswitch (D):
. N 4 o v e t h se w i t c hp l a t e( E )a l i t t l e a t a t i m e , t h e n s e c u r e i t a t t h e p o s i t i o n w h e r e y o u h e a r a f a i n t c l i c k w h e n t h e
switch cam (F)pushesthe switch (auto-stop).
. Checkthat the switch platecontactsthe switch bracket(G).
8 . Checkthe operationof the glassby operatingthe moonroof switch:From the tilt-up positionto the fully closed
position,from the fully open positionto the auto-stopposition,from the auto-stoppositionto the fully closed
posltron.
L Checkfor water leaks.Letthe water run fleely from a hosewithout a nozzle.Do not use a high-pressurespray
20-41
Moonroof
ClosingForceand OpeningDragCheck
1 . R e m o v et h e h e a d l i n e(rs e ep a g e2 0 - 5 4 ) .
2. Closingforce check:
. With a shop towel {A) on the leadingedge of the
g l a s s( B ) ,a f t a c ha s p r i n gs c a l e( C )a s s h o w n .
. Havean assistanthold the switchto closethe
glasswhile you measurethe force requiredto
stop it.
. Readthe force as soon as the glassstops moving,
then immediatelyreleasethe switch and spring
scale.
Closing Force; 200 290 N (20 30 kgf,44
4. Openingdrag check:Protectthe leadingedge of the
glasswith a shop towel (A).Measurethe effort
requiredto open the glass using a spring scale(B)
as shown.
66 tbl)
5 . lf the load is over 40 N (4 kgf,9 lbf),check;
. The side clearanceand glass heightadjustment
(seepage 20'37),
. F o r b r o k e no r d a m a g e ds l i d i n gp a r t s .l f a n y
s l i d i n gp a r t sa r e d a m a g e d r, e p l a c et h e m .
\
lf the force in not within specification,removethe
moonroof motor (seepage 20-41),then check:
. The gear portion and the inner cablefor breakage
and damage.lf the gear portion is broken,
r e p l a c et h e m o t o r .l f t h e i n n e rc a b l ei s d a m a g e d ,
removethe frame (seepage 20-42),and replace
the cable assembly(seepage20-44).
' T h e m o o n r o o fm o t o r ( s e ep a g e2 2 - 1 1 2 )I .f t h e
motor fails to run or doesn'ttu rn smoothlv.
replaceit (seepage 20-41),
. The opening drag. Go to step 4.
20-48
InteriorTrim
HATCHLOWERTRIM PANEL
oaoe20-53
HATCHSIDETRIM
page20 53
B.PILLARUPPEBTRIM
page20-50
TRIM
C-PILLAR
page20'51
DOOROPENINGTRIM
page20-50
A.PILLARTRIM
page20-50
R e m o v a l / l n s t a l l a t ipoang, e2 0 5 4
KICKPANEL
page20 50
Replacement,
page20-55
DOORSILLTRIM
page20-50
CARGOAREA FLOOR
page20-52
REARSIDESHELF
page20 5l
REARCENTERSHELF
page20-51
REARSIDETRIM PANEL
page20-51
CARGOFLOORMAT
page20-52
REARTRIM PANEL
page 20-52
20-49
InteriorTrim
Trim Removal/lnstallation- Door Area
NOTE:
. When prying with a flat-tipscrewdriver,wrap it with protectivetape to preventdamage.
. Takecare not to bend or scratchthe trim and panels.
1 . R e m o v et h e t r i m a s s h o w n .T o r e m o v et h e d o o r s i l l t r i m a n d B - p i l l a ur p p e rt r i m , r e m o v et h e r e a rs i d et r i m p a n e l
as necessary(seepage 20-51).
2. Installthetrim in the reverseorder of removal,and note these items:
. Replace
a n y d a m a g e dc l i p s .
. Apply liquid thread lockto the anchor bolts before reinstallatior,.
. Beforeinstallingthe anchorbolts, make sure there are no twists or kinks in the belts.
FastenerLocations
A>: Clip,2 B > r C l i p , 3 C > : C l i p , ?
(Black)
2ffi
Tl|t
{White)
FRONTSEATBELT
UPPER
ANCHORBOLT
7/16-20
UNF
32 N m (3.3kgf m,24 lbf.ft)
,"lF
\r{
A-PILLARTRIM
\
il-::7
KICKPANEL
/
ao-----
LowERANcHoRcAP
FRONTSEAT BELTLOWER
ANCHORBOLT
7/16-20UNF
32 N.m (3.3kgt.m,24lbl.ftl
REARSIDETRIM PANEL
20-50
Trim Removal/lnstallation- RearSideArea
NOTE:
'1.
To removethe rear side trim panel,removethese items:
. Rearseat cushionand rear seat-back(seepage20-80)
. Cargofloor mat and cargo areafloor (seepage 20-52)
. R e a rt r i m p a n e l{ s e ep a g e 2 0 - 5 2 )
2 . Removethe trim as shown. On the right side,disconnectthe cargo compartmentlight connector.
3 . Installthetrim in the reverseorder of removal,and note these items:
. Replace
. Make sure the cargo compartmentlight connectoris pluggedin properly.
. l f t h e t h r e a d s o n t h e r e a r s i d e t r i m p a n e lm o u n t i n gs e l f - t a p p i nEg Ts c r e w sa r ew o r n o u t , u s ea n o v e r s i z e sd e l f t a p p i n gE T s c r e w( P / N9 0 1 3 7 - S 1 A - E1o)1m a d es p e c i f i c a l lfyo r t h i s a p p l i c a t i o n .
t h e r e a rs i d es h e l f ,s l i pt h e r e a rs e a tb e l tt h r o u g ht h e s l i t i n t h e t r i m .
' A p p l y i i q u i dt h r e a dl o c k t ot h e a n c h o rb o l t sb e f o r er e i n s t a l l a t i o n .
. Beforeinstallingthe anchorbolts,make sure there are no twists or kinks in the belt.
Fasten€r Locations
A>:Clip,11
B> rClip,2
c>rClap,l
-..:.:'
TRIM
S I D ES H E L F
REARSEATSELT
SIDETRIM PANEL
SEAT
STRIKERCAP
S I L LT R I M
SELF-TAI
scREws
5x0.8mm
{ 0 . 4k g f m , 3 l b f . f t )
.. F . -\ *: : :- . n: \
,/\
,/
\*J
R E A RB U L K H E A O
COVER
REARSPEAKERCOVER
I
FRONTSEAT AELT
LOWERANCHORBOLT
REARSEAT BELTLOWER
\
7/16-20UNF
ANCHOF BOLT
\
32 N.m
7/16-20UNF
\
{ 3 . 3k g f m , 2 4 l b t . t t )
32 N m (3.3 kgf m, 24 lbf ft,
\
L O W E RANCHORCAP
20-51
lnteriorTrim
- CargoFloorArea
NOTE:
. When jrying with a flat-tipscrewdriver,wrap it with protectivetape to preventdamage'
. Takecare notto bend or scratchthe trim and panels.
( s e ep a g e2 3 - 1 1 ) '
1 . T o r e m o v et h e r e a rt r i m p a n e l ,r e m o v et h e c h i l ds e a tt e t h e ra n c h o r
2. Removethe trim as shown.
, n d r e p l a c ea n y d a m a g e dc l i p s '
3 . I n s t a l l t h et r i m i n t h e r e v e r s eo r d e ro f r e m o v a l a
Fastener Locations
A > :C l i p , 3 B > : C l i p . 4
j-=
E T r
\t
FLOORMAT
COVER
REARSEAT-BACK
-t
CARGOAREA FLO
7
To rearsade
trim panel.
To rearsidetrim
panel.
20-52
REARTBIM PANEL
Trim Removal/lnstallation- HatchArea
NOTE:
1. Removethe trim in the sequenceshown.
.
.
.
.
Hatchuppertrim panel
Left hatchside trim
Righthatchside trim
Hatchlower trim panel
, n d r e p l a c ea n y d a m a g e dc l i p s .
Fastener Locations
o>
A>;crip,a B>:crip,2 .>,l,l,Jil,l3
"-{q .1
\.
Y,]
3il;1,
n l f nl t
gg
E>:crip.2
itr^
O HATCHLowER TRrM
PANEL
HATCHLOWERTRIMPANEL
a- ,,) I
t7,
f.
)
HATCH UPPERTRIM PANEL
a
=- -1
a
->
.D HATCHUPPERTRIM PANEL
HATCHSIDETRIM
20-53
InteriorTrim
HeadlinerRemovaUlnstallation
NOTE:
. When prying with a flat-tip screwdriver,wrap itwith
protectivetape to preventdamage.
. Takecare not to bend and scratchthe headliner.
. Be carefulnot to damagethe dashboardand other
interiortrim.
3. From both rear passenger's,removethe caps (A),
and removethe screws,then removethe grab
h a n d l e s( B ) .
FastenerLocations
> : Screw,4
t , t;---iJ
. A-pillartrim, both sides(seepage 20-50)
. B-pillau
r p p e r t r i m ,b o t h s i d e s( s e ep a g e2 0 - 5 0 )
. Hatchweatherstrip,as necessary{seepage 2092\
. C - p i l l atrr i m , b o t hs i d e s( s e ep a g e2 0 - 5 1 )
. Moonroof switch (seepage22-'112)
. Spotlights(seepage 22-961
. Ceilinglight (seepage 22-96)
Removethe sunvisor{A) and holder {B)from both
srdes.
-1
-2
-3
-4
Removethe caps {C).
Removethe screws.
Removethe sunvisorfrom the body and holder.
Using a flat-tipscrewdriver,push the hook (D),
a n d t u r n t h e h o l d e r9 0 ' . t h e n p u l l i t o u t .
FastenerLocations
> : Screw,4
r(\'-r
\)*
5x0.8mm
5 N.m
{0.5kst m.4lbf ft}
20-54
)e
5x0.8mm
4 N.m
{0.4 kgf.m, 3 lbf.ft}
CarpetReplacement
4. Removethe headliner.
-1 Removethe socketplug (A).
- 2 R e m o v et h e r e m a i n i n gd o o r o p e n i n gt r i m { B }
from each roof portion.
-3 Detachthe clips (C),and releasethe fasteners
( D )b y p u l l i n gt h e f r o n t p o r t i o no f t h e h e a d l i n e r
(E)down.
-4 With the help of an assislant,releasethe clips
(F)of the headlinerfrom the moonroof frame
( G ) ,a n d r e l e a s et h e h e a d l i n efrr o m t h e c l i p s( H )
by slidingthe headlinerforward, and lowering
the headliner.
-5 Removethe headlinerthrough the passenger's
opening.
FastenerLocations
C>:Clip,3
F>:Clip,2
H>:Clip,2
a
o
SRScomponentlocations(seepage 23-13)and the
precautionsand procedures(seepage23-14)in the SRS
sectionbefore performingrepairsor service.
NOTE:
. Takecare not to damage,wrinkle. or twist the carpet.
. Be carefulnot to damagethe dashboardor other
interiortrim pieces.
. Frontseats,both sides(seepage 20-111
. Driver'sdashboardunder cover (seepage 20-60)
. Passenger'sdashboardIower cover (seepage
20-631
. Rearseatcushion(seepage 20-80)
. Kick panels,both sides(seepage 20-50)
. Door silltrim, both sides(seepage 20-50)
. Consoles,front and rear (seepage20-57)
2 . R e m o v et h e n u t ( A ) ,a n d u s i n ga h e xw r e n c h ,
releasethe clip (B),then removethe footrest(C).
FastenerLocations
Aa:Nut,1
B):Clip,'l
--'1
;tt4f
tj=\-/I
5 . Installthe headlinerin the reverseorder of removal,
I
-JrL
--\
l[il
A
6x1.0mm
9.8Nm
11.0kgf m,7.2 lbf.ft)
-o
. W h e n r e i n s t a l l i ntgh e h e a d l i n etrh r o u g ht h e
passenger'sdoor opening,be carefulnot to fold
or bend it, Also, be carefulnot to scratchthe
DOOy.
. C h e c kt h a t b o t hs i d e so f t h e h e a d l i n ear r e
securelyattachedto the trim.
. R e p l a c ea n y c l i p st h a t r e m a i ni n t h e r o o f d u r i n g
r e m o v a lR
. e i n s t a l l t h cel i p sb a c ki n t h e h e a d l i n e r
before installation.
(cont'd)
20-55
InteriorTrim
CarpetReplacement(cont'dl
Using a utility knife,cut the carpet(A) underthe
heaterareas(B),and cut out the parkingbrakelever
area (C)as shown, then pull backthe carpet.
A
B
4 . Removethe clip (A),and releasethe fasteners(B).
Pullthe carpetout from both rear side trim panels
(D),then removethe carpet(C).
FastenerLocation
A >: Clip.1
&z
tr
20-56
5. Installthecarpetin the reverseorder of removal,
. T a k ec a r en o t t o d a m a g e w
, r i n k l e ,o r t w i s t t h e
carpeL
. Make sure the seat harnessesare routed
correctly.
. S l i pt h e c a r p e tu n d e rt h e r e a rs i d et r i m p a n e lo n
each side properly.
. Replace
t h e c l i p i f i t ' sd a m a g e d .
. Reattachthe cut areasunder the heateraround
the parkingbrakelever with a wire tie.
. When installingnew carpet,cut the carpet(A)
underthe heaterareas(B),and around the
parkingbrakelever (C).After installingthe new
carpet,slip the carpetfrom the driver's and
passenger'sside through the spacebetweenthe
heaterunit and body, and reattachthe cut area
{C)around the parkingbrakeleverwith wire ties.
t
Consoles
Console,Frontand RearRemoval/lnstallation
NOTE:Takecare not to scratchthe front seal,
dashboard,and relatedparts.
1 . R e m o v et h e r e a rc o n s o l e( A ) .
-1 Slidethe front seatforward fully on each side.
-2 Removethe screws{B)from the rear portionof
the rearconsole,
-3 Slidethe front seat rearwardfully on each side.
- 4 P u l l t h ef r o n t p o r t i o no f t h e r e a rc o n s o l eu p t o
detachthe clips (C)and hooks (D),then release
the rearconsolefrom the front console(E).
- 5 S t a r t i n ga t t h e r e a r ,p u l l t h e r e a rc o n s o l eu p ,
then remove it.
2. Removethe front console(A).
- 1 P u l lo u t t h e d a s h b o a r dc e n t e rl o w e rc o v e r{ B )
to detachthe clips (C).
-2 Dlsconnectthe accessorypower socket
c o n n e c t o(rD ) .
3 R e m o v et h e c o n s o l eb o x m a t ( E ) .
- 4 R e m o v et h e b o l t s( F ) ,s c r e w s( G ) ,a n d c l i p s( H ) .
-5 Gently pull out the front consoleto releasethe
h o o k s( l ) a n dp i n s ( J ) .
FastenerLocations
C > : C l i p , 3 F > i B o l t , 2 G > : S c r e w . 2H ) : C l i p , 2
*..4' * q ' 4!-J - L } * fFJ \ . / -,-('E9'/
d
FastenerLocations
C >: Clip,2
B >:Screw,2
6x1.0mm
98Nm
(1.0kgt.m,7.2lbf.ft)
Installthe consolein the reverseorder of removal,
and note these ltems:
. R e p l a c ea n y d a m a g e dc l i p s .
. Make sure the accessorypower socketconnector
i s p l u g g e di n p r o p e r l y .
. P u s ht h e c l i p si n t o p l a c es e c u r e l y .
20-57
Consoles
Front ConsoleDisassembly/Reassembly
NOTE;Takecare not to scratchthe consoleand relatedparts.
Fastener Locations
):Screw,8
C*
FRONTCONSOLE
\
BEVERAGE
HOLDER
ASSEMBLY
',/
BOX
CONSOLE
20-58
,/
a
Dashboard
InstrumentPanelRemoval/
Installation
Driver'sDashboardLower Cover
NOTE:
. When prying with a flat-tipscrewdriver,wrap it with
protectivetape, and apply protectivetape aroundthe
relatedparts,to preventdamage.
. Takecare not to scratchthe dashboardand related
parts.
NOTE:Takecare not to scratchthe dashboardand
relatedParts.
1. Tilt the steeringcolumn down.
1. Removethe driver'sdashboardlower cover (A).
-1 Turn the lock knob (B)90".
-2 Gently pull out the left side to releasethe
h o o k s( C ) ,
-3 Pull out the panelto releasethe hooks (D).
2. Removethe steeringcolumn upper cover {seepage
17,9).
Removethe instrumentpanel (A).
-1 Gently pull out along the bottom to releasethe
c l i p s( B )a n d h o o k s( C ) .
-2 Gently pull out the upper portionto releasethe
c l i p s( D )a n d h o o k s( E ) .
FastenerLocations
B> : c l i p . 2
D D:,C l i p , 2
^*,
Installthecover in the reverseorder of removal,
and push the hook portions into placesecurely.
4 . Installthe panel in the reverseorder of removal,
and push the clip and hook portionsinto place
securery.
20-59
Dashboard
Driver'sDashboardUnderCover
Driver'sPocketRemoval/
lnstallation
relatedparts.
NOTE:
p an s .
1. Removethe driver'sdashboardunder cover (A).
- 1 T u r nt h e l o c kk n o b( B )9 0 ' .
-2 Gentlypull down the rear edgeto releasethe
clip(C).
-3 Pullthe cover away to releaseit from the clip
{D).
FastenerLocations
C >: Clip.1
n
1. Removethe driver's pocket(A)
-1 Removethe driver'sdashboardunder cover.
-2 Removethe screws(B).
-3 From behindthe dashboard,push the pocket
b a c kb y h a n dt o r e l e a s et h e c l i p s( C ) .
4 Release
t h e h o o k( D ) .
FastenerLocations
B):Screw,2 C>: Clip,2
','"\5
;;t='
\
)
Installthecover in the reverseorder of removal,
and push the clip portion into placesecurely.
20-60
2 . Installthe pocketin the reverseorder of removal,
and push the clip portionsinto placesecurely.
Shift LeverTrim Removal/lnstallation
NOTE:
parts.
1. Removethe glove box (seepage20-63).
4. Pull outthe shift levertrim (A) by hand to release
t h e r e m a i n i n gc l l p s( 8 , C ) a n d h o o k s( D ) ,a n d
disconnectthe hazardwarning switch connector(El,
then removethe trim.
FastenerLocations
B >:Clip,1
C > : C l ; p1,
2. Removethe shift knob.
,,.;w,
D>: Hook,3
-
, ,
U s i n ga r a t c h ew
t r e n c ha n d a n 1 1 i n c he x t e n s i o n
(A)wrapped with a shop towel (B),carefullyinsert
the extensionthrough the glove box opening,and
push the shift levertrim (C)from underthe trim to
releasethe clips (D)and hooks (E)of the left side.
Fastener Locations
D>clip,2
i:F
\V
E> H o o k , 2
.-a7
\rt1
Installthe trim in the reverseorder of removal,and
note these rtems.
. Make sure the hazardwarning switch connectot
is plugged in properly.
. Pushthe clip and hook portionsinto place
securely,
u
20-61
Dashboard
DashboardCenterPanelRemoval/lnstallation
NOTE:
protectivetape, and apply protectivetape around the
relatedparts,to preventdamage.
parts.
the write down the frequenciesfor the preset
buttons.
4. Pull out the centerpanel (A)to releasethe clips (B)
and hooks (C),and removethe harnessholder (D)
from the bracket(E).Disconnectthe audio unit
connector(F),antennalead (G),heaterswitch
connector(H)and heatercontrol unit connectors(l).
FastenerLocations
B ): Clip,8
*4
, F
. Driver'sdashboardlower cover (seepage20-59)
. Passenger'sdashboardlower cover (seepage
20-63).
. Glove box (seepage20-63).
. Shift levertrim {seepage20-61).
From the glove box and driver'sdashboardIower
cover openings,loosenthe bolts (A) securingthe
centerpanel (B).
Fastener Locations
A): Bolt,2
;.'
20-62
x 0.8 mm
5Nm
Installthe panel in the reverseorder of removal,
Make sure eachconnectoris pluggedin properly,
and antennalead is connectedproperly.
Pushthe clip portionsinto placesecurely.
Reconnectthe negativecableto the battery.
idle learn procedure{seepage
Do the ECN4/PCt\4
1l-139).
Enterthe anti-theftcode for the radio.then enter
Resetthe clock.
\
Passenger's
DashboardLower
CoverRemoval/lnstallation
relatedparts.
1. Removethe passenger'sdashboardlower cover
(A).
-1 Gently pull down the rear edge to releasethe
c t i p s( B ) .
-2 Pullthe cover away to releasethe pins (C)from
t h e h o l d e r s( D ) .
FastenerLocations
B>: Clip,3
A
I jl
GloveBox Removal/lnstallation
S R Sc o m p o n e n lto c a t i o n s( s e ep a g e2 3 - 1 3 a
) n dt h e
p r e c a u t i o nasn d p r o c e d u r e (ss e ep a g e2 3 1 4 )i n t h e S R S
relatedparts.
1. Removethe passenger'sdashboardlower cover.
2. While holding the glove box (A),removethe glove
box stop (B)on each side.
FastenerLocalions
>Boh.2
.-6\
{Ill
.-<,/fir-"b
B
tJ
r-3t.oi,t-'
10.5kgf m,
4 tbf.ft)
Installthe under cover in the reverseorder of
removal,and push the clip ponions into place
securety.
Removethe bolts,then removethe glove box.
4 . l n s t a l l t h eg l o v eb o x i n t h e r e v e r s eo r d e ro f
removal.
20-63
Dashboard
DashboardSide Vent RemovaU
Installation
BeverageHolderRemoval/
lnstallation
NOTE:
. Takecare not to scratchthe dashboard.
NOTE:
. Takecare not to scratchthe dashboard,
1. Removethe dashboard(seepage 20-66).
1. Removethe dashboard(seepage20-66).
2. Removethe steeringhangerbeam from the
dashboard(seepage 20-68).
2. Removethe screws,then removethe beverage
h o l d e r( A ) .
3. Removethe screws,then removethe air duct (A)
f r o m t h e d a s h b o a r d( B ) .
FastenerLocations
):Screw.2
FastenerLocations
):Screw, 7
6hD
t
4 . Remove the screws, lhen remove the slde vent (A).
Fastener Locations
):Screw,4
5 . l n s t a l l t h es i d ev e n t i n t h e r e v e r s eo r d e ro f r e m o v a l .
20-64
3 . Installthe beverageholder in the reverseorder of
removat.
Driver'sTray Removal/lnstallation
NOTE:
. Takecare not to scratchthe dashboard.
1. Removethe dashboard(seepage 20-66).
Passenger's
Tray Removal/
Installation
NOTE:
. Takecarenotto scratchthe dashboard.
. Puton glovesto protectyourhands.
2. Removethe beverageholder(seepage 20-64).
1 . Removethe dashboard(seepage 20-66),
3. Removethe screws,then removethe driver'stray
(A).
2 . Removethe steeringhanger beam from the
dashboard(seepage 20-68).
FastenerLocations
):Screw.3
3 . Removethe air duct (seestep 3 on page20-64).
4 . Removethe screws,then removethe passenger's
tray(A).
FastenerLocations
):Screw, 8
4, lnstallthe tray in the reverseorder of removal.
5. lnstallthe trav in the reverseorder of removal.
20-65
Dashboard
DashboardRemoval/lnstallation
SRScomponentlocations(seepage23-13)and the
4. From the centerpanelopening,removethe screws,
then removethe centerbracket(A).
FastenerLocations
):Screw,2
NOTE:
protectivetape, and apply protectivetape aroundthe
relatedpartsto preventdamage.
. Havean assistanthelp you when removing and
rd.
installing
thedashboa
. Takecare not to scratchthe dashboard,body, and
other relatedparts.
buttons.
Disconnectthe negativecablefrom the battery,and
wait at leastthree minutesbefore beginningwork.
Removethese items:
. Driver'sdashboardlower cover (seepage 20-59)
. Driver'sdashboardunder cover (seepage 20-60)
. Passenger'sdashboardlower cover (seepage
20-63)
. Glove box (seepage 20-63)
. Consoles,front and rear (seepage 20-57)
. Shift levertrim {seepage 20-61)
. Centerpanel (seepage 20-62)
. Kick panels,both sides(seepage 20-50)
. A-pillartrim. both sides(seepage 20-50)
. Steeringcolumn (seepage 17-9)
20-66
Removethe shift lever (seepage 13-51).
From outsideof the passenger'sdoor, gently pull
out along the edge of the dashboardside cover (A)
to releasethe hooks (B),then releasethe upper
hook (C),to removethe cover.
Driver's side:
7. From underthe dash,disconnectthe interiorwire
harnessconnector(A),driver'sdoor wire harness
connectors(B),side turn signallight connector(C).
roof antennaconnector(D),antennalead (E).clutch
switch connectors(F),and brakeswitch connector
(G),and disconnectthe floor wire harness
connectors(H)and engine compartmentwire
harnessconnectors(l)from the under-dashfuse/
r e l a vb o x ( J ) .
Middle portion:
8. Disconnectthe floor wire harnessconnectors(A)
a n dc o m b i n a t i o n
s u b h a r n e scso n n e c t o(rB ) .
Passenger'sside:
9. From under the dash,disconnectthe dashboard
wire harnessconnectors(A),EPSsubharness
connectors(B),enginecompartmentwire harness
connectors(C),A,/Csubharnessconnectors(D),
passenger'sdoor wire harnessconnectors{E),and
s i d et u r n s i g n a l i g h tc o n n e c t o(rF ) .
1 0 . D e t a c ha l l o f t h e h a r n e s sa n d c o n n e c t ocr l i p s .
(cont'd)
20-67
Dashboard
DashboardRemoval/lnstallation
(cont'd)
SteeringHangerBeam
Replacement
11. From outsidethe driver'sdoor, removethe caps (A),
then removethe bolts (8, C, D),and lift up on the
dashboard(E)to releaseit from the guide pins
(F.G) on the body.
FastenerLocations
B>rBolt.3 C>: Bolt,2 D>: Bolt,2
m6[-,,,,",",,-,F6't---''
ffi'!-v{/-
Kr*
w-
1, Removethe dashboard(seepage 20-66).
2. Removethese items from the dashboard:
.
.
.
.
lnstrumentpanel (seepage 20-59)
Driver'spocket(seepage20-60)
G a u g ea s s e m b l y( s e ep a g e2 2 - 6 4 )
Passenger'sairbag(seepage 23-'l14)
Removethe screws,thenremovethe glovebox
striker(A).
FasteneaLocations
):Screw,4
B
$7:
^/761:
/
,
-
{2.2kgf m, 16lbf.ftl
,. r:; 8 x 1.25mm
22Nm
(2.2kgf.m,16lbf.ft)
Carefullyremovethe dashboardthrough the front
d o o ro p e n i n g .
1 3 .lnstallthe dashboardin the reverseorder of
. Make sure the dashboardfits onto the guide pins
correctly.
. A p p l y l i q u i dt h r e a dl o c kt o t h e d a s h b o a r d
mounting bolts of the middle portion before
reinstallation.
. Beforetighteningthe bolts,make sure eachwire
harnessand control cablesare not pinched.
properly,and the antennalead is connected
propeny.
. Reconnectthe negativecableto the battery.
. Enterthe anti-theftcode for the radio,then enter
. Resetthe clock.
. D ot h e E C M / P C M
i d l el e a r np r o c e d u r ei s e ep a g e
'1-139).
1
20-68
\
4. Removethe bolts (A) and screws(B)securingthe
d a s h b o a r d( C )a n d s t e e r i n gh a n g e rb e a m( D ) ,a n d
disconnectthe power mirror switch connector(E)
and cruisecontrol main switchconnector(F).
S e p a r a t et h e d a s h b o a r da n d s t e e r i n gh a n g e rb e a m .
FaslenerLocations
5 . I n s t a l l t h eb e a mi n t h e r e v e r s eo r d e ro f r e m o v a l ,
. N 4 a kseu r et h e d a s h b o a r dw i r e h a r n e s s( G ) i s n o t
pinched.
properly.
A>rBolt,4 B>:Screw,9
5 N.m {0.5kgf m,4lbf,ftl
20-69
Seats
REARSEAT
page20-80
Seat-backLatchReplacement,
page20-81
Seat-backStrikerReplacement,
page20-81
Seat'backCoverReplacement,
page 20-82
SeatCushionCoverReplacement,
page20-84
FRONTSEAT
page20-i 1
page20 73
Disassembly/Reassembly-Driver's,
page20-74
Disassembly/Reassembly-Passenger's,
SeatCoverReplacement,page20-75
20-70
Front Seat Removal/lnstallation
For some models:SRScomponentsare locatedin this
area.Reviewthe SRScomponentlocations(seepage
23-'13)and the precautionsand procedures(seepage
23-14)in the SRSsectionbefore performingrepairsor
service.
NOTE
protectivetape to preventdamage.
. Takecare not to scratchthe body or tear the seat
covers.
4. Removethe bolts securingthe front seat.
FastenerLocations
> : Bolt,
@
1, Make sure you have the anti-theftcode for the radio,
butlons.
Disconnectthe negativecablefrom the battery,and
wait at least3 minutesbefore beginningwork.
3 . Removethe seattrackend covers(A)from the back
of both seattracks.
Outef:
1 0 x 1 . 2 5m m
lnner:
\
(cont'd)
20-71
Seats
(cont'dl
FrontSeatRemoval/lnstallation
Lift up the front seat,then detachthe harnessclip
(A).and disconnectthe seat belt switch connector
( B )a n d s e a tb e l tb u c k l et e n s i o n ecr o n n e c t o(rC ) .l f
, i s c o n n e ct th e s i d e
e q u i p p e dw i t h a s i d ea i r b a g d
a i r b a gc o n n e c t o (r D ) ,a n d o n t h e p a s s e n g e r 'sse a t ,
d i s c o n n e ct th e O P D Su n i tc o n n e c t o(rE ) .T h e
p a s s e n g e r 'sse a ti s s h o w n ,t h e d r i v e r ' ss e a ti s
s i m i l a re x c e p ti t h a sn o O P D Su n i tc o n n e c t o r .
6 . With the help of an assistant,carefullyremovethe
front seatth rough the front door opening.
, nd
7 . I n s t a l l t h es e a ti n t h e r e v e r s eo r d e ro f r e m o v a l a
notethese rtems:
. l\4akesure each connectoris plugged in properly.
. A p p l y l i q u i dt h r e a dl o c kt o t h e s e a tm o u n t i n g
bolts before reinstallatlon.
. Reconnectthe negativecableto the battery.
. Resetthe clock.
. Do the ECM/PCMidle learn procedure(seepage
11 - 1 3 9 ) .
20-72
- Driver's
FrontSeat Disassembly/Reassembly
For some models:SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations(seepage 23-13)
and the precautionsand procedures(seepage 23-14)in the SRSsectionbefore performingrepairsor service.
NOTE:
. Takecare not to tear the seamsor damagethe seatcovers,
. When prying with a flat-tipscrewdriver.wrap it with protectivetape to preventdamage.
' Apply multipurposegreasetothe moving portion of the seattrack.
. To preventwrinklesin the seat cushioncover,stretchthe materialevenlyoverthe pad.
Releasethe seatcushion
coverfrom the cushion
f r a m es p r i n g .
SEAT-BACK
10 x 'l.25mm
47 N.m {4.8kgf.m,
35 rbt.ft)
WIRETIE
RECLINECOVER
4
RECLINEKNOB
20-73
Seats
- Passenger's
FrontSeat Disassembly/Reassembly
For some models:SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations(seepage23-'13)
and the precautionsand procedures(seepage 23-14)beforedoing repairsor service.
NOTE;
. Takecare not to tear the seamsor damagethe seatcovers
. When prying with a flat-tipscrewdriver,wrap it with protectivetape to preventdamage
. Apply multipurposegreaseto the moving portion of the seattrack
. To Dreventwrinklesin the seat cushioncover,stretchthe materialevenlyover the pad.
. lvlakesure the rear seat accesscable is connectedproperlyon each side
. Replaceany damagedclips,and replacethe wire ties with new ones
SIDEAIRBAG
HARNESS
SEAT"BACK
Releasethe seatcushion
coverfrom the cushion
f r a m es p r i n g .
10 x 1.25mm
47 N.m (4.8kgf.m,
3s rbf.ft)
OPDSHARNESS
HANGERSPRING
CENTEBCOVER
WIRETIE
SEATCUSHION
FRAME/SEAT
TRACKS
/
REARSEAT
ACC€SSCABLE
,/CLIP
*r(".o,
ACCESSKNOB
v/
N
,/
/-
/
I
SLIDELEVER
/ H o o K
RECLINEKNOB
RECLINE
COVER
20-74
u
Front SeatCoverReplacement
23 13)and the precautionsand procedures(seepage
23-'14)in the SRSsectionbeforeperforming repairsor
service,
3 . Foldthe seat-backforward.
4. Release
t h e h o o k s( A ) ,a n d u n z i pt h e s e a t - b a c k
c o v e r( B ) .
NOTE:
. Takecare not to tear the seamsor damagethe seat
covers,
. On the passenger'sseatwith side airbag,do not
touch the OPDSsensorin the seat-backpad, and keep
it away from oil. Oil can corrodethe sensorcausingit
to fail.
. Puton glovesto protectyour hands.
Seat-backCover
'L
Removethe front seat isee page 20-71).
2. W i t h s i d ea i r b a g :F r o mu n d e rt h e s e a tc u s h i o n ,
detachthe side airbagconnectorclip (A),and on
the passenger'sseat,detachthe OPDSunit
c o n n e c t ocr l i p ( B ) .R e l e a s teh e h o o ks p r i n g s( C )
f r o m t h e s e a tc u s h i o nf r a m es p r i n g{ D ) ,t h e n p u l l
the guide cover (E)back,and removethe wire ties
(F).The passenger'sseat is shown, the driver'sseat
is svmmetricalexceptit has no OPDSunit
connector.
(cont'd)
20-75
8 . Using a flat-tipscrewdriverwrappedwith
protectivetape, insert it into the hook portions
( s e v e np l a c e so) f t h e h e a d r e srte a rt r i m i A ) f r o m t h e
headrestfront trim side. Prv up the hooks (B)to
releasethe labs (C)of the headrestfront trim (Di
w h i l e p u l l i n gt h e h e a d r e sftr o n tt r i m f o r w a r d ,a n d
removethe tflm.
9. Unzipthe headrestportionof the seat-backcover
( A ) ,t h e n r e m o v et h e z i p p e ri B ) ,a n d r e m o v et h e
cover.
D
/
A
1 0 .installthe cover in the reverseorder of removal,
. Fit all the hooksof the headrestfront trim into the
h o l e si n t h e h e a d r e srt e a rt r i m ,t h e n p u s ho n t h e
h e a d r e sttr i m u n t i lt h e h o o k ss n a pi n t o p l a c e .
. To preventwrinkleswhen installinga seat back
cover, make sure the materialis stretchedevenly
over the pad beforesecuringthe clips, hooks,
a n d h o o ks p r i n g s .
. M a k es u r et h e s i d ea i r b a gh a r n e s sO
, PDS
harness{passenger'sseat).and rear seataccess
cable(passenger'sseati are routed properly.
. lf necessary,reinitializethe OPDScontrol unit
( s e ep a g e2 3 - 1 2 4 ) .
(cont'd)
20-77
Seats
Front Seat CoverReplacement{cont'd)
SeatCushionCover
Outside:
1. Removethe front seat (seepage 20,71).
2. Removethese items from the front seat:
. Reclinecover,driver's seat (seepage 20-73)
passenger'sseat {seepage 20-74l
. Frontseat belt buckle{seestep 4 on page 23-6)
3. From underthe seat cushion,detachthe side
airbagconnectorclip, and on the passenger'sseat,
detachthe OPDSunit connectorclip. Releasethe
hook springsfrom the seatcushionframe spring,
then pull the guide cover back,and removethe
wire ties.
4. Releasethe hooks(A).
Inside:
20-78
Releasethe seat-backcover (A)from the cushion
frame spring (B),and releasethe hooks(C)from
u n d e rt h e s e a tc u s h i o n .
6 . R e m o v et h e s e a tc u s h i o nc o v e r( A )w i t h t h e s e a t
cushion pad from the seat cushionframe.
8. Installthecover in the reverseorder of removal,
and note these items;
. To preventwrinkleswhen installlnga seat
cushioncover, make sure the materialis
stretchedevenlyover the pad beforesecuring
t h e c l i p sa n d h o o k s .
. Make sure the side airbag harnessand OPDS
harness(passenger'sseat)are routed properly.
. Replaceany clips you removedwith new ones
( A ) .I n s t a l l t h e mw i t h c o m m e r c i a l l a
yvailable
upholsteryring pliers (B).
1 . Pull backthe edge of the seatcushioncover all the
way around.and releasethe clips {A),then remove
the seat cushioncover (B).
{,
r
:
r *
F
+
]
r
?
20-79
Seats
RearSeat Removal/lnstallation
NOTE:Takecare not to scratchthe body or tear the seatcovers.
'1.
Removethe rear seat as shown.To removethe seat-back,removethe front portion of the cargofloor mar lsee
page 20-52).
2. Installthe seat in the reverseorder of removal,and note these items:
'Beforeinstallingthecenteranchorboltsontheseat-backwiththecentershoulderbelt,makesurethereareno
twists or kinksin the belt.
. Make sure the seat-backslock securelv.
Fastener Locations
A > : B o l t , 2 B > r B o l t 1, C > : B o t t1,
D > : C l i p ,2
/-<.{\.--
K\| J ] . P F.i\-t-HAP
lltl
agr
f ( 1
Vt-
r_r+*.
8 x 1.25mm
22 N.m 12.2kgt m, 16lbf.ft)
CENTERPIVOTBOLT
8 x 1.25mm
22 N.m
{2.2kgf.m, 16lbf.ftl
RIGHTSEAT-BACK
\'7
SEAT.BACK
CENTERHINGE
BUSHING
LEFTSEAT.BACK
CENTERBELT
PIVOTBUSHING
PIVOT
BUSHING
CENTERANCHORBOLT
7/16-20UNF
32Nm
(3.3kgf m.24 lbt ftl
SEATBELTBUCKLE
6x1.0mm
9.8Nm
HOOK
SEATCUSHION
20-80
I
RearSeat-backLatchReplacement
1 . Removethe seat-back(seepage 20-80).
RearSeat-backStriker Replacement
NOTE:Takecare not to scratchthe interiortrim.
Removethe seat-backcover (seepage 20-82).
1 . R e m o v et h e r e a rs i d et r i m p a n e l( s e ep a g e2 0 - 5 ' l ) .
Removethe seat-backpad {A) from the seat-back
frame (B).On right seat-backwith centershoulder
belt,passthe centerbelt (C)through the hole in the
seat-backpad.
2. Removethe bolts,then removethe seat-back
striker(A).
FastenerLocations
) : Bolt,2
F
,-;1
8 x 1.25mm
22 N m 12.2kgl rn,
16 tbf.ft)
\
Removethe bolts,then removethe seat-backlatch
(A)from the seat-backframe (B),and releasethe
pivot pin {C)of the latch lever (D)from the seat'
backf rame.
3 . l n s t a l l t h es t r i k e ri n t h e r e v e r s eo r d e ro f r e m o v a l ,
and move the striker(A) up or down until it is
centeredin the seat-backlatch {B).
FastenerLocations
lnstallthe latch in the reverseorder of removal,and
make sure the seat-backlocksand unlocksproperly.
20-81
Seats
RearSeat-backCoverReplacement
NOTE:
. Takecare not to tear the seamsor damagethe seat
covers.
'1.
Removethe seat-back(seepage 20-80).
Removethe headrest.
5. On right seat-backiUsing a Torx T30 bit, remove
the bolts,then removethe belt holdertrim (A),and
removethe trim from the centerbelt (B).
FastenerLocations
) : Bolt,
A*\./-
6x1.0mm
9.8Nm
Pull up the latchcover (A)to teleasethe clips.then
remove it.
Fastener Locations
) : Clip,4
1W
Releasethe hook (A),and unzipthe seat-backcover
(B).The right seat-backis shown. the left seat-back
i ss i m i l a r .
4 . Pull up the outsideedge of the latch lever cover (A)
to releasethe clips, and releasethe cover from the
p i v o tp i n s( B )o f t h e l a t c hl e v e r{ C )w h i l e p u l l j n gt h e
latch lever.
Fastener Locations
D : Clip,2
i\r*
rJ
20-82
\
7. Pull backthe edge of the seat-backcover (A),and
r e l e a s et h e c l i p s{ B ) .
Pull backthe edge of the seat-backcover,and pull
out the seat-backframe {A) from the seat-backpad
{ B ) ,t h e n p u l l o u t t h e h e a d r e sgt u i d e( C )w h i l e
p i n c h i n gt h e e n d o f t h e g u i d e s a, n d r e m o v et h e m .
9. Removethe seat-backcover (A)from the seat-back
pad (B).On right seat-backwith centershoulder
belt, passthe centerbelt (C)through the hole in the
cover.
seat-bacl(
1 0 ,lnstallthe cover in the reverseorder of removal,
. To preventwrinkleswhen installinga seat-back
cover, make sure the materialis stretchedevenly
over the pad beforesecuringthe hooksand clips
. On right seat-back:When installingthe seat-back
frame to the pad, slip the centerbeltthrough the
hole in the seat-backcover and pad.
. Replaceany clips you removedwith new ones.
yvailable
I n s t a ltlh e m w i t h c o m m e r c i a l l a
upholsteryring pliers.
20-83
Seats
RearSeat CushionCoverReplacement
'1.
Removethe rear seat cushion (seepage 2O-80).
Releaseall the clips (A)from under the seat
c u s h i o n a, n d f o l d b a c kt h e s e a tc u s h i o nc o v e r( B ) .
4. Installthecover in the reverseorder of removal,
and note these items;
. To preventwrinkles,make surethe materialis
stretchedevenlyover the pad beforesecuring
t h ec l i p s .
. Replaceany clips {A) you removedwith new
o n e s .I n s t a ltlh e m w i t h c o m m e r c i a l l a
yvailable
u p h o l s t e r yr i n g p l i e r s( B ) .
B
Pull backthe edge of the seatcushioncover all the
way around,and releasethe clips (A),then remove
the seatcushioncover.
\
iw F
1.,
1L
ts+'
+.
i
1
l-,+
20-84
l
J
,+
l
r
l
Bumpers
Front BumperRemovaUlnstallation
NOTE:
. H a v ea n a s s i s t a nht e l py o u w h e n r e m o v i n ga n d i n s t a l l i n g
t h ef r o n tb u m p e r .
. Takecare not to scratchthe front bumper and body.
. Puton glovesto protectyour hands.
'L
Removethe front bumper as shown.
, n d n o t et h e s ei t e m s :
2 . I n s t a l l t h eb u m p e ri n t h e r e v e r s eo r d e ro f r e m o v a l a
. Make sure both front side markerlight connectorsare plugged in properly.
. Make sure the front bumper engagesthe hooksof the side spacersand upper beamson both sidessecurely.
. Replace
FastenerLocations
A ) , Screw, 2
B >: Screw,2
C>:Bolt.4
f
k/- '
{D[]
E>:Clip,2
D>:Clip,7
h
*S-
6
4
=$
t
ABSORBER
SIDESPACER
UPPERBEAM
LEFTFRONTSIDEMARKER
LIGHTCONNECTOR
' * D
;
e 3
INNER
FRONT
FENDER
e
BUMPER
ti-\
FEONTBUMPER
C l
I
A
E
FRONTAIR SPOILER
SPOILER
PLATE
AIR SPOILER
PLATE
6 x 1 . 0m m
9.8 N.m (1.0kgt.m,7.2lbf.ft)
20-85
Bumpers
RearBumperRemovaUlnstallation
NOTE:
' Havean assistanthelp you when removingand installingthe rear bumper.
. Takecare not to scratchthe rear bumper and body.
L R e m o v et h e r e a rb u m D e ra s s h o w n .
2. Installthe bumper in the reverseorder of removal,and note these items:
. Make sure both rear side marker light connectorsare pluggedin properly.
'Makesuretherearbumperengagesthehooksofthesidespacers,sidebrackets,andupperbracketsonboth
sidessecurely.
. Make sure the upper spacersof the rear bumper engagethe clips on the body securely.
Fastener Locations
A>:Bolt,2
/h-
\-P-
B)
: Screw, 2
ffiI"ut ^*
c >: Screw, 2
) : Clip,
?
ri)
XJ
\s
I
SIDEBRACKET
UPPERBRACKET
\
, 6 x 1 . 0m m
/ 9.eN.n
,/ 11.0kgl m,
1.2tbt.ttl
./
SIDESPACER
a
\
'-
:r
A
CAP
LEFTREARSIDEMARKER
LIGHTCONNECTOR
A
UPPERSPACER
D
REARBUMPER
20-86
Hood
Adjustment
'1.
Slightly looseneach hood hinge bolt,
2 . Adjustthe hood (A) alignmentin this sequence.
. A d j u s t t h e h o o d r i g h t a n d l e f t , a s w e al l s f o r w a r da n d r e a r w a r db, y u s i n gt h e e l o n g a t e dh o l e so n t h e h o o dh i n g e
(B).
. Turn the hood edge cushions(C),as necessary,to makethe hood iit flush with the body at the front and side
edges.
6x1.0mm
9.8 N.m
{1.0kgl.m,7.2 lbf.ftl
6x1.0mm
9.8 N.m
{1.0kgf.m,7.2lbf.ft}
3 . Adjustthe hood latch (D)to obtainthe proper height at the forward edge,and move the hood latch right or left
until the striker(E)is centeredin the hood latch.
Tighteneach bolt securely.
(contd)
20-87
Hood
Adjustment(cont'd)
5. Checkthat the hood opens properlyand locks
securely.
6. Apply body paint to the hinge mounting bolts and
a r o u n dt h e h i n g e s .
HoodSealReplacement
1 . Using a clip remover,detachthe clips,then remove
the hood seal (A).Takecare not to scratchthe hood.
Fastener
Locations
7. Apply multipurposegreaseto each locationof the
hood latch and hood hinge as indicatedby the
arrows.
I n s t a l l t h es e a li n t h e r e v e r s eo r d e ro f r e m o v a l a, n d
note these items:
. :I
20-88
HoodInsulatorReplacement
t e w i n d s h i e l dw a s h e rt u b e s( A ) .
FastenerLocations
'10
) : Clip,
H
t*'-&
,2V..=-'
(
\
Using a clip remover,detachthe clips. Releasethe
h o o k s( B ) ,t h e n r e m o v et h e h o o di n s u l a t o (r C ) .T a k e
care not to scratchthe hood.
I n s t a l l t h ei n s u l a t o irn t h e r e v e r s eo r d e ro f r e m o v a l ,
. Pushthe clips into placesecurely.
20-89
Hatch
Adjustment
1. Removethe support strut from each side (seepage 20-91).
2 . R e m o v e t h e C - p i l l a r t r i m f r o m e a c h s i d e ( s e e p a g e 2 0 - 5 ' l ) ,daonw
dn
p tuhl le r e a r p o n i o n o f t h e h e a d l i n e r ( s e e
page20-54).Takecare not to bend the headlinerexcessively.
3. Removethe reartrim panel (seepage 20-52).
4, Slightly looseneach bolt and nut.
5 . A d j u s t t h eh a t c h( A )a l i g n m e n it n t h e f o l l o w i n gs e q u e n c e .
. Adjustthe hatch hinges(B) right and left, as well as forward and rearward,using th e elongatedholes.
'Turnthehatchedgecushions(C),inoroutasnecessary,tomakethehatch(D).fitflushwiththebodyattheside
edges.
. Adjustthe fit betweenthe hatch and hatchopening by moving the striker(D).
8 x 1.25mm
22 N.m
{2.2kgf.m,16lbf.ft}
8 x 1.25mm
18 N.m 11.8kgf.m, 13 lbf.ft)
20-90
\
HatchSupportStrut Replacement
Tighteneach bolt and nut securely.
7 . Checkthat the hatchopens properlyand locks
securery.
Reinstallthe supportstruts securely.
1 . With the help of an assistant,use a flat-tip
screwdriver(A)to pry the supportstrut clips (B)
from each end of the supportstrut (C)at the hatch
and body, then releasethe supportstrut from the
pivot bolts (D).Do not removethe clips from the
supportstrut.
9 . R e i n s t a lal l l r e m a i n i n gr e m o v e dp a r t s .
1 0 .Apply multipurposegreaseto the pivot portion of
the hatch hinges{A) as indicatedby the arrows.
D
8 x 1.25mm
22 N.m(2.2kgf.m,16lbf ft)
2 . Set the clips (A) to the original position,then
reattachthe supportstrut (B)on the pivot bolts (C)
by pushingon the supportstrut.
20-91
Hatch
HatchWeatherstripReplacement
1 . R e m o v et h e h a t c hw e a t h e r s t r i{pA ) b y p u l l i n g o u t
on it.
t a r k{ B )o n t h e h a t c h
2 . L o c a t et h e p a i n t e da l i g n m e n m
weatherstrip.Allgn the paintedmark with the
alignmenttab in the the centerof the hatchopening,
p l l t h ew a y
a n d i n s t a l tl h e h a t c hw e a t h e r s t r i a
around in the directionshown. Make surethere are
no wrinklesin the weatherstrip.
3. Checkfor water leaks.
20-92
FuelFill Door
Adjustment
1. Removethe nut (A),and removethe fuel fill door
o p e ns p r i n g{ B ) .
5x0.8mm
1.8Nm
(0.18kgf.m,
1.3rbf.ft)
>t=-
7. Apply multipurposegreaseto each location
indicatedby the arrows.
8 . Apply body paint to the hinge mounting bolts and
around the hinges,
r'
2 . S l i g h t l yl o o s e nt h e h i n g em o u n t i n gb o l t s( A ) .
3 . A d j u s tt h e f u e lf i l l d o o r ( B )i n o r o u t u n t i li t ' sf l u s h
with the body, and up or down as necessaryto
a^rr.li7a
tha
n.nc
T i g h t e nt h e h i n g em o u n t i n gb o l t s .
5 . R e i n s t a l l t h feu e lf i l l d o o r s p r i n g .
6 . Checkthat the fuel f ill door opens properlyand
lockssecurely,and checkthat the rear of the door is
flush with the body.
20-93
ExteriorTrim
FrontGrille Replacement
1 . Removethe front bumper (seepage 20-85).
2 . Removethe front grille (A),Takecare not to scratch
the front bumper (B).
-1
-2
-3
-4
Removethe screws (C).
Removethe clips (D).
Releasethe bottom hooks(E)ofthe grille,
Pull out the boftom of the grille to releasethe
u p p e rh o o k s( F ) .
- 5 P u l lo u t t h e g r i l l et o r e l e a s et h e s l i t s( G ) f r o m
the ribs {H),then removethe grille.
FastqnErLocations
C >:Screw.4
D ) : Clip, 4
ll
-S---:
i")
F
3 . I n s t a l l t h eg r i l l ei n t h e r e v e r s eo r d e ro f r e m o v a l ,
a n d r e p l a c ea n y d a m a g e dc l i p s .
Reinstallthe front bumper.
20-94
\
Cowl CoversReplacement
1 . R e m o v et h e w i n d s h i e l dw i p e r a r m s ( s e ep a g e2 2 - 1 4 5 ) .
2. Removethe windshieldsidetrim from both sides(seestep 2 on page 20-19).
3. Pullthe hood rear seal (A) away from the cowl covers,then remove it, and using a clip remover,detachthe clips
(B)from the cowl covers.Takecare not to scratchthe cowl covers.
FastenerLocations
B> rClip,3 C>:Clip,8
:- ::::
= - --::;-:
4 . Detachthe clips (C)by carefullypulling the passenger'scowl cover {D) upward,to releasethe hooks{E),and pull
out the cover forward to releasethe hooks(F),then removethe cover.Takecare not to scratchthe body,
Detachthe clips (C)by carefullypulling the driver'scowl cover (G) upward.and pull out the cover forward to
releasethe hooks(H),then removethe cover.Takecare not to scratchthe body.
Installthecovers in the reverseorder of removal,and note these items:
. Pushthe clip portionsinto placesecurely.
. Reinstallboth windshieldside trim properly(seestep 26 on page 20-24).
20-95
ExteriorTrim
A-PillarCornerTrim Replacement
1 . Open the door.
Wrap a flat-tipscrewdriverwith protectivetape,
and apply protectivetape aroundlhe body to
preventdamage.Carefullyinserta flat-tip
screwdrivernext to the upper clip, and detachthe
c l i p b y p r y i n go n t h e A - p i l l a rc o r n e rt r i m ( A ) .T a k e
care not to scratchthe body and relatedparts.
5 . R e p l a c ea n y d a m a g e dc l i p s .
H o l dt h e t r i m u p , a n df i t t h e u p p e rc l i p a n d l o w e r
c l i p si n t ot h e h o l e si n t h e b o d y ,t h e n p u s ho n t h e
t r i m u n t i lt h e c l i p ss n a pi n t op i a c e .
FastenerLocation
3 . Closethe door half-way.
Pullthe A-pillercornertrim (A) out to detachthe
lower clips,then removethe trim.
FastenerLocations
20-96
\
RoofMolding Replacement
1 . Apply protectivetape to the body (A).Using a
flat-tipscrewdriverwrapped with protectivetape
(B),pry up on the roof molding (C).Takecare not to
scratchthe bodv.
4, Pull up and releasethe rear bracket(A)from the pin
(B),then removethe roof molding (C).
..:.::.l.
g
5 . Installthe molding in the reverseorder of removal,
. T a k ec a r en o t t o d a m a g et h e w i n d s h i e l dm o l d i n g .
. Make sure the roof molding is installedsecurely.
Pull up and slidethe roof molding to releasethe
front bracket(D)from the pin (E).
Pull up the front portion of roof molding.
20-97
ExteriorTrim
RearLicenseTrim Replacement
1. Removethe hatch lower trim panel (seepage 20-
3 . F r o mi n s i d et h e h a t c h ,r e l e a s et h e c l i p s( A , B ) w h i l e
h o l d i n gt h e r e a rl i c e n s et r i m ( C ) ,t h e n r e m o v el h e
trim, Takecare not to scratchthe hatch.
FastenerLocations
2. On insidethe hatch.removethe bolts securingthe
r e a rl i c e n s et r i m ( A )a n d h a t c hl o c kc y l i n d e r( B ) .
FastenerLocations
A>:Clip,2 B>:Clip.2
cHl
\ ! -
€:t+
> : Bolt,2
-)
, nd
note these rtems:
6x1.0mm
9.8 N.m (1.0kgf.m,7.2lbf.ftl
20-98
. Pushthe clip portionsinto placesecurely.
\
HatchSpoilerReplacement
'l.
Removethe hatch upper trim (seepage 20-53).
2. Removethe high mount brakelight (seepage2282).
4 . F r o mi n s i d et h e h a t c h ,r e l e a s et h e c l i p s ,w h i l e
p u l l i n gt h e h a t c hs p o i l e r( A )a w a y ,a n d r e l e a s et h e
fasteners(B),then removethe spoiler.Takecare
not to scratchthe body.
FastenerLocations
> : C l i p2.
3. From insidethe hatch,removethe bolts {A} and
n u t s( B ) .
t
Fastener Locaiions
A>: Bolt,2 Bar Nut,
fi'f$t-uLt*
/,fl
v_/
$. A
5 . I n s t a l l t h es p o i l e ri n t h e r e v e r s eo r d e ro f r e m o v a l ,
5x1.0mm
9.8Nm
(1.0kgf.m.7.2lbf.ft)
R e p l a c ea n y d a m a g e dc l i p s .
Replaceany damagedfasteners.Before
installingthe fastenerto the spoiler,cleanthe
spoilerbonding surfacewith a sponge
d a m p e n e di n a l c o h o l G
r ith
. l u et h e f a s t e n e w
a d h e s i v et a p e( 3 M 5 6 7 1 ,o r e q u i v a l e n t ) t toh e
spoiler.
Pushthe clip and fastenerportions into place
securely.
20-99
ExteriorTrim
EmblemReplacement
NOTE:When removingthe emblem,take care not to scratchthe body.
1. To removethe front
"H" emblem and front type emblem, removethe front bumper (seepage 20-85)
2. Cleanthe bonding surfacewith a spongedampenedin alcohol.After cleaning,keepoil, grease,and water from
getting on the surface.
3 . A p p l yt h e e m b l e m ,w h e r es h o w n .
. Wheninstalling
t h e s i d ei - V T E Ce m b l e mo n t h e b o d y ,a l i g nt h e a p p l i c a t i otna p ew i t h t h e e d g eo f t h e w h e e la r c h ,
then pressthe emblem into place,and removethe applicationtape.
. ' 0 3 m o d e l :W h e n i n s t a l l i n g
t h e L E Ve m b l e mo n t h e q u a r t e rg l a s s ,a l i g nt h e a p p l i c a t i o tna p ew i t h t h e e d g eo f t h e
, n d r e m o v et h e
b l a c kc e r a m i ca n d a l i g n m e n m
t a r ko n t h e q u a r t e rg l a s s t, h e n p r e s st h e e m b l e mi n t o p l a c e a
a p p l i c a t i o tna p e .
FRONTTYPEEMBLEM
FBONT"H" EMBLEM
FRONT"H" EMBLEMBASE
i
FBONTGRILLE
SCREWS
FRONTSi EMBLEMPLATE
PUSHNUTS
PINS
FRONTGRILLE
20-100
FRONTGRILLE
REARCIVICEMBLEM
LEVEMBLEM
(Leftsideonly)
('03model)
REARVERSIONEMBLEM
SIDE|-VTECEMBLEM
REAR"H" EMBLEM
Unit: mm {in.l
Adhesivetape:
3M 4213E,o. equivalent
Thickness:0.8mm (0.03in.)
REAR"H'' EMBLEM
APPLICATION
TAPE
Edoeol the blackceramic.
LEVEMBLEM
Ontoinsideface
Align.
of the guarterglass.
HATCHLINE
REARLICENSE
TRIM
REARsi EMBLEM
REARSiR EMBLEM
(Canada)
34
11.3)
, ilg
(1.93)
I
=-t
.,!!ll,'nt
(1.s31
50
{'!,9?)
CIVICEMBLEM
E d g eo f t h e
hatch.
ADHESIVETAPE
SIDEi-VTECEMBLEM
Left Side:
.
SIDEi.WEC
EMBLEM
Edge of the
hatch.
Right Side:
63 (2.5)
114(4.49)
F.l^6
^l
rh-
wheelarch.
.=4,
y'
Li.Est
Edgeof the
wheel arch.
APPLICATION
TAPE
BODY
LINE
BODY
LINE
112
o"f,r,ao.o"
(5'5s)
TAPE
4. After installingthe front "H" enblem and front type emblem, reinstallthe front bumper.
20-101
Fenderwell
FrontInnerFenderReplacement
NOTE:Takecare not to scratchthe body.
1, Removethe front inner fender (A).
-1 On the backofthe wheel arch,removethe screws(B).
- 2 F r o mu n d e r t h e f r o n tb u m p e r ( C )r, e m o v e t h e s c r e w( B )s e c ur i n gt h e f r o n t b u m p e r .s p l a s hs h i e l d( D ) ,a n d f r o n t
inner fender,and removethe clip (E)securingthe front air spoiler,front bumper,and front inner fender.
- 3 F r o m t h e w h e e la r c h ,r e m o v et h e c l i p s{ F ,G ) s e c u r i n gt h e f r o n t i n n e rf e n d e r( a n ds p l a s hs h i e l d )o n t h e b o d y .
- 4 R e l e a s teh e h o o k( H )o f t h e s p l a s hs h i e l d , t h e nr e m o v e t h e f r o n it n n e r f e n d e r .
FastenerLocations
B):Screw,4
E>:Clip,1
0*€
,ws
F > : C l i p ,1
G):Clip,8
2. Installthe inner fender in the reverseorder of removal,and note these items:
20-102
Front FenderFairingReplacement
1 . Removethe front inner fender as necessary(see
p a g e2 0 - 1 O 2 1 .
Open the front door. From outsidethe door,
r e m o v et h e u p p e rc l i p ( A ) ,a n d f r o m i n s i d et h e d o o r ,
removethe lower clip (A) securingthe front fender
f a i r i n g( B )a n d f r o n tf e n d e r( C ) .
FastenerLocations
3. From the wheel arch, removethe clip (A),and
releasethe clip (B),then removethe front fender
f a i r i n g( C ) .
FastenerLocations
A > : C l i p1,
B > : C l i p1,
J*.' -@
A>:Clip,2
J<a-'
4 . Installthe fender fairing in the reverseorder of
\
. R o u t et h e s i d et u r n s i g n a l i g h t h a r n e s s ( A )
through the slit (B)of the front fender fairing (C).
t h e c l i p so f t h e d o o r u p p e ra n d
lower ponions, installthe front fender fairing (A)
to the front fender (B) properlyas shown.
. Pushthe clips into placesecurely.
o --____--
20-103
Fenderwell
FuelPipeProtectorReplacement
1 . R e m o v et h e c l i p s ,t h e n r e m o v et h e f u e l p i p e
RearAir Outlet Replacement
1 . R e m o v et h e r e a rb u m p e r( s e ep a g e2 0 - 8 6 ) .
protector(A).Takecare not to scratchthe body.
Fastener Locations
r n e r e a ra t r
the body.
> : Clip,4
4
I n s t a l l t h ep r o t e c t o irn t h e r e v e r s eo r d e ro f r e m o v a l ,
. P u s ht h e c l i p si n t o p l a c es e c u r e l v .
20-104
I n s t a l l t h ea i r o u t l e t sb y p u s h i n go n t h e h o o k
p o r t i o n su n t i l t h eh o o k ss n a pi n t o p l a c e .
(
Openers
HATCHLOCK
CYLINDER
page20-1'l1
Replacement,
HATCHHANDLE
Replacement,
p a g e2 0 - 1 1 0
HATCHLATCH
Replacement,page20'110
FUELFILLDOORLATCH
page20-107
FUELFILLDOOROPENEBCABLE
page 20-107
Replacement,
FUELFILLDOOROPENER
Replacement,page20-109
I{OOD RELEASEHANDLE
page20-'106
HOODOPENERCABLE
Replacement,page20-106
z)-105
Openers
Hood OpenerCableReplacement
NOTE:
. Takecare not to scratchthe body and relatedparts.
l. Removethese items:
. Front bumper (seepage 20-85)
. F r o n ti n n e rf e n d e r ,l e f t s i d e ( s e e p a g e 2 0 - 1 0 2 )
. Kick panel,left side (seepage 20-50)
2. Disconnectthe hood openercable(A) from the hood latch {B) (seepage20-108),and removethe bolts (C),then
removethe hood releasehandle(D)from the body.
FastenerLocations
C>:Bolt,2
@m
6x1.0mm
9,8 N.m
11.0kgl.m, 7.2 lbl.ft)
E >:Clip,3
l,.t'.
W:"
Using a clip remover,detachthe clips (E),and removethe grommet (F)from the body, then removethe hood
openercablefrom the vehicle.Takecare not to bend the cable.
4 . I n s t a l l t h ec a b l ei n t h e r e v e r s eo r d e ro f r e m o v a l a
, n d r e p l a c ea n y d a m a g e dc l i p s .
20-106
FuelFill Door OpenerCableReplacement
SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations(seepage 23-13)and the precautions
and procedures(seepage 23-14)in the SRSsectionbeforeperformingrepairsor service.
NOTE;
. Takecare notto scratchthe body and relatedparts.
1. Removethese items from the left side of the vehicle:
. D o o rs i l l t r i m { s e ep a g e2 0 - 5 0 )
. R e a rs i d et r i m p a n e l( s e ep a g e2 0 - 5 1 )
2 . Pullthe carpetbackas necessary(seepage 20-55).
5.
Disconnectthe fuel fill door openercable (A)from the opener(B) (seestep 3 on page 20-109).
FastenerLocations
C > : C u s h i o n t a p e1,
D > : C l i p 1,
E > : Clip,2
4 . K C m o d e l :R e m o v e t h el e f tm i d d l ef l o o rc r o s s - m e m b egru s s e t( s e ep a g e2 0 - 1 1 3 ) .
5 . R e m o v et h e c u s h i o nt a p e{ C ) ,a n d r e l e a s et h e c a b l ef r o m t h e c l i p s( D ,E ) .
6 . R e m o v e t h e f u efli l l d o o r l a t c h( F ) f r o m t h eb o d y b y t u r n i n gi t 9 0 ' .
7. Removethe fuel fill door openercablefrom the vehicle.Takecare not to bend the cable
8 . I n s t a lt lh e o p e n e r c a b l e i n t h e r e v e r s e o r d e r o f r e m o v a l , r e p l a c e t h e c u s h i o n t a p e , a n d r e p l a c e t h e c l i p i f i t i s
oamageo.
20-107
Openers
Hood LatchReplacement
NOTE:
. Takecare not to scratchthe body.
1. Removethe bolts,then removethe hood latch (A)
from the body.
FastenerLocations
> i Bolt,3
--------------'
6x1.0mm
9.8 N.m (1.0kgf.m,7.2lbf.ft)
Disconnectthe hood openercable (B)from the
hood latch.Takecare not to bend the cable.
20-108
Installthe hood latch in the reverseorder of
. Apply multipurposegreaseto each locationof
the hood latch indicatedby the arrows.
. Make sure the hood openercable is connected
properly.
. Make sure the cableactuatesthe latch beforeyou
closethe hood,
. Adjustthe hood latchalignment(seestep 3 on
page 20-87).
. M a k es u r et h e h o o do p e n sp r o p e r l ya n d l o c k s
securely.
FuelFillDoorOpenerReplacement
1 . Using a flat-tipscrewdriverwrapped with
protectivetape, detachthe hooks(A) by prying the
front side cap (B),then remove it from the left door
s i l l t r i m ( C ) ,a n d l o o s e nt h e b o l t ( D )s e c u r i n gt h e
f u e lf i l l d o o r o p e n e r .
6x1.0mm
9.8 N.m
11.0kgf m,7.2 lbf.ft)
2. Removethe left door sill trim (seepage 20-50i.
3 . R e m o v et h e o p e n e r( A l f r o m t h e b o l t{ B ) .
4. Disconnectthe fuel fill door openercable (A),then
removethe openeriB). Takecare not to bend the
c ao t e .
5 . Installthe opener in the reverseorder of removal,
lMakesure the openercable is connected
properly.
lvlakesure the fuel fill door opens properlyand
lockssecurely.
20-109
Openers
HatchHandleReplacement
HatchLatchReplacement
'1.
. Hatchlower trim panel (seepage 20-53)
. Rear licensetrim panel (seepage 20-98)
2. Removethe rearwindow wiper motor (seepage
22-1461.
3. Disconnectthe hatch o p e n e rc a b l e1 A ) f r o mt h e
h a t c hh a n d l e( B ) ,a n d removethe nuts.
Fastener Locations
a : Nut,
6x1.0mm
9.8N.m
(1.0 kg{.m,7 2 tbt.{t\
Removethe hatch lowertrim panel (seepage 2053).
2. Disconnectthe hatch openercable (A),cylinder rod
(B).hatchactuatorconnector(C).and hatch latch
switch connector{D).and detachthe hatch actuator
connectorand hatch latch switch connectorfrom
the hatch.
FaslenerLocations
) : Bolt,3
ttb
()rI
a
,t.
4. Pull outthe hatch handle(A),then remove it.
-
L
i-'-3;li9#k g tm , 7 . 2 l bfft l
11,0
R e m o v et h e b o l t s ,t h e n p u l l t h eh a t c hl a t c h( E )o u t ,
then remove it.
I n s t a l l t h el a t c hi n t h e r e v e r s eo r d e ro f r e m o v a l a, n d
notethese items:
. Make sure each connectoris plugged in properly,
and the rod and cableare connectedproperly.
. l\4akesure the cable actuatesthe latch beforeyou
c l o s et h e h a t c h .
. Make sure the hatch opens properlyand locks
securely.
I n s t a l l t h eh a n d l ei n t h e r e v e r s eo r d e ro f r e m o v a l .
lMake
surethe hatchopenercableis connected
securely.
M a k es u r et h eh a t c ho p e n sp r o p e r l y .
20-110
HatchLockCylinderReplacement
NOTE;Put on glovesto protectyour hands.
'1.
Removethese items:
. Hatchlower trim panel (seepage 20-53).
. Rearlicensetrim (seepage 20-98).
4. Installthe lock cylinder in the reverseorder of
. Make sure the rod is connectedproperly.
. Make sure the hatchopens properlyand locks
securely.
2. Disconnectthe cylinder rod (A)
- . .
From outsidethe hatch,removethe bolt securing
the lock cylinder{A}.From insidethe hatch,pull the
l o c kc y l i n d e ro u t b y r e l e a s i n tgh e h o o k( B ) .
Fastener Location
6 x 1 . 0m m
9.8Nm
(1.0kgf m,7.2lbt.ftl
> : Bolt,1
rS'l-.
u-ar
*/t
20-111
Frame
SubframeReplacement
SubframeTorque
NOTE:After looseningthe subframemounting bolts,be sureto replacethem with new ones.
Referenceholesalignment:
SUBFRAME
REFERENCE
HOLE
( B o d yS i d e )
INSTALLATION
REFERENCE
HOLE
(Subframe
side)
INSTALLATION
REFERENCE
HOLE
SCREWDRIVER
or TAPEREDPUNCH
FRONTSUSPENSION
To body.
INSTALLATION
REFERENCE
HOLE
To body.
I
n
E
SPECIAL
' 1 4x 1 . 5mBOLTS
m
103 N.m
(10.5kgf.m,75lbf.ft)
Replace.
20-112
FrameStiffener,Brace,and GussetReplacement
FrameStiffener,Brace,and GussetTorque
NOTE:When installingthe middle floor cross member braceor gussets,torque the mounting hardwarein the
following sequenceto avoid damageto the quarterpanel.
MIDDLE
FLOOR
CROSS-MEMgER
BRACE/GUSSET
SIDEFRAMESTIFFENER
I
8 x 1 . 2 5m m
29 N.m
(3.0kgf m,22 lbf ft)
To body.
model:
Canada
U.S.model:
1 0x 1 . 2 5m m
38 N.m
(3.9kgf.m.28lbf.ftl
MIODLE
FLOOR
CROSS-MEMBER
BRACE
..
__!:::-| -
1 0 x 1 . 2 5m m
38 N m (3.9 kgt.m, 28 lbf.ftl
MIDDLE
FLOOR
CROSS.MEMBER
GUSSET
1 0 x 1 . 2 5m m
38Nm
(3.9kgf.m,28 lbl.ftl
20-113
Frame
FrameRepairChart
Top view
Unit:mm {in.}
o: Inner diametel
a
b1
b2
b3
cl
c2
c3
Forsublrameo1510.59)
Forenginemount e13 (0.511
Forenginemount o13 (0.51)
Forenginemount rl3 (0.51)
Formanualtransmission
mouoto13{0.5'
mounto13 10.5'
Formanualt.ansmission
mo!nt d13{0.51)
o
I
g
h
Fordampermounts11.5{0.45}
For damper centero78 (3.07)
Fordampermounts11.5(0.451
Fordampeimountd11.510.45)
Forsubframeo15 {0.591
Localinghole s25 {0.98}
Locatingholee50 (1.97)
\
VEFTICAL
UNE
20-114
K
m
n
p
q
Locatinghole d25 (0.981
Fortrailing.rm rl3 10.51)
Locatinghole o25 (0.981
Locatinghole s20 (0.79)
Trailingarm center
Reardampercenter
Forupperarm o13 (0.51)
t1, t2
x1
x2
Fortrailingarm d13 (0.511
For upper arm bracketcenterrl5 {0.59)
Locatingholes13 (0.51)
Foruppe.arm o13{0.511
For rear lower arm cent€r
Locatingholes50 (1.97)
Locatinghole s20 (0.79)
Locatinghole o25 (0.981
(cont'd)
20-115
Frame
I
FrameRepairChart(cont'dl
Sideview
Unitrmm {in.)
o: InnerdiameteJ
a
b1
b2
b3
cl
c2
c3
For subframe015 {0.59}
Forenginemount o13 (0.511
Forenginemount 01310.51)
Forenginemount 113(0.511
mount 013{0.51)
Formanualtrensmission
mount 613{0.51}
Formanualtrrnsmissionmounro13{0.51}
o
e
I
s
h
i
Fordampermounto11.5{0.45)
For damper centerr78 {3.07}
Fordampermounto11.5(0.45)
Fordampermountr11.5{0./t5l
Forsubtrameel5 10.591
Locatinghole o25 (0.98)
Locatinghole s 11.97)
\
SECTIOiIAA
BASE
UNE
trr2xt.6
l
VERTICAI
LINE
20-116
Frame
I
FrameRepairChart(cont'dl
Sideview
Unitrmm {in.)
o: InnerdiameteJ
a
b1
b2
b3
cl
c2
c3
For subframe015 {0.59}
Forenginemount o13 (0.511
Forenginemount 01310.51)
Forenginemount 113(0.511
mount 013{0.51)
Formanualtrensmission
mount 613{0.51}
Formanualtrrnsmissionmounro13{0.51}
o
e
I
s
h
i
Fordampermounto11.5{0.45)
For damper centerr78 {3.07}
Fordampermounto11.5(0.45)
Fordampermountr11.5{0./t5l
Forsubtrameel5 10.591
Locatinghole o25 (0.98)
Locatinghole s 11.97)
\
SECTIOiIAA
BASE
UNE
trr2xt.6
l
VERTICAI
LINE
20-116
m
p
q
Locatinghole o25 {0.98)
Fortrailingarm 613 {0.511
Locatinghole d25 {0.98}
Locatinghole r20 {0.79)
Trailingarm center
Reardamper centel
Forupperarm o13 (0.51)
11,t2
xl
x2
Fortrailingarm s13 {0.51}
For upper arm bracketcenter o15 {0.591
Locatingholeo13{0.51}
Forupperarm d13{0.51)
For rear lower arm centei
Locatingholeo50{1.97}
Locatinghole a20 {0.79}
Locetinghole s25 (0.98)
20-117
HVAC(Heating,
Ventilation,
andAir Gonditioningl
HeatingandAir Conditioning
21-2
SpecialTools
Comoonent
Location
lndex ........z t-'5
A/CService
Tiosand
Precautions
z t-o
A,/CRefrigerant
Oil
ReDlacement
z t-o
Troubleshooting
General
lnformation
21-8
Index .......21-9
DTCTroubleshooting
1ndex..............
21-10
21-11
SystemDescription.....................
CircuitDiagram
21-14
D T CT r o u b l e s h o o t i n. .g. . . . . . . . . . .z. .t .- .t .o
Recirculation
ControlMotor
..........
21-25
HeaterControlPowerandGround
Troubleshooting
........21-27
Circuits
Condenser
FanCircuit
Troubleshooting
......................
21-28
Fans
Radiator
andCondenser
CommonCircuit
......................
21-29
Troubfeshooting
Compressor
ClutchCircuit
T r o u b l e s h o o t i n. .g. . . . . . . . . . . . . 2
. .1. .-.3. .0
A,/CPressureSwitchCircuit
......................
21-32
Troubleshooting
Air Mix ControlMotor
.............
21-34
TestandReolacement
ModeControlMotor
.............
21-35
TestandReplacement
Recirculation
ControlMotor
.............
21-36
TestandReolacement
Evaporator
Temperature
Sensor
andTest .............
21-31
Reolacement
Test .................
21-38
PowerTransistor
HeaterControlPaneland
PushSwitchAssemblv
RemovalandInstallation........21-38
DustandPollenFilter
Reolacement
..21-39
BlowerUnitRemovaland
......21-39
lnstallation
BlowerUnitComoonents
R e D l a c e m e .n. t. . . . . . . . . . . . . . . . .2. .1. .- .4. 1. . .
Evaporator
Core
..21-42
Reolacement
*HeaterUnit/Core
..21-43
ReDlacement
HeaterValveCable
.....21-46
Adjustment
..........
21-47
CompressorReplacement
21-48
Comoressor
ClutchCheck ..........
Comoressor
ClutchOverhaul.....21-49
ThermalProtector
Compressor
R e o 1 a c e m e.n. .t . . . . . . . . . . . . . . . .2. .1. .- .5. 1. . .
ReliefValve
Comoressor
R e o l a c e m e n. .t. . . . . . . . . . . . . . . . .2. .1. .- .5. 1. . .
21-52
Reolacement............
Condenser
Recovery
..................
21-53
Refrigerant
......................
21-54
SystemEvacuation
21-55
SystemCharginS.........................
21-56
LeakTest..................
Refrigerant
21-57
A,/CSvstemTests ........................
HVAC{Heating,Ventilation,and Air Conditioning)
SpecialTools
Ret.No.
o
Tool Number
DescriDtion
07sAz-001000A
BackprobeSet
---2
att-,,/'Tt
e^t"'
T
21-2
KCe
"-t--'
Otv
2
Heatingand Air Gonditioning
VALVE
SERVICE
{LOW.PRESSUBE
SIDEI
EVAPORATOR
CORE
(Built-in
theheaterunit)
B e p l a c e m epnat ,g e2 1 4 2
SERVICE
VALVE
{HIGH-PRESSURE
SIDEI
RECEIVER/DRYER
COMPRESSOR
Beplacement,page21 47
CONOENSEB
ClutchCheck,page21-48
page 21-52
Replacement,
C l u t c hO v e r h a u lp, a g e2 1 - 4 9
ThermalProtectorCheck,page21-48
page21 51
ThermalProtectorReplacement,
R e l i eV
f a l v eR e p l a c e m e npta, g e2 1 5 1
Heatingand Air Conditioning
ComponentLocationIndex(cont'dl
RADIATORFAN RELAY
Test,page22-51
CLUTCHRELAY
Tesl, page 22-51
MOTORRELAY
Test, page 22-5I
'-t
/l
l-
I
T
I
-::--
t_]]l
BOX
UNDER.HOOD
FUSE/RELAY
-
-l
-
CONDENSERFAN
Test, page 22-51
\
.\\
... A/C PRESSURE
SWITCH
-
RADIATORFAN
CONOENSERFAN
21-4
HEATER
UNIT/CORE
page21-43
Beplacement,
BLOWEN
UNIT
page21-39
Removal
andInstallation,
BLOWERUNITCOMPONENTS
page21-41
Replacement,
HEATERVALVECABLE
page21-46
Adjustment,
DUSTAND
POLLEN
FILTER
page21'39
Replacement,
RECIRCULATION
CONTROLMOTOR
Test,page21-36
page21-36
Replacement,
MODE CONTROLMOTOR
Test,page21-35
page21-35
Replacement,
POWERTRANSISTOR
Test,page 21-38
AIR MIX CONTROLMOTOR
Test,page21'34
page21'34
Replacement,
EVAPORATORTEMPERATURE
SENSOR
page 21-37
Replacement,
Test,page21-37
PUSH SWITCHASSEMBLY
Removaland Installation,page21'38
HEATERCONTROLPANEL
RemovalandInstallation,page21 38
21-5
A/C ServiceTips and Precautions
A/C Refrigerant
Oll Replacement
R e c o m m e n d eP
d A Go i l : K E I H I NS P 1 0 :
Compressedair mixed with R-134aforms a
combustible
vapor.
T h e v a p o rc a n b u r n o r e x p l o d ec a u s i n gs e r i o u s
injury.
Never use compressedair to pressuretest
R - 1 3 4 as e r v i c ee q u i p m e not r v e h i c l ea i r
c o n d i t i o n i n sg y s t e m s .
A i r c o n d i t i o n i n gr e f r i g e r a not r l u b r i c a nvt a p o r
can irritateyour eyes,nose,or throat.
Be carefulwhen connectingserviceequipment.
Do not breatherefrigerantor vapor.
T h e a i r c o n d i t i o n i n sg y s t e mu s e sH F C - 1 3 4(aR - 1 3 4 a )
r e fr i g e r a n at n d p o l y a l k y l e n e g l y c(oPl A G )r e fr i g e r a n ot i l ,
w i t h C F C ' 1 2( R - 1 2r)e f r i g e r a n t
w h i c ha r e n o t c o m p a t i b l e
r e f r i g e r a not r m i n e r a l
l i l .D o n o t u s eR - ' 1 2
andminerao
oil in this system,and do not aftemptto use R 12
s e r v i c i n ge q u i p m e n td; a m a g et o t h e a i r c o n d i t i o n i n g
t ill result.
s y s t e mo r y o u r s e r v i c i n ge q u i p m e nw
U s eo n l y s e r v i c ee q u i p m e ntth a t i s U . L . - l i s t eadn d i s
certifiedto meet the requirementsof SAE J2210to
r e m o v eR - 1 3 4 af r o m t h e a i r c o n d i t i o n i n sg y s t e m .
lf accidentalsystem dischargeoccurs,ventilatethe
w o r k a r e ab e f o r er e s u m i n gs e r v i c e .
. P/N38897-Pl3-A01AH:'120m0 i4 fl oz)
. P/N38899-P13'A01:
40 m0 i1 1/3fl oz)
Add the recommendedrefrigerantoil in the amount
listedif you replaceany of the following parts.
. T o a v o i dc o n t a m i n a t i o nd.o n o t r e t u r nt h e o i l t o t h e
c o n t a i n eor n c ed i s p e n s e da, n d n e v e rm i x i t w i t h o t h e r
refrigerantoils.
. l m m e d i a t e la
y f'teu
r s i n gt h e o i l , r e i n s t a l l t h e
c a po n
the container,and seal it to avoid moisture
aosorpron.
. D o n o t s p i l lt h e r e f r i g e r a not i l o n t h e v e h i c l e i;t m a y
damagethe paint. lf it gets on the paint,wash it off
immediately.
, . 9l m p . o z )
C o n d e n s e r. . . . . . . . . . . 2m5A\ 5 1 6t l . o z 0
'1.4
E v a p o r a t o r. . . . . . . . .4. 5
. m0 (1113Il.oz, lmp.oz)
'10
L i n eo r h o s e . . . . . . . . . m 0 { 1 / 3f l . o z , 0 . 4l m p . o z )
'10
R e c e i v e r / D r y e.r. . . m 0 ( ' 1 1f3l . o z , 0 . 4l m p . o z )
Leakagerepair ....25 m0,1516
Il oz,0.9 lmp.oz)
. .o rc o m p r e s s orre p l a c e m e n l ,
C o m p r e s s o r. . . . . . . F
s u b t r a ctth e v o l u m eo f o i l d r a i n e d
from the removedcompressorfrom
1 3 0m 0 ( 4 1 / 3 f l . o z4, . 6 l m p . o z )a, n d
d r a i nt h e c a l c u l a t e vdo l u m eo f o i l
'130
f rom the new compressor:
m0
i . 4 1 1 f3l . o z , 4 . 6l m p . o z ) V o l u m eo f
removedcompressor= Volume to
d r a i nf r o m n e w c o m p r e s s o r .
R - 1 3 4 as e r v i c ee q u i p m e not r v e h i c l ea i r c o n d i t i o n i n g
systemsshould not be pressuretested or leaktested
withcompressed
air.
NOTE:Evenif no oil is drainedfrom
the removedcompressor,don't
d rain more than 50 m0 \1 2/3 fl.oz,
' 1 . 8l m p
o z ) f r o mt h e n e w
compressor.
A d d i t i o n ahl e a l t ha n d s a f e t yi n f o r m a t i o nm a y b e
obtainedfrom the refrigerantand lubricant
manufacturers.
. Always disconnectthe negativecablefrom the
parts.
b a t t e r yw h e n e v e r e p l a c i n ga i r c o n d i t i o n i n g
. Keepmoistureand dirt out of the system.When
d i s c o n n e c t i nagn y l i n e s ,p l u go r c a pt h e f i t t i n g s
immediately;don't removethe caps or plugs until
iust be{oreyou reconnecteach line.
' B e f o r ec o n n e c t i n g
a n y h o s eo r l i n e ,a p p l ya f e w d r o p s
of relrigerantoil to the O-ring.
. W h e nt i g h t e n i n go r l o o s e n i n ga f i t t i n g ,u s ea s e c o n d
wrench to supportthe matchingfitting.
. W h e n d i s c h a r g i ntgh e s y s t e m u
, s ea R - ' 1 3 4 a
station;don't
refrigerantrecovery/recycling/charging
releaserefrigerantinto the atmosphere.
21-6
r\
REMOVED
COMPBESSOR
A
l i
\..
rJ
\tb
NEW
COMPRESSOR
/- a\
i
\
t
l
r /
\:)-) -/
'r:l_
_ 0L
I "o*tttu" _*lH
,lEL.-
I I I DRAINING
A: 130 m0 {4 l/3 tl.oz,4.6lmp.oz)
I voLUME
],^
\
RECEIVER
LINEA
RECEIVER/DRYER
CONDENSER
LINE
Dischargehoseto the compressor{6 x 1.0 mm) : 9.8 N.m {1.0kgf.m,7.2 lbl.ft}
Dischargehoseto the condenser(5 x 1.0mml : 9.8 N.m {1.0kgt.m,7.2 lbf ft)
Condenserline to the condenser(6 x 1.0mm) : 9.8 N.m {1.0kgf,m,7.2 lbt.ft}
Condenserfine to the receiver/dryer{6 x 1.0mm} : 9.8 N.m (1.0kgt.fi,7.2lbt.ltl
ReceiverlineAtothe receiver/dryer{6 x 1.0mm} : 9.8 N.m {1.0kgf.m. 7.2 lbf.ft}
Receiverline A to the receiveiline B : 13 N.m (1.3kgr.m,9.4 lbf.ft)
Receiverline B and the suctionline to the evaporator(6 x 1.0mm) :9.8 N.m 11.0kgf.m,7,2 lbf.ft)
Suction line to the suction hose : 3l N m {3.2 kgf.m, 23 lbf ftl
Suctionhose1o the compressor(6 x 1.0mm) : 9.8 N.m 11.0kgf.m.?.2 lbf.lt)
Compressorto the compressor b.acket {8 x 1.25 mm) : 22 N m {2.2 kgt.m, 16 lbf.ft)
Compr€ssorbracketto the engineblock {10 x 1.25mm} : ,14N.m 14.5kgf.m,33 lbf.ft)
21-7
How to Retrievea DTC
The heatercontrol panel has a self-diagnosisfunction.To run the self-diagnosisfunction,do the following:
1 . T u r nt h e f a n s w i t c hO F F .
2. Pressandholdthe recirculationcontrol switch andthe rearwindow defoooerswitch down.
3 . T u r nt h e i g n i t i o ns w i t c ho N { l l i .
4. Releaseboth switches.The recirculationindicatorand the rearwindow defoggerindicatorcome on. The
recirculationindicatorgoes off 3 secondslater and the Ay'Cindicatorcomes on. then the self-diagnosiswill begin.
About 10 secondslater,the self-diagnosiswill finish and the A,/Cindicatorgoes off.
.lfanytroubleisfound.therecirculationindicatorblinksthediagnostictroublecode(DTC)toindicateafaulty
circuil or comDonent.
. lf the system is OK, the recirculationindicatorstaysoff.
atc INOICATOR
BECIRCULATION
INDICATOB
/A\
-:@
RECIRCULATION
CONTROLSWITCH
REARWINDOW
INDICATOR
OEFOGGER
@r
REARWINDOW
DEFOGGER
SWITCH
Examole of DTC indication Pattern IDTC7)
DTC 7
Recirculation +
indicatot
Recirculation+
indicalor
go6s oft
----->
Reseiting the Selt-diagnosis Function
Turn the ignition switch OFFto cancelthe self-diagnosisfunction.After completingrepairwork, run the self-diagnosis
f u n c t i o na o a i nt o m a k es u r et h a t t h e r ea r e n o o t h e rm a l f u n c t i o n s .
21-8
DTC{Recirculation
IndicationBlinks)
7
8
9
10
11
12
13
14
Detection ltem
A n o p e n i n t h e a i r m i x c o n t r o lm o t o rc i r c u i t
A short ln the air mix control motor circuit
A p r o b l e mi n t h e a i r m i x c o n t r o l i n k a q ed, o o r ,o r m o t o r
An open or shon in the mode control motor circuit
A p r o b l e mi n t h e m o d ec o n t r o l i n k a g ed, o o r s ,o r m o t o r
A p r o b l e mi n t h e b l o w e rm o t o rc i r c u i t
A problem in the EEPROMin the heatercontrol panel;
the control oanel must be reolaced
An ooen in the evaDoratortemDeraturesensorcircuit
A short in the evaDoralortemoeraturesensorcircuit
Page
( s e ep a q e2 1 - 1 6 )
( s e eD a o e2 1 - ' 1 6 )
( s e ep a q e2 1 -1 7 )
( s e eo a q e2 1 - 1 8 )
( s e ep a q e2 1 1 9 1
( s e ep a q e2 1 - 2 0 )
( s e ep a g e2 1 - 3 8 )
(seepaqe 21-23)
( s e eo a q e2 1 - 2 4 1
In case of multiple problems,the recirculationindicatorwill indicateonly the DTCwith the least number of blinks.
ln caseof an intermittentfailure,the heatercontrol panelwill storethe DTCuntil the ignition is turned off.
21-9
\
Index
{
Also check for
Svmptom
Diagnosticprocedure
RecirculationControl Motor
Recirculationcontrol doors do not
C l e a n l i n e sasn d t i g h t n e s so f a l l
changebetweenFreshand Recirculate CircuitTroubleshooting(seepage connectors
21 251
HeaterControlPowerandGround B l o w nf u s eN o .' 1 4( 1 0 Ai)n t h e
Both heaterand Ay'Cdo not work
(see
CircuitsTroubleshooting
page21-27)
Condenserfan does not run at all (but
radiatorfan runs with the Ay'Con)
Both fans do not run with the A,/Con
Compressorclutchdoes not engage
(both fans run with A,/Con)
A/C system does not come on (both
fans and compressor)
fuse/relay
box
under-dash
Poorgroundat G501
C l e a n l i n easns dt i g h t n e sosf a l l
conneclors
. P o o rg r o u n da t G 3 0 1
. C l e a n l i n e sasn d t i g h t n e s so f a l l
connectors
R a d i a t oarn dC o n d e n s e
Fra n s
B l o w nf u s eN o . 1 ( 2 0 A )a n d N o . 4
CommonCircuitTroubleshooting (20A)in the under-hoodfuse/relay
( s e ep a g e2 1 - 2 9 )
box
P o o rg r o u n da t G 3 0 l
C l e a n l i n e sasn dt i g h t n e s so f a l l
connectors
CompressorClutchCircuit
T r o u b l e s h o o t i n(qs e eD a q e2 1 - 3 0 ) connectors
Ay'CPressureSwitch Circuit
B l o w nf u s eN o . 1 ( 2 0 A )a n d N o . 4
(20A)in the under-hoodfuse/relay
T r o u b l e s h o o t i n(gs e ep a g e2 1 - 3 2 )
box
Poor ground at G301
connectors
C o n d e n s eFr a nC i r c u i t
Troubleshooting{seepage 21-28)
a
\
!
21-10
a
SystemDescription
HeaterControlPanelInputsandOutputs
HEATERCONTFOLPANELCONNECIORS
CONNECTOR
A {r/rP)
CONNECTORB (22P)
W res deoitema eterm nals
CONNECTOR
Cavity
_|
Wire color
\ln Y
2
3
LT GRN
PNK/BLU
BLU
GRNA/EL
GRNA/VHT
BLUI/EL
BLU/RED
5
6
7
8
I
GRN
10
11
YEL/RED
YEVBTU
YEL/BLK
BLK
BLK/YEL
.
14
CONNECTOR
B
Cavity
Sional
AIRMIXPOTENTIAL
+5V
S E N S OC
RO M M O N
GROUND
OUTPUT
AIR MIX HOT
OUTPUT
INPUT
INPUT
INPUT
OUTPUT
INPUT
OUTPUT
OUTPUT
OUTPUT
INPUT
OUTPUT
INPUT
INPUT
A,/CPRESSURE
SWITCH
RECIRCULATE
FRESH
POWER
TRANSISTOR
BLOWERFEEDBACK
AIR MIX COOL
MODEDEF
MODEVENT
REARWINDOWDEFOGGER
RELAY
GROUND
l G 2( P o w e r )
on
Wire color
Siqnal
1
2
3
4
5
6
7
8
9
BLIVRED
--T
PNVBLK
R E A RW I N D O WD E F O G G ES
RW I T C HL E D
A./CSWITCHLED
RECIRCULATIO
CN
ONTROL
S W I T C HL E D
AIR MIX POTENTIAL
BRN
EVAPORATOR
TEIMPERATURE
SENSOR
INPUT
INPUT
INPUT
OUTPUT
OUTPUT
GAUGE
ASSEMBLY
al' 'TDr ri
LT GRN
L TG R N / B L K
10
11
14
ic
16
17
18
19
20
RED
RED/BLK
BLU
LT GRN/RED
YEVRED
YEUGRN
WHT/BLU
RED/BLU
RED/YEL
BRN^,^/HT
22
REDA/r'HT
TAILLIGHTSRELAY
INPUT
REARWINDOWDEFOGGER
SWITCH
INPUT
A/C SWITCH
RECIRCULATIO
CN
ONTROL
SWITCH
INPUT
INPUT
OUTPUT
OUTPUT
OUTPUT
OUTPUT
OUTPUT
MODE4
MODE3
M O D E2
M O D E1
I G N( P o w e d
(Not used)
(cont'd)
21-11
SystemDescription(cont'dl
The air conditioningsystem removesheatfrom the passengercompartmentby circulatingrefrigerantthrough the
system as shown below.
BLOWER
FAN
\
\
\ r\,u
/
EXPANSIONVALVE
(Metersthe required
amount of refrigerant
into the evaporator)
APOBATORTEMPERATURE
SENSOR
THERMALPROTECTOR
(Opensthe compressorclutchcircuit
when the compressottemperature
becomestoo high)
A/C PRESSURESWITCH
When the refriqerantis below
196kPa(2.0kgi/cm',28psi)
or above3,140kPa(32 kgf/cm'
455 psi),the Py'cpressure
switchopensthe circuitto
the Py'Cswitch and stopsthe
air conditioningto protectthe
compressor-
RELIEF
VALVE
(Relieves
pressure
at thecompressor
w h e nt h ep r e s s u ri e
st o oh i g h )
A/C COMPRESSOR
(Suctionand comoression)
RECEIVER/DRYER
(Trapsdebris,and
\-^
removesmorsturel
/CONDENSER
(Radiationof heat)
I
vAPoR
HrcHPRESSURE
-:--l
[ '....
Low PREsSUBE
LrourD
tffi
Low PREssURE
vAPoR
refrigerantwhich does not containchlorofluorocarbons.Pay attentionto the
This vehicleuses HFC-134a(R-'134a)
following serviceitems:
. D o n o t m i x r e f r i g e r a n tCs F C - 1 2
( R - 1 2a) n d H F C - 1 3 4(aR - 1 3 4 aT) .h e ya r e n o t c o m p a t i b l e .
'!0)
. U s eo n l y t h e r e c o m m e n d e p
d o l y a l k y l e n e g l y c(oPl A G) r e f r i g e r na t o i l ( K E l H l NS P
designedfortheR-134a
(PAG)
recommended
refrigerant
with
retrigerant
oil will resultin
compressor.Intermixingthe
oil
any other
compressorfailure.
. AllAy'Csystem parts (compressor,dischargeline, suction line,evaporator,condenser,receiver/dryer.
expansion
valve,O-ringsfor joints) have to be designedfor refrigerantR 134a.Do not exchangewith R-'12parts.
. Use a halogengas leakdetectordesignedfor refrigerantR-134a.
. R-12and R-134arefrigerantservicingequipmentare not interchangeable.
Use only a recovery/recycling/charging
s t a t i o nt h a t i s U . L . - l i s t eadn d i s c e r t i f i e dt o m e e tt h e r e q u i r e m e n tosf S A EJ 2 2 1 0t o s e r v i c eR - 1 3 4 a i r c o n d i t i o n i n g
system.
. Always recoverthe refrigerantR-134awith an approvedrecovery/recycling/charging
stationbeforedisconnecting
any Ay'Cfifting.
21-12
GircuitDiagram
UNDEN
rcODFUSVRELIYSOX
UNOER
DASN
fUSE/8EIlYBOX
|GNUION
SWTCfi
lG2HoI ii 0l\lllll
+.
\
C}F
rG2/
BLK/RED
l
;
.I
/
Y
I
\ IHEFMAI
PBorEcro8 I
I
*n*,*,
lTl
| <l I CLUTCH
tf
_l
.
G301
MUITIPLD(
CONTFOI
UNITI
-!10.
T
RADIATOS\ NADIATOS
) tAl'/
/ swtlcll
oT0n
I
B LX
I
G301
21-14
j
19S"F
193"C) l
I
I
n
A/CPnESSUEt
swTOt
irgF 8Ll
T
t...iCF
BLU
CONDEN$N
MOTOB
I
I
8u(
I ilnthoundor dasiluse/lelay
box
-
BU/YEL
-8lU/wH'I
EVAPORATOB
TEMPERATUNESENSOR
sn 4-Lrenil
m
::-:::: ., . a/c
YEUBLU
YEL/NED
M DEF
MODEl
BED/YEI
Mq)EI
RED/8LU
M00€2
M00t3
WHT/8LU
MOOE3
YEL/GRN
MOOEI
M00l
co TnoL
MOTOS
s
LTGRI'l
ffftH,,
F*u,*
GNNMHT
8U
I
GRN/YEL
8LK--..-...-l
(
f
coNNEcroFrir.Pt
mxr{EcroB
! {2P)
G5'1
G602
21-15
DTCTroubleshooting
DTC7:An Openin theAir Mix ControlMotor
Circuit
DTC8:A Shortin theAir Mix ControlMotor
Circuit
1. Test the air mix control motor {seepage 2'l-341.
1. Testthe air mix control motor(see page 21-341.
ls the air mix control motor OK?
YES-Go to step 2.
N O - R e p l a c et h e a i r m i x c o n t r o lm o t o r . l
2. Disconnectthe air mix control motor 5P connector.
3. Disconnectheatercontrol panel connectorsA {14P)
a n dB ( 2 2 P ) .
4. Checkfor continuitybetweenthe following
terminalsof heatercontrol panel connectorsA
(14P)and B (22P)and the air mix control motor 5P
connector,
14P:
5P:
No.5
N o .1
No.4
No.2
No.2
No.3
N o .1
No.9
ls the ait mix control motor OK?
YES-Go to step 2.
NO-Replace the air mix contorol motor.I
2. Disconnectthe air mix control motor 5P connector.
3. Disconnectheatercontrol panelconnectorsA (14P)
andB (22P).
heatercontrol panelconnectorA (14P)terminals
No. 1, 2, 3, and 9 individually,and betweenbody
ground and heatercontrol panelconnectorB (22P)
A {I4PI
HEATERCONTROL
PANELCONNECTOR
22P:
No.6
5P:
No.3
HEATERCONTFOL PANELCONNECTORB I22P1
Wire side ol lem.letehi.6ls
YES-Check for loosewires or poor connectionsat
heatercontrol oanel connectorsA (14P)and B (22P)
and at the air mix control motor 5P connector.lf the
connectionsare good. substitutea known-goodair
mix control motor, and recheck,lf the symptom/
indicationgoes away, replacethe originalair mix
control motor. lf the symptom/indicationcontinues,
substitutea known-goodheatercontrol panel,and
recheck.lf the symptom/indicationgoes away,
replacethe original heatercontrol panel.l
N O R e p a i ra n y o p e n i n t h e w i r e ( s )k e t w e e n t h e
heatercontrol panel and the air mix control
motor.l
21-16
W i r e s i d eo i l e m a e l e r m i n a l s
Y E S - R e p a i ra n y s h o r t t o b o d y g r o u n dl n t h e
wire(s)betweenthe heatercontrol panel and the air
mix control motor.l
5. Turn the ignition switch ON (ll),and checkthe same
terminalsfor voltage.
HEATERCONTROLPANELCONNECTOR
A {14PI
DTC9: A Problemin the Air Mix Control
Linkage,
Door,or Motor
1, Test the air mix control motor (seepage 21-34).
ls the air mix control motor OK?
YES-Substitute a known-goodheatercontrol
panel,and recheck.lf the symptom/indicationgoes
away, replacethe original heatercontrol panel.l
NO-Replace the air mix control motor, or repair
t h e l i n k a g ea n d d o o r . l
B I22PI
ls there any voltage?
YES-Repair any short to power in the wire(s)
betweenthe heatercontrol panel and the air mix
control motor. This short may also damagethe
heatercontrol panel.Repairthe short to power
before replacingthe heatercontrol panel.l
NO Substitutea known-goodair mix control
motor, and recheck.lf the symptom/indicationgoes
away, replacethe originalair mix control motor. lf
the symptom/indicationcontinues,substitutea
known-goodheatercontrol panel,and recheck.lf
originah
l e a t e rc o n t r o lp a n e l . I
21-17
DTCTroubleshooting.(cont'd)
DTC10:An Openor Shortin the Mode
ControlMotorCircuit
1. Test the mode control motor (seepage 21-35).
5 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d c h e c kt h e s a m e
t e r m i n a l sf o r v o l t a g e .
HEATEB
CONTROL
PANEL
CONNECTOR
A {14P)
ls the mode cottol motor OK?
YES Go to step 2.
NO Replacethe mode control motor.I
2. Disconnectthe mode control motor 10Pconnector.
s (14P)
3 . D i s c o n n e cht e a t e rc o n t r o lp a n e lc o n n e c t o r A
and B \22P1.
Checkfor continuitybetweenbody ground and
h e a t e rc o n t r o lp a n e lc o n n e c t oA
r ( 1 4 P t)e r m i n a l s
N o . 2 , 1 0 ,a n d 1 1 i n d i v i d u a l l ya,n d b e t w e e nb o d y
g r o u n da n d h e a t e rc o n t r o lp a n e lc o n n e c t o B
r (22P)
'17,
1 8 ,1 9 ,a n d 2 0 i n d i v i d u a l l y .
t e r m i n a l sN o .
HEATER
CONTROL
PANEL
CONNECTOR
A {14PI
Wire side of femaleterminal
B {22PI
3
tl
12
5
X
15 T6
6
1 1 1 8 t 9 2A 21 22
RED/YEL
WHT
B {22P)
ls there any voltage?
YES-. Repairany short to power in the wire(s)
betweenthe heatercontrol panel and the mode
control motor. This short may also damagethe
heatercontrol panel.Repairthe short to power
before replacingthe heatercontrol panel.l
NO- Go to step 6.
W i r e s i d e o f f e m a L el e r m i n a l s
Y E S R e p a i ra n y s h o r t t o b o d y g r o u n di n t h e
wire(s)betweenthe heatercontrol panel and the
mode control motor.l
NO
21-18
Go to step 5.
Turn the ignition switch OFF,and checkfor
continuitybetweenthe following terminalsof
heatercontrol panel connectorsA (14P)and B (22P)
and the mode control motor 10Pconnector.
14P:
10P:
'10
N o .2
No.
No.10
No,1
N o .1 1
No.2
22P:
N o .1 7
N o .1 8
No.19
N o .2 0
10P:
No.8
No.6,9
No.5
N o .4 , 7
DTC11:A Problemin the ModeControl
Linkage,
Doors,or Motor
1. Testthe mode control motor (seepage 21-35).
ls the mode control motor OK?
YES Substitutea known-goodheatercontrol
NO Replacethe mode control motor, or repairthe
l i n k a g ea n d d o o r s . l
HEATER
PANELCONNECTOR
A (14PI
CONTROL
MODECONTROLMOTORlOPCONNECTOR
HEATERCONTROLPANELCONNECTORB {22PI
YES-Check for loosewires or poor connectionsat
heatercontrol panelconnectorsA (14P)and B (22P),
and at the mode control motor 10Pconnector.lf the
connectionsare good, substitutea known-good
mode control motor, and recheck.lf the symptom/
indicationgoes away. replacethe original mode
control motor.lfthe symptom/indicationcontinues,
substitutea known-goodheatercontrol panel,and
recheck.lf the symptom/indicationgoes away,
replacethe originalheatercontrol panel.l
NO Repairany open in the wire(s)betweenthe
heatercontrol Daneland the mode control motor.l
21-19
HeatingandAir Gonditioning
DTCTroubleshooting{cont'd)
DTC12:A Problemin the BlowerMotor
Circuit
'1.
C h e c kt h e N o . 1 2 ( 4 0 A ) f u s ei n t h e u n d e r - h o o d
fuse/relaybox, and the No. 14 (10A)fuse in the
7. Checkfor continuitybetweenthe No. 3 terminal of
the power transistor4P connectorand body ground.
POWERTRANSISTOR4P CONNECTOR
2
Are the tuses OK?
3
o
NO Replacethe fuse(s),and recheck.l
2. Connectthe No. 2 terminal of the blower motor 2P
connectorto body ground with a jumper wire.
BLOWERMOTOB2PCONNECTOR
4
BLK
YES-Go to step 2.
Wire side ol temaleterminals
YES-Go to step 8.
JUMPER] BLU/BLK
NO-Check for an open in the wire betweenthe
power transistorand body ground. lf the wire is OK,
checkfor poor ground at G502.I
8 . Connectthe No. 1 and No. 3 terminalsof the power
transistor4P connectorwith a jumper wire.
TRANSISTOR
4PCONNECTOR
POWER
Does the blowet motor run?
YES Go to step 4,
NO Go to step 17.
5. Disconnectthe jumper wire.
6. Disconnectthe power transistor4P connector.
Does the blower motor tun at high speed?
Y E S - G o t o s t e p1 0 .
NO-Repair open in the wire betweenthe power
transistorand the blower motor.l
1 1 . Disconnectlhe jumper wire.
21-20
1a
Disconnectheatercontrol panelconnectorA (14P).
1 3 .Checkfor continuitybetweenthe No. 7 and No. 8
terminalsof heatercontrol panel connectorA (14P)
a n d b o d y g r o u n di n d i v i d u a l l y .
HEATER
CONTNOL
PANEL
CONNECTOR
A {14PI
1 5 . Reconnectheatercontrol panel connectorA (14P).
lo.
Test the power transistor(seepage 21-38).
ls the power transistorOK?
YES Checkfor loosewires or poor connectionsat
heatercontrol panel connectorA (14P)and at the
power transistor4P connector.lf the connections
are good, substitutea known-goodheatercontrol
NO
Replacethe power transistor.I
1 7 . Disconnectthe jumper wire.
1 8 . Disconnectthe blower motor 2P connector.
1 9 . Measurethe voltagebetweenthe No, 1 terminal of
the blower motor 2P connectorand body ground.
YES Repairany shortto body ground in the
power transistor.I
BLOWERMOTOR2PCONNECTOR
BLU/WHT
NO Go to step 14,
1 4 . Checkfor continuitybetweenthe following
terminalsof heatercontrol panelconnectorA ( 14P)
and power transistor4P connector.
'l4Pt
4P:
No.4
No.7
No.8
No.2
HEATER
CONTROL
PANEL
CONNECTOR
A (14P)
z 3
I
T 8
9
4 1 5 1 6
r ol x l I
1 2 l1 3l 1 4
BLU/YEL
YES- Replacethe blower motor.l
)
8LU/RED
NO Go to step 20.
ILU/YEL
4PCONNECTOR
POWER
TRANSISTOR
2 1 .Removethe blower motor relayfrom the underhood fuse/relaybox, and test it (seepage 22-511.
ls the relay OK?
YES Go to step 22.
YES Go to step 15.
NO- Replacethe blower motor relay.l
NO Repairany open in the wire(s)betweenthe
heatercontrol paneland the power transistor.l
(cont'd)
21-21
DTCTroubleshootinglcont'd)
the blower motor relay 4P socketand body ground.
25. Turn the ignition switch OFF,
the blower motor relay 4P socketand body ground.
BLOWERMOTORRELAY4PSOCKET
2
4
1
3
YES-Go to step 23.
NO Replacethe under-hoodfuse/relaybox.t
YES-Repair open in the BLUIr'/HTwire between
the blower motor relay and the blower motor.l
23. Turn the ignitionswitch ON {ll).
Measurethe voltage betweenthe No. 2 terminal of
the blower motor relay 4P socketand body ground,
YES-Go to step25.
NO Repairopenin thewire betweenthe No.14
fusein the under-dash
fuse/relay
boxandthe
blowermotorrelay.I
21-22
blower motor relay and body ground. lf the wire is
O K ,c h e c kf o r p o o r g r o u n da t G 3 0 1 . 1
\
DTC14:An Openin the Evaporator
Temperature
SensorCircuit
1. Removethe evaporatortemperaturesensor(see
p a g e2 1 - 3 7 ) .
2. Measurethe resistancebetweenthe No. l and
No. 2 terminalsof the evaporatortemperature
sensor.
x D i pt h e s e n s o ri n i c ew a t e r ,a n d m e a s u r e
resistance.Then pour hot water on the sensor,and
c h e c kf o r c h a n g ei n r e s i s t a n c e .
heatercontrol panelconnectorB (22P)and the
No. 1 terminal of the evaporalortemperature
s e n s o r2 P c o n n e c t o r .
B {22P)
EVAPORA
TORTEMPERATURE
SENSOR
ll#l
t-l
SENSOR
2PCONNECTOR
EVAPORATOR
TEMPERATURE
lI UT-TU
l , l , l l
---r---T--I
t
^
11c))-l
\9/
T e r m i n asl i d eo f m a l et e r m i n a l s
YES Go to step 5.
NO Repairopen in the wire betweenthe heater
control panel and the evaporatortemperature
sensor.I
5. Disconnectheatercontrol panelconnectorA (14P).
RESISTANCE
k0
50
10
68
20
86'F
30'c
TEMPERATURE
ls the tesistancewithin the specificationsshown
on the graph?
NO Replacethe evaporatortemperature
sensor.I
3. Disconnectheatercontrol panelconnectorB {22P).
(cont'd)
21-23
DTCTroubleshooting{cont'd)
heatercontrol panel connectorA (14P)and the
No, 2 terminal of the evaporalortemperature
sensor2P connector.
HEATER
CONTROL
PANELCONNECTOR
A {14PI
LT GRN
DTC15:A Shortin the Evaporator
Temperature
SensorCircuit
1. Removethe evaporatortemperaturesensor(see
p a g e2 1 - 3 7 ) .
2. Testthe evaporatortemperaturesensor(seepage
21-37J.
ls the resistance within the specifications shown
on the graph?
YES Go to step 3.
NO Replacethe evaporatortemperature
sensor.!
EVAFORATOR
TEMPERATURE
SENSOR
2PCONNECTOR
Disconnectheatercontrol panel connectorB l22Pl.
YES-Check for loosewires or Doorconnectionsat
heatercontrol panel connectorA ('l4P)and B l22Pl
and at the evaporatortemperaturesensor2P
connector.lf the connectionsare good, substitutea
known-goodheatercontrol panel,and recheck.lf
original heatercontrol panel.l
heatercontrol panel connectorB {22P)and body
ground.
HEATER
CONTROL
PANELCONNECTOR
B (22P)
\
NO Reoairooen in the wire betweenthe heater
control panel and the evaporatortemperature
sensor.I
YES Repairshort to body ground in the wire
betvveenthe heatercontrol paneland the
evaporatortemperaturesensor.I
NO-Substitute a known-goodheatercontrol panel,
and recheck.lf the symptom/indicationgoes away,
replacethe original heatercontrol panel.I
21-24
RecirculationControlMotor CircuitTroubleshooting
1 . C h e c kt h e N o . 1 4 ( ' 1 0 A ) f u sien t h e u n d e r - d a s h f u s e /
relay box.
8. Checkfor continuitybetweenthe No. 5 and No. 6
terminalsof heatercontrol panelconnectorA (14P)
and body ground individually.
ls the f use OK?
YES Go to step 2.
A I14P)
HEATER
CONTROL
PANELCONNECTOR
NO- Replacethe fuse, and recheck.l
2. Disconnectthe recirculationcontrol motor 5P
conneclor.
lvleasurethe voltage betweenthe No. 5 terminal of
the recirculationcontrol motor 5P connectorand
body ground.
RECIRCULATIONCONTROLMOTOR
5P CONNECTOR
YES Repairany shortto body ground in the
recirculationcontrol motor.l
NO-Go to step 9.
9. Turn the ignition switch ON (ll),and checkthe same
wires for voltage.
A Il4PI
PANELCONNECTOR
HEATER
CONTROL
YES Go to step 5.
NO- Repairopen in the wire betweenthe No. 14
fuse in the under-dashfuse/relaybox and the
recirculationcontrol motor .l
6 . Testthe recirculationcontrol motor {seepage 2136),
ls the recirculationcontrol motor OK?
YES Go to step 7.
NO- Replacethe recirculationcontrol motor, or
r e p a i rt h e l i n k a g ea n d d o o r s . I
7 . Disconnectheatercontrol panel connectorA (14P).
ls therc any voltage?
Y E S R e p a i ra n y s h o n t o p o w e ri n t h e w i r e ( s )
betweenthe heatercontrol panel and the
recirculationcontrol motor. This shon may also
d a m a g et h e h e a t e rc o n t r o lp a n e l .R e p a i rt h e s h o n
to power before replacingthe heatercontrol
p an e l .I
N O - G o t o s t e p1 0 .
{cont d r
21-25
RecirculationControl Motor CircuitTroubleshooting(cont'd!
10. Turn the ignition swirchOFF.
11. Checkfor continuitybetweenthe following
terminalsof heatercontrol panel connectorA ( 14P)
and the recirculationcontrol motor 5P connector.
'l4Pt
5P:
No.5
N o .1
No.6
No.2
HEATER
CONTROL
PANEL
CONNECTOR
A {14P}
Wiresideol temaleterminats
RECIRCULATION
CONTROL
MOTOR5PCONNECTOR
Wiresideol lemaleterminals
heatercontrol panel connectorA ( 14P)and at the
recirculationcontrol motor 5P conneclor.lf the
heatercontrol panel,and recheck.lf the symptom/
indicationgoes away, replacethe original heater
control panel,I
NO Repairany open in the wire{s)betweenthe
heatercontrol panel and the recirculationcontrol
motor.l
21-26
HeaterControlPowerand GroundCircuitsTroubleshooting
1 . C h e c kt h e N o . 1 4( 1 0 A ) f u s ei n t h e u n d e r - d a s h
fuse/relaybox.
6. Checkfor continuitybetweenthe No. l3terminal of
heatercontrol panelconnectorA (14P)and body
g round.
ls the f use OK?
A (1ilP)
HEATER
CONTRoLPANELCONNEcToR
YES-Go to step 2.
N O - R e p l a c et h e f u s e ,a n d r e c h e c k . l
2. Disconnectheatercontrol panelconnectorA{'14P).
1 2 3
I
8 9
4 5 6
r0t, 1 l 12
.o
3. Turn the ignition switch oN (ll).
4. Measurethe voltage betweenthe No. l4terminal
of heatercontrol panelconnectorA (14P)and body
grouno.
A {14P}
PANELCONNECTOR
HEATER
CONTROL
2 3
7 8 I 1 0l ,
4
11 12
14
BLK
5 6
14
BLK/YEL
healercontrol panel connectorA (14P).lfthe
heatercontrol panel,and recheck.lf the symptom/
indicationgoes away, replacethe original heater
control panel.l
heatercontrol paneland body ground. lf the wire is
O K ,c h e c kf o r p o o r g r o u n da t G 5 0 1I.
YES-Go to step 5.
NO Repairopen in the wire betvveenthe No. 14
heatercontrol panel.l
21-27
CondenserFanCircuitTroubleshooting
NOTE:lf neitherthe condenserfan nor the radiatorfan
work, go to Radiatorand CondenserFansCommon
CircuitTroubleshooting(seepage21-29).
f u s e / r e l a yb o x ,a n d t h e N o . 1 4 ( 1 0 A ) f u s ei n t h e
4 . C o n n e ctth e N o . l a n d N o . 2 t e r m i n a l s o f t h e
condenserfan relay 4P socketwith a jumper wire.
CONDENSERFAN RELAYitP SOCKET
Are the tuses OK?
JUMPERWIRE
YES-Go to step 2.
NO Replacethe fuse(s),and recheck.t
2. Removethe condenserfan relayfrom the
under-hoodfuse/relaybox, and test it
( s e ep a g e2 2 - 5 1 ) .
Does the condenser lan tun?
ls the relay OK?
YES-Go to step 5.
YES Go to step 3.
NO Go to step8.
NO- Replacethe condenserfan relay.l
3. Measurethe voltage betweenthe No, 2 terminal of
the condenserfan relay 4P socketand body ground.
CONDENSERFAN RELAYilP SOCKET
CONDENSER
FAN FELAY4PSOCKET
r-,_-l
1
2 |
Flr
\----1--rl
IELK/YEL
d,
I
YES-Go to step 4.
NO-Replace the under-hoodfuse/relaybox.l
YES Replacethe under-hoodfuse/relaybox.t
N O - R e p a i r o p e ni n t h e w i r e b e t w e e nt h e N o . 1 4
c o n d e n s efra n r e l a y . l
Disconnectthe jumper wire.
21-28
Radiatorand CondenserFans
CommonCircuitTroubleshooting
9 . Disconnectthe condenserfan 2P connector,
1 0 .Checkfor continuitybetweenthe No. 1 terminal of
the condenserfan relay 4P socketand the No. 2
terminal of the condenserfan 2P connector.
CONDENSER
FANRELAY4PSOCKET
NOTE;lf both fans and the Ay'Ccompressorclutchdo
not work when the Ay'Cswitch is on, go to Ay'CPressure
Switch CircuitTroubleshooting(seepage 21-32l,.
1. Checkthe No. 1 {20A}and No. 4 (20A)fuses in the
under-hoodfuse/relaybox, and the No. 14 (10A)
fuse in the under-dashfuse/relaybox.
Are the tuses OK?
YES Go to steD2.
NO Replacethe fuse(s),and recheck.l
CONDENSERFAN 2P CONNECTOR
2. Removethe condenserfan relavfrom the
under-hoodf use/relaybox.
3 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ; .
YES Go to step 11.
NO- Repairopen in the wire betweenthe
c o n d e n s efra n r e l a ya n d t h e c o n d e n s efra n , I
'11.
Checkfor continuitybetweenthe No. 1 terminal of
the condenserfan 2P connectorand body ground.
FAN2PCONNECTOR
CONDENSER
2
1
-l
r-,
FANRELAY4PSOCKET
CONDENSER
1
2 l
f---r---
l,l,l
lar-vverl
oI
BLK
o
YES Go to step 5.
radiatorfan relay,and the condenserfan relay.l
YES- Replacethe condenserfan motor.I
condenserfan and body ground. lf the wire is oK,
c h e c kf o r p o o rg r o u n da t G 3 0 1 . 1
l e c o n d e n s efra n r e l a y .
6 . R e i n s t a tl h
7 . M a k es u r et h e I V Cs w i t c hi s O F F .
(cont'd)
21-29
Radiatorand CondenserFans
CommonCircuitTroubleshooting
(cont'dl
9. Using a BackprobeSet, measurethe voltage
betweenthe No. 6 terminal of ECN4
connectorB
{24P)and body ground with the ECMconnectors
connecteo.
ECMCONNECTOR
B {24P}
CompressorClutchCircuit
Troubleshooting
f u s e / r e l a yb o x ,a n dt h e N o . 1 4 { 1 0 A ) f u s ei n t h e
Are the tuses OK?
YES Go to step 2.
NO Replacethe fuse(s),and recheck.I
2. Checkthe enginecoolanttemperature,the throttle
positionsensor,and the idle speed (usethe Honda
PGMTesterPGM-Fldata list if possible).
ls the coolant temperaturc above nomal, the
throttle position sensor rcading too high, or the
idle speed too low?
YES UDdatethe ECM if it does not have the latest
so{tware,or substitutea known-goodECM,then
originaE
l CM.I
NO Repairopen in the wire betweenthe radiator
fan relay,the condenserfan relay and the ECM.t
YES Troubleshootand repairthe causeof the
high enginecoolanttemperature,high throttle
positionsensor reading,or low idle speed.l
NO-Go to step 3.
3. Removethe compressorclutchrelay from the
under-hoodfuse/relaybox, and test it (seepage 225 1) .
ls the relay OK?
YES Go to step 4.
NO Replacethe compressorclutch relay.I
the compressorclutch relay 4P socketand body
ground.
COMPfiESSON
CLUTCHBELAY'P SOCKET
YES Go to step 5.
NO Replacethe under-hoodfuse/relaybox.I
21-30
\
5. Connectthe No. 1 and No. 2 terminalsof the
compressorclutch relay 4P socketwith a jumper
wire.
COMPRESSORCLUTCHRELAY4P SOCKET
L Turn the ignition switch OFF.
10. Reinstallthecompressorclutch relay.
11. l\4akesure the Ay'Cswitch is OFF.
1 2 . T u r nt h e i g n i t i o ns w i t c hO N { l l ) .
JUMPERWIRE
13. Uslng the BackprobeSet, measurethe voltage
betweenthe No. 18 termina!of ECI\4connector
E {31P)and body ground with the ECMconnectors
connected.
ECMCONNECTOR
E 131P}
2
3 t 4 5
6
1
1 4 1 5 16
Does the compressor clutch click ?
22 23 24
26
27
E
9
m
21
29
31
RED
YES Go to step 6.
N O - G o t o s t e p1 4 .
8. Measurethe voltagebetweenthe No. 3 terminal of
the compressorclutch relay 4P socketand body
ground.
COMPRESSOR
CLUTCHRELAY4PSOCKET
goes away with a known-goodECIM,replacethe
o r i g i n aE
l CM.I
c o m p r e s s ocr l u t c hr e l a ya n d t h e E C M . I
1 4 . D i s c o n n e ct h
t e j u m p e rw i r e .
15. Disconnectthe compressorclutch lPconnector.
YES-Go to step 9.
NO Repairopen in the wire betweenthe No. 1 4
compressorclutch relay,I
{cont'd)
21-31
Compressor
ClutchCircuit
Troubleshooting(cont'dl
16. Checkfor continuitybetweenthe No. lterminal of
the compressorclutch relav 4P socketand the No. l
terminal of the compressorclutch 1Pconneclor.
COMPRESSON
CLUTCHRELAY4PSOCKET
A/C PressureSwitch Circuit
Troubleshooting
'1.
Turn the ignition switch ON {ll).
2. Turn the blower switch on, and checkfor blower
motor operatron.
Does the blower motor run on all speeds?
YES Go to step 3.
NO Troubleshootthe blower motor circuit(see
page21-20).
4. Disconnectheatercontrol panelconnectorA ('14P).
COMPRESSORCLUTCH1P CONNECTOR
Terminalside of male terminals
YES-Check the compressorclutchclearance,the
thermal protector,and the compressorclutchfield
c o i l ( s e ep a g e2 1 - 4 8 ) . I
heatercontrol panelconnectorA {14P)and body
ground.
HEATER
CONTROL
PANELCONNECTOR
A (I4P}
NO-Repair open in the wire betweenthe
compressorclutch relay and the compressor
clutch.l
Wire side of femaletermina's
YES Go to step 7.
1 . S t a nt h e e n g i n e .
21-32
8. Connectthe No.4terminal ofheatercontrol
connectorA (14P)to body ground with a jumper
wire,
the A,/Cpressureswitch 2P connectorand the No. 9
terminal of under-dashfuse relav box connector
F t12Pt.
HEATER
CONTROLPANELCONNECTOR
A I14P}
A/C PRESSURE
SWITCH2PCONNECTOR
BLU
2 3
7 8 I
4
r 0 l x 11
5 6
12 l 3 t 4
JUMPER
WIBE
UNDER.OASHFUSE/RELAYBOX CONNECTORF (12P)
W i r es i d eo f f e n a l e l e r r r i n a l '
Wiresideoffemale
terminals
Does the A/C system come on?
YES Replacethe heatercontrol panel.!
YES Go to step 12.
NO Referto the multiplexcontrol system (see
p a g e2 2 - 1 6 8 ) . 1
pressure
under-dashfuse/relaybox and the A,,/C
switch.I
9 . Usingthe BackprobeSet,connectthe No. 9
terminal of under-dashfuse/relaybox connector
F ( 1 2 P t)o b o d y g r o u n dw i t h a j u m p e rw i r e .
1 2 . Checkfor continuitybetweenthe No. 1 and No. 2
terminalsof the A,/Cpressureswitch.
A/C PRESSURE
SWITCH
BOXCONNECTOR
F{12P}
UNOER.DASH
FUSE/RELAY
2
6 1
B g l r ot l
5
l2
BLU/WHT
JUMPER
WIRE
Does the NC system come on?
YES Go to step 10.
NO- Referto the multiplexcontrol system (see
p a g e2 2 - 1 6 8 ) . 1
'1.
N O T EC
: h e c kf o r m u l t i p l e xc o d e si n m o d e F o l l o w
the troubleshooting{or any codesfound. lf no
codesare found, subsititutea known-9ood
m u l t i p l e xc o n t r o lu n i ta n d a E C Mo n e a t a t i m e .
1 0 . Disconnectthe Ay'Cpressureswitch 2P connector
and under-dashfuse/relaybox connectorF { 12P).
YES Repairopen in the wire betweenthe heater
control panel and the A,/Cpressureswitch.l
'13.check for properAy'Csystem pressure.
ls the pressure within specitications?
YES Replacethe AilCpressureswitch.l
NO
Repairthe AilCpressureproblem.I
21-33
Air Mix ControlMotorTest
1. Disconnectthe 5P connectorfrom the air mix
control motor.
2. Connectbatterypowertothe No. l terminal ofthe
air mix control motor, and ground the No. 2
t e r m i n a l t; h e a i r m i x c o n t r o lm o t o rs h o u l dr u n ,a n d
stop at Max Cool.lf it doesn't,reversethe
connections;theair mix control motor should run,
and stop at Max Hot. lf the air mix control motor
does not run, remove it. then checkthe air mix
control linkageand door for smooth movement.
Air Mix ControlMotor Replacement
1 . Removethe under-dashfuse/relaybox (seepage
22-491.
Disconnectthe 5P connector{A) from the air mix
control motor (B).Removethe self-tappingscrews
and the air mix control motor from the heaterunit.
R e m o v et h e r o d ( C )f r o m t h e a r m ( D )o f t h e a i r m i x
controi motor.
,.,:l'
. lf the linkageand door move smoothly,replace
the air mix control motor.
. l f t h e l i n k a g eo r d o o r s t i c k o rb i n d ,r e p a i r t h e ma s
needed.
. lf the air mix control motor runs smoothly,go to
step 3.
AIRMIX CONTROLMOTOR
3 . Installthe motor in the reverseorder of removal.
After installation,make surethe motor runs
smoothly.
3 . Measurethe resistancebetweenthe No. 4 and
No. 5 terminals.lt should be between2.1 k to
3 . 9k Q .
4 . Reconnectthe air mix control motor 5P connector,
t h e nt u r n t h e i g n i t i o ns w i t c hO N { l l ) .
Using the BackprobeSet, measurethe voltage
betweenthe No. 3 and No. 4 terminals.
Max Cool about 1V
Max Hot
about 4 V
lf eitherthe resistanceor voltage readingsare not
as specified,replacethe air mix cotrol motor.
21-34
\'
Mode ControlMotor Test
'1.
Disconnectthe 10Pconnectorfrom the mode
control motor.
Mode ControlMotor Replacement
1 . R e m o v et h e E C M( s e ep a g e 1 1 - 4 ) .
2. Removethe relay mount bracketbolt, and move
Connectbatterypower to the No. 1 terminal of the
mode control motor, and groundthe No. 2
terminal;the mode control motor should run
smoothly and stop at Defrost.lf it doesn't,reverse
the connections;the mode control motor should
run smoothly and stop at Vent.When the mode
control motor stops running,disconnectbattery
power immediately.
the relaysout of the way.
3 . Disconnectthe 10Pconnector{A) from the mode
control motor (B).Removethe self-tappingscrews
and the mode control motor from the heaterunit.
MODECONTROLMOTOR
3. lfthe mode control motor does not run in step 2,
remove it, then checkthe mode control linkageand
doors for smooth movement.
4 . lnstallthe motor in the reverseorder of removal.
lvlakesure the pin on the linkageis properly
engagedwith the motor. After installation.make
sure the motor runs smoothly.
. lf the linkageand doors move smoothly. replace
the mode control motor.
. l f t h e l i n k a g eo r d o o r s s t i c ko r b i n d ,r e p a i r t h e m
as neeoeo.
. lfthe mode control motor runs smoothly,go to
step 4.
4 . Use a digital multimeterwith an output of 1 mA or
lessat the 20 k Q range.With the mode control
motor running as in step 2, checkfor continuity
b e t w e e nt h e N o . 4 , 5 , 6 , 7 , 8 , a n d 9 t e r m i n a l sa n d
t h e N o . 1 0t e r m i n a li n d i v i d u a l l yT.h e r es h o u l db e
c o n t i n u i t yf o r a m o m e n ta t e a c ht e r m i n a la s t h e
motor moves past each mode position.
lf there is no continuityfor a moment at each
terminal. replacethe mode control motor.
21-35
RecirculationControlMotor Test
RecirculationControlMotor
Replacement
I
1. Disconnectthe 5P connectorfrom the recirculation
control motor.
1 . R e m o v et h e E C M( s e ep a g e1 1 - 4 ) .
Incorrectlyapplying power and ground to
the recirculationcontrol motor will damge it.
Follow the instructionscarefullv.
2. Connectbattervoower to the No. 5 terminal ofthe
recirculationcontrol motor, and ground the No. 1
and No. 2 terminals;the recirculationcontrol motor
should run smoothly.To avoid damagingthe
recirculationcontrol motor, do not reversepower
and ground. Disconnectthe No. 1 or No. 2
terminalsfrom ground;the recirculationcontrol
motor should stop at Freshor Recirculate.Don't
cyclethe recirculationcontrol motor {or a long time.
Removethe relay mount bracketbolt.and move
the relaysout of the way,
Disconnectthe 5P connector(A)from the
recirculationcontrol motor (B),Removethe selftapping screwsand the recirculationcontrol motor
from the blower unit.
RECIRCULATION
CONTROL
MOTOR
Installthe motor in the reverseorder of removal.
Make sure the pin on the motor is properly
engagedwith the linkage.After installation.make
sure the motor runs smoothly.
lf the recirculationcontrol motor does not run in
step 2, remove it, then checkthe recirculation
control linkageand doors for smooth movement.
. lfthe linkageand doors move smoothly,replace
the recirculationcontrol motor.
. l f t h e l i n k a g e o r d o o r s s t i c k obr i n d ,r e p a i r t h e m
as neeoeo.
21-36
\
EvaporatorTemperatureSensor
Replacement
1 . Removethe driver'sdashboardlower cover (see
page 20-59)and the under cover (seepage 20-60).
Removethe under-dashfuse/relaybox (seepage
22-491.
EvaporatorTemperatureSensor
Test
l. Dip the sensorin ice water, and measurethe
resistancebetweenits terminals
EVAPORATOR
TEMPERATURE
SENSOR
evaporatortemperaturesensor(B),then remove
the connectorclip (C).Removethe self-tapping
screw,and carefullypull out the evaporator
temperature.
Terminalside ol male terminals
2 . Then pour hot water on the sensor,and check{or a
changein resistance.
3 . Comparethe resistancereadingswith the
specificationsshown in the graph;the resistance
should be within the specifications
4. Installthe sensorin the reverseorder of removal,
RESISTANCE
k9
t0
32
0
50
10
68
20
86 'F
30'c
TEMPERATURE
21-37
PowerTransistorTest
1. Disconnectthe 4P connectorfrom the power
Iranslslor.
2, Measurethe resistancebetweenthe No. 1 and
No. 2 terminalsof the power transistor.lt should be
'1.4
1 . 5k Q .
about
. lf the resistanceiswithln the specifications,
go to
step 3.
. lf the resistanceis notwithin the specifications,
replacethe power transistor.
a
HeaterControlPaneland Push
Switch AssemblyRemovaland
Installation
1 . Removethe centerpanel (seepage 20-62).
Removethe dials (A),then removethe self-tapping
screwsand the heatercontrol panel (B)from the
centerpanel (Cl. Removethe self-tappingscrews
and the push switch assembly(D)from the center
panel.
POWERTRANSISTOB
C a r e f u l l yr e l e a s et h e l o c kt a b o n t h e N o . 4 t e r m i n a l
(BLUI/EL)(A) in the 4P connector,then removethe
terminaa
l n d i n s u l a t ei t f r o m b o d y g r o u n d .
\
3 . lnstallthe control panel and push switch assembly
in the reverseorder of removal.After installation,
operatethe control panel controlsto see whether it
worKspropeny.
functionto confirm that
4 . Runthe self-diagnosis
there are no problemsin the system (seepage218).
(To112
power
o w e rssource
2V p
o u r c eo
on
n vvehicle)
ehicle)
Reconnectthe 4P connectorto the power transistor.
S u p p l y1 2v o l t st o t h e N o . 4 c a v i t yw i t h a j u m p e r
wire.
T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d c h e c kt h a tt h e
b l o w e rm o t o r r u n s .
. lf the blower motor does not run, replacethe
power rranstsror.
. l f t h e b l o w e rm o t o r r u n s , t h ep o w e r t r a n s i s t o r i s
oK.
21-38
Dustand PollenFilterReplacement
The dust and pollenfilters should be replacedevery
3 0 , 0 0 0m i l e s( 4 8 . 0 0 0
k m ) o r 2 4 m o n t h sw h i c h e v e r
comes first. Replacethe filters more often if the air flow
i s l e s st h a n u s u a l .
1. Openthe glove box. Removeboth glove box stops,
then let the glove box hang down (seepage 20 63).
2 . R e m o v et h e f i l t e rl i d ( A ) f r o mt h e b l o w e ru n i t ,t h e n
p u l l o u t t h e f i r s td u s ta n d p o l l e nf i l t e r( B ) .S l i d et h e
secondfilter to the left,and pull it out.
BlowerUnit Removaland
lnstallation
23-13)and precautionsand procedures(seepage 23-14)
in the SRSsectionbeforeperforming repairsor service.
buttons.
2. Disconnectthe batterynegativecable,and wait 3
minutesbefore beginningworK.
3. Removethe right kick panel (see page 20-50),
passenger'sdashboardlower cover,and the glove
box {seepage 20-63).
4. Cut the plasticcross bracein the glove box opening
with diagonalcuttersin the area shown. Remove
and discardthe plasticcross brace,
Removethe filter {A) from the housing (B),and
replacethe filter.
Cut heare.
4. Installthe filters in the reverseorder of removal.
{cont'd)
21-39
Blower Unit Removaland Installation{cont'd}
Removethe steeringhangerbeam bracketcover
from the right side of the glove box opening,then
removethe bolts and the olove box frame.
10. Disconnecttheconnector{A) from the recirculation
control motor, then removethe wire harnessclip
{B).Removethe mounting bolts,the mounting nuts
a n d t h e b l o w e ru n i t ( C ) .
Removethe ECM(seepage 11-4).
1 . Removethe EPScontrol unit (seepage 17-67).
6 x 1 . 0m m
I
9.8N.m(1.0kgt.m,
7.2tbt.ftl
8 . Disconnectand removethe PGM-Flmain relays
and bracketassembly,then removethe ECM
bracket.
9 . Disconnectthe connectors{A) from the blower
motor and the power transistor,then removethe
wire harnessclips (B)and the connectors(C).
Removethe self-tappingscrewsand the bracket(D).
A
6x1.0mm
9.8 N.m (1.0kgf.m,
?.2 tbf.ft)
1 1 .I n s t a l l l h eu n i t i n t h e r e v e r s eo r d e ro f r e m o v a l .
M a k es u r et h a tt h e r ei s n o a i r l e a k a g e .
Reconnectthe negativebatteryterminal.
'13.
D o t h e e n g i n ec o n t r o lm o d u l e( E C M )i d l e l e a r n
procedure
{ s e ep a g e1 1 - 1 3 9 ) .
1 4 . Enterthe anti-theftcode for the radio,then enter
21-40
\
Blower Unit ComponentsReplacement
Nole these items when overhaulingthe blower unit;
' The recirculationcontrol motor (A),the power transistor(B),the blower motor (C),and the dust and pollenfiltefs (D)
can be replacedwithout removingthe blower unit.
. Beforereassembly,make surethatthe recirculationcontrol linkageand doors move smoothly.
. After reassembly,make surethe recirculationcontrol motorruns smoothly (seepage 2j-36).
A
21-41
a
EvaporatorCoreReplacement
1 . Recoverthe refrigerantwith a recovery/recycling/
chargingstation(seepage 21-53).
5. Carefullypull out the evaporatorcore without
bendingthe pipes.
Removethe bolt, then disconnectthe suctionline
(A) and the receiverline (B)from the evaporator
core.
6x10mm
9.8N.m(1.0kgt.m,7.2lbf.ft)
Removethe blower unit (seepage 21-39).
Removethe self-tappingscrewsand the expansion
valve cover.
21-42
6 . Installthecore in the reverseorder of removal,and
note these items.
. lfyou're installinga new evaporatorcore, add
r e f r i g e r a not i l ( K E l H l NS P - ] 0 )( s e ep a g e2 1 - 6 ) .
. Replacethe O-ringswith new ones at eachfitting,
and apply a thin coat of refrigerantoil before
installingthem. Be sure to use the correctO-rings
f o r H F C - 1 3 4(aR - ' 1 3 4 tao) a v o i dl e a k a g e .
. l m m e d i a t e l y a f t eurs i n g t h eo i l , r e i n s t a l l t h e c a p
on the container,and seal it to avoid moisture
absorotion.
. Do not spill the refrigerantoil on the vehicle;it
may damagethe paint. lf the refrigerantoil
contactsthe paint,wash it off immediately.
. Chargethe system (seepage 21-55).
HeaterUnit/CoreReplacement
SRScomponentlocations(seepage23'13),and
precautionsand procedures(seepage 23-14)in the SRS
1. Make sure you have the anti-theftcode forthe radio,
then write down the freouenciesfor the radio's
Dresetbuttons.
6. Slidethe hose clamps (A) back,then d isconnectthe
inlet heaterhose (B)and the outlet heaterhose (C)
from the heatercore. Enginecoolantwill run out
when the hosesare disconnected;drain it into a
clean drip pan. Be sure not to let coolantspill on
the electricalpartsor the paintedsurfaces.lf any
coolantspills,rinse it off immediately.
Disconnectthe negativecablefrom the battery,
Disconnectthe suctionand receiverlinesfrom the
evaporator core (see page 21-42).
4 . From underthe hood, open the cableclamp (A),
then disconnectthe heatervalve cable (B)from the
heatervalve arm (C).Turn the heatervalve arm to
the fully openedpositionas shown
7 . Removethe bolt and the heatervalve,then remove
the mounting nut from the heaterunit. Takecare
not to damageor bend the fuel lines and the brake
lines,etc.
W h e nt h e e n g i n ei s c o o l ,d r a i nt h e e n g i n ec o o l a n t
from the radiator(seepage 10-6).
8 x 1.25mm
12 N.m (1.2kgf.m,8.7lbf.ft)
(cont'd)
21-43
HeaterUnit/CoreReplacement(cont'd)
8. Removethe dashboard{seepage 20-66).
1 1 . R e m o v et h e m o u n t i n gb o l t s ,t h e m o u n t i n gn u t s ,
and the heaterunit.
9. Disconnecttheconnectors(A) from the blower
motor, the recirculationcontrol motor, the mode
control motor, and the power transistor,then
removethe wire harnessclips (B)and the
connector(C).Removethe self-tappingscrewsand
the bracket(D).
7 t ,
5 x 1 . 0m m
9.8 N.m
11.0kgl m,
7.2 tbf.ftl
12. Removethe self-tappingscrewsand the expansion
1 0 ,Disconnectthe connectors(A) from the evaporator
temperaturesensorand the air mix control motor,
then removethe wire harnessclips (B) and the
connector(C).Removethe self-tappingscrew and
the cover (D).Disconnectthe heatervalve cable (E).
valve cover (A).Carefullypull out the evaporator
core (B)so you don't bendthe inlet and outlet pipes.
Removethe grommet (C),then removethe selftapping screwsand the flange cover (D).Bemove
the self-tappingscrewsand the pipe cover (E),then
carefullypull out the heatercore (F)so you don't
bend the inlet and outlet oioes.
@
21-44
13. Installthe heatercore and the evaporatorcore in
the reverseorder of removal.
14. Installthe heaterunit in the reverseorder of
. Do not interchangethe inlet and outlet heater
hoses,and installthe hoseclamps securely.
. Refillthecooling systemwith engine coolant(see
page 10-6).
. Adjust the heatervalve cable (see page2'l-461.
. Make sure that there is no coolantleakage.
. Make sure that there is no air leakage.
. Referto evaporatorcore replacement{seestep 6
o n p a g e2 1 - 4 2 ) .
. Do the enginecontrol module (ECl\4)idle learn
the customer'sradio stationDresets.
21-45
HeaterValveCableAdjustment
1 . F r o mu n d e r t h eh o o d ,o p e nt h e c a b l ec l a m p{ A ) ,
then disconnectthe heatervalve cable (B)from the
heatervalve arm {C).
5, From under the hood,turn the heatervalve arm {C)
to the fully closedpositionas shown, and hold it.
Attachthe heatervalve cable (B)to the heatervalve
a r m ,a n d g e n t l yp u l l o n t h e h e a t e rv a l v ec a b l e
housingto take up any slack,then installthe heater
v a l v ec a b l eh o u s i n gi n t ot h e c a b l ec l a m p( A ) .
.'.-:',,
- " l l
......
t
From under the dash,disconnectthe heatervalve
c a b l eh o u s i n gf r o m t h e c a b l ec l a m p( A ) ,a n d
disconnectthe heatervalve cable (B)from the air
m i x c o n t r o l i n k a g e{ C ) .
\
t.- l
,
\'r2t'
'
''' '
::"'
Set the temperaturecontrol dial on Max Cool with
the ignition switch ON (ll).
Attachthe heatervalve cable (B)to the air mix
control linkage(C)as shown above,then snap the
h e a t e rv a l v ec a b l eh o u s i n gi n t ot h e c a b l ec l a m p( A ) .
21-46
CompressorReplacement
1 . l f t h e c o m p r e s s oirs m a r g i n a l l yo p e r a b l er,u n t h e
engineat idle speed,and let the air conditioning
work for a few minutes,then shut the engine off.
8. Removethe mounting bolts and the compressor.
presetbuttons.
3. Disconnectthe negativecablefrom the battery.
4. Recoverthe refrigerantwith a recovery/recycling/
5. Removethe alternator(seepage 4-29).
6. Removethe Ay'Ccondenserfan assembly(seepage
10-10).
7. Disconnectthecompressorclutchconnector(A),
removethe bolts,then disconnectthe suction line
( B )a n d t h e d i s c h a r g el i n e( C ) f r o mt h e c o m p r e s s o r .
Plug or cap the lines immediatelyafter
disconnectingthem to avoid moistureand dust
contamination.
6 x '1.0mm
9.8 N.m
11.0kgt.m,
7.2 tbl.ttl
u1/
(
o
8 x 1 . 2 5m m
22 N.m12.2kgf.m.
9 . I n s t a l l t h ec o m p r e s s oirn t h e r e v e r s eo r d e ro f
. Beforeinstallingthe new compressor,checkfor
m e t a lo r o t h e rc o n t a m i n a t i o inn t h e l i n e .R e p l a c e
any contaminatedparts.
. lf you're installinga newcompressor,you must
calculatethe amount of refrigerantoil to be
removedfrom it (seepage 21-6).
. Replacethe O-ringswith new ones at each fitting,
installingthem. Be sure to use the correctO-rings
f o r H F C - 1 3 4{aR - 1 3 4 at o
) a v o i dl e a k a g e ,
. U s er e f r i g e r a not i l ( K E l H l NS P - ' 1 0f o
) r HFC-134a
K E I H I Ns p i r a lt y p e c o m p r e s s oor n l y .
. To avoid contaminatlon,do not returnthe oilto
the containeronce dispensed,and never mix it
with other refrigerantoils.
. l m m e d i a t e l ya f t e ru s i n gt h e o i l , r e i n s t a l l t h ec a p
absorption.
. Do not spill the refrigerantoil on the vehicle;it
may damagethe paint. lf the refrlgerantoil
. D o t h e e n g i n ec o n t r o lm o d u l e( E C M )i d l e l e a r n
p r o c e d u r e( s e ep a g e1 1 - ' 1 3 9 ) .
. Enterthe antitheft code for the radio,then enter
21-47
a
CompressorClutchCheck
1 . Checkthe armatureplatefor discoloration,peeling,
or other damage.lf there is damage,replacethe
clutch set (seepage 21-49),
Checkthe rotor pulley bearingplay and drag by
rotatingthe rotor pulley by hand.Beplacethe
clutchset with a new one if it is noisy or has
excessiveplay/drag(seepage 21-49).
4. Releasethe field coil connectorf rom the holder,
then disconnectit. Checkthe thermal protectorfor
continuity.lf there is no continuity,replacethe
t h e r m a lp r o t e c t o (r s e ep a g e2 1 - 5 1 ) .
NOTE:The thermal Drotectorwill have no
. hen
c o n t i n u i t ya b o v e2 5 2 t o 2 7 0 " F\ 1 2 2 l o 1 3 2 ' C )W
t h et e m p e r a t u r e
d r o p sb e l o w2 4 1t o 2 1 9 ' F( 1 1 6t o
104'C),the thermal protectorwill have continuity.
,\.
Measurethe clearancebetweenthe rotor pulley (A)
and the armatureplate (B)all the way around.lf the
clearanceis not within specifiedlimits, removethe
armatureplate (seepage 21-49)and add or remove
shims as neededto increaseor decreaseclearance.
Checkresistanceof the field coil. lf resistanceis not
within specifications,replacethe field coil
( s e ep a g e2 1 - 4 9 ) .
FieldCoil Resistance: 3.05 3.35ohmsat68"F
Clearance: 0.510.15 mm {0.02010.006in.)
N O T ET
: h e s h i m sa r e a v a i l a b l ei n f o u r t h i c k n e s s e s :
0 . 1m m . 0 . 2m m , 0 . 4m m , a n d0 . 5m m .
21-48
t20"c)
Compressor
ClutchOverhaul
A,/Cclutch holder,Robinair10204.Kent-MooreJ37872,
or HondaTool and EquipmentKMT-J33939,
yvailable
1 . R e m o v et h e c e n t e rn u t ( A )w h i l e h o l d i n gt h e
armatureplatewith a commerciallyavailableA,/C
c l u t c hh o l d e r( B ) .
1 7 . 6N . m
{1.8kgf.m,
13 tbt.ft)
3. lf you are replacingthe field coil, removethe snap
ring (A) with snap ring pliers,then removethe rotor
pulley (B).Be careful not to damagethe rotor pulley
or tne compressor.
\ot
-@
/@h"
.ffi
Removethe armatureplate (A) and shim(s)(B),
taking care not to losethe shim(s).lf the clutch
needsadjustment,increaseor decreasethe
number and thicknessof shims as necessary,then
reinstallthearmatureDlate,and recheckits
clearance(see page21-481.
4. Removethe bolt and holder (A).then disconnect
the field coil connector(B).Loosenthe clamp screw
(C)to iree the field coil wire. Removethe snap ring
{ D ) w i t hs n a pr i n g p l i e r s t, h e n r e m o v et h e f i e l dc o i l
(E).Be careful not to damagethe field coil or the
comoressor.
N O T ET
: h e s h i m sa r e a v a i l a b l ei n f o u r t h i c k n e s s e s :
0 . 1 m m , 0 . 2 m m , 0 . 4 m m , a n d 0 . 5m m .
9-=-g
7.4 N.m
(0.75kgf m,
5 tbf.ft)
----------------
"\)
(cont'd)
21-49
CompressorClutchOverhaul(cont'd)
5. Reassemblethe clutch in the reverseorder of
disassembly,and note these items:
. I n s t a l l t h ef i e l dc o i lw i t h t h e w i r e s i d ef a c i n g
down, and align the boss on the field coil with the
h o l ei n t h e c o m p r e s s o r .
. Cleanthe rotor pulley and compressorsliding
surfaceswith contactcleaneror other
non-petroleumsolvent.
. I n s t a l l n e w s n a pr i n g s ,n o t et h e i n s t a l l a t i o n
direction,and make surethey are fully seatedin
the groove.
. Make sure that the rotor pulleyturns smoothly
after it's reassembled,
. R o u t ea n d c l a m pt h e w i r e sp r o p e r l yo r t h e y c a n
be damagedby the rotor pulley.
21-50
CompressorThermalProtector
Replacement
1. Removethe bolt,the ground terminal (A),and the
holder (B).Disconnectthe field coil connector(C).
then removethe thermal protector(D).
CompressorReliefValve
Replacement
2 . Removethe reliefvalve (A) and the O-ring (B).Plug
the openingto keepforeign mafterfrom entering
the system and the compressoroil from running
out.
7.4 N.m
(0.75kgf.m,
5 rbf.ftl
A
9,8 N.m
(1.0kgf m,7.2lbf.ft)
Replacethe thermal protector(A)with a new one,
and apply siliconesealant(B)to the bottom of the
thermal Drotector.
Clean the mating surfaces.
4 . Installa new O-ringon the reliefvalve, and apply a
thin coat of refrigerantoil to the O-ring.
Removethe plug, and installand tightenthe relief
valve.
Chargethe system (seepage21-55).
A
3. lnstall in the reverse order of removal.
21-51
GondenserReplacement
Removethe front bumper {seepage 20-85).
Removethe bolts,then disconnectthe discharge
line (A) and the condenserline (B)from the
condenser.Plug or cap the lines immediatelyafter
disconnectingthem to avoid moistureand dust
conlamtnaflon.
4, Removethe mounting bolts,then removethe
condenserby lifting it up. Be carefulnot to damage
the radiatoo
r r t h e c o n d e n s efri n s w h e n r e m o v i n o
the condenser.
6 x '1.0mm
9.8 N.m ('1.0kgf.m,
7.2 tbl.ftl
t
t-
-"'.
f,
-li
:.--\ ----
.:)-
- -'
5 . l n s t a l l t h ec o n d e n s eirn t h e r e v e r s eo r d e ro f
removal,and note these items.
6x1.0mm
9.8 N.m ('1.0kgf.m,7.2lbf.ft)
,t\
6x1.0mm
9.8 N.m (1.0kgt.m.7.2lbf.ft)
21-52
. l f y o u ' r ei n s t a l l i n ga n e w c o n d e n s e ra,d d
r e f r i g e r a not i l ( K E l H l NS P -1 0 )l s e ep a g e2 1 ' 6 ) .
. Replacethe O-ringswith new ones at eachfitting,
installingthem. Be sure to usethe correctO-rings
t ov o i dl e a k a g e .
f o r H F C - 1 3 4(aR - ' 1 3 4 a ) a
. lmmediatelyafter using the oil, reinstallthecap
absorption.
. D o n o t s p i l l t h er e f r i g e r a not i l o n t h e v e h i c l e ; i t
may damagethe paint.lf the refrigerantoil
. Be carefulnot to damagethe radiatoror the
condenserfins when installingthe condenser.
RefrigerantRecovery
Air conditioningrefrigerantor lubricantvapor
can irritateyour eyes,nose.or throat.
Do not breatherefrigerantor vapor
1. Connecta R-134arefrigerantrecovery/recycling/
chargingstation{A) to the high-pressureservice
port (B)and the low-pressureserviceport (C),as
shown, following the equipmentmanufacturer's
instructions.
1!l
Use only serviceequipmentthat is U.L.-listedand is
r e m o v eH F C - 1 3 4(aR - 1 3 4 af r) o m t h e a i r c o n d i t i o n i n g
system.
lf accidentalsystemdischargeoccurs,ventilatethe
work area before resumingservice
-'',
r:
i
-
'=i
-:
t:
(
-
r
Additionalhealthand safetyinformationmay be
manufacturers.
lvleasurethe amount of refrigerantoil removed
from the Ay'Csystem after the recoveryprocessis
completed.Be sure to put the same amount of new
refrigerantoil backinto the Ay'Csystem before
chargrng.
21-53
SystemEvacuation
. Air conditioningrefrigerantor lubricantvapor
. Be carefulwhen connectingserviceequipment.
. Do not breatherefrigerantor vapor.
r e m o v eH F C - 1 3 4(aR - 1 3 4 a ) f r o m
t h e a i rc o n d i t i o n i n q
system.
chargingstation(A)to the high-pressureservice
pon (B)and the low-pressureserviceport (C),as
shown,following the equipmentmanufacturer's
instructions.Evacuatethe system.
-i -
r4.t
work area before resumingservice.
Additionalhealthand safety informationmay be
manufacturers.
1. When an Ay'Csystem has been openedto the
atmosphere,such as during installationor repair,it
must be evacuatedusing a R-134arefrigerant
recovery/recycling/charging
station(lf the system
has been open for severaldays,the receiver/dryer
should be replaced,and the system should be
evacuatedfor severalhours.)
lf the low-pressuredoes not reachmore than 93.3
k P a{ 7 0 0m m H g ,2 7 . 6i n . H g )i n 1 5 m i n u t e st,h e r ei s
probablya leak in the system.Partiallychargethe
system,and checkfor leaks(seestep 3 on page 2156).
21-54
SystemCharging
2 . Evacuatethe system(seepage 21'54).
Do not breatherefrigerantor vapor,
3 . Add the same amount of new refrigerantoil to the
systemthat was removedduring recovery.Use
only KEIHINSP-10refrigerantoil.
4 . Chargethe system with the specifiedamount of
dn di s
U s eo n l y s e r v i c ee q u i p m e ntth a t i s U . L . ' l i s t e a
certifiedto meet the requirementsof SAEJ2210to
r e m o v eH F C - 1 3 4{aR - 1 3 4 af r) o m t h e a i r c o n d i t i o n i n g
system.
Additionalhealthand safetyinformationmay be
manufacturers.
R-134arefrigerant.Do not overchargethe system;
the compressorwill be damaged.
Selectthe appropriateunits of measurefor your
refrigerantchargingstation.
Refrigerant capacity:
500 to 550 g
0.50to 0.55 kg
1 . 1 0t o 1 . 2 1l b s
17.6to 19.4oz
Checkfor refrigerantleaks(seepage 21'56).
c h a r g i n gs t a t i o n( A )t o t h e h i g h - p r e s s u rsee r v i c e
pon (B)and the low-pressureserviceport {C),as
instructions.
Checkfor system performance(seepage 21-58).
21-55
RefrigerantLeakTest
Leakdetector,HondaTool and EquipmentYGK-H-10PM
vvailable
chargingstation(A)to the high-pressureservice
port (B)and the low-pressureserviceport (C),as
anstructions.
Compressedair mixed with R-134aforms a
combustiblevapor.
The vapor can burn or explodecausingserious
injury.
Neverusecompressed
airto pressure
test
R - 1 3 4 as e r v i c ee q u i p m e n ot r v e h i c l ea i r
conditioningsystem.
A i r c o n d i t i o n i n gr e f r i g e r a not r l u b r i c a nvt a p o r
Do not breatherefrigerantor vapor
certiifiedto meet the requirementsof SAE J2210to
r e m o v eH F C - 1 3 4(aR - 1 3 4 af r) o m t h e a i r c o n d i t i o n i n g
system.
work area before resumingservice.
R - 1 3 4 as e r v i c ee q u i p m e n o
t r v e h i c l ea i r c o n d i t i o n i n g
systemsshould not be pressuretestedor leaktested
with compressedair.
manufacturers.
Open the high pressurevalve to chargethe system
to the specifiedcapacity,then closethe supply
valve,and removethe chargingsystem couplers.
Selectthe appropriateunits of measurefor your
refrigerantchargingstation.
Refrigerant capacity:
500 to 550 g
0.50to 0.55kg
1 . 1 0t o 1 . 2 1l b s
17.6to 19.4oz
3 . Checkthe systemfor leaksusing a R-134a
refrigerantleak detectorwith an accuracyof 14 g
(0.5oz) per year or better.
lf you find leaksthat requirethe systemto be
opened(to repair or replacehoses,fittings,etc.),
recoverthe system.
After checkingand repairingleaks,evacuatethe
system.
21-56
A/C SystemTests
Pressure
Test
Test results
(high)
Discharge
pressure
abnormallyhigh
svmotom3
pressure
Afterstoppingcompressor,
to
dropsquickly,andthencontinues
Beduced
or no airflow through
condenser
hot.
Lineto condenser
is excessively
DGaUSe
Air in system
Cloggedcondenser
or radiator
fins
or radiatorfan not
Condenser
Restrictedflow of refrigerantin
discharge
pressure Highand low pressures
arebalanced . Faultycompressor
Discharge
valve
Low
soonafterstoppingcompressor,
. Faultvcomoressor
seal
sideis hioherthannormal.
valve
Faultyexpansion
Outletof expansionvalve is not
gaugeindicates
Moisturein system
frosted,low pressure
(low)
Suction
pressure
low
abnormally
Suctionpressure
high
abnormally
Expansion
valveis not frosted,and
lineis not cold.Low
low-pressure
pressure
gaugeindicates
vacuum,
is low,andthe Frozenevaporator
Discharge
temperature
air flow from vents is restricted.
Exoansion
valveis frosted.
Receivetdryer
outletis cool,and inlet Cloggedreceiver/dryer
is warm (shouldbe warm during
ooeralton),
Low pressure
hoseandcheckjointare E x p a n s i o nv a l v e o p e n t o o l o n g
around
coolerthanthetemperature
evaoorator,
in system
refrigerant
Excessive
is loweredwhen
Suctionpressure
..nrlenser
is cooled bv water.
areequalized
Highand low pressure
is stopped,
assoonasthecompressor
while
andbothgaugesfluctuate
Suctionand
dascharge
pressures
abnormallv
hioh
Suctionand
pressure
discharge
abnormally
low
leaks
Fefrigerant
' Frozenexpansion
valve
(Moisturein system)
. Faultyexpansion
valve
Faultygasket
valve
Faultyhigh pressure
Foreignpaniclestuckin high
or radiator
Reduced
airflow throughcondenser. . Cloggedcondenser
fins
' Condenser
or radiatorfan not
workinoorooerlv
Cloggedor kinkedlow-pressure
hoseand metalend
Low-pressure
hoseoarts
areasarecoolerthanevaoorator,
valve C l o g g e d h i g h - p r e s s u r el i n e
Temperature
aroundexpansion
is too low comparedwith thataround
:omoressor
clulchis dirtv.
lomoressorbolt(s)aredirtv.
; o m D r e s s o ro a s k e t i s w e t w i t h o i l .
:omoressor
shaftsealleakinq
no aroundbolt(s)
iet
no
Recover,evacuate(seepage21-54),
and rechargewith specifiedamount
{seeoaoe21 55).
Clean
Checkfan voltageand rpm.
Checkfan direction.
restricted
lines.
Replace
the compressor.
Beplace
. Replace
valve.
the expansion
. Recover,evacuatefor at least
30 minutes,and rechargewith
sDecified
amount.
Recover,evacuatefor at least
with
30 minutes,and recharge
amount.
specified
valve.
the expansion
Beplace
Runthe fan with compressoroff, then
checkevaooratottemoeraturesensor.
eanor reolace,
Replacereceaver/dryer.
Bepairor replace.
Recover,evacuate,and rechargewith
qnp.ifie.lamo'rnr
Replace
the compressor.
Clean
Checkvoltageand fan rpm.
Checkfan direction.
Repairor replace.
Repairor replace,
Reolace
the comDressor,
Tiohtenbolt{s)ot reolacecomDressor,
acethe comoressor.
(cont'd)
21-57
A/C SystemTests(cont'd)
PerformanceTest
' Compressedair mixed with R-134aforms a
combustiblevapor.
. T h e v a p o rc a n b u r n o r e x p l o d ec a u s i n gs e r i o u s
Injury.
. Never use compressedair to pressuretest
R - 1 3 4 as e r v i c ee q u i p m e n ot r v e h i c l ea i r
conditioning
systems.
Open the glove box. Removeboth glove box stops,
then let the glove box hang down (seepage 20-63).
4 . Inserta thermometer(A) in the centervent, and
placeanotherthermometer{B) nearthe blower unit.
can irritateyour eyes,nose,or throar.
Do not breatherefrigerantor vapor.
The performancetest will help determineif the air
conditionersystem is operatingwithin specifications.
cenified to meet the requirementsof SAE J2210to
r e m o v eH F C - 1 3 4(aR - 1 3 4 a l f r o m
t h e a i rc o n d i t i o n i n g
system.
R - 1 3 4 as e r v i c ee q u i p m e n ot r v e h i c l ea i r c o n d i t i o n i n g
systemsshould not be pressuretestedor leaktested
with compressedair.
manufacturers.
1 . Connecta R-134arefrigerantrecover/recycling/
chargingstationto the high-pressureserviceport
and the low-pressureserviceport, following the
D e t e r m i n et h e r e l a t i v eh u m i d i t ya n d a i r
Iemperarure.
21-58
Test conditions:
.
.
.
.
Avoid direct sunlight.
Open the hood.
Open the front doors.
Sel the temperaturecontrol dial on Max Cool,the
mode control dial on Vent,and the recirculation
control switch on Recirculate.
. Turn the A,/Cswitch on and the fan switch on Max.
. R u nt h e e n g i n ea t 7 5 0 r p m .
. N o d r i v e ro r p a s s e n g e risn v e h i c l e .
A f t e r r u n n i n gt h e a i r c o n d i t i o n i n fgo r I 0 m i n u t e s
underthe above test conditjons,read the delivery
temperaturefrom the thermometerin the center
vent, the intaketemperaturenear the blower unit,
and the high and low system pressurefrom the Ay'C
g au g e s .
7. To completethe charts:
.
.
.
.
.
.
.
.
M a r k t h ed e l i v e r y t e m p e r a t u a
r el o n gt h e v e r t i c a l i n e .
Mark the intaketemperature(ambientair temperature)along the bottom line.
Draw a line straightup from the air temperatureto the humidity.
M a r ka p o i n t 1 0% a b o v ea n d 1 0% b e l o w t h eh u m i d i t yl e v e l .
From each point. drawa horizontalline acrossthe deliverytemperature.
The delivervtemperatureshould fall betweenthetwo lines
Completethe low-sidepressuretest and high-sidepressuretest in the same way.
Anv measurementsoutsidethe line may indicatethe needfor further inspection.
kPa
(ksl{cm')
Lpsrl
2500[25) _
360l
{kgflcm')
Lpsil
600
{6t
80 yo
a0 0/"
tssl
2000
(201
1280
HUMIDITY
LEVEL
30 9o
fcl
1500{1s}
,21o)
30%
80%
1000(101
:1401
500 {5)
171l
DELIVERY
PRESSURE
100
{11
h4l
INTAKE
PRESSURE
OELIVERY
TEMPERATURE
68
t20l
I
I
86
77
t30)
t25l
INTAKETEMPEBATURE
I
95
(35)
104
{40)
.F
{'cl
21-59
BodyElectrical
\
Body Electrical
SpecialTools
tntorrnaiion.'......
22,3
RelayandControlUnit Locations.....22-7
Connectors
and Harnesses
22-13
Fuse/Relay
Boxes...............................
22-44
PowerDistribution.............................
22-46
GroundDistribution...........................
22-4A
Under-dash
Fuse/Relay
Box ..............
22-49
Battery ..............
Relays................
*lgnitionSwitch ..............
22-50
22-51
22-53
*Gauges
C o m p o n e nLto c a t i o Inn d e x . . . . . . . . . . . . . . . . 22-54
.......
S e l f - d i a g n o sPt irco c e d u r .e. . . . . . . . . . . . . . . . . 22-56
........
CircuitDiagram
22-54
G a u g eB u l bR e p l a c e m e n. .t . . . . . . . . . . . . . . . .22
. . . .63
....
GaugeAssemblyReplacement
22-64
CoolantTemperature
......
G a u g eT r o u b l e s h o o t i n.g. . . . . . . . . . . . . . . . 22-64
VehicleSpeedSignalCircuit
Troubleshooting
22-65
VSSReplacement
22 61
ExteriorLights
C o m p o n e nLto c a t i oInn d e x . . . . . . . . . . . . . . . . 22-68
.......
C i r c u iD
t iagram
22--71
DaytimeRunningLightsControi
U n i tI n p u tT e s t( C a n a d a .) . . . . . . . . . . . . . . . .22-7
. . . . .6. .
H e a d l i g hAtd , u s t m e n .t . . . . . . . . . . . . . . . . . . 22-74
H e a d l i g hRr e p l a c e m e n. .t. . . . . . . . . . . . . . . . . . .22-79
.........
CombinationLightSwitch
Test/Replacement
22-AO
B u l bR e p l a c e m e n t
22-41
T a i l l i g hRt e p l a c e m e n. .t . . . . . . . . . . . . . . . . . . . .22-82
....
HighMountBrakeLightReplacement......22-42
LicensePlateLightReplacement..............
22-43
S i d eM a r k e L
r i g h tR e p l a c e m e n. .t. . . . . . . . . .22-43
....
BrakePedalPositionSwitchTest ..............
22-44
SideTurn SignalLightReplacement........22-84
Turn Signal/Hazard
Flasher System
C o m p o n e nLto c a t i o Inn d e x . . . . . . . . . . . . . . . . 22-85
.......
C i r c u iD
t iagram
22 A6
Turn Signal/Hazard
RelaylnputTest ........22-87
HazardWarningSwitchTest
22-88
Entry Lightscontrol system
ComponentLocationIndex .......................
22-89
C i r c u iD
t iagram
. . . . . . . 2. .2 9 0
lgnitionKeySwitchTest .....................,......
22-9'l
l g n i t i o nK e yL i g h tT e s t . . . . . . . . . . . . . . . . . . . . . 2
. .2. .-.9. .1. . .
C o n t r oUl n i tI n p u tT e s t . . . . . . . . . . , . . . . . . . . . . 2
. .2. .9. 2
.....
InteriorLights
22-94
CircuitDiagram
.........22-95
CeilingLighVSpotlights
T e s V R e p l a c e m e. n
. .t. . . . . . . . . . . . . . . . . . . . .2. .2. -. .9.6. . . . .
RearCeilingLightTesVReplacem
ent ........22-96
CargoAreaLightTest/Replacem
ent .........22-97
HatchLatchSwitchTest ..,..,.......................
22-97
*Audio System
22-98
CircuitDiagram
.........22,99
AudioUnit Removal/lnstallation
...............
22-1OO
Audio Unit ConnectorReplacement.........22-101
SpeakerReplacement................................
22-102
RoofAntennaRep1acement
....................-..
22-103
Rear Window Defogger
ComponentLocationIndex ...........
22-104
C i r c u iD
t i a s r a m. . . . . . . . . . . . . . . . . . . . . : : : : : . : :22-105
.::.
FunctionTest
D e f o g g eW
r i r eR e p a i r. . . . . . . . . . . . . . . . . . . . . . .22-106
..........
N o i s eC o n d e n s eCra p a c i t y T e s. t. . . . . . . . . . .22-107
....
Moonroof
C o m p o n e nLto c a t i o Inn d e x . . . . . . . . . . . . . . . . 2. .2. .-.1. .O B
CircuitDiagram
.........22-109
MoonroofControlUnitInputTest .............
22-'l10
S w i t c hT e s V R e p l a c e m e. n
. .t. . . . . , . . . . . , . . .2. .2. .- .11. .2.
MotorTest
.................
22-112
LimitSwilchTest
......22-'l'13
Auto-stopSwitchTest ................................
22-113
PowerMirrors
22-114
CircuitDiagram
.........22-115
FunctionTest
.............
22-116
P o w e rM i r r o rS w i t c hT e s t . . . . . . . . . . . . . . . . . . 2. .2. .-.l .l .7.
PowerMirrorActuatorTest .......................
22-117
PowerMirrorActuatorReplacement........22-11A
* Horns
22-120
CircuitDiagram
.........22-121
H o r nT e s V R e p l a c e m e. n
. .t. . . . . . . . . . . . . . . . .2. .2. -. .1. 2. -2.
HornSwitchTest
.,....22-122
\
PowerWindows
22 124
ComponentLocationIndex ..........
::::.:
c i r c u i tD i a g r a m. . . . . . . . . . . . . .......... . . . . : . : : : : .22-125
M a s t eS
r w i t c hI n p u tT e s t . . . . . . . . . . . . . . . . . . .22-126
........
22-128
MasterSwitchTest
......
D r i v e r 'W
s i n d o wM o t o rT e s t . . . . . . . . . . . . . . .22-129
Passenger's
WindowSwitchlnputTest ... 22- t30
Passenger's
WindowSwitchTest .............
22-132
22 132
Passenger's
WindowMotorTest ..............
22-133
lMaster
SwitchReplacement......................
Passenger's
WindowSwitch
22-133
Replacement
Wipers/Washers
22-134
C i r c u iD
t iagram
RearWindowWiperIntermiftent
........
C o n t r oU
l n i tI n p u tT e s t . . . . . . . . . . . . . . . . . . .22-138
Wiper/Washer
Switch
22-140
TesVReplacement
..
C o n t r oU
l n i tI n p u tT e s t . . . . . . . . . . . . . . . . . . . . . .2.2. .-.1. .4. 1
WiperMotorTest
22-143
22-144
WasherMotorTest
WasherFluidLevelSwitchTesV
.......
R e p l a c e m e(nCt a n a d a.l . . . . . . . . . . . . . . . . . .22-144
WindshieldWiperMotor Replacement.... 22-145
RearWindowWiperMotor
Replacement
22-146
....
W a s h eR
r e s e r v oR
i r e p l a c e m e n. .t. . . . . . . . . .22-146
. . . 147
...
W a s h eTr u b e sB e p l a c e m e n. .t. . . . . . . . . . . . . .22
Accessory Power Socket
.........22-149
CircuitDiagram
AccessoryPowerSocket
. .t. . . . . . . . . . . . . . . . . . . . .2. .2. .- .14. .9. . . .
T e s V R e p l a c e m e. n
Keyless/Power Door Lock System
22-150
.........22-151
CircuitDiagram
22-153
KeylessReceiver
Unit InputTest ...............
22-155
ControlUnit InputTest ...............................
D o o rL o c k A c t u a t o r T e s. .t. . . . . . . , . . . . . . . , . .2, 2. ,-.1. .5. .8
. .5. .9
H a t c hL o c k A c t u a t o r T e s. .t. . . . . . . . . . . . . . . . .2. .2. -. 1
22-160
DoorLockKnobSwitchTest ......................
22-160
DoorLockSwitchTest ................................
.......22-161
TransmitterTest
T r a n s m i t t ePrr o g r a m m i n .g. . . . . . . . . . . . . . . . .2. 2. .-.1. .6. 1
lmmobilizerSystem
22-162
componentLocationIndex ...........
...
S y s t e mD e s c r i p t i o .n. . . . . . . . . . . . . . . :. . . : . . : . :22-163
22-164
CircuitDiagram
Troubleshooting
lmmobilizerControlUnit
- R e c e i v eRre p l a c e m e n. .t. . . . . . . . . . . . . . . . .22-167
........
Multiplex ControlSystem
22,164
ComponentLocationIndex ...........
:.:..:.::.:
c i r c u i tD i a g r a m. . . . .... . . . . . . . . . . . . . . . . . . . . . . :22-169
22-17'l
SvstemDescriDtion
22,112
Troubleshooting
M u l t i o l eC
x o n t r oUl n i tI n D uTt e s t . . . . . . . . . . .2.2. - 1 7 5
BodyElectrical
SpecialTools
Ref. No.
Q)
o)
o
Tool Number
07wAz-001010A
O7LAJ-PT3O2OA
07TAz-001020A
Description
MPCSServiceConnector
Test Harness
BackProbeAdaotet
1
1
1
@
22-2
Otv
Tipsand Precautions
Before Troubleshooting
1. Checkapplicablefuses in the appropriatefuse/relay
oox.
Some connectorshave a clip on their side used to
attachthem to a mount bracketon the body or on
a n o t h e rc o m p o n e n tT. h i sc l i p h a sa p u l lt y p e l o c k .
Some mountedconnectorscannot be disconnected
unlessyou first releasethe lock and removethe
connectorfrom its mount bracket(A).
2. Checkthe batteryfor damage.stateof charge,and
cleanand tight connections.
. Do not quick-chargea batteryunlessthe battery
ground cable has been disconnected,otherwise
you will damagethe alternatordiodes.
. Do not attemptto crankthe enginewith the
batteryground cable looselyconnectedor you
w i l l s e v e r e l yd a m a g et h e w i r i n g .
Handling Connectors
. Make surethe connectorsare clean and have no
l o o s ew i r e t e r m i n a l s .
. Make sure multiplecavity connectorsare packedwith
dielectricgrease(exceptwatertight connectors).
. All connectorshave push-downreleasetype locks(A).
Nevertry to disconnectconnectorsby pulling on their
wires; pull on the connectorhalvesinstead.
Alwavs reinstallDlasticcovers,
Beforeconnectingconnectors,make sure the
terminals(A) are in placeand not bent.
(cont'd)
22-3
BodyElectrical
GeneralTroubleshootingInformation(cont'd)
Checkfor looseretainer(A)andrubberseals(B).
The backsof some connectorsare packedwith
dielectricgrease.Add greaseif necessary.lf the
greaseis contaminated,replaceit.
HandlingWires and Harnesses
. Securewires and wire harnessesto lhe frame with
their respectivewire ties at the designatedlocations.
. Removeclips carefully;don't damagetheir locks(A).
S l i p p l i e r s( A ) u n d e rt h e c l i p b a s ea n dt h r o u g ht h e
hole at an angle,then squeezethe expansiontabs to
r e l e a s et h e c l i p .
J
lnsertthe connectorall the way and make sure it is
securelvlocked.
Positionwires so that the open end of the cover faces
oown.
After installingharnessclips, make sure the harness
doesn't interferewith any moving pans.
Keepwire harnessesaway from exhaustpipes and
other hot parts,from sharp edgesof bracketsand
holes,and from exposedscrewsand bolts.
Seatgrommets in their grooves properly{A). Do not
leavegrommets distorted(B).
| . , ./ f
.ll
----E;
'l/ F.
I
22-4
t/
lwtl"//
\--------\
tflr'---'..-
It
Testingand Repairs
. Do not usewires or harnesseswith brokeninsulation.
Replacethem or repairthem by wrappingthe break
withelectricaltape.
. After installingparts,make surethat no wires are
o i n c h e du n d e rt h e m .
. When using electricaltestequipment,followthe
manufacturer'sinstructionsand those describedin
t h i sm a n u a l .
. l f p o s s i b l ei ,n s e r t t h ep r o b eo f t h e t e s t e r f r o m t h ew i r e
side (exceptwaterproofconnector).
UsebackDrobeadaotor07TM-0010204.
Referto the instructionsin the HondaTerminal Kit for
identificationand reolacementof connectorterminals.
( c o n td )
22-5
BodyElectrical
Five-stepTroubleshooting
'1.
Verify The Complaint
T u r n o n a l l t h e c o m p o n e n t si n t h e p r o b l e mc i r c u i t
to verify the customercomplaint.Note the
symptoms.Do not begin disassemblyor testing
until you have narroweddown the problem area.
2. AnalyzeThe Schematic
Look up the schematicfor the problem circuit.
Determinehow the circuit is supposedto work by
tracingthe currentpathsfrom the power feed
through the circuitcomponentsto ground. lf
severalcircuitsfail at the same time, the fuse or
g r o u n di s a I i k e l yc a u s e .
Basedon the symptoms and your understandingof
the circuitoperation,identifyone or more possible
causesof the problem.
3. lsolateThe ProblemBy TestingThe Circuit
Make circuitteststo checkthe diagnosisyou made
i n s t e p2 . K e e pi n m i n d t h a t a l o g i c a ls, i m p l e
procedureis the key to efficienttroubleshooting.
Testfor the most likelycauseof failure first, Try to
make tests at pointsthat are easilyaccessible.
4. Fix The Problem
Oncethe specificproblem is identified.make the
repair.Be sure to use propertools and safe
proceoures.
5. Make Sure The CircuitWorks
Turn on all componentsin the repairedcircuit in all
modes to make sure you've fixed the entire
problem.lf the problemwas a blown fuse, be sure
to test all of the circuitson the fuse. Make sure no
n e w p r o b l e m st u r n u p a n d t h e o r i g i n a p
l roblem
does not recur.
22-6
Wire Color Codes
The following abbreviationsare usedto identifywire
colors in the circuitschematics:
w H T . . . . . . . . . . . . . . . . . . . . , . , . White
............
Y E L . . . . . . . . . . . . . . . . . . . . . . , , .Y. .e.l.l .o. w
,......
B 1 K . . . . . . . . . . . . . . . . . . . . . . . . . . .B
. .l.a. .c. k. . . . .
B L U. . . . , . . . . . . . . . . . . . . . . . . . . . . .B. .l.u. .e. . . .
G R N . . . . . . . . . . . . . . . . . . . . . . . .G
. .r.e. .e.n. . . . . . .
R E D. . . . . . . . . . . . . . . . . . . . . . . . . . . .Red
........,
o R N . . . . . . . . . . . . . . . . . . . . . . . . Orange
.............
P N K . . . . . . . . . . . . . . . . . . . . . . . .P
. .i,n. k. . . . . . . . .
B R N . . . . . . . . . . . . . . . . . . . . . . . .Brown
.............
G R Y . . . . . . . . . . . . . . . . . . . . . . . .Gray
............,
P U R . . . . . . . . . . . . . . . . . . . . . . . .P
. .u. .r .p.l.e. . . . . .
1 T 8 1 U . . . . . . . . . . . . . . . . . . . . . Light
. . . . . ,Blue
.....
1TGRN....................L
. .i.g. h
. .G
t. ,r.e. .e n
The wire insulationhas one color or one color with
anothercolor stripe.The secondcolor is the stripe.
Relayand Control Unit Locations
EngineCompartment
BLOWERMOTORRELAY
RADIATORFAN
RELAY
HORNRELAY
CONDENSERFAN
RELAY
ELDUNIT
UNDER-HOOD
FUSE/RELAY
BOX
\...
,-:1-'...
22-7
Relayand GontrolUnit Locations
Dashboard
RUNNINGLIGHTSEELAYlCanada)
_DAYTIME
lWirecolorsrRED,RED/YEL,I
andRED/8LU
LRED/BLK
I
BEAMCUTRELAYlcanada) _
_LOW
REDMHT,
RED/BLK,
colors:
lWire
I
andRED/BLU
LBEDA/EL
I
KEYLESSRECEIVER
UNIT
CRUISECONTROLUNIT
'
':
'-.:-
..? ;,
POWERWINOOW RELAY
TURN SIGNAL/HAZARDRELAY
TAILLIGHTRELAY
;
.[:_- -
-l:r
UNDER.DASH
FUSE/RELAY
BOX
--
MULTIPLEXCONTROLUNIT
22-8
(cont'd)
22-9
Relayand Control Unit Locations
a
Dashboard(cont'd)
L
\
SRSUNIT
EPSCONTROLUNIT
AIR/FUEL
RATIOSENSOR
RELAY
[WirecolorsrWHT,WHT/RED, I
OBNandBLK/ORN
I
22-10
PGM.FIMAINRELAY1
lWirecolors:YEUBLK,
WHT/BLKand RED/YEL
LWHT/BLK,
PGM.FIMAN RELAY2
fwirecolors:YEUBLK,
I
YEUBLKand GRN/YELI
LYEUGRN,
Rearand Roof
OPENRELAY MOONROOF
Wirecolors:GRNI/EL,
GRN, I
BLKandYEL/GRNI
LRED/YEL,
MOONROOF
CLOSERELAY
GRN, l
fwire colors:GRN/BLK,
BLKand YEL/GRNI
IGRN,AtVHT,
REARWINDOWWIPERINTERMITTENT
CONTBOL
UNIT
22-11
Relayand ControlUnit Locations
Door and Seat
Driver'sDoor:
l\:
].\
POWERWINDOWMASTERSWITCH
lHasbuilt-incontrolunit)
Passenger's
Seat:
22-12
Gonnectors
and Harnesses
a
GonnectorIndex
"G" for ground
ldentification
numbershavebeenassigned
to in-lineconnectors.
The numberis preceded
by the letter"C" for connectors,
terminalsor "T" for non groundterminals.
Hamess
Location
EngineCompartment
Dashboard
Others{Floor,Door,
Trunk.and Roo{l
Not€s
Startersubharness
C 1 0 2a n dC 1 0 3
T1 andT2
T 1 0 1a n dT 1 0 2
(seepage22-15)
Batterygroundcable
T3
G'l and ( T4
{seepage22-l!)
Enginegroundcable
{seepage22-14)
Enginewire harness
C l 0 l t h r o u g hC 1 0 4
G1 0 1
Enginecompartment
wire harness G201andG202
{riohtbranchi
Enginecompartment
wire harness G301
(leftbrench)
Enginecompartment
wire harness
(dashboard)
(seepage22 16)
(seepage22 18)
(seepage22 18)
(seepage22-18)
c401
C451and C452
C501throughC503
c551
c851
G402
EPSsubharness
C 1 5 1a n d C 1 5 2
G'151
\seepage22 241
Dashboard
wire harness
A
lleftbranch)
C504throughC510
G501andG503
(seepage22-26)
L e f ts i d et u r n s i g n a l l i g h t
c506
(seepage22-26)
Dashboard
wire harness
A
(rightbranch)
C50lthroughC503
C 5 l l t h r o u g hC 5 1 5
C852andC853
G502
(seepage22-26)
lseepage22-26)
Rightside turn si9nal light
sub harness
Dashboard
wire harnessB
ECMwire harness
(seepage22-30)
C40lthrough
C403
c510
G40l
c101
cl52
C451
through
C453
c511
{seepage22-32}
G451
Floorwireharness(frontside)
C402
andC403
c453
C508
andC509
c512
G551
(see page 22'34)
Floorwire harness(rearside)
C553and C554
(seepage22-34)
Roo{wire harness
Hatchwire harness
Driver'sdoorwire harness
c507
C553andC554
C504andC505
5 1 4a n dC 5 1 5
)552
(seepaqe22-38)
c851 rhrouoh c853
( s e ep a q e 2 2 . 4 3 i
C 5 5 1a n . l C 5 5 ?
P a s s e n q e r ' sd o o r w i . e h a r n e s s
T eh a r n e s s
/C wire harness
( s 6 ep a q e 2 2 ' 3 9 )
(see paqe 22-40)
( s e eo a o e 2 2 - 4 1
(seeoaqe22-42i
22-13
and Harnesses
Connectors
Gonnectorto Harnesslndex
BatteryGroundCable
Connectoror Terminal
Cavities
T3
2
Location
Left side of enqinecompartment
Left side of enginecompartment
Batterv
Connectsto
Notes
Bodygroundviabattery
qroundcar)le
B a t t e r vn e o a t i v et e r m i n a l
EngineGround Cable
r4
Cavities
5
4
focation
Riohtsideof enoine
Rightsideof enginecompartment
Connec{sto
Bodygroundviaengine
ENGINEGROUNDCABLE
BATTERYGROUNDCABLE
\.....
22-14
Notes
StarterSubharness
Alternator
Knocksensor
Startersolenoid
c102
Ret
10
8
5
7
Cavities
4
1
1
6
c103
6
1
T1
2
T101
4
1
I
r2
r102
Location
Connoc,ts
to
Right side of eng;necompartment
Front of engine
Middle of enginecompartment
Front of enginecompartment
F r o n t o f e n g a n ec o m p a r t m e n t
L€tt sideof enginecompartment
Middleor enoinecomDanment
Under-hood
fuse/relay
box
Alternator
Batterv
Notes
Enginewire harness(see
page22 16)
o a a e2 2 - 1 6 )
Underhoodfuse/relay
box
Stanermotor
Battervpositiveterminal
STARTERSUB HARNESS
22-15
Connectorsand Harnesses
Connectorto HarnessIndex(cont'dl
EngineWireHarness
position(CMP)sensor
Camshaft
Lllr sensor
EC[,4connectorA
ECI/lconnectorB
(ECT)
Enginecoolanttemperature
sensor
Engineoil pressure
switch
EVAPcanisterpurgevalve
ldleair control(lAC)valve
lgnitioncoilNo. l
lgnitioncoilNo.2
lgnitioncoilNo.3
lgnitioncoilNo.4
IniectorNo. 1
InlectorNo.2
IniectorNo.3
IniectorNo.4
Intakeairtemperature
{lAT)sensor
2
3
3
24
2
28
18
4
5
6
7
25
24
20
19
12
TDCsensor
Throttleposition(TP)sensor
Vehiclespeedsensor(VSSI
VTCoil controlsolenoidvalve
VTECoil pressureswitch
VTECsolenoidvalve
c 101
8
11
10
27
29
30
3
c102
22
1
2
3
3
3
3
3
2
2
2
2
2
3
3
3
2
2
2
20
Transmission
housing
Leftsideof engine
Rightsideofengine
Underglovebox
Underglovebox
Leftside of engine
BightsideoI engine
Leftside of intakemanifold
Left sideof intakemanifold
Middleof enginecompartment
Middleof enginecompanment
Leftsideof intakemanifold
Leftsideof engine
Left side of intakemanifold
housing
Transmission
Rightsideo{ engine
Rightsideof engine
Rightsideof engine
Underrightsideof dash
Frontof enginecompanment
Frontof enginecompartment
22-16
ECMwire harness{seepage
22-321
(seepage
Startersubharness
22-15)
(seepage
Startersubharness
22 151
....-
10
11
13
14
22-17
Connectorto HarnessIndex{cont'dl
EngineCompartmentWire Harness(Rightbranch)
Connsctoror Terminal
ABSmodulator-control
unit
Bearwasher
motor
RightfrontABSwheelsensor
Rightfrontairbags€nsor
Bightfrontparkinglight
Rightfrontsidemarkerlight
Rightfrontturn signallight
Rightheadlight
Righthorn
wash€rfluidlevelswitch
Windshield
washermotor
G201
G202
Cavitiss
8
12
1
10
11
2
7
6
2
2
2
2
2
2
I
2
2
Location
Bightsideo{ enginecompartment
Behindrightsideof {rontbumper
Rightsideot enginecompartment
Behindrightsideof frontbumper
Behindrightheadlight
Behindrightsideof Jrontbumper
Behindfrontbumper
Behindrightsideof trontbumper
Behindriohtsideof frontbumoer
Behindrightsideof trontbumper
Behindrightsideof Jrontbumper
Connectsto
Notes
Canada
Bodygroundvia€ngine
compartment
wtreharness
Bodygroundviaengine
.omnerhent
wire harness
\
22-18
ENGINECOMPARTMENT
WIRE
HARNESS
(cont'd)
22-19
Connectors
and Harnesses
Connectorto HarnessIndex (cont'dl
EngineCompartmentWire Harness(Left branch)
AirJuel(A,,/F)
ratiosensor
Brakefluidlevelswitch
Condenser
fan motor
Cruisecontrolactuator
ELDunit
Foglightconnector
LeftfrontABSwheelsensor
Leftfrontairbagsensor
Leftfrontparkinglight
Leftfrontsidemarkerlight
Leftlrontturnsignallight
Leftheadlight
Lefthorn
Radiatorfan motor
Radiator
fan switch
Secondary
heatedoxygen(SHO2S)
Testtachometer
connector
Windshield
wipermotor
Under'hood
fuse/relay
box
connector
A {seepage22-44)
Under-hood
f use/relay
box
connectorB (seepage22-44)
Underhoodfuse/relay
box
connector
C (seepage22-44)
Underhoodfuse/relay
box
D (seepage22 44)
connector
fuse/relay
Under-hood
box
24
22
2
2
25
1
9
2
2
4
3
,l
3
4
Frontof enginecompanment
Leftsideof enginecompartment
Leftsideo{ enginecompartment
Underrightsideof cowlcover
Under'hood
f use/relay
box
Leftsideof enginecompanment
Behindleftsideof frontbumper
Behindleftheadlight
Behindleftsideof frontbumper
Eehindleftheadlight
Behindleftheadlight
Behindfrontbumper
11
7
2
5
2
Leftsideof enginecompanment
L.Jnder
leftsideof cowlcover
L.Jnder
hoodfuse/relay
box
I
5
L.Jnder
hoodfuse/relay
box
10
12
L.Jnder'hood
f use/relay
box
12
17
13
20
21
23
l
2
2
2
2
2
3
l
2
2
5
underhoodfuse/relay
box
6
fuse/relay
Under-hood
box
\
22-20
l'
\-
ENGINECOMPARTMENTWIRE
HARNESS
(conr'd)
22-21
and Harnesses
Connectors
Connectorto HarnessIndex (cont'd)
EngineCompartmentWire Harness(Dashboard)lcont'dl
Cavities
Location
1
Undermaddle
of dash
12
Underleftsideof dash
Foglightconnector
Under'dash
fuse/relay
box
connector
F (seepage22-45)
Underdash
fuse/relay
box
G (seepage22-45)
connector
Underdash
fuse/relay
box
connector
H (seepage22'45)
fuse/relay
Under-dash
box
connector
| (seepage22'45)
Under-dash
fuse/relay
box
connector
J (seepage22-45)
c151
c401
1
Underrightsideot dash
c451
I
c452
9
UnderrightsideoJdash
c501
10
'10
UnderrightsideoI dash
c502
6
4
Underrightsideol dash
c502
6
8
5
10
Undermiddleof dash
1
5
5
10
3
2
5
3
8
Underleftsideol dash
12
2
c503
c851
'14
G402
1' I
Connectsto
EPSsubharness
{seepage2224)
wire harnessB
Dashboard
(seepage22-30)
ECMwire harness(seepage
22-321
ECMwire harness(seopage
22 32)
Dashboard
wire harnessA
(seepage22-26)
Dashboard
wire harnessA
USA
lsee page 22-261
Dashboard
wire harnessA
Canada
(seepage22-26)
Dashboard
wire harnessA
(seepage22-26)
Floorwireharness(seepage
22-34l'
,VCwire harnesslsee page
22-43\
Eodygroundviaengine
..mdarlma.t
22-22
Notes
Oplion
w,rc harncss
BOX
FUSE/RELAY
UNDER-DASH
WIRE
ENGINECOMPARTMENT
D
'
-
' 1_-1.:,
-.,.i
ifa.: ,, ..j
,
. -,,
-g'-.t
';.-a
22-23
Connectorto Harnesslndex (cont'dl
EPSSubharness
EPScontrolunitconnectorA
EPScontrolunitconnectorB
EPScontrolunitconnector
C
EPSmotor
EPStorquesensor
c151
2
,l
3
1
6
c152
4
G151
5
22-24
Cavities
2
2
20
2
6
2
I
Location
Underrightsideofdash
Underrighrsideof dash
Middleof enginecompanment
Connectsto
Enginecompartment
wire
harness(seepage22-18)
ECI\,4
wire harness(seepage
22-321
aodygroundvia EPS
Notes
EPSSUB HARNESS
22-25
DashboardWire HarnessA {Leftbranchl
Accessorypower socket
Audioantenna
Brakepedalpositionswitch
Clutchinterlockswitch
Clutchpedalpoistionswitch
Cruisecontrolunit
Cruisemainswitch
Daytimer!nning lightscontrolunit
Daytimerunninglightsrelay
Gaugeassembly
connector
A
GaugeassemblyconnectorB
Hazardwarningswitch
Heatercontrol panelconnectorA
Heatercontrol panelconnectorB
HVACpush switch assembly
Keyless
receiverunit
Low beamcut relay
Optionalsecurityconnector
Powermirrorswitch
Under-dash
fuse/relay
box
connector
K (seepage22-45)
Under'dashfuse/relaybox
L {seepage22-45}
Underdashfuse/relay
box
connectorM lsee page22'45)
Under-dash
fuse/relay
box
connectorN (seepage22-45)
UndeFdash
fuse/relay
box
connector
O (seepage22-45)
UndeFdash
fuse/relay
box
connectorY(seepage22 45)
c504
22
2
26
30
29
6
28
I
8
20
11
18
19
10
5
3
27
,I4
2
2
4
2
2
14
5
14
4
22
22
10
22
'14
10
5
5
16
13
17
Undermiddleof dash
] Underleftsideof dash
] Underleftsrdeof dash
| Underleftsideof dash
I Underleftsideof dash
Underlettsideof dash
I Behindgaugeassembly
i Behindgaugeassembly
Behindhazardwarnningswitch
Behindheatercontrolpanel
Behindheatercontrolpanel
] BehindHVACswitchassembly
I Undermiddleof dash
lUnderleftsideofdash
Underlefrsideof dash
UnderleftsideoI dash
ln the under-dash
fuse/relay
box
l0
In the under-dash
fuse/relay
box
12
ffi
Canada
Canada
In the undeFdash
fuse/relay
box
In the underdashfuse/relay
box
12
11
Inthe under-dash
fuse/relay
box
L
In the under-dash
fuse/relay
box
c505
Underleftsideot dash
c506
34
c507
1
c508
Undermiddleof dash
c509
24
c510
25
G501
1
Undergaugeassembly
G503
21
Undermiddleof dash
12
Undermiddleol dash
(seepage22'40)
(seepage22-40)
Leftsideturo signallight
suonarness
Roofwire harness(seepage
22 3Al
Floorwire harness{seepage
22-341
Floorwire harness(seepage
22 34J
Dashboard
wire harnessB
(seeoaoe22-30)
Body ground via dashboard
Body ground via dashboard
Left Side Turn Signal Light Sub harness
Leftsideturn signallight
c506
22-26
35
34
Cavities
Location
2
B e h i n d l e f t s i d e t u r n s i g n a ll i g h t
2
Under left side of dash
Connectsto
Dashboard
wire harnessA
Noles
WIRE
DASHBOARD
A
HARNESS
,./
-19
20
34
LEFTSIDETURN SIGNAL LIGHT
SUB HARNESS
I
2s
). \'u
)t
30
(cont'd)
22-27
DashboardWire HarnessA (Rightbranch)
Connecloror Terminal
Cavities
Location
20
Eehindaudiounit
10
Audiounitconnector
c501
6
c502
5
4
c502
5
8
c503
4
5
tJnderrightsideof dash
c5' 11
c512
c514
ca52
c853
Undermiddleof dash
12
8
Undermiddleof dash
8
2
9
10
6
2
21
Undermiddleofdash
3
'l
G502
Undermiddleof dash
Connectsto
Enginecompartment
wire
harness(seepage22,18)
Enginecompanmentwire
Enginecompartment
wire
Enginecompartment
wire
ECN4
wire harness(seepage
22-321
Floorwire harness{seepage
22-341
Rightsideturn signallight
suonarness
Passenger's
doorwire
harness(seepage22 4l)
Passenger's
doorwire
harness(seepage22 4'l)
A,/Cwire harness(seepage
22-43)
ly'Cwire harness(seepage
22-431
Eodygroundvia dashboard
Notes
USA
Canada
Right Side Turn Signal Light Sub harness
ConnectororTorminal
Rightsideturn signallight
c5't3
22-28
1
8
Cavities
Location
2
Eehindrightsideturn signallight
2
Underriohtsideof dash
Connectsto
Dashboard
wire harnessA
Not€s
WIBE
DASHBOARO
HARNESS
A
'---/...'
T
I
22-29
Connectors
and Harnesses
Connectorto HarnessIndex(cont'd)
DashboardWire HarnessB
Collqctor or Terminal
C a b l e reel
2
1
17
16
't9
Cavities
Locatiol|
5
In steeringcolumncover
4
1
1
4
Undermiddleof dash
18
Undermiddleofdash
14
5
Underleft sideof dash
Combination
lightswitch
Driver'sairbaginflator
lgnitionkey switch
lgnitionswitch
lmmobilizer
controlunit receiver
Passenger's
airbaginflator
SRSunitconnector
A
Wiper/washerswitch
Underdashfuse/relay
box
connectorAlseepage22,45)
Under dashluse/relaybox
connectorB (seepage22-45)
Under'dash
fuse/relay
box
connectorC (seepage22-45)
Under-dash
fuse/relay
box
connector
S lseepage22-45)
Under'dash
fuse/relay
box
connectorX(seepage22 45)
c401
10
c402
12
10
Undermiddleof dash
c403
11
4
Undermiddleof dash
G510
14
12
Undermiddlesideof dash
G40l
22-30
18
I
3
5
6
6
Underleftsideofdash
14
1
2
8
8
Under left sideof dash
Undergaugeassembly
Connectsto
Enginecompartment
wire
harness(seepage22-'18)
22-34J
22-341
Dashboard
wire harnessA
(seeoaoe22-26)
Bodygroundviadashboard
Notes
WIRE
OASHBOARD
HARNESS
B
22-31
Connectors
and Harnesses
ECMWire Harness
Connectoror TerminiF
Arrruert/vrl ralo sensorretay
Datalinkconnector
EC[/lconnectorE
PGM-Flmainrelay1
PGM-Flmainrelay2
Under-dash
fuse/relay
box
connector
D (seepage22 45)
Underdashfuse/relay
box
connectorE lsee page22-45)
connectorR lsee page22-45)
c10'1
I Re- lcavities
8
7
6
1
4
4
2
L
Location
Eehindglovebox
Undermiddleof dash
Behindglovebox
Behindglovebox
Behindglovebox
In the under-dash
fuse/relay
box
Inthe under-dash
fuse/relay
box
3
6
In the under-dash
fuse/relay
box
4
20
Underrlghtsideof dash
c152
1' I
8
c451
I
c452
10
4
c453
14
6
UndermiddleoI dash
c511
12
G451
22-32
Connectsto
Undermiddleof dash
Undergaugeassembly
page22'16)
EPSsubharness(seepage
22-24)
Enginecompanment
wire
harness{seepage22-18)
Enginecompartment
wire
harness{seepage22-18)
22-34)
Dashboard
wire harness
A
{seeoaoe22-26)
Bodygroundvia ECMwire
harness
Notes
ECMWIREHARNESS
22-33
Connectorto Harnesslndex (cont'd)
FloorWire Harness(Frontsidel
Connec-tor
or Terminal
I
Driver'sseatbeltswitch
Driver'ssideairbaginflator
Driver'ssideimpactsensor
Leftside seatbelt buckletensioner
Memoryerasesignal(MES)connector
Parkingbrakeswitch
Passenger's
seatbelt switch
Passenger's
sideairbaginflator
Passenger's
sideimpactsensor
Rightsideseatbeltbuckletensioner
SRSunitconnector
B
SRSunitconnector
C
Under-dashfuse/relaybox
connector
P {seepage22-45)
Under-dash
fuse/relay
box
connectorO (seepage22,45)
c402
c403
Ref
uavftres
11
l0
13
12
19
9
5
3
7
4
20
21
11
3
2
2
4
2
1
3
2
2
4
18
8
18
'r8
8
22
23
c453
10
4
Location
I Underdriver'sseat
i Underdriver'sseat
I Leftside offloor
Underdriver'sseat
Underdashfuse/relay
box
1Middleoffloor
Underpassenger's
seat
Underpassenger's
seat
Rightsideoffloor
Underpassenger's
seat
I Undermiddleof dash
Undermiddleof dash
Underdashfuse/relay
box
Underdashfuse/relay
box
]
I
Undermiddleof dash
Undermiddleof dash
6
Undermiddleof dash
c508
2
4
Undermiddleof dash
c509
14
6
Undermiddleofdash
c512
1
8
10
6
G551
22-34
I
4
connects to
Undermiddleof dash
I
Undermiddleof dash
] Unaermiddleof aasn
L,nderpassenger's
seat
Dashboard
wire harnessB
{seepage22 30)
Dashboard
wire harnessB
(seepage22-30)
ECMwire harness(seepage
22-321
Dashboard
wire harnessA
(seepage22-26)
Dashboard
wire harnessA
\see page 22-26)
Dashboard
wire harnessA
{seepage22-26)
Enginecompartment
wire
harness(seepage22 18)
OPDSunitharness(seepage
22-421
Bodygroundviafloorwire
Nol6s
- 10
11
FLOORWIREHARNESS
( c o n t ' d)
22-35
Gonnectors
and Harnesses
a
Connectorto HarnessIndex (cont'dl
Floor Wire Harness {Rear side}(cont'dl
Cargoarea
Driver'sdoorswitch
EVAPemissionbypasssolenoidvalve
EVAPemissioncontrolcanistervent
shutvalve
Fuelpump/sending
unit
Fueltankpressure
sensor
Left back-uplight
Left rearABS wheel sensor
Leftrearsidemarkerlight
Left rear speaker
Leftrearturn signallight
Leftsideseatbelttensioner
LefttaillighVbrake
light
(rearwindow
Noisecondenser
defogger)
(rearwindowwiper)
Noisecondenser
Passenger's
door switch
Rearwindowwiperintermiftent
controlunit
Rightback-uplight
Righttaillighvbrake
tight
Rightrearturn signallight
BightrearABSwheelsensor
Rightrearsidemarkerlight
Rightrearspeaker
Rightsideseatbelttensioner
c554
6
2
24
2
1
2
2
LeftB pillar
Fueltank
Fueltank
I
3
25
1
26
4
2A
5
27
'13
5
3
2
2
2
2
2
2
3
2
Fueltank
Fueltank
Lefttaillight
Left rear offloor
Behindleftsideof rearbumper
Leftquarterpanel
Lefttaillight
LeftB-pillar
Lefttaillight
Rightquarterpanel
18
10
11
2
1
20
Rightquarterpanel
R i g hB
t pillar
Rightq uarterpanel
22
20
21
15
19
12
11
7
2
3
2
2
2
2
2
12
Righttai ight
Righttaillight
Righttaillight
Rightsideof cargoarea
Behindrightsideof rearbumper
Rightquanerpanel
RightB-pillar
Rightquanerpanel
I
12
Rightquanerpanel
side of cargo area
rearseal bdcl
Rightsideof cargoarea
22-36
H a t c hw i r e h a r n e s s( s e ep a g e
22 39)
H a t c hw i r e h a r n e s s( s e e p a g e
Bodv ground vta
Bodygroundviafloorwire
FLOORWIREHARNESS
22-37
Connectors
and Harnesses
RoofWire Harnsss
Moonroofclose
relay
Moonrool control unit
Moonroofmotor
Moonrootopenrelay
Moonroofpositionsensor1
N4oonroofpositionsensor2
Moonroofswitch
Rearceilinglight
SpotlighVceiling
light
c507
22-38
6
I
7
8
5
1
2
10
Cavities
5
5
2
5
2
4
5
3
4
8
tocation
Middleof roof
Middleof roof
Middleof roof
Middleof roof
MiddleoI roof
Middleof roof
Frontof roof
N4iddleof roof
Frontof roof
Connectsto
Dashboard
wire harnessA
(seeoaoe22-261
Notes
HatchWire Harness
Connectoror Torminal
Hatchlatchswitch
Hatchlockactuator
Highmountbrakelight
Licenseplatelight connectorA
Licenseplatelight connectorB
Rearwindowde{ogger
connector
A
I
3
Cavities
2
2
2
2
2
1
B
Bearwindowdetoggerconnector
10
1
LeftC-pillar
Bearwindowwipermoto.
c553
6
2
4
12
Middleof hatch
Rightquanerpanel
c554
l
2
Rightquanerpanel
( )
7
8
Location
Middleo{ hatch
Middleof hatch
Behindhighmountbrakelight
Middleof hatch
Middleof hatch
RightC-pillar
Connects to
Notes
22-341
)2-34\
22-39
Connectors
and Harnesses
Connectorto Harnesslndex (cont'd)
\,
Driver'sDoorWire Harness
Driver'sdoor lockactuator
Driver'sdoorlockknobswitch
Driver'sdoor lockswitch
Driver'sdoorspeaker
Driver'spowerwindow motor
Left power mirror actuator
Left tlveeter
Powerwindow masterswitch
c504
c505
ReI
9
10
1
7
2
3
Cavities
2
3
3
2
Location
8
5
20
Driver'sdoor
Driver'sdoor
Driver'sdoor
Driver'sdooa
Driver'sdoor
Driver'sdoor
Driver'sdoor
Driver'sdoor
6
't3
6
2
DRIVER'SOOORWIREHABNESS
22-40
Connectsto
A
Dashboard
wire harness
\seepage22-261
A
Dashboard
wire harness
Notes
Passenger'sDoor Wire Harness
Passenger's
doorlockactuator
Passenger's
doorspeaker
powerwindowmotor
Passenger's
powerwindowswitch
Passenger's
Rightpowermirroractuator
Righttweeter
c514
Rel
6
I
5
1
4
3
2
Cavities
2
2
2
5
6
2
13
Passenger's
door
Passenger's
door
Passenger's
door
Passenger's
door
Passenger's
door
Passenger's
door
1
6
Location
Connectsto
Notes
Dashboard
wire harnessA
(seepage22'26)
Dashboard
wire harnessA
lsee oeoe 22-26\
PASSENGER'S
DOORWIREHABNESS
22-41
and Harnesses
Gonnectors
Connectorto Harnesslndex {cont'dl
OPDSUnit Harness
ConnoctororTorminal
OPDSunit
Cavitios
2
1
I
Location
In frontpassenger's
seat
Underfrontpassenger's
seat
FLOORWIBEHARNESS
22-42
Connectsto
Floorwareharness(seepage
22-34)
Notes
A/C Wire Harness
Connoctoror Terminal
Air mix controlmotor
Blowermotor
Evaporator
temperature
sensor
Modecontrol motor
Powertransistor
Recirculation
controlmotor
c851
Rel
I
2
8
3
4
1
1
Cavities
5
2
2
10
5
1
Undermaddle
of dash
Undermiddleof dash
Undermiddleol dash
c852
6
21
Undermiddleofdash
c853
5
,]
Undermiddleo{ dash
Location
Connec'tsto
Notes
Enginecompartment
wire
Dashboard
wire harnessA
{seepage22 26i
Dashboard
wire harnessA
lsee oaoe 22-261
22-43
Fuse/Relay
Boxes
Connectorto Fuse/RelayBox Index
Under-hoodFuse/RelayBox
Socket
Ref
14
2
Ay'Ccompressorclutch relay
B
Blower motor relay
c
15
9
C o n d e n s efra n r e l a y
D
E
E L Du n i t
H e a d l i g hrte l a y1
Headlightrelay 2
Horn relay
Radiatorfan relay
Rearwindow defoqqerrelay
T1 (Batterv)
T101 (Alternator)
-
I
L'
-
1'
11
to
5
6
10
'l
J
|
||
-
-
-
T---r .-:-
t L _ _| . 1 I
t
t
t
L
"
"
tr
T
T
tTt Tr
,/^-------lFr
-/1-l
szl:!)
lrt
lview of tront sidel
22-44
Startersubharness(seeoaqe22-15)
Startersubharness{seeoaoe22-'15}
8
7
a-------) |
-
4
4
4
t t-l t t_l t tIl L l L l t l ' " . -
""""-l-
r^l
tt
Terminal
Connects to
2
Enginecompartmentwire harness(seepage 22-18)
4
5
Enginecompartmentwire harness(seepage22-18)
4
4
14
7
E n g i n ec o m p a r t m e nwt i r e h a r n e s s( s e ep a g e2 2 - 1 8 )
3
Enginecompartmentwire harness{seepage 22-18)
4
{View of back side)
Under-dashFuse/RelayBox
Socket
B
c
D
E
F
G
H
Ref
Terminal
2
3
1
5
6
14
5
19
9
I
20
13
12
10
3
J
K
24
22
27
26
7
M
N
o
P
Powerwindow relay
o
6
10
25
14
18
R
S
Startercut relay
T
Taillightrelay
Turn signal/hazardrelay
U
11
1:
.o^
;;
4
8
2
in
a
Floorwire harness(seepage 22-34)
ECMwire harness(seepage 22-32)
Dashboardwire harnessB (seepage 22-30)
Multiplexcontrol unit servicecheckconnector
l
l
17
2
Optionalconnector
Optionalconnector
Floorwire harness(seepage22-34)
28
I
13
{Plugsdirectly into the multiplexcontrol unat)
( P l u q sd i r e c t l vi n t ot h e m u l t i D l e cx o n t r o lunrl)
l5
to
W ( M e m o r ye r a s es i g n a l( M E S )
connector)
X
Y
:
11
'10
Connects to
Dashboardwire harnessB {seepage 22-30)
Dashboardwire harnessB {seepage 22-30)
Dashboardwire harnessB (seepage 22-30)
ECMwire harness(seepage 22-32)
ECI\4wire harness(seepage 22-32)
Enginecompartmentwire harness(seepage 22-'l8l
Enginecompartmentwire harness(see page 22-181
E n g i n ec o m p a r t m e nwt i r e h a r n e s s( s e ep a g e2 2 - 1 8 )
Enginecompartmentwire harness(see page 22-18)
Dashboardwire harnessA (seepage 22-26)
Floorwire harness(seepage 22-34)
l t
tn--rl
I U LI L.]L.J
h - - n UL]L]UL]
I] L] L] LI L]
!3
12
22-45
PowerDistribution
Fuseto Componentslndex
Under-hoodFuse/RelayBox
Fuse
Number
'I
Amps
204
15A
WireColor
Component(sl or Circuit(s) Protected
BLUI/EL Condenserfan motor
BLU/RED Ay'Ccompressorclutch
WHT/GRN Dashlights,Front parkinglights,Frontside marker lights,Licenseplate
l i q h t ,R e a rs i d em a r k e rl i q h t s T
, ailliqhts
15A
WHT/BLU C a r q oa r e al i q h t ,C e i l i n ql i q h t s l. q n i t i o nK e v l i q h t .S o o t l i o h t s
BLU/BLK Radiatorfan motor
WHT/BLK Turn siqnal/hazardrelav,Turn siqnal liqhts
WHT/BLK CKPsensor,ECM,IACvalve, lmmobilizercontrol unit-receiver,Injectors,
15A
WHT/GRN Brakelights,Brakesignals(to ABS modulator-controlunit, Cruisecontrol
20A
10A
B L U / R E D i1Orns
WHT/GRN ABS modulatorcontrol unit
, a u g ea s s e m b l yl,m m o b i l i z e r
WHT/RED A u d i o u n i t ,D a t al i n kc o n n e c t o(rD L C )G
7.5A
5
204
10A
P G M - Fm
I a i n r e l a v1 a n d 2 . T D Cs e n s o r
7
unit, ECM)
8
9
control unit-receiver,lmmobilizerindicatorlight. Keylessreceiverunil,
lvlultiDlexcontrol unit
10
40A
11
30A
IJ
40A
40A
14
40A
t5
15A
16
17
204
WHT/RED ABSmodulator-control
unit
BLK/YEL Noisecondenser,Rearwindow defoqqer
BLU^^/HT Blower motor
WHT/BLK No. 7 fuse (in the under-dashfuse/relavbox), Powerwindow relav
WHT/RED No.2 and No.3 fuses (in the under-dashfuse/relavbox)
REDI/EL Daytimerunning lightscontrol unit (Canada),Daytimerunning lights relay
{ C a n a d a )H, i o hb e a mi n d i c a t o lri q h t .L e f th e a d l i q h t
18
19
20
15A
60A
WHT
Multiplexcontrol unit
RED
D a v t i m er u n n i n ql i q h t sc o n t r o lu n i t ( C a n a d a )R. i o h th e a d l i o h t
WHTiBLU EPScontrol unit
80A
40A'
50A'?
WHT
Batterv.Power distribution
lgnition switch (BAT)
* 1 :U S A
" 2. Canada
l
l
II
I
E'l
22-46
t4 " t |
t
l
lI
l - - -
E,l E,l r--r r---rt__J i; i6'!/'
E,l E,l E,l
l'lr]n
r L__J,a
,..r^{-------l^-,
n[:]$"Lrt
O: Sparefuse
t
t
" N2,
Eol E l f__--l
|
|
nf
- r^l
Fuse
Number
Amps
1
15A
2
3
204
10A
10A
5
6
7.5A
7
204
I
7.5A
9
10A
10
7.54
11
7.5A
7.5A
12
13
't4
10A
10A
1E
Wire Color
Component(s) or Circuit(s) Protected
BLKA/VHT l g n i t i o nc o i l s
WHT/RED Airlfuelratiosensor,ECM
RED/BLU D a y t i m er u n n i n gI i g h t sc o n t r o lu n i t{ C a n a d a )
BLI(ORN Air/fuel ratio sensorrelay,Alternator,CMP sensor,Cruisecontrol main
switch,Cruisecontrol unit. ELDunit, Evaporativeemission(EVAP)bypass
solenoidvalve, Evaporativeemission(EVAP)canisterpurge valve,
Evaporativeemission(EVAP)canistervent shut valve,SecondaryH02S,
Vehiclespeed sensor
Not used
Y E U G R N Moonroof control unit, Moonroof open and close relay,Powerwindow
relaV
GRN
Moonroof motor
YEURED A u d i o u n i t
GRN
OPDSunit, Rearwindow wiper motor, Rearwindow washer motor, Rear
window wiper intermittentcontrol unit
YEL
Back-uplights,Cruiseindicatorlight, EPScontrol unit, Gaugeassembly,
Keylessreceiverunit, Multiplexcontrol unit, Securitycontrol unit
connector(optional)
BLIVORN ABS modulator-controlunit
YEURED D a y t i m er u n n i n ol i o h t sc o n t r o lu n i t ( C a n a d a )
PNK
S R Su n i t
BLK/YEL A,,/C
compressorclutch relay,Blower motor relay,Condenserfan relay,
Heatercontrol panel,Power mirror actuator,Power mirror defogger
(Canada),Radiatorfan relay,Rearwindow defoggerrelay,Recirculation
control motor
Not used
17
15A
18
19
15A
7.5A
20
21
22
23
24
25
30A
Notused
YEL/BLK E C M ,F u e lp u m p
BLK/YEL >H> Unrr
Y E U G R N Accessorypower socket
Y E U B L K T u r ns i q n a l / h a z a rrde l a v T
, u r ns i q n a l i o h t s
G R N / B L K M u l t i p l e xc o n t r o lu n i t ,W i n d s h i e l dw a s h e rm o t o r .W i n d s h i e l dw i o e r m o t o r
204
20A.
G R N / B L K Passenqer'swindow motor
GRN,A/VHT Driver'swindow motor
lo
Not used
Not used
Notused
_ _ ^ :
Hr tl_l
f at-t
at\t I
r^,rl fl
!!;r -
!f 3 3 9: , i ; s ! ! s
Fnf
|rnITf
22-47
GroundDistribution
Groundto ComponentsIndex
Componentor circuit qrounded
Ground
Batterv,Transmissionhousinq
En g i n e
G1 0 1
G 15' ]
ECM(PGis BLK;LGis BRN/YEL)
BLK:IACvalve,lgnitioncoils,Vehiclespeedsensor,VTECsolenoidvalve
switch
BRNA/EL:
Camshaft
oosition(CMP)sensor.CKPsensor,TDCsensor.VTECoil pressure
EPScontrolunit
G201
ELDunit. Multiplexcontrol inspectionconnector,Multiplexcontrol unit, Powerwindow relay,Rear
window washer motor, Rightfront parkinglight, Rightfront side marker light, Rightfront turn signal
light,Turn signal/hazardrelay,Washerfluid level sensor(Canada), Windshieldwasher motor,
WindshieldwiDer motor
G202
G301
ABSmodulator-control
unit
G401
G402
G4 5 1
G501
G502
G503
G551
G552
22-48
Blower motor relay,Brakefluid level switch,Condensorfan motor, Cruisecontrol actuator,Leftfront
parkinglight, Leftfront side marker light, Leftfront turn signallight, Radiatorfan motor, Radiatorfan
swrtcn
Combinationliqht switch,lqnitlon kev srvitch,Wiper/wasfrersr,virch
Left and riqht airbaqsensors,SRS unit
Datalink connector(DLC)
Clutchinterlockswitchm Clutchpedal positionswitch (for cruisecontrol),Cruisecontrol main switch,
Cruisecontrol unit, Daytimerunning lightscontrol unit (Canada),Driver'sdoor lock knob switch,
Driver'sdoor lockswitch,Driver'spower window motor, Heatercontrol panel,Left power mirror
defogger(Canada),left side turn signal light, Moonroof control unit, Monroof open and close relays,
'1,
Moonroof positionsensor Moonroof seitch,Power mirror switch,Powertransistor,Powerwindow
masterswitch.SDotliqhts
Accessorypower socket,Gaugeassembly,Keylessreceiverunit, lvlultiplexcontrol unit, Right power
m i r r o rd e f o g g e {r C a n a d a )
A u d i ou n i t
Driver'sseat belt switch,Fuelgauge sendingunit, Fuelpump, Memory erasesignal(IMES)connector,
OPDSunit. Riohtseat belt switch
High mount brakelight, Licenseplate lights,Rearwindow defogger,Rearwindow defoggernoise
condenser.Rearwindow wioer motor, Hatchlatch switch
Back-uplights,Brakelights,Rearside marker lights,Rearturn signal lights,Rearwindow wiper noise
condenser,Rearwindow wiper intermittentcontrol unit, Taillights
Removaland Installation
SRScomponentlocations{seepage 23-13)and
Removal
presetbuttons.
5. Removethe mounting bolt, and slidethe underdash fuse/relaybox (A) down from the bracket{B).
6. Disconnectthe backside from connectorsfrom the
back of the under-dashfuse/relaybox, and remove
the fuse/relaybox.
N O T E : T h eS R Sc o n n e c t o irs a s p r i n g - l o a d eldo c k
type (seepage 23-11).
lnstallation
2. Disconnectthebatterynegativecable,then
disconnectthe positivecable,and wait at least
three minutes.
1. Installthe under-dashfuse/relaybox in the reverse
order of removal and connectall connectorsto the
3. Removethe driver'sdashboardlower cover (see
page 20-59).
2 . I n s t a l l t h ed r i v e r ' sd a s h b o a r dl o w e rc o v e r .
4. Disconnectthe connectorsfrom the fuse side of the
3. Connectboth the negativecable and positivecable
to the battery.
5. Confirmthat all systemswork properly,
6 . D o t h e e n g i n ec o n t r o lm o d u l e( E C M )i d l e l e a r n
22-49
Battery
Battery Test
A batterycan explodeif you do not follow the
proper procedure,causingseriousinjury to anyone
nearby.Follow all procedurescarefullyand keep
sparksand open flames away from the battery.
Use eithera JCI or BearARBSTtester,and follow the
manufacturer'sprocedures.lf Vou don't have one of
these computerizedtesters,follow this conventional
test procedure:
1. Be sure the temperatureof the electrolyteis
between70'F (21"C)and 100'F(38'C).
2. Inspectthe batterycasefor cracksor leaks.
. l f t h e c a s ei s d a m a g e d r, e p l a c e t h eb a t t e r y . l
. lf the case looksOK, go to step 3.
3. Checkthe indicatorEYE.
. lf the EYEindicatesthebafteryischarged,goto
step 4.
. l f t h e E Y Ei n d i c a t e s al o w c h a r g e ,g o t o s t e p 7 .
4. Apply a 300 amp load for 15 secondsto removethe
surfacecharge.
5, Wait 15 seconds,then apply a test load of 280 amps
for 15 seconds.
6. Recordbatteryvoltage.
. l f v o l t a g ei s a b o v e 9 . 6 v o l t s , t h e
b a t t e r yi s O K . l
. l f v o l t a g ei s b e l o w 9 . 6 v o l t sg, o t o s t e p T .
7 . C h a r g et h e b a t t e r yo n H i g h( 4 0a m p s )u n t i lt h e E Y E
shows the batteryis charged,plus an additional30
minutes.lf the batterychargeis very low, it may be
necessaryto bypassthe charger'spolarity
protectioncircuitry.
. l f t h e E Y Ei n d i c a t e s t h eb a t t e r yi s c h a r g e d w i t h i n
3 hours,the batteryis OK.l
. lf the EYEindicatesthebatteryis notcharged
within 3 hours,replacethe battery.l
22-50
{
Relays
PowerRelayTest
Usethischanto identifythetypeof relay,thendo the
testlistedfor it.
type 1:
NOTE:Turnsignal/hazard
relayinputtest(seepage2287).
Relay
A'lCcomoressor
clutchrelav
Airlfuel ratio sensorrelav
Condenserfan relay
H e a d l i o hrte l a v1
H e a d l i q hrte l a v2
H o r nr e l a v
Powerwindow relay
R a d i a t oIra n r e l a y
Reverserelav
Startercut relav
T a i l l i q h rt e l a V
D a y t i m er u n n i n gl i g h t sr e l a y
{ C a n a d)a
Test
Normally-open
type A
type 2:
P G M - FmI a i nr e l a v1
P G M - Fm
l a i n r e l a v2
Blower motor relav
Rearwindow defoqoerrelav
Moonroofclose relay
Moonroof oDenrelav
Low beam cut relav {Canada)
Normally-open
tvpe B
F i v et e r m i n a l
type
Normally-open
type A:
PGM-FImain relay 1
PGM-FImain relay 2
type 1:
Checkfor continuitvbetweenthe terminals.
. Thereshould be continuitybetweenthe No. 1 and
N o , 2 t e r m i n a l sw h e n p o w e ra n d g r o u n da r e
connectedto the No. 3 and No. 4 terminals.
. Thereshould be no continuitybetweenthe No. 1 and
N o . 2 t e r m i n a l sw h e n p o w e ri s d i s c o n n e c t e d .
type 2:
(cont'd)
22-51
Relays
PowerRelayTest (confdl
Normally-open
type B:
Five-terminal
type
Checkfor continuitybetweenthe terminals.
C h e c kf o r c o n t i n u i t yb e t w e e nt h e t e r m i n a l s .
. Thereshould be continuitybetweenthe No. 1 and
N o . 3 t e r m i n a l sw h e n p o w e ra n d g r o u n da r e
connected
t o t h e N o .2 a n d N o . 4 t e r m i n a l s .
' Thereshould be no continuitybetweenthe No, 'l and
No. 3 terminalswhen power is disconnected.
. T h e r es h o u l db e c o n t i n u i t yb e t w e e nt h e N o . 1 a n d
N o . 2 t e r m i n a l sw h e n p o w e ra n d g r o u n da r e
c o n n e c t e tdo t h e N o . 3 a n d N o . 5 t e r m i n a l s .
. T h e r es h o u l db e c o n t i n u i t yb e t w e e nt h e N o . 1 a n d
N o . 4 t e r m i n a l sw h e n p o w e ri s d i s c o n n e c t e d .
tF-gr
tJ 1l
Rearwindow defonn* *O,
type 1:
6:)
rc*V
.r{{
(n F, t )\
\
s3.
Blower motor relay
type 1:
type2:
type 2;
22-52
lgnitionSwitch
Test
S R Sc o m p o n e n lto c a t i o n s( s e ep a g e2 3 - 1 3 a
) nd
precautionsand procedures{seepage 23-'l4)in the SRS
1, Removethe driver's dashboardlower cover {see
page 20-59).
2. Disconnectthe 5P connectorfrom the under-dash
fuse/relaybox.
WHT/RED
Wiresideof
f e m a l tee r m i n a l s
BLK/YEL
BLK/WHT
BLK/RED
\
Terminal WHT/
BLK/ BLK/ BLK/
RED WHT YEL RED WHT
p.J,i""-\ (ACC)
(BAT) flGl) trc2t (sr)
o (LocK)
| (ACC)
o- --o
_H
[ (oN)
c)III (START)
o _H
lf the continuitychecksdo not agreewith the table,
replacethe steeringlock assembly(seepage'17-121.
22-53
Gauges
\-
PARKINGBRAKESWITCH
p a g e1 9 - 1 0
FUELGAUGESENDING
p a g e1 1 - 1 5 6
SWITCH
ENGINEOILPRESSURE
page8-4
GAUGEASSEMBLY
Procedure,page22-56
SelJ-diaqnostic
page22 63
Gauqedulb Replacement,
Rep6cement,page22-64
CoolantTemperatureGauge
page22'64
TroLrbleshooting,
VEHICLESPEEDSENSOR{VSS)
page22-65
Troubleshooting,
BRAKEFLUIDLEVELSWITCH
p a g e1 9 - 1 0
\
22-54
CONNECTOR
B
lgreenJ
CONNECTORA
(bluel
SPEEDOMETER
VehicleSpeedSignalCircuit
page22-65
Troubleshooting,
TACHOMETEB
\7
t----/
\
_ / \
i . . _ ODO/TRIPMETER
FUELGAUGE
Test,page11-156
22-55
Gauges
v
Self-diagnosticProcedure
The gaugeassemblyhas a self-diagnosisfunction.
. T h e B e e p e rD r i v eC i r c u i C
t heck
. The IndicatorDrive CircuitChecL
. The LCDSegmentsCheck
. The GaugesDrive CircuitCheck(Speedometer,Tachometer,Fuelgauge,Coolanttemperaturegauge)
. T h e C o m m u n i c a t i oLni n eC h e c k( t h ec o o l a n t t e m p e r a t u rsei g n a l i n e b e t w e e nt h e g a u g ea n d E C M )
NOTE:Indicatorsare also controlledvia the communicationline.
Enteringthe self-diagnosis
f unction:
Beforedoing the self-diagnosisfunction,checkthe No. 9 (10A)fuse in the under-hoodfuse/relaybox and No. 10 {7.5A)
fuse in the under'dashfuse/relaybox.
1. Pushand hold the trip/resetbutton.
2 . T u r nt h e l i g h t i n gs w i t c hO N .
4 . W i t h i n5 s e c . ,t u r n t h e l i g h t i n gs w i t c hO F F ,t h e n O N a n d O F Fa g a i n .
5. Within 5 sec.,releasethe trip/resetbutton,then push and releasethe buttonfour times reDeatedlv.
NOTE:
. While in the self-diagnosismode, the dash lights brightnesscontrolleroperatesnormally.
'Whileintheself-diagnosismode,thetrip/resetbuttonisusedtostartthebeeperdrivecircuitcheckandthegauge
drive cicuit check.
. lf the vehiclespeedexceeds1.2 mph 12km/h)orthe ignition switch is tu rned OFF,the self,diagnosis mode ends.
oN flrl
lgnition
OFF
Switch
Lighting
Switch
Trip/Reset
Switch
->
5 sec.
Move to selt-diagnosis mode.
5 sec.
The BeeperDriveCircuitCheck:
When enteringthe self-diagnosismode, the beepersoundsfive times
TheIndicatorDriveCircuitCheck:
When enteringthe self-diagnosismode,the following indicatorsblink.
Seatbelt indicator,Door/hatchindicator,Brakesystem,Lowfuel indicator,Maintenancerequiredindicator(USA),
) , i l p r e s s u r el i g h t .
W a s h e rf l u i d l e v e li n d i c a t o (r C a n a d a O
22-56
\
The LCDSegmentCheck:
W h e ne n t e r i n gt h e s e l f - d i a g n o s m
i s o d e ,t h e o d o / t r i ps e g m e n tb l i n k sf i v et i m e s .
TheGaugeDriveCircuitCheck:
W h e ne n t e r i n gt h e s e l f - d i a g n o s m
i s o d e ,t h e s p e e d o m e t e trh, e t a c h o m e t e rt ,h e f u e l g a u g e ,a n d t h e c o o l a n t
g a u g en e e d l e ss w e e pf r o m t h e m i n i m u mp o s i t i o nt o m a x i m u mp o s i t i o nt,h e n r e t u r nt o t h e m i n i m u m
temperature
posrtron.
NOTE:After the beeperstops soundingand the needlesreturnto the minimum position,pushingthe trip/resetbutton
s t a r t st h e b e e p e rd r i v ec i r c u i tc h e c k( o n eb e e p )a n d t h e g a u g ed r i v ec i r c u i tc h e c ka g a i n .
T h e c h e c kc a n n o tb e s t a r t e du n t i l t h en e e d l e sr e t u r nt o t h e m i n i m u mp o s i t i o n .
Self-diagnosis
mode
ON
OFF
Trip/Reset
switch
9loFF _---
causeneedlesXl"
Beeper
ON
;;
r
n =--llJL--
f---U---------l
r-r r-r r-r .-1 r-r
r-r
lll u u l_lL__l
I
@,
[-----l
l-l
The needlessweepfrom the
minimum positionto the
maximum position,then return
t o t h e m i n i m u mp o s i t i o n -
5 sec
The Communication Line Check:
In the self-diagnosismode, after the odo/trip LCDsegmentscheck,the self-diagnosisstartsthe communicationline
cnecK.
l f a l l s e g m e n t sc o m e so n , t h e c o m m u n i c a t i o lni n e i s O K .
" E r r o r "i s i n d i c a t e d ,
l f t h ew o r d
t h e r ei s a m a l f u n c t i o ni n t h e c o m m u n i c a t i o lni n e b e t w e e nt h e g a u g ea s s e m b l yt.h e
m u l t i D l e cx o n t r o lu n i t .a n d t h e E C M .
Faulty:
Normal:
iD
:-l!:!!JlJ!J
t l
i-
f l
O i -
,-
t
--
-
,-
r-
i-
,
| | | t t f
i-
r-
Endingthe self-diagnosisfunction:
T u r nt h e i g n i t i o ns w i t c hO F F .
N O T E lrf t h e v e h i c l es p e e de x c e e d s1 . 2m p h { 2 k m / h ) t, h e s e l f d i a g n o s i sf u n c t i o ne n d s .
22-57
Gauges
CircuitDiagram
'
UflOEN fiOOOFUSE/8ILAY
8OX
ECM/PCM
V
I
-r'
r--l
l J ,
I
I 8|
COOLANI
TEMPfNAIUFT
SPIEDOMEIENTACHOMEIIR FUTLGAUGI GAUGE
Norll0AlFUSE
8L(
-o-
22-58
ii-ciorurnn
coNNECron
N o 2 0 i o A: lU S A
ti) l To mxr I
MAi{IIiIANCE
ft0unlD
[{0tcaTo8
LIGH]
(LEDI
(cont'd)
22-59
Gauges
I
CircuitDiagram(cont'dl
No2il5AlFUSE
ilnlh.undi hooq
llu!./rcl.ybox r
DASH
LGHTS
Yt
Yl
t
'-
l
-t
WASHEF
Itut0
I!VEL
6t0tc ToR
UGHT
(tDl
J
ls?2
I
BLUIYEL
I
J
cSutsE
m n0L
a
22-60
'-
./
ib-n'rnoL
UNIT
tNGniEorL
PRESSUBE
swtTcH
lCld.d Eisin.3topp.d
l
iopd Ersin.runni.s
i
I
!
i
I
I
L
--t
DAYTIME
BUNN|NG
LIGHTS
@NTROL
UNII
I
;
I
-.-..
I
i
icmadd
(cont'd)
22-61
Gauges
\"
GRNIfiED
I
\""'7
V
GAUGIASSEi|BLY
LEFTTUN
SIGI'IAL
II'{DICATOR
LTCHTS
HIGHSEAM
-|.
IMMOBITIZER
ltDtcATon r/: \ tilucaToB
f,il
CoME|NAT|ON
LtctlTswtTclt
vll9i,]
\,
tMf,tOBtUZEn
@l\tTRoL
UN|I ftCtIVER
J
22-62
GaugeBulb Replacement
LIGHT{1.4WI
RIGHTTURNSIGNALINDICATOR
CRUISE
HIGHBEAMINOICATOR
LIGHT{1.4W)
ITORLIGHT{I.4W)
LEFTTURNSIGNALINDICATORLIGHTl1.il wl
GAUG€LIGHT{1.4WI
GAUGELIGHT{1.4W}
IMMOBILIZENINDICATOR
LTGHT
{1.4Wl
22-63
Gauges
GaugeAssemblyReplacement
CoolantTemperature
Gauge
Troubleshooting
1 . Removethe instrumentpanel (seepage 20-59),
t h e n r e m o v et h e u p p e rc o l u m nc o v e r{ s e ep a g e1 7 -
2. P l a c ea c l e a ns h o pt o w e l ( A )u n d e rt h e g a u g e
assemblyto preventscratchingthe steering
c o l u mn o r d a s hp a n e l .
Beforetesting,checkthe No. I { 10A)fuse in the underhood fuse/relaybox and the No. '10(7.5A)fuse in the
under dash fuse/relaybox.
1. Startthe engine,and checkthe malfunction
i n d i c a t o lra m p ( M l L ) .
3 . Removethe screwsfrom the gauge assembly(B).
Does the MIL come on?
YES- Troubleshootthe causeof the ECM DTC(see
p a g e11 - 5 7 )a, n d r e c h e c k .
NO-Go to step 2.
2. Checkfor a multiplexcontrol unit DTC(seepage
22,168).
ls a DTC indicated?
YES Troubleshootingthe causeof the multiplex
control unit DTC{seepage 22-168),and recheck.
NO Go to step 3.
4. Disconnectthe connectors(C),and removethe
g a u g ea s s e m D r y .
I n s t a l l t h eg a u g ea s s e m b l yi n t h e r e v e r s eo r d e ro f
removal.
3 . D o t h e c o m m u n i c a t i o lni n ec h e c kw i t h t h e s e l f diagnosisprocedure(seepage 22-56).
ls the word "Error" indicated on the odo/ttip
d isplay ?
YES The gaugecannot receivethe signalfrom the
multiplexcontrol unit and the ECI\,4.
Checkfor an
open in the WHT/GRNwire (gaugeconnector
t e r m i n a lB1 3 ) .l f n o o p e ni s f o u n d ,g o t o s t e p5 .
NO Go to step 4.
4. Do the gaugedrive circuitcheckwith the selfd i a g n o s i sp r o c e d u r e( s e ep a g e2 2 - 5 6 ) .
Does the temperaturegauge needle sweep lrom
the minimum position to the maximum, then tetutn
to the minimumposition?
YES Go to step 5.
NO Replace
t h e g a u g ea s s e m b l y . l
5. Substitutea known-goodECM and recheck.
Did the symptom/ ind ication go away?
YES Replace
theECM.
NO Substitutea known good gaugeassembly.lf
g a u g ea s s e m b l y . l
22-64
I
VehicleSpeedSignalCircuitTroubleshooting
Special Tools Required:
Test Harness07LAJ-PT3020A
5. Connectthe WHT test harnesscliD(B)to the
positiveprobe of a voltmeter,and connectthe RED
test harnessclip (C)to the negativeprobe.
Beforetesting,inspectthe No. 4 (10A)and No. 10 (7.5A)
fuses in the under-dashfuse/relaybox.
1. Disconnectthe 3P connectorfrom the vehicle
speedsensor(VSS){A).
le thara
h2ltarv
v^ltada?
Connectthe test harnessonly to the enginewire
harness.
wire betweenthe
NO Repairopen in the BLK,/YEL
VSS and the under-dashfuse/relaybox.l
3 . Connectthe REDtest harnessclip (B)to the positive
probe of an ohmmeter.Coverthe white (C)and
green {D)test harnessleadswith protectivetape (E).
4 . Checkfor continuitybetweenthe REDtest harness
c l i p a n d b o d yg r o u n d ,
7 . Disconnectthe WHT test harnessclip (B).
8 . C o n n e ctth e G R Nt e s th a r n e s sc l i p{ D )t o t h e
positiveprobe of a voltmeter.
YES Go to step 5.
N O R e p a i ro p e ni n t h e B L Kw i r e b e t w e e nt h e V S S
a n dG1 0 1 . I
Is there 5 V or more?
YES- Go to step 9.
NO Repairshort or open in the BLUMHT or WHT/
GRNwire betweenthe VSS and the cruisecontrol
u n i t ,o r t h e E C M . I
(cont'd)
22-65
Gauges
VehicleSpeedSignalCircuitTroubleshooting(cont'dl
14. Disconnectthe 22Pconnector"8" from the gauge
assemDry.
1 0 .Connectthe other test harnessconnector(A)to the
V S S( B ) ,
GAUGE
ASSEMBLY
CONNECTOR
B (22P)
'15.
Connectthe positiveprobe of a voltmeterto the
BLU/WHTwire and the negativeprobeto ground.
1 1 .R aisethe front of the vehicle,and make sure it is
securelysupported.
' t 2 .Put
t5.
'16.
Slowly rotateone wheel with the other wheel
blocked.
the vehiclein neutralwith the ignitionswitch
o N { |)| ,
Does voltage pulse f rom 0 to about 5 V or more?
Slowly rotateone wheel with the other wheel
blocked.
YES- Replacethe speedometerassembly.I
Does voltage pulse ttom 0 to about 5 V ot morc?
YES Go to step 14.
NO Replacethe VSS.I
22-66
NO Repairopen in the BLUMHTwiTe between
the VSS and the speedometer.l
I
J
VSS Replacement
1. Removethe intakeresonator.
2. Disconnectthe 3P connectorfrom the vehicle
speed sensor{VSS)(A).
Removethe mounting bolt, then removethe VSS.
4 . lnstallthe VSS in the reverseorder of removal.
22-67
ExteriorLights
GomponentLocationIndex
UNDER.HOOD
FUSE/RELAY
BOX
HEADLIGHT
RELAY1
Test,page22-51
HEADLIGHT
RELAY2
Test,page22-5'l
BRAKEPEDALPOSITION
swtTcH
Test,page22-84
Adjustment,page l9'6
0/
SIDETURN SIGNAL LIGHT
page22-84
Replacement,
\
/
FRONTTURNSIGNAL
LIGHT
, g e2 2 8 1
B u l bB e p l a c e m e npt a
HEADLIGHTS
page22 79
Replacement,
Adjustment.page22-78
page22-81
Eulb Replacement,
22-68
PARKINGLIGHT
B u l bR e p l a c e m e npt a, g e2 2 - 8 1
FRONTSIDEMARKERLIGHT
Bulb Replacement,page22 83
-a-.,_
z
HIGHMOUNTBRAKELIGHT
page22-82
Replacement,
LICENSE
PLATELIGHTS
page22-83
Replacement,
BACK.UPLIGHT
page22-82
Replacement,
REARSIDEMARKERLIGHT
page22-83
Replacement,
TAILLIGHTSsnd BRAKELIGHTS
page22-82
Replacement,
REARTURNSIGNALLIGHT
(cont'd)
22-69
ExteriorLights
!
ComponentLocationIndex(cont'dl
DAYTIMERUNNINGLIGHTSRELAY{Canadal
[Wirecolors:RED,REDryEL,
I
andRED/BLU I
LRED/BLK
Test,page22-51
BEAMCUTRELAY
{Canadal_
_LOW
WirecolorsrREDMHT,
RED/BLK,I
andRED/BLU
I
LREDryEL
Test,page22-51
DASH LIGHTSBRIGHTNESS
CONTROLLER
. . i
'
:'
\
--,': -
' i,-'-'l
/
DRLINDICATOR
LIGHT{Canadal
HIGH BEAM INDICATORLIGHT
page22-63
Bulb Replacement,
COMBINATION
LIGHTSWITCH
page22-80
TesVReplacement,
oAYTIME RUNNING LIGHTSCONTROLUNIT lcanada)
InputTest,page22-76
I
t-
-
FUSE/
UNDER.DASH
RELAYBOX
22-70
LET]
FBOIII
SIDE
MAiKEE
L.IGHT
f,IGHT
TSONT
s]0E
MANXtF
IJGIIT
IETT
NEANSIDE
MAircN
IIGHT
I ucEr\6E
I PI.ATE
|fiIli
I
8L.l(
_o
22-71
ExteriorLights
CircuitDiagram- Canada
t
J
t
J
UNOEN
HOOO
FUSE/8ELAY
BOX
N ol 9 l 8 0 A l
J
) to.o
- i50Al
No.1'l
loa)
WHT ED
IT
N o . ! 0S( 7A lusE
r
d.3hl
V
RED,I
I- _ l
'2
/', t-\
\ rc|'/moN
. rcz/ swfrcH
I EAr
\
,'orrro"
-.
vG2Horin0N{ll)
) INDICAIOF
-/ l'lcli;
*01
I
I
I
BU1
BED
'l'I
I
I
=
.|
DNL
A
\y
II
TIGHT
luDl
RED/
BLU
,
12
l
t1
{ r-
oorr,",rr.,ro
uctrrscournoLu,'r"
J
l
I I
8
SLU/BID
3
!3
||MoS|UZEn
CONTNOL
UNIT RECEIVEB
SYSIIMUGHI
VY
I
t0
,{
--t
RE
ll
T
GNfl/FEO
DAYTIME
BUNNINC
LIGHTS
EfLAY
II
tU
HT/BI
In
RE
fifili{*1l,.H'
I
) No12
i l7.5Al
BI(
BI
BI
G8N
17
Y
I
GRI\/NED
II
I
f'
r\
(
88A(E
I FiUrD
2 , LTVEL
[./ SWITCH
F\ PANKNG
; } BNAXE
+./ swrTcH
'nddoM
I
I
i
i
G301
cl.1
G501
\,
22-72
J
J
DASH
LIGHTS
COMEINATION
LIGHT
SWIqI
TTFT
TRONT
3r0E
MABKER
LIG}IT
LEFT
PAfiX*'IG
LIG}IT
BLI(
!
t
BL](
l
G301
!
I
l
G301
BIGHT
PANKNG
LIGIIT
FIGIIT
FBONT
SIDE
MAfircF
LJGHT
l5w)
LEFT
TAIILGl T
LEFT
BEAFSIDE
LJGHT
RIGHT
RIAFSIDI
I/IAFrc8
UCHT
NEHI
I LICENSE
IAILUOHI I PLAII
I LIGNTS
(twr2l
|
8LI
I
I
G552
I
22-73
ExteriorLights
CircuitDiagram- BrakeLights
UiDENHOOD
FUSE/NEUYBOX
SATIISY
\
22-74
r!o7l15A)
I
|
,r-T-v--rrni'citr
\
CircuitDiagram- Back-upLights
UiDEN H@DFUSI/8EIAY
80)(
22-75
ExteriorLights
DaytimeRunningLightsControlUnit InputTest- Canada
T h e D R Li n d i c a t o lri g h ti n t h e g a u g ea s s e m b l yw i l l c o m e o n w h e n y o u t u r n t h e i g n i t i o ns w i t c ht o O N ( l l )w i t h t h e
headlightswitch off and the parkingbrakese1.lt should go off when you turn on the headlightswitch and releasethe
parkingbrake.lf it comes on at any other time, do the control unit input test.
r i l l g l o w a t h a l fi t s n o r m a li n t e n s i t y .
N O T EW
: h e nt h e d a y t i m er u n n i n gl i g h t sa r e o n ,t h e h i g h b e a mi n d i c a t ow
1. Removethe driver'sdashboardlower cover (seepage 20-60).
2 , D i s c o n n e c t t hle4 P c o n n e c t o r ( Af)r o m t h e d a y t i m er u n n i n gl i g h t s c o n t r oul n i t ( B ) .
RED/BLU
RED/BLU
GRN/BLK
GNN/BLK
GRN/ORN
BLU/RED
RED/YEL
YEL/RED
Inspectthe connectorand socketterminalsto be sure they are all makinggood contact.
. lf the terminalsare bent,loose orcorroded, repairthem as necessary,and recheckthesystem.
' lf the terminalslook OK, go to step 4.
22-76
\
4. Makethese input tests at the connector,
.lfanytestindicatesaproblem,findandcorrectthecause,thenrecheckthesystem.
. lf all the input tests prove OK,the control unit must be faulty. Replaceit.
2
Wire
Test condition
RED/BLU U n d e a
r ll
conditions
12
YEL/RED
Cavity
lgnitionswitch
o N( r )
BLK
7
10
U n d e ra l l
conditions
BLK
U n d e ra l l
conditions
REDI/EL C o m b i n a t i o n
light switch ON
/ =f\\
1
'11
3
5
6
8
RED/BLU
Combination
light switch ON
{iD), and
dimmer switch
inHIGH
RED/BLK C o m b i n a t i o n
light switch ON
(iD), and
dimmer switch
inHIGH
G R N / B L K C o mb i n a t i o n
light switch ON
(iD), and
dimmer switch
inHIGH
G R N / O R NParkingbrake
l e v e ro u l l e d
B L U / R E DC o m b i n a t i o n
l i g h ts w i t c hO F F
WHT/BLU lgnitionswitch
o N0 r )
t5
GR N / R E D lgnition switch
o N( | | )
Test:Desiredresult
Possiblecauseif resultis not obtained
Blown No. 14 (40A)fuse in the
B l o w nN o . 3 { 1 0 A ) f u s ei n t h e
A n o p e ni n t h e w i r e
B l o w nN o . l 2 ( 7 . 5 A ) f u s ei n t h e
Thereshould be batteryvoltage.
An open in the wire
C h e c kf o r c o n t i n u i t yt o g r o u n d : . P o o rg r o u n d{ G 5 0 ' 1 )
. An oDenin the wire
T h e r es h o u l db e c o n t i n u i t v .
. P o o rg r o u n d( G 5 0 1 )
Checkfor continuityto ground:
' A n o p e ni n t h e w i r e
Thereshould be continuitv.
B l o w nN o . 1 5 ( 1 5 A )f u s ei n t h e
Faultyheadlightrelay 2
Faultycombinationlight switch
An open in the wire
Connecta jumper wire between
B l o w nb u l b
No.3 andNo.1terminals.
Faultylow beam cut relay
B o t hh e a d l i g h t (sH I G H a) n d
Faultycombinationlight switch
h i g h b e a mi n d i c a t o lri g h t
Poor ground (G50'l)
s h o u l dc o m eo n .
An open in the wire
Connecta jumper wire between . B l o w nb u l b
. Faultycombinationlight switch
N o . 5 a n d N o . 1 1t e r m i n a l s .
.
(
H
I
G
H
)
R i g h th e a d l i g h t
should
Poor ground (G50'1)
c o m eo n .
C h e c kf o r c o n t i n u l t yt o g r o u n d
. Faultycombinationlight switch
. P o o rg r o un d { G 5 0 1 )
C h e c kf o r c o n t i n u i t yt o g r o u n d :
There should be continuitv.
Faultyparkingbrakeswitch
F a u l t yh e a d l i g hrt e l a y s
Short to ground
A n o o e ni n t h e w i r e
. B l o w nN o . 1 0 ( 7 . 5 A f)u s e i n t h e
. FaultyDRLindicator
. A n o o e ni n t h e w i r e
Faultybrakesystem indicator
Attachto ground:
T h e D R Li n d i c a t o lri g h ts h o u l d
c o m eo n .
Attachto ground:
T h e b r a k es y s t e ml i g h ts h o u l d
c o m eo n .
22-77
ExteriorLights
\
HeadlightAdjustment
2. Parkthe vehicle7.5 m (25 ft) away from a wall or a
screen(A).
Headlightsbecomevery hot during use;do not
touch them or any attachinghardwareimmediately
afterthey have beenturned off.
7.5m {25ftl
Beforeadiustingthe headlights:
. Parkthevehicleon a levelsurface.
. Makesurethetire pressures
arecorrect.
. Thedriveror someonewho weighsthe sameshould
sit in the driver'sseat.
'1.
Cleanthe outer lens so that you can seethe center
of the headlights(A).
3 . O p e nt h e h o o d .
22-78
HeadlightReplacement
5
T u r nt h e l o w b e a m so n .
'1.
Determineifthe headlightsare aimed properly.
2 . Disconnectthe connectors(A)from the headlight
(B).
Removethe front bumper (seepage 20-85).
Verticaladjustment:
Measurethe height ofthe headlights(A).The lights
should reflect52 mm (2.'1in.) below headljght
h e i g h t( B ) .
i
6. lf necessary,adjustthe headlightsto local
requirementsby turning the verticaladjuster.
Removethe five mounting bolts,then removethe
corner upper beam (C)and headlightassembly.
Installin the reverseorder of removal.
5 . After replacement,adjustthe headlightsto local
requirements.
22-79
ExteriorLights
CombinationLight Switch Test/Replacement
1. Removethe driver's dashboardlower cover (seepage 20-60).
2. Removethe steeringcolumn covers(seepage 17-9).
3 , D i s c o n n e c t t hle6 P c o n n e c t o r ( Af)r o m t h e c o m b i n a t i o nl i g h ts w i t c h( B ) .
4 . Removethe tlvo screws,then slide out the combinationlight switch.
5 . Inspectthe connectorterminalsto be surethey are all makinggood contact.
. lf the terminalsare bent, looseor corroded,repair them as necessary, a nd recheckthe system.
.lftheterminalslookOK,checkforcontinuitybetweentheterminalsineachswitchpositionaccordingtothe
tables.
- lf the continuityis not as specified,replacethe switch.
Light switch:
\
Telmint
12
5
4
Position
OFF
Headlight switch
o--
LOW
Passingswitch
HIGH
OFF
o--
ON
o-
Turn signalswitch:
Terminal
\
2
10
Position
LEFT
----o
NEUTRAL
RIGHT
22-80
o--
11
13
Bulb Replacement
Headlight:
FrontTurn SignalLight:
ParkingLight:
1. Disconnectthe 3P connector(A)from the headlight.
1 . R e m o v et h e i n n e rf e n d e r( s e ep a g e2 0 - 1 0 2 ) .
Headlight{high/low): 60/55 W
2. Disconnecttheconnectors(A) from the lights.
Frontturn signallight:
Parkinglight:
21W
5W
f-rI
A-
-'-+l
)/
2. Removethe rubbercover (B).
Pullthe retainingspring (C)away from the bulb (D),
then removethe bulb.
Installa new bulb in the reverseorder of removal.
Make sure the notchesin the bulb align with the
t a b sl n t h e h e a d l i g h t .
Turn the bulb sockets(B) 45'counterclockwiseto
removethem from the headlighthousing.
4 . Installthe new bulb(s)in the reverseorder of
removat.
22-81
ExteriorLights
TaillightReplacement
HighMount BrakeLight
Replacement
1 . Removethe rearbumper(seepage20-86).
2 . Openthetailgate,anddisconnect
the connectors
1. Open the hatch.
(A)fromthetaillight(B).
2. Removethe plastictrim.
Brako/Taillight; 2115W
TurnSignalLight: 21 W
Back-upLight:
21W
3. Disconnectthe2P connectors(A)from the high
m o u n tb r a k el i g h t( B ) .
High Mounl BrakeLight:
5W x 5
=\\
ili--- _\
\
, \ .
r B ---'a
t
\r
\
Removethe mounting nuts and bolts,then remove
t h et a i l l i g h t .
Carefullyremovethe high mount brakelight.
5 . lnstallthe light in the reverseorder of removal.
Turn the bulb socket45' counterclockwise
to
removethe bulb socket.
When installingthe taillight.checkthe gasket;if it is
distortedor stayscompressed,replaceit.
After installingthe taillight.run water over the
taillightto make sure it does not leak.
'
22-82
LicensePlateLight Replacement
1 . Removethe hatch lower trim panel (seepage20-
P u l l t h el i c e n s ep l a l el i g h ta s s e m b l yo u t . a n d
disconnectthe 2P connector(A) from the light.
Side Marker Light Replacement
1. Carefullyprythe light(A)outofthe rearbumper,
(B)fromthe light.
anddisconnect
the 2Pconnector
Becarefulnotto damagethe rearbumper.
Side Marker Light:
5W
LicensePlateLight: 5Wx2
'[-J^
,^f , t lo \
+tiP'-
' f l ^
t
\-J
"/
\==-^
3 . S e p a r a t et h e l e n s( B )a n d h o u s i n g( C ) ,t h e n r e m o v e
2 . Removethe bulbsocket(A)by turningit 45'
counterclockwise.
thenreolace
the bulb.
the bulb.
4 . l n s t a l l t h el i g h ti n t h e r e v e r s eo r d e ro f r e m o v a l .
22-83
ExteriorLights
BrakePedalPositionSwitch Test
1. Disconnectthe4P connector(A) from the brake
pedal positionswitch {B).
SideTurn SignalLight Replacement
NOTE:Be careful nol to damagethe fender.
1 . P u s ht h e r e t a i n i n gs p r i n g( A ) .a n d r e m o v et h e s i d e
t u r n s i g n a l i g h t( B ) ,
Side Turn Signal Light:
5W
Checkfor continuitybetweenthe No. 1 and No. 2
termtnals.
. T h e r es h o u l db e c o n t i n u i t yw h e n t h e b r a k ep e d a l
rs presseo.
. Thereshould be no continuitywhen the brake
pedal is released.
terminals{with cruisecontrol).
T h e r es h o u l db e n o c o n t i n u i t yw h e n t h e b r a k e
pedal is pressed.
T h e r es h o u l db e c o n t i n u i t yw h e n t h e b r a k ep e d a l
is released.
lf necessary,adjustor replacethe switch,or adjust
t h e p e d a lh e i g h t( s e ep a g e1 9 - 6 ) .
22-84
2. Disconnectthe 2P connector{C)from the light.
TurnSignal/Hazard
Flasher
COMBINATION
LIGHT/TURN
SIGNALSWITCH
Test,page22-80
page22-80
Beplacement,
TURNSIGNALINDICATOR
LIGHTS
(lnthegaugeassembly)
page22'63
BulbReplacement,
HAZARDWARNINGSWITCH
Test,page22-88
page22-88
Replacement,
TURNSIGNAL/HAZARDRELAY
InputTest,page22-87
FUSE/RELAY
BOX
UNDER.DASH
22-85
TurnSignal/Hazard
Flasher
CircuitDiagram
\
DASH
Ut\toEB
TUSVRILAY
8OX
UNDff HOOD
FUSUftIIY8OX
'No20lr0A
USA
No.2{
l50A):Cmada
J
fiIGHTT
INDICATON
IIGHT
11.1W)
FBONT
!
22-86
RelayInputTest
TurnSignal/Hazard
1 . R e m o v e t h e t u r ns i g n a l / h a z a rrde l a y( A )f r o m t h e u n d e r - d a sfhu s e / r e l a yb o x ( B ) .
000i0!1000
00u!u0
Inspectthe relay and fuse/relaybox socketterminalsto be sure they are all makinggood contact
. lf the terminalsare bent.loose,or corroded,repairthem as necessary,and recheckthesystem.
Make these input tests at the fuse/relaybox.
.lfanvtestindicatesaproblem,findandcorrectthecause,thenrecheckthesystem.
. l f a l l t h e i n p u t t e s t sp r o v eO K , t h e t u r ns i g n a l / h a z a rrde l a ym u s t b e f a u l t y .R e p l a c ei t
Cavitv
1
3
2
Possiblecauseil resultis not obtained
Test: Desired result
. P o o rg r o u n d( G 2 0 1 )
. An ooenin thewire
Thereshould be continuiw.
' Blown No. 19 (7.5A)fuse in the
(
ground:
for
voltage
to
Check
lgnitionswitch ON ll)
Hazardwarning switch Thereshould be batteryvoltage.
. Faultyhazardwarning switch
OFF
. Blown No. 5 {10A)fuse in the
ground:
warningswitch Checkfor voltageto
Hazard
voltage.
There
be
battery
should
ON
lgnitionswitchOFF
. An ooen in the wire
. P o o rg r o u n d( G 2 0 1G
, 3 0 1 ,G 5 0 1 ,
(
C o n n e cN
t o . 2 t e r m i n a l t oN o . 3
l g n i t i o ns w i t c hO N l l )
G553)
G502,
terminal:
and turn signal switch
. Faultyturn signalswitch
in Rightor Left position R i g h to r l e f tt u r n s i g n a l i g h t s
. A n o D e ni n t h e w i r e
s h o u l dc o m e o n .
. P o o rg r o u n d( G 2 0 1G
, 3 0 1 ,G 5 0 1 ,
C o n n e cN
t o . 2 t e r m i n a tl o N o . 3
lgnitionswitch OFF
G502,
G553)
Hazardwarning switch t e r m r n a l :
H a z a r dw a r n i n gl i g h t ss h o u l d
ON
. An open in lhe wire
c o m eo n .
Tesl condition
U n d e ra l l c o n d i t i o n s
22-87
TurnSignal/Hazard
Flasher
HazardWarningSwitch Test
1 . Removethe centerpanel (seepage 20-62).
2 . Disconnectthe 10Pconnector(A)from the hazard
w a r n i n gs w i t c h( B ) .
3 . Pushout the hazardwarning switch from behind
t h e c e n t e rp a n e l( C ) .
4 . Checkfor continuitybetweenthe terminalsin each
lf the continuityis not as specified,replacethe bulb
( D )o r t h e h a z a r dw a r n i n gs w i t c h .
\
Termin6l
1
;;;-_-\
OFF
ON
22-88
@
2
4
7
10
Entry Light ControlSystem
CEILINGLIGHT/SPOTLIGHTS
Test,page22-96
page22-96
Replacement,
REARCEILING
LIGHT
Test,page22-96
page22-96
Replacement,
FRONTPASSENGER'S
DOORSWITCH
IGNITIONKEYLIGHT
Test,page22-91
IGNITIONKEY SWITCH
lest, page22-91
HATCHLATCHSWITCH
Test,page22-97
DRIVER'SDOORSWITCH
AREALIGHT
CARGO
Test,page22-97
page22 97
Replacement,
22-89
EntryLightControlSystem
t
CircuitDiagram
J
'No.20({0A)
USA
UiIOTf,HOOD
fUSE/8ELAY
BOX
EiIIpN
SMTqI
lGlHoTin0Nilll
nd STAnT
0D
CEILING
UGHT
Y
I
I
\
DtrVTN'S
DOOR
Locx
(NOB
s!t/tTc8
ORIVEBS
DOOR
SWITCH
PASSTNGERS
DOOB
SWITCH
i9r"..d l
IGNIlx)N
KEY
SWtTCH
l'
J
j
BU
I
G()t
J
22-90
\
lgnition KeySwitch Test
NOTE:For more key-inbeeperinformation,referto the
circuitdiagram (seepage 22-90)and input test (see
page 22-921.
lgnition Key Light Test
1 . Removethe steeringcolumn upper and lower
covers(seepage 17-9).
Disconnectthe 6P connector,
When the ignition key is in the ignition switchthe
multiplexcontrol unit sensesground through the
closedignition key switch.When you open the driver's
door, the multiplexcontrol unit sensesground through
the closeddoor switch and soundsthe beeper.
1. Removethe steeringcolumn upper and lower
c o v e r s( s e ep a g e ' 1 7 - 9 ) .
i'
/.'
2. Disconnectthe 6P connector.
The LEDshouldcome on when power is connected
to the No. 6 terminal and ground is connectedto
N o .5 t e r m i n a l .
lf the LEDdoes not come on, replacethe ignition
swrtch.
3 . Checkfor continuitybetweenthe No. 1 and No. 2
termrnars.
. There should be continuitywith the key in the
ignition switch.
. Thereshould be no continuitywith the key
removedfrom the ignitionswitch.
lf the continuityis not as specfied,replacethe
ignition switch.
22-91
EntryLightControlSystem
Control Unit Input Test
1. Beforetesting,trou bleshootthe m u ltiplex control system (seepage22-172).
2. Removethe dashboardlower cover.
3. Disconnectthe under-dashfuse/relaybox connectors.
NOTE:All connectorsare wire side of femaleterminals.
UNDER.DASH
FUSE/RELAY
BOXCONNECTOR
K Il7PI
UNDEB-DASIJ
FUSE/RELAYBOX CONNECTOR
O {,I2PI
GRN/RED
UNDEB.DASH
FUSE/RELAY
BOXCONNECTOR
P {18PI
3
4
5
6),/18.
GRN LT GRN/REO
UNOER.DASHFUSE/REI"AY
BOX CONNECTOBX I8PI
1
,/13
4
5
7
8
8ED/WHT WHT/BLK
UNDER.DASH
FUSE/RELAY
BOXCONNECTOR
Y {13PI
YEL/RED
4 . Inspectthe connectorand socketterminalsto be sure they are all making good contact.
. lf the terminalsare bent, looseorcorroded, repairthem as necessary,and recheckthe system.
22-92
I
maketheseinputtestsat theconnector'
stilldisconnected,
5. Withtheconnectors
. lf anvtestindicates
the system
a problem,find andcorrectthe cause,then recheck
. lf allthe inpultestsproveOK,go to step6.
Cavitv
K2
o7
X8
Possiblecquseil resultis not obtained
Test:Desiredresult
Test condition
Wire
8LU/ORN lJnderallconditions Checkfor continuitybetweenthe K2
terminalandthe keylessreceiver
No.2 terminal:
unit5Pconnector
Thereshouldbecontinuitv.
GRN/RED C e j l i n gl i g h t s w i t c h i n Attachto ground:
comeon.
Ceilinglight(s)should
middle position.
An open in the wire
BlownNo.3 (7.5A)fusein the underhood
Blownbulb
Faultyceilinglight
An ooenin the wire
in the underhood
ElownNo.3 (7.5A)fuse
fuse/relay
box
Faultyignitionkeylight(LED)
An ooenin the wire
r l l c o n d i t i o n s Attachto ground:
WHT/BLK U n d e a
lgnitionkeylightshouldcomeon.
on the under-dash
connectors
box,and maketheseinputtestsat the appropriate
to the underdashfuse/relaV
the connectors
6. Reconnect
fuse/relay
box.
.lfalltheinputtestsproveOK,themultiplexcontrolunitmustbefaulty.Replacetheunder'dashfuse/relaYboxassemblY
Cavitv
P18
Q3
o4
X5
Wire
RED
GRN
Test condition
C h e c kf o r v o l t a g et o g r o u n d :
Thereshould be 1 V or less.
H a t c hc l o s e d
Thereshouldbe 5 v or more.
Driver'sdooropen
C h e c kf o r v o l t a g e t o g r o u n d :
Thereshould be 1 V or less.
Driver'sdoorclosed
Thar. shoul.lhe 5 V or more.
Thereshouldbe 1 V or less.
Checkforvoltageto ground:
Thereshouldbe 5 Vor more.
door
LTGRN/ Passenger's
BED
Passenger's
door
croseo
RED^vHT lgnitionkey inserted
intothe ignition
lgnitionkey removed
from the ignition
Y8
YEURED Driver'sdoorlock
knob switchlocked
Driver'sdoorlock
kn6h cwirch Inl6cke.l
Posq!!!c sq!!ej1!.9!!!!j
Poorground(G552)
Fauhyhatchlatchswitch
An openinthewire
Faultyhatchlatchswitch
Shorttooround
Faultydrlver'sdoorswitch
An oDenin thewire
Faultydriver'sdoorswitch
Test:Desiredresult
H a t c ho p e n
'
'
.
.
doorswitch
Faultypassenger's
An oneninthewire
doorswitch
Faultypassenger's
Shor o oround
Poorground(G401)
Faultyignitionkeyswitch
An ooenin the wire
Thereshould be 5 V or more.
F a u l t yi g n i t i o n k e y s w i t c h
Short to ground
Poorground{G501)
Faultydriver'sdoorlockknobswitch
An ooenin thewire
Shortto oround
Thereshouldbe 5 V or more.
€d
22-93
InteriorLights
u
J
v
J
$
J
CEILING
LIGHT/SPOTLIGHTS
Test,page22-96
page22-96
Replacement,
REARCEILING
LIGHT
Test,page22-96
page22-96
Replacement,
HATCHLATCHSWITCH
Test,page22-97
CARGOAREALIGHT
fesl, page 22-97
page22-97
Replacement,
22-94
CircuitDiagram
STAB
ctu[G
LIGHT
MUITIPLEX
c0NTlot
UIIIT
\
J
HATCH
LATClI
swtTcH
22-95
Interior Lights
CeilingLight/SpotlightsTest/
Replacement
RearCeilingLight Test/
Replacement
1 . Turn the ceiling lighvspotlightsswitchesOFF.
1 . Turn the light switch OFF.
2 . Carefullypry off the lens {A) wilh a small
screwdnver,
2 . Carefullypry offthe lens (A) with a small
screwdriver.
CeilingLight:
Spotlight:
5W
5Wx2
CeilingLight: 8 W
x 1-0 mm
5x1.0mm
\A
A.
3. Removethe two screwsand the housing(B).
t e 4 Pc o n n e c t o(rC )f r o m t h e h o u s i n g .
3. Removethe two mounting screws.
5. Checkfor continuitybetweenthe terminalsin each
4. Disconnectthe 3P connector(B)from the housing
\
P."lil;-
Terminal
-----_l
il
oFF
celL,"ca,c",
MIDDLE
isoottiohts\
'uir
a}-+4
oN
re
SPOTLIGHTS
I C e i l i n ql i o h t
r o F F - - i
R
ON
o
-o
-o
(.F.O
Terminal
Position
G-
L
1
2
3
OFF
MIDDLE
OFF
ON
{c).
ON
o
G -@- O
OFF
lf the continuityis not as specified,checkthe bulb.
l f t h e b u l bi s O K , r e p l a c et h e c e i l i n gl i g h v s p o t l ihgt s .
22-96
lf the continuityis not as specified,checkthe bulb.
l f t h e b u l b i s O K , r e p l a c et h e r e a rc e i l i n gl i g h t .
CargoArea Light Test/Replacement Hatch Latch Switch Test
1 . Open the hatch.
Carefullypry out the cargo area light (A).
'1.
Open the hatch.
Removethe hatch lower trim panel (seepage 20-
s3).
CargoArea Light: 5W
Disconnectthe 2P connector{A) from the hatch
l a t c h( B ) ,
Disconnectthe 2P connector(B)from the light.
Checkfor continuitybetweenthe No. 1 (+) and
N o . 2 ( ) t e r m i n a l sT. h e r es h o u l db e c o n t i n u i t y .
lf there is no continuitv,checkthe bulb. lf the bulb
is OK, replacethe cargo area light.
4 . Checkfor continuitybetweenthe No. 1 and No. 2
terminals.
. Thereshould be continuitywith the hatch open
. Thereshould be no continuitywith the hatch
ctoseo.
lf the continuityis not as specified,replacethe
hatch latch.
22-97
AudioSystem
AUOIOUNIT
Removal/f
nstallation,
Daoe22-100
pa-ge
Connector
Terminals,
22-101
RIGHTDOOBTWEETER
page22-102
Replacement,
ROOFANTENNA
page22-'1
Replacement,
03
ANTENNA SUB LEAD
DRIVER'SDOORSPEAKER
page22 102
Replacement,
LEFTREARSPEAKER
page22-102
Replacement,
RIGHT
REARSPEAKER
page22-102
Replacement,
ANTENNA LEAD
22-98
t
CircuitDiagram
'
/ 8AT
--------F
\
\
f!tACC
/
No.20ioA)
:USA
WHT/FED
ACC
HoTinACC
lllmd0Nllll
AUDIO
UflIT
t
-
DRIVER'S
DOORSPEArcF
r
a
-
IEFITWEETER
r
:
PASSE!{GIF'S
DOOB
SPEAKES
-
r
a
SIGIITTWEETEB
O
LEFTFEAB
SPEA(I8
e
?
a
NrcBTREAF
SPEAKEF
22-99
AudioSystem
!\,
Audio Unit Removal/lnstallation
NOTE:
parts.
Removethe heatercontrol panel (seepage 21 38).
R e m o v et h e f o u r m o u n t i n gb o l t sa n d t h e a u d i ou n i t
from the radio brackets.
presetbuttons.
2. Removethe driver's dashboardlower cover (see
page20-59).
3. Removethe two mounting bolts,then pull out the
centerpanel (A).
7 . I n s t a l l t h ea u d i ou n i ti n t h e r e v e r s eo r d e ro f
4 . Disconnectthe audio connector(B)and antenna
lead (C),heatercontrol panelconnectors(D) and
HAVCpush switch assembly(E),then removethe
center panel.
22-100
. Make sure the audio unit and A/C connectorsare
pluggedin properly,and the antennalead is
connectedproperly.
\v
Audio Unit ConnectorReplacement
Cavity
1
2
3
4
5
Wire
YEUGRN
YEURED
PNK
Connectsto
Roof antenna
ACC (Power)
Not used
Not used
R i o h tr e a rs D e a k e(r+ I
6
BLU^/vHT
(+)
LeftrearsDeaker
7
8
GRN/YEL
Front oassenqer'sdoor sDeaker{+)/Riqht tweeter (+)
Driver'sdoor speaker{ + )/Lefttweeter (+ )
Liqhts on siqnal
Constantpower
Not used
Not used
Not used
9
10
GRN/BLK
RED/BLK
WHT/RED
11
12
Notused
14
ta
to
11
18
19
20
BLU/YEL
BLU/BLK
GRY/RED
LT GRN
RED
BLK
R i o h tr e a rs o e a k e (r Left rear sDeaker(
Front passenqer'sdoor speaker( )/Riqhttweeter{
Driver'sdoor sDeaker( )/Lefttweetr ( Dashliqhts briqhtnesscontroller
Gr o u n d( G 5 0 3 )
AUDIOUNIT2OPCONNECTOR
22-101
AudioSystem
SpeakerReplacement
DoorSpeaker:
Rear:
1 . R e m o v et h e d o o r p a n e l( s e e p a g e 2 0 - 4 ) .
1 . Removethe speakercover (A).
2. Pullthe top of the speaker{A) straightout, just
enoughto releasethe upper clip. lf you pull the
speakerout too far, you will damagethe lower clips
(C).Then lifi the speakerstraightup to releasethe
lower clips.
2. Removethe three screws,then disconnectthe 2P
3. Disconnectthe 2P connector(B),and removethe
speaKer.
Tweeter:
Carefullypry the tweeter (A) out of the mirror mount
cover,then disconnectthe 2P connector(B)from the
tweeter.
'-----d
22-102
connector(B)from the speaker(C).
RoofAntennaReplacement
1. Removethe rear part of headliner(seepage20-54).
2, Disconnectthe antennalead connector(A) and 1P
connector(B)from the roof antenna(C).
3. Removethe mounting nut and the antenna.
22-103
RearWindow Defogger
t
*:Rearwindow defoggerswitch is built into the heatercontrol panel.
UNDER.HOOD
FUSE/RELAY
BOX
J
REARWINDOWDEFOGGER
RELAY
Test,page22-51
REARWINDOW
DEFOGGER
SWITCH+
u
I
NOISE
CONDENSER
page22 107
CapacityTest,
REARWINDOWDEFOGGEB
Function
Test,page22 106
DefoggerWire Repair,page22 106
J
22-104
J
CircuitDiagram
;Hl}lj.'fl,1fl1fi"
t
T f,rAiwrxDow
,74 DEfOGGES
I SWrcfl
BEATERcoNrf,oLpANrL(\iP\/
L
INDIATOR
ILEDI
J
22-105
RearWindowDefogger
FunctionTest
DefoggerWire Repair
NOTE:
. Be carefulnot to scratchor damagethe defogger
wires with the testerprobe.
. Beforetesting,checkthe No. 11 (30A)fuse in the
'14('10A)
under-hoodfuse/relaybox and No.
fuse in
the under-dashfuse/relaybox.
NOTE:To make an effectiverepair,the brokensection
m u s t b e n o l o n g e rt h a n o n e i n c h .
1. Lightly rub the area aroundthe brokensection(A)
with fine steelwool, then clean it with alcohol.
1. Checkfor voltage betweenthe verticaI dividersand
body ground with the ignitionswitch and defogger
switch ON.
There should be voltageas shown.
. lf there is no voltage.checkfor:
- faulty defoggerrelay.
- an open in the BLK,BLK,/YEL,
or YEL/BLKwire.
- taulty heatercontrol panel.
. lf there is batteryvoltage,goto step 2.
2. Carefullymask above and below the brokenportion
of the defoggerwire (B)with transparenttape {C).
Mix the silverconductivepaint thoroughly.Using a
small brush,apply a heavy coat of paint extending
about 1/8 inch on both sidesof the break.Allow 30
minutesto dry.
6V
2 . Checkfor continuitybetweenthe negativeterminal
( B )a n d b o d y g r o u n d .
lf there is no continuity,checkfor:
. a n o p e n i n t h e B L Kw i r e .
. Poor body ground at the window antennacoil
mounting bolt.
Touchthe voltmeterpositiveprobe to the halfway
point of each defoggerwire. and the negative
probeto the negativeterminal,
Thereshould be about 6 V with the ignitionswitch
and the defoggerswitch ON.
. l f t h e v o l t a g ei s a s s p e c i f i e dt ,h e d e f o g g e r w l r ei s
oK.
. lf the voltage is not as specified,repairthe
defoggerwire.
- l f i t i s m o r et h a n 6 V , t h e r ei s a b r e a ki n t h e
n e g a t i v eh a l fo f t h e w i r e .
- lf it is lessthan 6 V, there is a breakin the
positivehalf of the wire.
22-106
Checkfor continuityin the repairedwire.
5 . Apply a secondcoat of paint in the same way. Let it
dry 3 hours before removingthe tape.
NoiseGondenserCapacityTest
1 . Removethe right rear side trim panel (seepage 2066).
Disconnectthe 2P connector(A)from the noise
condenser.
Noise condenser capacity:
0.47 a 0.09 microfarads
Use a commerciallyavailablecondensertester.
Connectthe condensertester probes,and the
measurecondensercapacity.
4. lf it is not within the specification,replacethe noise
condenser.
22-107
Moonroof
MOONROOF
SWITCH
f e $ , p a g e2 2 - 1 1 2
R e p l a c e m epnat ,g e2 2 - 1 2
T e s tp. a g e 2 2 - 1 1 2
page20-41
Replacement,
MOONROOFLIMIT SWITCH
Test,page22-113
\|.
MOONROOF
CONTROLUNIT
InputTest,page22-'l10
MOONROOFAUTO-STOPSWITCH
Test,page22'113
22-108
MOONROOF
OPENRELAY
GRN, I
lwire colors:GRN/YEL,
BLKandYEUGRNI
LRED/YEL,
Test,page22-51
MOONROOF
CLOSERELAY
GRN, I
lwire colorsrGRN/BLK,
BLKand YEL/GRNI
LGRN/WHT,
Test,page22-51
CircuitDiagram
UNDIR OAS8FUSE/NILAY
MX
No.20lOAl:US
No.20150
) :Canda
A Clos.dfom lh€ ruto nop poshio. to lh€ doed porhion
B Clo!.d in th€ lilt or do3.d poilion
C : Clo!.d in anyop.n (io! riltl posirion
D Clos.d in th€ tilt po6iiion
BL|(
8LI
+
I
G50t
G5{1
22-109
Moonroof
MoonroofControlUnit Input Test
I
J
b
J
1 . R e m o vteh eh e a d l i n e( sr e ep a g e2 0 - 5 4 ) .
(A)fromthecontrolunit(B).
2 . Disconnect
the 5Pconnector
GRN/WHT
1
2
3
LT GRN
4
5
Wire sideof
RED/YEL BLK
Inspectthe connectorand socketterminalsto be sure they are all making good contact.
. lf the terminalsare bent, looseor corroded,repairthem asnecessary.and recheckthesystem.
$ J
22-110
4- Reconnect
the moonroolcontrolunit5Pconnector,
andmaketheseinputtestsattheconnector.
. lf all the inputtestsproveOK,go to step5.
Caviiy
Wire
5
BLK
,l
Test condition
Test:Desiredresuh
Possiblecaus6if result is not obtained
Underallconditions
Thereshouldbe continuity.
Poorground(G501)
An openin the wire
YEUGRN lgnitionswitchON (ll)
There should be baftery voltage.
BlownNo.6 (7.54)tusein the under
dashfuse/relaybox
An openin the wire
lgnitionswitchON (ll)
Moonroofclosed
Thereshould be 1V or less.
Poorground(G501)
Faultymoonroof auto-stopswitch
An openinthewire
Moonroof open
Thereshouldbe batteryvoltage.
Shorttoground
Faultymoonroofauto-stop
switch
LT GRN
Disconnectthe
moonroofcontrolunit5Pconnector,
andmakethese;nputtests
at the connector
'lfanytestindicatesaproblem,findandcorrectthecause,thenrecheckthesystem.
. lf all the inputtestsproveOK,the controlunit mustbefaultv.Replace
it.
Cavity
Wire
Test condition
3
RED//EL lgnitionswitchON lll)
2
cRN,4/VHTl g n i t i o n s w i t c h O N ( l l )
Test:Desiredrosult
Connecta jumperwire betweenNo,
3 and No.5 terminals.
Moonroofmotorshouldrun
(opened).
Poorground(G501)
BlownNo.6 (7.5Aifusein the under'
dashfuse/relaybox
BlownNo.7120Alfuse
inthe under
dashfuse/relay
box
Faultymoonroofopenrelay
Faultymoonroofcloserelay
FaultymoonrooJmotor
A n o p e n ; nt h e w i r e
Connecta jumperwire betweenNo.
Poorground(G501)
2 and No.5 terminals.
BlownNo.6 (7.5Aifusein the under
I\,4oonroof
motorshouldrun {closed). dashfuse/relay
box
ElownNo.7 (20A)fusein the under
dashfuse/relaybox
Faultymoonroofopenrelay
Faultymoonroolcloserelay
Faultymoonroof motor
An openin thewire
22-111
Moonroof
Motor Test
Switch Test/Replacement
'1
. Carefullypry the moonroof switch (A) out of the
headlin
er.
\
J
1 . R e m o v et h e h e a d l i n e(rs e ep a g e2 0 - 5 4 ) .
2. Disconnectthe 2P connectorfrom the moonroof
motor.
2. Disconnectthe5P connector(Blfrom the moonroof
swtrcn.
3. Checkfor continuitybetweenthe terminalsin each
Terminal
\
--\
Pi.iti..
1
4
5
Terminal
pl.iri""---\
OPEN
\7
CLOSE
(,
o
lf the motor does not run. replaceit,
TILT
-o
4 . lf the continuityis not as specified.replacethe
moonroof switch.
22-112
\
FO
CLOSE
OPEN
3. Checkthe motor by connectingpower and ground
accordinoto the table.
NOTE:See closingforce check(seepage20-48)for
motor clutchtest.
J
Limit Switch Test
Auto-stopSwitch Test
l . Removethe headliner(seepage 20-54).
1 . Removethe headliner(seepage 20-54).
2. Disconnectthe 4P connectorfrom the moonroof
2 . Disconnectthe 2P connectorfrom the moonroof
auto-stopswitch.
limit switch.
Checkfor continuily betweenthe terminalsin each
NOTE:Turn the motor by hand with the wrench.
NOTE:
. Turn the motor by hand with the wrench,
. The auto-stoppositionis about 145 mm (5.75in.)
from fully closed.
Terminal
\
Position
TILT
1
3
o-
o-
4
Terminal
OPEN
Position
CLOSE
BotwoenAUTO-STOP
andCLOSE
moonroof limit switch.
1
2
Between OPEN and
AUTO.STOP
lf the continuityis not as specified,repairor replace
the auto-stopswitch.
22-113
PowerMirrors
POWERMIRRORS
FunctionTest,page22-116
page20-15
Replacement,
ActuatorTest,page22-117
ActuatorReplacemenl,page22-118
q3:.[
---\,--,-'/
-:,)
j-' ',i. it .i/
'\ \,
-,''
-o
t:
'
-lo'
,.'7
POWERMIRRORand
MIRRORDEFOGGERSWITCH
lesl, page22-111
page22-117
Replacement,
$r22-114
CircuitDiagram
'1
UiIDTSrcODR]SE/R€LAY
8OX
t
rcilmoN
s1/vtTcH
UiD$ DASH
N'SUnIIAY8OX
ih.a i|0At :Usa
J
22-115
PowerMirrors
FunctionTest
1. Removethe driver's pocket(seepage 20-60).
2. Reachthrough the pocketopening,and push out
the power mirror switch (A).
, \
Left mirror
7 . C o n n e ctth e N o . 2 t e r m i n a tl o t h e N o . l 0 t e r m i n a l ,
a n dt h e N o . 5 ( o r N o . 1 2 )t e r m i n a tl o t h e N o . 6
t e r m i n aw
l i t h j u m p e rw i r e s .T h e l e f tm i r r o rs h o u l d
t i l t d o w n ( o r s w i n gl e f t ) w i t ht h e i g n i t i o ns w i t c hO N
flr).
. l f t h e m i r r o r d o e sn o t t i l t d o w n ( o r d o e sn o t s w i n g
left),checkfor an open in the GRN/WHT(or BLU/
Wl-lT)wirebetweenthe left mirror and the 13P
conneclor,lf the wire is OK, checkthe left m irror
actualor.
. lf the mirror neithertiltsdown nor swings left.
r e p a i rt h e B L U / B L K
wire.
. l f t h e m i r r o r w o r k sp r o p e r l yc, h e c k t h em i r r o r
RED B
SWIICN,
Right mirror
W i r es i d eo f
t e m a l et e r m i n a l s
WHT/RED
RED/BLK
RED/YEL
o n n e c t o(rB )f r o m t h e s w i t c h .
3 . D i s c o n n e c t t h e ' 1 3cP
4. Choosethe appropriatetest basedon the
symptom:
. Both mirrors don't work, go to step 5.
. Left mirror doesn'twork, go to step 7.
. Rightmirror doesn'twork, go to step 8.
. Defoggerdoesn'twork (Canada),go to step 9.
8 . C o n n e ctth e N o . 2 t e r m i n a l t ot h e N o . 1 1t e r m i n a l ,
a n d t h e N o . 5 { o r N o . 1 3 )t e r m i n a tl o t h e N o . 6
terminaw
l i t h j u m p e rw i r e s .T h e r i g h tm i r r o rs h o u l d
tilt down (or swing left)with the ignition switch ON
( ).
. lf the mirror does not tilt down (or does not swing
left),checkfor an open in the GRN/WHT(or WHT/
R E D ) w i r eb e t w e e nt h e r i g h tm i r r o ra n d t h e 1 3 P
connector.
lf the wire is OK, checkthe right mirror actuator.
. l f t h e m i r r o r n e i t h e r t i l t s d o w n o r s w i n g sl e f t ,
repalrthe RED|YELwire.
' l f t h e m i r r o r w o r k sp r o p e r l yc. h e c k t h em i r r o r
swrrcn.
Both mirrors
Defogger(Canada)
5. Checkfor voltage betweenthe No. 2 terminal and
b o d y g r o u n dw i t h t h e i g n i t l o ns w i t c hO N ( l l ) .
There should be batteryvoltage.
. lf there is no batteryvoltage,checkfor:
- b l o w n N o . 1 4 ( 1 0 A )f u s e i n t h e u n d e r ' d a s h
fuse/relaybox.
- a n o p e ni n t h e B L K r y E L
wire.
. lf there is batteryvoltage,goto step 6.
6. Checkfor continuitybetweenthe No. 6 terminal
. lf there is no continuity,checkfor:
- a n o p e ni n t h e B L Kw i r e .
- p o o r g r o u n d( G 5 0 1 ) .
. lf there is continuity,checkboth mirrors
i n d i v i d u a l la
y s d e s c r i b e di n t h e n e x tc o l u m n .
22-116
9 . C o n n e ctth e N o . 1 a n d N o . I t e r m i n a l sw i t h a
jumper wire, and checkfor voltage betweenthe
N o . 2 t e r m i n a lo f t h e m i r r o rc o n n e c t oar n d b o d y
ground.Thereshould be batteryvoltageand both
m i r r o r ss h o u l dw a r m u p w i t h t h e i g n i t i o ns w i t c h
oN t).
. l f t h e r ei s n o v o l t a g eo r n e i t h e r w a r m su p , c h e c k
for:
- a n o p e n i n t h e B L K I / E Lo r o R N w i r e .
- b l o w n N o . 1 4 ( ' l 0 A ) f u s ei n t h e u n d e r - d a s h
fuse/relaybox.
. l f o n l y o n e f a i l st o w a r m u p , c h e c k :
- its defogger.
- p o o r g r o u n d( G 5 0 1G
, 502)
. l f b o t hw a r m u p , c h e c k t h e d e f o g g e r s w i t c h .
PowerMirror Switch Test
Power Mirror ActuatorTest
1 . Removethe driver'spocket(seepage 20-60).
1 , Removethe door panel (seepage 20-4).
2 . Reachthrough the pocketopening,and push out
the power mirror switch (A).
2 . Disconnectthe 6P connector(A) from the power
m i r r o ra c t u a t o r( B ) .
3 . Disconnectthe 13Pconnector(B)f rom the switch.
Checkactuatoroperationby connectingpower and
ground accordingto the table.
Mirror Switch:
\.f9.-'"1L
Position
2
CF
UP
5
6
10
o-
o
11
12
13
--o
o-
-c)
G
TILTDOWN
o
oo
SWINGLEFT
o
SWING RIGHT
@
4
o
o
o
@
!
-o
RIGHT
6
TILTUP
-o
o-
Terminal
\
Position
-o
UP
4. lf the mirror fails to work properly,replacethe
mtrror actuator.
DefoggerTest {Canada);
"[T
5 . C h e c kf o r c o n t i n u i t yb e t w e e nt h e N o . 1 a n d N o . 2
terminalsof the 6P connector.Thereshould be
continuity.lf there is no continuity,checkfor an
open circuit.
RIGHT
Defogger Switch (Canadal:
\
Te.minal
tlf
il;;;
ON
I
8
o
o
OFF
5 . lf the continuityis not as specified,replacethe
power mirror switch.
22-117
PowerMirrors
PowerMirror Actuator Replacement
'1.
Removethe power mirror (seepage 20-15).
\
4
8. Removethe three Torx screws,and separatelhe
actuator(A)from the mirror housing{B).
2 . Carefullyremovethe mirror holderfrom the mirror
h o u s i n gG
. e n t l yp u l l i t o u t b y h a n d( s e ep a g e2 0 - 1 5 ) .
3 . Disconnectthe connector.
4 . Removethe cover,then removethe two Torx
screwsfrom the mirror connector.
5 . Recordthe terminal locationsand wire colors.
6 . Cut the wire harnesswith the wire cutter.
9 . Routethe wire harness{A) ofthe new actuator
t h r o u g ht h e h o l ei n t h e b r a c k e (t B ) .
\
J
7. Removethe three screws,and separatethe mirror
housinqfrom the mirror base.
J
22-118
10. lnsertthe terminalsinto the connectorin the
o r i g i n aa
l r r a n g e m e nat s s h o w nb e l o w .
LEFTMIRROR
CONNECTOR RIGHTMIRROR
CONNECTOR
*:Canada
'l'1.
Reassemblein the reverseorder of disassembly.
Be carefulnot to breakthe mirror holderwhen
reinstallingit to the actuator.
1 2 .R e i n s t a l l t h m
e i r r o ra s s e m b l yo n t h e d o o r .
tJ.
Operatethe power mirror to ensuresmooth
operation.
22-119
Horns
\
UNDER-HOOD
FUSE/RELAY
BOX
HORNRELAY
Test,page22-51
.-
:.."'
HORNSWITCH
fesl, page22-122
HORNS
Test,page22 122
B e p l a c e m e npt a
, g e2 2 1 2 2
CABLEREEL
page23,119
Replacement,
*r
22-120
J
GircuitDiagram
J
22-121
Horns
Horn Test/Replacement
1 . Removethe front bumper {seepage 20-85).
Horn Switch Test
1 . Removethe steeringcolumn covers(seepage '179).
Disconnectthe 1Pconnector(B),and removethe
horn (A).
Disconneclthe dashboardwire harnessB 5P
connector(A) from the cable reel (B).
|. . . . : .../..
...,
3 . Testthe horn by connectingbatterypower to the
terminal (A) and ground to the bracket(B).The horn
s h o u l ds o u n d .
Using a jumper wire . connectthe dashboardwire
harnessB 5P connector(A) No. 2 terminal to body
g r o u n d.
. lf the horns sound,goto step 4.
. l f t h e h o r n sd o n o t s o u n d ,c h e c k t h e s ei t e m s :
- Horn relay
- N o . 7 ( 1 5 A ) f u s ei n t h e u n d e r - h o o fdu s e / r e l a y
box
- Horns (see page 22-122).
- An open in the wire
4. lf it fails to sound, replaceit.
22-122
I
wire harnessB 5P
4. Reconnect
the dashboard
the hornswitch
connector
{A),anddisconnect
(B).
positive1Pconnector
wheelto
1 . Usinga jumperwire,connentthe steering
8 . Closethecontactsbetweenthe hornplateandthe
contactplate.
. lf the hornssound,replacethesteeringcolumn.
. l f t h eh o r n s d on o t s o u n dr,e p l a c e t hheo r na n d
contactplate.
Using a jumperwire, connectthehorn switch
positive1Pconnector(B)to ground
. lf the horns sound,go to step 6.
. l f t h e h o r n sd o n o t s o u n d ,r e p l a c e t h e c a b lree e l .
6 , Reconnectthe horn switch positive1Pconector(B).
22-123
PowerWindows
I
J
t
J
UNDER.DASH
FUSE/RELAY
BOX
al.l ' -f..--.-L - . : :
POWERWINDOWRELAY
Iest, page22-51
FRONTPASSENGER'S
WINDOWMOTOR
Test,page22-132
DRIVER'SWINDOWMOTOR
Test,page22-129
POWERWINDOW MASIER SWITCH
InputTest.Daqe22.126
Test,page22--128
page22-133
Replacement,
FRONTPASSENGER'SWINDOW SWITCH
I n D uT
t e s l ,p a q e2 2 - 1 3 0
f est, page 22-132
\
22-124
J
CircuitDiagram
'No.20il0A)
: USA
UNOERHMO FUSI/8tLAY8OI
tGt'TtoitswtTcfi
--+r
U/
o'F
BTTYEL
lGl HOTin 0N {ll)
tnd STABT{llll
WHT/BU
22-125
PowerWindows
MasterSwitch Input Test
NOTE:Thepowerwindowcontrolunitis builtintothe powerwindowmasterswitch,andit onlycontrolsthe driver's
windowoperations.
1. Removethe windowmasterswitch{A)(seepage22-133).
(B)from the masterswitch.
2. Disconnect
the 14Pconnector
GRN/WHT
. lf theterminals are bent, looseorcorroded, repairthem as necessary,and recheckthesystem.
22-126
4. Withthe connectorstill disconnected,maketheseinputtests attheconnector.
.lfanytestindicatesaproblem,findandcorrectthecause.thenrecheckthesystem.
. l f a l l t h e i n p u t t e s t sp r o v eO K ,g o t o s t e p5 .
Cavity
Wire
Test condition
10
BLK
U n d e ra l l c o n d i t i o n s
14
11
GRN^,^/HT l g n i t i o ns w i t c hO N ( l l )
2
GRN/BLK
1
RED/YEL C o n n e ctth e N o .
RED/BLK
'l'1
and
N o . 7 t e r m i n a l sa, n d t h e
N o , 4 a n d N o . 1 4t e r m i n a l s ,
and turn the ignition switch
Test:Desiredresult
Checkfor continuityto
grouno:
Thereshould be continuity.
Checkfor voltageto
ground:
voltage.
Checkfor driver'swindow
molor operaflon:
I t s h o u l dr u n ( t h ed r i v e r ' s
w i n d o w m o v e sd o w n ) .
Possiblecauseif result is not
obtained
. P o o rg r o u n d{ G 5 0 ' 1 )
. An openin thewire
B l o w nN o . 6 ( 7 . 5 A f)u s e i n
the under-dashfuse/relay
box
Blown No. 22,23 l2OA)tuse
in the under-dashfuse/
relay Dox
Faultypower window relay
P o o rg r o u n d( G 2 0 1 )
An open in the wire
. Faultydriver'swindow
motor
oN flr).
3
B L U / R E DConnectthe No. 2 and No. 1 Checkfor passenger's
t e r m i n a l sa, n dt h e N o . 3
BLU/WHT a n d N o . 1 0t e r m i n a l sa, n d
t u r n t h e i g n i t i o ns w i t c hO N
fir),
window motor operation:
I t s h o u l dr u n ( t h e
passenger'swindow moves
oown).
Faultypassenger'swindow
motor
swatch
An open in the wire
5. Reconnectthe 14Pconnectorto the switch,and performthe following input tests.
. lf all the input tests prove OK, the control unit must be faulty. Replacethe power window masterswitch.
Cavity
Wire
Test condition
13
ORN
C o n n e ctth e N o . 1 1 a n d
N o . 7 t e r m i n a l sa, n d t h e
N o . 4 a n d N o . 1 4t e r m i n a l s ,
and turn the ignition switch
Checkfor voltagebetween
t h e N o . 1 3a n d N o . 1 4
termtnals:
About6Vshouldbe
indicatedwith the driver's
window motor running.
o N0 r ) .
Possible cause if result is not
obtained
. Faultydriver'swindow
molor
22-127
Driver'sWindow Motor Test
Motor Test:
PulserTest:
1 . Removethe door panel (seepage 20-4).
Disconnectthe 4P connector(A)from the driver's
window motor.
1 . Reconnectthe 4P connectorto the driver'swindow
motor, and reconnectthe 20Pconnectorto the
power window masterswitch.
Connectthe test leadsof a voltmeterto the No, 3
and No. 4 terminalsof the driver'swindow motor
4P connector.
Run the motor usingthe masterswitch.The
voltmetershould read about 6 V.
lf the voltageis not as specified,checkfor an open
in the wires. lf the wires are OK, replacethe driver's
window motor.
Testthe motor in each directionby connecting
batterypower and ground accordingto the table.
When the motor stops running,disconnectone
lead immediatelv.
\
Terminal
il;;'-\
2
UP
e
DOWN
@
o
e
4 . lf the motor does not run or fails to run smoothly,
replacerL
22-129
PowerWindows
Passenger's
Window Switch Input Test
1 . Removethe switch panel (seepage 20-4).
2 . Disconnectthe 5P connector(A)from the switch (B).
o
'' "'"1.
BLU/WHT
GRN/BLK
Inputthe connectorand socketterminalsto be sure they are all making good contact.
. lf theterminals are bent, looseor corroded,repairthem as necessary,and recheckthesystem.
4 . Reconnectthe connector,and using a back probe, makethese input tests at the connector.lf any test indicatesa
problem,find and correctthe cause,then recheckthe svstem,
Cavitv
3
Wire
Test condition
G R N / B L K lgnitionswitch ON
{l l )
2
BLD,A/VHT lgnitionswitch ON
( )
At the master
window switch,
pressand hold
down the
passenger'sswitch
BLU/RED lgnitionswitch ON
(||)
At the master
window switch,
p u l lu p a n d h o l d
the passenger's
switch
22-130
Test:Desiredresult
Checkfor voltageto
grouno:
voltage.
Checkfor voltageto
ground:
voltage.
Checkfor voltageto
grouno:
voltage.
B l o w nN o . 6 ( 7 , 5 A ) f u s ei n t h e
B l o w nN o . 2 2 { 2 0 A ) f u s ei n t h e
Faultypower window relay
An open in the wire
P o o rq r o u n d( G 2 0 1 )
Faultymasterwindow switch
An open in the wire
Faultymasterwindow switch
An open in the wire
5. Disconnect
the 5Pconnector,
andmaketheseinputtests.
Cavitv
1
Wire
Test condition
RED
Connectthe No. 2
Checkfor passenger's
RED/BLU t e r m i n a tl o t h e N o . window motor operation:lf
Faultymaster'swindow switch
An open in the wire
1 t e r m i n a la
, n dt h e should run (the passenger's
N o . 4 t e r m i n a tl o
window moves down),
moror.
t h e N o . 5 t e r m i n a l , There should be battery
a n dt u r n t h e
voltage.
ignition switch ON
{ll),and pressthe
down button on
the power window
masterswitch for
the passenger's
window.
6. lf allthe tests prove OK, the switch must be faulty. Replaceit.
22-131
PowerWindows
Passenger's
Window Switch Test
1 . Removethe switch panel (seepage 20-4).
Removethe power window switch (A) from the
doorpanel.
Passenger's
Window Motor Test
1 . Removethe passenger'sdoor panel (seepage204).
passenger'spower window motor.
Disconnectthe 5P connector(B)from the
passenger'spower window switch.
Terminalside of
tfiTtTtT;Etl
'-r--r-,Jl
l'
Testthe motor in each directionby connecting
batterypower and ground accordingto the table.
When the motor stops running,disconnectone
l e a di m m e d i a t e l y .
\
\Torminal
Poiition\
Terminal
Dl*;;;__\
1
2
4
UP
UP
DOWN
1
I
o
o
o
OFF
DOWN
swtlcn.
22-132
lf the motor does not run or fails to run smoothly,
reptacert.
MasterSwitch Replacement
'1.
Passenger's
Window Switch
Replacement
Removethe door grip (seepage 20-4).
2 . Removethe power window masterswitch (A)f rom
t h e d o o rp a n e l .
1 . Removethe door grip {seepage 20-4).
2 . Removethe power window switch (A) from the
o o o rp a n e r .
3 . Disconnectthe 14Pconnector(B)from the switch.
Removethe three screwsand the switch from the
switch panel.
3 . Disconnectlhe 5P connector(B)from the switch.
4 . Removethe two screwsand the switch from the
switch panel.
22-133
Wipers/Washers
WINDSHIELD
WIPERARMS and LINKAGE
page22-'145
Replacement,
WIPER/WASHERSWITCH
Test,page22-140
Replacement,page
22 140
WINDSHIELD
WIPERMOTOR
Test,page22-'143
page22-145
Replacement,
UNDER.DASH
FUSE/RELAY
BOX
INTERMITTENT
WIPERCIRCUIT
l l nt h em u l t i p l ecxo n t r oul n i t )
InputTest,page22-138
22-134
WASHER
TUBES
page22-147
Replacement,
WASHER
RESERVOIB
page22'146
Replacement,
WASHERFLUIDLEVELSWITCH{Canada)
TesI,page22-144
page22-144
Replacement,
REARWINOOWWASHERMOTOR
Test,page22-144
page22 146
Replacement,
WINDSHIELD
WASHERMOTOR
fesl, page22 144
page22-146
Beplacement,
CONDENSER
CapacityTest,page22 107
REARWINDOWWIPERINTERMITTENT
CONTROL
UNIT
InputTest,page22'138
REARWINDOWWIPERMOTOR
f e$, page22-143
page22 146
Replacement,
BEARWINDOWWIPERARM
page22 146
Replacement,
22-135
Wipers/Washers
\ 1
CircuitDiagram- Windshield
'7{
FL]SE/8ELAY
BOX
UNOENHOOD
F;^--il
U-I^--
I
-':-;--u,Hr-
IGNITIONSWITCN
6\
o,f-''*""
MULTIPIIX
coiln0L
UNIT
L\'
\,!
22-136
CircuitDiagram- RearWindow
UI\IOIF H@OFUSE/RELAY
MX
BATTERY
-;i
r--------------l No'g,soA, ro2o. |
(-;1_=l----_--_fww{"-'
No2olaoAl
:USA
GNMOIIISW|ICH
/,^1\
\+y
l
lErHorb0Ni||l
I
andsra8r
0
ffAn w$tDowwtPEE
INTE$'ITTEI'IT
C{)NNOL
UI'/IT
f---------------
li
22-137
Wipers/Washers
RearWindowWiperIntermittentGontrolUnit InputTest
1 . Remove
the rightrearsidetrim panel{seepage20-51).
(A)fromthe rearwindow.wiDer
the 20Pconnector
intermittent
controlunit(B).
2 . Disconnect
LTGRN/REO
WHT/RED
WHT/RED
LT GRN
LT GRN/BLK
Inspecttheconnector
andsocketterminalsto be suretheyareall makinggoodcontact.
. lf theterminalsare bent,looseorcorroded,repairthemas necessary,
andrecheckthe
system.
. lf theterminalslookOK,go to step4.
22-138
\
4. With the connectorstill disconnected,maketheseinput tests at the connecrors.
' lf all the input tests prove OK, the control unit must be faultv. Replaceit.
Cavitv
Wire
GRN
Tesl condition
lgnitionswitch ON
flr)
10
6
4
BLK
U n d e ra l l
conditions
WHT/RED lgnitionswitch ON
LT GRN/
RED
LT GRN
( l l )a n d r e a r
window washer
switch ON
lgnition switch ON
( l l )a n d r e a r
window wiper
switch ON
lgnition switch ON
flr)
20
LT GRN/
BLK
lgnitionswitch ON
(ll)
voltaqe.
. B l o w nN o . 9( 1 0 A ) f u sien t h e
under-dash
fuse/relay
box
. An openin thewire
Checkfor continuity
to
grouno:
Thereshouldbe continuitv.
Poor ground (G553)
vortage.
B l o w nN o . 9 ( 1 0 A )f u s ei n t h e
Faultyrearwlndow wiper/
washer switch
Attachto groundl
The rearwindow wiper motor
s h o u l dr u n .
Attachto ground:
The rear window wiper motor
s h o u l dr u n .
voltage.
B l o w nN o . 9 ( 1 0 A ) f u s ei n t h e
Faultyrearwindow wiper motor
An open in the wire
B l o w nN o . 9 ( 1 0 A )f u s ei n t h e
Faultyrearwindow wiper motor
A n o D e ni n t h e w i r e
22-139
Wipers/Washers
Wiper/WasherSwitch Test/Replacement
lowercover{seepage20-60).
1 . Remove
the driver'sdashboard
Removethesteeringcolumncovers(seepage17-9).
(A)fromthewiper/washer
switch{B)
Disconnecl
the 14Pconnector
Removethe two screws,then pull out the wiper/washerswitch.
Inspectthe connectorterminalsto be sure they are all making good contact.
. lf the terminalsare bent, looseor corroded,repairthem as necessary,and recheckthe system.
.lftheterminalslookOK,checkforcontinuitybetweentheterminalsineachswitchpositlonaccordingtothe
tables,
- lf the continuityis not as speciiied,replacethe switch.
Terminal
Position
6
4
14
l2
12
11
o- -{
o-
OFF
tNl
o-
LO
HI
Mist switchON
r
Washor 3witch ON
J
22-140
ControlUnit InputTest
l . Beforetesting,troubleshootthe multiplexcontrol system lsee page22-jj2).
2 . Removethe dashboardlower cover,
3 . Disconnectthe under-dashfuse/relaybox connectorsB, G, J, X and y
NOTE:All connectorsare wire side of female terminals.
UNDER-DASH
FUSE/RELAY
BOX
CONNECTOR
B I6PI
UNDER.DASH
FUSE/RELAY
BOX
CONNECTOR
G {1OP)
UNDER-DASH
FUSE/RELAY
BOX
CONNECTOR
J {8PI
WHT/BLU
\
l-,1
€ l l
l-rl
l-,1
- llTtl
F_j-JF-#
1 4 1 5 1 76 l 8 l
lslrlzlol
\
BLU/RED
BLU/WHT
UNDER.DASH
FUSE/RELAY
BOX
CONNECTOR
X I8PI
BLU/BLK
. lf the terminalsare bent, looseor corroded,repairthem as necessary,and recheckthesystem.
. l f t h e t e r m i n a l sa r e O K ,g o t o s t e p5 .
(cont'd)
22-141
Wipers/Washers
ControlUnit Input Test (cont'dl
J
\
5. Reconnectthe connectors,and make these input tests at the connector.
. l f a l l t h e i n p u t t e s t s p r o v e O K , t h e m u l t i p l e x c o n t r ou ln i tm u s t b e f a u l t y .R e p l a c e
t h e u n d e r - d a sfhu s e / r e l a yb o x
assembly.
Cavity
J4
Y6
BI
E'0
Wire
BLK
Test condition
U n d e ra l l
conditlons
BLK
U n d e ra l l
conditions
WHTiBLU lgnitionswitch ON
{ l l )a n d w a s h e r
switch ON
BLU/RED lgnitionswitch ON
( l l )a n d w i p e r
switch OFF(wiper
motor stopped)
G7
BLUA/VHT lgnitionswitch ON
( l l )a n d w i p e r si n
p a r kp o s i t i o n
x1
B L U / B L K l g n i t i o ns w i t c hO N
( l l )a n d w i p e r
switch in INT
Test:Desiredresult
T h e r es h o u l db e 1 V o r l e s s .
T h e r es h o u l db e 1 V o r l e s s .
vortage.
voltage.
voltage.
voltage.
. P o o rg r o u n d( G 5 0 1 )
. AnoDeninthewire
. Poor ground (G502)
. A n o D e ni n t h e w i r e
Faultywiper/washerswitch
An open in the wire
F a u l t yw i n d s h i e l dw i p e r m o t o r
An open in the wire
B l o w nN o . 2 0 ( 2 0 A ) f u s ei n t h e
F a u l t yw i n d s h i e l dw i p e r m o t o r
An ooen in the wire
B l o w nN o . 2 0 ( 2 0 A ) f u s ei n t h e
An oDenin the wire
J
\
L
22-142
J
Wiper Motor Test
Windshield:
RearWindow:
1. Open the hood,and carefullyremovethe cap nuts
and the wiper arms. Make surethey do not touch
the hood.
1. Open the hatch,and removethe hatchtrim panel
(seepage 20-53).
2. Disconnectthe4P connector{A) from the motor {B).
2, Removethe hood seal andcowl cover.
3 . D i s c o n n e c t t h5eP c o n n e c t o(rA ) f r o mt h e m o t o r ( B ) .
Testthe motor by connectingbatterypower and
ground accordingto the table. lf the motor does not
run or fails to run smoothly,replaceit.
Testthe motor by connectingbatterypower and
ground accordingto the table. lf the motor does not
run or fails to run smoothly,replaceit.
Terminal
P-"-,tion
LOWSPEED
HIGHSPEED
Telminal
Battery
Connected
1
o
2
4
O
O
o
5 . Testthe wiper motor park switch by connectingan
a n a l o gv o l t m e t e rb e t w e e nt h e N o , 5 ( + ) t e r m i n a l
a n d g r o u n d ,a n d r u n t h e m o t o ra t l o w o r h i g hs p e e d .
T h ev o l t m e t e rs h o u l di n d i c a t e1 2V a n d 4 V o r l e s s
alternately.lf it does not, replacethe motor.
@
o
4 . Testthe wiper motor park switch by connectingan
a n a l o gv o l t m e t e rb e t w e e nt h e N o . 4 ( + ) t e r m i n a l
and ground, and run the motor. The voltmeter
should indicate12 V and 4 V or lessalternatelv.lf it
does not, reolacethe motor.
.l
J
j
22-143
Wipers/Washers
WasherFluidLevelSwitch Test/
- Canada
Replacement
WasherMotorTest
1. Partiallyremovethe right inner fender (seepage
20-'t021.
2. Disconnectthe 2P connectors(A) from the washer
motors (B).
1 . Partiallyremovethe right innerfender (seepage
20-102).
Disconnectthe 2P connector{A) from the washer
level switch.
Testthe washer motor by connectingbattery
power and ground accordingto the lable.
3 . Removethe washer fluid level switchfrom the
Terminal
Battery
Connected
1
2
@
o
reservoir.
NOTEF
: l u i dm a y f l o w o u t t h e o p e n i n g .
4 . Checkfor continuitybetweenthe terminalsin each
float (B) positionaccordingto the table.
4. lf the motor does not run, replaceit,
Terminal
2
Position
FLOATUP
FLOATDOWN
o- ---o
lf the continuityis not as specified.replacethe
swtTcn.
22-144
WindshieldWiper Motor Replacement
1 . Open the hood. Removethe nuts (A) and the
w i n d s h i e l dw i p e ra r m s ( B ) .
5 . S c r i b ea l i n e ( A )a c r o s st h e l i n ka n d w l n d s h i e l d
wiper linkageto show the original adjustment.
Separate
t h e w i n d s h i e l dw i p e r l i n k a g e( B )f r o m t h e
w i p e r m o t o r( C ) .
N.m
(3.2ksf.m,23 lbt.ft)
Removethe hood seal and cowl cover.
Djsconnectthe 5P connector(A)from the wiper
motor (B).
9.8 N.m (1.0
Installin the reverseorder of removal,and note
lhese items.
Apply multipurposegreaseto the moving parts.
Beforereinstallingthe wiper arms,turn the wiper
switch ON, then OFFto returnthe wiper shaftsto
the oark oosition.
lf necessary,replaceany damagedclips,
Checkthe wioer motor oDeration.
R e m o v et h e b o l t s( C ) ,m o v ew i n d s h i e l dw i p e r
l i n k a g ea s s e m b l y{ D ) t o w a r dt h e p a s s e n g e r 'ssi d e
of the vehicle until it slidesoff of the pin (E),then
removethe assembly.
22-145
Wipers/Washers
RearWindow Wiper Motor
Replacement
WasherReservoirReplacement
1 . Partiallyremovethe right inner fender.
1 . Open the hatch,and removethe hatchtrim panel
(seepage 20-53).
Disconnectthe 2P connectors(A)irom the washer
motors (B) and level switch (Canada).
Removethe mounting nut (A),the wiper arm (B)
and the specialnut (C).
A
9.8N.m {1.0kgf.m,
7.2rbf.ftl
B
8 N.m 10.8kgt.m,
6.0rbf.ft)
3 . Disconneclthe tubes (C)from the washer motors.
Removethe three bolts (A) and the washer
reservoir(B).
Disconnect
the 4Pconnector
{A),removethethree
mountingbolts(B),thenremovethe rearwindow
wiDermotor(C).
A
9.8 N.m
(1.0kgt.m,
7.2 tbf.tt)
B
9.8 N.m
{1.0kgt.m,7.2lbfftl
4 , Installin the reverseorder oI removal,and note
these items.
Apply multipurposegreaseto the moving parts.
Beforereinstallingthe wiper arm, turn the wiper
switch ON, then turn OFFto returnthe wiper
shaft to the Darkoositon.
lf necessary,replaceany damagedclips.
Checkthe wiDer motor operation.
-
22-146
WasherTubesReplacement
1 . Removethe rightinnerfender{seepage20-102).
2 . Remove
the washernozzles
andclips,thenremovethetubes.
<=>
r"-----------='
--==':?-
L-!
(cont'd)
22-147
Wipers/Washers
WasherTubesReplacement(cont'dl
3 . I n s t a l il n t h e r e v e r s e o r d e r orf e m o v a lT. a k ec a r en o t t o p l n c h t h e w a s h e r t u b e sC. h e c kt h e w a s h e ro p er a t i o n .
22-148
AccessoryPowerSocket
CircuitDiagram
AccessoryPower Socket Test/
Replacement
1 . Carefullypry the accessorypower socket(A) out
from the centerlower cover.
Disconnectthe 2P connector(B)from the socket.
Inspectthe connectorterminalsto be sure they are
all making good contact.
. lf the terminalsare bent, loose orcorroded,
repairthem as necessary,and recheckthe
system.
4 . Turn the ignition switchACC (l), and checkfor
voltage betweenthe No. 'l and No. 2 terminals.
. Thereshould be batteryvoltage.
. lf there is no baneryvoltage,checkfor:
- p o o r g r o u n d{ G 5 0 2 ) .
- an open in the wire.
- b l o w n N o . 1 8 ( 1 5 A ) f u s ei n t h e u n d e r - d a s h
fuse/relaybox.
22-149
DoorLockSystem
Keyless/Power
Test,page22-161
P r o g r a m m i n gp,a g e2 2 - 1 6 1
DRIVER'SDOORLOCKSWITCH
Test,page22-160
RECEIVER
UNIT
lnput Test,page22-153
IGNITIONKEYSWITCH
Test,page22-91
PASSENGER'S
DOORLOCKACTUATOR
Test,page22 158
MUTIPLEXCONTROLUNIT
DRIVER'SDOORSWITCH
DRIVER'S
DOORLOCK
SWTICH
ACTUATOR/KNOB
Actuator
Test,page22-158
KnobSwitchTest,page22 160
HATCHLATCHSWITCH
Test,page22-97
HATCHLOOKACTUATOR
Test,page22 159
PASSENGER'SDOORSWITCH
-
22-150
\
J
CircuitDiagram
UNOEE
DASH
fUSE/SELAYBOX
8OX
UiDENHooDFUSE/RETIY
-)
/ 8Ar
\
\
cl-
lG1,/
lG1HoTin0N(lllaidSTAfft(llll
l3
IT
I
BLK
I
G502
UI'IDE8DASH
f USE/RETAY
80X
MULTIPUX
CONTNo!
Uflfi
I
J
000R
Loc(KNOE
tl
xtY
\"2
PASSTNGtrS
0008100(
ACTUATOi
t'-F>
Li___JDBt!'t8'S
000R100(
ACTUATOB
t
(cont'd)
22-151
Keyless/PowerDoor LockSystem
J
\
HOOD
UNDEN
FU8E/BELAY
MX
l\br t15a)FUSE
t"-
HORN
SWTCH
UNDEN
DAS}I
FUSE/8ELAY
8OX
t J
Y,,,
mMErNAllofl
LIGHISWITCH
DFIVES'S
DOOB
TOCK
6WTCH
Df,IVEB'S
0008
swtrcH
plo'.d
l
tG tltot\t
IGY
stvrTcH
HATCH
LATCH
swlrol
\
22-152
KeylessReceiverUnit Input Test
1. Removethe driver'sdashboardlower cover (seepage 20-59).
2 . R e m o v et h e a u d i ou n i t ( s e ep a g e2 2 - 1 0 0 ) .
3. Disconnectthe 5P connector(A)from the keylessreceiverunit (B).
WHT/RED
e a kl li n gg o o dc o n t a c t .
4 . I n s p e c t t h e c o n n e c t o r a n d s o c k e t t e r m i n a l s t o b e s u r e t h e y a rm
. lf the terminalsare bent.Iooseorcorroded, repairthem as necessary,and recheckthesystem.
. lf the terminalsare OK, go to step 5.
t
(cont'd)
22-153
KeylessReceiverUnit Input Test (cont'dl
With the connectorstill disconnecled,makethe input test at the connector.
.lftestindicatesaproblem,findandcorrectthecause,thenrecheckthesystem.
. lf the inputtest provesOK, goto step 6.
Cavity
2
Wire
Test condition
BLU/ORN U n d e ra l l
conditions
Test:Desiredresult
Checkfor continuitybetween
t h e N o . 2 t e r m i n a la n dt h e
N o . 2 t e r m i n a lo f t h e
connectorK { 17P).
There should be continuitv.
An open in the wire
Reconnectthe 5P connector,and make these input tests at the connector.
.lfanytestindicalesaproblem,findandcorrectthecause,thenrecheckthesystem.
. lf all the inputtests prove OK, replacethekeylessreceiverunit.
Cavitv
1
Wire
BLK
YEL
Test condition
U n d e ra l l
conditions
lgnition switch
o N( | | )
WHT/RED U n d e a
r ll
conditions
22-154
Test:Desiredresult
There should be 1 V or less.
voltaqe.
voltaqe.
. Poor ground (G502)
. An oDenin the wire
Blown No. 10 {7.5A)fuse in lhe
An ooen in the wire
' B l o w nN o . 9 ( 1 0 A )f u s ei n t h e
Control Unit Input Test
1. Beforetesting,trou bleshootthe m u ltiplexcontroI system (seepage 22-172).
2, Removethe dashboardlower cover.
3. Disconnectthe under-dashfuse/relaybox connectors.
NOTE:All connectorsare wire side of female terminals.
FUSE/RELAY
BOX
UNDER.DASH
CONNECTOR
C {1itPl
BLU
UNDER.DASH
FUSE/RELAY
BOX
CONNECTOR
F I12P)
BOX
UNDER-OASH
FUSE/RELAY
CONNECTOR
J {8PI
BLU/RED
FUSE/RELAY
BOX
UNDER.DASH
CONNECTOR
K {17PI
BLU/ORN
UNDER.DASH
FUSE/RELAY
BOX
CONNECTOR
M Il2PI
FUSE/RELAY
BOX
UNDER.OASH
P I18PI
CONNECTOR
YEL/BLKYEL/BLK YEL YEL
UNDER.DASH
FUSE/RELAY
BOX
CONNECTOR
O (8P)
,/1,/ 3
GRN
4
5
6
UNDER-DAsH
FUsE/neLeY
sbx
X (8P)
CONNECTOR
YEL YEL/BLK
FUSE/RELAY
BOX
UNDER.DASH
Y {13P)
CONNECTOR
8
LT GRN/RED
RED/WHT
WHT/BLK YEL/RED WHT/GRN WHT/BLU
4. Inspectthe connectorand socketterminalsto be sure they are all making good contact.
. lf the terminalsare bent, loose orcorroded, repairthem as necessary,and recheckthesystem.
(cont'd)
22-155
Control Unit Input Test (cont'dl
5. Reconnect
all connections
to the underdashfuse/relay
box,and maketheseinputtestsat the appropriate
connectors
on the under-dash
fuse/relay
box.
'lfanytestindicatesaproblem,findandcorrectthecause,thenrecheckthesystem.
. lf all the inputtestsproveOK,goto step6.
Cavitv
c1'l
Wire
8LU
Test condition
Underall conditions
Test:Desiredresult
Aftachto ground:
Parking,
sidemarker,license
platelights,andtajllightsshould
comeon.
Possible
causeif resultis notobtained
B l o w nN o . 2( 1 5 A ) f u si en t h eu n d e r
hoodfuse/relaybox
Faultytaillightrelay
Faultyunder-dash
fuse/relay
box
An onen in rhc wire
BLU/BEO Underall conditions
Attachto ground:
Headlights
shouldcomeon.
WHT/RED Underall conditions
B l o w nN o .1 5o r 1 7( 1 5 A ) f u si en t h e
underhoodfuse/relay
box
Faultyheadlight
relay'1or 2
An ooen in the wire
J2
B l o w nN o . 9( 1 5 A ) f u si e
n t h eu n d e r hoodfuse/relay
box
An oncn in thc wirc
J6
BLK
Underall conditaons
Thcreshoulnhc 1 V or lpqs
OBN
Under allconditions
Attachto ground:
The horns should sound.
Under all conditions
H a t c ho p e n
H a t c hc l o s e d
Checkfor voltageto groundl
Thereshoul.lhe 5 V or more
Driver'sdooropen
C h e c kf o r v o l t a g et o
There should be 1 V
C h e c kf o r v o l t a g e t o
Thereshould be 5 V
Poorground(G501)
An ooenin the wire
BlownNo.7 (15A)fuse
in the under
hoodfuse/relay
box
Faultyhornrelay
Faultyhorns
An 6nen in rhe wire
J7
ElownNo.16(20A)fusein the under
hood fuse/relaybox
An oocn in ihc wi.c
P18
BED
Poorground(G552)
Faultyhatchlatchswitch
An oncn in rhc wirF
GBN
Driver'sdoorclosed
o4
X5
Y1
LT GRN
/RED
REDAVHT
Passenger's
dooropen
Passenger's
doorclosed
C h e c kf o r v o l t a g e t o g r o u n d l
There should be sVor more
lgnition key inserted into
the ignitionswhch
lgnitionkeyremovedfrom
rhe ionitionswitch
WHT/BLK Driver'sdoorlockknob
switchunlocked
Driver'sdoorlockknob
Y8
g.ound:
or less
ground:
or more.
YEURED Driver'sdoorlockknob
switch locked
There should be 5 V
There should be 1 V
ground:
or more.
groundl
or less.
Ihere should be 5 V
There should be 1 V
groundl
or more.
groundl
or less.
Faulty hatch latch switch
. Faultydriver'sdoorswitch
. An ooenin thewire
Faultydriver'sdoorswitch
Shortto oround
Faultypassenger's
doorswitch
An ooeninthewire
. Faultypassenger's
doorswitch
. Shortto oround
Poorground{G401)
An ooeninthewire
Shortto oround
Poorground(G50'l)
An openin thewire
Shortto oround
Poorground(G50'l)
An oncn inihewire
Driver'sdoorlockknob
switch unlocked
Y10
WHT/GRN Drtver's door lock switch
unlocked
Driver'sdoorlockswitchin
Y12
WHT/BLU Driver'sdoorlockswitch
locked
Driver'sdoorlockswitchin
There should be 5Vor more
C h e c kf o r v o l t a g e t o g r o u n d l
Therc shorl.l be 5V or m6rp
'l
There should be V or less.
C h e c kt o r v o l t a g e t o g r o u n d :
There should be 5Vor more
' Faultydriver'sdoorlockknobsw;tch
. Shorrto oround
Poorground(G501i
Faultydriver'sdoorlockswitch
An ooenin the wire
Short to o rolrnd
Poorground(G501)
An oDenin the wire
F a u l t yd r i v e r ' s d o o r l o c k s w i t c h
J
22-156
6. Disconnect
the M, P,K andJ connectors
fromthe underdashfuse/relay
box,and maketheseinputtestsat the connectors.
.lfalltheinputtestsproveOK,themultiplexcontrolunitmustbefaulty.Replacetheunder-dashfuse/relayboxassembly.
Cavitv
K2
Wire
Test condition
BLU/ORN Underall conditions
M7
M9
YEUBLK
M6
M8
YEUBLK
P16
P17
YEL
YEUBLK
YEL
YEL
ConnectJ7 terminalto [,47
lMgl terminal,and Mg
lMTl terminaltoJ4
Test:Desiredresult
Checkfor continuitybetween
the K2terminalandthe keyless
receiver
unit5Pconnector
disconnected:
Thereshouldbe continuitv.
Checkactuatoroperation:
Thedriver'sdoorlockactuator
shouldlock lunlockl
ConnectJ7 terminalto M6
lMSl terminal,and M8
lM6l terminaltoJ4
The passenger's
doorlock
actuatorshouldlock iunlockl
Connect
J7 terminalto P17
lP16l terminal,and P16
l P 1 7 l t e r m i n a l t Jo4
The hatchlockactuatorshould
lock lunlockl
Pdsiblo c6useif resultis not obtain€d
An openin the wire
Faultydriver'sdoorlockactuator
An openin the wire
Faultypassenger's
doorlockactuator
An openin the wire
. Faultyhatchlockactuator
. An openin the wire
-
22-157
I
Keyless/Power
DoorLockSystem
Door LockActuatorTest
Driver'sdoor:
Passenger'sdoor:
1 . R e m o v et h e d r i v e r ' sd o o r p a n e l( s e e p a g e 2 0 - 4 ) .
1 . R e m o v et h e p a s s e n g e r 'dso o r p a n e l( s e e p a g e 2 0 4).
2. Disconnectthe 2P connectorfrom the actuator.
2. Disconnectthe 2P connectorfrom the actuator,
ground accordingto the table.To preventdamage
to the actuator,apply batteryvoltageonly
momenlanry.
\
Terminal
ilil;lll
LOCK
UNLOCK
'l
e
e
2
e
e
to the actuator,apply batteryvoltageonly
momenlanty.
\
Terminal
2
P."I,l.;--\
LOCK
UNLOCK
e
e
e
o
4 . lf the actuatordoes not operateas specified,
repracerr.
22-158
lf the actuatordoes not operateas specified,
reprace[,
Hatch Lock Actuator Test
1. Open the hatch.
2. Removethe hatch lower trim panel lsee page 2053).
3. Disconnectthe 2P connectorfrom the hatch lock
actualor.
Terminalside of
J
4. Checkactuatoroperationby connectingpower and
to the actuator,apply batteryvoltage only
momentaflty.
\Terminal
Po.irion\
1
@
LOCK
UNLOCK
o
22-159
Keyless/Power
DoorLockSystem
Door LockKnob Switch Test
1 . Remove
the driver'sdoorpanel(seepage20-4).
Disconnect
fromthe actuator.
the3Pconnector
Door LockSwitch Test
'1.
Removethe driver'sdoor panel (seepage 20-4).
Removethe two mounting screwsand the door
lock switch.
Tr
NO
I
. t i
I
. l
I
(
. 1
I
1
term anals.
. Thereshould be continuitywhen the door lock
knob switch is in the LOCKEDposition.
. Thereshould be no continuitywhen the door lock
knob switch is in the UNLOCKEDposition.
termtnals.
. Thereshould be continuitywhen the door lock
knob switch is in the UNLOCKEDposition.
. Thereshould be no continuitywhen the door lock
knob switch is in the LOCKEDposition.
5. lf the continuityis not as specified,replacethe door
locl(actuator.
22-160
Checkfor continuitybetweenthe terminals.
. Thereshould be continuitybetweenthe No. 1
and No. 2 terminalswhen the door lock switch is
in the LOCKEDposition.
. Thereshould be continuitybetweenthe No. 2
and No. 3 terminalswhen the door lock switch is
in the UNLOCKEDposition.
lf the continuityis not as specified.replacethe door
lock switch.
TransmitterTest
TransmitterProgramming
NOTE:
. l f t h e d o o r su n l o c k o r l o c k w i t h t h e t r a n s m i t t ebru, t
the LEDon the transmitterdoes not come on, the LED
is faulty. Replacethe transmitter,
. l f a n y d o o r i s o p e n ,y o u c a n n o t l o c k t h e d o o r w i t h t h e
transmrtter.
. lf you unlockedthe doors with the transmitter,but do
not open any of the doors within 30 seconds,the
doors relockautomatically.
. The doors do not lock or unlockwith the transmitterif
the ignition key is insertedin the ignition switch.
Storingtransmittercodes:
The codes of up to three transmitterscan be storedin
the keylessreceiverunit memory. (lf a fourth code is
stored.the code which was input first will be erased.)
NOTE:lt is importantto maintainthe time limits
betweenthe steps.Make sure the doors and the hatch
are closed.
1 . T u r nt h e i g n i t i o ns w i t c hO N ( l l i .
1. Pressthe lock or unlock buttonfive or six times to
resetthe transmitter.
. lf the lockswork, the transmitteris OK.
. lf the locksdon't work, go to step 2.
2. Open the transmitterand checkfor water damage.
. lf you find any water damage,replacethe
transmrtter.
. lf there is no waterdamage,go to step 3.
2. Within 1 to 4 sec.,push the transmitterlock or
unlockbutton with the transmitteraimed at the
receiverin the multiplexcontrol unit behindthe
d r i v e r ' ss i d eo f t h e d a s h .
3. Within 1 to 4 sec.,turn the ignition switch OFF.
4. Within 1 to 4 sec.,turn the ignition switch ON (ll).
'l
5. Within to 4 sec.,push the transmitterlock or
unlock buttonwith the transmitteraimed at the
receiverin the multiplexcontrol unit behindthe
d r i v e r ' ss i d eo f t h e d a s h .
6. Within 1 to 4 sec.,turn the ignitionswitch OFF.
3. Replacethe transmitterbattery(A)with a new one,
and try to lock and unlockthe doors with the
transmitterby pressingthe lock or unlock button
five or six times.
. lf the doors lock and unlock,the transmifteris OK.
. lf the doors don't lock and unlock,go to step 4.
7 . W i t h i n4 s e c . t, u r n t h e i g n i t i o ns w i t c hO N ( l l ) .
8. Within 1 to 4 sec.,push the transmitterlock or
unlockbuttonwith the transmifteraimed at the
receiverin the mupltiplexcontrol unit behindthe
driver's side of the dash.
9. Within 1 to 4 sec.,turn the ignition switch OFF,
'10.
W i t h i n4 s e c . t, u r n t h e i g n i t i o ns w i t c hO N ( l l ) .
1 1 . W i t h i n1 t o 4 s e c . ,p u s ht h e t r a n s m i t t elro c ko r
unlockbutton with the transmitteraimed at the
r e c e i v e irn t h e m u l t i p l e xc o n t r o lu n i t b e h i n dt h e
driver'sside of the dash.
1 2 . C o n f i r my o u c a n h e a r t h es o u n do f t h e d o o r l o c k
actuators.Within 1 to 4 sec.,push the transmitter
lock or unlockbutton again,
4 . Reprogramthe transmitter,then try to lock and
u n l o c kt h e d o o r s .
. l f t h e d o o r sl o c k a n du n l o c k . t h e t r a n s m i t t e
i srO K .
. l f t h e d o o r sd o n ' t l o c k a n du n l o c k r, e p l a c e t h e
transmitter.
13, Within 10 sec.,aim the transmitters(up to two
additionalones)whose codesyou want to store at
the receiver,and pressthe transmitterlock or
unlockbuttons.
Confirmthat you can hear the sound of the door
lock actuatorsafter eachtransmittercode is stored.
1 4 . T u r nt h e i g n i t i o ns w i t c hO F F ,a n d p u l l o u t t h e k e y .
'15.
Confirm proper operationofthe transmitter.
22-161
lmmobilizerSystem
INOICATOR
LIGHT
page 22 63
Bulb Replacement,
ECM
page 11-4
Replacement,
Substituteknown-goodfor testing,
p a g e1 1 - 5
IMMOBILIZER
CONTROLUNIT.RECEIVER
page22-165
Troubleshooting,
page22-167
Replacement,
TRANSPONDER
(8uiltintothe ignitionkey)
22-162
SystemDescription
The vehicleis equippedwith an immobilizersystemthat will disablethe vehicleunlessthe proper ignition key is used.
This system consistsof a transponderlocatedin the ignition key, an immobilizercontrol unit-receiver,an indicator
l i g h t ,a n d t h e E C M .
When the key is insertedin the ignition switch and turned to the ON {ll) position,the immobilizercontrol unit-receiver
sendspower to the transponderin the ignition key.The transponderthen sendsa coded signal backto the immobilizer
control unit-receiverwhich then sendsa coded signalto the ECI\4.
IMMOBILIZER
CONTROLUNIT.RECEIVER
KEYCYLTNDER
iEl'JUiliii'tlun"oona"|.r
lf the proper key has been used,the immobilizerindicatorlight will come on for about 2 seconds,then go off.
lf the wrong key has been used or the code was not receivedor recognizedby the unit,the indicatorlight will come
on for about 2 seconds,then it will blink until the ignition switch is turned OFF.
lf the ignition switch is turned OFF,the indicatorwill blinkfor about 5 secondsto signalthat the unit has reset
correctly,then the indicatorwill go off.
lf the customerhas lost his key,and cannot startthe engine,contactHondaCustomerRelations.
IMMOBILIZER
INDICATOR
LIGHTBLINKING
PATTERN:
IGNITIONSWITCH
ON
OFF
PROPER
KEY
INSERTED
INDICATOR
LIGHT
WRONGKEY
INSERTED
INDICATOR ON
LIGHT
ON
OFF
(| i.,
)
22-163
lmmobilizerSystem
CircuitDiagram
'
UNDTRrcODFUSE/RELAY
8OX
t
J
t
I
\
J
No20(LAl r USA
rGNtTt0i/
swlrcH
lct HoTin0N{ll)
.ndSIAnTl|l)
F G N
8ELAY1
YEUBIJ(
0R8
itAWStY
tct
tGPl
tGPz
EC
LGI
22-164
LG2
LG3
|M0CD
. PA8(II'IG
DATA
LIN(
SMIG
CONNECIOR SWITCH
.8nA{E
{0Lcl
FTUID
I!VEL
SWTfi
)
Troubleshooting
Beforetroubleshootingthe immobilizersystem,
troubleshootany EClvlDiagnosticTroubleCodes(DTCS)
( s e ep a g e1 1 - 3 )a, n d m a k es u r et h e E C Mh a s n o
malfunction.
5. Disconnectthe 7P connector(A)from the
i m m o b i l i z ecr o n t r o lu n i t - r e c e i v e( B
r ),
Note these items beforetroubleshooting:
. Due to the actionof the immobilizersystem,the
enginetakesslightly more time to startthan on a
vehiclewithout an immobilizersystem.
. When the system is normal,and the proper key is
inserted,the indicatorlight comes on for 2 seconds,
then it will go off.
. If the indicatorstartstoblink after 2 seconds,or if the
enginedoes not start.removeany other immobilizer
keysor large key fobs on the key ring,then repeatthe
startingprocedure.
lf the engine still does not start,continuewith this
procedure.
Checkfor voltage betweenthe immobilizercontrol
unit-receiver7P connectorNo. 7 terminal and body
ground.
1. Turn the ignitionswitch ON {ll) with proper key.
I
2. Checkto see if the immobilizerindicatorlight
c o m e so n .
YES-Go to step 7.
Does the indicator light blink?
NO Checkfor these problems;
YES Disconnectthe 7P connectorfrom the
immobilizercontrol unit-receiver,then go to step 9.
. B l o w nN o . 9 { 1 0 A ) f u s ei n t h e u n d e r - h o o fdu s e /
relay box.l
. An open in the WHT/REDwire.l
NO Checkfor these problems,then go to step 3.
. Blown No. 9 (10A)fusein the under-hood
fuse/relaybox.I
. An open in the wire betweenthe gaugeassembly
a n d t h e i m m o b i l i z ecr o n t r o lu n i t - r e c e i v e r . l
. A f a u l t yi m m o b i l i z eirn d i c a t o lri g h t , I
. An open in the wire betweenthe gauge assembly
and the under-hoodfuse/relaybox.l
1 . Checkfor voltage betweenthe immobilizercontrol
ground with the ignition switch ON {ll).
YES- Go to step 8.
NO Checkfor these problems:
Removethe driver'sdashboardlower cover (see
page 20-59).
Removethe steeringcolumn lower cover (seepage
11-9).
. B l o w nN o . 6 ( 1 5 A ) f u s ei n t h e u n d e r - h o o d
fuse/relaybox,I
. F a u l t yP G M - Fm
l a i n r e l a y1 , t
. A n o p e ni n t h e Y E U B L Kw i r e . l
l
(cont'd)
22-165
lmmobilizerSystem
Troubleshooting(cont'dl
8. Checkfor voltage betvveenthe immobilizercontrol
unit-receiver7P connectorNo. 6 terminal and No. 1
rermlnat.
Checkfor continuitybetweenthe immobilizer
control unit-receiver7P connectorNo. 2 terminal
a n d E C Mt e r m i n a lE 2 7 .
YES Go to step 12.
Y E S - G o t o s t e p1 3 .
NO Checkfor these problems,
wire.I
N O - R e p a i tr h e o p e ni n t h e R E D / B L U
. Open on the BRNI/ELwire.l
. F a u l t yE C M . I
9. Removethe driver's dashboardlower cover (see
page20-59).
10. Removethe steeringcolumn lower cover (seepage
17-9).
1 3 .Reconnectthe 7P connectorto the immobilizer
control unit-receiver.
1 4 . Checkfor voltage betweenthe immobilizercontrol
ground with the parkingbrakelever pulled,then
released.
ls there 1 V or less,then 5 V or more?
11. Disconnectthe 7P connector(A) from the
immobilizercontrol unit-receiver(B).
YES Replacethe immobilizercontrol unit-receiver.
After replacingthe immobillzercontrol unitreceiver,rewritethe unit with a HondaPGM
Tester.l
NO Checkfor these problems:
{
. Faultyparkingbrakeswitch or a poor body
ground of the parkingbrakeswitch.l
. R e p a i rs h o r to r o p e ni n t h e G R N / O R N
w i r e .I
-
22-166
t
lmmobilizerControl Unit-ReceiverReplacement
'L
Removethe driver'sdashboardlower cover (see
page20-59).
2 . Removethe steeringcolumn covers(seepage 17-
3 . Disconnectthe 7P connector(A)from the
immobilizercontrol unit-receiver(B).
I
Removethe two screwsand the immobilizer
control unit-receiverfrom the ignition key cylinder
J
(c).
5 . Installthe immobilizercontrol unit-receiverin the
reverseorder of removal.
6 . After replacement,rewritethe unit with a Honda
PGM Tester,then checkthe immobilizersystem.
22-167
MultiplexControlSystem
lr,
J
REARCEILINGLIGHT
Test,page22'96
LIGHT/SPOTLIGHTS
Test,page22-96
ASSEMBLY
GAUGE
IGNITIONKEYLIGHT
Test,page22'91
ECM
MULTIPLEXCONTROLUNIT
{Builtinto the under-dash
fus6/relav boxl
Troubleshooting,page22'172
t
22-168
I
CircuitDiagram
UiIDM HOOD
IUSE/NEUY
BOX
'
I'10.20
:usA
{a0AJ
UNDEf,
DASH
ib.a)l50A):C.nd.
FUSE/NEUYBOX
IGNITiON
SWITCH
--_to
/ BAI \
oJ\
tcl ./
BLI,'YEL
J
MULTIPLEX
c0NT80r
tNsPECTror!
CONNECIOF
HAICII
LATCH
SWITCH
G201
{cont'd)
22-169
MultiplexControlSystem
CircuitDiagram(cont'd)
J
l'1o.3
tUSt
l7.5AJ
lln$.uidt hoodr
itutefd4bor I
V
I
wHTPLU
l0
t--t---
lrfl |
lE
lnv*| > | ucHT
lt A
l'*'
Y l
I'
CIILINGLIGHT
I.l|MOBItEER
@NTIOL
UIIIT
RECEIVEE
VI
I
J
{
22-170
I
SystemDescriptions
The MultiplexControlSystem hasfour internal
functions:
. Multiplexing
( s e n dm u l t i p l es i g n a l so v e rs h a r e d
wtres)
. Wake up/sleep(runsat full power only on demandto
reducebatterydraw)
. Fail-safe(fixesor ignoresfaulty signals)
. Self-diagnosis(Mode 1 for the system,Mode 2 for
i n p u tl i n e s )
The systemcontrolsthe functionof these circuits:
. E n t r yl i g h t c o n t r o(l i g n i t i o nk e y l i g h t a n d c e i t i n gl i g h t )
. Wiper/washerintermittentwipe and park functions
. Keyless/powerdoor lock
. Meter assembly,temperaturegauge,and indicator
lights
. HVAC(compressorand fan control)
. K e y - i nr e m i n d e r
. H e a d l i g hrte m i n d e r
. Seatbeltreminder
I
J
MultiplexCommunication
To reducethe number of wire harnesses,digital signals
a r e s e n tv i a s h a r e dm u l t i p l e xc o m m u n i c a t i o lni n e s
r a t h e rt h a n s e n d i n gn o r m a le l e c t r i c asl i g n a l st h r o u g h
i n d i v i d u awl i r e s .
. The input signalsfrom each switch are convertedto
digital signalsat the centralprocessingunit (CpU).
. T h e d i g i t a ls i g n a l s a r e s e n t f r o m t h e t r a n s m i t t i nu gn i t
t o t h e r e c e i v i n gu n i t a s s e r i a ls i g n a l s .
. The transmittedsignalis convertedto a switch signal
at the receivingunit, and it operatesthe related
componentor monitors a swltch.
. There are exclusivecommunicalionlines between
the ECM,the gauge assembly,and the under,dash
fuse/relaybox.
Wake-upand Sleep
The multiplexcontrol system has "wake-up" and
"sleep" functions
to decreaseparasiticdraw on the
batterywhen the ignitionswitch is OFF.
. ln the sleep mode,the multiplexcontrol unit stops
functioning(communicationand CPUcontrol)when it
is not necessaryfor the systemto operate.
. As soon as any operationis requested(for example,a
door is unlocked),the relatedcontrol unit in the sleep
mode immediatelywakes up and beginsto function.
. When the ignition switch is turned OFF,and the
driver'sor front passenger'sdoor is opened,then
closed,there is about a 10 seconddelay beforethe
control unit goes from the wake-upmode to the sleep
mode.
. lf any door is open,the sleep mode will not function.
. l f a k e y i s i n t h e i g n i t i o ns w i t c h ,t h e s l e e pm o d ew i l l
not function.
. When in sleep mode,the draw is reducedfrom
70 80 mA to lessthan 10 mA.
Fail-safe
To preventimproper operation,the multiplexcontrol
system has a fail-safefunction.In the

02-03 Honda Civic Si Service Manual

Transcription

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