Honda S2000 (00-03) Service Manual

INTRODUCTION
Al l i nl ormat i on cont ai ned i n t hi s manual i s based on t he l at est

product i nf ormat i on avai l abl e at t he t i me of pri nt i ng. We reserve
t he ri ght t o make changes at any t i me wi t hout not i ce. No pan of
t hi s publ i cat i on may be reproduced, or st ored i n a ret ri eval
syst em, or t ransmi t t ed, i n any t orm by any means, el ect roni c,
mechani cal , phot ocopyi ng, recordi ng, or ot herwase, wi t hout t he
pri or wri t t en permi ssi on of t he publ i sher. Thi s i ncl udes t ext ,
f i gures, and t abl es.
As
vou
read t hi s manual .
you
wi l l f i nd i nf ormat i on t hat i s
preceded by a
FOTileEl
symbol. The purpose of this message is
t o hel p prevent damage t o your vehi cl e, ot her propert y, or t he
envi ronment .
*Transaxl e
H
*Body z-lQ!
^ l l / -
Fi rst Edi t i on 09/ 2002 1, 104pages HONDA MOTOR CO. , LTD.
All Rights Reserved Service Publication Office
Speci f i cat i ons appl y t o U. S. A. end Canada
A3 sclions with
*includ6
SRS componnts;
speciel precaulioos ere required when servicing.
r ef dl
How to Use Thi s Manual -
Thi s manual i s di vi ded i nt o 23 sect i ons. The f i rst page of each
sect i on i s marked wi t h a bl ack t ab t hat l i nes up wi t h i t s
correspondi ng t humb i ndex t ab on t hi s page and t he back cover.
You can qui ckl y f i nd t he f i rst page of each sect i on wi t hout
l ooki ng t hrough a f ul l t abl e of cont ent s. The symbol s pri nt ed at
t he t op corner ot each page can al so be used as a qui ck
reference.
Each sect i on i ncl udes:
1. At abl e of cont ent s, or an expl oded vi ew i ndex showi ng:
.
Part s di sassembl y sequence.
.
Bol t t orques and t hread si zes.
.
Page ref erences t o descri pt i ons i n t ext .
Di sassembl y/ assembl y procedures and t ool s.
I nspecl ron,
Test i ng/ t roubl eshoot i ng.
Repai r.
Adj ust ment s.
2.
3.
4.
5.
6.
Safety Messages-
Your saf et y, and t he saf et y of ot hers, i s very i mport ant . To hel p
you make inlormed decisions we have provided safety
messages and ot her sal et y i nf ormat i on t hroughout t hi s manual .
Of course. i t i s not pract i cal or possi bl e t o warn you about al l t he
hazards associ at ed wi t h servi ci ng t hi s vehi cl e. You must use
your own good
l udgment .
You wi l l f i nd i mponant saf et y i nf ormat i on i n a vari et y ot I orms
i ncl udi ng:
.
Satety Labels
-
on the vehicle.
.
Safety Messages
-
preceded by a safety alert symbol
I
and
one of t hree si gnal words, DANGER, WARNI NG, or CAUTI ON.
These si gnal words mean:
rGrnGErir
yff
s'lt i.:,5*\:3,or
sERrouslY HURr if
EENIE y;Jf#,?3
i:'i!',"t"oJsERrouslY
HURr it
tGEllITttIl
l',i fi[ff
t,tt n
vou
don't lorrow
.
I nst rucl i ons- howt o servi cet hi s vehi cl e correct l v and saf el v.
) o
General Informati on
Chassis and Paint Codes-
2000 Model . . . . . . . . . . . . . . . . . . 1- 2
2001 Model . . . . . . . . . . . . . . . . . . 1- 3
2002 Model . . . . . . . . . . . . . . . . . . 1- 4
2003 Model . . . . . . . . . . . . . . . . . . 1- 5
l denti fi cati on Number Locati ons ........ 1-6
Warni ng/Cauti on Label Locati ons ...... 1-7
Under-hood Emi ssi on
Cont r ol Label . . . . . . . . . . . . . . . 1- 11
Li ft and Support Poi nts ........................ 1-13
Towi ng . . . . . . 1- 14
Par t sMar ki nS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 15
Servi ce Precauti on ......... 1-16
Revi sedComponent Ter ms . . . . . . . . . . . . . . . . . 1- 17
General lnformation
Chassi s and Pai nt Codes
-
2000 Model
Vehicle ldentif ication Number
JHMAP1 1 4
*
Y T OOOOO1
[[rrtl tr
c d e f g h
a, Manutacturer, Make and Type of Vehicle
JHM: HONDA MOTOR CO., LTD
HONDA Passenger vehi cl e
Line, Body and Engine Type
APl : S2000/F20C1
Body Type and Transmission Type
' l
: 2-door Converti bl e/6-speed Manual
Vehicle Grade
(Series)
4: Base Model
Check Di gi t
Model Year
Y: 2000
Factory Code
T: Tochi gi Factory i n Japan
Seri al Number
For U. S. model : 000001
c.
d.
e.
T.
(t.
h.
r Canada model : 800001
Vohicle ldentification Numbe.
and Federal Motor Vehicle
Safety Standard Certilication.
Vehicle ldentification Number
and Canadian Motor Vehicle
Saf ety Standard Cortif ication.
1-2
r 00000 r F20C1
a
a. Engi ne Type
F20C1i 2.0 A DOHC VTEC Sequenti al Mul ti port
Fuel -i nj ected engi ne
b. Seri al Number
U. S. model : 1000001
Canada model : 1100001
Engi ne Number
Transmission Number
SCYM
I
I
a
Transmission Type
SCYM: 6- speed Ma nual
Seri al Number
1000001
Paint Code
Code Col o r
NH- 547
NH- 565
NH-630t\4
R- 510
Ber l i na Bl ack
G rand Pri x Whi te
Si l verstone Metal l i c
New For mul a Red
COLOR LABEL
Chassi s and Pai nt Codes
-
2001 Model
JHMAP1 1 4
*
1 T 000001
[[ttrtt
c d e f g h
d.
Manutacturer, Make and Type of Vehicle
JHM: HONDA MOTOR CO.. LTD
AP1: S2000/F20C1
1 : 2-door Converti bl e/6-speed Manual
Vehi cl e Grade {Seri esl
4: Base Model
Check Digir
Model Year
1: 2OO1
Factorv Code
Seri al Number
For U. S. model : 000001
e.
s.
h.
For Canada model : 800001
and Federal Motor Vhicle
Saf etv Standard Certif ication.
Vehicle ldontilication Number
and Canadian Motor Vehicle
Safety Standard Certif ication.
101o(Xt1 F20C1
a
a. Engine Type
F2,C' l i 2.0 A DOHC VTEC Sequenl i al Mul ti port
b. Serial Number
U. S. model : 1010001-
Engine Number
Transmission Number
SCYM
a
Transmission Type
SCYM: 6-speed Manual
Seri al Number
1000001
Paint Code
Code Col or
B.66P
NH-547
NH-565
NH-630M
R- 510
Y.52P
Montecarl o Bl ue Pearl
(Canada
model onl y)
Ber l i na Bl ack
Grand Pri x Whi te
(U.S.
model onl y)
Si l verstone Metal l i c
New For mul a Red
SDa Yel l ow Pearl
COLOR LABEL
1-3
General lnformation
Chassis and Paint Codes
-
2002 Model
JHMAP1 1 4
*
2 T 000001
rrtti rt
c d e f g h
b.
Manutacturer, Make and Type of Vehicle
JHM: HONDA MOTOR CO.. LTD
AP1: S2000/F20C1
1 : 2-door Converti bl e/6-speed l \4anual
Vehi cl e Grade
(Seri es)
4: Base Model
Check Digit
Model Year
2: 2OO2
Factory Code
Seri al Number
U. S. model : 000001
G.
d.
e.
t.
g.
h.
Vehicle ldentification Numbet
and Fede.al Motor Vehicle
Safety Standard Certification.
and Canadi an Mot or Vehi cl e
Safety Standard Certif ication.
1-4
1020001 F20C1
a
a. Engine Type
F20C1: 2.0 0 DOHC VTEC Sequenti al Mul ti port
b. Seri al Number
U. S. model : 1020001
model : 1120001
Engine Number
Transmission Number
Paint Code
SCYM
a
Transmission Type
SCYM: 6-soeed Manual
Number
2000001
0
Code Col or
B- 513M
NH-547
N H-5s2 tvr
NH-565
R- 510
Y-52P
Nuerburgri ng Bl ue l \4etal l i c
Ber l i na Bl ack
Sebri ng Si l ver Metal l i c
Grand Pri x Whi te
New Formul a Red
l ndv Yel l ow Pear l
( U. S.
model onl v)
0
COLOR LABEL
Chassis and Paint Codes
-
2003 Model
JHMAPT 1 4
*
3 T 000001
rrtttl tr
c d e f
g h
d.
Manufacturer. Make and Type of Vehicle
JHM: HONDA MOTOR CO. , LTD
Li ne, Body and Engi ne Type
AP1: S2000/F20C1
1 : 2-door Converti bl e/6-speed Manual
Vehi cl e Grade {Seri es)
4: Base N4odel
Check Di gi t
Model Year
3: 2003
Factory Code
T: Tochi gi Fact or y i n Japan
Seri al Number
U. S. model : 000001
e.
t.
s.
h.
Vehi cl e l dent i t i cat i on Number
and Federal Mot or Vehi cl e
Saf elv Standard Certif ication.
Vehi cl e l dent i f i cat i on Number
and Canadi an Mot or Vehi cl e
SafetY Standard certitication.
1040001 F20C1
I
a
a. Engi ne Type
F20C1: 2.0 0 DOHC VTEC Sequenti al Mul ti port
b. Seri al Number
U. S. model : 1040001
SCYM
a
a. Transmission Type
SCYIVI: 6-sDeed Manual
2000001
Engine Number
Transmission Number
Paint Code
t
I
Code Col o r
B- 513M
NH- 547
NH.552M
NH-565
R- 510
Y 52P
N H-630M
Suzuka Bl ue Met al l i c 1U. S. model onl y)
Ber l i na Bl ack
Sebr i ng Si l ver Met al l i c
Grand Pri x Whi te
New For mul a Red
Spa Yel l ow Pear l
( U. S.
model onl y)
Si l ver st one Met al i c
( U. S.
model onl v)
COLOB LAAEL
1-5
General Information
ldentification Number Locations
Vehi cl e l dent i l i cat i on Numbel l Vl N)
1-6
Engi ne Numbel
Transmi ssi on Numbe.
(l ocat ed
under t ransmi ssi on)
c
Warning/Caution Label Locations
CABLE REEL CAUTION
INSTALLATION OF THE SRS CABLE REEL IS
CRITICAL TO THE PROPER OPERATION OF THE SRS SYSTEM.
REFER TO THE SERVICE MANUAL FOR DETAILEO
INSTALLATION INSTRUCTIONS.
DRIVER MODULE DANGER
EXPLOSIVE/FLAMMABLE
STORAGE TEMPERATURES MUST NOT EXCEED
2OO'F I93'CI, FOR PROPER HANDLING STORAGE
ANO DISPOSAL PROCEDURES, REFER TO SERVICE
MANUAL SRS SUPPLEMENT,
FIRST AID
IF CONTENTS ARE SWALLOWED, INDUCE
VOMITING. FOR EYE CONTACT, FLUSH EYES
WITH WATER FOR 15 MINUTES, IN EVERY CASE,
GET PROMPT MEDICAL ATTENTION.
KEEP OUT OF REACH OF CHILDREN.
THE AIRBAG INFLATOR IS EXPLOSIVE AND, IF
ACCIDENTALLY DEPLOYED, CAN SERIOUSLY
HUBT OR KI LL YOU.
.
DO NOT USE ELECTRICAL TEST EOUIPMENT
OR PROAING DEVICES. THEY CAN CAUSE
ACCI DENTAL DEPLOYMENT.
.
NO SERVICEABLE PARTS INSIDE, DO NOT
DI SASSEMBLE,
.
PLACE AIRBAG UPRIGHT WHEN REMOVED.
.
FOLLOW SERVICE MANUAL INSTRUCTIONS
CAREFULLY,
(cont' d)
1-7
General Information
: t \ \ t I r ! I a
CAUTION
TO AVOID SERIOUS INJURY:
.
FOR MAXIMUM SAFETY PROTECTION IN ALL
TYPES OF CRASHES, YOU MUST ALWAYS
WEAR YOUR SAFETY BELT.
.
DO NOT INSTALL REARWARD FACING CHILD
SEATS IN ANY FRONT PASSENGER SEAT
POStTTON.
.
DO NOT SIT OR LEAN UNNECESSARILY CLOSE
TO THE AIRBAG.
.
DO NOT PLACE ANY OBJECTS OVER THE
AIRBAG OR BETWEEN THE AIRBAG AND
YOURSELF.
.
SEE THE OWNEB' S MANUAL FOR FURTHER
INFORMATION AND EXPLANATIONS.
DEATH OR SERI OUS I NJURY CAN OCCUR.
.
CHI LDREN 12 AND UNDER CAN BE KI LLED BY
THE AI RBAG.
.
NEVER PUT A REAR-FACING CHILD SEAT IN
THE FRONT.
.
SIT AS FAR BACK AS POSSIBLE FROM THE
AI RBAG.
.
ALWAYS USE SEAT BELTS AND CHILD
RESTRAINTS.
SRS I NFORMATI ON
U. S. A. model
FRONT PASSENGER MODULE
AIRBAG WARNING
FLIP VISOR OVER.
'1
DANGER
a
Warni ng/Cauti on Label Locati ons
(cont' dl
SRS WARNI NG I NFORMATI ON
U, S, A, model
SRS I NFORMATI ON
Canada model
0
,:,.l
I
../l
. ' . ,
MONITOR NOTICE
FRONT PASSENGER AIRBAG WARNING
I CHI LO SEAT}
0
EXPLOSIVE/FLAMMABLE
STORAGE TEMPEBATURES MUST NOT EXCEED
2OO' F {93' C). FOR PROPER HANDLI NG STORAGE
AND DISPOSAL PROCEDURES REFER TO
SERVICE MANUAL SRS SUPPLEMENT.
FI RST AI O
IF CONTENTS ARE SWALLOWED, INDUCE VOMITING,
FOR EYE CONTACT, FLUSH EYES WITH WATER
FOR
, I 5
MI NUTES.
IN EVERY CASE, GET PROMPT MEDICAL ATTENTION.
KEEP OUT OF REACH OF CHI LDREN.
THE AIRBAG INFLATOR IS EXPLOSIVE AND, IF
ACCIDENTALLY DEPLOYED. CAN SERIOUSLY
HURT OR KILL YOU,
.
DO NOT USE ELECTRICAL TEST EOUIPMENT
OR PROBING DEVICES. THEY CAN CAUSE
ACCIDENTAL DEPLOYMENT.
.
NO SERVICEABLE PARTS INSIDE. DO NOT
DISASSEMBLE.
.
PLACE AIRBAG UPRIGHT WHEN REMOVED.
.
CAREFULLY.
NO SERVICEABLE PARTS INSIDE.
REFER TO SERVI CE MANUAL FOR DETAI LED
INSTRUCTIONS.
CHILDREN CAN BE KILLED OR INJURED BY THE
PASSENGER AIRBAG.
MAKE SURE ALL CHILDREN USE SEAT BELTS
OR CHILD SEATS,
SEAT BELT TENSI ONER WARNI NG
EXPLOSIVE, MATERIAL INSIDE
YOU CAN BE SERIOUSLY HURT OR BURNED.
.
DO NOT TAMPER OR DISASSEMBLE
NO SERVICEABLE PARTS INSIDE.
.
REFER TO SEBVICE MANUAL FOR
COMPLETE INSTRUCTION,
1- 8
SRS WARNI NG {HOOD)
STEERING COLUMN NOTICE
SUPPLEMENTAL RESTRAINT SYSTEM
(SRSI
THIS VEHICLE IS EOUIPPED WITH DRIVER AND
FRONT SEAT PASSENGER AIRBAGS. ALL SRS
ELECTRICAL WIRING AND CONNECTORS ARE
COLORED YELLOW. TAMPERING WITH,
DISCONNECTING, OR USING ELECTRICAL TEST
EOUIPMENT ON THE SRS WIRING CAN MAKE
THE SYSTEM INOPERATIVE OR CAUSE
ACCIOENTAL FIRING OF THE INFLATOR.
THE AIRBAG INFLATOB IS EXPLOSIVE AND,
IF ACCIDENTALLY DEPLOYED. CAN SERIOUSLY
HURT YOU,
CAREFULLY.
TO PREVENT SRS OAMAGE, REMOVE STEERING
WHEEL BEFORE REMOVING STEERING SHAFT
CONNECTING BOLT.
'r:.:l
_-
i ' . , \
.
..t
,
..t
ttt
t.
"i..'lr
(cont' d)
1-9
General Information
Warning/Caution Label Locations
(cont'd)
1- 10
a
Under-hood Emission Control Label
(2000-2002
Modelsl
Emission Group ldentilication
Exampl e:
VEHI CL E EM I SSI ON C ONTRO L ORMATI ON
OATALYST
lili;81.lll;
B o n d a Mo l o r Co . L t d .
2OVAGFFF
*#
2000 model ;
FEDERAL
THI S VEHI CLE CONFORMS TO U, S. EPA NLEV
REGULATIONS APPLICABLE TO 2OOO MODEL YEAR
NEW LEV PASSENGER CARS AND CALI FORNI A
REGULATIONS APPLICABLE TO 2OOO MODEL YEAR
NEW LEV PASSENGER CAR.
2001 model :
FEDERAL
THI S VEHI CLE CONFORMS TO U, S. EPA NLEV
REGULATIONS APPLICABLE TO 2OO1 MODEL YEAR
NEW LEV PASSENGER CAR,
CANADIAN TIER 1
THI S VEHI CLE CONFORMS TO CANADI AN TI ER 1
STANDARDS FOR 2OO1 I\4ODEL YEAR NEW
PASSENGER CARS.
2OO2 model:
FEDERAL and CANADIAN TIER 1
THI S VEHI CLE CONFORMS TO U. S. EPA NLEV
REGULATIONS APPLICABLE TO 2OO2 IVl ODEL YEAR
NEW LEV PASSENGER CARS.
Engine and Evaporative Families:
Engi ne Fami l y:
a. Model Year
Y: 2000
1: 2001
2t 2002
b. Manufacturer Subcode
HNX: HONDA
c. Fami l y Type
V: LDV
d. Di spl acement
e. Sequence Characters
Evaporative Family:
Model Year
Y: 2000
'l:
2001
2t 20Oz
Manulacturer Subcode
HNX: HONDA
Fami l y Type
R: EVAP/ORVR
Canister Work Capacity
Sequence Characters
2 HNX V 02.0 DYC
r [ t - r
t l l
a b c d e
2 HNX R O13O AAF
t r r r I
t l
a b c d e
D.
d.
1-11
General Information
Under-hood Emission Control Label
(2003
Model)
Emission Group ldentif ication
Exampl e:
m @
2003 model:
FEDERAL and CANADIAN TIER 1
THI S VEHI CLE CONFORMS TO U. S. EPA NLEV
NEW LEV PASSENGER CARS AND CALIFORNIA
REGULATIONS APPLICABLE TO 2003 MODEL YEAR
NEW LEV PASSENGER CARS.
1-12
Engine and Evaporative Families:
Engi ne Fami l y:
a. Model Year
3: 2003
b. Manufacturer Subcode
HNX: HONDA
c. Family Type
V: LDV
d. Di spl acement
e. Sequence Characters
Evaporative Family:
Model Year
3: 2003
Manutacturer Subcode
HNX: HONDA
Family Type
R: EVAP/ORVR
Canister Work Capacity
Sequence Characters
3 HNX V O2.O RJC
t r f r I
t t t
a b c d e
2 HNX B O13O AAA
Tf t r I
t t l l
a b c d e
a ,
b.
d.
e.
a
)
Lift and Support Points
l f you are
goi ng
to remove heavy components such as
suspensi on or the fuel tank from the rear of the vehi cl e,
fi rst suooort the front of the vehi cl e wi th a tal l safety
stand. When substanti al wei ght i s removed from the
rear of the vehi cl e, the center of gravi ty can change and
cause the vehi cl e to ti p forward on the hoi st,
Frame Hoist
1. Posi ti on the hoi st Ii ft bl ocks
(A),
or safetv stands,
under the vehi cl e' s front support
poi nts (B)
and rear
support
poi nts (C).
2. Rai se the hoi st a few i nches, and rock the vehi cl e
gentl y to be sure i t i s fi rml y supported.
3. Rai se the hoi st to ful l hei ght, and i nspectthe l i ft
ooi nts
(B
and C) for sol i d contact wi th the l i ft bl ocks.
Safety Stands
To support the vehi cl e on safety stands, use the same
support
poi nts (B
and C) as for a frame hoi st. Al ways
use safety stands when worki ng on or under any
vehi cl e that i s supported onl y by a
j ack.
./. ,.
Floor Jack
1. Bl ock the rear wheel s when rai si ng the front of the
vehi cl e; bl ock the front wheel s when rai si ng the
rear of the vehi cl e.
Pl ace the bl ocks behi nd and ahead of the wheel s.
2. Rai se the vehi cl e hi gh enough to i nsert the satety
stands.
3. Adj ust and
pl ace
the safety stands so the vehi cl e
wi l l be approxi matel y l evel , then l ower the vehi cl e
onto them.
Wi th rubber or shop towel .
1- 13
General lnformation
Towi ng
l f the vehi cl e needs to be towed, cal l a
professi onal
towi ng servi ce. Never tow the vehi cl e behi nd another
vehi cl e wi th
j ust
a rope or chai n. l t i s very dangerous.
Emergency Towing
Fl at-bed Equi pment- The operator l oads the vehi cl e
on the back of a truck. Thi s i s the onl v recommended
way of transporti ng the S2000.
Tie Down Bracket Hole Locations:
Front:
FRONT TIE DOWN
BRACKET HOLE
Rear;
''#:
,,
,,
-.-:..
,i
i
1-14
c
.
Thi s vehi cl e can onl y be transported on a fl at-bed.
.
Tryi ng to l i ft or tow the vehi cl e by the bumpers wi l l
cause seri ous damage. The bumpers are not
desi gned to suppon the vehi cl e' s wei ght.
Towing Hook Installation:
To avoi d damage to the car, use the towi ng hook for
strai ght, fl at ground
towi ng onl y. Do not tow at an angl e.
The towi ng hook shoul d not be used to tow the vehi cl e
onto a fl at bed. Do not use i t as a ti e down.
.
Remove the cover from the rear or front bumper.
.Instal l
the rear or front towi ng hook securel y i nto the
bol t hol e behi nd the bumper through the openi ng.
The towi ng hook i s l ocated i n the tool ki t i n the trunk.
Rear:
REAR BUMPER
OPENING
golr
xoLe
(behi nd
openi ngl
TOWING HOOK
OPENING
COVER
BOLT HOLE
(behi nd
openi ng)
)
Parts Marking
To deter vehi cl e theft, certai n maj or components are marked wi th the vehi cl e i denti fi cati on number {Vl N). Ori gi nal
parts have sel l -adhesi ve l abel s. Repl acement body
parts wi l l have sel f-adhesi ve l abel s, and the repl acement engi ne
and transmi ssi on wi l l have the VIN pl ate attached wi th a break-off bol t.
NOTE: Be careful not to damage the
parts marki ng l abel s duri ng body repai r. Mask the l abel s before repai ri ng the
part.
I
!
1 0
1- 15
General Information
Service Precaution
Adhesive Wheel Balance Weight
The wheel s of thi s model are not desi gned to mount the bal ance wei ght on the outer si de of the wheel . Instead, mount
the sel f-adhesi ve bal ance wei ght on the i nner si de of the wheel s. Note the fol l owi ng servi ce ti ps and i nstal l the
wei ghts securel y.
.
Use onl y sel f-adhesi ve wheel bal ance wei ghts to bal ance the wheel s of the car.
.
The wheel s and wei ght must be 41.F
(5"C)
or above duri ng i nstal l ati on.
.
Do not damage the wheel when removi ng the bal ance wei ght,
'
After removi ng the bal ance wei ghl , remove the adhesi ve resi due from the wheel usi ng a degreasi ng creantng agenr.
' Removedust andf or ei gnmat er i al
f r om t he sur f ace of t hewheel anddegr easet he sur f ace bef or e appl yi ng t he new
bal ance wei ght.
'
Use the IPA
(i sopropyl
al cohol ) or brake cl eaner asthe degreasi ng agent, and l etthe surl ace drythoroughl y after
degreasi ng.
'
Peel off the backi ng from the bal ance wei ght wi th care, do not touch the adhesi ve surface. Pl ace the bal ance wei ght
on the wheel l engthwi se to the wheel .
' Pr esst heent i r esur f aceof t hebal ancewei ght wi t h5t oTkgof f or cesot hebal ancewei ght ' st apeadher est ot he
wheel securel y.
.
Rock the bal ance wei ght l i ghtl y and make sure that i t i s properl y
secured to the wheel .
.
Do not pl ace
one bal ance wei ght on top of another.
'
When you cannot measure the amount of wei ght at the adhesi on posi ti on wi th the wheel ba l a nce machi ne, ta ke the
amount of unbal ance at the outer ri m and cal cul ate the amount of wei ght usi ng the conversi on factor betow.
Sel ect the bal ance wei ght that i s the cl osest to the cal cul ati on.
Conversi on factor for the adhesi on posi ti on:
Front wheel : 2.9
Rear wheel : 2. 5
Example:
l f the unbal ance at the front ri m i s 15 grams, i t i s cal cul ated as ;
1S x 2.9
=
43.5 gr.
Therefore, the unbal ance i s 43.5 grams.
t
There must be clearance.
1- 16
BALANCE WEIGHT
)
)
Revised Component Terms
Begi nni ng wi th
' 01
model s, the fol l owi ng component terms have been changed to conform wi th the standards i n SAE
document J1930. l f youf i ndat er mor abbr evi at i oni na' 01 or l at er manual t hat i s unf ami l i ar t o
you, check t hi s l i st . I f a
term i s not l i sted bel ow, i t di d not change.
' 00
and Earlier Models
'01
or Later odels
Description Honda Abbreviations Description New Abbreviations
SAE recommendation
Heated Oxygen Sensor
(for
some model s)
HO2S Ai r Fuel Rati o Sensor A,/F SENSOR
Brake Swi tch
Brake Pedal Posi ti on Swi tch BPP Swi tch
Cl utch Swi tch
Cl utch Pedal Posi ti on Swi tch
Di stri butor l oni ti on Rotor Dl Rotor Di stri butor Rotor
Functi on Sensor
Engi ne Speed Fl uctuati on
Sensor
RPM Fl uctuati on
Senso r
Evaporati ve Emi ssi on Control
Ca n i ster
EVAP Control Cani ster Evaporati ve Emi ssi on
Cani st er
EVAP Cani ster
Evaporati ve Emi ssi on Control
Cani ster Vent Shut Val ve
EVAP Control Cani ster
Vent Shut Val ve
Evaporati ve Emi ssi on
Cani ster Vent Shut Val ve
EVAP Cani ster Vent
Shut Val ve
Evaporati ve Emi ssi on Purge
Control Sol enoi d Val ve
EVAP Purge Control
Sol enoi d Val ve
Evaporati ve Emi ssi on
Cani ster Purqe Val ve
EVAP Cani ster Purge
Exhaust Gas Reci rcul ati on
Val ve Li ft Sensor
EGR Val ve Li ft Sensor Exhaust Gas Reci rcul ati on
Val ve Posi ti on Sensor
EGR Val ve Posi ti on
Senso r
EGR Control Sol enoi d
Val ve
Val ve Vacuum Control
Sol enoi d Val ve
EGR Val ve Vacuum
Vacuum Control Val ve
EGR Vacuum Control
Val ve
Val ve Vacuum Control
Sol enoi d Val ve
EGR Val ve Vacuum
Radi at or Fan Cont r ol Modul e Fan Control Modul e
Fuel Tank Evaporati ve
Emi ssi on Val ve
Fuel Tank Vapor/Li qui d
SeDarati on Val ve
ORVR Vent Shut Val ve
Fuel Tank Vapor Control
Val ve
ORVR Vapor Reci rcul ati on
Tube
Fuel Tank Vapor Reci rcul ati on
Tube
Fi rst l dl e Themo Val ve
l dl e Ai r Control Thermal
Val ve
IAC Thermal Val ve
Fuel l ni ect or l ntecror
Fuel Inj ecti on Ai r Control
Val ve
FIA Control Val ve Intake Ai r Bypass Control
Val ve
Fuel Inj ecti on Ai r Control
Sol enoi d Val ve
FIA Control Sol enoi d
Val ve
Intake Ai r Bypass Control
Themal Val ve
Intake Ai r BvDass Check Val ve IAB Check Val ve I nt ake Mani f ol d Runner
Control Vacuum Check Val ve
I MRC Vacuum Check
Val ve
l nt ake Mani f ol d Runner
Control Actuator
IMRC Actuator
I nt ake Mani f ol d Runner
Control Actuator Wi re
IMRC Actuator Wi re
Di aohr aqm
IAB Control Di aphragm I nt ake Mani f ol d Runner
Control Actuator Di aohraqm
I MRC Di aphr agm
Intake fvl ani fol d Runner
Control l vl odul e
I MRC Modul e
I
(cont' d)
1-17
General Information
Revised Component Terms
(cont'd)
' 00
and Earlier Models
'01
or Later odels
Description Honda Abbreviations Description New Abbreviations
SAE recommendation
Sol enoi d Val ve
IAB Control Sol enoi d
Val ve
Intake l \4ani fol d Runner
I MRC Sol enoi d Val ve
Intake Ai r Bypass Vacuum
Tank
IAB Vacuum Tank Intake Mani fol d Runner
Control Vacuum
I MRC Vacuum
Reservoi r
Intake Ai r Bypass Val ve Body
Assembl v
IAB Val ve Body
Assembl v
Intake Mani fol d Runner
Control Val ve
I MRC Val ve
Breather Chamber
Oi l /Ai r Separator
Fuel Pressure Regul ator
Pressure Regul ator Vacuum
Ai r Control Val ve Check Val ve Secondary Ai r Inj ecti on
Control Vacuum Check Val ve
Ai r Control Vacuum
Check Val ve
Ai r Control Val ve Vacuum
Ta nk
Secondary Ai r Inj ecti on
Control Vacuum Reservoi r
Ai r Cont r ol Vacuum
Reservoi r
Ai r Control Sol enoi d Val ve Secondary Ai r Inj ecti on
Control Vacuum Control
Sol enoi d Val ve
Ai r Control Val ve
Vacuum Control
Sol enoi d Val ve
Ai r Pump
Secondarv Ai r l ni ecti on Pumo Ai r Pump
Ai r Control Val ve Secondary Ai r Inj ecti on Pump
Control Val ve
Ai r Control Val ve
Ai r Pump El ectri c Current
Sensor
Secondary Ai r Inj ecti on Pump
El ectri c Current Sensor
Ai r Pump El ectri c
Current Sensor
Shi fVCl utch Pressure Control
Sol enoi d Val ve Set
Shi ft Sol enoi d and Automati c
Transaxl e Cl utch Pressure
Control Sol enoi d Val ve Set
SS and A/T Cl utch
Pressure Control
Shi ft Control Sol enoi d Val ve
Set
Shi ft Sol enoi d and Torque
Converter Cl utch Sol enoi d
Val ve Set
SS and TCC Sol enoi d
Val ve Set
Shi fvl ock-up Cl utch Control
Sol enoi d Val ve Assy
Shi ft Sol enoi d and Torque
Converter Cl utch Sol enoi d
Val ve
SS and TCC Sol enoi d
Val ve
Shi ft Control Sol enoi d Val ve Shi ft Sol enoi d Val ve A SS Val ve A
Shi ft Control Sol enoi d Val ve
B
Shi ft Sol enoi d Val ve B SS Val ve B
Throttl e Val ve Control
Modul e
Throttl e Actuator
Lock-up Cl utch Control
Torque Converter Cl utch
Sol enoi d and Automati c
Transaxl e Cl utch Pressure
Control Sol enoi d Val ve Set
TCC Sol enoi d and A,/T
Cl utch Pressure Control
Lock-up Cl utch Control
Sol enoi d Val ve
Torque Convener Cl utch
Sol enoi d Val ve
TCC Sol enoi d Val ve
Automati c Transaxl e Posi ti on
Swi tch
A"/T Gear Posi ti on
Switch
Transmi ssi on Range Swi tch TR Swi tch
Vari abl e Val ve Ti mi ng and
Val ve Li ft El ectroni c Control
Pressure Swi tch
VTEC Pressure Swi tch Var i abl e Val ve Ti mi ng and
Val ve Li ft El ectroni c Control
Pressure Swi tch
VTEC Oi l Pressure
Swi tch
1- 18
L
L
Specifications
I
Electrical
Item Measurement Oualification Standard or New Service Limit
l gni t i on coi l Rat ed vohag 12V
Fi ri ng order 1 3 4 2
Spark pl ug Tvpe NGK: PFRTG' 11S
DENSO: PK22PR L11S
Gap 1. 0 1. 1 mm {0. 039 0. 043 i n. ) 1. 3 mm {0. 05' l i n. )
l gni t i on t i mi ng At i dl e
( check
t he r ed mar k)
5l : 2' BTDC at 800150 rpm i n neut ral
Al t er nat or -
compr essor bel t
Tensi on adj ust ment Aut o adj ust er t ype
OLr t put At 13. 5 V and
nor mal engr ne
t emperai ure
105 A
Brush l engt h 10. 5 mm
(0. 41
i n. ) 1. 5 mm
(0. 06
i n. )
St art er Oul put
Commut at or mi ca dept h 0. 4 0. 5 mm
(0. 016
0. 020 i n. )
0. ' 15 mm
(0. 006
i n. )
Commut at or runout 0. 02 mm
( 0. 001
i n. ) max. 0. 05 mm
(0. 002
i n. )
Commut at or O. D. 28. 0 28. 1 m m
(1
. 102
-
' l
. 106 i n. l 27. 5 mm
( 1. 083
i n. )
Brush l engt h 15. 8 16. 2 mm
(0. 62
0. 64 i n. ) 11. 0 mm { 0. 43 i n. )
Brush spri ng t ensi on
(new)
15. 7 17. 7 N {' 1. 60 1. 80 k9f , 3. 53 3. 97 l bs)
Standards and Service Limits
t ,
I
En
t l
ne
Item Measurement Oualification Standard or New Service Limit
Compressi on Pressure
Checkat 250 rpm wi t h wi de open
throftle.
{See Desi gn Specs f or rat i o. )
Nomi nal 1, 570 kPa
{16. 0 kgf / cm , 228
psi )
Mi ni mum 930 kPa
(9.5
kgflcm', 135 psi)
Maxi mum 200 kPa
vari at i on
I (2. 0
ksf / cm' , 28 psi )
2-2
L (
L O
)
I
o
a
nder Head
tem Measurement Oualificetion Stand.rd or New Service Limit
Head
0. 05 mm {0. 002 i n. )
Hei ght 104. 95' 105. 05 mm
(4. 132-
4. 136 i n. )
Camshaf t End
pl av 0. 05 0. 15 mm
(0. 002
0. 006 i n. ) 0. 30 mm
(0. 012
i n. )
Camshaf t
-t o-hol der
oi l cl earance 0. 060 0. 099 mm
(0. 002
0. 004 i n. ) 0. ' 15 mm
(0. 006 i n. )
Tot al runout 0. 03 mm
(0. 001
i n. ) max. 0. 04 mm
(0. 002
i n. )
Cam l obe hei ght I nt ake, pri mary 33. 677 mm 11. 326 i n. )
I nt ake, mi d 36. 533 mm
(1. 438
i n. )
Intake, 33. 961 mm
(1. 337
i n. )
Exhaust ,
pnmary
33. 716 mm
( 1. 327
i n. )
Exhaust ,
mad
35. 928 mm
( 1. 414
i n. )
Exhaust , 33. 994 mm
(1. 338
i n. )
Cl ear ance
( col d) 0. 21
"
0. 25 mm
(0. 008
0. 010i n. )
ExhaLrst 0. 25 0. 29 mm
(0. 010
0. 011 i n. )
St em O. D. I nt ake 5. 48 5. 49 mm
(0. 2157-0. 2162 i n. ) 5. 45 mm { 0. 215
i n. )
Exhaust 5. 45 5. 46 mm
(0. 2146
0. 2150 i n. ) 5. 42 mm 10. 213 i n. )
St em t o gui de cl earance lntake 0. 02 0. 05 mm 10. 001 0. 002 i n. ) 0. 08 mm
(0. 003
i n. )
Exhaust 0. 05 0. 08 mm {0. 002-0. 003 i n. ) 0 . 1 1 mm( 0 . 0 0 4 i n . i
l nt aKe 1. 05
-
1. 35 mm 10. 041 0. 053 i n. ) 1. 80 mm
(0. 071
i n. )
(0. 049
0. 061 i n. ) 2. 00 mm
(0. 079
i n. )
st em i nst al l ed hei ght l nt aKe 44. 1 44. 4 mm
(1. 736
1. 748 i n. ) 44. 7 mm
( 1. 760
i n. )
Exhaust 44. 2 44. 5 mm \ 1. 140
1. 152i n. | 44. 8 mm
(1. 764
i n. )
Val ve spri ngs Fr ee l engt h l nt aKe 49. 77 mm
(1. 959 i n. )
Exhaust 50. 39 mm {1. 984 i n. )
Val ve gui des t.D. I nt ake 5. 510 5. 530 mm
(0. 2169
0. 2177 i n. ) 5. 55 mm
(0. 219
i n. )
Exhaust 5. 510 5. 530 mm {0. 2169 0. 2177 i n. ) 5. 55 mm
(0. 219
i n. )
I nst al l ed hei ght I nt ake 15. 2 16. 2 mm
(0. 598
0. 638 i n. )
(0. 630
0. 669 i n. )
Rocker arms Ar m t o shaf t cl ear ance l nt aKe 0. 021 0. 041 mm {0. 0008 0. 0016 i n. ) 0. 07 mm
(0. 003
i n. )
Exhaust 0. 021 0. 041 mm {0. 0008 0. 0016 i n. ) 0. 07 mm
(0. 003
i n. )
2-3
Enqi ne Bl ock
t
l-.
ne
Item Measuremont
Clualification Standard or New Service Limit
Bl ock
0. 07 mm
(0. 003
i n. )max. 0. 10 mm
( 0. 004
i n. )
Bore di amet er
87. 010 87. 020 mm
(3. 4256
3. 4260 i n. 87. 070 mm
(3. 4279
i n.
E o r l l 87. 000 87. 010 mm 13. 4252 3. 4256i n. )87. 070 mm
(3. 4279
i n.
Bore l aper
0. 05 mm
(0. 002
i n. )
Rebori ng l i mi t
0. 25 mm
(0. 01
i n. )
Pi st on Ski rt No lefter 86.993 87.006 mm {3. 4292
-
3.4254 in.t 86. 980 mm
(3. 4244
i n. l
Lener B 86. 983 86. 996 mm
(3. 4245
3. 4250 i n. ) 86. 970 mm {3. 4240 i n.
Cl ear ance i n cyl i nder
0. 004 0. 027 mm
(0. 0002
0. 0011 i n. ) 0. 04 mm
10. 002 i n. )
Bi ng gr oove wi dr h Top 1. 235 1. 265 mm
(0. 0486
0. 0498 i n. )
' 1. 285
mm (0. 0506 i n. )
Second 1. 230 1. 245 mm (0. 0484
0. 0490 i n. ) 1. 265 mm (0. 0498
i n. )
oi l 2. 005 2. 025 mm
(0. 0789
-
0. 0797 i n. ) 2. 05 mm
10. 081 i n. )
Pi st on ri ngs Ri ng- t o- gr oove cl ear ance Top 0. 045 0. 090 mm
(0. 0018
0. 0035 i n. ) 0. 135 mm (0. 005
i n. )
Second 0. 040 0. 070 mm (0. 0016
0. 0028 i n. ) 0. 13 mm
( 0. 005
i n. )
Ri ng end gap
Top 0. 25 0. 35 mm
(0. 010
0. 014 i n. ) 0. 60 mm (0. 024
i n
)
Second 0. 60 0. 75 mm
(0. 024
0. 030 i n. ) 0. 90 mm
(0. 035
i n. )
oi l 0. 20 0. 70 mm
(0. 008
0. 028 i n. ) 0. 80 mm
(0. 031
i n. )
Pi st on pi n
o.D.
22. 961 22. 965 mm {0. 9040 0. 9041 i n_ 22. 953 mm
(0. 9037
i n. )
Pi n- t o- pi st on cl ear ance
-0. 003
1 0. 0060 mm
I 0. 00012 +0. 00024 i n. )
0. 010 mm
(0. 0004
i n. )
Connecting rod Pi n l o rod cl earance
0. 018 0. 035 mm
(0. 0007
0. 0014 i n. ) 0. 04 mm
(0. 0016
i n. )
Smal l - end bor e di amet er
22. 961 22. 965 mm 10. 9040 0. 9041 i n. )
Lar ge end bor e di amet er Nomi nal 51. 0 mm
{ 2. 01 i n. )
End pl ay i nst al l ed on cr ankshaf t
0. ' 15 0. 30 mm
(0. 006
0. 012 i n. i 0. 40 mm
( 0. 016
i n. )
Cr ankshaf t Mai n
j our nal
di amet er
54. 976 55. 000 mm
(2. 1644
2. 1654 i n. )
Bod j ournal
di amet er
47. 976 48. 000 mm {1. 8888 1. 8898 i n. )
Rod/ mai n j our nal
t aper
0. 005 mm
(0. 0002
i n. ) max. 0. 006 mm
(0. 0002
i n. )
Bod/ mai n j ournal
out of round
0.004 mm 10.0002 i n.)max. 0. 006 mm
(0. 0002
i n. )
End pl ay
0. 10 0. 35 mm
( 0. 004
0. 014 i n. ) 0. 45 mm
( 0. 018
i n. )
Runout
0. 03 mm 10. 001 i n. ) max. 0. 04 mm
(0. 002
rn. )
Cr ankshaf t
beanngs
N4!'nl991l9l9j9{lal oir clearance
Rod beari ng cl earance
_0.911
0441-rlg4gg1 0,00lg1!,1
0. 030 0. 054 mm
(0. 0012
0. 0021 i n. )
0. 050 mn1(0. 0020 i nJ
0. 060 mm
(0. 0024
i n. )
t
Lubrication
Item Measuaement
Oualification Standard or New Service Limit
Engi ne oi l Capaci t y
5. 6 4
(5. 9
US qt , 4. 9 l mp qt ) f or engi ne overhaul
4. 8 0
(5. ' l
US qr, 4. 2 l mp qt )
f or oi l change, i ncl udi ng f i t t er
4-5 0
(4. 8
US qt , 4. 0 l mp qt i f or
oi l change, wi t hout f i l t er
Oi l p u mp I nner - t o- out er r ot or cl ear ance
0. 02 0. 15 mm
(0. 001
0. 006 i n. ) 0. 20 mm
{0. 008i n. )
Pump housi ng t o-out er rot or cl earance
0. 15 0. 21 mm
(0. 006
-0. 008
i n. ) 0. 23 mm {0. 009 i n. )
Pump housi ng t o out er rot or axi al
cl earance
0. 02 0. 07 mm
(0. 001
0. 003 i n. ) 0. 12 mm 10. 005 i n. )
Oi l pressure wi t h oi l t emperat ure at
176. F
{80. C)
Ar i dt e 250 kPa (2. 5
kgt cm' , 36 psi )
At 3,000 rpm 590 kPa {6. 0 kgt cm' , 85 psi )
2-4
L
)
I
Coo
Item Measurement Oualification Standard or New Servic Limit
Radi at or Cool ant capaci t y
( i ncl udes
engi ne,
heat er , hoses and r eser voi r )
Engi ne over haul 7. 6 0
( 8. 0
US qt , 6. 7l mp q0
Cool ant change 6. 5 0
( 6. 9
US
qt , 5. 7l mp ql i
Reservoi r Cool ant capaci t y 0. 6 0 { 0. 6 US qt , 0. 5 l mp q0
Radi at or cap Openi ng pressure 93- 123 kPa
(0. 95
1. 25 kgf l cm' , 14 18 psi )
Thermost at Openi ng t emPerat ure Begi ns t o open 169 r76"F
(76
80' C)
Ful l y open 194' F
(90' C)
Val ve l i f t at f ul l y open 10. 0 mm
(0. 39
i n. ) mi n-
Cool i ng f an Ther moswi t ch
"ON"
t emper at ur e 196 203. F
(91
95' C)
Ther moswi t ch
"OFF '
t emper at ur e Subt ract 5 15' F
(3
8' Ci f rom act ual
"ON"
t emperat u re
Fuel and Emi ssi ons
Item Measurement Oualitication Standard or New Service Limit
r equl at or
Pressure with regulator
vacuum hose di sconnect ed
320 370 kPa r 3. 3 3. 8 Lgf . cm' , 47 b4 psi l
Fuel t ank Capacity 50 0
( ' 13. 2
US
qal ,
11. 0 l mp qal )
Engi ne i dl e l dl e speed wi t h headl i ght s
and r adi at or f an of f
I n Neut ral 800150 rpm
l dl eCO % 0. 1 max.
Glutch
hem Measuroment Oualilication Standard or New Service Limit
Cl ut ch pedal Hei ght Fr om t he f l oor 189 mm
(7. 44
i n. )
St roke 115 125 mm
( 4. 53 4. 92 i n. )
Pl ay 9
- ' 17
mm
( 0. 4
0. 7i n. )
Runout on cl ut ch mat i ng surf ace 0. 05 mm
(0. 002 i n. )max. 0. 15 mm
(0. 006
i n. )
Cl ut ch di sc Ri vet head dept h 1. 2 1. 7 mm
(0. 047
0. 067 i n. ) 0. 2 rnm {0. 008 i n. )
Ri vet head t hi ckness 8. 2 8. 9 mm
(0. 32
0. 35 i n. ) 6. 0 mm
(0. 241
, n. )
0. 03 mm {0. 001 i n. }max. 0. 15 mm
(0. 006
i n. )
Hei ght of di aphr agm spr i ng f i nger s
{ eel er gauge and
speci al t ool
0. 4 mm
(0. 016
i n. ) max. 0. 6 mm
(0. 024
i n. )
2-5
Manual Transmission
hem Measurement Oualitidtion Standard or New Service Limit
Transmi ssi on
f l ui d
Capaci t y At f l ui d chanqe 1. 48 0
( 1. 56
US
qt . , 1. 30l mp qt )
At overhaul 1. 62 0 { 1. 71 US qr . , 1. 43 l mp qt )
Mai nshat t End pl ay 0. 14 0. 2' l mm {0. 006 0. 008 i n. ) Adjust
Di amet er of t ransmi ssi on housi ng bal l
beaf l nq cont act area
27. 987 28. 000 mm
( 1. 1018
1. 1024 i n. )
27. 94 mm
( 1. 100
i n. )
Diameter of 4th/5th gears contact area 34. 987 35. 000 mm
(1. 3774
1. 3180 i n. )
34. 94 mm 11. 376 i n. )
Diameter o{ 6th gear contact area 38.984 39.000 mm
(1. 5348
1. 5354 i n. )
38. 94 mm
(1. 533
i n. )
Diameter of clutch housing bali
bear| n0 cont act area
28. 002 28. 015 mm
( 1. 1024
1. 1030 i n. )
27. 95 mm 11. 100 i n. )
Runout 0. 02 mm
( 0. 001i n. ) max.
0. 05 mm
(0. 002
i n. )
Mai nshaf t 3rd
gear
t.D. 40. 009 40. 025 mm
11. 5752 1. 5758 i n. )
Thi ckness 35. 09 35. 17 mm
(1. 381
1. 385 i n. ) 34. 97 mm
( 1. 377
i n. )
End pl ay 0. 06 0. 19 mm {0. 002 0. 007 i n. ) 0. 3 mm
(0. 012
i n. )
Mai nshaf t 3rd
gear drst ance
co ar
t.D. 28.002 28.012 mm
( 1. 1024
1. 1028 i n. )
o.D. 34. 989 35. 000 mm
(1. 3775
1. 3780 i n. )
Length 35. 23 35. 28 mm 11. 387 1. 389 i n. )
Mainshaft 4th
and 5t h gear s
LD. 47. 009 47. 025 mm
( 1. 8507
1. 8514 i n. )
(1. 256
1. 259 i n. ) 31. 77 mm
( 1. 251
i n. )
End pl ay
0. 06 0. 19 mm
(0. 002
0. 007 i n. ) 0. 3 mm
( 0. 012
i n. )
Mai nshaf t 4t h
and 5t h gears
di st ance col l ar
t.D. 35. 002 35. 012 mm
11. 3780 1. 3784 i n. )
o.D. 41. 989 42. 000 mm
(1. 6531
1. 6535 i n. )
Lengt h 32. 03 32. 08 mm {1. 261 1. 263 i n-)
Mai nshaf t 6t h
gear
LD. 44. 009 44. 025 mm
(1. 7326
1. 7333 i n. )
( 1. 137
1. 141 i n. ) 28. 77 mm
(' l . 133
i n)
End pl ay
0. 06 0. ' 19 mm
(0. 002
0. 007 i n. ) 0. 3 mm
(0. 012
i n)
Count ershaf t Di amet er of r ear si de cover needl e
oear t ng cont act ar ea
30. 020 30. 029 mm
( 1. 1819
1. 1822 i n. )
29. 97 mm 11. 180 i n. )
Di amet er of t r ensmi ssi on housi ng si de
needl e bear i ng cont act ar ea
34. 002 34. 018 mm
(1. 3387
1. 3393 i n. )
33. 95 mm {1. 337 i n. )
Di amet er of 2nd oear cont act ar ea 43.984 44.000 mm
{ 1. 7317 1. 7323 i n. }
43-93 mm
(1. 730
i n. )
Di amet er oI cl ut ch housi ng si de bal l
beari ng connt act area
28. 002 28. 015 mm
( 1. 1024
1. 1030 i n. )
27. 95 mm
( 1. 100
i n. )
Runout 0. 02 mm 10. 001 i n. ) max. 0. 05 mm {0. 002 i n. )
Count ershaf t 1st
gear
LD. 57. 010 57. 029 mm
12. 24t 5 2. 2452i n. 1
( 1. 228
1. 231 i n. ) 31. 06 mm { 1. 223 i n. )
End pl ay
0. 04 0. 22 mm {0. 002 0. 009 i n. ) 0. 3 mm
( 0. 012
4n. )
Count ershaf t 1st
gear orsl ance
col l ar
o. D. 50. 987 51. 000 mm
(2. 007a
2. 0079 i n. )
Length 28. 03 28. 08 mm
( 1. 104
1. 106 i n. )
Count ershaf t 2nd
gear
r.D. 43.984 44.000 mm
\ 1. 1311 1. 1323 i n. l
Thrckness 32. 88 32. 96 mm {1. 294 1. 298 i n. ) 32. 76 mm
( 1. 290
i n. )
End pl ay
0. 04 0. 17 mm
(0. 002
0. 007 i n. ) 0. 3 mm
( 0
012 i n. )
)
I
L .
a
a
item Measuremenl Oualification Standard or New Service Limit
Countershaft
reverse gear
LD. 50.009 50.025 mm
{1. 9689 1. 969s i n. )
(1. 039
1. 042 i n. ) 26. 26 mm 11. 034 i n. i
End pl ay 0. 04- 0. 22 mm {0. 002 0. 009 i n. ) 0. 3 mm
(0. 012
i n. )
Countershaft
reverse gear
di st ance col l ar
o.D. 37. 989 38. 000 mm
11. 4956 1. 4961 i n. )
Lengt h 25. 53 25. 58 mm {1. 005 1. 007 i n. )
Secondar y shaf t Daamet er of bal l beari ng cont act area 31. 002 31- 013 mm
\ 1. 2205
1. 22t 0 i n. l
30. 95 mm
( 1. 219
i n. )
Di amet er of pr opel l er shaf t si de
t aper ed r ol l er bear i ng cont act ar ea
41. 002 41. 018 mm
11. 6142 1. 6149 i n. )
40. 95 mm
( 1. 612
i n. )
Di amet er of t ransmi ssi on housi ng si de
t apered rol l er beari ng cont act area
35. 009 35. 025 mm
( 1. 3783 1. 3790 i n. )
34. 96 mm
(1. 376 i n. )
Runout 0. 02 mm
(0. 001
i n. ) max. 0. 05 mm {0. 002 i n. )
St art i ng t orque
(prel oad) 1. 86 2. 84 N m
(19. 0
29. 0 kgf . cm, 16. 5 25. 2l bf i n)
Adj ust
Shift fork Fi nger t hi ckness 1 2 shift tork 7. 4 7. 6 mm
(0. 29
0. 30 i n. )
3 4 shift fork 6. 2 6. 4 mm
(0. 24
0. 25 i n. )
5 6 shift fork 6. 2 6. 4 mm
(0. 24
0. 25 i n. )
Reverse shift fork 6. 2 6. 4 mm
(0. 24
0. 25 i n. )
F9'k-!9'"1!9!Pl!99v9ll!!I9t!9
Gr oove To l 2 s h i f t l e v e r
0. 35 0. 65 mm {0. 014 0. 026 i n. )
17. 2
-
17. 4 mm {0. 677 0. 685 i n. )
1,0! rn rnl!.0991!.1
17. 1 mm {0. 673 i n. )
To shi f t arm A 17. 2 17. 4 mm 10. 677 0. 685 i n. ) 17. 1 mm {0. 673 i n. )
Shi t t arm A t.D. 16. 000 16. 027 mm
(0. 6299
0. 6310 i n. )
Fi nger wi dt h 16. 8 17. 0 mm
(0. 661
0. 669 i n. ) 16. 7 mm {0. 657 i n. i
Shi f t arm A t o shi f t f orks 0. 2 0. 6 mm
(0. 008
0. 024 i n. ) 0. 7 mm
(0. 028
i n. )
1' 2 shi f t l ever Fi noer wi dt h 17. 0 17. 2 mm
( 0. 669
0 677 i n. ) 16. 9 mm {0. 665 i n. )
Leverto-shift forks and pieces 0 0. 4 mm
(0
0. 016 i n. ) 0. 5 mm
(0. 020
i n. )
1' 2 shi f t
pi ece
Gr oove To shi f t arm A 17. 2 17. 4 mm
( 0. 677
0. 685 i n. i 17. 1 mm {0. 673 i n. i
3 4 shi f t
pi ece
Gr oove To shift arm A 17. 2 17. 4 mm
(0. 677
0. 685 i n. )
' 17. 1
mm
(0. 673
i n. )
Reverse shift
pi ece
Gr oove To 1-2 shi f t arm A 17. 2 17. 4 mm
(0. 677
0. 685 i n. ) 17. 1 mm {0. 673 i n. )
To shi f t arm A 17. 2 17. 4 mm
(0. 677
0. 685 i n. ) 17. 1 mm {0. 673 i n. )
Synchro ri ng Ri ng-t o-gear cl earance
(ri ng pushed agai nst gea. )
srh and 6rh gears 0. 75 1. 00 mm
(0. 030
0. 039 i n. ) 0. 4 mm
( 0. 016
i n. )
Reverse
gear 0. 85 1 10 mm 10. 033 0. 043 i n. i 0. 4 mm
(0. 016
i n. )
Doubl e cone Out er syncro ri ng t o synchro cone
cl earance
(ri ng pushed agai nst gear)
1st and 2nd gears 0. 70 1. 09 mm
(0. 028
0. 043 i n. ) 0. 3 mm
(0. 012
i n. )
3r d and 4t h gear s 0. 90 1. 39 mm
(0. 035
-0. 055
i n. ) 0. 3 mm
(0. 012
i n. )
Synchr o cone t o- gear cl ear ance
( r i ng
pushed agai nst gear )
1st , 3r d and 4t h
qear s
0. 50 1. 04 mm
(0. 020
0. 041 i n. ) 0. 3 mm
( 0
012 i n. )
2nd gear 0. 65
' 1. 78
mm
(0. 026
0. 070 i n. ) 0. 3 mm
(0. 012
i n. )
Out er synchro ri ng-t o-gear cl earance
(ri ng pushed agai nst gear)
1st , 3rd and 4t h
gears
0. 95 1. 68 mm
(0. 037
0. 066 i n. i 0. 6 mm {0. 024 i n. )
2nd gear 0. 70 1. 82 mm
(0. 028
0. 072 i n. ) 0. 6 mm
(0. 024
i n. )
Oi l pump l nner rot or-t o-out er rot or radi al 1. 14 mm
(0. 006
i n. ) max. 0. 20 mm 10. 008 i n. i
Rot or t o-t ransmi ssi on housi ng Radi al cl ear ance 0. 1 0. 2 mm
(0. 004
0. 008 i n. ) 0. 22 mm 10. 009 i n. )
0. 03 0. 07 mm
(0. 00' l
0. 003; n. ) Adj ust
2-7
itom Measurement Oualification Slenderd or New Service Limit
Di f f er ent aal oi l Capacity At oi l chanoe 0. 74 0
( 0. 78
US
qt . , 0. 65l mp qt )
0. 77 4
(0. 81
US qt . , 0. 68l mp qt )
Dri ve pi ni on
St art i ng t orque
(prel oad)
(Add
addi t i onal val ue t o act ual st art i ng
t orque measurement )
Addi t i onal val ue0. 88 1. 37 N m
(9. 0
14. 0 kgf . cm, 7. 81 12. 2 l bf i ni
Adiust
Ri ng gear
Backl ash t o dr i ve pi ni on
0. 09 0. 11 mm
(0. 0035
0. 0043i n) Adj ust
Di f f erent i al Tot al st art i ng t orque measured wi t h
push/ pul l cauqe
1 4 3 0 N
l t . 4 3. t kaf , 1. 2 2. 1l bf )
Adj ust
Differential
t l
L (
Rot at i onal ol av m6asured at out si de 0 10 mm {0 0. 39 i n. )
St ani ng l oad measur ed at out si de 34 N
( 3. 5
kgf , 7. 7 l bf )
Angl e of rack gui de
screw l oosened
Item Meas||rem6nt Oualification Standard or New Servace Limit
Wheel al i gnment Camber Fr ont at
l nspect | on
0' 30' +30'
Front at
adl ust ment
0' 30' a 10'
Rear at 1' 30' +30'
Rear at 1"30' + 1o'
Caster Ff ont at
I nspect r on
6"OO' ! 45'
Rear at
adl ust ment
6' 00' + 15
Tot al Toe Front 0+2 mm
( 0+
1/ 16 i n. )
Rear l N 642
( 1/ 4t
1/ 16 i n. )
Front wheel t urni ng angl e I nsi de wheel 34' 00' a 2'
Out si de wheel 29"00' { Ref er ence)
Runout Axi al 0 0. 7 mm
(0
0. 03 i n. ) 2. 0 mm
(0. 08
i n. )
Radi al 0 0. 7 mm { 0 0. 03 i n. ) 1. 5 mm ( 0. 06 i n. )
Whoel beari ngs End pl ay
Front 0 0. 05 mm (0
0. 002 i n. )
Rear 0 0. 05 mm
(0
-
0. 002 i n. )
2-8
L (
L
L
I
Brakes
llem Measurement Ouelificetion Standard or New Service Limit
Parki ng brake
l ever
Distance traveled whn
pul l ed wi t h 196 N
(20
kgf , 44 l bf l oI
g
13 cl i cks shoul d l ock t he br aks
Brake pedal Pedal hei ght
(carpet removed) 179 mm { 7 1/ 16 i n. )
Free pl ay 1 5 mm
( 1/ 16- 3/ 16
i n. )
Mast er cyl i nder Pi st on t o pushr od cl ear ance 0-0. 4 mm l 0 0. 02 i n. )
Brake di sc Thi ckness Front 24. 9-25. 1 mm
{0. 98 0. 99 i n. }
23. 0 mm
(0. 91
i n. )
Rear 11. 9- 12. 1 mm
10. 469 0. 476 i n. i
10. 0 mm
(0. 39
i n. )
Runout Front 0. 10 mm
(0. 004
i n. )
Bear 0. 10 mm {0. 004 i n. )
Paral l el i sm Front and rear 0. 015 mm
(0. 0006
i n. )
Erake pads Thi ckness Front 9. 5- 10. 5 mm
(0. 37-0. 41
i n. )
1. 6 mm
(0. 06
i n. )
Rear 8. 9 9. 1 mm
(0. 35-0. 36
i n. )
1. 6 mm
(0. 06
4n. )
Air Conditi
o
a
on
Item Measurement Ouelification Slandsrd or Nw I Servic Limit
Ref ri gerant Type HFC' 134a {R' 134a)
Capacity of system 600 650
s
(21
23 oz)
Ref r i ger ant oi l Tvpe SP-10
(P/ N
38897-P13' A01AH or 38899-P13-A01)
Capaci t y of component s Condenser 25 m4
(5/ 6l l
o2, 0. 9l mp o. )
Evaporat or 40 m4 i 1 1/ 3 f l o?, 1. 4 l mp oz)
Each l i ne and
hose
10 mq
( 1/ 3
t l o2, 0. 4l mp oz)
Recei ver 10 m0 { 1/ 3 f l o2, 0. 4l mp ozi
Compressor 130 150 m0
(4. 4-5. 1
f l oz, 4. 6 5. 3 l mp ou )
Compressor Fi el d coi l r esi st ance Ar 68"F
(20"C)
3. 05- 3. 35 Q
Pul l ev- t o- pr essLt r e
pl at e
cl ear ance 0. 5a0. 15 mm {0. 02t 0. 005 i n. )
2-9
Item Ma3uremeift Ouelilicetion Specificstion
OI MENSI ONS Over al l l engt h 4, 120 mm
( 162. 2
i n. )
Over al l wi dt h
' 1, 750
mm
(68. 9
i n. )
Ov or al l hei ght 1, 285 mm {50. 6 i n. )
2, 400 mm (94. 5
i n. )
Track Front 1, 470 mm
(57. 9
i n. )
Rear 1, 510 mm
(59. 5
4n. )
Gr ound cl ear ance 130 mm {5. 1 i n. )
Seat i ng capaci t y
WEI GHT
(U. S. A. }
Gross Vhi cl e Wei ght Rat i ng
(GVWB)
3, 385 rbs
WEIGHT
(CANADA)
Gross Vehi cl e Wei ght Rat i ng
(GVWR)
1, 535 kg
E NGINE Tvpe Water-cooled, 4-stroke DOHC VTEC gasoline
engine
Cyl i nder arrangement I nl i ne 4- cyl i nder , l ongi t udi nal
Bore and st roke 87. 0 x 84. 0 mm {3. 43 x 3. 31 i n. )
Di spl acement 1, 997 c mr
( m0) ( 121. 9
c u i n. )
Comprsssi on rat i o 1 1 . 0
Chai n dri ven, DOHC VTEC 4 val ves
percvl i nder
Lubrication system Forced, wet sump, wi t h t rochoi d pump
Oi l pump di spl acement At 6, 000 enqi ne rpm 58. 4 4
(61. 7
US qt , 51. 4 l mp qt )/ mi nut e
Wat er pump
di spl acement At 6, 000 engi ne rpm 172 0
(182
US
qt , 151 l mp qt )/ mi nut e
Fuel requi red Premi um UNLEADED gasol i ne wi t h 91 Pump Oct ane
Number or hi gher
STARTER Tvpe
Gear r edLr ct i on
Normal out put 1.0 kw
Nomi nal vol t age 12V
Hour rat i ng 30 seconds
Direction ol rotation Clockwise as viewed from oear end
CLUTCH Cl ut ch Si ngl e pl at e dry, di aphram spri ng
Cl ut ch f ri ct i on mat eri al surf ace 188 cm:
(29
sq-i n. )
MANUAL
TRANSMI SSI ON
Tvpe Synchronized 6-speed forward, 1 reverse
Pri mary reduct i on Di r ect 1r 1
Gear rat i o 1st 3. 133
2nd 2. 045
3rd 1. 481
4th 1 . 1 6 1
5th 0.970
6th 0. 810
Reverse 2. 800
Secondary reduct j on gear Tvpe Si ngl e hel i cal gear
Gear ratio 1. 160
DIFFERENTIAL Fi nal reduct i on gear Tvpe Spi ral bevel gear
Gear rat i o 4. 100
t ,
t
I
I
Design Specifications
2-10
t (
t
t
I
Item Measurement Clualification Specmcetion
STEERI NG Type Electric, oowerassisted rack and
pinion
Over al l r at i o
Turns, lock-to-lock 2. 4
St eer i ng wheel di amet er 360 mm
( 14. 1
i n. )
SUSPENSI ON Front I ndependent doubl e wi shbone, coi l spri ng wi t h st abi l i zer
Rear I ndependent doubl e wi shbone, coi l spri ng wi t h st abi l i zr
Shock absorber Front and rear Tel escopi c, hydr aul i c, ni t r ogen qas f i l l ed
WHEEL
ALI GNMENT
Camber Front 0"30'
Rear 1' 30'
Caster Fr ont 6"00'
Tot al t oe Front 0 mm
(0
i n. )
I n 6 mm { 1/ 4 i n. )
ERAKES Type of service brake Front Power' assi st ed sel f -adj usl i ng vent i l at ed drsc
Rear Powerassisted selt-adjusting solid disc
Type of parki ng brake Mechani cal act uat i ng, rear wheel s
Pad {riction surface area Front 42 cm' x 2
( 6. 5sq i n x2)
Rear 28 cm' x 2
( 4. 3sq
i n x 2)
TI RES Size of tires Front 205/ 55 R16 89W
Rear 225150 R16 92W
Slze oI sparo tire T12sl 70 D16 96M
AI R
CONDI TI ONI NG
Cool i ng capaci t y 3, 320 Kcal / h
(13, 170
BTU/ hl
Compressor Type/Manufacturer Scrol l / KEl Hl N
Number of cyl i nders
Capacity 85. 7 m0l rev.
(5. 23
cu i n/ rev. )
Maxi mum speed 12, 000 rpm
Lubri cant capaci t y 130 mO (4 1/ 3 f l oz)
Lubracant t ype sP- 10
Condenser Corrugat ed f i n
Evaporator Tvpe Cor r uqat ed f i n
Bl ower Type Sirocco fan
Mot or i nput 220 Wt12 V
Speed cont r ol 7 speed manual A, / C
Maxi mum capaci t y 430 ml h 115, 200 cu f rl h)
Temperature control
Ref ri gerant HFC 134 a { R 134 a)
Ouant i t y 600 650
s { 21
- 23f l oz)
2-11
Itsm Moasuroment Clualificetion Specilication
ELECTRI CAL
RATIN GS
Battery 12V 36 AH/ s hours
Starter 1 2 V - 1 . 0 k W
Alternator 1 2 V 1 0 5 A
Fuses UndeFhood fuse/relay box 100A, 40A, 30A, 20A, 15A, r0A, 7. 5A
Underhood sub f use/ rel ay
box
70A, 604, 30A, 20A
Underdash lLrse/relay box 20A, 15A, 10A, 7. 5A
Li ght bul bs Hadl i qht hi gh beam 1 2 V- 5 5 W
Headl i ghl l ow beam 1 2 V 3 5 W
Front t urn si enal l i ght s 12V 21W
Reart urn si gnal l i ght s 12V 21W
Brake/Taillights 12V 2115W
Hi gh mount br ake l i ght LED
Back-up l i ght s 12V 21W
Li cense
pl at e l i ght 1 2 V 5 W
Tr unk l i ght 12V 3. 4W
Spot l i ght s 1 2 V 5 W
Gauge l i ght s 12V 3W, 2W
I ndi cat or l i qht s 12V 1. 12W, 1. 4W
Panel and
pi l ot l i ght s 12 V 0.56 W, 0.91 W, LED
Body Specifications
Uni t mm l i n.l
o
o
2-13
t
t
Mai ntenance
Lubri cants and Fl ui ds ................. 3-2
Maintenance Schedule for Normal
Conditions
(2000
Modell
Li st ed by Di st ance/ Ti me . . . . . . . . . . . . . . . . . . . . . 3-4
Maintenance Schedule for Severe
Conditions
{2000
Model)
Li st ed bv Di st ance/ Ti me . . . . . . . . . . . . . . . . . . . . . 3-6
and Severe Conditions
(2000
Modell
Li sted by Mai ntenance/l tem.......................................... 3-8
Conditions
t2001-2003
Modelsl
Li sted by Di stance/Ti me ..................... 3-10
Maintenance Schedule for Severe
Conditions
(2001
-2003
Modelsl
Li sted by Di stance/Ti me ..................... 3-12
and Severe Conditions
{2001-2003
Modelsl
Li sted by Mai ntena nce/l tem ......................................... 3-14
Lubri cants and Fl ui ds
For the detai l s of l ubri cati on poi nts and type of l ubri cants to be appl i ed, refer to the i l l ustrated i ndex and vari ous work
procedures (such
as Assembl y/Reassem bl y, Repl acement, Overhaul . Instal l ati on, etc.)contai ned i n each secti on.
NO. LUBRICATION POINTS LUBRICANT
1 E ng ine Honda Motor Oi l
(Ameri can
Honda P/N 08798-9023,
Honda Canada P/N CA66806). 10W 30 i s the preferred
mot or oi l f or opt i mum f uel economy and year r ound
protecti on. Look for the APl .
Certi fi cati on seal shown bel ow. Make sure i t saVs
"For
Gasol i ne Enqi nes. "
2 Transmi ssi on Honda l \4TF
(P/N
08798-9016)' '
?
Br ake l i ne { i ncl udes ABS l i ne) Honda DOT3 Br ake Fl ui d
( P/ N
08798- 9008) ' '
Cl ut ch l i ne Honda DOT 3 Brake Fl ui d
(P/N
08798-9008)
'
5
6
7
Rel ease fork
Shi ft l ever pi vot
Sl ave cvl i nder
Super Hi gh Temp Ur ea Gr ease
(P/N
08798-9002)
8 Thr ot t l e cabl e end { Dashboar d l ower
panel
hol e) Si l i cone
qr ease
9
1 0
' 11
12
1 4
t 5
t o
Throttl e cabl e end
(Throttl e
l i nk)
Brake master cyl i nder
pushrod
Battery termi nal s
Fuel f i l l door
Hood hi nges and hood l atch
Tr unk hi nges and l at ch
Door hi nges, upper and l ower
Door openi ng detent
l \4ul ti -pu rpose grease
1 7 Cal i per
pi st on
seal , Dust seal , Cal i per
pi n,
Pi st on Honda Cal i oer Grease {P/N 08C30-BC234M)
1 8 Ai r condi t i oni ng compr essor Compressor oi l : SANDEN: SP-10
(P/N
38897-P13' A01
AH or 38899- P13- A01)
For Ref r i ger ant : HFC- 134 a
( R- 134
a)
1 9 Di fferenti al Hypoi d gear oi l
API cl assi fi cati on GL5 or GL6,
Vi scosi tv: SAE 90
API CERTIFICATION SEAL Recommended Engi ne Oi l
Engi ne oi l vi scosi ty for ambi ent temperature ranges
100' F
40' c
*
1: Al ways use Honda Manual Transmi ssi on Fl ui d
(MTF).
Usi ng motor oi l can cause sti ffer shi fti ng because i t does
not contai n the Drooer addi ti ves.
*
2:Al ways use Honda DOT 3 Brake Fl ui d. Usi ng a non Honda brake fl ui d can cause corrosi on and decrease the l i fe of
the system.
t
-20 -30
3-2
L
NOTE:
Lubri cate al l hi nges, l atches, and l ocks once a
year.
In corrosi ve areas, more frequent l ubri cati on i s necessary.
We recommend Honda Whi te Li thi um Grease.
3-3
Maintenance Schedule for Normal Conditions
(2000
Modell
Listed by Distance/Time
Servi ce at t he i ndi cat ed di st anc ort i me, whi chever comes t i rst . For Canada model s, t hi s t wo-page l rai nt enance Schedul e out l i nes t he
mi ni mum requi red mai nt enance,
Accordi ng t o st at e and f ederal rogul at i ons, f ai l ure t o do t he mai nt enance i t ems marked wi t h ast eri sk
( *
) wi l l not voi d cust omer' s emi ssi ons
warrant i es. However, Honda recommends t hat al l mai nt enance servi ces be done at t he recommended i nt erval t o ensure l ong-t erm rel i abi l i t y
Repl ace cool ant l see
page 1O 8) Capaci t y: 6. 5 0
(6. 9
US
qt ,
5. 7 l mp qt ). Use Honda Al l Season Ant i f reeze/ cool ant Type 2
Repl ace brake f l ui d
(see page 19 8). Use Honda DOT 3 Brake Fl ui d. Fi l l t o bet ween marks on reservoi r.
n
D
! Replace coolant
(see page 10'8) Capacity: 6.5
q
{6.9 US qt, 5.7 lmp qt}. Use Honda All Season Antifreeze/coolant Type 2.
mi / 144, 000 km/ 6
yars
I Reol ace t ransmi ssi on t l ui d. l . 4S0(1. 56USqt , 1. 30 l mp qt ). Use Honda NI TF
(seo page 13-3)
E Repl ace brake f l ui d
(see page 19 8). Use Honda DOT 3. Fi l l t o bet ween marks on reseruoi r'
!
D
n
n
Check i dl e speed. Shoul d be 800: 150 rpm i n neut ral
(see page 11-100).
Replace coolant
(see page 10-8). Capacityi 6.5 0 16.9 US qt, 5.7 lmp qt)- Use Honda All Season antifreeze/coolant Type 2.
I nspect val vecl earance(col d)l nt ake: 0. 21-0. 25mm(0. 008 0. 0' 10 i n. l Exhaust 0. 25 0. 29mm{0. 010 0. 01 1 i n. )
(se page 6-39).
Repl ace spark pl ugs. Use NGK
(PFR7G
-
1 1) or DENSO {PK22PR
-
111). Gapr 1. 0 11mm(0. 039 0 043 i n. ) {see
page 4-19).
L
3-4
I
A
T
B
fl
t
u
L,
f
L- l
L- l
r
I
L.
L-
I
I]
T
Ll
Do t he i t ems i n pans A, B, and C as requi red f or mi l eage/ t i me i nt erval l i st ed.
Repl ace engi ne oi l ( see page 8- 5) . Capaci t y wi t hout { i l t er change: 4. 5 0
( 4. 8
US qt , 4. 0 l mp qt ) , wi t h f i l t er change: 4. 8 0
( 5. 1
USqt , 4. 2
l mp
qt ) .
Check t i r e i nf l at i on and condi t i on-
Repl ace engi ne oi l f i l t er
( see page 8 6) .
I nspect f r ont and r ear br akes
( see page 19 12) .
.
Check pads and di scs f or wear
( t hi ckness) ,
damage, and cr acks.
.
Check cal i per s I or damage, l eaks, and t i ght ness of mount bol t s.
Check
par ki ng br ake adj ust ment . Shoul d be f ul l y appl i ed wi t hi n I t o 13 cl i cks.
I nspect t i e' r od ends, st eer i ng gear box, and boot s
( see page
' 17- 5) .
.
Check r ack gr ease and st eer i ng l i nkage.
.
Check boot s f or damage and l eaki ng gr ease.
.
Check f l ui d l i ne f or damage and l eaks.
l nspect suspensr on component s.
.
Check bol t s f or t i ght ness.
.
Check condi t i on of bal l
j oi nt
boot s f or det er i or at i on and damage.
l nspect dr i veshaf t boot s. Check boot s f or cr acks and boot bands { or t i ght ness
( see page 16- 3) .
I nspect br ake hoses and l i nes { i ncl udi ng ABS} . Checkt he mast er cyl i nder , pr opor t i oni ng cont r ol val ve, and ABS modul at or t or damage
and l eakage
( see page 19- 26) .
Check al l f l ui d l evel s and condi t i on of t l ui ds; check f or l eaks. l f necessar y, add MTF
( see page 13' 3) , engi ne cool ant , br ake f l ui d, and
wi ndshi el d washer I l ui d.
l nspect cool i ng syst em hoses and connect i ons
( see page 10- 2) .
.
Check f or damage, l eaks, and det er i or at r on.
.
Check f or pr oper f an oper at i on.
I nspect exhaust syst em' . Checkcat al yt i cconver t er heat shi el d, exhaust pi pe, andmuf f l er { or damage, l eaks, andt i ght nessl seepage9- 4) .
I nspect f uel l i nes and connect i ons . Check f or l oose connect i ons, cr acks and det er i or at i on; r et i ght en I oose connect i ons and r epl ace
damaged pans ( s ee page 11' 101) .
Repl ace ai r cl eaner el ement ,
I nspect dr i ve bel t , f or cr acks and damage.
.
Al t er nat or compr essor bel t : I nspect aut o t ensi oner i ndi cat or , Needs no adust ment { see
page 4 25} ,
Repl ace di f f er ent i al oi l . 0. 74 0
( 0. 78
US qt , 0. 65 l mp qt i -
Use hypoi d gear oi l GL5 or GL6
( see page 15- 6) .
Repl ace t he ai r condi t i oni ng f i l t er
( see page 21 42) .
.
Repl ace i t t wi ce as of t en
( at
30, 000 mi l e i nt e. val ) i f t he vehi cl e i s dr i ven most l y i n ur ban ar eas t hat have hi gh concent r at i ons ol soot i n t he
ai r f r om i ndust r y and di esel oower ed vehi cl es.
.
Repl ace i t whenever ai r f l ow f r om t he cl i mat e cont r ol syst em i s l ess t han nor mal ,
L
3-5
Maintenance Schedule for Severe Gonditions
(2000
Modell
Servi ce at t he i ndi cat ed di st ance or t i me, whi chever comes l i rst . l Js t hi s schedul e i f t he vehi cl e i s dri ven MAI NLY i n Canada or i n any oJ t he
f ol l owi ng condi t i ons; i f onl y OCCASI ONALLY dri ven i n t hese condi t i ons, use t he Normal Condi t i ons schedul e
(see page 3-4).
Accordi ng t o st at e and l ederal rogul at i ons, t ai l ure t o do t he mai nt enance i t ems marked wi t h ast eri sk
( *
warranties. Howevet. Honda rcommends that allmaintenance services be done at the recommended interval to ansure long-tetm reliability.
Severe Driving Conditions
.
Less t han 5 mi l es {8 km) per t ri p or, i n f reezi ng t emperat ures, l ess t han 10 mi l es
(16
km}per t ri p
.
I n ext remel y; hot weat her
(over90"F/ 32' C)
.
Ext ensi ve i dl i ng or l ong peri ods of st op and-go dri vi ng
.
Trai l er t owi ng, dri vi ng i n mount ai ns
.
On muddy, dust y, or de' i ced roads
D Repl ace cool ant
(see page 10-8). Use Honda Al l Season Ant i f reeze/ cool ant Type 2.
.
Capacity: 6.5 0
(6.9
US
qt,
5.7 lmp qt)
! Repl ace brake f l ui d
(see page 19-8).
' Us e Ho n d a DOT3 .
'
Fillto between marks on reservoir-
75,000mi/120,000 km/ 5 years
I Replace coolant
(see page 10-8). Use Honda All Season Antifreezo/coolant Type 2.
.
Capaci t y: 6. 5 0
(6. 9
US qt , 5. 7l mpqt )
90,000 mi/144,000 km/ 6
years
! Repl ace brake f l ui d
(see page 19-8).
.
Use Honda DOT 3 brake f l ui d; f i l l t o bet ween marks on reservoi r.
tr
tr
tr
tr
Check i dl e speed'
(see page 11' 100). : 800 t 50 rpm
Repl ace cool ant l see
page 10' 8)- Use Honda Al l Season Ant i f reeze/ coo l a nt Type 2.
.
Capaci t y: 6. 5 0
(6. 9
US
qt , 5. 7 l mp q0.
I nspect val ve cl earance
(col d)
I nt ake: 0. 21 0. 25 mm
(0. 008
0. 010 i n. ), Exhaust : 0. 25 0. 29 mm
(0. 010
0. 011 i n. ) l see
page
6' 39).
Repl acespar kpl ugs, UseNGK( PFR7G- 11) oTDENSO( PK22PR- L11) Gapr 1. 0 1. 1 mm
( 0. 039
0. 043 i n. ) l see page 4- 19) .
3-6
L
L
t
Do t he i t ems i n part s A, B, and C as requi red f or mi l eage/ t i me i nt erval
n
A
!
!
tr
tr
tr
B
n
!
u
!
tr
tr
l:]
tr
!
u
tr
c
tr
u
tr
Beplace engine oil and lilter
(see page 8-6). Capacity with lilter change: 4.8 0
(5
1 US qt, 4.2 lmp qt)
I nspect f ro; t and rear brakes, every 6 mont hs i l vehi cl e i s dri ven l ess t han 7, 500 mi l e
(12, 000 km) per year (see page 19-12)
'
Check
pads and di scs f or wear {t hi ckness), damage, and cracks.
'
Check cal i pers f or damage, l eaks, and t i ght ness of mount bol t s.
Check t i re i nf l at i on and condi t i on.
I nspect t i e rod ends, st eeri ng
gearbox, and boot s l see
page 17-5).
.
Check rack
grease and st eeri ng l i nkage.
.
Check boots for damage and leaking grease.
.
Check f l ui d l i nes f or damage and l eaks.
I nspect suspensi on component s,
.
Check bolts for tightness.
.
Check condition of ball
joint
boots for deterioration and damage-
lnspect driveshaft boots. Check boots for cracks and boot bands for tightness
(see page 16-3).
Repl ace ai r cl eaner el ement l see
page 11 123).
Repl ace di f f erent i al oi l . 0. 74 0 {0. 78 US
qt , 0. 65 l mp qt ). Use hypoi d gear oi l GLS or GL6
(see page 15-6}
Check parki ng brake adj ust ment . Shoul d be f ul l y appl i ed wi t hi n I t o 13 cl i cks
Lubri cat e l ocks, l at ches, and hi nges wi t h Honda whi t e l i t hi um grease.
I nspect brake hoses and l i nes
(i n; l udi ng ABS). Check t he mast er cyl i nder,
proport i oni ng cont rol val ve, and ABS modul at or f or damage and
l eakage {see
page 19-26).
checl i f l ui d l evel s and condi t i on of f l ui ds; check f or l eaks. l f necessary, add MTF
(see page 13-3), or engi ne cool ant ' brake f l ui d' and
wi ndshi el d washer f l ui d.
I nspect cool i ng syst em hoses and connect i ons
(see page 10-2)
.
Check f or damage, l eaks, and det eri orat i on.
.
Check for proper fan operation.
I nspect exhaust syst em.
t
Check cat al yt i c convert er heat shi el d, exhaust pi pe, and muf f l er f or damage, l eaks, and t i ght ness
(see page 9-4)
I nspect f uel l i nes and connect i ons. ' Check f or l oose connect i ons, cracks and det eri orat i on; ret i ght en l oose connect i ons and repl ace
damaged
part s (see
Page
11-10' l ).
Checkl

t i ght s. Checkf unct i on of al l i nt eri orand ext eri or l i ght s, andt he
posi t i onsof t he headl i ght s
(see page 22-72)
I nspect t he vehi cl e underbody. Check t he pai nt f or damage, scrat ches, st one chi ppi ng, and dent s.
I nspect dri ve bel t . Look f or cracks and damage.
.
Alternator compressor belt: Inspect auto tensioner indicator. Needs no adjustmenl
Repl ace ai r condi i i oni ng f i l t er, every 15, OOO mi l es i f vehi cl e i s dri ven most l y where ai r has hi gh concent rat i on of soot f rom i ndust ry and
di esel
powered vehi cl es; al so repl ace i t anyt i me ai rf l ow i s l ess t han usual
(see page 21-42).
Repl ace t ransmi ssi on f l ui d. Use Honda MTF.
.
1. 48 0 { 1. 56 US
qt , 1. 30l mpqt )
3-7
Maintenance Schedule for Normal and Severe Conditions
(2000
Modell
Listed by Maintenance ltem
Servi ce at t he i ndi cat ed di st ance or t i me, whi chever comes f i rst .
.
l f dri ven i n normal condi t i ons, do i t ems wi t h a dot
(a).
. l f dr i veni nsever econdi t i onsor nor mal l ydr i veni nCanada, dot heci r cl e( Ol anddot ( Ol i t ems.
L (
Ser vi ce at t he i ndi cat ed di st ance or t i me, whi chever
comes f i r st .
mi l es x 1000 3. 75 1.5 11.25 15 1875 22.5 26.25 30 33.75
km x 1000 6 12 18 24 30 42 48 60
112 1112 2112
Repl ace engi ne oi l Normal Condi t i ons: Every 7, 500 mi l es
(12, 000
km)or 1 year
Severe Condi t i ons: Every 3, 750 mi l es 16, 000 km) or 6 mont hs
Repl ace engi ne oi l t i l t er \ ormal Condi t i ons: t very ot her oi l chang(
Severe Condi t i ons: Every oi l change
Repl ace ai r cl eaner el ement
{ o' t '
a
I nspecl val ve cl ear ance Adj ust onl y i f noi sy.
Repl ace spark pl ugs
I nspect dri ve bel t
o
I nspect i dl e speed'
Repl ace engi ne cool ant
Bepl ace t r ansmi ssi on f l ui d
Bepl ace di f f er ent i al oi l .l o
I nspect f ronl and rear brakes o a o
Check parki ng
brake adj ust ment a o
Repl ace ai r condi t i oni ng f i l t er
*' *'
a
Lubri cat e l ocks, hi nges, and l at ches a l
Checkt i re i nf l at i on and condi t i on at l east once a mont h a o a a a
Inspecttie-rod ends, steering gearbox, and boots
i-)
a o
I nspect suspensron component s a a a
I nspect dr i veshaf t boot s a a
(i ncl udi ng
ABS) o a
I nspect al l f l ui d l evel s and condi t i on of f l ui d a a
I nspect cool i ng syst em hoses and connect i on a o
I nspect exhausl syst em' o a
l nspect f uel l i nes and connect i ons' o a
Check l i ght s and cont r ol s
I nspect vehi cl e under body
t ,
NOTE:
\ - ,
(
l l f t he vehi cl e i s dri ven i n dust y condi t i ons, repl ace t he ai r cl eaner el ement every l 5, 000 mi l es
(24, 000
kmi , i f not , repl ace i t every
30, 000 mi l es
(48, 000
km).
2 Repl acet heai r condi t i oni ngf i l t er ever yl 5, 000mi l es( 24, 000km) i f t hevehi cl ei sdr i venmost l ywher eai r hasahi ghconcent r at r onof soot
,
f rom i ndust ry and di esel -powered vehi cl es; al so repl ace i t an), t i me ai rf l ow i s l ess t han usual .
I
r-y
I
'
Accor di ng t o st at e and f eder al r egul at i ons, f ai l ur e t o do t he mai nt enance i t ems mar ked wi t h an ast er i sk
( ' ) wi l l
not voi d cust omr ' s emi ssi ons
war r ant i es. However , Honda r ecommends t hat al l mai nt enance ser vi ces be done at t he r ecommended i nt er val t o ensur e l ong t er m r el i abi l i t y.
3-8
L
t
41.25 15 18.75 56.25 60 63.75 11.25 15 78. 75 86.25 90 93.75 97. 5 101.25105 108.75112.5 120
12 18 84 90 96 102 108
' n4
120 126 132 138 144 150 162 168 181 187
't92
3 31t2 4 4112 5 5112 6 61t2 1 7 1t2 I
Normal Condi t i ons: Every 7, 500 mi l es
(12, 000
kml or 1 year
Severe Condi t i ons: Every 3, 750 mi l es
(6, 000 km) or 6 mont hs
Normal Condi t i ons: Every ot her oi l change
o a o o o a
Adj ust onl y i l noi sy. a
o
o o a
a
o o a
o o o
o a o a o a
a o a o a o a o a o a
a a
o a a a o O
o o o
o o o C o c
a a o a o a o a a a o
a l a o a o a o a c a
a l a o o a o C o o o
a o c a o o o a o a
a a o o o a
a a a o a a
a o a a o a
a a a a a a
o o a a a o
o !) a o o
o o c a o
o
a
I
3-9
Maintenance Schedule for Normal Conditions
(2001-2003
Models)
Servi ce at t he i ndi cat ed di st ance or t i me, whi chever comes f i rst . Thi s t l rvo-page Mai nt enance Schedul e out l i nes t he mi ni mum requi red
mai nt enance. For Canada model s, use t he Mai nt enance Schedul e f or Severe condi t i ons.
Accordi ng t o st at e and f ederal regul at i ons, f ai l ure t o do t he mai nt enance i t ems marked wi t h ast eri sk
( *
warranties. However, Honda recommends that all maintenance services be done at the recommended intervalto ensure long-term reliability.
Check i dl e speed. Shoul d be 800150 rpm i n neut ral (see page 11 100).
I nspect val ve cl ear ance { col d) l nt ake: 0. 21- 0. 25 mm
( 0. 008
0. 010i n. ) Exhaust : 0. 25- 0. 29mm( 0. 010 0. 011i n. ) ( seepage6- 39) .
Repl ace spark USeNGK( PFR7G 11) or DENSO { PK22PR 111) . Gap: 1. 0 1. 1 mm
( 0. 039
0. 043 i n. ) ( see page 4, 19) .
Repl ace t ransmi ssi on f l ui d. 1. 48 0 11. 56 US qt , 1. 30 l mp qt ).
Use Honda MTF
(see page
' 13-3).
120,000 years, then replace every 60,000 mi/96,000 km/5 years
! BeDl ace enqi ne cool ant
(see page
10-8). Capaci t v: 6. 5 4
(6. 9
US
qt , 5. 7
l mp at ). Use Honda Al l Season Ant i f reeze/ cool ant Tvpe 2.
3- 10
\,
A
!
tr
!
L ]
!
!
n
!
t_l
!
!
!
!
u
tr
L- l
!
Do t he i t ems i n part s A, B, C, and D as t equi red f or mi l eage/ t i me i nt erval l i st ed
Repl ace engi ne oi t
( see page 8- 5) .
, . Capaci t y
wi r hout { i l t er change: 4. 5 0
( 4. 8
us qt , 4. 0 l mp qt ) , wi t h f i l t er change: 4. 8 0
( 5. 1
uS qt , 4. 2
l mp
qt )
Check t i r e i nf l at i on and condi t i on.
Repl ace engi ne oi l f i l t er
( see page I 6) .
I nspect f r ont and r ear br akes
( see page
' 19_12) .
'
Check
pads and di scs f or wear
( t hi cknessi , damage, and cr acks.
.
Check cal i per s f or damage, l eaks, and t i ght ness of mount bol t s
Check par ki ng br ake adj ust ment . l t shoul d be f ul l y appl i ed wi t hi n I t o 13 cl i cks
I nspect t i e- r od ends, st eer i ng gear box, and boot s
( see page 17- 5)
.
Check r ack gr ease and st eer i ng l i nkage.
.
Check boot s f or damage and l eaki ng gr ease.
.
Check f l ui d l i ne f or damage and l eaks.
I nsDect sLr soensi on component s,
.
'
Check condi t i on of bal l i oi nt boot s f or det er i or at i on and damage.
I nspect dr i veshaf t boot s. Check boot sf or cr acks and boot bands f or t i ght ness
( see page 16 3)
I nspect br ake hoses and l i nes
( i ncl udi ng
ABS) . Checkt he mast er cyl i nder ,
pr opor t i oni ng cont r ol val ve, and ABS modul at or f or damage
and l eakage { see
page 19 26) .
Check a

l ] ui d l evel i and condi t i on of f l ui ds; check f or l eaks. l f necessar y, add MTF
( see page 13 3) , engi ne cool ant , br ake f l ui d, and
wi ndshi el d washer f l ui d.
( see page 10- 2)
.
Checl
l or damage, l eaks, and det er i ot al i on.
.
Check f or pr oper f an oper at i on-
I nspect exhaust syst em . Check cat al yt i c conver t er heat shi el d, exhaust pi pe, and muf f l er f or damage, l eaks, and t i ght ness
( see page 9- 4)
I nspect f uel l i nes i nd connect i ons . Check f or l oose connect i ons, cr acks and det er i or at i on; r et i ght en l oose connect i ons and r epl ace
damaged
par t s ( see page
' 11- 101) .
Repl ace ai r cl eaner el ement .
I nspect dr i ve bel t , f or cr acks and damage.
'
Al t er nat or compr essor bel t : I nspect aut o t ensi oner i ndi cat or , needs no adust ment { see
page 4- 25)
Repl ace di f f er ent i al oi l . O- 74 0
( 0. 78
US qt , 0. 65 l mp qt ) . Use hypoi d gear oi l GL5 or GL6
( see page 15- 6)
Repl ace t he dust and pol l en f i l i er
( see page 21 42) .
.
Rept ace i t t wi ce as of t en
( at
3O, OOO mi l ; i nt er val i i f t he vehi cl e i s dr i ven most l y i n ur ban ar eas t hai have hi gh concent r at i ons of soot i n t he
ai r f r om i ndust r y and di esel ' power ed vehi cl es.
.
Repl ace i t whenever ai r f l ow f r om t he cl i mat e cont r ol syst em i s l ess t han nor mal
D
! Repl ace brake fl ui d every 3 years (i ndependent
of mi l eage).
\-
3- 11
Maintenance Schedule for Severe Conditions
(2001-2003
Models)
L
Servi ce at t he i ndi cat ed di st ance ort i me, whi chever comes f i rst . Use t hi s schedul e i f t he vehi cl e i s dri ven l vl Al NLY i n Canada or i n any ot t he
f ol l owi ng condi t i ons; i f onl y OCCASI ONALLY dri ven i n t hese condi t i ons, use t he Normal Condi t i ons schedul e
(see page
3-10).
According to state and federal regulations, failure to do the maintenance items marked with asterisk
( *
) will not void customer's emissions
warranties. However, Honda recommends that all maintenance services be done at the recommended intervalto ensure long-term reliability.
Severe Driving Condhions
.
Less t han 5 mi l es
(8
km) per
t ri p or, i n f reezi ng t emperat u res, l ess t han 10 mi l es
(16
km) per t ri p
.
In extremely; hot weather (over
90'F/32'Ci
.
Ext ensi ve i dl i ng or l ong peri ods of st op-and go
dri vi ng, such as a t axi or a commerci al del i verv vehi cl e
.
Trai l er t owi ng, dri vi ng i n mount aans
.
On muddy, dust y, or de-i ced roads
60,000 mi/ 96,000 km/ 4 years
D Repl ace t r ansmi ssi on l l ui d. 1. 480( l . 56USqt , 1. 30l mpqt ) . UseHondaMTF{ seepage133)
7 years
Check i dl e speed'
(see page 11-100). : 800 + 50 rpm
I nspect val ve cl earance
(col d)l nt ake: 0. 21-0. 25
mm
(0. 008
0. 010 i n. ), Exhaust : 0. 25 0. 29mm1O. O1O O. O1 I i n. )
(see page
6-39)
Repl ace spark pl ugs.
Use NG K 1PFR7G 11) or DENSO
1PK22PR 111)Gap: 1. 0 1. 1 mm{0. 039 0. 043 i n. ) (see page 4-19i .
120, 000 mi / 192, 000 km/ I years
E Repl ace t ransmi ssi on f l ui d.
' 1. 48
011. 56 US qt , 1. 30l mp qt ).
UseHonda MTF {see
page 13-3).
tr
!
!
120, 000 mi / 1 years, then every 60,000 mi/ 96,000 km/ 5 years
l f Beol ace enqi ne cool ant
(see paqe
1O 8)- Capaci t v: 6. 5 0
(6. 9
US
qt . 5. 7
l mo qt ).
Use Honda Al l season Ant i f reeze/ cool ant Tvoe 2.
3-12
r-l
B
!
al
I
u
t i
L]
!
ft
Ll
J
t l
l
L]
t l
r l
tl
D
L]
!
Do t he i t ems i n pans A, B, C, D, and E as requi red f or mi l eage/ t i me i nt erval
Bepl ace engi ne oi l and f i l t er
(see page 8 6). Capaci t y wi t h f i l rer change: 4. 8 0
(5
1 US qt , 4. 2 l mp qt )
I nspect f ront and rear brakes, every 6 mont hs i f vehi cl e i s dri ven l ess t han 7, 500 mi l e per year (see page 19
' 121.
.
Check pads and di scs f or weat
(t hi ckness).
damage, and cracks
.
Check cal i pers f or damage, l eaks, and t i ght ness of mount bol t s.
Check t i re i nf l at i on and condi t i on.
I nspect t i e-rod ends, st eeri ng gearbox, and boot s
(see page 17 5).
.
Check rack
grease and st eeri ng l i nkage.
.
Check boot s f or damage and l eaki ng grease.
.
Check f l ui d l i nes f or damage and l eaks.
i nsoect susoensaon component s.
.
.
Check condi t i on of bal l i oi nt
boot s f or det eri orat i on and damage.
I nspect dri veshaf t boot s. Check boot s f or cracks and boot bands l or t i ght ness l see
page 16-3).
Repl ace ai r cl eaner el ement
(see page 11 123).
Repl ace di f f erent i al f l ui d. 0. 74 4
(0. 78
US
qt , 0. 65 l mp
qt )
Use hypoi d gear oi l GL5 or GLo {see
page 15-6).
Check
parki ng brake adi ust ment . l t shoul d be f ul l y appl i ed wi t hi n I t o 13 cl i cks.
Lubri cat e al l hi nges, l ocks and l at ches wi t h Honda whi t e l i t hi um grease.
I nspect brake hoi es and l i nes
(i ncl udi ng
ABSi . Check t he mast er cyl i nder,
proport i oni ng cont rol val ve, and ABS modul at or f or damage and
l eakage
(see page 19-26)-
checl i f l ui d l evei s and condi t i on of f l ui ds; check f or l eaks. l f necessary, add N4TF
(see page 13-3), or engi ne cool ant ' brake f l ui d' and
wi ndshi el d washer f l Lri d.
(see page 10-2)-
.
Check f or damage, l eaks, and det eri orat i on.
.
Check f or Drooer f an ooerat i on,
I nspect exhaust svst em. Check cat al yt i c convert er heat shi el d, exhaust
pi pe, and muf f l er f or damage, l eaks, and t i ght ness l see
page 9_4)
I nspect f uel l i nes and connect i ons. Check f or l oose connect i ons, cracks and det eri orat i on; ret i ght en l oose connect i ons and repl ace
damaged part s (see page 11-101).
Check al l l i ght s. Check f unct i on of al l i nt er; or and ext eri or l i ght s, and t he
posi t i ons ol t he headl i ght s {see
page 22-72).
I nspect t he vehi cl e underbody. Check t he
pai nt f or damage, scrat ches, st one chi ppi ng, and dent s
I nspect dri ve bel t . Look f or cracks and damage.
.
Al t ernat or compressor bel t : I nspect aut o t ensi oner i ndi cat or. Needs no adj ust ment
Repl ace ai r condi i i oni ng f i l t er, every 15, 000 mi l es
(24, OOO
km) i f vehi cl e i s dri ven most l y where ai r has hi gh concent rat i on of soot f rom
i ndust rv and di esel -powered vehi cl es; al so repl ace i t an! ' t i me ai rf l ow i s l ess t han usual {see
page 21-42)
[ ] Repl ace brake f l ui d eve. y 3
years (i ndependent
of mi l eage).
\
3- 13
Maintenance Schedule for Normal and Severe Conditions
(2001-2003
Modelsl
Listed by Maintenance ltem
Service at the indicated distance ortime, whichever comes first.
.
l f dri ven i n normal condi t i ons, do i t ems wi t h a dot {O}.
.
l f dri ven i n severe condi t i ons or normal l y dri ven i n Canada, do t he ci rcl o {O) and dot 1a) i t ems.
Service at the indicated distance or time, whichever
comes first,
mi l es x 1000 3.75 7. 5 11.25 18. 7522.5 26.25 30 33.75
km x 1000 6 12 r8 21 30 36 42 48 51 60
1t2 11t2 2 2\ n
Bepl ace engi ne oi l
Normal Conditions: Every7,500 miles 112,000 km)or 1 year
Severe Conditions: Every 3,750 miles
(6,000
km)or 6 months
Repl ace engi ne oi l f i l t er Normal Condi t i ons: Every 15, 000 mi l es
(24, 000
km)or 1 year
Severe Conditions: Every oilchange
Repl ace ai r cl eaner el ement ' o*'
o a
I nspect val ve cl ear ance
Adjust only if noisy.
Repl ace spark pl ugs
I nspect dri ve bel t
o
I nspect i dl e speed'
Eepl ace engi ne cool ant
Ar 120,000 miles
(192,000
km) or 10 years, then every 60,000
mi l es
(96, 000
km)or 5 years.
Repl ace t ransmi ssi on t l ui d
Replace differential fluid
o a
Inspect front and rear brakes
o o o a o
Every 3 years.
Check parking
brake adjustment
o a
Repl ace dust and pol l en I i l t er
*' r'
a
Lubdcate locks, hinges, and latches
o o
Checktire intlation and condition at least once a month Evry 7, 500 mi l es
(12, 000
km)
Inspecttie-rod ends, steering gearbox, and boots
o a o o o
Inspect suspension components
c a o a o
Inspect driveshaft boots
o a o a o
(i ncl udi ng
ABSI
a o
I nspect al l f l ui d l evel s and condi t i on of f t ui d
o a
Inspectcooling system hoses and conneclion
o o
I nspect exhaust syst em'
a a
I nspect f uel l i nes and connect i ons'
o o
Check l i ght s and cont rol s
o o
I nspect vehi cl e underbody
o o
L
' Accordi ng
t o st at e and t ederal regul at i ons, f ai l ure t o dot he mai nt enance i t ems marked wi t h an ast eri sk 1' l wi l l not voi d cust omer' s emi ssi ons
warranties, However. Honda recommends that all maintenance services be done atthe recommended intervalto ensure long,term reliability.
NOTE:
l lfthe vehicle is driven in d usty cond itions, replacethe air cleaner element every l5,000 miles 124,000 kml, if not, replace itevery 30,0OO miles
(a8,O00
km).
2 Replace the dust and pollen filter every 15,000 miles
(24,000kmlif
the vehicle is driven rnostly where air has a high concentration of soot
f rom i ndust ry and di esel -powered vehi cl es; al so repl ace i t anvt i m ai rf l ow i s l esst han usual .
3-14
o
o
L
\-
41.25 45 48.75 52.5 5625 60 67.5 71.25 15 78. 7582. 5 86 25 90 93.75 97.5 10125 105 108.75112.5 124
12 78 84 90 s6 102 108 t 1 4 120 126 144 150 168 181 181 192
3 4 4112 5 5112 6 6112 1 8
Normal Condi t i ons: Everv 7, 500 mi l es
(12, 000
km) ot 1 year
Severe Condi t i ons: Every 3, 750 mi l es
(6, 000
km) or 6 mont hs
Normal Condi t i ons: Every 15, 000 mi l es 124, 000
km)or 1 year
( . 1
a o o
a
Adi ust onl y i f noi sy. o
o
a
a
o
o
At 12o, oOO mi l es
(192, 000
km) or 10
Years,
t hen everv 60, 000 mi l es
(96, 000
km) or 5 years
I l l -t
t -i t -T [ -l l l l
o a
a
a
o o o
(l
o a a a a O
Every 3 years
o o o o a a
o
o
a
o c a-:
Every 7, 500 mi l es
(12, 000 km)
l f
-
.T-T-
a
(_)
o a o o il o a a
o c a a
.-l
o a o
a a o a a a
a a a a o a
o a a a a a
a o o o a o
a a a a O a
o o
i-_l
i,l
o
-l -)
o
\-
Engi ne El ectri cal
Engine Electrical
Soeci al Tool s
Starting System
Component Locat i on I ndex . . . . . . . . , . . . . .
Ci rcui t Di agram
St art er Ci rcui t Troubl eshoot i ng
Clutch lnterlock Switch Test
St art er Sol enoi d Test . . . . . . . . . . . . . . . .
Starter Performance Test
St art erRepl acement . . . . . . . . . . . . , . .
St art er Overhaul . , . . . , . . . . . . . . . . . . . . . . .
lgnition System
Component Locat i on I ndex . . . . . . . . . . . . . .
Ci rcui t Di agram
l gni t i on Ti mi ng I nspect i on
Spark Pl ug I nspect i on
Charging System
Comoonent Locat i on I ndex . . . . . . . . . . . . . .
Ci rcui t Di agram
Chargi ng Ci rcui t Troubl eshoot i ng
Alternator-com oressor Belt
I nspect i on and Repl acement . . . . . . , . . , , . . . . . . . . . .
Al t ernat or Reol acement
Aut o-t ensi oner I nspect i on/ Repl acement
Al t ernat or Overhaul . . . . . . . . . . . . . . . .
Cruise Control
Comoonent Locat i on I ndex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
Ci rcui t Di agram
. ' . . . . . " 4-36
Sympt om Troubl eshoot i ng I ndex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
Crui se Cont rol Uni t I nput Test . . . . . . . . . . . 4-38
Mai n Swi t ch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
Mai n Swi t ch/ l ndi cat or/ l l l umi nat i on
Test . . . . . . . . . . . . . . . . . . . . 4-41
Mai n Swi t ch/ l ndi cat or Bul b Repl acement . . . . . . . . . . . . . . . . . . 4-41
SeVResume Swi t ch Test . . . . . . . . . . . . . . . . . . . . 4-42
SeVResume Swi t ch Rep1acement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
Crui se Cont rol Act uat or Test . . . . . . . . . . . . . 4-43
Crui se Cont rol Act uat or Repl acement . . . . . . . . . . . . . . . . . . . . . . . . 4-44
Act uat or Cabl e Repl acement . . . . . . . . . . . . . 4-45
Act uat or Cabl e Adj ust ment . . . . . . . . . . . . ' . . 4-46
Clutch Pedal Position Switch Test ' ... 4-47
Brake Pedal Position Switch Test ' .".' 4-47
4-2
4-3
4-4
4-5
4-6
4-7
4-7
4-8
4-10
4-16
4-' tl
4- 18
4-' t 9
4-20
4-21
4-22
4-25
4-26
4-27
4-29
Engi ne El ectri cal
Speci al Tool s
-"-FJ
..-NN
{^-''
@
Number Tool Number Description Otv
o
ai
07746-0010400
07749-0010000
Attachment, 52 x 55 mm
Dri ver
'1
1
\-
\
Starting System
Component Location Index
ENGI NE CONTROL
MODULE I ECMI
CLUTCH INTERLOCK SWITCH
est , page 4-6
IGNITION SWITCH
STARTER
Troubl eshoot i ng,
page 4-5
Sol enoi d Test , page 4-7
Perf ormance. page 4-7
Repl acement ,
page 4' 8
Overhaul , page 4-10
ENGINE START SWITCH
\
4-3
Starting System
Ci rcui t Di agram
4-4
\-
\-
Starter Circuit Troubleshooting
NOTE:
.
Ai r temperature must be between 59' and 100"F
(15'
and 38" C) dur i ng t hi s
pr ocedur e.
.
After thi s test, or any subsequent repai r, reset the
engi ne control modul e
(ECM)
to cl ear any di agnosti c
t r oubl e codes { DTCS) { see
page 11- 3) .
.
The battery must be i n good condi ti on and ful l y
cnar geo.
Recommended Procedure:
.
Use a starter system tester.
.
Connect and operate the equi pment i n accordance
wi th the manufacturer' s i nstructi ons.
Allernate Procedure
1. Hook up t he f ol l owi ng equi pment :
.
Ammeter, 0 400 A
.
Vol tmeter,0 20 V
(accurate
wi thi n 0.1 vol t)
.
Tachometer, 0
' 1200
rpm
Remove t he No. 2 { 15 A) f use f r om t he under - dash
fuse/rel ay box.
Turn the i gni ti on swi tch ON {l l } wi th the cl utch
pedal depressed, and
push the engi ne start swi tch.
Did the starter crank the engine normally?
YES The starti ng system i s OK.l
NO Go to step 4.
\-
4-5
4. Check the battery condi ti on. Check el ectri cal
connecti ons at the battery, the negati ve battery
cabl e to body, engi ne
ground cabl es, and the
starter for l ooseness and corrosi on. Then try
st ani ng t he engi ne agai n.
Di d the stattet crank the engi ne?
YES Repai ri ng the l oose connecti on fi xed the
probl em. The starti ng system now i s OK.l
NO l f the starter wi l l not crank the engi ne at al l , go
to step 5, l f i t cranks the engi ne errati cal l y or too
sl owl y,
go to step 7. l f i t won' t di sengage from the
fl ywheel ri ng gear when you rel ease the swi tch,
check for the Jol l owi ng unti l you fi nd the cause.
.
Sol enoi d
pl unger and swi tch mal functi on
.
Di rty dri ve
gear or damaged overrunni ng cl utch
5. Make sure the transmi ssi on i s i n neutral , then
di sconnect the BLK,^/VHT wi re
(A)
from the starter
sol enoi d
(B).
Connect a
j umper
wi re from the
battery
posi ti ve termi nal to the sol enoi d termi nal .
Di d the starter crank the engi ne?
YES Go to step 6.
NO Remove the starter and repai r or repl ace as
necessary.
(cont' d)
Starting System
Starter Circu it Troubleshootin g
(cont'dl
6. Check the fol l owi ng wi res i n the order l i sted unti l
you fi nd the open ci rcui t.
.
Between the i gni ti on swi tch and the starter cut
rel ay.
.
Between the i gni ti on swi tch and the start swi tch.
.
Between the start swi tch and l he starter cut rel ay.
.
Between the start swi tch and body ground.
.
Between the staner cut rel ay and the starter.
.
Check the i gni ti on swi tch, the start swi tch. the
cl utch i nterl ock swi tch, and those connectors.
.
Substi tute a known-good starter cut rel ay.
7. Check the cranki ng vol tage and current draw,
ls cranking voltage greater than or equal to 8.5
volts and current draw less than or equal to 380
amps?
YES Go to step 8.
NO
-
Remove and di sassembl e the starter, and
check for the fol l owi ng unti l you fi nd the cause.
.
Open ci rcui t i n starter armature commutator
segments
.
Starter armature draggi ng
.
Shorted armature wi ndi ng
.
Excessi ve drag i n engi ne
8. Check engi ne speed dur i ng cr anki ng.
ls engine speed above 100 rpm?
YES Go to step 9.
NO Remove and di sassembl e the starter, and
check tor the fol l owi ng unti l you fi nd the cause.
.
Excessi vel y worn staner brushes
.
Open ci rcui t i n commutator brushes
.
Di rty or damaged hel i cal spl i ne or dri ve gear
.
Faul ty dri ve gear
cl utch
9. Remove the starter and i nspect i ts dri ve gear and
the fl ywheel ri ng gear for damage. Bepl ace any
damaged parts.l
Clutch lnterlock Switch Test
1. Di sconnect the connector from the cl utch i nterl ock
swi tch, then remove the cl utch i nterl ock swi tch.
b
Check the cl utch i nterl ock swi tch connector
termi nal s for conti nui ty. There shoul d be no
conti nui ty between the termi nal s wi th the button
(A)
rel eased. and there shoul d be conti nui ty wi th
the button pressed.
CLUTCH INTER LOCK SWITCH CONNECTOR
Termi nal si de oI mal e t ermi nal s
l f the cl utch i nterl ock swi tch i s faul ty, repl ace i t.
Instal l the cl utch i nterl ock swi tch, and adj ust i t
(see
page
12-41.
4-6
Starter Solenoid Test
1. Check the hol d-i n coi l for conti nui ty between the S
termi nal and the armature housi ng l ground). There
shoul d be conti nui tv.
.
l f there i s conti nui ty, go to step 2.
.
l f there i s noconti nui ty. repl acethe sol enoi d.
Check the
pul l -i n
coi l for conti nui ty between the S
termi nal and M termi nal . There shoul d be
conti nui ty.
.
l f there i s conti nui ty, the sol enoi d i s OK.
.
l fthere i s no conti nui ty, repl ace the sol enoi d.
1 .
Starter Performance Test
Di sconnect the wi res from the S termi nal and the
M t er mi nal .
Make the connecti ons as descri bed bel ow usi ng as
heavy a wi re as
possi bl e (preferabl y
equi val ent to
the wi re used for the vehi cl e). To avoi d damagi ni g
the starter, never l eave the batterv connected for
more than 10 seconds.
Connect the battery as shown. Be sure to
di sconnect the starter motor wi re from the sol enoi d.
l f the starter
pi ni on pops
out, i ti sworki ng properl y.
Di sconnect the battery from the M termi nal . l f the
pi ni on
does not retract, the hol d-i n coi l of the
sol enoi d i s worki ng properl y.
(cont' d)
4-7
Starting System
Stafter Performance Test
{cont'dl
5. Di sconnectthe battery from the starter body. l fthe
pi ni on retracts i mmedi atel y, i t i s worki ng properl y.
Cl amp the starter fi rml y i n a vi se.
Connect the starter to the battery as descri bed i n
the di agram bel ow, and confi rm that the motor
sta rts and keeps rotati ng.
7.
l f the el ectri c current and motor speed meet the
speci fi cati ons when the battery vol tage i s at 1 1.5 V,
the starter i s worki ng properl y.
Specifications:
1 .0 kw 90 A or less
(Electric
current),
3,000 rom or more
4-8
Starter Replacement
' 1.
Make sure you have the anti -theft code for the radi o,
then wri te down the frequenci es for the radi o' s
preset buttons.
Di sconnect the negati ve cabl e from the battery,
then di sconnect the
posi ti ve
cabl e.
Move the auto-tensi oner
(A)
to rel i eve tensi on from
the al ternator-compressor bel t, and remove the
bel t
( B) .
4. Remove the auto-tensi oner.
&
8 x 1. 25 mm
22 N. m
(2. 2
kgf . m, 16l bf . f t l
8x 1. 25 mm
22 N m
(2. 2 kgf . m, 16l bf . f t )
\-
Di sconnect the 4P connector
(A)
from the al ternator
(B),
and di sconnect the BLK wi re from the
al ternator B l ermi nal
(C).
E x 1. 25 mm
12 N. m
(1. 2
kgt . m,
9 tbf.ft)
Remove the mounti ng bol ts, then remove the
al ternator.
10 x 1.25 mm
,14
N'm (4.5 kgf.m, 33 lbf ftl
10 x 1, 25 mm
44 N. m
(4. 5
kgt . m, 33l bf . f t )
7. Di sconnect the starter cabl e from the B termi nal on
the staner sol enoi d
(A),
BLK,^/VHTwi re from the S termi nal
(C).
I N. m
(0. 9
ksf . m, 7 l bt . f t )
Remove the two bol ts securi ng the starter, then
remove the starter.
l nstal l i n the reverse order of removal . Make sure
the cri mped si de ofthe ri ng termi nal i s faci ng out.
Connect the posi ti ve cabl e and negati ve cabl e to
the battery.
Start the engi ne to make sure the starter operates
properl y.
Enter the anti -i heft code for the radi o, then enter
the customer' s radi o stati on presets.
Set the cl ock.
Pr ef or m t he engi ne sont r ol modul e
( ECM)
i dl e l ear n
pr ocedur e ( see page 11- 100) .
q,
t t
l
I
8 x 1. 25
\
- . t - -
10x 1. 25 mm
44 N.m
(4.5
kgt.m,
33 tbf.frl
9.
10.
' l
1.
12.
t 5 .
14.
4-9
Starting System
Starter Overhaul
Disassembly/Reassembly
8 r
' 1. 25
mm
I x 1.25 mm
9 N.m
(0.9
kgf m,7 l bt.ft)
\ -
i (
STARTER SOLENOID
WASHER
PINION DRIVE LEVER
1
r ) ,/,.",o,^,,. / 6x1omm
\ 7
@n/ /
83Nm1o88ksr m'
"'j@
#ffi #.,\
ou. **#o / - \ e( : t ! Seb
GLUTCHASSEMBLY
/ \ A$ ,___.-. \
G
clurcHsroP
r"\r*"o\>)b--)a
W, ) _ \
--
/
)9***"7o
'B'us'i'*'
^RMATURE^SSEMBL'
/,/
/ it,\
sr*rrui
q.-
''*",*l,o*"
/
-)No)/G\
N$$$$$$$^, , * ' " ' o' r ( on
/ Kt
/--\*-\
^r-)*.,' "' u' '
*o,.".* \
' /
*
^ A 1 \ I NTERNAL GEAR
'/
--"*{()/ffi
%
3,J.H:].'.H,,,
.ra
N Wq,n>
scREw. 4xo. 7mm / t \ q(
( ) )
1 . 5 N. m
/ \ \ \ i K- Y.
(0.15kqr.m.1.rbr.ft)
rrlour
"iur*
"ûr\o.".*y;aruREHousrNG
@
BRUSH HOLDER PLATE
4-10
1. Remove the staner
(see page 4-8).
2. Di sassembl e the staner.
Armature Inspection and Test
3. Inspect the armature for wear or damage due to
contact wi th the permanent magnet. l f there i s wear
or damage, repl ace the armature.
Check the commutator
(A)
surface. l f the surface i s
di rty or burnt, resurface i t wi th emery cl oth or a
l athe wi thi n the fol l owi ng speci i i cati ons, or
recondi ti on wi th # 500 or # 600 sandpaper
(B).
5. Check the commutator di ameter, l f the di ameter i s
bel ow the servi ce l i mi t, reDl ace the armature.
Commutator Diameter
Standard {New}:28.0-28.1 mm {1.102 1.106 i n.l
Seryi ce Li mi t: 27.5 mm
(1.083
i n.l
Measure the commutator runout.
.
l f the commutator runout i s wi thi n the servi ce
l i mi t, check the commutator for carbon dust or
brass chi ps between the segments.
.
l f the commutator runout i s not wi thi n the servi ce
l i mi t, repl ace the armature.
Commutator Runout
Standard {New}: 0.02 mm
(0.001
i n.l max.
Service Limit: 0.05 mm
(0.002
in.)
(cont' d)
4-11
Starting System
Starter Overhaul
(cont'dl
7. Check the mi ca depth
(A).
l f the mi ca i s too hi gh
(B),
undercut the mi ca wi th a hacksaw bl ade to the
proper
depth. Cut away al l the mi ca
(C)
between
the commutator segments. The undercut shoul d
not be too shal l ow, too narrow, or V-shaped
(D).
Commutator Mica Depth
Standard
(New):
0.4-0.5 mm
(0.010
0.020 i n.)
Servi ce Li mi t: 0.15 mm
(0.006
i n.)
8. Check for conti nui ty between the segments ofthe
commutator, l f an open ci rcui t exi sts between any
segments, repl ace the armature.
M
4-12
9. Pl ace the armature
(A)
on an armature tester
(B).
Hol d a hacksaw bl ade
(C)
on the armature core.
l f the bl ade i s attracted to the core or vi brates whi l e
the core i s l urned, the armature i s shorted. Repl ace
the armature.
B ^
Check wi th an ohmmeter that no conti nui ty exi sts
between the commutator
(A)
and armature coi l
core {B), and between the commutator and
armature shaft
(C).
l f conti nui ty exi sts, repl ace the
armature.
10.
!
\-
Starter Brush Inspection
11. l vl easure the brush l ength. l f i t i s not wi thi n the
servi ce l i mi t, repl ace the brush hol der assembl y.
Brush Length
Standard
(New):
15.8 16.2 mm 10.62 0.64 i n.)
(0.43
i n.)
Starter Field Winding Test
12. Check for conti nui ty between the brushes
(A).
l f
there i s no conti nui ty, repl ace the armature
housi ng
( B) .
A
/ \
/ \ \
/
\ \
B
\ '
Check for conti nui ty between each brush
(A)
and
the armature housi ng {B).
l f there i s conti nui ty,
repl ace the armature housi ng.
1 5 .
Starter Brush Holder Test
14. Check that there i s no conti nui ty between the
(+
)
br ush hol der { A) and( ) br ush hol der
( B) .
l f t her e
i s conti nui ty, repl ace the brush hol der assembl y.
Insert the brush
(A)
i nto the brush hol der, and bri ng
the brush i nto contact wi th the commutator, then
attach a spri ng scal e
(B)
to the spri ng
(C).
Measure
the spri ng tensi on at the moment the spri ng l i fts off
t he br ush.
Spring Tension:
15.7 17.7N
(1.6
-1.8kgf.3.53
3.97 l bfl
(cont' d)
4-13
Starting System
Stafter Overhaul
(cont'dl
' 16.
Pry back each brush spri ng wi th a screwdri ver. then
posi ti on the brush about hal fway out of i ts hol der,
and rel ease the spri ng to hol d i t there.
I nst al l t he ar mat ur e i n l he housi ng, and i nst al l t he
brush hol der. Next,
pry
back each brush spri ng
agai n, and push t he br ush down unt i l i t seat s
agai nst the commutator, then rel ease the spri ng
agai nst the end of the brush.
NOTE: To seat new brushes, sl i p a stri p of # 500 or
# 600 sandpaper, wi th the gri t si de up, between the
commutator and each brush, and smoothl y rotate
the armature. The contact surface ofthe brushes
wi l l be sanded to the same contour as the
commutator.
1 7 .
4-14
18. Instal l the starter end cover
(A)
to retai n the brush
hol der
( B) .
BOLT, 5 x 1, 0 mm
5. 9 N m
(0. 6 ksf m, 4. 3l bf f t )
J-lt'l'n.-.-..----@
\-
Overrunning Clutch Inspection
,| 9.
Sl i de the overrunni ng cl utch al ong the shaft.
Repl ace i t i f i t does not sl i de smoothl y.
20. Hol d the
pl anetary gear shaft
(A),
and turn the
overrunni ng cl utch assembl y
(B)
both ways. l f i t
does not l ock i n ei ther di recti on or i t l ocks i n both
di recti ons, reDl ace i t.
l f the starter dri ve gear (C)
i s worn or damaged,
repl ace the overrunni ng cl utch assembl y; the gear
i s not avai l abl e separatel y.
Check the condi ti on of the torque converter ri ng
gear
i f the starter drj ve gear teeth are damaged.
Reassembl e the starter i n reverse order of
di sassembl y.
21.
4-15
lgnition System
Gomponent Location Index
IGNITION COIL/IGNITION CONTROL
MODULE
(ICMIASSEMBLIES
'.ilt,
'..
-i\l;.,,,t1.'.---l
-
SPARK PLUGS
I nspect i on,
page 4-19
t\].
\ \ i
4-16
\-
Circuit Diagram
MAIN UNDIR- H@D FUST/iEIAY MX
4-17
lgnition System
l gni ti on Ti mi ng l nspecti on
1 .
4.
5.
Connect the Honda PGM Tester to the data l i nk
connector {DLC), and check for DTC' s. l f a DTC i s
present, si agnose and repai r the cause before
i nspect i ng t he i gni t i on t i mi ng.
Start the engi ne. Hol d the engi ne at 3,000 rpm wi th
no l oad
( i n
Neut r al ) unt i l t he r adi at or f an comes on,
t hen l et i t i dl e.
Check the i dl e speed, and adj ust i t i f necessary
(see
page 11- 100) .
Fol l ow the tester' s prompts to get the tester i n the
"SCS"
mode
(see
Tester Operator' s Manual )
Connect the ti mi ng l i ght to the No. 1 i gni ti on coi l
4-18
6. Ai m the l i ght toward the
poi nter
{A). Check the
i gni ti on ti mi ng under no l oad condi ti ons:
headl i ghts, bl ower fan, and al r condi ti oner are not
operati ng. l f the i gni ti on ti mi ng di ffers from the
speci fi cati on bel ow, repl ace the Engi ne Control
Modul e
( ECM) ( see page 11- 3) .
l gni ti on Ti mi ng:
5' a2' BTDC
(BED
mark l B)) at i dl e i n Neutral
Turn the i gni ti on swi tch OFF.
Di sconnect the PGM tester and the ti mi ng l i ght.
7.
Spark Pl ug Inspecti on
' 1.
Inspect the el ectrodes and cerami c i nsul ator.
Burned or worn el ectrodes may be caused by;
'
Advanced i gni t i on t i mi ng
.
Loose spar k pl ug
.
Pl ug heat range too hot
.
Insuffi ci ent cool i ng
Foul ed pl ug may be caused by:
.
Retarded i gni ti on ti mi ng
'
Oi l i n combust i on chamber
.
Incorrect spark
pl ug gap
.
Pl ug heat r ange t oo col d
.
Excessi ve i dl i ng/l ow speed runni ng
'
Cl ogged ai r cl eaner el ement
.
Deteri orated i gni ti on coi l s
Worn or detormed
electrodes
1' .
l -pt op. . g"p
I
'
Oi l -f oul i ng
<
.
Carbon doposits
I
.
Cracked center
f
el ect rode i nsul at or
2. Do not adj ust t he
gap
of
pl at i num t i p pl ugs ( A) ;
repl ace the spark
pl ug i f the
gap i s out of
speci fi cati on.
Electrode Gap:
Standard
(New):1.0
1.1 mm
(0.039
0.043 i n.)
(0.015
i n.l
Repl ace t he pl ug at t he speci f i ed i nt er val , or i f t he
center ei ectrode i s rounded
(A).
Use onl y the spark
pl ugs l i st ed bel ow.
Spark Pl ugs:
NGK: PFRTG-l 1S
DENSO: PK22PB-L11S
Appl y a smal l quant i t y of ant i - sei ze compound t o
the
pl ug threads, and screw the pl ugs i nto the
cyl i nder head fi nger-ti ght. Then torque them to
25 N. m
( 2. 5
kgf . m, 18l bf . f t ) .
4.
4-19
Charging System
_ . -
=
='-
'_=__=;:==,,,ii
\
i i
rt
_1. i \
_:--
_-=
\
i =
= , ,
\
! : r l i
\ ' \
\
-
-ai- \,\ \.
- -----*\
I \
- - - - - - - - r -
l ' - . \
t -. l i , l \ . t .
\,\'r
\, i'..
AUTO.TENSIONER
l nspecti on/Repl acement, page 4-27
ELECTRICAL LOAD DETECTOR IELDI
(Located
i n the mai n under-hood tuse/rel av box)
S<]
,'.
ALIERNATOR COMPRESSOR BELT
Inspecti on and Repl acement, page 4-25
CHARGING SYSTEM
A\
| -
- |
V/
INDICATOR
IGNITION SWITCH
v
g
i "
ALTERNATOR
Al ternator/Regul ator Test, page 4-22
Repl acement, page 4' 26
4-20
Ci rcui t Di agram
MAINUNDER HOODfUSE/RTLAYEOX
No. { 1{ l OAl / : : \ Nol 2i OAl
8u(
G202
4-21
Gharging System
Chargi ng Ci rcui t Troubl eshooti ng
l f the chargi ng system i ndi cator does not come on or
does not go off, or the battery i s dead or l ow, test the
fol l owi ng i tems i n the order l i sted bel ow:
Battery
(see page 22-39)
Chargi ng system i ndi cator
Al t er nat or and r egul at or ci r cui t
Al ternator control system
Charging System Indicator Test
1. Tur n t he i gni t i on swi t ch ON
( l l ) .
Does the charging system indicator come on?
YES Go to step 2.
NO Go to step 6.
St an t he engi ne.
Does the charging system indicatot go otf?
YES Chargi ng system i ndi cator ci rcui t i s OK. Go
to the Al ternator and Regul ator Ci rcui t Test. I
NO Go to step 3.
Di sconnect the al ternator 4P connector from the
al ternator.
Tur n t he i gni t i on swi t ch ON
( l l ) .
YES Turn the i gni ti on swi tch OFF, and repaj r the
short i n the WHT/BLU wi re. l f the WHT/BLU wi re i s
shorted to ground, the vol tage regul ator i n the
al ternator may be damagedl
NO Go to step 9.
al ternator.
2.
5.
3.
4.
6.
7.
4-22
8. Connect the al ternator 4P connector termi nal No. 3
t o body gr ound wi t h a
j um per wi r e. Tur n t he
i gni t i on swi t ch ON
( l l ) .
AITERNATOR 4P CONNECTOR
l 2
3 4
L (WHT
f emal e t er mi nal s
/BLU)
9.
YES Go to step 9.
NO Turn the i gni ti on swl tch OFF. Check for a
bl own No. 6
( 15
A) f use and a bl own char gi ng
syst em l i ght bul b. l f t he f use and bul b ar e OK,
repai r the open i n the BLKI/EL or WHT/BLU
wi r e t o t he i ndi cat or bul b. l
Measu re the vol tage at the No.
' l
termi nal of the
al ternator 4P connector wi th the i gni ti on swi tch ON
0 r ) .
ALTEBNATOR 4P CONNECTOR
l s there battery vol tage?
YES Go to Al ternator and Regul ator Ci rcui t Test.
I
NO Repai r open i n the BLK/YEL wi re between the
al t er nat or and t he dr i ver ' s under - dash f use r el ay
box. t
Alternator and Regulator Circuit Test
l . Be sure the battery connecti ons are good, and that
the battery i s suffi ci entl y charged and i n good
condi ti on
(see page 22 39).
2. Connect a VAT-40
(or
equi val ent tester), and turn
the sel ector swi tch to posi ti on 1
(starti ng).
LOAD AOJUSTER FULL FIELD TESTER
{CARBON
PI LE) LEAD IBLU)
VOLT
SELECTOR
VOLTMETER
NEGATI VE
LEAO I BLK)
VOLTMETER
POSITIVE
LEAD {RED)
FIELD
SELECTOR
TEST SELECTOR
swtTcH
\
"h'u. rr"r.*
\caBLE
{BLK)
POSITIVE TESTER
CABLE IRED)
INDUCTIVE
PICK.UP
INOUCTIVE
PICK-UP IGRN)
TERMINAL
3.
4.
6.
7 .
Shi ft to Neutral , and start the engi ne. Hol d the
engi ne at 3,000 rpm, wi th no l oad unti l the radi ator
fan comes on, then l el i t i dl e.
Rai se t he engi ne speed t o 2, 000 r pm, and hol d i t
t her e.
Is thete vol tage over 15.1 V?
YES Repl ace t he r ear housi ng assembl y. l
NO Go to step 5.
Rel ease the accel erator
pedal , and l et the engi ne
i dl e.
Make sure al l accessori es are turned off. Turn the
sel ector swi tch to
posi ti on 2
(chargi ng).
Remove the i nducti ve
pi ck-up, and zero the
ammeter.
Pl ace the i nducti ve pi ck-up over the B termi nal wi re
of the al ternator so that the arrow poi nts away from
the al ternator.
8.
4-23
L Rai se the engi ne speed to 2.000 rpm, and hol d i t
t her e.
l s there vol tage Iess than 13.5 V?
YES Go to Al ternator Control System Test,l
NO Go to step 10.
10. Appl y a l oad wi th the VAT 40 unti l the baftery
vol t age dr ops t o bet ween 12 13. 5V.
l s the amperage 87.5 A or more?
YES The chargi ng system i s OK.l
NO Repai r or repl ace the al ternator
(see page 4-
29).a
( cont ' d)
Charging System
3.
Charging Circuit Troubleshooting
(cont'd)
Alternator Control System Test
t
1 . Check for proper operati on of the el ectri cal l oad
detector
(ELD)
by checki ng that the mal tuncti on
i ndi cator l amp
(Ml L) (see page 1 1-3). l f a DTc i s
present, di agnose and repai r the cause betore
conti nui ng wi th thi s test.
al ternator.
Start the engi ne, and turn the headl i ghts
(hi gh
beam) ON.
Measure vol tage between the al ternator 4P
connector termi nal No. 2 and the
posi ti ve
termi nal
of the battery.
c
1 2
3
,4
BATTERY
ALTERNATOR
4P CONNECTOR
{WHT/ GRNI
Wi re si de of
l emal e t ermi nal s
5.
6.
ls thete 1 V or less?
YES Go to step 8.
NO Go to step 5.
Turn the headl i ght and i gni ti on swi tch OFF.
Di sconnect engi ne control modul e
{ECM)
connect or C { 31P) .
4-24
7. Check for conti nui ty between the ECM connector C
t er mi nal No. 2 and body gr ound.
ECM CONNECTOR C {31PI
Wi r e si de of f emal e t er mi nal s
l s there conti nui ty?
YES Repai r short to
ground i n the wi re between
the al ternator and ECI\4.I
NO Check that the termi nal s are fi rml y seated at
the connectors. l f OK, substi tute a known-good
PCM and r echeck { see
page 11- 4) . l f pr escr i bed
vol tage i s now avai l abl e, repl ace the ori gi nal ECM
( see page 1' l - 5) . I
8, Tur n t he headl i ght and i gni t i on swi t ch OFF.
9. Di sconnect ECM connector C
(31P).
10. Check for conti nui ty between the ECM connector C
t er mi nal No. 2 and al t er nat or 4P connect or t er mi nal
No. 2.
ECM CONNECTOR C { 31P} 4PCONNECT(
YES Repai r the al ternator
(see page 4-29).1
NO Repai r an open i n the wi re between the
al t er nat or and ECM. I
Alternator-compressor Belt Inspection and Replacement
1. Check that the
poi nter (A)
onthe auto-tensi oner
housi ng i s not beyond the edge of the i ndi cator ri b
{B} on the tensi oner base.
(A)
the al ternator bel t
(B),
and remove the al ternator-
compressor bel t.
3. l nstal l the new bel t i n the reverse order of removal .
4-25
Charging System
Alternator Replacement
1. Make sure you have the anti -theft code for the radi o,
preset buftons.
2. Di sconnect the negal i ve cabl e front the battery,
then di sconnect the posi ti ve cabl e.
3. Move the auto-tensi oner
(A)
the al ternator bel t
(Bl ,
and remove the al ternator-
compressor bel t.
(A)
from the al ternator
( B) ,
and di sconnect BLK wi r e f r om t he al t er nat or B
t er mi nal
( C) .
4.
I x 1. 25 mm
1 2 N m
(1. 2
kgf . m,
I tbf.ft)
4-26
5. Remove the mounti ng bol ts, then remove the
al ternator.
10 x 1. 25 mm
10 x 1. 25 mm
44 N m {4. 5 kgf m, 33l bf . f t }
Instal l the al ternator and al ternator-compressor
bel t i n the reverse order of removal
Connect the posi ti ve cabl e and negati ve cabl e to
the battery.
Enter the anti -theft code for the radi o, then enter
Set the cl ock.
Perform the engi ne control modul e
(ECl \i l )
i dl e l earn
8.
9.
7.
10.
44 N. m 14. 5 kgf . m, 33l bf . f t )
Auto-Tensioner Inspection/Replacement
1 . Check whether there i s a change i n the
posi ti on of
the auto-tensi oner before starti ng the engi ne and
after starti ng the engi ne, l f there i s a change i n the
posi ti on,
repl ace the auto-tensi oner.
Check for abnormal noi se from the tensi oner
pul l ey.
l f abnormal noi se i s heard, remove the auto-
tensi oner and repl ace the tensi oner
pul l ey.
Turn off the engi ne. Move the auto-tensi oner
(A)
wi th the bel t tensi oner rel ease tool to rel i eve
tensi on from the al ternator-compressor bel t
(B),
then remove the bel t.
4. Attach a torque wrench
(A)
to the
pul l ey bol t.
Measur e t he t or que on t he t ensi oner i nt er nal spr i ng
wi th movi ng the torque wrench i n the di recti on
shown. l f the measurement i s l ess than the
speci fi ed val ue, repl ace the auto-tensi oner.
Specified Torque: 26.2 N.m
(2.67
kgt.m,
19.3 tbt.ftl
Move the auto-tensi oner wi thi n i ts l i mi t wi th the
bel t tensi on rel ease tool i n the di recti on shown,
check that the tensi oner moves smoothl y and check
for abnormal noi se whi l e movi ng the tensi oner. l f
the tensi oner does not move smoothl V or there i s
abnormal noi se, repl ace the autc-tensi oner.
(cont' d)
4-27
Charging System
Auto-Tensioner Inspection/Replacement
(cont'dl
6. Remove the auto-tensi oner.
8 x 1. 25 mm
8 x 1. 25 mm
22 N.m {2.2 kgf.m, 16lbl'ft)
22 N.m (2.2
kgt.m, 16l bf ftl
7. l f necessary. to remove the pul l ey
bol t, secure the
auto-tensi oner i n a bench vi se wi th soft
j aws.
To
prevent
damage to the tensi oner, al ways use soft
j aws
or equi val ent materi al s between the tensi oner
and t he vi se.
4-28
\.
8. Remove the
pul l ey
bol t
(l eft-hand
threads), and
repl ace the tensi oner
pul l ey,
(i 1. 3
kgf . m. 31 l bl . f t l
Alternator Overhaul
Exploded View
STATOR
DRIVE.END COVER
BEARING
RETAINER
, \
FRONT BEARING
7 \ /
( - " \ I
\ \ i
(,D
GJ_ |
!0ii^>
*-!/
|
u/
//
s*
''-:t
l/
i
_ \ i i
+
\ \:iii
\ \
-"..-
\
-\\-
'sraroa
\
Xi.Altfi""
-
'--.-
-
..
IBt9uo*
BRUSH HOLDER
PULLEY LOCKNUT
l 11N. m 111. 3 kgt . m,
81.7 lbf.ftl
SPACER RING
TERMINAL PLATE
INSULATOR
' -.
.
..
.-.BUSH
RECTIFIER
ASSEMBLY
BRUSH HOLDER
INSULATOR
REAR BEARING
q
Q9 r:
{ , \
,''...lp
TERMINAL
INSULATOR //
(cont' d)
'sl:'d
J.F^FI,
,t'.+
REAR HOUSING
4-29
END COVER
Charging System
Alternator Overhaul
(cont'd)
Special Tools Required
.
Dri ver 07749-0010000
.
Attachment, 52 x 55 mm 07746-0010400
NOTE: Refer to the Expl oded Vi ew as needed duri ng
t hi s
pr ocedur e.
1. Test the al ternator and regul ator before you
remove them
(see page 4-22).
2. Remove the al ternator
(see page 4-26).
3. l f the front beari ng needs repl aci ng, remove the
pul l ey
l ocknut wi th a 10 mm wrench
(A)
and a
22 mm wrench
(B).
l f necessary, use an i mpact
wrencn.
Remove the three fl ange nuts
(A)
and the screw
(B)
from the al ternator, then remove the
pl ate
termi nal
1C) _
a."8
g
-------.....---a
t '
4-30
5. Remove the washer nut
(A)
and i nsul ator
(B)
from
the
"B"
termi nal , then remove the end cover
(C)
and dust seal
( D) .
a-9
6. Remove the brush hol der.
@
E
6:Or
d l
r[,F
7. Remove the vol tage regul ator.
A
B o
/ \ l
JThJF.
@
t g
R:i-..
/rss56\
(Y'W-s\
PH]{{]d
I
I l l l
l / l r I
\n""^- -/
\!)Lbl
8. Remove the four screws
(A),
then remove the
recti fi er
(B)
and rubber seal
(C).
10. Remove the four i nsul ators
(A),
rear
and washer
( C) .
housi ng
( B) ,
^4u
(cont' d)
4-31
Charging System
Alternator Overhaul
(cont'dl
11.
(l f you are not repl aci ng the front beari ng and/or
rear beari ng, go
to step 18). Remove the rotorfrom
the stator dri ve end housi no.
Inspect the rotor shaft for gal l i ng,
and i nspect the
beari ng
j ournal
surface i n the stator housi ng for
sei zure marks.
.
l f ei therthe rotor or stator housi ng i s damaged,
repl ace the al ternator.
.
l f both the rotorand the stator housi ng are OK,
go
to step 13.
Remove the rear beari ng usi ng a
pul l er
as shown.
12.
4-32
14. Wi th a hammer and commerci al l y avai l abl e tool s
shown, i nstal l a new rear beari ng on the rotor shaft.
' 15.
Remove the front beari ng retai ner pl ate,
' 16.
Supportthe stator housi ng i n a vi se, and dri ve out
the front beari ng wi th a brass dri ft
(A)
and hammer.
Wi th a hammer and the speci al tool s, i nstal l a
front beari ng i n the stator housi ng.
17.
07749-0010000
077i16-0010iO0
Rectifier Test
18. Check for conti nui ty i n each di recti on, between the
B termi nal and P termi nal s, and between the E
t er mi nal and P t er mi nal s of each di ode
pai r ,
Al l di odes shoul d have conti nui ty i n onl y one
di recti on. Because the recti fi er di odes are desi gned
to al l ow current to
pass
i n one di recti on, and the
recti fi er i s made up of ei ght di odes
(four pai rs). you
must test each di ode i n both di recti ons for
conti nui ty wi th an ohmmeter that has di ode
checki ng capabi l i ty: a total of 16 checks.
.
l f any di ode i s faul ty, repl ace the recti fi er
assembl y. { Di odes ar e not avai l abl e separ at el y. )
.
l f al l t he di odes ar e OK,
got o st ep 19.
(cont' d)
P,
P,
P]
P.
^ ^ \ Y F
,
'-fd\
t'
'
4-33
Charging System
Alternator Overhaul
(cont'd)
Alternator Brush Inspection
19. Measure the l ength of both brushes
(A)
wi th a
ver ni er cal i per
( B) .
.
l f ei ther brush i s shorter than the servi ce l i mi t,
repl ace the brush assembl y.
.
l f brush l ength i s OK, goto
step 20.
Alternator Brush Length:
Sl andard
{New): 10.5 mm
{0.41 i n.}
Servi ce Li mi l : 1.5 mm
{0.06 i n.l
Rotor Sl i p Ri ng Test
20. Check that there i s conti nui ty between the sl i p ri ngs
(A).
.
l fthere i s conti nui ty, go to step 21.
.
l f there i s no conti nui ty, repl acethe al ternator.
Then check that there i s no conti nui ty between
each sl i p ri ng and the rotor
(B)
and the rotor shaft
{c).
.
l f there i s no conti nui ty, goto
step 22.
.
l f there i s conti nui ty, repl ace the al ternator.
21.
4-34
Stator Test
22. Check that there i s conti nui ty between each pai r
of
l eads
(A).
.
l f there i s conti nui ty, go to step 23.
.
l fthere i s no conti nui ty. repl ace the al ternator.
Check for no conti nui ty between each l ead and the
coi l core
(B).
.
l f there i s no conti nui ty, gol o
step 24.
.
l f there i s conti nui ty, repl ace the al ternator.
Reassembl e the al ternal or i n reverse order of
di sassembl y, and note these i tems:
.
Be careful not to get any grease
or oi l on the sl i p
r i ngs.
.
l f you removed the pul l ey,
ti ghten i ts l ocknutto
1 1 1 N. m
( 1
1. 3 kgf m, 81. 7 l bf . f t ) when you
rei nstal l i t.
24.
I
Cruise Control
CRUISE CONTROL
INDICATOR LIGHT
BRAKE PEDAL POSITION SWITCH
Test , page 4 47
Adj ust ment ,
page 19' 6
Test , page 4 42
Bepl acement , page 4-42
CONTROL SET/RESUME SWITCH
ACTUATOR CABLE
Adj ust ment ,
page 4-46
Bepi acement ,
page 4-45
CRUISE CONTROL MAIN SWITCH
Test, page 4 40
Repl acement,
page 4-41
CRUI SE CONTROL UNI T
I nput Test , page 4 38
CRUISE CONTROL ACTUATOR
Test, page 4 43
Repl acement, page 4 44
4-35
Cruise Control
Ci rcui t Di agram
I
I
I
A
lliffi*
T
BmlY$
I
I
V
I*,
r
cnu$ coMtot i ir $[rdr
rG BUrcSW mAxtSW MA SYr
cxutsE @flxo( uul
MoroB loloR acruAToi
otfN cr05r cl,uTor cnustm s|tooilftB ctu.Totsw crs
4-36
Symptom Troubl eshooti ng Index
NOTE:
'
The number s i n t he t abl e show t he t r oubl eshoot i ng sequence.
.
Before troubl eshooti ng,
-
check that the speedometer works
properl y.
-
checkt he No. 23
( 10
A) and No. 6
( 15
A) f uses i n t he under - dash f use/ r el ay box, and No. 47
( 10
AX No. 47
( 15
A) ) f use
i n t he mai n under - hood f use/ r el ay box.
check t hat t he hor n sounds.
-
check the tachometer to see i f i t works
properl y.
Crui se control cannot be set. 1. Check mai n swi tch
(see page 4-41 )
.
Poor gr ound: G 101
.
Open ci rcui t, l oose
2. Check SET/RESUME swi tch {see
page 4-42)
3. Test brake
pedal posi ti on swi tch
(see page 4-47) and or di sconnected
check i ts adj ustment
(see page 12-4). termi nal s; BLKryEL,
4. Test cl utch
(see page 4-47) and LT GRN, LT GRN/
check i t s adl ust ment
( see page 12- 4) . RED, GRY, ORN,
WHT/BLK
5. Check cr ui e 4 -
Cr ui se cont r ol can be set , but
i ndi cat or l i ght does not go on.
Cr ui se speed i s not i ceabl y
hi gher or l ower t han what
was sel .
Excessi ve overshooti ng or 1. Check crui se control actuator and cabl e adj ustment
undershooti ng when tryi ng to 2.
(see page 4' 46)
9qt
speqd]-, Check crui se control uni t {see
page 4-
SDeed fl uctuates on a fl at
r
1. Check crui se control actuator and cabl e adj ustment
road wi th crui se control set. 2.
(see page 4 46)
Check uni t
(see
oaqe 4'
Vehi cl e does not decel erate
' 1.
Check SET/RESUl vl E swi tch
(see page 4-42)
or accel erate accordi ngl y 2. Check crui se control uni t
(see page 4-38)
when SET/RESUME button i s
pushed.
Set speed does not cancel
when brake pedal i s pressed.
Set speed does not cancel
when cl ut ch pedal i s pr essed.
Poor gr ound: G501
Open ci r cui t . l oose
or di sconnected
t er mi nal sr YEL,
LT GRN
1 , Check di mmi ng ci rcui t i n gauge (see page 22' 47)
2. Check crui se control uni t {see
page 4-38}
1. Check crui se control actuator and cabl e adj ustment
2.
(see page 4-46)
Check crui se control uni t
(see
Daqe 4-
Open ci rcui t, l oose or
di sconnected
t er mi nal s: LT GRN/
1. Test brake
pedal posi ti on
swi tch
(see page 4-47) and
check i t' s adj ustment
(see page 12-4).
2. Check crui se control uni t
(see paqe
4-38
1. Test cl ut ch pedal posi t i on swi t ch
( see page 4' 47) and
l Shor t t o
gr ound i n
2. Check cr ui se cont r ol uni t .
check i ts adi ustment
(see page 12-4).
i
the PNK wi re
di sconnected
termi nal s, short to
not cancel 1. Check mai n swi t ch
( see page
when mai n swi tch i s pushed 2. Check crui se control uni t
(see page 4-38)
1. Check SE l / HbSUME swr t ch
( see page 4-
2. Check crui se cont rol uni t
(see page 4-38) di sconnected
t er mi nal s: LT GRN/
Bt K
nor resume
when RESUME but t on i s
pushed (wi th
mai n swi tch on,
and set speed temporari l y
cancel l ed by pressi ng the
I I
: ' 02- 03 model s
4-37
Gruise Gontrol
Cruise Control Unit Input Test
SRS components are l ocated i n thi s area, revi ew the SRS component l ocati ons, precauti ons,
and
procedures i n the
SRS secti on
(24)
before performi ng repai rs or servi ce.
1. Remove t he knee bol st er under t he st eer i ng col umn.
2. Di sconnect t he l 4Pconnect or f r om t hecr ui se cont r ol uni t .
3. Inspect the connector and connector termi nal s to be sure they are maki ng good
contact.
4. l f the termi nal s are bent, l oose, orcorroded, repai rthem as necessary, and recheckthesystem.
5. Perform the fol l owi ng i nput test, at the 14P connector.
. l f at est i ndi cat esapr obl em, f i ndandcor r ect t hecause, t henr echeckt hesyst em.
.
l f al l the tests prove OK, check the crui se control actuator operati on and adj ust the actuator cabl e.
CRUiSE CONTBOL UNIT CONNECTOR
(14PI
\,
l
I
Wi r esr de of f emal e t er mr na s
Cavity Wire color Test condition Test: Desired result Possible cause if result is not
obtained
1 BRN,ryVHTConnect to termi nal 4
( BLf i EL) wi t h
a
j umper
wi r e, and
turn i gni ti on swi tch
on.
The magneti c cl utch shoul d
cl i ck and t he out put l i nk shoul d
be l ocked.
Faul ty actuator
Poor gr ound ( G301)
An open i n the wi re
2 GRY l gni t i on swi t ch ON
( l l ) ,
mai n swi t ch ON
and brake
pedal
rel eased
Check for vol tage to ground:
Ther e shoul d be 0 V wi t h t he
brake pedal pressed. and there
shoul d be battery vol tage wi th
the brake
pedal rel eased.
Faul ty brake swi tch
Faul ty mai n swi tch
Bl own No. 47
( 10
A)
(
No. 47
( 15
A)
)
f use i n t he mai n
under-hood fuse/rel av box
3 BLK U nder al l condi t i ons Check for conti nui ty to ground:
There shoul d be conti nui ty.
Poor ground (G402)
4 BLKI/EL l gni ti on swi tch ON
( l l )
There shoul d be battery vol tage.
Bl own No. 47
( 10
A)
(
No. 47
( 15A)
) f use i n t he mai n
under-dash f use/rel ay box
An oDen i n t he wi r e
5 WHT/BLK Wi th brake pedal
pressed
and rel eased
Check f or vol t age t o gr ound:
.
Bl ownNo. 4T{ 10A)
( No. 47
Ther eshoul d be bat t er y vol t age
( 15A)
) f use i nt he mai n
wi th the brake
pedal pressed,
under-hood fuse/rel ay box
and there shoul d be 0 V wi th the
.
Faul ty brake swi tch
brake Dedal rel eased.
.
An oDen i n the wi re
: ' 02- 03 model s
4-38
Cavity Wire color Test condition Test: Desired result Possible cause it result is not
obtained
6 LT GRN/
RED
l gni t i on swi t ch ON
( l l ) ,
mai n swi t ch ON
and SET button
DUSneO
When t est i ng t er mi nal No. 6,
there shoul d be no vol tage on
t er mi nal No. 7.
When t est i ng t er mi nal No. 7,
there shoul d be no vol tage on
t er mi nal No. 6.
Bl own No. 47
(10
A)
(
No. 47
( 15
A) )
f use i n t he mai n
Faul t y hor n r el ay
Faul ty sevresume swi tch
Faul t y cabl e r eel
1 LT GRN/
BLK
l gni ti on swi tch ON
( l l ) ,
mai n swi t ch ON
and RESUME button
pusneo
9 BRN Connect the BRN
t er mi nal t o t er mi nal
4 {BLK,/YEL) wi th a
j umper
wi r e.
Connect the BRN/
BLK t er mi nal t o body
gr ound. Tur n t he
i gni ti on swi tch ON
{ } .
Check the actuator motor: You
shoul d be abl e t o hear i t r un.
Faul ty actuator
An open i n t he wi r e 1 l BR N/BLK
1 0 B LUIVE L l gni ti on swi tch ON
{ l l ) , at t ach t o gr ound.
Cr ui se i ndi cat or l i ght shoul d
come on.
Bl own No. 5 { 7. 5 A) f use i n t he
under-dash fuse/rel ay box
Bl own crui se control i ndi cator
Faul ty crui se control i ndi cator
ci r cui t i n gauge assembl y
An ooen i n t he wi r e
' t2
WHT/BLK Rai se the rear of
vehi cl e, and shi f t t o
Neut r al . l gni t i on
swi tch ON
(
l l ), mai n
swi tch ON and rotate
one r ear wheel whi l e
hol di no t he ot her
Check vol tage between No. 12
( +) and
No. 3
(
) t er mi nal s :
Ther e shoul d be 0 V and about
5 V or battery vol tage
al ternatel y.
Faul ty vehi cl e speed sensor
Faul ty speedometer ci rcui t i n
t he gauge assembl y
An open i n t he wi r e
1 3 LT GRN l gni ti on swi tch ON
( l l )
and mai n swi t ch
ON
Bl own No. 47
( 10
A)
(
No. 47
( 15A)
) f use i n t he under - dash
fuse/rel ay box
Faul ty mai n swi tch
1 4 PNK Cl utch pedal pressed
and r el eased
Check for conti nui ty to ground:
There shoul d be no conti nui ty
wi th the cl utch pedal pressed,
and there shoul d be conti nui ty
wi th the cl utch oedal rel eased.
Faul ty cl utch swi tch
Mi sadj usted cl utch
pedal
posi t i on
swi l ch i nst al l at i on
: ' 02- 03 model s
6. l f any test i ndi cates a
probl em,fi nd
and correct the cause, then recheckthe system. l f al l the i nput tests
prove OK,
the control uni t may be faul ty. Substi tute a known-good crui se control uni t and reset. l f the system works properl y,
r epl ace t he cr ui se cont r ol uni t .
4-39
Cruise Gontrol
Main Switch Test
1. Car ef ul l y
pr y
t he cr ui se cont r ol mai nswi t chout of
t he i nst r ument panel , t hen di sconnect t he
connector from the swi tch.
i ,
l
2. Check for conti nui ty between termi nal s No. 6 and
No. 1, and between termi nal s No. 6 and No. 5 on
the swi tch. There shoul d be conti nui ty when the
swi tch i s pushed. and no conti nui ty when the
swi tch i s pushed agai n.
CRUISE CONTROL MAIN
SWITCH CONNECTOR
Termi nal si de of mal e t ermi nal
4-40
3.
5.
Check for conti nui ty betl veen the No.2 and No.3
t er mi nal s. Ther e shoul d be cont i nui t y.
l f a fai l ure occurs between termi nal s No. 6 and
No. 1, repl ace the crui se control mai n swi tch.
l f a fai l ure occurs between termi nal s No. 6 and
No. 5, and between the No. 2 and No. 3, check the
crui se control mai n swi tch i ndi cator and
i l l umi nat i on
( see page 4- 41) .
Main Switch/lndicator/lllumination
Test
( l l ) .
Tur n t he l i ght i ng
swi tch and the crui se control mai n swi tch {A) ON.
Check t hat t he i l l umi nat i on i ndi cat or
( B)
and t he
i ndi cator l i ght
(C)
i n the crui se control mai n swi tch
come on.
l f the i ndi cator does not come on. remove the
swi tch and repl ace the bul b.
l f the i ndi cator does not come on after the bul b has
been repl aced, repl ace the crui se control mai n
swi tch.
Mai n Swi tch/l ndi cator Bul b
Replacement
1. Careful l y
pry the crui se control mai nswi tch(A) out
of the i nstrument oanel , then di sconnect the
connector from the swi tch.
Repl ace the i ndi cator bul b
(B)
or the swi tch, as
need.
4-41
Gruise Control
Set/Resume Switch Test
1. Remove the two screws securi ng the sevresume
swi tch, then remove the swi tch.
i
. : -
SET/RESUME SWITCH CONNECTOR
2 3 4 5
Ter mi nal si de of f emal e t er mi nal s
Di sconnect the connector from the swi tch.
Check the set swi tch for conti nui ty between the
No. 3 and No. 5 termi nal s of the connector. There
shoul d be conti nui ty whi l e pressi ng the swi tch
down, and no conti nui ty when the swi tch rel eased.
Check the resume swi tch for conti nui ty between
t he No. 1 and No. 3 t er mi nal s of t he connect or .
Ther e shoul d be cont i nui t y whi l e
pr essi ng t he
swi tch down, and no conti nui ty when the swi tch
reteaseo.
l f ei ther swi tch i s faul ty, repl ace the swi tch
assemot y.
l f swi tch i s OK, but swi tch fai l ure i s occurred on the
crui se control uni t i nput test, check and repai r the
wi re harness on the swi tch ci rcui t.
6.
4-42
Set/Resume Switch Replacement
1 . Remove the two screws securi ng the seVresume
swi tch, then remove the swi tch.
Di sconnect the connector from the swi tch.
Repl ace the swi tch.
\l
I
Cruise Gontrol Actuator Test
1. Di sconnect the 4P connector from the crui se
control actuator.
Remove the actual or cover.
Connect battery power to the No. 2 termi nal of the
4P connector, and connect
ground to the No. 1
t er mi nal .
Check the magneti c cl utch for proper engagement.
A cl i cki ng sound shoul d be heard and the output
l l nkage shoul d be l ocked.
l f the output l i nkage i s not l ocked, repl ace the
crui se control actuator assembl y.
t . Wi th
power
and
ground
sl i l l connected as i n step 3,
connect battery
power
to the No. 4 termi nal and
ground to No. 3 termi nal , and check that the output
l i nkage starts to turn from ful l cl osed posi ti on and
stops at ful l opened
posi ti on
by the motor i n the
actuator.
Reverse
power
and ground at connector termi nal s,
No. 4 and No. 3, and check that the output l i nkage
reverses and stops at the ful l cl osed
posi ti on.
7.
TRAVEL
l f the output l i nkage moves sl uggi shl y, or the motor
does not operate
properl y,
repl ace the crui se
control actuator assembl v.
4-43
Cruise Gontrol
Crui se Control Actuator Repl acement
1 . Remove the actuator cover. and di sconnect the 4P
connector from the crui se control actuator.
Di sconnect the actuator cabl e end
(A)
from the
out put l i nkage
( B) .
and r emove l he cabl e
( C)
f r om
the crui se control actuator.
B
4-44
3. Remove the crui se control actuator assembl y.
{./3;k?#ff'ksr.m.
7.2 rbr.ft r
5.
Reol ace the actuator, and i nstal l the new crui se
control actuator i n the reverse order of removal .
Adj ust the actuator cabl e on the crui se control
actuator si de
(see page 4-46).
1 .
Actuator Gable Replacement
Remove the actuator cover, and di sconnect the 4P
connecl or from the crui se control actuator.
Di sconnect the actuator cabl e end
(A),
and remove
the cabl e 1B) from the crui se control actuator.
3. Remove the accel erator pedal assembl y.
6 x 1 . 0 mm
13 N. m
(1. 3
kgf . m,
9.4 tbf.ftl
4. Di sconnect the actuator cabl e end
(A)
from the arm
(B)
on the accel erator pedal assembl y {C).
Repl ace the actuator cabl e, and i nstal l the new
cabl e i n the reverse order of removal .
Adj ust the actuator cabl e on the crui se control
actuator si de
(see page
4-46).
4-45
i
Cruise Control
2.
Actuator Cable Adjustment
1 . Hol d the cabl e sheath, removi ng al l sl ack from the
throttl e cabl e.
Turn the adj usti ng nut
(A)
unti l i t i s 3 mm
(1/8
i n, )
away from the throttl e cabl e bracket,
3 mm { 1/ 8 i n. }
N. m
(1. 0
kgf m,
tbt.ft)
\
B
9.8
7.2
3. Ti ghten the l ocknut
(B).
The throttl e cabl e defl ecti on
shoul d now be 4 6 mm
( 0. 16
0. 24 i n. ) .
Remove the actuator cover, then di sconnect the
actuator cabl e end from the crui se control actuator.
4-46
6.
5. Turn the adj usti ng nut {A) unti l i t i s I mm
(0.35
i n.)
away from l he actuator cabl e bracket when the
throftl e l i nkage starts open.
9 mm
{0. 35
i n. )
Pul l the cabl e so that the adj usti ng nut
(A)
the bracket, and ti ghten the l ocknut
(B).
touches
Veri fy that the throttl e l i nkage starts open when the
actuator cabl e i s
pul l ed
9 mm
(0.35
i n.) di stance
from the starti ng poi nt by rotati ng the actuator
l i nkaoe.
7.
Clutch Pedal Position Switch Test
1. Di sconnect the connector from the cl utch Dedal
Dosi ti on swi tch, then remove the swi tch.
Checkthe cl utch Dedal oosi ti on swi tch connector
termi nal s for conti nui ty. There shoul d be conti nui ty
between the termi nal s wi th the button
(A)
rel eased,
and there shoul d be conti nui ty wi th the button
pressed.
CLUTCH PEDAI- POSITION SWITCH CONNECTOR
Ter mi nal si de of mal e t er mi nal s
l f the cl utch pedal posi ti on swi tch i s faul ty, repl ace
rt.
Instal l the cl utch pedal posi ti on
swi tch. and adj ust i t
(see page l 2-4).
Brake Pedal Position Switch Test
1. Di sconnectthe brake
pedal posi ti on
swi tch
connector, and remove the swi tch.
2. Check for conti nui ty between the No. 1 and the
No. 4 termi nal s of the brake
connector. There shoul d be conti nui ty when the
button
(A)
i s pressed.
BRAKE PEDAL POSITION SWITCH CONNECTOR
t----r------l
l l r | 2 l l
I I
t---T---' tl
l l
3 4
) l
I
L_____r_______r
I
Termi nal si de of mal e t ermi nal s
3. Check for conti nui ty between the No. 2 and the
No. 3 termi nal s. There shoul d be conti nui ty when
the button i s rel eased.
4. l f the brake pedal posi ti on
swi tch i s faul ty, repl ace
rt.
5. Instal l the brake pedal posi ti on swi tch, and adj ust i t
(see page 19-6).
4-47
Engi ne Assembl y
Engi ne Removal
NOTE:
.
Use fender covers to avoi d damagi ng
pai nted
surfaces.
.
To avoi d damage, unpl ug the wi ri ng connectors
careful l y whi l e hol di ng the connector
porti on.
.
Mark al l wi ri ng and hoses to avoi d mi sconnecti on.
Al so, be sure that they do not contact other wi ri ng or
hoses, or i nterfere wi th other
parts.
1. Remove the hood support rod from the dri ver' s
si de of the car, then use i t as shown to fi x the hood
i n a verti cal posi ti on.
preset buttons.
Di sconnect the negati ve cabl e from the battery fi rst,
posi ti ve cabl e.
Remove the battery.
Remove the transmi ssi on
(see page
' 13-5).
5-2
6. Di sconectthe engi ne control modul e
(ECM)
connectors
(A)
from the EcM.
. 11
1. Di sconnect the mai n wi re harness connector
(B).
Remove the vacuum tank.
9. Remove the throttl e cabl e
(A)
by l ooseni ng the
l ocknut
(B),
then sl i ppi ng the cabl e end out of the
accel erator l i nkage. Take care not to bend the cabl e
when removi ng i t. Al ways repl ace any ki nked cabl e
wi th a new one.
Remove the four bol ts
(A)
securi ng the el ectri cal
power
steeri ng
(EPS)
control uni t
(B).
10.
1 1. Remove the battery cabl e
(A)
from the mai n
under-hood fuse/rel ay box, then remove the
harness cl amos
(B).
Remove the banery cabl e
(A)
from the auxi l i ary
under-hood fuse box, and remove the
ground
cabl e
( B)
and har ness cl amps
( C) .
13. Remove the grommet (D),
then
pul l
out the Ecfvl
connectors.
(cont' d)
5-3
Engine Assembly
Engine Removal
(cont'dl
Rel i eve the fuel pressure (see page 11-105).
Remove the fuel feed hose
(A),
fuel return hose
(B)
and brake booster vacuum hose
(C).
Remove the evaporati ve emi ssi on
(EVAP)
cani ster
nose.
14.
t 5 .
16.
5-4
!
17. Remove the two bol ts securi ng the engi ne stop
bracket.
18.
19.
20.
21.
22.
Remove the radi ator cap.
Rai se the hoi st to ful l hei ght.
Remove the front ti res/wheel s.
Loosen the drai n pl ug i n the radi ator, and drai n the
engi ne cool ant
(see page 10-8).
Dr ai n t he engi ne oi l . Rei nst al l t he dr ai n bol t usi ng a
new washer {see
page
8-5).
'1
23. Remove the engi ne stop bracket cushi on
(A),
then
remove the engi ne stop bracket
(B).
24. Lower the hoi st.
25. Remove the heater hoses
(A)
and l ower radi ator
hose
( B) .
rl\l
*----/-,:'
;
(cont' d)
5-5
Engine Assembly
Engine Removal
(cont'd)
Attach the chai n hoi st to the engi ne as shown.
Take care not to damage the VTEC sol enoi d val ve.
21.
5-6
29.
28. Remove the support nut from the l eft si de engi ne
mount bracket.
Remove the support nut
(A)
and four mounti ng
bol ts
(B),
then remove the ri ght si de engi ne mount
bracket {C).
Check that the engi ne i s compl etel y free of vacuum
hoses, fuel and cool ant hoses, and el ectri cal wi ri ng.
Sl owl y rai se the engi ne about 150 mm
(6
i n.).
Check once agai n that al l hoses and wi res are
di sconnected from the engi ne.
Rai se the engi ne al l the way, and remove i t from
the vehi cl e.
30.
3 1 .
Engi ne Instal l ati on
1. Instal l the accessory brackets, and ti ghten thei r bol ts to the speci fi ed torques.
8 x 1 .25 mm
22 N.m
12.2
kgt.m, 16lbt.ftl
,l
10 x 1. 25 mm
i*il N.m
14.5 kgf.m,33 lbf.ftl
10 x 1. 25 mm
38 N. m
(3.9
kgf.m,28 lbt.ftl
Green bol t s.
(cont' d)
5-7
Engine Assembly
Engine Installation
(cont'd)
2. Instal l the engi ne i nto
posi ti on
i n the vehi cl e.
Rei nstal l the mounti ng bol ts/support nuts i n
the sequence gi ven. Fai l ure to fol l ow thi s
seouence mav cause excessi ve noi se and
vi brati on, and reduce bushi ng l i fe.
3. Instal l the ri ght si de engi ne mount bracket, then
ti ghten the bol ts and nut i n the numbered sequence
shown.
10 x 1. 25 mm
38 N.m
{3.9 ksf.m,28l bt.ft)
Yel l ow bol ts.
tbt
/b
5-8
4. Ti ghten the support nut on the l eft si de engi ne
mount bracket.
/ 12
x 1. 25 rnf i
/ 54N m
,
y'/
15.5 ksrni, a0
'}t.ttl
..i:@
5. I nst al l t he upper r adi at or hose.
6. l nstal l the heater hoses
(A)
and l ower radi ator hose
( B) .
Rai se the hoi st to ful l hei ght.
Instal l the engi ne stop bracket
(A),
then i nstal l the
engi ne stop bracket cushi on
(B).
8 x 1. 25 mm
22 N. m 12. 2 kgf . m, 16l bf . f t l
1 .
8.
10.
1 1 .
Instal l the front ti res/wheel s.
Lower the hoi st.
Ti ghten the two bol ts securi ng the engi ne stop
bracket.
12. Instal l the evaporati ve emi ssi on
(EVAP)
cani ster
hose.
" f f i t
&
\${qry
[ . \
-
L I
{cont' d)
5-9
Engi ne Assembl y
Engi ne Instal l ati on
(cont' dl
Instal l the brake booster vacuum hose
(A),
fuel
return hose
(B)
and fuel feed hose
(C),
usi ng new
washers
(D).
14. Push the engi ne control modul e {ECM) connectors
through the bul khead, then i nstal l the grommet (A).
Instal l the battery cabl e
(B)
on the auxi l i ary under-
hood fuse box. Instal l the ground cabl e
(C)
and
har ness cl amps
( D) .
13.
6 x 1 . 0 mm
12 N. m
{r. 2 kgt . m, 8. 7l bf . f t )
5-10
16. Connect the ECM connectors
(A)
andmai nwi re
harness connector
(B),
' 17.
l nstal l the harness cl amps
(A),
then i nstal l the
battery cabl e
(B)
on the mai n under-hood fuse/rel ay
box.
.t
i i
18. I nst al l t he el ect r i cal
power st eer i ng
( EPS) cont r ol
uni t.
6 x 1 . 0 mm
12 N. m
(1. 2 kgf . m, 8. 7 l bf . f t )
19. I nst al l t he vacuum t ank.
6 x 1 . 0 mm
12 N. m
(1. 2
kgf . m, 8. 7 l bf . f t l
,R
l)
,
20. Instal l the throttl e cabl e
(see page 11-125), then
adj ust t he cabl e
( see page 11- 124) .
21. I nst al l t he t r ansmi si on
( see page 13- 66) .
22. Cl ean the battery
posts and cabl e termi nal s wi th
sandpaper, then assembl e them and appl y
grease
to prevent corrosi on.
23. Ref i l l t he engi ne wi t h engi ne oi l
( see page 8- 5) .
24. Refi l l the radi ator wi th engi ne cool ant, and bl eed
ai r from the cool i ng system wi th the heater val ve
open
(see page 10-8).
25. Check that the transmi ssi on shi fts i nto gear
smoothl y.
26. l nspect for fuel l eaks. Turn the i gni ti on swi tch ON
(l l ) (do
not operate the starter) so that the fuel
pump
runs for about 2 seconds and
pressuri zes the fuel
l i ne. Repeat thi s operati on two or three ti mes, then
check for fuel l eakage at any
poi nt i n the fuel l i ne.
27. Perform the engi ne control modul e
(ECM)
i dl e l earn
28. I nspect t he i dl e speed
( see page 1' l - 100) .
29. Inspect the i gni ti on ti mi ng
(see page 4- 18).
30. Enter the anti -theft code for the radi o, then enter
the customer' s radi o stati on
presets.
31. Set t he cl ock.
5- 11
Engi ne Mechani cal
Cylinder Head
Soeci al Tobl s . . . . . . . . . . . . . 6-2
Comoonent Locat i on l ndex . . . . . . . . . . . . . . . . . , , . . . . . . . . . . . . . . . . . . . . . 6-3
DTC Troubl eshoot i ng . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
VTEC Sol enoi d Val ve Test . . . . . . . . . . . . . . . . . 6-9
VTEC Rocker Arms Test . . . . . . . . . . . . . . . . . . . . . 6-10
Val ve Cl earance Adj ust ment . . . . . . . . . . . . . 6-12
Crankshaf t Pul l ey Removal and l nst al l at i on . . . . . . . . . . . . . . 6-14
Cam Chai n Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 15
Cam Chai n I nst al l at i on . . . . . . . . . . . . . . . . . . . . . . . 6- 19
Chai n Case Oi l Seal I nst al l at i on . . . . . . . . 6-24
Cvl i nder Head Removal . . . . . . . . . . . . . . . . . . . . . 6-25
Camshaf t Gear Removal . . . . . . . . . . . . . . . . . . . . 6-3' l
Cyl i nder Head I nspect i on f or Warpage . . . . . . . . . . . . . . . . . . . . . . 6-32
Rocker Arms and Shaf t s Di sassembl y/ Reassembl y . 6-33
Rocker Arms and Shaf t s I nspect i on . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
Camshaf t l nsoect i on . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
Val ves, Spri ngs, and Val ve Seal s Removal . . . . . . . . . . . . . . . . 6-38
Val ve I nspect i on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
Val ve St em-t o-Gui de Cl earance l nspect i on . . . . . . . . . . . . . . . 6-39
Val ve Gui de Reol acement . . . . . . . . . . . . . . . . . 6-40
Val ve Seat Recondi t i oni ng . . . . . . . . . . . . . . . . 6-42
Val ves, Spri ngs, and Val ve Seal s I nst al l at i on . . . . . . . . . . . . 6-44
Camshaf t Gear I nst al l at i on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45
Cvl i nder Head I nst al l at i on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 45
Cyl i nder Head Cover I nst al l at i on . . . . . . 6-53
Cyl i nder Head
Speci al Tool s
r { l -
- - -
. = r
Ref.No. Tool Number Description Otv
ul
@
@
@
o
@
@' t
!r-J
@-+
@
o
@
@
Cz)
OTHAH-PJ7O,1OB
07JAA-001020A
07JAB-001020A
07JAB-001040A
07LAK-PR30r 00
07NAJ-P07010A
07406-0020201
07406-0070300
07MAJ.PYAO11A
07MAJ-PY40120
OTZAJ.PNAAl OO
o7142.0010100
07746-0010400
07749-0010000
07757-PJ 1010A
Val ve Gui de Reamer , 5. 5 mm
Socket, 19 mm
Hol der Handl e
Hol der Attachment, 50 mm
Gauge Joi nt Adapter
Pressure Gauge Adaptor
AilT Pressure Hose
A"/T Low Pressure Gauge WPanel
Av/T Pressure Hose
,2,210
mm
A,/T Pressure Hose Adaptor
VTEC Ai r Adapter
Val ve Gui de Dri ver, 5.5 mm
Attachment, 52x55 mm
Dri ver
Val ve SDri nq Comoressor Attachment
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
DOWEL PIN
EXHAUST CAMSHAFT
I nspecI ron,
page 6-36
E , "' *o"'
Bl------
RUBBER sEAL
TDC1 SENSOR
o-*' "o
/
t t ^
ts*
ge
RUBBER SEAL
B
DOWEL PIN
INTAKE CAMSHAFT
GEAR
ROCKER ARM
ASSEMBLY
Overhaul ,
page 6-33
l nspecl t on,
page 6-34
EXHAUST CAMSHAFT
GEAR
I nst al l at i on,
page 6-53
'ii'ti'
lS...''.-. i :-=-'J
@,^-r5
\..-:@
i--\_..
s)'.i\
(cont' d)
Cylinder Head
(cont'd)
VALVE KEEPERS
EXHAUST VALVE SEAL
VALVE
EXHAUST VALVE GUIDE
Inspecti on, page
6-39
Repl acement , page
6 40
fr
WASHER
WASHER
]O
EXHAUST VALVE
v"
Removal , page 6-38
Instal l ati on, page
6 44
INTAKE VALVE
Removal , page
6 38
Insl al l ati on, page
6-44
CAM CHAIN
AUTO-TENSIONER
DOWEL PIN
6-4
CAM CHAIN
Removal , page 6-15
I nst al l at i on, page 6-19
CAM CHAI N GUI DE
CHAIN CASE
I CKPI SENSOR
IDLER PULLEY BASE
IDLER PULLEY COLLAR
IDLER PULLEY
PULLEY BOLT
Eepl acement,
page 6-' 14
CRANKSHAFT PULLEY
Repl acement,
page 6-14
CHAIN CASE OIL SEAL
I nst al l at i on,
page 6-24
6-5
Cyl i nder Head
DTC Troubleshooting
DTC P1259: A
probl em
i n t he WEC Oi l
Pressure Swi t ch ci rcui t or VTEC Sol enoi d
Val ve ci rcui t .
Speci al Tool s Bequi red
.
Pressure gauge adaptor 07NAJ-P07010A
.
A,/T l ow pressure gauge W/panel 07406-0070300
.
A' /T pressure
hose 07406-0020201
.
A,/T pressure
hose,2,21Q mm 0T| VIAJ-PY4o11A
.
A,/T pressure
adaptor 07MAJ-PY40120
1. Reset t he engi ne cont r ol modul e( ECM) ( see page
11- 4) .
Check the engi ne oi l l evel , and refi l l i f necessary.
Start the engi ne.
3. Warm up the engi ne to normal operati ng
t emper at ur e
( cool i ng
f an comes on) .
4. Road test the vehi cl e:
Accel erate i n 1st gear
to an engi ne speed over
6,000 rpm. Hol d that engi ne speed for at Ieast 2
seconds. l f DTC P1259 i s not repeated duri ng the
fi rst road l est, repeat thi s test two more ti mes,
l s DTC P 1259 i ndi cated?
YES Go to step 5.
NO l ntermi ttent fai l ure, system i s OK at thi s ti me.
Check for poor
connecti ons or l oose wi res at VTEC
sol enoi d val ve and ECM. I
5. Turn the i gni ti on swi tch OFF.
6-6
6. Di sconnecl the VTEC oi l pressure
swi tch 2P
connector.
7. Check for conti nui ty on the VTEC oi l
pressure
swi tch between the pressure
swi tch 2P connector
t er mi nal s No. I and No. 2.
VTEC OIL PRESSURE SWITCH
2P CONNECTOR
Termi nal si de oJ m4e
I er mt nat s
Is therc conti nui ty?
YES
-
Go to step 8.
NO Repl ace the VTEC oi l
pressure
swi tch.l
( l l ) .
Measure the vol tage between the VTEC oi l
pressure
swi tch harness 2P connector termi nal No.
1 and body ground.
/
r
\----r
r_-_---------t I
\ 2 , / t wM
\---'l
|
{BLU/BLK)
l
A
(v)
I
I
_l_
Wi re si de of femal e
I er mt nat s
l s thete battery vol tage?
YES- Go to step
' 10.
NO- Inspect for an open or short to ground i n the
wi re between the VTEC oi l pressure
swi tch and the
ECM
(C10).
l f the wi re i s OK, substi tute a known-
good ECM and recheck.I
10. Measure vol tage across the VTEC oi l pressure
swi tch harness 2P connector.
VTEC OIL PRESSURE SWITCH
HARNESS 2P CONNECTOR
Wi re si de of femal e termi nal s
l s there battety vol tage?
YES- Go t o st ep 11.
NO--Repai r an open i n the wi re between the VTEC
oi l
pr essur e swi t ch and G101. 1
Di sconnect the VTEC sol enoi d val ve 1P connector.
Check for conti nui ty on the VTEC sol enoi d val ve
between the sol enoi d val ve 1P connector termi nal
and body
ground.
VTEC SOLENOID VALVE
1P CONNECTOR
Termi nal sade of
mal e t er mi nal
l s there 14 30 Q ?
YES Go to step 14.
NO Repl ace the VTEC sol enoi d val ve. I
1 1 .
=-;
14. Remove the VTEC oi l
pressure swi tch
(A)
and
i nst al l t he speci al t ool s as shown, t hen r ei nst al l t he
VTEC oi l
pressure swi tch.
16r
/l ::=' l
,,/ fr
07406-0070300
-
07 406-0020201
ot
OTMAJ- PY4011A
ano
07MAJ- PY40120
07NAJ-P07010A
, . . , ]
1 5 .
{2.2 kgf.m, 16 lbf ft)
Reconnect the VTEC sol enoi d val ve 1P connector
and VTEC oi l
pressure swi tch 2P connector.
Connect a tachometer.
Warm up the engi ne to normal operati ng
t emper at ur e
( cool i ng
f an comes on) .
Check oi l pressure at engi ne speeds of 1,000, 2,000
and 5, 000 r pm. Keep measur i ng t i me as shor t as
possi bl e because t he engi ne i s r unni ng wi t h no
l oad
( l ess
t han 1 mi nut e) .
l s pressure bel ow 49 kPa (0.5 kgf/cnf
,7
psi )?
YES Go to step 19.
NO Inspect the VTEC sol enoi d val ve {see
page 6'
9) . r
Di sconnect the VTEC sol enoi d val ve 1P connector.
Attach the battery
posi ti ve cabl e to the VTEC
sol enoi d val ve t er mi nal .
St an t he engi ne and check oi l pr essur e at an engi ne
speed of 5,000 rpm.
l s pressute above 390 kPa (4.0 kgf/cm'
,
57
psi )?
YES Go to step 23.
NO Inspect the VTEC sol enoi d val ve {see
page 6-
9). r
(cont' d)
18.
t o .
17.
19.
20.
22.
6-7
Gylinder Head
I
I
DTC Troubleshooting
(cont'd)
Wi th the battery posi ti ve
termi nal sti l l connected to
the VTEC sol enoi d val ve, measure vol tage between
C10 and body gr ound.
ECM CONNECTOR C {13P)
VTM {BLU/BLKI
Wl r e si de of f emal et er mi nal s
Isthere battety vol tage above 5,000 rpm?
YES Go to step 24.
NO Repl ace the VTEC pressure
swi tch.l
Di sconnect the battery posi ti ve
cabl e from the
VTEC sol enoi d val ve termi nal .
Check for conti nui ty between the VTEC sol enoi d
val ve harness 1P connector termi nal and the ECM
connect or t er mi nal 812.
VTEC SOLENOID VALVE HARNESS
1P CONNECTOR
ECM CONNECTOR B
(25
PJ
Is there continuity?
YES Go to step 27.
NO Repai r an open i n the wi re between the ECM
(B
12) and VTEC sol enoi d val ve connector.l
24.
25.
26.
6-8
27. Check for conti nui ty between the VTEC sol enoi d
val ve 1P connector termi nal and body ground.
VTEC SOLENOID VALVE HARNESS
1P CONNECTOR
Wi re si de of f emal e
I ermrnal
ls thete continuity?
YES Repai r a short i n the wi re between the ECM
(B
12) and VTEC sol enoi d val ve connector.t
NO Substi tute a known-good ECM and recheck
(see
page 11-5). l f symptom/i ndi cati on goes away,
r epl acet he or i gi nal ECM
( see page
11- 4) . 1
VTEC Solenoid Valve Test
Di sconnect the 1 P connector from the VTEC
sol enoi d val ve.
Measure resi stance between the termi nal and body
gr ound.
Resi stance: 14 30 i )
' 1.
6 x 1 . 0 mm
12 N. m
(1. 2
kgf m. 8. 7 l bf f t l
3. l f the resi stance i s wi thi n speci fi cati ons, remove the
VTEC sol enoi d val ve assembl y
(A)
from the
cyl i nder head, and check the VTEC sol enoi d val ve
fi l ter
(B)
for cl oggi ng. l f there i s cl oggi ng, repl ace
the engi ne oi l fi l ter, VTEC sol enoi d val ve fi l ter, and
t he engi ne oi l .
V
4. l f the fi l ter i s not cl ogged. push the VTEC sol enoi d
val ve wi th your fi nger and check i ts movement.
l f the VTEC sol enoi d val ve i s normal , check the
engi ne oi l pr essur e,
6-9
Gyl i nder Head
WEC Rocker Arms Test
.
Gauge
j oi nt
adapter 07LAK-PR30100
.
WEC ai r adapter 07ZAJ-PNAA100
1. Remove t he cyl i nder head cover .
2. SettheNo. l pi ston
at top dead center
(TDC
) {see
step 2 on
page
6- 12).
3, Move the secondary rocker arm {A} for No. 1
cyl i nder. The secondary rocker arm shoul d move
i ndependentl y of the mi d rocker arm
(B).
.
l f the secondary rockerarm does not move,
remove the mi d, pri mary and secondary rocker
arms as an assembl y, and check that the pi stons
i n the mi d and pri mary rocker arms move
smoothl y.
.
l f any r ocker ar m needs r epl aci ng, r epl acet he
mi d, pri mary
and secondary rocker arms as an
assembl y.
6- 10
7.
Check that the ai r
pressure
on the shop ai r
compressor
gauge i ndi cator i s over 400 kPa
(4
kgfl cm' ,57 psi ). Make sure no water i n the ai r
hose and ai r compressor tank.
Inspect the val ve cl earance
(see page 6-12).
Remove the No. 3 and No. 4 camshaft hol der bol ts,
and i nstal l the VTEC ai r adapters
(A)
fi nger-ti ght.
Instal l the
gauge j oi nt
adapter
(B)
to the i nspecti on
hol e
(C),
then i nstal l the 8 x
' 1.25
mm bol t
(D)
to the
gauge j oi nt
adapter.
Connect the two ai r hoses
(E)
to each VTEC ai r
adapters.
9. Wi th the speci fi ed ai r pressure
appl i ed and the
pi ston at TDC, move the secondary rocker arm
(A).
The mi d rocker arm
(B). pri mary
rocker arm
(C)
and
secondary rocker arm shoul d move together. l f the
three rocker arms do not move together, repl ace
the rocker arms as a set.
Remove the speci al tool s.
Ti ghten the camshaft hol der bol ts to 22 N m
(2.2
kgf.m, 16 l bf.ft).
Instal l the cyl i nder head cover
(see page 6-53).
10.
1 1 .
6- 11
Cyl i nder Head
Valve Clearance Adjustment
NOTE; Adj ust the val ves onl y when the cyl i nder head
temoerature i s l ess than 100' F
(38"C).
1. Remove the cyl i nder head cover.
2. Set the No. 1 oi ston at top dead center
(TDC).
The
TDC marks
(A)
on the cam chai n sprocket shoul d
al i gn wi th the cyl i nder head surface.
Sel ect the correct thi ckness feel er gauge for the
val ves you' re goi ng to check.
Intake: 0.21-0.25 mm {0.008-0.010
i n.}
Exhaust: 0.25-0.29 mm
(0.010-0.011
i n.)
Adiusting screw location:
INTAKE
' . _.
i
1.
- 1
,]
t
. - l
6-12
4. Insert the feel er gauge (A)
between the adj usti ng
screw and the end ofthe val ve stem and sl i de i t
back and f or t h; you shoul d f eel a sl i ght amount of
dr ao.
l f you feel too much or too l i ttl e drag, l oosen the
l ocknut {A), and turn the adj usti ng screw
(B)
unti l
the drag on the feel er gauge i s correct.
A
7 x 0. 75 mm
20 N m {2. 0 kgf . m. 14l bl f t )
Ti ghten the l ocknut and recheck the cl earance.
Repeat the adj ustment, i f necessary.
7. Rotatethe crankshaft 180' cl ockwi se
(camshaft
gears
turn 90' )
Check and. i f necessary, adj ust the val ve cl earance
on No. 3 cyl i nder .
Rotate the crankshaft 180' cl ockwi se
(camshaft
gears
turn 90' )
; . , L
10.Check and, i f necessary, adj usl the val ve cl earance
on No. 4 cvl i nder .
' : :
a l
ir:':/
11. Rotate the crankshaft
' 180' cl ockwi se
(camshaft
gears turn 90")
Check and, i f necessary, adj ust the val ve cl earance
on No. 2 cyl i nder .
l nstal l the cyl i nder head cover
(see page 6-53).
6-13
Cyl i nder Head
Crankshaft Pul l ey Removal and l nstal l ati on
.
Hol der handl e 07JAB- 001020A
.
Hol der attachment, 50 mm 07JAB-0010404
.
Socket, 19 mm 07JAA-0010204
or a commer ci al l y- avai l abl e 19 mm socket
Removal
1. Hol d t he pul l ey wi t h hol der handl e
( A)
and hol der
attachment
(B).
B
07JAB-001040A
07JAA-001020A
( or
Commer ci al l y
avai l abl e)
2. Remove the bol t wi th a heavy duty 19 mm socket
( C)
and br eaker bar .
6- 14
Installation
1. CI ean t he bol t
( A) ,
washer
( B) , pul l ey ( C)
and
crankshaft
(D).
Lubri cate as shown bel ow.
ai: Clean
O: Lubricate
"\
D.
l,
t w \ l l
L- J
\
- J I | \ . J \
t l t \ - }
- : r 5
\ Ll
.
-.,"313....
L
-ri I
- ! at oaaaa
| .\:o
I t
i l
E
2. Instal l the crankshaft pul l ey, and ti ghten the bol t to
245 N.m
(25.0
kgf m, 181 l bf.ft). Do not use an
amoact wrench.
ôooo
Cam Chai n Removal
.
Hol der handl e 07JAB-0010204
.
Hol der attachment, 50 mm 07JAB-0010404
.
Socket, 19 mm 07JAA-0010204
or a commerci al l y avai l abl e 19 mm socket
NOTE:
.
Use fender covers to avoi d damagi ng
pai nted
surfaces.
.
careful l y whi l e hol di ng the connector
porti on.
.
To avoi d damagi ng the cyl i nder head, wai t unti l the
engi ne cool ant temperature drops bel ow I00' F
(38' C)
before l ooseni ng the cyl i nder head bol ts.
.
Mark al l wi ri ng and hoses to avoi d mi sconnecti on.
hoses, or i nterfere wi th other
part.
.
Keep the cam chai n away from magnets. A
magneti zed cam chai n may mi sfi re or cause fal se DTCS.
1. Make sure
you have the anti -theft code for the radi o,
then wri te down the freouenci es for the radi o' s
Dreset buttons.
2. Di sconnect the negati ve cabl e from the banery fi rst.
then di sconnect the Dosi ti ve cabl e.
Drai n the engi ne cool ant
(see page 10-8).
Drai n the engi ne oi l
(see page 8-5).
Di sconnect the ai r control sol enol d val ve connector,
then remove the vacuum hoses and the ai r cl eaner
housi ng/i ntake ai r duct assembl y
(see page
6-25).
4.
6. Remove the vacuum tank.
Loosen the water pump pul l ey bol ts.
(A)
to remove tensi on
from the al ternator-compressor bel t
(B),
then
remove the al ternator-compressor bel t.
7.
(cont' d)
6- 15
)
Cylinder Head
Cam Chain Removal
(cont'dl
9. Remove the water bypass hose
(A),
then remove
the three bol ts
(B)
securi ng the water bypass tube
{c).
10. Remove t he wat er pump pul l ey.
'r',to+
0
n 0 ,
,o od)
6- 16
1 1 .
1 2 .
Remove the auto-tensi oner
(see page 4-27!-
Remove the al ternator {see
page 4-26).
Remove the i dl er pul l ey (A),
then remove the i dl er
pul l ey
base
( B) ,
Remove the throttl e cabl e
(see
step 9 on page 5-3).
Rel i eve fuel pressure (see page 11-105).
Remove the fuel feed hose, fuel return hose and
brake booster vacuum hose
(see
step 9 on
page
6-
Remove the evaporati ve emi ssi on
(EVAP)
cani ster
hose
(see
Remove the bol t securi ng the i ntake mani fol d
bracket, and remove the ai r hose
(see
step 11 on
page 6-26).
Remove the water outl et cover
(see
step 12 on
page
6-261.
Remove the two bol ts securi ng the i ntake mani fol d
bracket, and remove the water bypass hose
(see
step 13 on page 6-271.
' t7
.
' 14.
15.
16,
1 q
20.
18.
21. Remove the engi ne wi re harness connectors and
wi r e har ness cl amps f r om t he cyl i nder head and
i ntake mani fol d.
.
Four fuel i nj ector connectors
.
l ntake ai r temperature
(l AT)
sensorconnector
.
l dl e ai r control
(l AC)
val ve connector
.
Throttl e posi ti on (TP)
sensor connector
.
Mani fol d absol ute
pressure (MAP)
sensor
connecl or
.
Engi ne cool ant temperature
(ECT)sensor
connector
.
Pri mary heated oxygen sensor
(pri mary
HO2S)
connector
.
VTEC sol enoi d val ve connector
.
VTEC pressure swi tch connector
.
Crankshaft
posi ti on (CKP)
sensor connector
22. Remove the four bol ts securi ng the exhaust
mani fol d cover
(see
step 15 on
page 6-271.
23. Remove the heat shi el d
(see
step 16 on
page
6-27).
24. Remove the exhaust mani fol d cover. then remove
the exhaust mani fol d bracket and exhaust mani fol d
{see step 17 on
page
6-28).
25. Remove the di psti ck. Posi ti ve Crankcase Venti l ati on
(PCV)
hose and breather hose {see step 18 on
page
6-28t.
26. Remove the i gni ti on coi l cover,then remove the
i gni ti on coi l s
(see
step 19 on
page
6-28).
27. Remove the cyl i nder head cover
(see
step 21 on
page
6-29).
28. Set t he No. I pi st onat t opdeadcent er ( TDC)
( see
29. Remove the end cover and nozzl e from the cam
chai n auto-tensi oner
(see
step 23 on
page
6-29).
30.
5 t ,
Thread a nut onto the 5 x 0.8 mm bol t, then thread
the bol t i nto the mai ntenance hol e i n the cam chai n
auto-tensi oner
(see
step 24 on
page 6-29).
Turn the bol t cl ockwi se to compress the cam chai n
auto-tensi oner, and l ock the bol t wi th the nut
(see
step 25 on page 6-291.
Remove the cam chai n auto-tensi oner
(see
step 26
on page 6-30).
Loosen the rocker arm adj ustl ng screws
(see
step
27 on
page
6-30).
Remove the camshaft hol ders and camshafts.
Remove the rocker arm assembl y
(see
step 29 on
page 6-30).
Remove the i dl er gear/i dl er gear col l ar/washer
assembl y, Do not drop the washer i nto the chai n
case
(see
Remove the cyl i nder head bol ts
(see
step 31 on
page 6-31). To prevent warpage, unscrew the bol ts
i n sequence 1/3 turn at a ti me; repeat the sequence
unti l al l bol ts are l oosened.
Remove the cyl i nder head.
Remove the oi l pan.
(cont' d)
32.
33.
34.
35.
36.
37.
38.
?q
' l
6-17
Gylinder Head
Gam Chain Removal
(cont'dl
40. Hol d the
pul l ey
wi th hol der handl e
(A)
and hol der
attachment
(B).
07JAB-001040A
c
07JAA-001020A
(or
Commerci al l y-
avai l abl e)
4' t.
42.
Remove the bol t wi th a heavy duty 19 mm
( C)
and br eaker bar .
Remove the chai n case.
6- 18
43. Remove t he oi l
pump
chai n
gui de.
44. Remove t he cam chai n.
Cam Chain Installation
.
Hol der handl e 07JAB-0010204
.
Hol der attachment,50 mm 07JAB-0010404
.
Socket, 19 mm 07JAA-001020A
or a commerci al l y avai l abl e
' 19
mm socket
1. Set the crankshaft sprocket so that the No. 1 pi ston
i s at top dead center
(TDC).
Al i gn the key
(A)
on the
sprocket and crankshaft wi th the poi nter (B)
on the
cvl i nder bl ock.
2. Instal l the cam chai n wi th the col ored pi ece (A)
al i gned wi th the
punch
mark
(B)
on the crankshaft
sDrocKel .
3. I nst al l t he oi l
pump
chai n gui de.
6 x 1 . 0 mm
12 N. m
{1. 2 kgf . m, 8. 7 l bf . f t l
(cont' d)
6-19
Gyl i nder Head
Cam Chai n Instal l ati on
(cont' d)
4. Remove ol d l i qui d gasket from the chai n case
mati ng surfaces, bol ts and bol t hol es,
5. Cl ean and dry the chai n case mati ng surfaces.
6. Appl y l i qui d gasket, part No. 08718-0009, evenl y to
the cyl i nder bl ock mati ng surface of the chai n case
and to the i nner threads of the bol t hol es.
NOTE: Do not i nstal l the parts i f 5 mi nutes or more
have el apsed si nce appl yi ng l i qui d gasket. Instead,
reappl y l i qui d gasket after removi ng ol d resi due.
Appl y l i qui d gasket
al ong the broken l i ne.
I nst al l t he dowel pi ns ( A)
and chai n case
( B)
usi ng a
new O-ri ng
(C).
7.
B
6 x 1 . 0 mm
12 N. m
(1, 2
kgf . m, 8. 7 l bf . f t )
10 x 1. 25 mm
,14
N.m
6-20
9.
10.
Remove ol d l i qui d gasket from the oi l
pan mati ng
surfaces, bol ts and bol t hol es.
Cl ean and dry the oi l
pan mati ng surfaces.
Appl y l i qui d gasket, part No. 08718 0009, evenl y to
the cyl i nder bl ock mati ng surface of the oi l pan and
t o t he i nner t h r eads of t he bol t hol es. I nst al l t he oi l
pan.
have el apsed si nce appl yi ng l i qui d gasket. Instead,
reappl y l i qu i d gasket after removi ng ol d resi due.
Appl y l i qui d gasket
al ong t he br oken l i ne.
Ti ghten the bol ts i n two orthree steps. In the fi nal
step, ti ghten al l bol ts, i n sequence, to 12 N m
( 1. 2
kgf m, 8. 7 l bf . f t ) .
1' t .
12. Cl ean the bol t
(A),
washer
(B), pul l ey (C)and
crankshaft (D).
Lubri cate as shown bel ow.
O: Cl ean
O: Lubricato
"\
--,..,303....
trlilllllTrilrl
l-tft""
i /
B
13.Instal l the crankshaft pul l ey,
and ti ghten the bol t to
245 N.m
(25.0
kgf.m, 181 l bf.ft). Do not use an
i mDact wrench,
07JAB-001040A
07JAA-001020A
-oooo
14. Measure the di ameter of each cyl i nder head bol t at
poi nt
A and poi nt
B
(see
step 1 on page
6-45).
l f ei ther di ameter i s l ess than 1 1.5 mm
(0.45
i n.),
repl ace the cyl i nder head bol t.
15. Cl ean the cyl i nder head and bl ock surfaces.
16. Appl y l i qui d gasket, pan
No. 08718-0009, to the
shaded areas of the cyl i nder head gasket
mati ng
surface of the bl ock and chai n case
(see
step 3 on
page
6-45).
17. Instal l the dowel pi ns
and new cyl i nder head gasket
{see step 4 on page
6-46).
18. Appl y l i qui d gasket. part
No.08718-0009, to the
cyl i nder head mati ng surface ofthe bl ock and chai n
case wi thi n 5 mm from the edge ofthe cyl i nder
head gasket (see
19. l nst al l t he cyl i nder head on t he bl ock.
20. Appl y engi ne oi l to the threads and under the heads
of al l the cyl i nder head bol ts.
2' 1. Ti ghten the cyl i nder head bol ts i n sequence to
29 N.m
(3.0
kgf.m, 22 tbf.ft). Use a beam-type
torque wrench. When usi ng a preset-type
torque
wrench. be sure to ti ghten sl owl y and do not
overti ghten. l f a bol t makes any noi se whi l e you
are
torqui ng i t, l oosen the bol t and reti ghten i t
(see
step
8 on
page
6-46).
22. Ti ghten al l cyl i nder head bol ts i n two steps
(90. per
step). l f you
are usi ng a new cyl i nder head bol t.
ti ghten the bol t an extra 90"
(see
step 9 on page
6-
46) .
23. Ti ghten the 8 mm bol ts to 22 N.m
(2.2
kgf.m,
16 tbf.ft),
24. Make sure the crankshaft pul l ey
i s at TDC
(see
step
11 on page
6-47).
25. Pl ace the i dl er gearrcam
chai n sprocket assembl y
i nto the cyl i nder head
(see
step 12 on page
6-47).
(cont' d)
6-21
Gylinder Head
Cam Chain Installation
(cont'dl
26. Instal l the cam chai n on the sprocketwi th the
punch mark
(A)
al i gned wi th the center of the two
col ored
pi eces (B).
Fi t the cam chai n sprocket assembl y i nto the
cyl i nder head.
Turn the i dl er gear countercl ockwi se to rel i eve cam
chai n free
pl ay,
and check the al i gnment of the TDC
marks
(C)
on the cam chai n sprocket wi th the
cyl i nder head surface. If the cam chai n sprocket i s
not posi ti oned at TDC, remove the assembl y from
the cvl i nder head and reposi ti on the cam chai n to
bri ng the cam chai n sprocket to TDc.
27.
6-22
29. Appl y engi ne oi l to the i dl er gear center bol t
threads. Instal l a new O-ri ng on the bol t.
30. Instal l the washer on the i dl er gear, a nd ti ghten the
i dl er gear center bol t
(see
31. Cl amp the cam chai n auto-tensi oner i n a soft-j awed
vi se
(see
step 17 on
page 6-48),
32. Turn the 5 x 0.8 mm bol t cl ockwi se to compress the
bottom of the auto-tensi oner. then i nsert the set
pi n
(see
step
' 18
on
page 6-48).
33, Remove the 5 x 0.8 mm bol t from the mai ntenance
hol e. l nstal l a new O-ri ng, then i nstal l the nozzl e
and end cover
(see
step 19 on
page 6-48).
34. Instal l the cam chai n auto-tensi oner i n the cyl i nder
head wi th new O-ri ngs
(see
35. Remove the mai ntenance bol t from the cyl i nder
head
(see
step 21 on
page 6-48).
36. Remove the set
pi n from the cam chai n auto-
tensi oner, Rei nstal l the mai ntenance bol t wi th new
washer
(see
step 22 on
page 6-48).
37. I nst al l t he r ocker ar m assembl ! .
38. Check the al i gnment of the TDC marks on the cam
chai n sprocket wi th the cyl i nder head surface
(see
step 23 on
page 6-49).
39. Al i gn the TDC marks on the i ntake camshaft
gear
and the exhaust camshaft
gear, and i nstal l the
camshafts
(see
step 25 on
page
6-49).
40. Appl y engi ne oi l t ot he bol t t hr eads of al l t he
camshaft hol der bol ts.
41. Putthe camshaft hol ders on the cyl i nder head, then
ti ghten al l bol ts to 22 N.m
(2.2
kgf m, 16 l bf.ft)
(see
step 27 on
page
6-49).
42. Make sure the camshaft
gears
are at TDC.
43. Adj ust the val ve cl earance
(see page
6-12).
44. Instal l the cyl i nder head cover
(see page 6-53).
45.
46.
48.
47.
Instal l the exhaust mani fol d usi ng new gaskets and
new sel f-l ocki ng nuts {see step 3' l on
page 6-50).
Instal l the exhaust mani fol d bracket. Make sure the
smooth si des of the washers face the exhaust
mani fol d bracket
(see
step 32 on page
6-50).
Put the exhaust mani fol d cover on the exhaust
ma ni fol d.
Instal l the heat shi el d
(see
step 34 on
page
6-50).
Ti ghten the four bol ts securi ng the exhaust
mani fol d cover
(see
l nstal l the water bypass hose, and ti ghten the two
bol ts securi ng the i ntake mani fol d bracket
(see
step
37 on page
6-51).
Instal l the water outl et cover
(see
step 38 on page
6- 51) .
Instal l the ai r hose. and ti ghten the bol t securi ng
the i ntake mani fol d bracket
(see
step 39 on page 6-
Instal l the evaporati ve emi ssl on
(EVAP)
control
cani ster hose
(see
step 40 on
page
6-52).
Instal l the fuel feed hose, fuel return hose and
brake booster hose
(see
I nst al l t he i dl er pul l ey
base
( A) ,
t hen i nst al l t he i dl er
pul l ey ( B) .
50.
3 t .
52.
53.
54.
55.
10 x 1. 25 mm
44 N. m
{4.s kgf.m, 33 lbf.ft)
' 10
x 1, 25 mm
4il N.m
(4.5
kgf m,
33 tbf.fr)
6 x 1 . 0 mm
12 N. m
11. 2
kgf . m, 8. 7 l bf . f t )
56.
57.
58.
Instal l the al ternator
(see page 4-26).
Instal l the auto-tensi oner {see
page 4-27).
Instal l the water pump pul l ey.
6 x 1 . 0 mm
' 14
N. m
{1. 4 kgf . m,
10 tbt.ft)
59. Instal l the water bypass hose
(A).
and ti ghten the
three bol ts
(B)
securi ng the water bypass tube.
5 x 1 . 0 mm
12 N. m
(1. 2
kgf . m, 8. 7 l bt . f t l
6 x 1 . 0 mm
1 2 N m
{1.2 kgf.m, 8.7 lbf.ft)
(cont' d)
>1r',
-a n)f
o
"o9-,,
5;9il
6-23
Gyl i nder Head
60.
Cam Chai n Instal l ati on
(cont' dl
Instal l the al ternator-compressor bel t.
l nstal l the vacuum tank.
tbf.ft)
Instal l the ai r cl eaner housi ng/i nl ake ai r duct
assembl y, then i nstal l the vacuum hoses. Connect
the ai r control sol enoi d val ve connector
(see
step
43 on page 6- 52) .
I nst al l t he t hr ot t l e cabl e
( see page 11- 125) , t hen
adj ustthe cabl e
(see page 11-124\.
After i nstal l ati on. check that al l tubes, hoses and
connectors are i nstal l ed correctl y.
After assembl y, wai t at l east 30 mi nutes before
f i l l i ng t he engi ne wi t h oi l
( see page 8- 5) .
Refi l l the radi ator wi th engi ne cool ant, and bl eed
open {see
page
' 10-8).
Inspect for fuel l eaks. Turn ON
(l l )
the i gni ti on swi tch
(do
not operate the starter) so that the fuel
pump
pressuri zes the fuel
check for fuel l eakage at any poi nt i n the fuel l i ne.
I nspect t he i dl e speed
( see page 11- 100) .
I nspect t he i gni t i on t i mi ng
( see page 4- 18) .
Connect the negati ve battery cabl e fi rst, then
connect the posi ti ve cabl e.
62.
6 1 .
61.
7 1 .
64.
65.
66.
69.
10.
72. Reset the cl ock.
6 x 1 . 0 mm
' t2
N.m
{1.2 kgf.m,8.7
6-24
Chai n Case Oi l Seal Instal l ati on
.
Dri ver 07749-0010000
.
Attachment, 52 x 55 mm 07746-0010400
1. Use the speci al tool s to dri ve a new oi l seal
squarel y i nto the chai n case to the speci fi ed
i nstal l ed hei ght.
07749-0010000
077i16-0010,100
il
2. Measure the di stance between the chai n case
surface
(A)
and the ol l seal
(B).
Oi l Seal Instal l ed Hei ght:
34.0-34.7 mm {1.34-1.37 i n.)
34. 0-34. 7 mm
(1. 3i 1-1. 37 i n. )
Cylinder Head Removal
NOTE:
'
Usef ender cover st o
avoi d damagi ng pai nt ed
su rfaces.
.
careful l y whi l e hol di ng the connector porti on.
.
To avoi d damagi ng the cyl i nder head, wai t unti l the
engrne cootant temperature drops bel ow 100"F
(38.C)
before l ooseni ng the cyl i nder head bol ts.
.
Mar k al l wi r l ng and hoses t o avoi d mi sconnect i on.
hoses, or i nterfere wi th other part.
preset
buttons.
2. Di sconnect the negati ve cabl e from the battery fi rst,
then di sconnect the posi ti ve
cabl e.
3. Dr ai n t he engi ne cool ant
{ see
page
10- 8} .
4. Dr ai n t he engi ne oi l
( see page
8- S) .
5. Di sconnectthe ai rcontrol sol enoi d val ve connector
(A).
then remove the vacuum hoses
(B)
and the ai r
cl eaner housi ng/ i nt ake ai r duct assembl y
( C) .
6. Move the auto-tensi oner
(A)
to remove tensi on
from the al ternator bel t
(B),
then remove the
al ternator-compressor bel t.
A
Remove the throttl e cabl e
(A)
by l ooseni ng the
l ocknut
(B),
then sl i ppi ng the cabl e end out of the
accel erator l i nkage. Take care not to bend the cabl e
when removi ng i t. Al ways repl ace any ki nked cabl e
wi th a new one.
7.
(cont' d)
6-25
Cylinder Head
(cont'd)
8. Rel i eve fuel pressure.
9. Remove the fuel feed hose
(A),
fuel returnhose{B)
and brake booster vacuum hose
(C).
10. Remove the evaporati ve emi ssi on
(EVAP)cani ster
nose.
tt',,;Z:i
".':::-G
i..-.
, , ' ' 2
l.:::'/
:2
(,ii
6-26
1 1. Remove the bol t
(A)
securi ng the i ntake mani fol d
bracket, and remove the ai r hose
(B).
' 12.
Remove the water outl et cover.
iij\-
13. Remove two bol ts
(A)
securi ng the i ntake mani fol d
bracket, and remove the water bypass hose
(B).
Remove the engi ne wi re harness connectors and
wi re harness cl amps from the cyl i nder head and
i ntake mani fol d.
14.
Four fuel i nj ector connectors
l ntake ai r temperature
(l AT)
sensor connector
l dl e ai r control
(l AC)
val ve connector
Throttl e posi ti on (TP)
sensor connector
Mani fol d absol ute pressure (MAP)
sensor
connecror
Engi ne cool ant temperature {ECT) sensor
connecl or
Pri mary heated oxygen sensor
(pri mary
HO2S)
connecror
VTEC sol enoi d val ve connector
VTEC oressure swi tch connector
Crankshaft Dosi ti on
(CKPI
sensor connector
15. Remove the four bol ts securi ng the exhaust
mani fol d cover.
" \ ,
, ) ,
l - i
16. Remove the three bol ts
(A).
and l oosen the bol t {B),
t hen r emove t he heat shi el d
( C: .
(cont' d)
1rfu
6-27
Gylinder Head
(cont'dl
17. Remove the exhaust mani fol d cover, then remove
the exhaust mani fol d bracket
(A)
and the exhaust
mani fol d
(B).
Remove the di psti ck
(A). posi ti ve
crankcase
venti l ati on
(PCV)
hose
(B)
and breather hose
(C).
18.
6-28
19. Remove t he i gni t i on coi l cover { A) , t hen r emove t he
20.
',1
/
21. Remove the cyl i nder head cover,
Set the No. 1 pi ston at top dead center {TDC). The
TDC marks
(A)
on the cam chai n sprocket shoul d
al i gn wi th the cyl i nder head surface.
22.
.-j,r.a.-\i,
l - t l L
' - - /
23. Remove the end cover
(A)
and nozzl e
(B)
from the
cam chai n auto-tensi oner.
A B
Thread a nut {A) onto a 5 x 0.8 mm bol t that i s at
l east 40 mm l ong
(B),
then thread the bol t i nto the
mai ntenance hol e i n the cam chai n auto-tensi oner.
24.
25. Turn the bol t cl ockwi se to compress the cam chai n
auto-tensi oner, and l ock the bol t wi th the nut.
(cont' d)
6-29
Cyl i nder Head
(cont'dl
26, Remove the cam chai n auto-tensi oner.
27. Loosen the rocker arm adj usti ng screws
(A).
A
M;
6-30
28.
29.
Insert the bol ts
(A)
i nto the rocker shaft hol der. then
remove the rocker arm assembl y {B).
30. Remove the i dl er gear/cam
chai n sprockevwasher
assembl v. Do not droo the washer i nto the chai n
case.
31. Remove the cyl i nder head bol ts. To prevent
warpage, unscrew the bol ts i n sequence 1/3 turn at
a ti me; repeat the sequence unti l al l the bol ts are
roose.
32. Remove the cyl i nder head.
2.
Camshaft Gear Removal
1 . Remove the di psti ck,
posi ti ve crankcase venti l ati on
(PCV)
hose and breather hose
(see
step 18 on
page
6-28).
Remove the i gni ti on coi l cover, then remove the
i gni ti on coi l s
(see
step 19 on
page 6-28).
Remove the cyl i nder head cover
(see
step 21 on
page 6-29).
Loosen the rocker arm adj usti ng screws
(see
step
27 on
page 6-30).
Hol d the camshaft wi th an open-end wrench, then
l oosen the camshaft
gear mounti ng nut.
7. Remove the camshaft
gear.
6-31
Cylinder Head
Cylinder Head Inspection for Warpage
1 . Remove the cyl i nder head
(see page
6-25).
Inspect the camshaft
(see page
6-36).
Check the cyl i nder head for warpage. Measure
al ong the edges. and three ways across the center.
.
l f warpage i s l ess than 0.05 mm
(0.002
i n.)
cyl i nder head resurfaci ng i s not requi red.
.
l f warpage i s between 0.05 mm
(0.002
i n.) and
0.2 mm
(0.008
i n.), resurface the cyl i nder head.
.
Maxi mum resurface l i mi t i s 0.2 mm
(0.008
i n.)
based on a hei ght of 105 mm
( 4. ' 13
i n. ) .
Cylinder Head Height:
Standard
(Newl :
104.95- 105.05 mm
( 4. 132- 4. t 36
i n. l
PRECISION STRAIGHT EOGE
a
,:l'. ,-',r-.
'l
-
' l
.'>+
6-32
Rocker Arms and Shafts Disassembly/Reassembly
NOTE:
. l dent i f ypar t sast heyar er emovedt oensur er ei nst al l at i oni nt hei r or i gi nal l ocat i ons.
.
Inspect rocker shafts and rockerarms
(see page 6-34).
.
Rocker arms must be i nstal l ed i n the same posi ti on i f reused.
.
Pri orto reassembl i ng, cl ean al l the
parts i n sol vent, dry them, and appl y l ubri cantto any contact
poi nts.
.
Bundl e the rocker arms wi th rubber bands to keep them together as a set
INTAKE ROCKER
ARM ASSEMBLY
RUEBER BAND
No. 2 ROCKER
SHAFT HOLDER
EXHAUST ROCKER
ARM ASSEMBLY
EXHAUST
INTAKE ROCKER SHAFT
\
\
\
g . q
fil.rtil
I=r.--1=T
lûr_LI:J
t
f i ,fitl
=] | t-
a l l i t r
g t @
I
No. 3 ROCKER
SHAFT HOLDER
m n
Itf fi
l l t
I t
rH q-l
-tU/ u
-/*
,',. t
ruo.s#rrn
l-I-Tl
I I
sH*ittot-oin
...fr-Tx.l ; lR,
= : : i - l u
RUBBER BAND
/ No.4 RocKER
/
sHAFr HoLDER
I
ROCKER
6-33
Cylinder Head
4.
Rocker Arms and Shafts Inspection
1 . Remove the di psti ck,
posi ti ve
crankcase venti l ati on
{PCV) hose and breather hose
(see
step 18 on page
6-28).
Remove the i gni ti on coi l cover. then remove the
i gni ti on coi l s
(see
step 19 on
page
6-28).
Remove the cyl i nder head cover
(see
step 21 on
page 6-29).
Loosen the rocker arm adj usti ng screws
(see
step
27 on page 6-30).
Insert the bol ts i nto the rocker shaft hol der. then
remove l he rocker arm assembl y
(see
step 29 on
page
6-30).
Measure the di ameter of the shaft at the fi rst rocker
tocal on.
7.
8. Zero the
gauge
{A) to the shaft di ameter.
6-34
9. Measure the i nsi de di ameter of the rocker arm. and
check i t for an out-of-round condi ti on,
Rocker Arm-to-Shaft Clearance:
Standard
(Newl:
0.021 0.041 mm
{0.0008 0.0016 i n.)
{0.003 i n.l
Reoeat for al l rocker arms and both shafts. l f the
cl earance i s over the l i mi t, repl ace the rocker shaft
and al l overtol erance rocker arms. l f any rocker arm
needs repl acement, repl ace al l three rocker arms i n
that set {pri mary, mi d, and secondary).
10.
11. Inspect the rocker arm pi stons (A).
Push each
pi ston manual l y.
l f i t does not move smoothl y, repl ace the rocker
arm assemDry.
NOTE:
.
When reassembl i ng the
pri mary rocker arm
(B),
careful l y appl y ai r pressure to i ts oi l
passage.
.
Appl y oi l to the pi stons when reassembl i ng.
6-35
Cylinder Head
Camshaft Inspection
NOTE: Do not rotate the camshaft duri ng i nspecti on.
1. Remove the di psti ck, posi ti ve
crankcase venti l ati on
{PCV) hose and breather hose
(see
step 18 on page
6-28).
2. Remove the i gni ti on coi l cover,then removethe
i gni ti on coi l s
(see
step 19 on page
6-28).
3. Remove the cyl i nder head cover
(see
step 21 on
page
6-29).
4, Loosen the rocker arm adj usti ng screws
(see
step
27 on page 6-30).
5. Remove the camshaft hol ders and camshafts.
6. Insert the bol ts i nto the rocker shaft hol der, then
remove the rocker arm assembl y
(see
step 29 on
page
6-30).
7. Di sassembl e the rocker arm assembl y.
8. Put the rocker shaft hol ders, camshafts and the
camshaft hol ders on the cyl i nder head, then ti ghten
the bol ts to the speci fi ed torque.
Specified torque:
8 x 1.25 mm
22 N.m
(2.2
kgt.m, 16l bf.ft)
Apply engine oilto the bolt threads.
9. Seat the camshafts by
pushi ng
them toward the
rear end of the cyl i nder head.
6-36
15.
10. Zer ot he di al i ndi cat or agai nst t he end of t he
camshaft, then push
the camshaft back and forth
and read the end pl ay. l f the end pl ay i s beyond the
servi ce l i mi t, repl ace the cyl i nder head and recheck.
l f i t i s sti l l beyond the servi ce l i mi t, repl ace the
camshaft,
Camshaft End Play:
Standard
(Newl :
0.05 0.15 mm
(0.002
0.006 i n.)
(0.012
i n.)
11. U nscrew the camshaft hol der bol ts two turns at a
ti me, i n a cri sscross pattern. Then remove the
camshaft hol ders and the rocker shaft hol ders from
t he cyl i nder head.
12. Li ft the camshafts out of the cyl i nder head, wi pe
them cl ean, then i nspect the l i ft ramps. Repl ace the
camshaft i f any l obes are pi tted,
scored, or
excessrvel y worn.
13. Remove the camshaft mounti ng bol ts
(A),
dowel
pi ns (B)
and camshaft pl ates (C)
on both camshafts.
Wi pe t hem cl ean and l ubr i cat e t he mount i ng bol t
threads wi th cl ean engi ne oi l . Torque the bol ts to
39 N. m
( 4. 0
kgf m, 29 l bf . f t ) .
Cl ean the camshaftj ournal surfaces i n the cyl i nder
head, then set the camshafts back i n pl ace. Pl ace a
pl ast i gage
st r i p acr oss each
j our nal .
Instal l the camshaft hol ders, then ti ghten the bol ts
to the speci fi ed torque as shown i n step 7.
39 N. m
(4.0
kgf.m,
29 rbf.ft).
14.
16. Remove the camshaft hol ders. Measure the wi dest
porti on
of
pl asti gage on each
j ournal .
.
l f the camshaft-to-hol dercl earance i s wi thi n
l i mi ts,
go
to step 17.
.
l f the camshaft-to-hol der cl earance i s beyond the
servi ce l i mi t and the camshaft has been reol aced,
repl ace the cyl i nder head.
.
l f the camshaft-to-hol der cl earance i s beyond the
servi ce l i mi t and the camshaft has not been
repl aced,
go
to step 18.
camshaft-to-Holder Oil Glearance:
Standard
(New):
0.060 0.099 mm
(0.002
0.004 i n.l
(0.006
i n.)
Check the total runout wi th the camshaft supported
on V-bl ocks.
.
l f the total runout of the ca mshaft i s wi thi n the
servi ce l i mi t, repl ace the cyl i nder head.
.
l f the total runout i s beyond the servi ce l i mi t,
repl ace the camshaft and recheck the camshaft-
to-hol der oi l cl earance. l f the oi l cl earance i s sti l l
out of tol erance, repl ace the cyl i nder head.
Camshaft Total Runout:
Standard
(Newl :
0.03 mm {0.001
i n.) max.
(0.002
i n.)
' t7
.
18. Measur e cam l obe hei ght .
Cam Lobe Hei ght Standard
(New):
INTAKE EXHAUST
PRIMARY 33.677 mm
( 1. 326
i n. )
33. 716 mm
{ 1. 327 i n. )
MI D 36.533 mm
( 1. 438
i n. )
35.928 mm
{ 1. 414 i n. )
SECONDARY 33. 961
( 1. 337
mm
I n . )
33.994 mm
{ 1. 338 i n. )
til
t,
INTAKE
PRI MID SEC
EXHAUST
SEC MID PRI
Tt c
PRI: PRIMARY
T/C: TIMING CHAIN
vc
MI O: MI D SEC: SECONDARY
I nspect t h i s area f or wear.
6-37
Cyl i nder Head
Valves, Springs, and Valve Seals Removal
Special Tools Bequired
Val ve spri ng compressor attachment 077 57
-P
J' 1010A
l denti fy the val ves and val ve spri ngs as they are
removed so that each i tem can be rei nstal l ed i n i ts
or i gi nal posi t i on.
1. Remove t he cyl i nder head
( see page 6- 25) .
2. Usi ng an appropri ate-si zed socket
(A)
and
pl asti c
mal l et
(B),
l i ghtl y tap the val ve retai ner to l oosen
the val ve keepers.
I nst al l t he spr i ng compr essor . Compr ess t he spr i ng
and remove the val ve keeDers.
07757-PJ1010A
6-38
4. Instal l the val ve gui de seal remover.
5. Remove the val ve seal .
Valve Inspection
1 . Remove the val ves
(see page
6-38)
Measure the val ve i n these areas.
Intake Valve Dimensions
A Standard l Newl : 35.90-36.10 mm
( 1. 413
1. 421 i n. )
B Standard {Newl : 108.85 109.15 mm
14.285-
4.297 in.l
C Standard {Newl; 5.,t8 5.49 mm
{0.2157 0.2161 i n.)
C Servi ce Li mi t: 5.45 mm {0.215 i n.)
D Standard l Newl : 0.55 0.85 mm
{0.022 0.033 i n.)
D Servi ce Li mi t: 0.40 mm 10.016 i n.)
Exhaust Valve Dimensions
A Standard
(New):
30.90-31.10 mm
11.217 1.224 i n.l
B Standard l New): 107.60- 107.90 mm
l4.236
4.24A tn.)
C Standard {New): 5.45 5.45 mm
(0.2146
0.2150 i n.l
C Servi ce Li mi t: 5.42 mm
{0.213 i n.)
D Standard lNew): 0.85 1.15 mm
(0.033
0.045 i n.)
O Service Limit: 0.70 mm
(0.028
in.l
Valve Stem-to-Guide Clearance
lnspection
1 . Remove the val ves
(see page 6-38)
Sl i de the val ve out of i ts gui de
about 10 mm, then
measure the
gui de-to-stem cl earance wi th a di al
i ndi cator whi l e rocki ng the stem i n the di recti on of
normal thrust
(wobbl e
method).
.
l f the measurement exceeds the servi ce l i mi t,
recheck i t usi ng a new val ve,
.
l f the measurement i s nowwi thi n the servi ce
l i mi t, reassembl e usi ng a new val ve.
.
l f t he measur ement wi t h a newval ve st i l l
exceeds the servi ce l i mi t, go to step 3.
Intake Valve Stem-to-Guide Clearance:
Standard
(New):
0.04-0.10 mm
(0.002-0.004
i n.)
10.008
in.)
Exhaust Valve Stem-to-Guide Clearance;
Standard
(Newl :
0.10-0.16 mm
(0.004-0.006
i n.l
Seruice Limit: 0.22 mm
(0.009
in.)
Subtractthe O,D. ofthe val ve stem, measured wi th
a mi crometer, from the l .D. of the val ve gui de,
measured wi th an i nsi de mi crometer or bal l gauge.
Take the measurements i n three
pl aces
al ong the
val ve stem and three pl aces
i nsi de the val ve gui de.
The di fference between the l argest gui de
measurement and the smal l est stem measurement
shoul d not exceed the servi ce l i mi t.
Intake Valve Stem-to-Guide Clearance:
Standard
(New):
0.02 0.05 mm
(0.001
0.002 i n.l
(0.003
i n.)
Exhausl Valve Stem-to-Guide Clearance:
Standard
(New):
0.05 0.08 mm
{0.002 O.OO3 i n.}
Servi ce Li mi t: 0.11 mm 10.004 i n.l
6-39
Cylinder Head
Valve Guide Replacement
Special Tools Requir6d
.
Val ve gui de
dri ver, 5.5 mm 07742-0010' 100
.
Val ve gui de reamer, 5.5 mm 07HAH-PJ70108
1. Inspect val ve stem-to-gui de cl earance
(see page
6-
39 ).
2. As i l l ustrated bel ow, use a commerci al l y avai l abl e
ai r-i mpact val ve gui de dri ver
(A)
modi fi ed to fi t the
di ameter of the val ve gui des. In most cases. the
same procedure
can be done usi ng the speci al tool
and a conventional hammer.
A
I
idiT,T.)
^ l I
----------7\
/----------- t
|
\
tr
r--------------r
- - 8 7 m m
_ -
s ? m m
- ' t
(3.43
i n.l l 2.21i n.l
10.8 mm
{0.,12 in.l
4.
Sel ect the proper
repl acement gui des, and chi l l
them i n the freezer secti on of a refri oerator for
about an hour.
Use a hot pl ate
or oven to evenl y heat the cyl i nder
head to 300' F
(150"C).
Moni tor the temperature
wi th a cooki ng thermometer. Do not get the head
hotter than 300' F
(150' C);
excessi ve heat may
l oosen the val ve seats.
oF-\
\Yg
6-40
5. Worki ng from the camshaft si de, use the dri ver and
an ai r hammer t o dr i ve t he
gui de
about 2 mm
(0.1
i n.) towards the combusti on chamber. Thi s wi l l
knock off some of the carbon and make removal
easi er. Hol d the ai r hammer di rectl y i n l i ne wi th the
val ve gui de
to
prevent
damagi ng the dri ver.
6. Turn the head over and dri ve the
gui de
out toward
the camshaft si de of the head.
l f a val ve gui de won' t move, dri l l i t out wi th a 8 mm
( 5/ 16
i nch) bi t , t hen t r y agai n. Dr i l l gui des onl y i n
extreme cases; you
coul d damage the cyl i nder
head i f the gui de breaks.
Remove the new gui de(s)
from the freezer. one at a
ti me, as vou need them.
7.
9. Appl y a t hi n coat of cl ean engi ne oi l t ot heout si de
of the new val ve gui de. Instal l the
gui de from the
camshaft si de of the head; use the speci al tool to
dri ve the
gui de i n to the speci fi ed i nstal l ed hei ght
( A)
of t he
sui de
{ B) . l f you have al l 16 gui des t o do,
vou mav have to reheat the head.
Val ve Gui de Instal l ed Hei ght:
Intake: 15.2 16.2 mm
(0.598
0.638 i n.)
Exhaust: 16.0 17.0 mm 10.630 0.669 i n.l
07742-0010100
I T
10.Coat both reamer and val ve gui de wi th cutti ng oi l .
Rotate the reamer cl ockwi se the ful l l ength of the
val ve gui de bor e.
1 1 .
OTHAH-PJ7O1OB
Conti nue to rotate the reamer cl ockwi se whi l
removi ng i t from the bore.
Thdroughl y wash the gui de i n detergent and
to remove any cutti ng resi due.
14. Check the cl earances wi th a val ve
(see page
6-39).
Veri fy that a val ve sl i des i n the i ntake and exhaust
val ve gui des wi thout exerti ng
pressure.
12.
13.
6-41
Cylinder Head
Valve Seat Reconditioning
1 . Inspect val ve stem-to-gui de cl earance
(see page
6-
39). l f the val ve gui des
are worn, repl ace them
(see
page
6-40) before cutti ng the val ve seats.
Renew the val ve seats i n the cyl i nder head usi ng a
val ve seat cutter.
Careful l y cut a 45" seat, removi ng onl y enough
materi al to ensure a smooth and concentri c seat.
Bevel the upper and l ower edges at the angl es
shown i n the i l l ustrati on.
Check the wi dth of the seat and adj ust accordi ngl y.
I NTAKE: 40'
Make one more very l i ght pass wi th the 45" cutter
to remove any possi bl e
burrs caused by the other
cutters.
Valve Seat Width:
Intake:
Standard {New}: 1.05 1.35 mm
{0.041 0.053 i n.}
(0.071
i n.l
Exhaust:
Standard
(New):
1.25 1.55 mm
(0.049
0.061 i n.)
10.079
i n.l
6-42
6, After resurfaci ng the seat, i nspect for even val ve
seati ng: Appl y Prussi an Bl ue compound
(A)
to the
val ve face. l nsert the val ve i n i ts ori gi nal l ocati on i n
the head, then l i ft i t and snap i t cl osed agai nst the
seat several ti mes.
1.
* u ,
"-/;
' ( . "
The actual val ve seati ng surface
(B),
as shown by
the bl ue comDound, shoul d be centered on the seat.
.
l f i t i st oo hi gh
( cl oser t ot heval vest em) , you
must make a second cut wi th the 67.5
"
cutter to
move i t down, then one more cut wi th the 45
"
cutter to restore seat wi dth.
.
l f i t i st oo l ow( cl oset ot heval ve edge) , you must
make a second cut wi th the 40' cutter
(i ntake
si de) or the 30' cutter
(exhaust
si de) to move i t up.
then make one more cut wi th the 45" cutter to
restore seat wi dth.
NOTE: The fi nal cut shoul d al ways be made wi th
the 45' cutter.
8. Insert the i nl ake and exhaust val ves i n the head and
measure val ve stem i nstal l ed hei ght
(A).
Intake Valve Stem Installed Height:
Standard
(New):
44.1
-
44.4 mm
{1.736
-
1.748 i n.)
Servi ce Li mi t: 44.7 mm 11.760 i n.)
Exhaust Valve Stem Installed Height:
Standard
(New):
44.2 44.5 mm
{1.740
-
1.752 i n.)
(1.764
i n.)
l f val ve stem i nstal l ed hei ght i s over the servi ce
l i mi t, repl ace the val ve and recheck. l f i t i s sti l l over
the servi ce l i mi t, repl ace the cyl i nder head; the
val ve seat i n the head i s too deeD.
9.
6-43
Gyl i nder Head
Valves, Springs, and Valve Seals Installation
Val ve spri ng compressor attachment 07757-PJ1010A
1. Coat t he val ve st ems wi t h engi ne oi l . I nst al l t he
val ves i n t he val ve gui des.
2. Check that the val ves move up and down smoothl y.
3. I nst al l t he spr i ng seat s on t he cyl i nder head.
4. I nst al l t he newval veseal s
( A)
usi ng t he val ve gui de
seal i nst al l er
{ B) .
NOTE: The exhaust val ve seal { C) has a bl ack spr i ng
(D),
and the i ntake val ve seal
(E)
has a whi te spri ng
(F).
They are not i nterchangeabl e.
6-44
5. I nst al l t he val vespr i ng and val ve r et ai ner . Pl acet he
end of the val ve spri ng wi th cl osel y wound coi l s
toward the cyl i nder head.
6. I nst al l t he val ve spr i ng compr essor . Compr ess t he
spr i ng and i nst al l t he val ve keeper s.
07757-PJ1010A
Li ghtl y tap the end of each val ve stem two or three
ti mes wi th a
pl asti c mal l et
(A)to
ensure
proper
seati ng of the val ve and val ve keepers. Tap the
val ve stem onl y al ong i ts axi s so you do not bend
the stem,
7 .
c_)
Camshaft Gear Installation
1. Instal l the camshaft
gear (A).
Appl y engi ne oi l to the threads of the camshaft
gear mounti ng nut
(B),
then i nstal l i t.
Hol d the camshaft wi th an open-end wrench, then
ti ghten the camshaft gear mounti ng nut.
Specified torque:
118 N.m
(12.0
kgf.m, 86.8 l bf.ft)
Cylinder Head Installation
1. Measure the di ameter of each cyl i nder head bol t at
ooi nt A and ooi nt B. l f ei ther di ameter i s l ess than
' I
1. 5 mm
( 0. 45
i n. ) , r epl ace t he cyl i nder head bol t .
2. CIean the cyl i nder head and bl ock surfaces.
3. Appl y l i qui d gasket, part No. 08718-0009, to the
shaded areas
(A)
of the cyl i nder head gasket
mati ng surface of the bl ock and chai n case.
(cont' d)
B 50 mm {2. 0 i n. )
A 45 mm 11. 8 i n. )
*#*
*'h,i
6-45
Cylinder Head
Gylinder Head Installation
(cont'd)
Instal l the dowel
pi ns (A)
and the new cyl i nder head
gasket (B).
B
Appl y l i qui d gasket, part No. 08718-0009, to the
cyl i nder head mati ng surface of the bl ock and chai n
case wi t hi n 5 mm of t he edge of t he cyl i nder head
gasket.
6-46
6.
7.
Instal l the cyl i nder head on the bl ock.
Appl y engi ne oi l t o t he t hr eads and under t he heads
of al l t he cyl i nder head bol t s.
8. Ti ghten the cyl i nder head bol ts i n sequence to
29 N m
(3.0
kgf.m, 22 l bf ft). Use a beam-type
torque wrench. When usi ng a
preset-type torque
wrench, be sure to ti ghten sl owl y and do not
overti ghten. l f a bol t makes any noi se whi l e
you are
torqui ng i t, Ioosen the bol t and reti ghten i t.
Ti ghten al l cyl i nder head bol ts i n two steps {90'
per
step). l f you are usi ng a new cyl i nder head bol t,
ti ghten the bol t an extra 90".
SECOND STEP
Ti ghten the 8 mm bol ts
(A)ro
22 N.m
(2.2
kgf.m,
16l bf . f t ) .
9.
10.
12.
1 1 . Make sure the crankshaft pul l ey i s at top dead
center
(TDC).
Al i gn the TDC mark
(A)
on the
crankshaft
pul l ey wi th the
poi nter (B)
on the chai n
Assembl e the i dl er gear (A)
and cam chai n
sprocket
(B)wi th
three mounti ng bol ts
(C).
Torque the bol ts to 14 N.m
(1.4
kgf.m. 10 l bf.ft)
13. Pl ace the assembl y i nto the cyl i nder head.
/1,
(@
,I
14. Instal l the cam chai n on the sprocket, then fi tthe
i dl er gear col l ar i nto the cyl i nder head.
15. Turn the i dl er gear countercl ockwi se to rel i eve cam
chai n free pl ay,
and check the al i gnment of the TDC
marks {A) on the cam chai n sprocket wi th the
cyl i nder head surface. l f the cam chai n sprocket i s
not posi ti oned at TDC, remove the i dl er gea r from
the cvl i nder head and reoosi ti on the cam chai n to
bri ng the cam chai n sprocket to TDC.
16.Appl y engi ne oi l t o t he
center bol t threads
(A).
the bol t.
i dl er gearrcam chai n sprocket
I nst al l a new O' r i ng
( C)
on
-/B
A
10 x 1. 25 mm
i t g Nm
(5. 0
kgt . m,
36 rbf.ft)
Instal l the washer
(B)
on the cam chai n sprocket, and
ti ghten the center bol t.
(cont' d)
1,\ei.
17.
6-4t
Gylinder Head
(cont'd)
18. Cl amp the cam chai n auto-tensi oner i n a soft-i awed
vi se.
19. Turn the 5 x 0.8 mm bol t
(A)
cl ockwi se to compress
the bottom of the auto-tensi oner, then i nsert the set
pi n ( B) ,
P/ N 14511- PCX- 005.
Remove the 5 x 0.8 mm bol t from the mai ntenance
hol e. Instal l a new O-ri ng
(A),
then i nstal l the nozzl e
{ B) and end cover
( C) .
1\
"--_._
7f----_
--\
/ a--\
6x1. 0mm
1 \ \ l 2 N . m
o---===-}--/ {1 2 ksf m' 87l bt f t l
\J
20,
.{}--..-
t-
-:----
6-48
21. l nstal l the cam chai n auto-tensi oner
(A)
i n the
cyl i nder head wi th new O-ri ngs
(B).
B
6 x 1 . 0 mm
12 N.m
(1.2
ksf.m,8.7l bf.ft)
22. Remove the mai ntenance bol t
(C)from
the cyl i nder
head.
23. Remove the set
pi n (A)
from the cam chai n auto-
tensi oner. Rei nstal l the mai ntenance bol t
(B)wi th
new washer
(C).
\
' -
-i.
f,\
/.
l."i
<-
")@.W
B '
29 N. m
{3. 0 kgf . m, 22l bf . f t )
23.
24.
l nstal l the rocker arm assembl y.
Check the al i gnment of the TDC marks {A) on the
cam chai n sprocket wi th the cyl i nder head surface.
25. Al i gn the TDC marks
(B)
on the i ntake camshaft
gear (C)
and the exhaust camshaft gear (D),
and
i nstal l the camshafts.
26. Appl y engi ne oi l to the bol t threads of al l the
camshaft hol der bol ts.
27. Put the camshaft hol ders on the cyl i nder head. then
t i ght en al l bol t s t o 22 N. m { 2. 2 kgf . m, 16l bf . f t ) .
Cyl i nder Head Bol ts Torque Sequence:
28. Make sure the camshaft gears are at TDC.
Adj ust the val ve cl earance
(see page
6-12).
Instal l the cyl i nder head cover
(see page 6-53).
29.
(cont' d)
6-49
Gylinder Head
(cont'd)
Instal l the exhaust mani fol d
(A)
usi ng new gaskets
(B)
and new sel f-l ocki ng nuts
(C).
3 1 .
10 x 1 , 25 mm
44 N. m
(4. 5
kgf . m. 33l bt . f t l
32. Instal l the exhaust mani fol d bracket
(D).
Make sure
the smooth si des of the washers {E)
face the
exhaust mani fol d bracket.
6-50
\.
34.
Put the exhaust mani fol d cover on the exhaust
mani fo l d.
l nstal l the heat shi el d.
35.
6 x 1 . 0 mm
9.8 N.m {1.0 kgf m,7.2 l bf ft)
Ti ghten the four bol ts securi ng the exhaust
mani fol d cover.
8 x
' 1. 25
mm
22 N. m
(2. 2
kgf . m, 16l bf . f t )
I
8 x L 2 5 mm
22 N. m
(2. 2
ksf . m, 16l bf . f t )
36. Instal l the i ntake mani fol d
(Al wi th
a new gasket (B).
8 x 1.25 mm
22N.n
kgl.m, 16 lbl ft)
37. Instal l the water bypass hose
(A),
and ti ghten the
two bol ts
(Bl
securi ng the i ntake mani fol d bracket.
t\-.--
\3
B
10 x 1.25 mm
il4
N.m
{,1.5 kgf.m,33 lbf.ft}
Instal l the water outl et cover
(A)
wi th a new O-ri ng
( B) .
12 N. m
{1. 2 ksf m, 8. 7 l bf . f t )
(cont' d)
6-51
Cylinder Head
(cont'd)
Instal l the ai r hose
(A),
and ti ghten the bol t
(B)
securi ng the i ntake mani fol d bracket.
39.
I'
' 10
x 1.25 mm
44 N.m
{,1.5 kgf.m.33 l bt.ftl
l nstal l the evaporati ve emi ssi on
(EVAP)
control
cani ster hose.
6-52
\
41. Instal l the brake booster vacuum hose
(A),
tuel
return hose
(B)
and fuel feed hose
(C).
usi ng new
washer s
( D) .
Instal l the al ternator-compressor bel t.
Instal l the ai r cl eaner housi ng/i ntake ai r duct
assembl y
( A) ,
t hen i nst al l t he vacuum hoses
( B)
Connect the ai r control sol enoi d val ve connector
(c).
mm
(1. 2
kgf . m, 8. 7 l bt . f t )
43.
6 x 1 . 0
12 N. m
\
44. Instal l the throttl e cabl e
adj ust the cabl e
(see page
11-1241.
45. After i nstal l ati on. check that al l tubes, hoses and
connectors are i nstal l ed correctl y.
46. After assembl y, wai t at l east 30 mi nutes before
fi l l i ng the engi ne wi th oi l
(see page 8-5).
47. Refi l l the radi ator wi th engi ne cool ant. and bl eed
open
(see page
10-8).
48. Connect the negati ve battery cabl e fi rst, then
connect the posi ti ve
cabl e.
49. Inspectforfuel l eaks. Turn the i gni ti on swi tch ON
(l l )
{do not operate the starter) so that the fuel pump
pressuri zes
the fuel
check for fuel l eakage at any
poi nt
i n the fuel l i ne.
50. Perform the engi ne control modul e
(ECM)
i dl e l earn
51. I nspect t he i dl e speed
( see page 11- 100) .
52. I nspect t he i gni t i ont i mi ng
( see page
4- 18) .
53. Enter the anti -theft code for the radi o, then enter
54. Set the cl ock.
1 .
Cylinder Head Cover Installation
Instal l the head cover gasket i n the groove of the
cyl i nder head cover.
Set the spark
pl ug
seal
(A)
on the spark
pl ug
tube.
l nstal l the cyl i nder head cover
(B)
on the cyl i nder
nead.
NOTE:
.
Take care not to damage the spark
pl ug
seal s
when i nstal l i ng the cyl i nder head cover.
.
Vi sual l y i nspect the spark pl ug
seal s for damage.
(cont' d)
6-53
Gylinder Head
Cylinder Head Cover Installation
(cont'dl
3. Inspect the cyl i nder head cover washers. Repl ace
any washers and rubber seal s that are damagedor
deteri orated.
4. Cl ean the washer mati ng surfaces ofthe cyl i nder
neao cover.
5. l nstal l the head cover washers
(A).
6. Make sure the rubber seal s
(B)
are securel y seated
on the cyl i nder head cover.
7. Ti ghten the bol ts i n two orthree steps. l n the fi nal
step, ti ghten al l bol ts, i n sequence, to 12 N.m
{ 1. 2
kgf . m, 8. 7 l bf . f t ) .
6-54
8. I nst al l t he i gni t i on coi l s
( A) ,
t hen i nst al l t he i gni t i on
coi l cover
( B) .
x 1. 0 mm
g
12 N. m
{1. 2 kgf m,
8.7 tbt.ft)
6 x 1 . 0 mm
12 N. m
(1. 2
kg{. m, 9. 7l bf . f t l
Instal l the Dosi ti ve crankcase venti l ati on
(PCV)
hose
(A)
and breather hose {B), then i nsert the
di psti ck
(C).
After assembl v, wai t at l east 30 mi nutes before
f i l l i ng t he engi ne wi t h oi l { see
page 8- 5) .
10.
:,)
Engi ne Mechani cal
Engi ne Bl ock
Speci al Tool s . . . . . . . . . . . . . 7-2
Component Locat i on I ndex . . . . . . . . . . . . . . . . . , . . . . . . . . . . , . . . . . , , . . . . , 7-3
Fl ywheel Removal and I nst al l at i on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Connect i ng Rod and Crankshaf t End Pl ay
I nspect i on . . . . . . . . . . . . . . 7-6
Crankshaf t Mai n Beari ng Repl acement . . . . . . . . . . . . . . . . . . . . . . 7-7
Connect i ng Rod Beari ng Repl acement . . . . . . . . . . . . . . . . . . . . . . 7-9
Crankshaf t and Pi st ons Removal . . . . . . . . . . . . . . . -. . . . . . . . . . . . . . . . 7
-11
Crankshaf t I nspect i on . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Bf ock and Pi st on I nsoect i on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Cyl i nder Honi ng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 16
Pi st on, Pi n and Connect i ng Rod Repl acement . . . . . . . . . . 7-17
Pi st on Ri ng Repl acement . . . . . . . . . . . . . . . . . . . 7-20
Pi st on f nst al l at i on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
Crankshaf t l nst al l at i on . . . . . . . . . . . . . . . . . . . . . . . 7-24
Pul f ey End Crankshaf t Seal I nst al l at i on-l n Car . . . . . . . . . . . 7-26
Transmi ssi on End Crankshaf t Seal
f nst al f at i on-l n Car . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
Engi ne Bl ock
Special Tools
7-2
Ref.No. Tool Number
07LAB-PV00100
O7LAD.PT3O1OA
07749-0010000
07948-SB00101
Description
oty
1
Ri ng Gear Hol der
Seal Dr i ver
Dri ver
Dri ver Attachment
1
1
1
!D
6\
o
o
MAI N BEARI NGS
Oi l cl earance, page 7-7
Sel ect i on,
st ep 1 on page 7 8
LOWER BLOCK
OOWEL PIN
FLYWHEEL
THRUST WASHERS
CRANKSHAFT OIL SEAL
I nst al l at i on, page 7 26
CRANKSHAFT
End pl ay, page 7-6
Runout , Taper and Out -of -Round,
pagei 13
I nst al l at i on, page 7' 24
(cont' d)
7-3
WASHER
*i'h
' " h \ :
\-lY,
'ri
.;:-':1//
Engi ne Bl ock
(cont'dl
(
a:x
t >: <
\ffi
SNAPRNG
(': l/
^r'
ra?-.-.' ,, ^-,0
:k;
(\ \g<
.,
\prsroN prN
PISTON
Removal , page 7- 11
Measurement, page 7' 14
Removal , page 7-' 17
I nst al l at i on, st ep 1 on page 7-' 19
I nspect i on, st ep 1 on page 7-18
CONNECTING ROD
End pl ay, page 7 6
Smal l end measurement , st ep 1 on
page 7-' 18
SNAP RING
u-
__
&--__......_
Cl earance,
page 7 9
Sel ect i on, st ep 3 on page 7 10
CONNECTING ROD
BEARING CAP
CONNECTING ROD BOLT
7- 4
Flywheel Removal and Installation
Ri ng gear hol der 07LAB-PV00100
1. Rem ove the tra nsm i ssi on
(see page 13-5),
2. Remove the pressure pl ate and cl utch di sk {see
page 12-7).
3. Remove the ei ght fl ywheel bol ts.then separate the
fl ywheel from the crankshaft fl ange. After
i nstal l ati on, ti ghten the bol ts i n the sequence
shown,
07LAB-PV00r00
12 x 1. 0 mm
127 N. m {13. 0 kgt . m, 94l bf . f t }
07LAB-PV00100
RI NG GEAR
I nspecr f l ng gear
t eet h f or wear or damage.
I nst al l t he cl ut ch di sk and
pressure pl at e (see page
't2-11).
Instal l the transmi ssi on {see
page 13-66). 5.
' 1.
i'i.,
7-5
Engi ne Bl ock
Connecting Rod and Crankshaft End Play Inspection
1 . Remove the oi l pump (see page 8-9).
Measure the connecti ng rod end
pl ay wi th a feel er
gauge between the connecti ng rod and crankshaft.
Connecting Rod End Play:
Standard
(New):
0.15 0.30 mm
(0.006
0.012 i n.l
(0.016
i n.)
l f the connecti ng rod end
pl ay i s out-of-tol erance,
i nstal l a new connecti ng rod, and recheck. l f i t i s
sti l l out-of-tol erance; repl ace the crankshaft
(see
page 7- l 1) .
7-6
4. Push the crankshaft fi rml y away from the di al
i ndi cator, and zero the di al agai nst the end of the
crankshaft. Then pul l the crankshaft fi rml y back
toward the i ndi cator; the di al readi ng shoul d not
exceed the servi ce l i mi t.
Crankshaft End Play:
Standard {Newl : 0.10 0.35 mm
( 0. 004
- 0. 014
i n. )
Servi ce Li mi t: 0.45 mm {0.018 i n.l
l f the end
pl ay
i s excessi ve, repl ace the thrust
washers and recheck. l f i t i s sti l l out of tol erance,
repl ace the crankshaft.
Crankshaft Main Bearing Replacement
Main Bearing Clearance Inspection
' 1.
To check mai n beari ng-to-j ournal oi l cl earance,
remove the l ower bl ock and beari ng hal ves.
(see
page 7- 1 1) .
2. Cl ean each mai n
j our nal
and bear i ng hal f wi t ha
cl ean shop t owel .
3. Pl ace one stri p of
pl asti gage across each maan
j ou
r nal .
NOTE: l f the engi ne i s sti l l i n the vehi cl e when you
bol t the l ower bl ock down to check cl earance, the
wei ght of the crankshaft and fl ywheel wi l l fl atten
the
pl asti gage further than
j ust
the torque on the
cap bol t and
gi ve you an i ncorrect readi ng. For an
accurate readi ng, support the crank wi th a
j ack
under the counterwei ghts, and check onl y one
beari ng at a ti me.
Rei nstal l the beari ngs and l ower bl ock, then torque
the bol ts to 29 N.m
(3.0
kgf m, 22 l bf.ft) + 60' .
NOTE: Do not rotate the crankshaft duri ng
i nsDecti on,
Remove the l ower bl ock and beari ngs agai n, and
measure the wi dest
pan
of the
pl asti gage.
Main Bearing-to-Journal Oil Clearance:
Standard {New): 0.017 0.041 mm
(0.0007
0.0016 i n.)
(0.0020
i n.l
4.
6. l f the
pl asti gage measures too wi de or too narrow,
(remove
the engi ne i f i t' s sti l l i n the vehi cl e),
remove the crankshaft, and remove the upper hal f
ofthe beari ng. Instal l a new, compl ete beari ng wi th
the same col or code(s), and recheck the cl earance.
Do not fi l e, shi m, or scrape the beari ngs or the caps
to adj ust cl earance.
7. l f the pl asti gage shows the cl earance i s sti l l
i ncorrect, try the next l arger or smal l er beari ng
(the
col or l i sted above or bel ow that one), and check
agai n. l f the proper cl earance cannot be obtai ned
by usi ng the appropri ate l arger or smal l er beari ngs,
reol ace the crankshaft and start over.
(cont' d)
7-7
Engi ne Bl ock
Crankshaft Main Bearing Replacement
{cont'd)
Main Bearing Selection
Crankshaft Bore Code Location
1. Numbers or l etters or bars have been stamped on
the end of the bl ock as a code for the si ze of each of
the 5 mai n
j ournal
bores. Wri te down the crank
oore cooes,
l f you
can' t read the codes because of accumul ated
di rt and dust. do not scrub them wi th a wi re brush
or scraDer. Cl ean them onl v wi th sol vent or
detergent.
No. 5 JOURNAL
{FLYWHEEL ENOI
No. 1 JOURNAL
IPULLEY ENDI
,.U
.i?+
. ' \ ' *i -:
'..1i:|,t/
7-8
Main Journal Code Location
2. The mai n
j ournal
codes are stamped on the No. 1
weo.
No. 1 JOURNAL 5 JOURNAL
Use the crank bore codes and crank
j ournal
codes
to sel ect the appropri ate repl acement beari ngs
from the fol l owi ng tabl e.
NOTE:
.
Col or code i s on the edge of the beari ng.
.
When usi ng beari ng hal ves of di fferent col ors, i t
does not matter whi ch col or i s used i n the top or
bottom.
Crank
bore
coale
crank bore
l o l
Ao r l
2 o J
Bo r l l
3or
C or l l l
4 o r
D or l l l l
----------->
Smallsr boa.ing lThickell
Mai n
iournal
cooe
''-i:
,'-'
l o r l
2or l l
3 or l l l
4 or llll
5 or l l l l l
6 or l l l l l l
Pi nk/
Yellow
Yellow
Yellow/
Gaoon
Gren
Yel l ow
Green
G16en
Green/
Brown
Green
Green
Green/
Brown
Brown
Green
Green/
Brown
Brown
Brown/
Bl ack
Green/
Brown
e,own
$ff,lfln/
aracr
Brown
Brown/
Black
Bl ack
Black/
Bl ue
Connecting Rod Bearing Replacement
Rod Bearing Clearance Inspection
1. Remove the connecti ng rod cap and beari ng hal f
( see page 7- ' 1 1) .
2. Cl ean the crankshaft rod
j ournal
and beari ng hal f
wi th a cl ean shop towel .
3. Pl ace
pl asti gage across the rod
j ournal .
4. Rei nstal l the beari ng hal f and cap, and torque the
bol t to 25 N.m
(2.5
kgf m, 18 l bf.ft) + 90' .
NOTE: Do not rotate the crankshaft duri ng
i nspecti on.
5. Remove the rod cap and beari ng hal f, and measure
the wi dest part of the
pl asti gage.
Connecting Rod Bearing"to-Journal Oil
Cl earance:
Standard
(New):
0.030 0.054 mm
10.0012 0.0021 i n.)
(0.0024
i n.)
l f the pl asti gage measures too wi de or too narrow,
remove the upper hal f of the beari ng, i nstal l a new,
compl ete beari ng wi th the same col or code(s), and
recheck the cl earance. Do not fi l e, shi m, or scrape
the beari ngs or the caps to adj ust cl earance.
l f the pl asti gage shows the cl earance i s sti l l
i ncorrect. try the next l arger or smal l er beari ng
(the
col or l i sted above or bel ow that one), and check
cl earance agai n. l f the
proper cl earance cannot be
obt ai ned by usi ng t he appr opr i at e l ar ger or smal l er
beari ng, repl ace the crankshaft and start over.
7 .
Rod Bearing Selestion
1. Inspect each connecti ng rod for cracks and heat
damage.
Connecting Rod Big End Bore Code Locations
2. Each rod has a tol erance range from 0 to 0,024 mm
(0.0009
i n.), i n 0.006 mm
(0.0002
i n.)i ncrements,
dependi ng on the si ze of i ts bi g end bore. l t' s then
stamped wi th a number or bar
(' 1,
2, 3 or 4/1, l l , l l l , or
l l l l ) i ndi cati ng the range. You may fi nd any
combi nat i on of number s and bar s i n any engi ne,
(Hal f
the number or bar i s stamped on the beari ng
cap, the other hal f on the rod.).
l f you can' t read the code because of an
accumul ati on of oi l and varni sh. do not scrub i t
wi th a wi re brush or scraper. Cl ean i t onl y wi th
sol vent or detergent.
(cont' d)
7-9
Engi ne Bl ock
Connecting Rod Bearing Replacement
(cont'd)
Connecting Rod Journal Code Location
3. The connecti ng rod
j ournal
codes are stamped on
t he No. 1web.
Connecting Rod Journal Code Location
(Letters
or
Bars)
No. l JOURNAL No.
i l JOURNAL
. . 1
1 1 1 1 1 r l
7-10
Use the bi g end bore codes and rod
j ournal
codes
to sel ect appropri ate repl acement beari ngs from
the fol l owi ng tabl e.
NOTE: Col or code i s on the edge of the beari ng.
Larger big end bore
Bi g end
DOte
code
@
----------'>
Smallor bearing {Thickerl
Smal l el
rod
j ournal
Smal l er
bearing
{Thicker}
Red
Pink
Yetlow Green
Pi nk Vellow Green Brown
Yellow Green Brown Black
Green Brown Black Blue
Crankshaft and Piston Removal
1. Remove the cam chai n
(see page
6-15).
2. Remove the oi l pump (see
step 1 on page
8-9).
3. Remove the 8 mm bol ts.
O
'ffff$ll:
repeat the sl
o
:J,,-'
i
J....
LO;
iJ
,1
.,
t l i ' -
I
@
t =
5. Remove the l ower bl ock and beari ngs. Keep al l
beari ngs i n order.
6. Remove t he r od caps and bear i ngs. Keep al l caps
and beari ngs i n order.
7. Li ft the crankshaft out of the engi ne, bei ng careful
not to damage the
j ournal s.
(cont' d)
7- 11
Engi ne Bl ock
Crankshaft and Piston Removal
(cont'dl
l f you can feel a ri dge of metal or hard carbon
around the top of each cyl i nder, remove i t wi th a
ri dge reamer
(A).
Fol l ow the reamer manufacturer' s
i nstructi ons. l f the ri dge i s not removed, i t may
damage the pi ston as i t i s pushed
out,
9. Use the wooden handl e of a hammer
(A)
to dri ve
out the pi stons (B).
' I
l .
Rei nstal l the connecti ng rod beari ngs and caps
after removi ng each pi ston and connecti ng rod
assembl y.
To avoi d mi xup on reassembl y, mark each pi ston
and connecti ng rod assembl y wi th i ts cyl i nder
numDer .
NOTE:The exi sti ng number on l he connecti ng rod
does not i ndi cate i ts posi ti on
i n the engi ne, i t
i ndi cates the rod bore si ze.
10.
7-12
Crankshaft Inspection
Out-of-Round and Taper
1. Remove the crankshaft from the cvl i nder bl ock
(see
page 7- 1 1) .
2. Cl ean the crankshaft oi l
passages wi th
pi pe
cl eaner s or a sui t abl e br ush.
3. Check the keyway and threads.
4. Measure out-of-round at the mi ddl e of each rod
and mai n
j ournal
i n two
pl aces, The di fference
between measurements on each i ournal must not
be more than the servi ce l i mi t.
Journal Out-of-Round:
Standard
(New):
0.004 mm {0.(X)02 in.) max.
(0.0002
i n.)
Measure taper at the edge of each rod and mai n
j ournal .
The di fference between measurements on
each
j ournal
must not be more than the servi ce
l i mi t .
Journal Taper:
Standard {New): 0.005 mm
(0.0002
i n.l max.
(0.0002
in.l
J J l -
T-T
5.
Straightness
6. Pl ace the cyl i nder bl ock on the surface
pl ate.
7. Cl ean and i nst al l t he bear i ngs on t he No. 1 and
No. 5
j ournal s
of the cyl i nder bl ock.
8. Lower the crankshaft i nto the bl ock.
9. Measur e r unout on al l mai n
j our nal s.
Rot at e t he
crankshaft two compl ete revol uti ons. The
di fference between measurements on each
j ournal
must not be more than the servi ce l i mi t.
Crankshaft Total Indicator Runout:
Standard {Newl : 0.03 mm {0.001
i n.) max.
Servi ce Li mi t: 0.04 mm {0.002
i n.)
7-13
Engi ne Bl ock
Block and Piston Inspection
1 . Remove the crankshaft and
pi stons (see page 7-1 1).
Check the Di ston for di storti on or cracks.
Measure the
pi ston
di ameter at a
poi nt
16 mm
(0.6
i n.) from the bottom of the ski rt. There are two
standard-si ze pi stons (No
Letter or A, and B). The
l etter i s stamped on the top of the
pi ston.
Letters
are al so stamped on the bl ock as cyl i nder bore
si zes.
Piston Diameter:
Standard lNew):
No Leftor
(or
A): 86.993 87.006 mm
8.4219
-3.4254
in.l
B: 86.983 86.996 mm
(3.4245-
3.4250 i n.)
Service Limit:
No Letter {or A}: 86.980 mm
(3.4244
in.}
B: 86.970 mm
(3.4240
i n.l
16 mm
{0. 6 i n. }
I
Oversize Piston Diameter:
0.251 87.233 87.246 mm {3.4344 3./849 in.}
SKIRT DIAMETER
7-14
4. Measure wear and taper i n di recti on X and Y at
three l evel s i n each cyl i nder as shown. l f
measurements i n any cyl i nder are beyond the
Oversi ze Bore Servi ce Li mi t, repl ace the bl ock. l i
the bl ock i s to be rebored, reJer to step 7 after
rebori ng,
Cylinder Bore Size:
Standard {New):
Aor l : 87. 010- 87. 020 mm
{3.4256 3./1260 in.)
B or l l : 87.000 87.010 mm
13.4252 3.4256 in.l
(3.4279
in.)
Oversize:
0.251 87.250 87.260 mm
(3.4350
3.4354 in.l
Rebori ng l i mi t: 0.25 mm {0.01 i n.} max.
Bore Taper:
Limit:
(Difference
between tirst and third
measurement) 0.05 mm
(0.002
i n.)
6 mm
(0. 2
i n. )
t
r tr-71
t l l a
l l - 1
IJI
JL
I ^
6 mm {0. 2 i n. l
First
Measurement
Second
Third
Measuremnt
Scored or scratched cyl i nder bores must be honed.
Check the top of the bl ock for warpage. Measure
al ong the edges and across the center as shown.
Engi ne Bl ock Warpage:
Standard
(New):
0.07 mm
(0.003
i n.l max.
(0.004
i n.l
PRECI SI ON STRAI GHT EDGE
7. Cal cul ate the di fference between the cyl i nder bore
di ameter and the
pi ston di arneter. l f the cl earance
i s near or exceeds the servi ce l i mi t, i nspect the
Di ston and cvl i nder bl ock for excessi ve wear.
Piston-to-Cylinder Clearance:
Standard {New): 0.004 0.027 mm
(0.0002
0.0011 i n.)
Service Limit: 0.04 mm {0.002
in.)
+l<
BlsJAo#-Io-cYLrNDER
7-15
Engi ne Bl ock
Cyl i nder Honi ng
The cyl i nder l i ners are made wl th FRM
({i ber
rei n{orced
metal ). Hone the cyl i nders onl y as descri bed here.
1. Measure the cyl i nder bores
(see
step 3 on page 7-
14). l f the engi ne bl ock i s to be reused, hone the
cVl i nders and remeasure the bores. Scored or
scratched cyl i nder bores must be honed.
2. Hone the cyl i nders usi ng the fol l owi ng equi pment,
materi al s and methods:
.
Use onl y a r i gi d hone.
.
Honi ng stones: GC-600-J or fi ner stones for
nonferrous metal s
.
Pressu re: 200
-
300 kPa
(2
3 kgf/cm' ,28-43 psi )
.
Honi ng r pm: 45- 50
.
Honi ng thi ckness; Less than 0.02 mm
(0.0008
i n.)
Do not hone more than 20 cycl es,
.
Honi ng l ubri cant: Oi l type
.
Honi ng pattern:
60 degree cross-hatch
(A)
.
Hone cl eani ng: Cl ean the stones every fi ve cycl es.
When honi ng i s compl ete, thoroughl y cl ean the
engi ne bl ockof al l metal parti cl es,
Wash the
cyl i nder bores wi th hot soapy water, then dry and
oi l them i mmedi atel y to
prevent
rusti ng. Never use
sol vent, i t wi l l onl y redi stri bute the gri t on the
cyl i nder wal l s.
l f scori ng or scratches are sti l l present i n the
cyl i nder bores after honi ng to the servi ce l i mi t,
rebore the cyl i nders. Some l i ght verti cal scori ng
and scratchi ng i s acceptabl e i f i t i s not deep enough
to catch your fi ngernai l and i f i t does not run the ful l
l ength of the bore.
?
4.
7-16
Pi ston, Pi n, and Connecti ng Rod Repl acement
Disassembly
1. Remove the pi ston from the cyl i nder bl ock
(see
p a g e 7 1 1 ) .
2. Appl y engi ne oi l t o t he pi st on pi n snap r i ngs
( A) ,
and turn them i n the ri ng grooves unti l the end
gaps are l i ned up wi th the cutouts i n the
pi ston pi n
bor es
( B) .
NOTE: Take care not to damage the ri ng grooves.
Remove both snap ri ngs
(A).
Start at the cutout i n
the pi ston pi n bore. Remove the snap ri ngs
careful l y so they do not go fl yi ng or get l ost. Wear
eve Drotecti on.
I
4, Heat the
pi ston and connecti ng rod assembl y to
approxi matel y
' 158"F
{70' C), then remove the
pi st on pi n.
(cont' d)
7-17
Engi ne Bl ock
Piston, Pin, and Connecting Rod Replacement
{cont'd)
Inspection
NOTE: Inspect the pi ston, pi ston pi n and connecti ng rod
when they are at room temperature.
1. Measu. e t he di amet er of t he pi st on pi n.
Piston Pin Diameter:
Standard
(New):
22.961 22.965 mm
10.9040 0.9041 i n.)
(0.9037
in.)
2. Zerc l he di al i ndi cator to the pi ston pi n
di ameter.
7-18
3. Check the di fference between the Di ston Di n
di ameter and pi ston pi n hol e di ameter i n the pi ston.
Piston Pin-to-Piston Clearance:
Standard {New): 0.0030 to +0.0060 mm
I O.OO012 to +0.00024 i n.l
Servi ce Li mi t: 0.010 mm {0.0004 i n.)
Measure the pi ston pi n-to-connecti ng
rod cl earance,
NOTE: When r epl aci ng t he connect i ng r od, al so
repl ace the
pi ston pi n
as a set.
Piston Pin-to-Connecting Rod Clearance:
Standard
(New):
0.018 0.035 mm
10.0007 0.0014 i n.,
Reassembly
1. I nst al l a new pi st on pi n snap r i ng
( A) .
Coat the
pi ston pi n bore i n the
pi ston
and the
connecti ng rod, and the pi ston pi n
wi th engi ne oi l .
Heat the
pi ston
to about 158"F
(70"C).
4. Instal l the
pi ston pi n (A).
Assembl e the
pi ston (B)
and connecti ng rod
(C)wi th
the
"l N"
mark {D) and
the reference mark
(E)
on the same si de.
I nst al l t he r emai ni ng new snap r i ng
( F) .
Tur n t he snap r i ngs i n t he r i ng gr ooves
unt i l t he
end gaps are posi ti oned at the bottom of the pi ston.
7-19
Engi ne Bl ock
Piston Ring Replacement
1 .
2.
Remove the
pi ston from the cyl i nder bl ock
(see
page 7- 1 1) .
Usi ng a ri ng expander
(A),
remove the ol d pi ston
r i ngs
( B) .
Cl ean al l ri ng grooves thoroughl y wi th a squared-
off broken ri ng or ri ng groove cl eaner wi th a bl ade
to fi t the
pi ston grooves.
The t op and second r i ng gr ooves ar e 1. 2 mm
( 0. 05
i n. ) wi de. The oi l r i ng gr oove i s 2. 0 mm
( 0. 08
i n. ) wi de. Fi l e down a bl ade i f necessar y. Do
not use a wi re brush to cl ean the ri ng grooves, or
cut the ri ng grooves deeper wi th the cl eani ng tool s.
NOTE: l f the pi ston i s to be separated from the
connecti ng rod, do not i nstal l new ri ngs yet.
7-20
4. Usi ng a
pi ston, push a new ri ng
(A)
i nto the
cyl i nder bor e 15 20 mm
( 0. 6
0. 8 i n. ) f r om t he
bottom,
- *
B
Measure the pi ston ri ng end-gap
(B)
wi th a feel er
gauge:
.
l f t he gap i st oosmal l , checkt osee i f
you
have
the
proper ri ngs for your
engi ne.
.
l f the gap i s too l arge, recheck the cyl i nder bore
di ameter agai nst the wear l i mi ts
(see page
7-14).
l f the bore i s over the servi ce l i mi t. the cvl i nder
bl ock must be rebored.
Pi ston Ri ng End-Gap:
Top Ri ng
Standard l Newl : 0.25 0.35 mm
( 0. 010
0. 014 i n. )
(0.024
i n.)
Second Ri ng
Sl andard {New): 0.60 0.75 mm
(0.024-
0.030 i n.)
(0.035
i n.,
Oi l Ri ng
Standard
(New):
0.20 0.70 mm
l O.O08 0.028 i n.)
(0.031
i n.l
7. Rotate the ri ngs i n thei r
grooves to make sure they
do not bi nd.
Posi ti on the ri ng end gaps as shown:
OI L RI NG GAP
About 90'
SECOND RING GAP
About 45"
8.
TOP RING GAP
and SPACER
RING GAP PISTON PIN
9. After i nstal l i ng a new set of ri ngs. measure the
fl ng-ro-groove ctearances:
Top Ri ng Cl earance
Standard
(New):
0.045 0.090 mm
(0.0018
0.0035 i n.)
(0.005
i n.)
Second Ring Clearance
Standard {New): 0.040- 0.070 mm
10.0016
-
0.0028 i n.)
(0.005
i n.)
7-21
6. Instal l the ri ngs as shown. The top ri ng
(A)
has a R1
mark and the second ri ng
(B)
has a R2 mark. The
manufacturi ng marks
(C)
must be faci ng upward.
Top Ri ng
(st andardl :
A: 2. 8 mm { 0. 11 i n. l
B: 1. 2 mm 10. 05 i n. l
Second Ri ng (St andard):
A: 3. 2 mm {0. 13 i n. l
B: 1. 2 mm {0. 05 i n. }
===_,/
-'\.----l
: :
- - - - - ' \ -
l b i l
- ' \
t)
ll ,----..t.L
[|-..-"
(l
i t \
t | \ - -
A--
/
\.4
B-
\'-
-!====:l
,/
\57
\ *U
re:\
SZ
rpd%a
\n**44d
,.ZuR\
\=/
Piston Ring Dimensions:
A
Engi ne Bl ock
Piston Installation
lf the crankshaft is already installed
1. Set the crankshaft to bottom dead center
(BDC)
for
each cyl i nder .
2. Remove the connecti ng rod caps, then i nstal l the
ri ng compressor, and check that the beari ng i s
secur el y i n pl ace.
3. Posi ti on the arrow {A)faci ng the ti mi ng chai n si de
of t he engi ne.
Posi ti on the pi ston i n the cyl i nder, and tap i t i n
usi ng t he wooden handl e of a hammer
( A) ,
l \4ai ntai n downward force on the ri ng compressor
(B)
to prevent the ri ngs from expandi ng before
enteri ng the cyl i nder bore.
4.
5. Stop after the ri ng compressor
pops free, and
check the connecti ng rod-to-crank
j ournal
al i gnment before
pushi ng the pi ston i nto pl ace.
7-22
6, Checkthe connecti ng rod beari ng cl earance wi th
pl asti gage
{see
page 7-9).
7. Appl yengi ne oi l t ot het hr eads of t he connect i ng
rod bol ts.
8. l nstal l the rod caps wi th beari ngs, then ti ghten the
connecti ng rod bol ts i s sequence to 25 N.m
{2.5 kgf.m. 18 l bf.ft),
9. Ti ghten the connecti ng rod bol ts an addi ti onal 90".
1 .
lf the crankshaft is not installed
Remove the connecti ng rod caps, then i nstal l the
ri ng compressor, and check that the beari ng i s
securel y i n pl ace.
Posi ti on the arrow
(A)
faci ng the ti mi ng chai n si de
of t he engi ne.
Posi ti on the pi ston i n the cyl i nder. and tap i t i n
usi ng the wooden handl e of a hammer
(A).
Mai ntai n downward force on the ri ng compressor
(B)
to prevent the ri ngs from expandi ng before
enteri ng the cyl i nder bore.
4. Posi ti on al l Di stons at too dead center.
.;
.,;':,.-;a
',t.:.1::,'l
7-23
Engi ne Bl ock
Crankshaft Instal l ati on
.
Dri ver 07749-0010000
.
Dri ver attachment 07948-S800101
1. Check t he connect i ng r od bear i ng cl ear ance wi t h
pl asti gage
{see
page
7-9).
2. Check t he mai n bear i ng cl ear ance wi t h pl ast i gage
(see page 7-6).
3. Appl y engi ne oi l t o t he mai n bear i ngs and r od
bea n ngs.
4. I nst al l t he bear i ng hal ves i n t he cyl i nder bl ock and
connecl l ng roos.
5. Hol d the crankshaft so rod
j ournal
No. 2 and rod
j our nal
No, 3 ar e st r ai ght up, and l ower t he
crankshaft i nto the bl ock.
Instal l the thrust washers
(A)
on both edges of the
No. 4 mai n bear i nq r ecess.
1.
9.
Appl y engi ne oi l to the threads of the connecti ng
rod bol ts.
Seat the rod
j ournal s
i nto connecti ng rod No. 1 and
connect i ng r od No. 4. I nst al l t he connect i ng r od
caps and bol ts fi nger' ti ght. Instal l the caps so the
beari ng recess i s on the same si de as the recess i n
the rod.
Rotate the crankshaft cl ockwi se, and seat the
j ournal s
i nto connecti ng rod No. 2 and connecti ng
r od No. 3, I nst al l t he connect i ng r od caps and bol t s
fi ngerti ght.
7-24
10.
1 1 .
Ti ghten the connecti ng rod bol ts i n sequence to 25
N.m
(2.5
kgf m, 18 i bf ft).
Ti ghten the connecti ng rod bol ts an addi ti onal 90' .
Appl y l i qui d gasket , par t No. 08718- 0009, evenl yt o
the cyl i nder bl ock mati ng surface of the l ower bl ock
and to the i nner threads of the bol t hol es.
have el apsed si nce appl yi ng l i qui d gasket. l nstead,
reappl y l i qu i d gasket after removi ng ol d resi due.
Appl y l i qui d gasket al ong
t he br oken l i ne.
13.
14.
Put the l ower bl ock on the cvl i nder bl ock.
Ti ghten the beari ng cap bol ts i s sequence to
29 N m
(3.0
kgf.m, 22 l bf.ft).
Ti ghten the beari ng cap bol ts an addi ti onal 60' .
Ti ghten the 8 mm bol ts i n sequence to 22 N.m
(2.2
kgf.m, 16 l bf.ft).
t 9 .
16.
18.
17. Use the sDeci al tool s to dri ve a new oi l seal
squarel y i nto the bl ock to the speci fi ed i nstal l ed
hei ght.
077'19-0010000
079,18"S800101
Measure the di stance between the crankshaft
(A)
and oi l seal { B) .
Oi l Seal Instal l ed Hei ghi :
5.5 6.5 mm 10.22 0.26 i n.l
Instal l the oi l
pump (see
step 1
' l
on
page 8-1 1).
I nst al l t he cam chai n { see
page 6- 19) .
' 19.
20.
7-25
Engi ne Bl ock
Pulley End Crankshaft Seal
Instal l ati on
-
In Car
'
Seal dri ver 07LAD-PT3o10A
1. Dry the crankshaft oi l seal housi ng.
2. Usi ng the seal dri ver, dri ve i n the crankshaft oi l seal
unti l the dri ver bottoms agai nst the chai n case,
07LAD.PT3OlOA
7-26
Transmission End Crankshaft Seal
l nstal l ati on
-
In Car
.
Dri ver 07749-0010000
.
Dri ver attachment 07948-S800101
1. Dry the crankshaft oi l seal housi ng.
2, Use the speci al tool s to dri ve a new oi l seal
squarel y i nto the bl ock to the speci fi ed i nstal l ed
hei ght.
079it8-S800101
Measure the di stance between the crankshaft {A)
and oi l seal { B) .
Oi l Saal Instal l ed Hei ght:
5.5-6.5 mm 10.22 0.26 i n.l
{0.22*0.26 i n.l
' .i.. "
-
'..i
Engi ne Mechani cal
Engi ne Lubri cati on
Speci al Tool s
Number Tool Number Description otY
e 07912- 6110001 Oi l Fi l t er Wr ench 1
BAFFLE PLATE
KNOCK SENSOR
\
\
OI L PUMP
\
CHAI N TENSI ONER
+DRAI NBOLT
OIL PUMP
Overhaul , page
8-8
I nspect i on,
st ep 6 on page 8-10
ENGI NE OI L COOLER
page 8. 7
CRANKSHAFT
ENGI NE OI L COOLER
CENTEN BOLT
OIL PUMP
CHAI N GUI DE
ENGI NE OI L PRESSURE SWI TCH
Ci rcui t Di agram, page 22-47
Swi t ch t est , page 8-4
Oi l pressure t est , page 8-4
OI L PAN
CHAIN CASE
8-3
Engine Lubrication
Oil Pressure Switch Test
1, Remove the YEURED wi re
(A)
from the engi ne oi l
pressure
swi tch
(B).
Check for conti nui tv between the oosi ti ve termi nal
( C)
and t he engi ne
( gr ound) ,
Ther e shoul d be
conti nui ty wi th the engi ne stopped. There shoul d
be no cont i nui t y wi t h t he engi ne r unni ng,
l f the swi tch fai l s to operate, check the engi ne oi l
l evel . l f t he engi ne oi l l evel i s OK, check t he engi ne
or l Dr essur e,
3.
,'1.:'(.,)"
,
8-4
Oil Pressure Test
l f the oi l pressure i ndi cator l i ght stays on wi th the
engi ne r unni ng, check t he engi ne oi l l evel . l f t he oi l
l evel i s correct:
1. Connect a tachometer or a Honda PGN4 Tester.
2. Remove t he engi ne oi l
pr essur eswi t ch, and i nst al l
an oi l
pr essur e gauge ( A) .
Start the engi ne. Shut i t off i mmedi atel y i f the
gauge regi sters no oi l
pressure. Repai r the probl em
before conti nui ng.
Al l ow the engi ne to reach operati ng temperature
(fan
comes on at l east twi ce). The pressure shoul d
DE:
Engi ne Oi l Temperature: 176' F
(80' C)
Engi ne Oi l Pressure:
At ldle: 250 kPa
(2.5
kgl /cm' ,36
psi )
mi ni mum
At 3,OOO rpm: 590 kPa
(6.0
kgf/cm', 85 psi)
mi ni mum
l f oi l pressure i s NOTwi thi n speci fi cati ons. i nspect
these rtem:
.
Check the oi l fi l ter for cl oggi ng.
.
Checkt he oi l
pump ( see page 8- 8) .
4.
5,
Engi ne Oi l Repl acement
NOTE: Under normal condi ti ons, the oi l fi l ter shoul d be
repl aced at every other oi l change. Under severe
condi ti ons. the oi l fi l ter shoul d be reol aced at each oi l
cnange.
Change interval
Evory 7,500 miles
(12.000
kml or 12 months
(Normal
conditions)
Every 3,750 miles
(6.000
kml or 6 months
{Severe conditionsl.
1, War m up t he engi ne,
2. Remove the drai n bol t
(A),
and drai n the engi ne oi l .
3. Rei nstal l the drai n bol t wi th a new washer {B).
4. Refi l l wi th the recommended oi l
(see p3g"
3-2;.
Capacity
4.5 0
(/r.8
US qt)
at oil change.
4.8 0
(5.1
US qt)
at oil change including filier.
5.6
g
(5.9
US qt)
after engine ovorhaul.
5. Run the engi ne for more than 3 mi nutes. then check
for oi l l eakage.
8-5
Engine Lubrication
Engine Oil Filter Replacement
Speci al Tool s Requi red
Oi l Fi l ter Wrench 07912-61 1000' 1
1. Remove the oi l fi l ter wi th the speci al oi l fi l ter
wr encn.
2. I nspect t he t hr eads
( A)
and r ubber seal
( B)
on t he
new fi l ter. Wi pe off the seat on the engi ne bl ock,
then appl y a l i ght coat of oi l to the fi l ter rubber seal .
Use onl y fi l ters wi th a bui l t-i n bypass system.
3, I nst al l t he oi l f i l t er by hand.
4. After the rubber seal seats, ti ghten the oi l fi l ter
cl ockwi se wi th the speci al tool ,
Ti ghten: 7/8 turn cl ockwi se.
Ti ghteni ng torque: 22 N.m
(2.2
kgf.m, 16l bf ft)
8-6
5. l f ei ght numbers
(1
to 8) are pri nted around the
outsi de of the fi l ter, use the fol l owi ng procedure to
ti ghten the fi l ter.
.
Spi n the fi l ter on unti l i ts seal l i ghtl y seats agai nst
t he engi ne oi l cool er , and not e whi ch number i s
at the bottom.
.
Ti ghten the fi l ter by turi ng i t cl ockwi se seven
numbers from the one
you noted. For exampl e. i f
number 2 i s at the bottom when the seal i s seated,
ti ghten the fi l ter unti l the number 1 comes
around the bottom.
Number when rubbel
seal is seated.
Number af t er t i ght eni ng.
Number when
r ubber seal i s
1 2 3 5 6 1
Number after
ti ghteni ng
8 1 2 3 5 6 1
6. Af t er i nst al l at i on, Ji l l t he engi ne wi t h oi l upt ot he
speci fi ed l evel , run the engi ne for more than 3
mi nutes, then check for oi l l eakage.
Oi l Jet Inspecti on
1. Remove t he oi l
i et ,
and i nspect i t asf ol l ows.
Make sur e t hat a 1. 5 mm
( 0. 06
i n. ) di amet er dr i l l
wi l l go t hr ough t he nozzl e hol e
( A) ( ' 1. 6
mm
( 0. 06
i n. ) di amet er ) .
I nser t t he end of a 1. 1 mm
( 0. 04
i n. ) dr i l l i nt o t he
oi l i nt ake
( 1. 2
mm
( 0. 05
i n. ) di amet er ) .
Make sure the check bal l {B) moves smoothl y and
has a st r oke of appr oxi mat el y 4. 0 mm
( 0. 16
i n. ) .
Check the oi l
j et
operati on wi th an ai r nozzl e. l t
shoul d take at l east 200 kPa
(2.0
kgfl cm' ,28 psi )
to unseat the check bal l .
NOTE: Repl ace the oi l
j et
assembl y i f the nozzl e i s
damaged or bent .
Mounti ng torque i s cri ti cal . Be very preci se
when
i nst al l i ng.
Torque; 16 N.m {1.6 kgf m, 12l bf.ft)
1. 6 mm {0. 06 i n. )
2.
8-7
Oi l Pump Overhaul
Exploded View
PUMP COVER
RELIEF VALVE
DOWEL PIN
PUMP HOUSING
DOWEL PIN
Val ve must sl i de treel y
i n housi ng bore.
Repl ace i f scored.
SEALING BOLT
39 N.m
(i0.0
kgl.m,29lbf.ltl
DOWEL PINS
OUTER ROTOR
\F
6 x 1 . 0 mm
12 N. m
(1. 2
kgf . m, 8. 7 l bf . f t l
8-8
Removal
1. Remove the cam chai n
(see page 6-' 15).
2, Remove t he oi l pump chai n t ensi oner .
3. Remove the baffl e
pl ate.
4. Remove the three bol ts securi ng the oi l pump.
5. Remove the oi l
pump (A).
oi l
pump
chai n
(
crankshaft sprocket
(C).
B) and
Oil Pump Overhaul
(cont'd)
Inspection
6. Remove the DumD cover.
7. Check the i nner-to-outer rotor radi al cl earance
between the i nner rotor
(A)
and outer rotor
(B),
l f
the i nner-to-outer rotor radi al cl earance exceeds
the servi ce l i mi t, repl ace the outer rotor and oi l
pump housi ng.
Inner Rotor.to.Outer Rotor Radial Clearance
Standard
(New):
0.02 0.15 mm
10.001 0.006 i n.)
(0.008
i n.)
8. Check the housi ng-to-rotor axi al cl earance between
the rotor
(A)
and pump housi ng
(B).
l f the housi ng-
to-rotor axi al cl earance exceeds the servi ce l i mi t,
repl ace the outer rotor and oi l
pump housi ng.
Housing-to-Rotor Axial Clearance
Standard l Newl : 0.02 0.07 mm
(0.001
0.003 i n.l
8-10
9. Check the housi ng-to-outer rotor radi al cl earance
between the outer rotor
(A)
and pump housi ng
(B).
l f l he housi ng-to-outer rotor radi al cl earance
exceeds the servi ce l i mi t, reol ace the outer rotor
and oi l
pump
housi ng.
Housing-to-Outer Rotor Radial Clearance
Standard
(Newl :
0.15
-
0.21 mm
(0.006
0.008 i n.)
Servi ce Li mi t: 0.23 mm {0.009 i n.}
Inspect both rotors and the
pump
housi ng for
scori ng or other damage. Repl ace pans i f
necessary.
10.
Instal l ati on
11. Squeeze t he new oi l pump chai n t ensi oner
( A) ,
t hen
i nst al l t he set cl i p
( B)
on i t as shown.
NOTE; The set cl i p i s suppl i ed wi th the oi l
pump
chai n t ensi oner .
\ns\a\\ \he c\ankshat s$\ocke\ \N\,
ti{
!\f\$
c\a\n
( B)
and oi l
pump ( C) .
\')..
13. Ti ghten the bol ts on the oi l
pump.
x 1. 25 mm
22 N.m
(2.2 ksf.m, 16 lbl ft)
' -/ 6
x 1. 0 mm
at 12 N. m
S? {1. 2 ksf m.
B
8.7 rbr.ft)
14. Instal l the baffl e
pl ate.
6 x 1 . 0 mm
12 N. m
(1. 2
kgt m. 8. 7l bf . f t )
,j',
'
,.1''
:,'."
::'
(cont' d)
8- 11
Oi l Pump Overhaul
(cont' dl
Set the crankshaft sprocket so that the No. 1 pi ston
i s at top dead center
(TDC).
Al i gn the key
(A)
on the
sprocket and crankshaft wi th the
poi nter (B)
on the
cyl i nder bl ock.
16, Move the cam chai n so that the col ored
pi ece
{A)
al i gns wi th the
punched
mark
(B)
on the crankshaft
sprocket,
i -
)
8-12
11. I nst al l t he oi l
pump
chai n gui de ( A)
and oi l pump
chai n t ensi oner
( B) ,
I
6 x 1 . 0 mm
12 N. m
{1. 2 kgt . m, 8. 7 l bf . f t }
x 1. 0 mm
12 N. m
(1. 2
kgf . m, 8. 7 l bf . f t )
8 x 1. 25 mm
22 N.m 12.2 kgf.m. 16 l bf.ftl
18. Remove the set cl i p from the oi l
pump
chai n
renstoner.
19. I nst al l t he cam chai n
( see page 6- 19) .
i . - .
Engi ne Mechani cal
Intake Manifold and Exhaust System
I nt ake Mani f ol d Removal / l nst al l at i on . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Mani f ol d Removal / l nst al l at i on . . . . . . . . . . . . . . . . . . . . .
Exhaust Pi pe and Muf f l er Repl acement . . . . . . . . . . . . . . . . . . . . .
9-2
9-3
9-4
tbf.ft)
AIR CONTROL VALVE
TNTAKE AtR I
TEMPERATURE
I
{rAT)SENSOR
I
\
j
8 x 1 . 2 5 mm
\ \ I
22/Nin l2.2kst.m, 16 lbf.fr)
\ \ o - R t N G l /
\ \
-i ' """J/,no"*.,
,ENG,NEcooLANr
\ \ I ^.c:\q /
Beptace.
/ TEMPERATURE |ECT)
\ Q\
i
5' 97
g4\::"
/
1,,T,"f1,.,.,0,n,
. \ Ri \ =/
' ,
/ . . ' . R, NG
ffi1-,
{;/:;ffi***
x" */
q>
N
)'.;;7 I
ffi^#\e
t uc\
G" \ w( i
, , \ W" \ \ * ! , , 0, " -
e. \ l l
-
o-RtNG \
12 N.m
\/)
Bepl ace
\
{1 2 ksf m' 8 7 l bf rtr
Intake Manifold RemovaUlnstallation
NOTE: Use new O-ri ngs and gaskets
when reassembl i ng.
THROTTLE
BODY
8 x 1.25 mm
22 N.m
{2.2 ksf.m, 16l bf.ft)
4
5 x 0 . 8 mm
6 N. m
{0. 6 kgf m,
\
8 x 1 . 2 5 mm
\
22 N. m
(2. 2
kgf . m. 16l bf . f t )
GASKET
\
Repl ace
\
\ \ '
\ ^<a\
,"*,XDN$
t
K
\ / *
./g ^&
,"
o A'Y
BLEED BOLT \Z-
')
9.8 N.m
*
-
{ 1. 0 kgf m,
Ai \
7.2 tbf.ftt /
"/\
IDLE AIR CONTROL
{IAC} VALVE
I NTAKE MANI FOLD
Repl ace i f cracked or
i f t he mat i ng surf ace i s
oamageo,
d q b
# \
'i13
\
10 x 1. 25 mm
44 N. m
{4. 5 kgf . m, 33 l bf . f t l
I NTAKE MANI FOLD
BRACKETS
l 0 x 1. 25 mm
44 N. m
{4.5 ksf.m, 33 lbt.ftl
I
9-2
Exhaust Manifold RemovaUlnstallation
NOTE: Use new gaskets and sel f-l ocki ng nuts when reassembl i ng.
8 x
' l .25
mm
22 N.m
(2.2
ksf.m, 16 lbt ftl
6 x 1 . 0 mm
12 N. m
{1. 2 kg{ m,
8.7 rbf.ftt
6 x 1 . 0 mm
12 N. m
{1. 2 kgf . m.
8.7 rbf.ftt
8x 1. 25 mm
22 N. m
(2.2
kgf.m, 16 lbf ft)
0 f o
' 14
N. m
{1. 4 kgf . m, 10 l bt f t }
GASKET
Repl ace.
SELF.LOCKING NUT
8 x 1. 25 mm
31 N m 13. 2 kg{. m, 23 l bf . f t }
Repl ace.
PRIMARY HEATED
OXYGEN SENSOR
I PRI MARY HO2SI
44 N. m
(4. 5 kgf . m, 33l bt . f t l
EXHAUST MANIFOLD
l 0x 1. 25 mm
44 N. m
(4.5 kgf m.33 lbl.ft)
EXHAUST MANIFOLD
BRACKET
' , - l
; l
di
l.l
- . .
+
9-3
NOTE: Use new gaskets and sel f{ocki ng nuts when reassembl i ng.
SELF.LOCKING NUT
10 x 1.25 mm
33 N.m
(3.,1kgf.m,25
lbl'ft)
Repl ace.
Exhaust Pipe and Muffler Replacement
E x 1. 25 mm
22 N.m 12.2 kgf.m, 16 lbl ft)
Repl ace.
Ti ght en t he bol t s i n st eps,
al t ernat i ng si de-t o-si de.
6 x 1 , 0 mm
12 N. m
(1. 2
kgl . m, 8. 7 l bf . f t l
THREE WAY CATALYTIC
CONVERTER ITWCI
-zGASKET
/"'
RePlace'
SECONDARY HEATED
OXYGEN SENSOR
ISECONDARY HO25I
44 N.m {4.5 kgl .m,33 l bt.ft)
6 x 1 . 0 mm
12 N. m {1. 2 kgf . m, 8. 7 l bf . f t )
9-4
Engi ne Cool i ng
Cooling System
Comoonent Locat i on I ndex . . . , . . , . . . . . . .
Radi at or Cao Test . . . . . . . . . . . . . . . .
Radi at or Test
Fan Motor Test
Thermost at Test . . . . . . . . . . . . . . . . . . . . . .
Wat er Pump I nspect i on
Wat er Pump Repl acement
Cool ant Repl acement . . . . . . . . . . . . .
Thermost at ReDl acement
Radi at or and Fan Reol acement . . . . . . . . . . . . . . . . . . . . .
Fan Controls
Component Locat i on I ndex . . . . . . . . . . . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 12
Ci r cui t Di agr am . . . . . . . . . 10- 14
Radi at or Fan Ci rcui t Troubl eshoot i ng . . . . . . . . . . . . . . . . . . . . . . . . 10-15
Radi at or Fan Swi t ch Ci rcui t
Troubl eshoot i ng
(Open)
. . . . . . . . . . . . . . . . . 10- 17
Radi at or Fan Swi t ch Ci rcui t
Troubl eshoot i ng
(Short )
. . . . . . . . . . . . . . . . 10-17
Radi at or Fan Swi t ch Test . . . . . . . . . . . . . . . . . . . 10-18
10-2
10-5
1p- 5
10-6
10-6
tu- I
10-7
10-8
10- 10
10- 11
Cooling System
COOLANT
RESERVOIR
RADIATOR
Repl acement , page 10' 1 1
RADIATOR CAP
\
/'-'
'1'
UPPER RADIA
LOWER
,/ ,/
.""*oY
,/
O-RI NG
RADIATOR FAN SWITCH
Test , page 10-18
FAN MOTOR
Test , page' 10-6
Repl acement ,
page 10- 11
RADIATOR FAN SHROUD
Repl acement , page 10-1 1
A/ C CONDENSER
FAN SHROUD
RADIATOR FAN
Repl acement , page 10 11
DRAIN PLUG
/
RADIA'I TOR HOSE
10-2
IDLE AIR CONTROL
IIAC) VALVE
HEATER VALVE
OIL COOLER BYPASS HOSE
WATERBYPASS TUBE
\
THERMOSTAT
COVER
\
uppenmDrAroRHosE
LOWER RADIATOR HOSE
(cont' d)
HEATER HOSES
i
-.,!,'jj
N
l
ti l
l
10-3
Cooling System
{cont'd)
- - i ' - : ' f .
l r r _' ,
\
' *
\
WATER PUMP
I nspect i on, page 10-7
ENGI NE COOLANT TEMPERATURE
{ECTI SENSOR
THERMOSTAT
Repl acement, page 10-' l 0
Inspecti on, page 10-6
THENMOSTAT
COVER
WATER
COVER
OUTLET
\
O.RING
THERMOSTAT
HOUSING
WATER
I
PUMP
\
l)
o'\,
$ s \ \ i
\ es, ' ,
O. RI NG
RUBBER SEAL
10- 4
Radiator Cap Test
1. Remove the radi ator cap
(A).
wet i ts seal wi th
engi ne cool ant, then i nstal l i t on the pressure tester
( B) ( commer ci al l y
avai l abl e) .
Appl ya pr essur eof 93 123kPa
( 0. 95
1. 25
kgfl cm' , 14- 18
psi ).
Check for a drop i n
pressure.
4. l f the pressure drops, repl ace the cap.
Radiator Test
1. Wai t unti l the engi ne i s cool , then careful l y remove
the radi ator cap and fi l l the radi ator wi th engi ne
cool ant to the top of the fi l l er neck.
2. Attach the pressure tester
(A)(commerci al l y
avai l abl e) to the radi ator and appl y a
pressure
of
93 123 kPa
(0.95
1.25 kg7cm' , 14 18 psi ).
Inspect for engi ne cool ant l eaks and a drop i n
pressure.
Remove the tester and rei nstal l the radi ator cap.
Check for engi ne oi l i n the cool ant and/or cool ant
t he engi ne oi l .
3.
4.
10-5
Cooling System
Fan Motor Test
1. Di sconnect the 2P connectors from the radi ator fan
motor
(A)
and condenser fan motor
(B).
Test the motor by connecti ng battery power to the
No. 2 termi nal and
ground
to the No. 1 termi nal .
l f the motor fai l s to run or does not run smoothl y,
repl ace i t.
3.
10-6
Thermostat Test
Repl ace the thermostat i f i t i s open at room
temperature.
To test a cl osed thermostat:
1. Suspend the thermostat
(A)
i n a contai ner of water.
Do not l et the thermometer
(B)
touch the bottom of
the hot contai ner.
,,
3.
Heat the water and check the temperature wi th the
thermometer. Check the temperature at whi ch the
thermostat fi rst opens, and at whi ch i t i s ful l y open.
Measure the l i ft hei ght of the thermostat when i t i s
f ul l y open.
STANDARD THERMOSTAT
Li ft hei ght: above 10.0 mm
{0.39
i n.l
Starts openi ng: 169 176"F176 80"C)
Ful l y open: 194' F {90"C)
1 .
2.
Water Pump Inspection
, 1'
..:.'
4.
5.
Turn the water pump countercl ockwi se. Check that
i t turns freel y.
Check for si gns of seal l eakage. A smal l amount of
"weepi ng"
from the bl eed hol e
(A)
i s normal .
fMove the auto-tensi oner to remove tensi on from
the al ternator-compressor bel t, then remove the
al ternator-compressor bel t
(see
step 8 on page 6-
15) .
Remove t he wat er
PumP Pul l eY.
6 x 1 . 0 mm
14 N. m
(1. 4
kgf . m,
10 tbf.ft)
1 .
2.
Water Pump Replacement
7.
Move the auto-tensi oner to remove tensi on from
the al ternator-compressor bel t. then remove the
al ternator-compressor bel t
(see
step 8 on
page
6-
15) .
Remove the water pump pul l ey.
Remove the water pump (A)
by removi ng the si x
bol ts,
10 x 1. 25 mm
44 N m {4.5 kgf.m,33 l bt ftl
Cl ean and i nspect the O-ri ng
groove and the mati ng
surface wi th the thermostat housi ng.
I nst al l t he wat er pump, wi t h a new O- r i ng { B} , i n t he
reverse order of removal .
Cl ean up t he spi l l ed engi ne cool anl .
5.
b .
1^,
i
Br
i ,
i ' ,i
,,),;J
10-7
Cooling System
Coolant Replacement
1 . Set the heater temperature control di al to
maxi mum heat.
Remove the radi ator cap.
Loosen the drai n
pl ug (A),
and drai n the cool ant.
Remove the drai n bol t
(A)
from the ri ght si de of
cvl i nder bl ock.
,-,t---
t he
A
83 N.m
(8.5
kgf.m,61 lbf.ftl
After the cool ant has drai ned, appl y l i qui d gasket,
P/N 08718-0009, to the drai n bol t threads, then
rei nstal l the bol t wi th a new washer and ti ghten
i t securel y.
Ti ghten the radi ator drai n
pl ug
securel y.
10-8
7. Remove, dr ai n, and r ei nst al l t he r eser voi r . Fi l l t he
tank to the MAX mark wi th Honda Al l Season
Anti freeze/Cool ant Type 2
(P/N
O1999-9001).
Remove the bl eed cap
(A)from
the heater bypass
tube.
Loosen the ai r bl eed bol t
(A)
i n the i ntake mani fol d.
then
pour
Honda Al l Season Anti freeze/Cool ant
Tvoe 2 i nto the radi ator to the bottom of the fi l l er
neck. Do not l et cool ant spi l l on any el ectri cal parts
or the
pai nt. l f any cool ant spi l l s, ri nse i t off
i mmedeatel y.
NOTE:
.
Al ways use Honda Al l Season Anti freeze/Cool ant
Type 2
(P/N
OL999-9001). Usi ng a non-Honda
cool ant can resul t i n corrosi on, causi ng the
cool i ng system to mal functi on or fai l .
.
Honda Al l Season Anti freeze/Cool ant Tvpe 2 i s a
mi xture of 50% anti freeze and 50% water.
Premi xi ng i s not requi red.
Engine Coolant Rsfill Capacity
Iincluding
reservoir capacity or 0.6 0
(0.6
US
qt)l:
6.5 0
(6.9
US
$l
9.8 N.m {1.0 kgt.m,7.2lbl.ft)
9.
1 1 .
10.
12.
Ti ghten the bl eed bol t as soon as cool ant starts to
run out i n a steady stream.
Instal l the bl eed cap on the heater bypass tube as
soon as cool ant starts to run out i n a steady stream.
Wi th the radi ator cap off, start the engi ne and l et i t
run unti l warmed up {radi ator fan comes on at l east
twi ce). Then, i f necessary, add more Honda Al l
Season Anti freeze/Cool ant Type 2 to bri ng the l evel
back up to the bottom of the fi l l er neck.
Put the radi ator cap on ti ghtl y, then run the engi ne
agai n and check f or l eaks.
10-9
Cooling System
Thermostat Replacement
'
r/a
Y r t
l ' - --/ . /
/' ;-' s,
"1,' -' l t'
../
Radiator and Fans Replacement
FAN MOTOR
CONNECTOR
UPPEF RADIA
A/C CONDENSER FAN
SHROUD ASSEMBLY
LOWER RADIATOR
HOSE
RADIATOR FAN
SWITCH CONNECTOR
FAN MOTOR
CONNECTOR
3. Di sconnect the fan motor connectors and radi ator fan swi tch connector.
4. Removet he r adi at or upper br acket s and cushi ons, t hen pul l
upt he r adi at or .
5. Remove both fan shroud assembl i es and other Darts from the radi ator.
6, Instal l the radi ator i n the reverse order of removal . Make sure the upper and l ower cushi ons are set securel y.
7. Fi l l t he r adi at or wi t h engi ne cool ant and bl eed t he ai r .
LOWER
CUSHION
TOR HOSE
6 x 1 . 0 mm
7 N. m
(0. 7
RADIATOR FAN
SHROUD ASSEMBLY
1. 0 mm 6 x
7 N.m {0.7 kgl.m, 5 lbf ftl
RADIATOR FAN
swtTcH
2 , 1 Nm
{2.4 kgf.m, 17 lbf.ftl
10- 11
Fan Controls
RADIATOR FAN ASSEMBLY
Mot or Test , page 10 6
A/C CONDENSER FAN RELAY
Test , st ep 10 on page 23-41
RADIATOB FAN RELAY
Test , st ep 10 on
page 23-41
RADIATOR FAN SWITCH
Test, page 10 18
A/ C CONDENSER FAN ASSEMBLY
Mot or Test , page 10-6
UNDER-HOOD
FUSE/RELAY BOX
10-12
Symptom Troubleshooting Index
Before performi ng
any troubl eshooti ng procedures
check:
.
Fuses
.
Grounds
.
Cl eanl i ness and ti ghtness of al l connectors
SYMPTOM PROCEDURE
Radi ator tan does not run at al l Radi ator Fan Ci rcui t Troubl eshooti ng
{see
page 10-15).
Radi ator fan does not run for engi ne cool i ng. but i t runs
wi th A/C ON
Radi ator Fan Swi tch Ci rcui t Troubl eshooti ng
(Open)
(see page
10-17).
Radi ator fan runs wi th i gni ti on swi tch ON
(l l ),
Ay' C OFF,
and engi ne temperature bel ow 199' F
(93' C)
Radi ator Fan Swi tch Ci rcui t Troubl eshooti ng
(Short)
(see page 10-17).
10- 13
Fan Controls
GflnoN swtTcH
Circuit Diagram
/ 8AT \
\ c 2 8 l
IG2 HOT h ON II||
I
I
I
-mhrito
I
I
I
t
G201
G301
I
L .
MAIfl UNOEE-HOOD FUSE/8ETAY BOX
10- 14
Radiator Fan Gircuit Troubleshooting
1. Check t he No. 57
{ 20A} f use i n t he mai n under - hood
fuse/rel ay box. and the No. 20
(7.5A)
fuse i n the
under-dash fuse/rel ay box.
ls the fuse (s) OK?
YES- Go to step 2.
NO Repl ace the fuse
(s)
and recheck.I
2. Remove the radi ator fan rel ay from the mai n under-
hood fuse/rel ay box, and test i t
(see page 22-40]| .
ls the relay OK?
YES Go to step 3.
NO Repl ace the radi ator fan rel ay.l
3. Measure the vol tage between the No. 1 termi nal of
the radi ator fan rel ay 4P socket and body ground,
RADIATOR FAN RELAY 4P SOCKET
Termi nal si de ot femal e termrnars
ls there battety voltage?
YES Go to step 4.
NO- Repl ace the under-hood fuse/rel ay box.!
4. Connect the No. 1 and No. 2 termi nal s of the
radi ator fan rel ay 4P socket wi th a
j umper
wi re,
RAOIATOR FAN RELAY 4P SOCKET
JUMPER
WIRE
Termi nal si de of f emal e t ermi nal s
Does the radiator fan run?
YES Go to step 5.
NO Go to step 6.
Di sconnect the
j umper,
and turn the i gni ti on swi tch
ON
(l l ).
Check for vol tage between the No. 3
termi nal of the radj ator fan rel ay 4P socket and
body ground.
RADIATOF FAN RELAY 4P SOCKT
Termi nal si de ot femal e termi nal s
ls there battery voltage?
YES-Go to step L
NO-Check for an open i n the wi re between the
under-hood fuse/rel ay box and under-dash fuse/
rel ay box.t
(cont' d)
10- 15
Fan Gontrols
Radiator Fan Circuit Troubleshooting
(cont'd)
7 .
Di sconnect the radi ator fan motor 2P connector.
Check for conti nui ty between the No. 2 termi nal of
the radi ator fan rel ay 4P socket and the No. 2
termi nal of the radi ator fan motor 2P connector.
RADIATOR FAN EELAY 4P SOCKET
RADIATOR FAN MOTOR2P CONNECTOR
ls there continuity?
YES Go to step 8.
NO Repai r open i n the wi re between the under
hood fuse/rel ay box and the radi ator fan motor 2P
connector termi nal No. 2.I
Check for conti nui ty between the No. 1 termi nal of
the radi ator fan motor 2P connector and body
g rou nd.
RADIATOR
YES- Repl ace the radi ator fan motor.l
NO Check for an open i n the wi re between
radi ator fan motor 2P connector termi nal No. 1 and
body ground. l f the wi re i s OK, check for a poor
gr ound at G201. 1
FAN MOTOR 2PCONNECTOR
rBl
L+
l*-
Y
10- 16
9. Rei nstal l the radi ator fan rel ay.
Di sconnect the radi ator fan swi tch 2P connector.
Connect the No, 1 and No. 2 termi nal s, of the
radi ater fan swi tch 2P connector wi th a
j umper
wi re.
RADIATOR FAN SWITCH
2P CONNECTOR
JUMPER
WIRE
Does the radi ator fan tun?
YES Repl ace the radi ator fan swi tch.l
NO- Go to step 12.
Remove the
j umper
wi re, and measure the vol tage
between the No. 2 termi nal of the radi ator fan
swi tch connector and body ground.
BAOIATOR FAN SWITCH
2PCONNECTOR
YES Check for an open i n the wi re between
radi ator fan swi tch 2P connector termi nal No. 1 and
gr ound at G301. 1
NO Repai r open i n the wi re between the radi ator
fan swi tch termi nal No. 2 and the under-hood
fuse/rel ay box.I
10.
1 1 .
Radiator Fan Switch Circuit
Troubl eshooti ng
(Openl
1. Di sconnect the radi ator fan swi tch 2P connector.
2. Turn the i gni ti on swi tch ON
(l l ).
3. Measure vol tage between the No.2 termi nal ofthe
radi ator fan swi tch 2P connector and body ground.
BADIATOR FAN SWITCH
2PCONNECTOR
Is there battery voltage?
YES Go to step 4,
NO
-
Repai r open i n the wi re between the radi ator
fan swi tch 2P connector termi nal No. 2 and under-
hood fuse/rel ay box.l
Turn the i gni ti on swi tch OFF, and check for
conti nui ty between the No. 1 termi nal of the
radi ator fan swi tch 2P connector and body ground.
RADIATOR FAN SWITCH 2P
CONNECTOR
YES Repl ace the radi ator fan swi tch.I
NO Check for an open i n the wi re between the
radi ator fan swi tch 2P connector termi nal No. 1 and
gr ound at G301. t
Radiator Fan Switch Circuit
Troubl eshooti ng
(Shon)
1, Remove the radi ator fan rel ay from the mai n under-
hood fuse/rel ay box, and test i t
(see page22-401.
ls the rclay OK?
VES Go to step 2.
NO Repl ace the radi ator fan rel ay.I
2. Remove the radi ator fan swi tch, and test i t {see
page 10- 18) .
l s the radi ator f an swi tch OK?
YES
-
Go to step 3.
NO Repl ace the radi ator fan swi tch.l
3. Di sconnectthe negati ve cabl e from the battery.
4. Di sconnect Engi ne Control N4odul e
(ECM)
connector A
(25P)
and the under-hood fuse/rel ay
box 16P connector.
5. Check for conti nui ty between the No. 2 termi nal of
the radi ator fan swi tch 2P connector and body
gr ound.
RADIATOR FAN SWITCH
2P CONNECTOR
YES Repai r short i n the wi re between the radi ator
fan swi tch 2P connector termi nal No. 2 and mai n
under-hood fuse/rel ay box. I
NO Repl ace the mai n under-hood fuse/rel ay box.
I
10-17
Fan Gontrols
Radiator Fan Switch Test
NOTE: Bl eed ai r from the cool i ng system after i nstal l i ng
the radi ator fan swi tch
(see page 10-81.
1. Remove the radi ator fan swi tch from the radi ator
( see page' ! 0- 11) .
2. Suspend the radi ator fan swi tch
(A)
i n a contai ner
of water as shown.
Heat the water and check the temperature wi th a
thermometer. Do not l et the thermometer
(B)
touch
the boftom of the hot contai ner.
Measure the conti nui ty between termi nal No. 1 and
termi nal No. 2 accordi ng to the tabl e.
\
Telminal
ffi
1
swrTcH
ON
195' -203' F
(91"-95' C)
G
-o
OFF
5' -15"F
(3' -8' C) l owe
than the temperature
when it
qoss
on
10- 18
Fuel and Emi ssi ons
Fuel and Emissions Systems
Speci al Tool s . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 2
General Troubl eshoot i ng
I nf ormat i on
DTC Troubl eshoot i ng I ndex . . . .
Sympt om Troubl eshoot i ng
I ndex . . . . . . . . . . . . . . .
Syst em Descri pt i ons . . . . . . . . . . . . . . . .
PGM-Fl System
Component Locat i on I ndex . . . .
DTC Troubl eshoot i ng . . . . . . . . . . . . . .
MI L Ci rcui t Troubl eshoot i ng . . .
DLC Ci rcui t Troubl eshoot i ng . .
I nj ect ors Repl acement . . . . . . . . . . . . .
Pri mary HO2S Repl acement . . .
Secondarv HO25
Repl acement
ldle Gontrol System
Component Locat i on l ndex . . . .
DTC Troubl eshoot i ng . . . . . . . . . . . . . .
A,/C Signal Circuit
Tr oubl eshoot i nS . . . . . . . . . . . . . . . . . . .
Al t ernat or FR Si gnal Ci rcui t
St art er Swi t ch Si gnal Ci rcui t
El ect ri cal Power St eeri ng
(EPS)
Si gnal Ci rcui t
Brake Pedal Posi t i on
Swi t ch Si gnal Ci rcui t
Tr oubl eshoot i nS . . . . . . . . . . . . . . .
l dl e Speed I nspect i on
ECM l dl e Learn Procedure . . . . . .
Fuel Supply System
Comoonent Locat i on l ndex . . . .
PGM-Fl Mai n Rel ay Ci rcui t
Tr oubl eshoot i ng . . . . . . . . . . . . . . . . . . .
Fuel Pressu re Rel i evi ng . . . . . . . . . . .
Fuel Pressure Test . . . . . . . . . . . . . . . . . . .
Fuel Pump Test
Fuel Li nes I nsoect i on
Fuel Tu be/Ou ick-Con nect
Fi t t i ng Precaut i ons . . . . . . . . . . . . . . .
Fuel Tube/Qu ick-Con nect
Fi t t i ngs Remova1 . . . . . . . . . . . . . . . . . .
Fuel Tu be/Ou ick-Con nect
Fi t t i ngs I nst al l at i on . . . . . . . . . . . . . . .
Fuel Pressu re Regul at or
Rep1acement . . . . . . . . . . . . . . . . . . . . . . . . . 11- 113
Fuel Fi l t er Repl acement . . . . . . . . . . . 11- l 13
Fuel Pump/ Fuel Gauge Sendi ng
Uni t Repl acement . . . . . . . . . . . . . . . . . 11- 114
Fuel Tank Repl acement . . . . . . . . . . . 11- 115
Fuel Gauge Sendi ng Uni t
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 119
Low Fuel I ndi cat or Li ght
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1- 120
lntake Air System
Component Locat i on I ndex . . . . 11-121
Throt t l e BodyTest . , . . . . . . . . . . . . . . . . . 11-122
Ai r Cl eaner El ement
Rep1acement . . . . . . . . . . . . . . . . . . . . . . . . . 1 1- 123
Throt t l e Cabl e Adj ust ment . . . . . . 11-124
Throt t l e Cabl e Removal /
l nst al l at i on . . 11-125
Throttle Body Removal/
l nst al l at i on . . 11-126
Th rottle Body Disassembly/
Reassemb1y . . . . . . . . . . . . . . . . . . . . . . . . . . 11-127
Catalytic Converter System
DTC Troubl eshoot i ng . . . . . . . . . . . . . . 11-128
PCV System
PCV Val ve I nspect i on and
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1- 129
EVAP System
DTCTr oubl eshoot i ng . . . . . . . . . . . . . . 11- 131
EVAP Two Way Val ve Test . . . . . . 11-145
Fuel Tank Vapor Cont rol Val ve
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 l - 146
Fuel Tank Vapor Cont rol Val ve
Repf acement . . . . . . . . . . . . . . . . . . . . . . . . . 11- 147
Pulsed Secondary Air
Injection System
DTC Troubl eshoot i ng . . . . . . . . . . . . . . 1 1-149
Ai r Pump/ Ai r Pump Rel ay
Removal / l nst a l l at i on . . . . . . . . . . . . 1 1-159
Ai r Pump Rel ay Test . . . . . . . . . . . . . . . . 11- 160
Ai r Pump/ El ect ri c Current
Sensor Removal /
I nst al l at i on . . 11- 160
11- 3
11- 6
1 1- 9
1 1 - 1 0
11-41
11- 43
11- 81
1 1-85
1 1-85
11-87
11-87
1 1- 90
11- 91
1 1-94
1 1-96
1 1-97
1 1-98
11- 99
11- 100
11- 100
1 1 - 1 0 1
11-102
1 1- 105
11- 105
11-107
1 1- 108
1 1 - 1 1 0
1 1 - 1 1 0
1 1 - 1 1 1
Speci al Tool s
ffi
M"
0/u
o
---)
Aitt".'
K-F
lf
i ..-?
At"-
o
Ref. No. Tool Number Descri pti on otv
It
'ti
@
@
A973X-O41.XXXXX
07JAz-0010008
07sAz-001000A
07vAJ-0040100
07406-004000A
Vacuum Pump/Gauge, 0 30 i n.Hg
Vacuum/Pressure Gauge. 0 4 i n.Hg
Backprobe Set
Fuel Pressure Gauge Adapter
Fuel Pr essur e Gauoe
1
,]
2
1
'l
11-2
General Troubleshooting
lntermittent Failures
Information
The term
"i ntermi ttent
fai l ure" means a system may
have had a fai l ure, but i t checks OK now. l f the
Mal functi on Indi cator Lamp
(Ml L)
on the dash does not
come on, check for poor
connecti ons or l oose wi res at
al l connectors rel ated to the ci rcui t that vou are
troubl eshooti ng.
Opens and Shorts
"Open"
and
"Short"
are common el ectri cal terms. An
open i s a break i n a wi re or at a connecti on, A short i s
an acci dental connecti on of a wi re to ground
or to
anot her wi r e. I n si mpl e el ect r oni cs, t hi s usual l y means
somethi ng won' t work at al l . Wi th compl ex el ectroni cs
( such
as ECM' S) t hi s can somet i mes mean somet hi ng
works, but not the way i t' s supposed to.
How to Use the PGM Tester or a Scan Tool
l f the MIL {Mal functi on Indi cator Lamp) has come on
1. St ar t t he engi ne and check t he Ml L.
2. l f the l \4l L stays on, connect the Honda PGM Tester
(A)
or an OBDII scan tool to the data l i nk connector
( DLC) ( B) .
For' 00-0' l model s, the DLC i s l ocated under the
passenger' s
si de of the dashboard.
For' 02-03 model s, the DLc i s l ocated behi nd the
dri ver' s si de of the front consol e.
' 00-01
model s:
'02-03
models:
( l l ) .
Check the di agnosti c troubl e codes
(DTC)
and note
i t. Then al so check the freeze frame data. Refer to
the DTC Troubl eshooti ng Index and begi n the
appropri ate troubl eshooti ng procedure.
NOTE;
.
Freeze data i ndi cates the engi ne condi ti ons when
the fi rst mal functi on, mi sfi re or fuel tri m
mal functi on was detected.
.
The scan t ool andt he Honda PGf MTest er can
read the DTC, freeze frame data, current data,
and ot her engi ne cont r ol modul e
( ECM)
dat a.
.
For speci fi c operati ons, refer to the user' s
manual that came wi th the scan tool or Honda
PGM Tester.
lf the MIL did not come on
l f the MIL di d not come on but there i s a dri veabl i l i ty
probl em, refer to the Symptom Troubl eshooti ng Index
i n thi s secti on.
lf you can't duplicate the DTC
Some of the troubl eshooti ng i n thi s secti on requi res
you to reset the ECM and try to dupl i cate the DTC. l f the
probl em i s i ntermi ttent and you
can' t dupl i cate the code,
do not conti nue through the procedure. To do so wi l l
onl y resul t i n confusi on and, possi bl y.
a needl essl y
reol aced ECM.
{cont' d)
11- 3
General Troubleshooting Information
(cont'd)
How to Reset the ECM
You can reset the ECM i n ei ther of two ways:
NOTE: after resetti ng the ECM, do the ECM i dl e l earn
pr ocedur e ( see page 11' 100) .
Reset the ECM with the OBD ll scan tool or
Honda PGM Tester
1. Turn the i gni ti on swi tch ON {l l ).
Do not start the
e ng i ne.
2. Use t he OBD l l scan t ool or Honda PGM Test er t o
cl ear the DTC.
NOTE: For the speci fi c operati ons, refer to the use' s
manual that came wi th the scan tool or Honda PGM
Tester.
Reset the ECM by removing the fuse
1. Tur n t he i gni t i on swi t ch OFF.
2. Remove the No. 25 BACK UP
(7.5
A) fuse
(A)
from
the under-dash fuse/rel ay box
(B)
for 60 seconds.
.!:i
How to End a Troubleshooting Session
(required
after any troubleshootingl
1. Reset the ECM as descri bed above.
Di sconnect the OBDII scan tool or Honda PGM
Tester from the data l i nk connector
(DLC).
NOTE:
.
The ECM i s part of the i mmobi l i zer system. l f you
repl ace the ECM. i t wi l l have a di fferent
i mmobi l i zer code. I n or der f or t he engi ne t o st an,
you must r ewr i t e t he i mmobi l i zer code wi t h t he
Honda PGM Tester.
.
Do r he i dl e l ear n pr ocedur e ( see page 11- 100) .
11-4
How to Remove the ECM for Testing
NOTE:
'
Make sure
you have the anti theft code for the rad i o,
preset
buttons before
you di sconnect the negati ve cabl e
from the battery.
.
Enter the anti theft code, then enter the customer' s
radi o stati on
presets, and set the cl ock after
you
reconnect the negati ve cabl e to the battery.
l f the i nspecti on for a troubl e code requi res vol tage or
resi stance checks at the ECM connectors, remove the
ECM and test i t:
1. Di sconnectthe negati ve cabl e trom the battery.
2. Remove t he l ef t si de ki ck panel ( A) t oexposet he
ECM
( B) .
B
9.6 N.m,
(1.0
kgt m,
7.2 tbl.ttl
3. Remove the two bol ts from the ECM
(B).
4. Di sconnect the ECM connectors.
5. l nstal l the ECM i n the reverse order of removal .
6. Reconnect the negati ve cabl e to the battery.
7. Do t he i dl e l ear n
pr ocedur e
{ see
page 1 1- 100) .
How to Troubleshoot Circuits at the ECM
.
Di gi tal mul ti meter KS-AHfvl -32-003
(1)or
a
commer ci al l y avai l abi e di gi t al mul t i met er
.
Backprobe Set 07SAZ-0010004
(2)
1. Connect the backprobe adapters
(A)to
the stacki ng
patch
cords
(B),
and connect the cords to a
mul t i met er
( C) .
oTsAz-ooloooA
s
Usi ng t he wi r e i nsul at i on as a gui de f or t he
contoured ti p ofthe backprobe adapter, gentl y sl i de
the ti p i nto the connector from the wi re si de unti l i t
touches the end of the wi re termi nal .
l f you
cannot get to the wi re si de of the connector
or the wi re si de i s seal ed
(A),
di sconnect the
connector and l ouch the tester probe (B)
to
termi nal s
(C)
from the termi nal si de. Do not force
the probe
i nto the connector.
Do not punct ur e
t he i nsul at i on on a wi r e.
Punctures can cause
poor
or i ntermi ttent
el ectri cal connecti ons.
07sAz-001000A
How to Substitute the ECM for Testing
Purposes
Use thi s procedure i f you need a known-good ECM to
test a vehi cl e. l t al l ows you to swap a ECM from a
"donor"
vehi cl e wi thout havi ng to
program i t to the test
vehi cl e' s i gni ti on key.
1. Di sconnect the negati ve cabl e from the battery on
the test vehi cl e.
2. Cut a temporary i gni ti on key for the l est vehi cl e
wi t h a non- i mmobi l i zer key bl ank.
3. Remove the ECM from the test vehi cl e.
4.
\N
r'rte the test v ehic\e' s \,1\N on the ECM y ou
iust
removed to avoid confusing it with the donor
vehi cl e' s ECM.
5. Di sconnectthe negati ve cabl e from the battery on
t he donor vehi cl e.
6. Remove the known-good ECM from the donor
vehi cl e, and i nstal l i t i n the test vehi cl e.
7. Tape the donor vehi cl e' s i gni ti on key head-to-head
to the test vehi cl e' s temporary key
(A).
The ECM
wi l l recogni ze the code from the donor vehi cl e' s
key
( B)
and al l ow you t o st an t he engi ne wi t h t he
temporary key.
After compl eti ng your tests, rei nstal l both ECMs,
and destroy the temporary key.
Reconnect the negati ve cabl e to the battery. 9.
11- 5
DTC Troubl eshooti ng Index
' : These
DTCS ar e i ndi cat ed by a bl i nki ng l vl al f unct i on I ndi cat or Lamp
( Ml L) when
t he SCS ser vi ce si gnal l i ne i s
j umped
wi th the Honda PGM Tester.
' ' :
' 02-03
model s
DTC
{MlL indication
'
Temporary DTC Detection ltem Note
P0107
(3)
Mani fol d Absol ute Pressure
(MAP)
Sensor Ci rcui t
Low Vol taoe
( see
page 11- 43)
P0108
(3)
Mani fol d Absol ute Pressure
(MAP)
Sensor Ci rcui t
Hi oh Vol taqe
( see page 11- 44)
P0112
( 10)
Intake Ai r Temperature {l AT) Sensor Ci rcui t Low
Vol taqe
( see page 11- 46)
P0113
( 10)
Intake Ai r Temperature
(l AT)
Sensor Ci rcui t Hi gh
Vol taoe
( see page 11- 47)
P0116 { 86) P01 l 6 Engi ne Cool ant Temper at ur e
( ECT)
Sensor Range
/Performance Probl em
( see page 11- 48)
P0117
( 6)
Engi ne Cool ant Temperature
(ECT)
Sensor Ci rcui t
Low InDut
( see page 1' l - 48)
P0118
( 6)
Engi ne Cool ant Temperature
(ECT)
Sensor Ci rcui t
Hi qh I nput
( see page 11- 49)
P0122 Q\ Throttl e Posi ti on {TP) Sensor Ci rcui t Low Inout
(see
Daqe 1' 1-50)
P0123 { 7) Throttl e Posi ti on
(TP)
Sensor Ci rcui t Hi qh Input
( see
Daqe 11- 53)
P0128
( 87) '
'
P0128 Cool i nq Svstem l \4al f uncti on
(see
Daqe
' 1
1-54)
P0131
( 1)
Pri mary Heated Oxygen Sensor
(Pri mary
H02S)
(Sensor
1) Ci rcui t Low Vol taqe
( see page
' 11- 55)
P0132
( 1)
(Pri mary
H02S)
( Sensor
1) Ci r cui t Hi oh Vol t aqe
( see page 11- 56)
P0133
( 61)
P0' 133 Pri mary Heated Oxygen Sensor
(Pri mary
HO2S)
( Sensor
1) Sl ow Response
( see page 11- 57)
P0135
( 41)
(Pri mary
HO2S)
{ Sensor 1) Heat er Ci r cui t Mal f unct i on
( see page 11- 61)
P0137 {63) P0136 Secondary Heated Oxygen Sensor
(Secondary
HO2S)
(Sensor
2) Ci rcui t Low Vol taqe
(see page 1 1-58)
P0138
( 63)
P0136 Secondary Heated Oxygen Sensor
(Secondary
HO2S)
( Sensor
2) Ci r cui t Hi oh Vol t aqe
( see page 1' l - 59)
P0139
(63)
P0136 Secondary Heated Oxygen Sensor
(Secondary
HO2S)
(Sensor
2) Sl ow Resoonse
( see page 1l - 60)
P0141
( 65)
Secondary Heated Oxygen Sensor
(Secondary
HO2Si {Sensor 2) Heater Ci rcui t Mal functi on
( see page 11- 61)
P017 r
( 45)
P0170 Fuel Svstem Too Lean
( see
Daqe 11- 63)
PO17 2 t45J P0170 Fuel Svstem Too Ri ch { see Daoe 11- 63)
P0300 and some
of
P0301
( 71)
P0302172)
P0303
(73)
P0304
(74)
P1399 Random Mi sfi re
(see page 11-64)
P0301
( 71)
P1399 No. 1 Cvl i nder Mi sf i r e
(see
Daoe 1' l -65)
P0302 {.72t P1399 No. 2 Cvl i nder Mi sf i r e
( see
oaoe 11- 65)
P0303
(73)
P1399 No. 3 Cvl i nder Mi sf i r e
(see
oaoe 1' l -65)
P0304
(74)
P1399 No. 4 Cvl i nder Mi sf i r e {see oaoe
' 11-65)
11- 6
DTC
{Ml L i ndi cati on
P0325
(23)
Knock Sensor Ci rcui t Mal functi on
( see
Daqe 11- 70)
P0335
(4)
Crankshaft Posi ti on
(CKP)
Sensor Ci rcui t No
Si qnal
( see page 11- 73)
P0336
(4)
Crankshaft Posi ti on l CKP) Sensor l ntermi ttent
Interruoti on
( see page 11- 73)
P0410
( 60)
P0410 Ai r Pumo Ci rcui t Mal functi on
( see
oaoe 11- 149)
P0411
( 60)
P0411 Secondarv Ai r Ini ecti on Svstem Incorrect Fl ow
( see
Daqe 1 1- 153)
PO420167l Catal vst System Effi ci encv Bel ow Threshol d
( see
Daqe 11- 128)
P0451
{ 91) P0451 Fuel Tank Pressure
(FTP)
Sensor Range/
Performance Probl em
( see page 11- 131)
P0452
( 91)
P0450 Fuel Tank Pressure
(FTP)
Sensor Ci rcui t Low
Vol taoe
( see page 11- 132)
P0453
(91)
P0450 Fuel Tank Pressure
(FTP)
Vol taqe
( see page 11- ' 133)
P0500
( 17)
Vehi cl e Speed Sensor
(VSS)
Ci rcui t Mal functi on
( see paqe
11- 75)
P0505
( 14)
P0505 l dl e Control Svstem Mal functi on
( see paqe
1l - 91)
P1 106
( 13)
P1 106 Barometri c Pressure
(BARO)
Sensor Range/
Performance Probl em
( see page 11- 77)
P] 107
( 13)
Earometri c Pressure
(BARO)
Sensor Ci rcui t Low
Vol taqe
( see page 11- 77)
P1108
( 13)
Barometri c Pressure
(BARO)
Vol taqe
( see page
11- 77)
P1121 tl l P't't21 Throttl e Posi ti on
(TP)
Sensor Lower Than
ExDected
( see page 11- 51)
P1122 17 ) P1122 Throttl e Posi ti on
(TP)
Sensor Hi gher Than
Exoected
{ see
page 11- 52)
P1 128
( 5)
P1124 Mani fol d Absol ute Pressure
(MAP)
Sensor Si gnal
Lower Than ExDected
( see page 11- 45)
P1129
{ 5) P1' t 29 Mani fol d Absol ute Pressure
(MAP)
Sensor Si gnal
Hi qher Than Exoected
( see page 11- 45)
' :
These DTCS are i ndi cated by a bl i nki ng l vl l L when the SCS servi ce si gnal l i ne i s
j umped
wi th the Honda PG fvl
Tester.
(cont' d)
11-7
DTC Troubleshooting Index
(cont'd)
' :
These DTCs are i ndi cated by a bl i nki ng MIL when the SCS servi ce si gnal l i ne i s
j umped
wi th the Honda PGM
Tester.
DTC
{MlL indication
'
P1259 122) P1257 VTEC Svstem Mal functi on
(see page
6-6)
P1297 120) El ectri cal Load Detector
(ELD)
Ci rcui t Low
Vol taqe
( see page 11- 78)
P1298
l20l El ectri cal Load Detector
(ELD)
Ci rcui t Hi gh
Vol taqe
( see page 11- 79)
P] 361
( 8)
Camshaft Posi ti on
(CMP)
Sensor A
(Top
Dead
center
(TDC)
Sensor) l ntermi ttent l nterruDti on
( see page 11- 71)
P1362
( 8)
Camshaft Posi ti on
{CMP) Sensor A
(Top
Dead
Center
(TDC)
Sensor) No Si qnal
( see page
1 1- 7 1)
P1366
(58)
Camshaft Posi ti on
(CMP)
Sensor B
(Top
Dead
Center
(TDC)
Sensor) Intermi ttent Interruoti on
( see page 11- 71)
P1367
( 58)
Camshaft Posi ti on
(CMP)
Sensor B {Top Dead
Center {TDC) Sensor) No Si qnal
( see page 1l - 71)
P1410 { 60) Pl 410 Ai r Pumo Mal functi on
( see
oaqe l 1- 155)
Pl 415
( 83)
Ai r Pump El ectri c Current Sensor Ci rcui t Low
Vol taqe
( see
page 11- 156)
P1416
( 83)
Ai r Pump El ectri c Current Sensor Ci rcui t Hi gh
Vol taqe
( see page
' 11- 158)
P1456
( 90)
P1456 Evaporati ve Emi ssi ons
(EVAP)
Control System
Leakaoe
(Fuel
Tank Svstem)
( see page 11- 135)
Pl 457
( 90)
P't451 Evaporati ve Emi ssi ons
(EVAP)
Control System
Leakaqe
(EVAP
Cani ster Svstem)
( see page 11- 140)
P1 5 1 9 { 1 4 ) l dl e Ai r Control
(l AC)
Val ve Ci rcui t Mal functi on
( see
Daoe 11- 92)
Pl 607
(
) Engi ne Control l vl odul e
(ECM)
Internal Ci rcui t
l \4al functi on
( see page 11- 80)
11- 8
These symptoms DO NOT tri gger Di agnosti c Troubl e Codes
(DTCs)
or cause the Mal functi on Indi cator Lamp
(Ml L)
to
come on. l f the MIL i s reported on, check for DTCS. l f the vehi cl e has one of these symptoms, do the di agnosti c
procedure for i t, i n the sequence l i sted, unti l you fi nd the cause.
Symptom Diagnostic
procedure
Also check for
Engi ne wi l l not st an
(Ml L
works OK, no DTCS set)
1. Testthe battery
(see page 22-39)
2. Testthe starter {see
page 4-7)
3. Test t he f uel pump( seepagel l - 107)
4. Troubl eshoot the PGM-Fl mai n rel ay ci rcui t
(see page 11
1021
compressi on
l ntake ai r l eaks
Locked up
engi ne
Broken ti mi ng
cha i n
Contami nated
fuel
Engi ne wi l l not sta rt
(Ml L
comes on and stays on,
or never comes on at al l , no
DTCS set)
Tr oubl eshoot t he MI L ci r cui t
( see page 11' 81)
Engi ne wi l l not sta rt
{i mmobi l i zer i ndi cator comes
on)
Troubl eshoot the i mmobi l i zer system
(see page 22-120)
Hard starti ng
(Ml L
1. Testthe battery
(see page 22-39)
2. Check t he f uel pr essur e( seepagel l - 105)
Low
compressaon
l ntake ai r l eaks
Contami nated
fuel
Col d fast i dl e too l ow
(Ml L
1. Do t he i dl e l ear n pr ocedur e ( see page
' 11- 100) .
2. Check t he i dl e soeed
( see
oaoe 11- 100)
Col d fast i dl e too hi gh
(Ml L
1. Dot he i dl e l ear n pr ocedur e ( see page 11- 100) .
2. Check t he i dl e speed
( see page 11- 100)
3. I nspecvadj ust t het hr ot t l ecabl e
( see page' 11- 124)
4. InsDect and test the throttl e bodv
(see
Daoe 11-122)
l dl e speed fl uctuates
(Ml L
1. Do t he i dl e l ear n pr ocedur e
{ see
page 11- 100) .
2. Check t he i dl e speed { see
page 11- 100)
3, l nspecvadj ust the throttl e cabl e
(see page 1' l -' 1241
4. Insoect and testthe throttl e bodv {see oaoe 11-122)
l ntake ai r l eaks
Low power
(Ml L
1. Check the fuel
pressure (see page 1 1-105)
2. l nspect and test the throttl e body
(see page 11-1221
3. InsDecvadi ust the throttl e cabl e {see oaoe 11-124)
Low
compressi on
Engi ne st al l s
(Ml L
1. Do t he i dl e l ear n pr ocedur e ( see page
' 11- 100) .
2. Check t he f uel pr essur e( seepagel l - 105)
3. Checkt he i dl e speed
( see page 11- 100)
4. Troubl eshootthe brake pedal posi ti on swi tch si gnal
ci r cui t
( see paqe
11- 99)
I nt ake ai r l eaks
Faul ty harness
and sensor
connefi rons
Di ffi cul t to refuel
(Ml L
1. Test t he f uel t ank vapor cont r ol val ve( seepagel l - 146)
2. Inspect the fuel tank si gnal tube between the fuel pi pe
and
the fuel tank vaoor control val ve
3. Inspect the fuel tank venl tube between the EVAP cani ster
and the fuel tank vapor control val ve
4. Check the EVAP cani ster
Fuel overfl ows duri ng
refuel i ng
{No DTCS set)
Repl ace the fuel tank vapor control val ve
(see page 1 1-147)
11- 9
System Descriptions
Elestronic Control System
The functi ons of the fuel and emi ssi ons control systems are managed by the engi ne control modul e (ECM).
Fail-safe Function
When an abnormal i ty occurs i n the si gnal from a sensor, the ECM i gnores the si gnal and assumes a pre-programmed
val ue for the sensor that al l ows the enqi ne to conti nue to run.
Back-up Function
When an abnormal i ty occurs i n the ECM, the i nj ectors are control l ed by a back-up ci rcui t i ndependent ofthe system to
per mi t
mi ni mal dr i vi ng.
Self-diagnosis
When an abnormal i ty occurs i n the si gnal from a sensor, the ECM suppl i es ground
for the MIL and stores the DTC i n
erasabl e memory. When the i gni ti on i s fi rst turned ON
(l l ),
the ECM suppl i es ground
for the MIL for 2 seconds to check
t he MI L bul b condi t i on.
Two Driving Cycle Detection Method
To prevent fal se i ndi cati ons, the
"two
dri vi ng cycl e detecti on method" i s used for some sel f-di agnosti c functi ons.
When an abnormal i ty occurs, the ECM stores i t i n i ts memory. When the same abnormal i ty recurs after the i gni ti on
swi tch i s turned OFF and ON
(l l )
agai n, the ECM turns on the l \411.
11- 10
EGM Data
You can retri eve data from the ECM by connecti ng the OBD l l scan tool or the Honda PGM Tester to the Data Li nk
Connector
(DLC).
The i tems l i sted i n the tabl e bel ow conform to SAE recommended
practi ce. The Honda PGl vl Tester
al so reads data beyond that recommended by SAE to hel p you fi nd the causes of i ntermi ttent
probl ems.
NOTE:
The
"operati ng
val ues" l i sted are approxi mate and may vary dependi ng on the envi ronment and the i ndi vi dual vehi cl e.
Unl ess noted otherwi se,
"at
i dl e speed" means i dl i ng wi th the engi ne compl etel y warmed up, i n neutral
posi ti on, and
the Ay' C and al l accessori es turned off.
Data Description ODerati no Val ue Fleeze Data
Di agnosti c
Troubl e Code
(DTC)
l f the ECM detects a
probl em. i t wi l l store i t as a code
consi sti ng of one l etter and four numbers. Dependi ng on
the Drobl em, an SAE-defi ned code
(Poxxx)
or a Honda-
defi ned code
(P1xxx)
wi l l be output to the tester.
l f no
probl em i s
detected. there i s no
outpul .
YES
Engi ne Speed The ECM computes engi ne speed from the si gnal s sent
from the Crankshaft Posi ti on
(CKP)
sensor. Thi s data i s
used for determi ni ng the ti me and amount of i nj ected fuel .
Near l y t he same as
tachometer i ndi cati on
At i dl e speed: 800+50
r Dm
YES
Vehi cl e Speed The ECM converts
pul se si gnal s from the Vehi cl e Speed
Sensor
(VSS)
i nto speed data.
Nearl y the same as
speeoomel er
i ndi cati on
YES
Ma n ifold
Absol ute
Pressure
( MAP)
The absol ute
pressure caused i n the i ntake mani fol d by
engi ne l oad and speed.
Wi th engi ne stopped:
Nearl y the same as
atmosphenc
pressure
At i dl e speed: 28 48
kPa
(2' 10
360 mmHg,
8. 3 14. 2 i nHo)
YES
Eng i ne
Cool ant
Temperature
(ECr)
The ECT sensor converts cool ant temperature i nto vol tage,
and sends a vol tage si gnal to the ECM. The sensor i s a
thermi stor whose i nternal resi stance changes wi th
cool ant temperature. The ECM uses the vol l age si gnal s
from the ECT sensor to determi ne the amount of i nj ected
f uel .
Wi th col d engi ne:
Same as ambi ent
temperature and IAT
Wi th engi ne warmed
up: approx. 176 212"F
(80
100' c)
YES
Pri mary
Heated
Oxygen
Sensor
( Pr i mar y
HO25) { Sensor
1) , Secondar y
Heated
Oxygen
Sensor
{Secondary
HO2S)
( Sensor
2l
The HO2S detects the oxygen content i n the exhaust
gas
and sends vol tage si gnal s to the ECM. Based on these
si gnal s, the ECM control s the ai rl fuel rati o. When the
oxygen content i s hi gh
(that
i s, when the rati o i s l eaner
than the stoi chi ometri c rati o), the vol tage si gnal i s l ower.
When the oxygen content i s l ow
(that
i s, when the rati o i s
ri cher than the stoi chi ometri c rati o), the vol tage si gnal i s
hl o her .
0. 0- 1. 25 V
At i dl e speed:
about 0. 1 0. 9 V
NO
{cont' d)
11-11
Fuel and Emissions
Systems
System Descriptions
(cont'd)
ECM Data
(cont' dl
Fuel system sl atus i s i ndi cated as
"open"
or
"cl osed".
Cl osed: Based on the HO2S output, the ECM determi nes
the ai rl fuel rati o and control s the amount of i nj ected fuel .
Open: l gnori ng HO2S output, the ECM refers to si gnal s
from the throttl e posi ti on
{TP), mani fol d absol ute
pressure (MAP),
i ntake ai r temperature (l AT),
barometri c
pressure (BARO)
and engi ne cool ant temperature
(ECT)
sensors to control the amount of i ni ected fuel .
At i dl e speed: cl osed
The ai r fuel rati o correcti on coeffi ci ent for correcti ng the
amount of i nj ected fuel when the Fuel System Status i s
"cl osed".
When the rati o i s l eaner than the stoi chi ometri c
rati o, the ECM i ncrease short term fuel tri m gradual l y,
and
the amount of i nj ecl ed fuel i ncreases. The ai r fuel rati o
gradual l y gets ri cher, causi ng a l ower oxygen content i n
the exhaust gas.
Consequentl y, the short term fuel tri m i s l owered, and the
ECM reduces the amount of i nj ected fuel . Thi s cycl e keeps
the ai rl fuel rati o cl ose to the stoi chi ometri c rati o when i n
c-1s99!
!eqp,9!g!c!.
Long term fuel tri m i s computed from short term fuel tri m
and i ndi cates changes occuri ng i n the fuel suppl y system
over a l ong per i od.
l f l ong t er m f uel t r i m i s hi gher t han 1. 00. t he amou nt of
i nj ected fuel must be i ncreased. l f i t i s Iower than 1.00. the
qlnq!!! !1!!igclgllgeljlru9! !9
rqduced.
The IAT sensor converts i ntake ai r temoerature i nto
vol tage and si gnal s the ECM. When i ntake ai r
temperature i s l ow, the i nternal resi stance of the sensor
and t he vol t age si qnal i s hi gher .
Based on the accel erator pedal posi ti on,
the openi ng
e of the throtl l e val ve i s i ndi cated.
l gni t i on t i mi ng i s t he i gni t i on advance angl e set by t he
ECM. The ECM matches i gni ti on ti mi ng to the dri vi ng
condi ti ons.
CLV i s the engi ne l oad cal cul ated from the l vl Ap data.
Short Term
Fuel Tr i m
Cal cul ated
Load Val ue
(CLV)
0. 73 1. 47 YES
YES
Long Term
Fuel Tr i m
I nt ake Ai r
Temperature
{IAT)
l gni t i on
Ti mi ng
Wi t h col d engi ne:
Same as ambi ent
At i dl e speed:
5' + 5" BTDC wi th the
SCS ser vi ce si gnal l i ne
j umped
wi th the Honda
PGM
At i dl e speed:
22 42%
At 2,500 rpm wi th no
l oad:
21 48yo
11-12
EGM Electrical Connections
To ECTGAUGE
To fiADIATOB FAN aELAY,
MDIATOR FAN SWITCH
OBATTERY{lOOA}'A
OBACK UP ACC(3OA)*A
osroP{10A)*A
OI Gl MAI NI 4OA)' A
Oacc snsAl *A
@AIR PUMP{60A}*B
ONo.25 EAcK uPl 7.5A).c
OrNo.6 ACGnsAl.c
OI No, 5I NSTRUMENT LI GHT BACK UP LI GHT{ 7. 5A) *C
@No. 2 FUEL PUMP SRS{ 15A) ' C
ONo. 4 rcN cot L{r5A)*c
@No,3 ENGINE START{7.5AI.C
@No.21 STARTER SIGNAL{7.5A)*C
*A:in
the main under-hood tuse/relty box
*B:in
the auxiliarv undr-hood tuse box
*C:in
the under-dash luse/relav box
IMMOBIIEEN
INDICAIOR LIGIIT
To IMMOaILIZER RECEIVER
Io TMMOBIUZEF RECETvER
.IEST
{cont' d)
11- 13
System Descriptions
(cont'dl
ECM Electrical Connections
(cont' dl
No.2 IGNITION COIL
VIECPNESSURE
AIR CONTiOL SOLENOID VALVE
11-14
ECM Inputs and Outputs at Connector A
(32P)
NOTE: St andard bat t ery vol t age i s 12 V.
Terminal Wire color ferminal name Description Signal
YEUGBN Sends ECT si gnal t o ECT Wi t h i gni t i on swi t ch ON
(l l ):
dut y cont rol l ed
2 RED SAVS
(AI R
CONTROL VALVE
VACUUM CONTROL
SOLENOI D VALVE)
Dr i ves ai r cont r ol val ve
vacuum cont r ol sol enoi d
Wi t h i gni t i on swi t ch ON
( l l ) :
bat t er y vol t age
wi t h ai r
pump wor ki ng: about 0 v
3 ORN 2WBS
(EVAP
BYPASS
SOLENOI D VALVE)
Dri ves EVAP bypass sol enoi d Wi t h i gni t i on swi t ch ON
(l l ):
baf t ery vol t age
4 LT GRN/ VSV l EVAP
CANI STER VENT
SHUT VALVE)
Drives EVAP canister vent
shut val ve.
(l l ):
bat t ery vol t age
6 REDI / EL PCS {EVAP CANI STEB PURGE
VALVEi
Dri ves EVAP cani st er
purge Wi t h engi ne runn; ng, engi ne cool ant , bel ow 149"F
(65"C):
battery voltage
Wi t h engi ne runni ng, engi ne cool ant , above 149"F
i 65"C): dut v cont rol l ed
9 BLU,ryVHT VSS
(VEHI CLE
SPEED
SENSOR
( VSSi I NPUT
SI GNAL)
Sends vehi cl e speed sensor
( VSS) s i gnal .
Dependi ng on vehi cl e speed:
pul ses
1 0 BBN SCS l SERVI CE
CHECK
SI GNAL)
Detects service check
connect or si gnal
(t he
si gnal
causi ng a DTC i ndi cat i on)
Wi t h t he serui ce check si gnal shoned wi t h t he
PG lvl Testei about 0 V
Wi t h t he servi ce check si gnal opened: abol t 5 V
or batterv voltaoe
12 PNK I MOLI\,1 P
(I
MMOBI LIZER
I NDI CATOR LI GHT)
Dri ves i mmobi l i zer i ndi cat or
l i ght .
Wi t h i mmobi l i zer i ndi cat or l i ght t ur ned ON: about
wi t h i mmobi l i zer i ndi cat or l i ght t ur ned OFF:
1 3 PNVBLU I MOEN
(I MMOBI LI ZER
FNABI F SI GNAL)
Sends i mmobi l i zer enabl e
sronal .
GRN/ / EL I MOFLR
(I I VI MOBI LI ZER FUEL
PUMP RELAY)
Dri ves f uel pump rel ay. O V f or 2 seconds af t er t urni ng i gni t i on swi t ch ON
{l l )- t hen bat t erv vol t aqe
1 7 RED ACC
(! VC
CLUTCH RELAY) 0rives A,/C clutch relay. Wi t h compressor ON: about 0 V
Wi t h comDressor OFF: bat t erv vol t aqe
1 8 GRN/ OBN MI L
(MALFUNCTI ON
I NDI CATOR LAMP)
Dri ves Ml L. Wi t h N4l Lt urned ON: about 0 V
Wi rh Ml l i rrrned OFF: bat t erv vol t aoe
1 9 BLU NEP
( ENGI NE
SPEED PULSE) out oLr t s enqi ne speed
pul se. Wi t h enqi ne r unni nq:
pul ses
20 GRN FANC l RADI ATOR
FAN
CONTROL)
Dri ves radi at orf an rel ay. Wi t h radi at or f an runni ng: about 0 V
With radiat.)rlan stooDed: batterv voltaoe
( cont ' d)
System Descriptions
(cont'dl
EGM Inputs and Outputs at Connector A
(32P)
Wi re si de of f emal e t ermi nal s
NOTEr St andard bat t ery vol t age i s 12 V.
Terminal Wire color ferminal name Description
Si gnel
2 l GRY K LI NE
Sends and r ecei ves scan t ool
st qnal ,
Wi t h i gni t i on swi t ch ON { l l ) : bat t er y vot t age
24 BLU/ ORN STS {STARTER SWITCH
SI GNAL}
Det ect s st ar t er swi t ch si gnat , Wi t h st a( er swi t ch ON l l l l ) : bat t er y vol t age
With starter switch OFF: about 0 V
I MOCO
l I MMOEI LI ZER CODE) Det ect s i mmobi l i zer si qnal .
BLU/ BLK EPSLD
(ELECTRICAL
P/S
LOAD DETECT)
Det ect s P/ S l oad si gnal Wi t h st eeri ng wheel at f ul l l ock: bat t ery vol t age
moment af l l y
Wi t h st eeri nq wheel st at i onarvt about 0 V
21 BLU/RED ACS
(AVC
SWI TCH SI CNAL) Detects Ay'C switch signal. With A,/C switch ON: about 0 V
With ty'C switch OFF: about 5 V
2A 8LU APR
(AI R
PUMP RELAY) Dri ves ai r pump rel ay. Wi t h i gni t i on swi t ch ON
( l l ) :
about 0 V
Wi t h ai r Dumo wor ki na: bat t er v vol t aoe
29 LT GRN PI ANK (FUEL
TANK
PBESSLJRE
(FTP)
SENSOR)
Detects fuel tank pressure
{FTP) sensor si onal
Wi t h i gni l i on swi t ch ON { l l ) and f uel t i l l cap:
opened: about 2. 5V
30 GRN/ REDELD Det ect s ELD si gnal . Wi t h parki ng l i ght s t urned on at i dl e: about 2. 5
3. 5 V
Wi t h hi gh beam headl i ght s t urned on at i dl e:
about 1. 5 2. 5 V
32 WHT/ BLK BKSW (BRAKE
PEDAL
POSI TI ON SWI TCH)
Det ect s brake pedal posi t i on
Wi t h brake
pedal
rel eased: about 0 V
With brake oedal Dressed: batterv voltaoe
11- 16
ECM Inputs and Outputs at Connector B
(25P1
NOTE: Standard battery voltage is 12 V.
Terminsl
numb6r
Wire color Terminal name Description Signel
1 YEUBLK I GPl
(POWER
SOURCE) Power source for ECM control With ignition switch ON
(ll):
battery voltage
With ionition switch OFFi about 0 V
2 BLK PG1 I POWER GROUND) Ground f or ECM cont rol Less t han 1. 0 V at al l t i mes
3 RED l NJ2
( No. 2I NJECTOR)
/ es No. 2 i ni edor Wi t h i gni t i on swi t ch ON l l l ): banery vol t age
Wi t h engi ne runni ng: dut y cont rol l ed
4 BLU l NJ3
( No. 3I NJECTOB)
r' es No, 3 i ni ect or,
5 YEL l NJ4 {No. 4I NJECTOB) / es No. 4 i ni ect or ,
9 YEUBLK I GP2
(POWER
SOURCE) Power source f or ECM cont rol
ci rcui t
(l l ):
banery vol t age
Wi rh i dni ri on swi rch OFF: abort 0 V
1 0 BLK PG2
(POWER
GROUND) Ground tor EClvt control
ci rcui t .
Lesst han 1. 0 V at al l t i mes
1 BRN l NJl
( No. 1
I NJECTOR) Dr i ves No. 1 i nl ect or . With ignition switch ON
(ll):
battery voltage
Wi t h enoi ne r unni no: duw cont r ol l ed
'12
G RN/YEL VTS
(WEC
SOLENOI D Dr i ves VTEC sol enoi d val ve. Wi t h engi ne at l ow rpm: abol t 0 V
Wiih endine at hioh rom: batterv voltaoe
20 BBN/YEL LG1
(LOGI C
GROUND) Ground tor ECIM control Less t han 1. 0 V at al l t i mes
21 WHT/RED VBU I VOLTAGE EACK UP) Power source for ECM control
crrcurt,
r ower sout ce l or u t L
Battery vokage at all times
22 BB NI/EL LG2
(LOGI C
GROUNDi Ground I or ECM cont rol
ct rcut t ,
Less t han 1. 0 V at al l t i mes
23 BLIVRED I ACV
(I DLE
AI F CONTROL
VALVE}
Dr i ves I AC val ve. Wi t h engi ne r unni ng: dut y conl r ol l ed
System Descriptions
(cont'd)
ECM Inputs and Outputs at Connector C
(31P}
PO2SHTC
(PRI MARY
HEATED Dri ves pri mary
heared oxygen
OXYGTN SENSOF HFATER sensor heal er. Wi t h f ul l y warmed up engi ne runni ng: dut ,
al t er nat or cont r ol Wi t h f ul l y war med up engi ne r unni ngt about I V
si gnal . Wi t h engi ne r unni ng at l ow el ect r i cal t oad: about
No. 1 i gni t i on coi l . Wi t h i gni l i on swr t ch ON { l l i . 0 V
Det ect s al t ernat or FR si gnal . up engi ne runni ng: 0 V bat t ery
engi ne at l ow engi ne speedl
Wi t h engi ne at hi gh engi ne speed
( vehi cl e
HEAI ED OXYGEN SENSOR oxygen sensor heat er. Wi t h f ul l y warmed up engi ne runni ng: dut y
Wi t h i gni t i on swi t ch ON {l l ):
Wi t h engi ne runni ngi pul ses
SHO2S
(SECONDARY
HEATED Derect s secondary heat ed
OXYGEN SENSOR, SENSOR 2) oxygen sensor
(sensor
2)
opened f r om i dl e wi t h f ul l y,
warmed up engi ner above 0. 6 V
OXYGEN SENSOR, SENSOR 1) oxygen sensor
(sensor
1) war med Lr p eng' ne: above 0. 6 V
Wi t h i gni t i on swi t ch ON { l l ) : about 3 V
swi t ch ON
( l l ) :
about 5 V
VCC' r SI - \ SOR VOLTAGE) Power sour ce t o MAP sensor
.:,
Terminal
numoel
Wire color Termi nal name D6c.iption Signal
20 GBN TDCl P
(CAMSHAFT
POSI TI ON
(CMP)
SENSOR
(TOP
DEAD
CENTEF {TDC) SENSORi A P
SI DF)
Detects CMP
(TDC)
sensor A. Wi t h engi ne runni ng: pul ses
2 l RED TDCl M
(CAMSHAFT POSI TI ON
(CMP}SENSOR (TOP
DEAD
CENTER
(TDC)
SENSOR)A M
SI DE)
Ground f or CMP
(TDC)
sensor
22 BED/BLU et ect s knock sensor si onal , Wi t h enoi ne knocki no: oul ses
24 WHT/BLK ECS l AI R PUMP ELECTRI C
CURRENI SENSOR)
Det ect s ai r
p! mp el ect ri c
currenr sensot st onat .
(l l ):
0. 5 V
Wi t h , i r nl l mo worki no: about 2- 5 V
25 RED/YE L I AT {I NTAKE AI R
TFMPERATURE SENSOR)
Detects IAT sensor signal. Wi t h i gni t i on swi t ch ON
(l l ):
about 0. 1- 4. 8 V
l . l enen. l i no on i nrake ai r t emnerat ure)
26 REDA/VHT ECT
(ENGI NE
COOLANT
TEMPERATURE SENSOR)
Detects ECT sensor signal. Wi t h i gni t i on swi t ch ON
(l l ):
about 0. 1 4. 8 V
t deoendi no on enoi ne cool ant t emoerat ure)
27 RED/ BLK TPS {THBOTTLE POSITION
SENSOR)
Det ect s TP sensor si gnal . Wi t h t hrot t l e f ul l y open: about 4. 8 V
With throttle fullv closed: about 0-3 V
28 YEVBLU VCC2 I SENSOR VOLTAGE) Provides sensor voltage. Wi t h i gni t i on swi t ch ON {l l ): about 5 V
Wi t h i oni t i on swi t ch OFF: about 0 V
29 YEL TDC2P
(CAMSHAFT
POSI TI ON
(CMP)SENSOR
l TOP DEAD
CENTER
(I DC}SENSOB)
8 P
SI DEI
Det ect s CMP
(TDC)
sensor B. Wi t h engi ne runni ng: pul ses
30 BLK TDC2M
(CAIV]SHAFT POSITION
(CMP)
SENSOR
(TOP
DEAD
CENTER
(TDC)
SENSOR) B M
SI DEI
Ground f or CMP
(TDC)
sensor
B.
{cont ' d)
System Descriptions
(cont'd)
Vacuum Hose Routing
AIR CONTROL VALVE VACUUM
CONTROL SOLENOID VALVE
{i,Z?\''AW'*7
FRONT OF
VEHICLE
FUEL
PRESSURE
REGULATOR
EVAPORATIVE
EMtSStON
IEVAP}
CANISTER PURGE VALVE
AIR CONTROL
VALVE
PURGE JOINT
AIR CONTROL VACUUM RESERVOIR
11-20
Vacuum Distribution
-1. @
i, SECONDARY HEATED OXYGEN SENSOR {SECONDARY
1 PRIMARY HEATEO OXYGEN SENSOR
(PRIMARY
HO2S)
(SENSOR
1)
HO2SI TSENSOR 2l
MANI FOLD ABSOLUTE PRESSURE {MAP) SENSOR
I NTAKE AI R TEMPERATURE {I ATI SENSOR
O EVAPoRATIVE EMISSIoN {EVAP} CANISTER FILTER
@0 EVAPORATIVE EMISSION {EVAP) CANISTER PURGE
VALVE
4!] EVAPORATIVE EMISSION
(EVAPI
CANISTER VENT
SHUT VALVE
E EVAPORATIVE EMISSION
(EVAP)
TWO WAY VALVE
C3 EVAPORATIVE EMISSION {EVAP) BYPASS SOLENOID
VALVE
@
FUEL TANK PBESSURE IFTP) SENSOR
8' FUEL TANK VAPOR CONTROL VALVE
@ FUEL TANK vAPOR RECIRCULATION VALVE
Q' PURGE JOINT
(10
AIR PUMP
@9 AIR CONTROL VALVE VACUUM CONTROL SOLENOID
VALVE
(@
AIR CONTROL VALVE
O] AIR CONTROL VACUUM RESERVOIR
@. AtR coNTRoL VAGUUM CHECK VALVE
ENGI NE COOLANT TEMPERATURE
(ECT)
SENSOR
KNOCK SENSOR
IDLE AIR CONTROL {IACI VALVE
THROTTLE BODY
I NJECTOR
FUEL PRESSURE REGULATOB
FUEL FI LTER
FUEL PUMP
FUEL TANK
FUEL PULSATION DAMPER
POSITIVE CRANKCASE VENTILATION
(PCV)
VALVE
THREE WAY CATALYTIC CONVERTER
AI R CLEANER
EVAPORATIVE EMISSION
(EVAPI
CANISTER
(cont' d
)
11-21
System Descriptions
(conf
d)
PGM-FI System
The Programmed Fuel Inj ecti on
(PGM-Fl )
system i s a
sequenti al mul ti port fuel i nj ecti on system.
Alternator Control
The al ternator si gnal s the ECM duri ng chargi ng. The
ECM then control s the vol tage generated
at the
al ternator accordi ng to the el ectri cal l oad determi ned
by the ELD
(El ectri cal
Load Detector) and dri vi ng mode.
Thi s reduces engi ne l oad to i mprove fuel economy.
A/C Switch
The Ay' C
(ai r
condi ti oni ng) swi tch si gnal s the ECM
whenever there i s a demand for cool i no.
A/C Compressor Clutch Relay
When the ECM recei ves a demand for cool i ng from the
Ay' C system, i t del ays the compressor from bei ng
energi zed, and enri ches the mi xture to assure smooth
transi ti on to the Iy' C mode.
Barometric Pressure
{BARO) Sensor
The BARO sensor i s i nsi de the ECM. l t converts
atmospheri c pressure
i nto a vol tage si gnal that
modi fi es the basi c durati on of the fuel i ni ecti on
di scharge.
Crankshaft Position
(CKP)
Sensor
The CKP sensor determi nes ti mi ng for i nj ecti on of each
cyl i nder and al so detects engi ne speed.
The ECM detects mi sfi ri ng by usi ng the CKP sensor to
moni tor fl uctuati ons i n crankshaft sDeed. l t wi l l then set
DTCs dependi ng on how much mi sfi ri ng occurs.
11-22
Engine Coolant Temperature
(ECT)
Sensor
The ECT sensor i s a temperature dependent resi stor
(thermi stor).
The resi stance of the thermi stor decreases
as the engi ne cool ant temperature i ncreases.
Intake Air Temperature
llATl Sensor
The IAT sensor i s a temperature dependent resi stor
(thermi stor).
The resi stance of the thermi stor decreases
as the i ntake ai r temDerature i ncreases.
THERMISTOR
THERMISTOR
Ini ector Ti mi ng and Durati on
The ECM contai ns the memory for basi c di scharge
durati on at vari ous engi ne speeds and mani fol d
pressures.
The basi c di scharge durati on, after bei ng
read oul from the memory, i s further modi fi ed by
si gnal s sent from vari ous sensors to obtai n the fi nal
di scharge durati on.
By moni tori ng l ong term fuel tri m, the ECM detects l ong
term mal functi ons i n the fuel system, and wi l l set a DTC
i f the mal functi on occurs duri ng two consecuti ve tri ps.
l gni ti on Ti mi ng Control
The ECM cont ai ns t he memor y f or basi c i gni t i on t i mi ng
at vari ous engi ne speeds and mani fol d ai r fl ow rates. l t
al so adj usts the ti mi ng accordi ng to engi ne cool ant
remperarure.
Knock Sensor
The knock control system adj usts the i gni ti on ti mi ng to
mi ni mi ze knock.
PI EZO CERAMI C
OI APHRAGM
TERMI NAL
Mani tol d Absol ute Pressure IMAPI Senso]
The MAP sensor converts mani fol d absol ute
pressure
i nt o el ect r i cal si onal s t o t he ECM.
SENSOR UNI T
Primary and Secondary Heated Oxygen Sensors
{HO2Sl
The heated oxygen sensors detect the oxygen content
i n the exhaust gas, then sends a si gnal to the ECM
whi ch vari es the durati on of i nj ecl i on accordi ngl y. To
stabi l i ze i ts output, the sensors have an i nternal heater.
The pri mary sensor i s i nstal l ed i n the exhaust pi pe. The
secondary sensor i s i nstal l ed i n the TWC.
HEATER
By control l i ng the ai rl fuel rati o wi th sensors, the
deteri orati on of the
pri mary
sensor can be eval uated by
i ts feedback peri od. When the feedback peri od exceeds
a cer t ai n val ue dur i ng st abl e dr i vi ng condi t i ons, t he
sensor i s consi dered deteri orated and the ECM sets a
DTC.
Starting Control
When the engi ne i s started, the ECM provi des a ri ch
mi xture by i ncreasi ng i nj ector durati on.
(cont' d)
11-23
System Descriptions
(cont'd)
Throttle Position
(TPl
Sensor
The TP sensor i s a
potenti ometer
connected to the
thronl e val ve shaft. As the throttl e posi ti on
changes. the
sensor vari es the si gnal vol tage to the ECM. The TP
sensor i s not repl aceabl e apart from the throttl e body.
Comshaft Position
{CMP Sensor
(Top
Dead Center
(TDC)
sensors)
The CMP Ay' B
(TDC
1/21 sensor determi nes i gni ti on
ti mi ng at start up
(cranki ng)
and when crank angl e i s
aDnor mal .
BRUSH HOLDER
11-24
ldle Control System
When the engi ne i s col d, the A,,/C compressor i s on. the
transmi ssi on i s i n gear. the brake pedal i s pressed,
the
P/S l oad i s hi gh, or the al ternator i s chargi ng, the ECl vl
control s current to the IAC val ve to mai ntai n the correct
i dl e speed. Refer to the System Di agram to see the
functi onal l ayout of the system.
Brake Pedal Position Switch
The brake
pedal posi ti on
swi tch si gnal s the ECM when
the brake
pedal
i s
pressed.
Eleclrical Power Steering
(EPS)
Signal
The EPS si gnal s the ECM when the
power
steeri ng l oad
i s hi gh.
Engine Start Switch
The engi ne start swi tch si gnal s the ECM when the
engi ne i s cr anki ng.
ldle Air Control llAC) Valve
To mai ntai n the proper i dl e speed, the IAC val ve
changes the amount of ai r bypassi ng the throttl e body
i n response to an el ectri cal si gnal from the ECNI.
VALVE
To INTAKE
MANI FOLD
From AI R
CLEANER
Fuel Supply System
Fuel Cut-off Control
Duri ng decel erati on wi th the throttl e val ve cl osed,
current to the i nj ectors i s cut off to i mprove fuel
economy at speeds over 1,050 rpm
Fuel cut-off acti on al so occurs when engi ne speed
exceeds 9,000 rpm, regardl ess of the posi ti on
of the
throttl e val ve, to protect
the engi ne from over-rewi ng.
Fuel Pump Control
When the
j gni ti on
i s turned ON
(l l ),
the ECM grounds
the PGM-Fl mai n rel ay whi ch feeds current to the fuel
pump
for 2 seconds to
pressuri ze
the fuel system. Wi th
t he engi ne r unni ng, t he ECM gr ounds
t he PGM- Fl mai n
rel ay and feeds current to the fuel pump.
When the
engi ne i s not r unni ng and t he i gni t i on i s ON
( l l ) ,
t he
ECM cuts ground
to the PGM-FI mai n rel ay whi ch cuts
current to the fuel pump.
PGM.FI Mai n Rel ay
The PGM-Fl rel ay contai ns two separate rel ays. One i s
energi zed whenever the i gni ti on i s on whi ch suppl i es
battery vol l age to the ECM, power
to the i nj ectors, and
power for the second rel ay. The second rel ay i s
energi zed to suppl y power to the fuel pump
for 2
seconds when the i gni ti on swi tch i s ON
(l l ),
and when
t he engi ne i s r unni ng.
Intake Air System
Refer to the System Di agram to see the functi onal
l ayout ofthe system.
Throttle Body
The throttl e body i s a si ngl e-barrel si de draft type. The
l ower porti on
of the throttl e val ve i s heated by engi ne
cool ant from the cyl i nder head.
TWC
{Three.Way Catalytic Converterl
The TWC converts hydrocarbons
(HC),
carbon
monoxi de
(CO),
and oxi des of ni trogen {NOx) i n the
exhaust gas to carbon di oxi de
(CO2).
ni trogen
(N2),
and
water vapor.
THREE WAY
CATALYSTS
FRONT OF
VEHICLE
(cont' d)
11-25
System Descriptions
(cont'dl
Positive Crankcase Ventilation {PCV}
System
The PCV val ve prevents bl ow-by
gases from escapi ng
i nto the atmosphere by venti ng them i nto the i ntake
mani f ol d.
/
BREATHEB
/
PIPE
/
,
$:a-- \
PCV
VALVE
I NTAKE
MANIFOLD
-
: BLOW-BY VAPOR
:
FRESH AI R
0
11-26
Evaporative Emission
(EVAPI
Control
System
Refer to the System Di agram to see the functi onal
l avout of the system.
EVAP Canister
The EVAP cani ster temporari l y stores fuel vapor l rom
the fuel tank unti l i t can be
purged back i nto the engi ne
and bu(ned
(re{er
to the Sysi em Di agram to see the
functi onal l aVout of the svstem).
EVAP Canister Purge Valve
When the engi ne cool a nt temperatu re i s bel ow 149' F
(65' C),
the ECM turns off the EVAP cani ster
purge val ve
whi ch cuts vacuum to the EVAP cani ster.
Fuel Tank Pressure
(FTPI
Sensor
The FTP sensor converts fuel tank absol ute Dressure
i nt o an el ect r i cal i nDut t o t he ECM.
SENSOR CHI P
ldle Control System
The i dl e speed of the engi ne i s control l ed by the l dl e Ai r Control
(l AC)
val ve:
.
After the engi ne starts, the IAC val ve opens for a certai n amount of ti me. The amount of ai r i s i ncreased to rai se the
i dl e soeed.
.
When the engi ne cool ant temperature i s l ow, the IAC val ve i s opened to obtai n the
proper fast i dl e speed. The
amount of bypassed ai r i s thus control l ed i n rel ati on to engi ne cool ant temperature.
AIR INTAKE
DUCT
INTAKE
MANIFOLD
YEL/
8LK
INTAKE
MANIFOLD
ENGI NE
COOLANT
ENGI NE
COOLANT
BLK
:-
Rry
+;-l<rxf$r%r,,
*-t-"
THROTTLE
BOOY
BLK
:-
AIR INTAKE
DUCT
RESONATOR
BlY
J
'""
l
Yfru%g',
L-J
BLK BLK
I
(cont' d)
\r.ro"oro*
From
.
PGM-Fl
-
MAIN
RELAY
From
YEL/
I
PGM-FI
BLK
-
MAIN
RELAY
Intake Air System
Thi s system suppl i es ai r for engi ne needs. A resonator i n the ai r i ntake duct provi des addi ti onal si l enci ng as ai r i s
drawn i nto the svstem.
11-27
System Descriptions
(cont'dl
Pulsed Secondary Air Injection
The Pul sed Secondary Ai r Inj ecti on advances the acti vati on of the catal yti c converter and reduces the hydrocarbons
(HC),
carbon monoxi de
(CO),
and oxi des of ni trogen
(NOx)
i n the exhaust gas.
The system operates after the engi ne starts under the fol l owi g condi ti ons:
.
The engi ne cool ant temperature i s between 32' F and 158"F {0"C and 70"C)
.
The di fference i s more than 36' F
(20' C)
between the engi ne cool ant temperature when the engi ne i s started and
when the engi ne was stopped i n the previ ous dri vi ng cycl e.
AIR CONTROL VACUUM
CHECK VALVE
No. 6ACG -
(15A)
FUSE
AI R PUMP
>-
{604I FUSE
! , , 1
::l
AI R PUMP
RELAY
When the engi ne i s col d and fi rst started, the ai r
pump pumps fresh ai r i nto the exhaust porl s. The amount of ai r
enteri ng the exhaust i s regul ated by an ai r control val ve whi ch i s control l ed by the ECM. The system does not work for
more than 60 seconds at a ti me. Actual operati ng ti me wi l l very dependi ng on the di fference between engi ne cool ant
temDerature and i ntake ai r temDerature.
When fresh ai r reacts wi th any unburned exhaust
gases,
the exhaust gas temperatures ri se. Thi s ri se i n temperature
promotes faster warm-up of the catal yti c converter. resul ti ng i n cl eaner emi ssi ons du ri ng col d stan-up.
When the ai r i nducti on system i s not operati ng, the ai r control sol enoi d cl oses the ai r control val ve to prevent any
exhaust
gases from fl owi ng back i nto the sytem.
CONTROL SOLENOID VALVE
AI R PUMP
11-28
Evaporative Emission
{EVAP} Control Diagram
The EVAP control s mi ni mi ze the amount of fuel vapor escapi ng to the atmosphere. Vapor from the fuel tank i s
temporari l y stored i n the EVAP cani ster unti l i t can be purged
from the cani ster i nto the engi ne and burneo.
' TheEVAPc ani s t er i s pur gedby dr awi ngf r es hai r t hr oughi t andapor t ont hei nt ak emani f ol d. Thepur gi ngv ac uum
i s control l ed by the EVAP cani ster pu.ge
val ve, whi ch i s open whenever engi n6 cool ant temperature i s above
149" F
( 65" C) .
'
When vapor pr essur e
i n t he f uel t anki shi gher t hant heset val ueof t heEVAPt wowayval ve, t heval veopensand
regul ates the fl ow of fuel vapor to the EVAp cani ster.
'
Dur i ng r ef uel i ng, t he f uel t a nk vapor cont r ol val ve openswi t h t he pr essur e
i nt hef uel t ank, andf eedst hef uel vaoor
to the EVAP cani ster.
EVAPCANISTER
VCMTSHUT
FUEL TANX VAPOR
CONTROI VAIVE
FUEL]ANXVAPOS
/
SfGNAITUSE
/
EVAP
\ / Two wAY
/
Flon tlo.6
ACG l ! sAt
B!(/
. !,n
rh6 unde. dash
iitRN
YEr-/Bru
L_ tT GBI\|/
EVAPAYPASS
faNKvAPOA
solNotovalvE
RECIRCLA1ION TUBE
i
t' ,
=
EVAP CANISTER FItTi
SENSOFS
(cont' d)
11-29
System Descriptions
[cont'd)
ECM Circuit Diagram
u""'
"r./neo
El
:Ffl
- GRN/ hED I
I MAPSENSOR
I
rFt
lf--
|
ECTSENSOR
t Fl
L - l
IATSNSOF
H t l
TPSENSOF
HO2S(SENSOBI)
SECONDARY
HO2S ISENSOR 2)
t - t c 1 0 l
-I
ALK/
YEL
+
c.0.
BLK/
YEI
I
Y
tr
JUNCTION
CONNECTOR
11- 30
elulwrlt
_,_{9M_erutwrr
__fffil
-.1
fFq!l
-1f--
|
YEL/BtU
- BRN/ YEL
v
tr
BLK
+
G30r
T f-l
-i"\ |
-S'.Er".f-
VAfVE
T t---_--------_---1
--t -1
I I
t t t l
l l l i - , . , - . - . 1
t i t i ( A) l
I l r v l
[ F l
AIT
IMMOBI!IZEB
RECENEA.CONTROT
UNIT
(cont' d)
AIR PUMP ELECTRIC
CUNfiENTSENSOR
11- 31
System Descriptions {cont'd)
ECM Circuit Diagram
(cont' dl
T---
I d l
L p l
No.2INJECIoR
No.3III|JECTOR
--t
L____9 |
No.alNJECToR
11-32
To EPS CONISO! UNr
No,1 IGNITION COIL
Tr--.-.-----------
iYEr
---
r--l_l ," I
r/GRN
----l
ff-------tr-|.---)SpaFx I
I ll
rcM
I
L-rftr\ PLUG
I
------Lf:
I
tcM PIUG
No.4 lGNlllON COt!
No.2lGNlllON COIL
F-----,------t
I r o l
lfr---+sPARKl
I l
rcM
I
LjTF- PruG
I
l - l
No.3lGNlTlON COlt
eurrr
---!-auler
-_l
t q l
l - l
AN CONTFOL
SOI.ENOIDVALVE
---f---r
- - 1 - |
EVAPCANISTER
SOIENOID VALVE
CANISTER VENT
SHUTVAIVE
(cont' d)
11- 33
System Descriptions
(cont'd)
ECM Circuit Diagram
(cont' d)
r YEL
Y
tr
c303
J
l--Btu---------------l
TACHOMETER
- -CONNECTOR
COOLANT
GAUGE
TACHOMETER
11- 34
c102
JUNCTION
CONNECTOR
VTEC OIL
PRSSURE
DATALIN(
CONNECTOR
-caoa -ctot
|-8tK.-------l}-B|.I-.--l}_Btx
t -
v
E E
(cont' d)
11- 35
System Descriptions
(cont'd)
ECM Circuit Diagram
(cont' dl
FUSES
A:No.21 STARTEF SIGNAUt.5A)
B:No.2 FUEL PUMP SBS(t5A)
c: No. 6ACG( 15A)
DrNo.5 INSTAUMENT LrGHT
aacK uPticttllT.5A)
E: No. al GNCOl Ll l 5A)
__,__\r_
11- 36
"-'_
PBESSURESWITCH
WHT/G8N
BLK/YEL
n.o
--95;--""rr"ro
_w|lfler-x ________J$l
_w"T/u*" _______{f"v
I
]
BBAKE PEDA!
I
POSTTTONSWITCH
| "o,ur,rr"roa a l-
I c20t- _t G
-]-wHr/GRN
----
CONNECTORC
CONNECTOS A
WHT/GRN
LK,/YEI"
CONNECIOS D
UNDEB,DASH
FUSE/REUYAOX
FUSES
F:No,25 AACK UP{7.5A1
G: STOP( r 0Al
FTBACK UPACC(3OA)
lrlGl MAIN(aoA)
J: ACGS( l 5Al
K:BATTERY(r0OA)
t r e
t
coNNEcroR a
I
I
wHT la
11-37
How to Set Readiness Codes
Maltunction lndicator Lamp
(MlLl
lndication
{ln relation to Readiness Codes}
The vehi cl e has certai n
"readi ness
codes" that are oart
of the on-board di agnosti cs for the emi ssi ons systems.
l f the vehi cl e' s battery has been di sconnected or gone
dead, i f the DTCS have been cl eared, or i f the ECM has
been reset, these codes are reset. In some states,
pan
of the emi ssi ons testi ng i s to make sure these codes are
set to compl ete. l f al l of them are not set to compl ete,
the vehi cl e may i ai l the emi ssi on test, or the test cannot
be fi ni shed.
To check i f the readi ness codes are comDl ete, turn the
(l l ),
but do not start the engi ne. The
MIL wi l l come on for 15-20 seconds. If i t then goes off,
the readi ness codes are compl ete. l f i t bl i nks several
ti mes, one or more readi ness codes are not compl ete.
To set readi ness codes from i ncompl ete to compl ete,
do the procedure for the appropri ate code.
11- 38
Catalytic Converter Monitor and Readiness
Code
NOTE:
.
Do not turn the i gni ti on swi tch off duri ng the
orocedure.
.
Al l readi ness codes are cl eared when the battery i s
di sconnected or when the ECM i s cl eared wi th the
OBD l l scan tool or Honda PGM Tester.
.
Low ambi ent temperatures or excessi ve stop-and-go
traffi c may i ncrease the dri ve ti me needed to swi tch
the readi ness code from i ncompl ete to compl ete.
.
The readi ness code wi l l not swi tch to compl ete unti l
al l t he enabl e cr i t er i a ar e met .
.
l f af aul t i nt he secondar y HO2S syst em causedt he
MIL to come on, the readi ness code cannot be set to
compl ete unti l you correct the faul t.
Enable Criteria
.
ECT at
' 158"F
(70"C)
or hi gher.
.
Intake ai r temperature
(l AT)
at 20' F
(
7"C) or hi gher.
.
Vehi cl e speed i s steady. and vehi cl e speed sensor
(VSS)
reads more then 25 mph
(40
km/h).
Procedure
1, Connect t he scan t ool t ot hevehi cl e' s dat a l i nk
connector
(DLC),
and bri ng up the tool ' s generi c
OBD l l mode.
Start the engi ne.
Test-dri ve the vehi cl e under stop-and-go condi ti ons
wi th short
peri ods
of steady crui se. After about 5
mi l es
(8
km). the readi ness code shoul d swi tch
trom i ncompl ete to compl ete.
l f the readi ness code i s sti l l set to i ncompl ete, check
for a temporary DTC. l f there i s no DTC, one or
more of the enabl e cri teri a were probabl y not met;
repeat the
procedure.
3.
Evaporative Emissions
(EVAPI
Control
System Monitor and Readiness code
NOTE:
.
Al l readi ness code are cl eared when the battery i s
.
The enabl e cri teri a musl be repeated i fthe i ntake ai r
temperature
(l AT)
drops l ower then 36' F
(20' C)
from
i ts val ue at engi ne start up.
Enable Criteria
.
At engi ne start up, ECT and IAT are hi gher then 32"F
(0' C)
, but l ower then 95' F {35"C)
.
At engi ne stan up, the ECT and IAT are wi thi n 12' F
(7"C)
of each other.
Procedure
' 1.
Connect the scan tool to the vehi cl e' s data l i nk
connector {DLC), and bri ng up the tool ' s generi c
OBD l l mode.
2. St ar t t he engi ne.
3. Test-dri ve the vehi cl e under stop-and-go condi ti ons
wi th short
peri ods
of steady crui se. After about 2.5
mi l es
(4.0
km), the readi ness code shoul d swi tch
from i ncompl ete to compl ete.
4. l f the readi nesscode i ssti l l setto i ncompl ete, check
for a temporary DTC. l fthere i s no DTC, one or
more of the enabl e cri teri a were probabl y
not met;
rePeat the Orocedure.
Air Fuel Ratio
(A/F)
Sensor Monitor and
Readiness Code
NOTE:
.
Do not turn the i gni ti on swi tch off duri ng the
proceoure.
.
Al l readi ness codes are cl eared when the battery i s
Enable Criteria
ECT at 140' F
(60"C)
or hi gher.
Procedure
1. Connect the scan tool to the vehi cl e' s data l i nk
connector
(DLC),
OBD l l mode.
2. Start the engi ne.
3. Test-dri ve the vehi cl e under stop-and-go condi ti ons
wi th shon
peri ods
of steady crui se. Duri ng the
dri ve, decel erate
(wi rh
the throttl e ful l y cl osed) for
5 seconds. After about 3.5 mi l es
(5.6
km), the
readi ness code shoul d swi tch from i ncompl ete to
compl et e.
4. l f the readi ness code i s sti l l setto i ncompl ete. check
for a temporary DTC. l f there i s no DTC. the enabl e
cri teri a was probabl y not met; repeat the
procedure.
Air/Fuel Ratio
(A/Fl
Sensor Heater Monitor
Readiness Code
NOTE: Al l readi ness codes are cl eared when the batterv
i s di sconnected or when the ECM i s cl eared wi th the
Procedure
1. Connect the scan tool to the vehi cl e' s data l i nk
connector
(DLC),
OBD l l mode.
2. Start the engi ne, and l et i t i dl e for 1 mi nute. The
readi ness code shoul d swi tch from i ncomDl ete to
compl ete.
3. l f t her eadi nesscodei sst i l l set t o i ncompl et e, check
for a temporary DTC. l f there i s no DTC, repeat the
procedure.
(cont' d)
11- 39
How to Set Readiness Codes
(cont'dl
Misfire Monitor and Readiness Code
'
Thi s readi ness code i s al ways setto avai l abl e
because mi sfi ri ng i s conti nuousl y moni tored
.
Moni tori ng
pauses, and the mi sfi re counter resets, i f
the vehi cl e i s dri ven over a rough road
.
Moni tori ng al so
pauses, and the mi sfi re counter
hol ds at i ts current val ue, i f the throttl e
posi ti on
changes more than a predetermi ned val ue, or i f
dri vi ng condi ti ons fal l outsi de the range of any
rel ated enabl e cri teri a.
Fuel System Monitor and Readiness Code
.
Thi s readi ness code i s al wavs set to avai l abl e
because the tuel system i s conti nuousl y moni tored
dur i ng cl osed l oop oper at i on.
.
fvl oni tori ng
pauses when the catal yti c converter,
EVAP control system, and H02S moni tors are acti ve.
.
Moni tori ng al so
pauses when any rel ated enabl e
cri teri a are not bei ng met. Moni tori ng resumes when
the enabl e cri teri a i s agai n bei ng met.
Comprehensive Component Monitor and
Readiness Code
Thi s readi ness code i s al ways set to avai l abl e because
the comprehensi ve component moni tor i s conti nuousl y
r unni ng whenever t he engi ne i s cr anki ng or r unni ng.
11-40
PGM-Fl System
ELECTRICAL LOAD
DETECTOR
(ELDI
Troubleshooting,
page 1' l -78
CAMSHAFT POSITION {CMPI SENSOR
{TOP DEAD CENTER
(TDC)2
SENSOR) B
Troubl eshooti ng,
page 1 1-7' 1
CAMSHAFT POSITION
(CMP)
SENSOR {TOP DEAD CENTER
{TCD) SENSOR} A
TroLrbl eshooti ng.
page 11- 71
INTAKE AIR TEMPERATURE
IIATI SENSOR
Troubl eshoot i ng,
page 11' 46
ENGINE COOLANT TEMPERATURE
IECTI SENSOR
Troubl eshooti ng,
page 11- 48
THROTTLE POSITION ITP)
SENSOR
Troubl eshoot i ng,
page 11- 50
KNOCK SENSOR
Troubl eshoot i ng,
page 11' 70
MANI FOLD ABSOLUTE
PRESSURE I MAP) SENSOR
Troubl eshoot i ng, page 1 1-43
CRANKSHAFT POSITION {CKPI SENSOR
Troubl eshooti ng, page 1 1-73
PNIMARY HEATED OXYGEN
SENSOR {PRIMARY HO2S)
{SENSOR' l l
Troubl eshoot i ng.
page 1 l -55
Repl acement , page 11-89
SECONDARY HEATED OXYGEN
SENSOR {SECONDARY H02S)
(SENSOB
2)
Troubl eshoot i ng,
page 1 1-58
Repl acement , page I l -89
(cont' d)
11-41
PGM-FI System
(cont'd)
/,/
il-..:--
\|\
DATA LINK CONNECTOR IDLCI
(' 02-03
model s)
General Troubl eshoot i no l nf ormat i on.
page 11- 3
11-42
DTG Troubleshooting
DTC P0107: MAP Sensor Circuit Low Voltage
(l l )
2. Check the MAP wi th the scan tool .
3.
5.
6.
l s apprcx. 101 kPa (760 nmHg, 30 i n.Hg), 2.9 v
i ndi cated?
YES Intermi ttent fai l ure, system i s OK at thi s ti me.
Check for
poor
connectl ons or l oose termi nal s at
the IVIAP sensor and at the ECM.I
NO Go to step 3.
Di sconnect the MAP sensor 3P connector.
Turn the i gni ti on swi tch ON { l l ).
Measure vol tage between MAP sensor 3P
connect or t er mi nal s No. 1 and No. 2.
MAP SENSOR 3P CONNECTOR
(GRN/WHT}
l s there about 5 V?
YES Go to step 7.
NO Repai r open i n the wi re between the ECM
(C
19) and t he MAP sensor . l
Check the MAP wi th the scan tool .
l s appt ox. 2 kPa ( 15 mmHg, 0. 6 i n. Hg) , 0. 5 v or
l ess i ndi cated?
YES Go to step 8.
NO
-
Repl ace the MAP sensor,I
7.
9. Di sconnect the ECM connector C
(31P).
10. Check for conti nui ty between MAP sensor
connector termi nal No, 3 and body
ground.
Wi re si de of temal e termi nal s
YES Repai r short i n the wi re between the Ecfvl
( C17)
and t he MAP sensor . l
(see page 11-5). l f normal MAP i s i ndi cated, repl ace
t he or i gi nal ECM. I
11-43
PGM-FI System
DTC Troubleshooting
(cont'dl
DTC P0108: MAP Sensor Ci rcui t Hi gh Vol t age
1. Start the engi ne. Hol d the engi ne at 3,000 rpm wi th
no l oad
(i n
neutral ) unti l the radi ator fan comes on.
then l et i t i dl e.
l s apptox. 101 kPa (760 nmHg, 30 i n.Hg), 2.9 V or
hi gher i ndi cated?
YES Go to step 3.
NO Intermi ttent fai l ure, system i s OK at thi s ti me.
Check for poor connecti ons or l oose termi nal s at
t he MAP sensor and at t he ECM. I
4. Di sconnectthe MAP sensor 3P connector,
5. l nstal l a
j umper
wi re between MAP sensor 3P
connect or t er mi nal s No. 2 and No, 3.
SGl {GRN/WHT} MAP
IGRN/RED)
JUMPER WIRE
Turn the i gni ti on swi tch ON
(
l l ).
Check the l \4AP wi th the scan tool .
l s about 101 kPa (760 mmHg,30 i n.Hg),2.9 V or
hi gher i ndi cated?
YES Go to step 8.
NO Repl ace t he MAP sensor . t
Remove t he
j umper
wi r e.
6.
7.
11-44
9. l \4easure vol tage between MAP sensor connector
t er mi nal s No. 1 and No. 2.
l s l here about 5 V?
YES Go to step 10.
(C7)
and the MAP sensor.t
Turn the i gni ti on swi tch OFF,
Instal l a
j umper
wi re on the ECM connector
termi nal s between C7 and C 17.
ECM CONNECTOR C 131P)
SG1 {GRN/WHT)
--+r
1 2 4 5
l r l l e l s l r o l
t l 12 l 3 1 4 15 16 t
l r e l r sl
zc
l zi i zl
24 25 26
414-InFV
MAP {GRN/ RED)
JUMPEB WIRE
Turn the i gni ti on swi tch ON {l l ).
Check the l \4AP wi th the scan tool .
l s about 101 kPa (760 mmHg, 30 i n.Hg), or 2.9 V
or higher indicated?
YES Substi tute a known-good ECM and recheck
(see page
1 1-5). l f normal l \4AP i s i ndi cated, repl ace
t he or i gi nal ECM. t
( C
17) and t he MAP sensor . t
10,
' I
l .
DTC Pl 128: MAP Sensor Si gnal Lower Than
Expected
( l l ) .
l s 54.1 kPa (406 mmHg, 16.0 i n.Hg, 1.6 V) or
highet indicated?
YES l ntermi ttent fai l ure, system i s OK at thi s
t i me. l
NO- Repl ace the MAP sensor.l
DTC Pl 129: MAP Sensor Si gnal Hi gher Than
Expected
' 1.
Start the engi ne. Hol d the engi ne at 3,000 rpm wi th
no l oad
(i n
neutral ) unti l the radi ator fan comes on,
l s 36.9 kPa (277 nmHg, 10.9 i n.Hg, 1.1 V)or | ess
i ndi cated?
YES l ntermi ttent fai l ure, system i s OK at thi s
t i me. l
NO- Repl ace the MAP sensor.l
11- 45
PGM-FISystem
6.
7.
DTC Troubleshooting
(cont'dl
DTC P0112: IAT Sensor Circuit Low Voltage
(l l )
2. Checkthe l ATwi th the scan l ool .
l s302"F (150"C)or hi gher (or H-Li mi t i n Honda
mode of PGM Tester) or 0 V indicated?
YES- Go to step 3.
NO Go to step 8.
Di sconnect the IAT sensor 2P connector.
Check the IAT wi th the scan tool .
l s 302' F(150' C)or hi gher (or H-Li mi t i n Honda
mode of PGM Tester)or 0 V i ndi cated?
YES Go to step 5.
NO Repl ace the IAT sensor.l
Di sconnect the ECM connector C
(31P).
Check the conti nui ty between IAT sensor 2P
connector termi nal No, 2 and body ground,
IAT SENSOR 2P CONNECTOR
l s therc conti nui ty?
YES- Repai r short i n the wi re between the EC| M
(C25)
and the IAT sensor. t
(see page 11-5). l f normal IAT i s i ndi cated, repl ace
11-46
8. Check the temperature readi ng on the scan tool . Be
aware that i f the engi ne i s warm. the readi ng wi l l
be hi gher t han ambi ent t emper at ur e. l f t he engi ne
i s col d, the IAT and ECT wi l l have the same val ue.
ls the cortect ambient temperature indicated?
the IAT sensor and at the ECl vl .I
NO Repl ace the IAT sensor. t
DTC P0113: I AT Sensor Ci rcui t Hi gh Vol t age
' l .
(l l )
2. Check the IAT wi th the scan tool .
l s
"
4"F ( 20' C) ot l ess (or L-Li mi t i n Honda
mode ot PGM Tester) or 5 V i ndi cated?
YES Go to step 3.
NO l ntermi tent fai l ure, system i s OK at thi s ti me.
Check for
poor
connecti ons or l oose termi nal s at
t he I AT sensor and t he ECM. I
Di sconnect the IAT sensor 2P connector.
Connect IAT sensor 2P connector termi nal s No. 1
and No. 2 wi t h a
j umper
wi r e.
IAT SENSOR 2P CONNECTOR
3.
, \
SG2I GRN/ YEL)
> 2 /
\-,^- -//
5.
JUMPER WIRE
IAT
(RED/YEL)
Wi re si de oJ l emal e termi nal s
l s 4' F ( 20"C) or l ess (or L-Li mi t i n Honda
mode of PGM Tester) or 5 v i ndi cated?
YES Go to step 6.
NO Repl ace the IAT sensor.I
IAT
7. Connect ECM connector termi na l s C18 and C25
wi t h a i umDer wi r e.
ECM CONNECTOR C {3IP)
l 2 5 1 6 9 1 0
11 12 1 7 18 1 9 20 21 22
24 2
126 ln I
a 30
{RED/YEL)
SG2
(GRN/YELI
JUMPER WIRE
(l l ).
l s 4' F (
-
20' C) or l ess (or L-Li mi t i n Honda
mode of PGM Tester)or 5 V i ndi cated?
(see page l ' 1-5). l f normal IAT i s i ndi cated, repl ace
NO- Repai r open i n the wi re between the EC[4
( C18,
C25) and t he l ATsensor . l
8.
9.
11-41
PGM-FI System
DTC Troubleshooting
(cont'd)
DTC P0116: ECT Sensor Range/Performance
Probl em
NOTE: l f DTC P0117 and/or Po' l ' 18 are stored at rhe
same ti me as DTC P0116, troubl eshoot those DTCS fi rst,
then reckeck for DTC P0116.
no l oad
(i n
2. Check the ECT wi th the scan toot.
ts 176 212' F (80- 100' C)or 0.47 0.78 V
i ndi cated?
YES Intermi ftent fai l ure, system i s OK at thi s ti me.
Check the thermostat and the cool i ng system.I
NO Check the thermostat and the cool i ng system.
l f they are OK, repl ace the ECT sensor.l
11-48
DTC P0117: ECT Sensor Circuit Low Voltage
(l l )
2. Check the ECT wi th the scan tool .
l s 302"F (150"C) or hi gher (or H-Li mi t i n Honda
mode of PGM Tester) or 0 V indicated?
YES- Go to step 3.
Check for poor
connecti ons or l oose wi res at the
ECT sensor and at t he ECM. I
3. Di sconnect the ECT sensor 2P connector,
l s 302' F (150"C) or hi gher (ot H-Li mi t i n Honda
mode ot PGM Tester)or 0 V i ndi cated?
YES Go to step 5.
NO Repl ace the ECT sensor.l
Di sconnect the ECM connector C
(31P).
Check for conti nui ty between ECT sensor 2P
connector termi nal No. 2 and body ground.
5.
6.
1.
ECT SENSOB 2P CONNECTOR
YES Repai r short i n the wi re between the ECM
( C26)
and t he ECT sensor . l
(see page 11-5). l f normal ECT i s i ndi cated, repl ace
t he or i gi nal ECM. t
DTC P0118: ECT Sensor Ci rcui t Hi gh Vol t age
( l l ) .
l s 4"F ( 20"C) or l ess (or L-Li mi t i n Honda
mode ot PGM Tester) or 5 V indicated?
YES Go to step 3.
the ECT sensor and at the ECM. !
4. Di sconnect the ECT sensor 2P connector.
5. Connect ECT sensor 2P connector termi nal s No. 1
and No. 2 wi t h a
j umper wi r e.
ECT SENSOR 2P CONNECTOR
t \
SG2 IGRN/YEL)
> 2 /
\,..- -,"
ECT {RED/WHTI
JUMPER WIRE
( l l ) .
Check the ECT wi th the scan tool .
l s 4"F ( 20' C) ot l ess (or L-Li mi t i n Honda
mode ot PGM Tester) or 5 V indicated?
YES- Go to step 8.
NO Repl ace the ECT sensor.l
6.
7.
8.
9.
10.
1 1 .
Connect ECM connector termi nal s C18 and C26
wi th a
j umper
wi re.
2 4 5 7 8 9 1 0
t l 12 14 1 7 18 m 2
24 25 26 n
+
n 30
ECT IRED/WHT) SG2 {GRN/ YEL)
JUMPER WIRE
(l l ).
Check the ECT wi th the scan tool .
l s 4' F (- 20' C) or l ess (or L-Li mi t i n Honda
mode ol PGM Testet) or 5 V indicated?
(see page 11-5). l f normal ECT i s i ndi cated, repl ace
NO- Repai r open i n the wi re between the ECM
(C
18, C26) and the ECT sensor.l
11-49
PGM-FI System
DTC Troubleshooting
(cont'dl
DTC P0122: TP Sensor Circuit Low Voltage
1. Turn the i gni ti on swi tch oNfl l )
2. Check the throttl e posi ti on
wi th the scan tool .
Is there about 670 when the throttle is f ully closed
and about 90% when the throttle is fully opened?
YES Intermi ttent fai l ure, system i s OK at thi s ti me,
Check for poor
connecti ons or l oose wi res at the TP
sensor and at t he ECM. I
NO Go to step 3.
4. Di sconnectthe TP sensor 3P connector.
( l l ) .
6. Measure vol tage between TP sensor 3P connector
TP SENSOR 3P CONNECTOR
SG2 {GRN/ YEL) VCC2
(YEL/BLU)
Wi re si de ol femal e termi nal s
YES Go to step 7.
NO Go to step 13.
Turn the i gni ti on swi tch OFF. 7.
11- 50
1 0 .
8. At the sensor si de, measure resi stance between TP
sensor 3P connector termi nal s No. 1 and No. 2 wi th
the throttl e {ul l y cl osed.
l s t her e about 0. 5 0. 9kQ?
YES Go to step 9.
NO Repl ace the throttl e body.t
Measure resi stance between TP sensor 3P
connect or t er mi nal s No. 2 and No. 3 wi t h t he
throttl e ful l y cl osed.
9.
Termi nal si de of mal e termi nal s
l s there about 4.5 kQ ?
YES Go to step 10.
NO Repl ace the throttl e body.t
Reconnect the TP sensor 3P connector.
1 1 .
12.
(l l ).
fMeasure vol tage between ECM connector
t er mi nal s C18 and C27.
2 4 5 1 8 9 10
12 1 4 t 5 1 7 IE 1 9 20 21 22
24 25 26 21
+
30
TPS IRED/BLK)
L
,<l\
sG2{GRN/ YEL)
13.
l s thete about 0.3 V when the thtottl e i s tul l y
closed and about 4.5 V when the throttle is fully
opened?
(see page 1 1-5). l f the TP sensor vol tage i s now
nor mal , r epl ace t he ECM. !
NO Repai r short i n the wi re between the ECM
(C27)
and the TP sensor. !
Measure vol tage between ECM connector
t er mi nal s Cl 8 and C28.
ECM CONNECTOR C {31P}
sG2
= r------r----_'r---'i
|
| |
8
|
e
L l o I
2 4 5
l l 12 1 4 1 5 16 1 1 uldryL4zl
24 6 26 n
l n l s o A
,(}
VCC2 {YEL/BLU}
YES Repai r open i n the wi re between the ECM
( C28)
and t he TP sensor . l
(see page 11-5). l f prescri bed vol tage i s now
avai l abl e, r epl ace t he or i gi nal ECM, I
DTC Pl 121: TP Sensor Si gnal Lower Than
Expected
( l l )
2. Check the throttl e
posi ti on wi th the scan tool .
ls 9.4o/" or higher indicated when the throttle is
ful l y opened?
YES
-
Intermi ttent fai l ure, system i s OK at thi s
t i me. l
NO
-
Repl ace the TP sensor
(throttl e
body).I
11- 51
PGM-FISystem
DTG Troubleshooting
(cont'd)
DfC P1122:TP Sensor Signal Higher Than
ExDected
1. Turn the i gni ti on swi tch oN
(l l ).
2. Check the thronl e posi ti on wi th the scan tool .
ls 14.1o/o ot Iess indicated when the throttle is f ullv
clo6ed?
YES
-
Intermi ttent fai l ure, system i s OK at thi s
t r me. I
NO
-
Repl ace the TP sensor
(throttl e
body).I
11-52
\
DTC P0123: TP Sensor Ci rcui t Hi gh Vol t age
( l l ) .
2. Check the throttl e
posi ti on wi th the scan tool .
ls there approx. 6o/" when the throttle is fully
closed and approx. 90o/" when the throttle is f ully
opened?
the TP seri sor and at the ECM.I
NO Go to step 3.
4. Di sconnect the TP sensor 3P connector.
( l l l .
6. At the wi re harness si de, measure vol tage between
TP sensor 3P connect or t er mi nal s No. 1 and No. 3.
SG2IGRN/YEL) VCC2
(YEL/BLU)
Wi re si de oJ femal e termi nal s
YES Repl ace the throttl e body.l
NO Go to step 7.
7. Measure vol tage between ECM connector
t er mi nal s C' 18 and C28,
SG2
(GRN/YEL)
8 | I l t 0 2 5
l l 12 l 4 1 1 8 119 12A 121 122
25 26 21 8 t t 2 9 1 3 0
VCC2 {YEL/BLU)
l stherc about 5 V?
{ C l 8) and t he TP sensor . l
NO-Substi tute a known-good ECM and recheck
(see page 11-5). l f
prescri bed vol tage i s now
avai l abl e r epl ace t he or i gi nal ECM. I
11- 53
PGM-FI System
DTC Troubleshootihg
(cont'd)
DTG P0128: Cooling System Malfunction
('02-03
modelsl
NOTE: l f the DTCS l i sted bel ow are stored at the same
ti me as DTC P0128. troubl eshoot those DTCs fi rst. then
recheck for P0128.
P0107, P0108, P1128, P1129t Mani fol d Absol ute
Pressure
(MAP)
Sensor
P1106, P' 1107, P1108: Bar omet r i c Pr essur e
( BARO)
Sensor
P1259: VTEC System
P01 16, P0117. P0118: Engi ne Cool ant Temper at ur e
(ECT)
Sensor
P0112, P0113: I nt ake Ai r Temper at ur e
( l AT)
Sensor
P0335, P0336: Crankshaft Posi ti on
(CKP)
Sensor
P0300: Random Mi sfi re
P0301, P0302, P0303, P0304: No. 1, No. 2, No. 3 or No. 4
Cyl i nder Mi sfi re
P0505: l dl e control System
P1519: l dl e Ai r Cont r ol
( l AC) Val ve
DTC P0128 can occasi onal l y set when the hood i s
opened whi l e the engi ne i s runni ng.
1. Check the engi ne cool ant l evel
ls the engine coolant level low?
YES Refi l l the engi ne cool ant. l f necessary, repai r
t he cool i ng l eakage. I
NO- Go t o st ep 2.
(l l ),
and make sure the
A,/C is off.
3. Check the radi ator fan.
Does the radiatot fan keep running?
YES Check the radi ator fan ci rcui t
(see page 10-
15). radi ator fan swi tch ci rcui t
(see page
10-17), and
the radi ator fan swi tch
(see page 10-18). l f they are
OK, substi tute a known-good ECM and recheck
(see
page 11-5). l f the symptom/i ndi cator goes away,
r epl ace t he or i gi nal ECM. I
NO- Repl ace the thermostat l see
page 10-10).1
11- 54
DTC P0131: Pri mary HO2S
(Sensor
1) Ci rcui t
Low Vol t age
1. Reset t he ECM { see
page 11- 4} .
no l oad
( i n
neut r al ) unt i l t he r adi at or f an comes on.
3. Check the pri mary HO2S {Sensor 1) output vol tage
wi th the scan tool duri ng accel erati on usi ng wi de
open throttl e.
Does the voltage stay at 0.5 V or less?
YES Go to step 4.
Check for poor
the
pri mary
HO2S
(Sensor
' 1)
and at the ECNi l . t
Check t he f uel pr essur e ( see page 11- 105) .
l s i t notmal ?
YES Go to step 5.
NO Repai r t he f uel suppl y syst em. l
Di sconnect the pri mary HO2S {Sensor 1) 4P
connector.
St ar t t he engi ne and l et i t i dl e.
Check t he
pr i mar y
HO2S
( Sensor
1) out put vol t age
Does i t stay at 0.5 V or l ess?
YES Go to step 9.
NO Repl ace t he
pr i mar y HO2S
( Sensor
1) . I
Di sconnect t he ECM connect or C { 31P) .
5.
6.
7.
8,
9.
10.
1 1. Check for conti nui ty between
pri mary HO2S
( Sensor
1) 4P connect or t er mi nal No, 1 and body
g rou nd.
PRIMARY HO2S lsensor 1)
ilP
CONNECTOR
W| l e sr de ol l emal e t er mr nal s
Is there conti nui ty?
( C16)
and t he
pr i mar y HO2S
( Sensor
1) . 1
NO Substi tute a known' good ECM and recheck
(see page 11-5). l f the symptom/i ndi cati on goes
away, r epl ace t he or i gi nal ECM. I
11- 55
PGM-FI System
DTC Troubleshooting
(cont'd)
(Sensor
l l Ci rcui t
High Voltage
1. Reset t he ECM
( see page 11- 4) .
2. Stan the engi ne. Hol d the engi ne at 3.000 rpm wi th
no l oad
(i n
3. Check the pri mary HO2S
(Sensor
1) output vol tage
Does the voltage stay at 0.9 V ot mote?
YES
-
Go to step 4.
NO- Intermi ttent fai l ure. system i s OK at thi s ti me.
Check for poor
the Pri mary HO2S
(Sensor
1) and at the ECM.I
5. Di sconnect the
pri mary
HO2S {Sensor 1) 4P
connecl or.
6. Connect pri mary
HO2S
(Sensor
1) 4P connector
t er mi nal s No. 1 and No. 2 wi t h a
j umper
wi r e.
PRIMARY HO2S {Sensor 1)
,lP
CONNECTOR
PHO2S
(WHTI
sG2
(GRN/YELI
JUMPER WIRE
t--=---l
LJ-ril___i
t t - l
f--r---1
l 3 1 4 l
11-56
1.
8.
9.
10.
1 1 .
12.
(l l ).
Check the pri mary HO2S
(Sensor
' 1)
output vol tage
Is therc 0.9 V or more?
YES Go to step 9.
NO- Repl ace t he pr i mar y HO2S
( Sensor
1) . I
Connect ECM connect or t er mi nal s C16 and C18
wi th a
j umper
wi re.
ECM CONNECTOR C 131PI
2 4 5 7 8 I 1 0
11 12 t 4 15 1 1 1E 19 20 21 ?2
25
+
21
+
a 30
PHO2S IWHTI SG2 {GRN/YEL)
JUMPER WIRE
(l l ).
Check the pri mary HO2S
(Sensor
' 1)
output vol tage
l s thete 0.9 V ot morc?
{see
page 11-5). l f the symptom/i ndi cati on
goes
away repl ace the ori gi nal ECM. t
NO-Repai r open i n the wi re between the ECM
( C16,
C18) and t he
pr i mar y
HO2S
( Sensor
1) . 1
(Sensor
1) Ci rcui t
Sl ow Response
NOTE: l f DTC P0131, P0132 and/or P0135 are stored at
the same ti me as DTC P0133, troubl eshoot those DTCS
fi rst, then recheck for DTC P0133.
1. Reset t he ECM
( see page 11- 4| .
no l oad
{i n neutral ) unti l the radi ator fan comes on.
3. Test-dri ve under the fol l owi ng condi ti ons.
.
55 mph
(89km/n)
steady speed
.
M/T i n 6th gear
.
Unti l readi ness code or Temporary DTC P0133
comes on
4. Check for a Temporary DTC wi th the scan tool .
ls Temporaty DTC P0133 indicated?
YES Repl ace the pri mary
HO2S
(Sensor
1).1
NO
-
l nl ermi ttent fai l ure, system i s OK at thi s ti me.
Check for poor
t he pr i mar y
HO2S
( Sensor
1) and at t he ECM. t
11-57
PGM-FI System
DTG Troubleshooting
(cont'dl
DTC P0137: Secondary HO2S
(Sensor
2)
Ci rcui t Low Vol t age
1. Reset t he ECM
( see page 1 1- 4) .
no l oad
( i n
neut r al ) unt i l t he r adi at or f an comes on.
3. Check the secondary HO2S
(Sensor
2) output
vol tage at 3,000 rpm wi th the scan tool .
Does the voltage stay at 0.3 V or less?
YES Go to step 4.
NO Intermi ttent fai l ure. system i s OK at thi s ti me.
t he secondar y HO2S
( Sensor
2) and at t he ECM. I
5. Di sconnect the secondary HO2S
(Sensor
2) 4P
connector.
(Sensor
2) output
vol tage wi th the scan tool .
Does the vol tage stay at 0.3 V or l ess?
YES Go to step 8.
NO Repl ace t he secondar y HO2S
( Sensor
2) . I
(31P).
11- 58
10. Check for conti nui ty between secondary HO2S
(Sensor
2) 4P connector termi nal No. 2 and body
g rou nd.
SECONDARY HO2S
ISENSOR 2l
irP
CONNECTOR
{ C15) and t he secondar y HO2S
( Sensor
2) . 1
NO
-
Substi tute a known-good ECM and recheck
(see page 11-5). l f the sym ptom/i nd i cati on goes
away, repl ace the ori gi nal ECM.I
DTC P0138: Secondary HO2S
(Sensor
2)
Ci rcui t Hi gh Vol t age
1. Reset the Ecl vl
(see page 1 1-41.
no l oad
(i n
3. Check the secondary HO2S {Sensor 2) output
Does the voltage stay at 0.6 V or more?
YES Go to step 4.
Check for poor
the secondary HO2S
(Sensor
2) and at the ECM. r
5. Di sconnect the secondary HO2S
(Sensor
2) 4P
connector.
6. Connect secondary HO2S
(Sensor
2) 4P connector
termi nal s No. 1 and No. 2 wi th a
j umper
wi re.
SECONDARY HO25
ISENSOR 2l
ilP
CONNECTOR
SG2 IGRN/YELI
SHO2S IWHT/RED)
Termi nal si de ol mal e t ermi nal s
JUMPER WI RE
7.
8.
10.
(l l ).
Check the secondary HO2S
(Sensor
2) output
l s there 0.6 V or more?
YES Go to step 9.
NO Repl ace the secondary HO2S
(Sensor
2).1
Connect ECM connect or t er mi nal s C15 and C18
wi t h a
j umper
wi r e,
ECM CONNECTOR C
(31PI
JUMPER WIRE
{WHT/RED} SG2 {GRN/ YELI
1 2 3
l u l u l
9 1 0
l 3 14 1 7 18 20 21
6 26 n n a 30
Wi re si de of Iemal e termi nal s
1 1. Turn the i gni ti on swi tch ON
(l l l .
(Sensor
2) output
ls there 0.6 V or morc?
(see page I 1-5). l f the symptom/i ndi cati on goes
NO
-
Repai r open i n the wi re between the ECM
( C15,
C18) and t he secondar y HO2S
( Sensor
2) . 1
sHo2s
11- 59
PGM-Fl System
DTC Troubleshooting
(cont'd)
DTG P0139: Secondary HO2S
(Sensor
2) Slow
Resoonse
page 11- 41.
2. Stan the engi ne. Hol d the engi ne at 3,000 rpm wi th
no l oad
(i n
(Sensor
2) oul put
Does the vol tage stay wi thi n 0.3- 0.6 V for 2
mi nutes?
YES Repl ace the secondary HO2S
(Sensor
2).1
the secondarv HO2S
(Sensor
2) and at the ECl vl .!
11- 60
3.
4.
DTC P0135: Primary HO2S
(Sensor
1) Heater
Ci rcui t Mal f unct i on
DTC P0141: Secondary HO2S(Sensor 2)
Heater Circuit Malf unction
NOTE: Informati on marked wi th an asteri sk
(*
) appl i es
to DTC P0141.
1. Reset t he ECM
( see page 11- 4) .
2. St an t he engi ne.
l s DTC P0135 ot P0141 i ndi cated?
YES- Go to step 3.
Check for poor
the pri mary
HO2S
(Sensor
1) or secondary HO2S
( Sensor
2) and at t he ECM. I
Di sconnect the H02S
(pri mary
or secondary
*
)
(Sensor
1 or Sensor 2
*
) 4Pconnecror,
5. At the HO2S si de, measure resi stance between
HO2S 4P connector termi nal s No. 3 and No. 4.
PRIMARY HO2S lsensor 1l SECONDARY HO2S {Sensor 2,
4PCONNECTOR 4P CONNECTORT
Termi nal si de of wi re si de of
mal e termi nal s femal e termi nal s
l s there about 3.3 A (12 14.3 A
)"
?
YES Go to step 6.
NO- Repl ace t he pr i mar y
HO2S
( Sensor
1) or
secondary HO2S
(Sensor
21
x
.1
6. At the HO2S si de, check conti nui ty be&veen body
ground and HO2S 4P connector termi nal s No. 3
and No. 4 i ndi vi dual l y.
PRIMARY HO2S (Sonsoi'll
SECONDARY HOzS {Sensor2)
4PCONNECTOR ilP
CONNECTORT
YES Repl ace the HO2S
(pri mary
or secondary
*
)
(Sensor
1 or Sensor 2
*
). t
NO Go to step 7.
(l l ).
Measure vol tage between H02S 4P connector
t er mi nal No. 3 and No. 4.
PRIMARY HO2S
(Sensor
1) SECONDARY HO2S tsensor 2l
4PCONNECTOR 4P CONNECTOR*
7.
8.
Wi re si de of
f emal e t ermi nal s
Termi nal si de of
mal e t er mi nal s
Wi re si de of
femal e termi nal s
YES Go to step L
NO- Go to step 13.
rcr
f-fi]
pozsnrc
( BLK/
I
I
I Z I { BLK/ WHTI
YEL) f--t--
-
3 l 4 l
l
L-{o---l
so2sHTc
{BLK/WHT)
t Gl
IBLK/
YEL}
(cont' d)
Termi nal si de of
mal e t ermi nal s
11- 61
PGM-FISystem
q
10.
1 1 .
DTG Troubleshooting
(cont'dl
Di sconnect ECM connector C {31P)
Check for conti nui ty between the connector
t er mi nal C1
( C11) *
andbodygr ound.
cM CoNNECTOB C t31P)
( C1,
C11
*
) and HO2S { pr i mar y or secondar y
x
)
( Sensor
1, Sensor 2
*
) . 1
NO Substi tute a known-good ECfvl and recheck
(see page 1' l -5). l f the symptom/i ndi cati on
goes
' 12.
Measure vol tage between
pri mary HO2S 4P
connect or t er mi nal No. 3
( secondar y
HO2S No 4)
*
and body ground.
PRIMARY HO2S
(snsor
1) SECONDAFY HO2s {sensor 2)
4PCONNECTOR 4P CONNECTOR'
1 1 l 2 l l l l T z l h c '
F-+_- l l l --#l l BLK/YEL)
| ) A | I 1 t l -
l " l - l l r - r l
I
' cl
-,.1-
rv)
|BLK/YELI
(V)
Y Y
Wi r e si de of Ter mi nal si de of
f emal e t er mi nal s mal e t er mi nal s
YES Go to step 13.
NO Repai r open i n the wi re between the pramary
Ho2S
(Sensor
' l ),
secondary HO2S
(Sensor
2)
*
and No. 6 ACG
(
15 A) f use. I
11-62
14. Reconnect the HO2S 4P connector.
15. Di sconnect the ECM connector C
(31P)'
( l l ) .
t er mi nal s 82 and C1
( 82
and C1 1)
*
ECM CONNECTORS
(BLK/WHT)}
l s there 0.1 V ot l ess?
( c1
and c11)
x
and t he Ho2s
( pr i mar y
or
secondar y
*
) ( Sensor ' 1, Sensor 2
*
) . I
(see page
' 1
1-5). l f the symptom/i ndi cati on
goes
(BLKI
B
(25P)
2 3 5
P02SHTC
{BLK/WHT)
9 t 1 0 l l 1Z
2A z1 ?2 /1./
c l 31P)
1 1 2 8 1 9 t 0
l l l 1 2 l 1 3 1 1 4 15 1 6 17 16 t 9 N 21 2
s02sHTc
/ 1. / 16
26 zl a a 30
DTC P0171: Fuel System Too Lean
DTC P0172: Fuel System Too Rich
NOTE: l f some of the DTCS l i sted bel ow are stored at
the same ti me as DTCP0171 and/or P0' 172,
troubl eshoot those DTCS fi rst, then recheck for P0171
andl ot P0172.
P0107, P0108. P1128,P1129t Mani fol d Absol ure
Pressure
(MAP)
Sensor
P0135: Pri mary Heated Oxygen Sensor
(pri mary
H02S)
( Sensor
1) Heat er
P0137, P0138: Secondary HO2S
(Sensor
2)
P0141: Secondary HO2S
(Sensor
2) Heater
P1259: VTEC System
1. Check the fuel pressure (see page 11-' 105).
l s l uel pressure
OK?
YES Go to step 2.
NO Check these i tems:
.
l f t he pr essur e i st oo hi gh. Checkt hef uel
pressure
regul ator, and the fuel return pi pe.l
.
l f t he pr essur e
i st oo l ow. Checkt hef uel pump,
the fuel feed pi pe,
the fuel fi l ter, and the fuel
pressure regul ator.l
no l oad
(i n
3. Check t he pr i mar y
HO2S
( Sensor
1) out put wi t h t he
scan tool .
Does it stay less than 0.3 V or more than 0.6 V ?
YES Repl ace the pri mary
HO2S
(Sensor
1), I
NO Go to step 4.
5. Wi th a vacuum pump,
appl y vacuum to the EVAP
cani ster purge val ve from the i ntake mani fol d si de.
Does i t hol d vacuum?
YES Check the val ve cl earances and adj ust i f
necessary. l f the val ve cl earances are OK, repl ace
the fuel i nj ectors.l
NO Repl ace the EVAP cani ster purge val ve. t
11- 63
PGM-FISystem
DTC Troubleshooting
(cont'd)
DTC P0300: Random Mi sf i re and Any Combi nat i on of t he Fol l owi ng:
DTC P0301: No. 1 Cylinder Misfire
DTG P0302: No. 2 Cylinder Misfire
DTG P0303: No. 3 Cylinder Misfire
NOTE:
. l f t hemi sf i r i ngi sf r equent enought ot r i gger det ect i onof i ncr easedemi ssi onsdur i ngt woconsecut i vedr i vi ngcycl es,
the MIL wi l l come on, and DTC P0300 {and some combi nati on of P0301 through P0304) wi l l be stored.
.
l f the mi si i ri ng i s frequent enough to damage the catal yst, the MIL wi l l bl i nk wheneve r the mi sfi ri ng occurs. and DTC
PO3OO
(and
some combi nati on of P0301 through P0304)wi l l be stored. When the mi sfi ri ng stops, the MIL wi l l remai n
on.
1. Troubl eshoot the fol l owi ng DTCS fi rst i f any of them were stored al ong wi th the random mi sfi re DTC(S):
P0107, PO108, P1128, P1' 129: l \4ani fol d Absol ute Pressure
(MAP)
Sensor
(see page
' l ' l
-52)
P0131, P0132: Pr i mar y Heat ed Oxygen Sensor
( pr i mar y
HO2S) { see
page 11- 65)
P017' 1,P0172t Fuel Meteri ng
(see page 11-65)
P0335. P0336: Crankshaft Posi ti on
(CKP)
Sensor{see
page I1-81)
P0505: l dl e Control System
(see page 11-100)
P1259:VTEC System
(see page
6-6)
p1361,
P1362, P' ]366, P1367: Camshaft Posi ti on
(CMP)
Sensor
(Top
Dead Center
(TDC)
Sensor) A,/B
(see page 1 1-
9 1 )
P15' 19: l dl e Ai r Control
(l AC)
Val ve
(see page 1 1-102)
2. Test-dri ve the vehi cl e to veri fy the symptom.
3. Fi ndthesymptom i n the chart bel ow, anddothe rel ated
procedures i n the orderl i sted unti l you fi nd the cause.
Svmptom
Procedure{s)
Also check for:
Random mi sfi re onl y at
l ow RPM and l oad
Check fuel pressure
(see page 11-105).
.
LOW COmpreSSl On.
.
Low
qual i t v
f uel .
Random mi sfi re onl y
duri ng accel erati on
Checkf uel
pr essur e
{ see
page 11- 105) . Mal functi on i n the
VTEC system
(see
Daqe 6-6).
Random mi sf i r e at hi gh
RPM and l oad, or under
random condi ti ons
Checkf uel
pr essur e ( see page 11- 105) . Correct val ve
cl earance
(see page
6-6).
11- 64
tt
DTC P0301: No. 1 Cyl i nder Mi sf i re
DTC P0304: No. 4 Cylinder Misf ire
1. After checking and recordingthe freeze data, reset
the ECM
(see page
1 1-4). l f there i s no freeze data of
the mi sfi re,
j ust
cl ear the DTC.
2. Start the engi ne, l i sten for a cl i cki ng sound at the
i nj ector at the probl em
cyl i nder
Does i t cl i ck?
YES Go to step 3.
NO Go to step 30.
4. Exchange the i gni ti on coi l from the probl em
cyl i nder wi th one from another cyl i nder.
5. Test-dri ve the vehi cl e several ti mes i n the range of
the freeze data or under vari ous condi ti ons i f there
was no freeze data.
6, Check for a DTC or Temporary DTC wi th the scan
t ool .
ls DTC P0301, P0302, P0303 or P0304, or
Temporary DTC P1399 i ndi cated?
YES Go to step 7.
NO Intermi ttent mi sfi re due to poor contact atthe
i gni t i on coi l connect or
( no
mi sf i r e at t hi s t i me) . 1
7. Determi ne whi ch cyl i nder(s) had the mi sfi re.
Does the misfire occut in the othet cylinder wherc
the ignition coil was exchanged?
YES Repl ace t he f aul t y i gni t i on coi l . t
NO Go to step 8.
Exchange the spark pl ug
from the
probl em
cyl i nder
wi th one from another cyl i nder.
Test-dri ve the vehi cl e several ti mes i n the range of
was no freeze data.
Check for DTC or Temporary DTC wi th a scan tool .
l s DTC P0301, P0302, P0303 or P0304, or
YES Go to step 12.
NO Intermi ttent mi sfi re due to spark pl ug foul i ng,
etc.
(no
mi sfi re at thi s ti me).I
Determi ne whi ch cyl i nder had the mi sfi re.
Does the misf ire occur in the other cylinder where
the spark plug was exchanged?
YES Repl ace the faul ty spark
pl ug.t
NO Go to step 13.
Exchange the i nj ector from the probl em cyl i nder
wi t h one f r om t he anot her cyl i nder .
Let the engi ne i dl e for 2 mi nutes.
was no freeze data.
(cont' d)
8.
9.
' 10.
' l t .
, l t
13.
14.
15.
t o .
11- 65
PGM-FI System
DTC Troubleshooting {cont'd)
17. Check for a DTC or Temporary DTC wi th the scan
r ool .
ls DTC P0301, P0302, P0303 ot P0304, ol
YES' - Go to step 18.
NO
-
Intermi ftent mi sfi re due to bad contact i n the
i nj ector connector
(no
mi sfi re at thi s ti me).I
18. Determi ne whi ch cyl i nder had the mi sfi re.
Does the misf ire occu in the other cylinder wherc
the injector was exchanged?
YES Repl ace t he f aul t y i nj ect or
( seepagel l -
87) . t
NO Go to step 19.
20. Di sconnect the i gni ti on coi l 3P connector from the
probl em cyl i nder.
( l l ) .
22. Measure vol tage between i gni ti on coi l 3P
connector termi nal No. 3 and body
ground.
IGNITION COIL 3P CONNECTOR
Wi re si de of
t emal e t er mi nal s
YES Go to step 23.
NO Repai r open i n the wi re bet\i veen the No 4
COI L
( 15A)
f use and t he i gni t i on coi l . l
11- 66
24. Check for conti nui ty between i gni ti on coi l 3P
YES Go to step 25.
NO Repai r open i n the wi re between the i gni ti on
c o i l a n d G1 0 1 . I
Di sconnect ECM connector C
(31P)
25.
26. Check for conti nui ty between body ground
and the
ECM connector termi nal
(see
tabl e).
IGPLSl {WHT}
YES
-
Repai r short i n the wi re between the ECM
and t he i gni t i on coi l . l
NO Go to step 27.
IGPL33
Wi re si de ot f emal e t ermi nal s
PROBLEM
CYLINDER
DTC EC t\4
TERMINAL
WI RE
COLOR
No.
' l
P0301 c4 WHT
No . 2 P0302 c12 WHT/G RN
No . 3 P0303 c 13 WHT/BLK
No . 4 P0304 c 1 4 WHT/BLU
27. Con nect the a ppropri ate
i gn i ti on coi l 3P connector
termi nal No.
' 1
to body ground wi l h a
j umper
wi re
{see tabl e).
PROB LE I\4
CYLINDER
DTC WI RE
COLOR
No. 1 P0301 WHT
No. 2 P0302 WHT/GRN
No. 3 P0303 WHT/BLK
No. 4 P0304 WHT/BLU
and the
ECM connector termi nal
(see
tabl e).
YES Go to step 29.
NO- Repai r open i n the wi re between the ECM and
t he i gni t i on coi l . l
(cont' d)
ECM CONNECTOR C 13lPI
IGPLS3
Wi re si de oI f emal e t ermi nal s
PROB LE I\4
CYLINDER
DTC EC N4
TERMINAL
WI RE
COLOR
No. 1 P0301 c4 WHT
No. 2 P0302 WHT/GRN
No. 3 P0303 c13 WHT/BLK
No . 4 P0304 cl 4 WHT/BLU
11-67
PGM-FI System
DTC Troubleshooting
(cont'd)
29. Check the engi ne compressi on
(see page
6-32).
ls the engine compression OK?
(see page 11-5). l f the symptom/i ndi cati on
goes
NO Repai r t he engi ne. l
31. Di sconnect ECM connector B
(25P).
( l l )
33. Measure vol tage between body
ground and the
ECfvl connector termi nal
(see
tabl e).
ECM CONNECTOR B
(25PI
INJ3
(BLU}
I NJ4{YEL}
PROBLEM
CYLINDER
DTC EC t\4
TERMINAL
WI RE
COLOR
No. 1 P0301 t t t l BRN
No. 2 P0302 83 RED
N o . 3 P0303 B4 BLU
No. 4 P0304 E' 5 YEL
34.
35.
l s therc battery vol tage?
YES Go to step 34.
NO Go to step 42.
Di sconnect the i nj ector 2P connector from the
probl em cyl i nder.
11- 68
44.
37.
36. Measure resi stance betvveen i ni ector 2P connector
INJECTOR 2P CONNECTOR
I s t her e 10
g
13 Q?
YES Go to step 37.
NO Repl acet he i nj ect or
( see page 11- 87) . I
Exchange the i nj ector from the
probl em cyl i nder
wi th one from another cyl i nder.
Let the engi ne i dl e for 2 mi nutes.
was no freeze data.
Check for a DTC or Temporary DTC wi th the scan
t ool .
l s DTC P0301, P0302, P0303 or P0304, or
Temporary DTC P1399 indicated?
YES Go to step 41.
NO Intermi ttent mi sfi re due to i nj ector
mal functi on, etc.I
Determi ne whi ch cyl i nder had the mi sfi re.
Does the mi sf i re occur i n the other cyl i nder where
the injectot was exchanged?
YES Repl ace the faul ty i nj ector.l
{see
page 1 1-5). l f the symptom/i ndi cati on
goes
away, repl ace the ori gi nal ECl vl .l
Di sconnect the i nj ector 2P connector from the
pr obl em cyl i nder .
( l l ) .
38.
39.
42.
43.
41.
46.
47.
45, Measure vol tage between i nj ector 2P connector
t er mj nal No. 2 and body gr ound.
INJECTOR 2P CONNECTOR
I GP
(YEL/ BLK}
I s there battety voltage?
YES
-
Go to step 46.
NO
-
Repai r open i n the wi re between the i nj ector
and t he PGM- Fl mai n r el ay. !
Check for conti nui ty between body
ground
and the
ECI\4 connector termi nal
(see
tabl e),
ECM CONNECTOR B (25P)
INJ3
(BLU}
INJ,I(YEL)
and t he i nj ect or . I
NO Go to step 48.
PROBLEM
CYLINDER
DTC ECM WI RE
TERIVIINAL COLOR
No. 1 P0301 8 1 1 BRN
No. 2 P0302 B3 RED
No. 3 P0303 B4 BLU
N o . 4 P0304 B5 YEL
48. Connect i nj ector 2P connector termi nal No. I to
body ground wi th a
j umper
wi re
(see
tabl e).
INJECTOR2P CONNECTOR
I
rTa
rf-
INJ
JUMPEn wruEl
Wi . e si de of f emal e t er mi nal s
PROBLEM
CYLINDER
DTC WI RE
COLOR
No. 1 P030' 1 BRN
No. 2 P0302 RED
No. 3 P0303 BLU
No. 4 P0304 YEL
49. Check for conti nui ty between body ground and the
ECM connector termi nal s
(see
tabl e).
ECM CONNECTOR B
(25P)
INJ3IBLUI
INJ4(YELI
YES Repl ace the i nj ector, then recheck.l
NO Repai r open i n the wi re between the ECM and
the i nj ector.I
PROBLEM
CYLINDER
DTC ECM
TERI\4INAL
WI RE
COLOR
No. 1 P030 1 8 1 1 BRN
No. 2 P0302 B3 RED
No . 3 P0303 B4 BLU
No . 4 P0304 B5 YEL
11- 69
PGM-FI System
DTC Troubleshooting
(cont'd)
DTC P0325: Knock Sensor Ci rcui t Mal f unct i on
1. Reset t he ECM
( see page 11- 4) .
no l oad
(i n
3. Hol d the engi ne at 3,000 4,000 rpmfor' 10 seconds,
l s DTC P0325 i ndi cated?
YES Go to step 4.
Check for
poor
the knock sensor and at the ECM.I
5. From under neath the vehi cl e, reach above the
front of the starter motor, and di sconnect the knock
sensor 1P connect or .
(31P),
then check for
conti nui ty between ECI\4 connector termi nal s C22
and body ground.
ECM CONNECTOR C 131P}
YES Repai r short i n the wi re between ECI\4
(C22)
and the knock sensor.l
NO Go to step 7.
Wi re si de ol l emal e t ermi nal s
11-70
8.
7. Connect knock sensor connector termi nal No. 1to
body
ground wi th a
j umper
wi re.
KNOCK SENSOR 1P CONNECTOR
KS
(RED/BLU)
JUMPER WIRE
Check for conti nui ty between ECM connector
termi nal C22 and body ground.
Is there continuity ?
YES Go to step 9.
( C22)
and t he knock sensor . l
9. Substi tute a known-good knock sensor and recheck.
YES-Substi tute a known-good ECM and recheck
(see page 11-5). l f symptom/i ndi cati on
goes away,
NO- Repl ace t he or i gi nal knock sensor . I
wi re si de of t emal e t ermi nal s
DTC P1361: CMP
(TDC)
Sensor A ,ntermittent
I nt errupt i on
DTC Pl 362: CMP
(TDC)
Sensor A No Si gnal
DTC P1366: CMP
(TDC)
Sensor B Intermittent
Interru ption
DTC P1367: CMP
(TDC)
Sensor B No Si gnal
NOTE: I nf or mat i on mar ked wi t h an ast er i sk
( *
) appl i es
to DTC P1366 0r DTC P1367.
' 1.
Reset t he ECM
( seepage
l 1- 4)
l s DTC Pl 361, Pl 362, P1366 and/or P1367
i ndi cated?
YES
-
Go to step 3.
NO Intermi ttent fai l u re, system i s OK at thi s ti me.
CMP
(TDC)
sensor A, CMP
(TDC)
sensor B
*
and at
t he EcM. I
Di sconnect the CMP
(TDC)
sensor A and CMP {TDC)
sensor B
*
2P connectors.
l \4easure resi stance between CMP
(TDC)sensor
2P
CMP {TDCI SENSOS A 2P CONNECTOR
CMP {TDC) SENSOR B 2P CONNECTOR*
Is there 1,850 2,450 Q ?
YES Go to step 6.
NO Repl ace the CMP
(TDC)
sensor A and/or CMP
( TDC)
sensor B
* ( seepage6- 3) . I
3.
4.
6. Checkfor continuity to body ground on all
t er mi nal s i ndi vi dual l y.
CMP
(TDC}
SENSOR A 2P CONNECTOR
CMP
(TDC)
SENSOR B 2P CONNECTOR*
.-J r---------L'-
t---T-----Tl
l r i
|
?
r l
--r--r-
9 9
-L _L
YES Repl ace the CMP
(TDC)
sensor A and/or CMP
(TDC)
sensor B
x (see page 6-3).1
NO Go to step 7.
(cont' d)
11-71
PGM-FISystem
DTC Troubleshooting {cont'd)
7. Reconnect CMP {TDC) sensor A and CMP
(TDC)
sensor B
*
2P connectors.
Di sconnect ECI\4 connector C
(31P).
l vl easure resi stance between ECM connector
t er mi nal s C20 and C21
( C29
and C30)
*
.
ECM CONNECTOR C I31P}
o
TDC 1P
IGRN)
\9
1 2 4 5 1
i
1 0
1 l 12 13 t 4 15 16 1 7 18 20 21 22
24 25 26 21 2A 30
TDC 2P
(YELI'
,^\
TDC 1M
(REDI
l s thete 1,850- 2,450 Q ?
YES Go to step 10.
NO Repai r open or short i n the faul ty sensor
wi r e{ s) . 1
d ,
9.
TDC 2M
{BLKIA
11-72
' 10.
Check for conti nui ty between body ground and
ECM connector temi nal C20
(C29) *
.
ECM CONNECTOR C
(31P)
Wi re si de o{ f emal e t ermi nal s
ls therc continuity?
YES
-
Repai r short to body ground i n the faul ty
sensor wi re(s).1
TDC l P I GRNI
DTC P0335: CKP Sensor No Si gnal
DTC P0336: CKP Sensor lntermittent
I nt errupt i on
page l 1- 41.
ls DTC P0335 and/or P0336 indicated?
YES Go to step 3.
Check for
poor
the CKP sensor and at the ECM.I
Di sconnect the CKP sensor 3P connector, and
measure resi stance between CKP sensor 3P
4.
CKP SENSOR 3P CONNECTOR
.
r------:'1
,
lr-E-l-Jl
|
- "
t l
l # l
__T--T-
t l
cKP-
|
L-----r
CKP+
(wHrl
| /^\ l (Btul
--\4-
l sthere 1,850 2,450 Q ?
YES Go to step 5.
NO Repl ace the CKP sensor
(see page
6-3).1
5. Check for conti nui ty between CKP sensor 3P
connector terml nal No. I and body ground and
t er mi nal No. 2 and body gr ound i ndi vi dual l y.
CKP SENSOR 3P CONNECTOR
YES Repl ace the CKP sensor
(see page
6-3).1
NO-Go to step 6.
Reconnect the CKP sensor 3P connector.
Di sconnect ECM connector C
(31P),
and measure
resi stance between the ECM connector termi nal s
C8 and C9.
6.
1.
CKP+
(BLUI
l 2 4 5 7 E 9 t0
1 1 12 l 3 1 4 1 7 1 8 20 21 22
24 25 27 2E 30
CKP_
{WHT}
l s there 1,850 2,450 Q ?
YES Go to step 8.
NO- Repai r open i n the wi re between the ECM
(C8,
C9) and CKP sensor . l
(cont' d)
11-73
PGM-FI System
DTC Troubleshooting
(cont'dl
8. Check for conti nui ty between ECM connector
termi nal C8 and body ground.
ECM CONNECTOR C 13, I P)
YES Repai r short i n the wi re between ECM
t er mi nal C8 and t he CKP sensor . I
(see page
1 1-5). l f the symptom/i ndi cati on goes
CKP+
(BLU}
11-74
\
DTC P0500: VSS Circuit Malfunction
1. Reset t he ECM
( see page 11- 4)
no l oad { i n neut r al ) unt i l t he r adi at or f an comes on,
Test-dri ve wi th the transmi ssi on i n 2nd gear
accel erate to 4,000 rpm, then decel erate to 1,500
rpm wi th the throttl e ful l y cl osed for at l east 5
seconds.
4. Check for a DTC wi th the scan tool .
YES Go to step 5.
Check for
poor
connecti ons or l oose termi nal s
between the VSS and at the ECM.I
6. Rai se t he vehi cl e.
7. Di sconnect the VSS 3P connector.
( l l ) .
9. l vl easure vol tage between VSS 3P connector
t er mi nal No. 1 and body
gr ound.
VSS 3P CONNECTOR
YES Go to step
' 1
1.
NO Go t o st ep 10.
l 2 5 7 E 9 1 0
11 12 15 16 1 1 t 9 20 21 22
24 % 26 21 2E n 30
VCC2 {YEL/BLUI
10. Measure vol tage between ECM connector termi nal
C28 and body gr ound.
Wi re si de oI t emal e t ermi nal s
( C28)
and VSS. I
goes
Measure vol tage between the VSS 3P connector
11.
VSS 3P CONNECTOR
IBRN/YELI
YES Go to step 12.
NO Repai r open i n the wi re between the Ecl vl
{820, 822) and the VSS. t
{cont' d)
11-75
PGM-FI System
DTC Troubleshooting
(cont'dl
13. Reconnect the VSS 3P connector.
( l l ) .
15. Rai se t he r ear of t he vehi cl e, and make sur e i t ' s
securel y supported. Hol d one wheel , and sl owl y
rotate the other.
' 16.
l vl easure vol tage between ECM connector
t er mi nal s A9 and 820.
ECM CONNECTORS
Does vol tage pul se
between 0 V and about 5 V?
(see page 11-5). l f the symptom/i ndi cari on goes
away, repl ace the ori gi nal ECM. t
NO Go to step 17.
18. Di sconnect ECM connector A
(32P).
' 19.
Tur n t he i gni t i on swi t ch ON { l l ) .
20. Hol d one wheel , and sl owl y rotate the other.
B l25Pl
11-76
termi nal s A9 and B20.
ECM CONNECTORS
Does voltage pulse between 0 V and about 5 V?
(see page 1 1-5). l f the symptom/i ndi cati on goes
NO Repai r short or open i n the wi re between the
VSS and the ECM, i f the wi re i s OK, repl ace the VSS
{see
page 22-52). !
B
(25P)
DTC Pl106: BARO Sensor Range/Perfoma nce
Probl em
1. Reset t he ECM
( see page 11- 4)
2. Startthe engi ne. Hol d the engi ne at 3,000 rpm wi th
no l oad { i n neut r al ) unt i l t he r adi at or f an comes on,
3. Test-dri ve wi th the transmi ssi on i n 4th gear.
4. Accel erate for 5 seconds usi ng wi de open throttl e.
l s Temporary DTC P1106 i ndi cated?
goes
NO Intermi ttent fai l ure, system i s OK at thi s
t i me. l
DTC Pl 107: BARO Sensor Ci rcui t Low Vol t age
DTC Pl 108: BARO Sensor Ci rcui t Hi gh
Vol t age
1. Reset t he ECM
( see page 11- 4) .
( l l ) .
l s DTC P1107 or P1108 i ndi cat ed?
(see page 1 1-5). l f the symptom/i ndi cati on
goes
NO- Intermi ttent fai l ure, system i s OK at thi s
t i me. I
11-77
PGM-FI System
DTC Troubleshooting
(cont'd)
DTC P1297: ELD Circuit Low Voltage
1. Reset the ECI\4
(see page 11-4).
2. Stan the engi ne.
3, Turn on the headl i ghts.
YES Go to step 4.
NO l ntermi ttent fai l ure, system i s OK at thi s tl me.
the ELD and at the ECM. t
4. Turn the i gni ti on swi tch and headl i ghts OFF.
5. Di sconnectthe ELD 3P connector.
(l l ).
7. Measure vol tage between ELD 3P connector
t er mi nal No. 3 and body gr ound
ELD 3P CONNECTOR
{GRN/ RED)
Wi re si de ot I emal e t ermi nal s
YES. - Repl ace t he ELD. I
NO Go to step 8.
T 2 3
ELD
11-78
(32P).
t er mi nal A30 and body gr ound.
ECM CONNECTOR A
(32PI
Wi re si de oI femal e termi nal s
l s Ihere conti nui ty?
YES- Repai r short i n the wi re between the ECM
(A30)
and the ELD. !
NO Substi tute a known,good ECM and recheck
{see
page
1 1-5). l f the symptom/i ndi cati on goes
away. repl ace the ori gi nal ECM.I
2 3 4 6 9 t0
12 t3 t5 1 7 1 8 m 21
25 26 21 28 29 30
ELD {GRN/ RED}
o'
DTC P1298: ELD Ci rcui t Hi gh Vol t age
1. Reset t he ECM
( see page 11- 4)
3, Turn on the headl i ghts.
YES Go to step 4.
t he ELD and at t he ECM. I
4. Turn the i gni ti on swi tch and headl i ghts OFF.
5. Di sconnect the ELD 3P connector.
( l l )
7. Measure vol tage between ELD 3P connector
ELD 3P CONNECTOR
I Gl
(BLK/ YEL)
YES Go to step 8.
NO Repai r open i n the wi re between the No. 6
ACG
( 15
A) f use and t he ELD. I
Tur n t he i gni t i on swi t ch OFF.
10.
1 1 .
9. Connect ELD 3P connector termi nal No. 3 to body
gr ound wi t h a
j umper
wi r e.
'
ELD 3P CONNECTOR
Di sconnect ECM connector A
(32P)
Check for conti nui ty between the ECM connector
termi nal
(A30)
and body ground.
ECM CONNECTOR A
(32PI
l s thete conti nui ty?
YES Go to step 12.
(A30)
and the ELD.a
(cont' d)
11-79
2 3 4 5 6 E 9 t0
12 14 17 r6 19 m 21 23 24
26 27 28 29 30 32
ELD {GRN/ REOI
o
PGM-FI System
DTC Troubleshooting
{cont'd)
12. Check for conti nui ty between ELD 3P connector
t er mi nal No, 2 and body gr ound.
ELD 3P CONNECTOR
YES Go to step 13.
NO Repai r open i n the wi re between ELD
connect or t er mi nal No. 2 and G201. 1
13. Reconnect the ELD 3P connector and ECM
connector A
(32P).
St ar t t he engi ne and l et i t i dl e.
Whi l e measuri ng vol tage between ECM connector
termi nal s A30 and 820, turn the headl i ghts on
(l ow).
ECM CONNECTORS
Does the voltage drcp?
(see page 11' 5). l f the symptom/i ndi cati on goes
NO Repl ace the ELD. t
14.
t c .
A {32P)
11-80
DTC Pl 607: ECM I nt ernal Ci rcui t Mal f unct i on
1. Reset t he ECM
( see page' l ' l - 4; .
2. Tur n t he i gni t i on swi t ch ON { l l ) .
3. Wai t 30 seconds.
YES
-
NO Go to step 4.
(l l ).
6. Wai t 10 seconds.
YES- Substi tute a known-good ECM and recheck
{see
page 11-5). l f the symptom/i ndi cati on goes
Ask the customer i f the battery ever went dead.l
MIL Ci rcui t Troubl eshooti ng
1 . Turn the i gni ti on swi tch ON { l l ), and watch the
Mal f unct i on I ndi cat or Lamp
( Ml L) .
Does the MIL come on and stay on?
YES l f the MIL al ways come on and stays on,
go
to step 21. But i f the MIL someti mes works
normal l y, fi rst check for these
probl ems.l
.
An i ntermi ttent short i n the wi re between the
ECM
( A10)
and t he dat a l i nk connect or { DLC) .
.
ECM { A18) and t he gauge assembl y.
NO l f t heMl Li sal waysof f . got ost ep2. But i f t he
MIL someti mes works normal l y, fi rst check for
these probl ems.l
.
A l oose No. 5 I NSTRUMENT LI GHT BACK UP
LIGHT
(7.5A)
fuse i n the under-dash fuse/rel ay
box,
.
A l oose ACG S
( 15A) f use
i n t he under - hood
fuse/rel ay box.
.
A l oose No. 2 FUEL PUMP SRS
( 15A) f use
i n t he
.
A poor
connecti on at ECM termi nal 418.
.
An i ntermi ttent open i n the GRN/ORN wi re
between the ECM
(A18)
and the
gauge assembl y.
.
ECM
(C19)
and the MAP sensor.
.
ECM
(C28)
and TP sensor, vehi cl e speed sensor
(VSS),
ai r
pump
el ectri c current sensor, or fuel
tank
pressure (FTP)
sensor.
.
PGM- Fl mai n r el ay.
Tur n t he i gni t i on swi t ch OFF and t hen ON
( l l )
agai n.
ls the Iow oil ptessure light on?
YES
-"Go
to step 3.
NO Check for these
probl ems.l
.
A bl own No. 5I NSTRUMENT LI GHT BACK UP
LIGHT
(7.5A)fuse
i n the under-dash fuse/rel ay
box.
.
A short or open i n the wi re between No. 5
I NSTRUI \ 4ENT LI GHT BACK UP LI GHT
( 7. 5A} f use
and t he gauge assembl y.
3. Try to stan the engi ne.
nâ. r ha andi ha <t ^r l ?
YES
-
Go to step 4.
NO Go to step 7.
5. Connect Ecl vl connector termi nal Al S to body
ground wi th a
j umper
wi re.
ECM CONNECTOR A {32P}
l 2 3 4 6 I 10
12 13 t5 1 7 16 m 21 24
E 26 27
+
29 30 32
I MI L I GRN/ ONNI
JUMPER WI RE I
(l l ).
l s the MIL on?
{see
page 11-5). l f the symptom/i ndi cati on
goes
NO Check for an open i n the wi res between the
ECM {A18)
and the gauge assembl y. Al so check for
a bl own MI L bul b. l
(cont' d
)
11- 81
PGM-FI System
MIL Ci rcui t Troubl eshooti ng
(cont' d)
I nspect t he ACG S
( 15A)
f use i n t he mai n under -
hood fuse/rel ay box.
l s the f use OK?
YES Go to step 9.
NO
-
Check for these
probl ems.l
.
A shon i n t he wi r e bet ween t he ACG S
( 15A) f use
and t he PGM- Fl mai n r el ay.
.
A short i n the wi re between the PGM-FI mai n
rel ay and the ECM, i nj ectors, or IAC val ve.
I nspect t he No. 2 FU EL PUMP SRS
( 15A)
f use i n t he
under-dash f use/rel ay box.
l s the f use OK?
YES Go to step
' 10.
NO Check for these probl ems.
I
.
A shor t i n t he wi r e bet ween t he No. 2 FUEL
PUMP SRS
( 15
A) f use and t he PGM- Fl mai n r el ay
or t he SRS uni t .
.
A short i n the wi re between the PGM-Fl mai n
rel ay and the fuel pump.
.
A faul ty PGM-Fl mai n rel ay or faul ty fuel pump.
9.
11-82
10.Di sconnect ECN4 connect or C { 31P) .
ECM connect or t er mi nal s C19 and C28 i ndi vi dual l y.
ECM CONNECTOR C
(31PI
1 1 .
12.
2 5 7 8 I t0
11 12 t 3 1 4 r5 1 7 18 2A 21 22
24 25 26 27 28 n 30
vcc2
(YEL/BLU)
vccl
o(O
(YEL/BEDI
YES Go to step 12.
NO Go t o st ep 13.
Di sconnect the 3P connector from each of these
sensors, one at a ti me, and check for conti nui ty
between body ground and ECM connector termi nal
C19 and C28 i ndi vi dual l y.
.
MAP sensor
.
Vehi cl e speed sensor
(VSS)
.
Fuel tank pressure
{FTP) sensor
.
TP sensor
.
Ai r pump el ect r i cal cur r ent sensor
Is therc continuity?
YES Repai r shon to body ground i n the wi re
bet ween t he ECM
( C19)
and t he MAP sensor , or t he
ECM
(C28)
and the TP sensor, VSS, FTP sensor or
a; r
pump
el ect r i cal cur r ent sensor .
NO Repl ace the sensor that made conti nui ty to
body ground go away when di sconnected.l
Di sconnect the i nj ectors and IAC val ve connectors.
14.
t 5 .
(l l ).
Measure vol tage between body ground and ECIM
connect or t er mi nal s B1 and 89 i ndi vi dual l y.
ECM CONNECTOR B {25P}
Wi r e si de ot t emal e t er mi nal s
YES
-
Go to step 16.
NO Check for these
probl ems:
.
An open i n the wi re(s) between the PGfM-Fl mai n
rel ay and ECM connector termi nal s B1 and 89.
.
Poor connecti ons at the PGM-FI mai n rel ay.
.
A f aul t y PGM- Fl mai n r el ay
( see page 11- 102) .
Repai r or repl ace
parts as needed.
IGPl
(YEL/BLKI
t o .
17.
18.
19.
Reconnect the connectors to the sensors, then
reconnect ECM connector C
(31P).
(l l ).
Measure vol tage between body
ground and ECM
connector termi nal s 82, 810, 820, and B22
i ndi vi dual l y.
ECM CONNECTOR B {25P}
:
LGI
(BRN/ YELI
Wi re si de ot l emal e t ermi nal s
l s there l ess than 1.0 V ?
YES Substi tute a known-good ECfvl and recheck
goes
NO Repai r open i n the wi re(s) that had more than
1.0 V between G' 101 and the ECI\4
(82,
Bl 0, 820,
B22l . a
Connect an OBD l l scan tool /Honda PGM Tester
( see page 1 1- 3) .
(l l ).
Read the OBD l l scan tool /Honda PGM Tester.
Are any DTCs i nd i cated?
YES Go to the DTC Troubl eshooti ng Index.l
NO Go to step 24.
(cont' d)
20.
2 1 .
22.
11- 83
PGM-FI System
MIL Circuit Troubleshooting
(cont'dl
(32P).
26. Check for conti nui ty between body ground and
Data Li nk Connector
(DLC) (16P)
termi nal No. 15.
DATA LINK CONNECTOR
(DLCI
Il6PI
Wi re si de of f emal et ermi nal s
YES Repai r short i n the wi re between the DLC and
t he EcM
( A21) . t
NO Go to step 27.
11-84
27.
28.
(l l ).
Measure vol tage between ECM connector termi nal
410 and body gr ound.
ECM CONNECTOR A I32PI
scs {BRNt
l z 3 6 9 10
12 1 3 t6 1T t6 19 m 21 24
25 26 ? B 29 32
Wi re si de ot t emal e t ermi nal s
YES Go to step 29.
NO
-
Repai r short i n the wi re between the DLC and
t he EcM
( A10) . 1
30. Di sconnect ECM connector A {32P).
31. Reconnect the negati ve cabl e to the battery.
32, Tur n t he i gni t i on swi t ch ON
( l l ) .
l s the MIL on?
YES Repai r short i n the wi re between the gauge
assembl y and t he ECM
( A18) .
f
DLC Circuit Troubleshooting
l f the ECM does not communi cate wi th the OBD l l scan
tool , Honda PGM Tester, or l /M test equi pment, do thi s
troubl eshooti ng procedure.
1. Measure vol tage between DLC termi nal No.8 and
body ground.
DATA LI NK CONNECTOR
(DLC}
I 16P)
Is there battery vol tage?
YES Go to step 2.
NO Repai r open i n the wi re between DLC termi nal
No. 8 and t he ACGS
( 15A) f use
i n t he under - hood
fuse/rel ay box.l
Measure vol tage between DLC termi nal s No.8 and
No. 12.
DATA LINK CONNECTOR
(DLCI
YES Go to step 3.
No. 8 and body gr ound
{ G401) . I
4.
5.
3. Measure vol tage between DLC termi nal s No.8 and
No. 13.
DATA LINK CONNECTOR IDLC)
(16P}
YES Go to step 4.
No. 8 and body gr ound ( G
101) . I
(
l l ).
Measure vol tage between DLC termi nal s No. 13 and
No. 15.
DATA LI NK CONNECTOR {DLCI
l s there 8.5 V ot mote?
YES Go to step 10.
NO Go to step 6.
(cont' d)
6.
11- 85
PGM-FI System
DLC Circuit Troubleshooting
(cont'd)
(32P).
Make sure the
OBD l l scan tooi or Honda PGM Tester i s
di sconnected from the DLC.
Check for conti nui ty between DLC termi nal No. 15
and body ground.
OATA LINK CONNECTOR
(DLC) (16P)
YES Repai r short to ground i n the wi re between
DLC termi nal No. 15 and the ECM
(A21).
After
repai ri ng the wi re, check the DTC wi th the OBD l l
scan tool /Honda PGM Tester and go to the DTC
Troubl eshooti ng i ndex. I
NO Go to step 9.
9. Check for conti nui ty between DLC termi nal No. 15
and ECM t er mi nal 421.
DATA LINK CONNECTOR
{DLC)
(16P)
12 t 3 5 l r /
K-L|NE
I
(cRY)
| /.
ECM CONNECTOR A
(:
,9
l2Pl
K.LINE
{GRY)
2 6
) | s
l 0
12 t 3 1 7 1E 1 9 m 21l ./ 24
26 n a 29 30 32
11- 86
(see page 11-5). l fthe symptom/i ndi cati on goes
No. 15 and the ECM
(A21).
After repai ri ng the wi re,
check the DTC wi th the OBD l l scan tool /Honda
PGM Tester and go to the DTC Troubl eshooti ng
I ndex. l
(32P).
Make sure the
OBD l l scan tool or Honda PGM Tester i s
di sconnected from the DLC.
13, Measure vol tage between DLC termi nal s No. 13 and
No. 15.
DATA LINK CONNECTOR
(DLC)
{16P)
Wi re si de ot temal e termi nal s
l s there 0 V?
NO
-
Repai r short to power i n the wi re between the
DLC t er mi nal No. 15 and t he ECM
( A21) ,
Af t er
repai ri ng the wi re, check the DTC wi th the OBD l l
scan tool /Honda PGM Tester and go to the DTC
Troubl eshooti ng i ndex. !
1 .
2.
lnjector Replacement
Rel i eve the fuel pressure (see page' 11-105).
Remove the fuel rai l cover
(A),
then di sconnect the connectors from the i nj ectors
(B).
12 N. m
(1. 2
kgf , m,
8. 7l bf . f t )
3. Di sconnect t he vacuum hose and f uel r et ur n hosef r omt hef uel pr essur e r egul at or
{ C) . Pl ace a r ag or shop t owel
over the hoses before di sconnecti ng them.
4. Di sconnect t he f uel hose( D) f r omt hef uel r ai l
( E) .
Remove t he vacuum pi pes ( F) .
5. Removet he r et ai ner nut s { G) andbol t s( H) f r omt hef uel r ai l and har ness hol der
( l ) .
6. Di sconnectthe PCV val ve
(J).
7. Di sconnect the fuel rai l .
8. Remove the i nj ectors from the i ntake mani fol d
(K).
(cont' d)
{1. 2 kgf m,
8.7 rbf.ftl
11-87
PGM-FISystem
Injector Replacement
(cont'dl
9. Sl i de new cushi on ri ngs
(A)
onto the i nj ectors
(B).
12 N. m 11. 2
kgf . m, 8. 7 l bt f t )
10. Coat new O-ri ngs
(C)wi th
cl ean engi ne oi l , and
put them on the i ni ectors.
11. Insert the i nj ectors i nto the fuel rai l
(D).
12. Coat newseal r i ngs( E) wi t hcl eanengi neoi l , andpr esst hemi nt ot hei nt akemani f ol d.
' 13.
Instal l the i nj ectors i n the i ntake mani fol d.
14. Instal l and ti ghten the retai ner nuts.
15. Connect t hei uel hoset ot hef uel r ai l wi t h new washer s.
16. Connectthevacuum hosesandfuel retu rn hose to the fuel pressure regul ator.
' 17.
Connect the PCV val ve.
(l l ),
but do not operate the starter. After the fuel pump runs for approxi matel y 2
seconds, the fuel pressure i n the fuel l i ne ri ses. Repeat thi s 2 or 3 ti mes, then check whether there i s any fuel
r eaKage.
11- 88
Primary HO2S Replacement
1. Di sconnect the
pri mary
HO2S 4P connector
(A).
A
2. Remove the
pri mary
HO2S
(B).
44 N. m {4. 5 kgf m. 33l bf f t }
Instal l the pri mary HO2S i n the reverse order of
removal .
3.
,/' .,' ,' .,
. _ . / , ,
'i>1-:l
___1-l
==
Secondary HO2S Replacement
l . Dl sconnect the secondary HO2S 4P connector
(A).
2. Remove the secondary HO2S
(B).
44 N.m
(4.5
kgf.m,33 l bt.ft)
Insl al l the secondary HO2S i n the reverse order
r emoval ,
11- 89
ldle Gontrol System
--
-''"--
-
-
"";t t-'t'tt'
-
11- 90
DTC Troubleshooting
DTC P0505: ldle Control System Malfunction
NOTE: l f DTC Pl 519 i s stored atthe same ti me as DTC
P0505, troubl eshooti ng DTC P1519 fi rst, then recheck
for DTC P0505.
' 1.
St ar t t he engi ne. Hol d t he engi ne at 3, 000 r pm wi t h
no l oad
(i n
2. Check the engi ne speed at i dl e wi th no' l oad
condi ti ons: headl i ghts, bl ower fan, radi ator fan,
and ai r condi ti oner off.
l s the i dl e 800+ 50 rpm?
YES Intermi ttent fai l ure, system i s OK at thi s
t i me. t
NO l f the i dl e speed i s l ess than 750 rpm, go to
step 3; i f i fs 850 rpm or hi gher, go
to step 4.
3. Di sconnectthe 3P connectorfrom the IAC val ve.
Dose the engine speed increase or fluctuate?
YES Check the i dl e speed
(see page 11-100). l f the
i dl e wi l l not adj ust properl y,
cl ean the ports i n the
throttl e body. t
NO Repl ace the IAC val ve.l
5. Remove the i ntake ai r duct from the throftl e body.
6. Start the engi ne and l et i t i dl e.
7. Bl ock both the upper and the l ower ports (A)
i n the
throttl e body wi th your fi ngers.
Does the engine stall?
YES
-
Repl ace the IAC val ve. t
NO Check for vacuum l eaks, test the throttl e body
(see page 11-122l ,, and repai r as necessary.l
11- 91
ldle Control System
DTC Troubleshooting
(cont'd)
DTC Pl 519: I AC Val ve Ci rcui t Mal f unct i on
1. Reset t he ECM
( see page 11- 4; .
( l l ) .
l s DTC P 1519 i ndi cated?
YES Go to step 3,
Check for
poor
the IAC val ve and at the ECM.I
4. Di sconnectthe IAC val ve 3P connector.
(l l i .
6. Measure vol tage between IAC val ve 3P connector
gr ound.
IAC VALVE 3P CONNECTOR
I GP {YEL/ BLK}
YES Go to step 7.
NO Repai r open i n the wi re between the IAC val ve
and t he PGM- Fl mai n r el ay. I
Z 3
7.
11-92
8. Check for conti nui ty between body
ground and IAC
val ve 3P connect or t er mi nal No. 1.
2 3
PGl {BLK)
YES Go to step 9.
and G' 101. 1
Di sconnect ECM connector B
(25P).
ground and
ECM connector termi nal B23.
ECM CONNECTOR B
(25P)
9.
10.
l 2 3 4 5
,/1,/ ,/
I 10
' l t
12
,/ ,/1,/,/
20 21 22 23
,/1,/
tacv
ia'
(BLK/REDI
YES Repai r shon i n the wi re between the IAC
val ve and t he ECM
( 823) . I
NO Go to step 11.
1 1. Connect IAC val ve 3P connector termi nal s No. 1
and No. 3 wi th a i umoer wi re.
tacv
(BLK/RED}
JUMPER WIRE
Check for conti nui ty between ECM connector
termi nal B23 and body ground.
ECM CONNECTOR B {25PI
(BLK/REO}
2 3 4 5
,/ ,/1,/
I t0 1 l 12
,/1,/1,/),/
2A 21 22 23
,/1,/
tAcv
n
Wi re si de of femal e termi nats
YES Go to step 13.
and t he ECM
( 823) . 1
' t4.
15.
13. Remove the
j umper
wi re from the IAC val ve 3P
connector, then reconnect the IAC val ve 3P
connector.
(l l ).
ground
and ECM
connector termi nal 823.
ECM CONNECTOR B I25PI
I 2 3 4 5
,/1,/1,/
9 1 0 11 12
,/l//1,/
20 21 22 23
,/1,/
tAcv
(8LK/REDI
YES-Substi tute a known-good ECM and recheck
{see
page
1 l -5). l f the symptom/i ndi cati on goes
away, repl ace the ori gi nal ECM. t
NO Repl ace the IAC val ve.I
11-93
ldle Control System
A/C Si gnal Ci rcui t Troubl eshooti ng
2. Di sconnect the A/C pressure swi tch connector.
( l l ) .
termi nal s A27 and 820.
ECM CONNECTORS
l s therc about 5v?
YES Go to step 5.
NO Go to step 12.
6. Reconnect the A' l C pressure swi tch connector.
7. Turn the i gni ti on swi tch oN
(l l ).
11- 94
A
(32P)
8. Momentari l y connect ECM connector termi nal s A17
and B20 wi th a i umoerwi re several tames.
ECM CONNECTORS
JUMPER WIRE
ls there a clicking noise lrom the NC comptessor
cl utch?
YES Go to step 9.
NO Go to step 16.
Sta rt the engi ne.
Turn the bl ower swi tch ON.
Turn the Ay' C swi tch oN.
Does the NC operate?
YES- The ai r condi t i oni ng si gnal i s OK. l
NO- Go t o st ep 16.
Di sconnect EcM connector A
(32P)
9.
1 0 .
1 1 ,
12.
13.
15.
14. Check for conti nui ty between body ground and
ECM connector termi nal 427.
ECM CONNECTOR A
(32P)
YES Repai r short i n the wi re between ECM {A27)
and the Ay' C pressure
swi tch.I
( see page' 11- 5) ,
l f vol t age i s now nor mal , r epl ace
the ori gi nal ECM. l f not, check the A,/C system for
other symptoms.l
Momentari l y connect mai n under-hood fuse/rel ay
box l 6P connector termi nal No. 1 1 to body ground
wi t h a
j umper
wi r e sever al t i mes.
NOTE: The mai n under-hood fuse/rel ay box 14P
connector i s on the bottom of the fuse box. When
you
unbol t and i nvert the fuse box, l eave the upper
cover on i t to
prevent
short ci rcui ts.
MAIN UNDER.HOOD FUSE/RELAY BOX
CONNECTOR D
(15P)
1 3 4
,/ 1,/
1 9 l l 12 l 4
ACC
(RED)
JUMPER WI RE
ls therc a clicking noise f rom the A/ C compressor
cl utch?
( A17)
and t he A, / C cl ut ch r el ay. t
NO Check the Ay' C system for other symptoms. I
l 2 3 6 I l 0
12 1 5 1 7 18 19 20 21 24
25 26 21 2A 29 30 32
ACS
(BLU/REDI
f)
' 16.
ECM CONNECTORS
l s there l ess than 1.0 V ?
away, repl ace the ori gi nal ECM. l f not, i nspect the
Ay' C system
(see page
21-8). t
NO Repai r open i n the wi re between the ECI\4
(A
27) and the Ay' C pressure
swi tch, or between the
Ay' C pressure
swi tch and the heater control
panel .l
A
(32P)
Wi re si de of l emal e t ermi nal s
11- 95
ldle Control System
Alternator FR Signal Circuit Troubleshooting
1. Di sconnect the al ternator
4P connector.
(l l )
t er mi nal s B20 and C5.
l s thete about 5 V?
YES Go to step 4.
NO Go to step 14.
5. Reconnect the al ternator 4P connector.
no l oad
(i n
7. l vl easure vol tage betl veen ECM connector
t er mi nal s 820 and C5.
Does the voltage decrease when the headlights
and rear wi ndow defogger are turned on?
YES The al ternator FR si gnal i s OK I
NO- Go t o st ep 8.
9. Di sconnect ECI\4 connector C
(3' l P).
10. Di sconnectthe al ternator 4P connector.
11- 96
1 1 , Connect al ternator 4P connector termi nal No 4 to
body
ground wi th a
j umPer wi re.
ALT 4P CONNECTOR
2
ALTF
3 4
(WHT/RED)
JUMPER WIRE
12.
ground and
ECM connector termi nal C5.
ECM CONNECTOR C
(31P)
ALTF
(WHT/RED}
Is there conti nui tY?
YES Test the al ternator
(see
step
' 1
on
page 4-23).
I
(C5)
and the al ternator.l
13. Turn the i gni tl on swi tch OFF.
(31P)
-r
'.)\
1 2 4 5 1 8 9 10
11 12 1 4 1 1 o 2A 21 22
?4
'25
26 27 28 ZJ 30
and
ECM connector termi nal C5.
ECM CONNECTOR C 13l PI
ALTF
{WHT/RED)
Wi re si de of f emal e t ermi nat s
(C5)
and the al ternator. t
(see page 11-5). l f prescri bed vol tage i s now normal ,
I 2 4 5 7 8 9 10
A
\ 2)
l l 12 15 1 7 18 2A 21 22
24 25 26 27 28 n 30
Starter Switch Signal Circuit
Troubleshooting
NOTE: The cl utch pedal must be pressed.
1. Measure vol tage between Ecl vl connector
termi nal s A24 and 820 wi th the l gni ti on swi tch i n
the ON {l l )
posi ti on
and the engi ne start button
pressed.
YES The starter swi tch si gnal i s OK.l
NO- Go t o st ep 2.
2. Inspect the No. 21 STARTER SIGNAL
(7.5
A) fuse i n
the under-dash fuse/rel ay box.
ls the f use OK ?
YES- Repai r open i n the wi re between the ECM
(A24}
ANd thE NO. 21 STARTER SIGNAL
(7.5
A)
f use. I
NO
-
(A24)
and the No. 21 STARTER StcNAL {7.5 A} fuse
or t he PGM- Fl mai n r el ay. Repl ace t he No. 21
STARTER SI GNAL
( 7. 5
A) f use. l
ECM CONNECTORS
11-97
ldle Gontrol System
1 .
2.
Electrical Power Steering
(EPS)
Signal Circuit Troubleshooting
( l l ) .
ECM CONNECTORS
wi re si de of f emal e t ermi nal s
YES Go to step 6.
NO- Go t o st ep 3.
4. Turn the steeri ng wheel to the ful l l ock
posi ti on.
t er mi nal s 426 and 820.
l s there battery vol tage bri etl y?
YES The EPS si gnal i s OK. l
NO Go t o st ep 10.
7. Di sconnectthe EPS control uni t 14P connector.
A
(32P1
11- 98
9, Measure vol tage between EPS control uni ttermi nal
No. 13 and body
gr ound.
EPS CONTROL UNIT 14P CONNECTOR
EPSLD {BLU/BLK}
YES Substi tute a known-good EPS control uni t
and r echeck. l
(426)
and the EPS control uni t.l
Di sconnect the EPS control uni t 14P connector.
10.
' 1 1 .
14.
t 5 .
t o .
13. l Measure vol tage between EPS control uni t termi nal
No. 13 and body gr ound.
EPS CONTROL UNIT 14P CONNECTOR
EPSLD I BLU/ BLK}
YES-Substi tute a known-good EPS control uni t
and recheck,l
NO Go to step 14.
(32P).
ECM connector termi nal 426.
ECM CONNECTOR A
(32PI
2 3 6 9 10
12 l 3 1 5 /
111
t 8 t 9 2A 2 l
25 26 27 a 29 30 32
EPSLD {BLU/ALK)
ls thete continuity?
YES
-
(426)
and the EPS control uni t.l
( see page
1 1- 5) . l f t he vol t age i s now nor mal ,
Brake Pedal Position Switch Signal
Ci rcui t Troubl eshooti ng
1, Check t he br ake l i ght s.
Are the brake l i ghts on wi thout prcssi ng
the brake
pedal ?
YES-l nspectthe brake
pedal posi ti on
swi tch
adj ustment
(see page
19-6). t
NO Go to step 2.
2. Press the brake pedal ,
Do the brake lights come on?
YES Go to sl ep 3.
NO Go to step 4.
termi nal s A32 and 820 wi th the brake pedal
pressed.
YES-The brake pedal posi ti on
swi tch si gnal i s
oK. t
NO
-
(A32)
and the brake pedal posi ti on
swi tch.l
Inspect the STOP
(' l 0A)
fuse i n the under-hood
fuse/rel ay box.
l s the f use OK?
YES-' Repai r open i n the wi re between the brake
pedal posi ti on
swi tch and the STOP
(10A)
fuse.
Inspect the brake pedal posi ti on
swi tch
(see page 4-
471. a
NO
-
{A32) and the STOP
(10A)
fuse. Repl ace the STOP
( 10A)
f use. r
I
11-99
ldle Control System
ldle Speed Inspection
NOTE:
.
Leave the IAC val ve connected
.
Before checki ng the i dl e speed, check these i tems:
-
The MIL has not been reported on
-
l gni t i on t i mi ng
-
Spark
pl ugs
-
Ai l cl eaner
-
PC\ system
'
On Canadi an model s. pul l the parki ng brake l ever up.
Start the engi ne, then check that the headl i ghts are
off.
1. Di sconnect the EVAP cani ster
purge val ve 2P
connecror.
2. Connect a tachometer.
3, Start the engi ne. Hol d the engi ne at 3,000 rpm wi th
no l oad
(i n
4. Check the i dl e speed wi th no-l oad condi ti ons:
headl i ghts. bl ower fan, radi ator fan. and ai r
condi ti oner off.
l dl e speed shoul d be: 800t50 rpm
5. l dl e the engi ne for 1 mi nute wi th the heater fan
swi tch on Hl and the ai r condi ti oner on' then check
t he i dl e speed.
l dl e speed shoul d be: 900a50 rpm
NOTE:
l f the i dl e speed i s not wi thi n speci fi cati on, see
Symptom Chart.
6. Reconnect the EVAP cani ster
purge val ve 2P
connecror,
11- 100
ECM ldle Learn Procedure
The i dl e l earn
procedure must be done so that the ECM
can l earn the engi ne i dl e characteri sti cs.
Do the i dl e l earn procedure whenever
you do any of
these acti ons:
.
Di sconnect the batterY.
.
Repl ace the ECM or di sconnect i ts connector'
.
Reset the ECM.
NOTE. Eras\ng DTCS N\th Honda PGM Testei does
requi re the i dl e l earn
procedure to be done agai n.
.
Remove t he No. 6 ECU
( ECM) ( 15A) f use
f r om t he
.
Remove the No. 41 BATTERY
(100A)
fuse from the
under-hood fuse/rel ay box.
.
Remove the PGM-FI mai n rel ay.
.
Remove the battery wi re from the under-hood fuse/
rel ay box.
.
Di sconnect any of the connectors from the under-
.
Di sconnect the connector
(C404)
between the
dashboard wi re harness A and dashboard wi re
harness B,
.
Di sconnect the Gl termi nal .
.
Adj ust the i dl e speed.
To compl ete the i dl e l earn
procedure do thi s:
1. Make sure al l el ectri cal i tems
(A/C,
audi o, rear
wi ndow defogger, l i ghts, etc.) are turned off
2. Startthe engi ne. Hol d the engi ne speed at 3,000
r pm wi t h no l oad
( i n
Par k or neut r al ) unt i l t he
radi ator fan comes on, or the engi ne cool ant
t emper at ur e r eaches 176' F
( 80" )
212" F { 100" ) .
3. Let the engi ne i dl e for about 5 mi nutes wi th the
throfti e ful l y cl osed and wi th al l el ectri cal i tems off.
NOTE: l f the radi ator fan comes on duri ng thi s step, the
ti me when i t i s operati ng must not be i ncl uded i n the 5
mi nut es.
Fuel Supply System
FUEL PRESSURE REGULATOR
Repl acement , page 1 1-1 13
FUEL RAI L
FUEL FILL CAP
FUEL TANK
FUEL RETURN LI NE
I nspect i on, page 11 108
FUEL FILTER
FUEL GAUGE SENOI NG UNI T
Test , page 11 119
Repl acement , page
11 114
FUEL TUBE/OUICK.CONNECT FITTINGS
Precaut i ons, page 11-' l 10
Di sconnect i on, oaqe 1 1-1 10
Connect i on. page I 1- 1 1 1
FUEL PUMP
Te s t , p a g e 1 1 l 0 7
PGM.FI MAIN RELAY
Troubl eshoot i ng, page
1 1-102
11- 101
Fuel Supply System
PGM-Fl Main Relay Circuit Troubleshooting
Turn the i gni ti on swi tch OFF, then di sconnect the
PGM-Fl mai n rel ay 7P connector.
ground and
PGM-Fl mai n rel ay 7P connector termi nal No. 3.
PGM.FI MAIN RELAY 7P CONNECTOR
YES Go to step 3.
NO Repai r open i n the wi re between the PGM-FI
mai n r el ay and G101. 1
ground and PGM-Fl
mai n rel ay 7P connector termi nal No. 7.
T
(WHT/GRNI
YES Go to step 5.
NO Go to step 4.
1 .
11-102
4. Check for a bl own ACG S
(15
A) fuse i n the under-
ls the luse blown?
YES Repai r the short i n the wi re between the
PGM- FI mai n r el ay and t he ACG S
( 15, A) f use. l
NO
-
Repai r the open i n the wi re between the PG l M-
Fl mai n r el ay and t he AcG s
( 15A)
f use. l
(l l ),
and measure
vol tage between body
ground and PGM-Fl mai n
rel ay 7P connector termi nal No. 5.
(BLK/YEL}
Wi re si de o{ temal e termi nal s
YES Go to step7.
NO Go to step 6.
Check for a bl own No. 2 FUEI PU MP SRS
(15A)
fuse i n the under-dash fuse/rel ay box.
ls the luse blown?
YES Repai r short i n the wi re between the PGI\4-Fl
mai n r el ay and t he No. 2 FUEL PUMP SRS
( 15A)
f use. l
NO Repai r open i n the wi re between the PGM-Fl
mai n r el ay and t he No. 2 FUEL PUMP SRS
( 15A)
f use. I
6.
Z 3
4 5 6 1
t G1
7. Push the cl utch pedal i n, then turn the i gni ti on
swi tch ON
(l l ),
and
press
the engi ne start bufton.
Measure vol tage between body ground
and PGM-Fl
mai n rel ay 7P connector termi nal No. 2.
YES
-
Go to step 9.
NO Go to step 8.
Check for a bl own No. 21 STARTER SIGNAL
(7.5A)
fuse i n the under-dash fuse/rel ay box.
l s the f use bl own?
YES Repai r short i n the wi re between the PGM-Fl
mai n rel ay and the No. 21 STARTER SIGNAL
(7.5A)
f use. l
NO Repai r open i n the wi re between the PGM-Fl
mai n r el ay and t he No. 21 STARTER SI GNAL
(7.5A).
t
Turn the i gni ti on swi tch OFF, and di sconnect ECM
connector A
(32P).
8.
L
10. Check for conti nui ty between PGM-FI mai nrel ayTP
connector termi nal No. 1 and ECM connector
t er mi nal A15.
PGM.FIMAIN BELAY 7P CONNECTOR
YES Go to step 12.
NO- Repai r open i n the wi re between the PGM-FI
mai n r el ay and t he ECM
( A15) . r
Reconnect ECM connector A
(32P)
and the PGM-Fl
mai n rel ay 7P connector.
(l l ),
and measure
vol tage between ECM connector termi nal s B1 and
B20, and between Bg and 820 i ndi vi dual l y.
1 1 .
12.
ECM CONNECTON B {25P}
I r cPl
0
3 5
1 1 1Z
21 22 23
LGl
(BRN/YEL}
YES
-
Go to step 13.
NO Check for an open i n the wi res between the
PGM- Fl mai n r el ay and t he EcM
( 81,
B9) . l f r he
wi r es ar e OK, r epl ace t he PGM- Fl mai n r el ay. l
(cont' d)
11- 103
Fuel Supply System
PGM-Fl Main Relay Circuit Troubleshooting
(cont'd)
13. Tur n t he i gni t i on swi t ch OFF, t hen ON
( l l )
agai n,
and measure vol tage between ECM connector
t er mi nal s 415 and 82 wi t hi n t he f i r st 2 seconds
after the i gni ti on swi tch i s turned ON
(l l ).
ECM CONNECTORS
l s there 1.0 V or l ess?
YES The PGM-Fl mai n rel ay may be faul ty; go to
st ep 14. 1
(see page
1 1-5). l f the vol tage i s now normal ,
r epl ace t he or i gi nal ECf M. I
14. Remove t he PGM- FI mai n r el ay.
A l 32Pl
11-104
15. Connect battery power to PGM-FI mai nrel ayTP
connector termi nal No. 2 and connect
ground to the
PGM- Fl mai n r el ay 7 P connect or t er mi nal No. 1.
Then check for conti nui ty between PGM-Fl mai n
rel ay 7P connector termi nal s No. 5 and No. 4.
NOTE: Use t he t er mi nal number s shown. l gnor e
the termi nal numbers mol ded i nto the rel ay.
YES Go to step 16.
NO Repl ace the PGM-Fl mai n rel ayand recheck
t he ci r cui t . l
16. Connect battery
power to PGM-Fl mai nrel ayTP
connector termi nal No. 5. and connect ground to
PGM-Fl mai n rel ay 7P connector termi nal No. 3.
Then check for conti nui ty between PGM-FI mai n
r el ay 7P connect or t er mi nal s No. 7 and No. 6.
YES Go to step 17.
NO Repl ace the PGM-Fl mai n rel ay and recheck
t he ci r cui t . I
17. Connect battery powerto PGM-FI mai n rel ay 7P
connector termi nal No. 6, and connect
ground to
PGM- Fl mai n r el ayTPconnect or t er mi nal No. 1.
Then check for conti nui ty between PGM-Fl mai n
r el ay 7P connect or t er mi nal s No. 5 and No. 4.
Is thete conti nui ty?
YES The PGM- Fl mai n r el ay i s OK. l
NO Repl ace t he PGM- Fl mai n r el ay and r echeck
t he ci r cui t . I
Fuel Pressure Relieving
Before di sconnecti ng fuel l i nes or hoses, rel ease
pressure from the system by l ooseni ng the fuel
pul sati on damper on top of the fuel rai l .
preset
buttons.
2, Di sconnectthe negati ve cabl e from the battery.
3. Remove l he f uel f i l l cap.
4. Remove the i ntake mani fol d cover
(A).
Use a wrench on the fuel pul sati on damper
(A)
at
t he f uel r ai l .
Pl ace a rag or shop towel
(B)
over the fuel pul sati on
oamper .
Sl owl y l oosen the fuel
pul sati on
damper one
compl ete turn.
NOTE: Repl ace al l washers whenever the fuel
pul sati on damper i s l oosened or removed.
1.
22 N. m
12.2 kgl n,
16 tbf.ftl
Fuel Pressure Test
.
Fuel pressure gauge 07406-004000A
.
Fuel pressure gauge adapter 07VAJ-0040100
1, Make sure
then wri te down the frequencl es for the radi o' s
preset buttons.
2. Di sconnect the negati ve cabl e from the battery.
3. Remove t he f uel f i l l cap.
4. Remove the i ntake mani fol d cover
(A).
Use a wrench on the fuel pul sati on damper
(A)
at
the fuel rai l .
A
22 N. m
l2.2kgl m.
16 tbf.ft)
' B
1.
Pl ace a rag or shop towel
(B)
over the fuel pul sati on
damper .
Sl owl y l oosen t he f uel pul sat i on damper one
compl ete turn,
(cont' d)
11- 105
Fuel Suppl y System
8.
9.
Fuel Pressure Test
{cont'd)
Remove the fuel pul sati on damper from the fuel
r ai l .
Attach the fuel pressure gauge attachment and fuel
pressure gauge.
07vaJ-0040100
1 1 ,
Di sconnect the vacuum hose
(A)
from the fuel
pressure regul ator
(B)
and
pi nch
i t cl osed wi th a
cl amp
( C) .
Reconnect the negati ve battery cabl e, then start
t he engi ne and l et i t i dl e.
.
l f the engi ne starts, go to step 13
.
l f the engi ne does not stan,
go
to step 12.
Check t o see i f t he t uel pump i s r unni ng: r emove
t he f uel f i l l cap and l i st en t o t he f uel f i l l pon whi l e
an assi stant turns the i gni ti on swi tch ON
(l l ), you
shoul d hear the
pump run for about 2 seconds
when t he i gni t i on t ur ned ON
( l l ) .
.
l f the fuel pump
runs,
go
to step 13.
.
l f the fuel pump does not run, test i t
(see page
11-107J.
Read the pressure gauge (wi th
the fuel pressure
regul ator vacuum hose di sconnected and cl amped).
The pressure
shoul d be 320
-
370 kPa
{3.3
-
3.8 kgfi cm' , 47
-
54
psi ).
.
l f t he pr essur e i sOKandt heengi ne i s r unni ng,
go to step 14. l f the engi ne i s not runni ng, repai r
t he cause, t hen cont i nue t hi s t est .
.
l f t he pr essur e i s out of spec, got o st ep 14.
10.
12.
11- 106
14. Wi t h t he engi ne r unni ng, unpi nch and r econnect
the vacuum hose and read the gauge agai n.
The pressure
shoul d be 260
-
310 kPa
12.7
-
3.2 kgl l cm' ,38
-
46 psi ).
. l f t hef uel
pr essur e i s OK, t he t est i s compl et e.
.
l f t he
pr essur e i sout of spec, got ost ep 15.
' 15.
Di sconnect the vacuum hose from the pressure
regul ator agai n whi l e you watch the
pressure
gauge. The pressure
shoul d ri se when you
di sconnect the hose,
.
l f t he pr essur e di d not r i se, r epl acet hef uel
pressure regul ator
(see page
' 1 ' 1-1
15).
'
l f the
pressure ri ses, but al l your readi ngs were
l ower than speci fi ed, check for a cl ogged fuel
fi l ter and for l eaks i n the fuel l i nes.
.
l f the
pressure ri ses, but al l your readi ngs were
hi gher than speci fi ed, check for a pi nched or
cl ogged fuel return hose or l i ne.
16. Reconnect the vacuum hose, remove the
pressure
gauge, and rei nstal l the fuel pul sati on damper wi th
a new washer. Ti ghten the fuel pul sati on damper to
22 N.m
(2.2k9f.m,
16 l bf.ft).
NOTE: Di sassembl e and cl ean the fuel pressure
gauge attachment thoroughl y after use.
Fuel Pump Test
l f you
suspect a
probl em wi th the fuel pump, check that
the fuel pump
actual l y runs; when i t i s ON, you wi l l hear
some noi se i f you l i sten to the fuel fi l l port wi th the fuel
fi l l cap removed. The fuel
pump
shoul d run for 2
seconds when i gni ti on swi tch i s fi rst turned on. l f the
fuel
pump
does not make noi se. check as fol l ows;
' 1.
Removet he r ear t r ay
( see page 20- 71) .
2, Remove the access
panel from the fl oor.
4. Di sconnect the fuel pump 5P connector.
5. Connect t he PGM- FI mai n r el ayTPconect or
t er mi nal s No. 4 and No. 5 wi t h a
j umper
wi r e.
FUEL PUMP
(YEL/GRNI
2 3
4 5 6 7
t G' l
(BLK/ YELI
JUMPER WIBE
7.
(l l ).
Check that banery vol tage i s avai l abl e between fuel
pump 5P connector termi nal No. 5 and body
ground when the i gni ti on swi tch i s turned ON
(l l ).
.
l f battery vol tage i s avai l abl e, check the fuel
pump ground. l f the
ground i s OK, repl ace the
f uel pump ( see page 11- 114) .
.
l f there i s no vol tage, checkthe wi re harness
(see
page 11- 102) .
FUEL PUMP 5P CONNECTOR
FUEL PUMP
(YEL/GRNI
11-107
Fuel Supply System
Fuel Line Inspection
Check the fuel system l i nes, hoses, and fuel fi l ter for damage, l eaks, or deteri orati on, and repl ace parts
as needed.
22 N.m
(2.2
kgt.m, 16l bf.ft)
37 N.m
(3.8
kgt m, 27 lbf.ft)
11- 108
Check al l hose cl amps and reti ghten i f necessary.
: Do not di sconnect the hose from the l i ne at these i oi nts.
; *
10- 15 mm
{0. 39-0. 59 i n. )
Cl amp i n t he mi ddl e.
Cl amo i n t he mi ddl e.
11- 109
Fuel Supply System
Fuel Line/Ouick-Connect Fittings
Precautions
The fuel tube/qul ck-connect fi tti ngs assembl y connects
the i n-tank fuel DumD to the fuel feed l i ne and the fuel
r et ur n l i ne. When r emovi ng or i nst al l i ng t he f uel pump
and fuel tank, i t i s necessary to di sconnect or connect
the qui ck-connect f i tti ngs.
Pay attenti on to the fol l owi ng:
.
Thefuel tubes{A) and qui ck-connect fi tti ngs
(B)
are
not heat-resi stanU be careful not to damage them
duri ng wel di ng or other heat-generati ng procedures.
.
The fuel tubes and qui ck-connect fi tti ngs are not
aci d-proof; do not touch i t wi th a shop towel whi ch
was used for wi pi ng baftery el ectrol yte. Repl ace them
i f they came i nto contact wi th el ectrol yte or
somet hi ng si mi l ar .
.
When connecti ng or di sconnecti ng the fuel tubes and
qui ck-connect
fi tti ngs, be careful not to bend or twi st
them excessi vel y. Repl ace them them damaged.
A di sconnected qui ck-connect fi tti ngs can be
reconnected, but the retai ner on the mati ng l i ne cannot
be reused once i t has been removed from the l i ne.
Repl ace the retai ner when
.
repl aci ng the fuel pump.
.
r epl aci ng t he f uel f i l t er .
.
r epl aci ng t he f uel f eed l i ne.
.
repl aci ng the fuel return l i ne.
.
i t has been removed from the l i ne.
.
i t i s damaged.
1 1 - 1 1 0
Removal
1 . Rel i eve f uel pr essur e ( see page
11- 105) .
Check the fuel qui ck-connect fi tti ngs for di rt, and
cl ean i f necessary.
Hol d t he connect or { A) wi t h one hand, and squeeze
the retai ner tabs {B) wi th the other hand to rel ease
t hem f r om t he l ocki ng pawl s ( C) .
Pul l t he connect or
off.
NOTE:
.
Be careful not to damage the l i ne
(D)
or other
parts. Do not use tool s.
.
l f the connector does not move, keep the retai ner
tabs pressed down, and al ternatel y pul l and push
the connector unti l i t comes off easi l y.
.
Do not remove the retai ner from the l i ne; once
removed, the retai ner must be repl aced wi th a
new one.
4. Checkthe contact area
(A)
o{ the l i ne
(Bl
for di rt and
oamage.
.
l f the surface i s di rty, cl ean i t..
.
l f the surface i s rusty ordamaged, repl acethe
fuel pump, fuel fi l ter, fuel Jeed l i ne or fuel return
l t ne.
To prevent damage and keep forei gn matter out,
cover the di sconnected connector and l i ne end wi th
pl asti c bags
(A).
NOTE:
.
The retai ner cannot be reused once i t has been
removed from the
pi pe.
Repl ace the retai ner when
-
repl aci ng the i uel pump.
-
repl aci ng the fuel fi l ter.
-
-
repl aci ng the fuel return l i ne.
-
i t has been removed from the l i ne.
-
i t i s damaged.
5.
lnstallation
1. Check the contact area
(A)
of the l i ne
(B)
for di rt and
damage, and cl ean i f necessary.
2. I nser t a newr et ai ner
( A)
i nt ot heconnect or
( B)
i f t he
retai ner i s damaged, or after
.
r epl aci ng t he f uel pump.
.
repl aci ng the fuel fi l ter.
.
.
repl aci ng the fuel return l i ne,
.
removi ng the retai ner from the l i ne.
(cont' d)
11-111
Fuel Supply System
Fuel Line/Ouick-Connect Fittings Installation
(cont'dl
3. Before connecti ng a new fuel tube/qui ck-connect
fi tti ng assembl y {A), remove the ol d retai ner from
t he mat i ng l i ne.
4. Al i gn the qui ck
connect fi tti ngs wi th the l i ne
(A),
and al i gn t he r et ai ner { B) l ocki ng pawl s wi t h t he
connector
(C) grooves. Then press
the
qui ck-
connect fi tti ngs onto the l i ne unti l both retai ner
pawl s l ock wi th a cl i cki ng sound
NOTE: l f i t i s hard to connect. put a smal l amount of
new engi ne oi l on t he l i ne end.
Connection with new retainer:
11-112
Reconnection to existing retainer:
5. Make sure the connecti on i s secure and that the
pawl s are fi rml y l ocked i nto pl ace;
check vi sual l y
and by
pul l i ng
the connector.
6. Reconnect the negati ve cabl e to the battery, and
t ur n t he i gni t i on swi t ch ON { l l ) . The f uel pump wi l l
run for about 2 seconds, and fuel pressure
wi l l ri se.
Repeat 2 or 3 ti mes, and check that there i s no
l eakage i n the fuel suppl y system.
Fuel Pressure Regulator
Replacement
1. Pl ace a shop towel under the fuel pressure
regul ator, then rel i eve fuel pressure (see page 11-
105) .
2. Di sconnectthe vacuum hose and fuel return hose.
3. Remove the two 6 mm retai ner bol ts
(A)
and the
fuel pressure regul ator
(B).
7.
4. Appl y cl ean engi ne oi l to a new o-ri ng
(C),
and
careful l y i nstal l l t i nto i ts proper posi ti on.
Instal l the fuel pressure regul ator and the 6 mm
retai ner bol ts.
Reconnect the vacuum hose and fuel return hose.
(l l ),
but do not operate
the starter. After the fuel pump runs for about 2
seconds, the fuel pressure i n the fuel l i ne ri ses.
Repeat thi s two or three ti mes, then check whether
t her e i s any f uel l eakage.
Fuel Filter Replacement
The fuel fi l ter shoul d be reDl aced whenever the fuel
pressure drops bel owthe speci fi ed val ue
(320
370 kPa,
3. 3 3. 8kgf l cm' , 47 54psi wi t ht hef uel
pr essur e
regul ator vacuum hose di sconnected and
pi nched)
after
maki ng sure that the fuel pump and the fuel
pressure
regul ator are oK.
1. Remove t he f uel t ank uni t
( see page
11- 114) .
2. Remove the fuel fi l ter
(A).
D
Instal l the
pan i n the reverse order of removal wi th
a new base
gasket,
then check these i tems:
.
When connecti ng the wi re harness, make sure
the connecti on i s secure and the termi nal 1B)
i s
fi rml v l ocked i nto the Dl ace.
.
Check that the tab of the cl amp
(C)
does not
i nterfere wi th the wi re harness,
.
Do not push the l ower
part
ofthe sucti on fi l ter
(D).
.
When i nstal l i ng the fuel gauge sendi ng uni t
(E),
make sure the connecti on i s secure and the
connector i s fi rml y l ocked i nto
pl ace. Be careful
not to bend or twi st i t excessi vel y.
1 1 - 1 1 3
Fuel Supply System
Fuel Pump/Fuel Gauge Sendi ng Uni t Repl acement
1. Remove the reartray
(see page 20-71).
2. Remove the access panel fromthefl oor.
4. Di sconnect the fuel pump 5P connector.
5. Remove the fuel fi l l cap.
6. Rel i evet hef uel
pr essur e ( see
st epT on
page 11-
103) .
7. Di sconnect the qui ck-connect fi tti ngs from the fuel
pump.
8. Remove t he bol t s
( A)
andt hef uel t ankuni t { B) .
9^-
e E
11-114
9. Remove the bracket
(A),
the fuel fi l ter
(B),
the fuel
gauge sendi ng uni t
( C) ,
t he hose
( D) ,
and t he wi r e
har ness
( E) .
tl
When connecti ng the fuel
pump, make sure the
connecti ons are secure and the sucti on fi l ter
(H)
i s
fi rml y connected the fuel pump (l ).
l nstal l the uni t i n the reverse order of removal wi th
a new base gasket, then check these i tems:
.
When connecti ng the wi re harness, make sure
the connecti on i s secure and the termi nal
(F)
i s
fi rml y l ocked i nto the pl ace.
.
Check t hat t he t ab of t he cl amp
( G)
doesnot
i nterfere wi th the wi re harness.
.
Do not
push
the l ower part of the sucti on fi l ter.
.
When i nst al l i ng t he f uel gauge sendi ng uni t ,
make sure the connecti on i s secure and the
connector i s fi rml y l ocked i nto pl ace. Be careful
not to bend or twi st i t excessi vel y.
.
Check for fuel l eaks.
10.
1 1 .
Fuel Tank Replacement
Removal
2. Rel i ve t he f uel pr essur e{ see page 11- 105) .
3. Dr ai n t he f uel t ank: Remove t he f uel t ank uni t
( see
page 1 1- 114) . Usi ng a hand pump, hose, and a
contai ner sui tabl e for gasol i ne, draw the fuel from
the fuel tank.
Remove the brake fl ui d from the master cyl i nder
reservoi r wi th a syrl nge.
NOTE: Do not spi l l brake fl ui d on the vehi cl e; i t may
damage the
pai nt; i f brake fl ui d does contact the
pai nt, wash i t off i mmedi atel y wi th water.
Removet he r ear t r ay
( see page 20- 71) .
Remove the access
panel (A)
from the fl oor, and
di sconnect the fuel tank 5P connector
(B).
5.
6.
7, Di sconnect both ABS rear wheel sensors2P
connectors
(A),
and
push the connectors out
(B).
Remove the fuel
pi pe
cover
(A),
and di sconnect the
fuel fi l l neck tube
(B),
the fuel tank vapor
reci rcul ati on tube
(C)
and the fuel tank vapor si gnal
t ube
( D) f r om
t he f uel f i l l
pi pes ( E) ,
9. Loosen the rear wheel nuts sl i ghtl y, then rai se the
vehi cl e and make sure i t i s securel y supported.
10. Remove t he r ear wheel s.
(cont' d)
1 1 - 1 1 5
Fuel Suppl y System
(cont'd)
11. Remove the bol ts from both ABS rear wheel sensor
harness brackets
(A).
6 x 1 . 0 mm
9.8 N.m {1.0 kgf.m,7.2 l bf.ft)
NoTE: Lef t si de i s shown
12. Remove bot h cal i per shi el ds
(A).
6 x 1 . 0 mm
NOTE: Lef t si de i s shown.
9. 8 N
D
(1. 0
kgf m, 7. 2 l bt . f t l
1 1 - 1 1 6
13. Di sconnect both
parki ng brake cabl es
(A),
and
move them out of the way
8 x 1. 25 mm
22 N.m
(2.2
kgf.m, 16 lbt.ftl
NOTE: Lef t si de i s shown.
14. Di sconnect t he brake hoses f rom bot h rear brake
l i nes usi ng a 10 mm f l ar e- nut wr ench.
,
li'r
t l
NOTEr Lef t si de i s shown.
15. Remove the fl ange bol t
(A)from
both rear dampers
( B) .
NOTE: Left si de i s shown.
Remove t he cani st er cover { A) , r ear suspensi on
sti ffener
(B),
and the
propel l er
shaft
(C) (see page
16-17 ).
t o .
10 x 1. 25 mm
45 N. m
{4. 6 kgf . m,
33 tbf.ft)
6 x 1 . 0 mm
9. 8 N. m
n. 0 kst m. 7. 2 l bt . f t l
17. Remove the muffl er {A).
-
'')/,.
6i . - / . :
'|d:<;.:'.f:
: f : g
- J
18.
33 N.m {3.4 kgf.m,25 l bt.ftl
Di sconnect the qui ck-connect fi tti ngs
(A) (seepage
11- 110) .
(cont' d)
11-117
10 x 1, 25 mm
Fuel Supply System
(cont'd)
19. Di sconnect the fuel tank vapor vent tube
(A).
then
remove the bol t
(B)
and the EVAP cani ster
(C).
Di sconnect the hose
(A)
and fuel vent tube {B},
then
remove the fuel tank vapor vent tube from the tube
hol der
(C).
Remove the bol ts
(D)
and the fuel vent
assembl v
( E) .
A B
12 N.m,
l2.2 kgi n,
16 tbt.ftl
20.
1 1 - 1 1 8
21. Pl ace a
j ack
or other support under the rear
suspensi on subframe
(A).
Remove the mounti ng
bol ts
(B)
and the rear suspensi on subframe
(A).
12 x 1, 5 mm
59 N.m,
(6.0
kgf m,
iA
lbf.ftl
Pl ace the
j ack
or support under the fuel tank
(A)
and
remove the mounti ng bol ts
(B)
and the fuel tank.
8 x 1. 25 mm
45 N.m, {4.6 kgf.m, 33 lbl.ft}
22.
B
14 x 1. 5 mm
103 N. m,
110. 5 kgf . m, 7. 6l bf . f t l
Installation
1. I nst al l t he f uel t ank i n t he r ever se or der of r emoval .
2. After i nstal l i ng, bl eed the brake system
(see page
19- 8) , and adj ust t he wheel al i gnment
( see page 18'
5) .
3. Check for fuel l eaks.
Fuel Gauge Sending Unit Test
NOTE: For the fuel gauge system ci rcui t di agram, refer
t o t he Gauges Ci r cui t Di agr am
( see page 22- 44) .
1. ChecK t he No. 5 I NSTRUMENT LI GHT BACK UP
LIGHT
(7.5
A) fuse i n the under' dash fuse/rel ay box.
.
l f t hef use i s OK, checkf or an open i nt heYEL
wi re between the
gauge
assembl y and the No. 5
I NSTRUMENT LI GHT BACK UP LI GHT
( 7, 5
A)
fuse.
.
l f t hef use i s bl own, r epl ace i t , andcheckf or an
open i n the YEL wi re between the
gauge
assembl V and t he No. 5 I NSTRUMENT LI GHT
BACK UP LI GHT { 7. 5 A) f use.
Remove the rear tray
(see page 20-71).
Remove the access panel from the fl oor.
Di sconnect the fuel pump
5P connector.
Measure vol tage between fuel pump
5P connector
termi nal s No. 1 and No.2 wi th the i gni ti on swi tch
ON
(l l ).
There shoul d be about 5 to 8 V.
.
l f t hevol t age i s as speci f i ed, got ost ep6.
.
l f the vol tage i s not as speci fi ed, check for:
-
an open or short i n the YEL/BLK or BLK wi re.
-
poor gr ound ( G601) .
-
a faul ty mai n
pri nted
ci rcui t board i n the gauge
assemory.
FUEL PUMP 5P CONNECTON
(YEL/8LKI
4.
(cont' d)
1 1 - 1 1 9
Fuel Suppl y System
Fuel Gauge Sending Unit Test
(cont'd)
7. Remove the bol ts and the fuel tank uni t
(see page
11- 114) .
8. Measure the resi stance between the No. 1 and
No. 2 termi nal s wi th the fl oat at E
(EMPTY).
LOW
{LOW FUEL INDICATOR LIGHT IS ON), 1/2
(HALF
FULL) and F
{FUtL)
posi ti ons.
l f you do not get the fol l owi ng readi ngs, repl ace the
fuel gauge sendi ng uni t.
Fl oat Posi ti on Resi stance
(
Q ) Hei ght
( mm)
( i n.
)
82. 9 a 1, 9
(3.26
+ 0.0748)
1t2 52 58 154.2 +
't.2
(6.07
a 0.0472)
LOW 114.4 120.4 215. 5
(8.48)
E 130
' l 32
222. 4 X 1. 9
(8.77
+ 0.0748)
To prevent the fuel pump from runni ng. remove the
No. 2 FU EL PUMP SRS
( 15
A) f use f r om t he under -
dash fuse/rel ay box.
Connect the fuel pump
5P connector.
(l l )
wi th the fl oat at F
(FULL) posi ti on.
. l f t hef uel
gauge i ndi cat es
" F" ,
t he syst em i s OK.
.
l f the fuel gauge
does not i ndi cate
"F",
repl ace
the
gauge
assembl y.
10.
1 1 .
11-120
\
1 .
Low Fuel Indicator Test
Do the fuel gauge sendl ng uni t test
(see page 1 1-
1 1 9 ) .
.
l f the system i s OK, go to step 2.
.
l f the system has any mal functi on, repai r i t.
Turn the i gni ti on swi tch oN
(l l )
wi th the fl oat at
E
(EMPTY) posi ti on.
.
l { the l ow fuel i ndi cator i s on, go to step 3.
.
l f t he l ow f uel i ndi cat or i s not on. r ef er t ot he l ow
fuel i ndi cator Ci rcui t Di agram
(see page 22-47)
and check the ci rcui t.
3. Li ft the fl oat above LOW posi ti on.
'
l f the Iow fuel i ndi cator goes off, the system i s OK.
.
l f the l ow fuel i ndi cator i s sti l l on, refer to the l ow
fuel i ndi cator Ci rcui t Di agram
(see page 22-47)
and check the ci rcui t.
Intake Air System
AI R CLEANER
Repl acement , page 1 1-123
,,.,,,r,,?i-.
e
ii'
THROTTLE CABLE
Adi ustment, page I 1-' 124
Removal / l nst al l at i on, page 1 1- 125
THROTTLE BOOY
Test , page 11-122
Removal / l nst al l at ; on, paqe
1 1-126
Di sassembl y/ Reasseni bl t , paqe
11-127
11-121
hake Air System
Throttle Body Test
NOTE; Do not adj ust the throftl e stop screw. l t i s preset
al the factory.
1. Wl th the engi ne off, check the throttl e cabl e
operati on.The cabl e shoul d operate wi thout
bi ndi ng or st i cki ng.
.
l f the cabl e operates OK, goto
step 2.
.
l f the cabl e bi nds or sti cks, check i t and i ts routi ng.
l f i t' s faul ty, reroute i t or repl ace i t and adj ust i t
( see page 11- ' 124) , t hen go t o st ep 2.
2. Operate the throttl e l ever by hand to see i f the
throttl e val ve and/or shaft are too l oose or too ti ght,
.
l f there i s excessi ve pl ay i n thethrottl e val ve
shaft, or any bi ndi ng i n the throttl e val ve at the
ful l y cl osed posi ti on.
repl ace the throttl e body.
.
l f the throttl e val ve and shaft are OK, go to step 3.
3. Check for cl earance
(A)
between the throttl e stop
screw
(B)
and the throttl e l ever
(C)
ar rhe ful l y
cl osed posi ti on.
l f there i s any cl earance, repl ace
the throttl e body
(see page
' 1 ' l -126).
Do not ad.i ust
the throttl e stop screw.
11-122
AIR CLEANER ELEMENT
Air Cleaner Element Replacement
CLEANER HOUSI NG COVER
\
\ =
AIR CLEANER HOUSING
/ , 1
,// i ,.
///
2,1.:^
I l'..
' )
, - l ' \
\ .
\
t....
s7
.-
L|u",,..'/
:-+:'-.'::9
11-123
Intake Air System
Throttle Cable Adjustment
1 .
2.
3.
Check cabl e free
pl ay at the throttl e l i nkage. Cabl e
f r ee
pl ay ( A) shoul d
be 4 6 mm
( 3/ 16-
l i a i n. ) .
l f f r ee
pl ay ( A)
i snot wi t hi nspec( 4- 6mm, 3/ 16 1/
4 i n.) l oosen the l ocknut
(B),
turn the adj usti ng nut
(C)
unti l the free
pl ay (A)
i s as speci fi ed, then
reti ghten the l ocknut
(B).
Wi th the cabl e
properl y adj usted, check the throttl e
val ve to be sure i t opens ful l y when
you push the
accel erator
pedal to the fl oor. Al so check the
throftl e val ve to be sure i t returns to the i dl e
posi ti on
whenever
you
rel ease the accel erator
oeoar .
11-124
Throttle Cable Removal/lnstallation
1. Ful l y open the throttl e val ve, then remove the
throttl e cabl e
{A)from the throttl e l i nk
(B).
Remove t he cabl e housi ng
( C) f r om
t he cabl e
bracket
(D).
Remove the nuts
(A),
then remove the accel erator
pedal (B)
al ong wi th the throttl e cabl e
(C)
and the
actuator cabl e
(D).
@
t \
A
8 x 1, 25 mm
13 N. m
(1. 3
kgf m,
9,4 tbf.ft)
Pul l the throttl e cabl e
(C)
and the actuator cabl e
(D)
out toward the passenger
compartment.
@
a
5. Remove the throttl e cabl e
(A)
and the actuator
cabl e
(B)
from the accel erator pedal
bracket
(C).
6. Instal l i n the reverse order of removal .
7. After i nstal l i ng, start the engi ne. Hol d the engi ne at
3,000 rpm wi th no l oad
(i n
neutral ) unti l the radi ator
fan comes on, then l et i t i dl e.
8. Hol d t he cabl e sheat h, r emovi ng al l sl ackf r omt he
cabl e.
L Turn the adj usti ng nut
(A)
unti l i t i s 3 mm
(' l l 8
i n.)
away from the cabl e bracket
(B).
9.8 N m,
{1 0 kgf' m,
7.2 tbt.ftl
Ti ghten the l ocknut
(C).
The cabl e free pl ay
shoul d
now be 4 6 mm 13116 1/4 i n).l f free pl ay
i s not
wi thi n specs, l oosen the l ocknut, turn the adj usti ng
nut unti l the free pl ay
i s as speci fi ed, then reti ghten
the l ocknut.
Wi th the cabl e properl y adj usted, check the throttl e
val ve to be sure i t opens ful l y when you push
the
accel erator pedal
to the fl oor. Al so check the
throttl e val ve to be sure i t returns to the i dl e
posi ti on
whenever you rel ease the accel erator
pedal .
10.
3 mm { 1/ 8 i n. l
' l ' 1.
11-125
Intake Air System
Throttle Body Removal/lnstallation
NOTE;
.
Do not adiust the throttle stop screw.
.
After reassem bl y, adj u st the cru i se co ntrol actuator ca bl e
(see page 4-46), a nd the th rottl e cabl e
(see page 1 1- 124).
.
The TP sensor i s not removabl e.
THROTTLE CABLE
22 N. m
(2. 2
kgf . m. 16l bf . f t )
TP SENSOR
MAP SENSOR
11-126
Throttle Body Disassembly/Reassembly
{
o
2 1 N m
10. 21 kgf m. 1. 5 l bt . f t )
MAP SENSOR
TP SENSOR
11-127
DTC Troubleshooting
DTC P0420: Catalytic System Efficiency
Bel ow Threshol d
NOTE: l f some of the DTCS l i sted bel ow are stored at
the same ti me as DTC P0420, troubl eshoot those DTCS
fi rst, then recheck for DTC P0420.
P0137, P0138: Secondary Heated oxygen Sensor
(secondary
H02S)
(Sensor
2)
P0141: Secondary H02S
(Sensor
2) heater
1. Reset t he ECM
{ see
page I 1- 4) , t hencont i nuet o
steps 2 through 5 to reset the readi ness code.
2. Start the engi ne. Hol d the engi ne at 3.000 rpm wi th
no l oad
(i n
Dri ve on a hi ghway for about 10 mi nutes wi thout
stoppi ng. Your speed can vary.
Wi th the transmi ssi on i n 4th gear, dri ve at a steady
speed bet ween 50 62mph( 80 100km/ h) f or 30
seconds.
Repeat step 4 three ti mes. Between each repeti ti on,
cl ose the throttl e compl etel y for
' 1
2 seconds. l f
the engi ne i s stopped duri ng thi s part of the
procedure, go
to step 3 and do the procedure agai n.
Check for a Temporary DTC wi th the scan tool .
Does the scan tool indicate Tempotary DTC
P0420?
YES
-
Check the three way catal yti c converter
(TWC).
l f necessary, repl ace the TWC.I
NO
-
Check for readi ness code compl eti on. l f the
readi ness i s compl ete, i t was a i ntermi ttent fai l ure,
system i s OK at thi s ti me. l f the readi ness i s
i ncompl el e, repeal steps 2 through 5. !
11-128
\
PCV System
PCV Valve Inspection and Test
1 . Check the PCV val ve
(A),
hoses
(B),
and
connecti ons for l eaks or restri cti ons.
At i dl e, make sure there i s a cl i cki ng sound from the
PCV val ve when the hose between the PCV val ve
and i ntake mani fol d i s l i ghtl y pi nched
{A)wi th
your
f i nger s or pl i er s.
l f there i s no cl i cki ng sound, check the PCV val ve
grommet for cracks or damage, l f the grommet i s
OK, repl ace the PCV val ve and recheck.
11-129
EVAP System
FUEL TANK PRESSURE
(FTP}
SENSOR
EVAPORATIVE EMISSION {EVAP)
TWO WAY VALVE
|
. . . . -
-
. . :
' . . - : . . .
EVAPORATIVE EMISSION {EVAP)
CANISTER VENT SHUT VALVE
FUEL TANK VAPOR
CONTROL VALVE
Test , page l 1' 146
Repl acement ,
page 11 147
EVAPORATIVE EMISSION
(EVAP)
BYPASS SOLENOID VALVE
: - -
'
-
-.,,,,
t
"
(
t'",.
2
:';':"
,.-;;../tttt a
-
j
EVAPORATIVE EMISSION {EVAPI
CANISTER PURGE VALVE
Test , page 11- 135
11- 130
DTC Troubleshooting
DTC P0451: FTP Sensor Ra nge/Perfo rmance
Probl em
Vacuum Pump/Gauge,0 30 i n. Hg A973X-041-XXXXX
2. Turn the i gni ti on swi tch ON(l l ).
3. Moni tor FTP sensor vol tage wi th the Honda PG l vl
Tester, or measure vol tage between ECM
connect or t er mi nal s A29 and C18.
SG2 {GRN/YELI
l s there about 2.5 V?
YES- Go to step 4.
NO Repl ace the FTP sensor.I
PTANK {LT GRN)
5. Di sconnect the hose between the EVAP two way
val ve and the FTP sensor at the EVAP two way
val ve end.
Ait973X-041-
6. Connect a vacuum pump
to the open end of the
hose.
( l l ) .
8. Moni tor FTP sensor vol tage wi th the Honda PGM
Tester, or measure vol tage between ECM
connector term i na l s A29 and C18, and very sl owl y
to squeeze the vacuum pump.
L The vol tage shoul d smoothl y drop from about 2.5 V
down to about 1.5 V. Stop appl yi ng vacuum when
the vol tage drops to about 1.5 V or damage to the
FTP sensor may occur.
Does the voltage drcp to about 1.5 V and hold?
YES l ntermi ttent fai l ure, system i s OK at thi s ti me.
Check for poor
connecti ons at the FTP sensor and
t he EcM. I
NO
-
Repl ace the FTP sensor.l
11- 131
EVAP System
DTC Troubleshooting
(cont'dl
DTC P0452: FTP Sensor Circuit Low Voltage
1. Check the vacuum l i nes of the FTP sensor for
mi sr out i ng, l eakage, br eakage, and cl oggi ng.
Arc the vacuum l i nes OK?
YES Go to step 2.
NO Repai r or r epl ace vacuum l i nes as
necessary.I
2. Reset the ECM
(see page 11-4)
3. Remove t he f uel f i l l caP.
( l l ) .
5. Moni tor FTP sensor vol tage wi th the Honda PGM
Tester. or measure vol tage between body
ground
and ECl vl connector termi nal A29.
ECM CONNECTOR A {32P)
2 3 6 9 t 0
1 5 1T 1a 1 9 m 21
6 26 n a 29 30 32
PTANK
(LT
GRN)
Check for
poor connecti ons or Ioose termi nal s at
t he FTP sensor and at t he ECM. I
NO Go to step 6.
11-132
7. Rei nst al l t he f uel f i l l caP
8. Di sconnect the FTP sensor 3P connector'
( l l )
10. Measure vol tage between FTP sensor 3P connector
t er mi nal s No. 1 and No. 2
FTP SENSOR 3P CONNECTOR
VCC2 {YEL/BLU)
Is there about 5 V?
YES Go to step 1
' 1.
NO
-
Repai r open i n the wi re between the FTP
sensor and the ECM
(C28).4
1 t
t J .
1 4 ,
I 1. Measure vol tage between FTP sensor 3P connector
PTANK ILT GRN)
SG2
I GRN)
Wi re si de of {emal e t ermi nal s
Is there about 5 V?
YES Repl ace the FTP sensor.I
NO Go to step 12.
(32P)
Check for conti nui ty between FTP sensor 3P
PTANK
I LTGRN'
Isthere conti nui ty?
YES Repai r short i n the wi re between the FTP
sensor and the ECM
(A29).
t
(see page I 1-5). l f the FTP sensor readi ng are now
nor mal , r epl ace t he or i gi nal ECM. I
DTC P0453: FTP Sensor Circuit High Voltage
1. Check the vacuum l i nes of the FTP sensor l or
mi srouti ng, l eakage, breakage, and cl oggi ng.
Are the vacuum l i nes OK?
YES Go to step 2.
necessar y. I
2. Reset t he ECM
( see
page 11- 4) .
( l l ) .
5. l vl oni tor FTP sensor vol tage wi th the Honda PGM
Tester. or measure vol tage between body ground
and ECM connector termi nal A29.
ECM CONNECTOR A {32P)
2 3 6 / I t0
12 13 t 5 17 1 8
1 1 9
m 21 24
25 26 n 6 l 2 s 30 32
PTANK ILT GRN)
Wi re si de of femal e termi nats
YES Intermi ttent fai l ure. system i s OK at thi s ti me.
Check for poor
t he FTP sensor and at t he ECM. I
NO Go to step 6.
(cont' d)
11- 133
EVAP System
DTC Troubleshooting
(cont'd)
6.
7.
8.
10.
Rei nstal l the fuel fi l l cap.
Di sconnect the FTP sensor 3P connector.
(l l ).
Measure vol tage between FTP sensor 3P connector
Wi re si de of {emal e termi nal s
YES Go to step
' l
1.
NO Repai r open i n the wi re between the FTP
sensor and t he ECM
( C18) . I
11- 134
11. Measure vol tage between FTP sensor 3P connector
PTANK
(LT
GRN)
SG2
(GRN}
YES Repl ace the FTP sensor.l
NO Go to step 12.
termi nal s A29 and C18.
SG2
(GRN/ YEL)
YES
-
Repai r open i n the wi re between the FTP
sensor and t he ECM
( A29) , I
(see page 1 1-5). l f the FTP sensor readi ngs are now
nor mal , r epl ace t he or i gi nal ECM. I
ECM CONNECTORS
PTANK
(LT
GRN)
DTC Pl456: EVAP Control System
(Fuel
Tank Svst em)
Leakage
The fuel system i s desi gned to al l ow speci fi ed
maxi mum vacuum and
pressure
condi ti ons. Do not
devi ate from the vacuum and
pressure
tests as
i ndi cated i n these procedures. Excessi ve pressure/
vacuum woul d damage the EVAP components or cause
eventual fuel tank fai l ure.
Vacuum Pump/ Gauge, 0- 30 i n. Hg A973X- 041- XXXXX
Thi s i s a two-tri p code; once cl eared. i t cannot be
reproduced i n one tri p. Al so, certai n speci fi c dri vi ng
and ambi ent condi ti ons must occur before the ECM wi l l
compl ate the system checks. addi ti onal test dri ves may
sti l l not meet the speci fi c condi ti ons needed to
reproduce the code. l f necessary. use the test dri ve
procedures for setti ng the readi ness code
(see page
l 1-
38) .
Fol l ow these troubl eshooti ng procedures careful l y to
ensure the i ntegri ty of the system and to confi rm the
cause of the probl em
or code.
NOTE: Fresh fuel has a hi gher vol ati l i ty that wi l l create
greater pressure/vacuum. The opti mum condi ti on for
testi ng i s fresh fuel , and must be l ess than a ful l tank of
gas. l f possi bl e,
to assi st i n l eak detecti on, add 1 gal l on
of fresh fuel to the tank {as
l ong as i t wi l l not fi l l the
tank),
j ust
before starti ng these procedures.
Fuel Fi l l Cap Check
1. Check t he f uel f i l l cap
( t he
cap must say
" l f
not
ti ghtened 3 cl i cks check engi ne l i ght may come
on" ) .
ls the proper tuel fill cap installed and properly
ti ghtened?
YES Go to step 2.
NO Repl ace or ti ghten the cap.l
2. Check t he f uel f i l l cap seal .
Is the fuel fill cap seal missing or damaged?
YES Repl ace the fuel fi l l cap
(gray
or bl ack
col or ed cap) . 1
NO The f uel f i l l cap i s OK. Go t o st ep 3,
5.
7.
EVAP Canister Purge Valve Test
3. Di sconnect the vacuum hose from the EVAP purge
j oi nt (A),
and connect a vacuum pump
to the hose.
A973X-041-XXXXX
(l l ).
Appl y vacuum to the hose.
Does the valve hold vacuum?
YES-The EVAP cani ster purge val ve i s OK. Go to
st ep 12.
NO Go to step 6.
Di sconnect the EVAP cani ster purge val ve 2P
connecl or.
(cont' d)
11- 135
EVAP System
DTC Troubleshooting
(cont'd)
Check for conti nui ty between EVAP cani ster
purge
val ve 2P connect or t er mi nal No. 2 and body gr ound.
EVAP CANISTER PURGE
VALVE 2P CONNECTOR
PCS (RED/YELI
YES Go to step 9.
NO
-
Repl ace the EVAP cani ster
purge val ve.l
(32P).
Check for conti nui ty between EVAP cani ster purge
val ve 2P connector termi nal No. 2 and body
ground.
EVAP CANISTER PURGE
VALVE 2P CONNECTOR
PCS
(RED/YEL)
YES Repai r short i n the wi re between the EVAP
cani st er pur ge val ve and t he ECM
( 46) . 1
( see page 1l - 5) . l f t he sympt om/ i ndi cat i on
goes
8.
9.
10.
1 2
i1'
2
o
11- 136
EVAP Bypass Solenoid Valve Test
1 1. Di sconnect both vacuum hoses from the EVAP two
way val ve
(A),
and connect a vacuum
pump to the
cani ster
port on the two way val ve.
Connect ECM connecter termi nal 43 to bodv
ground wi th a
j umper
wi re.
ECM CONNECTOR A {32PI
Wi re si de ol {emal e termi nal s
( l l ) ,
Does the val ve hol d vacuum?
YES Go to step 15.
NO Go to step 20.
f
4973X-041
13.
14.
2WBS IORNI
l 2 3 6 I t 0
1Z 13 15 /
117
16 1 9 m 21 24
6 26 21 6 29 30 32
JUMPER WIRE
t t .
t o .
Di sconnect the EVAP bypass sol enoi d val ve 2P
connector.
Check for conti nui ty between EVAP bypass
sol enoi d val ve 2P connector termi nal No. 2 and
body ground.
EVAP BYPASS SOLENOID
VALVE 2P CONNECTOR
2WBS
2
IOFN)
o
YES Go to step 18.
NO- Repai r open i n the wi re between the EVAP
bypass sol enoi d val ve and the ECM
(A3).I
17.
18.
19.
(l l ).
Measure vol tage between EVAP bypass sol enoi d
ground.
EVAP BYPASS SOLENOIO
VALVE 2P CONNECTOR
2
IGl
(BLK/YEL}
Wi re si de o{ f emal e t ermi nal s
YES Repl ace the EVAP bypass sol enoi d val ve
(A)
and t he o- r i ngs
( B) . 1
NO Repai r open i n the wi re between the EVAP
bypass sol enoi d val ve and No. 6 ACG
(15
A) fuse. !
(cont' d)
11-137
EVAP System
DTC Troubleshooting
(cont'd)
20. Pl ug the upper port (A)
of the EVAP two way val ve.
Whi l e moni tori ng FTP sensor vol tage wi th the
Honda PGM Tester, or measuri ng the vol tage
between ECM connector termi nal s A29 and C18,
sl owl y pump the vacuum pump
unti l the vol tage
drops to about 1.5 vol ts.
Does the voltage drop to 1.5 V and hold for at
least 20 seconds?
YES-The EVAP bypass sol enoi d val ve/EVAPtwo
way val ve i s OK. Go to step 22.
NO Repai r l eak from the EVAP bypass sol enoi d
val ve, EVAP two way val ve, FTP sensor
,or
o-ri ngs.
I
21.
11- 138
Wi re si de of Jemal e t ermi nal s
EVAP Canister Vent Shut Valve Test
22. Di sconnect the vacuum hose from the EVAP
cani ster fi l ter, and connect a vacuum pump to the
hose.
f..=
23.
24.
A973X-041-
(l l ).
Appl y vacuum to the hose wi th 5 strokes of the
pump.
Does the valve hold vacuum?
YES- Go to step 25.
NO The EVAP cani ster vent shut val ve i s OK. Go
to step 30.
Di sconnect the EVAP cani ster vent shut val ve 2P
connecl or.
Check for conti nui ty between EVAP cani ster vent
shut val ve 2P connector l ermi nal No. 2 and body
gr ouno.
EVAP CANISTER VENT
SHUT VALVE 2P CONNECTOR
vsv
(LT
GRN/WHT)
25.
26.
27.
2
a
28.
29.
YES- Go to step 28.
NO- Repl ace the EVAP cani ster vent shut val ve
(A)
and o- r i ng
( B) . I
(32P)
Check for conti nui ty between EVAP cani ster vent
shut val ve 2P connector termi nal No. 2 and body
gr ound.
EVAP CANISTER VENT
SHUT VALVE 2P CONNECTOR
vsv
{LT GRN/WHT)
Wi re si de ol t emal e t ermi nal s
YES- Repai r short i n the wi re between the EVAP
cani ster vent shut val ve and the EcM {A4) I.
NO-Substi tute a known-good ECM and recheck
goes
I Z
r1
30.
Vacuum Hoses and Connections Test
Perform the fuel tank vapor control val ve test {see
page 11- 4) ,
l sthetuel tank vapor control val veOK?
YES-Go to step 31.
NO
-
Repl ace the fuel tank vapor control val ve.I
Ti ghten the fuel cap 3
"cl i cks".
then moni tor the
FTP readi ngs wi th the Honda PGM Tester.
Start the engi ne, and l et i t i dl e for 5 mi nutes.
ls the reading abov 4 mmHg pressure or below
4 mmHg vacuum?
YES-Substi tute a known-good ECM and retest. l f
the symptom/i ndi cati on
goes away, repl ace the
or i gi nal ECM. I
NO Check the fol l owi ng parts for l eaks: I
.
Fuel tank
(A)
.
Fuel f i l l cap
( B)
.
Fuel f i l l
pi pe ( C)
.
Fuel t ank vapor cont r ol val ve
( D)
.
Fuel t ank vapor r eci r cul at i on val ve
( E)
.
Fuel tank vapor reci rcul ati on tube
(F)
.
Fuel t ank vapor si gnal t ube
( G)
.
Fuel tank vapor control vent tube
(H)
-
Repai r or repl ace
parts
as needed,
5 t .
32.
33, Check the FTP sensor readi ng.
11- 139
EVAP System
DTC Pl457: EVAP Control
(EVAP
Canister Svstem)
System Leakage
The fuel system i s desi gned to al l ow speci fi ed
maxi mum vacuum and
pressure condi ti ons. Do not
devi ate from the vacuum and pressure tests as
i ndi cated i n these procedures. Excessi ve pressure/
vacuum woul d damage the EVAP components or cause
eventual fuel tank fai l ure.
.
Vacuum
pump/gauge,0
30 i n.Hg A973X-041-XXXXX
.
Vacuum/ pr essur e gauge, 0 4 i n. Hg 07JAZ- 0010008
Thi s i s a two-tri p code; once cl eared, i t cannot be
reproduced i n one tri p. Al so, certai n speci fi c dri vi ng
and ambi ent condi t i ons must occur bef or e t he ECM wi l l
compl ate the system checks. addi ti onal test dri ves may
sti l l not meet the speci fi c condi ti ons needed to
reproduce the code, l f necessary, use the test dri ve
procedures for setti ng the readi ness code
(see page 11
38) .
Fol l ow these troubl eshooti ng procedures careful l y to
ensure the i ntegri ty of the system and to confi rm the
cause of the Drobl em or code.
NOTE: Fresh fuel has a hi gher vol ati l i ty that wi l l create
greater pressure/vacuum. The opti mum condi ti on for
testi ng i s fresh fuel , at l east hal f. but l ess than a ful l tank.
l f possi bl e,
to assi st i n l eak detecti on, add 1 gal l on of
fresh fuel to the tank
(as
l ong as i t wi l l not fi l l the tank),
j ust
before starti ng these
procedures.
EVAP Canister Pu.ge Valve Test
1. Di sconnect the vacuum hose from the EVAP purge
j oi nt (A),
and connect a vacuum pump to the hose.
DTC Troubleshooting
(cont'dl
11-140
A973X.041-XXXXX
2. Connect ECM connector termi nal 46 to bodv
gr ound wi t h a
j umper
wi r e.
ECM CONNECTOR A I32P)
Appl y vacuum t o t he hose.
YES Go to step 5.
NO-The EVAP cani ster purge val ve i s OK. Go to
st ep 10.
Di sconnect the EVAP cani ster purge val ve 2P
connector.
Check for conti nui ty between EVAP cani ster
purge
val ve 2P connect or t er mi nal No. 2 and body gr ound.
3.
4.
5.
7.
6.
EVAPCANISTER PURGE
VALVE 2P CONNECfOR
2
o
PCS {RED/YEL}
Wi r e si de of i emal e t er mi nal s
YES Go to step 8.
cani st er pur ge val ve and t he ECM
( 46) . I
8.
9.
(l l ).
Measure vol tage between EVAP
purge cani ster
ground.
EVAP CANISTER PURGE
VALVE 2P CONNECTOR
Z
IG1 {BLK/YEL)
Wi re si de o{ fmal e termi nal s
YES Repl ace the EVAP cani ster
purge val ve.I
NO
-
Repai r open i n the wi re between the EVAP
cani ster
purge val ve and the No. 6 ACG
(15
A)
f use. l
EVAP Bypass Solenoid Valve Test
10. Di sconnect both vacuum hoses from the EVAP two
way val ve {A), and connect a vacuum
pump to the
cani ster
port
on the two way val ve.
A
(l l ).
YES The EVAP bypass sol enoi d val ve/EVAP two
way val ve i s OK. Go to step 18,
NO Go to step 13.
Di sconnect the EVAP bypass sol enoi d val ve 2P
connecror.
body
ground.
EVAP BYPASS SOLENOID
VALVE 2P CONNECTOR
l 2
2WBS
{ORN}
o
1 1 .
12.
t 5 .
't
4.
(cont' d)
11-141
EVAP System
l o .
17.
DTC Troubleshooting
{cont'd)
YES- Go to step 16.
NO-Repl ace the EVAP bypass sol enoi d val ve
(A)
and o- r i ngs
( B) . 1
(32P).
body ground.
EVAP BYPASS SOLENOIO
VALVE 2P CONNECTOR
Wi re si de of f emal e t rmi nal s
YES Repai r the short i n the wi re between the
EVAP bypass sol enoi d val ve and the ECM
(A,3).
t
11-142
19.
EVAP Canister Vent Shut Valve Test
18. Di sconnect the vacuum hose from the EVAP
cani ster vent fi l ter, and connect a vacuum
pumo
to
the hose.
4973X-041-XX)
Connect ECM connector termi nal 44 to bodv
gr ound wi t h a
j umper
wi r e.
ECM CONNECTOR A I32PI
{LT GRN/WHT)
2 3 6 9 10
12 13 15
/ 117
IE 1 9 m 21 24
26 n a 29 i2
JUMPER WI RE
( l l )
YES The EVAP cani ster vent shut val ve i s OK. Go
to step 27.
NO Go to step 22.
Di sconnect the EVAP cani ster vent shut val ve 2P
connector.
20.
22.
23.
25.
24. Check for conti nui ty between EVAP cani ster vent
shut val ve 2P connector termi nal No. 2 and body
g rou nd.
SHUT VALVE 2P CONNECIOR
r+
l '
2 l
vsv
-_-f-
ILTGFN/WHTI
@
L
Wne si de ofl ema termi nal s
l sthere conti nui ty?
YES Go to step 25.
cani st er vent shut val ve and t he EcM { A4) . 1
Turn the i gni ti on swi tch ON {l l ).
Measure vol tage between EVAP cani ster vent shut
ground.
EVAP CONTROL CANISTER VENT
SHUT VALVE 2P CONNECTON
t 1 t z l
l G 1
r r r I
(BLK/ YELI
I
, ()\
Wi re si de of
\ 7 f em6l e t er mi nal s
-I
YES Repl ace the EVAP cani ster vent shut val ve
( A)
and t he o- r i ng
( B) . I
cani st er vent shut val ve and t he No. 6 ACG
( 15
A)
f use. I
29.
Canister System Leak Test
28. Connect two three-way T-fi tti ngs
(A)
i ntothehose
from the EVAP cani ster to the EVAP two way val ve
Connect the FTP sensor to one of the tee T-fi tti ngs
and the vacuum
pump to the other.
Remove the vent hose from the EVAP cani ster vent
shut val ve
(A)
and cap the
port (B)
to seal the fresh
ai r vent for the EVAP cani ster.
(l l ).
Honda PGM Tester, or measuri ng vol tage between
ECM connector termi nal s A29 and C18, sl owl y
pump t he vacuum
pump.
(cont' d)
30.
J t .
11-143
EVAP System
DTC Troubleshooting
{cont'd)
32. Cont i nue t o
pump
vacuum unt i l t he vol t age dr ops
t o about 1. 5 V. Make sur e t hat t he engi ne cool ant
temperature i s sti l l above
g5' F
{35' C) and your
vacuum pump has no l eak.
33. Check the vol tage for 20 seconds.
Does the voltage drop to 1.5 V and hold I or at
l east 20 seconds?
YES Inspect the EVAP cani ster vent shut val ve
l i ne and connect i ons, I
NO Go to step 34.
35. Di sconnect the
qui ck-connect
fi tti ng
(A)
from the
EVAP cani ster, and pl ug the cani ster port(B).
( l l ) .
ECM connector termi nal s A29 and C18, sl owl y
pump
l ne vacuum pump.
38. Conti nue to pump vacuum unti l the vol tage drops
t o about 1. 5 V. Make sur e t he engi ne cool ant
temperature i s sti l l above 95' F
(35' C)
and
Vour
vacuum oumo has no l eak.
36.
:----
-ta
-'
_;,r-lt.-l?
11-144
39. Moni tor the vol tage conti nuousl y for 20 seconds.
Does the voltage drop to 1.5 V and hold for at
least 20 seconds?
YES Inspect the fuel tank vapor control l i ne and
connect i ons. l
NO Go to step 40.
4' 1. Di sconnect the
purge
l i ne hose
(A)
from the
cani st er at t he met al l i ne and pl ug t he hose( B) .
( l l ) .
ECM connect or t er mi nal s A29 and C18, sl owl y
pump
t he vacuum pump.
cont i nue t o
pump
vacuum unt i l t he vol t age dr ops
t o about
' l . 5
V. Make sur e t hat t he engi ne cool ant
temperature i s sti l l above 95' F
(35"C)
and your
vacuum pump has no l eak.
45. Check the vol tage for 20 seconds.
Does the vol tage drop to 1.5V and hol d at l east 20
seconds?
YES Inspect the EVAP cani ster purge val ve l i ne
and connecti ons. l f they are OK, test the EVAP two
way val ve, and fuel tank vapor control val ve test
( see page 11- 145) . I
NO Repl ace t he EVAP cani st er . l
42.
43.
44.
EVAP Two Way Valve Test
t . Remove t he f uel f i l l cap.
Di sconnect the vapor l i ne from the EVAP two way
val ve
(A).
Connect i t to a TJi tti ng
(B)
from the
vacuum gauge and t he vacuum
pump as shown.
3. Appl y vacuum sl owl y and conti nuousl y whi l e
watchi ng the
gauge.
The vacuum shoul d stabi l i ze momentari l y at 0.8
2. 1 kPa { 6
-
16 mmHg, 0. 2 0. 6 i n. Hg) .
l f the vacuum stabi l i zes
(val ve
opens) bel ow 0.8 kPa
( 6
mmHg, 0. 2 i n. Hg) or above 2. 1 kPa { 16
mmHg.
0.6 i n.Hg), i nstal l a new val ve and retest.
4. Move the vacuum
pump hose from the vacuum
fi tti ng to the
pressure fi tti ng, and move the vacuum
gauge hose from the vacuum si de to the pressure
si de
(A)
as shown.
' .
5. Sl owl y
pressuri ze the vapor l i ne whi l e watchi ng the
gauge. The pressure shoul d stabi l i ze momentari l y
above 1. 0 kPa
( 8
mmHg, 0. 3 i n. Hg) .
.
l f the
pressure momentari l y stabi l i zes
(val ve
opens) above 1. 0 kPa
( 8
mmHg, 0. 3i n. Hg) , t he
val ve i s OK.
.
l f the
pressure
stabi l i zes bel ow 1.0 kPa
(8
mmHg,
0.3 i n.Hg), i nstal l a new val ve and retest.
11-145
EVAP System
Fuel Tank Vapor Control Valve Test
Vacuum pump/ gauge, 0
30 i n. Hg A973X- 041- XXXXX
Float Test
' 1.
Make sur e t he f uel t ank i s l ess t han hal f f ul l .
2. Removet hef uel f i l l capt o r el i evet hef uel t ank
pressure,
then rei nstal l the cap.
3. Remove the l uel pi pe cover. Di sconnect the fuel
tank vapor reci rcul ati on tube
(A),
and connect a
vacuum pump
t o t he hose.
Pl ug the fuel tank vapor reci rcul ati on pi pe (B).
Appl y vacuum to the fuel tank vapor reci rcul ati on
hose { A) .
.
l f the vacuum hol ds, repl ace the fuel tank vapor
control val ve
(see page 1 1' 147 ).
.
l f the vacuum does not hol d, the fl oat i s OK. Go
to step
' l
of the val ve test.
A973X-041-XXXXX
ffih
A
5.
11-146
Valve Test
1. Make sur e t he f uel t ank i s l ess t han hal f f ul l .
3. Remove the fuel pi pe cover. Di sconnect the fuel
t ank vapor si gnal hose
( A) .
....f.
tt.
4. Di sconnect the vacuum hoses
{A) from the EVAP
cani ster {B). and then
pl ug
the ports wi th pl ugs (C).
A973X-041-XXXXX
B A C
Di sconnect the vacuum hose
(D)
from the EVAP
cani st er vent shut val ve
( E) ,
and connect a vacuum
pump to the EVAP cani ster vent shut val ve.
Pump t he vacuum pump 80 t i mes.
'
l f t he vacuum hol ds, go
t o st ep 7.
.
l f t he vacuum does not hol d, got o st ep9.
E
5.
'>'.
7. Connect a second vacuum pump to the fuel tank
vapor si gnal hose
(A).
8. Appl y vacuum
(1 pump) to the fuel tank vapor
si gnal tube
(A),
then check the vacuum on the
pump i n step 6.
.
l f the vacuum hol ds, repl ace the fuel tank vapor
cont r ol val ve
( see page 11' 140) .
.
l f the vacuum i s rel eased, the fuel tank vapor
cont r ol val ve i s OK.
9. Di sconnect the fuel tank vapor
qui ck di sconnect
from the EVAP cani ster, then
pl ug the port on the
cani ster. Reappl y vacuum
(80 pumps).
.
l f t hevacuum hol ds, r epl acet hef uel t ankvapor
cont r ol val ve
( see page 11- 140) .
.
l f t hevacuum does not hol d, i nspect t he EVAP
cani ster vent sut val ve o-ri ng. l f the o-ri ng i s OK,
repl ace the EVAP cani ster and repeat step 4.
Fuel Tank Vapor Control Valve
Replacement
1 .
4.
Remove t he f uel t ank
( see page 11- 115) .
Remove the fuel tank vapor control val ve
(A)
from
t he f uel t ank
( B) .
Repl ace the base
gasket (C).
Instal l the fuel tank vapor control val ve
(A).
I nst al l t he f uel t ank { see
page' 1 1- 121) ,
11-147
Pulsed Secondary Air Injection System
CONTROL SOLENOIO VALVE
Troubl eshooti ng, page 1 1-' 153
AIR CONTROL VALVE
Troubl eshooti ng, page 1 1-153
,/'::
il'
\i,\
Ii
'l-i
''
-
\r..
AI R PUMP
Removal / l nst al l at i on, page' 1 1-159
Troubl eshoot i ng, page
11- 149
- =-
..'.':.
ELECTRICAL CURRENT SENSOR
Removal / l nst al l at i on, page 1 1-160
Troubl eshoot j ng, page 1 1-156
---=\-:
AIR PUMP RELAY
Removal /l nstal l ati on,
paqe
1 1
-159
Test, page
l ' 1-160
11-148
DTC Troubleshooting
DTC P0410: Ai r Pump Ci rcui t Mal f unct i on
1. Reset t he ECI M
( see page 11- 4) .
2. Make sur e t he engi ne cool ant t emper at ur e i s over
32
' F
(0
' C)
and bel ow 158
' F
(60
"C)
wi th the scan
t ool .
3. St ar t t he engi ne. Dur i ng ai r pump oper at i on, hol d
the engi ne at i dl e speed wi th no l oad
(i n
neutral ) for
at l east 10 seconds.
l s Tempotaty DTC P0410 i ndi cated?
YES Go to step 5.
Check for
poor
the ai r control val ve vacuum control sol enoi d val ve
and at t he ECM. I
5. Check t he ai r
pump.
Does the air
pump operate?
YES Go to step 36.
NO Go to step 6.
7. Checkt he AI R PUMP
( 60
A) f use i n t he auxi l l ar y
under-hood fuse box.
l s the l use OK?
YES Go to step 8.
NO Repai r short i n the wi re between AIR PUMP
( 60
A) f use and t he ai r pump. Then r epl ace t he AI R
PUMP
( 60
A) f use. I
8. Remove the l eft-front i nner fender
(see page 20-
105) .
9. Di sconnect t he ai r
pump el ect r i cal cur r ent sensor
2P connect or .
10. Tur n t he i gni t i on swi t ch oN
( l l ) .
1 1. At the l eft engi ne compartment wi re harness si de,
measure vol tage between ai r
pump
el ectri cal
current sensol 2P connector termi nal No. 1 and
body
ground.
AIR PUMP ELECTRICAL CURRENT SENSOR
2P CONNECTOR
YES- Go to step 12.
NO Repai r open i n the wi re between the ai r pump
el ectri cal current sensor and the AIR PUMP
(60
A)
f use i n t he auxi l l ar y under - hood f use box. l
At the ai r pump el ectri cal current sensor si de, check
for conti nui ty between ai r
pump el ectri cal current
sensor 2P connect or t er mi nal s No. 1 and No. 2.
2P CONNECTOR
(WHT/RED}
YES Go to step 14.
NO Repl ace the ai r pump el ectri cal current
sensor . l
(cont' d)
11- 149
DTC Troubleshooting
(cont'd)
14. Reconnect the ai r ou m o el ectri cal current sensor.
15. Di sconnect the l arge ai r pump rel ay 2P connector.
(l l )
17. Measure vol tage between l arge ai r pump rel ay 2P
LARGE AIR PUMP RELAY 2P CONNECTOR
YES Go to step 18.
NO- Repai r open i n the wi re between the ai r pump
el ectri cal current sensor and the ai r
pump
rel ay,I
19. Do the ai r
pump
rel ay test
(see page 11-160).
ls the air pump relay OK?
YES
-
Go to step 20.
NO Repl ace the ai r pump rel ay. I
(l l ).
11- 150
21. Connect l arge ai r
pump rel ay 2P connector
t er mi nal s No. 1 and No. 2 wi t h a i umoer wi r e.
LARGE AIR PUMP RELAY 2P CONNECTOR
(WHT/REDI
IWHT/GRN}
JUMPER WI RE
Wi re si de ot t emal e t ermi nal s
Does the air pump
opetate when the
jumper
wite is
connected?
YES- Go to step 22.
NO Go t o st ep 31.
23. Di sconnect the
j umper
wi re from the l arge ai r
pump rel ay 2P connector.
24. Di sconnect the smal l ai rpump rel ay 2P connector.
25. Checktor conti nui ty between smal l ai r pump rel ay
2P connector termi nal No. 2 and body ground.
SMALL AIR PUMP RELAY 2P CONNECTOR
Wire side o{l lemale termina\s
YES Go to step 26.
NO Repai r open i n the wi re between the ai r
pump
r el ay and body gr ound. I
26.
27.
(32P).
Check for the conti nui ty betvveen ECM connector
termi nal A28 and body ground.
ECM CONNECTOR A
(32P)
2 3 4 6 I t 0
12 13 15 17 18 r9 2A 21 24
26 n a 29 32
APR
(BLU)
i.)
Wi re si de of t emal e t ermi nal s
YES Repai r short i n the wi re between the ai r
pump
rel ay and the EcM
(A28).1
NO Go to step 28.
Connect smal l ai r
pump rel ay 2P connector
t er mi nal No. 1 t o body
gr ound wi t h a
j umper
wi
SMALL AIR PUMP RELAY 2P CONNECTOR
termi nal A28 and body
ground
ECM CONNECTOR A I 32PI
2 3 6 I t0
12 13 r5 17 18 19 20 21 24
% 26 2l m 29 30 32
APR {BLU)
o
goes
away, r epl ace t he or i gi nal EcM. l
NO- Repai r open i n the wi re between the ai r
pump
rel ay and the Ecl \4
(A28).I
Di sconnect t he
j umper
wi r e f r om t he l ar ge ai r
pump rel ay 2P connector.
Di sconnect the ai r
pump 2P connector.
30.
5 t .
32.
(cont' d)
11- 151
Pulsed Secondary Air lnjection System
DTC Troubleshootang
(cont'd)
33. Check for conti nui ty between l arge ai r pump rel ay 2
P connect or t er mi nal No. 2 and ai r pump 2P
connector termi nal No. 1.
LARGE AIR PUMP RELAY
2P CONNECTOR
YES Go to step 35.
NO Repai r open i n the wi re between the pump
r el ay and t he ai r
pump.
!
Check for conti nui ty between the ai r pump 2P
AI R PUMP 2P CONNECTOR
YES Repl ace t he ai r pump. l
NO-Repai r open i n the wi re between the ai r pump
and body gr ound. I
34.
11-152
35.
50.
Do t he ai r pump r el ay t est
( see page 11- 160) .
ls the ait
punp relay OK?
YES Go to step 37.
NO Repl ace t he ai r
pump
r el ay. l
Di sconnect ECM connector A {32P).
Reconnect the negati ve cabl e to the battery.
( l l ) .
Measure vol tage between ECM connector termi nal
A28 and body ground.
ECM CONNECTOR A
(32P1
Wi re si de o{ t emal e t ermi nal s
l s there vol tage?
YES Repai r shortto power i n the wi re uetwo
t he ai r pump r el ay and t he ECM
( A28) . 4
l see
page 11-5). l f the symptom/i ndi cati on goes
away, repl ace the ori gi nal ECN4.I
37.
38.
39.
40.
2 3 4 6 I t 0
12 t3 15 17 1 8 t 9 20 21 24
25 26 n n 29 32
APR {BLUI
DTC P0411: SecondaryAi r I nj ect i on Syst em
l ncorrect Fl ow
1. Reset t he ECM
( see page 11- 4) .
2. Make sure the engi ne cool ant temperature i s over
32
" F
( 0' C)
and bei ow 158
" F
( 60
" C) wi t h
t he scan
I OOI .
3. Start the engi ne. Whi l e the ai r
pump
operates, l et
t he engi ne i dl e wi t h no l oad
( i n
neut r al ) f or at l east
10 seconds.
YES Go to step 5.
Check for
poor
the ai r control val ve vacuum control sol enoi d val ve
and at r he EcM. l
6. Check the vacuum l i nes of the ai r pump system for
mi srouti ng, l eakage. breakage, and cl oggi ng.
Are the vacuum Ii nes OK?
YES Go to step 7.
necessary.l
7. Reset t he ECM
( see page 11- 4) .
32
' F
(0
' C)
and bel ow 158
"F
(60
"C)
wi th the scan
t ool .
10.
9. Di sconnect the vacuum hose from the ai r control
val ve
(A),
and connect a vacuum gauge
to the hose.
Start the engi ne. Whi l e the ai r pump operates, l et
the engi ne i dl e wi th no l oad
(i n
neutral ).
ls there vacuum while the air
pump operates?
YES Go t o st ep 11.
NO Go to step 17.
Di sconnect the ai r control val ve vacuum control
sol enoi d val ve 2P connector.
Check for the conti nui ty between the ai r control
val ve vacuum control sol enoi d val ve 2P connector
termi nal No. 2 and body ground.
AIR CONTROL VALVE VACUUM CONTROL
SOLENOID VALVE 2P CONNECTOR
Wi re si de ol l emal e termi nal s
YES Go to step 14.
NO Repl ace the ai r control val ve vacuum control
sol enoi d val ve. !
(cont' d)
1 1 .
11- 153
Pulsed Secondary
Air Iniection System
14.
15.
DTC Troubleshooting
(cont'dl
Di sconnect ECM connector A {32P),
Check for conti nui ty between ai r control val ve
vacuum control sol enoi d val ve 2P connector
gr ound.
17.
control val ve vacuum control sol enoi d val ve and
the Ecl \i l
(A2).
t
{see
page 1 1-5). l f the symptom/i ndi cati on
goes
Check t he No. 6 ACG
(
15 A) f use i n t he under - dash
fuse/rel ay box.
l s the l use OK?
YES Go to step 18.
NO Repai r short i n the wi re between No. 6 ACG
( 15
A) f use and t he
gauge assembl y. Then r epl ace
t he No. 6 ACG
( 15
A) f use. l
t o .
11- 154
18.
19.
20.
Di sconnect the ai r control val ve vacuum control
(l l ).
Measure vol tage between ai r control val ve vacuum
control sol enoi d val ve 2P connector termi nal No. 1
and body
gr ound.
Wi re si de oI {emal e t ermi nal s
Is there battery voltage?
YES Go to step 21.
NO Repai r open i n the wi re between the No. 6
ACG
( 15
A) f use i n t he under - dash f use/ r el ay box
and ai r control sol enoi d val ve.l
Reconnect the ai r control val ve vacuum control
(32P).
Turn the i gni ti on swi tch oN {l l ), and measure
vol tage between ECM connector termi nal A2 and
body ground.
l s there l ess than 1.0 V?
YES Repai r open i n the wi re between the ai r
control val ve vacuum control sol enoi d val ve and
the ECM
(A2).
l f the wi re i s OK, repl ace the aar
control val ve vacuum control sol enoi d val ve.I
(see page 11-5), l f the symptom/l ndi cati on
goes
a 1
22.
24.
DTC Pl 410: Ai r Pumo Mal f unct i on
1. Reset t he ECM { see page 11- 4) .
32
' F
(0"C)
and bel ow 158
' F
(60' C)
wi th the scan
tool .
Start the engi ne. Whi l e the ai r
pump
operates, l et
the engi ne i dl e wi th no l oad
(i n
neutral ) for at l east
10 seconds,
Check for a Temporary DTC wi th the scan tool .
YES Repl ace the ai r pump.l
Check for poor
t he ai r pump
and t he ai r pump r el ay. I
4.
11- 155
Pulsed Secondary
Air Iniection System
DTC Troubleshooting
(cont'd)
DTC Pl 415: Ai r Pump El ect ri cal Current
Sensor Ci rcui t Low Vol t age
1. Reset t he ECM
( see page 11 4) .
( l l ) .
3. Check for a DTC wi th the scan tool .
YES
-
Go to step 4.
Check for poor connecti ons or Ioose termi nal s at
the ai r
pump
el ectri cal current sensor and the
ECM.
Di sconnect the ai r pump el ectrl cal current sensor
3P connector.
( l l ) .
Measure vol tage between ai r pump el ectri cal
current sensor 3P connector termi nal s No. 1 and
No . 2 .
3P CONNECTOR
YES Go to step 8.
NO Go to step 17.
4.
5.
6.
7 .
r-Fir
I l ,
r l
-1-l--
L,()J
vcc2
\+/
sG2
(YEL/BLU} IGRN}
11- 156
9. Di sconnectthe ECIM connector C
(31P).
10. Checkfor conti nui ty between ai r
pump
el ectri cal
current sensor 3P connector termi nal No. 3 and
body
ground.
3P CONNECTOR
ECS
(WHT/BLK)
1 1 .
pump el ectri cal current sensor and the ECI\4
l c24l . a
NO Go to step
' l
1.
Connect ai r pump el ectri cal current sensor 3P
connect or t er mi nal s No. 2 and No. 3 wi t h a
j umper
3P CONNECTOR
(WHT/BLK)
1 2 3
ia
12. Check for conti nui ty betl veen ECM connector
ECM CONNECTOR C
(31P)
1 2 4 5 7 8 9 10
11 12 t 3 1 7 20 21 22
/_l:
(
^ t c F t t . ^ t o 1 t .
- | - | | . " | . ' | .
\
Ecs
9IWHTIELKI
n l l c o l : m n , /
:l
sG2
IGRN/YELI
YES Go to step 14.
NO
-
(C24)
and the ai r
pump
el ectri cal current sensor.I
Di sconnect the
j umper
wi re from the ai r
pump
el ectri cal current sensor 3P connector.
Reconnect ECM connector C
(31P)
and the ai r
pump
el ectri cal current sensor 3P connector.
(l l ).
14.
t 5 .
1 2 4 5 7 I I 10
t1 12 t o t c t o 1 7 18 2A 21 22
24 25 26 27 28 30
ECS
(WHT/BLK)
16. Measure vol tage between body ground
and ECM
connector termi nal C24.
ECM CONNECTOR C {3IP}
Wi re si de ol f emal e t ermi nal s
(see page
1l -5). l f the symptom/i ndi cati on goes
NO Repl ace the ai r pump
el ectri cal current
sensor , l
ECM CONNECTOR C {3IP}
sG2
IGRN/YEt}
I I I 1 1 0 2 4 5
1 l 12 15 1 1 19 t 20 121 t 22
25 ?6 23 l l a 3 0
vcc2
IYEL/BLUI
Wi re si de oI femal e termi nal s
(C28)
and the ai r
pump
el ectri cal current sensor.I
NO
-
{see
page 1 1-5). l f vol tage i s normal , repl ace the
or i gi nal ECM. I
11-157
Pulsed Secondary Air lniection System
4.
5.
6.
7.
DTC Troubleshooting
(cont'd)
DTC Pl 416: Ai r Pump El ect ri c Current Sensor
Ci rcui t Hi gh Vol t age
1. Reset t he ECM
( see page 11- 4) .
2. Tur n t he i gni t i on swi t ch ON { l l )
3, Check for a DTC wi th the scan tool .
YES Go to step 4.
NO Intermi ttent fai l ure, system i s OK at thi s ti me,
Check for
poor
the ai r
pump el ectri cal current sensor and at the
ECM. T
Di sconnect the ai r
pump el ectri cal current sensor
3P connector,
( l l ) .
Nl easure vol tage between ai r
pump
el ectri cal
current sensor 3P connector termi nal s No. 1 and
No. 2.
3P CONNECTOR
ls there about 5 V?
YES Repl ace the ai r pump el ectri cal current
sensor . l
NO Go to step 8.
r--F_}--r
l 1 1 2 l 3 l
]---T---
L_,(/r_1
vcc2
\+/
sG2
IYEL/BLU)
(GRN)
11- 158
ECM CONNECTOR C
(31PI
sG2
{GRN/ YEL)
8 I 9 r 0 I 2 4 5
11 1Z 1 4 1 1 l 1 9 I Z A I U 1 2 2
25 26 27 23 t t a t 3 0
vcc2
{YEL/BLU)
( C18)
and t he ai r pump el ect r i cal cur r ent sensor . l
(see page 1 1-5). l f vol tage i s normal . repl ace the
or i gi nal ECM. I
Ai r Pump/Ai r Pump Rel ay Removal /l nstal l ati on
Remove the front bumper
(see page 20-92).
Remove t he ai r pump ( A) ,
and t he ai r pump r el ay
( B) .
'L
2.
8 x 1. 25 mm
22N.m
12.2 kgt m,
6 x 1 . 0 mm
9. 8 N. m (1. 0
kgf m,
7.2 tbt.ttl
5 x 1 . 0 mm
9 . 8 Nm( 1 . 0 k g I . m,
7. 2l bt . f t )
15 tbf.ft)
AI R PUMP RELAY
2P CONNECTOB
{Large)
AIR PUMP RELAY
2P CONNECTOR
( S
m ai l )
3. Instal l i n the reverse order of removal .
11- 159
Air Pump Relay Test
Check for conti nui ty between the termi nal s accordi ng to
t he t abl e.
.
There shoul d be conti nui ty between the 41 and A2
termi nal s of the ai r pump rel ay 2P l arge connector
when power and
ground
are connected to the B1
t er mi nal of t he ai r pump r el ay 2P smal l connecl or .
.
There shoul d be no conti nui ty between the 41 and 42
termi nal s when power i s di sconnect from the ai r
pump
2P smal l connector.
\
Termi nal
;"r""r
(s1)
--\
A1 M
Connected
r\ r\
Disconnected
11- 160
Air Pump Electrical Current Sensor
RemovaUl nstal l ati on
1. Pul l away the l eft i nner fender as necessary {see
page
20- 105) .
2. Di sconnect the ai r
pump el ectri cal current sensor
2P connector
(A),
and remove the l ower cover
(B),
then di sconnect the ai r
pump el ectri cal current
sensor 3P connector {C).
Remove the ai r pump el ectri cal current sensor
(D).
Instal l i n the reverse order of removal .
3.
4.
@l
Transaxle
Glutch
Speci al Tool s
. . . . . . . . . 12-2
Component Locat i on I ndex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3
Clutch Pedal, Clutch Pedal Position Switch,
and Cl ut ch I nt erl ock Swi t ch Adj ust ment . . . . . . . . . . . . . 12-4
Cl ut ch Mast erCyl i nder Repl acement . . . . . . . . . . . . . . . . . . . . . 12-5
Sl ave Cyl i nder Repl acement
. . . . . . . . . . 12-6
Cf ut ch Repl acement . . . . . . . . . . . . . . . . . . . . . . . . 12-l
Clutch
Speci al Tool s
o
. f ,
.a )/
: . "
6
12-2
Ref. No. Tool Number
Description Oty
o)
(a
o
@
07LAB-PVO0 1 00 or 07924-PD20003
07LAF-PT00110
07746-0010200
07749-0010000
07936- 3710100
Ri ng Gear Hol der
Cl utch Al i gnment Shaft
Dri ver
Remover Handl e
1
1
'l
1
1
CLUTCH PEOAL
Adj ust ment , page l 2-4
RESERVOIR
RELEASE FORK
M/T ASSEMBLY
LOCK PIN
CLUTCH LINE
RELEASE
FORK BOOT
CLUTCH
HOSE CLIP
RELEASE BEARING
I nspect i on, page 12 7
SLAVE CYLINDER
Repl acement, page 12-6
CLUTCH DISC
Removal , page 12 7
l nst al l at i on, st ep I on page 12- 11
PRESSURE PLATE
Removal , page 12-7
l nstai l ati on, step 1 on page 12-11
Repl ace.
CLUTCH HOSE
BANJO BOLT
FLYWHEEL
I nsoect i on, st ep 1on
paqe
12- 9
Repl acement, step
' l
on
-page
12 I
12-3
Glutch
Clutch Pedal, Clutch Pedal Position Switch, and Clutch Interlock Switch
Adjustment
NOTE:
.
To checkthe cl utch
(see page 4-
47 ) .
.
To check the cl utch i nterl ock swi tch
(see page 4-6).
.
The cl utch i s sel f-adj usti ng to compensate for wear.
.
l f there i s no cl earance between the mastercyl i nder
pi ston
and
push rod, the rel ease beari ng i s hel d
agai nst the di aphragm spri ng, whi ch can resul t i n
cl utch sl i ppage or other cl utch
probl ems.
1. Loosen l ocknut
(A),
and back offthe cl utch swi tch
(B)
unti l i t no l onger touches the cl utch pedal (C).
H
9. 8 N. m
(1. 0 kgt . m, 7. 2 l bt . f t l
2. Loosen l ocknut
(D),
and turn the
push rod
(E)
i n or
out to
get the speci fi ed hei ght
(F)
and stroke
(G)
at
the cl utch oedal .
Cl utch Pedal Stroke: 115 125 mm {4.53
4.92 i n.)
Clutch Pedal Height: 189 mm
(7.44
in.)
3. Ti ghten l ocknut
(D).
4. Wi th the cl utch
pedal rel eased, turn the cl utch
Dedal Dosi ti on swi tch {B)
i n unti l i t contacts the
cl utch
pedal (C).
{1. 0 kgf m,
7.2 tbf.ft)
12-4
5. Turn the cl utch
pedal posi ti on swi tch {B) i n an
addi ti onal 3/4 to 1 turn.
6. Ti ghl en l ocknut
(A).
7. Loosen l ocknut
(H)
andthe cl utch i nterl ock swi tch
(
t ) .
8. Press the cl utch pedal to the fl oor.
9. Rel ease t he cl ut ch
pedal
' 15- 20
mm
( 0. 59- 0. 79
i n. )
from the ful l y depressed
posi ti on, and hol d l t there.
Adj ust the
posi ti on of the cl utch i nterl ock swi tch
(l )
so that the engi ne wi l l start wi th the cl utch
pedal i n
thi s
posi ti on.
10. Ti ght en l ocknut
( H) .
Clutch Master Cylinder Replacement
NOTE: Do not spi l l brake fl ui d on the vehi cl e; i t may
damage the pai nt; i f brake fl ui d does contact the
pai nt.
wash i t off i mmedi atel y wi th water
1. The brake fl ui d may be sucked out through the top
of the master cyl i nder reservoi r
(A)
wi th a syri nge.
1 5 Nm( 1 . 5 k g f . m,
11 tbt.ft)
Di sconnect the cl utch l i ne
(B)
from the cl utch
master cyl i nder. Pl ug the end of the cl utch l i ne and
reservoi r hose wi th a shop towel to prevent
brake
fl ui d from comi ng out.
Pry out the l ock pi n (A),
and pul l
the
pedal pi n (B)
out of the yoke. Remove the nuts
(C).
4. Bemove the cl utch master cyl i nder
(A).
-.--1i:,.'1.
,-_-::-:-:=---_-,;.,1,'a)
Instal l the cl utch master cyl i nder i n the reverse
order of removal . Ti ghten the master cyl i nder
mount i ng nut st o 13 N. m
( 1. 3
kgf . m, 9. 4 l bf f t ) .
Bl eed the cl utch hydraul i c system
(see
step 6 on
page 12- 6) .
12-5
Clutch
Slave Cylinder Replacement
NOTE; Do not spi l l brake fl ui d on the vehi cl e; i t may
damage the
pai nt; i f brake fl ui d does contact the
pai nt,
wash i t off i mmedi atel y wi th water.
' 1.
Remove the banj o bol t
(A)
and washers
(B),
then
di sconnect the cl utch hose {C) from the sl ave
cyl i nder {D). Pl ug the end of the cl utch hose wi th a
shop towel to
prevent brake fl ui d from comi ng out.
E
Remove the two boi ts
(E)
and sl ave cyl i nder,
Pul l t he boot
( A)
back and appl y br ake assembl y
l ube or equi val ent rubber
grease to the boot and
sl ave cyl i nder rod
(B).
Rei nstal l the boot.
(Brake
Assmbly Lubel
Appl y super hi gh t emp ur ea gr ease t o t he t i p of t he
sl ave cyl i nder r od.
4.
12-6
5. I nst al l t he sl ave cyl i nder i n t he r ever se or der of
removal . Use new banj o bol t washers,
NOTE: Make sur e t he boot i s i nst al l ed on t he sl ave
cyl i nder .
29 N m 13.0
kgl.m,22 lbf.ft)
8 x 1.25 mm
22 N m {2.2 kgf m.16l bf ftl
6. Bl eed the cl utch hydraul i c system. Ti ghten the
bl eeder screw to 9.8 N m
(1.0
kgf.m, 7.2 l bf ft).
NOTE: Be careful not to damage the sl ave cyl i nder
by overti ghteni ng the bl eeder screw.
.
Attach a hose to the bl eeder screw
(A),
and
suspend the hose i n a contai ner of brake fl ui d.
.
Make sure there i s an adequate suppl y of fl ui d at
the cl utch master cyl i nder, then sl owl y
pump the
cl utch
pedal unti l no more bubbl es appear at the
bl eeder hose.
.
Refi l l the cl utch master cyl i nder wi th fl ui d when
done.
.
Al ways use onl y Honda DOT 3 brake fl ui d.
.
Confi rm cl utch operati on, and check for l eaki ng
f l ui d.
I
Cl utch Repl acement
.
Cl utch al i gnment shaft 07LAF-PToo110
.
Remover handl e 07936- 3710100
.
Ri ng gear hol der 07LAB-PVoo100 or
07924-PD20003
.
Dri ver 07749-0010000
.
Attachment,32 x 37 mm 07746-0010200
Pressure Plate and Glutch Disc Removal
1. Check t he di aphr agm spr i ng f i nger s hei ght -
vari ati on usi ng the di al i ndi cator
(A).
l f the vari ati on
i s more than the servi ce l i mi t, repl ace the
pressure
pl ate.
Standard
(New):
0.4 mm
(0.016
i n.) max.
(0.024
i n.l
2. Instal l the speci al tool s.
07LAF-PT00110
07936-3710100
07LAB-PV00100 or 07924-PD20003
To
prevent warpi ng, unscrew the pressure pl ate
mounti ng bol ts {A) i n a cri sscross
pattern i n several
steps, then remove the
pressure pl ate (B).
Remove t he r el ease bear i ng
( C)
f r om t he pr essur e
pl ate.
ii,
*%G;ts'F
5. Inspect the fi ngers of the di aphragm spri ng
(A)
l or
wear at the rel ease beari ng contact area.
Inspect the
pressure pl ate surface for wear, cracks,
and bur ni ng.
Inspectforwarpage usi ng a strai ght edge
(A)
and
feel er
gauge (B).
Measure across the
pressure pl ate
(C).
l f the warpage i s more than the servi ce l i mi t,
repl ace the
pressure pl ate.
Standard l Newl : 0.03 mm {0.001
i n.) max.
7.
-;---- \")
\-q,yz
(cont' d)
12-7
Glutch
Clutch Replacement
(cont'd)
8. Remove the cl utch di sc and sDeci al tool s.
Inspect the l i ni ng of the cl utch di sc for si gns of
sl i ppi ng or oi l . l f t he cl ut ch di sc i s bur ned bl ack or
oi l soaked, repl ace i t.
Measure the cl utch di sc thi ckness. l f the thi ckness
i s l ess than the servi ce l i mi t, repl ace the cl utch di sc.
Standard
{Newl ; 8.2 8.9 mm
(0.32-0.35
i n.l
{0.24
i n.,
9.
10.
@r j
12-8
11. Measure the ri vet depth from the l i ni ng surface
(A)
to ri vets
(B),
on both si des. l f the ri vet depth i s l ess
than the servi ce l i mi t, repl ace the cl utch di sc.
Standard l New): 1.2 1.7 mm {0.047-0.067 i n.)
(0.00e
i n.l
Flywheel lnspection
1. l nspect the ri ng gear teeth for wear and damage.
2. Inspect the cl utch di sc mati ng surface on the
fl ywheel for wear, cracks, and burni ng.
3. Measure the fl ywheel
(A)
runout usi ng a di al
i ndi cator
(B)
through at l east two ful l turns. Push
agai nst the fl ywheel each ti me you turn i t to take up
the crankshaft thrust washer cl earance. l f the
runout i s more than the servi ce l i mi t, repl ace the
fl ywheel and recheck the runout. Resurfaci ng the
fl ywheel i s not recommended.
Standard
(New):
0.05 mm {0.002 i n.) max.
(0.24
i n.l
Turn the i nner race of the bal l beari ng
(A)
wi th your
fi nger. The bal l beari ng shoul d turn smoothl y and
qui etl y. Check that the bal l beari ng outer race fi ts
ti ghtl y i n the fl ywheel . l f the race does not turn
smoothl y,
qui etl y, or fi t ti ght i n the fl ywheel ,
r epl ace t he bal l bear i ng.
4.
,-:':
I r ! ,
Flywheel Replacement
1. I nst al l t he speci al t ool .
a\
07LAB-PVo0100 or
0792{-PD20003
Remove the fl ywheel mounti ng bol ts i n a cri sscross
pattern i n several steps, then remove the fl ywheel .
Remove the bal l beari ng
(A)
from the fl ywheel
(B).
{cont' d)
Clutch
Clutch Replacement
(cont'dl
4. Dri ve the new bal l beari ng i nto the fl ywheel usi ng
the speci al tool s as shown. Appl y a l i ght coat of oi l
to the beari ng surface.
07749-0010000
Al i gn the hol e i n the fl ywheel wi th the crankshaft
dowel pi n,
and i nstal l the fl ywheel . l nstal l the
washer and mounti ng bol ts fi nger-ti ght.
l nstal l the speci al tool . then torque the fl ywheel
mounti ng bol ts i n a cri sscross
pattern
i n several
steps.
12 x
' 1. 0
mm
127 N. m
{13, 0 kgf . m, 94l gf . f t l
'j.l@7..1
' \ - ' \ - - - - - - 2 , '
iii:.-
-
..2J
12-10
\
Release Bearing Inspection
Check the rel ease beari ng for excessi ve
pl ay
by
spi nni ng i t by hand. i f there i s excessi ve
pl ay,
repl ace
the rel ease beari ng wi th a new one
NOTE: The rel ease beari ng i s packed wi th grease. Do
not wash i t i n sol vent.
Clutch Disc and Pressure Plate Installation
1. Appl y a t hi n, uni f or m coat of super hi gh t emp ur ea
grease (P/N
08798-9002) to the spl i nes
(A)
of the
cl ut ch di sc
( B) .
Sl i de t he cl ut ch di sc ont o t he
mai nshaft, and remove extra overfl ow
grease.
2. I nst al l t he r i ng gear hol der .
t ^"
' '
(4_9!E!-E!_it
Pl ,',
o7s36'371o10o
I lt ,.,,.
0TLAF
-PIoo11o
l l , / '
t' lt'
t J z B
(P/N
08798-9002t
4.
Instal l the cl utch di sc usi ng the speci al tool s.
Appl y super hi gh temp urea grease
{P/N 08798-
9002) i nto the
groove (A)
of the rel ease beari ng {B}.
then i nstal l the rel ease beari ng on the
pressure
pl ate (C).
Instal l the
pressure pl ate
and the mounti ng bol ts
( Dl f i nger t i ght .
Make sur e t he r el ease bear i ng does
not come off.
+'iFEASEH
lPlN 08798-90021
07LAB-PV00'100
.
5.
=== 07924-PD20003
4!::--!-\. . /
\ \ _ |
'.a'
1 , , ,
,g;
...
6. Torque the mounti ng bol ts i n a cri sscross
pattern.
Ti ghten the bol ts i n several steps to
prevent
war pi ng t he di aph r agm spr i ng.
PRESSUBE PLATE MOUNTING BOLT TOROUE:
25 N.m
(2.6
kgf.m, r9l bf' ft)
/zo
- o\
/@^
-. 6\
O
i . _ ,
l O
t
- .
u
.\Qo
9,'
1. Remove the speci al tool s.
Make sur e t he di aphr agm spr i ng f i nger s ar e al l t he
same hei ght.
12-11
Transaxle
Manual Transmi ssi on
Soeci al Tool s
Transmi ssi on Fl ui d I nspect i on
and Reol acement . . . . . . . . . . . . . . . . . . . . .
Back-up Li ght Swi t ch Test . . . . . . . . . .
Gearshi f t Mechani sm
Reol acement . . . . . . . . . . . . . . . . . . . . . . , . . . . . . . 13- 4
Transmi ssi on Remova1 . . . . . . . . . . . . . . . 13-5
Count ershaf t Reassembl y . . . . . . . . . . 13-41
Secondary Shaf t Di sassembl y . . . 13-45
Secondary Shaf t I nspect i on . . . . . . . 13-45
Secondary Shaf t Reassembl y . . . . 13-46
Shi f t Forks Cl earance
f nsoect i on . . . . . . . 13-47
Shi f t Forks Di sassembl y
/ Reassembl y
. . . 13-49
Synchro Ri ng and
Gear I nsoect i on . . . . . . . . . . . . . . . . . . . . . . . . 13-50
Synchro Sl eeve and Hub
I nspect i on and Reassembl y . . . . 13-51
Oi l Pumo Cl earance
l nsoect i on . . . . . . . 13-52
Secondary Shaf t Prel oad
Adj ust ment . . . . . 13-53
Mai nshaf t Thrust Cl earance
Adi ust ment
. . . . . 13-54
Transmi ssi on Reassembl y . . . . . . . . . 13-55
Transmi ssi on I nst al l at i on . . . . . . . . . . . 13-66
13-2
13-3
13-3
Transmi ssi on Di sassembl y . . . . , . . .
Mai nshaf t Assembl y Cl earance
I nspect i on
Mai nshaf t Di sassembl y
Mai nshaf t I nspect i on
Mai nshaf t Reassembl y
Shift Arm Rod Assembly
Di sassembl y/ Reassembl y . . . . . . .
Cou ntershaft Assembly
Cl earance I nspect i on
Count ershaf t Di sassembl y . . . . . . . . .
Count ershaf t I nspect i on . . . . . . . . . . . . .
13-12
13-27
13-30
13-31
13-32
13-35
13-36
, l
?-?e
13-40
Speci al Tool s
\
*
Must be used wi th commerci al l y avai l abl e 3/8"- 16 sl i de hammer.
* *
Part of Mai nshaft Inspecti on Tool Set,07GAJ-PG2010A.
ll
ai-
-)
@
e
rl)r
I i 7
Itr
t
o
n.i]
. : ,
@
,6,
- - : -
.
i:_.,
^. . ' .
@
i,,.
---
tt
t..
--.---,,,]
o
,i .
-' f
o
,,,
5)t
@
/it
\
I l
a
\-'
'::
'
"l :,'
o
oTat?
o @
lr'--\,
i t
\..-
_
,,,/
@
Ref.No. Tool Number Description Otv
" q
07GAJ- PG20110
"(9
07GAJ-PG20130
q 07JAB-0010204
o 07LAD-PW5060' r
I
07PA8,0014300
I I
07RAB- T840108
' (I
I 07736-4010008
I
07746-001o3oo
g
I
07746-0010500
q0
07746-0010600
q
I
07746-0030100
I
07746-0030300
(9
I
07746 0030400
I
07749-0010000
' 9
07946-M800000
I I
07947-68s0300
a, | 07965-5450500
Mai nshaf t Hol der
Mai nshaf t Base
Hol der Handl e
At t achment , 40 x 50 mm l . D.
Mai nshaft Hol der
Fl ange Hol der
Adj ustabl e Beari ng Pul l er, 20
-
40 mm
Dri ver, 40 mm l .D.
Attachment, 30 mm l .D.
Dr i ver
Dr i ver , 30 mm l . D.
Attachment. 45 mm
Attachment. 35 mm LD.
1
1
1
1
1
1
1
1
1
1
1
1
1
'I
1
1
'l
13-2
Transmi ssi on Fl ui d Inspecti on and
Replacement
2.
1 . Par k t he vehi cl e on l evel gr ound, and t ur n t he
engi ne OFF.
Remove t he oi l f i l l er
pl ug ( A)
and t he washer
( B) ,
check the condi ti on of the fl ui d, and make sure the
fl ui d i s at the
proper l evel
(C).
3. l f the transmi ssi on fl ui d i s di rty, remove the drai n
pl ug ( A)
and dr ai n t he f l ui d.
c
44 N. m
{4. 5
kgf . m,
33 rbf.ftl
Fluid Capacity
1.48 0
(1.56
US
qt)
at fl ui d change
1.62A f
.l 1US gt) at overhaul
Al ways use Honda Manual
Tr ansmi ssi on Fl ui d
( MTF) .
l f i t i s not
avai l abl e,
you may use an API ser vi ce
SG, SH or SJ gr ade mot or oi l wi t h a
vi scosi ty of SAE 10 W-30 or 10 W-40
as a temporary repl acement.
5. Rei nst al l t he oi l f i l l er
pl ug ( C)
wi t h a new washer
( D)
Back-Up Light Switch Test
1. Di sconnectthe back-up l i ght swi tch
(A)
2P
connector,
1.
25 N.m 12.5
kst.m, 18l bf ft)
Check the conti nui ty between the termi nal s. There
shoul d be conti nui ty when the shi ft l ever i nto
reverse,
l f necessary, repl ace the swi tch.
Remove the shi ft l ever knob, boot hol der, shi ft boot,
shi ft l ever, and the shi ft l ever spri ng
(see page 13-
Remove the three way catal yti c converter
(TWC)
(see
step 20 on
page 13-8).
Remove the propel l er shaft
(see page 16-17).
Pl ace the fl oor
j ack
under the transmi ssi on, and
remove the three transmi ssi on rear mount bol ts
(see
step 31 on
page 13-10).
B
2.
3.
4.
6.
8. Lower the transmi ssi on rear end 65 mm
(2.56
i n ),
then remove the back-up l i ght swi tch usi ng a 3/8"
cr owf oot wr ench
( 19
mm)
( B) .
13-3
Gearshift Mechanism Replacement
6 x 1 . 0 mm
9. 8 N m 11. 0 kgf m,
7.2tbf.tt)
5 x 1 . 0 mm
9. 8 N. m 11. 0 kgt m,
7.2tbt.tt)
-t-"-"
'" tEVER HOUSING
.ttt"''n
t'vER KN.B
LOCKNUT
10 x 1. 25 mm
9 N. m {0. 9 kgf . m, 7l bf f t )
BOOT HOLDER
//-'/'-"
SEIFT BOOT
SHIFT LEVER BOOT C
SHIFT LEVER SPRING
13-4
Transmission Removal
NOTE: Use fender covers to avoi d damagi ng
pai nted
surfaces,
1. Di sconnect t he negat i ve
(
) cabl ef i r st , t hent he
posi ti ve (+
) cabl e from the battery. Remove the
battery.
2- Loosen the l ocknut, then remove the shi ft l ever
knob.
4.
Remove the center consol e
(seepage20-76).
Remove the boot hol der {A) and the shi ft boot
(B).
5. Remove the three bol ts, then remove the shi ft l ever
(A)
and the shi ft l ever spri ng
(B)
: - ' j
"-1j-''
(cont' d)
(cont'd)
6. Remove t he ai r cl eaner housi ng assembl y.
5
Turn the steeri ng wheel to the strai ght-ahead
posi ti on,
then remove the key from the i gni ti on
swi tch to l ock the steeri ng col umn. Make a
reference mark
(A)
across the steeri ng
j oi nt (B),
Loosen the upper steeri ng
j oi nt
bol t
(C),
and
remove the l ower steeri ng
j oi nt
bol t {D). Di sconnect
the steeri ng
j oi nt
from the
gear
box.
7.
13-6
9.
10.
Remove the al ternator-comDressor bel t and the
al ternator
(see page
4-25).
Di sconnect the 1P connector {A), then remove the
four mounti ng bol ts and the Ay' C compressor
(B).
Remove the four exhaust mani fol d cover mounti ng
bol ts.
11.
12. Remove the heat shi el d
(A),
then remove the
exhaust mani fol d cover.
13. Remove the upper starter motor mounti ng bol t
(A)
and upper i ntake mani fol d bracket mounti ng bol t
(B).
Di sconnect the hose
(C)
from the sucti on val ve.
14. Di sconnect the TDC1
(A)
and TDC2 {B) sensor
connectors.
' 15.
Remove t he sDl ash shi el d.
4
6
e
(cont' d)
13-7
(cont'dl
16. Di sconnect the 2P connector
(A)
from the steeri ng
17. Di sconnect the torque sensor 3P connector
(C),
and
remove the wi re harness cl amp
(D).
' 18.
Remove the wi re harness
(A)
and mounti ng bol t,
then remove the i ntake mani fol d stay
(8).
13-8
19.Di sconnect the heated oxygen sensor
(HO25)
{A),
secondary heated oxygen sensor {secondary
HO2S)
(B),
and the back-up l i ght swi tch
(C)
connectors, then remove the wi re harness from the
transmi ssi on.
Remove the three way catal l ti c converter
(TWC)
(A)
and gaskets (B).
a
21. Remove the exhaust mani fol d bracket
(A)
and the
exhaust mani f ol d
( B) .
22.
23.
Remove the propel l er shaft
(see page 16-17).
Remove the four shi ft boot hol der mounti ng bol ts.
24, Remove the rel ease fork boot
(A),
then careful l y
remove the sl ave cyl i nder
(B).
Do not operate the
cl utch
pedal once the sl ave cyl i nder has been
removed.
Pul l out the rel ease fork
(A)
from the rel ease fork
hanger. Wedge a shop towel
(B)
between the
openi ng i n the cl utch housi ng and the rel ease fork
to hol d the rel ease fork i n
pl ace.
(cont' d)
13-9
(cont'dl
Remove the fi ve l ower transmi ssi on mounti ng
bol ts.
Pl ace a fl oor
j ack
under the front sub frame and the
engi ne mounti ng sti ffener.
Remove the two center mounti ng bol ts.
Loosen the four mounti ng bol ts 75 mm
(3.0
i n.) as
snown.
21.
28.
29.
1 . 1
\
.
- . . . - t
mm
) i n. )
13- 10
Lower the front subframe i n unti l i t touches the four
l oosened mounti ng bol ts.
Pl ace the fl oor
j ack
under the transmi ssi on, and
remove the three transmi ssi on rear mount bol ts.
Lower the transmi ssi on. Di sconnect the oi ck-uD
sensor connector
(A),
then remove the wi re
har ness
( B)
f r om t he t r ansmi ssi on.
)
33. Remove the three upper tra nsm i ssi on mounti ng
bol ts.
Pul l the transmi ssi on away from the engi ne unti l i t
cl ears the mai nshaft, then l ower the transmi ssi on
on t he
j ack.
Remove the transmi ssi on rear mount from the
t r ansmi ssi on housi ng.
13- 11
Transmission Disassembly
Exploded View-Rear Cover
t--rr-.._
--=-g
11
[l
t\if5
B l
,/--
-"'t-':
6)
@)--"''
x_=----'
7*_-3
X
=--D
\v
----=P=\
-\.1)
8'...
q-
f1 \
l l . '
U
o*--.--
\a'o
o
13-12
(D
27 mm LOCKNUT
Repl ace.
' 162
*
0
-
162 N.m
(16.5 -
0
*
16.5 kgt.m,
119* 0* ' l 19l bf . f t l
O 27 mm SPRING WASHER
O BACK-UP RING
O O.RING
Repl ace.
O COMPANION FLANGE
G) 40 x 60 X 9 mm OIL SEAL
Repl ace.
O BALL BEARING
Repl ace.
@ REAR COVER
O SHIFT ARM B
@ CONICAL SPRING WASHER
Repl ace.
O 8 mm SPECIAL BOLT
31 N. m {3. 1 kgf . m, 22l bf . t t l
@ SHIFT LEVER HOUSING
(}
6 mm FLANGE BOLT
12 N m 11. 2 kgf . m, 8. 7 l bf . f t )
@ 8 mm FLANGE BOLT
27 N.m {2.8 kgf.m,20 lbf.ft)
@ HARNESS BRACKET
@ o-RrNG
Repl ace.
@ SHIFT ROD TUBE
@ SECONDARY SHAFT ASSEMBLY
See page 13-45
@ BEARING OUTER RACE
@ SHIM
O HARNESS CLAMP
(cont' d)
13- 13
(cont'd)
Exploded View-Transmission Housing
60
@
/
,,--t\
do o
\-:)
t //// rA
d , ( 9 H
,./ G)
@
x\,,
-cr\\-_-
-.o
@---'-r..^
tl
13-14
.]) 29 mm LOCKNUT
{Left-hand threads)
Repl ace.
172
*0 *
172 N. m (17. 5 -
0
*
17. 5 kgf , m,
127-0-127l bf . l t l
(2)
29 mm SPRING WASHER
O 30 x 64x20 mm NEEDLE BEARI NG
O, sEcoNoaRY DRtvE GEAR
O OIL PUMP SHAFT
@ oI L PUMP GEAR
O 6 mm FLANGE BOLT
12 N. m {1. 2 kgt . m, 8. 7 l bf . f t )
@ OIL PUMP PLATE
o SPRI NG L. 19. 1 mm {0. 75 i n. }
(s)
STEEL BALL
O ot l PUMP RoroR
@ BEARING OUTER RACE
@ SHI M
Sel ect i on.
(}
otl GUTDE PLATE s
@ WASHER
Bepl ace.
@ DRATN PLUG
39 N. m
{4. 0 kgf . m, 29l bf . f t }
@ 14 x 20 DowEL Pt N
(D
o-RrNG
Reol ace.
@ PICK-UP sENsoR
@ 6 mm FLANGE BOLT
12 N. m (1. 2
kgf m. 8. 7 l bt f t )
Q]) FILLER PLUG
44 N. m
(4. 5
kgt . m, 33l bf f t )
@ WASHER
Repl ace.
@ SET SCREW
@ SPRI NG L. 27. 4 mm 11. 08 i n. l
@ STEEL BALL
@ 16x 26 x 7 mm ol L SEAL
Repl ace.
@ 12 mm WASHER
Repl ace.
@ 12 mm DRAI N PLUG
39 N.m lil.o kst.m,29 lbf.ft)
@ SPRI NG L. 23 mm (0. 91
i n. ) {BLACK)
@ 8 mm FLANGE BOLT
27 N. m {2. 8 kgt . m. 20l bt . f t )
@ TRANSMISSION HANGER A
@ TRANSMISSION HANGER
@ OIL GUIDE PLATE M
@ 82 mm sHlM
Sel ect i on.
@ SUGTI oN GUI DE
@ crRcLrP
@ OIL PUMP STRAINER
D SPRI NG 1. 23 mm
(0. 91
i n. )
(SI LVERT
@ SPRI NG 1. 32 mm {1. 26 i n. }
(E
WASHER
Repl ace.
O BACK.UP LIGHI SWITCH
@ TRANSMISSION HOUSING
(cont' d)
13- 15
(cont'd)
Exploded View-Clutch Housing
61
- \
@
I
@
-.'A ^-- -,--@
@--=-ssR-'-,
-.-e
"
e..,
-
@'
FJ-.-
*--"-"*9
\n
1-----.-'
S:.-------t
^Qg- -_@
trE)
13- 16
O coUNTERSHAFTASSEMBLy
O 68 mm SNAP RING
1O
MAINSHAFT ASSEMBLY
O 64 mm SPRING WASHER
O otL GUrDE TUBE
G] REVERSE SHAFT HOLDER
O REvERSE GEAR sHAFT
O THRUST wASHER
9 20 x25 x 26.5 mm NEEDLE BEARING
.O REVERSE IDLER GEAR
O 34 mm SEALING BOLT
69 N.m (7.0
kgf.m,51 l bf.ft)
(n
8 mm WASHER
Repl ace.
d0 8 mm FLANGE BOLT
34N m
(3.5
kgf.m,25l bf.tr)
O 14 x 20 DowEL PtN
(}
SHIFT FORK ASSEMBLY
O SHIFT ARM ROD ASSEMBLY
( l 8x, l 0Pl N
(}
SELECT RETURN SPRING
@ CLUTCH RELEASE HANGER
ED RELEASE HANGER SPRING
(}
8 mm SPECIAL BOLT
27 N. m {2. 8 kgf m. 20 l bf . f t }
@ EREATHER PLATE
@ 6 mm FLANGE BOLT
12 N m
(1. 2
kgf . m, 8. 7 l bf . f t l
] 6 mm FLANGE BOLT
12 N. m
{1. 2 kgf , m, 8. 7 t bf . f t l
q'
RELEASE BEARI NG GUI DE
@ 28 x
il3
x 7 mm OIL SEAL
Repl ace.
' 8 x 6 3 Pl N
0 10 mm FLANGE BOLT
44 N. m 14. 5 kgt . m, 33 l bt . f t )
@ CLUTCH HOUSI NG
@ 1.2 SHIFT FORK
O REVERSE sHIFT FoRK
QA T-2 SHIFT LEVER
@ MAGNET
(cont' d)
13-17
(cont'd)
.
Fl ange hol der 07RAB- TB40108
.
Adj ust abl e bear i ng
pul l er , 20 40 mm 07736- 4010008
.
Mai nshaft hol der 07PAB-0014300
.
Rear Gover Removal
1. Remove the four bol t, and remove the shi ft l ever
housi ng.
2. Lower the shi ft rod
(A),
then remove the 8 mm
speci al bol t
(B),
spri ng washer
(C),
and shi ft arm B
( D) .
B 9
E E
_ l
13- 18
3. Remove the I mm fl ange bol ts i n a cri sscross
pattern i n several stePs,
Remove the rear cover {A) and 14 x 20 dowel pi ns
{ B) .
Remove the shi ft rod tube and O-ri ngs from the
rear cover.
R
t l
l t
l t
l l
g
6. Rai se the 27 mm l ocknut tab from the
qroove
i n the
secondarv shaft.
Instal l the speci al tool onto the compani on fl ange,
and l oosen the 27 mm l ocknut.
7.
a' ::.1-.:,
8. Remove the 27 mm l ocknut
(A),
spri ng washer
(B).
back- up r i ng
( C) ,
and O- r i ng
{ D) ,
Remove the compani on fl ange
(A)
usi ng a
commer ci al l y avai l abl e bear i ng
pul l er ( B)
as shown.
(cont' d)
13- 19
Manual
Transmi ssi on
Transmission
Disassembly {cont'd}
10. Remove t he oi l seal .
1 l . Remove the secondary shaft
(A)
from the rear
cover
(B)
usi ng a press (C)
as shown.
' 12.
Remove t he bal l bear i ng
( D) f r omt he r ear cover '
13-20
13. Remove the beari ng outer race
(A)
and shi m
(B)
from the rear cover
(C).
Remove the beari ng outer race
(A)
from the rear
cover
(B)
usi ng the speci al tool s as shown.
-I6
SLIDE HAMMER
(commerci al l y avai l abl e)
' 14.
Transmission Housing Removal
l . Remove t he oi l pump gear
shaf t and oi l pump gear .
I
- l
l'-"1
t l
H
qroove
i n the
countershaft.
13-21
3. I nst al l t he speci al l ool ont o t he mai nshaf t spl i ne,
and l oosen the 29 mm l ocknut
(l eft-hand
threads).
07PAB-001A300
4. Remove the 29 mm l ocknut and spri ng washer,
(cont'd)
Remove the needl e beari ng
(A)
usi ng a
pul l er ( B)
as shown.
Remove the secondary dri ve
gear (A)
usi ng a
pul l er ( B)
as shown.
13-22
7. Remove the 6 mm fl ange bol ts, then remove the oi l
pump pl ate (A),
spri ng, steel bal l , and oi l
pump
rotors
(B).
g @
^--.----...:
I
u.
w
8. Remove t he dr ai n
pl ug ( A) ,
f i l l er pl ug ( B) ,
12 mm
drai n pl ug (C),
washers, set screws
(D),
spri ngs,
steel bal l s, and
pi ck-up sensor
(E).
1 1 .
bd
Remove the 8 mm tl ange bol ts i n a cri sscross
oattern i n several steos.
' @
Remove the transmi ssi on
dowel
pi ns (A).
housi ng and 14 x 20
- e e e e ? F
wd"'m
' 12.
Remove the beari ng outer race
(A)
usi ngthe
speci al tool as shown, then remove the shi m
(B)
and oi l gui de pl at e
S.
3/ 8"
. 16
SLI DE HAMMER
(commerci al l v
avai l abl e)
Remove t he 16x26x7 mm oi l seal f r om t he
(cont' d)
07736-A010008
13-23
(cont'dl
Remove the ci rcl i p
(A).
then remove the sucti on
gui de ( B)
and oi l
pump
st r ai ner
( C) f r om
t he
Remove the 82 mm shi m(s)
(A)
and oi l gui de pl ate
M.
@*-^
14.
15.
ti.-
,
lil:l61lt
13-24
L
16. Remove t he oi l gui det ube( A) andmagnet ( B) .
' 17.
Remove the I mm fl ange bol t and washer, then
remove the reverse shaft hol der
(A),
thrust washer
(B),
reverse
gear
shaft
(C),
and needl e beari ng
(D).
19.
18. Remove t he 10 mm f l ange bol t , t hen r emove t he I
x 63 pi n (A)
and l -2 shi ft l evers
(B).
Remove the 5 x 25 spri ng pi n (B)
from shi ft arm A
wi th a 5 mm pi n dri ver, then remove the shi ft rod
(c).
Remove the shi ft arm A from the i nterl ock
(D),
then
remove the sel ect return spri ng
(E)
and the 8 X 40
pi n ( F) .
20.
t -
.J----r--..-
\ , /
22.
21. Remove t he 1- 2 shi f t pi ece.
Remove the 34 mm seal i ng bol t
(A)
from the cl utch
nous I ng.
Expand the 68 mm snap ri ng
(B)
on the
countershaft bal l beari ng, and remove i t from the
gr oove
usi ng a
pai r of snap
r i ng pl i er s.
Remove the mai nshaft, countershaft, and shi ft
forks assembl i es
(C),
and remove the 64 mm spri ng
washer, reverse i dl er gear (D),
thrust washer.
(conl ' d)
23.
24.
13-25
(cont'dl
Remove the 6 mm fl ange bol ts and rel ease beari ng
gui de ( A) .
Remove the I mm speci al bol ts, cl utch rel ease
hanger
( B)
and r el ease hanger spr i ng
( C) .
Remove the 6 mm fl ange bol ts and breather
pl ate
( D) .
Remove the oi l seal from the cl utch housi ng.
26.
24.
27.
13-26
Mainshaft Assembly Clearance Inspection
NOTE:
.
l f repl acement i s requi red, al ways repl ace the
synchro sl eeve and hub as a set.
.
Supportthe beari ng i nner race, and
push down on
the mai nshaft as shown.
1 . Measure the cl earance between 3rd gear (A)
and
t he bal l bear i ng
( B)
wi t h a f eel er
gauge,
.
l f the cl earance i s more than the servi ce l i mi t, go
to steD 2.
.
l f the cl earance i s wi thi n the servi ce l i mi t,
go to
step 4.
Standard: 0.05-0.19 mm
(0.002
0.007 i n.l
(0.012
i n.)
3.
2. l vl easure the di stance of the di stance col l ar.
.
l f di stance i s notwi thi n the standard, repl ace the
di stance col l ar wi th a new one
.
l f di st ance i swi t hi nt he st andar d,
got o st ep3
Standard: 35.23 35.28 mm
(1.387
1.389 i n.)
Measure the thi ckness of 3rd
gear.
.
l f t het hi cknessof 3r d gear i s l esst hant heser vi ce
l i mi t, repl ace 3rd gear wi th a new one.
.
l f t het hi ckness of 3r d gear i swi t hi nt he ser vi ce
l i mi t, repl ace the 3rd/4th synchro hub wi th a new
one,
(1.381
1.385 i n.l
(cont' d)
13-27
Mainshaft Assembly Clearance Inspection
{cont'd)
4. Measure the cl earance between 4th gear (A)
and
di st ance col l ar
( B) .
l f t he cl ear ance i s mor e t han t he
servi ce l i mi t, go
to step 5.
Standard: 0.06-0.19 mm {0.002-0.007 i n.}
Servi ce Li mi i : 0.3 mm
10.012 i n.)
B
Measure di stance
O on the di stance col l ar.
.
l f di st anceO i s not wi t hi nt hest andar d, r epl ace
the di stance col l ar wi th a new one.
.
l f di st anceO i swi t hi nt he st andar d, got o st ep6.
Standard; 32.03-32.08 mm
{1.261 1.253 i n.l
13-28
6. fMeasure the thi ckness of 4th gear.
.
l f t het hi ckness of 4t h gear i s l esst han ser vi ce
l i mi t, repl ace 4th gear wi th a new one.
.
l f the thi ckness of 4th gear i swi thi n the servi ce
l i mi t, repl ace the 3rd/4th synchro hub wi th a new
one.
(1.256
1.259 i n.l
{1.251 i n.)
7. Measure the cl earance between 5th gear (A)
and
the di stance col l ar
(B).
l f the cl earance i s more than
the servi ce l i mi t, go
to step 8.
Standard: 0.06-.0.19 mm
(0.002-0.007
i n.l
Servi ce Li mi t: 0.3 mm {0.012 i n.}
,1.,,,,.'---
....
-'.--.-..,,a.'
8, Measure di stance O on the di stance cotrar.
.
l f di st ance O i s not wi t hi nt hest andar d, r epl ace
.
l f di st ance@ i swi t hi nt he st andar d,
got ost ep9.
Standard: 32.03 32.08 mm {1.251-
1.263 i n.l
Measure the thi ckness of 5th gear.
.
l f the thi ckness of 5th gear i s l ess than the servi ce
l i mi t, repl ace sth gear wi th a new one.
.
l f the thi ckness of 5th gear i s wi thi n the servi ce
l i mi t, repl ace the 5th/6th synchro hub wi th a new
one.
Standard: 31.89 31.97 mm {1.256- 1.259 i n.)
(1.251
i n.)
9.
t : - - -
10. Measure the cl earance between 6th
gear (A)
and
the mai nshaft
(B).
l f the cl earance i s more than the
servi ce l i mi t, go to step 11.
(0.002-0.007
i n.l
(0.012
i n.)
Measure the thi ckness of 6th
gear.
.
l f thethi ckness of 6th
gear i s l essthan the servi ce
l i mi t, repl ace 6th gear wi th a new one.
.
l f thethi ckness of 6th
gear i s wi thi n the servi ce
l i mi t, repl ace the 5th/6th synchro hub wi th a new
one.
(1.137-1.141
i n.)
Servi ce Li mi t: 28.77 mm 11.133
i n.
1 1 .
- - - - . - l
13-29
Mainshaft Disassembly
l . Support bal l beari ng
(A)
wi th a commerci al l y
avai l abl e beari ng separator, and remove the bal l
beari ng usi ng a press
as shown.
Remove t he 3r d gear , 35
x 30 x 35 mm needl e
beari ng. di stance col l ar, doubl e cone synchro,
synchro spri ng, and 3rd/4th synchro sl eeve.
Support 4th gear (A)
wi th a commerci al l y avai l abl e
beari ng separator, and remove the 3rd/4th synchro
hub
(B),
doubl e cone synchro, and 4th gear
usi ng a
oress as snown,
PRESS
13-30
4.
1.
Remove the 42 x 47 x 30.5 mm needl e beari ng,
di stance col l ar,sth gear, synchro ri ng, and synchro
spr i ng.
Support 6th gear (A)wi th
a commerci al l y avai l abl e
beari ng separator, and remove the 5th/6th synchro
hub/sl eeve
(B),
synchro ri ng, synchro spri ng. and
6th
gear
usi ng a press
as shown.
Remove the 39 x 44 x 26 mm needl e beari ng.
Support bal l beari ng
(A)wi th
a commerci al l y
avai l abl e beari ng separator, and remove the bal l
beari ng usi ng a press
as shown.
PRESS
Mainshaft Inspection
1. Inspect the
gear surface and the beari ng surface for
wear ano oamage.
2. Measure the mai nshaft at Doi nts
A, B, C, and D. l f
anv Dart of the mai nshaft i s l ess than the servi ce
l i mi t, repl ace i t wi th a new one.
Standard:
A
(Rear
cover end ball bearing contact area):
27. 987 28. 000 mm
( 1. 1018
1. 1024i n. 1
B
{4th/5th
gears contact area}:
34.987-35.000 mm
(1.3774
1.3780 i n.)
C
(6th gear contact area):
38.984-39.000 mm
(1.5348
1.5354 i n.)
D
(Clutch
housing end ballbearing coniact areali
28.002 28.015 mm
(1.102/r
1.1030i n.1
Service Limit:
A: 27. 94 mm
( 1. 100
i n. )
B: 34.94 mm
(1.376
i n.)
C: 38.94 mm
(1.533
i n.)
D: 27. 95 mm
( 1. 100
i n. )
Cl ut ch housi ng
end
Rear cover
eno
3. Inspect for runout by supporti ng both ends of
mai nshaft. Rotate the mai nshaft two compl ete
revol uti ons when measuri ng the runout. l f the
runout i s more than the servi ce l i mi t. repl ace the
mai nshaft wi th a new one.
Standard: 0.02 mm 10.001 i n.l max.
{0.002
i n.}
13-31
Mainshaft Reassembly
Exploded View
Thin edge of the outer
lacq faces 6th goar
Thin edge of the outer
race faces 3rd
gear
ANGULAR BALL BEARING
Check f or wear and operat i on.
Not e t he di rect i on of
i nst al l at i on.
/,,,sYNcHRo
RING
SYNCHRO
SPRING
5TH/6TH
HUB
SYNCHRO
5TH/6TH
SYNCHRO
SLEEVE
SYNCHRO SPRING
SYNCHRO RING
3 5 x 4 0 x 3 5 mm
NEEOLE BEARING
Check f or wear
ano operat | on.
28 x 35 x 36. 2 mm
DISIANCE COLLAR
\urroro^
3 9 x 4 4 x 2 6 mm
NEEDLE BEARI NG
Check f or wear
ano opet at on.
"4..
,6, i9;*==---28x64x18mm
(a
s}*d5
Rtl*,?:iL'$f."
\ | /
-7\ - of i nsral l at i on.
\ 7
\ oammsPRr Nc
MAI NSHAFT
NEEOLE BEARING
Check for wear
ano operaton.
3 5 x 4 2 x 6 8 mm
DISTANCE COLLAR
sTH GEAR
42 x 47 x 30.5 mm
NEEDLE BEARING
Check for wear and operati on.
'//,,.3RD
GEAR
DOUBLE CONE SYNCHRO
SYNCHRO SPRI NG
3RD/ 4TH SYNCHRO SLEEVE
SYNCHRO HUB
SYNCHRO SPRING
CONE SYNCHRO
4TH GEAR
x 47 x 30.5 mm
13-32
WASHER
.
Dr i ver , 40 mm 1. D. 07746- 0030100
.
Attachment, 30 mm l .D.07746-0030300
thi s
procedure.
' 1.
Support 2nd
gear (A)
on steel bl ocks, then i nstal l
t he bal l bear i ng { B) usi ng t he speci al t ool s and a
press
as shown.
NOTE: The thi n edge of the outer race faces 6th
gear ,
I nst al l t he 39 x 44 x 26 mm needl e bear i ng, 6t h
gear ,
synchro ri ng, and synchro spri ng.
Instal l the 5th/6th synchro hub
(A)
and sl eeve
(B)
by
al i gni ng t he st ops
( C) .
2.
PRESS
PRESS
4. Press the 5th/6th synchro hub usi ng the speci al tool
as shown. After i nstal l i ng, checkthe operati on of
the 5th/6th svnchro hub and sl eeve.
077,16-0030100
Instal l the synchro spri ng, synchro ri ng, 42 x 47 x
30.5 mm needl e beari ng,5th
gear, di stance col l ar,
and 4th gear.
I nst al l t he doubl e cone synchr o
( A)
and synchr o
spr i ng { B) as shown.
{cont' d)
13-33
' 1.
Mainshaft Reassembly
(cont'd)
Instal l the 3rd/4th synchro hub
(A)
and sl eeve
(B)
by
al i gni ng the stops
(C).
Press the 3rd/4th synchro hub usi ng the speci al tool
as shown. After i nstal l i ng, check the operati on of
the 3rd/4th synchro hub and sl eeve
07746-0030'100
8.
PRESS
13-34
9. Instal l the doubl e cone synchro
(A)and
synchro
sprl ng
(B)
as shown.
I nst al l t he di st ance col l ar
( A) , 35
x 40 x 35 mm
needl e bear i ng
( B) ,
and 3r d gear ( C) .
10.
11. I nst al l t heangul ar bal l bear i ng
( A) wi t ht het hi n
edge of the outer race faci ng 3rd
gear (B).
Use the
speci al tool and a press.
PRESS
Shift Arm Rod Assembly
Disassembly/Reassembly
Refer to reassembl i ng, cl ean al l the
parts i n sol vent, dry
them, and appl y l ubri cant to any contact
parts.
5 x 25 SPRI NG PI N
SHIFT ARM A
13-35
Gountershaft Assembly Glearance Inspection
NOTE: l f repl acement i s requi red, al ways repl ace the
1 . Measure the cl earance between 2nd gear (A)
and
the countershaft
(B)
wi th a feel er gauge.
l f the
cl earance i s more than the servi ce l i mi t, go
to
step 2.
(0.002
0.007 i n.l
13-36
2. Measure the thi ckness of 2nd gear.
.
l f t het hi cknessof 2nd gear i s l esst hant he
servi ce l i mi t, repl ace 2nd gear wi th a new one.
.
l f t het hi cknessof 2nd gear
i swi t hi nt he ser vi ce
l i mi t, repl ace the 1sV2nd synchro hub wi th a new
one.
(1.294
1.298 i n.)
{1.290 i n.)
Measure the cl earance between
' 1st
gear (A)
and
the di stance col l ar
(B).
l f the cl earance i s more than
the servi ce l i mi t, go to step 4.
(0.002
0.009 i n.)
(0.012
i n.)
--:-
-
--=-
=>
4. Measure di stance O on the di stance cottar.
.
l f di stance O i s notwi thi nthe standard, repl ace
the di stance col l ar wi l h a new one.
.
l f di st anceO i swi t hi nt he st andar d,
got ost ep 5.
(1.104
1.106 i n.l
5. Measure the thi ckness of 1st gear.
.
l f t het hi ckness of 1st gear i s l esst hant heser vi ce
l i mi t, repl ace 1st gear wi th a new one.
.
l f thethi ckness of 1st gear i swi thi n the servi ce
l i mi t, repl ace the 1sV2nd synch ro hub wi th a new
one.
Standard: 31.18
-
31.26 mm {1.22A-
1-231 i n.l
i n.)
6. Measure the cl earance between reverse
gear (A)
and the di stance col l ar {B). l f the cl earance i s more
than the servi ce l i mi t, go to step 7.
(0.002-0.009
i n.)
(0.012
i n,.
Measure di stance @ on the di stance col l ar.
.
l f di stance @
i s notwi thi n the standard, repl ace
.
l f di st anceO i swi t hi nt he st andar d,
got o st ep8.
Standard: 25.53 25.58 mm {1.005 1.007 i n.)
7.
(cont' d)
13-37
Countershaft Assembly Clearance
lnspection
(cont'dl
8. fvl easure the thi ckness of reverse gear.
.
l f the thi ckness of reverse gear
i s l ess than the
servi ce l i mi t, repl ace reverse gear
wi th a new one.
.
l f thethi ckness of reverse gear i s wi thi n the
servi ce l i mi t, repl ace the reverse synchro hub
wi th a new one.
(1.039
1.042 i n.)
(1.034
i n.)
13-38
Countershaft Disassembly
1. Remove the
Remove the i nner race
(A)
usi ng a commerci al l y
avai l abl e beari ng separator and a
press
as shown.
needl e beari ng.
@
P
ruW
ffi
groove i n the
countershaft.
4. Securel y cl amp the 4th and 5th gears i n a bench
vi se wi th wood bl ocks
(A).
Remove t he 27 mm l ocknut
( B)
and spr i ng washer
(c).
/--N
| ' . ' l
)'{Y
6. Remove the bal l beari ng usi ng a press as shown.
PRESS
7. Remove the remai ni ng
parts from the countershaft.
13-39
Gountershaft lnspection
1. Inspect the gear
surface and the beari ng surface for
wear and damage.
2. fMeasure the countershaft at
poi nts
A. B, C, and D. l f
any part
of the countershaft i s l ess than the servi ce
l i mi t, repl ace i t wi th a new one.
Standard:
A
(Rear
cover end needle bearing contact areal:
30. 020 30. 029 mm
( 1. 1819- 1. 1822
i n. )
B
(Transmission
housing end needle bearing
contact areal:
3,1.002 34.018 mm
(1.3387
1.3393i n|
C l2nd
gear
contast area):
'tr3.98i[
44.000 mm |'1.7317
1.1323 in.l
D
{Clutch housing end ball beafing contact areal:
28.002
-
28.015 mm
11.1024- 1.1030 i n.l
Service Limit:
A: 29.97 mm
(1.180
i n.)
B: 33.95 mm
(1.337
i n.)
C:
/8.93
mm
(1.730
i n.l
D: 27.95 mm 11.100 i n.l
Rear cover
end
13-40
3. Inspectfor runout by supporti ng both ends of
countershaft. Rotate the countershaft two compl ete
revol uti ons when measuri ng the runout. l f the
runout i s more than the servi ce l i mi t, reDl ace the
countershaft wi th a new one.
Standard; 0.02 mm
(0.001
i n.) max.
(0.002
i n.)
Countershaft Reassembly
Exploded View
@--
/A
r3r*
28x58x l 8 mm
BALL BEARING
Check f or wear
ano operaoon.
4 4 x 5 0 x 2 8 mm
NEEDLE BEARI NG
Check f or wear and
operat i on.
FRICTION DAMPER
SPRING
1ST/2ND SYNCHRO SLEEVE
(cont' d)
27 mm LOCKNUT
Repl ace.
1 6 2 - 0 - 1 5 2 Nm
116. 5- 0- - 16. 5kgt . m,
1 1 9 * 0 - 1 1 9 | b f . f t )
l ST/2ND SYNCHRO HUS
/R\
i.wj------=..-34 x s7 x 20 mm
X
sYNcHRo SPRTNG
a*'
:|::513;:*|.""0
DOUBLE CONE
SYNCHRO
FRICTION DAMPER
l ST GEAR
5 1 x 5 7 x 2 3 mm
NEEDLE BEARING
Check f or wear and
operat i on.
REVERSE SYNCHRO SLEEVE
38 x, (l x 26 mm
NEEDLE BEARING
Check f or wear and
operat i on.
REVERSE GEAR
SYNCHRO RING
SYNCHRO SPRING
REVERSE SYNCHRO HUB
mm SPRING wASHER
CONE
13-41
Countershaft Reassembly
(cont'd)
.
Dr i ver , 40 mm 1. D. 07746- 0030100
.
Attachment, 30 mm 1.D.07746-0030300
.
Aftachment, 35 mm l .D.07746-0030400
thi s
procedure.
1. I nst al l t he 44 x 50 x 28 mm needl e bear i ng and 2nd
gear ,
2, Instal l the fri cti on damper
{A), doubl e cone synchro
( B) ,
and synchr o spr i ng
( C)
as shown.
I nst al l t he 1sV2nd synchr o hub
( A)
and sl eeve
( B)
as
snown.
13-42
4. I nst al l t he synchr o spr i ng
( A)
and doubl e cone
synchro {B) as shown.
Instal l the fri cti on damper on the 1st gear,
then
i nstal l the
' 1st
gear
by al i gni ng the grooves
as
snown.
7.
I nst al l t he 5l x 57 x 23 mm needl e bear i ng, di st ance
col l ar , and 38 x 43 x 26 mm needl e bear i ng.
Instal l the reverse gear.
l nst al l t he synchr o r i ng and synchr o spr i ng.
Instal l the reverse synchro hub
(A)
and sl eeve {B).
8.
9.
1 1 .
10. I nst al l t he bal l bear i ng { A) usi ng t he speci al t ool s
ano a oress as snown.
Secur el y cl amp t he 4t h and 5t h
gear s
i n a bench
vi se wi th wood bl ocks
(A).
I nst al l t he spr i ng washer
( B)
and 27 mm l ocknut
( C) .
Ti ghten the 27 mm l ocknut to the speci fi ed-val ue.
Tor que: 162- 0- - t 62Nm
( 16. 5- * 0- - 16. 5kgt . m,
119- t 0- 119| bf . f t )
(cont' d)
' t 2.
13.
PRESS
13-43
Gountershaft Reassembly
(cont'd)
14. Stake the l ocknut tab i nto the
groove.
15. l nst al l t he needl e
speci al t ool s and
beari ng i nner race
(A)
usi ng the
a
press
as shown.
PRESS
07746-0030400
13-44
beaf l ng.
@
16. l nstal l the needl e
1 .
Secondary Shaft Disassembly
Remove the tapered rol l er beari ngs usi ng a
commerci al l y avai l abl e beari ng separator and a
press as shown.
PRESS
Secondary Shaft Inspection
' 1.
Inspect the
gear
surface and the beari ng surface l or
wear and damage.
2. Measure the countershaft at
poi nts A, B, and C. l f
any part of the secondary shaft i s l ess than the
servi ce l i mi t, repl ace i t wi th a new one.
Standard:
A
{Bal l beari ng contact area}:
31.002
-
31.013 mm 11.2205
-
1.2210 in.l
B {Plopeller shaft end tapered roller bearing
contact areal :
41. 002 41. 018 mm
{ 1. 6142
1. 6149i n. )
C
(Transmission
end taper6d roller bearing
contact areal:
35.009 35.025 mm
(r.3783
-
1.3790 i n.)
Service Limit:
A: 30.95 mm {1.219 i n.)
B: 40.95 mm {1.612 i n.)
C: 38.94 mm {1.376 i n.)
(cont' d)
13-45
Manual Transmission
Secondary Shaft Inspection
(cont'd)
l nspect for runout by supporti ng both ends of
secondary shaft. Rotate the secondary shaft two
compl ete revol uti ons when measuri ng the runout.
l f the runout i s more than the servi ce l i mi t, repl ace
the secondary shaft wi th a new one.
Standard: 0.02 mm
(0.001
i n.) max.
Servi ce Li mi t: 0.05 mm {0.002 i n.l
Rotate two compl ete
revol uti ons.
13-46
Secondary Shaft Reassembly
Special Tools Requird
.
Attachment. 45 mm 07947-6890300
.
Beari ng attachment 07LAD-PW50601
' 1.
I nst al l t he t aper ed r ol l er bear i ngs usi ng t he speci al
tool and a Dress as shown,
-6890300
07LAD-PWs0601
Shift Forks Clearance Inspection
NOTE: l f repl acement i s requi red. al ways repl ace the
1. Measure the cl earance between the each shi ft fork
(A)
and i ts matchi ng synchro sl eeve
(B).
l f the
cl earance exceeds the servi ce l i mi t, go to step 2.
Standard: 0.35 0.65 mm {0.014 0.026 i n.)
(0.039
i n.)
2. Measure the thi ckness of the shi ft fork fi noers.
.
l f the thi ckness of the shi ft forkfi nger i s l essthan
the standard, repl ace the shi ft fork wi th a new
one.
.
l f t het hi ckness of t he shi f t f or kf i nger i swi t hi n
the standard. repl ace the synchro sl eeve wi th a
new one.
Standard:
1-2 Shi ft Fork: 7.4-7.6 mm
(0.29
0.30 i n.)
3-4. 5-6, Reverse Shift Fork:
6.2 6.i [ mm
10.2i + 0.25 i n.]
3. Measure the cl earance between each shi ft fork,
reverse shi ft pi ece and shi ft arm A. l f the cl earance
10.008-0.024 i n.)
4. Measure the wi dth ofthe shi ft arm A.
.
l f t hewi dt h of t he shi f t ar m Ai s l esst hant he
servi ce l i mi t, reDl ace the shi ft arm A wi th a new
one.
.
l f t hewi dt h of t heshi f t ar m Ai swi t hi nt heser vi ce
l i mi t, reol ace the shi ft fork or the reverse shi ft
pi ece wi th a new one.
{0.661 0.669 i n.}
(0.657
i n.)
(cont' d)
13-47
Shift Forks Clearance Inspection
(cont'dl
Measure the cl earance between the 1-2 shi ft l ever
and each shi ft fork and shi ft
pi ece. l f the cl earance
Standard: 0-0./r mm
(0-0.016
i n.l
(0.020
in.)
I . 2 SHI FT FORK
1-2 SHIFT PIECE
13-48
SHIFT PIECE
6. Measur et hewi dt h of t he 1- 2 shi f t l ever .
.
l f t hewi dt h of t he 1- 2 shi f t l ever i s l esst hant he
servi ce l i mi t, repl ace the 1-2 shi ft l ever wi th a
new one.
.
l f t hewi dt h of t he 1- 2 shi f t l ever i swi t hi nt he
servi ce l i mi t, repl ace the shi ft fork or shi ft pi ece
wi th a new one.
Standard: 17.0
-
17.2 mm {0.669-0.677
i n.)
(0.665
i n.)
REVERSE
Shift Forks Disassembly/Reassembly
Pri or to reassembl i ng, cl ean al l the parts i n sol vent, dry them, and appl y l ubri cant to any contact
parts.
1. 2 SHI FT FORK
3-, 1SHI FT PI ECE
x 22 SPRING PIN
Repl ace.
REVEFSE SHIFT PIECE
s-6 sHtFT 3-4 SHTFT
(
!=n6.+
13-49
Synchro Ri ng and Gear Inspecti on
1. Inspect the i nsi de of the synchro ri ng
(A)
for wear.
Inspect the synchro sl eeve teeth and matchi ng
teeth on the synchro ri ng
(B)
for wear
(rounded
off).
Inspect the synchro sl eeve teeth
(C)
and matchj ng
teeth on the gear for wear
(rounded
off).
@"
I
I
GOOD WORN
t l
WORN
\ /
GOOD
13-50
4. Inspect the
gear hub thrust surface 1A)
for wear.
Inspect the cone surface
(B)
for wear and
rougnness,
Inspect the teeth on al l gears (C)
for uneven wear,
scori ng,
gal l i ng. and cracks.
Coat the cone surface of the gear (B)
wi th oi l , and
pl ace the synchro ri ng on i t. Rotate the synchro ri ng,
maki ng sure that i t does not sl i p.
Measure the cl earance between the synchro ri ng
(A)
and
gear (B)
al l the way around. Hol d the
synchro ri ng agai nst the
gear evenl y whi l e
measuri ng the cl earance. l f the cl earance i s l ess
than the servi ce l i mi t, repl ace the synchro ri ng and
syncnro cone.
Synchro Ring-to-Gear Clearance
Standard:
5th, 6th gear: 0.75
-
1.00 mm
(0.030-
0.039 i n.)
Reverse
gear: 0.85- 1.10 mm
(0.033
0.043 i n.l
Servi ce Li mi t:0.4 mm
(0.016
i n.)
7 .
6.
8.
Double Cone Synchro-to-Gear Clearance
Standard:
O: Outer Synchro Fing to Synchro Cone
1st,2nd, gear:0.70
1.09 mm
(0.028
0.043 i n.)
3rd.4th gear:0.90
1.39 mm
(0.035
0.055 i n.)
@: Synchro Cone to Gear
l st,3rd,4th gear: 0.50 1.04 mm
2nd gear;
(0.020
0.04r i n.)
0.65 1.78 mm
{0.026 0.070 i n.l
O: Outer Synchro Ring to Gear
l st,3rd,4th gear: 0.95 1.68 mm
(0.037
0.066 i n.l
0.70
-
1.82 mm
(0.028
0.072 i n.l
2nd gear:
Service Limit:
O: 0.3 mm
(0.012
i n.)
O: 0. 3 mm { 0. 012 i n. )
O: 0.6 mm
{0.024 i n.)
o
I
Synchro Sleeve and Hub lnspection
and Reassembly
1. l nspect gear teeth on al l synchro hubs and synchro
sl eeves for rounded off corners, whi ch i ndi cate
wear .
2. Instal l each synchro hub
{A} i n i ts mati ng synchro
sl eeve
(B),
and check for freedom of movement. Be
sure to match the three sets of l onger teeth
(C) (120
degrees apart) on the synchro sl eeve wi th the three
sets of deeper grooves (D)
i n the synchro hub. Do
not i nstal l the synchro sl eeve wi th i ts l onger teel h
i n the 1sV2nd synchro hub sl ots {E) because i t wi l l
damage the spri ng ri ng.
NOTE: l f repl acement i s requi red, al ways repl ace
the synchro sl eeve and synchro hub as a set.
B
13-51
Manual Transmission
Oil Pump Glearance Inspection
1 . Measure the radi al cl earance between the i nner
rotor
(A)
and the outer rotor
(B).
l f the cl earance
exceeds the servi ce l i mi t, repl ace the
pump rotor'
lnner Rotor-to-Outer Radial Clearance
Standard: 0.14 mm 10.006 i n.l max
Servi ce Li mi i : 0.20 mm {0.008
i n.}
2. fvl easure the radi al cl earance between the outor
rotor
(B)
and the transmi ssi on housi ng
(C).
l f the
cl earance exceeds the servi ce l i mi t. repl ace the
pump
rotor.
Rotor-to-Transmission Housing Badial Clearance
(0.004
0.008 i n.l
13-52
3. Measur e t he axi al cl ear anceont he
pump
r ot or . l f
the cl earance exceeds the standard, sel ect the
appropri ate rotor for the correct cl earance from the
chart bel ow.
Rotor-to-Transmission Housing Axial Clearance
(0.001
0.003 i n.)
Outer and Inner Botor Set
Part Number Thickness
21168- PCY- 0000 9. 95 9. 97 mm
{ 0. 392 0. 393 i n. )
21169- PCY- o000 9. 93 9. 95 mm
( 0. 391
0. 392 i n. )
c 2' 1 170-PCY-0000 9. 9' l
- 9. 93
mm
( 0. 390
0. 391 i n. )
Secondary Shaft Preload Adjustment
1. I nst al l t he oi l gui de pl at e
S, shi m
( A)
and t he
beari ng outer race
(B)
on the transmi ssi on housi ng
(see
l nstal l the rear cover, then ti ghten the I mm fl ange
bol ts i n a cri sscross panern
i n several steps.
8 x 1. 25 mm
27 N.m
(2.8
kgf.m, 20 lbf.ft)
Rotate the secondary shaft i n both di recti ons to
seat the tapered rol l er beari ng.
Measure the turni ng torque ofthe secondary shaft
by rotati ng i t i n both di recti ons wi th a torque
wrench.
Standard: 1.86-2.84N' m
{19 29 kgf' cm.
16.5
-
25.2 l bf.i n)
5. l f the
prel oad
i s not wi thi n the standard, sel ect a
shi m that wi l l provi de
correct
prel oad.
Shi m
Part Number Thickness
41381-PCY-00000.90 mm
(0.0354
n.
B 41382-PCY-00000.93 mm
(0.0366
n.
c 41383-PCY-o0000.96 mm {0.0378n,
D 41384-PCY-o0000.99 mm
(0.0390
n.
E 41385-PCY-00001. 02 mm
( 0. 0402
n.
F 41386-PCY-00001. 05 mm
( 0. 0413
n.
41387-PCY-0000
' L08
mm
(0.0425
i n.
n 41388-PCY-00001. 1 1 mm
( 0. 0437
i n
41389-PCY-00001. 14 mm
( 0. 0449
i n
J 41390-PCY-00001. 17 mm { 0. 0461 i n
K 41391- PCY- 0000
'1.2O
mm 10.0472
L 41392-PCY-00001. 23 mm
( 0. 0484
n.
M 41393-PCY-00001 .26 mm
(0.0496
n.
N 41394-PCY-00001. 29 mm
( 0. 0508
n.
o 41395-PCY-00001. 32 mm
( 0. 0520
n.
P 41396-PCY-o0001. 35 mm { 0. 0531n,
o 41397-PCY-00001.38 mm
(0.0543
n.
R 41398-PCY-00001. 41 mm
( 0. 0555
i n. l
s 41399-PCY-00001. 44 mm
( 0. 0567
i n.
T 4' ]400-PcY-00001. 47 mm
( 0. 0579
i n. )
13-53
Mainshaft Thrust Clearance Adiustment
.
Mai nshaf t hol der 07GAJ' PG20110
.
Mai nshaft base 07GAJ-PG20130
1. I nst al l t he mai nshaf t assembl y i n t he cl ut ch
houst ng.
2. I nst al l t he oi l gui de pl at e M and 82 mm shi m( s)
( A)
i nto the transmi ssi on housi ng.
I nst al l t he t r ansmi ssi on housi ng ont o t he cl ut ch
housi ng, then ti ghten the 8 mm fl ange bol ts i n a
cri sscross
pattern i n several steps.
8 x 1.25 mm
27 N.m
(2.8
kgf m, 20 l bf.ft)
Attach the speci al tool to the mai nshaft as fol l ows:
.
Back-out the mai nshaft hol der bol t
(A)
and l oosen
t he t wo hex bol t s
( B) .
.
Fi t the hol der over the mai nshaft so i ts l i p i s
t owar ds t he t r ansmi ssi on.
.
Al i gn t he mai nshaf t hol der ' s l i p ar ound t he
groove at the i nsi de of the mai nshaft spl i nes,
then ti ghten the hex bol ts.
3.
4.
13-54
5. Seat the mai nshaft ful l y by tappi ng i ts end wi th a
pl ast i c hammer .
6. Thr eadt he mai nshaf t hol der bol t i n unt i l i t j ust
contacts the wi de surface of the mai nshaft base.
7 . Zerc a di al
gauge (A)
on the end of the mai nshaft.
07GAJ-PG20110
07GAJ-PG20130
Turn the mai nshaft hol der bol t cl ockwi se; stop
turni ng when the di al gauge has reached i ts
maxi mum movement. The readi ng on the di al
gauge i s the amount of mai nshaft end pl ay.
NOTE: Do not turn the mai nshaft hol der bol t more
than 60 degrees after the needl e of the di al
gauge
stops movi ng may damage the transmi ssi on.
l f the readi ng i s wi thi n the standard, the cl earance
i s correct. l f the readi ng i s not wi thi n the standard,
r echeck t he shi m t hi ckness.
Standard: 0.14
-
0.21 mm
(0.006
0.008 i n.)
9.
82 mm Shi m
Parts Number Thickness
23931-PR8-F0000. 60 mm
( 0. 0236
i n
B 23932-PR8-F0000.63 mm
(0.0248
n
c 23933-PR8-F0000. 66 mm
( 0. 0260
n
D 23934-PR8-F0000. 69 mm { 0. 0271n
E 23935-PR8-F0000.72 mm
(0.0283
n.
F 23936-PR8-F0000. 75 mm
( 0. 0295
n.
G 23937-PR8-F0000.78 mm
(0.0307
n.
n 23938-PR8-F0000. 81 mm
( 0. 0319
n,
23939-PR8-F0000. 84 mm
( 0. 0331
n,
J 23940-PR8-F0000, 87 mm
( 0. 0343
n.
K 23941-PR8-F000 0.90 mm {0.0354n.
23942-PR8-F000 0.93 mm
(0.0366
i n.
M 23943-PR8-F0000. 96 mm
( 0. 0378
i n
N 23944-PR8-F0000.99 mm
(0.0390
i n
o 23945-PR8-F0001. 02 mm
( 0. 0402
i n
P 23946-PR8-F000
' 1. 05
mm { 0, 0413 i n.
o 23947-PR8-F000 1. 08 mm { 0. 0425 i n.
R 23948-PR8-F0001. 11 mm
( 0. 0437
i n.
S 23949-PR8-F000
' 1. 14
mm
( 0. 0449
i n.
T 23950-PR8-F000 1. 17 mm
( 0. 0461
i n.
23951-PR8-F0001. 20 mm
( 0. 0472
i n.
Transmission Reassembly
.
Dri ver 07749-0010000
.
Attachment, 42 x 47 mm 07746-0010300
.
Attachment,62 x 68 mm 07746-0010500
.
Dri ver, 30 mm LD. 07946-M800000
.
Attachment, 35 mm l .D. 07965-5450500
.
Mai nshaft hol der 07PAB-0014300
.
Attachment, T2 x 75 mm 07746-0010600
.
Attachment, 40 x 50 mm LD. 07LAD-PW50601
.
Dr i ver , 40 mm 1. D. 07746- 0030100
.
Fl ange hol der 07RAB- T84010B
.
Hol der handl e, 07JAB-0010204
Transmission Housing Installation
NOTE: Pri or to reassembl i ng, cl ean al l the parts
i n
sol vent, dry them, and appl y l ubri cate to any contact
surfaces.
1. I nst al l t he oi l seal
( A)
usi ng t he speci al t ool s.
Instal l the rel ease beari ng gui de (A),
the cl utch
r el ease hanger
( B) ,
r el ease hanger spr i ng
( C) ,
and
the breather ol ate
(D).
(cont' d)
2.
,,1<
D
,,
p\
'
)\d.
0
4.0-1t.5 mm
10. 16 0. 18 i n. l
1'3-55
(cont'd)
Instal l the thrust washer
(A)
and 64 mm spri ng
washer
(B).
69 N.m
(7.0
ksf m, 51 lbf.ft)
l nstal l the reverse i dl er gear (C),
mai nshaft,
countershaft, and shi ft fork assembl i es
(D)
wi th the
snap ri ng
pl i ers,
and set the 68 mm snap ri ng
(E)
i nto the
groove
ofthe countershaft beari ng.
NOTE: Check that the snap ri ng i s securel y seated
i n the groove of the countershaft beari ng.
Standard:0-6.93 mm
(0
-0.273
i n.,
Appl y l i qui d gasket (P/N
08718-0001) to the threads
of the 34 mm seal i ng bol t
(F),
then i nstal l the
34 mm seal i ng bol t.
4.
13-56
6. I nst al l t he 1- 2 shi f t
pi ece.
l nstal l the sel ect return spri ng
(A)
and the 8x40
pi n
(B)
onto the transmi ssi on. then i nstal l the i nterl ock
(c).
7.
Instal l the shi ft arm A by al i gni ng the i nterl ock
fi nger and the shi ft fork grooves.
9. I nst al l t heshi f t r od
( A)
i nt ot he i nt er l ock assembl y
(B)
wi th i t recessed hol e
(C)
toward the top of the
transmi ssi on {D), then i nstal l the 5 x 25 spri ng pi n
( E
) .
10.Instal l the outer si de
i nst al l t he i nner si de
' l -2
shi ft l ever
(A)
fi rst, then
1-2 shi ft l ever
(B).
1 1 .
il4
N m {4.5 kgf m, 33 lbf.ftl
I nst al l t he 8 x 63
pi n ( C) ,
t hen t i ght en t he 10 mm
fl ange bol t
(D),
t -
-
I
-
. l
\ t . t
12. Instal l the needl e beari ng
(A),
reverse gear
shaft
(B),
thrust washer
(C),
and reverse shaft hol der
(D),
then
i nstal l the washer and 8 mm fl ange bol t.
34 N. m {3. 5 kgl . m,
25 rbt.ftt
13. I nst al l t heoi l gui det ube ( A)
and magnet ( B) .
r
14, I nst al l t he oi l gui de pl at e M and 82 mm shi m( s)
( A) .
I
)t-^
{cont' d}
13-57
t 5 .
(cont'd)
Instal l the oi l
pump
strai ner
(A),
sucti on gui de (B),
and ci r cl i p
( C) .
16. l nst al l t he 16x26x7 mm oi l seal
( A)
as shown.
c
A'
-----_
\
(
--"\1^\
/ l - \
\l-
13-58
18.
17. I nst al l t he oi l gui de pl at e
S and shi m { A) , t hen
i nst al l t he bear i ng out er r ace
( B)
usi ng t he speci al
tool s as shown.
07749-0010000
07746-0010500
Remove the di rty oi l from the transmi ssi on housi ng
seal i ng surface. Appl y l i qui d gasket (P/N
08718-
0001) to the seal i ng surface. Be sure to seal the
enti re ci rcumference of the bol t hol es to prevent oi l
r eaKage.
NOTE:
.
l f 5 mi nutes have passed after appl yi ng l i qui d
gasket, reappl y i t and assembl e the housi ngs.
.
Al l ow i t to cure at l east 20 mi nutes after
assembl y before fi l l i ng the transmi ssi on wi th oi l .
- -
Li qui d gasket
19. I nst al l t he 14 x 20 dowel
pi ns ( A) ,
t r ansmi ssi on
housi ng
( B) .
I mm f l ange bol t s, t r ansmi ssi on
hanger
( C) ,
and t r ansmi ssi on hanger A
( D) .
20.
21. Appl y l i qui d gasket (P/N
of the set screws
(A),
then i nstal l the steel bal l s and
spnngs,
A
C 22 N. m
(2. 2
kgt . m, 16 l bf f t l
2 5 N m \ 2 5 Nm \ , - L t 2 7 . 1 mm
i??Ji';,''
\no@t'
l88iri'
----ffi *._1
_
--.
rb
-.,
-
"-----..-l
q-
A
22.
23.
2 2 N m
l2.2 kgt .n,
16 rbf.ft)
39 N. m {4. 0 kgf . m, 29 l bf . f t l
L: 27. 4 mm
( 1. 08 i n. )
F
22 N. m
l2.2 kgl m,
16 tbf.ft)
L: 23 mm
{0. 91 i n. )
(Bl ack)
{2. 2 kgf . m. 15l bt . f t )
Instal l the washer
(B)
and back-up l i ght swi tch
(C).
l nst al l t he washer s 1A) , dr ai n
pl ug ( B) ,
f i l l er pl ug ( C) ,
12 mm dr ai n pl ug
{ D) , and
pi ck- up sensor
( E)
wi t h a
new O-ri ng.
24.
I {l.s t<gt.m,
6 x Lo mm
33 tbf.ftl
12 N. m 11. 2 kgf . m. 8. 7 l bf . f t )
of the set screws
(F),
then i nstal l the steel bal l s and
spnngs.
{cont' d)
@\
13-59
{cont'dl
Instal l the oi l
pump
outer rotor S, steel bal l
(A),
spr i ng
{ B) , oi l pump pl at e ( C) .
12 N. m
(1. 2
kgf . m, 8. 7 l bt . f t l
Instal l the secondary dri ve gear (A)
on the
countershaft usi ng the speci al tool as shown.
26.
13-60
27. Instal l the needl e beari ng
(A)
on the countershaft
usi ng the speci al tool as shown.
_
1i l x 1. 5 mm
, y' L. 40 mm { 2. 76 i n. l Ml N.
HEX NUT
07965-SA50500
28. Instal l the spri ng washer and 29 mm l ocknut.
,j,i
j'i-r.
t
t-.
F
-''--
i
!_
,$
29. Instal l the speci al tool on the mai nshaft, then
ti ghten the 29 mm l ocknut
(l eft-hand
threads) to the
speci fi ed val ue.
Torque 172- 0
--
172 N.m
( 17. 5- 0- * 17. 5k 91. m,
127- o
-
127 lbf.ttl
30. Stake the 29 mm l ocknut tab i nto the
groove.
31. Instal l the oi l
pump gear
and oi l
pump gear shaft.
(cont' d)
c
f=l
r.l
Y
fF,h
f t f f i i
i
. --
--:: -:)'--
I
,
l / +. : .
r r '
i - @
u,:l]*?,i'i:
.-.==l
,1
.1-'=1
:.
13-61
(cont'dl
Rear Cover Installation
NOTE: Pri or to reassembl i ng, cl ean al l the parts i n
sol vent, dry them, and appl y l ubri cate to any contact
su rfaces.
1. I nst al l t he bear i ng out er r ace
( A)
tool s as shown.
I nst al l t he shi m and t he bear i ng out er r ace i nt o t he
rear cover usi ng the speci al tool s as shown.
I
/A\
v
13-62
3. Instal l the secondary shaft assembl y i nto the rear
cover,
Instal l the new bal l beari ng
(A)
usi ng the speci al
t ool s and ol d bear i ng
( B) .
5. I nst al l t he oi l seal
( Al
usi ng t he speci al t ool s.
49-0010000
il6-0010300
07LAD-PW50601
l nst al l t he compani on f l ange
( A)
tool as shown.
6.
00
4. 5-5. 0 mm
7. I nst al l t he O- r i ng
( A) ,
back- up r i ng
( B) ,
spr i ng
washer
(C),
and 27 mm l ocknut
{D).
I nst al l t he speci al t ool on t he compani on f l ange,
then ti ghten the 27 mm l ocknut the to the speci fi ed
vat ue.
Torque 162- 0
-*
162 N' m
( 16. 5- * 0- * 16. 5kgf . m.
119-- 0
-*
119| bi .ft)
OTRAB-TB4O1OB
8.
-----...',..
07JAB-001020A
{cont' d)
13-63
(cont'd)
9. Stake the 27 mm l ocknut tab i nto the oroove.
10. Instal l the shi ft rod pi pe
and O-ri ngs.
I
R
t l
l l
!
t l
l l
v
'.1
- l . .
J
''i
,.
.')
13-64
' 11,
Remove the di rty oi l fromthe rear cover seal i ng
surface. Appl y l i qui d gasket (P/N
08718-0001) to the
seal i ng surface. Be sure to seal the enti re
ci rcumference of the bol t hol es to
prevent
oi l
r eaKage.
NOTE:
.
l f 5 mi nutes have passed
after appl yi ng l i qui d
gasket,
reappl y i t and assembl e the housi ngs.
.
assembl y before fi l l i ng the transmi ssi on wi th oi l ,
- -
Liquid gasket
Instal l the 14 x 20 dowel pi ns (A),
rear cover
assembl y
(B),
harness bracket
(C),
harness cl amp
{ D) , and 8 mm f l ange bol t s.
12.
R F
E E
13. Ti ghten the 8 mm fl ange bol ts i n a cri sscross
8 x 1. 25 mm
27 N.m {2.8 kgf.m,20l bf ft)
14. Lower the shi ft rod
(A),
then i nstal l the shi ft arm B
(B),
spri ng washer
(c),
and 8 mm speci al bol t.
15. I nst al l t he shi f t l ever housi ng.
6 x 1 . 0 mm
9. 8 N. m
(1. 0
kgt , m. 7. 2l bt . f t )
13-65
Transmi ssi on Instal l ati on
1. I nst al l t he t r ansmi ssi on r ear mount l Ai .
10 x 1. 25 mm
38 N.m (3.9
kgf.m.28l bf.ft)
Check the two dowel pi ns
are i nstal l ed i n the cl utch
housi ng.
Appl y super hi gh temp urea grease (P/N
08798-
9002) to the rel ease fork {A), rel ease hanger
(B),
and r el ease bear i ng gui de ( C) .
I nst al l t he r el ease
f or k i nt o t he openi ng i n t he cl ut ch housi ng.
{P/ N 08798-9002}
13-66
4. Pul l t he r el ease f or k
( A)
out unt i l i t st ops. t hen
wedge a shop towel
(B)
between the rel ease fork
and cl utch housi ng to hol d the rel ease fork i n pl ace.
6.
B
Pl ace t he t r ansmi ssi on on a t r ansmi ssi on
j ack,
and
r ai se i t t o t he engi ne l evel .
l nstal l the three upper transmi ssi on mounti ng bol ts.
12 x 1.25 mm
64 N.m
(6.5
kgf m. 47 lbt ftl
7. I nst al l t he wi r e har ness
( A) t o
t he t r ansmi ssi on,
then connect the Di ck-uo sensor connector
(B).
-
r
ar'-] I
8. Rai se the transmi ssi on, then i nstal l the three
transmi ssi on rear mount bol ts.
10 x 1. 25 mm
38 N. m
(3. 9
kgf . m, 28 l bf . f t )
9. Pl ace a fl oor
j ack
under the front subframe and the
engi ne mounti ng sti ffener, and rai se i t to the frame.
SPECIAL BOLTS
Repl ace.
14 x 1. 5 mm
1' t 6 N. m
(11. 8 ksf . m, 85. 3 l bf . f t )
. ' . . . / . j
SPECIAL BOLTS
Repl ace.
12 x 1. 25 mm
59 N.m 16.0 kgf.m, 43 lbf.ft)
10. Ti ghten thefourmounti ng bol ts, and i nstal l the two
center mounti ng bol ts.
11. Instal l the fi ve l ower transmi ssi on mounti ng bol ts.
10 x 1.25 mm
12x 1.25 mtn
64 N. m {6. 5 kgf m. 47 l bt f t )
(cont' d)
13-67
1 t
t J ,
Transmission Installation
(cont'd)
Remove the shop towel , and i nstal l the rel ease fork
onto the rel ease hanger,
Appl y super hi gh urea greese (P/N
08798-9002)to
the end of the sl ave cvl i nder
push
rod
(A).
Instal l
t he sl ave cvl i nder
( B)
and t he r el ease f or k boot
( C) .
{P/N 08798-9002)
ria.
(P/N
08798-90021
14. Instal l the four shi ft boot hol der mounti nq bol ts.
l
6 x 1 . 0 mm
9. 8 N m
(1. 0
kgf . m, 7. 2 l bf . f t l
'..ar.'.-
. :a,a:a,:--.
13-68
15.
t o.
Instal l the
propel l er
shaft
(see page 16-18).
Instal l the
gasket
{A), exhaust mani fol d
(B),
and the
exhaust mani fol d bracket
(C).
SELF.LOCKING NUT
Repl ace.
8 x 1. 25 mm
31 N.m 13.2 kgt.m.
23 rbf.ftl
Instal l the gaskets (A)
and three way catal yti c
converter
(TWC) (B).
17.
SPECIAL BOLT
Repl ace.
8 x 1. 25 mm
22 N. m
(2. 2
ksf m, 16l bl . f t l
SELF.LOCKING NUT
Repl ace.
10 x 1. 25 mrn
33 N. m {3. 4 kgf . m, 25 l bf f t l
18. Instal l the wi re harness
(A)
onto the transmi ssi on,
then connect the heated oxygen sensor
(H02S) (B),
secondary heated oxygen sensor
(secondary
HO2S)
{C),
and the back-up l i ght swi tch
(D)
connectors.
x 1. 25 mm
24 N. m
{2. 4 kgf . m.
17 rbf.ft)
19. l nstal l the i ntake mani fol d bracket
(A)
l ower
mounti ng bol t, then l nstal l the wi re harness
(B)
on
the i ntake mani fol d bracket.
10 x 1. 25 mm
, t l
N. m
14. 5 kgf . m.
33 tbt.ft)
21
20. Reconnect the torque sensor 3P connector
(A),
and
i nst al l t he wi r e har ness cl amp
( B) .
Reconnect the 2P connector
(C)
to the steeri ng
gearbox (D).
I nst al l t he spl ash shi el d.
(cont' d)
13-69
Transmission lnstallation
(cont'd)
23. Connect the TDC1
(A)
and TDC2
(B)
sensor
connectors.
Instal l the upper i ntake mani fol d bracket mounti ng
bol t
(A)
and upper starter motor mounti ng bol t
(B).
Connect the hose
(C)
to the sucti on varve.
24.
A
8 x 1,25 mm
22 N.m
l2.2 kgl n,
16l bl m)
B
10 x 1.25 mm
44 N.m
(,t.5
kgf.m,33 lbt.ftl
13-70
25. Instal l the heat shi el d.
6 x 1 . 0 mm
9. 8 N. m
(1. 0
kgf . m, 7. 2l bf . f t l
I nst al l t he exhaust mani f ol d cover.
8 x 1. 25 mm
22 N. m {2. 2 kgf . m, 16l bf . f t l
27. Instal l the Ay' C compressor, then connect the 1 P
connecror.
10 x
' 1. 25
mm
29.
Instal l the al ternator and the al ternator-compressor
bel t
(see page 4-25).
Connect the steeri ng
j oi nt (A)
by al i gni ng the
reference marks {B).
4 4 N m
(4. 5 kgt . m,
33 tbf.ft)
8 x 1.25 mm
22N rn
(2.2
kgf.m, 16l bf.ft)
' .
.l
.
..t,'
. .
- . . , r
30. I nst al l t he ai r cl eaner housi ng assembl y.
6 x 1 . 0 mm
12 N.m 11.2
kgf.m,8.7 l bf.ft)
31. Instal l the shi ft l ever spri ng and the shi ft l ever.
6 x 1 . 0 mm
9. 8 N. m
{1. 0 kgf . m,
7.2 tbt.ftl
@
{cont' d)
13-71
Transmission Installation
(cont'd)
32. Instal l the shi ft boot and the boot hol der.
Instal l the center consol e
(see page
20-76).
Instal l the shi ft l ever knob, and ti ghten the l ocknut.
10 x 1. 25 mm
9 N. m 10, 9 kgf . m,
7 tbf.ftl
13-72
35.
36.
37.
38.
39.
40.
Instal l the battery. Connect the
posi ti ve (+
) cabl e
fi rst, then the negati ve
(
) cabl e to the battery.
Check the transmi ssi on fl ui d {see
page l 3-3).
Test-dri ve the vehi cl e.
Check the cl utch operati on.
Check the transmi ssi on for noi se and smooth
operatron.
Check the front wheel al i gnment
(camber
angl e.
caster angl e, and front toe)
(see page 18-5).
Transaxle
Rear Differential
Soeci al Tool s . . . . . . . . . . . . . 15-2
Precautio ns for Torsen Type
Li mi t ed Sl i p Di f f erent i al
(LSD)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-3
Torsen Type Li mi t ed Sl i p
Di f f erent i al
(LSD)
Operat i on Check . . . . . . . . . . . . . . . . . . . . . . . . . 15-3
Syst em Descri pt i on . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-4
Di f f erent i al Oi l I nspect i on and Repl acement . . . . . . . . . . . . . 15-6
Di f f erent i al Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 15-7
Di f f erent i al Case Assembl y Removal and
I nst al l at i on . . . . . . . . . . . . . 15-9
Oi l Seal Repl acement . . . . . . . . . . . . . . . . . . . . . . . . . 15- 10
Backl ash l nspect i on . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 11
Di f f erent i al Di sassembl y . . . . . . . . . . . . . . . . . . . . 15-12
Di f f erent i al Reassembl v . . . . . . . . . . . . . . . . . . . . . 15-18
Di f f erent i al I nst al l at i on . . . . . . . . . . . . . . . . . . . . . . . 15-26
Di f f erent i al Mount Reol acement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-29
Rear Differential
Speci al Tool s
19
lz
I
@
I
,9
tFfl'
15-2
Ret. No. Tool Number Description Qtv
(t
@
@
@
@
@
@
ao
o
07JAD-P190100
07JAB-001020A
07LAD-PW50601
07MAC-S100200
07MAD-PR90100
07NAD,PX40100
OTRAB-TB4O,1OB
07725-0030000
07746-0030100
07746-0030300
07749-0010000
1
1
l
l
i
i
Oi l Seal Dri ver
Hol der Handl e
Attachment, 40 x 50 mm l .D.
Bal l Joi nt Remover. 28 mm
Attachment, 45 x 55 mm l .D.
Compani on Fl ange Hol der
Uni versal Hol der
Dri ver, 40 mm l .D.
Dri ver
Precautions for Torsen Type
Limited Slip Differential
(LSD)
.
The Torsen di fferenti al s are mechani cal l i mi ted sl i p
di fferenti al s whi ch del i ver the avai l abl e Dower to the
wheel s and axl es wi th the most gri p or resi stance as
the engi ne torque output i ncreases.
.
Avoi d repai r procedures that requi re the engi ne
runni ng wi th one rear wheel rai sed; such as an on-
car-wheel bal ancer.
.
Do not tow the vehi cl e wi th the rear wheel s on the
g rou no.
.
Never di smantl e any
part
ofthe di fferenti al other
than ri ght and l eft tapered rol l er beari ngs.
.
To opti mi ze the Torsen di fferenti al s, equi p your
vehi cl e wi th rear ti res of the same brand. the same
si ze, and wi th even wear.
Torsen Type Limited Slip
Differential
(LSDI
Operational Check
The Torsen type l i mi ted sl i p di fferenti al
(LSD)
di stri butes opti mum power between the two dri vi ng
axl es accordi ng to the di fference i n torque demanded
by the dri vi ng wheel s. U nder no ci rcumstances shoul d
the engi ne be started wi th ei ther wheel rai sed off the
ground,
such as usi ng an on-car-wheel bal ancer or
when transporti ng the vehi cl e i n the event of acci dent.
1. Set the parki ng
brake, and bl ock the rear wheel s.
2. Rai se the rear ofthe vehi cl e, and make sure i t i s
securel y supported.
3. Wi th the engi ne off. shi ft the transmi ssi on i nto 1st
gear, and rel ease the
parki ng
brake.
4. Rotate ei ther rear wheel by hand, and check that
the other wheel rotates i n the oDDosi te di recti on.
Check both wheel s.
5. l f the opposi te rear wheel does not rotate, or i f you
cannot spi n t he r ear wheel s at al l , t he l i mi t ed sl i p
di fferenti al i s faul ty and shoul d be repl aced.
15-3
Rear
Differential
System Description
The vehi cl e uses the Torsen type l i mi ted sl i p di fferenti al
(LSD)
whi ch i s rubber mounted to the sub-frame
Construct'ron
.
The Torsen type LSD assembl y consi sts of the two si de gears, ei ght
pl anetary gears, three si de washers, tvvo center
washers, a gear case cover and a
gear case.
.
The pl anetary gear consi sts of the short and l ong
pl anetary gears, and the l ong
pl anetary gear meshes hori zontal l y
wi th the si de gear. The two
pl anetary gears mesh wi th the si de
gears at both ends.
.
The
pl anetary gears are housed i n the
pockets of the gear case.
.
The l eft and ri ght output shafts are engaged wi th the si de
gears
.
TheTor sent ype LSDassembl y i s a non- ser vi ceabl e
par t except t het aper ed r ol l er bear i ngs. l f t heTor sent ype( LSD)
assembl y i s faul ty, i t must be repl aced as an assembl y.
POCKETS
GEAR
CASE COVER
SIDE WASHEB
tr
15- 4
Operation
.
Strai ght-road dri vi ng
The di fferenti al carri el and gears rotate together as a uni t when both wheel s rotate at the same speed. Turni ng efl ort
from the fi nal dri ven gears
are di rectl v transmi tted to both wheel s.
.
When roundi ng a curve
When the vehi cl e rounds a curve, the di fferenti al al l ows the outer wheel to rotate a l i ttl e faster than the Inner wheel .
When thi s takes pl ace,
the short and l ong pi ni on gears rotate, and wal k around the si de gears i n the di recti ons
shown l f, for exampl e, the ri ght shaft i s rotated i n a countercl ockwi se d i recti on wi th the di fferent
j al
carri erhetd
stati onary, the force i s transmi tted through the ri ght si de gear,
short pi ni on gears
and l ong pi ni on gears
to the l eft
si de gear,
causi ng the l eft shaftto rotate i n a cl ockwi se di recti on. Thi s al l ows the outerwheel to tua ao.".,."a
t han t he i nner wheel when t he vehi cl e goes
ar ound a t ur n.
tt Rotati on of the gear
I
Gear operati on by
thrust torque
t2)
( 1t
SIDE
WASHER
SIDE
WASHER
CENTER
WASHER
SIDE
WASHER
i r Rot at i on of t he gear
When l i mi ti ng di fferenti al acti on
The l i mi ted sl i p di fferenti al acts to l i mi t the di fferenti al acti on when ei ther wheel sl i ps on i ce or snow or on rurns.
Thi s i s done by usi ng the fri cti on created between each gear
and di fferenti al carri er:
(1)
The pi ni ons
are forced agai nst the di fferenti al carri er by the force as they are rotated and repel l ed outward.
(2)
The ends of the pi ni on gears
are hel d fi rml y agai nst the di fferenti al carri er due to the si de thrust from the
hel i cal l y cut gear s.
l2l
t
Gear operati on by
tn rusl torque
Si ower
CENTER
WASHER WASHER
Wi th the pi ni on gears l ocked, the torque appl i ed to the sl i ppi ng wheel i s reduced and the torque del i vered to the
other wheel i s i ncreased.
PI NI OR GEARS
PINIOR GEARS
15-5
Rear Differential
Differential Oil Inspection and Replacement
l . Wi th the vehi cl e on l evel
ground, i nspect the
di fferenti al oi l wi th engi ne OFF.
Remove the oi l fi l l er
pl ug (A)
and seal i ng washer
(B),
then check the condi ti on of the oi l , and make
sure the oi l i s at the
proper l evel
(Cf,
The oi l l evel must be up to the fi l l hol e. l f i t i s bel ow
the hol e, add the recommended oi l unti l i t runs out,
then rei nstal l the oi l fi l l er pl ug wi th a new seal i ng
washer ,
l f the dl fferenti al oi l i s di rty, remove the drai n
pi ug
( D) ,
and dr ai n t he oi l .
3.
4.
15-6
5. Cl ean t he dr ai n
pl ug, t hen r ei nst al l wi t h a new
washer , and r ef i l l t he di f f er ent i al wi t h t he
recommended oi l to the Droper l evel .
Oi l capaci ty
0.74 0
(0.78
US
$),
at oi l change
O.77 A
Q.A1US
qt). at overhaul
Recommended oil
Hypoid gear oil
API Classification GL5 or GL6.
Viscosity: SAE # 90
6. Rei nst al l t he oi l f i l l er
pl ug wi t h a new washer .
Differential Removal
Bal l
j oi nt
remover,2S mm 07N4AC-S100200
1. Make a reference marks across the
propel l er
shaft,
the transmi ssi on, and the rear di fferenti al , then
remove the propel l er
shaft
(see page
16-17).
2. Remove the cotter
pi n
from the l ower arm bal l
j oi nt
castl e nut, and remove the nut.
NOTE:
.
To avoi d damagi ng t he bal l j oi nt , i nst al l a hex nut
on to the threads of the bal l
j oi nt.
.
Be careful not to damage the bal l
j oi ntbootwhen
i nstal l i ng the remover,
07MAC-S100200
Separate the bal l
j oi nt
from the l ower arm wi th the
speci al tool
(see page 18- 10).
Remove the ABS sensor harness from the upper
ar m.
F1
'w
4
4.
\ l ' ' i i
5. Make a reference marks
(A)
across the i nboard i oi nt
(B)
and the rear di fferenti al
(C).
Remove the si x i nboard
j oi nt
mounti ng bol ts
(D)
and nuts
(E),
then remove the i nboard
j oi nl
from
the rear di fferenti al .
Remove the rear suspensi on sti ffener
(A).
6.
7.
(cont' d)
,,"f
.3.
15-7
Rear Differential
Diff erential Removal
(cont'd)
8. Remove the cani ster cover.
10.
Pl ace a fl oor
j ack
under the rear di fferenti al
Remove the four di fferenti al mount bracket B
mountang nuts.
t r . \ ' . . - -
,af .--:=
15-8
1 1. Remove the four di fferenti al mount A mounti ng
bol ts,
' 12.
Lower the rear di fferenti al onthefl oorj ack.
Remove the ri ght and l eft di fferenti al mount
bracket A from the di fferenti al
(see page 15-29).
t J .
Differential Case Assembly Removal and Installation
1. Remove the output shafts {A) from the di fferenti al
case assembl y usi ng t he pr y
bar s
( B) .
2. Remove the ten mounti ng bol ts i n a cri sscross
pattern
an several steps, then remove the
di fferenti al case assembl v.
3. Remove the di rt and oi l from the seal i ng surfaces.
08718-0001) to the seal i ng
surface. Be sure to seal the enti re ci rcumference of
the bol t hol es to prevent
oi l l eakage.
NOTE:
.
l f 5 mi nutes have passed
after appl yi ng l i qui d
.
Al l ow i t to cure at l east 20 mi nutes after assem-
bl y before fi l l i ng the di fferenti al wi th oi l .
Li qui d gasket
Instal l the di fferenti al case assembl y, then torque
the 10 mounti ng bol ts i n a cri sscross
pattern
i n
several steps.
s B H g o
H T I ] US
'o1l*T,.-.',r,0*,
u
ff fiq
B
--------------S
-
15-9
Rear Differential
Oi l Seal Repl acement
Oi l seal dri ver 07JAD-P190100
1. Remove the output shafts 1A)
from the di fferenti al
case assembl y usi ng the
pry bars
(B),
2. Remove the oi l seal from the di fferenti al case
assembl y,
{r;j
15- 10
3. l nst al l t he oi l seal usi ng t he speci al t ool s as shown.
07JAO-P190100
4. Repeat steps
' l
through 3 for the other si de.
-='-./
i',
Backlash Inspection
1. Remove the output shafts and di fferenti al case
assembl y
(see page 15-9).
2. Thor oughl y cl ean t he r i ng gear
and dr i ve pi ni on
teeth, and
pai nt
the ri ng gear
teeth wi th Prussi an
Bl ue l i ght l y and evenl y.
3. Rotate the pi ni on three ful l turn i n the forward and
reverse di recti ons to produce
a contact
pattern
on
the ri ng gear.
Good contact pattern
4. Measure the backl ash of the ri ng gear,
.
Set t he di al gauge t i p at a r i ght angl e t o t he r i ng
gear
teeth.
.
Measure four poi nts
on the ri ng gear 90' apart.
.
Backl ash wi l l be wi thi n the standard i f at one
poi nt t he r i ng gear
backl ash i s wi t hi n t he
standard, mi ni mum measurement of 0.05 mm or
above and the di fference between the maxi mum
and mi ni mum measurements do not exceed 0.07
mm.
.
Both adj ustment screws must be adj usted.
For exampl e; i f you turn one adj ustment screw
one notch cl ockwi se, you must turn the other
adj ustment screw one notch countercl ockwi se.
Backl ash:
Standard: 0.09
-
0.11 mm
(0.0035
0.0043 i n. )
Mi ni mum: 0.05 mm {0.0020 i n.
I
Difference range: 0.07 mm
(0.0028
in. )
15- 11
Rear Differential
Y-
nq
,,df#w\,
X \ w \ \ , ,
w^@m
'@
f l t * \
rP,.l
\,
o
6n
I O D
t l ( }
t \ l
t i
@@A
:\g/
Differential Disassembly
Exploded View
@
\ \
;W
BGA.
(fr'a
/ / /
@ @ @ @ )
?q6)
\
(i*?
\ - \
\
\
@
A: 24 N. m 12. 4 kgf m, 17 l bf . f t )
B: 45 N. m (4. 6
kqt . m, 33 l bt . f t )
C: 22 N. m {2. 2 kgf . m,
' 16l bf . f t l
D: 75 N. m
(7. 6
kgt . m, 55l bf . f t )
E: 11 N m
(1. 1
kgf . m. 8l bt . f t )
@ BEARING CAP
@ LOCK PLATE
@ OUTPUT SHAFT
@CLIP
Repl ace.
q!)
OIL SEAL
Repl ace.
q,
FILLER PLUG
45 N. m (' r. 6
kgf . m. 33l bf . f t )
qOSEALI NG
WASHER
Reol ace.
@ DIFFERENTIAL CASE
@SEALI NG WASHER
Repl ace.
O' DRAIN PLUG
45 N m 1,1.6 kgf.m, 33 lbt.ft)
, OIL SEAL
Repl ace.
@ CLIP
Reol ace.
@ OUTPUT SHAFT
@ LOCK PLATE
@ EEARING CAP
13} BREATHER PLATE
O LOCKNUT
Reol ace.
_
127-284 N.m
(r3.0-29.0
kgf.m, 94-210 l bf.ftl
(a)DRIVE
PINION WASHER
OCOMPANION FLANGE
OoIL SEAL
,
Repl ace.
Q)SPACER
Q)TAPERED
ROLLER BEARING
q)BEARING
OUTER RACE
(!)
DIFFERENTIAL CARRIER HOUSING
OBEARING oUTER RACE
(}PINION
SPACER
Reol ace.
OTAI'ERED RoLLER BEARING
@THRUST WASHER
@
DR|VE PtNtON
(]D
ADJUSTMENT SCREW
q'AEARING
OUTER RACE
U'TAPERED ROLLER BEARING
ORING GEAR
@TORSEN LSD ASSEMBLY
@
TAPERED ROLLER BEARING
ED
BEARING OUTER RACE
Q' ADJUSTMENT SCREW
(cont' d)
15- 13
Rear Differential
(cont'dl
.
.
Compani on Jl ange hol der 07RAB' T840108
1. Careful l y cl amp the rear di fferenti al i n a vi se.
2. Pry out the output shafts
(A)
wi th the pry bars
(B).
ia..
15-14
3. Remove the output shafts.
Remove the 10 mounti ng bol ts i n a cri sscross
Dattern i n several steps, then remove the
di ff erenti al case assembl y.
4.
ar-=i
I
l t r '
I
:.=-
1.. !:.,
7. Remove the adj ustment screws
(A),
beari ng outer
races
(B),
and Torsen LSD assembl y
(C).
8. Instal l the speci al tool s on the compani on fl ange,
then remove the l ocknut
{A) and
pi ni on
washer
(B).
07RAB-TBito10B
(cont' d)
07JAB-001020A
15- 15
5. Make a mark on the beari ng cap. adj ust screw, and
di fferenti al carri er case.
ng caps. Remove the l ock pl ates and beari
a
I
e 9
b E
\ 4 -
Sl
rer $+
-u
E H e H
Y,F-'-;
ll
s
f Py. ;
\ z /
I / -
q
Rear Differential
(cont'dl
Remove the compani on fl ange usi ng a
commerci al l y avai l abl e beari ng
pul l er as shown.
Remove the dri ve
pi ni on (A)
and
pi ni on
spacer
(B)
by tappi ng on the dri ve
pi ni on wi th a pl asti c
hammer .
10.
15- 16
1 1. Remove the beari ng outer race
(A),
tapered rol l er
beari ng
(B),
thrust washer
(C),
and oi l seal
(D)
from
the di fferenti al carri er housi ng.
Remove the beari ng outer race from the di fferenti al
car r i er housi ng.
12
13. Remove the tapered rol l er beari ng
(A)
andthrust
washer
(B)
from the dri ve
pi ni on (C)
usi ng a
commerci al l y avai l abl e beari ng separator and a
Dress as snown.
Remove the tapered rol l er beari ngs from the
Torsen LSD assembl y usi ng a commerci al l y
avai l abl e bear i ng pul l er as shown.
14.
i i I i ]
16.
15. Remove the ten mounti ng bol ts i n a cri sscross
pattern i n several steps, then remove the ri ng gear.
Remove the breather pl ate (A),
fi l l er pl ug (B),
drai n
pl ug ( C) ,
and seal i ng washer s.
#\^
(cont' d)
15-17
Rear Differential
(cont'd)
17. Remove t he oi l seal s.
15- 18
Differential Reassembly
.
Attachment, 40 x 50 mm l .D. 07LAD-PW50601
.
Dr i ver , 40 mm 1. D. 07746- 0030100
.
Attachment,30 mm l .D. 07746-0030300
.
At t achment , 45 x 55 mm l . D. 07MAD- PR90100
.
Dri ver 07749-0010000
.
Attachment, TS x 80 mm 07NAD-PX40100
.
Fl ange hol der 07RAB- T840108
.
Hol der handl e 07JAB-001020A
.
Uni versal hol der 07725-0030000
.
Oi l seal dri ver 07JAD-PLgo100
1. Appl y Hondal ock 1
(P/N
08713-0001)to the surface
of t he r i ng
gear and 10 mount i ng bol t s
Hondalock 1
I nst al l t he r i ng gear . t hen t i ght en t he 10 mount i ng
bol ts i n a cri sscross
pattern
i n several steps.
2.
o
C
(a\
:<-4,/
-.--_../
r .
c , / . .
t J . ' - - 1 -
" - 1 ' 1
e - - 9
3. Instal l the tapered rol l er beari ng usi ng the speci al
tool s and a Dress as shown.
l nstal l the standard thrust washer 3.47 mm {0.1366
i n.)
(A)
onto the dri ve
pi ni on (B).
Then i nstal l the
tapered rol l er beari ng {C) usi ng the ol d
pi ni on
sDacer {D) and speci al tool s as shown.
4.
5. Instal l the beari ng outer races {A)
i nto the
di fferenti al carri er housi ng usi ng the speci al tool s
as shown,
(cont' d)
\
15- 19
Rear Differentaal
(cont'd)
6. Appl y l ubri cant to the tapered rol l er beari ng, then
i nstal l the dri ve pi ni on and pi ni on spacer i nto the
di fferenti al carri er housi ng.
7. Appl y l ubri cant to the tapered rol l er beari ng, then
i nstal l the l apered rol l er beari ng and thrust washer
(A)
usi ng the speci al tool s whi l e hol di ng the dri ve
pi ni on ( B) .
46-0030100
07746-0030300
15-20
8. I nst al l t he oi l seal usi ng t he compani on f l ange and
soeci al tool as shown.
46-0030100
9. Appl y mol ybdenum grease to the surface end of
t he compani on f l ange, t hen i nst al l t he compani on
fl ange, dri ve pi ni on washer. and l ocknut.
, t V. ,
10. I nst al l t he speci al t ool t o t he compani on f l ange,
then ti ghten the l ocknut to 20 N.m
(2.0
kgf.m,
14 tbf.ft).
07RAa-TB40t0B
Rotate the dri ve oi ni on several ti mes to assure
proper
tapered rol l er beari ng contact. Measure the
dri ve pi ni on turni ng torque.
1
' I.
'-.'--
-.
/
,..'it .
'. i
ir
Li'
|
.:"1
'
'i-r
12. Ti ght en t he l ocknut t o 127 N. m
( 13. 0
kgf . m.
94 l bf.ft), then remove the sDeci al tool .
07RAB.TB4O1OB
Rotate the dri ve oi ni on several ti mes to assure
proper tapered rol l er beari ng contact. Measure the
dri ve
pi ni on
turni ng torque.
'
l f the dri ve
pi ni on turni ng torque exceedsthe
standard, repl ace the di stance
pi ece.
.
l f t hedr i ve
pi ni ont ur ni ngt or que l esst hant he
standard, adj ust by ti ghteni ng the l ocknut a l i ttl e
at a ti me, but keep the torque wi thi n 127
-
284
N. m
( 13. 0
29. 0 kgf . m, 94 210l bf . f t ) . l f t hi s i s
not possi bl e, repl ace the
pi ni on
spacer.
Turning Torque:
0.88 1.37 N.m
(9.0
14.0 kgf.cm.
7.8 12. t l bf.i n) +Tp(l romstep11)
Tp: Actual measurement of dri ve
pi ni on
turni ng
torq ue
{cont' d)
15-21
Rear Differential
14.
(cont'dl
Instal l the Torsen LSD assembl y
(A),
beari ng outer
races
(B),
adj ustment screws
(C)
onto the
NOTE:
.
Rei nstal l the adj ustment screws i n thei r ori gi nal
posi ti on on the di fferenti al carri er housi ng.
.
Al i gn the threads of the adj ustment screws and
I nst al l t he bear i ng caps { A) whi l e al i gni ng bot h t he
ma rks
(B)
on the threads of the adj ustment screws
and bear i ng caps, t hen i nst al l t he mount i ng bol t s
fi ngerti ght.
t 5 .
15-22
16. Measure the backl ash of the ri ng gear.
Set the di al gauge ti p at a ri ght angl e to the ri ng
gear
teeth.
Measure four poi nts on the ri ng gear 90" apan.
Backl ash wi l l be wi thi n the standard i f at one
poi nt the ri ng
gear
backl ash i s wi thi n the
standard, mi ni mum measurement of 0.05 mm or
above and the di fference between the maxi mum
and mi ni mum measurements do not exceed 0.07
mm.
Both adj ustment screws must be adj usted.
Backl ash:
Standerd: 0.09
' -
0.11 mm 10.0035 0.0043 i n.)
Mi ni mum: 0.05 mm
(0.0020
i n.)
Difference range: 0.07 mm
(0.0028
in.)
17. Ti ghten the beari ng cap mounti ng bol ts.
18. Thoroughl y cl ean the ri ng
gear
and dri ve
pi ni on
teeth, and
pai nt
the ri ng gear teeth wi th Prussi an
Bl ue l i ght l y and evenl y.
19. Rotate the pi ni on three ful l turns i n the forward and
reverse di recti ons to produce a contact
pattern on
the ri ng gear. Duri ng thi s operati on resi stance
shoul d be appl i ed to the ri ng gear.
45 N. m {4. 6 kgt . m, 33l bf . f t l
20. Check the tooth contact, and adj ust i t i f needed.
.
Toe Contact: Use a thi nner thrust washer to
move the dri ve
pi ni on away from the ri ng gear.
.
Heel Contact: Use a thi cker thrust washer to
move the dri ve pi ni on toward from the ri ng gear.
.
Fl ank Contact: To move the ri ng gear away from
the dri ve
pi ni on, ti ghten the adj ustment screw on
the dri ve
pi ni on si de and l oosen the adj ustment
screw on the ri ng gear si de. Recheck backl ash
after adj usti ng the adj ustment screws. l f out of
speci fi cati on, adj ust as descri bed under Toe
Contact.
.
Face Contact: To move the ri ng
gear
toward the
dri ve
pi ni on, ti ghten the adj ustment screw on the
ri ng gear si de and l oosen the adj ustment screw
on the dri ve
pi ni on si de. Recheck backl ash after
adj usti ng the adj ustment screws. l f out of
speci fi cati on, adj ust as descri bed under Heel
Contact.
Correct Tooth Contact
A
Toe Contact
z7-'l\
r
-:
/
\
-'J
(cont' d)
15-23
Rear Differential
(cont'dl
Heel Contact
Flank Cont.cl
Face Contast
Part Number Thi ckness
41361-PCZ-003 3. 08 mm
( 0. 1213
n,
B 41362-PCZ-003 3. 11 mm
( 0. 1224
n.
c 41363-PCZ-003 3. 14 mm
( 0. 1236
n.
D 41364-PCZ-003 3. 17 mm
( 0. 1248
n,
E 41365-PCZ-003 3. 20 mm
( 0. 1260
n.
F 41366-PCZ-003 3. 23 mm
( 0. 1272
n.
G 41367-PCZ-003 3. 26 mm
( 0. 1283
n.
t-l 41368.PC2"003 3. 29 mm { 0. 1295n.
41369-PCZ-003 3. 32 mm
( 0. 1307
n.
41370-PCZ-003 3. 35 mm
( 0. 1319
n.
K 41371. PC2- 0033. 38 mm
( 0. 1331
n.
L 4't31 2-PCZ-003 3. 41 mm { 0. 1343n,
M 41373-PCZ-003 3. 44 mm { 0. 1354n .
41314,PCz.-003 3. 47 mm
( 0. 1366
n.
o 41375-PCZ-003 3. 095 mm
( 0. 1219
n. )
P 41376-PCZ-0033. 125 mm
( 0. 1230
n, )
o 41377
-PCZ-003
3. 155 mm
( 0. 1242
n. l
R 41378-PCZ-0033. 185 mm { 0. 1254n. )
s 4' t379-PCZ-0033. 215 mm
( 0. 1266
n. )
T 41380-PCZ-0033. 245 mm
( 0. 1278
n. )
AA 41381-PCZ-003 3. 275 mm
( 0. 1289
n. )
AO 41382.PCz.-OO33. 305 mm
( 0. 1301
n. )
AP 41383-PCZ-003 3. 335 mm
( 0. 1313
n. )
AO 41384-PCZ-003 3. 365 mm
( 0. 1325
n
AR 41385-PCZ-0033. 395 mm
( 0. 1337
n
AS 41386-PCZ-0033.425 mm
(0.' 1348
n. )
AT 41387-PCZ-0033. 455 mm
( 0. 1360
n. )
N
":
Standard
15-24
21. Rotate the Torsen LSD assembl y several ti mesto
assure
proper
tapered rol l er beari ng contact.
Measure the Torsen LSD assembl y prel oad
usi ng
t he push/ pul l gauge.
.
l f theTorsen LSD assembl y
prel oad
exceeds the
standard. adj ust by l ooseni ng the adj ustment
screws a notch at a ti me.
.
l f t heTor sen LSDassembl y
pr el oad
i s l esst han
the standard, adj ust by ti ghteni ng the adj ustment
screws a notch at a ti me.
Standard: 14
-30
N
( 1. 4- 3. 1
kgt , 3. 1 6. 8 l bf l
22. Instal l the l ock pl ates (A).
2-."1N
G)i-o;
22 N.m (2.2
kgf m, 16 lbl ft)
23. I nst al l t he oi l seal usi ng t he speci al t ool s as shown.
07JAO-P190100
24. I nst al l t he br eat her
pl at e ( A) ,
f i l l er pl ug ( B) ,
dr ai n
pl ug ( C) ,
and seal i ng washer s.
A^\
9-- 9'.
}3\
c
\..-z \.
4 5 N m
(4. 6
kgt . m,
33 rbt.ft)
25. Remove the di rty oi l from the di fferenti al case
seal i ng surface. Appl y l i qui d gasket
(P/N
08718-
0001) to the seal i ng surface.
Be sure to seal the enti re ci rcumference of the bol t
hol es to prevent oi l l eakage.
NOTE:
.
l f 5 mi nutes have passed afterappl yi ng l i qui d
.
assembl y before fi l l i ng the di fferenti al wi th oi l .
- - '
Li qui d gasket
26. l nstal l the di fferenti al case assembl y.
(cont' d)
15-25
Rear Differential
(cont'd)
Ti ghten the 10 mounti ng bol ts i n a cri sscross
24 N.m {2.4 kgf.m, 17 l bf.ft)
28. I nst al l t he cl i ps
( A)
on t he out put shaf t s, t hen i nst al l
the output shafts
(B).
27.
ili
. l l
- J . '
1 l
I
i:_ -.
15-26
\
1 .
Differential lnstallation
Instal l the ri ght and l eft di fferenti al mount bracket A
to the rear di fferenti al
(see page 15-29).
Pl ace the rear di fferenti al on the fl oor
j ack,
and
rai se i t to the mounti ng l evel .
Instal l the four di fferenti al mount bracket B
mounti ng nul s.
12 x 1. 25 mm
75 N. m (7. 6
kgf m, 55l bf f t l
_ - j
=
4. Instal l the ri ght and l eft di fferenti al mountbracketA
mounti ng bol ts.
10 x 1. 25 mm
45 N. m
(4. 6
kgf . m, 33 l bf . f t )
l nst al l t he cani st er cover.
6 x 1 . 0 mm
9. 8 N. m
{1. 0 kgf . m, 7. 2 l bf f t }
6. Instal l the rear suspensi on sti ffener,
6 x 1 . 0 mm
9. 8 N. m
(1. 0
kgf . m, 7. 2 l bf . f t )
Instal l the i nboard
j oi nts (A)
onto the rear
di fferenti al by al i gni ng the reference marks
(B).
7.
I
Repl ace.
SPECIAL BOLT
' 10
x 1. 25 mm
A
83 N m {8. 5 kgt . m, 61 l bl . f i )
(cont' d)
10 x 1. 25 mm
45Nm14. 6kgf . m,
33 tbf.ft)
15-27
Rear Differential
.a=:\
\mr{-B
69-78 N.m
6<
{7.0-8.0 kgf.m.
51-58 tbt.ftl
9, Instal l the ABS sensor harness onto the upper arm.
Differential Installation
(cont'dl
Instal l the bal l
j oi nts
onto the l ower arms
(A),
then
i nstal l the castl e nuts
(B)
and new cotter pi ns.
NOTE: Make sure the bal l
j oi nt
boot i s not damage
or cracks.
rbf.ftl
Instal l the
propel l er
shaft to the transmi ssi on and
the rear di fferenti al by al i gni ng the reference marks
( see page
16- 181.
,/__-.-'
6 x 1. 0 mm
9. 8 N. m
(1. 0
kgl . m, 7. 2
10.
15-28
Differential Mount Replacement
NOTE: l f the i nstal l i ng the rear di fferenti al and mount assembl es, ti ghten the di fferenti al mount bracket B mounti ng
nuts fi rst, then the di fferenti al mount bracket A mounti ng bol ts,
12 x 1, 25 mm
64 N.m 16.5 kst.m, 47 lbt.ftl
12 x' 1. 25 mm
75 N. m
(7. 6
kgf . m, 55l bt . f t )
10 x 1. 25 mm
4 5 N m
(4.6
kgf m,
33 tbf.ft)
DIFFERENTIAL MOUNT B
RUBBER ASSEMBLY
12 x 1, 25 mm
64 N. m
(6.5 kgf.m, 47 lbf.ftl
10 x 1 . 25 mm
45 N. m
(4.6 kgl.m,33 lbl.ft)
' 12
x 1.25 mm
64 N.m
(6.5 kgf m,47 l bf.ftl
15-29
Transaxle
Driveline/Axle
Speci al Tool s . . . . . . . . . . . . . 16-2
Dri veshaf t l nsoect i on . . . . . . . . . . . . . . . . . . . . . . . . . 16-3
Dri veshaf t s Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 16-3
Dri veshaf t s Di sassembl y . . . . . . . . . . . . . . . . . . . 16-5
Dri veshaf t s Reassembl y . . . . . . . . . . . . . . . . . . . . 16-8
Dri veshaf t s l nst al l at i on . . . . . . . . . . . . . . . . . . . . . . 16-15
Propel l er Shaf t I nspect i on . . . . . . . . . . . . . . . . . 16-16
Propel l er Shaf t Removal . . . . . . . . . . . . . . . . . . . . 16-17
Propel l er Shaf t I nst al l at i on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-18
Driveline/Axle
Speci al Tool s
T
16-2
Ref. No. Tool Number Descriotion Oly
o
n)
0TrvtAc-s100200
07xAc-001020A
Bal l Joi nt Remover , 28 mm
Threaded Adaoter. 24 x 1.5 mm
1
Driveshaft Inspection
1 .
3.
Check the i nboard boot
(A)
and outboard boot
(B)
on the dri veshaft
(C)
for cracks, damage, l eaki ng
grease, and l oose boot bands
(D).
l J any damage i s
found, reDl ace the boot and boot bands.
Turn the dri veshaft by hand, and make sure the
spl i nes
(E)
and
j oi nt
are not excessi vel y l oose.
Make sure the dri veshaft i s not twi sted or cracked;
i f i t i s, repl ace i t.
Driveshafts Removal
Bal l j oi nt remover, 28 mm 07MAC-S100200
1. Loosen the wheel nuts sl i ghtl y
2. Rai se the rear of the vehi cl e, and support i t wi th
safety stands i n the proper l ocati ons
( see page 1- 13) .
3. Remove the wheel nuts and rear wheel s.
4. Li ft up the l ocki ng tab
(A)
on the spi ndl e nuts
(B),
then remove the nut.
Remove the cotter
pi n (A)
j oi nt
castl e nut
(B),
and remove the nut.
NOTE;
.
To avoi d damagi ng t he bal l j oi nt , i nst al l a hex nut
on t o t he t hr eads of t he bal l j oi nt .
.
Be careful not to damage the bal l j oi nt boot when
i nstal l i ng the remover.
07MAC-S100200
,#-......-o
6. Separ at e t he bal l j oi nt f r om t he l ower ar m
( C) wi t h
t he speci al t ool
( see page 18- ' 10: .
(cont' d)
i " I
- 7. .
. . - ' ' . '
" . ( , ' ' :
16-3
Driveline/Axle
Driveshafts Removal
(cont'dl
7. Remove the ABS sensor harness
(A)
from the
upper ar m,
A
Make reference marks
(A)
across the i nboard
j oi nt
(B)
and the rear di fferenti al
(C).
9. Remove the si x i nboard
j oi nt
mounti ng bol ts
(D)
and nuts
(E),
then remove the i nboard
j oi nt
from
the rear di fferenti al .
Pul l the knuckl e outward, and remove the i nboard
j oi nt
from the rear di fferenti al .
' 10.
16-4
11. Pul l t he knuckl e out war d, and r emove t he
dri veshaft outboard
j oi nt
from the wheel hub usi ng
a
pl asti c hammer.
12. Remove the dri veshaft.
Driveshafts Disassembly
.
Threaded adaptet,24x 1.5 mm 07XAC-0010204
.
Sl i de hammer , commer ci al l y avai l abl e
lnboard Joint Side:
1. Remove the boot bands. Be careful nottodamage
the boot.
.
l f the boot band i s a doubl e l oop type
(A),
l i ft up
the band bend
(B),
and
push
i t i nto the cl i p
(C).
.
l f the boot band i s a l ow profi l e
type
(D). pi nch
the boot band usi ng a commerci al l y avai l abl e
boot band pi ncers (E).
Double Loop Typ
Low Profile Type
2. Make a mar k
( A)
on each r ol l er
( B)
and i nboar dj oi nt
(C)to
i denti fy the l ocati ons of rol l ers and grooves
i n the i nboard
j oi nt.
Then remove the i nboard
j oi nt
on the shop towel
(D).
Be careful not to drop the
rol l ers when separati ng them from the i nboard
i oi nt .
Make a mar k
( A)
on t he r ol l er s
( B)
and spi der
( C) t o
i denti fy the l ocati ons of rol l ers on the spi der. then
remove the rol l ers.
Remove the ci rcl i p
(D).
Make a mark
(E)
on the spi der and dri veshaft to
i denti fy the
posi ti on
of the spi der on the shaft.
Remove the spi der usi ng a commerci al l y avai l abl e
beari ng remover
(F).
(cont' d)
16-5
Driveline/Axle
7.
Driveshafts Disassembly
(cont'd)
Wrap the spl i nes on the dri veshaft wi th vi nyl tape
(A)
to
prevent
damage to the boot.
Remove the i nboard boot. Be careful not to damage
the boot.
9. Remove the vi nyl tape.
16-6
Outboard Joint Side:
1. Pry up the three tabs
(A)wi th
a screwdri ver, then
l i ft up the end of the band. Be careful not to
damage the boot.
2. Sl i de the outboard boot to the i nboard
j oi nt
si de Be
careful not to damage the boot.
3. Wi pe offthe grease
to expose the dri veshaft and
the outboard
j oi nt
i nner race.
4. Make a mark
(A)
on the dri veshaft {B) at the same
posi ti on
of the outboard
j oi nt
end
(C).
5. Careful l y cl amp the dri veshaft i n a vi se.
B
Remove the outboard
j oi nt
{A) usi ng the speci al
t ool and a commer ci al l y avai l abl e 5/ 8" x 18 sl i de
hammer
( B) .
Remove the dri veshaft from the vi se. 7.
8. Remove the stop ri ng from the dri veshaft.
Wrap the spl i nes on the dri veshaft wi th vi nyl tape
(A)
to
prevent
damage to the boot.
Remove the outboard boot and boot band
(B).
Be
careful not to damage the boot.
Remove the vi nyl tape.
10.
1 1 .
16-7
Driveline/Axle
INBOARD BOOT
clRcLlP
*/
/ B J
! i
01t /^\
v
/-1
o99 lt
,"
-
Itt
spioen
g
\
Driveshafts Reassembly
Exploded View
Use t he
grease i ncl uded
i n t he i nboard boot set .
Use t he grease i ncl uded
i n t he i nboard boot set .
--------_l
STOP RING
Repl ace.
tu@a
BANDS
-
--.1
a'-
DRIVESHAFT
t----..\
OUTBOARD JOINT
16-8
.
Boot band tool , KD-3191 or equi val ent, commerci al l y
avai l abl e
.
Boot band pi ncers, Kent-Moore J-35910 or equi val ent,
commer ci al l y avai l abl e
thi s orocedure.
Inboard Joint Side:
1. Wrap the spl i nes wi th vi nyl tape
(A)
to
prevent
damage to the i nboard boot.
l nstal l the i nboard boot to the dri veshaft, then
remove the vi nyl tape. Be careful not to damage the
i nboard boot.
Instal l the spi der
(A)
onto the dri veshaft
(B)
by
al i gni ng t he mar ks
( C)
on t he spi der and t he end of
the dri veshaft.
Fi t the ci rcl i p
(D)
i nto the dri veshaft groove. Al ways
rotate the ci rcl i p i n i ts groove
to make sure i t i s ful l y
seated.
5. Fi t the rol l ers
(A)
onto the spi der
(B)
asshown,and
note these i tems;
.
Rei nstal l the rol l ers i n thei r ori gi nal posi ti onson
the spi der by al i gni ng the marks
(C).
.
Hol d the dri veshaft poi nted up to prevent
the
rol l ers from fal l i ng off.
Pack the i nboard
j oi nt
wi th the
j oi nt grease
i ncl uded i n the new dri veshaft set.
Grease quantily
Inboardi oi nt: 150- 160 g (5.3
5.6 oz)
6.
l Jse t he
. . ?-r=.r? l- .-__--
use t ne gr ease I nci uoeo
i
i n t he i nboar d boor sel . I
(cont' d)
16-9
Driveline/Axle
(cont'd)
7. Fi t the i nboard
j oi nt
onto the dri veshaft, and note
these i tems:
.
Rei nstal l the i nboard
i oi nt
onto the dri veshaft by
( A)
on t he i nboar d
j oi nt
and
the rol l ers.
.
Hol d the dri veshaft so the i nboard
i oi nt
poi nts up
to prevent i t from fal l i ng off.
Adj ust the i nboard
j oi nt
unti l the rol l ers are i n the
mi ddl e of the
j oi nt.
Fi t the boot
(A)
ends onto the dri veshaft
(B)
and the
i nboard
j oi nt (C).
9.
16-10
front of the vehi cl e.
10. l nstal l the boot bands wi th the band end toward to
Pul l up t he sl ack i n t he band by hand.
Mark a
posi ti on (A)
on the band
' 10
14 mm
(0.4
0. 6 i n. ) f r om t he cl i p
( B) .
1 1 .
12.
13. Thread the free end ofthe band through the nose
secti on ofthe commerci al l y avai l abl e boot band
tool KD-3191 or equi val ent
(A),
and i nto the sl ot on
t he wi ndi ng mandr el
( B) .
Pl ace a wrench on the wi ndi ng mandrel of the boot
band tool , and ti ghten the band unti l the marked
spot
(C)
on the band meets the edge ol the cl i p.
Li ft up the boot band tool to bend the free end of
the band 90 degrees to the cl i p. Center-punch the
cl i p, t hen f ol d over t he r emai ni ng t ai l ont o t he cl i p,
1 4 .
t c .
17.
16. Unwi nd the boot band tool , and cut off the excess
free end ofthe band to l eave a 5
..
10 mm
(0.2
0.4
i n.)tai l protrudi ng
from the cl i p.
Bend the band end
(A)
by tappi ng i t down wi th a
nammer .
NOTE:
.
Make sure the band and cl i p do not i nterfere wi th
anythi ng and the band does not move,
.
Remove any grease remai ni ng on the
surroundi ng surfaces.
{cont' d)
's
16- 11
Driveline/Axle
(cont'dl
Outboard Joint Side:
1 . Wrap the spl i nes on the dri veshaft wi th vi nyl tape
(A)
to
prevent
damage to the outboard boot.
2. Instal l the new ear cl amp band
(B)
and outboard
boot. Be careful not to damage the outboard boot.
Remove the vi nyl tape.
Instal l the new stop ri ng i nto the dri veshaft
groove
( A) .
16-12
5. l nse rt the dri veshaft
(A)
i nto the outboard
j oi nt (B)
unti l the stop ri ng
(C)
i s cl ose to the
j oi nt.
To compl etel y seat the outboard
j oi nt, pi ck up the
dri veshaft and
j oi nt,
and drop them from about 10
cm
(4
i n.) onto a hard surface. Do not use a
hammer as excessi ve force may damage the
dri veshaft. Be careful not to damage the threaded
secti on
(A)
of the outboard
j oi nt.
7. Check the al i gnment of the
pai nt
mark
(A)
wi th the
out boar d
j oi nt
end
( B) .
Pack the outboard
j oi nt
wi th the
j oi nt
grease
i ncl uded i n l he new
j oi nt
boot set:
Grease quantity
Outboard
i oi nt:
119 129914.2 4.5o2)
9. Adj ust the l ength of the dri veshafts to the fi gure
bel ow, then adj ust the boots to hal fway between
ful l compressi on and ful l extensi on. Make sure the
ends of the boots seat i n the grooves
of the
dri veshaft and
j oi nt.
Left Driveshaft: 579 584 mm {22.8 23.0 in.l
Right Driveshaft: 624 629 mm(24.6 24.8 in.l
10.Fi t the boot
(A)
ends onto the dri veshaft
(B)
and
outboard
j oi nt (C).
(cont' d)
16- 13
Driveline/Axle
1 1 .
(cont'd)
Set the new ear cl amp band
(A)
by threadi ng the
tab
(B)
i nto hol es
(C)
of the band.
Cl ose the ear
porti on (A)
of the band wi th a
commer ci al l y avai l abl e boot band
pi ncer s
Kent-Moore J-35910 or equi val ent {B).
' t 2.
16-14
Check the cl earance between the cl osed ear
porti on
of the band. l f the cl earance i s not wi thi n the
standard. cl ose the ear Dorti on of the band farther.
14. Repeat steps 12 and 13 Jor the band on the other
end of the boot.
3.0 mm 10.r2 i n.) MAX
Driveshafts Installation
1. Pul l t he knuckl e out war d. and i nst al l t he out boar d
j oi nt
i nto the rear hub.
2. Instal l the i nboard
j oi nt (A)
i ntothe rear di fferenti al
(B)
by al i gni ng the reference marks
(C),
then i nstal l
the si x i nboard
j oi nt
mounti ng bol ts
(D)
and nuts
{E).
, o
-/ 10 x 1. 25 mn
t
83 N. m
{8. 5 kgf . m,
61 tbt.ft)
3. Instal l the knuckl e
(A)
onto the l ower arm
(B).
Be
careful not to damage the bal l
j oi nt
boot
(C).
Wi pe
off the grease
before ti ghteni ng the nut at the bal l
j oi nt.
Torque the castl e nut
(D)
to the l ower torque
speci fi cati on, then ti ghten i t onl y far enough to
al i gn the sl ot wi th the pi n hol e. Do not al i gn the nut
by l ooseni ng i t.
NOTE: Make sure the bal l j oi nt boot i s not damage
or cracks.
E =\
W
\,<
' 12
x 1. 25 mm
69-78 N. m
(7.0-8.0
kg{'m,
4s-51 rbf.ft)
Instal l the new cotter pi n (E)
i nto the
pi n
hol e, and
bend the cotter
pi n.
Instal l the ABS sensor harness
(A)
on the upper
ar m.
6 x 1 . 0 mm
9. 8 N. m,
(1. 0
kgf . m, 7. 2 l bf f t l
(cont' d)
16- 15
Driveline/Axle
Driveshafts Installation
(cont'dl
Instal l a new spi ndl e nut
(A),
then ti ghten the nut.
After ti ghteni ng, use a dri ft to stake the spi ndl e nut
shoul der
(B)
agai nst the dri veshaft.
A 1 2 x 1 . 5 mm
24 x 1.5 mm 108 N.m
245 N.m
(11.0
kgf.m,
(25.0kgt.m, 79.6l bl .ft)
'181
lbf.ftl
1.
9.
8.
Cl ean the mati ng surfaces of the brake di sc and the
rear wheel , then i nstal l the rear wheel wi th the
wheel nuts,
Turn the rear wheel by hand, and make sure the
cl earance between the dri veshaft and
ci rcumference
parts.
Check the rear wheel al i gnment, and adj ust i t i f
necessary
(see page 18-5).
16- 16
Propeller Shaft Inspection
2.
1 . Shi ft i nto neutrai
posi ti on.
Rai se the vehi cl e off the
ground, and suppon i t wi th
(see page 1-' 13).
Check the uni versal
j oi nt
boots for damage and
deteri orati on. l f the boots are damaged or
deteri orated, repl ace the propel l er shaft.
Check the
j oi nts
for excessi ve
pl ay
or rattl e. l f the
uni versal
j oi nts
have excessi ve
pl ay
or rattl e,
repl ace the
propel l er shaft.
5. l nstal l a di al i ndi cator
(A)
wi th i ts needl eonthe
center of the
propel l er shaft
(B).
6. Turn the
propel l er shaft sl owl y, and check the
runout. l f the runout exceeds the servi ce l i mi t,
repl ace the
propel l er shaft.
Runout:
i n.l
1 .
Propeller Shaft Removal
Rai se the vehi cl e off the ground,
and make sure i t' s
securel y supported.
Remove the propel l er
shaft protector.
Make a reference mark
(A)
across the
propel l er
shaft
(B)
and the transmi ssi on fl ange
(C).
4. Separ at e t he
pr opel l er
shaf t f r om t he t r ansmi ssi on.
5. l Make a reference mark
(A)
across the
propel l er
shaft
(B)
and the rear di fferenti al fl ange
(C).
Separate the
propel l er
shaft from the rear
di fferenti al , then remove the
propel l er
shaft,
't-rt,
\-
16-17
Driveline/Axle
Propeller Shaft Installation
' t .
t
Instal l the
propel l er
shaft
(A)
onto the rear
di fferenti al
(B)
(C).
NOTE: When the
propel l er shaft i s repl aced, al i gn
the whi te marks
(D)
on the new
propel l er shaft wi th
the whi te mark on the di fferenti al ,
SPECIAL BOLTS
Repl ace.
8 x 1, 25 mm
32 N. m
(3. 3 kgt m. 24l bf . f t l
l nstal l the oropel l er shaft {.A) to the transmi ssi on
(B)
(Cl .
NOTE: When the
propel l er
shaft i s repl aced, al i gn
the whi te marks
(D)
on the new
propel l er shaft wi th
t he whi t e mar k on t he t r ansmi ssi on,
SPECIAL BOLTS
Repl ace.
8 x 1. 25 mm
32 N. m {3. 3 kgf . m, 24l bf . f t )
16- 18
3. Instal l the
propel l er shaft protector (A).
8 x 1. 25 mm
22 N. m 12. 2 kgf . m,
' 16l bf . f t )
Steering
Steering
Speci af Tool s . . . . . . . . . . . . . 17
-2
Component Locat i on I ndex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-3
St eeri ng Wheel Rot at i onal Pl ay Check . . . . . . . . . . . . . . . . . . . . . . . 17-4
Power Assi st Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-4
St eeri ng Li nkage and Gearbox I nspect i on . . . . . . . . . . . . . . . . . 17-5
St eeri ng Wheel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l 7-6
St eeri ng Wheel Di sassembl y and Reassembl y . . . . . . . . . 17-7
St eeri ng Wheel I nst al l at i on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-8
St eeri ng Col umn Removal and I nst al l at i on . . . . . . . . . . . . . . . 17-9
St eeri ng Shaf t Removal and I nst al l at i on . . . . . . . . . . . . . . . . . . . . 17-10
St eeri ng Col umn/ Shaf t I nspect i on . . . . 17-12
St eeri ng Lock Repl acement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-13
Rack Gui de Adi ust ment . . . . . . . . . . . . . . . . . . . . . 17-14
(EPS)
17-15
Steering
Special Tools
Ref.No. Tool Number DescriDtion Oty
o 071\4AA-S10020A Locknut Wrench, 43 mm l
AIRBAG
ASSEMBLY
STEERING GEARBOX
Rack Gui de Adj ustment, page 17
-14
ELECTRICAL POWER STEERING IEPS)
page 17- 18
STEERI NG WHEEL
Removal , page 17-6
Di sassembl y/ Reassembl y,
page 11- j
I nst al l at i on, page 17-8
STEERING COLUMN
St eeri ng Col umn Removal and I nst al l at i on,
page 17-9
St eeri ng Col umn I nspect i on,
page 17-12
St eeri ng Lock Repl acement ,
page' 11- 13
STEERING SHAFT
St eeri ng Shaf t Removal and I nst al l at i on,
page 17- 10
St eeri ng Shaf t I nspect i on,
page 17
-12
Removal / l nst al l at i on.
page 23-65
17-3
Steering
Steering Wheel Rotational Play
Gheck
1. Turn the front wheel s to the strai ght ahead posi ti on.
2, l vl easure how fa r you can turn the steeri ng wheel
l eft and ri ght wi thout movi ng the front wheel s.
.
l f the
pl ay i s wi thi n the l i mi t, the gearbox and
l i nkage ar e OK.
'
l f the
pl ay
exceedsthe l i mi t, adj ustthe rack gui de
(see page 17-14). l fthe pl ay i s sti l l excessi ve after
rack gui de adj ustment, i nspect the steeri ng
l i nkage and gearbox
{see
page 17-5).
ROTATIONAL PLAY: 0-10 mm l0-0,39 in,)
17-4
' 1.
Power Assist Check
Stan the engi ne, l et i t i dl e.
Attach a commerci al l y avai l abl e spri ng scal e to the
steeri ng wheel . Wi th the engi ne i dl i ng and the
vehi cl e on a cl ean, dr y f l oor ,
pul l
t he scal e as
shown and read i t as soon as the ti res begi n to turn.
l f the scal e reads no more than 34 N
(3.5
kgf, 7.7 Ibf),
the power assi st i s OK. l f i t reads more, check the
steeri ng l i nkage for damage
(see page 17-5), and
check t he r ack gui de adj ust ment
( see page 17- 14) .
Steering Linkage and Gearbox Inspection
STEERING GEARBOX
I nspect l or l oose mount i ng bol t s.
GEARBOX MOUNTING CUSHIONS
I nspect l or det eri orat i on.
STEERING COLUMN
l nspect for l oose col umn
mounti nq bol ts and nuts.
STEERING JOINTS
Check f or l oose
i oi nt
bol t s.
TIE.ROD LOCKNUT
Check for l oose l ocknut.
BALL JOINT BOOT
l nspect for damage and deteri orati on.
\r,.-*oo
a"o,o,-,-,o,",
l nspect I or f aul t y movement
ano oamage.
BOOT
I nspect f or damage and det eri orat i on.
17-5
Steering
Steering Wheel Removal
SRS components are l ocated i n thi s area, Revi ew the
SRS component l ocati ons, precauti ons, and procedures
i n the SRS secti on before performi ng repai rs or servi ce
( see page 23- 10) .
1. Make sure
you
have the anti -theft code for the radi o,
then wri te down the radi o stati on oresets.
2. Al i gn the front wheel s strai ght ahead, then remove
the dri ver' s ai rbag Jrom the steeri ng wheel
{see
page 23-65).
3. Di sconnectthe crui se control swi tch connector
(A)
and horn swi tch connector {B).
4. Loosen the steeri ng wheel bol t {A).
17-6
5. I nst al l a commer ci al l y avai l abl e st eer i ng wheel
pul l er (A)
on the steeri ng wheel
(B).
Free the
steeri ng wheel from the steeri ng col umn shaft by
turni ng the
pressure
bol t
(C)
of the
pul l er,
Note these items when removing the steering
wheel :
.
Do not t ap on t he st eer i ng wheel or t hest eer i ng
col umn shaft when removi ng the steeri ng wheel .
.
l f
Vout hr eadt he
pul l er
bol t s
( D)
i nt ot hewheel
hub more than fi ve threads, the bol ts wi l l hi t the
cabl e reel and damage i t. To prevent
thi s, i nstal l
a pai r of
j am
nuts fi ve threads up on each
pul l er
bol t.
6.
B
Remove the steeri ng wheel pul l er,
then remove the
steeri ng wheel bol t and steeri ng wheel from the
sl eefl ng col umn.
Steering Wheel Disassembly/Reassembly
STEERING WHEEL
\ i ** t
{?'%\-l
Y' - / \
I
.o"{.,,*,.
HORN PLATE
SLIDE SCREWS
Ag>
@ { (
#
*w
I
HORN PLATE COVEB
\h:
Y,
CRUISE CONTROL SWITCH
WHEEL LOWER COVER
I
v
\
CAP
I
ACCESS PANEL
17-7
Steering
Steering Wheel Installation
1. Before i nstal l i ng the steeri ng wheel , make sure the
front wheel s are al i gned strai ght ahead, then center
the cabl e reel
(A).
Do thi s by fi rst rotati ng the cabl e
reel cl ockwi se unl i l i t stoos. Then rotate i t
countercl ockwi se about two and hal f turns. The
ar r ow mar k
( B)
on t he cabl e r eel l abel
poi nt
shoul d
poi nt strai ght up.
Posi ti on the two tabs
(A)
of the turn si gnal
cancel l i ng sl eeve
( B)
as shown, and i nst al l t he
steeri ng wheel on to the steeri ng col umn shaft,
maki ng sure the steeri ng wheel hub
(C)
engages
the
pi ns (D)
of the cabl e reel and tabs of the
cancel i ng sl eeve. Do not tap on the steeri ng wheel
or steeri ng col umn shaft when i nstal l i ng the
steeri ng wheel .
2.
17-8
3. lnstallthe steering wheet bolt and tighten it.
39 N m {4. 0 kgf m, 29l bf . f t }
7.
Connect the horn swi tch connector and crui se
control swi tch connector.
Instal l the dri ver' s ai rbag, and confi rm that the
system i s operati ng properl y (see page 23-66).
Reconnect the battery.
Check the horn, crui se control sevresume swi tch,
and turn si gnal cancel l i ng for proper
operati on.
For' 01-03 model s; reset the cl ock.
Steeri ng Col umn Removal and Instal l ati on
SRS components are l ocated i n thi s area. Revi ew the SRS component l ocati ons, precauti ons, and
procedures i n the
SRS secti on before performi ng repai rs or servi ce
(see page 23-10).
Removal
1. Record the radi o stati on presets, and di sconnect the battery.
2. Remove the d ri ver' s a i rbag
(see page 23-65). steeri ng wheel , and cabl e reel
(seepage23-72).
3, Remove the col umn covers
(A)
{' 1. 6 kgl m. 12 l bf . f t l
22 N.m {2.2 kgf.m, 16 lbt ft)
A
4. Remove the combi nati on swi tch assembl y
(B)
from the steeri ng col umn shaft by di sconnecti ng the connectors
and removi ng the screws.
5. Di sconnect the i gni ti on swi tch connectors from the under-dash fuse/rel ay box.
6. Remove t he st eer i ng
j oi nt
bol t
( C) .
7. Remove t he st eer i ng col umn
( D)
by r emovi ng t he at t achi ng nut s{ E} andbol t s( F) .
@G
(cont' d)
17-9
16 N. rn
Steering
Steeri ng Col umn Removal and
Installation
(cont'dl
lnstallation
2.
1 . I nst al l t he st eer i ng col umn, and make sur e t he
wi res are not caught or
pi nched
by any
parts.
Insertthe l ower end ofthe steeri ng
j oi nt (A)
onto
t he st eer i ng shaf t
{ B)
( l i ne
up t he bol t hol e
( C) wi t h
the fl at porti on (D)
on the shaft).
3. Pul l on the steeri ng
j oi nt
to make sure that the
steeri ng
j oi nt
i s ful l y seated, but do not pul l
excessi vel y on the
j oi nt.
Then i nstal l the steeri ng
j oi nt
bol t
(E)
and ti ghten i t to the speci fi ed torque.
US thru VIN JHMAP 114.YT008411
Canada thru VIN JHMAP 114.YT800750
Torque: 22 N'm
(2.2
kgf.m, 16 lbf.ft)
US from VIN JHMAP 114.YT008412
Canada trom VIN JHMAP 114.YT800751
Torque: 29 N.m
13.0
kgf m, 22 l bf.ftl
4, Fi ni sh t he i nst al l at i on, and not e t hese i t ems:
.
Make sure the wi re harness i s routed and
fastened properl y.
.
Make sure the connectors are properl y connected.
.
Rei nstal l the steeri ng wheel
(see page 17-8).
.
Reconnect the battery and reset the radi o presets.
-
Enter the anti -theft code for the radi o. then
enter the customer' s radi o stati on presets.
-
For ' 01- 03 model s; set t he cr ocK.
.
Veri fy crui se control , horn, and turn si gnal swi tch
opera on.
.
Check wheel al i gnment
( see page
18- 5) .
17-10
1 .
Steering Shaft Removal and
Instal l ati on
Removal
Remove the steeri ng col umn
(see page
17-9).
Mar k
( A) t he
st eer i ng
j oi nt ( B)
and pi ni on shaf t
( C)
to i denti fy the posi ti on
of the
j oi nt
on the
pi ni on
shaft.
Remove the steeri ng
j oi nt
bol ts
{D).
Di sconnect the steeri ng
j oi nt
from the
pi ni on
shaft
by pul l i ng the steeri ng shaft
(E).
Remove the steeri ng
j oi nt (B)
from steeri ng shaft.
Remove the steeri ng shaft.
5.
6.
lnstallation
1, Appl y mul ti purpose grease to the i nsi de surface of
t he pi ni on dust seal
( A) .
Insert the steeri ng shaft
(B)
i nto the engi ne
compartment careful l y to avoi d damagi ng the
pi ni on dust seal . Make sure the shaft comes out of
f r ame hol e.
I nst al l t he st eer i ng col umn wi t h t he col umn
mounti ng nuts and col umn hol der
(see page 17-9).
Sl i p the
j oi nt (A)
of the col umn shaft onto the
steeri ng shaft {B), then l oosel y i nstal l the
j oi nt
bol t
(C) (l i ne
up the bol t hol e
(D)
wi th the fl at porti on (E)
of the shaft). Pul l the steeri ng shaft toward the
col umn.
5. Sl i p the upper end
(A)
ot the steeri ng
j oi nt
onto the
17-11
7.
steeri ng shaft
(B) (from
the engi ne companment).
Be sure the steeri ng
j oi nt
and steeri ng shaft are
al i gned wi th the serrati ons; the
j oi nt
shoul d sl i p on
freel v. l f not, reposi ti on the serrati on of the steeri ng
i oi nt.
Li ne up the bol t hol e
(C)
wi th the fl at porti on (D)
of
the shaft
(B),
and l oosel y i nstal l the upper
j oi nt
bol t
(E).
Pul l the steeri ng
j oi nt
j oi nt
i s ful l y seated.
Sl i p on t he l ower end
( F)
of t he st eer i ng
j oi nt by
( G)
on t he
pi ni on shaf t
( H)
and
j oi nt.
(l )
wi th groove around
(J
) the
pi ni on shaft, and i nstal l the l ower
j oi nt
bol t
(K)
and ti ghten i t by band. Don' t torque the bol t
yet.
Pul l the steeri ng
j oi nt
i oi nt
i s
ful l y seated.
Pul l the steeri ng shaft toward the
pi ni on
shaft. Then
ti ghten the upper
j oi nt
bol t {E}. The l ower
j oi nt
bol t
(K)
{both i n the engi ne companment), and the
i oi nt
bol t on col um shaft
(under
the dashboard) to the
speci fi ed torque.
US thru VIN JHMAP 114.YT008411
Torque: 22 N.m
(2.2
kgf.m, 16 lbf.ftl
US from VIN JHMAP 114.YT008412
Canada from VIN JHMAP 114.YT800751
Torque: 29 N.m
(3.0
kqf.m, 22 lbf.ft)
Steering
Steering Column/Steering Shaft Inspection
Check the steeri ng col umn bal l beari ng
{A) and the steeri ng
j oi nt
beari ngs
(B)
for pl ay
and
proper
movement. l f any
beari ng i s noi sy or has excessi ve pl ay, repl ace the steeri ng col umn as an assembl y.
Check the retai ni ng col l ar
(C)
for damage. l f i t i s damaged, repl ace the steeri ng col umn as an assembl y.
Check the absorbi ng
pl ates
{D) for di storti on or breakage. l f there i s di storti on or breakage repl ace the steeri ng
col umn as an assembl y.
Check the steeri ng shaft
(E)
for bendi ng and damage.
Check the
j oi nt
dust seal
(F)
for deteri orati on and damage.
6401
US thru VIN JHMAP 11i1.YT008411
Canad. t hru VI N JHMAP 114. YT800750
Torque: 22 N. m
(2. 2
US f rom VI N JHMAP 114. YT008412
Canada f rom VI N JHMAP 114. YT800750
Torque: 29 N. m
(3. 0
kgf . m, 22 l bf . f t l
..@@
6 x 1 . 0 mm
9. 8 N. m
(1. 0
kgf . m, 7. 2 l bt . f t )
17-12
Steering Lock Replacement
1. Remove the steeri ng col umn
(see page 17-9),
2. Center DUnch each of the two shear bol ts, and dri l l
thei r heads off wi th a 5 mm {3/16 i n.) dri l l bi t. Be
careful not to damage the swi tch body when
removi ng the shear bol ts.
;-:'
'
5.
6.
7 .
Remove the shear bol ts from the swi tch body.
Instal l the swi tch body wi thout the key i nserted.
Loosel y ti ghten the new shear bol ts.
Insert the i gni ti on key. and check for proper
operati on of the steeri ng wheel l ock and that the
i gni ti on key turns i reel y.
Ti ghten the shear bol ts
(A)
unti l the hex heads
(B)
twist off.
A
17-13
Steering
Rack Guide Adjustment
Special Tools Roquired
Locknut wrench, 43 mm 07MAA-S100204
1. Set the wheel s i n the strai ght ahead posi ti on.
2. Remove the sDl ash shi el d.
3. Remove the l ower radi ator hose bracket
(A).
9. 8 N. m
(1. 0
kgf . m, 7. 2l bt f t l
Loosen the rack gui de screw l ocknut
(A)wi th
the
speci al tooi , then l oosen the rack gui de screw
(B).
07MAA-S100200
Ti ghten the rack gui de screw to 25 N.m
(2.5
kgf.m,
18 l bf.ft), then l oosen i t.
Reti ghten the rack gui de
screw to 3.9 N.m
(0.4
kgf.m, 2.9 l bf.ft) then back i t off to the speci fi ed
a ng r e.
Speci ti ed Return Angl e: 15 + 5"
5.
6.
, - \
17-14
7. Ti ghten the l ocknut to 25 N.m
(2.5
kgf.m, 18l bfft)
whi l e hol di ng the rack gui de screw.
8. Instal l the l ower radi ator cl amp.
9. Check for ti ght or l oose steeri ng from l ock to l ock.
10. Perform fol l owi ng i nspecti ons:
.
Steeri ng wheel rotati onal
pl ay (see page 17-4).
.
Power assi st wi th vehi cl e parked (see page 17
-41.
(EPSI
EPS Gomponents
Soeci al Tool s
Component Locat i on I ndex . . . . . . . . . . . . . .
General Troubl eshoot i ng I nf ormat i on
DTC Troubl eshoot i ng I ndex
Sympt om Troubl eshoot i ng I ndex . . . . . . . . . . . . . . .
Syst em Descri pt i on . . . . . . . . . . . . . . . . .
Ci rcui t Di agram
DTC Troubl eshoot i ng . . . . . . . . . . . . . . .
EPS I ndi cat or Ci rcui t Troubl eshoot i ng . . . . . . . . . . . . . . . . . . . . . . .
Memori zi ng t he Torque Sensor Neut ral Posi t i on . . . . . .
St eeri ng Gearbox Removal and l nst al l at i on
St eeri ng Gearbox Overhaul
Torque Sensor Repl acement
Rack Gui de Rem ova l / l nst a l l at i on . . . . . . . . . . . . . . .
Rack End Removal and I nst al l at i on
Gearbox Bracket Removal/lnstallation
Bal l Joi nt Boot Reol acement . . . . . . . . . . . . . . . . . .
EPS Cont rol Uni t Removal / l nst al l at i on
t / - t o
17-17
17
-18
17- 22
17-23
17-24
17-26
I t - 26
17-42
17
-45
17-46
17-53
17-54
17-54
't7-55
17-58
17-58
17-59
EPS Components
Special Tools
@
ai)
o
Ref.No. Tool Number Description otv
or
a\
11\
G)
07MAC-S100200
07746-0010100
07749-0010000
07974-6790000
Bal l Joi nt Remover , 2S mm
Attachment. 32 x 35 mm
Dri ver
Oi l Seal Dr i ver
,l
1
,l
,l
17-16
MAI N UNDER-HOOD
FUSE/RELAY BOX
EPS CONTROL UNIT
EPS Control Uni t Bemoval /
Instal l ati on, page 17-59
DATA LINK
CONNECTOR I16PI
UNDER-HOOD FUSE BOX
GAUGE ASSEMBLY
UNDEB.DASH FUSE/RELAY BOX
TOROUE SENSOR
Torque Sensor Bepl acement, page 17-54
STEERING GEARBOX
St eeri ng Gearbox Removal
and l nst al l at i on, page 17-46
St eeri ng Gearbox Ovrhaul , page 17-53
Rack Gui de Bemoval / l nst al l at i on,
page 17-54
Rack End Removal and I nst al l at i on, page 17-55
Gearbox Bracket Removal / l nst al l at i on, page 17-58
Bal l Joi nt Boot Repl acement ,
page' 17-58
17-17
EPS Gomponents
EPS Indicator
Under normal condi ti ons. the EPS i ndi cator comes on
when the i gni ti on swi tch i s turned to the ON
(l l ) posi ti on,
then goes off after the engi ne i s started. Thi s i ndi cates
that the bul b and i ts ci rcui t are operati ng correctl y.
l f there i s any troubl e i n the system after the engi ne i s
started, the EPS i ndi cator wi l l stay on, and the power
assi st i s turned off.
When EPS i ndi cator comes on, the control uni t
memori zes the DTC. In thi s case, the control uni t wi l l
not acti vate the EPS system after the engi ne starts
agai n, but i l keeps the EPS i ndi cator on.
When DTC 11, 12, ot 13 i s stored i n the control uni t, the
EPS i ndi cator wi l l stay on unti l the DTC i s erased. Even
though the system i s operati ng normal l y, the EPS
i ndi cator wi l l come on under the fol l owi ng condi ti ons:
.
When the vehi cl e i s barel y movi ng, 0.62 mph
(1
km/h)
or stopped, and the engi ne speed i s 2.000 rpm or
hi gher for about 3 mi nutes.
.
When the engi ne speed i s 500 rpm or l ess, and the
vehi cl e i s travel l i ng at a speed of 6.2 mph
(10
km/h)
or more for about 3 mi nutes.
To determi ne the actual cause of the
probl em. questi on
the customer about the condi ti ons duri ng whi ch the
probl em occured, taki ng the above condi ti ons i nto
consi derati on.
Diagnostic Trouble Code
(DTCI
.
l f the CPU cannot be acti vated. or i tfai l s, the EPS
i ndi cator comes on, but the DTC i s not memori zed.
.
The memory can hol d any number of DTCS. However,
when the same DTC i s detected more than once, the
most recent DTC i s wri tten over the pri or DTC.
therefore onl y one occurance i s memori zed.
.
The l owest DTC i s i ndi cated fi rst. The DTCs are
i ndi cated i n ascendi ng order, not i n the orderthat
they occurred.
.
The DTCS are memori zed i n the EEPROM
(non-
vol ati l e memory) therefore the memori zed DTCs
cannot be erased by di sconnecti ng the battery.
Perform the soeci fi ed Drocedures to ci ear DTCS.
Self-diagnosis
Sel f-di agnosi s can be cl assi fi ed i nto two categori es:
.
Ini ti al di agnosi s: performed ri ght after the engi ne
starts and unti l the EPS i ndi cator
goes
off.
.
Regul ar di agnosi s: performed ri ght afterthe i ni ti al
di agnosi s unti l the i gni ti on swi tch i s turned OFF.
The EPS control uni t
performs
the fol l owi ng functi ons
when a probl em i s detected by sel f-di agnosi s:
' 1.
Turns on the EPS i ndi cator.
2. Memori zes the oTC.
3. Stops power assi st and manual steeri ng operati on
resumes.
NOTE:
.
When DTC 23
(a probl em wi th the ci rcui tfor
engi ne speed si gnal ) i s detected, the
power
assi st wi l l return to normal when the vehi cl e
speed i s 6.2 mph
(10
km/h) or above.
,
Fot OfCs21,22, and 23the EPS i ndi catorwi l l go
off automati cal l V, and the system returns to
nor ma l .
Restriction on Power Assist Operation
Repeated extreme steeri ng force. such as turni ng the
steeri ng wheel conti nuousl y back-and-forth wi th the
vehi cl e stopped. causes an i ncrease of power
consumoti on i n the EPS motor. The i ncrease of el ectri c
current causes the motor to heat uo. Because thi s heat
adversel y affects the system. the control uni t moni tors
the el ectri c current of the motor.
When the control uni t detects heat bui l d-up i n the motor.
i t reduces the el ectri c current to the motor
gradual l y
to
protect the system, and i t restri cts the power assi st
operati on. The EPS i ndi cator does not come on duri ng
thi s functi on.
When steeri ng torque i s not appl i ed to the steeri ng
wheel , or when the i gni ti on i s turned off, the control
uni t wi l l restore the power assi st gradual l y unti l i t' s ful l y
restored
(after
about 8 mi nutes).
EPS Control Unit Noise
A rel ay sound or
"cl i ck"
can be heard from the EPS
control uni t about 30 seconds after the i oni ti on swi tch i s
turned off. Thi s sound i s normal .
Torque Sensor Neutral Position
The EPS control uni t stores the torque sensor neutral
posi ti on i n the EEPROM. Memori ze the torque sensor
neutral posi ti on whenever the gearbox i s removed and
i nstal l ed, or when the l orque sensor or EPS control uni t
i s reDl aced.
NOTE: The toroue sensor neutral oosi ti on i s not
effected when erasi ng the DTCs.
17-18
How to Troubleshoot EPS DTCs
The troubl eshooti ng fl owchart
procedures
assume that
the cause of the probl em
i s sti l l
present
and the EPS
i ndi cator i s sti l l on. Fol l owi ng the fl owchart when the
EPS i ndi cator does not come on can resul t i n i ncorrect
di agnosi s.
The connector i l l ustrati ons show the femal e termi nal
connectors wi th a si ngl e outl i ne and the mal e termi nal
connectors wi th a doubl e outl i ne.
1. Ouesti on the customer about the condi ti ons when
the probl em
occured, and try to reproduce the
same condi ti ons for troubl eshooti ng. Fi nd out
when the EPS i ndi cator came on, such as duri ng
EPS control , after EPS control . when the vehi cl e
was at a certai n speed, etc.
2. When the EPS i ndi cator does not come on duri ng
the test dri ve, but troubl eshooti ng i s done based on
the DTC, check for l oose connectors, poor
termi nal
contact, etc., before you start troubl eshooti ng.
3. Afte r trou bl eshooti ng. cl earthe DTC and test-dri ve
the vehi cl e. Be sure the EPS i ndi cator does not
come on,
How to Retrieve EPS DTCs
Honda PGM Tester Method:
1. Wi th the i gni ti on swi tch OFF, connect the Honda
PGM Tester
(A)to
the 16P data l i nk connector
(DLC)
(B)
l ocated under the dash on the
passenger' s
si de
of the vehi cl e.
\
2. Turn the i gni ti on ON
(l l ),
and fol l ow the
prompts
on
the PGM Tester to di spl ay the DTC(S) on the screen.
After determi ni ng the DTC, refer to the DTC
troubl eshooti ng i ndex.
NOTE: See the Honda PGM Tester user' s manual
for speci fi c i nstructi ons.
Service Check Signal Circuit Method:
PGM Tester
(A)
to the 16P data l i nk connector
(DLC)
(B)
l ocated under the dash on the
passsenger' s
si de
of the vehi cl e.
B A
Short the SCS ci rcui t to body ground
usi ng the
Honda PGM Tester.
( l l ) .
(cont' d)
17-19
, \
EPS Components
(cont'dl
4. The bl i nki ng frenquency i ndi cates the DTC. DTCS
are i ndi cated by a seri es of l ong and short bl i nks.
Add the l ong and short bl i nks together to determi ne
the DTC. After determi ni ng the DTC. refer to the
DTC troubl eshooti ng i ndex,
The system wi l l not i ndi cate the DTC unl ess these
condi ti ons are met:
.
Set the front wheel s i n the strai ght ahead dri vi ng
posi ti on.
.
The i gni ti on swi tch i s turned ON
(l l ).
.
The engi ne i s stopped.
'
The SCS ci rcui t i s shorted to body ground before
the i gni ti on swi tch i s turned ON
(l l ).
Example ot DTC 12
Short bl i nks
{two
times)
*l
Examolo ot DTC 23
Di sconnect the Honda PG M Tester from the DLC.
17-20
How to Clear EPS DTCs
PGM Tester
(A)
(DLC)
{B) l ocated under the dash on the
passenger' s si de
of the vehi cl e.
(l l ),
and cl ear the
DTC(S) by fol l owi ng the screen
prompts on the
PGM Tester.
2
li - .,/
----==
r
-
-tt"=-=,,-.,-
,,
+rri
Service Check Signal Circuit Method:
NOTE: Use thi s procedure when the PGM Tester
software does not match the yearl model vehi cl e you
are worki ng on.
' 1.
Wi th the i gni ti on swi tch OFF, connect the Honda
PGM tester
(A)
(DLC)
(B)
l ocated under the dash on the passenger' s
si de
of the vehi cl e.
4.
Whi th the vehi cl e on the
ground,
set the front
wheel s i n the strai ght ahead dri vi ng posi ti on.
Short the SCS ci rcui t to body
ground
usi ng the
Honda PGM Tester.
Turn the steeri ng wheel 45 degrees to the l eft from
the strai ght ahead dri vi ng posi ti on, and hol d the
steeri ng wheel i n that posi ti on.
(l l ).
The EPS i ndi cator
comes on, then i t goes off after 4 seconds.
Wi thi n 4 seconds after the EPS i ndi cator goes off,
return the steeri ng wheel to the strai ght ahead
dri vi ng posi ti on
and rel ease the steeri ng wheel .
The EPS i ndi cator comes on agai n 4 seconds after
rel easi ng the steeri ng wheel .
Wi thi n 4 seconds after the EPS i ndi cator comes on,
turn the steeri ng wheel 45 degrees to the l eft agai n
and hol d i t i n that posi ti on.
The EPS i ndi cator
qoes
off after 4 seconds.
5.
7.
8. Wi thi n 4 seconds afterthe EPS i ndi cator goes off,
dri vi ng posi ti on agai n and rel ease the steeri ng
wheel . The EPS i ndi cator bl i nks twi ce 4 seconds
after rel easi ng the steeri ng wheel , i ndi cati ng that
the DTC was erased.
NOTE: l f the EPS i ndi cator does not bl i nk twi ce, an
error was made i n the procedure and the DTC was
not erased. Turn the i gni ti on swi tch OFF, and
repeat the operati on from the step 3.
9. Turn the i gni ti on swi tch OFF wi thi n 5 seconds after
the EPS i ndi cator bl i nks twi ce.
NOTE: l f the i gni ti on swi tch i s not turned OFF
wi thi n 5 seconds after the EPS i ndi cator bl i nks, the
system wi l l go
to the memori zi ng mode of the
torque sensor neutral
posi ti on.
To avoi d thi s, turn
the steeri ng wheel 45 degrees to l eft from the
strai ght ahead dri vi ng
posi ti on
and turn the i gni ti on
swi tch OFF. Thi s wi l l return the svstem to the al ert
mooe.
10. Di sconnect the Honda PGM Tester from the DLC.
1 1 , Perform the DTC code output operati on, and be
sure that the code has been erased.
EPS INDICATOB
STEEN {G
17-21
DTC
Detection ltem
Note
DTC: 1 Power rel ay stuck ON
(see page 17-28)
Drc 2 Fai l -sate rel ay stuck ON
(see page l 7-28)
DTC: 3 LOW FET
(Motor
dri ve transi stor) stuck ON {see
page 17-28)
DTC: 4 UP FET
(Motor
dri ve transi stor) stuck ON
(see page
' 17-29)
DTC: 5 Open to body
ground i n the motor ci rcui t
(see page 17-30)
DTC: 1 1 Di fference of hi gh vol tage and l ower vol tage on the torque sensor
(see page 17' 32)
DTC: 12 A
probl em wi th vol tage for torque sensor VT3
(see page 17-33)
DTC: 13 A
probl em wi th average of vol tage for torque sensor VTl and W2 {see
page 17-32}
DTC: 14 Open or short to body ground i n the torque sensor ci rcui t
(see page 17-34)
DTC: 21 A probl em wi th the vol tage for l G l
(see page 17-35)
DfC:22 Excessi ve change of the vehi cl e speed sensor si gnal
( see page 17' 36)
A probl em wi th average for vehi cl e speed and engi ne speed { see
page 17- 36)
DTC: 23 A
probl em
wi th the ci rcui t for engi ne speed si gnal {see
page l 7-37}
DTC: 30 A
probl em wi th the sub-mi crocomputer
(see page 17-38)
DTC: 31 A probl em wi th the i ni ti al current sensor offset
(see page 17-38)
DTC: 32 A probl em wi th the mai n current sensor offset
( see page' 17- 38)
DTC: 33 A orobl em wi th the current sensor
(see page 17-38)
DTC: 34 A
probl em
wi th the mai n mi crocomputer {see
page l 7-39)
DTC: 35 A probl em wi th the sub-mi crocomputer {see
page 17-39)
DTC: 36 A probl em wi th the change of the motor vol tage
(see page 17-39)
DTC; 37 A
probl em wi th the motor vol tage
( see page 17- 40)
DTC; 50 to 62 A probl em wi th the CPU i n the EPS control uni t
(see page 17-42)
17-22
Symptom Diagnostic procedure
Also check for
EPS i ndi cator does not
come on
EPS Indi cator Ci rcui t Troubl eshooti ng
(see page 17' 42)
EPS i ndi cator does not go
off and no DTC is stored
EPS Indi cator Ci rcui t Troubl eshooti ng
(see page 17-42)
EPS i ndi cator does not stay
on, no DTC i s stored, and
there i s no
power
assi st
1. Check the RED wi re between the EPS control uni tandthe
motor for a short to ground. Repai r as needed.
2. l f the RED wi re i s OK, repl ace the steeri ng gearbox (short
i n
the motor).
17-23
EPS Components
System Description
EPS Control Unit lnputs and Outputs for Connector A
(2P)
EPS CONTROL UNITCONNECTOR A {2P}
Wi r e si de of f emal e t er mi nal s.
EPS CONTROL UNIT CONNECTOR A
(14P}
Tormanal
numbet
Wir6 color Terminel sign
{Terminal namel
Description
Trminals Conditions
llonition Switch ON llll)
Vohage
GRN MOTOR
{Mot or mi nus}
Drives the actuator motor 1- Gr ound
2 MOTOR +
{Motor o!us)
Drives the actuator motor 2 Ground
EPS Gontrol Unit Inputs and Outputs for Connector B
(14P)
Terminel
numbl
Wirs color Terminal sign
{Terminal narne)
Description Measuremnt
Te.minals Conditions
on Switch ON {ll)l
Voltage
'l
YEL t G1
(l oni t i on
1
Power source for activating 1-Ground l oni t i on swi t ch ON
( l l )
Batterv voltaqe
l qni t i on swi t ch OFF
2 WHT/BLK VSP
(Vehi cl e
speed
pul se)
Detects vehicle speed signal
fr.jm the soeedometer
2-Ground Turn t he rear wheel
3 PNK vs1
{Voltaoe sensor 1
Detects torque sonsor
4 BLK G ND2
l Ground 2)
Ground f ort he EPS cont rol
unt
5 BLU NEP
l Enqi ne oul se)
Det ect s t achomet er si gnal 5-Ground St a(t he ongi ne About 3 V 6V
6 BLK GNDl
( Gr ound
1
Gr ound l or t he EPS cont r ol
uni t
1 BLU/ RED
l Vol t aoe f ade)
Dri ves t he t orque sensor
8 BRN
(Servi ce
check si onal )
11 WHT/ GRN vs2
(Vol t aqe
sensor 2)
Detects torque sensor
12 YEUBLU Dri ves t he EPS i ndi cat or
l i oht
12- Gr ound St art t he enoi ne Batterv voltaqe
t onr uon swt r cn ui i
BLU/BLK
( Power
st eer i ng si gnal )
Provades i dl e speed' up
si gnal t o t he ECM
l 3- Gr oundSt an t he engi ne and
t ur n t he st eer i ng wheel
1. ' { ul l l ock
Battery voltage
1 4 LT BLU DLC
i Dara l i nk connect or)
Communi cat es wi t h Honda
PGM-Tester
17-24
EPS Control Unit Inputs and Outputs for Connector C
(2P)
EPS CONTROL UNIT CONNECTOR C I2PI
Terminal
numoea
Wire color Terminal sign
l Te. mi nal name)
Description Measurement
Termi nal s Conditions
(lonition
Switch ON {ll)}
Vohege
8LK PG
(Power ground)
Ground f or t he act uat or 1-Ground
2 WHT/BED + B
(Plus
batterv)
Power source fot the 2-Ground At al l t i mes Bat t ery vol t age
17-25
EPS Components
Circuit Diagram
UNDER-OASH
FUSE/RELAY AOX
TOROUE SENSOF 3P CONNECTOR
GAUGE ASSEMBLY CONNECTOR A (1' P)
GAUGE ASSEMELY CONNECTOA A
(T2PI
GAUGE ASSEMBTY CONNECTOF C {2OP)
Term nal si de of femal e tef mi nal s
TOROU
SENSOF
17-26
Wre side oi le male rermina ls
Wi r e si de oi f emal er er m nal s
_+*
h
.L---r-_r
MOTOA CONNECTOR I2P)
/-+'
t 2 t l l
er m nal si de ol f emal e l er mi hal s
EPS CONTROL UNIT
( : connectorl
EPSCONTEO! UNITCONNECTOR C {2P) EPS
l i ; connat or ) l a:
t 2 t 1 l
Ter mi na si de of f ema et er m nal s
CONNECTOR I
(14P)
DATA LTNKCONNECTOR (16p)
ffi
Wr r e si de ot i ema e l e. mi nal s
CONTBOI UNIT CONNECTOR A (2P)
tllu
W r e si de ot i ema et er mi nal s
Ter mr nal si de of f enal e l er f i i na s
17-27
EPS Components
DTC Troubleshooting
DTC 1: Power Rel ay St uck ON
DTG 2: Fail-safe Relay Stuck ON
1. Cl ear t he DTC.
3. Wai t at l east 10 seconds.
Does the EPS i ndi catot come on and DTC 1 or
DTC 2 i ndi cated?
YES
-
Check for l oose EPS control uni tconnectors.
l f necessary, substi tute a known-good EPS control
uni t and recheck.l
NO The system i s OK at thi s ti me.I
17-28
DTC 3: Lower FET Stuck ON
1, Di sconnect EPS control uni t connector A
(2P)
and
the motor 2P connector.
2. Check for conti nui ty between EPS control uni t
connect or A
( 2P)
t er mi nal No. 2 and mot or 2P
connect or t er mi nal No. 1.
FPS
CONTROL UNIT
MOTOR 2P CONNECToR
db-r'rrrriCrOn I tzpt
MOTOR+
(RED}
YES
-
Go to step 3.
NO
-
Repai r open i n the wi re between EPS control
uni t and the motor.I
3. Check for conti nui ty between the EPS control uni t
connector A
(2P)
termi nal No. I and motor 2P
MOTOR 2P CONNECTOR
EPS CONTROL UNI T
CONNECTOR A {2PI
MOTOR_
(GRN)
Ter mi nal si de oJ f emal e t er mi nal s
YES Go to step 4.
NO Repai r open i n the wi re between the EPS
control uni t and the motor.l
connect or A
( 2P)
EPS CONTROL UNIT
CONNECTOR A I2P}
MOTOR+
(REDI
MOTOR_
{GRN}
Termi nal si de of l emal e t ermi nal s
ts there conti nui ty?
YES Repai r short between the RED and GRN
wi res for the EPS motor ci rcui t.l
NO Repl ace the steeri ng gearbox. (Short
ci rcui t to
body ground i nsi de the gearbox).I
DTC 4: Upper FET Stuck ON
1. Di sconnect EPS control uni t connector C
(2P).
connector C
(2P)
EPS CONTROL UNIT
coNNECTOn C {2P}
Termi nal si de of femal e termi nal s
YES-Check for l oose EPS control uni t connectors.
uni t and recheck.l
NO- Repai r open i n the wi re between the EPS
control uni t and the body ground (G351).
t
17-29
EPS Gomponents
DTC Troubleshooting
(cont'd)
DTC 5: Open I n The Mot or Wi re Harness
1. Cl ear t he DTC.
2. Sta rt the engi ne.
3. Turn the steeri ng wheel to ri ght or l eft, and wai t 10
seconds or more.
Does the EPS i ndi cator come on?
YES Go to step 4.
NO-Check for l oose wi res or
poor
connecti ons. l f
the connecti ons are
good, the system i s OK at thi s
t i me. l
4. Stop the engi ne, and veri fy the DTC
Is DTC 5 i ndi cated?
YES- Go to step 5.
NO-Perform the appropri ate troubl eshooti ng for
the code i ndi cated.I
5. Check t he EPS
( 70
A) f use i n t he auxi l i ar y under -
hood fuse box, and rei nstal l the Juse i f i t i s OK.
l s the f use OK?
YES Go to step 6.
NO
-
Repl ace the fuse and recheck. !
6. Make sure the i gni ti on swi tch i s OFF, then
di sconnect EPS control uni t connector C
(2P).
17-30
7. Measure the vol tage between termi nal No. 2 and
body
ground.
EPS CONTROL UNIT
CONNECTOR C {2PI
-rD
(WHT/RED)
8.
YES Go to step 8.
NO
-
Repai r open i n the wi re between the EPS
(70
A) fuse and the EPS control uni t.l
Check for conti nui ty between EPS control uni t
connect or C
( 2P) t er mi nal No. I and body
gr ound
EPS CONTROL UNIT
CONNECTOR C {2P)
YES Go to step 9.
control uni t and body
ground
(G35' l ).1
Di sconnect EPS control uni t connector A
(2P)
and
9.
connector A
(2P)
termi nal No. 2 and motor 2P
MOTOR 2P CONNECTOR
EPS CONTROL UNIT
CONNECTOR A {2PI
MOTOR+
(RED)
YES Go to step 1 1.
NO- Repai r open i n the wi re between EPS control
uni t and the motor.I
1 1. Check for conti nui ty between the EPS control uni t
connector A
(2P)
FPS
CONTROL UNIT
MoToR 2p coNNEcroR
db-rrrrrrecron n tzpt
MOTOR_
(GRN)
YES Go to step 12.
connect or A
( 2P)
EPS CONTROL UNIT
CONNECTOR A I2P)
Termi nal si de of f emal e t erm; nal s
YES
-
Repai r short to body ground i n the wi re
between the EPS control uni t and the motor.l
connector A {2P) termi nal No. 2 and body
ground.
EPS CONTROL UNIT
CONNECTOR A
(2P}
t J .
Moron+
f^T-\
{ R E D }
. - - z l l ,
(.o)
I
L
YES Repai r short to body ground i n the wi re
between the EPS control uni t and the motor.l |
NO Check for Ioose EPS control uni t connectors. l f
necessary, substi tute a known-good EPS control
uni t and r echeck. I
17-31
EPS Components
DTC Troubleshooting
(cont'd)
DTC 11, 13: Torque Sensor
1. Cl ear the DTC.
YES Go to step 3.
NO-Check for l oose wi res or poor connecti ons. l f
t i me. l
3. Stop the engi ne, and veri fy the DTC.
l s DTC 11 or 13 i ndi cated?
YES
-
Go l o step 4.
NO
-
Perform the appropri ate troubl eshooti ng for
the code i ndi cated.l
di sconnect EPS control uni t connector B
(14P).
5. Check f or cont i nui t y bet ween t er mi nal No. 3and
body ground.
EPS CONTROL UNIT
cONNECTOR B {1i t P)
YES
-
Go to step 6.
NO- Go to step 9.
Di sconnect the torque sensor 3P connector. 6.
17-32
7. Check for conti nui ty between the appropraate
torque sensor 3P connector termi nal and body
gr ound
( see
t abl e) .
TOROUE SENSOR 3P
CONNECTOR
vs2
{WHT/GRN)
VS1 I PNKI
8.
{8LU/ REDI
YES
-
Repai r short to body ground i n the
appropri ate sensor ci rcui t between the torque
sensor and the EPS control uni t.l
NO Go to step 8.
On the sensor si de, check for conti nui ty between
the torque sensor 3P connector termi nal No. 2 and
body
ground.
TOROUE SENSOR 3P
CONNECTOR
PVF
{ BLU/ BED}
YES The EPS system i s OK at thi s ti me. Check for
l oose EPS control uni t connectors. l f necessary,
substi tute a known-good EPS control uni t and
recheck.l
NO Repl ace the torque sensor.l
Termi nal name Torque Sensor terminal No.
VS1
'l
PVF 2
VS2 3
9. Check for conti nui ty between the appropri ate EPS
control uni t connector B
(14P)
and torque sensor 3P
connector termi nal s {see tabl e).
10.
Termi nal
name
Torque
Sensor
termi nal No.
EPS control
uni t
termi nal No,
VS1 1 3
PVF 2 7
VS2 3 1 1
EPS CONIBOL UN|r
@NNECTOR Bh' P)
'OROIJE SENSOfi 3P
CONNECTOR
Ter mi nal s de ol f emal et er mi nal s
YES Go to step 10.
NO Repai r open i n the appropri ate torque sensor
ci rcui t between the EPS control uni t and the torque
sensor . I
On the sensor si de, check for resi stance between
torque sensor 3P connector termi nal s No. 1 and No.
2, and bet ween t er mi nal s No. 2 and No. 3.
Termi .al si de of l enal e termi .al s
l sthe resi stance between 12 14 Q (at 20",
68"F)?
YES-The EPS system i s OK at thi s ti me. Check for
r echeck, I
NO Repl ace the l orque sensor.l
TOROUE SENSOq 3P
CONNECIOR
DTC 12: Torque Sensor PVF
1. Cl ear t he DTC.
Does the EPS indlcator come on?
YES Go to step 4.
NO Check for l oose wi res or
poor
connecti ons. l f
the connecti ons are good, the system i s OK at thi s
t t me. l
4. Veri fy the DTC.
l s DTC 12 i ndi cated?
YES Check for l oose EPS control uni t connectors.
l f necessary. substi tute a known-good EPS control
uni t and r echeck. l
NO
-
the code i ndi cated.I
17-33
EPS Components
DTG Troubleshooting
(cont'd)
DTC 14: Torque Sensor
(Resi st ance)
1. Cl ear t he DTC.
3. Turn the steeri ng wheel ful l y to the l eft, and hol d i t
i n that posi ti on for 10 seconds or more.
Does the EPS indicator come on?
YES Go to step 4.
poor
connecti ons. l f
t i me. l
YES- Go to step 5.
NO- Perform the appropri ate troubl eshooti ng for
di sconnect the torque sensor 3P connector and EPS
control uni t connector B
(14P).
6. Check for conti nui ty between torque sensor 3P
connect or t er mi nal s No, 1 and No. 2.
TOROUE SENSOR 3P
CONNECTOR
Termi nal si de of {emal e t ermi nal s
YES Repai r short between the BLU/RED and PNK
wi res i n the torque sensor ci rcui t between the
torque sensor and the EPS control uni t.l
NO Go to step 7.
17-34
7, Check for conti nui ty between torque sensor 3P
TOROUE SENSOR 3P
CONNECTOR
(BLU/RED}
l ermi nal si de of f emal e t ermi nal s
YES Repai r short between the WHT/GRN and
BLU/RED wi res i n the torque sensor ci rcui t between
the torque sensor and the EPS control uni t.l
NO Go to step 8.
Check for conti nui ty between torque sensor 3P
TOROUE SENSOR 3P
CONNECTOR
vs2
(wHT/GRN)
Termi nal si de ol l emal e termi nal s
YES Repai r short between the WHT/GRN and PNK
wi res i n the torque sensor ci rcui t between the
torque sensor and the EPS control uni t.l
NO Go to step L
8.
9. On the sensor si de, check for resi stance between
the torque sensor 3P connector termi nal s No. 1 and
No.2, and between termi nal No. 2 and No. 3.
TOROUE SENSOR 3P
CONNECTOR
Ter mi nal si de oI mal e t er mi nal s
l s the resi stance between 12- 13 Q (at20' ,
68' F)?
YES-The EPS system i s OK at thi s ti me. Check for
recheck.l
NO
-
Repl ace the torque sensor,I
2.
3.
DTC 21: Vol t age For l G1
' 1.
check t he I NSTRUMENT LI GHT
( 7. 5
A) f use i n t he
under-dash fuse/rel ay box, and rei nstal l the fuse i f
i t i s OK.
NOTE: Al l i ndi cators except the chargi ng system
i ndi cat or wi l l not come on when t he I NSTRUMENT
LIGHT
(7.5
A) fuse i s bl own.
l s the tuse OK?
YES Go to step 2.
NO Repl ace the fuse and recheck.l
Dl sconnect EPS control uni t connector B
(14P).
(l l ).
Measure the vol tage between termi nal No, 1 and
body
ground.
EPS CONTROL UNIT
CONNECTOR B {.l4P}
Termi nal si de of Iemal e termi nal s
YES Check for l oose EPS control uni tconnectors.
uni t and recheck.l
NO Check for an open i n the wi re between the
under-dash fuse/rel ay box and the EPS control uni t,
and repai r i t i f necessary. l f the wi re i s OK, check
for an open ci rcui t i nsi de the under-dash fuse/rel ay
box. l
17-35
EPS Components
DTG Troubleshooting
(cont'dl
DTC 22: Vehi cl e Speed Si gnat
NOTE:
.
l f the l \4l L i ndi cator i s ON, troubl eshootthe PGM-Fl
system iirst.
.
When the engi ne i s runni ng at 2,000 rpm or above
and the vehi cl e speed i s 0.62 mph
(
l km/h) or bel ow
for 3 mi nutes, the EPS i ndi cator comes on.
1. Test-dri ve the vehi cl e.
ls the vehicle speedometer working correctly?
YES Go to step 2.
NO Perform the speedometer system
troubl eshooti ng
(see page 22-53). a
Bl ock the front wheel s and rel ease the
parki ng
oraKe.
Rai se the vehi cl e, and make sure i t i s securel y
supported.
Di sconnect EPS control uni t connector B
(14P).
17-36
6. Bl ock the ri ght rear wheel , and sl owl y rotate the l eft
rear wheel and measure the vol tage between EPS
control uni t connector B {14P) termi nal No. 2 and
body ground.
EPS CONTROL UNIT
CONNECTOR B I 14P}
{WHT/BLK)
Termi nal si de oJ femal e termi nal s
Does the voltage pulse 0 V and 5 V ?
l f necessary. substi tute a known-good EPS control
uni t and recheck.I
NO Repai r open or short to body ground i n the
wi re between the EPS control uni t and body ground,
or faul ty the speedometer.I
DTC 23: Engi ne Speed Si gna
NOTE: l f the MIL i ndi cator i s on, troubl eshootthe PGM-
Fl probl em fi rst,
1. Start the engi ne and check the tachometer.
l s the tachometer worki ng correctl y?
YES Go to step 2.
NO Go to step 5.
2. Connect a commerci al l y avai l abl e spri ng scal e to
the steeri ng wheel .
3. Pul l on the scal e to measure when the front wheel s
start to move. l f the system i s i n good condi ti on,
the scal e shoul d read no more than 34 N {3.5 kgf,
1 .7 tbt).
]t
ls the measurement within the specification?
YES The system i s OK at thi s ti me.I
NO
-
Go to step 4.
Test-dri ve the vehi cl e wi th the vehi cl e above 6.2
mph
( 10
km/ h) .
Does EPS provi de power assi st?
YES Go to step 5.
NO Perform the troubl eshooti ng for DfC 22.a
Oi sconnect EPS control uni t connector B
(14P).
Start the engi ne.
5.
6.
7.
9.
10.
1 1 .
8. l vl easure the vol tage between the No. 5 termi nal
and body
ground.
,rrn"r"Ôourri))u'"",^;*
uni t and recheck.l
NO Go to step 9.
(32P).
Check for conti nui ty between ECl vl connector
t er mi nal A' 19 and EPS cont r ol uni t
( 14P) connect or
t er mi nal No. 5.
YES Go to step 12.
NO
-
Repai r the open i n the wi re between the EPS
control uni t and the ECM.I
12. Di sconnect gauge assembl y connector C
(20P).
YES
-
Repai r the short i n the wi re between the EPS
cont r ol uni t and t he ECM. I
NO Check for l oose EPS control uni t connectors. l f
17-37
EPS Gomponents
DTC Troubleshooting
(cont'dl
DTC 30: Su b-Microcomputer
1. Cl ear t he DTC.
2. St an t he engi ne.
YES Go to step 4.
poor
connecti ons. l f
t i me. l
4. Veri fy the DTC.
YES Check for l oose EPS conl rol uni t connectors.
NO Perform the appropri ate troubl eshooti ng for
17-38
DTC 31, 32, 33: Mot or Current Sensor
1. Cl ear the DTC.
2. Stan the engi ne.
YES Go to step 4.
poor
connecti ons. l f
t r me. l
4. Veri fy the DTC.
l s DTC 31, 32, ot 33 i ndi cated?
uni t and recheck.l
DTC 34, 35: EPS Cont rol Uni t l nt ernal Ci rcui t
1. Cl ear t he DTC.
Does the EPS i ndi catot come on?
YES Go to step 4.
poor
connecti ons. l f
t i me. l
4. Veri fy the DTC.
l s DTC 34 ot 35 i ndi cated?
5.
DTC 36: Charge of the Motor Voltage
1. Cl ear t he DTC.
3. Turn the steeri ng wheel to ri ght or l eft, and wai t 10
seconds or more.
Doesthe EPS i ndi catot come on?
YES Go to step 4.
poor connecti ons. l f
t i me. l
YES Go to step 5.
NO
-
the code i ndi cated. !
Check t he EPS
( 70
A) f use i n t he auxi l i ar y under -
hood fuse box. and rei nstal l the fuse i f i t i s oK.
l s the tuse OK?
YES Go to step 6.
NO- Repl ace the fuse recheck.l
Di sconnect EPS control uni t connector C
(2P).
(cont' d)
17-39
EPS Gomponents
DTC Troubleshooting
(cont'dl
7. Measure the vol tage between termi nal No.2 and
body ground.
EPS CONTROL UNIT
CONNECTOR C
(2P)
+B
{WHT/REDI
ls therc battery voltage?
YES Check for l oose EPS control uni t connectors,
uni t and recheck.l
(70
A) fuse and the EPS control uni t.I
17-40
DTC 37: Motor Voltage
1. Check t he EPS { 70 A) f use i n t he auxi l i ar y under -
hood fuse box, and rei nstal l the fuse i f i t i s OK.
l s the f use OK?
YES
-
Go to step 2,
NO Repl ace the fuse and recheck. t
connector C
(2P)
EPS CONTROL UNI T
CONNECTOR C I2PI
Termi nal si de of t emal e t ermi nal s
YES Go to step 3.
NO-Repai r open i n the wi re be&veen the EPS
cont r ol uni t and body gr ound ( G351) .
t
Di sconnect EPS control uni t connector A
(2P)
and
connector A
(2P)
FPS CONTROL UNIT
MOTOR 2P CONNECTOR
dbirircron I tzpt
MOTOR+
{RED)
YES-Go to step 5.
NO Repai r open i n the RED wi re between the EPS
control uni t and the motor.I
connector A
{2P)termi nal
No. 1 and motor 2P
MOTOR 2P CONNECTOR
EPS CONTROL UNIT
CONNECTOR A
(2PI
MOTOR_
{GRN)
l s there conl i nui ty?
YES Go to step 6.
NO Repai r open i n the GRN wi re between the EPS
6. Check for conti nui w between EPS control uni t
connector A {2P) termi nal No. 1 and body
ground.
EPS CONTROL UNIT
CONNECTOR A
(2PI
7.
YES Repai r short to body ground i n the GRN wi re
NO Go to step 7.
connector A
(2P)
EPS CONTROL UNIT
CONNECTOR A I2P)
MoroR+
afr)
{ RED)
r - - - - 1
z l r l
6
-L
Termi nal si de ol l emal e t ermi nal s
Is thete conti nui ty?
YES Repai r short to body ground i n the RED wi re
NO Check for l oose EPS control uni t connectors. l f
17-41
EPS Components
DTC Troubleshooting
(cont'd)
DTC 50 to 62: Central Processing Unit
(CPU)
1. Cl ear the DTC.
YES Go to step 4.
poor
connecti ons. l f
t ame. l
4. Veri fy the DTC.
l s DTC 50 to 62 i ndi cated?
NO- Perform the appropri ate troubl eshooti ng for
17-42
EPS Indicator Circuit
Troubl eshooti ng
1. Tur n t he i gni t l on swi t ch ON
( l l ) ,
st ar t t he engi ne,
and watch the EPS i ndi cator.
Does the EPS indicator come on?
YES- l f the EPS i ndi cal or comes on and goes
off, i t' s
OK. l f the EPS i ndi cator stays on or bl i nks, go to
step 13.
NO Go to step 2.
2. Turn the i gni ti on swi tch OFF, then ON
(l l )
agai n,
and watch the brake system i ndi cator.
Does the brake system indicatot come on?
YES Go to step 3.
NO Repai r open i n the i ndi cator power
source
ci r cui t . l
.
Bl own I NSTRUMENT LI GHT
( 7. 5
A) f use.
.
Open i n the wi re between the INSTRUMENT
LI GHT
( 7. 5
A) f use and gauge
assembl y.
.
Open ci rcui t i nsi de the under-dash fuse/rel ay box.
4. Check t he EPS i ndi cat or bul b i n t he gauge
assemor y.
l s the bul b OK?
YES
-
Go to step 5.
NO Repl acet he EPS i ndi cat or bul b. t
( l l ) .
6, Connect
gauge assembl y connector A
(14P)
termi nal No. 14 to body ground wi th a
j umper
wi re.
GAUGE ASSEMBLY CONNECTOR A {14PI
1 2 3 4
1 8 9 0l) 11 3114
JUMPER
WIRE
WLP
{YEL/BLU}
YES Go to step 7.
NO Repl ace the bul b ci rcui t board i n the
gauge
assembl y. I
8. Di sconnect EPS control uni tconnector B
(14P).
(l l ).
10. Connect EPS cont r ol uni t connect or B( 14P)
t er mi nal No. 12 and body gr ound wi t h a
j umper
wi re.
EPS CONTROL UNIT
CONNECTOR B I14PI
Does the EPS i ndi catot come on?
YES Go t o st ep 11.
NO Repai r open i n the wi re between the
gauge
assembl y and the EPS control uni t.l
11. Check for conti nui ty between body
ground and EPS
control uni t connector B {14P} termi nal s No. 4 and
No. 6 i ndi vi dual l y.
EPS CONTROL UNIT
CONNECTOR B I14PI
GNDl IBLKI
Is thete continuity?
YES Go to step 12.
NO Repai r open i n the wi res between the EPS
cont r ol uni t and body
gr ound ( G201
and G402) . 1
Measure the vol tage between EPS control uni t
connect or B
( ' l 4P) t er mi nal
EPS CONTROL UNIT
CONNECTOR B I14PI
I NSTRUMENT LI GHT
( 7. 5
A) f use and t he EPS
cont r ol unr t . l
{cont' d)
17-43
EPS Components
13.
14.
t c .
EPS Indicator Circuit Troubleshooting
(cont'dl
Di sconnect EPS control uni t connector B
(14P).
Di sconnect the connectors from the fol l owi ng uni ts.
.
ECM {32P)
.
ABS control uni t
.
SRS control uni t
connect or B
( 14P)
gr ound.
EPS CONTROL UNIT
CONNECTOR B llilP)
YES Repai r short to body ground i n the SCS
ci r cui t . l
NO
-
Go to step 17.
17. Turn the i gni ti on swi tch OFF. then remove the
Honda PGM Tester.
18. ConnectEPS control uni t connector B
(' 14P).
( l l ) .
t o .
17-44
20. Measure the vol tage between data l i nk connector
( 16P) t er mi nal
DATA LINK CONNECTOR
(16PI
Is there about 6 V?
YES Go to step 21.
NO Repai r open i n the wi re between the data l i nk
connect or
( 16P)
and t he EPS cont r ol uni t . l
22. Connect al l di sconnected connectors.
23. Di sconnect EPS control uni t connector B
(14P).
(l l ),
and startthe engi ne.
Does the EPS i ndi cator go off?
YES Go to step 25.
NO Repai r short to body
ground i n the wi re
between the EPS i ndi cator and the EPS control uni t.
I
25. Inspect the bul b ci rcui t board i n the gauge
assembl y
(see page 22-47).
l s i t normal ?
l f necessary substi tute a known-good EPS control
uni t and recheck.l
NO Repl ace t he bul b ci r cui t boar d i n t he gauge
assembl y. l
scs
(BRN)
Memorizing the Torque Sensor Neutral Position
The toroue sensor neutral oosi ti on must be memori zed
whenever the gearbox i s removed or i nstal l ed, or when
the torque sensor or EPS control uni t i s repl aced. Note
that the toroue sensor neutral Dosi ti on i s not affected
when erasi ng the DTC.
PGM tester
(A)
to the 16P Data Li nk Connector
(DLC) (B)
l ocated under the dash on the passenger' s
si de of t he vehi cl e.
Wi th the vehi cl e on the ground, set the front wheel s
i n the strai ght ahead dri vi ng
posi ti on.
Shor t t he SCS ci r cui t t o body gr ound usi ng t he
Honda PGM Tester.
Turn the steeri ng wheel 45 degrees to the l eft from
the strai ght ahead dri vi ng
posi ti on, and hol d the
steeri ng wheel i n that
posi ti on.
Tur n t he i gnl t i on swi t ch ON
( l l ) .
The EPS i ndi cat or
comes on, then i t goes off after 4 seconds.
Wi thi n 4 seconds after the EPS i ndi cator goes off,
dr i vi ng posi t i on and r el ease t he st eer i ng wheel .
The EPS i ndi cator comes on agai n 4 seconds after
r el easi ng t he st eer i ng wheel .
2.
4.
7. Wi thi n 4 seconds after the EPS i ndi cator comes on,
turn the steeri ng wheel 45 degrees to the l eft agai n
and hol d i t i n that posi ti on.
The EPS i ndi cator
goes
off after 4 seconds.
8. Wi thi n 4 seconds after the EPS i ndi cator
goes
off,
dri vi ng
posi ti on and rel ease the steeri ng wheel . Do
not move the steeri ng wheel before turni ng the
i gni ti on swi tch OFF.
NOTE; l f the steeri ng wheel i s moved, the torque
sensor neutral
posi ti on
cannot be wri tten to
memory.
L The EPS i ndi cator bl i nks twi ce 4 seconds after
rel easi ng the steeri ng wheel . then i t bl i nks three
ti mes 5 seconds after. Then, the i ndi cator goes off.
The t or que sensor neut r al
posi t i on i s memor i zed.
NOTE: l f the EPS i ndi cator stays on, there was an
error i n wri ti ng the torque sensor neutral
posi ti on
to memory. Repeat the
procedure
starti ng from
step 3.
11. Di sconnect the Honda PG M Tester from the DLC.
17-45
EPS Components
Steering Gearbox Removal and Installation
Bal l
j oi nt
remover, 28 mm 07MAC-S100200
Removal
Note these i tems duri ng removal r
.
Usi ng sol vent and a brush, wash any oi l and di rtoff
the gearbox. Bl ow dry wi th compressed ai r.
.
Be sure to remove the steeri ng wheel before
di sconnecti ng the steeri ng
j oi nt.
Damage to the cabl e
reel can occur.
then wri te down the frequenci es for the radi o
preset buttons. Di sconnect the negati ve cabl e from
the battery.
2. Rai se the vehi cl e, and make sure i t i s securel y
supported.
3. Remove the front wheel s-
4. Remove the dri ver' s ai rbag
(see page 23-65).
5. Remove the steeri ng wheel
(see page 17-6).
6. Pl ace a mark
(A)
on the steeri ng
j oi nt (B)
and the
pi ni on
shaft {C) to i denti fy the posi ti on of the
j oi nt
on the
pi ni on
shaft.
@
7.
L
Remove the l ower
j oi nt
bol t {D)
from the steeri ng
j oi nt .
Loosen the upper
j oi nt
bol t
(E)
on the steeri ng
j oi nt,
and pul l the steeri ng
j oi nt
ful l y to the steeri ng shaft
( F)
si de.
\
17-46
9. From the underthe dashboard; l oosen the
j oi nt
bol t
(A)
on the col umn, and pul l the steeri ng shaft
(B)
ful l v to the col umn si de.
From the engi ne companment; di sconnect the
steeri ng
j oi nt (A)
and pi ni on shaft
(8)
by movi ng the
steeri ng
j oi nt
toward the steeri ng shaft
(C).
' 10.
, - 1
' 11.
Remove and di scard the cotter
pi n (A)Jrom
the
12 mm nut
(B).
then remove the nut.
B
12 x 1.25 mm
07MAC-S100200
Separ at e t he t l e- r od bal l j oi nt and knuckl e usi ng t he
speci al t ool
( see page 18- 10) .
Remove the seven cl i ps {A) and the two fl ange
bohs
( B) ,
t hen r emove t he spl ash shi el d
( C) .
' 13.
6 x l . 0 mm
14. Remove the stabi l i zer bar hol der brackets {A) from
the frame, and l ower the stabi l i zer bar
(B).
6 6
Di sconnect the ground cabl e
(A)
and motor 2P
connector
(B).
Loosen the harness band
(C),
and
rel ease the wi re harness
(D)
from the
gearbox.
After di sconnecti ng the connector,
put a pi ece of
tape over the steeri ng
gearbox
connector to protect
i t from dust, di rt, and forei gn materi al s.
(cont' d)
17-47
EPS Components
(cont'dl
16. Di sconnect the torque sensor 3P connector
(A).
After di sconnecti ng the connector,
put
a
pi ece
of
tape over the steeri ng gearbox connector to protect
i t from dust, di rt, and forei gn materi al s.
' 17.
Remove the four gearbox mounti ng bol ts.
Right side:
Left side:
f,
H
--'\-r:
-=.1' l t'
.'ii,,ir'
)
t---:,tA
17-48
18. Pul l the steeri ng gearbox toward the front. Move
the steeri ng gearbox to the passenger' s si de and
remove i t.
lnstallation
1. Before i nstal l i ng the gearbox, centerthe steeri ng
rack wi thi n i ts stroke.
2. Pass the dri ver' s si de of the steeri ng
gearbox
through the l eft wheel housi ng. Pl ace the steeri ng
gearbox
on the front subframe, and move i t i nto the
or i gi nal
posi t i on.
3. Instal l the four gearbox mounti ng bol ts.
Ri ght si de:
10 x 1.25 mm
(3
N.m
{4. 4 kof m, 32 l bf . f t ) a
\_ll
\ f l H
Left side:
10 x 1. 25 mm
,(l
N.m
14. 4 ksf . m, 32l bf . f t l
{cont' d)
17-49
EPS Components
(cont'dl
4, Connect the torque sensor 3P connector
(A).
Connect the motor 2P connector
(A)
and
ground
cabl e
(B).
Secure the wi re harness
(C)
wi th the
{1. 0 kgt . m, 7. 2 l bt . f t }
17-50
6. Rai se the stabi l i zer bar
(A)
to the ori gi nal posi ti on,
and i nst al l t he st abi l i zer bar hol der br acket { B) .
7. I nst al l t he spl ash shi el d
( A) wi t h
t he seven cl i ps
( B)
and two fl ange bol ts
(C).
12 x 1. 25 mm
83 N. m
(8.5
kgf.m.
61 tbt.ftl
6 x
' 1.0
mm
9.8 N.m
{1.0 kgf' m,7.2l bf.ft)
ffi
8. Wi pe off any
grease
contami nati on f rom the bal l
j oi nt
tapered secti on and threads. Then reconnect
the ti e-rod ends
(A)to
the steeri ng knuckl es
(B),
and
ti ghten the 12 mm nut
(C)
to the speci fi ed torque.
D C
Instal l the new cotter pi ns (D).
and bend them as
snown.
From the engi ne companment, sl i p the l ower
end {A) of the steeri ng
j oi nt (B)
by al i gni ng the
marks
(C)
on the
pi ni on
shaft
(D)
and
j oi nt.
10.
12.
11. From the under the dashboard,
push
the steeri ng
shaft
(A)
ful l y to engi ne compartment si de, but do
not push excessi vel y on the steeri ng shaft. Then
ti ghten the
j oi nt
bol t
(B)
(A)
wi th the
groove
around
(B)
the
pi ni on
shaft, and i nstal l the l ower
j oi nt
bol t
(C)
and the upper
j oi nt
bol t
(D)
US rhru VIN JHMAP 114.YT008411
Torque: 22 N m
(2.2
kgf m, 16 lbf.ft)
US from VIN JHMAP 114 YT008412
Canada from VIN JHMAP 114.YT800751
Torque: 29 N.m
(3.O
kgt.m,221b1.11,
{cont' d)
17-51
EPS Gomponents
(cont'd)
13. i nst al l t he st eer i ng wheel
( see page 17- 8) .
14. I nst al l t he dr i ver ' s ai r bag
( see page 23- 65) .
15. Reconnectthe negati ve cabl e to the battery.
16. Instal l the front wheel s, and adj ust the front wheel
al i gnment
(see page 18-5).
17. After i nstal l ati on, perform the fol l owi ng checks.
.
Make sure the steeri ng gearbox wi res are not
caught or
pi nched by any
parts.
.
Make sure the steeri ng
gearbox connectors are
properl y connected.
.
Tur n t he i gni t i on swi t ch ON { l l ) , and check t hat
the EPS i ndi cator
goes off,
'
l f
you repl acedthe steeri ng
gearbox assembl y,
l et the EPS control uni t memori ze the torque
sensor neutral posi ti on (see page 17-45).
.
Test-dri ve the vehi cl e;
-
Check that the EPS i ndi cator l i ght does not
come on.
-
Check the steeri ng wheel spoke angl e. Recheck
and adl ust the front wheel al i gnment, i f
necessary.
.
Reset the radi o
presets.
.
For ' 01- 03 model s; set t he cl ock.
17-52
Steering Gearbox Overhaul
Exploded View
MOUNTING BUSHING
Inspect for damage and
deteri orati on.
BOX BRACKET
STEERING GEARBOX ASSEMBLY {MOTOR)
l l the gearbox i s faul ty, repl ace
i t as an assembl y.
LOCK WASHER
Repl ace.
/ ,o-RtNG
,/ ,/
^"'"""'
r' ,/ .,
RACK GU|DE
@, / / /
ou,,,
E(/"
P
\-
9'
--,,*,"o
\q- .)
@
\
BOOT BAND
Repl ace.
TOROUE SENSOR ASSEMBLY
l f the torque sensor i s faul ty,
repl ace i t as an assembl v.
TI E. ROD CLI P I nspect f or damage and
det eri orat i on.
BOOT
17-53
EPS Components
Torque Sensor Replacement
Note these i tems duri ng repl acement:
.
Do not al l ow dust, di n, or other forei gn mal eri al s to
enter the
gearbox.
.
Do not try to di sassembl e the torque sensor assembl y.
l f the l orque sensor i s faul ty, repl ace i t as an
assembl y.
.
l f t het or quesensor i s r epl aced, t he EPS cont r ol uni t
must memori ze the torque sensor neutral posi ti on
( see page 17- 45) .
1. Center the steeri ng rack wi thi n i ts stroke.
Remove the torque sensor assembl y
(A),
2.
D
8 x 1. 25 mm
20 N. m
12. 0
kgf . m.
14 tbf.ftl
A
/ : ' /
3.
5.
6.
Coat the new O' ri ng {B) wi th mul ti purpose grease,
and careful l y fi t i t on the torque sensor housi ng.
Appl y mul ti purpose
grease to the needl e beari ng
( C)
i n t he gear box housi ng.
I nst al l t he t or que sensor assembl y
( A)
on t he
gear box housi ng by engagi ng t he
gear .
The al phabet stampi ng
(for
exampl e
"AB")
{D) on
the
pi ni on shaft al i gns wi th the rack gui de screw
(E)
when the rack i s i n the strai ght ahead dri vi ng
posi ti on.
When i nstal l i ng the torque sensor assembl y, make
sure the
"al phabet"
stampi ng
("48")
i s wi thi n the
r ange shown.
Ti ght en t he 8 mm f l ange bol t s
( F) .
17-54
Rack Guide Removal/lnstallation
NOTE: Duri ng removal /i nstal l ati on, do not al l ow dust,
di n, or other forei gn materi al s to enter the
gearbox.
1 .
5.
grease l o the sl i di ng surface of
the rack gui de, and i nstal l i t onto the gearbox
ho usr ng.
Coat the new O-ri ng
(E)
wi th mul ti purpose
grease,
and careful l y fi t i t on the rack gui de screw
groove.
I nst al l t he spr i ng, r ack gui de scr ew, and l ocknut .
Adj ust the rack gui de screw
(see page 17-14).
After adj usti ng, check that the rack moves
smoothl y by sl i di ng the rack ri ght and l eft.
Rack End Removal and Installation
.
Attachment, 32 x 35 mm 07746-0010100
.
Dri ver, 07749-0010000
Removal
Note these i tems duri ng removal /i nstal l ati on:
.
Do not al l ow dust, di rt, or other forei gn materi al s to
enter the gearbox.
.
Do not di sassembl e the steeri ng gearbox
assembl y
(motor).
l f the motor i s faul ty, repl ace i t as an
assembl y,
1. Remove t he boot bands { A) anddi scar dt hem.
Remove the ti e-rod cl i ps
(B),
and pul l the boots
away from the ends of the gearbox.
NOTE: After removi ng the boot, check for water,
di rt, or other forei gn matter on the bal l screw
surface
(C)
and i nteri or of the boot. l f contami nated,
cl ean the bal l screw, gearbox housi ng, and boot
compl etel y.
b
2. Unbend the l ock washer.
Hol d the fl at surface secti ons
{A) on the passenger' s
si de steeri ng rack shaft wi th one wrench, and
unscrew both rack ends
(B)
wi th another wrench.
Be careful not to damage the shaft surface wi th the
wrench. Remove the l ock washer
(C)
and di scard i t.
(cont' d)
17-55
EPS Components
Rack End Removal and Installation
(cont'd)
4, Check the rubber stop
(A)
for damage or
deteri orati on. l f the rubber stop i s damaged or
deteri orated, reol ace i t.
Grasp the l eft rack end, and
pul l
the rack shaft al l
the wav to the l eft. Careful l v remove the rubber
stop by pryi ng i t out ofthe
gearbox housi ng
(B)
wi th a fl at ti p screwdri ver {C) on the cut-out
porti on
{D) so as not to damage the housi ng.
l f the rubber stop was removed,
posi ti on
the new
rubber stop
(A)
i n the gearbox housi ng, then dri ve
i t i n usi ng the speci al tool s as shown. Make sure
that the speci al tool
presses agai nst the metal
porti on
{B) of the rubber stop.
07746-0010100
07749-0010000
17-56
lnstallation
1. l nst al l t he new l ock washer { A) ont her ackshaf t .
Al i gn the l ock washer tabs
(B)
wi th sl ots
(C)
i n the
r ack shaf t . I nst al l t he r ack end
( D)
whi l e hol di ng
wi th l ock washer i n pl ace. Repeat thi s step for the
other si de of the rack shaft.
2. Hol d the fl at surface secti ons {E)
on the
passenger' s
si de of the steeri ng rack shaft wi th a wrench, and
ti ghten both rack ends. Be careful not to damage
the shaft surface wi th the wrench.
3. Bend the l ock washer
(A)
back agai nst the fl at spots
on t he r ack end
j oi nt
housi ng.
Appl y mul ti purpose grease
to the ci rcumference
(A)
of the rack end
j oi nt
housi ng.
o-Gr
Appl y a l i ght coat of si l i cone grease
to the boot
grooves
{B) on the rack ends.
Center the steeri ng rack wi thi n i ts stroke. Instal l the
boots
(A)
i n the rack end wi th the ti e-rod cl i ps
(B).
Cl ean off any grease
or contami nati on from the
groove
around {C} on housi ng.
{bN
7.
a'.RE-As!x
(P/ N:
08733-B070El
6.
After i nstal l i ng the boots, wi pe the grease
off the
thread secti on
(D)
of rack end.
9.
8. l nstal l the new boot band
(A)
by al i gni ng the tabs
(B)
wi th hol es
(C)
of the band.
Cl ose the ear porti on (A)
of the band wi th
commer ci al l y avai l abl e pi ncer s,
Oet i ker 1098 or
equi val ent
( B) .
SIi de the rack ri ght and l eft to be certai n that the
boots are not deformed or twi sted.
'1
0.
tf,
, t l
17-57
EPS Components
Gearbox Bracket RemovaU
l nstal l ati on
1. Remove the bracket cl amo bol t
(A)
from the
gearbox bracket
(B),
then pry open the bracket to
remove i t from the gearbox.
Instal l the gearbox bracket on the gearbox wi th the
bracket cl amp bol t toward the rear.
Adj ust the di stance between the bracket mounti ng
bol t hol e {A} and the gearbox mounti ng bol t hol e
(B)
to the di mensi on shown. Make sure the bracket
mounti ng bol t hol es are
paral l el wi th gearbox
mountl ng bol t hol es.
2.
A
8 x 1. 25 mm
25 N. m 12. 5 kgf . m,
18 tbf.ft)
4. Instal l the bracket cl amp bol t, and ti ghten i t to 25 N.
m
(2.5
kgf.m, 18 l bf ft).
17-58
Ball Joint Boot Replacement
Oi l seal dri ver, 07974-6790000
1. Remove the boot from the ti e-rod end, and wi pe the
ol d grease off the bal l
pi n.
2. Packt he l ower ar ea of t he bal l
pi n ( A) wi t h
f r esh
mul t| purpose grease.
Pack the i nteri or of the new boot
(B)
and l i p {C) wi th
fresh mul ti purpose
grease.
Note these i tems when i nstal l i ng new grease:
.
Keep grease off the boot i nstal l ati on secti on
(D)
and the tapered secti on
(E)
i f the bal l pi n.
.
Do not al l ow dust, di rt, or other forei gn materi al s
to enter the boot.
I nst al l t he new boot { A) usi ng t he speci al t ool . The
boot must not have a gap at the boot i nstal l ati on
secti ons
(B).
After i nstal l i ng the boot, check the bal l
pi n tapered secti on for
grease contami nati on, and
wi pe i t i i necessary.
07974-6790000
-Gl
A
4.
EPS Control Uni t Removal /l nstal l ati on
1 . Make sure you have the anti ,theft code for the radi o,
then wri te down the frequenci es for the radi o
preset
buttons. Remove the battery.
Remove the EPS control uni t.
3. Di sconnect the EPS control uni t connectors.
4. l nstal l the EPS control uni t i n the reverse order of
removal .
NOTE: l f the EPS control uni t i s repl aced. the EPS
control uni t must memori ze the torque sensor
neutral posi ti on (see page 17-45).
17- 59
Suspensi on
Front and Rear Suspension
Speci al Tool s . . . . . . . . . . . . . 18-2
Wheel Al i gnment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18- 5
Wheel Beari ng End Pl ay I nspect i on . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-9
Wheel Runout I nspect i on . . . . . . . . . . . . . . . . . . 18-9
Bal l Joi nt Removal . . . 18-10
Front Suspension
Knuckl e/ Hub Reol acement
Bal l Joi nt Boot Repl acement . . . . . . . . . . . . . . . . . .
St abi l i zer Bar Repl acement . . . . . . . . . . . . . . . . . . . . . .
St abi l i zer Li nk Removal / l nst al l at i on
LowerArm Removal / l nst al l at i on . . . . . . . . . . . . . . .
Upper Arm Repl acement
Damper/ Spri ng Repl acement
Rear Suspension
Knuckl e/ Hub Repl acement
Bal l Joi nt Boot Repl acement . . . . . . . . . . . . . . . . . . . . .
St abi l i zer Bar Repl acement . . . . . . . . . . . . . . . . . . . .
St abi l i zer Li nk Removal / l nst al l at i on
Lower Arm Remova l / l nst a l l at i on . . . . . . . . . . . . . . .
Upper Arm Remova l / l nst a l l at i on . . . . . . . . . . . . . . .
Cont rol Arm Repl acement
Damper/ Spri ng Repl acement
18- 11
18- 16
18-17
18- 18
18- 19
18-20
18-22
18-28
t at -55
18-34
18-34
18-35
18-37
18-38
18-39
Speci al Tool s
ar_\
o
i!.l
@
@. o, )
D
Ref.No. Tool Number
Description
OtY
a)
o\
@
lrl
@
a
@
/o
(iE
07GAF-SD40100
07GAF-SD40200
07GAG-SD40700
07JAF-SH20330 or
07933-H83000A
wi thout adj usti ng bol t
07MAC-S100200
07746-0010400
07746-0010500
07746-0010600
07749-0010000
07965-SD90100
Hub Di s/Assembl y Tool , 42 mm
Hub Di s/Assembl y Tool
Bal l Joi nt Boot Cl i p Gui de. 42 x 44 mm
Bushi ng Base
Bal l Joi nt Remover . 28 mm
Attachment. 52 x 55 mm
Dr i ver , 15 x 1351
SuDoort Base
,]
1
1
1
1
1
1
1
18-2
Front Suspension:
STABILIZER BAR
Removal , st ep 1 on page 18-23
Di sassembl y/ l nspect i on, st ep 1 on page 18-24
Reassembl y, st ep 1 on page 18-25
I nst al l at i on, st ep 1 on page 18-26
ARM
Repl acement , page 18' 20
STABILIZER LINK
Removal /l nstal l ati on, page 18' 18
KNUCKLE/HUB
Repl acement, page 18-l 1
LOWER ARM
Removal / l nst al l at i on, page 18, 19
18-3
{cont'dl
Rear Suspensi on:
LOWER ARM
Removal /l nstal l ati on, page 18-35
CONTROL ARM
Repl acement,
page 18-38
BAR
REAR DAMPER
Removal , st ep 1 on
page 18-40
Di sassembl v/ l nspect i on, st ep' l on
page 18-41
Reassembl y, st ep 1 on page 18-41
I nst al l at i on, st ep 1 on page 18-42
UPPER ARM
Removal /l nstal l ati on,
page 18-37
KNUCKLE/HUB
STABILIZER LINK
Removal / l nst al l at i on,
page 18-34
18- 4
Wheel Alignment
The suspensi on can be adj usted for caster, camber, and
toe. However, each of these adj ustments are
i nterrel ated to each other, For exampl e, when
you
adj ust toe, l he camber changes. Therefore, you must
adj ust the fronvrear al i gnment whenever you adj ust
caster, camber, or toe.
Pre-Alignment Checks
For proper
l nspecti on and adj ustment of the wheel
al i gnment, do these checks:
1. Rel ease the parki ng
brake to avoi d an i ncorrect
measurement.
2, Make sur e t he suspensi on i s not modi f i ed.
3. Check the ti re si ze and ti re pressure.
Ti re si ze:
Front:205/55R16 89W
Rear: 225l50R15 92W
Tire pressure:
Front/rear:
220 kpa
|2.2 kgt lcm",32
psil
4. Check the runout of the wheel s and ti res.
5. Check t he suspensi on bal l
j oi nt s.
{ Hol d a wheel
wi th your hands, and move i t up and down and
ri ght and l eft to check for wobbl i ng.)
7.
Bounce the suspensi on up and down several ti mes.
Check the hei ght of each suspensi on. Make sure
the vehi cl e i s empty, i s parked
on a l evel surface,
and has properl y i nfl ated ti res
(the
treadwear
i ndi cator must not be showi ng). l fthe hei ght i s out
of speci fi cati on, adj ust the l oad as necessary.
Hei ght:
Front:192 202 mm
FRONT
I
T
The hei ght f rom t he ground t o t he cent er of t he head
of t he l ower arm' s f ront bushi ng bol t .
Rar:220 230 mm
The hei ght f rom t he ground t o t he cent er ol t he head
of t he l ower arm' s rear bushi no bol t .
(cont' d)
FRONT
t
18-5
Wheel Alignment
(cont'dl
Front Caster Inspection/Adiustment
Use commerci al l v avai l abl e computeri zed four wheel
al i gnment equi pment l o measure wheel al i gnment
{caster, camber, toe, and turni ng angl e) Fol l owthe
eoui Dment manufacturer' s i nstructi ons.
1. Check the caster angl e. l f adj ustmenti s requi red,
go to step 2.
Front caster angl e: 6' 00' + 15'
2. Hol d t he f l ange bol t
( A)
on t he r ear of t hel ower ar m,
and l oosen t he sel f - l ocki ng nut
( B) .
B
' 12
\1.25 mm
Turn the adj usti ng cam col l ar
(C)
unti l the caster i s
correct.
After adj usti ng, ti ghten the sel f-l ocki ng nut whi l e
hol di ng the fl ange bol t.
18-6
Front Camber Inspection/Adiustment
Use commerci al l y avai l abl e computeri zed four wheel
al i gnment equi pment to measure wheel al i gnment
(caster.
camber, toe, and turni ng angl e) Fol l owthe
equi pment manuJacturer' s i nstructi ons.
1. Check the camber angl e. l f adj ustment i s req ul red,
go to step 2.
Front camber angl e:
-0' 30' t
10'
2. Hol d t he adj ust i ng bol t
( A)
ont hef r ont of t hel ower
arm, and l oosen the sel f-l ocki ng nut
(B).
B
12 x
' 1.25
mm
78 N.m {8.0 kgf m.58 l bf ft)
,
--
-11'',
Turn the adj usti ng bol t unti l the camber i s correct.
hol di ng the adj usti ng bol t.
Rear Camber Inspection/Adjustment
Use commerci al l v avai l abl e comDuteri zed four wheel
al i gnment equi pment t o measur e wheel al i gnment
(caster,
camber, toe, and turni ng angl e). Fol l ow the
equi pment manufacturer' s i nstructi ons.
1. Check the camber angl e. l f adj ustment i s req u i red.
go to step 2.
Rear camber angl e: 1"30' + 10'
2. Hol d the adj usti ng bol t
(A)
on the control arm, and
l oosen the sel f-l ocki ng nut
(B).
4.
54 N. m
(5. 5
kgf . m,
40 tbf.ft)
Turn the adj usti ng bol t unti l the camber i s correct.
hol di ng the adj usti ng bol t.
Front Toe Inspection/Adjustment
Use commer ci al l y avai l abl e comput er i zed f our wheel
al i gnment equi pment t o measur e wheel al i gnment
(caster,
equi pment manufacturer' s i nstructi ons.
1. Centerthe steeri ng wheel spokes.
2. Check t he t oe. l f adj ust ment i s r equi r ed, got ost ep
Front toe-i n: 0 + 2 mm
(0 + 0.08 i n.l
3, Hol d the ti e-rod end
(A),
and l oosen the ti e-rod
l ocknut
(B).
33 tbt.ftl
Turn the ti e-rod unti l the toe i s correct.
After adj usti ng, ti ghten the l ocknut whi l e hol di ng
the ti e-rod end. Reposi ti on the rack-end boot i f i t i s
twi sted or di sl ocated.
(cont' d)
4,
5,
, . / B
18-7
Wheel Al i gnment
(cont' d)
Rear Toe Inspection/Adiustment
Use commerci al l y avai l abl e computeri zed four wheel
(caster,
equi oment manufacturer' s i nstructi ons.
' 1.
Rel ease the
parki ng
brake to
prevent
an i ncorrect
measurement.
2. Check the toe. l f adj ustment i s requ i red, go
to step
Rear toe-i n: 6.0 t 2 mm
(0.25
+ 0.08 i n.l
3. Hol d the adj usti ng bol t ofthe control arm
(A),
and
l oosen the sel f-l ocki ng nut
(B).
Hol d the adj usti ng
bol t of the l ower arm {C), and l oosen the sel f-
l ocki ng nut
( D) .
B
12 x1.25 mm
54 N.m (5.5
kgf.m,
i l ol bf.ftl
- ) t , . i
12 x 1. 25 mm
74 N m 17. 5 kgl m. 54l bt . f t )
Turn both adj usti ng bol ts i n opposi te di rectl ons
unti l the toe i s correct.
NOTE: Adj ust the rear toe by adj usti ng the control
arm and the l ower arm by the same amount i n
opposi te di recti ons to each other
(for
exampl e,
when you move the control arm out, move the
l ower arm i n, and vi se versa).
After adj usti ng, ti ghten both sel f-l ocki ng nuts whi l e
hol di ng the respecti ve adj usti ng bol ts.
18-8
Turning Angle Inspection
Use commerci al l v avai l abl e comouteri zed four wheel
{caster, camber, toe. and turni ng angl e). Fol l ow the
eoui Dment manufacturer' s i nstructi ons.
1. Turn the front wheel ri ght and l eft whi l e appl yi ng
the brake. and check the turni ng angl es of both
wneet s.
Turni ng angl e:
lnward wheel; 34"00'
t
2"
Outward wheel: 29'00'
(reference)
l f the turni ng angl es are out of speci fi cati on or the
i nward turni ng angl es di ffer between the ri ght and
l eft, check the toe, and adj ust accordi ngl y.
l f the toe adj ustment i s correct but the turni ng
angl es are out of speci fi cati on, check for bent or
damaged suspensi on component s.
Wheel Bearing End Play lnspection
1 . Rai se the vehi cl e, and suppon i t wi th safety stands
i n the proper l ocati ons
(see page 1-13).
Remove the wheel s, then rei nstal l the wheel nuts.
Attach the di al gauge. Pl ace the di al
gauge agai nst
t he hub f l ange.
Front:
2.
?
Rear:
Measur e t he bear i ng end pl ay movi ng t he br ake
di sc i nward or outwa rd.
Standard:
Front/rear:0 0.05 mm
(0
0.002 i n.l
l f t he bear i ng end pl ay measur ement i s mor e t han
the standard, repl ace the wheel beari ng.
Wheel Runout Inspection
' 1.
4.
Rai se the vehi cl e, and support i t wi th safety stands
i n the
proper
l ocati ons
(see page 1-13).
Check for a bent or deformed wheel .
Set up the di al
gauge as shown, and measure the
axi al r unout by t ur ni ng t he wheel .
Front and rear wheel axial runout:
Standard: 0 0.7 mm {0-0.03
i n.)
Servi ce l i mi t: 2.0 mm 10.08 i n.)
Readj ust the di al
gauge to the posi ti on shown. and
measure the radi al runout.
Fronl and rear wheel radial runout:
Standard: 0-0.7 mm {0 0.03 i n.)
Servi ce l i mi t: 1.5 mm
(0.06
i n.)
l f the wheel runout i s out of speci fi cati on, check the
wheel beari ng end
pl ay.
l f the beari ng end
pl ay i s wi thi n the speci fi cati on
but the wheel runout i s more l han the servi ce l i mi t,
r epl ace t he wheel .
18-9
Bal l Joi nt Removal
Bal l j oi nt remover, 28 mm 07MAC-S100200
1. Instal l a hex nut onto the threads of the bal l
j oi nt.
Make sur e t he nut i s f l ush wi t h t he bal l j oi nt
pi n
end to
prevent
damage to the threaded end of
the bal l
i oi nt
pi n.
2. Appl y gr ease t o t he speci al t ool ont hear easshown
(A).
Thi s wi l l ease i nstal l ati on of the tool and
prevent damage to the pressure bol t
(B)
threads.
3. Instal l the speci al tool as shown. l nsert the
j aws
careful l y, maki ng sure not to damage the bal l
j oi nt
boot. Adj ust the
j aw
spaci ng by turni ng the
Dressure bol t.
07MAC-S100200
12 mm
HEX NUT
18- 10
4. Once the speci al tool i s i n pl ace, turn the adj usti ng
bol t
(A)
as necessary to make the
j aws paral l el .
Then hand-ti ghten the pressure bol t
(B),
and
recheck the
j aws
to make sure they are sti l l
paral l el .
After maki ng the adj ustment to the adj usti ng bol t,
make sure the head ofthe adj usti ng bol t
(A)
i s i n
the
posi ti on
shown to al l ow the
j aw (C)
to pi vot.
Wi th a wrench, ti ghten the pressure bol t
(B)
unti l
the bal l
j oi nt pi n pops l oose from the steeri ng or
suspensi on arm. l f necessary, appl y
penetrati ng
type l ubri cant to l oosen the bal l
j oi nt pi n.
Remove the tool , then remove the nut from the end
of t he bal l j oi nt pi n, and pul l t he bal l j oi nt out of t he
steeri ng or suspensi on arm. Inspect the bal l
i oi nt
boot, and repl ace i t i f damaged.
1.
Front Suspension
Knuckle/Hub Replacement
Exploded View
SPINDLE NUT
24 x 1.5 mm
329 N.m
(33.5
kgf.m.2,|2 lbf.ft)
Repl ace.
Appy a smal l amount of engi ne oi l
t o t he seat i ng surf ace.
LOWER ARM
BALL JOINT
12 x 1.25 mm
64 N.m
(6.5
kgf.m, 47 lbf.ftl
7
HUB CAP
//
Checktot delormation and damaqe.
d^^/q
,-,----{g /Y /
BEARI NG
Repl ace.
Check l or def ormat i on
ano oamage,
SCREW
5 mm
4. 9 N. m
(0. 5
kgt . m,
3.6 tbf.ft)
BOOT CLIP
BALL JOINT BOOT
Repl ace.
FLAT-HEAD SCREW
6 x 1 . 0 mm
9. 8 N. m {1. 0
kgf . m,
7.2 tbt-ft)
(cont' d)
Check l or def ormat i on,
damage, and cracks,
BRAKE DISC
18- 11
Front Suspension
(cont'd)
SpecialTools Required
.
Bal l
j oi nt
.
Beari ng dri ver attachment, T2 x 75 mm 07746-0010600
.
Dri ver, 07749-0010000
.
Support base, 72 x 78/82.6 mm 07965-SD90100
.
Hub di s/assembl y tool , 07GAF-SD40200
' 1.
Rai se the front ofthe vehi cl e, and suppon i twi th
safety stands i n the
proper l ocati ons
( see page 1- 13) .
2. Remove the wheel nuts
(A)
and the front wheel .
3. Remove the brake hose bracket mounti ng bol t
(A).
9 . 8 Nm
(r.0
kgt.m,
7 .2 tbt.ttl
' ,
108 N m
'
111.0 ksf.m,
79.6 tbf.ft)
Remove the cal i per bracket mounti ng bol ts
(B),
and
r emove t he cal i per assembl v
( C) f r om
t he knuckl e.
To
prevent
damage to the cal i per assembl y or
brake hose, use a shon pi ece of wi re to hang the
cal i per assembl y from the undercarri age. Do not
twi st the brake hose wi th force.
18-12
5. Remove the fl ange bol ts
(A)
and wheel sensor
(B)
from the knuckl e
(C).
Do not di sconnect the wheel
sensor connector.
A
9 . 8 N m
(1. 0
kgf . m,
7.2 tbl.ttl
l r
6. Remove the 6 mm brake di sc retai ni ng screws
(A).
A
9. 8 N. m
{1. 0 kgf . m,
7.2lbt.ttl
1. Screw two 8 x 1.25 mm bol ts
(B)
i nto the di sc to
push i t away from the hub. Turn each bol t two turns
at a ti me to
prevent cocki ng the di sc excessi vel y,
Remove the brake di sc from the knuckl e.
Check the hub for damage and cracks. 9.
i i /
r
t l
pi n (A)from
the ti e-rod end bal l
j oi nt,
then remove the nut
(B).
B
12 x
' 1. 25
mm
54 N. m
15.5 kgf m.,l0 lbf ft)
1 1 .
07MAC-S100200
Remove the ti e-rod bal l
j oi nt
from the knuckl e usi ng
t he speci al t ool
( see page 18- 10) .
Remove the cotter
pi n (A)
j oi nt ,
and r emove t he cast l e nut
( B) .
,--------'tg
14 x 1. 25 mm
56-69 N. m
(6. 0-7. 0
kgt . m. 43-51 l bt . f t l
13. Remove t he l ower ar m bal l
j oi nt
f r om t he knuckl e
usi ng t he speci al t ool
( see page 18- 10) .
14. Remove the l ock pi n (A)
from the upper arm bal l
i oi nt, and remove the castl e nut
(B).
12 x 1.25 mm
49-59 N m
15,0-6.0 kgf
.m,
36-4:t l bf
.ft
)
Remove the upper arm bal l
j oi nt
from the knuckl e
usi ng the speci al tool
(see page 18-10).
Remove the knuckl e.
Remove the hub cap
(A).
16.
11.
' 18.
/a
t ' . -
r )
v
@^--"''-
Rai se the stake
(B)
of the spi ndl e nut
(C),
and
remove the nut and
pul ser (D).
(cont' d)
18- 13
Front Suspensi on
19.
Knuckl e/Hub Repl acement
(cont' dl
Separate the hub
(A)from
the knuckl e
(B)
usi ng a
hydraul i c
press.
Be careful not to deform the spl ash
guard.
Hol d the hub to keep i t from fal l i ng when
presseo
crear.
Remove the screws
(A),
snap ri ng
(B),
and the
spl ash guar d ( C) f r om
t he knuckl e
( D) .
/
Press
I
, ]
' t
18-14
21. Pr ess t he wheel bear i ng
( A)
out of t heknuckl e{ B}
usi ng t he speci al t ool s and a
pr ess.
piess
07746-00'10600
Press the wheel beari ng i nner race
(A)
out of the
hub
( B)
usi ng a commer ci al l y avai l abl e bear i ng
separator {C) and a
press.
49-0010000
23.
24.
Wash t he knuckl e and hub t hor oughl y i n hi gh f l ash
poi nt
sol vent before reassembl y.
Press a new wheel beari ng
(A)
i nto the knuckl e
(B)
usi ng the ol d beari ng
(C).
a steel pl ate (D),
the
speci al tool , and a press, Pl ace the wheel beari ng
on the knuckl e wi th the
pack
seal si de {metal col or)
faci ng i nsi de. Be careful not to damage the sl eeve
of t he Dack seal .
I
B
25. I nst al l t he snap r i ng
( A)
secur el y i n t he knuckl e
( B)
D
4.9 N.m 10.5 ksf.m. 3.6 l bf ft)
I nst al l t he spl ash guar d
{ C) , and t i ght en t he scr ews
( D) .
BLACK COLOR
27.Wash the spi ndl e thoroughl y i n hi gh fl ash poi nt
sol vent before reassembl y,
I nst al l t he hub
( A)
ont o t he knuckl e { B) usi ng t he
speci al tool s and a hydraul i c press. Take care not to
deform the spl ash
guard.
29. I nst al l t he pul ser ( A) .
28.
n-'.X./
\#
./ln*r.u^
e\'/ ?"rlidi.-,
242 tbl.ftl
30. Appl y a smal l amount of engi ne oi l t o t he seat i ng
sur f ace of a new spi ndl e nut
( B) .
I nst al l t he nut , and
ti ghten i t to the speci fi ed torque. Stake the nut
shoul der agai nst the dri veshaft wi th a dri ft.
I nst al l t he hub cap
( C) .
(cont' d)
18- 15
Front Suspension
32.
(cont'dl
Instal l the knuckl e i n the reverse order of removal ,
payi ng parti cul ar attenti on to the fol l owi ng i tems:
.
j oi nt
boot when
i nst al l i ng t he knuckl e.
.
Use a new spi ndl e nut and new sel f-l ocki ng nuts
on reassemoty.
.
Ti ghten al l mounti ng hardware to the speci fi ed
torque val ues,
.
Ti ghten the castl e nut to the l ower torque
speci fi cati on, then ti ghten onl y far enough to
al i gn the sl ot wi th the bal l
i oi nt
pi n hol e. Do nol
al i gn by l ooseni ng the castl e nut.
.
Instal l a new cotter pi n or l ock pi n on the castl e
nuts after torqui ng.
.
Before i nstal l i ng the brake di sc, cl ean the mati ng
surface of the hub and the i nsi de of the brake
di sc.
.
Before i nstal l i ng the wheel , cl ean the mati ng
surface of the brake di sc and the i nsi de of the
wneet ,
.
Check the wheel al i gnment, and adj ust i t i f
necessary
(see page 18-5).
18- 16
Bal l Joi nt Boot Repl acement
Bal l j oi nt boot cl i p gui de, 07GAG-SD40700
' 1.
Remove the boot cl i p and the boot.
2. Pack the i nteri or and l i p of the new boot {A) wi th
fresh grease. Do not contami nate the l ower col l ar
of the boot
(B)
wi th
grease.
A
Wi pe the
grease
off the tapered secti on of the
pi n
(C),
and
pack the base
(D)
wi th fresh grease.
I nst al l t he boot ont o t he bal l
j oi nt pi n,
t hen squeeze
i t gentl y
to force out any ai r. Do not l et di rt or other
torei gn materi al s get i nto the boot.
Adj ust the speci al tool wi th the adj usti ng bol t
(A)
unti l i ts base i s
j ust
above the
groove
around the
bottom of the boot. Then sl i de the cl i p over the tool
i nto the posi ti on (B)
on the boot.
After i nstal l i ng a boot, wi pe any grease offthe
exposed por t i on of t he bal l j oi nt pi n.
Stabilizer Bar Replacement
1 .
2.
Rai se the front of the vehi cl e, and support i t wi th
proper l ocati ons
( see page 1- 13) . Remove t he f r ont wheel .
Remove the cl i ps
(A)
and fl ange bol ts
(B),
then
remove the spl ash
guard (C).
9.8 N.m {1.0 kqf.m,7.2l bt ftl
Remove the sel f-l ocki ng nuts {A) whi l e hol di ng the
j oi nt pi ns (B)
wi th a hex wrench
(C),
and di sconnect
t he st abi l i zer l i nks
( D) f r om
t he st abi l i zer bar
( E)
on
the ri ght and l eft.
A
10 x 1, 25 mm
38 N. m {3. 9 kgf . m.
28 tbf.ftl
4. Remove the bol ts
(A)
and bushi ng hol ders
(B).
then
remove the bushi ngs
(C)
and the stabi l i zer bar
(D).
A
l nstal l the stabi l i zer bar i n the reverse order of
r emoval .
NOTE: Refer to Stabi l i zer Li nk Repl acement to
connect the stabi l i zer bar to the l i nks.
5.
10 x 1. 25 mm
39 N. m
(4. 0
kgf . m.
18-17
Front Suspension
Stabilizer Link Removal/lnstallation
1 . Rai se the front of the vehi cl e, and support i t wi th
proper l ocati ons
(see page 1-13). Remove the front wheel .
Remove spl ash guard (see page 18-17).
Remove the sel f-l ocki ng nut
(A)
and fl ange nut
(B)
whi l e hol di ng the respecl i ve
j oi nt pi ns (C)
wi th a
hex wrench
(D).
and di sconnect the stabi l i zer l i nk
( E)
f r om t he st abi l i zer bar
( F)
and t he l ower ar m
( G) .
l nstal l the stabi l i zer l i nk to the stabi l i zer bar and
l ower arm wi th the
j oi nt pi ns set at the center of
thei r range of movement.
18- 18
5. l nstal l the sel f-l ocki ng nut and fl ange nut, and
l i ghtl y ti ghten.
6, Pl ace a
j ack
under the l ower arm, and rai se the
suspensi on to l oad the stabi l i zer.
7. Ti ghten the sel f-l ocki ng nut
(A)
and tl ange nut
(B)
to
the speci fi ed torque val ues whi l e hol di ngthe
respecti ve
j oi nt pi ns (C)
wi th a hex wrench
(D).
A
10 x 1.25 mm
38 N.m
10 x
' 1.25
mm
29 N.m
8. After 5 mi nutes o{ dri vi ng, re-ti ghten the sel f-
l ocki ng nut of the
j oi nt
connected to the stabi l i zer
bar agai n to the speci fi ed torque val ue.
Lower Arm Removal/lnstallation
.
Bal l
j oi nt
1. Rai se the front of the vehi cl e, and support i t wi th
proper l ocai ons {see
page 1-13).
Remove the front wheel .
2. Remove l he fl ange nut
(A)
whi l e hol di ng the
j oi nt
pi n (B)
wi th a hex wrench
(C),
and di sconnect the
st abi l i zer l i nk
( D) f r om
t he l ower ar m
( E) .
A
10 x 1.25 mm
29 N m
(3.0 kgf.m, 22 lbf.ft)
(A),
and di sconnect the
damper
( B)
f r om t he l ower ar m
( C)
10 x 1. 25 mm
6 4 N m
(6.5 kgf.m, 47 lbf.ft)
4. Remove the cotter pi n (A)from
the l ower arm bal l
(B).
Remove the l ower arm bal l
j oi nt from the knuckl e
usi ng the speci al tool
(see page 18-10).
(A)
and sel f-l ocki ng
cam nut
(B).
then remove the cam
pl ate
{C).
adj usti ng bol t
(D),
cam col l ar
(E),
fl ange bol t
(F),
and the l ower arm.
5.
6.
12 x 1. 25 f i m
78 N. m
(8. 0 kgf . m, 58l bf . f t )
B
12 x' l . 25 nm
78 N. m
{8.0 kgf rn, 58 lbf.ft}
(cont' d)
18- 19
Front Suspension
{cont'd)
7. l nst al l t he l ower ar m i n t he r ever se or der of
removal payi ng parti cul ar
attenti on to the fol l owi ng
i tems:
.
j oi nt
boot when
connecti ng the l ower arm to the knuckl e.
.
Use a new sel f-l ocki ng cam nut and a new sel f-
l ocki ng nut on reassembl y.
.
toroue val ues.
.
Fi rsti nstal l al l the components and l i ghtl y ti ghten
bol ts and nuts, then pl ace a
j ack
under the l ower
arm, and rai se the suspensi on to l oad the wei ght
before ful l y ti ghteni ng to the speci fi ed torque
val ues,
.
j oi nt pi n hol e. Do not
.Instal l
a new cotter
pi n
on the castl e nut after
torqui ng.
.
wheel .
.
necessary {see
page l 8-5).
18-20
Upper Arm Replacement
.
Bal l
j oi nt
remover,23 mm 07MAC-S100200
proper l ocati ons
(see page 1-13), Remove the front wheel .
(A)
andthewheel sensor
har ness
( B) f r om
t he upper ar m
( C) .
A
6 x 1 . 0 mm
9. 8 N. m
(1. 0 kgf . m, 7. 2 l bl f t )
Remove t he l ock pi n (A)
f rom t he upper arm bal l
j oi nt ,
and r emove t he cast l e nut { Bl .
07MAC-S100200
12 x 1. 25 mm
49-59 N. m
4.
{5.0-6.0 ksf.m,36-43 l bt ftl
j oi nt
from the knuckl e
( see page 18- 10) .
3.
5. Remove the fl ange bol ts {A). and the upper arm.
12 x 1. 25 mm
103 N.m
(10,5
kgt.m, 75.9l bt.ftl
I nst al l t he upper ar m i n t he r ever se or der of
i tems:
j oi nt
boot when
connecti ng the upper arm to the knuckl e.
t or que val ues,
Fi rst i nstal l al l the susDensi on comoonents and
l i ghtl y ti ghten bol ts and a nut, then pl ace a
j ack
under the l ower arm, and rai se the suspensi on to
l oad the wei ght before ful l y ti ghteni ng to the
sDeci fi ed toroue val ues.
al i gn t he sl ot wi t h t he bal l
l nstal l a new l ock Di n on the castl e nut after
t or qui ng.
sur f ace of t he br ake di sc and t he i nsi de of t he
wheel .
Check t he wheel al i gnment , and adj ust i t i f
necessary
(see page
18-5).
18-21
Front Suspension
Damper/Spri ng Repl acement
Exploded View
LOWER SPRING MOUNTING CUSHION
Check for deteri orati on and damage.
a9
g
SELF.LOCKING NUT
10 x 1.25 mm
29 N.m
(3.0
kgf.m,22l bf.ftl
Bepl ace.
Check f or det eri orat i on and damage.
COVER PLATE
\auupstop
Check f or weakness and damage.
A
DAMPER MOUNTING coLLAR
n-.'
SPRING MOUNTING CUSHION
_.-ousr
covER SLEEVE
/
Check f or bendi ng and damage.
[:gl '
unecK ror oenorng ano oamage'
V -,or.r aou., ."o
. , r-
Check f or def ormat i on and damage.
f=
5r'-
BUMP sroP PLArE
18-22
Strut spri ng compressor, Brani ck MST-580A or Model
7200, or equi val ent. commerci al l y avai l abl e.
Removal
(see page 1-13). Remove the front wheel .
2. Remove t he f l ange bol t
( A)
andbr akehose
mounti ng bracket
(B)from
the damper.
Remove the cotter
pi n (A)
j oi nt,
and remove the castl e nut
(B)
,--6.
B'
,/-
A
j oi nt
from the knuckl e
( see page 18- 10) .
4.
5. Remove the fl ange nuts
(A)trom
the top of the
oamper .
Remove the fl ange bol t
(A)
at the bottom of the
oamper .
{cont' d)
18-23
Front Suspension
Damper/Spring
Replacement
(cont'd)
1 . Lower the l ower arm, and remove the damper
assembl y
(A).
I
t
18-24
Disassembly/lnspection
1. Compress the damper spri ng wi th the
commerci al l y avai l abl e strut spri ng compressor {A)
accordi ng to the manufacturer' s i nstructi ons, then
remove the sel f-l ocki ng nut {B).
Do not compress
the spri ng more than necessary to remove the nut.
4.
Rel ease the
pressure from the strut sprl ng
compressor, then di sassembl e the damper as
shown i n the Expl oded Vi ew.
Reassembl e al l of the
parts, except the spri ng.
Compress the damper assembl y by hand, and
check for smooth operati on through a ful l stroke.
both compressi on and extensi on. The damper
shoul d extend smoothl y and constantl y when
compressi on i s rel eased. l f i t does not, the gas i s
l eaki ng and the damper shoul d be repl aced
5. Check f or oi l l eaks, abnor mal noi ses, or bi ndi ng
duri ng these tests.
2.
3.
Reassembly
1. Assembl e al l of the damper components except the
sel f-l ocki ng nut onto the damper uni t. Al i gn the
spri ng bottom end
(A),
the stepped
pan
of the
l ower spri ng mounti ng cushi on, and the step on the
l ower spri ng seat
(B).
Instal l the damper assembl y on a commerci al l y
avai l abl e strut spri ng compressor
(C).
Posi ti on the damper mounti ng base as shown.
VIEWING FROM TOP
,11
t 3' 4 1 1 3 '
3.
STUD BOLT
Compress the damper spri ng wi th the spri ng
compressor.
Instal l a new sel f-l ocki ng nut
(A)
on the damper
shaft.
{3.0 kst.m,22 l bf.ftl
Hol d the damper shaft wi th a hex wrench {B). and
ti ghten the sel f-l ocki ng nut to the speci fi ed torque.
(cont' d)
f(
1
i . ,
l r ' - -
- r
-
\
- ' r >
\ ^ ' . . \ - \ J t :
\ V
A
10 x' 1, 25 mm
, '
\
18-25
Front Suspension
Damper/Spring Replacement
(cont'dl
lnstallation
1. Lower the l ower arm, and
posi ti on the damper
assembl y {A) i n the body.
Loosel y i nstal l the fl ange nuts
(A)
onto the damper
studs.
A
10 x 1.25 mm
49 N.m
(5.0 kgt.m,36lbt.ft)
2.
18-26
3. Posi ti on the damper bottom on the l ower arm
(A),
and connect the l ower arm and the l ower bal l i oi nt
{ B) .
t ;
-\1,
4.
5.
10 x 1. 25 mm
6 4 N m
(6. 5 kgl . m, 47 l bf . f t l
Instal l the fl ange bol t
(C),
and l i ghtl y ti ghten.
Rai se the suspensi on unti l the vehi cl e
j ust
l i fts off
the safety stand.
Instal l the castl e nut
(A)
onto the l ower bal l
j oi nt pi n,
and ti ghten i t to the speci fi ed torque.
7.
@-o
I nst al l t he cof t er
pi n ( B) .
Ti ght en t he f l ange bol t connect i ng t he damper
bottom to the l ower arm to the speci fi ed torque.
14 x 1. 25 mm
59-69 N. m
(6. 0-7. 0 kgt . m,
il3-51 lbf.ftl
9. Ti ghten the fl ange nuts on the top of the damper to
the soeci fi ed toroue.
10. Instal l the brake hose mounti ng bracket
(A)
and the
fl ange bol t
(B)to
the damper, and ti ghten the bol t
Ex 1. 25 mm
22 N.m
(2.2
kgf.m, 16l bf.ftl
r(
18-27
Rear Suspension
KNUCKLE
r )
iAri
Exploded View
LOWER ARM BALL JOINT
12 x 1, 25 mm
64 N. m
(6.5 kgf.m,47 lbf.ft)
WHEEL BEARING
Repl ace.
SNAP RING
I
l
l
I
BOOT CLIP
SPLASH GUARD
Check f or del ormat i on and damage.
SCREW
5 mm
4 . 9 N m
l 0. s kgf . m, 3. 6l bf . f t )
FLAT-HEAD SCREW
6 x
' 1. 0
mm
9. 8 N. m
(1. 0
kgt . m, 7. 2 l bf . f t |
245 N. m
(25. 0
kgt m. 181 l bf . f t l
Repl ace.
Appy a smal l amount o{ engi ne oi l
t o t he seat i ng surf ace.
BALL JOINT BOOT
Repl ace.
BRAKE DISC
Check f or de{ormat i on,
damage, and cracks.
18-28
.
Hub di s/assembl y tool attachment, 42 mm
07GAF-SD40100
.
Bal l
j oi nt
.
Beari ng dri ver attachment,62 x 68 mm 07746-0010500
.
Dri ver, 07749-0010000
.
Support base,72 x 78182.6 mm 07965-5D90100
.
Attachment, 52 x 55 mm 07746-0010400
Rai se the rear of the vehi cl e, and support i t wi th
( see page
1- 13) .
Remove the wheel nuts
(A)
and rear wneer. 2.
1 .
A
108 N. m
{11. 0 kgf . m,
79.6 tbf.ftl
3. Remove the cal i per bracket mounti ng bol ts
(A).
and
remove the cal i per assembl y
(B)
from the knuckl e.
To prevent
damage to the cal i per assembl y or
brake hose, use a short
pi ece
of wi re to hang the
cal i per assembl y from the undercarri age. Do not
twi st the brake hose wi th force.
10 x 1. 25 mm
55 N. m
{5.6 kgf.m, il1
lbf ft)
I
o""
4. Remove t he f l ange bol t
( A)
andwheel sensor ( B)
from the knuckl e. Do not di sconnect the wheel
sensor connecl or.
A
6 x 1 . 0 mm
9.8 N m {1.0 kgf m.7.2 l bf.ft)
i
5. Rai se t he st ake
( A)
of t hespi ndl enut ( B) . and
remove the nut.
A
24 x 1.5 mm
245 N.m
(25.0
kgf.m, 181 l bf.ft)
(cont' d)
18-29
Rear Suspension
Knuckle/Hub
RePlacement
(cont'dl
Remove the 6 mm brake di sc retal ni ng fl at-head
screws
(A).
l'1.0
kgf m, 7 2 lbf ft)
7. Scr ew t l vo 8 x 1. 25 mm bol t s
( B)
i nt ot hedi sct o
push l t away from the hub Tu rn each bol t tl vo turns
at a ti me to
prevent cocki ng the di sc excessi vel y
8. Remove the brake di sc from the knuckl e
L Check the hub for damage and cracks.
10. Remove the sel f-l ocki ng
nut
(A),
cam
pl ate (B),
and
adj usti ng bol t
(C),
then di sconnect the control arm
(D)
from the frame
' 12
x 1. 25 mm
54 N. m
(5. 5 kgt . m, 40 l bf f t )
L
18-30
t 5 .
11. Remove t he l ock
pi n ( A) f r om
t he cont r ol ar mbal l
(B)
B
12 x 1.25 mm
49-59 N.m
' . :
. . y , .
07MAC-S100200
12. Remove t he cont r ol ar mbal l
j oi nt f r om t h e knuckl e
( see page 18- 10)
NOTE: Turn the control arm
(C)
outward to i nstal l
t he bal l
j oi nt r emover '
13. Remove the control arm.
14. Remove t he cot t er
pi n ( A) f r om
t he l ower ar m bal l
j oi nt,
(B).
07MAC-S100200
12 x 1. 25 mm
68-78 N. m
(7. 0-8. 0 kgf m,
51-58 l bf . f t l
Remove t he l ower ar m bal l
j oi nt
( see page 18- 101
(5. 0-6. 0 kgf m, 36-43 l bf f t l
,4$:.'
I
.i^\
' -
-
' ( .
. /
' 16.
Remove the l ock pi n (A)
from the upper arm bal l
j oi nt,
(B).
17.
18.
B
12x' 1, 25 mr n
49-59 N. m
{5. 0-6. 0 kgf . m, 36-i B l bt f t }
j oi nt
from the knuckl e
( see paSe
' 18- 10) .
Remove the dri veshaft outboard
j oi nt
{A) from the
knuckl e by tappi ng the dri veshaft end wi th a pl asti c
hammer
( B)
whi l e pul l i ng
t he knuckl e
( C)
out war d.
-
-.._..,,:.
r,...'\
.;z +':.
.,.
t-
';l '.-
)
20.
19. Separate the hub
(A)from
the knuckl e
(B)
usi ng the
speci al tool and a hydraul i c press.
Be careful notto
deform the spl ash guard. Hol d the hub to keep i t
from fal l i ng when pressed
cl ear.
Remove the screws
(A),
snap ri ng
(B),
and the
spl ash guar d ( C)
( D) .
(cont' d)
18-31
Rear Suspension
21.
(cont'dl
Press the wheel beari ng
(A)
out of the knuckl e
(B)
usi ng t he speci al t ool s and a pr ess,
07746-0010,100
Pross
t
)'
--.
Press the wheel beari ng i nner race
(A)
out of the
hub
( B)
usi ng t he speci al t ool , a commer ci al l y
avai l abl e beari ng separator {C), and a
press.
07GAF-SD40100
07749-0010000
I
n
22.
18-32
23. Wash the knuckl e and hub thoroughl y i n hi gh fl ash
poi nt sol vent before reassembl y.
24. Pr ess a new wheel bear i ng
( A)
i nt ot heknuckl e( B)
usi ng t he ol d bear i ng
( C) ,
a st eel pl at e ( D) .
t he
speci al tool , and a
press. Pl ace the wheel beari ng
on the knuckl e wi th the
pack seal si de
(metal
col or)
faci ng i nsi de. Be careful not to damage the sl eeve
of the
pack
seal .
07965-SD90100
25. I nst al l t he snap r i ng
( A)
secur el y i n t he knuckl e
( B) .
D
5 x 1 . 0 m m
4. 9 N. m
(0. 5
kgf . m, 3. 6 l bf f t )
{:""""
O7-,-^
Vr "
===-_9
, B
I nst al l t he spl ash guar d
{ C) , and t i ght en t he scr ews
( D) .
BLACK COLOR
:-.L|-='.u
' F : _
t ' r
' - \
Press
28.
27. I nst al l t he hub { A) ont o t he knuckl e
( B)
usi ngt he
speci al tool s and a hydraul i c press. Be careful not
to deform the spl ash guard.
Press
077,19-0010000
Instal l the knuckl e i n the reverse order of removal
payi ng parti cul ar
attenti on to the fol l owi ng i tems:
.
Be car ef ul not t o damage t he bal l
j oi nt boot when
i nstal l i ng the knuckl e.
.
Use a new spi ndl e nut on reassembl y.
.
Before i nstal l i ng the new spi ndl e nut, appl y a
small amount o{ engine oil to the seating sur{ace
of the nut. After ti ghteni ng, use a dri ft to stake the
spi ndl e nut shoul der agai nst the dri veshaft.
.
Ti ghten al l mountj ng hardware to the speci fi ed
torque val ues.
.
al i gn t he sl ot wi t h t he bal l
j oi nt pi n or cl i p hol e.
Do not al i gn by l ooseni ng the castl e nut.
. I nst al l
a new cot t er
pi n
or I ock pi n
on t he cast l e
nut after torqui ng.
.
Before i nstal l i ng the brake di sc, cl ean the mati ng
surface of the hub and the i nsi de of the brake
di sc.
.
wneet .
.
necessary (see page
18-5).
Ball Joint Boot Replacement
Bal l
j oi nt
boot cl i p
gui de,
07cAG-SD40700
1. Remove the boot cl i p and the boot.
2. Pack the i nteri or and l i p of the new boot
(A)
wi th
fresh grease.
Do not contami nate the l ower col l ar
of the boot
(B)
wi th grease.
4.
Wi pe the grease
off the tapered secti on of the
pi n
(C),
and pack
the base
(D)
wi th fresh grease.
Instal l the boot onto the bal l
j oi nt pi n,
then squeeze
i t gentl y to force out any ai r. Do not l et di rt or other
forei gn materi al s get i nto the boot.
For the upper and l ower arm bal l
j oi nt,
adj ust the
speci al tool wi th the adj usti ng bol t
(A)
unti l i ts base
i s
j ust
above the groove
around the bottom of the
boot. Then sl i de the cl i p over the tool i nto the
posi ti on (B)
on the boot.
For the control arm bal l
j oi nt,
set the boot on the
j oi nt pi n,
and
press
i t wi th the speci al tool unti l
there i s no gap
at the bottom of the boot
(A).
After i nstal l i ng a boot, wi pe any
grease
offthe
exposed porti on
of the bal l
j oi nt pi n.
7.
18-33
Rear Suspension
Stabilizer Bar Replacement
' 1.
Rai se the rear of the vehi cl e, and suppon i t wi th
{ see
page 1- 13} . Remove t he r ear wheel
Remove the sel f-l ocki ng nuts
(A)
j oi nt pi ns (B)
wi th a hex wrench
(C).
and di sconnect
the stabi l i zer l i nks
(D)
from the stabi l i zer bar {E) on
the ri ght and l eft.
A
10 x 1 ,25 mm
43 N.m
(i1.4
kgf.m, 32 lbf.ftl
Remove the bol ts
(A)
and bushi ng hol ders
(B),
then
remove the bushi ngs
(C)
and the stabi l i zer bar
(D)
l nstal l the stabi l i zer bar i n the reverse order of
removal .
NOTE: Refer to Stabi l i zer Li nk Repl acement to
connect the stabi l i zer bar to the l i nks.
18-34
Stabilizer Link Removal/lnstallation
1 . Rai se the rear of the vehi cl e, and support i t wi th
proper l ocati ons
( see page 1- 13) . Remove t he r ear wheel .
(A)
and fl ange nut
(B)
whi l e hol di ng the respecti ve
j oi nt pi ns (C)
wi th a
hex wrench
(D),
and di sconnect the stabi l i zer l i nk
(E)
from the stabi l i zer bar
(F)
and the l ower arm
(G).
l nstal l the stabi l i zer l i nk to the stabi l i zer bar and
Iower arm wi th the
j oi nt pi ns set at the center of
t ner r r ange.
4. Instal l the sel f-l ocki ng nut and fl ange nut. and
l i ghtl y ti ghten.
5. Pl ace a
j ack
under the l ower arm, and rai se the
suspensi on to l oad the stabi l i zer bar.
6. Ti ghten the sel f-l ocki ng nut 1A) and fl ange nut
(B)
to
the speci fi ed torque val ues whi l e hol di ng the
respecti ve
j oi nt pi ns (C)
wi th a hex wrench
(D).
10 x 1. 25 mm
29 N m
(3.0
kgf.m,22 lbf.ft)
7. After 5 mi nutes of dri vi ng. re-ti ghten the sel f-
l ocki ng nut of the
j oi nt
connected to the stabi l i zer
bar agai n l o the speci fi ed torque val ue.
.
Bal l
j oi nt
remover. 28 mm 07MAC-SL00200
proper
l ocati ons
( see page
1- 13) . Removet he r ear wheel .
2. Remove the fl ange nut
(A)
j oi nt
pi n (B)wi th
a hex wrench
(C).
and di sconnect the
stabi l i zer l i nk
(D)
from the l ower arm
(E).
A
10 x 1. 25 mm
29 N. m
(3. 0
kgf . m, 22l bf . f t )
Remove t he f l ange bol t
(A),
and di sconnect t he
damper
(B)
from the l ower arm
(C).
(cont' d)
'r-l
18-35
Rear Suspension
(cont'd)
pi n (A)
j oi nt,
(B).
/ r-----'------
-
\
07MAC-S100200
|
._
.,,
9-*-----.
12 x 1. 25 mm
69-78 N. m
A
12 x 1. 25 mm
123 N. m
(12.5
kgf.m. 90.4 lbf.ft)
B
12 x 1 .25 mm
1il N.m
{?.5
kgt.m, 54lbt.ft)
{?.0-8.0
kgl .m,
51-58 tbf.ft)
j oi nt
from the knuckl e
( see page 18- 10) .
Remove the fl ange bol t
(A),
sel f-l ocki ng nut
(B),
cam
pl ate
{C). adj usti ng bol t
(D).
and the l ower arm
( E
) .
18-36
l nstal l the l ower arm i n the reverse order of
removal
payi ng pani cul ar attenti on to the fol l owi ng
t r ems:
.
j oi ntbootwhen
connecti ng the l ower arm to the knuckl e.
.
Use a new sel f-l ocki ng nut on reassembl y.
.
torque val ues,
.
Fi rst i nstal l al l the components and l i ghtl yti ghten
bol ts and nuts, then
pl ace
a
j ack
under the l ower
arm, and rai se the suspensi on to l oad the wei ght
before ful l y ti ghteni ng to the speci fi ed torque
val ues.
.
al i gn by l ooseni ng t he cast l e nut .
.
Instal l a new cotter
pi n on the castl e nut after
t or qur ng.
.
surface ofthe brake di sc and the i nsi de ofthe
wneet.
.
necessary
(see page 18' 5).
Upper Arm Removal/lnstallation
.
Bal l
j oi nt
remover. 28 mm 07MAC-S100200
( see page 1- 13) . Remove t he r ear wheel .
(A)
and the wheel sensor
har ness
( B) f r om
t he upper ar m
( C) .
A
6 x 1 . 0 mm
9. 8 N. m
(1. 0
kgf m. 7. 2l bf . f t )
Remove t he l ock pi n
{A)
f rom t he upper arm bal l
j oi nt ,
and remove t he cast l e nut
(Bl .
3.
07MAC-S100200
12 x 1. 25 mm
49-59 N. m
{5. 0-6. 0 kgt m, 36-4: l l bl f t }
4. Remove t he upper ar m bal l
j oi nt
( see page
18- 10) .
6.
(A),
and the upper arm.
12 x 1. 25 mm
132 N. m {13. 5 kgf . m, 97. 6 l bf . f t l
Insl al l the upper arm i n the reverse order of
i tems;
.
j oi nt
boot when
connect i ng t he upper ar m t o t he knuckl e.
.
toroue val ues,
.
Fi rst i nstal l al l the suspensi on components and
l i ghtl y ti ghten bol ts and a nut, then
pl ace
a
j ack
sDeci fi ed toroue val ues.
.
j oi nt pi n
hol e, Do not
.l nstal l
a new l ock
pl n
on the castl e nut after
rorqurng.
.
wneel .
.
Checkthe wheel al i gnment, and adj ust i t i f
necessary
(see page 18-5).
18-37
Rear Suspensi on
Control Arm Replacement
.
Bal l
j oi nt
1. Rai se the rear of the vehi cl e. and support i t wi th
{ see
page 1- 13) . Remove t he r ear wheel .
2. Remove the sel f-l ocki ng nut
(A),
cam
pl ate (B),
and
adj usti ng bol t
(C),
then di sconnect the conl rol arm
(D)
from the frame.
' 12
x 1.25 mm
54 N.m {5.5 kgf.m, 40l bf.ft)
Remove the l ock pi n (A)
from the conl rol arm bal l
j oi nt.
(B)
Remove the control arm bal l
j oi nt
from the knuckl e
usl ng t he speci al t ool
( see page 18- 10) .
NOTE:Turn the control arm
(C)
outward to i nstal l
t he bal l j oi nt r emover .
Remove the control arm.
4.
5.
07MAC-S100200
18-38
6. Instal l the control arm i n the reverse order of
removal payi ng parti cul ar attenti on to the fol l owi ng
rrems:
.
j oi ntbootwhen
connecti ng the control arm to the knuckl e.
.
Use a new sel f-l ocki ng nut on reassembl y.
.
torque val ues.
.
Fi r st i nst al l al l t he suspensi on component s and
l i ghtl y ti ghten a bol t and nuts, then
pl ace a
j ack
speci fi ed torque val ues.
.
speci fi cati on. then ti ghten i t onl y far enough to
.Instal l
a new l ock pi n on the castl e nut after
t or qui ng.
.
wneet.
.
necessary
(see page 18-5).
Exploded View
RUBBER MOUNTING BUSHING
Check for deteri orati on and damage.
H'*,'
16)
\-,2
---
11--,-----
U
SELF.LOCKING NUI
10 x 1. 25 mm
49 N.m 15.0
kgf m,36 lbf.ftl
Repl ace.
DAMPER MOUNTING COLLAR
/,i-:\
.,,/"DUSf
COVER PLATE
-/DUST
COVER END
)'
Check f or def ormat i on and damaqe.
/DUST COVER SLEEVE
--\-
Check for bendi ng and damage.
t l
g
BUMP STOP PLATE
LOWER SPRING MOUNTING CUSHION
Check f or det eri orat i on and damage.
fZ>-'-'
\gUr' l pSrOp
Check f or weakness and damage.
{cont' d)
18-39
Rear Suspension
2.
(cont'dl
Strut spri ng compressor, Brani ck MST-580A or Model
7200, or equi val ent. commerci al l y avai l abl e
Removal
proper Iocati ons
(see page 1-13). Remove the rear wheel .
Remove the spare ti re from the trunk.
Remove the fl ange nuts {A) from the top of the
oamper .
(A)
at the bottom of the
damper .
18-40
5. Lower the l ower arm, and remove the damper
assembl y
(A).
Disassembly/lnspection
1, Compress the damper spri ng wi th the
commerci al l y avai l abl e strut spri ng compressor {A)
accordi ng to the manufacturer' s i nstructi ons, then
remove the sel f-l ocki ng nut
(B).
Do not compress
the spri ng more than necessary to remove the nut.
Rel ease the
pressure from the strut spri ng
compressor, then di sassembl e the damper as
shown i n the Expl oded Vi ew.
Reassembl e al l of the
parts,
except the spri ng.
Compress the damper assembl y by hand, and
check for smooth operati on through a ful l stroke,
both compressi on and extensi on. The damper
shoul d extend smoothl y and constantl y when
compressi on i s rel eased. l f i t does not, the gas i s
l eaki ng and t he damper shoul d be r epl aced.
Check f or oi l l eaks, abnor mal noi ses, or bi ndi ng
du ri ng these tests.
Reassembly
1. Assembl e al l of the damper components except the
sel f' l ocki ng nut onto the damper uni t. Al i gn the
spri ng bottom end
(A),
the stepped
part
of the
l ower spr i ng mount i ng cushi on, and t he st ep on t he
l ower spri ng seat
(B).
I nst al l t he damper assembl y on a commer ci al l y
avai l abl e strut spri ng compressor
(C).
Posi ti on the damper mounti ng base as shown.
VIEWING FROM TOP
25'30' a 3' 25'30' a 3"
Compress the damper spri ng wi th the spri ng
compressor,
(cont' d)
4.
STUD BOLT
18-41
Rear Suspensiton
(cont'd)
5. l nstal l a new sel f-l ocki ng nut
(A)
on the damper
shaft.
A
10 x 1. 25 mm
29 N. m
(3. 0 kgl . m, 22 l bl . f t l
,'-_\
Hol d the damoer shaft wi th a hex wrench
(B),
and
ti ghten the sel f-l ocki ng nut to the speci fi ed torque.
18-42
lnstallation
1. Lower the l ower arm. and posi ti on the damper
assembl y
(A)
i n the body.
2. Loosel y i nst al l t he f l ange nut s
( A)
ont ot hedamper
studs,
10 x 1. 25 mm
49 N.m
(5. 0
kgf . m,
36 tbf.ftl
3. Posi ti on the bottom ofthe damper on the l ower
ar m
( A) .
Instal l the fl ange bol t
(B),
and l i ghtl y ti ghten.
Rai se the suspensi on unti l the vehi cl e
j ust
l i fts off
the safety stand.
Ti ghten the fl ange bol t
(B)
Ti ghten the fl ange nuts on the top of the damper to
the speci fi ed torque.
1.
18-43
Brakes
Conventional Brake Components
Soeci al Tool s
. . . . . . . . . . . . . 19-2
Comoonent Locat i on I ndex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19- 3
Brake Syst em I nspect i on and Test s . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-4
Brake Pedal and Brake Pedal Posi t i on
Swi t ch Adi ust ment . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-6
Parki ng Brake Check and
Adj ust ment . , . . . . . . . . . . . . 19-7
Brake Syst em Bl eedi ng . . . . . . . . . . . . . . . . . . . . . . 19-8
Brake Svstem Indicator Circuit
Di agr am . . . . . . . . . . . . . . . . . . . 19- 10
Parki ng Brake Swi t ch Test . . . . . . . . . . . . . . . . . 19-11
Brake Fl ui d Level Swi t ch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-11
Front Brake Pads l nspect i on/
ReDl acement . . . . . . . . . . . 19- 12
Front Brake Di sc I nspect i on . . . . . . . . . . . . . . . 19-14
Fr ont Br ake Cal i per Over haul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19- 15
Mast er Cyl i nder/ Brake Boost er
Reol acement . . . . . . . . . . . 19-16
Mast er Cyl i nder l nspect i on . . . . . . . . . . . . . . . . 19-17
Mast er Cyl i nder Pushrod Cl earance
Adj ust ment . . . . . . . . . . . . . . 19- 17
Brake Boost erTest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-19
Rear Brake Pads I nspect i on/
Repl acement . . . . . . . . . . . 19-20
Rear Brake Di sc I nspect i on . . . . . . . . . . . . . . . . 19-22
Rear Brake Cal i per Removal / l nst al l at i on . . . . . . . . . . . . . . . . . . . . 19-23
Rear Brake Cal i oer Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
' 19-24
Brake Hoses and Li nes l nsoect i on . . . . 19-26
Brake Hose Repl acement . . . . . . . . . . . . . . . . . . . 19-27
Parki ng Brake Cabl e Repl acement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-28
ABS
(Anti-lock
Brake Systeml
Components
... 19-31
Speci al Tool s
Rel .No. Tool Number Description Otv
o
07JAG-SD40100 Pushrod Adi ustment Gauqe 1
FRONT BRAKES
Front Brake Pads, I nspect i on/
Front Brake Di sc
I nspect i on, page 19- 14
Front Brake Cal i per
Over haul , page 19' 15
INDICATOR
Brake Syst em I ndi cat or Ci rcui t
Di agr am,
page l 9- 10
Parki ng Brake Swi t ch
Test , page 19-11
Brake Fl ui d Level Swi t ch
Test , page 19-11
BRAKE PEDAL
Erake Pedal and Brake Pedal Posi t i on
Swi t ch Adj ust ment , page 19-6
REAR BRAKES
Rear Brake Pads I nspect aon/
Repl acement ,
page l 9' 20
Rear Brake Di sc
l nspect i on, page 19-22
Rear Brake Cal i per
Removal / l nst al l at i on,
paqe
19-23
Rear Brake Cal i per
Overhaul ,
page 19-24
MASTER CYLINDER
Brake Syst em Bl eedi ng, page 19-8
Mast er Cyl i nder
Repl acement , page l 9- 16
Mast er Cyl i nder
Mast er CVl i nder Pushrod
Cl earance Adj ust ment ,
page 19-17
BBAKE HOSES/ LI NES
Brake Hoses and Li nes
l nsoect i on. oaqe 19-26
Brai e Hoses Bdpl acement ,
page' 19-27
PARKING BRAKE CABLE
Parki ng Brake Check and
Adj ust ment ,
page 19-7
Parki ng Brake Cabl e
Repl acement ,
page 19' 28
BRAKE BOOSTER
Brake Boost er
Repl acement ,
page 19' ' 16
Brake Boost er Test , page
' 19' 19
19-3
Gonventional Brake Components
Brake System Inspection and Tests
Brake System Test
Brake pedal sinks/fades when braking
1. Start the engi ne, and l et i t warm up to operati ng temperature.
2. Attach a 2-i nch pi ece of maski ng tape al ong the bottom ofthe steeri ng wheel , and draw a hori zontal reference
marK across tI.
3. Wi th the transmi ssi on i n Neutral , press and hol d the brake pedal l i g htl y
(about
the same
pressu re needed to keep
an A,/T-equi pped car from creepi ng), then rel ease the
parki ng
brake.
Whi l e st i l l hol di ng t he br ake
pedal ,
hook t he end of t he t ape measur e behi nd i t . Then pul l t he t ape up t o t he
steeri ng wheel , noti ng where the tape measure l i nes up wi th the reference mark you made on the maski ng tape.
Appl y steady
pressure
to the brake
pedal for 3 mi nutes.
Watch the tape measure.
.
i f i t moves l ess than 10 mm, the master cvl i nder i s OK.
.
i f i t moves more than 10 mm repl ace the master cyl i nder.
4.
5,
6.
Mast er Cyl i nder Look for damage or si gns of fl ui d l eakage at:
.
Reservoi r or reservoi r grommets
.
Li ne
j oi nt s
Between master cvl i nder and booster
Bul gi ng seal at reservoi r cap, Thi s i s a
si gn of f l ui d cont ami nat i on.
Look f or damage or si gns of f l ui d l eakage at :
.
Li ne
j oi nts
and banj o bol t connecti ons
.
Hoses and l i nes, al so i nspect f or t wi st i ng or
Bul gi ng, twi sted, or bent l i nes.
Look for damage or si gns of fl ui d l eakage at:
.
Pi ston seal
.
Banj o bol t connecti ons
Sei zed or st i cki ng cal i per
pi ns.
Look for damage or si gns of fl ui d l eakage at:
.
Li ne
j oi nts
19-4
Rapid brake pad wear, Vehicle vibration
(after
a long
dri ve), or Hi gh, hard brake pedal
1. Dr i ve t he vehi cl e unt i l t he br akes dr ag or unt i l t he
pedal i s hi gh and har d. Thi s can t ake 20 or mor e
brake pedal appl i cati ons duri ng an extended test
dri ve.
2. Wi t h t he engi ne r unni ng, r ai se t he vehi cl e on a l i f t ,
and spi n al l f our wheel s by hand.
ls there brake drag at any of the wheels?
YES Go to step 3.
NO- Look for other causes of the
pad
wear, hi gh
pedal ,
or vehi cl e vi br at i on. l
3. Turn the i gni ti on swi tch to l ock
(O), pump
the brake
pedal to depl ete the vacuum i n the brake boosl er,
and then spi n the wheel s agai n to check for brake
dr ag.
ls thete brake drag at any of the wheels?
YES Go to step 4.
NO-Repl ace the brake booster.l
4. Wi thout removi ng the brake l i nes, unbol t and
separate the master cyl i nder from the booster, then
spi n the wheel s to check for brake drag.
l s there brake drag at any of the wheel s?
YES- Go t o s t e p S.
NO Check the brake
pedal posi ti on
swi tch
adj ustment and pedal free
pl ay.l
Loosen the hydraul i c l i nes at the master cyl i nder,
then spi n the wheel s to check for brake drag.
ls there brake dtag at any of the wheels?
YES- Go to step 6.
NO
-
Repl ace the master cyl i nder.l
Loosen the bl eeder screws at each cal i per, then
spi n the wheel s to check for brake drag.
ls there brake drag at any of the wheels?
YES Di sassembl e and r epai r t he cal i per on t he
wheel (s) wi th brake drag.l
NO Look for and repl ace any damaged brake l i nes.
l f al l brake l i nes are OK. repl ace the ABS
modul at or . l
19-5
Brake Pedal and Brake Pedal Position Switch Adiustment
Pedal Height
' t .
Di sconnect the brake Dedal Dosi ti on swi tch
connector, l oosen the brake
pedal posi ti on
swi tch
l ocknut
(A),
and back off the brake
pedal posi ti on
swi tch {B) unti l i t i s no l onger touchi ng the brake
pedal .
Li ft up the carpet and the i nsul ator cutout
(C).
Measure the pedal hei ght
(D)
from the mi ddl e of
the ri ght si de cener of the
pedal pad
{E).
Standard Pedal Height
(wi th
carpet removed): 179 mm
(7
1/16 i n.l
\
-
-
'-.-,
tt'tll
-
.
" '
' - - - _' ,
p;,' ,'
19-6
5. Check the brake pedal free pl ay.
3. Loosen the
pushrod l ocknut {A), and screwthe
pushrod i n or out wi th pl i ers unti l the standard
pedal hei ght from the fl oor i s reached. After
adj ustment, ti ghten the l ocknut fi rml y. Do not
adj ust the pedal hei ght wi th the
pushrod pushed i n.
{1, 5 kgf . m. 11 l bl f t l
Screw i n the brake Dedal Dosi ti on swi tch unti l i ts
pl unger i s ful l y pushed i n
(threaded
end
(A)
touchi ng the pad (B)
on the pedal arm). Then back
off the swi tch 1/4 turn to make 0.3 mm
(0.01
i n.) of
cl earance between the threaded end and the Dad.
Ti ghten the l ocknut fi rml y.
NOTE: The brakes wi l l drag i f there i s no cl earance.
Connect the brake Dedal oosi ti on swi tch connector.
Make sure that the brake l i ghts go
off when the
oedal i s rel eased.
4.
0. 3 mm
(0. 01
i n. )
i:
\.-
Pedal Free Play
1. Wi th the engi ne stopped, i nspectthe pedal free
pl ay ( A)
on t he
pedal pad ( B)
by
pushi ng t he pedal
by hand.
Fr ee Pl ay: 1 5mm( 1/ 16 3/ 16i n. l
l f the
pedal
free
pl ay
i s out of speci fi cati on, adj ust
the brake pedal posi ti on swi tch
(C).
l f the pedal free
pl ay i s i nsuffi ci ent, i t may resul t i n brake drag.
Parking Brake Check and
Adiustment
Check
1. Pul l t he
par ki ng br ake l ever
( A) wi t h
196 N
( 20
kgf ,
44 l bf) force to ful l y appl y the parki ng brake. The
parki ng brake l ever shoul d be l ocked wi thi n the
speci fi ed cl i cks {B).
Lever Locked Clicks: 9 13
P!lled up with 1gO N {20 kgf,44lbfj
2. Adj ust the
parki ng brake i f the l ever cl i cks are out of
speci fi cati on.
Adjustment
NOTE: After rear brake cal i per servi ci ng, remove the
cent er consol e, l oosen t he
par ki ng br ake adj ust i ng nut ,
startthe engi ne. and press the brake pedal several
ti mes to setthe sel f-adj usti ng brake before adj usti ng
t he par ki ng br ake.
1. Bl ock t he f r ont wheel s. t hen r ai se t he r ear of t he
vehi cl e, and support i t wi th safety stands i n the
pr oper l ocat i ons
( see page 1- 13) .
2. Make sur e t he
par ki ng br ake ar m i A) ont her ear
br ake cal i per cont act s t he br ake cal i per pi n ( B) .
(cont' d
)
19-7
Parking Brake Gheck and
Adjustment
(cont'd)
5 . Pul l t he par ki ng br ake l ever up one cl i ck.
Remove the center consol e
(see page 20-76).
Ti ghten the adj usti ng nut
(A)
unti l the parki ng
brakes drag sl i ghtl y when the rear wheel s are
t ur ned.
6. Rel ease the
parki ng
brake l ever ful l y, and check
that the parki ng
brakes do not drag when the rear
wheel s are turned. Readj ust i f necessary.
7. Make sur e t he
par ki ng
br akes ar e f ul l y appl i ed
when the
parki ng
brake l ever i s pul l ed up ful l y.
8. Rei nstal l the center consol e.
19-8
Brake System Bleeding
NOTE:
.
Do not r euse t he dr ai ned f l ui d.
.
Al ways use Honda DOT 3 Brake Fl ui d.
.
Make sure no di n or other forei gn matter i s al l owed
to contami nate the brake fl ui d.
.
Do not spi l l brake fl ui d on the vehi cl e; i t may damage
the
pai nt; i f brake fl ui d does contact the pai nt, wash i t
off i mmedi atel y wi th water.
.
The reservoi r on the master cyl i nder must be at the
MAX
(upper)
l evel mark at the start of the bl eedi ng
procedure and checked after bl eedi ng each brake
ca\i Der. Add tl ui d as reoui red.
1. Makesur et he br akef l ui d l evel i n t he r eser voi r i s at
t he MAX
( upper )
l evel l i ne
( A) .
2. Have someone sl owl y
pump
the brake pedal
several ti mes, then appl y steady pressure.
Starti ng at the l eft-front, l oosen the brake bl eed
screw to al l ow ai r to escape from the system. Then
ti ghten the bl eed screw securel y.
Repeat the
procedure
for each wheel i n the
sequence shown bel ow unti l ai r bubbl es no l onger
appear in the fluid.
5. Refi l l the master cyl i nder reservoi r to the MAX
( upper )
l evel l i ne.
BLEEDING SEOUENCE:
, Front Right 0 Rear Ri ght
O Front Left O Rear Lelt
Pressure Bleeding
Instal l the appropri ate
power probe pressure bl eeder
adapter onto the master cyl i nder.
Use the bl eedi ng sequence above, and fol l ow the
bl eedi ng i nstructi ons that come wi th your pressure
bl eeder .
Bleed Screw Locations
FRONT:
REAR:
19-9
Brake System Indicator Circuit Diagram
.CONVEBTAALE
TOP CONIAOL UNrI
UNDEN.OASH FUSE/
REIAYBOX
PANKING BRAKE SwlTCH
CIOSEO: ldor up
GAUGE
ASSEMALY
.DAYTIME RUNNING IIGHTS
CONTROI UNIT
(Canad.
6odl onlvl
EAAKEFI.UID
LEVEL SWTTCH
ALK
I
-:
G30t
19- 10
Parking Brake Switch Test
1 .
2.
Remove the center consol e, and di sconnect the
connector
(A)from
the swi tch
(B).
Check for conti nui ty between the posi ti ve
termi nal
(C)
and body ground:
.
Wi th the brake l ever up, there shoul d be
conti nui ty.
'
Wi th the brake l ever down. there shoul d be no
conti nui ty.
NOTE
(Canada);
l f the parki ng brake swi tch i s OK,
but the brake system i ndi cator does not work, do
the i nput test for the dayti me runni ng l i ghts control
uni t
{see
page
22-66).
Brake Fluid Level Switch Test
Check for conti nui ty between the termi nal s
(A)
wi th the
fl oat i n the down posi ti on
and the up
posi ti on.
.
Remove the brake fl ui d compl etel y from the reservoi r.
Wi th the fl oat down, there shoul d be conti nui ty.
.
Fi l l t he r eser voi r t o t he MAX
( upper )
l evel
( B) .
Wi t h
the fl oat up, there shoul d be no conti nui ty.
19- 11
Frequent i nhal ati on of brake pad dust, regardl ess of
materi al composi ti on, coul d be hazardous to your
heal th.
.
Avoi d breathi ng dust
parti cl es.
.
Never use an ai r hose or brush to cl ean brake
assembl i es. Use an OSHA-aooroved vacuum
cr eaner .
Front Brake Pads Inspection/Replacement
' 1.
Loosen the front wheel nuts sl i ghtl y. Rai sethefront
of the vehi cl e, and support i t wi th safety stands i n
the
proper
l ocati ons
(see page 1-13). Remove the
front wheel s.
2. Hol d t he cal i per
pi n ( A) wi t h
a wr ench, bei ng
car ef ul not t o damaget he
pi n boot . Removet he
cal i per bol t
(B)
wi th another wrench, and pi vot the
cal i per
(C)
up out of the way. Check the hoses and
pi n boots for damage and deteri orati on.
Remove the
pad shi ms
(A), pad retai ners
(B),
and
pads ( C) .
19-12
4. Usi ng verni er cal i pers, measure the thi ckness of
each brake pad l i ni ng. The measurement does not
i ncl ude t he
pad backi ng pl at e ( A) t hi ckness.
Brake Pad Thickness:
Stsndard: 9.5 10.5 mm
(0.37
0.41 i n.)
(0.06
i n.)
l f the brake
pad thi ckness i s l ess than the servi ce
l i mi t, repl ace the front pads as a set.
Cl ean the cal i per thoroughl y; remove any rust, and
check for grooves and cracks.
Check the brake di sc for damage and cracks.
Instal l the pad retai ners
(A).
7 .
9. Appl y Mol ykote M77 grease
or Dai kal ub 528D
grease
to the pad si de of the shi ms
(A)
and back of
the pads (B).
Wi pe excess grease offthe shi m.
Contami nated brake di scs or pads reduce stoppi ng
abi l i ty. Keep grease
off of the di scs and pads.
A
Instal l the brake pads
and
pad
shi ms correctl y.
Instal l the pad wi th the wear i ndi cator
(C)
on the
i nsi de.
l f you
are reusi ng the
pads.
al ways rei nstal l the
brake pads i n thei r ori gi nal
posi ti ons
to prevent
a
momentary l oss of braki ng effi ci ency.
' 10.
1 1 .Push i n the
pi ston (A)
so that the cal i per wi l l fi t over
the pads. N4ake sure the pi ston boot i s i n posi ti on
to
prevent damagi ng i t when pi voti ng the cal i per
down.
D
32 N.m
(3.3
ksf.m,24l bf.ftl
12. Pi votthe cal i per
(B)
down i nto posi ti on,
bei ng
careful not to damage the pi n boot. Hol d the cal i per
pi n (C)
wi th a wrench, bei ng careful not to damage
the
pi n
boot. Instal l the cal i per bol t
(D),
wi th
another wrench, and torque i t to proper
soeci fi cati on,
13. Press the brake pedal several ti mes to make sure
the brakes work, then road-test
NOTE: Engagement of the brake may requi re a
greater pedal stroke i mmedi atel y after the brake
pads
have been repl aced as a set. Several
appl i cati ons of the brake pedal wi l l restore the
normal pedal stroke.
14. After i nstal l ati on. check for Ieaks at hose and l i ne
j o:nts
or connecti ons, and reti ghten i f necessary.
19- 13
Front Brake Disc Inspection
Runout
1. Loosen the front wheel nuts sl i ghtl y, then rai se the
proper l ocati ons {see
page 1- 13). Remove the front
wneet s.
2. Removet he br ake
pads ( see page 19- 12) .
3. Inspect the di sc surface for damage and cracks.
Cl ean the di sc thoroughl y, and remove al l rust.
4. Use wheel nuts and sui tabl e fl at washers
(A)
to
hol d t he di sc secur el y agai nst t he hub. t hen mount
a di al i ndi cator as shown, and measure the runout
at 10 mm { 0. 4 i n. ) f r om t he out er edge of t he di sc,
Brake Disc Runout:
(0.004
i n.)
5.
108 N m
(11 kgf m, 79.6, l bf ft)
l f the di sc i s beyond the servi ce l i mi t, refi ni sh the
brake di sc.
Max. Refi ni sh Li mi t: 23.0 mm
(0.91
i n.l
NOTE;
.
l f t he br akedi sc i s beyondt heser vi ce l i mi t f or
refi ni shi ng, repl ace i t
(see
step 7 on
page 18-12).
.
A new di sc shoul d be refi ni shed i f i ts runout i s
gr eat er t han 0. 10 mm
( 0. 004
i n. ) .
19- 14
Thickness and Parallelism
1. Loosen the front wheel nuts sl i ghtl y, then rai se the
proper l ocati ons
(see page 1-13). Remove the front
wnee t s.
2. Remove t he br ake pads
{ see
page 19- 12) .
3. Usi ng a mi crometer, measure di sc thi ckness at
ei ght
poi nts, approxi matel y 45" apart and 10 mm
(0.4
l n.) i n from the outer edge of the di sc. Repl ace
the brake di sc i f the smal l est measurement i s l ess
t han t he max. r ef i ni shi ng l i mi t .
Brake Di sc Thi ckness:
Standard: 24.9-25.1mm
(0.98
0.99 i n.)
Max. Refi ni shi ng Li mi t:23.0 mm
{0.91
i n.)
Brake Di sc Paral l el i sm: 0.015 mm {0.0006 i n.} max.
NOTE:Thi s i s the maxi mum al l owabl e di fference
between the thi ckness measurements.
l f t he di sc i s beyond t he ser vi ce l i mi t f or par al l el i sm,
refi ni sh the brake di sc.
NOTE; l f the brake di sc i s beyond the servi ce l i mi t
for refi ni shi ng, repl ace i t
(see
step 1 on page 18-' 12).
4.
Front Brake Caliper Overhaul
Do not spi l l brake fl ui d on the vehi cl e; i t may damage the pai nt; l f brake fl ui d gets on the pai nt, wash i t off
i mmedi atel y wi th water.
To prevent
dri ppi ng, cover di sconnected hose
j oi nts
wi th rags or shop towel s.
Cl ean al l
parts
i n brake fl ui d and ai r dry; bl ow out al l passages wi th compressed ai r.
Before reassembl i ng, check that al l parts are free of di rt and other forei gn parti cl es.
Repl ace parts wi th new ones as speci fi ed i n the i l l ustrati on.
Make sure no di rt or other forei gn matter gets i n the brake fl ui d,
Make sure no grease or oi l gets on the brake di scs or pads.
When reusi ng pads,
al ways rei nstal l them i n thei r ori gi nal posi ti ons to prevent l oss of braki ng effi ci ency.
Do not reuse drai ned brake fl ui d.
Coatthe pi ston, pi ston
seal groove, and cal i per bore wi th cl ean brake fl ui d.
Repl ace al l rubber parts wi th new ones.
After i nstal l i ng the cal i per, check the brake hose and l i ne for l eaks, i nterference, and twi sti ng.
a
- r cFr asEi J:
Honda
(
al i pcr or ease
( P
N 08C30 80234M)
8 x 1. 25 mm
CALIPEB AOLT
32 N.m {3.3 kgf m,
BRAKE HOSE
SEALI NG WASHERS
I NNER SHI M B
---------*d.
0, l
t /
W
WEAR INDICATON
I nst al l i nner pad w t h
i t s wear i ndi cat or downward.
CALIPER EODY
PISTON BOOT
6-=^"
.:
q!!4s!n
PIN BOOT
' 12
x 1. 25 mm
FLANGE BOLTS
108Nm{ 11. 0k gt . m,
79.5 tbf.ft)
Frequent i nhal ati on of brake pad dust, regardl ess of materi al composi ti on, coul d be hazardous to
your heal th.
.
parti cl es.
.
Never use an ai r hose or brush to cl ean brake assembl i es. Use an OSHA-aooroved vacuum cl eaner.
Remove, di sassembl e, i nspect, reassembl e, and i nstal l the cal i per, and note these i tems:
CALIPEF
BRACKET
=^.
#.q!A9$
PtN AOOTS
Repl ace.
BANJO BOLT
3 4 N m
{3.5 kg{ m,
25 tbf.ftl
I NNER SHI M A
OUTERPAD SHI M
\
BRAKE PADS
BRACKET
19- 15
Conventional Brake Gomponents
Master Cylinder/Brake Booster Replacement
NOTE:
Do not spi l l brake fl ui d on the vehi cl e; i t may damage the
pai nt; l f brake fl ui d does contact the pai nt, wash i t off
1. Di sconnect the brake fl ui d l evel swi tch connectors.
2. Remove the brake fl ui d from the master cyl i nder reservoi r wi th a syri nge
3. Di sconnect the brake l i nes from the master cyl i nder. To
prevent spi l l s, cover the l i ne
j oi nts
wi th rags or shop
towel s.
4. Remove the master cyl i nder mounti ng nuts and washers.
5. Remove the master cyl i nder from the brake booster.
6, Di sconnect the vacuum hose from the brake booster,
7. Remove the l ock pi n and cl evi s
pi n.
8. Remove the four brake booster mounti ng nuts.
9. Pul l the brake booster forward, and removethe brake booster f rom the engi ne compartment. Becareful notto
bend or damage the brake l i nes when removi ng i t.
10. l nstal l l he brake booster and master cyl i nder i n the reverse order of removal , and note these i tems.
.
Repl ace al l rubber
parts and the
gasket wi th new ones whenever removed.
.
Coat t hel i pof t henewr odseal wi t h r ecommended seal
gr ease i n t he mast er cyl i nder set .
. I nst al l
t her odseal ont ot he br ake boost er wi t h i t s gr ooved si det owar dt he mast er cyl i nder .
.
Adj ust the
pushrod l ength before i nstal l i ng the booster
(see
step 5 on page 19-18)
.
Fi l l the master cyl i nder reservoi r, and bl eed the brake system
(see page 19-8).
.
Af t er i nst al l at i on, checkt hebr akepedal hei ght and br ake
pedal f r ee
pl ay ( see page 19- 6) and adj ust i f necessar y.
IODSEAL
t b
LOCXPIN
r 8 ( l
crEvts
19- 16
Master Cyl i nder Inspecti on
NOTE:
.
Before reassembl i ng, checkthat al l parts
are free of
dust and other forei gn parti cl es.
.
Do not try to di sassembl e the master cyl i nder
assembl y. Repl ace the master cyl i nder assembl y wi th
a new Dart i f necessarv.
.
Do not al l ow di rt or forei gn matter to contami nate the
br ake f l ui d.
,z-7--T\ .- RESERVOIR CAP
f - ^l '
Check f or bt ockage
\E+_/ of vent holes.
,/RESERVOIR SEAL
r ?. \ ) - chF. k f or . l ^mane . n. l
\ g
det er i or at r on.
9-----.-
STRAINER
Remove accumul at ed
sedi ment .
MASTER CYLINDER
Check {or l eaks, rust, and damage.
Master Cylinder Pushrod Clearance
Adjustment
Pushrod adj ustment gauge
07JAG-SD40' 100
NOTE; Master cyl i nder pushrod-to-pi ston
cl earance
must be checked and adj ustments made, i f necessary,
before i nstal l i ng the master cyl i nder.
1. Set t hespeci al t ool
( A)
ont he mast er cyl i nder body
(B), push
i n the center shaft
(C)
unti l rhe top of i t
contacts the end ofthe secondary pi ston (D)
by
t ur ni ng t he adj ust i ng nut
( E) .
Wi thout di sturbi ng the center shaft' s
posi ti on.
i nstal l the speci al tool
(A)
onto the booster.
( 0
760 mmHg. 30 i n. Hg) 07JAG-SDro100
l nst al l t he mast er cyl i nder nut s
( B) ,
and t i ght en t o
the speci fi ed torque.
Connect the booster i n-l i ne wi th a vacuu m gauge
( C)
0 101 kPa
( 0
760 mmHg, 30 i n. Hg) t o t he
boost er ' s engi ne vacuum suppl y, and mai nt ai n an
engi ne speed t hat wi l l del i ver 66 kPa
( 500
mmHg,
20 i n. Hg) vacuum.
(cont' d)
3.
15 N. m {1. 5 kgl m,
11 tbt.ftl
19-17
Master Cylinder Pushrod Clearance Adiustment
(cont'd)
5, Wi th a feel er
gauge
{A),
measure the cl earance
between the gauge body and the adj usti ng nut
(B)
as shown.
l f the cl earance between the gauge body and the
adj usti ng nut i s 0.4 mm
(0.02
i n.), the pushrod-to-
pi ston cl earance i s 0 mm. However, i f the cl earance
between the
gauge body and the adj usti ng nut i s
0 mm, the
push rod-to-pi ston cl earance i s 0 4 mm
(0.02
i n.) or more. Therefore. i t must be adj usted
and rechecked.
Cl earance: 0 0.4 mm
(0
0.02 i n.l
l f the cl earance i s i ncorrect, l oosen the star l ocknut
(A),
and turn the adj uster
(B)
i n or out to adj ust.
.
Adj ust the cl earance whi l e the speci fi ed vacuum
i s appl i ed to the booster.
.
Hol d the cl evi s
(C)
whi l e adi usti ng.
0-0.4 mm {0-0.02 i n.)
A
22 N.m
{2.2
ksf m, 16l bf.ft}
Ti ghten the star l ocknut securel y.
Remove t he speci al t ool { D) .
6.
7.
07JAG-SD40100
19- 18
9. Check the
pushrod l ength
(A)
as shown i f the
booster i s removed. l f the l ength i s i ncorrect,
l oosen the
pushrod l ocknut
(B),
and turn the cl evi s
(C)
i n or out to adj ust.
116 mm
(i 1. 6 i n. )
15 N. m
(1. 5
kgf , m, 11 l bf f t l
10. I nst al l t he mast er cyl i nder
( see page 19- 16) .
Brake Booster Test
Functional Test
' 1.
Wi th the engi ne stopped, press
the brake pedal
several ti mes to depl ete the vacuum reservoi r, then
press
the
pedal
hard and hol d i t for 15 seconds. l f
the pedal
si nks, ei ther the master cyl i nder i s
bypassi ng i nternal l y, or the brake system
(master
cyl i nder, l i nes, modul ator, proporti oni ng val ve, or
cal i per ) i s l eaki ng.
2. Start the engi ne wi th the brake pedal pressed.
l f the
pedal
si nks sl i ghtl y, the vacuum booster i s
operati ng normal l y. l f the pedal hei ght does not
vary, the booster or check val ve i s faul ty.
3. Wi t h t he engi ne r unni ng, pr ess
t he br ake pedal
l i ght l y. l f t he br ake
pedal
si nks mor e t han 10 mm
(3/8
i n. ) i n 3 mi nutes, the master cyl i nder i s faul ty,
Leak Test
1. Press the brake pedal wi th the engi ne runni ng, then
stop the engi ne. l f the pedal
hei ght does not vary
whi l e pressed for 30 seconds, the vacuum booster
i s OK. l f the pedal
ri ses, the booster i s faul ty.
2. Turn the i gni ti on swi tch to l ock
(0)
and wai t
30 seconds, press
the brake pedal
several ti mes
usi ng normal pressure.
When the pedal i s fi rst
pressed, i t shoul d be l ow. On consecuti ve
appl i cat i ons, t he pedal hei ght shoul d gr adual l y
ri se. l f the pedal posi ti on
does not vary, check the
booster check val ve.
3. Di sconnect the brake booster vacuum hose
(check
val ve bui l t-i n)
(A)
at the booster
(B).
Start the engi ne, and l et i t i dl e. There shoul d be
vacuum avai l abl e. l f no vacuum i s avai l abl e, t he
check val ve i s not worki ng properl y.
Repl ace the
brake booster vacuum hose and check val ve, and
retest.
Start the engi ne. and then pi nch the brake booster
vacuum hose between the check val ve and the
DOOSter.
Turn the i gni ti on swi tch to l ock
(0),
and wai t
30 seconds. Press the brake pedal several ti mes
usi ng normal pressure.
When the pedal i s fi rst
pressed, i t shoul d be l ow. On consecuti ve appl i cati ons,
t he pedal hei ght shoul d gr adual l y
r i se.
.
l f t he pedal posi t i on does not var y, r epl acet he
brake booster
(see page 19-16).
.
l fthe pedal posi ti on
vari es, repl ace the brake
booster vacuum hose/check val ve assembl y.
5.
19- 19
Gonventional
Brake Components
Rear Brake Pads Inspection/Replacement
Frequent inhalation of brake pad dust. regardless
of material composition, could be hazardous to
your health.
'
Parti cl es.
.
assembl i es. Use an OSHA-approved vacuum
cl eaner .
Rai se the rear of the vehi cl e, and support i t wi th
proper l ocati ons {see
page
1- 13) . Remove t he r ear wheel .
Rel ease the parki ng brake.
Hol d the cal i per
pi n
{A)
wi th a wrench, bei ng
careful not to damage the pi n boot. Remove the
two cal i per bol ts
(B)
wi th another wrench and
cal i per
(C)
from the bracket.
Thoroughl y cl ean the outsi de of the cal i per to
prevent dust and di rt from enteri ng i nsi de.
Support the cal i per wi th a pi ece of wi re so i t does
not hang from the brake hose.
2.
3.
19-20
4. Remove the
pad shi ms
(A)
and brake
pads (B).
Usi ng verni er cal i pers, measure the thi ckness of
each brake
pad l i ni ng. The measurement does not
i ncl ude the
pad backi ng
pl ate (A)
thi ckness.
Brake Pad Thi ckness:
Si andard: 8.9 9.1 mm
(0.35
-
0.36 i n.)
(0.06
i n.)
5.
I
,l
t
6. Remove the pad retai ners.
. . . . . . . . .
10.
7.
8.
9.
' I
t .
Cl ean the cal i per thoroughl y; remove any rust, and
check for grooves
and cracks.
Check the brake di sc for damage and cracks.
Instal l the pad retai ners.
Appl y Mol ykote M77 grease
or Dai kal ub 528D
grease
to the pad si de of the shi ms
(A).
Wi pe
excess grease
off the shi m.
Contaml nated brake di scs or
pads
reduce stoppi ng
abi l i ty. Keep grease
off of the di scs and pads.
I nst al l t he br ake pads ( B)
and
pad
shi ms on t he
cal i per bracket. Instal l the i nner pad wi th i ts wear
i ndi cator l C) faci ng up ward.
l f you are reusi ng the pads,
al ways rei nstal l the
brake pads i n thei r ori gi nal posi ti ons
to prevent
a
momentary l oss of braki ng effi ci ency.
12. Rotate the cal i per
pi ston (A)
cl ockwi se i nto the
cyl i nder, then al i gn the cutout
(B)
i n the
pi ston
wi th
the tab
(C)
on the i nner pad
by turni ng the pi ston
back. Lubri cate the boot wi th rubber grease
to
avoi d twi sti ng the pi ston
boot. l f the pi ston
boot i s
twi sted, back i t out so i t i s posi ti oned properl y.
23 N.m
{2.3 kgf m,
17 tbf,ftl
I nst al l t he br ake cal i per
( D) .
Hol d t he cal i per pi n ( E) wi t h
a wr ench, bei ng car ef ul
not to damage the pi n
boot. Instal l the cal i per bol ts
(F)
wi th another wrench, and torque the cal i per
bol ts to the proper
speci fi cati on.
After i nstal l ati on, check for l eaks at hose and l i ne
j oi nts
and connecti ons, and reti ghten i f necessary.
Press the brake
pedal
several ti mes to make sure
the brakes work, then road-test.
NOTE: Engagement of the brake may requi re a
greater pedal
stroke i mmedi atel y after the brake
pads have been repl aced as a set. Several
appl i cati ons of the brake
pedal
wi l l restore the
normal pedal stroke.
1 4 .
15.
t o _
19-21
Rear Brake Disc Inspection
Runout
1. Rai se the rear of the vehi cl e. and support i t wi th
proper l ocati ons
(see page
1- 13
) .
2. Remove the brake
pads (see page 19-20).
3. Inspect the di sc surface for damage and cracks.
Cl ean the di sc thoroughl y. and remove al l rust
4. Use wheel nuts and sui tabl e fl at washers
(A)to
hol d the di sc securel y agai nst the hub, then mount
a di al i ndi cator
(B)
as shown, and measure the
runout at 10 mm
(0.4
i n.) from the outer edge of the
di sc.
Brake Disc Runout:
Service Limit: 0.10 mm {0.004
in.)
l f the di sc i s beyond the servi ce l i mi t, refi ni sh the
brake di sc. Do not use an engi ne-dri ven on-car
brake l athe. Use onl y a motor-dri ven on-car brake
l athe.
Max. Rofi ni shi ng Li mi i : 10.0 mm
(0.39
i n.)
NOTE: A new di sc shoul d be refi ni shed i f i ts runout
i s
gr eat er t han 0. 10 mm
( 0. 004
i n. ) .
108 N. m {11 kgf . m, 80l bf . f t l
19-22
Thickness and Parallelism
1. Loosen the rear wheel nuts sl i ghtl y, then rai sethe
proper l ocati ons
(see page 1-13). Remove the rear
wneer s.
2. Remove the brake
pads (see page 19-20).
3. Usi ng a mi crometer
(A),
measure di sc thi ckness at
ei ght poi nts, approxi matel y 45' apart and 10 mm
(0.4
i n.) i n from the outer edge of the di sc, Repl ace
the brake di sc i f the smal l est measurement i s l ess
t han t he max. r ef i ni shi ng l i mi t .
Brake Disc Thickness:
(0.469-0.476
i n.l
Max. Refi ni shi ng Li mi t: 10.0 mm
(0.39
i n.)
Brake Di sc Paral l el i sm: 0.015 mm
(0.0006
i n.) max.
Thi s i s the maxi mum al l owabl e di fference between
the thi ckness measurements.
l f the di sc i s beyond the servi ce l i mi t for
paral l el i sm,
refi ni sh the brake di sc. Do not use an engi ne-dri ven
on-car brake l athe. Use onl y a motor-dri ven on-car
brake l athe.
NOTE: l f the brake di sc i s beyond the servi ce l i mi t
for refi ni shi ng, repl ace i t
(see
step 7 on
page 18-30).
4.
10 mm
(0. 4
i n. )
Frequent inhalalion of brake
pad
dust, regardless
of material composition, could be hazardous to
your health.
.
Avoi d breathi ng dust parti cl es.
.
assembl i es. Use an OSHA-approved vacuum
cteaner.
.
Thoroughl y cl ean the outsi de of the cal i per to
prevent dust and di rt from enteri ng i nsi de.
Rear Brake Caliper Removal/lnstallation
Bl ock the front wheel s, l oosen the rear wheel nuts
sl i ghtl y, rai se the rear of the vehi cl e. and support i t
wi th safety stands i n the proper l ocati ons {see
page
1- 13) .
Remove the rear wheel s.
Rel ease the parki ng brake.
Remove the cal i per shi el d {A).
6 x 1 . 0 mm
9. 8 N. m
{1. 0 kgl m,
1.2tbf.ft1
5.
3.
Remove the brake hose mounti ng bracket
(A)
from
the rear cal i oer bodv.
6 x 1 . 0 mm
9 . 8 Nm
11.0 kgf.m,7.2 lbt ft)
6. Remove the cabls clip
(A)
from the
parking
brake
cabl e
( B) .
7. Di sconnect the
parki ng
brake cabl e end from the
parki ng
brake arm
(C).
Remove the banj o bol t
(A),
and di sconnect the
brake hose
(B).
Remove the two seal i ng washers
(C),
and repl ace them. Do not spi l l brake fl ui d on
the vehi cl e; i t may damage the pai nt; i t brake fl ui d
gets
on the
pai nt,
wash i t off i mmedi atel y wi th
wal er.
E
23 N.m {2.3 kgt.m, 17 lbf ftl
Hol d the cal i per pi n (D)
wi th a wrench, bei ng
careful not to damage the
pi n
boot. Remove the
two cal i per bol ts
(E)
wi th another wrench, and
remove the cal i per
(F)
from the bracket.
Instal l the rear brake cal i per i n the reverse order of
removal . and note these i tems:
.
When i nstal l i ng the cal i per, al i gn the cutout i n the
pi ston wi th the tab on the i nner pad (see
step 6
on page 19- 21) .
.
Check the brake hose and cal i per fi tti ng for l eaks,
and ti ghten the banj o bol t i f necessary.
.
Check the brake hoses for i nterference and
twi sti ng.
.
Contami nated brake di scs or
pads
reduce
stoppi ng abi l i ty. Keep grease off ofthe di scs and
Daos.
A
34 N. m
{3.5 kgl m.
25 tbf.ft,
10.
19-23
Rear Brake Caliper Overhaul
Frequent i nhal ati on of brake
pad dust, regardl ess of materi al composi ti on, coul d be hazardous to
your heal th.
.
parti cl es.
.
Never use an ai r hose or brush to cl ean brake assembl i es. Use an OsHA-approved vacuum cl eaner.
Di sassembl e. i nspect, and reassembl e the cal i per, and note these i tems:
.
Cl eanal l
par t s i n br ake f l ui d and ai r dr y; bl owout al l
passages wi t h compr essed ai r .
.
Before reassembl i ng, check that al l
parts
are free of di rt and otherforei gn
parti cl es.
.
Repl ace parts wi th new ones as speci fi ed i n the i l l ustrati on.
.
Make sure no di rt or other forei gn matter gets i nto the brake fl ui d.
.
Make sure no grease or oi l
gets on the brake di scs or
pads.
.
Do not reuse drai ned brake fl ui d.
.
.
Coatthe pi ston, pi stonseal groove, and cal i per bore wi th cl ean brake fl ui d.
.
Reol ace al l rubber oarts wi th new ones.
19-24
#:!@ :Honda cal i per grease (P/N
08c30-Bo234M)
6 x' l 0 mm
9. 8 N m {1. 0 kt q. m, 7. 2 l bf . f t )
\
CALI PER SHI ELD
\
\ e
m
dP
L."-J
*
@
23 N.m
(2.3
kgf.m, 17 lbf.ftl
a^.
CALIPER BODY
8 x 1. 25 mm
23 N. m
(2.3
kts.m, 17 lbl.ft)
PI N A
PIN BOOTS
<-
PAD SPRING
RETAINER
PAD SHIM
BRAKE PADS
/
ourER PAD sHrM
1l / l3il,l"fu.,"
'lffi
/,
(s6ksf
m"rl rbr'ftl
WIJ
/
-
@,-
PIN B
BLEED SCREW
8.8 N.m
10.9 kgt.m,
6.s tbt.frl
8 x 1. 25 mm
=^
-q!4-$n
stLtcoNE
SPRING WASHER
SLEEEVE PISTON
BEARI NG A
ADJUSTING BOLT
CAM BOOT
Bepl ace.
RETURN SPRING
AOJUSTI NG SPRI NG B
SPRI NG COVER
PISTON ASSEMBLY
-PI STON BOOT
19-25
Brake Hoses and Li nes Inspecti on
1, Inspectthe brake hoses for damage, deteri orati on, l eaks, i nterference, and twi sti ng.
2. Check t he br ake l i nes f or damage, r ust i ng, and l eakage. Al so check f or bent br ake l i nes.
3. Check for l eaks at hose and l i ne
j oi nts
or connecti ons, and reti ghten i f necessary.
4. Check t he mast er cyl i nder and ABS modul at or uni t f or damage and l eakage.
NOTE: Repl ace the brake hose cl i p whenever the brake hose i s servi ced.
MASTER CYLINoEB-to-BRAKE LINE
15 N. m
(1. 5
kqf m. r1 l bf . f t l
BRAKE LINE-to-BRAKE HOSE
15 N.m
(1.5
kgf.m, 11 l bf.ftl
MOOULATOR UNIT-to-
BRAKE LI NES
15 N. m
{1. 5 kgf . m,
11 t bf . f t l
BRAKE HOSE.to.CALIPER
{BANJO BOLTI
34 N m
(3, 5 kgf . m, 25 l bf . f t )
BRAKE LINE-to'BRAKE HOSE
15 N.m 11.5
kgf.m, 11 l bf.ft)
BRAKE HOSE-to-CALIPES
IBANJO BOLTI
3,r N.m {3.5 kgf m,25 l bf.ftl
PROPORTIONING CONTROL VALVE-to-
BRAKE LI NE
15 N m {1. 5
kgf m, 11 l bf . f t }
19-26
Brake Hose Replacement
NOTE;
.
Before reassembl i ng, check that al l
parts are free of
dust and other forei gn
parti cl es.
'
Repl ace parts wi th new ones whenever speci fi ed to
do so.
.
Do not spi l l brake l l ul d on the vehi cl e; i t may damage
the
pai nt; i f brake fl ui d
gets
on the pai nt, wash i t off
' 1.
Repl ace the brake hose
(A)
i f the hose i s twi sted,
cr acked, or i f i t l eaks.
3.
Di sconnect the brake hose from the brake l i ne
(B)
usi ng a 10 mm f l ar e- nut wr ench
( C) .
Remove and di scar d t he br ake hose cl i p
( A) f r om
t he br ake hose
( B) .
; - . .
4. Remove t he banj o bol t { C) , and di sconnect t he
brake hose from the cal i per.
Remove the brake hose from the knuckl e and
damper bracket.
6. l nst al l t he br ake hose { A) on t he knuckl e and
damper bracket wi th two 6 mm fl ange bol ts
(B)
and
the 8 mm fl ange bol t
(C)
fi rst, then connect the
brake hose to the cal i per wi th the banj o bol t
(D)
and
new seal i ng washer s
( E) .
f'
,...-1.
: - - -
! ' i .
J.
. ;
; '
. "-.:
6 x 1 . 0 mm
9.8 N.m
{1.0 kgt.m,
1.2 tbt ltl
D
34 N.m
{3.5 kgf.m.
25 tbf.ft)
8 x 1. 25 mm
22 N.m
l 2.2kgl m,
16 tbf.fr)
7. I nst al l t he br ake hose
( A)
on t he upper br ake hose
br ackel
( B) wi t h
a new br ake hose cl i p
( C) .
D
Connect t he br ake l i ne
( D)
t o t he br ake hose.
After i nstal l i ng the brake hose, bl eed the brake
system
(see page 19 8).
Do the fol l owi ng checks:
.
Check t he br ake hose and l i ne
j oi nt
f or l eaks, and
ti ghten i f necessary
(see page 19-26).
.
Check the brake hoses for i nterference and
twi sti ng.
8.
9.
10.
19-27
Conventional Brake Gomponents
PARKING BRAKE CABLE
Check f or f aul t y movement .
BIGHT PARKING BRAKE CABLE
Check for faul ty movement.
Parking Brake Cable Replacement
Exploded View
22 N.m
(2.2
kgf.m, 16 lbt.ftl
PARKING BRAKE SWITCH
22 N.m
\ \
(2.2
kgf.m, 16 l bt.ftl
--------
--------..-
I
CABLE ADJUSTING NUT
CABLE EOUALIZER
PARKING BRAKE LEVER
Check f or smoot h
19-28
NOTE:
.
The
parki ng
brake cabl es must not be bent oI
di storted. Thi s wi l l l ead to sti ff operati on and
premature fai l ure.
.
Refer to the Expl oded Vi ew as needed duri ng thi s
proceoure.
1. Remove t he cal i per shi el d.
2. Rel ease the parki ng brake l everful l y, and remove
the brake hose cl i p
(A)from
the
parki ng brake
cabl e
( B) .
A
Di sconnect the parki ng brake cabl e end from the
parki ng brake arm
(C).
19-29
Brakes
Conventi onal Brake Gomponents ................... 19-1
ABS
(Anti-lock
Brake Systeml Components
General Troubl eshoot i ng I nf ormat i on . . . . . . . . . . . . . . . . . . . . . . . 19-33
DTC Troubl eshoot i ng I ndex . . . . . . . . . . . . . . 19-37
Ci rcui t Di agram . . . . . . . . . 19-46
ABS I ndi cat or Ci rcui t Troubl eshoot i ng . . . . . . . . . . . . . . . . . . . . . . 19-56
ABS Modul at or-Cont rol Uni t Removal and
I nst al l at i on . . . . . . . . . . . . . 19-59
Wheel Sensor I nspect i on . . . . . . . . . . . . . . . . . . . 19-60
Wheel Sensor Reol acement . . . . . . . . . . . . . . 19-60
ABS Components
Component Location lndex
DATA LINK CONNECTOR {16P}
MAI N
UNDER. HOOD FUSE/ RELAY BOX
RI GHT-FRONT WHEEL SENSOR
I nspect i on, page' 19-60
LEFT.REAR
WHEEL SENSOR
Inspecti on, page 19-60
Repl acement, page
19-60
RI GHT-REAR WHEEL SENSOR
ABS MODULATOR.CONTROL UNIT
Removal and Instal l ati on, page 19-59
LEFT.FRONT WHEEL SENSOR
Inspecti on, page l 9-60
I
UNDER-DASH FUSE/RELAY BOX
19-32
General Troubl eshooti ng Informati on
ABS lndicator
.
l f t hesyst em i s OK, t heABS i ndi cat or
goesof f 2
seconds after turni ng the i gni ti on swi tch ON
(l l )
wi t hout st ar t i ng t he engi ne. and t hen comes on agai n
and
goes off 2 seconds l ater after starti ng the engi ne.
Thi s occur s because t he ABS cont r ol uni t i st ur ned
on bv the l G2 oower source.
.
The ABS i ndi cator comes on when the ABS control
uni t detects a
probl em
i n the svsl em. However, even
though the system i s operati ng
properl y, the i ndi cator
wi l l come on under these condi ti ons:
-
Onl y the dri ve wheel s rotate
-
One dri ve wheel i s stuck
-
The vehi cl e goes i nt o a spi n
-
The ABS conti nues to operate for a l ong ti me.
-
The vehi cl e i s subj ected to an el ectri cal si gnal
di sturbance
To determi ne the actual cause ofthe
probl em, questi on
the customer about the
probl em. taki ng the
above-l i sted condi ti ons i nto consi derati on.
.
When a probl em i s detected and the ABS i ndi cator
comes on, there are cases when the i ndi cator stays
on unti l the i gni ti on swi tch i s turned OFF, and cases
when the i ndi cator
goes off automati cal l y when the
system returns to normal .
-
DTC 61 or 62:The ABS i ndi cator goes off
automati cal l v when the system returns to normal .
-
DTC 11, 13, 15, 11, 31, 32, 33, 34, 35, 36, 37, 38, 54,
71. or 8' 1: The ABS i ndi cat or st ays on unt i l t he
i gni ti on swi tch i s turned OFF whether or not the
system returns to normal .
-
Dr c' t2, 1 4, 1 6, 18, 21, 22, 23, 24, 41, 42, 43, 44, 51,
52, or 53: The ABS i ndi cator goes off when the
vehi cl e i s dri ven agai n and the system i s OK after
t he i qni t i on swi t ch i s t ur ned f r om OFF t o ON { l l ) .
Diagnostic Trouble Code
(DTCI
.
The memory can hol d any number oJ DTCS. However,
when the same DTC i s detected more than once. the
more recent DTC i s wri tten over the earl i er one.
Therefore, when the same Drobl em i s detected
repeatedl y, i t i s memori zed as a si ngl e DTC.
.
The DTCS are i ndi cated i n the order they occurred,
begi nni ng wi th the most recent.
.
The DTCS are memori zed i n the EEPROM
(non-
vol ati l e memory). Therefore, the memori zed DTCs
are not cl eared when the battery i s di sconnected. the
i gni ti on swi tch i s turned off, or the system returns to
normal , Do the speci fi ed procedures to cl ear the
DTCs.
Self-diagnosis
.
Sel f-di agnosi s can be cl assi fi ed i nto two categori es:
-
I ni t i al di agnosi s:
Done ri ght after the engi ne starts and unti l the ABS
i ndi cator goes off
-
Regul ar di agnosi s:
Done ri ght after the i ni ti al di agnosi s unti l the
i gni ti on swi tch i s turned OFF
.
When a probl em i s detected by sel f-di agnosi s, the
system does the fol l owi ng:
-
Turns the ABS i ndi cator on
-
Memori zes the DTC
-
Stops ABS control
Kickback
The
pump motor operates when the ABS i s functi oni ng,
and the fl ui d i n the reservoi r i s forced out to the master
cyl i nder , causi ng ki ckback at t he br ake
pedal .
Pump Motor
.
The pump motor operates when the ABS i s
f unct i oni ng.
.
The ABS control uni t checks the pump motor
oDerati on when the vehi cl e i s staned the fi rst ti me
after the i gni ti on swi tch i s turned ON
(l l ),
You may
hear the motor operate at thi s ti me, but i t i s normal .
(cont' d)
19-33
ABS Components
(cont' dl
How to Troubleshoot ABS DTCs
The troubl eshooti ng fl owchart procedures assume that
the cause of the probl em i s sti l l present and the ABS
i ndi cator i s sti l l on. Fol l owi ng the fl owchart when the
ABS i ndi cator does not come on can resul t i n i ncorrect
di agnosi s.
The connector i l l ustrati ons show the femal e termi nal
connectors wi th a si ngl e outl i ne and the mal e termi nal
connectors wi th a doubl e outl i ne,
1. Ouesti on the customer about the condi ti ons when
the
probl em occured, and try to reproduce the
same condi ti ons for troubl eshooti ng. Fi nd out
when t he ABS i ndi cat or came on, such as dur i ng
ABS control , after ABS control . when the vehi cl e
was at a certarn speed, etc.
2. When the ABS i ndi cator does not come on duri ng
the test-dri ve, but troubl eshooti ng i s done based on
the DTC, check for l oose connectors. poor termi nal
contact, etc., before you start trou bl eshooti ng.
3. After troubl eshooti ng, cl ear the DTC, and test' dri ve
the vehi cl e. Make sure the ABS i ndi cator does not
come on.
How to Retrieve ABS DTCs
PGM Tester
(A)to
the 16P data l i nk connector
(DLC)
( B)
under t he passenger ' s si de of t he dashboar d.
19-34
( l l ) ,
and f ol l ow t he
prompts
on the PGN4 Tester to di spl ay the DTC{S)
on the screen. After determi ni ng the DTC, refer to
t he DTC Tr oubl eshoot i ng I ndex.
for sDeci f i c i nstructi ons.
Service Check Signal
(SCSI
Circuit Method;
PGM Tester
(A)
(DLC)
l B) under the
passenger' s si de oi the dashboard.
2. Shorithe SCS c\rcurtto body ground usingthe
Honda PGM Tester.
(l l )
wi thout the brake
pedal pressed.
NOTE: l f the brake
pedal
i s pressed when turni ng
the i gni ti on swi tch ON { l l ), the system shi fts to the
DTC cl ea ri ng mode.
4. The bl i nki ng frequency i ndi cates the DTC. DTCs are
i ndi cated by a seri es of l ong and short bl i nks. One
l ong bl i nk equal s 10 shor t bl i nks. Add t he l ong and
shon bl i nks together to determi ne the DTC. After
determi ni ng the DTC, refer to the DTC
Troubl eshooti ng Index.
NOTE:
.
l f the DTC i s not memori zed, the ABS i ndi cator
wi l l go off for 3.6 seconds, and then come back
on.
.
l f the ABS i ndi cator stays on, troubl eshoot for
"ABS
i ndi cator does not
go
off"
(see
step 1 on
page 19- 57) .
The svstem will not indicate the DTC unless these
condi ti ons are met:
.
The brake oedal i s not
pressed,
.
The i gni t i on swi t ch i s t ur ned ON { l l ) ,
.
The SCS ci rcui t i s shorted to body ground before
t he i gni t i on swi t ch i s t ur ned ON
( l l ) .
ExamDl e of OTC 15
Short bl i nks
{five times}
Exsmpl of OTC 22
Di sconnect the Honda PGM Tester from the DLC.
6.
Long blinks {two times}
How to Clear ABS DTCs
PGfM Tester {A) to the l 6Pdata l i nk connector
(DLC)
( B)
under t he passenger ' s si de of t he dashboar d.
2. Tur n t he i gni t i on swi r ch oN
( l l ) ,
and cl ear t he
DTC(s) by fol l owi ng the screen
prompts
on the
PGM Tester.
Service Check Signal
(SCS)
Circuit Method:
PGM Tester
(A)
(DLC)
{B) under the
passenger' s si de of the dashboard.
B A
Short the SCS ci rcui t to body
ground usi ng the
Honda PGM Tester.
Press the brake
pedal .
(cont' d)
19-35
ABS Components
(cont' d)
7.
(l l )
whi l e conti nui ng to
press
the brake pedal .
After the ABS i ndi cator goes off, rel ease the brake
peoar.
After the ABS i ndi cator comes on,
press
the brake
pedal
agai n.
After the ABS i ndi cator goes off, rel ease the brake
peoar .
You cannot cl ear the DTC unl ess these condi ti ons
are met;
.
The vehi cl e speed i s 6 mph
(10
km/h) or l ess.
.
The SCS ci rcui t i s shorted to body ground
before
the i gni ti on swi tch i s turned ON
(l l ).
.
The brake pedal i s pressed
before the i gni ti on
swi tch i s turned ON
(l l ).
19-36
10.
After a few seconds, the ABS i ndi cator bl i nks twi ce
and the DTC i s cl eared. l f the i ndi cator does not
bl i nkt wi ce, r epeat st eos l t hr u7. l f t heABS
i ndi cator stays on after i t bl i nks twi ce, check the
DTC, because a
probl em was detected duri ng i ni ti al
di agnosi s before shi fti ng to DTC cl eari ng mode.
Di sconnect the Honda PGM Tester from the DLC.
DTCTroubl eshooti ng Index
DTC Detection ltem
Note
DTC: 11 Ri oht-front wheel sensor {oDen/short to bodv
qround/short
to
power) (see paqe
19-48
Df Ci ' \2 Ri oht-front wheel sensor
(el ectri cal
noi se/i ntermi ttent i nterrupti on)
(see
Daoe 19-49
DTC: 13 Left-front wheel sensor
(open/short
to body
qround/short
to
power) see oaqe 19-48
DTC: 14 Left-f ront wheel sensor
(el ectri cal
noi se/i ntermi ttent i nterrupti on) {see oaoe 19-49
DTC: 15 Ri oht-rear wheel sensor
(oDen/short
to bodv
qround/short
to
power) see oaoe 19-48
DTC: 16 Ri oht-rear wheel sensor
(el ectri cal
noi se/i ntermi ttent i nterrupti on) see oaoe l 9-49
DTC: 17 Left-rear wheel sensor
(ooen/short
to bodv
qround/short
to
power)
see Daqe 19-48)
DTC: 18 Left-rear wheel sensor
(el ectri cal
noi se/i ntermi ttent i nterrupti on) see Daqe l 9-49
DTC: 21 Ri qht-front
pul ser see oaoe 19- 51
DfC:22 Left-front Dul ser
( see
Daoe 19- 51
DTC:23 Ri qht - r ear
pul ser see
paqe
19- 51
Drc24 Left-rear DUl ser
( see
Daoe 19- 51
DTC: 31 Sol enoi d
{ see oaoe 19' 51
DTC:32 Sol e noi d
( see paqe
19- 51
DTC:33 Sol e noi d see Daqe 19- 51
DTC:34 Sol e noi d
{ see oaqe 19- 51
DTC:35 Sol enoi d
( see
Daoe 19- 51
DTC:36 Sol enoi d
see Daqe' 19 51
DTC:37 Sol enoi d
l see Daqe 19- 51
DTCr38 Sol enoi d
( see
oaqe 19- 51
DTC:41 Ri oht-front wheel l ock l see
paqe
19-52
DfCt42 Left-front wheel l ock l see
page
19-52
DTC:43 Ri qht - r ear wheel l ock
see Daoe 19-52
DTC:44 Left-rear wheel l ock
see Daoe 19- 52
DTC:51 Motor l ock
see
page 19- 52
DTC:52 fvl otor stuck OFF
see oaoe 19-53
DTC:53 Motor stuck ON
see
paqe
19-53
DTC:54 ABS fai l -safe rel ay see oaoe 19-54
DTC:61 LowFSR +Bvol t aqe see Daoe
' !9-54
DTC:62 Hi oh FSR +B vol t aqe
see Daoe l 9-54
DTC:71 Di fferent di ameter ti re
see Daqe 19-55
DTC: 81 Cenl ral Processi no Uni t
(CPU)
di aqnosi s, and ROl vl /RAM di aqnosi s see Daoe 19- 55
ABS Components
symptom Diacnostic
procedure
Also check for
ABS i ndi cator does not come on ABS Indi cator Ci rcui t Troubl eshooti ng
{see
page
19- 56)
ABS i ndi cator does not go off and no
DTC is stored
ABS Indi cator Ci rcui t Troubl eshooti ng
(see
step 1
on oaoe 19-57)
19-38
System Description
ABS Control Unit Inputs and Outputs for 25P Gonnector
*
1: When measured wi th the ABS control uni t 25P connector termi nal No. 7 connected to body ground wi th a
j umper
(cont' d)
-'-.._.-
-'^
2
c)
FiW
4
STOF
5
RLW
ti
RRW
1
8
FSR
I
N/R
__l
1 0
DLC
F
2
)
1 3
SCS
1 4
RLW
(-)
l l
RF
t
tv
)
1 6
tcz
G|\D1
25
18
FRW
(.)
Terminal
number
Wi re
color
Termi nal si gn
(Termi nal
namel
Description Measurement
(Disconnect
the ABS control unit
_
connector)
Terminals Conditions Voltage
2 BLU FRW{ )
(Front-ri ght
wneel
neqal rve,
Detects ri ght-front
wheel sensor si gnal
2 1 8 Wheel Spi n wheel
at 1 turn/second
AC: 0.053 V or
above
Reference
Osci l l oscope
0. 15 Vp- p or
above
3 BLU/
ORN
FLW
( +
)
(Front-l eft
wneel
posi t i ve)
Detects left-front
4 WHT/
BLK
STOP Detects brake swi tch
sr gnal
4
. GND
Brake pedal Pressed Battery
Vol taqe
Rel eased Bel ow 0. 3 V
5 YEL/
RED
RL W( + )
(Rear-l eft
wneel
posi ti ve)
Detects l eft-rear
at l turn/second
AC: 0. 053 V or
above
Reference
Osci l l oscope
0. 15 Vp- p or
above
6 BLU/ RRWH
YEL
( Rea
r - r i ght
wneel
negat rve)
Detects ri ght rear
6 1 5
1 BLU/
RF N ( War ni ng
l amD)
Dri ves ABS i ndi cator 7 GND ABS i ndi cat or
( l gni t i on
swi t ch ON
t ) )
ON
OFF
8 WHT/
GRN
FSR +B
( ABS
I ai l
safe rel ay
batterv)
Power source for the
ABS fai l -safe rel ay
8 GND Every ti me Battery
Vol t age
9 WHT/
.
BLU
MR + B
( Mot or
r el ay
batterv)
Power source for the
motor rel ay
I GND Every ti me Battery
Vol tage
1 0 LT
BLU
DLC Communi cat es wi t h
( Dat a
l i nk t he Honda PGM
connector) Tester
19-39
System Description
(cont'dl
Terminal
numDer
Wire
col or
Termi nal si gn
(Terminal
namel
Description Measurement {Disconnect the ABS control unit
connector,
Terminals Conditions Voltaoe
' t2
BRN/
WHT
FLWH
{Frontl eft
wneel
negat ave)
Detects left-front
Wheel Spi n wheel
at 1 turn/second
AC: 0.053 V or
above
Reference
Osci l l oscope
0. 15 Vp- p or
aoove
1 3 BRN
(Servi ce
cnecK
si onal )
connector si gnal
(DTC
i ndi cati on or
DTC cl eari nq)
' t4
G RY/
RED
RLW
( ' )
(Rear-l eft
wheel
neoatave)
Detects Ieft-rear
at l turn/second
AC: 0.053 V or
aDove
Reference
Osci l l oscope
0. 15 Vp- p or
above
l 5 GRN/
WHT
RRW
(+
)
(Rear-ri ght
wheel
oosi ti ve)
Detects ri ght-rear
1 5 6
l o YEV
BLK
t G2
(l qni ti on
2)
Power source for
acti vati no the svstem
16 GND Battery
Vol taoe
1 8 GRN/
BLK
FRW
( +)
(Front-ri ght
wheel
posi ti ve)
Detects ri ght-front
at l turn/second
AC: 0.053 V or
ADOVE
Reference
Osci l l oscope
0. 15 Vp- p or
above
24 BLK GNDl
( G
r ound 1
Gr ound
25 BLK GND2
( Gr ound
2)
Gr ound
19-40
Features
When the brake
pedal i s pressed duri ng dri vi ng, the wheel s can l ock before the vehi cl e comes to a stop. In such an
event, the maneuverabi l i ty of the vehi cl e i s reduced i f the front wheel s are l ocked, and the stabi l i ty of the vehi cl e i s
reduced i f the rear wheel s are l ocked, creati ng an extremel y unstabl e condi ti on. The ABS preci sel y control s the sl i p
rate of the wheel s to ensure maxi mum gri p force from the ti res, thereby ensuri ng the maneuverabi l i ty and stabi l i ty of
t he vehi cl e.
The ABS cal cul ates the sl i p rate of the wheel s based on the vehi cl e speed and the wheel speed, then i t control s the
brake fl ui d pressure to reach the target sl i p rate.
Grip Force of Tire and Road Surlace
TARGET SLIP RATE
COEFFICIENT OF
FRICTION
(cont' d)
19-41
System Description
(cont'dl
COMPONENTS MAIN FUNCTION
Wheel sensor The wheel sensor outputs the speed si gnal to the ABS control uni t
accordi nq to the Dul ser' s rotati on soeed.
Modul ator-
control uni t
ABS control uni t The ABS control uni t processes the si gnal from the wheel sensor,
then outouts the ABS control si onal to the modul ator uni t.
Modul at or uni t The modul ator uni t recei ves the control si gnal , then control s brake
fl ui d oressure for each wheel .
Motor rei ay
(i nsi de
of the ABS
control uni t)
The motor rel ay dri ves the ABS pump motor.
ABS fai l -safe rel ay
(i nsi de
of the
ABS control uni t)
The ABS fai l -safe rel ay cuts the power to the sol enoi d val ve when
the Drobl em i s detected.
MOOUIATOF
UNIT
19-42
ABS Gontrol Unit
Main Control
The ABS control uni t detects the wheel speed based on the wheel sensor si gnal i t recei ved, then i t cal cul ates the
vehi cl e speed based on the detected wheel speed. The control uni t detects the vehi cl e speed duri ng decel erati on
based on the rate of decel erati on.
The ABS control uni t cal cul ates the sl i p rate of each wheel , and transmi ts the control si gnal to the modul ator uni t
sol enoi d val ve when t he sl i p r at e i s hi gh.
The pressure reducti on control has three modes:
pressure
reduci ng, pressure retai ni ng, and pressure i ntensi fyi ng,
Self-diagnosis Function
1. The ABS cont r ol uni t i s equi pped wi t h a mai n CPU and a sub- CPU. Each CPU checks t he ot her f or pr obl ems.
2. The CPUs check the ci rcui l of the system.
3. TheABSc ont r ol uni t t ur ns ont heABSi ndi c at or whent heuni t det ec t s apr obl em, andt heuni t s t ops t hes y s t em.
4. The sel f-di agnosi s can be cl assi fi ed i nto these two categori es:
.
l ni t i al di agnosi s
.
Regul ar di agnosi s
On-board Di agnosi s Functi on
The ABS can be di agnosed wi th the Honda PGM Tester.
The ALB Checker cannot be used wi th thi s system. For ai r bl eedi ng, and checki ng wheel sensor si gnal s. use the Honda
PGM Tester. See the Honda PGM Tester user' s manual s for speci fi c operati ng i nstructi ons.
(cont' d)
19-43
ABS Components
System Description
(cont'd)
ABS Modulator
The ABS modul ator consi sts of the i nl et sol enoi d val ve, outl et sol enoi d val ve, reservoi r, pump, pump motor, and the
dampi ng chamber. The modul ator reduces the cal i per fl ui d pressu re di rectl y. l t i s a ci rcul ati ng-type modul ator
becauset he br akef l ui dci r cul at est hr ought hecal i per , r eser voi r , andt hemast er cyl i nder , Thehydr aul i ccont r ol
has
three modes: pressure i ntensi fyi ng,
pressure retai ni ng, and
pressure reduci ng. The hydraul i c ci rcui t i s an i ndependent
four channel tvpe, one channel for each wheel .
MASTEE CYLI NOER
MODULATOR
_.1
FH HL
RR FL
H,,, li"'J.l1,Tiilîllt'iL.::...!..,,
Pressure i ntensi fyi ng mode: In l et va l ve open, outl et val ve cl osed
Mast er cyl i nder f l ui d i s pumped out t o t he cal i per .
Pressure retai ni ng mode: Inl et val ve cl osed, outl et val ve cl osed
Cal i per f l ui d i s r et ai ned by t he i nl et val ve and out l et val ve.
Pressure reduci ng mode: Inl et val ve cl osed, outl et val ve open
Cal i per fl ui d fl ows through the outl et val ve to the reservoi r.
Motor operati on mode: When stani ng the pressure reduci ng mode, the pump motor i s ON.
When stoppi ng ABS operati on, the
pump motor i s OFF.
The r eser voi r f l ui d i s pumped
out by t he pump, t hr ough t he dampi ng chamber , t o t he
mast er cyl i nder .
19-44
GEAR PULSEB
Wheel Sensors
The wheel sensors are the magneti c contactl ess type. As the gear pul ser teeth rotate past the wheel sensor' s magneti c
coi l . AC current i s generated. The AC frequency changes i n accordance wi th the wheel speed. The ABS control uni t
detects the wheel sensor si gnal frequency and thereby detects the wheel speed.
rt LOW SPEED
Wheel Speed and Modulator Control
WHEEL SPEED
INLET
VALVE
ON
OFF
0
o
MoroR
I
r l
^ . F
When the wheel speed drops sharpl y bel ow the vehi cl e speed,the i nl et val ve cl oses and i f necessary, the outl et val ve
opens momentari l y to reduce the cal i per fl ui d pressure.
The
pump
motor starts at thi s ti me. As the wheel speed i s
restored, the outl et val ve cl oses, and the i nl et val ve opens momentari l y to i ncrease the cal i per fl ui d
pressure.
19-45
ABS Gomponents
Circuit Diagram
MAIN UNDER-HOOD FUSE/RELAY BOX
CONNECTOBS
18P CONNECTOR {Onumbe' }
GAUGE ASSEMBLY CONNECTORS BRAKE SWITCH
4P CONNECTOR
16P coNNEcroR {Cnumber)
9 t l 1 1 1 1 4
WHEEL SENSOB
2P CONNECTOR
FRONT
IEIL
( 1 r
l 2 F)
REAR
------_
tfiT;?l
LE=!
Ter mi nal s i de of
mal e t er mi nal s
7P CONNECTOR
I r l 2 l l 3 l
l 4
5 6 7 l
([ number) 12P CONNECTOR {trnumber) OATA LINK CONNECTOR {16P)
19-46
-r!rr0'
ABS CONTROL UNIT25P CONNECTOR
Wi r e si de of f emal e t er mi nel s
19-47
2 l 3 i 4 l s l 6 i 7 l a
9
ABS Gomponents
DTC Troubl eshooti ng
DTC 11, 13, 15, 17: Wheel Sensor
(Open/ Short
t o Body Ground/ Short t o Power)
' 1.
Di sconnectthe ABS control uni t 25P connector.
3. Measure the vol tage between the appropri ate
wheel sensor { * ) ci r cui t t er mi nal of t he ABS
control uni t 25P connector and body ground (see
t abl e) .
DTC ADpropri ate Termi nal
11
(Rl qht-front)
No. 18: FRW
( +)
13
(Left-front)
15
( Ri qht - r ear )
No. 3: FLW
( +
)
No. 15: RRW
( +
17
(Left-rear)
No. 5: RLWi +)
4.
YES Repai r short to power i n the {
+
) ci rcui t wi re
between the ABS modul ator control uni t and the
appropri ate wheel sensor. I
NO Go to step 4.
ABS CONTROL UNI T 25P CONNECTOR
Wi re si de of f emal e t erml nal s
19-48
5. Check for conti nui ty between the appropri ate
wheel sensor
( +
) ci r cui t t er mi nal and body gr ound
{ see
t abl e) .
DTC Apptopriate Tetminal
11
( Ri qht - f r ont )
No. 18: FRW
( +)
13
(Left-front)
No. 3: FLW
( +)
15
( Ri qht - r ear )
No. 15: RRW
( i
)
17
(Left-rear)
No. 5: RLW
( +
)
YES Go to step 6.
NO Go to step 7.
Di sconnect the wi re harness 2P connector from the
appropri ate wheel sensor, then check for conti nui ty
bet ween t he
( +
) and
(
) t er mi nal s of t he wi r e
har ness and body gr ound.
YES Repai r shor t t o body gr ound i n t he
( +) or (
)
ci rcui t wi re between the ABS modul ator-control
uni t and t he wheel sensor . l
NO Repl ace t he wheel sensor . l
\
ABS CONTROL UNIT 25P CONNECTOB
7. Check the resi stance between the appropri ate
wheel sensor
( +
) and
(
-
) ci r cui t t er mi nal s
( see
t abl e) .
DTC AoDroDriate Terminal
{+ I Si de ) Si de
11
(Ri qht-front)
No. 18: FRW( - l No. 2: FRW
(
13
(Left-front)
No. 3: FLW
( +i
No. 12: FLW
(
15
( Ri qht - r ear )
N0. 15: RBW
( r )
No, 6: RRW
(
' 17
(Left-rear)
No.5: BLW
(+
) No. 14: RLW
(
FLW
{_}
(BRN/ WHTI
RLW
(_) (GRY/ RED)
l s the resi stance between 450 2,000 Q ?
YES Check f or a l oose ABS cont r ol uni t 3l P
connector. l f necessary, substi tute a known-good
ABS modul ator-control uni t, and recheck.l
NO Go to step L
8. Di sconnect the wi re harness 2P connector from the
appropri ate wheel sensor, and check the resi stance
between the
(+
) and { ) termi nal s of the wheel
sensor.
Isthe resi stance between 450 2,000A?
YES Repai r open i n t he
( +) or (
) ci r cui t wi r e, or
shor t bet ween t he
( +) ci r cui t
wi r e and t he
(
)
ci rcui t wi re between the ABS modul ator-control
uni t and t he wheel sensor . l
NO Repl ace t he wheel sensor . a
ABS CONTROL UNIT 25P CONNECTOR
FRW I+) {GRN/BLK) RRW (+}
{GRN/WHT)
DTC 12, 14, 16, 18i Wheel Sensor
(Electrical
Noi se/ l nt ermi t t ent I nt errupt i on)
NOTE: l f the ABS i ndi cator comes because of el ectri cal
noi se, the i ndi cator goes off when you test-dri ve the
vehi cl e at 19 mph
( 30
km/ h) .
1. Vi sual l y check for appropri ate wheel sensor and
pul ser i nstal l ati on
(see
tabl e). Measure pul ser-to-
sensor cl earance. Inspect the pul sers for chi pped or
damage teeth
{see
page 19-60).
DTC Aoorooriate Wheel Sensor
t t Ri qht-front
1 4 Left-front
1 6 Ri qht-rear
1 8 Left-rear
Are the wheel sensot and pulser installed
cotrectl y?
YES Go to step 2.
NO Rei nstal l or repl ace the appropri ate wheel
sensor or
pul ser . l
Di sconnect the ABS control uni t 25P connector.
(cont' d)
19-49
ABS Components
DTC Troubleshooting
(cont'd)
Measure the resi stance between the appropri ate
wheel sensor
(
+
) and
( -
( see
t a bl e ) .
l s there l ess than 450 Q ?
YES Go to step 1.
NO Go to step 4.
DTC Appropriate Terminal
l +) Si de
(
) Si de
12
(Ri qht-front)
No. l 8: FFW
(*
) No. 2: FRW{
14
(Left-front)
No. 3: FLW
( +)
No. 12i FLW
(
16
( Ri qht - r ear )
No, 15: BRW{ - No, 6: BBW
(
18
(Left-rear)
No. 5: RLW
( +)
No, l4r RLW
(
19-50
4. Check for conti nui ty between the appropri ate
wheel sensor
(
+ ) ci rcui t termi nal and other wheel
sensor
( +
( see
t abl e) .
DTC Approp ate
Terminal
Other Termi nal
1 2 No. ' 181
FRW { + )
No. 3 No. No. 5
1 4 No. 3:
FLW
( +
)
No. ' 18 No. 15 No . 5
t o No. 15:
RRW
(+
)
No.
' 18
No. 3 No. 5
' 18
No. 5:
RLW
( +)
No. 18 No. 3 No. 15
FLW
(+} (BLU/ ORN}
RLW
(+)
-\J
,..1
2 3 4 5 6 7
9
24
t
25
10 12 1 4
RRW {+)
(YEL/RED}
5.
{GBN/WHT)
FRW
(+I
{GRN/BLK)
YES Repai r short i n the wi re between the
appropri ate wheel sensor and the other wheel
sensor . I
NO Cl ear the DTC. and test-dri ve the vehi cl e. l f
the ABS i ndi cator comes on and the same DTC i s
i ndi cared, repl ace the ABS modul ator-control
uni t . I
Di sconnect the harness 2P connector from the
appropri ate wheel sensor, and check the resi stance
between the
(
+
) si de and the
(
) si de of the wheel
sensor.
l s there l ess than 450 S) ?
YES Repl ace the wheel sensor.
NO Repai r short to wi re between the appropri ate
wheel sensor
( +)
and
(
) ci r cui t s. l
DTC 21, 22, 23, 24: Pulser
1. Cl ear t he DTC
( see
st ep 1 on page 19- 35) .
2. Test - dr i ve t he vehi cl e at 19 mph
( 30
km/ h) or mor e.
Does the ABS i ndi cator come on, and are DTCs 21,
22, 23, 24 indicated ?
YES Go to step 3.
NO The system i s OK al thi s ti me. t
3. Check the appropri ate pul ser gears for a chi pped or
damaged tooth
(see
tabl e).
DTC Appropriate Pulser
. , 1
Ri qht-front
22 Left-front
23 Ri oht - r ear
24 Left-rear
Are the pul ser gears OK?
YES Check for l oose termi nal s i n the ABS control
uni t 25P connector. l f necessary, substi tute a
known-good ABS modul ator-control uni t, and
recheck.l
NO Repl ace the dri veshaft or hub uni t wi th the
chi pped pul ser gear . I
DTC 31, 32, 33, 34, 35, 36, 37, 38: Solenoid
1. Cl earthe DTC
(see
step 1 on
page
19-35).
2. Tur n t he i gni t i on swi t ch ON { l l } .
3. Veri fy the DTC.
Doesthe ABS i ndi cator come on, and are DTCs 31,
32, 33, 34, 35, 36, 37, 38 indicated?
r echeck. l
NO
- The
syst em i s OK at t hi s t i me. l
19-51
ABS Components
DTC Troubleshooting
(cont'd)
DTC 41, 42,t|(|, 44: Wheel Lock
1. Li f t up t he vehi cl e so al l f our wheel sar eof f t he
ground, and rel ease the
parki ng brake.
2. Check for brake drag wi th the brakes hot.
Do the brakes drag?
YES Repai r the brake drag.l
NO Go to step 3.
3. Check the i nstal l ati on of the appropri ate wheel
sensor
(see
tabl e).
DTC ADoroDriate Wheel
4'1 Ri qht-front
42 Left-front
43 Ri qht - r ear
44 Left-rear
l s i t cotrect?
YES- Go to step 4.
NO
-
Rei nstal l the wheel sensor correcl l y.I
Connect the PGM Tester to the DLC.
Choose MISC TEST from the ABS menu, then
sel ect functi on test.
Choose the out sol enoi d for the appropri ate DTC
(see
tabl e), and fol l ow the on screen prompts.
Appl y the brakes, and have an assi stant attempt
to rotate the appropri ate wheel for the DTC, then
act uat e t he out sol enoi d. When t he sol enoi d i s
actuated. the wheel shoul d rotate, and then l ock
up.
Di d the wheel rotate?
YES
-
The probabl e cause was that the veh i cl e
spun dur i ng cor ner i ng. l f t he pr obl em r ecur s,
check for l oose connectors, or try a known-good
ABS modul ator-control uni t. I
NO Check for l oose ABS modu l ator-control
uni t connecl ors. l f necessary, repl ace the ABS
modul at or - cont r ol uni t . I
5.
7.
19-52
DTC 51: Motor Lock
1 . Check the ABS MOTOR
(30
A) fuse i n the mai n
under-hood fuse/rel ay box, and rei nstal l the fuse i f
i t i s oK.
l s the f use OK?
YES Go to step 2.
NO Repl ace the fuse, and recheck.l
2. Di sconnect the ABS control uni t 25P connector.
3. Measure the vol tage between the ABS control uni t
25P connector termi nal No. 9 and body
ground.
ABS CONTROL UNIT 25P CONNECTOF
MR +B IWHT
-\;
,rt\
2 3 4 5 6 7
8 I
-
( \ /
I Y
l t I
t0 12 1 4 6
+B
6,
Wi re si de ol femal e termi nal s
YES- Go to step 4.
NO Repai r open i n the wi re between the ABS
MOTOR {30 A) fuse and the ABS control uni t.I
connect the ABS control uni t 25P connector.
Cl ear the DTC
(see
step 1 on
page 19-35).
Test-dri ve the vehi cl e at 6 mph
(10
km/h) or more.
Does the ABS i ndi cator come on, and i s DTC 51
i ndi cated?
YES Repl ace the ABS modul ator-control uni t.I
NO The syst em i s OK at t hi s t i me. l
DTC 52: Motor Stuck OFF
' 1.
Check the ABS MOTOR
(30
A)fuse i n the mai n
under-hood fuse/rel ay box, and rei nstal l the fuse i f
i t i s OK.
Is the tuse OK?
YES Go to step 2.
NO
-
Repl ace the fuse, and recheck.l
2. Di sconnect the ABS control uni t 25P connector.
ls there batt.ety voltage?
recheck.l
MOTOR
(30
A) fuse and the ABS control uni t.I
DTC 53: Motor Stuck ON
1. Cl ear the DTC
(see
2, Test-dri ve the vehi cl e.
Does the ABS indicatot come on, and is DTC 53
i ndi cated?
YES Repl ace the ABS modul ator-control uni t.l
NO The system i s OK at thi s ti me.l
19-53
ABS Components
DTC Troubleshooting
(cont'dl
DTC 54: ABS Fail-safe Relay
1. Cl ear the DTC
(see
step 1 on
page 19-35).
Does the ABS indicator come on, and is DTC 54
i ndi cated?
YES Repl ace the ABS modul ator-control uni t.l
NO Intermi ttent fai l ure; the vehi cl e i s OK al thi s
t r me. l
19-54
DTC 61, 62: FSR * B Voltage
1. Cl earthe DTC
(see
step 1 on
page 19-35).
2. Test - dr i ve t he vehi cl e at 6 mph { 10 km/ h) or mor e.
Does the ABS indicator come on?
YES
-
Go to step 3.
NO The system i s OK at thi s ti me.l
3. Veri fy the DTC.
l s DTC 61 or 62 i ndi cated?
YES- Check the chargi ng system. I
NO- Do the appropri ate troubl eshooti ng for the
DTC. I
DTC 71: Different Diameter Tire
1. Cl ear the DTC
(see
Does the ABS indicator come on, and is DTC 71
indicated?
YES
-
Make sure al l four ti res are the speci fi ed si ze
and are i nfl ated to
proper
speci fi cati on.l
NO
-
Intermi ttent fai l ure; the vehi cl e i s OK at thi s
t i me. l
DTC 81: Cent ral Processi ng Uni t
(CPU)
Di agnosi s, and ROM/ RAM Di agnosi s
1. Cl ear the DTC
(see
step 1 on
page
19-35).
Does the ABS indicatot come on, and is DTC 81
i ndi cated?
YES
-
Repl ace the ABS modul ator-control uni t.l
NO l ntermi ttent fai l ure; the vehi cl e i s OK at thi s
t i me. l
19-55
ABS Components
ABS lndicator Circuat Troubleshooting
ABS indicator does not come on
(l l ),
and watch the ABS
i ndi cator.
Does the ABS i ndi cator come on?
YES The system i s OK at thi s ti me.l
?
5.
6.
NO
-
Go to step 2.
Tur n t he i gni t i on swi t ch OFF t hen ON
( l l )
agai n.
Does the fuake system indicator come on?
YES Go to step 3.
NO Repai r open i n the i ndi cator
power
source
ci r cui t . l
.
Bl own I NSTRUMENT LI GHT
( 7. 5
A) f use.
.
Open i n the wi re between the INSTRUMENT
LI GHT
( 7. 5
A) f use and gauge assembl y.
.
Open ci rcui t i nsi de the fuse box.
Di sconnect the ABS control uni t 25P connector.
( l l ) .
Does the ABS indicator come on?
recheck.l
NO Go to step 6.
Check t he ABS i ndi cat or bul b i n t he gauge
assemor y.
l s the bul b OK?
YES Go to step 7.
NO Repl ace t he ABS i ndi cat or bul b. l
Remove the gauge assembl y
(see page 22-52).
7.
8.
19-56
9.
10.
Di sconnect the gauge assembl y 16P connector.
Check for conti nui ty between the gauge assembl y
16P connect o r t er m i nal No. 8 and body gr ound.
GAUGE ASSEMBLY 16P CONNECTOR
YES Repai r short to body ground i n the wi re
between the
gauge assembl y and the ABS control
uni t . l
Connect the
gauge assembl y 16P connector, and
di sconnect the
gauge
assembl y 12P connector.
12P connect or t er mi nal No. I and body
gr ound.
IBLK}
YES Check for l oose termi nal s i n the gauge
assembl y connectors. l f the connector i s OK,
r epl ace t he gauge assembl y. I
NO* Repai r open i n the wi re between the gauge
assembl y and body
gr ound ( G501) . 1
1 1 .
12.
2 3 4 5
6 / 1 d I 10 11 12
GND
'/\'
ABS indicator does not go
off
' 1,
Check t he ABS +B( 20A) f use i n t he mai n under -
hood fuse/rel ay box, and rei nstal l the fuse i f i t i s OK.
l s the f use OK?
YES Go to step 2.
NO Repl ace the fuse, and recheck. l f the fuse i s
bl own, check for a short to body ground i n thi s fuse
ci rcui t. l f the ci rcui t i s OK, repl ace the ABS
modul ator-control uni t. I
Check the R/C MIRROR
(7.5
A) fuse i n the
under-dash fuse/rel ay box, and rei nstal l the fuse i f
i r i s oK.
l s the l use OK?
YES Go to step 3.
NO Repl ace the fuse, and recheck. l f the fuse i s
bl own, check for a short to body ground i n thi s fuse
ci r cui t . I
Di sconnect the ABS control uni t 25P connector,
Measure the vol tage between the ABS control uni t
YES Go to step 5.
( 20
A) f use and t he ABS cont r ol uni t . t
( l l ) .
3.
5.
FSR
2 3 4 5 6 1
I
^ t - / \
Y - l
\
__
l t l
rcLj l -
10 12
I
2 3 4 5 6 7
3
24
3
25
t 0 12 1 4
18
tcz
1 .
8.
25P connect or t er mi nal No. 16 and body
gr ound.
{YEL/BLKI
Wi re si de of t emal e t ermi nal s
YES Go to step 7.
NO Repai r open i n the wi re between the R/C
MIRROR
(7.5
A) fuse and the ABS control uni t.I
Check for conti nui ty between the ABS control uni t
IBLK)
YES Go to step 9.
control uni t and body ground (G303).I
{cont' d)
2 3 4 5 6 7
3
24
I
25
10 12 t o
18
GNDl
+ B
19-57
ABS Components
9.
10.
ABS Indicator Circuit Troubleshooting
(cont'd)
(l l ).
Connect the ABS control uni t 25P connector
gr ound wi t h a
j umper
wi r e.
WALP NEU
2 3 4 5 6 1
I
24
t
25
10 12 1 41 5
] E
JUMPER
WIRE
1 1 .
Does the ABS i ndi cator go otf?
recheck.l
NO Go t o s t e p l l .
Con nect the
ga
uge assem bl y 16P co nnector
gr ound wi t h a
j umper
wi r e.
Does the ABS i ndi cator go ofl ?
YES Repai r open i n the wi re between the gauge
assembl y and the ABS control uni t.l
NO Check for l oose gauge assembl y connectors.
l f the connector i s OK, repl ace the gauge
assembl y. l
19-58
ABS Modulator-Control Unit Removal and Installation
NOTE:
.
Donotspi l l brake fl ui d on the vehi cl e; i t may damage the
pai nt; i f brake fl ui d gets on the
pai nt, wash i t off
.
Take care not to damage or deform the brake l i nes duri ng removal and i nstal l ati on.
.
Topr event t hebr akef l ui df r omf l owi ng, pl ugandcover t hehoseendsandj oi nt swi t hashopt owel
or equi val ent
materi al .
Removal
1. Pul l uot hel ock( B) of t heABScont r ol uni t 25P connect or
( C) ,
t hen di sconnect t he connect or .
FLARE NUT
To righl-tront
To left-rear
To right-rear
To left-front
mm NUT
s. 8 N m 11. 0
kgf . m, 7. 2l bf . f t l
--G
mm EOLT
---' 9. 8 N. m 11. 0 kcI m, 7. 2l bf f t )
2. Di sconnect the si x brake l i nes.
3. Remove the two 6 mm nuts.
4. Remove the ABS modul ator-control uni t
(A).
lnstallation
1. l nstal l the ABS modul ator-control uni t, then ti ghten the two 6 mm nuts.
2, Al i gnthe connecti ng surface of the ABS control uni t 25Pconnector.
3. Pushi nt hel ockof t heABscont r ol uni t 25P connect or unt i l
you hear i t cl i ck i nt o
pl ace, t hen co n nect t he con nect or '
4. Bl eed the brake system, starti ng wi th the front wheel s.
5. Start the engi ne, and check that the ABS i ndi cator
goes off.
6. Test-dri ve the vehi cl e, and check that the ABS i ndi cator does not come on
19-59
ABS Components
Wheel Sensor Inspection
Inspect the front and rear pul sers
for chi pped or
damaged teeth.
Measure the ai r gap between the wheel sensor and
pul ser
al l the way around whi l e rotati ng the pul ser.
Remove the rear brake di sc to measure the gap
on
the rear wheel sensor. l f the gap
exceeds 1.0 mm
( 0, 04
i n) , check f or a bent suspensi on ar m.
Standard:
Front/Rear: 0.4 1.0 mm
(0.02
0.04i n.)
Front/Bear
0, 4- 1. 0 mm
10. 02-0. 0i t i n. l
1 .
19-60
Wheel Sensor Replacement
NOTE; Instal l the sensors careful l y to avoi d twi sti ng the
wi res.
Front:
6 mm BOLT
9, 8 N. m
(1. 0
kgf . m, 7. 2l bf . f t )
Rear: \
mm BOLT
WHEEL SENSOR
9. 8 N. m (1. 0
kgI . m,
1.2 tbt.ftl
6 mm BOLT
9. 8 N. m (1. 0
kgf m,
7. 2l bf . f t l
9. 8 N m {1. 0 kgl . m, 7. 2 l bf f t )
Body
Doors
Comoonent Locat i on l ndex . . . . . . . .
Door Panel Removal /
I nst al l at i on
Door Out er Handl e
Repl acement
Door Lat ch Reol acement . . . . . . . . . . . .
Door Gl ass and Regul at or
Reol acement
Door Gl ass Adj ust ment . . . . . . . . . . . . . . .
Door Sash Hol der
Repl acement
Door Sash Hol der
Adi ust ment
Door Gl ass Out er Weat herst ri o
Repl acement
Door Weatherstrip
Reol acement
Door Wedge and Door Wedge
Hol der Reol acement . . . . . . . . . . . . . . . .
Door Posi t i on and Door St ri ker
Adj ust ment
Mirrors
Component Locat i on I ndex . . . . . . . .
Power Mi rror Repl acement . . , . . . , .
Mi rror Hol der ReDl acement . . . . . . . .
Rearview Mirror
Reol acement
Glass
Component Locat i on l ndex . . . . . . . .
Gl ass Repl acement Process . . . . . . .
Wi ndshi el d Repl acement . . . . . . . . . . . .
Rear Wi ndow Reol acement . . . . . . . .
Convertible Top
Convertible Top Assembly
Repl acement
Convert i bl e Too Cl ot h
Reol acement
Rear Wi ndow Repl acement . . . . . . . .
Rear Wi ndow Lower Mol di ng/
Rear Wi ndow Harness Hol der
Repl acement
Convert i bl e Top Cl ot h Repai r . . . . .
Convert i bl e Top Lock Handl e
Repl acement
Convert i bl e Top Lock Handl e
Operat i on Load
Adjustment
20-2
20-4
20-5
20-7
20-8
20-'t'l
20-'15
20- 16
20-16
20-17
20-17
20- 18
20-20
20-21
20-21
20-22
20-23
20-25
20-29
20-32
20-35
20-38
20-40
20-43
20-47
20-48
20-49
20-49
Convert i bl e Top Mot or
Repl acement . . 20- 50
Convert i bl e Too St ri ker
Reol acement . . 20-50
A-Pi l l ar-Header Weat herst ri o
and A- Pi l l ar Mol di ng
Repl acement . . . . . . . . . . . . . . . . . . . . . . . . . 20-51
B-Pi l l ar Out er Weat herst ri p
Drai n Tank and Lower Drai n
Hose Reol acement . . . . . . . . . . . . . . . . . . . 20-52
Convert i bl e Top Cover Snap
Reol acement . . 20- 53
Removable Hardtop
Comoonent Locat i on l ndex . . . . . . . . 20-54
I nt eri or Tri m Removal /
l nst al l at i on . . . . . . 20-55
Headl i ner Removal /
l nst al l at i on . . . . . . 20-56
Roof Mol di ng Repl acement . . . . . . . . 20-57
Hardtop Lower Weatherstrip
Roof Front Tri m
Reol acement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20- 61
Hardt oo Lock Handl e
Reol acement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20- 61
Roof Si de Lock Reol acement . . . . . . 20-62
Hardt op St ri ker Repl acement . . . . . 20-63
Body Si de Cat ch Assembl y
Body Side Catch
Roof Posi t i on Adj ust ment . . . . . . . . . . . 20-65
Interior Trim
Component Locat i on I ndex . . . . . . . . 20-67
Tri m Rem ova l / l nst a l l at i on
Front Roof Area . . . . . . . . . . . . . . . . . . . . 20-68
Tri m Removal / l nst al l at i on
Door Area . . . . 20-69
Tri m Remova l / l nst al l at i o n
Seat Si de Area . . . . . . . . . . . . . . . . . . . . . . 20-70
Tri m Remova l / l nst a l l at i on
Rear Tray Area . . . . . . . . . . . . . . . . . . . . . . 2O-71
Tri m Removal / l nst al l at i on
Trunk Area .. 20-73
Carpet Repl acement . . . . . . . . . . . . . . . . . . . . 20-7 4
*
Cent er Carpet Repl acement . . . -. . . . 20-75
Gonsoles
Cent er Consol e Removal /
I nst al l at i on
Wi nd Def ect or Repl acement . . . . . .
Rear Consol e Removal /
l nst al l at i on
Rear Consol e Box
Repl acement
Dashboard
l nst rument Panel Removal /
l nst al l at i on
Radi o Panel Removal /
I nst al l at i on
Front Consol e Cover Removal /
l nst al l at i on
Passenger' s Dashboard Lower
Cover Removal / l nst a l l at i on . . . . .
Passenger' s Si de Vent
Removal / l nst al l at i on . . . . . . . . . . . . . . . .
*
Dashboard Removal /
I nst al l at i on
Seats
Seat Remova l / l nst a l l at i on . . . . . . . . . . .
Seat Di sassem bl y/ Reassem bl y
-
Driver' s
Seat Di sassembl y/ Reassembl y
Passenger' s
Seat Cover Repl acement . . . . . . . . . . . .
Bumpers
Front Bumper Removal /
I nst al l at i on
Rear Bumper Removal /
l nst al l at i on
Hood
Adjustment
Hood I nsul at or Repl acement . . . . . .
Fuel Fill Door
Adj ust ment
Exterior Trim
Cowl Cover Repl acement . . . . . . . .
Rear Tray Openi ng Mol di ng
Reol acement
Rear Wi ndow Lower Mol di ng
Reol acement
Embl em Reol acement . . . . . . . . . . . . .
A-Pi l l ar Ext eri or Tri m
Reol acement
20-100
20-101
20-102
20-102
20-103
20-104
Fenderwell
I nner Fender Repl acement . . . . . . 20-105
St rakes Repl acement . . . . . . . . . . . . . . . 20-106
Fenderwel l Tri m
Reol acement . . . . . . . . . . . . . . . . . . . . . . . . . 20-107
Rear Ai r Out l et
Reo1acement . . . . . . . . . . . . . . . . . . . . . . . . . 20-107
Openers
Hood Ooener Cabl e
ReDl acement . . . . . . . . . . . . . . . . . . . . . . . . . 20-109
Fuel Fi l l Door Opener
Cabl e Reol acement . . . . . . . . . . . . . . 20-1 10
Hood Rel ease Handl e
Reo1acement . . . . . . . . . . . . . . . . . . . . . . . . . 20- 111
Hood Lat ch Reol acement . . . . . . . . 20-111
Trunk Li d Lat ch
Reol acement . . . . . . . . . . . . . . . . . . . . . . . . . 20-1 12
Trunk Li d Lock Cyl i nder
Reol acement . . . . . . . . . . . . . . . . . . . . . . . . . 20- 1 13
Frame
Front Subframe
Repl acement . . . . . . . . . . . . . . . . . . . . . . . . . 20- 1 14
Rear Subf rame
Repl acement . . . . . . . . . . . . . . . . . . . . . . . . . 20- 1 15
*
Fr ame Repai r Char t . . . . . . . . , , . . , . . . . . 20- 116
20-76
20-77
20-78
20-79
20-80
20-80
20-81
20-81
20-82
20-82
20-85
20-86
20-87
20-88
20-89
20-92
20-93
20-94
20-96
Trunk Lid
Adj ust ment . . . . . . . . 20-97
Trunk Li d Torsi on Bar
Repl acement . . 20-98
Trunk Li d Rubber Prot ect or
Trunk Li d Weat herst ri p
Reol acement . . 20-99
Doors
WEDGE HOLOER
G
GLASS OUTER
WEATHERSTRIP
r)
@
ts+a
DETENT ROD
/
yo'
#'*e e^/
w>
@(hJ"te
i.%-.
DooRwEDGE b
TWEETER GRILLE
(' 02-03
model s)
DOOR
Posi t i on Adj ust ment ,
page 20' 18
*b{
ft
\,/
I
I
SPEAKER
AY
\J
\
ADAPTER
DOOR GLASS
INNER WEATHERSTRIP
PLASTIC
TWEETER
(' 02-03
model s)
DOOR GRI P
COLLAR
(' 02-03
model s)
Passenger'si
swrrcH PANEL
/9
/ / 8 s
tr
POWER WINDOW
swrTcH
\\..-
qi
20-2
GLASS
Repl acement ,
page 20-8
Adj ust ment , page 20-l ' l
FRONT LOWER
CHANNEL
/ DOOR
SASH HOLDER
/ Repl acement ,
I
page 20-15
/
Adj ust ment ,
f
Page
20' 16
I
GLASS STOP
o
trF
/
)N
DOOR GLASS
REGULATOB
Bepl acement,
page 20-8
REGULATOR
LOWER PATCH
DOOR STRIKER
Adj ustment,
page 20-18
N
LOCK CYLI NDER
CYLINDER SWITCH
LATCH
PROTECTOR
PROTECTOR
RETAINER CLIP
DOOR OUTER HANDLE
ROD CRANK
FRONT LOCK ROD
HANDLE
0
HANDLE
ROD PROTECTOR
DOOR LATCH
Repl acement,
page 20 7
usn
/i'tl:\
/l:, J
w
I NNER
POWER DOOR
LOCK ACTUATOR
\ o Q
o"- An
*Fy'
'r.9
I NNER HANDLE CASE
20-3
Doors
Door Panel RemovaUl nstal l ati on
Tri m pad remover, Snap-on A 177A, or equi val ent, commerci al l y avai l abl e.
NOTE:
.
Take care not to scratch the door panel
anddoor,
.
When pryi ng wi th a fl at-ti p screwdri ver, wrap i t wi th protecti ve
tape to prevent
damage.
' 1.
Remove t he door panel i n t he number ed sequence. Remove t he door
panel
wi t h as l i t t l e bendi ng as possi bl e
t o
avoi d cr easi ng or br eaki ng l t .
2. I nst al l t he panel i nt he r ever se or der of r emoval , and not e t hese i r ems:
.
Repl ace any damaged cl i ps.
.
Make sure the connectors are pl ugged
i n properl y.
.
Check the wi ndow and power
door l ock operati ons.
Fastener Locations
A>: Scr ew, 1 B>: Scr ew, 1 C>: Scr ew, ' t D>: Cl i p, I E>: Ct i p, 6
/.\ /\. /^\ .---A A
tlpr
(
F>
(F::["
L----l
J94
-
Er-r
12 mm
-
{ 0. 47 i n. }
(1TwEETER
CONNECTOR
(' 02
03 model s)
Di sconnect ,
,tilPowER
wtNDow
SWITCH CONNECTOR
Di sconnect ,
95 mm {3. 74 i n. )
TRIM PAO REMOVER
t
r
-)?
t
I
O INNER HANDLE cAsE
Turn t he case, and sl i p
t he i nner handl e t hrough
t he hol e i n t he case.
1 m m
{0. 04 i n. l
.5 CAP
20-4
(' OOOR
PANEL
Door Outer Handl e Repl acement
NOTE:
.
Put on gl oves to
protect your hands.
.
Take care not to scratch the door
.
Take care not to bend each rod.
' 1.
2.
3.
Remove these i tems:
.
Door oanel
.
Pl asti c cover, as necessary
(see page 20-2)
Remove the door outer handl e i n numbered sequence
l nstal l the outer handl e i n the reverse order of removal , and note these i tems:
.
Make sure the cyl i nder swi tch harness i s routed properl y.
.
Make sure the cyl i nder swi tch connector i s
pl ugged i n properl y, and each rod i s connected securel y.
.
When i nstal l i ng the l ock cyl i nder, l eave the outer handl e bol ts l oose so the outer handl e
protector does not
i nterfere wi th the l ock cyl i nder i nstal l ati on, then ti ghten the handl e bol ts
. I ns t al l t her et ai ner c l i pont heout er handl e, t heni ns t al l t hel oc k c y l i nder . Bes ur et her et ai ner c l i pi s f ul l y s eat ed
i n the sl ot on the l ock cyl i nder.
.
Make sure the door l ocks and opens
properl y.
.
When rei nstal l i ng the door panel , make sure the pl asti c cover i s i nstal l ed properl y and seal ed around i ts
peri meter.
Fastener Locations
O Rai se t he
gl ass f ul l y.
LOCK CYLINDER
CYLINDER SWITCH
HOLE SEAL
A>: Sc r ew, 1 B>r Sc r ew, 1
C=" O-
i!] RETAINER CLIP
- - ' . : . ' \ J
-
)};i
a\
\
\ , l ?\
. .
ROD PROTECTOR
i9-, HARNESS CLIPS
Det ach.
{cont' d)
:-,
O CYLINDER SWTTCH HARNESS
CONNECTOR
Di sconnect ,
20-5
Doors
Door Outer Handle Replacement
(cont'd)
Fastener Locations
>
: Bolt, 2
I i I \tF,----:\
)
: Bolt, 1
I
i
lllllrr--1
CO : Nut, 1
@
F>: Sc r ew. 1
I" ;r
\i'/--
G) : Sc r e w, 2
f)'-'---,-'-
\}-
@ Tur n t he out er handl e,
and remove i t f rom out er handl e rod.
JOINT
OUTER HANDLE
O Scr i be a l i ne ar ound
t he out er handl e rod on
t he
j oi nt
t o show t he ori gi nal
adl ust ment . OUTER HANOLE ROD
@ Pul l out t he out er handl e.
OUTER HANDLE
PROIECTOR ROD
0 6 x 1 . 0 mm
9.8 N.m
(1.0
kgf m,
7.2 tbl.ftl
JOI NT
n - -
v
@6 x 1 , 0 mm
9. 8 N. m 11. 0 kgt . m.
7. 2l bf . f t l
i1O OUTER HANDLE
PROTECTOR
f' ?5' \
i ' - r . 1
r \ r i 7
c ' 1
,
\.'
l l j l 6x1. omm
9. 8 N. m {1. 0 kgf . m,
7.2tbl.ftl
( ?6x 1. omm
6 N.m {0.6 kgf m.
4 lbf.fr)
LATCH
20-6
Door Latch Replacement
NOTE:
.
Put on
gl oves to
protect your hands.
.
Take care not to scratch the door.
.
Take care notto bend each rod.
1. Remove t he out er handl e
( see page 20- 5) .
2. Remove the door l atch i n numbered sequence.
3. Instal l the l atch i n the reverse order of removal , and note these i tems:
.
Make sure the actuator connectors are
pl ugged i n
properl y, and each rod i s connected securel y
.
l \,4ake sure the door l ocks and opens
properl y.
.
When rei nstal l i ng the door panel , make sure the pl asti c cover i s i nstal l ed
properl y and seal ed around i ts
peri meter.
Fastener Locations
DOOR LATCH
A) : Sc r e w, 3
ClF"
Di sconnect t he i nner
handl e r od.
@ Di sconnect t he rear
l ock rod-
REAR LOCK ROD
/
r
_--,,,,-.
)P
.,
,i .,
6.'
.-, -
..
"
I NNEB HANDLE
A 1 . 1
v. i
\ \
@ FRONT LOCK ROD
O CONNECTORS
Di sconnect.
Det ach t he i nner
handl e rod.
Di sconnect t he f ront
l ock rod.
' ROD CRANK
20-7
Doors
Door Glass and Regulator Replacement
NOTE:
.
Put on gl oves
to protect your hands.
.
Take care notto scratch the door.
.
Take care not to drop the wi ndow gl ass i nsi de the door.
1. Remove these i tems:
.
l nner handl e and r od cr ank
( see page
20- 7)
.
Pl asti c cover
(see page
20-2)
2. Remove the door gl ass
and regul ator i n numbered sequence:
'
Hol d the adj usti ng bol ts wi th a hex wrench when removi ng the l ocknuts.
.
Scri be a l i ne around the stabi l i zer mounti ng bol t, the gl ass mounti ng bol ts, and the regul ator mounti ng nuts to
show the ori gi nal l ocati ons.
Fastener Location
A>: Bol t , 1
{MIED
STABILIZER
Scr i be a l i ne
around t he bol t .
OLoosen t he bol t .
8 x 1. 25 mm
22 N. m
(2.2
kgf.m,
16 tbf.ft)
OCaref ul l y move t he gl ass unt i l you
can remove t ne gl ass st op.
6 x 1 . 0 mm
5 N.m {0.5 kgf.m,
4 tbt.ft)
1
!s
. _)ir'
t . , * L
: - /
-jso_-__.._-.<
./ v^
.a
i r , ,
1
a .
,
".':-
--.:r""'
NUT
20-8
Faslenel Locations
B
>:
Bol t . 3
O Caref ul l y move t he gl ass down Ll nt i l you
can see t he bol t s.
6 x1. 0 mm
I N.m {0.8
kgf m,
6 rbt.ft)
I'
@ Scri be a l i ne around t he bol l s
(Three pl acesi .
I
/ t
'tt'"-'
'"'
' (
:
' ;,"io
""' tt:
'
'
_t . -
l
- a n
(cont' d)
) Remove t he gl ass
f rom t he requl at or.
20-9
Doors
Door Glass and Regulator Replacement
(cont'd)
Fastener Locations
Ca: Nut , 2 o
O
: Nut . 2 F>: Bol t . 2
('
Scri be a l i ne around t he nut s.
@8x 1. 25mm
12Nm( 1, 2k gf . m,
lgf.ft)
@ REGULATOR
E
>
: Bol t,3
td\
l r l @
t
@ coNNEcToR
Di sconnect
and det ach.
6 x 1 . 0 mm
8 N. m
{0.8 k9f.m,
6 tbf.ftl
Loosen.
/
OLOCKNUT
8 x 1.25 mm
12 N.m {1.2 kgf.m,
,&
@ HARNss
CLIP
Det ach.
9 tbf.ftl
ADJUSTING BOLT
Instal l the gl ass
and regul ator i n the reverse order of removal . and note these i tems:
.
Hol d the adj usti ng bol ts wi th a hex wrench when i nstal l i ng the l ocknuts.
.
Before i nstal l i ng the regul ator, Appl y mul ti purpose grease
to al l the sl i di ng surfaces ofthe regul ator.
.
Make sure the connector i s pl ugged i n properl y.
.
Rol l the gl ass
up and down to see i f i t moves freel y wi thout bi ndi ng.
' Makesur et hat t her ei snocl ear ancebet weent hegl assandr oof weat her st r i pswhent hegl assi scl osed.
.
Adj ust the
posi ti on
of the
gl ass
as necessary
(see page
20-1 1).
.
Check for water l eaks
{see step 17 on page 20-14),
.
Test-dri ve and check for wi nd noi se and rattl es.
'
When rei nstal l i ng the door
panel ,
make sure the
pl asti c
cover i s i nstal l ed properl y
and seal ed around i ts
Derrmel er.
=--"--
:--r--r1,,
'\
Y,t;.)'',
,;
b-(
1(.'
20-10
Door Glass Adiustment
NOTE:
.
Check the A-pi l l ar-header weatherstri p, roof
weatherstri ps and B-pi l l ar weatherstri p for damage or
deteri orati on. and repl ace them i f necessary.
.
Wi pe each weatherstri p and the front l ower channel
cl ean wi th a shop towel .
.
Lubri cate the front l ower channel wi thShi n-Etsu
grease P/N08798-9013.
Pl ace the vehi cl e on a fi rm, l evel surface.
Secure the converti bl e top wi th both converti bl e
top l ock handl es.
Make sure they are l ocked securel y.
Lower the gl ass ful l y.
.
Door
panel (see page 20-4)
.
Plastic cover
(see page 20-21
.
A-pi l l a r-heade r weath erstri p, pi l l ar porti on (see
page 20- 51)
.
Roof si de weatherstri p
(see page 20-40)
.
Roof corner weatherstri p
(see page 20-35)
.
B-pi l l ar weatherstri p
(see page 20-40)
Cl ose the door. Check the door fi t to the body
openi ng.
Rai se t he gl ass f ul l y.
At the measuri ng
poi nts (A,
B, C), measure and
record cl earances
"H"
and
"B"
between the gl ass
( D)
and t he mol di ng
( E)
and t he gl ass ( D)
and t he
retai ner
(F).
Adj ust the cl earance as descri bed i n
steps 9 thru
' 10.
4.
1 .
7.
5.
Measuri ng Poi nt A
-\
"8"
Clearance
Measuri ng Poi nt B
"H"
Cl e. rance
Measuri ng Poi nt C
"8"
Cl earance
"H"
Cl earance
Cl earance {Standal d cl earancel
U ni t : mm
( i n. )
l \4easuri ng Poi nt B c
Cl earance
" H"
4
( 0. 16)
?
( 0. 1
1 )
I
( 0. 31)
" 8"
1 1
( 0. 43)
1 4
( 0. 55)
1 8
{ 0. 71)
8. Move the door sash hol der al l the way forward
(see
page 20- 15) .
(cont' d)
\
,v
"8"
Cl earance
20-11
Doors
Door Glass Adjustment
(cont'dl
9. Adj ust cl earance
"H"
as fol l ows:
-1
Loosen the bol ts
(A)
securi ng the stop pl ates (B).
-2
Loosen the bol ts
(Cl securi ng
the gl ass
{D).
-3
Move the gl ass up or down, as wel l as, forward and rearward to al i gn i t wi th the retai ner and mol di ng. Move
the gl ass
unti l cl earcnce
"H"
i s wi thi n the speci fi ed l i mi ts.
-4
Ti ghten the bol ts securi ng the gl ass.
-5
Press the stop pl ates agai nst the gl ass
stops
(E).
-6
Fasten the stop pl ates. Check that the stop pl ates contact the gl ass
stops evenl y.
A
8 x 1. 25 mm
22 N,m
12.2 kbt.rn,
16 rbr.ftl
"H"
Clearance
c
6 x 1 . 0 mm
8 N. m {0. 8 kgf . m,
6 tbf.ft)
.\\
) : .
' -.i...\
.t\.
:
...//.\
t r ' '
20-12
10. Adj ust cl earance
"8"
as fol l ows:
Push the gl ass (A)
outward 10 mm
(0.39
i n.), then l i ghtl y push
the stabi l i zer
(B)
agai nst the
gl ass.
Ti ghten the bol t
(C)
securi ng the stabi l i zer. Check thatthe gl ass
moves smoothl y.
Loosen the l ocknuts
(D).
Turn the adj usti ng bol ts
(E)
unti l the cl earance
"8"
i s wi thi n the speci fi ed l i mi ts. Turn the front and rear
adj usti ng bol ts the same amount to keep the regul ator
(F) paral l el wi th the seati ng su rface of the door.
Ti ghten the l ocknuts. Make sure that the ends of the adj usti ng bol ts sti l l proj ect
out of the l ocknuts.
Move the gl ass up and down to seat i t, then measure cl earance
"8"
at the desi gnated l ocati ons.
Measure cl earance
"H"
agai n to make sure i t i s sti l l wi thi n the speci fi ed l i mi ts at the desi gnated l ocati ons.
Repeat the above steos unti l the correct cl earance are obtai ned.
Adiusting Bolt Top Edge of Glass
Clockwise
-
Moved out
Counter-clockwise
"8"
Cl earance
- 1
-2
-3
-5
-6
-7
ird
c
8 x 1.25 mm
22 N.n 12.2 kgt m,
16 tbf.ft)
D
8 x 1. 25 mm
12 N. m
{1, 2
kgf . m,
9 rbf.ftl
(cont' d)
20-13
Doors
Al i gn t he door sash hol der wi t h t he
gl ass usi ng t he
adj usti ng bol t at the bonom of the door sash hol der
( see page 20- 16) .
After the cl earances have been adj usted
properl y,
rei nstal I each weatherstri p.
13. Check that the gl ass moves smoothl y.
14. Rai se t he gl ass ( A) f ul l y,
and check t hat t he gl ass
contacts each weatherstri p
(B)
evenl y. Measuri ng
poi nts are descri bed at step 7.
Front roof pillar :
Door Glass Adjustment
{cont'd)
' l t .
12.
i
Rool :
Cnt er pi l l ar:
20-14
t c .
t o .
Attach the
pl asti c cover, and i nstal l the door
panel
(see page 20-4).
Make sure that the top i s l ocked securel y, then ral se
the gl ass ful l y, and cl ose the doors.
Check for water l eaks. Run water over the roof and
on the seal i ng area as shown, and note these i tems:
.
Use a 12 mm
( 1/ 2
i n. ) di amet er hose
( A) .
.
Adj ust the rate of water fl ow
(B).
.
Do not use a nozzl e,
.
Hol d the hose about 300 mm
(12
i n.) away from
the door.
17.
12 mm
( 1/ 2
i n. )
7-'
t ,
A
150 mm
(6
i n. )
I
-A
18.
19.
l f there are l eaks, recheck the work
performed,
and
check the door
gl ass, weatherstri p, A-pi l l ar mol di ng.
and retai ner adj ustment.
Test-dri ve and check for wi nd noi se.
Door Sash Holder Replacement
NOTE:
.
Put on gl oves
to
protect your
hands.
.
' 1.
a-.?
.
Door gl ass (see page 20-8)
.
Door weatherstri p, as necessary {see
page 20-171
Remove the door sash hol der i n numbered sequence;
.
Hol d the adj usti ng bol t wi th a hex wrench when removi ng the l ocknut.
.
Scri be a l i ne around the l ocknutto showthe ori gi nal adj ustment.
Instal l the hol der i n the reverse order of removal , and note these i tems:
.
Adj ustthe posi ti on
ofthe door sash hol der
(see page 20-16).
.
(see
step 17 on
page
20-14).
.
'
When rei nstal l i ng the door panel , make sure the pl asti c
and seal ed around i ts
pefl mel er,
Fasrener Localions
A > c
a:
Nur , l
O6 x l . o mm
9. 8 N. m 11. 0 ksf . m,
7. 2l bl . t t l
---1-'-,-=
>
: Bolt, 2
â:\
l Lrro
: Scr ew, 4 B
n.--
{J*
@ HOIE SEAL
G] LOCKNUT
8 x 1. 25 mm
12 N. m { 1. 2 kgf . m,
I tbf.fi)
o
t
ii-''..-',
j
' ' !a
Di sconnect .
ADJUSTING
AOLT
? SPEAKER
\ ,
20-15
Doors
1 .
2.
Door Sash Holder Adjustment
Loosen t he l ocknut
( A)
whi l e hol di ng t he adj ust i ng
bol t
(B)
wi th a hex wrench.
Adjusting Bolt Top Edge of Holder
Clockwis
Counterclockwise
A
8 x 1. 25 mm
12 N. m
(1. 2 kgl . m,
9 rbt.ft)
3. Al i gn t he door sash hol der { C) wi t h t he
gl ass usi ng
the adj usti ng bol t at the bottom of the door sash
hol der, l \4ake sure that there i s no cl earance
between the end of channel
(D)
and gl ass surface.
4. Ti ghten the l ocknut securel y.
5. Rei nstal l al l remai ni ng removed
pans.
6, Check for water l eaks
(see
step 17 on page 20-' 14).
7. Test-dri ve and check for wi nd noi se and rattl es.
t
20-16
Door Glass Outer Weatherstrip
Replacement
NOTE:
.
Put on gl oves to
protect your hands.
.
Take care notto scratch the door and door mol di ng.
1. Remove t he door sash hol der { see
page 20- 15) .
2. Starti ng atthe rear, prythe oute r weatherstri p
(A)
up, and detach the cl i ps
(B,
C).
Fastoner Locations
B>: Cl i p, 1 C) : Cl i p, 6
l nstal l the weatherstri p i n the reverse order of
r emoval , and r epl ace any damaged cl i ps.
Door Weatherstrip Replacement
NOTE:
.
.
Use a cl i p remover, to remove the cl i ps.
1. Remove t he door panel
{ seepage20- 4) .
2. Remove the door weatherstri p as shown.
3. Instal l the weatherstri p i n the reverse order of
removal , and note these i tems:
.
.
l f the ol d weatherstri p i s to be rei nstal l ed, scrape
off al l traces of ol d EPT seal er and butyl tape,
then cl ean the weatherstri p surface wi th al cohol .
.
Gl ue the new weatherstri p i nto pl ace usi ng EPT
seal er and butyl tape.
Fastener Locations
A) : Scr ew, 2 B
EPT SEALER
Thi ckness:5 mm (0.2 i n.)
Wi dth:5 mm {0.2 i n.l
BUTYL TAPE
Thi ckness: 1 mml 0.04 i n.l
Wi deth: 5 mm {0.2 i n.l
WEATHERSTRIP
Door Wedge and Door Wedge
Holder Replacement
NOTE: Take care not to scratch the door and body.
1. Remove l he door wedge and the door wedge
hol der as shown.
2. Instal l the wedge and wedge hol der i n the reverse
order of removal , and when i nstal l i ng the door
wedge hol der, adj ust i t up or down unti l the door
wedge i s centered i n the hol der.
Fastens. Locations
2 B
6 x 1 . 0 mm
9.8 N.m
(1.0
kgf.m,
7.2 tbl.ttl
DOOR WEDGE
)
: Screw,
rN,",,,,-
\).*
)
: Screw
@
, 2
6 x 1 . 0 mm
9. 8 N. m
(1. 0
kgf . m,
7 .2 tbf.ftl
DOOR WEDGE
HOLOER
\ ^ .
20-17
Doors
Door Position and Door Striker Adjustment
NOTE:
.
Af t er i nst al l i ngt hedoor , checkf or af l ushf i t wi t ht hebody, t hencheckf or equal
gaps bet ween t he t r ont , r ear , and
bottom door edges and the body. Check l hat the door and body edges are
paral l el .
.
Pl ace the vehi cl e on a fi rm. l evel surface when adj usti ng the door.
.
Pl aceashopt owel on t he
j ack
t o
pr event
damage t o t he door when hol di ng t he door .
' 1.
Removet he door wedge hol der
( A) ( see page 20- 17) .
I x 1.25 mm
29 N.m 13.0
kgf.m,
22 tbt.ttl
4.
Sl i ghtl y l oosen the stri ker mounti ng screws
(B).
Adj ust the door al i gnment i n thi s sequence:
.
Adj ust at l he hi nges
( C) :
-
Loosent he door mount i ng bol t s
( D)
sl i ght l y, andmovet hedoor i nor out unt i l i t ' s f l ush wi t h t he body.
-
Remove the i nner fender
(see page 20-105), then sl i ghtl y l oosen the hi nge mountl ng bol ts
(E).
and move the
door backward or forward, up or down as necessary to equal i ze the gaps.
' Tur nt hedoor c us hi ons ( F) , as nec es s ar y , t omak et her ear of t hedoor f l us hwi t ht hebody .
Make sure the door and body edges are
paral l el , and the door i s fl ush wi th the body. Ti ghten the door and hi nge
mounti ng bol ts, and recheck.
D
8x 1. 25 mm
29 N. m {3. 0 kgf . m,
22lbf.ttl
20-18
5. Adj ust the stri ker
(A);
.
Move the stri ker In or Out to make the l atch fi t ti ghter or l ooser.
.
Move the stri ker Up or Down to al i gn i t wi th the l atch openi ng.
m
\
-i-:-
---
8 x 1. 25 mm
1 8 Nm( 1 . 8 k g f . m,
13 tbf.ft)
. . . . . -
- ;
g i
6 x 1 . 0 mm
9. 8 N' m
{1, 0 kgf . m,
7.2tbl,ftl
6.
7.
Make sure the door l atches properl y. Ti ghten the screws
(B).
and recheck.
Al i gn the door wedge hol der
(C)
up or down unti l the door wedge
(D)
i s centered i n the hol der. Ti ghten the screws
(F),
and recheck.
8. Appl y mul ti purpose grease
to the
pi vot porti ons
ofthe hi nges
(A)
i ndi cated bythe arrows.
Appl y body pai nt
t o t he hi nge and door mount i ng bol t s, and ar ound t he hi nges.
Check f or wat er l eaks
( see
st ep 17 on page 20 14) .
Test-dri ve and check for wi nd noi se.
9.
' 10.
' I
1.
20-19
Mirrors
LOCK BOLT
POWER MIRROR
Repl acement ,
page 20-21
POWEB MIRROR ACTUATOR
Repl acement,
page 22-106
TOOTHED LOCK WASHER
g
.''
\//
HoLD SPRING
=---'.
HOOK PLATE
/'=,-\2
t-- 1
q . "
/ f
\,/v
.@
BRACKET COVER
REARVIEW MIRROB
, )
, . . , 1 , r
!'.:;r,
20-20
Power Mirror Replacement
NOTE: To avoi d scratchi ng the door, be sure to hol d the
mi r r or whi l e r emovi ng or i nst al l i ng t he nut s.
.
Door sash hol der
( see page 20- 15)
.
Pl asti c cover, as necessary
(see page
20-2)
2. Di sconnectthe connector
(A),
and detach i t from
the door.
Fastoner Locations
4.
6x 1. 0mm
9.8 N.m
(1.0
kgf.m.7.2 tbt.ftl
Support the mi rror
(B)
wi th one hand, remove the
nuts
(C).
then remove the mi rror.
Instal l the mi rror i n the reverse order of removal ,
and note these i tems:
.
.
Adj ustthe posi ti on
ofthe door sash hol der
(see
page
20- 16) .
.
(see
step 17 on
page
2O-14).
.
.
When rei nstal l i ng the door panel ,
make sure the
pl asti c
and seal ed
around i ts perl meter.
ca: Nur ,
@
,a
o a
Mirror Holder Replacement
NOTE: Put on
gl oves
to protect your hands-
1. Careful l y pul l
outthe bottom edge ofi he mi rror
hol der
{A} by hand. Take care not to scratch the
mi rror.
Separate the mi rror hol der from the actuator
(B)
by
sl owl y pul l i ng
them apart whi l e detachi ng the cl i ps
(C)
and rel easi ng the hooks
(D).
Reattach the hooks of the mi rror hol der to the
actuator, then
posi ti on
the mi rror hol der on the
actuator. Careful l y push
on the cl i p
porti ons
of the
mi rror hol der unti l the mi rror hol der l ocks i nto
prace.
Check the actuator operati on.
';';''li1'
) . '
\l
20-21
Mirrors
Rearview Mirror RePlacement
NOTE:
.
Take care not to scratch the cover and mi rror stay.
.
When pryi ng wi th a fl at-ti p screwdri ver, wrap i t wi th
protecti ve tape to
prevent damage
1. Remove the rearvi ew mi rror as shown
2. Instal l the mi rror i n the reverse order of removal .
REARVIEW
MIRROR
LOCK BOLT
Turn count ercl ockwi se
t o I oosen enough t o
sl i de t he mi rror cl own.
BRACKET COVER
MOUNTING LUG
20-22
Glass
WINDSHIELD MOLDING
FASTENER, 2
(Cl i p
t ype, body si de)
:\
i ,
/ i / _.
MoLD|NG
ill/.
stDEsEAL,2
LOWER RUBBER DAM
Fn
V i{rin
20-23
Glass
Component
Location Index
(cont'dl
Removable Hardtop
RUBBER DAM
G
@
e
\
SPACER,
p-...
{ 2 \
-
\
,-o*ri'ro.rr"....
\
(Sel f' adhesi ve{YPe,
\ ol ass si de)
LOWER FASTENER, 2
(Sel f-adhesi ve-type, rooJ si de)
SIDE RUBBER DAM,2
REAR WINDOW
Gl ass Repl acemenl Process,
page 20-25
Repl acement,
page 20-32
MOLDI NG
44
ta'
20-24
Glass Replacement Process
NOTE:
.
Thi s procedure
i s a general
descri pti on ofthe gl ass
repl acement
process.
For detai l s about fastener and
rubber dam l ocati ons, wi ndshi el d {see
page
20-29),
rear window
(see page
20-32l,.
.
Put on gl oves
.
Wear eye protecti on
whi l e cutti ng the
gl ass
adhesi ve
wi th pi ano wi re.
.
Use seat covers to avoi d damagi ng any surfaces.
' 1.
To remove the gl ass. fi rst remove the rel ated parts,
wi ndshi el d
(see page
20-29), rear wi ndow
(see
page
20-32).
2. Di sconnect the connectors from the
gl ass
termi nal s.
3. Remove the mol di ng
(A)
from the edge of the gl ass
(B).
l f necessary, cut the mol di ng wi th a uti l i ty kni fe.
4. l f the ol d
gl ass
i s to be rei nstal l ed, make al i gnment
marks across the gl ass
and body wi th a grease
pencl l
at the four poi nts.
Appl y protecti ve
tape al ong the edge of the body
and the rel ated parts.
1 .
Usi ng an awl , make a hol e through the adhesi ve
from i nsi de the vehi cl e at the corner porti on
of the
gl ass, wi ndshi el d
(see page
(see page
20-32).
Push a pi ece of pi ano wi re through the hol e, and
wrap each end around a pi ece
of wood,
Wi th a hel per on the outsi de, pul l the pi ano wi re
{A)
back and forth i n a sawi ng moti on. Hol d the
pi ano
wi re as cl ose to the wi ndshi el d as
possi bl e
to
prevent
damage to the body and dashboard.
Careful l y cut through the rubber dam and adhesi ve
around the enti re wi ndshi el d.
(cont' d)
20-25
Glass
Glass Replacement Process
(cont'd)
9. Careful l y remove the gl ass.
' 10.
Wi th a kni fe, scrape the ol d adhesi ve smooth to a
thi ckness of about 2 mm {0.08 i n.) on the bondi ng
surface around the enti re
gl ass
openi ng fl ange:
.
Do not scrape down to the pai nted surface of the
body; damaged pai nt wi l l i nterfere wi th proper
bondi ng.
.
Remove any remai ni ng parts from the body.
1
' t.
Cl ean the body bondi ng surface wi th a sponge
dampened i n al cohol . After cl eani ng, keep oi l ,
grease and water from
getti ng on the cl ean surface.
12. l f the ol d
gl ass i s to be rei nstal l ed, use a
putty kni fe
to scrape off al l of the ol d adhesi ve and any
remai ni ng parts from the
gl ass. Cl ean the i nsi de
face of the
gl ass wi th al cohol where new adhesi ve
i s to be appl i ed. Make sure the bondi ng surface i s
kept free of water, oi l and
grease.
13, Gl ue the rubber dam
(A),
fastener
(B),
and other
parts to the i nsi de Jace of the gl ass (C).
wi ndshi el d
(see page 20-29), rear wi ndow
(see page 20-32). Be
careful not to touch the gl ass where adhesi ve wi l l
be appl i ed.
-
Insi de
N ^
*
-A..-"
-N
-u-
20-26
14. Gl ue the mol di ng
(A)
wi th adhesi ve tape
(B)
to the
edge ofthe
gl ass (C),
wi ndshi el d
(see p
age 20-291,
rear wi ndow
(see page 20-32). Be careful not to
touch the gl ass where adhesi ve wi l l be appl i ed.
Instal l the fastener
(A)
to the body, wi ndshi el d
(see
page 20-29), rear wi ndow
(see page 20-321.
t 5 .
16. l f the new gl ass i s to be i nstal l ed, set the gl ass (A)
i n the openi ng, and center i t. Make al i gnment
marks
(B)
across the gl ass and body wi th a grease
penci l
at the four ooi nts shown. Be careful not to
touch the gl ass where adhesi ve wi l l be appl i ed.
Remove the gl ass.
Wi th a sponge, appl y a l i ght coat of gl ass pri mer
around the edge of the
gl ass (A)
between the
r ubber dam
( B)
and mol di ng
( C)
as shown, t hen
l i ghtl y wi pe i t off wi th gauze or cheesecl oth,
wi ndshi el d
( see page 2O- 291, r ear wi ndow( see
page
20-32).
.
Appl y gl ass pr i mer t o t he mol di ng.
.
Do not appl y body pri mer
to the gl ass, and do not
get
body and gl ass pri mer
sponges mi xed up.
.
Never touch the pri med surfaces wi th your hands.
l f you
do, the adhesi ve may not bond to the gl ass
properl y,
causi ng a l eak after the gl ass i s
i nst a l l ed.
.
Keep water, dust, and abrasi ve materi al s away
from the pri med
surface.
,./
,ll : Apply glas3 primer here.
' t7
.
18.
l nsi de
19. Wi th a sponge, appl y a l i ght coat of body
pri merto
t he or i gi nal adhesi ve r emai ni ng ar ound t he
wi ndshi el d openi ng fl ange, wi ndshi el d
(see page
(see page 20-32). Let the body
pri mer
dry for at l east 10 mi nutes.
.
Do not appl y gl ass pri mer
to the body, and be
careful not to mi x up gl ass and body pri mer
sponges.
.
Never touch the pri med surfaces wi th your
hands.
.
Mask offthe i nteri or parts
before pai nti ng the
fl ange.
Before fi l l i ng a cartri dge, cut a
"V"
i n the end of the
nozzl e
(A)
as shown.
10 mm {0. 39 i n. l
(cont' d)
: Apply body primr here.
/)7
20-27
Glass
Glass Replacement
Process
(cont'd)
21. Pack adhesi ve i nto the cartri dge wi thout ai r
pockets
to ensure conti nuous del i very. Putthe cartri dge i n a
caul ki ng
gun, and run a bead of adhesi ve
(A)
around the edge oJ the
gl ass (B)
between the
rubber dam
(C)
and mol di ng
(D)
as shown,
wi ndshi el d
(see page 20-29), rear wi ndow
(see
page 20-32). Appl y the adhesi ve wi thi n 30 mi nutes
after appl yi ng the gl ass pri mer. Make a sl i ghtl y
thi cker bead at each corner'
Use sucti on cups to hol d the
gl ass over the openi ng,
al i gn i t wi th the al i gnment marks made i n step 3 or
16. and set i t down on the adhesi ve Li ghtl y
push
on the
gl ass unti l i ts edges are ful l y seated on the
adhesi ve al l the way around. Do not open or cl ose
the doors unti l the adhesi ve i s dry.
Scrape or wi pe the excess adhesi ve off wi th a putty
kni fe or towel . To remove adhesi ve from a
pai nted
surface or the
gl ass, wi pe wi th a soft shop towel
damoened wi th al cohol .
24. Let the adhesi ve dry for at l east t hour,thenspray
water over the
gl ass and check for l eaks. Mark
l eaki ng areas, and l et the gl ass dry, then seal wi th
seal ant:
.
Let the vehi cl e stand for at l east 4 hours after
gl ass i nstal l ati on. l f the vehi cl e has to be used
wi thi n the fi rst 4 hours. i t must be dri ven sl owl y.
.
Keep the gl ass dry for the fi rst hour after
i nstal l ati on.
o\
\ A \
rnsiae
fiJ
.,,\r
^-
fil'..
c
23.
20-28
25. Rei nstal l atl remai ni ng removed
parts. Instal l the
rearvi ew mi rror after the adhesi ve has dri ed
thoroughl y
(wi ndshi el d)
NOTE: Advi se the customer notto do the fol l owi ng
thi ngs for 2 to 3 days:
.
Sl am the doors wi th al l the wi ndows rol l ed up.
.
Twi st the bodv excessi vel v
(such
as when goi ng
i n and out of dri veways at an angl e or dri vi ng
over rough, uneven roads).
Windshield Replacement
NOTE: Fami l i ari ze yoursel f wi th the gl ass repl acement
process (see page 20-25).
Parts Removal
Fi rst remove these i tems:
.
Rearvi ew mi rror {see
page 20-22)
.
Front roof rai l tri m
(see page 20-68)
.
Wi ndshi el d wi per arms
(see page 22-1 14)
.
Cowl cover
(see page 20-101)
Cutting Positions
Sl i p the pi ano wi re through the adhesi ve at each posi ti on as shown, and
pul l
back the
pi ano wi re i n di recti on i ndi cated
by arrow.
FASTENER
FASTENER
PIANO WIRE
PIANO WIRE
WINDSHIELD
(cont' d)
/it
ltli
' ! l !
iil
- . -
, ,
, ' \
\ , \
i i \
\ i
i
T
i
r i \
i i i i - l
-a-'\-"::8.
... .. .>.. i
t ' . .
..
' :;,i /
20-29
Glass
Wi ndshi el d Repl acement
(cont' d)
Rubber Dams and Fastener Installation, and Primer Application
.
Be sure the rubber dams and fasteners l i ne up wi th the al i gnment marks,
' Gl uet her ubber damswi t hadhesi vet ape{ N| TTO501l \ i l , or equi val ent ) , andgl uet hef ast ener wi t hadhesi vet ape
(3M
4215, or equi val ent).
.
To gl ue the mol di ng, appl y
pri mer (3M
N-200, or equi val ent) to the areas between the al i gnment marks of the
wi ndshi el d.
UPPER RUSBER DAM
UPPER CORNER
RUBBER DAM
LOWR RUBBEB
DAM
LOWER RUBBER
DAM
ALI GNMENT
MARKS
Appl y pri mer here.
UPPER SEAL
MOLDING
SIDE SEAL
!r
Molding Installation
.
Be sur e t he al i gnment mar k of t he mol di ng l i ne up wi t h t he al i gnment mar k of t he wi ndshi el d.
.
GI ue t he mol di ng wi t h adhesi ve t ape
( 3M
4212, or equi val ent ) .
.
Gl ue t he mol di ng seal s t o t he mol di ng.
ALIGNMENT
MARKS
ALI GNMENT MARK
MOLDI NG
ALI GNMENT MARK
MOLDING
ADHESIVE
TAPE
WINDSHIELD
MOLDI NG
13.5 mm {0.53 in.) FASTENER
l rt mm
{0. 55 i n. )
WINDSHIELD
20-30
WI NDSHI ELD
Fastener
(body
sidel Installation/Body Primer Application
: Appl y bodv pri mer here.
16 mm
(0. 63
i n. )
6 mm {0. 24 i n, l
Glass Primer and Adhesive Application
.l',,jli
: Apply glass prime. here.
13 mm
(0. 51
i n. )
16 mm
10. 63 i n. l
5 mm
10. 2
i n. )
9 mm 10.35 i n.l
ADHESIVE
WI NDSHI ELD
H
r+)
1,4
f -
"",0"
fl
,/7
LOWER
8xf,tER
ibTf;''.r
UPPER RUBEER
DAM
2mm
{0.08 i n.)
+
E ]
rnsiae
I L..
M.LD'NG
--)&, //
'--*<Y
q\>
8 mm
(0. 31
i n. )
UPPER RUBBER
DAM
WI NOSHI ELO
20-31
Gl ass
Rear Window Replacement
Removable Hardtop
NOTE:
.
To remove and i nstal l the rear wi ndow, remove the roof from the body.
.
Pl ace the roof on padded supports to
prevent
damage.
.
Have an assi stant hel o vou remove and i nstal l the rear wi ndow.
.
Fami l i ari ze
yoursel f wi th the gl ass repl acement process
{see
page 20-25}.
.
Remove the rear wi ndow and mol di ng as an assembl y. l f the mol di ng i s damaged. repl ace i t.
LOCK HANDLE
ROOF SI DE
LOCK
SUPPORT
SUPPORT
REAR WINOOW
Parts Removal
Remove these i tems. and di sconnect the rear wi ndow defogger connectors:
.
Headl i ner
(see page
20-56)
.
Rearwi ndow l owertri m
(see page 20-55)
Cutting Positions
Sl i p the
pi ano wi re through the adhesi ve at each posi ti on as shown, and
pul l back the pi ano wi re i n di recti on i ndi cated
by arrow. For the upper
porti on,
cut the adhesi ve wi th the uti l i ty kni fe from i nsi de whi l e pushi ng the rear wi ndow out.
Cut t hl s area wi t h a ut i l i t y kni f e.
FASTENER
PIANO WIRE
PIANO WIRE
SPACER
PIANO WIRE
MOLOI NG
FASTENERS
20-32
ADHESIVE REAR WINDOW
SPACER
FASTENER
PIANO WIRE
Rubber Dams, Fasteners, and Spacers Installation
.
Be sure the rubber dams, fasteners, and spacers l i ne up wi th the al i gnment marks.
.
Gl uet he upper f ast ener wi t h adhesi vet ape
( 3M
4215, or equi val ent ) a nd t he l owe r f ast ener wi t h ad hesi ve t a De
( 3M
5312, or equi val ent ) .
.
Gl ue t he r ubber dams and spacer s wi t h adhesi ve t ape
( N
I TTO 501M, or equi val ent ) .
UPPER
FASTENER
l Two Pl aces)
srDE RUBBER DAM
ALI GNMENT
MARKS
ALI GNMENT
MARK ./
ALI GNMENT MARK
"u"".i oarrr
RUBBER
DAM
Appl y pri mer and
uret hane adhesi ve,
16 mm REAR WI NDOW
17"?ii?!i"*'
$Ao.'nr".Nr
MARKS
FASTENER
REAR WINOOW
(Two places)
SPACER
ALIGNMENT MARKS
Molding lnstallation
To g\ue
the molding, apply a light coat o{ pr'rmer (3M
N-2O0, or equrvalent) to the bottom area on the ou$-rde of rhe
rear wi ndow
,
and gl ue t he mol di ng wi t h uret hane adhesi ve.
(cont' d)
REAR wlNDOW
20-33
Glass
{cont'd)
Fastoner {roof side} lnstallation/Body Primer Application
Gl ue the l ower fasteners wi th adhesi ve tape
(3M
4256, or equi val ent).
li/i,i/tt I t ppty bodr
p.imf. h?r'.e.
Uni t mm { i n. )
Glass Primer and Adhesive Application
il/i'///l : Apptr
gl$s ptimet herc.
Uni t i mm { i n. )
( Two pl aces)
1610. 631
31 {1. 21
lAl
portion: AOHESIVE
ALIGNMENT
MANKS
RUBBER
DAM
11
t0.55) t0.o8t
REAN
wtNDow
1210.171
33. 5
11. 32) {1. aol
ALIGNMENT
MARK
[B]
portion:
2 to.oE)
SIDE RUSBER OAM
-TI
***)Lo--=--
+ -\"o.o,"o
[C]
ponion:
ln3ide
20-34
SPACER
MOLDING
Convertible Top
' 00-01
Model s
LINK STOP RUBBER SPACER
(Wi th
removabl e hardtopi
CONVERTIBLE TOP CLOTH
Repai r, page 20 48
wtNDow
Repl acement ,
page 20-43
CONVERTIBLE TOP
COVER
PLATE B
r\ [
aaoa rora--{q
CONVERTIBLE TOP
COVER SNAP
Repl acement ,
page 20-53
CORNER TRI M
\o*r
\ , / l
SET
PLATE A
i
I
- / nE, t nLvwEn
,----
coll.v.ERTlBLE TOP
REAR LOWER
RETAINER
HANDLE
LINK
STOP
,r/"iili#ie*are
SIDE CONVERTIBLE TOP
RETAINER
(cont' d)
CONVERTIBLE TOP
LOCK HANDLE
Repl acement ,
page 20-49
Operat i on Load Adj ust ment ,
page 20 49
CONVERTIBLE
ASSEMBLY
Repl acement ,
page
20 38
TOP
ROOF CORNEB
WEATHERSTRIP
ROOF RETAINER
ROOF SIDE
WEATHERSTRIP
SEAL TAPES
CONVERTIBLE TOP
TOP TRIM
20-35
Convertible Top
(cont'd)
'02-03
Models
Repai r, page 20-48
REAR WINOOW
HARNESS HOLDER COVER
CONVERTIBLE TOP
COVER
9o
t/
CONVERTIBLE TOP
COVER SNAP
Repl acement ,
page 20-53
l-*q
\ SET
-.-/SbitiHiiir-le
roe
REAR WI NDOW
LOWER MOLDING
Repl acement ,
page 20-47
REAR WINDOW
PLATE A
CABLE GUIDE
4
REAR WINDOW
HARNESS HOLDER
Repl acement ,
Daae 20 47
. REAR WINDOW
LINK STOP RUBBER SPACER
(Wi th
removabl e hardtop)
DEFOGGER
CONVERTIBLE TOP
TOP TRIM
SEAL TAPE
. +
CONVERTIBLE TOP
HOLDER PLATE
LINK STOP
CONVERTIBLE
CORNER TRIM
REAR LOWER
RETAINER
RAIN RAIL
TOP
HANDLE
LI NK
STOP
SILENCER
SIDE CONVERTIBLE TOP
RETAINER
CONVERTIBLE TOP
LOCK HANOLE
Repl acement,
page 20-49
Operati on Load Adj ustment,
page 20-49
CONVERTIBLE TOP
ASSEMBLY
Repl acement ,
page 20-38
CONVERTIBLE
TOP MOTOR
Repl acement,
page 20-50
ROOF CORNER
WEATHERSTRIP
20-36
ROOF RETAINER
.,
coNvERTIBLE TOP
-STRIKER
///'
Re?lacement'
Page
20'50
-43t
\=,,.,
t!
B-PILLAR
OUTER WEATHERSTRIP
Repl acement,
page 20-52
@
E
PIPE
ase 20-52 page
DRAIN VALVE
A.PILLAR MOLDING
Repl acement,
page 20-51
20-37
Convertible Top
Convertible Top Assembly Replacement
NOTE:
.
Have an assi stant hel p you remove the converti bl e top assembl y.
.
Take care not to scratch the top cl oth and body.
.
Put on
gl oves
to protect your
hands.
' l f t het opdoesnot movewi t ht heconver t i bl et opswi t ch, di sconnect t heemer gencyconnect or near t hepassenger ' s
ki ck panel
l see
page
22-' 147l ., and move the top by hand.
1. Remove both rear tray si de tri ms
(see page 20-71).
2. Bemove the top i n the numbered sequence.
3. Instal l the converti bl e top i n the reverse order of removal , and note these i tems:
.
Make sure the connectors are pl ugged i n properl y.
.
Check operati on ofthe top.
' Checkt hat eacht opl ockhandl ewor kssmoot hl y.
l f necessar y, adj ust t he hook posi t i on ( see page 20- 49) .
'
Check that each door gl ass
contacts the weatherstri ps evenl y.
.
Check for water l eaks {see step 17 on page 20-14).
.
Test-dri ve and check for wi nd noi se and raftl es.
Fastener Locations
A>: Bol t , 2 B>: Bol t , 12 C
a:
Nur , 11
( 8ody
col or ) { Gol d)
D>: Ct i p, 2
)4
tI5
I]
O RIGHT SIDE
CONVERTIELE TOP RETAINER
6 x 1 . 0 mm
9. 8 N. m 11. 0 kgt m,
7 .2 tbt.ttl
BAND
(' 02-03
model s)
"r,/*"*,*
'
,î
6 x 1 . 0 mm
9. 8 N. m 11. 0 kgf . m, 7. 2l bf . f t )
(0
Pul l back t he carpet .
\ <\-'""'-i*-t\\,,
\
1
*. ' ' \
' \"
"
;'
...t"
t '
. i , . t r - '
I
c : /
d"4 rN.
lrrl r' >' -
'l't"-
..
-,. (' 02
03 model s)
6 x 1 . 0 mm
9. 8 N. m 11. 0 kgt . m, 7. 2 l bf f t )
8,7
Bt7
20-38
A{
!I] LEFT CORNER GUSSET
Fatten6r Locations
E>: Bol t , 10 F>: Ct i p. 2
'00
model
'01-03
models
d\- Flk.. -4E5-
{!i!]!!r
tE,]urPrr'rr
!/4)E\'4
( ,
G>: Cl i p, 2
l o
/Gt\
H
Vt o
OMove t he t op l o t hi s posi t i on
usi ng t he convert i bl e t op swi t ch
l ocat ed i n t he cent er consol e.
@Li f t up t he t op assembl y.
ocLrPs
CONVERTIBLE TOP
ASSEMBLY
DAM SEAL
rai l l rom t he body, and
remove t he t op assembl y.
REAR WINDOW
RAIN RAIL
CONVERTIBLE TOP
RAIN
RAIN RAIL
BANO
{' 02-03model s)
wectoa
/
!'a\
onnecr
/ !
'
detach.//
], ]i
,,(o^^ lliA
29 N. m
13.0 kgf.m,22 lbf.ftl
r*/,' "--=-' *
REAR TRAY
OPENING MOLDING
REAR WINDOW DEFOGGER
SUB.HARNESS CONNECTOR
(' 02
03 model s)
@CONNECTOR
Di sconnecl and
det acn.
FUEL FILL DOOR
OPENER BRACKET
MOLDING
BAND
(Both
si des)
(' 02-03
modet s)
RA| N RAt L
20-39
Convertible Top
Convertible Top Cloth Replacement
NOTE:
.
Take care notto scratch the top frame.
.
Put on gl oves
.
Wear eye
protecti on
when removi ng the ri vets wi th a dri l l .
.
When removi ng the ri vets, dri l l hol es i n the ri vets wi th a 4 mm {0.16 i n.) dri l l .
'
Thi si l l ust r at i onshowst hel ef t si deof t he vehi cl e, r epeat t he pr ocedur e
on t he r i ght si de i n t he same manner .
Cloth Replacement
1. Remove the conveni bl e top assembl y
(see page 20-38),
2. Remove the converti bl e top cl oth i n the numbered sequence.
3, Instal l the cl oth i n the reverse order of removal , and note these i tems:
' Topr event wr i nkl eswheni nst al l i ngt hecl ot h, makesur et hemat er i al
i s st r et ched evenl y over t he f r ame bef or e
securi ng the screws and ri vets.
' Af t er i nsl al l i ngt hecl ot h, r ei nst al l t het opassembl y. Checkt heoper at i onof t het op, andi nspect t hecl ot hf or
wr i nkl es.
.
Check that the weatherstri p fi t fl ush.
' Checkt hat eachdoor gl asscont act st heweat her st r i psevenl y,
l f necessar y. adj ust each r et ai ner
( see page 2O- 11) .
'
(see
step 17 on
page
20-14).
.
Fastener Localions
e ) : 7 B ) : c ) , D>: Cl i p. 2
Scrgw.
q,ttr'
Screw, 2
( Bl ack)
@
Screw.
{Si l ver)
@
Bet ore removi ng t he screws,
scri be a l i ne around t he screws.
When rei nst al l i ng t he ret ai ners,
al i gn t hem wi t h t hese marks.
20-40
OROOF BETAI NER
F- : Ri vet , 6
, . . .
Removal I nst al l at i on
. ' ' /
,Q'.t
Y\-..-
'
\ !...-
\,,,
/
Fastener Locations
C>: Scr ew, 4 E
(Si l ver)
)
: Screw
x-/
O Rel ease t he cl ot h
f rom t he f ront edge of t he f rame.
RIVET
Out er di amet e. 4 mm
( 0. 16 i n. )
BIVET TOOL
O Rel ease t he cl ot h
f rom t he f ront and cent er bows.
dX Remove t he ri vet , t hen
remove t he t ensi on wi re.
TENSI ON
WI RE
SPRI NG
(i t
Bemove t he screw, and
sl i p t he t ensi on wi re t hrough
t he hol e i n t he f r ame.
TENSI ON
WI RE
Remove f rom t he f rame.
Remove
t he f l vet ,
illt Remove
t ne f l vet .
O Rel ease t he t ast ener and
cl ot h t rom t he rear bow.
(' 00-01 model s onl y)
F
. F
aL
rQ
,al 11
, i rI
FRONT BOW
Remove t he cl ot h f rom t he
cent er
pi l l ar port i on of t he
f rame.
REAR BOW
Bel ease t he t ensi on cl ot h by
rel easi ng t he f ast ener f rom
(' 02-03
model si
CENTER
BOW
l.
i,
{I SET PLATE B
(cont' d)
Rel ease t he cl ot h
{rom each bow.
.!!] SEAL TAPE
Thi ckness:
3 mm
.9
SET PLATE A
CONVEBTIBLE TOP CLOTH
flETAINER
CONVEBTIBLE TOP FRAME
20-41
Convertible Top
Convertible Top Cloth Replacement
(cont'dl
Reinstalling the Cloth to each Bow
Make sure the al i gnment notch ofthe cl oth i s i n the center porti on
ofthe retai ner. After rei nstal l i ng, press
on the
rel arners securety.
Center Donion:
ALIGNMENT
NOTCH
Cloth and Weatherstrip Check
RETAINER
Make sure t here are no wri nkl es or scrat ches.
B-PILLAR
WEATHERSTRIP
\r,_
\
B-PILLAR
RETAINER
The door gl ass cont act s
t he weat herst ri ps evenl y
on each si de.
l f necessary, adj ust
eacn ret at ner.
ROOF RETAINER
ROOF St OE
WEATHERSTRIP
RETAINERS
The weat herst ri p shoul d f i t f l ush.
20-42
'00-01
Models
NOTE:
.
Take care not to scratch the top frame.
.
Wear eye protecti on when removi ng the ri vets wi th a
dr i l l .
' 1.
Open the roof, and remove these i tems:
'
Seat, both si des
(see page 20-86)
.
Door si l l tri m, both sl des
(see page 20-69)
.
Rear si de trl m. both si des
(see page
20-70)
.
Rol l bar l ower tri m, both si des
(see page 20-70)
2. Cl ose the roof. Remove the cl i ps that hol d the rear
tray tri m, the rear tray si de tri m, and the rear tray
( see page 20- 71)
Remove the spare ti re cover and the spare ti re,
Remove the rear tray and the rear tray tri m th rough
t he t r unk openi ng.
Li ft the converti bl e top cl oth
(A)
that overl aps the
top of the rear wi ndow
(B),
and remove the patch
(C)
from the roof zi pper.
3.
.l
20-43
6. Open the roof, and l i ft up the center consol e
(see
page 20-761.
7. Remove the rear consol e and the rear consol e box
(see page 20-78).
8. Cl ose the roof. Remove both rol l bars and the rear
tray si de tri m
(see page 20-52).
9. Remove t he 1' 1 nut s, t hen r emovet he r ear l ower
converti bl e top retai ner
(A),
ri ght si de converti bl e
top retai ner
(B),
and l eft si de converti bl e top
r et ai ner
( C) .
Fastenea Locations
f :
(cont' d)
Nut, 1
0
Convertible Top
10.
(cont'd)
Open the roof hal f-way, and remove the two cl i ps
(A,
B) on each si de of the top between the quarter
panel and the roof.
Fastener Locations
A>: Cl i p, 2 B>: Cl i p, 2
r O
-.r- e
=)=F
Hte
(^lrj
4
11. Pl ace a rear fender cover {A) on the trunk.
12. Li ft up the rai n rai l
(B),
and pl ace i t on top of the
fender cover.
Usi ng a marker or whi te-out, draw a ci rcl e
(C)
ar ound each of t he' 11 al umi ni um r i vet s.
13.
. . . . .
. - ' : ' -
"
-
)'
-' . t ,
20-44
14. Pul l the rai n rai l
{A) up. and turn i t i nsi de-out. Wi th
the rai n rai l resti ng on the roof
(B),
dri l l out the
r i vet s
( C) wi t h
a 4 mm
( 0. 16
i n. ) dr i l l
( D) .
The
washers
(E)
on the rai n rai l are not reused.
Remove the rai n rai l ,
Usi ng a fl at-ti p screwdri ver, pry apart the two brass
ri vets
(A)
hol di ng the l ower roof
(B)
to the l ower
part
of the wi ndow
(C).
-l:-,,.t--
15.
16.
17. Rel ease the fasteners
(A)
to expose the zi pper
(B),
and remove the end stops
(C)
from both ends of the
zi DDer .
Careful l y unzi p the rear wi ndow
(D)
from the roof
(E),
then remove the wi ndow. Hol d the zi pper ti ght
to keep i t from fal l i ng i nto any crevi ces.
18.
19. Zi p the new wi ndow
(A)
onto the roof
(B),
maki ng
sure the al i gnment notches
(C)
are l i ned up.
It may take several attempts to l i ne up the marks.
Turn the converti bl e top cl oth
(A)
i nsi de out, and
appl y a new
patch (B)
on the zi pper
(C).
Make sure the al i gnment notch
(D)
al i gns wi th the
mi ddl e of the rear wi ndow
(E).
\ ' . . :
'l
. 1
a
21. Pl ace the converti bl e toD cl oth on the rear wi ndow.
(cont' d)
20-45
Convertible
Top
(cont'd)
22. Secure the l ower
part
of the rear wi ndow
(A)
to the
l ower part of the converti bl e top cl oth
(B)
wi th new
two-pi ece brass ri vets
(C).
Attach the converti bl e top cl oth, rear wi ndow, and
rai n rai l together wi th new
pop ri vets and washers.
Make sure the crush end of each ri vet i s faci ng the
rear of the car when the rai n rai l i s si fti ng i n pl ace.
3/ 16' x 3/ 8" 3116 x112' 3/ 16
A>: Ri vet , 3 B>: Ri vet , S C>: Washer , 11
23.
0
20-46
24. Setthe rai n rai l i n posi ti on, and i nstal l the cl i ps
between the
quarter panel and the roof.
Rei nstal l the l eft si de converti bl e top retai ner
(A),
ri ght si de converti bl e top retai ner
(B),
and rear
l ower converti bl e top retai ner
(C).
Fastener Locations
O:
Nut , 11
6 x 1 . 0 mm
9.8 N.m
{1.0 kgl .m, 7.2l bf ft}
26. Rei nst al l al l r emai ni ng i nt er i or component s and
t r i m
pi eces.
27. Check for water l eaks
(see
step 17 on
page 20-14).
Rear Window Lower Molding/Rear Window Harness Holder Replacement
'02-03
Models
NOTE:
.
Put on gl oves to protect your hands.
.
Take care not to scratch the top cl oth.
.
Use seat covers to avoi d damagi ng any surfaces.
1. Lower the converti bl e top cl oth by operati ng the
converti bl e top.
2. From outsi de the rear wi ndow, remove the mol di ng
(A)
from the edge of the rear wi ndow
(B).
From
i nsi de the rear wi ndow, remove the rear wi ndow
harness hol der cover
(C)
from the rear wi ndow
harness hol der
(D),
and di sconnect the rear wi ndow
defogger connectors
(E).
Remove the rear wi ndow
harness hol der from the i nsi de face of the rear
wi ndow. l f necessary, cut the mol di ng wi th a uti l i ty
kni fe.
Cl ean the edge of the rea r wi ndow wi th al cohol
wher e new mol di ng and har ness hol der ar e t o be
i nstal l ed. Make sure the bondi ng surface i s kept
free of the water, oi l ,
grease.
4. Appl y
pri mer (3M
N-200, or equi val ent) to the areas
of the rea r wi ndow
(A)
where the mol di ng and
har ness hol der wi l l be gl ued, and appl y pr i mer ( 3M
C-100, or equ i val ent) to the groove of the mol di ng
(B)
and to the harness hol der
(C).
Be sure the
har ness hol der l i nes up wi t h t he al i gnment mar ks
{ D) .
'ti;',.t,
: Apply primer here.
o-.
\J. \B
Gl ue t he mol di ng and har ness hol der t o t he r ear
wi ndow wi th urethane adhesi ve.
Scrape or wi pe the excess adhesi ve off wi th a
putty
kni fe or towel . To remove adhesi ve from the rear
wi ndow, use a soft shop towel dampened wi th
al cohol .
6.
20-4t
Convertible
Top
Conveftible Top Cloth Repair
1. The fol l owi ng tool s and suppl i es are requi red to
repai r the top cl oth.
.
Repai r cl oth
.
Adhesi ve
(Sunstar
332, or equi val ent)
.
Uti l i ty kni fe
'
Rul er
.
Sandpaper
2. Appl y a
pi ece of t he r epai r cl ot h
( A) t o
t he i nsi de
surface of the top cl oth at the damaged area. Cut
through both the damaged cl oth
(B)
and the repai r
cl ot h usi ng a r ul er
( C)
and a ut i l i t y kni f e
( D) .
A C
Cut a pi ece of repai r cl oth
(A)
so i t overl aps the
r epai r openi ng as shown.
3.
30- 50 mm
{ 1. 2- 2. 0 i n. )
REPAIR CLOTH
20-48
Cl ean the repai r cl oth where adhesi ve wi l l be
appl i ed.
Appl y the adhesi ve
(A)
to the repai r cl oth
(B)
and
top cl oth {C) as i ndi cated by the arrows.
f-
A
6. Push f i r ml y on t he r epai r cl ot h.
Scrape or wi pe the excess adhesi ve off wi th a soft
shop t owel dampened wi t h al cohoL.
Let the adhesi ve dry. Fol l ows the manufacturer' s
r ecommendat i ons f or dr yi ng t i me.
Check f or wat er l eaks
( see
st ep 17 on
page
20- 14) .
1.
9.
Conveftible Top Lock Handle
Repl acement
NOTE: Take care not to scratch the top frame.
' 1.
Remove the converti bl e top l ock handl e as shown.
2. l nstal l the handl e i n the reverse order of removal ,
and appl y mul ti purpose grease to the spri ngs and
the movi ng poni ons,
Fastener Locations
A) : Scr ew. l B>: Scr ew, 1
'00
model
'01-03
models
CONVERTIBLE TOP
LOCK HANOLE
Convertible Top Lock Handle
Operation Load Adiustment
NOTE: Take care not to scratch the i nteri or parts.
1. Remove both reartray si de tri m
(see page 20-7' 1).
2. Cl ose the top, then l ock i t securel y wi th both l ock
handl es { A} .
Loosen the l ocknut
(B)
on the l i nk stop
(C)
on each
sr de.
Adj ust the l i nk stop
(C)
on each si de unti l i t makes
contact wi th the l i nk set bracket
(D).
There shoul d
be no cl earance between the converti bl e top stri ker
( E)
and t he hook
( F) .
Ti ghten the l ocknut, and check that the l ock handl e
works smoothl y on each si de.
Rei nstal l al l removed parts.
3.
4.
t
. .
I
20-49
Convertible Top
Convertible Top Motor
Replacement
NOTE:
.
Take care not to scratch the i nteri or parts.
.
Put on gl oves to
protect your hands.
.
Rol l bar upper t r i m
( see page 20- 71)
.
Corner gusset (see page 20-38)
2. Remove the converti bl e top motor as shown.
3. Instal l the motor i n the reverse order of removal .
.
.
Appl y mul ti purpose grease to the
gear poni on.
.
Check the motor operati on.
Fastonor Locations
Ai t : Nut , 3
d
6 x 1 . 0 mm
9. 8Nm( 1. 0kgl . m,
7.2 rbf.ft)
20-50
Gonvertible Top Striker
Replacement
NOTE: Take care not to scratch the i nteri or parts.
1. Remove the wi ndshi el d header i nteri or tri m
(see
page
20-68).
2. Remove the converti bl e top stri ker as shown.
3. l nstal l the stri ker i n the reverse order of removal .
Fastonor Locations
A
>
: Screw, 2
f')--
w*
i
, A
\ A
CONVERTIALE TOP
STRIKER
(' 00' 01
model s shape)
6 x l . 0 mm
9. 8Nm11. 0kgf . m,
7.2 tbt.lrl
CONVERTIBLE TOP
STRIKER
('02'03
models shape)
s=
A-Pillar-Header Weatherstrip and A-Pillar Molding Replacement
NOTE:
.
Take care not to scratch the body.
.
Use a cl i p remover, to remove the cl i ps.
1. Remove the A-pi l l ar-header weatherstri p and A-pi l l ar-mol di ng as shown.
2. Instal l the weatherstri p and mol di ng i n the reverse order of removal , and note these i tems:
. l f t heol dmol di ngi st ober ei nst al l ed, scr apeof f t hedoubl e- f acedadhesi vet ape, t hencl eant hemol di ngsur f ace
wi th al cohol . G l ue the new doubl e-faced adhesi ve tape
l 3M
4252, or equi val ent) to the mol di ng.
'
When i nst al l i ng t he mol di ng, f i r st t i ght en t he scr ew at t op of t hemol di ng.
.
. l f t heol dweal her st r i pi st ober ei nst al l ed, scr apeof f al l t r acesof ol dEPTseal er andbut yl t apes. l hencl eant he
weatherstri p surface wi th al cohol . Gl ue the new EPT seal er and butyl tapes to the weatherstri p.
.
When i nstal l i ng the weatherstri p, al i gn the roof cl i p hol e on the weatherstri p wi th the hol e on the mol di ng.
.
Before i nstal l i ng the weatherstri p, fol d the separator of the butyl tape at the roof porti on.
After i nstal l i ng the
weatherstri p, careful l y pul l the separator away.
.
Press the butyl tape porti ons
to make the adhesi ve sti ck.
'
Checkthateach door gl asscontacts the weatherstri p evenl y.
.
Checkforwater l eaks
(see
step 17 on
page
20-14).
Fastener Locetions
B>: Sc r ew, 5
A.PILLAR
MOLDI NG
A
BUTYL TAPE
Thi ckness: 1mm
( 0. 04
i n. )
Wi dt h: 5 mm
( 0. 2
i n. )
A>: Cl i p, 4
{ 8ot h si des)
B
AB
B
Thi ckness: 3 mm
( 0. 1
an. )
Wi dt hr 5 mm
(0. 2
i n. )
SEALER
TAPE
Thi ckness: 1mm
{0. 04 i n. }
Wi dt h: 5 mm
( 0. 2
i n. )
MOLDING
20-51
Gonvertible Top
B-Pillar Outer Weatherstrip
Replacement
NOTE:
.
Take care notto scratch the body
.
Use a cl i p remover. to remove the cl i ps.
1. Remove the B-pi l l ar outer weatherstri p as shown.
2. Instal l the weatherstri p i n the reverse order of
.
.
l f the ol d weatherstri p i sto be rei nstal l ed, scrape
off al l traces of ol d butyl t8pe, then cl ean the
weatherstri p surface wi th al cohol . Gl ue the new
butyl tape i nto posi ti on.
Fastgnsr Locations
A>: Scr ew, 1 BD: Cl i p, 1
B.PILLAR OUTER
WEATHERSTRIP
BUTYLTAPE
Thi ckness: 1. 5 mm
(0. 06
i n. )
Wi dt h: 4 mm {0. 16 i n. )
C> : Cl i p , l
20-52
Drain Tank and Lower Drain Hose
Replacement
NOTE:
.
Take care not to scratch the body
.
Take care not to drop the screw.
1. Remove the conveni bl e top assembl y
(see page 20-
38).
2, Remove the drai n tank and l ower drai n hose as
shown.
3. Instal l i n the reverse order of removal , and note
these i tems:
.
Repl ace the cl i p i f damaged.
.
Make sure the l ower drai n hose i s i nserted to the
drai n val ve properl y.
.
Make sure the drai n tank i s connected to the
l ower drai n hose
properl y.
Fastener Locations
, 1
B>: Cl i p, 1 A
>
: Screw
@
LOWER DRAIN
HOSE
-i
r \ '
,..1 :...-r...
DRAIN VALVE
Convertible Top Cover Snap Replacement
NOTE: Take care not to scratch the converti bl e top
cover.
' 1.
Usi ng a snap ri ng pl i ers (A),
remove the nut
(B)
from the snap
(C).
then remove the snap from the
converti bl e top cover
(D).
Instal l the cover snap i n the reverse order of
removal ,
20-53
Removable Hardtop
REAR WINDOW
DEFOGGER GROUND
HARNESS
\r?
I -
oqo
ROOF
Posi ti on Adj ustment,
page 20-65
wrNDow
q3
ROOF SIDE
TRIM END CAP
STUD BOLT
Component Locat i on I ndex,
page 20-24
Gl ass Bepl acement Process,
page 20-25
Repl acemenl ,
page 20 32
WEATHERSTRIP
Repl acement ,
page 20' 60
wtNDow
DEFOGGER HARNESS
WINDOW
LOWER TRIM
page 20-55
REAR WINDOW BRACKET
page 20-55
lts\
9r
".r)*, t*,t
\ \ase
20-55 ROOF SIDE LOCK
Repl acement,
page 20-62
%
cusHloN
HARDTOP LOCK
HANDLE
Repl ac_e_ment,
_,,....--.\d
page 20-6'l
,r-rr--\\
{ r " \ \ \
q' v"
\ v
\ &{b
\ -
UPPER DOOR GLASS
WEATHERSTRIP
page 20'57
ROOF MOLDING
Repl acement,
page 20' 57
ROOF RETAINER
page 20 57
BODY SIDE CATCH
ASSEMBLY
Reol acement , oaqe 20-63
Bodv S, de Cal i h
-Repl acement ,
page 20 64
Hardt op Swi t ch Test ,
page 22' 150
ROOF FRONT TRIMS
Repl acement ,
page 20-61
20-54
Interior Trim Removal/lnstallation
NOTE:
.
Put on gl oves to protect your
hands.
.
To remove and i nstal l the i nteri or tri m, remove the roof from the booy.
.
tape to prevent
damage.
.
Use a cl i p remover to remove the rear wi ndow l ower tri m cl i ps.
.
Take care not to bend or scrach the i nteri or tri m.
1. Remove the tri m as shown.
2. Instal l the tri m i n the reverse order of removal , and note these i tems;
.
Repl ace the damaged adhesi ve tape and any damaged cl i ps.
.
Push the cl i p poni ons
i nto pl ace
securel y.
' Bef or epeel i ngawayt headhesi vebacki ngf r omt headhesi vet apeof t heendcap, i nst al l t her oof si det r i mon
the roof tentati vel y to check the posi ti on
of the tri m end.
'
When i nstal l i ng the roof si de tri m, fi rst i nstal l the front end, and i nsert the l ower end i nto the end cap, then
push
l he corner porti on
agai nst the roof securel y, Make sure there i s no cl earance between the tri m and cap.
Fastenor Locations
Clip, I
(bot h
si des)
Clip, 3 C) : Bol t , 4
UPPER DOOR GLASS
,
WEATHERSTRIP
B.PILLAR TRIM
ADHESIVE TAPE
(3M5078,
or equi val ent )
Thi ckness: 1 mm
(0. 04
i n. )
Wi dt h: 5 mm
( 0. 2
i n. )
nb, tu
SNf-
ary
REAR WINDOW
LOWER TRIM
6 x 1 . 0 mm
9. 8 N. m
{1. 0 kgf m,
7.2 tbf.ftt
View from outside:
l l
C C
r-
\ \ \
u
RooF srDE TR|M
WINDOW
DEFOGGER CONNECTOR
(Lef t
si de onl y)
Sl i p t he connect or t hrough
t he hol e i n t he rear pi l l ar
t ri m.
ROOF SIDE TRIM
END CAP
SIDE TRIM
B.PILLAR TRIM
20-55
Removable Hardtop
Headliner RemovaUlnstallation
NOTE:
.
Put on
gl oves
to
protect your hands.
.
To remove and i nstal l the headl i ner, remove the roof from the body.
.
Have an assi stant hel p you remove and i nstal l the headl i ner.
.
Take care notto bend or scrach the headl i ner.
.
B-pi l l ar tri m, both si des
(see page 20-55).
.
Hardtop l ock handl e, both si des {see
page 20-61).
.
Upper door gl ass weathersti rp, front edge
poni ons from both si des as necessary {see
page 20-57)
2. Remove both front edge
porti ons of the u pper door
gl ass weatherstri ps
(A) (seepage20-57).
Fastenea Locations
B>: c l i p. 8
A
Rel ease the cl i ps
(B)
by sl i di ng the headl i ner
(C)
forward, then remove the headl i ner.
Instal l the headl i ner i n the reverse order of removal , and check that the cl i p
porti ons are securel y attached to the
roof.
@
20-56
Roof Molding Replacement
NOTE:
.
Put on
gl oves
to
protect your hands.
.
To remove and i nstal l the roof mol di ng, remove the roof from the body.
.
Take care not to scratch the roof.
.
Use a cl i p remover to remove the cl i p.
. l f t heol dr et ai ner i st obei nst al l ed, scr i beal i near oundt hemount i ngscr ewsbef or er emovi ngt her et ai ner .
Removal
Remove the rear pi l l ar tri m
(see page
20-55), then remove the roof mol di ng as shown.
Fastene. Locations
A> t Cl i p, l B
>:
Screw,
' t
C
)
: Screw, 3
, 1 F
>:
Nur , 2
*: CORROSION RESISTANT SCREW
ROOF MOLDING
E
)
r Screw
o b
\J
D>: Scr ow' 4
( Si l ver )
fi liiIicr"
Be{ore removi ng t he screws, scri be
a l i ne around t he screws
(Si x pl aces).
ROOF RETAINER
UPPER OOOR GLASS
WEATHERSTRIP
(cont' d)
20-57
Removable Hardtop
Roof Molding Replacement
(cont'd)
lnstallation
Instal l the roof mol di ng i n the numbered sequence, and note these i tems:
Before rei nstal l i ng the roof mol di ng, cl ean the roof surface where the seal ant wi l l be appl i ed.
When r ei nst al l i ngt he r et ai ner . al i gn i t wi t ht hemar ksf or t heor i gi nal
posi t i ons.
Check that the weatherstri p i s securel y i nstal l ed to the retai ner.
Check that the door gl ass contacts the weatherstri p evenl y. l f necessary, adj ust the retai ner,
(see
step 1 1 on
page 20-66).
Fa3tener Locations
C) : Scr ew, 3 D
>:
Scr ew, 4 E
>:
Sc. ew, I F
>:
Nut , 2
*
(Si l ved
@F
) : Cl i p, 1
B>: Sc r ew. 1
hlll
lrr#ffia lrr- tfi#r+'A
I'.r]]]]]]]]]]]]]u ti ,Dir*rlrg
Yil
l1.l;;,.;',11
: Sealant
(Cemedine 336, or equivalontl
5 x 0 . 8 mm
4 N' m
(0. 4 kgf m, 3 l bf . f t )
@UPPER DOOR GLASS
WEATHERSTRIP
r\
{ l ' } r l D
\-./ @. ,
ROOF MOLDING
*: CORROSION RESISTANT SCREW
seal ant t o t he back
of t he roof mol di ng
t he roof as shown.
@BOOF MOLOING
OAppl y seal ant to the
edge of the roof
as shown.
OAppl y seal ant t o t he edge of
t he roof mol di ng, t o t he roof ,
i nt o t he hol der of t he roof ret ai ner,
and i nt o t he gap under t he mol di ng
I
A
!DROOF RETAINER
3 N. m
(0. 3
20-58
Weatherstrip Check
NOTE:
.
Make sure the hardtop i s l ocked securel y wi th both l ock handl es and both roof si de l ocks.
.
Check that the weatherstri p i s securel y i nstal l ed to the retai ner.
.
.
Check that the door gl ass
contacts the weatherstri p evenl v.
.
(see
step 11 on
page
20-66).
ROOF SIDE DOOR
WEATHERSTRIP
- - - t _t _. . - - .
_
- _- - -
' . . t . .
'
.\.
ROOF RETAINER
ROOF RETAINER
ooor gl ass cont act s
t he weat herst ri p evenl y
on each si de.
l f necessary, adj ust
t he ret ai ner,
UPPER DOOR GLASS
WEATHERSTRIP
20-59
Removable Hardtop
Hardtop Lower Weatherstrip Replacement
NOTE:
.
To remove and i nstal l the hardtop l ower weatherstri p, remove the roof from the body
.
Take care not to scratch the roof,
.
Use a cl i p remover to remove the cl l ps.
1. Remove the rear wi ndow l ower tri m
(see page 20-55).
2, Remove the hardtop l ower weatherstri p as shown.
3. Instal l the weatherstri p i n the reverse order of removal , and note these i tems:
.
Before i nstal l i ng the weatherstri p, cl ean the roof bondi ng surface wi th al cohol .
. l f t heol dweat her st r i pi st obei nst al l ed, scr apeof f t hedoubl e- f acedadhesi vet ape, t hencl eant heweat her st r i p
surface wi th al cohol . Gl ue the new doubl e-faced adhesi ve tape
(3M
5304, or equi val ent) to the weatherstri p.
.
.
Before i nstal l i ng the weatherstri p, fol d the edge of the adhesi ve backl ng from the doubl e-faced adhesi ve tape.
After i nstal l i ng the weatherstri p, careful l y
pul l the adhesi ve backi ng away.
.
Press the doubl e-faced adhesi ve tape
porti on
to make the adhesi ve sti ck.
Fastener Locations
A) : Sc r e w, 2 B> : c l i p , 2 C
p
: Cl i p, 19
ff
. : l t I -
\e:>
DOUBLE. FACED
ADHESIVE TAPE
Thi ckness:0.8 mm
(0.03 i n.)
Wi dth: 6 mm
(0.24
i n.)
EPT SEALER
Thi ckness: 3 mm
(0. 1
i n. )
Wi dt h: 5 mm
( 0. 2 i n. )
UPPER DOOR GLASS
WEATHERSTRIP
\
lAl
portions:
HARDTOP LOWER
WEATHERSTRIP
A
A
Adhesi ve t ape area.
A
20-60
1 .
Roof Front Trim Replacement
NOTE:
.
To remove and i nstal l the rooffronttri m. remove the
roof from the body.
'
Scrap off al l traces of the ol d tri m, then cl ean the
roof bondi ng surface wi th a sponge dampened i n
al cohol . After cl eani ng. keep oi l , grease, and water
from getti ng
on the surface.
Appl y pri mer (3N4
N-200, or equi val ent)to the areas
where the roof front tri m wi l l be appl i ed.
Appl y the roof front tri m
(A
and B):
-1
Peel the adhesi ve backi ng
(C)from
the front
edge of the tri m.
-2
Center and fi t the tri m agai nst the roof.
-3
Appl y the tri m to the roof whi l e peel i ng the
remai ni ng adhesi ve backi ng
(D)
from i t a l i ttl e
at a ti me. Check that the tri m i s
parai l el
and
free of wri nkl es.
-4
Remove the appl i cati on tape.
Hardtop Lock Handle Replacement
NOTE:
.
To remove and i nstal l the hardtop l ock handl e,
remove the roof from the body.
.
Take care not to scratch the headl i ner.
1 . Remove the hardtop l ock handl e as shown.
Instal l the handl e i n the reverse order of removal ,
.
Appl y mul ti purpose grease to the spri ngs and the
movi ng porti ons.
.
Appl y l i qui d thread l ock to the thread of the
(A)
screw before rei nstal l ati on.
Fastener Locations
A>: Scr ew, l B) : Scr ew, 1
LIOUID THREAD
LOCK
6 mm 2 mm
10. 24i n. ) 10. 08 i n. l
/D:n:-)
6 x 1 . 0 mm
12 N. m
(1. 2 kgt . m,
8.7 rbf.ft)
B
20-61
Removable Hardtop
Roof Side Lock Replacement
NOTE:
.
Put on
gl oves
to
protect your hands.
.
To remove and i nstal l the roof si de l ock, remove the
roof from the body.
.
.
l f t he ol d l ocki st o be i nst al l ed, scr i bea l i ne ar ound
the mounti ng bol ts before removi ng the l ock.
1. Remove the B-pi l l ar tri m {see
page
20-55).
2. Remove the roof si de l ock as shown.
l nstal l the l ock i n the reverse order of removal , and
note these rtems:
.
l f t heol d l ock i st o be i nst al l ed, al i gnt he l ockwi t h
the marks for the ori gi nal
posi ti on.
.
Appl y mul ti purpose grease to the spri ngs and the
movi ng porti ons.
.
l f necessary. adj ustthe l ock al i gnment; referto
the roof
posi ti on
adj ustment
(see page
20-65).
Fastener Locations
A
>:
Bol t, 3
{1. 0 kgf . m, 7. 2 l bf . f t l
20-62
Application
-6{
Grease
Hardtop Striker Replacement
NOTE:
'
To remove and i nstal l the hardtop stri ker, removethe
roof from the body.
.
Take care not to scratch the i nteri or parts.
1. Remove the wi ndshi el d header i nteri or tri m
(see
page 20-68).
2. Remove the hardtop stri ker as shown.
3. Insl al l the stri ker i n the reverse order of removal .
Fastener Locations
A>: Sc. w, 2
f!,\:r.-r
\a*
6 x 1 . 0 mm
' 16
N. m
{1. 7 ksf . m, 12l bf . f t l
Body Side Catch Assembly
Replacement
NOTE: Put on
gl oves
to
protect your hands.
1. Remove the roof from the body. Take care not to
bend or scratch the tri m and
panel s.
2. Remove the rear si de ti rm
(see page 20-70).
3. On l eft si de, detach and di sconnect the connector
(A),
then detach the harness cl i p
(B).
Fastener Locations
C
>:
Bol r , 2 D
>:
Bol t . 2
4. Remove the bol ts
(C,
D), then remove the body si de
catch assembl v {E).
(cont' d)
20-63
Removable Hardtop
Body Side Catch Assembly
Replacement
(cont'dl
oi i"
|
. ' 1'
, <
|
' e
t . /
6 x 1 . 0 mm
9 . 8 N m
(1. 0 kgf . m,
7.2tbl.ftl
29 N.m
(3.0
kgf.m.
22 tbt.ttl
Grease the catch.
Rei nstal l the catch assembl y
(E)
on the corner
gusset (F)
and the converti bl e top frame; ti ghten
the bol ts
(G.
H). On l eft si de, reconnect the
connector
(l ).
Rei nstal l al l of the removed parts.
Remove the l ower cl i p
(A)
fasteni ng the B-pi l l ar
outer weatherstri o
(B)
from outsi de of the front
door openi ng. Make sure the center ofthe cl i p hol e
al i gns wi th the center of the hol e i n the converti bl e
top frame
(C),
l f necessary, l oosen the mounti ng
bol t
(D),
and move the converti bl e top frame
sl i ghtl y unti l the hol es al i gn. Then ti ghten the bol t,
and i nstal l the cl i p.
Fastener Locations
G>: Bol t , 2 H
>:
Bol t , 2
u] l @
( Ll ] i - n
8 x 1. 25 mm
29 N. m
(3. 0
kgf m,
22 tbt.ttl
8x 1. 25mm
,
7.
20-64
Body Side Catch Replacement
1 . Remove the body si de catch assembl y from the
body
(see page 20-63).
Remove the body si de catch as shown.
Instal l the catch i n the reverse order of removal ,
.
Appl y mul ti purpose grease to each l ocati on as
i ndi cated by the arrows.
.
Appl y l i qui d thread l ock to the screw before
rei nstal l ati on.
Fastener Location
5 x 0 . 8 mm
4 N. m
{0.4 kst m.3 l bf.ft)
BODY SIDE
CATCH BASE
BODY SIDE CATCH
Grease Application
>
: Screw, 1
f\t",,,'-
\,,"
Roof Position Adjustment
NOTE: Have an assi stant hel p you adj ust the roof posi ti on.
1. Remove the B-pi l l ar tri m from both si des
(see page 20-55), and make sure both l ock handl es
(A)
androofsi de
6 x 1 . 0 mm
9.8 N.m
(1.0
kgf m,7.2l bt ftl
K
8 x 1.25 mm
22 N.m
(2.2
kgf.m, 16l bf.ft)
Measui ng Poi nt I A]
Measuri ng Poi nt [ B]
ROOF MOLDI NG
LOCK
8 a l m m
(0.31
0.04 i n.)
UNLOCK
1 4 1 l mm
{0.55 + 0.04 i n.}
t
.r)
6 . 6 a 1 mm
(0.26
A 0.04 i n.)
2. Set the roof
(C)
onto the body
(D):
.
l \/l ake sure the l ock pi ns
{E) of both roof si de l ocks are securel y i nserted i nto the body si de catches
(F).
.
l Make sure the rear wi ndow defogger harnesses are not pi nched.
Adj ust the roof al i gnment:
- 1
Checkt hat t her e i s no cl ear ance bet ween t he st r i ker
( G)
and t he boss
( H)
of t he l ock handl e at t he measur i ng
poi nts (A),
and check that the cl ea ra nce i s wi l h i n speci fi cati on at the measu ri ng poi nts
IBJ
onthebottomof
both rear pi l l ars.
-2
To fi t the boss i nto the stri ker, and to adj ust the verti cal cl earance to the speci fi cati on, l oosen the roof si de
l ock mounti ng bol ts
(l ),
then move the roof up or down, as wel l as. forward and rearward.
- 3
Toadj ust t he hor i zont al cl ear ance bet ween bot h si deedgesof t he r oof andt he r ear t r ayopeni ng mol di ng
( J)
to the speci fi cati on, l oosen the hol der pl ate mounti ng bol ts
(K),
then move the roof to the ri ght or l eft.
-4
Fasten both roof si de l ocks.
-5
Lock the roof securel y wi th both l ock handl es and roof si de l ocks.
-6
Recheck the roof al i gnment.
(cont' d)
184 mm
17.24 in.l
:/'
20-65
Removable Hardtop
Roof Position Adjustment
(cont'dl
4. l f the roof al i gnment i s sti l l not wi thi n speci fi cati on, unl ock the roof, and repeat the
precedi ng
steps.
5. l f the roof al i gnment i s not wi thi n speci fi cati on, check the body si de catches, and check for body de{ormati on.
6. Lockthe roof
(A)
securel y wi th both l ockhandl es(B) and roof si de l ocks
(C).
Checkthe l evel di fference between
the roof and body
(D)
at the measuri ng poi nt
LAl .l f the di fference i s notwi thi n speci fi cati on, removethe roof
from the body, and adj ust the di fference wi th the spacers
(E)
that are i nstal l ed between the l ock handl e and the
roof,
SPACER: Thickness= 1 mm 10.04 in.) Measurlng Point [AJ :
7. Set the roof onto the body, and l ock i t securel y. Check that the weatherstri p fi ts fl ush, and check that each door
gl ass contacts the weatherstri p evenl y. l f necessary. adj ust the retai ner; refer to the roof mol di ng repl acement
(see page 20-57).
8. Removethe roof fromthe body, and rei nstal l the B-pi l l artri m onthe roof.
9. Set the roof onto the body. and l ock i t securel y. Reconnect the rear wi ndow defogger connectors securel y.
10. Make sure that the roof i s l ocked securel y, then rai se the door
gl ass ful l y, and cl ose the doors.
11. Check for water l eaks. Run water over the roof and on the seal i ng area as shown, and note these i tems:
.
Use a 12 mm
( 1/ 2
i n. ) di amet er hose
( A) .
.
Adj ust the rate of water fl ow
(B).
.
Do not use a nozzl e.
.
Hol d the hose about 200 mm
(7.9
i n.) away from the door.
12 mm
( 1/ 2
i n. )
*_r*
CI
itY
A
70 mm 12. 8 i n. l
200 mm
(7. 9
i n. l
20-66
Interior Trim
A-PILLAR INTERIOR
TRIM
page 20-68
WINDSHIELD HEADER
INTERIOR TRIM
page 20' 68
CARPETS
Bepl acement,
page 20-1 4
CONVERTIBLE TOP COVER PIN
page20- 70
REAR TRAY
page 20-71
ROLL BAR
UPPER TRIM
page 20-71
REAR TRAY
REAR TRIM
page 20-71
REAR TRAY
SIDE TRIM
page 20-71
CONVERTIBLE TOP COVER
'aa.
l .
MALE HOOK
page 20-71
REAR SIDE TRIM
page 20 70
ROLL BAR LOWER TRIM
page 20-70
CENTER CARPET
KICK PANEL
page 20-69
DOOR SI LLTRI M
page 20-69
SPARE TIBE COVER
page 20' 13
t -
TRUNK FLOOR TRIM PANEL
page 20 73
TOOL BOX LID
page 20-73
TOOL BOX
page 20 73
REAR TRI M PANEL
page 20-73
TRUNK SIDE TRIM PANEL
page 20-13
20-67
lnterior Trim
Trim Removal/lnstallation
-
Front Roof Area
NOTE:
.
Put on
gl oves
to
protect your
hands.
.
tape to
prevent
damage.
.
Take care not to bend or scratch the tri m and oanel s.
1. Remove the tri m i n numbered seouence.
2. Instal l the tri m i n the reverse order of removal . and note these i tems:
.
.
Make sure the connector i s pl ugged
i n properl y.
.
Push the cl i p
porti ons i nto pl ace
securel y.
. l f t het hr eadsont hevi sor scr ewsar ewor nout , useanover si zedscr ew( P/ N90132- 523- 0030)
made speci f i cal l y
for thi s appl i cati on.
F stener Locations
A
>:
Screw,2 B
):
Screw,
d-\ ,K\
(1r)l P
i l l D
-\.-r'
Y-/
2 C) : Cl i p, 4 D
>:
Cl i p, 2
\
OsuNVtsoR
5 x 0 , 8 mm
, l Nm{ 0. 4kgt . m,
3 tbf.ftt
osulvrson
,/ lire
/ q
@sPorLrGHr
/
20-68
' 1.
-
Door Area
NOTE:
.
Put on
gl oves
to
protect your hands.
.
When pryi ng wi th a fl at-ti p screwdri ver, wrap i t wi th protecti ve tape to prevent damage.
.
Take care not to bend or scratch the tri m and Danel s.
Remove the tri m as shown.
Instal l the tri m i n the reverse order of removal , and note these i tems:
.
.
Push the cl i p porti ons i nto pl ace securel y.
Clip, 1
l,g
SII[gsqI
,,711
t q
F 3tenel Locations
A>t Cl i p, 3 B>: c| i p. l
w 2im
er Tle
c D,
D
: Cl i p, 1
M
tffi\
I
I:TTrFF
Y)
A.PILLAR.HEAOER
WEATHERSTRIP
Pul l back as necessary.
i_
i
I
,.. ;
-'
t/
\ai
KICK PANEL
_-z-(
l c ' r
SIDE TRIM REAR
/
SILL TRIM
TAB
20-69
Interior Trim
-
Seat Side Area
NOTE:
.
Put on gl oves
to
protect your hands.
.
tape to prevent
damage.
.
Take care not to bend or scratch the tri m and
panel s.
1. Remove the door si l l tri m
(see page
20-69).
2. Remove the tri m as shown.
3. Instal l the tri m i n the reverse order of removal . and note these i tems:
.
.
Push the cl i p
porti ons
securel y i nto pl ace.
.
Wi th removabl e hardtop: Makesurethe rear wi ndow defogger connector i s pl ugged
i n properl y eftsi de onl y).
Fastener Locations
A
>:
Screw,l B
):
Screw,2
ftP:ao [D]trn.]I1r]:]r"
<-,/
ROLL BAR
UPPER TRIM
ROLL BAR
LOWER TNIM
F
C>: oi p, ? D>: Cl i p, 1
CAP
REAR SIDE TRIM
(Left
si de wi th
convert i bl e t op onl y)
GROMMET
(Left
si de wi th removabl e
hardtop onl y)
CONVERTIBLE TOP
COVER PIN
6 x 1 . 0 mm
REAR WINDOW
DEFOGGER CONNECTOR
(Left
si de wi th removabl e
hardtoD onl v)
REAR
::$
L r [
-
.,f
iii-;
l.f\
' "
- \
COAT
HANGER
20-70
COAT HANGER
4 N m 10. ' l kgt . m, 3 l bf . f t l
SI OE TRI M
-
Rear Tray Area
NOTE:
.
Put on
gl oves to
protect your hands.
'
When
pryi ng wi th a fl at-ti p screwdri ver. wrap i t wi th protecti ve tape to
prevent damage.
.
Take care not to bend or scratch the top cl oth, rear wi ndow, tri m and
panel s.
1, Remove t he t r i m i n number ed sequence.
2. l nstal l the tri m i n the reverse order of removal , and note these i tems:
.
.
Appl y l i qui d thread l ock to the anchor bol ts before rei nstal l ati on.
.
Before i nstal l i ng the anchor bol ts, make sure there are no twi sts or ki nks i n the seat bel t.
.
Push the cl i p
porti ons i nto
pl ace
securel y.
Fast6ner Locations
B>: Cl i p, 7
l Cl
/@l
H
Vf o
r\e
1 ,
i '>-----
i -'
\ . . -
I - ' L -
A>: Cl i p, a
a _
'#!
l-f
REAR TRAY STOPPER
(' 02-03
model s)
@ REAR TRAY
REAR TRAY
STOPPER
(' 02-03
model s)
x 1. 0 mm
9. 8 N. m {1. 0 kgf . m, 7. 2l bf . f t }
(' 02-03
model s)
(cont' d)
O REAR TRAY REAR TRIM
20-71
lnterior Trim
-
Rear Tray Area
(cont'dl
Fastener Locations
C>: Bol t , 8 D
>:
Scr ew, 4
CONVERTIBLE TOP
COVER PIN
' 00-0l model s:
Outsi de and mi ddl e.
' 02-03
model s: Outsi de onl y.
Fastener Locations
O ROLL BAR AND UPPER TRIM ASSEMBLY
Fi rst remove the these i tems:
. Rear
consol e
. Rear
si de t ri m
6] SEAT BELT UPPER ANCHOR BOLT
@ @ r 6 x
7/16-20UNF
t \ "-, {: 3*' . m. 24' bf . f t )
r \6\"\
4
uPPER ANcHoR cAP
a/
D
V
Sl i p t he seat bel t
t hrough t he hol e i n
t he r ol l bar upper t r i m.
'02-03
models shape
8 x 1. 25 mm
22 N.m 12.2 kgl m,
16 rbf.ft)
G
>:
Cl i p, 1
'00-01
models shaoe
O HARNESS cLIP
Detach
(l eft
si de onl y).
(' 02-03
model s)
OSEAT BELT
LOWER ANCHOR BOLT
7/16-20UNF
32 N.m, {3.2 ksf.m,
24 tbt,ft)
Fi rst remove the seat.
E>: Cl i p, 1 F>: oi p. 1
@4 .^-ts!-^\
-4.
S 7:7n ! fl+-
\ r/
-/E\
\-/ u4)
r(D
P
Vf o
@ REAR TRAY
SI DE TRI M
-
- : ' : : : " : : -
-
"-::"
'
"l
'
. . :
' '
O HARNESS GROMMET
Rel ease i t f rom t he t ri m
(l ef t
si de onl y).
(' 02-03
model s)
20-72
Tri m Removal /l nstal l ati on
-
Trunk Area
NOTE:
.
Put on
gl oves to
protect your hands.
.
When
pryi ng wi th a fl at-ti p screwdri ver, wrap i t wi th protecti ve tape to prevent damage.
.
Take care not to bend or scratch the tri m and panel s.
1. Remove t he t r i m as shown.
2. l nstal l the tri m i n the reverse order of removal , and note these i tems:
.
.
Push t he cl i ps i nt o pl ace secur el y.
Fastener Locations
A>: Cl i p, 18 B> r Cl i p, a c
>:
Cl i p, 3
, ^ t t ; . : i
T
-Fl
,.{tr]
TOOL BOX
RI GHTTBUNKSI DE
TRIM PANEL
SPARE TIRE COVER
V.
LEFT TRUNK SIDE
TRIM PANEL
TRUNK FLOOR
TBIM PANEL
REAR TRI M PANEL
TOOL AOX LID
V
V
20-73
lnterior Trim
Carpet Replacement
NOTE:
.
Put on
gl oves
to
protect your
hands,
.
Take care not to damage. wri nkl e, or twi st the carpets.
.
Becar ef ul not t odamaget he dashboar d or ot her i nt er i or t r i m
pi eces.
1. Remove these i tems, then remove the carpet as shown:
.
Seat
(see page 20-86)
.
Ki ck panel
{see
page
20-69)
.
Front consol e cover
(see page 20-81)
.
Rear si de tri m
(see page 20-70)
2. Instal l the carpet i n the reverse order of removal . and note these i tems:
.
Make sure the seat harness i s routed correctl y.
.
.
Appl y l i qui d thread l ock to the anchor bol t and seat mounti ng bol ts before rei nstal l ati on.
.
Before i nstal l i ng the l ower anchor bol ts, make sure there are no twi sts or ki nks i n the seat bel ts.
.
Push the cl i ps i nto pl ace
securel y.
Fastener Locations
A> : Bo l t , 2 B> : Sc r e w, 4 Car Nut . 2 D>: Cl i p, 1/ r E>: Cl i p, 10 F
>:
Cl i p, 2
ACCELERATON
PEDAL STOP
SEAT HARNESS
DRI VER' S CARPET
RETAINERS
FASTENER
FASTENER
CENTER CARPET
Pul l back as
necessary.
FASTENERS
To center carpet.
'i*"')y
TUNNEL
SIDE CLIP
DOUBLE.FACED
ADHESIVE TAPE
(3M
85603, or equi ral ent)
FLOOB MAT HOLDEB
1' 02-03 model s)
lf necessary, remove it.
TUNNEL SIDE
NET
PASSENGER'S
CARPET
SEAT BELT LOWER
ANCHOR BOLT
7/ 16-20UNF
32 N. m
(3.3
kgt.m,2il lbt ft)
3>j
g'",
20-74
Center Carpet Replacement
SRS components are l ocated i n thi s area. Revi ewthe SRS component l ocati ons {see
page
23-9) and the
precauti ons
and
procedures (see page 23-10) i n the SRS secti on before
performi ng repai rs or servi ce,
NOTE:
.
Put on gl oves to
protect your hands.
.
Take care not to damage, wri nkl e, or twi st the carpet.
.
Becar ef ul not t o damage t he dashboar d or ot her i nt er i or t r i m pi eces.
.
Before di sconnecti ng the negati ve cabl e from the battery, make sure you have the anti -theft code for the radi o, then
wri tedown the frequeci es for the radi o' s preset buttons.
.
Di sconnect the negati ve cabl e from the battery, and wai t at l east 3 mi nutes before begi nni ng work.
1. Remove these i tems, then remove the center carpet as shown:
.
Dashboard {see
page 20-82)
.
Rear consol e
(see page 20-78)
.
The har ness cl i ps secur i ng t he SRS wi r e har ness and st eer i ng hanger beam wi r e har ness.
.
Cut the carpet i n the areas shown.
2. Instal l the center carpet i n the reverse order of removal , and note these i tems:
.
Make sure the SRS wi re harness and steeri ng hanger beam wi re harness are routed correctl y, and cl i pped i nto
pt ace.
.
.
Push the cl i ps i nto pl ace securel y.
'
Refasten the cut areas wi th wi re ti es.
.
.
Enter the anti -theft code for the radi o, then enter the customer' s radi o stati on
presents.
.
Reset the cl ock.
.
Do t he PCM i dl e l ear n
Fastener Locations
A>: Aok . 2 B>: Cl i p, 14 C>: Cl i p, 2
ftr ,,Th /If
/ \ / \ , / \ ,
,/
\J
CENTER
CARPET
CARPET
6 x 1 , 0 mm
9. 8 N. m
(' 1. 0
kgf . m, 7. 2l bf . f t )
STEERING HANGER
BEAM WIRE HARNESS
SRS WI RE
HARNESS
cV
B
FASTENERS
, - B !
B r . .
Bv-
,
D,B
FASTENERS
Cut here.
CENTER CARPET
20-75
Consoles
Center Console RemovaUlnstallation
NOTE:
.
When
pryi ng
wi th a fl at-ti p screwdri ver, wrap i t wi th protecti ve tape to prevent damage.
.
Take care not to scratch the front seat, dashboard and rel ated parts.
.
Remove the shi ft knob by turni ng i t countercl ockwi se.
1. Remove the center consol e as shown.
2. Instal l the center consol e i n the reverse order of removal . and note these i tems:
.
.
Make sure the connectors are
pl ugged
i n properl y.
.
Push the cl i p
poni ons i nto pl ace
securel y.
.
Instal l the shi ft knob i n numbered seouence.
Fastener Locations
A
>:
Cl i p, 5 B>: Cl i p. 2 C> : Cl i p.
+
SHIFT KNOB
@SHI FT KNOB
By hand, t hread
t he shi f t knob
on t he shaf t .
@ l Vove to proper
posrtron.
By hand, t hread sei urel y.
) o
k
*,-*.q
. ) } '
' o \ , " n , n " , o " * " , ,
\O
CONSOLE
HAZARD WARNING
SWITCH CONNECTOR
Forward
t he l ocknut down.
t A
. \
v t \ c
,l
^N,,-
-1r
:;/8o
':'
j.,.
B
20-76
Wind Deflector Replacement
' 01-03
Models
NOTE:
.
When pryi ng wi th a fl at-ti p screwdri ver, wrap i t wi th protecti ve tape to prevent damage.
.
Take care notto scratch the rear consol e upper l i d and rel ated
parts.
1. Remove the wi nd defl ector as shown.
2. Instal l the wi nd defl ector i n the reverse order of removal .
.
Appl y l i qui d thread l ock to the th read of the A screws before rei nstal l ati on.
.
Make sure the caps are i nstal l ed securel y onto the screws.
Fastener Locations
A) : Sc r e w. 2
LI OUI D THREAD LOCK
REAR CONSOLE
UPPER LI D
WIND DEFLECTOB
20-77
Consoles
Rear Consol e Removal /l nstal l ati on
NOTE:
.
When pryi ng wi th a fl at-ti p screwdri ver, wrap i t wi th protecti ve tape to
prevent damage.
.
Take care not to scratch the front seat and rel ated
parts.
'
Center consol e
(see page 20-76)
.
Rear t r ay
( see page 20- 71)
.
Rol l bar l ower tri m, both si des
(see page 20-70)
Remove the rear consol e as shown.
Instal l the rear consol e i n the reverse order of removal , and note these i tems;
.
.
Make sure the connectors are pl ugged i n
properl y.
.
Fastoner Locations
A>: Scr . w, 4 B>: Scr ew, l o
CONSOLE
c
>
: Cl i p.5 D>: Cl i p, 4
+
d
-+
REAR CONSOLE
BACK BOARD
TRUNK LI D
OPENER SWITCH
CONNECTOR
Di sconnect .
REAR CONSOLE
BOX
ft::E:7l::.--'1
'f-
=i
, - - 9
I
1
.::j tt: ..
t:
I
/1
20-78
Rear Console Box Replacement
NOTE: Take care not to scratch the front seat and rel ated parts.
' 1.
Remove these i tems, then remove the rear consol e box as shown;
.
Rol l bar upper tri m, both si des
(see page 20-71]
' Spar et i r e
2. Remove the rear consol e box as shown,
3. Instal l the rear consol e box i n the reverse order of removal .
Fastsne. Locations
A>: Sc r ew, 4
5 x 0 . 8 mm
4 N. m
{0. 4
kg{. m,
3 rbf.ftl
HARNESS CLI P
Det ach.
REAR CONSOLE BOX
20-79
Dashboard
Instrument Panel Removal /
Installation
NOTE:
.
protecti ve tape, and appl y protecti ve tape around the
rel ated pans, to prevent damage.
.
Take care not to scratch the dashboard and rel ated
parts,
1. Remove t he i nst r ument
panel asshown.
2. Instal l the panel i n the reverse order of removal ,
.
.
pl ugged i n
properl y.
.
Push the cl i p poni ons i nto pl ace securel y.
Fastener Locrtions
A> : Sc r e w, 2 B> : Cl i p . 2 CF:
I NSTRUMENT PANEL
Cl i p, 4
,/:i
.I,
)
: Cl i p. 2
(-
'--
)
: Cl i p. 2
CRUISE CONTROL
MAIN SWITCH
CONNECTOR
ENGI NE
START
swtTcH
CONNECTOR
20-80
Radio Panel RemovaUlnstallation
NOTE:
.
When pryi ng wi th a fl at-ti p screwdri ver, wrap l t wi th
protecti ve tape, and appl y
protecti ve tape around the
rel ated
parts, to prevent damage.
.
pans.
1. Remove t he r adi o panel as shown.
2. I nst al l t he
panel i n t he r ever se or der of r emoval .
.
.
Push the cl i p
porti ons i nto pl ace securel y.
Fastener Locations
5 B) : Cl i p , 2
)
: Cl i p,
.raa
=-
TABS
RADIO PANEL
Front Console Cover Removal/
Instal l ati on
NOTE:
.
When pryi ng wi th a fl at-ti p screwdri ver. wrap i t wi th
protecti ve
tape, and appl y protecti ve tape around the
rel ated parts, to prevent damage.
.
parts.
1. Remove the front consol e cover as shown.
2. Instal l the cover i n the reverse order of removal ,
.
.
Fastener Locations
, 1
B> r Cl i p . 2
)
: Screw
0."
Passenger's Dashboard Lower
Gover Removal /l nstal l ati on
NOTE:
.
protecti ve tape, and appl y protecti ve tape around the
rel ated parts,
to
prevent
damage.
.
parts.
1. Remove the passenger' s
dashboard l ower cover as
shown,
2. Instal l the cover i n the reverse order of removal ,
.
.
Push the cl i p porti ons i nto pl ace
securel y.
Fastener Locations
A) : Cl i p, 6
l5=,.'
i;';-
20-81
Dashboard
Passenger's Side Vent Removal and
lnstallation
1. Wrap a fl at-ti p screwdri ver wi th protecti ve tape,
and appl y
protecti ve tape around the rel ated
parts
to prevent damage. Careful l y i nsert a fl at-ti p
screwdri ver next to the cl i p
(A),
and detach the cl i ps
by
pryi ng on the
passenger' s si de vent
(B).
Take
care not to scratch the dashboard and rel ated
parts.
Fastener Locations
A>: Cl i p, 2
Remove the vent by rel easi ng the hooks
(C).
Rei nstal l the hook portl ons ot the vent fi rst. then
push the cl i p porti ons i nto pl ace securel y.
2.
3.
/
.-.
---.2- - a
.
'...
.\___t
20-82
Dashboard RemovaUlnstallation
SRS comoonents are l ocated i n thi s area. Revi ew the
SRS component l ocati ons
(see page 23-9) and the
precauti ons and procedures
(see page 23-10) i n the SRS
secti on bel ore
performi ng repai rs or servi ce.
NOTE:
.
When
pryi ng wi th a fl st-ti p screwdri ver, wrap i t wi th
protecti ve tape, and appl y
protecti ve tape around the
rel ated
parts to
prevent damage.
.
Have an assi sl ant hel p
you
when remove and i nstal l
the dashboard.
.
Take care not to scratch the dashboard, body and
other rel ated parts.
.
Preset
buttons.
2. Di sconnect the negati ve cabl e from the battery, and
wai t at l east 3 mi nutes before begi nni ng work.
.
Radi o
panel (see page 20-80)
.
Audi o uni t {see
page 20-89}
.
Steeri ng col umn
(see page 17-9)
.
Passenger' s dashboard l ower cover {see
page
20- 81)
.
Front consol e cover, both si des
(see page 20-81)
.
Passenger' s ai rbag assembl y
(see page 23-65)
.
Ki ck panel , both si des
(see page 20-69)
.
Front
pi l l artri m, both si des
(see page 20-68)
4. Di sconnect the engi ne wi re harness connector
(A),
engi ne compartment wi re harness connectors
(B),
door wi re
harness connectors
(C),
rear wi re harness connector
(D),
steeri ng hanger beam wi re harness connectors
(E),
SRS
mai n harness connector {F), radi o antenna harness connector
(G),
ECM connector
(H}.
keyl ess entry control uni t
connector
(
l ), and converti bl e toD control uni t connector
(J).
K
6 x 1 . 0 mm
9. 8 N. m
(' 1. 0
kg' t . m,
7. 2 t bt . f t l
1. 0 mm
N. m {1. 0 kgf . m,
rbf.ft)
Remove the ground bol ts
(K).
Detach al l of the harness and connector cl i ps.
(cont' d)
\-.--..-
K
6 x
9.8
7.2
- = - .
20-83
Dashboard
Dashboard Removal/lnstallation
(cont'd)
7. From outsi de the doors. remove the caps
(A),
then remove the bol ts
(8,
C, D) and screws {E), and l i ft up on the
dashboard
(F)
to rel ease i t from the
gui de pi ns (G
).
Take care not to scratch the center consol e and shi ft knob.
Fasten6r Locations
A>: Bol t , 2 B>: Bol t , 2 C 2 D>: Scr ow, 2
{1\
>
: Bolt,
(t t rm (ii
DtE
6 x 1 . 0 mm
9. 8 N. m 11, 0 kgt . m,
7.2 tbt.ttl
'
\*
6 x 1 . 0 mm
9. 8 N. m {1. 0 kqf . m,
7.2 tbt.ftl
Careful l y remove the dashboard through the front door openi ng.
l nstal l the dashboard i n the reverse order of removal , and note these i tems:
.
Make sure the dashboard fi ts onto the gui de pi ns
correctl y.
.
Before ti ghteni ng the bol ts, make sure the dashboard wi re harness and steeri ng hanger beam wi
not pi nched.
.
pl ugged i n properl y.
.
.
Enter the anti -theft code for the radi o, then enter the customer' s radi o stati on
presets.
.
Reset the cl ock
.
Do t he PCM i dl e l ear n pr ocedur e ( see page 11- 100) .
re narness are
20-84
\
Removal / l nst al l at i on, paqe
20-86
Di sassembl y/ Reasseni bl t Dri ver' s, page 2O-87
Di sassembl y/ Reassembl y Passenger' s, page2O-88
Seat Cover Replacement; page
2O-8r-9
Seats
Seat Removal/lnstallation
NOTE: Take care not to scratch the body or tear l he seat covers.
2.
1 . Remove the seat as shown.
Instal l the seat l n the reverse order of removal , and note these i tems:
.
Sl i p the seat bel t through the sl i ts i n the seat bel t
gui de properl y
.
Make sure the seat bel t swi tch connector i s pl ugged i n properl y,
.
Appl y l i qui d thread l ock to the seat mounti ng bel ts before rei nstal l ati on
Fastener Locations
A>: Bol t , 2 B
10 x 1. 25 mm
29 N.m {3.0
kgl .m,
22tbl.ftl
I x 1. 25 mm
22 N.m {2.2 kgt.m,
16 rbr.ftt
)
: Bolt. 2
I DI D
SEAT BELT GUIDE
SEAT BELT
Remove {rom the
seat bel t gui de.
SEAT BELT
SWITCH HARNESS
(Dri ver' s)
SEAT BELT
SWITCH CONNECTOR
Di sconnect
(dri ver' s).
20-86
Seat Disassembly/Reassembly
-
Driver's
NOTE:
.
Make sure the bushi ng and pi vot
washer are i nstal l ed correctl y.
.
Appl y mul ti purpose grease
to the movi ng porti on
of th seat track.
.
To prevent wri nkl es i n the seat-back cover, stretch the mal eri al evenl y over the
pad,
.
Rei nstal l the connecti ng wi re through the hol es i n the hooks.
PIVOT NUT
8 x 1.25 mm
22Nml 2.2ksl .m,
16 tbf.ftt
PIVOT
WASHER
BUSHI NG
INNER SEAT TRACK
, , ' i / t \ ' '
\ t['b^1
>\ u\
-?
xdox i
/
sEAr BELr I
swfTcH
| ,
HARNESS
,//
/
cLrP
I /
t ,
:LfPS
I A
r.
lol" a- -
Pul l back.
SEAT.BACK
RECLINE ADJUSTER
Rel ease the cl i ps as
necessary, then pul l
back the seat-back
cover.
HOO|(
10 x 1.25 mm
,07
N.m 14.8 kgt.m,
35 rbr.ft)
10 x 1. 25 mm
,17
N.m
(4.8
kgf.m,
3s rbt.ftl
8 x 1.25 mm
22 N.n
12.2ksi.m,
r6l bt.ftl
CONNECTING
WIRE
10 x 1.25 mm
47 N.m
(4.8
kgf.m,35l bt.ftl
HOOK
RECLINE KNOB
20-87
Seats
Seat Disassembly/Reassembly
-
Passenger's
NOTE:
.
l Make sure the bushi ng and
pi votwasher are i nstal l ed correctl y.
.
grease to the movi ng
porti on of the seat track.
' Topr event wr i nkl esi nt heseat - backcover , st r et cht hemat er i al evenl y over t he
pad'
.
Adj ustthe connecti ng cabl e as necessary.
.
Make sure the connecti ng cabl e i s connected
properl y
Rel ease t he cl i ps as
necessary, t hen pul l
back t he seat -back
d
10 x 1. 25 mm
4 7 N m
(4. 8 kql . m.
35 tbf.ftl
I x 1.25 mm
22N.n
l2.2 kgl m,
16 rbf.ftl
SEAT.
PIVOT NUT
8 x 1.25 mm
22N m 12.2 kgt.m,
16 tbf.ft)
PI VOT WASHER
SEAT CUSHION
BUSHI NG
10 x 1. 25 mm
4 7 N m
14. 8
kgf . m,
3s rbf.ft)
INNER SEAT TRACK
CONNECTI NG
CABLE
10 x 1. 25 mm
4 7 N m
{4.8
ksf.m,35 l bf.ft)
HOOK
l :
'
20-88
RECLINE KNOB
Seat Cover Replacement
NOTE:
.
Take care not to tear the seams or damage the seat covers.
.
Put on
gl oves
to
protect your hands,
Seat-back Cover
1. Remove the seat-back cover i n numbered sequence.
2. Instal l the cover i n the reverse order of removal , and note these i tems:
' Topr event wr i nkl eswheni nst al l i ngaseat - backcover , makesur et hemat er i al
i s st r et ched evenl y over t he pad
before securi ng the cl i ps, fasteners and hooks.
.
Repl ace the rel eased cl i ps wi th new ones usi ng commerci al l y avai l abl e uphol stery pl i ers.
.
Repl ace any damaged headrest cover cl i ps.
Fastenor Locations
A>: Scr ew4 B>: Scr ew' 2
HEAOREST
COVER
/ d
. )
l i ,,-:r
@ sE,
GU
1r, /
@
O HOOKS
CLIPS
Rel ease.
(cont' d)
C>; Cl i p, 4
20-89
Seats
Seat Cover Replacement
(cont'dl
FASTENER
O CLIP
Pul l back t he edge of t he cover
on t he cent er
pad al l t he way
around, and rel ease t he cl i ps.
i.{.
i . r \ \
. . . . - \
--/ ""11
back t he cent er
Pad
CLIP
Rel ease f rom undert hepent er
pad.
@SEAT.BACK
COVER
Pul l backt he edge o{t he cover
al l t he way around, and rel ease
t he f ast ener, t hen remove t he cover.
20-90
I
Seat Cushion Cover
1. Remove the seat
(see page 20-86).
2, Remove the seat cushi on, dri ver' s {see
page 20-87), passenger' s (see page 20-88).
3. Remove the seat cushi on cover i n numbered sequence.
4. Instal l the cover i n the reverse order of removal , and note these i tems;
' Topr event wr i nkl eswheni nst al l i ngaseat cushi oncover , makesur et hemat er i al
i s st r et ched evenl y over t he
pad
bef or e secur i ng t he cl i ps.
.
Repl ace the rel eased cl i ps wi th new ones usi ng commerci al l y avai l abl e uphol sl ery ri ng pl i ers.
ID CLIP
Rel ease f rom under t he seat cushi on
OPul l back t he edge
of t he cover al l t he
-
TRIM CORDS
l Cover si de)
Clip installation:
UPHOLSTERY BING
PLI ERS
OSEAT CUSHI ON COVER
Remove t he cover f rom
t he pad/ f rame.
SEAT CUSHI ON
WIRE
(Pad
si de)
OcLtP
Rel ease.
NEW CLI P
20-91
Bumpers
Front Bumper Removaulnstallation
NOTE:
.
Have an assi stant hel p
you remove and i nstal l the front bumper.
.
Take care notto scratch the front bumper and body.
.
Put on gl oves to
protect your hands.
1. Remove the front bumoer as shown.
2. Instal l the bumDer i n the reverse order of removal , and make sure the front bumper engages the hooks of the
corner upper beams and front fenders securel y
Fastonor Locations
A>: Bol t , 5 B>: Bol t , 9 C>: Bol t , 2 C) : Sc r ew, 2
tr
@@ 0r='
\FENDER
ABSORBER
6 x 1 . 0 mm
9. 8 N. m
(1. 0
kgf . m,
7.2 tbf.ftl
FRONT BUMPER
A
B
l
+
t-"..--.-

l
6 x 1 . 0 mm
9. 8 N. m
{1. 0
kgf . m,
7.2 tbt.kl
FRONT BUMPER
UPPER STI FFENER
FRONT BUMPER BEAM
\ gF.
=_l:-.----J
L
---
i r l
' ' -
\
20-92
Rear Bumper Removal /l nstal l ati on
NOTE:
.
Have an assi stant hel p you remove and i nstal l the rear bumper.
.
Take care notto scratch the rear bumoer and bodv.
.
Put on gl oves
to
protect your hands.
1. Remove t he r ear bumDer as shown.
2. Instal l the bumper i n the reverse order of removal , and note these i tems:
.
Make sure the rear bumper engages the hooks
(bumper
spacers and under the tai l l i ght) on each si de securel y.
.
Make sure the l i cense pl ate
l i ght connector i s pl ugged i n properl y.
.
Fastener Locations
B>: Cl i p, 2 C A
>
: Screw,2
[E EP
..---l
"; ' . -. : l
-1
L---/-\f-'-'-'-'-
.
t ,
>
: Cl i p, 5
I
E*>.
m*
HOOKS
REAR BUMPER AEAM
r'l
"
,-:,-.,-
REAR BUMPER
20-93
Hood
1 .
)
Adjustment
Sl i ghtl y l oosen each hood hi nge bol t.
Adj ust the hood al i gnment:
.
Adj ust t he hood r i ght and l ef t , as wel l asf or war dandr ear war d, byusi ngt heel ongat edhol esont hehoodhi nge
(A).
.
Turn the hood edge cushi ons
(B),
as necessary. to make the hood fi t fl ush wi th the body at front and si de edges.
6 x 1 . 0 mm
9.8 N.m 11.0 kgt m,
7.2l bf.ft)
. 1. 1 i
. , . i '
. i : . . .
,.
6x 1. 0 mm
9.8 N.m {1.0 kgt.m,
7.2 tbf.ft)
Adj ust the hood l atch
(C)
to obtai n the proper hei ght at the forward edge, and move the hood l atch ri ght on l eft
unti l the stri ker
(D)
i s centered i n the hood l atch.
Ti ghten each bol t securel y.
20-94
7.
Check that the hood opens
properl y
and l ocks
securel y.
Appl y body
pai nt
to the hi nge mounti ng bol ts and
around the hi nges.
Remove the ai r gui de pl ate cover
(see page 20-1 1 1),
then remove the l atch cover
(A).
Appl y
mul ti purpose grease to each l ocati on of the hood
l atch
(B)
and hood hi nge
(C)
as i ndi cated by the
arrows.
20-95
Hood
Hood Insulator Replacement
NOTE:
.
Take care notto scratch the hood.
.
Use a cl i p remover to remove the cl i ps.
1. Remove the hood i nsul ator i n numbered sequence.
2. l nstal l the i nsul ator i n the reverse order of removal . and note these i tems:
.
.
Push the cl i ps i nto pl ace securel y.
.
Make sure the wi ndshi el d washer tubes are connected
properl y.
Fastengr Locations
A>: Cl i p, 10 B
>
: Cl i p. 2
o cLrPs
O HooK
O HooD
INSULATOR
OWINOSHIELD WASHER TUBES
Bel ease from the I cl i ps,
and di sconnect.
20-96
Trunk Li d
a
1 .
2.
Adjustment
Sl i ghtl y l oosen each bol t.
Adj ust t he t r unk l i d al i gnment :
.
Adj ust the trunk l i d ri ght and l eft, as wel l as forward and rearward, by usi ng the el ongated hol es on the trunk l i d
hi nges( A) .
.
Turn the trunk l i d edge cushi ons
(B)
i n or out as necessary. to make the trunk l i d fi t fl ush wi th the body at the
rear and si de edges.
.
Adj ust the fi t between the trunk l i d and the trunk l i d openi ng by movi ng the stri ker
(C).
6 x
' 1. 0
mm
9. 8 N. m (1. 0
kgf . m,
7.2 tbf.ftt
6 x 1 . 0 mm
9. 8 N. m
(1. 0
kgf . m,
1.2 tbt.ttl
*'.*:':-''''
i -
3. Ti ghten each bol t securel y.
4. Make sure the trunk l i d opens properl y and l ocks securel y.
5. Appl y body
pai nt
to the trunk l i d mounti ng bol ts and around the hi nges.
/.1 /
/,/;,/.,/i
20-97
Trunk Lid
Trunk Lid Torsion Bar Replacement
NOTE:
.
Take care not to scratch the bodv.
.
.
Useat or si on bar t ool t o r emove and i nst al l t het or si on bar s.
.
Fi rst remove ri ght torsi on bar, and remove the l eft torsi on bar.
1. Remove the trunk l i d torsi on bar as shown,
2. Instal l the torsi on bar i n the reverse order of removal , and note these i tems:
.
Ther i ght t or si onbar hasapi eceof r ubber oni t asshown. I nst al l t her i ght andl ef t t or si onbar si nt hei r pr oper
l ocati ons.
.
Make sure the trunk l i d opens
properl y and l ocks securel y.
20-98
a
Trunk Lid Rubber Protector
Replacement
NOTE;
.
Take care not to scratch the trunk l i d.
.
Use a cl i p removerto remove the cl i ps.
' t .
Remove the trunk l i d rubber protector as shown.
Instal l the protector i n the reverse order of removal ,
.
.
Push the cl i p
porti ons
i nto
pl ace
securel y.
Fastonel Locations
A >
: Cl i p, 8
RUBBER
PROTECTORS
RUBBER
PROTECTORS
Trunk Lid Weatherstrip
Replacement
1. Remove the trunk l i d weatherstri p by pul l i ng i t off.
2. Locat e t he
pai nt ed
al i gnment mar k
( A)
ont het r unk
l i d weatherstri p
(B).
Al i gn the pai nted mark wi th the
al i gnment tab i n the center of the trunk, and i nstal l
the weatherstri p al l the way around faci ng i n the
di recti on shown. Make sure there are no wri nkl es i n
the weatherstri p.
20-99
Fuel Fill Door
Adjustment
1. Sl i ghtl y l oosen the hi nge mounti ng bol ts
(A).
6 x 1 , 0 mm
9.81{.m 11.0 kgf.m,
7.2 tbt.frl
Adj ust the fuel fi l l door
(B)
i n or out unti l i t' s fl ush
wi th the body, and up or down as necessary to
equal i ze the gaps.
Ti ghten the hi nge mounti ng bol ts.
Check that the fuel fi l l door opens
properl y
and
l ocks securel y.
20-100
5. Appl y mul ti purpose grease to each l ocati on
i ndi cated by the arrows.
Appl y body pai nt to the hi nge mounti ng bol ts and
around the hi nges.
o.
_
_1---.
I
l , t
1- l
Exterior Trim
Cowl Cover Replacement
NOTE;
.
.
Use a cl i p remover to remove the cl i ps.
1. Remove the wi ndshi el d wi per arms l see
page 22-112).
2. Remove t he cowl cover asshown.
Instal l the cover i n the reverse order of removal , and note these i tems:
.
.
Push the cl i p
porti ons i nto pl ace
securel y.
Fastener Locations
A
>: Cl i p, 7 B
>:
Cl i p, 9
n
\ /
= Fr I - l
\ Y U
REAR HOOD SEAL
20-101
Exterior Trim
Rear Tray Openi ng Mol di ng
Replacement
NOTE:
.
.
Be careful not to
pry
too far or
you may bend the
mol di ng.
.
1. Remove these i tems:l hen remove the rear tray
openi ng mol di ng as shown:
.
Converti bl e top assembl y
(see page 20-38)
'
B-pi l l ar outer weatherstri ps, both si des
(see page 20' 52)
.
Drai n tank, both si des
(see page 20-52)
2. Remove the rear tray openi ng mol di ng as shown.
Fastenel Locations
A> : Bo l t , 1 0
MOLDING
@
REAR TRAY
OPENI NG MOLDI NG
6 )( 1. 0 mm
9. 8 N. m
(1. 0
kgl . m,
7.2 tbl.ltl
3. I nst al l t he mol di ng i n t he reverse order of removal .
20-102
\
Rear Window Lower Molding
Replacement
NOTE: Take care not to scratch the body.
1. Remove the rear wi ndow l ower mol di ng as shown.
2. Instal l the mol di ng i n the reverse order of removal ,
and repl ace the cl i p i f i t' s damaged.
Fastener Locations
A>: Sc r eul I
>:
Cl i p. 1
s'
?
$ r o
a
Emblem Replacement
NOTE: When removi ng the embl ems. take care not to scratch the body.
Appl y the embl ems where shown, and note these i tems:
.
Cl ean the body surface wi th a sponge dampened i n al cohol .
.
After cl eani ng. keep oi l , grease and water from getti ng
on the surface.
Adhesive tape: 3M
,12'13E,
or equivalent
Thi ckness 0.8 mm 10.03 i n.)
Uni t mm {i n.)
'00-01
modelsi
FRONT BUMPER
ADHESIVE
EMBLEM
T
ADHESIVE
EMBLEM
REAR
"H"
EMBLEM
APPLICATION FRONT SIDE
20-103
Exterior Trim
A-pillar Exterior Trim Replacement
NOTE:
.
Keep dust away from the worki ng area.
.
When worki ng at l ower temperatures, heat the body and tri m wi th a hai r dryer.
Body: about 59' F
(
15"C)
Tri m: about 86"F
(30' C)
.
When heati ng the tri m, heat i t evenl y and gradual l y to prevent deformati on,
.
Cl ean the body bondi ng surface wi th a sponge dampened i n al cohol .
.
After cl eani ng. keep oi l ,
grease and water from getti ng on the surface.
1. Remove these i tems, then
peel up the ol d tri m whi l e heati ng i t wi th a hai r dryer.
.
A-pi l l ar-header weatherstri p
(see page
20-51)
.
A-pi l l ar mol di ng, both si des
(see page 20-51)
2. Appl y the tri m i n the numbered sequence, and note these i tems:
.
Al i gn the appl i cati on tape wi th the A-pi l l ar as shown.
.
When pressi ng the tri m, sl owl y
press i t from the corner to
prevent ai r bubbl es and wri nkl es.
. l f t her ear eai r bubbl esi nt het r i m, peel
up t he t r i m, t hen r eappl y i t .
.
After rei nstal l i ng al l removed
parts, checkthatthe body col or i s covered bythetri m.
ALI GNMENTMARK OWI NDSHI ELDHEADER
ALI GNMENTMARKS
EXTERIOR TRIM Al i gn t hem wi t h t he end of t he
wi ndshi el d header ext er i or t r i m.
A.PILLAR TRIM
ALIGNMENT NOTCH
{Body f l ange)
WI NDSHI ELD
MOLDI NG
WINDSHIELO HEADER
EXTERIOR TRIM
Al i gn t he appl i cat i on t ape
wi t h t he A- pi l l ar .
@) A.PILLAR TRIM
20-104
Fenderwell
a
Inner Fender Repl acement
1. Remove the front wheel .
2. Remove t he i nner f ender as shown.
3. I nst al l t he i nner f ender i n t he r ever se or der of r emoval , and r epl ace any damaged cl i ps.
D
r Clip,
x
"#
Fastener Locations
A>: Bol t , 5 B) : Sc r ew. 2 C
{rl}rF
(
} ltr>
'-t-/
\-/
FRONT BUMPER
FRONT UNDEB
COVER
FRONT SPLASH
SHI ELD
INNER FENDER
6 x 1 . 0 mm
9 . 8 Nm( 1 . 0 k g l . m,
7.2 tbl.ttl
I
nc .
u :
c
/"f
i;'t{
I , i
49 A
. i :
C l
a
20-105
Fenderwell
Strakes Replacement
1. Remove the strakes as shown.
2. l nstal l the strakes i n the reverse order of removal
Fastener Locations
A>: Bol t , 2 B>: Bol t , 4 C>: Sc r ew. 3
F
A
I
6 x 1 . 0 mm
9. 8 N. m
(1. 0
7.2 rbf.ftl
FRONT BUMPER
INNER
FENDER
REAR
STRAKE A
...6.
,
I
FRONT STRAKE
20-106
I
Fenderwell Trim Replacement
NOTE:The steel core i n the fenderwel l tri m cannot be
restored to i t ori gi nal shape once i t i s bent. Repl ace the
fenderwel l tri m when the steel core i s bent.
1. Remove the fenderwel l tri m by pul l i ng i t out.
2. Instal l the fenderwel l tri m, and note these i tems:
.
Cl ean the body bondi ng surl ace wi th a sponge
dampened i n al cohol .
.
After cl eani ng, keep ei l , grease
and waterfrom
getti ng
on the cl ean surface.
.
Appl y cl ear seal ant i n the groove of the tri m at
the area i ndi cated by the arrow.
.
Scrape or wi pe the excess seal ant off wi th a soft
shop towel dampened i n al cohol .
Seal ant: Cemedi ne P/N 08712-0004, or equi val ent
a
Rear Air Outlet Replacement
.
Rear tri m panel (see page 20-73)
.
Rear bumper {see
page 20-93)
Remove the rear ai r outl et as shown.
I nst al l t he ai r out l et i n t he r ever se or der of r emoval ,
.
.
Fastener Locations
A>: Cl i p. 2
(1.r4
-
x
REAR AIR OUTLET
2.
?
20-107
Openers
.::._':
HOOD LATCH
TRUNK LI D
LOCK CYLINOER
Repl acement ,
page 20-1 13
TRUNK LID LATCH
FUEL FILL OOOR OPENER CABLE
Repl acement , page 20 1' 10
FUEL FILL DOOB OPENER
page 20-110
HOOD RELEASE HANOLE
Repl acement ,
page 20' 1 1 1
HOOD OPENER CABLE
20-108
Hood Opener Cable Replacement
NOTE:
.
Put on
gl oves
.
Take care not to scratch the body and rel ated parts.
.
Take care notto bend the cabl e.
.
Inner fender
(see page 20-105)
.
Ki ck panel (see page 20-69)
.
Front bumper
(see page 20-92)
.
Ai r gui de pl ate
2. Di sconnect t he hood opener cabl e
( A) f r omt he
hood l at ch
( 8)
andhoodr el easehandl e( C) ( seepage20- 111) .
Fastenor Locations
D>: Cl i p, 1 E
>:
Cl i p, 6
##)
'rl)
_ '
I
3.
4.
Usi ng a cl i p remover, detach the cl i ps
(D.
E) and remove the grommet
{F)
from the body, then remove the hood
opener cabl e. Take care not to bend the cabl e,
Instal l the cabl e i n the reverse order of removal . and note these i tems;
.
.
Route the cabl e through the hol e
(G)
i n the body.
20-109
Openers
Fuel Fill Door Opener Cable Replacement
NOTE:
.
Put on
gl oves to
protect your hands
.
Take care not to scratch the body and rel ated
parts
.
Take care not to bend the cabl e.
' 1.
.
Rear si de tri m
(see page 20-70)
.
Rear tray
(see page 20' 71)
.
Trunk si de tri m
panel , l eft si de
(see page 20-73)
2. Removethefuel fi l l door opener knob
(A)
from the fuel fi l l door opener bracket
(B)
byturni ng l t90' , and remove
the fuel fi l l door l atch
(C)from
the body i n the same way.
Fastener Location
E
>:
Cabl e cushi on,l
Remove the fuel fi l l door opener cabl e {D).
l nstal l the cabl e i n the reverse order of removal wi th a new cabl e cushi on
(E).
3.
4.
.\
' f l
-l vl
. ;-t
/
_
-::....
20-110
a
Hood Release Handle Replacement
NOTE: Take care not to bend the caore.
1. Remove the ki ck panel (see page 20-69).
2, Remove the hood rel ease handl e as shown,
3. Instal l the handl e i n the reverse order of removal ,
.
l Make surethe hood openercabl e i s connected
propefl y.
'
Make sure the hood opens properl y.
Fa3tenor Locations
A) : Bol t , 2
(JJ
@
HOOD OPENER CABLE
6 x 1 . 0 mm
9. 8 N. m {1. 0 kgf . m,
7.2 tbt.ttl
HOOD RELEASE HANDLE
Hood Latch Replacement
NOTE: Take care not to bend the cabl e.
Replacement
1. Remove the ai r gui de pl ate
cover, then remove the
hood l atch as shown.
2. l nstal l the l atch i n the reverse order of removal , and
note these ttems:
.
Appl y grease to the hood l atch.
.
Make sure the hood opener cabl e i s connected
propefl y.
.
Adj ustthe hood l atch al i gnment {see step 3 on
page 20-94).
.
Make sure the hood l ocks securel y.
Fastener Locations
A>: Bol t , 3 B>: Oi p, 3
@
5 x 1 . 0 mm
9. 8 N. m
{1. 0 kgt . m,
7.2 tbf.ttl
(cont' d)
20-111
Openers
Hood Latch Replacement
(cont'd)
Grease Application
1. Remove the l atch cover, and Appl y mul ti purpose
grease to each l ocati on of the hood l atch i ndi cated
by the arrows.
20-112
Trunk Lid Latch Replacement
NOTE:
'
Put on gl ovest o pr ot ect your hands.
.
Take care not to scratch the body
.
Take care not to bend the cyl i nder rod
' 1.
Remove t he t r unk l i d l at ch as shown.
' i ^
l nstal l the l atch i n the reverse order of removal , and
note these rtems:
.
N4ake sure the connector i s
pl ugged i n
properl y
and the opener cabl e i s connected
properl y.
.
Make sure the trunk l i d opens
properl y and l ocks
securel y.
Fastener Locations
)
: Bolt. 2
lnl f-:l
rnurux LtD LArcH
-l
--'
6 x 1 . 0 mm
9. 8 N. m
{ 1. 0 kgf m, 7. 2l bf f t }
t
A
' 01-03
model s shape
{Wi t h
handl e}
Trunk Lid Lock Cylinder Replacement
NOTE:
.
Take care notto scratch the body.
.
Take care notto bend the cyl i nder rod.
1. Remove t he t r unk l i d l ock cyl i nder as shown.
2. Instal l the cyl i nder i n the reverse order of removal ,
.
Make sure the cyl i nder rod i s connected properl y.
.
l \4ake sure the trunk l i d opens properl y.
Fastener Locations
A
>
: Bol t,2
,Sc.r{\
{UI ] E
] CYLINDER ROD
TRUNK LIO
LOCK CYLINDER
6 x 1 . 0 mm
9. 8 N. m {1. 0 kgf . m,
7.2 rbf.ft)
20-113
Frame
Front Subframe Replacement
After l ooseni ng the subframe mounti ng bol ts, be sure to repl ace them wi th new ones'
Reference holes alignment:
SUBFRAME
INSTALLATION
REFERENCE HOLE
{Subframe si de)
E t -
V A
/ 9 9
I /./
t//
x 1.25 mm
N.m {3.9
kgf.m,
tbt.ftl
10
38
2a
INSTALLATION
REFERENCE HOLE
I x 1.25 mm
22N.m l2.2kgl..n,
16 rbf.ftl
LEFT GUSSET
8 x 1.25 mm
22N.m 12.2kgl.m,
16 rbf.ftl
To body.
- To bodv.
t o oooy.
RIGHT GUSSET
12 x 1,25 m.n
59 N.m
(6.0 ksf.m,
43 tbf.ftl
Repl ace.
10 x 1. 25 mm
38 N. m
(3. 9
kgf m,
28 tbt.ftl
10 x L25 mm
38 N. m 13. 9 kgf . m,
28 tbf.ftt
1i l x 1. 5 mm
116 N. m
{11. 8 kgf . m,
85.3 tbt.ftt
Repl ace.
- Y
.:1
'..
ia..
1+.lr
-,'
__
-:
\.\
20-114
Rear Subframe Replacement
After l ooseni ng the subframe mounti ng bol ts, be sure to repl ace them wi th new ones.
Reference holes alignment:
SUBFRAME
(Body
si de)
SCREWORIVER or
TAPERED PUNCH
INSTALLATION
REFERENCE HOLE
REAR SUBFRAME
INSTALLATION
REFERENCE HOLE
To body.
- / , _\ \ , t t ,
L , t - - 7 - - J
) i A
t \ of i ) a
} V f l
?
o
S
I t
e ) l
- $ * \
/
\ i
B tr) ,.ru ,,'.
]1
59 N.m
(6.0
ksf.m,,|:} tbf.ftt
I
Rept ace.
14 x 1. 5 mm
lg?rT;T
{10 5 ksr'm' 76 rbr'ft1
REAR SUSPENSION
STI FFENER
10 x 1. 25 mm
45 N. m (, 1. 6
k91. m, 33l bt . f t )
To body.
20-115
Frame
Frame Repair Chart
Top View
Uni t rmm
(i n. )
d: lnner diameter
CE IER
ut{E
POI NT
a
b
o
t
s
For bumper beam 010 {0. 4)
For tie down s23 x 30
(0.9
x 1 21
For stabilizer d24 {0.91
For stabilizer d24 {0.9}
For upper arm al3
(0.5)
Damper center
For subt rame o17
(0. 7)
POINT
h For upper arm 613 {0. 5)
i For subf rame s17 10. 7)
j For subframe 617 {0.7)
k Locate hole o25
(1.01
I Fort ransmi ssi on mount bracket d13 l 0 5l
m For transmission mount bracket o13
(0.5)
n For transmission mount brackst 613 {0.5)
VEFTNAL
LINE
12.11
20-116
POINT
o Locate hole o15 10.59)
p For rear subframe 11610.63l
q For rear subtrame 616 {0.631
r Rear dampe. cnter 650 12.01
s For rear subfr.rne 616 10.6i|l
t Locate hol6 r20 {0.81
(cont' d)
20-117
Frame
Frame Repair Chart {cont'd)
SideView
Uni t mm
(i n. )
o: l nner di amet er
POI NT
a For bumper beam o10 {0.41
b For tie down o23 x 30 {0.9
x 1 2)
c For stabilizer s24 10.9)
d For stabilizer s24 {0.91
e For upper ar m ol 3
( 0. 51
f Dampel centet
g For subt r ame 617
( 0. 71
POINT
h For upper ar m s13 { 0 51
i For subf r ame o17 { 0. 7)
i
For subframe s17 {0.7)
k Locat e hol e 625l l . 0)
I Fortransmission mount bracket 613
(0
5)
m For transmission mount btacket 613 {0 5)
n For transmission mount bracket t13 {0.5)
SECTION AA
SECTION BB
BASE
UltE
20-118
POINT
o Locate hole s15 10.59)
$
Cs\ rsar s\bhaNsd$\$S3\
q
For rear subframe 016 {0.631
r Rer damper centor ,50
(2.0)
s For rear Bublramo 116 lo.fill
t Locale hole s20 {0.8}
SECT|O

OO
20-119
a
HVAC
(Heating,
Ventilation,
and Ai r Condi ti oni ngl
Heati ng and Ai r Condi ti oni ng
Speci af Tool s . . . . . . . . . . . . . 21-2
Component Locat i on I ndex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21- 3
A, / C Servi ce Ti ps and Precaut i ons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-6
A"/ C Ref ri gerant Oi l Repl acement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2' l -6
General Troubl eshoot i ng I nf ormat i on . . . . . . . . . . . . . . . . . . . . . . . 21-8
DTC Troubl eshoot i ng I ndex . . . . . . . . . . . . . . 21-9
Ci rcui t Di agram . . . . . . . . . 21-14
Reci rcul at i on Cont rol Mot or Ci rcui t
Tr oubl eshoot i nS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21- 24
Heat er Cont rol Power and Ground Ci rcui t s
Tr oubl eshoot i nS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21- 25
Condenser Fan Ci rcui t Troubl eshoot i ng . . . . . . . . . . . . . . . . . . . . 21-27
Radi at or and Condenser Fans Common Ci rcui t
Troubf eshoot i nS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-28
Compressor Cl ut ch Ci rcui t Troubl eshoot i ng . . . . . . . . . . . . . 21-29
Ay' C Pressure Swi t ch Ci rcui t Troubl eshoot i ng . . . . . . . . . . . 21-31
Ai r Mi x Cont rol Mot or Test and Repl acement . . . . . . . . . . . 21-33
Mode Cont rol Mot or Test and Reol acement . . . . . . . . . . . . . . 21-34
Reci rcul at i on Cont rol Mot or Test and
Repl acement . . . . . . . . . 21- 35
Evaporat orTemperat ure SensorTest . . . . . . . . . . . . . . . . . . . . . . . . 21-36
Power Transi st or Test . . . . . . . . . . . . . . . . . . . . . . . . 21-36
Heat er Cont rol Panel Removal and I nst al l at i on . . . . . . . . . 2' l -37
Bl ower/ Evaporat or Uni t Removal and I nst al l at i on . . . . 21-38
Bl ower/ Evaporat or Uni t Component s
Repl acement . . . . . . . . . 21- 39
*
Heat er Uni VCore Reol acement . . . . . . . . . 21-40
Dust and Pol l en Fi l t er Repl acement . . 21-42
Heat er Val ve Cabl e Adj ust ment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-43
Compressor Repl acement . . . . . . . . , . . . , . , , , 21-44
Compressor Cl ut ch Check . . . . . . . . . . . . . . . . . 21-46
Compressor Cl ut ch Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-47
CompressorThermal Prot ect orRepl acement . . . . . . . . . . . 21-49
Compressor Rel i ef Val ve Repl acement . . . . . . . . . . . . . . . . . . . . . . 21-49
Condenser Reol acement . . . . . . . . . . . . . . . . . . . 21- 50
Ref ri gerant Recovery . . . . . . . . . . . . . . . . . . . . . . . . . 21-51
Syst em Evacuat i on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-52
Syst em Chargi nS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-53
Ref ri gerant Leak Test s . . . . . . . . . . . . . . . . . . . . . . . 21-54
f uc syst em Test s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-55
Blower/Evaporator Unit Components Replacement
Note these i tems when overhaul i ng the bl ower/evaporator uni t:
.
The reci rcul ati on control motor
(A),
the powertransi stor (B),
and the bl ower motor
(C)can
be repl aced wi thout
removi ng the bl ower/evaporator uni t.
. l f you' r ei nst al l i nganewevapor at or cor e( D) , addr ef r i ger ant oi l ( KEI HI N
SP- 10)
( seepage2l - 6) .
.
l f necessarV, removethe expansi on val ve
(E).
.
Repl ace t he O- r i ngs wi t h newones at eachf i t t i ng and appl yat hi n coat of r ef r i ger ant oi l bef or e i nst al l i ng t hem.
Be sure to use the correct O-ri ngs for HFC-134a {R-134a) to avoi d l eakage.
.
l mmedi atel y after usi ng the oi l . rei nstal l the cap on the contai ner, and seal i t to avoi d moi stu re absorpti on.
.
Rei nstal l the eva
porator
tem
peratu re senso r
(F)
i n i ts ori gi nal l ocati on.
.
Before reassembl y, make surethatthe reci rcul ati on control l i nkage and doors move smoothl y.
.
After reassembl y, makesurethe reci rcul ati on control motor runs smoothl y
(see page
21-35).
.
Make sure no ai r i s l eaki ng from the upper housi ng {G) and the l ower housi ng
(H)
fi tti ng.
21-39
Heater Unit/Core Replacement
SRS comoonents are l ocated i n thi s area. Revi ew the
SRS component l ocati ons, precauti ons, and procedures
(see page 23-10).
1. Make sure
Dreset buttons.
2. Di sconnectthe negati ve cabl e from the battery.
3. Remove the heat shi el d of the exhaust mani fol d
(see
step 16 on page 6-27l,.
4. From under the hood, open the cabl e cl amp
(A),
then di sconnect the heater val ve cabl e
(B)
from the
heater val ve arm
(C).
Turn the heater val ve arm to
the ful l y opened posi ti on as shown.
5. When the engi ne i s cool , drai n the engi ne cool ant
from the radi ator
(see page 10-8).
21-40
7.
Remove the mounti ng bol t from the heater val ve.
Sl i de the hose cl amps
(A)
back, then di sconnect the
i nl et heater hose
(B)
and the outl et heater hose {C)
from the heater uni t. Engi ne cool ant wi l l run out
when the hoses are di sconnected; drai n i t i nto a
cl ean dri p
pan. Be sure not to l et cool ant spi l l on
the el ectri cal
pans or the pai nted surfaces. l f any
cool ant spi l l s, ri nse i t off i mmedi atel y.
Remove the mounti ng nut from the heater uni t.
Take care not to damage or bend the fuel l i nes, the
brake l i nes, etc.
8 x
' 1. 25
mm
13 N. m
( 1. 3
ksf . m, 9. 4l bl f t )
j.'
..:,
' ...aa' :'
6 x 1 . 0 mm
9.8 N.m
{1.0 kgt.m,
7 .2 tbt.ttl
8. Remove the dashboard {see
page 20-82).
9. Remove the bl ower/evaporator uni t
( see page 21- 38) .
10. Remove the mounti ng bol ts, the center brackets
(A),
and the audi o brackets
(B).
8 x 1,25 mm
22 N.m 12.2 kgf.m, 16l bt ft)
l -
6 x 1 , 0 mm
9. 8 N. m
(1. 0
kgf . m, 7. 2 l bf . f t l
8 x 1.25 mm
2 2 Nm
{2.2 kgf.m, 16 l bf.ft}
Remove the SRS uni t {see
page 23' 75),
Remove the sel f-tappi ng screws and the defroster
outl et
(A),
then remove the wi re harness cl i ps
(Bi .
1 1 .
12.
Di sconnect the connectors
(A)
from the mode
control motor and the ai r mi x control motor, then
remove the wi re harness cl i p {B).
Remove the
mounti ng nuts, the mounti ng bol t, and the heater
uni t
( C) .
6 x 1 . 0 mm
9. 8 N. m
{1. 0 kgf . m,
7.2 tbf.lrl
6 x 1 . 0 mm
9 . 8 N m
11. 0 ksf . m, 7. 2l bf . f t l
/
\
4. Remove the sel f-tappi ng screw and the passenger' s
heater outl et
(A),
then remove the sel f-tappi ng
screw and the cl amp
(B).
Be careful not to bend the
i nl et and outl et pi pes duri ng the heater core
(C)
removal , and oul l out the heater core.
B---_
t
___|.+
(cont' d)
rK
M-
21-41
Heating and Air Conditioning
Heater Unit/Core Replacement
(cont'dl
15. Instal l the heater core i n the reverse order of
removal .
' 16.
l nstal l the heater uni t i n the reverse order of
.
Do not i nterchange the i nl et and outl et heater
hoses, and i nstal l the hose cl amps securel y.
.
Refi l l the cool i ng system wi th engi ne cool ant
(see
page
10-8).
.
Adj ust the heater val ve cabl e
(see page 21-43).
.
Make sure that there i s no cool ant l eakage.
.
Make sure that there i s no ai r l eakage.
.
For evaporator and Ay' C-rel ated i nformati on, refer
to bl ower /evaporator uni t removal and
i nstal l ati on
(see page 21-38).
.
Do the ECM i dl e l earn procedure
{ see
page 11- 100) .
.
.
For' 01-03 model s, reset the cl ock.
21-42
4. l nstal l the fi l ter i n the reverse order of removal
Dust and Pollen Filter Replacement
The dust and
pol l en fi l ter shoul d be repl aced every
30,000 mi l es under normal condi ti ons, or every 15,000
mi l es under extremel y dusty or sooty condi ti ons.
Reol ace the fi l ter more often i f the ai r fl ow i s l ess than
usua L
1. Open t he hood.
2. Remove the cl i ps
(Al and
the hood seal
(B).
Li ftthe
ri ght si de of the cowl cover
(C)
up, and remove the
dust and
pol l en
fi l ter
(D)
as shown. Be careful not to
damage the hood seal when removi ng the cl i ps.
C B
Remove the fi l ter
(A)from
the housi ng
(B).
Repl ace
the fi l ter.
Heater Valve Cable Adjustment
1 . From under the hood, open the cabl e cl amp
(A),
then di sconnect the heater val ve cabl e
(B)
from the
heater val ve arm
(C).
From under the dash, di sconnect the heater val ve
cabl e housi ng f r om t he cabl e cl amp
( A) ,
and
di sconnect the heater val ve cabl e
(B)
from the ai r
mi x cont r ol l i nkage { C) .
4.
Set the temperature control di al on Max Cool wi th
t he i gni t i on swi t ch ON
( l l ) .
Attach the heater val ve cabl e {B) to the ai r mi x
control l i nkage
(C)
as shown above. Hol d rhe end
of the heater val ve cabl e housi ng agai nst the stop
( D) ,
t hen snap t he heat er val ve cabl e housi ng i nt o
t he cabl e cl amp
( A) .
From under the hood, turn the heater val ve arm
(C)
to the ful l y cl osed
posi ti on
as shown, and hol d i t.
Attach the heater val ve cabl e
(B)
to the heater val ve
arm. and gentl y pul l on the heater val ve cabl e
housi ng to take up any sl ack, then i nstal l the heater
val ve cabl e housi ng i nto the cabl e cl amp {A).
21-43
Compressor Replacement
1. l f the compressor i s margi nal l y operabl e. run the
engi ne at i dl e speed, and l et the ai r condi ti oni ng
work for a l ew mi nutes, then shut the engi ne off.
2. Make sure
preset buttons.
3. Di sconnect the negati ve cabl e from the battery.
4. Recover the refri gerant wi th a recovery/recycl i ng/
chargi ng stati on
(see page 21-511.
5. Remove the ai r cl eaner housi ng
(see
step 5 on
page
6-25).
6. Remove the alternator
(see page 4-26).
7. Remove the nuts, then di sconnect the sucti on l i ne
(A)
and the di scharge l i ne
(B)from
the compressor.
PIug or cap the l i nes i mmedi atel y after
di sconnecti ng them to avoi d moi sture and dust
contami nati on.
x 1. 0 mm
9. 8 N. m
(1. 0
kgf . m,
7.2 tbl.ltl
21-44
8, Di sconnect the compressor cl utch connector, then
remove the mounti ng bol ts and the compressor.
10 x 1.25 mm
il4
N.m
(4.5
kgt m,
33 rbf.ftt
9. l f necessary. remove the mounti ng bol ts and the
compressor bracket,
8 x 1. 25 mm
22 N. m
12.2 kgl.m,
16 tbf.ft)
\
10. l nst al l t he comDr essor i n t he r ever se or der of
.
l f you' re i nstal l i ng a newcompressor, you must
cal cul ate the amount of refri gerant oi l to be
removed from i t
(see page 21-6).
.
Repl ace the O-ri ngs wi th new ones at each fi tti ng,
and appl y a thi n coat of refri gerant oi l before
i nstal l i ng them. Be sure to use the correct O-ri ngs
f or HFC 134a
( R- 134a) t o
avoi d l eakage.
.
Use r ef r i ger ant oi l
( KEl Hl N
SP- 10) f or HFC- 134a
KEIHIN spi ral type compressor onl y.
.
To avoi d contami nati on, do not return the oi l to
the contai ner once di spensed, and never mi x i t
wi th other refri gerant oi l s.
.
l mmedi at el y af t er usi ng t he oi l , r ei nst al l t he cap
on the contai ner, and seal i t to avoi d moi sture
aosorpl ron.
.
Do not spi l l t he r ef r i ger ant oi l ont hevehi cl e; i t
may damage the pai nt. l f the refri gerant oi l
contacts the
pai nt,
wash i t off i mmedi atel y.
.
Charge the system {see
page 21-53).
.
Do the ECM i dl e l earn procedure
( see page 11- 100) .
.
the customer' s radi o stati on
presets.
.
For
' 01-03
model s. reset the crocK.
21-45
Compressor Clutch Check
1 . Check the armature pl ate for di scol orati on,
peel i ng,
or other damage. l f there i s damage, repl ace the
cl utch set
(see page 21-47).
Check the rotor pul l ey beari ng pl ay and drag by
rotati ng the rotor pul l ey
by hand. Repl ace the
cl utch set wi th a new one i f i t i s noi sy or has
excessi ve
pl ay/drag
{see
page
21-47).
Measure the cl earance between the rotor
pul l eV (A)
and the armature pl ate
{B)
al l the way around. l f the
cl earance i s not wi thi n speci fi ed l i mi ts, remove the
armature
pl ate (see page 21-47) and add or remove
shi ms as needed to i ncrease or decrease cl earance.
Cl earance: 0.5+0.15 mm {0.02040.006 i n.)
NOTE: The shi ms are avai l abl e i n four thi cknesses:
0. 1 mm, 0. 2 mm. 0. 4 mm, and 0. 5 mm.
21-46
4. Rel ease the fi el d coi l con nector f rom the ho l der,
then di sconnect i t. Check the thermal
protector
for
conti nui ty. l f there i s no conti nui ty, repl ace the
thermal
protector (see page 21-49).
NOTE: The thermal protector wi l l have no
conti nui ty above 252to262F 1122 to 128"C). When
the temperature drops bel ow 241 to 219' F
(' 116
to
104' C), the thermal
protector wi l l have conti nui ty.
Check resi stance of the fi el d coi l . l f resi stance i s not
wi thi n speci fi cati ons, repl ace the coi l
(see page 21-47).
Field Coil Resistance: 3.05 3.35 ohms at
68"F {20' C)
'it
t
Compressor Clutch Overhaul
Special Tool Required
A,/C cl utch hol der, Robi nai r
' 10204,
Kent-Moore J37872,
or Honda Tool and Equi pment KMT-J33939,
1. Remove the center nut
(A)
armature pl ate wi th a commerci al l y avai l abl e A,/C
cl utch hol der
(B).
' 17. 5
N. m 11. 8 kgf . m,
13 rbf.ftl
Remove the armature pl ate (A)
and shi m(s) {B),
taki ng care not to l ose the shi m(s). l f the cl utch
needs adj ustment, i ncrease or decrease the
number and thi ckness of shi ms as nesessary, then
rei nstal l the armature pl ate, and recheck i ts
cl earance
(see page
21-46).
NOTE: The shi ms are avai l abl e i n four thi ckness:
0. 1 mm, 0. 2 mm, 0. 4 mm, and 0. 5 mm.
3, l f you are repl aci ng the fi el d coi l , remove the snap
ri ng {A) wi th snap ri ng pl i ers,
then remove the rotor
pul l ey (B).
Be careful not to damage the
pul l ey
and
compressor.
Remove the bol t and hol der
(A),
then di sconnect
the fi el d coi l connector
(B).
Loosen the cl amp screw
(C)
to free the fi el d coi l wi re. Remove the snap ri ng
( D)
wi t h snap r i ng pl i er s, t hen r emove t he f i el d coi l
(E).
Be careful not to damage the fi el d coi l and
comDressor.
.-__-.\-)
-g
@
ffi
e--.--=-o
{0. 75 kgf . m, 5 l bf . f t )
(cont' d)
7. 4 N. m
21-47
(
Compressor Clutch Overhaul
(cont'd)
5. Reassembl e the cl utch i n the reverse order of
di sassembl y, and note these i tems:
' l nst al l
t he f i el d coi l wi t h t he wi r e si de f aci ng
down, and al i gn the boss on the fi el d coi l wi th the
hol e i n the compressor.
.
Cl ean t he r ot or pul l ey
and compr essor sl i di ng
surfaces wi th contact cl eaner or other
non-petrol eum sol vent.
. I nst al l
new snap r i ngs, not e t he i nst al l at i on
di recti on, and make sure they are ful l y seated i n
the
groove.
.
Make sure that the rotor
pul l ey
tu rns smoothl y
after i t' s reassembl ed.
.
Rout e and cl amp t he wi r es pr oper l y
or t hey can
be damaged by the rotor pul l ey.
21-48
Compressor Thermal Protector
Replacement
1. Remove t he bol t , t he gr ound t er mi nal { A) , andt he
hol der
(B).
Di sconnect the fi el d coi l connector
(C),
then remove the thermal protector (D).
7. 4 N. m
(0. 75
kgf . m, 5 l bf . f t l
2.
3.
A
Instal l the thermal protector i n the reverse order of
r emoval .
Compressor Relief Valve
Repl acement
' 1.
3.
Recover the refri gerant wi th a recove ryl recycl i ng/
char gi ng st at i on
( see page 21 51) .
Remove t he r el i ef val ve i A) , and t he O- r i ng
( B) .
Pl ug
the openi ng to keep forei gn matter from enteri ng
t he syst em and t he compr essor oi l f r om r unni ng
out .
Cl ean the mati ng surfaces.
Repl ace the O-ri ng wi th a new one at the rel i ef
val ve, and appl y a thi n coat of refri gerant oi l before
i nst al l i ng i t .
Remove the
pl ug,
and i nstal l and ti ghten the rel i ef
val ve.
Char ge t he syst em
( see page 21- 53) .
9. 8 N. m
(1. 0 kgf . m,
21-49
Condenser Replacement
1 .
3.
Recover the refri gerant wi th a recovery/recycl i ng/
char gi ng st at i on
( see page 21- 51) .
Remove t he ai r cl eaner housi ng
( see
st ep 5 on
page
6-25).
Remove the bol ts, then remove the upper mount
brackets from the radi ator.
6 x 1 . 0 mm
9, 8 N. m {1. 0
kgf . m. 7. 2 l bt . f t )
Remove the bol ts. then di sconnect the di scharge
l i ne
( A)
and t he condenser l i ne
( B)
f r om t he
condenser. Pl ug or cap the l i nes i mmedi atel y after
di sconnecti ng them to avoi d moi sture and dust
conr amt naI | on.
, - a.
6 x 1 . 0 mm
9. 8 N. m
(1. 0
kgf . m,
7.2 tbl.ttl
6 x 1 . 0 mm
9. 8 N. m {1. 0 kgf . m, 7. 2 l bt . f t )
4.
21-50
5. Remove the bol ts and the upper mount brackets
(A),
then remove the condense.
(B)
by l i fti ng i t up. Be
careful not to damage the radi ator or the condenser
fi ns when removi ng the condenser.
s-------\
i B \
6 x 1 . 0 mm
9.8 N.m {1.0 kgt.m, 7.2l bf.ftl
Instal l the condensor i n the reverse order of
removal . and note these i tems:
.
l f you' re i nstal l i ng a new condenser, add
r ef r i ger ant oi l
( KEl Hl N
SP- 10)
( see page 2' 1- 6) .
.
Repl ace the O-ri ngs wi th new ones at each fi tti ng,
and appl y a thi n coat of refri gerant oi l before
i nstal l i ng them. Be sure to use the correct O-ri ngs
f or HFC- 134a
( R- 134a) t o
avoi d l eakage.
.
l mmedi atel y after usi ng the oi l , rei nstal l the cap
on the contai ner, and seal i t to avoi d moi sl ure
absorDti on,
.
Do not spi l l the refri gerant oi l on the vehi cl e; i t
may damage the
pai nt. l f the refri gerant oi l
contacts the
pai nt, wash i t off i mmedi atel y.
.
Be careful not to damage the radi ator or the
condenser fi ns when i nstal l i ng the condenser.
.
Charge the system {see
page 21-53).
Refrigerant Recovery
Ai r condi ti oni ng refri gerant or l ubri cant vapor
can i rri tate your eyes, nose, or throat.
Be careful when connecti ng servi ce equi pment.
Do not breathe refri gerant or vapot.
Use onl y servi ce equi pment that i s U.L.-l i sted and i s
certi fi ed to meet the requi rements of SAE J2210 to
r emove HFC- 134a
( R- 134a) f r om
t he ai r condi t i oni ng
sysrem.
l f acci dental system di scharge occurs, venti l ate the
work area before resumi ng servi ce
Addi ti onal heal th and safety i nformati on may be
obtai ned from the refri gerant and l ubri cant
manufacturers.
r.1i.,.',,,-':ir-- =,,'-
I
"l
i-.-':l::
.
1. Connect a R-134a refri gerant recovery/recycl i ng/
chargi ng stati on
(A)
to the hi gh' pressure servi ce
port (B)
and the Iow-pressure servi ce port (C) (see
page 2' 1- 3) , as shown. f ol l owi ng t he equi pment
manufacturer' s i nstructi ons.
Measure the amount of refri gerant oi l removed
from the A,/C system after the recovery process i s
compl eted. Be sure to put the same amount of new
refri gerant oi l back i nto the A,/C system before
cnar gr ng.
21-51
(
(
System Evacuation
Use onl y ser vi ce equi pment t hat i s U. L. - l i st ed and i s
r emove HFC- 134a
( R- 134a)
f r om t he ai r condi t i oni ng
system.
l f acci dental system di scharge occurs. venti l ate the
work area before resumi ng servi ce
manufacturers.
1. When an 4!/C system has been opened to the
atmosphere, such as duri ng i nstal l ati on or repai r, i t
must be evacuated usi ng a R-]34a refri gerant
recovery/recycl i ng/chargi ng stati on
(l f
the system
has been open for several days, the recei ver/dryer
shoul d be repl aced, and the system shoul d be
evacuated for severai hours.
)
.
can i rri tate
your
eyes, nose, or throat.
'
'
Do not breathe refri gerant or vapor.
21-52
2. Connect a R-134a refri gerant recovery/recycl i ng/
chargi ng stati on
(A)
to the hi gh-pressure servi ce
port (B)
and the l ow-pressure servi ce
port
{C)
(see
page 2l -3), as shown, fol l owi ng the equi pment
manufacturer' s i nstructi ons. Evacuate the svstem.
l f the l ow-Dressure does not reach more than 93.3
kPa
(700
mm Hg, 27.6 i n.Hg) i n 15 mi nutes, there i s
probabl y
a l eak i n the system. Parti al l y charge the
system, and check for l eaks
(see
step 3 on
page
21-
541.
,t:itt
.t,
l = = -
==;
i
i|]ll
Y
System Charging
ceni fi ed to meet the requi rements of S AE J2210l o
remove HFC-134a
(R-134a)
from the ai r condi ti oni ng
system.
work area bel ore resumi ng servi ce.
manufactu rers.
1. Connect a R-' 134a refri gerant recovery/recycl i ng/
chargi ng stati on
(A)
port (B)
and the l ow-pressure servi ce port (C)
{see
page 21-3), as shown, fol l owi ng the equi pment
manuf acturer' s i nstructi ons.
at
.
can i rri tate your eyes, nose. or throat.
'
.
I
1,7 ,,_,,
.,, -
,..
I
i =--' -' ==' -'
l
i ' r ; ; l
l ,
i l
lt ,.
itLillt
il
t
21-53
2. Evacuate the system
(see page
21-52).
3. Add the same amount of new refri gerant oi l to the
system that was removed duri ng recovery. Use
onl y KEIHIN SP-10 refri gerant oi l .
4. Charge the system wi th the speci fi ed amount of
R-134a refri gerant. Do not overcharge the system;
the compressor wi l l be damaged.
Sel ect the appropri ate uni ts of measure for you r
ref ri gerant chargi ng stati on.
Refrigerant capacity:
550 to 600
g
0.55 to 0.60 kg
1.2 to 1.3 l bs
19.4 to 21.2 oz
5. Check for refri gerant l eaks
(see page 21-54).
6. Check for system performance (see page 21-56).
Refrigerant Leak Test
Special Tool Required
Leak detector. Honda Tool and Equi pment YGK-H-10PM
certi i fi ed to meet the requi rements of SAE J2210 to
r emove HFC- 134a
( R- 134a)
f r om t he ai r condi t i oni ng
system.
wor k ar ea bef or e r esumi ng ser vi ce.
R- 134a ser vi ce equi pment or vehi cl e ai r condi t i oni ng
systems shoul d not be pressure tested or l eak tested
wi th compressed ai r.
manufacturers.
.
Compressed ai r mi xed wi th R-134a forms a
combusti bl e vapor.
.
The vapor can bur n or expl ode causi ng ser i ous
i nj ur y.
.
Never use compressed ai r to pressure test
R- 134a ser vi ce equi pment or vehi cl e ai r
condi t i oni ng syst em.
.
Ai r condi t i oni ng r ef r i ger ant or l ubr i cant vapor
can i rri tate your eyes, nose, or throat.
'
.
21-54
1. Connecta R-134a refri gerant recovery/recycl i ng/
chargi ng stati on
(A)
port (B)
port (C) (see
page 21-3), as shown, fol l owi ng the equi pment
manufacturer' s i nstructi ons.
4.
5.
Open the hi gh pressure val ve to charge the system
to the speci fi ed capaci ty, then cl ose the suppl y
val ve, and remove the chargi ng system coupl ers.
Sel ect the appropri ate uni ts of measure for your
ref ri gerant chargi ng stati on.
Befrigerant capacity:
550 to 600
g
0.55 to 0.60 kg
1. 2 t o 1. 3 l bs
19.4 to 21.2 oz
Check the system for l eaks usi ng a R-134a
refri gerant l eak detector wi th an accu racy of 14 g
(0.5
oz)
per year or better.
l f you fi nd l eaks that requi re the system to be
opened
(to
repai r or repl ace hoses, fi tti ngs, etc.),
recover the system.
After checki ng and repai ri ng l eaks, evacuate the
system.
A/C System Tests
Pressure Test
Test results Related svmDtoms Probabls causo Remedv
Di scharge (hi gh)
pressure
abnormal l y hi gh
At t er st opprng compressor,
pressure
drops t o about 196 kPa
(2. 0
kgt / cm' , 28 psi l qui ckl y, and t hen
f al l s oradual l v.
Ai r i n syst em Hecover, evacuat e
(see page 2l -51),
and recharge wi t h speci f i ed amount
(see page 21-53).
Reduced or no ai r f l ow t hrough
conoenser
Cl ogged condenser or
radi at or f i ns
Condenser or radi at or f an not
worki no orooerl v
Cl ean
Check vol t age and f an rpm.
Check f an di rect i on.
Li ne t o condenser i s excessi vel y hot . Hest ri ct ed t l ow of rel ri gerant i n Rest ri ct ed l i nes
l Jrscharge
pressure
abnormal l y l ow
Hi gh and l ow pressures
are
bal anced soon af t er st oppi ng
compressor. Low si de i s hi gher t han
normal .
Faul t y compressor di scharge
Faul t y compressor seal
Repl ace t he compressor.
Out l et of expansi on val ve i s not
f rost ed, l ow-pressure gauge
i ndi cat es vacuum.
Faul t y expansron val ve
Moi st ure i n syst em
.
Repl ace
.
Recover, evacuate, and rechatge
wi t h soeci f i ed amount .
Suctron {l ow)
pressure
abnormal l y l ow
Expansi on val ve i s not f rost ed, and
l ow-oressure l i ne i s not col d. Low,
oressure oauoe i ndi cat es vacuum.
Frozen expansron val ve
(Moi sture
i n system)
Faul t v exoansi on val ve
.
Recover, evacuat e, and recharge
wi t h speci f ; ed amount .
.
Reol ace
Di scharge t emperat ure i s l ow, and
t he ai r f l ow f rom vent s i s rest ri ct ed.
l _rozen evaporat or Run t he f an wi t h compressor of f ,
t hen check evaporat or t emperat ure
sensor.
Expansi on val ve i s f rost ed Cl oqqed expansi on val ve Cl ean or repl ace.
Recei ver/ dryer out l et i s cool , and
i nl et i s warm
(shoul d
be warm
du. i nq oDerat i on)-
Cl ogged recei vet dryer Fl epl ace
Suctron pressure
abnormal l y hi gh
Low-pressure hose and check
I oi nt
are cool er t han t he t emperat ure
around evaoorat or.
t xpansron val ve open t oo l ong Repai r or repl ace.
Sucti on pressure i s l owered when
condenser i s cool ed bv water.
Excessi ve ret ri gerant i n syst em Recover, evacuat e, and recharge
wi t h soeci f i ed amount .
Hi gh and l ow-pressure are
equal i zed as soon as t he
compressor i s st opped, and bot h
oauoes f l uct uat e whi l e runni no.
Faul t y gasket
Faul t y hi gh-pressure val ve
Forei gn pani cl e
st uck i n hi gh-
HePl ace t he compressor.
Suct i on and
di scharge
pressures
abnormal l v hi oh
Reduced ai r f l ow t hrough
condenser,
Cl ogged condenser or
radi at or f i ns
Condenser or radi at or f an not
worki no orooerl v
ul ean
Check vol t age and f an rpm.
Check f an di rect i on.
Suct i on ancl
di scharge
pressure
abnormal l y l ow
Low-pressure hose and met al end
areas are cool er t han evaporat of .
Cl ogged or ki nked l ow-pressure
nose oans
Bepai r or repl ace.
Temperat ure around expansi on
val ve i s t oo l ow compared wi t h t hat
around recei ver/ rl rver
Cl ogged hi gh-pressure l i ne Heparr or repl ace.
Ref ri gerant l eaks ComDressor ci ut ch i s d i rt v. Compressor shaf t seal l eaki nq ReDl ace t he comDressor.
Compressor bol t (s) are di rt y. Leaki ng around bol t (s) I rght en bol t (s) or repl ace
comoressor.
ComDressor oasket i s wet wi t h oi l - Gasket l eaki nq Repl ace t he compressor.
{
{
a
A/C System Tests
(cont'dl
Performance Test
can i rri tate vour
eyes, nose, or throat.
Be car ef ul when connect i ng ser vi ce equi pment .
The performance test wi l l hel p determi ne i f the ai r
condi ti oner system i s operati ng wi thi n speci fi cati ons.
Use onl y ser vi ce equi pment t hat i s U. L. - l i st ed and i s
r emove HFC 134a
( R- 134a) f r om
t he ai r condi t i oni ng
system.
work area before resumi ng servi ce.
R- ' 134a ser vi ce equi pment or vehi cl e ai r condi t i oni ng
systems shoul d not be pressure tested or l eak tested
wi th compressed ai r.
manufacturers.
1. Connect a R 134a refri gerant recovery/recycl i ng/
chargi ng stati on to the hi gh-pressure servi ce port
port, fol l owi ng the
equi pment manuf act ur er ' s i nst r uct i ons.
2. Det er mi ne t he r el at i ve humi di t y and ai r
l em
peral Ure.
Compressed ai r mi xed wi th R-134a forms a
combusti bl e vapor.
The vapor can bur n or expl ode causi ng ser i ous
i nj ur y.
Never use compressed aar to pressure test
R- 134a ser vi ce equi pment or vehi cl e ai r
condi ti oni ng systems.
21-56
3.
4.
Remove the
passenger' s dashboard l ower cover
(see page 20-81).
l nsert a thermometer
(A)
i n the center vent, and
pl ace another thermometer {B)
near the bl ower uni t.
Test condi ti ons:
.
Avoi d di rect sunl i ght,
putthe top up.
.
Open the hood.
.
Open the front doors.
.
Set the temperature control di al on Max Cool , the
mode control di al on Vent, and the reci rcul ati on
control swi tch on Reci rcul ate.
.
Turn the A,/C swi tch on and the fan swi tch on Max.
.
Run t he engi ne at 1, 500 r pm.
.
No dri ver or passengers i n vehi cl e.
Af t er r unni ng t he ai r condi t i oni ng f or 10 mi nut es
under the above test condi ti ons, read the del i very
temperature from the thermometer i n the center
vent, the i ntake temperature near the bl ower uni t,
and the hi gh and l ow system
pressure from the A,/C
gauges.
5.
7. To compl ete the charts:
.
Markthe del i ve ry tem peratu re al ong the verti cal l i ne.
.
Mark the i ntake temperature
(ambi ent
ai r temperal ure) al ong the bottom l i ne.
.
Draw a l i ne strai ght up from the ai r temperature to the humi di ty.
.
Mar k a poi nt 10 % above and 10 % bel owt he humi di t y l evel .
.
From each poi nt,
draw a hori zontal l i ne across the del i very temperature.
.
The del i very temperature shoul d fal l between the two l i nes.
.
Compl ete the l ow-si de pressure
test and hi gh-si de pressure test i n the same way.
.
Any measurements outsi de the l i ne may i ndi cate the need for further i nspecti on.
(!rrl!m')
2900
-l
(301
|
ta3ol I
2500
{25)
t3601
980
n0l
{ t r ol
'190
ls) -
1 1 1
HUMIDITY
LEVEL
HUMIDITY
LEVEL
2000
t20l
I 2Bol
1500
(rs)
12101
(lpl/!m' )
t?,r
DELI VERY
fc)
86
t30)
400
Irl ,
l 57l
HUMIOIIY
IEVEL
OELIVERY
PRESSURE
300
( 31
l13l
200
\ 21
l2al
INTAKE
PRESSURE
95
{ 351
t0o
fii
INTAKE
PRESSURE
86
(30)
11
( 251
68
t20)
(40)
fc)
21-57
I
Body Electrical
Body El ectri cal
Gener al Tr oubi eshoot i ng
I nf or mat i on
Rel av and Control
Uri i t Locati ons ........
Connectors and
Harnesses
Fuse/Rel av Boxes .......
Power Di si ri buti on .....
Ground Di stri buti on ..
8at t er v . . . . . . . . . . . . . . . . . . . . . . . . .
Rel avs' . . . . . . . . . . . . . . . . . . . . . . . . . .
*l gni ti on
Swi tch
Test . . . . . . . . . . - . . . . . . . . . . . . . . . . . . . . . . . - . . . - . .
*Gauges
Comoonent Locat i on I ndex . . . . . . . .
Gauge Bul b Repl acement . . . .
Ci rcui t Di agram
Gauge Assembl y
*Audi o
System
Component Locat i on I ndex . . . . . . . . 22-A7
Ci rcui t Di agram . . . . . . . . . . . . . . . . . . . . . 22' 88
Audi o Uni t Removal . . . . . . . . . . . . . 22 89
Audi o Uni t Connect or
Rep1acement . . . . . . . . . . . . . . . . . . . . . . 22-eg
Radi o Remot e Swi t chTest . . . 22-90
SpeakerRepl acement . . . . . . . . . . 22-91
Mast Ant enna
Rep1acement . . . . . . . . . . . . . . . . . . . . . . 22. 92
Accessory Power Socket
Componen! Location Index ........ 22-93
Ci rcui t Di agram . . . . . . . . . . . . . . . . . . . . . 22-94
TesVHepl acement . . . . . . . . . . . . . 22 95
Horn
Ci rcui t Di agram
HornTest . . . . . . . . . . -. . . . . . . . -. . . . . . . . . . .
Switch Test
Trunk Opener
Component Locat i on I ndex . . -. -. , .
Ci rcui t Di agram
Trunk Opener Switch Test ...
Trunk Opener Sol enoi d
Test . . . . . . -. -. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Mirrors
Component Locat i on I ndex . . . -. . . .
Ci rcui t Di agram
Function Test
Power Mi rror Swi t ch Test . . . .
Power Mi rror Act uat or
Test -. . . . . . . . -. . . . . . . -. , . . . , . , . . , , , . , . , . ,
Power Mirror Actuator
Repl acement
Wiper/Washer
Ci rcui t Di agram
Intermittent Wiper Control
Ci rcui t 1nput Test . . . . . . . . . . . . . . .
Wiper,A/Vasher Switch
TesVRepl acement . . . . . . . . . . . . .
Wi perMot orTest -. . . . . . -. . . . . . . . -.
Washer Mot or Test . . . . . . . . . . . . . . .
Washer Reservoi r
Bepl acement
Wi ndshi el d Wi per Mot or
Repl acement
Keyless/Power Door Locks
Component Locat i on I ndex . . . . . . . . 22 130
Ci rcui t Di a9ram . . . . . . . . . . . . . . . . . . . . . 22-131
Keyless Door Lock Control
Uni t f nput Test . . . . . . . . . . . . . . . . . . . . . . 22-132
l gni t i on Key Swi t ch Test . . . . . . . 22-135
Driver's Door Lock Knob
Swi t chTest . . . . . . . . . . . . . . . . . . . . . . . . 22-136
Driver's Door Lock
Act uat orTest . . . . . . . . . . . . . . . . . . . . . 22-136
Passenger's Door Locl
Act uat or Test . . . . . . . . . . . . . . . . . . . . . 22-137
Dri ver' s Door Key Cyl i nder
Swi t chTest . . . . . . . . . . . . . . . . . . . . . . . . 22-131
Transmi t t er Test . . . . . . . . . . . . . . . . . . . . 22-138
Transmitter Proqrammina ... 22-138
onvertible Top
Component Location Index ........ 22-139
Ci rcui t Di a9ram . . . . . . . . . . . . . . . . . . . . . 22-140
Syst em Desci pt i on . . . . . . . . . . . . . . . . 22-142
Convenible Top Switch
Te s t , . . . ,
22-52
22-52
22-53
. . 22-54
Troubl eshoot i ng . . . . . . . . . . . . . . . . 22-55
Cool ant Temperat ure Gauge
Ci rcui t Troubl eshoot i na . . . . 22-55
Li qhts-on, Kev-i n, Seat Bel t
Remi nder System
Ci rcui t Di a9ram . . . . . . . . . . . . . . . . . . . . . 22-56
Svst em l nput Test . . . . . . . . . . . . . . . . . 22-57
Exterior Lights
22-2
22-5
22-9
22-32
22-35
22-38
22-39
22-40
22-43
22-44
22 46
22 41
Bepl acement
VSS Repl acement . . . . . . . . . . -. . . . . .
VSS Ci rcui t
Troubl eshoot i ng . . . . . . . . . . . . . . -.
Mai nt enance Requi red
I ndacat or Beset Procedure
Tachomet er Ci rcui t
22-96
22-91
22 91
22-9a
22 99
22-100
22 101
22. 101
22. 102
22-103
22 104
22-105
22 105
22-106
22 101
22-108
22-110
22111
22-1t2
22- 112
22-114
22-115
22-1t 6
22- 117
22-119
22-120
22 121
22-122
22-123
22 124
22-125
22 124
22-129
22 129
22-143
Convrtible Top Control
Uni t l nput Test . . . . . . . . . . . . . . . . . . . 22-144
Convertible Top Motor
J
Test 22-141
Removabl e Hardtop
Component Locat i on I ndex . . . . . . . . 22' 1 49
Convert i bl e Top Di sabl e
Swi t chTest . . . . . . . . . . . . . . . . . . . . . . . . 22-150
Rear Window Defogger
Component Location Index ........ 22'151
Ci rcui t Di agram . . . . . . . . . . . . . . . . . . . . . 22-153
Swi t ch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-155
Funct aonTest . . . . . . . . . . . . . . . . . . . . . . . . . 22-156
Def ogger Wi re Repai r . . . . . . . . . . . 22-157
Component Locat i on I ndex . - . . . . . .
Ci r cui t Di agr am
Br ake Li ght s
Ci r cui t Di a9r am . . . . . . . . . . . . . . . . .
Back- up Li ght s Ci r cui t
Di a9r am . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Combi nat i on Li ght Swi t ch
TesVRepl acement . . . . . . - . . . . . .
DRL Cont r ol Uni t
I nput Tes t . . . . . . . . . . . . . . . . . . . . . . . . . . .
HI D Lamp Syst em
Tf oubl eshoot i ng . . . . . . . . . . . . . . . .
HI D Bul b Remov al . . . . . . . . . . . . . . . .
Headl i ght Repl acement . . . . . . . .
Headl i ght Adj ust ment . . . . . . . . . .
Si de Tur n Si gnal Li ght
Repl acement
Tai l l i ght Repl acement . . . . . . . . . . .
Hi gh Mount Br ake L, ght
Repl acement
Li cense Pl at e Li ght
Repl acement
Turn Si qnal /Hazard
Fl ash6r System
Component Local i on I ndex . . . . . . . .
Ci rcui t Di agram
Turn Si gnal / Hazard Rel ay
I nput Test . . . . . . . . . . . . . . . . . . . _. _. _. . .
Hazard Warni ng Swi t ch
Test . . . . . , . . . , . , , , - , . . . _. . . . . . . . . . . . . . . ,
Interior Lights
Component Locat i on I ndex , , , , , . . .
Ci rcui t Di agram
Cei l i n9/ Spot l i ght s Test . . . . -. . . .
Trunk Li ght Test
Trunk Lid Latch Switch Test .
Dash Li qhts Bri qhtness
Contr-oller
Ci rcui t Di agram
Cont rol l er I nput Test . . . . . . . . . . . . .
Repl acement
mmobi l i zer System
Component Locat i on I ndex . , . , . . -.
Syst em Descri pt i on . . . . . . . . . . . . . .
Ci rcui t Di agram
Troubl eshoot i ng
l mmobi l i zer Recei ver Uni t
PowiiiWinilb-i
Ci rcui t Di agram
l Mast er Swi t ch Test . . . . . . . . -. . . . . .
Mast er Swi t ch
I nput Test . . . . . . . . . . . . . . . . . . . . . . . . . . .
Passenger's Window Switch
T6 d / e a ^ l 2 . a mo n r
Dri ver' s Wi ndow
Mot or Test . . . . . . . . . . . . . . . -. . . . . . -. . .
Passenger's Window Motor
22-59
22-61
22 64
22-64
22 65
22-66
22-64
22 69
22 t 1
22 t 2
22 14
22-7 4
2 2 1 5
22-16
2 2 1 1
2 2 1 4
2 2 1 9
22 80
22-81
22 82
22 A3
22-83
22-84
22-45
J
Test
Body Electrical
(
{
{
Tips and Precautions
Betore Troubleshootin g
1. Check appl i cabl e fuses i n the appropri ate fuse/rel ay
box.
2. Check the bal tery for damage, state of charge, and
cl ean and ti ght connecti ons.
.
Do not qui ck-charge
a battery unl ess the battery
ground
cabl e has been di sconnected, otherwi se
you wi l l damage the al ternator di odes.
.
Do not attempt to crank the engi ne wi th the
battery ground cabl e l oosel y connected or you
wi l l sever el y damage t he wi r i ng.
3. Check the al ternator-comDressor bel t tensi on.
Handling Connectors
.
Make sure the connectors are cl ean and have no
l oose wi re termi nal s,
.
Make sure mul ti pl e cavi ty connectors are packed wi th
di el ectri c
grease (except
waterti ght connectors).
.
Al l connectors have push-down rel ease type l ocks
(A).
22-2
.
Some connectors have a cl i p on thei r si de used to
attach l hem to a mount bracket dn the body or on
another component. Thi s cl i p has a
pul l type l ock.
.
Some mounted connectors cannot be di sconnected
unl ess you fi rst rel ease the l ock and remove the
connector from i ts mount bracket
(A).
Never try to di sconnect connectors by
pul l i ng on thei r
wi res; pul l on the connecl or hal ves i nstead.
Al ways rei nstal l
pl asti c
covers.
Before connecti ng connectors, make sure the
termi nal s
(A)
are i n
pl ace
and not bent.
J
Check for l oose retai ner
(A)
and rubber seal s
(B).
The backs of some connectors are
packed
wi l h
di el ectri c grease.
Add grease i f necessary. l f the
grease
i s contami nated, repl ace i t.
(P/N
08798-90011
Insert the connector al l the way and make sure i t i s
securel y l ocked.
Posi ti on wi res so thal the open end of the cover faces
down.
Handling Wires and Harnesses
.
Secure wi res and wi re harnesses to the frame wi th
thei r respecti ve wi re ti es at the desi gnated l ocati ons.
.
Remove cl i ps careful l y; don' t damage thei r l ocks
(A).
Sl i p pl i er s ( A)
under t he cl i p base and t hr ough t he
hol e at an angl e, then squeeze the expansi on tabs to
rel ease the cl i o.
After i nstal l i ng harness cl i ps, make sure the harness
doesn' t i nterfere wi th any movi ng parts,
Keep wi re harnesses away from exhaust pi pes
and
other hot parts.
from sharp edges of brackets and
hol es, and from exposed screws and bol ts.
Seat grommets
i n thei r grooves properl y (A).
Do not
l eave grommets
di storted
(B).
-W
R
I t
(cont' d)
l / o
) t /
r1J \ t/
5E;j=-
't
t,
I
22-3
Body Electrical
(
{
General Troubleshooting
lnformation
(cont'dl
Testing and Repairs
.
Do not use wi res or harnesses wi th broken i nsul ati on.
Repl ace them or repai r them by wrappi ng the break
wi th el ectri cal tape.
.
After i nstal l i ng
parts, make sure that no wi res are
pi nched under them.
.
When usi ng el ectri cal test equi pment, fol l ow the
manufacturer' s i nstructi ons and those descri bed i n
t hi s manual .
.
l f
possi bl e,
i nsertthe
probe
of the testerfrom thewi re
si de
(except
waterproo{ connector).
22-4
Use back
probe adaptor 07TAz-0010204
Refer to the i nstructi ons i n the Honda Termi nal Ki t for
i denti fi cati on and repl acement of connector termi nal s.
Five-step Troubleshooting
1. Veri fy The Compl ai nt
Turn on al l the components i n the probl em
ci rcui t
to veri fy the customer compl ai nt. Note the
symptoms. Do not begi n di sassembl y or testi ng
unti l you have narrowed down the
probl em
area.
2. Anal yze The Schemati c
Look up the schemati c for the
probl em
ci rcui t.
Determi ne how the ci rcui t i s supposed to work by
traci ng the current paths
from the
power
feed
through the ci rcui t components to ground.
l f
several ci rcui ts fai l at the same ti me, the fuse or
ground i s a l i kel y cause,
Based on the symptoms and your
understandi ng of
the ci rcui t operati on, i denti fy one or more possi bl e
causes of the probl em.
3. l sol ate The Probl em By Testi ng The Ci rcui t
Make ci rcui t tests to check the di agnosi s you made
i n step 2. Keep i n mi nd that a l ogi cal , si mp,e
procedure
i s the key to effi ci ent troubl eshooti ng.
Test for the most l i kel y cause oI Iai l ure fi rst. Try to
make tests at poi nts
l hat are easi l y accessi bl e.
4. Fi x The Probl em
Once the speci fi c probl em
i s i denti fi ed, make the
repai r. Be sure to use
proper
tool s and safe
procedures.
5. Make Sure The Ci rcui t Works
Turn on al l components i n the repai red ci rcui t i n al l
modes to make sure you' ve
fi xed the enti re
probl em.
l fthe probl em
was a bl own fuse, be sure
to test al l of the ci rcui ts on the fuse. Make sure no
new probl ems
turn up and the ori gi nal probl em
does not recur,
Wire Color Codes
The fol l owi ng abbrevi ati ons are used to i denti fy wi re
col ors i n the ci rcui t schemati cs:
WHT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wnr r e
YE1. . . . . . . . . . . . . . . . , . . . . . . . . . . . . . . . . . . . . . Yel l ow
B1K. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bl ack
B1U. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bl ue
GRN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gr een
RED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red
ORN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Or ange
PNK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pi nk
BRN. . . . . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Br own
GRY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gr ay
PUR. . . . . . . . . . . . , . . . . . . . . . . . . . . . . . . . . . . . . Pur pl e
1T81U. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Li ght Bt ue
1TGRN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ll ght Gr een
The wi re i nsul ati on has one col or or one col or wi th
another col or stri pe. The second col or i s the stri pe.
WHT IBLK
22-5
Relay and Control Unit Locations
{
a
ABS MODULATON UNIT
Engine Gompartment
EPS CONTROL UNIT
MAIN UNDER.HOOD
FUSE/RELAY BOX
INTERMITTENT WIPER RELAY
{'02-03 models)
AUXILIARY
UNDER-HOOD FUSE BOX
AIR PUMP RELAY
BLOWER MOTOR RELAY
CONDENSER FAN RELAY
RADIATOR
FAN RELAY
A/C COMPRESSOR
CLUTCH RELAY
22-6
HORN RELAY
ELD UNIT
a
Dashboard
l{lGH BEAM CUT RELAY lcanadal
f
Wi re col ors: RED/ BLU, ORN, I
LBLU
and BLU/ RED
I
{'00-01 modelsl
I Wi re
col ors: GRN/ REO, CAru, I
L
GRN/ BLK, BLK and BLUAr' YHT
. l
REAR wlNDOW DEFOGGER RELAY
{'02-03 modelsl
f
Wi re col ors: WHT/GBN, ELIVRED,
L
YEVBLU, and YEUBLK
DOOR LOCK CONTROL UNIT
CRUI SE CONTROL UNI T
/
ECM
UNDER.DASH FUSE/RELAY BOX
TURN SIGNAL/HAZARD RELAY
f
Wi re col ors: BLK,/RED, cBN/WHLI
I and BLK I
TAILLIGHT RELAY
l Wi re
col ors: RED/BLK, WHT/GRNI
LWHT/GRN
and BLU
J
REAR WINDOW DEFOGGER RELAY
lwith hardtopl
{'00-01 modelsl
ZTN
7=<
\ l
3 q
)_)
7t
'
-
--
: :
---
L-l
L_l
tr-
S
L I
-:l
L I
-
I
-
- -
f
Wi re col orsr BLVBED, WHT/GRN,
I
LYEUBLK
and BLK,/YEL
J
22-7
Relay and Control Unit Locations
Dashboard and Door
IG2 RELAY
fwi re
col ors: BLK/RED,
I
LLT
BLU, BLUAVHT and YEL
I
POWER SOCKET RELAY
Wi re col orsr WHT/RED,
LT BLU, YEURED and BLU,lwHT
POWER WINDOW
MASTER SWITCH
(Has
bui l t -i n cont rol uni t )
OAYTIME RUNNING LIGHTS
CONTROL UNIT
(Canadal
CONVERTIBLE TOP
CONTROL UNIT
CHANGE RELAY f02-03 models)
IWi re col ors: BLVRED, BRN,
1
L
LT GRNAVHT, BLK/^/EL and BLK
I
22-8
Connectors and Harnesses
Connector Index
Tl , T6 end
(+
)
( see pag6 22 14)
C204, C303 and C402
t hrough C404, C451
C501 t hrough C504
.
2: ' 02-03 model s
22-9
Gonnectors and Harnesses
Connestor to Harness Index
EPS Subharness
22-10
Connector or Terminal Cavities Location Connects to Notes
EPS cont rol uni t connect or C 2
I
2
2
Ri ght si de oI engi ne companment
Left side of engine compartment Lef t engi ne compart ment wi re
harness
(see
oaoe 22-16)
T1
T6
l
7
Ri ght si de of engi ne companment
Lef t si de o{ engi ne compart ment
Mai n under hood f use/ r el ay
Auxi l i ar y undeFhood f use
G351
3 Ri ght si de of engi ne compart ment Body ground vi a EPS
suDnarness
8afterv Batterv oositive terminal
Battery Ground Cable
Connector or Terminal Cavities Location Connects lo Notes
4 Ri ght si de o{ engi ne compar t ment Body ground via battery
Batterv Batterv neqative terminal
Starter Cable
Connector or Trminal Ret Cavities Location Connects to Nols
r2
T3
n
I
1 l
6
Lef t si de of engi ne compart ment
Left side ot engine compartment
St aner mot or
Engi ne bl ock
Auxi l i ary under-hood f use
Left side ot enqine compartment Bodv
qr ound
vi a st ar t er cabl e
Engi ne Ground Cabl e
Connector orTorminal Cavities Location ;onnecls to Notes
'10
Let t si de of enqi ne compart ment Enqi ne block
12 Rear beam Rear beam
ground vi a engi ne
oround cabl e
EPS Gearbox Ground Cabl e
Conncto. or Terminal Cavities Location ;onnects to Notes
14
Lef t si de of enqi ne compart ment EPS
qear
G4
1 4 Front beam Front beam vi a EPS gearbox
oround cabl e
BATTERY GROUND CABLE
a
EPS SUBHARNESS
STARTER CABLE
(+t
EPS GEARBOX
GROUND CABLE
ENGI NE GROUND CABLE
22-11
(
Connector to Harness Index
(cont'dl
Engine Wire Harness
Connector or Terminal C.vitie3 Location Connecis to Notes
IVC compressor clutch
Al t ernat or
Back-up l i ght swi t ch
CKP sensor
CMP {TDC) sensor A
CMP {TDC) sensor B
ECM connector B
ECM connect or C
Engi ne cool ant t emperat ure
(ECT)
sensor
l dl e ai r cont rol {l AC) val ve
Intake airtemperature
(lAl
sensor
Knock sensor
Map sensor
No. 1 i gni t i on coi l
No. 1 injector
No. 2 i nj ect or
No. 3 i nj ect or
No. 4 i nj ect or
Primary heated oxygen sensor
t PHO2S)
Seconda.y heated oxygen sensor
(sHo2s)
Staner solenoid
Throftle position
1TP) sensor
Vehi cl e speed sensor
(VSS)
VTEC oil pressure switch
VTEC sol enoi d val ve
cr 01
C102 {Junction connector)
C103
(Connect
t o C104)
c104 {connect t o c103}
1 1
6
34
20
28
24
3
5
7
32
30
33
22
I
1 0
29
1 2
2
36
1 4
1 8
19
17
1
2
3
2
2
2
3
2
1
3
3
3
3
2
2
2
2
4
4
1
3
3
2
1
1 6
20
2
2
Left side ofengine compartment
Mi ddl e of t ransmi ssi on
N, l i ddl e of engi ne
Mi ddl e oI engi ne
Ri ght si de of engi ne compart ment
Behi nd l ef t ki ck panel
Behind left kick panel
Mi ddl e oI engi ne
Mi ddl eof engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
N4i ddl e of engi ne
Mi ddl e of t ransmi ssi on
Mi ddl e ot t ransmi ssi on
Left side ol engine companment
Mi ddl e ot t ransmi ssi on
Eehi nd l ef t ki ck panel
Behi nd l ef t ki ct oanel
Dashboard wi re harness A
lsee
page 22-22)
T10t
r102
T103
1 Main under-hood fuse/relay box
Alternator
Fndi ne ni l nr c. cr r r p
qwi t
h
G 10'1 8 Maddl e of engi ne Engi ne ground vi a engi ne
22-12
a
mff
\ -1. . . --
' 16
1 7
1 8
ENGINE WIRE HARNESS
22-13
4
(
{
(cont'dl
Bight Engine Compartment Wire Harness
Connector or Terminal Ret Cavitie3 Location
Connects to Notes
ABS ri ght f ront wheel sensor
Ay'C pressure switch
Condenser f an mot or
ELD uni t l see
page 22-321
EPS cont rol uni t connect or A
EPS cont rol uni t connect or I
EPS t orque sensor
EPS mot or
Horn
(l ow)
Horn
(hi gh)
Mai n underhood f use/ rel ay box
connector A
(see page 22-32)
Mai n under' hood {use/ rel ay box
connector B
(see page 22-32)
Mai n unde. hood f use/ rel ay box
connect or C
(see page 22-32)
Mai n unde. hood f use/ rel ay box
connect or D
(see page 22-32)
Radi at or f an mot or
Ri ght f ront parki ng l i ght
Ri ght f ront t urn si gnal l i ght
Ri ght headl i ght
(hi gh
beam)
Bi ght headl i ght
(l ow
beam)
Ri ght si de t urn si gnal l i ght
Wi ndshi el d washer mot or
c201
c202
c203
c204
1 0
1
1 4
2
5
23
22
6
' l l
1 2
8
I
1 7
20
21
24
1 9
1 8
2
2
2
3
2
1 4
3
2
1
1
1 8
7
3
1 6
2
2
2
3
2
2
2
6
7
' 18
Mi ddl e of engi ne companment
Left side of engine compartment
Underhood f use/ rel ay box
Lef t si de of engi ne companment
Mi ddl e of engi ne compart ment
Bi ght si de of engi ne compart ment
Bi ght si de of engi ne compart ment
Behi nd ri ght headl i ght
Ri ght si de ol engi ne compart ment
Behi nd ri ght si de ot dash
Behi nd ri ght si de of dash
Dashboard wi re harness B
(see page 22-18)
(see page 22' 18)
(see page 22-18)
tsee naoe 22-22)
'02-03
mooers
G201
7 Ri ght si de of engi ne compar t ment Body ground vi a ri ght
engi ne companment wi re
22-14
ENGINE COMPARTMENT
WIRE HARNESS
22-15
(cont'd)
Left Engine Compartment Wire Haness
Connec-tor or Terminal Cavities Location Connects to Notes
ABS left front wheel sensor
ABS modul at or uni t
Ai r
pump
el ect ri c current sensor
Ai r pump el ect ri c current sensor
connector B
Ai r pump
Ai r pump rel ay connect orA
Ai r pump rel ay connect or B
Auxi l i ary under' hood f use box
connect or A
(see page 22-34)
Auxi l i ary underhood f use box
connect or B {see
page 22-34)
Brake f l ui d l evel swi t ch
cruise control actuator
EVAP cani st er purge val ve
I nt ermi t t ent wi per rel ay
Left tront parking light
Lef t f ront t urn si gnal l i ght
Lef t headl i ght
(hi gh
beam)
Lef t headl i ght l l ow beam)
Lef t si de t urn si gnal l i ght
Radiator fan switch
Secondary air control valve vacuum
cont rol sol enoi d val ve
Test t achomet er connect or
Wi ndshi el d wi per mot or
c30'!
c302
c303
c35r
1 0
26
' 14
1 5
5
7
4
24
1 2
' 19
2A
2 7
1 7
9
1 1
6
8
1
29
1 8
23
20
22
2 1
2
25
2
3
2
2
2
2
3
2
4
2
6
2
2
3
2
2
2
2
2
5
1 4
1 4
2
Left side ol engine compaftment
Let t si de of engi ne companment
Auxi l i ary under-hood f use box
Auxiliary under-hood fuse box
LeIt side oI engine compartment
Left side oI engine compartment
Behi nd l ef t headl i ght
Eehi nd l ef t headl i ght
Eehi nd l ef t headl i ght
Behi nd l ef t headl i ght
Left side ol engine compartment
Under left side ol dash
Under left side of dash
tJnder left side of dash
Dashboard wire harness B
(see page 22-18)
{see
page 22-18)
\see
page 22 221
EPS subharness {see
page
,2-1.)\
'02-03
G301
G302
G303
2 Left side ofengine compartment
Eody ground vi a l ef t engi ne
compart ment wrre harness
Eody ground vi a l ef t engi ne
compart ment wi re harness
Body ground vi a l ef t engi ne
. ^mn. r t mpnt wi r p hr r ness
22-16
LEFT ENGINE COMPARTMENT
WIRE HARNESS
26 25
24
'17
' 1 6
t 5
'ftt|--'-'
r'1;i$
/i';
"t;
-r.,ffi-...'
22-17
(cont'd)
Dashboard Wire Harness B
(Left
branch)
Connector or Terminal Ret Cavities Location Connec't3 to Notes
Brake pedal position
switch
Cabl e reel
Clutch
pedal position switch
Clutch interlock switch
Combi nat i on l i ght swi t ch
Cruise control unit
Hi gh beam cut rel ay
lgnition key switch
Intermittenl wiper relay
l mmobi l i zer recei ver uni t
Rear wi ndow del ogger rel ay
Wi ndshi el d wi per/ washer swi t ch
c301
c302
c401
c402
c402
c403
c404
t 8
8
1 0
' t 1
I
6
3
1
2
7
l
1 1
4
1 4
5
5
1 4
't4
2
2
' 14
1
4
6
1 6
24
L, nder l et t si de of dash
Under l ef t si de of dash
Under l ef t si de ot dash
Under l ef t si de oI dash
Under left side oI dash
Left engine compa.tment wire
harness
(see page 22-16)
Left engine compartment wire
harness
(see page 22-16)
Rearwi re harness
(see page
22-24')
Dashboard wire harness A
lsee
page 22-22)
lsee
page 22-221
\see
page 22-221
lsee oeoe 22-22\
Canada
'00-0'1
model s
'02-03
mooet s
'00,01
mooers
'02-03
G401 5 Under left side oI dash Body ground vi a dashboard
wire harness B
22-18
't',
1?
13 14 15
( Cont i nues
t o r i ght br anch)
UNDER. DASH
FUSE/ RELAY
DASHBOARO WI RE
HARNESS B
BOX
4
( cont ' d
)
22-19
{
a
a
{cont'dl
Dashboard Wire Harness B
(Right
branch)
Connector orTorminal Cavitios Location Connects to Notes
Accessory power socket relay
Ai r mi x cont rol mot or
Blower motor
Convert i bl e t op mot or emergency
Convert i bl e t op mot or emergency
connector B
Convertible top control unit connector
Convertible top switch
Daytime running lights control unit
Dat a l i nk connect or l DLC)
Dat a l i nk connect or
(DLC)
Di ode l DFL)
Evaporat or t emperat ure sensor
Hazard warni ng swi t ch
l G 2 rel ay
Mode control motor
Parking brake switch
PGM-Fl mai n rel ay
Rear window de{ogger switch
Recirculation control motor
c201
c202
c203
c451
c4s2
2
8
1 2
20
1 1
5
7
26
I
23
I
6
22
3
1 0
24
2 1
1 4
1 6
1a
5
7
2
2
2
1 4
6
1 4
2
2
1 0
5
7
1
7
5
5
7
6
'7
2
Under mi ddl e of dash
Under ri ght si de of dash
Middle of floor between seats
Under ri ght si de ot dash
Mi ddl e of f l oor bet l veen seat s
Middle of floor between seats
lvliddle ot floor betlveen seats
Ri ght engi ne compart ment
wi re harness
(see page 22' 14)
Ri ght engi ne companment
wi re harness
(see page 22 14)
Fi ght engi ne compart ment
wi re harness l see
page 22-14)
lsee
page 22-221
Roof wi re harness
(see page
22-26)
Canada
'00-01
model s
'02-03
Canada
Har dt oP
i
G402 1 7 Body gr ound vi a dashboar d
\
22-20
3
(Cont i nues
t o l ef t branch) 10
11 12
13
1 4
1 5
DASHBOARD WIRE HARNESS B
22-21
a
a
(cont'd)
Dashboard Wire Harness A
Conn6ctor or Teraninal Cavitie3 Location Connectsto Notes
Antenna ampl i fi er
Audi o uni t
Convertible top control unit connector
Cruise control main switch
ECM connector A
Engine start switch
Gauge assembl y connector A
Gauge assembl y connector B
Gauge assembl y connector C
Gauge assembl y connector o
Heater control
panel
Keyless door lock control unit
Radio remote switch
Rear wi ndow defogger swi tch
c 101
c204
c303
c402
c402
c403
c404
c451
c501
c501
c502
c503
c504
1 1
1 8
I
1
1 4
1 2
1 1
5
6
22
3
20
24
24
1 0
1 9
I
1
2
2 1
2
20
1 0
6
5
1 4
1 2
20
30
1 8
6
6
1 8
1 4
6
24
1 4
1 8
3
1 4
Behi nd audi o uni t
Behi nd audi o uni t
Behi nd gauge assembl y
Behi nd ri ght ki ck panel
Engi ne wi re harness
(see
page 22 12]'
Ri ght engi ne companment
wi re harness {see
page 22 14)
Left engine compartment wire
harness
(see page 22-' 16)
Dashboard wi re harness I
l see
page 22-18)
l see
page 22-18)
Dashboard wi re harness I
{see
page
22-18)
l see
page 22-18)
{see
page 22-18)
Rearwi re harness
(see page
22-24')
Rear wi re harness
(see page
22-24)
Dri ver' s door wi re harness
{see
page 22-28)
SRS mai n harness {see
page
22-27)
Passenger' s door wi re
harness i see oaoe 22-29)
'02-03
' 00
01
mooet s
'02-03
'00-01
model s
'02
03
G50l 26 Body gr ound vi a dashboar d
Body gr ound vi a dashboar d
22-22
a
o
1 o
8 i \
1 1 1 2 1 3
1 4
OASHBOARD WI RE HABNESS A
22-23
(cont'd)
Rear Wire Harness {Left blanch)
Connector orTrminal Cevitios Locetion Connocts to Notes
ABS left rearwheel sensor
Condenser
Di ode
Driver's door switch
Driver's seat belt switch
EVAP bypass solenoid valve
EVAP control canister vent shut valve
Fuel
pump/ f uel gauge
sendi ng uni t
Fuel t ank pressure sensor
Hi gh mount brake l i ght
Left convertible top motor
Left back-up light
Left brake/taillight
Left rear side marker light
Lef t reart urn si gnal l i ght
Rear wi ndow def ogger
change relay
Trunk l i ght
Trunk opener swi t ch
Trunk opener sol enoi d/ l at ch swi t ch
c40l
cs01
c501
c601
c602
1
1 1
3
9
1 0
23
8
20
5
'17
1 6
1 8
24
1 9
1
2
2
1 4
2
2
2
I
2
2
2
5
3
2
2
2
3
2
2
2
2
3
22
1 2
2
1 4
Left side oltrunk
Left side oltrunk
Behind left corner gusset
Under driver's seat
Left side of underfloor
Lef t si de of underl l oor
Mi ddl e of t uel t ank
Left side ot undertloor
Mi ddl e of t runk l i d
Behind left corner gusset
Behi nd i ef t t ai l l i ght assembl y
Behi nd l ef t l ai l l i ght assembl y
Eehi nd l ef t t ai l l i ght assembl y
Behi nd l ef t t ai l l i ght assembl y
Lef t si de of t runk
Mi ddl e of t runk
Behind rear console between seat-
back
Mi ddl e of t runk l i d
Eehind left kick panel
Left side oftrunk
Left side oftrunk
(see page 22-18)
lsee
page 22-22)
Hardtop subharness
(see
page 22-30l,
Rearwi ndow def ogger
sr bhar ness l sce nadc 22- 31)
'02,03
mooels
'02-03
model s
' 02-03
mooet s
'00-01
mooet s
'02-03
mooels
Hardtop
'02-03
G601 Body g. ound vi a rear wi re
22-24
(Cont i nues
t o ri ght branch)
( Cont i nues
t o r i ght br anch )
(cont' d)
22-25
(cont'd)
Rear Wire Harness
(Right
branch)
Connector or Terminal Cavities Location Connects to Notes
ABS right rear whee, sensor
Accessory power socket
Li cense
pl at e l i ght
Passenger' s door swi t ch
Ri ght conveni bl e t op mot or
Ri ght back up l i ght
Ri ght brake/ t ai l l i ght
Ri ght rear si de marker l i ght
Ri oht rear t urn si onal l i oht
4
3
I
1
2
7
6
5
a
2
2
2
1
2
2
3
2
,
Bj ght si de of t runk
Behi nd rear consol e bet l veen seat -
Behi nd rear bumper
Behi nd ri ght corner
gusset
Eehind right corner gusset
Behi nd ri ght t ai l l i ghr
Behi nd ri ght t ai l l i ght
Behi nd ri ght t ai l l i ght
achi nrl ri oh ai l l i ohr
G602 10 Body ground vi a rear wi re
Roof Wire Harness
Connector or TeIminal Cavities Location Connects to Notes
Cei l i ng/ sopt l i ght s
c452
1
2
4
2
Roof area
L, nder ri ght si de of dash Dashboard wi re harness B
i see oaoe 22-18)
(Cont i nues
t o l ef t branch)
REAR WIRE HARNESS
(Cont i nues t o l ef t branch)
WIRE HARNESS
22-26
REAR WIRE HARNESS
SRS Main Hamess
Connector or Terminal C.vitie3 Location Connects to Notes
Cable reel
Driver's seat belt tensioner
Memory erase si gnal
(MES)
connect or
Passenger's airbag inflator
Passenger's seat belt tensioner
Under-dash fuse/relay box connector
A
(see page 22-33)
c503
5
9
'l
7
8
6
2
4
2
2
2
2
2
1 8
2
3
Under l ef t si de ot dash
Behi nd dri ver' s seat -back
Under-dash f use/ rel ay box
Undr ri ght si de of dash
Behind passenger's
seat-back
Mi ddl e of f l oor
Under-dash l use/ rel ay box
Under l ef t si de ot dash Dashboard wi re harness A
G801 10 Middle of floor Body ground vi a SRS mai n
lgnition Switch Lead
Connctor or Terminel Cavitie3 Location
Conn6cts to
Under dash fuse/relay box connector
B l see oaoe 22-33)
3 7 L.Jnder left side of dash
SRS MAI N HARNESS
UNDER.DASH
FUSE/RELAY BOX
N\
it
'
"-
IGNITION SWITCH LEAD
22-27
(cont'd)
Driver's Door Wire Harness
Connector or Terminal Cavities Locltion Connocts to Notos
Dri ver' s door key cyl i nder swi t ch
Dri ver' s door l ock act uat or
Dri ver' s door l ock knob swi t ch
Dri ver' s door speaker
Dri ver' s wi ndow mot or
Left power mirror actuator
Lett tweeter
Power mi rror swi t ch
Power window master switch
c502
1
I
9
3
6
1
1 0
5
4
2
2
2
3
2
3
2
' 10
1 4
' 18
Dri ver' s door
Dri ver' s door
Driver's door
Driver's door
Driver's door
Driver's door
Driver's door
Dri ver' s door
Driver's door
Behind left kick panel Dashboard wire harness A
Isea oa(,e 22-221
'02-03
moo6rs
DRIVER'S DOOR WIRE HARNESS
22-28
Connoctor or Torminal Cavitios Localion Connects to Notes
Passenger's door lock actuator
Passenger's door speaker
Passenger's window motor
Pass6nger's window switch
Ri ght power
mi rror act uat or
Ri ght t weet er
c504
6
3
5
4
2
1
2
2
2
3
2
1 4
Passenger's door
Passenger's door
Passenger's door
Passenger's door
Passnger's door
Passenger's door
Behi nd ri ght ki ck panel
(see
oeoe 22-221
' 02,03
Passenger's Door Wire Harness
PASSENGER'S DOOR WIRE HARNESS
22-29
{
{
(cont' d)
HARDTOP:
2
4 Rearwi re harness {see
page
22 241
Rear wi ndow def ogger connect or
( +)
GROUND WIRE
HARDTOP SUBHARNESS
22-30
J
CONVERTIBLE TOP:
Left side ot rear wandow
Lef t si deof t runk
\
,/.
/
::-2'/
=a/
REAR WINDOW DEFOGGEN
SUBHARNESS
22-31
Fuse/Relay Boxes
{
{
Connector to Fuse/Relay Box Index
Mai n Under-hood Fuse/Rel ay Box
5
Socket Ref Terminal Connects to
Ay' C compressor cl utch rel ay
B
Bl ower motor rel ay
c
Condenser fan rel ay
D
Di ode
ELD U ni t
Hor n r el ay
Headl i ght rel ay
' l
Headl i ght r el ay 2
Radi ator fan rel av
I t
3
1 4
1 1
I J
1
9
4
1 0
7
8
2
' 18
'l
4
3
4
1 6
2
3
4
Ri ght engi ne compartment wi re harness
(see page 22-14)
Ri ght engi ne compartment wl re harness
(see page 22-14)
Ri ght engi ne compar t ment wi r e har ness
( see page 22- 14)
(see page 22-14)
(see page 22-14)
T1 Batterv Dosi ti ve cabl e
(see
Daoe 22-10)
T101 5 Enqi ne wi r e har ness
( see paqe
22- 12)
22-32
-
Socket Bef Terminal Connects to
B
c
D
E
Memory erase si gnal
(MES)
connector
Rear wi ndow defogger rel ay
(' 00-01
model s)
Staner cut rel ay
Tai l l i ght rel ay
Turn si onal /hazard rel av
5
1
7
8
9
5
6
1 0
2
7
,|
1
1
4
3
SRS mai n harness
(see page
22-27)
l gni ti on swi tch harness
(see page 22-27)
Opti onal connector
Opti onal connector
Opti onal connector
SRS mai n harness
(see page
22-27)
Under-dash Fuse/Relay Box
ttftftft
o a a o
Lt L_l L_lL_l
t l
t l
t l
f r3l f 27l
ltzl lza_)
L
rr
l f zsl
f rol f zrl
f sl f zgl
f
ef
f zzf
I zl-1
f z . l - I
- - t 2 0
1
! " 1 f r sl
=
-
: L18-l
l i ! i - -
= = L
17_l
t ? l
1 6
l z ) , . . .
L r _ t
f 1 1 I
22-33
Fuse/Relay Boxes
Connector to Fuse/Relay Box lndex
(cont'dl
Auxiliary Under-hood Fuse Box
Socket Ret Terminal Connects to
B
2
1
2
3
Lef t engi ne compar t ment wi r e har ness
( seepage22- 16)
Lef t enqi ne comDar t ment wi r e har ness
( seepaqe22- 16)
22-34
Power Distribution
J )
J )
Fuse to Components Index
Main Under-hood Fuse/Relay Box
*
1: ' 00- 01 model s
*
2:
' 02-03
model s
Fuse
Number
Amps Wire Color Component{s} or Circuit{s} Protected
41 100 A Battery, Power di stri buti on
4 0 A WHT l gni ti on swi tch {BAT}
43 204 B E DAr'r'HTDayti me runni ng l i ghts control uni t
(Canada),
Ri ght headl i ght
(hi gh/l ow
oeam,
44
Not used
45 20A' RED/YEL Dayti me runni ng l i ghts control uni t
(Canada),
Gauge assembl y, Hi gh beam
i ndi cator l i ght, Hi gh beam cut rel ay
(Canada),
Left headl i ght
(hi gh/l ow
beam)
46 1 5 A WHT/GRNData l i nk connector
(DLC),
PGM-Fl mai n rel ay
47
' r 0 A* ' l
WHT/GRN ABS modul ator uni t, Brake l i ghts, Crui se control uni t, ECM, Hl gh mount
brake l i ght, Horn(s)
1 5 4 * 2
48 2 0 A WHT/GRNABS modul ator uni t
49 1 0 A WHTi BLK Hazard warni ng l i ghts
50 3 0 A WHT/BLU ABS modul ator uni t
40A WHT/BLK No. 17 and 18 fuses
(i n
the under-dash fuse/rel aV box)
52 204 GRY/REDRi ght converti bl e top motor
53
Not used
54 3 0 A YEL No.22,29! 24,25, 26 and 27 fuses
(i n
the under-dash fuse/rel av box)
55 204 GRY Left converti bl e top motor
56 40A BLU,^/VHTBl ower motor
57 20A. BLU/BLK Radi ator fan motor
58 204 BLUIYEL Condenser fan motor
BLU/RED A,/C compressor cl utch
59 Not used
frnn]q
L__l Ll Ll
42
t5d car
u
L\Zl
I ll-- )
53 l 5ol E l tr-rl ?
* -F.]f
I t\
lill [i]ro:lrr I
E ta.l:l
u
x
Fll rr &ra
I I | | 1611 It
I l s l 4 l 9
)
(cont' d)
5
J
22-3
Power Distribution
{
{
{
Under-dash Fuso/Relay Box
syst em l i ght , Crui se cont rol uni t ,
Crui se cont rol mai n swi t ch, ELD uni t , EVAP bypass sol enoi d val ve' EVAP cani st er vent
15A 8Lf i EL
--pr"". - "l @l ay,
Condenser f an rel ay, Heat er cont rol
A-udi o-uni t l i ght , Crui se cont rol mai n swi t ch l i ght , Front parki ng l i ght s, Gauge l ' ght s'
Hazard warn; ng swi t ch l i ght , Heat er cont rol
panel l i ght s, Keyl ess doot l ock cont rol un' t '
Li cense
pl at e l i ght , Opt i on connect or, Conveni bl e t op swi t ch l i ght s, Radi o remot e
Ecl t 4- . Gur ge assumbl v. Hpal er cont r ol
panel l mmobi l i l er
Fuse to Components
Index
(cont'dl
f13l f27l
f12l f26l
ro f21l
- el f 23l
f 8l f r r l
f 21-
T1 - 1
= =
L' l
Tr r - . ]
fl
1_l
!
33ls
I l
I ,
'
'I
r[ t [ l
L_J L-J
,-H
22-36
Fuse
Numbor
Amps Wire Color Component(s) or Circuit(s) Protected
60A WHT Ai r
pump
el ectri c current sensor
EPS control uni t
7 0 A WHT/RED
34 20^' WHT/GRN Rear wi ndow defogger
Not used
36
Not used
Auxiliary Under.hood Fuse Box
22-37
Ground
Distribution
I
{
Ground to Components Index
Ground
Component or ci rcui t
grounded
,
Battery
Engi ne bl ock
Enqi ne bl ock
G2
G4 EPS
qearbox
G 1 0 1 CKP sensor . Dat a l i nk connect or
( DLC) ,
ECM
( PG1
and PG2 ar e BLK; LG l and LG2 ar e BHN/ YEL) , I AU
val ve, l qni ti on coi l s, l mmobi l i zer recei ver uni t, PGM-Fl mai n rel ay, vss, vTEc oi l
pressure swi tch
shel i l ng between the EcM these components have BRNryEL wi res: cKP sensor, TDC sensor 1 and 2
{cMP sensor A and B). Pri marv HO2S. Secondarv HO2S, Knock sensor
G 201 Bl r."r "r"t"r *E C-d"*"r f"n motor, ELD uni t, EPS control uni t, Front parki ng l i ght
(ri ght),
Front
t ur n si gnat t i ght
( r i ght ) ,
Radi at or f an mot or , Ri ght headl i ght
( l ow
beam) , si de t ur n si gnal l i ght
( r i ght ) ,
Wi ndshi el d washer mot or
G301 Al r
pu-p tl a,/, Br"Le fl ui d l evel swi tch, crui se control actuator, Front parki ng l i ght
(l eft),
Front turn
si gnal i i ght fi eft),
Radi ator fan swi tch, Left headl i ght
(l ow
beam), Si de turn si gnal l i ght
(l eft),
Wi ndshi el d
wi per motor, l ntermi ttent wi per rel ay
(' 02-03
model q)
G302 Ai r
pump
ABS modul at or uni t
( 2
wi r es)
G303
u55 | EPS COnt rOl Unt t
G401 CtLrtct'
p"aat posi ti on swi tch, Cl utch i nterl ock swi tch, Combi nati on l i ght swi tch, Data l i nk connector
(DLC),
l gni ti on key swi tch, Intermi ttent wi per rel ay {' oo-01
model s). Turn si gnal l haza.d rel ay
'
Wi ndshi el d wi per/washer swi tch, Rear wi ndow defogger swi tch
(' 00-01
model s)
G402 di se cortrrohj ni t, Da' 1i me runni ng l i ghts control uni t
(Canada) (2
wi res), EPS control uni t, Heater
control Danel , Converti bl e top control uni t
(3
wi res). Po*er transi stor
G 501 crul "" | .nai n s*i rcr' , Dri ver' s door key cyl i nder swi tch, Dri ver' s door l ock actuator, Engi ne start swj tch,
Gauge assembl y
(2
wi res), Keyl ess door l ock control uni t, Power mi rror swi tch, Passenger' s wi ndow
swi tch, Power wi ndow master swi tch. converti bl e top control uni t, Radi o remote swi tch, Rear wi ndow
defoqqer swi tch
(' 02-03
model s)
Audi o uni t
G601 AcceCory
power sockd, Dri ver' s seat bel t swi tch, Fuel gauge sendi ng uni t
(2
wi res), Hi gh mount brake
l l ght, Trunk opener sol enoi d/l atch swi tch, Rear wi ndow defogger subharness connector
(opti on)
(' 00-01
model s). Condenser and Di ode
(for
rear wi ndow defogger change ci rcul t) {' 02-03
model s), Rear
wi ndow defoqqer
(converti bl e top for' 02-03 model s).
pl us
eveMhi ng
grounded through G901
aa"l "up l i gt' t
(i efvri ght).
Li cense
pl ate l i ght, Rear turn si gnal l i ght {l efvl i ght).
Rear si de marker l i ght
l l efr/ri oht). Tai l l i oht
(l efu
ri oht)
G801 SRS uni t
( 2
wi r es)
G 901 conrerri bl " t.D di ""bl " swi tch, Rear wi ndow defogger rel ay
(' 00-01
model s),
pl us everythi ng
grounded
Rear wi ndow defoqqer G902
22-38
-
Battery
Battery Test
Use ei ther a JCI or Bear ARBST tester, and fol l ow the
manufacturer' s procedures.
l f you
don' t have one of
these computeri zed testers, fol l ow thi s conventi onal
test procedure:
1. Be sure the temperature of the el ectrol yte i s
between 70' F
(21' C)
and 100' F
(38"C).
2. Inspect the battery case for cracks or l eaks.
.
l f the case i s damaged, repl acethe battery.l
.
l f the case l ooks OK, go
to step3.
3. Check the i ndi cator EYE.
.
l f the EYE i ndi catesthe battery i scharged, goto
step 4.
.
l f t he EYE i ndi cat esa l owchar ge, got ost ep7.
4. Appl y a 300 amp l oad for 15 seconds to remove the
surface charge.
5. Wai t 15 seconds, then appl y a test l oad of 280 amps
for 15 seconds.
6. Record baftery vol tage.
.
l fvol tage i s above 9.6 vol ts, the baftery i s OK.l
.
l f vol t age i s bel ow9. 6vol t s, got ost ep7.
7. Charge the battery on Hl gh
(40
amps) unti l the EYE
shows the battery i s charged, pl us an addi ti onal 30
mi nutes. l f the battery charge i s very l ow, i t may be
necessary to bypass the charger' s pol ari ty
protecti on
ci rcui try.
.
l f the EYE i ndi cates the battery i s charged wi thi n
3 hours, the battery i s OK.l
.
l f the EYE i ndi cates the battery i s not charged
wi thi n 3 hours. repl ace the battery.I
A battery can expl ode i f
you
do not fol l ow the
proper procedure,
causi ng seri ous i nj ury to anyone
nearby. Fol l ow al l procedures
careful l y and keep
sparks and open fl ames away from the battery.
22-39
Relays
Power Relay Test
Use thi s chart to i dentl fy the type of rel ay, then do the
test l i sted for i t.
NOTE: For the turn si gnal /hazard rei ay i nput test
(see
page 22-781.
*
1:
' 00- 01
model s
*
2: ' 02- 03 model s
Rel ay Test
Accessorv
power
socket rel ay
See
page 22-40
Nor mal l y open
type A
AJC comDressor cl utch rel ay
Condensor {an rel av
Headl i qht rel av 1
Headl i qht rel av 2
Hi qh beam cut rel ay
(Canada)
Hor n r el ay
l G2 r el av
Radi ator fan rel av
Starter cut rel ay
Tai l l i qht r el ay
Rear wi ndow defoqqer rel ay
Bl ower motor rel ay See
page 22-41
Nor mal l y open
tvDe B
l ntermi ttent wi oer rel av
*
2 See
page 22-41
Fi ve termi nal
tVDe A
Inl ermi ttent wi per rel ay
*
1 See
page 22-42
Fi ve termi nal
type B
Rear wi ndow defogger
chanqe rel av
*
2
Rear wi ndow defogger
(elav *
2
22-40
Normally-open type A:
Check for conti nui ty between the termi nal s.
.
There shoul d be conti nui tv between the No. 1 and
No.2 termi nal s when power and ground are
connected to the No. 3 and No. 4 termi nal s
.
There shoul d be no conti nui w between the No. 1 and
No. 2 termi nal s when
power
i s di sconnected.
Five-terminal type B:
.
There shoul d be conti nui ty between the No, 1 and
No. 2 t er mi nal s when power and gr ound
ar e
connected to the No. 3 and No. 5 termi nal s.
.
There shoul d be conti nui ty between the No. 1 and
No. 4 termi nal s when power i s di sconnected.
Intermi ttent wi per rel ay
(' 00-01
model s)
Rear wi ndow defogger rel ay
(' 02-03
model s)
Rear wi ndow defogger change rel ay {' 02-03 model s)
il
l,-a
\5y
{cont' d)
22-41
Relays
Power Relay Test
(cont'd)
Normally-open type B:
'
power and ground are
.
There shoul d be no conti nui w between the No. 1 and
power
i s di sconnected.
22-42
Five-terminal type A:
Check for conti nui l y between the termi nal s.
.
power and
ground are
.
There shoul d be conti nui w between the No.2 and
No. 4 termi nal s when Dower i s di sconnected.
Intermittent wiper relay
('02-03
models)
lgnition Switch
J
rest
SRS components are l ocated i n thi s area. Revi ew the
SRS component l ocati ons, precauti ons,
and
procedures
(see page
23-10).
preset buttons.
2. Di sconnect the battery negati ve cabl e.
3. Di sconnect the 7P connector from the under-dash
fuse/rel ay box.
ORN
(IG2.A)
WHT
(BAT-A}
BLK/RED
(IG2.B}
BLK/YEL
0G 1-B)
WHT/BLK
(BAT-B)
BLK/ YEL {I G1. A)
\ _ t
4. Check for conti nui ty between the termi nal s i n each
swi tch posi ti on accordi ng to the tabl e.
\rorminal
t."'t..1\
WHT/
RED
tacc)
Er1
"t+, WHT
{BAT.
A)
BLK/
YEI-
l t Gl - A)
l t Gl - B)
ORN
tG2-A)
o {LocK)
I tacc) o-
--o

toN) C+ o o-
l f the conti nui ty checks do not agree wi th the tabl e,
repl ace the el ectri cal swi tch.
After reconnecti ng the battery, enter the anti -theft
code for the radi o, then enter the customer' s radi o
statron
presets.
22-43
Gauges
a
a
ENGINE OIL PRESSURE SWITCH
page 8-4
VEHICLE SPEED SENSOR {VSS}
Troubl eshoot i ng,
page 22-53
Repl acement ,
page 22 52
GAUGE ASSEMBLY
Bul b Fepl acement , page 22 46
FUEL GAUGE SENDI NG UNI T
page 11- 1 19
PARKING BRAKE SWITCH
page 19' ' l I
BRAKE FLUID LEVEL SWITCH
page 19 1l
22-44
I
D9' ' . . . . --> D16
A1. . . - - - . . - . > A6
A7. . . . . . .
. >
A14
B1- . . . . - . - - - - -
>
85
86- ' . . . . . . - . - > 812
c 1 .
. > c 1 0
c11. . . - - - - - - - . > C20
Gauge/Tarminal Location Index:
CONNECTOR A CONNECTOR D
CONNECTOR C
FUEL GAUGE
22-45
Gauges
Gauge Bulb Replacement
GAUGE LIGHTS {2,0 W}
SEAT BELT
REMINDER
LTGHT {1.12
W)
SRS INDICATOR
LTGHT 11. 12 Wl
LOW FUEL INDICATOR
Lr GHT { 1. 12 Wl
LI GHT
(3.0 W x 3)
MALFUNCTION INDICATOR
LEFT TURN SIGNAL
INDICATOR LIGHT
t 1. 12 W)
ABS INDICATOR
LI GHT {1. 12 WI
BRAKE SYSTEM
LTGHT
(1.12
Wl
CHARGING SYSTEM
LTGHT {1.12
W)
LOW ENGINE OIL PRESSURE
I NDI CATOR LI GHT
(1. 12
W)
DRL INDICATOR
LTGHT
(1.12
W)
(Canadal
LAMP
(Mt L)
{1. 12 W)
IMMOBILIZER INDICATOR
LTGHT { 1. 12 Wl
DOOR INDICATOR
LrGHT
(1.12W) MAINTENANCE REOUIBED INDICATOR {REMINDER}
LTGHT {1. 12
W}
TRUNK INDICATOR
LTGHT t1.12Wl
CRUISE INDICATOR
LTGHT {1.4 W}
HI GH BEAM
INDICATOR
LTGHT 11. 12 Wt
EPS INOICATOR
LTGHT {1. 12W1
GAUGE LIGHTS 13.O W)
22-46
Ci rcui t Di agram
lEt
ECM
DAvllME
:
rcM
RUNNING
I
IIGHTS I
CONTEOL
. . u! L. . _. . - J
(cont' d)
MAINUNDER HOOD fUSE/BILAY BOX
I
I
m l
DRL
!DrcATON
UGI{T
l1.r2w)
22-47
Gauges
Circuit Diagram
(cont'dl
.
E?S
c0rvn0t
UI{IT
'
co[vEFn&t
T0t
c0Nnot
UMT
.
cSulsE
MMIOL
UI{IT
l "
I
I
G501
22-48
rcYESS
DOOF LOCK
CONIFOL
UI\IIT
8lx
I
G6o1
RED/l{r{r
t,
/'F\ lcl'llllol'l
[ - l ]
r GY
Y SWITCH
11
qo$d.
8Ll(
I
I
I
_o
Gr01
( cont ' d)
22-49
Gauges
Circuit Diagram
(cont'd)
aBs sns
MODUIATOS UI{II
UI{IT
GAUCE ASSEMEIY
22-50
I'{0.6{1541
FUSE
\7
I
-
EUNr' ltNG
^Di,,orn _,2 |
ucHrs
\
CONTBOT
{Cdrdal
22-51
Gauges
2.
?
Gauge Assembly Replacement
1 . Lower the steeri ng col umn, and remove the dri ver' s
ai rbag, steeri ng wheel . steeri ng col umn covers
cabl e reel , and combi nati on swi tch assembl y {see
page 17- 9) .
Remove the i nstrument panel (see page 20 80).
Remove the screws
(A)from
the
gauge assembl y
{B),
and spread a protecti ve cl oth
(C}
on the
steenng col umn.
c A
(D),
and remove the
gauge assembl y.
Remove the screws and the
gauge
assembl y
brackets,
6. l nstal l i n the reverse order of removal .
22-52
VSS Replacement
1 .
3.
Rai se the vehi cl e, and make sure i t i s securel y
su
pported.
Di sconnect the 3P connector from the vehi cl e
speed sensor
(VSS).
Remove the mounti ng bol t, then remove the VSS.
l nstal l i n the reverse order of removal .
J )
J )
Vehicle Speed Signal Circuit Troubleshooting
Note; l f the MIL i ndi cator i s ON, troubl eshoot the PGM-
Fl probl em fi rst.
1. Rai se t he vehi cl e, and make sur e i t i s secur el y
supponed.
2. Di sconnect the VSS 3P connector.
3. Tur n t he i gni t i on swi t ch ON { l l } .
Check for vol tage between the VSS 3P connecl or
No. 3 t er mi nal and body
gr ound.
VSS 3P CONNECTOR
l s thete l ess than 1 V?
YES Go to step 5.
NO Repai r open or hi gh resi stance i n the BRN/
YEL wi re between the VSS and G 101. I
)
___a-
J
22-53
5. Measure vol tage between the VSS 3P connector
No. 1 t er mi nal and body gr ound
VSS 3P CONNECTOR
ls thete apptox. 5 V?
YES Go to step 6.
NO- Repai r shon i n the YEUBLU wi re between
t he VSS and t he ECM. I
(cont' d)
Gauges
Vehicle Speed Signal Circult
Troubleshooting
(cont'dl
Reconnect the VSS 3P connector, and put the car i n
neutral wi th the i gni ti on swi tch ON
(l l ).
Sl owl y rotate the
propel l er
shaft.
Measure vol tage betr,/veen the gauge assembl y
connector C
(20P)
No. 3 termi nal and body ground.
GAUGE ASSEMBLY CONNECTOB C {2OP}
Does voltage pulse trcm 0 to approx. 5 V?
YES Check connecti ons, and i f necessary, repl ace
the
pri nted ci rcui t board.l
NO Go to step 9.
Di sconnect the 3P connector from the vehi cl e
speed sensor l VSS).
( l l ) .
Measure the vol tage between the vss 3P
connector No.2 termi nal and body ground.
ls there approx. 5 V?
YES Repl ace the VSS. !
NO
--
Repl ace the short to ground or open i n the
BLU,^/vHT wi re. t
7.
8.
9.
10.
1 1 .
12.
22-54
Mai ntenance Requi red Indi cator
Reset Procedure
How to Reset:
Push and hol d the tri p button. turn the i gni ti on swi tch
ON
( l l ) ,
and cont i nue hol di ng t he t r i p but t on I or mor e
than 10 seconds.
At 5,900
(9,440)
to 6.100
(9.760
Bl i nks f or 10 seconds when t he
Comes on and stays on whi l e At 7, 400
( 11, 840)
1 . 600 t 12. 1
) J
Tachometer Circuit
Troubl eshooti ng
NOTE: l f the MIL i ndi cator i s on, troubl eshoot the PG l M-
Fl Drobl em fi rst.
1. Remove the gauge assembl y
(see page 22-52).
2. Di sconnect the gauge assembl y connector C
(20P)
and t he ECM connect or A
( 32P)
3. Check for conti nui ty between the gauge assembl y
connector C {20P) No. 5 termi nal and ECM
connect or A { 32P) No. 19 t er mi nal .
CAUGE ASSEMBTY CONIVECTOF C I2OPI
J )
YES Go to step 4.
NO Repai r open i n the BLU wi re between the
gauge
assembl y and t he EcNi l . l
connect or C
( 20P)
No. 5 t er mi nal and body gr ound.
YES Repai r shor t t o
gr ound i n t he BLU wi r e
between the gauge assembl y and the ECl vl .I
NO Go to step 5.
Reconnect the gauge assembl y connector C
(20P)
and the ECM connector A {32P).
Check the EPS system tot DfC 22 ot 23.
l s DTC 22 or 23 present?
YES Go to the EPS system Troubl eshooti ng Index.
l f OK, substi tute a known-good ECM and rel est the
ci r cui t . l f OK, r epl ace t he ECl M. l
NO Check for conti nui ty between the gauge
assembl y connect or A14 t er mi nal and t he EPS
conl r ol uni t connnect or 812 t er mi nal , and t he
gauge assembl y connect or C5 t er mi nal and t he EPS
cont r ol uni t connect or B5 t er mi nal . l f OK. r epl ace
the mai n pri nted
ci rcui t board i n the gauge
assembl y. l
4.
5.
6.
)
I
J
22-55
2.
3.
Coolant Temperature Gauge Circuit
Troubl eshooti ng
1 . Check for PGM-Fl DTCS.
l s DT C P01 16, P0117, or P0118 i ndi cat ed?
YES Go t o t he ECM DTC Tr oubl eshoot i ng I ndex. l
NO Go to step 2.
Remove t he gauge assembl y { see
page
22- 52) .
Di sconnect the gauge assembl y connecter C
(20P)
and the ECM connecter A {32P).
connect or C
( 20P)
No. 7 t er mi nal and ECM
connect or A
( 32P)
No. 1 t er mi nal .
GAUGE ASSEMBLY CONNECTOR C {2OP}
YES Go to step 5.
NO Repai r open i n the YEVGRN wi re between the
gauge assembl y and t he ECM. I
connect or C
( 20P)
No. 7 t er mi nal and body gr ound.
YES Check the output from the ECM fi rst, i f OK,
repai r shon to body
ground i n the YEL/GRN wi re
bet ween t he gauge assembl y and t he ECM. I
NO Check connect i ons, l f OK, r epl ace t he mai n
pr i nt ed ci r cui t boar d i n t he gauge assembl y. I
Lights-on, Key-in, Seat Belt Reminder System
MAIN UNOEi.IIOOO FUSARELAY EOX IGNIIION SWITCH
Circuit Diagram
ORIVEBS
SEAT 6ELT
stvtlcS
fctcad: l
L',Ylrn unhctLd J
OFIVEF'S
D@R
swrTcH
fc56.d: I
Looo. opan J
22-56
J
1 .
2.
System lnput Test
Remove the gauge
assembl y
(see page
22-52).
Inspectthe al l connectors and socket termi nal s to be surethey are al l maki ng good
contact.
.
l f t he t er mi nal ar e bent , l oose, or cor r oded, r epai r t hem as necessar y. and r echeckt he syst em.
.
l f the termi nal s l ook OK,
go
to step 3.
GAUGE ASSEMBLY CONNECTOR A I 14PI
BLU/ RED
GAUGE ASSEMBLY CONNECTOR B I 12P)
,,7*
J
Wi re si de of
femal e termi nal s
GAUGE ASSEMBLY CONNECTOR C {2OP}
RED/WHT
{cont' d)
REO/ BLK
22-57
Lights-on, Key-in, Seat Belt Reminder System
System Input Test
(cont'dl
Wi th the connectors connected, back
probe
the connectors and make these i nput tests.
. l f anyt est i ndi cat esapr obl em, f i ndandcor r ect t hecause, t henr echeckt hesyst em.
.
l f al l the i nput tests
prove OK, the gauge assembl y must be faul ty; repl ace i t.
Cavity Wi re Test condition Test: Desird resull Possible cause il result is not obtained
B4 YEL l gni ti on swi tch
oN
( l r )
Check for vol tage to
ground:
.
Bl own No. 5
( 7. 5
A) f use i n t he
.
B5 WHT/REDUnder al l
condi ti ons
Check tor vol tage to
ground:
Bl own No. 25
(7.5
A) fuse i n the
under-dash f use/rel ay box
B3 RED/BLK Combi nati on
l i ght swi tch
ON
Bl own No. 23
(10
A) fuse i n the
Faul ty tai l l i ght rel ay
Faul ty combi nati on l i ght swi tch
An ooen i n the wi re
RED,A/VHTl gni ti on key i s
i nserted i nto
t he i gni t i on
swi tch
ground:
There shoul d be 1 V or l ess.
Faul ty i gni ti on key swi tch
l gni ti on key
not i n i qni ti on
ground.
There shoul d be 5 V or more.
Faul ty i gni ti on swi tch.
Short to
qround
i n the wi re.
A'1 BLU/RED l gni ti on swi tch
ON
( l l )
and
dri ver' s seat
bel t unbuckl ed
ground:
There shoul d be
' 1
V or l ess.
Faul ty dri ver' s seat bel t swi tch
Poor gr ound
( G601)
l gni ti on swi tch
ON
( l l )
and
dri ver' s seat
bel t buckl ed
ground.
Faul ty dri ver' s seat bel t swi tch.
Short to
ground i n the wi re.
B8 BLK Under al l
condi ti ons
Check for conti nui ty to
ground:
There shoul d be conti nui w.
.
.
Ito GRN Dri ver' s door
oDen
Faul ty dri ver' s door swi tch
Dri ver' s door
ctoseo
ground.
.
Faul ty dri ver' s door swi tch.
.
Short i n the wi re.
ON
( l l )
and t r i p
reset button
oresseo
Check the beeper operati on.
The beeper shoul d come on.
Faul ty beeper
Poor
gr ound ( G501)
Faul tv
qauoe
assembl v
B5 WHT/RED
B8 BLK
22-58
Exterior Lights
Component Location lndex
HEADLIGHT RELAY 1
{Rightl
Test , page 22-40
MAIN UNDER-I{OOD
FUSE/RELAY BOX
HEADLIGHTS/FRONT PARKING LIGHTS
Repl acement , Daqe 22-71
HI D Bul b Remova-I , page
22-69
Adj ust ment , page 22-72
HfD Troubfeshooting, page 22-68
SI DE TURN SI GNAL LI GHT
Repl acement , page 22' 74
FRONT TURN SIGNAL LIGHT
HIGH MOUNT
BRAKE LIGHT
LICENSE PLATE LIGHT
Repl acement , page
22-75
(cont' d)
r ) A f - , - -
r i
n n l
- - i ;
f =
LJ t _I L L r L=r Lr
L : i i
1 - I l L
SIDE MARKER LIGHT
22-59
Exterior Lights
(cont'd)
DASH LIGHTS BRIGHTNESS
CONTROLLER
I nput Test , page 22-85
-
HIGH BEAM CUT RELAY
(Canadal
fWi re
col ors: RED/BLU, oRN,
I
LBLU
and BLU/RED
.l
Test, page 22-40
BEAM I NOI CATOR LI GHT
Bul b Locat i ons,
page 22 46
DRL INDICATOR LIGHT {Canada)
Bul b Locat i ons, page 22-46
n
COMBINATION LIGHT
swtTcH
TesVRepl acement ,
page 22-65
DAYTIME RUNNING
LIGHTS CONTROL
UNI T {Canadal
IG2 RELAY
fWi re
col ors: 8Ll (RED, YELI
LBLUAVHT
and LT BLU
l
Test, page 22-40
AILLIGHT RLAY
[Wi re
col ors: RED/BLK, WHT/GRN,
I
LWHT/GRN
and BLU
I
Test, page 22-40
-
L
-
,
=
-l
--
-
T-t
t l
l l
22-60
Circuit Diagram
-
USA
HEl0!o1T
li$*)
;15s199
fff*
LlGNI
, . , ?' d5-i
22-61
Exterior Lights
Ci rcui t Di agram
-
Canada
DRL
INDICATOF
LIGIII
V
I
SLUN.|.iHI
RGNT
HEADLIGHT
(Hioh
beaml
i5sw)
I ^ L
I*-I
I
.CONVERTIBLE
I iHh*'
I
i,lfltu
I Y
GRNWHI G8I']]WF]I
l_r
@isu+,
I
I Le'..' ue l
I
I
-
HEADL|GHT
' -i-_-
(35W)
OAYTIME FUNN NG LIGNTS CONTROL UN]T
MA N UNOR-HOOO FUSE/FELAY 8OX
LEFT
NEADLIGHT
(3sw)
UNOER-OASH
FIJSE/RELAY
BOX
NEAOLIGHT
FELAY 1
UNOER DASH
FUSE/REUYEOX
''"-'T;_:
t t
? J
( P ]
I RIGHT I L]CENSE
I TA LIIGHT I PTITE
lou lii8il
t l
LX BLK
H
BIK
{
G5m
ED/BLK 8ED/BLK RO/8I( RED/BIK BEO/AIX 8EI
t t t t l
.r\ /r\ ,+\ ,,r\ i
( 9 ( 9 ( 9 ( 9 ( t ) (
liF[* l:A'd; lh',[ llt"^{ l!i['o'.,
I
P^8(NG
I
p^R!|iG
I
SD!
|
SrqE
| {5!v)
I LIGHT I LGHT I [^R(EF I MAFKEF I
lo, l,*, lllff, liiil |
BLK BLK 8LK BLK 8LK 8
l l
t l
I t
; :
G30J G201 G401
Exterior Lights
MAIN UMEN HOOO
FUSE/BELAY BOX
Circuit Diagram
-
Brake Lights
22-64
t{A|t ut{0ln-8000
FUSE/8ELIY BOX
Circuit Diagram
-
Back-up Lights
BAC(-UP
LIGHT
1
RGHT
_/ ucxr
i
i21wl
i
{21W1
J )
1 .
2.
3.
4.
Combination Light Switch Test/Replacement
Remove the steeri ng col umn covers
(see page
17-9).
Di sconnectthe 16P connector
(A)trom
the combi nati on l i ght swi tch {B).
Remove the two screws, then
pul l
out the combi nati on l i ght swi tch.
Inspect the connector termi nal s to be sure they are al l maki ng good
contact.
.
l f the termi nal s are bent, l oose or corroded, repa i r them as necessa ry, a nd recheck the system.
' l f t het er mi nal sl ookOK, checkf or cont i nui t ybet weent het er mi nal si neachswi t chposi t i onaccor di ngt ot he
tabl es.
-
l f the conti nui ty i s not as speci fi ed, repl ace the swi tch.
Light switch:
Uin"l
Position
6 4 12 13
Headl i ght swi t ch
OFF
o-
LOW
o
o
HIGH
Passing switch
OFF
ON
Turn signal switchi
l--___Ig-'9
Position
2 1 1 10
LEFT o
NEUTRAL
RIGHT
o
J )
) r ,
___-.4.
22-65
Exterior Lights
Daytime Running Lights Control Unit Input Test
-
Canada
1. Di sconnectthe 14P connector
(A)
from the dayti me runni ng l i ghts control uni t
(B).
2.
BLU/RED RED/BLU YEL/BLK
Inspect the connector and socket termi nal s to be sure they are al l maki ng
good contact'
.
l f the termi nal s are bent, l oose orcorroded, repai rthem as necessary, and recheckthe system'
.
l f the termi nal s l ook OK. go to step 3.
22-66
3. Make these i nput test at the connecror.
. l f anyt est i ndi cat esapr obl em, f i ndandcor r ect t hecause, t henr echeckt hesyst em,
.
l f al l the i nput tests prove
OK,thecontrol uni t must befaul ty; reprace rr.
Cavity Wi re Test condition Test: Desired result Possible cause if result is not obtained
2 RED/BLU Under . al l
condt t t ons
Bl own No.54
(30
A) fuse i n the
Bl own No. 27
(10
A) fuse i n the
12 YEUBLK l gni ti on swi tch ON
flr)
.
Bl own No. 19
(7.5
A) fuse i n the
.
Faul t y l G2 r el ay
. An ^nah i n t ha \ ^, i r 6
4 BLK Under al l
condi ti ons
There shoul d be conti nui tv.
.
Poor ground (G402)
.
7 BLK U nder al l
condi t i ons
.
Poor gr ound ( c402)
.
3 RED/YEL Combi nat i on l i ght
swi tch ON
(=D)
Check for vol tage to ground;
Bl own No. 45
( 20
A) f use i n t he
Faul t y headl i ght r el ay 2
5 REDA/VHTCombi nat i on l i ght
swi tch ON
(3D)
There shoul d be baftery vol tage.
El own No. 43
(20
A) fuse i n the
Faul ty headl i ght rel ay 1
1 REDANHT Combi nati on l i ght
swi tch ON
(=D),
and di mmer swi t ch
i n HI GH
Connect a
j umper
wi re between
No. 3 and No. 1 t er mi nal s.
Lef t headl i ght ( Hl cH)
and hi gh
beam i ndi cator l i ght shoul d
come on.
j
.
Bl own bul b
I
.
Faul ty hi gh beam cut rel ay
.
.
.
1 1 RED/ORN Combi nat i on l i ght
swi tch ON
(=D),
and di mmer swi tch
i n HI GH
Connect a
j umper
wi re between
No. 5 and No. 11 t er mi nal s.
Ri ght headt i ght ( HI GH)
shoul d
come on.
Bl own bul b
1 0 RED/BLU Com bi nat i on l i ght
swi tch ON {=D},
and di mmer swi t ch
i n HI GH
.
.
.
Poor gr ound ( c401)
-
6 G R NA/VHT Parki ng brake l ever
up
Ther e shoul d he c. j nt i nr r i i w
Faul ty parki ng
brake swi tch
Ah ^ n6h i ^ +l ' - . ^ , i . ^
I BLU/ REDUnder al l
condi t i ons
ground:
There shoul d be batterv vol taoe.
Faul ty headl i ght rel ays
9 BLU/'|/HT l gni ti on swi tch ON
{ | | )
Bl own bui b
Bl own bul b
-
1
Attach to ground;
The DRL i ndi cat or l i ght shoul d
come on.
Attach to ground:
The brake system l i ght shoul d
come on.
GRN/ REDl gni t i on swi t ch ON
flr)
22-67
Exterior
Lights
HID Lamp System
Troubl eshooti ng
Never turn on the combi nati on l i ght swi tch before
fi tti ng the HID bul bs to thei r bul b sockets and
compl et i ng t he r eassembl y of t he headl i ght
assembl y.
1. Check t he No. 43
( 20
A) and No 45
( 20
A) f usei n
the mai n under-hood fuse/rel ay box.
Are the fuses OK?
YES Go to step 2.
NO Repl ace the fuse
(s),
and recheck l
2. Substi tute a known-good HID bul b and recheck.
Does the headlight low beam come on?
YES Repl ace t he HI D bul b. l
NO Go to step 3.
3. Turn the combi nati on l i ght swi tch ON
4. Measure the vol tage between the No 2termi nal of
the i nverter uni t 2P connector and body
ground.
TNVERTER UNI T 2P CONNECTOR
-l
1 2
Wi re si de ol femal e l ermi nal s
Is l here bauery vol tage?
YES Go to step 5.
under-hood fuse/rel ay box and the i nverter uni t.l
22-68
5. Check f or vol t age bet ween t he No. l t er mi nal of t he
i nverter uni t 2P connector and bbdy
ground.
I NVERTER UNI T 2P CONNECTOR
2
Wi r e si de of l emal e t er mi nal s
l s there l ess than 1 V ?
YES Substi tute a known-good i nverter, and
recheck. l f the symptom/i ndi cati on
goes away,
r epl ace t he or i gi nal i nver t er uni t . I
NO Repai r open i n the wi re between the i nverter
uni t and body
ground. l f the wi re i s OK, check for
poor gr ound at G201 or G301. t
HID Bulb Removal
A transi ent hi gh tensi on
(25,000
V) occurs at the
bul b sockets of the hi gh i ntensi ty di scharge
(Hl D)
l amps when the combi nati on l i ght swi tch i s turned
ON. l t may cause seri ous el ectri cal shock or
el ectrocuti on i f you
do not observe the cauti ons
bel ow.
.
Never turn on the combi nati on l i ght swi tch
bel ore l i tti ng the HID bul bs to thei r bul b sockets
and compl eti ng the reassembl y ofthe headl i ght
assemotv.
.
Do not servi ce the headl i ghts assembl y i n wet
condi ti ons, such as rai n or snow, near a spri nkl er
system. or when your hands are wet to prevent
el ectrocuti on.
.
Do nottouch the surface ofthe HID bul bs wi th
your
bare hands and do not stai n i t wi th anv oi l s
and fats.
.
Do not di sassembl e the i nvener uni t and the
i gni ter uni t.
.
Do not turn on the HID bul b by usi ng a
power
source other than the battery mounted i n your
vehi cl e.
1. Make sure you
have the
anti -theft code for the radi o.
then write down the frequencies for the radio,s
preset
buttons.
2. Turn the combi nati on l i ght swi tch OFF.
3. Di sconnectthe
battery negati ve cabl e, then
disconnect the positive
cable.
4. Remove the front part
of the i nner fender as
necessary (see page 20-105).
5. Di sconnect 2P connector
(A)trom
the i nverter uni t.
Remove the Torx bol t usi ng a tamper-proof Torx
T25 bit.
Turn the cover
(B)
45o countercl ockwi se to remove
i t from the headl i ght assembl y.
7.
(cont' d)
22-69
Exterior
Lights
HID Bulb Removal
(cont'dl
8. Pul l the retai ni ng spri ng
(A)
away from the bul b
(B),
then remove the socket and the bul b
(C).
9. Turn the bul b 45" countercl ockwi se to remove i t
from the socket.
22-70
10. l nstal l the new bul b i n the reverse order of removal .
11. After reconnecti ng the battery, enter the anti -theft
code for the radi o, then enter the customer' s radi o
statron Dresets.
Headl i ght Repl acement
Headl i ghts become very hot duri ng use; do not
t ouch t hem or any at t achi ng har dwar e i mmedi at el y
after they have been turned off.
1 .
2.
Remove the front bumper
(see page 20-92).
Remove the front part of the i nner fender as
necessary
(see page 20-105).
(A)
from the headl i ghts.
4. Remove the four bol ts, then remove the corner
upper beam
(B).
Headlight (High)i
Headl i ght
(Low):
Front Turn Si gnal Li ght:
Front Parking Light:
3.
55W
3 5 W
21 W
5 W
5. Remove the four bol ts, then remove the headl i ght
assemot y.
6.
7.
Instal l the headl i ght i n the reverse order of removal .
After repl acement, adj ust the headl i ghts to l ocal
requi rements
(see page
22-721.
22-71
Exterior Lights
tl
!a
Headlight Adiustment
Betore adiusting tho headlights:
'
Parkthe vehi cl e on a l evel surface.
.
Make sure the ti re
pressures are correct.
.
The dri ver or someone who wei ghts the same shoul d
si t i n the dri ver' s seat.
1, Cl ean the outer l ens so that
you
can see the center
oi the headl i ghts
(A).
Headl i ghts become very hot duri ng use; do not
touch them or any attachi ng hardware i mmedi atel y
after thev have been turned off.
22-72
1
Park the vehicle 7.5 m
(25
ft) awa.y from a wall or a
scren
(A).
3. Open the hood.
7.5 m
(25
ftl
Turn the l ow beams on.
Determi ne i f the headl i ghts are ai med properl y.
Vertical adiustment:
Measure the hei ght ofthe headl i ghts
(A).
The l i ghts
shoul d refl ect 52 mm
(2.1
i n.) bel ow headl i ght
hei ghr
{ B) .
6. l f necessary, adj ust the he,adl i ghts to l ocal
requi rements by turni ng the verti cal adj uster
(A).
A
..",4<7
22-73
Exterior Lights
Si de Turn Si gnal Li ght Repl acement
1. Push t he si de t ur n si gnal l i ght ( A) f or war d, t hen
remove i t from the fender.
Si de Turn Si gnal Li ght Bul b: 5 W
(B)from
the l i ght.
22-7 4
Tai l l i ght Repl acement
NOTE; For bul b repl acement, see the owner' s manual .
1. Open t he t r unk l i d and
pul l back t he t r unk t r i m
panel (see page 20-73).
2. Di sconnect the connectors
(A)from
the tai l l i ght.
Brake/Tai l l i ght: 2115W
Back-up Li ght: 21W
Turn Si gnal Li ght: 21W
Side Marker Light: 5 W
Remove the four mounti ng nuts
(B),
then pul l out
t he t ai l l i ght .
Before i nstal l i ng the tai l l i ght, check the gasket. l f i t
i s di storted or stays compressed, repl ace i t.
Instal l the tai l l i ght i n the reverse order of removal .
After i nstal l i ng the tai l l i ght. run water over i t to
make sure i t does not l eak,
]t
5.
6.
Hi gh Mount Brake Li ght
Replacement
4.
Open t he t r unk l i d.
(A)
from the hi gh
mount br ake l i ght
( B) .
Remove the fi ve mounti ng nuts, then
pul l
out the
hi gh mount brake l i ght.
Instal l the hi gh mount brake l i ght i n the reverse
order of removal .
After i nstal l i ng the hi gh mount brake l i ght, run
water over i t to make sure i t does not l eak.
1 .
2.
License Plate Light Replacement
1 . Remove the l i cense
pl ate
l i ght assembl y, and
di sconnect the 2P connector from i t.
Li cense Pl ate Li ght Bul b;5 W
:
2. Take the l ens off. then reol ace the bul b.
22-75
Turn Si gnal /Hazard
Fl asher
4
{
UNDER.DASH
FUSE/RELAY BOX
TURN SIGNAL INDICATOR LIGHTS
(l n
the gauge assembl y)
Bul b Locati ons,
page 22 46
COMBINATION LIGHT/
TURN SIGNAL SWITCH
Test , page 22-65
HAZARD WARNING SWITCH
Test , page 22 79
TURN SIGNAL/HAZARD RELAY
I nput Test ,
page 22' 78
-i\
- - .
r ' \ r
\ " ' =
, - 9
=
'-
-
I
=
L J
L ]
=
I
22-76
a
Ci rcui t Di agram
UNDR.OASH
FUSE/FLAY BOX
6\ t * " , . 1
v| ni < o-; LN' ; LT=r-t
\:-/
L
",,..,
N0.23 (r0A)
I
BI-K
G3OJ c:301
BLX
@2
MAIN UNOEF-HooO 'USAREL^Y 80X
I
I
l l
r J
DASH LIGHTS
BRIGNTI{ESS
co.lTRol.lER
/{n
th. ga'{6\
SLK 8\K
11
LEFTIURN SIGM! LIGHT
G501 Cr20r c20r c6o2
Turn Si gnal /Hazard
Fl asher
Turn Signal/Hazard
Relay Input Test
1. Remove the turn si gnal /hazard rel ay {A)from the under-dash fuse/rel ay box
(B)
InsDect the connector and socket termi nal s to be sure they are al l maki ng
good contact.
.
l f the termi nal s are bent, l oose, orcorroded, repai rthem as necessary, and recheckthe system
.
l f the termi nal s l ook OK, go to step 3.
Make these i nput tests at the fuse/rel ay box.
. l f anvt est i ndi cat esaDr obl em, f i ndandcor r ect t hecause, t henr echeckt hesyst em.
.
l f al l the i nput tests
prove OK,theturn si gnal /hazard rel ay must befaul ty; repl ace i t.
Cavity Test condiiion
Test: Desired result Possible cause if result is not obtained
2 Under al l condi t i ons Check for conti nui ty to ground:
Poor
gr ound ( G401)
3 l gni t i on swi t ch ON
( l l )
There shoul d be batterY vol tage.
Bl own No. 7
( 7. 5
A) f use i n t he under
dash fuse/rel ay box
Faul ty hazard warni ng swi tch
Hazard warni ng swi tch
ON, i gni ti on swi tch
OFF
Bl own No. 49
(10
A) fuse i n the under-
hood fuse/rel ay box
1 Hazard warni ng swi tch
ON and connect No. 1
and No. 2 t er manal s
Hazar d l i ght s shoul d come on. Poor gr ound ( G201,
G301. G501,
G 602)
Faul ty turn si gnal swi tch
l gni t i on swi t ch ON
( l l )
and connect No. 1 and
No. 2 t er mi nal s; t ur n
si gnal swi t ch i n r i ght or
l eft Dosi ti on.
Ri ght or l eft turn si gnal l i ghts
shoul d come on,
22-78
Hazard Warning Switch Test
1. Remove the center consol e
(see page
20-76),
2. Di sconnect the I0P connector
(A)
from the hazard
warni ng swi tch
(B).
Remove the two screws and the hazard warni ng
SWI TCN.
Check for conti nui ty between the termi nal s i n each
swi tch posi ti on
accordi ng to the tabl e.
4.
l f the conti nui ty i s not as speci fi ed, repl ace the
i l l umi nat i on bul b { C) or t he swi t ch.
\
Termi nal
;""tta" \
2 4 8 9 10
OFF
"l
o o
-o
ON o o
-o
o o
o
-@
O
22-79
Interior Lights
DRIVER'S DOOR SWTCH
DOOR SwlTCH
TRUNK LATCH SWITCH
Test, page 22-83
22-80
Ci rcui t Di agram
UNDEB.DASIT
FUSE/FELAY BOX
' .r.' Fl -wHrBruT
t l
I
s*t,"^
|
,Y"
l_i
I
f
cbsd:
I
L lrunk lid oten.J
TBUNK
LAICFl
swtTcH
OSI VEBS
000R
SW]TCN
fobsed l
gIU/ALK
+
BLK
G60t
GRN
t
I
MA N UNDEB HOOD FUSE/BELAYEOX
d
OFF
MIDDLE
22-81
Interior Lights
Cei l i ng/Spotl i ght Test
Turn the cei l i ng/spotl i ghts swi tch OFF.
Pry off the l ens {A).
Cei l i ng/Spotl i ght Bul b: 5W
1 .
2.
3,
4.
Remove the two screws and the cei l i ng/spotl i ght
hous I ng.
(B)
from the housi ng
(c).
22-82
swi tch
posi ti on accordi ng to thdtabl e.
\
Termi nal
;il;
---tl\
1 2
BODY
GROUND
CEI LI NG LI GHT
OFF
MIDDLE
re'o
ON o r @
----o
SPOTLIGHTS
ON
R I
OFF
,
- o N
OFF
G
- - o
G
-----o
bul bs or t he l i ght .
Trunk Light Test
Open t he t r unk l i d.
Pr y out t he t r unk l i ght assembl y.
Trunk Li ght Bul b: 5W
3, Di sconnect the 2P connector from the housi ng.
4. Open the trunk l i ght cover.
5. Check f or cont i nui t y bet ween t he No. 1and No. 2
t er mr nal s.
6. l f there i s no conti nui ty, repl ace the bul b or the l i ght.
1 .
2.
Trunk Lid Latch Switch Test
1. Open t he t r unk l i d.
2. Di sconnect the 3P connector from the trunk l atch.
t r unk l i d posi t i on accor di ng t o t he t abl e.
\
Termi nal
ill'l";-ll\
2
OPEN
o o
cLosEo
4. l f the conti nui ty i s not as speci fi ed, repl ace the
t r unk l at ch.
22-83
Dash Lights Brightness Controller
| /,il\
L-+r
>F 8rx/YEL
\ l c1-r/
Circuit Diagram
t
I
I
I
T
I
I
+
c{01
MAIN UItDEfi HOOOFUSE/BEIAY 8OX
UiIDER DASH
FUS[/NELAYEOX
22-84
Controller Input Test
1. Remove the gauge
assembl y
(see page
22-52).
2. I nspect t hegaugeassembl yconnect or B( 12P) t er mi nal st obesur et heyar eal l maki ng good
cont act .
.
l f the termi nal s are bent, l oose, orcorroded. repai rthem as necessary, and recheck the system.
.
l f the termi nal s l ook OK. go to step 3.
RED/BLK YEL WHT/RED
Wi re si de of
J
)
A
(cont' d)
J
22-85
Dash Lights Brightness Gontroller
1
1
Controller Input Test
(cont'dl
3. Reconnect the connectors to the gauge assembl y.
4. Back probe the connector and make these i nput tests.
. l f al l t hei nput t es t s pr ov eOK, t hec ont r ol l er s wi t c hboar dor t hemai npr i nt edc i r c ui t boar di nt hegauge
assembl y must be faul ty; repl ace i t.
Cavitv Wi re Test condition Test: Desired result Possible cause if result is not obtained
B3 RED/BLK Combi nat i on
l i ght swi tch
ON {)00!) or
Bl own No. 23 { 10 A) f use i n t he
Faul t y t ai l l i ght r el ay
Poor gr ound
{ G401)
oN
( I )
Bl own No. 5
( 7. 5
A) f use i n t he
underdash fuse/rel ay box
B5 WHT/REDUnder al l
condi ti ons
.
Bl own No. 25
( 7. 5
A) f use i n t he
.
B8 BLK Under al l
condi ti ons
There shoul d be l ess than 1 V.
B9 BLK Under al l
condi ti ons
810 RED Combi nati on
l i ght swi tch
ON
(i 001)
or
Connect to ground:
Dash l i ght s shoul d come on f ul l
bri ght.
22-86
-
Audio System
I
RADIO REMOTE SWITCH
Test, page 22-90
ACCESSORY POWER SOCKET RELAY
[Wi .e
col ors: WHT/BED, LT BLU;l
LYEL/RED
and BLUAVHT
l
Test, page
22-40
\
':.r
i
'
,.,\
r,,
AUDIO UNIT
Removal , page 22-89
Connector Bepl acement, page
22-89
LEFT TWEETER {'02-03 modelsl
TWEETER
('02-03
modelsl
PASSENGER'S DOOR SPEAKER
ORI VER' S DOOR SPEAKER
Fepl acement , page 22-91
ANTENNA
/
' t
I
',-4
1
ANTENNA LEAD
Audio System
Ci rcui t Di agram
DlsH Lictlls
BB|GHflESS
c0f{Ti0tun
E SIE
srAiT
slvtTcH
v
I
G502
MAINUNOEN HOOD FUSgffIAY 8OX
AUOIOUl{T
o @ o @
LINTWEETEB' DRIVEI'S PASSEIGETS ftGHITWEEIIS'
0008 sPflxES Doons'urcn
LIGHT |
-
l0.55wril
lij
a
lu' ]lnu ]l:r*" ll"',
22-88
1 .
Audi o Uni t Removal
Make sure you have the anti -theft code for the radi o.
preset buttons.
Remove the radi o panel (see page 20-80).
Remove the four mounti ng screws
(A).
Di sconnect the 20P connector {B) and antenna l ead
( C) f r om
t he audi o uni t .
2.
3.
5.
6.
Audio Unit Connector Replacement
When repl aci ng an audi o uni t connector, match the
wi r es t o t he cavi t i es l i st ed i n t he f ol l owi ng t abl e.
Cavi t i es 4, 5, 6, 11, 12, 13, 15 and 16 ar e not used.
Cavitv Wire Connect to
1 YEL/ GRN Ant enna ampl i f i er
2 WHT/REDACC
(Mai n
stereo power
suoDr v,
3 GRN/ REDRadi o remote swi tch
7 GRN/ BLKPassenger' s door speaker
(+
),
RI G HT Tweet er
( +
) '
8 GRNI/EL Dri ver' s door speaker
(+
),
LEFT Tweet er
( +) '
9 RED/ BLK Li ohts-on si onal
1 0 WHT/BLU Constant
power
1 4 YEL/BLU Radi o remote swi tch
(MUTEI
17 LT GRN Passenger' s door speaker
(
)
RI GHT Tweet er
(
) '
1 8 GRY/REDDri ver' s door speaker
(
)
LEFT Tweeter
(
)'
l q
RED Dash l i ghts bri ghtness
cont r ol l er
20 BLK G r ound { G502)
: ' 02- 03 model s
22-89
Audio System
J
J
1 .
Radio Remote Switch Test
Remove the i nstrument panel (see page 20-80).
(A)
from the swi tch.
Remove the three mounti ng screws
(B).
Measure resi stance between the No. 5 and No.6
termi nal s i n each swi tch
posi ti on accordi ng to the
tabl e.
l f the resi stance i s not as speci fi ed, repl ace the
swi tch.
t
3.
4.
Position Resistance
OFF Aoorox. 10 k Q
VOL. UP
( +)
Approx. 307.3 k Q
VOL, DOWN
( )
Approx.46.8 k Q
CH ADDr ox. 906. 6 k Q
MODE Aoorox. 2.6 k O
22-90
I
swi tch
posi ti on accordi ng to the tabl e.
i l l umi nati on bul b{s)
(B)
or the swi tch.
\
Terminal
t ""-
----- ----\
3 1
COMBINATION LIGHT SWITCH ON
G o
COMBINATION LIGHT SWITCH OFF
Wi th the MUTE swi tch ON, check for conti nui ty
between the No.2
(+)
and No. 1
(
) termi nal s.
There shoul d be conti nui ty. l f there i s no conti nui ty,
reol ace the swi tch.
J
Speaker Replacement
Speaker:
1. Remove the door panel (see page
2O-4).
2. Remove the three mounti ng screws.
J 3. Di sconnect the 2P connector from the soeaker.
Tweeter
('02-03
modelsl:
20-4).
2. Remove the two screws.
3. Di sconnect the 2P connector from the tweeter.
22-91
Audio System
1 ,
2.
Mast Antenna Replacement
Open the trunk l i d.
Remove the ri ght si de trunk tri m
panel (see page
20-731.
Di sconnect the 2P connector from the antenna
ampl i f i er .
22-92
4. Remove the antenna
(A).
r
7.
Remove the antenna nut
(B)
and spacer
(C).
Di sconnect the antenna l ead
(D)
from the antenna
ampl i f i er .
Loosen the mounti ng bol t from the antenna
ampl i f i er .
Remove the antenna amPl i fi er.
5.
6.
J
t
ACCESSORY POWER SOCKET
TesVRepl acement, page 22-95
ACCESSORY POWER SOCKET RELAY
[Wi re
col ors: WHT/RED, YEURED,
J
LBLUMHT
and LT BLU
l
Test, page 22-40
) z
,,
Gi rcui t Di agram
IGN TION SW TCH
6;\\
afrl
I
I
WHTi REO
WHT.+ WHT/8LK
ACCESSOFY
POWER
SOCKET
MAIN UNDER,HOOO FUSE/ RELAY BOX
WBT/NED
BLK
I
I
--
G50t
ENGINE
SIART
swlTcH
V
V
I
8LU,'WHT
I
I
t l
l l
ELUAVHT 8LU/WIiT
I
I
I
.4
-
IG? RLAY
'
SIARTEF CUI
BEL^Y
LT BLU
-J-
CLU]CH
INTERLOCK
swtTcH
22-94
J
Test/Replacement
1 .
2.
3.
Remove the rear consol e
(see page 20-78).
Di sconnect the 2P connector.
Inspect the connector termi nal s to be sure they are
al l maki ng good
contact.
.
l f the termi nal s are bent, l oose or corroded,
repai r them as necessary, and recheck the
system.
.
l f t het er mi nal s l ook OK, go
t o st ep 4.
WHT/RED
Turn the i gni ti on swi tch ACC
(l ),
and check for
vol tage between the No.
' 1
and No. 2 termi nal s.
.
.
l f there i s no battery vol tage, checkfor:
-
bl own No. 9
( 10
A) f use i n t he under - dash
fuse/rel ay box.
-
faul ty accessory power
socket rel ay
-
poor gr ound ( c401,
G60' 1)
-
an open i n t he wi r e.
) J
4 .
)
A
J
22-95
5. Remove the housi ng and socket.
Horn
HORN{l ow)
(' 00-03
model s)
Test / Bepl acement , page 22' 97
MAI N UNDER. HOOD
FUSE/RELAY BOX
: t
l l l l r r
, / \
(' 02-03 model s)
TesVRepl acement ,
page 22-97
22-96
J
Ci rcui t Di agram
)
) J
22-97
2.
3.
Horn Test/Replacement
1 . Remove the front bumper
(see page
20-92)
(' 00-03
model s).
Open the hood
(' 02-03
model s).
(A),
and remove the
hor n
( B) .
Test the horn by connecti ng battery
power
to the
termi nal
(A)
and groundi ng
to the bracket {B). The
hor n shoul d sound.
5. l f i t fai l s to sound, repl ace i t.
Horn
2.
1 .
Horn Switch Test
Remove t he st eer i ng col umn upper and l ower
cover {see
page 17-9).
Di sconnect the dashboard wi re harness B 4P
connector
(A)
from the cabl e reel
(B).
Check for conti nui ty between the cabl e reel No. 2
t er mi nal and body gr ound i n each swi t ch
posi t i on
.
l f there i s conti nui ty. the horn swi tch i s OK.
.
l f there i s no conti nui ty,
go to step 4.
\
Terminal
Position
2 Body ground
Pushed o-
--11
Released
3.
22-98
4. Remove the dri ver' s ai rbag
(see page 23-65).
Check for conti nui ty between the cabl e reel No. 2
termi nal
(A)
and the horn swi tch
posl ti ve termi nal
( B) .
.
l f t her e l s nocont i nui t y, r epl acet hecabl e r eel
(see page 23-72) and check for
proper operati on.
.
l fthere i s conti nui ty, repl ace the horn swi tch.
Trunk Li d Opener
TRUNK OPENER SWITCH
Test, page 22-' 101
f
,_,
/t
''
'//
ltt
"
-'t'
':':'t':'
\ :
\ -
"-'-..-=-
-r I
( . ,
TRUNK OPENER SOLENOIO/
LATCH SWITCH
Sol enoi d Test ,
paqe
22 101
Lat ch Swi t ch Test page 22-83
.l
{
Trunk Lid Opener
UNOER.DASH
FUSAFEUY 8OX
MAIN UNDER.HOOO
FUSE/BEUY 8OX
TRUNK INDICATOR
uGHl
TRUNKLI GHT
I
I
I
I
SLU/8LK
KEYLESS
I
D@N L@K
I
co.{?Rol t2
v q
t l
BIfiEL BLfiEL
r l
r l
I
8L&YEL
Circuit Diagram
soLENo,D jl
:*sl-
BLK
G601
22-100
Trunk Opener Switch Test
Remove the rear consol e
(see p age 20-78| | .
Di sconnect the 2P connector from the swi tch.
3. Check for conti nui ty between the No. l and No.2
t er mi nal s.
.
There shoul d be conti nui ty when the swi tch i s
pusneo.
.
There shoul d be no conti nui ty when the swi tch i s
rel eased.
4. l f the conti nui ty check i s not as speci fi ed, repl ace
the swi tch.
1 .
2.
1 .
Trunk Opener Solenoid Test
Open the trunk l i d.
Di sconnect the 3P connector from the trunk l atch.
Termi hal si de of
mal e t ermi nal s
3. Check sol enoi d operati on by connecti ng power
and
ground
accordi ng to the tabl e. To prevent
damage
to the sol enoi d, appl y battery vol tage onl y
momentari l y.
\
Termi nal
iltfi." \
1 2
UNLOCK
e e
l f the sol enoi d does not operate as speci fi ed,
repl ace i t.
22-101
Power Mirrors
POWER MIRROR SWITCH
Test, page 22-105
POWER MIRROR
Functi on Test,
Page
22-104
Actuator Test,
Page
22-105
Reol acement, Daqe 20-21
Aci uator Repl acehent,
Page
22 106
,/
22-102
Ci rcui t Di agram
MAiN UNOR HooD 'USE/BEUY BOX
UNDEE.DASH
FUSE/8ELAY EOX
LEFT
I
22-103
Power Mirrors
I
{
1 .
Function Test
Remove the dri ver' s door
panel (see page 20-4).
Di sconnect the 10P connector {A) from the
power
mi rror swi tch
(B),
and i nspect the termi nal s. l f the
termi nal s are OK,
go to step 3.
RED GRN/WHT RED/BLU YEL/BLK
3. Choose the appropri ate test based on the
symptom:
.
Both mi rrors don' t work,
go to step 4.
.
Left mi rror doesn' t work, go to step 6.
.
Ri ght mi rror doesn' t work, go to step 7.
Both mirrors
4. Reconnect the 10P connector, and check for vol tage
between the No. 9 termi nal and body
ground wi th
t he i gni t i on swi t ch ON
( l l ) .
l vl ove the mi rror sel ector swi tch to the l eft or ri ght
and hol d down the mi rror swi tch i n any di recti on.
.
l f there i s no batteryvol tage, check for:
-
bl own No.
' 19
{7.5
A) fuse i n the under-dash
fuse/rel ay box.
-
an open i n t he YEVBLK wi r e.
.
l f there i s battery vol tage, go to step 5.
22-104
-
5. Check for conti nui ty between the No. 10 termi nal
and body
ground.
Move the mi rror sel ector swi tch to the l eft or ri ght
and hol d down the mi rror swi tch i n any di recti on
.
l fthere i s no more than 1 V, check for:
-
an open i n t he BLK wi r e.
-
poor ground (G50' l
).
.
l f there i s l ess than 1 V, check both mi rrors
i ndi vi dual l y as descr i bed i n t he next col umn.
Left miror
6, Connect the No. 9 termi nal to the No. 7 termi nal .
and the No. 5
(or
No. 4) termi nal to body
ground
wi th
j umper
wi res. The l eft mi rror shoul d ti l t down
(or
swi ng l eft) wi th the i gni ti on swi tch ON
(l l ).
'
l f the mi rror does not ti l t down
(or
does not swi ng
l eft), check for an open i n the GRN/WHT
(or
RED)
wi re between the l eft mi rror and the 10P
connector. l f the wi re i s OK, check the l eft mi rror
actual or.
.
l f the mi rror nei ther ti l ts down nor swi ngs l eft,
repai r the REDI/EL wi re.
.
l f the mi rror works
properl y, check the mi rror
swi tch.
Right mirror
7. Connect the No. 9 termi nal to the No. 6 termi nal ,
and t he No. 5
( or
No. 3) t er mi nal t o body gr ound
wl th
j umper
wi res. The ri ght ml rror shoul d ti l t
down
(or
swi ng l eft) wi th the i gni ti on swi tch ON
(l l ).
.
l f t he mi r r or does not t i l t down { or does not swi ng
l eft), check for an open i n the GRNMHT
(or
BLU/
WHT) wi re between the ri ght mi rror and the 10P
connector,
l f the wi re i s OK, check the ri ght mi rror actuator.
.
l f the mi rror nei therti l ts down nor swi ngs l eft,
repai r the RED/BLU wi re.
.
l f t he mi r r or wor ks
pr oper l y, checkt he mi r r or
swi tch.
Power Mirror Switch Test
1. Remove t he dr i ver ' s door panel ( seepage20- 4) .
2. Di sconnect the 10P connector from the power
m i r r or swi t ch.
Check for conti nui tV between the termi nal s i n each
swi tch posi ti on
3.
4.
\
Termi nal
F;ani";ll\
3 4 5 6 7 9 10
UP
Dol/vll
L. LEFT
RI GHT
OFF
G-
: , ,
^ I
o-
c---.
-
o-_
_{-+-{l
I U P
.
DoryN
R LTI
RIGHT
I
orp-
, Fo
--.-.--
-o
- --::
---t-O
!
- o
o
: ]
o-
r
o
o
-a
swi tch.
Power Mirror Actuator Test
20-4).
2. Di sconnect the 3P connector from the Dower mi rror.
Check actuator operati on by connecti ng power
and
ground
r,_ ]1ry1
Position
1 2
TILT UP
J @
TILT DOWN
o o
SWING LEFT o o
SWI NG RI GHT
o o
l f the mi rror fai l s to work properl y, repl ace the
mtrror acIual or.
4.
22-105
Power Mirrors
2.
3.
Power Mirror Actuator Replacement
' t .
Remove the
power mi rror from the door
(see page
20-21).
Record the termi nal l ocati ons and wi re col ors.
Cutthe wi re harness wi th a wi re cutter.
Careful l y
pul l out the bottom edge of the mi rror
hol der by hand.
Separate the mi rror hol der from the actuator by
sl owl y
pul l i ng them apart.
22-106
7.
6. Remove the screws and the actuator from the
housr ng.
Rovte the wi re harness of the new actuator through
the hol e of the mi rror housi ng, then i nstal l the new
actuator i n the reverse order of removal .
l nsert the termi nal s i nto the connector i n the
ori gi nal arrangement as shown bel ow.
Lsft and right
Termi nal si de o{ mal e termi nal s
Reassembl e the mi rror i n the reverse order of
di sassembl y.
Be careful not to break the mi rror hol der when
rei nstal l i ng i t to the actuator.
Operate the
power mi rror to check that the actuator
works smoothl y.
8.
9.
' 10.
Wiper/Washer
J
J )
WINOSHIELD WASHER TUBE
Repl acement, page 22-1 15
WINDSHIELO WIPER ARMS
and LINKAGE
Repl acement, page 22-1 14
WIPER/WASHER SWITCH
TesVRepl acement , page 22-l 1 1
{' 00-01 model s)
fwi re
col ors: GRN/BLK,
I
I GRN,
BLK, GRN/ RED
I
Land
BLU/WHT
I
Test, page 22 40
INTERMITTENT WIPER CIRCUIT
(l n
the gauge assembl y)
I nput Test , page 22- 110
WINDSHIELD WASHER MOTOR
Test . page 22-112
WI NDSHI ELD WI PER MOTOR
Test , page 22-' 112
Repl acement . page
22 114
)
(' 02-03
model s)
fwi re
col ors: cBN/BLK,
' l
I GRN, BLK, GRN/ RED
La nd BLU,/WHT l
Test, page 22-40
J
22-107
Wiper/Washer
Ci rcui t Di agram
GBNTBLK
GRN/8LK
rl
I
G5N/BLK
tr.$fl 6:rtunr
I\1A N UNDER NOOD FUSE/RELAY BOX
No4r (r00aj No 12
{rcA)
UNOEE OASFl
FUSE/BELAY BOX
BLKryfiI
I l - F - - + - - J \
ool " '
I
dl ut f ouu,
No 13 ( 7 5A)
WINDSIIIELD WIPEN MOTOR
UNDEF OASH
FUSEFELAY BOX
G20r
22-108
J
!"'l,T.i9J
D>-
.'*.,
f33loo^)
F*
UNOER DASH
FUSE/FELAYEOX
G50r
22-109
Wiper/Washer
{
{
Intermittent Wiper Control Circuit Input Test
1. Remove the
gauge assembl y {see
page 22' 52).
2. l nspect the al l connectors and socket termi nal s to be sure they are al l maki ng good contact.
.
l f the termi nal s are bent, l oose, or corroded, repa i r th em as necessa ry, and recheck the system
.
go to step 3.
GAUGE ASSEMBLY CONNECTOR B
(I2P) GAUGE ASSEMSI.Y CONNECTOB C {2OP)
YEL WHT/ REO
? 3 4 5
6 7 8 I 1 0 11
8LK GRN BLU/ORN
Wi r e si de of f emal e t er mi nal s Wi r e si de of f emal e t er mi nal s
3. Make these i nput tests at the connector.
. l f anvt est i ndi cat esapr obl em, f i ndandcor r ect t hecause, t henr echeckt hesyst em.
.
l f al l the l nput tests
prove
OK, the
gauge assembl y must be faul ty; repl ace i t.
1 2 3 5 6 1 8
,/ r/
11 12 t c
,/ ,/
WHT/BLK
BLU/ BLK
Cavi ty Wi re Test condition Test: Desired result Possible cause if resuh is not obtained
B4 YEL l gni t i on swi t ch ON
0r )
There shoul d be battery
vol taoe.
Bl own No. 5
(7.5
A) fuse i n the
B5 WHT/REDU nder al l
condi t i ons
ground:
vol tage.
Bl own No. 54 { 30
A) f use i n t he
mai n under-hood fuse/rel ay box
Bl own No. 25
( 7. 5
A) f use i n t he
B8 BLK Under al l
condi ti ons
gr ound;
There shoul d be conti nui tv
.
.
B9
B1' l GRN l gni t i on swi t ch ON
flr)
Check {or vol tage to
ground:
vorrage.
Bl own No. 8
( 20
A) f use i n t he
Faul ty Intermi ttent wi per rel ay
c' 11 BLU/ ORNl gni ti on swi tch ON
(
)
ground:
vol tage.
Bl own No. 13
( 7. 5
A) f use i n t he
Faul ty wi per motor
c12 BLU/BLK l gni ti on swi tch ON
( l l )
and wi per
swi tch at INT
ground:
vol tage.
Bl own No. 12
( 15
A) f use i n t he
Faul ty wi per swi tch
c 13 WHT/BLK l gni ti on swi tch ON
( l
l ) and washer
swi tch ON
vol tage.
Bl own No. 12
( 15
A) f use i n t he
Faul ty washer swi tch
22-110
J
J
J
Wiper/Washer Switch Test/Replacement
1. Lower the steeri ng col umn, and remove the steeri ng col umn covers
(see page 17-9).
2. Di sconnect the
' 14P
connector from the wi Der/washer swi tch.
3. Remove the two screws, then pul l
out the wi per/washer swi tch.
4. Check for conti nu i ty betwee n the term i na l s i n each swi tch posi ti on
accord i ng to the ta bl e. l f the conti nui ty i s not as
speci fi ed, repl ace the swi tch.
\
Terminal
t""--
--l
4 1 4 13 12 1 1
OFF
o-
--o
INT
o-
(-/-
LO
o-
--o
HI
o-
Mist switch ON
o-
--u
Washer switch ON
.a
J
22-111
Wiper/Washer
1
J
Wiper Motor Test
1. Open the hood and remove the cap nuts and the
wi per arms
(see page 22-1' 14]-.
2. Remove the hood seal and cowl cover
(see page
22-114],.
3. Di sconnect the 5P connector from the wi per motor.
Test the motor by connecti ng battery power and
ground
accordi ng to the tabl e. l f the motor does not
run or fai l s to run smoothl y, repl ace i t.
Position
Terminal
1 2 4
LOW SPEED o @
HIGH SPEED o o
5. Connect an anal og vol tmeter between the No. 5
(
+
)
and No. 3
(
) termi nal s, and run the motor at l ow
or hi gh speed. The vol tmeter shoul d i ndi cate 0 V
and 5 V or more al ternatel y. l f i t does not, repl ace
the motor,
22-112
-
Washer Motor Test
Remove the ri ght i nner tender {see
page 20-105).
(A)
from the washer
mot or
( B) .
Test the washer motor by connecting battery
power
to termi nal No. 1 and ground to termi nal
No. 2.
l f the motor does not run or fai l s to run smoothl y,
repl ace the motor.
1 .
Washer Reservoir Replacement
1. Pul l away the ri ght i nner fender.
2. Di sconnect the washer tube
(A)
and washer motor
2P connector
(B).
USA:
9.8 N.m (r.0tgr.ln, 7.2lbtft)
3. Remove the bol ts, then separate and remove the
fi l l er neck
(C)
from the washer reservoi r
(D).
4. Remove the washer reservoi r.
5. Instal l i n the reverse order of removal . Check the
washer motor operati on.
9. 8 N m 110t gt m, 7, 2l bl hl
22-113
WiperlWasher
I
4
Wiper Motor Replacement
1 . Open the hood, and remove the cap nuts and the
wrper arms.
2.
?
Remove the hood seal and cowl cover.
(A)
from the wi per
motor
(B).
4. Remove the bol ts, then remove wi ndshi el d wi per
l i nkage assembl y
( C) .
10 x 1. 25 mm
18 N m {1. 8 kgf . m, 13l bf . f t l
6 x 1 , 0 mm
9. 8 N. m
(1. 0
kgf m, ?. 2 l bf . f t )
22-114
J
5. Remove the three mounti ng bol ts and nut from the
wi per l i nkage
(A)
to remove the wi per motor
(B).
6. Instal l i n the reverse order of removal , and note
these i tems:
.
Grease al l movi ng
parts.
.
Before rei nstal l i ng the wi per arms, turn the wi per
swi tch oN, then OFF to return the wi per shafts to
the park posi ti on.
.
l f necessary, repl ace any damaged cl i ps
.
Check the wi per motor operati on,
{1. 5 kgf . m, 11l bf . f t l
)
t
Washer Tube Replacement
1. Remove the front bumper and the ri ght i nner fender
(see page
20-105).
2. Remove the washer nozzl es and cl i Ds, then remove the tube.
3. I nst al l i nt her ever seor der of r emoval , Takecar enot t opi ncht hewasher t ube. Checkt hewi ndshi el dwasher
oDeraI| on.
J
/a- \
la+
-mr
22-115
lmmobilizer System
IMMOBILIZER RECEIVER UNIT
Troubl eshooti ng, page 22-' 120
Repl acement, page 22- 121
TRANSPONDER
(Bui l t
i nt o t he i gni t i on key)
IGNITION KEY
(Mast er
and val et keys)
IMMOBILIZER INDICATOR LIGHT
Bul b Locat i on, page 22-46
22-116
\
"l
J
J
System Description
The vehi cl e i s equi pped wi th an i mmobi l i zer system that wi l l di sabl e the vehi cl e unl ess the proper i gni ti on key i s used.
Thi s system consi sts of a transponder l ocated i n the i gni ti on key, an i mmobi l i zer recei ver uni t, an i ndi cator Ii ght, and
t he EcM.
The vehi cl e has two ki nds of kevs.
.
The bl ack master key for:
-
i gni ti on swi tch.
-
door l ocks.
-
trunk l ock.
.
The gray val et key for:
-
-
door l ocks.
When the key i s i nserted i n the i gni ti on swi tch and turned to the
(l l ) posi ti on,
the i mmobi l i zer recei ver uni t sends
power
to the transponder i n the i gni ti on key. The transponder then sends a coded si gnal back through the i mmobi l i zer
recei ver uni t to the ECM.
.
The i mmobi l i zer system can store up to si x key codes,
. l f i t i snecessar yt or ewr i t et heECl vl , t hedeal er needst hecust omer ' svehi cl e. al l
i t s mast er keys and val et keys, and
the Honda PGM Tester equi pped wi th an i mmobi l i zer program
card wi th the l atest versi on of PGM Tester software.
Any key that i s not l earned duri ng rewri ti ng wi l l no l onger start the engi ne, except keys dupl i cated wi th the l l co Code
Key Dupl i cator.
. l f t hecust omer hasl ost hi skey, andcannot st ar t t heengi ne, cont act HondaCust omer Rel at i ons.
.
l t i s possi bl e
to add ONE new key wi thout reprogrammi ng al l of the keys
(fol l ow
the prompts i n the PGM Tester
l Ml \4OBl menu).
I
I MMOBI LI ZER RECEI VER UNI T
\
FUEL SUPPLY
SYSTEM
22-117
lmmobilizer System
{
4
System Description
(cont'd)
. l f t hepr oper keyhasbeenused, t hei mmobi l i zer i ndi cat or l i ght wi l l come on f or about 2 seconds, t hen
go
of f .
. l f t hewr ongk ey has beenus edor t hec odewas not r ec ei v edor r ec ogni z edby t heECM. t hei ndi c at or l i ght wi l l c ome
on for about 2 seconds, then i t wi l l bl i nk unti l the i gni ti on swi tch i s turned OFF. For accurate i mmobi l i zer system
di agnosi s,
get as much i nformati on from the customer as
possi bl e. A bl i nki ng i ndi cator l i ght means the key was not
recogni zed.
. l f
t he i gni t i on swi t ch i st ur ned OFF, t he i ndi cat or wi l l bl i nk f or about 5 seconds t o si gnal t hat t he i mmobi l i zer syst em
has been set correctl y, then the i ndi cator wi l l go off,
NOTE: Large metal obj ects, key fobs, other i mmobi l i zer keys. and other transponders can i nterfere wi th the
i mmobi l i zer si gnal . l f an i ntermi ttent
probl em i s suspected, remove the i gni ti on key from the key ri ng
Probl em Part set PGM-Tester
reoui i ed 7
O Master or val et key has been l ost or addi ti onal
master or val et kev i s reoui red.
Bl ank key YES
CD Al l master and val et keys have been l ost. Bl ank kev x 2. or 3 YES
t l mmobi l i zer recei ver uni t does not work. l mmobi l i zer r ecei ver uni t NO
@ ECNI does not work. ECM YES
O l gni ti on swi tch does not work. l gni ti on swi tch
Master keys, and val et key
(rekey
al l l ock
cvl i nders to the new kev).
YES
6) Door kev cvl i nder i s broken. Door kev cvl i nder
(rekev
the cvl i nder) NO
22-118
-
MAINUNOTR XOOO FUS/RELIY 8OX
Circuit Diagram
IGY
<--l fl
---1__J
I
No5{7.54)
FUST
) -
rcn EP2 ti/toco tMotN
ECM
UIDER-0ASli
FUST/8ELIY 8OX
) -
22-119
lmmobilizer System
{
Troubleshooting
Fol l ow thi s
procedure i f the vehi cl e does not start. or
after rewri ti ng the ECM wi th the PGM-Tester and the
vehi cl e does not start.
Note these items belore troubleshooting:
.
Due to the acti on of the i mmobi l i zer svstem, the
engi ne takes sl i ghtl y more ti me to start than a vehi cl e
wi thout an i mmobi l i zer system.
.
When the system i s normal , and the proper key i s
i nserted, the i ndi cator l i ght comes on for 2 seconds,
then i t wi l l go off.
.
l f t he i ndi cat or st ar t st o bl i nkaf t er 2seconds, or i f t he
engi ne does not start, repeat the stani ng
procedure.
l f the engi ne sti l l does not start, troubl eshoot the
system.
1. Usi ng a scan tool . check for a Di agnosti c Troubl e
Code
( DTC) ( see page 11- 3) .
YES Repl ace t he ECM
( see page 11- 4) . 1
NO Go to step 2.
(l l )
wi th the
proper key.
Check to see i f the i mmobi l i zer i ndi cator Ii ght
comes on.
Does the indicatot tight blink?
YES Go to step 4.
NO Check for these probl ems:
.
an open i n the PNK wi re between the gauge
assembl y and ECM.
.
a f aul t y i mmobi l i zer i ndi cat or l i ght . l
2.
3.
22-120
J
Check for vol tage between the No. 1 termi nal and
body
ground wi th the i gni ti on swi tch turned ON
(
l l l .
YES Go to step 6.
NO Check for these probl ems:
.
a bl own No. 2
( 15
A) f use i n t he under - dash
fuse/rel ay box,
.
a bl own No. 46
(15
A) fuse i n the mai n under-
.
an open i n the YEL/BLK wi re between the PGM-FI
mai n rel ay and i mmobi l i zer recei ver uni t.
.
afaul ty PGI\4-Fl mai n rel ay.t
RED/BLU
) J
)
and body gr ound.
YES Go to step 7.
NO Repai r open i n the BRN wi re between the
i mmobi l i zer r ecei ver uni t and G 101. t
and t he ECM.
YES Go to step 8.
NO Repai r open i n the RED/BLU wi re between the
i mmobi l i zer uni t and ECI Vl . l
8, Check for conti nui ty between the No. 3 termi nal
and ECM.
YES Repl ace the i mmobi l i zer recei ver uni t. l f the
engi ne sti l l won' t start. substi tute a known-good
ECM, and r echeckl
NO Repai r open i n the PNVBLU wi re between the
i mmobi l i zer uni t and ECM. I
) J
22-121
l mmobi l i zer Recei ver Uni t
Replacement
1 .
5.
6.
Remove the steeri ng col umn covers
(see page 17-
(A)
from the
i mmobi l i zer r ecei ver uni t
( B) .
(C)
from the i gni ti on
key swi tch.
Remove the four screws, and remove the
i mmobi l i zer recei ver uni t from the i gni ti on key
cyl i nder .
After repl acement, make sure the i mmobi l i zer
i ndi cator l i ght bl i nks correctl y.
NOTE: The Ecl vl does not need to be
reprogrammed i f onl y the recei ver has been
reptaceo.
Power Windows
PASSENGER'SWINDOW SWITCH
TesVRepl acement,
page 22-128
PASSENGER'S WINDOW MOTOR
Test, page 22-129
POWER WINDOW MASTER
swtTcH
(Has
bui l t -i n cont rol uni t )
f est ,
page22- 124
=
Y- . ) ' . ' i
; - \ . "
\ - /
, /
' - - . , r /
Q\
DRIVER'S WINDOW MOTOR
f e$,
page 22-129
22-122
MAIN UNDEF.FiOOO FUSSRELAY 8OX IGNITION SWITCH
COI{VERIIBLE
'r0P
CONTROL
UNIT
f7
I
ELLI/ORN
Gircuit Diagram
Pou/EF WtNoow MASTEn SWTTCH
)
BLK
BLK
I
G501
IGS VgU VMPI IJP DN PWOFO
POWER WINOOW CONTNOL UNIT
cND ue@ or@ PLs SGND
REOTYEL
I
DRIVER'S WINDOWMOTOR
CONVEFfIBLE TOP COIITFOL UNII
22-123
Power Windows
{
{
{
Master Switch Test
2.
1 . Remove the dri ver' s door panel (see page 20-4).
Di sconnect the 14P connector from the
power
wi ndow master swi tch.
2 3 4 5 6
7 t1 9 10 11 12 t 3 t 4
22-124
3. Check the master
passenger' s swi tch for conti nui ty
between the termi nal s i n each swi tch
posi ti on
Dri ver' s Swi tch
NOTE: The dri ver' s swi tch i s combi ned wi th the
control uni t so you cannot i sol ate the swi tch to test
i t. l nstead, run the master swi tch i nput test
procedures (see
step5 on
page 22-1261.
Passenger' s Swi tch
\
Termi nal
1 3 4 6 12
Posirion
Slili"n
\
OFF
ON
OFF
G o
PASSENGER' S
swtTcH
UP
ON o-t-o
__ 'o
OFF
PASSENGER' S
swtTcH
DOWN
ON CF ff
OFF
l f the conti nui ty i s not as speci fi ed. repl ace the
swi tch.
1 .
2.
Master Switch Input Test
Remove the door panel (see page
20-4).
Remove the power wi ndow master swi tch
(A)
from the door
panel .
GRN/ ALK
RED/BLK
Wi re si de of
femal e termi nal s
?
BLU/ ORN
GRN/WHT
RED/WHT
BLU/REO
(B)
and the l Op connector
(C)
from the
power
wi ndow master swi tch.
Inspect the connectors and socket termi nal s to be sure they are al l maki ng good
contact.
.
l f the termi nal s are bent, l oose o r corroded, repai rthem as necessary, and recheck the svstem.
.
l f the termi nal s l ook OK, go to step 5,
(cont' d)
22-125
Power Windows
{
{
Master Switch Input Test
(cont'd)
Wi th the master swi tch sti l l di sconnected, make these i nput tests at the 14P connector'
.
l f al l t he i nput t est s
pr oveOK, got o st ep6
Cavitv Wire Test condition Test: Desired result Possible cause if result is not obtained
4 GRN/ BLK l gni t i on swi t ch ON
flr)
g rou nd:
vol taqe.
.
Bl own No. 8
( 20
A) f use i n t he
.
BLK U nder al l
condi t i ons
gr ound:
Ther e shoul d be cont i nui t v.
.
Poor gr ound
( G501)
.
BLU/RED Connect the No. 4
t er mi nal t o t he
No. 13 t er mi nal
and connect the
No. 4 t er mi nal t o
t he No. 12 t er mi nal ,
then turn the
(
l l ) .
Check for passenger' s
wi ndow motor:
It' s shoul d run
(the
wi ndow
moves up) .
Bl own No. 18
(20
A) f use i n the
Faul ty
passenger' s wi ndow motor
Faul ty passenger' s wi ndow swi tch
Faul ty converti bl e top control uni t
Poor
gr ound ( G501)
RED/1/VHT
o BLU,^/VHTConnect the No. 4
termi nal to the
No. 6 t er mi nal .
Check for
passenger' s
wi ndow motor:
It' s shoul d run
(the
wi ndow
moves oown,.
12 REDivVHT
11 GRNA//HTUnder al l
condi ti ons
gr ouno:
vol taoe.
.
Bl own No. 17
(20
A) fuse i n the
.
5 RED/BLK Connect the No. 5
(2)
termi nal to the
No. 11 t er mi nal
and connect the
t he No. 1 t er mi nal .
Check for dri ver' s wi ndow
motor:
It shoul d run
(the
wi ndow
moves up).
Faul ty dri ver' s wi ndow motor
3 REDI/EL Connect the No. 3
termi nal to the
No. 11 t er mi nal
and connect the
t he No. 1 t er mi nal .
Check for dri ver' s wi ndow
motor:
It shoul d run
(the
wi ndow
moves oownl .
22-126
J
6. Reconnect the master swi tch, and perform
the fol l owi ng i nput tests.
. l f anyt est i ndi cat esapr obl em, f i ndandcor r ect t hecause, t henr echeckt hesvst em.
.
l f al l the i nput tests prove
OK, go
to step 7.
7. l fal l the i nput tests proveOK,the power wi ndow master swi tch mustbefaul ty; repl ace i t,
Cavi ty Wire Test condition Test: Desired result Possible cause if result is not obtained
8 BLU Whi l e oper at i ng
the dri ver' s
wi ndow swi tch
Check for vol tage between
t he No. 8 and No. 2
I er m I na t s:
Ther e shoul d be 0- 5 V or
more re0eatedl v.
Faul ty dri ver' s wi ndow motor
Faul ty power
wi ndow master
swtrcn
2
BLK Under al l
condi ti ons
gr ouno;
.
Faul ty power
wi ndow master
swrl cn
'
1 4 BLU/ ORNl gni ti on swi tch ON
( l l ) ,
and conver t i bl e
top swi tch ON.
Pa rki ng brake l ever
UP,
Check for vol tage between
t he No. 14 and No. 1
t er mi nal s;
Ther es houl dbe0 SVor
more reoeatedl v.
Faul ty converti bl e top control uni t
Faul ty power
wi ndow master
swrl cn
22-127
Power Windows
Passenger's Window Switch Test/Replacement
1. Remove the swi tch and swi tch
panel from the door
pa n el .
Di sconnect the 6P connector from the swi tch,
Remove the two mounti ng screws from the swi tch
pa nel .
2.
3.
22-128
swi tch
Teiminal
Position
1 2 1
UP o-
_o
OFF
o
oo
DOWN
aF-r--
_o
_o
swi tch.
t
Driver's Window Motor Test
Moior Test:
1. Remove the dri ver' s door panel (see page
20-4).
2. Di sconnect the 4P connector from the wi ndow
moror.
Test the motor i n each di recti on by connecti ng
battery power
and ground accordi ng to the tabl e.
When the motor stops runni ng, di sconnecl one
l ead i mmedi atel y.
\
Terminal
or**r""
I]
1 2
UP o o
DOWN @ o
4, l f the motor does not run or fai l s to run smoothl y,
reptace tt.
Detect Circuit Test;
5. Connect the test l eads of an anal og ohmmeter to
t he No. 3 and No. 4 t er mi nal s.
6. Run the motor by connecti ng power and ground
to
t he No. 1 and No. 2 t er mi nal s. The ohmmet er
needl e shoul d move back and fonh al ternatel y. l f i t
does not, repl ace the motor.
1 .
Passenger's Window Motor Test
Remove the
passenger' s
door
panel (see page 20-
4t .
Di sconnect the 2P connector from the wi ndow
moIor.
Check wi ndow motor operati on by connecti ng
power
and ground accordi ng to the tabl e. When the
motor stops runni ng, di sconnect one l ead
i mmedi atel y,
\
Tel mi nal
Direction
1 2
UP @ o
DOWN o o
l f the motor does not run or fai l s to run smoothl y,
repl ace i t.
22-129
Keyless/Power
Door Locks
{
J
LOCK BUTTON
UNLOCK BUTTON
TRUNK BUTTON
PANIC BUTTON
TRANSMITTER
Test , page 22 138
Proqrammi ng,
page 22-' 138
IGNITION KEY SWITCH
Test, page 22-135
PASSENGER'S DOOR SWITCH
TRUNK OPENER SOLENOI O
Test , page 22-101
DRIVER'S DOOR
KEY CYLINDER SWITCH
Test, page 22-137
DRIVER'S DOOR LOCK ACTUATOR/
KNOB SWITCH
Actuator Test, page 22-136
Knob Swi tch Test, page 22-136
ORIVER'S DOOR SWITCH
KEYLESS DOOR LOCK CONTROL UNIT
Input Test, page 22-132
PASSENGER'S DOOR LOCK ACTUATOR
fesI, page 22 137
22-130
4
r t J
Ci rcui t Di agram
/ f ; \ ' | *; "01
*"\'rj|- BL,(YEL
f\-o-f
YEL-
- - t
HoRN FFi Av
I
Y
oaN
I
rF-L
Y5L
IGNITONSWITCH
UNOI.DASH
FUSEiBELAYBOX
8LK/YEI-
\
rGNlTtoN
./
!ilt." l-
ELrcwHr
'
lclosd
(ev
n r.redl
V
0008 s$/rTcH
f vi agaqe\
MAIN UNOER.HOOD FUSE/FELAY BOX
TBUNK
OPENER
swtTcH
17
I
BLfiEI
ELICYET
+
TBUNK
OPENEB
SOLENOO
0008 LocK xioB
n
onrvens W
KEY
IiJ,NDER
i._cf
Il
swrrcH j
-
r--i_]
2l UN! oCK
| |
. . # r
1 1
| ^l*l-
' " j l
oFIVEF'S I
oOOR LOCK I
ACIUATOR 1
No 23 110 )
FUSE
V
L
^ro^*
GûcE
l-,-.-- *
-l
^ssEMBrY
I iniN3i.r,-rnen I
V
I
REDA/VHI
I
l-
REoMHT
REOA''/HT
cEtUNG/
SPOILIGHTS
V
Lnr*r,
G501
->\7
I
I
LI
UNLOCX
KEYLESS
O@R LOCK
CONTROT UNIT
8LK
G()l
22-131
Keyless/Power
Door Locks
.i
I
Keyless Door Lock Control Unit Input Test
1. Di sconnect t he 18P connect or f r om t he keyl essdoor l ockcont r ol uni t '
GRN/ YEL
RED/BLK
PNK/BLK
BLK/YEL YEL/GRN
RED/WHT
WHT
YEL/BLK BLK/WHT
YEL
good contact'
.
l f the termi nal s are bent, l oose or corroded, repai rthem as necessary, and rech eck the system '
.
go to step 3.
22-132
I
3, Make these i nput tests at the connector.
. l f anyt est i ndi cat esapr obl em, f i ndandcor r ect t hecause, t henr echeckt hesvst em.
.
l f al l t he i nput t est s pr oveOK, got ost ep
4.
)
*
1;
' 00- 01
model s
*
2:
' 02-03
model s
)
Cavi ty Wire Test condition Test: Desired result Possible cause it result is not obtained
1 7 BLK Under al l
condi ti ons
grou nd:
There shoul d be conti nui tv
5 BLVYEL Under al l
condi ti ons
ground:
Faul ty trunk opener sol enoi d
8 WHT Under al l
condi ti ons
vol taqe.
Bl own No. 26
( 15
Al f use i n t he
t o YEL l gni ti on swi tch ON
flr)
vol tage.
Bl own No. 5
( 7. 5
A) f use i n t he
7 YEVGRN Connect l he No. 7
termi nal to the
No. 8 t er mi nal , and
the No. 6 termi nal
to the No. 17
t er mi nal
momentari l v.
Check door l ock operati on:
The dri ver' s door shoul d
untoct(.
Faul ty actuator
Bl own No. 26
( 15
Al f use i n t he
18 PNI(BLU Connect the No. 18
termi nal to the
No. I t er mi nal , and
t he No. 6 t er mi nal
to the No. 17
t er mi nal
momentari l y.
Check door l ock operatl on:
The passenger' s
door shoul d
unl ock.
PNI(BLK Connect the No. 6
termi nal to the
No. 8 t er mi nal , and
t he No. 7 and
No. 18 t er mi nal s t o
the No. 17 termi nal
momenl ant v.
Check door l ock operati on:
Both doors shoul d l ock.
RED/BLK Li ghti ng swi tch ON Check for vol tage to ground:
vol tage.
Bl own No. 23
( 10
A) f use i n t he
Faul ty tai l l i ght retay
ORN Under al l
condi t i ons
Check for vol l age to ground:
vottage.
Bl own No. 47
( 10
A) " or
( 15
A) ' '
fuse i n the under-hood fuse/
rel ay box
Faul ty horn rel ay
{cont' d)
J
22-133
Keyless/Power
Door Locks
J
I
Keyless Door Lock Control Unit Input Test
(cont'd)
4. Beconnect the connector to the control uni t, and
perform the fol l owi ng i nput tests at the keyl ess door l ock control
uni t connector,
. l f anyt est i ndi cat esapr obl em, f i ndandcor r ect t hecauset henr echeckt hesyst em'
'
l f al l the i nout tests
prove
OK, the control uni t must be faul ty; repl ace i t'
Cavity Wi re Test condition Tsst: Desired result Possible cause it result is not oblained
1 4 B LK/VVHT Dri ver' s or
passenger' s door
oDeneo
ground:
.
Faul ty door swi tch
.
2 GRNI/EL Al l doors cl osed
and cei l i ng/
spotl i ght swi tch
oosi ti on
"MIDDLE"
ground:
vol tage.
Bl own No. 24
(7.5
A) fuse i n the
Bl own cei l i ng/spoti i ghts bui b
1 0 YEUBLK Dri ver' s door l ock
knob i n LOCK
Faul ty dri ver' s door l ock
actuator
Poor ground
{G50' 1)
An ooen l n the wi re
I YEL Dri ver' s door l ock
knob i n UNLOCK
1 3 RED,A/VHTl gni ti on key i s i n
the i gni ti on swi tch
Faul ty i gni ti on key swi tch
Poor gr ound
( G401)
l 5 WHT Key cyl i nder
swi tch
posi ti on
" UNLOCK"
ground:
Faul ty dri ver' s key cyl i nder
switch
Poor gr ound
( G501)
22-134
lgnition Key Switch Test
2.
1 . Remove the steeri ng col umn upper and l ower
covers
(see page
17-9).
Di sconnect the 7P connector.
3. Check for conti nui ty between the No. 1 and No.3
t er mi nal s.
.
There shoul d be conti nui ty wi th the key i n the
.
There shoul d be no conti nui ty wi th the key
removed from the i gni ti on swi tch.
i gni ti on key swi tch.
J
22-135
Keyless/Power Door Locks
J
I
.a
Driver's Door Lock Knob Switch
Test
1. Remove t he dr i ver ' s door
panel ( seepage20- 4) .
(A)
from the door l ock
act uat or
( B) .
swi tch
\
Terminal
Position
A1 A2 A3
LOCK H
UNLOCK
o-
_ O
l f the conti nui ty i s not as speci fi ed, repl ace the door
l ock actuator assembl Y.
22-136
Driver's Door Lock Actuator Test
1. Remove t he dr i ver ' s door
panel ( seepage20- 4)
(A)from
the actuator
t B) .
Check actuator operati on by connecti ng
power and
ground accordi ng to the tabl e, To prevent damage
to the actuator, appl y battery vol tage onl y
moment ar i l y.
Tel mi nal
Posilion
B1 82
LOCK @ o
UNLOCK o o
It the actuator does not operate as speci fi ed,
reDl ace the door l ock actuator assembl y.
4.
)
Passenger's Door Lock Actuator
Test
' 1.
\
Termi nal
Posi t i on
,l
2
LOCK
UNLOCK
@
o
o
o
4.
Remove the passenger' s
door panel (see page
20-
4) .
(A)
from the actuator
( B) .
Check actuator operati on by connecti ng power
and
ground
accordi ng to the tabl e. To prevent
damage
to the actuator, appl y battery vol tage onl y
moment ar i l y.
l f the actuator does not operate as speci fi ed,
repl ace the door l ock actuator assembl y.
)
1 .
2.
Driver's Door Key Cylinder Switch
Test
Remove the door panel (see page
20-4).
(A)
from the key
cyl i nder swi tch.
swi tch posi ti on
accordi ng l o the tabl e.
Termi nal
Position
2
OFF
UNLOCK H
swrtch.
.
22-137
Keyless/Power
Door Locks
Transmitter Test
NOTE:
.
l f the doors unl ock or l ock wi th the transmi tter, but
the LED on the transmi tter does not come on, the LED
i s faul ty; repl ace the transmi tter.
.
l f anydoor i s open,
you cannot l ockt he door wi t ht he
transmi tter.
.
l f you unl ocked the doors wi th thetransmi tter, but do
not open any of the doors wi thi n 30 seconds, the
doors rel ock automati cal l y.
.
The doors do not l ock or unl ock wi th the transmi tter i f
the i gni ti on key i s i nserted i n the i gni ti on swi tch.
1. Press the l ock or unl ock button fi ve or si x ti mes to
reset the transmi tter.
.
l f the l ocks work, the transmi tter i s OK.l
.
l f the l ocks don' twork,
goto step 2.
2. Open the transmi tter and check for water damage.
.
l f you f i nd any wat er damage, r epl ace t he
transmi tter.l
.
l f t her e i s nowat er damage,
got o st ep 3.
3. Repl ace the transmi tter battery
(A)wi th
a new one,
and try to l ock and unl ock the doors wi th the
transmi fter by pressi ng the l ock or unl ock button
fi ve or si x ti mes.
.
l f the doors l ock and unl ock, thetransmi tter i s
oK. a
.
l f t hedoor s don' t l ockand unl ock, got ost ep 4.
Reprogram the transmi fter, then try to l ock and
unl ock the doors.
.
l f the doors l ock and unl ock, the transmi ner i s
oK. t
.
l f the doors don' t l ock and unl ock, repl ace the
transmi tter.l
22-138
Transmitter Programming
Stori ng transmi tter codes: The codes of up to three
transmi tters can be programmed i nto the keyl ess
recei ver uni t memory.
(l f
a fourth code i s stored, the
code whi ch was i nput fi rst wi l l be erased.)
NOTE: l t i s i mpor t ant t o mai nt ai n t he t i me l i mi t s
kretween the steps. Make sure the doors, the hood and
the trunk are cl osed.
1, Tur n t he i gni t i on swi t ch ON
( l l ) .
2. Wi thi n 1 to 4 sec.,
push the transmi tter l ock or
unl ock button wi th the transmi tter ai med at the
recei ver uni t behi nd the dri ver' s si de dash.
3, Wi thi n 1 to 4 sec., turn the i gni ti on swi tch OFF.
4. Wi thi n 1 to 4 sec., turn the i gni ti on swi tch ON
(l l ).
5. Wi thi n 1 to 4 sec.,
push
the transmi tter l ock or
6. Wi thi n 1 to 4 sec., turn the i gni ti on swi tch OFF.
7. Wi thi n 4 sec., turn the i gni ti on swi tch ON
(l l ).
8. Wi thi n 1 to 4 sec., push the transmi tter l ock or
9. Wi thi n I to 4 sec., turn the i gni ti on swi tch OFF.
10. Wi t hi n 4 sec. . t ur n t he i gni t i on swi t ch ON
( l l ) ,
1 1. Wi thi n 1 to 4 sec.,
push the transmi tter l ock or
Confi rm you can hear the sound of the door l ock
actuators. Wi thi n
' l
to 4 sec.,
push the transmi tter
l ock or unl ock button agai n. The keyl ess recei ver
uni t i s now i n the
program mode. You must push
the transmi tter l ock or unl ock button of the fi rst
transmi tter agai n to
program that remote.
Wi thi n 10 sec., ai m the transmi tters
(up
to two
addi ti onal ones) whose codes
you want to store at
the recei ver uni t, and Dress the transmi tter l ock or
unl ock buttons.
Confi rm that
you
can hear the sound of the door
l ock actuators after each transmi tter code i s stored.
14. Tur n t he i gni t i on swi t ch OFF, and pul l out t hekey,
15. Confi rm proper operati on of the transmi tters wi th
the new code{s).
12.
Convertible Top
Component Locati on Index
DRIVER'S WINDOW MOTOR
fest, page 22 129
Test, page 22-143
TOP SWITCH
CONVERTIBLE TOP
CONTROL UNIT
Input Test, page 22-' 144
CONVERTIBLE TOP MOTOR
EMERGENCY CONNECTOR
PASSENGER'S WINOOW MOTOR
fe$, page 22-129
RIGHT CONVERTIBLE TOP MOTOR
Test, page22-147
LEFT CONVERTIBLE TOP MOTOR
fesl , page22-147
22-139
Convertible Top
Ci rcui t Di agram
vss srcNrl
DBrV[\lG
CFCUII
f7
Y
I
l "
T
C0l'IVEFTIELI
TOP MOTOF
EM8GII'ICY
CONNECIOR
22-140
I{o.l2l1sAl
UiDEN DASH FUST/8ELIY 8OX
FUSE
MASTIF
swtTc|l
22-141
f - - - 1
DEFOGGER
CHANGT SEIAY
\-7
T
I
r l
Gt01
CONVERNBLT
IOP DISASLT
swIc1r
lolor.d l
Convertible
Top
{
System Description
The convertj bl e top can automati cal l y be opened and
cl osed by operati ng the converti bl e top swi tch
The converti bl e top system consi sts of the converti bl e
top swi tch, control uni t and the motors l ocated on the
converti bl e top assembl y. The top swi tch outputs open
and cl ose si gnal s to the control uni t. The control uni t
opens the dri ver' s and the
passenger' s power wi ndows
then about 0.5 second after the wi ndows start to open,
the control uni t operates the top motors to open or
cl ose the toD.
22-142
\a
Basic Operation
1. Pul l t he
par ki ng br ake l ever uP.
(l l ).
NOTE: The vehi cl e must be parked or travel i ng at
no more than 3 mph
(5
Km/h).
3- Rei ease the converti bl e top l ock handl es.
4. The top opens whi l e
pressi ng the top swi tch to the
OPEN
posi ti on.
5. The top cl oses whi l e pressi ng the top swi tch to the
CLOSE
posi ti on.
6. Rel ease the top swi tch to stop the operati on of the
top.
J
Convertible Top Switch Test
1. Removethe centerconsol e
(see page 20-761,
(A)
from the swi tch.
swi tch posi ti on
\
Terminal
Position \
2 3
OPEN
G
oo
o-
--o
CLOSE
G
_o
i l l umi nat i on bul b
( B)
or t he swi t ch,
22-143
Convertible Top
Convertible Top Control Unit Input Test
Remove the
passenger' s
dashboard l ower cover
(see page 20-81).
(A)
and 10P connector
(B)
from the converti bl e top control uni t
(C).
1 .
2.
Wi re si de of
*:
Wi th HardtoP
good contact.
.
l f the termi nal s are bent, l oose or corroded, repai rthem as necessary, and recheckthe system
.
l f the termi nal s l ook OK, go to step 4.
RED/WHT
A'I M A4 A5 A6
A8 A9 At0Al l 412A13
RED/BrK
/ dLr iwxiliii
WHT,/BLK BLU/REO
22-144
4. With the connectors still disconnected, make these input tests at the connectors.
.
l f any t est i ndi cat es a probl em, f i nd and correct t he cause, t hen recheck t he syst em.
.
lf all the input tests prove OK, go to step 5.
Wire Test condition Test: Desired result Possible cause if result isnotobtained
BLU/BLK Under al l condi t i ons Check f or vol t age t o ground:
There should be battery voltage.
Bl own No. 18
(20
A)f use i n t he
under-dash f use/ rel ay box
An ooen i n t he wi re
A13 WHT/REDUnder al l condi t i ons Check f or vol t age t o gr oundl
There should be baftery voltage.
El own No. 25
( 7. 5A) f use
i nt he
underdash f use/ rel ay box
A1
A8
4 1 1
BLK Under al l condi t i ons Check f or cont i nui t y t o ground:
There shoul d be cont i nui t y.
Poor ground (G402)
An open i nt hewi re
810 BLK Under al l condi t i ons check f or cont i nui t y t o
ground:
The. c shor l . l be. ont i nr i r v
.
Poor ground (G501)
.
A6 GRY/ REDUnder al l condi t i ons Check { or vohage t o gr ound:
El own No. 52 { 20 A) f { r se i n t he
mai n under hood f use/ r el ay box
A3 GRY Under al l condi t i ons Check f or vol t age t o ground:
There shoul d be bat t ery vol t age.
El own No. 55
(20A)
f use i nt he
mai n under-hood f use/ rel ay box
An ooen in the wire
A5 RED /VHT Di sconnect t he l ef t t op mot or 2P
connect or.
Connect t he A5 t ermi nal t o t he 46
t ermi nal {power) and 44 t ermi nal t o t he
A11 t ermi nal
(ground).
Assist the left side of the top with your
Check t he ri ght t op mot or
operat i on:
I t shoul d run {t he t op moves
opens),
Faul t y ri ght t op mot or
An open i n t he wi re
LT GRN/
RED
Disconnect the left top motor 2P
connect or,
Connect t he A4 t ermi nal t o t he A6
t ermi nal
(power)
and A5 t e. mi nal t o t he
A11 t ermi nal
(ground).
Assi st t he l ef t si de of t he t op wi t h your
Check t he ri ght t op mot or
operat ron:
I t shoul d run
(t he
t op moves
croses, .
Faul t y ri ght t op mot or
A2 RED/ BLU Di sconnect t he ri ght t op mot or 2P
Connect t he A2 t ermanal t o t he 43
t ermi nal
(power)and
A1 t ermi nal t o t he
A7 t ermi nal l ground).
Assi st t he ri ght si de ot t het opwi t h your
Check the left top motor
oper at i on:
I t shoul d r un
( t he
t op moves
opens) .
Faulty left top motor
An open i n t hewi r e
RED Disconnect the right top motor 2P
connect or ,
Connect t he A1 t er mi nal t o t he 43
t er mi nal
( power i
and 42 t er mi nal t o t he
47 t er mi nal
( gr ound) .
Assi st t he r i ght si de of t he t op wi t h your
Checkthe left top motor
operat i on:
I t shoul d run
(t he
t op moves
.
Faulty left top motor
.
An open i n t hewi re
B5* LT GRN Conver t ; bl e t oD di sabl e swi t ch cl osed Check f or cont i nui t y t o ground:
There shoul d be cont i nLri t y.
Faul t y conveni bl e t op di sabl e
Poor ground (G60' 1,
G901)
An oDen i nt hewi re
*:
With Hardtop
( cont ' d)
22-145
Gonvertible Top
.rl
J
Convertible Top Control Unit Input Test
(cont'd)
RED/WHT
RED/BLU GRN/RED
A1 A2 A3 A4 A5 A6
A O
A9 41041
't
N2 413414
RED/BLK BLK
5, Reconnect t he connect ors t o t he cont rol uni t , and make t he i nput t est s at t he connect ors.
. l f anvt est i ndi cat esaprobl em, f i ndandcorrect t hecause, t henrecheckt hesyst em
.
l f al l t he i nput t est s
prove
OK, t he cont rol uni t must bel aul t y; repl ace i t .
GRY RED YEL
BLU/ORN RED/BLU
GRY/RED
BLU/BLK
Wi re si de of
t emal e t ermi nal s
WHT
BLK BLK
slr neoivel cRN/wHT
WHT/RED
RED
B1 82 B3 B4
B6 87 BB B9 810
/BLK /
BLU/RED
BLU/WHT
RED/BLU
Cavitv Wire Test condition Test Oesired result Possible cause ifresult is notobtained
B3 BED/BLU Connect t he 83 t ermi nal t o t he Al 4
t ermi nal and 84 t ermi nal t o t he 810
t ermrnal ,
Check t he passenger' s wi ndow
motor operationi
I t shoul d run
(t he wi ndow
Fauhy passenger' s wi ndow
mot or
B4 RED Connect t he B4 t ermi nal t o t he A14
t ermi nal and 83 t ermi nal t o t he 810
Check the passenger's window
motor operalron:
I t shoul d run
(t he
wi ndow
Faulty passenger's window
moror
B1 YEL l gni t i on swi t ch ON { l l ) Check for voltage to ground:
Bl own No. 5
(7. 5
A) f use ant he
undeFdash fuse/relay box.
412 GRN,ryVHTParki ng brake l ever up Check f or cont i nui t y t o ground:
There should be continuitv.
'
Faulty parking brake switch
.
An onen i n t he wi re
A9 RED/ BLK lgnition switch ON
(ll),
top switch OPEN Checkl or vol t age t o ground:
There should be batterv voltaoe.
Bl own No. 12
(15
A) f use i n t he
under-dash f use/ rel ay box
Faul t yt op swi t ch
An ooen i n t hewi re
A10 RED/YEL l gni t i on swi t ch ON {l l ), t op swi t ch CLOSE Check for voltage to
ground:
Tha.c <hoDl.l hc haterv voltaoe.
B7 BLUAVHT lgnition switch ON
(ll), power window
mast er swi t ch mai n swi t ch ON, and
nassenocr's win.lows switch DOWN.
Check t or vol t age t o gr ound:
El own No. 8
( 20A) f use
i nt he
undeFdash fuse/relay box
Faul t y power powerwi ndow
master swttcn
Faul t v passenger' s wi ndow
An onen i n t he wi r e
B8 8LU/ RED l gni t i on swi t ch ON {l l },
power wi ndow
mast er swi t ch mai n swi t ch ON, and
passenger's window switch UP.
Check f or vol t age t o ground:
B9 RED/BLU l gni t i on swi t ch ON
(l l ), power wi ndow
master switch main switch ON
Checkf or vol t age t o ground:
Faul t y power wi ndow mast er
Faul t y passenger' s wi ndow
An d6en i n t he wi r e
Wire Testcondition Test: Desired rGsult Possible caure if resuh ia not obtainod
82 BLU/ ORN l gni t i on swi t ch ON
( l l ) , par ki ng br ake
lever up, operate the toP switch
Check for voltage between the
92 and bodygr ound:
Ther e s houl d be 0 SVor mor e
Faul t y t oP cont r ol uni t
Faul t y power wi ndow mast er
B6 WHT/BLK l gni t i on swi t ch ON {l l ), rai se t he rear of
the vehicle. and rotate one wheel slowlv
Check f or vol t age on t he B6 and
A8 t ermi nal s:
There shoul d be 0 5 V or more
Faulty VSS
Faul t y VSS si gnal dri vi ng ci rcui t
22-146
I
Convertible Top Motor Test
Right Top Motor:
l . Remove the ri ght corner gusset (see page 20-38).
(A)
from the ri ght top
mot or
( B) .
Assi st the l eft si de of the top wi th
your
hands.
Test the motor i n each di recti on by connecti ng
battery
power
and
ground
Te. mi nal
Direction
I
OPEN
@ o
CLOSE
o e
l f the motor does not operate as speci fi ed, repl ace
the motor.
l f the top does not work because of a top motor
fai l ure. go
to step 7 to cl ose the top manual l y.
3.
6.
1. Remove the
( see page 20- 81) .
Di sconnect the converti bl e top motor emergency
2P connector
(A).
9. Cl ose t he t op manual l y.
(cont' d)
22-147
Convertible Top
Convertible Top Motor Test
(cont'dl
Left Top Motor:
1. Remove the l eft corner
gusset (see page 20-38).
(A)from
the l eft top
motor {B).
3. Assi st the ri ght si de of the top wi th your hands.
4. Test the motor i n each di recti on by connecti ng
battery
power and ground accordi ng to the tabl e.
Terminal
Position
1 2
OPEN
o @
CLOSE
@ o
l f the motor does not operate as speci fi ed, repl ace
the motor.
l f the top does not work because of a top motor
fai l ure, go to step 7 to cl ose the top manual l y.
22-148
7. Remove the
(see page 20-81).
Di sconnect the converti bl e top motor emergency
2P connector
(A).
9. Cl ose the toD manual l v.
8.
Removable Hardtop
J
CONTROL UNIT
Input Test, page 22' 144
J
CONVERTIBLE TOP DISABLE SWITCH
Test , page 22 150
Removable Hardtop
J
{
Convertible Top Disable Switch Test
NOTE: For the converti bl e top di sabl e swi tch ci rcut
di agram, refer to the Converti bl e Top Ci rcui t Di agram
{see
page 22-140}and the RearWi ndow Defogger
Ci r cui t Di agr am
( see page 22- 153) .
1. Remove the l eft rear si de tri m
(see page 20-70).
2. Di sconnectthe 2P connector
(A)
from the
converti bl e top di sabl e swi tch {B).
\ ' - - i 9
-l'(\
-----,-..J-lr
22-150
3. Push the converti bl e top di sabl e swi tch.
Termi nal si de of mal e termi nal s
Check for conti nui ty between the No. I and No. 2
t er mi nal s.
swtl cn.
I
REAR WINDOW DEFOGGER RELAY
! 02-03
model s)
Wi re col ors: BL(RED, WHT/ GnN,
I
LYEUBLU and YEUBLK I
Test, page 22'40
UNDER-OASH
FUSE/RELAY AOX
REAR WINOOW DEFOGGER SWITCH
( ' 02
03 model s)
Test , page 22 155
I
REAR WINDOW OEFOGGER SWITCH
{ 00-01 rnodel s)
Test , page 22-155
(cont' d)
22-151
\.
{
(cont'd)
REAB WINDOW DEFOGGER
Functi on Test, page 22-156
Defogger Wire Repait, page 22-157
CONDENSER DIODE
(' 02-03
model s) 1' 02-03 model s)
CHANGE RELAY
(' 02-03
model s)
Test , page 22-40
22-152
J
Ci rcui t Di agram
' 00-01
model s
CLI]TCH
INTESLOCK
UNDEB DASN
sw TcH
FUSABELAY
80x
No23( 10
)
FLJSE
f7
I
I
swtTcH
) - l
GNtTtONSWTTCTI UNOEN,HooD FUSgEELAY 8OX
Nolr (r@
)
N0.12 (10
)
22-153
) t
MAIN UNDER.HOOO
FUSE,NELAY BOX
Circuit Diagram
(cont'd)
'02-03
models
IGNITION SWITCH
wirT--F wHT/slK
--l-g<lor-,
I
I I
uf BUdrEo
1-,,*,
l9+Jo,.^|
'
O_t BrK"vFl
UNDEF.DASH
FUSENELAY
80x
No.A {10 )
FUSE
V
I
I
F 7
oAsN Lto.frs
BRIi]HTNESS
CONIFOLLER
th
rho
9il4.1
YE!&K
BIJ(
'-.E
t <l
F
8LK
T
G601
I
i
coNoENsEs
I
BtK
I
REAR
OEFOCEF
REUY
FEAN
ICONVERTIBTEI
COIIVERTlBLE
TOP DISABLE
stvtTcH
(oc. d:
I
lHaftIopin I
[y'a
on vdridJ
GAUGE
ASSEMELY
CLUICH
INTEFLOCK
swtTcH
22-154
Switch Test
?0-01 models:
(see page 20-55).
2. Remove the rear wi ndow defogger swi tch
(A)
from
the center consol e, then di sconnect the 5P
connector {B}.
3. Check for conti nuty between the termi nal s i n each
swi tch posi ti on
\
Termi nal
Pi.iti""
-ll\
1 2 3 1 5
OFF
o-
-@- -o
o-
-o
ON
o o o-
-o-
o
l f the conti nui ty
j s
not as speci fi ed, repl ace the
i l l umi nati on bul bs
(C)
or the swi tch
( )
47
a
\
I 2 3 4 5
-\
)
'02-03
models:
1. Remove t he i nst r ument panel ( seepage20- 57) .
2, Remove the rear wi ndow defogger swi tch
(A),
then
di sconnect the 6P connector
(B).
3. Check for conti nuty between the termi nal s i n each
swi tch posi ti on
\ Termi na
Position \
2 3 I 5
OFF o o o @ o
ON o O G
rl
o- o
i l l umi nat i on bul bs
( C)
or t he swi t ch.
22-155
J
Y
Function Test
NOTE: Be careful not to scratch or damage the defogger
wi res wi th the tester
probe.
1. Check for vol tage between the posi ti ve termi nal
(A)
and body ground wi th the i gni ti on swi tch and
defogger swi tch ON.
.
l f there i s no vol tage, check for:
-
faul ty defogger rel ay.
-
faul ty defogger change rel ay
(' 02-03
model s).
-
f aul t y di ode
( ' 02- 03
model s) .
-
an open i n t he wi r e.
.
l fthere i s battery vol tage,
go to step 2.
Hardtop:
Convertible Top {'02-03
models):
A t +)
B { )
22-156
Check for conti nui ty between the negati ve termi nal
( B)
and body gr ound.
l f there i s no conti nui ty, check for an open i n the
defogger
ground wi re.
Touch the vol tmeter posi ti ve probe to the hal fway
poi nt of each defogger wi re, and the negati ve
probe to the negati ve termi nal ,
There shoul d be approxi matel y 6 V wi th the
i gni ti on swi tch and the defogger swi tch ON.
.
l f t hevol t age i s as speci f i ed, t he def ogger wi r e i s
oK.
.
l f the vol tage i s not as speci fi ed, repai r the
defogger wi re.
-
l f i t i s more than 6 V, there i s a break i n the
negati ve hal f of the wi re.
-
l f i t i s l ess than 6 V, there i s a break i n the
posi ti ve hal f of the wi re.
Defogger Wire Repair
NOTE: To make an effecti ve repai r, the broken secti on
must be no l onger t han one i nch.
' 1.
Li ghtl y rub the area around the broken secti on
(A)
wi th fi ne steel wool , then cl ean i t wi th al cohol .
2. Careful l y mask above and bel ow the broken Dorti on
of the defogger wi re
(B)
wi th cel l ophane tape
(C).
Thoroughl y mi x the si l ver conducti ve pai nt
usi ng a
smal l brush, appl y a heavy coat of the pai nt
extendi ng about 1/8" on both si des ofthe break.
Al l ow 25 mi nutes to drv.
Check for conti nui ty i n the repai red wi re.
Appl y a second coat of pai nt i n the same way. Let i t
dry 3 hours before removi ng the tape.
22-157
Restraints
Restraints
Speci al Tool s
. . . . . . . . . . . . . 23-2
Seat Belts
Component Locat i on I ndex . . . . . . . . . . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23-3
Seat Bel t Repl acement
. . . . . . . . . . . . . . . . . . . . . . . 23-4
f nspect i on
. . . . . . . . . . . . . . . . . . 23-7
SRS
(Supplemental
Restraint Systeml
Component Locat i on I ndex . . . . . . . . . . . . . . . . . . . . . . , . . . . . . . . . . . . , . . . . .
23-9
Precaut i ons and Procedures
. . . . . . . . . . . . . 23-10
General Troubl eshoot i ng l nf ormat i on . . . . . . . . , , , , , . . . . . , , , . , 29-17
Erasi ng t he DTC Memory
. . . . . . . . . . . . . . . . . . . 23-19
Troubl eshoot i ng I nt ermi t t ent Fai 1ures . . . . . . . . . . . . . . . . . . . . . . . 23-19
DTC Troubl eshoot i ng
I ndex
. . . . . . . . . . . . . . 23-20
Sympt om Troubl eshoot i ng
I ndex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-21
Syst em Descri pt i on . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 23-22
Ci rcui t Di agram
. . . . . . . . . 2g-23
DTC Troubl eshoot i ng
. . . . . . . . . . . . . . .
. . . . . . . . . . 23-24
SRS l ndi cat or Ci rcui t Troubl eshoot i ng
. . . . . . . . . . . . . . . . . . . . . . . 23-55
Component Re p
lace m ent/ln spectio n
Af t er Depl oyment . . . . . . . . . . . . . . . . . . . .
. . . . . . . 23-64
Dri ver' s Ai rbag Repl acement
. . . . . . . . . . . . 23-65
Passenger' s Ai rbag Repl acement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-67
Ai rbag Di sposal . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 23-69
Cabl e Reef Repl acement
. . . . . . . . . . . . . . . . . . . . 23-72
SRS Uni t Repl acement
. . . . . . . . . . . . . . . . . . . . . . . 23-75
) { ,
Restraints
* 1:
l ncl uded i n SRS Tool Set 07MAZ- SM50008
*2:
Use wi th the stacki ng
patch cords from T/N 07SAz-001000A, Backprobe Set.
o
ai
o
Special Tools
Ref.No. Tool Number
Description Oty
o-'
at
@
@
aa*?
07HAZ-SG00500
07PAz- 0010100
07SAZ.TB4011A
07TM-52501 1A
07TAZ-001020A
Depl oyment Tool
SCS Servi ce Connector
SRS Infl ator Si mul ator
SRS Si mul at or Lead C
Backorobe AdaDter, 17 mm
1
1
1
1
23-2
Seat Belts
J
SEAT BELT
Repl acement, page
23 4
Inspecti on, paqe 23-8
J
SEAT BELT BUCKLE
step
' l
on page 23-6
J
23-3
Seat Belts
Seat Belt Replacement
SRS component l ocati ons {see
page 23-9) and the
precauti ons and
procedures (see page 23-' 10) i n the SRS
secti on before
NOTE: Check the seat bel ts for damage, and repl ace
them i f necessary. Be careful not to damage them
dur i ng r emoval and i nst al l at i on.
Seat Belt
NOTE:
.
then wri te down the frequenci es for the preset
butl ons.
.
Di sconnectthe negati ve cabl e from the battery, and
wai t at l east 3 mi nutes before begi nni ng work
2.
1 . Remove these i tems:
.
Seat {see
page 20-86)
.
Rear si de tri m
(see page 20-70)
.
Spare ti re cover
(see page 20-73) and spare ti re
.
Rear tray/rol l bar and upper tri m assembl y
(see
page 20-711
Remove the seat bel t and retractor i n numbered
sequence.
23-4
-
OROLL
BAR and
UPPER TRIM ASSEMBLY
iZ]UPPER ANCHOR BOLT
7/ 16- 20 UNF
32 N m
(3.3 kgf.m, 24l bf.ft)
LOWER
)RETRACTOR/
SEAT BELT
, OUPPER
"ta
ANcHoR cAP
' 00-01
model s
snape
o
o
Di sconnect
t he seat
t ensi oner
connect or,
ORETRACTOR
BOLT
7/16-20 UNF
3 2 Nm
ANCHOR BOLT
7/16-20 UNF
32 N.m
13.3
kgf.m.
24 tbf.ft)
{3.3 kof m. 24 lbf ftl
a RETRACTOR MOUNTING
-
scREw
6 x 1 . 0 mm
, l
N. m
{0.4
kgf.m, 3 lbf ftl
'02-03
models
snape
(t
LOWER
ANCHOR BOLT
7/ 16-20 UNF
32 N. m
(3. 3 kgf . m,
24lbl.lrl
a- y
I I
/-
3. Instal l the bel t i n the reverse order of removal , and
note these i tems:
.
Check that the retractor l ocki ng mechani sm
functi ons
(see page
20-8).
.
Assembl e the washers, col l ar and busi ng on the
upper and l ower anchor bol ts. Refer to the
Anchor Bol t Constructi on
(see page
20,7).
.
Appl y l i qui d thread l ock to the anchor bol ts
before rei nstal l ati on.
.
Before i nstal l i ng the anchor bol ts, make sure
there are no twi sts or ki nks i n the seat bel t.
.
Make sure the seat bel t tensi oner connecl or i s
pl ugged
i n properl y.
.
.
.
Reset the cl ock.
.
Dothe PCM i dl e l ean procedure (see page 11-
100) .
(cont' d)
23-5
Seat Belts
J
a
Seat Belt Replacement
(cont'd)
Seat Belt Buckle
1. Remove the seat
(see page 20-86).
NOTE: To
get
to the seat bel t swi tch connector, remove the seat cushi on from the i nner seat track.
2. Remove the seat bel t buckl e i n numbered sequence
3. Instal l the buckl e i n the reverse order of removal , and note these i tems:
.
Assembl e the washers on the center anchor bol t. Refer to the Anchor Bol t Constructi on
.
Appl y l i qui d thread l ock to the center anchor bol t before rei nstal l ati on.
.
Appl y l i qui d thread l ock to the seat mounti ng bol ts before rei nstal l ati on
OSEAT
BELT
SWITCH CONNECTOR
Detach.
O Pul l up t he seat cushi on.
Do not
pul l
up i t i n t oo f ar.
a! ) 10 x 1. 25 mm
,t?
N.m
(4. 8 kgl . m,
35 tbt.ft)
I
6)8
x 1. 25 mm
22 N.m 12.2 kgl m,
16 tbf.ftl
]CENTER ANCHOR BOLT
7/16-20 UNF
34 N.m 13.5 ksI.m,25 l bf.ft)
23-6
Center anchor boh construciion:
WAVEWASHER COLLAR
TOOTHED
LOCK WASHER
CENTER ANCHOR
BOLT
23-7
'02-03
models
WAVE WASHER
\
CENTER ANCHOR
BOLT
TOOTHED
LOCK WASHER
TOOTHEO
LOCK WASHER
COLLAR
| , /
roorneo
\ I /
LOCKWASHER
\ qt /
le /IlYil
"v --r
/ \
LOWER SPRING
ANCHOR WASHER
BOLT
SPRI NG
WASHER
BUSHING
Seat Belts
./
{
Inspection
SRS component l ocati ons
(see page 23-9) and the
Drecauti ons
and
procedures
(see page 23-10) i n the SRS
secti on before
Retractor
' 1.
Before i nstal l i ng the retractor, check that the seat
bel t can be
pul l ed out freel y.
2. Make sure that the seat bel t does not l ock when the
retractor
(A)
i s l eaned sl owl y up to 15' from the
mounted
posi ti on. The seat bel t shoul d l ock when
the retractor i s l eaned over 40' . Do not attempt to
di sassembl e the retractor.
l nsi de
. i oi . *"
. 15' , ' 40'
'{
Forwgrd
Repl ace the seat bel t wi th a new assembl y i f there
i s any abnormal i ty. Do not di sassembl e any
part of
the seat bel t for any reason.
l-1-
t'i\t- |
l r P l
t , ) |
t-Tl-r
\ f 1 r
23-8
-
ln-vehicle
1. Check that the seat bel t i s not twi sted or caught on
anyl n I ng.
2. After i nstal l i ng the anchors, check for free
movement on the anchor bol ts. l f necessary,
remove the anchor bol ts and check that the
washers and other
parts are not damaged or
i mproperl y i nstal l ed.
3. Check the seat bel ts for damage or di scol orati on.
Cl ean wi th a shop towel i f necessary. Use onl y
soap and water to cl ean.
NOTE: Di rt bui l d-up i n the l oops of the upper
anchors can cause the seat bel ts to retract sl owl y.
Wi pe the i nsi de of the l oops wi th a cl ean cl oth
dampened i n i sopropyl al cohol .
4. Check that the seat bel t does not l ock when pul l ed
out sl owl y. The seat bel t i s desi gned to l ock onl y
duri ng a sudden stop or i mPact.
Make sure that the seat bel t wi l l retract
automati cal l y when rel eased.
On the
passenger' s seat bel t, check the seat bel t
retractor l ockl ng mechani sm ALR
(automati c
l ocki ng retractor). Thi s functi on i s for chi l d seats:
-1
Pul l the seat bel t al l the way out to engage the
ALR. The seat bel t shoul d retract wi th a
ratcheti ng sound, but not extend. Thi s i s
nor mal .
-2
To di sengage the ALR, rel ease the seat bel t and
al l ow i t to ful l y retract, then
pul l the seat bel t
out
part-way. The seat bel t shoul d retract and
extend normal l y.
Repl ace the seat bel t wi th a new assembl Y i t there
i s any abnormal i ty. Do not di sassembl e any
part of
the seat bel t for any reason.
6.
1 .
sRs
CAALE REEL
INDICATOR LIGHT
Troubl eshoot i n g, page 23-55
PASSENGER'S AIRBAG
Di sposal , page 23-69
DATA LINK
CONNECTOR
{DLCI
(16PI
UNIT
Repl acement , page
23, 75
PASSENGER'S SEAI BELT
TENSIONER
Reol acement . oaae 23-4
Di i posal , page
23' -59
DRIVER'S SAT EELT TENSIONER
Di sposal , page 23-69
I
23-9
sRs
Precautions and Procedures
General Precautions
Read the fol l owi ng
precauti ons careful l y before
performi ng ai rbag system servi ce. Observe the
i nstructi ons descri bed i n thi s manual , or the ai rbags
coul d acci dent al l y depl oy and cause damage or i nj ur i es.
.
Exceptwhen
performi ng el ectri cal i nspecti ons,
al ways turn the i gni ti on swi tch OFF, di sconnect the
negati ve cabl e from the battery, and wai t at l east 3
mi nutes before begi nni ng work.
NOTE: The memory i s not erased even i f the i gni ti on
swi i ch i s turned OFF or the battery cabl es are
di sconnected from the battery.
.
Use repl acement
parts whi ch are manufactured to the
same standards and
qual i ty
as the ori gi nal
parts. Do
not i nstal l used SRS
parts from another vehi cl e. Use
onl y new
parts when maki ng SRS repai rs.
.
Careful l y i nspect any SRS
part
before
you i nstal l i t.
Do not i nstal l any part that shows si gns ot bei ng
dropped or i mproperl y handl ed, such as dents, cracks,
or deformati on.
Before removi ng any of the SRS
parts (i ncl udi ng
di sconnecti on of the connectors), al ways di sconnect
the SRS connector.
23-10
.
Use onl y a di gi tal mul ti meter to check the system l f i t
i s not a Honda mul ti meter, make sure i ts output i s 10
mA {0.01 A) or l ess when swi tched to the l owest val ue
i n the ohmmeter range. A tester wi th a hi gher output
coul d cause acci dental depl oyment and
possi bl e
i nj ur y.
.
Do not
put
obj ects on the
passenger' s ai rbag.
.
The ori gi nal radi o has a coded theft
protectl on ci rcui t.
Be sure to
get the customer' s radi o code and wri te
down the frequenci es for the radi o
preset stati ons
before di sconnecti ng the battery cabl e.
.
Before returni ng the vehi cl e to the customer, enter
the customer' s radi o code, and radi o stati on
preset,
and set the cl ock.
Steering-related Precautions
Cabl e Reel Al i gnment
.
Mi sal i gnment of t he cabl e r eel coul d cause an open i n
the wi ri ng, maki ng the SRS system and the horn
i noperati ve. Center the cabl e reel whenever the
fol l owi ng i s performed (see
-
Instal l ati on ofthe steeri ng wheel
-
Instal l ati on of the cabl e reel
-
Instal l ati on ofthe steeri ng col umn
-
Other steeri ng-rel ated adj ustment or i nstal l ati on
.
Do not dl sassembl e the cabl e reel .
.
Do not appl y
grease to the cabl e reel .
.
l f the cabl e reel shows any si gns of damage or
contami nati on, repl ace i t wi th a new one. For
exampl e, i t does not rotate smoothl y.
Airbag Handling and Storage
Do not di sassembl e an ai r bag. l t has no ser vi ceabl e
parts.
Once an ai rbag has been depl oyed, i t cannot be
repai red or reused.
For temporary storage of an ai rbag duri ng servi ce,
observe the fol l owi ng precauti ons.
.
Store the removed ai rbag wi th the pad surface up.
Never put
anyt hi ng on t he r emoved ai r bag.
To prevent
damage to the ai rbag, keep i t free from
any oi l , gr ease,
det er gent , or wat et .
.
Store the removed ai rbag on a secure, fl at surface
away from any hi gh heat source
(exceedi ng
200' F/
93' C).
Never perform
el ectri cal i nspecti ons to the ai rbags,
such as measuri ng resi stance,
Do not posi ti on yoursel f i n front of the ai rbag duri ng
removal , i nspecti on. or repl acement.
Refer to the scrappi ng procedures
for di sposal of a
damaged ai rbag.
(cont' d)
23-11
sRs
(cont'dl
SRS Unit Precautions
.
Be careful not to bumo or i moact the SRS uni t
whenever the i gni ti on swi tch i s ON
(l l ),
or for at l east
for 3 mi nutes after the i gni ti on swi tch i s turned OFF.
.
Dur i ng i nst al l at i on or r epl acement , becar ef ul not t o
bump
(by
i mpact wrench, hammer, etc.) the area
around the SRS uni t. The ai rbags coul d acci dental l y
depl oy and cause damage or i nj ury.
After a col l i si on i n whi ch the ai rbags were depl oyed,
repl ace the SRS uni t and other rel ated components
(see page 23-64). After a col l i si on i n whi ch the ai rbags
were not depl oyed, i nspect for any damage or any
deformati on on the SRS uni t. l f there i s any damage,
reDl ace the SRS uni t.
.
Do not di sassembl e the SRS uni t.
.
Turn the i gni ti on swi tch OFF, di sconnect the battery
negati ve cabl e, and wai t at l east 3 mi nutes before
begi nni ng i nstal l ati on or repl acement of the SRS uni t.
or di sconnecti ng the 18P connector from the SRS uni t.
.
Be sure the SRS uni t i s i nstal l ed securel y wi th the
mount i ng bol t s t or qued t o 9. 8 N. m
( 1. 0
kgf . m,
7.2 tbfittl.
.
Do not spl l l water or oi l on the SRS uni t, and keep i t
away from dust.
.
Store the SRS uni t i n a cool
(l ess
than 104"F/40' C)
and dry
(l ess
than 807o rel ati ve humi di ty, no
mol sture) area.
23-12
Wring Precautions
Some of the SRS wi ri ng can be i denti fi ed by a speci al
yel l ow outer coveri ng, and the SRS connectors can be
i denti fi ed bv thei r vel l ow col or.
Observe the i nstructi ons descri bed i n thi s secti on.
.
Never attemptto modi fy. spl i ce, or repai r SRS wi ri ng.
l f t her e i s an open or damage i n SRS wi r i ng, r epl ace
the harness.
Be sure to i nstal l the harness wi res so they do not get
pi nched,
or i nterfere wi th other
pans.
.
Make sure al l SRS ground l ocati ons are cl ean, and
grounds
are securel y fastened for opti mum metal -to-
metal contact. Poor groundi ng
can cause i ntermi ttent
probl ems
that are di ffi cul t to di agnose.
Precautions for Electrical Inspections
.
When usi ng el ectri cal test equi pment, i nsertthe
Drobe of the tester i nto the wi re si de of the connector.
Do not i nsert the Drobe of the tester i nto the termi nal
si de of the connector, and do not tamper wl th the
connecror.
Use a U-shaped probe. Do not i nsert the probe
fo rci bl y.
Use speci fi ed servi ce connectors i n troubl eshooti ng,
Usi ng i mproper tool s coul d cause an error i n
i nspecti on due to
poor
metal -to-metal contact.
sRs
(cont'd)
Spring-loaded Lock Connector
Some SRS system connectors have a spri ng-l oaded
l ock.
Disconnecting
To rel ease the l ock, pul l the spri ng-l oaded sl eeve
(A)
toward the stop {B) whi l e hol di ng the opposi te hal f of
the connector. Then pul l the connector hal ves apart. Be
sure to Dul l on the sl eeve and not on the connector.
Connecting
1. To reconnect, hol d the
pawl -si de
connector, and
oress on the back of the sl eeve-si de connector i n
the di recti on shown. As the two connector hal ves
are pressed together, the sl eeve
(A)
i s pushed back
by the
pawl (C).
Do not touch the sl eeve.
When the connector hal ves are compl etel y
connected, the
pawl
i s rel eased, and the spri ng-
l oaded sl eeve l ocks the connector.
23-14
Backprobing Sprin
g-loaded Lock Connectors
When checki ng vol tage or resi stance on thi s type of
connector the fi rst ti me, vou must remove the retai ner
(A)
to i nsert the tester
probe
from the wi re si de.
NOTE: l t i s not necessary to rei nstal l the removed
retai ner; the termi nal s wi l l stay l ocked i n the connector
hous i no.
To remove the retai ner {A), i nsert a fl at-ti p
screwdri ver
(B)
between the connector body and the
retai ner, then careful l y
pry
out the retai ner. Take care
not to break the connector.
Disconnecting System Connectors
Before removi ng the ai rbag or SRS rel ated devi ces
(the
SRS uni t, the cabl e reel , and the seat bel t tensi oner
connectors), di sconnecti ng connectors from rel ated devi ces, or removi ng the dashboard or the steeri ng col umn,
di sconnect the ai rbag connectors and seat bel t tensi oner connectors to
prevent
acci dental depl oyment.
Turn the i gni ti on swi tch OFF, di sconnect the negati ve cabl e from the battery, and wai t at l east 3 mi nutes before
begi nni ng the fol l owi ng procedures.
.
Bef or edi sconnect i ngt heSRSuni t connect or ( 18P)
( A) f r omt he
SRS uni t , di sconnect bot h ai r bag 2Pconnect or s
( C,
D) and both seat bel t tensi oner 2P connectors
(E,
F).
.
Before di sconnecti ng the cabl e reel 2P connector
(B),
di sconnect the dri ver' s ai rbag 2P connector
(C).
sRs
4
(cont'd)
1. Di sconnect the battery negati ve cabl e, and wai t at
l east 3 mi nutes.
Driver's Airbag
2. Remove the access panel from the steeri ng wheel ,
then di sconnect the dri ver' s ai rbag 2P connector
(A)from
the cabl e reel .
Passenger's Airbag
3. Remove the
passenger' s
dashboard l ower cover
(see page
20-81), then di sconnect the passenger' s
ai rbag 2P connector {A} from the SRS mai n harness.
':-
-
"-^\'.
l
\
--""'=-\
\''
23-16
!,
Seat Belt Tensionar:
4. Remove the rol l bar uppertri m
(see page 20-7' l ),
then di sconnect the seat bel t tensi oner 2P
connector {A) from the SRS mai n harness.
J
DTC
(Diagnostic
Trouble Codesl
The sel f-di agnosti c functi on of the SBS al l ows i t to l ocate the causes of system probl ems
and then store thi s
i nformati on i n memory. For easi er troubl eshooti ng, thi s data can be retri eved vi a a data l i nk ci rcui t,
.
When you
turn the i gni ti on swi tch ON
(l l ),
the SRS i ndi cator wi l l come on. l f i t goes off after 6 seconds, the system i s
nor mal .
. l f t her ei sanabnor mal i t y, t hesyst eml ocat esanddef i nest hepr obl em. st or est hi si nf or mat i oni nmemor y, andt ur ns
the SRS i ndi cator on. The data wi l l remai n i n the memory even when the i gni ti on swi tch i s turned off or i f the battery
i s di sconnected.
.
When you connect the Honda PGM Tester to the 16P data l i nk connector
(DLC)to
short the SCS termi nal , and turn
the i gni ti on swi tch ON
(l l ),
the SRS i ndi cator wi l l i ndi cate the di agnosti c troubl e code
(DTC)
by the number of bl i nks.
.
When you connect the Honda PGM Tester to the 16P data l i nk connector
(DLC), you can retri eve the DTC i n the
Honda Syst ems
" SRS"
menu.
.
After readi ng and recordi ng the DTC, proceed wi th the troubl eshooti ng procedure for the code i ndi cated.
Precautions
.
Use onl y a di gi tal mul ti meter to check the system. l f i t i s not a Honda mul ti meter, make sure i ts output i s 10 mA
{0.01 A) or l ess when swi tched to the smal l est val ue i n the ohmmeter range. A tester wi th a hi gher output coul d
damage the ai rbag ci rcui t or cause acci dental ai rbag depl oyment and possi bl e i nj ury.
.
Whenev er t hei gni t i ons wi t c hi s ON{ l l } , or has beent ur nedOFFf or l es s t han3mi nut es , bec ar ef ul not t obumpt he
SRS uni t; the ai rbags coul d acci dental l y depl oy and cause damage or i nj uri es.
.
Before you remove the SRS mai n harness, di sconnect the dri ver' s ai rbag connector, the
passenger' s
ai rbag
connector, and seat bel t tensi oner connectors.
.
Ma ke su re the batte ry i s suff i ci entl y ch a rged. l f the battery i s dead or l ow, the measured val ues wi l l notbecorrect.
' Donot t ouc hat es t er pr obet ot het er mi nal s i nt heSRSuni t or har nes s c onnec t or s , anddonot c onnec t t het er mi nal s
wi th a
j umper
wi re. Use onl y the backprobe set and speci al tool s.
Reading the DTC
When the SRS i ndi cator i s on, read the DTC usi ng ei ther of the fol l owi ng methods:
PGM Tester
"SRS"
Menu Method
Connect the Honda PGM Tester
(A)
(DLCXB),
and fol l ow the Tester' s
prompts
i n the
"SRS"
menu. l f the Tester i ndi cates no DTC, DTC 9-1, or DTC 9-2, doubl e-check by usi ng the
"SCS"
menu method.
{cont' d )
\
23-17
sRs
(cont'd)
PGM Tester
"SCS"
Menu Method
(Retrieving
the flash codes)
The SRS i ndi cator i ndi cates the DTC by the number of bl i nks when the Honda PGM Tester i s connected to the DLC
(data
l i nk connector)
(16P).
1. Make sure the i gni ti on swi tch i s OFF.
2. Connect rhe Honda PGM Tester
(A)
to the data l i nk connector
(16PXB),
and fol l ow the Tester' s prompts i n the
"SCS"
menu to ground the SCS l i ne
(see
the Honda PGM Tester Operator' s Manual ).
3. Make sure the SCS l i ne i s
grounded, then turn the i gni ti on swi tch ON {l l ).
The SRS i ndi cator
(C)
shoul d come on
for about 6 seconds, and then
go
off. Then i t wi l l bl i nk to i ndi cate the DTC
(see
the tabl e bel ow).
. I ncl udi ngt hemost r ecent pr obl em, upt ot hr eedi f f er ent DTCScanbedi spl ayed.
.
In case of a conti nuous fai l ure, the DTC wi l l be i ndi cated repeatedl y
(see
exampl e 1 bel ow).
. l ncaseof ani nt er ml t t ent f ai l ur e. t heSRSi ndi cat or wi l l
i ndi cat et he DTC onet i me, t hen i t wi l l st ayon( see
exampl e 2 bel ow).
. l f acont i nuousandani nt er mi t t ent f ai l ur eoccur , bot hDTCSwi l l be i ndi cat ed as cont i nuous f ai l ur es.
' I ncaset hesyst emi snor mal ( no
DTc) , t he sRS i ndi cat or l i ght wi l l st ay on
( see
exampl e 3) '
1. Continuotls failur, SRS lndic8tor blinks likethis:
1 2 5 1 2 5 , l n ? q
Sr Second
3S 0.3s
Subcode {3)
OFF
Bulb chock
period
OFF
Bulb chock
priod
DTC 2-1
Mon r6c6nt ploblom
lndications
failure.
Mei n code { 2) subcode 11l Mai n code { l l Mai n cod6 { 11 Subcode
( l }
DTC 1-1
Scond-mostracsnt Third-mostrocsnt
problem problem
DTC 1-3
2. lntormittent tsilure, SRS Indic.tor blinks lik this:
ON
DTC 5-1
3. Normal {no feilure), SRS Indicatot blinks likethis:
ON
Read the DTC.
Turn the i gni ti on swi tch OFF, and wai t tor 10 seconds.
Di sconnect the Honda PGM Tester from the DLc
(' l 6P).
Do the troubl eshooti ng
procedure for the DTC.
OFF
Bulb chck
period
4.
5,
o,
7.
0.3 s
23-18
Erasing the DTC Memory
SCS Servi ce Connector 07PAZ-0010100
To erase the DTC(S) from the SRS uni t, use a Honda
PGM Tester
(see
the Honda PGM Tester SRS Vehi cl e
System Suppl ement) or the fol l owi ng
procedure.
1. Make sur e t he i gni t i on swi t ch i s OFF.
2. Connect the speci al tool
(A)
to the MES 2P
connector
(B).
Do not use a
j umper
wi re.
( l l ) .
4. The SRS i ndi cator wi l l come on for about 6 seconds,
and then go off. Remove the SCS servi ce connector
from the MES connector wi thi n 4 seconds after the
i ndi cator
goes
off.
5. The SRS i ndi cat or wi l l come on agai n. Reconnect
the SCS servi ce connector to the MES connector
wi thi n 4 seconds after the i ndi cator comes on.
6. When the SRS i ndi cator goes off, remove the SCS
servi ce connector from the MES connector wi thi n 4
seconos.
7. The SRS i ndi cat or wi l l bl i nk t wo t i mes i ndi cat i ng
that the memory has been erased.
8. Tur n t he i gni t i on swi t ch OFF, and wai t f or 10
seconds.
( l l )
agai n. The SRS i s
OK i f the SRS i ndi cator comes on for about 6
seconds and then
goes off.
Troubleshooting Intermittent Failures
l f there was a mal functi on, but i t doesn' t recur, i t wi l l be
stored i n the memory as an i ntermi ttent fai l ure, and the
SRS i ndi cator wi l l come on.
After checki ng the DTC, troubl eshoot as fol l ows:
1. Read the DTC
(see
"Readi ng
the DTC").
2. Erase the DTC memory
(see
"Erasi ng
the DTC
Memory").
3. Wi th the shi ft l ever i n neutral , startthe engi ne, and
l et i t i dl e.
The SRS i ndi cator wi l l come on for about 6 seconds
and then go off.
Shake the wi re harness and the connectors, take a
test dri ve
(qui ck
accel erati on,
qui ck
braki ng,
corneri ng), turn the steeri ng wheel ful l y l eft and
ri ght, and hol d i ttherefor 5to 10 seconds. l f the
probl em recurs, the SRS i ndi cator wi l l come on.
l f
you
can' t dupl i cate the i ntermi ttent fai l ure, the
svstem i s oK at thi s ti me.
23-19
sRs
{
DTC Detsction ltem Notes
ODen i n dri ver' s ai rbaq i nfl ator
(see
Daoe 23-24)
1-2 l ncreased resi stance i n dri ver' s ai rbao i nfl ator
(see
oaqe 23-241
1-3 Short to another wi re or decreased resi stance i n dri ver' s ai rbaq i nfl ator {see Daoe 23-26)
1- 4 Short to oower i n dri ver' s ai rbaq i nfl ator
(see
Daqe 23-28)
t - c Short to
qround
i n dri ver' s ai rbaq i nfl ator {see Daoe 23-30)
2-1 ODen i n oassenqer' s ai rbaq i nfl atol
(see
oaoe 23-32)
, _')
Increased resi stance i n oassenqer' s ai rbaq i nfl ator
(see
oaoe 23-32)
2-3 Short to another wi re or decreased resi stance i n passenger' s ai rbag
i nfl ator
(see page 23-33)
2-4 Short to Dower i n Dassenqer' s ai rbaq i nfl ator {see Daqe 23-35)
2-5 Short to oround i n Dassenoer' s ai rbao i nfl ator
(see paqe 23-36)
3-1 Ooen i n dri ver' s seat bel i tensi oner
(see paqe
23-38)
3-2 l ncreased resi stance i n dri ver' s seat bel t tensi oner
(see
oaqe 23-38)
Shon to another wi re or decreased resi stance i n dri ver' s seat bel t tensi oner {see
page
23-40)
3-4 Short to Dower i n dri ver' s seat bel t tensi oner
(see
oaoe 23-42)
3-5 Shon to
qround
i n dri ver' s seat bel t tensi oner
(see
Daoe 23-44)
4-1 Ooen i n oassenoer' s seat bel t tensi oner {see
page 23-46)
4-2 l ncreased resi stance i n oassenoer' s seat bel t tensi oner
(see
Daqe 23-46)
4-3 Short to another wi re or decreased resi stance i n passenger' s seat bel t
tensi oner
(see page 23-48)
4-4 Short to oower i n oassenoer' s seat bel t tensi oner
(see paqe
23-50)
4-5 Short to oround i n oassenoer' s seat bel t tensi oner
(see paqe
23-52)
5-1 l nternal fai l ure of SRS uni t
NOTE:
Before troubl eshooti ng DTCs 5-1 through 8-6, check battery/system vol tage.
l f vol tage i s l ow, repai r the chargi ng system before troubl eshooti ng the
SRS.
(see page 23-54)
5-2
5-3
5-4
o - l
6-2
6-3
6-4
6 - l
a-2
8-3
8- 4
8-6
9-1 Internal fai l ure of the SRS uni t. l f i ntermi ttent, i t coul d mean i nternal fai l ure
of the uni t or a Jaul ty i ndi cal or l i ght ci rcui t. Refer to Troubl eshooti ng
Intermi ttent Fai l ures
(see page 23-19).
NOTE: Before troubl eshooti ng DTC 9-1, check battery/system vol tage. l f the
vol taoe i s l ow. reDai r the charqi nq svstem before troubl eshooti nq the SRS.
(see
page 23-54)
9-2 Internal fai l ure of the SRS uni t. l f i ntermi ttent, i t coul d mean i nternal fai l ure
of the
power
suppl y
(VB
l i ne). Refer to Troubl eshooti ng Intermi ttent
Fai l ures
(see page 23-19).
NOTE: Betore troubl eshooti ng DTC 9-2. check battery/system vol tage. l f the
vol taqe i s l ow. reoai r the charqi nq svstem before troubl eshooti nq the SRS.
10- 1 Seat bel ttensi oners l and ai rbao(s)) deDl oved.
(see pase
23-54)
23-20
I
svmptom Diagnostic
procedure Also check for
SRS i ndi cator doesn' t come on SRS I ndi cat or Tr oubl eshoot i ng
( see
steo 1 on Daqe 23-55)
SRS i ndi cator stays on when i n
"SCS"
menu method
SRS l ndi cator Troubl eshooti ng
(see
step 1 on page 23' 57)
Inabi l i ty to retri eve DTCS wi th the
PGM Tester. Retri eve the fl ash
codes usi ng the SCS menu method
{ see Daoe 23- 18) .
) J
23-21
sRs
System Description
SRS Components
Airbags
The SRS i s a safety devi ce whi ch, when used wi th the seat bel t, i s desi gned to hel p protect the dri ver and passenger i n
a frontal i mpact exceedi ng a certai n set l i mi t. The system consi sts ofthe SRS uni t, i ncl udi ng a safi ng sensor and an
i mpact sensor
(A),
the cabl e reel
(B).
the dri ver' s ai rbag
(C)
and the passenger' s ai rbag
(D).
Seat Belt Tensioners
The seat bel t tensi oner 1E) i s l i nked wi th the SRS ai rbags to further i ncrease the effecti veness of the seat bel t. In a
front-end col l i si on, the tensi oner i nstantl y retracts the bel t fi rml y to secure the occupants i n thei r seats.
SRS Operation
The mai n ci rcui t i n the SRS uni t senses and
j udges
the force of i mpact and, i f necessary, i gni tes the i nfl ator charges. l f
battery vol tage i s too l ow or power i s di sconnected due to i mpact, the vol tage regul ator and the back-up power ci rcui t
respecti vel y wi l l keep vol tage at a constant l evel .
For the SRS to operate:
(1)
The i mpact sensor must acti vate and send el ectroni c si gnal s to the mi croprocessor.
{2)
The mi croprocessor must compute the si gnal s and send them to the ai rbag i nfl ators
(and
seat bel t tensi oners).
{3)
The i nfl ators must i gni te and depl oy the ai rbags
(and
acti vate the tensi oners).
Y
Self-diagnosis System
A sel f-di agnosi s ci rcui t i s bui l t i nto the SRS uni t; when the i gni ti on swi tch i s turned ON
(l l ),
the SRS i ndi cator comes on
and goes off after about 6 seconds i f the SRS i s operati ng normal l y.
l f the i ndi cator does not come on, or does not go
off after 6 seconds, or i f i t comes on whi l e dri vi ng, i t i ndi cates an
abnor mal i t y i n t he SRS. The SRS must be i nspect ed and r epai r ed as soon as
possi bl e.
For better servi ceabi l i ty, the SRS uni t memory stores a DTC that rel al es to the cause of the mal functi on, and the uni t i s
connected to the data l i nk connector
(DLC).
Thi s i nformati on can be read wi th the Honda PGM Tester when i t i s
connected to the DLC
(16P) (see page 23-11).
23-22
Ci rcui t Di agram
MAIN UNDEN-HOOO FUSE/8ILAY MX GNITION SWTCH
! -' oo-ozt voo"t t
[ , ' ornooe
UNDEn-oaslr
FUSE/RTLAY
BOX
lGl lOT in 0N lll)
DASHSOAFD
WIFEHAFNESS
DASHSOAFD
WBEHANNESS
SFS T\IOICATOF CFCUIT
I
T
I
SFS MAIN
HANNtSS
OASHEOAFO
hASt'tEss a
-
t l
NEO 8LK
| ,'--r I
u-' ..1-J
\,
PASSENGEE' S
SEATEELT
TENSIONEF
G501
t l
1l
r l
sFsMAr N
HANflESS
MEMORY ERASE
SIGNALIMES)
CONNECTOB
)
TEBMII{ALNUMEEB
\ I iEldi'i
: t , '
F
t \
I MAI_E
I
TTRIIIINAT
)
23-23
sRs
DTG Troubleshooting
DTC 1-1: Open i n Dri ver' s Ai rbag I nf l at or
DTC 1-2: Increased Resistance in Driver' s
Ai rbag I nf l at or
Special Tools Requirod
.
SRS i nfl ator si mul ator 07SAZ-T840' 11A
.
SRS si mul ator l ead C 07TAZ-S25011A
(see page 23-19).
(l l ),
and check that the
SRS i ndi cator comes on for about 6 seconds and
then goes off.
Does the SBS indicatot stay on?
YES- Go to step 3.
NO Intermi ftent fai l ure. system i s OK at thi s ti me.
Go to Troubl eshooti ng Intermi ttent Fai l ures
(see
page 23-19).
3. Turn the i gni ti on swi tch OFF, then di sconnect the
battery negati ve cabl e, and wai t for 3 mi nutes.
4. Di sconnect the dri ver' s ai rbag 2P connector from
the cabl e reel
(A).
Connect the SRS i nfl ator si mul ator
(2
Q connector)
and the si mul ator l ead to the cabl e reel .
23-24
10.
6. Reconnect the battery negati ve cabl e.
7. Erase the DTC memory.
8. Read the DTC.
l s DTC 1-1 or DTC 1-2 i ndi cated?
YES Go to step 9.
NO-Open or i ncreased resi stance i n the dri ver' s
ai rbag; repl ace the dri ver' s ai rbag
{see
page
23-65).1
Di sconnect the cabl e reel 2P connector from the
SRS mai n harness
(A).
07TAZ-S2501 1A
..->^_
\\/
"rt^.^;;mj
1 1 .Connect the SRS i nfl ator si mul ator
(2
Q
and the si mul ator l ead to the SRS mai n
Reconnect the battery negati ve cabl e.
Erase the DTC memory.
connector)
harness,
12.
13.
14. Read the DTC.
YES- Go t o st ep 15,
15.
16.
NO Open or i ncreased resi stance i n the cabl e reel ;
repl ace the cabl e reel
(see page
23-72).1
Di sconnect the passenger' s ai rbag 2P connector
(A)
and both seat bel t tensi oner 2P connectors
(B).
. t
J
23-25
17. Di sconnect the SRS uni t 18P connector
(A)
fromthe
SRS uni t. Do not di sconnect the speci al tool from
t he SRS mai n har ness.
' 1
8. Check resi stance between the No. 1 and No. 13
t er mi nal s of t he SRS uni t l 8P connect or . Ther e
shoul d be 2. 0 3. 0 Q.
SRS UNI T 18P CONNECTOR
lt
5 6 1 8 9
l r o I r i r z i l r
3 1 4 t 5 1 7 t o
GRN
l s the rcsi stance as speci l i ed?
YES
-
Faul ty SRS uni t or poor contact at the SRS
uni t 18P connect or and t he SRS uni t . Check t he
connecti on between the connector and the SRS
uni t . l f t he connect i on i s OK, r epl ace t he SRS uni t
( see page 23- 75) . 1
NO Open or i ncreased resi stance i n the SRS mai n
har ness; r epl ace t he SRS mai n har ness. l
sRs
DTG Troubleshooting
(cont'd)
DTC 1-3: Short to Another Wire or Decreased
Resi st ance i n Dri ver' s Ai rbag I nf l at or
.
sRs i nf l at or si mul at or 07sAz- TB4o11A
.
SRS si mul at or l ead C 07TM- S25011A
' 1.
Erase the DTC memory {see
page 23-19).
(l l ),
and check that the
then
goes
off.
Does the SRS i ndi cator stay on?
YES Go to step 3.
(see
page 23-19).
Di sconnect the dri ver' s ai rbag 2P connector from
the cabl e reel
(A).
07TAZ-S25011A
(2
Q connector)
6.
1 .
23-26
8. Read the DTC.
l s DTC 1-3 i ndi cated?
YES Go to step 9.
NO Short i n the dri ver' s ai rbag; repl ace the dri ver' s
ai rbag
(see page 23-65). !
SRS mai n har ness
( A) .
07TAZ-S25011A
---.-----.._--.-
\
-.--------
-\N
\v
I t
,--'1,=ft'.fi
07sAz-TB4o'l'lA
:
(2
Q connector)
and the si mul ator l ead to the SRS mai n harness.
Read the DTC,
YES Go to step
' 15.
NO Shon i n the cabl e reel ; repl ace the cabl e reel
( see page 23- 72) . 1
9.
10.
{
' t
1.
13.
14.
J
t 5 .
16.
Di sconnect the passenger' s
ai rbag 2P connector
(A)
(B).
.\ :l
J
23-27
17.
18.
Di sconnect the speci al tool from the SRS mai n
har ness.
Di sconnect the SRS uni t 18P connector
(A)
from the
SRS uni t .
Check resi stance between the No. 1 and No. 13
termi nal s of the SRS uni t 18P connector. There
shoul d be an open ci r cui t , or at l east 1 M 0.
' 19.
5 6 l 7 I I
t : v | " t ]
l,o I
rr
I
rz
ilr
1 4 l o 1 7 t 8
GRN
ls the rcsistance as specilied?
YES Faul ty SRS uni t; repl ace the SRS uni t
(see
page 23-75).I
NO Short i n the SRS mai n harness; repl ace the
SRS mai n har ness. l
1 E
16.
Di sconnect the passenger' s
(A)
and both seat bel t tensi oner 2P connectors {B).
17. Di sconnect the SRS uni t 18P connector {A)from the
SRS uni t .
18. Di sconnect the speci al tool from the SRS mai n
harness.
19. Reconnectthe battery negati ve cabl e.
20. Turn the i gni ti on swi tch ON {l l ).
21. Check for vol tage between the No. l termi nal ofthe
SRS uni t 18P connector and body ground,
and
between the No. 13 termi nal and body ground.
There shoul d be 0.5 V or l ess.
SRS UNIT 18P CONNECTOR
ls the voltage as specified?
(see
page
23- 75) . I
NO
' .
Short to power i n the SRS mai n harness;
r epl ace t he SRS mai n har ness. l
23-29
sRs
DTC Troubleshooting
(cont'd)
DTC 1-5: Short t o Ground i n Dri ver' s Ai rbag
l nf l at or
.
SRS i nfl ator si mui ator 07SAZ-T8401' l A
.
(see page 23-19).
2. Turn the i gni ti on swl tch ON
(l l ),
and check that the
then
goes off.
YES Go to step 3.
(see
page 23- 19) .
4. Di sconnect the dri ver' s ai rbag 2P connector l rom
the cabl e reel
(A).
07TAZ-SZ501rA
Connectthe SRS i nfl ator si mul ator
(2
Q connector)
Erase the DTC memory,
6.
7.
23-30
9.
10.
Read the DTc.
YES
-
Go to step 9.
NO Shortto
ground i n the dri ver' s ai rbag; repl ace
the dri ver' s ai rbag
(see page 23' 65).1
SRS mai n har ness
( A) .
07TAZ-S25011A
----R(N
\p
_---_--n.#
07sAz-T84011A
'-'
t
1 1 .Connectthe SRS i nfl ator si mul ator
(2
Q
and t he si mul at or l ead t o t he SRS mai n
connector)
har ness.
13.
14. Read the DTC.
YES
-
Go to sl ep 15.
NO Shortto ground
i n the cabl e reel ; repl ace the
cabl e reel
(see page
23-72).I
15. Turn the i gni ti on swi tch OFF, then dj sconnect the
16. Di sconnect the passenger' s
(A)
(B).
(A)
from the
SRS uni t .
har ness.
Check resi stance between the No. 1 termi nal of the
and
between the No. 13 termi nal and body ground.
There shoul d be an open ci rcui t, or at l east 1 M e .
18.
19.
Wi re si de of I emal e t ermi nal s
ls the resistance as specified?
(see
page
23- 75) . I
NO- Shor t t o gr ound i n t he SRS mai n har ness;
23-31
sRs
DTC Troubleshooting
(cont'dl
DTC 2-1: Open i n Passenger' s Ai rbag l nf l at or
DTC 2-2: I ncreased Resi st ance i n Passenger' s
.
SRS i nfl ator si mul ator 07SAZ-T840' l 1A
.
SRS si mul at or l ead C 07TM' S25011A
(see page 23-19).
(l l ),
and check that the
SRS i ndi cat or l i ght comes on f or about 6 seconds
and then goes off.
Doesthe SRS i ndi cator l i ght stay on?
YES Go to step 3.
(see
page 23- 19) .
4. Di sconnect the
passenger' s ai rbag 2P connector
f r om t he SRS mai n har ness
( A) .
Connect t he SRS i nf l at or si mul at or
( 2
Q connect or )
and t he si mul at or i ead t o t he SRS mai n har ness.
5.
23-32
8. Read the DTC.
l s DTC 2-1 or 2-2 i ndi cated?
YES Go to step 9.
NO Open or i ncreased resi stance i n the
passenger' s ai rbag; repl ace the passenger' s ai rbag
(see page 23-67).I
9. Turn the i gni ti on swi tch OFF, then di sconnectthe
10. Di sconnect t he dr i ver ' sai r bag 2Pconnect or
( A)
and
both seat bel t tensi oner 2P connectors
(B).
\|
12.
1 1. Di sconnect the SRS uni t 18P connector
(A)
from the
SRS uni t. Do not di sconnect the sDeci al tool from
the SRS mai n harness.
Check resi stance between the No. 10 and No. l 4
termi nal s of the SBS uni t
' l 8P
connector. There
shoul d be 2. 0 3. 0 Q.
lsthe resistance as specified?
YES Faul ty SRS uni t or poor
contact at the SRS
uni t connector. Check the connecti on; i f the
connecti on i s OK, repl ace l he SRS uni t
(see page
23-751.f
NO Open or i ncreased resi stance i n the SRS mai n
harness; repl ace the SRS mai n harness.!
Resistance in Passenger' s Airbag Inflator
.
SRS i nfl ator si mul ator 07SAZ-T84011A
.
SRS si mul ator l ead C 07TAZ-S25011,A
(see page 23- 19).
(l l ),
and check that the
then goes off.
Does the SRS indicator stay on?
YES- Go to step 3.
NO
-
Intermi ttent fai l ure, system i s OK at thi s ti me.
(see
page 23- 19) .
3. Turn the i gni ti on swi tch OFF. then di sconnect the
from the SRS mai n harness
(A)
07TAZ-S25011A
/____n
'r^r-r;;,-El]fi
Connecl the SRS i nfl ator si mul ator
(2
0 connector)
(cont' d)
23-33
sRs
DTC Troubleshooting
(cont'dl
8. Read the DTC.
YES Go to step 9.
NO Short i n the passenger' s ai rbag; repl ace the
passenger ' s ai r bag
( see page 23- 67) . 1
' 10.
Di sco n nect the d ri ver' s a i rbag 2P con nector {A) and
(B).
23-34
' l
1. Di sconneci the speci al tool from the SRS mai n
har ness.
Di sconnect the SRS uni t
' l 8P
connector
(A)
from the
SRS uni t .
12.
13. Check resi stance between the No. 10 and No. 14
termi nal s of the SRS uni t 18P connector.There
shoul d be an open ci rcui t. or at l east 1 M Q .
wi re si de of femal e termi nal s
ls the resistance as sqecified?
(see
page 23- 75) . I
I 3 4 5 6 7 8 I
10 12 I J 1 4 1 5 1 6 1 1
' 18
GRN
DTC 2-4: Short to Power in Passenger' s
.
SRS i nfl ator si mul ator 07SM-TB401' 1A
.
1. Erase the DTC memory {see
page 23-19).
(l l ),
and check that the
then goes
off.
YES Go to step 3.
(see
page
23- 19) .
ai rbag 2p connector
1A) .
5. Connect the SRS i nfl ator si mul ator
(2
e connecl or)
6. Reconnecl the battery negati ve cabl e.
8. Read the DTC.
YES Go to step 9.
NO Short to power
i n the passenger' s
ai rbag;
repl ace the passenger' s
ai rbag
(see page 23-67). t
10. Dj sconnect the dri ver' s ai rbag 2P connector
(A)
and
both seat bel t tensi oner
(B).
sRs
15.
13.
14.
DTC Troubleshooting
(cont'd)
' 11.
Di scon nect t he S RS uni t l 8Pconnect or ( A) f r omt he
SRS uni t.
haress.
( l l ) .
Check for vol tage between the No. 10 termi nal of
the SRS uni t 18P connector and body ground, and
between the No. 14 termi nal and body
ground.
Ther e shoul d be 0. 5 V or l ess.
SRS UNIT 18P CONNECTOB
(see
page 23-15).a
NO Shortto
power i n the SRS mai n harness;
r epl ace t he SRS mai n har ness. I
23-36
DTC 2-5: Short to Ground in Passenger' s
Ai rbag I nf l at o r
.
.
(see page 23-19).
2. Turn the l gni ti on swi tch ON
(l l ),
and check that the
then goes off.
Does the SRS i ndi cator staY on?
YES Go to step 3.
(see
page 23- 19) .
4, Di sconnect the
passenger' s ai rbag 2P connector
( A) .
Connect the SBS i nfl ator si mul ator
(2
0 connector)
and t he si mul at or l ead t o t he SRS mai n har ness.
5.
6. Reconnect the battery negative cable.
8. Read the DTC.
YES Go to step 9.
NO
-
Short to ground
i n the passenger' s
ai rbag;
repl ace the passenger' s
ai rbag
(see page
23-67).1
Turn the i gni ti on swi tch OFF. then di sconnect the
battery negative cable, and wait for 3 minutes.
Di sconnect the dri ver' s ai rbag 2P connector
(A)
and
(B).
10.
(A)
from the
SRS uni t.
harness.
Check resi stance between the No, 10 termi nal of
the SRS uni t 18P connector and body ground,
and
the No. 14 termi nal and body ground. The.e shoul d
be an open ci rcui t, or at l east 1 M Q .
' t 2.
13.
YES
-
Faul ty SRS uni t; repl ace the SRS uni t
(see
page
23-75).1
NO- Shont o gr ound
i n t he SRS mai n har ness;
repl ace the SRS mai n harness.l
,l
3 4 5 6 1 I I
10 l 1 12 t o 1 4 t 5 1 6 1 7 18
GRN GRN
23-37
sRs
DTC Troubleshooting
(cont'd)
DTC 3-1: Ooen in Driver' s Seat Belt Tensioner
DTC 3-2: Increased Resistance in Driver' s
Seat Bel t Tensi oner
.
SRS i nfl ator si mul ator 07SM-TB4011A
.
(see page 23- 19).
(l l ).
and check that the
then
goes off.
Does the SRS indicator staY on?
YES Go to steD 3.
(see
page 23- 19) .
4. Di sconnect the dri ver' s seat bel t tensi oner 2P
connector from the SRS mai n harness {A).
(2
Q connector)
07TAZ-S25011A
23-38
8. Read the DTC.
YES-Go to step 9.
NO-Open or i ncreased resi stance i n the dri ver' s
seat bel t tensi oner; repl ace the dri ver' s seat bel t
(see
Page
23-4).1
9. Turn the i gni ti on swi tch OFF, then di sconnecl the
10. Di sconnect the dri ver' s ai rbag connector
(Al .
passenger' s
ai rbag connector
(B),
and
passenger' s
seat bel t tensi oner connector
(C).
1 1 . Di sconnect the SRS uni t 18P connector
(A)
from the
SRS uni t. Do not di sconnect the sDeci al tool from
12. Check resi stance between the No. 4 termi nal and
the No. 11 termi nal of the SRS uni t 18P connector.
Ther e shoul d be 2. 0- 3. 0 Q.
\
GRN
-
+ 5 6 7 8 9
q
lofulTllts
1 4 t 3 t o 1 7 1 8
lcnrv
Wi re si de ot temal e termi nal s
YES
-
Faul tv SRS uni t or
poor
contact at the SRS
uni t 18P connector and the SRS uni t. Check the
connecti on; i f the connecti on i s OK, repl ace the
SRS uni t
(see page 23-75).1
NO-Ooen or i ncreased resi stance i n the SRS mai n
harness; repl ace the SRS mai n harness.l
23-39
sRs
DTC Troubleshooting lcont'd)
Resi st ance i n Dri ver' s Seat Bel t Tensi oner
.
SRS i nfl ator si mul ator 07SAZ-TB4011A
.
SRS si mul ator l ead C 07TM-S25011A
(see page 23-19).
(l l ),
and check that the
then
goes off.
YES Go to steD 3.
Go to Troubl eshooti ng l ntermi ttent Fai l ures
(see
page
23-19).
4, Di sconnect the dri ver' s seat bel t tensi oner 2P
connector from the SRS mai n harness
(A).
(2
Q connector)
rr^rt;am
23-40
Erase the DTC memory. 1.
8. Read the DTC.
YES Go to step 9.
NO Short i n the dri ver' s seat bel ttensi oner;
repl ace the dri ver' s seat bel t
(see page 23-4).t
battery negati ve cabl e, and wai t for 3 mi nutes,
{
10. Di sconnectthe dri ver' s ai rbag connector
(A),
passenger' s
ai rbag connector
(B),
and passenger' s
(C).
1
'1.
harness.
Di sconnect the SRS uni t 18P connector
(A)
from the
SRS uni t .
Check resi stance between the No. 4 termi nal and
the No. 1 1 termi nal of the SRS uni t 18P connector.
There shoul d be an oDen ci rcui t, or at l east 1 M o.
SBS UNI T I 8P CONNECTOR
YES
-
(see
page 23- 75) . 1
1 '
13.
23-41
sRs
DTC Troubleshooting
(cont'd)
DTC 3-4: Short to Power in Driver' s Seat Belt
Tensi oner
.
.
(see page 23-19).
(l l ),
and check that the
then goes off.
YES Go to step 3.
(see
page
23-19).
(A).
(2
O connector)
.r.^r6;am
23-42
8. Read the DTC.
YES-Go to step 9.
NO- Short to
power i n dri ver' s seat bel t tensi oner;
repl ace the dri ver' s seat bel t
(see page 23-4). !
9. Turn the i gni ti on swi tch OFF. then di sconnect the
t
(A),
passenger' s
ai rbag connector {B), and passenger' s
(C).
, / :
---------:-\
J
23-43
12.
1 1. Di sconnect the SRS uni t 18P connector
(A)
from the
SRS uni t.
Oi sconnect the speci al tool from the SRS mai n
harness.
(l l ).
Check for vol tage between the No. 4 termi nal of the
SRS uni t 18P connector and body ground. and the
No. 11 termi nal and body ground. There shoul d be
0.5 V or l ess.
ls the voltage as specitied?
YES-Faul ty SRS uni t; repl ace the SRS uni t
(see
page
23-75).I
NO Short to
power
i n the SRS mai n harness;
13.
14.
15.
sRs
DTC Troubleshooting
(cont'd)
DTC 3-5: Short to Ground in Driver' s Seat Belt
Tensi oner
.
.
(see page 23-19).
(l l ),
and check that the
then
goes
off.
Does the SRS indicatot stay on?
YES Go to step 3.
NO- Intermi ttent fai l ure, system i s OK at thi s ti me.
(see
page 23-19).
(A).
Connectthe SRS i nfl ator si mul ator
(2
O connecl or)
23-44
8. Read the DTC.
ls DTC 3-5 indicated?
YES- Go to step 9.
NO Short to
ground i n the dri ve/s seat bel t
tensi oner; repl ace the dri ver' s seat bel t
(see page
23-4l.a
3
(A),
passenger' s ai rbag connector
(8),
and
passenger' s
(C).
\ . ]
)
23-45
(A)
from the
SRS uni t .
12. Di sconnect the speci al tool from the SRS mai n
harness.
SRS uni t 18P connector and body ground, and the
No. 11 t er mi nal and body
gr ound. Ther e shoul d be
an open ci rcui t, or at l east 1 M Q .
Wi re si de ot I emal e t ermi nal s
ls the resistance as specitied?
YES
-
(see
page 23- 75) . 1
NO Short to
ground i n the SRS mai n harness;
sRs
DTC Troubleshooting
{cont'd)
DTC 4-1: Open in Passenger' s Seat Belt
Tensi oner
DTC 4-2: Increased Resistance in Passenger' s
Seat Bel t Tensi oner
.
.
(see page
23-19).
( l l ) ,
and check t hat t he
then
goes
off.
Does the SBS i ndi cator stay on?
YES Go to step 3.
(see
page 23-' 19).
4. Di sconnect the
passenger' s
seat bel t tensi oner 2P
connector from the SBS mai n harness
(A).
07TAZ-S25011A
\orroa.rroor,,o
(2
O connector)
23-46
8. Read the DTC.
YES Go to step 9.
NO-Open or i ncreased resi stance i n the
passenger' s
seat bel t tensi oner; repl ace the
passenger' s
seat bel t
(see page 23-4).1
\
(A),
passenger' s
ai rbag connector {B), and dri ver' s seat
bel t tensi oner connector
(C).
A
J
11. Di sconnect t he SRS uni t 18P connect or
( A) f r om
t he
SRS uni t. Do not di sconnect the speci al tool from
t he No. 12 t er mi nal of t he SRS uni t 18P connect or .
Ther e shoul d be 2. 0 3. 0 Q.
GRN
1 ! L , . l o
+ l s ti 1 8 9
o
l , o l
r r
l r z ] r s I
r a15 1 6 1 7
llcRN
ls the tesistance as specilied?
YES Faul ty SRS u ni t or poor contact at the SRS
uni t
' l 8P
connect or and t he SRS uni t . Check t he
connecti on; i f the connecti on i s OK, repl ace the
SRS uni t { see
page
23- 75) . 1
NO Open or i ncr eased r esi st ance i n t he SRS mai n
har ness; r epl ace t he SRS mai n har ness. l
sRs
DTC Troubleshooting
(cont'd)
DTG 4-3: Short to Another Wire or Decreased
Resistance in Passenger' s Seat Belt
Tensi oner
.
.
SRS si mul ator l ead C 07TM-S250114
(see page 23-19).
(l l ),
and check that the
then goes off.
Does the SFIS indicator stay on?
YES Go to step 3.
Go to Troubl eshooti ng Intermi ttent Fai l ures {see
page 23- 19) .
4. Di sconnect the
passenger' s
(A).
AZ-S25011A
\or"or-r"oorro
(2
0 connector)
23-48
8. Read the DTC.
YES Go to step 9.
NO-Shon i n the passenger' s
seat bel ttensi oner;
repl ace the
passenger' s
seat bel t
(see page 23-4).1
battery negati ve cabl e, and wai t for 3 mi nutes,
' 10.
Di sconnect the dri ver' s ai rbag connector
(A),
passenger' s
ai rbag connector
(B),
and dri ver' s seat
(C).
1 1 .Di sconnectthe speci al tool
(2
Q connector) from
a
23-49
13.
12. Di sconnect the SRS uni t 18P connector 1A)from the
SRS uni t .
t he No. l 2 t er mi nal of t heSRS uni t 18Pconnect or .
There shoul d be an oDen ci rcui t, or at l east 1 M Q .
YES Faul ty SRS uni t; repl ace the SRS uni t {see
page
23-7 5l .a
sRs
DTC Troubleshooting
(cont'dl
DTC 4-4: Short to Power in Passenger' s Seat
Bel t Tensi oner
.
SRS i nfl ator si mul ator 07SAZ-T840' l 1A
.
1. Er ase t he DTC memor y
( see page 23- 19) .
( l l ) ,
and check t hat t he
then
goes off.
Does the SRS i ndi catot stay on?
YES Go to step 3.
NO
-
Intermi ttent fai l ure, system i s OK at thi s ti me.
(see
page 23- 19) .
4. Di sconnect the passenger' s seat bel t tensi oner 2P
connector from the SRS mai n harness.
AZ-S25011A
\
orror-r"oor ro
Connect t he SRS i nf l at or si mul at or
( 2
Q connect or )
23-50
8. Read the DTC.
l s DTC 4-4 i nd i cated?
YES Go to step 9.
NO Short to power i n the
passenger' s seat bel t
tensi oner; repl ace the
passenger' s seat bel t
(see
page 23- 4) . 1
(A),
passenger' s
ai rbag connector
(B),
and dri ver' s seat
(C),
(A)
from the
SRS uni t.
harness,
(l l ).
Check for vol tage between the No. 5 termi nal of the
and the
No.
' 12
termi nal and body ground.
There shoul d be
0. 5 V or l ess.
SRS UNI T 18P CONNECI OR
t 5 .
13.
14.
ls the voltage as specilied?
YES Faul ty SRS uni t; repl ace the SRS uni t {see
page
23- 75) . I
NO Short to power i n the SRS mai n harness;
23-51
3t-'r
..
:r
sRs
DTC Troubleshooting
(cont'd)
DTC 4-5: Short to Ground in Passenger' s Seat
Bel t Tensi oner
.
SRS i nfl ator si mul ator 07SAZ-T8401 1A
.
SRS si mul ator l ead C 07TM-S25011A
(see page
23-19).
(l l ),
and check that the
then goes off.
YES Go to step 3.
NO- Intermi ftent fai l ure, system i s OK at thi s ti me.
(see
page 23- 19) .
(A).
Az-SZs011A
\orro.-rrnorro
(2
Q connector)
23-52
TL
f , \
8. Read the DTC.
YES- Go to step 9.
NO
-
Short to ground i n the passenger' s seat bel t
tensi oner; repl ace the passenger' s seat bel t
(see
page
23-4).1
\
(A),
passenger' s
ai rbag connector
(B),
and dri ver' s seat
(CI.
1. ,
) r ,
23-53
1' 1. Di sconnect the SRS uni t 18P connector
(A)
from the
SRS uni t .
harness.
and the
No. 12 t er mi nal and body gr ound. Ther e shoul d be
an open ci rcui t, or at l east 1 M Q.
12.
t 5 .
Is the resi stance as speci fi ed?
(see
page 23- 75) . 1
NO Shor t t o gr ound i n t he SRS mai n har ness;
r epl ace t he SRS mai n har ness. I
sRs
DTG Troubleshooting
(cont'd)
DTC 5-1, 5-2, 5-3, 5-4, 6-1, 6-2, 6-3, 6-4,7-1,7
-2,
7-3,8-1,8-2,8-3, 8-4, 8-6, 9-1, 9-2: Internal
Fai l ure of t he SRS Uni t
NOTE: Before troubl eshooti ng any of these DTCs, check
the battery/system vol tage. l f the vol tage i s Iow, repai r
the chargi ng system before troubl eshooti ng the SRS. l f
the battery/system vol tage i s now OK, ask the customer
i f the battery ever went dead.
(see page 23-19).
(l l ),
and check that the
then
goes off.
YES
-
Repl ace the SRS uni t
(see page 23-75).I
NO- l ntermi ttent fai l ure, system i s OK at thi s ti me.
Go to Troubl eshooti ng l ntermi ttent fai l ures
(see
page 23- 19) .
23-54
DTC 10-1: Ai rbags and/ or Seat Bel t
Tensi oners Depl oyed
The SRS uni t must be repl aced after any ai rbags and/or
tensi oners have depl oyed
(see page 23-75).
SRS Indicator Circuit Troubleshooting
The SRS Indicator Doesn' t Gome On
( l l ) ,
and see i f t he ot her
i ndi cators come on
(brake
system, etc).
Do the other indicators come on?
YES
-
Go to step 2.
NO
-
Go to step 8.
2. Turn the i gni ti on swi tch OFF, then remove the
gauge assembl y
(s
ee
page
22-521. Di sconnect
gauge
assembl y connector A and B from the gauge
assemDty.
Check resi stance between the No. I termi nal of
gauge assembl y connector B
(12P)
and body
gr ound. Ther e shoul d be 0- ' 1, 0 Q .
GAUGE ASSEMBLY CONNECTOR B {12P)
YES Go to step 4.
NO Open i n t he BLK wi r e of dashboar d wi r e
har ness A or f aul t y body gr ound t er mi nal
( G501) .
l f
the body ground
termi nal i s OK, repi ace dashboard
wi r e har ness A. I
2 J 4 5
6 1 8 9 10 t l
BLK
6)
4. Check for vol tage between the No. 4 termi nal of
(14P)
and body
ground wi thi n the fi rst 6 seconds afterturni ng the
(l l ).
There shoul d be 8.5 V or l ess.
GAUGE ASSEMBLY CONNECTOR A
(14P}
YES Faul ty SRS i ndi cator ci rcui t i n the gauge
assembl y; repl ace the gauge assembl y.l
NO Go to step 5.
(cont' d)
23-55
sRs
(cont'd)
6. Di sconnect SRS uni t connector 18P connector
(A)
from the SRS uni t
23-56
7. Di sconnect gauge assembl y connector A
(14P).
Connect a vol tmeter between the No. 4 termi nal of
(14P)
and body
ground. Turn the i gni ti on swi tch ON
(l l ),
and
measure vol tage. There shoul d be 0.5 V or l ess.
GAUGE ASSEMBLY CONNECTOR A {lirP)
(see
page 23-75).r
NO Short to power i n the PNK wi re of dashboard
wi re harness A or i n the SRS mai n harness; repl ace
the faul ty harness.l
Turn the i gni ti on swi tch OFF. Check the No. 5
(7.5A)
Juse i n the under-dash fuse/rel ay box,
l s the fuse bl own?
YES Go to step 10.
NO Go to step 9.
8,
-0
9. Connect a vol tmeter between the No. 4 termi nal of
gauge assembl y connector B
(12P)
and body
ground, Turn the i gni ti on swi tch ON fl l ), and
measure the vol tage. There shoul d be battery
vol tage.
GAUGE ASSEMBLY CONNECTOR B {12P)
assembl y or poor
contact at gauge
assembl y
connector B { 12P) and the gauge
assembl y; i f the
connecti on i s OK, repl ace the gauge assembl y.l
NO Open i n the under-dash fuse/rel ay box No. 5
(7.5A)
fuse ci rcui t, or open i n the YEL wi re of
dashboard wi re harness. l f the under-dash fuse/
r el ay box i s OK, r epl ace t he f aul t y har ness. I
Repl ace the No. 5
(7.5A)
fuse, then check to see i f
the i ndi cators comes on.
Do the indicators come on?
YES The system i s OK at thi s ti me. t
NO Repai r shont o gr ound i n t he under - dash f use/
r el ay box No. 5 { 7. 5A) f use ci r cui t . l
10.
Wi re si de of f emal e t ermrnal s
The SRS Indicator Stays On When ln
"SCS"
Menu Method
NOTE:
.
l f you
retri eve DTCS wi th the PGM Tester usi ng the
SRS menu method, retri eve fl ash codes wi th the
Tester i n SCS mode
(see page 23-18).
.
A new SRS uni t must sense the enti re system i s OK
before compl eti ng i ts i ni ti al sel f-test. The most
common cause of an i ncompl ete sel f-test i s the
fai l ure to repl ace al l depl oyed parts after a col l i si on,
i n pani cul ar,
seat bel t tensi oners.
.
An i ncompl ete sel f-test prevents
the PG M Tester from
retri evi ng DTCS, al though fl ash codes are avai l abl e i n
the Tester' s SCS mode.
1. Erase the DTC memory usi ng the MES connector
{ see
page 23- 19) .
Does the SBS indicator go off while you are
erasi ng the DTC memory?
YES Go to step 37.
NO Go to step 2.
2. Chec k t he No. 1( 10A) f us ei nt heunder - das h
fuse/rel ay box.
l s the f use OK?
YES Go to step 17.
NO Go to step 3.
3. Repl ace t he No. 1
( 10
A) f use.
(l l ),
and wai t for 30
seconds. Then turn the i gni ti on swi tch OFF.
5. Check t he No. 1
( 10
A) f use.
l s the tuse OK?
YES The sysrem i s OK at thi s ti me. t
NO Go to step 6.
6. Repl ace t he No. 1
( 10
A) f use.
(cont' d)
23-57
sRs
lcont'd)
7. Turn the i gni ti on swi tch OFF. Di sconnect the
Di sconnect the dri ver' s ai rbag connector
(A),
passenger' s ai rbag connector 1B), and both seat
bel t tensi oner 2P connectors
(C).
23-58
9. Di sconnectthe SRS uni t 18P connector
(A)from
the
SRS uni t.
10.
1 1 .
(l l ),
and wai t for 30
Check the No. 1
(10
fuse/rel ay box.
ls the tuse OK?
YES
-
Short to
ground i n the SRS uni U repl ace the
SRS uni t
(see page 23-75).1
NO Go to step 13.
Repl ace the No. I
(10
fuse/rel ay box.
Di sconnect the SRS mai n harness connector A
(2P)
from the under-dash fuse/ral ay box.
' t2.
13.
14.
-0
(l l ),
and wai t for 30
' 16.
Check t he No. 1
( 10A) f use
i n t he under - dash
fuse/rel ay box.
l s the f use OK?
YES Short to ground i n dashboard wi re harness
A; repl ace dashboard wi re harness A.I
NO Short to ground i n the under-dash fuse/rel ay
box; repl ace the under-dash fuse/rel ay box.l
17. Turn the i gni ti on swi tch OFF. Dl sconnect the
(A),
passenger' s
ai rbag connector
(B),
and both seat
bel t tensi oner 2P connectors
(C).
(cont' d)
23-59
sRs
(cont'd)
19. Di sconnet the SRS uni t 18P connector
(A)
from the
SRS uni t.
Connect a vol tmeter between the No.3 termi nal of
the SRS uni t 18P connector and body
ground. Turn
the i gni ti on swi tch ON l l l ), and measure vol tage.
20.
YES Go to step 25.
NO Go to step 22,
SRS UNIT I8P CONNECTOR
23-60
24.
23. Di sconnect SRS mai n harness connector A
(2P)
from the under-dash fuse/rel ay box.
SRS uni t
' l 8P
connector and the No. 1 termi nal of
SRS mai n harness connector A. There shoul d be
0 1 . 0 Q.
SRS MAIN HARNESS CONNECTOR A
(2P)
YES
-
Open i n the under-dash fuse/rel ay box or
poor
contact at SRS mai n harness connector A;
check the connecti on. l f the connecti on i s OK,
repl ace the under-dash fuse/rel ay box.l
NO Open i n SRS mai n wi re harness; repl ace the
SRS mai n wi r e har ness. l
I
Wi re si de ol t emal e t ermi nal s
25.
26.
27.
28.
Connect the No. 3 termi nal and the No. 6 termi nal
of the SRS uni t 18P connector wi th a
j umper
wi re.
(l l ).
Check the SRS i ndi cator.
Di d the SBS i ndi cator go ofl ?
YES- Faul t y SRS uni t ; r epl ace t he SRS uni t . l
NO Go to step 29.
30. Di sconnect the
j umper
wi re between the No. 3
t er mi nal and t he No. 6 t er mi nal of t he SRS uni t 18P
connector.
31. Checkt he No. 1
( 10A) f use
i nt he under - dash f use/
retay oox.
ls the f use OK?
YES- Go to step 35.
NO Go to step 32.
32. Repl ace the No. 1
(10A)
fuse.
-8
JUMPER WIRE
GRN GRN
3 4 5 6 7 I I
l 0 t1 12 13 t c 1 7 l o
4
34.
33. Remove the
gauge
assembl y
(see page 22-521, then
di sconnect gauge assembl y connector A from the
gauge assembl y.
A
SRS uni t 18P connector and body ground. There
shoul d be an oDen ci rcui t, or at l east 1 M Q.
ls the resistance as specilied?
assembl y; repl ace the gauge assembl y.I
NO
-
Shon t o
gr ound i n t he SRS mai n har ness or i n
dashboard wi re harness A; repl ace the faul ty
har ness. l
(cont' d)
SRS UNIT 18P CONNCTOR
23-61
sRs
SRS Indicator Gircuit Troubleshooting
(cont'dl
35. Remove the
gauge assembl y
di sconnect gauge assembl y connector A from the
gauge assemDr y.
36. Check resi stance between the No. 4 termi nal of
gauge
assembl y connector A
(14P)
and No. 6
termi nal of the SRS uni t 18P connector. There
shoul d be 1 Q or l ess.
GAUGE ASSEMBLY CONNECTOR A
(14P)
YES Faul ty SRS i ndi cator ci rcui t i n the
gauge
assembl y or poor contact at gauge assembl y
connector A
(14P);
Check the connecti on. l f the
connecti on i s OK, repl ace the gauge assembl y.l
NO Open i n t he SRS mai n har ness or i n
dashboard wi re harness A; repl ace the faul ty
har ness. I
PNK
l 2 3
|
^
l,zl/
1 I I 1 0
l
r l / l / l t +
o
Wi re si de ol l emal e t ermi nal s
GRN
3 4 5 6 1 I 9
10 11 12 t 5 o 1 7 18
23-62
37.
38.
l f necessary, remove the SCS servi ce connector
from the MES connector.
( l l ) .
Does the SRS indicator come on lor about 6
seconds and then go otl ?
YES-The system i s OK at thi s ti me.I
NO Go to step 40.
Di sconnet the SRS uni t 18P connector
(A)
from the
SRS uni t .
41. Connect a Honda PGM Tester
(A)
to the data l i nk
connector
(B)
and fol l ow the Tester' s
prompts i n
the
"SCS"
menu
(see
the Tester' s operati ng
ma nuar r .
-e
42. Check resi stance between the No.9 termi nal ofthe
SRS uni t 18P connector and body
ground. There
shoul d be 0- 1. 0 Q .
ls the rcsistance as specitied?
YES
-
Faul ty SRS uni t or
poor
contact at the SRS
uni t 18P connector; check the connecti on; i f the
connecti on i s OK, repl ace the SRS uni t
(see page
23-751..
NO Open i n the SCS l i ne between the No. 9
termi nal of the SRS uni t 18P connector and the
No.9 termi nal
(BRN
wi re) ofthe data l i nk connector
(DLC)
or open between the No. 4 termi nal of the
DLC and body ground. Repai r the open wi re
(s).
23-63
sRs
Component Replacement/lnspection After Deployment
NOTE: Before doi ng any SRS repai rs. use the PGM
Tester SRS menu method to check for DTCS; refer to the
DTC Troubl eshooti ng l ndex for the l ess obvi ous
depl oyed
parts (seat
bel t tensi oners, etc.)
After a col l i si on where the ai rbag(s) depl oyed, repl ace
these rtems:
.
SRS uni t
.
Depl oyed ai rbag{s)
.
Seat bel t tensi oners
Duri ng the repai r process, i nspect these areas:
.
I nspect al l t he SRS wi r e har nesses. Repl ace. don' t
repai r, any damaged harnesses.
.
I nspect t hecabl e r eel f or heat damage. l f t her e i s any
damage, repl ace the cabl e reel .
After the vehi cl e i s compl etel y repai red, turn the
(l l ).
l f the SRS i ndi cator comes on for
about 6 seconds and then goes off, the SRS i s OK. l f the
i ndi cator does notfuncti on properl y,
use the PGM
Tester SRS Menu Method to read the DTC{S). l f thi s
doesn' t retri eve any codes, use the Tester' s SCS menu
method {see
page
23-18). l f you sti l l cannot retri eve a
code, go to SRS Indi cator Ci rcui t Troubl eshooti ng.
23-64
g
Driver's Airbag Replacement
Removal
l east 3 mi nutes before begi nni ng work.
2. Remove the access
panel (A)
from the steeri ng
wheel , then di sconnect the dri ver' s ai rbag 2P
connector
(B)
from the cabl e reel .
3. Remove the cover
(A)
from the steeri ng wheel ,
remove the two Torx bol ts
(B)
usi ng a Torx T30 bi t,
then remove the dri ver' s ai rbag {C).
Di sconnect the horn connector from the steeri ng
wneet .
(cont' dl
23-65
sRs
Driver's Airbag Replacement
(cont'd)
Installation
1. Pl ace the new dri ver' s ai rbag
(A)
i nthesteeri ng
wheel , and secure i twi th new Torx bol ts
(B).
Instal l
the covers
(C).
B
9.8 N.m {1.0 kgf.m,7.2 l bf.ft)
23-66
I
2. Connect the cabl e reel 2P co nnecto r to the dri ver' s
ai r bag
( A) ,
t hen i nst al l t he access panel ( C)
on t he
steeri ng wheel .
Connect the battery negati ve cabl e.
After i nstal l i ng the ai rbag, confi rm proper
system
operatron:
.
(l l );
the SRS i ndi cator
shoul d come on for about 6 seconds and then go
off.
.
Make sure the horn works.
I
Passenger's Airbag Replacement
Removal
1. Di sconnectthe battery negati ve cabl e, and wai t at
2. Remove the passenger' s dashboard l ower cover
(see page 20-81 ). then di sconnect the passenger' s
(A)
from the SRS mai n harness.
3. Remove the three mounti ng nuts
(A)
from the
bracket. Cover the l i d and dashboard wi th a cl oth.
and
pry careful l y wi th a screwdri ver to l i ft the
passenger' s ai rbag
(B)
out of the dashboard.
NOTE: The ai rbag l i d has
pawl s
on i ts si de that
attach i t to the dashboard.
(cont' d)
:---
'
23-67
sRs
Passenger's Airbag Replacement
{cont'dl
Installation
1. Pl ace the new passenger' s ai rbag
(A)
i nto the
dashboard. Ti ghten the passenger' s ai rbag
mounti ng nuts
{B).
B
9.8 N.m
{1.0 kgt.m, 7.2 l bf ft)
23-68
I
2. Connect the
passenger' s
(Al to
Attach the
passenger' s
ai rbag connector to the
connector hol der
(B),
then rei nstal l the passenger' s
dashboard l ower cover {see
page 20-81).
After i nstal l i ng the ai rbag, confi rm proper
system
operati on: Turn the i gni ti on swi tch ON
(l l );
the SRS
i ndi cator shoul d come on for about 6 seconds and
then
go
OFF.
Airbag Disposal
Speci al Tool Requi red
Depl oyment Tool 07HAZ-SG00500
Before scrappi ng any ai rbags
(i ncl udi ng
those i n a
whol e vehi cl e to be scrapped). the ai rbags must be
depl oyed. l f the vehi cl e i s sti l l wi thi n the warranty
peri od. the Honda Di stri ct Servi ce Manager must gi ve
approval and/or speci al i nstructi ons before depl oyi ng
the ai rbags
(and
seat bel t tensi oners). Onl y after the
ai rbags
(and
seat bel t tensi oners) have been depl oyed
{as
the resul t of vehi cl e col l i si on, i or exampl e), can they
be scrapped. l f the ai rbags
(and
seat bel t tensi oners)
appear i ntact
(not
depl oyed), treat them wi th extreme
cauti on. Fol l ow thi s procedure.
Deploying Airbags In the Vehicle
l f an SRS equi pped vehi cl e i s to be enti rel y scrapped, i ts
ai rbags
(and
seat bel t tensi oners) shoul d be depl oyed
whi l e sti l l i n the vehi cl e. The ai rbags
(and
seat bel t
tensi oners) shoul d not be consi dered as sal vageabl e
parts and shoul d never be i nstal l ed i n another vehi cl e.
l . Turn the i gni ti on swi tch OFF, di sconnect the battery
negati ve cabl e, and wai t at l east 3 mi nutes.
2. Confi rm that each ai rbag and each seat bel t
tensi oner i s securel y mounted
3. Confi rm that the speci al tool l sfuncti oni ng properl y
by fol l owi ng the check procedure on the tool l abel .
Driver's Airbag:
4. Remove the access
panel (A),
dri ver' s ai rbag 2P connector
(B)
from the cabl e reel .
Passenger's Airbag:
5. Remove the
passenger' s
dashboard l ower cover,
passenger' s
ai rbag 2P
connector
(A)from
Seat Belt Tensioner:
6. Remove the seat bel t tensi oner
(see page 23-41,
then di sconnect the seat bel t tensi oner 2P
connector
(Al from
(cont' d)
\
23-69
sRs
Airbag Disposal
lcont'd)
7. Pul l the seat bel t
(A)
out al l the way and cut i t.
Cut off the ai rbag or seat bel t tensi oner connector,
stri p the ends of the ai rbag wi res and seat bel t
tensi onerwi res
(A),
and connectthe depl oyment
tool al l i gator cl i ps
(A)
to the ai rbags and seat bel t
tensi oners. Pl ace the depl oyment tool at l east 30
feet {10 meters} away from the vehi cl e.
23-70
9. Connect a 12 vol t battery to the tool .
.
l f t he gr een l i ght ont het ool comeson, t he i gni t er
ci rcui t i s defecti ve and cannot deDl ov the
components. Go l o Di sposal of Damaged
Components,
.
l f the red l i ght on thetool comes on, the
component i s ready to be depl oyed.
10. Push the tool ' s depl oyment swi tch. The ai rbags and
tensi oners shoul d depl oy
(depl oyment
i s both
hi ghl y audi bl e and vi si bl e: a l oud noi se and r api d
i nfl ati on ofthe bag, fol l owed by sl ow defl ati on).
.
l f t he ai r bagsdepl oyandt he gr een l i ght ont he
tool comes on, conti nue wi th thi s
procedure.
.
l f an ai rbag doesn' t depl oy, yet the green l i ght
comes ON, i ts i gni ter i s defecti ve. Go to Di sposal
of Damaged Components.
.
Duri ng depl oyment, the ai rbags, can become hot
enough to burn you. Wai t 30 mi nutes after
depl oyment before touchi ng the ai rbags.
11. Di spose ofthe compl ete ai rbag. No part of i t can be
reused. Pl ace i t i n a sturdy pl asti c bag
(A)
and seal
i t securel y.
Deploying Components Out of the Vehicle
l f an i ntact ai rbag or seat bel t tensi oner has been
removed from a scrapped vehi cl e, or has been found
defecti ve or damaged duri ng transi t, storage, or servi ce,
i t shoul d be deDl oved as fol l ows:
Confi rm that the speci al tool i s functi oni ng properl y
by fol l owi ng the check
procedure
on thi s
page or
on t he t ool l abel .
2. Posi ti on the ai rbag face up, outdoors on fl at ground
at l east 30 feet
(10
meters)from any obstacl es or
Deool e.
3. Fol l owst epsSt hr ough 11of t he i n- vehi cl e
depl oyment procedure.
Disposal of Damaged Components
1. l f i nstal l ed i n the vehi cl e, fol l ow the removal
procedure for the dri ver' s ai rbag
(see page 23-65),
passenger' s ai rbag
(see page
23-67), and seat bel t
tensioner
(see page 23-4).
2. In al l cases, make a short ci rcui t by cutti ng,
stri ppi ng, and twi sti ng together the two ai rbag
i nfl ator wi res and seat bel t tensi oner wi res.
Package the ai rbag or seat bel t tensi oner i n the
same packagi ng that the new repl acement part
came an.
Mark the outsi de of the box
"DAMAGED
AIRBAG
NOT DEPLOYED,' oT
,,DAMAG
ED SEAT BELT
TENSIONER NOT DEPLOYED" so i t does not get
confused wi th your parts
stock.
Contact your Honda Di stri ct Servi ce Manager for
how and where to return i t for di sposal .
4.
Deployment Tool Check
' 1.
Connect the
yel l ow cl i ps to both swi tch
protector
handl es on the tool ; connect the tool to a battery.
2. Push the operati on swi tch:
green means the tool i s
OK; red means the tool i s faul ty.
3. Di sconnect the battery and the
yel l ow cl i ps.
23-71
sRs
Cabl e Reel Repl acement
Removal
1. Make sure the front wheel s are al i gned strai ght
ahead.
Di sconnect the battery negati ve cabl e and wai t at
l east 3 mi nutes.
Remove the dri ver' s ai rbag l see
page 23-65).
Remove the steeri ng wheel
(see page 17-6).
Remove the col umn cover screws
(A),
then remove
the col umn covers
(8,
C).
r
23-72
6. Di sconnect the SRS mai n harness 2P connector {A)
from the cabl e reel
(B),
dashboard wi re harness 4P connector
(C)
from the
cabl e reel .
' 1.
Remove the screws {A) from the cabl e reel , then
remove the cabl e reel from the col umn.
Installation
1. Before i nstal l i ng the steeri ng wheel , the front
wheel s shoul d be al i gned strai ght ahead.
l east 3 mi nutes,
3. Set the cancel sl eeve
(A)
so that the
proj ecti ons (B
)
are al i gned verti cal l y.
4. Car ef ul l y i nst al l t he cabl e r eel
( A)
on t he st eer i ng
col umn shaft. Then connect the 4P connector
(B)
to
the cabl e reel , and connect the 2P connector {C) to
7.
Instal l the steeri ng col umn covers.
l f necessary, center the cabl e reel .
(New
repl acement cabl e reel s come centered.) Do thi s by
fi rst rotati ng the cabl e reel cl ockwi se unti l i t stops.
Then rotate i t countercl ockwi se
(aboul
2 1 /2 tu' ns)
unt i l t he ar r ow mar k on t he cabl e r eel l abel poi nt s
strai ght up.
Posi ti on the two tabs
(A)
of the turn si gnal
cancel l i ng sl eeve
( B)
as shown, and i nst al l t he
steeri ng wheel on to the steeri ng col umn shaft,
maki ng sur e t he st eer i ng wheel hub
( C)
engages
the
pi ns
i D) of the cabl e reel and tabs of the
cancel l i ng sl eeve, Do not tap on the steeri ng wheel
or st eer i ng col umn shaf t when i nsl al l i ng t he
steeri ng wheel .
(cont' d)
23-73
sRs
8.
Cable Reel Replacement
(cont'd)
Instal l the steeri ng wheel bol t
(A),
and ti ghten i t to
38 N.m
(3.9
kgf.m, 28 l bf.ft).
Connect the crui se control swi tch connector.
Instal l the dri ver' s ai rbag
(see page
23-66).
9.
10.
11.
23-7 4
12. After i nstal l i ng the cabl e reel , confi rm
proper
system operat| on:
.
(l l );
the SRS i ndi cator
shoul d come on for about 6 seconds and then go
off.
.
After the SRS i ndi cator has turned off. turn the
steeri ng wheel ful l y l eft and ri ght to confi rm the
i ndi cator does not come on.
.
Make sure the horn works.
SRS Uni t Repl acement
Removal
2. Di sconnect the ai rbag connectors and seat bel t
tensi oner connectors
(see page 23- 16).
(see page 20-76) and
audi o uni t
(see page 22-89).
4, Di sconnect t he SRS uni t 18P connect or
( A) f r om
t he
SRS uni t
( B) .
Remove the three Torx bol ts
(A)
from the SRS
then Dul l out the SRS uni t from the bracket.
unr t , 5.
lnstallation
1. I nst al l t he new SRS uni t
( A) wi t h
Tor x bol t s
( B) ,
t hen
connect the SRS uni t 18P connector
(C)
to the SRS
uni U push i t i nto posi ti on
unti l i t cl i cks.
NOTE: When ti ghteni ng the Torx bol ts to the
speci fi ed torque after repl acement. be careful to
t ur n t hem i n so t hat t hei r heads r est squar el y on t he
brackets.
Rei nst al l t he cent er consol e
( see page 20- 76) and
audi o uni t
( see page 22- 89) .
Reconnect the ai rbag connectors and seat bel t
t ensi oner connect or s
( see page 23- 16) .
After i nstal l i ng the SRS uni t, confi rm
proper
system
operati on: Turn the i gni ti on swi tch ON
(l l );
the SRS
i ndi cator shoul d come on for about 6 seconds and
t hen
go OFF.
2.
3.
4.
5,
9. 8 N. m {1. 0 kgf m, 7. 2l bf f t }
23-75

Honda S2000 (00-03) Service Manual

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Honda S2000 (00-03) Service Manual

Uploaded by

Copyright:

Available Formats

INTRODUCTION

Al l i nl ormat i on cont ai ned i n t hi s manual i s based on t he l at est

You might also like