Civic 1992 Eg3, Eg4, Eg5, Eg6, Eg7, Eg8, Eh1, Eh8, Eh9 Non-Usdm Manual-1

INTRODUCTION *General lnfo
How to UseThls Manuel-----------~

Thc 92 CIVIC Shop Monuol (Mainton•nco. Repoiir ond Con.sttuctlonl
1, devided lnto two volumes (volume 1 and volume 2).
Mak, 1u<e to refer both volumes when c&Hylng out 1et)flil or
m8intenanc:e of 92 ClVIC o, when vou w&nt to ltnow 119
~S_p_e_c_ia_l_T_o_o_l_s
__ ~a
specs
consiruct:ion,
Thlt manual lvolume 1) la dlv'tded !tito 8 s.ectlont. The l11s1 pJige ot
&&eh secdon Is mMked wrth a blKfe u1.b that llnes up wíth lts cor·
Specifications
re6')0nding thumb lnde,c tab on thl& pao,e. You een Qulckly lind the
fir&1 p.age of eecn 1ec1k>n whhout k>oklng through a luU table ol
comema. The avmbols p1ln1ed et me top comer et eath pngc c11n
eree be u&ed 11:9 a Qulck 1ete,ence svstem.
Maintenance
Eac::h se,c-t!on linctudes:
~~Qftll
1. A tabte ol co,uen1s, or an ell.ploded vM!w i~11 showing:
• P&11s dlusaemblV stiquenGc.
• Boh tOrQues &!'Id thread siies..
• Pa,ge rele,enees 10 descriplións in •~11.t. ~E_n_g_i_n_e
2. Dis11.SM:1mbty/n.s11,ombty p1oc1:dvre111, .and tool&.
3. rns-p&etion.
4. Teining/lloub1e-shooting,
5. Ré!p.air.
6. Ad)ustmenu. Cooling
Spectal lnformatlon ------------~

il@lf@N fndlotH • •nong po.. lbllty ot Hvtfe pe1&0n8' lniu1y Fuel and Emissions ....
or losa of llfe if ln•tructlons n.r• not followed,
CAUTION: lndicates • posslbility of perM>n•I injury

damage if ln.structlons &re not followed.
NOTE: GivH helpful information,

Dt equipmtint
Transaxle m;;c>J
CAUTION: Oet.ail.d descñpt!Qns of $1.ndMd W<>/'k$/top PIO·
oedures, Hfety prinolplu and ••rvic•
opeflltion, are not lncluded,
Please n<:it• 1hat thi11 manual contalN wamlng, •nd eautloot
•g•lns1 som• sp•olfic 11en,'ce met'hod• whlch could e•u&e PEA· ~l*_S_t_e_e_r_in_g ~
SONAL tNJURY, damage a vehict.l 01 lnlll(• h unnte, Pleue
undff1tend that ,h.. • wamlngs eannot eover ell conce'v~le wey,
In whioh s«Vice, wheth., or not r-ecommended by HONOA m~ht
be done, °' of INI poHible ha.:ardou.s con,•quenee, ot •verv con· Suspension
caivable way. nor could HONDA lnvutigato Al IUCh way.s. Anyone
uslng 1ervk• prooedunts o, toob, whtlther o, not recommtnd.ci by
HONDA. muit utis/y hlmulf thorouglt/'y that nelthe, personal aate·
ty nor vehlcte t,e,fety wlll be J.op•rdl.ud.
Brakes
AH info,maition contaiined in th1& mainual Is be&.ed on the l81n1 Pl'O- (lncluding ABS )
dvct information ave!lab14 at the dme ot mlntJng. We reserve the
right to mak.e chilnQe& at any time without notlce. No i>,an ot lhit
pu;blic,tion may be teproduced, &tored In ,euleval sys1em. ot
t13nsml1ud. in any form by .iny me.ins, electton!c, mechanlcal, *Body
photoc:opying, recordino, or otherwl68, whhout the p1k>r w,lnen
petmi&$ion of the pubfl&hef, This lndudes text, figures and 1ables.
flf&t Eóitlon 9/91 1514 pag,es HONDA MOTOR CO.• LTD.

*Heater and
AII Alghts Res.e,ved Sen,lee Publication Offloo Air Conditioner
• SIIIWOMbetow •re in VOlUMli 2,

Al NCtior'fS wlth º irlcll.lde SRS compO!!ffltl,
"Electrical
(lncluding SRS 11
.-.....
~I p,ec...,tlon11 ere teq_.ed, wht11t HrvldnlJ.
General lnformation
Chassis and Engine Number 1-2

ldentification Number Locations 1-6
Label Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 1- 7
Lift and Support Points . . . . . . . . . . . . . . . . . . . . 1-1 O
Service Precautions . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 3
Chassis and Engine Numbers
1 European Model (2-Door Hatchback)
Vehicleldentification Number----------. .....- EngineNumber---------------,
T
JHMEG33200S000001 816A2-1000001
Manufacturer, Code and Engine Type j___,

Vehicle Type ---------~ 816A2: 1600 DOHC 16-valves Multi-point
JHM: HONDA MOTOR CO., Fuel-injection VTEC Engine
LTD., JAPAN with CATA
HONDA Passenger car D 1382: 1300 SOHC 16-valves 1-carbureted
Line/Engine and Body Type ---~ Engine with CATA
EG3: CIVIC 1300/2-Door D 1582: 1500 SOHC 16-valves Dual-point
Hatchback Fuel-injection Engine
EG4: CIVIC 1 500/2-Door with CATA
Hatchback D15Z1: 1500 SOHC 16-valves Multi-point
EG5: CIVIC 1600/2-Door Fuel-injection VTEC-E Engine
Hatchback with CATA
EG6: CIVIC 1600 VTi/2-Door 016Z6: 1600 SOHC 16-valves Multi-point
Hatchback Fuel-injection VTEC Engine
Body and Transmission Type ---~ with CATA
3:2-Door Hatchback/5-speed O 1627: 1600 SOHC 16-valves Multi-point
Manual Fuel-injection VTEC Engine
4:2-Door Hatchback/4-speed with CATA far KG (Austria)
Automatic Serial Number ------------~
Vehicle Grade ------------' 816A2: 1000001 rv
2: DX (EG3: KG/KF/KS/KE) 01382: 2000001"'
4: DXi (EG4: KG) 01582: 5800001"'
5: LSi (EG4: KG/KF/KS/KE) D15Z1: 1700001"'
6: VEi (EG4: KG/KE) 01626: 1700001 rv
8: ESi (EG5: KG/KF/KS/KE) 01727: 1000001rv
9: VTi (EG6: KG/KF/KE)
Fixed Code -----------~
Auxiliary Number ___,
Factory Code -----------~ ....... ManualTransmission Number --------.
S: Suzuka Factory in Japan
520-1000001
ModelYear------------~
O: 1992 Transmission Type T__.
Serial Number ---------------'
S20: For except B 1 6A2
Y21: For -916A2
Serial Number ------------~
Automatic Transmission Number -----~

M24A-1000001
Transmission Type -------~ 1

Serial Number ------------~-
1-2
European Model (4-Door Sedan)
Vehicle ldentification Number (except KB) - Engine Number (except KB) ---------,
T
J H M EG854008000001 816A2-1000001
Manufacturar, Code and Engine Type J__,

Vehicle Type ----------' 816A2: 1600 DOHC 16-valves Multi-point
JHM: HONDA MOTOR CO., Fuel-injection VTEC Engine
LTD., JAPAN with CATA
HONDA Passengercar 01582: 1500 50HC 16-valves Oual-point
Line/Engine and Body Type ---~ Fuel-injection Engine with CATA
EG8: CIVIC 1500/4-Door 01626: 1600 50HC 16-valves Multi-point
Sedan Fuel-injection VTEC Engine
EH1: CIVIC 1600/4-Door with CATA
Sedan 4WD 01627: 1600 50HC 16-valves Multi-point
EH9: CIVIC.1600/4-Door Fuel-injection VTEC Engine
Sedan with CATA for KG (Austria)
Body and Transmission Type ------' and 4WD
5:4-0oor 5edan/5-speed Serial Number ----------------'
Manual 816A2: 1000001 rv
6:4-0oor 5edan/4-speed 01582: 5800001rv
Automatic 01626: 1700001 rv
Vehicle Grade------------' 01627 for KG (Autria): 1000001ru
4: OXi (EG8: KG/K5) 01627 for 4WO: 1100001 ru
5: L5i (EG8: KG/K5/KE)
8: ESi (EH9: KG/KF/KS/KE)
8: RT5i (EH1: KG)
9: VTi (EH9: KG/KF/KE) - Engine Number (KB) ------------.
Fixed Code -------------'
Auxiliary Number ------------' 01687-5000001
Factory Code -----------~
5: 5uzuka Factory in Japan
Engine Type J__,
ModelYear------------~ 01687: 1600 SOHC 16-valves Multi-point
O: 1992 Fuel-injection Engine without CATA
Serial Number ___,
Serial Number -------------~
Vehicle ldentification Number (KB) ----- - Manual Transmission Number --------
1 HGEH554* NL700001 820-1 000001
Manufacture r. Code and

Vehicle Type
1HG:H ONDA OF AMERICA
T Transmission Type
520: For except 816A2
Y21: For 816A2
522: For 4WO
T__,
MFG., INC. U.S.A. Serial Number ___,

HONDA Passengercar
Line/Engine and Body Type
EH5: CIVIC 1600/4-Door
Sedan Automatic Transmission Number -----~
Body and Transmission Type
5:4-Doo r Sedan/5-speed M24A-1000001
Manual
6:4-Doo r 5edan/4-speed Transmission Type -------- 1
Autom atic M24A: For 2WD
Vehicle Grade M25A: For 4WD
4: DX ( EH5: K8) Serial Number ---------------'
6: LX (E H5: K8)
Check Digit
Model Year
N: 1992
Factory Code
L: Ohio Factory in U.S.A. (East Liberty)
Serial Numb er
1-3
Chassis and Engine Numbers
Except European Model (2-Door Hatchback)
Vehicle ldentification Number ---------, ~ EngineNumber --------------,
Manufactur er, Code and

Vehicle Typ 9
T-
JHMEG33100S000001
~
Engine Type
81382-2000001
!___.
01382: 1300 SOHC 16-valves 1-carbureted
JHM: H ONDA MOTOR CO., Engine with CATA for KQ
L TO., JAPAN D 1383: 1300 SOHC 16-valves 1-carbureted
H ONDA Passenger car Engine without CATA for KT
Line/Engine and Body Type 01 583: 1500 SOHC 16-valves 1-carbureted
EG3:C IVIC 1 300/2-Door Engine without CATA for KP/KT/KY
Hatchback 01584: 1500 SOHC 16-valves 2-carbureted
EG4: CIVIC 1500/2-Door Engine with CATA for KQ
Hatchback 016A8: 1600 SOHC 16-valves Multi-point
EG5: CIVIC 1600/2-Door Fuel-injection Engine
Hatchback with CATA for KQ
Body and Transmission Type O 16A9: 1600 DOHC 1 6-valves Multi-point
3:2-Doo r Hatchback/5-speed Fuel-injection Engine
Manual without CATA for KP/KT
4:2-Doo r Hatchback/4-speed Serial Number ---------------'
Autom atic
Vehicle Grade
1: EL (E G3: KT), ex (EG3: KQ)
2: EX(E G4: KP/KT/KY) Manual Transmission Number ---------,
3: GL (E G4: KQ)
520-1000001
7: Si (EG4: KQ/KP/KT)
Fixed Code Transmission Type ---------' 1
Auxiliary Number Serial Number ------------~-
Factory Code
S: Suzuka Factory in Japan
Modal Year
O: 1992 Automatic Transmission Number ---------.
Serial Number
M24A-1000001
Transmission Type-------T~
M24A: 01 6A8 (KQ)
.
M48A: Except 016A8 (KQ)
SerialNumber-------------J
1-4
Except European Model (4-Door Sedan)
Vehicle ldentification Number -------, - EngineNumber---------------,
T
JHMEH85100S000001 81281-2000001
Manufacturer, Code and Engine Type !___.

Vehicle Type -------~ O 1 281 : 1 200 SOHC 1 6-valves 1-carbureted
JHM: HONDA MOTOR CO., Engine without CATA
LTD., JAPAN O 1 383: 1300 SOHC 16-valves 1-carbureted
HONDA Passenger car Engine without CATA
Line/Engine and Body Type ---~ O 1 584: 1 500 SOHC 1 6-valves 2-carbureted
EH8: CIVIC 1200/4-Door Engine without CATA
Sedan 016A8: 1600 DOHC 16-valves Multi-point
EG7: CIVIC 1300/4-Door Fuel-injection Engine
Sedan with CATA for KO
EG8: CIVIC 1 500/4-Door O 16A9: 1600 DOHC 16-valves Multi-point
Sedan Fuel-injection Engine
EH9: CIVIC 1600/4-Door without CATA for KP/KT
Sedan Serial Number ------------~
Body and Transmission Type ---~
5:4-Door Sedan/5-speed
Manual
6:4-Door Sedan/4-speed Manual Transmission Number -------~
Automatic
S20-1000001
Vehicle Grade ---------~
1:1.2 EL (EH8: KT), EL (EG7: KP)
Transmission Type ----------" 1
1.5 EL (EG8: KP/KT/KU)
Serial Number ------------~-
2: 1.2 EX (EH8: KU). EX (EG8: KP/
KT/KY)
3: GL (EG8: KO)
7: Si (EH9: KO/KP/KT/KY) Automatic Transmission Number -------,
Fixed Code ------------
Auxiliary Number ---------- M24A-1000001
Factory Code
S: Suzuka Factory in JAPAN
Model Year ·
___.
Transmission Type T~
M24A: 016A8 (KO)
O: 1992 M48A: Except 016A8 (KQ)
Serial Number -------------- Serial Number -------------
1-5
ldentification Number Locations
Chassis and Engine Chassis and Engine

Numbers (LHD) Numbers (RHD)
1-6
Label Locations
Warning/Caution Labels
A: DRIVER INFORMATION B: MAINTENANCE LID CAUTION
ALWAYS WEAR YOUR SEAT BELT JSRSI CAUTION !

J SRS
• THIS CAR IS EQUIPPED WITH A DRIVER AIRBAG AS A BEFORE MAINTENANCE, SWITCH OFF THE IGNITION.
SUPPLEMENTAL RESTRAINT SYSTEM (S.R.S.). ATIENTION
e IT IS DESIGNED TO SUPPLEMENT THE SEAT BELT. AVANT TOUT ENTRETIEN, COUPER LE CONTACT.
• IF YOUR SRS INDICATOR LIGHTS WHILE DRIVING, SEE ACHTUNG
YOUR AUTHORIZED HONDA DEALER. VOR WARTUNG ZÜNDUNG AUSSCHAL TEN.
ATIACHEZ TOUJOURS VOTRE CEINTURE J SRS I LET OP
• CE VEHICULE EST EQUIPE D'UN COUSSIN D'AIR POUR ZET HET KONTAKTSLOT AF ALVORENS MET HET
ONDERHOUD TE BEGINNEN.
LE CONDUCTEUR QUI CONSTITUE UN SYSTEME DE
RETENUE COMPLEMENTAIRE (S.R.S.I.
• CE COUSSIN D' AIR COMPLETE LA FONCTION DE LA
CEINTURE DE SECURITE.
• SI LE TEMOIN SRS S' ALLUME PENDANT LA CON-
DUITE, ADRESSEZ-VOUS A VOTRE CONCESSION-
NAIRE HONDA OFFICIEL.
SICHERHEITSGURTE
BEi JEDER FAHRT ANLEGEN I SRS I
• DIESES FAHRZEUG BESITZT EINEN FAHRER-AIRBAG
ALS ZUSATZLICHES RÜCKHALTESYSTEM (S.R.S.).
• ES IST EINE ERGANZUNG ZUM SICHERHEITGURT.
e WENN DUE SRS-KONTROLLEUCHTE WAHREND DER
FAHRT AUFLEUCHTET, UMGEHEND FINEN HONDA
HANDLER AUFSUCHEN.
DRAAG AL TIJD UW VEILIGHEIDSGORDEL !
J SRS
• DIT VOERTUIG IS UITGERUST MET EEN LUCHT-
KUSSEN AAN DE BESTUURDERSKANT AL TS EXTRA
BESCHERMING (S.R.S.I.
e DIT IS ONTWORPEN ALS EXTRA BESCHERMING BIJ
DE VEILIGHEIDSGORDEL.
• ALS HEL SRS-WAARSCHUWINGSLAMPJE GAAT
BRANDEN ONDEA HET RIJDEN. NEEM DAN KONTAKT (cont'd)
OP MET EEN HONDA DEALER.
1-7
Label Locations
Warning/Caution Labels (cont'd)
C: MONITOR CAUTION F: UNDER-HOOD WARNING
CAUTION SRS] I WARNING j SRS !

REFERTO THE SHOP MANUAL THIS VEHICLE IS EQUIPPEDWITH A DRIVER AIRBAG AS A
ATTENTION SUPPLEMENTAL RESTRAINT SYSTEM (SRS).
SE REPORTEAAU MANUEL O' ATELIER ALL S.R.S. ELECTRICAL WIRING ANO CONNECTORS ARE
WAARSCHUWING COLOREO YELLOW. DO NOT USE ELECTRICAL TEST
LEES HET WERKPLAATS HANDBOEK EQUIPMENT ON THESE CIRCUITS. TAMPERING WITH OR
ACHTUNG DISCONNECTING THE S.R.S. WIRING COULD RESULT IN
e WERKSTATT HANDBUCH LESEN ACCIDENTAL FIRING OF THE INFLATOR OR MAKE THE
• OER GASGENERATORIN DIESEM GEHAUSE SYSTEM INOPERATIVE, WHICH MA Y RESULT IN SERIOUS
DARF NUR FUR INSASSEN-RÜCKHAL TESYSTEME INJURY.
MIT LUFTSACK IN KRAFTFAHRZEUGE
MONTIERT WERDEN.
ATTENTION I
SRS I
CE VEHICULE EST EQUIPED'UN COUSSIN D' AIR DU COTE
DIE MONTAGE UNO DEMONTAGE CONDUCTEUR QUI CONSTITUE UN SYSTEME DE
DES GASGENERATORS RETENUE COMPLEMENTAIRE (S.R.Sl
DARF NUR VON DAFÜR TOUS LES FILS ET CONNECTEURS ELECTRIQUES DU
GESCHULTEM PERRSONAL SYSTEME DE RETENUECOMPLEMENTAIRE (S.R.S.) SONT
VORGENCHMEN VERDEN. DE COULEUR JAUNE. N'UTILISEZ PAS UN EQUIPEMENT
D'ESSAIS ELECTRIQUES SUR CES CIRCUITS. NE
D: COVER CAUTION TOUCHEZ PAS ET NE DEBRANCHEZ PAS LES FILS DU
SVSTEME S.R.S. CAR CECI POURRAIT DE TRADUIRE PAR
CAUTION i
SRS [ LE DECLENCHEMENT ACCIDENTEL DU GONFLEUR OU
ACHTUNG RENDRE LE SYSTEME INOPERANT ET VOUS EXPOSER
e REFERTO THE SHOP MANUAL AINSI A DE GRAVES BLESSURES.
e SE REPORTEAAU MANUEL D'ATELIER.
e WERKSTATT HANDBUCH LESEN.
WARNUNG I SRS I
DIESES FAHRZEUG IST MIT EINEM FAHRER-AIRBAG
e LEES HET WERKPLAATSHANDBOEK. (SRS) ALS ZUSATZLICHEM RÜCKHAL TESVSTEM
AUSGERÜSTET.
E: LABEL j AIRBAG j ALLE ELEKTRISCHEN KABEL, SOWIE DIE ZUGEHÓRIGEN
STECKVERBINDER DES S.R.S. -SVSTEMS SINO IN
GELBERFARBE AUSGEFÜHRT.
KEINE ELEKTRISCHEN PRÜGERATE AN DIE S.R.S.
-VERKABELUNG ANSCHLIEBEN. VERANDERN ODER
UNTERBRECHEN DER S.R.S -VERKABELUNG KANN
UNKONTROLLIERTES ZÜNDEN DES GASGENERATORS
AUSLÓSEN. ODER DAS SYSTEM AUBER FUNKTION
SETZEN. WAS ZU ERNSTHAFTEN VERLETZUNGEN
FÜHREN KANN.
WAARSCHUWING SRS [ i
DIT VOERTUIG IS UITGERUST MET EEN LUCHTKUSSEN
AAN DE BESTUURDERSKANT ALS EXTRA BESCHERMING
(S.R.S.).
ALLE ELEKTRISCHE LEIDINGEN EN AANSLUITIGEN VAN
DE S.R.S. ZIJN GEEL GEKLEURD. GEBRUIK GEEN
ELEKTRISCHETESTAPPARATUUR VOOR DEZE CIRCUITS.
KNOEIEN MET OF LOSKOPPELEN VAN DE S.R.S.
LEIDINGEN KAN LEIDEN TOT BRAND IN DE
VULINRICHTING OF TOT UITSCHAKELEN VAN HET
SVSTEEM DIT KAN TOT ERNSTIGEONGELUKKEN LEIDEN.
G: SLIP RING CAUTION
CAUTION j SRS [
e NO SERVICEABLE PARTS INSIDE.
e DO NOT DISASSEMBLE OR TAMPER.
e DO NOT DROP.
e STORE IN A CLEAN, DRY AREA.
1-8
SERVICE INFORMATION
ABS CAUTION
4WD CAUTION
BA TTERY CAUTION
SPARK PLUG
CAUTION
AIR CLEANER. OIL and
FILTER SERVICE
COOLING FAN CAUTION
TIRE INFORMATION
1-9
Lift and Support Points
Hoist
f•§Hmijj.,j¡ When heavy rear components such as suspension, fuel tank, spare tire and hatch are to be removed, place
additional weight in the luggage area befare hoisting. When substantial weight is removed from the rear of the car, the
canter of gravity may changa and can cause the car to tip forward on the hoist.
NOTE: Since each tire/wheel assembly weighs approximately 14 kg (30 lbs). placing the front wheels in the trunk will
assist with the weight transfer.
1. Place the lift blocks as shown.
2. Raise the hoist ;3 few inches and rock the car to be sure it is firmly supported.
3. Raise the hoist to full height and inspect lift points for solid support.
FRONT SUPPORT POINT LIFT BLOCKS REAR SUPPORT POINT
1-10
Floor Jack
1. Set the parking brake and block the wheels that are
not being lifted. ' • Always use safety stands when working on or
under any vehicle that is supported by only a
2. When lifting the rear of the car, put the gearshift jack.
lever in reverse (Automatic in PARK). • Never attempt to use a bumper jack for lifting or
supporting the car.
3. Raise the car high enough to insert the safety
stands.
4. Adjust and place the safety stands as shown on

page 1-1O so the car will be approximately level,
then lower the car onto them.
Front
Center the jack

bracket in the rniddle
of the jack lift platforrn. JACK LIFT PLATFORM
Rear
Center the jack

bracket in the middle
JACK LIFT PLATFORM of the jack lift platforrn.
1-11
Lift and Support Points
Safety Stands --------------------------,
FRONT SUPPORT POINT SAFETY STANDS REAR SUPPORT POINT
1-12
Service Precautions
Towing
For 4WD see also "4WD Disengagement". Front:
lf the car needsto be towed, call a professional towing CAUTION: On the car equipped with the front spoiler,
service. Never tow the car behind another car with just remove the spoiler when towing.
a rape or chain. lt is very dangerous.
Emergency Towing
There are three popular methods of towing a car:
Flat-bed Equipment-The operator loads the car on the

back of a truck. This is the best way of towing the car.
Wheel Lift Equipment-The tow truck uses two

pivoting arms which go under the tires (front or rear)
and lifts them off the ground. The other two wheels re-
main on the ground.
Sling-type Equipment- The tow truck uses metal

cables with hooks on the ends. These hooks go around
parts of the trame or suspension and the cables lift that
end of the car off the ground. The car's suspension and
body can be seriously damaged if this method of towing
is attempted.
lf the car cannot be transported by flat-bed, it should be

towed with the front wheels off the ground. lf due to TOW HOOKS
damage, the car must be towed with the front wheels
on the ground, do the following:
• Releasethe parking brake.

• Shift the transmission to Neutral (5-speed). lf the car
has an automatic transmission: Start the engine. Rear:
Shift to 04, then to Neutral. Shut the engine off.
NOTICE: lmproper towing preparation will damage
the transmission. Follow the above procedure exact-
ly. lf you can not shift the transmission or start the
engine (automatic transmission). the car must be
transported on a flat-bed.
• lt is best to tow the car no farther than 80 km (50
miles). and keepthe speed below 55 km/h (35 mph).
NOTICE:Trying to lift or tow the car by the bumpers

will cause serious damge. The bumpers are not de-
signad to support the car's weight.
TOW HOOK
1-13
Service Precautions
4WD Disengagement
The 4WD System shifts instantaneously and 4WD Disengagement

automatically from front wheel drive to tour wheel drive (For cars not equipped ABS)
when greater traction is needed. Manual Transmission:
f%9MMIN The 4WD system must be manually
1 . Located the orange disengagement fever ar the rear
of the engine compartment.
disengaged befare performing service that requires only
the front wheels or only the rear wheels to be turning.
Disengaging the system will prevent sudden movement
of the car, which may result in personal injury. DISENGAGEMENT LEVER
TOWING:
CAUTION: Befare towing the car with either the front
or rear wheels raised off the ground, placethe transmis-
sion in neutral and manually disengage the 4WD system
to prevent the raised wheels from turning.
lf possible, always tow the car with the front wheels off
the ground, and 4WD disengaged. Do not use the 2. Loosen the lock at the slotted end of the lever.
bumpers to lift the c:aror to support the car's weight
while towing. Check local regulations for towing with a NOTE: For better accessibility, use a socket and a
chain or frame-mounted tow bar. A chain may be at- long extension bar.
tached to the hooks shown in the illustration. Do not at-
tach a tow bar to either bumper. CAUTION: Do not loosen the lock bolt more than
lf the car is to be towed with front wheels on the 5-7 turns.
ground, observe the following precautions; Replacement is extremely difficult.
Manual Transmission
Shift the transmission to Neutral and turn the ignition
key to the 'T' position.
Automatic Transmission Unlocked Position Locked Position
First, check the automatic transmission fluid level (see (4WD off) MIDDLE BOLT (4WD on)
Section 14). Start the engine and shift to 04, then to N.
Return the ignition key to the "I" position.
CAUTION: .
• Do not tow with front wheels on the grond when the
automatic transmission fluid level is low or the
transmission cannot be shifted with the engine
running.
• Do not exceed 55 km/h (35 mph) or tow far
distances of more than 80 km (50 miles.)
LOCK BOLT
3. Move the . lever by turning the middle bolt

counterclockwise.
4. Tighten the lock bolt.
NOTE: After service or towing is completad return

the lever to the normal (4WD on) position and
tighten the lock bolt.
TOW HOOKS
1-14
Automatic transmission: 4WD Disengagement (For cars equipped with ABS)
1 . Locate the disengagement plate at the rear of the 1 . Locate the orange disengagement bolt at the front
transmission case behind the right front wheel. of the rear differential behind the left rear wheel.
DISENGAGEMENT DISENGAGEMENT
PLATE BOLT
2. Loosen the lock bolt in the notch on the plate. 2. Loasen the middle bolt fixing the lock plate.
NOTE: For better accessibility, use a socket anda NOTE: For better accessibility, use a socket anda
long extension bar. long extension bar.
CAUTION: Do not loosen the middle bolt more CAUTION: Do not loosen the iddle bolt more than
than 5- 7 turns. Replacement is extremely 5- 7 turns. Replacementis extremely difficult.
difficult.
Unlocked Locked Unlocked Posltion Locked Position
Position Posltion (4WD off) (4WD on)
(4WD off) (4WD onl .---- MIDDLE BOLT ------,
MIDDLE BOLT
LOCK BOLT
....__,1--- LOCK PLATE __J
,__ DISENGAGEMENT ---...J
BOLT
3. Turn the middle bolt counterclockwise until the 3. Turn the disengagement bolt counterclockwise un-
plate rotates about 150° and is stopped by the til the disengagement bolt rotates about 1 80º and
lock bolt. is stopped by the lock plate.
4. Tighten the lock bolt. 4. Tighten the middle bolt.
NOTE: After service or towing is completed, NOTE: After service or towing is completed,
return the plate to the normal (4WD on) position return the plate to the normal (4WD on) position
and tighten the lock bolt. and tighten the middle bolt.
1-15
Special Tools
Individual tool lists are located at the front of each section.
Specifications
Standards and Service Limits 3-2

Design Specifications 3-41
Body Specifications 3-50
Standards and Service Limits
- eym · - sectton 6
r der Hea d/Va I ve Tram
0128, 0138, 0158, 016A7 Engine
MEASUREMENT STANDARD (NEW) SERVICE LIMIT
\
Com- 250 min-1 (rpm) and Nominal 1,300 (13.0, 184)
1
pression wide open throttle Minimum 950 (9. 5, 135)
kPa (kg/cm2, psi) Maximum variation 200 (2,28)
Cylinder Warpage -- 0.05 (0.002)
head Height 94.95-95.05 (3.738-3.742) --
Camshaft End play 0.05-0. 1 5 (0.002-0.006) 0.5 (0.02)
Oil clearance 0.050-0.089 (0.002-0.004) 0.15 (0.006)
Runout 0.015 (0.0006) max. 0.03 (0.001)
Cam lobe Height 01281, 01382, 01383 IN 35.472 ( 1.3965) --
EX 35.693 (1.4052) --
01583, 01584 IN 36.603 (1.4411) --
EX 36.747 (1.4467) --
01582 IN 36.603 (1.4411) --
EX 36. 7 50 ( 1 .4468) --
016A7 IN 36.782 (1.4481)
EX 36.947 (1.4546)
Valve Valve clearance IN 0.18-0.22 (0.007-0.009) --
EX 0.23-0.27 (0.009-0.011) --
Valve stem O.O. IN 5.48-5.49 (0.2157-0.2161) 5.45 (0.2183)
EX 5.45-5.46 (0.2146-0.2150) 5.42 (O. 2134)
Stem-to-guide clearance IN 0.02-0.05 (0.0008-0.0020) 0.08 (0.003)
EX 0.05-0.08 (0.002-0.003) o. 11 (0.004)
Valve Width IN 0.85-1.15 (0.033-0.045) 1.6 (0.063)
seat EX 1.25-1.55 (0.049-0.061) 2.0 (0.079)
Stem installed height IN 46.985-47.455 (1.8498-1.8683) 47.705 (1.8781)
EX 48.965-49.435 ( 1.9278-1.9463) 49.685 (1.9561)
Valve Free length 01281, 01382, 01383 IN 47.97 (1.889) --
spring EX 49.19 (1.937) --
01582, 01583, 016A7 IN 48.58 (1.913) --
EX 49.19 (1.937) --
01584 IN 48.58 ( 1.913) --
EX 48.49 (1.909) --
Valve 1.0. IN 5.51-5.53 (0.217-0.218) 5.60 (0.220)
guide EX 5.51-5.53 (0.217-0.218) 5.60 (0.220)
lnstalled height IN 15.95-16.45 (0.628-0.648) --
EX 15.95-16.45 (0.628-0.648) --
Rocker Arm-to-shaft clearance IN 0.017-0.050 (0.0007-0.0020) 0.08 (0.003)
arm EX 0.018-0.054 (0.0007-0.0021) 0.08 (0.003)
3-2
Unit of length: mm (in)
- eym
r der Head/Vave
I Tram
· - sectiion 6
D15Z, D16Z Engine
1
Com- 250 min-1 (rpm) and Nominal 1,300 ( 13.0, 184)

pression wide open throttle Mínimum 1,1 50 ( 11.5,166)
head Height 92.95-93.05 (3.659-3.663) --
Camshaft End play 0.05-0.15 (0.002-0.006) 0.5 (0.02)
Oil clearance 0.050-0.089 (0.002-0.004) o. 1 5 (0.006)
Runout 0.015 (0.0006) max. 0.03 (0.001)
Cam lobe 015Z1 IN Primary 38.427 (1.5129) --
Height Secondary 32.292 (1 .2713) --
EX ..,-, o o-r /1 ,1059) --
7
1
D16Z6, D16Z7 IN Primary 35.900 (1.4134) --

Mid 38. 107 (1.5003) --
Secondary 36. 195 ( 1 .4250) --
1
EX 38.008 ( 1.4964) --
Valve Valve clearance IN 0.11:i-0.LL {O.uu7-0.009)
EX 0.23-0.27 (0.009-0.011) --
Valve stem O.O. IN 5.48-5.49 (0.2157-0.2161) 5.45 (O. 2183)
EX 5.45-5.46 (0.2146-0.2150) 5.42 (0.2134)
EX 0.05-0.08 (0.002-0.003) o. 12 (0.005)
Valve Width IN 0.85-1.15 (0.033-0.045) 1.6 (0.063)
seat EX 1.25-1.55 (0.049-0.061) 2.0 (0.079)
EX 53.165-53.635 (2.0931-2.1116) 53.885 (2.1215)
Valve Free length 015Z1 IN 54. 78 (2.157) --
spring EX 58.23 (2.293) *1 --
58.26 (2.294) *2 --
D16Z6, D16Z7 IN 57.97 (2.282) --
EX 58.41 (2.300) --
Valve I.D. IN 5.51-5.53 (0.217-0.218) 5.60 (0.220)
guide EX 5.51-5.53 (0.217-0.218) 5.60 (0.220)
EX 18.65-19.15 (O. 734-0. 754) --
arm EX 0.018-0.054 (0.0007-0.0021) 0.08 (0.003)
* 1: NIPPON HATSUJO made, * 2: CHUO HATSUJO made.
3-3
~ eym · - secf ion 6
r der H ea d/Va I ve Tram
D16A8, D16A9, Eng~e
MEASUREMENT STANDARD (NEW) ) SERVICE LIMIT
Com- 250 min - (rpm) and

1
Nominal 1,350 (13.5,192)
pression wide open throttle Minimum 950 (9.5, 135)
head Height 131.95-132.05 (5.195-5.199) --
OH clearance 0.050-0.089 (0.002-0.004) o. 1 5 (0.006)
Runout 0.015 (0.0006) max. 0.03 (0.001)
Cam Jobe Height IN 32.983 (1.299) --
EX 32.382 (1.275) --
Valve Valve clearance -- ------ --- . - .
IN 0.21-0.25.10.oos-=0,010-r --
EX 0.24-0.28(0.009-0.0111 --
Valve stem O.O.
'" IN
EX
6.58-6.59
6.55-6.56
(0.2591-0.2594)
(0.2579-0.2583)
6.55
6.52
(0.2579)
(0.2567)
Stem-to-guide clearance , IN 0.02-0.05 (0.0008-0:0020J- 0.08 (0.003)
'. EX 0.05-0.08 (0.002-0.003) o. 12 (0.005)
Valve Width IN 1.25-1.55 (0.049-0.061) 2.0 (0.079)
seat EX 1.25-1.55 (0.049-0.061) 2.0 (0.079)
EX 44.735-45.205 (1.761-1.780) 45.455 ( 1.. 790)
Valve Free length IN 47.49 (1.870) --
spring EX 46.89 (1.846) --
Squareness -- 1.6 (0.063)
Valve J.D. IN and EX 6.61-6.63 (0.260-0.261) 6. 65 (O. 262)
guide
3-4
- eym
r der Hea d/Vave
I Tram
· - sec1on
ti 6
B16A Engine
1
Com- 250 min-1 (rpm) and Nominal 1,300 ( 1 3.0, 184)

pression wide open throttle Minimum 950 (9.5, 135)
head Height 141.95-142.05 (5.589-5.593) --

Oil clearance 0.050-0.089 (0.002-0.004) o. 15 (0.006)
Aunout 0.015 (0.0006) max. 0.03 (0.001)
Cam lobe Height IN Primary 33.088 ( 1.303) --
Mid 36. 267 ( 1 .428) --
Secondary 34.978 ( 1.377) --
EX Primary 32.785 (1.291) --
Mid 35. 720 ( 1.406) --
Secondary 34.691 (1.366) --
Valve Valve clearance IN 0.21-0.25 (0.008-0.009) -- \
EX 0.24-0.28 (0.009-0.011) --
Valve stem O.O. IN 5.475-5.485 (0.2156-0.2159) 5.445 (0.2144)
EX 5.45-5.46 (0.2146-0.2150) 5.42 (0.2134)
EX 0.05-0.08 (0.002-0.003) o. 11 (0.004)
Valve Width IN 1.25-1.55 (0.049-0.061) 2.0 (0.079)
seat EX 1.25-1.55 (0.049-0.0611 2.0 (0.079)
EX 37.165-37.635 (1.463-1.482) 37.885 (1.492)
Valve Free length IN OUTER 40.92 (1.611) *1 --
spring 40.91 (1.610) *2 --
INNER 36.71 (1.443) --
EX 41.96 (1.652)* 1 --
41.94 (1.651)*2 --
Valve I.D. IN 5.51-5.53 (0.217-0.218) 5.55 (0.219)
guide EX 5.51-5.53 (0.217-0.218) 5.55 (0.219)
EX 12.55-13.05 (0.494-0.514) --

arm EX 0.025-0.052 (0.0009-0.0020) 0.08 (0.003)
*1: NIPPON HATSUJO made, *2: CHUO HATSUJO made.
3-5
Standard and Service Limits
- Engine Block - Sectío
I n 7
0128, 0138, D15B, 0152, 016A, 0162 Engine
MEASUREMENT STANDARD (NEWI SERVICE LIMIT
Cylinder Wapageof deck surface 0.07 (0.003) max. o. 1 O(0.004)
block 8ore diameter 75.00- 75.02 (2.953-2.954) 75.07 (2.956)
8ore taper -- 0.05 (0.002)
Reboringlimit -- 0.5 (0.02)
Pistan Skirt O.O. At 15 mm (0.59 in) 74.98- 74.99 (2.9520-2.9524) 74.97 (2.9516)
from bottom of shirt
Clearancein cylinder 0.01 -0.04 (0.0004-0.0016) 0.05 (0.002)
Groove width (for ring) Top 015Z1 1.02-1.03 (0.0402-0.0406) 1 .05 (0.041)
Except O 1 5Z1 1.22-1.23 (0.0480-0.0484) 1.25 (0.049)
Second 015Z1 1.22-1.23 (0.0480-0.0484) 1.25 (0.049)
Except O 1 5Z1 1.52-1.53 (0.0598-0.0602) 1.55 (0.061)
Oil 2.805-2.820 (0.1104-0.1110) 2.85 (0.112)
Piston Ring-to-groove Top 015Z1 0.030-0.055 (0.0012-0.0022) o. 13 (0.005)
ring clearance Except O 1 5Z1 0.035-0.060 (0.0014-0.0024) 0.13 (0.005)
Second 0.035-0.055 (0.0014-0.0022) o. 13 (0.005)
Ring end gap Top 0.15-0.30 (0.006-0.012) 0.60 (0.024)
Second 0.30-0.45 (0.012-0.018) o. 70(0.028)
Oil 0.20-0.70 (0.008-0.028) 0.80 (0.031)
Pistan Pin o.o. 18.994-19.000 (O. 7478-0. 7480) --
Pin-to-pistan clearance 0.010-0.022 (0.0004-0.0009) --
Connect- Pin-to-rod interference 0.014-0.040 (0.0006-0.0016) --
ing rod Small end bore diameter 18.96-18.98 (0.746-0.747) --
Large end bore diameter Nominal 0128, 0138 43.0 (1.69) --
01 58, 015Z 45.0 (1.77) --
016A, 016Z 48.0 (1.89) --
End play installed on crankshaft 0.15-0.30 (0.006-0.012) 0.40 (0.016)
Small end bore-to-large end bore parallelism 0.12 (0.005)/100 max. o. 1 5 (0.006/100
Crank- Main journal diameter 016A, 016Z 54.976-55.000 (2.1644-2.1654) --
shaft 0128, 0138, 0158, 0152 44.976-45.000 (1.7707-1.7717) --
Rod journal diameter 0128, 0138 39.976-40.000 (1.574-1.575) --
0158, 0152 41.976-42.000 (1.653-1.654) --
016A, 0162 44.976-45.000 (1.771-1.772) --
Taper 0.0025 (0.0001) max. 0.01 (0.0004)
Out-of round 0.0025 (0.0001) max. 0.01 (0.0004)
End play o. 10-0.35 (0.004-0.014) 0.45 (O.O 18)
Runout 0.015 (0.0006) max. 0.03 (0.0012)
Bearings Main bearing-to-journal Oil clearance
0128, 0138, 0158, 0152
No. 1 and 5 journals 0.018-0.036 (0.0007-0.0014) 0.05 (0.002)
No. 2, 3 and 4 journals 0.024-0.042 (0.0010-0.0017) 0.05 (0.002)
D16A, 0162
No. 1 and 5 journals 0.018-0.036 (0.0007-0.0014) 0.05 (0.002)
No. 2 and 4 journals 0.024-0.042 (0.0010-0.0017) 0.05 (0.002)
No. 3 journal 0.030-0.048 (0.0012-0.0019) 0.05 (0.002)
Rod bearing-to-journal oil clearance 0.020-0.038 (0.0008-0.0014) 0.05 (0.002)
3-6
- Eng"ne
1 BIock - sectiion 7
B16A Engine
Cylinder Warpage of deck surface 0.05 (0.0020) 0.08 (0.031)
block Bore diameter X 81.000-81.020 (3.1890-3.1898) } 81.070
y 81.000-81.015 (3.1890-3.1896) (3.1917)
Bore taper -- 0.25 (0.002)
Reboringlimit -- 0.25 (0.01)
Piston Skirt 0.D. At 15 mm (0.59 in) 80.98-80.99 (3.1882-3.1886) 80.97 (3. 1879)
from bottom of skirt
Clearancein cylinder 0.01-0.035 (0.0004-0.0014) 0.05 (0.002)
Ring groove width Top 1.030-1.040 (0.0406-0.0409) 1.060 (0.0417)
2nd 1.230-1.240 (0.0484-0.0488) 1.260 (0.0496)
Oil 2.805-2.820 (0.1104-0.111 O) 2.840 (O. 1118)
Piston Piston-to-ring clearance Top 0.045-0.070 (0.0018-0.0028) 0.130 (0.0051)
ring 2nd 0.045-0.070 (0.0018-0.0028)*1 } 0.130
0.040-0.065 (0.0015-0.0026)*2 (0.0051)
Ring end gap Top 0.20-0.35 (0.0079-0.0138) 0.60
2nd 0.40-0.55 (0.0157-0.0217) o. 70 (0.0276)
Oil 0.20-0.45 (0.0079-0.0177)*1
} 0.80 (0.0315)
0.20-0.50 (0.0079-0.0197)*2
Piston pin Dia meter 20.994-21.000 (0.8265-0.8268) --
Pin-to-piston clearance 0.010-0.022 (0.0004-0.0009) --
Connect- Pin-to-rod interference 0.013-0.032 (0.0005-0.0013) --
ing rod Small end bore diameter 20.968-20.981 (0.8255-0.8260) --
Large end bore diameter Nominal 48.0 (1.89) --
End play installed on crankshaft o. 1 5-0.30 (0.0059-0.0118) 0.40 (0.0157)
Crank- Main journal diameter
shaft No. 1, 2, 4 and 5 journals 54.976-55.000 (2.1644-2.1654) --
No. 3 journal 54.970-54.994 (2.1642-2.1651) --
Rod journal diameter 44.976-45.000 (1.7707-1.7717) --
Journal taper 0.005 (0.00020) max. --
Journal out of round 0.004 (0.00016) max. 0.006 (0.002)
End play 0.10-0.35 (0.0039-0.0138) 0.045 (0.0018)
Runout 0.020 (0.0008) max. 0.030 (0.0012)
Bearing Main bearing·to-journaloil clearance
No. 1, 2, 4 and 5 journals 0.024-0.042 (0.0009-0.0017) 0.050 (0.0020)
No. 3 journal 0.030-0.048 (0.0012-0.0019) 0.060 (0.0024)
Rod bearing-to-journaloil clearance 0.032-0.050 (0.0013-0.0020) 0.060 (0.0024)
* 1: TEIKOKUPISTONRING made
* 2: RIKENmade
3-7
- E ngme Lu brincanon - section 8
0128, 0138, 0158, 0152, 016A Engine
\
Engineoil Capacity f (US qt, lmp qt) 0128, 0138, 0158, 4.0 (4.2, 3.5) for engine overhaul
0152, 016A7 3.3 (3.5, 2.9) for oil change, including filter
3.0 (3.2, 2.6) for oil change, without filter
016A8, 016A9 4.3 (4.5, 3.8) for engine overhaul
3.6 (3.8, 3.2) for oil change, including filter
3.3 (3.5, 2.9) for oil change, without filter
Oil pump Displacement 0128, 0138, 0158, 45 ( 12, 1 O) @6,300
f (US gal, lmp gal)/ 0152, 016A7
min @min-1 (rpm) 016A8, D16A9 63 (17, 14) @6,800
lnner-to-outer rotor clearance 0.02-0.14 (0.001-0.006) 0.2 (0.008)
Pump body-to-outer rotor clearance o. 10-0. 175 (0.004-0.007) 0.2 (0.008)
Pump body-to-rotor axial clearance 0.03-0.08 (0.001-0.003) o. 1 5 (0.006)
Relief Pressuresettinq 80ºC (176ºF)
valve kPa (kq/crn>,psi) at idle 70 (0.7, 10) min.
at 3.000 min-1 (rpm) 350 (3.5, 50) min.
- E ngme Lu brl
ricatlion - sectiion 8
816A Engine
MEASUREMENT STANDARD(NEWI SERVICE LIMIT
1
Engine oil Capacity e (US qt, lmp qt) 4.8 (5.1, 4.2) For engine disassembly
4.0 (4.2, 3.6) For oil change, including oil filter
Oil pump Oisplacement 73 (19, 16) @7,800
e(US gal, lmp gal)/min@min-1 (rpm)
inner-to-outer rotor radial clearance 0.04-0.16 (0.0016-0.0063) 0.2 (0.0079)
Pump body-to-rotor radial clearance 0.10-0.19 (0.0039-0.0075) 0.2 (0.0079)
Pump body-to-rotor side clearance 0.02-0.07 (0.0008-0.0026) o. 1 5 (0.0059)
Relief Pressuresetting 80ºC ( 176ºF)
valve kPa (kg/cm2) at idle 70 (0.7, 10) min.
at 3.000 min-1 (rpm) 350 (3.5, 50) min.
3-8
- e oomg
r - sectíon 10
Unit of length: mm (mi
MEASUREMENT STANDARD (NEW)

Radiator Coolant capacity f (US gal, lrnp gal) M/T 816A
including engine, heater, cooling 4.8 (1.27, 1.06) for overhaul
line and reservoir 3.9 ( 1 .03, 0.86) for coolant change
reservoir capacity:
0.4 i (0.42 US qt, 0.35 lmp qt) 0128, 0138, 0158, 016A, 016Z
4. 5 ( 1 . 1 2, O. 99) for overhaul
3.6 (0.95, O. 79) for coolant change
0152
4.4 (1.08, 0.97) for overhaul
3.5 (0.92, O. 77) for coolant change
A/T 0128, 0158
4.4 (1.08, 0.97) for overhaul
3. 5 (0.92, O. 77) for coolant change
016A, 0162
4. 7 ( 1. 16, 1 .03) for overhaul
3.8 ( 1.00, 0.84) for coolant change
Radiator cap Opening pressure kPa (kq-crn", psi) 95-125 (0.95-1.25, 13.5-17.8)
Thermostat Start to opening ºC ( ºFl 015Z1 80-84 (176-183)
Except O 1 5Z 1 76-80 (169-176)
Fully open ºC ( ºFl 01521 95 (203)
Except O 1 5Z 1 90 (194)
Valve lift at fully open 8.0 (0.31) min.
Water Oisplacement 0128, 0138, 01 58, 125 (33.0, 27.5) @6,000
pump f (US gal, lmp gall/min 0152, 016A7
@min-1 (rpm) 01628, 016A9 112 (29.6, 24.6) @6,000
816A 140 (37.0, 30.8) @6,000
Cooling Thermoswitch "ON" temperature ºC ( ºFl 91.0-95.0 (196-203)
tan Thermoswitch "OFF" temperature ºC ( ºFl Subtract 3-8 (5-15) from actual "ON" temperature.
3-9
~ Fuel and Em"
ISSIlo n (Car buret ed E ngme - secf ion 11
Fuel pump Oisplacement ce (US oz, lmp oz)/min 760 (25. 7, 26.8) min.
Oelivery pressure kPa (kg/cm2, psi) 9-14(0.09-0.14, 1-2)
Fuel tank Capacity e (US gal, lmp gal) 45 (11.9, 9.9)
Engine ldle speed min '" (rpm) M/T A/T at !]]
with headlight and 0128, 01583 800 1,000
cooling f'an off
0138 800 --
81584 650 720
ldle CO % 0.1 max.
- F ue and E rmssson
. (PGM - FI E ngme - sectlion 11
Fuel pump Displacement ce (US oz, lmp oz) in 10 seconds 222 (7.5, 7.8) min.
Relief valve opening pressure kPa (kg/cm2, psi) 450-600 (4.5-6.0, 64-85)
Pressure Pressure with regulator vacuum hose
280-330 (2.8-3.3, 40-47)
regulator disconnected kPa (kg/cm2, psi)
Fuel tank Capacity e (US gal, lmp gal) 45 (11.9, 9.9)
Engine ldle speed min-1 (rpm) M/T A/T at !]]
with headlight and 01582, 016A, 0162 750 750
cooling fan off 0152 600 --
816A 750 --
ldle CO % 0.1 max.
....-- CIuc
t h - sec f ion 12
Clutch Pedal height to floor 164 (6.4) --
pedal Stroke 135 (5.3) --
Pedal play 12-21 (0.5-0.8) --
Oisengagement height to floor 83 (3.3) --
to carpet 55 (2.2) min. Reference --
Flywheel Clutch surface runout 0.05 (0.002) max. o. 15 (0.006)
Clutch Rivet head depth 1.3 (0.06) max. 0.2 (0.008)
disc Surface runout 0.8 (0.03) max. 1.0 (0.04)
Thickness ., 8. 1 -8.8 (0.32-0.35) 5.7 (0.22)
Clutch Pressure plate warpage 0.03 (0.001) max. 0.15 (0.006)
cover
3-10
~ 2WDM anua IT ransrmssron 520 - sectíon 13
111
MEASUREMENT STANDARD (NEW) 1

SERVICE LIMIT
Transmis- Capacity e (U.S.qt., lmp.qt.) 1.8 (1.9, 1.6) at oil change
sion oil 1. 9 (2.0, 1.7) at assembly
Mainshaft End play 0.13-0.20 (0.005-0.008) Adjust with shim
Diameter of ball bearing contact area 25.977-25.990 (1.0227-1.0232) 25.92 (1.020)
(clutch hosing side)
Diameter of third gear contact area 33.984-34.000 (1.3380-1.3386) 33.93 (1 .336)
Diameter of 4th, 5th gear contact area 26.980-26.993 (1.0622-1.0627) 26.93 (1.060)
(transmission hosing side)
Ronout 0.02 (0.0008) max. 0.05 (0.002)
Mainshaft I.D. 39.009-39.025 (1.5358-1.5364) 39.07 (1.538)
third and End play 3rd 0.06-0.21 (0.0024-0.0083) 0.33 (0.013)
fourth 4th 0.06-0.19 (0.0024-0.0075) 0.31 (0.012)
gears Thickness 3rd 30.22-30.27 (1.1898-1.1917) 30.15 (1.187)
4th 30.12-30.17 (1.1858-1.1878) 30.05(1.183)
Mainshaft I.D. 37.009-37.025 (1.4570-1.4577) 37.07 (1.459)
fifth gear End play 0.06-0. 19 (0.0024-0.0075) 0.31 (0.012)
Thickness 28.42-28.47 (1.1189-1.1209) 28.35 (1.116)
Counter- End play 0.17-0.38 (0.0067-0.0150) o. 53(0.021)
shaft Diameter of needle bearing contact area 30.000-30.015 (1.1811-1.1817) 29.95 (1.179)
Diameter of low gear contact area 35.984-36.000 ( 1.4167-1 .4173) 35.93 (1.415)
Runout 0.02 (0.0008) max. 0.05 (0.002)
Counter- I.D. 41.009-41.025 (1.6145-1.6152) 41.07 (1.617)
shaft low End play 0.03-0. 1 O (0.0012-0.0039) 0.22 (0.009)
gear Thickness 30.41-30.44 (1.1972-1.1984) 30.36 ( 1.195)
Counter- I.D. 44.009-44.025 ( 1.7326-1. 7333) 44.07 ( 1. 735)
shaft se- End play 0.03-0.11 (0.0012-0.0043) 0.23 (0.009)
cond gear Thickness 31.92-31.97 (1.2567-1.2587) 31.85 (1.254)
Spacer collar I.D. 32.988-32.998 (1.2987-1.2991) 33.04 (1.301)
(Countershaft o.o. 38.989-39.000 (1.5350-1.5354) 38.93 ( 1. 533)
second gear) Length 32.03-32.06 (1.2610-1.2622) 32.01 (1.260)
Spacercol· I.D. 27.002-27.012 (1.0631-1.0635) 27.06 (1.065)
lar (Main- O.D. 4th 33.989-34.000 (1.3381-1.3386) 33.93 ( 1.336)
shaft 5th 31.989-32.000 (1.2594-1.2598) 31.93 (1.257)
fourth and Length 4th 22.83-22.86 (0.8988-0.9000) 22.81 (0.898)
fifth gears) 5th 23.53-23.56 (0.9264-0.9276) 23.51 (0.926)
Reverse I.D. 15.016-15.043 (0.5911 -0.5922) 1 5.08 (O. 594)
ldler gear Gear-to-reversegear shaft clearance 0.032-0.077 (0.0013-0.0030) 0.14 (0.006)
Synchro ring Ring-to-gear clearance (ring pushed against gear) 0.73-1.18 (0.029-0.046) 0.4 (0.016)
Shift fork Shift fork finger thickness 6.4-6.5 (0.252-0.255) --
Fork-to-synchro sleeve clearance 0.25-0.45 (0.0098-0.0177) o.a 10.03>
Reverse Shift fork pawl groove width 12.7-13.0 (0.500-0.512) --
shift fork Fork-to-reverseidler gear clearance 0.5-1.1 (0.020-0.043) 1.8 (0.071)
Groove width 7.05- 7.25 (0.278-0.285) --
Fork-to-fifth/reverse shift piece pin clearance 0.05-0.35 (0.002-0.014) 0.5 (0.02)
Shift arm Diameter of shift rod contact area 13.005-13. 130 (0.5120-0.5169) --
A Shift arm A-to-shift rod clearance 0.005-0.230 (0.0002-0.0091) 0.35 (0.0138)
Shift arm Diameter of shift arm shaft contact area 13.973-14.000 (0.5501-0.5512) --
B Shift arm 8-to-shift arm shaft clearance 0.013-0.070 (0.0005-0.0028) 0.16 (0.0063)
Shift arm B-to-shift piece clearance 0.2-0.5 (0.0079-0.0197) 0.62 (0.0244)
Shift piece diameter of shift fork shaft
contact area 12.9-13.0 (0.5079-0.5118) 12.78 (0.5031)
3-11
- 2WD Manua IT ransrmssmn Y21 - sectiion 13
MEASUREMENT STANDARD (NEW} SERVICE LIMIT
1
Transmís- Capacity f. (U.S.qt., lmp.qt.) 2.3 (2.4, 2.0) at oíl change
slon oíl 2.4 (2. 5, 2. 1) at assembly
Maínshaft End play 0.11-0.18 (0.004-0.007) Adjust wíth shim
Oíameterof ball bearíng contact area 27.977-27.990 (1.101-1.102) 27.93 (1.10)
(clutch hosíng síde)
Oíameter of third gear contact area 37.984-38.000 (1.495-1.496) 37.93 (1.493)
Oiameter of ball bearíng contact area 27.987-28.000 (1.1018-1.1024) 27. 94 ( 1 . 1 O)
(transmission hosíng side)
Ronout 0.02 (0.0008) max. 0.05 (0.002)
Mainshaft 1.0. 43.009-43.025 (1.6933-1.6939) 43.08 ( 1.696)
third and End play 0.06-0.21 (0.0024-0.0083) · 0.33 (0.013)
fourth Thíckness 3rd 34.92-34.97 (1.3748-1.3768) 34.3 (1.350)
gears 4th 31.42-31.47 (1.2370-1.2390) 31.8 (1.252)
Mainshaft 1.0. 43.009-43.025 (1.6933-1.6939) 43.08 (1.696)
fifth gear End play 0.06-0.21 (0.0024-0.0083) 0.3 (0.012)
Thickness 31.42-31.47 (1.237-1.239) 31.3 11.232)
Counter- Oiameter of needle bearing contact area 33.000-33.015 (1.299-1.300) 32.95 (1.297)
shaft Oiameter of ball bearing contact area 24.980-24.993 (0.9835-0.9840) 24.93 (0.981)
Oiameter of low gear contact area 36.984-37.000 (1.4561 -1.4567) 36.93 (1.454)
Runout 0.02 (0.0008) max. 0.05 (0.002)
Counter- 1.0. 42.009-42.025 (1.6539-1.6545) 42.08 ( 1 .657)
shaft low End play 0.04-0.12 (0.0016-0.0047) Adjust with shim
gear
Counter- 1.0. 47.009-47.025 (1.8507-1.8514) 47.05 (1.852)
shaft se- End play 0.05-0.12 (0.0020-0.0047) Adjust with collar
cond gear Thickness 28.92-28.97 (1.1386-1.1405) 28.8 (1.134)
Spacer collar 1.0. 36.521-36.531 ( 1.4378-1.4382) 36. 541 ( 1.439)
(Counter- o.o. 41.989-42.000 (1.6531-1.6535) 4 1 . 94 ( 1 . 6 51 )
shaft Length A 29.02-29.04 (1.1425-1.1433) --
second gear) B 29.07-29.09 (1.1444-1.1453) --
Spacer 1.0. 31.002-31.012 (1.2205-1.2209) 31.06 (1.223)
collar o.o. 36.989-37.000 (1.4563-1.4567) 36.94 (1.454)
(Mainshaft Length 56.45-56.55 (2.2224-2.2264) --
fourth and 26.03-26.01
fifth gears)
(cont'd)
3-12
- 2WD M anuaIT ransrmssion Y21 ( cont'd) -
Reverse I.D.
MEASUREMENT
secf ion 13
STANDARD (NEW)
20.016-20.043 (0.7880-0.7891) 20.09
•
SERVICE LIMIT
(O. 7909)
ldle gear Gear-to-reverse gear shaft clearance 0.036-0.084 (0.0014-0.0033) o. 16 (0.006)
Synchro ring Ring-to-gear clearance (ring pushed against gear) 0.85-1.1 O (0.033~0.043) 0.4 (0.016)
Shift fork Shift fork finger thickness 7.4- 7.5 (0.291-0.295) --
Fork-to-synchro sleeve clearance 0.45-0.65 (0.018-0.026) 1.0 (0.039)
Reverse Shift fork pawl groove width 13.0-13.3 (0.511-0.524) --
shift fork Fork-to-reverse idler gear clearance 0.5-1.1 (0.020-0.043) 1.8 (0.07)
"L" groove width at fifth gear side 7.40-7.70 (0.291-0.303) --
at reverse gear side 7.05- 7.25 (0.278-0.285) --
Fork-to-fifth/reverse shift piece pin clearance
at fifth gear side 0.4-0.9 (0.016-0.035) --
at reverse gear side 0.05-0.45 (0.0020-0.018) --
Shift rod Groove width of shift arm contact area 11.8-12.0 (0.4646-0.4724) --
guide Shift rod guide-to-shift arm clearance 0.05-0.35 (0.002-0.014) 0.80 (0.031 l
Shift Groove width of shift arm contact area 7.9-8.0 (0.311-0.315) --
guide Shift rod guide-to-shift arm clearance 0.10-0.30 (0.004-0.012) 0.60 (0.024)
I.D. 14.000-14.068 (0.551-0.554) --
Guide-to-shaft clearance 0.011 -0.092 (0.0004-0.0036) o. 1 50 (0.0059)
Diameter of shift fork contact area 11.90-12.00 (0.469-0.472) --
Guide-to-shift fork clearance 0.20-0.50 (0.008-0.020) 0.80 (0.032)
Selector Diameter of shift rod guide contact area 11.90-12.00 (0.469-0.472) --
arm Arm-to-shift rod guide clearance 0.05-0.25 (0.002-0.010) 0.50 (0.020)
Groove width of interlock contact area 9.9-10.0 (0.390-0.394) --
Arm-to-interlock clearance 0.05-0.25 (0.002-0.010) o. 50 (0.020)
3-13
/
- 4WDM anua IT ransrmssron 522 - sec1on
f 13
1
Transmis- Capacity e (U.S. qt., Imp. qt] 2.4 (2.5, 2.1) at assembly
sion oíl 2.3 (2.4, 2.01 at oíl change
Mainshaft End play 0.08-0. 15 (0.003-0.006) Adjust wíth shím
Díameter of needle bearíng contact area 27.987-28.000 (1.1018-1.1024) 27.93 (1.100)
Diameter of 3rd gear contact area 34.984-35.000 (1.3773-1.37801 34.93 (1.3751
Díameter of 63/28C ball bearíng contact area 27.977-27.990 (1.1015-1.10201 27.92 (1.0991
Díameter of 6306/25 ball bearing contact area 24.987-25.000 (0.9837-0.98431 24.93 (0.9811
Runout 0.02 (0.0011 max. 0.05 (0.0021
Mainshaft I.D. 40.009-40.025 (1.5752-1.57581 40.07 (1.578)
3rd gear End play 0.06-0.21 (0.002-0.008) 0.3 (0.01)
Thíckness 32.42-32.47 (1.276-1.2781 32.3 (1.271
Maínshaft I.D. 40.009-40.025 (1.5752-1.5758) 40.07 (1.578)
4th gear End play 0.06-0.21 (0.002-0.0081 0.3 (0.011
Thickness 30.92-30.97 (1.217-1.2191 30.8 (1.211
Maínshaft I.D. 40.009-40.025 (1.5752-1.57581 40.07 (1.578)
5th gear End play 0.06-0.21 (0.002-0.008) 0.3 (0.01)
Thickness 30.42-30.47 (1. 198-1 .200) 30.3 (1.191
Counter- End play 0.05-0.30 (0.002-0.0121 0.5 (0.02)
shaft Diameter of needle bearing contact area 29.000-29.015 (1.1417-1.1423) 28.94 (1.1391
Diameter of ball bearing contact area 24.987- 25.000 (0.9837-0.9843) 24.93 (0.981)
Diameter of super-low 3 gear contact area 30.464-30.480 ( 1 .1994-1 .2000) 30.41 (1.1971
Runout 0.02 (0.0011 max. 0.05 (0.0021
Counter- I.D. 50.009- 50.025 (1.9689-1.9695) 50.07 (1.971)
shaft low End play 0.03-0.08 (0.001-0.0031 o. 18 (0.0071
gear Thíckness 32.95-33.00 (1.297-1.299) 32.83 ( 1 .2931
Counter- I.D. 50.009-50.025 (1.989-1.96951 50.07 (1.971)
shaft 2nd End play 0.03-0.08 (0.001-0.003) o. 18(0.007)
gear Thickness 32.92-32.97 (1.296-1.298) 32.8 (1.29)
Maínshaft I.D. 28.002-28.012 (1.1024- 1.1028) 28.06 (1.1051
4th gear & O.D. 34.989-35.000 ( 1.3775-1.3780) 34.93 (1.3751
5th gear Length 26.03-26.08 (1.025-1.027) 26.01 (1.0241
distance
collar
Counter- I.D. 36.48-36.49 (1 .436-1.437) 36.54 (1.4391
shaft 2nd O.D. 43.989-44.000 (1. 7318-1. 7323) 43.93 (1.730)
gear dis- Length 28.96-29.40 (1.140-1.157) Adjust wíth collar.
tance collar
Reverse I.D. 20.016-20.043 (O. 7880-0. 7890) 20.08 (0.791)
ídler gear Gear to shaft clearance 0.036-0.084 (0.0014-0.0033) o. 14 (0.006)
Super-low Distance of needle bearing contact area 23.984-23.993 (0.9443-0.9446) 23.93 (0.9421
1 st shaft
Super-low I.D. 30.000-30.013 ( 1. 1811 -1. 1816) 29.94 (1.179)
1 st gear Thíckness 62.95-63.00 (2.478-2.480) 62.83 (2.4741
Super-low Díameter of needle bearing contact area 22.987-23.000 (0.9050-0.9055) 22.93 (0.9031
2nd shaft End play 0.07-0.20 (0.003-0.008) Adjust with shim.
Diameter of ball bearing contact area 62/28 27.987-28.000 (1.1018-1.1024) 27.93 (1.100)
6204U 19.987-20.000 (0.7869-0.7874) 19.93 (0.785)
Runout 0.02 (0.0011 max. 0.05 (0.0021
{cont'd)
3-14
- 4WDM anua IT ransrrnssron 522 ( con t'd) - sectiion 13
MEASUREMENT STANDARD(NEW) SERVICE LIMIT
Super-low I.D. 37.009-37.025 (1.4570-1.4577) 37.07 (1.459)
2nd gear End play 0.03-0.16 (0.001-0.006) 0.24 (0.009)
Thickness 34.42-34.47 (1.355-1.357) 34.3 (1.35)
Super-low Diameter of needle bearing contact area 43.984-44.000 (1. 7318-1. 7323) 43.93 (1. 730)
3rd gear Width of needle bearing contact area 31.03-31.08 (1.222-1.224) 31.01 (1.221)
Super-low I.D. 23.000-23.013 (0.9055-0.9060) 23.06 (0.908)
2nd gear O.O. 31.989-32.000 (1.2594-1.2598) 31.93 (1.257)
distance Width 31.00-31.03 (1.220-1.222) 30.98 (1.220)
collar
Transfer Diameter of needle bearing contact area 27.987-28.000 (1.1018-1.1024) 27.93 (1.100)
shaft Diameter of taper bearing contact area 16.989-17.000 (0.6689-0.6693) 16.93 (0.667)
Width of transfer driven bevel gear contact area 45.01-45.05 (1.772-1.774) 45. 17 ( 1. 778)
Diameter of drive bevel gear contact area 35.002-35.018 (1.3780-1.3787) 34.95 ( 1.376)
Runout 0.02 (0.001 l max. 0.05 (0.002)
Transfer I.D. 34.009-34.025 (1.3389-1.3396) 34.07 (1.341)
driven gear Diameter of needle bearing contact area 54.000-54.015 (2.1260-2.1266) 53.94 (2. 124)
End play 0.04-0.13 (0.002-0.005) 0.21 (0.008)
Thickness 44.92-44.97 (1.690-1. 770) 44.8 (1.76)
Transfer I.D. 25.000-25.021 (0.9843-0.9851) 25.06 (0.987)
drive bevel Diameter of tapar bearing contact area 35.002-35.018 (1.3780-1.3787) 34.95 (1.376)
gear
Transfer Backlash 0.10-0.15 (0.004-0.006) Adjust with shim.
driven Diameter of taper bearng contact area 32007 35.002-35.018 (1.3780-1.3787) 34.95 ( 1.376)
bevel gear 320/28 27.987-28.000 (1.1018-1.1024) 27.93 (1.100)
Blocking Ring-to-gearclearance 0.85-1.10 (0.033-0.043) 0.4 (0.02)
ring
1 st/2nd Synchronizer sleeve groove width 7.95-8.05 (0.313-0.317) --
shift fork Shift fork-to-synchronizer sleeve clearance Thrust 0.45-0.65 (0.018-0.026) 1.0 (0.04)
& 3rd/4th Radial 0.05-0.45 (0.002-0.018) o.a <0.03l
shift fork Fork shaft-to-shift fork clearance 0.040-0.138 (0.0016-0.0054) --
5th shift Synchronizer sleeve groove width 5.75-5.85 (0.226-0.230) --
fork Shift fork-to-synchronizer sleeve clearance Thrust 0.25-0.45 (0.010-0.018) o.a 10.03¡
Radial 0.05-0.45 (0.002-0.018) o.a 10.03¡
Fork shaft-to-shift fork clearance
5th/Reverse shift fork shaft 0.005-0.070 (0.0002-0.0028) --
1 st/2nd shift fork shaft 0.440-0.670 (0.0173-0.0264) --
Reverse Shift fork pawl thickness 13.0-13.3 (O. 51-0. 52) --
shift fork Shift fork-to-reverse idle gear clearance 0.5-1.1 (0.02-0.04) 1.8 (0.07)
L-groove width 7.05-7.25 (0.278-0.285) --
Shift fork-to-5th/Reverse shift piece clearance 0.05-0.35 (0.002-0.014) 0.5 (0.02)
SHift Diameter or shift piece contact area 12.9-13.0 (0.508-0.512) --
arm A Shift arm-to-shift piece clearance 0.2-0.5 (0.01-0.02) 0.7 (0.03)
I.D. 16.000-16.068 (0.6299-0.6326) --
Shift arm-to-shaft clearance 0.011 -0.092 (0.0004-0.0036) --
(cont'd)
3-15
- 4WDM anuaIT ransrmssron S22 ( cont'd) - secf ion 13
MEASUREMENT STANDARD (NEWl SERVICE LIMIT
Shift arm Diameter of shift arm A contact area 11.9-12.0 (0.469-0.472) --
Shift arm-to-shift arm A clearance 0.05-0.25 (0.002-0.01 O) 0.5 (0.02)
Selectarm Diameter of shift arm A contact area 7.95-8.00 (0.313-0.315) --
Select arm-to-shift arm A clearance 0.10-0.25 (0.004-0.010} 0.5 (0.02)
Super-low Synchronizer sleeve groove width 5.75-5.85 (0.226-0.230) --
shift fork Shift fork-to-synchronizer sleeve clearance
Thrust 0.25-0.45 (0.010-0.018) 0.8 (0.03)
Radial 0.05-0.45 (0.002-0.018) 0.8 (0.03)
Super-low Shift piece-to-fork shaft clearance 0.040-0.138 (0.0016-0.0054) --
shift Diameter of super-low shift lever contact area 1 o. 1-10.2 (0.398-0.402) --
piece A Shift piece-to-super-low shift lever clearance o. 1 -0.3 (0.004-0.012) --
Super-low Diameter of super-low shift levar contact area 7.9-8.0 (0.311-0.315) --
shift Shift piece-to-super-low shift lever clearance 0.05-0.25 (0.002-0.010) 0.5 (0.02)
piece B
Disengage- Sleeve groove width 8.45-8.55 (0.333-0.337) --
ment fork Fork-to-sleeve clearance Thrust 0.45-0.65 (0.018-0.026) 1.0 (0.04)
Radial 0.2-1.1 (0.01-0.04) 1.5 (0.06)
3-16
- 2WD A uto mat.re Transrmssron M48A -
Transmis- Capacity e
MEASUREMENT
(US qt, lmp qt)
Sec1on
t. 14
STANDARD (NEW)
5.4 (5.7, 4.8) for overhaul
1
•
SERVICE LIMIT
sion fluid 2.4 (2.5, 2.1) for fluid change

Hydraulic Line pressureat 2,000 min-1(rpm) N or P 800-850 (8.0-8.5, 114-121) 750 (7.5, 107)
pressure 2nd clutch pressureat 2,000 min-1(rpm) 04 420 (4.2, 60) 370 (3. 7, 53)
kPa throttle fully closed throttle fully
(kg/cm2, closed
1
psi) 3rd clutch pressureat 2,000 min-1 (rpm) 04
800-850 (8.0-8.5, 114-121) 1
01281 throttle more than 1 /4 opened 750 (7.5, 107)
4th clutch pressureat 2,000 min-1(rpm) 04 throttle more
than 1 /4 opened
2nd clutch pressureat 2,000 rnin+ttrpm] 2 800-850 (8.0-8.5, 114-121) 750 (7.5, 107)
1st clutch pressureat 2,000 min-1(rpm) 04 or 03 800-850 (8.0-8.5, 114-121) 750 (7.5, 107)
Governor pressureat 37.5 mph (60 km/h) 151-161 (1.51-1.61, 21-23) 146 (1.46, 21)
Throttle pressure 8 Throttle fully closed o --
Throttle fully open 800-850 (8.0-8.5, 114-121) 750 (7.5, 107)
Throttle pressureA Throttle fully closed O- 5 (0-0.05, 0-1) --
Throttle fully open 515-530 (5.15-5.3, 73- 75) 510 (5.1, 73)
Hydraulic Line pressureat 2,000 min-1(rpm) N or P 850-900 (8.5-9.0, 121-128) 800 (8.0, 114)
pressure 2nd clutch pressureat 2,000 min-1(rpm) 04 420 (4.2, 60) 370 (3.7, 53)
(kg/cm2, closed
1
psi) 3rd clutch pressureat 2,000 min-1(rpm) 04
850-900 (8.5-9.0, 121-128) 1
01584 throttle more than 1 /4 opened 800 (8.0, 114)
4th clutch pressureat 2,000 min-1(rpm) 04 throttle more
than 1 /4 opened
2nd clutch pressureat 2,000 min-1 (rpm) 2 850-900 (8.5-9.0, 121-128) 800 (8.0, 114)
1st clutch pressureat 2,000 mm+ttrprnl 04 or 03 850-900 (8.5-9.0, 121-128) 800 (8.0, 114)
Governor pressureat 37.5 mph (60 km/h) 151-161 (1.51-1.61, 21-23) 146 (1.46, 21)
Throttle pressure8 Throttle fully closed o --
Throttle fully open 850-900 (8.5-9.0, 121-128) 800 (8.0,. 114)
Throttle pressure A Throttle fully closed 0-5 (0-0.05, 0-1) --
Throttle fully open 515-530 (5.15-5.3, 73- 75) 510 (5.1, 73)
(cont'd)
3-17
- 2WD Aut omatire T ransrmssren M48A ( cont'd) - sectiion 14
Hydraulic Line pressure at 2,000 min-1(rpm) N or P 800-850 (8.0-8.5, 114-121) 750 (7.5, 107)
pressure 2nd cfutch pressure at 2,000 min-1(rpm) 04 420 (4.2, 60) 370 {3. 7, 53)
{kg/cm2, closed
1
psi) 3rd clutch pressure at 2,000 min-1(rpm) 04
800-850 (8.0-8.5, 114-121) 1
01583 750 {7.5, 107)
throttle more than 1 /4 opened
4th clutch pressure at 2,000 min-1(rpm) 04 throttle more
than 1/4 opened
2nd clutch pressure at 2,000 min-1(rpm) 2 800-850 (8.0-8.5, 114-121) 750 (7.5, 107)
1 st clutch pressure at 2,000 min-1 (rpm) 04 or 03 800-850 {8.0-8.5, 114-121 l 750 (7.5, 107)
Governor pressure at 37.5 mph (60 km/h) 151-161 (1.51-1.61, 21-23) 146 ( 1 .46, 2 1 )
Throttle pressure B Throttle fully closed o --
Throttfe fully open 800-850 {8.0-8.5, 114-121) 750 (7.5, 107)
Hydraulic Line pressure at 2,000 rnin tírprn) N or P
r 800-850 {8.0-8.5, 114-121 l 750 {77.5, 107)
pressure 2nd clutch pressure at 2,000 min-1(rpm) 04 420 (4.2, 60) 370 (3. 7, 53)
(kg/cm2, closed
1
psi) 3rd clutch pressure at 2,000 min-1 (rpm) 04
800-850 {8.0-8.5, 114-121) 1
016A8, throttle more than 1 /4 opened 750 (7.5, 107)
D16A9 4th clutch pressure at 2,000 min-1(rpm) 04 throttle more
than 1 /4 opened
2nd clutch pressure at 2,000 min-1{rpm) 2 800-850 (8.0-8.5, 114-121) 750 (7.5, 107)
1st clutch pressure at 2,000 min-1(rpm) 04 or 03 800-850 (8.0-8.5, 114-121) 750 (7.5, 107)
Governor pressure at 37. 5 mph (60 km/h) 151-161 {1.51-1.61, 21-23) 146 (1.46, 21)
Stall speed min -1 (rpm) (check with car on level ground) 2,300-2,900 --
Clutch Cfutch initiaf clearance 1 st, 2nd 0.65-0.85 (0.026-0.033) --
3rd, 4th 0.40-0.60 (0.016-0.024) --
Clutch return spring free length 1 st 31.0 (1.22) 29.0 (1.14)
2nd, 3rd, 4th 30.5 (1.20) 28.5 (1.12)
Clutch disc thickness 1.88-2.00 (0.074-0.079) Until grooves
worn out
Clutch plate thickness 1st 1.55-1.65 (0.061-0.065) Oiscoloration
Except 1 st 1.95-2.05 (0.077-0.081) Oiscoloration
(cont'd)
3-18
~ 2WD Automatic Transmission M48A (cont' d) - Section 14
Clutch Clutch end plate thickness MARK 1 2.2-2.3 (0.087-0.091} Discoloration
01281, 01583 MARK 2 2.5-2.6 (0.098-0.102) j
MARK 3 2.8-2.9 (0.110-0.114)

MARK 4 3.1 -3.2 (0.122-0.126)
MARK 5 3.4-3.5 (0.134-0.138)
MARK 11 2.05-2.15 (0.081-0.085)
MARK 12 2.35-2.45 (0.093-0.096)
MARK 13 2.65-2. 75 (0.104-0.108)
MARK 14 2.95-3.05 (0.116-0.120)
MARK 15
MARK 16
3.25-3.35
3.55-3.65
(O. 128-0.132)
(0.140-0.144) '
Discolorati on
Clutch end plate thickness
01584, D16A8, D16A9
MARK 1
MARK 2
2.3-2.4
2.4-2.5
(0.091-0.094)
(0.094-0.098) ,,
Discoloration
MARK 3 2.5-2.6 (0.098-,-0.102)

MARK 4 2.6-2.7 (0.102-0.106)
MARK 5 2.7-2.8 (0.106-0.110)
MARK 6 2 .. 8-2.9 (0.110-0.114)
MARK 7 2.9-3.0 (0.114-0.118)
MARK 8 3.0-3.1 (O. 118-0.122)
MARK 9 3.1-3.2 (0.122-0.126)
MARK 10 3.2-3.3 (0.126-0.130)
MARK 11 2.0-2.1 (0.079-0.083)
MARK 12 2.1 -2.2 (0.083-0.087) '
MARK 13 2.2-2.3 (0.087-0.091) Discoloration
(cont'd)
3-19
~ 2WD Automati<:TransmissionM48A (cont'd)- Section 14
MEASUREMENT STANDARD (NEWI. SERVICE LIMIT
Trans- Diameter of needle bearing contact area
mission On mainshaft and stator shaft 19.980-19.993 (O. 7866-0. 7871 l Wear or damage
On mainshaft 2nd gear 35.975-35.991 (1.4163-1.4169)
On mainshaft 4th gear collar 31.975-31.991 (1.2589-1.2595)
On mainshaft 1 st gear collar 27.975-27.995 (1.1014-1.1022)
On countershaft (L.side) 36.004-36.017 (1.4175-1.4180)
On countershaft 3rd gear distance collar 31.975-31.991 (1.2589-1.2595)
On countershaft 4th gear 27.980-27.993 (1.1016-1.1021)
On countershaft reverse gear collar 29.980- 29.993 ( 1. 1803-1.1808)
On countershaft 1 st gear collar 29.980-29.993 {1.1803-1.1808)
On reverse idler gear shaft 13.990-14.000 {0.5508-0.5512) ,
On mainshaft 1 st gear 33.000-33.016 (1.2992-1.3000) Wear or damage
lnside diameter of needle bearing contact area
On mainshaft 2nd gear 41.000-41.016 (1.6142-1.6148) Wear or damage
On mainshaft 4th gear 38.000-38.016 (1.4961-1.4967) j
On countershaft 1 st gear 35.000-35.016 (1.3780-1.3786)

On countershaft 3rd gear 38.000-38.016 {1.4961-1.6967)
On countershaft 4th gear 33.000-33.016 {1.2992-1.2998)
On countershaft reverse gear 36.000-36.016 {1.4173-1.4179)
On reverse idler gear 18.007-18.020 {0.7089-0.7094)
On stator shaft (R. side) 26.000-26.013 {1.0236-1.0241 l
On stator shaft {stator side) 24.000-24.021 (0.9449-0.9457)
On reverse idler shaft holder 14.416-14.434 (0.5676-0.5683)
••
Wear or damage
End play
Mainshaft 1 st gear 0.08-0.24 (0.003-0.009)
Mainshaft 2nd gear 0.07-0.15 (0.003-0.006)
Mainshaft 4th gear 0.10-0.22 (0.004-0.009)
Countershaft 1 st gear 0.10-0.45 (0.004-0.018)
Countershaft 3rd gear 0.07-0.15 (0.003-0.006)
Countershaft 4th gear 0.07-0.15 (0.003-0.006)
Reverseidler gear 0.05-0.18 (0.002-0.007)
Countershaft reverse gear 0.10-0.45 (0.004-0.018)
Selector hub O.O. 51.87-51.90 (2.042-2.043) Wear or damage
Mainshhaft 4th gear collar length 40.00-40.05 (1.5748-1.5768)
Mainshaft 1 st gear collar length 25.00-25.15 (0.9843-0.9902)
Mainshaft 1 st gear collar flange thickness 2.5-2.6 (2.098-2.102) Wear or damage
Countershaft distance collar length 38.97-39.00 (1.534-1.535)
39.02-39.05 (1.536-1.537)
39.07-39.10 (1.538-1.539)
39.12-39.15 (1.540-1.541)
39.17-39.20 (1.542-1.543)
39.22-39.25 (1.544-1.545)
39.27-39.30 (1.546-1.547)
38.87-38.90 (1.530-1.531)
38.92-38.95 (1.532-1.533)
Countershaft reverse gear collar length 14.5-14.55 (0.571-0.573)
Countershaft reverse gear collar flange thickness 2.45-2.55 (0.096-0.100) Wear or damage
Countershaft 1 st gear collar length 14.50-14.55 (0.571-0.573)
Countershaft 1 st gear collar flange thickness 2.45-2.55 (0.096-0.100) Wear or damage
(cont'd)
3-20
- 2WD A ut ornat"re Trensrmssron M48A ( cont'd) - secti,on 14
Transmis- Mainshaft 2nd gear thrust washer thickness 3.47-3.50 (0.137-0.138) Wear or damage
sion 3.52-3.55 (0.139-0.140)
(cont'd) 3.57-3.60 (0.141-0.142)
3.62-3.65 (0.143-0.144)
3.67-3.70 (0.145-0.146)
3.72-3.75 (0.147-0.148)
3.77-3.80 (0.148-0.150)
3.82-3.85 (O. 151-0.152)
,,
3.87-3.90 (0.153-0.154) Wear or damage
Thrust washer thickness
Mainshaft 4th gear 4.45-4.55 (0.175-0.179) Wear or damage
Mainshaft ball bearing L. side
Mainshaft 1 st gear L. side
Mainshaft 1 st gear R. side
2.95-3.05
1.45-1.50
2.43-2.50
(0.116-0. 120)
(0.057-0.057)
(0.096-0.098)
t
Wear or damage
Countershaft 3rd gear thrust washer thickness 2.87-2.90 (0.113-0.114) Wear or damage
2.92-2.95 (0.115-0.116) '
2.97-3.00 (0.117-0.118)
3.02-3.05 (0.119-0.120)
3.07-3.10 (0.121-0.122)
3.12-3.15 (0.123-0.124)
3.17-3.20 (0.125-0.126)
3.22-3.25 (0.127-0.128)
3.27-3.30 (0.129-0.130)
3.32-3.35 (0.131-0.132)
3.37-3.40 (0.133-0.134) Wear or damage
Mainshaft 4th gear thrust washer thickness 2.93-3.00 (0.115-0.118) Wear or damage
One-way clutch contact area 1.0.
Countershaft 1 st gear
Parking gear
74.414-74.440 (2.930-2.931)
57. 755-57. 768 (2.2738-2.2743)
t
Wear or damage
Mainshaft feed pipe A, O.O. 8.97-8.98 (0.353-0.354) 8.95 (0.352)
Mainshaft feed pipe B, 0.D. 5.97-5.98 (0.2350-0.2354) 5.95 (0.234)
Countershaft feed pipe O .D 7.97-7.98 (0.3138-0.3142) 7.95 (9.313)
Mainshaft sealing ring thickness 1.980-1.995 (0.0780-0.0785) 1.80 (0.071)
Mainshaft bushing I.D. 6.018-6.030 (0.2369-0.2374) 6.045 (0.2380)
Countershaft bushing 1.0. 8.000-8.015 (0.3150-0.3156) 8.030 (0.3161)
Mainshaft sealing ring groove width 2.025-2.060 (0.0797-0.081) 2.080 (0.082)
Regulator Sealing ring contact I.D. 32.000-32.025 (1.260-1.261) 32.05 (1.262)
valvebody
Shifting Reverseshift fork finger thickness 5.90-6.00 (0.232-0.236) 5.40 (0.213)
device and Parking brake ratchet pawl -- Wear or
parking Parking brake gear -- other defect
brake control Throttle cam stopper height 18.5-18.6 (0.728-0.732) --
Servo Shift fork shaft bore 1.0. A 14.000-14.005 (0.5512-0.5514) --
body B 14.006-14.010 (0.5514-0.5516) --
e 14.011 -14.015 (0.5516-0.5518) --
Shift fork shaft valve bore 1.0. 37.000-37.039 (1.4567-1.4582) 37.045 (1.4585)
Oil pump Oil pump gear side clearance 0.03-0.05 (0.001-0.002) 0.07 (0.003)
Oil pump gear-to-body clearance Orive 0.240-0.266 (0.009-0.010) --
Driven 0.063-0.088 (0.002-0.003) --
Oil pump driven gear 1.0. 14.016-14.034 (0.5518-0.5525) Wear or damage
Oil pump shaft O.O. 13.980-13.990 (0.5504-0.5508) Wear or damage
(cont'd)
3-21
Standard and Service Limits
~ 2WDA ut ornaf re T ransm,ssron M48A ( cont'd)
STANDARD (New)
MEASUREMENT
Wire Dia. o.o. Free Length No. of Coils
Spring Orífice control valve spring 0.9 (0.035) 6.6 (0.260) 44.0 (1.732) 22.0
3-4 shift valve spring 0.7 (0.028) 9.6 (0.378) 32.9 (1.295) 6.4
3-4 shift ball spring 0.45 (0.018) 4.5 (0.177) 12.0 (0.472) 6.7
Cooler relief valve spring 1.1 (0.043) 8.4 (0.331) 36.4 ( 1 .433) 12.0
Relief valve spring 1.0 (0.039) 8.4 (0.331) 52.0 (2.047) 23.0
2-3 shift ball spring 0.4 (0.016} 4.5 (0.177} 14.7 (0.579} 7.3
1-2 shift ball spring 0.4 (0.016) 4.5 (0.177) 11.3 (0.445) B.O
Regulator valve 01281 1.8 (0.071) 14. 7 (O. 579) 86.5 (3.406) 16.5
spring A Others 1.8 (0.071) 14.7 (0.579) 88. 1 (3.468) 16.5
Regulator valve spring 8 1.8 (0.071) 9.6 (0.378) 44.0 ( 1.732) 7.5
Stator reaction spring 5.5 (0.217) *26.4 (1.039) 30.3 (1.193) 2.1
l.ock-up control 01281/01583 0.7 (0.028) 6.6 (0.260) 32.5 (1.280) 14.0
valve spring D 1 584/016A8/01 6A9 0.6 (0.024) 6.6 (0.260) 32.8 ( 1.291 l 15.8
Torque converter check valve spring 1.1 (0.043) 8.4 (0.331) 36.4 (1.433) 12.0
Modulator 01281/01583 1.2 (0.047) 9.4 (0.370) 26.3 (1.035) 8.0
valve spring 1.2 (0.047) 9.4 (0.370) 27.2 (1.071) 8.0
O 1 584/01 6A8 1.2 (0.047) 9.4 (0.370) 26.3 (1.035) 8.0
D16A9 1.2 (0.047) 9.4 (0.370) 26.4 ( 1.039) 8.0
Throttle valve A 01281/01583 1.1 (0.043) 8.5 (0.335) 22.3 (0.878) 8.1
spring 1.1 (0.043) 8.5 (0.335) 22.3 (0.878) 7.6
1.0 (0.039) 8.5 (0.335) 22.2 (0.874) 6.0
1.0 (0.039) 8.5 (0.335) 22. 1 (0.870) 5.5
O 1 584/D 1 6A8 1.0 (0.039) 8.5 (0.335) 22.2 (0.874) 6.0
D16A9 1.0 (0.039) 8.5 (0.335) 22. 1 (0.870) 5.5
1.0 (0.039) 8.5 (0.335) 22.5 (0.886) 7.3
1.0 (0.039) 8.5 (0.335) 22.3 (0.878) 6.6
Throttle valve A adjusting spring 0.8 (0.031) 6.2 (0.244) 27.0 (1.063) 8.5
Throttle valve 8 01281/01583 1.4 (0.055) 8.5 (0.335) 41 .4 ( 1.630) 8.4
spring 1.4 (0.055) 8.5 (0.335) 41.4 ( 1.630) 7.8
1.6 (0.063) 8.5 (0.335) 41.3 ( 1.626) 13.9
O 1 584/D 16A8 1.6 (0.063) 8.5 (0.335) 41.3(1.626) 13.9
D16A9 1.6 (0.063) 8.5 (0.335) 41.4 (1.630) 11. 7
1.6 (0.063) 8.5 (0.335) 41.3 (1.626) 15.0
*: lnside Diameter
3-22
- 2WD A ut ornat"re T ransrrusston M48A ( cont'd)
MEASUREMENT
Wire Dia.
STANDARD(New)
O.D. Free Length
•
No. of Coils
Spring Throttle valve 8 adjusting spring 0.8 (0.031 l 6.2 (0.244) 30.0 (1.181) a.o
3rd accumulator spring 2.9(0.114) 15.5 (0.689) 79.5 (3.130) 15.0
2nd accumulator spring 3.9 (0.154) 20.2 (O. 795) 74.9 (2.949) 10.9
4th accumulator spring 3.5 (0.138) 18.6 (O. 732) 77.4 (3.047) 10.2
Reverse timing valve spring 0.7 (0.028) 5.6 (0.220) 43.8 (1. 724) 21.7
Servo control valve spring 1.0 (0.039) 7.6 (0.299) 44.0 ( 1. 732) 18.2
Lock-up shift 01281/01583 0.7 (0.028) 8.1 (0.319) 39.0 (1.535) 15.4
valve spring D 1 584/D 16A8/D 16A9 1.1 (0.043) 8.1 (0.319) 51.8 (2.039) 22.3
Lock-up timing valve spring 1.0 (0.039) 6.6 (0.260) 52.3 (2.059) 30.1
Governor spring A 1.0 (0.039) 18.8 (O. 740) 32.9 (1.295) 4.1
Governor spring 8 0.9 (0.035) 11.8 (0.465) 27 .8 ( 1.094) 6.0
0.9 (0°.035) 11 .8 (0.465) 29.1 (1.146) 6.0
1 st-hold accumulator spring 4.0 (0.157) 21. 5 (0.846) 71. 7 (2.823) 8.3
Kick-down valve spring 1.0 (0.039) 1 o. 1 (0.398) 38.9 (1.531) 12.5
Orifice control valve spring 0.9 (0.035) 6.1 (0.240) 35.9 (1.413) 20.0
Shift timing valva spring 0.9 (0.035) 8.6 (0.339) 42.9 (1.689) 21.4
4th exhaust valve spring 0.9 (0.035) 6.1 (0.240) 43. 7 (1. 720) 20.3
Accumulator O 1 281 /O 1 583 1.2 (0.047) 7. 7 (0.303) 45.1 (1. 776) 19.8
valve spring O 1 584/01 6A8/01 6A9 1.2 (0.047) 7.7 (0.303) 45.6 (1.795) 21.8
Lock-up cut valve spring 0.7 (0.028) 7.6 (0.299) 29.0 (1.412) 18.0
Reverse control valve spring 0.7 (0.028) 7.6 (0.299) 37. 2 ( 1.465) 15.3
CPC (Clutch Pressure Control) 0.9 (0.035) 8.6 (0.339) 18.2 (0.717) 5.54
valve spring
Governor spring A 1.0 (0.039) 18.8 (0.740) 20.4 (0.803) 4.0
Governor spring 8 0.9 (0.035) 11.8 (0.465) 27.8 (1.094) 6.0
1 st accumulator one-way ball spring 0.29 (0.011 l 4.0 (0.157) 14.0 (0.551 l 13.0
1 st accumulator spring A 2.34 X 2.90 · 21.5 (0.846) 66. 7 (2.626) 10.2
(0.092 X 0. 114)
1 st accumulator spring 8 2.8 (0.110) 13.1 (0.516) 40.0 (1.575) 8.8
3-23
~ 2WDA ut orna1·ic T ransrmssron M24A - secf ion 14
1
Transmis- Capacity t (US qt, lmp qt) 5.9 (6.2, 5.2) far overhaul
sion fluid 2. 7 (2.8, 2.4) far fluid change
Hydraulic Line pressure at 2,000 min-1 (rpm) N or P 850-900 (8.5-9.0, 121-128) 800 (8.0, 114)
pressure
2nd clutch pressure at 2,000 min " " (rpm) 04 400 (4.0, 57) 350 (3.5, 50)
kPa
throttle fully closed throttle fully
(kg/cm2,
1 closed
850-900 (8.5-9.0, 121-128) 1
01626,
throttle more than 1 /8 opened 800 (B.O, 114)
016A8,
4th clutch pressure at 2,000 min-1 (rpm) 04 throttle more
016A7
than 1 /8 opened
2nd clutch pressure at 2,000 rnin"" (rpm) 2 850-900 (8.5-9.0, 121-128) 800 (8.0, 114)
1 st clutch pressure at 2,000 mín " ' (rpm) 04 or 1 850-900 (8.5-9.0, 121-128) 800 (8.0, 114)
Governor pressure 01626, 016A8 180-190 (1.80-1.90, 26-27) 175 (1.75, 25)
at 37.5 mph (60 km/h) 016A7 182-192 (1.82-1.92, 26-27) 177 (1.77, 25)
Throttle pressure B Throttle fully closed 0-15 (0-0.15, 0-2) --
Throttle fullv' open 850-900 (8.5-9.0, 121 -128) 800 (8.0, 114)
01626 Throttle fully open 505-520 (5.05-5.2, 72- 74) 500 (5.0, 71)
016A8 Throttle fully open 535-550 (5.35-5.5, 76-78) 530 (5.3, 75)
016A7 Throttle fully open 515-530 (5.15-5.3, 73-75) 510(5.1,73)
pressure
2nd clutch pressure at 2,000 min-1 (rpm) 04 400 (4.0, 57) 350 (3.5, 50)
kPa
throttle fully closed throttle fully
(kg/cm2,
1 closed
800-850 (8.0-8.5, 114-121) 1
01582
throttle more than 1 /8 opened 750 (7.5, 107)
than 1 /8 opened
2nd clutch pressure at 2,000 min-1 (rpm) 2 800-850 (8.0-8.5, 114-121) 750 (7.5, 107)
1 st clutch pressure at 2,000 min -1 (rpm) 04 or 1 800-850 (8.0-8.5, 114-121) 750 (7.5, 107)
Governor pressure at 37.5 mph (60 km/h) 180-190 (1.80-1.90, 26-27) 175(1.75,25)
Throttle pressure B Throttle fully closed 0-15 (0-0.15, 0-2) --
Stall speed min " " (rpm) (check with car on leve! ground) 2,400-2,800 --
(cont'd)
3-24
~ 2WDA ut ornatire T ransrmssron M24A ( cont'd) - sectlion 14
E
Clutch Clutch initial clearance 1st, 2nd 0.65-0.85 (0.026-0.033) --

3rd, 4th 0.40-0.60 (0.016-0.024) --
1 st-hold 0.5-0.8 (0.02-0.03) --
2nd, 3rd, 4th 30.5 (1.20) 28.5 (1.12)
1 st-hold 34.6 (1.36) 32.6 (1.28)
Clutch disc thickness 1 .88-2.00 (0.074-0.079) Until grooves
worn out
Clutch plate thickness 1st 1 .55-1 .65 (0.061 -0.065) Discoloration
Except 1 st 1.95-2.05 (0.077-0.081) Discoloration
Clutch end plata thickness MARK 1 2.3-2.4 (0.091-0.094) Discoloration
(except 1 st-hold) MARK 2
MARK 3
2.4-2.5
2.5-2.6
(0.094-0.098)
(0.098-0.102)
•
MARK 4 2.6-2.7 (0.102-0.106)
MARK 5 2.7-2.8 (0.106-0.110)
MARK 6 2.8-2.9 (0.110-0.114)
MARK 7 2.9-3.0 (0.114-0.118)
MARK 8 3.0-3. 1 (O. 118-0.122)
MARK 9 3.1-3.2 (0.122-0.126)
MARK 10 3.2-3.3 (0.126-0.130)
MARK 11 2.0-2.1 (0.079-0.083)
MARK 12 2.1- 2.2 (0.083-0.087)
MARK 13 2.2-2.3 (0.087-0.091) Discoloration
I
Clutch end plate thickness MARK 1 2.05-2.10 (0.081-0.083) Discoloration
( 1 st-hold) MARK 2 2.15-2.20 (0.085-0.087)
MARK 3 2.25-2.30 (0.089-0.091)
MARK 4 2.35-2.40 (0.093-0.094)
NO MARK 2.45-2.50 (0.096-0.098)
MARK 6 2.55-2.60 (0.100-0.102)
MARK 7 2.65-2. 70 (0.104-0.106) Discoloration
(cont'd)
3-25
- 2WD Automatic Transmlsslon M24A (cont'd) - Section 14
Trans- Diameter of needle bearing contact area

mission On mainshaft and stator shaft 22.980-22.993 (0.9047-0.9052) Wear or damage
On countershaft (L. side) 36.004-36.017 (1.4175-1.4180)
On countershaft 3rd gear distance collar 31.975-31.991 (1.2589-1.2595)
On countershaft reverse gear collar 31.975-31.991 (1.2589-1.2595)
On countershaft 1 st gear collar 31.975-31.991 (1.2589-1.2595)
On subshaft (L. side) 25.991-26.000 (1.0233-1.0236)
On subshaft 4th gear collar 27.980-27.993 (1.1016-1.1021)
On reverse idler gear shaft 13.990-14.000 (0.5508-0.5512)
On mainshaft 1 st gear 35.000-35.016 (1.3780-1.3786)
On mainshaft 4th gear 38.000-38.016 (1.4961-1.4967)
On countershaft 1 st gear 38.000-38.016 (1.4961-1.4967) Wear or damage
On countershaft 3rd gear 38.000-38.016 (1.4961-1.6967)
On countershaft 4th gear 33.000-33.016 (1.2992-1.2998) Woac [' darnaqe
On countershaft reverse gear 38.000-38.016 (1.4961-1.4967)
On subshaft 4th gear 32.000-32.016 (1.2598-1.2605)
On reverse idler gear 18.007-18.020 (O. 7089-0. 7094)
On stator shaft (R. side) 29.000-29.013 (1.1417-1.1422)
On stator shaft (stator sida) 27.000-27.021 (1.0630-1.1638)
On reverse idler shaft holder 14.416-14.434 (0.5676-0.5683) Wear or damage
End play
Mainshaft 1 st gear 0.08-0.24 (0.003-0.009)
Mainshaft 2nd gear 0.05-0.13 (0.002-0.0051)
Mainshaft 4th gear 0.05-0.135 (0.002-0.0053)
Countershaft 3rd gear 0.05-0.13 (0.002-0.0051)
Countershaft 4th ·gear 0.05-0.13 (0.002-0.0051)
Subshaft 4th gear 0.05-0.17 (0.002-0.007)
Reverse idler gear 0.05-0.18 (0.002-0.007)
Countershaft reverse gear 0.10-0.25 (0.004-0.010)
Selector hub O.O. 51.87-51.90 (2.042-2.043) Wear or damage
Mainshaft 4th gear collar length 45.00-45.03 11. 772-1. 773)
Mainshaft 1 st gear collar length 27.00-27.15 (1.063-1.069)
Countershaft distance collar length 38.97-39.00 (1.534-1.535)
39.02-39.05 (1.536-1.537)
39.07-39.10 (1.538-1.539)
39.12-39.15 (1.540-1.541)
39.17-39.20 (1.542-1.543)
39.22-39.25 (1.544-1.545)
39.27-39.30 (1.546-1.547)
38.87-38.90 (1.530-1.531)
38.92-38.95 (1.532-1.533)
Countershaft 1st gear collar flange thickness 2.4-2.6 (0.094-0.102) Wear or damage
Subshaft 4th gear collar length 24.0-24.1 (0.945-0.949) Wear or damage
Subshaft 4th gear collar flange thickness 3.00-3.15 (0.118-0.124) Wear or damage
(cont'd)
3-26
- 2WD Automatic Transmlsslon M24A (cont'd)- Section 14
E
Unit of length: mm lin)

Trans- Mainshaft 2nd gear thrust washer thickness 3.47-3.50 (0.137-0.138) Wear or damage
mission 3.52-3.55 (0.139-0.140) •
(cont'd) 3.57-3.60 (0.141-0.142)
3.62-3.65 (0.143-0.144)
3.67-3.70 (0.145-0.146)
3.72-3.75 (0.147-0.148)
3.77-3.80 (0.148-0.150)
3.82-3.85 (0.151-0.152)
3.87-3.90 (O. 153-0.154) Wear or damage
Mainshaft ball bearing L. side
Mainshaft 1 st gear L. side
Mainshaft 1 st gear R. side
3.45-3.55
1.45-1.50
3.43-3.50
(0.136-0.140)
(0.057-0.057)
(0.135-0.138)
t
Wear or damage
3.02-3.05 (O. 119-0.120) ••
3.07-3.1 O (O. 121-0. 122)
3.12-3.15 (0.123-0.124)
3.17-3.20 (0.125-0.126)
3.22-3.25 (0.127-0.128)
3.27-3.30 (0.129-0.130)
3.32-3.35 (0.131-0.132)
3.37-3.40 (0.133-0.134)
3.42-3.45 (0.135-0.136)
3.47-3.50 (0.137-0.138) Wear or damage
Mainshaft 4th gear thrust washer thickness 2.93-3.00 (0.115-0.118) Wear or damage
One-way clutch contact area 1.0.
Countershaft 1 st gear
Parkinggear
83.339-83.365 (3.2810-3.2821)
66.685-66.698 (2.6254-2.6259)
t
Wear or damage
Mainshaft feed pipe A, O.O. 8.97-8.98 (0.353-0.354) 8.95 (0.352)
Mainshaft feed pipe B, O.O. 5.97-5.98 (0.2350-0.2354) 5.95 (0.234)
Countershaft feed pipe O.O 7.97-7.98 (0.3138-0.3142) 7.95 (9.313)
Subshaft feed pipe O.O. 7.97-7.98 (0.3138-0.3142) 7.95 (0.313)
(29 mm and 35 mm)
Mainshaft bushing 1.0. 6.018-6.030 (0.2369-0.2374) 6.045 (0.2380)
Mainshaft bushing 1.0. 9.000-9.015 (0.3543-0.3549) 9.030 (0.355)
Countershaft bushing 1.0. 8.000-8.015 (0.3150-0.3156) 8.030 (0.3161)
Subshaft bushing 1.0. 8.000-8.015 (0.3150-0.3156) 8.030 (0.3161)
Regulator Sealing ring contact 1.0. 35.000-35.025 (1.3780-1.3782) 35.050 (1.3799)
valvebody
device and Parking brake ratchet pawl Wear or
parking Parking brake gear other defect
brake control Throttle cam stopper height 27.0-27.1 (1.063-1.067)
Servo Shift fork shaft bore 1.0. 14.000-14.010 (0.5512-0.5516) --
body Shift fork shaft valve bore 1.0. 37.000-37.039 ( 1.4567-1.4582) 37.045 (1.4585)
Oil pump Oil pump gear side clearance 0.03-0.05 (0.001-0.002) 0.07 (0.003)
Oil pump gear-to-body clearance Orive 0.210-0.265 (0.0083-0.0104) --
Driven 0.070-0. 125 (0.0028-0.0049) --
Oil pump driven gear 1.0. 14.016-14.034 (0.5518-0.5525) Wear or damage
(cont'd)
3-27
.-- 2WD A ut ornati1c T ransrrussron M24A ( cont 'd) - sectiion 14
STANDARD (NEW)
MEASUREMENT
Springs Regulator valve spring A 1.8 (0.07) 14.7 (0.58) 88.6 (3.49) 16.5
01626, Regulator valve spring B 1.8 (0.07) 9.6 (0.38) 44.0 (1.73) 7.5
D16A7, Stator reaction spring 5.5 (0.22) 26.4 (1.04) 30.3 (1.19) 2.1
01582 Torque converter check valve spring 1.1 (0.04) 8.4 (0.33) 33.8 ( 1.33) 12.5
Modulator valve spring 1.2 (0.05) 7.0 (0.28) 27.2 (1.07) 8.0
Helief valve spring 1.1 (0.04) 8.6 0.34) 37.1 (1.46) 13.4
Cooler check valve spring 1.1 (0.04) 8.4 (0.33) 33.8 (1.33) 12.5
Governor spríng A 1.0 (0.04) 18.8 (0.74) 32.9 ( 1.30) 4.1
Governor spríng 8 0.9 (0.04) 11.8 (0.47) 27.8 (1.09) 6.0
0.9 (0.04) 11.8 (0.47) 29. 1 ( 1. 1 5) 6.0
2- 3 orífice control valve spring 1.0 (0.04) 6.6 (0.26) 29.9(1.18) 14.7
4- :3 kick-down valve spring 1.0 (0.04) 6.6 (0.26) 29.9 (1.181 14.7
2/3 ·- 4 orífice control valve spring 1.0 (0.04) 8.6 (0.34) 52.2 (2.06) 18.2
Throttle valve spring A 1.0 (0.04) 8.5 (0.33) 22.2 (0.87) 6.0
Throttle valve spríng A 1.1 (0.04) 8.5 (0.33) 22.3 (0.87) 8.1
Throttle valve spríng A 1.1 (0.04) 8.5 (0.33) 22.3 (0.871 7.6
Throttle valve adjust spring B 0.8 (0.03) 6.2 (0.24) 30 (1.18) 8
Throttle valve adjust spring A 0.8 (0.03) 6.2 (0.24) 27 (1.06) 8.5
Throttle valve spring B 1.4 (0.06) 8.5 (0.33) 41.5 (1.63) 10.5
Throttle valve spríng B 1.4 (0.06) 8.5 (0.33) 41.5 (1.63) 11.2
1 - 2 shíft valve spring 0.45 (0.018) 5.1 (0.20) 52.8 (2.08) 29
1-2 shift valve ball spring 0.45 (0.018) 4.5 (0.18) 10.7 (0.42) 12.7
2-3 shift valve ball spring 0.4 (0.02) 4.5 (0.18) 14. 7 (0.58) 7.3
3-4 shíft valve spríng 0.9 (0.04) 9.6 (0.38) 32.5 (1.28) 10.3
1 st-hold accumulator spring 4.0 (0.16) 21.5 (0.85) 71.7 (2.82) 8.3
1 st accumulator spríng 2.6 (0.10) 24.3 (0.96) 79.8 (3.14) 8.5
2nd accumulator spring 3.5(0.14) 22 (0.87) 75.4 (2.97) 8.7
3rd accumulator spríng 2.9(0.11) 17.5 (0.69) 81.5 (3.21) 13.9
4th accumulator spring 2.8 (0.11) 16 (0.63) 85.0 (3.35) 15.8
Lock-up shift valve spríng 0.9 (0.04) 7.6 (0.30) · 73. 7 (2.90) 32
Lock-up timing valve spríng 0.8 (0.03) 6.6 (0.26) 61.5 (2.42) 27.6
Lock-up control valve spríng C 0.8 (0.03) 6.6 (0.26) 50.6 (1.99) 24.6
Lock-up control valve spring D 0.8 (0.03) 6.6 (0.26) 50.6 (1.99) 24.6
Lock-up control valve spring E 0.8 (0.03) 6.6 (0.26) 50.6 ( 1.99) 24.6
Governor cut valve spring 0.8 (0.03) 7.6 (0.30) 44.5(1.75) 17
CPC valve spríng A 0.8 (0.03) 8.4 (0.33) 25.5 (1.00) 8.1
CPC valve spríng B 0.8 (0.03) 8.4 (0.33) 25.5 (1.00) 8.1
Reversecontrol valve spríng 0.7 (0.03) 7.1 (0.28) 40 (1.57) 20.8
3- 2 tímíng valve spríng 1.2 (0.05) 8.6 (0.34) 46.9 (1.85) 15.2
3-2 kick-down spríng 1.3 (0.05) 8.6 (0.34) 45.6 (1.80) 17
Servo control valve spríng 0.9 (0.04) 6.4 (0.25) 34.1 (1.34) 17.5
2-1 timing valve spring 0.7 (0.03) 5.6 (0.22) 33 (1.30) 21. 7
4th exhaust valve spring 0.9 (0.04) 6.6 (0.26) 43.3 (1. 70) 22
(cont'd)
3-28
- 2WDA ut orna t"re T ransnussron M24A ( con t'd) - sec t",on 14
E
Unit of length: mm (in}
STANDARD(NEW)
MEASUREMENT
Wire Dia. O.D. Free Length No. of Coils
D16A8 Regulator valve spring B 1.8 (0.07) 9.6 (0.38) 44.0 (1.73) 7.5
Stator reaction spring 5.5 (0.22) 26.4 (1.04) 30.3 (1.19) 2.1
Torque converter check valve spring 1.1 (0.04) 8.4 (0.33) 33.8 (1.33) 12.5
Modulator valve spring 1.2 (0.05) 7.0 (0.28) 27.6 (1.09) 7.7
Relief valve spring 1.1 (0.04) 8.6 (0.34) 37.1 (1.46) 13.4
Cooler check valve spring 1.1 (0.04) 8.4 (0.33) 33.8 (1.33) 12.5
Governor spring A 1.0 (0.04} 18.8 (0.74) 18.0 (0.71) 4.0
Governor spring B 0.8 (0.03) 11.8 (0.47) 30.0 (1.18) 6.3
0.8 (0.03) 11.8 (0.47) 34.4 (1.35) 6.3
0.8 (0.03) 11.8 (0.47) 30.9 ( 1.22) 6.0
2- 3 orífice control valve spring 1.0 (0.04) 6.6 (0.26) 29.9 (1.18) 14.7
4-3 kick-down valve spring 1.0 (0.04) 6.6 (0.26) 29.9 (1.18) 14.7
2/3-4 orifice control valve spring 1.0 (0.04) 8.6 (0.34) 52.2 (2.06) 18.2
Throttle valve adjust spring B 0.8 (0.03) 6.2 (0.24) 30 (1.18) 8
Throttle valve adjust spring A 0.8 (0.03) 6.2 (0.24) 27 (1.06) 8.5
Throttle valve spring B 1.4 (0.06) 8.5 (0.33) 41.5 (1.63) 11 .2
Throttle valve spring B 1.4 (0.06) 8.5 (0.33) 41.6(1.64) 12.4
1 - 2 shift valve spring 0.5 (0.02) 6.1 (0.24) 52.0 (2.05) 18.8
1 - 2 shift valve ball spring 0.45 (0.018) 4.5 (0.18) 10.7 (0.42) 12.7
3-4 shift valve spring 0.8 (0.03) 9.6 (0.38} 27.1 (1.07} 7.8
1 st-hold accumulator spring 4.0 (0.16) 21.5 (0.85) 71. 7 (2.82) 8.3
1 st accumulator spring 2.6 (0.10) 24.3 (0.96) 79.8 (3.14) 8.5
2nd accumulator spring 3.5 (0.14) 22 (0.87) 75.4 (2.97) 8.7
3rd accumulator spring 2.9 (O. 11) 17.5 (0.69) 81.5 (3.21) 13.9
4th accumulator spring 2.8 (0.11) 16 (0.63) 85.0 (3.35) 15.8
Lock-up shift valve spring 0.9 (0.04) 7.6 (0.30) 73.7 (2.90) 32
Lock-up timing valve spring 0.7 (0.03) 6.6 (0.26) 64.3 (2.53) 22.4
Lock-up control valva spring C 0.8 (0.03) 6.6 (0.26) 50.6 (1.99) 24.6
Lock-up control valve spring D 0.8 (0.03) 6.6 (0.26) 50.6 ( 1.99) 24.6
Lock-up control valve spring E 0.8 (0.03) 6.6 (0.26) 50.6 (1.99) 24.6
Governor cut valva spring 0.8 (0.03) 7.6 (0.30) 44.5 (1.75) 17
CPC valve spring A 0.8 (0.03) 8.4 (0.33) 25.5 (1.00) 8.1
CPC valve spring B 0.8 (0.03) 8.4 (0.33) 25.5 (1.00) 8.1
Reversecontrol valve spring 0.7 (0.03) 7.1 (0.28) 40 (1.57) 20.8
3-2 timing valve spring 1.2 (0.05) 8.6 (0.34) 46.9 (1.85) 15.2
3-2 kick-down spring 1.3 (0.05) 8.6 (0.34) 45.6 (1.80) 17
Servo control valve spring 0.9 (0.04) 6.4 (0.25) 34.1 (1.34) 17.5
2-1 timing valva spring 0.7 (0.03) 5.6 (0.22) 33 (1 .30) 21.7
4th exhaust valve spring 0.9 (0.04) 6.6 (0.26) 43.3 ( 1. 70) 22
(cont'd)
3-29
- 4WDA u t orna f re T ransmrssron M25A - Secfon
I 14
MEASUREMENT STANDARD(NEW) SERVICELIMIT
1
Transmis- Capacity e (US qt. lmp qt) 6.4 (6.8, 5.6) for overhaul
sion fluid 3.2 (3.4, 2.8) for fluid change
pressure 2nd clutch pressure at 2,000 min-1 (rpm) 04 500 (5.0, 71) 450 (4.5, 61)
(kg/cm2, closed
1
850-900 (8.5-9.0, 121-128) 1
throttle more than 3/8 opened 800 (8.0, 114)
than 3/8 opened
2nd clutch pressure at 2,000 min-1 (rpm) 2 850-900 (8.5-9.0, 121-128) 800 (B.O, 114)
1st clutch pressure at 2,000 min-1 (rpm) 04 or 1 850-900 (8.5-9.0, 121-128) 800 (8.0, 114)
1st-hold clutch pressure at 2,000 min-1 (rpm) 1 850-900 (8.5-9.0, 121-128) 800 (8.0, 114)
Stall speed min-1 (rpm) (check with car on level ground) 2,300-2,900 --
Clutch Clutch initial clearance 1 st. 2nd 0.65-0.85 (0.026-0.033) --
3rd, 4th 0.40-0.60 (0.016-0.024) --
1st-hold 0.5-0.8 (0.02-0.03) --
2nd, 3rd, 4th 30.5 (1.20) 28.5 (1.12)
1 st-hold 34.6 (1.36) 32.6 (1.28)
Clutch disc thickness 1 .88-2.00 (0.074-0.079) Until grooves
worn out
Cfutch plate thickness 1 st 1.55-1.65 (0.061-0.065) Discoforation
Except 1st 1.95-2.05 (0.077-0.081) Oiscoloration
Clutch end plate thickness MARK 1 2.3-2.4 (0.091-0.094) Oiscoloration
(except 1 st-hold) MARK 2 2.4-2.5 (0.094-0.098) ••
MARK 3 2.5-2.6 (0.098-0.102)
MARK 4 2.6-2.7 (0.102-0.106)
MARK 5 2.7-2.8 (0.106-0.110)
MARK 6 2.8-2.9 (0.110-0.114)
MARK 7 2.9-3.0 (O. 114-0. 118)
MARK 8 3.0-3. 1 (O. 118-0. 122)
MARK 9 3.1-3.2 (0.122-0.126)
MARK 10 3.2-3.3 (0.126-0. 130)
MARK 11 2.0-2.1 (0.079-0.083)
MARK 12 2.1-2.2 (0.083-0.087) 1,
MARK 13 2.2-2.3 (0.087-0.091) Oiscoloration
I
Clutch end plate thickness MARK 1 2.05-2.10 (0.081-0.083) Oiscoloration
(1 st-holdl MARK 2 2.15-2.20 (0.085-0.087)
MARK 3 2.25-2.30 (0.089-0.091)
MARK 4 2.35-2.40 (0.093-0.094)
NO MARK 2.45-2.50 (0.096-0.098)
MARK 6 2.55-2.60 (0.100-0.102)
MARK 7 2.65-2. 70 (0.104-0.106) Discoloration
(cont'd)
3-30
- 4WD Automatic Transmlsslon
Trans-
MEASUREMENT
M25A (cont'd) - Sect,on 14
Diameter of needle bearing contact area

STANDARD(NEW)
•
SERVICE LIMIT
mission On mainshaft and stator shaft 19.980-19.993 (0.7866-0.7871) Wear or damage

On countershaft (L. side) 36.004-36.017 (1.4175-1.4180)
On countershaft 3rd gear distance collar 31.975-31.991 ( 1.2589-1.2595)
On countershaft reverse gear collar 29.980-29.993 (1.1803-1.1808)
On countershaft 1 st gear collar 31.975-31.991 (1.2589-1.2595)
On subshaft (L. side) 27.991-28.000 (1.1020-1.1024)
On subshaft 4th gear collar 29.980-29.993 (1.1803-1.1808)
On reverse idler gear shaft 13.990-14.000 (0.5508-0.5512) Wear or damage
On mainshaft 1 st gear 36.000-36.016 (1.4173-1.4179) Wear or damage
On mainshaft 4th gear 38.000-38.016 (1.4961-1.4967)
On countershaft 1 st gear 38.000-38.016 (1.4961 -1.4967)
On countershaft 3rd gear 38.000-38.016 (1.4961-1.6967)
On countershaft 4th gear 33.000-33.016 ( 1.2992-1.2998)
On countershaft reverse gear 36.000-36.016 (1.4173-1.4179)
On subshaft 4th gear 35.000-35.016 (1.3780-1.3786)
On reverse idler gear 18.007-18.020 (0.7089-0.7094)
On stator shaft (R. side) 26.000-26.013 ( 1.0236-1.0241)
On stator shaft (stator side) 24.000-24.021 (0.9449-0.9457) ·~
On reverse idler shaft holder 14.416-14.434 (0.5676-0.5683) Wear or damage
End play
Mainshaft 1 st gear 0.08-0.24 (0.003-0.009) --
Mainshaft 2nd gear 0.07-0.15 (0.003-0.006) --
Mainshaft 4th gear 0-0.08 (0-0.003) --
Countershaft 1 st gear 0.1-0.45 (0.004-0.018) --
Countershaft 3rd gear 0.07-0. 15 (0.003-0.006) --
Countershaft 4th gear 0.07-0.15 (0.003-0.006) --
Reverseidler gear 0.05-0.18 (0.002-0.007) --
Countershaft reverse gear 0.1-0.45 (0.004-0.018) --
Selector hub 0.D. 51.87-51.90 (2.042-2.043) Wear or damage
Mainshaft 4th gear collar length 46.50-46.53 (1.8307-1.8319) --
Mainshaft 1 st gear collar length 24.50-24.55 (0.9646-0.9665) --
Countershaft distance collar length 38.97-39.00 (1.534-1.535) --
39.02-39.05 (1.536-1.537) --
39.07-39.10 (1.538-1.539) --
39.12-39.15 (1.540-1.541) --
39.17-39.20 (1.542-1.543) --
39.22-39.25 (1.544-1.545) --
39.27-39.30 (1.546-1.547) --
38.87-38.90 (1.530-1.531 l --
38.92-38.95 (1.532-1.533) --
Countershaft 1 st gear collar flange thickness 2.45-2.55 (0.096-0.100) Wear or damage
Subshaft 4th gear collar length 24.0-24.1 (0.945-0.949) Wear or damage
Subshaft 4th gear collar length of needle bearing
contact area 21.0-21.1 (0.8268-0.8307) Wear or damage
(cont'd)
3-31
~ 4WDA ut ornafre T ransrmssron M25A ( cont'd) - secf ion 14
Trans- Mainshaft 2nd gear thrust washer thickness 3.47-3.50 (0.137-0.138) Wear or damage
mission 3.52-3.55 (0.139-0.140)
(cont'd) 3.57-3.60 (0.141-0.142)
3.62-3.65 (0.143-0.144)
3.67-3.70 (0.145-0.146)
3.72-3.75 (0.147-0.148)
3.77-3.80 (0.148-0.150)
3.82-3.85 (0.151-0.152)
3.87-3.90 (0.153-0.154) Wear or damage
t
Mainshaft ball bearing L. side 2.95-3.05 (0.1161-0.1201)
Mainshaft 1 st gear L. side 1.45-1.50 (0.057-0.057)
Mainshaft 1st gear R. side 2.43-2.50 (0.096-0.098) Wear or damage
·~
2.92-2.95 (0.115-0. 116)
2.97-3.00 (0.117-0.118)
3.02-3.05 (O. 119-0. 120)
3.07-3.10 (0.121-0.122)
3.12-3. 15 (0.123-0.124)
3.17-3.20 (0.125-0.126)
3.22-3.25 (0.127-0.128)
3.27-3.30 (0.129-0.130)
,.
r
3.32-3.35 (0.131-0.132)
3.37-3.40 (0.133-0.134) Wear or damage
Mainshaft 4th gear thrust washer thickness 2.93-3.00 (0.115-0.118) Wear damage
One-way clutch contact area I.D.
Parking gear 66.685-66.698 (2.6254-2.6259) Wear or damage
Mainshaft feed pipe A, O.D. 8.97-8.98 (0.353-0.354) 8.95 (0.352)
Mainshaft feed pipe B, O.D. 5.97-5.98 (0.2350-0.2354) 5.95 (0.234)
Countershaft feed pipe O.D 7.97-7.98 (0.3138-0.3142) 7.95 (9.313)
Subshaft feed pipe O.D. 5.97-5.98 (0.2350-0.2354) 5.95 (0.2343)
Countershaft bushing I.D. 8.000-8.015 (0.3150-0.3156) 8.030 (0.3161)
Subshaft bushing I.D. 6.018-6.030 (0.2369-0.2374) 6.045 (0.2380)
Regulator Sealing ring contact 1.0. 35.000-35.025 (1.3780-1.3782) 35.050 (1.3799)
valva body 32.000-32.025 ( 1. 2598-1.2608) 32.05 (1.262)
device and Parking brake ratchet pawl -- Wear or
parking Parking brake gear -- other defect
brakecontrol Throttle cam stopper height 27.0-27.1 (1.063-1.067) --
Servo body Shift fork shaft bore 1.0. A 14.000-14.005 (0.5512-0.5514) --
B 14.006-14.010 (0.5514-0.5516)
e 14.011-14.015 (0.5516-0.5518)
Shift fork shaft valve bore 1.0. 37.000-37.039 (1.4567-1.4582) 37 .045 ( 1 :4585)
Oil pump Oil pump gear side clearance 0.03-0.05 (0.001 -0.002) 0.07 (0.003)
Oil purnp gear-to-body clearance Orive 0.240-0.266 (0.009-0.010) --
Driven 0.063-0.088 (0.002-0.003) --
pil pump driven gear 1.0. 14.016-14.034 (0.5518-0.5525) Wear or damage
(cont'dl
3-32
- 4WDA ut oma feI Trans rmlsslIO n M25A (cont'd) - sec1on
ti 14
STANDARD(NEW)
MEASUREMENT
Wire Dia. 0.D. Free Length No. of Coils
Regulator valve spring B 1.8 (0.07) 9.6 (0.38) 44.0 (1.73) 7.5
Stator reaction spring 5.5 (0.22) 31.9 (1.26) 30.3(1.19) 2.1
Torque converter check valve spring 1.1 (0.04) 8.4 (0.33) 36.4 (1.43) 12
Relief valve spring 1.0 (0.04) 8.4 (0.33) 52.0 (2.05) 23
2nd orifice control valve spring 0.8 (0.03) 6.6 (0.26) 38.5 (1.52) 28
Servo orifice control valve spring 0.9 (0.04) 6.1 (0.24) 35.9 (1.41) 20
Throttle control valve B spring 1.6 (0.06) 8.5 (0.33) 41.3(1.63) 13.9
ThrottlecontrolvalveB adjusterspring 0.8 (0.03) 6.2 (0.24) 30.0(1.18) 8
1 - 2 shift spring 0.9 (0.04) 8.6 (0.34) 40.4 (1.59) 14.5
2-3 shift spring 0.8 (0.03) 8.6 (0.34) 35.8(1.41) 10.6
3-4 shift spring 0.8 (0.03) 7.6 (0.30) 59.7 (2.35) 22.7
1 st accumulator A spring 2.0 (0.08) 13.7(0.54) 71.3(2.81) 11.0 and 8.0
1 st accumulator B spring 3.2 (0.13) 24.3 (0.96) 59.5 (2.34) 5.8
4th accumulator spring 3.5 (O. 14) 18.6 (O. 73) 77.0 (3.03) 11
2nd accumulator spring 2.7 (0.11) 16.1 (0.63) 88.4 (3.48) 16.0
3rd accumulator spring 2.8 (O.111 15.5 (0.61) 78.7 (3.1 O) 15
L/C control springs 0.8 (0.03) 6.6 (0.26) 47.9 (1.89) 25.1
L/C timing valve B spring 0.9 (0.04) 5.6 (0.22) 43.6 (1.72) 30.1
CPC valve spring 1.4 (0.06) 9.4 (0.37) 31.6 (1.24) 10.9
L/C shift valve spring 1.1 (0.04) 8.1 (0.32) 51.0 (2.01) 21.3
4-2 kick down valve spring 0.9 (0.04) 6.4 (0.25) 42.7 (1.68) 20.8
Cooler relief valve spring 1.1 (0.04) 8.4 (0.33) 36.4(1.43) 12
Modulator valve springs A and B 0.9 (0.04) 8.6 (0.34) 18.2 (0.72) 5.54
Servo control valve spring 1.0 (0.04) 8.1 (0.32) 42.0 (1.65) 16.5
4th exhaust valve spring 0.9 (0.04) 6.6 (0.26) 37.0 (1.46) 18. 7
4-3 kick down valve spring 0.9 (0.04) 6.4 (0.25) 42.7 (1.68) 20.8
3-33
~ 1 erenf,a1 2WD M/T 820
D"ff - S ectiion 15
MEASUREMENT STANDARD INEW) SERVICE LIMIT
Ring gear Backlash 0.07-0.130 (0.0028-0.0051) o. 180 (0.0071)
Differential Pinion shaft bore diameter 18.000-18.018 (O. 7087-0. 7094) --
carrier Carrier-to-pinion shaft clearance 0.013-0.047 (0.0005-0.0019) 0.095 (0.004)
Drivershaft bore diameter 26.025- 26.045 ( 1.0246-1.0254) --
28.025-28.045 (1.1033-1.1041) --
Carrier-to-driveshaft clearance 0.045-0.086 (0.0018-0.0034) o. 14 (0.006)
Differential Backlash 0.05-0.15 (0.002-0.006) --
pinion gear Pinion gear bore diameter 18.042-18.066 (O. 7103-0. 7113) --
Pinion gear-to-pinion shaft clearance 0.055-0.095 (0.0021-0.0037) 0.150 (0.0059)
Set ring-to-bearing outer race 0-0.1 10-0.004) --
~ 1 erentl,a1 2WD M/T Y21

D"ff - Secti,on 15
Ring gear Backlash 0.085-0.142 (0.003-0.006) 0.200 (0.008)
Differential Pinion shaft bore diameter 18.000-18.016 (0.7087-0.7093) --
carrier Carrier-to-pinion shaft clearance 0.017-0.045 (0.001 -0.002) 0.100 (0.004)
Drivershaft bore diameter 28.000-28.021 (1.102-1.103) --
Carrier-to-driveshaft clearance 0.020-0.062 (0.001 -0.002) o. 120 (0.005)
Differential Backlash 0.05-0. 15 (0.002-0.006) --
pinion gear Pinion gear bore diameter 18.042-18.066 (O. 710-0. 711) --
Pinion gear-to-pinion shaft clearance 0.059-0.095 (0.002-0.004) o. 150 (0.006)
Set ring-to-bearing outer race 0-0.1 (0-0.0041 --
~ D"ff
1 erentira 1 2WD A/T M48A - Secti,on 15
MEASUREMENT STANDARD INEW) SERVICE LIMIT
Ring gear Backlash 0.082-0.137 (0.0032-0.0054) 0.2 (0.0079)
Differential Pinion shaft bore diameter 15.000-15.018 (0.5906-0.5913) --
Carrier-to-driveshaft clearance 0.025-0.063 (0.0010-0.0026) o. 1 2 (0.005)
pinion gear Pinion gear bore diameter 15.041-15.061 (0.5922-0.5930) --
Pinion gear··to-pinion shaft clearance 0.057-0.095 (0.0022-0.0037) o. 1 5 (0.006)
Set ring-to-bearing outer race 0-0.15 (0-0.006) Adjust with shim
3-34
- 1 eren tira 1 2WD A/T M24A -
D"ff
Final driven Backlash

MEASUREMENT
sectiion 15
0.071-0.129
STANDARD (NEW)
(0.0028-0.0051)
•
SERVICE LIMIT
--
gear
Differential Pinion shaft contact area I.D. 18.000-18.018 (15.8382-15.8540) --
carrier Carrier-to-pinion clearance 0.016-0.052 (0.0006-0.0024) 0.10 (0.004)
Drivershaft contact area I.D. 28.005-28.025 (1.1026-1.1033) --
Carrier-to-driveshaft clearance 0.025-0.066 (0.0010-0.0026) 0.12 (0.005)
Ball bearing contact area O.O. 40.002-40.018 ( 1.5749-1.5755) --
pinion gear 1.0. 18.042-18.066 (0.7103-0.7113) --
Pinion gear-to-pinion shaft clearance 0.059-0.095 (0.0023-0.0037) o. 1 5 (0.006)
Set ring-to-bearing outer race 0-0. 1 5 (0-0.006) Adjust with shim
- F ron t D"ff
1 eren t"ra l 4WD T ransrmssron - sec f ion 15
Ring gear Backlash 0.071-0.129 (0.0030-0.0050) --
Differential Pinion shaft bore diameter 18.000-18.018 (O. 7087-0. 7094) --
Carrier-to-driveshaft clearance 0.025-0.006 (0.0010-0.0026) 0.12 (0.005)
Ball bearing bore diameter 40.002-40.018 (1.5749-1.5755) --
· Differential Backlash 0.05-0.15 (0.002-0.006) Adjust with pinion
pinion gear washers
Pinion gear bore diamteter 18.042-18.066 (0.7103-0.7112) --
Pinion gear-to-pinion shaft clearance 0.059-0.095 (0.0023-0.0037) o. 1 5 (0.006)
- Rear D"ff
1 eren tiia14WD T ransrmesron w1ith ou t ABS - sectlion 15
Differential Oil capacity Replace 0.65 e (0.69 us. qt., 0.57 lmp.qtl --
carrier Disassemble o. 70 e (O. 74 us. qt., 0.62 Imp. qt) --
assembly
Differential Diameter of taper bearing contact area
carrier Front drive pinion bearing 57.979-58.009 (2.2826-2.2838) 58.06 (2.286)
Rear drive pinion bearing 71.979- 72.009 (2.8338-2.8350) 72.06 (2.837)
Side bearing 68.000-68.030 (2.6772-2.6783) 68.08 (2.680)
Differential Diameter of diff. pinion shaft contact a rea 18.000-18.018 (O. 7087-0. 7094) --
case Case-to-diff. pinion shaft 0.016-0.052 (0.0006-0.0020) 0.1 (0.004)
Diameter of drive shaft contact area 26.005-26.025 (1.0236-1.0246) --
Case-to-drive shaft clearance 0.025-0.066 (0.0010-0.0026) 0.12 (0.005)
Diameter of taper bearing contact area 40.002-40.018 (1.5749-1.5755) 39.95 (1.573)
Differential Backlash 0.05-0.15 (0.002-0.006) Adjust with washer
pinion gear I.D. 18.042-18.066 (O. 7103-0. 7113) --
Gear-to-pinion shaft clearance 0.059-0.095 (0.0022-0.0037) o. 1 5 (0.006)
Hypoid Backlash 0.11 -0. 16 (0.004-0.006) Adjust with a shim
drive pinion Diameter of taper bearing contact area
gear Front pinion bearing 27.987-28.000 (1.1018-1. 1024) 27.93 (1.100)
Rear pinion bearing 30.002-30.018 (1.1812-1.1818) 29.95 (1.179)
3-35
- Rear Dlff
1 erentira14WD Transrmssron w1lth ABS - sectlion 15
Clutch Fluid Capacity Disassembly 0.31 i (0.33 US. qt., 0.27 Imp. qt)
housing
Differential Oil capacity Replace o.93 e (0.98 us. qt., 0.82 Imp. qt) --
carrier Disassembly 1.00 e (1.06 us. qt., 0.88 Imp. qt) --
assembly
Hypoid Backlash o. 10-0. 15 (0.004-0.006) Adjust with shirn
drive pinion
gear
2-4 shift Fork projection width far 2-4 sleeve groove 6.8-6.9 (0.268-0.272) --
fark
Clearance of clutch hub to clutch peace 0.05-0.25 (0.002-0.100) max --
Preroad of hypoid drive pinion N•m (kg-m, lb-ft) 98-160 (10.0-16.3, 22-36) --
Total preroadof hypoiddrivepinionand bisccouscouplingunit
N•m (kg-m, lb-ft) 109-175 (11.1-17.8, 25-39) --
- St eermg - secti,on 17
MEASUREMENT STANDARD (NEWI
Steering Play at steering wheel circumference 0-1 O (0-0.39)
wheel Starting load at steering wheel circumference
N (kg, lb)
Manual steering 13-18 (1.3-1.8, 2.87-3.97)
Power steering Engine running 30 (3.0, 6.6)
25 (2.5, 5,5)
Gearbox Angle of rack-huide-screw loosened M/S 50° ± 10º
from locked position P/S LHD 20° ~ g:
RHD 25° max.
Preload at pinion gear shaft N•m (kg-cm, lb-in) M/S 0.5-1.7 (5-17, 4.3-14.B)
P/S 0.6-1.1 (6-11, 5.21-9.55)
Pump Pump pressure with valve closed LHD 8,000-9,000 (80-90, 1, 138-1,280)
(oil temp./speed: 40ºC (105ºF) min./idle. RHD 5,500-6,500 (55-65, 398-470)
Do not run far more than 5 seconds).
kPa (kg/cm2, psi)
Power Recommended power steering fluid HONDA Power Steering Fluid-V
steering Fluid capacity System LHD 1.1 (1.16, 0.97)
fluid e IUS qt, lmp qt) RHD 1.0 (1.06, 0.88)
Reservoir 0.4 (0.42, 0.35)
Power Deflection with 100 N ( 1 O kg, 22 lb) 8.0-12.0 (0.31-0.47) with used belt
steering between pulleys Except D16A8, D16A9 6.0-9.5 (0.24-0.37) with new belt
belt D16A8, D16A9 5.5-9.0 (0.22-0.35) with new belt
Tension measured with belt tension gauge 350-500 (35-50, 77-110) with used belt
N (kg, lb) Except D 16A8, D 16A9 500-700 (50-70, 110-154) with new belt
D16A8, D16A9 550-750 (55-75, 121-165) with new belt
M/S: manual steering, P/S: Power steering.
3-36
- suspens1on - sec tiion 18
E

Wheel B16A2 Camber Front -0°05' ± 1o --
alignment Rear -0°25' ± 1° --
Caster Front 1 ° 1 O' ± 1 ° --
Total toe Front O± 3.0 (O± 0.12) --
Rear 2.0 : ~, (0.08 : 1 g:g: --
Front wheel lnward wheel 36°03' --
Turning angle Outward wheel 30°37' --
Except 816A2 (2WD)
Camber ~ Front 0°00' ± 1 ° --
Rear -0°20' ± 1° --
Caster Front 1 ° 1 O' ± 1 ° --
Total toe Front O± 3.0 (O± 0.12) --
Rear 2.0 : f
(0.08 : g::) --
4WD Camber Front 0° 15' ± 1º --
Rear -0°25' ± 1° --
Caster Front 1 °05' ± 1° --
Total toe Front O ± 3.0 (O ± O. 12) --
Rear
without ABS 2.0 : f (0.08 : g:g:) --
with ABS O : 1 (O : g:g¿) --
Wheel Rim runout Aluminum wheel Axial 0-0.7 (0-0.028) --
Radial 0-0. 7 (0-0.028) --
Steel wheel Axial 0-1.0 (0-0.039) --
Radial 0-1.0 (0-0.039) --
Wheel End play Front o 0.05 (0.002)
bearing Rear o 0.05 (0.002)
3-37
- B rakes - sectlion 19
Parking Play in stroke at 200 N (20 kg, 44 lb) lever force To be locked when pulled --
brakelever 6-1 O notches
Foot brake Pedal height (with floor mat removed) A/T 160 (6.30) --
pedal M/T 165 (6.50) --
Free play 1-5 (0.04-0.20) --
Master Piston-to-pushrod clearance 0-0.4 (0-0.016) --
cylinder
Disc brake Disc thickness Front 21 .o (0.83) 19.0 (0.75)
O 1 38 30 except KQ 17.0 (0.67) 15.0 (0.59)
Rear 9.0 (0.35) 8.0 (0.31)
Oisc runout Front -- o. 1 O (0.004)
Rear -- o. 1 O (0.004)
Oisc parallelism Front and rear -- 0.015 (0.0006)
Front O 1 38 30 except KO 9.5 (0.37) 1.6 (0.06)
81 6A2, O 1627 (4WO) 10.0 (0.39) 1.6 (0.06)
Others 9.0 (0.35) 1.6 (0.06)
Rear 7.5 (0.03) 1.6 (0.06)
Rear brake 1.0. 4WO 200 (7.87) 201 (7.91)
drum 2WO 180 (7.09) 181 (7.13)
Lining thickness 2WO 4.5 (0.18) 2.0 (0.08)
4WO 4.0 (0.16) 2.0 (0.08)
Brake Characteristicsat 200 N (20 kg, 44 lb) pedalforce. Vacuum mmHg (inHg) Line pressure kPa (kg/cm2, psi)
booster 01627 (4WO) O (O) 1 31 ( 13. 1, 186)
without A8S 300 (11.8) 546 (54.6, 776)
500 (19. 7) 830 (83.0, 1. 180)
816A2 O (O) 131 ( 13. 1, 186)
without A8S 300 (11.8) 546 (54.6, 776)
500(19.7) 765 (76.5, 1,088)
016Z7 (4WO) and O (O) 92 (9.2, 131)
816A2 with A8S 300 (11.8) 557 (55. 7, 792)
500 (19.7) 874 (87.4, 1,243)
0138 30 O (O) 152 (15.2, 216)
300 (11.8) 531 (53.1, 755)
500 (19.7) 788 (78.8, 1, 1 20)
Others O (O) 152 (15.2, 216)
300 (11 .8) 638 (63.8, 907)
500 (19.7) 887 (88.7, 1,261)
3-38
~ A"1r C on dltl
1 1oner - sect"ion 22
STANDARD (NEW)
MEASUREMENT
MATSUSHITA NIPPONDENSO SAN DEN
Air candi- Lubricant capacity Condenser 15 ( 1 /2) 15 ( 1 /21 20 (2/31
tioner ce (ti oz) Evaprorator 35 (1-1/6) 35 (1·1/61 45 (1-1/2)
system Une or hose 10 (1/3) 10 (1/3) 10 (1/3)
Receiver 1 O ( 1 /3) 10 (1/3) 10 (1/3)
Com- Lubricant capacity 140-150 60-100 120-140
pressor cc(US oz, lmp oz) (4.73-5.07, 4.93-5.28) (2.03-3.38, 2.11-3.52) (4.06-4.73, 4.22-4.93)
Stator coil resistance 3.16-3.50 3.4-3.8 2.65-2.95
at 20°C (68ºFl O
Pulley-to-pressureplate clearance 0.4-0.6 0.35-0.65 0.35-0.65
0.016-0.024) (0.014-0.026) (0.014-0.026)
Compres- Deflection with 100 N ( 1 O kg, 22 lb) 6.5-10.5 (0.26-0.41) with used belt
sor belt between pulleys 5.0- 7.0 (0.20-0.28) with new belt
Tension measured with belt tension 350- 500 (35- 50, 77-11 O) with used belt
gauge N (kg, lb) 600-800 (60-80, 132-1761 with new belt
3-39
...- Electrical - Se ef ion 23
lgnition Rated voltage V 12
coil
0128, 0138,01583,01584 01582,D15Z, 0162, D16A, 816A
Primary winding resistance íl at 25ºC (77ºF) 0.5-0.7 0.6-0.8
Secondary winding resistancekíl at 25ºC (77ºF) 14.4-21.6 12.9-19.3
Spark Type See Section 23
plug Gap 1.1 (0.43)
lgnition At idling 0
8TDC D1281 (AIT): 22 ° (Red) 8TDC
timing 01583 (AIT): 12° (Red) 8TDC
D138, 01583 (MIT), 01584: 20º (Red) BTDC
Others: 16° (Red) 8TDC
Alternator Deflection with 100 N ( 1 O kg, 22 lb) 7.0-10.5 (0.28-0.41) with used belt
belt between pulleys Except B16A 5.5-8.0 (0.22-0.31) with new belt
B16A2 5.0- 7.0 (0.20-0.28) with new belt
Tension measuredwith belt tension gauge 350-550 (35-50, 77-110) with used belt
N (kg, lb) Except 816A 550- 750 (55- 75, 121-165) with new belt
816A2 700-900 (79-90, 154-198) with new belt
Alternator Output 13. 5 V at hot A 70
(NIPPON- Coil resistance (rotor) o 2.9 --
DENSO) Slip ring 0.D. 14.4 (0.567) 14.0 (0.551)
8rush length 10.5 (0.41) 5.5 (0.22)
8rush spring tension g (oz) 330 (11.6) --
Alternator Output 13.5 V at hot A 70
(MITSUBISHI) Coil resistance (rotor) o 3.4-3.8 --
Slip ring O.O. 22.7 (0.89) 22.2 (0.87)
8rush length 22.0 (0.87) 8.0 (0.31)
8rush spring tension g (oz) 300-450 (10.6-15.9) --
Alternator Output 13.5 V at hot A 80
(NIPPON- Coil resistance (rotor) o 2.8-3.0 --
DENSO) Slip ring O.O. 14.4 (0.567) 14.0 (0.551)
8rush length 10.5 (0.41) 5.5 (0.22)
8rush spring tension g (oz) 300-360 (10.6-12.7) --
Starter Type Direct drive
motor Mica depth 0.5-0.8 (0.020-0.031) 0.2 (0.008)
(HITACHI Commutator runout 0-0. 1 (0-0.004) 0.4 (0.016)
0.8 kW) Commutator O.O. 40.0 (1.574) 39.0 (1.535)
8rush length 14.5-15.5 (0.57-0.61) 11.0 (0.43)
8rush spring tension (new) N (kg, lb) 13(1.3,2.9) --
Starter Type Gear reduction
motor Mica depth 0.4-0.5 (0.016-0.020) o. 1 5 (0.006)
(MITSUBA) Commutator runout 0-0.02 (0-0.001) 0.05 (0.002)
1.0 kW, Commutator O.O. 28.0-28.1 (1.102-1.106) 27.5 (1.083)
1.2 kW, 8rush length 14.3-14. 7 (0.56-0.58) 9.3 (0.37)
1.4 kW) 8rush spring tension (new) N (kg, lb) 1.0, 1.2 kW 18.5-23.5 (1.85-2.35, 4.1-5.2) --
1.4 kW 16-18 (1.6-1.8, 3.5-4.0) --
Starter Type Gear reduction
motor, Mica depth 0.5-0.8 (0.020-0.031) 0.2 (0.008)
(MIPPON- Commutator runout 0-0.02 (0-0.001) 0.05 (0.002)
DENSO Commutator O.O. 29.9-30.0 (1.177-1.181) 29.0 (1.14)
1.0 kW, 8rush length 13.0-13.5 (0.51-0.53) 8.5 (0.33)
1.2 KW) 8rush spring tension (new) N (kg,lb) 1.0 kW 17.85-24.15 (1.5-2.415, 3.9-5.3) --
1.2 kW 14.0-20.0 ( 1.4-2.0, 3. 1-4.4) --
3-40
Design Specifications
ITEMS METRIC ENGLISH NOTES
OIMENSIONS Overall length 4,080 mm 160.6 in

20 H/B 4,090 mm 161.0in For Finland only
4,070 mm 160.2 in KQ
4,075 mm 160.4 in KV
Overall width 1,695 mm 66.7 in
Overall height 1,345 mm 53.0 in
Wheelbase 2,570 mm 101.2in
Track Front 1,475 mm 58.1 in
Rear 1.465 mm 57.8 in
Ground clearance 160 mm 6.3 in
150 mm 5.9 in Models with CATA.
except VEi
Seating capacity Except VTi Five (5)
VTi Four (4)
OIMENSIONS Overall length 4,405 mm 173.4 in
40 4,415 mm 173.8 in For Finnish model
4,395 mm 173.0 in KQ
Overall width 1,695 mm 66.7 in
Overall height 1,375 mm 54.1 in 2WD
1,395 mm 54.9 in 4WO
Wheelbase 2,620 mm 103.1 in
Track Front 1,475 mm 58.1 in
Rear 2WO 1,465 mm 57.8 in
4WO 1,455 mm 57.3 in
Ground clearance 160 mm 6.3 in
150 mm 5.9 in Models with CATA.
Seating capacity Except VTi Five (5)
VTi Four {4)
(cont'd)
3-41
WEIGHT Curb weight DX M/T 925 kg 2,039 lb KG,KF,KE
20 H/8 930 kg 2,050 lb KS
ex M/T 970 kg 2, 138 lb KQ
EX M/T 940 kg 2,072 lb KP
1,008 kg 2,222 lb KY
A/T 960 kg 2,1161b KP
1,028 kg 2,266 lb KY
GL M/T 970 kg 2, 138 lb KQ
A/T 1,001 kg 2,207 lb KQ
O Xi M/T 935 kg 2,061 lb KG
A/T 965 kg 2, 127 lb KG
LSi M/T 950 kg 2,094 lb KG, KF, KE
955 kg 2, 105 lb KS
A/T 980 kg 2, 161 lb KG, KF, KE
985 kg 2, 172 lb KS
VEi M/T 935 kg 2,061 lb KG, KE
E Si M/T 985 kg 2, 172 lb KG, KF
1,000 kg 2,205 lb KE
990 kg 2, 183 lb KS
A/T 1,015 kg 2,238 lb KG, KF
1,030 kg 2,271 lb KE
1,020 kg 2,249 lb KS
Si M/T 975 kg 2, 150 lb KP
1,016 kg 2,340 lb KQ
A/T 1,041 kg 2,295 lb KQ
VTi M/T 1,080 kg 2,381 lb KG, KE
1,085 kg 2,392 lb KS
Weight Distribution (Front/Rear)
DX M/T 565/360 kg 1,246/794 lb KG, KF, KE
570/360 kg 1,257/794 lb KS
ex M/T 599/371 kg 1,321/818 lb KQ
EX M/T 580/360 kg 1,279/794 lb KP
624/384 kg 1,376/847 lb KV
A/T 600/360 kg 1,378/794 lb KP
648/380 kg 1,429/838 lb KY
Gl M/T 602/374 kg 1,327/825 lb KQ
A/T 627/374 kg 1,382/825 lb KQ
DXi M/T 570/365 kg 1,257/805 lb KG
A/T 600/365 kg 1,328/805 lb KG
LSi M/T 585/365 kg 1,290/805 lb KG. KF, KE
590/365 kg 1,301/805 lb KS
A/T 615/365 kg 1,356/805 lb KG, KF, KE
620/365 kg 1,367/805 lb KS
VEi M/T 570/365 kg 1,257/805 lb KG,KE
E Si M/T 605/380 kg 1,334/838 lb KG, KF
615/385 kg 1,356/849 lb KE
610/380 kg 1,345/838 lb KS
A/T 635/380 kg 1,400/838 lb KG, KF
645/385 kg 1,422/849 lb KE
640/380 kg 1,411/8381b KS
Si M/T 600/375 kg 1,323/827 lb KP
624/392 kg 1,376/864 lb KQ
A/T 649/392 kg 1 ,431 /864 lb KQ
VTi M/T 680/400 kg 1,499/882 lb KG, KE
685/400 kg 1,510/882 lb KS
Max. Permissible Weight (Ee)
DX 1,370 kg 3,020 lb
EX, VEi, DXi, LSi, VTi 1,460 kg 3,219 lb
ESi, Si 1,500 kg 3,310 lb
3-42
WEIGHT Curb weight 1.5 EL M/T 970 kg 2, 138 lb KP

40 1,017 kg 2,242 lb KY
A/T 990 kg 2, 138 lb KP
1,037 kg 2,286 lb KY
1.5 EX M/T 985 kg 2, 171 lb KP
1,045 kg 2,304 lb KY
A/T 1,005 kg 2,216 lb KP
1,065 kg 2,348 lb KY
GL M/T 1,012kg 2,231 lb KQ
A/T 1,041 kg 2,295 lb KQ
DXi M/T 980 kg 2, 161 lb KG
985 kg 2, 172 lb KS
A/T 1,01 O kg 2,227 lb KG
1,015 kg 2,238 lb KS
LSi M/T 995 kg 2, 194 lb KG. KE
1,000 kg 2,205 lb KS
A/T 1,025 kg 2,260 lb KG, KE
1,030 kg 2,271 lb KS
DX M/T 1,080 kg 2,381 lb KB
A/T 1, 100 kg 2,425 lb KB
EX M/T 1,090 kg 2,403 lb KB
A/T 1, 11 O kg 2,447 lb KB
E Si M/T 1,030 kg 2,271 lb KG. KF, KE
1,035 kg 2,282 lb KS
A/T 1,060 kg 2,337 lb KG. KF, KE
1,065 kg 2,348 lb KS
Si M/T 1,052 kg 2,319 lb KQ
1,090 kg 2,403 lb KY
A/T 1,077 kg 2,374 lb KQ
1, 115 kg 2,458 lb KY
VTi M/T 1, 105 kg 2,436 lb KG, KF
1, 120 kg 2,469 lb KE
1, 11 O kg 2,447 lb KS
RTSi M/T 1, 130 kg 2,491 lb KG
A/T 1, 145 kg 2,524 lb KG
(cont'd)
3-43
ITEM METRIC ENGLISH NOTES
WEIGHT Weight Distribution (Front/Rear)
40 1.5 EL M/T 575/395 kg 1, 268/871 lb KP
625/392 kg 1,378/864 lb KY
A/T 595/395 kg 1,312/871 lb KP
649/388 kg 1,431/855 lb KY
1.5 EX M/T 590/395 kg 1,301/871 lb KP
633/412 kg 1,396/908 lb KY
A/T 610/395 kg 1,345/871 lb KP
657/408 kg 1,448/899 lb KY
GL M/T 610/402 kg 1,345/886 lb KQ
A/T 635/406 kg 1 ,400/895 lb KQ
DXi M/T 580/400 kg 1,279/882 lb KG
585/400 kg 1 , 290/882 lb KS
A/T 610/400 kg 1,345/882 lb KG
615/400 kg 1,356/882 lb KS
LSi M/T 595/400 kg 1,312/882 lb KG, KE
600/400 kg 1,323/882 lb KS
A/T 625/400 kg 1 ,378/882 lb KG, KE
630/400 kg 1,390/882 lb KS
DX M/T 655/425 kg 1,444/937 lb KB
A/T 680/420 kg 1,499/926 lb KB
EX M/T 660/430 kg 1,455/948 lb KB
A/T 685/425 kg 1,510/937 lb KB
E Si M/T 615/415 kg 1,356/915 lb KG, KF, KE
620/415 kg 1,367/915 lb KS
A/T 645/415 kg 1,422/91 5 lb KG, KF, KE
650/415 kg 1,433/915 lb KS
Si M/T 635/417 kg 1,400/91 9 lb KQ
649/441 kg 1,431 /972 lb KY
A/T 660/417 kg 1,455/919 lb KQ
680/435 kg 1,499/959 lb KY
V Ti M/T 675/430 kg 1,488/948 lb KG, KF
685/435 kg 1,510/959 lb KE
680/430 kg 1,499/948 lb KS
RTSi M/T 665/465 kg 1,466/1,025 lb KG
A/T 680/465 kg 1,499/1,025 lb KG
Max. Permissible Weight (EC)
1 . SEL, 1 . 5EX, DXi, LSi 1,500 kg 3,310 lb
DX, EX, ESi, VTi 1,520 kg 3,351 lb
RTSi 1,640 kg 3,616 lb
3-44
1
ENGINE Type Water-cooled, 4-stroke SOHC gasoline engine
Water-cooled, 4-stroke OOHC gasoline engine
Cylinder Arrangement ln-line 4-cylinder, transverse mount
8ore and Stroke 0128 75.0 x 67.5 mm 2.95 x 2.66 in
0138 75.0 x 76.0 mm 2.95 x 2.99 in
0158, 0152 75.0 x 84.5 mm 2.95 x 3.33 in
016A, 0162 75.0 x 90.0 mm 2.95 x 3.54 in
B16A 81.0 x 77.4 mm 3.19 x 3.05 in
Oisplacement 0128 1, 193 cm3 73.0 cu-in
0138 1,343 cm3 82.0 cu-in
0158,0152 1,493 cm3 91.0 cu-in
016A, 0162 1,590 cm3 97.0 cu-in
816A 1,595 cm3 97.3 cu-in
Compression Ratio 0128 8.6
0138 9.0
0158 9.2
0152 9.3
D16A7 9.1
0162 9.2
016A8, D16A9 9.5
816A 10.2
Valve Train 8elt driven, SOHC
8elt driven, OOHC
Lubrication System Forced and wet sump
Fuel Required O 1 281 Leaded gasoline with 85 R.0.N or higher*1 * 1 Unleaded gasoline
01383, 01583 Leaded gasoline with 91 R.O.N or higher*1 with 91 R.O.N. or
01382, 01582, 01584 Unleaded gasoline with 91 R.0.N or higher higher may also be
O 1 521 , O 16A8 used.
01626, 01627, B16A2 Premium unleaded gasoline 95 R.O.N *2 Premium unleaded
or higher gasoline with 95
016A9, 016A7 Premium leaded gasoline 98 R.0.N R.0.N. or higher
or higher*2 rnay also be used.
STARTER Makes/Type HITACHI/Oirect drive, 0.8 kW
MITSU8A/Gear reduction, 1.0 kW, 1.2 kW and
1.4 kW
NIPPONOENSO/Gearreduction, 1.0 kW and
1.2 kW
Normal Output 0.8 kW, 1.0 kW, 1.2 kW, 1.4 kW
Nominal Voltage 12 V
Hour Rating 30 seconds
Oirection of Rotation Clockwise as viewed from gear end
Weight HITACHI 0.8 kW 3.7 kg 8.2 lb
MITSUBA 1.0, 1.2 kW 3.4 kg 7.5 lb
1.4 kW 3.5 kg 7. 7 lb
NIPPONOENSO 1.0 kW 3.85 kg 8.49 lb
1.2 kW 3.4 kg 7.5 lb
(cont'd)
3-45

1
CLUTCH Clutch Type M/T Single plate dry, diaphragm spring

A/T Torque converter
Clutch Facing Area M/T 176 cm2 1
27 sq in
TRANS- Transmission M/T Synchronized 5-speed forward, 1 reverse
MISSION A/T 2WD 4-speed automtic with lock-up clutch, 1 reverse
4WD Electronically controlled
4-speed automatic, 1 reverse
Primary Reduction Direct 1 : 1
Type Manual
0128
0138 01627
0158 Dl 521 0162 B16A
4WD
016A
Gear Ratio SL -- -- -- 4.512 --
1 st 3.250 3.250 3.250 3.384 3.230
2nd 1.900 1.900 1.900 1.952 2.105
3rd 1.250 1.250 1.250 1.266 1.458
4th 0.909 0.909 0.937 0.942 1.107
5th 0.750 0.750 0.771 0.789 0.875
Reverse 3.153 3.153 3.153 3.000 3.000
Final Reduction I Gear ratio 4.250 3.722 4.250 4.428 4.266
I Gear type Single helical gear
Type Automatic
0128, 01582, 016Z7
01584 D16A8 D16A9 016A7
01583 D16Z6 4WD
Gear Ratio 1 st 2.722 2.600 2.720 2.600 2.722 2.600 2.526
2nd 1.555 1.393 1.500 1.393 1.500 1.468 1.428
3rd 1.027 0.975 1.027 0.926 1.027 0.975 0.974
4th 0.780 0.772 0.780 0.673 0.780 0.673 0.733
Reverse 1.954 1.954 1.954 1.954 1.954 1.954 1.954
Final Reduction I Gear ratio 3.937 4.333 3.937 4.333 3.937 4.333 4.333
I Gear type Single helical gear
3-46
AIR CON- Cooling Capacity 3,730 Kca/h 14,800 BTU/h

DITIONER - Conditions:
Compressor Speed 2,200 rpm
Outside Air Temperatura 35 - 20ºC
25 - 95 - 77 - 68ºF
-
1
Outside Air Humidity 80% 30%

Condensar Air Velocity 3.5 m/sec 11.5 ft/sec
Blower Capacity 430 m3/h 1 15, 188 cu ft/h at 12 V
Compressor Type/Makes Scroll type/SANDEN D 1 52, D 16A, D 1 62
No. of Cylinder --
Capacity 85.6 cc/rev 1
5.22 cy ub/rev
Max. Speed 10,000 m.in-1 (rpm)
Lubricant Capacity 120 ce 1 4.06 US oz, 4.22 lmp oz
Compressor Type/Make Vane rotary type/MA TSUSHITA 0128, 0138, 0158

No. of Cylinder 3
Capacity 150 cc/rev 1
9. 1 5 cu in/rev
Max. Speed 8,000 min-1 (rpm)
Lubricant Capacity 140 ce 1 4. 73 US oz. 4.93 lmp oz
Compressor Type/Make Swash-plate type/NIPPONDENSO B16A2

No. of Cylinder 10
Capacity 1 55.3 cc/rev 1
9.47 cu in/rev
Max. Speed 7,600 min-1 (rpm)
Lubricant Capacity 60-100cc 1 2.03-3.38USoz.
2.11-3.52 lmp oz
Condensar Type Corrugated fin type
Evaporator Type Corrugated fin type
Blower Type Sirocco tan
Motor Input 200 W/12 V
Speed Control 4-speed variable
Max. Capacity 430 m3/h 1 1 5, 188 cu ft/h at 12 V
AIR Temp. Control Air-mix type
CONDI- Comp. Clutch Type Dry, single plate, poly-V-belt drive
TIONER Power Consumption 42 W max./12 V
(cont'dl
Refrigerant Type R12
Ouantity 650 ~ ~0g 22.9 ~ ~.B OZ
(cont'dl
3-47

1
STEERING Type P/S Power assisted, rack and pinion

SYSTEM MIS rack and pinion
Overall Ratio VTi PIS LHD: 17.5 RHD: 17.6
Except VTi PIS LHD: 17.5 RHD: 17.0
MIS LHD: 19.0 RHD: 19.0
Turns, Lock-to-lockVTi PIS LHD: 3.3 RHD: 3.1
Except VTi PIS LHO: 3.6 RHD: 3.5
M/S LHD: 3.9 RHD: 3.9
SteeringWHeelDía. ExceptVEi and VTi 375 mm 14.8 in
VEi 380 mm 15.0 in
VTi 377 mm 14.8 in
SUS- Type, Front and Rear lndependent double wishbone, coil spring
PENSION Shock Absorber, Front and Rear Telescopic, hydraulic nitrogen gas-filled
WHEEL Camber
ALIGNME- Front VTi -0°05' ± 1°
NT 2WD except VTi 0°00' ± 1 °
4WD 0° 15' ± 1 °
Rear VTi -0°25' ± 1º
2WD except VTi -0°20' ± 1o
4WD -0°25' ± 1o
Caster
Front 2WD 1 º 10' ± 1º
4WD 1 °05' ± 1 o
Toe
Front Omm Oin
Rear In 2.0 mm In 0.08 in
BRAKE Type, Front Power-assisted self-adjusting ventilated disc
SYSTEM Rear Power-assisted self-adjusting solid disc or drum
Pad and Lining Surface Area: Front 35.8 cm2 x 2 5.5 sq in x 2 Disc, 190 mm día.
43.2 cm2 x 2 6.7sqinx2 Disc, 191 mm dia.
51.5 cm2 x 2 8.0 sq in x 2 Disc, 211 mm día.
Rear 21.0 cm2 x 2 3.26 sq in x 2 Disc
50.2 cm2 x 2 7.8 sq in x 2 Drum
Parking Brake Kind and Type Mechanical actuating, rear two wheel brakes
TIRE Size 175/70R13 82H
155R13 78S
185160R14 82H
195155 R15 84V
Spare tire VTi Í2D HIB) T135/70015
3-48
1
ELEC- Battary 12 V-47 AH, 36 AH, 38 AH/5 HR

TRICAL Startar 12 V-0.8 kW, 12 V-1.0 kW, 12 V-1.2 kW,
12 V-1.4 kW
Altarnator 12 V-70 A, 80 A
Fusas
In Tha Undar-Dash Fusa Box 7.5A, 10A, 15A, 20A, 30A
In The Undar-Hood Fusa/Ralay Box 7. 5 A, 1 O A, 1 5 A, 20 A, 30 A, 40 A, 50 A, 80 A
In The Under-HoodABS Fuse/Relay
Box 7. 5 A, 1 5 A, 20 A, 50 A
Haadlights High/Low 12 V-60/55 W
Front Turn Signal Lights 12V-21 W
Rear Turn Signal Lights 12 V-21 W
Brake/Tail Lights 12 V-21/5 W
High Mount Brake Light 12 V-21 CP KO and KY modal
Back-up Lights 12 V-21 W
License Plata Lights 12 V-5 W
Cailing Lights 12 V-8 W
12 V-5 W
Trunk/luggage Lights 12 V-3.4 W
Gauga Lights 12 V-3.0 W
lndicator Lights 12 V-1.12 W, 1.4 W
llllumination and Pilot Lights 12 V-1.4 W, 1.12 W, 0.84 W
12 V-0.91 W, 0.56 W, LEO
Haater lllumination Lights 12 V-1.4 W
Rear Fog light 12 V-21 W European and
KP model
3-49
Body Specifications
2-Door Hatchback: Unit: mm (in)
.... ¡:; ~
a:i <O ,...
!!! ~ !!!
,...ID a,ID ID
<O
....~ ...."!. ~
(0'€9) Qt,€' L
• • "'*
N
·~ iooÑ~
o.... o..:oo
----
<O <O <O <O
.
..... 'I""" ........
\
o,... OOOID
CI) a,,...,...
ID 0000
Ñ .,¡ .,¡ .,¡ .,¡
>
::i,:::
"'*
d
::i,:::
N
*
"ii
"D
o
E
.s::.
CII
·2
.5
u. .
;
3-50
4-Door Sedan: Unit: mm (in)
... "'
* ¡;;
¡:;:- *
,..: ,..:
~~
lll lll
CD lll
"":. "":.
5*(6.1>9196&' L
1r•I L ·v9) 9L&' L
~ .
... *5;¡a;*
rti
...
o .........
rti rti rti
..................
3-51
Maintenance
Lubrication Points 4-2

Maintenance Schedule 4-4
Lubrication Points
For the details of lubrication points and types of lubricants to be applied, refer to the lllustrated lndex and various work
procedures (such as Assembly/Reassembly, Replacement, Overhaul, lnstallation, etc.) contained in each section.
No. LUBRICATIONPOINTS LUBRICANT

Engine API Service Grade: SG or SF fuel efficient oil
2 Transmission Manual API Service Grade: SF or SG
SAE Viscosity: See chart below.
Automatic Honda Premium Formula or DEXRON® 11
Automatic transmission fluid
1 4
3 Brake Line
Clutch Line
Brake fluid DOT3 or DOT4
Brake fluid DOT3 or DOT4
5 Power steering gearbox Steering grease P/N 08733-B070E
6 Shift lever pivots (Manual) Silicone grease with molybdenum disulfide
7 Release fork (Manual)
8 Steering boots
9 Steering column bushings
10 Steering ball joints
11 Select lever (Automatic)
12 Pedal linkage
13 Brake master cylinder pushrod
Multi-purpose grease
14 Trunk hinges and latch (4-Door Sedan)
15 Door hinqes upper and lower
16 Door opening detents
17 Fuer filler lid
18 Engine hood hinges and engine hood latch
19 Clutch master cylinder pushrod
20 Throttle cable end
21 Rear brake shoe linkages
22 Tailgate hinges and latches (2-Door Hatchback)
23 Caliper Pistan seal, Dust seal,
Silicone grease
Caliper pin, Pistan
24 Power steering system Honda power steering fluid-V
25 Rear Differential (4WD only) Hypoid Gear oil (API GL5)
above -1 SºC (12ºF) SAE90, below -1 SºC (12ºF)
SAE 80
Recommended Engine Oil Recommended Manual Transmission Oil
API Service Grade: SG or SF fuel efficient oil. Select API Service Grade: SF or SG
the oíl for the car according to this chart.
. .11-111.11:
,20
1o 120
-30 -20 -10 O
20W
10
40
1 40 1 60 1 80 1 10~°F
20 30 40ºC
* 1 : Except 1 . 6 f Ambient temperature ranges

models
* 2: 1.6 e models CAUTION: Used engine oil may cause skin cancer if
-10 O 10 20 30 4Dºc repeatedly left in contact with the skin for prolonged
- 20 0 20 40 60 80 100°F periods. Although this is unlikely unless you handle
used oil on a daily basls. it is still advisable to
Ambient temperature ranges thoroughly wash your hands with soap and water as
soon as possible after handling used oil.
4-2
2-Door Hatchback:
@
@) @ (J) ®@ ® ®
CD@ @® @ ® ®@ 14
@)
4-Door Sedan 4WD:
@
@) @ (J) ®@ ® ®
CD@@ @®®
------rj
@ @
I
@
@
4-3
Maintenance Schedule
o o o
o co co a: - - - - a: - a:
o
Cfl
'<t
LO
'<t
LO a:
o CX) CX)
a: a: -
CX) '<t" '<t"
O
r-,
N
'<t
N
'<t a:
o
co co
(') co
(') a: - a: a:
ai
o o o a: E
LO M (')
B
"':::,
o
o
'<t"
'<t"
N
'<t"
N a: a: - a: - - -
Q)
a: a: -5
>
f---l----1f---l---l-+---+-+--+~+--+-f---l----1-+---l-+---+-+--+-+--+-+--+-f---l----1~+---l-+--+--I .o
-¡¡;
o CX) CX)
a: :::,
(') e:
(O
E
E -"'
o
O N N
a: - a: a: ·"'.; o
o
N e:
:i: o
M
o
i o a:
Q)
-5 j
(O
B ...
(O
"'~ f--+--+----l
o
Cl
e:
]
Q)
e: 'o
c5o
"'
Q)
E
o o
.;
-5"'e:
(O o
t: 2: ;¡;
o .; Q)
ñí >
t:
E e>
Q)
a, e
·.:; s:
"'·.,, o
(5 X
X E: 8 o :E
o o
a.
(O
Q)
a. o ·~ :i:
~ -~o m>
> rtÍ
~ o
"' 5
() o
-s ~
ºi ºi
E..;
E-~ E
-"'- Q)
> s
º"'
gE -¡¡;
> "'"'> ... §"'
. o
o e:
o ge: ~
~ 'fi
j
-~
o
E
Q)
e: o
e
o e:
o
...e: u
Q)
>
Q)
~ !
~ "'>
o
o
-o -o
e: Q)
.; "'
(O e:
"' e:
Q)
:§
~g
(O
(O
E (O (O
u o
Q)
Q)
-o a. O>
-e üi e -"'
e: (O
e:
-
~ o
<O
~o ~ ~
;.:: : 8
e: -e
B ºi
1
u "' ;¡;
a:; -e
e:
E
... ·¡¡¡
Q)
:::,
a: ~ Q) Q) Q)
e:
Q)
-a -~ ~
o (O o
§ u c.
"'
>
·.:;
·¡¡;
~ ~ 'B
e i o
·.:;
a,
a:
e: E 'Bi <
Q)
~ o
Cl..
;
ai .s ~
a,
"'
Q
·1:
E'
I
Q)
C/l e
:::,
~ o • o
a: '------'~------------------~------------------~----__J
4-4
o o o
o (O (O e: - - -
o
O)
<t
L()
<t
L()
o (X) (X)
(X) <t <t - - - - - - a: e: -
o (O (O
(O (") (")
Qi
o
L()
o
(")
o
(") E
BC/)
:::,
u
- - - - - - a: - - - - - .s Ql
>
.o
l---l---l--1-----1----1 E
o -¡¡; .:,,(.
8
(X) (X) :::,
(") e:
"'E o
ci
O
N
N N
-----m -"'
e:
~o
m> o... .s
Ql
(O (O
C/)
C/)
o,
L---J.--1----J B
u
o,
e: ~
;;:
C/)
Ql
E
o
u
<ii
O X
X
>
Ql
·¡¡; s:
u
c. :E
~ 1----'--1--
t
cii ~
Ql
>
e:
o
u
u
·;; :::,
> o
>
~
"'u
.s
-~
E~
E-~
.:,,(.-
ºo C/)
Ql
o E
- o
u
X <ii
"C >
Ql Ql
... .s::
C/) u
:: :E
"'o, ~ ~
e:
u ...e: .s::...
Ql C/)
·- e:
Ql o
1
u .S E
o,
u ;o
-a .~2'. ~E
Ql
a:
o o
Ql :::,
I V) e:
e:
4-5
Engine
Design and Operation . . . . . . . . . . . . . . . . . . . . . . 5-1

Engine Removal/lnstallation 5-13
Cylinder Head/Valve Train . . . . . . . . . . . . . . . . 6-1
Engine Block 7-1
Engine Lubrication 8-1
lntake Manifold/Exhaust System 9-1
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Design and Operation
Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Cam and Valve Mechanism
D 1521 engine (VTEC-E) 5-4
01626 engine (VTEC) 5-9
Outline
Description
01 5Z1 engine: VTEC-E, 1493 ce

016Z6 engine: VTEC, 1590 ce
Both engines are SOHC, inline 4 cylinder, water cooled, and multí-poínt ínjected.
These engines use the Honda Variable Valve Tíming and Lift Electronic Control System (VTEC-Eor VTEC) which allows
the timing and lift of the intake valves to be changed simultaneously.
D15Z1 engine (VTEC-E):
5-2
Major Specifications:
01521 engine (VTEC-E) 01 626 engine (VTEC)

Type Water-cooled, inline 4-cylinder, cross-flow
Oisplacement 1 ,493 cm3 (91.1 cu in) 1,590 cm3 (91.1 cu in)
Bore x Stroke 75.0 x 84.5 mm (2.95 x 3.33 in) 75.0 x 90.0 mm (2.95 x 3.54 in)
Compression Ratio 9.3 9.2
Cam and Valve Mechanism SOHC, VTEC-E SOHC,VTEC
Valve Train Belt Oriven
Fuel Supply System PGM-FI (Multi-Point lnjection)
D 16Z6 engine (VTECI:
5-3
Variable Valve Timing and Lift Electronic Control System --------
(D 1521 engine, VTEC-E)
This engine has a normal 4 valve per cylinder valve arrangement. At low RPM, the primary intake valve operates at nor-
mal lift while the secondary intake valve opens only slightly to prevent fuel accumulation in the intake port. At high RPM,
the secondary intake valve rocker arm is connected to the primay intake valve rocker arm to allow normal valve lift. A
synchronizing piston connects/disconnects the two intake valve rocker arms. Hydraulic pressureagainst a timing piston
moves the synchronizing piston one direction, while a stopper piston and return spring moves the synchronizing piston
back when hydiaulic pressure is released.
SECONDARY
ROCKER ARM
SYNCHRONIZING
PISTON
TIMING PISTON
CAMSHAFT
5-4
A variable valve timing and lift mechanism is used so the engine achieves both low fuel consumption and high output.
With this system, a very lean fuel/air is efficiently burned to achieve high torque characteristics and low fuel consump-
tion in the low rpm range, while in the high rpm range, high output, equivalent to that of a conventional 4-valve engine, is
achieved.
Variable Timing &

High Power Engine 2 valve Engine
Lift Engine
I~~
Primary
Lt.)V\
Valve Timing 1 •roe
AV\
(exhaust/intake)
Valve Lift
1
Exhaust lntake Exhaust lntake Exhaust lntake
Max. Power o o
Low rpm Torque o o
ldling Stability o o
Fuel consumption X o
*TDC = Top Dead Center *BDC Bottom Dead Center
O Optimum Characteristic
x = Worst Characteristic
---- VTEC-E Engine
----- 4 valva Engine

RPM switch
CI> over point ----- 2 valve Engine
~
o
O"
1-
rpm
5-5
Variable Valve Timing and Lift Electronic Control System·
(01521 engine VTEC-E)
Mechanism:
At Low Speed:
The primary rocker arrn and secondary rocker armare separated. Since both cam lobes, A and B, have different valve tim-
ing and lift, the lift of the secondary rocker arm is then small, so that one intake valve barely opens (one-valve control).
PRIMARY SECONDARY
ROCKER ARM ROCKER ARM
A and B cam lobes

drive the rocker arms
STOPPER PISTON separately.
TIMING SYNCHRONIZING
PIS TON PISTON
At High Speed:
The timing piston inside the primary rocker arm is shifted by hydraulic pressure in the direction shown. Both rocker arms,
primary and secondary, are then connected by the synchronizing piston. The secondary rocker arm is driven at the same
lift as the primary rocker arrn, so that valve operation becomes the same as an ordinary 4-valve engine.
OIL PRESSURE [)
Connected by hydraulic piston,

and driven only by the primary cam.
5-6
Control System:
The control system for this mechanism constantly monitors the changes in engine status such us load, rpm and vehicle
speed. This information is transmitted to the PGM-FIECU (Electronic Control Unit} to achieve optimum drivability under
all conditions.
Valve Timing Changa Conditions:

EngineSpeed: 2,500 min-1 (rpm).
Vahicle Spaed: 5 km/h (3 mph) min.
Water Tamperature: -5.3ºC (22.SºF) min.
EngineLoad: Judgad by intaka manifold negativa prassure
Engine speed
Vehicle speed
ELECTRONIC
CONTROL
UNIT
Water temp.
Engine load
SPOOL VALVE
-·-·-·-·~-·-·-·-·-·-·
mmHg
100
~:::,
"'"'
Q)
Q.
Q)
>
·¡::
"'
C)
Q) Hígh Speed
e: (2 valve)
"C
]
·e
"'E
Q)
.:,L
!9
-=
2 3 x 1000 rpm
Engine speed
5-7
Variable Valve Timing and Lift Electronic Control System
(D 1521 engine VTEC-E)
Explanationof Timing Mechanism Operation:
The variable valve timing and lift mechanism switches intake valve operation between single valve operation and two
valve operation depending upan engine speed. To help achieve switch-over, a timing plate is installed on the primary
rocker arm.
Hydraulic Pressure ON Hydraulic pressure OFF

G) Lift O: Switch-ovar is impossible as the timing G) Lift O: Switch-over is impossible as the timing is
Amount of lift plate is into the timing pistan. inserted into the timing pistan.
Hydraulic pressure ON
@ Lift process begins: The timing plate is

desengaged, and the timing pistan starts shif- @ Lift process begins: The timing plate alone
ting. The synchronizing pistan does not move starts shifting. The synchronizing pistan does
because of the lift. not move, because of the load imposed.
/,
e
o
·.::;
"':5
.!:!
"'
IJ)
Q)
ñ:
@ Lift O: The synchronizing pistan is pushed back
@ Lift O: Since the timing plate is pulled out, the by the return spring and the valve operation
valve operating mode starts to change from mode starts to change from 2-valve operation
1-valve operation to 2-valve operation from the to 1-valve operation from the moment when the
moment when the lift became zero. lift becomes zero.
© Lift O: Switch-ove, is completed. © Lift O: Switch-ove, is completed.

/.
Crank angle
5-8
Variable Valve Timing and Lift Electronic Control System· ----------.
(01626 engine VTEC)
The engine is equipped with multiple cam lobes per cylinder, providing one valve timing and lift profile at low speed anda
different profile at high speed. Switch-over from one profile to the other is controlled electronially, and is selected by
monitoring current engine speed and load.
MIO ROCKER ARM
CAMSHAFT
5-9
Variable Valve Timing and Lift Electronic Control System·
(01626 engine VTEC)
In general, it would be ideal if the high rpm performance of a racing engine and the low rpm performance of a standard
passenger car engine could be combined in a single engine. This would result in a maximum performance engine with a
wide power band. Two of the major differences between racing engines and standard engines are the timing of the in-
take/exhaust/valves and the degree of valve lift. Racing engines have longer intake/exhaust timing and a higher valve lift
than standard engines. The Honda Variable Valve Timing and Lift Electronic Control System takes this into account.
When vlave actuation is adjusted for low rpm timing and lift, low rpm torque is better than in a standard engine. When
valve actuation is then adjusted for high rpm timing and lift. output improves to the level that a racing engine can of-
fer.Until now. few variable valve timing systems have been commercialized. In those that have, only the time that both
valves are open (intake/exhaust overlap) could be changed. Honda's system is the first in the world in which the intake
valve timing and the degree of valve lift can be changed as needed, making it the most advanced valve train mechanism
available.
Comparison of Valve Lift of Racing Engines vs. Mass Produced Engines
Variable Timing &

Racing Engine Standard Engine
Lift Engine
Valve Timing
(exhaust/intake)
Valve Lift
.:, 1
Li.~\ Exhaust
"TDC
lntake
¡~ Exhaust lntake
1 /\11\
Exhaust lntake
Max. Power o o
Low rpm Torque o o
ldling Stability o o
*TDC = Top Dead Center * BDC Bottom Dead Center
O = Optimum Characteristic
The engine is equipped with two valve timing and lift settings which change according to driving conditions.
--- VTEC-E Engine

-·--- 4 valve Engine
_____ 2 valve Engine
Low rpm • I .. High rpm
~I
~I ---
1 RPM switch-over
point
1
1 /
/
1
/
rpm
5-10
Mechanism:
At low rpm:
As shown, the primary and secondary rocker arms located on both sides are not connected to the mid rocker arm, but are
driven separately by cam lobes A and B at different timing and lift. Although the mid rocer arm is following the center
cam lobe with the lost-motion assembly, it has no effect on the opening and closing of the valvas in the low rpm range.
At Low rpm:
SVNCHROl'i!IZING SYNCHRONIZING
PISTON A PISTON B
LOW SPEED
STOPPER PISTON CAM
• A and B cam lobes

drive the rocker arms
separately.
PRIMARY ROCER ARM MIO ROCKER SECONDARY

ARM ROCKER ARM
At High rpm:
When drivíng at hígh rpm, the built-ín piston moves in the dírection shown by the arrow in the figure below. As a result,
the primary, secondary, and mid rocker arms are linked by 2 hydraulic pístons (Iike a skewer) and the 3 rocker arms move
as a single unit. In thís state, all the rocker arms are dríven by cam lobe C opening and closing the valves at the valve tim-
ing and lift set for high operation.
At High rpm:
HIGH SPEED
CAM
OIL PRESSURE [::)
o o
*The rocker arms are linked
via the hydraulic piston.
Cam lobe C drives the rocker
arms.
5-11
Variable Valve Timing and Lift Electronic Control System
(01626 engine VTEC)
Controls:
The control system for this mechanism, as shown below, constantly monitors the changes in enginestatus such as load,
rpm and vehicle speed. This information is transmitted to the Control Unit.
Valve Timing Changa Conditions

Engine RPM: •:J,800min-1 (rpm).
Vehicle Speed: 1\11/T: 20 km/h (13 MPHl. A/T: 5 km/h (3 MPHl min.
Water Temperatura: 60°C (140ºF) min.
Engine Load: Judged by intake manifold negative pressure
Engine speed
Engine load
ELECTRONIC
CONTROL
UNIT
Vehicle speed
Water temp.
mmHg
a,
:5
en
en
a,
c.
e :
>
·;::;
ct1
o,
a,
e:
-o
2
'i:
High Speed
ct1
E
a,
-" Low Speed
~
.E:
500
4 5 6 x 1000 rpm
Engine speed
5-12
Engine Removal/lnstallation
Special Tools
Ref. No. Tool Number Description Oty Page Reference
CD 07KAK-SJ40101 Engine Tilt Hanger Set 5-23

@ 07MAK-PY30100 Engine Sub Hanger Stay 5-23
@ 07744-0010600 Pin Driver, 8.0 mm 5-22
1 CD
5-14
l·fMhfiihN
• Make surejacks and safety stands are placed proper-
5. Drain the coolant (see Section 10).
• Loosen the drain plug from the radiator lower
ly and hoist brackets are attached to the correct tank.
positions on the engine.
• Make sure the car will not roll off stands and fall
6. Drain the transmission oíl/fluid. Use a 1 O mm
while you are working under it.
(3/8") drive socket wrench to remove the drain
plug. Reinstall the drain plug using a new washer.
CAUTION:
• Use tender covers to avoid damaging painted
7. Drain the engine oil. Reinstall the drain plug using a
surfaces.
new washer.
• Unspecified items are common.
• Unplug the wiring connectors carefully while holding
8. Lower the hoist. Secure the hood as far open as
the connector portian to avoid damage.
possible.
• Mark all wiring and hoses to avoid misconnection.
Also, be sure that they do not contact other wiring or
9. Remove the tower bar (816A2 engine).
hoses or interfere with other parts.
1. Disconnect the battery negative terminal first, then

the positive terminal.
2. Removethe radiator cap.
l,s\@;!J@I Use care when removing the radiator

cap to avoid scalding by hot coolant or steam.
3. Raisethe hoist to full height.
4. Remove the front tires/wheels and the engine

splash shield. 8x1.25mm
22 N•m (2.2 kg-m, 16 lb-ft)
1 O. Removethe under-hood ABS fuse/relay box (LHDl.
11. Remove the air intake hose, the resonator and the
air cleaner assembly.
/
AIR CLEANER
6.-6 X 1.0 mm
10 N•m (1.0 kg-m,
7 ft-lb)
(cont'd)
UNDER HOOD ABS
FUSE/RELAY BOX
5-15
(cont' d)
12. Relieve fuel pressure by slowly loosening the ser- 14. Removethe throttle cable by loosening the locking-
vice bolt on the fuel filter about one turn (see Sec- nut, then slip the cable end out of the accelerator
tion 11). linkage.
f,s{fl;jfjj.,i¡Do not smoke while workig on the NOTE:

fuel system. Keep open flame away from work • Take care not to bend the cable when removing
area. Drain fuel only into an approved container. it. Always replace any kinked cable with a new
one.
CAUTION: • Adjust the throttle cable when installing (see
• Before disconnecting any fuel line, the fuel Section 11).
pressure should be relieved as described above.
• Place a shop towel ovar the fuel filter to prevent PGM-FI (except 01582) engine:
pressurized fuel from spraying over the engine.
13. Remove the fuel feed hose and charcoal canister CABLE END
hose from the intake manifold.
SERVICE BOLT
15N•m(1.5kg-m,
9 lb-ft)
WASHER
/
/Replace.
(i/ /
y
SANJO BOLT
~ 22 N•m (2.2 kg-m,
16 lb-h) ADJUSTING NUT
:.~~~:·4 PGM-FI (01582) engine:
THROTTLE CABLE
ADJUST NUT
CHARCOAL
CANISTOR HOSE
5-16
16. Remove the fuel return hose and brake booster
vacuum hose.
PGM-FI engine:
BRAKE BOOSTER
VACUUM HOSE
2-Carbureted engine:
1 5. Remove the engine wire harness connectors on the 1-Carbureted engine:

left side of engine compartment.
PCV HOSE FUEL HOSES
VACUUM HOSE HEATER HOSE

ENGINE WIRE
HARNESS (cont'd)
5-17
(cont'd)
2-Carbureted engine: 18. Remove the engine wire harness connectors, ter-
minal and clamps on the right side of engine
compartment.
FUEL HOSES
19. Remove the battery cable/starter cable from the
under-hood fuse/relay box and ABS power cable
from battery terminal.
VACUUM HOSE
ENGINE WIRE
HARNESS CONNECTORS
20. Remove the engine ground cable on the cylinder

1 7. Disconnect the connectors, then remove the fuel head.
emission control box (carbureted engine).
21. Remove the P/S belt and pump.
• Do not disconnect the P/S hoses.
EMISSION CONTROL
BOX
SOHC engine:
6x1.0mm
10 N•m (1.0 kg-m.
7 lb-ft) ENGINE GROUND
CABLE
CONNECTORS
8 x 1.25 mm
22 N•m (2.2 kg-m, P/S PUMP
16 lb-ft)
5-18
D16A7/D16A8 (DOHC) engine: 22. Remove the A/C belt and compressor.
• Do not disconnect the A/C hoses.
• Disconnect the connector.
ADJUSTING BOLT A/C BELT
A/C COMPRESSOB
8 x 1.25 mm
B x 1.25 mm 22 N•m (2.2 kg-m,
22 N•m (2.2 kg-m, 16 lb-ft)
16 lb-ft)
23. Remove the transmission ground cable and the ATF

cooler hoses (A/TI.
B16A2 (DOHC VTEC) engine:

TRANSMISSION
GROUND CABLE
6 x 1.0 mm
GROUND CABLE 1 O N•m ( 1.0 kg-m, 7_ lb-ft)
ATF COOLER
HOSES
8 x 1.25 mm
P/S PUMP
22 N•m (2.2 kg-m,
16 lb-ft)
(cont'd)
5-19
(cont'd)
24. Remove the upper and lower radiator hoses and the 25. Remove the A/T shift cable.
heater hoses.
LOCKING NUT
36 N·m (3.6 kg-m,
816A2 engine:
26 lb-ft)
HEATER HOSE
HEATER HOSE
UPPER HOSE
COTTER PIN
Replace.
Except B16A2 engine: 26. Remove the shift cable and select cable (M/T
4WDI.
SHIFT CABLE
HEATER RADIA TOR LOWER

HOSES HOSE
5-20
27. Raise the hoist to full height. 29. Removethe A/T shift cable (A/T).
28. Remove the exhaust pipe and stay.
8 x 1.25 mm
22 N•m (2.2 kg-m,
Single type:
16 lb-ft)
SELF-LOCKING NUT SHIFT CABLE
8 x 1.25 mm
22 N•m (2.2 kg-m, 16 lb-ft)
Replace.
GASKET
GASKET
Replace.
EXHAUST
PIPE A SHIFT CABLE
SELF-LOCKING NUT COVER
10 x 1.25 mm LOCK WASHER
55 N•m (5.5 kg-m, 6 x 1.0 mm
Replace. 14 N•m (1.4 kg-m,
40 lb-ft)
Replace. 10_ lb-ft)
Dual type: 30. Remove the clutch slave cylinder and pipe/hose
SELF-LOCKING NUT
8 xJ.25 mm assembly (M/T).
22 N•m (2.2 kg-m, • Do not disconnect the pipe/hose assembly.
GASKET 16 lb-ft)
6 x 1.0 mm
12 N•m (1.2 kg-m,
9 lb-ft)
SELF-LOCKING NUT
SELF-LOCKING NUT
10 x 1.25 mm
8x1.25mm
55 N•m (5.5 kg-m, 8 x 1.25 mm
40 lb-ft) 16 N•m (1.6 kg-m,
12 lb-ft) 22 N•m (2.2 kg-m,
16 lb-ft)
(cont'd)
5-21
(cont'd)
31. Removethe shift rod and the extension rod (M/T). 33. Removethe damper fork.
34. Disconnect the suspension lower arm ball joint with

the special tool. Refer to section 1 8 for proper
procedure.
SHIFT ROD
35. Removethe driveshafts.
NOTE:
• Coat ali precision-finished surfaces with clean
engine oil or grease.
• Tie plastic bags over the driveshaft end.
6 x 1.0 mm
10 N•m (1.0 kq-rn,
#7lb·ftl
DAMPER FORK
8 mm SPRING
PIN
8 x 1.25 mm
22 N•m (2.2 kg-m,
16 lb-ft)
10 x 1.25 mm
44 N•m (4.4 kg·m,
32. Removethe No. 1 propeller shaft by disconnect the 32 lb·ft)
V-joint (4WD). SELF-LOCKING NUT
12 x 1.25 mm
65 N•m (6.5 kg-m, 47 lb-ft)
Replace.
DRIVESHAFT
8x1.25mm
33 N•m (3.3 kg·m, 24 lb-ft)
5-22
36. Lower the hoist.
37. Attach the chain hoist to the engine.
EIGINE SUB
HANGER STAY
07MAK-PY30100
ENGINE TILT
HANGER SET
07KAK-SJ40101
(cont'd)
5-23
{cont'd) ~--~~~~~~~~~~~~~~~~~~~~~~~~~
38. Removethe left and right front stopper rubbers and 40. Remove the engine support nuts. loasen the
stopper brackets. mount bolt and pivot the engine side mount out of
the way.
STOPPER RUBBER
BOLT
ENGINE SIDE
MOUNT RUBBER
RIGHT FRONT STOPPER

RUBBER/BRACKET MOUNT BOLT
• Loosen
41. Removethe transmission mount nuts. loosen the

LEFT FRONT
mount bolt and pivot the transmission side mount
STOPPER RUBBER out of the way.
MOUNT NUTS
39. Aemove the rear engine mounting bracket.
REAR MOUNT MOUNT BOLT

RUBBER • Loosen
42. Raisethe chain hoist to remove all slack from the

chain.
43. Check that the engine is completely free of vacuum

hoses, fuel and coolant hoses, and electric wires.
44. Slowly raise the engine approximately 1 50 mm

(6").
Check once again that all hoses and wires have
been disconnected from the engine.
REAR MOUNTING 45. Raisethe engine all the way and remove it from the
BRACKET
car.
5-24
46. lnstall the engine in the reverse order of removal. • Check that the spring clip on the end of each
driveshaft clicks in to place.
NOTE:
After the engine is in place: CAUTION: Use new spring clips on installation.
• Torque the engine mounting bolts in sequence
shown below. • Bleed air from the cooling system at the bleed
bolt with the heater valve open.
CAUTION: Failure to tighten the bolts in the proper • Adjust the throttle cable tension.
sequence can cause excessive noise and vibration, • Check the clutch pedal free play (M/T).
and reduce bushing life; check that the bushings • Check that the transmission shifts into gear
are not twisted or offset. smoothly.
G) 12 x 1.25 mm
® 14 x 1.25 mm
85 N•m 18.5kg-m, 61 lb-ft)
55 N•m (5.5 kg-m.
40 lb-ft)
11
J •
'
@12x1.25mm
55 N•m (5.5 kg-m,
40 lb-ft)
@10x1.25mm
39 N•m (3.9 kg-m,28 lb-ftl (cont'd)
5-25
(cont'd)---------------------------~
• Adjust the tension of the following drive belts. • lnspect for fuel leakage.
Alternator belt (Section 23). After assembling fuel line parts, turn on the igni-
Power steering pump belt (Section 17). tion switch (do not operate the starter) so that
Air conditioner compressor belt (Section 22). the fuel pump operates for approximately two
• Clean battery posts and cable terminals with seconds and the fuel is pressurized. Repeatthis
sandpaper, assemble, then apply grease to pre- operation two or three times and check whether
vent corrosion. any fuel leakagehas occurred at any point in the
fuel line.
M/T:
12 x 1.25 mm
55 N•m (5.5 kg-m.
40 lb-ft)
4WD:
12 x 1.25 mm
55 N•m (5.5 kg-m,
40 lb-ft)
M/T:
--·--·-- '
1
·--l.._
---- ------ r~~

R. FRONT STOPPER
A/T 4WD:
12 x 1.25 mm
65 N•m (6.5 kg-m,
54 lb-ft)
M/T 4WD: ,.-,OUN_T . --· --- . -
~0
...------12 x 1.25 mm
55 N•m (5.5 kg-m,
1 40 lb-ft)
12 x 1.25 mm
65 N•m (6.5 kg·m,
I
54 lb-ft)
5-26
~
----
Mount
T and Bracket Bolts/Nuts T REAR MOUNT
RANSMISSION MOUNT arque Value specifications:
..
10 X 1.25
39 N•m (3 9 k
ml. 1
28 lb-ft) · g-m. 1
,/
¡- ENGINE SIDE
MOUNT
l. FRONT STOPPER
1
'
5-27
(cont'd)
Mount and Bracket Bolts/Nuts Torque Value Specifications:

ENGINE SIDE MOUNT
REAR MOUNT
01626 (A/TI. B16A2 (A/TI:
B16A2:
~T-R-A~S-M_I_S_S_IO~-M~O-U-N~~~- -1 0~x-,-_2-5~-m~~f~~--~~--~~-·
39 N•m (3.9 kg-m, '
2"{~
4WD:
TRANSMISSION
MOUNT BRACKET
---~------
R. FRONT STOPPER M/T: ' L. FRONT STOPPER
4WD: . CARS NOT EOUIPPEDA/C:

10 x 1.25 mm
12 x 1.25 mm
65 N•m (6.5 kg-m,
47 lb-ftl
5-28
Additional Torque Value Specifications:
(D1521. D1588) AL TERNATOA 8RACKET

12 x 1.25 mm INTAKE MANIFOLD
M/T and A/T: 60 N•m (6.0 kg-m, 43 lb-ft) 8RACKET
(01587, 01626)
FRONT
STIFFENER \
(A/T only)
\o
10 x 1.25 mm
45 N •m (4. 5 kg-m,
33 lb-ft)
10 x 1.25 mm
45 N•m (4.5 kg-m, 33 lb-ft)
ENGINESIDE
MOUNTING 8RACKET
EXHAUST MANIFOLD
8RACKET
10 x 1.25 mm
8 x 1.25 mm 55 N•m (5.5 kg-m, 40 lb-ft)
22 N•m (2.2 kg-m.
16 lb-ft)
P/S PUMP 8RACKET
A/C COMPRESSORBRACKET
8 x 1.25 mm
10 x 1.25 mm 22 N•m (2.2 kg-m,
45 N•m (4.5 kg-m, 33 lb-ft) 16 lb-ft) (cont'd)
5-29
(cont'd)
D16A6/7 (DOHC): ENGINE HANGER ENGINE SIDE MOUNTING

INTAKE MANIFOLD 10 x 1.25 mm BRACKET
BRACKET 45 N•m (4.5 kg-m,
33 lb-ft)
8 x 1.25 mm
22 N•m (2.2 kg·m.,
~---~~----- -~-
10 x 1.25 mm
16 lb·ftl 45 N•m (4.5 kg-m,
--------· 33 lb-ftl
~1"'1.25mm
45 N•m (4.5 kg-m. 33 lb-ftl
B16A2:
P/S BRACKET
HEAT SHIELD
-·--·---~ 1
A/C PUMP BRACKET ·~ 1
8x1.25mm 10x1.25mm
1 22 N•m (2.2 kg·m, 45 N•m (4.5 kg·m,
~-~-'------~31b·ftl_~--
10 x 1.25 mm
10 x 1.25 mm 45 N•m (4.5 kg-m.
45 N•m (4.5 kg-m, 33 lb·ft)
33 lb-ft)
5-30
Cylinder Head/Valve Train
Special Tool 6-2

VTEC (Troubleshooting -
0152/0162/816A engine) 6-3
0128/0138/0158/0152/
016A 7 /0162 engine 6-4
O1 6A8/01 6A9 engine . . . . . . . . . . . . . . . . . . . . . 6-69
B16A engine 6-95
Special Tools
Ref. No. Tool Number Description O'ty Page Reference
CD 07GAD-PH70100 Stem Seal driver 6-81

@ 07HAH-PJ70200 Stem Seal driver 6-44
@ 07HAH-PJ70100 Valve Guide Reamer, 5.5 mm 6-43, 111
© 07JAA-0010100 Socket Wrench, 1 7 mm 6-56, 89
® 07JAA-0010200 Socket Wrench, 19 mm 6-89, 120
® 07JAB-0010100 Pulley Holder Attachment 6-56, 89
(J) 07JAB-0010200 Handle 6-56, 89, 1 20
@ 07JAB-0010400 Pulley Holder Attachment HEX 50 mm 6-89, 120
® 07LAA-PR30100 Tappet Adjuster Wrench 6-126
@ 07LAJ-PR30100 Valve lnspection Set 6-61, 63, 124
®
1
07LAJ-PR30200 Air Stopper 6-61, 63, 124
@ 07LAJ-PT30100 or
07LAJ-PT3010A Test Harness 6-9
@ 07LAK-PR30100 Gauge Joint Adaptar · 6-15, 16
@_ 07NAJ-P070100 VTEC PressureGauqe Attachment 6-15, 16
@) 07406-0070000 Low PressureGauge 6.-1 5, 16
® 07742-0010100 Valve Guide Driver, 5.5 mm 6-42, 43, 111
® 07742-0010200 Valve Guide Driver, 6.6 mm 6-80
@) 07744-0010400 Pin Driver, 5.5 mm 6-76
@) 07757-PJ10100 Valve Spring CompressorAttachment 6-106
@) 07757-0010000 Valve Spring Compressor 6-38, 78, 1 06
® 07942-8920000 Valve Guide Driver 6-111
@ 07984-6570101 Valve Guide Reamer 6-81
@
. :;:;;J ~ ~
CD @ @@ @®
~
@
3
~
.> ~
/
~ @ @) ®®®
6-2
0128/0138/0158/0152/016A7 /D162 engine
VTEC (D15Z/D16Z/B16A engine) Valves and Valve Seals 6-38

Electrical Connections 6-4 Valves 6-40
Troubleshooting Cylinder Head 6-40
Self-diagnostic Procedure 6-6 Valve Seats 6-41
Troubleshooting Flowchart Valve Guides 6-42
SpoolValve 6-12 Valve Spring and Valves 6-44
Oil PressureSwitch 6-14 Camshaft/Seal and Rockerarms 6-45
SpoolValve lnspection 6-17 Cylinder Headlnstallation 6-48
D128/D 138/D 1 58/D 152 Timing Belt
D16A 7/D162 engine lllustrated lndex 6-52
lllustrated lndex 6-18 lnspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54
Cylinder HeadRemoval 6-24 Tension Adjustment 6-54
CamPulley 6-28 Removal 6-55
RockerArms lnstallation 6-58
Removal 6-28 RockerArms
Overhaul 6-30 Manual lnspection 6-60
RockerShaft CollarSelection 6-33 lnspection UsingSpecialTools 6-61
RockerArm and Lost Motion 6-34 Valve Clearance 6-65
RockerArm and Shaft 6-35
Camshaft lnspection 6-36
VTEC (0152/0162/816A engine)
Electrical Connectors
~·....,
MAIN RELAY
p
® 1 1- 1- 7
- ®~
IGNITION SWITCH
- ~ 5
1~ 8
@ 6 ~ ~
e
\:
~
~
(j) 3
.., 1
2
ru,cru MP
(j) 0 -
~
--
- o ®
. : ');I:
I"- -,
- ©
T 1
-·--
) L(J(AIT)
A25 IGP1 PG1 A23
.L Hl
'~ ®~
- '--; 81 IGP2 PG2 A24 ,
~ A ' .____ ~
8 89 STS FLR1 A7
01 V8U FLR2 A8 >-
A26 LG1
82 LG2 e
1
INJECTORS
~
~ - - -
'
811CYLP
No. 1
INJ1 A1 - yy
CYL SENSOR ~ No.2
---- -- 812 CYL M INJ2 A3
N~~ 3-
-- -- - - 813 TDC P INJ3 AS - -
T OC SENSOR ~
....__ - -- -- -- 814 TDC M INJ4 A2 ..
NÓ~ 4
-
------ ---- 815 CRNK P
CRA NK SENSOR ~
-- - - -- - 816 CRNK M
EACV
TO ELO UNIT 010 EL EACV A9 - YV
CHECK ENGINE
LIGHT
SPEED SENSOR @]
810 VSP WARN A13
~ •
F
-=-
SERVICE
CHECK
ACS 85 - TO A/C SWITCH
CONNECTOR
,.......,
04SCS ACC A15 VY
~ A/C COMPRESSOR CLUTCH

RELAY
RADIATOR FAN RELAY

r=,
DATA LINK 07 TXD/RXD FANC A12
M/T CLUTCH
CONNECTOR ~
SWITCH
D 1 SZ 1 englne ~ w
COOLANT
E
only TEMPERATURE
¡r--------- 1
1
D~ 87 CLSW
87 ATNP
83 AT03
SWITCH
ATLSA A19
__ ,
1
...--,
1
1
B4ATD4 ATLS8 A17
-- -- - - - - ------ -~
1 A/T LOCK-UP • A/T LOCK -UP I
1 CONTROL ij ! CONTROL
1 ,
1-' r )t. ~ - SOLENOID e SOLENOID
.·-,...........-
1 VALVE 8 VALVE A
1 p
l ____ _: __ _J ...__ ~ -~
N
..__ _ _J
1 ---
,.....- ~-
FUSES - - - - - - - - - - - - - - - -
03 1 G) 8ACK UP (7 .S Al•
H4- 04 1
1
1
@ BATTERY (80 Al•
@IG (50 A)•
~·
SHIFT POSITION
SHIFT POSITION
INOICATOR
1 © STOP. HORN (20 Al•
CONSOLE P 03 04 1 @ ECU (15 A)•
1
SWITCH 1 @ ACG (SI (15 Al
1 (j) 8ACK-UP LIGHTS (10 Al
...&.. 1 @ REAR DEFROSTER RELAY
._ - J 1 HEATER MOTOR RELAY
COOLING FAN MOTOR RELAY (7.5 Al
(A/Tl @ STARTER SIGNAL (7.5 Al
*: UNDER-HOOD FUSE/RELA Y BOX
6-4
~ ,. ___________.--/
019 VCC1 VREF 016 TO A/T CONTROL
UNIT (4WO)
020 VCC2
021 SG1
-------o 1022 SG2
MAP 11-::10-----1f--++--------o 01 7 PB
SENSOR~- 1--------'
THROTTLE
ANGLE~ ,~r-O-~--lf--+--------0 0110TH e IGP1 A21 ~,IGNITER
SENSOR t-------+--e-,-G-P_2_A_2_2----lc~ 1 · UNIT
016A9
angina) ~~:~::~-- ---------- 010VIOL
1
-- - ----------
,--------------
1
-
1015Z1 angina) ,EGR VALVE ~f-0---+-----~-<> 012 EGRL (Excapt 016A7, 016A8,
: LIFT SENSOR "..__-o---- 016A9 angina)
,_ - - 1 VA1.VE - - - - - - - -----------------
.TIMING OIL .----+---_i9t-lo_ .~
(Excapt 016A7,
016A8, 016A9
1
: ·PRESSURE _.._
06 VTM
~-------'--------!
VTS A4
w
SPOOL SOLENOIO
1
...._=
1
1
angina) L -~V~Jl:.C_tt __ .:::=.:_ _ VAL VE I
P/S OIL
PRESSURE
~------------------1
SWITCH
BBPSW 0
BRAKE-SWITCH
02 BKSW ·- _______ ID15Z1 angina) ,~
1
ES A11 - 1
TA SENSOR
<, EGR CONTROL I
016 TA ___ SOLENOIO VALVE :
r-
-
[!]
TW SENSOR
.....
013TW
PGS A20 0-----<::>-'-
PURGE CUT-OFF
SOLENOIO VALVE
lvDvO-'--<>------'
,.
HEATEO ~
t
1
1 02 SENSOR I
1 1
(016Z6, 1
·-
016Z7, : 1
B16A2 1 v
A6 HTCNTL
angina) 1
I
,.__.AJ
r,,.,,rvv -- . . 1I. -----e----- 0140z ACGCA16 ~
1 1 t-------+--.-A_C_G_F_0_9~---o-~I ~
1 1
~------ ~0-2_S_E_Ñ_S_O_R~--4
(016A7.: 11# A ,11" l : ALTERNATOR
016A8 1 l 1,q 7v v 1 014 02
angina) : ~ 1
1
--------------- 1
03 LABEL
1
1 A A A 1
V V v
r: v=:
1
1 1* A.,,?' 1
1 DBVS+
101521
1
L./.r>:
angina) D161P-,VS-
--
1
__ .J ______
-- - 014 IP+
1/\AA V V V
1
1
A6 HTCNTL
1
----------------~
LAF
SENSOR
Al U U AJ Al Alt AU AII A11 A11 A2\ AU AU 11 11 11 11 11 111 IU 111 01 DI DI 07 DI D11 011 DU DIJ Dlt 0!1
ººººººººººººº 00000000 ººººººººººº

.
ººººººººººººº ºººººººº
U Al AIIAUA1'111AUAU.UIAUAU U 14 lt II ltllUIUllt
ººººººººººº
DI U Dt DI 011 011 OU Dll 011 OH DU
TERMINAL LOCATION
6-5
VTEC
Troubleshooting- Self-diagnostic Procedures
l. When the Check Engine light has been reported on, do the following:
1. Connect the Servuce Check Connector terminals with a jumper wire as shown (The 2P Service Check Connector
is located under the dash on the passenger side of the car). Turn the ignition switch on.
LHD: RHD:
3P CONNECTOR
NOTE:
SERVICE CHECK · Do not attach
CONNECTOR the jumper wire.
3P CONNECTOR
NOTE:
Do not attach
the jump wire.
SERVICE CHECK
CONNECTOR
/
2. Note the CODE: the Check Engine light indicates a failure code by the length and number of blinks. The Check
Engine light can indicate simultaneous component problems by blinking separata cedes, one after another. Problem
codes 1 through 9 are indicated by individual short blinks. Problem codes 1 O through 48 are indicated by a series
of long and short blinks. The number of long blinks equals the first digit, the number of short blinks equals the
second digit.
Separlite Problems:
Short
~= See Problem CODE 1
= See Problem CODE 14
Long short
Simultaneous Problems:
~= See Problem CODE 1 and 3
~= See Problem CODE 3 and 4
= See Problem CODE 3 and 14
CHECK
ENGINE
LIGHT
6-6
11. ECU Reset Procedure
1. Turn the ignition switch off.
2. Remove the BACK UP fuse (7.5 A) from the under-hood fuse/relay box far 10 seconds to reset the ECU.
NOTE: Disconnecting the BACK UP fuse also cancels the radio preset stations and the clock setting. Make note
of the radio presets befare removing the fuse so you reset them.
BACK UP
~J:U=='=SE =----
111. Final Procedure (this procedure must be done after any troubleshooting)
1. Remove the Jumper Wire.
NOTE: lf the Service Check Connector is jumped, the Check Engine light will stay on.
2. Do the ECU Reset Procedure.
3. Set the radio preset stations and the clock setting.
(cont'dl
6-7
VTEC
Troubleshooting- Self-diagnostic Procedures(cont'd)
SELF-OIAGNOSIS PAGE
SYSTEM INDICATEO (Except PAGE
INOICATOR 8LINKS (D1 582 engine)
D 1582 engine)
o ECU 11-219 11-270
1 OXYGEN SENSOR (Except D 16A9 engine) 11-223, 225 11-274
3 MANIFOLD A8SOLUTE PRESSURE(MAP 11-242 11-276
5 SENSOR) 11-246 11-280
4 CRANK ANGLE (CRANK SENSOR) 11-250 11-282
6 COOLANT TEMPERATURE (TW SENSOR) 11-252 11-284
7 THROTTLE ANGLE 11-254 11-286
8 TDC POSITION (TOC SENSOR) 11-250 11-282
9 No. 1 CYLINDER POSITION (CYL SENSOR) 11-250 -
10 INTAKE AIR TEMPERATURE(TA SENSOR) 11-256 11-288
11 IMA SENSOR (016A9 engine) 11-258 -
12 EXHAUST GAS RECIRCULATIONSYSTEM (EGR) 11-386 -
14 ELECTRONICAIR CONTRL (EACV) 11-300 11-316
15 IGNITION OUTPUT SIGNAL 11-260 11-290
16 FUEL INJECTOR (D1582 engine) - 11-338
17 VEHICLE SPEEDSENSOR 11-262 11-292
19 A/T LOCK-UP CONTROL SOLENOIO VALVE A/8 11-264 11-294
20 ELECTRONICLOAD DETECTOR (ELD) 11-266 -
21 SPOOL SOLENOID VALVE 6-12 -
22 VALVE TIMING OIL PRESSURESWITCH 6-14 -
OXYGEN SENSOR HEATER (01626, 01627,
41
816A2 engine)
11-230 -
41 LAF SENSOR HEATER (01521 engine) 11-236 -
FUEL SUPPLY SYSTEM (01626, 01627,
43 11-240 -
81 622 engine)
48 LAF SENSOR (O 1521 engine) 11-226 -
• lf codes other than those listed above are indicated, verify the code. lf the code indicated is not listed above, replace
the ECU.
• The Check Engine light may come on, indicating a system problem when, in fact, there is a poor or intermittent electri-
cal connection. First, check the electrical connections, clean or repair connections if necessary.
• The Check Engine light and 04 indicator light may light simultaneously when the self-diagnosis indicator blinks 6, 7
and 1 7 Check the PGM-FI system according to the PGM-FI control system troubleshooting, then recheck the 04 in-
dicator light. lf it lights, see page 14-316.
• The Check Engine light does not come on when there is a malfunctionn in the Electric Load Detector circuits. However,
it will indicate the codes when the Service Check Connector is jumped.
6-8
DIGITAL
~CJ
TEST HARNESS
- 07LAJ-PT30100
or
07LAJ-PT3010A
NOT USED
.&.! Al AS Al A9,1'11AIJA15A17419A21 .. 23A2Sl1 93 IS 17 19911913815 01 03 05 07 09 01101l0UDIJDl9D21
oooooooooooooooooooooo#ct(;)ooooooooooooo
o o o o o o o o o o o o o o o o o o o o o <><>·o:,"J,o.o o o o o o o o o o o o
A2 A4 .1.1 Al A10A12AHA18All.1.l0.l.22.\24AH82 14 16 18 110 S12114 IUi 02 Do1 D6 08 010012014 011011020 022
TERMINAL LOCATION
6-9
VTEC
Troubleshooting-Self-diagnostic Procedures (cont' d)
CAUTION:
• Puncturing the insulation on a wire can cause poor or intermittent electrical connections.
• For testing at connectors other than the test harness, bring the tester probe into contact with the terminal from the
connector side of wire harness connectors in the engine compartment. For female connectors, just touch lightly with
the tester probe and do not insert the probe.
RUBBER SEAL TESTEA PROBE
WIRE HARNESS
TERMINAL
6-10
How To Read Flowcharts
A flowchart is designed to be used from start to final repair. lt's like a map showing you the shortest distance. But
beware: if you go off the "rnao " anywhere but a "stop" svrnbot. you can easily get lost.
! START ! Describes the conditions or situation to start a troubleshooting flowchart.

(bold type)
1 ACTION ! Asks you to do something; perform a test, set up a condition etc.
( DECISION) Asks you about the result of an action, then sends you in the appropriate troubleshooting direction.
STOP The end of a series of actions and decisions, describes a final repair action and sometimes directs you to
(bold type) an earlier part of the flowchart to confirm you repair.
NOTE:
• the term "lntermittent Failure" is used in these charts. lt simy means a system rnay have had a failure, but it checks
out OK at this time. lf the Check engine light on the dash does not come on, check for poor connections or loose
wires at all connections relatad to the ciricuit that you are troubleshooting.
• Most of the troubleshooting flowcharts have you reset the ECUand try to duplicate the problem code. lf the problem
is intermittent and you can't duplicate the code, do not continua through the flowchart. To do so will only result in
confusion and, possibly, a needlessly replaced ECU.
• "Open" and "Short" are common electrical terms. An open is a break in a wire or at a connection. A short is an
accidental connection of a wire to ground or to another wire. In simple electronics, this usually means somethinq
won't work at all. In complex electronics (like ECU's). this can sometimes mean something works, but not the way
it's supposed to.
• lf the electrical readings are not as specified when using the test harness, check the test harness connections before
proceeding.
6-11
VTEC
Troubleshooting Flowchart-Spool Valve
<, 1 /' 1 »:
/
·/O)- -[fil-
J <, >" 1 <,
Self-diagnosis Check Engine light indicates code 21: A problem in the Spool Valve circuit.
Engine is running.
Check Engine light has been
reported on.
With service check connector
jumped (page 6-6), CODE 21
is indicated.
Do the ECU Reset Procedures

(paga 6-7).
Start the engine.
lntermittent failure. system is OK

at this time (test drive may be
Is Check Engine light on and does NO necessary).
it indicate CODE 21 ? Check for poor connections or
loose wires at spool valve and
YES ECU.
Turn the ignition switc:h OFF.
Disconnect the 1 P connector

from the spool valva.
Check for continuity between 1 P

connector terminal and body
---_.¿.;¡@o+--,
D
ground.
NO
Is there 14-30 n? Replace the spool valve.
YES
To page 6-13
6-12
From page 6-1 2

oººººººººººººººººººº ººººººººººº
A4
Connect the ECU test harness.

connector terminal and A4 ter-
minal.
< Does continuity exist?
YES
) NO Repair open in wire between ECU
and spool valve connector.

connector terminal (harness
side) and body ground.
< Does continuity exist?

~~~~~~~~~~~~~--'
) YES
Repair short in wire between
ECU and spool valve connector.
NO
Substituta a known-good ECU

and recheck. lf symptom/indica-
tion goes away replace the
original ECU.
6-13
VTEC
Troubleshooting Flowchart- Oil Pressure Switch
'· : / <, 1 /
/
[a- -[ID-
l <, .,..,... ' <,
Self-diagnosis Check Engine light indicates code 22: A problem in the Oil Pressure Switch circuit.
Englne is running.
reponed on.
jumped (page 6-6), CODE 22
is indicated.

(page 6-7).
Turn the ignition switch ON.

Is Check Engine light on and does NO necessary).
it indicate CODE 22? Check for poor connections or
loose wires at oil pressure switch
YES and ECU.
Turn the ignition switch OFF.
Disconnect the 2P connector

from the oil pressure switch.
Check for continuity between

BLK terminal and body ground.
NO Repair open in BLK wire between

Does continuity exist?
2P connector and body ground.
YES
Connect the ECU test harness.

BLU/BLK terminal and 06 ter-
minal.
NO Repalr open in BLU/BLK wire bet-

Does continuity exist? ween ECU and 2P connector.
YES
Check for continuity between 06
terminal and body ground.
YES Repair short in BLU/BLK wire bet-
Does continuity exist? ween ECU and 2P connector.
NO
06
To page 6-15
6-14
D15Z1, D16Z6 englne VTEC PRESSUREGAUGE
A/T LOW PRESSUREGAUGE ATTACHMENT B16A2 engine:
From page 6-14
07406-0070000 07NAJ-P070100 A/T LOW PRESSUREGAUGE
07406-0070000
01521, 01626 engine:

Remove the oil pressure switch ~
install the special tools, th~
reinstall the oil pressure switch.
816A2 engine:
Remo ve 1 O mm sealing bolt and
connect oil pressure gauge.
Connect a tachometer (Section

11).
OIL PRESSURE GAUGE JOINT ADAPTOR

SWITCH 07LAK-PR30100
Start the engine and warm it up
• Use new 0-ring • Use new washer when
to normal operating temperature.
when installing. installing the sealing bolt.
Check oil pressure at engine

speeds of 1,000, 3,000 and
5,000 min-1 (rpm), 01521:
1,000 and 3,000 rnírr ' (rpm). NOTE:
Keep measuring time as short as
possible because engine is running
with no load (within one minute).
Is pressure below 50 kPa (0.5 NO

kg/cm2, 7 psi)? lnspect the spool valve.
YES

the 2 terminals on the oil
pressure switch.
OIL PRESSURE
<
I
SWITCH
_ Does continuity exist?
·~~~~~~>NO . · Replace oil pressure switch.
YES
Oisconnect the 1 P connector

from the spool valve.
Attach the battery positive ter-

minal to the GRN/WHT terminal.
To page 6-16
D
© (cont'd)
6-15
VTEC
Troubleshooting Flowchart- Oil PressureSwitch ( cont' d)
From page 6-1 5

01521, 01626 englne VTEC PRESSUREGAUGE
A/T LOW PRESSURE GAUGE ATTACHMENT B16A2 engine:
07406-0070000 07NAJ-P070100 A/T LOW PRESSUREGAUGE
Start the engine and check oil 07406-0070000
pressure at engine speeds of
5,000 min-1 (rprn). 01521
engine: 3,000 rnin" (rprn).
OIL PRESSURE
SWITCH
• Use new 0-ring • Use new washer when
when installing. installing the sealing bolt
NOTE:
Keep measuring time as short as
possible because engine is running
with no load (within one minute).
Is pressure above 400 kPa (4

kg/cm2, 57 psi), 01521 engine: NO
above 250 kPa (2.5 kg/cm2, 36 lnspect the spool valve.
psi).
YES

the 2 terminals on the oil
pressure switch under above
condition.
< Does continuity exist? )

. ·
NO
Replace oll pressure switch.
I
'--~~~~~~~~~~~~
YES

and recheck. lf symptom/lndica-
tion goes away replace the
original ECU.
6-16
Spool Valve lnspection
1. DiscÓnnect the 1 P connector from the spool valve. 4. lf filters are normal, push the spool valve with your
2. Measure resistance between the terminal and body finger and check its movement.
ground. • lf spool valve is normal, check the engine oil
Resistance: approx 14-30 ohms pressure.
6x1.0mm
12 N•m ( 1.2 kg-m, 9 lb-ftl
D
-----+Uo u-t----,
3. lf the resistance is within specifications, remove

the spool valve assembly from the cylinder head,
and check the spool valve filter for clogging.
• lf there is cologging, replacethe engine oil filter
and the engine oil.
SPOOL VALVE
ASSEMBLY
SPOOL VALVE
FILTER
Replace.
6 x 1.0 mm
12 N•m 11.2 kg-m. 9 lb-ftl
6-17
lllustrated lndex
D15Z engine:
CAUTION: To avoid damaging the cylinder head, wait until the coolant temperature drops below 38ºC (100°F) befare
removing it.
NOTE:
• Use new 0-rings and gaskets when reassembling.
• Use liquid gasket, Part No. OY740-99968 .
., Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact parts.
¡
CYLINDER HEAD
6x1.0mm
COVER
10 N•m (1.0 kg-m, CYLINDER HEAD BOL TS
Apply oil to spark
7 lb-ftl
w7as,a1Uag.
plug tube seal 10 x 1.25 mm
73 N•m (7.3 kg·m, 53 lb-ftl
Apply clean engine oil
to bolt threads and
washer contact
surface.
Replace.
8 x 1.25 mm
24 N•m (2.4 kg·m,
17 lb-ft)
TIMING BELT
I nspection/ Adjustment,
page 6-54
Replacement,
page 6-55
6-18
NOTE: Use new 0-rings and gaskets when reassembling.
, Prior to reassembling, clean all the parts in solvent, drv them, and apply lubricant to any contact parts.
ROCKER ARM
ASSEMBLY 8 x 1.25 mm
Overhaul, page 6-31 22 N·m (2.2 kg-m,
lnspection, page 6-34 16 lb-ft)
ADJUSTING 6 x 1.0 mm
SCREWS 12 N•m (1.2 kg-m,
Adjustment, 6-65 9 lb-ft)
VAL VE KEEPERS
~PRING RETAINER
~ INTAKE VALVE SPRING
~VALVESEAL
~SPRING SEAT
e': -----VALVEGUIDE
r1 OIL SEAL

f:J Replace.
0-RING f1;
Replace. @
EXHAUST~
SPRING »>: ~
VALVE SEAL
lnspection, page 6-40

Replacement, page 6-42
Reaming, page 6-43
CYLINDER HEAD
Removal, paga 6-24
lnstallation, page 6-48
Warpage, page 6-40
Valve seat reconditioning, 8 x 1.25 mm
page 6-42 38 N•m
INTAKE VALVE (3.8 kg-m, 27 lb-ft)
Removal, page 6-38 6 x 1.0 mm
lnstallation, page 6-44 12 N•m (1.2 kg-m,
9 lb-ft)
(cont'd)
6-19
lllustrated lndex
016Z6 engine:
CAUTION: To avoid damaging the cylinder head. wait until the coolant temperature drops below 38ºC (100ºF) before
removing it.
NOTE:
• Use liquid gasket, Part No. OY740-99968.
, Prior to reassernbünq, clean all the parts in solvent, dry them, and apply lubricant to any contact parts.
6x1.0mm CYLINDER HEAD

10 N•m (1.0 kg-m, COVER
7 lb-ft) Apply oil to spark plug tube
sea! when installing.
CYLINDER HEAD BOL TS

10 x 1.25 mm
73 N•m (7 .3 kg-m, 53 lb-ft)
to bolt threads and
washer contact surface.
/
8 x 1.25 mm
24 N•m (2.4 kg-m,
17 lb-ft)
Replace.
TIMING BELT
I nspection/Adjustment,
page 6-54
Replacement,
page 6-55
6-20
~ Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact parts.
8 x 1.25 mm
LOST MOTION ASSEMBLY HOLDER ~ 22 N•m (2.2 kg-m,
"x~·~ ~ 16 lb-hl
6x1.0mm
12 N•m (1.2 kg-m,
9 lb-ftl
Replace.
-,
VAL VE KEEPERS
SPRINGR~ •
EXHAUST VALVE S/~
VALVESEAL~-
~
f
SPRING SEAT 0-R~
Replace.
VALVE GUIDE
Reaming, page 6-43
CYLINDER HEAD
Removal, page 6-24 EXHAUST VAL VE
Warpage, page 6-40 TIMING BELT
Valve seat reconditioning, BACK P~ATE
page 6-42
INTAKE VALVE
Removal, page 6-38
(cont'dl
6-21
lllustrated lndex
0128, 0138, 0158, D16A7 engine:

llfustrated: D 1 6A 7 engine
CAUTION: To avoid damaging the cylinder head, wait until the coolant temperature drops below 38°C (100°F) befare
removing it.
NOTE:
Prior to reassernbllnq, clean all the parts in solvent, dry them, and apply lubricant to any contact parts.
~Ó~~~i: ~!AD BOLTS

65 N•m (6.5 kg-m, 49 lb-ft)
Apply clean engine oíl
/
to bolt threads and
washer contact
surface.
\ INTAKE MANIFOLD
»:
»>
TIMING BELT
I nspection/ Adjustment,
page 6-54
Replacement,
page 6-55
-e
Ij¡h' <; INTAKE MANIFOLD
BRACKET
~ ~
8•125mmp
24 N•m (2.4 kg-m, 17 lb-ftl
(cont'd)
6-22
NOTE: Use only new 0-rings and new gaskets when reassembling.
, Prior to reassembling, clean all the parts in solvent, dry then, and apply lubricant to any contact parts.
6 x 1.0 mm
12 N•m (1.2 kg-m, 9 lb-ftl
ROCKER ARM ASSEMBL Y
Disassembly, page 6-33
8 x 1.25 mm lnspection, page 6-35
22 N•m (2.2 kg-m, 16 fb·ftl
VALVE KEEPERS
t~t--"'!¿__::::::::,¡¡_ ADJUSTING SCREWS
Adjustment, page 6-65
SPRING RETAIN~R \
8 x 1.25 mm
24 N•m 12.4 kg-m, 17 lb·ftl
VALVESPRI~
CAMSHAFT
EXHAUSTV~LVE _:::;.- lnspection, 6-36
SEAL
Replace. ~ 0-RINGS
Replace.
VALVE SPRING----~
SEAT ""\.
EXHAUST_.........t
VAL VE \
GUIDE
~~~
t
CAMSHAFT PULLEY
\ Replace.
INTAKE VALVE GUIDE
\
Removal, page 6-28
-.
lnstallation, page 6-4 7
8 x 1.25 mm lnstallation,
38 N•m page 6-45
(3.8 kg-m, 27 lb-ftl Replace.
INTAKE VALVE
CYLINDER HEAD
Removal, lnspection,
Removal, page 6-24
Dimension, page 6-39
Warpage, page 6-40
Reconditioning valve seat,
Reconditioning valve
EXHAUST VAL VE page 6-41
seat, page 6-41
lnstallatión, page 6-48
6-23
Cylinder Head
Removal
Engine removal is not required far this procedure. 0128. 0138, 01583 engine:
CAUTION: To avoid damaging the cylinder head,

wait until the coolant temperature drops below
38ºC (100° F) before loosening the retaining bolts.
NOTE:
• lnspect the timing belt befare removing the
cylinder head.
• Turn the crankshaft pulley so that the No. 1
piston is at top-dead-center (page 6-58).
• Mark all emissions hoses befare disconnecting
them.
1. Oisconnect the negatíve terminal from the battery.
2. Drain the coolant (See section 1 O).
• Removethe radiator cap to speed draining.
3. Relieve fuel pressure.
f•\fr\;j.ij@N Do not smoke while working on fuel

system, keep open flame or spark away from work
area. Drain fuel only into an approved container.
6. Remove the PCV hose, fuel hoses vacuum hose
4. Remove the air flow tube.
and water bypass hose.
5. Remove the fuel feed hose and charcoal canister
0128, D13B, 01583 engine:
D16A7 engine:
BREATHER PIPE
VACUUM HOSE
6-24
01584 engine. 8. Remove the throttle cable and the throttle control
cable (A/T) from the throttle body.
NOTE:
PCV HOSE • Take care not to bend the cable when removing
it. Always replace any kinked cable with a new
one.
• Adjust the throttle cable when installing (See
section 1 1 ) .
THROTTLE
CONTROL CABLE
FUEL HOSES THROTILE CABLE
7. Disconnect two connectors, then remove the fuel 9. Remove the engine wire harness connectors and
emission control box. wire harness clamps from the cylinder head and the
• Do not remove the vacuum tubes. intake manifold.
• Four injector connectors
• TA sensor connector
FUEL EMISSION
CONTROL BOX
• EACV connector
6 x 1.0 mm • Throttle sensor connector
10 N•m (1.0 kg-m, • MAP sensor connector
7 lb-ft)
• Ground terminal (at thermostat cover)
• TW switch connector (for cooling fan)
• Oxygen sensor connector
• TW sensor connector (for emission)
• Temperature unit connector
• Spool valve connector (O 162, D1 52 engine)
• Oil pressure switch connector (0162, 01 52
engine)
• EGRlift sensor connector (D1 52 engine)
CONNECTORS
(cont'd)
6-25
Cylinder Head
Removal (cont' d)
1 O. Disconnect spark plug wire at spark plugs. 14. Remove the emission vacuum hoses and water
Remove the distributor. bypass hoses from the intake manifold assembly.
11. Remove the engine ground cable on the cylinder 1 5. Remove the radiator upper hose and heater hose
head cover. from the cylinder head.
12. Remove the P/S belt and pump. 16. Remove the water bypass hose from intake
• Do not disconnect the P/S hoses. manifold.
8 x 1.25 mm
24 N•m (2.4 kg-m,
33 lb-ft) \
PIS\
~~
~ WATER BYPASS HOSE
I
8 x 1.25 mm
24 N•m (2.4 kg-m, 17 lb-ftl
HEATER HOSE
1 7. Removethe intake manifold bracket.
18. Remove the self-locking nuts and disconnect the

13. Removethe P/S bracket. exhaust manifold and exhaust pipe A.
19. Removethe exhaust manifold bracket.
20. Remove the PCV hose, then remove the cylinder

P/S BRACKET head cover.
10 x 1.25 mm 21. Removethe timing belt upper cover.

45 N•m (4.5 kg-m,
33 lb-ft) 22. Loosen the timing belt adjusting bolt 180° to
releasethe belt tension.
23. Push the tensioner to releasetension from the tim-

ing belt, then retighten the adjusting bolt.
10 x 1.25 mm
45 N•m 14.5 kg-m. 33 lb-ftl
ADJUSTING BOLT
45 N·m (4.5 kg-m, 33 lb-ft)
6-26
24. Remove the belt from the cam pulley. NOTE: Separate the cylinder head from the block
with a flat blade screwdriver as shown.
CAUTION: Do not crimp or bend

the tlming belt more than 90°
or less than 25 mm (1 in) in
•
No Good
25. Remove the cylinder head bolts, then remove the

cylinder head.
CAUTION: To prevent warpage, unscrew the bolts

in sequence 1 /3 turn at a time: repeat until all bolts
are loosened.
26. Remove the intake manifold and exhaust manifold
CYLINDER HEAD BOL T LOOSENING SEQUENCE from the cylinder head.
6-27
Cam Pulley Rocker Arms
Removal Remo val
1. To ease reassembly, rurn the pulley until the "UP" 1. Loosen the adjusting screws.
mark faces up, and the front timing mark is aligned
as shown below. 016Z engine:
016A7, 0162 engine:
ADJUSTING SCREWS
0128, 0138,
TDC mark aligned with

the pointer on cylinder
head back cover.
0152 engine:
TDC GROOVES
AOJUSTING SCREWS
Align front timing mark on
pulley with the valve cover
surface.
l>MARK
F
015Z engine:
TDC GROOVES ADJUSTING SCREWS

Align with triangle mark
( t> <l) on cylinder head back
cover.
2. Remove the retaining bolt and the cam pulley.
6-28
0128, 0138, 0158, D16A7 engine: 01 SZ engine:
-+--1
6 mm BOLT 8 mm BOLTS 6 mm BOLT
\ -¡ ~I ----,-1 ---.1 ~
o e, • • • •
ADJUSTING SCREW
2. Unscrew the cam holder bolts , then remove the 8 e G 0 0

rocker arrn assembly.
e L-1 _ __JI_--+-, _ __,_¡ _ ___,! •
NOTE: 1 1
• Unscrew the cam holder bolts two turns at a
time, in a criss-cross pattern, to prevent damag-
ing the valves or rocker arm assembly.
• When removing the rocker arm assembly, do not
remove the cam holder bolts. The bolts will keep 0128, 0138, 0158, D16A7 engine:
the carn holders, the springs and the rocker arrns
on the shaft.
016Z engine:

l
j j j •
1
1
6 mm BOLT 8 mm BOLTS
6-29
Rocker Arms
Overhaul~·~~~~~~~~~~~~~~~~~~~~~~~~~~~-
NOTE:
• ldentify parts as thev are removed to ensure reinstallation in original locations.
• lnspect rocker shafts and rocker arms (page 6-34).
• Rocker arms must be installed in the same position if reused.
• When removing or installing rocker arm assembly, do not remove bearing cap bolts. The bolts will keep the holders,
springs and rocker arms on the shaft.
0162 engine:
INTAKE ROCKER SHAFT
j
ROCKER SHAFT ROCKER SHAFT
COLLAR
'- ~~~==-. ~-=-v::_-_-_-~-

. . .-_. ._'. ."'
COLLAR
Selection, (4 places)
page6-38
L -"_'"'::_-º_-_º-:___j~ INTAKE
ROCKER ARMS ROCKER ARM
ASSEMBLY
COLLAR RUBBER BAND
COLLAR
-o ~
wf
r A
B A B¡A B
ROCKER SHAFT ROCKER SHAFT

SPRING SPRING
(4 places)
t
EXHAUST ROCKER
ARMB
f
EXHAUST ROCKER SHAFT
Letter"B" is stamped Letter"A" is stamped

on rockerarm. on rocker arm.
6-30
0152 engine:
~-----,.~NTAKE RIR SHAF:r----,
ROCKER ARMSL '-----' ......___ _,, ._. :=_j INTAKE

ROCKER ARM
TIMING PLATE RUBBER BAND ASSEMBLY
ROCKER SHAFT ROCKER SHAFT TIMING PLATE
(4 places)
¿
COLLAR
(4 places)
SPRING
COLLAR
@/
EXHAUST ROCKER EXHAUST

ARM B ROCKER ARMA
(4 places) (4 places)
\ I
ROCKER SHAFT ROCKE
SPRING SPRING
(4 places) EXHAUST ROCKER SHAFT
Letter "B" is stamped Letter "A" is stamped

on rocker arm. on rocker arm. (cont'd)
6-31
Rocker Arms
Overhaul (cont' d)
NOTE:
• ldentify parts as they are removed to ensure reinstallation in original locations.
• lnspect rocker shafts and rocker arms (page 6-35).
• When removing or installing rocker arm assembly, do not remove bearing cap bolts. The bolts will keep the holders,
springs and rocker arms on the shaft.
0128. 0138, 0158, ROCKER SHAFT B

016A7 engine: (3 places)
ch t A~~"·'ri
ROCKER SHAFT A
(2 places)
---t I il
Position mark
Letter "B" is stamped

on rocker arm.
Letter "A" is stamped
on rocker arm.
6-32
Rocker Shaft Collars
Selection (D 162 engine) ----- Selection (0152 engine)
CAUTION: lf the codes are indecipherable because of CAUTION: lf the codes are indecipherable because of
an accumulation of dirt and dust, do not scrub them an accumulation of dirt and dust, do not scrub them
with a wire brush or scraper. Cleanthem only with sol- with a wire brush or scraper. Clean them only with sol-
vent or detergent. vent or detergent.
Cam Holder Distance Code Location (Marks) Cam Holder Distance Code Location (Marks)
Marks have been stamped on the upper face end of the Marks have been stamped on the upper face end of the
cylinder head as a code for the distance of each cam cylinder head as a code for the distance of each cam
holder. holder.
Use them, and the marks stamped on the rocker shaft Use them, and the marks stamped on the rocker shaft
collar (code for collar length), to choose the correct collar (code for collar length), to choose the correct
rocker shaft collars from the table below. rocker shaft collars from the table below.
~Mffl
No.4
Fitting Table
Head Marks
No.1
A B e
n
-K-Length
D E F
No.4
Fitting Table
Head Marks
No. 1
A B e
Jl D E
Length
F
Collar Marks A B e D E F Collar Marks H 1 J K L M
Rocker Shaft Collar Rocker Shaft Collar
Marks Part Number Length mm (in) Marks Part Number Length mm (in)
12.325-12.375 8.975-9.025
A 14651-POS-OOO H 14651-P07-000
(0.4852-0.4872) (0.3533-0.3553)
12.275-12.325 8.925-8.975
B 14652-POS-OOO 1 14652-P07-000
(0.4833-0.4852) (0.3513-0.3533)
12.225-12.275 8.875-8.925
e 14653-POS-OOO
(0.4813-0.4833)
J 14653-P07-000
(0.3494-0.3513)
12.175-12.225 8.825-8.875
D 1 46 54- POS- 000 K 14654-P07-000
(0.4793-0.4813) (0.3474-0.3494)
12. 1 25-12. 1 75 8. 775-8.825
E 14655-POS-OOO L 14655-P07-000
(0.4774-0.4793) (0.3455-0.3474)
12.075-12.125 8.725-8.775
F 14656-POS-OOO M 14656-P07-000
(0.4754-0.4774) (0.3435-0.3455)
6-33
Rocker Arms and Lost Motion Assemblies
lnspection (0162, 0152 engine)
NOTE: When reassernbtlnq the primary rocker arm, 01521 engine:

carefully apply air pressure to oil passageof the rocker
arm.
NOTE: Set the timing plate and return spring as
1. lnspect the rocker arm pistan. Push it manually. shown below.
- lf it does not move smoothly, replace the rocker
arm assembly.
01626 engine: RETURN SPRING TIMING PLATE
SECONDARV
ROCKER ARM
I
PRIMARV ROCKER
ARM
CAM HOLDER
01521 engine:
01626 engine only:
PRIMARY ROCKER 2. Pushing the rocker arm top gently with the finger
ARM will cause it to sink slightly. lncreasing the force on
I TIMING PISTON
it will cause it to sink deeper.
- lf the lost motion assembly does not move
TIMING SPRING smoothly, replace it.
SVNCHRONIZING
PISTON
GROOVE@
tÍ(N)
~
SECONDARV
ROCKER ARM
NOTE:
• Apply oil to the pistons when reassembling.
• Bundle the rocker arms with a band to prevent
them from separating.
6-34
Rocker Arms and Shafts
Clearance
Measure both the intake rocker shaft and exhaust 3. Measure inside diameter of rocker arm and check
rocker shaft. for out-of-round condition.
1. Measure the diameter of shaft at the first rocker Rocker Arm Radial Clearance:
location. Service Limit: 0.08 mm (0.003 in)
Surface should be smooth.
MICROMETER
lnspect rocker arm

tace for wear.
2. Zero the gauge to the shaft diameter.
4. Repeatfor all the rockers.

- lf the clearance is over the service limit, replace
the rocker shaft and all over-tolerance rocker
arms.
6-35
Camshaft
lnspection
NOTE: 2. Seat the camshaft by pushing it toward the rear of

• Do not rotate the camshaft during inspection. the cylinder head.
• Remove the rocker arms and rocker shafts.
3. Zara the dial indicator against the end of the carn-
1. Put the camshaft and the cam holders on the shaft. Push the camshaft back and forth, and read
cylinder head, then tighten the bolts to the the end play.
specified torque.
Camshaft End Play:
Specified torque: Standard (New): 0.05-0.15 mm
8 mm bolts: 22 N•m (2.2 kg-m, 16 lb-ft) (0.002-0.006 in)
6 mm bolts: 12 N•m (1.2 kg-m, 9 lb-ft) Service Limit: 0.5 mm (0.02 in)
0128, 0138, 0158, 016A7 engine:
6 mm BOLTS 8 mm BOLTS
016Z6, 015Z1 engine:
4. Remove the bolts, then remove the cam holders

from the cylinder head.
- Lift camshaft out of cylinder head, wipe clean,
then inspect lift ramps. Replace camshaft if
lobas are pitted, scored, or excessively worn.
- Clean the camshaft bearing surfaces in the
cylinder head, then set camshaft back in place.
- lnsert plastigage strip across each journal.
5. lnstall the cam holders and tighten the bolts to the

specified torque.
8 mm BOLTS
6 mm BOLTS (cont'd)
6-36
Camshaft
lnspection (cont'd)
6. Removethe cam holders, then measurethe widest 8. Check the cam lobe height wear.
portion of the plastigage on each journal.
Cam lobe height standard (New)
Camshaft Bearing Radial Clearance: Unit mm (in)
Standard (New): 0.050-0.089 mm INTAKE EXHAUST
(0.002-0.004 in) 0128, 0138
Service Limit: 0.15 mm (0.006 in) 35.458 (1.3960) 35.693 (1.4052)
engine
O 1 582 engine 36. 603 ( 1 .44 1 1 ) 36.750 (1.4468)
01583, 01584
36.603 (1.4411) 36.747 (1.4467)
engine
016A7 engine 36.782 (1.4481) 36.947 (1.4546)
0152 PRI 38.427 (1.5129)

37.997 (1.4960)
engine SEC 32.292 (1.2713)
PRI 35.900 ( 1.4134)
0162
SEC 36.195 (1.4251) 38.008 (1.4960)
engine
MIO 38.107 (1.5003)
PRI: Primary cam lobe, SEC: Secondary cam lobe.
MIO: Mid cam lobe, T/8: Timing belt.
~ []][ID]
7. lf the camshaft bearing radial clearance is out of
toleran ce:
- And the camshaft has already been replaced,
you must replace the cylinder head.
- lf the camshaft has not been replaced, first T 18 EXH J N EXH T /8
EXH IN EXH
check the total runout with the camshaft sup- - O 15Z engine - D 16Z engine
ported on V-blocks.
Camshaft Total Runout:

Standard (New): 0.015 mm (0.0006 in)
Service Limit: 0.030 mm (0.0010 in)
Rotate camshaft
while measuring.
Check this area for wear.
- lf the total runout of the camshaft is within

tolerance, replace the cylinder head.
lf the total runout is out of tolerance, replacethe
camshaft and recheck. lf the bearing clearance
is still out of tolerance, replace the cylinder
head.
6-37
Valves and Valve Seals
"
NOTE: ldentify valves and valve springs as the are 2. lnstall the spring compressor. Cornpress the spring
removed so that each ítem can be reinstalled in its and remove the valve keeper.
original position.
1. Using an appropriate-sized socket .and plastic

mallet, lightly tap the valve retainer to loosen the
valve keepers before installing the valve spring
compressor.
PLASTIC MALLET
VALVE SPRING
COMPRESSOR
07757-0010000
SOCKET
6-38
015Z engine:
lntake Valve Oimensions
B A Standard (New): 27.4-27.6 mm
-1~0 (1.08-1.09 in)

B Standard (New): 118.82-119.12 mm
[~
e (4.678-4.690 in)
C Standard (Newl: 5.48-5.49 mm
(0.2157-0.2161 in)
t1 [) C Sarvice Limit: 5.45 mm (0.215 in)
O Standard (Naw): 0.85-1.15 mm
(0.033-0.045 in)
O Sarvice limit: 0.65 mm (0.026 in)
Exhaust Valva Dimansions

A Standard (New): 23.4-23.6 mm
(0.92-0.93 in)
8 Standard (Naw): 116.20-116.50 mm
(4.575-4.587 in)
016Z angina: C Standard (New): 5.45-5.46 mm
lntaka Valva Dimansions (0.2146-0.2150 in)
A Standard (Naw): 29.9-30.1 mm C Servica Limit: 5.42 mm (0.213 in)
(1.18-1.19 in) O Standard (Naw): 1.05-1.35 mm
B Standard (Naw): 117.42-117.72 mm (0.041-0.053 in)
(4.623-4.635 in) O Service Limit: 0.95 mm (0.037 in)
C Standard (New): 5.48-5.49 mm
(0.2157-0.2161 in) 0128, 0138, 0158, 016A7 engina:
C Sarvica Limit: 5.45 mm (0.215 in) lntake Valve Oimensions
D Standard (New): 0.85-1. 15 mm A Standard (New): 28.9-29.1 mm
(0.033-0.045 in) (1.14-1.15 in)
O Sarvica Limit: 0.65 mm (0.026 in) B Standard (Naw): 113.82-114.12 mm
(4.481-4.493 in)
Exhaust Valve Oimensions C Standard (New): 5.48-5.49 mm
A Standard (New): 25.9-26.1 mm (0.2157-0.2161 in)
(1.02-1.03 in) C Service Limit: 5.45 mm (0.215 in)
B Standard (New): 114.60-114.90 mm O Standard (New): 0.85-1.15 mm
(4.512-4.524 in) (0.033-0.045 in)
C Standard (New): 5.45-5.46 mm D Sarvice Limit: 0.65 mm (0.026 in)
(0.2146-0.2150 in)
C Service Limit: 5.42 mm (0.213 in) Exhaust Valve Dimensions
O Standard (Naw): 1.05-1.35 mm A Standard (Naw): 24.9- 25. 1 mm
(0.041-0.053 in) (0.98-0.99 in)
O Servica Limit: 0.95 mm (0.037 in) 8 Standard (New): 117.40-117.70 mm
(4.622-4.634 in)
C Standard (Naw): 5.45-5.46 mm
(0.2146-0.2150 in)
C Sarvica Limit: 5.42 mm (0.213 in)
o Standard (New): 1.05~ 1 .35 mm
(0.041-0.053 in)
D Servica Limit: 0.95 mm (0.037 in)
6-39
Valves Cylinder Head
Valve Movement Warpage
Measure the guide-to-stem clearance with a dial indi- NOTE: lf the camshaft bearing clearances (page 6-41)
cator while rocking the stem in the direction of normal are not within specification. the head cannot be
thrust (wobble method). resurfaced.
lntake Valve Stem-to-Guide Clearance: lf the camshaft bearing radial clearances are within
Standard (New): 0.04-0.10 mm specifications, check the head far warpage.
(0.002-0.004 in)
Service Limit: 0.16 mm (0.006 in) • lf warpage is less than 0.05 mm (0.002 in)
cylinder head resurfacing is not required.
Exhaust Valve Stem-to-Guide Clearance: • lf warpage is between 0.05 mm (0.002 in) and
Standard (New): 0.10-0.16 mm 0.2 mm (0.008 in), resurface cylinder head.
(0.004-0.006 in) • Maximum resurface limit is 0.2 mm (0.008 in)
Service Limit: 0.22 mm (0.009 in) based on a height of 93 mm (3.66 in).
Valve extended 10 mm out from seat.
• lf measurement exceeds the service limit,

recheck using a new valve.
• lf measurement is now within the service limit,
reassemble using a new valve.
• lf measurement still exceeds limit, recheck using
alternate method below. then replace valve and Measure along edges, and 3 ways across center.
guide, if necessary.
NOTE: An alternate method of checking guide to

stem clearance is to subtract the O.O. of the valve
stem, measured with a micrometer, from the 1.0. of
the valve guide, measured with an inside
micrometer or ball gauge. Take the measurements
in three places along the valve stem and three
places inside the valve guide. The difference be-
tween the largest guide measurement and the
smallest stem measurement should not exceed the
service limit.
Cylinder Head Height:
lntake Valve Stem-to-Guide Clearance: 0152, 0162 engine:
Standard (New): 0.020-0.050 mm Standard (New): 92.95-93.05 mm
(0.001-0.002 in) (3.6594-3.6634 in)
Service Limit: 0.080 mm (0.003 in) Service Limit: 0.05 mm (0.002 in)
01 28, 0138, 0158, 016A 7 engine:
Exhaust Valve Stem-to-Guide Clearance: Standard (New): 94.95-95.05 mm
Standard (New): 0.05-0.08 mm (3.7382-3.7421 in)
(0.002-0.003 in) Service Limit: 0.05 mm (0.002 in)
Service Limit: O. 11 mm (0.004 in)
6-40
Valve Seats
Reconditioning
1. Renew the valve seats in the cylinder head using a

valve seat cutter.
NOTE: lf the guides are worn (page 6-40), replace

them (page 6-42) befare cutting the valve seats. VALVE
SEAT
VALVE SEAT PRUSSIAN BLUE COMPOUND

CUTTER 6. The actual valve seating surface, as shown by the
blue compound, should be centered on the seat.
• lf it is too high (closer to the valve stem), you
must make a second cut with the 60º cutter to
move it down, then one more cut with the 45º
cutter to restare seat width.
• lf it is too low (closer to the valve edge), you
move it up, then one more cut with the 45º cut-
ter to restare seat width.
2. Carefully cut a 45° seat, removing only enough
material to ensure a smooth and concentric seat. NOTE: The final cut should always be made
with the 45° cutter.
3. Bevel the upper edge of the seat with the 30º cut-
ter and the lower edge of the seat with the 60º cut- 7. lnsert the intake and exhaust valves in the head
ter. Check the width of seat and adjust and measure the valve stem installed height.
accordingly.
0128, 0138, 0158, D16A7 engine:
4. Make one more very light pass with the 45º cutter lntake Valve Stem lnstalled Height:
to remove any possible burrs caused by the other Standard (New): 46.99-47.46 mm
cutters. (1.850-1.868 in)
Valve Seat Width: Exhaust Valve Stem lnstalled Height:
Standard (New): Standard (New): 48.97-49.44 mm
lntake: 0.85-1.15 mm (0.033-0.045 in) (1.9278-1.946 in)
Exhaust: 1.25-1.55 mm (0.049-0.061 in) Service Limit: 49.69 mm (1.956 in)
Service Limit:
lntake: 1 .6 mm (0.06 in) 015Z, 016Z engine:
Exhaust: 2.0 mm (0.08 in) lntake, Exhaust Stem lnstalled Height:
Standard (New): 53.17-53.64 mm
(2.0931-2.112 in)
8. lf the valve stem installed height is over the service

limit, replace the valve and recheck. lf its still over
the service limit, replace the cylinder head; the
valve seat in the head is too deep.
5. After resurfacing the seat, inspect for even valve VALVE STEM
INSTALLED HEIGHT
seating: Apply Prussian Blue compound to the
valve tace, and insert the valve in its original loca-
tion in the head, then lift and snap it closed against
the seat several times.
6-41
Valve Guides
Replacement
1. As illustrated in the removal steps of this procedure 4. Working from the camshaft side, usethe driver and
use a comrnercially-available air-impact driver atan air hammer to drive the guide about 2 mm
tachment which may needto be modified to fit the towards the combustion chamber. This will knock
diameter of the valve guides. In most cases, the off sorne of the carbon and make removal easier.
same procedure can be done using Valve Guide
Drivers anda conventional hammer. Tool numbers
are included in the procedure.
VALVE GUIDE DRIVER

5.3 mm
o~------.,1= (0.21 in_j
87mm +- JTr
(3.43 in)
57mm
(2.24 in)
10.8 mm
(0.42 in)
· 2. Select the proper replacement guides and chill

them in the freezer section of a refrigerator for
about an hour.
3. Use a hot plate or oven to evenly heat the cylinder

head to 150ºC (300ºF). Monitor the temperature
with a cooking thermometer.
CAUTION:
• Always wear safety goggles or a face shield
when using the air hammer.
• Hold the air hammer directly in line with the
valve guide to prevent damaging the driver.
5. Turn the head over and drive the guide out toward
the camshaft side of head.
CAUTION: lf a valve guide still won't move, drill it out with a

• Do not use a torch; it may warp the head. 5/16 inch bit, then try again.
• Do not get the head hotter than 1 50 ° C (300 ° F);
excessive heat may loosen the valve seats. CAUTION: Drill guides only in extreme cases; you
• To avoid burns, use heavy gloves when handling could damage the cylinder head if the guide breaks.
the heated cylinder head.
6. Remove the new guides from the refrigerator, one
ata time, as you need them.
6-42
Valve Guide Reaming
7. Slip a 6 mm steel washer and the correct driver at- NOTE: Far new valve guides only.
tachment over the end of the driver. (The washer
will absorb sorne of the impact and extend the life 1. Coat both the reamer and valve guide with cutting
of the driver). oil.
2. Rotate the reamer clockwise the full length of the

valve guide bore.
3. Continue to rotate the reamer clockwise while

DRIVER 6 mm WASHER ATTACHMENT removing it from the bore.
8. lnstall the new guide(s) from the camshaft side of 4. Thoroughly wash the guide in detergent and water
the cylinder head; drive each one in until the attach- to remove any cutting residue.
ment bottoms on the head. lf you have all sixteen
guides to do, you rnav have to reheat the head one 5. Check the clearance with a valve (page 6-40).
or two more times. - Verify that the valve slides in the valve guide
without exerting pressure.
Turn reamer in
clockwise direction
only.
REAMER
HANDLE
NOTE: Valve guide replacement can be performed

with this special tool.
Valve Guide lnstalled Height:

D162, D1 52 engine:
lntake: 17.85-18.35 mm (0.703-0.722 in)
Exhaust: 18.65-19. 1 5 mm (O. 734-0. 754 in)
D12B, D138, D158, D16A7 engine:

lntake: 15.95-16.45 mm (0.628-0.648 in)
Exhaust: 15.95-16.45 mm (0.628-0.648 in)
VALVE GUIDE
REAMER, 5.5 mm
VALVE GUIDE 07HAH-PJ70100
":tJ;;·;;~·
CYLINDER HEAD
6-43
Valve Springs and Valves
Valve Spring and Valve Seal lnstallatlon Sequence
NOTE: Exhaust and intake valve seals are NOT interchangeable.
/VALVE KEEPERS
VALVE SPRING
RETAINER
VALVE SPRING
NOTE: Place the end of valve ::)

EXHAUST VALVE SEAL
spring with closely wound coils
(BLACK SPRING)
toward the cylinder head.
Replace.
INTAKE VALVE SEAL

(WHITE SPRING)
Replace.
SPRING SEAT
NOTE: lnstall the valve spring seats
before installing the valve seals.
VALVE GUIDE SEAL DRIVER

07HAH- PJ70200
VALVE SEAL
Replace.
6-44
Camshaft/Seal and
Valve Springs and Valves Rocker Arms
Valve lnstallation lnstallation
CAUTION: Whan tapping tha valva stams tap it at a CAUTION:

right angla to tha stam and so as not to bend the stem. • Make sure that all the rockers are in alignment with
the valves when torquing the rocker assembly bolts.
• When installing the valves in the cylinder head, • To prevent the rocker arm assembly from coming
coat the valve stems with oil before inserting them apart, leave the cam holder holding bolts in the
into valve guides, and make sure the valves move holes.
up and down smoothly.
1. After wiping down the cam and journals in the
• When the valves and springs are in place, lightly cylinder head, lubricate both surfaces and install
tap the end of each valve stem two or three times the camshaft.
to ensure proper seating of the valve and valve
keepers. 2. Set the camshaft and camshaft seal as shown
below.
3. lnstall the camshaft seal with the open side (spring)

facing in.
, Lubricate the cam lobes after reassembly.

PLASTIC MALLET
4. lnstall the oil control orifice as shown.
• Use a new 0-ring when installing.
OIL CONTROL
ORIFICE
CAMSHAFT "-....... 0-RING
Keyway up. ~Replace.
VALVE STEM END

Apply oíl.
CAMSHAFT SEAL
Seal housing surface should be dry.
Apply a light coat of oil to camshaft
and inner lip of seal.
(cont'd)
6-45
Camshaft/Seal and Rocker Arm
lnstallation (cont'd)------------------------
4. Apply liquid gasket to the head mating surface of 6. Tighten each bolt two turns at a time, in the se-
the No. 1 and No. 5 or No. 6 cam holders. quence shown below, to ensure that the rockers do
- Apply liquid ~¡asketto the shaded areas. not bind the valves.
Specified torque:
8 mm bolts: 22 N•m (2.2 kg-m, 16 lb-ft)
6 mm bolts: 12 N•m (1.2 kg-m, 9 lb-ft)
D16Z engine:
6 mm BOLT 6 mm BOLT
I®
1 1
@ 1
(J) CD ® ®
No. 5 No. 1
® © @ ® @
I®
5. Set the rocker arm assembly in place and loosely in-
stall the bolts. @
1 1 1
- Make sure that the rocker arms are properly 1 1 1
positioned on the valve stems. 6 mm BOLT 8 mm BOLTS 6 mm BOLT
6-46
015Z engine: 7. lnstall the timing belt back cover.

8. lnstall the cam pulley.
1 1 1 1 1 1
@ (J) @ CD ® ®@
@ ® © @ ® @)@
1 1 1 1
1
8 x 1.25 mm
38 N•m
0128, 0138, 0158, D16A7 engine: (3.8 kg-m, 27 lb-ftl
6 mm BOLT
8 mm BOLTS
\ 19 @
1 1
®
1
(J) @
1
CD ®
1 1 1
©
1
@
l 1 1
@ ® @ ® @ @
1 1 1 1 1 1
1
6 mm BOLT 8 mm BOLTS
6-47
Cylinder Head
lnstallation
lnstall the cylinder head in the reverse order of removal:

01584 engine:
NOTE:
• Always use a new head gasket.
• Cylinder head and engine block surface must be CARBURETOR
clean.
• Turn the crankshaft so that No. 1 piston is at
TDC (page 6-59).
1 . lnstall the intake manifold and tighten the nuts in a

criss-cross pattern in 2 or 3 steps, beginning with
the inner nuts.
015Z, 016A7, 016Z engine:
INTAKE MANIFOLD GASKET

Replace.
Bx1.25mm
23 N•m (2.3 kg-m,
17 lb-ft)
INTAKE MANIFOLD
BRACKET
1
01582:
~~
Bx 1.25mm
23 N•m (2.3 kg-m, 17 lb-ft)
8
J.
x _25 mm
1
. 22 N•m (2.2 kg-m, 16 lb-ft)
0128, 0138, 01583 engine:
8 x 1.25 mm
23 N•m (2.3 kg-m, INTAKE MANIFOLD
17 lb-ft)
8 x 1.25 mm
23 N·m (2.3 kg-m, 17 lb-ft)
8 x 1.25 mm
22 N•m (2.2 kg-m, INTAKE MANIFOLD
16 lb-ft) BRACKET
6-48
2. lnstall the exhaust manifold and tighten the nuts in 0128, 0138 engine:
a criss-cross pattern in 2 or 3 steps, beginning with
the inner nut.
016A7, 0162 engine:
GASKET
22 N•m
r
8x1.25mm
(2.2 kg-m, 16 lb-ftl

8x1.25mm
32 N•m (3.2 kg-m, 10 x 1.25 mm
23 lb-ft) 45 N·m
(4.5 kg-m, 33 lb-ft)
0158 engine:
EXHAUST MANIFOLD
3. lnstall the catalytic converter on the exhaust

manifold, then install the exhaust manifold
assembly.
015Z engine:
Q_XVGENSENSOR
BRACKET ----
ax 1.25 mm 8 x 1.25 mm
32 N•m (3.2 kg-m, 23 lb-ft) 32 N•m
(3.2 kg-m,
23 lb-ft)
GASKET
Re place. GASKET
Replace.
6-49
Cylinder Head
lnstallation (cont'd)------------------------
4. lnstall two dowel pins, head gasket, and cylinder 5. lnstall the bolts that secure the intake manifold to
head. its bracket, but do not tighten them yet.
NOTE: 6. Tighten the cylinder head bolts in two steps.

• Apply clean engine oil on the bolt threads and 1 st step: 30 N·m (3.0 kg-m, 22 lb-ft)
washer contact surface. 2nd step:
• Always use a new cylinder head gasket. 0162, 0152 engine:
• Turn the cam pulley to TDC before installing. 73 N·m 17 .3 kg-m, 53 lb-ft)
0128, 0138, 0158, 016A7 engine:
65 N•m (6.5 kg-m, 47 lb-ft)
CYLINOER HEAO BOL TS TIGHTENING SEQUENCE
0162 engine:
®
10 x 1.25 mm
65 N•m (6.5 kg-m,
47 lb-ft)
® @
CYLINDER HEAD BOLT
10 x 1.25 mm
73 N•m (7 .3 kg-m. 53 lb-ft)
0152 engine:
GASKET
Replace. ® ® ®
DOWEL
PINS
SELF LOCKING NUT

10 x 1.25 mm
5.5 N··m (5.5 kg-m, 40 lb-ft)
CYLINDER HEAD BOLT

10 x 1.25 mm
73 N•m (7.3 kg-m, 53 lb-ft)
6-50
0128. 0138, 0158, 016A7 engine: 11. Adjust the valve timing (page 6-63).
CYLINDER HEAD TOROUE SEOUENCE 12. Apply liquid gasket to the head mating surface of
the No. 1 and No. 5 or No. 6 cam holders, then in-
stall the cylinder head cover.
CYLINDER HEAD BOLT

10 x 1.25 mm
65 N•m (6.5 kg-m, 47 lb-ft)
0162. 0152 engine:

7. lnstall the exhaust pipe A on the exhaust manifold.
NOTE:
8. Tighten the bolts far intake manifold bracket. • Carefully apply oíl with your finger to the shaded
area when installing the cylinder head cover.
9. lnstall the exhaust pipe A on its bracket. • Visually check the spark plug seal far damage.
1 O. After the installation, check that the tubes, hoses

and connectors are installed correctly.
6-51
Timing Belt
lllustrated lndex
D16Z, D15Z engine:

NOTE:
• Refer to Section 23, for alternator belt adjustment.
• Refer to Section 22, for A/C compressor belt adjustment.
• Refer to Section 1 7, for P/S pump belt adjustment.
• Before removing, rnark direction of rotation.
RUBBER SEAL
Replace when damaged
or deteriorated.
TIMING BELT
Replace every 100,000 km
(60,000 miles) or 60 months.
8x1.25mm
38 N•m (3.8 kg-m,
27 lb-ft)
Apply lubricant.
UPPER COVER
6 x 1.0 mm
10 N•m (1.0 kg-m. 7 lb-ft)
LOWER COVER
Remove the six bolts.
lnstall with concave

surface facing in.

surface facing out.
TIMING BELT CRANKSHAFT
ORIVE PULLEY PULLEY
Remove any oíl. Remove any oíl.
6 x 1.0 mm
10 N•m
1 ( 1.0 kg-m, 7 lb-ft)
ADJUSTING BOLT
45 N•m RUBBER SEAL
(4.5 kg-m, 33 lb-ftl Replace when
For adjustment onlv, damged or
do not remove. deteríorated.
6-52
012A, 0138, 0158, 016A7 engine:
TIMING BELT WASHER and

Replace every 100,000 km GROMMET
8x1.25mm
38 N•m (3.8 kg-m,
27 lb-ft)
Apply oíl.
ADJUST BOLT
45N•m
(4.5 kg-m, 33 lb-ft)
For adjustment only,
do not remove.
UPPERCOVER
LOWER COVER
Remove the
four bolts.
Remove lnstall with concave

any oil. surface facinq in.

surface facing out.
Remove
any oíl.
14 x 1.25 mm
185 N•m
(18.5 kg-m, 134 lb-ft)
Apply engine oil to
the bolt threads, but
\
RUBBERSEAL
not to the surface that or deteriorated.
contacts the washer.
6-53
Timing Belt
lnspection Tension Adjustment
NOTE: CAUTION: Always adjust the timing belt tension with

• Replacethe belt if oil soaked. the engine cold.
• Remove any oil or solvent that gets on the belt.
NOTE:
1. Remove the cylinder head cover. • The tensioner is spring-loaded to apply proper ten-
sion to the belt automatically after making the
2. Remove the timing belt upper cover. following adjustment.
• Always rotate the crankshaft counterclockwise
3. lnspect the timing belt for cracks and oil soaking. when viewed from the pulley side.
Rotating it clockwise may result in improper adjust-
ment of the belt tension.
1. Remove the cylinder head cover.
2. Remove the timing belt upper cover.
3. Set the No. 1 pistan at TDC (page 6-60).
4. Loasen the adjusting bolt 180º.

lnspect this
area for wear.
5. Rotate the crankshaft counterclockwise 3-teeth on

the camshaft pulley to create tension on the timing
belt.
4. lf the pulley bolt loosens while turning the crank,
tighten it to specified torque. 6. Make sure the timing belt and the cam pulley are
engaged securely.
Specified Torque:
185 N·m (18.5 kg·m. 134 lb-ft) 7. Torque the adjusting bolt to 45 N·m (4.5 kg-m,
33 lb-ft).

tighten it to specified torque.
Specified Torque:
185 N•m (18.5 kg-m, 134 lb-ft)
6-54
Removal
CAUTION: lnspect the water pump when replacíng the 4. Remove the P/S bracket.
timing belt (page 10-16).
5. Loasen the alternator adjusting bolt and pivot nut,
NOTE: then remove the belt.
• Turn the crankshaft so that No. 1 pistan is at top-
dead-center (page 6-53 and 54). P/S BRACKET
• Befare removing the timing belt, mark its direction of
rotation if it to be reused.
1. Remove the splash shield.
V
2. Removethe power steering pump.
10 x 1.25 mm
• Do not disconnect the P/S hoses. 45 N•m (4.5 kg-m,
33 ..... ,
8x1.25mm
24 N•m (2.4 kg-m.
33 lb-ft)
10 x 1.25 mm
45 N•m (4.5 kg-m, 33 lb-ftl
6. Remove the cruise control actuator and the P/S

tank bracket.
7. Remove the engine support nuts. Loasen the

mount bolt and pivot the engine side mount rubber
8 x 1.25 mm out of the way.
24 N•m (2.4 kg-m, 17 lb-ft)
SUPPORT NUT
10 x 1.25 mm
55 N•m (5.5 kg-m,
3. Rernove the A/C compressor adjust pulley with 40 lb-ft)
bracket and the belt (with A/C), then remove the
alternator belt.
ADJUST PULLEY
ALTERNATOR
BELT
10 x 1.25 mm
55 N•m (5.5 kg-m,
t
I
40 lb-ftl P/S TANK
\ • Loosen BRACKET
(cont'd)
A/C BELT
6-55
Timing Belt
Removal (cont' d)
1 O. Remove the special bolt and crankshaft pulley.

10 ·r
CAP NUT 6 x 1.0 mm
(1.0 kg·m. 7 lb-hl
11. Remove the timing belt upper cover and the lower
cover.
~
12. Loosen the timing belt adjusting bolt 180° to WASHER AND GROMMET
release the belt tension.
13. Push the tensioner to releasetension from the belt,

then retighten the adjusting bolt.
14. Remove the timing belt from the pulleys.
012A, 0138, 0158, 016A7 engine:

TIMING BELT
UPPER COVER
6 x 1.0 mm
1 O N•m ( 1.0 kg-m, 7 lb-ft)
LOWER COVER
Removethe four
bolts.
6x1.0mm
10 N•m (1.0 kg-m, 7 lb·ftl
ADJUSTING BOLT
45N•m
Replacewhen (4.5 kg-m, 33 lb-ft)
damaged or For adjustment only;
deteriorated. do not remove.
14 x 1.25 mm
185 N·m (18.5 kg-m,
134 lb·ftl
Apply oil to the bolt
threads, but not to the
surface that contacts
the washer.
HANDLE BELT TENSIONER

07JAB-0010200
6-56
D16Z, D15Z engine:
6 x 1.0 mm
10 N•m (1.0 kg-m,
7 lb-ft)
RUBBER SEAL
or deteriorated.
ADJUSTING BOL T UPPER COVER

45 N•m (4.5 kg-m. 33 lb-ftl
For adjustment only;
do not remove.
LOWER COVER
CRANKSHAFT UPLLEY
Remove any oil.
RUBBER SEAL
or deteriorated.
6 x 1.0 mm
10 N•m 11.0 kg-m,
7 lb-ft)
6-57
Timing Belt
lnstallation
1. lnstall the timing belt in the reverse order of
rernoval;
Only key points are described here.
2. Position the crankshaft and the cam pulleys as

shown before installing the timing belt.
A Set the crankshaft so that the No. 1 piston is at

top-dead-center (TDC).
NOTE: Align the groove on the teeth side of the

timing belt drive pulley to the ,O, pointer on the oil
pump.
8 D128, D138, D158 engine: Align the TDC

marks on the cam pulley with the cylinder head
upper surface. 3. lnstall the timing belt tightly in the sequence
D16A7, 0162 engine: Align the TDC mark on shown.
the cam pulley with pointer on the back cover. CD Timing belt drive pulley (crankshaft) -+ @ Ad-
D152 engine: Align the TDC marks on the cam justing pulley -+ @ Water pump pulley -+ @ cam-
pulley with pointers (triangle marks) on the back shaft pulley.
cover.
0128, 0138, 0158 engine: "UP" MARK
TDC MARK 016A7, 016Z engine:
CYLINOER HEAD
UPPER SURFACE
015Z engine:
KEY
POINTER ON
TIMING BELT
BACK COVER
6-58
4. Loosen the adjusting bolt, and retighten it after ten- CAM PULLEY:
sioning the belt. 0128, 0138. 0158 engine: TDC marks aligned with
the cylinder head upper
"UP" MARK surface.
5. Rotate the crankshaft about 4 or 6 turns clockwise
so that the belt may fit in position on the pulleys.
6. Adjust the timing belt tension (page 6-54).
7. Check the crankshaft pulley and the cam pulley at

TDC.
CRANKSHAFT PULLEY: ~
016A7. 0162 engine:
TDC mark aligned with the TDC MARK

pointer on timing belt
back cover.
TDC MARK
0152 engine:
TOC MARK
(Painted white)
POINTERON TIMING
BELT BACK COVER
8. lf the cam pulley is not positioned at TDC. remove

the timing belt and adjust the positioning following
the procedure on page 6-58. then reinstall the tim-
ing belt.
NOTE: Refer to page 6-55 for timing belt removal.
After installation, adjust the tension of each belt.

• See section 23 for alternator belt tension
adjustment.
• See section 22 for A/C compressor belt tension
adjustment.
• See section 1 7 for P/S pump belt tension
adjustment.
6-59
Rocker Arms
Manual lnspection (0162 engine) Manual lnspection (0152 engine)
1. Set the No. 1 piston at TDC. 1. Set the No. 1 piston at TDC.
2. Removethe cylinder head cover. 2. Removethe cylinder head cover.
NOTE: Apply oil to spark plug tube oil seal with NOTE: Apply oil to spark plug tube oil seal with
your finger when installing cylinder head cover. your finger when installing cylinder head cover.
3. Push the intake mid rocker arm on the No. 3. Move the intake secondary rocker arm on the No. 1
cylinder manually. cylinder manually.
4. Check that the intake mid rocker arm moves in- 4. Check that the intake secondary rocker arms move
dependently of t:he primary and secondary intake independently of the primary intake rocker arm.
rocker arms.
MIO ROCKER ·
ARM
PRIMARY ROCKER
ARM
SECONDARY PRIMARY
SECONDARY ROCKER ROCKER ARM ROCKER
ARM • Push and pull. ARM
5. Check the intake mid rocker arm of each cylinder at 5. Check the intake secondary rocker arm of each
TDC. cylinder at TDC.
• lf the intake mid rocker arm does not move, • lf the intake secondary rocker arm does not
remove the mid, primary and secondary intake move, remove the primary and secondary intake
rocker arms as an assembly and check that the rocker arms as an assembly and check that the
pistons in the mid and primary rocker arms move pistons in the secondary and primary rocker
smoothly. arms move smoothly.
• Replacethe intake rocker arms as an assembly if • Replacethe intake rocker arms as an assembly if
there is any abnormality. there is any abnormality.
6-60
lnspection Using Special Tools (0162 engine)
CAUTION: 3. Remove the sealing bolt and washer from the in-
• Before using the Valve lnspection Tool, make sure spection hole and connect the Valve lnspection
that the air pressure gauge on the air compressor in- Tool.
dicates over 250 kPa (2.5 kg/cm2• 36 psi).
• lnspection the valve clearance before rocker arm
inspection.
• Cover the timing belt with a shop towel to protect
the belt.
• Check the intake mid rocker arm of each cylinder at
TDC.
2. Plug the relief hole with the special tool (Air AIR STOPPER
Stopper). 07LAJ- PR30200
Grind the shaded area
when not installed air
WASHER VAL VE INSPECTION

Replace. SET
1
07LAJ-PR30100
INSPECTION
• Pull the dial and
HOLE
AIR STOPPER turn to adjust.
07LAJ-PR30200
RELIEF HOLE
(cont'd)
6-61
Rocker Arms
lnspection Using Special Tools (0162 engine, cont'd)
4. Apply specified air pressure to the rocker arm syn- 6. Remove the special tools.
chronizing piston A/B, after loosening the regulator
valve on the valve inspection set. 7. Check for smooth operation of the lost motion
assembly. lt is compressed slightly when the intake
Specified Air Pressure: mid rocker arm is lightly pushed and compressed
250 kPa (2.5 kg/cm2, 36 psi) deeply when tfie mid rocker arm is strongly pushed.
• Replacethe lost motion assembly if it does not
5. Make sure that the intake primary and secondary move smoothly.
rocker arms are mechanically connected by piston
and that the mid rocker arm does not move when
pushed manually.
LOST MOTION
ASSEMBLY
SECONDARY ROCKER
ARM
• lf the intake mid rocker arms move independent- 8. After inspection, check that the Check Enginelight
ly of the primary and secondary rocker arms, does not come on.
replace the rocker arms as a set.
6-62
Rocker Arms
lnspection Using Special Tools ~0152 engine)
CAUTION: 3. Remove the sealing bolt and washer from the in-
• Before using the Valve lnspection Tool, make sure spection hole and connect the Valve lnspection
that the air pressure gauge on the air compressor in- Tool.
dicates oVer250 kPa (2.5 kg/cm2, 36 psi).
• lnspect the valve clearance before rocker arm
inspection.
• Cover the timing belt with a shop towel to protect
the belt.
• Check the intake mid rocker arm of each cylinder at
TDC.

Grind the shaded area when
not installed air stopper.
2. Plug the relief hole with the special too! (Air
Stopper). AIR STOPPER
07LAJ- PR30200
Replace. HOLE • Pull the dial and

INSPECTION turn to adjust.
RELIEF HOLE
AIR STOPPER
07LAJ - PR30200
4. Apply specified air pressure to the intake rocker

arm timing pistan, after loosening the regulator
valve on the valve inspection set.
Specified Air Pressure:

250 kPa (2.5 kg/cm2, 36 psi)
(cont'd)
6-63
Rocker Arms
lnspection Using Special Tools (0152 engine, cont'dl
5. With the specified air pressureapplied, push up the 6. Stop applying air pressure and push up the timing
timing plate; the synchronizing piston will pop out plate; the synchronizing piston will return to its
and engage the intake secondary rocker arm. original position with a click.
Visually check the engagement of the synchroniz- Visually check the disengagement of the syn-
ing piston. chronizing pistons.
NOTE: NOTE:
• The synchronizing piston can be seen in the gap • When the timing plate is pushed up, it will
between the secondary and primary rocker disengage the timing piston letting the syn-
arms. chronizing piston return to its original position
• When the timing plate is engaged in the groove by the return spring.
A on the timing piston, the piston will be lock- • Heplacethe intake rocker arms as an assembly if
ed in the pushed out position. there is any abnormality.
TII\IIING PLA TE
At Low RPM:
RETURN SPRING
TIMING
PLATE
PRIMARY ROCKER
SECONDARV ARM
ROCKER ARM
At Hight RPM:
7. Removethe special tools.
SECONDARV 8. After inspection, check that the Check Enginelight

ROCKER ARM
does not come on.
TIMING SPRING
AIR PRESSURE
PRIMARY ROCKER ARM
6-64
Valve Clearance
Adjustment
NOTE: 015Z engine:

• Valves should be adjusted cold when the cylinder
head temperature is less than 38°C (100º F). No.4 No. 2
Adjustment is the same for intake and exhaust
valves.
• lf the pulley bolt loosens while turning crank, tighten
it to specified torque.
Specified Torque:
185 N·m (18.5 kg-m, 134 lb-ft)
0128, 0138, 0158, 01687 engine:
No.4 No. 3 No.2 No. 1

INTAKE
016Z engine:
No.4 No. 3 No. 2 No. 1
No.4 No. 3 No.2 No. 1
No.4 No. 3 No.2 No. 1

No. 3 No.2 No. 1
2. Set No. 1 pistan at TDC. "UP" mark on the pulley
EXHAUST
should be at top, and TDC marks should align with
cylinder head upper surface (D 1 28, D138, D 1 58
engine) or TDC groove should align with pointer(s)
on the timing belt back cover (D16A 7, D1 62, D1 52
engine). The crankshaft pulley should be at TDC.
Number 1 pistan at TDC:

D16A7, D16Z engine:
D12B,013B,015B
englne:
TDC mark aligned

with the pointer
on timing belt
back cover.
TDC MARKS (cont'd)
6-65
Valve Clearance
Adjustment (cont' d)
0152 engine: 0162, D152 engine:
INTAKE and EXHAUST VALVE

TDC MARK LOCKNUTS 7 x 0.75 mm
20 N•m (2.0 kg-m. 14 lb-ft)
POINTERS
3. Adjust valves on No. 1 cylinder.
lntake: 0.18-0.22 mm (0.007 -0.009 in)

Exhaust: 0.23-0.27 mm (0.009-0.011 in)
4. Loosen locknut and turn adjustment screw until

feeler gauge slides back and forth with slight
amount of drag.
5. Tighten locknut and check clearance again. Repeat
0128, 0138, 0158, D16A7 engine:
adjustment if necessary.
CAUTION: Do not overtighten the locknuts, for

the rocker arms are madeof aluminum.
INTAKE and EXHAUST VALVE

LOCKNUTS 7 x O. 75 mm
14 N•m (1.4 kg-m, 10 lb-ftl
6-66
6. Rotate crankshaft 180° counterclockwise (carn
pulley turns 90°). The "UP" rnark should be at ex- 0128, 0138, 0158 engine:
haust side. Distributor rotor should point to No. 3
plug wire. Adjust valve on No. 3 cylinder.
Number 3 piston at TDC:

016A7, 0162 engine:
"UP" MARK
0152 engine:
"UP" MARK
0128, 0138, 0158 engine:
"UP" MARK
8. Rotate crankshaft 180° counterclockwise to bring

No. 2 pistan to TDC. The "UP" mark should be at
0152 engine: intake side. Distributor rotor should point to No. 2
"UP" MARK
plug wire. Adjust valves on No. 4 cylinder.
7. Rotate crankshaft 180° counterclockwise to bring 0128, 0138, 0158 engine:

No. 4 piston to TDC. Both TDC grooves are once
again visible and distributor rotor should point to
No. 4 plug wire. Adjust valves on No. 4 cylinder.
Number 4 piston at TDC:
016A7, 0162 engine:
"UP" MARK
O15Z engine:
"UP" MARK
6-67
016A8/D16A9 engine
lllustrated lndex 6- 70
Cylinder Head Removal 6- 72
Camshaft Pulleys 6- 76
Camshaft lnspection 6- 76
Valves 6-78
Valve Seats 6- 78
Valve Guides 6-80
Valve Spring and Valves 6-81
Cylinder Head lnstallation . . . . . . . . . . . . . . . . . 6-82
Camshaft/Seal and Rocker arms . . . . . . . . 6-83
Timing Belt
lllustrated lndex 6-86
lnspection 6-87
Tension Adjustment . . . . . . . . . . . . . . . . . . . . . 6-87
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-88
lnstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-90
Valve Clearance 6-92
lllustrated lndex-------------------------
016A8, 016A9 engine:
CAUTION: To avoid damaging the cylinder head, wait until the coolant temperature drops below 38°C (100ºFl befare
removing it.
NOTE:
Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact parts.
CAP NUT
6 x 1.0 mm
10 N•m (1.0 kg-m,
7 lb-ft)
1 WASHER and
GROMMET
6x1.0mm ~
10 N•m 11.0 kg-m,
7 lb-ft) CYLINDER HEAD
COVER
UPPER COVER
---::'?"' RUBBER SEALS
or deteriorated.
6 x 1.0 mm
10 N•m (1.0 kg-m,
7 lb-ft)
8 x 1.25 mm
24 N•m (2.4 kg-m,
17 lb-ft)
DISTRIBUTOR
38 N•m (3.8 kg-m,

27 lb-ft)
CAMSHAFT
PULLEY
Removal, page 6-76
lnstallation,
page 6-83
OIL SEAL
Replace.
6-70
, Prior to reassembling, clean all the parts in solvent, dry them, and apply lubrican! to any contact parts.
CYLINDER HEAD
BOLTS
11 x 1.25 mm
SPRING RETAINER 66 N•m (6.6 kg-m, 48 lb-ft)
VAL VE KEEPERS
-.
to threads and
~ under the bolt heads.
EXHAUST VALVE
SPRING
Removal, page 6- 72 INTAKE VALVE GUIDE

Reconditioning valve Replacement, page 6-80
seat, page 6-78 Reaming, page 6-81
Warpage, page 6-80
CYLINDER
Replace HEAD GASKET _..,,.,,
TIMING BELT
lnspection/Adjustment, ~
page 6-87 •.
Removal, page 6-88
6x1.0mm
10 N•m
(1.0 kg-m,
7 lb-ft)
ENGINE SIDE MOUNT

STUD BOLT
40 N•m (4.0 kg-m, 29 lb-ft)
ADJUSTING BOLT
45 N•m (4.5 kg-m, 33 lb-ftl
Loosen, but do not remove
6-71
Cylinder Head
Removal
Engine removal is not required far this procedure. 6. Remove the fuel return hose and brake booster
vacuum hose.
CAUTION: To avoid damaging the cylinder head,
wait until the coolant temperature drops below
38ºC (100ºFl befare loosening the retaining bolts.
NOTE:
• lnspect the timing belt befare removing the
cylinder head.
• Turn the crankshaft pulley so that the No. 1
pistan is at top-dead-center (page 6-91 ).
• Mark ali emissions hoses befare disconnecting
them.
1. Disconnect the negative terminal from the battery.
2. Drain the coolant (see Section 1 O).
3. Relieve fuel pressure.
¡.q¡.¡&;j.ijN Do not smoke while working on fuel

FUEL RETURN
HOSE
4. Remove the air flow tube.

7. Removethe throttle cable and throttle control cable
5. Remove the fuel feed hose and charcoal canister (A/T).
NOTE:
• Take care not to bend the cable when removing
it. Always replace any kinked cable with a new
CANISTER HOSE one.
• Adjust the throttle cable when installing (see
Section 11) .
THROTTLE CONTROL
CABLE THROTTLE CABLE
AIR FLOW TUBE LOCKING NUT

ADJUSTING. NUT
6-72
9. Remove the engine wire harness connectors and 12. Removethe P/S bracket.
wire harness clamps from the cylinder head and the
intake manifold. 1 3. Remove the P/S tank bracket.
• Four injector connectors
• TA sensor connector 14. Remove the engine support nuts. Loasen the
• EACV connector mount bolt and pivot the engine mount rubber out
• Throttle sensor connector of the way.
• MAP sensor connector
• Ground terminal (at thermostat cover) ENGINE SIDE
MOUNT RUBBER
• TW.switch connector (for cooling fan) SUPPORT NUT
• TW sensor connector (for emission)
• TDC/CRANK/CYL sensor connector
1 O. Remove ground cable from the cylinder head.
11 . Remove the P/S belt, then remove the P/S pump.
ADJUSTING BOL T
SIDE MOUNT BOL T

10 x 1.25 mm P/S TANK
55 N•m (5.5 kg-m, BRACKET
40 lb-ft)
15. Remove two stud bolts from the side mounting

bracket then remove the P/S side bracket.
10 x 1.25 mm
45 N·m (4.5 kg-m.
33 lb-ft)
8x1.25mm
22 N•m (2.2 kg-m,
16 lb-ft)
STUD BOLT
40 N•m (4.0 kg-m,
30 lb-ft)
10 x 1.25 mm
45 N•m (4.5 kg-m,
33 lb-ft)
(cont'd)
6-73
Cylinder Head
Removal (cont' d)
1 6. Remove two timing belt lower cover bolts and a 25. Pushthe tensioner to releasetension from the tirn-
back cover mount bolt. ing belt, then retighten the adjusting bolt.
1 7. Remove the radiator upper hose and heater hose

ADJUST BOLT
18. Remove the water bypass hose from intake
45 N·m (4.5 kg-m,
manifold. • Push the belt tensioner 33 lb-ft)
bracket.
~
WATER BVPASS RADIATOR

HOSE UPPERHOSE
TENSIONER
BRACKET
HEATER HOSE
19. Remove the intake manifold bracket.

26. Remove the belt from the cam pulley.
20. Remove the self-locking nuts and disconnect the
exhaust manifold and exhaust pipe A.
21 . Remove the exhaust manifold bracket. CAUTION: Do not crimp or bend

the timing belt more than 90°
22. Remove the PCV hose from the cylinder head or less than 25 mm (1 in) in diameter.
cover.
24. Loosen the timing belt adjusting bolt 180° to

No Good
6-74
27. Remove the camshaft pulleys. 30. Remove the cylinder head bolts, then remove the
cylinder head.
28. Loasen the rocker arm locknuts, then remove the
camholders. CAUTION: To prevent warpage, unscrew the bolts
in sequence 1 /3 turn ata time; repeat until all bolts
are loosened.
CYLINDER HEAD BOLT LOOSENING SEQUENCE

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

IN
29. Removethe rocker arm. NOTE: Separate the cylinder head from the block
with a flat blade screwdriver as shown.
NOTE: Rocker arms must be installed in the same
possition if reused.
ROCKER ARM
31 . Remove the intake manifold and exhaust manifold

6-75
Camshaft Pulleys Camshafts
Rernoval~~~~~~~~~~~----. lnspection
1. To ease reassembly, turn the pulley until the "UP" NOTE:

marks faces up, and the front timing marks are • Do not rotate camshaft during inspection; loosenthe
aligned with the both mark on the pulleys. adjust screws before starting.
• Removethe rocker arms before inspection.
"UP" marks
1. Seat camshafts by pushing them toward distributor
end of cylinder head. .
2. Zero dial indicator against end of distributor drive,

then push camshafts back and forth, and read the
end play.
Camshaft End Play:

(0.002-0.006 in.)
Service Limit: 0.5 mm (0.02 in.)
. Align the marks on the pulleys.
2. Remove the pulley retaining bolts and washers,

then remove the pulleys.
KEY
PIN DRIVERS, 5.0 mm

07744-0010400
CAMSHAFT
3. Remove the camshaft holder bolts from the

cylinder head.
NOTE: Unscrew the camshaft holder bolts, two

turns at a time, in a crisscross pattern, to prevent
damaging valves or rocker arms.
• Lift camshaft out of cylinder head, wipe clean,

then inspect lift ramps. Replace camshaft if ·
lobes are pitted, scored, or excessively worn.
CAMSHAFT PULLEV • Clean the camshaft bearing surfaces in the

• lnsert plastigage strip across each journal.

NOTE: Before removing camshafts assembly,
check camshaft end play. • lnstall the camshaft holders and torque bolts to
values and in sequence shown on page 6-84.
6-76
4. Measure widest portian of plastigage on each jour- - lf the total runout of the camshaft is within
nal. tolerance, replace the cylinder head.
Camshaft Bearing Radial Clearance: - lf the total runout is out of tolerance, replacethe
Standard (New): 0.050-0.089 mm camshaft and recheck. lf the bearing clearance
(0.002-0.004 in.) is still out of tolerance, replace the cylinder
Service Limit: 0.15 mm (0.006 in.) head.
6. Measure camshaft height.

PLASTIGAGE STRIP
lntake Standard: 32.983 mm (1.2985 in.)

Exhaust Standard: 32.382 mm (1.2749 in.)
5. lf camshaft bearing radial clearance is out of lnspect this area for wear.
tolerance:
• And camshaft has already been replaced, you

must replace the cylinder head.
• lf camshaft has not been replaced, first check
total runout with the camshatt supported on V-
blocks.
Camshaft Total Runout:

Standard (New): 0.003 mm (0.001 in.)
Rotate camshaft
while measuring.
<!\
6-77
Valves Valve Seats
Replacement Reconditioning
NOTE: ldentify valves and valve springs as they are 1. Renew the valve seats in the cylinder head using
removed so that each item can be reinstalled in its valve seat cutters.
original position.
NOTE: lf guides are worn, replace them (page
1. Tap each valve stem with a plastic mallet to loasen 6-80) befare cutting valve seats.
valve keepersbefare installing spring compressor.
2. lnstall spring compressor. Compress spring and

remove valve keeper.
CUTTER INTAKE EXHAUST

45° 07780-0010800 07780-0010300
30° 07780-0012900 07780-0012200
60° 07780-0014000 07780-0014000
HOLDER 07781-0010201 and 07781-0010301
2. Carefully cut a 45° seat, removing only enough

material to ensure a smooth and concentric seat.
lntake Valve Dimensions
3. Bevel the upper edge of seat with the 30º cutter
and the lower edge of seat with 60º cutter.
(1.177-1.185 in.)
Check width of seat and adjust accordingly.
(4.0937-4.1055 in.)
4. Make one more very light pass with the 45º cutter
to remove any possible burrs caused by the other
(0.2591 -0.2594 in.)
cutters.
C Service Limit: 6.55 mm (0.258 in.)
D Standard (New): 1.05-1.35 mm
(0.041 -0.053 in.)
D Service Limit: 1.00 mm (0.039 in.)
Exhaust Valve Dimensions
A Standard (New): 26.9-27 .1 mm
(1.059-1.067 in.)
(4.0421 -4.0539 in.)
(0.2579-0.2583 in.) Seat Width -----
C Service Limit: 6.52 mm (0.257 in.)
(0.065-0.077 in.)
D Service Limit: 1.45 mm (0.057 in.)
6-78
Valves
Valve Movement
5 .. 1. Measure the valve movement with a dial indicator

while rocking the stem in the direction of normal
thrust (Wobble Method).
lntake Valve Movement

(0.0016-0.004 in.)
Exhaust Valve Movement
(0.004-0.006 in.)
PRUSSIAN BLUE COMPOUND
6. The actual valve seating surface, as shown by the Valve extended 1 O mm out from seat.
• lf it is too high (closer to the valve stem). you
move it down, then one more cut with the 45°
cutter to restore seat width.
• lf it is too low (closer to valve edge). you must
make a second cut with the 30° cutter to move
it up, then one more cut with the 45° cutter to
restore seat width.
NOTE: The final cut should always be made with

the 45° cutter.
7. lnsert intake and exhaust valves in head and
recheck using new valve.
measure valve stem installed height.
• lf measurement is now within service limit,
reassemble using new valve.
lntake Valve Stem lnstalled Height:
• lf measurement still exceeds fimit, recheck using
alternate method below, then replace val ve and
guide, if necessary.
Exhaust Valve Stem lnstalled Height:
stem clearance is to subtract the O.O. of the valve
stem, measured with a micrometer, from the I.D. of
micrometer or ball gauge.
Take the measurements in three places along the
valve stem and three places inside the valve guide.
The difference between the largest guide measure-
ment and the smallest stem measurement should
not exceed the service limit.
lntake Valve Stem-to-Guide Clearance

(0.001-0.002 in.)
Service Limit: O.OSmm (0.003 in.)
Exhaust Valve Stem-to-Guide Clearance
8. lf valve stem installed height is over service limit, (0.002-0.003 in.)
replace valve and recheck. lf still over service limit, Service Limit: O. 11 mm (0.004 in.)
replace cylinder head; the valve seat in the head is
too deep.
6-79
Valves Guides Cylinder Head
Replacement Warpage
NOTE: NOTE: lf camshaft bearing clearances are not within

• For best results, heat cylinder head to 150°C specification, the head can not be resurfaced (page
(300°F) before removing or installing guides. 6-76).
• lt may be necessaryto use an air hammer to remove
sorne valve guides. lf camshaft bearing radial clearances are within
specificatíons, check head for warpage.
CAUTION: To avoid burns, use heavy gloves when
handling heated cylinder head. · • lf warpage is less than 0.05 mm (0.002 in.)
cylinder head resurfacíng is not required.
1. Drive the valve guide out from the bottom of the
cylinder head. • lf warpage is between 0.05 mm (0.002 in.) and
0.2 mm (0.008 in.), resurface cylinder head.
• Maxímum resurface limit is 0.2 mm (0.008 in.)

based on height of 131 .8 mm (5.19 in.).
PRECISION STRAIGHT EDGE
2. Orive in a vew valve guide to the specified depth

little by little.
lntake: 19.4 mm (0.76 in.)

Exhaust: 19.0 mm (0.75 in.)
VALVEGUIDE-_
·
J
--........
// 77
J: Measure h ere.
7 77/77
Me asure along edges. and 3 ways across center.
VALVE GUIDE DRIVER, 6.6 mm

07742-0010200
Cylínder Head Heíght:

Standard New: 132.0 mm (5.20 in.)
6-80
Valve Guides and Valve Springs/Valve Seals
Valve Guides Reaming
NOTE: For new valve guides only. REAMER HANDLE
1. Coat reamer and valve guide with cutting oil.
2. Rotate reamer clockwise the full length of the valve Turn reamerin
guide bore. clockwisedirection
only.
3. Continua to rotate reamer clockwise while
removing.
4. Throughly wash the guide in detergent and water

to remove any cutting residue.
5. Check clearance with valve.
Valve Springs/Valve Seals lnstallation Sequence ------------
NOTE: Exhaust and intake valve seals are NOT interchangeable.
NOTE: Placethe valvespring ~~ VALVE KEEPERS

with closelywound coils the
cylinderhead.
~ VALVE SPRING
AETAINl::R
VALVE SPRING
~-SPRING
~SEAT
NOTE: lnstallthe valvespringseats
beforeinstallingthe valvespringseals.
VALVE GUIDE SEAL
INSTALLER
07GAD-PH70100
VALVE SEAL
6-81
Valves Cylinder Head
lnstallation lnstallation
When installing valves in cylinder head, coat valve 1. Instan the cylinder head in reverse arder of remov-
stems with oíl befare inserting into valve guides, and al:
make sure valves move up and down smoothly.
• Always use a new head gasket.
When valves and springs are in place, lightly tap the end • Cylinder head and engine block durface must be
of each valve stem two or three times to ensure proper clean.
seating of valve and valve keepers (use plastic mallet). • "UP" mark on timing belt pulley should be at the
top.
NOTE: Cylinder head dowel pins and oil control jet
PLASTIC must be aligned.
MALLET CYLINDER HEAD
GASKET
--JII EXHAUST VALVE INT AKE VAL VE

. 11 STEM STEM
2. Tighten cylinder head bolts in two steps. In the first
step tighten all bolts, in sequence, to about 30 N·m
(3.0 kg-m, 22 lb-ft); in the final step tighten, in
same sequence, to 66 N•m (6.6 kg-m, 47 lb-ftl
NOTE:
• Apply engine oíl to the cylinder head bolts and
the washers.
• Use the longer bolts at the position No. 1 and
No. 2 as shown.
CVLINDER HEAD BOLTS TORQUE SEQUENCE
(J) (!)
6-82
Cam/Rocker Arm and
Camshaft Seal/Pulley
lnstallation
3. lnstall the intake manifold and tighten the nuts in a CAUTION:

crisscross pattern in 2 or 3 steps, beginning with • Make sure that the keyways on the camshafts are
the inner nuts. facing up. (No. 1 cylinder TDC).
• Valve locknuts should be loosened and adjust
screws backed off befare installation.
• Replacethe rocker arms in these original positions.
8 x 1.25 mm
23 N·m (2.3 kg-m, 1. Place the rocker arms on the pivot bolts and the
17 lb-ft)
valve stems.
4: lnstall the exhaust manifold and bracket.

2. lnstall the camshafts and the camshaft seals with
the open side (spring) facing in.
MANIFOLD GASKET
NOTE:
Re place. • "I" or "E" marks are stamped on the camshaft
8 x 1.25 mm holders.
22 N•m (2.2 kg-m. • Do not apply oil to the holder mating surface of
16 lb-ft) SELF LOCKING NUT camshaft seals.
32 N•m (3.2 kg-m,
23 lb-ft)
Replace.
EXHAUST CAMSHAFT HOLDERS
8 x 1.25 mm
22 N•m (2.2 kg-m,
16 lb-ft)
INTAKE CAMSHAFT HOLDERS
(cont'd)
6-83
Cam/Rocker Arm and Camshaft Seal/Pulley
lnstallation (cont' d)
3. Apply liquid gasket to the head mating surfaces of 5. Set the camshaft seal as shown below.
the No. 1 and No. 6 camshaft holders, then install
them, along with the No. 2. 3. 4 and 5.
Seal housing surface should be dry.

Apply a light coat of oil to camshaft
and inner lip of seal.
4. Tighten the camshaft holders temporarily. 6. Tighten each bolt two turns at a time in the se-
• Make sure that the rocker arms are properly quence shown below to insure that the rockers do
positioned on the valve stems. not bind on the valves.
6x1.0mm
10 N•m (1.0 kg-m, 7 lb-ftl
6-84
7. lnstall the timing belt back cover.
B. lnstall the camshaft pulleys.
KEY
CAMSHAFT PULLEYS
6-85
T.umnq
. Belt
lllustrated lndex
NOTE:
• Refer to Sectí
: Refer
Refer to Sect:~~ 22,
to Seer 23, for
for A/C
alternator
co belt adjustment
• Before rernovmg, 7 • to,dir
ron 1 mark PIS p. ump
rnpressor belt ad'justrnent.
belt adjust .
ectron of rotation. ment ·
CYLINDER HEAD
COVER
6 x 1.0 mm
10 N•m 11 O
-~
8 x 1.25 mm RUBBER SEAL @

38 N•m 13.8 k Replace when
27 lb-ftl g-m, damaged or
Apply lubricant. deteriorated.
6 x 1.0 mm
10N•m(10 . kg-m, 7 lb-ftl
UPPER COVER
LOWER COVER
Remove t he four bolts.
6-86

• Replacethe belt if oil soaked. the engine cold.
• Removeany oil or solvent that gets on the belt.
NOTE:
1. Removethe timing belt upper cover. • The tensioner is spring-loaded to apply proper ten-
2. Removethe cylinder head cover. following adjustment.
3. lnspect the timing belt far cracks and oil soaking. when viewed form the pulley side.
Rotating it clockwise may result in improper adjust-
ment of the belt tension.
1. Removethe timing belt upper cover.
2. Removethe cylinder head cover.
3. Set the No. 1 piston at TDC (page 6-90).
4. Loasenthe adjusting bolt 180º.
C)
Rotate pulley
and inspect belt.
l
'
Direction of Rotation.
4. lf the pulley bolt loosens while turning the crank, 5. Rotate the crankshaft counterclockwise 3-teeth on
tighten it to specified torque. the camshaft pulley to create tension on the timing
belt.
Specified Torque:
185 N·m (18.5 kg-m, 134 lb-ft) 6. Make sure the timing belt and the cam pulley are
engagedsecurely.
7. Torque the adjusting bolt to 45 N·m (4.5 kg-m, 33

lb-ft).

Specified Torque:
185 N•m ( 18.5 kg-m, 134 lb-ft)
6-87
Timing Belt
Removal
CAUTION: lnspect the water pump when replacing the 4. Remove the P/S tank bracket.
timing belt.
5. Remove the engine support nuts. Loosen the
NOTE: mount bolt and pivot the engine side mount rubber
• Turn the crankshaft so that No. 1 piston is at top- out of the way.
dead center (page 6-90 and 91 ).
• Before removing the timing belt, mark its direction of
SUPPORT NUT
rotation if it to be reused.
10 x 1.25 mm
55 N•m (5.5 kg-m.
1. Remove the splash shield. ENGINE SIDE
40 lb·ftl
MOUNT RUBBER
2. Remove the power steering pump.

8x1.25mm ADJUSTING BOL T

24 N•m (2.4 kg-m.
33 lb-ftl
SIDE MOUNT BOL T

10 x 1.25 mm
55 N•m (5.5 kg-m. P/S TANK
40 lb-ft) BRACKET
• Loosen
8 x 1.25 mm 6. Loosen P/S bracket bolt, then turn up the side

24 N•m (2.4 kg-m._ 17 lb-ftl
bracket as shown.
3. Remove the A/C compressor adjust pulley with
bracket and the belt (with A/C). then remove the
alternator belt.
ADJUST PULLEY
10 x 1.25 mm
8x1.25mm 45 N•m (4.5 kg-m,
24 N•m (2.4 kg-m, 33 lb-ftl
17 lb-ft) A/C BELT
6-88
7. Removethe timing belt upper cover. 11. Loosen the timing belt adjusting bolt 180° to
8. Removethe valve cover.
12. Pushthe tensioner to releasetension from the belt,
9. Remove the special bolt with special tools, then then retighten the adjusting bolt.
remove crankshaft pulley.
13. Removethe timing belt from the pulleys.
1 O. Removethe timing belt lower cover.
CVLINDER HEAD
6x1.0mm COVER
1 O N•m (1.0 kg-m, 7 lb-ft)
UPPER COVER \
TIMING BELT
ADJUSTING BOL T
45 N•m
(4.5 kg-m, 33 lb-ft)
For adjustment only;
do not remove.
SEAL RUBBER
Replace when
damaged or
deteriorated.
Remove any oil.
A/T:
PULLEV HOLDER ATT.
M/T: HEX 50 mm
07JAA-0010200
PULLEV HOLDER ATT.

07JAB-0010100
HANDLE SOCKET WRENCH, 19 mm

07JAB-0010200 07JAA-0010200
6-89
Timing Belt
lnstallation
1. lnstall the timing belt in the reverse arder of

removal;
2. Position the crankshaft and the cam pulleys as ®

shown befare installing the timing belt. @
A Set the crankshaft so that the No. 1 pistan is at


timing belt drive pulley to the ,G pointer on the oíl
pump.
Align the TDC mark on the cam pulley with

pointer on the back cover.
3. lnstall the timing belt tightly in the sequence

shown.
G) Timing belt drive pulley (crankshaft) -+ @ Ad-
justing pulley -+ @ Water pump pulley -+ © lntake
camshaft pulley -+ ® Exhaust camshaft pulley.
@
.(l. POINTER ON
OILPUMP
~o
~
6-90
4. Loasen the adjusting bolt, and retighten it after ten- CAMSHAFT PULLEY:
sioning the belt.
5. Rotate the crankshaft about 4 or 6 turns clockwise "UP" MARK

7. Check the cranshaft pulley and the cam pulley at

TDC.
CRANKSHAFT PULLEY:
TDC MARK
8. lf the cam pulley is not positioned at TDC, remove

TOC MARK
(Painted white)
the procedure on page 6-90, then reinstall the tlm-
ing belt.
NOTE: Refer to page 6-88 for timing belt removal.

• See section 2;3 for alternator belt tension
adjustment.
adjustment.
adjustment.
Direction l
of rotation. '
6-91
Valve Clearance
Adjustment
NOTE: 3. Adjust valves on No. 1 cylinder.

• Valves should be adjusted cold when the cylinder
head temperatura is less than 38ºC (100ºF). lntake: 0.13-0.17 mm (0.005-0.007 in)
Adjustment is the same for intake and exhaust Exhaust: 0.15-0.19 mm (0.006-0.008 in)
valves.
• lf the pulley bolt loosens while turning crank, tighten 4. Loosen locknut and turn adjustment screw until
it to specified torque. feeler gauge slides back and forth with slight
amount of drag.
Specified Torque:
185 N·m (18.5 kg-m, 134 lb-ft)
EX
No. 1 No. 2 No.4
No. 1 No. 2 No. 3 No.4

IN
2. Set No. 1 piston at TDC. "UP"mark on the pulleys 5. Tighten locknut and check clearance again. Repeat
should be at top, and TDC marks should align with adjustment if necessary.
intake and exhaust pulleys.
"UP" MARK
TDC MARK .
. 6-92
6. Rotate crankshaft 180° counterclockwise (cam 8. Rotate crankshaft 180° counterclockwise to bring
pulley turns 90° ). The "UP" mark should be at ex- No. 2 pistan to TDC. The "UP" mark should be at
haust side. Distributor rotor should point to No. 3 intake side. Distributor rotor should point to No. 2
plug wire. Adjust valve on No. 3 cylinder. plug wire. Adjust valves on No. 4 cylinder.
7. Rotate cranshaft 180° counterclockwise to bring

No. 4 pistan to TDC. Both TDC grooves are once
again visible and distributor rotor should point to
No. 4 plug wire. Adjust valves on No. 4 cylinder.
6-93
m
B16A engine
VTEC (D152/D16Z/B16A engine) Valve Seats 6-109

Electrical Connections 6-4 Cylinder Head 6-11 O •• ••
Troubleshooting Valve Guides 6-111 --1
Self-diagnostic Procedure 6-6 Valve Springs and Valves 6-112
Troubleshooting Flowchart Rockerarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-113
Spool Valve 6-12 Cylinder Head lnstallation 6-114
Oil PressureSwitch 6-14 Camshaft/Seal 6-115
Spool Valve lnspection 6-17 Timing Belt
B16A engine lllustrated lndex 6-117
lllustrated lndex 6-96 lnspection 6-118
Cylinder Head Removal 6-98 Tension Adjustment 6-118
Rocker Arms Removal 6-119
Removal 6-102 lnstallation . . . .. . . . . . . .. . . . . . .. . . . . . . . . . . . . 6-1 21
Locations 6-103 Rocker Arms
RockerArms and Lost Motion 6-104 Manual lnspection 6-123
RockerArms and Shafts 6-105 lnspection Using Special Tools 6-124
Camshaft lnspection 6-106 Valve Clearance 6-126
Valves 6-108
lllustrated lndex
B16A engine:
CAUTION: To avoid damaging the cylinder head, wait until the coolant temperatura drops below 38ºC (100ºFl befare
removing it.
NOTE:
~ Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact parts.
6 x 1.0 mm
10 N•m (1.0 kg-m, 7 lb-ft)
1
6 x 1.0 mm
10 N•m (1.0 kg-m,
7 lb-ft)
IN. CAMSHAFT
RUBBER SEALS
or deteriorated.
10 x 1.25 mm
51 N•m (5.1 kg-m,
37 lb-ft)
CAMSHAFT
PULLEY
SPOOL VALVE
0-RING
Replace.
6-96
CYLINDER HEAD ROCKER ARM ASSEMBL Y
BOLTS (PRIMARY, MIO, SECONDARY)
11 x 1.5 mm
85 N•m (8.5 kg-m, 61 lb-ft)
Apply clean engine oil IN VAL VE SPRING INNER
to threads and
under the bolt heads.
LOST MOTION
ASSEMBLY
@~
SEARING BOL TS
50 N•m (5.0 kg-m, 36 lb-ft)
HEAD OIL CONTROL

ORIFICE
0-RING
Replace.
6-97
Cylinder Head
Rernoval ~·~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
Engine removal is not required for this procedure. 6. Removethe throttle cable at the throttle body.
CAUTION: To avoid damaging the cylinder head, wait 7. Removethe throttle control cable form the throttle
until the coolant temperature drops below 38ºC body (A/T only).
(100°F) befare loosening the retaining bolts.
NOTE:
NOTE: • Take care not to bend the cable when removing
• lnspect the timing belt before removing the cylinder it. Always replace any kinked cable with a new
head. one.
• Turn the crankshaft pulley so that the No. 1 piston is • Adjust the throttle cable when installing (See
at top-dead-center (page 6-121). Section 1 1 ) .
• Mark all emissions hoses before disconnecting them.
1. Disconnect the negative terminal from the battery.
2. Drain the coolant (see Section 1 O).
• Removethe radiator cap to speed draining.
3. Relievefuel pressure.
f •f&dMIJiN Do not smoke while working on fuel

4. Removethe air flow tube.
5. Remove the fuel feed hose and charcoal canister THROTTLE CABLE
hose form the intake manifold.
8. Rernove the fuel return hose and brake booster

vacuum hose.
BREATHER HOSE
BRAKE BOOSTER
HQSE
CANISTER WATER BYPASS HOSE

HOSE
6-98
9. Remove the engine wire harness connectors and 11 . Remove the engine ground cable on the cylinder
wire harness clamps from the cylinder head and the head cover.
intake manifold.
• Four injector connectors 12. Remove the P/S belt and pump.
• TA sensor connector • Do not disconnect the P/S hoses.
• EACV connector
• Throttle sensor connector 13. Remove the P/S lower bracket and heat shield.
• Ground terminal (at thermostat cover)
• TW switch connector (for cooling tan)
• TW sensor connector (for emission) 8x1.25mm HEAT SHIELD
24 N•m (2.4 kg-m,
17 lb-ft)
• Spool valve connector
• Oil pressure switch connector
1 O. Remove the radiator upper hose and heater hose.

P/S LOWER
BRACKET
10 x 1.25 mm
45 N•m 14.5 kg-m.
33 lb-ft)
WATER BYPASS RADIATOR
HOSE UPPER HOSE
1 7. Remove the intake manifold bracket.
1 8. Remove the self-locking nuts and disconnect the

exhaust manifold and exhaust pipe A.
19. Remove the exhaust manifold bracket.
20. Remove the PCV hose, then remove the cylinder

head cover.
21 . Remove the timing belt upper cover.

HEATER HOSE
(cont'd)
6-99
Cylinder Head
Removal(cont'd)~~~~~~~~~~~~~~~~~~~~~~~~-
22. Loosen the tirning belt adjusting bolt 180 ° to 25. Removethe camshaft pulleys.
23. Push the tensioner to releasetension from the tirn-

ing belt, then retighten the adjusting bolt.
26. Loosen the adjust screw and camshaft holders,

then remove the camshaft and rocker arms.
24. Removethe belt from the cam pulley. ADJUST SCREW
CAUTION: Do not crimp or bend

/ the timing belt more than 90º or
less than 25 mm (1 in) in dlameter.
No_Good
ADJUST SCREW
6-100
25. Remove the cylinder head bolts, then remove the NOTE: Separate the cylinder head from the block
cylinder head. with a flat blade screwdriver as shown.
CAUTION: To prevent warpage, unscrew the bolts

in sequence 1 /3 turn at a time; repeat until all bolts
are loosened.
CYLINDER HEAD BOL T LOOSENING SEOUENCE
' ©
26. Remove the intake manifold and exhaust manifold

6-101
Rocker Arms
Removal
1. Hold the rocker arms together with a rubber band 3. Screw 12 mm bolts into the rocker arm shafts.
to prevent thern from separating. Removeeach rocker arm while slowly pulling out ot
in take and exhaust rocker arm shafts.
RUBBER BAND
2. Remove the intake and exhaust rocker shaft oil

control orífice, then remove the spool valve and the
sealing bolts. ROCKER ARM SHAFTS
NOTE: The shapes of the oíl control orifice of the
intake and exhaust are different. ldentify the parts
as they are removed to ensure reinstallation in the
original locations.
EX ORIFICE
0-RING
6-102
Locations
CAUTION: After installing the locker shaft orífice, try to turn the rocker shaft to make sure that the orífice has been in-
serted in the hole of rocker shaft correctly. lf the orífice is in place, it should not turn.
NOTE:
• ldentify parts as they are removed to ensure reinstallation in original locations.
• lnspect rocker shafts and rocker arms (pages6-104 and 105).
, Prior to reinstalling, clean all the parts in solvent, dry them and apply lubricant to any contact surfaces.
INTAKE ROCKER ARM ASSEMBLIES
1 / CYLINDER NUMBER
1 1
No. 3 No. 1
1 1
SEALING BOLTS 20 mm ----- RUBBER BAND

60 N•m (6.0 kg-m, 43 lb-ftl INTAKE OIL
CONTROL ORIFICE
1
INTAKÉ ROCKER
SHAFT
r
0-RINGS
WASHERS
HOLE
(OIL CONTROL
o~
Replace. ORIFICEJ
!
EXHAUST OIL
EXHAUST ROCKER CONTROL ORIFICE
SHAFT
--- RUBBER BAND
1
No. 1
._ ..___~_...__ __ __.! ~ CYLINDER NUMBER
EXHAUST ROCKER ARM ASSEMBLIES
6-103
Rocker Arms and Lost Motion Assemblies
lnspection
NOTE: When reassembling the primary rocker arrn. 2. Removethe lost motion assembly from the cylinder
carefully apply air pressure to the oil passage of the head and inspect it. Pushing it gently with the
rocker arm. finger will cause it to sink slightly. lncreasing the
force on it will cause it to sink deeper.
- lf the lost motion assembly does not move
smoothly, replace it.
PRIMARY ROCKER ARM
Push
' LOST MOTION ASSEMBL Y
PISTONS
1. lnspect the rocker arm piston. Push it manually.

- lf it does not move smoothly, replacethe rocker
arm assembly.
PRIMARY
MID
o~/
CJJ Q
SECONDARY
v=
· Check piston movement
NOTE:
• Apply oil to the pistons when reassembling.
• Bundle the rocker arms with a rubber band to
prevent them from separating.
6-104
Clearance
Measure both the intake rocker shafts and exhaust 3. Measure inside diameter of rocker arm and check
rocker shafts. for out-of-round condition.
1. Measure diameter of shaft at first rocker location. Rocker Arm Radial Clearance:
lnspect rocker arm

face for wear.
2. Zero gauge to shaft diameter. Repeat for all rockers.

- lf over limit, replace rocker shaft and all over-
tolerance rocker arms.
NOTE: lf any rocker arm needs replacement,

replace all three rocker arms in that set (primary,
mid, and secondary).
MICROMETER
CYLINDER BORE.
GAUGE
6-105
Camshafts
lnspection
NOTE:
• Do not rotate the camshaft during inspection.
• Removethe rocker arms and rocker shafts.
1. Put the camshaft and cam holders on the cylinder

head, and then tighten the bolts to the specified
torque.
Specified Torque:
9-G): 8 mm bolts 22 N•m (2.2 kg-m, 16 lb-ft)
•-•: 6 mm bolts 11 N•m ( 1.1 kg-m, 8 lb-ft)
4. Remove the bolts, then remove the cam holders

- Lift camshaft out of cylinder head, wipe clean,

then inspect lift ramps. Replace camshaft if
lobes are pitted, scored, or excessively worn .
•• • E) •
- Clean the camshaft bearing surfaces in the
- lnsert plastigage strip across each journal.
5. Put the camshaft on the cylinder head, then install

the cam holders, and then tighten the bolts to the
specified torque, as shown in the left column on
•• •
this page.
6. Measure widest portian of plastigage on each

journal.
2. Seat the camshaft by pushing it toward distributor
end of cylinder head. Camshaft Bearing Radial Clearance:
3. Zero the dial indicator against end of distributor (0.002-0.004 in.)
drive, then push the camshaft back and borth, and Service Limit: 0.15 mm (0.006 in.)
read the end play.
PLASTIGAGE STRIP
Camshaft End Play:
(0.002-0.006 in.)
Service limit: 0.5 mm (0.02 in.)
6-106
7. lf camshaft bearing radial clearance is out of 8. Check the wear of the cam lobe height.
toleran ce:
Cam lobe height standard (New):
- And camshaft has already been replaced, you
must replace the cylinder head. INTAKE EXHAUST
33.088 mm 32.785 mm
- lf camshaft has not been replaced, first check PRIMARY
(1.3027 in) (1.2907 in)
· total runout with the camshaft supported on V-
blocks. 36.267 mm 35.720 mm
MID
(1.4278 in) (1.4063 in)
Camshaft Total Runout: 34.978 mm 34.691 mm
SECONDARY
Standard (New): 0.15 mm (0.0006 in) (1.3774 in) (1.3658 in)
Rotate camshaft
while measuring
Check this area for wear.
Cam Position
- lf the total runout of the camshaft is within

tolerance, replace the cylinder head. IN EX
- lf the total runout is out of tolerance, replace the
camshaft and recheck. lf the bearing clearance PRI MID SEC PRI MID SEC
is still out of tolerance, replace the cylinder
head.
T/B T/B
T/B: TIMING BELT

PRI: PRIMARY
MID: MID
SEC: SECONDARY
6-107
Valves
Replacement ~~~~~~~~~~~~~~~~~~~~~~~~~~~--.
NOTE: ldentify valves and valve springs as they are Valve Demensions
removed so that each ítem can be reinstalled in its
original position.
1. Tap each valve stem end perpendicularly with a

hammer gripe bottom (refer to page 6-113) to B
loasen valve keepers befare installing spring
compressor.
D
A[~
CAUTION: When tapping, care should be taken ~~
not to bend the valve stem.
2.
+e O]
lnstall spring compressor. Compress spring and 11
remove valve keeper.
f
VALVE SPRING
COMPRESSOR
07757-0010000 lntake Valve
(1.2953-1.3031 in)
(3.9764-3.9882 in)
C Standard (New): 5.475 -5.485 mm
(0.2156-0.2159 in)
C Service Limit: 5.445 (0.2144 in)
(0.0413-0.0531 in)
D Service Limit: 0.85 mm (0.0335 in)
Exhaust Valve
(1.0984-1.1063 in)
(3.9606-3.9724 in)
C Standard (New): 5.450 -5.460 mm
(0.2146-0.2150 in)
e Service Limit: 5.420 (0.2134 in)
D Standard (New): 1.65-1 .95 mm
(0.0650-0.0768 in)
3. lnstall the special tool as shown. D Service Limit: 1.45 mm (0.0571 in)
4. Removethe valve guide seal.
6-108
Valve Seats
Reconditioning-----------------------------,
1. Renew the valve seats in the cylinder head using a 5. After resufacing the seat, inspect for even valve
valve seat cutters. seating: Apply Prussian Blue Compound to the
valve face, and insert valve in original location in
1J~-1-
NOTE: lf guides are worn, replace them befare the head, then lift it and snap it closed against the
cutting the valve seats. seat severa!times.
ACTUALSEAT17JING. ~
SURFACE ~
1
VAL VE
SEAT
I
PRUSSIAN BLUE COMPOUND I
6. The actual valve seating surface, as shown by the

• lf it is too high (closer to the valve stem). you
move it down, then one more cut with the 45 °
cutter to restare seat width.
• lf it is too low (closer to the valve edge). you
must make a second cut with the 30° cutter to
move it up, then one more cut with the 45º cut-
ter to restare seat width.
NOTE: The final cut should always be made with

2. Carefully cut a 45° seat. removing only enough the 45° cutter.
material to ensure a smooth and concentric seat.
7. lnsert intake and exhaust valves in the head and
3. Bevelthe upper edge of the seat with the 30º cut- measurevalve stem installed height.
ter and the lower edgeof the seat with the 60º cut-
ter. Check width of seat and adjust accordingly. lntake Valve Stem lnstalled Height:
4. Make one more very light pass with the 45° cutter (1.4750-1.4935 in)
to remove any possible burrs caused by the other Service Limit: 38.185 mm (1.5033 in)
cutters. ExhaustValve Stem lnstalled Height:
Valve Seat Width: (1.4632-1.4817 in)
Standard: 1.25-1.55 mm (0.049-0.061 in.) Service Limit: 37 .885 ( 1 .4915 in)
Seat Width -r--)---.J" VALVE STEM

INSTALLED HEIGHT
B. lf valve stem installed height is over the service

limit, replacevalve and recheck. lf still over the ser-
vice limit, replace cylinder head; the valve seat in
the head is too deep.
6-109
Cylinder Head Valves
Warpage Valve Movement
NOTE: lf camshaft bearing clearances (page 6-106) Measure the guide-to-stem clearance with a dial in-
are not within specification, the head cannot be dicator while rocking the stem in the direction of normal
resurfaced. thrust (wobble method).
lf camshaft bearing radial clearance are within lntake Valve Stem-to-Guide Clearance:
specifications, check the head for warpage. Standard (New): 0.05-0.11 mm
(0.0020-0.0043 in)
• lf warpage is less than 0.05 mm (0.002 in.) Service Limit: 0.15 mm (0.0059 in)
cylinder head resurfacing is not required.
• lf warpage is between 0.05 mm (0.002 in.) and Exhaust Valve Stem-to-Guide Clearance:
0.2 mm (0.008 in.), resurface cylinder head. Standard (New): 0.10-0.16 mm
• Maximum resurface limit is 0.2 mm (0.008 in.) (0.0039-0.0063 in)
based on a height of 142 mm (5.59 in.). Service Limit: 0.24 (0.0094 in)
PRECISION STRAIGHT EDGE Valve extended 1 O mm out from seat.

recheck using a new valve.
• lf measurement is now within the service limit,
reassemble using a new valve.
• lf measurement still exceeds limit, recheck using
alternate method below, then replace valve and
quide, if necessary.

stem clearance is to subtract the 0.D. of the valve
stem, measured with a micrometer, from the 1.0. of
micrometer or ball gauge.
Cylinder Head Height: Take the measurements in three places along the
Standard (New): 141.95-142.05 mm valve stem and three places inside the valve guide.
(5.5886-5.5925 in) The difference between the largest guide measure-
ment and the smallest stem measurement should
Measure along edges, and 3 ways across center. not exceed the service limit.
lntake Valve Stem-to-Guide Clearance:

(0.0010-0.0022 in)
Service Limit: O.OSO mm (0.0031 in)
Exhaust Valve Stem-to-Guide Clearance:

(0.0020-0.0031 in)
Service Limit: 0.11 O mm (0.0043 in)
6-110
Valve Guides
Replacement Valve Guide Reaming
NOTE: NOTE: For new valve guides only.

• For best results, heat cylinder head to 1 50ºC
(300ºF) before removing or installing guides. 1. Coat both reamer and valve guide with cutting oil.
• lt may be necessary to use an air hammer to remove
sorne valve guides. 2. Rotate the reamer clockwise the full length of the
valve guide bore.
CAUTION: To avoid burns. use heavy gloves when
handling heated cylinder head. 3. Continue to rotate the reamer clockwise while
1. Orive the valve guide out from the bottom of the removing it from the bore.
cylinder head.
4. Thoroughly wash the guide in detergent and water
to remove any cutting residue.
5. Check clearance with a valve (page 6-110).

• Verify that the valve slides in the IN, EX valve
guides without exerting pressure.
REAMER HANDLE
Turn reamer in
clockwise direction
only.
2. Drive in a new valve guide to the specified depth.
VALVE GUIDE DRIVER

07742-8920000
~ ~
VALVE GUIDE REAMER, 5.5 mm
07HAH-PJ70100
Valve Guide lnstalled Height:

lntake: 12.55-13.05 mm (0.4941-0.5138 in)
Exhaust: 12.55-13.05 mm (0.4941-0.5138 in)
VALVE GUIDE --/
-7-,,7
r---r_.l._
l __
~easure here.
........7~-7---7..-l...-7~,-7...-7~7......,7~7-r--
6-111
Valve Springs and Valve Seals
Valve Spring and Valve Seal lnstallation Sequence
NOTE: Exhaust and intake valve seals are NOT interchanqeable.
VALVE KEEPERS
/ VALVE SPRING
~RETAINER
-1 -
INTAKE VALVE SPRING
-=' /VALVESPRJNG
~~:i~~ ~ EXHAUST VAL VE SEAL

(BLACK SPRING)
• ~~:G / ~YR,plac,
INTAKE VALVE SEAL

(WHITE SPRING)
Replace. ~toward
NOTE: Place the end of valve
spring with closely wound coils
the cylinder head.
~
1
SPRING SEAT
NOTE: lnstall the valve spring seats
before installing the valve seals.
VALVE SEAL
Replace.
6-112
Rocker Arms
Valve lnstallation lnstallation -...-----------,
• When installing valves in cylinder head, coat valve 1. lnstall the rocker arms in the reverse order of
stems with oil before inseting into valve guides, and removal:
make sure valves move up and down smoothly. • Valva adjusting locknuts should be loosened and
adjusting screw backed off before instllation.
• When valves and springs are in place, lightly tap the • The component parts must be reinstalled in the
end of each valve stem two or three times to ensure original locations.
proper seating of valve and valve keepers (use ham-
mer gripe bottom). 2. lnstall the lost motion assembly.
3. Instan the rocker arms while passsing the rocker

arm shaft through the cylinder head.
NOTE: Removethe rubber band after installing the

rocker arms.
ROCKER ARMS
12 mm BOLT
4. lnstall the orífices. lf the holes in the rocker arm

shaft and cylinder head are not in line each other,
mount a 12 mm bolt on the rocker arm shaft and
rotate the shaft.
NOTE: The shapes of the orífices for the intake

HAMMER GRIPE and exhaust are different. The orificas must be in-
stalled in the original locations.
6-113
Cylinder Head
lnstallation
1. lnstall the cylinder head in the reverse arder of 3. Tighten cylinder head bolts in two steps. In the first
removal: step, tighten all bolts in sequence, to about 30 N•m
• Always use a new head and manifold gasket. (3.0 kg-m, 22 lb-ft). In the final step, tighten in
• The cylinder head gasket is a metal gasket. Take same sequenceto 85 N•m (8.5 kg-rn, 61 lb-ft).
care not to bend it.
• Rotate the crankshaft, set the No. 1 pistan at NOTE: Apply clean engine oil to the bolt threads
TDC (page 6--121). and under the bolt head.
2. lnstall the cylinder head gasket, dowel pins and the CYLINDER HEAD BOLT TORQUE SEQUENCE
head oil control orifice on the cylinder head.
11x1.5mm
85 N•m (8.5 kg-m, 61 lb-ftl
CYLINDER HEAD
GASKET
0-RING
Replace.
~\
OIL CONTROL
ORIFICE
4. lnstall the intake manifold and tighten the nuts in a

criss-cross pattern in two or three steps, beginning
with the inner nuts.
GASKET
IN MANIFOLD
,
8 x 1.25 mm
26 N•m (2.6 kg-m, 19 lb-ftl
BRACKET
8 x 1.25 mm
22 N•m (2.2 kg-m, 16 lb-ft)
6-114
Camshafts
lnstallation
5. lnstall the exhaust manifold and tighten the new 1. lnstall the camshafts and camshaft oil seals.
self-focking nuts in a criss-cross pattern in two or
three steps, beginning with the inner nuts. NOTE:
• lnstall the camshafts with keyway facing up.
• lnstall the oil seal with the spring side tace in.
• The oíl seal housing surface should be dry.
• Set the 0-ring and dowel pin in the oil passage
of the No. 3 camshaft holder.
0-RING Replace
GASKET and DOWEL PIN
Replace.
!
8 x 1.25 mm
24 N•m (2.4 kg-m,
17 lb-ft)
2.
Keyway is facing up.
Apply liquid gasket to the head mating surface of

the No. 1 and No. 5 camshaft holders on both the
intake and exhaust side. Confirm that the camshaft
keyway are face up, then. place the holders,
together with the No. 2, No. 3 and No. 4 camshaft
holders, on the cylinder head.
SELF-LOCKING NUT
8 x 1.25 mm NOTE: The arrows marked on the camshaft
32 N•m (3.2 kg-m, 23 lb-ft) holders shoud point to the timing belt.
Replace. 10 x 1.25 mm
34 N•m (3.4 kg-m, 25 lb-ft) CAMSHAFT HOLDERS
10 x 1.25 mm
45 N•m (4.5 kg-m,
d
33 lb-ft) No. 5 No.4 No. 3 No. 2 No. 1
l l
(!]
o
IN
~
o
o o o
Apply liquid gasket

to the shaded areas.
(cont'd)
6-115
Camshafts
lnstallation ( cont' d)
3. Temporarily tighten the bolts of the camshaft 5. Tighten the bolts in the sequence shown below.
holders and the comshaft holder pipes.
CAMSHAFT HOLDER
PIPES
IN
•• o • e •
•• • • •
4. Push the camshaft oíl seal securely against the 0-8: 8 x 1.25 mm 22 N•m (2.2 kg-m, 16 lb-ft)
base of the camshaft holder.
8-e: 6 x 1.0 mm 11 N•m (1.1 kg-m, 8 lb-ftl
6. lnstall the back cover of the timing belt.
7. lnstall the camshaft pulleys.
CAMSHAFT OIL SEALS
10 x 1.25 mm
51 N•m (5.1 kg·m, 37 lb-ft)
6-116
Timing Belt
lllustrated lndex --------------------------
NOTE:
• Refer to section 23 for alternator belt adjustment.
• Refer to section 22 for A/C compressor belt adjustment.
• Refer to section 17 for P/C pump belt adjustment.
• Mark direction of rotation befare removing.
WASHER AND
CAP NUT 6 x 1.0 mm GROMMET
10 N•m 11.0 kg-m,~lb-ftl CYLINDER
~ HEADCOVER
i@
e
RUBBERSEALS
Replace when
damaged or
deteriorated.
TIMING BELT
Replacement, paga 6-11 9
Replace every 100,000 km
10 x 1.25 mm
51 N•m (5.1 kg-m,
37 lb-ft)
SPECIALBOLT
ADJUSTING BOLT
10 x 1.25 mm 6 x 1.0 mm
55 N•m 15.5 kg-m, 40 lb-ftl 10 N•m (1.0 kg-m,
For adjustment only, 7 lb-ft) 6 x 1.0 mm
do not remove. 10 N•m (1.0 kg-m,
7 lb-ft)
14 X 1.25 mm
180 N•m (18.0 kg-m, 130 lb-ft)
Apply oíl to the bolt threads,
but not to the surface that
contacts the washer.
6-117
Timing Belt

• Replacethe belt if oíl soaked. the engine cold.
• Remove any oil or solvent that gets on the belt.
NOTE:
1. Remove the cylinder head cover. • The tensioner is spring-loaded to apply proper ten-
2. lnspect the timing belt for cracks and oil soaking. following adjustment.
when viewed from the pulley side.
lnspectthis area Rotating it clockwise may result in improper adjust-
for wear. ment of the belt tension.
2. Set the No. 1 pistan at TDC (page 6-121 ).
3. Loasen the adjusting bolt 180º.
ADJUSTING BOL T
55 N•m
(5.5 kg-m, 40 lb-ft)
Rotatepulley
andinspectbelt.
3. lf the pulley bolt loosens while turning the crank, 4. Rotate the crankshaft counterclockwise 3-teeth on
tighten it to specified torque. the camshaft pulley to create tension on the timing
belt.
Specified Torque:
180 N·m (18.0 kg-m, 130 lb-ftl 5. Make sure the timing belt and the cam pulley are
engaged securely.
6. Torque the adjusting bolt to 55 N•m (5.5 kg-m,

40 lb-ft).

Specified Torque:
180 N·m (18.0 kg-m, 130 lb-ft)
6-118
Removal
CAUTION: lnspect the water pump when replacing the 4. Remove the P/S lower bracket and heat shield.
timing belt.
5. Loosen the alternator adjusting bolt and pivot nut,
NOTE: then remove the belt.
• Turn the crankshaft so that No. 1 piston is at top-
dead-center ( page 6-1 2 1 ) .
• Before removing the timing belt, mark its direction of HEAT SHEILD
rotation if it to be reused. 8x1.25mm
24 N•m (2.4 kg-m.
17 lb·ft)
1. Removethe splash shield.
2. Removethe power steering pump.

P/S LOWER BRACKET
6. Removethe P/S tank bracket.
7. Remove the engine support nuts. Loosen the

mount bolt and pivot the engine side mount rubber
out of the way.
SUPPORT NUT
3. Remove the A/C compressor adjust pulley with ENGINE SIDE

bracket and the belt (with A/C), then remove the MOUNT RUBBER
alternator belt.
10 x 1.25 mm
55 N•m (5.5 kg-m,
40 lb-ft) P/S TANK
• Loosen BRACKET
A/C BELT (cont'd)
6-119
Timing Belt
Removal (cont' d)
8. Remove the cylinder head cover. 11. Loosen the timing belt adjusting bolt 180º to
release the belt tension.
9. Remove the special bolt and crankshaft pulley.
12. Push the tensioner to release tension from the belt,
1 O. Removethe timing belt middle cover and the lower then retighten the adjusting bolt.
cover.
13. Remove the timing belt from the pulleys.
""""V'A".';;,J..._..... LOWER COVER

Remove the tour
bolts.
6x1.0mm
10 N•m
(1.0 kg-m, 7 lb-ft)
14 x 1.25 mm
' 180 N•m (18.0 kg-m,
"-.. 130 lb-ft)
Apply oil to the bolt
ADJUSTING BOL T threads, but not to the
55 N•m surface that contacts
(5.5 kg-m. 40 lb-ft) the washer.
For adjustment only; SCOKET WRENCH, 19 mm
do not remove. 07JAA-0010200
PULLEY HOLDER
ATTACHMENT
07JAB-0010200
6-120
lnstallation
1. lnstall the timing belt in the reverse order of

removal;
2. Position the crankshaft and the cam pulleys as

shown before installing the timing belt.
A Set the crankshaft so that the No. 1 piston is at


timing belt drive pulley to the '1 pointer on the oil
pum p.
B Align the TDC marks of intake and exhaust

pulleys.
3. Jnstall the timing belt tightly in the sequence

shown.
"UP" MARK
G) Timing belt drive pulley (crankshaft) -+ @ Ad-
justing pulley -+@ Water pump pulley -+ @) lntake
camshaft pulley -+ ® Exhaust camshaft pulley.
TDC MARK
TDC MARK
(PULLEY)
(cont'd)
6-121
Timing Belt
4. Loosenthe adjusting bolt. and retighten it after ten-

sioning the belt. "UP" MARK
5. Rotate the crankshaft about 4 or 6 turns clockwise

7. Check the crankshaft pulley and the cam pulley at

TDC.
CRANKSHAFT PULLEY:
TDC MARK
{)
-' ,- ,
TDC CROOVES
~Q
\) ~o,L
.,),.) L"
v
8. lf the cam pulley is not positioned at TDC, remove

the procedure on page 6-122, then reinstall the
timing belt.
NOTE: Refer to page 6-119 for timing belt

removal.

• See section 23 for alternator belt tension
adjustment.
adjustment.
adjustment.
6-122
Rocker Arms
Manual lnspection
1. Set the No. 1 cylinder at TDC. 4. Remove the valve cover.
2. Remove the plug wire cover and the plug wires. 5. Push the mid rocker arm on the No. 1 cylinder
manually.
3. Remove the plug clamps while pulling up on the
lock. 6. Check that the mid rocker arm moves independent-
ly of the primary and secondary intake rocker arms.
SECONDARY
ARM ROCKER ARM
7. Check the mid rocker arm of each cylinder at TDC.

• lf the mid rocker arm does not move, rernove the
mid prirnary and secondary rocker arms as an
assembly and check that the pistons in the mid
and primary rocker arms move srnoothly.
• Replacethe rocker arms as an assembly if there
is any abnormality.
PLUG WIRE
CLAMP
LOCK
(cont'd)
6-123
Rocker Arms
lnspection Using Special Tools
CAUTION: 3. Remove the bolt and washer from the inspection

• Before using the special tool (Valve lnspection Set), hole and connect the special tool (Valve lnspection
make sure that the air pressuregauge on the air com- Set).
pressor indicates over 250 kPa (2.5 kg/cm2, 36 psi).
• lnspect the valva clearance before rocker arm
inspection.
• Cover the timing belt with shop towel to prevent the
belt.
• Check the mid rocker arm of each cylinder at TDC. AIR STOPPER
07LAJ- PR30200
wmto\
2. Plug the relief hole with the special tool (Air REGULATOR VALVE
Stopper). • Pull the lever and
WASHER
Replace.
6-124
4. Apply specified air pressure to the rocker arm
pistons after loosening the regulator valve on the
valve inspection set.
Specified Air Pressure:

250 kPa (2.5 kg/cm2, 36 psi)
- 500 kPa (5.0 kg/cm2, 71 psi)
5. Make sure that the intake primary and secondary

rocker arms are mechanically connected by pistons
and that the mid rocker arms do not move when
pushed manually.
MID ROCKER SECONDARY

ARM ROCKER ARM
PRIMARY
LOST MOTION
ROCKER ARM
ASSEMBLY
• lf the mid rocker arms independently of the

primary and secondary rocker arrns, replace the
rocker arms, as a set. ·
6. Removethe special tools.
7. Check for smooth operation of the lost motion

assembly. lt is compressed slightly when the mid
rocker arm is lightly pushed and compressed deeply
when the mid rocker arm is strongly pushed.
• Replacethe lost motion assembly if it does not
move smoothly.
8. After inspection, check that the ECU does not

come on.
6-125
Valve Clearance
Adjustment
NOTE:
• Valves should be adjusted when the cylinder head
temperature is less than 38ºC (100° F).
Adjustment is the same for intake and exhaust
valves.
• lf the pulley bolt loosens while turning crank, retor-
que it to 120 N•m (12.0 kg-m, 87 lb-ft).
1. Removecylinder head cover.
INTAKE
No. 4 No. 3 No. 2 No. 1
3. Adjust valve clearance on No. 1 cylinder.
lntake: 0.15-0.19 mm (0.006-0.007 in.)

No. 1
Exhaust: 0.17-0.21 mm (0.007-0.008 in.)
No.4 No.3 No. 2
EXHAUST
4. Loasen the locknut and turn the adjustment screw
until feeler gaugeslides back and forth with a slight
amount of drag.
2. Set No. 1 piston at TDC. "UP" mark on the pulley
should be at top, and TDC grooves on the pulley
should align with the pointer on timing belt back
cover. TDC grooves (white paint) on the crankshaft
pulley should align with pointer on the timing belt
lower cover.
Number 1 piston at TDC
"UP" MARK
LOCKNUT 7 x 0.75 mm
20 N•m (2.0 kg-m, 14 lb-ft)
TDC MARK
6-126
5. Tighten locknut and recheck clearance again. 7. Rotate crankshaft 180° counterclockwise to bring
Repeat adjustment if necessary. No. 4 pistan to TDC. Both TDC grooves are once
again visible. Adjust valves on No. 4 cylinder.
FILLER GAUGE Number 4 piston at TDC
6. Rotate the crankshaft 180° counterclockwise 8. Rotate crankshaft 180° counterclockwise to bring
(cam pulley turns 90°). The "UP" mark should be No. 2 piston to TDC. The "UP" marks should be on
on the exhaust side. Adjust valve on No. 3 cylinder. the intake side. Adjust valves on No. 2 cylinder.
Number 3 piston at TOC Number 2 piston at TOC
"UP"' MARKS
6-127
Engine Block
Special Tools 7-2

Flywheel and Orive Plate . . . . . . . . . . . . . . . . . . 7-6
Rod and Main Bearings . . . . . . . . . . . . . . . . . . . . . 7- 7
Pistons and Crankshaft Removal 7-11
Crankshaft 7-13
Oil Jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Cylinder Block :...................... 7 -1 5
Piston Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 -1 7
Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 8
Piston Rings 7-20
Piston lnstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
Oil Seal 7-23
Crankshaft lnstallation 7-23
Oil SeaIs 7-27
Oil Pan Replacement 7-28
Special Tools
Ref. No. Tool Number Description Oty Paga Reference
CD 07LAB-PV00100 Ring Gear Holder 7-6

or 07924-PD20003
@ 077 49-0010000 Driver 7-23, 27
@ 0794 7 - SB00200 Seal Driver 7-23
@ 07948-SB00101 Driver Attachment 7-23, 27
® 07973-PE00200 Pilot Collar 7-17, 19
® 07LAF-PR30100 Pilot Collar 7-17, 20
0 07973-PE00310 Piston Pin Driver Shaft 7-17, 19, 20
® 07973-PE00320 Piston Pin Driver Head 7-17, 19, 20
® 07973-PE00400 Piston Pin Base lnsert 7-17, 19
@) 07GAF-PH60300 Piston Pin Base lnsert 7-17, 20
1
@ 07973-SB00100 Piston Base Head 7-17, 19
® 07HAF-PL201 02 Piston Base Head 7-17,20
@ 07973-6570500 Piston Base 7-17, 20
® 07973-6570600 Piston Base Spring 7-1 7
) () » » rnJ))))))))))))fü))))) Q )
®® (J) ® ®@
i¡
@
@® @
7-2
Engine Block
lllustrated lndex/Except B 16A
, Lubricate all interna! parts with engine oil during reassembly.
NOTE:
• Apply liquid gasket to the mating surfaces of the R. side cover and oil pump case before installing them.
• Use liquid gasket, part No. OY740-99986.
• 0128, 0138, 0158, 0152, 016A, 0162 engine is shown, they are similar.
6x1.0mm
\~/2'
DRAIN BOLT 12 N•m (1.2 kg-m, FLYWHEELCOVER
45 N•m (4.5 kg-m, 33 lb-ft) g lb ft) (M/T)
6 x 1.0 mm OIL PAN GASKET O mm

12 N•m (1.2 kg-m, 9 lb-ft)
1
• 120 N•m
1~
(12.0 kg-m, 87 lb-ft)
01626:
11 x 1.5 mm
52 N•m
OIL PAN -------...
Apply liquid gasket to

I
(5.2 kg-m, 38 lb-ft) these points.
Except 01626:
10 x 1.25 mm
45N•m
(4.5 kg-m, 33 lb-ft)
Apply engine oil to the bolt
threads and the washers.
NOTE: After torquing
each cap, turn crankshaft
to check for binding.
MAIN BEARINGS-
Selection, page 7-9~.~100----------~
NOTE: New main bearings must
be selected by matching crank
and block identification markings.
CRANKSHAFT~~~~~~~-e~I Check for cracks.
6 x 1.0 mm
11 N•m (1.1 kg-m, 8 lb-ft) ....,'"'i!i' ,.-.---- CRANK SEAL
lnstallation,
page, 7-23
OIL SCREEN-----l~~Á
~ Replace.
8 x 1.25 mm
24 N•m (2.4 kg-m, 17 lb-ft) 6 x 1.0 mm
~ 11 N•m (1.1 kg-m,
' ~ 81b-ft)
R. SIOE COVER
OIL PUMP OOWEL PIN Apply liquid gasket
Overhaul, page 8-11 to mating surface.
Removal/lnspection;,,
page 8-1 1 ""-
.:
Grooved sides face outward.
NOTE: Thrust washer thickness
is fixed and must not be changed
by grinding or shimming.
BREATHINGPORT COVER
0-RING MOUNT BOLTS
Replace.
6 x 1.0 mm
CRANK SEAL 6 x 1.0 mm 11 N•m (1.1 kg-m, 8 lb-ft)
lnstallation, page 8- 1 2 11 N•m (1.1 kg-m, Apply liquid gasket to
Replace. 8 lb-ft) the bolt threads.
7-3
Engine Block
llustrated lndex/B16A
, Lubricate all interna! parts with engine oil during reassembly.
NOTE:
• Apply liquid gasket to the mating surfaces of the R. side cover and oil pump case befare installing them.
• Use liquid gasket, part No. OY740-99986.
6x1.0mm
12 N•m (1.2 kg-m,
WASHER
9 lb-ft)
11 x 1.5 mm
78 N•m (7.8 kg-m, 56 lb-ft)
Apply engine oil to the bolt
threads and the washers.
NOTE: After torquing OIL PAN
each cap, turn crankshaft
to check for binding.
OIL PAN GASKET,
Replace. •
12 x 1.0 mm
105 N•m (10.5 kg-m, OIL SCREEN
76 lb-ft) '-....
FLYWHEEL~~
J ~ 2x ~."~ ~~ kg-m,
FLYWHEEL COVER 9 lb-ft)
MAIN BEARING CAP
MAIN BEARINGS
Selection, page 7-9, 10
NOTE: New main bearings must
be selected by matching crank
and block identification markings.
.6 X 1.0 mm
12 N•m (1.2 kg-m,
l CRANKSHAFT
lnstaftatlon, oece 7-23
9 lb-ft)
OIL JET BOLT
(8 x 0.75 mm)
16 N•m (1.6 kg-m, 12 lb-ft)
CRANK SEAL A>.=,-----;,- OIL JET
lnspection, 7-14
Replace.
R. SIDE COVER
Apply liquid gasket
to mating surface.
8 x 1.25 mm
THRUST WASHERS 24 N•m (2.4 kg-m,
Grooved sides face outward. 17 lb-ft)
NOTE: Thrust washer thickness CRANK SEAL
is fixed and must not be changed / lnstallation, page 8-12
by grinding or shimming.
OIL PUMP
0-RING Overhaul, page 8-11
Replace. 6x1.0mm
11 N•m (1.1 kg-m. Removal/1nspection,
page 8-11
7-4 8 lb-ft)
lllustrated lndex
NOTE: New rod bearings must be selected by matching connecting rod assembly and crankshaft identification markings
(page 7-10).
--:,il Lubricate all interna! parts with engine oil

. 11 during reassembly.
]---
PISTON RINGS
Measurement, pages 7-20 and 21
Alignment, page 7-22
PISTON PIN
Removal, page 7-15 PISTON
lnstallation, page 7-19-------.. ~ lnspection, page 7-14, 15
lnspection, page 7-18 ~ NOTE: Before removing piston, inspect the
top of the cylinder bore for carbon build-up or
ridge. Remove ridge if necessary, page 7-12
CONNECTINGROD ENGINEBLOCK
End play, page 7-8
Cylinder bore inspection, page 7-15
Selection, page 7-18
Warpage inspection, page 7-16
Cylinder bore honing, page 7-16
CONNECTINGROD
BEARINGS
Clearance, page 7-9
Selection, page 7-9,
lnspect top of each cylinder bore

for carbon build-up or ridge
before removing piston.
Remove ridge if necessary, page 7-1 2
CONNECTINGROD BEARINGCAP-----~ CONNECTINGROD CAP NUT

lnstallation, page 7-23 Except B16A engine
NOTE: lnstall caps so the 9 x 0.75 mm
bearing recess is on the
same side as the recess
in the rod.
®--.------- 32 N•m 13.2 kg-m,
23 lb-ftl
B16A engine
9 x 0.75 mm
41 N•m (4.1 kg-m, 30 lb-ft)
After torquing each bearing
cap, rotate crankshaft to
check for binding.
7-5
Flywheel and Orive Plate
Replacement
Manual Transmission: Automatic Transmission:

Except B16A: Remove the six drive plate bolts, then separate the
Remove the six flywheel bolts, then separate the drive plate frorn the crankshaft flange. After installa-
flywheel from the crankshaft flange. After installation, tion, tighten the bolts in the críss-cross pattern.
tighten the bolts in the criss-cross pattern.
RING GEAR HOLDER

07LAB-PV00100 or
07924- PD20003
ENGINE
RING GEAR BLOCK
lnspect ring gear
teeth for wear or
damage.
----==:.._ RING GEAR HOLDER

07LAB-PV00100 or
07924- PD20003
B16A:
RING GEAR HOLDER
07LAB-PV00100 or
07924-PD20003
RING GEAR 12 x 1.0 mm

lnspect ring gear 105 N•m
teeth for wear or (10.5 kg-m, 76 lb-ftl
damage.
7-6
Connecting Rod and Crankshaft
End Play
Pushthe crank firmly away from the dial indicator, and

zero the dial against the end of the crank. Then pull the
Connecting Rod End Play: crank firmly back toward the indicator; dial reading
Standard (New): 0.15-0.30 mm should not exceed service limit.
(0.006-0.012 in.)
Crankshaft End Play:

Standard(New): 0.10-0.35 mm
• lf out-of-tolerance, install a new connecting rod. (0.004-0.014 in.)
• lf still out-of-tolerance, replace the crankshaft Service Limit: 0.45 mm (0.018 in.)
(pages 7-11 and 7-23).
• lf end play is excessive. . inspect the thrust
washers and thrust surface on the crankshaft.
Replaceparts as necessary.
NOTE: Thrust washer thickness is fixed and must

not be changed either by grinding or shimming.
Thrust washers are installed with grooved side fac-
ing outward.
7-7
Main Bearings
Clearance
1. To check main bearingclearance, remove the main

caps and bearinghalves.
2. Clean each maín journal and bearíng half with a

clean shop rag.
3. Place one strip of plastigage across each main

journal.
NOTE: lt the engine is still in the car when you bolt

the main cap down to check clearance, the weight
of the crank and flywheel will flatten the plastigage
further than just the torque on the cap bolt, and
give you an incorrect reading. For an accurate
reading, support the crank with a jack under the
counterweights and check only one bearing at a 6. lf the plastigage measurestoo wide or too narrow,
time. (remove the engine if it's still in the car), remove
the crank, and remove the upper half of the bear-
4. Reínstallthe bearingand cap, then torque the bolts. ing. lnstall a new, complete bearingwith the same
color code (select the color as shown on the next
1st step: 25 N•m (2.5 kg-m, 18 lb·ft) page), and recheck the clearance.
Final step:
D12B,D13B,D15B,D15Z,D16A: CAUTION: Do not file, shim, or scrape the bear-
45 N·m (4.5 kg-m, 33 lb-ft) ings or the caps to adjust clearance.
01626: 52 N·m (5.2 kg-m, 38 lb-ft)
B16A: 78N·m (7.8 kg-m, 66 lb-ftl 7. lf the plastigage shows the clearance is still incor-
rect, trv the next largeror smaller bearing (the color
NOTE: Do not rotate the crank during inspection. listed above or below that one). and check again.
5. Removethe cap and bearing again, and measure NOTE: lf the proper clearance cannot be obtained
the widest part of the plastigage. by using the appropriate larger or smaller bearings,
replace the crank and start over.
Main BearingClearance:
D12B.D13B,D15B.D15Z
Standard (New):
No. 1, 5 Journals:
0.018-0.036 mm (0.0007-0.0014 in.)
No. 2, 3, 4 Journals:
0.024-0.042 mm (0.0010-0.0017 in.)
D16A,D16Z
Standard (New):
No. 1, 5 Journals:
0.018-0.036 mm (0.0007-0.0014 in.)
No. 2, 4 Journals:
0.024-0.042 mm (0.0010-0.0017 in.)
No. 3 Journals:
0.030-0.048 mm (0.0012-0.0019 in.)
816A
Standard (New):
No. 1, 2. 4, 5 Journals:
0.024-0.042 mm (0.0010-0.0017 in.)
No. 3 Journals:
0.030-0.048 mm C0.0012-0.0019 in.)
7-8
Rod Bearings Main Bearing
Clearance Selection
1. Removethe connecting rod cap and bearing half. B16A

Crank Bore Code Location (Marks)
2. Clean the crankshaft rod journal and bearing half
with a clean shop rag. Marks have been stamped on the end of the block as a
code for the size of each of the 5 main journal bores.
3. Place the plastigage across the rod journal. Use then, and the numbers stamped on the crank
(codes for main journal size). to choose the correct
4. Reinstall the bearing half and cap, and torque the bearings.
nuts.
Torque
Except B16A: 32 N·m (3.2 kg-m, 23 lb-ftl
B16A: 41 N•m (4.1 kg-m, 30 lb-ftl
NOTE: Do not rotate the crank during inspection.
5. Removethe rod cap and bearing half and measure

the widest part of the plastigage.
Connecting Rod Bearing Clearance:
Except B16A
Standard (Newl: 0.020-0.038 mm
(0.0008-0.0015 in.)
B16A engine
Standard (Newl: 0.032-0.050 mm
Main Journal Code Locations (Numbers)
(0.0013-0.0020 in.)
Bearing ldentification
Color code is on the --------. Larger crank bore

PLASTIGAGE STRIP
edge of the bearing
6. lf the plastigage measurestoo wide or too narrow,
!
l
A or I B or II C or 111 D or 1111 1
remove the upper half of the bearing, install a new,
complete bearing with the same color code (select
the color as shown on the next pagel. and recheck Smaller bearing (thicker)
l
the clearance.
Red Pink Yellow Green
CAUTION: Do not file, shirn, or scrape the bear- 21 or
or III Pink Yellow Green Brown
ings or the caps to adjust clearance. 3 or 111 Yettow Green Brown Black
4 or 1111 Green Brown Black Blue
7. lf the plastigage shows the clearance is still incor-
rect, try the next larger or smaller bearing (the color Smaller Smaller
listed above or below that one). and check main bearing
clearance again. journal (thicker)
NOTE: lf the proper clearance cannot be obtained

by using the appropríate larger or smaller bearings,
replace the crank and start over. (cont'd)
7-9
Main Bearings Rod Bearings
Selection (cont'd)------- Selection
Except B16A
Crank Bore Code Location (Marks) Rod Coda Location (Numbers)
Marks have been stamped on the end of the block as a Nurnbers have been stamped on the side of each con-
code for the size of each of the 5 main journal bores. necting rod as a code for the size of the big end. Use
Use them, and the numbers stamped on the crank them, and the letters stamped on the crank (codes for
(codes for main journal size), to choose the correct rod journal size). to choose the correct bearings.
bearings.
CAUTION: lf the codes are indecipherable because of
CAUTION: lf the codes are indecipherable because of an accumulation of dirt and dust, do not scrub them
an accumulation of dirt and dust, do not scrub them with a wire brush or scraper. Cleanthem only with sol-
with a wire brush or scraper. Clean them only with solvent or detergent.
vent or detergent.
Half of number is
stamped on bearing
cap and the other
half is stamped on
rod.
Rod Journal Code Locations lletters)
FLYWHEEL END
(No. 5 JOURNALI
Main Journal Code Location (Numbers)
Bearing ldentification
l
Color code is on the __
Larger big end bore
edge of
Bearing ldentification the bearing. 2 4
3
.
Larger crank bore 1
Color code is -----------
on the Smaller bearing (thicker)
edge of
the bearing.
A B I C D A or I
B or II
Red Pink Yellow
------<• Cor III Green
l
Smaller bearing (thicker)
O or 1111 Pink Yellow Green Brown
Red Pink Yellow Green
Smaller Smaller Yellow Green Brown Black
Pink Yeflow Green Brown rod bearing
journal (thicker) Green Brown Black Blue
Yellow Green Brown Black
Green Brown Black Blue

Smaller Smaller
main bearing
journal (thicker)
7-10
Pistons an d Crankshaft
Removal
1. Rernove the o1-1 pan asse rnbly. 3. Rernovethe oil screen.
2. Rernove the right s1ºde cover. 4. Remove the oil purnp.
Except B16A:
Except B16A:
OIL SCREEN
RIGHT SIDE
COVER
GASKET
Replace.
DOWEL PIN
0-RING
Replace.
B16A:
816A:
RIGHT SIDE
COVER
OIL PUMP
(cont'd)
7-11
Piston and Crankshaft
Removal (cont'd)
5. Removethe bolts and the bearing cap. 8. Removethe upper bearing halves from the connec-
ting rods and set them aside with their respective
CAUTION: To prevent warpage, unscrew the bolts caps.
in sequence 1 /3 turn ata time; repeat the sequence
until all bolts are loosened. 9. Reinstallthe main caps and bearings on the engine
in proper order.
MAIN BEARING CAP BOLTS LOOSENING SEQUEN CE
1 O. lf you can feel a ridge of metal or hard carbon
around the top of each cylinder, remove it with a
ridge reamer. Follow the reamer manufacturer's
instructions.
CAUTION: lf the ridge is not removed, it may

damage the pistons as they are pushed out.
6. Removethe rod caps/bearings and main caps/bear-

ings. Keep all caps/bearings in order. 11 . Use the wooden handle of a hammer to drive the
pistons out.
7. Lift the crankshaft out of the engine, being careful
not to damage journals.
12. Reinstall the rod bearíngs and caps after removíng

each piston/connecting rod assembly.
13. Mark each piston/connectíng rod assembly with its

cylinder number to avoid mixup on reassembly.
CRANKSHAFT
NOTE: The existíng number on the connectíng rod
does not indícate its posítion in the engine, it in-
dicates the rod bore size.
7-12
Crankshaft
lnspection
• Clean the crankshaft oíl passageswith pipe cleaners Out-of-Round and Taper
or a suitable brush.
• Measure out-of-round at the middle of each rod
• Check the keyway and threads. and main journal in two places.
Alignment • The difference between measurements on each

journal must not be more than the service limit.
• Measure runout on ali main journals to make
sure the crank is not bent. Journal Out-of-Round:
Except 816A:
• The difference between measurements on each Standard (New): 0.0025 mm (0.0001 in.) max.
journal must not be more than the service limit. Service Limit: 0.010 mm (0.0004 in.)
Crankshaft Total lndicated Runout: 816A:

Except 816A: Standard (New): 0.004 mm (0.0002 in.) max.
Standard (Newl: 0.015 mm (0.0006 in.) max. Service limit: 0.006 mm (0.0002 in.)
EB
816A:
Standard (New): 0.02 mm (0.0008 in.) max.
Service Limit: 0.03 mm (0.0012 ·in.)
DIAL INDICATOR
Measure out-of-
,.
round at middle.
Measure taper
at edges.
f
(
f
• Measure taper at edges of each rod and main
journal.
• The difference between rneasurements on each

journal must not be more than the service limit.
Journal Tapar:
Service Limit: 0.01 O mm (0.0004 in.)
7-13
Oil Jet Pisto ns
lnspection lnspection
NOTE: lnspection for 816A engine. 1. Check the piston for distortion or cracks.
1. Removethe oil jet and carry out the inspection as NOTE: lf cylinder is bored, an oversized pistan
follows. must be used.
• Make sure that a drill of 1 . 1 mm dia can go 2. Measure piston diameter ata point A from bottom
through the nozzle hole ( 1 .2 mm dia.). of skirt.
• lnsert the other end of the drill ( 1. 1 mm dia.)
from the oil intake ( 1 .2 mm dia.) and check if the A: 15 mm (0.59 in.)
check ball moves smoothely and it has a stroke
of approximately 4 mm. Piston Diameter:
• Confirm that the check ball does not activate by Except B16A:
the air pressure of less than 196 kPa (2.0 Standard (New): 74.98- 74.99 mm
kg/cm2, 28 psi). (Reserveof idle oil pressure). (2.9520-2.9524 in.)
NOTE: Replacethe assembly if the oíl jet nozzle
is damaged or bent. B16A:
(3.1882-3.1886 in.)
- -- -1.2mm
A ......
1--------1 SKIRT DIAMETER
~
.>" CHECKBALL
SPRING
16 N•m (1.6 kg·m, 12 lb·ftl
2. When installing, the torque must be ocntrolled

accurately.
Torque: 16 N·m (1.6 kg-m, 12 lb-ft)
7-14
Cylinder Block
lnspection
3. Calculate difference between cylinder bore 1. Measure wear and taper in directions X and Y at
diameter on page 7-15 and pistan diameter. three levels in each cylínder as shown.
E
Pisten-to-Block Clearance
Except B 16A:
(0.0004-0.0016 in.)
816A:
Standard (New): 0.010-0.035 mm X
(0.0004-0.0014 in.)
SERVICE LIMIT
0.05 mm (0.002 in.)....,.¡...,_
Oversize Pisten Diameter

Except B16A: Cylinder Bore Size: Except B16A
0.25: 75.23-75.24 mm (2.9618-2.9622 in.) Standard (New): 75.00- 75.02 mm
0.50: 75.48-75.49 mm (2.9716-2.9720 in.) (2.9528-2.9535 in.)
B16A: Oversize
0.25: 81.23-81.24 mm (3.1980-3.1984 in.) 0.25: 75.25- 75.27 mm (2.9626-2.9634 in.)
0.50: 75.50- 75.52 mm (2.9724-2.9732 in.)
4. Check the pistan pin-to-pistan clearance. Coat the
piston pin with engine oil. Bore Taper
lt should then be possible to push the pistan pin in- Limit: (Difference between first and third measure-
to the pistan hale with thumb pressure. ment) 0.05 mm (0.002 in.)
Cylinder Bore Size: B16A
Pisten Pin-to-Pisten Clearance:
Standard (New):
Except B16A:
X: 81.000-81.020 mm (3.1890-3.1898 in.)
Service Limit: 0.010-0.022 mm
Y: 81.000-81.015 mm (3.1890-3.1896 in.)
(0.0004-0.0009 in.)
Y Measure Point: 50-55 mm (1.97-2.17 in.)
from block top surface.
B16A:
(0.0004-0.0009 in.) Oversize
0.25: 81.25-81.45 mm (3.1988-3.2067 in.)
Bore Taper
Limit: (Difference between first and third measure-
ment) 0.05 mm (0.002 in.)
(cont'd)
7-15
Cylinder Block
lnspection (cont'd) Bore Honing ------------.
• lf measurements in any cylinder are beyond 1. Measure cylinder bores as shown on page 7-1 5. lf
Oversize Bore Service Limit, replacethe block. the block is to be re-used, hone the cylinders and
remeasure the bores.
• lf block is to be rebored, refer to Piston
Clearance lnspection (page 7-14 and 15) after 2. Hone cylinder bores with honing oil anda fine (400
reboring. grit) stone in a 60 degree cross-hatch pattern.
NOTE: Scored or scratched cylinder boresmust be

honed.
Reboring Limit: 0.50 mm (0.020 in.)
2. Check the top of the block for warpage.

Measure along the edges and across the center as
shown.
SURFACES TO BE MEASURED
3. When honing is complete, thoroughly clean the

engine block of all metal particles. Wash the cylin-
der bores with hot soapy water, then dry and oil irn-
mediately to prevent rusting.
NOTE: Never use solvent, it will only redistribute

the grit on the cylinder walls.
4. lf scoring or scratches are still present in cylinder

Engine Block Warpage: bores after honing to service limit, rebore the
Except 816A: engine block.
Service Limit: 0.10 mm (0.004 In.) NOTE: Sorne light vertical scoring and scratching
is acceptable if it is not deep enough to catch your
B16A: fingernail and does not run the full length of the
Standard (New): 0.05 mm (0.0020 in.) bore.
Service Limit: O.OSmm (0.0031 in.)
PRECISION STRAIGHT EDGE
NOTE:
• After honing, clean the cylinder thoroughly with
soapy water.
• Only scored or scratched cylinder bores must be
honed.
7-16
Piston Pins
Removal/Except B16A ------, Removal/816A ---------.
1. Assemble the special tools as shown. 1. Assemble the special tools as shown.
PISTON BASE HEAD

PISTON BASE HEAD 07HAF-PL20102
07973-SB00100
~~lu1~ .
'
1 -J
/ ' PISTON BASE SPRING

PISTON BASE 07973-6570600
07973-6570500 07973-6570600 07973-6570500
2. Adjust the length of pistan pin driver to 53 mm

(2.09 in) as shown. 2. Adjust the length of pistan pin driver to 51. 7 mm
(2.04 in) as shown.
PISTON PIN DRIVER HEAD
07973-PE00329
PISTON PIN
DRIVER HEAD
07973-PE00320 --t- •I
¡/ [--~j
A.-
----- .c=J
..._ PISTON PIN DRIVER
SHAFT
07973-PE00310
1 - PISTON PIN
DRIVERSHAFT
07973-PE00310
llll
IL.11
PILOT COLLAR
07973-PE00200
NOTE: Use hydraulic press.

When pressing pin in or out, NOTE: Use hydraulic press.
make sure that the recessed When pressing pin in or out,
portien of the piston aligns make sure that the recessed
with the lips on the collar. portion of the piston aligns
with the lips on the collar.
3. Placethe piston on the special tool and press the

pin out with a hydraulic press.
3. Placethe pistan on the special tool and press the
pin out with a hydraulic press.
7-17
Connecting Rods Piston Pins
Selection -------------. lnspection
Each rod is sorted into one of four tolerance ranges 1. Measure the diameter of the piston pin.
(from O to 0.024 mm, in 0.006 mm increments) depen-
ding on the size of its big end bore. lt's then stamped PistonPin Diameter:
with a number ( 1, 2, 3 or 4) indicating that tolerance. Except 816A:
You may find anv combination of 1, 2, 3 or 4 in any Standard (New): 18.994-19.000 mm
engine. (0.7478-0.7480 in)
Oversize: 18.997-19.003 mm
Normal8ore Size: 0128, 0138: 43 mm (1.69 in) (0.7479-0.7481 in)
0158, D15Z: 45 mm (1.77 in)
D16A, D16Z, 8168: 48 mm B16A:
(1.89 in) 20.994-21.000 mm (0.8265-0.8268 in)
Oversize: 20.997-21.003 mm
NOTE: (0.8267-0.8269 in)
• Referencenumbers are for big end bore size and
do NOT indicate the position of rod in engine. NOTE: AII replacement piston pins are oversize.
• lnspect connecting rod for cracks and heat
damage.
CONNECTING ROD BORE

REFERENCE NUMBER
o
Half of number is stamped on
bearing cap, the other half on
connecting rod.
2. Zero the dial indicator to the piston pin diameter.
lnspect bolts
and nuts for
stress cracks.
7-18
lnstallation/Except B16A --------..
3. Measure the piston pin-to-piston clearance. 1. Use a hydraulic press for installation.
NOTE: Check the piston for distortion or cracks. • When pressing pin in or out, be sure you position
the recessed flat on the piston against the lugs
lf the piston pin clearance is greater than 0.024 on the base attachment.
mm (0.0009 in). remeasure using an oversize The arrow must tace the
piston pin. timing belt side of the
engine and the connecting
rod oil hole must tace the
Piston Pin-to-Piston Clearance:
rear of the engine.
(0.0004-0.0009 in)
CONNECTING ROD
OIL HOLE
2. Adjust the length of pistan pindriver to 53 mm

(2.09 in) as shown.
-.
PISTON PIN DRIVER HEAD
07973-PE00320
4. Check the difference between pistan pin diameter
and cannecting rod small end diameter.
Piston Pin-to-Connecting Rod lnterference:

Adjust the length of
Except B16A: piston pin driver to
Standard (New): 0.014-0.040 mm 53 mm (2.09 in)
(0.0006-0.0016 in) 53 mm
(2.09 in) PISTON PIN DRIVER SHAFT
B16A:
Standard (New): 0.013-0.032 mm + 07973-PE00310
(0.0005-0.0013 in.)
Embossed mark
facing up.
íl
L1J
.__ ,
PISTON PIN
PISTON PIN BASE INSERT

07973-PE00400
NOTE: lnstall the assembled pistan and red with

the oil hole facing the rear of the engine.
7-19
Piston Pins Piston Rings
lnstallation/816A --------, - EndGap------------,
1. Use a hydraulic press for installation. 1. Using a pistan, push a new ring into the cylinder
bore 15-20 mm (0.6-0.8 in.) from the bottom.
• When pressing pin in or out, be sure you position
the recessed flat on the pistan against the lugs 2. Measure the pistan ring end-gap with a feeler
on the base attachment. gauge:
• lf the gap is too small, check to see if you have

the proper rings for your engine.
• lf the gap is too large, recheck the cylinder bore

diameter against the wear limits on page 7-1 5.
lf the bore is over limit, the engine block must be
rebored.
Piston Ring End-Gap: Except B16A

The arrow must tace the
timing belt side of the Top Ring
engine and the connecting Standard (New): 0.15-0.30 mm
rod oil hole must face the (0.006-0.012 in.)
rear side of the engine.
Second Ring
2. Adjust th~e length of pistan pin driver to 51 . 7 mm (0.012-0.018 in.)
(2.04 in) as shown. Service Limit: O. 70 mm (0.028 in.)
Oil Ring
Standard (New): 0.2-0.7 mm (0.008-0.028 in.)
PISTON PIN Service Limit: 0.80 mm (0.032 in.)
------- DRIVER HEAD
07973-PE00320 Piston Ring End-Gap: B16A
Top Ring
-r
PISTON PIN
~ DRIVER SHAFT Standard (New): 0.20-0.35 mm
51.7 mm 07973-PE00310 (0.008-0.014 in.)
(2.04 in.) Service Limit: 0.6 mm (0.02 in.)
__L 1 , Second Ring
íl . Standard (New): 0.40-0.55 mm
c-~<~íll
Embossed mark (0.016-0.022 in.)
L
facing up. ~ -- PISTON PIN Service Limit: 0.7 mm (0.03 in.)
PILOT COLLAR Oil Ring
07LAF-PR~100 (0.008-0.018 in.)
TEIKOKU PISTONRINGmade
0.20-0.50 mm
(0.008-0.020 in.)
__..- PISTON PIN BASE INSERT RIKENmade
,~
-- 07GAF-PH60300 Service Limit: o.a mm (0.03 in.)
--- PISTON BASE

07973-6570500
NOTE: lnstall the assembled pistan and rod with

the oil hale facing the rear of the engine. PISTON RING 15-20 mm
"
(0.6-0.8 in)
+
T
7-20
Replacement Land Clearances --------~
1. Using a ring expander, remove the old piston rings. After installing a new set of rings, measurering-to-land
clearances:
2. Clean all ring grooves thoroughly.
Top Ring Clearance
NOTE: Standard (New):
• Use a squared-off broken ring or ring groove 01521: 0.030-0.055 mm (0.001-0.002 in.)
cleaner with blade to fit piston grooves. B16A: 0.045-0.070 mm (0.0018-0.0028 in.)
• Top ring groove is 1 .O mm (0.039 in.) wide Except 01521 and B16A:
(01521 and 816A) or 1.2 mm (0.047 in.) wide 0.035-0.060 mm (0.001-0.002 in.)
(except 01521 and 816A). Service Limit: 0.13 mm (0.005 in.)
• Second ring groove is 1.2 mm (0.047 in.) wide
(Dl 521 and 816A) or 1.5 mm (0.059 in.) wide Second Ring Clearance
(except Dl 521 and 816A). Standard (New):
• Oil ring groove is 2.8 mm (0.11 in.) wide. Except 816A:
• File down blade if necessary. 0.035-0.055 mm (0.001-0.002 in.)
B16A: 0.045-0.070 mm (0.0018-0.00281 in.)
CAUTION: Do not use a wire brush to clean ring TEIKOKUPISTONRINGmade
lands, or cut ring lands deeper with cleaning tool. 0.040-0.065 mm (0.0015-0.0026 in.)
RIKENmade
NOTE: lf pistan is to be separated from connecting Service Limit: 0.13 mm (0.005 in.)
rod, do not install new rings yet.
3. lnstall new rings in proper sequence and position

(page 7-22).
FEELER GAUGE
NOTE: Do not reuse old pistan rings.
RING EXPANDER
7-21
Piston Rings Pistons
Alignment ------------, lnstallation
1. lnstall the rings as shown. Befare installing the piston, apply a coat of
engine oil to the ring grooves and cylinder
ldentify top and second rings by the chamfer on the bores.
edge, and make sure they are in proper grooves on
1. lf the crankshaft is already installed:
pistan.
• Removethe connecting rod caps and slip short
sections of rubber hose over the threaded ends
of the connecting rod bolts.
• lnstall the ring compressor, check that the bear-
TOP RINGS Sectional view
ing is securely in place, then position the pistan
B16A
1
0128, 0138, 0158,
1 c=J
0162
in the cylinder and drive it in using the wooden
handle of a hammer.
015Z, B16A
• Stop after the ring compressor pops free and
SECONO RINGS Sectional view
check the connecting rod-to-crank journal align-
B16A
1
01584,
\ D
0128, 0138, 01583,
ment befare driving piston into place.
• lnstall the rod caps with bearings, and torque
01582 0152, 016A,016Z the nuts.
Torque:
2. Rotate the rings in grooves to make sure they do
Except 816A: 33 N•m (3.3 kg-m, 23 lb-ft)
not bind.
B16A: 41 N·m (4.1 kq-rn, 30 lb-ftl
3. The manufacturing marks must be facing upward.
2. lf the crankshaft is not installed:
• Remove the rod caps and bearings, install the
MARK
ring compressor, then position the piston in the
TOP RING -- ~ MARK cylinder and drive it in using the wooden handle
of a hammer.
• Position all pistons at top dead center.
<8-
SECONDRING -~
Thearrowmustface-.........___ /
the timingbelt side ~
of the engine andthe <:»
connectingred oil hole
must face the intake
manifold.
OIL RING SPACER
CONNECTING ROO
OIL JET
R(~
4. Position the ring end gaps as shown:
DONOTpositionanyringgap RU8BER HOSES

SECOND ¡ ," pistón thrust surtaces NOTE: Maintain downward force on the ring com-
pressor to prevent rings from expanding befare
entering the cylinder bore.
------~
Approx. 90° :
1
\ \ ApProx: : OIL RING

O
GAP
/' 90°
TOP RING GAP PACER GAP
DONOTpositionany ring gap OIL RING

in line with pistenpin hole. GAP
7-22
Oil Seal Crankshaft
The seal surface on the block should be Before installing the crankshaft, apply a coat
dry. of engine oil to the main bearings and rod
Apply a light coat of oil to the crankshaft bearings.
and to the lip of seal.
1. lnsert bearing halves in the engine block and con-
1. Using the special tool, drive flywheel-end seal into necting rods.
the right side cover.
2. Hold the crankshaft so rod journals for cylinders
No. 2 and No. 3 are straight down.
3. Lower the crankshaft into the block, seating the

rod journals into connecting rods No. 2 and No. 3,
and install the rod caps and nuts finger-tight.
DRIVER ATTACHMENT lnstallsealwith the

part numberside Groovedsides tace
07948-8800101 outward.
facing out.
2. Confirm clearance is equal all the way around with 4. Rotate the crankshaft clockwise, seat journals into
a feeler gauge. connecting rods No. 1 and No. 4, and ínstall the rod
caps and nuts finger-tight.
Clearance: Except B16A:
0.2-0.8 mm (0.01-0.03 in.) NOTE: lnstall caps so the bearing recess is on the
same side as the recess in the rod.
B16A: 0.5-0.8 mm (0.02-0.03 in.)
5. Check rod bearing clearance with plastigage (page
R. SIDE
COVER
7-7), then torque the capnuts.
Torque:
Except 816A:
32 N•m (3.2 kg-m, 23 lb-ftl
816A: 41 N·m (4.1 kg-m, 30 Jb-ft)
NOTE: Reference numbers on connecting rod are

for big-end bore tolerance and do not indicate the
position of pistan in the engine.
6. lnstall the thrust washers on the No. 4 journal. Oil

the thrust washer surfaces.
NOTE: Refer to page 8-1 3 for installation of the oil

pump side oil seal.
Lineup the markwhen (cont'd)

installing connecting rod
cap.
7-23
Crankshaft
lnstallation (cont'dl ------------------------
7. lnstall the main bearing caps. 9. Apply liquid gasket to the block mating surface of
Check clearance with plastigage (page 7-91. then the right side cover.
tighten the bearing cap bolts in 2 steps.
NOTE:
First step: 25 N•m (2.5 kg-m, 18 lb-ft) • Use liquid gasket, Part No. OY740-99986.
Second step: Except 01626 and B16A • Check that the mating surfaces are clean and
45 N·m (4.5 kg-m, 33 lb-ft) dry before applying liquid gasket.
01626: 52 N·m (5.2 kg-m, 38 lb-ftl • Apply liquid gasket by starting with an even
B16A: 78 N•m (7.8 kg-m, 56 lb-ftl band, centered between edges of the mating
surface.
NOTE: Coat the thrust washer surfaces and bolt • To prevent leakageof oil, apply liquid gasket to
threads with oil. the inner threads of the bolt holes.
MAIN BEARING CAP BOLTS TIGHTENING SEQUENCE • Do not apply liquid gasket to 0-ring grooves.
• Do not install the parts if 20 minutes or more
have elapsed since applying liquid gasket.
lnstead, reapply liquid gasket after removing old
residue.
• After assembly, wait at least 30 minutes before
filling the engine with oil.
• Apply a light coat of oil to the crankshaft and to
the lip of seal.
• Use a new 0-ring and apply oil when installing it.
Except B16A:
Apply liquid
gasket to inside
B16A:
R. SIDE COVER
B16A:
BEARING CAP
NOTE: The No.3 bearing bolts are longer bolts.
Apply liquid gasket
8. lnstall the baffle plate. to shaded area.
(816A only)
7-24
1 O. lnstall the R. side cover on the engine block. 11. Apply liquid gasket to the block mating surface of
the oil pump, then install it on the engine block.
NOTE: Do not apply liquid gasket to 0-ring

grooves.
Except 816A:
RIGHT SIDE
COVER
! Apply liquid gasket

to inside of broken
line.
6x1.0mm
12 N•m (1.2 kg-m,
9 lb-ft)
Apply liquid
DOWEL PIN
gasket to the
bolt thread.
OIL PUMP HOUSING
B16A:
Apply liquid
gasket to shaded
area.
(cont'd)
7-25
Crankshaft
lnstallation (cont'd) ~~~~~~~~~~~~~~~~~~~~~~~~
NOTE: 14. Tighten the oil pan bolts and nuts as shown.
• Apply a light coat of oil to the crankshaft and to the
lip of seal.
• Use new 0-rings and apply oil when installing them.
OIL PAN BOLTS/NUTS TORQUE SEQUENCE
12. lnstall the oil screen. 6x1.0mm
12 N•m (1.2 kg-m. 9 lb-ft)
Except B16A:
8 x 1.25 mm
24 N•m (2.4 kg-m,
17 lb-ft)
6x1.0mm
0-RING
11 N•m ( 1.1 kg-m, Replace.
8 lb-ft) B16A:
13. lnstall the oil pan gasket and the oil pan.
NOTE: Use a new oil pan gasket. O O 0 4D

1
o •
Apply liquid gasket GASKET
to these points. Replace.
7-26
Oil Seals
lnstallation
NOTE: 2. Measure the flywheel-end seal thickness and the oil

• Engine removal is not required. seal housing depth. Using special tool, drive the
• The seal surface on the block should be dry. flywheel-end seal into the rear cover to the point
Apply a light coat of grease to the crankshaft and to where the clearance between the bottom of the oil
the lips of the seals. seal and the rear cover is 0.2-0.8 mm
(0.01 -0.03 in) (page 7-18).
1. Using the special tool, drive in the timing pulley-end
seal until the driver bottoms against the oil pump. NOTE: Align the hole in the driver attachment with
When the seal is in place, clean any excess grease the pin on the crankshaft.
off the crankshaft and check that the oil seal lip is
not distorted.
DRIVER
07749-0010000
5EAL DRIVER
0794 7 -5800200 DRIVER ATTACHMENT
lnstall seal with the 07948-5800101
part number side lnstall seal with the
facing out. part number side
facing out.
7-27
Oil Pan
Replacement(4VVD)~~~~~~~~~~~~~~~~~~~~~~
1%HifliflN
• Make sure jacks and safety stands are placed proper-
8. Remove the driven gear from the transfer case.
ly and hoist brackets are attached to correct posi- NOTE: Be careful not to damage the thrust sim
tions on the engine. (See Section 11 and mating surface.
• Apply parking brake and block rear wheels, so car
will not roll off stands and fall on you while working
under it.
Removal:
1. Remove the engine splash shield (page 5-15).
2. Drain the engine oil.
3. Drain the transmission oíl/fluid.
4. Remove the exhaust pipe A (page 5-21).
5. Disconnect the propeller shaft at the transmission

(page 5-8).
6. Remove the L. side cover protector.

(A/T only)
7. Remove the transfer left side cover from the

transfer housing.
NOTE: Be careful not to damage the thrust shim

and mating surface.
ORIVE GEAR
9. Aemove the transfer case from the clutch housing.
1 O. Remove the clutch case cover.
TRANSFER
\T SHIM 11 . Removethe oil pan by removing the bolts and nuts.
Replace.
TRANSFER LEFT
SIDE COVER
7-28
lnstallation: 3. Apply liquid gasket to the clutch housing (M/T) or
torque converter housing {A/T) mating surface of
lnstallation in the reverse order of removal. the transfer case.
Use liquid gasket Part No. OY740-99986.
1 . Thoroughly clean the mating surface of the oil pan M/T
and engine case. Apply liquid gasket to both sur-
face of the gasket.
Apply liquid gasket
OIL PAN GASKET .,.,,-.-"=_,·,.._~to these points.
Replace. ""'
A/T
NOTE: lnstall the special seal as shown.
NOTE:
• Replace gaskets and 0-rings at disassembly.
• Check that the mating surfaces are clean and Apply liquid gasket.
SPECIAL SEAL
dry before applying liquid gasket. Replace.
• Apply liquid gasket evenly, in a narrow bead
centered on the mating surface.
• To prevent leakageof oíl, apply liquid gasket to
the inner threads of oíl, apply liquid gasket to the
inner threads of the bolt holes.
have passedafter applying liquid gasket. lnstead
reapply liquid gasket after removing old one.
• Fill the case with clean engine oíl 30 minutes
after assembly.
2. Tighte the bolts as shown below.
NOTE: Tighten bolts and nuts in two steps and tor- {cont'd)
que the bolts in a criss-cross pattern.
7-29
Oíl Pan
Replacement (4WD) (cont' d)
4. lnstall the transfer housing on the clutch or torque 6. lnstall the following parts in the transfer housing.
converter housing. • Driven gear thrust shim
• Driven gear
and mating surface, and keep them clean. NOTE: Be careful not to damagethe thrust shim
and mating surface, and keep them clean.
10 x 1.25 mm
45 N•m (4.5 kg-m,
33 lb-ft)
/
- DRIVEN GEAR THRUST SHIM
0-RING -
Replace.
TRANSFER CASE
5. lnstall the following parts on and in the transfer

shaft and transfer housing.
• Orive gear thrust shim 8 x 1.25 mm
/
• Orive gear (lubricate with oil) 26 N•m (2.6 kg-m, 19 lb-ftl
• Transfer thrust shim
• Transfer left side cover.
7. lnstall the L. side cover protector (A/T only).
and mating surface, and keep them clean. 8. lf necessary, perform the following inspections
(See Section 13 or 14).
• Tooth contact between the transfer driven and
drive gears.
• The backlash at the companion flange.
• The transfer driven gear preload.
• The total preload.
ORIVE GEAR THRUST

SHIM
\
0-RING
74.5 x 2.5 mm
Replace.
Apply liquid gasket to threads.
7-30
Engine Lubrication
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

lllustrated lndex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Oil Level lnspection . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Oil Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Oil Filter Replacement . . . . . . . . . . . . . . . . . . . . . . 8- 7
Oil Pressure Test 8-8
Oil Pump lllustrated lndex 8-9
Oil Pump Removal/lnspection 8-11
Special Tools
CD 07746-0010400 Attachment, 52 x 55 mm 1 8-12

@ 07749-0010000 Driver 1 8-12
@ 07942-6110001 Oil Filter Socket 1 8-7
1 @ q ~
~
CD @ @
8-2
Engine Lubrication
lllustrated lndex
NOTE:
• Use new 0-rings when reassembling.
• Apply oil to 0-rings before installation.
• Use liquid gasket, Part No. 08740-99968.
OIL PRESSURE SWITCH

D15Z1, D16Z6 engine: 18 N•m (1.8 kg-m, 13 lb-ftl
Apply liquid gasket to the
threads when installing.
Oll PUMP
lllustrated index, 0-RING OIL BREATHER
page 8-9. Replace. CHAMBER
lnspection, page 8-11 .
6 x 1.0 mm
Apply liquid gasket
11 N•m (1.1 kg-m.
to the mating surface
8 lb-ft)
of the block.
OIL FILTER
Replacement, page 8- 7
718 turn or 22 N•m
~ (2.2 kg-m, 16 lb-ft)
""1/1:lJ Replace every 10,000 km
Apply liquid gask

these points.
OIL PAN
GASKET
Replace.
8x1.25mm
24 N•m (2.4 kg-m,
17 lb-ft)
6 x 1.0 mm
6x1.0mm 12 N•m ( 1.2 kg-m, 9 lb-ft)
11 N•m (1.1 kg-m,
8 lb-ft)
DRAIN PLUG
WASHER 28mm
Replace. 45 N•m (4.5 kg-m, 33 lb-ft)
8-3
Engine Lubrication
lllustrated lndex
NOTE:
• Use new 0-rings whenever reassembling. OIL PRESSURE SWITCH
18 N•.m (1 .8 kg-m, 13 lb-ft)
• Apply oil to 0-rings befare installation.
1 /8 in. 8SP (British Standard
• Use liquid gasket, Part No. 08740-99968. Pipe Taper) 28 Threads/inch.
Use proper liquid sealant.
Except D15Z1, D16Z6 and B16A2 engine:
fi1llit PCV VALVE

~ 18 N•m (1.8 kg-m,
,-----13 lb·ft)
OIL PUMP
Overhaul, page 8-9
Removal/lnspection, page 8-11
Apply liquid gasket to OIL BREATHER
mating surface of engine block. CHAMBER
6 x 1.0 mm
11 N•m (1.1 kg-m,
8 lb-ft)
OIL PAN Replacement, page 8- 7

GASKET Replace every 10,000 km
Replace. (6,000 miles).
Tighten according to instructions
7~
on filter.
I
6x1.0mm
11 N•m (1.1 kg-m, ~"'
8 lb-ft)
GASKET ·
~w
Replace.
8x1.25mm
24 N•m (2.4 kg-m, OIL PAN
17 lb-ft)
6 x 1.0 mm 6x1.0mm
11 N•m(1.1 kg-m, 12 N•m (1.2 kg-m, 9 lb-ft)
8 lb-ft)
DRAIN PLUG
Replace. 28mm
45 N•m (4.5 kg-m, 33 lb-ft)
8-4
ºTE
N ·
.
orings w e
h neverr
. e assembling.
llation.
• Use ne~ - 0-rings before ins~40-99986.
• Apply o1_1 to ket, Part No. 08
• Use liquid gas
6 x 1.0 mm kg -rn, 9 lb-ft)
12N•m(1.2
816A2 engine:
OIL PAN
OIL BREATHER 0-RING 1 O mm •

CHAMBER Replace. 6
12X N•m• (1 . 2 kg-m,
9 lb-ft)
6x1.0mm km 9lb-ftl
12 N•m (1.2 g- .
BUFFLEPLATE
OIL JET BOLT 12 lb-ftl

16 N•m (1.6 kg-m,
OIL JET
ENGINE
OIL COOLER
0-RING
Replace.
OIL FILTER a e 8-7
R place every '
J
Replacement, ~ 000 km
(6e 000 miles}. . to instructions

Ti~hten accordmg SWITCH
on filter. OIL PRESSURE 13 lb-ftl
18
N•m (1.8 k~--mh, Standard
S p (Britis . h
1 /8 in. 8 28 Threads/me .
Pipe Taper) . id sealant. OIL PUMP a e 8-10 1
Use proper liqui Overhaul, ps gection, page 8-1
Remov?l/1~ P asket to k
Apply liquid g of engine bloc .
mating surface
8-5
Oil Level Engine Oil
lnspection Replacement
1. Check engine oil with the engine off and the car 1. Warm up the engine.
parked on level ground.
2. Drain the engine oil.
2. Make certain that the oil level indicated on the
dipstick is between the upper and lawer marks.
3. lf the level has dropped clase to the lower mark,

add oil until it reaches the upper mark.
CAUTION: lnsert the dipstick carefully to avoid

bending it.
OIL PAN DRAIN PLUG

45 N•m (4.5 kg-m, 33 lb-ft) Replace.
3. Reinstall the drain plug with a new washer, and

refill with the recommended oil.
Requirement API Service Grade: SG ar SF

Change Every 1 0,000 km (6,000 miles) or
6 months.
o .-...__ UPPER MARK Capacity f (US qt, lmp qt)

/ After engine
o .-...__ LOWER MARK At change
Enginetype
overhaul including filter
016A8,
4.3 (4.5, 3.8) 3.6 (3.8, 3.2)
D 1 6A9 engine
816A2 engine 4.8 (5.1, 4.2) 4.0 (4.2, 3.5)
Except D16A8,
D16A9,B16A2 4.0 (4.2, 3.5) 3.3 (3.5, 2.9)
engine
Engine Oil Viscosity for Outside Temperatura Ranges.
. . ..
•
• . • •
•
• ~
• •
• .,,
-
~ • •2
-30 -20 -10 o 10 20 30 40ºc

- 20 0 20 40 60 80 100°F
Ambient temperature ranges
* 1 : Exeept 1 . 6 f engine
*2: 1.6 e engine
8-6
Filter
Replacement
CAUTION: After the engine has been run, the exhaust 3. lnstall the oil filter by hand.
pipes will be hot; be careful when working around the
exhaust manifold. 4. After the rubber seal is seated, tighten the oil filter
clockwise with the special tool.
1. Remove the oil filter with the special oil filter
socket. Tighten: 7/8 turn clockwise.
Tightening torque: 22 N·m (2.2 kg-m, 16 lb-ft)
2. lnspect the threads and rubber seal on the new
filter. CAUTION: lnstallation using other than the above
Wipe off seat on engine block, then apply a light procedure could result in serious engine defects
coat of oil to the filter rubber seal. due to oil leakage.
NOTE: Use only filters with a built-in bypass

system.
~ Apply oil to rubber seal

. 1 befare installing.
OIL FILTER SOCKET

07912-6110001
ENGINE OIL WARMER

1816A2 engine only)
ENGINE OIL WARMER

(B16A2 englne only)
(cont'd)
8-7
Filter Oíl Pressure
Replacement (cont' d) Test
Eight numbers _( 1 to 8) are printed on the surface of lf the oil pressure warning light stays on with the engine
the filter. running, check the engíne oíl level. lf the oíl level is
correct:
The following explains the procedure for tightening
filters using these numbers. 1. Connect a tachometer.
1) Make a mark on the cylinder block under the 2. Remove the oil pressure sender and ínstall an oíl
number that shows at the bottom of the filter pressure gauge.
when the rubber seal is seated.
3. Start the engine and allow it to reach operating
2) Tighten the filter by turning it clockwise seven temperature (fan comes on at least twíce).
nurnbers from the marked point. For exarnple, if
a mark is made under the number 2 when the 4. Pressureshould be:
rubber seal is seated, the filter should be tighten-
ed until the number 1 comes up to the marked Engine Oil Pressure:80°C (176ºF)
point.
At ldle: 70 kPa (0.7 kg/cm2,
1 O psi) rninimum
At 3,000 min-1 (rpm): 350 kPa (3.5 kg/cm2,
50 psi) minimum
• lf oil pressure is within specifications, replace

the oil pressure sender and recheck.
• lf oil pressure is NOT within specifications. in-
spect the oil pump (pages 8- 1 1 and 1 2).
Numberwhenrubber Numberafter tightening.

sealis seated.
Number when rubber

1 2 3 4 5 6 7 8
seal is seated
Nurnber after tightening 8 1 2 3 4 5 6 7
5. After installation, fill the engine wíth oil up to the

specified level, run the engine for more than 3
minutes, then check for oil leakage.
ADAPTER
( 1 /8" x 28BSPT)
8-8
Oil Pump
lllustrated lndex
NOTE:
• Apply oil to 0-rings befare installation.
Except 816A2 engine:
6 x 1.0 mm
7 N•m (0.7 kg-m, 5 lb-ftl
OUTER ROTOR
lnspection, 8-11
INNER ROTOR
6 x 1.0 mm
11 N•m (1.1 kg-m, 8 lb-ftl
PUMP COVER
Re place.
Oll SEAL
Replace.
PUMP HOUSING
6x1.0mm
11 N•m ( 1.1 kg-m, 8 lb-ftl
(cont'd)
8-9
Oillllustrated
Pump lndex (cont'dl
NOTE.. w. 0-rings whenf r eassembling.

e installation.
•• Apply
Use ne011 to 0-rings
· be or
B16A2:
6 x 1.0 mm 5 lb-ftl
7N•m (0.7 kg-m,
OUTER ROTOR 8-1 1

lnspection, page
INNER ROTOR 8-11 0-RING

lnspection, page Replace.
8 x 1.25 mm 17 lb-ftl
24 N•m (2.4 kg-m,
8 x 1.25 mmk 17 lb-ftl

24 N•m (2.4 g-m.
6 x 1.0 mm 8 lb-ft)
11 N•m (1.1 kg-m,
8-10
Removal/lnspection
1. Drain the engine oíl. 1 O. Removethe screws from the pump housing, then
separate the housing and cover.
2. Turn the crankshaft and align the white groove on
the crankshaft pulley with the pointer on the timing 11. Check the radial clearance on the pump rotor.
belt cover.
lnner Rotor-to-Outer Rotor Clearance
3. Remove the valve cover and timing belt upper Standard (New):
cover. Except 816A2 engine: 0.02-0.04 mm
(0.001 -0.002 in)
4. Remove the alternator belt. B16A2 engine: 0.04-0.16 mm
(0.002-0.006 in)
5. Removethe crankshaft pulley and remove the tirn- Service Limit: 0.2 mm (0.008 in)
ing belt lower cover.
OUTER ROTOR
6. Removethe timing belt and drive pulley.
7. Removethe oil pan.
8. Removethe oil screen.
9. Remove the mount bolts and the oil pump

assembly.
Except B16A2:
0-RING
DOWEL PIN Replace.
INNER ROTOR
12. Check the axial clearance on the pump rotor.
Housing-to-Rotor Axial Clearance

Standard (New):
Except B16A2 engine: 0.03-0.08 mm
(0.001-0.003 in)
B16A2 engine: 0.02-0.07 mm
(0.001-0.003 in)
OIL SCREEN
HOUSING
OIL PUMP ROTORS (cont'dl

ASSEMBLY
8-11
Oil Pump
Removal/lnspection ( cont' d)
13. Check the radial clearance between the housing 1 7. Reassemble the oil pump, applying liquid gasket to
and the outer rotor. the pump housing screws.
Housing-to-Outer Rotor Clearance 18. Check that the oíl pump turns freely.
Standard (New):
Except B16A2 engine: 0.10-0.18 mm 19. Apply a light coat of oíl to the seal lip.
(0.004-0.007 in)
B16A2 engine: 0.04-0.16 mm 20. lnstall the two dowel pins and new 0-ring on the
(0.002-0.006 in) cylinder block.
21 . Apply liquid gasket to the cylinder block mating
surface of the oil pump.
NOTE:
· • Check that the mating surfaces are clean and
dry before applying liquid gasket.
• Apply liquid gasket evenly, in a narrow bead
centered on the mating surface.
• Do not apply liquid gasket to the 0-ring grooves.
• To prevent leakage of oil, apply liquid gasket to
the inner threads of the bolt hales.
OIL PUMP HOUSING
Except 816A2 angina:
Apply liquid
gasket to the inside
of broken line.
14. lnspect both rotors and pump housing for scoring

or other damage. Replace parts if necessary.
15. Remove the old oil seal from the oíl pump.
1 6. Gently tap in the new oil seal until the tool bottoms
on the pump using the special tools. PUMP HOUSING
816A2 angina:
PUMP HOUSING

have elapsed since applying liquid gasket.
lnstead, reapply liquid gasket after removing old
ATTACHMENT,
residue.
52 x 55 mm • After assembly, wait at least 30 minutes before
07746-0010400 filling the engine with oil.
8-12
22. lnstall the oil purnp assernbly to the engine block. 23. lnstall the screen.
24. lnstall the oil pan (see Section 7).

Except 816A2 engine
OIL PUMP ASSEM8L Y 25. lnstall the tirning belt (see Section 6).
Apply liquid gasket
to the block mating
surface.
0-RIN~
Repfa~~- -,
SCREEN
8 x 1.25 mm
24 N•m (2.4 kg-m,
17 lb-ft)
816A2 engine
OIL PUMP ASSEM8L Y

Apply liquid gasket
SCREEN to the block mating
6x1.0mm 8x1.25mm surface.
11 N•m 24 N•m (2.4 kg-m,
17 lb-ft)
0-RING
Replace.
6 x 1.0 mm
11 N•m (1.1 kg-m,
8 fb-ft)
8-13
lntake Manifold/Exhaust System
lntake Manifold 9-2

Exhaust Manifold 9- 7
Exhaust Pipe and Muffler 9-13
lntake Manifold
Replacement
NOTE: Use new 0-rings and gaskets whenever reassembling.
01281, 01382, 01383, 01583 engine:
PCV VALVE
1 INSULATOR
8x1.25mm
21 N•m (2.1 kg-m. 15 lb-ftl
GASKET
Replace.
EACV
GASKETS
Replace.
0-RING
Replace.
THERMOVALVE _//.
15 N•m (1.5 kg-m._q
11 lb-ftl min.
8 x 1.25 mm WATER BVPASS HOSE

INTAKE MANIFOLD 23 N•m (2.3 kg-m. 17 lb-ft)
Replace if cracked or
if mating surtaces are
damaged.
INT AKE MANIFOLD BRACKET
8 x 1.25 mm
24 N•m (2.4 kg-m, 17 lb-ftl
9-2
~
l&iE:[I
01584 eng·me:
PCV VALVE
GASKET
8 x 1.25 mm
22 N•m (2 2
16 lb-ftl . kg·m,
w\
ATER BYPASS HOSE
INTAK E MANIFOLD BRACKET
(cont'd)
9-3
lntake Manifold
Replacement (cont' d)
NOTE: Use new 0--rings and gaskets whenever reassembling.
01582 engine:
6x1.0mm
11 N•m (1.1 kg-m,
8 lb-ft)
THROTILE BODY
6 x 1.0 mm
12 N•m (1.2 kg-m,
91b-ft) ~
7NOERHEAD
EACV/ /
0-RING
Replace.
INTAKE MANIFOLD
GASKET
Re place.
INTAKE MANIFOLD
8 x 1.25 mm
8x1.25mm 23 N•m (2.3 kg-m, 17 lb-ftl
24 N•m (2.4 kg-m,
17 lb-ftl
9-4
01521 engine:
INTAKE MANIFOLD 8 x 1.25 mm

Replace if cracked or 21 N•m (2.1 kg-m, GASKETS
if mating surfaces 15 lb-ftl Re place.
are damaged.
MAP SENSOR
'- /le,c:p~1::5BBJ
~
o.----- Replace.
EACV
Be
I
careful not /
to damage.
INTAKE MANIFOLD GASKET

BRACKET Repl¡¡ce.
8 x 1.25 mm
24 N•m (2.4 kg-m,
8x1.25mm 8 x 1.25 mm
17 lb-ft)
24 N•m (2.4 kg-m, 23 N•m (2.3 kg-m,
17 lb-ft) 17 lb-ft)
(cont'd)
9-5
lntake Manifold
NOTE: Use new gaskets and 0-rings when reassembling.
016A2, D16A7, D16A8, 016A9, 01626, 01627 engine:
5 x 0.8 mm
6 N•m (0.6 kg-m,
4 lb-ft)
INT AKE MANIFOLD

GASKET
EACV
Be careful not
to damage.
INTAKE MANIFOLD
BRACKETS
8 x 1.25 mm
23 N•m (2.3 kg-m,
17 lb-ft)
to damage.
6x1.0mm
11 N•m (1.1 kg-m.
8 lb-ft)
9-6
Exhaust Manifold
Replacernent~~~~~~~~~~~~~~~~~~~~~~~~~~~~---.
NOTE: Use new gaskets whenever reassembling.
01281. 01382. 01383 engine:
EXHAUST MANIFOLD
GASKET
\
EXHAUST MANIFOLD
SELF LOCKING NUT

8 x 1.25 mm
32 N•m (3.2 kg-m,
23 lb-ftl
Replace.
8 x 1.25 mm
24 N·m (2.4 kg-m, 17 lb-ft)
EXHAUST MANIFOLD
BRACKET
10 x 1.25 mm
45 N•m (4.5 kg-m, 33 lb-ftl
(cont'd)
9-7
Exhaust Manifold
Replace~ent (cont'd)~~~~~~~~~~~~~~~~~~~~~~
NOTE: Use new gaskets whenever reassembling.
01583, 01584 engine:
CYLINDER HEAD
8x1.25mm
24 N·m (2.4 kg-m,
17 lb-ft)
o
OXYGEN SENSOR
45 N•m (4.5 kg-m,
33 lb-ft) ~ ..
SHROUD
r!i~f:~::::ST MANIFOLD SELF LOCKING NUT

8 .x 1.25 mm
32 N•m (3.2 kg-m,
10 x 1.25 mm 23 lb-ft)
45 N•m (4.5 kg-m.
Replace.
33 lb-ft)
EXHAUST MANIFOLD
BRACKET
9-8
01582 engine:
8x1.25mm EXHAUST MANIFOLD

22 N•m (2.2 kg-m, GASKET
16 lb-ftl Replace.
8x1.25mm
22 N•m (2.2 kg-m,
16 lb-ftl
OXYGEN SENSOR
45 N•m (4.5 kg-m, SHROUD
-:
33 lb-ft)
SELF-LOCKING NUT
8 x 1.25 mm
32 N•m (3.2 kg-m,
23 lb·ftl
Replace.
EXHAUST MANIFOLD
BRACKET
EXHAUST MANIFOLD
(cont'd)
9-9
Exhaust Manifold
Replacemen1t (cont'd)
NOTE: Use new gaskets and new self-locking nuts when reassembling.
CAUTION: In handling a metal gasket, care should be taken not to bend it or damage the contact surface of the gasket.
D1521 engine:
OXYGEN SENSOR
8 x 1.25 mm 45 N•m (4.5 kg-m,
22 N•m (2.2 kg-m, 33 lb-ft)
16 lb-ft) \
EXHAUST MANIFOLD
COVER
10 x 1.25 mm
32 N•m (3.2 kg-m,
23 lb-ft)
6x1.0mm
10 N•m (1.0 kg-m,
71b-hl~
CONVERTER
COVER
EXHAUST MANIFOLD
BRACKET
SELF-L¿ NUT \
10 x 1.25 mm EXHAUST
~:::,~T
55 N•m 15.5 kg-m, PIPEA
40 lb-ft)
Replace. 8 x 1.25 mm
24 N•m (2.4 kg-m,
17 lb-ft)
9-10
D16A, D16Z engine:
OXYGEN SENSOR
45 N•m (4.5 kg-m.
33 lb-ftl
Be careful not to damage.
(with CATA)
8 x 1.25 mm EXHAUST MANIFOLD
22 N•m (2.2 kg-m, GASKET (METAL)
l
16 lb-ft) SELF-LOCKING NUT
8 x 1.25 mm
32 N•m (3.2 kg-m,
23 lb-ft)
8 x 1.25 mm
22 N•m (2.2 kg-m,
16 lb-ftl
EXHAUST PIPE A EXHAUST MANIFOLD

BRACKET
EXHAUST MANIFOLD.
10 x 1.25 mm COVER
45 N•m 14.5 kg-m,
SELF-LOCKING NUT
33 lb-ft)
10 x 1.25 mm
55 N•m (5.5 kg-m,
40 lb-ft)
(cont'd)
9-11
Exhaust Manifold
NOTE: Use new gaskets and new self-locking nuts when reassembling.
CAUTION: In handling a metal gasket, care should be taken not to bend it or damage the contact surface of the gasket.
B 16A engine:
8 x 1.25 mm
22 N•m (2.2 kg-m,
16 lb-ftl
SELF-LOCKING NUT
8x1.25mm
32 N•m (3.2 kg-m,
23 lb-ft)
Replace.
GASKETS
Replace.
8 x 1.25 mm
24 N•m (2.4 kg-m,
17 lb-ft)
EXHAUST MANIFOLD
BRACKET
EXHAUST
SELF-LOCKING NUT PIPE A
10 x 1.25 mm
55 N•m (5.5 kg-m,
40 lb-ft)
Replace.
9-12
Exhaust Pipe and Maffler
Replacement
NOTE: Use new gaskets and self-locking nuts when reassembling.
0128, 01383, 01583, 0152 engine:
8 x 1.25 mm
22 N·m (2.2 kg-m, 16 lb-ftl
Replace.
Tighten the bolts in steps,
alternating side-to-side.
8 x 1.25 mm
22 N·m (2.2 kg-m,
10 x 1.25 mm
39 N•m (3.9 kg-m, 28 lb-ft) -----...
~
@~,A)1=-p
GASKET
Replace.
:
EXHAUST PIPE A ~
\
8 x 1.25 mm
8x1.25mm 22 N•m (2.2 kg-m, 16 lb-ft)
SELF-LOCKING NUT
10 x 1.25 mm 22 N•m (2.2 kg-m, Replace.
55 N·m (5.5 kg-m, 16 lb-ftl
40 lb-ftl Tighten the nuts in steps,
Reolace. alternating side-to-side.
(cont'd)
9-13
Exhaust Pipe and Muffler
Replacemen11: (cont' d)
01382, 01582, 01584 engine:
HEAT SHIELD
~~
6x1.0mm
.> ~
10 N•m (1.0 kg-m. 7 lb-ft)

0
~
~GASKET
Replace.
10 x 1.25 mm
34 N•m (3.4 kg-m, 25 lb-ftl --P".).,,'"/
Replace. \ ' 8x1.25mm

""" 22 N•m (2.2 kg-m. 16 lb-ft)
EX PIPE B Replace.
--~~~- GASKET
~ Replace.
'•Q• ~ CATALYTIC
~
~~ CONVERTER
F::<ao A>P \\1
•. ,,, il
'a GASKET
Replace.
8 x 1.25 mm
16 N•m (1.6 kg-m,
12 lb-ft)
Replace.
8 x 1.25 mm
22 N•m (2.2 kg-m. 16 lb-ft)
Replace.
Tighten the nuts in steps,
Replace. alternating side-to-side.
9-14
D16A7, D16A9 engine:
1
8x1.25mm
22 N•m (2.2 kg-m, 16 lb-ft)
Replace.
alternatmq side-to-side.
GASKET
8 x 1.25 mm SELF-LOCKING NUT

22 N•m 12.2 kg-m, 16 lb-ftl 8 x 1.25 mm
Replace. • 16 N•m (1.6 kg-m, 12 lb-ft)
Tighten the bolts in steps, \ Replace.
alternating side-to-side. EXHAUST PIPE
BRACKET
(cont'd)
9-15
Exhaust Pipe and Muffler
Replacement (cont'd)
B16A2, 016A8, 01626 engine:
¡
MUFFLER
!@
HEAT SHIELD
6 x 1.0 mm
10N•m(1.0kg-m, ~
71b·hl ~.., ~
6¡
o@l
SELF-LOCKING NUT
10 x 1.25 mm
34 N•m (3.4 kg-m, 25 lb-ft)
GASKET
Replace.
@
~GASKET
Replace.
PIPEA
CATALYTIC CONVERTER
8 x 1.25 mm
22 N•m (2.2 kg-m, 16 lb-ftl
Replace.
9-16
01627 engine (4WD):
8 x 1.25 mm
22 N•m 12.2 kg-m,
16 lb-ft)
~'
SELF-LOCKING NUT
10 x 1.25 mm
34 N•m 13.4 \' 25 lb-ft)
····~@
GASKET
8 x 1.25 mm
22 N•m (2.2 kg-m, 16 lb-ft)
Replace. SELF-LOCKING NUT
¡
Tighten the nuts in steps, 8x1.25mm
alternating side-to-side. 16 N•m (1.6 kg-m. 12 lb-ft)
Replace.
EXHAUST PIPE
BRACKET
9-17
Cooling
lllustrated lndex . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . 10-2

Radiator
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
Refilling and Bleeding .. . .. . .. .. .. .. .. .. .. 10-1 O
Cap Testing 10-12
Pressure Testing . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 2
Thermostat
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0-1 3
T esting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0-1 3
Water Pump
lllustrated lndex .. .. .. .. .. .. . .. . .. .. .. .. .. . 10-14
lnspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 6
Cooling
lllustrated lndex
f·§MMIUIN System is under high pressure when RADIATOR

engine is hot. To avoid danger of releasing scalding
coolant. remove cap only when engine is cool.
CAUTION: When pouring coolant, be sure to shut the

relay box lid and not to let coolant spill on the electrical
RADIATOR CAP
parts or the painted portian. lf any coolant spills, rinse it
off immediately.
NOTE:
• Check all cooling system hoses for damage, leaks or
deterioration and replace if necessary.
• Check all hose clamps and retighten if necessary.
Total Cooling System Capacity: lncluding

reservoir 0.4 i (0.42 US qt, 0.35 lmp qt)
0128L, 01382, 01383, 01 583 engine:
M/T 4.5 i (1.19 US gal, 0.99 lmp gal)
A/T 4.4 i (1.16 US gal, 0.97 lmp gal)
1
r
COOLANT
RESERVOIR
FAN MOTOR
Test for operation
with 12 V DC applied.
r
CONNECTING
PIPE
HEATER HOSES
10-2
Total Cooling System Capacity: lncluding RADIATOR
reservoir 0.4 f (0.42 US qt, 0.35 lmp qt)
D1 584 engine:
M/T 4.5 e (1.19 US gal, 0.99 lmp gal)
A/T 4.4 e ( 1. 16 US gal, 0.97 lmp gal)
RADIATOR CAP
Pressure test, page 10-1 2
6x1.0mm
10 N•m~7 lb·fü COOLANT
RESERVOIR
LOWER
RADIATOR
HOSE
/
CONNECTING
PIPE
BYPASS HOSES
10-3
Cooling
lllustrated lndex
¡.g,.,;Mjj.ljQ Systemis under high pressure when RADIATOR

Refilling, page 10-1 O
Leak test, page 10-1 2
coolant, remove cap only when engine is cool. lnspect soldered joints and
seams for leaks.
CAUTION: When pouring coolant, be sure to shut the Blow dirt out from between
relay box lid and not to let coolant spill on the electrical core fins with compres sed air.
lf insects, etc .. are clogging
parts or the painted portion. lf any coolant splíls, rinse it
radiator, wash them off with
off immediately. low pressure water.
NOTE:
UPPER HOSE
reservoir 0.4 f (0.42 US qt, 0.35 lmp qt)
01582 engine:
M/T 4.5 e(1.19 US gal, 0.99 lmp gal)
A/T 4.4 f (1.16 US gal, 0.97 lmp gal)
1
SELF-LOCKING NUT
«:
4.5 N•m (0.45 kg-m, 3.3 lb-ft)
\
\\
DRAIN PLUG
t
COOLANT
RESERVOIR
FAN MOTOR
-:
Test for operation
with 12 V OC applied.
LOWER
RADIATOR
HOSE
ATF COOLER
HOSES
HEA TER HOSES
10-4
Total Cooling System Capacity: lncluding RADIATOR CAP
reservoir 0.4 f (0.42 US qt, 0.35 lmp qt) Pressure test,
01 521 engine: page 10-12
M/T 4.4 e ( 1 .16 US gal, 0.97 lmp gal)
RADIATOR
Refilling, page 10-1 O
Leak test, page 1 0-1 2
lnspect soldered joints and
seams for leaks.
Blow dirt out from between
6 x 1.0 mm
'~\
10 N•m
'
11.0 kg-m,
COOLANT
RESERVOIR
LOWER
FAN MOTOR RADIATOR
Test for operation HOSE
EACV
HEA TER HOSES
10-5
Cooling
lllustrated lndex ---------------------------
fWh;foiidN System is under high pressure when

coolant, remove cap only when engine is cool.
RADIATOR CAP
CAUTION: When pouring coolant, be sure to shut the
parts or the painted portion. lf any coolant spills, rinse it
off immediately.
NOTE:

reservoir 0.4 e (0.42 US qt, 0.35 lmp qt)
016A7, 01626, 01627 engine:
M/T 4.5 f (1.19 US gal, 0.99 lmp gal)
A/T 4. 7 f ( 1.24 us gal, 1 .03 lmp gal)
COOLANT
6 x 1.0 mm RESERVOIR
10 N•m (1.0 kg-m, 7 lb-ftl DRAIN PLUG
<,
FAN MOTOR
Test for operation
with 1 2 V OC applied.
HEATER HOSES
10-6
Total Cooling System Capacity: lncluding RADIATOR
reservoir 0.4 f (0.42 US qt, 0.35 lmp qt) Refilling, page 1 0-1 O
016A8, 016A9 engine: Leak test, page 1 0-12
lnspect soldered joints and
M/T 4.5 e (1 .19 US gal, 0.99 lmp gal) seams for leaks.
A/T 4.7 f (1.24 US gal, 1.03 lmp gal) Blow dirt out from between
core fins with compressed air.
lf insects, etc., are clogging
radiator, wash them off with
RADIATOR CAP low pressure water.
10 N•\. 7 lb·hl
6 x 1.0 mm
COOLANT
RESERVOIR
/
FAN MOTOR
Test for operation LOWER
RADIATOR
HOSE
HEA TER HOSES
10-7
Cooling
f,§H;ldMd System is under high pressure when RADIATOR

coolant, remove cap only when engine is cool.
CAUTION: When pouring coolant. be sure to shut the

parts or the painted portion. lf any coolant spills, rinse it
off immediately.
NOTE:
• Check all cooling systern hoses for darnage, leaks or
• Check all hose clarnps and retighten if necessary.
• Use new 0-rings when reassernbling.
Total Cooling Systern Capacity: lncluding

reservoir 0.4 f (0.42 US qt, 0.35 lrnp qt)
B16A2 engine:
M/T 4.8 e (1.27 US gal, 1.06 lrnp gal)
6x1.0mm
10 N•m (1.0 kg-m, 7 lb-ftl /
COOLANT
RESERVOIR
FAN MOTOR
Test for operation
with 12 V OC applied.
THERMOSTAT HOUSING
ENGINE OIL
COOLER
HEATER HOSES
10-8
Radiator
Replacement~~~~~~~~~~~~~~~~~~~~~~~~~~~__,
1. Drain the radiator coolant. 5. Removethe tan shroud assemblies and other parts
2. Remove the upper and lower radiator hoses, and from radiator.
ATF cooler hoses.
3. Disconnect the tan motor connector. lnstall the radiator in the reverse order of removal:
4. Removethe radiator upper brackets, then pull up
the radiator. NOTE:
• Set the upper and lower cushions securely.
• Fill the radiator and bleed the air.
6 x 1.0 mm
10 N•m (1.0 kg-m,
UPPER BRACKET 7 lb-ftl \
ANO CUSHION
RESERVOIR HOSE
<,
RADIATO~
RESERVOIR TANK
UPPER HOSE
t.....:::::::,~---./
6x1.0mm
10 N•m (1.0 kg-m,
7 lb-ftl
LOWER CUSHION
COOLING FAN/SHROUD
ASSEMBLV
FAN MOTOR
CONNECTOR
10-9
Radiator
Refilling and Bleeding
f•Sl@-féjj.ijdRemoving the radiator cap while the 4. Remove the reservoir from its holder by pulling it
engine is hot can cause the coolant to spray out, straight up. Drain the coolant, then put the reser-
seriously scalding you. Always Iet the engine and voir back in its holder.
radiator cool down befare removing the radiator cap.
5. When the coolant stops draining, apply liquid
CAUTION: When pouring coolant, be sure to shut the gasket to the drain bolt threads, then reinstaff the
relay box lid and not let coolant spill on the electrical bolt with a new washer. Tighten it securely.
parts or the paint. lf any coolant spills, rinse it off
immediately. 6. Tighten the radiator drain plug securely.
1. Start the engine. Slide the heater temperature con- 7. Mix the recommended antifreeze/coolant with an
trol lever to maximum heat and turn off the engine. equal amount of water in a clean container.
Make sure the engine and radiator are cool to the
touch. NOTE:
• Use only HONDA-RECOMMENDEDantifreeze/
2. Remove the radiator cap. coolant.
• For best corrosion protection, the coolant con-
3. Loasen the drain plug on the bottom of the radiator centrations must be maintained year-round at
and remove the drain bolt on the engine block. Let 50% MINIMUM. Coolant concentrations less
the coolant drain out. than 50% may not provide sufficient protection
against corrosion or freezing.
CAUTION:
• Do not mix different brands of antifreeze/
coolant.
• Do not use additional rust inhibitors or anti-rust
ENGIN E
products; they may not be compatible with the
DRAIN BOLT
40 N•m (4.0 kg-m, recommended coolant.
29 lb-ft) ......,,l.:\.,.,,...,<f',.l/
WASHER Radiator Coolant Refill Capacity: lncluding
Replace. reservoir 0.4 f (0.42 US qt, 0.35 lmp qt)
ENGINE M/T A/T

TYPE f (US gal, lmp gal)
D128 [8l 3.6 (0.95, 0.79) 3.5 (0.92, 0.77)
D138 [8j 3.6 (0.95, O, 79) 3.5 (0.92, 0.77)
D158 [8l 3.6 (0.95, o. 79) 3.5 (0.92, 0.77)
D152 [8j 3.5 (0.92, 0.77) --
D16A [8j 3.6 (0.95, o. 79) 3.8 (1.00, 0.84)
D162 [8l 3.6 (0.95, 0.79) 3.8 (1.00, 0.84)
816A [8j 3.9 (1.03, 0.86) --
~
RADIATOR
DRAIN PLUG
10-10
8. Pour coolant into the radiator up to the base of the
filler neck.
9. Loosen the bleed bolt on top of the engine. Tighten

it again when coolant comes out in a steady stream
with no bubbles.
1 O. Refill the radiator to the base of the filler neck. Put

the cap on the radiator, and tighten it only to the
first stop. Start the engine and let it run until it
warms up (the radiator cooling tan comes on at
least twice).
11. Turn off the engine. Check the level in the radiator,
add coolant if needed. lnstall the radiator cap, and
tighten it fully.
12. Fill the reservoir to the MAX mark. lnstall the reser-
voir cap.
10-11
Radiator
Cap Testing
1. Removethe radiator cap, wet its seal with coolant,

then install it on the pressure tester.
2. Apply a pressure of 95-125 kPa (0.95-1.25

kg/cm2, 14-18 psi).
3. Check for a drop in pressure.
PRESSURE TESTER
RADIATOR
CAP
ADAPTOR
(for small cap)
PressureTesting
1. Wait until the engine is cool, then carefully remove

PRESSURE TESTER
the radiator cap and fill the radiator with coolant to
the top of the filler neck. \ ADAPTOR
2. Attach the pressure tester to the radiator and apply

a pressure of 95-125 kPa (0.95-1.25 kg/cm2,
14-18 psi).
3. lnspect for coolant leaks and a drop in pressure.
4. Removethe tester and reinstall the radiator cap.
NOTE:
• Check for engine oil in the coolant and/or
coolant in the engine oil.
• Check for ATF in the coolant and/or coolant in
the A TF (A/TI.
10-12
Thermostat
Replacernent ~~~~~~~~~~~~~~~~~~~~~~~~~~~--,
NOTE: Use new gaskets and 0-rings when reassem-
bling.
PIN
THERMOSTAT
COVER
THERMOSTAT
MOUNTING RUBBER
Replace.
THERMOSTAT THERMOSWITCH
lnstall with pin up. A93
22-26 N•m (2.2-2.6 kg-m,
16-19 lb-ft)
Testing
Replacethermostat if it is open at room temperature.
To test a closed thermostat:

1 . Suspend the thermostat in a container of water as
shown.
2. Heat the water and check the temperature with a

thermometer. Check the temperature at which the
thermostat first opens and at full lift.
CAUTION: Do not let the thermometer touch the

bottom of the hot container.
3. Measure the lift height of the thermostat when its

full open.
STANDARD THERMOSTAT
Starts opening:
D15Z1: 82±2ºC (180±4ºF)
Others: 78±2ºC (172±4ºF)
Fully open:
D15Z1: 95°C (203ºF)
Others: 90°C (194ºF)
Lift height: a.o mm (0.31 in)
10-13
Water Pump
lllustrated lndex
NOTE: BLEED BOLT

• Use new 0--rings and new special bolts 10 x 1.25 mm
reassembling. 1 O N•m ( 1.0 kg-m, 7 lb-ftl
Except B 16A2:
TEMPERATURE GAUGE
SENDER
Apply liquid gasket
to the threads.
6x1.0mm
11 N•m
(1.1 kg-m,
TW SENSOR 8 lb-ft)
18 N•m (1.8 kg-m,
13 lb-ft)
WATER OUTLET
COVER
Apply liquid gasket
to mating surface.
THERMOSWITCH
A93
22-26 N•m
w...NG
(2.2-2.6 kg-m, 16-19 lb-ftl
\
Cj--~==~~ -
_j.. _ _ _ _ Replace.
0-RING
/~~
~=u=:n 0-RING t
Replace. \
6 x 1.0 mm
10 N•m (1.0 kg-m,
7 lb-ft)
lnspection,
page 10-16
0-RING
Re place.
ALTERNATOR
ADJUST BRACKET
6x1.0mm
12 N•m (1.2 kg-m, 10 x 1.25 mm
9 lb-ft) 45 N•m (4.5 kg-m,
33 lb-ft)
10-14
B16A2:
WATER OUTLET
COVER
Apply liquid gasket
to mating surface.
BLEED BOLT
10
10 1.25(1.0
x
N•m
mm
kg-m, 7 lb-ftl
Replace.
WATER PUMP
lnspection, \ THERMO SWITCH
page 10-16 A93
22-26 N•m
::,..,,___,.L~~Oo~I
L.._.r.:--,G,(:;: :2: :.2:";{j'.!A:l;\\-19l~ftl
Replace.
THERMOSTAT HOUSING
0-RING
ASSEMBLY
Replace.
10-15
Water Pump
lnspection --------------. Replacement -----------.
1. Remove the tirning belt (page 6-59). 1. Remove the timing belt (SOHC: page 6-55, DOHC:
page 6-88, 816A2: page 6-119).
2. Check that the water purnp pulley turns freely.
2. Removethe water purnp by removing five bolts.
3. Check for signs of seal leakage.
NOTE: A srnall arnount of "weeping" from the

bleed hole is normal.
Except B16A2: 0-RING

Replace.
BLEED HOLE
BLEED HOLE
B16A2:
BLEED HOLE
10 x 1.25 mm
45 N•m (4.5 kg-m. ALTERNATOR
33 lb-ft) ADJUST BRACKET
3. lnstall the water pump in the reverse arder of

removal.
BLEED HOLE
10-16
Fuel and Emissions
Carbureted Engine . . . . . . . . . . . . .. . . . . . . . . . . . . 11-1

Fuel-lnjected Engine . . . . . . . . . . . . . . . . . . . . . . . . 11-185
Fuel and Emissions (Carbureted Engine)
Special Tools 11-2 Accelerator Pump . . . . . . . . . . . . . . . . . . . . . . 11-112

Component Locations Float Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-115
lndex 11-3 Automatic Choke
System Description [1-Carbureted Engine] 11-119
Vacuum Connections 11-8 Choke Opener 11-120
Electrical Connections . . . . . . . . . . . . . . . 11-18 Choke Coil Tension
Troubleshooting and Linkage 11-122
Self-Diagnostic Procedures 11-21 Choke Linkage 11-123
How to Read Flow Charts 11-24 Choke Coil Heater 11-124
PGM-CARBControl System Fast ldle 11-126
System Description . . . . . . . . . . . . . . . . . . . 11-25 Automatic Choke and Fast ldle
(2-Carbureted Engine] 11-128
Symptom-to System Chart . . . . . . . . . 11-26
Choke Linkage 11-129
Troubleshooting Flow Charts
Oxygen Sensor . . . . . . . . . . . . . . . . . . . . . . 11-30 Choke Opener 11-130
Vehicle Speed Sensor 11-32 Fast ldle 11-133
Manifold Absoluta Pressure
Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-34 r1 ;eª.:'.'o: i'~~-~~-~'.".~~---·
Replacement
11-135 ~
11-136 ~
Vacuum Switch . . . . . . . . . . . . . . . . . . . . . 11-38
Coolant Temperature Sensor ... 11-40 (2-Carbureted Engine]
lgnition Coil Signal . . . . . . . . . . . . . . . . . 11-42 Removal 11-137
Electric Load Detector . . . . . . . . . . . . 11-44 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-138
lntake Air Temperature Sensor 11-46 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-140
A/T Lock-up Control Solenoid Synchronization . . . . . . . . . . . . . . . . . . . . . . . . 11-141
Valve A/B 11-48 Fuel Supply System
Input Troubleshooting Flow Charts Symptom-to-Sub System Chart . . . 11-142
Power Source and Ground . . . . . . 11-50 System Description . . . . . . . . . . . . . . . . . . . 11-143
A/T Shift Position Signal . . . . . . . . . 11-52 Fuel Filters . . . .. . . . . . . . .. . . . . . . . . . . . . . . . . . 11-144
Clutch Switch Signal . . . . . . . . . . . . . . 11-54 Fuel Pump 11-145
P/S Oil PressureSwitch Fuel Tank 11-148
Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-56 Air lntake System
Air Conditioning Signal . . . . . . . . . . . 11-58 Symptom-to-Sub System Chart . . . 11-149
Brake Switch Signal . . . . . . . . . . . . . . . 11-60 Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-150
Wiper/Washer Switch Signal . . . 11-62 lntake Air Control System . . . . . . . . . . 11-152
Carburetor Emission Control System
Symptom-to-Sub System Chart . . . 11-64 Symptom-to-Sub System Chart . . . 11-154
System Description . . . . . . . . . . . . . . . . . . . 11-68 System Description . . . . . . . . . . . . . . . . . .. 11-155
ldle Control System . . . . . . . . . . . . . . . . . . . 11-70 Tailpipe Emissions 11-155
Vacuum Controlled Secondary .... 11-81 Catalytic Converter .. . . . . . . . . .. . . . . . . . 11-156
. Slow Air Jet Control System . . . . . . 11-84 Feedback Control System . . .. . . . . . . 11-157
Power Valve 11-89 Throttle Control . . . . . . . . . . . . . . . .. . . . . . . . 11-162
Primary Slow Mixture Cut-off Positive Crankcase Ventilation . . . . 11-165
Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . 11-96
Evaporative Emission Controls . . . . 11-168
ldle Speed/Mixture . . . . . . . . . . . . . . . . . . . . 11-104
Special T ools
Special Tools --------------------------,

Ref. NO. Tool Number Description Oty Remarks
G) 07LAA-PT50101 02 Sensor Socket Wrench
@ 07LAJ-PT30100 Test Harness
or
07LAJ-PT3010A Test Harness
@) 07411-0020000 Digital Circuit Tester
® 07614-0050100 Fuer Une Clamp
@ © ®
11-2
Component Locations
lndex·
[01382 EUROPE& KQ Engine]
CONTROL BOX A/C IDLE BOOST AIR BLEED VAL VE INTAKE AIR TEMPERATURE ITA)
page 11-9 SOLENOID VAL VE Testing, page 11-153 SENSOR
Troubleshooting, page 11-159
COOLANT TEMPERATURE OXYGEN 102)SENSOR

(TWI SENSOR Troubleshooting, page 11-30
(KG, KS, KF) (KE, KQ)
PGM-CARB CONTROL UNIT PGM-CARB CONTROL UNIT

Self-diagnosis Procedure. page 11-21 Self-diagnosis Procedure, page 11-21
11-3
Component Locations
lndex
CD 1584 (KQ CARB) Engine]
CONTROL BOX INNER VENT SOLENOID VALVE AIR LEAK SOLENOID VALVE
Troubleshooting, page 11-1 5 Troubleshooting, page 11-180 Troubleshooting, page 11-87
Troubleshooting,
paga 11-44
EACV P/S ou, PRESSURE SWITCH

Troubleshooting, paga 11-159 Troublashooting, page 11-56
A/T LOCK-UP CONTROL SOLENOID COOLANT TEMPERATURE OXYGEN 102) SENSOR
V ~L VE A/B (TW) SENSOR Troublashooting, page 11-30
Troubleshooting, page 11-48 Troublashooting, page 11-40
PGM-CARB CONTROL UNIT

Salf-diagnosis Procadure, paga 11-21
11-4
(01281, 01383 EXCEPT EUROPE and 01583 Engine]
AIR VENT CUT-OFF SOLENOID A/C IDLE BOOST SOLENOID VAL VE

VALVE (KV) Troubleshooting, page 11- 73
THERMOVAL VE
11-5
Component Locations
lndex
[ 1 -Carbureted Engine]
FUEL TANK
FUEL FEED PIPE Replacement, page 11-148
CARBURETOR
Removal, page 11-135
Replacement, page 11-1 37
CHARCOAL
CANISTER [Except KP, KT. KU]
Testing, page 11-171
FUEL FILTER (REARI

Replace every 2 years or 40,000 km
(24,000 miles) whichever comes first.
FUEL PUMP
Replacement page 11-14 7
FUEL FILTER (FRONT) (Except KP, KT, KU, KYJ

Replacement, page 11-144 FUEL TANK
Replace every 2 years or 40,000 km Replacement, page 11-148
(24,000 miles). whichever comes first.
(2-Carbureted Engine]
CARBURETOR
Removal, page 11-137
Replacement, page 11-1 38
Reassembly, page 11-140
Synchronization, page 11-141
CHARCOAL
CANISTER
FUEL FILTER (REAR)

(24,000 miles) whichever comes first.
FUEL PUMP
Replacement page 11-14 7
FULE FILTER (FRONT)
(24,000 miles), whichever comes first. FUEL RETURN PIPE
11-6
[ 1-Carbureted Engine l
AIR CONTROL DIAPHRAGM AIR CLEANER ELEMENT

Testing, page 11-153 • EC, KO: Replaceevery
2 years or 40,000 km (24,000
miles) whichever comes first.
• Others: Replaceevery 1
year or 20,000 km (12,000 miles)
whichever comes first.
THROTTLE CABLE
lnspection/Adjustment, page 11-150
PCV VALVE
(2-Carbureted Engine)
AIR CONTROL DIAPHRAGM PCV VALVE AIR CLEANER ELEMENT

Testing, page 11-153 Testing, page 11-166 Replace every
2 years or 40,000 km (24,000
miles) whichever comes first
THROTTLE CABLE AIR BLEED VALVE

lnspection/Adjustment, page 11-150 Testing, page 11-153
11-7
System Description
Vacuum Connection
(01382 EUROPE & KO Engine]
CONTROL
BOX
CHARCOAL
CANISTER
FRONT OF VEHICLE
11-8
Control Box
VACUUM CONTROL
SOLENOID VAL VE VACUUM HOLDING SOLENOID VALVE
(Section 23) Troubleshooting, page 11-176
POWER VALVE
CONTROL SOLENOID VAL VE
PURGE CUT-OFF
SOLENOID VALVE
Troubleshooting,
page 11-174
VACUUM SWITCH
Troubleshooting,
page 11-85
MANIFOLD ABSOLUTE
PRESSURE (MAPI
SENSOR CHECK VALVE
11-9
System Description
Vacuum Connection
[01584 (KQ CARB) Engine]
CONTROL
BOX
INNER VENT
SOLENOID VALVE
FRONT OF VEHICLE
11-10
Control Box
VACUUM CONTROL
SOLENOID VALVE
(Section 23)
IDLE BOOST SOLENOID VALVE

Troubleshooting, page 11- 77
POWER VAL VE CONTROL SOLENOID VAL VE

MANIFOLD ABSOLUTE
PRESSURE (MAPI
SENSOR
Troubleshooting, CHECK VALVE
page 11-34
VACUUM SWITCH A/C IDLE BOOST SOLENOID

Troubleshooting, page 11-38 VALVE
11-11
System Description
Vacuum Connection
[01281, 01383 EXCEPT EUROPEand 01583 (EXCEPTKV) Engine]
FRONT OF
VEHICLE
11-12
CD 1583 (KV) Engine]
AIR VENT CUT-OFF

SOLENOID VAL VE
A/C IDLE BOOST

SOLENOID VALVE
"
FRONT OF VEHICLE
11-13
System Description
Vacuum Connection
[D 1382 EUROPE & KO Engine]

®
¡
TO
CARBURETOR
TO
FUEL -
TANK
G) OXYGEN (02) SENSOR @) AIR BLEED VALVE

@ MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR @ CHECK VALVE
@ VACUUM SWITCH @ THROTTLE CONTROLLER
@ ELECTRONIC AIR CONTROL VALVE (EACV) @ CHARCOAL CANISTER
@ A/C IDLE BOOST THROTTLE CONTROLLER @ TWO-WAY VALVE
@ A/C IDLE BOOST SOLENOID VALVE @ AIR VENT CUT-OFF DIAPHRAGM
(J) POWER VALVE @ VACUUM HOLDING SOLENOID VALVE
@ POWER VALVE CONTROL SOLENOID VALVE @ PURGE CUT-OFF SOLENOID VALVE
@ SECONDARY DIAPHRAGM @ CATL YTIC CONVERTER
@) AIR LEAK SOLENOID VALVE @ THERMOVALVE
@ AIR FILTER @ PCV VALVE
@ CHOKE OPENER @ VACUUM CONTROL SOLENOID VALVE
@ FAST IDLE UNLOADER
@ AIR CONTROL DIAPHRAGM
11-14
(01584 (KQ CARB) Engine]
r=============================~®
TO
FUEL
TANK
G) OXYGEN (021 SENSOR @) AIR CONTROL DIAPHRAGM

@ MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR @ AIA BLEED VAL VE
@ VACUUM SWITCH @ CHECK VALVE
@ IDLE BOOST THROTTLE CONTROLLER @ TWO-WAY VALVE
@ IDLE BOOST SOLENOID VALVE @) INNER VENT SOLENOID VALVE
(!) THROTTLE CONTROLLER @ AIR VENT CUT-OFF SOLENOID VALVE
@ A/C IDLE BOOST SOLENOID VALVE @ PCV VALVE
@ POWER VALVE @ CA TAL YTIC CONVERTER
@) POWER VALVE CONTROL SOLENOID VALVE @ VACUUM CONTROL SOLENOID VALVE
@ AIR LEAK SOLENOID VALVE
@ CHOKE OPENER
@ THERMOWAX VALVE
@ THERMOVALVE
11-15
System Description
Vacuum Connection
[01281, 01383 EXCEPT EUROPEand 01583 (Except KV) Engine]
G) A/C IDLE BOOST THROTTLE CONTROLLER (J) AIR CONTROL DIAPHRAGM

@ A/C IDLE BOOST SOLENOID VALVE @ AIR BLEED VALVE
@ SECONDARY DIAPHRAGM @ CHECK VALVE
@ POWER VALVE @) THROTTLE CONTROLLER
@ CHOKE OPENER @ PCV VALVE
@ FAST IDLE UNLOADER @ THERMOVALVE
11-16
[01583 (KV) Engine] @
=====~:;1ll
r:
TO
FUEL
TANK
Q) A/C IDLE BOOST THROTTLE CONTROLLER @ CHECK VALVE

@ A/C IDLÉ BOOST SOLENOID VALVE @) THROTTLE CONTROLLER
@ SECONDARY DIAPHRAGM @ PCV VALVE
@ POWER VAL VE @ THERMOVALVE
@ CHOKE OPENER @ CHARCOAL CANISTER
@ FAST IDLE UNLOADER @ TWO-WAY VALVE
(j) AIR CONTROL DIAPHRAGM @ AIR VENT CUT-OFF DIAPHRAGM
@ AIR BLEED VALVE @ AIR VENT CUT-OFF SOLENOID VALVE
11-17
System Description
Electrical Connections
[01382 EUROPE& KQ Engine] MAIN FUSE BOX FUSE BOX

CD
+ 1-~--t----o.. @
--....-~@-3""<>--+---~~----+-o81G1~t---f-A-C~G-(~S~}-+-~~~--....-~-,
......
BATTERY IGNITION 115 Al
MAN FUSE BOX: SWITCH
(i)
BA TTERY 180 Al
@IG 150 Al
@ BACK UP (7.5 A}...._ _.
IGNITION.
COIL
I ª
A/C SWITCH
VACUUM
SWITCH
A/C CLUTCH GRN/ ~------------~ ....-~----+--•
RELAY WHT
y'
V
8LU/ 8LU
GRN '
8LU/ 8LK/ 8LU/ GRN/ RED/GRN/ WHT/ WHT/ 8LK/
RED RED 8LU YEL WHT WHT 8LU WHT RED 8LU YEL
08 89 07 83 81 016 018 016 017 01 O
. ACS ACC NE EACV+ EACV - TW SG PB VCC V8U IG1
PGM-CARB CONTROL UNIT
08 011 019 021 82 87 816 812 814 811 813
VSP CLS 02 LG PG FCS IUS-2 PGS ves SLS-1 PJS
RED GRN/ BLLI/ 8LU/ 8LU/
ORN ORN GRN WHT
CLUTCH
SWITCH
G101 G401 G101 G101 G201 G201(RHD: G301l

(RHD: G301)
SOLENOID VAL VE:
(D PRIMARY SLOW MIXTURE CUT-OFF
@ A/C IDLE BOOST
@ PURGE CUT-OFF*
@ VACUUM CONTROL*
@ AIR LEAK*
@ POWER VALVE*
(2) VACUUM HOLDING*
*: In the control box
81 83 85 87 a, 811 813 BIS DI 03 05 07 09 011 DIJ OH, 017 019 021
ºººººººº ººººººººººº
ºººººººº
ez 84 ee et e10 e12 eic ere
02 o• o••
06 oa 010 012 01• o,, 020 022
11-18
MAIN FUSE BOX
+ G)
BATTERY
MAIN FUSE BOX: @ © FUSE BOX;
G) BATTERY (80 Al
@IG (50Al G) ACG (SI (15 Al
@ BACK
STOP. UP
HORN @WIPER. WASHER
@ (7 .5 (20
Al Al .__ ..... (20A)
IGNITION
COIL
= WHT/ GRN/
COOLING G301 GRN 8LK
A/C FAN
SWITCH RELAY WIPER/
TW WASHER
=l,:Y°'
SHIFT POSITION ~ A/C ~ SENSOR SWITCH UNT
CONSOLE 1 ~LUTCr ~L TER·
8LK/
8LK/
YEL SWÓÁ~
1
1
~~:/ GRN/REO8LK/flN WHT/

YEL
G N/ YEL/
GRN 8LU RE.O YEL 8LU WHT 8LK
011 012 010 08 89 810 07 83 81 016 018 015 017 022 03 013 014 01 02
ATNPAT04ATD3ACSACCFANC06 NE EACV+EACV-TW SG P8 VCC BKSW INTW PC EL V8U IG1
ACG-C PGM-CARB CONTROL UNIT
811
09 05 011 019 021 82 84 86 88 813 815
VSP PSW CLS o, LG PG LC-A LC·8 87 FCS-R FCS-L
SLS-1 814
(VPI ves
816
IUS-2 PJS IUS-1
YEL/ WHT 8 K GRN/ GRN/ G NI RED/ 8LU/ 8LU/ RED 8LU/ WHT/
T
1
8LK BLK YEL GRN GRN ORN WHT GRN
1 8LK/
REO 1 1
YEL GRN/ BLU/
l
1 RED YEL
8RN/
YEL/ YEL/ 8LK
8LU WHT CD ®
I
G101 G401 G301 G401 G101 G101
= l
BLK
G101
=
SOLENOID VALVE:
G) A/T LOCK-UP CONTROL (Al
@ A/T LOCK-UP CONTROL (8)
G301
=
G101
@ PRIMARY SLOW MIXTURE CUT-OFF (RIGHT)

@ PRIMARY SLOW MIXTURE CUT-OFF (LEFT)
@ AIR LEAK
@ VACUUM CONTROL*
(J) A/C IDLE BOOST*
@ POWER VALVE*
@ IDLE BOOST*
@) AIR VENT CUT-OFF
@ INNER VENT
*: In the control box
81 83 BS 81 99 811 BIJ BIS 01 Dl OS 07 09 011 DIJ OIS 011 019 OZI
00000000
ºººººººº
e2 e, e& ea e10 e12 eu 01& ººººººººººº
02 04 06 08 DIO 012 014 016 018 OZO 022
11-19
System Description
Ele~trical Connection
(01281, 01383 EXCEPTEUROPEand 01583 Engine]
MAIN FUSE BOX
+}--~::i....,,c--~>-+--~
BATTERY IG (50 Al
BATTERY (80 Al IGNITION
SWITCH
FUSE BOX
ACG (SI
(15 Al
DELAY
CONTROL
y
UNIT
BLK/
RED YEL
~~E ~
BOOST
SOLENOID
~e~~T CUT-OFF
SOLENOID
VALVE VALVE (KV onlyl
G201
I I
(RHD:G3011
G201 (RHD:G301 I
11-20
Troubleshooting
Self-Diagnostic Procedure ------------------------.
[D 1382 EUROPE & KO and 01584 (KO CAR8) Englne]

Turn the ignition on, remove the door sill molding and pull the carpet back to expose the control unit, and observe the
LED on the control unit. The LED indicates a system failure code by its blinking frequency.
The control unit LEDcan indicate any number of simultaneous component problems by blinking separate codes, one after
another.
[RHD]
[LHDJ LEO
LED
PGM-CARB
CONTROL
= See Problem CODE 1 UNIT

= See Problem CODE 1,2 and 3
SELF-DIAGNOSIS
SYSTEM INDICATED PAGE
INDICATOR BLINKS
1 OXYGEN CONTENT 11-30
2 VEHICLE SPEEDPULSEA 11-32
3 MANIFOLD A8SOLUTE PRESSURE 11-34
4 VACUUM SWITCH SIGNAL 11-38
5 MANIFOLD ABSOLUTE PRESSURE 11-36
6 COOLANT TEMPERATURE 11-40
8 IGNITION COIL SIGNAL 11-42
9 ELECTRICLOAD DETECTOR(ELD)* 11-44
10 INTAKE AIR TEMPERATURE** 11-46
11 A/T LOCK-UP CONTROL SOLENOID VALVE A/8* 11-48
14 ELECTRONICAIR CONTROL 11-160
*: D 1 584 (KQ CAR8) Engine

**: 01382 EUROPE& KO
lf CODE 7, 1 2, 13 (or more than 14), count the number of blinks again; if the indicator is in fact blinking these codes,
substitute a known-good control unit and recheck. lf the indication goes away, replace the original control unit. The con-
trol unit LEO may come on, indicating a system problem, when, in fact, there is a poor or intermittent electrical connec-
tion. First, check the electrical connections, clean or repair connections if necessary. (cont'd)
11-21
Troubleshooting
Self-Diagnosis Procedure (cont'd)
lf the inspection for a particular failure code requires the test harness, remove the left door (LHD: right door) sill molding
and pull the carpet back to expose the control unit. Unbolt the ECUbracket. Connect the test harness. Check the system
according to the procedure described for the appropriate code(s) listed on the following pages.
\---\~
-:
DIGITAL CIRCUIT
TESTER
/J..1.----TEST
or
HARNESS
07LAJ-PT30100
07LAJ-PT3010A
07411 -0020000
BI BJ es 87 89 811 813 BIS 01 03 OS 07 09 DI 1 013 OIS 017 019 021
ºººººººº
82 e• 86 81 EUO 812 BU 816
02 D• 06 08 010 012 OU Olfi 018 DZO 022
11-22
CAUTION:
• For testing at connectors other than the test harness. bring the tester probe into contact with the terminal from the
connector side of wire harness connectors in the engine compartment. For female connectors. just touch lightly with
RUBBER SEAL TESTEA PROBE
WIRE HARNESS
TERMINAL
11-23
Troubleshooting
How to Read Flowcharts
A flowchart is designed to be used from start to final repair. lt's like a map showing you the shortest distance. But
beware: if you go off the "map" anywhere but a "stop" symbol, you can easily get lost.
!START! Describes the conditions or situation to start a troubleshooting flowchart.

(bold type)
! ACTION j Asks you to do something; perform a test, set up a codition etc.
STOP The end of a series of actions and decisions, describes a final repair actiona and sometimes directs you
(bold type) to an earlier part of the flowchart to confirm your repair.
NOTE:
• The term "lntermittent Failure" is used in these charts. lt simply means a system may have hada failure, but it checks
out OK through ali your tests. You may need to road test the car to reproduce the failure or, if the problem was a
loose connection, you may have unknowingly solved it while doing the tests. In any event, if the LED on the control
unit does not come on, check for poor connections or loose wires at ali connectors related to the circuit that you
are troubleshooting.
• Most of the troubleshooting flowcharts have you reset the control unit and try to duplicate the problem code. lf the
problem is intermittent and you can't duplicate the code, do not continue through the flowchart. To do so will only
result in confusion and, possibly, a needlessly replaced control unit.
• "Open" and "Short" are common electrical terms. An open is a break in a wire or at a connection. A short is an
accidental connection of a wire to ground orto another wire. In simple electronics, this usually means something won't
work at all. In complex electronics (like control unit's), this can sometimes mean something works, but not the way
it's supposed to.
proceeding.
11-24
PGM-CARB Control Unit
System Description
[01382 EUROPE& KO and 01584 (KO CARB) Engine]
The Control Unit contains logic circuits that sense the inputs and apply outputs as required to control emissions and
effect smooth engine performance.
INPUTS CONTROL UNIT OUTPUTS
Oxygen Sensor l ldle Function 1 EACV

Vehicle Speed Signa! Primary Slow Mixture Cut-off
MAP Sensor
l Feedback Function Solenoid Valve
y
Vacuum Switch 1
ldle Boost Solenoid Valve*
TW Sensor
Electric Load Detector*
TA Sensor**
h> l Fuel Cut-off 1
A/C ldle Boost Solenoid Valve
Air Leak Solenoid Valve
Power Valve Control Solenoid
lgnition Coil Signar Valve
A/C Switch Signa! I Evaporative Function 1 Vacuum Control Solenoid
A/T Shift Position Signa! Valve
Clutch Switch Signa!
Battery Voltage (IGN. 1)
I Back-up Function 1
Purge Cut-off Solenoid Valve* *
A/T Lock-up Control Solenoid
Battery Voltage (Bat) Valve A/B*
P/S Oil Pressure Switch Signal*
Brake Switch Signal*
Wiper/Washer Switch (INT) Signa!*
*: O 1 584 (KQ CARB) Engine

* *: O 1382 EUROPE& KQ Engine
Control Unit Back-up Functions

1. Fail-Safe Function
When an abnormality occurs in signa! from a sensor, the control unit ignores that signal and assumesa preprogrammed
value that allows the engine to continue to run.
. 2. Back-up Function
When an abnormality occurs in the control unit itself, a back-up circuit independent of the system permits minimal
driving.
3. Self-diagnosis Function (LEOindicator).

When an abnormality occurs in a signal from a sensor, the control unit indicates the LEOon the control unit, stores
the failure code in erasable memory and indicates the code with a LEOon the control unit anytime the ignition is on.
11-25
Symptom-to System Chart
(01382 EUROPE & KO Engine]

NOTE: Across each row in the chart, the systems that could be sources of a symptom are ranked in the arder the should
be inspected startinq with G). Find the syrnptorn in the left colurnn, read across to the most likely source, then refer
to the page listed at the top of that column. lf inspection shows the system is OK, try the next most likely system@, etc.
PGM-CARB CONTROLSYSTEM
.:
PAGE
PGM-CARB MANIFOLD COOLANT
VEHICLE IGNITION
O XY GEN ABSOLUTE VACUUM TEMPERA-
CONTROL SPEED COIL
SENSOR PRESSURE SWITCH TURE
UNIT PULSER SIGNAI
SENSOR SENSOR
SYMPTOM
50 30 32 34,36 38 40 42
SELF-DIAGNOSISINDICATOA
(LEO) BLINKS {!}or{Sr 0 0 $or$ 0 $ ©
ENGINEWON'T START
DIFFICULT TO START ENGINE

@)
WHEN COLO
WHEN COLO
FAST IDLE
OUT OF ®
SPECIFIC
ROUGH IDLE ® @ @
IRREGULAR
IDLING WHEN
WARM
ENGINE SPEED ®
TOO HIGH
WHEN
WARM
ENGINE SPEED ®
TOO LOW
WHILE
WARMING ® @ @
FREQUENT UP
STALLING
AFTER
WARMING ® ®
UP
MISFIRE OR
ROUGH ® @ @ @
RUNNING
POOR
PERFOR- FAILS
MANCE EMISSION ® @ G)
TEST
LOSS OF @)
POWER
@
* CODE 7, 9, 11, 12, 13, or exceeds 14: count the nurnber of blinks again. lf the indicator is in fact blinking these codes,
substitute a known-good control unit and recheck. lf the indication goes away, replace the original control unit.
@: When the self-diagnosis indicator is on, the back-up system is in operation.
Substitute a known-good control unit and recheck. lf the indication goes away, replace the original control unit.
11-26
PGM-CARB CONTROL SYSTEM EMISSION CONTROL
INTAKE ELECTRONIC OTHER
A/T CLUTCH
AIR A/C IAIR CONTROL EMISSION
SHIFT CARBURETOR FUEL SUPPLY AIR INTAKE
TEMPERA- SWITCH VAL VE CONTROL
POSITION SIGNAL
TURE SIGNAL
SIGNAL
SENSOR
46 52 54 58 64 142 149 160 154
@ <Gr
@ G)
G)
@ G) @
@ G) ® ®
@ G)
G)
G) @
G) CD
G) @
@ ® @ @
@ @ CD @
11-27
Symptom-to System Chart
[D 1584 (KQ CARB) Engine]

NOTE: Across each row in the chart, the systems that could be sourcesof a symptom are ranked in the order they should
be inspected starting with G). Find the symptom in the left column, read across to the most likely source, then refer
to the page listed at the top of that column. lf inspection shows the system is OK, try the next most likely system@, etc.
PAGE PGM-CARB CONTROL SYSTEM
PGM-CARB MANIFOLD COOLANT

VEHICLE IGNITION ELECTRIC
OXYGEN ABSOLUTE VACUUM TEMPERA-
CONTROL SPEED COIL LOAD
SENSOR PRESSURE SWITCH TURE
UNIT PULSEA SIGNA! DETECTOR
~ SENSOR SENSOR
SYMPTOM
~ 50 30 32 34,36 38 40 42 44
SELF-DIAGNOSIS INDICA-
TOR (LED) BLINKS $or0 0 w {i}or{tr 0 © {!} {!}
ENGINE WON'T START
DIFFICULT TO START EN-

GINE WHEN COLO
@)
WHEN
COLO FAST
IDLE OUT @)
OF
SPECIFIC
ROUGH
IRREGULAR IDLE
@) @ @
IDLING
WHEN
WARM
ENGINE SPEED
@) @
TOO HIGH
WHEN
WARM
ENGINE SPEED
@)
TOO LOW
WHILE
WARMING @) @ @
FREOUENT UP
STALLING
AFTER
WARMING
@) @
UP
MISFIRE OR
ROUGH @) @ @ @
RUNNING
FAILS EMIS-
POOR
SION TEST
@) @ G)
PERFOR-
MANCE LOSS OF
@) @
POWER
-
* CODE 7, 12, 13, or exceeds 14: count the number of blinks again. lf the indicator is in fact blinking these codes, substi-
tute a known-good control unit and recheck. lf the indication goes away, replace the original control unit.
@: When the self-diagnosis indicator is on, the back-up system is in operation.
Substitute a known-good control unit and recheck. lf the indication goes away, replace the original control unit.
11-28
PGM-CARB CONTROL SYSTEM EMISSION CONTROL
ELEC-
LOCK-UP A/T WIPER/ CAR- FUEL AIR
CLUTCH P/S OIL BRAKE TRONIC OTHER
CONTROL SHIFT A/C WASHER BU RETOR SUPPLY INTAKE
SWITCH PRESSURE SWITCH AIR EMISSION
SOLENOID POSITION SIGNAL SWITCH
SIGNAL SWITCH SIGNAL CONTROL CONTROL
VAL VE SIGNAL SIGNAL
VAL VE
48 52 54 56 58 60 62 60 142 149 160 154
-03} ®
@ G)
G)
CD @
G) @ @
@ @ G)
CD
G) @
G) CD
G) @
@ @ @ @
@ @ G) @
11-29
PGM-CARB Control System
Troubleshooting Flowchart - Oxygen Sensor
{t} Self-diagnosis LED indicator indicates CODE 1 : A problem in the Oxygen (0 2) Sensor circuit.
The oxygen sensor, detects the oxygen content in the exhaust gas, and inputs the control unit. In operation, the control
unit receives the signals from the sensor and varias the duration during which fuel is injected. The oxygen sensor is in-
stalled on the exhaust manifold.
STOICHIOM ETRIC
AIR-FUEL RATIO
VOLTAGE (V
1
RICH AIR-FUEL LEAN

LED indicates CODE 1 . RATIO
Remove BACK UP fusa in the

under-hood relay box far 1 O sec-
onds to reset control unit.
Warm up engineto normal operat-

ing temperatura (the cooling tan
comes on).
NO lntermittent failure (test drive

Does LEOindicate CODE 1
may be necessary).
YES
lnspect fuel pressure at the fuel

filter.
NO Repair fuel supply system (page

Is pressure as specified ?
11-1421
YES
Disconnect wire harness from in-

dicated 02 sensor.
Warm up engineto normal operat-

ing temperatura again, then open
the throttle wide open then clase
it.
(To page 11-31) DIGITAL 02 SENSOR

CIRCUIT
TESTER
07411-0020000
11-30
(From page 11-30)
Measurevoltage betweenthe con-

nector terminal and body ground.
02 SENSOR
SOCKET WRENCH
07LAA-PT50101
45 N·m (4.5 kg-m, 33 lb-ft)
Is voltage above 0.6 V at wide
open throttle and below 0.4 V NO
when the throttle is quickly >--------! Replace 02 sensor.
released? '-----------------_J
YES
Stop engine.
Reconnect02 sensor.
0.4-0.6 V7
Connect the test harnessbetween
the control unit and connector
(page 11-22). 019 (+) 021
.---~~~~-~-1--.(-)
ºººººººº ººººººººº
Restart and warm up engine to ºººººººº ººººººººººº
normal operating temperatura,
then open the throttle wide open
then close it.
Measurevoltage betweenD19 (+)

terminal and 021 (-) terminal.

Repair open or short in WHT wire
open throttle and below 0.4 V \-N_O ~
between control unit (019) and
when the throttle is quickly
the 02 sensor.
released?
YES
Substitute a known-good control

unit and recheck. lf symptom/
indication goes away, replace
the original control unit.
11-31
Troubleshooting Flowchart - Vehicle Speed Sensor
{V- Self-díagnosís LEO índícator indicates CODE 2: A problem in the Vehícle Speed círcuit.
The signa! generated by the speed sensor, produces pulses when the front wheels turn.
LEO indicates COOE 2.

the control unti and connector
(page 11-22).
Block rear wheelsand set the park-

P,fA!;@f@ Block
rear wheels befare
ing brake. Jack up the front of the
jacking up front of car.
car and support with safety
stands.
Turn the ignition switch ON. 0-5 V 7

1 1
09(+) 021 (-)
Slowly rotate front wheel and
measurevoltage between 09 (+)
terminal and 021 (-) terminal. ºººººººº
ºººººººº
NO
Ooesvoltage pulse O V and 5 V 7 Turn the ignition switch OFF.
YES
Substituta a known-good control OisconnectO connector from the

unit and recheek. lf prescribed control unit only, not the wire
voltage in now available replace harness.
Slowly rotate front wheel and

measurevoltage between 02 ( +)
-Repalr open or short
In YEL/RED, YEL/
NO WHT wlre between
Ooesvoltage pulseO V and 1 2 V ?
control unit (091 and
YES the speed sensor.
-Faulty speed sensor.
Substituta a known-good control
unit and recheck. lf prescribed
voltage is now available replace
0-12 V7
09 (-)
ºººººººº
ºººººººº D2(+)
11-32
Troubleshooting Flowchart - MAP Sensor
_r:';-t Self-daignosis LED indicator indicates CODE 3: Most likely an electrical problem in the Manifold Absolute Pressure
"\..:;.,[" (MAP) Sensor system.
~ Self-diagnosis LED indicator indicates CODE 5: Most likely a mechanical problem (broken hose) in the Manifold Ab-
~ solute Pressure (MAP) Sensor system.
The MAP sensor converts manifold absolute pressure into electrical signals and inputs the control unit.
SENSOR UNIT
OUTPUT
VOLTAGE
(v) 3.5
o 5 10 15 20 25 30 (in. Hg) GAUGE

100 200 300 400 soo 600 7IIO (mm Hg) READING
-Engine is warm and running.

-LEO indicates CODE 3.
Remove BACK UP fuse in the

under-hood relay box for 1 O sec-
Stan the engine and allow to idle.

Does LED indicate CODE3 ?
may be necessary).
YES
(01382 EUROPE& KQ Engine] (01584 (KO CAR8) Enginel

the MAP sensorand wire harness.
(To page 11-35)
11-34
(From page 11-34)
Measure voltage between RED ( +)

terminal and GRN (-) terminal.
NO Measurevoltage between RED( +)

Is there approx. 5 V 7
YES
Repair open in GRN/
Measure voltage between WHT YES BLU wire between con-
Is there approx. 5 V ?
(+) terminal and GRN (-) termi- trol unit (018) and MAP
nal. NO sensor.
-Replace MAP sen-

sor.
NO -Rapair short in WHT
wire between
YES control unit (015) and
MAP sensor.

Turn the ignition switch OFF. the control unit and connector
(page 11-22).

the control unit and connector Measure voltage between D17
(page 11-22). ( +) terminal and O 18 (-) terminal
with the ignition switch on.
Tum the ignition switch ON. Repair open in WHT /

YES RED wire between
control unit (017) and
NO MAP sensor.
Measurevoltage between D 1 5 ( +)
terminal and 018 (-) terminal. Substituta a known-good control
unit and rechack. lf prescribad
voltaga is now availabla, replace
tha original control unit.
017 (+)
ooooooootooi
ºººººººº 5V7
ºººººººº 00000000~
018 (-)
NO Repair open in WHT wire
Is there approx. 3 V ? between control unit (015) and
MAP sensor.
YES
Substituta a known-good control 015(+)

unit and recheck , lf symptom/
indication goes away, replace 0000000~
3V7
ººººººº~~
018(-)
(cont'd)
11-35
Troubleshooting
Flowchart
--MAP Sensor (cont'd)----------
LEO indicates GODE 5.
Remove BACK U P fuse in the

Start engine and keep engine

speed at idle.

Does LEOindicate CODE5 r
may be necessary).
YES
(01382 EUROPE& KQ EngineJ (01584 (KQ CAR8) Engine]
Stop engine.
Remove #21 hose from the vac-

uum hose manifold and connect a
T-fitting from a vacuum gauge
between the vacuum hose mani-
fold and the MAP sensor.
Start engine. VACUUM

PUMP/GAUGE
T-FITTING
T-FITTING
NO
Is there vacuum ? Repair as necessary.
YES (01584 (KQ CAR8) Engine]
Connect a vacuum pump to #21

hose and apply vacuum.
#21 HOSE
NO
Does it hold vacuum ? Replace #21 hose.
YES
(To page 11-37)
11-36
(From page 11-36) (01382 EUROPE& KQ Engine] [01584 (KQ CARB) Engine]
TEST HARNESS TEST HARNESS
07 LAJ-PT30200 "e----- 07LAJ-PT30200
Stop engine.
Connect the test harness between

the MAP sensor and wire harness.
Measure voltage between WHT

(+) terminal and GRN (-) termi-
nal.
NO
Is there approx. 3 V ? Replace MAP sensor.
YES

11-37
Troubleshooting Flowchart-Vacuum Switch
-$self-diagnos.is LED indicator indicates CODE4: A problem in the vacuum switch.
The vacuum switch converts carburetor ported vacuum into electrical signals and inputs the control unit.
-Engine is warm running. [D 1382 EUROPE& KQ Engine] [D 1584 (KQ CAR8) Engine]

under-hood relay box for 1 O sac-
Disconnect the BP connector on No.7

the control box.
[D13B2 EUROPE& KQ Engine] [D15B4 (KQ CAR8) Engine]
Start the engine.
Measureresistancebetween No. 1
terminal and No. 7 terminal on the
control box.
T-FITTING
Remove#4 hose from the vacuum

YES hose manifold and connect a T-
Does continuity exist ? fining from a vacuum gauge
between the vacuum hose mani-
NO fold and the vacuum switch.
-Replace vacuum
switch.
Is there more than 30 mmHg of ,_N_O _,
-Repair open BLK/
vacuum ?
YEL or BRN wire in
YES the control box.
Check routing of #4 hose.

(To page 11-39)
11-38
(From page 11-38) (01382 EUROPE& KQ Engine] [D 1584 (KQ CAR8) Engine]
Measure voltage between BLK/

YEL terminal and body ground on
the wire harness.
BRN
NO Repair open in BLK/YEL wire be-

Is there battery voltage ? tween connector and ACG(S)
fuse.
YES
Turn the ignition switch OFF. [D1584 (KQ CAR8) Engine]

(01382 EUROPE& KQ Engine]
Reconnect the connector to the

control box.

(page 11-22).
Remove#4 hose from the vacuum

hose manifold and connect a vac-
uum pump.
12 V?
Apply vacuum.
013
11 021
(+) (-)
Measure voltage between D 13 00000000

( +) terminal and 021 (-) termi-
00000000
nal.
NO Repair open in BRN wire

Is there battery voltage ? between control unit (013) and
vacuum switch.
YES

11-39
Troubleshooting Flow Chart- TW Sensor
-$ Self-diagnosis LEOindicator indicates CODE 6: Most likely a problem in the Coolant Temperature (TW) Sensor circuit.
The TW sensor is a temperature dependant resistor (thermistor). The resistance of the thermistor decreases as the coolant
ternperature increases as shown below.
RESISTANCE
(kn) 20 .....-:-~---r----.----,
10T"~t-----t---t---~
5-r---.:---t---t---;
THERMISTOR 1-t--t----"lllr---t---;
0.5-t--t-----t-
...,.....,.--~
0.1 Jr--it---+--.r-+--r....,..
-20 o 20 40 so so 100 120 re,
-4 32 68 104140176212 248 rF)
LEO indicates CODE 6.

COOLANT TEMPERATURE


Does LEO indicates CODE 6 ?
may be necessary).
YES
TW SENSOR
Warm up engine to normal operat-
ing temperatura (the cooling tan
comes on).
Disconnect the 2P connector on

the TW sensor.
Measure resistancebetween the 2

terminals on the TW sensor.
NO GRN/WHT
Is there 200-400 n? Replace TW sensor.
YES
(To page 11-41)
11-40
(From page 11-40)
1
Measure voltage between RED/
WHT (+) terminal and body
ground.
NO
Is there approx. 5 V ? Turn the ignition switch OFF.
YES

(page 11-22).

WHT (+) terminal and GRN/WHT
(-) terminal.
Repair open In GRN/

WHT, GRN/BLU wire
between control unlt
YES (018) and TW sensor.

Measurevoltage between D 1 6 ( +)
1
Repair open in RED/

YES WHT wire between
control unit (016) and
NO TW sensor.
-Substituta a known-good con-

trol unit and recheck. lf pre-
scribed voltage is now avail-
able, replace the original con-
trol unit.
-Repair short in RED/WHT wire
between control unit (016) and
TW sensor.
ºººººººº ººººººº 4"ºº
016 (+) 018 (-)
u
5V7
11-41
Troubleshooting Flowchart- lgnition Coil Signal
-$-self-diagnosis LED indicator indicates CODE8: A problem in the ignition coil signal circuit.
This signal allows the control unit to monitor the engine.
Remove BACK UP fusa in the


Does LED indicates CODE 8 ?
may be necessary).
YES
Start the engine.
Connect the test harness between 8V7

the control unit and connector 1
(page 11-22). 07(+) 021(-)
ºººººººº ººº~ºººººº
Measure voltage between D7 (+)
terminal and D21 (-) terminal. ºººººººº ººººººººººº
NO Repair short or open BLU wire
Is voltage above approx. 8 V ? between control unit (07) and
ignition coil.
YES

indication goes away. replace
11-42
Troubleshooting Flowchart- Electric Load Detector
[D 1584 (KQ CARB) Engine]
{!)- Self-diagnosis LED indicator indicates CODE 9: A problem in the Electric Load Detector circuit.
LEO lndlcates CODE 9.

speed at idle.
Turn on headlights.
NO lntennlttent failure, system is OK

Does LED indicates CODE 9 t. at this time (test drive may be
necessary).
YES
MAIN FUSE BOX
Remove the main fuse box.
Disconnect the 3P connector from

the electric load detector.
BLK/
YEL
YEL ( +) terminal and BLK ( - }
terminal.
NO Measure voltage between BLK/

Is there battery voltage ? YEL ( +} terminal and body
ground.
YES
-YES Repair open In BLK wire

Is there battery voltage ? between the 3P con-
nector and G301.
NO
Repair open in BLK/YEL wire be-

tween ACG (SI ( 15 Al and the 3P
connector.
(To page 11-45)
11-44
(From page 11-44)
Measure voltage between GRN/

RED terminal and body ground.
Repalr open or short in GRN/REO

NO wire between control unlt (014)
Is there 4.5-5 V 7 and the 3 P connector. lf wire is
YES OK, substltute a known good con-
trol unit and recheck.
Connect the 3 P connector to the

electric load detector.
Connect the test harness between Condition Voltage

Headlight switch, first position( • ) 2.9-3.1 V
(page 11-221.
Headlight switch, second position (el 1.9-2.2 V
lgnition switch ON 3.4-3.5 V
Turn the ignition switch on.
Under the conditions listed in the

chart to the right, measure vol-
tage between D 14 ( + l terminal 021 (-)
and D21 ( - ) terminal.
00000000
00000000
014 (+)
Listed Voltage ?
Is the voltage listed in the chart NO

Faulty electric load detector.
available?
YES

unlt and recheck. lf symptom/indl-
cation goes away, replace the
original control unit.
11-45
TroubleshootingFlowchart- TA Sensor [D 1382 EURO PE & KQ Engine]
@ Self-diagnosis LED indicator indicates CODE 1 O: Most likely a problem in the lntake Air Temperature (TA) Sensor circuit.
The TA sensor is a temperature dependant resistor (thermistor). The resistance of the thermistor decreases as the intake
air temperature increases as shown below.
RESISTANCE
(kO) 20---------,,.-- ....
10-+-~+----lf-----+--~
5+--~--..._--+------t
THERMISTOR 0.1..1.,.-1~--'---1-..,...;:1111
-20 O 20 40 60 80 100 120 (ºCl
-4 32 68 104140176212248 lºFI
INTAKE AIR TEMPERATURE

under-hood relay box far 1 O sec-

Does LED indicates CODE 1 O r may be necessary).
YES

the TA sensor.
Measure resistance between the 2

terminals on the TA sensor.
NO
Is there 1 -4 kO ? Replace TA sensor.
YES
(To page 11-4 7)
11-46
(From page 11-46)
,-

RED (+) terminal and body
ground.
NO
Is there approx. 5 V ? Turn the ignition switch OFF.
YES
Measure voltage between GRN/ Connect the test harness between

RED (+) terminal and GRN/WHT the control unit and connector
(-) terminal. (page 11-22).
Repair open in GRNI

WHT. GRN/BLU wire
Is there approx. 5 V ? between control unit
(018) and TA sensor.
YES

unit and recheck. lf symptom/ Turn the ignition switch ON.
Measure voltage between D14
( +) terminal and O 18 (-) termi-
nal.
Repair open in GRNI

YES RED, (LHD: REDIYEL,
Is there approx. 5 V ? GRNIRED) wire be·
tween control unlt
NO (D141 and TA sensor.
- Substituta a known-good con-

trol unit and recheck. lf
prescrlbed voltage is now
available, replace the original
control unit.
- Repairshort In GRN/RED(LHD:
RED/VEL. GRN/REDI wlre be-
tween control unlt (0141 and
TA sensor.
00000000
ºººººººº ºººººº ~ºº
014 (+) 018 (-)
LJ
SV?
11-47
TroubleshootingFlowchart-A/T Lock-up Control Solenoid Valve A/B
[D1584 (KQ CARB) Engine] A/T only)
@ Self-diagnosis LEO indicator indicates CODE 11: A problem in the A/T Lock-up Control Solenoid Valve A (or B) circuit.
Remove 8ACK UP fuse in the

under-hood relay box for 1 O se-
conds to reset control unit.
Test drive necessary.

Orive the car for several miles so
that the transmission upshifts and
downshifts several times.
NO lntermittent fallure (test drlve may

Does LED indicates CODE 11
be necessary).
YES
Connect the test harness to the

main harness only, not to the con-
trol unit (page 11-22).
LOCK-UP
CONTROL SOLENOID VALVE
the lock-up control solenoid valve.
A/B

*: Lock-up Control Solenoid Valve 8
or 86* and body groun.
YES Repalr short in YEL or GRN/BLK*

Does continuity exist ? wlre between control unlt (84 or
86*1 and the 2P connector.
NO
(To page 11-491
11-48
(To page 11-48)
Reconnect the 2P connector. ººººººººººº

Measure resistance between 84
or 86 * terminal and 82 terminal.
Check for continuity in YEL or

NO GRN/8LK * wire between control
Is there 15-22 O 7 unit (84 or 86*) and the 2P con-
YES nector.
Faulty lock-up control

YES solenold valve (section
Does continuity exist ?
14).
NO
Repair open in YEL or GRN/8LK*

wlre between control unlt (84 or
86*1 and the 2P connector.

unit and recheck. lf symptom/indi-
original control unit.
11-49
Input TroubleshootingFlowchart- Power Source (IG 1, Bat) and Ground
lnspection of Powar Source

(IG1, Bat) and Ground.

(page 11-22).
0000000000 02[1
Check for continuity between the

82
ººººººººººº -=
body ground and the following
terminals individually: • 82, • __L
021.
Repalr open in BLK/REO,
BRN/BLK wire between con-
NO trol unlt (021) and G101.
Ooas continuity exist 7
Repair open In BLK wire be-
YES tween control unit (821 and
G101.
12 V 7
01 (+) 0211-1
Measure voltage between O 1 ( + 1
terminal and 021 ( - ) terminal.
00000000
ººººººººº
Is there battery voltage ? lnspect BACK UP fusa.
YES
NO
Turn the ignition switch ON. Is BACK UP fusa OK 7 Replace fuse.
YES
Repairopen in WHT /BLU wire be-

tween BACK UP fusa and control
unlt (01).
021 1-)
00000000 0000000000
Measure voltage between 02 ( +)
terminal and 021 (-) terminal. ºººººººº ºººººººººº
021+)
12 V?
NO
Is there battery voltage ? Turn the ignition switch OFF.
YES
lnspect ACG (SI (15 A) fuse
Powar Source (IG1, Bat) and NO

Is ACG (SI (15 A) fuse OK ? Replace fuse.
Ground are OK.
YES
Repair open in BLK/YEL wlre be-

tween ACG IS) (15 A) fusa and
control unit (02)
11-50
Input TroubleshootingFlowchart - A/T Shift Position Signal {A/T only)
Thís signals the control unit when the transmission is in ~ , ~ , 1 D3 j or ~ .
lnspection of A/T Shift Position

Slgnal.
Tum the ignition switch ON.
Observethe A/T shift indieator and

select each position separately.
NO See A/T shift position indlcator in-

Does the indicator light properly 7
spection (section 23).
YES

the control unit and connector.
But disconnect D connector from
the wire harness only, not the 12 V ?
control unti (page 11-22).
011 (+) 021 (-l
00000000
Turn the ignition switch ON. 12 V?
00000000
Measure voltage between O 1 2

(+), 011 (+), 010 (+) terminal 010 (+)
and 021 ( - ) terminal.
Substituta known-good control

NO unlt and rachack. lf prescribed
Is there battery voltage ?
voltaga is now available, raplace
YES the original control unit.
Reconnect D connector to the wire

harness. OV?
011 (+) 021 (-)
Measure voltage between O 11

( +) terminal and 021 ( - 1 termi- ºººººººº
nal in (N] or CE] . ºººººººº
YES Repairopen in GRN wire between

Is there voltage ? control unit (D111 and combina-
tion meter.
NO
(To page 11-531
11-52
(To page 11-52)
12 V?
Measure voltage between O 11 1 1
( +) terminal and 021 ( - ) termi- 011 (+) 021 (-)
nal in ali other shift positions ex- 00000000
cept ffi] or !E] .
ºººººººº
NO Repairshort in GRNwire between
Is there battery voltage ? combination meter and control
unit (011).
YES
021 (-)
( +) terminal and 021 ( - ) termi-
nal in~. ºººººººº
OV?
YES Repalr open in GRNIBLKwire be-
Is there voltage ? tween control unit (012) and
combinatlon meter.
NO
021 (-1
Measure voltage between 012
( +) terminal and 021 ( - ) termi-
00000000
nal in all other shift positions ex-
cept ~.
ºººººººº 012 (+I
12 V?
NO Repalr short in GRN/BLK wlre be-

Is there battery voltage ? tween combination meter and
control unit (012).
YES
Measure voltage between O 1 O 00000000

( +) terminal and d21 ( - ) termi- 00000000
nal in~.
010 (+)
OV?
YES Repair open in GRNIBLU wire be-
Is there voltage ? tween control unit (010) and
NO combination meter.
021 (-1
Measure voltage between O 1 O
(+) terminal and 021 (-) termi- 00000000
nal in all other shift positions ex- 00000000
cept ~.
12 V?
NO Repalr short in GRNIBLUwire be-

Is there battery voltage ? tween combinatlon meter and
control unit (010).
YES
A/T Shlft Position Signal is OK.
11-53
Input TroubleshootingFlowchart - Clutch Switch Signal (M/T only)
This signals the control unit when the clutch is engaged.
lnspection of Clutch Switch

Slgnal.
Connectthe test harnessbetween

(page 11-22).

(+l terminal and D21 (-)
terminal.
12 V?
1 1
011 (+) 021 (-)
ºººººººº
ºººººººº
GRN
NO
Is there battery voltage ? Turn the ignition switch OFF.
YES

the clutch switch.

2 terminals on the clutch switch.
Depress the clutch pedal.
Replace the clutch

Does continuity exist ? switch.
NO
Repair short in GRN wire be-

tween control unit (011) and
clutch switch.
Substitute a known-good con-
prescribed voltage is now
control unit.
(To page 11-55)
11-54
(Frnm page 11-54)
OV?
011 (+) 021 (-)
00000000
ºººººººº
YES
Is there voltage ? Turn the ignition switch OFF.
NO

the clutch switch.
Connect GRN terminal to BLK

terminal.
NO Replace the clutch

Is there voltage ?
switch.
YES
Repair open in GRN wire be-

tween control unit (011) and
clutch switch.
Repalr open in BLK wire be-
tween clutch switch and
G401.
Clutch Switch Signal is OK.
11-55
Input Troubleshooting Flowchart - P/S Oil Pressure Switch Signal
[D1584 (KQ CARB) Engine]
The signals the control unti when the power steering load is high.
lnapection of PIS 011 Preaaure

Switch Signal.

(page 11-22).
OV?
05(+1 021 1-1
ºººººººº
Measure voltage between O 5 ( + )
terminal and 021 ( - 1 terminal.
ºººººººº
YES
Is there voltage 7 Tum the ignition switch OFF.
NO
Disconnect the 2 P connector on

the PIS oil pressure switch.
Connect BRN/REDterminal to BLK

terminal.
NO Replace the PIS oil

Is there voltage 7
preaaure switch.
YES
Repair open in BRN/RED wire

between control unit (051 and
P/S oil pressure swtich.
Repair open in BLK wlre be-
tween P/S oil pressure switch
and G301.
Tum steering wheel slowiy.
(To page 11-571
11-56
(From page 11-56)
1
12 V?
Measure voltage between 05 ( +) 051+) 0211-)
terminal and 021 ( - ) terminal
while steering wheel is turning. ºººººººº
00000000
NO
Is there battery voltege 7 Tum the ignition switch OFF.
YES

the P/S oil pressure switch.

2 terminals on the P/S oil pressure
switch.
YES Replace the P/S oil

Does continuity exist 1
pressure switch.
NO
Repair short in BRN/REOwire
between control unit (D5) and
P/S oil pressure switch.
Substituta a known-good con-
prescribed voltage in now
control unit.
P/S Oit Pressure Switch Signal

is OK.
11-57
Input Troubleshooting Flowchart - Air ConditioningSignal
This signals the control unit when the A/C switch is on.
lnspection of Air Conditioning

Signal.

(page 11-22). 89
Connect 89 terminal to 82
terminal.
NO Connect the 8LK/REDterminal of
BLKIBED-p
Doas A/C opérate ? the 4P connector on the A/C
clutch relay to body ground.
YES
Start angina. NO See Alr conditioner ln-

Does A/C opereta ?
spection (sectlon 22).
YES
81owarswitch ON.
Repalr open in 8LK/REO wire be-
tween control unit (89) and A/C
clutch relay.
00000000
00000000
08(+)
A/C switch ON.
NO
Measure voltage between DB ( + )
Does A/C operate ? terminal and D 21 ( - ) terminal.
YES
Air Conditioning Signal is OK.

NO Repalropen in 8LU/REO
Is voltage below 3 V ? wire between ECU (08)
and A/C switch.
YES

unit and recheck. lf prescribed
voltage is now avallable, replace
11-58
Input TroubleshootingFlowchart - Brake Switch Signal
· [D 1584 (KQ CARB) Engine]
This signals the control unit when the brake pedal is depressed
lnspection of Brake Switch Signa!.
Are the brake lights on without

YES lnspect the brake switch (sectlon
depressing the brake pedal 7 19).
NO
Depress the brake pedal.
NO lnspect STOP, HORN (20 Al fuse

Do the brake lights come on ?
(main fuse box).
YES
NO Replace fusa.
Is fuse OK 7
YES
lnspect the brake switch (sectlon

19).

the control unti and connector
(page 11-22).
(To page 11 -61 )
11-60
(To page 11-60)
00000000
ºººººººººº02~(-)
ºººººººº ºººººººººº022 (+)
(+) terminal and 021 (-)
terminal.
NO Repair open in GRN/WHT wire be-

Is there battery voltage ? tween the brake switch and con-
trol unit (022)
YES
Brake switch signal is OK.
11-61
Input Troubleshooting Flowchart WIPER/WASHER Switch Signal r INT")
1

This signal the control unit when the wiper/washer switch (INT) is ON.
lnspection of Wlper/Washer
Switch Signal IINTI.
Does the wiper/washer switch NO See the wlper/washer switch in-

(INT) operate properiy ? spection (sectlon 231.
YES

(page 1 1-22).
12 V 7
Turn the wiper/washer switch
03(+1 021 (-)
"INT".
00000000
00000000
Measurevoltage between D3 ( +)
terminal and D21 ( - ) terminal.
NO Repair open in YEL/BLU wire be-

Is there battery voltage ? tween the wiper/washer switch
and control unit 103).
YES
Wiper/Washer Switch Signal is

OK.
11-62
Carburetor
Symptom-to-Sub System Chart ------------------
[ 1-Carbureted Engine]
NOTE:
• Across each row in the chart, the sub systems that could be sources of a symptom are ranked in the order they should
be inspected, starting with G). Find the symptom in the left column, read across to the most likely source, then refer
to the page listed at the top of that column. lf inspection shows the system is OK, trv the next system @, etc.
• Before starting inspection, check that other items that affect engine performance are within specification. Check the
self-diagnosis indicator (PGM-CARB), valve clearance, air cleaner, and PCV valve. In addition, check the ignition tirn-
ing, function of the vacuum and centrifuga! advance, and the condition of the spak plugs. lf those items are ali within
specitications, begin with the troubleshooting listed in pages 11-64 and 11-65.
PAGE AIR VENT

AUTOMATIC
CUT-OFF
IDLE SPEED/ IDLE CHOKE/
DIAPHRAGM
MIXTURE BOOST FAST IDLE
SYMPTOM SYSTEM
FLOAT LEVEL
~ 104 70 119 115, 173
ENGINE WON'T START G)
DIFFICULT TO
WHEN COLO G) @
START ENGINE
WHEN WARM @
WHEN COLO FAST
IDLE OUT OF @ G)
SPECIFICATION
WHEN WARM
IRREGULAR
IDLING
ENGINE SPEED TOO G) @ @
HIGH
WHEN WARM
ENGINE SPEED TOO G) G)
LOW
ROUGH IDLE/
FLUCTUATION
G) @ @
FREQUENT
WHILE
WARMING UP
@ G)
STALLING AFTER
WARMING UP
G) @ @
MISFIRE OR ROUGH
RUNNING
G) G)
POOR LOSS OFF POWER @
PERFORMANCE
AFTERBURN G)
HESITATION/SURGE
11-64
PRIMARY
SLOW
SLOW VACUUM ACCELE-
POWER MIXTURE
AIR JET CONTROLLED RATOR
VAL VE CUT-OFF
CONTROL SECONDARY PUMP
SOLENOID
VAL VE
89 96 84 81 112
@ @
CD @
CD @
@ @
@
@
@ @
@ CD
CD CD
@
@ CD @
@ CD
11-65
Carburetor
Symptom-to-Sub System Chart -------------------
[2-Carbureted Engine]
NOTE:
to the page listed at the top of that column. lf inspection shows the system is OK, try the next system ®· etc.
self-diagnosis indicator, valve clearance, air cleaner, and PCV valve. In addition, check the ignition timing, function
of the vacuum and centrifuga! advance, and the condition of the spark plugs. lf those items are all within specifica-
tions, begin with the troubleshooting listed in pages 11-66 and 11-67.
PAGE SYSTEM CARBURETOR

AUTOMATIC AIR VENT
IOLE SPEEO/ A/C IDLE CHOKE/ CUT-OFF
MIXTURE BOOST FAST IOLE (INNER VENT)
SYSTEM SOLENOIO
SYMPTOM
VAL VE
~ 104 70 128 180, 182
ENGINE WON'T START CD

OIFFICULT TO
WHEN COLO CD @
START ENGINE
WHEN WARM @
WHEN COLO FAST
IOLE OUT OF
SPECIFICATION
CD
WHEN WARM
IRREGULAR
ENGINE SPEEO
TOO HIGH
CD @ ®
IOLING
WHEN WARM
ENGINE SPEEO
TOO LOW
CD CD
ROUGH IOLE/
FLUCTUATION CD ® @
FREQUENT
WHILE
WARMING UP
@ CD
STALLING
AFTER
WARMING UP CD @ @
MISFIRE OR
ROUGH RUNNING
@ CD
POOR
LOSS OFF
POWER
@
PERFORMANCE
AFTERBURN @
HESITATION/SURGE
11-66
CAR BU RETOR
PRIMARY
SLOW VACUUM ACCELER-
SLOW MIXTURE
POWER VALVE AIR JET PISTON ATOA
CUT-OFF
CONTROL CONTROL PUMP
SOLENOID VALVE
89 96 84 84 114
@ @
G) @
G) @
@
@
@
CD
CD CD
@
@ CD @
G)
11-67
Carburetor
System Description [1-Carbureted Engine]----------------.
The carburetor is a fixed venturi type of compact 2-barrel down draft with excellent fuel atomization characteristic. lt
has primary and secondary throttle bores, and fuel is supplied through the primary bore at normal driving speed while
it is supplied through both the primary and secondary bores at high driving speed.
This carburetor has three stories structure: choke valve is attached to air horn body of the upper side, venturi, float chamber
and accelerator purnp, choke housing are attached to mixing body of the middle, and primary and secondary throttle
valve, secondary diaphragm and pilot screw are attached to throttle body of the lower side.
SECONDARY
DIAPHRAGM
THROTTLE CONTROLLER
FAST IDLE UNLOADER
PRIMARY SLOW MIXTURE

A/C CUT-OFF SOLENOID VALVE
IDLE BOOST
THROTTLE
CONTROLLER
(A/C only)
11-68
System Description [2-Carbureted Engine]----------------.
This carburetor assembly consists of two side-draft carburetors, each Óf which has a variable venturi.
The variable venturi carburetors allow a smooth increase of engine speed and engine output due to the change in venturi
area in proportion to carburetor intake air flow rate.
CHOKE OPENER DIAPHRAGM
THERMOWAX VALVE
INNER VENT
SOLENOID VALVE
PRIMARY SLOW MIXTURE CUT-OFF

SOLENOID VALVE
ACCELERATOR
PUMP
THROTTLE CONTROLLER
TO ENGINE
AIR VENT CUT-OFF

SOLENOID VALVE
11-69
Carburetor
ldle Control System
Description
This system maintains a stable idle speed under different engine loads.
1-Carbureted Engine:
ldle control is accornplished using the A/C idle boost throttle controller.
2-Carbureted Engine: ·
ldle control is accomplished using two throttle controllers, the idle boost throttle controller and throttle controller.
The control unit monitors the inputs shown and directs voltage to the solenoid valves.
The A/C idle boost solenoid valve is energized

when the A/C compressor is energizad, applying vacuum to the A/C idle boost throttle controller.
when the A/C compressor is energized, releasing vacuum to the throttle controler.
The idle boost solenoid valve is energized (2-Carbureted Engine only)

when the headlights and blower switch is on, applying vacuum to the idle boost throttle controller.
(01382 EUROPE & KQ EngineJ
SPEED SENSOR 4------'1'------,
VACUUM CLUTCH SWITCH

A/C SWITCH ...... 02 SENSOR
IDLE BOOST o
a:
THROTTLE 9---'ll'--'l'-P} TW SENSOR
CONTROLLER !z02 !::
MA~ • {
U::>
\
SENSOR
A/C
SWITCH~--~
A/C
IDLE BOOST
SOLENOID VALVE
T
1
-'--
11-70
[01281. 01383 EXCEPT EUROPEand 01583 Engine]
I A/C IDLE BOOST

SOLENOID VALVE
DELA Y
CONTROL 1 A/C
UNIT j SIGNALS
A/C
IDLE BOOST
THROTTLE CONTROLLER
[01584 (KQ CAR8l EngineJ
A/C SPEED SENSOR

IDLE BOOST
THROTTLE .,.___ _,,....,J TW SENSOR
CONTROLLER 9------'N~ A/C SWITCH
CLUTCH SWITCH
~-~~ A/T SHIFT
POSITION
CONSOLE
SWITCH
a:
w
:e
:±~º
s: ~
=-= w 1-
<(
a: S:
CD
-
CL -
s:
(1)
ELD
-:¡:-
'
IDLE BOOST
1
SOLENOID
VALVE
11-71
Carburetor
ldle Control System [ 1-Carbureted Engine]
Testing 4. Check the idle speed with the A/C on.

1. Start the engine and warm up to normal operating
temperature (the cooling fan comes on). ldle speed should be:
2. Check the idle speed with headlights, heater blow-

er. rear window defogger, cooling fan and air con- Manual 800 ± 50 min-1 (rpm)
ditioner off. Automatic 1,000 ± 50 min-1 (rpm) ([]] or [e)
ldle speed should be:
• lf not, disconnect the vacuum hose (KY: # 20)
from the A/C idle boost throttle controller and
Manual 800 ± 50 min-1 (rpm) check the vacuum.
Automatic 1,000 ± 50 min-1 (rpm) 00 or [e)
There should be vacuum.
• lf OK, go to step 4.
- lf there is vacuum, check the throttle valve shaft
far binding or sticking and replace the A/C idle
• lf not, got to step 3.
boost throttle controller.
3. Disconnect the vacuum hose (KY: # 20) from the
- lf there is no vacuum, go to A/C idle boost sole-
A/C idle boost throttle controller and check the
noid valve troubleshooting (page 11-73).
vacuum.
There should be no vacuum.
,1'~,-_:-
VACCUM PUMP/ ¡: ( A/C
GAUGE IDLE BOOST
THROTTLE CONTROLLER
• lf there is no vacuum, check the throttle valve

shaft far binding or sticking and replace the A/C
idle boost throttle controller.
• lf there is vacuum, go to A/C idle boost solenoid
valve troubleshooting (page 11- 73).
11-72
Troubleshooting Flowchart A/C ldle Boost Sole- noid Valva
The A/C idle boost solenoid valve is energized when the A/C compressor is energized, applying vacuum to the diaphragm
of the idle boost throttle controller. This increases the idle speed when the A/C compressor is on.
lnspectlon of A/C ldle 8oost Sole- [KV] [Except KV]

noíd Valve
A/C HOLE
800ST SOLENOIOVAL VE A/C ILOE 800ST
SOLENOIOVALVE
'1'
Disconnect the lower vacuum
hose of the solenoid valve from
the joint and connect a vacuum
pump.
Disconnect vacuum hose (KY:

# 20) of the solenoid valve from
the vacuum hose manifold and
connect a vacuum gauge.
[KV]
Start the engine.
Apply vacuum. ·
[Except KV]
Is vacuum indicated on the >-Y_E_S__ --i

gauge?
NO
Disconnect the connector on the
Blower switch ON. solenoid valve.
Turn the A/C switch ON.

Start the engine.
Measure voltage between RED (01382 EUROPE& KQ

( +) terminal and BLK ( - l Engine]
terminal. Check the self-
dlagnosis lndlcator
(page 11-21 ). lf OK.
YES check the input trouble-
Is there voltage ?
shooting (page 11-26).
NO (01281, 01383 EX-
CEPT EUROPE and
01583 Engine]
Replace the solenoid valve.
(To page 11- 74) See Air Conditloner ln-
spection (section 21).
(cont'd)
11-73
Carburetor
ldle Control System [ 1-Carbureted Engine] (cont'd) -----------.
(From page 11- 73)
Is vacuum indicated on the >-N_O _, Turn the ignition switch OFF.

gauge?
YES
control box.
Start the engine.
Blower switch ON.

A/C ldle 8oost Solenoid Valva Is
OK.
Measure voltage between RED
( +) terminal and BLK ( - )
terminal.
YES Replace the solenoid

valva.
NO

( +) terminal and body ground.
Repair open in 8LK wlre

YES between the solenoid
Is there battery voltage?
valva and G201 (RHD:
NO G301).
[D 1281, 01383 EXCEPTEUROPE

and D 1583 Engine]
lnspect open in REO wira batween
the solenoid valva and delay con-
trol unit.
lf OK, sea Air Condltioner inspec-
tion (sectlon 21 1.
Check the self-diagnosis indicator
(paga 11-21 1. lf OK, inspect open
in REDwire between the solenoid
valva and control unit 1816).
11-74
ldleControl
System (2-Carburated Engine]----------------.
Testing
# 6 VACUUM HOSE
temperatura (the cooling fan comes on).
2. Check the idle speed with headlights, heater blow-

er, rear window defogger, cooling fan and air con-
ditioner off.
Manual 650 ± 50 min-1 (rpm)

Automatic 720 ± 50 mírr- (rpm) ([ID ar [e])
• lf OK, go to step 5. THROTTLE CONTROLLER

• lf not, go to step 3.
• lf there is vacuum, check the throttle valve shaft
3. Disconnect the # 20 vacuum hose at idle boost for bidningor sticking and replacethe throttle con-
throttle controller and check vacuum. troller.
• lf there is no vacuum, check the # 6, # 22 and
There should be no vacuum # 12 vacuum line for proper connection, cracks,
blockage ar disconnected hose. lf OK, go to the
A/C idle boost solenoid valve troubleshooting
(page 11-79).
5. Check the idle speed with headlights and heater

blower on.

Automatic 850 ± 50 min-1 (rpm) ([ID or [e])
• lf OK, go to step 7.
6. Disconnect the # 20 vacuum hose at idle boost

throttle controller and check vacuum.
IDLE BOOST THROTTLE CONTROLLER

shaft for binding or sticking and replace the idle
boost throttle controller.
• lf there is vacuum, go to idle boost solenoidvalve
(pag 11- 77).
4. Disconnect the # 6 vacuum hose at throttle con-

troller and check vacuum.
IDLE BOOST
THROTTLE CONTROLLER
(cont'd)
11-75
Carburetor
ldle Control System (2-Carbureted Engine] (cont'd) ----------
• lf there is vacuum, check the throttle valve shaft 9. Disconnect the # 6 vacuum hose at throttle con-
for binding or sticking and replace the idle boost troller and check vacuum.
throttle controller.
• lf there is no vacuum, check the # 20 and # 12 There should be no vacuum.
vacuum line for proper connection, cracks, block-
age or disconnected hose. lf OK, go to the idle # 6 VACUUM HOSE
boost solenoid valve troubleshooting (page
11-77).
7 .. · Check the idle speed with the A/C on.
Manual 780 ±50 min-1 (rpm)

Automatic 1,000 ± 50 min-1 (rpm) 00 or Ce])
8. Disconnect the # 20 vacuum hose at idle boost

THROTTLE CONTROLLER
throttle controller and check vacuum.
shaft for binding or sticking and replacethe throt-
# 20 VACUUM HOSE tle controller.
• lf there is vacuum, go to A/C idle boost solenoid
valve (page 11-79).
IDLE BOOST THROTTLE CONTROLLER
• lf there is vacuum, check the throttle valve shaft

for binding or sticking and replace the idle boost
throttle controller.
• lf there is no vacuum, check the # 20 and # 1 2
age or disconnected hose. lf OK, go to the idle
boost solenoid valve troubleshooting (page
11-77).
11-76
Troubleshooting Flowchart ldle Boost Solenoid Valve
The idle boost solenoid valve is energized when there is electric load on the engine, applying vacuum to the diaphragm
of the idle boost throttle controller. This increases the idle speed when the headlights and blower switch is on.
IDLE BOOST
lnspection of ldle Boost Solenoid
Valve. SOLENOID VAL VE
Open the control box.

hose of the solenoid valva from
pum p.
Disconnect # 20 vacuum hose of

the solenoid valve from the vacu-
um hose manifold and connect a
#20 HOSE !....
I
n VACUUM
PUMP/GAUGE
vacuum gauge.
Start the engine.
Apply vacuum.
Is vacuum indicated on the

gauge? Turn the ignition switch OFF.
NO

control box.
WHT/
GRN
Headlights and blower switch ON. Start the engine.
Measure voltage between

WHT/GRN ( +) terminal and BLK
( - ) terminal.
Check the self-

dlagnosis indicator
YES (page 11-21 l.
Is there voltage ?
lf OK. check the input
Apply vacuum. NO troubleshooting (page
11-28).
(To page 11-78) (cont'd)
11-77
Carburetor
ldleControl
System [2-Carbureted Engine]--------------
(From paqe 11- 77)
Is vacuum indicated on the NO

Y!:S
control box.
Start the engine.
Headlights and blower switch ON.

WHT/GRN (+)terminal and BLK
( - ) terminal.
ldle Boost Solenoid Valve is OK.

YES Replace the solenold
valve.
NO

WHT/GRN (+)terminal and body
ground.

YES Repair open in BLK wire
between the solenoid
NO valve and G301.

(page 11-21 l. lf OK. inspect open
in WHT/GRN wire between the
solenoid valve and control unit
(815).
11-78
Troubleshooting Flowchart A/C ldle Boost Solenoid Valve
The A/C idle boost solenoid valve is energized when the A/C compressor is energized, applying vacuum to the diaphragm
of the throttle controller. This increases the idle speed when the A/C compressor is on.
A/C IDLE
lnspection of A/C ldle Boost Sole- BOOST SOLENOID
noid Valve VALVE

pump.
Disconnect # 22 vacuum hose of

the solenoid valve from the vacu- #22 VACUUM
um hose manifold and connect a HOSE
vacuum gauge.
Start the engine.
Apply vacuum.
BLK
Is vacuum indicated on the >'-'N~º'----1

YES
Blower switch ON. Disconnect the connector on the

control box.

Start the engine.

( +) terminal and BLK ( - )
terminal.
Check the self-
diagnosis indicator
YES (page 11-211.
Is there voltage ?
lf OK, check the input
NO troubleshooting (page
11-281.
(To page 11-80) (cont'dl
11-79
Carburetor
ldle Control System [2-Carbureted Engine] (cont'd)
(From page 11- 79)
YES
Is vacuum indicated on the gauge ? Turn the ignition switch OFF.
NO

control box.
Start the engine.
Blower switch ON.

A/C ldle Boost Solenoid Valve is
OK.
( + ) terminal and BLK ( - ) termi-
nal on the control box.

valve.
NO

( +) terminal and body ground.

Is there battery voltage ? between the solenoid
valve and G301.
NO

(page 11-21). lf OK, inspect open
in RED wire between the solenoid
valve and control unit (816).
11-80
Vacuum Controlled Secondary
[1-Carbureted Enginel-----------,
Description
This system is designed to control vacuum bypass into the air cleaner to keep the secondary throttle valve closed in
order to improve drivability when the engine is cold.
[D1382 EUROPE & KO Engine]
SECONDARY / MAP
SENSOR
{
.....
o
a:
SPEED SENSOR
TW SENSOR
DIAPHRAGM
A/C SWITCH
!z t::
oz
pq VACUUM {
SWITCH
(.) ::,
CLUTCH
SWITCH
02 SENSOR
AIR LEAK
SOLENOID VAL VE
AIR FILTER -
...
l
_L
(01281, 01383 EXCEPT EUROPEand 01583 Engine]
11-81
Carburetor
Vacuum Controlled Secondary [ 1-Carbureted Engine] (cont'd) ------
Testing
[01281, 01383 EXCEPTEUROPEand 01583 • lf it holds vacuum, check the vacuum line for
Engine] proper connection or cracks. lf OK, replace the
1. Disconnect the secondary diaphragm vacuum hose thermovalve.
and attach a spare piece of hose between the
diaphragm and a vacuum pump. 4. Start the engine and warm up to normal operating
temperature (the cooling fan comes on).
2. Open the throttle valve fully and apply a vacuum.
Check the diaphragm rod moves as vacuum is 5. Apply vacuum.
applied and that the vacuum then remains steady. lt should hold vacuum.
• lf it does not hold vacuum, check the vacuum line

for proper connection, blockage or disconnected
hose. lf OK, replace the thermovalve.
6. Disconnect the vacuum hose from the 3-way joint

and connect to a vacuum pump/gauge.
Apply a vacuum.
lt should not hold vacuum.
SECONDARY DIAPHRAGM
• lf the vacuum does not hold or the rod does not

move, first check the hose for proper connection
and condition, then replace the diaphragm and
recheck.
3. Disconnect the vacuum hose from the 3-way joint,

connect a vacuum pump and apply vacuum. • lf vacuum does not hold, test is complete.
NOTE: The engine coolant temperature must be • lf vacuum is held, check the hose, the 3-way joint
below 60ºC (140°F). and clean the vacuum port.
lt should not hold vacuum.
11-82
Testing
(01382 EUROPE & KQ Engine) • lf there is vacuum, check the vacuum line (airfilter
and 3-way joint) proper connection or blockage.
1. Disconnect the secondary diaphragm vacuum hose lf OK, go to the air leak solenoid valve
and attach a spare piece of hose between the troubleshooting {page 11-85).
diaphragm and a vacuum pump.
2. Open the throttle valve fully and apply a vacuum. temperature (the cooling fan comes on).
Check the diaphragm rod moves as vacuum is
applied and that the vacuum then remains steady. 5. Reconnect the vacuum hose to the secondary
diaphragm.
6. Raise the engine speed to 5,000 min-1 (rpm), then

clase the throttle suddenly.
And then check the secondarydiaphragmfor smooth
movement.
• lf not. check the vacuum line for proper connec-

tion, cracks or disconnected hose. lf OK, go to
the air leak solenoid valve troubleshooting (page
11-85).
SECONDARY DIAPHRAGM
• lf the vacuum does not hold or the rod does not

move, first check the hose for proper connection
and condition, then replace the diaphragm and
recheck.
3. Disconnect the secondary diaphragm vacuum hose

and connect a vacuum pump. Check vacuum.
NOTE: The engine coolant temperature must be
below 65°C (149ºF)
11-83
Carburetor
Slow Air Jet Control System --------------------
Description
To maintain optimum air-fuel ratio, the slow air jet control system controls air flow into the primary jets of the carburetor
throats. When the car is being started, or running in the power mode, the control unit energizes the air leak solenoid
valve [01584 (KQ CARB) Engine: in the air cleaner) to close the extra air passage, increasing fuel flow.
n:=::::,:::::;;aJ~ f---, SLOW

AIR
SPEED SENSOR
JET
MAP
{ ..., ..,_.___Jf..__,"--
o TW SENSOR
SENSOR ,X: O-----'l'--.11'.1"'
A/C SWICH ~!=
VACUUM{
oz
(.)::,
SWITCH
02 SENSOR -...,~~
AIR LEAK
SOLENOID VAL VE
AIR
-=-
-r-
1
FILTER -'-
[D 1584 (KQ CARBI Engine]
SPEED SENSOR
A/C SWITCH
AIR LEAK TW SENSOR
SOLENOID
02 SENSOR
VAL VE
CLUTCH
SWITCH
T
1
--'-
11-84
Troubleshooting Flow Chart Air Leak Solenoid Valve
The air leak solenoid valve is energized when the car is being started, or running in the power mode, to close the extra
air passage, increasing fuel flow. ·
[01382 EUROPE & KO Engine]
lnspection of Air Leak Solenoid

Valve.
Disconnect the # 2 vacuum hose

from the carburetor and connect
a vacuum pump, then cap the car- #2 VACUUM
buretor. HOSE
Disconnect the # 21 vacuum VACUUM

hose from the vacuum hose PUMP/GAUGE
manifold and connect a vacuum
pump, then cap the vacuum hose AIR LEAK
manifold. SOLENOID VALVE
Start the engine and apply vacu-

um to the # 21 vacuum hose wi-
thin 1 O seconds.
Start the engine and warrrr up to

normal operating temperature (the
cooling fan comes on).
Apply 100 mm Hg (4 in. Hg) vacu-

um to the # 2 hose. ~
BLK BLU/
GRN
Does solenoid valve hold vacuum

when ralease the vacuum # 21 ...N_O__ ___.. Turn the ignition switch OFF.
hose?
YES
control box.

um to the # 21 hose within 1 O
seconds.

BLU/GRN ( +) temrinal and BLK
(-) terminal.
(To page 11-86) (To page 11-86) (cont'd)
11-85
Carburetor
SlowAirJet Control
System (cont'd)----------------
(From page 11-85) (From page 11-85)
Is there battery voltage when Replace the solenoid

release the vacuum # 21 hose ? valve.
Apply vacuum to the # 21 hose.
NO

BLU/GRN ( +) terminal and body
ground.
Repairopen In BLKwire
Is there battery voltage when between the solenold
ralease the vacuum # 21 hose ? valve and G201 (RHD:
G301).
NO
Check the self-diagnosisindicator

(page 11-21 ) . lf OK. inspect open
in BLU/GRN wire between the
solenoid valve and control unti
(811).
Apply 100 mmHg (4 in.Hg) vacu-

um to the hose.
Does solenoid valve hold YES

vacuum? Turn the ignition switch OFF.
NO

control box.

um to the # 21 vacuum hose
within 1 O seconds.

BLU/GRN ( +) terminal and BLK
( - ) terminal.
Check the self-

YES diagnosis indlcator
Is there voltage ? (page 11-21).
lf OK. check the input
Air Leak Solenoid Valve is OK. NO troubleshooting (page
11-26).
11-86
Troubleshooting Flow Chart Air Leak Solenoid Valve
The air leak solenoid valve is energized when the car is being started, or running in the power mode, to close the extra
air passage, increasing fuel flow.
(01584 EUROPE (KQ CARB) Engine]
lnspection of Air Leak Solenoid

Valve.

a vacuum pump, then cap the car-
buretor.
VACUUM
PUMP/GAUGE
Disconnect the # 21 vacuum
hose from the vacuum hose
manifold and connect a vacuum
pump, then cap the vacuum hose
manifold.

within 1 O seconds.
Start the engine and warm up to

normal operatingtemperature (the
Hold engine of 2,000 min-1

(rpm).
Apply 100 mm Hg (4 in.Hg) vacu-

um to the # 2 hose.
Does solenoid valve hold NO

vacuum ? Turn the ignition switch OFF.
YES
Disconnect the 3P connector near
the air cleaner.

um to the # 21 hose within 1 O
seconds.
Hold engine at 2,000 min r !

(rpm).

BLU/YEL ( +) terminal and body
ground.
11-87
Carburetor
SlowAirJet Control
System (cont'd)------------------.
Check the self-

dlagnosls lndicator
(page 11-21). lf OK.
Is there battery voltage ? repair open in BLUNEL.
BLU/GRNwlre between
YES
the solenoid valve and
control unti (B 11 ) .
Replace the solenoid valva.
Does solenoid valve hold vacuum

YES
when release the vacuum # 21 Turn the ignition switch OFF.
hose?
NO

the air cleaner.

within 1 O seconds.
Hold engine of 2,000 min - 1

(rpm).

BLU/YEL ( + ) terminal and BLK
( - ) terminal.
Check the self-

diagnosis indicator
Air leak solenoid valve is OK.
(page 11-21). lf OK.
Is there battery voltage when YES
substituta a known-
ralease the vacuum # 21 hose ?
good control unit and
NO retest. lf symptom goes
away. replace the origi-
nal control unit.
Replace the solenold valva.
11-88
Power Valve
Description
This system is provided to supply supplementary fuel into the prirnarv main fuel passage when the vehicle is operated
in the power mode.
In normal driving modes other than acceleration, manifold vacuum is applied on the diaphragm of the power valve and
the valve is closed. When the throttle valve is suddenly opened to accelerate the vehicle, the power valve opens because
of the decreased manifold vacuum and supplies additional fuel to the primary main fuel passage through the power jet,
providing smooth acceleration performance.
(01382 EUROPE& KQ and 01584 (KQ CAR8) Engine]
When the power valve control solenoid valve is activated by the control unit, the power valve is opened because the
solenoid valve does not allow vacuum to act on the power valve.
6-1---'1'--,;-. SPEED SENSOR

MAP {
SENSOR _....,,.__,,..} TW SENSOR
POWERVALVE
CONTROL 6--~~~VACUUM
SOLENOID SWITCH
VALVE
POWER TO
VAL VE INTAKE
MANIFOLD
--=-
-r
~1
J_
(01281, 01383 EXCEPT EUROPEand 01583 Engine]
THERMO VAL VE
TO
INTAKE
MANIFOLD
POWER
VALVE
(cont'd)
11-89
Carburetor
Po~er ~alve (cont'd)~~~~~~~~~~~~~~~~~~~~~~~
[D1584 (KQ CARB) Engine]
POWER VALVE
CONTROL
SOLENOID
VAL VE
<>----~} TW SENSOR
o----~ VACUUM SWITCH
T
1
_J_
TO INT AKE MANIFOLD
11-90
Power Valve
[1-Carbureted Engine]------------------
Testing • lf not. check the # 14 and # 1 2 vacuum fine for

[01382 EUROPE & KO Engine] proper connection, cracks, blockage or discon-
1. Disconnect the # 14 vacuum hose from the vacu- nected hose. lf OK, go to the power valve con-
um hose manifold and connect a vacuum pump. trol solenoid valve troubleshooting (page 11-94).
Apply vacuum and listen for a clicking noise from
the power valve. 4. Warm up to normal operating temperature (the cool-
ing tan comes on).
¡AUGE
VACUUM
PUMP/ 5. Check the vacuum.
#14 VACUUM
HOSE
• lf not, check the # 14 and # 1 2 vacuum fine for

proper connection, cracks, blockage or discon-
nected hose. lf OK, go to the power valve con-
trol solenoid valve troubleshooting (page 11-90).
• lf a clicking sound is heard, go on to step 2.

• lf no sound is heard, replacethe power valve and
retest.
2. Disconnect the # 14 vacuum hose from the carbu-

retor and connect a vacuum gauge to the hose.
#14 VACUUM
HOSE
3. Start the engine and check the vacuum.

There should be no vacuum for about 3 seconds
after the engineis started. And there should be vacu-
um within 15 seconds after the engine is started.
NOTE: The engine coolant temperature must be be-

low 30ºC (86°F) (cont'd)
11-91
Carburetor
Power Valve [1-Carbureted Engine] (cont'd} ---------------.
Testing • lf there is vacuum, check the vacuum hose for

[01281, 01383 EXCEPTEUROPEand 01583 Engine] proper connection. lf OK, replace the ther-
movalve.
1. Disconnect the # 14 vacuum hose from the vacu-
um hose manifold and connect a vacuum pump.
4. Warm up to normal operating temperature (the cool-
Apply vacuum and listen for a clicking noise from
ing fan comes on).
the power valve.
5. Check the vacuum.
#14 VACUUM
HOSE There should be vacuum.
• lf there in no vacuum, check the # 14 and # 18

age or disconnectedhose. lf OK, replacethe ther-
movalve.
• lf a clicking sound is heard, go on to step 2.
• lf no sound is heard, replace the power valve and

retest.
2. Disconnect the # 14 vacuum hose from the carbu-

retor and connect a vacuum gauge to the hose.
#14 VACUUM
HOSE

below 30°C (86ºF)
11-92
Power Valve
(2-Carbureted Engine]-------------------,
Testing • lf not, check the # 14 and # 1 2 vacuum line for
1 . Disconnect the # 14 vacuum hose from the vacu- proper connection, cracks, blockage or discon-
um hose manifold and connect a vacuum pump. nected hose. lf OK, go to the power valve con-
Apply vacuum. trol solenoid valve troubleshooting (page 11-94).
lt should hold vacuum. 4. Warm up to normal operating temperature (the cool-

ing tan comes on).
5. Check the vacuum.
• lf not, check the # 14 and # 1 2 vacuum line for

nected hose. lf OK, go to the power valve con-
trol solenoid valve troubleshooting (page 11-94).
• lf it does not hold vacuum, replacethe diaphragm

and retest (page 11-133).

um hose manifold, and connect a vacuum
pump/gauge to the manifold.

There should be no vacuum for about 3 seconds
after the engine is started. And there should be vacu-
um within 15 seconds after the engine is started.

below 30°C (86°F).
(cont'd)
11-93
Carburetor
Power Valve (cont'd)~~~~~~~~~~~~~~~~~~~~~~~
Troubleshooting Flowchart Power Valve Control Solenoid Valve
The power valve control solenoid valve is energized when the car is being started or engine coolant temperature is cold.
[01382 EUROPE& KO Enginel [01584 (KO CAR8l Engine]

lnspection of Power Valva Control
Solanoid Valve.

pump.
POWER VALVE
Disconnect # 14 vacuum hose of CONTROL
the solenoid valve from the vacu- SOLENOID VALVE
um hose manifold and connect a
vacuum gauge.
Start engine.
Apply vacuum for about 3 se-

conds after the engine is started.
[01584 IKO CAR8) Engine]

Is vacuum indicated on the YES
gauge?
NO
control box.

BLU/WHT ( + ) terminal and BLK
Warm up engine to normal oper-
( - ) terminal for about 3 seconds
ating temperature (cooling fan
after the engine is started.
comes on).
YES Raplaca tha solanoid

valva.
NO

BLU/WHT ( + l terminal and body
ground.
Rapairopen in BLK wire

YES batween the solanoid
valve and G201 (RHD:
NO G3011.
(To page 11-95) Check the salf-diagnosis indicator

(page 11-211. lf OK, inspect open
in BLU/WHT wire batween the
solenoid valva and control unit
(813).
11-94
(From page 11-94)
Is vacuum indicated on the NO

gauge ? Turn the ignition switch OFF.
YES
control box.
Power Valve Control Solenoid
Vale is OK.
Start the engine.

BLU/WHT ( +) terminal and BLK
( - ) terminal.
Check the self-
diagnosis indicator
(page 11-21). lf OK,
Is there voltage ? substitute a known-
good control unit and
NO retest. lf symptom goes
away, replace the origi-
nal control unit.
11-95
Carburetor
Primary
Slow Mixture Cut-off Solenoid
Valve----------------.
Description
This system is designed for fuel economy and to prevent the catalytic converter from over-heating caused by unburned
fuel when decelerating the vehicle.
The primary slow mixture cut-off solenoid valve is provided to cut-off the idle mixture passage upstream of the bypass
port to prevent the engine from running on after the ignition switch is turned off.
This solenoid valve also functions to stop the mixture flow from the slow fuel system during vehicle deceleration in order
to save the fuel consumption. When the vehicle is decelerating, the control unit identifies the condition and deactivates
the solenoid valve to clase the mixture passage.
[01382 EUROPE& KO Engine]

SPEED SENSOR
CONTROL 0--.J!'-~-'I'-· CLUTCH SWITCH

l.:51--+---1'-Q UNIT } TW
SENSOR
PRIMARY SLOW
MIXTURE CUT -OFF MAP {
SOLENOID VALVE SENSOR
~====::J
A/C
SWITCH
T
1
-L
l
9-4--~r-.- SPEED SENSOR

o--,,--~- A/C SWITCH
o------'H~ } TW SENSOR
o----~r-.- WIPER/WASHER
SWITCH
CLUTCH SWITCH 4-...4-,f,._':9"4-'¡t""°'

BRAKE SWITCH
A/T SHIFT POSITION 4---1'-+----'
CONSOLE SWITCH
/=
T
1
..L.
l
PRIMARY SLOW
MIXTURE CUT -OFF
SOLENOID VAL VE
11-96
Primary Slow Mixture Cut-off Solenoid Valve [1-Carbureted Engine]--- ....
Troubleshooting Flowchart Primary slow Mixture Cut-off Solenoid Valve
The primary slow mixture cut-off solenoid valve is provided to cut-off the idle mixture passage between the fuel/air
passage and bypass port for preventing run-on when the ignition switch is turned off.
The solenoid valve also functions to cut-off the mixture flow under deceleration.
lnspection of Primary Slow Mix-

ture Cut-off Solenold Valve.
Check the clicking sound of sole-

noid valve.
PRIMARY SLOW
CUT-OFF SOLENOID VALVE
Ooes the solenoid valve click ? Turn the ignition switch OFF.
YES
Oisconnect the 2P con-
nector.

BLK/YEL ( + l terminal and body YEL
ground.
YES
Is there battery voltage ? Replace the solenoid
valve.
NO
Repalr open In BLK/YEL,

GRN/YEL wlre between the
solenoid valve and control
unit (87).
Start the engine and warm up to Check the self-diagnosis in-
normal operating temperature (the dicator (page 11-21). lf OK,
cooling tan comes on). check the input
troubleshootlng (page
11-26).
(To page 11-98)

(cont'dl
11-97
Carburetor
Primary Slow Mixture Cut-off Solenoid Valve [1-Carbureted Engine]1----
(cont'd)
(From page 11-97)
Raiseengine speedto 5,000 min-1

(rpm) and close the throttle sud-
denly.
NO
Does the solenoid valve click 7 Turn the ignition switch OFF.
YES
1
Disconnect the 2P connector.
Start the engine.
Raiseengine speedto 5,000 min-1

(rpm) and close the throttle sud-
denly.
Mea su re voltage between

BLK/YEL ( + l terminal and body
ground.
Check the self-
1 diagnosis indlcator
NO (page 11-21).
Is there no voltage for a moment 7
lf OK, check the Input
I YES troubleshooting (page
11-26).
Replace the solenoid valva.
Primary Slow Mixture Cut-off
Solenoid Valva is O K.
11-98
Troubleshooting Flowchart Primary Slow Mixture Cut-off Solenoid Valve
[01281, 01383 EXCEPT EUROPE and 01583 Enginel

ture Cut-off Solenoid Valve.
Check the clicking sound of

solenoid valve.
PRIMARY SLOW
Does the solenoid valve click ? Turn the ignition switch OFF.
YES
Disconnect the 2P connector.

BLK/YEL ( + ) terminal and body
ground.

valve.
NO
Repair open or short in BLK/YEL

wire between the 2P connector
and the ignition switch as well as
ACG(S) fuse.
Primary Slow Mixture Cut-off

Solenoid Valve is OK.
(cont'd)
11-99
Carburetor
· Primary Slow Mixture Cut-off Solenoid Valve [1-Carbureted Engine]
(cont'd)
Replacement 4. Connect the respective terminals to a new connec-
tor and install a new terminal retainer.
1. Remove the 2P connector, and open the harness NOTE:
clamp on the idle controller bracket. Disconnect the • Be sure to connect the terminal before installing
solenoid valve harness from the clamp. the terminal retainer.
CAUTION: Take care not to apply excessive force • Replacethe connector and terminal retainer with
on the clamp at it is broken easily. the new ones.
• Note the location ot the terminal.
PRIMARV SLOW MIXTURE

PRIMARY SLOW
MIXTURE CUT-OFF
SOLENOID VALVE
5. Secure the harness with the clamp as shown in the

drawing.
2. Disconnect the terminal retainer from the connec-

tor and remove the two terminals.
3. Replace the solenoid valve.
11-100
PrimarySlow Mixture Cut-off SolenoidValve [2-Carbureted Engine]-----
Troubleshooting Flow Chart Primary Slow Mixture Cut-off Solenoid Valve
The primary slow mixture cut-off solenoid valve is provided to cut-off the idle mixture passage between the fuel/air pas-
sage and bypass port for preventing run- on when the ignition switch is turned off.
The solenoid valve also functions to cut-off the mixture flow under deceleration.
PRIMARY SLOW MIXTURE

ture Cut-off Solenold Valve
Check the clicking sound of each

solenoid valva by means of a
stethoscope.
NO
Does the solenoid valve click 7 Turn the ignition switch OFF.
YES
Connect the test harness B be-

tween the control unit and con-
nector (page 11-22).
Start the engine and warm up to Right solenoíd valve: Measure vol-
tage between 87 (+)terminal and Right solenoid valve:
normal operating temperature (the
82 ( - ) terminal. Repair open or short in
cooling tan comes on).
left solenoid vavle: Measure vol- YEL, GRN/YEL wire be-
tage between 88 ( + ) terminal and tween the solenoid
82 ( - ) terminal. valve and control unlt
187). lf OK, replace the
solenoid valve.
Left solenold valve:
YES
Repair open or short in
Is there battery voltage ? GRN/RED RED/GRN,
wire between the sole-
NO noid valve and control
unit (88). lf OK. inspect
open in BLK wire be-
Check the self-diag11osisindicator
(page 11-21). lf OK. check the in- tween the solenoid
put troubleshooting (page 11-28). valve and G101. and
replace the solenoid
valve.
82...!..=..l.JIB (+I
(To page 11-102)
12 V? (cont'd)
11-101
Carburetor
Primary Slow Mixture Cut-off Solenoid Valve (2-Carbureted Engine] ----
(cont'd)
(From page 11-101)
•
Raise engine speed to 5,000
rninr "(rpm) and e lose the
throttle suddenly.
NO
Does the solenoid valve click ? Turn the ignition switch OFF.
YES
Connect the test harness B be-

tween the control unit and con-
Start the engine.
Raise engine speed to 5,000

min-1 (rpm) and e lose the
throttle suddenly.
Right solenoid valve: Measure vol-

tage between 87 ( +) terminal and
B2 ( - ) terminal.
Left solenoid valva: Measure vol-
Primary Slow Mixture Cut-off tage between B8 ( +) terminal and
Solenoid Valve is OK. B2 ( - ) terminal.
Check the self-
diagnosis indicator
(page 11-21 ).
NO
Is there no voltage far a moment ? lf OK, check the input
troubleshooting (page
YES 11-28).

1
11-102
Replacement 5. Connect the respective terminals to a new connec-
1. Removethe 3P connector and cut the harnessband. tor and install a new terminal retainer.
NOTE:
• Be sure to connect the terminal before installing
the terminal retainer.
• Replacethe connector and terminal retainer with
the new ones.
• Note the location of the terminal.
GRN/
BLK RED
HARNESS
BAND
SOLENOID TERMINAL RETAINER
VALVE
(RIGHTl
2. Remove the carburetor (page 11-137).
3. Disconnect the terminal retainer from the connec- 6. Securethe harness with the calmp as shown in the
tor and remove the terminals. drawing and use the harness band to hold the two
harnessestogether.
CONNECTOR
TERMINAL RET AINER

(Replace)
4. Replacethe solenoid valve.
11-103
Carburetor .
ldle
Speed/Mixture----------------------~
CD 1382 Engine (KS)J 4. Turn the ignition switch OFF. Restart the engine and
lnspection/ Adjustment hold engine at idle for 2 minutes. And hold engine
at 3,000-3,500 rnirr" (rpm) for 1 minute.
Propane Enríchment Method Check idle speed with the headlights, heater blow-
er, rear window defogger, cooling tan and air con-
fMHéfolN Do not smoke during thís procedure, ditioner off.
Keep any open flame away from your work area.
ldle speed should be: 800 ±50 min-1 (rpm)
NOTE:
• This procedure requires a propane enrichment kit.
• Check that the self diagnosis indicator before
making idle speed and mixture inspections.

temperature (the cooling tan comes twice).
2. Disconnect the # 8 vacuum hose from the intake air

control diaphragm and clamp the hose end.
THROTTLE STOP
SCREW
Adjust the idle speed, if necessary, by turning the

throttle stop screw.
NOTE: lf the idle speed is excessively high, check
the throttle control system (page 11-163).
INT AKE AIR CONTROL
DIAPHRAGM 5. Disconnect the 2P connector from the EACV and dis-
connect the hose from the EACV, then cap the
EACV.
3. Connect a tachometer.
CAP
TACHOMETER
TACHOMETER ·coNNECTOR
EACV
RUBBER
CAP
11-104
6. Disconnect the # 2 vacuum hose from the carbure-
tor, then cap the carburetor.
o Maximum Engine Speed
o
CAP
o
.... I
lf
~
o
o Full
PROPANE VOLUME
Engine speed increase should be: 20 ± 10 min-1

(rpm)
#2 VACUUM HOSE • lf engine speed does not increase per specifica-

tion, mixture is improperly adjusted. Go to step
10.
7. Disconnect air cfeaner intake tube from air intake • lf engine speed increases per specification, go to
duct. step 14.
8. fnsert the hose of the propane enrichment kit into 1 O. Remove the air cleaner and close the propane con-
the intake tube about 1 O cm. trol valve.
NOTE: Check that propane bottfe has adequategas 11. Remove the mixture adjusting screw hole cap.
before beginning test.
MIXTURE ADJUSTING
SCREW HOLE CAP
PROPANE ENRICHMENT
KIT
9. With engine idling, depress push button on top of

propane device, then slowly open the propane con-
trol- valve to obtain maximum engine speed.
Enginespeed should increase as percentage of pro-
pane injected goes up.
NOTE: Open the propane control valve slowly; a

sudden burst of propane may stall the engine. (cont'd)
11-105
Carburetor
ldle
Speed/Mixture
(cont'd)-------------------
12. Start engine and warm up to normal operating tem- (01281, 01383 EXCEPTEUROPE,01382 EUROPE&
perature; the cooling tan will come on. KQ (Except KS) and 01583 Engine]
13. Reinstall the propane enrichment kit and recheck CO Meter Method
maximum propane enriched engine speed.
fMHV@N Do not smoke during this procedure. Keep
• lf the propaneenriched speed is too low, mixture any open flame away from your work area.
is too rich: turn the mixture screw 1 /4-turn clock-
NOTE: Check that the self-diagnosis indicator before
wise and recheck.
making idle speed and mixture inspections [D 1 382 EU-
• lf the propane enriched speed is too high, mix-
ROPE & KQ (Except KSI Engine].
ture is to lean: turn the mixture screw 1 /4-turn
counterclockwise and recheck.
1. Start the engine and warm it up to normal operating
temperature (the cooling fan comes twice).
14. Close the propane control valve speed and remove
the BACK UP fuse for 1 O seconds to reset control
unit. Recheck idle speed.
[LHO]
ldle speed should be: 800 ±50 min-1 (rpml
TACHOMETER
• lf idle speedis as specified (step 4), go to step 15.
• lf idle speed is notas specified, adjust by turning
throttle stop screw, then repeat steps 1 3 and 14.
1 5. Remove propane enrichment kit and reconnect air

cleaner intake tube on the air intake duct.
1 6. Reinstall the mixture adjusting screw hole cap.
17. lf equippedwith air conditioner, check the idle speed

with the A/Con.
ldle speed should be: 800 ±50 min+ ! (rpml

BATTERY
RUBBER CAP
[RHO]
TACHOMETER
RUBBER
Adjust the idle speed, if necessary, by turning the CAP TACHOMETER
CONNECTOR
adjusting screw.
11-106
3. Turn the ignition switch OFF. Restart the engine and 6. [D1382 EUROPE& KQ (Except KS) Engine]
hold engine at idle for 2 minutes. And hold engine Disconnect the # 2 vacuum hose from the carbure-
at 3,000-3,500 mirr ' (rpm) for 1 minute. tor, then cap the carburetor.
Check idle speed with the headlights, heater blow-
er, rear window defogger, cooling fan and air con-
ditioner off. CAP

Automatic 1,000 ± 50 min-1 (rpm) ( [0 or [IJ)
# 2 VACUUM HOSE
7. [D1382 EUROPE& KQ (Except KS) Engine]

Disconnect the 2P connector from the EACV and dis-
connect the hose from the EACV, then cap the
THROTTLE STOP EACV.
SCREW

throttle stop screw.
the throttle control system (page 11-163).
4. Calibrate the NDIR CO Meter in accordance with the

manufacturer's recommended procedures.
lnsert exhaust gas sampling probe into the tailpipe
at least 40 cm.
5. Turn the ignition switch OFF. Restart the engine and

hold engine at idle for 2 minutes. And hold engine
EACV
at 3,000-3,500 rnírr ' (rpm) for 1 minute.
Check specification for idle CO with cooling fan, air
conditioner OFF and headlights OFF.
Specified COo/o: below 0,2%
• lf idle CO is as specified, go to step 13.

• lf not, go to step 6 through 12.
(cont'd)
11-107
Carburetor
ldle
Speed/Mixture (cont'd)--------------------
8. [01382 EUROPE& KQ (Except KSI Englne] [01281, 01383 EXCEPTEUROPEand 01583
Disconnect the wire harness from the 02 sensor. Engine]
HOLE CAP
- Turning mixture adjusting screw

02 SENSOR
clockwise: CO reading decreases
counterclockwise: CO reading increases
9. (01382 EUROPE& KQ (Except KS) Engine]
Turn the ignition switch OFF. Restart the engine and Readjustidle speed if necessary, and recheck idle
hold engine at idle for 2 minutes. and hold engine co.
at 3,000-3,500 rnirr ' (rpm) for 1 minute.
Check specification for idle CO. 11. [O1382 EUROPE& KQ (Except KS) Engine]
Reconnect the connector and hose.
Specified CO%: 2.5 ± 0.5% Remove BACK UP fuse for 1 O seconds to reset con-
trol unti.
• lf not, specification, go to step 1 O.
1 2. CD 1382 EUROPE& KQ (Except KS) Engine]
Turn the ignition switch OFF. Restart the engine and
1 O. Remove mixture adjusting screw hole plug and hold enqine at idle for 2 minutes. And hold engine
adjust by turning mixture adjusting screw to ob- at 3,000-3,500 mirv ' írprn) for 1 minute.
tain proper CO reading. Recheck idle CO.
(01382 EUROPE& KQ (Except KS) Engine] Specified CO%: 0.2%
• lf idle CO is as specified, go to step 1 3.

• lf not, check the self-diagnosis indicator (page
11-21 ). lf not, inspect the EACV {page 11-1591
and the catalytic converter {page 11-156), then
repeat step 6.
13. Recheck idle speed.
Manula 800 ± 50 min-1 (rprn)

Automatic 1,000 ± 50 min-1 (rpm) (ffi] or [E]l
• lf idle speed is as specified, go to step 14.

throttle stop screw, then repeat step 4.
11-108
14. Reinstall the mixture adjusting screw hoel cap. [01584 (KQ CARB) Engine]
15. lf equipped with air conditioner, check the idle speed CO Meter Method
l·fMM@id
with the A/C on.
Do not smoke d unng
. t h.rs procedure. Keep
ldle speed should be: any open flame away from your work area.
NOTE: Check that the self-diagnosis indicator before

making idle speed and mixture inspections
Manual 800 ± 50 min+ t (rpm)
Automatic 1,000 ± 50 min -1 (rpm) 11]] or [E], 1. Start the engine and warm it up to normal operating
temperature (the cooling fan comes twice).
RUBBER
CAP
Adjust the idle speed, if necessary, by turning
the adjusting screw
3. Check the fast idle lever.
Fast idle lever should not be seated against fast idle

cam.
FAST IDLE LEVER
• lf not, replace the left carburetor (page 11-137)

(cont'd)
11-109
Carburetor
ldle
Speed/Mixture (cont'd)--------------------
4. Check idle speed with the headlights, heater blow- 7. Disconnect the 2P connector from the EACV and
er, rear window defogger, cooling tan and air con- disconnect the hose from vacuum hose manifold,
ditioner off. then cap the hose end.
Disconnect #2 vacuum hose from vacuum hose
ldle speed should be: manifold, then cap the hose end.

Automatic 720 ± 50 min-1 (rpm) <!]] or [f:}
Adjust the idle speed, if necessary, by turning

the throttle stop screw.

the throttle control {page 11-1 59).
EACV
HOSE
8. Disconnect the wire harness from the 02 sensor.
~
THROTTLE STOP SCREW
5. Calibrate the NDIRCO Meter in accordancewith the

manufacturer's recommended procedures.
lnsert exhaust gas sampling probe into the tailpipe
at least 40 cm.
6. Turn the ignition switch OFF. Restart the engine and 1 O. Turn the ignition swi_tch OFF. Restart the engine
hold engine at idle for 2 minutes. And hold engine and hold engine at idle for 2 minutes. And hold
at 3,000-3,500 rnirr ' (rpm) for 1 minute. engine at 3,000-3,500 mirr ' (rpm) for 1 minute.
Check specification for idle CO with cooling tan, air minute.
conditioner OFF and headlights OFF. Check specification for idle CO.
Specified CO%: 0.5% Specified CO%: 2.5±0.5%
• lf idle CO is as specified, go to step 15. • lf not, specification, go to step 11 .

• lf not, go to step 7 through 13.
11-110
11. lf not within specification, remave mixture adjust- 1 5. Check the idle speed with the headlights and
ing screw hale caps and adjust by turning mixture blower switch ON.
adjusting screws to obtain proper CO reading.
MIXTURE ADJUSTING
Manula 700 ± 50 min-1 (rpm)
SCREW
Automatic 850 ± 50 min-1 (rpm) ([[] ar [fJ)
HOLE CAP
Turning mixture adjusting screw

clockwise: CO reading decreases
counterclockwise: CO reading increases Adjust the idle speed, if necessary, by turning
the adjusting screw A.
• Readjustidle speed if necessary, and recheck idle
co.
1 6. lf equipped with air conditioner, check the idle
12. Turn the ignition switch OFF. Reconnectthe connec- speed with the A/C on.
tor and hose.
1 3. Remove BACK UP fuse for 1 O seconds to reset con-
trol unit and recheck idle speed. Manual 780 ± 50 min-1 (rpm)
Automatic 1,000 ± 50 min-1 (rpm) ([[] or [fJ)

Autamatic 720 ± 50 min-1 (rpm) (ffi] ar [Ij)
Specified CO%: 0.5%

throttle stop screw, then repeat step 5.
14. Reinstall the mixture adjusting screw hole caps.
ADJUSTING SCREW B
Adjusting the idle speed, if necessary, by turning

the adjusting screw B.
11-111
Carburetor
AcceleratorPump
[1-Carbureted
Engine]---------------
Description
The fuel flow from the accelerator pump is further regulated by the temperature-sensitive bypass valve in the carburetor.
is depressed suddenly at low engine speeds.
When the accelerator pedal is depressed, the pump rod, which is connected to the throttle lever, pushes down on the
accelerator pump diaphragm. This opens the outlet check valve and allows fuel to be pumped up to the accelerator pump
nozzle, where it is sprayed into the carburetor's primary throat.
When the accelerator pedal is released, the accelerator pump diaphragm is pushed up by its spring and this closes the
outlet check valve. Fuel, from the float chamber, flows into the accelerator pump chamber through the inlet check valve
so that the pump will be ready when the accelerator pedal is again depressed suddenly.
The fuel flow from the accelerator pump is further regulated by the temperature-sensitive bypass valve in the carburetor.
When the engine is cold, the bypass portian of the valve is closed so that the accelerator pump nozzle will get the rnaxi-
mum of fuel available. When the engine warms up to its normal operating temperature, the bypass valve opens and this
allows sorne of the fuel, which would ordinarily be routed to the nozzle, to be bled back into the float chamber of the
carburetor.
u\
'º)
ACCERELATION: ,J 'íR'I
OUTLET CHECK
VALVE
PUMP
LEVER
CHECK VALVE
PUMP DIAPHRAGM
DECRELATION: f
When engine is cold

valve is closed.
When engine is hot,

valve is open.
11-112
lnspection
1. Before measuring the accelerator pump linkage trav-

el, make sure the pump shaft travels freely through-
out the pump stroke. Make sure the pump lever is
in contact with the pump shaft.
Do not bend
PUMP SHAFT this tang
Measure accelerator
pump travel here.
2. To check linkage travel, measure gap between bot-

tom end of pump lever (tang) and stop as shown.
Limits: 16.5 ± 16.9 mm (0.65-0.67 in.)
11-113
Carburetor
Accelerator Pump
[2-Carbureted Engine]----------------.
Description
To prevent the temperary delay of the air/fuel mixture flow at acceleration, the accelerator pump is provided to supply
additional fuel to the left/right-side carburetor.
PUMP
LEVER
--
NOZZLE
ACCERELATION:
?.! DECRELATION:
NOZZLE
INLET CHECK
VALVE
When the acceleration pedal is down, the accelerator pump diaphragm gets down through the pump lever connected
with the throttle lever. At this time, since the inlet check valve is closed, the diaphragm chamber is pressurized and push-
es up the outlet check valve, so that fuel is injected from the acceleration nozzle. The fuel pressurized in the diaphragm
chamber also flows into the right-side carburetor and is injected from the acceleration nozzle as in the left-side carburetor.
When the accelerator pedal is up, the acceleration pump diaphragm returns by the working of the spring, and the inlet
check valve opens, so that the fuel in the float chamber flows into the diaphragm. At this time, since the outlet check
valve is closed, the air intake from the nozzle side does not occur.
11-114
Float
Level
[1-Carbureted Engine]-----------------__,
Description
The float system consist of float, float chamber, float valve and valve seat. When the fuel level in the float chamber
drops as fuel is consumed, the float and float valve move downward and fuel is pumped into the float chamber. When
the fuel level in the float chamber rises, the float moves upward until the float valve reaches the valve seat, and fuel
pump stops. The float system repeats this movement at drive so that constant fuel level is maintained in the carburetor
at every time.
In addition, a valve pin is attached to the float valve so that the movement of the float is absorbed at car tilting or vibra-
tion and constant fuel level is maintained at every time.
FLOAT VALVE CLOSED

VALVE SEAT
FLOAT VALVE
VALVE PIN
FLOAT
FLOAT VALVE
FLOAT CHAMBER
SPRING
FLOAT VALVE OPEN
VALVE PIN
(cont'd)
11-115
Carburetor
Float
Level[1-Carbureted
Engine]-----------------
Adjustment {01281, 01383 EXCEPTEUROPEand 01583
Engine]
[01382 EUROPE& KQ EngineJ
f,§H@lfiN Do not smoke during this procedure. Keep
f,ijH;j.,jjhd Do not smoke while
working on fuel sys- any open flame away from your work area.
tem. Keep open flame away from work area.
1. Remove float arm pin by lightly tapping it with a
1. Place the car on level ground. slender pin from long leg side as shwon, then remove
float.
2. Start and warm up the engine, snap the throttle be-
tween idle and 3,000 min-1 (rpm) severa! times NOTE: Never tap the float leg.
then allow it to idle.
3. When the fuel level stabilizes, check that it is cen-

tered in the inspection window.
2. Reassemble float in reverse order.
3. Measure float level by attaching a float level gauge

to the center of float.
Float Level (from Gasket):

34.5-36.5 mm (1.36-1.44 in.)
CLEARANCE
0-0. 1 mm (0-0.04 in.)
4. lf the fuel level is not centered, adjust it by slowly
turning the adjusting screw.
5. Paint the adjustment screw with white paint after

adjustment.
NOTE: Do not turn the adjusting screw more than

1 /8-turn every 15-seconds.
r
FLOA T LEVEL GAUGE
07401-0010000
ADJUSTING SCREW
4. Adjust level by turning adjusting screw in or out if
necessary.
5. Paint adjusting screw after adjustment.
11-116
Float
Level
(2-Carbureted Engine]-------------------,
Description
The float system consists of a float, a float chamber, a float valve and a valve seat. When the fuel level in the chamber
decreases with the fuel consumption, the float and the float valve go down, and fuel flows into the chamber. When the
fuel level in the chamber increases, the float valve goes up, and the float valve reaches the valve seat, so that fuel stops
flowing into the chamber. The float system repeats this movement during driving to maintain a certain quantity of fuel
in the carburetor.
In addition, the valve pin is equipped with the float valve so that the movement of the float can be absorbed at the time
of car tilting and vibrating and stable fuel level can be obtained.
Float Valve Closed Float Valve Open
FLOAT VALVE
FLOAT CHAMBER
(cont'dl
11-117
Carburetor
Float Level [2-Carbureted Engine]
(cont'd)
Adjustment
1. Remove the carburetors (page 11-137).
2. Remove the float chambers.
3. Using the float level gauge, measure the float level

with the float tip lightly contacting the float valve
and the carburetor float chamber surface inclined
about 30° from vertical.
Float Level: 16± 1 mm (0.6 ±0.04 in.)
11-118
Automatic Choke
[1-Carbureted Engine]-----------------.
Description
This system provides easy engine starting under a wide range of air temperatures.
The system consists of the following:

a) The choke valve and its linkage system
b) The choke heater electrical circuit
e) The choke opener
d) The fast idle and fast idle unloader system
The choke valve is located in the primary throttle bore of the carburetor. When the engine is not running, the choke valve
angle is determined by the bimetallic coil spring acting against the choke return spring. When the engine is running, the
choke opener also affects the choke valve angle.
When the engine is started, electric current supplied to the main choke heater causes the bimetallic coil spring to open
the choke valve. As the air temperature in the choke cap rises, the thermal switch turns on and electric current is also
directed to the secondary choke heater. This speeds the opening of the choke valve during its final stages. The combina-
tion of heater and thermistor keeps the bimetallic coil spring at a constant high temperature.
CHOKE
VAL VE
CHOKE
CAP
CHOKE
OPENER
LEVER
11-119
Carburetor
Choke Opener
(1-Carbureted
Enginel----------------
Description
The fast idle cam is engaged and disengaged by depressing the accelerator pedal, and is also disengaged by the fast
idle unloading mechanism.
The unloading mechanism consists of a fast idle unloader, and thermovalve. When the coolant temperature reaches the
set temperature of thermovalve, it closes to shut off the vacuum bleed. This allows the diaphragm of the unloader to
retract by manifold vacuum.
THERMOVALVE BIMETALLIC CHOKE

COIL COVER
SPRING
ROD
CHOKE CHOKE
OPENER VAL VE
CHOKE
DALVE
LE VER POSITIVE
CHOKE
OPENER TEMPERA TU RE
LEVER COEFFICIENT
HEATER
Choke Opener
This system is designed to promote easy starting. When starting the engine, manifold vacuum is transmitted to the choke
opener; thus the choke valve is opened a fixed amount.
Thermovalve works to open the choke valve in response to engine coolant temperatura. When the engine coolant
temperature is below the set temperatura of thermovalve, it opens and manifold vacuum is bled from the valve. In this
situation the choke opener diaphragm is retracted to an intermediate position because of the balance between the
vacuum and the spring force of the choke opener.
When the engine coolant temperature exceeds the set temperatura of thermovalve, it closes to shut off the vacuum bleed
and this allows the choke opener to retract fully and pull the choke valve open.
11-120
Testing 4. lf coolant temperature is below about 14°C
(57.2ºF), Tab A on the choke opener lever should
1 . Disconnect the 2P connector of the choke coíl not be seated against the carburetor.
heater.
2. Open and close the throttle fully to let the choke

close.
3. Start the engine.
The choke valve should partially open.
• lf the choke partially opens, go on to step 4 or

step 5, depending on coolant temperature.
• lf the choke does not open partially, check the
linkage for free movement, repair as necessary,
and retest. Coolant Temperature
• lf the choke valve still does not open partially, below 14ºC (57.2ºFl
check the choke opener diaphragm: Remove the
choke opener, and connect a vacuum pump.
Block the orífice in the opener while you apply • lf Tab A is not seated, go on to step 5.
enough vacuum to pull the opener rod all the way • lf Tab A is seated, disconnect the # 18 vacuum
in, the stop. hose from the choke opener.
CHOKE
CHOKE OPENER
OPENER
VACUUM PUMP/GAUGE
OPENER ROD
# 18 VACUUM HOSE
- lf the rod will not stay in, replace the opener.
- lf the rod stays in, check the vacuum port in the
carburetor for blockage.
- lf Tab A comes off its seat, check the # 18 vacu-
NOTE: After replacing or reinstalling the choke um line for proper connection or disconnected
opener, retest it, then adjust it if necessary (page hose. lf OK, replace the thermovalve.
11-123).
(cont'dl
11-121
Carburetor
Choke Opener [ 1-Carbureted Engine] Choke Coil Tension and linkage
(cont'd) [ 1-Carbureted Engine]
5. lf coolant temperature is above about 25°C (77°F), lnspection (COLO ENGINE)
Tab A on the choke opener lever should be seated
against the carburetor. 1. Remove the air cleaner.
2. Open and close the throttle fully to let the choke

close.
The choke valve should close completely.
NOTE: Above about 28ºC (82ºF) the choke will not

close completely, but should still close to less than
3 mm (1 /8 in.).
• lf the choke closes properly, go on to the fast idle

unloader test on page 11-127.
• lf the choke does not close properly, spray its link-
age with carburetor cleaner, and check the link-
TABA age for sings of mechanical binding {use a spray
Coolant temperature can with an extension on the nozzle to reach the
above 25°C (77ºF)
linkage).
• lf Tab A is not seated, check the # 18 vacuum
line for proper connection, cracks, blockage or CAUTION: Carburetor cleaner is very caustic;
disconnected hose. lf OK, replace the ther- always wear safety goggles or a tace shield when
movalve. spraying.
• lf the choke still does not clase properly, remove

the choke cover {page 11-120) and inspect the
linkage for free movement. Repairor replaceparts
as necessary. Then reinstall the cover and adjust
it so the index marks line up, and retest.
• lf the choke still does not clase properly, replace
the cover (page 11-124).
INDEX
MARKS
01382
EUROPE &
KQ ENGINE
11-122
Choke
Linkage
[1-Carbureted
Engine]-----------------
Adjustment
5. Remove the check valve, and reconnect the choke
NOTE: opener hose.
• This check is not necessary unless the linkage has
been bent, choke opener has been replaced, or the car 6. Hold both levers together, then push them toward
has poor cold starting. the diaphragm again until they stop (Tab A on the
• This check can be made with the engine HOT or opener lever seats against the carburetor), and meas-
COLO. ure the clearance at the choke valve.
Measure clearance here

1. Remove the choke cover (page 11-120).
2. While holding the choke valve closed, open and close

the throttle fully to engage the choke and fast idle
linkage.
3. Disconnect the choke opener hose from the vacu-

um hose manifold, and attach a check valve to it as
shown. Then pressurize the choke opener with low
pressure compressed air, 103-586 kPa (15-85
psi) is OK, to hold the bleed valve in it closed.
CHOKE ORIVE
LEVER
~ 1--- Measure clearance here
DIAPHRAGM
ROO
OPENER DIAPHRAGM 2nd Stage Clearance:
2.9 ± 0.09 mm (0.114 ± 0.0035 in.)
\ BLEEO VAL VE Adjust clearance by bending Tab A.
7. While still holding opener lever Tab A against its seat,
release the choke drive lever, and meassure the
clearanceat the choke valve (Tab Con the drive lever
should stay seated against the spring loop; if not,
repeat step 2 and recheck):
CHOKE OPENER LEVER
Measure clearance here
COMPRESSED AIR
<>~.--
CHECK VALVE
4. Gently push the choke opener lever towards the

opener until is stops (until you feel the opener rod
seat against the pressurized bleed valve), then pull
the choke drive lever down against the opener lever
(to take all free play out of the linkage), and meas-
ure the clearance between the choke blade and
casting:
SPRING LOOP
1 st Stage Clearance
0.88 ± 0.07 mm (0.035 ± 0.003 in.)
Adjust clearance by bending Tab D.
3rd Stage Clearance:

5.25 ± 0.20 mm (0.206 ± 0.008 in.)
11-123
Carburetor
Choke Coil Heater [ 1-Carbureted Engine]1---------------
Testing Replacement·
Start the engine and let it run. As the engine reaches 1. Remove the air cleaner.
normal operating temperature, the choke valve should
fully open: 2. Remove the 2P connector .
• lf it does, go on to the fast idle unloadedtest on paqe.

• lf it doesn't inspect the linkage, and clean or repair
it as necessary (page 11-122).
• lf the choke still does not open all the way, discon-
nect the connector, and measure voltage between
WHT /BLU ( +) terminal and body ground.
There should be battery voltage with the engine

running.
CHOEK
CAP
3. Disconnect the terminal retainer from the connec-

tor and remove the two terminals.
- lf there is no voltage, inspect open in WHT /BLU

wire between the connector and the alternator.
lf OK, inspect the alternator (section 23).
TERMINAL
RETAINER
(Replace)
11-124
4. [01382 EUROPE & KQ Engine]
Using a 5/32" or 4.1 mm diameter drill, drill out the
rivets and remove the choke cover.
CHOKE
COVER
CAUTION: Cover the carburetor with a clean shop
rag to prevent chips from falling into the carburetor
throat.
(01281. 01383 EXCEPT EUROPE and 01583

Engine)
Remove the screws and remove the choke cover.
5. Reinstall the cover and adjust it so that index marks

align (01382 EUROPE& KQ Engine:, then secure it
with rivets).
CHOKE
COVER
7. Reconnect the connector and reinstall the air cleaner.
INDEX
MARKS
6. Connect the respective terminals to a new connec-

tor and install a new terminal retainer.
NOTE:
• Be sure to connect the terminal before installing
the terminal retainer.
• Replacethe connector and terminal retainer with
the new ones.
• Note the location of the terminal.
CHOKE COIL
HEATER
PRIMARY SLOW
MIXTURE CUT -OFF
SOLENOID VALVE
11-125
Carburetor
Fast ldle
[1-Carbureted Engine]-------------------
Description
Unloader mechanism
When a cold engine is started, the closed choke valve is opened a fixed amount by the linkage whenever the accelerator
pedal is depressed beyond a certain point. This mechanism prevents the air fuel mixture frorn becoming excessively rich
when additional acceleration is required.
FAST IDLE CAM GUIDE
FAST IDLE LEVER CA/
THROTTLE VALVE
Fast idle mechanism

Before starting the cold engine, it is necessary to depress the accelerator pedal once in order to disengage the fast idle
cam from the fast idle lever. When the accelerator pedal is released slowly, the fast idle cam is initially positioned by
the bimetallic coil spring according to the ambient temperature.
As the choke heater warms the bimetallic coil spring, the lever rotates clockwise, opening the choke valve. The fast
idle cam and lever will remain where originally set unless the throttle is depressed to wide open.
When the engine runs smoothly, the idle speed can be reduced by slowly depressing the accelerator pedal.
J Before Starting l During Warming up
FAST IDLE LEVER CHOKE VALVE FAST IDLE CAM
_;~L....
THROTTLE VALVE
FAST IDLE CAM Opening angle varias
according to cam position.
11-126
Testing
1. Disconnect the # 18 hose from the fast idle un-

loader.
FAST IDLE UNLOADER
5. Reconnect the hose.
6. Warm up to normal operating temperature (the cool-

CAP ing fan comes on).
2. Open and close the throttle fully to engage the fast When the engine warms up, it speed should drop
idle cam. below 1.400 min-1 (rpm) as the unloader pulls the
interna! choke linkage off the fast idle cam.
• lf fast idle does not drop below 1 ,400 min-1

(rpm). disconnect the # 18 hose, and check the
vacuum.
VACUUM
3. Start the engine. PUMP/GAUGE
# 18 VACUUM HOSE
Fast idle should be 3,200 ± 500 min-1 (rpm)
Adjust the fast idle speed, if necessary, by turn- • lf there is no vacuum, check the # 18 vacuum line
ing the fast idle adjusting screw. for proper connection, cracks, blockage or discon-
nected hose. lf OK, replace the thermovalve.
• lf there is vacuum, replace the fast idle unloader,

and then inspect the choke coil tension and link-
age (page 11-122).
11-127
Carburetor
Automatic Choke and Fast ldle [2-Carbureted Engine]
Description
This system provides easy engine starting under a wide range of air temperatures.
The system consists of the following:
a) The choke valve and its linkage system

b) The choke opener (page 11-130).
e) The fast idle system (page 11-133).
The choke valves are located in the air intakes of the carburetors. When the engine is not running, the choke valva angle
is determined by the thermowax valve. When the angine is running, the choke opener also affects the choke valva angle.
The choke opener adjusts the choke valve for increased air flow once the engine begins to fire. lt operates in two steps
according to coolant temparature.
The automatic choke system is controlled by the thermowax valve; as coolant temperature rises, the valve's piston ex-
tends which causes the fast idle cam to gradually rotate and decrease idle spead.
Engine coolant is fed through a passage in the carburetor's cast front bracket to prevent carburetor icing and to improve
cold driveability by improving vaporization of the air/fuel mixture. Since excessiva heat can cause fuel percolation, a
thermovalve is used to shut off the coolant flow at temperatures above the thermovalve set temperature.
COOLANT
TO
THERMOVAL VE
11-128
Choke Linkage [2-Carbureted Engine]
Adjustment 4. Cap the end of the # 18 vacuum hose and apply

vacuum.
1. Remove the carburetor (page 11-137).
5. Turn the choke drive lever clockwise until Tab B
2. Disconnect the # 18 vacuum hose from the choke seats againstthe stopper, and measureclearancebe-
opener and leave open to atmosphere. Disconnect tween the choke valve and casting.
the # 28 vacuum hose and connect a vacuum pump.
Apply at least 200 mm Hg (8 in. Hg)
NOTE: lf vacuum drops below 200 mm Hg (8 in.

Hg), slowly reapply vacuum until you can maintain
the highest level without losing vacuum.
3. Turn the choke drive gear clockwise and measure

the clearance between the choke valve and the
casting.
I
VACUUM PUMP/GAUGE
~-"'
.. A
t
#28 VACUUM
HOSE
~'~J=\===¡=¡= Measure here 2nd Stage Clearance:
M/T: 3.85±0.2 mm (0.152±0.008 in.)
A/T: 4.05±0.2 mm (0.159±0.008 in.)
CHOKE VALVE Adjust clearance by bending Tab B
lf the clearance can not adjust, replace the left car-

buretor (page 11-137).
1st Stage Clearance:

M/T: 1.65±0.15 mm (0.065±0.006 in.)
A/T: 1.75±0.15 mm (0.69±0.006 in.)
Adjust clearance by bending Tab A.
11-129
Carburetor
Choke Opener [2-Carbureted Engine]
Description
Thermovalve operaresto open the choke valve in responseto engine coolant temperature. When the engine coolant tem-
perature is below the set temperature of thermovalve (15°C). it opens and manifold vacuum is bled from the opener.
In this situation the choke opener diaphragm is retracted to an intermediate position because of the balance between
the vacuum and the spring force of the choke opener.
When the engine coolant ternperature exceeds the set ternperature of therrnovalve (15°C), it closes to shut off the vacu-
um bleed and allows the choke opener to retract fully and pull the choke valve open.
CHOKE OPENER
11-130
Testing (COLO ENGINE) Testing (HOT ENGINE)
NOTE: Enginecoolant temperature must be below 15ºC 1. Start the engine and warm up to normal operating
(59°F) . temperature (the cooling fan comes on).
1. Disconnect the # 28 vacuum hose from the choke 2. Disconnect the # 18 vacuum hose from the choke
opener and connect a vacuum pump. opener and connect a vacuum pump.
lt should hold vacumm
VACUUM PUMP/GAUGE CHOKE OPENER
# 18 VACUUM HOSE
• lf it does not hold vacuum, check the # 18 vacu-
• lf there is no vacuum, check the # 28 vacuum
um hose far proper connection, cracks, blockage
hose far proper connection, cracks, brockage or
or disconnected hose. lf OK, replace the ther-
disconnected hose.
movalve and retest.
3. Disconnect the # 18 vacuum hose from the choke
opener, the connect a vacuum pump.
# 18 VACUUM HOSE
lt should not hold vacuurn.
• lf it holds vacuum, check the # 18 vacuum hose

far proper connection, cracks, blockageor discon-
nected hose. lf OK, replace the thermovalve and
retest. (cont'd)
11-131
Carburetor
Choke Opener [2-Carbureted Engine]
(cont'd)
Choke Opener Diaphragm Testing
1. Disconnect the # 1 8 vacuurn hose frorn the vacu-

um hose manifold.

um hose manifold and connect a vacuum pump.
tf
\
VACUUM PUMP/GAUGE CHOKE OPENER
3. Apply vacuum.
Vacuum should stabilize at 100 to 200 mm Hg (4

to 8 in. Hg) and it should pull the opener rod.
• lf not, check the linkage for signs of mechanical

binding and replace the left carburetor (page
11-137).
4. Cap the end of the # 18 vacuurn hose and apply

vacuum.
lt should pull the opener rod.
CAP
• lf not, replace the left carburetor (page 11-137).
11-132
Fast ldle [2-Carbureted Engine]
Description
Fast ldle Mechanism
The choke valves are located in the air intakes of the carburetors. When the engine is not running, the choke valve angle
is determined by the thermowax valve. When the engine is running, the choke opener also affects the choke valve angle.
The choke opener adjusts the choke valve for increased air flow once the engine beings to fire. lt operates in two steps
according to coolant temperature.
The automatic choke system is controlled by the thermowax valve; as coolant temperature rises. the valve's piston ex-
tends which causes the fast idle cam to gradually rotate and decrease idle speed.
Befare Starting During Warming Up
Fast ldle Unloader Mechanism .

When a cold engine is started, the closed choke valve is opened a fixed amount by the linkage whenever the accelerator
pedal is depressed beyond a certain point. This mechanism prevents the air fuel mixture from becoming excessively rich
when additional acceleration is required.
CHOKE VALVE UNLOADER ROO
(cont'd)
11-133
Carburetor
Fast ldle (2-Carbureted Engine] (cont'd)
lnspection/Adjustment
1. Start the enqine and warm up to normal operating

2. Stop the engine.
3. Disconnect both coolant hoses from the thermowax

valve and cap the end of hoses.
4. Apply cold water and cool down the wax.
FAST IDLE
ADJUSTING SCREW
• lf not, replace the left carburetor (page 11-137).
6. Reinstall both coolant hose.

temperature (the cooling tan comes on).
8. Check the fast idle lever.
5. Connect a tachometer and check the idle speed. Fast idle lever should not be seated against fast idle
cam.
IDLE SPEED [min-1 (rpm)]
2000
1000
FAST IDLE
o ..-~~~~~~~~~~~~~~~~~~~ LEVER
-20-10 O 10 20 30 40 50 60 70 80 90100110·
WAX TEMPERATURE (ºC)
• lf not, replace the left carburetor (page 11-1 37).

fast idle adjusting screw.
11-134
Removal [ 1-Carbureted Engine]
f•in §toY.,;UilJIN Do not smoke while working on fuel system. Keep any open flame away from you work area. Drain fuel
an approved container ..
AIR INTAKE
DUCT
/~
HOT AIR
TUBE
r:
THROTTLE
CABLE
11-135
Carburetor
Replacement [ 1-Carbureted Engine]
AIR HORN
CHOKE
OPENER
SECONDARY
THROTTLE
BODY
~e /1
IDLE BOOST
THROTTLE CONTROLLER
THROTTLE CONTROLLER DIAPHRAGM
11-136
Removal [2-Carbureted Engine]
f•§i.fohlfiN Do not smoke while working on fuel system. Keep and open flame away from you work area. Drain fuel
in to an approved container.
AIR CLEANER
ELEMENT
SCREENS
11-137
Carburetor
Replacement [2-Carbureted Engine]
THROTTLE CONTROLLER
~
1 © "'
THERMOWAX VALVE
º~o
"
<:>
"
~
CROSSOVER PIPE
O©
·®
FUEL VAPOR PIPE
IDLE BOOST
THROTTLE CONTROLLER
PRIMARY SLOW
MIXTURE CUT -OFF
SOLENOID VALVE
RIGHT CARBURETOR
~--
AIR VENT CUT-OFF SOLENOID VAL VE
11-138
v,
@~ HOLE CAP
ij 1 /;
(:®<C» MIXTURE
ADJUSTING SCREW
Tf
i Tf 8@CD~~
.
rt:.~
® l!I)
s Q
!?a~
®
VACUUM CHAMBER~ \\ n ...... ~.E&

~¿&c:9 ~ ®· c:9
VACUUM PISTON=:i
SPRING
9
~
~· 1
.,.,.
NEEDLEJET~
~
~
POWER VALVE
~~J:
NOZZLE
· ·~:: : : 1
STOPPER~
ii
li e
fl JET HOLDER--¡\ n ~
NEEDLE &---.._-----JET PRIMARY SLOW
~
'f ~sEAT
VALVE
l
'
~¡
~~· PRIMARY MAIN
J~
ff ~
~ VALVE SECONDARY MAIN
~ ~ JET
VACUUM~ ~FLOAT
PISTON __..,
~
~ 4:,
~~
v~FLOAT CHAMBER
'!!> 1 PUMP DIAPHRAGM
; ~SPRING
~
j ~COVER
1
11-139
Carburetor
Reassembly (2-Carbureted Engine]
1. lnsert the left carburetor's throttle shaft end (forked), 7. Tighten the screws in the sequence shown.
between the washers on the right carburetor's throt-
tle shaft end.
2. Instan new 0-rings on the fuel vapor pipe, then in-

stall it.
3. Set the left and right carburetors up.
LEFT CARBURETOR RIGHT CARBURETOR

THROTTLE SHAFT THROTTLE SHAFT
CHOKE SHAFT
SPRING
4. Connect the choke shaft spring.
5. Instanthe front braket, with new gaskets, but don't

tighten its screws yet.
CAUTION: Make sure the screw length is correct

or you may damage the carburetors.
6. Check that the choke and throttle shafts move

smoothly without binding.
11-140
Synchronization [2-Carbureted Engine]
1. Remove the air cleaner cover and element. 5. Measure the air flow using the carburetor syn-
chronizer.
2. Removethe air intake screens and air intake flanges.
- lf the flow rates are identical, remove the syn-
chronizer and reinstall the remaining parts in the
reverse order of disassembly.
FLANGES - lf the air flow rates are different, loosen the ad-
justing screw lock nut and adjust as necessary.
The adjusting screw only affects the right carbu-
retor; turning the screw clockwise decreases air
flow and counterclockwise increases air flow.
lf the flow rates can't be balanced, check for air
leaks or carbón build-up on a throttle valve.
3. lnstall the carburetor synchronizer.
CARBURETOR
SYNCHRONIZER
6. Tighten the adjusting screw lock nut and recheckthe

flow rates. Adjust as necessary.
7. Removethe carburetor synchronizerand reinstallthe

remaiing parts in the reverse order of disassembly.
4. Connect a tachometer, start the engine and allow

it to reach its normal operatingtemperature; the cool-
ing tan will come on.
11-141
Fuel Supply System
Symptom-to-sub System Chart
NOTE:
• Across each row in the chart, the sub systems that could be sources of a symptom are ranked in the arder they should
be inspected, starting with (D. Find the symptom in the left column, read across to the most likely source, then refer
to the page listed at the top of that column. lf inspection shows the system is OK, try the next system @, etc.
self-diagnosis indicator (PGM-CARB), valve clearance, air cleaner, and PCV valve. In addition, check the ignition tim-
ing, function of the vacuum and centrifuga! advance, and the condition of the spark plugs. lf those items are ali within
specifications, begin with the troubleshooting listed in this page.
PAGE
FUEL FUEL FUEL CONTAMI-
Fil TEAS PUMP TANK NATED FUEL
SYMPTOM ~ 144 145 147 *
ENGINE WON'T START @ G) @
MISFIRE OR
ROUGH RUNNING
G) G)
POOR
PERFORMANCE LOSS OF
POWER
G) G)
* Fuel with dirt. water or a high percentage of alcohol is considerad contaminated.
11-142
System Description
The fuel supply system consists of the fuel tank, fuel filter, fuel pump, carburetor and fuel lines.
The combinations of the carburetor and engine valiations are:
• Down-draft, two barrel type single carburetor
• Cross-flow CV constant vacuum type twin carburetor
[ 1-Carbureted Engine)
FUEL FEED
PIPE FUEL TANK
FUEL FILTER CAP
CANISTER
FUEL FILTER (FRONTI FUEL

[D 1382 EURO PE & KO Engine) RETURN PIPE
[2-Carbureted Engine)
FUEL FEED
PIPE FUEL TANK
FUEL FILTER (REAR)
FUEL PUMP
FUEL RETURN
FUEL FILTER
PIPE
(FRONT)
11-143
Fuel Supply System
Fuel Filters
Replacement Rear
Replaceboth front and rear filters at every 2 years or 1. Block front wheels. Jack up the rear of the car and
40,000 km (24,000 miles) whichever comes first. support with jackstands.
fWf.j;jflMji Do not smoke while working on the 2. Pushin the tab of the fuer filter to releasethe holder,
fuel system. Keep open flame away from work area. then remove the filter from its bracket.
Front 3. Attach fuel line clamps to the fuer lines and discon-
nect the lines from the filter.
1. Use fuel line clamps to pinch off the fuel lines.
CAUTION: To avoid damaging the fuel lines when
2. Disconnect the fuel lines and remove the fuer filter. disconnecting, slide back the clamps then twist the
lines as you pull.
CAUTION: When disconnecting the fuel lines, slide
back the clamps then twist the lines as you pull, to 4. lnstall in the reverse order of removal.
avoid damaging them.
3. lnstall the new fuel filter.
4. Removethe fuel line clamps.
[O 1382 EUROPE& KO Engine]
FUEL UNE CLAMP

FUEL FIL TER
07614-0050100
(01584 (KQ CAR8) Engine]
FUEL FILTER
11-144
Fuel Pump
Description
The simple mechanical fuel pump is driven by an eccentric cam on the camshaft. The pump is installed on the distributor
mounting through a thick bakelite insulator to prevent heat transmission from the cylinder head.
As the camshaft rotates, the eccentric cam causes the pump rocker arm to rise and fall. When the rocker arm pulls the
diaphragm down against the spring force, the inlet valve opens and allows fuel to enter from chamber A into chamber
B. When the diaphragm is released by the return movement of the rocker arrn, the spring forces the diaphragm upward,
producing pressure in the space above the diaphragm. This pressure closes the inlet valve and opens the outlet valve.
Now fuel is forced from chamber B to chamber C. The fuel from the fuel pump enters the carburetor through a float
valve in the float chamber. lf the chamber is full, the float valve clases to that no fuel can enter. When this happens,
the fuel is forced from chamber C to the fuel tank through the fuel return line.
SUCTION
From fuel tank

CHAMBER A
INLET VALVE
CHAMBER B
DIAPHRAGM
PULL ROD
ROCKER ARM
DELIVERY
CHAMBER C
Return to
fuel tank
To Carburetor
OUTLET VALVE
(cont'd)
11-145
Fuel Supply System
Fuel Pump (cont'd)
Testing 4. Remove pressure gauge and hold a graduated

container under the hose.
f,¡¡.jmljjf¡;
Do not smoke during the test. Keep any
open flama away from your work area. 5. Start the engine, and allow it to idle for 60 se-
NOTE: Check for a clogged fuel filter and/or fuel line be- conds, then stop the engine.
fore checking fuel pump pressure.
Fue! volume should be 833.3 cm? (27.9 oz).
1. Disconnect the fuel line at the fuel filter in the en-
• lf fuel volume is less than specified, replace the
gine compartment, and connect a pressuregauge to
fuel pump and re-test.
itas shown.
NOTE: Check for a clogged fuel filter and/or fuel line
2. Disconnect the fuel return line at the fuel pump and
before replacing pump.
plug the return fitting with a plug.
GRADUATED
LITER OR QUART
CONTAINER
3. Start the engine, and allow it to idle until pressure 6. Remove the plug from fuel pump return fitting and
stabilizes, then stop engine. reconnect return line.
Pressure should be:

6.8-22.6 kPa
(0.07-0.23 kg/cm2, 1.0-3.2 psi)
• lf gauge shows at least 6.8 kPa (0.07 kg/cm2,

1 .O psi), go on to step 4.
• lf gauge shows less than 6.8 kPa (0.07 kg/cm2,
1.0 psi), replace pump and re-test.
11-146
Replacement
f •§4.foJ@iNDo not smoke while working on fuel sys-

1. Attach fuel line clamps to fuel pump lines.
2. Disconnect fuel lines at fuel pump.
CAUTION: When disconnecting fuel lines, slide back

clamps then twist lines as you pull, to avoid damag-
ing them.
FUEL PUMP
3. Removefuel pump.
4. lnstall in the reverse order of removal.
CAUTION: Make sure that the fuel lines are connected

properly and securely.
11-147
Fuel Supply System
Fuel Tank~~~~~~~~~~~-----~~~~~~~~~~~~~~~----.
Replacement
f,j:,Y.f;pjjJjJDo not smoke while working on fuel system. Keep open flame away from area.
1. Block front wheels. Jack up the rear of the car and support with jackstands.
2. Remove the drain bolt and drain the fuel into an approved container.
3. Remove the rea, seat (section 20).
4. Disconnect the fuel gauge sending unit connector.
5. Remove the fuel hose protector.
6. Remove the heat shield.
7. Disconnect the hoses.
CAUTION: When disconnecting the hoses, slide back the clamps, then twist hoses as you pull. to avoid damaging
them.
8. Place a jack, or other support, under the tank.

9. Remove the strap nuts and let the straps fall free.
1 O. Remove the fuel tank.
NOTE: The tank may stick on the undercoat applied to its mount. To remove, carefully pry it off the mount.
11. Instan a new washer on the drain bolt, then instan parts in the reverse order of removal.
DRAIN BOLT
50 N·m (5.0 kg-m. 36 lb-ft)
11-148
Air lntake System
Symptom-to-sub System Chart -------------------
NOTE:
be inspected, starting with (D. Find the symptom in the left column, read across to the most likely source, then refer
to the page isted at the top of that column. lf inspection shows the system is OK, try the next system @, etc.
self-diagnosis indicator (PGM-CARB). valve clearance, air cleaner, PCV valve. In addition, check the ignition timing,
function of the vacuum and centrifuga! advance, and the condition of the spark plugs. lf those items are ali within
PAGE
THROTTLE CABLE AIR INTAKE CONTROL
~
150 152
----------====
SYMPTOM
LOSS OF POWER CD
AFTERBURN CD
HESITATION/SURGE CD
11-149
Air lntake System
Throttle Cable-------------------------
lnspection/ Adjustment lnstallation
1. Warm up the engine to normal operating tempera- [1-Carbureted Engine]

ture (the cooling tan comes on).
1. Disconnect the hosefrom the throttle controller and
2. Check that throttle cable operates smoothly with no connect a vacuum pump to the controller, then ap-
binding or sticking. Repair as necessary. ply vacuum.
3. Start the engine and check cable free-play at throt-

tle linkage at idle. Cabledeflection should be 4-10
mm (3/16-3/8 in.)
[ 1-Carbureted Engine]
ADJUSTING NUT
VACUUM
PUMP/GAUGE
----- THROTTLE CONTROLLER
2. Fully open the throttle and choke valves, then close

the throttle valve. Now, releasethe choke valve; the
throttle linkage will be off the fast idle cam.
LOCKNUT
3. lnstall the throttle cable in the throttle linkage.

LOCKNUT
THROTTLE CABLE ADJUSTING NUT
THROTTLE CABLE
THROTTLE LINKAGE 3mm
4. lt deflection is not within specs, loosen locknut and

turn adjusting nut until you can deflect cable as 4. Turn the adjusting nut until it is 3 mm ( 1 /8 in.) away
specified. Then tighten locknut. from the cable bracket.
Tighten the locknut.
5. With cable properly adjusted, check throttle valve
to be sure it opens fully when you push accelerator 5. Disconnect the vacuum pump and reconnect the
pedal to the floor. throttle controller hose.
CAUTION: Check throttle valve to be sure it returns

to idle position whenever you release accelerator.
11-150
1. Disconnect the # 6 vacuum hose from the throttle

controller and connect a vacuum pump to the con-
troller, the apply vacuum.
THROTTLE CONTROLLER
2. Fully open the throttle valve, then install the throt-

tle cable in the throttle linkage and install the cable
housing in the throttle bracket.
3. Warm up the engine to normal operating tempera-

ture (the cooling fan comes on).
4. Removethe cable housing from the throttle brack-

et, set the adjusting nut on the throttle bracket.
Adjust the adjusting nut so that its free play is O mm.
5. Removethe cable housing from the throttle brack-

et, reset the adjusting nut and tighten the locknut.
ADJUSTING NUT
THROTTLE
BRACKET
THROTTLE CABLE
6. Disconnect the vacuum pump and connect the # 6

vacuum hose.
11-151
Air lntake System
lntake Air Control System ----------------------
Description
The air intake system supplies filtered, temperature-controlled air to the carburetor. lt consists of the air cleaner, air in-
take pipe, carburetor, intake manifold and intake air control system.
The intake air control system maintains uniform air temperature inside the air cleaner (approximately 25ºC, 77ºF). The
carburetor receives fresh air, controlled within a narrow temperature range, regardless of outside temperature.
COLD - Below 25ºC (77ºFl (approx.) HOT - Above 25°C (77ºF) (approx.)
p
~
Bleed Valve - closed, manifold vacuum builds. - open, manifold vacuum bleeds off.
Diaphragm - vacuum pulls up on control door. - interna! spring pushes down on control
door.
Air Control Door - rises, pre-heated air enters (outside air - falls, outside air enters (heated air
blocked). blocked).
Check Valve - prevents vacuum loss from air control diaphragm at wide-open throttle.
Fixed Orífice - prevents rapid pressure changes. Allows smooth operation of control door.
[ 1-Carbureted Engine)
AIR CONTROL
DIAPHRAM AIR BLEED VALVE
;r
HOT AIR TOINTAKE
INTAKE MANIFOLD
DUCT
FIXED
ORIFICE
CHECK-·
VAL VE
AIR CONTROL HOT AIR

DIAPHRAGM INTAKE DUCT
11-152
NOTE: lntake air temperature must be below 25°C 1. Start the engine and warm up to normal operating
(77ºF) temperature (the cooling tan comes on).
1. Disconnect the air intake duct and start the engine. The air control door should be down.
The air control door should rise.
AIR CONTROL DOOR

AIR INT AKE DUCT
• lf not, disconnect the vacuum hose from the air

control diaphragm, and connect a vacuum pump. • lf not, disconnect the vacuum hose from the air
control diaphragm, and connect a vacuum pump.
- lf there is no vacuum, replace the air control

diaphragm and retest.
- lf there is vacuum, replacethe air bleed valve and
retest.
AIR CONTROL
DIAPHRAGM
- lf there is vacuum, replace the air control di-
aphragm and retest.
- lf there is no vacuum, check the vacuum hose for
nected hose, and replace the air bleed valve.
11-153
Emission Control System
Sympton-to-sub System Chart -------------------
NOTE:
to the page listed at the top of that column. lf inspection shows the system is OK, try the next system @, etc.
• Befare starting inspection, check that other items that affect engine performance are within specification. Check the
self-diagnosis indicator (PGM-CARB), valve clearance, air cleaner, and PCV valve. In addition, check the ignition tim-
ing, function of the vacuum and centrifuga! advance, and the condition of the spark plugs. lf those items are all within
PAGE
FEEDBACK THROTTLE EVAPORATIVE
CONTROL CONTROL CONTROL
SYMPTOM ~ 157 162 168
ENGINE WON'T START G)
WHEN COLO G)
OIFFICULT TO ST ART
ENGINE
WHEN WARM G) @
WHEN COLO FAST
IOLE OUT OF G) @
SPECIFICATION
WHEN WARM
ENGINE SPEEO G)
TOO HIGH
IRREGULAR IOLING
WHEN WARM
ENGINE SPEEO G)
TOO LOW
ROUGH IOLE/
FLUCTUATION
G)
WHILE
WARMING UP
G)
FREOUENT STALLING
AFTER
WARMING UP
G)
MISFIRE OR
ROUGH RUNNING
LOSS OFF
POWER
G)
POOR PERFORMANCE
AFTERBURN G) @
HESITATION/SURGE G)
11-154
System Description--------- TailpipeEmissions------- .....
(01382 EUROPE& KQ and 01584 (KQ CAR8) Engine] lnspection
The emission control system includes the feedback con-
trol system, catalytic converter, throttle control system, NOTE: lt is not possible to use a CO meter to adjust the
positive crankcase ventilation system and evaporative idle mixture; the effect of the catalytic converter prevents
control system. accurate tracking of such small changes in air-fuel ratio.
[01281, 01383 EXCEPT EUROPE and 01583 Engine] f•fM,;!Jjjdd Do not smoke duringthis procedure.Keep
The emission control system includes the throttle con- any open flame away from your work area.
trol system, positive crankcase ventilation system and
1. Follow steps the propane enrichment method (KS
* evaporative control system. *: KY only
only).
The emission control systems are designed to meet fed-
2. Warm up and calibrate the CO meter according to
eral and state emission standards.
the meter manufacture's instructions.
3. Check idle CO with the headlights, heater blower,

rear window defogger, cooling tan, and air condition-
er off.
Specified C0%
KO: 0.5%
Ex. KO Others: 0.2%
11-155
Catalytic Converter [D 1382 EUROPE & KQ and D 1584 (KQ CARB) Enginel
Description lnspection
The 3-way catalytic converter is used to convert lf excessive exhaust system back-pressure is sus-
hydrocarbons {HC), carbon monoxide (CO), and oxides pected, remove the catalytic converter from the car and
of nitrogen (NOx) in the exhaust gas, to carbon dioxide make a visual check for plugging, melting or cracking of
(C02), dinitrogen (N2) and water vapor. the catalyst. Replace the catalytic converter if any of
the visible area is damaged or plugged.
CATALYTIC
CONVERTER HEAT SHIELD
Removal lnstallation, section 9
lnspect housing for cracks or
other damge.
HOUSING lnspect element for clogging
by looking through the inside.
FRONT OF
VEHICLE
t
Replace
HEAT-SHIELD
10 N·m (1.0 kg-m,

71 lb-ft)
11-156
Feedback Control [01382 EUROPE & KQ and 01584 (KQ CAR8) Engine]
Description
Air-fuel mixture ratio feedback on this vehicle is performed using the oxygen sensor, the EACV and the control unit. The
oxygen sensor, sends the signal to the control unit on arder to judge whether the air-fuel ratio is richer or leaner than
the stoichiometric air-fuel ratio. The control unit receives other signals from speed sensor, TW sensor, vacuum switch,
ignition coil, MAP sensor and TA sensor, and sends the electric current to the EACV.
The EACV opens the air passage from the air cleaner case to the intake manifold in proportion to the intensity of the
electric current received from the control unit.
This feedback system has four functions:
1. air-fuel ratio control
2. shot air control
3. deceleration air supply
4. hot engine start control
1. Air-fuel ratio control
The system is designed to achieve a stoichiometric air-fuel mixture ratio making the most of the three-way catalyst
performance to give a simultaneous reduction of hydrocarbons, carbon monoxide and oxides of nitrogen. The carbu-
retor air-fuel mixture is basically calibrated on the richer side of the stoichiometric ratio, and the air supply through
the EACV dilutes the mixture for controlling the mixture close to the stoichiometric.
The system performs feedback function in most of the driving conditions based on the output from the oxygen sen-
sor. However, the system stops this feedback function when the engine needs richer or leaner mixture for the oper-
ating condition, such as when the vehicle is in a power mode, or when the engine is warming up.
2. Shot air control
The system provides air into the intake manifold to improve emissions performance and prevent afterburning due
to the over-rich mixture during short deceleration.
The control unit receives signals of vehicle speed, engine coolant temperature, intake manifold vacuum and engine
speed. And shot air is induced from the EACV when the manifold vacuum increases suddenly except when the vehi-
cle is moving at a very low speed with the engine coolant temperature below the normal operating level.
The amount of air supplied into the intake manifold depends on the amount of the manifold vacuum increase.
(cont'd)
11-157
Feedback Control [D 1382 EUROPE & KQ and D 1584 (KO CAR8) Engine]-
(cont'd)
3. Deceleration air supply
This system is designed to improve emission performance by supplying aír into the intake manifold during decelera-
tion in relatively high engine speed.
The control unit receives signals from the MAP sensor, TW sensor, speed sensor, vacuum switch, gear position switch
and ignition coil, and identifies driving conditions for deceleration air supply. The control unit transmits the electric
current to the EACV which opens and supplies air into the intake manifold.
4. Hot engine start control
This system is designad to provide air into the intake manifold for engine starting when engine coolant temperature
is very high.
The control unit receives the signa) of engine coolant temperatura. When it is higher than the normal temperatura,
the EACV is activated to supply air into the intake manifold befare the vehicle speed exceeds the set speed.
[ 1-Carbureted EngineI VACUUM SWITCH

CLUTCH SWITCH
..+<,.--.o---,.__,
<>-'f'--'T'--'1' .. A/C SWITCH

<>----'1'-_,,_.} TW SENSOR
1
1
1 T
1
1
----L
.t
1
1
1
1
O L---------------------------------------------------------------~J
ELD
11-158
Troubleshooting Flow Chart EACV
lnspection of EACV.
Start the engine and warm up to [01382 EUROPE& KO Enginel (01584 (KO CAR8) Engine]
normal operating temperatura (the
(01382 EUROPE& KQ Engine):

Remove the air cleaner cover.
[D 1584 (KQ CARB) Engine):
Disconnect the EACV hose from
the air cleaner.
EACV
Raise the engine speed to 5,000

min-1 (rpm)
YES
Is there vacuum ? (page 11-21). lf OK. replace the
EACV and retest.
NO
Raise the engine speed to 5,000

min " ' (rpm), then close the
throttle suddenly.
NO
Is there vacuum ? Check the self-diagnosis indicator
(page 11-21).
YES
YES Go to EACV trouble-

Does LED indicate code 14 ? shootin g flowchart
(page 11-160).
NO
Check the hose for proper con-

nection. cracks. brockage or dis-
connected hose. lf OK. replace
the EACV and retest.
EACV is OK.
(cont'd)
11-159
Feedback Control [D 1382 EURO PE & KQ and D 1584 (KQ CAR8) Engine]
(cont'd)
Troubleshooting Flowchart EACV
-@- Self-diagnosis LED indicator indicates CODE 14: A problem in the Electronic Air Control Valve (EACV) circuit.
The EACV opens the air passage from the air cleaner case to the intake manifold in proportion to the intensity of the
electric current received from the control unit.
[01382 EUROPE& KO Engine] [O 1584 (KO CAR8) Engine]

TOINTAKE TO AIR
MANIFOLD CLEANER
VALVE VAL VE
TO SHAFT
INTAKE
MANIFOLD
-Englne is running.

under-hood relay box for 1 O se-
conds to reset control unit.
Start engine.
NO lntermittent failure (test drlving

Does LEO indicates CODE 14 ?
may be necessary).
YES
Stop engine.
[01382 EUROPE& KQ Engine] [O 1584 (KQ CAR8) Engine]
EACV
the EACV.
Measure resistance between the

2 terminals on the EACV.
(To page 11 -1 61 )
EACV
11-160
(From page 11-160)
NO
Is there 6-20 O ? Replace EACV.
YES
Check for continuity to body
ground on each terminal on the
EACV.
YES
Does continuity exist ? Replace EACV.
NO
Reconnect the 2P connector to

EACV.
Connectthe test harnessbetween

the control unit and connector.
Disconnect "B" connector from ººººººººººº
the main wire harness only, not
the control unit (page 11-22).
82
~
terminal and the body ground.
NO Repair open In BLK wire between

Does continuity exist ? control unit (82) and G101.
YES
6-20 O?
n
81 83
Measure resistance between B1
( +) terminal and 83 ( - ) terminal.
Repair open in GRN/WHT, BLU

NO wlre between control unit (811
Is there 6-20 íl ? and EACV or BLU/YEL, BLU/GRN
wire between control unit (83)
YES
and EACV.
unlt and recheck. lf prescribed
voltage is now available replace
the original control unlt.
11-161
Throttle Control System
Description
The throttle controller functions as a dashpot and a cranking opener. The dashpot is provided to control hydrocarbon
emissions during vehicle deceleration or during shifting gears by preventing the throttle valve from shutting rapidly.
When the engine is at idle, intake manifold vacuum is applied on the diaphragm of the throttle controller through the
orifice of the install pipe or solenoid valve and pulls up the diaphragm rod, so that the throttle valve is in the idle position.
After the vehicle starts to run, and as the intake manifold vacuum decreasesthe vacuum stored in the throttle controller
leaks through the orifice of the install pipe or solenoid valve and throttle controller ceases to pull the diaphragm rod.
When the vehicle deceralates or when the manual transmission is shifted, the throttle valve closes rapidly to the position
where the throttle valve lever is stopped with the diaphragm rod, and gradually returns to the idle position as high intake
manifold vacuum slowly reaches the diaphragm of throttle controller through the orifice of install pipe or solenoid
valve.
During cranking with the starter, the spring in the throttle controller pushes the throttle valve open a certain amount
for assisting engine starting.
[01382 ERUOPE& KQ Engine] [01281, 01383 EXCEPTEUROPEand 01583 Engine]

THERMOVAL VE
THROTTLE
CONTROLLER
[01584 (KQ CAR8) Engine]
r-c>-4-----+-.. SPEED SENSOR

A/C }TW SENSOR
IDLE BOOST
THROTTLE
i=====~: A/C SWITCH
()-----'!'-• CLUTCH SWITCH
CONTROLLER
()-----'!'-• A/T SHIFT
POSITION
CONSOLE
SWITCH
T
1
-L.
11-162
Testing (HOT ENGINE) [ 1 -Carbureted EngineJ

2. Disconnect the # 6 vacuum hose from the throttle

controller and check the engine speed.
Engine speed should be:
Manual 2,200±500min-1 (rpm)

Automatic 1,900±500 min-1 (rpm)
ADJUSTING SCREW
[ 1-Carbureted EngineJ [2-Carbureted Engine)
THROTTLE CONTROLLER
• lf the engine speed does not change, connect a
vacuum pump to the # 6 vacuum hose and check
vacuum.
# 6 VACUUM HOSE THROTTLE

CONTROLLER
• lf the engine speed is excessively high, adjust by

turning the adjusting. (cont'd)
11-163
Throttle Control System (cont'd)
VACUUM
PUMP/GAUGE
---
THROTTLE CONTROLLER
# 6 VACUUM HOSE
- lf there is no vacuum;
check the # 6 vacuum hose for proper connec-
tion, cracks, blockage or disconnected hose and
replace the thermovalve.
check the # 6, # 1 2 vacuum hose for proper con-
nection, cracks, blockage or disconnected hose.
lf OK, go to A/C idle boost solenoid valve
troubleshooting (page 11-79).
- lf there is vacuum, replace the throttle controller
and retest.
3. Reconnect the # 6 vacuum hose and check the idle

speed.
ldle speed should be within specification (page

11-104).
11-164
Positive Crankcase Ventilation
Description
A positive crankcase ventilation (P.C.V.) system is used to vent oil-contaminating blow-by gas from the crankcase back
through the air intake system. A baffled chamber separatas oil particles from the blow-by gas, to prevent the intake svs-
tem from being soiled or contaminated.
In proportion to the negative pressure on the intake manifold, the P.C. V. valve installed at the exit part of the breather
chamber is lifted and the blow-by gas is sucked directly into the manifold.
CRANK
CASE
BREATHER
CHAMBER
~ BLOW-BY VAPOR
CRANK ____.r- ~
CASE Q FRESHAIR
(cont'd)
11-165
Positiva Crankcase Ventilation (cont'd)
PCV Valve Test 2. Removethe PCV valve from the intake mainfold and
connect a vacuum pump.
1. Check the crankcase ventilation hoses and connec-
tions for leaks and clogging.
/PCVVALVE
BREATHER HOSE
~.-- ·-' "'

VACUUM PUMP/GAUGE
3. Pinch the hose as illustrated above, apply 400- 500

mmHg (16-20 in. Hg) of vacuum, unpinch the hose
and promptly check for a clicking sound at the PCV
valve.
• lf no clicking sound is heard, replace PCV valve

[2-Carbureted Engine]
and recheck.
BREATHER HOSE
11-166
Blow-by Filter Test
lnspect the condition of the blow-by filter.
• Replace the filter in the following instances:
- When ·the filter is stuck fast and oil is dripping or

seeping through.
- When the filter is covered with dust and dirt so
that clogging is evident.
( 1-Carbureted Engine1
BLOW-BY
FILTER
BLOW-BY
CASE
11-167
Evaporative Emission Control
[01382 EUROPE & KQ, 01583 (KV) and 01584 (KQ CARB) Engine]
Description
The evaporative controls are designad to minimiza the amount of fuel vapor escaping to the atmosphere. The system
consists of the following components.
A. CharcoalCanister
A canister for the temporary storage of fuel vapor until the fuel vapor can be purged from the canister into the engine
and burned.
B. Vapor Purge Control System
Canister purging is accomplished by drawing fresh air through the canister and into the carburetor. The ported vacu-
um is controlled by the purge control diaphragm valve and the *purge cut-off solenoid valve.
*: D1382 EUROPE& KQ Engine
C. Fuel Tank Vapor Control System

The Fuel Cut-Off Valve and Liquid Vapor Separator prohibit liquid fuel entering the two-way valve. When fuel vapor
pressure in the fuel tank is higher than the set value of the two-way valve, the valve opens and regulates the flow
of fuel vapor to the canister.
D. Air Vent Cut-Off Diaphragm
When the engine is not running, the air vent passage in the float chamber is cut-off by the valve attached to the
diaphragm so that fuel vapor in the float chamber can be vented into the charcoal canister. When the engine is run-
ning, manifold vacuum holds the cut-off diaphragm open. * The vacuum holding solenoid valve stabilizes the manifold
vacuum at the diaphragm.
* * The air vent cut-off solenoid valve controls the manifold vacuum of the diaphragm.
*: D 1 382 EUROPE & KQ Engine
* *: D 1 563 (KY) Engine
E. Fuel Filler Cap

A two-way valve in the fuel filter cap acts as a safety device if the evaporative control system malfunctions.
F. CarburetorFuel Cut-Off
When the engine is not running, the fuel passagesfor the slow primary fuel metering system are cut-off by a solenoid
valve so that fuel in the float chamber cannot enter the carburetor bore.
11-168
[01382 EUROPE & KQ Engine)
PURGE CUT-OFF
SOLENOID VALVE
AIR VENT
CUT-OFF
DIAPHRAGM
D---"'--- SPEED SENSOR

MAP { CLUTCH SWITCH
SENSOR ~~~TROL <>-Jl'--- A/C SWITCH
TW SENSOR
a:
o
11)
TO 7" z
FUEL
1 w
..L 11)
TANK CHARCOAL
CANISTER l ~
(01583 (KV) Englne]
AIR VENT CUT-OFF

AIR VENT SOLENOID VAL VE
CUT-OFF
DIAPHRAGM
T
1
--'--
TO
FUEL
l
TANK CHARCOAL
CANISTER
(cont'd)
11-169
Evaporative Emission Control [D 1382 EUROPE& KQ, D 1583 (KV) and --
D 1584 (KQ CAR8) Engine] (cont'd)
The evaporative controls are designed to minimize the amount of fuel vapor escaping to the atmosphere. The system
consists of the following components.
A. CharcoalCanister
A canister for the temporary storage of fuel vapor until the fuel vapor can be purged from the canister into the engine
and burned.
B. Vapor Purge Control System
Canister purging is accomplished by drawing fresh air through the canister and into a port on the throttle body. The
ported vacuum is controlled by the Purge Control Diaphragm Valve.
When the coolant temperatura is above 55ºC the thermovalve directs manifold vacuum to the purge control
diaphragm valve.
When the coolant temperature is below 55°C the thermovalve does not provide manifold vacuum to the purge con-
trol diaphragm valve.

The Fuel Cut-Off Valve and Liquid Vapor Separator prohibit liquid fuel entering the two-way valve.
When fuel vapor pressure in the fuel tank is higher than the set value of the two-way valve, the valve opens and
regulates the flow of fuel vapor to the canister.
D. Carburetor Vapor Control System
The air vent cut-off solenoid valve regulates air flow to the carburetor float bowls. When the ignition switch is turned
OFFthe outer air vent passageopens, so that fuel vapor in the float bowls can be vented into the charcoal canister.
When the ignition switch is turned ON the air vent cut-off solenoid valve opens the inner air vent passage, so that
fuel vapor in the float bowls can be vented into the air cleaner.
There is also an inner vent solenoid valve to control air flow to the carburetor float bowls. When the ignition switch
is turned ON the inner vent solenoid valve normaly opens the sub inner air vent passage, but will only allow fuel
vapor to be vented to the air cleaner.
AIR VENT
CUT-OFF
SOLENOID VALVE
INNER VENT
SOLENOID VAL VE
T
1
-'--
]_
FUEL TANK CHARCOAL
CANISTER
11-170
[01382 EUROPE& KQ and 01584 (KQ CAR8)
Engine]
NOTE: Enginecoolant temperature most be below 55ºC 1. Oisconnect the # 7 vacuum hose at the purge con-
(131 ºF). trol diaphragm valve and connect a vacuum
pump/gauge to the hose.
1. Oisconnect the # 7 vacuum hose at purge control
diaphragm valve and connect vacuum pump/gauge
to the hose.
PURGE CONTROL
DIAPHRAGM VALVE
PURGE CONTROL
DAIPHRAGM VALVE
VACUUM
PUMP/GAUGE
VACUUM PUMP/GAUGE
# 7 VACUUM HOSE
2. Start the engine and allow to idle. temperature (the cooling fan comes on).
There should be no vacuum. There should be vacuum.
• lf there is vacuum, go to step 3.

• lf there is no vacuum, go to hot engine test (next
column). • lf there is no vacuum;
• lf there is vacuum;
[01382 EUROPE& KQ Engine]:
[01382 EUROPE& KQ Engine]:
go to purge cut-off solenoid valve trouble-
go to purge cut-off solenoid valve trouble-
[01 583 (KY) Engine]:
[01584 (KQ CAR8) Engine]:
check the # 7 vacuum hose for proper connec-
tion, cracks, brockage. or disconnected hose.
replace the thermovalve and retest.
[01584 (KQ CARB) Engine]:
replace the thermovalve and retest.
(cont'd)
11-171
Ev~porative Emission Controls [D 1382 EUROPE & KQ, D 1583 (KV) and--
3. Disconnect a vacuum pump/gauge and reconnect
hose. "PCV" FITTING
4. Remove fuel filter cap.
5. Removethe canister purge air hose from trame and

connect hose to· a vacuum gauge as shown.
VACUUM PUMP/
GAUGE
LcHARCOAL
CANISTER
• lf vacuum remains steady, go on to step 7.

• lf vacuum drops, replacethe canister and retest.
9. Restart the engine. Reconnect the hose to the

6. Raise engine speed to 3, 500 min-1 (rpm). canister PCV fitting.
Vacuum should appear on the gauge within PURGEside vacuum should drop to zero.
minute.
• lf PURGEside vacuum does not drop to zero,
• lf vacuum appearson the gauge in 1 minute, re- replace the canister and retest.
move the gauge and go on to step 8.
• lf no vacuum, disconnect the vacuum gauge and 1 O. Connect a vacuum pump to TANK fitting as shown,
reinstall the fuel filler cap. and apply vacuum.
7. Remove the charcoal canister and check far signs lf should not hold vacuum.
of damage. "TANK" FITTING
• lf damaged, replace the canister.

• lf OK, go on to step 8.
8. Stop the engine. Disconnect the hose from the

canister PCV fitting.
Connect a vacuum pump to the canister PURGEfit-
ting as shown, and apply vacuum.
Vacuum should remain steady.
• lf it does not hold vacuum, reinstall fuel filler cap

and canister; test is complete.
• lf it holds vacuum, replace canister and retest.
11-172
Air Vent Cut-off Diaphragm 6. Turn ignition off. Vacuum should drop to zero.
[D1382 EUROPE& KQ and D1583 (KV) Engine]
7. Oisconnect the vacuum pump from vacuum holding
1. Oisconnect the # 8 vacuum hose at the air vent cut- solenoid valve hose and connect to air vent cut-off
off diaphragm and install a vacuum pump/gauge to diaphragm. Apply vacuum.
the hose.
3. Turn ignition switch on.
4. Apply vacuum. Vacuum should remain steady.
• lf vacuum holds go no to step 5.

• lf vacuum does not hold, check the # 8, # 12 Vacuum should remain steady.
vacuum line for proper connection, cracks or dis-
connected hose. • lf vacuum remains stable, diaphragm is OK.
(01382 EUROPE& KQ Engine]: • lf vacuum decrease, replace diaphragm and

retest.
lf OK, go to the air vent cut-off solenoid valve
[01583 (KY) Engine]:
lf OK, go to the vacuum holding solenoid valve

5. Start engine allow to idle and check for vacuum.

Vacuum should be available.
• lf vacuum is available, go to step 6.

• lf vacuum is not available, check the # 8, # 12
vacuum line for proper connection, crocks or dis-
connected hose.
[01382 EUROPE& KQ Engine):
lf OK, go to the air vent cut-off solenoid valve

troubleshooting {page 11-176).
[01583 (KY) Engine):
lf OK, go to the vacuum holding solenoid valve

11-173
Evaporative Emission Controls [D 1382 EUROPE & KQ, D 1583 (KV) and --
P 1584 (KQ CARB) Engine] (cont'd)
Troubleshooting Flowchart Purge Cut-off Solenoid Valve
When the engine coolant temperature is above the set temperature of the TW sensor, the purge cut-off solenoid valve
is activated by the control unit receiving signals from each sensor.
[01382 EUROPE& KO Engine]
lnspection of Purge Cut-off Sole- PURGE CUT-OFF

noid valve. SOLENOID
VALVE

the joint and connected a
vacuum pump.

from the joint and connect a vacu-
um gauge.
Start the engine.
Apply vacuum.
NOTE: Engine coolant temperature

must be below 55°C (131 ºFl.
YES
gauge?
NO
control box.
Start the engine.
BLK
Warm up to normal operating Measure voltage GRN/ORN ( +)
temperature (the cooling fan terminal and BLK terminal.
comes on).
YES
Is there battery voltage ? Replace the solenoid
valve.
NO
Measure voltage GRN/ORN (+)

(To page 11-175)

(To page 11-175)
11-174

Is there battery voltage? between the solenoid
valve and G201 (RHD:
NO G3011

(page 11-21 ). lf OK, inspect open
in GRN/ORN wire between the
solenoid valve and control unit
(812).

YES
control box.
Start the engine.
Purge Cut-off Solenoid Valve is

OK.
ORN ( + ) terminal and BLK ( - )
terminal.
Check the self-

diagnosis indicator
(page 11-211.
YES lf OK, substitute a
Is there voltage ? known-good control
unit and retest. lf sym-
NO
ptom goes away,
replace the original con-
trol unit.
(cont'd)
11-175
Evaporative Emission Controls [D 1382 EURO PE & KO, D 1583 (KV) and--
D 1584 (KO CAR8) Engine] (cont'd)
Troubleshooting Flow Chart Vacuum Holding Solenoid Valve
When the engine is not running, the air vent passage in the float chamber is cut-off by the valve attached to the diaphragm
so that fuel vapor in the float chamber can be vented into the charcoal canister. When the engine is running, manifold
vacuum holds the cut-off diaphragm open. The vacuum holding solenoid valve stabilizes the manifold vacuum at the
diaphragm.
VACUUM HOLDING
lnspection of Vacuum Holding SOLENOID
Solenoid Valve. VAL VE
VACUUM
PUMP/
GAUGE
from the vacuum hose manifold
and connect a vacuum pump.
Disconnect the lower hose of the

solenoid valve from the joint.
Apply 100 mmHg (4 in. Hg) vacu-

um to the hose.

vacuum? Replace the solenoid valve.
NO
NO
Does solenoid valve hold
vacuum? Turn the ignition switch OFF.
YES
Disconnect the BP connector on
the control box.
Measure voltage between BLK/ BLK

YEL ( +) terminal and BLK ( - )
terminal.
YES
Is there battery voltage? Replace the solenoid
valve.
Vacuum Holding Solenoid Valve is
OK. NO
(To page 11-177)
11-176
(From page 11-176)

YEL (+) terminal and body
ground.
Repair open in BLK/YEL

NO wlre between the ignl-
Is there battery voltage? tlon switch and the
connector as well as
YES ACG(S) fuse.
Repair open in BLK wire between

the solenoid valve and G201
(RHD: G301).
(cont'd)
11-177
Evaporative Emission Controls [D1382 EUROPE & KQ, 01583 (KV) and--
D 1584 (KQ CARB) Engine] (cont'd)
Troubleshooting Flow Chart Air Vent Cut-off Solenoid Valve
When the engine is not running, the air vent passagein the float chamber is cut-off by the valve attached to the diaphragm
so that fuel vapor in the float chamber can be vented into the charcoal canister. When the engine is running, manifold
vacuum holds the cut-off diaphragm open. The air vent cut-off solenoid valve controls the manifold vacuum at the di-
aphragm.
[01583 (KV) Engine]
lnspection of Air Vent Cut-off

Solenold Valve.

from the vacuum hose manifold
and connect a vacuum gauge.
Disconnect the # 1 2 vacuum VACUUM

hose from the joint and connect PUMP/
a vacuum pump. GAUGE
Apply 100 mmHg (4 in. Hg) vacu-

um to the hose.

gauge?
NO
Apply 100 mmHg (4 in.Hg) vacu-

um to the hose.
Is vacuum indicated on the Turn the ignition switch OFF.

gauge?
YES
Disconnect the 4P connector of
the solenoid valve.
BLK/
YEL

BLK/YEL ( + ) terminal and BLK
( - ) terminal.
BLK
YES
Is there battery voltage ? Replace the solenold
valve.
NO
Air Vent Cut-off Solenold Valve Is
OK. (To page 11-179)
11-178
(From page 1 1- 1 78)

YEL (+) terminal and body
ground.
Repair open in BLK/YEL

NO wire between the igni-
Is there battery voltage ? tlon switch and the
/
connector as well as
YES ACG(Sl fuse.
Repair open in BLK wire between

the solenoid valve and G201
(RHD:G3011
(cont'dl
11-179
Evaporative Emission Controls ,CD 1382 EURO PE & KQ, D 1583 (KV) and --
Troubleshooting Flow Chart lnner Vent Solenoid Valve
The inner vent solenoid valve remains closed during engine cranking in order to facilitate engine startability by preventing
fuel vapor in the float chamber from drawing into carburetor.
When the engine starts to run, the inner vent solenoid valve is activated to open the passage from air cleaner case.
[01584 (KO CARBJEngineJ
INNER VENT
lnspection of lnner Solenoid SOLENOID VALVE
Valve.
Removethe air cleaner cover and

filter element.
1
Disconnect two vacuum hose
a vacuum pump.
Apply vacuum. VACUUM PUMP/GAUGE
Does solenoid valve hold NO Replace the solenoid valve.

vacuum? BLK/YEL
YES
Start the engine.
Apply vacuum.

vacuum?
NO

the air cleaner.
lnner Vent Solenoid Valva is OK.
Start the engine.

YEL ( + l terminal and BLK ( - l
terminal.
YES Replace the solenold

Is there voltage ?
valve.
NO
(To page 11-181)
11-180
(From paga 11-180)
1
Me asure voltage between
BLK/YEL ( +) terminal and body
ground.
YES Repair open In BLK wlre

Is there battery voltage ? batwaen the solanoid
valva and G101.
NO
Check tha BLK/YEL wira batween

the lgnltion switch and the sole-
noid valva as well as No. ACG(S)
fusa.
(cont'dl
11-181
Evaporative Emission Controls [O 1382 EURO PE & KQ, D 1583 (KV) and --
D 1584 (KQ CARB) Engine] (cont'd)
Troubleshooting Flow Chart Air Vent Cut-off Solenoid Valva
The air vent cut-off solenoidvalve remainsclosedduring enginecrankingin orderto facilitate enginestartability by preventing
fuel vapor in the float chamber from drawing into carburetor.
When the engine starts to run, air vent cut-off solenoid valve is activated to open the passage from air cleaner case.
(01584 (KQ CARB) Engine]
lnspection of Air Vent Cut-off

Solenoid Valve.
Disconnect the upper hose of the

solenoid valve from the air clean-
er and connect a vacuum pump.
Disconnect the lower hose of the

solenoid valve.
Apply vacuum.
AIR VENT CUT-OFF SOLENOID VAL VE
Does solenoid val ve hold NO

vacuum? Replace the solenoid valve.
YES
Start the engine.
Apply vacuum.

vacuum?
NO
Air Vent Cut-off Solenoid Valve is

OK.

the air vent cut-off solenoid valve.
Start the engine.
(To page 11-183)
11-182
(From page 11-182)
1
YEL/BLK ( +) terminal and body
ground at the 14P connector.

BLK/YEL wire between
YES the solenoid valve and
the 14P connector.
NO lf OK, replace the sole-
noid valve.
Repair open or short in YEL/BLK,

BLK/YEL wlre between the igni-
tion switch and the 14P connec-
tor as well as No. ACG (S) fuse.
(cont'd)
11-183
Evaporative EmissionControls [D 1382 EURO PE & KO. D 1583 (KV) and
01584 (KQ CAR8) Engine] (cont'd)
Two-Way Valve 4. Move hand purnp hose from vacuum to pressure fit-
ting, and move vacuum gauge hose from vacuum
1. Remove the filler cap. to pressure side as shown.
2. Remove vapor line from the fuel tank and connect

a T-fitting from a vacuum gauge and vacuum pump
as shown.
T-FITTING
3. Slowly draw a vacuum while watching the gauge. 5. Slowly pressurize the vapor line-while watching the
gauge.
Vacuum should stabilize at 5 to 1 5 mmHg (02. to
0.6 in.Hg). Pressure should stbilize at 1 O to 35 rnrnHg (0.4 to
1.4 in.Hg).
• lf vacuum stabilizes rnornentarily (two-way valve
opens) between 5 and 15 rnrnHg (0.2 and 0.6 in. • lf pressure rnomentarily stabilizes (valve opens)
Hg), go on to Step 4. at 1 O to 35 mmHg (0.4 to 1.4 in.Hg), the valve
is OK.
• lf vacuurn stabilizes (valve opens) below 5 rnrnHg
(0.2 in.Hg) or above 15 rnrnHg (0.6 in.Hg). install • lf pressure stabilizes below 1 O rnrnHg (0.4 in. Hg)
new valve and retest. or above 35 rnrnHg (1.4 in.Hg), install a new valve
and retest.
11-184
Fuel and Emission (Fuel-lnjected Engine)
Special Tools 11-186 System Descirption ..................................•. 11-297
Component Locations Troubleshooting Flowcharts (Except 01582 engine)
lndex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-187 Electric Air Control Valve 11-300
System Description Air Conditioning Signa! . . . . . . . . . .. . . . . . . . . . . . . . . . . 11-302
Vacuum Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-193 Alternator FR Signa! . . . . . . . . . . . . . .. . . . . . . . . . . .. . . . . 11-304
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-200 A/T Shift Position Signa! 11-306
Troubleshooting M/T Clutch Switch Signa! (D15Z1 englnel 11-308
Troubleshootlng Guida 11-204 Starter Switch Signa! . . . . . . . . . . . . . . . . . . . . . . . . . .. . . 11-31 O
Self-diagnostic Procedures 11-208 8rake Switch Signa! . . . . . . . . . . . . . • .. . . . . . . . . . .. . . . . 11-312
How to Read Flowcharts 11-214 P/S 011 Pressure Switch Signal 11-314
Troubleshooting Flowcharts (D1582 engine)
Electronic Air Control Valve . . . . . . . . . . . . . . . . . . . . 11-316
PGM-FIControl System Air Conditioning Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-318
Troubleshooting Flowcharts (Except 01582 engine) Alternator FR Signa! .........................•..... 11-320
System Description . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . 11-21 6 A/T Shift Position Signa! . . . . . . . . . . . . . . . . . . . . . . . . 11-322
Engine Will Not Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-218 Starter Switch Signa! . . . . . . . . . . . . . . . . . . . . . . • . . . . . . 11-324
Electronic Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-219 Fast ldle Valve (Except 01582. D15Z1
Oxygen Sensor (D16A7. D16A8 enginel .. 11-223 engine) ...•......................................... 11-325
(D16Z6. D16Z7. ldle Speed Setting 1 1-326
816A2 enginel 11-225
LAF Sensor (D15Z 1 engine) 11-226 Fuel Supply System
Oxygen Sensor Heater System Troubleshooting Guide 11-331
(D 1626, D 16Z7. 816A2 engine) 11-232 System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-332
Fuel Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 -332
LAF Sensor Heater ID 15Z 1 engine) 11-236
Fuel lnjectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-334
Fuel Supply System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-240
Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-343
Manifold Absoluta Pressure Sensor 11-242
Fuel Filter . . . . . . . . . . . .. . . . .. . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . 11-344
TDC/CRANK/CYL Sensor . . . . . . . . . . . . . . . . . . . . . . . . 11-250 Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . 11 -346
Coolant Temperatura Sensor 11-252 Main Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-349
Throttle Angle Sensor 11-254 Fuel Sub Pump (4WD) 11-352
lntake Alr Temperatura Sensor 11-256 Sub Fuel Cut-off Relay 11-354
IMA Sensor ....................•...................... 11-258 Fuel Tank 11-357
lgnition Output Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-260
Vehicle Speed Sensor 11-262 Air lntake System
A/T Lock-up Control Solenoid Valva 11-264 System Troubleshooting Guide . . . . . .. . . . . . . . . . . . . . 11-360
Electric Load Detector (D15Z 1 engine) 11-266 System Description . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . 11-361
Troubleshooting Flowcharts (01582 engine) Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 -362
Electronic Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-270 Throttle Cable 11-364
Oxygen Sensor 11-274 Throttle 8ody . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . 11-366
Manifold Absoluta Pressure Sensor 11-276 Tandem Control System (01582 engine) 11-374
TDC/CRANK Sensor 11-282 Throttle Control System (D1582 engine) ..•.•. 11-379
Coolant Temperatura Sensor 11-284
Throttle Angle Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-286
System Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . 11-381
lntake Air Temperatura Sensor 11-288
System Description . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . 11-382
lgnltion Output Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-290 Tailpipe Emission 11-382
Vehicle Speed Sensor 11-292 Catalytic Converter . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 11 -383
A/T Lock-up Control Solenoid Valve 11-294 Exhaust Gas Recirculation System (D1521
enginel 11-386
ldle Control System Positiva Crankcase Ventilation System 11-392
System Troubleshooting Guide .. .. . .. . .. . . . . . . . . . . 11-296 Evaporative Emission Controls . . . .. . . . . . . . . . . . . . . . . 11-394
Special Tools
Special Tools
Ref. No. Tool Number Description Q'ty Remarks
CD 07LAA-PT50101 02 Sensor Socket Wrench 1

or
07LAJ--PT301 OA
@ O 7406--0040001 Fuel Pressure Gauge Set 1
@-1 07406-0040100 PressureGauge ( 1)
Component Tools
@-2 07406-0040201 Hose Assy ( 1)
@ 07999-PD6000A Test Harness 1
® 07411 -0020000 Digital Circuit Testar 1
( )@)
CD
1
@ @
-t)ID
L<u~
2J ~ c.U:)g}
@-1 @-2
@
© ®
11-186
Component Locations
lndex MANIFOLD
MANIFOLD THROTTLE ABSOLUTE
ABSOLUTE ANGLE SENSOR PRESSURE PURGE CONTROL SOLENOID
B16A2, PRESSURE Troubleshooting, (MAPI SENSOR VAL VE
D16A8, (MAPI SENSOR page 11-254 (D16A8, D16A9 enginel Troubleshooting, page 11-396
D16A9 engine: (B 16A2 enginel Troubleshóoting, EACV
Troubleshooting, page 11-242, 246 P/S OIL
page 11-242, 248 PRESSURE
~~ SWITCH
Troubleshooting,
page 11-314
INTAKE AIR
TEMPERATURE
(TA) SENSOR
FAST IDLE 1016A8, 016A9
VAL VE enginel
lnspection Troubleshooting,
page 11-325 page 11-256
TDC/CRANK/CYL~~~~~~~-;J;5:~~::~~~~~ INTAKE AIR
SENSOR TEMPERATURE
Troubleshooting, (TAi SENSOR
page 11-250 (B16A2 enginel
Troubleshooting,
IGNITER UNIT page 11-256
Troubleshooting,
page 11-260
OXYGEN 102)
SENSOR
(016A8 engine)
Troubleshooting,
HEATEO page 11-223
OXYGEN (02) COOLANT
. SENSOR LOCK-UP CONTROL TEMPERATURE
(B16A2 engine) SOLENOIO VALVE A/B (TW) SENSOR
Troubleshooting, Troubleshooting, Troubleshooting,
page 11-225, 230 page 11-264 page 11-252
D16A7, 01626,
01627 engine:
THROTTLE MANIFOLD PURGE CONTROL SOLENOIO
ANGLE SENSOR ABSOLUTE VAL VE
FAST IOLE Troubleshooting, PRESSURE EACV Troubleshooting, page 11-396
VAL VE page 11-254 (MAPI SENSOR Troubleshooting
lnspection Troubleshooting, page 11-300 '
page · 11-325 page 11-242, 246
INTAKE AIR
TEMPERATU RE
(TAi SENSOR
Troubleshooting,
page 11-256
TOC/CRANK/CYL
SENSOR
Troubleshooting,
page 11-250
IGNITER UNIT
Troubleshooting, --~~""""íftt----~~~~lli.~~J:.~¡
page 11-260
LOCK-UP CONTROL
SOLENOIO VALVE A/B
Troubleshooting, HEATEO Troubleshooting,
page 11-264 OXYGEN (02) page 11-314
SENSOR
(01626, 01627 englne)
Troubleshooting,
page 11-242, 240
COOLANT OXYGEN (02)
TEMPERATURE SENSOR
(TWI SENSOR (D16A7, D16A8 engine)
Troubleshooting, Troubleshooting,
page 11-252 paga 11-223
11-187
Component Locations
lndex
01521 engine:
THROTTLE MANIFOLD EACV PURGE CONTROL SOLENOID
ANGLE SENSOR ABSOLUTE Troubleshooting, VAL VE
Troubleshooting, page 11-254 PRESSURE paga 11-300 Troublashooting, page 11 -396
(MAP) SENSOR
Troubleshooting, 'tNTAKE AIR
page 11-242, 246 TEMPERATURE
(TA) SENSOR
Troubleshooting,
ELD (Electric paga 11-256
Load Detector)
Troublashooting,
page 11-266
TDC/CRANK/CYL
SENSOR
\_~~J;f::::=-~~2ii~
Troublashooting, .
paga 11-250
(Linear Alr
IGNITER UNIT
Fuel ratio)
SENSOR
Troublashooting,
paga 11-226, 236
COOLANT P/S OIL
TEMPERATURE PRESSURE
(TW) SENSOR SWITCH
Troublashooting, Troubleshooting,
paga 11-252 paga 11-314
D 1582 engine:
TANDEM VALVE TANDEM VALVE CONTROL THROTTLE ANGLE SENSOR

CONTROL DIAPHRAGM SOLENOID VALVE Troublashooting, paga 11-286
Testing, paga 11-380 Troubleshooting, page 11-374
MANIFOLD ABSOLUTE PRESSURE T roubleshooting,

IMAP) SENSOR page 11-400
Troublashooting, paga 11-276, 280
IGNITER UNIT
Troublashooting,
paga 11-290

(TAi SENSOR
Troublashooting, page 11-288
COOLANT TEMPERATURE DASHPOT DIAPHRAGM OXYGEN(02)SENSOR

(TWI SENSOOR Testing, 11-380 Troublashooting, paga 11-274
11-188
Exept 01582 engine:
THROTTLE BODV THROTTLE CABLE
lnspection, page 11-366 lnspection/Adjustment,
Disassembly, page 11-368 page 11-364
PCV VALVE
AIR CLEANER --.._.+--i..tY,

Disassembly,
page 11-362
RESONATOR
01582 engine:
THROTTLE CABLE
lnspection/Adjustment, page
11-365
lnstallation, page 1 1 -365
11-189
Component Locations
lndex~~~~~~~~~~~~~~~~~~~~~~~~~~~
LHD:
IMA SENSOR
Troubleshooting,
page 11-258
FUEL
CUT-OFF
RELAY
Operation
page 11-354
Testing
page 11-355
MAIN RELAY
Relay Testing, page 11-349
ELECTRONIC CONTROL UNIT (ECUI
Self-diagnostic Procedures, page 11-208
Troubleshooting, page 11-218, 270
RHD:
SERVICE CHECK CONNECTOR C2Pl

Self-diagnostic Procedures, page 11-208
IMA SENSOR
Troubleshooting,
page 11-258
MAIN RELAY
ELECTRONIC CONTROL UNIT (ECU) Relay Testing, page 11-349
Self-diagnostic Procedures. page 11-208 Troubleshooting, page 11-350
11-190
Exept 01582 englne: PRESSURE REGULATOR FUEL PUMP
Testing, page 11-343 Testing, page 11-34 7
Replacement, page 11-344 Replacement, page 11-348
FUEL RETURN
PIPE
FUEL FILTER
FUEL VAPOR
Troubleshooting, page 11-396 PIPE
FUEL PIPE
FUEL INJECTORS
Replalcement, page 11-335
01582 engine:
FUEL PUMP
FUEL FILLER
CAP
Replacement,
page 11-357
Troubleshooting,
page 11-338 PRESSURE REGULATOR
Replacement, page 11-342 Testing, page 11-343
Replacement page 11-344
11-191
Component Locations
lndex
4WD:
PRESSURE REGULATOR FUEL SUB PUMP FUEL PUMP

Testing, paga 11-343 Testing, Testing, page 11-34 7
Replacement, page 11-344 page 11-352 Replacement. page 11-348
--=:::::::::::=-----1--
Replacement,
page 11-358
FUEL VAPOR
PIPE
FUEL INJECTORS FUEL PIPE

11-192
System Description
VacuumConnections~~~~~~~~~~~~~~~~~~~~~~~~~
D16A7, D16Z6, D16Z7

D16A8, D16A9 engine:
TO
TWO-WAY
VAL VE
(016A7,
01626, 01627
----,
engine)
1
1
1
1
1
1
PURGE CONTROL I
CHARCOAL SOLENOID VAL VE I
CANISTER Troubleshooting, :
I page 11-396 1
L I
FRONT OF
VEHICLE PRESSURE
D 1582 engine: REGULATOR
MANIFOLD ABSOLUTE PRESSURE

(MAPJ SENSOR
TO TWO-WAY VALVE
PURGE CUT-OFF
SOLENOID VAL VE
CHACOAL
CANISTER
FRONT OF ~
VEHICLE (cont'd)
11-193
System Description
Vacuum Connections (cont'd) ---------------------
B16A2 engine:
MAP SENSOR
Troubleshooting,
paga 11-242, 248
TO
TWO-WAY
VAL VE
PURGE CONTROL
SOLENOID VALVE
Troubelshooting,
page 11-396
CHARCOAL
CANISTER
FRONT OF
VEHICLE PRESSURE
REGULATOR
015Z1 engine:
EGR VALVE CONTROL BOX
page 11-195
TO
TWO-WAY
VAL VE
CHARCOAL
CANISTER
Troubleshooting,
page 11-396
PRESSURE
FRONT OF
REGULATOR
VEHICLE
11-194
Control Box
(015Z1 englne only)
CONSTANT VACUUM CONTROL (CVCI EGR CONTROL SOLENOID VALVE

VAL VE Troubleshooting, apge 11-386
(cont'd)
11-195
System Description
Vacuum Connections (cont'd)
Except D15Z1. 01582 (016A7. 01626

engine: 01627, B16A engine)
r---------.
' '
1 1
'
1
':
: -~j
(Except
B16A2
engine)
(B16A2
-.. .,.-------'
engine)
@
G) OXYGEN 102) SENSOR @ FUEL TANK

@ MANIFOLD ABSOLUTE PRESSURE IMAP) SENSOR @ AIR CLEANER
(Except B 16A2 engine) @RESONATOR
@ MANIFOLD ABSOLUTE PRESSURE (MAPI SENSOR @ CATALYTIC CONVERTER
IB16A2 enginel @PCV VALVE
@ FAST IDLE VALVE @ PURGE CONTROL DIAPHRAGM VALVE
@ FUEL INJECTOR @ PURGE CONTROL SOLENOID VALVE
(:!) PRESSURE REGULATOR @TWO-WAY VALE
@ FUEL FILTER
@ FUEL PUMP
11-196
01521 engine:
@
r.==========================~!f!l@
G) OXYGEN (02) SENSOR @) RESONNA TOR

@ MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR @ EGR VALVE
@ ELECTRONIC AIR CONTROL VALVE (EACV) @ CONSTANT VACUUM CONTROL (CVC) VALVE
@ FUEL INJECTOR @ EGR CONTROL SOLENOID VALVE
@ PRESSURE REGULATOR @ CATALYTIC CONVERTER
@ FUEL FILTER @ PCV VALVE
(Z) FUEL PUMP @ CHARCOAL CANISTER
@ FUEL TANK @ PURGE CONTROL DIAPHRAGM VALVE
@ AIR CLEANER @ PURGE CONTROL SOLENOID VALVE
@ TWO-WAY VALVE
(cont'd)
11-197
System Description
· Vacuum Connections (cont'd) --------------------
01582 engine:
r,=============================~@
'----<O
G) OXYGEN (02) SENSOR @TANDEM VALVE CONTROL DIAPHRGM

@ MANIFOLD ABSOLUTE PRESSURE (MAPI SENSOR @ TANDEM VALVE CONTROL SOLENOID VALVE
@ ELECTRONIC AIR CONTROL VALVE IEACV) @ DASHPOT DIAPHRAGM
@ AIR CLEANER @PCV VALVE
@ MAIN INJECTOR @ CHARCOAL CANISTER
@ AUX. INJECTOR @ PURGE CONTROL DIAPHRAGM VALVE
<i) PRESSURE REGULATOR @ PURGE CUT-OFF SOLENOID VALVE
@ FUEL FILTER @TWO-WAY VALVE
@ FUEL PUMP
@ FUEL TANK
11-198
System Description
Electrical ConnectionsExcept D 1582 engine]
~·
MAIN RELAY
® 1 1- 1- 7
--,
IGNITION SWITCH ® 5 !~ 8
® 6 ~ ~ p FUEL PUMP
1 ...-, 1
3 2
@ ~ Q)
-=
1
i® r - -, ®
'' '>1' •
L r-_¡(A/TI H A25 IGP1 PG1 A23
¡. A ® ~
......
'----<
81 IGP2
89 STS
PG2 A24
FLR1 A7
>----:..=
, >---
~
01 V8U FLR2 AS .....----
A26 LG1
82 LG2 e'
INJECTORS
~
No. 1
--- -- - 811 CYL P INJ1 A1
--
- vv
CYL SENSOR
~ No. 2
T DC SENSOR
-~ - -
- - -
812 CYL M
813 TDC P
INJ2 A3
INJ3 AS -
N~4
NÓ.3
-c.
vv -
-~ - - 814 TDC M INJ4 A2 ----- vv ----...,--
- --- --- 815 CRNK P

CRA NK SENSOR
,____ - --- - 816 CRNK M
EACV
TO ELD UNIT 010 El EACVA9 - vv
CHECK ENGINE
LIGHT
SPEED SENSOR @] 810 VSP WARN A13 ,-
f -=
-~
'
.F
SERVÍCE
CHECK
ACS 85 TO A/C SWITCH
CONNECTOR
rrr D4SCS ACC A15
8----
- vv
A/C COMPRESSOR CLUTCH
RELAY
,......., RADIATOR FAN RELAY

DATA LINK
M/T CLUTCH
07 TXD/RXD FANC A12 - -- ..
e~
CONNECTOR ~
, SWITCH
[!] O 15Z1 engine
COOLANT
only ' TEMPERA TURE
~
J ,---------
87 CLSW ...= SWITCH
87 ATNP
1
1 83 ATD3 ATLSA A19
1
1 ..-
1
B4ATD4 ATLS8 A17
-------- --- ------ - ::-¡
-
»:
1 -1 A/T LOCK-UP A/T LOCK -UP I
-' .,. lj
1 CONTROL CONTROL 1
l~
1 ,
SOLENOID SOLENOID
1 -
VALVE 8
1
- VALVE A
·~
1 ,__,, p
,-------__J 1--
~ --= _ _J
·-
r"' N
1 1-- 1 --- FUSES - - - - - - - - - - - - - - - -
1 ,~ ~-
03
1
1 G) 8ACK UP 17.5 Al*
1 H4--- 04 1
1 @ 8ATTERY 180 Al*
1
1
1
SHIFT POSITION ,, SHIFT POSITION
1
1
@IG (50 Al*
@ STOP. HORN (20 Al*
CONSOLE 04 INDICATOR 1
1 @ ECU 115 Al*
SWITCH ~03 1
1
1 @ ACG (SI 115 Al
1
1 Q) 8ACK-UP LIGHTS 110 Al
1
1
1
.....
-=
1
1
@ REAR DEFROSTER RELAY
HEATER MOTOR RELAV
L--------------------------------~
(A/T)
COOLING FAN MOTOR RELAY (7.5 Al
@ STARTER SIGNAL 17.5 Al
11-200 •: UNDER-HOOO FUSE/RELA Y BOX
·~
[I] -
---___.,-,/
019 VCC1 VREF 016 o-----<::• TO AfT CONTROL
UNIT (4WO)
020 vccz
021 SG1
022 SG2
MAP ~o--++-1~~~~~--<"l 017 PB
SENSOR!..____§==..... >--------~
THROTTLE
I
ANGLE I ,__0110TH e_1_G_P_1_A_z_1__,M4 IGNITER
SENSOR
e IGP2 A22 1
r----[-J--~- - ----------
~ UNIT
016A9 =
englne) IMA
SENSOR l 010 VIOL
1 --------- - ----------
,--------------
1
(015Z1 engine) EGR VALVE 3:_1.,._-0----t------~-<> 012 EGRL (Except 016A7, 016A8,
: LIFT SENSOR '~-o-I___ 1----------'
016A9 englne)
'- - - 1 VALVE - - - - - - -
(Except D16A7, 1 TIMING Oll ~--+---~lo- ¡ . 06 VTM VTS A4
016A8, 016A9
engine)
: PRESSURE _...._
LSVl!ITCH __ = _
----------
P/S OIL
~1--------'--------l
SPOOL SOLENOIO
__________________
VAL VE !1 ¡
IAlA PRESSURE
~
t SWITCH
BRAKE SWITCH BB PSW
(015Z1 engine)
0
'---------+---o---<->--ó'02BKSW -----------------
TA SENSOR ES A11
- EGR CONTROL
-
'-
'- -... - 015TA ,.. ~q_L~~~~ Y ~L .Y~ 1
- '
- 013TW PURGE CUT-OFF
SOLENOIO VALVE
r-
HEATEO ¡ []]
TW SENSOR PGS AZO vv
1
ID16Z6,
1
1
1
O. SENSOR I
1
f @]
•
016Z7, :
B16A2 A6 HTCNTL
1
engine) 1
1
~~A~Á'·\~:r-----~~:----------+---------~--~_0_1_4_0_2__ --1 __ A_c_G_c_A_1_6_::---o-~I l'i"\
1
1 : ACGF09 ~
(016A7.1
1------ o;SENSOR - - ¡ ALTERNATOR
,.,,¿' l
-!-
1 .... A I
016A8 014 02
engine) IA'I /v v :
--------------- 1
03 LABEL
1
1
vvv '
11#
l"'I
A
08VS+
(01521 .r: V
englnel 016 IP-. VS-

T __ J _
- - - ,a- 014 IP+
.r>
AAA
VVv A6 HTCNTL
1 1
1 1
L----------------J
LAF
SENSOR
A1 O Al Al AIIAUAUA11AUA21AUA.U 11 11 U 11 11 IIIIUIII D1 DI DI 07 Dt DII 011 DII 017 Dtl DZI
ººººººººººººº ºººººººº 00000000000
.
ººººººººººººº Al U Ali AU AH Ali .1.11 .1.21 AU u, AU
ºººººººº
12 h 11 11 11t 112 114 111
00000000000
DI o, DI DI DIIIIU DU 0110\IDU DU
TERMINAL LOCATION
11-201
System Description
Electrical Connections [01582 engine]
MAIN RELAY
@ FUEL PUMP
,---~~~~~--~O"'-o----t----C>-kl~O--.-,N--'llv~~~o-Q-------lcP
To
starter---------'
TDC/CRANK
SENSOR
MAP
SENSOR
PA
SENSOR
THROTTLE
ANGLE
SENSOR
SERVICE
CHECK
CONNECTOR r------
1
1
1
1
TW SENSOR IGNITER
1
1 UNIT
1
1
TA SENSOR 1
1
_________ dJ1
OXYGEN
SENSOR
Jr
ALTERNATOR
SPEED
SENSOR
Al AS AS Al Al A11AIIA15A17 81 83 85 87 81 811813815 817 811 C1 es C5 C7 e, Cl1 Cli C11 FU SES

G) BATTERY 180 A)*
000000000
000000000 ºººººººººº
0000000000
00000000
00000000
@IG (50A)•
@ ECU (15 Al*
@) ACG (S) (15 A)
A2 A4 Al Al A10A12Al4AUAI! 82 84 81 B1 810 812 814 811811820 C2 C4 CI CI CIOC12C14C11 @ STARTER SIGNAL (7.5 A)
@ BACK-UP LIGHTS (10 AJ
(J) BACK-UP (7.5 A)*
TERMINAL LOCA TION *: UNDER·HOOD FUSE/RELA Y BOX
11-202
Troubleshooting
Troubleshooting Guide
[Except 01582 engine]------------
NOTE: Across each row in the chart, the systems that could be sources of a symptom are ranked in the arder they
should be inspected starting with CD. Find the symptom in the left column, read across to the most likely source, then
refer to the page listed at the top of that column. lf inspection shows the system is OK, try the next most likely system
@, etc.
OXYGEN MANIFOLD COOLANT THROTTLE INTAKE AIR IMA IGNITION VEHICLE

(Dl 521 engine: ABSOLUTE TDC/CRANK/CYL TEMPERA- ANGLE TEMPERA- SENSOR OUTPUT SPEED
ECU LAFI* PRESSURE SENSOR TURE
I-P_A_G_E~~~~SYSTEM'l-~~~1--~~~--+~~----1~~~~-+-PG_M_·_Fl--+~~----1~~~~~~4-~~-1-~~~ TURE 1016A9
SENSOR SENSOR SENSOR SENSOR SENSOR engine) SIGNAL SENSOR
223• 225• 226•
SYMPTOM 218 242, 246 250 252 254 256 258 260 262
230, 236
CHECK ENGINE LIGHT**

TURNS ON
CHECK ENGINE LIGHT

BLINKS
ENGINE WON'T START

CD @ @
DIFFICULT TO START
ENGINE WHEN COLD @ CD
WHEN COLD
FAST IDLE @
OUT OF SPEC
ROUGH IDLE @
IRREGULAR
IDLING WHEN WARM
RPM TOO @
HIGH
WHEN WARM
RPMTOO @
LOW
WHILE
WARMING UP @
FREQUENT
STALLING
AFTER
WARMING UP
MISFIRE OR
ROUGH @
RUNNING
POOR FAILS
PERFORM- EMISSION @
ANCE TEST
LOSS OF
POWER @ @
* lf codes other than those listed above are indicted, count the number of blinks again. lf the indicator is in fact blinking
these codes, substitute a known-good ECU and recheck. lf the indication goes away, replace the original ECU.
lf the Check Engine light is on while the engine is running, jump the servíce check connector. lf no code is dísplayed
(Check Engine,light stays on steady). the back-up system is in operation.
Substitute a known-good ECU and recheck. lf the indication goes away, replace the original ECU.
11-204
PGM-FI IDLE CONTROL FUEL SUPPLY EMISSION CONTROL
LOCK-UP VAL VE ELECTRONIC
ELECTRIC SPOOL TIMING OIL OTHER OTHER AIR EGR OTHER
CONTROL AIR FUEL
LOAD SOLENOID IDLE FUEL INTAKE CONTROL E MISS ION
SOLENOID PRESSURE CONTROL INJECTOR
DETECTOR VALVE CONTROLS SUPPLY SYSTEM CONTROLS
VALVE SWITCH VAL VE
264 266 6-12 6-14 300 296 334 331 360 386 381
CJ
-, 1 /
-[01- -101-
" 1 /
/ 1 <, / 1 <,
G) @
@ G) @ @
G) @
@ G) @
G) @ @
@ G) @
G) @
G)
@ @ @ Q) @
11-205
Troubleshooting
Troubleshooting Guide [D 1582 engine]
NOTE:
A cross each row in the chart, the systems that could be sources of a symptom are ranked in the order they· should be
inspected starting with G). Find the symptom in the left column, read across to the most likely source, then refer to
the page listed at the top of that column. lf inspection shows the system is OK, try the next most likely system @, etc.
MANIFOLD COOLANT INTAKE AIR

f- ECU OXYGEN ABSOLUTE TDC/CRANK TEMPERA- T~~OGTL~LE TEMPERA-
P_A_G_E~~~~~s;:_SYSTEM~~~~~-+~~~~-+-~~~~...-~P-G-M--F-l~+-~~~---.,--~~~--1-~~~~--1
SENSOR PRESSURE SENSOR TURE SENSOR TURE
SENSOR SENSOR SENSOR
SYMPTOM 270 274 276, 280 282 284 286 288
CHECK ENGINELIGHT
TURNS ON Oor~ ~r61::
/ 1 '
SELF-DIAGNOSIS INDICATOR
(LEO) BLINKS
ENGINEWON'T START @
DIFFICULT TO START
ENGINEWHEN COLO @ CD
WHEN COLO
FASTIDLE @
OUT OF SPEC
ROUGH IDLE @
IRREGULAR
IDLING WHEN WARM
RPM TOO
HIGH
WHEN WARM
RPM TOO @)
LOW
WHILE
WARMING UP ®
FREOUENT
STALLING
AFTER
WARMING UP
MISFIRE OR
ROUGH @
RUNNING
POOR FAILS
PERFORM- EMISSION @
ANCE TEST
LOSS OF
POWER @
* lf codes other than those listed above are indicted, count the number of blinks again. lf the indicator is in fact blinking
these codes, substitute a known-good ECU and recheck. lf the indication goes away, replace the original ECU.
lf the Check Engine light is on while the engine is running, jump the service check connector. lf no code is displayed
(Check Engine light stays on steady). the back-up system is in operation.
Substituta a known-good ECU and recheck. lf the indication goes away, replace the original ECU.
11-206
EMISSION
PGM-FI IDLE CONTROL FUEL SUPPLY
CONTROL
VEHICLE LOCK-UP OTHER OTHER OTHER

EGNITION ELECTRONIC FUEL
CONTROL IDLE AIR
OUTPUT SPEED AIR CONTROL FUEL EMISSION
SOLENOID INJECTOR INTAKE
SIGNAL SENSOR VAL VE CONTROLS SUPPLY CONTROLS
VAL VE
290 292 294 316 296 338 331 360 381
' 1 /
-[01-
/ 1 '·
® CD
CD ®
® CD
® CD
CD ®
CD
CD @
@ Q)
CD
@ CD
11-207
Troubleshooting
Self-diagnostic Procedures
l. When the Check Engine light has been reportad on, do the following:
1. Connect the Servuce Check Connector terminals with a jumper wire as shown (The 2P Service Check Connector
is located under the dash on the passenger side of the car). Turn the ignition switch on.
LHD: RHD:
3P CONNECTOR
NOTE:
SERVICE CHECK
CONNECTOR
3P CONNECTOR
NOTE:
Do not attach
the jump wire.
SERVICE CHECK
CONNECTOR
./
2. Note the CODE: the Check Engine light indicates a failure code by the length and number of blinks. The Check
Engine light can indicate simultaneous component problems by blinking separata codes, one after another. Problem
codes 1 through 9 are indicated by individual short blinks. Problem codes 1 O through 48 are indicated by a series
of long and short blinks. The number of long blinks equals the first digit, the number of short blinks equals the
second digit.
Separate Problems:
Short
= Sea Problem CODE 14
Long short
~= Sea Problem CODE 1 and 3
~= Sea Problem CODE 3 and 4
· = See Problem CODE 3 and 14
11-208
11. ECU Reset Procedure
2. Remove the BACK UP fuse (7.5 Al from the under-hood fuse/relay box for 10 seconds to reset the ECU.
NOTE: Disconnecting the BACK UP fuse also cancels the radio preset stations and the clock setting. Make note
of the radio presets before removing the fuse so you reset them.
111. Final Procedure (this procedure must be done after any troubleshooting)
1. Remove the Jumper Wire.
NOTE: lf the Service Check Connector is jumped, the Check Engine light will stay on.
2. Do the ECU Reset Procedure.
3. Set the radio preset stations and the clock setting.
(cont'd)
11-209
Troubleshooting
Self-diagnostic Procedures(cont' d) ------------------
PAGE
SELF-DIAGNOSIS PAGE
SYSTEM INDICATED (Except
INDICATOR 8LINKS (D1582 engine)
D 1582 engine)
o ECU 11-219 11-270
1 OXYGEN SENSOR (Except D 16A9 engine) 11-223, 225 11-274
3 MANIFOLD A8SOLUTE PRESSURE(MAP 11-242 11-276
5 SENSOR) 11-246 11-280
4 CRANK ANGLE (CRANK SENSOR) 11-250 11-282
6 COOLANT TEMPERATURE(TW SENSOR) 11-252 11-284
7 THROTTLE ANGLE 11-254 11-286
8 TDC POSITION (TDC SENSOR) 11-250 11-282
9 No. 1 CYLINDER POSITION (CYL SENSOR) 11-250 -
10 INTAKE AIR TEMPERATURE(TA SENSOR) 11-256 11-288

11 IMA SENSOR (D16A9 engine) 11-258 -
12 EXHAUST GAS RECIRCULATIONSYSTEM (EGR) 11-386 -
14 ELECTRONICAIR CONTRL (EACV) 11-300 11-316
15 IGNITION OUTPUT SIGNAL 11-260 11-290
16 FUEL INJECTOR (D 1582 engine) - 11-338
17 VEHICLE SPEED SENSOR 11-262 11-292
19 A/T LOCK-UP CONTROL SOLENOID VALVE A/8 11-264 11-294
-=~~}~-=-- ~ -,~, ni\

-El::EG-"FRQNIG-l-0
An -
- '- _.. -:/-..-
• ~66---- -
(_2j) SPOOL SOLENOID VALVE 6-12 -
@, VALVE TIMING OIL PRESSURESWITCH 6-14 -
OXYGEN SENSOR HEATER (01626, 01627,

41 11-230 -
B 16A2 enginel
--
~-1--
.
-- H::-Af SENSOR-l=lfiATER-.(D-1-52..:1-en.gir::Ul) 11-236 --==--- -
FUEL SUPPLY SYSTEM (D 1626, D 1 627,
43 11-240 -
B 1622 engine)
~- -1:AF SENSOR (D152-1-eAgine) 11-226 -~--
• lf codes other than those listed above are indicated, verify the code. lf the code indicated is not listed above, replace
the ECU.
• The Check Engine light may come on, indicating a system problem when, in fact, there is a poor or intermittent electri-
cal connection. First, check the electrical connections, clean or repair connections if necessary.
• The Check Engine light and o. indicator light may light simultaneously when the self-diagnosis indicator blinks 6, 7
and 17 Check the PGM-FI system according to the PGM-FI control system troubleshooting, then recheck the D. in-
dicator light. lf it lights, see page 14-316.
• The Check Engine light does not come on when there is a malfunctionn in the Electric Load Detector circuits. However,
it will indicate the codes when the Service Check Connector is jumped. ·
11-21 O
lf the inspection for a particular failure code requires the test harness, remove the right door sill molding and pull the
carpet back to expose the ECU. Unbolt the ECUbracket: Turn the ignition switch off and connect the test harness. Check
the system according to the procedure described for the appropriate code(s) listed on the following pages.
l
LHD:
ECU BRACKET
RHD:
\-
(cont'd)
ECU ~
BRACKET
11-211
Troubleshooting
Self-diagnostic Procedures
(cont'd)-----------------
Except 01582 engine:
DIGITAL
~C]
TEST HARNESS
- 07LAJ-PT30100
or
07LAJ-PT3010A
NOT USED
ººººººººººººººººººººº ººººººººººº
ººººººººººººººººººººº
Al .... Al A8 A10A12A14A1fA18A20A22A24.l.2fi 12 IM 16 88 810 912 114 811
02 04 D6 Oll 01001201• 016018020 022
TERMINAL LOCATION
01582 engine:
Al U., Al U AIIA1U1Ul1 11 U U U U 1111111111111,, e, et e, Cl e, CUCUCII
000000000 ºººººººººº 00000000

000000000
U U U U A1UtH1011lU
ºººººººººº ºººººººº
U 14 11 11111eu,1u111111u cz e, CI e, CUCUCUCII
TERMINAL LOCATION
11-212
CAUTION:
• For testing at connectors other than the test harness, bring the tester probe into contact with the terminal from the
connector side of wire harness connectors in the engine compartment. For female connectors, just touch lightly with
RUBBER SEAL TESTER PROBE
WIRE HARNESS
TERMINAL
11-213
Troubleshooting
How to Read Flowcharts
A flowchart is designad to be used from start to final repair. lt's like a map showing you the shortest distance. But
beware: if you go off the "map" anywhere but a "stop" symbol, you can easily get lost.
j START ! Describes the conditions or situation to start a troubleshooting flowchart.

(bold type)
I ACTION ! Asks you to do something; perform a test, set up a condition etc.
STOP The end of a series of actions and decisions, describes a final repair action and sometimes directs you to
(bold type) an earlier part of the flowchart to confirm you repair.
NOTE:
• the term "lntermittent Failure" is used in these charts. lt simy means a system may have had a failure, but it checks
out OK at this time. lf the Check engine light on the dash does not come on, check for poor connections or loose
wires at all connections related to the ciricuit that you are troubleshooting.
• Most of the troubleshooting flowcharts have you reset the ECUand try to duplicate the problem code. lf the problem
is intermittent and you can't duplicate the code, do not continue through the flowchart. To do so will only result in
confusion and, possibly, a needlessly replaced ECU.
• "Open" and "Short'.' are common electrical terrns. An open is a break in a wire or at a connection. A short is an
accidental connection of a wire to ground or to another wire. In simple electronics, this usually rneans something
won't work at all. In cornplex electronics (like ECU's), this can sornetimes mean something works, but not the way
it's supposed to.
proceeding.
11-214
PGM-FI Control System
System Description
INPUTS ELECTRONICCONTROLUNIT OUTPUTS

TDC/CRANK/CYL Sensors lnjectors
MAP Sensor Main Relay (Fuel Pump)
TW Sensor Check Engine Light
TA Sensor EACV
Throttle Angle Sensor A/C Compressor Clutch Relay
Oxygen Sensor lgniter Unit
LAF Sensor lnjector Timing and Duration Purge Control Solenoid Valve
EGR Valve Lift Sensor EGRControl Solenoid Valve
o
Vehicle Speed Sensor Electronic ldle Control Oxygen (LAF) Sensor Heater
IMA Sensor Alternator
Starter Signal Other Control Functions A/T l.ock-up Solenoid Valve A/B
Alternator FR Signa! Spool Solenoid Valve
Air conditioning Signa! ECU Back-up Functions Tandem Valve Control
A/T Shift Position signa! (D15 82 engine)
Battery Voltage (IGN. 1 )
M/T Clutch Switch Signa!
Brake Switch Signa!
P/S Oil Pressure Switch Signal
Electic Load Detector
Valve timing Oil Pressure Switch
lnjector Timing and Duration

The ECUcontains memories for the basic discharge durations at various engine speeds and manifold pressures. The bas-
ic discharge duration, after being read out from the memory, is further modified by signals sent from various sensors
to obtain the final discharge duration.
Electronic Air Control

Electronic Air Control valve (EACV)
When the engine is cold, the A/C compressor is on, the transmission is in gear (A/T only) or the alternator is charging,
the ECU controls current to the EACV to maintain correct idle speed.
lgnition Timing Control

• The ECUcontains memories for basic ignition timing at various engine speeds and manifold pressures. lgnition timing
is also adjusted for coolant temperature.
Other Control Functions

1 . Starting Control
When the engine is started, the ECU provides a rich mixture.
2. Fuel Pump Control
• When the igniti~n switch is initially turned on, the ECU supplies ground to the main relay that supplies current to
the fuel pump for two seconds to pressurize the fuel system.
• When the engine is running, the ECU supplies ground tothe main relay that suppleis current to the fuel pump.
• When the engine is not running and the ignition is on, the ECU cuts ground to the main relay which cuts current
to the fuel pump.
11-216
3. Fuel Cut-off Control
• Ouring deceleration with the throttle valve closed, current tothe injectors is cut off to improve fuel economy at
speeds over following rpm:
• 01582 engine: 1300 min-1 (rpm) • 016A8,
• 01521 engine: 850 min-1 (rpm) O 16A9 engine: 990 min-1 (rpm)
• 016A7 engine: 990 min-1 (rpm) • 816A2 engine: 990 rnin"" (rpm)
• 016Z6,
01627 engine: M/T 1000 min-1 (rpm)
A/T 990 rnin"" (rpm)
• Fuel cut-off action also takes place when engine speed exceeds, 01582 engine: 6800 min-1 (rpm). 01521 en-
gine: 6300 mirr" (rpm). D16A7 engine: 7250 mirr? (rprn), 01626, D16Z7, 016A8, D16A9 engine: 7400 min-1
(rpm). 816A2 engine: 8100 rnirr ' (rpm) regardless of the position of the throttle valve, to protect the engine from
overrevving.
4. A/C Compressor Clutch Relay

When the ECU receives a demand for cooling from the air conditioning system (compressor control unit] , it delays
the compressor from being energized, and enriches the mixture to assure smooth transition to the A/C mode.
5. Purge Control Solenoid Valve

When the coolant temperature is below O 1 5Z 1 engine: 7 5 ºC ( 167°F). O 1 582 engine: BOºC ( 176 ºF) Others: 70°C
(158ºF) the ECUsupplies a ground to the purge control solenoid valve which cuts vacuum to the purge control valve.
6. EGRControl Solenoid Valve (EGRCSV)

When the EGRis required for control of oxides of nitrogen (NOx) emissions, the ECU supplies ground tot he EGRCSV
which supplies regulated vacuum to the EGR valve.
7. Alternator Control
The system controls the voltage generated at the alternator in accordance with the electric load and drive mode, and
reduces the engine load to improve the fuel economy.
8. Tandem Valve Control Solenoid Valve

Depending on coolant temperature and engine speed, the ECU supplies ground tothe tandem valve control solenoid
valve which opens the tandem valve. The opening and closing of the tandem valve maintains good atomization of
the fuel injected by the main fuel injector.
9. Lock-up Control Solenoid Valve (A/T)

The speed and throttle angle sensor inputs to the ECU are sued to send an on/off voltage signal to the lock-up control
solenoid valve for precise timing of the torque converter lock-up systern.
ECU Back-up Functions

1. Fail-Safe Function
When an abnormality occurs in a signal from a sensor, the ECU ignores that signal and assumes a pre-programmed
valve that allows the engine to continue to run.
2. 8ack-up Function
When an abnormality occurs in the ECU itself, the inejctors are controlled by a back-up circuit independent of the
system in arder to permit minimal driving.
3. Self-diagnosis Function (Check Engine light)

When an abnormality occurs in a signal from a sensor, the ECU lights the Check Engine light and stores the failure
code in erasable memory. When the ignition is initially turned on, the ECU supplies ground for the Check Engine light
for two seconds.
11-217
TroubJeshoo1ting Flowchart Engine Will Not Start
Enginewill not start.
Watch the Check Engine light

and turn the ignition switch ON
Did the Check Enginelight NO Perform troubleshooting on page

come on at ali? 11-219.
YES
Did the Check Enginelight NO Perform troubleshooting on page

go off after two seconds?
11-220.
YES
Connect the test harness be-

tween the ECU and connector A23
(page 11-212).
00000000000 Oºººººººº ººººººººººº
ºººººººººººoºººººººº ººººººººººº
---1
Turn the ignition switch ON. A24
Less than 1 V?
Measure voltage between body

ground and the following ter-
minals individually: A23, A24
í
NO Repair open in wire between ECU
Is there less than 1 V? and G 1 O 1 on wire that more than
1 v.
YES
lnspect Fuel Pressure (page

11-332).
NO
Is fuel pressure OK? Repair as necessary.
YES
Perform ignition system check

(section 23).
11-218
Troubleshooting Flowchart --
Check Engine light never comes

on leven for two seconds) after
ignition is turned on.
NO
Is the oil pressure light on? lnspect BACK UP LIGHTfuse.
YES
Turn the ignition switch OFF. Is BACK UP LIGHTfuse OK? Replace fuse.
YES
Connect the test harness bet-
ween the ECU and connector Repair open in YEL between
(page 11-212). BACK UP LIGHT and gauge
assembly.
Connect A 13 terminal to body A13

ground.
Replace the light

bulb.
Repair open in
Is Check Enginelight on? GRN/ORN wire be-
tween ECU (A 131
and gauge as-
YES sembly.
A23
00000000000 O 00000000
ºººººººººººoºººººººº
A24
le88than1 V7·@
ground and the following ter- ~
minals individually: ·A23, •A24. G101
Repair open in wire

NO between ECU and
Is there less than 1 V?
G1 O 1 that had more
YES than 1 V.
Substitute a known-good ECU

and recheck. lf symptom/ indica-
tion goes away, replace the
original ECU.
(cont'd)
11-219
Troubleshooting Flowchart - ECU
(cont'd}--------------
NOTE: When there is no code stored, the Check

Check Engine light stays on or Enginelight will stay on if the service check con-
comes on after two seconds. nector is jumped.
Connect the service check con-

nector with a jumper wire (page
11-208).
Does Check Enginelight YES Go to self-diagnostic procedures

indicate any CODE? (page 11-21 O).
NO
Remove the jumper wire from
the service check connector.
ººººººººººººº ºººººººº 04 (+) 022 (-)
1.__5 V?-J

Try to start the engine.

YES tween the ECU and connector
Did the engine start?
(page 11-212).
NO
Measure voltage between 04 (+)

Connect the service

YES
Is there approx. 5V? check connector with
a jumper wire.
NO
Repair short to body ground in

BRN wire between the ECU (04) Measure voltage be-
and service check connector. tween 04 (+) terminal
and 022 (-) terminal.
* Repair open in BRN wire be- YES

tween ECU (041 and service Is there approx. 5V?
check connector.
Repair open in GRN/WHT NO
Remove and inspect the ECU (15
A) fuse in the under-hood wire between service check
fuse/relay box. connector and ECU (022). Remove the jumper
wire from the servíce
check connector.
NO
Is the fuse OK? Replacethe fuse.
(To page 11-221)
YES
• NOTE: After repair, disconnect the service check con-
nector jumper wire, test drive the car, and recheck the
(To page 11-221) Check Engine light for a code.
11-220
(From pa!!e 11-220) (From page 11-220)
lnspect the ACG (S) ( 15 A) fuse in Turn the ignition

the under-dash fuse box. switch OFF.
NO
Is the fuse OK? Replace the fuse. Disconnect "A" con-
nector from the ECU.
YES

Turn the ignition
switch ON.
Oisconnect the 3P connector of

each sensor one ata time: Substitute a known-good ECU
• MAP sensor
and recheck. lf symptom/indica- NO Is the Check Engine
• EGR valve lift sensor tion goes away. replace the light ON?
(O 1 5Z 1 engine) original ECU.
• Throttle angle sensor YES
Repair short to body

ground in GRN / ORN
NO wire between the ECU
Does Check Engine light Replace the sensor that caused (A 13) and Check
remain ON? the light to go out.
Engine light.
YES
Connect the test harness.

Disconnect the "O" connector
from the ECU only, not the main
wire harness. (page 11-212). ººººººººººººº ºººººººº ººººººººº01ílo
ººººººººººººº ºººººººº ººººººººº o
020
-1-
Check for continuity between ~
body ground terminals O 19, Continuity
020.
Repair short to body ground *: B 16A2 engine
in YEL/GRN* wire between Except B 16A2 engine (YEL/RED)
ECU (019) and MAP sensor.
YES
Does continuity exist? Repair short to body ground
in YEL(WHT wire between
NO ECU (0201 and throttle angle
sensor or EGR valve lift sen-
Reconnect all the sensor connec- sor (01521 enginel.
tors.
Reconnectthe "O" connectorto
the ECU.
(To page 11-2221
(cont'dl
11-221
Troubleshooting Flowchart ECU (cont'd)
(From page 11-221)

ººººººººººººº ººººººººººº
minal individually: •A26, •82.
ºººººººººººº ººººººººººº
A26 82
~ Less than 1 V?
NO Repair open in 8LKI

Is there less than 1 V? RED (A26) or 8RN/
8LK (82) and G101.
YES
Measure voltage between A26

(-) and the following: 81 (+) and
A25(+).
Measure voltage between A26 81 (+)

(-) and the following: 81 (+) and
A25 (+). ººººººººººº
ººººººººººº ººººººººººº
A25(+~l~A_2_6_(_-_l~~~~~~BATTERV
VOLTAGE?
Repair open In VELIBLK wire

NO between ECU (A25, 81 l and
Is there battery voltage? main relay.
Check main relay and wiring
YES connectors at main relay.

original ECU.
11-222
Troubleshooting Flowchart - Oxygen Sensor [D16A7, D16A8 engine]
1 '9E r::=tJ Self-diagnosis Check Engine light indicates code 1: A problem in the Oxygen (02) Sensor circuit.
The Oxygen sensor detects the oxygen content in the exhaust gas, and inputs the ECU. In operation, the ECUreceives the signals from
the sensor and varíes the duration during which fuel is injected. The oxygen sensor is installed on the exhaust manifold.
STOICHIOMETRIC
AIR-FUEL RATIO
RICH-- AIR--LEAN
FUEL
RATIO

reportad on.
jumpled (page 11-2081, CODE
1 is indicated.
Do the ECU Reset Procedure

(page 11-209).
lnspect pressure regulator (page

11-343).
NO Replace the pressure regulator

Is it normal?
(page 11-3441
YES
Warm up engine to normal

operating temperature (cooling
fan comes on).
Startinq at 1600 min" 1 trpm), · ac-

celerate using wide open throttle
for at least 5 seconds. Then de-
celerate for at least 5 seconds
with the throttfe completely
closed.
lntermittent failure, system is OK

Is Check Engine warning light on >-N_O __, at this time. Check for poor con·
and does LEOindicate CODE 1 . nectlons · or loose wires at 02
sensor and ECU.
YES (cont'd)
(To page 11-224)
11-223
Troubleshooting Flowchart Oxygen Sensor [D 16A 7, D 16A8 engine]
(cont'd)
(From page 11-223)
Disconnect engine wire harness

from the 02 sensor.

operating temperature again,
then open the throttle wide
open, then quickly release it.
Measurevoltage betweenthe con-

02 SENSOR
DIGITAL CIRCUITTESTER SOCKET
07411-002000 WRENCH 33 lb-ft)
Is voltage above 0.6 V at wide 07LAA-PT50101 .
open throttle and below 0.4 V >-N_O --J
Replace 02 sensor.
released?
YES
Stop engine.
Reconnect the oxygen sensor.

tween the ECU and connector
(page 11-212).
014(+) 022 (-)
L_J
Above 0.6V7
Restart and warm up engine to
Below 0.4V7
normal operating temperature,

(+) terminal and 022 (-) ter-
minal.

Repair short or open in WHT wire
open throttle and below 0.4 V >-N_O ___,
between ECU (D14) and 02 sen-
sor.
released?
YES

and recheck. lf symptom/ indi-
original ECU.
11-224
TroubleshootingFlowchart - Oxygen Sensor [01626, 01627, B16A2 engine]
<, 1 ./ <, 1 / .
-1 ül- -ITJ-
/ 1 <, / 1 <,
Self-diagnosis Check Engine light indicates code 1: A problem in the Oxygen (02) Sensor circuit.
The Oxygen sensor detects the oxygen content in the exhaust gas and signals the ECU. In operation, the ECU receives the signals from
the sensor and varies the duration during which fuel is injected. The oxygen sensor has an internar heater. The heater stabilizes the sen-
sor's output. The oxygen sensor is installed in the exhaust manifold.
SENSOR
ZIRCONIA TERMINAL
ELEME\ -
STOICHIOMETRIC
VOLTAGE (V)
~flkiü~A
AIR-FUEL RATIO
HEATER ~
.......__.
HEATER
TERMINAL
<, 1 / <, 1 /
-(C:ll-
/ 1 <,
-ITJ-
/ 1 <,
RICH .... AIR-
FUEL
---+ LEAN
RATIO
reportad on.
With service check connecjor
jumpled (page 11-208), CODE
, is indicated.

(page 11-209).

ating temperatura (cooling fan
comes on).
Aun engine for 60 seconds.
Road test with the transmission

in 2nd gear (M/T: 4th gear).
Starting at 1600 mírr ' (rpm), ac-
celerate using wide open throttle
for at least 5 seconds. Then
decelerate for at least 5 seconds
with the throttle completeiy clos-
ed.

Is Check Engine light on and does NO at this time. Check·for poor con-
it indicate CODE 1? nectlons or loose wires at 02
sensor and ECU.
YES
Go to page and perform test for

CODE 43 (page 11-240)
11-225
Troubleshooting Flowchart - LAF Sensor [D 1521 engine] -------
-[ O
....._ 1
1- -[]i]-
,.,, 1 .,,-
Self·diagnosis Check Engine light indicates code 48: A problem in the Linear Air Fuel ratio (L@ Sensor circuit.
,.-- 1 <c >: 1 <,
SENSOR The LAF sensor operates over a wide air/fuel range. HEATER
TERMINALS
., !8"·9@ SENSOR
TERMINALS
<, 1 .,......... <, 1 _,,,,....
-[01-
/ 1
-[ID-
1 <, <, /
Engine is running.
reportad on. With service
check connector jumped
(page 11-2081, CODE48 is in-
dicated.

(page 11-209).
LEAN
Start the engine.
NO Road test with the transmission

Is Check Enginelight on and does
in 3rd gear. Hold the engine
it indicate CODE 48?
speed 1500 rnln" ' (rpm). lntermittent failure,
YES system is OK at this
time (test drive may be
necessary).
Is Check Enginelight on and does Check for poor con-
it indicate CODE 48? nections or loose wires
YES at LAF sensor and ECU.

(page 11-2121. NOTE: Use DIGITAL CIRCUIT
TESTER
(To page 11-2271

~;e~º c~;;/arness )
ECU (014) terminal
( and LAF sensor
(page 11-230).
11-226
(From page 11-226)

ween the ECU and connector
(apge 11-212)
With the ignition switch OFF,

wait far at least two minutes.
Measure voltage between O1 6

minal.
ººººººººººººº ºººººººº ':)í;ipQ@:tút ººººººººººº
ººººººººººººº ºººººººº ?W'hJHii.i#it ººººººº ºº
016 (+) 022 (-)
'---'
more than
0.5 V?
Go to wire harness )
open or short check:
NO
Is there more than 0.5 V? ECU (O16) terminal
and LAF sensor
YES
(page 11-230).

08 (+) 022 (-)

more than
0.5 V?
Go to wire harness )
NO open or short check:
Is there more than 0.5 V? ECU (DB) terminal
and LAF sensor
YES (page 11-230).
NO Oisconnect the SP connector

Is there more than 5.0 V?
from the LAF sensor.
YES
11-227
Troubleshooting Flowchart LAF Sensor (01521 engine) (cont'd)
Measure voltage between 03 (+) Measure voltage between 08 (+)

terminal and 022 (-) terminal. terminal and 022 -) terminal.
YES
Is there more than 5.0 V? ReplaceLAF sensor.
NO

original ECU.
1 0.3-4.9
V?J,
ººººººººººººº ºººººººº }H~~º! <;~ººººººº

ººººººººººººº ºººººººº . :Q,Q:; ºººººººººº
022 H.
L
Go to wire harness)
NO NO open check:
Is there 0.3-4.9 V? Is there more than 4.9 V? ECU (03) terminal
and LAF sensor ·
YES (page 11-230).
YES
Go to wire harness)
short check:
ECU (03) terminal
( and LAF sensor
Warm up engine to normal oper- (page 11-230).
comes on).

ººººººººººººº ºººººººº 000 000000
Measure voltage between 016 016 (+) 022 (-)

minal. · 2.6-2.8 V?
(To page 11-229)
11-228
(From page 1 1 -228)
Measure voltage between D8 (+)

lsthere 2.6-2.8 V?
YES
ººººººººººººº ºººººººº 014 (+) 022 (-)
l----l
more than 0.4 V?
NO
Is there less than 2.8 V? ReplaceLAF sensor.
YES
Measure voltage between D 14 Substitute a known-good ECU

(+) terminal and D22 (-) ter- and recheck. lf symptom/in-
minal. dicaton goes away, replace the
original ECU.

ººººººººººººº ºººººººº 000 ºººººº
08 (+) 022 (-)
stabilized 3.0-3.2 V?
Ge to wire harness )
short check:
NO ECU (014) terminal
Is there more than 0.4 V?
and LAF sensor
YES (page 11-230).

original ECU.
(cont'd)
11-229
Troubleshooting Flowchart-·LAF Sensor [D1521 engine] (cont'd) -----.
* Table:
Wire harness short check:
WIRE COLOR
1 ECU
COOE MAIN WIRE ENGINE WIRE
TERMINAL
Turn the ignition switch OFF. HARNESS HARNE SS
1
41 A6(HTCNTL) ORN/BLK YEL/BL K
(page,
1
11-48) A23 (PG1) BLK
--
Disconnect "O" connector from
the ECU only, not the main wire 022 (SG2) GRN/WHT
-
--
.harness (page 11-212). 03 (LABEL) BLU/YEL WHT
48 08 (VS +) WHT/BLU
1 014 (IP +) ORN/BLU
Check for continuitv to body 016 (IP -, VS -) BLU/GRN ORN
ground on indicated terminals.
* see table
1
YES Disconnect the 8p connector
I
NO
1
and recheck. lf symptom/indica- Check for continuity to body
tion goes away. replace the ground on indicated terminals.
original ECU. * see table
1
Repair short in the in-
YES
Does continuity exist? dicated sensor wires.
I NO
* see table
Replace LAF sensor.

W1re ha rness open check :
WIRE COLOR (ENGINEWIRE HARNESS SIDEI:

BLK (A23)
GRN/WHT
02 SENSOR
SOCKET
(022)
WRENCH
Disconnect "O" connector from 07LAA-PTS0101
the ECU only, not the main wire
harness (page 11-212).
Oisconnect the 8p connector

Check for continuity between in-

dicated terminals and wire
harness.
• see table
WHT/BLU
Repair open in the in- (08)
NO
Does continuity exist? dicated sensor wires. ORN/BLU (014)
* see table
YES
lnspect for poor terminal to ter-

minal contact at LAF sensor con-
nector and ECU.
lf terminal contact is OK. replace
LAF sensor.
11-230
Troubleshooting Flowchart Oxygen Sensor Heater ---------
(01626, 01627, B16A2 engine]
.: :(61:: _ : :[![]:: :
/ 1 ................... 1 <,
Self-diagnosis Check Engine light indicates code 41: A problem in the Oxygen (02) Sensor Heater circuit.
816A2 engine:
Engine Is running.
Check Englne light has been
reportad on. With service
(page 11-208), CODE41 Is in- 10-40 O
dicated. ""='"""'---- DIGITAL
CIRCUIT
TESTEA
07411-002000
(paga 11-209).
Start the engine.

lntermittent failure,
system Is OK at this
NO necessary).
Is Check Engine light on and does
it indicate CODE 41? Check for poor con-
nections or loose wires
YES at 02 sensor and ECU.
Stop the engine 01626, 01627

engine:
Oisconnect the 4P connector

from the 02 sensor.
Measure resistance between ter-

minals C and O on the 02 sensor.
10-40 o
NO DIGITAL
Is there 10-40 íl Replace 02 sensor. CIRCUIT
TESTEA
YES 07411 -002000
(To page 11-233)
11-232
B16A2 engine:
(From page 11-2321

ground on terminals C and D of
the 02 sensor.
YES
Does continuity exist? Replace O:z sensor.
·NO 02 SENSOR
SOCKET
Check for continuity between WRENCH
terminal D and terminals A and B 07LAA-PT50101
individually.
YES
Does continuity exist? Replace Ozeensor.
NO
At 02 sensor harness, measure

voltage between YEL/BLK (+) ~
terminal and ORN/ BLK ( - 1 ter- 02 SENSOR
minal. 45 N•m (4.5 kg-m,
ORN/ YEL/ 33 lb-ft)
BLK BLK (+)
02 SENSOR
YES SOCKET
Is there battery voltage? Disconnect the "A" connector
WRENCH
from the ECU.
07LAA-PT50101
NO
Measure voltage between At 02 sensor harness, measure

YEL/BLK (+) terminal and body voltage between YEL/BLK (+I
ground. terminal and ORN/ BLK (-) ter-
minal.
YES Repair short in ORN /

BLK wire between
ECU (A6) and 02 sen-
NO sor.
NO Repair open in YEL/

Is there battery voltage? BLK wire between 02
sensor and main relay.
YES
Reconnect the 02 sensor con-

nector.
(To page 11-234) (To page 11-2341
(cont'd)
11-233
Troubleshooting Flowchart - Oxygen Sensor Heater ---------
(01626, 01627, B16A2 engine] (cont'd)
(From page 11 -233)
(From page 11-233)
Connect the test harness "A"

connector to the main wire
harness only, not the ECU (page
11-212).
Connect an ammeter between

terminals A6 (+) and A26 (-).
• Monitor over a 5 minutes
period.
Replace02 sensor. Is the current less than 0.1 A?•
NO

and recheck. lf symptom/indlca-
tlon goes away, replace the
original ECU.

02 sensor.

11-212).
Measure voltage between A6 (+)

terminal and A23 (-) terminal.
Repair open ORN /

NO
BLK wire between
ECU (A61 and 02 sen-
YES sor.

original ECU.
11-234
TroubleshootingFlowchart LAFSensor Heater [01521 engine]----
<, 1 / <; 1 /
-(o\-~[][)- Self-diagnosis Check Engine light indicates code 41: A problem in the Linear Air Fuel ratio (LAF)
,,- 1 <, ,,- , <, Sensor Heater circuit .
-ra1-
<,
.,,...,
J
1
-cm-
.....................
<, /
1
1
/
<,
Englne is running.
reported on. With service
(page 11-208), CODE 41 in-
dicated.

(page 11-209).
Start the engine.

system is OK at this
NO necessary).
Is Check Engine light on and does
it indicate CODE 41? Check for poor con-
YES at LAF sensor and ECU.
Stop the engine


minals A and B on the LAF sen-
sor.
NO
Is there 3- 1 3 íl ? Replace LAF sensor.
YES
(To page 11-237)
1.1-236
(From page 11-236)
Check far continuity to body

ground on each terminal on the
LAF sensor.
YES
Does continuity exist? Replace LAF sensor.
NO
Check far continuity between

terminal A and terminals C - H in-
dividually.
YES
Does continuity exist? Replace LAF sensor.
NO

rpm at idle.

YEL/BLK (+) terminal and body
ground.
YES Measure voltage YEL/Bl,.K (+)

Is there approx. 7 V?
terminal and BLK (-) terminal.
NO

Is there battery voltage? Repair open in BLK wire between
LAF sensor and G 1 O 1 .
YES

(To page 11-238) and recheck. lf symptom/indica-
tion goes away. replace the
original ECU.
(cont'd)
11-237
Troubleshooting Flowchart-LAF Sensor Heater [D1521 engine] (cont'd)
(From page 11-237)
-,

ween the ECU and connector.
Disconnect "A" connector from
the ECU only, not main wire
1°
0090000000000
000000000000 1ººººº
00000
ººº
ººº
A6
Check for continuity between A6

Repair short In ORN/BLK,

YES
Does continuity exist? YEL/BLK wire between ECU (A6)
and LAF sensor.
NO

Check for continuity ORN/BLK,

YEL/BLK wire between ECU (A6)
and LAF sensor.
Repair open in ORN/BLK,

YES YEL/BLK wire between ECU (A61
and LAF sensor.
NO

original ECU.
11-238
Troubleshooting Flowchart Fuel Supply System [D 1626, D 1627
816A2 engineJ
-rol-
<,
,,......
1
1
.,........
<,
-cm-
<,
/
'
1
/
<,
Self-diagnosis Check Engine light indicates code 43: Most likely a problem in the Oxygen (02) Sensor
circuit or a problem in the Fuel Supply System.
-rnr
<, 1 / <, 1 /
-Cal-
/ 1 ........_..,...... 1 <,

reported on.
jumped (page 11-208). CODE
43 is indicated.
or contlnued from code 1 .
Is the 43 code accompanied by YES

Go to Fuel Supply
the Check Engine light and poor
System (page 11-331).
driveability?
NO
(page 11-209).

fan comes on).
Hold engine at 3,000 min-1

(rpm) for two minutes.
(A/T: Transmission in or(E].1 [El
NO
Is the Check Engine light on and necessary).
does it indicate CODE 43? Check for poor connections or
loose wires at 02 sensor and
YES ECU.

(page 11-212).
With the ignition switch OFF, NOTE:

wait for at least two minutes.
• Use DIGITAL CIRCUIT TESTEA
• Use 2 Volt range.
lnstall a jumper wire on the test

ººººººººººººº ºººººººº ººººººººººº
harness between A6 and A26.
00
A6
ºººººººººA26 ºººººººº ººººººººººº
JUMPER WIRE

ºººººººººººº ºººººººº 014
ºººº (+)
A26 (-) Voltage should start at
(+) terminal and A26 (-) terminal
as soon as the ignition switch is
L__ 0.4-0.5 V when the
ignition switch is first
turned on. turned on, anddecrease
to below 0.1 V in less
than two minutes.
(To page 11-241).
11-240
(From page 11-240) ººººººººººº
ººººººººººººA26 (-1 000000
014 (+)
ºººº
~ Volteg• ahould •rart et ____J
0.4-0.5 V whan the lgnltlon
Is there O. 1 V or less when the switch is fir1t turned on. end
ignition switch is first turned Disconnect the 4P connector decrease to below o., v 1n
on? from the 02 sensor. lesa than two minutes.
NO
Measure voltage between D 14
!+) terminal and A26 !-) ter-
minal.
YES
Is there more than O. 1 V? Replace 02 sensor.
NO
Disconnect the "D" connector

Disconnect the 4P connector from the main wire harness.
from the 02 sensor.
Measure voltage between D 14

(+) terminal and A26 (-) ter-
minal.
YES Repair short in WHT

Is there more than O. 1 V? wire between ECU
(0141 and 02 sensor.
NO
Measure voltage at the engine Substituta a known-good ECU
wire harness side of the 02 sen- and recheck. lf symptom/indica-
sor connector between GRN/ tion goes awav, replace the
WHT (-) and WHT (+). original ECU.
Is there more than O. 1 V? Replace 02 sensor.
NO
Repair open in WHT wire be-

tween ECU (014) and 02 sensor.
lf wire is OK, check for open in
GRN/WHT wire between ECU
(0221and 02 sensor.
816A2 englne: 01626, 01627

engine:
GRN/
WHT (-)
02 SENSOR 02 SENSOR 02 SENSOR

SOCKET 45 N•m (4.5 kg-m, DIGITAL SOCKET
WRENCH 33 lb-ft) CIRCUIT WRENCH
07LAA-PT50101 TESTER 07LAA-PT50101
07411-002000
11-241
Troubleshooting Flowchart --- MAP Sensor ---------------
-ro1--m-
<, I / <, 1 /
Self-diagnosis Check Engine light indicates code 3: An electrical problem in the Manifold Absolute Pressure
, 1 ......._.,.......... 1 <, (MAP) Sensor system.
<, 1 ................... 1 /
-[01--0]-
/ 1 ,.,.... 1 <,
Self-diagnosis Check Engine light indicates code 45: Most likely a problem in the Fuel Metering System.
Pressure (MAP) Sensor system.
The MAP sensor converts manifold absolute pressure into electrical signals and inputs the ECU.
B16A2 englne: VACUUM
VACUUM Except 816A2 CAVITY
CAVITY engine:
Engine is warm and running.

reported on. OUTPUT
With service check connector VOLTAGE
3 is indicated. (v) 3.5
3.0
Do the ECU Reset Procedure 2.0

(page 11-209).
1.5
o 5 10 15 20 25 30 (In. Hgl GAUGE

READING
~-------1_0_0~200 300 400 500 600 700 (mmHgl
Start the engine and allow it to lntermittent failure,
idle. system is OK at this
necessary).
Check for poor con-
nection or loose wires
Is Check Engine light on and NO
at MAP sensor and
does it indicate CODE 3?
ECU.
YES MAP SENSOR
Except B 16A2
engine:

YEL/ MAP SENSOR
GRN

from the MAP sensor.
(To page 11-243)
11-242
n
5 V?
(From page 11-242)
0191+1 021 H

(YEL/GRN) * (+) ter-
YEL/RED
minal and body ground.

YES •: B16A2 engine
YEL/RED (YEL/GRN) * (+) ter-
Is there approx. 5V?
minal and GRN/WHT (GRN/
NO BLU)* (-) terminal.
Connect the test harness "D"

connector to the ECU only, not NO Repair open in GRN/
Is there approx. 5V? WHT. GRN/BLU (GRN/
to the main wire harness (paga
11-212). BLU)* wire between
YES
ECU (021) and MAP
sensor.
(+) terminal and D21 (-) ter-
minal. *: B16A2
engine
NO
Repair open in YEL/REO (+) terminal and GRN/WHT
YEL/GRN IYEL/GRN)* wire be- (GRN/BLU) * (-) terminal.
tween ECU (019) and MAP sen-
sor.

original ECU.
YES

the MAP sensor.

(page 11-212).
(To page 11-244)
(To page 11-244)

(cont'd)
11-243
-Troubleshooting Flowchart ---MAP Sensor (contd)
(From page 11-:243) (From page 11-243)
Measure voltage between D 1 7

(+) terminal and 021 (-1 ter-
minal.
Connect the test harness "D"

connector to the ECU only, not
to the main wire harness (page
11-212). Is there approx. 3 V ? >N-º------1l Replace MAP sensor. 1
'------~-------/
YES

original ECU. 3 V 7
Measure voltage between D17 n
(+) terminal and D21 (-) ter- 017 ';' ~21 (-)
minal.
1 ~~~~~~~~~~~~~ 1 ~~~~~~~~ 1::;1:==:11 ~~~~~~~~:~-~ 1
<--------~--
Repair short in WHT wire be-
tween ECU (017). and MAP
sensor.
I Is there approx. 5 V? ;----1 YES
Repair open in WHT wire be-
tween ECU (017) and MAP
NO sensor.

and recheck. lf prescribed
voltage is now available, replace
the original ECU.
(cont'd)
11-244
Troubleshooting Flowchart-MAP Sensor [Except B16A2 engine]· (cont' d)-
-m-
...... 1 /
tal
...... 1 /
.......... 1 <,
--- 1 ......

reported on.
jumped (page 11-208), CODE
5 is indlcated.

(page 11-209).
Start the engine and keep engine

rpm at 2000 for one minute.
lntermittent failure, system is

OK at this time (test drive
Is Check Engine light on and does NO may be necessary).
it indicate CODE 5? >------1 Check vacuum hoses, pipes
and connections.
Make sure all connectors are
YES
secure.
Stop the engine.
Remove the MAP sensor from

throttle body.
VACUUM PUMP/
GAUGE
Connect a vacuum pump to the

MAP sensor and apply vacuum.
Replace.
Does it hold vacuum? Replace MAP sensor.
YES PORT
Start the engine.
Put your finger over the MAP

port on throttle body.
(To page 11-24 71
11-246
(From page 11-246)
NO Remove restriction from throttle

Is there manifold vacuum? bodv.
YES
Stop the engine.

(page 11-212).
n
3V7
017 (+) 021 (-)

t+) terminal and 021 (-} ter- ººººººººººººº ºººººººº
minal. ººººººººººººº ºººººººº
NO
YES
Start the engine and allow it to

idle.
NO
Is there approx. 1 V? Replace MAP sensor.
YES

original ECU.
11-247
Troubleshooting Flowchart-MAP Sensor [816A2 engine]--------
' 1 /
-O]-
' 1 /
-(tC::ll-
/ 1 ' / 1 '
- Check Engine light has been

reportad on.
5 is lndicated.

(page 11-209).

rpm at 2000 for one minute.

may be necessary).
Is Check Engine light on and does NO
Check vacuum hoses, pipes
it indicate CODE 5? >--------1
and connections.
YES secure.
MAP SENSOR
Stop the engine.
Disconnect #21 hose from the VACUUM PUMP/

throttle body, connect vacuum GAUGE
pump to the hose and apply
vacuum.
~r----
#21 HOSE
NO Connect a vacuum pump to the

Does it hold vacuum? MAP sensor and apply vacuum.
YES
YES
Connect a T-fitting from a Repalr vacuum leak in hose

vacuum gauge between the routing between MAP sensor
throttle body base and #21 and intake manifold.
hose.
(From page 11-2491
11-248
(From page 11-248)
Start the engine.
NO Remove restrictlon from throttle

Is there manifold vacuum7 body.
YES
Stop the engine.

(page 11-212).
n
3V7
D17 (+) D21 (-)
Measure voltage between O1 7 ººººººººººººº 00000000

minal.
ººººººººººººº 00000000
NO
YES

idle.
NO
YES

and recheck. lf symptom/lndica-
original ECU.
11-249
PG M - FI Control System
Troubleshooting Flowchart TDC/CRANK/CVL Sensor
<, 1 / <, \ /
-[01- -[IJ- Self-diagnosis Check Engine light indicates code 4: A problem in the CRANK Sensor circuit.
<,
-ro1- -m-
/ 1 '/ 1
<, J .................... 1 ............
Self-diagnosis Check Engine light indicated code 8: A problem in the TDC Sensor circuit.
_, 1 '/ t <,
_'[C:Jl- -[!]-
-c, 1 /', 1 /
Self-diagnosis Check Engine light indicates code 9: A problem in the CYL Sensor circuit.
> ' <, / \ <,
The CRANK sensor determines timing for fuel injection and ignition of each cylinder and also detects engine RPM. The TDC sensor
determinesignition timing at start-up (cranking) and when crank angle is abnormal. The CYLsensor detects the position of No .1
cylinder for sequential fuel injection to each cylinder.
<, .1 ..,, <, 1 .,,,,.. <, 1 / <, t /
-[Ol--[TI--OJ-or-[TI-
.,,..,,, 1 -c.>: 1 ..................... 1 <, / 1 '
Check Englne light has been

reportad on.
4, 8 and/or 9 are indicated.

(apge 11-209). CYL CRANK TDC
ROTOR ROTOR ROTOR
Start the engine.

system is OK at this
necessary).
Is Check Engine light on
Check for poor con-
and does it indicate CODE
4, 8 or 9?
at TPC/CRANK/CYL
YES sensor and ECU.
Stop the engine.
Disconnect the BP connector

from the TDC/CRANK/CYL sen-
sor.
View from
F G Terminal side
(To page 11-251)
11-250
(From page 11-250)
1
SENSOR ECU WIRE
Measure resistance between ter- SENSOR CODE
TERMINAL TERMINAL COLOR
minals of the indicated sensor.
*see table 8 815 8LU/GRN
CRANK 4
F 816 8LU/YEL
e 813 ORN/8LU
TDC 8
NO Replace the distributor G 814 WHT/8LU
Is there 350- 7000? sub-assembly (Section D 811 ORN
23). CYL 9
YES H 812 WHT

ground on both terminals of the
indicated sensor.
YES Replace the distributor

Does continuitv exist? sub-assembly {Section
23).
NO
Reconnect the connector. CRANK:

main wire harness only, not to
1°ººººººººººººº 1º
000000000000
o
000000
000000
816
350-700{1?
the ECU (page 1 1-2121.
TDC:
Measure resistance between ter- 813
minals of the indicated sensor on
test harness.
*see table
1°ººººººººººººº1º o
000000000000 ººººººººººº
CYL:
811
1°ººººººººººººº1º o
350-700{1?
NO Repair open in the in-

Is there 350- 7000? dicated sensor wires.
•see table
YES

ground on 815, 813 and 811
terminals.

YES
- ground in the indicated
sensor wires.
*see table
NO

and recheck. lf symptom{indica-
origina! ECU.
11-251
Troubleshooting Flowchart ---TW Sensor-----------------
<,
-f O!-
/
1
1
/
<,
-m-
<,
/
1
1
/
<,
Self-diagnosis Check Engine light indicates code 6: A problem in the Coolant Temperature (TW) Sensor circuit.
The TW sensor is a temperature dependant resistor (thermistor). The resistance of the therrnistor decreasesas the coolant temperature
increases as shown below.
RESISTANCE
(kO)
20-r.---,.--.-----,---,
10-t-"lkt--t---t----1
5+--'lr--t----i----1
...... 1 / ...... 1 / THERMISTOR O 20 40 60 80 100120 ( 'C)

-[O!-
,,, 1 ......
-[I]-
»: 1 <,
-4 32 68104140176212248(ºF)
COOLANT TEMPERATURE

reported on.
jumped lpage 11-208), CODE
6 is indicated.

(page 11-209).

necessary).
Is Check Engine light on and does '\.N_O _
Check for poor connections or
it indicate COOE 6?
loose wires at TW sensor and
ECU.
YES

ating temperatura (cooling fan
comes on).
Oisconnect the 2P connector from

the TW sensor.

NO
Is there 200-400 m Replace TW sensor.
YES
(To page 11-253)
11-252
TW SENSOR
(From page 11-2521

WHT and body ground.

YES WHT ( +) terminal and GRN/WHT D16A7, 01626 and GRN/WHT
Is there approx. 5V ?
( -1 terminal. D 1627 engine shown;
Others engine:
NO TW sensor located
under distributor.
Repair open in GRN/
WHT wire between
YES
ECU 10221 and TW
Substitute a known-good ECU sensor.
A/T (016Z7 engine original ECU.
onlyl
r-----
, - - --- -- - -·----------------.
1
1 Disconnect the 22P connector
1
from the A/T control unit.
'1
1
1
1
1
1
1
Is there approx. 5 V? Replace the A/T control unlt.
1
, NO
~ - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - - - - .. J
Connectthe test harness"D" con-

nector to the ECUonly, not to the
main wire harness(page 11-212).
Turn the ignition switch ON. ººººººººººººº ºººººººº

(+) terminal and 022 (-1 ter-
minal.
Repair open or short in RED/

Is there approx. 5V? WHT wire between ECU (013)
and sensor.
NO

and recheck. lf symptom/lndlca-
tlon goes away, replace the
original ECU.
11-253
Troubleshooting Flowchart ---Throttle Angle Sensor-----------
-101--0J-
<, 1 ,,,,..........._ 1 .,,.....
Self-diagnosis Check Engine light indicates code 7: A problem in the Throttle Angle Sensor circuit.
/' I <, .,.,..,. 1 ..........
The throttle angle sensor is a potentiometer. lt is connected to the throttle valve shaft. As the throttle angle changes, the throttle angle
sensor varíes the voltage signal to the ECU.
BRUSH
HOLDER OUTPUT VOLTAGE (V)
3
2
1
0.5 THROTTLE
º1ocL=E=..,_----F-U-L-L......__ OPENING
THROTTLE
-rol-
' 1 /
-[IJ-
' 1 /
,,,. 1 ' / 1 '
Engine Is runnlng.
reportad on.
jumped (page 11-2081, CODE
7 is lndicated.

(page 11-2091.
Start the engine.

lntermittent fallure. system is OK
necessary).
Is Check Engine light on and does NO Check for poor connections or
it indicate CODE 7? >-------1
loose wlres at throttle angle sen-
sor and ECU.
YES

GRN/WHT

from the throttle angle sensor.
YEL/
WHT
Measure voltage between YEL/

(-) terminal.
NO Measure voltage between YEL/

Is there approx. 5V ? WHT ( +) terminal and body
ground.
YES
(To page 11-255) (To page 11-255)
11-254
!From page 11-254) (From page 11-254)
Repair open in GRN/

Is there approx. 5V ? WHT wire between
Turn the ignition switch OFF. ECU (022) and throttle
angla sensor.
NO

Reconnect the 3P connector.

Connect the test harness between the ECU and connector
tween the ECU and connector (page 11-212).
(page 11-212).

( +) terinal and D22 (-) terminal.
Repalr open In YEL/

ECU (020) and throttle
angla sensor.
NO
Substituta a known-good
ECU and recheck. lf pre-
Measure voltage between D 11 ( +) able. replace the · original
terminal and D22 (-) terminal. ECU.

ººººººººººººº ºººººººº ººººººººº 0201+1 022 H
~J
011 1+1
ººººººººººººº
00000000
Is voltage 0.5 V at full close

A/T (01627 englne only)
throttle, and approx. 4.5 V at r---------- ----- - - -- -- --,
full open throttle? NO Disconnect the 22P connector
NOTE: There should be a
from the A/T control unit.
smooth transition from 0.5 V
to approx. 4.5 V as the
throttle is depressed.
YES Is voltage 0.5 V at full clase Replace throttle
throttle,a nd 4.8 V at full angle sensor.
Substituta a known-good ECU open throttle? Repair open or
and recheck. lf symptom/indica- NOTE: There should be a short in RED/BLUor
tion goes away. replace the smooth transition from LT GRN wire be-
original ECU. 0.5 V to 4.8 V as the tween ECU (O 11).
throttle is despressed. and throttle angle
sensor.
YES
Replace the A/T control unit.
11-255
Troubleshooting Flowchart ---TA Sensor-------------------
<,
-[ Q
/
1
1
1- -[ill--
/
<,
<,
/
'
'
/
..........
Self-diagnosis Check Engine light indicates code 1 O: A problem in the lntake Air Temperature (TA) Sensor circuit.
TheTA-sensor is a temperature dependant resistor (thermistor). The resistance of the thermistor decreases as the intake air temperature
RESISTANCE (kQ)
20...,...----r~-,-~----.~----.
IO+a,111<r~-;-~---t~-""-1
5+----.----+~---t~--;
THERMISTOR 0 20 40 60 80 100 120 ( 'C)

--4 32 68104140176 212 248 ( •F)

01521, 016A7, 01626, 01627 engine:
GRN/
Check Engine light has been WHT
reported on.
jumped (page 11-208),_Gº~-
1 O is indicated.

(page 11-209)

system is OK at thls
NO necessaryl.
Is Check Engine light on and
Check for poor con-
does it indicate CODE 1 O?
YES at TA Sensor and ECU.

from the TA sensor.
016A8, D16A9 engine:

2 terminals on the TA sensor.
Is there 0.4-4.0 kf!? Replace TA sensor.
VES
(To page 11-257)
11-256
(From page 11-256)

YEL ( +) terminal and body
ground.
YES Measure voltage between RED/

Is there approx. 5 V ? YEL (+) terminal and GRN/WHT
( - ) terminal.
NO
Repair open in GRN/
NO WHT wire between
Turn the ignition switch OFF. Is there approx. 5 V ?
ECU (022) and TA sen-
sor.
YES
Connect the test harness"D" con-
nector to the ECUonly, not to the Substituta a known-good ECU
main wire harness (pa9e 11-212). and recheck. lf symptom/indica-
original ECU.

0151+1
r-s~?
(+) terminal and 022 1-) ter- ººººººººººººº ºººººººº ººººººº 000
minal. ººººººººººººº ºººººººº ºººººººººº
022 1-1
YES Repair open or short in RED/YEL

Is there approx. 5V? wire between ECU (015) and TA
sensor.
NO

the original ECU.
11-257
Troubleshooting Flowchart-- IMASensor [D16A9engine only]----
Self-diagnosis Check Engine light indicates code 11: A problem in the IMA Sensor circuit.

reportad on.
11 is indicated.

(page 11-209).

OK at this time (test drlve may
Is check Enginewarning light on ? >-N_0 ---1 be necessary).
and does LED indicate CODE 11 ? Check for poor connections of GRN/RED
looae wires at the IMA sensor GRN/WHT YEL(WHT
YES connector.

the IMA sensor.
Measure resistancebetween A ter-

minal and C terminal on IMA sen-
sor harness.
NO IMASENSOR
Is there 4-6 kn ? Replace IMA sensor.
YES
Measureresistancebetween A and
B terminals and between C and B
terminaIs.
Does the sum of the two resis- >N_O _¡

Replace IMA sensor.
tance checks equal 4-6 kCl ?
YES

(-) terminal on the wire harness.
(To page 6-259)
11-258
(From page 6-258)

NO
Is there approx. 5 V ? WHT ( +) terminal and body
ground.
YES
Repair open in GRN/
ECU. (0221 and IMA
NO sensor.
the ECU and connector (page Turn the ignition switch OFF.
6-212)

Tum the ignition switch ON. the ECU and connector (page
6-212).
Measure voltage between O 1 O

(+) terminal and 022 (-) termi- Turn the ignition switch ON.
nal.

(+) terminal and 022 (-) termi-
nal.
Repair open in YEL/

ECU (D20) and IMA
NO sensor.

and recheck. lf prescribed volt·
age is now available. replacethe
original ECU.

ººººººººººººº ºººººººº ººººººººº
020(+) 022(-1
u
5V7
NO Repairopen or short in GRN/REO

Is voltage 0.5-4.5 V ? wire between ECU(010) and IMA
sensor.
YES
tion goes away. replace the orig-
inal ECU. ººººººººººººº ºººººººº 010(+) 022(-1
0.5-4.6 V7
11-259
Troubleshooting Flowchart --- lgnition Output Signal
-[al- -[Jil-
<, I / <, 1 /
Self-diagnosis Check Engine light indicates code 15: A problem in the lgnition Output Signa! circuit.
/ 1 <, / 1 '<,
»:
-ral- -DIJ-
<, \ <, 1 /
, 1 ...... / 1 ~ ......

reported on.
jumped lsee. page 11-208),
CODE 15 is indicated.

lpage 11-209).
Start the engine.

NOTE: lf the engine won't start, it
may take 20 seconds of cranking to
set the code.
lntermlttent failure, system is OK

Is Check Enginelight on and does NO necessary).
it indicate CODE 15? >1 Check for poor connections or
loose wires at igniter unit and
YES ECU.

from the distributor
Measure voltage between BLK /

ground.

Is there batterv voltage ?
tween the 2P connector and igni·
tion switch.
YES
(To page 11-261)
11-260
(From page 11-260)
10V7---
A21 l+I
ºººººººººº ºººººººº ººººººººººº

Connect the test harness between ºººººººººº o
00000000
the ECU and connector (page A22 l+I A26 H
11-212). LJ
10 V?
Measure voltage individually be-

tween A21 C+I. A22 (+) ter-
minals and A26 (-) terminal.
Replace the igniter unit.

NO Repair open or short in VEL/
Is there approx. 1 O V7
GRN wire between igniter
YES unit and ECU (A21 or A22).
NOTE: lf the YEL/GRN wire was

Substitute a known-good shorted, the igniter may be damaged.
ECU and recheck. lfsymptom/
indication goes away. replace
the original ECU.
11-261
Troubleshooting Flowchart --- Vehicle Speed Sensor------------
-f Q 1- -[][]-
<, 1 ..,...... <, 1 /
Self-diagnosis Check Engine light indicates code 17: A problem in the Vehicle Speed Sensor circuit.
/' 1 <, / 1 <,
The signa) generated by the speed sensor produces pulses when the front wheels turn.
~ -[ill-
~' 1 /
/ ' '-

reported on.
Wíth servíce check connector
17 is índicated.

(page 11-209)
Road test necessary.

In 2nd gear accelerate to ,
4,000 min-1 (rpm) then de-
celerate to 1, 500 min " 1 (rpm)
with throttle fully closed.
lntermittent feilure, system is OK
at this time.
Is Check Enginelight on and NO loose wires at speed sensor and
does ít indicate CODE 17? ECU.
YES
Block rear wheels and set the

parking brake. Jack up the front
f,@,,;@jfld Block
rear wheels before
of the car and support with safe-
jacking up front of
ty stands.
car.

(page 11-212)

A26 (-) 810 (+)
Block the right front wheel and 1 !
slowly rotate left front wheel and 0-12 V?
measu re voltage between B1O
minal.
Does voltage pulse O V and 12 NO

V?
YES
Substítute a known-good ECU

and recheck. lf symptom/ (To page 11-263)
índícation goes away, replace
the original ECU.
11-262
(From page 11-262)
1
Disconnect the B connector from
harness.
1
l
Block the right front wheel and
slowly rotate left front wheel and
measure voltage between B1 O
minal.
- Repair short in
YEL/BLU wire be-
1 tween ECU (810)
and the speed son-
Does voltage pulse o V and NO
sor, speedometer,
12 V?
cruise control unit or
A/T control unit
YES
1 (01627 engine
only).
Substitute a known-good ECU - Repair open in
and recheck. lf symptom/indica- YEL/BLU wire be-
tion goes away, replace the tween ECU (810)
original ECU. and speed sensor.
- lf wire is OK, test
the speed sensor
(Section 23).
11-263
Troubleshooting Flowchart--A/T Lock-up Control SolenoidValve
Self-diagnosis Check Engine light indicates code 19: A problem in the Lock-up Control Solenoid Valve A (or Bl
circuit.
Check Eingine light has been

reported on.
1~ is indicated.

(page 11-209)
LOCK-UP
Test drive necessary. CONTROL
Drive the car for several miles so SOLENOID
that the transmission upshfts and VAL VE
downshifts several times.

OK at this time.
Does Check Engine light indicate >-N_O __, Check for poor connections or
CODE 19? loose wlres at lock-up Control
Solenold Valves and ECU.
YES

main harness only, not to the ECU
(page 11-212)


A 19 or A 17 * and body ground. *: Lock-up Control Solenoid Valve B
YES Repair short in YEL or GRN/BLK*

Does continuity exist? wire between ECU (A 19 or
A 1 7 *) and the 2P connector.
NO
(To page 11-265)
11-264
(From page page 11-264)
Measure resistance between A 19

or A17" terminal and A26 termi-
nal.
NO Check for continuity in YEL or

Is there 14-25 O ? GRN/BLK wire between ECU
(A 19 or A 17 *) and the 2P
YES connector.
YES Faulty lock-up control

Does continuity exist? solenoid valve (page
11-14).
NO
Repair open in YEL or GRN/BLK*

wire between ECU (A 19 or
A 17 *) and the 2P connector.

tion goes away, replace the orig-
inal ECU.
11-265
Troubleshooting Flowchart-- Electric Load Detector [D 1521 engine] --
-00-
<, 1 /
Self-diagnosis Check Engine light indicates code 20: A problem in the Electric Load Detector circuit.
~ oo :=
/ 1 '-
/ 1 '-

jumped (page 11-2081. CODE20
is indicated.

(page 11-209)

rpm at idle.
Turn on headlights.
Does Check Engine light indicate NO necessary).
CODE 20?. Check for poor connections or
loose wires at C202 (ELDI and
YES ECU.
Remove the under-hood fuse/

relay box and remove the fuse/
relay box lower cover.

from the e1ectricload detector.
ELD

YEL (+)terminal and BLK (-) ter-
minal.
NO Measure voltage between BLK/

Is there battery voltage? YEL ( + 1 terminal and body
ground.
YES
Repair open In BLK

Is there battery voltage? wire between the 3P
connector and G201.
NO
Repair open in BLK/YEL wire

between ACG (SI (15A) and the
3P connector.
(To page 11-267)
11-266
(From page 11-266)

GRN/RED terminal and body
ground.
NO Aepalr open or short In GAN/AED

Is there 4.5-5 V7 wlre between ECU (0101 and the
3P connector.
YES lf wlre Is OK, substituta a known-
good ECU and recheck.
Connect the 3P connector to the

electric load detector.

(page 11-212).
(To page 11-268)
(cont'd)
11-267
Troubleshooting Flowchart-Electric Load Detector [D 1521 engine] (cont' d)
(From page ·11-267)

Condition Voltage
Headlight switch, first position (•) 2.5-3.5 V
Headlight switch, second position ( •) 1.5-2.5 V
idle.
Under the conditions listed in the

chart to the right, measure
voltage between 010 (+) ter-
minal and A26 (-) terminal. ººººººººººººº 00000000
ºººººººººººº ºººººººº
A26(-I 010(+)
._l Usted Voltage? _.!
Is the voltage listed in the chart NO Faulty electric load detector.

available?
YES

origina! ECU.
11-268
Troubleshooting Flowchart -- ECU[01582 engine]---------
Check Engine light nevar comes

on (even for two secondsl after
ignition is turnad on.
NO
Is the oil pressure light on? lnspect BACK UP LIGHTfuse.
YES
Turn the ignition switch OFF. Replace fuse.
Is BACK UP LIGHTfuse OK?
YES
ween the ECU and connector Repair open in YEL between
(page 11-212) BACK UP LIGHT and gauge
assembly.
Connect 86 terminal to body 000000000 00000000

ground. 000000000 00000000
86
-L._
Replace the light

bulb.
NO Repalr open in
Is Check Enginelight on? GRN/ORN wire be-
tween ECU(861 and
gauge assembly.
YES
0000000000 00000000
0000000000 00000000
y
A2 A4 Al A18
~
Less than 1 V? l
minals individually: •A2, •A4,
•A16, •A18. G101
Repair open in wire

NO between ECU and
G 1 O 1 that had more
YES than 1 V.

and recheck. lf symptom/ indica-
original ECU.
11-270
NOTE: When there is no code stored, the Check
Check Engine light stays on or Engine light will stay on if the service check con-
comes on after two seconds. nector is jumped.
Connect the service check con-

nector with a jumper wire (page
11-208).
Does Check Engine light YES Go to self-diagnostic procedures

indicate any CODE? (page 11-210)
NO
ººººººººº ºººººººººº
000000000
Remove the jumper wire frorn
the service check connector.
ººººººººº
820 (+) C12 (-1
5 V?
Try to start the engine.
YES Connect the test harness be-

Did the engine start? tween the ECU and connector.
NO

terminal and C 1 2 (-) terminal.
Connect the service

YES check connector with
Is there approx. SV?
a jumper wire.
NO

BRN wire between the eCU (820) Measure voltage be-
and service check connector. tween 820 ( +) terminal
and C 12 ( - l terminal.
Repair open in 8RN wire be- YES

tween ECU (820) and service Is there approx. SV?
check connector.
Repalropen in GRN/WHT wire NO
Remove and inspect the ECU ( 1 5
Al fuse in the under-hood between service check con-
fuse/relay box. nector and ECU (C12). Remove the jumper
wire from the service
check connector.
NO
Is the fuse OK? Replace the fuse.
(To page 11-272)
YES
* NOTE: After repair, disconnect the service check con-
nector jumper wire, test drive the car, and recheck the
(To page 11-272) Check Engine light for a code.
(cont'd)
11-271
Troubleshooting Flowchart - ECU [01582 engine] (cont'd)
(From page 11--271) (From page 11-271)
lnspect the ACG (S) ( 15 A) fuse in Turn the ignition

the under-dash fuse box. switch OFF.
Is the fuse OK? Replace the fuse. Disconnect "A" con-

nector from the ECU.
YES

Turn the ignition
switch ON.
Disconnect the 3P connector of

each sensor one at a time: Substitute a known-good ECU
• MAP sensor and recheck. lf symptom/lndica- NO Is the Check Engine
• Throttle angle sensor tlon goes away, replace the light ON?
original ECU.
YES

NO ground in GRN/ORN
Does Check Engine light Replace the sensor that caused wire between the ECU
remain ON? the light to go out. (86) and Check Engine
light.
YES
Connect the test harness.

Disconnect the "C" connector C13 C15
000000000 0000000000
wire harness. (page 11-212).
000000000 0000000000

body ground termina Is C 13, C 1 5.
~
Continuity
YEL/GRN wire between ECU
(C15) and MAP sensor.
YES Repair short to body ground in
YEL/WHT wire between ECU
NO (C13) and throttle angle
sensor.
Reconnect all the sensor connec-
tors.
Reconnect the '·'C" connector to
the ECU.
(To page 11-273)
11-272
(From page 11-272)
.- -1 -~1 I
A13 l+l A15 (+)
Meas u re voltage between A 1 B BATTERY 0000000000 00000000

BOLTAGE? 0000000000 00000000
1'--------'A1s,-)
(-) and the following: A 13 ( +)
and A15 (+).
¡ 1
Repair open in VEL/BLK wire

NO between ECU (A 13. A 15) and
Is there battery voltage? main relay.
Check main relay and wlring
YES connectors at main relay.

and recheck. lf svmptcm/tndica-
original ECU.
11-273
Troubleshooting Flowchart- Oxygen Senser [D 1582 engine] ------
j 9f0 Self-diagnosis Check Engine light indicates code 1: A problem in the Oxygen (02) Sensor circuit.
The Oxygen sensor detects the oxygen content in the exhaust gas, and inputs the ECU. In operation, the ECUreceives the signals from
the sensor and varíes the duration during which fuel is injected. The oxygen sensor is installed on the exhaust manifold.
STOICHIOMETRIC
AIR-FUEL RATIO
RICH-- AIR--LEAN
FUEL
RATIO

reported on.
1 is indicated.

(page 11-209).
tnspect pressure regulator (paga

11-343).
NO Replace the pressure regulator

Is it normal?
(page 11-344)
YES

fan comes on).
Roadtest with the transmission in

2nd gear (M/T: 4th gear). Start-
ing at 1400 min-1 (rpm), acceler-
ate using ide open throttle for at
least 5 seconds. Then decelerate
for at least 5 seconds with the
throttle completely closed.

Is Check Engine warning light on ,_N_0 --1 at thls time. Check for poor con-
and does LEDindicate CODE1 . nections or loose wires at 02 sen-
sor and ECU.
YES
(To page 11-275)
11-274
(From page 11-274)
Disconnect engine wire harness

from the 02 sensor.

operating temperature again,
02 SENSOR
SOCKET
Measurevoltage between the con- DIGITAL WRENCH 02 SENSOR
CIRCUIT 07LAA-PT5010 45N•m
TESTER (4.5 kg-m, 33 lb-ftl
07411-002000

open throttle and below 0.4 V NO
when the throttle is quickly ,__ ___, Replace 02 sensor.
released? ~-------·--------_¡
YES
Stop engine.
Reconnect the oxygen sensor.
000000000 0000000000 00000000

tween the ECU and connector 000000000 0000000000 0000000
(From page 11-212) C16 (+I
A18 (
Above 0.6 V?
Below 0.4 V?
Restart and warm up engine to
normal operating temperature,
open, then quickly ralease it.
Measure voltage between C 16

( +) terminal and A 18 ( - )
terminal.

Repair short or open in WHT wire
open throttle and below 0.4 V >-N_O __¡
between ECU (C161 and 02
sensor.
released?
YES

and recheck. lf symptom/ indi-
original ECU.
11-275
Troubleshooting Flowchart -- MAP Sensor [D 1582 engine]
<, 1 / <, 1 /
-[01--[IJ-
/ 1 ......._,......... 1 <,
Self-diagnosis Check Engine light indicates code 3: An electrical problem in the Manifold Absolute Pressure
(MAP) Sensor system.
<, 1 .,,,..., 1 /
-1 al- -[TI-
,,, 1 '-/ 1 <,
Self-diagnosis Check Engine light indicates code 45: Most likely a problem in the Fuel Metering System.
Pressure (MAP) Sensor system.
The MAP sensor converts manifold absolute pressure into electrical signals and inputs the ECU.
SILICON VACUUM OUTPUT

DIAPHRAGM CAVITY VOLTAGE
(v) 3.5
3.0
<, 1 ................... ' /

0.5
-[01--[TI-
/ 1 <c >" 1 <,
o 5 1O 15 20 25 30 (In. Hgl GAUGE
READING
100 200 300 400 500 600 700 (mm Hgl
Engine is warm and running.

reportad on.
3 is indicated. ·

(page 11-209).
Start the engine and allow it to lntermittent failure,

idle. system is OK at this
necessary).
Check for poor con-
nection or loose wires
Is Check Engine light on and NO
at MAP sensor and
does it indicate CODE 37
ECU.
YES

YEL/ MAP SENSOR
GRN

from the MAP sensor.
(To page 11-277)
11-276
(From page 11-276)
.--~~~~~~---~~~~~~~--.....-~~~-c_1---1s~
000000000 0000000000 0000000 SW
Measure voltage between 000000000 0000000000 000000 ~ 1
YEL/GRN ( +) terminal and body

ground. C14u
YES Measure voltaqe between Y.EL/

Is there approx. 5V? GRN ( + l terminal and GRN/BLU
NO ( - ) terminal.
Connect the test harness "C"

connector to the ECU only, not NO Repair open in GRN/
Is there approx. 5V? BLU wire between
11-212). YES ECU (C14) and MAP
sensor.
Measure voltage between C 1 5

( + l terminal and C 14 ( - ) ter-
minal.
NO
Repair open in YEL/GRN wire (+) terminal and GRN/BLU
between ECU (C15) MAP ( - ) terminal.
sensor.

original ECU.
YES

the MAP sensor.

(page 11-212).
(To page 11-278)
(To page 11-278)

(cont'd)
11-277
- Troubleshooting Flowchart --- MAP Sensor [D 1582 engine] (cont' d) ---
1

( +) terminal and C 14 ( - ) ter-
minal.

11-212). Is there approx. 3 V ? >--N-º-------i1 Replace MAP sensor. 1
'------~~-~----"
YES

original ECU. ~
Measure voltage between C 11 C11b
(+) terminal and C14 (-)
minal.
ter-
00000000010000000000100000 00
I
svr
1 000000000 0000000000 000000~ 1
C14~
<-~--
- Repair short in WHT wire
between ECU (C11) and MAP
Is there approx. 5 V? YES
.------, sensor.
I - Repair open in WHT wire
between ECU(C11) and MAP
NO sensor.

and recheck. lf prescrlbed
voltage Is now avallable, replace
the original ECU. ¡
(cont'd)
11-278
Troubleshooting Flowchart-MAP Sensor (01582 engine] (cont'd)
-OJ-
' 1 /
-[OI-
' 1 /
,, 1 ' ,, 1 '

reported on.
Wlth service check connector
5 is indicated.

(page 11-209)

speed at 2000 for one minute.

may be necessary).
Is Check Engine light on and does NO
it indicate CODE 5? >------1 Check vacuum hoses, pipes
and connections.
YES secure.
#21 HOSE
Stop the engine.
Disconnect #21 hose from the

throttle body, connect vacuum
pump to the hose and apply
vacuum.
VACUUM PUMP/
GAUGE
NO Connect a vacuum pump to the

Does it hold vacuum? MAP sensor and apply vacuum.
YES
YES
Connect a T-fitting from a Repair vacuum leak in hose

vacuum gauge between the routing between MAP sensor
throttle body base and #21 and intake manifold.
hose.
(To page 11-28H
11-280
(From page 11-281)
Start the engine.
NO Remove restrlctlon from throttle

Is there manifold vacuum7 body.
YES
Stop the engine.
Connect the test harnes be-

(To page 11-212)
.--~~~~~~---~~~~~~~-.r-~~C-1~1~
000000000 0000000000 00000 00 3 V?
Measure voltag between C 11 000000000 0000000000 000000 ~ 1
( + l terminal and C 14 ( - l
terminal. C1~
NO
Is there approx. 3 V ? Replace MAP serisor.
YES

idle.
NO
YES

and recheck. lf symptom/lndlca-
original ECU.
11-281
Troubleshooting Flowchart TDC/CRANK Sensor [D 1582 engine]
1 / 1 /
-f Qj- -[I]-
<, <,
Self-diagnosis Check Engine light indicates code 4: A problem in the CRANK Sensor circuit.
-m-
/ 1 <, / 1 <,
-f OI-
<, 1 .................... 1 /
Self-diagnosis Check Engine light indícated code 8: A problem in the TDC Sensor circuit.
/ 1 <, / 1 <,
The CRANK sensor determines timing far fuel injection and ignition of each cylinder and also detects engine RPM. The TDC sensor
determines ignition timing at start-up (cranking) and when crank angle is abnormal.
<, ,1 ,,,, 1 / ....... 1 /
-Cal--w-
,,,,,,,. 1 ,.,,..,,. 1 <,
or -[TI-
.,,. 1 <,

reported on.
Jumped(page 11-2081, CODE
4, 8 and/or 9 are indicated.
CRANK
Do the ECU Reset Procedure ROTOR
(page 11-2091.
Start the engine.

lntermittent failure, sys-
tem is OK at this time
(test drive may be
necessarvl.
Is Check Engine light on NO Checkforpoorconnec-
and does it indicate CODE
tions or loose wires at
4 or 8? TDC/CRANK sensor
and ECU.
YES
Stop the engine.

from the TDC/CRANK sensor.
(To page 11-283)
11-282
(From page 11-282)
SENSOR ECU WIRE

Measure resistance between ter- SENSOR CODE
TERMINAL TERMINAL COLOR
minals of the indicated sensor.
*see table E C1 BLU/GRB
CRANK 4
D C2 BLU/TEK
NO Replace the distributor TDC 8

e C3 ORN/BLU
Is there 350- 700n? sub-assembly ISection B C4 WHT/BLU
23).
YES
Check tor continuity to body

ground on both terminals of the
indicated sensor.
YES Replace the distributor

Does continuity exist? sub-assembly (Section
231.
NO
Reconnect the connector.
CRANK:
Connect the test harness to the 1

e,
main wire harnessonly, not to the
ECU (page 11-212). 000000000
ºººººººººº ººººººº 1
350-700 07
000000000
ºººººººººº 0000000
C2
minals of the indicated sensor on
1 1
test harness.
*see table TDC:
l
1
C3
ººººººººº ºººººººººº 000000 350-700 fl?

000000000
ºººººººººº 000000
C4
1 1
NO Repair open in the in-

lsthere 350-700n? dicated sensor wlres.
*see table
YES

ground on C 1 or C 3 terminals.

YES ground in the indicated
sensor wires.
*see table
NO

and recheck. lf symptom/indlca-
original ECU.
11-283
Troubleshooting Flowchart---TW Sensor [01582 engine] --------
<, 1 / <, 1 /
-[ ül- -[IJ-
/ 1 <, »: 1 <,
Self-diagnosis Check Engine light indicates code 6: A problem in the Coolant Temperature (TW) Sensor circuit.
The TW sensor is a temperature dependant resistor (thermistor). The resistance of the thermistor decreases as the coolant temperature
RESISTAN CE
(k!l)
20.,...,...---,---..-----r----,
tO~lo.4---+---+-----i
5+-~ .......-1----+----1
-m- o 20 40 60 80 100 120 e ·e¡

<,
THERMISTOR
-rol-
1 / <, 1 /
-4 32 68 104 140 176 21 2 248 ( "F)

,,, <, ,,, 1 <,
COOLANT TEMPERATURE

reported on.
jumped (paga 11-2081, CODE
6 is indicated.

(page 11-209).
lntermlttent fallure. system is OK

necessary).
Is Check Engine light on and does ),N_0 1 Check for poor connections or
it indicate CODE 6? loase wires at TW sensor and
ECU.
YES

ating temperature ( cooling tan
comes on).
Disconnect the 2 P connector from

the TW sensor.

NO
Is there 200-400 m Replace TW sensor.
YES
(To page 11-285)
11-284
(From page 11-284) TW SENSOR
Measure voftage between RED/

WHT and body ground.
GRN/WHT (-)
WHT ( +) terminal and GRN/WHT
( - ) terminal.
NO
Repair open in GRN/
ECU (C 12) and TW
sensor.
Turn the ignition switch OFF. Substitute a known-good ECU
original ECU.
Connect the test harness"C" con-

nector to the ECU only, not to the
main wire harness(page 11-212).
000000000 0000000000
000000000 0060000000
C6 l+l C12 (-)
Measure voltage between C6 ( +)

LJ
5 V?
terminal and C 12 ( - ) terminal.
Repair open or short in RED/

Is there approx. 5V? WHT wire between ECU (C6) and
sensor.
NO

original ECU.
11-285
PG M-FI Control System
Troubleshooting Flowchart ---Throttle AngleSensor [O 1582 engine]---
<, I r" 1 ,..........
-( Qj--[IJ-
>;
Self-diagnosis Check Engine light indicates code 7: A problem in the Throttle Angle Sensor circuit.
/ 1 ................. 1 <,
The throttle angle sensor is a potentiometer. lt is connected to the throttle valve shaft. As the throttle angle changes, the throttle angle
sensor varies the voltage signa! to the ECU.
BRUSH
HOLDER OUTPUT VOLTAGE (V)
3
2
1
0.5 THROTTLE
º101=:LE=-..------F-U_L_L....._ OPENING
THROTTLE
..... 1 /
-rol- -[IJ-
' 1 /
,,, 1 ..... / 1 .....
Engine is running.
reported on.
jumped (page 11-2081, CODE
7 is indicated.

(page 1 1 -2091.
Start the engine.

necessary).
Is Check Engine light on and does NO Check for poor connections or
it indicate CODE 7? ;,----------1
loose wires at throttle angle sen-
sor and ECU.
YES

from the throttle angle sensor.

(-) terminal.
NO Measure voltage between YEL/

Is there approx. 5V ? WHT ( +) terminal and body
ground.
YES
(To page 11-2871 (To page 11-2871
11-286
Repair open in GRN/

Turn the ignition switch OFF. ECU (C12) and throttle
angla sensor.
NO


Connect the test harness between the ECU and connector
tween the ECU and connector (paga 11-212).
(page 11-212).

( +) terminal C 12 ( - l terminal.
Repair open in YEL/

ECU (C131 and throttle
angle sensor.
NO
Substitute a known-good
ECU and recheck. lf pre-
Measurevoltage between C7 ( + l able. replace the original
terminal and C 12 ( - l terminal. ECU.
1
C13 (+J
000000000 0000000000 o 1
5 V?
000000000 0000000000
I e 11._2 _1 -_, _ ____,,
000000000 0000000000 0.5 V at full close throttle?

000000000
ºººººººººº C12(-l
4.5 V at full open throttle?
1 1
Is voltage 0.5 V at full close Replacethrottle an-
throttle, and approx. 4.5 V at gle sensor.
full open throttle? Repairopen or short
NO
NOTE: There should be a in RED/BLU,LT GRN
smooth transition from O. 5 V wire between ECU
to approx. 4. 5 V as the (C7), and throttle
throttle is depressed. . angla sensor.
YES

original ECU.
11-287
Troubleshooting Flowchart --TA Sensor [01582 engine]
-00-
<, I ,. . . . . <, 1 /
-[ Q j- Self-diagnosis Check Engine light indicates code 1 O: A problem in the lntake Air Temperature (TA) Sensor circuit.
/ 1 <, / 1 <,
The TA sensor is a temperature dependant resistor (thermistor). The resistance of the thermistor decreases as the intake air temperature
in creases as shown below. ·
RESISTANCE (kíl)
20~~~~.--~.....-~--.
10+-"1r+~~t-~-t-~---,
5+---'lk---~+-~-t-~---,
THERMISTOR o 20 •o eo ao 100 120 1 ·e,

......._ I »: <, 1 /
-rol- -00-
/ 1 <, / 1 <,
-4 32 68 104140 176 212 248 ( 'F)

reportad on.
jumped (page 1 1 -208), CODE GRN/WHT
10 Is indicated.

(page 11-209).

system Is OK at this
time (test drive may
Is Check Engine light on and NO be necessary).
does it indicate CODE 1 O? Check for poor con-
nections or loose
YES
wires at TA sensor
and ECU.

from the TA sensor.

2 terminals on the TA sensor.
Is there 0.4- 4.0 kíl? Replace TA sensor.
YES
(To page 11-289)
11-288
(From page 11-288)

ground.

Is there approx. 5 V ? YEL ( +) terminal and GRN/WHT
( - ) terminal.
NO
Repair open in GRN/
NO WHT wlre between
Turn the ignition switch OFF. Is there approx. 5 V ?
ECU (C121 and TA sen-
sor.
YES
to the main wire harness (page Substitute a known-good ECU
11-212). and recheck. lf symptom/indica-
original ECU.

1
C5 (+I
Measure voltage between C5 (+)

terminal and C12 (-) terminal.
000000000
000000000 ºººººººººº
ºººººººººº
00 00000
00000~
1
SV?
1
C12~
YES Repair open or short in RED/YEL

Is there approx. 5V? wire between ECU (C51 and TA
sensor.
NO

the original ECU.
11-289
Troubleshooting Flowchart --- lgnition Output Signal [D 1582 engine]
<, 1 .,........ <, 1 /
-[ICJ]- -[][]-· Self-diagnosis Check Engine light indicates code 15: A problem in the lgnition Output Signal circuit.
/ 1 <, / 1 .........

reported on.
jumped (see page 11-208),
CODE 15 is indicated.

(page 11-209).
Start the engine.

NOTE: lf the engine won't start, it
may take 20 seconds of cranking to
set the code.

Is Check Enginelight on and does NO necessary)
it indicate CODE 157 >--------i Check for poor connections or
loose wires et igniter unit and
YES ECU.

from the distributor
Measure voltage between BLK /

ground.

Is there battery voltage ? tween the 2P connector and igni-
tion switch.
YES
(To page 11-291)
11-290
(From page 11-290)
10V?---~
8151+) 8171+)
00000000
Connect the test harness be- 00000000
A18 (-)
(page 11-212).
Measure voltage individually be-

tween B 1 5 ( +). B 17 ( + ) termi-
nals and A 18 (-) terminal.
Replace the igniter unit.

Is there approx. 1 O V?
NO Repairopen or short RED/GRN
wires between igniter unit and
YES ECU 1815 or 817).
NOTE: lf the RED/GRN wire was

Substitute a known-good shorted, the igniter may be damaged.
ECU and recheck. lf symptom/
the original ECU.
11-291
Troubleshooting Flowchart --- Vehicle Speed Sensor [D1582 engine] ---
<, I /-....... 1 / .
-[Q!- -[]I]- Self-diagnosis Check Engine light indicates code 17: A probtem in me Vehicle Speed Sensor circu_it.
/ 1 <, / 1 <,
The signal generated by the speed sensor produces pulses when the front wheels turn.

reported on.
17 is indicated.

(page 11-209).
Road test necessary.

In 2nd gear accelerate to 4,000
min-1 (rpm), then decelerate to
1,500 rnln " (rpm) with throttle
fully closed.
lntermittent failure, system id OK

Is Check Engine light on and NO et this time.
does it indicate CODE 17? Check for poor connections or
loose wires a speed sensor and
YES ECU.
Block rear wheels and set the

parking brake. Jack up the front
f'5§H-MMN Block
rear wheels before
of the car and support with safe-
jacking up front of
ty stands.
car.

(page 11-212)
Turn the ignition switch ON. 000000000 00000000

00000000 00000000
Block the right front wheel and A18(-) 816 (+)
measure voltage between B 16 OV+->12V?
( + ) terminal and A 1 8 ( - ) ter-
minal.
Does voltage pulse O V and 1 2 NO

V?
YES

and recheck. lf symptom/ (To page 11-293)
the original ECU.
11-292
(From page 11-292)
1
Disconnect the "B" connector
wire harness.
1
1
Block the right front wheel and
measure voltage between B 16
( +) terminal and A 18 ( - ) ter-
minal.
- Repair short in
YEL/BLU wire be-
1 tween ECU (816)
and the speed sen-
Does voltage pulse o V and NO
sor speedometer, or
12 V?
crulse control unit.
YES - Repair open in
1 VEL/8LU wire be-
tween ECU (816)
Substituta a known-good ECU and speed sensor.
and recheck. lf symptom/indica- - lf wire is OK, test
tlon goes away, replace the the speed sensor
original ECU. (Section 23).
11-293
Troubleshooting Flowchart-- A/T Lock-up Control Solenoid Valve ---
[D 1582 engine]
Self-diagnosis Check Engine light indicates code 19: A problem in the Lock-up Control Solenoid Valve
circuit.

reportad on.
19 is indicated.

(page 11-209).
Test drive necessary.

Drive the car for several miles so
that the transmission upshfts and
downshifts severaltimes.
lntermittent fallure, system is OK

at this time.
Does Check Engine light indicate >-N_0 1 Check for poor connections or
CODE 19? loose wires at lock-up control
solenoid valve and ECU.
YES

main harnessonly, not to the ECU
(page 11-212)

Check for continutiy between A8

and body groun.
YES Repairshort in YEL wire between

ECU (AS) and the 2P connector.
NO
(To page 11-295)
11-294
(From page 11-294)
Reconnect the 2P connector. 0000000000 00000000

0000000000 00000000
AS A18
Measure resistance between A8
terminal and A 18 terminal. 14-250?
NO Check for continuity in YEL wire

Is there 14-25 O ? between AS terminal and the 2P
connector.
YES
YES Faulty lock-up control

Does continuity exist? solenoid valve (section
14).
NO
Repairopen in YEL wire between

ECU (AS) and the 2P connector.

tion goes away, replace the orig-
inal ECU.
11-295
ldle Control System
System Troubleshootinq Guide
NOTE:
• Across each row in the chart, the sub systems that could be sources of a symptom are ranked in the order thev should
be inspected, starting with G). Find the symptom in the left column, read across to the most likely source, then refer to
the paqe listed at the top of that column. lf inspection shows the system is OK, try the next system (2), etc.
• lf the idle speed is out of specification and the Check Enginelight does not blink CODE14, go to inspection described
on page 11-299.
AIR ALTER· AIT M/T PIS OIL HOSES

PAGE IOLE CLUTCH STARTER BRAKE FAST
CONOI- NATOR SHIFT SWITCH PRESSURE ANO
AOJUSTING EACV SWITCH SWITCH IOLE
TIONING FR POSITION SIGNAL SWITCH CONNEC-
SCREW 015Zl engine SIGNAL SIGNAL VAL VE
~ SIGNAL SIGNAL SIGNAL only) SIGNAL TIONS
SYMPTOM
~~ 326. 328* 300, 316* 302, 318* 304, 320* 306, 322* 308 310, 324* 312 314 325 -
OIFFICUL T TO ST ART
ENGINE WHEN COLO CD
WHEN COLO FAST IDLE OUT OF
SPEC 11,000-2,000 rpm)
@ ® CD
ROUGH IDLE
® CD
WHEN WARM ENGINE
SPEED TOO HIGH @ CD @ ® @
ldle speed is below
specilied rpm (no
load)
® CD
ldle speed does not
increase after initial
start up.
CD
On models with
WHEN
WARM
automatic transmis-
sion, the idle speed
droos in cear
® CD
ENGINE
ldle speeds drops
SPEED
TOO LOW
when air conditioner
in ON
® CD
ldle speed drops
when steering wheel
is turning
® CD
ldle speed lluctuates
with electrical load ® @ CD
FREOUENT
WHILE WARMING
UP ® CD
STALLING
CD ®
AFTER WARMING
UP
FAILS EMISSION TEST

CD
*: D 1 582 engine
11-296
System Description ---------------------------.
The idle speed of the engine is controlled by the Electronic Air Control Valve (EACV).
The valve changes the amount of air bypassing into the intake manifold in response to electric current sent from the ECU.
When the EACV is activated, the valve opens to maintain the proper idle speed.
Except 01582 eingine:

TO MAIN
RELAV
i
VEL/ BLU/ _-"- GRN/
ECU
BLK
BLK YEL WHT
1
VARIOUS SENSORS
EACV
01582 engine:
VARIOUS
SENSORS
A TO MAIN
RELAY
t
YEL/
BLK
~T
(cont'd)
11-297
ldle Control System
System Description (cont'd)
1. After the engine starts, the EACV opens for a certain time. The amount of air is increased to raise the idle speed
about 150-300 min " ' (rpm).
2. When the coolant temperature is low, the EACV is openedto obtain the proper fast idle speed.The amount of bypassed
air is thus controlled in relation to the coolant temperatura.
ENGINE SPEED
(mm", rpm)
COOLANT TEMPERATURE
lºCI
-20 o 20 40 60 80
11-298
1. When the idle speed is out of specification and the Check Engine light does not blink COD E 14, check the following
items:
• Adjust the idle speed (page 11-326, 328*)
• Air conditioning signal (page 11-302, 318 *)
• Alternator FR signal (page 11-304, 320*)
• A/T shift position signal (page 11-306, 322 *)
• M/T clutch switch signal (D 1521 engine only) (page 11-308)
• Starter switch signal (page 11-31 O, 324 *)
• Brake switch signal (page 11 -31 2)
• P/S oil pressure switch signal (page 11-314)
• Fast idle valve (page 11-325)
• Hoses and connections
• EACV and its mounting 0-rings
*: D 1 582 engine
2. lf the above items are normal, substitute a known-good EACV and readjust the idle speed (page 11-326, 328*).
• lf the idle speed still cannot be adjusted to specification (and the Check Engine light does not blink CODE 14)
after EACV replacement, substitute a known-good ECUand recheck. lf symptom goes away. replace the original
ECU.
11-299
ldle Control System
Troubleshooting Flowchart --- EACV ------------------
<, 1 /, 1 /
-[01- -(JI]- Self-diagnosis Check Engine light indicates code 14: A problem in the Electric Air Control Valve (EACV) circuit.
/ 1 <, / 1 ........ _
The EACV changes the amount of air bypassing the throttle body in responseto a current signal from the ECU in order to maintain the
proper idle speed.
TO INTAKE FROM AIR
COIL MANIFOLD CLEANER
VALVE SPRING
.arr
<, 1 /
' 1 /
-[01-
/ 1 <, EACV
/ 1 '

reportad on.
jumped (paga 11-208), CODE
14 is indicated.

(page 11-209)
YÚ/
Start the engine. BLK
With the engine running and the

Is Check Engine light on and accelerator pedal released,
does it indicate CODE 14? disconnect the 2P connector
from the EACV. lntermittent failure,
YES system is OK at this
time (test driving may
be necessary).
Remove the 2P connector from
Is there a reduction in engine YES Check for poor con-
the EACV.
rprn? nection or loose wires
at EACV and ECU.
NO
Substituta a known-good EACV

and retest.
(To page 11-301)
11-300
(From page 11-300)
Measure voltage between the

YEL/BLK wire and body ground.
NO Repair open in YEL/BLK wire be-

tween EACV and main relay.
YES
Turn the ignition switch off and

reconnect the 2P connector the
EACV.

11-212)
A9 (+) A23 (-)

ººººººººººººº
00000000
Momentarily connect A9 ter-
minal to A23 terminal several
times.

YES and retest. lf symptom/indica-
Does the EACV click? tion goes away, replace the
original ECU.
NO
Repair open or short in GRN/

WHT or BLU/YEL wire between
EACV and ECU (A9). lf the wire
is OK, replace the EACV.
11-301
ldle Control System
Troubleshooting Flowchart---Air Conditioning Signal -----------
This signals the ECU when there is a demand for cooling from the air conditioning system.
lnspection of Air Condition-

ing Signal.

tween the ECU and connector.
Disconnect "B" connector from
the main wire hamess only, not
the ECU (page 11-212).
1
85 (+)
1
5 V? ººººººººººººº ººººººººººº
ºººººººººººº
A26 (-)
1 1
Substituta a known-
good ECU and re-
NO check. lf prescribed
Is there approx. 5 V? voltage is now avail-
able, replace the orig-
YES inal ECU.
Reconnect "B" connector to the

main wire harness. 1
A15
~------~~------~
1
Clicking? 0000000 00000 ºººººººº ººººººººººº
Momentarily connect A 1 5 ter-
minal to A26 terminal several
1 ºººººººººººº ºººººººº ººººººººººº
A26
times. . 1
Is there a clicking noise from the >-N_0 -1

Connect the BLK/RED terminal of
A/C compressorclutch? the 4P connector on the A/C
YES
co_BLK/RED
~ View from wire harness side
_Start the engine. Is there a clicking noise from the NO See Air conditioner in-
A/C compressorclutch? spection (section 22).
YES
Blower switch ON.

Repair open in BLK/REDwire be-
tween ECU (A 1 5) and A/C clutch
relay.
(To page 11-303)
11-302
r---- Less than 1 V 7 -----
(From page 11-302) 85 (+)
A/C switch ON.

~~~~~~~~~~~~º ~~º~~~~~ 1 11111 ~~~~~~~~~~~
1 1
A26H
Does A/C operare ? Measure voltage between 85 (+)

YES
Repair open in 8LU/

NO RED wire between
Is voltage less than 1 V?
Air conditioning signal is OK. ECU (85) and A/C
pressure switch.
YES

original ECU.
11-303
ldle Control System
Troubleshooting Flowchart ---Alternator FR Signal ------------
This signals the ECUwhen the alternator is charging.
lnspection of Alternator FR
signa l.

Disconnect "O" connector from
.------------4.5 V?------------.
09(+)
ººººººººººººº 00000000
ºººººººººººº ºººººººº
A26 (-)
( +) terminal and A26 (-1 ter-
minal.

NO
Is there approx. 4.5 V? and recheck. lf prescribed
YES the original ECU.
Reconnect "O" connector to the

main wire harness.

comes on).
.------------Voltage ?-------------,
( +) terminal and A26 (-) ter-
minal. ºººººººººººº ºººººººº
A26(-)
Does the voltage decreasewhen

headlights and rear defogger are
NO Stop the engine.
turned on ?
YES
(page 11-209).
Alternator FA signal is OK.
(To page 11-305)
11-304
(From paga 11-304)
Disconnect "D" connector from

ECU only, not the main wire
harness.
Disconnect the negativa battery

cable from the battery. D9
Check for continuity between D9 ººººººººººººº ºººººººº
YES Disconnect GRN connector from Continuity ?

Does continuity exist ? the alternator.
NO
Disconnect GRN connector from GRN CONNECTOR
the alternator.
Connect BLU wire to body

ground.
Check for continuity between D9
Check for continuity between D9 See Alternator lnspec-

terminal and body ground. Ooes continuity exist ?
tion (section 23).
YES

YES
Repair short in PNK or BLU wire
NO between ECU (091 and alter-
nator.
Repair open in PNK or BLU wire

between ECU CD91 and alter-
nator. Sea Alternator lnspec-
tion Csection 23).
11-305
ldle Control System
Troubleshooting Flowchart ---A/T Shift Position Signal -------------
This signals the ECU when the transmission is in Neutral or Park.
lnapection of A/T Shift Poaitll)n

Signal.
Observethe A/T shift indicator and

NO See A/T Shift Position lndicator

Does the indicator light properly?
lnspection (section 14).
YES

the ECU (page 11-21 2) 5 V?
87 (+)

0000000000000 ooo 0000 Oo.ddoe.
:q,t¡: :1mi 00000000000
ºººººººººººº ºººººººº ººººººººººº

1
A26 (-)
minal.

NO and recheck. lf prescribed

main wire harness.
Start the engine.
(To page 11-307)
11-306
(From page 11-306)
.------ Leas than 1 V7-----.
87 (+)
A26 (-)

terminal and A26 (-) terminal
with the transmission in [fil and
[E] individualfy.
NO Repair open in GRN wire

Is there lessthan 1 V? between ECU (87) and gauge
assembly.
YES
5 V?
87 (+)
minal with the transmission in
gear. A26 (-)
NO Repair short in GRN wire
Is there approx. 5 V? between ECU (87) and gauge
assembly.
YES
less than 1 V?-----,

83 (+)
Measure voltage between 83 or
ºººººººººººº
A26 (-) 84 (+) *
84 * terminal and A26 (-) ter-
Less than 1 V?
~ or ~ individually. *:~
Repair open in GRN/8LU or

NO GRN/8LK wire between ECU(83
Is there less than 1 V? or 84*) and Shift Position Con-
YES sole Switch.
5 V?
83 (+)
Measure voltage between 83 or

84 * (+) terminal and A26 (-) ter-
~~~~~~~~~~~~º º ~~~~~~
A26 (-) 84 (+)*
111ll!lllí ~~~~~~~~~~~
ffi] or [E]. 5 V?
Repair short in GRN/8LU or

NO GRN/8LK * wire between ECU
(83 or 84 *) and Shift Position
YES Console Switch.
A/T shift position signal is OK.
11-307
ldle Control System
Troubleshooting Flowchart - M/T Clutch Switch Signal (01521 engine]
This signals the ECU when the clutch is engaged.
lnspectlon of clutch switch

signal.
Connect the test harness be- 1

tween the ECU and connector B7 (+I
(pagel 1-212). 1
Less than 1 V?
5V
A26 (-)
1 1
Measure voltage between ·87 (+I

NO
Is voltage less than 1 V? Turn the ignition switch OFF.
YES
from the clutch switch.

the A terminal and B terminal on
the clutch switch.
NO Replace the clutch

Does continuity exist? switch.
YES
Measure voltage between PNK/

Depress the clutch pedal. BLK ( +) terminal and body
ground.
Measure voltage between 87 (+) Repair open in PNK/

NO
terminal and A26 (-) terminal. Is there approx. 5 V? BLK wire between ECU
(87) and the clutch
YES switch.
(To page 11-309) Repair open in BLK wire be-

tween the clutch switch and
G301.
11-308
(From page 11-308)
1
NO
Is there approx. 5 V? Turn the ignition switch OFF.
YES
Clutch switch signal is OK. Disconnect the 2P connector
from the clutch switch.

YES Replace the clutch
switch.
NO

main wire harness only, not the
ECU.
Repair short in PNK/

YES B LK wire between
ECU (87) and the
NO clutch switch.

and recheck. lf prescribed volt-
age is now available, replace the
original ECU.
11-309
Id le Control System
Troubleshoo
ting Flowchart --- Starter Switch Signal ------------
This signals the ECU when the engine is cranking.
lnspection of Starter Switch

Signa l. BATTERY
..----- VOL TAGE?
89
ººººººººººººº !?~gi' ººººººººººº

ºººººººººººº . g~g ººººººººººº
A26 (-)
(page 11-212)

with the ignition switch in the
start position.
NO lnspect STARTER SIGNAL(7.5A)

fuse
YES
Is STARTER SIGNAL(7.5A)
OK?
fuse
------i
~._
Replace fuse. __¡
YES
Repair open in BLU/WHT wire

between ECU (B9) and
STARTER SIGNAL (7 .5A) fuse.
Starter switch signal is OK.
11-31 O
ldle Control· System
Troubleshooting Flowchart -- Brake Switch Signal ----------------
This signals the ECU when the brake pedal is depressed.
lnspection of Brake Switch Sig-

nal.
Are the brake lights on without ,_Y_E_S _, lnspect the brake switch (section
depressing the brake pedal? 19).
NO
NO lnspect STOP LIGHT (20 A) fuse

Do the brake lights come on?
(under-hood fuse/relay box).
YES
NO
Is fuse OK? Replace fusa.
YES
Connect the test harness to the lnspect the brake switch (section
main wire harness only, not to the 19).
ECU (page 11-212).
(To page 11-313)
11-312
(From page 11-312)
ºººººººººººº 00000000 ºººººººººº
1 A26 I-) 02(+1
Measure voltage between 02 (+) I BATTERY
----VOL TAGE?
with the brake pedal depressed.
1
Repair open in GRN/WHT wire
NO
Is there battery voltage? between the brake switch and
ECU 102).
I YES
Brake switch signal is OK.
11-313
ldle Control System
Troubleshooting Flowchart - P/S Oil Pressure Signal
This signals the ECU when the power steering load is high.
lnspection of P/S Oil Pressure

Signel
Connect the test harness be- ººººººººººº

tween the ECU and connector ººººººººººººA26 (-) ºººººººººº
(page 11-212).
1
More than 1 V?


from the P/S oil pressure switch.
Is there more than 1 V?
NO
Connect BRN/RED terminal to
Start the engine. BLK terminal.
NO Replaca P/S oil pras-

Turn steeringwheel slowly. Is there more than 1 V?
sure switch.
YES
Measure voltage between 88 (+) Repair open in BRN/RED wire
terminal and A26 (-) terminal P/S OIL
between ECU (BB) and P/S oil
while steering wheel is turning. PRESSURESWITCH BRN/RED
pressure switch or BLK wire
between P/S oil pressure switch
and G302.
NO
YES

P/S oil pressure signal is OK. from the P/S oil pressure switch.
YES Replace P/S oil pres-

sure switch.
NO
Repair short in BRN/RED wire

between ECU (BBI and P/S oil
pressure switch.
lf wire is OK, substitute a
known-good ECUand recheck. lf
prescribed voltage is now
ECU.
11-314
ldle Control System
Troubleshooting Flowchart --- EACV [01582 engine]---------
1 /-......... 1 _...,,
-[O!- -[ill-
<,
Self-diagnosis Check Engine light indicates code 14: A problem in the Electric Air Control Valve (EACV) circuit.
/ 1 <, / 1 .......
The EACV changes the amount of air bypassing the throttle body in response to a current signal from the ECU in order to maintain the
proper idle speed.
TOINTAKE FROMAIR
MANIFOLD CLEANER
VALVESHAFT
VAL VE
<, 1 /
-rol-
<, 1 /
-[ill-
/ 1 ' COIL
.,, 1 -....
Check Engine light has been BLU/YEL

reported on.
jumped (page 11-2081. CODE
14 Is indicated.
YEL/BLK

(page 11-209).
Start the engine.
EACV
With the engine running and the
Is Check Engine light on and accelerator pedal released,
does it indicate CODE 14? disconnect the 2P connector
from the EACV.
YES
lntermittent failure, sys-
tem is OK at this time
Remove the 2P connector from (test drlving may be
the EACV. Is there a reduction in engine YES
necessaryJ.
rpm?
Check for poor conec-
tlon or loose wires at
NO EACV and ECU
Substitute a known-good EACV

and retest.
(To page 11-317)
11-316
(From page 11-316)

YEL/BLK wire and body ground.
NO Repalr open in YEL/BLK wire be-

tween EACV and main relay.
YES
Turn the ignition switch off and

reconnect the 2P connector the
EACV.

connector to the main wire har-
ness only, not the ECU (page
11-212).
A11
0000000000 00000000
0000000000 00000000
Momentarily connect A 11 ter-

minal to A2 terminal severa!
times.

YES and retest. lf symptom/indica-
Does the EACV click?
original ECU.
NO
Repairopen or short In GRN/WHT,

BLU/YELwlre between EACV and
ECU (A 11 ). lf the wire is OK,
replace the EACV.
11-317
Id le Control System
Troubleshooting Flowchart --Air ConditioningSignal[D1582 engine]
This signals the ECU when there is a demand for cooling from the air conditioning system.
lnspection of Air Condition-

ing Signal.

the main wíre harness only, not

ººººººººº
00000000 000000
00000000
00000000
A18 (-) 88 (+)
l__ 5V? ___)
Measurevoltage between 88 ( +)
terminal and A 18 ( - ) terminal.
Substituta a known·
good ECU and re·
NO check. lf prescribed
Is there approx. 5 V? voltage is now avail-
able, replace the orig-
YES inal ECU.

main wire harness. 83
000000000 00000000
Momentarily connect 83 ter- 00000000 00000000
minal to A 1 8 terminal severa!
times. A18
'-----Clicking? __J
Isthere a clicking noise from the >-N-º------1 Connect the BLK/RED terminal of
A/C compressorclutch? the 4P connector on the A/C
YES
m_BLK/RED
~ View from wire harness side
Start the engine. Is there a clicking noise from the NO See Air conditioner in-
A/C compressorclutch? spection (section 22).
YES
Blower switch ON.
Repair open in BLK/REDwire be·

tween ECU (83) and A/C clutch
relay.
(To page 11-319)
11-318
(From page 11-318)
000000000 00000000
00000000 00000000
A/C switch ON. A18 (-) 88 (+)
Less than 1 V?
NO Measure voltage between 88 ( +)

Does A!C operate ?
terminal and A 18 ( - ) teminal.
YES
Repalr open in BLU/

NO RED wire between
Is voltage less than 1 V?
ECU (BB)and A/C pres-
Air conditioning signal is OK.
sure switch.
YES

original ECU.
11-319
ldle Control System
Troubleshooting Flowchart --- Alternator FR Signal [D 1582 engine] ----
This signals the ECU when the alternator is charging.
lnspection of Alternator FR
signa l.


000000000 00000000
00000000 00000000
A18(~ 814(+1
Measure voltage between B 14 L__ 4.5 V? ---1
( +) terminal and A 1 8 ( - ) ter-
minal.

NO
Is there approx. 4.5 V? and recheck. lf prescribed

main wire harness.

comes on).
Measure voltage between B 14 000000000 00000000

( + ) terminal and A 1 8 ( - ) ter-
minal. 00000000 00000000
A18 H 814 l+l
L__ Voltage? ____J
Does the voltage decrease when NO
headlights and rear defogger are >-------! Stop the engine.
turned on?
YES
(page 11-209).
Alternator FR signal is OK.
(To page 11-321)
11-320
(From page 11-320)

ECU only, not the main wire
harness.
Disconnect the negativa battery

cable from the battery. 000000000 00000000
000000000 00000000
814
Check for continuity between B 14 -L
Continuity?
YES Disconnect GRN connector from

Does continuity exist ? the alternator.
NO
Oisconnect GRN connector from
the alternator.
Connect BLU wire to body

ground. Check for continuity between B 14
Check for continuity between B 14 See Alternator lnspec-

terminal and body ground. tion (section 23).
YES

YES
Repair short in PNK, 8LU wire be-
NO tween ECU (8141 and alternator.
Repair open in PNK. BLU wlre be-

tween ECU (814) and alternator.
See Alternator lnspec-
tion (section 23).
11-321
ldle Control System
Troubleshooting Flowchart-A/T Shift Position Signal [01582 engine] ---
This signals the ECU when the transmission is in Neutral or Park.
lnapection of A/T Shift Poaít-i'>n

Signa l.
Observethe A/T shift indicator and

NO See A/T Shift Posltion lndicator

Does the indicator light properly7
lnspection {section 14).
YES

the ECU (page 11-212). 1
87 (+)
1 000000000 000000 00000000

Turn the ignition switch ON. 5V? 00000000
00000000
A18 (-)
Measure voltage between 87 1 1
{ + l terminal and A 1 8 ( - l ter-

minal.

NO and recheck. lf prescribed
Is there approx. 5 V7
voltage Is now avallable, replace

main wire harness.
Start the engine.
(To page 11-322)
11-322
(From page 11-322)
1
87 (+)
1 000000000 000000 00000000

Less than 1 V?
00000000 00000000
A18 H
1
terminal and A 18 (-) terminal
with the transmission in lli] and
[El individually.
NO Repair open in GRN wire

Is there less than 1 V? between ECU (87) and gauge
assembly.
YES
5V? 000000000 00000000

Measure voltage between 87 ( +) 00000000 00000000
terminal and A 1 8 ( - ) terminal
with the transmíssíon in gear. A18 (-)
1 1
NO Repair short in GRN wire

Is there approx. 5 V? between ECU (B7) and gauge
assembly.
YES
811 (+)
000000000 00000000
Me asure voltage between B 11 00000000 00000000
( + ) terminal and A 18 ( - ) termi-
A18 (-)
nal with the transmission in 1 04 1
'-------- Less than 1 V? --------~
Repair open in GRN/BLK wire be-

NO
tween ECU (8111 and shift posi-
tion console switch.
YES
811 (+ 1
000000000 00000000
Measure voltage between B 11 00000000 00000000
( + ) teminal and A 18 ( - ) terminal
with the transmission in [NJ or [fJ. A18 (-)
'----------- 5V? -------------'
NO Repair short in GRN/8LK wire be-

Is there approx. 5 V? tween ECU (B111 and shift posi-
YES tion console switch
A/T shift position signal is OK.
11-323
ldle Control System
Troubleshooting Flowchart --- Starter Switch Signal [D 1582 engine] ---.
This signals the ECU when the engine is cranking.
lnspection of Starter Switch

Signal. 1
813 (+)
BATTERY 000000000 00000000

VOLrGE? 00000000 00000000
tween the ECU and connector A18 (-)
(page 11-212). 1
Measure voltage between B 13

( +) terminal and A 18 ( - ) termi-
nal when the ignition switch in the
start position.
NO lnspect STARTER SIGNAL(7. 5A)

fuse
YES
Is STARTER SIGNAL(7 .5A) fuse

OK?
--i Replace fusa.
~'-~~~~~~~~~--'
YES
Repair open in BLU/WHT wire

between ECU (B 13) and
STARTERSIGNAL (7.5AI fusa.
Starter switch signal is OK.
11-324
Fast ldleValve
[Except 01582, 01521 engine]-------------,
To prevent erratic running when the engine is warming
up, it is necessary to raise the idle speed. The fast idle NOTE: The fast idle valve is factory adjusted; it should
air bypass valve is controlled by a thermowax plunger. not be disassembled.
When the engine is cold, the engine coolant surround-
ing the thermowax contracts the plunger, allowing ad- 1. Remove the intake air duct from the throttle body.
ditional air to be bypassedinto the intake manifold so that
the engine idles faster. When the engine reaches oper- 2. Start the engine.
ating temperature, the vlave colses, reducing the amount
of air bypassing into the manifold. 3. Put your finger over the lower port in throttle body
and make sure that there is air flow with the engine
cold (coolant temperature below30ºC, 86ºF).
IDLE
ADJUSTING
SCREW
FAST
IDLE
VAL VE
• lf not, replace the fast idle valve and retest.
Replace
AIR BYPASS
VAL VE
-.,...--~r,---WAX 12 N·m
(1.2 kg-m, 9 lb-ft)
4. Warm up the engíne (cooling tan comes on).
5. Check that the valve is cornpletelv closed. lf not, air suc-

tion can be felt at the lower port in the throttle body.
• lf any suction is felt, the valve is leaking. Replace
the fast idle valve and recheck.
11-325
ldle Control System
ldleSpeed Setting [Except
01582 engine]-------------
lnspection/Adjustment 3. Disconnect the 2P connector from the EACV.

EACV
2. Connect a techometer. l_
LHD:
TECHOMETER
2P
CONNECTOR
4. Start the engine with the accelerator pedal slightly

depressed.Stabilize the engine speed at 1000, then
slowly release the pedal until the engine idles.
RHD: TECHOMETER 5. Check idling in no-loadconditions: headlights,blower

fan, rear defogger, cooling fan, and air conditioner
are not operating.
NOTE: (KS) Remove No. 16 (7.5 A) fuse in the

under-dashfuse box, then check that the headlights
and side marker lights are off.
Manual 015Z1 engine: 420 ± 50 min-1 (rpm)

Others: 420 ± 50 min-1
Automatic 420 ± 50 min " ' (rpm) (in [fil or [E])
2P CONNECTOR Adjust the idle speed, if necessary, by turning the

idle adjusting screw.
11-326
IDLE ADJUSTING SCREW
6. Turn the ignition switch OFF.
7. Reconnect the 2P connector on the EACV, then re-

rnove BACK UP fuse in the under-hood fuse/relay
box for 1 O seconds to reset the ECU.
8. Restart and idle the engine with no-load conditions

for one minute, then check the idle speed.
NOTE: (KS)RemoveNo. 16 (7. 5 A) fuse in the under-

dash fuse box, then check that the headlights and
side marker lights are off.
Manual D 1521 engine: 600 ± 50 min :" (rpm)

Others: 750 ± 50 rnin-1 (rpm)
Automatic 750 ± 50 min-1 (rpm) (in [fil or [e])
9. ldle the engine for one minute with headlights (Hi)

ON and check the idle speed.
Manual 01521 engine: 700 ± 50 min-1 (rpm)

Others: 750 ± 50 min" ' (rprn)
Automatic 750 ± 50 min-1 (rpm) (in [fil or [e])
1 O. Turn the headlights and rear defogger off.

ldle the engine for one minute with heater fan switch
at HI and air conditioner on, then check the idle
speed.
Manual D 1521 engine: 810 ± 50 rnin-1 (rpm)

Others: 810 ± 50 rnin " (rpm)
Autornatic 810 ± 50 rnirv ' (rprn) (in [fil or [e])
NOTE: lf the idle speed is not within specification,

see Systern Trobleshooting Guide on page 11-296.
11-327
ldle Control System
ldle
Speed Setting [01582 engine]----------------
lnspection/Adjustment 3. Disconnect the 2P connector from the EACV.

LHD:
TACHOMETER
4. Start the engine with the accelerator pedal slightly

depressed. Stabilize the engine speed at 1000, then
slowly release the pedal until the engine idles.
5. Check idling in no-load conditions: headlights, blower

fan, rear defogger, cooling fan, and air conditioner
are not operating.
NOTE: (KS) Remove No. 16 (7. 5 A) fuse in the

under-dashfuse box, then check that the headlights
RHD: and side marker lights are off.
TECHO METER
- ldle speed should be:

Automatic 625 ± 50 min-1 (rpm) (in [fil or [e] )

idle adjusting screw.
2P CONNECTOR
11-328
IDLE ADJUSTING SCREW '
7. Reconnect the 2P connector on the EACV, then re-

move BACK UP fuse in the under-hood fuse/relay
box for 1 O seconds to reset the ECU.
8. Restart and idle the engine with no-load conditions

for one minute, then check the idle speed.
NOTE: (KS)Remove No. 16 (7.5 A) fuse in the under-

dash fuse box, then check that the headlights and
side marker lights are off.
Manual 810 ± 50 rnin" (rpm)

Automatic 810 ± 50 min" ' (rpm) (in [N] or [e])
9. ldle the engine for one minute with headlights (Hi)

ON and check the idle speed.
Manual 810 ± 50 rnin "! (rpm)

Automatic 810 ± 50 min-1 (rpm) (in üSiJ or [e] )
1 O. Turn the headlights and rear defogger off.

ldle the engine for one minute with heater tan switch
at HI and air conditioner on, then check the idle
speed.
Manual 810 ± 50 rnin ' ' (rpm)

Automatic 810 ± 50 rnln " (rpm) (in üSiJ or [e])
NOTE: lf the idle speed is not within specification,

see System Trobleshooting Guide on page 11-296.
11-329
Fuel Supply System
System TroubleshootingGuide --------------------
NOTE: Across each row in the chart, the systems that could be sources of a symptom are ranked in the order they
s:::
should be inspected starting with (D. Find the symptom in the left column, read across to the most likely source , then
refer to the page listed at the top of that colurnn. lf inspection shows the system is OK, try the next most likely system
@, etc.
PAGE FUEL PRES SU RE FUEL FUEL MAIN CONTAMI-

INJECTOR REGULATOR FIL TER PUMP RELAY NATED FUEL
~ 334, 338* 343 344 346 349 -
ENGINE WON'T START @ Q) ®

DIFFICULT TO START ENGINE
WHEN COLO OR HOT
Q)
ROUGH IDLE Q) ®
MISFIRE OR
ROUGH
RUNNING
Q) @ ®
FAILS
POOR
PERFORMANCE
EMISSION
TEST
® Q)
LOSS OF
POWER
@ ® Q)
WHILE
FREOUENT
WARMING
UP
CD
STALLING AFTER
WARMING Q)
UP
*: 816A2 engine
11-331
Fuel Supply System
System Description Fuel Pressure ----------
The fuel supply system consists of a fuel tank, in-tank Relieving

high pressure fuel pump, main relay, fuel filter, pres-
sureregulator, injectors, and fuel delivery and return lines.
This system delivers pressure-regulated fuel to the injec-
l• 11JHU@I
1
Do not smoke while working on the fuel system.

tors and cuts the fuel delivery when the engine is not Keep open flamas or sparks away from the work area.
running. • Be sure to relieve fuel pressure while the engine is off.
NOTE: Before disconnecting fuel pipes or hoses, release

pressure from the system by loosening the 6 mm serv-
ice bolt on top of the fuel filter.
1. Disconnect the battery negative cable from the bat-

tery negativa terminal.
2. Remove fuel filter cap.
3. Use a box end wrench on the 6 mm service bolt at

the fuel filter, while holding the psecial banjo bolt
with another wrench.
4. Place a rag or shop towel over the 6 mm service bolt.
5. Slowly loosen the 6 mm service bolt one complete

turn.
SERVICE BOL T
15 N·m 11.5 kg-m, 11 lb-ftl
NOTE:
• A fuel pressure gauge can be attached at the 6 mm
service bolt hole.
• Always replace the washer between the service
bolt and the special banjo bolt, whenever the serv-
ice bolt is loosened.
• Replace all wahers whenever the bolts are
removed.
11-332
lnspection 01582 engine: FUEL PRESSURE GAUGE
07406-0040001
1. Relieve fuel pressure (page 11-332).
2. Remove the service bolt on the fuel filter while hold-

ing the banjo bolt with another wrench. Attach the
special tool.
3. Start the engine. * Measure the fuel pressure with

the engine idling and vacuum hose of the pressure
regulator disconnected from the pressure regulator.
Pressure should be:

Except D 1582 engine:
280-330 kg/cm2, 40-47
kPa (2.8-3.3 psi)
D1582 engine:
PRESSURE
240-279 kPa (2.45-2.85 kg/cm2, 35-41 psi) REGULATOR
4. Reconnect vacuum hose to the pressure regulator.

*· lf the engine will not start, turn the ignition switch
Pressureshould be: on, wait for two seconds, turn it off, then back on
Except D1582 engine: again and read the fuel pressure.
215-265 kPa (2.15-2.65 kg/cm 2, 31-38 psi)
D1582 engine:
200-240 kPa (2.04-2.45 kg/cm2• 29-35 psi) • lf the fuel pressure is notas specified, first check the
fuel pump (page 11-3471. lf the pump is OK, check
Except01582 engine: the following:
FUEL PRESSURE GAUGE
07406-0040001 lf the pressure is higher than specified, inspect for:
Pinched or clogged fuel return hose or piping.
Faulty pressure regulator (page 11-343)
lf the pressure is lower than specified, inspect for:
Clogged fuel filter.
Faulty pressure regulator (page 11-343)
Leakage in the fule line.
11-333
Fuel Supply System
Fuel
lnjectors [Except
01582 engine]----------------
Testing lf the engine cannot be started:
NOTE: Check the following items before tesing: idle 1. Removethe connector of the injector, and measure
speed, ignition timing and idle CO % the resistance between the 2 terminals of the
injector.
lf the engine will run:
1 . With the engine idling, disconnect each injector con- Resistance should be: 10-13 n
nector individually and inspect the change in the
idling speed.
• lf the idle speed drop is almost the same for each

cylinder, the injectors are normal.
• lf the idle speed or quality remainsthe same when

you disconnect a particular injector, replace the
injector and re-test.
2. Check the clicking sound of each injector by means

of a stethoscope when the engine is idling.
• lf the resistance is not as specified, replace the

injector.
• lf the resistance is as specified, check the

pressure (page 11-332).
- lf the fuel pressure is as specified, check the
following:
• Whether there is any short-circuiting, wire
breakage or poor connection in the YEL/BLK
wire between the main relay and the injector.
breakage or poor connection in the wire be-
• lf any injector fails to make the typical clícking tween the injector and the ECU.
sound, check the sound again after replacing the
injector. lf all is OK, check the ECU (page 11-219).
- lf clicking sound is still absent, check the fol-

lowing.
breakage or poor connection in the YEL/BLK
wire between the main relay and the injector.
breakage or poor connection in the wire be-
tween the injector and the ECU.
lf ali is OK, check the ECU (page 11-219) and

main relay (page 11 -349).
11-334
Replacement
P!§fo;!Jjjfji Do not smoke when working on the fuel system. Keep open flames away from your work area.
1. Relievefuel pressure (page 11-332).
2. Disconnect the connectors from the injectors.
3. Disconnect the vacuum hose and fuel return hose from the pressure regulator.
NOTE: Placea rag or shop towel over the hoses before disconnecting them.
4. Disconnect the fuel hose from the fuel pipe.
5. Loasenthe retainer nuts on the fuel pipe and harness holder.

HARNESS HOLDER
6. Disconnect the fuel pipe.
7. Removethe injectors from the intake manifold.
12 N•m
11.2 kg-m, 9 lb-ft)
0-RING-
Replace.
CUSHI~
RING º
Replace. ~
INJECTOR~
SEAL
RING
Replace.
'"ª
8. Slide new cushion rings onto the injectors.
9. Coat new 0-rings with clean engine oil and put them on the injectors.
1 O. lnsert the injectors into the fuel pipe first.
11. Coat new seal rings with clean engine oil and press them into the intake manifold. (cont'd)
11-335
Fuel Supply System
Fuel lnjectors [Except 01582 engine] (cont'd)
12. lnstall the injectors and fuel pipe assembly in the manifold.
CAUTION: To prevent damage to the 0-ring, installthe injectorsin the fuel pipe first, then installthem in the intake
manifold.
FUEL
PIPE
FUEL
PIPE
1 3. Align the center line on the connector with the mark on the fuel pipe.
(015Z1 engine only)
MARKINGS
14. lnstall and tighten the retainer nuts.
15. Connect the fuel hose to the fuel pipe with new washers. INJECTOR
16. Connect the vacuum hose and fuel return hose to the pressure regulator.
1 7. lnstall the connectors on the injectors.
18. Replace the 6 mm service bolt washer and tighten the bolt.
19. Turn the ignition switch ON but do not operate the starter. After the fuel pump runs for approximately two seconds,
the fuel pressure in the fuel line rises. Repeatthis two or three times, then check whether there is any fuel leakage.
11-336
Fuel Supply System
Fuel lnjectors [D 1582 engine] --------------------
Troubleshooting Flowchart
l ,,,..-
-[ ú!- -[ill-
<, <, 1 ,,,,...,
Self-diagnosis Check Engine light indicates code 16: A problem in the fuel injector circuit.
/ 1 <, / 1 <,
The injectors are the solenoid-actuated constant-stroke pintle type consisting of a solenoid, plunger needle valve and housing. When
current is applied to the solenoid coil, the valve lifts up and pressurized fuel is injected. Because the needle valve lift and the fuel pressure
are constant. the injection quantity is determinad by the length of time that the valve is open (i.e., the duration the current is supplied to
the solenoid coil). The injector is sealed by two 0-rings anda mount rubber. This also reduces operating noise.
0-RINGS
MAIN
INJECTOR
AUX.
INJECTOR
FIL TER SOLENOID COIL
MOUNT RUBBER
<, ¡ -r >: 1 /
-101--0IJ-
/ ., ....._,,... 1 <,
Check engine light has been

reportad on.
16 is indicated.

(page 11-209).
Check for loose wires or connec-

tors at fuel injectors.
NO
Are connections OK? Repair as necessary.
YES
Start engine and hold at 2,000

min-1 (rpm) for 1 minute. NOTE: lf engine will not start, continua crank-
ing for at least 1 5 second to reproduce CODE
on ECU.
(To page 11-339)
11-338
(Frorn page 11-338)
1
Does the engine start and run NO Is Check Engine warning light NO See Troubleshooting
at 2000 rnin" 1 (rpm) for 1 on and does LEO indi cate Guide (page 11-206).
minute. CODE 16 r 1
YES
YES
Is Check Engine warning light lntermittent failure

NO
on and does LED indicate (test drive may be
CODE 16? necessary.)
YES Turn the ignition switch OFF.

1

from the auxiliary injector.
from the main injector.
Measure resistan ce between

the 2 terminals of the injector.
the 2 terminals. of the injector.
NO Replace the in-
Is resistance 6-1 O O?
jector.
1
YES
NO Replace the in-

Is resistance 0.6-1 .6 o? jector.
YES
Connect voltmeter positive to

the main injector's YEL,,SLK Measure voltage between the
wire and negative to body auxiliary injectors YEL wire and
ground. body ground.
Repair open in YEL/

Is there battery voltage for two NO BLK wire between
seconds? main injector and - Repair open or short in
main relay. YEL. BRN wire between
YES aux. injector and ECU (A 1.
A3).
NO - Substitute a known-good
Turn the ignition switch OFF. Is there approx. 1 OV?
ECU and recheck. lf
YES prescribed voltage is now
available, replace the origi-
Disconnect the 2P connector nal ECU.
from the auxiliary injector.

the 2 terminals of the injector.
1
(To page 11-340) (To page 11-340)
(cont'd)
11-339
Fuel Supply System
Fuel
lnjectors [01582 engine] (cont'd)-----------------
1
NO Replace the in-
Is resistance 6-10 Oi'
jector.
1
YES
from the main injector.
YEL/BLK wire of auxiliary in- 1
jector and negative to body
ground.

Turn the ignition switch ON. main injector's RED wire and
body ground.
Repair open in YEL/

Is there battery voltage for two NO BLK wire between - Repair short in
secondsi' the 2P connector RED w ir e
and the main re lay. between main in-
YES jector and ECU
(A5. A7)
NO - Substilula a known-
Is there approx. 1 O V?
good ECU and re-
YES check. lf pre-
YEL wire of auxiliary injector
acribad voltage is
and negative to body ground.
now available.
replace the origi-
Turn the ignition switch OFF. nal ECU.

YEL/BLK wire of auxiliary in-
jector and negative to body
ground.
- Repair open in
YEL, BRN wlre
between auxilia-
ry injector and
ECU (A1. A3).
Is there approx. 1 OV?
NO - Substituta a
known-good ECU
YES and recheck. lf
prescribed volt-
age is now avail-
able. replace the
original ECU.

main injector's RED wire and
body ground. Turn the ignition switch ON.
1 1
(To page 11-341) (To page 1 1 -341 )
11-340
Substitute a known-
YES good ECUand recheck.
Is there approx. 10V? lf symptom/indication
goes away, replaca tha
NO original ECU.
- Repair open in RED wire bet-

ween main injactor and ECU
(A5, A7). Substituta a known-
- Substitute a known-good ECU good ECU and rechack.
Is there battery voltage for 2 YES
and recheck. lf prescribed lf prascribed voltage in
seconds? now available, replaca
voltage is now available, re-
place the original ECU. NO the original ECU.

tween the ECUand connector
(page 11-212).
Connect following terminals indi-

vidually to A18 •A12 •A14
- Rapair open in YEL/

Turn the ignition switch ON. BLK wire between
aux. injactor and
main ralay.
Is there battery voltage at YEL/ NO - Rapair open in GRN
BLK wire of aux. injector ? /YEL wira between
YES main relay and ECU
(A12, A14).
- Replace main relay.
- Repair open in BLK wire bet-

ween G101 (thermostat hous-
ing) and ECU (A2. A4).
- Substituta a known-good ECU
voltage in now available. rep
place the original ECU.
(cont'd)
11-341
Fuel Supply System
Fuel
lnjectors [01582 engine] (cont'd)-------------------.
Replacement
IIMMMN
Do not smoke while working on fuel system. Keep open flame or spark away from work area.
1. Relieve fuel pressure (page 11-332)
2. Remove the air intake chamber.
3. Disconnect the 2P connector from the injector.
4. Loosen the screws, then remove the injector from the throttle body.
NOTE:
Place a rag or shop towel over the throttle body.
5. Coat new 0-rings with clean engine oil and put them on the injector.
6. lnsert the injector into the throttle body.
NOTE:
After the injector is insertad, be sure that it turns smoothly about 30°.
7. Turn the ignition switch ON but do not opérate the starter. A fter the fuel pump runs for approx. 2 seconds, the
fuel pressure in the fuel line rises. Repeat this two or three times, then check whether there is any fuel leakage.
'«1
1
SET PLATE
Re place
\ ;
MOUNT RUBBER -,
Replace
11-342
Pressure Regulator
Description Testing
The fuel pressure regulator maintains a constant fule
pressure to the injectors. When the difference between t,Q.foflWIN Do not smoke during the test. Keep open
the fuel pressure and manifold pressure exceeds 3.0 flames away from your work area.
kg/cm2 (43 psi) (Except D 1 582 engine), 2. 55 kg/cm2
(36 psi) (D 1 582 engine), the diaphragm is pushed up- 1. Attach a pressure gauge to the service port of the
ward, and the excess fuel is fed back into the fuel tank fuel filter (page 11-333).
through the return line.
Pressure should be:
Except O 1582 engine:
CLOSE 280-330 kPa (2.8-3.3 kg/cm2, 40-47 psil
01582 engine:
INTAKE 240-279 kPa (2.45-2.85 kg/cm2, 35-41 psi)
MANIFOLD (with the regulator vacuum hose disconnectedl
VACUUM
DIAPHRAGM Except D 1582 engine: FUEL PRESSUREGAUGE

07406-0040001
VACUUM.
]};/~·:
FUEL
INLET
l/
FUEL PRESSURE GAUGE

01582 engine: 07406-0040001
OPEN
\ '------·-·/"'"
~;
~,·~1
INTAKE
MANIFOLD
VACUUM
DIAPHRAGM
~~!
'~·=~':
-------·n
PRESSURE
FUEL REGULATOR
INLET
2. Reconnect the vacuum hose to the pressure

regulator.
3. Checkthat the fuel pressureriseswhen the vacuum

hosefrom the regulator is disconnected again.
lf the fuel pressure did not rise, replace the

FUEL pressure regulator.
RETURN (cont'd)
11-343
Fuel Supply System
Pressure Regulator (cont' d) Fuel Filter ------------,
Replacement Replacement
i@.fo@ijjQ Do not smoke while working on fuel sys-

i·W·Miidi
• Do not smoke while working on fuel system.
Keep open flame away from work area.
1. Place a shop twoel under pressure regulator, then • While replacing be careful to keep a safe
relieve fuel pressure (page 11-332). distance between battery terminals and any
2. Disconnect the vacuum hose and fue! return hose. tools.
3. Remove the two 6 mm mounting bolts. The filter should be replaced every 2 years or 40,000 km
(24,000 miles), whichever comes first or whenever the
Except 01582 engine: 0-RING fuel pressuredrops below the specified value (280-330
/ Replace kPa, 2.8-3.3 kg/cm2, 40-47 psi) (01582 engine:
v 240-279 kPa, 2.45-2.85 kg/cm2, 35-41 psi) with the
pressureregulatorvacuum hose disconnected)after mak-
ing sure that the fuel pump and the pressure regulator
are OK.
1. Disconnect the battery negative cable from the bat-
terv negative terminal.
2. Place a shop towel under and around the fule filter.
3. Relieve fuel pressure (page 11-332).
4. Removethe 12 mm banjo bolt and the fuel feed pipe

from the filter.
5. Remove the fuel filter clamp and fuel filter.
6. When assembling, use new washers, as shown.

SERVICE BOL T
15 N·m (1.5 kg-m, 11 lb-ftl WASHER
Replace
r-
~
NOTE: D
• Replace the 0-ring.
12 N·m (1.2 kg-m, 9 lb-ft)
• When assemblingthe regulator, apply clean engineoil

10 N·m (1.0 kg-m,
7 lb-ft)
38 N·m (3.8 kg-m,
28 lb-ft)
NOTE: Clean the flared joint of high pressure hoses thoroughly

before reconnecting them.
to the 0-ring and assemble it into its proper position,
taking care not to damage the 0-ring.
11-344
Fuel Supply System
Fuel Purnp··~~~~~~~~~~~~~~~~~~~~~~~~~~~
Description
Becauseof its compact impellerdesign, the fuel pump is installedinside the fuel tank, therebysavingspaceand simplifyingthe
fuel line system.
---_ FUEL FILTER
FUEL PUMP CROSS SECTION (Side view) PUMP ASSEMBLY CROSS SECTION (Top view)
DISCHARGE PORT\, ----
CASING
PUMP CASING
ARMATURE COIL
IMPELLER
The fuel pump is comprisedof a DC motor, a circumferenceflow pump, a reliefvalvefor protecting the fuel line systems. a check
valve for retaining residualpressure. an inlet port. anda dischargeport. The pump assemblyconsistsof the impeller(driven by
the motor). the pump casing (which forms the pumping chamber). and the pump cover.
OPERATION
( 1) When the engine is started, the main relay actuates the pump, and the motor turns the impeller.
Differential pressure is generated by the numerous grooves around the impeller.
(2) Fuel entering the inlet port flows inside the motor from the pumping chamber and is forced through the discharge
port via the check valve. lf fuel flow is obstructed at the discharge side of the fuel line, the relief valve will open to
bypass the fuel to the inlet port and prevent excessive fuel pressure.
(3) When the engine stops, the pump stops automatically. However, a check valve clases by spring action to retain the
residual pressure in the line, helping the engine to restart more easily.
11-346
Testing 4WD:
i,f,if·•·j,,jj.,¡¡
Do not smoke during the test. Keep open
flame away from your work area.
lf you suspect a problem with the fuel pump, check that

the fuel pump actually runs; when it is ON, you will hear
sorne noise if you hold your ear near the fuel pipe. The
fuel pump should run for two seconds when the ignition
switch is first turned on. lf there is no noise at the fuel
pipe, check as follows:
1. Remove the rear seat (section 20).
2. Remove the maintenance lid.
3. Disconnect the 2P connector.
CAUTION: Be sure to turn the ignition switch OFF

befare disconnecting the wires.
4. Disconnect the main relay connector and connect

the BLK/YEL ® wire and YEL/GRN(j) wire with a
jumper wire.
• lf battery voltage is available, replace the fuel

pum p.
• lf there is no voltage, check the fuel pump
ground and wire harness.
JUMPER
WIRE
5. Check that battery voltage is available at the fuel

pump connector when the ignition switch is turned
ON (positive probe to the YEL/GRNwire, negative
probe to the BLK wire}.
2WD:
YEL/
GRN (+l
(cont'd)
11-347
Fuel Supply System
Fuel Pump (cont'd}~~~~----~~~~~~~~~~~~~~~~~--,
Replacement 4WD:
l@.foMj.,iQoo not smoke while working on fuel sysem.

Keep open flames away from your work area.
1. Relievefuel pressure (page 11-332).
2. Removethe rear seat (section 20).
3. Removethe maintenance lid.
4. Disconnect the fuel lines and connector.
5. Removethe fuel pump mounting nuts.
6. Remove the fuel pump frorn the fuel tank.

28 N·m (2.8 kg-m,
20 lb-ft)
2WD:
28 N•m (2.8 kg-m.

20 lb-ftl
11-348
Main Relay -----------------------------,
Description Relay Testing

NOTE:lf the car starts and coninues to run, the main
The main relay actually contains two individual relays. relay is OK.
This relay is installed at the left side (RHD: right side) of
the cowl. 1. Remove the main relay.
One relay is energized whenever the ignition is on which
supplies the battery voltage to the ECU, power to the 2. Attach the battery positive terminal to the No. 6 ter-
injectors, and power for the second relay. minal and the battery negative terminal to the No.
The second relay is energized for 2 seconds when the 8 terminal of the main relay. Then check for continui-
ignition is switched on, and when the engine is running ty between the No. 5 terminal and No. 7 terminal
which supplies power to the fuel pump. of the mian relay.
• lf there is continuity, go on to step 3.
• lf there is continuity, replace the relay and retest.
No. 8 No. 6 No. 2
MAIN RELAV
BATTERY
VOLTAGE
IGNITION 1----<~ .........µ,,¡-T'-''+---
SWITCH
!:t::~Rt--~>-~....~~+-4----41..-:'!l"ll'-..;...c:>-~
ECU TO IGN.1
'--~~~~~tNJECTOR
FUEL PUMP TO GROUND

TO ECU (A25, 81)
TO ST. SWITCH
TO ECU (A7, 81 TO FUEL PUMP
3. Attach the battery positive terminal to the No. 5 ter-

minal and the battery negative treminal to the No.
2 terminal of the main relay. Then check that there
is continuity between the No. 1 terminal and No. 3
terminal of the main relay.
• lf there is continuity, go no to step 4.

• lf there is no continuity, replace the relay and
retest.
4. Attach the battery positive terminal to the No. 3 ter-

minal and the battery negative terminal to the No.
8 terminal of the main relay. Then check that there
is continuity between the No. 5 terminal and No. 7
terminal of the main relay.
• lf there is continuity, the relay is OK.

• lf there is no continuity, replace the relay and
retest. (cont'd)
11-349
Fuel Supply System
Main
Relay
(cont'd)-----------------------
- Engine will not start.
- lnspection of main relay and
relay harness.
Disconnect the main relay con-

nectors.

BLK terminal @ and body
ground.
NO / Repair open in BLK wire between

main relay and G101.
1
YES
Measure the voltage between

YEL/WHT terminal G) and body
ground.
- Replace ECU (15A) fuse.

NO - Repair open in the YEL/WHT
Is there battery voltage? wire between the main relay
YES and the ECU 11 SA) fuse.

BLK/YEL terminal ® and body
ground.
- Replace ACG (S) (1 SA) fuse.

NO - Repair open in the BLK/YEL
wire between the main relay
YES and the ACG(S) (15A) fuse.
Turn the iqnition switch to the

START position.
BLK (2)
YEL/
Measure the voltage between WHT 1
BLU/WHT terminal @ and body YEL/
ground. BLK 3
Repair open in the BLU/WHT

NO
Is there battery voltage? wire between the main relay and
the ignítion switch.
YES
(To page 11-351)
11-350
(From page 11-350)
Turn the ignition switch off.
A7
Connect the test harnes be-
Disconnect "A" connector from 000 ººººººººº ºººººººº ººººººººººº
000 ººººººººº ºººººººº ººººººººººº
AS

GRN/YEL terminal @ and the
following terminals; A 7, AB.
NO Repair open in GRN/YEL wire

Does continuity exist? between ECU (A 7, AS) and main
relay.
YES Battery voltage?
Reconnect "A" connector to the

rr-,
A23 H A25 81
ECU. (+l l+l
ººººººººººº ººººººººººº
Connect the main relay connec-
tor.

A23 (-) terminal and the follow-
ing terminals: A25 (+) Bl (+).
Repair open in the YEL/BLK
wire @ between the ECU
NO (A25, B 1 ) and main relay.
Is there battery voltage? Replace main relay.
YES Battery voltage?
A7 (+) A23 (-)
ooo 00000000 to:6.d!dtHi 00000000000
ººººººººººººº ºººººººº t.iliiii ººººººººººº

Connect a voltmeter between A 7
minal.

Is there battery voltage for two YES and recheck. lf symptom/indica-
seconds when the ignition
switch is first turned on?
original ECU.
NO
Check the main relay (page

11-349).
11-351
Fuel Supply System
Fuel
Sub Pump
[4WDJ---------------------
Description
Becauseof its compact impellerdesign, the fuel sub pump is installedinsidethe fuel tank, thereby savingspaceand simplifying
the fuel line system.
FUEL PUMP CROSS SECTION PUMP ASSEMBLY CROSS SECTION

(Side viewl
PUMP COVER
PUMP COVER GROOVES
DISCHARGE
CHECK VALVE ARMA TURE COIL PORT
The fuel sub pump in comprisedof a OC motor, a circumferenceflow pump, a relief valva for protecting the fuel line systems,
a check valva for retaining residual pressure, an inlet port. and a discharge port. The pump assembly consists of the
impeller(drivenby the motor). the pump casing(which forms the pumping chamber). and the pump cover.
Operation
1. When the engine is started, the fuel cut-off relay actuates the pump, and the motor turns together with the impeller.
Differentialpressureis generatedby the numerousgrooves around the impeller.
2. Fuel entering the inlet port flows insine the motor from the pumping chamberand is torced through the dischargeport via
the check valva.
lf fuel ñow is obstructed at the dischargeside of the fuel line, the relief valve will open to bypassthe fuel to the inlet port
and prevent excessivefuel pressure.
3. When the engine stops, the pump stops automatically. However,a check valve closesby spring action to retain the residual
pressurein the line, helping the engine to restart more easily.
11-352
Replacement Testing
· 1f$.j;jhj.i.Q Do
not smoke while working on fuel @ §M@dQ Do not smoke during the test. Keep open
system. Keep open flama away from work area. flame away from your work area.
1. Remove the rear seat, then remove the maintenance 1. Remove the fuel sub pump.
access cover.
2. Measurethe amount of fuel flow for a minute by con-
2. Remve the fuel pump mounting nuts. necting battery positive to the D terminal, and nega-
tiva to the B terminal.
· 3. Remove the fuel sub pump from the fuel tank.
6 N·m (0.6 kg-m 41b-ft)
(-)
Amount should be:

760 cm3 (25. 7 oz) min. in a minute at 12V
• lf the fuel sub purnp is OK, check for:

• Clogged fuel filter.
• Clogged fuel line.
• Fuel cut-off relay failure (page 11-354).
11-353
Fuel Supply System
Sub Fuel Cut-off Relay~~~~~~~~~~~~~~~~~~~~~-
IGNITION SWITCH (IG 11 r- BLK/YEL

FUEL SUB PUMP
YEL/BLK
SUB
IGNITION PULSE SIGNAL ~ BLU FUEL
·CUT-OFF'
RELAY
FLOAT SWITCH
BLK
1
Operation
The switch is on when the right side fuel tank contains fuel. When power from the battery is supplied to the sub fuel
cut-off relay and the engine is started by turning the ignition switch on, the ignition pulse signa! is imput to the relay
from the primary side of the ignition coil, the fuel sub pump operates and fuel is fed from the right to the left side.
The ignition pulse signa! is not generated by the primary side of the ignition coil when the engine stops;
therefore, the fuel sub pump does not operate. Also, the float switch turns off when there is no fuel in the right side
tank, so the sub fuel pump does not operate.
11-354
Testing 7. Turn the ignition swithc ON.
1. Keep the ignition switch in the OFF position. Battery voltage should be available.
2. Disconnect the 7P connector.
• · lf there is no voltage, check the wiring between
3. Check for continuity between the BLK wire © in the the ignition coil and the fuel cut-off relay.
connector and body ground.
8. Turn the igniton switch OFF.
Connect a jumper wire between the YEL/BLK wire
@ and BLK/YEL wire @.
9. Turn the igniton switch ON.
The fuel sub pump shoufd work.
SUB • lf the fuel sub pump does not work, remove the
FUEL maintenance access cover. Check that battery
CUT-OFF voltage is avaiable at the fuel sub pump connec-
RELAY tor when the ignition switch is turned ON (posi-
{]
i tive probe to the YEL/BLK wire, negative probe
to the BLK wire).
GRN/
~
BLU G) YEL/BLK @
s-.
RED~
BLK@ BLK/
YEL@
4. Attach the positive probe of voltmeter to the lf battery voltage is available, replace the fuel
BLK/YELwire@ and the negative probe to the BLK pump.
wire @).
- lf ther is no voltage, check for continuity between
5. Turn the ignition switch ON. teh YEL/BLK wire in the connector and the sub
fuel cut-off relay.
Battery voltage should be available.
• lf there is no voltage, check the wiring from the
ignition switch and the fuel cut-off relay as well
as ACG (S) (15A) fuse.

Attach the positive probe of voltmeter to the BLU
wire CD and the negative probe to the BLK wire @).
(cont'd)
11-355
Fuel Supply System
Sub FuelCut-off Relay(cont'd)--
1 O. Rernove the fuel sub purnp frorn the fuel tank.
11. Attach the positive probe of voltrneter to the

GRN/REDwire@ and the negative probe to the BLK
wire@.
12. Suspend the float switch in a container of water as

shown.
FLOAT SWITCH
13. Check for continuity between the GRN/REDwire@

and the BLK wire @.
• lf there is no continuity, replace the float switch.
lf all the testes are OK, replace the sub fuel cut-off relay
and retest.
11-356
Fuel Supply System
FuelTank [2\ND]~~~~~~~~~~~~~~~~~~~~~---.
Reolacement
f•f.§.,;jfjj.ij¡Do not smoke while working on fuel system. Keep open flame away from work your work area.
1 . Block front wheels. Jack up the rear of the car and support with jackstands.
2. Removethe exhaust pipe heat shield.
3. Remove the drain bolt ~nd drain the fuel into an approved container.
4. Remove the rear seat, and maintenance lid.
5. Disconnect the connectors from the fuel gauge sending unit and the fuel pump, then remove the fuel feed line and
return hose.
CAUTION: Be sure to turn the ignition switch OFFbefore disconnecting the wires.
6. Removethe fuel hose protectors.
CAUTION: When disconnecting the hoses. slide back the clamps. then twist hoses as you pull to avo id damaging
them.
8. Place a [ack, or other support, under the tank.
9. Removethe strap bolts and nuts, and let the straps fall free.
1 O. Removethe fuel tank.
11. lnstall a new washer on the drain bolt and the fuel pump line, then install parts in the reverseorder of removal.
-c.=:::::;~~--f---,f¡:_:j:J~WASHER
Replace.
FUEL GAUGE
SENDING UNIT
EXHAUST
PIPE
HEAT
SHIELD
40 N•m""'""------11-8
14.0 kg-m. 29 lb-ftl
11-357
Fuel Supply System
FuelTank [4\IVD]~~~~~~~~~~~~~~~~~~~~~~~
Replacement
f,p4'jmij!VidDo not smoke while working on fuel system. Keep open flame away from work your work area.
1. Block front wheels. Jack up the rear of the car and support with jackstans.
2. Remove the exhaust pipe, exhaust pipe heat shield ánd muffler (section 9).
3. Remove the propeller shaft and rear differential (section 16).
4. Remove the exhaust pipe heat shield.
5. Remove the drain bolt and drain the fuel into an approved container.
6. Remove the rear seat, and maintenance lid.
7. Disconnect the connectors from the fuel gauge sending unit and the fuel purnp, then remove the fuel feed line and
return hose.
CAUTION: Be sure to turn the ignition switch OFF befare disconnecting the wires.
8. Remove the fuel hose protectors.
CAUTION: When disconnecting the hoses, slide back the clamps, then twist hoses as you pull to avoid damaging them.
1 O. Place a jack, or other support, under the tank.
11. Rernove the strap bolts and nuts, and let the straps fan free.
12. Remove the fuel tank.
13. Instan a new washer on the drain bolt and the fuel pump line, then instan parts in the reverse order of removal.
28 N·m
(2.8 kg-m,
20 lb-ftl
WASHER
Replace .
........__~~~WASHER
Replace.
DRAIN BOLT
50 N·m (5.0 kg-m, 36 lb-ft)
TANK !
STRAPS 22 N·m (2.2 kg-m, 16 lb-ftl
FUEL HOSE
PROTECTOR
11-358
Air lntake System
System Troubleshooting Guide -------------------
NOTE: Across each row in the chart, the sub systems that could be sources of a symptom are ranked in the order they
should be inspected starting with G). Find the symptom in the left column, read across to the most likely source, then
refer to the page listed at the top of that column. lf inspection shows the system is OK, try the next system @, etc.
PAGE
THROTTLE CABLE THROTTLE BODY
----------====
~
SYMPTOM 364 366
WHEN COLO FAST IOLE OUT OF SPEC G) @
WHEN WARM ENGINE SPEEO TOO HIGH @ G)
LOSS OF POWER G)
01582 engine:
L:::
-------====
PAGE TANOEM THROTTLE
THROTTLE THROTTLE
CONTROL CONTROL
CABLE BOOY SYSTEM SYSTEM
SYMPTOM 365 370 374 379
OIFFICULT TO START ENGINE WHEN COLO G)
WHEN COLO FAST IOLE OUT OF SPEC @ @ G)
WHEN WARM ENGINE SPEED TOO HIGH @ @ G)
WHEN WARM ENGINE SPEEO TOO LOW CD
FREOUENT STALLING WHILE WARMING UP G) @ G)
LOSS OF POWER @ @ G)
11-360
System Description
The system supplies air for ali engine needs. lt consists of the air cleaner, air intake pipe, throttle body, EACV, fast idle
valve, tándem control system (D1582 engine). throttle control system (D 1 582 engine), and intake manifold. A resonator
in the air intake pipe provides additonal silencing as air is drawn into the system.
TO MAIN
RELAY
YEL/
i BLU/____,tt----GRN/
ECU
BLK
BLK YEL WHT
l
VARIOUS SENSORS
AIR CLEANER
01582 engine:·
VARIOUS AIR CLEANER
SENSORS
TO MAIN
RELAY
~
i
YEL/
~ BLK
WHT
11-361
Air lntake System
Air Cleaner
Air cleaner Element Replacement
AIR CLEANER COVER
EC, KQ: Replace every 2 years or

40,000 km (24,000 miles). whichever
comes first.
Except EC, KQ: Replace every
1 year or 20,000 km ( 12,000 miles),
whichever comes first.
AIR CLEANER CASE
11-362
Air lntake System
Throttle Cable
[Except
01582 engine]----------------.
lnspection/ Adjustment lnstallation

1 . Warm up the engine to normal operating tem- 1. Fully open the throttle valve, then install the throt·
perature (cooling tan comes on). tle cable in the throttle linkage and install the cable
housing in the cable bracket.
2. Check that the throttle cable operates smoothly
with no binding or sticking. Repairas necessary. 2. Warm up the engine to normal operating
temperature (the cooling tan comes on).
3. Check cable free play at the throttle linkage. Cable
deflection should be 10-12 mm (0.39-0.47 in.) BRACKET
ADJUSTING
LOCKNUT NUT
THROTTLE INNER WIRE ADJUSTING

LINKAGE NUT
3. Hold the cable sheath, removing ali slack from the

cable.
4. Turn the adjusting nut until it is 3 mm away from

DEFLECTION the cable bracket.
10-12 mm
5. Tighten the locknut. The cable deflection should
now be 1 O- 1 2 mm. lf not, see lnspection/
Adjustment.
4. lf deflection is not within specs, loosen the locknut
and turn the adjusting nut until the deflection is as
specified. BRACKET
ADJUSTING NUT
5. With the cable properly adjusted, check the throttle
valve to be sure it opens fully when you push the
accelerator pedal to the floor. Also check the throt-
tle valve to be sure it returns to the idle position
whenever you releasethe accelerator.
3mm
11-364
Throttle Cable [01582 engine]--------------------,
lnspectlon/ Adjustment lnstallation

1. Warm up the engine to normal operating tempera- 1. Fully open the throttle valve, then install the throt-
ture (cooling fan comes on). tle cable in the throttle linkage and install the cable
housing in the cable bracket.
2. Check that the throttle cableoperatessmoothly with
no binding or sticking. Repair as necessary. 2. Warm up the engine to normal operating teperature
(the cooling fan comes on).
3. Disconnect vacuum hose from the dashpot di-
aphragm and connect a vacuum pump to the 3. Disconnect vacuum hose from the dashpot
diaphragm. daphragm and connect a vacuum pump to the di-
Apply vacuum. aphragm.
VACUUM PUMP/GAUGE
4. Check cable free play at the throttle linkage. Cable 4. Hold the cable sheath, removing all slack from the
deflection should be 10-12 mm (0.39-0.47 in.)
cable.
LOCKNUT ADJUSTING 5. Turn the adjusting nut until it is 3 mm away from

the cable bracket.
6. Tighten the locknut.
3mm
Deflection10-12 mm
5. lf deflection is not within specs. loosenthe locknut and

turn the adjustingnut until the deflection is as speci-
fied. CABLE BRACKET
6. With the cable properly adjusted, check the throttle

valve to be sure it opens fully when you push the
acceleratorpedalto the floor. Also checkthe throttle 7. Disconnect the vacuum pump and connect the vacu-
valveto be sureit returnsto the idle positionwhenever um hose.
you release the accelerator.
11-365
Air lntake System
Trottle Body [Except O 1582 engine]-----------------
The throttle body is of the single-barrel side-draft type.
The lower portion of the throttle valve is heated by CAUTION: Do not adjust the throttle stop screw.
engine coolant which is fed from the cylinder head. The lt is preset at the factory.
idle adjusting screw which increases/decreases bypass
air and the canister/purge port are located on the top of 1. Start the engine and allow it to reach normal oper-
the throttle body. ating temperature (cooling fan comes on).
IDLE ADJUSTING
2. Disconnect the vacuum hose (to the canister) from
THROTTLE
ANGLE SCREW the top of the throttle body; connect a vacuum gauge
SENSOR to the throttle body.
tf
THROTTLE VACUUM
1 PUMP/GAUGE
VAL VE
3. Allow the engine to idle and check that the gauge

THROTTLE indicates no vacuum.
STOP • lf there is vacuum, check the throttle cable
SCREW (page 11-364).
4. Check that vacuum is indicated on the gauge when

the throttle is opened slightly from idle.
• lf the gauge indicates no vacuum, check the
throttle body port. lf the throttle body port is
clogged, clean it with carburetor cleaner.
5. Stop the engine and check that the throttle cable

operates smoothly without binding or sticking.
• lf there are any abnormalities in the above steps.
check for:
Excessive wear or play in the throttle valve

shaft.
Sticky or binding throttle lever at full close
position.
- Clearance between throttle stop screw and
throttle lever at full clase position.
11-366
THROTTLE LEVER
no clearance.
THROTTLE STOP SCREW.
(Non-adjustable)
Replacethe throttle body if there is excessive play in

the throttle valve shaft or if the shaft is binding or
sticking.
(cont'd)
11-367
Air lntake System
Throttle Body[Except O 1582 engine]
(cont' d)------------
Diassembly
22 N•m ~ -----THROTTLE CABLE

(2.2 kg-m,
16 lb-ft)
r
A/T THROTTLE
CONTROL
CABLE
11-368
CAUTION:
• The throttle stop screw is non-adjustable.
• After reassembly, adjust the throttle cable (page 11-364). and A/T throttle control cable (section 141for cars with
A/T. .
MANIFOLD
ABSOLUTE
PRESSURE
(MAP) SENSOR
D15Z1 engine:
Troubleshooting,
page 11-242, 246
0-RING
Re place
THROTTLE IDLE ADJUSTING

ANGLE SCREW
SENSOR
D16A7.D16Z6,
01627, D16A8,
A 16A9 engine:
MANIFOLD
ABSOLUTE B 16A2 engine:
PRESSURE
(MAP) SENSOR
0-RING
THROTTLE
ANGLE
SENSOR
11-369
Air lntake System
ThrottleBody
[01582 engine]-------------------
Description
The throttle body is of the single-barrel down-draft type. The idle adjusting screw, which opens the throttle valve., and the canister
purge port are located on the bottom of throttle body.
AIR INTAKE
¡__;;~~~~~~CHAMBER
0-RING
GASKET
1"
11-370
lnspection
CAUTION : Do not adjust the throttle stop screw since it
cannot be reset except at the 1factory. IDLE ADJUSTING
SCREW
1 . Start the engineand warm it up to normal operating
temperature(the cooling fan comeson).
2. Disconnectthe vacuumhose (to the canister) from the

throttle body and connect a vacuum gauge to the
throttle body.
+-There should be
no clearance.
/
THROTTLE LEVER
Replacethe throttle body if there is excessiveplay in the

throttle valve shaft or if the shaft is binding or sticking.
3. Allow the engine to idle and check that the gauge

indicates little or no vacuurn.
• lf there is rneasurable vacuurn, check the throt-

tle control systern (page 11-380).
4. Check that vacuurn increases when the throttle is

opened slightly frorn idle.
• lf there is no increase in vacuurn, check the

throttle body port. lf the throttle body port is
clogged, cleant it with carburetor cleaner.
5. Stop the engine and check that the throttle cable

operates smoothly without binding ot sticking.
• lf there are any abnorrnalities in the above steps,

check for:
- Excessivawear or play in the throttle valve shaft.

- Sticky or binding throttle levar at full close
position.
- Clearancebetween idle adjusting screw andthrot-
tle levar at full close position.
Icont'd)
11-371
Air lntake System
Throttle Body
[01582 engine] (cont'd)----------------
Disassembly
TANDEM VALVE TANDEM VALVE

CONTROL CONTROL SOLENOID
VALVE
DIAPHRA\
DASHPOT
DIAPHR\
~_...,.._~
MAIN INJECTOR
AUX. INJECTOR
THROTTLE
ANGLE SENSOR
PRESSURE REGULATOR
11-372
Air lntake System
Tandem Control
System [01582 engine]---------------
Description
The tandem valve is employed to improve atomization of fuel which is injected by the main fuel injector in responseto various
engine operating conditions.
When the tandem valve control solenoid valve is de-activated, venturi vacuum is not applied to the diaphragmchamberof the
tandem valve control diaphragm,so the tandem valve is nearly closed. The narrow clearancebetweenthe tandem valve and inner
wall of the throttle body generatesa rapid air flow which prometes atomization of the injected fuel from the main fuel injector.
When the tandem valve control solenoidvalve is activated, venturi vacuum is applied on the tandem vatvecontrol diaphragmand
the tandem valve is opened in responseto venturi vacuum which representsthe air flow rate through the venturi.
Therefore good atomization of the injected fuel is provided regardlessof air flow rate.
º""--Eh
,----lf--111~ 1BLK
ntTT ACG(SI
FUSE
TANDEM VALVE CONTROL SOLENOID

VALVE ON
OR
ANO
(AITI
COOLANT TEMPERATURE COOLANT TEMPERATURE ENGINE SPEED ABOVE 1,500 min-1 (rpm)
ABOVE 70°C (160°F) BELOW 70°C (160ºF)
(M/T)
ENGINE SPEED ABOYE 2,000 rnln " ' (rpm)
(When atmospheric pressure is below 550 mm
Hg)
or
ENGINE SPEED ABOYE 2,800 min-1 (rpm)
(When atmospheric pressureis above 550 mm
Hgl
11-374
TANDEM VALVE CONTROL
DIAPHRAGM
lnspection of Tandem Con-
trol System
Disconnect the vacuum hose

from the tandem valve control di-
aphragm and connect a vacuum
gauge to the hose.
Start engine and allow to idle.

NOTE: Coolant temperaturernust
be below 70'C (160°F).
YES Disconnect the 2P connector

Is there vacuum ? from the tandem valve control
solenoid valve.
NO
Replace the solenoid

Is there vacuum ?
valve.
NO

ECU.
Check for continuity to ground

on the ORN wire.
Repair short to
YES ground at ORN wire
Is there continuity to ground ? between ECU (82)
and the 2P connec-
NO tor.
Raise engine speed to,
• Manual: 3,000 min-1 (rpm)
• Automatic: 2,000 min-1 Substituta a known-good
(rpm)
ECU and recheck. lf symptom
goes away. replace the origi-
nal ECU.
NO Disconnect the 2P connector

Is there vacuum ? from the tandem valve control
solenoid valve.
YES
(To page 11-376) (To page 11-376)

(cont'd)
11-375
Air lntake System
Tandem Control
System (01582 engine]
(cont'd)------------
(From page 11-375) (To page 11-375)
Measure voltage between BLK

/YEL ( + l terminal and ORN
(-) terminal at 3,000 min " '
(rpm).
ORN
Remove the solenoid

valve from the throt-
tle body and check
Is there battery voltage ? the port for block-
age. lf the port is OK.
NO replace the solenoid
valve.

BLK/YEL ( +) terminal and body
ground.
Repairopen in
Is there battery voltage ? BLK/YEL wire between
the 2 P connector and
ACG(Sl (15A) fuse.
YES
Connect the test harness

between the ECU and con-
ººººººººº
ººººººººº 0000000000
000000000
00000000
00000000
82
Check for continuity of ORN wire

between ECU (82) and the 2P
connector.
Repair open in ORN

wire between ECU
Does continuitv exist ?
( 82) and the 2P con-
nector.
YES
Substituta a known-good
goes away, replace the origi-
(To page 11-377) nal ECU.
11-376
(From page 11-378)

ating temperature (the cooling
tan comes on).
Slowly open the throttle.
NO Substituta a known-good
Is there vacuum ? ECU and recheck. lf symptom
goes away. replace the origi-
YES nal ECU.
Tandem control system is

OK.
(cont'd)
11-377
Air lntake System
Tandem Control System [D 1582 --
engine] (cont'd)
Tandem Valve Control Diaphragm Testing
1 . Check the tandem valve shaft for binding_ or sticking.
2. Check the tandem valve for smooth movement.
• lf any fault is foUnd, clean the linkage and shafts

with carburetor cleaner.
3. Disconnect the vacuum hose from the tandem valve

control diaphragm and connect a vacuum pump to the
diaphragm.
4. Apply vacuum and check that ® of the tandem valve is

in close contact with the stopper when the tandem
valve is fully open.
\
VACUUM PUMP/GAUGE
• lf any fault is found, replace the tandem valve

control diaphragm.
11-378
Throttle Control
System (01582 engine]----------------
Description
The dashpot diaphragm functions as a cranking opener.

When the engine is at idle, intake manifold vacuum is applied on the dashpot diaphragm and pulls up the diaphragm
rod, so that the throttle valve is in the idle position.
During cranking with the starter. the spring in the dashpot diaphragm pushes the throttle valve open a certain amount
for assisting engine starting.
.__--++-~---;.,u----oASHPOT
DIAPHRAGM
THROTTLE VALVE
(cont'd)
11-379
Air lntake System
Throttle Control
System [01582 engine] (cont'd)-------------
Testing • lf the engine speed does not change, connect a
1. Start the engine and warm up to normal operating vacuum purnp to the vacuum hose and check
temperature (the cooling tan comes on). vacuum.
2. Disconnect the vacuurn hose frorn the dashpot There should be vacuum.
diaphragm and check the engine speed.
Engine speed should be:

Manual 2,500± 500 rnin" ' (rpm)
Automatic 2,500± 500 min-1 (rpm)
DASHPOT DIAPHRAGM
VACUUM PUMP/GAUGE
- lf there is no vacuum, check the vacuum hose for

nected hose and replace the 3-way joint.
16 HOSE - lf there is- vacuurn, replacethe dashpot diaphragm
and retest.
3. Reconnect - the vacuum hose and check the idle

speed.
• lf the engine speed is excessivelyhigh, adjust the
engine speed by bending TAB. ldle speed should be wíthtn specification (page
11-328).
TAB
11-380
System Troubleshooting Guide-------------------
NOTE: Across each row in the chart, the systems that could be sources of a symptom are ranked in the arder they
should be inspected starting with CD. find the symptom in the left column, read across to the most likely source, then
refer to the page listed at the top of that coumn. lf inspection shows the system is OK, try the next most fikely system
@, etc.
Except 016A9 engine:

POSITIVE
PAGE CATALYTIC EGR SYSTEM CRANKCASE EVAPORATIVE
CONVERTER (D1521 engine only) VENTILA TION EMISSION
SYSTEM CONTROLS
~
SYMPTOM ~ 383 386 392 294
ROUGH IDLE Q) ®
FREQUENT AFTER
STALLING WARMING UP CD
MISFIRE OR
ROUGH
RUNNING
CD
POOR
FAILS
PERFORMANCE
EMISSION
TEST
CD ® ®
. LOSS OF
POWER CD ®
POSITIVE
SYSTEM EVAPORATIVE
CRANKCASE
~·
EMISSION
VENTILAITON
CONTROLS
SYSTEM
-----===
SYMPTOM
392 394
ROUGH IDLE CD
FAILS
POOR
PERFORMANCE
EMISSION
TEST
CD
11-381
System Description-------, Tailpipe Emission--------
lnspection
The ernission control system includes a three-way cata-
lytic converter, .. exhaust gas recirculation (EGR)system, 11§.foJmijJ Do not smoke during this procedure.
crankcase ventilation systern and evaporative control Keep any open flame away from your work area.
system. The ernissioncontrol systern is designedto rneet
federal and state emission standards. 1. Start the engine and warm up to normal operating
temperature (cooling tan comes on).
.. : O 1521 engine
2. Connect tachorneter.
3. Check idle speed and adjust the idle speed, if naces-

sary (page 11-326, 328).
4. Warm up and calibrate the CO meter according to

the meter manutacture's instructions.
5. Check idle CO with the headights, heater blower,

rear window defogger, cooling tan, and air condition-
er off.
Specified CO%:
With CATA: 0.1 % maximum
Without CATA: 1.0± 1.0 %
• lf unable to obtain this reading:

On With CATA, see ECU troubleshooting guide
(page 11-204, 206).
On other models, adjust by turning the adjusting
screw of the IMA sensor.
ADJUSTING SCREW
- lf unableto obtain a CO reading of specified % by

this procedure, check the engine tune-up condi-
tion.
11-382
Catalytic Converter ---------------------------.
Oescription
The 3-way catalytic converter is used to convert hydrocarbons (HC), carbon monoxide (CO), and oxides of nitrogen
(NOx) in the exhaust gas to carbon dioxide (C02), dinitrogen (N2) and water vapor.
HOUSING
FRONT OF
VEHICLE
(cont'd)
11-383
Catalytic Converter (cont'd)
lnspection
lf excessive exhaust system back-pressure is suspected, remove the catalytic converter from the car and make a visual
check for plugging, melting or cracking of the catalyst. Replacethe catalytic converter if any of the visible area is dam-
aged or plugged.
Except D15Z1. D16A8 engine:
HEAT SHIELD
22 N•m
GASKET
Replace
GASKET
Replace
1 O N•m ( 1.0 kg-m. 7 lb-ftl
11-384
34N·m
13.4 kg-m, 25 lb-ftl
01521 engine:
HEAT
SHIELD
HEAT
SHIELD
GASKET
Replace.
10 N·m
( 1 .O kg-m, 7 lb-ft)
34N·m
D16A8 engine:
34N·m
13·4 kg-m, 25 lb-ftl
22 N·m
-------..
12,2 kg-m, 16 lb-ftl GASKET
Replace.
~ HEAT SHIELD
10 N·m (1.0 kg-m, 7 lb-ftl
11-385
Exhaust Gas Recirculation
System [01521 engine]-----------
T,oubleahooting Flowchart
.:::~::_ : : r¡fl:: : Self diagnosis Check Engine light indicates code 12: A problem in the Exhaust Gas Recirculation
,,,.
1
<, , ,.L...!f-J,(EGR) system.
The EGRSystem is designed to reduce oxides of nitrogen emissions (NOx) by recirculating exhaust gas through the EGR
valve and the intake manifold into the cornbustion chambers. lt is comprised of the EGRvalve, CVC valve, EGRcontrol
solenoid valve, ECU and various sensors.
The ECU memory contains ideal EGRvalve lifts for varying operating conditions. The EGRvalve lift sensor detects the
amount of EGRvalve lift and sends the information to the ECU. The ECUthen compares it with the ideal EGRvalve lift
which is determined by signals sent from the other sensors. lf there is any difference between the two, the ECUfurther
controls current to the EGRcontrol solenoid valve.
TO ACG (SI
(15Al FUSE
t
BLK/ ORN/
YEL~~~- -~~~~~~~~~~
BLU
cvc
EGR VAL VE
CONTROL
SOLENOID
VAL VE
ECU /1---lv ARIOUS

rBLK \¡----JSENSORS
YEL/ WHT/
WHT BLK
EGR VALVE GRN/
LIFT SENSOR WHT
11-386
' 1 /
-[18)1- -[ill-
' 1 /
/ 1 ' / 1 '

reported on.
jumped (page 11-2081. CODE
12 is indicated.

(page 11-209).
Road test necessary: Warm up

the engine to normal operating
temperature (cooling tan comes
on).
Drive the car on the road for ap- VACUUM PUMP/
prox. 10 minutes. With the #16 HOSE GAUGE
transmission in low gear, keep
~'1'
the engine speed in the 1700-
2500 range.

at this time. ',,, ',,~
Is Check Engine light on and does ~N_O _,
) /i' \
it indicate CODE 12?
loose wires at EGRvalve, control
YES box and ECU.
~l)~
With the engine at idle. disconnect
the #16 hose from the EGRvalve
l
and connect a vacuum pump/
gauge to the hose.
Disconnect2P connector frorn the

YES
Is there any vacuum? control box and check the #16
hose for vacuum again.
NO
Move the vacuum pump/gauge to

the EGRvalve.
(To page 11-388) (To page 11-388)

(cont'd)
11-387
Exhaust Gas Recirculation
System (01521 engine] (cont'd)-------
(From page 11-38 7) (From page 11-387)
Check vacuum hose
routing of the entire
With the engine at idle, apply YES EGR system. lf hose
200 mmHg of vacuum to the EGFf Is there any vacuum ?
routing is OK, replece
valva. EGR control solenoid
NO
valva.
Turn the ignition switch OFF and
disconnect the "A" connector
from the ECU.
Check for continuity to ground on

ORN/BLU wire of 2P connector.
Repair short in ORN/

YES B LU wire between
EGR. control solenoid
NO valve and ECU (A11).

and retest. lf symptom/indica-
original ECU.
Does the engine stall or run NO

rough and does the EGR valve >< Replace EGR valva.
hold vacuum?
YES

the control box.

YEL ( +) terminal on the main wire
harnessand body ground.
NO Repair open in BLK/YEL wire

Is there battery voltage ? between the solenoid valve and
ACG (S) (15A) fuse.
YES
Reconnect the vacuurn pump/ 1 BLK/

gauge to the #16 hose. YEL (+)

idle.
(To page 11-389)
11-388
(From page 11-388)
Connect the battery positive termi-

nal to the A terminal of the 2P
connector. While watching the
vacuum gauge, connect the bat-
tery negative terminal to the B
terminal.
Is there approx. 200 mmHg with- >N_0 --1

in 1 second? inspect the #16 and #1 O hoses for
leaks, restrictions, or misrouting.
YES

NO
reconnect the 2P connector to Are the hoses OK? Correctas necessary.
the EGR control solenoid valve.
YES
EGR
VAL VE ~~
LIFT SENSOR ~-0-is_c_o_n_n_e_c_t_th_e_._l_o_w_e_r_h_o_s_e_on VACUUM PUMP/
EGR control solenoid valve and GAUGE
connect a vacuum gauge to the
hose.

idle.
Disconnect 3P connector from

the EGR valve. Is there 150 250 mmHg of >--N_0 --1
Replace CVC valva.
vacuum?
YES
Turn the ignition switch ON. Replace the EGR control sola-
noid valva.

(-) terminal.
WHT (+) terminal and body
NO ground.
YES
(To page 11-390) (cont'd)
(To page 11 -390)
11-389
ExhaustGasRecirculation
System [D1521engine](cont'd)-------
Repair open in GRN/
is there approx. 5 V?
EGR valve and ECU
NO (022).
Connect the test harness "O"

11-212).

minal.
Repair open in YEL/

EGR valve and ECU
NO (0201.

the original ECU.

the EGR valve.

(page 11-212).

minal.

Is the voltage approx. 1.2 V with
NO WHT/BLK wire between EGR
no vacuum applied and approx.
valve and ECU (012).
4. 3 V with 200 mm Hg of vacu-
lf wire is OK, replace the EGR
um applied (to the EGRvalve)? valve.
YES
(To page 11-391)
11-390
(From page 11-390)
Does the voltage consistently

NO
increase/decrease as the Replace the EGR valva.
vacuum increases/decreases?
YES
Reconnect the #16 hose to the

EGRvalve.

idle.
Connect A 11 terminal to A26

terminal with a jumper wire.
NO Repair open in ORN/BLU wire

Did the engine stall or run rough? between ECU (A 11) and control
solenoid valva.
YES

original ECU.
11-391
Positive Crankcase Ventilation System
Oescription lnspection (Except 01582 engine)
The Positive Crankcase Ventilation (PCV) system is 1. Check the crankcaseventilation hoses and connec-
designed to prevent blow-by gas from escaping to the tions for leaksand clogging.
atmosphere. The PCV valve contains a spring-loaded
plunger. When the engine starts, the plunger in the PCV
valve is lifted in proportion to intake manifoldvacuumand PCV
the blow-by gas is drawn directly into the intake manifold. HOSE
Except 01582 engim,:
BREATHER
HOSE
PCV
VAL VE
PCV
VAL VE
2. At idle, makesure there is a clicking sound from the

.. : BLOW-BY VAPOR PCV valve when the hose between PCV valve and
<:=> : FRESH AIR intake manifold in lightly pinchedwith your fingers or
01582 engine: pliers.
BREA THER HOSE
PCV VALVE
BREATHER • lf there is no clicking sound, check the PCVvalve

CHAMBER grommet for cracksor damage. lf the grommet is
OK, replacethe PCVvalve and recheck.
.. : BLOW-BY VAPOR
<:=> : FRESH AIR
11-392
lnspection [01582 enginel
1. Check the crankcasé ventilation hoses and connec-
tions for leaks and clogging.
BREATHER HOSE
2. At idle, make sure there is a clicking sound from the

PCV valve when you lightly pinch the PCV hose with
your fingers or pliers.
• lf no clicking sound is heard, replacePCVvalveand

recheck.
11-393
Evaporative IEmission
Controls---------------------
Description
The evaporative controls are designed to minimize the amount of fuel vapor escaping to the atmosphere. The system
consists of the following components:
A. Charcoal Canister
A canister for the temporary storage of fue! vapor until the fuel vapor can be purged from the canister into the engine
and burned.
8. Vapor Purge Control System

Canister purging is accomplished by drawing fresh air through the canister and into a port ont he throttle body. The
purging vacuum is controlled by the purge control diaphragm valve and the purge control solenoid valve.
PURGECONTROL SOLENOID VALVE OFF AFTER

STARTING ENGINE
COOLANT TEMPERATURE ABOVE D 15Z 1 engine: 75°C (167°F)

Others: 70°C (158°F)
01582 engine:
PURGECUT-OFF SOLENOID VALVE OFF I

I 5 SECONDS AFTER STARTING ENGINE
ANO
I COOLANT TEMPERATUREABOVE 80°C (176°F) 1 I THROTTLE VALVE NOT FULLY CLOSED I

When fuel vapor pressure in the fue! tank is higher than the set value of the two-way valve, the valve opens and
regulates the flow of fuel vapor to the canister.
11-394
VEL/ - TO MAIN
l
VARIOUS
BLK RELAV
SENSORS
BLK ~ > ECU (::]
FUEL TANK
PURGE
CONTROL
DIAPHRAGM
VAL VE
f
FRESH
D 1582 engine: AIR
PURGE CUT-OFF
SOLENOID VALVE
/
BLK/VEL
RED
ACG(Sl
FUSE
PURGE CONTROL
DIAPHRAGM VALVE
11-395
Evaporative EmissionControls [ExceptD 1582 engine] (cont' d}------
PURGE CONTROL
lnspection of Evaporative DIAPHRAGM VAL VE
Emission Controls
CANISTER
#7 VACUUM
HOSE
Disconnect # 7 vacuum hose

from the purge control dia-
phragm valve (on the charcoal
canister) and connect a vacuum
gauge to the hose.
Start the engine and allow it to VACUUM PUMP/

idle. GAUGE
NOTE: Engine coolant tempera-
ture must be below D 1 5Z 1
engine: 75°C (167°F), Others:
70°C (158ºF).
YES Disconnect the 2P connector

Is there vacuum ? YEL/
from the purge control solenoid
BLK (+).
valve.
NO

BLK ( +) terminal and RED (-) PURGE CONTROL
terminal. SOLENID VALVE
lnspect vacuum hose

YES routing.
lf OK, replace purge
control solenoid valve.
NO

BLK ( +) terminal and body
ground.
(To page 11-397) (To page 11-397)
11-396
Repair open in YEL/

NO BLK wire between
Warm up the engine to normal Is there battery voltage ?
main relay and the 2P
connector.
fan comes on). YES
lnspect RED wire for an open to

body ground between ECU (A20)
and the connector.
lf wire is OK, substituta a
known-good ECU and recheck. lf
symptom goes away, replace
the original ECU.
Check for vacuum at #7 vacuum

hose after starting the engine.
NO
Is there manifold vacuum? Disconnect the 2P connector.
YES
lnspect vacuum hose
Is there manifoldvacuum? routing.
lf OK, replace purge
control solenoid valve.
YES
lnspect for a short in RED wire

between ECU (A20) and the con-
nector.
lf wire is OK, substitute a
Reconnectthe hose. known-good ECU and recheck. lf
symptom goes away, replace
the original ECU.
Removefuel filler cap.
(To page 11-398) (cont'dl
11-397
Evaporative EmissionControls [Except O 1582 engien] (cont' d)----- ....
(From page 11-397)
VACUUM PRESSURE
GAUGE 0-4 in. Hg
Connect a vacuum gauge to can-

ister purge air hose.
URGE
HOSE
Start the engine and raise speed to

3,500 min-1 (rpm)
PURGE AIR HOSE
Does vacuum appear on gauge NO

Replace the canister.
within 1 minute ? -----~
YES
See two-way valve test to com-

plete.
Evaporatlve emission controls
are OK.
11-398
Evaporative Emission
Controls [01582 engine]--------------
lnspection of Evaporative
Emission Controls
PURGE CONTROL
DIAPHRAGM VALVE
Disconnect #7 hose from the
purge control diaphragm valve
(on the charcoal canister) and
connect a vacuurn gauge to the
hose.
VACUUM PUMP/GAUGE
Start the engine and allow to idle.

NOTE: Engine coolant temperature
must be below 80 'C (176 ·F).

YES
Is there vacuum ? from the purge control solenoid
valve.
NO
YEL/
BLK
RED

YEL/BLK ( +) terminal and
GRN(-) terminal.
lnspect # 7 hose rout-

YES ing. lf OK. replace
purge cut-off solenoid
valva.
NO

YEL/BLK ( +) terminaland body
ground.
(To page 11-401) (To page 11-401)
11-400
(From page 11-400) · (From page 11-400)
NO Repalr open in YEL/BLK.

Warm up the engine to normal Is there battery voltage ? BLK/YEL wire between
operating temperatura (cooling ACG(Sl(15AI fuse and
fan comes on) . YES the 2 P con nector.
Connect the test harness to

the main wire harness onlv.
not the ECU.
0000000000
0000000000
A6
Check far continuity of RED

wire between ECU (A6) and
the 2 P connector.
Repair open in RED wire

Does continuity exist ? between ECU (A6) and
Check far vacuum at 17 hose 1 O the connéctor.
seconds after starting the engine. YES
Check with the throttle valva
slightly opened.
and recheck. lf symptom goas
away, replace the original ECU.
NO
Is there manifold vacuum ? Disconnect the 2 P connector.
YES
lnspect # 7 hose rout-
Is there manifold vacuum ? ing. lf OK. purga cut-
off solenoid valva.
YES
Turn the ignition·switch OFF.
Reconnect the hose. Disconnect "Aºº connector from

ECU.
Remove fuel filler cap. Check far continuity to ground

on RED wire.
(To page 11-402)

(To page 11-402)
(ccnt'd)
11-401
Evaporative
Emission
Control
,(01582 engine]
(cont'd)----------
(From page 11-4011
(From page 11-401)
Repalr short to ground
YES in RED wire between
Is there continuity to ground ?
ECU (A6) and the con-
nector.
NO
Substituta a known- good

Connect a vacuum gauge to can- goes away, replace the origi-
ister purge air hose. nal ECU.
Start the engine and raise

speed to 3,500 min·1 (rpm).
VACUUM/PRESSURE
GAUGE, 0-4 in. Hg
..----- PURGE AIR HOSE
Does vacuum appear on gauge NO

within 1 minute ? >-------<
Replace the canister.
1
YES
See two-way valve test to

complete.
Evaporative emission controls
are OK.
11-402
Controls [KV only]----------------
1. Aemovethe fuel filler cap. 6. Aaiseenginespeedto 3,500 rnin"" (rpm).
Vacuumshould appearon gaugewithin 1 minute.
2. Start the engineand allow to idle.
• lf vacuum appearson gauge in 1 minute, remove
3. Disconnect vacuum hose at the purge control día- gauge, test is complete.
phragmvalve (on the charcoalcanister)and connect a
vacuum gaugeto the hose. • lf no vaccum, disconnect vacuum gauge and rein-
stall fuel filler cap:
PURGE CONTROL
DIAPHRAGM VALVE
7. Removecharcoalcanisterand checkfor signsof dam-
age or defects.
• lf detective, replacecanister.
8. Stop engine. Disconnect upper vacuum hose from

canister"PCV" fitting.
Connecta vacuumpump to canister"purga" fitting as
shown, and apply vacuum.
Vacuumshould remainsteady.
VACUUM PUMP/GAUGE
• lf there is no vacuum, check vacuum hose for
"'
blockage,cracksor disconnectedhose, as well as
vacuum port for blockage.
/
4. Disconnect the vacuum gauge and reconnect the
hose.
5. Connecta vacuumgaugeto canisterpurge air hose.
VACUUM/PRESSURE VACUUM PUMP/GAUGE

GAUGE. 0-4 in. Hg.
• lf vacuum drops, replace canister and retest.
9. Restart engine. Reconnect hose to canister "PCV"

fitting.
"PURGE" side vacuum should drop to zero.
• lf "PURGE" difr vacuum does not drop to zero,

repalce the canister and retest.
11-403
Controls--------------------~
Two-Way Valve Test 4. Move vacuum pump hose from vacuum to pressure
1. Removethe fuel filler cap. fitting, and move vacuumgauge hosefrom vacuumto
pressureside as shown.
2. Removevapor line from the fuel tank and connect to
T-fitting from vacuum gauge and vacuum pump as
shown.
2WD:
'VACUUM PUMP/
GAUGE
4WD:
4WD:
3. Apply vacuumslowly and continuously while watching 5. Slowly pressurizethe vapor line while watching the
the gauge. gauge.
Vacuumshould stabilizemomentarilyat 5 to 1 5 mmHg Pressureshould stabilizeat 1 O to 35 mmHg (0.4 to 1.

(0.2 to 0.6 in. Hg). 4 in. Hg).
• lf vacuum stabilizes(valve opens) below 5 mmHg • lf pressuremomentarily stabilizes (valve opens) at
(0.2 in. Hg) or above 15 mmHg (0.6 in. Hg), install 10 to 35 mmHg (0.4 to 1.4 in. Hg), the valve is
new valve and retest. OK.
• lf pressurestabilizes below 10 mmHg (0.4 in. Hg)
or above 35 mmHg (1.4 in. Hg), install a new valva
and retest.
11-404
Clutch
Special Tools 12-2

Pedal Free Play
Adjustment 1 2-4
Clutch Master Cylinder
Overhaul/lnspection . . . . . . . . . . . . . . . . . . . . . 12-5
Removal/lnstallation . . . . . . . . . . . . . . . . . . . . . 1 2-6
Disassembly 12- 7
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12- 7
Slave Cylinder
Overhaul/lnspection . . . . . . . . . . . . . . . . . . . . . 1 2-8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-9
lnstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2-9
Pressure Plate
Removal/lnspection . . . . . . . . . . . . . . . . . . . . . . 12-1 O
Clutch Disc
Removal/lnspection . . . . .. . . . . . . . . . . . . . . . . 12-11
Flywheel
lnspection 12-12
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2-1 2
Release Bearing
Removal/lnspection . . . . . . . . . . . . . . . . . . . . . . 12-13
lnstallation 12-14
Clutch Disc, Pressure Plate
lnstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . . . 12-14
Special T ools
Special Tools
Ref. No. Tool Number Description Oty Remarks
CD 07JAF-PM7010A Clutch Alignment Tool 1 Except 816A2

CD-1 07JAC-PM7011A Clutch Alignment Disc ( 1)
(D-2 07JAF-PM7012A Clutch Alignment Shaft ( 1) Component Tools
(D-3 07936-3710100 Handle ( 1)
@ 07LAF- PR30200 Clutch Alignment Tool 1
@-1 07LAF-PR30210 Clutch Alignment Shaft ( 1)
@-2 07JAC-PM7011A Clutch Alignment Disc ( 1) Component Tools
@-3 07936-3710100 Handle ( 1)
@ 07LAB-PV00100 Ring Gear Holder 1 07924-PD20003
© 07749-0010000 Outer Handle A 1
® 07746-0010100 Outer Driver, 32 x 35 mm
o o
~ ~
G)-1 G)-2 G)-3 @-1 @-2 @-3
1
G) @
© ®
12-2
lllustrated lndex
NOTE:
• Whenever the transmission is removed, clean and grease the release bearing sliding surface.
• lf the parts marked * are removed, the clutch hydraulic system must be bled.
*RESERVOIR
HOSE\ *RESERVOIR
COTTER PIN
Replace.
,;--~---
.--- *CLUTCH MASTER CYLINDER

Overhaul/lnspection, pa9e 12-5
*CLUTCH MASTER
Adjustment, CYLINDER
page 12-4
CLUTCH DISC
RELEASE BEARING
Removal/lnspection, page 1 2-13
TRANSMISSION
lnspection, page 1 2-12

Replacement, paqe 1 2-12
PRESSURE PLATE
Removal/lnspection, page 12-1 O
*CLUTCH PIPE
*CLUTCH HOSE
12-3
Pedal Free Play
NOTE: 2. Loosen locknut B, and turn the push rod in or out

• The clutch is self-adjusting to compensate for wear. to get the specified stroke and height at the clutch
• Total clutch pedal free play is 9-15 mm (0.35-0.59 pedal.
in}.
3. Tighten locknut B.
CAUTION: lf there is no clearance between the
master cylinder piston and push rod, the ralease 4. Thread in the clutch pedal switch A in until it con-
bearing is held against the diaphragm spring, which tacts the clutch pedal.
can result in clutch slippageor other clutch problems.
5. Turn the switch in further 1 /4-1 /2 turn.
1. Loasen locknut A, and back off the pedal switch until
it no longer touches the clutch pedal. 6. Tighten locknut A.
CLUTCH PEDAL
SWITCH A
LOCKNUT A
10 N•m {1.0 kg-m, 8 lb-ftl
LOCKNUT B
18 N•m 11.8 kg-m, 13 lb-ft)
@(STROKE AT PEDAL): 135-145 mm (5.31-5.71 in)

@(PEDAL PLAY): 1.0-10.0 mm (0.04-0.37 in)
© (CLUTCH PEDAL HEIGHT): 164 mm (6.46 in)
@(CLUTCH PEDAL DISENGAGEMENTHEIGHT): 83 mm (3.27 in) minimum to the floor.
12-4
Overhaul/lnspection -------------------------
RESERVOIR CAP
MASTER CVLINDER BODV

• Check the cylinder wall for
scoring or wear.
8 x 1.25 mm 10 N·m (1.0 kg-m,

13 N·m (1.3 kg-m,
~81b-ft)
91b-f<) ~
°'
0-RING
Replace.
VALVE GUIDE
~
tZ2ll
.-12
SPRING RETAINER ~HAO VALVE SEAL
NOTE:
VALVE STEM
Check for damage or
bending.
VAL VE SPRING
RETURN SPRING
- ----PUSH ROO
- 'iiñiiiei
8 x 1.25 mm
18 N•m ( 1.8 kg-m, 13 lb-ft)
Re place.
.12-5
Removal/lnstallation
CAUTION: 4. Remove the master clutch cylinder assembly.

• Avoid spilling brake fluid on painted surfaces, as it may
damage the finish.
• Plug the end of the clutch pipe and reservoir hose with
a shop towel to prevent fluid from flowing out of the
clutch pipe and reservoir hose after disconnecting.
1. The brake fluid may be sucked out through the top

of the master cylinder reservoir (see section 19).
2. Disconnect the clutch pipe and clutch hose from the

clutch master cylinder.
CLUTCH PIPE
15 N·m (1.5 kg-m, 11 lb-ftl
I
CLUTCH MASTER CYLINDER
ASSEMBLY
5. lnstall the clutch master cylinder in the reverse ar-

der of removal.
NOTE: Bleed the clutch hydraulic system (see

page12-6).
3. Pry out the cotter pin, and pull the pedal pin out of
the yoke. Remove the nuts.
NUT
13 N•m ( 1.3 kQ-m, 9 lb-ft)
PEDAL PIN
12-6
Disassembly -----------, Reassembly -----------.
CAUTION: Avoid spilling brake fluid on paint as it may CAUTION:

damage the finish. • Befare assembling, make sure all parts are complete-
ly clean.
1. Remove the dust seal from the master cylinder. • Replace parts with new ones whenever specified to
do so.
2. Pry the circlip off the master cylinder. • Do not allow dust or water to enter the system.
• Do not mix different brands of brake fluid as they may
not be compatible.
• Do not reuse the brake fluid which was drained out.
• Avoid spilling the brake fluid on painted surfaces. as
it may damage the finish.
1. Assemble the piston noting the proper direction of

the parts (page 12-5).
MASTER CYLINDER
ASSEMBLY
3. Carefully remove the piston by applying air pressure

through the clutch line hose. -~ Push the pisten in until it engages
the pawl of the retainer.
CAUTION:
• Hold a shop towel over the master cylinder, to 2. Slide the piston assembly into the mastert cylinder.
stop the pistan in case it comes out suddenly.
• Plug the end of the clutch hose port with a shop 3. lnstall the circlip in the groove of the master cylinder.
towel to prevent fluid from coming out.
• Clean all disassembled parts in solvent and blow
through all ports and passageswith compressed
air.
PISTON ASSEMBL Y
4. lnstall the dust seal.
12-7
Slave Cylinder
Overhaul/lnspection~~~~~~~~~~~~~~~~~~~~~~~~
SLAVE CYLINDER BODY

lnspect the cylinder wall for
scoring or wear.
SLAVE CYLINDER SPRING

lnstall with small end
facing piston.
l
BLEEDER SCREW
1 O N·m ( 1.0 kg-m, 8 lb-ft)
-,
PISTON CUP A
Replace.
Check that it is fitted securely

over cylinder body.
SLAVE CYLINDER PISTON

lnspect for wear or damage.
(Molybdenum
Disulfied)
12-8
Slave Cylinder
Removal lnstallation
1. Oisconnect the clutch pipe from the slave cylinder. 1. lnstall the slave cylinder assembly on the clutch
housing.
CAUTION:
• Avoid spilling brake fluid on the painted surfaces,
as it may damage the finish.
15 N·m ( 1.5 kg-m. 11 lb-ft)
• Plug the end of the clutch pipe with a shop towel
to prevent brake fluid from coming out.
2. Removethe slave cylinder from the clutch housing.
SLAVE
CYLINDER
ASSEMBLY
(Molybdenum
Disulfidel 8 x 1.25 mm
22 N·m (2.2 kg-m, 16 lb-ft)
2. Bleed the clutch hydraulic system.
Remove and check for signs of leaking • Attach a hose to the bleeder screw and suspend
or deterioration. the hose in a container of brake fluid.
• Make sure there is an adequate supply of fluid at
the master cylinder, then slowly pump the clutch
pedal until no more bubbles appear at the bleed-
er hose.
• Refill the master cylinder fluid when done.
• Use only DOT 3 or 4 brake fluid.
12-9
Pressure Plate
Removal/lnspection
1. lnspect the fingers of the diaphragmspring for wear 5. lnspect the pressureplate surface for wear, cracks,
at the release bearing contact area. or burning.
2. Check the diaphragm spring fingers for height us- 6. lnspect the fingers of the diaphragm spring for wear
ing the special tools and a feeler gauge. at the release bearing contact area.
Standard (New): 0.8 mm (0.03 in) Min. 7. lnspect for warpage using a straight edge and feel-
Service Limit: 1 .O mm (0.04 in) Max. er gauge. Measure across the pressure plate.
Standard (New): 0.03 mm (0.001 in) Min.

STRAIGHT EDGE
CLUTCH ALIGNMENT TOOL

Except B16A2: 07JAF-PM7012A
B16A2: 07LAF-PR30200
3. lnstall the ring gear holder, handle and Clutch Align- FEELER GAUGE
ment Shaft.
4. To prevent warping, unscrew the pressure plate

mounting bolts two turns at a time in a criss-cross
pattern, then remove the pressure plate.
CLUTCH ALIGNMENT SHAFT

RING GEAR HOLDER Except B16A2: 07JAF-PM7012A
07LAB-PV00100 B16A2: 07LAF-PR30210
HANDLE
07936-3710100
12-10
Clutch Disc
Removal/lnspection
1. Removethe clutch disc and special tools. 4. Measure the depth from the lining surface to the
rivets, on both sides.
2. lnspect lining of the clutch disc for signs of slipping
or oil. Replaceit, if it is burned black or oil soaked. Rivet Depth:
Standard (New): 1.3 mm (0.051 in)
CLUTCH DISC

Except B16A2: 07JAF-PM7012A
B16A2: 07LAF-PR30210
HANDLE
07936-3710100
3. Measure the clutch disc thickness.
Clutcl:l Disc Thickness:

12-11
/
Flywheel
lnspection Replacement
1. lnspect the ring gear teeth for wear or darnage. 1. lnstall the ring gear holder.
2. lnspect the clutch disc rnating surface on the 2. Rernove the flywheel mounting bolts and the
flywheel for wear, cracks or burning. flywheel.
3. Measure the flywheel runout using a dial indicator

through at least two full turns. Push against the
flywheel each time you turn it to take up the crank-
shaft thrust washer clearance.
NOTE: The runout can be measuredwith engine in-

stalled.
Standard (New): 0.05 mm (0.002 in) Max.

RING GEAR HOLDER

07LAB-PV00100
3. Remove the ball bearing from the flywheel.
4. Turn the inner race of the flywheel bearingwith your

finger. The bearing should turn smoothly and quiet-
ly. Check that the bearing outer raee fits tightly in
the flywheel. Replace the bearing if the race does
not turn smoothly, quietly, or fit tight in the flywheel.
12-12
Release Bearing
Removal/lnspection
3. Orive in the new bearing into the flywheel using the 1. Remove the boot from the clutch housing.
special tools.
OUTER HANDLE A
2. Removethe releasefork from the clutch housing by
07749-0010000 squeezingthe releasefork set spring with pliers. Re-
move the release bearing.
RELEASE BEARING
OUTER DRIVER,
32 x 35 mm
07746-0010100
4. Align the hole in the flywheel with the crankshaft

dowel pin and install the flywheel. lnstall the bolts
finger-tight.
5. lnstall the specialtool, then torque the flywheel bolts

in a criss-cross pattern, as shown. RELEASE FORK
Torque: 120 N•m ( 12.0 kg-m, 87 lb-ftl

3. Check the release bearing for play by spinning it by
Except B16A2: hand.
CAUTION: The bearing is packed with grease. Do

not wash it in solvent.
RING GEAR HOLDER

07LAB-PV00100
B16A2:
4. Replacethe bearing with a new one if there is ex-

cessive play.
RING GEAR HOLDER

07LAB-PV00100
12-13
Release Bearing Clutch Disc, Pressure Plate
1. With the releasefork slid between the release bear- 1. lnstall the ring gear holder.
ing pawls, install the bearing on the mainshaft while
inserting the release fork through the hole in the 2. lnstall the clutch disc using the special tools.
clutch housing.
2. Align the detent of the release fork with the release

fork bolt, then press the releasefork over the release
fork bolt. PRESSUREPLATE
30 N•m (3.0 kg-m, 22 íb-ft) -~

(Molybdenum
Disulfidel

07LAB- PVOO100 816A2: 07LAF-PR30210
HANDLE
07936-3710100
(Molybdenum 3. lnstall the pressure plate.

Disulfidel
3. Move the releasefork right and left to make sure that

the fork fits properly against the bearing, and that CLUTCH DISC
the bearing slides smoothly.
HANDLE
07936-3710100

07LAB-PV00100 B16A2: 07LAF-PR30210
4. lnstall the boot.
12-14
. cross pattern as shown.
4. Torque the bolts in a nsat a time to prevent warp-
Tighten them two turns. a
'ª
ing the d . phragm spnng.
Except B 16A2: B16A2:
8 x 1.25 mm 19 lb-ft)
26 N·m (2.6 k~-m. 8 x 1.25 mm
26 N·m (2.6 kg-m,
19 lb-ft)
I
RING GEAR HOLDER
07LAB-PV00100
07JAF-PM7012A
RING GEAR HOLDER
07LAB-PV00100
07LAF-PR30210
HANDLE
07936-3710100
HANDLE
07936-3710100
12-15
Manual Transmission
820 Model
Manual Transmission . . . . . . . . . . . . . . . . . . . . . . 13-1
V21 Model
Manual Transmission 13-43
822 Model
Manual Transmission 13-85
S20 Model
Manual Transmission
Shift Fork Assembly
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2 Disassembly/Reassembly 13-23
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3 Clearance lnspection 13-24
Back-up Light Swtich Synchro Sleeve, Synchro Hub
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3 lnspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-25
Transmission Assembly lnstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-25
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-4 Synchro Ring, Gear
lllustrated lndex . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-8 lnspection 13-26
Transmission Housing Shift Rod
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1O Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-27
Reverse Shift Fork Clutch Housing Bearing
Clearance lnspection 13-11 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-28
Reverse ldler Gear Mainshaft Thrust Shim
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-12 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-30
Mainshaft, Countershaft, Shift Fork Transmission
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-12 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-33
Mainshaft Assembly Transmission Assembly
lndex 13-13 lnstallation 13-37
Clearancelnspection . . . . . . . . . . . . . . . . . . 13-14 Gearshift Mechanism
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-15 Overhaul 13-41
lnspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-16
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-17
Countershaft Assembly
lndex 13-18
Clearance lnspection . . . . . . . . . . . . . . . . . . 1 3-19
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-20
lnspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-21
Reassembly 13-21
Special Tools
Special Tools
CD 07744-0010600 Pin Driver, 8.0 mm

@ 07LGC-0010100 Snap Ring Plier
@ 07746-0030100 lnner Handle C
© 077 46-0030400 lnner Driver, 35 mm
® 07746-0030300 lnner Driver, 30 mm 1
® 07744-0010200 Pin Driver, 3.0 mm 1
(J) 07744-0010400 Pin Driver, 5.0 mm 1
® 07JAC-PH80000 Adjustable Bearing Remover Set 1
@-1 07JAC-PH80100 Bearing Remover Attachment (1)
Component
@-2 07JAC-PH80200 Remover Handle Assembly ( 1)
Tools
@-3 07741-0010201 Remover Weight (1)
® 07749-0010000 Outer Handle A 1
@) 07746-0010300 Outer Driver, 42 x 47 mm 1
® 07746-0010400 Outer Driver, 52 x 55 mm 1
@ 07GAJ-PG20102 Mainshaft Clearance lnspection Tool Set 1
@-1 07GAJ-PG20110 Mainshaft Holder ( 1)
Component
@-2 07GAJ-PG20120 Collar ( 1)
Tools
@-3 07GAJ-PG20130 Mainshaft Base ( 1)
@ 07979-PJ40001 Magnet Stand Base 1
1 G) @ ®
¿;;?
/
~ ~
@-1
® @) @
® @-2
®
®
/ 0
f®-3 @-1
8 E9
@-2 @-3
@
@
13-2
Maintenance Back-up Light Switch
Transmission Oil Replacement
NOTE: Check the oil at operating temperatura, engine NOTE: To check the switch, see section 23.
OFF, and the car on level ground.
1. Disconnect the connector, then remove the switch
1. Remove the oil filler plug, then check the level and connector from the connector clamp.
condition of the oil.
2. Remove the switch.
Proper Level
3. lnstall the new washer and switch.
2. The oil level must be up to the filler hale. lf it is be-

low the hale, add oil until it runs out, then reinstall
the oil filler plug.
3. lf the oil is dirty, remove drain plug and drain trans-

mission.
4. Reinstall the drain plug with a new washer, and refill

to proper level.
NOTE: The drain plug washer should be replaced at BACK-UP LIGHT SWITCH WASHER
every oil change. 25 N•m (2.5 k11-m,18 lb-ft) Replace.
5. Reinstall the oil filler plug with a new washer.
Oil Capacity
1.8 e (1.9 U.S. qt.) after drain.
1 .9 e (2.0 U.S. qt.) after overhaul.
Use only SAE 10W-30 or 10W-40, SF or SG grade.
DRAIN PLUG
40 N•m (4.0 kg-m, 29 lb-ft)
13-3
Transmission Assembly
Remo val
i1SMhMMN
3. Disconnect the starter cables and transmission
ground wire.
ly ,and hoist brackets are attached to correct position
on the engine. 4. Remove the engine wire harness clamp.
• Apply parking brake and block rear wheels so car will
not roll off stands and fall on you while working 5. Disconnect the back-up light switch and speed sen-
under it. sor connectors.
CAUTION: Use fender covers to avoid damaging

painted surfaces.
BACK-UP LIGHT
SWITCH CONNECTOR
1. Disconnectthe battery negative ( - ) and positive ( +)
cables from the battery.
2. Removethe resonator, air intake hose, and air clean-

er case.
AIR CLEANER AIR INT AKE

RESONATOR CASE HOSE
STARTER TRANSMISSION
CABLES GROUND WIRE
6. Remove the clutch pipe bracket and slave cylinder.
NOTE: Do not opérate the clutch pedal once the

slave cylinder has been removed.
BRACKET SLAVE
CYLINDER
13-4
7. Remove the transmission housing bolts. 9. Remove exhaust pipe A.
GASKETS
EXHAUST PIPE A
8. Rernove the driveshafts and interrnediate shaft (see
section 16).
NOTE: Coat all precision finished surfaces with 1 O. Rernove the shift rod and extension rod.
clean engine oil or grease. Tie plastic bags over the
driveshaft ends.
SET RING EXTENSION ROO

Replace.
DRIVESHAFTS
J
SHIFT ROO
----..... PIN DRIVER, B.O mm

07744-0010600
(cont'd)
Replace.
13-5
Removal (cont'd)
11. Removethe splash guard and front stopper bracket. 13. Place a jack under the transmission.
14. Remove the transmission side mount.
TRANSMISSION
~IDE MOUNT
FRONT STOPPER
BRACKET
SPLASH GUARO
12. lnstall the bolts in the cylinder head and attach a 1 5. Remove engine stifferers and the clutch cover.
chain hoist to the bolts, then lift the engine slightly
to unload the mounts.
D16A8, D16A9:
CHAIN HOIST
13-6
1 6. Remove the transmission rear mount bolts and trans-
rnission housing bolts.
1 7. Pull the transmission away from the engine until it

clears the mainshaft.
13-7
lllustrated lndex
Refer to the drawing below far the transmission disassembly/reassembly.

Clean all parts thoroughly in solvent and dry with compressed air.
, Lubricate all parts with oil befare reassembly.
NOTE: This transmission uses no gaskets between the major housings; use P/N 08718-0001 sealant. Assemble
the housings within 20 minutes after applying the sealant and allow it to cure at least 30 minutes after assembly
befare filling the transmission with oíl.
13-8
NOTE: Always clean the magnet@ whenever the transmission housing is disassembled.
Torque Value
A - 15 N•m (1.5 kg-m, 11 lb-ft)
B - 28 N·m J.2.8 kg-m, 21 lb-ft)
e- 32 N·m (3.2 kg-m, 23 lb-ft)
(D BALL BEARING @ 3RD/4TH SHIFT FORK @) 14 x 20 mm DOWEL PIN

@ 5TH SYNCHRO HUB @ STEEL BALL @) 72 mm THRUST SHIM (*1)
@ 5TH SYNCHRO SLEEVE (@ 5 x 10 mm ROLLER 80 mm THRUST SHIM (*2)
@) SVNCHRO SPRING @ 5TH SHIFT FORK Selection, See section 1 5
@ SVNCHRO RING @ 1ST/2ND SHIFT FORK @ DIFFERENTIAL ASSEMBLY
@ 5TH GEAR @ 5TH/REVERSE SHIFT FORK See section 1 5
(J) 32 x 37 x 23.5 mm SHAFT @ 14 x 25 x 17.5 mm OIL SEAL
NEEDLE BEARING @ 65 mm THRUST SHIM ( * 1) Replace.
@ SPACER COLLAR 70 mm THRUST SHIM (*2) @ 35 x 56 x 8 mm OIL SEAL
® 34 x 39 x 23 mm Selection, page 13-28 Replace.
NEEDLE BEARING @OIL GUIDE PLATE @SHIFT ROO
@) 4TH GEAR @WASHER Replace. @BOOT
@ SYNCHRO RING @ BACK-UP LIGHT SWITCH @ OIL GUIDE PLATE
@ SVNCHRO SPRING 25 N·m (2.5 kg-m, 18 lb-ft) @ 30 x 47 x 21 mm
@ 3RD/4TH SYNCHRO SLEEVE @ BREATHER CAP NEEDLE BEARING (* 1)
@ 3RD/4TH SVNCHRO HUB @ RELEASE PIPE STA V 30 x 55 x 21 mm
@3RD GEAR @ TRANSMISSION HANGER B NEEDLE BEARING (*2)
@34 x 39 x 27.5 mm @) 1 O mm SEALING BOLT @ COUNTERSHAFT
NEEDLE BEARING 10 N·m (1.0 kg-m, 8 lb-ft) @36 x 41 x 25.5 mm
@MAINSHAFT @) 32 mm SEALING BOLT NEEDLE BEARING
@WASHER 25 N·m (2.5 kg-m, 18 lb-ft) @ 1ST GEAR
@) SPRING WASHER ®) 35 x 62 x 8 mm OIL SEAL (*3) @ FRICTION DAMPER
@) BALL BEARING 40 x 62 x 9 mm OIL SEAL (*4) @) SVNCHRO RING
@ 26 x 42 x 7 mm OIL SEAL Re place. @ SYNCHRO SPRING
Re place. @) OIL DRAIN PLUG @ 1ST/2ND SYNCHRO HUB
@ 28 mm PLUG BOLT 40 N·m (4.0 kg-m, 29 lb-ft) @ REVERSEGEAR
55 N•m (5.5 kg-m. 40 lb-ft) ®) OIL FILLER PLUG @ SYNCHRO SPRING
@ 1ST/2ND SELECT SPRING 45 N,m (4.5 kg-m, 33 lb-ft) @ SYNCHRO RING
@ SHIFT ARM SHAFT @ WASHER Replace. @) FRICTION DAMPER
@ INTERLOCK GUIDE BOLT @) TRANSMISSION HOUSING @) DISTANCE COLLAR
40 N•m (4.0 kg-m, 29 lb-ft) @) OIL GUTTER PLATE @) 39 x 44 x 27 mm
@ CLUTCH HOUSING @ 52 mm SNAP RING NEEDLE BEARING
® @) REVERSELOCK CAM @) 2ND GEAR
@ REVERSESHIFT HOLDER @) REVERSESELECT SPRING @)3RD GEAR
@) REVERSEIDLER GEAR @) REVERSESELECT RETAINER @) 4TH GEAR
@ REVERSEIDLER GEAR SHAFT @SHIFT ARM C @5TH GEAR
@ 5 x 22 mm SPRING PIN @) SHIFT ARM B @ BALL BEARING (*1)
Replace. @) INTERLOCK NEEDLE BEARING (*2)
@3 x 12 mm SPRING PIN @ COLLAR @) BALL BEARING
Replace. @ SHIFT ARMA @) SPRING WASHER
@ 1ST/2ND SHIFT FORK SHAFT @) SPRING WASHER @LOCKNUT
@ 5TH/REVERSE SHIFT PIECE @ MAGNET 110-0-110 N·m
@SPRING @) SET BALL SPRING BOLT 11.0-0-11.0 kg-m.)
22 N·m (2.2 kg-m. 16 lb-ft) ( 80-0-80 lb-ft
*1: Exce~ 01626, 01627, 016A7, 016A8, D16A9

*2: 01626, 01627, 016A7, 016A8, 016A9
*3: Except D16A8, 016A9
*4: D16A8, 016A9
13-9
Transmission Housing
Remo val
NOTE: Placethe clutch housing on two pieces of wood 6. Separate the transmission housing from the clutch
thick enough to keep the mainshaft from the hitting the housing and wipe it clean of the sealant.
workbench.
7. Removethe thrust shim and oil guide plate from the
1. Remove the back-up light switch. transmission housing.
2. Remove the transmission hanger B.

OIL GUIDE PLATE THRUST SHIM
3. Remove the transmission attaching bolts.
TRANSMISSION
HANGER B
Replace.
TRANSMISSION HOUSING
BACK-UP LIGHT SWITCH
4. Remove the 32 mm sealing bolt. 8. Removethe 1 O mm sealing bolt and oil gutter plate.
5. Expand the snap ring on the countershaft ball bear-

ing and remove it from the groove using a pair of
1 O mm SEALING BOL T
snap ring pliers.
SNAP RING PLIER
07LGC-0010100
¡
SNAP RING OIL GUTTER PLATE
13-10
Reverse Shift Fork
Clearance lnspection
1. Measurethe clearancebetweenthe reverseshift fork 3. Measurethe clearancebetweenthe reverseidler gear

and shift piece pin. and reverse shift fork.
Standard: 0.05-0.35 mm (0.002-0.014 in) Standard: 0.5-1.0 mm (0.020-0.043 in)

ServiceLimit: 0.5 mm (0.020 in) ServiceLimit: 1.8 mm (0.071 in)
REVERSE SHIFT FORK
REVERSE SHIFT FORK
2. lf the clearance exceeds the service limit, measure 4. lf the clearance exceeds the service limit, measure
the width of the groove in the reverse shift fork. the width of the reverse shift fork pawl groove.
Standard:7.05-7.25 mm (0.278-0.285 in) Standard:12.7-13.0 mm (0.500-0.512 in)
lf the width exceeds the standard, replace the

L-GROOVE
reverse shift arm with a new one.
REVERSE SHIFT FORK
lf the width is within the standard, replace the
reverse shift fork with a new one.
lf the width of the groove exceeds the standard,
replace the reverse shift fork with a new one.
lf the width of the groove is within the standard,
replace the 5th/reverse shift piece with a new one.
13-11
Mainshaft, Countershaft,
Reverse ldler Gear Shift Fork
Removal Disassembly
1. Remove the reverse shift holder. 1. Remove the interlock guide bolt from under the
clutch housing
2. Remove the shift arm B attaching bolt.
2. Remove the reverse idler gear shaft and gear.

INTERLOCK GUIDE BOL T
SHAFT 3. Removethe mainshaft and countershaft assemblies
/
with the shift fork from the clutch housing.
NOTE: Beforeremoving the mainshaft and counter-

shaft assernblies, tape the rnainshaft spline to pro-
íl
tect it.
REVERSE IDLER
GEAR
13-12
Mainshaft Assembly
lndex
NOTE: The 3rd/4th and 5th synchro hubs are installed with a press.
~ Prior to reassembling, clean all the parts in solvent, dry them and apply lubricant to any contact surfaces.
3RD/4TH SYNCHRO
HUB
BALL BEARING
lnspect for wear
or operation.
lnspection, page 1 3-24
SYNCHRO RING
SYNCHRO RING
5TH GEAR
\
3RD GEAR
32 x 37 x 23.5 mm
' 34 x 39 x 27. 5 mm
NEEDLE BEARING
lnspect for wear
or operation.
~.c11.-~
NEEDLE BEARING
lnspect for wear or
operation.
SPACER COLLAR
34 x 39 x 23 mm
.....__ MAINSHAFT rnrinm,11L..-- NEEDLE BEARING
lnspect for wear
lnspection, page 13-1 5
or operation.
SYNCHRO RING
<,
· SYNCHRO SPRING
13-13
Mainshaft Assembly
NOTE: lf replacement is required, always replace the 3. Measure the clearance between 4th gear and the
synchro sleeve and hub as a set. spacer collar.
1. Measurethe clearance between 2nd and 3rd gears. Standard: 0.06-0.19 mm (0.002-0.004 in)
Standard: 0.06-0.21 mm (0.002-0.008 in)
~._.--;~~~--e=:
'sTH GEAR
4. lf the clearance exceeds the service lirnit, measure

distance ® on the spacer collar.
Standard: 22.83-22.86 mm
(0.899-0.900 in)
2. lf the clearance exceeds the service limit, measure Service Limit: 22.81 mm (0.898 in)
the thickness of 3rd gear.
(1.190-1.192 in)
4TH GEAER
SIDE
5. lf distance ® is more than the service limit, replace

the spacer collar with a new one.
lf distance ® is within the service limit, measurethe
thickness of 4th gear.
(1.186-1.188 in)
Service limit: 30.05 mm (1.183 in)
lf the thickness of 3rd gear is less than the service

limit, replace 3rd gear with a new one.
lf the thickness of 3rd gear is within the service limit,
replace the 3rd/4th synchro hub with a new one.
lf the thickness of 4th gear is less than the service

limit, replace 4th gear with a new one.
lf the thickness of 4th gear is within the service limit,
13-14
Disassem_bly
6. Measure the clearance between the spacer collar and 1. Remove the ball bearing using a bearing puller as
5th gear. shown.
Standard: 0.06-0.19 mm (0.002-0.004 in)

BALL
BEARING
iiij( . .........---4TH GEAR

--J~~,:\'r. - -e:::::
........._5TH GEAR
7. lf the clearance exceeds the service limit, measure

distance @ on the spacer collar.
(0.926-0.928 in)
. CAUTION: Remove the synchro hubs using a press
---
..J
and steel blocks as shown. Use of a jaw-type puller
5TH GEAR can cause damage to the gear teeth.
SIDE
2. Support 4th gear on steel blocks as shown and press

the shaft out of the 5th synchro hub.
8. lf distance@ is more than service limit, replace the
spacer collar with a new one.
lf distance ® is within the service limit, measure
(1.119-1.121 in)
Service Limit: 28.35 mm ( 1 .116 in)

replace the 5th synchro hub with a new one.
13-15
Mainshaft Assembly
Disassembly (cont' d) lnspection
3. In the same manner as above, support the 3rd gear 1. lnspect the gear surface and bearingsurface for wear
on steel blocks and pressthe shaft out of the 3rd/4th or damage, then measurethe mainshaft at points A,
synchro hub. B, C and D.
Standard: A: 21.987-22.000 mm
(0.8656-0.8661 in)
B: 26.980-26.993 mm
(1.0622-1.0627 in)
C: 33.984-34.000 mm
(1.3380-1.3386 in}
D: 25.977-25.990 mm
(1 .0227-1.0232 in)
Service Limit: A: 21 .93 mm (0.8634 in)
B: 26.93 mm (1.0602 in)
C: 33.93 mm (1.3358 in)
O: 25.92 mm (1.0205 in}
lnspect oil passages

for clogging
lf any part of the mainshaft is less then the service

limit, replace it with a new one.
2. lnspect for runout.
Standard: 0.02 mm (0.001 in) min.

Service Limit: 0.05 mm (0.002 in}
NOTE: Support the mainshaft at both ends as

shown.
Rotate two complete

revolutions.
lf the runout exceeds the service limit, replace the

mainshaft with a new one.
13-16
Reassembly
CAUTION: When installing the 3rd/4th and Sth synchro 2. lnstall the 5th synchro hub using a press as shown.
hubs. support the shaft on the steel blocks and install
synchro hubs using a press.
1. Support 2nd gear on steel blocks as shown, then in-

stall the 3rd/4th synchro hub using a press.
INNER HANDLE C
NOTE: After installation, inspect the operation of 07746-0030100
the 3rd/4th synchro hub set.
INNER DRIVER.
30 mm
07746-0030300
STH SYNCHRO HUB
INNER HANDLE C
07746-0030100
INNER DRIVER.
35 mm
07746-0030400
3. lnstall the ball bearing using a press as shown.
INNER HANDLE C
07746-0030100
INNER DRIVER.
30 mm
07746-0030300
13-17
lndex
NOTE: The 3rd, 4th and 5th gears are installed with a press.
Prior to reassembling, clean all the parts in solvent, dry them and apply lubricant to any contact surfaces. The
3rd, 4th and 5th gears, should be installed without lubrication using a press.
LOCKNUT Replace.
110-0-110 N·m
./ ( 11.0-0-11.0 kg-m)
/' 80-0-80 lb-ft
lnspect far wear ar

operatian.
BALL BEARING (*11
{ NEEDLE BEARING (*21
SYNCHRO SPRING ,.__ 5TH GEAR
3RD GEAR
•-~:r,~~~~-- SYNCHRO RING

lnspectian, page 13-26
FRICTION DAMPER
2ND GEAR
Replace.
39 x 44 x 27 mm
NEEDLE BEARING
lnspect far wear ar
1ST GEAR aperatian.
--- SPACER COLLAR
lnspectian, page 13- 19
---~--~-- FRICTION DAMPER

Replace.
37 x 42 x 25 mm
NEEDLE BEARING - SYNCHRO RING
lnspect far wear ar ~~~~ lnspectian, page 13-26
aperatian.
SYNCHRO SPRING
COUNTERSHAFT
REVERSE GEAR
1ST/2ND SYNCHRO HUB
*1: Exce~ 01626, 01627, 016A7, 016A8, 016A9

*2: 01626, 01627, 016A7, 016A8, 016A9
13-18
NOTE: lf replacement is required, always replace the 3. Measurethe clearance between 2nd and 3rd gears.
synchro sleeve and hub as a set.
Standard: 0.03-0.11 mm (0.001-0.004 in)
1. Measure the clearance between countershaft and
1st gear. 3RD GEAR
Standard: 0.03-0.10 mm (0.001-0.004 in)

ServiceLimit: 0.22 mm (0.009 in)
1ST GEAR
SPACER 2ND GEAR

COLLAR

(1.261-1.262 in)

the thickness of 1 st gear.
(1.197-1.198 in)
5. lf distance@ is more than the service limit, replace

lf distance@ is within the service limit, measurethe
thickness of 2nd gear.
(1.257-1.259 in)
lf the thickness of 1 st gear is less than the service

limit, replace 1 st gear with a new one.
lf the thickness of 1 st gear is within the service lirnit,
replace the 1 st/2nd synchro hub with a new one.
lf the thickness of 2nd gear is less than the service

limit, replace 2nd gear with a new one.
lf the thickness of 2nd gear is within the service limit,
replace the spacer collar with a new one.
13-19
Disassembly
CAUTION: Remove the gears using a press and steel 3. Support 4th gear on steel blocks as shown and press
blocks as shown. Use of a jaw-type puller can damage the shaft out of 5th and 4th gears.
the gear teeth.
1. Raise the locknut tab from the groove of the shaft

and remove the locknut and the spring washer.
CHISEL
AB
LOCKNUT
4. Support 1 st gear on steel blocks as shown and press

the shaft out of 3rd gear.
2. Remove the bearings using a bearing puller as

shown.
BEARING
13-20
lnspection Reassembly
1. lnspect the gear surfaces and bearing surfaces for CAUTION:

wear or damage, then measure the countershaft at • Pressthe 3rd, 4th and Sth gearson the countershaft
points A, 8 and C. without lubrication.
• When installing the 3rd, 4th and Sth gears, support
Standard: A: 30.000-30.015 mm the shaft on steel blocks and install the gears using
(1.1811-1.1817 in) a press.
B: 35.984-36.000 mm
(1.4167-1.4173 in) 1. lnstall the needle bearing on the countershaft.
C: 24.980-24.993 mm
(0.9835-0.9840 in)
~ 37 x 42 x 25 mm
Service Limit: A: 29.95 mm (1.1791 in) .,--NEEDLE BEARING
B: 35.93 mm (1.4146 in)
C: 24.93 mm (0.9815 in)
COUNTERSHAFT
2. Assemble the parts below as shown.
NOTE: Check that the finger of the friction damper

is securely set in the groove of the 1 st/2nd synchro
e HUB.
lf any part of the countershaft is less than the serv-

ice limit, replace it with a new one.
39 x 44 x 27 mm
2. lnspect for runout. - NEEDLE BEARING
Standard: 0.02 mm (0.0008 in) min.

1="'11~--- SPACER COLLAR
Service Limit: 0.05 mm (0.0020 in) ~-,l_C:::,,) ..._--FRICTION DAMPER
-- REVERSE GEAR
1ST/2ND
- SYNCHRO HUB
Rotate two complete

revolutions.
3. Placethe parts assembled in Step 2, then install the
parts on the countershaft.
countershaft with a new one. (cont'd)
13-21
Reassembly (cont' d)
4. Support the countershaft on a steel block as shown

and install 3rd gear using the special tools and a 7. lnstall the bearings using a press as shown.
press.
INNER HANDLE C
07746-0030100
BEARING
INNER DRIVER, ----'-"_...,
35 mm
07746- 0030400 INNER DRIVER. ---1P11""""4'.
30 mm
07746-0030300
5. lnstall 4th gear using the special tools and a press

as shown.
INNER DRIVER.
35mm 8. lnstall the spring washer, tighten the locknut, then
07746-0030400
stake the locknut tab into groove.
LOCKNUT
110-0-110 N·m
(11.0-0-11.0 kg-m, 80-0-80 lb-ft)
6. lnstall 5th gear using a press as shown.
13-22
Shift Fork Assembly
Disassembly/Reassembly
NOTE:
• When disassembling, pay attention to the steel balls as the springs may force them out.
• When assembling, install the shift fork shaft with its detents facing the hole where the balls are insertad.
~ Prior to reassembling, clean all the parts in solvent, dry them and apply lubricant to any contact parts.
5TH/REVERSE
-- SHIFTFORKSHAFT
5TH/REVERSE
SHIFTFORK
1 ST/2ND SHIFTFORK
3RD/4TH
SHIFTFORK
1.0-1.5 mm
PIN DRIVER,3.0 mm - (0.039-0.059 inl
07744-0010200
1ST/2ND
SHIFTFORK
SHAFT
\ 3 x 12 mm
SPRINGPIN
Replace.
Replace.
13-23
Shift Fork Assembly
1. Measurethe clearancebetween each shift fork and 4. Measure the clearance between the 3rd/4th shift
its matching synchro sleeve. fork and shift arm B.
Standard: 0.25-0.45 mm (0.010-0.018 in) Standard:0.2-0.5 mm (0.008-0.020 in)

ServiceLimit: 0.8 mm (0.032 in) ServiceLimit: 0.62 mm (0.024 in)
3RD/4TH SHIFT FORK
SHIFT FORK
the thickness of the shift fork fingers. the width of the shift arm B.
Standard:6.4-6.5 mm (0.252-0.255 in) Standard: 12.9-13.0 mm (0.508-0.512 in)
SHIFT FORK
3. Replacethe part that is out of tolerance. lf it is the 6. Replacethe shift arm B with a new one if the width
sleeve, the hub must also be replaced. is beyond the standard value.
13-24
Synchro Sleeve, Synchro Hub
lnspection lnstallation
1. lnspect gear teeth on all synchro hubs and sleeves Each synchro sleeve has three sets of longer teeth ( 1 20
for rounded off corners, which indicate wear. degreesapart) that must be matched with the three sets
of deeper grooves in the hub when assembled.
2. lnstall each hub in its mating sleeve and check for
freedom of movement. NOTE: lnstalling the synchro sleeve with its longer
teeth in the 1 st/2nd synchro hub slots will damage
NOTE: lf replacementis required,always replacethe the spring ring.
SYNCHRO LONGER TEETH

HUB
SLEEVE
HUB
SYNCHRO
SLEEVE
13-25
Sychro Ring, Gear
lnspection -·--------------------------------.
SYNCHRO SPRING
1. lnspect the inside of the synchro ring for wear.
2. lnspect the synchro sleeve teeth and matching teeth

on the synchro ring for wear (rounded off).
00
GOOD WORN
SYNCHRO RING
3. lnspect the synchro sleeve teeth and matching teeth

on the gear for wear (rounded off).
00
GOOD WORN
4. lnspect the gear hub thrust surface for wear.
5. lnspect the cone surface for wear or roughness.
6. lnspect the teeth on ali gears for uneven wear, seor- -----------'=:,:::r
ing, galling, cracks.
7. Coat the cone surface of the gear with oil and place
the synchro ring on the matching gear. Rotate the
ring, making sure that it does not slip.
Measure the clearance between the ring and gear ali

the way around.
NOTE: Hold the ring against the gear evenly while

measuring the clearance,
Ring-to-Gear Clearance
(0.0335-0.0433 in)
8. Separate the synchro ring and gear, then coat them

SYNCHRO RING
with oil.
GEAR
9. lnstall the synchro spring on the synchro ring, then
set it aside for later reassembly.
13-26
Shift Rod
Removal
1. Remove the differential assembly. 5. Removeshift arms C and 8, and the interlock, then
remove the reverse select spring and retainer.
2. Remove the 28 mm plug bolt and 1 st/2nd select
spring. 6. Remove the shift arrn A attaching bolt, the set ball
spring bolt, set spring, and steel ball.
3. Remove the shift arm B attaching bolt.
7. Remove shift arm A.
4. Remove the shift arm shaft.
8. Remove the reverse lock cam.
NOTE: Be careful not to lose the steel ball.
9. Remove the magnet.
SHIFT ARM C
SHIFT ARM B
~
INTERLOCK~~
~o
SHIFT ARMA
~~ SHIFT ARM SHAFT
\ 1ST/2ND SELECT SPRING
fa
SHIFT ROO
28 mm PLUG BOLT
BOOT
13-27
Clutch Housing Bearing
Replacement
Mainshaft 3. Orivethe new oil seal into the clutch housing using
the special tools.
1. Remove the ball bearing using the special tools.
ADJUST ABLE BEARING

REMOVER SET
07JAC-PHBOOOO
OUTER DRIVER, 42 x 4 7 mm
07746-0010300
\
OUTER HANDLE A
07749-0010000
4. Drive the ball bearing into the clutch housing using

2. Remove the oil seal from the clutch housing.
the special tools,
OUTER DRIVER,
OIL SEAL 52 x 55 mm OUTER HANDLE A
Replace. 97746-0010400 07749-0010000
13-28
Countershaft 2. lnstall the oil guide plate, then drive the needle bear-
1 . Remove the needle bearing using the special tools, ing into the clutch housing using the special tools.
then remove the oil guide plate.
ADJUST ABLE BEARING

REMOVER SET
07JAC-PH80000
NEEDLE BEARING
OIL GUIDE PLATE
OUTER DRIVER,
52 x 55 mm OUTER HANDLE A
07746-0010400 07749-0010000
OIL GUIDE PLATE
13-29
Mainshaft Thrust Shim
Adjustment
1. Removethe thrust shim and oil guide plate from the 65 mm Thrust Shim: Except D16Z6, D16Z7, D16A7,
transmission housing. D16A8. D16A9
2. lnstall the 3rd/4th synchro hub. spacer collar, 5th PART NUMBER THICKNESS
synchro hub, ball bearing, and thrust washer on the A 23931-PL3-A10 0.60 mm (0.0236 in)
mainshaft. lnstall the assembly in the transmission 8 23932-PL3-A10 0.63 mm (0.0284 in)
housing. e 23933-PL3-A10 0.66 mm (0.0260 in)
3RD/4TH SYNCHRO HUB D 23934-PL3-A10 0.69 mm (0.0272 in)
E 23935-PL3-A10 O. 72 mm (0.0283 in)
F 23936-PL3-A 1O O. 75 mm (0.0295 in)
G 23937-PL3-A10 O. 78 mm (0.0307 in)
SPACER COLLAR H 23938-PL3-A10 0.81 mm (0.0319 in)
1 23939-PL3-A10 0.84 mm (0.0331 in)
J 23940-PL3-A10 0.87 mm (0.0343 in)
5TH SYNCHRO HUB
K 23941-PL3-A10 0.90 mm (0.0354 in)
L 23942-PL3-A10 0.93 mm (0.0366 in)
M 23943-PL3-A10 0.96 mm (0.0378 in)
N 23944-PL3-A 10 0.99 mm (0.0390 in)
3. Measure the distance 8 between the end of the o 23945-PL3-A 1O 1.02 mm (0.0402 in)
transmission housing and thrust washer. p 23946-PL3.....:A 1 O 1.05 mm (0.0413 in)
Q 23947-PL3-A10 1 .08 mm (0.0425 in)
NOTE:
• Use a straight edge and feeler gauge. R 23948-PL3-A 1O 1. 11 mm (0.0437 in)
• Measure at three locations and average the s 23949-PL3-A10 1. 14 mm (0.0449 in)
readings. T 23950-PL3-A 10 1.17 mm (0.0461 in)
u 23951-PL3-A 10 1.20 mm (0.0472 in)
4. Measurethe distance C between the surfaces of the V 23952-PL3-A 1O 1.23 mm (0.0484 in)
clutch housing and bearing inner race. w 23953-PL3-A 10 1.26 mm (0.0496 in)
X 23954-PL3-A 10 1.29 mm (0.0508 in)
NOTE: y 23955-PL3-A 1O 1.32 mm (0.0520 in)
• Use a straight edge and feeler gauge. z 23956-PL3-A 1O 1.35 mm (0.0531 in)
• Measure at three locations and average the
AA 23957-PL3-A 10 1 .38 mm (0.0543 in)
readings.
AB 23958-PL3-A10 1 .41 mm (0.0555 in)
END OF CLUTCH HOUSING AC 23959-PL3-A 10 1.44 mm (0.0567 in)
-----,.-----,---~-r-.-L AD
AE
AF
. 23960-PL3-A
23961 -PL3-A 10
23962-PL3-A
10
1O
1.47 mm (0.0579
1.50 mm (0.0591
1.53 mm (0.0602
in)
in)
in)
AG 23963-PL3-A 10 1.56 mm (0.0614 in)
AH 23964-PL3-A 10 1. 59 mm (0.0626 in)
Al 23965-PL3-A10 1.62 mm (0.0638 in)
AJ 23966-PL3-A10 1.65 mm (0.0650 in)
AK 23967-PL3-A10 1.68 mm (0.0661 in)
INNER RACE OF BALL BEARING AL 23968-PL3-A 1O 1.71 mm (0.0673 in)
AM 23969-PL3-A 10 1.74 mm (0.0685 in)
5. Select the proper shim (or shim pair) on the basis of AN 23970-PL3-A 10 1. 77 mm (0.0697 in)
the following calculations: AO 23971-PL3-A 10 1.80 mm (0.0709 in)
NOTE: Do not use more than two shims.
(Basis Formula)
(B)+ (C) - 0.95 shim thickness
Example of calculation:
Distance B (2.00 mm) + Distance C (0.09 mm) =
2.09 mm subtract the spring washer height (0.95 mm)
= the required thrust shim ( 1. 14 mm)
13-30
70 mm Thrust Shim: 01626, 01627, 016A7, 016A8, 6. Checkthe thrust clearancein the mannerdescribed
016A9 below.
PART NUMBER THICKNESS NOTE:

A 23931-PL3-800 0.60 mm (0.0236 in) • Cleanthe thrust washer, spring washer and shim
8 23932-PL3-800 0.63 mm (0.0284 in) thoroughly befare installation.
e 23933-PL3-800 0.66 mm (0.0260 in) • lnstall the thrust washer, spring washer and shim
D 23934-PL3-800 0.69 mm (0.0272 in) properly.
E 23935-PL3-800 O. 72 mm (0.0283 in)
F 23936-PL3-800 O. 75 mm (0.0295 in) a. lnstall the shims selected in the transmission
housing.
G 23937-PL3-800 O. 78 mm (0.0307 in)
b. lnstall the thrust washer and spring washer in
H 23938-PL3-800 0.81 mm (0.0319 in)
the mainshaft.
1 23939-PL3-800 0.84 mm (0.0331 in)
J 23940-PL3-800 0.87 mm (0.0343 in)
K 23941-PL3-800 0.90 mm (0.0354 in)
L 23942-PL3-800 0.93 mm (0.0366 in)
M 23943-PL3-800 0.96 mm (0.0378 in)
N ---- MAINSHAFT
23944-PL3-800 0.99 mm (0.0390 in)
o 23945-PL3-800 1.02 mm (0.0402 in)
p 23946-PL3-800 1.05 mm (0.0413 in)
Q 23947-PL3-800 1.08 mm (0.0425 in)
~ _.---- SPRING WASHER
R 23948-PL3-800 1. 11 mm (0.0437 in)
s 23949-PL3-800 1 .14 mm (0.0449 in)
T
u
239 50- PL3- 800
23951-PL3-800
1.17 mm (0.0461
1.20 mm (0.0472
in)
in)
((©)))
V 23952-PL3-800 1.23 mm (0.0484 in)
w 23953-PL3-800 1.26 mm (0.0496 in) c. lnstall the mainshaft in the clutch housing.
X 23954-PL3-800 1.29 mm (0.0508 in) d. Placethe transmission housingover the main-
y 23955-PL3-800 1.32 mm (0.0520 in) shaft and onto the clutch housing.
z 23956-PL3-800 1.35 mm (0.0531 in) e. Tighten the clutch and transmission housings
AA 23957-PL3-BOO 1.38 mm (0.0543 in) with several 1 O mm bolts.
A8 239 58- PL3- 800 1.41 mm (0.0555 in) f. Tap the mainshaft with a plastic hammer.
AC 23959-PL3-800 1.44 mm (0.0567 in)
AD 23960-PL3-800 1.47 mm (0.0579 in) 7. Check the thrust clearancein the mannerdescribed
AE below.
23961-PL3-800 1.50 mm (0.0591 in)
AF 23962-PL3-800 1.53 mm (0.0602 in)
CAUTION: Measurement should be made at room
AG 23963- PL3-800 1.56 mm (0.0614 in)
temperature.
AH 23964-PL3-800 1.59 mm (0.0626 in)
Al 23965-PL3-800 1.62 mm (0.0638 in) a. Slide the mainshaft base and the collar over the
AJ 23966-PL3-800 1.65 mm (0.0650 in) mainshaft.
AK 23967-PL3-800 1.68 mm (0.0661 in)
AL 23968-PL3-800 1. 71 mm (0.0673 in)
AM 23969-PL3-800 1.74 mm (0.0685 in)
AN 23970-PL3-800 1. 77 mm (0.0697 in)
AO 23971-PL3-800 1 .80 mm (0.0709 in)
____:. -,
~/
- //~/
Jp
r;::.Í
MAINSHAFT BASE
07GAJ-PG20130
COLLAR
07GAJ-PG20120
(cont'd)
13-31
Adjustment (cont'd)
b. Attach the mainshaft holder to the mainshaft as e. Zero a dial gauge on the end of the mainshaft.
follows:
• Back-out the mainshaft holder bolt and loos-
en the two hex bolts.
• Fit the holder over the mainshaft so its lip is
towards the transmission.
• Align the mainshaft holder's lip around the
groove at the inside of the mainshaft splines,
then tighten the hex bolts.
MAINSHAFT HOLDER
BOLT
HEX
BOLTS
MAGNET ST ANO
BASE
07979-PJ40001
f. Turn the mainshaft holder bolt clockwise; stop

turning when the dial gauge has reached its max-
imum movement. The reading on the dial gauge
c. Seat the mainshaft fully by tapping its end with is the amount of mainshaft end play.
a plastic hammer.
CAUTION: Turning the shaft holder bolt more
d. Thread the mainshaft holder bolt in until it just than 60 degreesafter the needle of the dial gauge
contacts the wide surface of the mainshaft base. stops moving may damage the transmission.
g. Clearance is correct if reading is between

0.11 -0. 18 mm (0.004-0.007 in).
lf not, recheck necessary shim thickness.
13-32
Transmission
Reassembly
1. lnstall the magnet and reverse lock cam. 6. lnsert shift arm shaft B in the clutch housing
2. Set shift arm A on the clutch housing, then install 7. lnstall the spring collar, spring, and steel ball into the
the shift rod. case. Compress the ball and insert the shift arm
shaft.
3. lnstall the spring washer and shift arm A attaching
bolt. 8. lnstall shift arm C in shift arm A, then insert the shift
arm shaft.
4. lnstall the steel ball, spring and set ball spring bolt.
9. lnstall the reverse select retainer and reverse select
5. lnstall shift arm B in the interlock, then set it on the spring onto shift arm shaft.
clutch housing.
1 O. lnstall the differential assembly.
* 8 x 1.0 mm 6 x 1.0 mm
e/
32 N·m (3.2 kg-m, 23 lb-ftl 15 N·m (1.5 kg-m, 11 lb-ft)
i
SHIFT ARM
REVERSELOCK CAM
~ REVERSE SELECT RETAINER
SHIFT ARM 8----~
•
INTERLOCK--~~
SHIFT ARMA
BOOT
(cont'd)
13-33
Transmission
11. Set the 36mm spring washer and washer. 13. lnstall the spring washer and shift arm B attaching
bolt.
12. lnstall the mainshaft, countershaft, and shift fork as-
semblies. 14. lnstall the 1 st/2nd select spring, 28mm plug bolt,
and interlock guide bolt.
NOTE: Align the finger of the interlock with the
groove in the shift fork shaft. NOTE: Apply liquid gasket (PIN 08718-0001 )to
the threads of the 28 mm plug bolt and interlock
guide bolt.
MAINSHAFT /COUNTERSHAFT
SHIFT FORK ASSEMBL Y
8 x 1.0 mm
32 N•m (3.2 kg-m, 23 lb-ftl
INTERROCK GUIDE BOL T

40 N·m (4.0 kg-m, 29 lb-ft)
1 5. lnstall the reverse idler gear and reverse idler gear

shaft.
SHAFT
REVERSE IDLER
GEAR
13-34
16. lnstall the reverse shift holder. 18. lnstall the oil gutter plate and 1 O mm sealing bolt.
NOTE: Apply liquid gasket (P/N 08718-0001) to

the threads of the 1 O mm sealing bolt.
1 O mm SEALING BOL T
1 O N•m (1.0 kg-m, 8 lb-ft)
17. lnstall the oil guide plate and 72 mm thrust shim on

the transmission housing.
OIL GUTTER PLATE
72 mm
THRUST SHIM 19. Apply liquid gasket to the transmission mating sur-
face of the clutch housing.
NOTE: This transmission uses no gaskets between

the major housings; use liquid gasket (P/N
08718-0001). Assemble the housing within 20
minutes after applying the liquid gasket and allow
it to cure at least 30 minutes after assembly before
filling it with oil.
(cont'd)
13-35
Transmission
20. lnstall the transmission housing. 23. Tighten the transmission housing attaching bolts in
the numbered sequence shown below.
21. Lower the transmission housing with the snap ring
expanded and set the snap ring in the groove of the 8 x 1.25 mm
countershaft bearing. Torque: 28 N·m(2.8 kg-m, 20 lb-ft)
NOTE: Check that the snap ring is securely seated

in the groove of the countershaft bearing.
22. lnstall the 32 mm sealing bolt.

the threads.
32 mm SEALING BOL T SNAP RING PLIER

25 N·m (2.5 kg·m, 18 lb-ft) 07LGC-0010100
I
24. lnstall the back-up light switch and transmission

hanger B.
TRANSMISSION
HANGER B
-,
4.6-8.3 mm
(0.18-0.33 in]
Replace.
13-36
lnstallation
1. lnstall the dowel pins. 4. Placethe transmíssion on the transmíssíonjack, and

raíse it to the engine leve!.
5. lnstall the transmission mounting bolts and rear

mount bolts.
12 x 1.25 mm
60 N·m (6.0 kg-m, 43 lb-ftl
DOWEL PINS
2. Apply grease to the parts as shown.
NOTE: Useonly molybdenum disulfide greasein this

step.
6. Raise the transmission, then install the transmission
side mount.
(Molibdenum
disulfidel
(Molibdenum
disulfide)
12 x 1.25 mm
65 N•m (6.5 kg-m, 47 lb-ftl
3. lnstall the release fork boot.
(cont'd)
13-37
7. Removethe chain hoist. 9. lnstall the front stopper bracket.
1 O. lnstall the splash guard.
12 x 1.25 mm
65 N•m (6.5 kg-m. 47 lb-ft)
CHAIN HOIST
!
10 x 1.25 mm
45 N·m (4.5 kg-m,
33 lb-ft)
8. lnstall the clutch cover. SPLASH GUARO
11. lnstall the shift rod, spring pin and clip.
12. lnstall the torque rod.
EXTENSION ROD 8 x 1 .25 mm

22 N•m (2.2 kg-m. 16 lb-ftl
8 x 1.25 mm
24 N·m (2.4 kg-m. 17 lb-ftl
8 x 20 mm
SPRING PIN
Replace.
fj....
'---- PIN DRIVER. B.O mm
07744-0010600
13-38
13. lnstall exhaust pipe A. 17. lnstall the transmission attaching bolts.
•¡
8 x 1.25 mm
22 (2.2 kg-m. 16 lb-ftl
12 x 1.25 mm
60 N•m (6.0 kg-m, 43 lb-ft)
/ -~
GASKET /
Replace.
8 x 1.25 mm 10 x 1.25 mm
16 N•m (1.6 kg-m, 55 N·m (5.5 kg-m,
12 lb-ft) 40 lb-ft)
14. lnstall the intermediate shaft and driveshafts. 18. lnstall the slave cylinder, then install the clutch pipe
stay.
15. lnstall the ball joint onto the lower arm.
1 6. lnstall the damper fork.

6 x 1.0 mm
10 N•m (1.0 kg-m, 8 lb-ft)
10 x 1.25 mm
44 N•m (4.4 kg-m,
32 lb-ft)
12 x 1.25 mm
65 N•m (6.5 kg-m, 47 lb-ftl (cont'dl
13-39
1 9. Connect the speed sensor and back-up light switch 22. Refill the transmission with oíl.
connectors and transmission ground wire.
23. Connect the positive ( +) and negative ( - ) cables
, 20. lnstall the wire harness clamp. to the battery.
24. Check the clutch operation.
8 x 1.25 mm 25. Shift the transmission and check for smooth

22 N·m (2.2 kg-m, 16 lb-ft)
operation.
BACK-UP LIGHT
SWITC\ONNECTOR
CLAMP
ST ARTER TRANSMISSION
CABLES GROUND WIRE
21. lnstall the resonator, air cleaner case, and air intake
hose.
AIR CLEANER CASE
13-40
Gearshift Mechanism
1
Overhaul
22 N•m kg=. 16 lb-ftJ
CHANGE LEVER KNOB

8 N·m (0.8 kg-m, 6 lb-ft)
EXTENSION
¡
BOLT
EXTENSION MOUNT
RUBBER
BOOT¡
¡t·V
~ 1o
CHANG~
LEVER ~ e rf"' COLLAR
DUST 22 N·m
SEAL A . (2.2 kg-m,
16 lb-ft)
CHANGE
LEVER
BALL S~AT <:.> EXTENSION
~::e~GE ~ ~OUNT STOPPE~ RJe~place.
DUST B
SEAL ~'-.-.J ~ ' "'"f8
® ,;r@
REAR JOINT BUSHING
~ 22 N·m
CHANGE BALL HOLDER •
(2.2 kg-m, 16 lb-ft)
PIN
RETAINER
BOOT
SPRING
PIN
Replace.
13-41
Y21 Model
Manual Transmission
Special Tools . . . . . .. . . . . . . . . . . . . . .. . . . . . .. . . 13-44 Mainshaft Assembly

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-45 lndex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-61
Back-up Light Switch Clearance lnspection 13-62
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-45 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-63
Transmission Assembly lnspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-64
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-46 Reassembly 13-65
Gearshift Mechanism Countershaft Assembly
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-4 7 lndex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-66
lllustrated lndex . . . . . . . . . .. . . . . . . . . .. . . . . . . 13-48 Clearance lnspection 13-67
Transmission Housing Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-68
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-50 lnspection .. . . . . . . . . .. . . . .. . . . . . . . . . . . . . . . 13-69
ReverseShift Fork, Reverseldler Gear Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-70
Clearance lnspection . . . .. . . .. .. . . . .. . 13-51 Synchro Ring, Gear
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-52 lnspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-7 2
Change Holder Assembly Synchro Sleeve, Synchro Hub
Clearance lnspection . . . . . . . . . . . . . . . . . 13-53 lnspection 13-73
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-55 lnstallation 13-73
Disassembly/Reassembly 13-56 Clutch Housing Bearing
Mainshaft, Countershaft, Diferential Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-7 4
Assemblies Mainshaft Thrust Shim
Removal 13-57 Adjustment 13-76
Shift Rod Transmission
Removal . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-58 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-79
Shift Fork, Shift Piece Transmission Assembly
Clearance lnspection 13-58 lnstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-83
Shift Fork Assembly
Disassembly/Reassembly 13-60
Special Tools
Special Tools -------------------------,

G) 07744-0010600 Pin Driver, 8.0 mm
@ 07744-0010200 Pin Driver, 3.0 mm
© 07744-0010400 Pin Driver, 5.0 mm
® 07746-0030100 lnner Handle C
® 07746-0030400 lnner Driver, 35 mm
(j) 07746-0030300 lnner Driver, 30 mm
® 07JAC-PH80000 Adjustable Bearing Remover Set 1
@-1 07JAC-PH80100 Bearing Remover Attachement (1)
@-2 07 JAC-PH80200 Remover Handle Assembly ( 1) Component Tools
@-3 07741-0010201 Remover Weight (1 )
® 07749-0010000 Outer Handle A
@) 07746-0010300 Outer Driver, 42 x 47 mm
® 07746-0010400 Outer Driver, 52 x 55 mm
@ 07746-0041100 PILOT DRIVER,28 mm
@ 07GAJ-PG20102 Mainshaft Clearancelnspection Tools Set 1
@-1 07GAJ-PG20110 Mainshaft Holder ( 1)
Component Tools
@-2 07GAJ-PG20130 Mainshaft Base (1)
® 07979-PJ40001 Magnet Stand Base 1
1
/~ G) @ ®
@-3
ti
@-1
@ @ @-2
® (j)
®
®
@~~~~
@) ® @
®
@)
13-44
NOTE: Check the oil at operating temperature, engine NOTE: To check the switch, see section 23.
OFF, and the car on level ground.
1. Disconnect the connector, then remove the
1. Remove the oil filler plug, then check the level and switch connector from the connector clamp.
2. Remove the switch.

Proper Level
2. The oil level must be up to the filler hale. lf it is be-

low the hole, and oil until it runs out, then reinstall
3. lf the oil is dirty, remove drain plug and drain trans-

mission.
4. Reinstallthe drain plug with a new washer, and refill

to proper level.
NOTE: The drain plug washer should be replacedat

every oil change.
BACK-UP LIGHT SWITCH WASHER
25 N·m (2.5 kg-m, 18 lb-ft) Replace.
5. Reinstall the oíl filler plug with a new washer.
011 Capaclty
2.2 e (2.3 U.S. qt.) after draln.
2.3 e (2.4 U.S. qt.) after overhaul.
Use only SEA 10W-30 or 10W-40, SF or SG grade.
OIL FILLER PLUG

45 N·m (4.5 kg-m, 33 lb-ft)
DRAIN PLUG
40 N·m (4.0 kg-m. 29 lb-ftl
13-45
Renioval ~~~~~~~~~~~~~~~~~~~~~~~~~~~~---,
NOTE: Differences between the 520 model MT and Y21 2. Removethe transmissionrear mount bolts and trans-
model MT are covered in this page. Refer to page 13-4 mission housing bolts.
for the information not covered in this page.
1. Remove the torque rod and shift rod.
TRANSMISSION
REAR MOUNT
IJ
ff PIN DRIVER, 8.0mm
07744-0010600
13-46
Gearshift Mechanism
Overhaul
lll EXTENSION
EXTENSTION
END RUBBER
@?
EXTENSION
END COLLAR
22 N·m
(2.2 kg-m, 16 lb-ft)
-
:::?:·
amai
SPRING
PIN
Replace.
13-47
lllustrated lndex
Refer to the drawing below far the transmission disassembly/reassembly.

Clean all parts throughly in solvent and dry with compressed air.
~ Lubricate all parts with oil befare reassembly.
NOTE: This transmission uses no gaskets between the major housings; use Honda Genuine Liquid Gasket (P/N
08718-0001). Assemble the housings within 20 minutes after applying the sealant and allow it to cure at least
30 minutes after assembly befare filling the transmission with oil.
®-·-----::
®------
@-----···.,
@
®---~
@--- ........ J
®
@----· ----®
@ ::,. )),---®
@----~·
® ~~~ '----®)
®
q¡¡¡¡,.ar.~--@)
@---___,_¡
~==-=-®
®----
®
@
llffl..-----@·
c®.~5
~@
@)
~~---©
13-48
NOTE: Always clean the magnet @ whenever the transmission housing is disassembled.
Bolt Sise Torque Value

A 6 x 1.0mm 12 N·m (1.2 kg-m, 9 lb-ft)
B 6 x 1.0mm 15 N·m (1.5kg-m, 111b-ft)
e 8 x 1.0mm 15 N·m ( 1. 5kg-m, 11lb-ft)
D 8 x 1.25mm 24 N·m (2.4kg-m, 171b-ftl
E 8 x 1.25mm 28 N·m (2.8kg-m, 20lb-ft)
F 8 x 1.0mm 32 N·m (3.2kg-m, 231b-ft)
G) BALL BEARING @ REVERSE IDLER GEAR SHAFT BOL T @ MAGNET

@ STOPPER RING 55 N·m (5.5 kg-m, 40 lb-ftl @ 14 x 20mm DOWEL PIN
@ TAPER RING @ TRANSMISSION HANGER B ® 35 x 56 x 8mm OIL SEAL
@) NEEDLE BEARING @) BREATHER CAP Replace.
@ COLLAR @ TRANSMISSION HANGER A @ DIFFERENTIAL ASSEMBL Y
@ SYNCHRO RING @ BACK-UP LIGHT SWITCH See section 1 5
(J) SYNCHRO SPRING 25 N·m (2.5 kg-m, 18 lb-ftl @ 14 x 25 x 16mm OIL SEAL
@ STH/REVERSE SYNCHRO SLEEVE @ 14mm WASHER Replace. Replace.
@ STH/REVERSE SYNCHRO HUB @ 16mm SEALING BOL T @ SHIFT ROO
@) SYNCHRO RING 30 N·m (3.0 kg-m, 22 lb-ft) @ BOOT
@ 5TH GEAR @ 32mm SEALING BOL T @ OIL GUIDE PLATE
@ 38 x 43 x 26 mm NEEDLE BEARING 25 N·m (2.5 kg-m, 18 lb-ftl @ 33 x 60 x 20mm
@) SPACER COLLAR @ 40 x 62 x 9mm OIL SEAL Replace. NEEDLE BEARING
@ 4TH GEAR @ STEEL BALL @ BEARING RETAINER PLATE
@ SYNCHRO RING @ SPRING @ LOCK WASHER
@ SYNCHRO SPRING @) 12mm WASHER Replace. @ COUNTERSHAFT
@ 3RD/4TH SYNCHRO HUB @) SET BOLT @) 40 x 50mm THRUST SHIM
@ 3RD/4TH SYNCHRO SLEEVE 22 N·m (2.2 kg-m, 16 lb-ft) ® 37 x 42 x 25mm
@) 3RD GEAR @ OIL FILLER PLUG NEEDLE BEARING
@ MAINSHAFT 45 N·m (4.5 kg-m, 33 lb-ft) @ 1ST GEAR
@ WASHER @) 20mm WASHER Replace. @) FRICTION DAMPER
@ SPRING WASHER @ OIL DRAIN PLUG @ SYNCHRO RING
@ BALL BEARING 40 N·m (4,0 kg-m, 28 lb-ftl @) SYNCHRO SPRING
@ 28 x 41 x 7mm OIL SEAL Replace. @ 14mm WASHER Replace. @) 1ST/2ND SYNCHRO HUB
@ REVERSE IDLER GEA SHAFT @ 80mm THRUST SHIM @ REVERSE GEAR
@ REVERSE IDLER GEAR @) SNAP RING @ OUTER SVNCHRO RING
@ REVERSE SHIFT FORK @ SHIFT PIECE SHAFT @ SYNCHRO CORN
@ 5 x 22mm SPRING PIN Replace. @ INTERLOCK @ INNER SVNCHRO RING
@ 3 x 22 mm SPRING PIN Replace. @ SHIFT PIECE (@ FRICTION DAMPER
@ STH/REVERSE SHIFT FORK SHAFT @ SHIFT ARM HOLDER (@ DIST ANCE COLLAR
@ 5TH/REVERSE SHIFT FORK @ SELECT ARM @ 42 x 47 x 23.5mm
@ 5TH/REVERSE SHIFT PIECE @) SELCT RETURN SPRING NEEDLE BEARING
@) 3RD/4TH SHIFT FORK SHAFT @ 1 Omm THRUST SHIM @ 2ND GEAR
@ 3RD/4TH SHIFT FORK @ 10mm WASHER @ 3RD GEAR
@ 1ST/2ND SHIFT FORK SHAFT @) LOCK COLLAR @ 4TH GEAR
@ 1ST/2ND SHFT FORK @) 3 x 16mm SPRING PIN @ 5TH GEAR
@ OIL GUTTER PLATE Replace. @ NEEDLE BEARING
@ 72 mm THRUST SHIM @ 8mm SPRING WASHER @ BALL BEARING
@) OIL GUIDE PLATE @ CHANGE PIECE @ SPRING WASHER
@ 10 mm WASHER Replace. @ SEALING BOL T @ LOCKNUT Replace.
22 N·m (2.2 kg-m, 16 lb-ftl 110-0-110N·m
@ SPRING 11.0-0-11.0kg-m,)
@ STEEL BALL ( 8o-o-8olb-tt
@ Oll CHAMBER PLATE
13-49
Removal
NOTE: Placethe clutch housing on two pieces of wood 3. Remove the transmission housing attaching bolts.
thick enough to keep the mainshaft from the hitting the
warkbench.
1. Remove the back-up light switch.
2. Remove the transmission hanger B.
3. Remove the set bolts, springs, and steel balls.
¡
4. Remove the ,32mm sealing bolt.
5. Expandthe snap ring on the countershaft ball bear-

ing and remove it from the groove using a pair of
STEEL BALL
TRANSMISSION HANGER B snap ring pliers.
2. Remove the reverse idler gear shaft bolt.

SNAP RING PLIER
07LGC-0010100
REVERSE IDLER GEAR SHAFT BOLT
13-50
Reverse Shift Fork,
Reverse ldler Gear
6. Separate the transmission housing from the clutch 1. Measurethe clearancebetween the reverseshift fork
housing and wipe it clean of the sealant. and 5th/reverse shift piece pin.
7. Remove the thrust shim and oil guide plate from the Standard:
transmission housing. Reverse Side: 0.05-0.45mm (0.002-0.018in)
5th Side: 0.4-0.9mm (0.016-0.035in)
THRUST SHIM 5TH/REVERSE SHIFT PIECE PIN
2. lf the clearance exceeds the standard, measurethe

width of the groove in the reverse shift fork.
Standard:
8. Removethe 1 6mm sealing bolt, then remove the oil Reverse Side: 7.05-7.25mm (0.278-0.285in)
gutter plate. 5th Side: 7.40-7.70mm (0.291-0.303in)
16mm SEALING BOL T

replace the reverse shift fork with a new one.
replace the 5th/reverse shift piece with a new one.
(cont'd)
13-51
Reverse Shift Fork,
Reverse ldler Gear
Clearance lnspection (cont'd) --- Removal
3. Measurethe clearancebetween the reverseidlergear 1. Remove the reverse shift fork.

and reverse shift fork.
Standard: 0.5-1.1mm (0.020-0.043in) REVERSE SHIFT FORK

Service Limit: 1.8mm(0.071in)
REVERSE IDLER GEAR
REVERSE SHIFT FORK
2. Shift the 3rd/4th shift fork to the 4th side, then

4. lf the clearance exceeds the service limit, measure remove the reverse idler gear and shaft.
the width of the reverse shift fork pawl groove.
Standard: 13.0-13.3mm(0.512-0.524)
REVER E IDLER GEAR

reverse shift fork with a new one.
13-52
Change Holder
1. Measurethe clearance between the shift piece and 3. Measurethe clearance between the select arm and
shift arm interlock.
Standard: 0.1-0.3mm (0.004-0.012in) Standard: 0.05-0.25mm (0.002-0.01inl

Service Limit: 0.6mm (0.024in) Service Limit: 0.5mm (0.020in)
INTERLOCK
SHIFT PIECE
SHIFT ARM
the width of the groove in the shift piece. the width of the interlock.
Standard: 8.1-8.2mm (0.319-0.329in) Standard: 13.0-13.Jmm (0.512-0.524in)

replace the shift piece. lf the width exceeds the standard, replace the in-
lf the width of the groove is within the standard, terlock.
replace the shift arm. lf the width is within the standard, replace the in-
terlock.
(cont'd)
13-53
Change Holder
Clearance lnspection (cont'd)
7. Measurethe clearancebetween the select arm and 9. Measurethe clearancebetween the shift arm holder
shim. and change piece.
Standard: 0.01--0.2mm (0.0004-0.008in) Standard: 0.05-0.35mm (0.002-0.014ln)

Service Limit: O.Smm (0.031in)
SELECT ARM
/
SHAFT ARM HOLDER
CHANGE PIECE
THRUST SHIM
8. lf the clearanceexceedsthe standard, select the ap-

propriate thrust shim for the correct clearancefrom 1 O. lf the clearance exceeds the service limit, measure
the chart below. the groove of the change piece.
Standard: 11.8-12.0mm (0.465-0.472in)

PART NUMBER THICKNESS
A 24435-689-000 0.8 mm (0.031inl
B 24436-689-000 1.0 mm (0.039in)
e 24437 - 689- 000 1.2 mm (0.047in)
D 24438-689-000 1.4 mm (0.055in)
E 24439-689-000 1.6 mm (0.063in)
lf the groove exceeds the standard, replace the

change piece.
lf the groove is within the standard, replace the
change piece.
13-54
Remo val
11 . Measure the clearance between the select arm and 1. Removethe shift piece shaft, then remove the shift
change piece. piece and inter lock.
Standard: 0.05-0.25mm (0.002-0.01in)

Service Limit: 0.5mm (0.020in)
SHIFT PIECE SHAFT
SELECT ARM
SHFT PIECE
INTERLOCK
12. lf the clearance exceeds the service limit, measure 2. Remove the change holder assembly.
the width of the select arm.
Standard: 11.9-12.0mm (0.469-0.472in)
lf the width exceedsthe standard, replacethe select

arm.
change piece. CAHNGE HOLDER ASSEMBLY
13-55
Change Holder Assembly
Disassembly/Reassembly
, Prior to reassembling, clean all the parts in solvent, dry them and apply lubricant to any contact surfaces.
10 mm THRUST SHIM
SELECT RETU~
10 mm WASHER
LOCK COLLAR
STEEL BALL
3 x 16 mm SPRING PIN
Replace.
SHIFT ARM HOLDER
SELECT ARM
PIN DRIVER, 3.0 mm

07744-0010200
13-56
Mainshaft, Countershaft,
Differential Assemblies
Removal
1. Removethe mainshaft and countershaft assemblies 3. Remove the chamger plate.

with the shift fork from the clutch housing.
NOTE: Before removing the mainshaft and counter-

shaft assemblies, tape the mainshaft spline to pro-
tect it.
CHAMBER PLATE
2. Remove the differential assembly.
DIFFERENITAL ASSEMBL Y
13-57
Shift Rod Shift Fork, Shift Piece
Removal Clearance lnspection
1. Remove the change piece attaching bolt and spring NOTE: The synchro sleeve and suynchro hub should be
washer. replaced as a set.
2. Remove the set bolt, then remove the spring and 1. Measure the clearance between the synchro sleeve
steel ball. and shift fork.
3. Removethe shift rod, then removethe change piece. Standard: 0.45-0.65 mm (0.018-0.026 in)
SYNCHRO SLEEVE
SHIFT FORK
SPRING WASHER
2. lf the clearance exceeds the service limti, measure
the width of the shift fork fingers.
Standard: 7.4-7.5 mm (0.291-0.295 in)
SHIFT FORK
lf the width of the shift fork fingers exceedsthe stan-

dard, replace the shift fork with a new one.
lf the width of the shift fork fingers is within the stan-
dard, replace the synchro sleeve with a new one.
13-58
3. Measure the clearance between the shift piece asnd
shift fork shafts.
Standard: 0.2-0.5 mm (0.008-0.020 in)

SHIFT FORK SHAFT
/
SHIFT PIECE

the width of the shift piece.
Standard: 11.9-12.0 mm (0.469-0.472 in)
lf the width of the shift piece exceeds the standard,

replace the shift fork with a new one.
lf the width is within the standard, replace the shit
fork shaft a new one.
13-59
Shift Fork Assembly
Disassembly/Reasembly
NOTE: lnstall the spring pins, so their grooves are 180º apart.
Disassembly: Removewith the 3 mm spring pin and 5 mm spring pin.
Reassembly; lnstall the 5 mm spring pin first, then install the 3 mm spring pin.
5TH/REVERSE SHIFT FORK SHAFT
3RD/4TH SHIFT FORK
5TH/REVERSE SHIFT FORK

Re place.
Replace. o
1ST/2ND SHIFT FORK
Replace.
PIN ORIVE. 5.0 mm

07744-0010400 3RD/4TH SHIFT FORK SHAFT~
PIN DRIVER. 3.0 mm 1ST/2ND SHIFT FORK SHAFT
07744-0010200
STH/REVERSE SHIFT PIECE
13-60
Mainshaft Assembly
lndex
NOTE: The 3rd/4th and 5th synchro hubs are installed with a press.
Prior to reassembling, clean ali the parts in solvent, dry them and apply lubricant to any contact surfaces.
The 3rd/4th and 5th synchro hubs, however, should be installed with a press befare lubricating them.
BALL BEARING
4TH GEAR
lnspection,
page 13-20
SYNCHRO RING
NEEDLE BEARING
lnspect for wear
or operation.
3RD/4TH
SYNCHRO
HUB SYNCHRO RING
u,...___..(~~-- lnspection, page 13-30
(~)____ SYNCHRO
~,i\ SPRING
5TH/REVERSE SYNCHRO
~~~~~-- SLEEVE
3RD/4TH 5TH/REVERSE SYNCHRO
SYNCGRO HUB
SLEEVE
~~~'\~-- 5TH GEAR

3RD GEAR lnspection, page 13-21
~NEEDLE BEARING
lnspect for wear
or operation.
MAINSHAFT
lnspection, page13-22
13-61
Mainshaft Assembly
NOTE: lf replacement is required, always the synchto 3. Measure the clearance between 4th gear and the
sleeve and hobs as a set. spacer collar.
1. Measurethe clearance between 2nd and 3rd gears. Standard: 0.06-0.21 mm

(0.002-0.008 in)
Standard: 0.06-0.21mm ServiceLimit: 0.3 mm (0.012 in)
(0.002-0.008 in}

distance A on the spacer collar.
(1.025-1.027 in)
2. lf the clearance exceeds the service lirnit, meas-
4TH GEAR
ure the thickness of 3rd gear.
SIDE
Standard: 34.92-34.97 mm 1 1
(1.375-1.377 in)
5. lf distance A is more than the standard replace the

lf distance A is withtin the standard measure the
(1,237-1,239 in)

limit, replace of 3rd gear with a new one.
lf the thickness of 3rd gear is within the service lirnit,
replace the 3rd/4th synchro hub with a new one. lf the thickness of 4th gear is less than the service
lf the thickness of 4th gear is within the service lirnit,
13-62
Disassembly
6. Measure the clearance between 5th gear and the NOTE: Removethe synchro hubs using a press and steel
spacer collar. blocks as shown. Use of a jow-tipe puller can cause
damage to the gear teeth.
Standard: 0.06-0,21 mm
(0.002-0.008 in) 1. Remove the ball bearing using th bearing puller as
Service Limit: 0.3 mm (0.012 in) shown.
4TH GEAR
5TH GEAR
7. IF the clearanceexceeds the service limit, measure

distance B on the spacer collar.
(1.025-1.027 in)
5TH GEAR
SIDE - 2. Support 5th gear on steel blocks as shown and press
the shaft out of the 5th synchro hub.
1 1
8. lf distance B is more than the standard replace the

lf distance B is within the standard measure the
Standard: 31.42-31 .47 mm

(1.237-1,239 in)

replacethe 5th/reverse synchro hub with a new one.
(cont'dl
13-63
Mainshaft Assembly
Disassembly (cont'd) lnspection
3. In the same manner as above, support the 3rd gear 1. lnspect the surface and bearing surface for wear or
on steel blocks and pressthe shaft out of the 3rd/4th damage, then measure the mainshaft at points A,
synchro hub. B, and C.
Standard: A: 27.977-27.990 mm
(1,1015-1,1020 in)
B: 37.984-38.000 mm
( 1.4954-1.4960 in)
C: 27.987-28.000 mm
(1.1018-1.1024 in)
ServiceLimit: A: 27.930 mm ( 1 .0996 in)
B: 37.930 mm (1.4933 in)
C: 27.940 mm (1.1000 in)
lf any part of the mainshaft is less than the service

Standard; 0.02 mm (0.001 in)

NOTE: Support the mainshaft at both ends as

shown.
lf the runout exceeds the service lirnit, replace the

mainshaft with a new one.
13-64
Reassembly
CAUTION: 3. lnstall the 5th/reverse synchro hub using th special

• Press the 3rd/4th and 5th synchro hubs on the main- tools and a press.
shaft without lubrication.
• When installing the 3rd/4th and 5th synchro hubs,
INNER HANDLE C
support the shaft on steel blocks and instan the syn- 07744-0030100
chro hubs using a press.
• lnstall the 3rd/4th and 5th synchro hubs with a maxi-
mum pressure of 2.000 kg.
1. Support 2nd gear on steel blocks as shown, then in- INNER DRIVER. 35 mm 5TH/REVERSE
stall the 3rd/4th synchro hub using the special tools 07744-0030400 SYNCHRO HUB
and a press.
INNER HANDLE C
L
07744-0030100
DRIVER, 35 mm
07744-0030400
4. lnstall the ball bearing using the special tools and a

press.
2ND GEAR
INNER HANDLE C
07744-0030100
INNER DRIVER. 30 mm
07744-0030300
2. After installed, check the operation of the 3rd/4th

synchro hub set.
13-65
lndex
NOTE: The 4th and 5th gears are installed with a press.
The 4th and 5th gears, should be installed without lubrication using a press.
OUTER SYNCHRO RING

lnspection, page 13-30.
SYNCHRO SPRING LOCKNUT Replace.

110-+0-+110 N·m
(11-+0-+ 11 kg-m.
REVERSE GEAR
80-+0-+80 lb-ft)
SPRING WASHER
SYNCHRO RING
THRUST SHIM NEEDLE BEARING

Selection, page 13-25 lnspect for wear lnspect for wear
or operation. or operation.
~ SPACER COLLAR
~ Selection, page 1 3-25
COUNTERSHAFT
~ FRICTION DAMPER
~. INNER SYNCHRO RING

~ lnspection, page 13-30
SYNCHRO CONE
13-66
1. Measure the clearance between the 1 st gear and 3. Measure the clearance between the 2nd and 3rd
thrust shim. gears.
Standard: 0.04-0. 12 mm Standard: 0.05-0.12 mm

(0.0016-00.0047 in) (0.0020-0.0047 in)
2ND GEAR
THRUST SHIM
1ST GEAR
3RD GEAR
2. lf the clearanceexceedsthe service limit, select the 4. lf the clearanceexceedsthe service limti, select the
appropriate thrust shim for the correct clearance appropriate thrust shim for the correct clearance
from the chart below. from the chart below.

A 23921-PK5-900 1.95 mm (0.0768 in) PART NUMBER THICHNESS
B 23922-PK5-900 1.96 mm (0.0772 in) 29.02-29.04 mm
A 23917-P21-010
(1.1425-1.1433 in)
e 23923-PK5-900 1.97 mm (0.0776 in)
29.07-29.09 mm
D 23924-PK5-900 1.98 mm (0.0780 in) B 23918-P21-010
(1.1445-1.1453 in)
E 23925-PK5-900 1.99 mm (0.0783 in)
F 23926-PK5-900 2.00 mm (0.0787 in)
G 23927-PK5-900 2.01 mm (0.0791 in)
H 23928-PK5-900 2.02 mm (0.0795 in)
1 23929-PK5-900 2.03 mm (0.0799 in)
j 23930-PK5-900 2.04 mm (0.0803 in)
K 23931-PK5-900 2.05 mm (0.0807 in)
L 23932-PK5-900 2.06 mm (0.0811 in)
M 23933-PK5-900 2.07 mm (0.0815 in)
N 23934-PK5-900 2.08 mm (0.0819 in)
o 23935-PK5-900 2.09 mm (0.0823 in)
p 23936-PK5-900 2. 1 O mm (0.0827 in)
13-67
Disassembly -----------------------------.
NOTE: Removethe gears using a pressand steel blocks 3. Removethe bearingouter race,then remove the nee-
as shown. Use of a jow-tipe puller can damage the gear dle bearing using a bearing puller as shown.
teeth.
1. Raisethe locknut tab from the groove of the shaft

and remove the locknut and the spring washer.
HISEL
AB
LOCKNUT
Replace.
2. Remove the ball bearing using a bearing puller as

shown. 4. Support 4th gear on steel blocks as shown and press
the shaft out of 5th and 4th gears.
BEARING PULLER
BALL BEARING
13-68
lnspection
1. lnspect the surface and bearing surface for wear or 2. lnspect for runout.
damage, then measurethe contershaft at points A,
B, and C. Standard: 0.02 mm (0.001 in)
Standard: A: 24.980-27 .993 mm
(0.9835-1, 1021 in) NOTE: Support the countershaft at both ends as
B: 36.984-37.000 mm shown.
(1.4561 -1.4567 in)
C: 33.000-33.015 mm
(1.2992-1.2998 in)
ServiceLimit: A: 24.940 mm (0.9819 in)
B: 36.930 mm 11.4539 in)
C: 32.950 mm(1.2972 in)

countershaft with a new one.
lf any part of the coustershaft is less than the serv-

ice limit, replace it with a new one.
13-69
Reassembly
CAUTION: 2. Assemble the parts below as shown.

• Press the 4th and 5th gears on the countershaft
without lubrication NOTE: Check that the fingers ot the triction damp-
• When installing the 4th and 5th gears, support the er is securely set in the grooves of the 1 st/2nd svn-
shaft on steel blocks and instan the gears using a chro hub.
press.
• Instan the 4th and 5th gears with a maximum pres-
sure of 2,600 kg.
1. lnstall the thrust shim and needle bearing on the

countershaft.
NEEDLE BEARING
" THRUST SHIM

2ND GEAR
a,;;"'---SPACER COLLAR
FRICTION DAMPER
COUNTERSHAFT
,Hi---SYNCHRO CONE
OUTER SYNCHRO
RING
SYNCHRO SPRING
1ST/2ND
SYNCHRO HUB
3. Place the parts assembled in Step 2, then install

the parts on the countershaft.
13-70
4. Support the countershaft on a steel block as shown 6. lnstall the needle bearing, then install the ball bear-
and install 4th gear using the special tools and a ing using the special tools an da press.
press.
INNER HANDLE C
07744-00300100
INNER HANDLE C
07744-0030100 BALL BEARING
INNER DRIVER, 35 mm
07744-0030400
7. lnstall the spring washer, tighten the locknut, then

stake the locknut tab into groove
5. Support the countershaft on a steel block as shown
and install 5th gear using the special tools and a LOCK NUT
press. 110-+0-+ 110 N·m
(11-+0-+ 11 kg-m, 80 -+ O -+ 80 lb-ftl
LOCKNUT
13-71
Synchro Ring, Gear
lnspectión------------------------------,
1. lnspect the synchro ring and gear. SYNCHRO SPRING ........_
A : lnspect the inside of the synchro ring for wear.
B : lnspect the synchro sleeveteeth and matching

teeth on the synchro ring for wear (rounded
off). Q O SYNCHRO RING
GOOD WORN
C : lnspect the synchro sleeve teeth and matching
teeth on the gear for wear (rounded off). B
00
GOOD WORN
O : lnspect the gear hub thrust surface for wear.
E : lnspect the cone surface for wear or

roughness.
F : lnspect the teeth on all gears for uneven wear,

scoring, galling, cracks.
2. Coat the con e surface of the gear with oil and place
Measure the clearance between the ring and gear

all the way around.

measuring the clearance.
(0.0335-0.0433 in)
Double Cone Synchro-to-Gear Clearance

Standard:
A: (Outer Synchro Ring to Synchro Cone)
0.5-1.0 mm (0.0197-0.0394 in)
B: (Synchro Cone to Gear)
0.5-1.0 mm (0.0197-0.0394 in)
C: (Outer Synchro Ring to Gear) SYNCHRO RING
0.95-1.68 mm (0.0374-0.0661 in)
SYNCHRO CONE
Service Limit:
A OUTER SYNCHRO RING
A: 0.3 mm (0.0118 in)
B : 0.3 mm (0.0118 in) e
C : 0.6 mm (0.0236 inl
lf the clearance exceeds the service limit, replace

the synchro ring and synchro cone.
3. Separata the synchro ring and gear, then coat them

with oil.

set it asida for later reassembly.
13-72
lnspection lnstallation
1. lnspect gear teeth on all synchro hubs and sleeves Each synchro sleeve has three sets of longer teeth ( 1 20
for rounded off corners, which indicates wear. degrees apart) that must tbe matched with the three sets
freedom of movement. NOTE: lf replacementis required, always replacethe
NOTE: lf replacementis required, always replacethe
SLEEVE
SYNCHRO LONGER TEETH
HUB
HUB
SYNCHRO
SLEEVE
13-73
Replacement
Mainshaft 3. Orive in the new oil seal into the clutch housing us-
ing the special tools.
1. Removethe ball bearing using the special tools.
ADJUST ABLE BEARING REMOVER SET

07JAC-PH80000
OUTER HANDLE A
07749-0010000
<,
4. Orive the ball bearing into the clutch housing us-

2. Remove the oíl seal from the clutch housing. ing the special tools.
OUTER HANDLE A OUTER DRIVER, 52 x 55 mm
:
07749-001000 007746-0010400
BALL BEARING
PILOT DRIVER, 28 mm
07746-0041100
13-74
Countershaft 3. lnstall the oil guide plate, then drive in the needle
1. Bend the tab on the lock washer down, then rernove bearing into the clutch housing using the special
the bolt and bearing retainer plate. tools.
NEEDLE BEARING
BEARING RETANER PLATE
OUTER HANDLE A
07749-0010000 OUTER DRIVER, 52 x 55 mm
~ 07746-0010400
2. Rernove the needle bearing using teh special ~

tools, and rernove the oil guide plate.
ADJUSTABLE BEARING REMOVER SET

07JAC-PH80000 4. lnstall the bearing retainer plate and new lock wash-
er. then bend the tab against the bolt head.
8 x 10 mm
15 N·m (1.5 kg-m, 11 lb-ftl
13-75
Adjustment
1. Remove the 72 mm thrust shim and oíl guide plate 4. Measurethe distance B between the surfaces of the
form the transmission housing. clutch housing and bearing inner race.
NOTE:
• Use a straight edge and feeler gauge.
readings.
END OF CLUTCH HOUSING
-a----r----._____--.-,--L
INNER RACE OF BALL BEARING
2. lnstall the 3rd/4th synchro hub, spacer collar, 5th

synchro hub, collar, ball bearing, and 28 mm wash-
er on the mainshaft. lnstall the assembly in the trans-
mission housing.
3. Measure the distance A between the end of the

transmission housing and 28 mm washer. 5. Selcet the proper shim (or shim pair) on the basis of
the following calculations;
NOTE:
• Use a straight edge and feeler gauge. NOTE: Do not use more than two shims.
readings. (Basis Formula)
(A) + (B) - 1 .00 = shim thickness
Example of calculation;
Distance A (2.05 mm) + Distance B (0.09 mm) =
2. 14 mm subtract the spring washer height ( 1 .00
mm) = the required thrust shim ( 1 . 1 4 mm l
28 mm THRUST /
WASHER
MAINSHAFT
BALL BEARING
13-76
72 mm Thrust Shim 6. Check the thrust clearancein the mannerdescribed
below.
A 23931-P21-000 0.60 mm (0.0236 in) NOTE:
B 23932-P21-000 0.63 mm (0.0284 in) • Cleanthe thrust washer, spring washer and shim
e 23933-P21-000 0.66 mm (0.0260 in) thoroughly before installation.
• lnstall the thrust washer, spring washer and shim
o 23934-P21-000 0.69 mm (0.0272 in)
properly.
E 23935-P21-000 O. 72 mm (0.0283 in)
F 23936-P21-000 O. 75 mm (0.0295 in) a. lnstall the shims selected in the transmission
G 23937-P21-000 O. 78 mm (0.0307 in) housing.
H 23938-P21-000 0.81 mm (0.0319 in) b. lnstall the thrust washer and spring washer in
l 23939-P21-000 0.84 mm (0.0331 in) the mainshaft.
J 23940-P21-000 0.87 mm (0.0343 in)
K 23941-P21-000 0.90 mm (0.0354 in)
L 23942-P21-000 0.93 mm (0.0366 in)
M 23943-P21-000 0.96 mm (0.0378 in) ----- MAINSHAFT
N 23944-P21-000 0.99 mm (0.0390 in)
o 23945-P21-000 1.02 mm (0.0402 in)
p 23946-P21-000 1 .05 mm (0.0413 in)
Q 23947-P21-000 1 .08 mm (0.0425 in) ---- SPRING WASHER
R 23948-P21-000 1. 11 mm (0.0437 in)
s 23949-P21-000 1. 14 mm (0.0449 in) ((©)))
T 23950-P21-000 1.17 mm (0.0461 in)
u 23951-P21-000 1.20 mm (0.0472 in)
V 23952-P21-000 1.23 mm (0.0484 in)
w 23953-P21-000 1 .26 mm (0.0496 in) c. lnstall the mainshaft in the clutch hosing.
X 23954-P21-000 1.29 mm (0.0508 in) d. Placethe transmission housingover the main-
y 1.32 mm (0.0520 in) shaft and onto the clutch housing.
23955-P21-000
e. Tighten the clutch and transmission housings
z 23956-P21-000 1.35 mm (0.0531 in)
with several 1 O mm bolts.
AA 23957-P21-000 1.38 mm (0.0543 in) f. Tap the mainshaft with a plastic hammer.
AB 23958-P21-000 1.41 mm (0.0555 in)
AC 23959-P21-000 1 .44 mm (0.0567 in) 7. Check the thrust clearancein the mannerdescribed
AD 23960-P21 -000 1.47 mm (0.0579 in) below.
AE 23961-P21-000 1.50 mm (0.0591 in)
AF 23962-P21-000 1.53 mm (0.0602 in) temperature.
AG 23963-P21-000 1.56 mm (0.0614 in)
AH 23964-P21-000 1. 59 mm (0.0626 in) a. Slide the mainshaft base and the collar over the
Al 23965-P21-000 1 .62 mm (0.0638 in) mainshaft.
AJ 23966-P21-000 1 .65 mm (0.0650 in)
AK 23967-P21-000 1.68 mm (0.0661 in)
AL 23968-P21-000 1. 71 mm (0.0673 in)
AM 23969-P21-000 1. 74 mm (0.0685 in)
AN 23970-P21-000 1.77 mm (0.0697 in)
AO 23971-P21-000 1.80 mm (0.0709 in)
~~~~"("
r~ MAINSHAFT BASE
07GAJ-PG20130
(cont'd)
13-77
Adjustment {cont'd)
b. Attach the mainstiaft holder to the mainshaft as e. Zero a dial gauge on the end of the mainshaft.
follows:
• Back-out the mainshaft holder bolt and loos-
en the two hex bolts. MAGNET STAND BASE
07979-PJ40001
• Fit the holder over the mainshaft so its lip is
towards the transmission.
• Align the mainshaft holder's lip around the
groove at the inside of the mainshaft splines,
then tighten the hex bolts.
MAINSHAFT HOLDER
BOLT
HEX
BLOTS ......,...~=-~•
MAINSHAFT CLEARANCE INSPECTION TOOLS SET
07GAJ-PG20102
MAINSHAFT
HOLDER
07GAJ-PG20110
...._
f. Turn the mainshaft holder bolt clockwise; stop
turnig when the dial gaugehas reachedits maxi-
mum movement. The reading on the dial gauge
is the amount of mainshaft end play.
CAUTION: Turnig the shaft holder bolt more than

e . Seat the mainshaft fully by tapping its end with 60 degrees after the needle of the dial gauge
a plastic hammer. stops moving may damage the transmission.
d . Thread the mainshaft holder bolt in until it just
contacts the wide surface of the mainshaft base. g. Clearance is correct if reading is between
O. 11-0.18 mm (0.004-0.007 in).
13-78
Transmission
Reassenibly ~~~~~~~~~~~~~~~~~~~~~~~~~~~~-,
1. Set the change piece. 6. lnstall the differential assembly.
2. Instan the shift rod.
DIFFERENTIAL ASSEMBL Y
3. lnstall the steel ball, spring, and set bolt.
4. Instan the change piece attaching bolt.
SET BOLT
12x 1.0mm
8x _0 mm 22 N·m (2.2 kg-m, 16 lb-ft)
1
37 N·m (3.7 kg-m, 27 lb-fty
tf
7. Set the 28 mm spring washer and washer.
8. lnstall the mainshaft, countershaft and shift fork as-

semblies.
NOTE: Align the finger of the interlock and groove

of the shift fork shaft.
5. Instan the chamber plate.
6 x 1.0 mm
12 N·m (1.2 kg-m, 9 lb-ft)
(cont'd)
13-79
Transmission
Reassembly Icont' d)
9. lnstall the change holder assembly. 11. Measure the distance A after mounting the shift
piece shaft. lf not correct, check installation.
Distance A: 11.9-12.3 mm (0.469-0.484 in)
6 x 1.0 mm
15 N·m (1.5 kg-m,
11 lb-ft)
6 x 1.0 mm
12 N·m (1.2 kg-m, 9 lb-ftl
1 O. lnstall the shift piece and interlock, then install the

shift piece shaft. 12. Shift the 3rd/4th shift fork to the 4th gear side, then
install the reverse idler gear and shaft.
REVERSE IDLER GEAR
INTERLOCK
13-80
13. lnstall the reverse shift fork. 1 5. lnstall the oif gutter plate.
6 x 1.0 mm 16. Bend the hook of the oil gutter plate , then install the
15 N·m (1.5 kg-m, 11 lb-ftl
1 6 mm_ sealing bolt.
14. lnstall the oil guide plate and 72 mm thrust shim into
17. Apply liquid gasket to the transmission mating sur-
NOTE: This transmission uses no gasket between

the major housing; use Honda Genuine liquid gasket
OIL GUIDE PLATE (P/N08718-0001 ). Assemble the housing within
20 minutes after applying the liquid gasket and al-
low it to cure at least 30 minutes after assembly be-
fore filling it with oil.
(cont'd)
13-81
Transmission
Reassembly (cont'd) -----------------------
18. lnstall the 14 x 20 mm dowel pins. 21 . Check that the snap ring is securely seated in the
groove of the countershaft gearing.
19. lnstall the transmission housing by alining the groove
in the housing with finger on the stopper ring. Dimension A as installed: 4.6-8.3 mm
(0.181-0.327 in)
GROOVE FINGER
20. Lower the transmission housing with the snap ring 22. Tighten the transmission housing attaching bolts in
expanded and set the snap ring in the groove of the the numbered sequence as shown.
countershaft bearing.
SNAP RING PLIER

07LGC-0010100
•••••
SNAP RING
13-82
lnstallation (cont'd)
1-<I
23. Tighten the reverse idler gear shaft bolt. NOTE: Differencesbetween the S20 model MT and Y21
model MT are covered in this page. Refer to page 13-4
for the information not covered in this page.
1. lnstall the transmissionattaching bolts and transmis-

sion rear mount bolts.
12 x 1.25 mm
60 N·m (6.0 kg-m, 43 lb-ftl
10 x 1.25 mm
55 N·m (5.5 kg-m, 40 lb-ftl
24. lnstall the steel balls, springs, and set bolts.
25. lnstall the back-up light switch and transmission

hanger B. 2. lnstall the torque rod and shift rod.

25 N·m (2.5 kg-m, 18 lb-ft)
8 x 1.25 mm
22 N·m (2.2 kg-m. 16 lb-ft)
12x1.0mm
22 N·m (2.2 kg-m, 16 lb-ft)
13-83
522 Model
Manual Transmission
Special Tools 13-86 Mainshaft Assembly

Service Precautions . . . . . . . . . . . . . . . . . . . . . . 13-88 lndex 13-121
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-90 Clearancelnspection 13-122
Back-up Light Switch lnspection .. .. . . .. . . .. . . .. . . . . .. .. . . . . . . . . 13-123
Replacement.............................. 13-90 Countershaft Assembly
Gearshift Mechanism lndex 13-124
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-91 Clearancelnspection .. .. .. .. .. .. . . .. . 13-125
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-92 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-126
Transmission Assembly lnspection .. .. . . . . . . . . . . . . . . . . . . .. .. . . . . . . 13-126
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-93 Reassembly 13-127
lllustrated lndex . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-94 Transfer Shaft
-a
Shift Arm Cover Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-127
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-98 Shift Fork, Select Fork
Ea
Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-99 · Clearancelnspection 13-128
Transfer Synchro Ring, Gear
lnspection 13-1O 1 lnspection 13-129
Drive/Driven Gears Synchro Sleeve, Synchro Hub
Disassembly . 13-102 lnspection .. . . . .. . . . .. . .. . . . . .. . . . . . . . . . . . 13-130
L. Side Cover Race lnstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 3-130
Replacement . 13-102
Transfer Driver Gear
. bl Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-131
D 1sassem y 13- 103
Driven Geár Preload Mainshaft Thrust Shim
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-104 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-134
Thrust Shim Selection 13-106 Super-low 2nd Shaft
Driven Gear Reassembly . . . . . . . . . . . . 13-109 Thrust Shim Adjustment . . . . . . . . . . . . 13-137
Drive/Driven Gears Reassembly. . . 1 3-111 Transmission
Transmission Housing Reassembly. . . . . . .. .. . . . . . . . . . . . . . . . . . . . . 13-138
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-117 Transmission Assembly
ReverseShift Fork lnstallation .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-142
Clearancelnspection . . . . . . . . . . . . . . . . . 13-118
Mainshaft, Countershaft
Removal 13-119
Special Tools
Special Tools -----------------------~

Ref. No. Tool Number Description Remarks
G) 07744-0010400 Pin Driver, 5.0 mm
@ 07749-0010000 Outer Handle A
@ 07746-0010500 Outer Driver, 62 x 68 mm
@ 07926-SD90000 Flange Holder
® 07746-0010400 Outer Driver, 52 x 55 mm
® 07JAJ-PH80200 Drivern Gear Dummy Shaft
{J) 07KAF- PS30200 Bering Race Remover
® 07JAJ-PH80100 Drive Gear Gauge
® 07746-0030100 lnner Handle C
@) 07746-0030400 lnner Driver, 35 mm
/ G) @
@
@
1
(?; ~ ~
.CJIC@
@ ® ®
® ® @)
13-86
Special Tools -------------------------
@ 07JAD-PL90100 Oil Seal Driver
@ 07746-0030200 lnner Driver, 25 mm
@ 07746-0010300 Outer Driver, 42 x 47 mm
@ 07746-0041100 Pilot Driver, 28 mm
@ 07JAC-PH80000 Adjustable Bearing Remover Set
® 07746-0010600 Outer Driver, 72 x 75 mm
@ 07746-0010200 Outer Dirver, 37 x 40 mm
@) 07GAJ-PG20110 Mainshaft Holder
® 07979-PG40001 Magnet Stand Base
@ @ @
@ @ @ '
® cP
~
®
~
@
9 @) ®
13-87
Service Precaution
(without ABS)
The Real Time 4WD system allows instantaneous shift Operations Requiring 4WD Disengagement
from 2WD to 4WD automatically when greater traction
is needed. To prevent accidents or injuries, the system • When using test appliances;
must be released befor performing any services on the Speedometertester, .braketester, chassis dynamom-
differential unit. eter, etc.
To release 4WD CAUTION: Apply the parking brake and block the rear
wheels before using a speedometertester. When you
With the engine stopped, turn the shift bolt (painted use a chassis dynamometer, fix the car body with a
orange) as described below. rope to prevent it from moving.
DISENGAGEMENT LEVER
1. Loosen the lock bolt A.
2. Move the lever by turning the lock bolt A counter- • When running the engine with the car jacked up.
clockwise.
3. Confirm that the lever is in the fully disengaged po-

sition by rocking the cat back a_nd forth while plac-
ing slight counterclockwise pressureon the lock bolt
A.
4. Tighten the lock bolt A.
Torque: 12 N·m ( 1.2 kg-m, 9 lb-ft)
NOTE: When the engine starts with the 4WD sys-

tem disengaged, the rear differential clutch warning
light should come on.
• When towing with raised front or rear wheels.
<2WD> <4WD>
DISENGAGEMENT LOCK BOLT A

LEVER
13-88
(with ABS)
from 2WD to 4WD automatically when greater traction
is needed. To prevent accidents or injuries, the system • When using test appliances;
must be released before performing any services on the Speedometertester, brake tester, chassis dynamom-
differential unit. eter, etc.
To release 4WD CAUTION: Apply the parking brake and block the rear
wheels before using a speedometer tester. When you
DISENGAGEMENT
BOLT
• When running the engine with the car jacked up.

2. Align the mark on the disengagement bolt B with

"2" to disengage the 4WD system.
3. Align the place C with the cutout in the disengage-

ment bolt B and tighten the lock bolt A to the speci-
fied torque.

tem disengaged,the rear differential clutch warning • When towing with raised front or rear wheels.
should come on.
<2WD> <4WD>
DISENGAGEMENT BOL T B
CAUTION: After servicing, be sure to engine the

4WD system (align the alignment mark "4") and
tighten the lock bolt A securely.
Stop the engine and disconnect the ABS 82 fuse in
LOCK BOLT A ALIGNMENT MARK the engine compartment for more 3 seconds.
The self-dlagnosis lamp of the ABS control unit
should stop blinking.
13-89
NOTE: Check the oil at operating ternperature, engine NOTE: To check the switch, see section 23.
OFF, and the cot on leve! ground.
1. Disconnect the connector, then remove the switch
1. Rernovethe oil filler plug, then check the leve! and connector from the connector clamp.
2. Rernove the switch.
Proper Level. WASHER
---=--/
Replace.
2. The oil leve! rnust be up to the filler hole, lf it is be-

low the hole, add oil until it runs out, then reinstall
3. lf the oil is dirty, rernove drain plug and drain trans-

rnission.
4. Reinstall the drain plug with a new washer, and refill

to proper leve!.
Oíl Capacity
2.2 (2.3U.S. qt.) after drain.
2.3 (2.4U.S. qt.) after overhaul.
Use only SEA 10W-30 or 10W-40, SF or SG grade.
OIL FILLER PLUG

45N·m (4.5kg-m, 331b-ft)
OIL DRAIN PLUG

40N·m (4.0kg-m, 291b-ft)
13-90
Gearshift Mechanism
Cable Adjustment
Select Cable Shift Cable
1. Remove the console (see section 20). 1. Remove the console (see section 20).
2. With the transmission in neutral, check that the 2. Place the transmission in 4th gear.
groove in the lever bracket is aligned with the index
mark on the select cable. 3. Measure the clearance between the gearshift lever
.V
bracket and stopper while pulling the lever
backward .
GEARSHIFT LEVER
~ LOCKNUTS
LOCKNUTS
INDEX MARK ON SELECT CABLE
-
@--[Q~_¡- I _ --¡~ ADJUSTER
\ -. GROOVE
4. lf the clearance is outside specifications, loosen the
GEARSHIFT LEVER BRACKET
nuts and turn the adjuster in or out until the corrct
clearance is obtained.
NOTE:
• After adjustment, check operation of the gearshift
rever.
• Also check that the threads C of the cables do not
extend out of the cable adjuster by more than 1 Omm
(0.39in).
3. lf the index mark is not aligned with the groove in
the cable, loasen the lock nuts and turn the adjuster
as necessary. • l©1c11_11_tf f_)Ilc
--j r=:: =i © ~
13-91
Gearshift Machanism
Overhaul
NOTE:
• Do not bend the shift cable and selector cable while dis/reassembling the gearshift mechanism.
Replace the cables whenever they are damage.
(:?} GEARSHIFT
U LEVER
V-Eiiiii,1
LEVER BRACKET
Replace.
FLOATING COLLAR
COTTER PINS~
Replace. t
©
SELECTOR CABLE
CHANGE CABLE
BRACKET
13-92
Removal
NOTE: Differences between the S20 model MT and S22 COTTER PIN LOCKNUT
model MT are covered in this page. Refer to page 13-4 Replace
for the intormation not covered in this page.
1. Remove the driveshifts and intermediate shaft. ~® ='"''•\1111

2. Removethe cotter pis, then loosenthe locknuts and
remove the shift and select cables.
NOTE: Take care not to bend the cables when remov-

ing it and lift the cableshanging by wire it up to the body.
3. Remove the mounting bolts, then remove the

propeller shaft.
COMPANION FLANGE
32 N·m (3.2kg-m, 231b-ftl
13-93
lllustrated lndex
Refer to the drawing below for the transmission disassembly.

Clean all parts thoroughly in solvent and dry with cornpressed air.
, Lubricate all parts with oíl befor reassembly.
NOTE: This transmission uses no gaskets between the majar housings; use Honda Genuine Liquid Gasket (P/N
08718-0001 ).
Assemble the housings within 20 minutes after applying the sealant and allow it to cure at least 30 minutes after
assembly befare filling the transmission with oil.
e
13-94
A 6 x 1.0mm 12 N·m (1.2 kg-m, 9 lb-ft)
B 6 x 1.0mm 15 N·m (1.5kg-m, 111b-ft)
e 8 x 1.25mm 26 N·m (2.6kg-m, 191b-ft)
G) TRANSMISSION HOUSING @ SPRING (L.= 24.2 mm) @ SHIFT ARM SHAFT

@ 18mm SEALING BOLT @ 10mm WASHER Replace. @ BACK-UP LIGHT SWITCH
35 N·m (3.5kg-m. 251b-ft) @ TRANSMISSION HANGER 25 N·m (2.Skg-m, 181b-ftl
@ 32mm SEALING BOLT @ CLUTCH PIPE STA Y @ 14mm WASHER Replace.
70 N·m (7.0kg-m. 511b-ft) @ OIL COLLECT PLATE @ SET BOLT
@ OIL DRAIN PLUG @ OIL GUTTER PLATE 22 N·m (2.2kg-m, 161b-ft)
40 N·m (4.0kg-m, 291b-ft) @ INTERLOCK @ 12mm WASHER Replace.
@ 14mm WASHER Replace. @ SHIFT ARMA @ SPRING (L.=20.7 mm)
® 40 x 76 x 9mm OIL SEAL @ SUPER LOW SELECT RETAINER @ STEEL BALL
Re place @ SUPER LOW RETURN SPRING @ SHIFT ARM COVER
(J) OIL FILLER PLUG @ SELECT RETURN PIN @ INTERLOCK BOLT
45 N·m (4.5kg-m, 331b-ft) 12 N·m (1.2kg-m. 91b-ft) 40 N·m (4.0kg-m. 291b-ft)
@ STEEL BALL @ SELECT RETURN SPRING @ SET BOLT
@ SPRING @ 5 x 25mm SPRING PIN 22 N ·m (2.2kg-m, 161b-ftl
@) 12mm WASHER Replace. Replace. @ 6mm WASHER Replace.
@ SET BOLT @) SELECT LOCK CAM @) BREATHER CAP
22 N·m (2.2kg-m. 161b-ft) @ SHIFT ARM @ SHIFT LEVER
@ 20mm WASHER Replace. ® 18mm PLUG @ SELECT LEVER
@ SUPER LOW SHIFT LEVER BOLT 40 N·m (4.0kg-m. 291b-ft) @ 16 x 23 x 5mm OIL SEAL
40 N ·m (4.0kg-m. 291b-ft) Replace.
@ 8 x 14mm DOWEL PIN
@ REVERSE IDLER GEAR SHAFT BOLT
55 N·m (5.5kg-m, 401b-ftl
13-95
lllustrated lndex
Refer to the drawing below far the transmission disassembly.

Clean all parts thoroughly in solvent and dry with compressed air.
, Lubricate all parts with oíl befare reassembly.
NOTE: This transmission uses no gaskets between the majar housings; use Honda Genuine Liquid Gasket (P/N
08 71 8 - 0001 ) .
Assemble the housings within 20 minutes after appluing the sealant and allow it to cure at least 30 minutes after
assembly befare filling the transmission with oil.
G)
--@
13-96
NOTE: Always clean the magnet @ whenever the tr_ansmission housing is disassembled.

A 6 x 1.0mm 12 N·m (1.2 kg-m, 9 lb-ft)
B 6 x 1.0mm 17 N·m ( 1. 7kg-m, 121b-ft)
e 8 x 1.25mm 26 N·m (2.6kg-m, 1 Slb-ft)
D 10 x 1.25mm 45 N·m (4.5kg-m, 33lb-ft)
CD 3 x 22mm SPRING PIN @ 28 x 34 x 35mm @) 5TH/REVERSE SHIFT @OIL GUIDE PLATE

Replace. NEEDLE BEARING PIECE @ 0-RING Replace.
@ 1 ST/2ND SHIFT FORK @ SUPER LOW SHIFT @) LOCK WASHER @) SPEED SENSOR
PIECE A LEVER Replace. @ CLUTCH HOUSING
@ SUPER LOW SHFT @ SUPER LOW SHIFT @) OIL GUIDE PLATE @ THRUST SHIM
PIECE A PIECE B @) 75 mm THRUST SHIM Selection, page 13-106
@ 1 ST /2ND SHIFT FORK @ 3 x 16mm SPRING PIN Selection, page 13-134 @ TRANSFER ORIVE GEAR
@ 80mm SNAP RING Replace. @) BALL BEARING @ BEARING INNER RACE
@ DIFFERENTIAL ASSEMBL Y @ SUPER LOW SHIFT FORK @) 5TH SYNCHRO SLEEVE @ BEARING OUTER RACE
See section 1 5 SHAFT @ 5TH SYNCHRO HUB @ 0-RING Replace.
(2) 60mm SNAP RING @ LOCK WASHER Replace. @ SYNCHRO SPRING @) TRANSFER THRUST SHIM
@ LOCKNUT Replace. @ SUPER LOW SHIFT FORK @ SYNCHRO RING Selection, page 13-106
110-+0-+ 110N·m @ 47 mm THRUST SHIM @ 5TH GEAR @) TRANSFER L. SIDE
11.0-+0-+ 11.0kg-m, Selection, page 13-137 @ 35 x 40 x 26mm NEEDLE COVER
80-+ O-+ 801b-ft @ BALL BEARING (6204) BEARING @) SELECT SLEEVE
@ SPRING WASHER @ SPACER COLLAR @ SPACER COLLAR @) TRANSFER SPACER
@ BALL BEARING @ 28 x 34 x 35mm @ 4TH GEAR COLLAR
@ 5TH GEAR NEEDLE BEARING @ SYNCHRO RING @DOWEL PIN A
@ 4TH GEAR @ FRICTION DAMPER @ SYBCHRO SPRING @) TRANSFER HOUSING
@ 3RD GEAR @ SUPER LOW 2ND GEAR @) 3RD/4TH SYNCHRO @)SPRING
@ 3ND GEAR @ SYNCHRO RING SLEEVE @STEEL BALL
@ 44 x 50 x 24mm @ SYNCHRO SPRING @ 3RD/4TH SYNCHRO HUB @) SELECT FORK
NEEDLE BEARING @ SUPER LOW SYNCHRO @) 3RD GEAR @DOWEL PIN B
@) SPACER COLLAR SLEEVE @ MAINSHAFT @) 35 x 54 x 8mm OIL SEAL
Selection, page 13-125 @ SUPER LOW SYNCHRO @ SPRING WASHER Repalce.
@ FICTION DAMPER HUB @ BALL BEARING @ TRANSFER DRIVEN GEAR
@ SYNCHRO RING @) SUPER LOW 2ND SHAFT @ 28 x 41 x 7mm OIL SEA @ BEARING INNER RACE
@ SYNCHRO GEAR ® BALL BEARING Replace. (@ BEARING OUTER RACE
@) REVERSE GEAR @) THRUST WASHER @) MAGNET @ TRANSFER SPACER
@ 1ST/2ND SYNCHRO HUB @) 28 x 34 x 35mm THRUST @) REVERSE IDLER GEAR @ 0-RING Replace.
@ 1ST GEAR NEEDLE BEARING SHAFT @ DRIVEN GEAR THRUST
@ THRUST SHIM @ SPACER COLLAR @) REVERSE IDLER GEAR SHIM
Selection, page 13-1 25 @) SUPER LOW 1 ST GEAR @ SPRING PIN Replace. _ Selection, page 13-106
@ SUPER LOW 3RD GEAR @) SPACER COLLAR @ LOCK COLLAR @ TRANSFER REAR COVER
@ COUNTERSHAFT ® THRUST WASHER (@ REVERSE SHIFT HOLDER @ THRUST WASHER
@) 44 X 50 X 24mm ® SPRING WASHER @ SUPER LOW SHIFT @ BEARING OUTER RACE
NEEDLE BEARING @) SPACER COLLAR PIECE BAR @) BEARING INNER RACE
@ OIL GUIDE PLATE @) 2.5 x 10mm SPRING PIN @ STEEL BALL @ 38 x 60 x 1 1 mm
@ BEARING OUTER RACE Replace. @ SPRING OIL SEAL Replace.
@ BEARING INNER RACE @ SUPER LOW 1ST SHAFT @ SPRING COLLAR @ COMPANION FLANGE
@) 28 x 34 x 35mm @) 5TH/REVESE SHIFT @ REVERSE SHIFT FORK @) TRANSFER DUST COVER
NEEDLE BEARING FORK @ 8 x 14 mm DOWEL PIN @SPRING WASHER
@ TRANSFER SHAFT @) 5TH SHIFT FORK @ 14 x 20 mm DOWEL PIN @ LOCKNUT Replace.
@ TRANSFER DRIVEN GEAR @ 3RD/4TH SHIFT FORK @ 2-4 SELECT LEVER @ 28mm WASHER
@ STOPPER BOL T @WASHER
13-97
Shift Arm Cover
Disassembly ---------------------------
1. Remove the shift arm cover. 3. Removethe back-up light switch, set bolts, springs,
and steel balls.
4. Remove the reverse lock cam.
REVERSE LOCK CAM
SET BOLTS BACK-UP LIGHT SWITCH

2. Remove the bolt and shift lever.
5. Removethe 18mm plug and inter lock, then remove

the shift arm shaft, shift arm A, retainer, and spring.
I
RETURN SPRING INTERLOCK
RETAINER
INTERLOCK BOL T 18mm PLUG

40N·m (4.0kg-m, 301b-ft) 40N·m (4.0kg-m, 301b-ft)
13-98
Reassembly .....,.......---------.
6. Remove the spring pin, then remove the select arm 1. lnstall the new oil seals in the shift arm cover
and select lever.
7. Remove the stopper bolt and shift lever.
SHIFT ARM COVER

PIN DRIVER, 5.0 mm
07744-0010400
5 x 25mm SPRING PIN

Replace.
OIL SEAL
Replace.
2. lnstall the select lever and select arrn, then install

the spring pin.
3. lnstall the shift arm with the stopper bolt,
PIN DRIVER, 5.0 mm

07744-0010400
5 x 25mm SPRING PIN

SHIFT ARM COVER Replace.
SELECT LEVER
SHIFT ARM COVER
STOPPER BOLT
12N ·m 11.2kg-m, 91b-ft) (cont'd)
13-99
Shift Arm Cover
Reassembly (cont'd)
4. Set the shift arm A into the interlock, then install it 9. lnstall the shift lever and breather cap.
to the shift arm cover.
NOTE: Align the punch mark on the shift lever with
5. lnstall the retainer and spring, then install the shift the one on shift arm A.
arm shaft. PUNCH MARKS
BREA THER CAP
6. lnstall the interlock bolt by align the bolt in the groove
of the interlock, then install the 18 mm plug. El
NOTE: Apply liquid gasket to the thread of the in-
terlock and 18 mm plug.
RETURN SPRING
~ RETAINER INTERLOCK
SHIFT ARM SHAFT
I 1 O. Apply liquid gasket to the transmission mating sur-

face of the shift arm cover, then install the shift arm
r
INTERLOCK BOL T
cover.
40 N·m (4.0 kg-m, 30 lb-ft)

the majar housings,use HondaGenuineliquid gasket
7. lnstall the reverse lock cam. (P/N 08718-0001 ). Assemble the housing within
8. lnstall the steel balls, springs, set bolts, and low it to cure at least 30 minutes after assembly be-
back-up light switch. fare filling it with oil.
6 x 1.0 mm REVERSE LOCK CAM

15 N·m (1.5 kg-m, 11 lb-ftl
SET BOLT
22 N·m 2.2 kg-m, 16 lb-ftl

25 N·m (2.5 kg-m, 18 lb-ftl
13-100
Transfer
lnspection ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~--,
Backlash Gear Tooth Contact
1. Set the disengagement lever in 2WD. 1. Place the disengagement lever in 2WD.
DISENGAGEMENT LEVER 2. Removethe transfer gear assembly from the clutch

housing.
ORIVE GEAR
THRUST SHIM
2. Using a dial indicator, measurethe backlash twice;

once at the top of the companion flange, then ro- ASSEMBLY
tate the companion flange 180° and measure it in
the same way. 3. Apply Prussian Blue to the driven gear teeth
evenly and reinstall it.
Standard: 0.10-0.15 mm (0.004-0.006 in)
4. Torque the gear holder mounting bolts.
DIAL INDICATOR
5. Turn the companion flange, then note tooth im-
pression on the drive gear at more than three
teeth.
-r».
GOOD CONTACT
COMPANION FLANGE
lf the pattern is too high or too low, correct as

per instructions described on page 13-11 3.
lf the backlash is outside the specifications, ad-
lf the tooth contact is correct, reassemblethe
just as per instructions described on page
drive gear assembly using new 0-ring
13-106.
13-101
Transfer
Drive/Driven Gear Reassembly -----. L. Side Cover Race Replacement
1. Set the disengagernent 2WD. NOTE: The outer race should be replaced with the bear-
ing as a set.
2. Rernovethe L. side cover and driven gear assembly
rnounting bolts, then remove the transmission dust 1. Remove the drive gear bearing race using a bear-
cover. ing puller as shown.
3. Rernove the L. side cover, transfer thrust shim, and

0-ring.
4. Remove the drive gear and drive gear thrust shim.
5. Rernovethe driven gear assembly, driven gear thrust

shirn, and 0-ring.
2. lnstall the bearing outer race using the special tools.
OUTER HANDLE A
07749-0010000
8 x 1.25 mm
26 N·m (2.6 kg-m, 20 lb-ftl
OUTER DRIVER.
62 x 68 mm
07746-0010500
L. SIDE COVER
13-102
Transfer Driven Gear Disassembly -------------------.
1. lnstall the driven gear assemblyinto the clutch hous- 4. Remove the companion flange from the driven
ing, tighten the bolts. gear shaft.
8 x 1.25 mm
26 N·m (2.6 kg-m, 20 lb-ftl 5. Removethe driven gear from the transfer rear
cover by tapping the driven gear shaft.
"/ DRIVEN GEAR
DRIVEN GEAR ASSEMBL V
2. Hold the companion flange using a special tool,

then remove the locknut with a 32 mm socket.
6. Remove the taper roller bearing from the driven
gear shaft using a bearing puller.
DRIVEN GEAR
T APER ROLLER
FLANGE HOLDER
07926-5090000
3. Removethe driven gear assembly. (cont'd)
13-103
Transfer
Transfer Driven Gear Disassembly Driven Gear Preload Adjustment -
(cont'd)
7. Remove the oil seal. NOTE: Cleanali tools and parts thoroughly in solvent and
dry with compressed air.
1. lnstall the bearing outer race using the special

tools.
OUTER DRIVER,
8. Remove the bearing outer races and washer from

the transfer rear cover.
2. lnstall the washer and bearing outer race using

the special tools.
OUTER DRIVER,
OUTER HANDLE A
07749-0010000
WASHER
BEARING OUTER RACE
3. Lubricate the races with clean gear oil.
13-104
4. lnstall the taper roller bearing onto the Driven Gear 7. Hold the dummy shaft by inserting the end of a
Dummy Shaft, then install the Driver Gear Dummy screwdriver into the hole in the shaft, then torque
Shaft in the transfer rear cover. the 22 mm locknut to about 1 O N·m ( 1 .O kg-m, 8
lb-ft).
DRIVEN GEAR DUMMY SHAFT
07 JAJ-PH80200
T APER ROLLER BEARING / DRIVER
I
REAR COVER
22 mm LOCKNUT
10 N·m (1.0 kg-m, 8 lb-ft)
8. Turn the companion flange several times to assure

normal bearing contact.
9. Measure preload using a torque wrench.
Standard: 0.5-0.8 N·m

(5.0-8.0 kg-m, 4.3-6.9 lb-in)
5. lnstall the taper roller bearingonto the dummy shaft.
6. lnstall the companion flange, spring washer, and 22

mm locknut on the dummy shaft
NOTE:
• Use a new 22 mm locknut.
• Do not install the oil seal.
• lnstall the lock washer with the dished side
toward the transfer rear cover.
1 O. lf the preload is outside the above limits, readjust

by turning the locknut.
NOTE: Do not overtighten the locknut.
13-105
Transfer
Thrust Shim Selection ---------------------------.
1. Remove the taper roller bearing using special tool. 4. lnstall the L. side cover without the bolts.
5. To determine driven gear thrust shim thickness, ro-

tate the companion flange several times to seat the
BEARING RACE REMOVER
T APEA ROLLER BEARING 07KAF-PS30200 bearings, measure the clearance between the trans-
\ !
fer rear cover and transfer case at several locations
with a feeler gauge, then record the average.
NOTE: The clearance should be taken while press-

ing the dummy shaft all the way in.
ORIVE GEAR
2. lnsert the dummy shaft assembly into the transfer

housing.
3. Lubricate the taper roller bearing with clean gear oil,

then install it on the Orive Gear Gauge. lnstall the
bearing and gauge onto the transfer shaft.
NOTE:
• Do not install the drive gear thrust shim.
• Pull the dummy shaft assembly out slightly to al-
low the drive gear gauge to seat.
FEELER GAUGE
TRANSFER REAR
COVER
6. The correct shim thickness is determined by record-
ing the average clearance between the transfer rear
cover and the transfer case, then adding to subtract-
ing the machining tolerance, which is etched in to
the driven gear .
. ~ DRIVEN GEAR
NOTE: The number on each pinion is plus ( +) or mi-
nus (-) tolerance in hundredth's of the a millimeter.
'DUMMY SHAFT
07JAJ-PH80200
Example 1:
TAPER ROLLER BEARING • Clearance measured in Step 5: 1.08 mm
• Machining tolerance etched in the driven gear:
(+2)
Corrected shim thickness:

1 .08 + 0.02 = 1. 1 O mm
Example 2:
• Clearance measured in Step 5: 1 .08 mm
(-3)
Corrected driven gear thrust shim thickness:

1.08 - 0.03 = 1.05 mm
13-106
ETCHED MARK
8. The correct shim thickness is determined by record-
THICKNESS MARK ing the clearance between the transfer case and the
L. side cover, then adding or subtracting the machin-
ing tolerance, which is etched into the drive gear.
Example 1:
• Machining tolerance etched in the drive gear:
(+2)
Corrected shim thickness:

1.04 + 0.02 = 1.06 mm
Driven Gear Thrust Shim
Example 2:
PART NUMBER THICKNESS • Clearance measured in Step 7: 1.04 mm
1 29481-PH8-000 0.50 mm (0.0197 in) • Machining tolerance etched in the drive gear:
(-1)
2 29482-PH8-000 0.85 mm (0.0335 in)
3 29483-PH8-000 0.90 mm (0.0354 in) Corrected driven gear thrust shim thickness:
4 29484-PHS-OOO 0.95 mm (0.0374 in) 1.04 - 0.01 = 1.03 mm
5 29485-PHS-OOO 1.00 mm (0.0394 in)
6 29486-PHS-OOO 1 .05 mm (0.0413 in)
7 29487-PHS-000 1. 1 O mm (0.0433 in)
TOLERANCE MARK
8 29488-PHS-OOO 1. 15 mm (0.0453 in)
9 29489-PH8-000 1.20 mm (0.0472 in)
10 29491-PH8-000 1.25 mm (0.0492 in)
11 29492-PHS-OOO 1.30 mm (0.0512 in)
7. To determine the L. side cover thrust shim thickness

measure the clearance between the transfer L. side
cover and transfer case at several locations with a
feeler gauge, and record the average.
Transfer Thrust Shim
NOTE: The clearance should be measured while
pressing the L. side cover all the way against the PART NUMBER THICKNESS
transfer case. 1 29461-PH8-901 0.30 mm (0.0118 in)
2 29462-PHS-901 1.00 mm (0.0394 in)
3 29463-PH8-901 1 .03 mm (0.0406 in)
4 29464-PH8-901 1.06 mm (0.0417 in)
5 29465-PH8-901 1.09 mm (0.0429 in)
6 29466-PHS-901 1.12 mm (0.0441 in)
7 29467-PHS-901 1. 1 5 mm (0.0453 in)
8 29468-PHS-901 1. 18 mm (0.0465 in)
9 29469-PH8-901 1.21 mm (0.0476 in)
10 29471 -PHS-901 1.24 mm (0.0488 in)
11 29472-PHS-901 1 .27 mm (0.0500 in)
12 29473-PH8-901 1.30 mm (0.0512 in)
13 29474-PHB-901 1 .33 mm (0.0524 in)
(cont'd)
13-107
Transfer
Thrust Shim Selection (cont'd) -------------------
9. lnstall two 1. 75 mm "dummy" shims (P/N 11 . lnstall the drive gear onto the transfer shaft.
29415-PHB-OOO) on the transfer shaft.
1 2. Place the shim selected in Step 7 on the l. side
cover, then install the cover on the transfer case.
DUMMY SHIMS
TRANSFER SHAFT
TRANSFER THRUST SHIM

L. SIDE COVER
1 O. Press the taper roller bearing on the drive gear.
1 3. Rotate the companion flange severa! times to seat

the bearings, measurethe clearancebetween the l.
side cover and transfer case at severa! locations
while pushing against the l. side cover, and record
the average.
INNER HANDLE C
.-..--.-- 0774-0030100
ORIVE GEAR
INNER DRIVER. 35 mm
07746-0030400 FEELER GAUGE
13-108
Driven Gear Reassembly ------
14. Subtract the clearancemeasuredin Step 13 from 3. 5 1. Removethe driven gear dummy shaft from the trans-
mm to obtain the correct shim thickness. fer rear cover.
Example:
• Clearance measured in Step 13: 1.57 mm DRIVEN GEAR DUMMY SHAFT
-.___.....,, 07JAJ-PH80200
• Thickness of dummy shims: 3.5 mm
Corrected drive gear thrust shim:

1.57 + 3.5 = 1.93 mm thickness
Thrust Shim

29411-PH8-000 0.48 mm (0.0189 in)
29412-PHB-OOO 1.57 mm (0.0618 in) ~-- COMPANION FLANGE
"==-
29413-PHB-OOO 1.63 mm (0.0642 in)
29414-PHB-OOO 1.69 mm (0.0665 in)
29415-PHB-OOO 1. 75 mm (0.0689 in)
2. lnstall the oil seal using the special tools into the
29416-PH8-000 1.81 mm (0.0713 in)
transfer rear cover.
29417-PH8-000 1.87 mm (0.0736 in)
29418-PH8-000 1 .93 mm (0.0760 in)
Oll SEAL DRIVER
29419-PH8-000 1.99 mm (0.0783 in)
07JAD-Pl90100
3. Coat the main and side sealinglips of the oil seal with
grease.
(cont'd)
13-109
Transfer
Driven Gear Reassembly (cont'd) -------------------
4. lnstall the taper roller bearing on the drive gear. 6. Temporarily install the drive gear assembly and
mounting bolts in the transfer case.
INNER HANDLE C
0774-0030100
ORIVE GEAR
TAPER ROLLER BEARING

7. Tighten the locknut to the specified torque.
5. lnstall the following parts in the transfer rear cover; Torque: 120 N·m (12 kg-m, 87 lb-ftl
• Drive gear
• Transfer spacer (new spacer)
• Companion flange
• Spring washer
• 22 mm locknut
NOTE: lnstall the spring washer with the dished side

toward the companion flange.
THRUST SHIM
E>
~ COMPANION FLANGE
~JN..,.Ut-T--- SPRING WASHER

FLANGE HOLDER
07926-8090000
13-11 O
Drive/Driven Gear Reassembly---,
8. Remove the drive gear assembly from the transfer 1. Apply liquid gasket to the clutch housing mating sur-
case, and measure the preload. face of the transfer case.
NOTE: Before measuring the preload, rotate the NOTE: This transmission uses no gasket between
companion flange severa! times to assure normal the major housings; use HondaGenuineliquid gasket
bearing contact. (P/N 08718-0001 ). Assemble the housing within
Preload: 0.8-1.1 N·m low it to cure at least 30 minutes after assembly be-
(8.0-11.0 kg-cm, 7.0-9.5 lb-in) fore filling it with oil.
2. lnstall the transfer case on the clutch housing.
NOTE: lf the preloadexceeds 1.1 N·m (11.0 kg-cm,

9. 5 lb-in). replacethe transfer spacer with a new one
and readjust. Do not try to adjust the preload by
loosening the locknut.
9. lf the preload is less than 0.8 N-m (8 kg-cm, 7 lb-

in), adjust by turning the locknut in a little atan time. TRANSFER CASE
NOTE: Replacethe transfer spacer with a new one

if the preload is still outside the above limits when
the locknut is tightened to 230 N·m (23 kg-m, 166
lb-ft).
10x 1.25mm
45 N·m (4.5 kg-m, 33 lb-ft)
(cont'd)
13-111
Transfer
Drive/Driven
Gear Reassembly (cont'd)----------------
3. lnstall the following parts in and on the transfer case 5. Measure the total bearing preload;
and shaft;
a. Rotate the companion flange severa!times to as-
- transfer thrust shim sure normal bearing contact.
- drive gear (lubricant with clean gear oil) b. Set the disengagement lever in 2WD.
- drive gear thrust shim c. Measure the preload with a torque wrench.
- L. side cover and bolts
The total bearing preload should be O. 7 -1.0
N·m (7.0-1 O.O kg-cm, 6.1-8. 75 lb-in) greater
ORIVE GEAR THRUST SHIM than the preload on the driven gear assembly
alone (see page 13-109, step 8).
Example:
lf the preload of the driven gear assembly alone
10 x 1.25 mm / was 0.9 N·m (9 kg-cm, 7.9 lb-in), the total bear-
45 N·m (4.5 kg-m,
33 lb-ft)
ing preload should be between 1.6 N·m (16 kg-
_v.;;_--...·--,.,,..._, cm, 14 lb-in) and 1.9 N·m (19 kg-cm, 16 lb-in)
OISENGAGEMENT LEVER
Replace.
L. SIOE COVER
4. lnstall the following parts;
- driven gear thrust shim

- driven gear assembly and bolts
6. lf the preload is outside of the specifications, ad-

just if by replacing the transfer thrust shim.
• lf the total bearing preload is lessthan the specifi-

cation, reducethe size of the transfer thrust shim.
• lf the total bearing preload exceeds the specifi-
cation, increase the size of the transfer thrust
shim.
ORIVEN GEAR ASSEMBL Y
13-112
7. After the bearing preload has been adjusted proper- e . lf the backlash is outside the specifications, ad-
ly, measure the gear backlash. just by changing the driven gear and drive gear
thrust shims.
a. Place the disengagement lever in 2WD.
DISENGAGEMENT LEVER
.& ORIVEN GEAR

• THRUST SHIM
/
b. Using a dial indicator, measure the backlash at
the top of the companion flange, then rotate the 8. Check for proper tooth contact after the backlash
companion flange 180° and measure again. adjustment has been completed.
Backlash: 0.10-0.15 mm (0.004-0.006 in) a . Removethe driven gear assembly from the trans-
fer case, and coat the driven gear teeth evenly
with Prussian Blue.
b. Reinstallthe driven gear assembly in the transfer
case and tighten the bolts to the specified torque.
e. With the disengagement lever in 2WD, rotate the
companion flange one full turn in both directions.
DIAL INDICA TOR
COMPANION FLANGE
(cont'd)
13-113
Transfer
Drive/Driven
GearReassembly
(cont'd)----------------
d . Removethe driven gear assemblyfrom the trans-
fer case and note the tooth impression on the
gear.
NOTE: Compare the tooth impression of the gear

with the examples below and fallow the appropri-
ate adjustment instructions.
Continue the check and adjustment procedureuntil
the tooth contact is correct.
DRIVEN GEAR
THRUST SHIM
I Í
I CORRECT TOOTH CONTACT I I
¡~:
1 '
1 1
I~'
HEEL CONTACT
~----------------J1
'
lf the pattern shows heel contact, it indicates too

IMPROPER TOOTH CONTACT much backlash. To correct, reduce the thickness of
the drive gear thrust shim. The thickness of the
TOF CONTACT FLANK CONT ACT
transfer thrust shim must also be reduced by the
amount by which the drive gear thrust shim thick-
ness is reduced.
NOTE: The driven gear thrust shim will have to be

changed also to compensate far the change in
backlash.
HEEL CONT ACT

HEEL CONTACT FACE CONT ACT
TOE CONTACT
t
TRANSFER THRUST SHIM ORIVE GEAR THRUST SHIM
lf the pattern shows toe contact, use a thicker drive
gear thrust shim and increase the thickness of the
transfer thrust shim an equal amount.
TOE CONTACT
DRIVEN GEAR
• THRUST SHIM
13-114
FACE CONT ACT TRANSFER THRUST SHIM
To correct tace contact, use a thicker driven gear

thrust shim to move the driven gear away from the
drive gear.
\ ORIVE GEAR THRUST SHIM
The backlash should remain within the limits.
lf the backlash cannot be held within the limits (page

13-11 3), make correction in the same manner as for
ORIVEN GEAR
HEEL CONTACT.
THRUST SHIM
FACE CONTACT
ORIVE GEAR THRUST SHIM

9. After the correct gear tooth contact, remove the
transfer drive and driven gears.
1 O. Apply liquid gasket to the clutch housing and trans-

fer case mating points on the driven gear mating
surface.

the major housings; use Honda Genuineliquid gasket
(P/N 08718-0001 ). Assemble the housing within
low it to cure at least 30 minutes after assembly be-
FLANK CONTACT
lf the pattern shows flank contact, move the driven

gear in toward the drive gear by using a thinner shim
for the driven gear.
The backlash must remain within the limits.
lf the backlash exceeds the limits ( 13-113), make

correction in the same manner as for TOE
CONTACT.
FLANK CONT ACT
Apply liquid gasket to mating surfaces of

clutch and transfer housing.
(cont'd)
13-115
Transfer
Drive/Driven Gear Reassembly {cont'd) -----------------,
1 1 . lnstall the thrust shim and a new 0-ring on the driven 14. lnstall the transfer dust cover.
gear assembly, then install the assemblyin the trans-
fer case. 15. Measure the total bearing preload after assembly.
12. lnstall the drive gear thrust shim and drive gear onto
the transfer shaft.
13. Place the transfer thrust shim and 0-ring on the L.

side cover and install them on the transfer case.
NOTE:
• Lubricant a new 0-ring with gear oil.
• Apply liquid gasket (P/N 08718-0001 l to the
threads.
ORIVE GEAR THRUST SHIM
0-RING
10 x 1.25 mm
45 N·m (4.5 kg-m, 33 lb-ftl
Replace.
8 x 1.25 mm
26 N·m (2.6 kg-m, 19 lb-ftl
8 x 1.25 mm
TRANSFER DUST COVER 26 N·m (2.6 kg-m, 19 lb-ft)
13-116
Rernoval~~~~~~~~~~~~~~~~~~~~~~~~~~~~~-,
NOTE: Placethe clutch housing on two piecesof wood 4. Removethe 32 mm sealing bolt.
thick enough to keep the mainshaft from the hitting the
workbench. 5. Expandthe snap ring on the countershaft ball
bearing and remove it from the groove using a
1. Removethe set bolt, spring, and steel ball. pair of snap ring pliers.
2. Removethe super-low shift lever bolt and reverse

idler shaft bolt.
REVERSE IDLER GEAR SHAFT BOLT 32 mm SEALING BOLT
SNAP RING
SET BOLT
3. Removethe transmission attaching bolts.

6. Separatethe transmission housing from the
clutch housing and wipe if clean of the sealant.
7. Removethe thrust shim, oil guide plate, and

super-low 2nd shaft thrust shim from the trans-
mission housing.
MAINSHAFT THRUST SHIM
SUPER-LOW 2NO SHAFT

THRUST SHIM ~
I .
13-117
Reverse Shift Fork
Clearance lnspec~on~~~~~~~~~~~~~~~~~~~~~~~~~
1. Measurethe clearancebetween the reverseshift fork 3. Measurethe clearancebetween the reverseidler gear
and Sth/reverse shift piece pin. and reverse shíft fork.
Standard: 0.05-0.35 mm Standard: 0.5-1.1 mm (0.020-0.043 in)

(0.002-0.014 in) Service Limit: 1.8 mm (0.071 inl
Service Limit: r0.5 mm (0.020 in)
5TH/REVERSE SHIFT PIECE REVERSE SHIFT FORK
REVERSE SHIFT FORK
2. lf the clearance exceed the service lirnit, measure

the width of the groove in the reverse shift fork.
Standard: 7.05- 7.25 mm

(0.278-0.285 in) 4. lf the clearance exceeds the servíce limít, measure
the width of the reverse shift fork pawl groove.
(0.512-0.524 in)

replace the reverse shift fork 'with a new one.
replace the 5th/reverse shíft piece with a new one.

lf the wídth is within the standard, replace the
13-118
Mainshaft, Countershaft
Rernoval~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~--.
1. Remove the reverse idler gear and shaft from the 3. Remove the following parts, in the order shown,
clutch housing. from the clutch housing.
G) SPECIAL BOL T
@LOCK PLATE
@ 5TH/REVERSE SHIFT FORK SHAFT
@ 5TH SHIFT FORK
-.
REVERSE IDLER GEAR @ 3RD/4TH SHIFT FORK
@ REVERSE SHIFT FORK
2. Remove the following parts, in the order shown,

from the reverse shift holder assembly.
G) 1ST/2ND SHIFT FORK SHAFT

@ SUPER-LOW SHIFT PIECE BAR
@ SUPER-LOW SHIFT LEVER
@) SUPER-LOW SHIFT PIECE A
@ 1 ST /2ND SHIFT FORK
4. Removethe reverse shift holder assembly from the

clutch housing.
r
®
I
1
1
® @
©
®
(cont'd)
13-119
Mainshfat, Countershaft
Removal
(cont'd)--------------------------.
5. Rernovethe following parts from the clutch housing., 6. Removethe mainshaft and countershaft assemblies
and super-low 2nd shaft from the clutch housing.
G) SUPER-LOW SHIFT FORK SHAFT ASSEMBL Y
@ BALL BEARING
@ SPACER COLLAR
@ NEEDLE BEARING COUNTERSHAFT ASSEMBL Y
/
@ FRICTION DAMPER
@ SUPER-LOW 2ND GEAR
(J) SYNCHRO RING
@ SYNCHRO SPRING
@ SUPER-LOW SYNCHRO SLEEVE
@) SUPER-LOW SYNCHRO HUB
@ THRUST WASHER MAINSHAFT
ASSEMBLY
@ THRUST NEEDLE BEARING
@ SUPER-LOW 1 ST GEAR
@ NEEDLE BEARING
@ SPACER COLLAR
@ NEEDLE BEARING
@ THRUST WASHER
@) SPRING WASHER
@) SPACER COLLAR
@ SUPER-LOW 1 ST SHAFT
7. Remove the taper roller bearing from the transfer

shaft.
8. Remove the differential assembly from the clutch

housing.
DIFFERENTIAL ASSEMBL Y T APER ROLLER BEARING
SUPER-LOW 2ND SHAFT
r·
13-120
Mainshaft Assembly
·lndex~~~~~~~~~~~~~~~~~~~~~~~~~~~~-
NOTE: After assembled, check the operation of the 3rd/4th synchro hub set.
SYNCHRO SPRING
I BALL BEARING .
.,,....- lnspect for wear or operation.
3RD GEAR
lnspection,
page 13-122
NEEDLE BEARING 5TH GEAR

lnspect for wear lnspection, page 13-123
or operation.
MAINSHAFT
lnspection, page 13-1 23
- SPACER COLLAR
Selection, paga 13-122
3RD/4TH SVNCHRO SLEEVE
-- 3RD/4TH SYNCHRO HUB
STOPPER
13-121
Mainshaft Assembly
Clearance lnspe~ion~~~~~~~~~~~~~~~~~~~~~~~~-
NOTE: lf replacement is required, always the synchro 3. Measure the clearance between 4th gear and the
sleeve and hubs as a set. spacer collar.
1. Push down on the bearing inner race about 30 kg Standard: 0.06-0.21 mm

(66 lb) using a socket wrench, then measure the (0.002-0.008 in)
clearance between 2nd and 3rd gears. Service Limit: 0.3 mm (0.012 in)
(0.002-0.008 in)

(1.025-1.027 in)
the thickness of 3rd gear.
®
....- 4TH GEAR SIDE
Standard: 34.92-34.97mm
(1.375-1.377in)
Service Limit: 34.3 mm (1.350 in) 1 1
5. lf distance ®is more than the service limit, replace

lf distance ® is within the service lirnit, measure
the thicknes sof 4th gear.
(1.217-1.219 in)

limit, replace 3rd gear with a new one.
lf the thickness of 3rd gear is within the service limit,
13-122
lnspection------------,
6. measure the clearance between 5th gear and the 1. lnspect the surface and bearing surface for wear or
spacer collar. damage, then measure the mainshaft at points A,
Standard: 0.06-0.21 mm B, and C.
(0.002-0.008 in)
Service Limit: 0.3 mm (0.012 in) Standard: A: 27.977-27.999 mm
(1.1015-1.020 in)
B: 34.984-35.000 mm
(1.3773-1.3780 in)
C: 27.987-28.000 mm
(1.1018-1.1024 in)
Service Limit: A: 27.920 mm (1.0992 in)
B: 34.930 mm (1.4933 in)
C: 27.930 mm (1.0996 in)
lnspect oil passages for clogging.
5TH GEAR
7. lf the clearance exceeds the service limit, measu re

distance B on the spacer collar.
(1.025-1.027 in)
lnspect for wear
Service Limit: 26.01 mm (1.024 in) or damage.
lf any part of the mainshaft is less than the service
r
1
1
5TH GEAR SIDE 2. lnspect for runout.

<, @
Standard: 0.02 mm (0.001 in)
Service Limit: O.OS mm (0.002 in)
8. lf distance@ is more than the service limit, replace
the spacer collar with a new one. NOTE: Support the mainshaft at both ends as
lf distance @ is within the service limit, measure shown.
the thickness of 5th gear.
(1.198-1.120 in)
lf the thickness of 5th gear is less than the service lf the runout exceeds the service limit, replace the
limit, replace 5th gear with a new one. mainshaft with a new one.
replacethe 5th/reverse synchro hub with a new one.
13-123
lndex~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
NOTE: The 5th gears are installed with a press.
, Prior to reassembling,clean all the parts in solvent, dry them and apply lubricant to any contact surfaces.
LOCKNUT
Replace.
110-+0-+ 11O N·m
(11-+0-+11 kg-m,
/ 80-+0-+80 lb-ft)
/ J3 mm SPRING WASHER
SYNCHRO RING
BALL BEARING
lnspect for wear
or operation.
1ST GEAR
~~~~
NEEDLE BEARING
lnspect for wear
or operation.
----,.HRUST SHIM
u:J
Selection, page 1 3-1 2 5
~ SUPER-LOW 3RD GEAR

NEEDLE BEARING
SPACER COLLAR
COUNTERSHAFT Selection, page 13-1 2 5
----- lnspection, page 13-126
FRICTION DAMPER
SYNCHRO RING
........_ REVERSE GEAR
1ST/2ND SYNCHRO HUB
13-124
Clearance lnspection --------------------------
1. Measurethe clearancebetween the super-low 3rd 1. Measure the clearance between the 2nd and 3rd
gear and thrust shim. gears.
Standard: 0.03-0.08 mm Standard: 0.03-0.08 mm

(0.0012-0.0031 in) (0.0012-0.0031 in)
2ND GEAR
2. lf the clearanceexceedsthe service limit, select the 2. lf the clearanceexceedsthe service limit, select the
appropriate thrust shim for the correct clearance appropriate spacer collar for the correct clearance
from the chart below. from the chart below.
PART NUMBER THICKNESS PART NUMBER THICKNESS
A 23921-PH5-900 1.95 mm (0.0768 in) A 23911-PK-500 29.03-29.05 mm (1.1429-1.1437 in)
B 23922-PH5-900 1.96 mm (0.0772 in) B 2391 2-PK-500 29.01-29.03 mm (1.1421-1.1429 in)
e 23923-PH5-900 1.97 mm (0.0776 in)

e 23913-PK-500 28.99-29.01 mm (1.1413-1.1421 in)
D 23914-PK-500 28.97-28.99 mm (1.1405-1.1413 in)
o 23924-PH5-900 1 .98 mm (0.0780 in)
E 23915-PK-500 28.95-28.97 mm (1.1400-1.1405 in)
E 23925-PH5-900 1 .99 mm (0.0783 in)
F 23926-PH5-900 2.00 mm (0.0787 in)
G 23927-PH5-900 2.01 mm (0.0791 in)
H 23928-PH5-900 2.02 mm (0.0795 in)
1 23929-PH5-900 2.03 mm (0.0799 in)
J 23930-PH5-900 2.04 mm (0.0803 in)
K 23931-PH5-900 2.05 mm (0.0807 in)
L 23932-PH5-900 2.06 mm (0.0811 in)
M 23933-PH5-900 2.07 mm (0.0815 in)
N 23934-PH5-900 2.08 mm (0.0819 in)
o 23935-PH5-900 2.09 mm (0.0823 in)
p 23936- PH5- 900 2.1 O mm (0.0827 in)
13-125
Disassembly ----------.... lnspection----------- .....
CAUTION: Remove the gears using a press and steel 1. lnspect the surface and bearing surface for wear
blocks as shown. Use of a jow-tipe puller can damage or damage, then measure the mainshaft at points
the gear teeth. A, 8, and C.
1. Raise the locknut tab from the groove of the shaft Standard: A: 29.000-29.015 mm
and remove the locknut and the spring washer. ( 1 . 1417 -1 . 1423)
B: 30.464-30.480 mm
(1.1994-1.2000 in)
C: 24.987-25.000 mm
l~_C:::L (0.9837-0.9843
Service Limit: A: 28.940 mm (1.1394 in)
in)
B: 30.410 mm (1.1972 in)

~ LOCKNUT
Replace.
C: 24.930 mm (0.9815 in)
lnspect oil passages or damage.
4. Support 4th gear on steel blocks as shown and

press the shaft out of ball bearing. lnspect for wear or damage.
A
lf any part of the countershaft is less than the serv-

ice tirnit, replace it with a new one.
BALL BEARING
Standard: 0.02 mm (0.001 in)
Service Limit:0.05 mm (0.002 in)
NOTE: Support the countershaft at both ends as

shown.
4TH GEAR

countershaft with a new one.
13-126
Countershaft Assembly Transfer Shaft
Reassembly ----------- Replacement
1. lnstall the ball bearing using the special tools and a 1. Remove the 2-4 select lever forrn the clutch
press. housing.
STOPPER BOL T
12 N·m (1.2 kg-m, 9 lb-ftl
BALL BEARING
I
LOCK WASHER
Replace.
6 x 1.0 mm
2. lnstall the spring washer, tighten the locknut, then 1 O N ·m (1.0 kg-m, 8 lb·ftl
stake the locknut tab into groove 2. Removethe 2-4 select fork, 2-4 select sleeve, and
transter spacer collar from the clutch housing.
LOCK NUT
110-+0-+ 100 N·m 3. Removethe transfer shaft, needlebearing,and trans-
(11-+0-+ 11 kg-m, 80-+0-+80 lb-ft) fer driven gear from the transfer side of the clutch
housing.
TAB
NEEDLE BEARING
TRANSFER SHAFT
13-127
Shift Fork, Select Fork
Clearance
lnspection-------------------------
NOTE: The synchro sleeve and synchro hub should be 2. lf the clearance exceeds the service limit, measure
replaced as a set. the width of the shift fork fingers.
1. Measure the clearance between the shift fork and Standard:

synchro sleeves.
SHIFT FORK THICKNESS
Standard: 1ST/2ND 7.4-7.5 mm
3RD/4TH (0.291-0.295 in)
SELECT 5.4-5.5 mm
1 ST/2ND 5TH (0.213-0.217 in)
0.45-0.65 mm
3RD/4TH
(0.018-0.026 in) 7.9-8.0 mm
SELECT SUPERLOW
(0.311-0.315 in)
5TH 0.25-0.45 mm
SUPERLOW (0.010-0.018 in)
Service Limit:

1ST/2ND
3RD/4TH 1 .O mm (0.039 in)
SELECT
5TH
0.8 mm (0.031 in)
SUPERLOW
:t=~,1
SHIFT FORK
lf the width of the shift fork fingers exceedsthe stan-
l dard, replace the shift fork with a new one.
:j * lf the width of the shift fork fingers is within the stan-

dard, replace the synchro sleeve with a new one.
====ill
•
SYNCHRO SLEEVE
13-128
Synchro Ring, Gear
lnspection
1. lnspect the synchro ring and gear. SVNCHRO SPRING
A : lnspect the inside of the synchro ring for wear.
B : lnspect the synchro sleeve teeth and matching

teeth on the synchro ring for wear (rounded off). SVNCHRO RING
GOOD WORN
C: lnspect the synchro sleeve teeth and matching

teeth on the gear for wear (rounded off).
GOOD WORN
D: lnspect the gear hub thrust surface for wear.
E: lnspet the cone surface for wear or roughness.
F: lnspect the teeth on all gears for uneven wear.

scoring, galling, cracks.
2. Coat the cone surface of the gear with oíl and place
Measurethe clearance between the ring and gear all

the way around.

measureing the clearance.
(0.0335-0.0443 in)
Double Cone synchro-to-Gear Clearance

Standard:
A: (Outer Synchro Ring to Synchro Cone)
0.5-1.0 mm (0.0197-0.0394 in)
B: (Synchro Cone to Gear)
0.5-1.0 mm (0.0197-0.0394 in)
C: (Outer Synchro Ring to Gear)
0.95-1.68 mm (0.0374-0.0661 in)
SVNCHRO RING
Service Limit:
A: 0.3 mm (0.0118 in) SVNCHRO CONE
B: 0.3 mm (0.0118 in) A
OUTER SVNCHRO RING
C: 0.6 mm (0.0236 in) e
lf the clearanceexceedsthe serivce limit, replacethe
synchro ring and synchro cone.
3. Separate the synchro ring and gear, then coat them

with oíl.

set it aside for later reassembly.
13-129
lnspection-------------, lnstallation-----------.
1. lnspect gear teeth on all synchro hubs and sleeves Each synchro sleeve has three sets of longer teeth ( 120
for rounded off corners, which indicates wear. degreesapart) that must be matched with the three sets
freedom of movement. NOTE: lnstalling the synchro sleeve with its longer
teeth in the 1 st/2nd synchro hub slots will damage
NOTE: lf replacementis required,always replacethe the spring ring.
SLEEVE LONGER TEETH
HUB
SYNCHRO
SLEEVE
13-130
Replacernent~~~~~~~~~~~~~~~~~~~~~~~~~~~--,
Mainshaft 3. Orive the ball bearing into the clutch housing us-
1. Remove the ball bearing and oil seal.
2. Orive the new oil seal into the clutch housing using
the special tools. OUTER DRIVER, 62 x 68 mm
07746-0010500 OUTER DRIVER A
07749-001000
OUTER DRIVER, 42 x 47 mm BALL BEARING

07746-0010300
\
PILOT DRIVER, 28 mm
OUTER DRIVER A 07746-004110
07749-001000
OIL SEAL
Replace.
(cont'd)
13-131
Replacernent (cont'd}~~~~~~~~~~~~~~~~~~~~~~~~-
Countershaft 3. Drive the needle bearing into the clutch housing us-
1. Remove the needle bearing using the special tools, ing the special tools.
and remove the oil guide plate.
OUTERDRIVERA
07749-0010000
2. lnstall the oil guide plate, and set the bearing onto
the clutch housing. OUTERDRIVER,52 x 55 mm
07746-0010400
/
NOTE: Position the bearing with the hole facing up.
13-132
Super-low 2nd shaft Transfer Shaft
1. Remove the ball bearing using the special tools. 1. Remove the needle bearing using the special tools
ADJUST ABLE BEARING

REMOVER SET
07 JAC-PHSOOOO
2. lnstall the needle bearing using the special tools.
NOTE: Position the bearing with the hole facing up.
2. lnstall the ball bearing using the special tools.
OUTER DRIVER A OUTER DRIVER, 72 x 75 mm

07749-0010000 07746-0010600
OUTER DRIVER, 52 x 55 mm
OUTER DRIVER A 07746-0010400
07749-0010000
<,
13-133
Transmísslon Housing Bearing Mainshaft Thrust Shim
Replacement -----------, Adjustment ----------
1. Remove the bearing outer race using the special 1. Remove the 75 mm thrust shim and oil guide plate
tools. form the transmission housing.
ADJUST ABLE BEARING

REMOVER SET
07 JAC-PH80000
2. lnstall the bearing outer race using the special tools.

2. lnstall the 3rd/4th synchro hub, spacer collar, 5th
synchro hub, ball bearing on the mainshaft. lnstall
the assembly in the transmission housing.
3. Measure the distance ®

between the end of the
transmission housing and mainshaft.
NOTE:
readings.
J
- . @_
I MAINSHAFT
3RD/4TH SYNCHRO HUB
OUTER DRIVER, 37 x 40 mm
07746-0010200 SPACER COLLAR
OUTER DRIVER A
07749-0010000
<,
13-134
4. Measure the distance B between the surfaces of 75 mm Thrust Shim
the clutch housing and bearing inner race.
NOTE: A 23941-PH8-900 1.20 mm (0.0472 in)
• Use a straight edge and feeler gauge. B 23942-PH8-900 1.23 mm (0.0484 in)
readings.
e 23943-PH8-900 1.26 mm (0.0496 in)
D 23944-PH8-900 1.29 mm (0.0509 in)
E 23945-PH8-900 1.32 mm (0.0520 in)
F 23946-PH8-900 1.35 mm (0.0531 in)
L
G 23947-PH8-900 1.38 mm (0.0543 in)
•® H 23948-PH8-900 1.41 mm (0.0555 in)
1
o i
o 1
J
K
23949-PH8-900
23950-PH8-900
23951-PH8-900
1.44
1.47
1.50
mm
mm
mm
(0.0567
(0.0579
(0.0591
in)
in)
in)
e:' L
M
23952-PH8-900
23953-PH8-900
1.53
1.56
mm
mm
(0.0602
(0.0614
in)
in)
N 23954-PH8-900 1.59 mm (0.0626 in)
~
BALL BEARING INNER RACE o 23955-PH8-900 1.62 mm (0.0638 in)
p 23956-PH8-900 1.65 mm (0.0649 in)
Q 23957-PH8-900 1.68 mm (0.0661 in)
R 23958-PH8-900 1.71 mm (0.0673 in)
s 23959-PH8-900 1.74 mm (0.0685 in)
T 23960-PH8-900 1.77 mm (0.0697 in)
u 23961-PH8-900 1.80 mm (0.0709 in)
V 23962-PH8-900 1.83 mm (0.0720 in)
5. Selcet the correct thickness thrust shim as follows; w 23963-PHS-900 1.86 mm (0.0732 in)
X 23964-PHS-900 1.89 mm (0.0744 in)
NOTE: Do not use more than two shims. y 23965-PHS-900 1.92 mm (0.0756 in)
(Basis Formula) z 23966-PH8-900 1.95 mm (0.0768 in)
(A) + (B) - 0.8 == shim thickness AA 23967-PHS-900 1.98 mm (0.0780 in)
AB 23968-PH8-900 2.01 mm (0.0791 in)
Example of calculation; AC 23969-PH8-900 2.04 mm (0.0803 in)
Distance ® (2.45 mm) + Distance@ (0.09 mm) AD 23970-PH8-900 2.07 mm (0.0815 in)
== 2. 14 mm subtract the spring washer height ( 1.00
AE 23971-PH8-900 2. 1 O mm (0.0827 in)
mm) == the required thrust shim ( 1. 74 mm)
AF 23972-PH8-900 2. 13 mm (0.0839 in)
AG 23973-PH8-900 2. 16 mm (0.0850 in)
AH 23974-PHS-900 2.19 mm (0.0862 in)
Al 23975-PH8-900 2.22 mm (0.0874 in)
AJ 23976-PH8-900 2.25 mm (0.0886 in)
AK 23977-PH8-900 2.28 mm (0.0898 in)
AL 23978-PHS-900 2.31 mm (0.0909 in)
AM 23979-PHS-900 2.34 mm (0.0921 in)
AN 23980-PH8-900 2.37 mm (0.0933 in)
(contd)
13-135
Adjustment (cont'd)------------------------,
6. Check the thrust clearance in the manner described b . Attach the mainshaft holder to the mainshaft
below. as follows:
• Back-out the mainshaft holder bolt and
NOTE: loosen the two hex bolts.
• Cleanthe washer, and spring washer, thrust shim • Fit the holder over the mainshaft so its lip
thoroughly before installation. is towards the transmission.
• lnstall the waseher, spring washer, and thrust • Align the mainshaft holder's lip around the
shim properly. groove at the inside of the mainshaft
splines, then tighten the hex bolts.
a. lnstall the shims selected in the transmission MAINSHAFT HOLDER
housing. BOLT
b. lnstall the washer and spring washer in the
HEX ~
mainshaft. BLOTS ~
=-~~ . ~
-í\;t~~MAINSHAFT
~~ "'"HOLDER
~ h 07GAJ-PG20110
~-Je
e . Seat the mainshaft fully by tapping its end
with a plastic hammer.
d . Thread the mainshaft holder bolt in until it just
contacts the wide surface of the mainshaft
c. lnstall the mainshaft in the clutch housing. base.
d. Placethe transmission housing over the main-
shaft and onto the clutch housing. e . Zero a dial gauge on the end of the mainshaft.
e. Tighten the clutch and transmission housings
with several 1 O mm bolts. f. Turn the mainshaft holder bolt clockwise;
stop turnig when the dial gauge has reached
7. Check the thrust clearance in the manner described its maximum movement. The reading on the
below. dial gauge is the amount of mainshaft end
play.
temperature. CAUTION: Turnig the shaft holder bolt more
than 60 degrees after the needle of the dial
a . Slide the mainshaft base and the collar over the gauge stops moving may damage the trans-
mainshaft. mission.
DIAL GAUGE
MAGNET STAND
BASE v'
07979-PG4001 MAINSHAFT HOLDER
07GAJ-PG20110
g . Clearance is correct if reading is between

0.10-0, 16 mm (0.0039-0.0063 in).
13-136
Super-low 2nd Shaft
Thrust Shim
Adjustment----------------------
1. Remove the super-low 2nd shaft thrust shim. 5. Selcet proper shim (or shim pair) on the basis of the
following calculations;
2. lnstall the synchro hub, synchro spring, synchroring
on the super-low 2nd shaft; install the assembly in NOTE: Do not use more than one shim.
a . Add measurement @ in step 3 to the measure-
3. Measure the distance @ between the end of the ment © in step 4.
transmission housing and super-low 2nd shaft.
b. Subtract the 0.07-0.20 mm (0.0027-0.0079
NOTE: in) from the distance in step 5-a.
Example:
B: 0.50 mm (0.0197 in)
readings.
C: + 1.00 mm (0.0394 in)
1. 50 mm (0.0591 in)
Max: 1.50 mm (0.0591 in)

- 0.07 mm (0.0028 in)
1.43 mm (0.0563 in)
Min: 1.50 mm (0.0591 in)

-0.20 mm (0.0079 in)
1.30 mm (0.0512 in)
e. The requiredthrust shim is 1.40 mm (0.0551 in).
~~~~~~~~~-++-. SPACER COLLAR PART NUMBER THICKNESS

l:.:==:~====~-f'--- BALL BEARING A 23750-PHB-900 1 .O mm (0.0394 in)
B 23751-PHB-900 1. 1 mm (0.0433 in)
e 23752-PHB-900 1.2 mm (0.0472 in)
D 23753-PHB-900 1.3 mm (0.0512 in)
4. Measurethe distance ©between the surfaces of E 23754-PHB-900 1.4 mm (0.0551 in)
the clutch housing and bearing inner race. · F 23755-PHB-900 1.5 mm (0.0591 in)
G 23756-PHB-900 1.6 mm (0.0633 in)
NOTE: H 23757-PHB-900 1.7 mm (0.0670 in)
readings.
) ciQ1
'----r T v~1
BALL BEARING
13-137
Transmission
Reassembly~~~~~~~~~~~~~~~~~~~~~~~~~~~-
NOTE: 3. lnstall the transfer shaft assemblyand 2-4 select rod.

• Use the correct thrust shim to assurethe proper maín-
shaft thrust clearance. 4. lnstall the dífferential assemblyin the clutch housing.
• For shím selectíon, refer to page 13-137.
• Usethe correct thrust shim to assurethe proper super- 5. Put the bearing on the transfer shaft.
low 2nd shaft thrust clearance.
• For shim selectíon, refer to page 13-137.
DIFFERNETIAL
1. lnstall the oíl guíde plate, maínshaft thrust shirn and
super-low 2nd shaft thrust shim.
MAINSHAFT
__. THRUST SHIM
SUPER-LOW 2ND SHAFT
THRUST SHIM
~
6. lnstall the spirng washer and thrust shim with the

angle agaínst the clutch housing as shown below.
lnstall the super-low 2nd shaft, countershaft and
mainshaft assemblies in the clutch housing.
2. lnstall the oíl gutter plate and oíl collect plate in the
transmission housing.
~_,./
COUNTERSHAFT ASSEMBL Y
6 x 1.0 mm
12 N·m (1.2 kg-m, 9 lb-ftl
OIL GUTTER PLATE
~
OIL COLLECT PLATE
-----....~f f ~~·
13-138
7. lnstall the super-low shift piece B and shift fork on 9. lnstall the following parts in the clutch housing;
the super-low shift shaft.
NOTE:
8. Assemble the super-low shift fork shaft assembly • Align the lug on the end of the super-low 1 st shaft
with the following parts, and install them on the with the groove in the clutch housing.
super-low 2nd shaft. • lnstall the spring washer with the dished end fi-
acing down.
NOTE: Note the installaion direction of the synchro
sleeve. CD SUPER-LOW 1 ST SHAFT
@ SPACER COLLAR
CD SUPER-LOW SYNCHRO HUB @ SPRING WASHER
@ SUPER-LOW SYNCHRO SLEEVE @ THRUST WASHER
@ SYNCHRO SPRING @ THRUST NEEDLE BEARING
@ SYNCHRO RING @ SUPER-LOW 1 ST GEAR
@ SUPER-LOW 2ND GEAR (J) NEEDLE BEARING
@ FRICTION DAMPER @ SPACER COLLAR
(J) NEEDLE BEARING @ NEEDLE BEARING
@ SPACER COLLAR @) THRUSTNEELDE BEARING
@ BALL BEARING @ THRUST WASHER
1 SUPER-LOW
SHIFT FORK
/SHAFT
íl
~VPIECEB
SUPER-LOW SHIFT
5 x 22 mm
~.........._ SPRING PIN
Repface.
' 6 x 1.0 mm
17 N·m (1.7 kg-m,
12 lb-ft)
SUPER-LOW SHIFT FORK
SUPPER-LOW 2ND SHAFT
Assembled View
(cont'd)
13-139
Transmission
Reassembly (cont'd)-----------------------
1 O. lnstall the reverseshift holder assemblyin the clutch 13. lnstall the following parts on the counter shaft;
housing.
1 1ST/2ND SHIFT FORK
2 SUPER-LOW SHIFT PIECEA
3 SUPER-LOWSHIFT LEVER
14. lnsert the steel balls and springs into the 5th shift
fork, then slide the shift fork through each shift piece
and shift lever.
NOTE: lnstall the shift fork shaft with the detent

hole facíng the maínshaft.
1 5. lnstall the super-low shíft piece bar in the reverse

shift holder assembly.
8 x 14 mm 1ST/2ND SHIFT FORK SHAFT SUPER-LOW SHIFT PIECE BAR
J 5TH SHIFT FORK
)íl
1ST/2ND SHIFT
FORK SHAFT
11. lnstall the following parts on the mainshaft;

DET<NT HbLE ~
1 REVERSESHIFT FORK
2 3RD/4TH SHIFT FORK 1
3 5TH SHIFT FORK STEEL BALLS
l
12. Slíde the shíft fork shaft down through each shift
fork.
NOTE: lnstall the shift fork shaft with the detent

groove facing the countershaft.
SHIFT FORK SHAFT

5TH/REVERSE SHIFT
DETENT HOLE 1 6. lnstall the reverse ídler gear and shaft in the clutch
FORK SHAFT
V housíng.
4'll
NOTE: lnstall the ídler shaft wíth the threads fac-
ing outsíde.
--- REVERSE IDLER GEAR SHAFT
13-140
1 7. Apply liquid gasket to the transmission mating sur- 20. Lower the transmission housing with the snap ring
face of the clutch housing. expanded and set the snap ring in the groove of the
counterhsaft bearing.
NOTE: This transmission uses nogasket between
the major housings; use Honda Genuine liquid gasket . 21 . lnstall the 32 mm sealing bolt.
20 minutes after applying the liquid gasket and al- NOTE: Apply liquid gasket (P/N08718-0001) to
low it to cure at least 30 minutes after assembly be- the threads of the sealing bolt.
SNAP RING
18. lnstall the 14 x 20 mm dowel pins.
19. lnstall the transmission housing.
22. Tighten the transmission housing attaching bolts in

the numbered sequence as shown.
...- CLUTCH HOUSING
14 x 20 mm DOWEL PINS
(cont'd)
13-141
Transmission Transmission Assembly
Reassembly (cont'd)----------. lnstallation-----------
23. lnstall the steel ball, spring, and set bolt. NOTE: Differences between the 2wd and 4 wd are co-
vered in this page. Refer to page 13-37 for the inforrna-
24. lnstall the reverse idler shaft bolt. tion not covered in this page.
25. lnstall the super-low shift lever bolt. 1. lnstall the rear rnount bolts.

the threads of the super-low shift lever bolt.
12 x 1.25 mm
60 N·m (6.0 kg-m. 43 lb-ft)
REVERSE IDLER GEAR SHAFT BOL T

55 N·m (5.? kg-m.40 lb-ftl
WASHER
Replace.
14 x 15 mm
80 N·m (B.O kg-m. 58 lb-ft)
WASHER
SET BALL
Replace. 2. lnstall the front stopper bolts.
22 N·m (2.2 kg-m, 16 lb-ft)
SUPER-LOW SHIFT LEVER BOL T
40 N·m (4.0 kg-m. 29 lb-ft)
10 x 1.25 mm
55 N·m (5.5 kg-m. 40 lb-ft)
13-142
3. lnstall the propeller shaft. COTTER PIN LOCKNUT
<.
Replace. .30 N·m (3.0 kg-m, 22 lb-ft)
4. lnstall the shift and selcet cables, then install the
washers and cotter pins.
5. lnstall the intermediate shaft and drivershafts. ~®

®
COMPANION FLANGE
PROPELLER SHAFT
32 N·m (3.2 kg-m, 23 lb-ft)
13-143
Automatic Transmission
2WD Automatic Transmission

M48A 14-1
M 24A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4-1 3 5
4WD Automatic Transmission 14-281
M48A
Special Tools 14-2 Main Valve Body 14-86

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-3 Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-88
Troubleshooting Regulator Valve Body 14-89
Electrical Troubleshooting . . . . . . . . . . . 14-46 Secondary Valve Body 14-90
Lock-up Control Solenoid Valve Servo Body 14-92
A/B 14-47 Lock-up Valve Body 14-94
Hydraulic System Governor Body . . . . . .. . . . . . . . . . . . . . . .. . .. . . . 14-95
Hydraulic System 1 st Accumulator I
Symptom-to-Component Chart . . . . 14-48 R. Side Cover 14-96
Road Test 14-52 Mainshaft 14-97
Stall Speed 14-55 Countershaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-100
PressureTesting 14-56 One-way Clutch/Parking Gear . . . . . . . . 14-103
Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-65 Clutch
lllustrated lndex . . . . . . . . . . . . . . . . . . . . . . . . 14-104
Transmission Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-106
Transmission Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-108
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-66 Torque Converter Housing Bearings
lllustrated lndex
Mainshaft Bearing
R. Side Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-70 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 14-112
Transmission Housing . . . . . . . . . . . . . . . . 14-7 2 Countershaft Bearing
Torque Converter Housing/ Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 14-113
Valve Body 14-74 Transmission Housing Bearing
R. Side Cover Mainshaft/Countershaft Bearing
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 76 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-114
Transmission Housing Reverse ldler Gear .. . . . . . . . . . . . . . . . . . . . . . . 14-11 5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 78 Transmission
Torque Converter Housing/ Reassembly . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . 14-116
Valve Body Parking Brake Stopper . . . . . . . . . . . . . . . . . . . 14-123
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-80 Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . 14-1 24
Valve Transmission
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-82 lnstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-125
Valve Caps . .. . . . . . .. . .. . . .. . . . . . . .. .. . .. . .. . 14-84 Shift Cable
Valve Body Removal/lnstallation . . . . . . . . . . . . . . . . . . . 14-129
Repair . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 14-85 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-130
Gearshift Selector . . . . . . . . . . . . . . . . . . . . . . . . . 14-131
Shift lndicator Panel . . . . . . . . . . . . . . . . . . . . . 14-1 32
Throttle Control Cable . . . . . . . . . . . . . . . . . . . 14-133
Special Tools
Ref No. Tool Number Description Oty Page Reference

G) 07HAC--PK40101 Housing Puller 14-79
@ 07JAC-PH80000 Adjustable Bearing Remover Set 14-112, 113
@-1 07JAC-PH80100 Bearing Remover Attachment 14-112, 113
@-2 07JAC-PH80200 Remover Handle Assembly 14-11 2, 113
@-3 07741-0010201 Remover Weight 14-11 2, 11 3
@ 07LAE-PX40000 Clutch Spring Compressor Set 14-106, 109
@-1 07GAE- PG40200 Clutch Spring Compressor Bolt 14-106, 109
@-2 07HAE-PL50100 Clutch Spring Compressor Attachment 14-106, 109
@-3 07LAE-PX40100 Clutch Spring Compressor Attachment 14-106, 109
© 07LGC-0010100 Snap Ring Pliers 14-114
® 07MAJ-PY40100 A/T Oil Pressure Gauge Hose Assembly 14-56
@-1 07MAJ-PY40110 Oil Pressure Gauge Hose 14-56
@-2 07MAJ.-PY40120 Oil Pressure Joint 14-56
® 07406-0020300 A/T Oíl Pressure Gauge Set 14-56
@-1 07406-0020201 A/T Oil Pressure Gauge Hose 14-56
(i) 07406-0070000 A/T Low Pressure Gauge 14-56
® 07746-0010500 Attachment, 62 x 68 mm 14-11 2, 11 3, 114
® 07746-0010600 Attachment, 72 x 75 mm 14-112, 114
® 07749-0010000 Driver 14-112, 113, 114
® 07923-6890202 Mainshaft Holder 14-77, 120
u
~
G)
' @-1
@
~O))IJl))Oi
~
~
é~
@-1 @-2 @-3
~
~
®
e,__ ~_
®·® ® ®
14-2
Description
The Automatic Transmission is a combination of a 3-element torque converter and dual-shaft automatic transmission
which provides 4 speeds forward and 1 speed reverse. The entire unit is positioned in line with the engine.
TORQUE CONVERTER, GEARS, AND CLUTCHES
The torque converter consists of a pump, turbine and stator, assembled in a single unit.
They are connected to the engine crankshaft so they turn together as a unit as the engine turns. Around the outside
of the torque converter is a ring gear which meshes with the starter pinion when the engine is being started. The entire
torque converter assembly serves as a flywheel while transrnitting power to the transmission rnainshaft.
The transrnission has two parallel shafts, the mainshaft and countershaft. The mainshaft is in line with the engine crank-
shaft. The mainshaft includes the clutches for 1 st, and 2nd/4th, and gears for 3rd, 2nd, 4th, Reverseand 1 st (3rd gear
is integral with mainshaft, while reverse gear is integral with 4th gear).
The countershaft includes 3rd clutch and gears for 3rd, and 4th, Reverse and 1 st.
4th and reverse gears can be locked to the countershaft at its center, providing 4th gear or Reverse, depending on which
way the selector is moved.
The gears on the mainshaft are in constant mesh with those on the countershaft. When certain combinations of gears
in the transmission are engaged by the clutches, power is transmitted from the mainshaft to the countershaft to provide
1 03 J, l 04 l, !]] and ffi].
HYDRAULIC CONTROL
The valve assembly includes the main valve body, secondary valve body, servo valve body, modulator valve body, regu-
lator valve body and lock-up shift valve body, through the respective separator plates.
They are bolted to the torque converter case as an assembly.
The main valve body contains the manual valve, 1-2 shift valve, 2-3 shift valve, 3-4 shift valve, pressure relief valve,
2nd orífice control valve, torque converter check valve and oil pump gear.
The secondary valve body includes the CPC valve, REV control valve, lock-up cut valve, kickdown valves,3-2 timing
valve, shift timing valve, 3rd orifice control valve and 4th exhaust valve.
The servo valve body contains the accumulator pistons, 3rd orifice control valve, throttle A and B valves, and the modu-
lator valve. The regulator valve body contains the lock-up timing valves, pressure regulator valve and lock-up control
valve. Fluid from the regulator passes through the manual valve to the various control valves.
The lock-up shift valve body contains the lock-up timing valve B and lock-up shift valve. The 1 st, 3rd and 4th clutches
receive oil from their respective feed pipes.
LOCK-UP MECHANISM
I,
In 104 pressurized fluid is drained from the back of the torque converter through an oíl passage, causing the lock-up
piston to be held against the torque converter cover. As this takes place. the mainshaft rotates at the same speed as
the engine crankshaft. Together with hydraulic control, an electronic control unit optimizes the timing of the lock-up
mechanism.
The lock-up shift valve body controls the range of lock-up according to vehicle speed and throttle pressure. The lock-up
timing valve controls the flow of oíl to the lock-up shift valve in 3rd and 4th gear (in i 04 I range).
The lock-up cut valve is housed in the secondary valve body and prevents lock-up from taking place when the throttle
is not opened sufficiently.
(cont'd)
14-3
Description
(cont'd)
GEAR SELECTION
The selector lever has six positions: [f] PARK, [fil REVERSE, [fil NEUTRAL,104 ! 1 st through 4th gear ranges, i 03 ! 1 st
through 3rd gear ranges, and (]] 2nd gear.
Position Descri'ption
[fJ PARK Front wheels locked; parking pawl engaged with parking gear on countershaft. AII
clutches released.
ffi] REVERSE Reverse; reverse selector engaged with countershaft reverse gear and 4th gear
clutch locked.
[fil NEUTRAL AII clutches released.
iD4! ORIVE General driving; starts off in 1 st, shifts automatically to 2nd, 3rd, then 4th,
( 1 through 4) depending on vehicle speed and throttle position. Downshift through 3rd, 2nd
and 1 st on deceleration to stop.
The lock-up mechanism comes into operation in 104 !.
iD3! ORIVE Far rapid acceleration at highway speeds and general driving; starts off in 1 st,
( 1 through 3) shifts automatically to 2nd, then 3rd, depending on vehicle speed and throttle
position. Downshifts through 2nd to 1 st on deceleration to stop.
(]] SECOND Far engine braking or better traction starting off on loose or slippery surface;
stays in 2nd gear, does not shift up or down.
Starting is possible only in [f] and [fil through the use of a slide-type, neutral-safety switch.
POSITION INDICATOR
A position indicator in the instrument panel shows what gear has been selected without having tolook down at the console.
14-4
LOCK-UP CONTROL
SOLENOIO VALVE
ASSEMBLY
TORQUE CONVERTER
2NO CLUTCH
1ST
CLUTCH
GOVERNOR BOOY
OIFFERENTIAL ASSEMBL Y
01584/016A9 is shown.
14-5
Description
Clutches~~~~~~~~~~~~~~~~~~~~~~~~~~~~
The tour speed automatic transmission uses hydraulically actuated clutches to engage or disengage the transmission
gears. When clutch pressure is introduced into the clutch drum, the clutch pistan is applied. This presses the friction
discs and steel plates together, locking them so they don't slip. Power is then transmitted through the engaged clutch
pack to its hub-mounted gear.
Likewise, when clutch pressure is bled from the clutch pack, the pistan releases the friction discs and steel plates, and
they are free to slide past each other while disengaged. This allows the gear to spin independently of its shaft, transmit-
ting no power.
[ 1 st Clutch]
The first clutch engages/disengages first gear, and is located at the end of the mainshaft, just behind the R side cover.
The first clutch is supplied clutch pressure by its oil feed pipe within the mainshaft.
[2nd Clutch]
The second clutch engages/disengages second gear, and is located at the center of the mainshaft. The second clutch
is joined back-to-back to the fourth clutch. The second clutch is supplied clutch pressure through the mainshaft by a
circuit connected to the regulator valve body.
[3rd Clutch]
The third clutch engages/disengages third gear, and is located at the end of the countershaft, opposite the R side cover.
The third clutch is supplied clutch pressure by its oil feed pipe within the countershaft.
[4th Clutch]
The fourth clutch engages/disengages fourth gear, as well as reverse gear, and is located at the center of the mainshaft.
The fourth clutch is joined back-to-back to the second clutch. The fourth clutch is supplied clutch pressure by its oil
feed pipe within the mainshaft. ·
[One-way Clutch]
The one-way clutch is positioned between the parking gear and first gear, with the parking gear splined to the counter-
shaft. The first gear provides the outer race surface, and the parking gear provides the inner race surface. The one-way
clutch locks up when power is transmitted from the mainshaft first gear to the countershaft first gear.
The first clutch and gears remain engaged in the 1 st, 2nd, 3rd, and 4th gear ranges in the ~. (Qi] or [lJ position.
However, the one-way clutch disengages when the 2nd, 3rd, or 4th clutches /gears are applied in the ~~ or 12]
position. This is because the increased rotational speed of the gears on the countershaft over-ride the locking "speed
range" of the one-way clutch. Thereafter, the one-way clutch free-wheels with the first clutch still engaged.
COUNTERSHAFT 1ST GEAR
•
LOCKS FREE
SPRAG
PARKING GEAR
NOTE: View from R. side cover side.
14-6
RING GEAR
MAINSHAFT
2ND GEAR
2ND CLUTCH
MAINSHAFT 4TH GEAR
COUNTERSHAFT
1ST GEAR
COUNTERSHAFT
REVERSE GEAR
REVERSE SELECTOR HUB
COUNTERSHAFT 4TH GEAR
. COUNTERSHAFT 2ND GEAR
COUNTERSHAFT 3RD GEAR
FINAL DRIVEN GEAR
(cont'd)
14-7
Description
Clutches {cont'd)~~~~~~~~~~~~~~~~~~~~~~~--.
Lock-up Clutch
1. Operation (clutch on)
With the lock-up clutch on, the oil in the chamber between the torque converter cover and lock-up piston is discharged,
and the converter oil exerts pressure through the piston against the converter cover. As a result, the converter turbine
is locked on the converter cover firmly. The effect is to bypass the converter, thereby placing the car in direct drive.
l Power flow I
The power flows by way of: LOCK-UP PISTON DAMPER SPRING
Engine
1 TORQUE CONVERTER
Orive plate COVER COMP
l
Torque converter cover
1
Lock-up piston
1
Oamper spring
1
Turbine
1
Mainshaft
2. Operation (clutch off) .

With the lock-up clutch off, the oil flows in the reverse of CLUTCH ON. As a result, the lock-up piston is moved away
from the converter cover; that is, the torque converter lock-up is released.
\ Power flow I
Engine
1
Orive plate
1
1
Pump
---t
1
Turbine To oíl cooler
1
IN~ET
Mainshaft
14-8
i\ PART TORQUE
CON-
1ST GEAR
lST
lST GEAR
ONE-WAY
2ND GEAR
2ND
3RD GEAR
3RD
4TH REVERSE
GEAR
PARKING
GEAR
POSITtON¡\ VERTER CLUTCH CLUTCH CLUTCH CLUTCH GEAR CLUTCH
~ o X X X X X X X o
[]] o X X X X X o o X
[ill o X X X X X X X X
lST o o o X X X X X X
[füJ 2ND o .*O X o X X X X X
3RD o *O X X o X X X X
lST o o o X X X X X X
2ND o *O X o X X X X X
~ 3RD o *0 X X o X X X X
4TH o *0 X X X o o X X
2 2ND o X X o X X X X X
O: Engaged x: Not Engaged *: Although the 1 st clutch engages, driving power in not transmitted as the one-way
clutch races.
OIL PUMP
MAINSHAFT
~ ~Li COUNTERSHAFT
ONE-WAY CLUTCH
TORQUE CONVERTER
"~
COUNTERSHAFT
2ND GEAR oíl= PARKING PAWL
COUNTERSHAFT
3RD GEAR
3RD CLUTCH
~
\ -~UNTERSHAFT
COUNTERSHAFT
REVERSE GEAR
1 ST GEAR
REVERSE SELECTOR
SERVO VALVE
(cont'd)
14-9
Description
Power Flow (cont' d)
Power transmission channels are shown in the following figures classified by positions [[], [IJ, 1 D3 l, 1 D4 l, [fil and [E:].
[fil Position
Each clutch is not connected because hydraulic pressure is retained by the manual valve in the main valve body.
( 1) Starting the engine causes the oil pump to operate immediately, filling the torque converter with ATF.
( 2) Power is not transmitted to the countershaft because the 1 st to the 4th clutches are releasaed (i.e. these clutches
have received no hydraulic pressure).
(31 Despite the clutch being released, the torque converter, oil pump and mainshaft rotate.
OIL PUMP
MAINSHAFT 2ND GEAR REVERSE IDLE GEAR
MAINSHAFT
MAINSHAFT MAINSHAFT 4TH GEAR REVERSE
GEAR
\
3RD GEAR 2ND CLUTCH
MAINSHAFT 1 ST GEAR
~~TCLUTCH
MAINSHAFT
ONE-WAY CLUTCH
PARKING PAWL
TORQUE CONVERTER
COUNTERSHAFT 1 ST GEAR
~RO CLUTCH
COUNTERSHAFT REVERSE GEAR
SERVO VALVE
REVERSE SELECTOR
14-10
(Il Position
(Il Positionis fixed at the 2nd speed.
Hydraulic pressure is applied to the 2nd clutch, which is then connected. Engine motive power is transmitted via the
torque converter to the mainshaft. Becausethe 2nd clutch is connected, motive power is transmitted from the mainshaft
2nd gear to the countershaft 2nd gear.
2ND CLUTCH
4TH CLUTCH MAINSHAFT REVERSE GEAR
MAINSHAFT REVERSE IDLE

2ND GEAR GEAR
\
MAINSHAFT
3RD GEAR
COUNTERSHAFT
ONE-WAY CLUTCH
<,
TORQUE CONVERTER COUNTERSHAFT
2N~ GEARO__ ....__

COUNTERSHAFT
3RD GEAR l
3RD CLUTGH
SERVO VALVE REVERSE SELECTOR
(cont'd)
14-11
Description
Po~er Flo~ (cont'd) ~~~~~~~~~~~~~~~~~~~~~~~
1 !
03 or 1 04 I Position
! !
In/ 03 or / 04 position, the throttle valve opening (engine load) is balanced with the car speed so as to transmit power
to the optimal gear of the 1 st. 2nd, 3rd and 4th gears (in 104 ! posltionl, Transmission channels are shown below for
each gear.
I D3 ! or 104 I Position, 1 st speed

( 11 Hydraulic pressure is applied to the 1 st clutch, resulting in clutch engagement. Engine power is transrnitted via the
torque converter to the mainshaft. Because the 1 st clutch is engaged, power is transmitted from the rnainshaft 1 st
gear to the counter shaft 1 st gear.
(21 Power is then transmitted from the one-way clutch to the parking gear and then to the countershaft.
OIL PUMP
2ND CLUTCH
MAINSHAFT REVERSE GEAR
REVERSE IDLE GEAR
TORQUE CONVERTER
COUNTERSHAFT COUNTERSHAFT 1ST GEAR

3RD GEAR
3RD CLUTCH COUNTERSHAFT REVERSE GEAR
14-12
I 03 !or 104 \ Position, 2nd speed
( 1) Hydraulic pressure is applied to the 2nd clutch, resulting in clutch engagement. Engine power is transmitted via the
torque converter to the mainshaft. Becausethe 2nd clutch is engaged, power is transmitted from the mainshaft 2nd
gear to the countershaft 2nd gear.
(2) When driving in the 2nd speed also, the 1st clutch is engaged. The 2nd speed rnechanisrn rotates the countershaft
faster than the 1 st speed rnechanisrndueto the gear ratio difference. This causes the one-way clutch to rotate idly,
resulting in no power being received frorn the 1 st speed rnechanism.
REVERSE IDLE GEAR MAINSHAFT

REVERSE
4TH CLUTCH GEAR
COUNTERSHAFT
ONE-WAY CLUTCH
TORQUE CONVERTER
SERVO VALVE
R~VERSE SELECTOR
(cont'd)
14-13
Description
Power Flow
(cont'd)-----------------------
I DJ ! or I D4 ! Position,
3rd speed
( 1) Hydraulic pressure is applied to the 3rd clutch, resulting in clutch engagement. Enginepower is transmitted via the
torque converter to the mainshaft, then from the mainshaft 3rd gear to the countershaft 3rd gear.
(2) Becausethe 3rd clutch is engaged, power is transmitted from the 3rd clutch to the countershaft, thus output can
be obtained from the transmission.
In 3rd speed also, the 1 st clutch is engaged, but without receiving power from the 1 st speed mechanism for the
same reason as in the case of 2nd speed.
MAINSHAFT
REVERSE
OIL PUMP
2ND CLUTCH GEAR
MAINSHAFT 2ND GEAR
MAINSHAFT REVERSE IDLE GEAR

3RD GEAR
COUNTERSHAFT
COUNTERSHAFT
4TH GEAR '-...._
~ ONE-WAY CLUTCH
TORQUE CONVERTER
-,
COUNTERSHAFT
0---'---+- ;It::-- PARKING PAWL

2ND GEAR
COUNTERSHAFT
3RD GEAR 1 \
~~!) CLUTCH COUNTERSHAFT REVERSE GEAR
14-14
I D4!Position. 4th speed
Hydraulic pressure is applied to the 4th clutch, resulting in clutch engagement. Engine power is transmitted via the tor-
que converter to the mainshaft, via the 4th clutch to the mainshaft 4th gear, then to the countershaft-mounted counter-
shaft 4th gear, then via the selector hub to the countershaft. Thus output can be obtained from the transmission.
In 4th speed also, the 1 st clutch is engaged, but without receiving power from the 1 st speed mechanism for the same
reason as in the case of 2nd speed.
OIL PUMP
MAINSHAFT 2ND GEAR REVERSE ID.LE GEAR
MAINSHAFT.
3RD GEAR
\
-,
J
MAINSHAFT
1 ..
~Jp:==~~~~~~~:;~=;;~~~~~====~~~
COUNTERSHAFT
4TH GEAR '-.,,,.. .
~coUNTERSHAFT
ONE-WAY CLUTCH
íl--~-,
COUNTERSHAFT
TORQUE CONVERTER 2ND GEAR
COUNTERSHAFT 1 1
•
3RD GEAR l.:::!.
SERVO VALVE
3RD CLUTCH
REVERSE SELECTOR
(cont'd)
14-15
Description
Power Flow (cont'd)~~~~~~~~~~~~~~~~~~~~~~-
[ffiPosition
( 1) The hydraulic pressure channel is switched by the manual valve to the 4th clutch and the servo valve, thus the 4th
clutch is engaged.
(2) Hydraulic pressure acts on the shift fork shaft. The shift fork interlocking with the shift fork shaft causes the reverse
selector to mesh with the reverse hub and the countershaft reverse gear.
(3) Engine power is transmitted vía the torque converter to the mainshaft. Becausethe 4th clutch is engaged, the power
drives mainshaft 4th and reverse gears united with the 4th clutch. Because, at this time, hydraulic pressure is ap-
plied to the servo valve, the reverse selector moves toward the countershaft reverse gear. This causes the power
from the mainshaft reverse gear to change its rotation direction via the reverse idle gear. This power is then transmit-
ted to the countershaft reverse gear, selector hub and then to the countershaft.
OIL PUMP MAINSHAFT 2ND GEAR

REVERSE IDLE GEAR
MAINSHAFT
I MAINSHAFT 1 ST GEAR
3RD GEAR
COUNTERSHAFT ~
4TH GEAR '-.......;
COUNTERSHAFT
2ND GEAR
}=--
TORQUE ·coNVERTER
~FORK
COUNTERSHAFT
3RD GEAR
3RD CLUTCH COUNTERSHAFT REVERSE GEAR
REVERSE SELECTOR
SERVO VALVE
14-16
~ Position
In ~ position, hydraulic pressure is not applied to each clutch resulting in idle rotation of the mainshaft, just like in [0
position. However, the mechanical parking mechanism interlocking with the manual vale causes the parking pawl to mesh
with the parking gear, thereby locking the countershait.
OIL PUMP
MAINSHAFT 2ND GEAR
REVERSE IDLE GEAR
MAINSHAFT
JRD GEAR 2ND CLUTCH
MAINSHAFT 1 ST GEAR
r·w
MAINSH~FT 1 ST CLUTCH
REVERSE /
MAINSHAFT
ONE-WAY CLUTCH
PARKING PAWL
[}-1-
TORQUE CONVERTER
COUNTERSHAFT
i
JRD GEAR
~.R.D CLUTCH
• COUNTERSHAFT REVERSE GEAR
SERVO VALVE
REVERSE SELECTOR
14-17
Description
Hydraulic Control ------------------------
In the hydraulic control unit, the regulator valve, manual valve and oíl pump connected to the torque converter are unified
and contained inside the valve body. The valve body includes the main valve body. the regulator valve body, the secon-
dary valve body, the servo body, and the lock-up valve body.
The oil pump is driven by splines on the right end of the torque converter which is attached to the engine. Oil flows
through the regulator valve, to maintain specified pressure through the main valve body to the manual valve, governor
valve, and servo body, directing pressure to each of the clutches.
REVERSE SHIFT
FORK
SERVO COVER
REVERSE TIMING
VALVE
SERVO CONTROL VAL VE
SHIFT FORK SHAFT

(SERVO VALVE)
REVERSE CONTROL.
VAL VE
2-3 SHIFT VALVE
. TORQUE CON VERTER CHECK VALVE
14-18
Regulator Valve
The regulator valve maintains a constant hydraulic pressuresent from the oil pump to the hydraulic control system. while
also furnishing oil to the lubricating system and torque converter.
Oil flows through 8 and 8'. The oil which enters through 8 flows through the valve orífice to A pushing the regulator
valve to the right. According to the level of hydraulic pressure through 8, the position of the valve changes, and the
amount of the oil through 8'. from D thus changes. This operation is continued, thus maintaining the line pressure.
(ENGINE NOT RUNNING) , (ENGINE RUNNING)
TO TORQUE CONVERTER
t TO RELIEF VAL VE
FROM OIL PUMP REGULATOR VALVE SPRING
Stator Reaction Hydraulic Pressure Control

Hydraulic pressure increase according to torque is performed by the regulator valve using stator torque reaction. The
stator shaft is splined in the stator and its arm end contacts the regulator spring cap. When the car is accelerating or
climbing (TorqueConverter Range),stator torque reaction acts on the stator shaft and the stator arm pushesthe regula-
tor spring cap-+ direction in proportion to the reaction. The spring compresses and the valve moves to increase the
regulated control pressure or line pressure. Une pressure is maximum when the stator reaction is maximum.
TORQUE CONVERTOR
CHECK VALVE
STA TOR REACTION SPRING
STATOR ARM
ST ATOR SHAFT ARM
(cont'd)
14-19
Description
Hydraulic
Control
(cont'd)---------------------,
Oil Pump
The externa! tooth gear type oil pump consists of a housing united with the main valve body, a pump drive gear, a pump
driven gear, and a pump shaft. the oil pump is installed on the torque converter housing. The pump's driving force is
transmitted by the torque converter pump (directly connected to the engine) to the pump drive gear that is connected
by a spline to the pump shaft. The gears are provided in the housing. The intake and exhaust lines and the torque convert-
er line are provided in the housing.
MAIN VALVE BODY
PUMP DRIVEN GEAR
ST ATOR SHAFT
PUMP ORIVE GEAR
MANUAL VALVE
14-20
- Hydraulic Flow D 1281 /D 1 583
DESCRIPTION DESCRIPTION DESCRIPTION DESCTIPTION

No. No. No. No.
OF PRESSURE OF PRESSURE OF PRESSURE OF PRESSURE
UNE 10 1ST CLUTCH 40 4TH CLUTCH 90 TORQUE CONVERTER

2 11 41 91
3 20 2ND CLUTCH 42 92
3' 21 50 THROTTLE A 93 OIL COOLER
3" 22 51 94 TORQUE CONVERTER
4 23 55 THROTTLE B 95 LUBRICATION
4' 24 56 96 TORQUE CONVERTER
5 30 3RD CLUTCH 60 GOVERNOR 97
6 MODULATOR 31 61 99 SUCTION
[ID Position
When the manual valve is in neutral, it prevents oíl from flowing to the shift valvas and clutches. The regulator valve
serves to maintain the line pressure at a constant level. The torque converter check valve prevents oil pressure within
the torque converter from falling below a predetemined limit.
2NDCLUTCH 20
ORI FICE CONTROL

SOLENOID~x
4TH ACCUMUU.TOR 2-3SHIFTVA\.VE ~ l\!O _
J[= . ~ __:~ ~~
2NO ACCUMULATOA
~·
]]
,. "11 se 1 ,X
11,g,, H==;~i=::"',c=,1
ss l ( 3flD ACCUMULATOR
LOCK..(JP CUT VAL VE
. "" 11
-
..,_
n
-1. ,· e-
1 11 "
'' (Q)
"""
'I THROTTLEVAlVE8
o,~u-(ID
= ""'!
ól
_,,c ~
=
11
= ~NORVALVE
:-"'11~
'11"
~ ~~ l!t
j '
11
OILCOOLER
u
J
............ ~
itb
1 RELIEF VAL VE REVERSE CONTROL YALYE
COOLER RELIEF VAL VE OILPUMP (cont'd)
NOTE: When used, "left" or "right" indicates direction on the flow chart.
14-21
Description
- Hy draurre FI ow 01281/01583 ( cont'd)
~ Position
Oil from the oil pump travels through the manual valve to the second clutch; second clutch is on. lt also flows through
the governor valve to the 1-2 and 2-3 shift valves. The modulator and throttle valves also receive oil from the pump.
2NDCLUTCH
,,~
" .. 4TH C\.UTCH
¿g. SHIFTTIMINOVA• vs
~
50
r
.,,
1011,li
,
Jt\f12II
~
.r~ """Nll
3-4SHIFT VALVE
1STACC~~-
"
fi -/
ti 11
líl íl!fi
1STCLUTCH 3RDCLUTCti
.---
"
4
º""'º·-~
SO,..ENOtO VAL VE x Xx tjeo _
-
~
4TH ACCUMULATOR )1 X JO)C 2-3SHIFTVALVE
2NO ACCUMULATOR
~ lll
!rr= __ ,.[L::.
,r
[ _____ ,
u
s
~-~ ' 11"11" ,X"

~~-
..
'e~
" ,_,U ... "°.~ "11 ~ SS 1 {JADAOCUMULAT~

11 55 '
==
Ir
= ¡'¡ - "
-.-
x,¡•o•,..,,.., n
= ' "" i l Fi H o
r
1·2SHIFTVAlrfJl
- --
.,. "
1r.
. ¡p-
- 5-~
:rn
.. _ ~~ "
- - .ur
11 " ,,. "\J 4THEXT KICK D0wN VAi.VE
n " n 11-:. - VAL VE
:!J
~
1 i.:=n .. 1r _
¿1 -;:;-;:;-;;; .
}-1J
l
LOCK·UP CUT VAL VE
~
LOCK.Vr'
' ¡=x==ii,,
CONTROL VALV
CLUTCH l'RESSUFll 4
"ir'( TIMINQ ~ J~ Uuuu10 ,:"
...,.
..., . 1
:J[ ..
CONTROL VALVE
.. L
'--\.
rr=;::D=: "o
"'
HROTTLE VAL VE A
n] .. 11 ..
~1b" 7ALVEx 11; "'lt

LOCK·UP~'!'fVAJ..VE
MANUAL • 1ro
'ª
I~ 1ollÍ21 ' • ·~ '• • n
~· .
L.Jlll ""'""""''
~
u¡~~~:
9Z
"1 u·•---uu
091•11"'~
' '
':::::: l 60
~ ~ 2NDOfllFICE
CONTROLVAlVE "
t\~)
I== R. 1 r, 11
~= 11 ·~ ~ ~
.. ¡ 11 11
..-- .©
so,... ....
rl l l;r,J .. j 1,.,.
...
(
1rn .
d:fllll!!; ~ •
SERVO ONTROL ~ --. '-<.
VAL VE •
REGULATORVALvt:
·1
w~LOCK.\JPTIMING
VA.LVEI u L :
" ÍÍb:.:.· OJ ;:;:!! ..di

THAOffl.E VAL VE B
-- HI
..
11
lf ~
l..- ~
D ;!_1--i~ u,y -- " <===
"J] . a: - .:ól
CIHE•-·IID
e
~ " SERVOVALVE
,'il
,-
=~,
·rr 11
"
TOROUE CONVERTER
~ =
:.l~
CHECK VALVE
i
VEANOA VAL YE
~ ,-
·J
i: tí _ .
\
I - -,
OIL COOLER
r; '
u •
~
"lJ 11:1
1
U U"-J
'n --, Al!:LIEFVALVE Al!VERSf CONTROL VAL VE
COOLER RELIEFVALYE otl.'1.JMP
14-22
i 03 ! or i 04 ! Position
1. 1st speed
The manual valve directs oil to the first clutch through the port (41 and inlet ( 1 O). Line pressure is applied to the governor
valve, modulator valve and throttle valves. In this transmission, two pressures from throttle valve A and the governor
valve oppose each other in attempting to move the shift valves. In the lst speed range, the 1-2 shift valve is moved to
the right since the pressure (60) from the governor valve is lower than the pressure (50) from throttle valve A. With
the 1-2 shift valve moved to the right, no oil is dírected to the 2nd, 3rd and 4th clutches; that is, only the first clutch is on.
lSTACC.UMULATOA r lSTCLUTCH lRDCLUTCH
2NDCLUTCH 20 ~o 4TH CLUTCH

d"" :: HIFT TIMING VAL VE "~~ (~ij
' ~~l -~
~~
4TH ACCUMULATOR
2ND ACCUMULA TC>f\
"~
~ l2_.,L
~
TORQUE CONVERTER
CHECK VALVE
~
I) OllCOO~LER __cl~
R
l~
u
~
"
RELIEFVALVE / REVERSE CONTROL VAL VE
COOLER RELIEF YALVE OILl'UW
NOTE: When used, "left" or "right" indicates direction on the flow chart. (cont'd)
14-23
Description
- Hydraulic Flow
01281/01583 (cont'd)--------------
/ 03 / or / 04 / Position
2. 2nd speed
As the vehicle picks up speed, this increase oil pressure from the governor valve. This pressure is applied to one end
of the 1-2 shift valve. When governor pressure (60) exceeds throttle pressure (50) and spring force combination, the
1-2 shift valve is moved to the left. This causes the transmission to upshift from first to second by admitting line pressure
(5) to the 2nd clutch through the 2-3 shift valve and manual valve. The accumulator reduces shock during shifting. The
first clutch remainson during this seriesof operationsbut no power is transmitted through this clutch since it is freewheeling
on the one-way clutch. At times the line pressure (5) from the LC shift valve through the LC timing valve A is cut by
the LC cut valve or LC timing valve A so the lock-up clutch remains released.
~Jfi"j Al
1ST ACCUMUL.ATOR
=·
.. 11 ..~,J '-=[D='J~
~L=Q_J--'~"11 '1STC'L'UTi"¡"''
[,DCLUTCH
2NDCLUTCH 20 4 o 4TH CLUTCH

IFTTIMINGVA•V• 50
lo11:••
• 11
3-4SHIFTVALVE
Dll •~ i
-
L
n n X -- - -
e:: €JI~
AilERSE TIMING VALVEll 38 j ,·· ._.._,
" ~---,._ ~ -.11 '' o

, ·L
r"'I[)-
r'L-1
-1,
n " ~ THAOTILEVAL YE A
LOCK·UPSHIFTVALVE 1
50- ~1
"'!?"
Htl I• ',¡¡ 11.•. 'n
====='l .u;;,
uu,11=
U~JJ-J:
w •
2NDOIUFICE JO
CONTROLVALVE
~ •. . - =,1
1 - n ~ .. ·l·I ··! '1'

. ( .
11 11
-
I 1
·1 . ..
SERVO ONTAOL 1\ 1
"<íJ)
•
[ V LOCK·UPr1M'i'No
b!JYALVE B ~i~w• =
~ THROTTLEVALVE 8
.. ·+ H ._ ..... ....,111-il-..
l
c,z,zu
";p
"9
L.l(jii
,LJ" '
OMR -~
51:RVOVALYE
~
_. e
1
TOROUECONVERTER
<; '/1 =
J
CHECK VALVE ~~NORVALYE
V , 'I . JI , "
~ ... 1ftl
1 -
1 [J
- -
RELIEF VALVI:
~ • uuu r., -
OILPUW'
NOTE:
• When used, "left" or "right" indicates direction on the flow chart.
• LC: Lock-up
14-24
I D3 ! or 1 04 ! Position
3. 3rd speed
With a further increase in vehicle speed, the governor pressure (60) is sufficient to overcome the throttle pressure (50)
and spring force combination working on the end of the 2-3 shift valve. The 2-3 shift valve is moved to the left. This
moves the shift valve to cut off line pressure (5) from the 2nd clutch. As the 2-3 shift valve so moves, it transmits line
pressure (5) to the 3rd clutch through an accumulator and causes the transmission to up shift from second to third. As
in the 2nd speed range, no power is transmitted through the first clutch because it is freewheeling on the one-way clutch.
''
3ADCLUTCH
2NDCLUTCH 2o 4o 4TH ClUTCH
OR/FICE COHTROL
4TH ACCUMULATOR 80LENOIÓ~~ ..

2NO ACCUMUL.ATOA
C:_-"- 1 lC~:. :~~~--

~
11
li"
"
n
"'
,,
LOCK.\JPCUT VAL VE
--
"-~
TOROUE CONVERTER
CHECK VAL VE '<, ~NORVALVE
/"'
11
OILCOO~LER~~-~
.,.
1
Lu 211_,,c
RELIEF VALVE
~ ./
\
AEVEI\SE CONTROL VAL VE

COOLER RELIEF VALVE OILPUW
14-25
Description
Hydraulic
Flow 01281/01583 (cont'd)--------------
1 04 j Position
4. 4th speed
The governor pressure passesthrough the manual valve and shift timing valve on it way to the 3-4 shift valve. As the
governor pressure increases with vehicle speed, it exceeds the throttle A pressure applied on the other end of the 3-4
shift valve and the spring force combination. The 3-4 shift valve is moved to the left. The line pressure passageto the
3rd clutch (30) is closed and the passageto the 4th clutch (42) is opened by the movement of 3-4 shiit valve. The 4th
clutch pressureline is then pressurizedto engagethe 4th clutch. At the sametime remaining3rd clutch pressureis released
by the movement of the 3rd orífice control valve as it opens the X exhaust port for the remaining pressure of the 3rd
clutch. The 4th clutch pressure is also applied on LC timing valve A to raise the lock-up release point approx. 30 km/h
so that quick acceleration at kick down from the 4th speed range remains possible. The other 4th clutch pressure is
transmitted to the kick down valve to hold the remaining 4th clutch pressure high during kick down from the 4th speed
range in order to reduce kick down shock. This remaining 4th clutch pressureacts to releasethe lock-up clutch by cutting
line pressure (5) at the LC cut valve.
1STCLUTCH
RELIEFVALVf.
COOLER RELIEF VALVE
NOTE:
• When used, "left" of "right" indicates direction on the flow chart.
• LC: Lock-up
14-26
00 Position
When the select leve! is placed in Reverse,this moves the manual valve, allowing line pressure (3) to travel to the servo
valve through the reverse control valve. The reverse shift fork, which is installed on the servo valve, moves the selector
into reverse gear. At the end of the servo valve stroke, the line pressure passage (3') opens and the 4th clutch pressure
line is pressurized. Provision are made to guard against accidental shifting into reverse while the vehicle is in motion.
When vehicle speed reaches a certain level (approx. 30 km/h), line pressure is cut by the governor pressure (60) which
activates the reverse control valve.
When shifting from the 00 !, !
to the ! D4 D3 ! or [gJ position, the servo control valve is moved to the left by first or second
clutch pressure. The servo control valve combines with the reverse shift fork shaft detent system to control movement
of the servo valve.
1STCLUTCH JRD CLUTCH
Mr·-····vE
2ND CLUTCH ao 4o 4TH CLUTCH
10 JO
HH ACCUMUL.ATOR 2-3SHIFTVALVJ1 ~ t::i'ISO __

ZNO ACCUMULATOR
-a-s- 11
- ,..;- n
"11 11 1
~ a ''' ©
THAOTTLEVALVE B
"J]
TORQUECONVERTER
"I =:..ri~ OOVERN
~' itLC:
CHECK VALVE
i \ ; •JI '1 ·~
I
OIL COOLER
- u u •• ~14íl
REI.IEF VALVf REVERSECONTROL VAL VE
COOLER AELIEF VAL VE
º""""'
14-27
Description
- Hydraulic Flow 01281/01583 (cont'd)
~ Position
The flow of fluid through the torque converter is the same as in the []] position. The line pressure ( 1) becomes the line
pressure (3) as it passes the manual valve. The line pressure (3) flows through the reverse control valve to the servo
valve, causing the reverse shift fork to be moved to the reverse position same as in the [fil position.
However, the hydraulic pressure is not supplied to the clutches. The power is not transmitted.
1STCUITCH 3AOCLUTCH
~o 4TH CLUTCH
so lllox H :MIHIFT..VALV!
ORlfl~ CONTROL
IOL!NOID~11
4TH ACCUMULATOA 2-3SHIFTVALVE, ~-J[IO
2NO ACCUMULATOA
LIII
:J
~
[[ _ ' "11"
~"
~2T-:~~ "11 '----i..D='J
..., lbO solí

=
. 1
- - - - JF.
)
4TH E>CT VALVE

b:! ~
IFf''"·"',
KICK"[DOWNlJE,ee;,
,~
- _,;,.¡ u
F=>,.,,,, n
r..
'" VAL VE
LOCK·UPCVT VALVE
..
1
,., "
n
·- (
.11 11 ..
~
r-,
.
,.11<1
] ''
THROTTU: VALV! 8
-~
, J] •:U I~
c
11
~·e>j/~
TOROUECONVEATIER
CHECK VALVE ~ ~NORV ...... VE
/ i e
-~ l2 _ .
J 110
\ n
t,
-
RELIEf VALVE
~
- u ......
REVER&f CONTROLVAL VE
- HI
COOlER'RE\.lEf VALVE OIL ........
14-28
Lock-up System D 1281 /D 1 583
Lock-up Operation
1 . Description
Lock-Up comes into operation in the j 04 ! position 2nd speed or above, depending on the vehicle speed, the opening
of the throttle, etc. for improved fuel economy and quieter operation.
2. Major Components
The L/C cut valve, L/C timing valve A, L/C shift valve, L/C timing valve B and L/C control valve combines to actuate
the L/C clutch.
THROTTLE B PRESSURE
LOCK-UP CUT VALVE No Lock-up Moda
L
__J
so
REGULATOR VALVE
99
COOLER RELIEF VALVE
NOTE:
• When used, "left" or "riqht" indicates direction on the flow chart.
• L/C: Lock-up (cont"d)
14-29
Description
Lock-up System 01281/01583 (cont'd) -------------
3. Operation
( 1) When the throttle opening is at predetermined value or higher in the 104 ! position 2nd speed or above, the throttle
B pressure is applied to at the end of the L/C cut valve, causing the valve to move to the left. This uncovers the
oil port, leading the line pressure to the L/C timing valve A.
(2) Governor pressure works on the end ot the L/C timing valve A only in the) 04 I position. Thus, as the governor
pressure increases, the L/C timing valve A is moved to the right, leading the line pressure from the L/C cut valve
to the L/C shift valve through the L/C timing valve A.
THROTTLE B PRESSURE
! ·---- UNE PRESSURE

......1----THROTTLE A PRESSURE
i,...,......___ GQVERNOR PRESSURE
LOCK-UP CUT VALVE Lock-up Control Mode
REGULATOR VAL VE
99
RELIEF VALVE
COOLER RELIEF VALVE
NOTE:
• When used, "left" or "right" indicates direction on the flow chart.
• L/C: Lock-up
14-30
(3) As the line pressure is applied to the right end of the L/C shift valve, the valve is moved to the left.
(4) Torque converter pressure from the regulator valve then flows through the L/C shift valve into the torque converter
from the right side (back side) of the L/C piston.
(5) Pressure in the right side of the L/C pistan makes the L/C pistan stroke and locks up the L/C clutch.
At the same time, the torque converter pressure in the L/C control valve from the L/C shift valve and L/C timing
valve B is applied on the left side of the L/C pistan. However, this pressure is maintained lower than the pressure
on the other side by the two opposing pressures working on both sides of the plunger in the L/C control valve. In
this way, lock-up capacity is controlled. The position of the plunger in the L/C timing valve B determines the lock-up
control, or full lock-up mode. lf the throttle A pressure working on the left end of the L/C timing valve B plunger
is greater than the governor pressure on the right end, lock-up capacity is controlled. Full lock-up is achieved in the
opposite case as the pressure to the left (back) side of the L/C piston is cut by the timing valve B and the remaining
pressure is released from the orífice of the L/C control valve.
(6) When the throttle opening is below the predetermined valve, the throttle B pressure is lowered gradually, causing
the L/C timing valve A to move to the left. At the same time, the L/C cut valve and L/C shift valve are also moved
to the right.
(7) As the L/C shift valve is moved to the right, the torque converter circuit switches to the left (back) side of the L/C
pistan to release the lock-up,
- LINE PRESSURE
- THROTTLE A PRESSURE
- GOVERNOR PRESSURE
Full Lock-up Mode

LOCK-UP CUT VALVE
_)
REGULATOR VALVE
99
COOLER RELIEF VALVE

NOTE:
• When used, "left" of "right" indicates direction on the flow chart.
• L/C: Lock-up
14-31
Description
Hydraulic Flow D 1 584/D 16A9
DESCRIPTION DESCRIPTION DESCRIPTION DESCTIPTION

No. No. No. No.
OF PRESSURE OF PRESSURE OF PRESSURE OF PRESSURE
1 UNE 10 1ST CLUTCH 41 4TH CLUTCH 91 TOROUE CONVERTER
2 UNE 11 1ST CLUTCH 42 4TH CLUTCH 92 TORQUE CONVERTER
3 UNE 20 2ND CLUTCH 50 THROTTLE A 93 OIL COOLER
3' UNE 21 2ND CLUTCH 51 THROTTLE A 94 TOROUE CONVERTER
3" UNE 23 2ND CLUTCH 55 THROTTLE B 95 LUBRICATION
4 UNE 24 2ND CLUTCH 56 THROTTLE B 96 TOROUE CONVERTER
4' UNE 30 3RD CLUTCH 60 GOVERNOR 97 TORQUE CONVERTER
5 UNE 31 3RD CLUTCH 61 GOVERNOR 99 SUCTION
6 MODULATOR 40 4TH CLUTCH 90 TOROUE CONVERTER X BLEED
[NJ Position
When the manual valve is in neutral, it prevents the oil from flowing to the shift valves and clutches.
The regulator valve maintains the line pressure at a constant level.
The torque converter check valve prevents oil pressure within the torque converter from falling below a predetemined limit.
111 r·
IST ACCUMUU.TOR
2NO CLUTCH 10 •o 4TH CLUTCH

..
SHIFT TlMING
VAL VE
ORIFICE CONTROL
SOLENOIO~~
=.r- 1
~"11 'º111
2·3 SHIFTVALVE~
·; "= " := 11
J-4SHIFTVALVll
' 11
fjJl~•"=-~1rl~r~~l~~~~~~~=~JL=,i
Xf,
'ST
C,L,UTCH3> [0RO,CLUTCH
~
3-.,~TIMIN VALVE
' . I==
= 1·2 SHIFT v~~l\(_\,VE.i,'.i.JJ..¡~·-;c,--'élll:ilnl
,:l'!,
- _[]JI
.,,,111 . LOCK·UP CONTROL
=====;iSOLENOID VALVE B 11 ~
~ .- ...
n .'JI 11. n "n '
111r 1
(11 • 1
'-=====LO·U TROL
~ •1t·l1h·~
W
LOCK-UP CUT VALVE CLU~CHPR~SS~~,.~ REVERSE TIMING ~
li[L ~
... L
CONTROL VALVE 11
LO~ •11"THROTTLE VALVE A
fis~~~:Eo;n 11.,
II fFn'i'
•.
.
{I ...'11 _
-,
'"'tlf'"'
• ·n L.·.
uu-uu,f
11
MOOULAT0R VAlVE 2ND ORIFICE H

r,:::=J CONTROL YAl.VE
I IL_ P. " r. 11
n ,1611,~ ''Ír ~ n "11 11 11 ..

un
f
• 1
====dbD
11 u lOCK-UP
VAlYE 8
T~MLNG
REGULATOR VALVE
·1 . .
THROTTLE VALYE
"Q) B
i~
lkc:='."""lit=:~c=!l
Lc5" . 11 "~~-~ 111 ~
~
o:: __-.01 SERVO VALVE =
.':.l_nJ;;-t--=-,
"~ , 11 = \,:,: ~o.;:.:~~NOF
C:
TOROUE CONVERTER
CHECK VAlVE I
\ ; 'JI • JI • 1 ·~
~- ~ LX_ ..
RELIEF YALVE REVERSE
J
CONTROL
1411
VAlVE
COOLER RELIEF VAL VE
14-32
(I] Position
Oil from the oil pump travels through the manual valve to the second clutch; the second clutch is on. lt also flows through
the governor valve to the 1-2 and 2-3 shift valves. The modulator valve and throttle valve B receive the oil from the
pump. The throttle valve A receives the oil from the modulator valve.
-o-
IST ACCUMULATOl!i
IST CLUTCH 3RO CLUTCH
. ü1· ~,
' ft., -
. .:mi
',· u
1
~ nn_n
!,~,,
I"L1"\..
,· M 11 ..
~,t
11
L .J ,;:nJ
Y..
- 1 u T~ll~TTlE "
VALVE A
(Q)
.
,....-
==¡-
"
~
'
SEJIVO YALVE
~,
_;-r=d]
, .. re
H
Ol•l•-(ID
=
=
,',¡
"
11
~
=
~- ~- . L ]
'/ ; ,
' "n
•
0/l.COOLER
r; - . :::J !~
u u ...............
l
RELIEF VALVE
~ ~ REVERSE CONTROL \IALVE
OIL l'UMI'
NOTE: When used, "left" of "right" indicates direction on the flow chart. (cont'd)
14-33
Description
Hydraulic Flow 01584/016A9 (cont'd)
1 03 ! or 04 ! Position
1
1. 1st speed
The manual valve directs the oil to the first clutch through the port (4) and inlet ( 1 O). The line pressure is applied to the
governor vafve, modulator valve and throttle valves. In this transmission, two pressures from the throttle valve A and
governor valve oppose each other in attempting to move the shift valves. In the first gear range, the 1-2 shift valve is
moved to the right since the pressure(60) from the governor valve is lower than the pressure (50) from the throttle valve
A. With the 1-2 shift valve moved to the right, no oil is directed to the 2nd, 3rd and 4th clutches; that is, only the first
clutch is on.
NOTE: When used, "left" of "right" indicates direction on the flow chart.
14-34
\ 03 \ or \ 04 \ Position
2. 2nd speed
The flow of fluid up the 1-2 and 2-3 shift valve is the same as in first gear. When the vehicle speed reaches the prescribed
value, the governer pressure increases.. At the 1-2 shift valve, the governer pressure (60) overcomes the throttle A pres-
sure and spring force combination. The 1-2 shift valve is moved to the left. The movement of the 1-2 shift valve causes
the hydraulic pressure lines to be changad. The line pressure (2) at the manual valve becomes line pressure (4), passing
through the clutch pressure control valve and 1-2 shift valve, becoming line pressure )5), and on to the 2-3 shift valve.
The 2-3 shift valve causes the line pressure (5) to become second clutch pressure (23). This pressure passes through
the orífice and manual valve to the second clutch and second accumulator, consequently the vehicle will move as the
engine power is transmitted.
The hydraulic pressure also flows to the first clutch. However no power will transmit by means of the one-way clutch.
14-35
Description
Hydraulic Flow 01584/016A9 (cont'd)
j D3 j or j 04 j Position
3. 3rd speed
The flow of fluid up to the 1-2 and 2-3 shift valve is the same as in second gear. When the vehicle speed reaches the
prescribed value, the governer pressure increases. In the 2-3 shift valve, the governer pressure overcomes the throttle
A pressure (50) and spring force combination. The 2-3 shift valve is moved to the left. The movement of the 2-3 shift
valve causes hydraulic line pressure to be changed and the oíl port leading to the second clutch is closed. The line pres-
sure passes through the manual valve, clutch pressure control valve, 1-2 and 3-4 shift valves to the third clutch and
third accumulator, consequently the vehicle will move as the engine power is transmitted.
The hydraulic pressure also flows to the first clutch. However no power will transmit by means of the one-way clutch
as in second gear.
lR
11T ACCUMULATO"
11! [I
ISTCLUT_:H 3RDCLUTCH
2NO CLUTCH 20 4TH CLUTCH

~'"
HIFT TIMING VALVE
ORIFICE CONTROl
r,=;~;F.~:::;¡===:,':l,;1=:.~.- ... ~
l. l .. mi
10 IIJ~II
,l •
f'I
3-4 SHIFT
YAl.VIE
Ji~ lll 10 JD
~-J
OLENOID•~ALVE •
• _. o• 2-3 SHIFT VALVE II l!lto
4TH ACCUMULATOR 2ND ACUUMULATOR
· ~ --+rnll
""rr=='-::--'~ ,e_·-~- ~~~~~!~ .. ~~
1 ~
ff.f.r·
.,t,;rr,, .. ~,~
..
~
Jll~lf~F•;•
===== ~i§·~~~~l~~l';'~~~i~l~l~~l~ LOCK-UPCONTROL
3~\:"~;M~,N~:~~·1-;'~2~vE!~l~=~~~~11~~1,
1HlfT ,JI 11 1 , ¡¡., n
.... ,ve "~-. []) 11
-u,;i=., ::=::=::)_,~~ 3RD ACCUM:~~~
___,.,
KICK ~F- · 1 ,t.:_
,..... In
~:::::::~,,l;i~~::::::: :, ~~ . : ~-~1 ~
,-,
~,~..::,·...
• llli-~·~ REVERS ..TIMING :;,v: ·-- ;-:4-a v:v• 'Jt .;=n~~=,, .
LOCK-vPCUTVALVE •
iu.~.~'l'ñrtl
n '11
~.
JI"
CLUTCHPRESIUAI!.
11°"'"°'-
11
[b ~
~·1Jil r-
~"
''il+tl91=Hll91RJ
-
11 ---... - ,U • •
_J;l
"_(o
•11n
~ VALVE •
L~
11 11 THROTTLI!VALV A
f,50LE ~ \\oo
11 __ IJ;: M~U~VALVE :'To
L .... 11 i /1» ,•, ,'] 'JI .,~'lr.::"'Jl
",,u••• dl.l'-'= """"'";
1 1 1 l
=
wu • B , 11, ... · a.. 1
u }t
•
--, u u u u u r,:
[Íj~nM-rlJ -@'-
J ~ MODULA-fOR 2ND OFIIFICE ,o
11 11 VALVE ... CONTROL VALVE
11
lL= 1 F = 1 r 11
TI ·~ ~.. 11 11 11
''Íí
,., .. ~ 1O
D l
'I .. .I©
--··~~¡.·+_. I
u
)
VALVE B
- ..
fHROTTLE
1( -
HI
·J ,.
..
[l__ o, oi.u-·mJ
•ll
__ . e
1
TOROUE
CHECK
CONVERTER
VALVE
'/
-- ;
..
"""" ""
1
r,
u
- .\,
\
u - •
- ' n
-
RELIEF VALVE REV(RSE CONTROLVALVE
COOLER FIELIEF VALVE
14-36
\ 04 I Position
4. 4th speed
The flow of fluid up to the 1-2, 2-3 and 3-4 shift valve is same as in the third gear.
The governer pressure is not directed by the manual valve and flows through the shift timig valve to the 3-4 shift valve.
When the vehicle speed reaches the prescribed value, the governer pressure increases. In the 3-4 shift valve, the govern-
er overcomes the throttle A pressure and spring force combination. The 3-4 shift valve is moved to the left. The pressure
(61 l movement of the 3-4 shift valve cause the hydraulic pressure line to be changed and the oíl port leading to the third
clutch is closed. The line pressure passes through the manual valve, clutch pressure control valve, 1-2 shift valve, 2-3
shift valve, 3-4 shift valve and manual valve to the fourth clutch and fourth accumulator, consequently the vehicle will
move as the engine power is transmitted.
The hydraulic pressure also flows to the first clutch. However no power will transmit by means of the one-way clutch
as in second and third gears.
m
11T ACCUMUlATl)ft
IST CLUTCH 3RD CLUTCH
.. . .....,, ---=
~I]
~
·~·-
l..(r-" "
,.,
SHIFT TIMING
VAlVE 1 ]) 11
"
-
2ND CLUTCH 4TH CLUTCH
" "
JO)(II I
3.4 SHIFT VALVE
"
OAIFICE CONTROL
·~
SOLENOIO~,
a.e ,.,
j
4TN ACCUMULATOR
2ND ACCUMULATOR
X X 01( 2-3 SHIFTVALVE., ~
:1
~ [])
u
F=
~ ¡e=_ __ - __ 2· so¡¡s '11
,,1(
,r .
.x
- 3-2 TlMING VALVE
1 "1
·~
'--L9='J
1(ss SS ¡( JRD ACCUMU~TOR
=
= o "
1-2: SH\FT
VAL VE
,.JI,
11
~-•
11 ' J,.
mil
n
~
~ uu
.
x¡,ox,..,,,...,
_
l
IJ,
¡::¡¡
n
,.,u
¡'¡ _"
1 ~
•a:, ~
. . J' 1r"
LOCK-UP CONTROL
\I•. SOLENOID VALVE B

1,
.
1 4TH E>tT __. KICK OOWN-
n ' n SS,.,
~ •. •...·,- u
VAL VE VAL VE
(11
'>l I ,:=¡],,
1 n n
LOCK-UP CONTROL
,¡jv,¡r41,, REVERSE TIMING VALVE
,- ~ _,. 11 ..
IL ~
LOCK-UP CUT VA.LVE
.n CLUTCH PRESSUAE
CONTROl VALVE
" ~ i<of
. .. íl
----, -
-
·L
r'I[)- I·11 ..
f ~~
LO THROTTLEVALVE A
.
¡'OLENOIO V4LVEA l.,
fFn7 MANUAt.VALVe
" L • .~ 'Jr;"'
. ....n
J4D L--.J' I\H {I 'H
-
~J
nn ""'"'"'"""
.: l -l,-
~! .~·1'- l
JJ.~ '
-0-
-et-
B -
lllOIO "1
2NOO-;t;.C;'"':IF
OOULAT•OAVALVE CONTROL V,UVE
lL= 1 P. " ===

·~ '
'º- - - 11
.J. ·~ -- .. 11 11
... 11
.
¡q LJ -111•1• ''Íf
d~ LOCK-UPLJ
REOULATOR
VALVE
''
u
"©
.
TIMING
VALVE8 ____:, ;c==!j
~ ·1 THROTTLEVALVE 8
11 ~ - " ~~::in
-- H ..........
.=I
J] ·rf .. --
11- _
bl ~t---11.J..
" ~ ""1
-
01110-(m
0::.-::-::-_ól SERVOVALVE
,e,, 11=7
-.
" " 11
TOROUE CONVERTER ~ "11 ' ~ ~G~z~:ENOR
CC
CHECKVALVE
,11,
.,.rn
/
i
OIL COOLER \ n
11
TI
1
1_
u
-
RElJEF VALVE
1:
=- .. ~ -
REVERSE CONTROL VALVE
1
-
COOLER RELIEF VALVE
14-37
Description
,-
Hydraulic Flow D 1 584/D 16A9 ( con t'd)
[fil Position
The flow of fluid through the torque converter circuit is the same as in the [E] position. The fluid ( 1) from the oil pump
flows through the manual valve and becomes the line pressure (3). lt passes through the reverse control vatve to the
servo valve, causing the shift fork shaft to be moved in the reversedirection. Also the fluid (3') flows through the manual
valve to the fourth clutch; the power is transmitted through the fourth clutch.
When driving forward and at about 30 km/h and the gear shift lever is shifted to the position, the governer pressure rnJ
(60) moves the reverse control valve to the left. This results in cutting off the oil passage which has líne pressure (3)
and is directed to the servo valve. Eventhough the manual valve is set to the position, the transmission will not shift rnJ
into reverse gear.
IST ACCUMULATOR
-~ij,1~
115 [!~
IST CLUTCH 3RD CLUTCH
'
2NO CLUTCH
J.;)
4Tl-t CLUTCH
~ SHIFT
VALVE
TIMING
L=Q__r-'
!>O
(.
,o.11
" "
I:: - "H~
tlll "
!Ü i'
" " 3~ SHIFT VALVE
OAIFICE CONTROL " "
--
SOLENOID~,
•• ox ~ JltlO _
2-3 SHIFT VALVE
----
2ND ACCUMULATOR
-:-rn1
-~1
4TH ACCUMULATOA
~ -- l""t:3
- ,,I[
1(--~- [[ ___ ~ '11
·~ ~~ l. ---,. 3·2 TIMING VALVE

• "11'
"11
,X
~
1 l" ·~
~ / JRo AccuMuU:ToA
1" -11
;e= :=o::ni
=
n lÍ _"
~'
' ,o
11
• H"º\., ....
l.
" 1-2 SHIFT VA~~j~ l 11 _ sn.__h_r, 1 ¡::i A
n '":11 . . X
LOCK-UP
SOLENOID
CONTROL
VALVE B
n " - lk_ 1 11 ~ rr . ,,-

:rn1 u ,-,- - - - I~
4TH
VAL VE
EXT
KICK DOWNt.:.:.
VAL VE
IF"
11 c;JI 1 1 n •• •
r1B !,,!O
-11- ,... 'Y.
r,...n...rL....
LOCK·UP CONTROL
11 ..
LOCK·UP CUT VALVE
rv ·I ~"1[~~97 CLUTCH
-
CONTROL
PAESSURE
u
VALVE
•
REVERSE
11[
TIMING J
VALVE
~,·u~
~
,¡-'
11
-.. -
.. ·11 • • "(Ó
IIID :J • l ·~
·L
11
l -;, " THROTTLE VALVE A
. --
'~
'"
[ SOLENOID VAlVE A
-
'
~
i4 D
MANUAL VALVE
1 . "fo 1 ; "
. 1 {l .. 2,ºI "'Ir.:= i x n
-
JJ' - - uur
uu¡~
'""''"''""" "
,zullo.
"
..
--®-- ' ' ' 2060 "1 l.~~
~ MODUL.AT~LVE 2NO ORIFICE )O
CONTROL VALVE
'"0--- -
l!::= F\. " rr
..
,.._..,.I
..
11
~ - 1 ..
-
" ,..,. 11
iJ •'fF e: .-..
~~1)
lj\z
• .
wr -
..
1( 1-.E.
iíl
1 Q
REGULATOR H
..-
VA.LV! u u
LOCK·UP TIMING
--
VALVE B
~j"~u
;;!! ¡ 1 TH::TTlE VAL VE B©
11 t~ --~ -I! _
~~91
-- ··-· Jl ltt =
-- 111.,¿5 "9
~·
"Ju
~~ l ir. __ '.01 º'"º. ·111 "
"
. ,'il
SERVO VALVE ~-
. ..) Is
" " 11
~ ' =
<:::'. ~~~~~~NOR
~- . C
TORQUE CONVERTER
/
CHECK VALVE
i
OIL COOLER \ a ~6~
~
11 1
t;
u
RELIEF
-
1:
VALVE ~ ~
u
REVERSE CONTROL
~-
~Jq[
- -
VALVE
COOLER RELIEF VAL VE Of.l ,u .. ,.
14-38
[!] Position
The flow of fluid through the torque converter is the same as in the I]] position. The line pressure ( 1) becomes the line
valve, causing the reverse shift fork to be moved to the reverse position same as in the ffi] position. However,
the hydraulic pressure is not supplied to the clutches. The power is not transmitted.
3RD Cl.UTCH
r 11 l'==0='
SHIFT TIMING VALVE 1
2ND ClUTCH
4TH ACCUMUL.ATOR 2NO ACCUMULATOfl

ORIFICE CONTROL
SOLENOIÓ~.11
2-3 SHIFT VALVE ~ t- lfio ~
~ ~-J =~,·. ="~11"~~2'11 ,'~,X~~~-ll~l~~~~~~f~(t~'i:~~c("il:~-~=

~
CSS-~---~~ ~ .
~~ l ~t~;~¡~~~~~~~][¡~~11~,~~;i~~~Í-li '~.,~~¡~~"'1~~ ~ 1,
l>T,IMING_~~:ven
1
11
~ t: .._.:J't.'..".a...o
_"' JRO ACCUMUheLAa¡TO"'R"'!;¡l'J-C:::,r'.
i~f
::::== u 11,;JI - soH 11 11 11 11,, n 1["_ {; " LlJ- ,
1-2SHIFTVA~~¡I\E~,,l';.¡¡Jlll¡,./Jllsl;:J-',JI~•~, c:1::] T
u Dl I I~
~ª_n;:~
LOCK-UP CONTROL J-Z w u L.I u
4011 r, 1,, ~' '=====SOLENOIO
VALVEB ji 1 11 _., - 4THEXT~ KICK OOWN u
1 t~SI l=0=====' L CK-UPCONTROL I ss .''~ ~ o • • ' ,,. :_ u VALVE f ~LVE~
LOCK-UPCUTV~LVE
,....
e v:L~,.
11 11 .
-
CLUTCH PRESSUREII
u -.11,- EV RSETIMINGVAL~~~:.
~
7 ................ - 4tl il 11 ': --'" •_R-, fs_!_ l[soL
o
\O 11 l •
II~ 1 C¡;cO=NT=R=OL=V=A=LV=E=~.,l===eJ
:::; _,_ fn::D=; '-<- - •II , ,
l u u ,,-~J[L~;:!, THROTILEVALVE A
..
"l •~n· ~- i'A~,~~tr~i~!ii~~~líll~.

fFSOLENOIOVALVEA e ~
1\ .fL ,,
IG
nn---
]41] ·"1 n
-= 2Jt~vE n::
)
===1.1 MOcuLAToR 2NC ORIFICE
CONTROL VALVell 'u
lL= 1 R. "' ...:=111
.. 11 :~11\1 '{/ \' ,... - ,,12 1i 11 10 2fr -r n "I ,. . . ..1 11

•
=
~O;K,UP TIMO~G
VALVE B
>,] 91
•EGULATOR VALVE
ffb_, 9J ~
....... ~ '-,,··~J~
- •,e
tti
• u
- •.!::• -:::::!!!!
~;·c-_, 'Ü,-:;;.,.11~•=•
,.di
=-~(Q)"°;
\ o)
THROTILEVALVE B
., JU
\'. ::,___ '@ ¡ == Jl IILé5 ........ --= =
"
. ""'!
- 'l ' "

j;---~~,,)~~~1--l~~"Lr~=:!!:::~,. il: d] seevc VALVE "'
,'11
JI
c
e::
~ =
-
TOROUECONVERTER
CHECK VALVE
'l .
ii ____:_ul~l
O>L C~OOLER
l" ~Jí_ .
j
RELIEF VAlVE / REVERSE CONTROLVALVE
COOLERRELIEF VAlVE OIL PUMP
14-39
Description
Lock-up System D 1584/D 16A9
Lock-UP Operation
1. No Lock-Up
The pressurizedfluid regulated by the modulator works on both ends of the lock-up shift valve and on the left side of
the lock-up control valve. Since, under this condition, the pressuresworking on both ends of the lock-up shift valve are
equal, the shift valve is moved to the right by the tension of the valve spring alone. The fluid from the oil pump will flows
through the left side of the lock-up clutch to the torque converter; i.e., the lock-up clutch is in OFF condition.
CLUTCH PRESSURE
THROTTLE
A PRESSURE
+
eox
l
(AT THE TIME OF KICK DOWN)
X
6
i
MODULATOR PRESSURE
UNE PRESSURE (FROM 1-2 SHIFT VALVE)
,fil.=
'~ .••T•TL.. .-.-.~:,.,.,,.,u=i~
LOCK-UP CONTROL
SOLENOID VALVE B
I~
~·'-·····-•••••.•••.•••••.·~·
~
• "• X
LOCK-UP CUT-OFF LOCK-UP
VALVE CONTROL
VALVE
LOCK-UP OFF
CONTROL
SOLENOID
VALVE A
L':::::=== ..---THROTTLE B PRESSURE
111!11-----------·------ . ----
r.====~~:;:=====~===t,l:===========~it----GOVERNORPRESSURE
TOROUE CONVERTER PRESSURE
TORQUE
CONVERTER
CHECK
VALVE
93
COOLER RELIEF VALVE
14-40
2. Partial Lock-Up
Lock-Up Control Solenoid Valave A: ON Lock-up Control Solenoid Valve B: OFF
The ECU switches the solenoid valve A to ON to release the modulator pressure in the left cavity of the lock-up shift
valve. The modulator pressure in the right cavity of the lock-up shift valve overcomes the spring force, thus the lock-up
shift valve is moved to the left side.
The torque converter pressure is separated to the two passages:
Torque Converter lnner Pressure: enterad into right sida-to engage lock-up clutch
Torque Converter Back Pressure: entered into left side-to disengage lock-up clutch
The back pressure (F2) is regulated by the lock-up control valve, whereas the position of the lock-up timing valve B is
determined by the governor pressure, tension of the valve spring and pressure regulated by the governor. Also the posi-
tion of the lock-up control valve is determinad by the throttle B pressure, back pressure of the lock-up control valva and
torque converter pressure regulated by the check valve. In low speed ranga, the throttle B pressure working on the right
side of the lock-up control valve is low, causing the valve to be moved to the right. With the lock-up control solenoid
valva B kept off, the modulator pressure is maintained in the left end of the lock-up control valva; in other words, the
lock-up control valve is moved byt slightly to the left side. This slight rnovement of the lock-up control valve causes
the back pressure to be lowered slightly, resulting in partial ..
CLUTCH PRESSURE (AT THE TIME OF KICK DOWNI

THROTTLE A PRESSURE I
M~DULATOR PRESSURE
f f f / UNE PRESSURE (FROM 1-2 SHIFT VALVEI
__ __.
. .._ OFF
LOCK-UP CONTROL
SOLENOID VALVE B
LOCK-UP CUT-OFF VALVE LOCK-UP

97
LOCK-UP CONTROL
CONTROL VAL VE
SOLENOID
VALVE A
L=== ----- THROTTLE B PRESSURE
91
OIL COOLER
99 - 9S
RELIEF VALVE
COOLER RELIEF VALVE

(cont'd)
NOTE: When used, "left" or "right" indicates direction on the flowchart.
14-41
Description
Lock-up System D 1584/D 16A9 (cont' d)
3. Half Lock-up
Lock-up Control Solenoid Valve A: ON Lock-up Control Solenoid Valve B: ON
The modulator pressure is releasedby the solenoid valve B, causing the modulator pressure in the left cavity of the lock-
up control valve to lower.
Also, the throttle A pressure in the left cavity of the lock-up timing valve B is low. However the governor pressure is
still low at this time, consequently the lock-up timing valve B is kept on the right side by the spring force.
With the lock-up control solenoid valve B turned ON, the lock-up control valve is moved somewhat to the left side, caus-
ing the back pressure (F2) to lower. This allows a greater amount of the fluid (F1) to work on the lock-up clutch so as
to engage the clutch. The back pressure (F2) which still exists prevents the clutch from engaging fully.
CLUTCH PRESSURE(AT THE TIME OF KICK DOWNI
THROTTLE A PRrSURE +I i
MODULA TOR PRESSURE
UNE PRESSURE (FROM 1·2 SHIFT VALVE)
LOCK-UP CONTROL
SOLENOID VALVE B
ON
97
9!L
ON
A 90 . 96
--- THROTTLE B PRESSURE

LOCK-UP
CONTROL
SOLENOID
VALVE A
...----..---------··-.....
......... __ ....,.r;- ~~
tJ!ll~1!5:!:zd ... -----------•1-1•--•---TORQUE CONVERTER PRESSURE
~
r;:::====f,j::;::;;;;;,======;:;;;,===jl===========---GOVERNORPRESSURE
50
91
. :'_ ~?_-~·.-.¿_~-- ~ . _·-~·-· ···· ;

==~=.:._
- .-
~~9~m~m¡¡w.;:;~é:'li~Z§:7'..Z~::
, _ :_. : :~:_-~
RELIEF VALVE
xw:r;a,::.rr.r.!7L.cr:r::r...
14-42
4. Full Lock-up
When the vehicle speed further increases, the governor pressure is increased.
The lock-up timing valve B overcomes the spring force and moves to the left side. Also this valve closes the oil port
leading to the torque converter check valve.
Under this condition, the throttle B pressure working on the right end of the lock-up control valve becomes greater than
that on the left end (modulator pressure in the left end has already been released by the solenoid valve B); i. e., the lock-
up control valve is moved to the left. As this happens, the torque converter back pressure is released fully, causing the
lock-up clutch to· be engaged fully.
CLUTCH PRESSURE
(AT THE TIME OF KICK DOWN)
THROTTLE A PRESSURE I MQDULA TOR PRESSURE
t t f 6 UNE PRESSURE (FROM 1-2 SHIFT VALVEI
... ············
6 :
X ! ON I LOCK-UP CONTROL
SOLENOID VAL VE B
LOCK-UP
CONTROL 97
VALVE
ON
90 96
LOCK-UP
CONTROL L::::==·----- THROTJLE B PRESSURE
SOLENOID LOCK-UP SHIFT
VALVE A VALVE
9 1
NOTE: When used, "left" or "right" indicates direction on the flowchart. (cont'd)
14-43
Description
Lock-up System D1584/D16A9 (cont'd) ---------------,
5. Deceleration Lock-Up
Lock-Up Control Solenoid Valve A: ON Lock-Up Control Solenoid Valve B: Duty Operation (ON .... OFF)
The ECUswitches the solenoid valve B to on and off alternately in high speed under certain condition. The slight lock-up
and half lock-up regions are maintained so as to lock the torque converter properly.
CLUTCH PRESSURE (AT THE TIME OF KICK DOWN)
,
THROTTLE A PRE~SURE
tI t
MODULATOR PRESSURE
LINE PRESSURE (FROM 1-2 SHIFT VALVEI
: LOCK-UP CONTROL
: SOLENOID VAL VE B
~=~ON
OFF
LOCK-UP CUT-OFF
97
VALV..:E=-----~•
LOCK-UP ON
CONTROL
SOLENOID 90
96 91 SS
VALVE A
L===·---THROTTLE B PRESSURE
tp:c;i:::r;l¡r:)J:D:uif.1 --------·-----------ñ .... ----+--TORQUE CONVERTER PRESSURE
TOROUE
CONVERTER
CHECK
. VALVE
93 91
90
- 94
OIL COOLER
99
14-44
Electronic Lock-up Control System
The electronic lock-up control system consists of the ECU, sensors, and 2 solenoid valves. Lock-up is electronically con-
trolled for comfortable driving under all conditions.
The ECU is located under the dashboard on the passenger's side.
Lock-up control
From sensor input signals, the ECU detects whether to turn the lock-up ON or OFF and activates lock-up control solenoid
valve A and/or B accordingly.
The combination of driving signals to lock-up control solenoid valves A and B is shown in the table below.
1\ Solenoid valve
A B
Lock-up condition \
Lock-up OFF OFF OFF
Lock-up, slight ON OFF
Lock-up, half ON ON
Lock-up, full ON ON
Lock-up Duty operation
ON
during deceleration OFF - ON
ECU
Vehicle Speed Signal
Throttle Angle
Signal
-¡¡¡
e
Cl
¡¡; Lock-up Control
e
.5! Solenoid Valve A
.'!:: Lock-up
111
Q
a. Control
::: Lock-up Control
:e
(1) Solenoid Valve B
Check Engine
Warning Light
Brake Light
Switch Signal
111
·¡¡;
Q
Coolant Temperature e
Signal e, e Self-Diagnosis
.!!! Q lndicator
Q ':.:
• u
:!:: e
G) :s
Englne RPM (1) u..
14-45
Troubleshootlnq
Electrical Troubleshooting 01584/016A9 --------------.
lf the lock-up control system is suspected to be faulty, do the following:
1. Check the Check Engine Light (816A9) or PGM-CAR8 control unit LED (D1 584).
D16A9
-1. lf the Check Engine Light comes on, check and inspect PGM-FI system according to PGM-FI Troubleshooting
(See Section 11 ).
01584
-1. lf the LEDblinks, check and inspect PGM-CAR8system accordingto PGM-CAR8 troubleshooting (SeeSection 11 ).
D16A9 01584
LEO
CHECK ENGINE LIGHT
2. D 16A9: lf the Check Engine Light does not come on or blink other than nineteen times;
D 1 584: lf the LEO does not blink other than eleven times;
Check and inspect according to the Symptom-to-Component Chart ( 14-48 thru 51).
3. Check the lock-up control solenoid valve ( 14-4 7).
14-46
Lock-up Control SolenoidValve A/B (01584/016A9)
Test Replacement
NOTE: Lock-up control solenoid valves A and B must be 1. Remove the mounting bolts and lock-up control sole-
removed/replaced as an assembly. noid valve assembly.
1. Disconnect the connector from the lock-up control NOTE: Be sure to remove or replace the lock-up con-
solenoid valve A/8. trol solenoid valves A and B as an assembly.
2. Measure the resistance between the No. 1 terminal 2. Check the lock-up control solenoid valve oil passages
{SOL. V A) of the lock-up control solenoid valve con- for dust or dirt and reptace as an assembly, if
nector and body ground and between the No. 2 ter- necessary.
minal {SOL. V B) and body ground.
STANDARD: 14.1-15.5 O (at 25ºC) LOCK-UP CONTROL

SOLENOID VAL VE
ASSEMBLY
View from
terminal side.
3. Replace the lock-up control solenoid valve assem- 3. Clean the mounting surface and oíl passages of the
bly if the resistance is out of specification. lock-up control solenoid valve assembly and install
a new base gasket.
4. Connect the No. 1 terminal of the lock-up control
solenoid valve connector to the battery positive ter- 4. Check the connector for rust, dirt or oil and recon-
minal and body ground. A clicking sound should be nect it securely.
heard. Connect the No. 2 terminal to the battery
positive terminal and body ground.
A clicking sound should be heard.
5. lf not, check for continuity between the ECU A 1 9

or A 17 harness and body ground (See Section 11 ).
6. Replace the tock-up control solenoid valve assem-

bty if there is continuity between the ECU A 19 or
A 17 harness and body ground (See Section 11 ).
14-47
Hydraulic System
Symptom-to-Component Chart -------------------
Check these items on the Check these items on the

SYMPTOM
PROBABLECAUSE LIST NOTESCHART
Engine runs, but car does not move in any gear. 1,6,7,16 K, L, R, S
Car moves in ffi] and 1 21, but not in I D3 I or f D4 l. 8, 29, 44, 48 C,M,O
Car moves in ~. ~. [[), but not in rn. 9, 30, 49 C, L
Car moves in ~. [Q;j, rn. but not in [ffi. 1, 11, 22, 34, 38, 39, C, L, Q
40
Car moves in [fil. 1, 8, 9, 1 O, 11, 46, C,D
47
Excessive idle vibration. 5, 17 8, K, L
Slips in all gears. 6, 7, 16 C, L, U
No engine braking in l 21 position. 9 C, D, L
Slips in 1 st gear. 8, 29, 44, 48 C,N,O,U
Slips in 2nd gear. 9, 20, 23, 30, 49 C, L, U
Slips in 3rd gear. 10, 21, 23, 31, 44 C, L, U
Slips in 4th gear. 11, 23, 32 C, L, U
Slips in reverse gear. 11, 32, 34 e
Fiares on 1 - 2 upshift. 3, 15 E, L, V
Fiares on 2-3 upshift. 3, 15, 24, 44 E, L, V
No upshift, trans stays in low gear. 14, 19, 23 G, L
No downshift to low gear. 12, 19 G, L
Late upshift. 14 L, V
Erratic shifting. 2, 14, 26 V
Harsh shift (up and down shifting). 2, 4, 15, 23, 24, 27, A, E, H, 1, L, V
47
Harsh shift ( 1 - 21. 2, 9 C, D,V
Harsh shift (2-3). 2, 10, 23, 24 C, O, H, L, V
Harsh shift (3-4). 2, 11, 23, 25 C, D, 1, L, V
Harsh kick-down shifts. 2, 23, 27, 28 L, V, Q
Harsh kick-down shift (2-1 ). 48 o
Harsh downshift at closed throttle. 15 E, T
Harsh shift when manually shifting to fTl. 33 L
Axle(s) slips out of trans on turns. 43, 50 L, P, O
Axle(s) stuck in trans. 43 L, Q
Ratcheting noise when shifting into IR/. 6, 7, 38, 39, 40 K, L, O
Loud popping noise when taking off in [ Rl. 38, 39, 40 L, Q
Ratcheting noise when shifting from [ffi to [f] or from 38, 39, 40, 45 L, Q
ffi]
to [fil.
Noise from trans in all selector lever positions. 6, 17 K, L, Q
Noise from trans only when wheels are rolling. 39, 42 L, Q
Gear whine, rpm related (pitch changes with shifts). 8, 13, 41 K, L, O
Gear whine, speed related (pitch changes with speed). 38, 42 L, Q
Trans will not shift into 4th gear in 1 04 /. 1, 21, 28, 32 L
Lock-up clutch does not lock up smoothly. 17, 36, 37 L
Lock-up clutch does not operate properly. 2, 3, 1 5, 18, 35, 36, E, L, V
37
Transmission has multitude of problems shifting. 43 L,Q
At disassembly, large particles of metal are found on
magnet.
14-48
PROBABLE CAUSE
1. Shift cable broken/out of adjustment.
2. Throttle cable too short.
3. Throttle cable too long.
4. Wrong type ATF.
5. ldle rpm too low/high.
6. Oil pump worn or binding.
7. Rgulator valve stuck.
8. 1 st clutch detective.
9. 2nd clutch detective.
10. 3rd clutch detective.
11. 4th clutch detective.
14. Modulator valve stuck.
15. Throttle B valve stuck.
16. A TF strainer clogged.
17. Torque convertor detective.
18. Torque convertor check valve stuck.
19. 1-2 shift valve stuck.
22. Servo control valve stuck.
23. Clutch pressure control (CPC) valve stuck.
24. 2nd orífice control valve stuck.
25. Orífice control valve stuck.
26. 3-2 kick-down valve stuck.
27. 4-3 kick-down valve stuck ,
28. 4th exhaust valve stuck.
29. 1 st accumulator detective.
30. 2nd accumulator detective.
31. 3rd accumulator detective.
32. 4th/reverse accumulator detective.
34. Servo valve stuck.
35. Lock-up timing valve stuck.
36. Lock-up shift valve stuck.
37. Lock-up control valve stuck.
38. Shift fork bent.
39. Reverse gears worn/damaged (3 gears).
40. Reverse selector worn.
41. 3rd gears worn/damaged (2 gears).
42. Final gears worn/damaged (2 gears).
43. Differential pinion shaft worn.
44. Feedpipe 0-ring broken.
45. 4th gears worn/damaged (2 gears).
46. Gear clearance incorrect.
47. Clutch clearance incorrect.
48. One-way (sprag) clutch detective.
49. Sealing rings/guide worn.
50. Axle-inboard joint clip missing.
(cont'd)
14-49
Hydraulic System
Symptom-to-Component Chart (cont'd)---------------
Check these items on the

The following symptoms can be caused ltems on the
PROBABLECAUSE DUE
by improper repair or assembly. NOTES CHART
TO IMPROPERREPAIR
Car creeps in [N]. R1, R2
Car does not move in ~ or ~· R4
Trans locks up in []]. R3, R12
Excessive drag in trans. R6 R, K
Excessive vibration, rpm related. R7
Noise with wheels moving only. R5
Main seal pops out. R8 s
Various shifting problems. R9, R1 O
Harsh upshifts. R11
PROBABLECAUSE DUE TO IMPROPERREPAIR

R1. lmproper clutch clearance.
R2. lmproper gear clearance.
R3. Parking brake lever installed upside down.
R4. One-way (sprag) clutch installed upside down.
R5. Reverse selector hub installed upside down.
R6. Oil pump binding.
R7. Torque converter not fully seated in oil pump.
R8. Main seal improperly installed.
R9. Springs improperly installed.
R10. Valves improperly installed.
R11. Ball check valves not installed.
R12. Shift fork bolt not installed.
14-50
NOTES
B. Set idle rpm in gear to specified idle speed. lf still no good, adjust motor mounts as outlined in engine
section of service manual.
c. lf the large clutch piston 0-ring is broken, inspect the piston groove for rough machining.
D. lf the clutch pack is seized or is excessively worn, inspect the other clutches for wear and check the
orífice control valves and throttle valves for free movement.
E. lf throttle valve B is stuck, inspect the clutches for wear.
G. lf the 1 -2 shift valve is stuck closed, the transmission will not upshift. lf stuck open, the transmission
has no 1st gear.
H. lf the 2-3 orifice control valve is stuck, inspect the 2nd and 3rd clutch packs for wear.
l. lf the 2/3-4 orifice control valve is stuck, inspect the 3rd and 4th clutch packs for wear.
J. lf the clutch pressurecontrol valve (CPC)is stuck closed, the transmission will not shift out of 1 st gear.
K. lmproper alignment of main valve body and torque convertor housing may cause oil pump seizure. The
symptoms are mostly an rpm-related ticking noise or a high pitched squeek.
L. lf the oil screen is clogged with particles of steel or aluminum, inspect the oil pump and differential
pinion shaft. lf both are OK and no cause for the contamination is found, replace the torque converter.
M. lf the 1 st clutch feedpipe guide in the R. side cover is scored by the mainshaft, inspect the ball bearing
for excessive movement in the transmission housing. lf OK, replace the R. side cover as it is dented.
The 0-ring under the guide is probably worn.
N. Replace the mainshaft if the bushings for the 1 st and 4th feedpipe are loose or damaged. lf the 1 st
feedpipe is damaged or out of round, replace it. lf the 4th feedpipe is damaged or out of round, replace
the R. side cover.
o. A worn or damaged one-way (sprag) clutch is mostly a result of shifting the trans in ~ or ~ while
the wheels rotate in reverse, such as rocking the car in snow.
P. lnspect the trame for collision damage.
o. lnspect for damage or wear:
1. Reverse selector gear teeth chamfers.
2. Engagement teeth chamfers of countershaft 4th and reverse gear.
3. Shift fork for scuff marks in center.
4. Differential pinion shaft for wear under pinion gears.
5. Bottom of 3rd clutch for swirl marks.
Replaceitems 1, 2, and 4 if worn or damaged. lf trans makes clicking, grinding or whirring noise, also
replace mainshaft 4th gear and reverse idler gear and countershaft 4th gear in addition to 1, 2, 3 or 4.
lf differential pinion shaft is worn, overhaul differential assembly and replace oil screen and thoroughly
clean trans, flush torque converter, cooler and lines.
lf bottom of 3rd clutch is swirled and trans makes gear noise, replace the countershaft and ring gear.
R. Be very careful not to damagethe torque converter housing when replacing the main ball bearing. You
may also damagethe oíl pump when you torque down the maín valve body. Thís will result in oil pump
seizure if not detected. Use proper tools.
s. lnstall the main seal flush with the torque converter housing. lf you push it into the torque converter
housing until it bottoms out, it will block the oil return passage and result in damage.
T. Harsh downshifts when coasting to a stop with zero throttle may be caused by a bent-in throttle valve
retainer/cam stopper. Throttle cable adjustment may clear this problem.
u. Check if separator plate is installed. lf it was not installed, the servo valve may have been pushed out
by hydraulic pressure causing a leak (interna!) affecting all forward gears.
v. Throttle cable adjustment is essential for proper operation of the transmission. Not only does it affect
the shift points if misadjusted, but also the shift quality and lock-up clutch operation.
A too long adjusted cable will result in throttle pressure being too low for the amount of engine torque
input into the transmission and may cause clutch slippage. A too short adjusted cable will result in too
high throttle pressures which may cause harsh shifts, erratic shifts and torque converter hunting.
14-51
Road Test
NOTE: Warm up the engine to operating temperature.
1. Apply parking brake and block the wheels. Start the engine, then move the selector lever to [Q;J position while
depressing the brake pedal. Depress the accelerator pedal, and release it suddenly. Engine should not stall.
2. Repeat same test in [QiJ positon.
3. Shift the selector lever to 104 ! position and check that the shift points occur at approximate speeds shown. Also
check for abnormal noise and clutch slippage.
01281 and 01583 engine:@il or l!h] Position
• Upshift
Throttle opening Unit of speed 1 st r- 2nd 2nd-+ 3rd 3rd-+ 4th
km/h 17-19 32-38 49-55

1 /8 throttle
rnph 11-12 20-23 31-34
km/h 29-37 58-70 93-105

4/8 throttle
mph 18-23 36-44 58-65
km/h 53-58 98-105 151-158

Full-opened throttle
mph 33-36 61-65 94-98
• Downshift
Throttle opening Unit of speed 4th-+ 3rd 3rd-+ 2nd 2nd-+ 1st
km/h -- 16-18 10-11

Full-closed throttle
mph -- 10-11 6-7
km/h 132-140 85-93 43-47

mph 82-87 53-58 27-29
• Lock-up: D4 Position
1 I
Throttle opening Unit of speed Lock-up ON
km/h 47-55
1 /8 throttle
mph 29-34
km/h 150-157
mph 93-98
14-52
D1584 engine: D4 ! or [Qi] Position
J
• Upshift
Throttle opening Unit of speed 1 st r- 2nd 2nd-+ 3rd 3rd - 4th
km/h 17-19 32-38 49-55

1 /8 throttle
mph 11-12 20-23 31-34
km/h 27-35 57-69 91-103

4/8 throttle
mph 17-22 35-43 57-64
km/h 53-58 102-109 156-163

mph 33-36 63-68 97-101
• Downshift
Throttle openíng Unit of speed 4th - 3rd 3rd - 2nd 2nd - 1st
km/h -- 16-18 10-11

mph -- 10-11 6-7
km/h 138-146 89-97 43-47

mph 86-91 55-60 27-29
• Lock-up:~ Position
Throttle openíng Unit of speed Lock-up ON
km/h 69-75
1 /8 throttle
mph 43-47
km/h 143-150
Full-openedthrottle
mph 89-93
(cont'd)
14-53
Road Test
(cont'd)
016A9 engine: [Q;J or ~ Position
• Upshift
Throttle opening Unit of speed 1 st r- 2nd Znd r+ 3rd 3rd-+ 4th
km/h 17-19 33-38 49-55

1 /8 throttle
mph 11-12 20-23 31-34
km/h 31-39 61-73 93-105

4/8 throttle
mph 19-24 38-45 58-65
km/h 58-63 111-118 156-164

mph 36-39 69-73 97-102
• Downshift
Throttle opening Unit of speed 4th-+ 3rd 3rd--+ 2nd 2nd -+ 1 st
km/h -- 16-18 10-11

mph -- 10-11 6-7
km/h 138-146 99-107 42-46

mph 86-91 62-66 26-29
• Lock-up: 1 D4I Position
Throttle openíng Unit of speed Lock-up ON
km/h 69-75
1 /8 throttle
mph 43-47
km/h 140-147
mph 87-91
4. Accelerate to about 35 mph (57 km/h) so the transmissíon is in 4th, then shift (Q;J to [IJ. The car should immediately
begin slowing down from engine braking.
CAUTION: Do not shift from [Q;J or ~ to [I] at speeds over 62.5 mph (100 km/h); you may damage the transmis-
sion.
5. Check for abnormal noise and clutch slippage in the following positions.
[I] (2nd Gear) Position

-1. Accelerate from a stop at full throttle. Check that there is no abnormal noise or clutch slippage.
-2. Upshifts and downshífts should not occur wíth the selector in this positíon.
[]] (Reverse)Posítion
Accelerate from a stop at full throttle, and check for abnormal noise and clutch slippage.
6. Test in [f] (Parking) Position

Parkcar on slope (approx. 16°). apply the parking brake, and shift into [f]posítion. Releasethe brake; the car should
not move.
14-54
Stall Speed
Test
CAUTION:
• To prevent transmission damage. do not test stall speed for more than 10 seconds ata time.
• Do not shift the lever while rising the engine speed.
• Be sure to remove the pressure gauge before testing stall speed.
1. Engageparking brake and block the front wheels.

2. Connect the tachometer, and start the engine.
3. After the engine has warmed up to normal operating temperature, shift into [QiJ.
4. Fully depress the brake pedal and accelerator for 6 to 8 seconds, and note engine speed.
5. Allow 2 minutes for cooling, then repeat same test in (Q;_], [l], and [[J.
NOTE: Stall speed in [Qi], ~. []] and [[] must be the same, and must also be within limits.
Stall Speed RPM:

Specification: 2, 750 rpm
Service Limit: 2,300-2,900 rpm
TROUBLE PROBABLE
CAUSE
Stall rpm high in [IJ, [oJJ, ~. and [[j • Low fluid level or oil pump output.
• Clogged oil strainer.
• Pressureregulator valve stuck closed.
• Slipping clutch
Stall rpm high in [o3J and ~ only • Slippage of 1 st clutch
Stall rpm low in [IJ. [oJJ, ~. and [[j • Engineoutput low, throttle cable misadjusted.
• Oil pump seized.
• Torque converter one-way clutch slipping.
14-55
Pressure Testing
··-·4@id
.9re testing, be careful of the rotating front wheels.
4. Start the engine and measure the respective
pressure as follows.
• Make sure lifts, jacks. and safety stands are placed • Une Pressure
properly. (see page 1-6 thru 1-8). • Clutch Pressure
• Clutch Low/High Pressure
CAUTION: • Throttle A/Throttle B Pressure
• Before testing, be sure the transmission fluid is filled • Governor Pressure
to the proper level.
• Warm up the engine before testing. 5. lnstall a new washer and the sealing bolt in the in-
spection hole and tighten to the secified torque.
1. Raise the car. (see page 1-6).
TOROUE: 18 N•m (1.8 kg-m, 12 lb-ftl
2. Warm up the engine, then stop the engine and con-
nect a tachometer. NOTE: Do not reuse old aluminum washers.
3. Connect the oíl pressure gauge to each inspection

hole(s).
TOROUE: 18 N·m ( 1 .8 kg-m, 12 lb-ft)
CAUTION: Connect the oil pressure gauge secure-

ly, be sure not to allow dust and other foreign par-
ticles to enter the inspection hale.
A/T OIL PRESSUREGAUGE SET

07406-0020003
(lncludes pressure hose set 07406-0020201)
A/T OIL PRESSURE

GAUGE HOSE
ASSEMBLY
07MAJ-PY40100
OIL PRESSURE--..._~
GAUGE HOSE
07MAJ-PY40110
OIL PRESSURE
JOINT
07MAJ-PV40120
A/T LOW
PRESSURE
GAUGE
07406-0070000
NOTE: Use the A/T Oil PressureGauge Set or A/T

Low Pressure Gauge replacing the oil pressure
gauge hose assembly. The A/T Oil PressureGauge
Hose (07406-00202011 may also be used.
14-56
• Line Pressure Measurement
NOTE: Higher pressures may be indicated if measurements are made in selector positions other than [H] or [EJ.
- 1. Set the parking brake and block both rear wheels securely.
- 2. Run the engine at 2,000 rpm.
- 3. Shift the select lever to [NJ or [EJ.
-4. Measure line pressure.
• 01281
SELECTOR FLUID PRESSURE

PRESSURE SYMPTOM PROBABLECAUSE
POSITION Standard Service Limit
Line [[]or~ No (or low) Torque con verter, oil 800-850 kPa 750 kPa
Une pressure pump pressure regula- (8.0-8.5 kg/cm2, (7.5 kg/cm2,
tor, torque converter 114-121 psi) 107 psi)
check valve, oil pump.
• 01583, 01584 and 016A9

Line [[] or [E] No (or low) Torque converter, oil 850-900 kPa 800 kPa
Line pressure pump pressure regula- (8.5-9.0 kg/cm2, (B.O kg/cm2,
tor, torque converter 1 21 - 1 28 psi) 114psi)
(cont'd)
14-57
Pressure Testing
(cont'd)
• Clutch Pressure Measurement
f,f,ú;IJ@id While testing, be careful of the rotating front wheels.
-1. Set the parking brake and block both rear wheels securely.
-2. Raisethe front of the car and support with safety stands.
-3. Allow the front wheels to rotate freely.
-4. Run the engine at 2,000 rpm.
-5. Measureeach clutch pressure.
1 ST CLUTCH PRESSURE
INSPECTION HOLE
3RD CLUTCH PRESSURE

INSPECTION HOLE
2ND CLUTCH PRESSURE

INSPECTION HOLE
4 TH CLUTCH PRESSURE
INSPECTION HOLE
14-58
• 01281

1 st Clutch [lliJ or [5;] No or low 1 st Clutch 800-850 kPa 750 kPa
1 st pressure (8.0-8.5 kg/cm2, (7. 5 kg/cm2,
114-121 psi) 107 psi)
2nd Clutch
(2nd hold)
rn No or low
2nd pressure
2nd Clutch 800-850 kPa
(8.0-8.5 kg/cm2,
750 kPa
(7 .5 kg/cm2,
114-121 psi) 107 psi)
2nd Clutch [Qi] or D4 ! ! No or low 2nd Clutch 420 kPa 370 kPa
2nd pressure (4.2 kq/cm-', (3. 7 kg/cm2,
3rd Clutch [lliJ No or low 3rd Clutch 60 psi) 53 psi)
3rd pressure (throttle control (throttle control
lever fully closed) lever fully closed)
4th Clutch [_!@ No or low 4th 4th Clutch 800-850 kPa 750 kPa
pressure (8.0-8.5 kg/cm2, (7.5 kg/cm2,
114-121 psi) 107 psi)
(throttle open (throttle open
more than 1 /4) more than 1 /4)
[]] Servo valve or 800-850 kPa 750 kPa
4th Clutch (8.0-8.5 kg/cm2, (7.5 kg/cm2,
114-121 psi) 107 psi)
• 01583, 01584 and 016A9

1 st Clutch ~or(Q;] No or low 1 st Clutch 850-900 kPa 800 kPa
1 st pressure (8.5-9.0 kg/cm2, (8.0 kg/cm2,
121-128 psi) 114 psi)
2nd Clutch [I] No or low 2nd Clutch 850-900 kPa 800 kPa
(2nd hold) 2nd pressure (8.5-9.0 kq/crn", (8.0 kg/cm2,
1 21 - 1 28 psi) 114 psi)
2nd Clutch ~or(Q;] No or low 2nd Clutch 420 kPa 370 kPa
2nd pressure (4.2 kg/cm2, (3.7 kg/cm2,
3rd Clutch [lliJ No or low 3rd Clutch 60 psi) 53 psi)
3rd pressure (throttle control (throttle control
lever fully closed) lever fully closed)
4th Clutch [Q;J No or low 4th Clutch 850-900 kPa 800 kPa
4th pressure (8.5-9.0 kq/crn", (8.0 kg/cm2,
121-128 psi) 114 psi)
(throttle open (throttle open
more than 1 /4) more than 1 /4)
[]] Servo valve or 850-900 kPa 800 kPa
4th Clutch (8.5-9.0 kq/crn", (8.0 kg/cm2,
1 21 - 1 28 psi) 114 psi)
(cont'd)
14-59
Pressure Testing
(cont'd)
• Clutch Low/High Pressure Measurement - 7. With the engine idling, lift the throttle control
lever up approximately 1 /2 of its possible travel
f·\@foMiN While testing, be careful of the and increase the engine rpm until pressure is in-
rotating front wheels. dicated on the oil pressure gauge, then measure
the highest pressure reading obtained.
-1 . Allow the front wheels to rotate freely.
-8. Repeat step - 7. for each clutch pressure being
- 2. Removethe cable end of the throttle control cable inspected.
from the throttle control lever.
NOTE: Do not loosen the locknuts, simply

unhook the cable end.
THROTTLE CONTROL
LEVER
THROTTLE CONTROL
LEVER
-3. Start the engine and let it idle.
-4. Shift the select lever to [5;J position.
- 5. Slowly move the throttle linkage to increase

engine rpm until pressure is indicated on the oil
pressure gauge. Then releasethe throttle linkage,
allowing engine return toan idle, and measure the
pressure reading.
-6. Repeat step -5. for each clutch pressure being

inspected.
14-60
3RD CLUTCH PRESSURE
INSPECTION HOLE
2ND CLUTCH PRESSURE

INSPECTION HOLE
4TH CLUTCH PRESSURE

INSPECTION HOLE
• 01281

2nd Clutch No or low 2nd 2nd Clutch 420-850 kPa 370 kPa
pressure (4.2-8.5 kg/cm2 (3. 7 kg/cm2,
60-121 psi) 53 psi)
3rd Clutch No or low 3rd Clutch varies with with lever released.
@] throttle opening 750 kPa
3rd pressure
(7.5 kg/cm2,
107 psi)
4th Clutch No or low 4th Clutch with lever in full
4th pressure throttle position.
• 01583, 01584 and 016A9

2nd Clutch No or low 2nd Clutch 420-900 kPa 370 kPa

2nd pressure (4.2-9.0 kg/cm2 (3.7 kg/cm2,
60-128 psi) 53 psi)
3rd Clutch No or low 3rd Clutch varies with with lever released.
U@ throttle openíng 800 kPa
3rd pressure
(8.0 kg/cm2,
114 psi)
4th Clutch No or low 4th Clutch with lever in full
4th pressure throttle position.
(cont'dl
14-61
Pressure Testing
(cont'd)
• Throttle A/Throttle B Pressure measurement
f,ffüMMN While testing, be careful of the rotating front wheels.
- 2. Remove the cable end of the throttle control cable from the throttle control lever.
NOTE: Do not loosen the locknuts, simply unhook the cable end.
-3. Shift the selector lever to [Q;], or [Qi] position.
- 5. Measure full-closed throttle A/B pressure.
-6. Move the throttle control lever to full-opened throttle position.
- 7. Measure full-opened throttle A/8 pressure.
THROTTLE B PRESSURE
INSPECTION HOLE
14-62
• D12B1andD15B3
SELECTOR PROBABLE FLUID PRESSURE

PRESSURE SYMPTOM
POSITION CAUSE Standard Service Limit
Throttle A illi] or l!h] No (or low) Throttle valve A 0-5 kPa (0-0.05 51O kPa
throttle Throttle kg/cm2, 0-1 psi) with (5.1 kg/cm2, 73 psi)
pressure modulator lever released. with lever in full
valve 515-530 kPa throttle position.
(5.15-5.3 kq/cm-',
73- 75 psi
with lever in full throt-
tle position.
Throttle B illi] or l!h] No (or low) Throttle valve B O kPa (O kq/crn", 750 kPa
throttle O psi) with lever (7.5 kg/cm2, 107 psi)
pressure released. with lever in full
800-850 kPa throttle position.
(8.0-8.5 kg/cm2,
114-121 psi)
with lever in full
throttle position.
• 01584

PRESSURE SYMPTOM
Throttle A illi] or l!h] No (or low) Throttle valve A 0-5 kPa (0-0.05 kg/ 510 kPa
throttle Throttle cm2, 0-1 psi) with (5.1 kg/cm2,
pressure modulator lever released. 73 psi) with lever in
valve 515-530 kPa full throttle position.
(5.15-5.3 kg/cm2,
73- 75 psi)
with lever in full
throttle position.
Throttle 8 [Qi] or [54) No (or low) Throttle valve 8 O kPa (O kg/cm2, 800 kPa
throttle O psi) with lever (8.0 kg/cm2, 114 psi)
pressure released. with lever in full throt-
850-900 kPa tle position.
(8.5-9.0 kg/cm2,
121-128 psi)
with lever in full
throttle position.
• D16A9

PRESSURE SYMPTOM
Throttle A illi] or 04 !
1 No (or low) Throttle valve A 0-5 kPa (0-0.05 kg/ 490 kPa
throttle Throttle cm2, 0-1 psi) with (4.9 kg/cm2, 70 psi)
pressure modulator lever released. with lever in full
valve 495-510 kPa throttle position.
(4.95-5.1 kq/crn".
70-73 psi)
with lever in full
throttle position.
Throttle B illi] or [Q;J No (or Jow) Throttle valve B O kPa 750 kPa
throttle (O kg/cm2, O psi) (7.5 kg/cm2, 107 psi)
pressure with Jeverreleased. with Jeverin full
800-850 kPa throttle position.
(8.0-8.5 kg/cm2,
114-121 psi)
with lever in full
throttle position.
(cont'dl
14-63
Pressure Testing
(cont'd)
• Govenor Pressure Measurement
f·\i,%jfjj.ij8 While testing, be careful of the rotating front wheels.

-2. Run the vehicle at 38 mph (60 km/h).
-3. Measure the governor pressure.
GOVENOR PRESSURE
INSPECTION HOLE

Govenor 104 ! or [Qi] No (or low) Govenor valve 151 -161 kPa 146 kPa
Govenor (1.51- (1.46 kg/cm2,
pressure 1.61 kq/crn>, 21 psi)
21 -23 psi)
14-64
Fluid Level
Checking/Changing
Checking Changing
NOTE: Check the fluid leve! with the engine at nor- 1. Bring the transmission up to operating temperature
mal operating temperature. by driving the car. Parkthe car on leve! ground, turn
the engine off, then remove drain plug.
1. Park the car on leve! ground. Shutt off the engine.
2. Reinstall the drain plug with a new washer, then
2. Remove the dipstick (yellow loop) from the refill the transmission to the upper mark on the
transmission and wipe it with a clean cloth. dipstick.
3. lnsert the dipstick into the transmission. Automatic transmission Capacity:

2.4 f (2.5 U.S. qts. 2.1 Imp. qt) at changa
4. Remove the dipstick and check the fluid leve!. lt 5.4 f (5. 7 U.S. qts. 4.8 Imp. qt) after overhaul
should be between the upper and lower marks.
DIPTICK (YELLOW LOOP)
/ º\1:i·
·~ FULL
ºd"' :'' \'
_¡::? --;-<-- ~ ~
~o...,
~d"'
. g~~ LOW
/\1
DIPSTICK
5. lf the leve! is below the lower mark, add fluid into

the tube to bring it to the upper mark. Use Honda
Premium Formula Automatic Transmission Fluid or DRAIN PLUG
an equivalent DEXRON® 11 Automatic Transmis- 40 N•m (4.0 kg-m, 29 lb-ft)
sion Fluid (ATF) only.
6. lnsert the dipstick back in the transmission.
14-65
Transmission
Removal
l·WúdHN
• Make sure lifts, jacks and safety stands are placed
7. Disconnect the speedometer sensor connector.
properly, and hoist brackets are attached to the cor-

rect position on the engine (see pagas 1-6 thru 1-8).
under it.
CAUTION: Use tender covers to avoid damaging

painted surfaces.
1. Disconnect the battery negative (-) and positive

(+) cables frorn the battery.
2. Remove the air intake hose.
3. Disconnect the starter motor and transrnission

ground cables.
4. Disconnect the lock-up control solenoid valve

connector.
5. Disconnect the throttle control cable at the control

lever.
6. Rernove the ATF cooler hoses at the joint pipes.

Turn the ends of the cooler hoses up to prevent 8. Remove the transmission housing rnounting bolts.
ATF frorn flowing out, then plug the joint pipes.
NOTE: Check for any signs of leakages at the hose

joints.
TRANSMISSION
GROUND CABLE
MOUNTING BOLT
9. Remove the drain plug and drain the automatic

OIL COOLER transrnission fluid (ATF). Reinstall the drain plug
CONTROL CABLE JOINT PIPES with a new sealing washer (see page 14-65).
14-66
1 O. Remove the cotter pins and castle nuts, then • For 016A9
separate the ball joínts from the lower arm (see
Sectíon 18). -1 . Pry the right driveshaft out of the differential.
11 . Remove the damper fork bolts, then separate the -2. Pry the left dríveshaft out of the intermedíate
damper fork and damper. shaft.
-3. Pull on the inboard joint and remove the right

and left driveshafts (see Section 16).
-4. Remove the intermediate shaft.
- 5. Tle plastic bags over the driveshaft and in-

termediate shaft ends.
NOTE: Coat ali precision finished surfaces with

clean engíne oíl or grease.
SELF-LOCKING
NUT
Re place. CASTER NUT COTTER PIN
DAMPER FORK Re place. Replace.
1 2. Remove the dríveshafts.
• Far 01281/01583/01584
-1 . Pry the right and left driveshafts out of the

differentíal.
-2. Pull on the inboard joint and remove the right PLASTIC BAG
-3. Tle plastic bags over the driveshaft ends.
NOTE: Coat ali precision finished surfaces with

clean engine oíl or grease.
(cont'd)
14-67
Transmission
Removal (cont'dl
13. Remove the splash shield. 15. Removethe exhaust pipe bracket, torque converter
cover and shift control cable holder. Then remove
the shift control cable by removing the cotter pin,
control pin and control lever.
CAUTION: Take care not to bend the shift control

cable while removing it.
16. Remove the 8 drive plate bolts one at a time while

rotating the crankshaft pulley.
ORIVE PLATE BOLT
SPLASH SHIELD
SHIFT
CABLE
6 x 1.0 mm BOL T '\.

CLIP
14. Remove the exhaust pipe A.

CONTROL
LEVER
ROLLER PIN
TORQUE CONVERTER
COVER
SELF-LOCKING NUTS
Replace. Replace.
EXHAUST PIPE A
14-68
1 7. Remove the stopper mount bolts. 19. Place a jack under the transmission and raise the
transmission just enough to take weight off of the
rnounts. then remove the transmission side mount.
TRANSMISSION
MOUNTING NUTS
SIDEM~
STOPPER MOUNT
BOLT
MOUNTING BOL T
20. Remove the transmission housing mounting bolts

18. Attach a hoisting bracket to the engine using the and rear engine mounting bolts.
distributor mounting bolt, then lift the engine
slightly.
HOISTING BRACKET
21. Pull the transmission away from the engine until it

clears the 1 4 mm dowel pins, then lower it on the
ENGINE
transmission jack.
14-69
lllustrated lndex
R. Side Cover ------
14-70
CD R.SIDE COVER @ MAINSHAFT LOCKNUT Replace.
® STEEL BALL ® 1 ST CLUTCH ASSEMBL Y
@ ONE-WAY SPRING @ 0-RING Replace.
@ SEALING WASHER Replace. ® THRUST WASHER
® SEALING BOL T ® THRUST NEEDLE BEARING
® 0-RING Replace. @) NEEDLE BEARING
(j) R.SIDE COVER GASKET Replace. ® MAINSHAFT F 1 ST GEAR
® DOWEL PIN @ THRUST WASHER
® 0-RING Replace. @ MAINSHAFT 1 ST GEAR COLLAR
@) 1 ST ACCUMULATOR PISTON @ PARKING BRAKE STOPPER
@ 1ST ACCUMULATOR SPRING A @ LOCK WASHER Replace.
@ 1 ST ACCUMULATOR SPRING B @ SPECIAL BOLT
@) 0-RING Replace. @ PARKING BRAKE LEVER
@ 1 ST ACCUMULATOR COVER @ PARKING BRAKE SPRING
@) SNAP RING @ PARKING BRAKE PAWL STOPPER
® 1 ST CLUTCH FEED PIPE @ PARKING BRAKE PAWL
@ 0-RING Replace. @ PARKING BRAKE PAWL SPRING
@ FEED PIPE FLANGE @ PARKING BRAKE PAWL SHAFT
@) SNAP RING ® DRAIN PLUG
@ ROLLER @) SEALING WASHER Replace.
® WASHER @) 5 mm BOLT
® 0-RING Replace. ® LOCK WASHER Replace.
@) THROTTLE CONTROL LEVER
® FEED PIPE FLANGE
@ THROTTLE CONTROL LEVER SPRING
@ 0-RING Replace.
@ SNAP RING ® TRANSMISSION HOUSING
@ 3RD CLUTCH FEED PIPE @) 0-RING Replace.
@) SPEED SENSOR
® COUNTERSHAFT LOCKNUT Replace.
® PARKING GEAR @) SEALING WASHER Aeplace.
@ ONE-WAY CLUTCH ® JOINT BOLT
® COUNTERSHAFT 1ST GEAR ® A TF COOLER PIPES
® NEEDLE BEARING ® ATF LEVEL GAUGE
® COUNTERSHAFT 1 ST GEAR COLLAR
TORQUE SPECIFICATIONS
Ref. No Torque Value Bolt Size Remarks

A 12 N·m (1.2 kg-m, 9 lb-ft) 6 x 1.0 mm
B 14 N·m ( 1 .4 kg-m, 1 O lb-ft) 6 x 1.0 mm Special bolt
e 22 N·m (2.2 kg-m, 1 6 lb-ft) 8 x 1.25 mm
E 18 N•m (1.8 kg-m, 13 lb-ft) 8 x 1.25 mm
F 8 N·m (0.8 kg-m, 6 lb-ft) 5 x 0.8 mm
G 29 N•m (2.9 kg-m, 21 lb-ft) 12 x 1.25 mm A TF cooler pipe joint bolt
1 40 N•m (4.0 kg-m, 29 lb-ft) 14 x 1.5 mm Drain plug
J 95 N·m (9. 5 kg-m, 69 lb-ft) 19 x 1.25 mm Mainshaft locknut (flange nut):
Left-hand threads
K 140-+ O-+ 140 N•m 23 x 1.25 mm Countershaft locknut
(14.0-+ O-+ 14.0 kg-m, (flange nut)
101 -+ O -+ 101 lb-ft)
L 65 N•m (6.5 kg-m, 47 lb-ft) 12 x 1.25 mm Stopper mount bracket bolt
M 39 N·m (3.9 kg-m, 28 lb-ftl 10 x 1.25 mm Transmission mount bracket bolt
14-71.
lllustrated lndex
14-72
G) REVEAS GEAR COLLAR @ HOLDER BOL T
@ NEEDLE BEARING @ WASHER
@ COUNTERSHAFT REVERSE GEAR @ REVERSE IDLER GEAR SHAFT SPRING
@ REVERSE SELECTOR @ REVERSE IDLER GEAR SHAFT HOLDER
@ REVERSE SELECTOR HUB @ REVERSE IDLER GEAR SHAFT
@ COUNTERSHAFT 4TH GEAR @ NEEDLE BEARING
(J) NEEDLE BEARING @ REVERSE IDLE GEAR SHAFT SPRING
@ DISTANCE COLLAR 28 mm Selectivo part @) STEEL BALL
@ COUNTERSHAFT 2ND GEAR @) LOCK WASHER Replace.
@) COTTERS @ THROTTLE CONTROL CABLE STA Y
@ THRUST NEEDLE BEARING @) TRANSMISSION HOUSING
@ COUNTERSHAFT 3RD GEAR @) TRANSMISSION HOUSING GASKET Replace.
@ NEEDLE BEARING @ REVERSE IDLER GEAR
@ THRUST NEEDLE BEARING @) SNAP RING
@ SPLINED WASHER Selectivo part @) TRANSMISSIN HOUSING MAINSHAT BEARING
@ 3RD CLUTCH ASSEMBL Y @) DOWEL PIN
@ 0-RING Replace. @) TRANSMISSION HOUSING COUNTERSHAFT BEARING
@ COUNTERSHAFT @) DIFFERENTIAL ASSEMBL Y
@ SPECIAL BOL T @) TORQUE CONVERTER HOUSING
@ LOCK WASHER Replace. @ OIL SEAL Replace.
@ REVERSE SHIFT FORK @) OIL SEAL Replace.
@ SNAP RING @) SET RING Selectivo part
@ THRUST WASHER @) TRNSMISSION HANGER
@ MAINSHAFT 4TH/REVERSE GEAR
@ NEEDLE BEARING
@ 4TH/REVERSE GEAR COLLAR
@ THRUST WASHER
@ 2ND/4TH CLUTCH ASSEMBL Y
® 0-RING Replace.
@ THRUST WASHER Selectivo part
@ MAINSHAFT 2ND GEAR
@ NEEDLE BEARING
@ MAINSHAFT
@ SEALING RING, 35 mm
@) NEEDLE BEARING
@ SET RING

A 12 N•m (1.2 kg-m, 9 lb-ft) 6 x 1.0 mm
B 14 N•m ( 1.4 kg-m, 1 O lb-ft) 6 x 1.0 mm Special bolt
D 34 N•m (3.4 kg-m, 25 lb-ft) 8 x 1.25 mm
14-73
lllustrated lndex
Torque Com,erter Housing/Valve Body ---------------
"
@
./
14-74
CD LOCK-UP VALVE BODY @ OIL FEED PIPE
@ LOCK-UP SEPARATOR PLATE ® OIL PUMP ORIVE GEAR
@ DOWEL PIN ® OIL PUMP DRIVEN GEAR SHAFT
© TOROUE CONVERTER CHECK VALVE SPRING ® OIL PUMP DRIVEN GEAR
® TOROUE CONVERTER CHECK VALVE @ BODY COVER
® REGULATOR VALVE BODY @ BYPASS BODY
(j) 0-RING Replace. @ LOCK WASHER Replace.
® STATOR SHAFT @ GOVERNOR BODY
® STOPPER SHAFT @ GOVERNOR BODY SEPARATOR PLATE
@ LOCK WASHER Replace. @ CONTROL SHAFT
® DETENT BASE @ ROLLER PIN
@ ACCUMULATOR COVER @ ROLLER
@ MAGNET @ WASHER
@ MAGNET HOLDER @ COTTER PIN Replace.
@ MAGNET COVER @ TOROUE CONVERTER HOUSING COUNTERSHAFT
® SERVO COVER NEEDLE BEARING
@ SERVO COVER SEPARATOR PLATE @) OIL GUIDE PLATE Replace.
@ MODULATOR VALVE BODY @) ATF STRAINER
@ SERVO BODY ® LOCK-UP CONTROL SOLENOID FILTER/GASKET
® SERVO SEPARATOR PLATE Replace.
® SECONDARY VAL VE BODY @) LOCK-UP CONTROL SOLENOID VALVE ASSEMBLY
@ DOWEL PIN @) CONTROL LEVER
@) SECONDARY SEPARATOR PLATE @ LOCK WASHER Replace.
® CHECK BALL @ SPECIAL BOLT
@ THROTTLE CONTROL SHAFT @ MAINSHAFT BEARING
@ E-RING ® OIL SEAL Replace.
® FILTER Replace. @) TOROUE CONVERTER HOUSING
® CHECK BALL @) SUCTION PIPE
@ MAIN VALVE BODY @) OIL FEED PIPE
@) DOWEL PIN ® DOWEL PIN
® MAIN SEPARATOR PLATE @) LOCK PLATE
@ COOLER RELIEF V AL VE SPRING
® COOLER RELIEF V AL VE NOTE: Only the 01584 and 016A9 use®@).
TOROUE SPECIFICATIONS

A 1 2 N·m ( 1 . 2 kg-m, 9 lb-ft) 6 x 1.0 mm
B 14 N·m (1.4 kg-m, 10 lb-ft) 6 x 1.0 mm Special bolt
14-75
R. Side Cover
Removal
NOTE:
• Clean all parts thoroughly in solvent or carburetor cleaner and dry with compressed air.
• Blow out all passages.
• When removing the transmission R.side cover, replace the following:
• R.side cover gasket
• Lock washers
• 0-rings
• Each shaft locknut
• Sealing washers
R. SIDE COVER
R. SIDE COVER GASKET
PARKING BRAKE PAWL
THROTTLE CONTROL
LEVER
. ONE-WAY CLUTCH
1ST GEAR
1ST GEAR
NEEDLE BEARING
1 ST GEAR COLLAR
PARKING BRAKE PAWL

SHAFT
STOPPER MOUNT
BRACKET
TRANSMISSION MOUNT
BRACKET
ATF LEVEL GAUGE
A TF COOLER PIPES
14-76
1 . Remove the transmission mount bracket and stop- 6. Remove the special tool from the mainshaft after
per mount. removing the locknuts.
2. Removethe 9 bolts securing the R. side cover, then 7. Remove the 1 st clutch, thrust washer, thrust nee-
remove the cover. dle bearing, needle bearing and 1 st gear from the
mainshaft.
3. Slip the special tool onto the mainshaft.
8. Remove the parking gear using a puller from the
4. Engage the parking brake pawl with the parking countershaft as shown. Then remove the counter-
gear. shaft 1 st gear, needle bearing and 1 st gear collar.
MAINSHAFT HOLDER
07923-6890202
MAINSHAFT.
5. Pry the lock tabs of the each shaft locknut, then

remove the locknuts from each shaft. PARKING GEAR
NOTE:
• Mainshaft locknut has left-hand threads. 9. Remove the thrust washer and 1 st gear collar from
• Clean the old countershaft locknut, it is used the mainshaft, and needle bearing and 1 st gear col-
when installing to press the parking gear on the lar from the countershaft.
countershaft.
1 O. Remove the parking brake paw/, spring, shaft, and
stopper from the housing.
11. Remove the parking brake lever from the control

shaft.
~NUT
1 2. Remove the throttle control lever and spring from
the throttle control shaft.
13. Remove the ATF cooler pipes and ATF level gauge.
14-77
Removal
/ TRANSMISSION HOUSING
/ MOUNTING BOLTS
LOCK WASHER
.,,,,,,.-- TRANSMISSION HOUSING
REVERSE GEAR COLLAR

NEEDLE BEARING
COUNTERSHAFT
SUB-ASSEMBL Y
\
14-78
NOTE: 7. Removethe mainshaft and countershaft together.
• Clean all parts thoroughly in solvent or carburetor
cleaner and dry with compressed air.
• Blow out ali passages.
• When removing the transmission housing, replace
the following:
• Transmission housing gasket.
Lock washer
1. Remove the throttle control cable stay.
2. Remove the transmission housing mounting bolts.
3. Align the spring pin with the transmission housing

groove by turning the control shaft.
4. lnstall the special tool on the transmission housing,

then remove the housing as shown.
8. Removethe differential assembly.
CONTROL SHAFT
5. Removethe reverse gear collar and needlebearing

from the countershaft.
6. Removethe lock bolt securing the shift fork, then

remove the fork with the reverse selector from the
countershaft.
14-79
Torque Converter Housing/Valve Body
Removal
li Oll FEED PIPE

SERVO DETENT BASE
ACCUMULATOR COVER
I
"".,__,,,,_.______,
ROLLER PIN
COTTER PIN
MAIN VAL VE BODY
BY-PASS BODY
A TF STRAINER
CONTROL LEVER
14-80
NOTE: 9. Remove the 1 bolt securing the regulator valve
• Clean all parts thoroughly in solvent or carburetor body, then remove the regulator valve body.
• Blow out all passages. 1 O. Removethe stator shaft and stopper shaft.
• When removing the valve body replace the
following: 11. Removethe cotter pin and roller pin from the con-
0-rings trol shaft, then remove the control shaft from the
Lock washers torque converter housing.
1 . Remove the lock bolt the control lever, 12·. Removethe 4 bolts securing the main valve body,
then remove the main valve body.
13. Remove the oil pump driven gear shaft, then

remove the oil pump gears.
14. Remove the 2 bolts securing the main separator

plata, then remove the main separator plate with
the 1 dowel pin.
15. Remove the 3 bolts securing the by-pass body,

then remove the by-pass body.
16. Remove the 3 bolts securing the governor body,

then remove the governor body and separator
plate.
1 7. Remove the ATF strainer.
LOCK WASHER
Replace.
2. Remove the oil feed pipes and suction pipe.
3. Removethe 2 bolts securing the servo detent base,

then remove the servo detent base.
4. Remove the 4 bolts securing the accumulator

cover, then remove the accumulator cover.
NOTE: The accumulator cover is spring loaded, to

prevent stripping the threads in the servo body,
press down on the accumulator cover while
unscrewing the bolts in a criss-cross pattern.
5. Remove the 4 bolts securing the modulator valve

body, then remove the modulator valve body.
6. Remove the 6 bolts securing the servo body, then

remove the servo body and separator plate.
7. Remove the 1 bolt securing the secondary valve

body, then remove the secondary valve body and
separator plate.
8. Remove the 5 bolts securing the lock-up valve

body, then remove the lock-up valve body and
separator plate.
14-81
Valve
Assembly
NOTE: Coat all parts with ATF before assembly. • Set the spring in the valve and install it in the valve
body. Pushthe spring in with a screwdriver, then in-
• Jnstallthe valve, valve spring and cap in the valve stall the spring seat.
body and secure with the roller.
ROLLER
VALVE BODY
14-82
• Slide the spring into the hole in the big end of the • Set the spring in the valve and install in the valve
shift valve. While holding the steel balls with the tips boy.
of your fingers, put the sleeve over the shift valve. lnstall the spring with a screwdriver, then install the
Place the shift spring in the shift valve, then slip it in- valve cap with the cutout aligned with the
to the valve body and install the valve cover. screwdriver.
SLEEVE
STEEL
BALL
SPRING
VALVE
• lnstall the manual valve in the direction shown, then

install the spring with the detent rollers.
• Set the valve spring in the valve and install it in the
valve body. Push the spring in with a screwdriver, MANUAL VALVE
then install the spring seat.
DETENT ROLLERS
SCREWDRIVER
14-83
Valve Caps
Description
• Caps with one projected tip and one flat end are in- • Caps with hollow ends are installed with the hollow
stalled with the flat end toward the spring. end away from the spring.
• Caps with a projected tip on each end are installed • Caps with notched ends are installed with the notch
with the smaller tip toward the spring. The small tip toward the spring.
is a spring guide. • Caps with flat ends and a hole through the center are
installed with the smaller hole toward the spring.
Toward outside of valve body.

Toward outside of valve bodv.
Toward spring. Toward spring.
• Caps with one projected tip and hollow end are in- • Caps with flat ends and a groove around cap are in-
stalled with the tip toward the spring. The tip is a stalled with the groove side toward the spring.
spring guide.
Toward spring.
Toward spring.
14-84
Valve Body
Repair
NOTE: This repair is only necessary if one or more of 5. Remove the #600 paper and thoroughly wash the
the valves in a valve body do not slide smoothly in their entire valve body in solvent, then dry with com-
bares. You may use this procedure to free the valves in pressed air.
the valve bodies.
6. Coat the valve with ATF then drop it into its bore. lt
1. Soak a sheet of #600 abrasive paper in ATF for should drop to the bottom of the bore under its own
about 30 minutes. weight. lf not, repeat step 4, then retest.
2. Carefully tap the valve body so the sticking valve

drops out of its bore.
CAUTION: lt may be necessary to use a small

screwdriver to pry the valve free. Be careful not to
r-VALVE
scratch the bore with the screwdriver.
3. lnspect the valve for any scuff marks. Use the ATF-
soaked #600 paper to polish off any burrs that are
on the valve, then wash the valve in solvent and VALVE
dry it with compressed air. /BODY
4. Roll up half a sheet of A TF-soaked paper and insert

it in the valve bore of the sticking valve.
Twist the papar slightly, so that it unrolls and fits
the bore tightly, then polish the bore by twisting
the paper as you push it in and out.
CAUTION: The valve body is aluminum and

doesn't require much polishing to remove any
burrs.
7. Remove the valve and thoroughly clean it and the

ATF-soaked valve body with solvent. Dry all parts with com-
#600 abrasive pressed air, then reassemble using ATF as a
paper
lubricant.
14-85
Main Valve Body
Disassembly/lnspection/Reassembly
NOTE:
• Replace valve body as an assembly if any parts are worn or damaged.
• Check all valves for free movement. lf any fail to slide freely, see Valve Body Repair on page 14-85.
• Coat ali parts with A TF befo re reassembly.
CAUTION: Do not use a magnet to remove the check halls; it may magnetizad the balls.
2ND ORIFICE CONTROL VALVE
CHECK BALLS
5 pes.
MAIN VAL VE BODY
ROLLER
CAP
14-86
Sectional View
CHECK BALLS
®
nr1"1!°1'~.e-~~~<D
MAIN VALVE BODY

(Sectional View)
-©
Section C-C
SPRING SPECIFICATIONS
Standard (New)
No. Spring
Wire Día. o.o. Free Length No. of Coils
CD Orifice control valve spring 0.9 (0.035) 6.6 (0.260) 44.0 ( 1. 732) 22.0
@ 3-4 shift valve spring 0.7 (0.028) 9.6 (0.378) 32.9 (1.295) 6.4
@ 3-4 shift ball spring 0.45 (0.018) 4.5 (0.177) 1 2.0 (0.4 72) 6.7
© Cooler relief valve spring 1.1 (0.043) 8.4 (0.331) 36.4 (1 .433) 12.0
® Relief valve spring 1.0 (0.039) 8.4 (0.331) 52.0 (2.047) 23.0
® 2-3 shift valve spring 0.7 (0.028) 7.6 (0.299) 43.0 (1.693) 12.7
(J) 2-3 shift ball spring 0.4 (0.016) 4.5 (0.177) 14.7 (0.579) 7.3
® 1-2 shift valve spring 0.5 (0.020) 4.5 (0.177) 44.5 (1.752) 35.1
® 1-2 shift ball spring 0.4 (0.016) 4.5 (0.177) 11 .3 (0.445) 8.0
14-87
Oil Pump
lnspection
1. lnstall the pump gears and shaft in the main valve 2. lnstall the oíl pump shaft and measure the side
body. clearance of the drive and driven gears.
Pump GearsSide (Radial)Clearance:

Standard (New): Orive gear
0.240-0.266 mm
(0.009-0.010 in)
Driven gear
0.063-0.088 mm
(0.002-0.003 in)
ORIVE GEAR
lnspect teeth for
wear or damage.
3. Measure the thrust clearance of the driven gear-to-
main valve body.
DRIVEN GEAR
Drive/Driven Gear thrust (Axial) Clearance:

(0.001-0.002 in)
OIL PUMP DRIVEN GEAR STRAIGHT EDGE

MAIN VAL VE BODY
14-88
Regulator Valve Body
NOTE:
• 81ow out all passages.
• Check all valves for free movement. lf any fail to slide freely, see Valve 8ody Repair on page 14-85.
1. Hold the regulator spring cap in place while removing the lock bolt . Once the bolt is removed, releasethe spring cap
slowly.
CAUTION: The regulator spring cap can pop out when the lock bolt is removed.
2. Reassembly is in the reverse order of disassembly.
NOTE:
• Coat all parts with A TF.
• Align the hole in the regulator cap with the hole in the valve body, press the spring cap into the body and tighten
the lock bolt.
LOCK BOLT
12 N•m
(1 .2 kg-m, 9 lb-ft)
/
REGULATOR VALVE
lnspect for wear, scratches
or scoring.
! ./ ~--CAP
LOCK-UP CONTROL
VALVE
/ o......____ ROLLER
SPRING SPECIFICATIONS SLEEVE

Standard (Newl
No. Spring
CD Regulator valve 01281 1 .8 (0.071 l 14.7 (0.579) 86.5 (3.406) 16.5

spring A Others 1.8 (0.071 l 14.7 (0.579) 88. 1 (3.468) 16.5
® Regulator valve spring 8 1.8 (0.071 l 9.6 (0.378) 44.0 ( 1. 732) 7.5
@ Stator reaction spring 5.5 (0.217) * 26.4 ( 1 .039) 30.3 ( 1. 193) 2.1
® Lock-up control 01281/01583 0.7 (0.028) 6.6 (0.260) 32.5 (1.280) 14.0
valve spring O 1 584/016A9 0.6 (0.024) 6.6 (0.260) 32.8 (1.291) 15.8
® Torque converter check valve spring 1.1 (0.043) 8.4 (0.331) 36.4 (1.433) 12.0
*: lnside Diameter
14-89
Secondary \lalve Body
NOTE:
• Check all valves tor free movement. lf any fail to slide freely, see Valve Body Repair on page 14-85.
• Coat ali parts with A TF befare reassembly.
CAUTION: Do not use a magnet to remove the check halls; it may magnetized the balls.
KICK-DOWN VALVE
ORIFICE CONTROL VALVE
SECONDARY VALVE BODY
. SHIFT TIMING VALVE
4TH EXHAUST VALVE
'
ROLLER
CAP
14-90
SECONDARY VALVE BODY
(Sectional View)
CHECK BALLS
Standard (New)
No. Spring
Wire Oia. O.O. Free Length No. of Coils
CD Kick-down valve spring 1.0 (0.039) 10.1 (0.398) 38.9 (1.531) 12.5
@ Orifice control valve spring 0.9 (0.035) 6.1 (0.240) 35.9 (1.413) 20.0
@ Shift timing valve spring 0.9 (0.035) 8.6 (0.339) 42.9 (1.689) 21.4
@ 4th exhaust valve spring 0.9 (0.035) 6.1 (0.240) 43.7 (1.720) 20.3
® Accumulator 01281/01583 1.2 (0.047) 7.7 (0.303) 45.1 (1.776) 19.8
valve spring 01584/016A9 1.2 (0.047) 7.7 (0.303) 45.6 (1.795) 21.8
® Lock-up cut valve spring 0.7 (0.028) 7.6 (0.299) 29.0 (1.412) 18.0
(z) Reverse control valve spring 0.7 (0.028) 7.6 (0.299) 37.2 (1.465) 15.3
® CPC (Clutch Pressure Control) 0.9 (0.035) 8.6 (0.339) 18.2 (0.717) 5.54
valve spring
14-91
Servo Body
NOTE:
• Coat all parts with ATF befare reassembly.
• Replace the 0-rings and filters.
COVER
REVERSE TIMING VAL VE
MAGNET HOLDER LOCK WASHER
..- SERVO DETENT BASE
SERVO COVER
SERVO COVER
SEPARATOR PLATE
Replace.
14-92
Standard (New)
No. Spring
1.2 (0.047) 9.4 (0.370) 26.3 (1.035) 8.0
01281/01583
Modulator 1.2 (0.047) 9.4 (0.370) 27.2(1.071) 8.0
CD valve spring 1.2 (0.047) 9.4 (0.370) 26.3 (1.035) 8.0
01584/016A9
1.2 (0.047) 9.4 (0.370) 26.4 ( 1 .039) 8.0
1.1 (0.043) 8.5 (0.335) 22.3 (0.878) 8.1
1.1 (0.043) 8.5 (0.335) 22.3 (0.878) 7.6
01281/01583
1.0 (0.039) 8.5 (0.335) 22.2 (0.874) 6.0
Throttle valve A 1.0 (0.039) 8.5 (0.335) 22.1 (0.870) 5.5
@
spring 1.0 (0.039) 8.5 (0.335) 22.2 (0.874) 6.0
1.0 (0.039) 8.5 (0.335) 22. 1 (0.870) 5.5
O 1 584/016A9
1.0 (0.039) 8.5 (0.335) 22.5 (0.886) 7.3
1.0 (0.039) 8.5 (0.335) 22.3 (0.878) 6.6
Throttle valve A adjusting
@ 0.8 (0.031) 6.2 (0.244) 27.0 (1.063) 8.5
spring
1.4 (0.055) 8.5 (0.335) 41.4 (1.630) 8.4
01281/01583 1.4 (0.055) 8.5 (0.335) 41.4 (1.630) 7.8
Throttle valve 8 1.6 (0.063) 8.5 (0.335) 41.3 (1.626) 13.9
© spring 1.6 (0.063) 8.5 (0.335) 41.3 (1.626) 13.9
O 1 584/01 6A9 1.6 (0.063) 8.5 (0.335) 41.4 ( 1.630) 11.7
1.6 (0.063) 8.5 (0.335) 41.3 (1.626) 15.0
Throttle valve 8 adjusting
® spring
0.8 (0.031) 6.2 (0.244) 30.0(1.181) 8.0
® 3rd accumulator spring 2.9(0.114) 15.5 (0.689) 79.5 (3.130) 15.0

0 2nd accumulator spring 3.9 (0.154) 20.2 (0.795) 74.9 (2.949) 10.9
® 4th accumulator spring 3.5 (0.138) 18.6 (O. 732) 77.4 (3.04 7) 10.2
® Reversetiming valve spring 0.7 (0.028) 5.6 (0.220) 43.8 (1.724) 21.7
@) Servo control valve spring 1.0 (0.039) 7.6 (0.299) 44.0 (1.732) 18.2
14-93
Lock-up Valve Body
NOTE:
• Check all valves for free movement. lf any fail to slide freely, see Valve 8ody Repair on page 14-85.
• Coat all parts with ATF befo re reassembly.
LOCK-UP SHl~ALVE
íl~ ROLLER
Standard (New)
No. Spring
CD Lock-up shift 01 281 /01 583 0.7 (0.028) 8.1 (0.319) 39.0 (1.535) 15.4
valve spring D1584/D16A9 1.1 (0.043) 8.1 (0.319) 51.8 (2.039) 22.3
@ Lock-up timing valve spring 1.0 (0.039) 6.6 (0.260) 52.3 (2.059) 30.1
14-94
Governor Valve
Disassembly/1 nspection/Reassembly
NOTE:
• Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air. Blow out all passages.
• Check that the governor works smoothly; replace it if it does not.
12 N·m (1.2 kg-m. 9 lb-ft)
• Coat all parts with ATF befo re reassembly.
GOVERNOR HOUSING GOVERNOR HOUSING ASSEMBLY

NOTE: Check that governor lnspect far wear. scratches, scoring or
works srnoothly. warpage.
DOWEL PIN
PIPE
lnspect far darnageto end.
SHAFT WOODRUFF KEY

lnspect far scoring or __,,_1 / lnspect far damage
scratches.
m
THRUST WASHERS
BY-PASS BODY COVER lnspect lace far wear or darnage.
<, GEAR
lnspect teeth far wear
or darnage.
Standard (New)
No. Spring
CD Governor spring A 1.0 (0.039) 18.8 (0.740) 20.4 (0.803) 4.0

@ Governor spring B 0.9 (0.035) 11.8 (0.465) 27.8 (1.094) 6.0
14-95
1 st Accumulator/R. Side Cover
Disassembly /lnspection/Reassembly
NOTE:
• Clean ali parts thoroughly in solvent or carburetor cleaner, and dry with compressed air. Blow out all passages.
• Coat all parts with A TF befare reassembly.
CI)1ST ACCUMULATOR
ONE WAY BALL
SPRING
SEALING WASHER __,_¡J

Replace. ~
SEALING BOLT~
17.5N•m
(1.75 kg-m. 13 lb-ft)
(%)1ST ACCUMULATOR-----
SPRING A
~~----- 0-RING
Replace.
~)-----1ST ACCUMULATOR COVER

-~~
SNAP RING
Standard (New)
No. Spring
CD 1 st accumulator one way ball spring 0.29 (0.0111 4.0 (0.157) 14.0 (0.551) 13.0
@ 1 st accumulator spring A 2.34 X 2.90 21.5 (0.846) 66. 7 (2.626) 10.2
(0.092 X 0. 114)
@ 1 st accumulator spring B 2.8 (0.110) 13.1 (0.516) 40.0 (1.575) 8.8
14-96
Mainshaft
Disassembly/lnspection/Reassembly-------------------,
NOTE:
• Lubricate all parts with ATF during reassembly.
• lnstall thrust needle bearings with unrolled edge of bearing retainer facing washer.
• lnspect thrust needle and needle bearings for galling and rough movement.
• Before installing the 0-rings, wrap the shaft splines with tape to prevent damaging the 0-rings.
• Locknut has left-hand threads.
LOCKNUT
19x1.25mm
95 N•m
(9.5 kg-m, 69 lb-ft)
/
~ ::~h;:dL~h;~~s
~ ASSEMBLY
0-RINGS
~Replace.
éD THRUST WASHER
~---THRUST NEEDLE
BEARING
NEEDLE BEARING
7
NEEDLE BEARINGS 1ST GEAR
MAINSHAFT
Check splines for ex-
cessive wear or THRUST WASHER
4TH/REVERSE
damage.
/ GEAR COLLAR
Check bearing surface 1ST GEAR COLLAR
for scoring, scratches
or excessive wear. / THRUST NEEDLE TRANSMISSION
-' BEARING HOUSING BEARING
THRUST SHIM
Selective part
líll'~e:!::::i~nu- -2ND GEAR

_,.,,. SEALING RING,
.,,,,.-- 35mm NEEDLE BEARING
THRUST NEEDLE
SEALING RING,
'lill!~m:s!!!~~--- BEARING
29mm
NEEDLE BEARING
SET RING
14-97
Mainshaft
lnspection
• Clearance Measurement 3. Torque the mainshaft locknut to 30 N·m (3.0 kg-m,

22 lb-ft).
NOTE: Lubricate all parts with ATF during
assembly. NOTE: Mainshaft locknut has left-hand threads.
1. Remove the mainshaft bearing from the transmis-

sion housing (see page 14-114).
2. Assemble the parts below on the mainshaft.
NOTE: Do not assemble the 0-rings while

inspecting.
LOCKNUT
1 ST CLUTCH ASSEMBL Y
THRUST WASHER
1 ST GEAR COLLAR
4. Hold the 2nd gear against the 2nd clutch.
TRANSMISSION HOUSING Measure the clearance between the 2nd gear and
BEARING the 3rd gear with a feeler gauge.
THRUST SHIM
NOTE: Take measurements in at least three places
4TH/REVERSE GEAR and take the average as the actual clearance.
COLLAR
~-" .,_,.___ THRUST SHIM STANDARD: 0.05-0.13 mm (0.002-0.005 in)
2ND/4TH CLUTCH
ASSEMBLY
THRUST WASHER.
36.5 x 51 mm 3RD GEAR 2ND GEAR
Selective
THRUST NEEDLE BEARING
2ND GEAR
NEEDLE BEARING
MAINSHAFT
FEELER GAUGE 2ND CLUTCH
THRUST WASHER,
c.:»:
36.5 x 51 mm
r-;r.==~
3RD GEAR
14-98
5. lf the clearance is out of tolerance, remove the
thrust washer and measure the thickness.
6. Select and install a new washer then recheck.
THRUST WASHER 36.5 x 51 mm

No. Part Number Thickness
1 90441-PC9-01 O 3.50 mm (0.138 in)

2 90442-PC9-01 O 3.55 mm (0.140 in)
3 90443-PC9-01 O 3.60 mm (0.142 in)
4 90444-PC9-01 O 3.65 mm (0.144 in!
5 90445-PC9-01 O 3. 70 mm (0.146 in)
6 90446-PC9-01 O 3. 75 mm (0.148 in)
7 90447-PC9-01 O 3.80 mm (0.1 50 in)
8 90448-PC9-01 O 3.85 mm (O. 152 in)
9 90449-PC 9-01 O 3.90 mm (0.1 54 in)
7. After replacing the thrust washer, make sure the

clearance is within tolerance.
14-99
Countershaft
Disassembly/lnspection/Reassembly -------------------.
NOTE:
• Lubricate all parts with ATF befare reassembly.
• lnstall thrust nee die bearings with unrolled edge of bearing retainer facing washer.
• lnspect thrust needle and needle bearings far galling and rough movement.
• Befare installing the 0-rings, wrap the shaft splines with tape to prevent damaging the 0-rings.
LOCKNUT
23 x 1.25 mm
140 - O - 140 N•m
------(14.0 - O - 14.0 kg-m,
------ 101 - O-+ 101 lb-ft)
--REVERSE GEAR
COLLAR
t,i§l~it•---NEEDLE BEARING
NEEDLE BEARING
Selective part
2ND GEAR
COTTERS
<. COUNTERSHAFT
Check splines far excessive wear or damage.
Check bearing surface far scoring, scratches or
excessive wear.
14-100
lnspection
• Clearance Measurement 3. Torque the countershaft locknut to 30 N•m (3.0

kg-m, 22 lb-ft).
assembly.
1. Remove the countershaft bearing from the

transmission housing (see page 14-114).
2. Assemble the parts below on the countershaft.

inspecting.
LOCKNUT
30 N•m
(3.0 kg-m, 22 lb-ft)
LOCKNUT
4. Measure the clearance between the 4th gear and
PARKING GEAR/1ST GEAR the reverse selector hub with a feeler gauge.
ONE-WAY CLUTCH ASSEMBLY
NEEDLE BEARING NOTE: Take measurements in at least three places

and take the average as the actual clearance.
1 ST GEAR COLLAR
TRANSMISSION HOUSING STANDARD:0.05-0.13 mm (0.002-0.005 in)
BEARING
. / REVERSE SELECTOR HUB
4TH GEAR REVERSE
/ /4THGEAR SELECTOR
HUB
I
NEEDLE BEARING
DISTANCE COLLAR, 28 mm \
Selective
2ND GEAR
-~~~@]/ THRUST NEEDLE BEARING
3RD GEAR
NEEDLE BEARING
28 mm
~ THRUST NEEDLE BEARING
SPLINED WASHER
Selective
3RD CLUTCH ASSEMBL Y
DIST ANCE COLLAR,

28 mm
4TH GEAR REVERSE

SELECTOR
HUB
(cont'd)
14-101
Countershaft
lnspection (cont' d)
5. Measure the clearance between the 3rd gear and 6. lf the clearance is out of tolerance, remove the
2nd gear with a feeler gauge, with the feeler gauge splined washer and/or distance collar and measure
frorn step 4 between the 4th gear and reverse the thickness and/or the width.
selector hub.
7. Select and install a new distance collar then
- 1 . Measure the clearance with the 3rd gear recheck.
pushed towards the 3rd clutch.
- 2. Measure the clearance with the 3rd gear DISTANCE COLLAR 28 mm

pushed towards the 2nd gear.
NOTE: Take measurements in at least three places 1 90503-PC9-000 39.00 mm (1.535 in)
2 90504-PC9-000 39.10 mm (1.539 in)
-3. Subtract the measurements of step-2. from 3 90505-PC9-000 39.20 mm (1.543 in)
step-3., and you have the clearance between 4 90507-PC9-000 39.30 mm (1.547 in)
the 3rd gear and 2nd gear.
5 90508-PC9-000 39.05 mm (1.537 in)
STANDARD: 0.05-0.13 mm (0.002-0.005 in) 6 90509-PC9-000 39.15 mm (1.541 in)
7 9051 O-PC9-000 39.25 mm (1.545 in)
8 90511-PCS-OOO 38.90 mm (1.531 in)
4TH GEAR 9 90512-PC9-000 38.95 mm (1.533 in)
8. After replacing the distance collar, make sure the

9. Select and install a new splined washer then

recheck.
SPLINED WASHER 35 x 50 mm
1 90411-PAS-OOO 3.00 mm (0.118 in)
2 90412-PA9-000 3.05 mm (O. 1 20 in)
3 90413-PAS-OOO 3.10 mm (0.122 in)
SPLINED WASHER
4 90414-PAS-OOO 3. 1 5 mm (O. 1 24 in)
5 9041 5-PA9-000 3.20 mm (0.126 in)
6 90416-PA9-000 3.25 mm (0.128 in)
I
DISTANCE COLLAR,
7
8
90417-PA9-000
90418-PA9-000
3.30 mm (0.130 in)
3.35 mm (0.132 in)
28mm 9 9041 9-PA9-000 3.40 mm (O. 134 in)
10 90423-PAS-OOO 2.90 mm (0.114 in)
11 90424-PA9-000 2.95 mm (0.116 in)
1 O. After replacing the splined washer, make sure the

14-102
One-Way Clutch/Parking Gear
Disassembly and lnspection
1. Separate the countershaft 1 st gear from the park- lnspect the parts as follows:
ing gear by turning the parking gear in the direction
shown.
PARKING GEAR
lnspect the parking
gear for wear or
scoring.
cou¿~
1 ST GEAR iAFT \
lnspect the one-way
clutch for damage or
faulty movement.
,
2. Removethe one-way clutch by prying it up with the lnspect the counter-

end of a screwdriver. shaft 1 st gear for wear
or scoring.
ONE-WAY CLUTCH
NOTE: lnstall in this
direction.
3. After the parts are assembled, hold the counter-

shaft 1 st gear and turn the parking gear in direction
shown to be sure it turns freely.
14-103
Clutch dex
lllustrated In
1ST CLUTCH
3RD CLUTCH
CH DISCS
CLUT d thickness:
Standar (O 076 in)
1.94 mm ..
f
CLUTCH DRUM
CH PLATES
CLUT d thickness:
Standar (O 079 in)
2.0mm ·
14-104
2ND/4TH CLUTCH
CH DISCS
CLUT thickness:
Standard (O 076 in)
1.94 mm .
RETUR N SPRING
H PLATES
CLUTC d thickness:
Standar (O 079 in) \UTCH PISTON
2.0 mm .
/
SNAP RING
·u~
CH DISCS
CLUT thickness:
Standard (O 076 in) / S~ETAINER
14-1o 5
1.94 mm .
CIRCLIP
Clutch
Disassembly
1. Removethe snap rings, then remove the clutch end 3. lnstall the special tools as shown.
plate, clutch discs and plates.
CLUTCH SPRING
COMPRESSOR
ATTACHMENT
07LAE-PX40100
/
SCREWDRIVER
CLUTCH SPRING
COMPRESSOR
ATTACHMENT
--~__..._ / 07HAE-PL50100
2. Remove the disc spring.
NOTE: For 2nd clutch.
CLUTCH SPRING
COMPRESSOR
BOLT ASSEMBL V
07GAE-PG40200
CLUTCH SPRING
COMPRESSOR
/ / ATTACHMENT
/ 07HAE-PL50100
CLUTCH SPRING
COMPRESSOR
BOLT ASSEMBL V
07GAE- PG40200
14-106
CAUTION: lf either end of the compressor attachment 5. Remove the circlip. Then remove the special tools,
is set over an area of the spring retainer which is unsup- spring retainer and return spring.
ported by the return spring, the retainer may be
damaged.
CIRCLIP
Set here. Do not set here.
6. Wrap a shop towel around the clutch drum and ap-

4. Compress the clutch return spring. ply air pressure to the oil passage to remove the
pistan. Place a finger tip on the other end while ap-
plying air pressure.
CLUTCH SPRING
COMPRESSOR
BOL T ASSEMBL Y
07GAE- PG40200
OIL PASSAGE
\ COMPRESSED AIR
HOSE NOZZLE
CLUTCH RETURN SPRING
14-107
Clutch
Reassembly
NOTE: 4. lnstall the piston in the clutch drum. Apply pressure

• Clean all parts thoroughly in solvent or carburetor and rotate to ensure proper seating.
cleaner, and dry with compressed air.
• Blow out all passages. NOTE: Lubricate the piston 0-ring with ATF before
• Lubricate all parts with ATF before reassembly. installing.
1. lnspect for a loase check valve. CAUTION: Do not pinch 0-ring by installing the
piston with force.
CHECK VALVE
PISTON
2. lnstall a new 0-ring on the clutch pistan.
3. Be sure that the disc spring is securely staked.

CLUTCH DRUM
NOTE: For 1 st, 3rd and 4th clutches.
5. lnstall the return spring and spring retainer and
¡¡ 0-R¡l,N~G.,.s_.----.-.
position the circlip on the retainer.
RETAINER
RETURN SPRING
14-108
6. lnstall the special tools as shown. CAUTION: lf either end of the compressor attach-
ment is set over an area of the spring retainer
which is unsupported by the retainer spring, the re-
tainer may be damaged.
CLUTCH SPRING
/ COMPRESSOR
/ ATTACHMENT
07LAE-PX40100
_ _.- CLUTCH SPRING

--- COMPRESSOR
ATTACHMENT
07HAE-PL50100
CLUTCH SPRING
COMPRESSOR
BOLT ASSEMBL Y
07GAE-PG40200
7. Compress the clutch return spring.
-----"- ..,,,,,...- CLUTCH SPRING

COMPRESSOR
ATTACHMENT
07HAE-PL50100
CLUTCH SPRING
COMPRESSOR
BOLT ASSEMBL Y
07GAE-PG40200
(cont'd)
14-109
Clutch
8. lnstall the circlip. 11 . Soak the clutch dises thoroughly in A TF for a

mínimum of 30 minutes.
12. Starting with a clutch plate, alternately install the

clutch plates and discs. lnstall the clutch end plate
with flat side toward the disc.
NOTE: Befare installing the plates and discs, make

sure the inside of the clutch drum is free of dirt or
other foreign matter.
CIRCLIP
9. Remove the special tools.
1 O. lnstall the disc spring.

DISCS ANO PLATES END PLATE
NOTE:
• Far 2nd clutch.
• lnstall the disc spring in the direction shown.
13. lnstall the snap ring.
SCREWDRIVER
14-110
14. Measure the clearance between the clutch end 1 5. lf the clearance is not within the service limits,
plate and top disc with a dial indicator. Zero the dial select a new clutch end plate from the following
indicator with the clutch end plate lowered and lift table.
it up to the snap ring. The distance that the clutch
end plate moves is the clearance between the NOTE: lf the thickest clutch and plate is installed
clutch end plate and top disc. but the clearance is still over the standard, replace
the clutch discs and clutch plates.
NOTE: Measure at three locations.
CLUTCH ENO PLATE
End Plate-to-Top Oisc Clearance: • 01281/01583
Clutch Service Limit Plate No. Part Number Thickness mm (in)

1 st 0.65-0.85 mm (0.026-0.033 in) 1 22551-PA9-010 2.3 mm (0.091)
2nd 0.65-0.85 mm (0.026-0.033 in) 2 22552-PA9-010 2.6 mm (0.102)
3rd 0.40-0.60 mm (0.016-0.024 in) 3 22553-PA9-010 2.9 mm (0.114)
4th 0.40-0.60 mm (0.016-0.024 in) 4 22554-PA9-010 3.2 mm (0.126)
5 22555-PA9-010 3.5 mm (0.138)
11 22561-PA9-010 2.15 mm (0.085)
12 22562-PA9-010 2.45 mm (0.096)
13 22563-PA9-010 2.75 mm (0.108)
14 22564-PA9-010 3.05 mm (0.120)
15 22565-PA9-010 2.35 mm (0.132)
16 22566-PA9-010 3.65 mm (0.144)
• 01584/016A9
Plate No. Part Number Thickness

1 22551-PC9-000 2.4 mm (0.094 in)
2 22552-PC9-000 2.5 mm (0.098 in)
3 22553-PC9-000 2.6 mm (0.102 in)
4 22554-PC9-000 2.7 mm (0.106 in)
5 22555-PC9-000 2.8 mm (0.110 in)
6 22556-PC9-000 2.9 mm (0.114 in)
7 22557-PC9-000 3.0 mm (0.11 8 in)
8 22558-PC9-000 3. 1 mm (0.122 in)
9 22559-PC9-000 3.2 mm (0.126 in)
10 22560-PC9-000 3.3 mm (0.130 in)
11 22561 -PC9-000 2. 1 mm (0.082 in)
12 22562-PC9-000 2.2 mm (0.086 in)
13 22563-PC9-000 2.3 mm (0.090 in)
PLA TE NUMBER
~ l Thickness
_..., ....__j t---'"t

END PLATE
14-111
Torque Converter Housing Bearings
Mainshaft Bearing Replacement
1. Pull up the mainshaft bearing and oíl seal using the 2. Orive in the new mainshaft bearing until it bottoms
special tools as shown. in the housing, using the special tools as shown.
DRIVER
077 49-0010000
ATTACHMENT, 62 x 68 mm
07746-0010500
ADJUSTABLE BEARING
REMOVER SET
07 JAC-PHSOOOO
3. lnstall the new oíl seal flush with the housing using
the special tools as shown.
DRIVER
07749-0010000
07746-0010600 .
14-112
Countershaft Bearing Replacement
1. Remove the countershaft bearing using the special

too l.
2. Replacethe oíl guide plate.
3. Orive the new bearing into the housing using the

special tools as shown.
DRIVER
07749-0010000
0-0.03 mm
(0.001 in)
OIL GUIDE PLATE

Replace.
14-113
Transmission Housing Bearings
Mainshaft/Countershaft Bearing Replacement
1. To remove the rnainshaft and countershaft bear- 2. Expandeach snap ring with snap ring pliers. insert
ings from the transmission housing, expand each the new bearing part-way into the housing using
snap ring with snap ring pliers, then push the bear- the special tools and a press as shown. lnstall the
ing out using the special tools and a press as bearíng with the groove facing outside the housing.
shown.
NOTE: Coat all parts with ATF.
NOTE: Do not remove the snap rings unless it's
necessary to clean the grooves in the housing. 3. Releasethe pliers, then push the bearing down into
the housing until the ring snaps in place around it.
SNAP RING PLIERS

07LGC-0010100
PRESS~
DRIVER
07749-0010000
ATTACHMENT
/ • MAINSHAFT
ATTACHMENT,
72 x 75 mm
07746-0010600
/
r-........1----1-----1........:.-. • COUNTERSHAFT
ATTACHMENT,
62 x 68 mm
07746-0010500
4. After installing the bearing verify the following:
• The snap ring is seated in the bearing and hous-

MAINSHAFT BEARING ing grooves.
DRIVER • The snap ring operates.
07749-0010000 • The ring end gap is correct.
ATTACHMENT
• MAINSHAFT
ATTACHMENT,
72 x 75 mm
END GAP: O- 7 mm
07746-0010600
(0-0.28 in)
/
r---'-----'-----í • COUNTERSHAFT
ATTACHMENT,
62 x 68 mm
07746-0010500
TRANSMISSION
HOUSING
14-114
Reverse ldler Gear
lnstallation
1. Assemble the reverse idler bearing holder. 3. lnstall the needle bearing on the idler gear shaft.
NOTE: Align the hole in the shaft with the spring.. 4. lnstall the reverse idler bearing holder into the
i~~::·~
26 kq-m, Jb:~ERSE IDLE71NG HOLDER 5. Tighten the reverse idler bearing holder bolts.
7 20 6. lnstall the spring and then tighten the retaining bolt

and washer.
l©- ~~
WASHER
6x1.0mm
12 N•m 1,1.2 kQ_-m, 9 lb-ft)
~ REVERSE ~ C.:
~ GEAR~~
STEEL BALL
2. lnstall the reverse idler gear.
NOTE: lnstall the reverse idler gear so that the

larger chamfer on the shaft bore faces the torque
converter housing.
STEEL BALL
REVERSE IDLER GEAR TRANSMISSION HOUSING

lnspect teeth for wear:
Chamfered end
14-115
Transmission/Valve Body
Reassembly
NOTE:
• Coat all parts with ATF.
• Replace the below parts:
• 0-rings
• Lock washers
• Gaskets
• Locknuts
• Sealing washer
1 ~
OIL FEED PIPE
4 BOLTS~ SERVO DETENT BASE
280LTS
___-s BOLTS
ACCUMULATOR COVER
MAIN VAL VE BODY
MAIN SEPARATOR PLATE
ATF STRAINER
14-116
1. lnstall the ATF strainer in the torque converter 5. lnstall the stator shaft and stopper shaft.
housing.
6. lnstall the 2 dowel pins, cooler relief valve and spr-
2. lnstall the main separator plate with 1 dowel pin ing in the main valve body.
and 2 bolts on the torque converter housing. Then
install the oil pump gears and oil pump driven gear 7. lnstall the regulator valve body with 1 bolt on the
shaft. main valve body.
NOTE: lnstall the oíl pump driven gear with its 8. lnstall the torque converter check valve and spring
grooved and chamfered side facing down. in the regulator valve body.
DRIVEN GEAR 9. lnstall the 2 dowel pins and separator plate on the
/ regulator valve body, then install the lock-up valve

body with 5 bolts.
1 O. lnstall the secondary separator plate with 2 dowel

~ pins on the secondary valve body, then install the
GROOVE CHAMFER secondary valve body on the main valve body with
D-
1 bolt.
DRIVEN GEAR
SHAFT 11 . lnstall the servo separator plate on the secondary
-"':.......~~~~~~~~~ valve body by inserting the throttle control shaft in-
DRIVEN GEAR to the secondary valve body.
il 12. lnstall the servo body on the secondary valve body

with 6 bolts and the lock plate.
1 3. lnstall the modulator valve body on the servo body

with 4 bolts.
3. lnstall the main valve body with 4 bolts. And make
sure the pump drive gear rotates smoothly in the 14. lnstall the accumulator cover on the servo body
normal operating direction and pump shaft moves with 4 bolts.
smoothly in the axial and normal operating
directions. 15. lnstall the servo detent base on the servo body with
2 bolts and new lock washers.
4. lf the pump gear and pump shaft do not move free-
ly, loosen the valve body bolts, realign the shaft, 16. lnstall the control shaft in the torque converter
and then retighten to the specified torque. housing, then install the roller pin through the
manual valve.
CAUTION: Failure to align the pump shaft correct-
ly will result in seized pump gear or pump shaft. 17. lnstall new cotter pin into the roller pin, then bend
the cotter pin.
18. lnstall the governor separator plate and governor

body with 3 bolts and new lock washers.
19. lnstall the by-pass body and body cover with 3

bolts.
20. lnstall 3 oil feed pipes in the servo body, pipe in

the main valve body and the suction pipe in the
{t ../ housing.
., D
e@~
ORIVE GEA;-""' ~
DRIVEN GEAR
DRIVEN
GEAR SHAFT (cont'd)
14-117
Transmission/TransmissionHousing
/ MOUNTING BOL TS
.,.,,--· TRANSMISSION HOUSING
MAINSHAFT~BLV
REVERSE GEAR COLLAR
NEEDLE BEARING
REVERSE GEAR
REVERSE SELECTOR
COUNTERSHAFT
SUB-ASSEMBL Y
\ DIFFERENTIAL
ASSEMBLY
14-118
21. lnstall the reverse idler gear and gear shaft holder in 25. lnstall the reverse gear, needle bearing and reverse
the transmission housing (page 14-115). gear collar on the countershaft.
22. lnstall the differential assembly in the torque con- 26. Align the spring pin with the transmission housing
verter housing. groove turning the control shaft.
23. lnstall the mainshaft sub-assembly and the 2 7. Place the transmission housing on the torque con-
countershaft sub-assembly together. verter housing.
SPRING PIN
Align the spring pin with
MAINSHAFT SÚB-ASSEMBLY COUNTERSHAFT the transmission housing
SUB-ASSEMBL Y groove.
24. Turn the shift fork shaft so large chamfered hole

facing fork bolt hole. Then install the shift fork and
GASKET
torque the lock bolt. Bend the lock tab against the
bolt head.
28. lnstall the transmission housing bolts and transmis-
sion hanger, then torque bolts to 34 N·m (3.4
kg-m, 25 lb-ft) in two or more steps as shown.
SHIFT FORK
6 x 1.0 mm
14 N•m
11.4 kg-m, 1 O lb-ft)
SHIFT FORK Face large chamfered

SHAFT hole in this side. 29. lnstall the throttle control cable stay and lock plate
on the transmission housing.
(cont'd)
14-119
Transmission/R. Side Cover
Reassembly (cont'd)
30. Slip the special tool onto the mainshaft. 35. Tighten the old locknut to press the parking gear to
specified torque, then loosen it.
TORQUE: 140 N•m (14.0 kg-m, 101 lb-ftl

MAINSHAFT HOLDER
07923-6890202
I LOCKNUT
Old locknut
MAINSHAFT
31 . lnstall the parking brake lever on the control shaft.
32. Assemble the one-way clutch and parking gear

with the countershaft 1 st gear.
33. lnstall the 1 st gear collar, needle bearing and park-

ing gear/1st gear assembly on the countershaft.
34. lnstall the parking brake pawl with shaft and spr-
ing, then engage the parking brake pawl to the
parking gear.
36. lnstall the 1 st gear collar and thrust washer on the
mainshaft.
37. lnstall new 0-rings on the mainshaft.
NOTE: Before installing the 0-rings, wrap the

shaft splines with tape to prevent damaging the 0-
rings.
38. lnstall the thrust washer, thrust needle bearing,

needle bearing and 1 st gear on the 1 st clutch, then
install them on the mainshaft.
14-120
39. lnstall new locknuts on each shaft, then tighten 40. Stake each locknut using a 3.5 mm punch.
them to specified torque.
• COUNTERSHAFT
TORQUE:
Mainshaft
95 N•m (9.5 kg-m, 69 lb-ft)
Countershaft
140 N•m (14.0 kg-m, 101 lb-ft)
NOTE: Mainshaft locknut has left-hand threads.
Left-hand thread Mark
0.7-1.7 mm
(0.03-0.07 in)
• MAINSHAFT
0.7-1.7 mm
(0.03-0.07 in)
(cont'd)
14-121
Transmission
Reassembly (cont'd)
41. Set the parking brake lever in the PARK position, 45. lnstall the throttle control lever with a new lock
then verify that the parking brake pawl engagesthe washer on the end of the throttle control shaft. ·
parking gear. Tighten the lock bolt and bend the lock tab.
42. lf the pawl does not engage fully, check the parking TOROUE: 8 N•m (0.8 kg-m, 6 lb-ft\
brake pawl stopper clearance as described on page
14-123. 46. lnstall the control lever with a new lock washer on
the end of the control shaft. Tighten the lock bolt
43. Tighten the lock bolt and bend over the lock tab. and beld lock tab.
ROLLER PIN TORQUE: 14 N•m (1.4 kg-m, 10 lb-ftl
PARKING BRAKE
LEVER
PARKING BRAKE
STOPPER
~
Measuring Distance
'-=--"
PARKING BRAKE
PAWL
PARKING GEAR PARKING BRAKE

PAWL SHAFT
44. lnstall the R. side cover.
TOROUE: 12 N·m (1.2 kg-m, 9 lb-ftl
4 7. lnstall the ATF cooler pipes with new sealing

washers.
TORQUE: 29 N•m (2.9 kg-m, 21 lb-ftl
48. lnstall the ATF level gauge.
14-122
Parking Brake Stopper
49. lnstall the transmission mount bracket on the 1. Set the parking brake lever in the PARK position.
2. Measure the distance between the. parking brake
TOROUE: 39 N·m (3.9 kg-m, 28 lb-ft) pawl and the parking brake lever roller pin as
shown.
STANDARD: 30.7-31.7 mm (1.21-1.25 in)

ROLLER PIN
TRANSMISSION MOUNT PARKING BRAKE
BRACKET LEVER
PARKING BRAKE
STOPPER
PARKING BRAKE
PAWL

PAWL SHAFT
3. lf the measurement is out of tolerance, select and

install the appropriate parking brake stopper from
the table below.
50. lnstall the stopper mount bracket on the transmis- PARKING BRAKE
STOPPER
sion housing.
I
-=rl,
12 x 1.25 mm
65 N•m
PARKING BRAKE STOPPER
Mark Part Number L1 L2

11.00 mm 11.00 mm
1 24537-PAS-003
0.433 in 0.433 in
10.80 mm 10.65 mm
2 24538-PA9-003
0.425 in 0.419 in
10.60 mm 10.30 mm
3 24539-PAS-003
0.417 in 0.406 in
4. After replacing the parking brake stopper, make

STOPPER MOUNT BRACKET sure the distance is within torelance.
14-123
TorqueConv~e~rt~e:r~~~~~~~~~~~~~~~~~~~l
Disassembly
6x1.0mm I
12 N•m C,.2 kg-m~
/
ORIVE PLATE
WASHER
RING GEAR/
TORQUE CONVERTER
ASSEMBLY
14-124
Transmission
lnstallation
1. lnstall the starter motor on the torque converter 4. lnstall the transmission side mount.
housing, and install the 14 mm dowel pins in the
torque converter housing.
-.
TRÁNSMISSION SIDE
45N•m MOUNT
14.5 kg·~~ÍARTER MOTOR
~ 14x20mm
D/WEL PIN
12 x 1.25 mm
55 N•m (5.5 kg-m, 40 lb-ft)
2. Place the transmission on a jack, and raise to the

engine level.
5. lnstall the remaining transmission housing moun-
3. Attach the transmission on the engine then install
ting bolts.
two transmission housing mounting bolts and 3
rear engine mounting bolts.
REAR ENGINE
MOUNTING BOL TS
MOUNTING BOL TS
12 x 1.25 mm
60 N•m (6.0 kg-m, 43 lb-ftl
MOUNTING BOL TS
12 x 1.25 mm
60 N•m (6.0 kg-m,
43 lb-ft) (cont'dl
14-125
Transmission
6. Remove the transmission jack and the hoist from 1 O. lnstall the stopper mounting bolts.
the engine.
7. Attach the torque converter to the drive plate with

8 bolts and torque to 12 N·m (1.2 kg-m, 9 lb-ftl.
Rotate the crankshaft as necessary to tighten the
bolts to 1 /2 of the specified torque, then final tor-
que, in a criss-cross pattern. Check for free rotation
after tightening the last bolt.
8. lnstall the shift cable with the roller, control pin and
new cotter pin on the control lever.
CAUTION: Take care not to bend the shift cable.
9. lnstall the shift cable cover, torque converter cover

and exhaust pipe bracket.
8 x 1.25 mm
\
10 x 1.25 mm
39 N•m
27 N•m (3.9 kg-m, 28 lb-ft)
6 x 1.0 mm (2.7 kg-m,
12 N•m 20 lb-ft)
(1.2 kg-m, 9 lb-ftl
11. lnstall the exhaust pipe A.
COTTER
PIN
SELF LOCKING NUT~

Replace.
6 x 1.0 mm
10 x 1.25 mm ~
12 N•m
55 N·m
(1.2 kg-m, 9 lb-ftl (5.5 kg-m,
40 lb-ft)
ROLLER PIN
Replace. SELF LOCKING NUTS

8 x 1.25 mm Replace.
22 N•m (2.2 kg-m. 8x1.25mm
16 lb-ft) 22 N·m (2.2 kg-m,
16 lb-ft)
14-126
12. lnatall the driveshafts. 13. lnstall the damper fork. And install the boll joint to
the lower arm with a new castle nuts and cotter
NOTE: Turn the right and left steering knuckle fully pins.
outward, and axial into the differential until you feel
its spring clip engage the side gear.
• For D1281/D1583/D1584
-1 . lnstall a new set ring on the end of the each

driveshaft.
-2. lnstall the right and left driveshafts (see Sec-

tion 16).
• For D16A9
- 1 . lnstall a new set ring on the end of the right

drive shaft and intermediate shaft.
-2. lnstall the intermediate shaft. 9
- 3. lnstall the right and left driveshafts (see Sec-

tion 16).
/
SELF-LOCKING NUT
Replace.
12 x 1.25 mm
10 x 1.25 mm 65 N•m
40 N•m (6.5 kg-m, 47 lb-ftl
(4.0 kg-m, 29 lb-ft)
14. lnstall the splash shield.
(cont'd)
14-127
Transmission
15. Connect the speedometer sensor connector.
SPEED SENSOR
CONNECTOR
16. Connect the ATF cooler hoses to the joint pipes.
1 7. Connect the throttle control cable.
18. Connect the lock-up control solenoid valve

connector.
19. Connect the starter motor and transmission ground

cables.
20. lnstall the air intake hose.
21. Refill the transmission with ATF (see page 14-65).
22. Connect the battery positive (+) and negative (-)

cables to the battery.
23. Check the ignition timing (see Section 23).
24. Start the engine. Set the parking brake, and shift
the transmission through all gears three times.
Check for proper shift cable adjustment.
25. Let the engine reach operating temperature with

the transmission in Neutral or Park, then turn it off
and check fluid leve!.
26. Roadtest as described on pages 14-52 thru 14-54.
14-128
Shift Cable
4. Removethe exhaust pipe A.

f•@·Mffolii Make sure lifts are placed properly (see
page 1-9 thru 1-11). 5. Removethe shift cable holder.
NOTE: LHD is shown; RHD is similar. 6. Removethe exhaust pipe bracket, torque converter
cover and shift cable cover.
1. Removethe center console (see page 20-80).
7. Removethe shift cable by removing the cotter pin,
2. Shift to [fil position, then remove the lock pin from control pin and control lever roller from the control
the cable adjuster. lever. Take care not to bend the cable when remov-
ing/installing it.
BRACKET
MOUNTING BOL TS
10 N•m (1.0 kg-m, 7 lb-ft)
3. Removethe shift cable bracket.
'
22 N•m (2.2 kg-m,
HEADER PIPE 16 lb-ft)
BRACKET
40 N•m (4.0 kg-m,

29 lb-ft)
8. lnstall the shift cable in the reverse order of

removal.
9. Check the cable adjustment on reassembly, on

page 14-130.
SHIFT CABLE 6 x 1.0 mm

BRACKET
12 N•m
(1.2 kg-m, 9 lb-ftl
14-129
Shift Cable
Adjustment
f!@.fo@iN Make sure lifts are placed properly (see 4. Check that the hole in the adjuster is perfectly
aligned with the hole in the shift cable. There are
page 1-9 thru 1-11).
two holes in the end of the shift cable. They are
NOTE: LHD is shown: RHD is similar. positioned 90° apart to allow cable adjustment in
1 /4 turn increments.
1. Start the engine. Shift to ~ position to see if the
reverse gear engages. lf not, refer to trouble-
shooting on page 1 4-48 thru 51 . ADJUSTER
SHIFT CABLE
2. With the engine off, remove the center console
(see page 20-80).
3. Shift to [fil position, then remove the lock pin from

the cable adjuster. ~~.·
~~
Cable Cable Exact

Too Short Too Long Alignment
LOCKNUT
LOCK PIN 5. lf not perfectly aligned, loosen the locknut on shift
(r
cable and adjust as required.
6. Tighten the locknut to 7 Nvrn (O. 7 kg-m, 5 lb-ft).
7, lnstall the lock pin on the adjuster. lf you feel the

SHIFT CABLE ADJUSTER
lock pin binding as you reinstall it, the cable is still
~ out of adjustment and must be readjsuted.
8. Move the select to each gear and verify that the

shift position indicator follows the shift position
console switch.
9. Start the engine and check the shift lever in all

gears. lf any gear does not work properly, refer to
troubleshooting on page 14-48 thru 51 .
1 O. lnsert the ignition key into the key cylinder on the

shift indicator panel, verify that the shift lock lever
is released.
14-130
Gearshift Selector
Disassembly/Reassembly------------------------,
NOTE: LHD is shown; RHD is symmetrical.
PUSH KNOB SELECT LEVER
/
~ KNOB
-~ LOCK PIN
~ Apply non-hardening
thread lock sealant.
10 N·m lb-ft) ./
(1.0 kg-m, 7 ~
SHIFT INDICATOR
PANEL
LEVER COVER
SILICONE
GREASE
CONTROL BRACKET
LOCK PIN ROO
Testing, see Section 23
10 N·m (1.0 kg-m, 7 lb-ft)
14-131
Shift lndlcator Panel
Adjustment
NOTE: LHD is shown; RHD is similar.
1. Check that the index mark of the indicator aligns

with the []] mark of the shift indicator panel with
the transmission in NEUTRAL.
2. lf not aligned,remove the center console. (see page

20-80).
3. Remove the shift indicator panel mounting screws

and adjust by moving the panel.
NOTE: Whenever the shift indicator panel is

removed, reinstall the panel as described above.
INDEX MARK
SHIFT INDICATOR
PANEL
MOUNTING SCREW
14-132
Throttle Control Cable
lnspection
NOTE: Before inspecting the throttle control cable, 3. Check that there is play in the throttle control lever
make sure; while depressing the accelerator pedal to the full-
throttle position.
• Throttle cable free play is correct (See Section
11 ) .
• ldle speed is correct (See Section 11 ).
• To warm up the engine to normal operating tem-
perature (cooling fan comes on).
1. Verify that the throttle control lever is synchronized

with the throttle linkage while depressing and
releasingthe accelerator pedal.
2. lf the throttle control lever is not synchronized with

the throttle linkage, adjust the throttle control
cable.
4. Removethe cable end of the throttle control cable

5. Check that the throttle control lever moves

smoothly.
THROTTLE LINKAGE
CABLE END
\THROTTLE CONTIIOL
LEVER
14-133
Adjustment
NOTE: Befare inspecting the throttle control cable, 3. Removethe free play of the throttle control cable
make sure; with the locknut, while pushing the throttle control
lever to the full-closed position as shown.
• Throttle cable free play is correct (See Section
11).
• ldle speed is correct (See Section 11).
• To warm up the engine to normal operating
temperatura (cooling tan comes on).
1. Verify that the throttle linkage is in the full-closed

position.
2. Loosen the locknut of the throttle control cable;

01584/016A8/016A9 at the throttle linkage.
THROTTLE LINKAGE
THROTILE CONTROL
LEVER
Push in this direction.
4. Tighten the locknut.
5. After tightening the locknuts, inspect the syn-

chronization and throttle control lever movement.
LOCKNUTS
O 1 281/01 583 at the throttle control cable stay
14-134
M24A
SpecialTools 14-136 Governor Body 14-237

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-13 7 1 st-hold Accumulator/
Troubleshooting R. Side Cover 14-238
Electrical Troubleshooting . . . . . . . . . . . 14-188 Mainshaft ,.... 14-239
Lock-up Control SolenoldValve Countershaft 14-242
A/B 14-189 One-way Clutch/Parking Gear 14-245
Hydraulic System Sub-shaft 14-246
Hydraulic System Sub-shaft Bearings . . . . . . . . . . . . . . . . . . . . . . . 14-24 7
Symptom-to-Component Chart .... 14-190 Clutch
Road Test . .. . .. . .. . . .. .. .. . . . . .. . . .. . .. .. .. . . 14_ 194 lllustrated lndex . . . . . . . . . . . . . . . . . . . . . . .. 14-248
Stall Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14_ 198 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-251
Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14_ 199 Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-253
PressureTesting .. .. .. .. .. .. .. . . .. . .. .. .. . . 14-200 Torque Converter Housing Bearings
Mainshaft Bearing
Transmission Replacement 14-257
Transmission Countershaft Bearing
Removal 14-207 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 14-258
lllustrated lndex Transmission Housing Bearing
R. Side Cover 14-212 Mainshaft/Countershaft Bearings
Transmission Housing . . . . . . . . . . . . . . . . 14-214 Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-259
Torque Converter Housing/ Sub-shaft Bearing
Valve Body 14-216 Replacement 14-260
R. Side Cover Reverseldler Gear 14-261
Removal 14-218 Transmission
Transmission Housing Reassembly 14-262
Removal . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . .. 14-220 Parking Brake Stopper
Torque Converter Housing/ lnspection/Adjustment 14-268
Valve Body Torque Converter 14-269
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-222 Transmission
Valve Caps 14-224 lnstallation 14-270
Valve Body Shift Cable
Repair 14-225 Removal/lnstallation 14-27 5
Valve Adjustment 14-276
Assembly 14-226 Gearshift Selector 14-277
Main Valve Body 14-228 Shift lndicator Panel 14-278
Oil Pump 14-230 Throttle Control Cable 14-279
RegulatorValve Body . . .. . .. . . .. . .. . . .. . . 14-231
Secondary Valve Body 14-232
Servo Body 14-234
Lock-up Valve Body 14-236
Special Tools
Ref No. Tool Number Description Oty Page Reference

G) 07GAB-PF50101 Maínshaft Holder 14-217, 264
® 07HAC-PK40101 Housíng Puller 14-219
@ 07JAC-PH80000 Adjustable Bearíng Remover Set 14-255, 256
@-1 07JAC-PH80100 Bearíng Remover Attachment 14-255, 256
@-2 07JAC-PH80200 Remover Handle Assembly 14-255, 256
@-3 07741-0010201 Remover Weight 14-255, 256
© 07LAE-PX40000 Clutch Spring Compressor Set 14-249, 252
©-1 07GAE-PG40200 Clutch Spring Compressor Bolt 14-249, 252
©-2 07HAE-PL50100 Clutch Spríng Compressor Attachment 14-249, 252
@-3 07LAE-PX40100 Clutch Spríng Compressor Attachment 14-249, 252
® 07LGC-0010100 Snap Ríng Plíers 14-245, 257, 258
® 07MAJ-PY40100 A/T Oíl Pressure Gauge Hose Assembly 14-200
@-1 07MAJ-PY40110 Oíl Pressure Gauge Hose 14-200
@-2 07MAJ-PY40120 Oíl Pressure Joínt 14-200
0 07406-0020003 A/T Oil Pressure Gauge Set 14-200
(Z)-1 07406-0020201 A/T Oíl Pressure Gage Hose 14-200
® 07406-0070000 A/T Low Pressure Gauge 14-200
® 07746-0010100 Attachment, 32 x 35 mm 14-245
@) 07746-0010500 Attachment, 62 x 68 mm 14-245, 255, 256, 257, 258
@ 07746-0010600 Attachment, 72 x 75 mm 14-255, 257
@ 07749-0010000 Driver 14-245, 255, 256, 257, 258
@-1
1 CD
~tjl)ljj))))I o
@-1 @-2 @-3
~1
@-2
®
@@)@ @
14-136
Description
The automatic transmission is a combination of a 3-element torque converter and triple-shaft automatic transmission
which provides 4 speeds forward and 1 reverse. The entire unit is positioned in line with the engine.
Torque Converter. Gears and Clutches

The torque converter consists of a pump, turbine and stator, assembly in a single unit. The torque converter is connected
to the engine crankshaft so they turn together as a unit as the engine turns. Around the outside of the torque converter
is a ring gear which meshes with the starter pinion when the engine is being started. The entire torque converter assem-
bly serves as a flywheel while transmitting power to the transmission mainshaft.
The transmission has three parallel shafts, the mainshaft, countershaft and sub-shaft. The mainshaft is in line with the
engine crankshaft.
The mainshaft includes the clutches for 1 st, and 2nd/4th, and gears for 3rd, 2nd, 4th, reverse and 1 st (3rd gear is in-
tegral with the mainshaft, while reverse gear is integral with the 4th gear).
The countershaft includes the 3rd clutch and gears for 3rd, 2nd, 4th, reverse, 1 st and parking. Reverse and 4th gears
can be locked to the countershaft at its center, providing 4th gear or reverse,dependingon which way the selector is moved.
The sub-shaft includes the 1 st-hold clutch and gear for 1 st and 4th.
The gears on the mainshaft are in constant mesh with those on the countershaft and secondary shaft. When certain
combinations of gears in the transmission are engaged by the clutches, power is transmitted from the mainshaft to the
countershaft via the sub-shaft to provide [Q;], ~. rn. [I] and [[] .
Hydraulic Control
The valve body assembly includes the main valve body, secondary valve body, regulator valve body, servo body, modu-
lator valve body, lock-up valve body, and governor body, through the respective separator plates.
They are bolted on the torque converter housing.
The main valve body contains the manual valve, 1-2 shift valve, 2-3 shift valve, 3-4 shift valve, 3-2 timing valve, 4th
exhaust valve, relief valve, and oil pump gears.
The secondary valve body contains the 4-3 kick-down valve, 3-2 kick-down valve, 2-3 orífice control valve, 2-1 timing
valve, Clutch Pressure Control (CPC) valve, servo control valve, reverse control valve, and governor cut valve.
The regulator valve body contains the pressure regulator valve, lock-up control valve, torque converter check valve, and
cooler relief valve.
The servo body contains the servo valve which is integrated with the reverse shift fork, throttle valves A and B, 2/3-4
orifice control valve, and accumulators.
The modulator valve body bolted on the servo body contains the modulator valve.
The lock-up valve body contains the lock-up shift valve and lock-up timing valve B, and is bolted on the regulator valve
body.
The governor body is bolted on the torque converter housing near the differential.
Fluid from the regulator passes through the manual valve to the various control valves.
Lock-up Mechanism
In [Q;] and ~ position, in 2nd, 3rd and 4th, pressurized fluid is drained from the back of the torque converter through
an oil passage, causing the lock-up piston to be held against the torque converter cover. As this takes place, the main-
shaft rotares at the same speed as the engine crankshaft. Together with hydraulic control, the ECUoptimizes the timing
of the lock-up mechanism.
The lock-up shift valve controls the range of lock-up according to the lock-up control solenoid valves A and B, and throt-
tle valve B. When the lock-up control solenoid valves A and B are mounted on the torque converter housing, and are
controlled by the ECU.
(cont'd)
14-137
Description
(cont'd)
Gear Selection
The selector lever has seven positions; [f] PARK, ffi] REVERSE, [m NEUTRAL,[Q;) 1 st through 4th positions, [QiJ 1 st
through 3rd positions, [II 2nd gear and O] 1 st gear.
Position Description
[fl PARK Front wheels locked; parking pawl engaged with parking gear on countershaft. AII
clutches released.
ffi) REVERSE Reverse; reverse selector engaged with countershaft reverse gear and 4th clutch
locked.
[ffi NEUTRAL AII clutches released.
~ ORIVE General driving; starts off in 1 st, shifts automatically to 2nd, 3rd, then 4th,
( 1 through 4) depending on vehicle speed and throttle position. Oownshifts through 3rd, 2nd
and 1 st on deceleration to stop.
The lock-up mechanism comes into operation in 2nd, 3rd and 4th when the
transmission in [Q;) or ~ .
~ ORIVE For rapid acceleration at highway speeds and general driving; starts off in 1 st,
( 1 through 3) shifts automatically to 2nd then 3rd, depending on vehicle speed and throttle
position. Oownshifts through lower gears on deceleration to stop.
rn SECONO Oriving in 2nd gear; stays in 2nd gear, does not shift up and down.
For engine braking or better traction starting off on loase or slippery surface.
O] FIRST Oriving in 1 st gear; stays in 1 st gear, does not shift up and down.
For engine braking.
Starting is possible only in [f] and [m position through use of a slide-type, neutral-safety switch.
Position lndicator
A position indicator in the instrument panel shows what gear has been selected without having look down at the console.
14-138
SPEEDOMETER SENSOR
DIFFERENTIAL
A TF LEVEL GAUGE
TORQUE CONVERTER
ASSEMBLY
1 ST -HOLD CLUTCH THROTTLE CONTROL

CABLE
14-139
Description
Clutches~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
The four speed automatic transmission uses hvdraulicallv actuated clutches to engage or disengage the transmission
gears. When clutch pressure is introduced into the clutch drurn, the clutch piston is applied. This presses the friction
discs and steel plates together, locking them so they don't slip. Power is then transmitted through the engaged clutch
Likewise, when clutch pressure is bled from the clutch pack, the piston releasesthe friction discs and steel plates, and
ting no power.
[ 1 st Clutch]
The first clutch engages/disengagesfirst gear, and is located at the end of the mainshaft, just behind the R side cover.
[ 1 st-hold Clutch]
The first hold clutch engages/disengages 1 st-hold or 1 position, and is located at the center of the sub-shaft. The 1 st-
hold clutch is supplied clutch pressure by its oil feed pipe within the sub-shaft.
[2nd Clutch]
[3rd Clutch]
The third clutch engages/disengages third gear, and is located at the end of the countershaft, opposite the R side cover.
The third clutch is supplied clutch pressure by its oil feed pipe within the countershaft.
[4th ClutchJ
The fourth clutch engages/disengages fourth gear, as well as reverse gear, and is located at the center of the mainshaft.
feed pipe within the mainshaft.
[One-way Clutch]
clutch locks up when power is transmitted from the mainshaft first gear to the countershaft first gear.
The first clutch and gears remain engaged in the 1 st. 2nd, 3rd, and 4th gear ranges in the ~' [!El or []] position.
However, the one-way clutch disengages when the 2nd, 3rd, or 4th clutches /gears are applied in the ~' [lliJ or []]
range" of the one-wav clutch. Thereafter, the one-way clutch free-wheels with the first clutch still engaged.
•
LOCKS FREE
SPRAG
PARKING GEAR
14-140
MAINSHAFT 3RD GEAR
LOCK-UP
CLUTCH
REVERSE SELECTOR
DIFFERENTIAL
(cont'd)
14-141
Description
Clutches (cont'd)~~~~~~~~~~~~~~~~~~~~~~~---,
Lock-up Clutch
1 . Operation (clutch on)
and the converter oil exerts pressure through the piston against the converter cover. As a result, the converter turbine
is locked on the converter cover firmly. The effect is to bypass the converter, thereby placing the car in direct drive.
I Power flow I
The power flows by way of: LOCK-UP PISTON DAMPER SPRING
Engine
1 TORQUE CONVERTER
Orive plate COVER COMP
1
· Torque converter cover
1
Lock-up pistan
¡
OUTLET
Damper spring
¡
Turbine
1
Mainshaft
2. Operation (clutch off)

With the lock-up clutch off, the oil flows in the reverse of CLUTCH ON. As a result, the lock-up pistan is moved away
I Power flow I
Engine
1
Orive plate
1
1
Pump
1
Turbine To oil cooler
¡
INLET
Mainshaft t
14-142
1ST GEAR 2ND GEAR 3RD GEAR
I~!El
TORQUE 1ST-HOLD 4TH REVERSE PARKING
1ST 2ND 3RD
CONVERTER CLUTCH GEAR GEAR
E CLUTCH CLUTCH CLUTCH GEAR CLUTCH
o X X X X X X X o
ffi] o X X X X X o o X
ffil o X X X X X X X X
1ST o X o X X X X X X
2ND o X 0* o X X X X X
@;]
3RD o X O* X o X X X X
4TH o X O* X X o o X X
1ST o X o X X X X X X
~ 2ND o X O* o X X X X X
3RD o X o· X o X X X X
[]] o X o· o X X X X X
[TI o o o X X X X X X
O: Operates, x : Doesn't operate, *: Although the 1 st clutch engages,driving power is not transmitted becausethe one-
way clutch slips.
[fil
Position
Hydraulic pressure is not applied to the clutches. Power is not transmitted to the countershaft.
~ Position
Hydraulic pressure is not applied to the clutches. Power is not transmitted to the countershaft.
The countershaft is locked by the parking pawl interlocking the parking gear.
1 ST-HOLD CLUTCH
TORQUE CONVERTER
<, 4TH CLUTCH
MAINSHAFT
COUNTERSHAFT
ONE-WAV CLUTCH
3RD CLUTCH
(cont'd)
14-143
Description
Po~er Flo~ (cont'd) ~~~~~~~~~~~~~~~~~~~~~~~
[!] Position
At O] position, hydraulic pressure is applied to the 1 st clutch and 1 st-hold clutch.
The power flow when accelerating is as totlows:
1. Hydraulic pressure is applied to the 1 st clutch on the mainshaft and power is transrnitted via the 1 st clutch to the
mainshaft 1 st gear.
2. Hydraulic pressure is also applied to the 1 st-hold clutch on the sub-shaft. Power transrnitted to the mainshaft 1 st
gear is conveyed via the countershaft 1 st gear to the one-way clutch, and via the sub-shaft 1 st gear to the 1 st-hold
clutch. The one-way clutch is used to drive the countershaft, and the 1 st-hold clutch drives the countershaft via
the 4th gears.
3. Power is transrnitted to the final drive gear and drives the final driven gear.
1ST-HOLD CLUTCH
TORQUE CONVERlrER SUB-SHAFT 1 ST GEAR
MAINSHAFT
4TH GEAR
MAINSHAFT
ONE-WAY CLUTCH
FINAL ·:\' PARKING GEAR

GEAR
COUNTERSHAFT
1ST GEAR
COUNTERSHAFT
4TH GEAR
FINAL DRIVEN GEAR
14-144
[Il Position
The power flow when decelerating is as follows;
1. Rolling resistance from the road surface goes through the front wheels to the final drive gear, then to the sub-shaft
1 st gear via the 4th gear and 1 st-hold clutch which is applied during deceleration.
2. The one-way clutch becomes free at this time because torque reverses.
3. The counterforce conveyed to the countershaft 4th gear turns the sub-shaft 4th gear via the mainshaft 4th gear.
At this time, since hydraulic pressure is also applied to the 1 st clutch, counterforce is also transmitted to the main-
shaft. As a result, engine braking can be obtained with 1 st gear.
1 ST-HOLD CLUTCH
SUBSHAFT 1ST GEAR
COUNTERSHAFT
FINAL ORIVE
GEAR
\ FINAL DRIVEN GEAR
(cont'd)
14-145
Description
Power Flow (cont' d)
rn Position
rn Position is provided to drive only 2nd speed.
1. Hydraulic pressure is applied to the 2nd clutch on the mainshaft and power is transmitted via the 2nd clutch to the
mainshaft 2nd gear.
2. Power transmitted to the mainshaft 2nd gear is conveyed vía the countershaft 2nd gear, and drives the countershaft.
3. Power is transmitted to the final drive gear and drives the final driven gear.
'
NOTE: Hydraulic pressure is also applied to the 1 st clutch, but since the rotation speed of the 2nd gear exceeds
that of 1 st gear, power from 1 st gear is cut off at the one-way clutch.
TORQUE CONVERlrER
2ND CLUTCH
COUNTERSHAFT
COUNTERSHAFT 2ND GEAR
FINAL DRIVEN GEAR
14-146
In ill;J or ~ position, the optimum gear is automatically selected from 1 st, 2nd, 3rd and 4th speeds, according to
conditions such as the balance between throttle opening (engine load) and vehicle speed.
~ or ~ Position, 1 st speed
1. Hydraulic pressure is applied to the 1 st clutch, which rotates together with the mainshaft, and the mainshaft 1 st
gear rotates.
2. Power is transmitted to the countershaft 1 st gear, and drives the countershaft via the one-way clutch.
NOTE: In ill;J or ~ position, hydraulic pressure is not applied to the 1 st-hold clutch.
TORQUE CONVERTER
1ST CLUTCH
MAINSHAFT
/
COUNTERSHAFT
ONE-WA Y CLUTCH
COUNTERSHAFT
1ST GEAR
FINAL DRIVEN GEAR

(cont'd)
14-147
Description
Power Flow (cont'd)
~ or ~ Position, 2nd speed
1. Hydraulic pressureis appliedto the 2nd clutch, which rotates together with the mainshaft, and the mainshaft 2nd
gear rotates.
2. Power is transmitted to the countershaft 2nd gear, and drives the countershaft.
NOTE: In [Q;] or ~ position, 2nd speed, hydraulic pressure is also applied to the 1 st clutch, but since the
rotation speed of 2nd gear exceeds that of 1 st gear, power from 1 st gear is cut off at the one-way clutch.
TORQUE CONVERTER
MAINSHAFT
COUNTERSHAFT
FINAL DRIVEN GEAR
14-148
~ or m:;J. Position, 3rd speed
1. Hydraulic pressure is applied to the 3rd clutch. Power from the mainshaft 3rd gear is transmitted to the countershaft
3rd gear.
NOTE: In [Q;J or [Qi] position, 3rd speed, hydraulic pressure is also applied to the 1 st clutch, but since the rotation
speed of 3rd gear exceeds that of 1 st gear, power from 1 st gear is cut off at the one-way clutch.
TORQUE CONVERTER
MAINSHAFT 3RD GEAR
MAINSHAFT
COUNTERSHAFT
FINAL ORIVE
GEAR
COUNTERSHAFT
3RD GEAR
FINAL DRIVEN GEAR
(cont'dl
14-149
Description
Power Flow (cont'd)
~ Position, 4th speed
1. Hydraulic pressure is applied to the 4th clutch, which rotates together with the mainshaft, and the mainshaft 4th
gear rotates.
2. Power is transmitted to the countershaft 4th gear, and drives the countershaft.
NOTE: In~ position, 4th speed, hydraulic pressure is also applied to the 1 st clutch, but since the rotation speed
of 4th gear exceeds that of 1 st gear, power from 1 st gear is cut off at the one-way clutch.
TORQUE CONVERTER MAINSHAFT 4TH GEAR
4TH CLUTCH
COUNTERSHAFT
FINAL ORIVE
GEAR
FINAL DRIVEN GEAR
14-150
rn:J Position
1. Hydraulic pressure is switched by the manual valve to the servo valve, which moves the reverse shift fork to the
reverse position. The reverse shift fork engages with the reverse selector, reverse selector hub and the countershaft
reverse gear.
2. Hydraulic pressure is also applied to the 4th clutch. Power is transmitted from the mainshaft reverse gear via the
reverse idler gear to the countershaft reverse gear.
3. Rotation direction of the countershaft reverse gear is changed via the reverse idler gear.
MAINSHAFT REVERSE
TORQUE CONVERTER GEAR
MAINSHAFT
COUNTERSHAFT

FINAL ORIVE
GEAR
REVERSE SELECTOR
COUNTERSHAFT
REVERSE GEAR
14-151
Description
Hydraulic Control ------------------------
The valve bodies include the main valve body, secondary valve body, regulator valve body, servo body, lock-up valve
body and modulator valve body.
The oif pump is driven by splines behind the torque converter which is attached to the engine. Oil flows through the
regulator valve to maintain specified pressure through the main valve body to the manual valve, directing pressure to
each of the clutches.
R. SIDE COVER
SECONDARY
VALVE BODY
REGULATOR
VALVE BODY MAIN VALVE
BODY
LOCK-UP CONTROL
SOLENOID VALVE
ASSEMBLY
D16Z6/D16A8/D16A7
is shown.
14-152
Main Valve Body
The manual valve, 1-2 shift valve, 2-3 shift valve, 3-4 shift valve, 4th exhaust valve, 3-2 timing valve, and relief
valve are all built into the main valve body.
The primary function of this valve body is switching oil passageson and off and controlling the hydraulic pressure going
to the hydraulic control system.
2-3 SHIFT VALVE

3-4 SHIFT VALVE
4TH EXHAUST VALVE
3-2 TIMING VALVE
1-2 SHIFT VALVE
Secondary Valve Body

The secondary valve body is located on the main valve body. The 3-2 kick-down valve, 4-3 kick-down valve, 2-3
orifice control valve, governor cut valve, 2-1 timing valve, reverse control valve, servo control valve, and clutch pres-
sure control (CPC) valve are built into the secondary valve body.
4-3 KICK-DOWN
VALVE GOVERNOR CUT VALVE
REVERSE CONTROL
VAL VE
(cont'd)
14-153
Description
Hydraulic Control (cont'd) ---------------------
Servo Body
The servo body is located on the secondary valve body.
The servo valve which is integrated with the shift fork, throttle valve A and B, 2/3-4 orifice control valve, and accumula-
tor pistons are ali built into the servo body.
Modulator Valve Body

The modulator valve body with the modulator valve is located on the servo body.
MODULATOR VALVE
BODY
2/3-4 ORIFICE
CONTROL VALVE
SERVO VALVE/
SHIFT FORK SHAFT
SERVO BODY

The regulator valve body is located on the main valve body. The regulator valve body consists of the regulator valve,
torque converter check valve, cooler check valve, and lock-up control valve.
LOCK-UP CONTROL VALVE TORQUE CONVERTER

CHECK VALVE
14-154
RegulatorValva
The regulator valve maintains a constant hydraulic pressure from the oil pump to the hydraulic control system, while
also furnishing oíl to the lubricating system and torque converter.
Oíl flows through B and B'. The oil which enters through B flows through the valve orífice to A, pushing the regulator
valve to the right. According to the level of hydraulic pressure through B, the position of the valve changes, and the
amount of the oíl through B' from O thus changes. This operation is continued, thus maintaining the line pressure.
(ENGINE RUNNING)
(ENGINE NOT RUNNING)
To TORQUE CONVERTER
t t
From OIL PUMP
To RELIEF VALVE

Hydraulic pressure increase, according to torque, is performed by the regulator valve using stator torque reaction. The
stator shaft is splined to the stator and its arm end contacts the regulator spring cap. When the car is accelerating or
climbing (Torque Converter Range),stator torque reaction acts on the stator shaft and the stator arm pushes the regula-
tor spring cap in this-+ direction in proportion to the reaction. The spring compresses and the valve moves to increase
the regulated control pressure or line pressure. Une pressure is maximum when the stator reaction is maximum.
REGULATOR VALVE
STA TOR SHAFT ST ATOR SHAFT ARM
(cont'd)
14-155
Description
Hydraulic Control (cont'd) ----------------------.
Lock-up Valve Body

The lock-up valve body with the lock-up shift valve and lock-up timing valve is located on the regulator valve body.
LOCK-UP SHIFT VALVE
LOCK-UP TIMING VALVE
Accumulator Pistons
The accumulator pistons are built into the servo body and R. side cover. The 1 st-hold clutch accurnulator piston is in
the R. side cover, and the 1 st, 2nd, 3rd, and 4th clutch accumulator pistons are built in the servo body.
1ST-HOLD ACCUMULATOR
PISTON
4TH ACCUMULATOR PISTON
1 ST ACCUMULATOR PISTON
2NO ACCUMULATOR PISTON

SERVO BOOV
3RD ACCUMULATOR PISTON
14-156
General Chart of Hydraulic Pressure
Line Pressure
Oil Pump - Regulator Valve - Torque Converter Pressure
(
Lubrication Pressure
Distribution of Hydraulic Pressure
I
Line Pressure
• Regulator Valve - Torque Converter Pressure
• Manual Valve To Select Line Pressure
l
• Modulator Valve Modulator Pressure
• 1-2 Shift Valve

• 2-3 Shift Vavle Clutch Pressure
• 3-4 Shift Valve
• Throttle Valve A Throttle A Pressure
• Throttle Valve B Throttle B Pressure
• Governor Valve Governor Pressure
NO. DESCRIPTION OF PRESSURE NO. DESCRIPTION OF PRESSURE NO. DESCRIPTION OF PRESSURE

1 UNE 16 1 ST-HOLD CLUTCH 57 THROTTLE B
2 UNE 18 LINE 58 THROTTLE B
3 LINE 20 2ND CLUTCH 60 GOVERNOR
3' LINE 21 2ND CLUTCH 61 GOVERNOR
3" LINE 25 LINE 90 TORQUE CONVERTER
4 LINE 30 3RD CLUTCH 91 TORQUE CONVERTER
4' LINE 31 3RD CLUTCH 92 TOROUE CONVERTER
5 UNE 40 4TH CLUTCH 93 OIL COOLER
5' UNE 41 4TH CLUTCH 94 TOAOUE CONVERTER
5" LINE 50 THROTTLE A 95 LUBRICATION
6 MODULATOR 51 THROTTLE A 96 TOROUE CONVERTER
6' MODULATOR 52 THROTTLE A 97 TORQUE CONVEATER
10 1ST CLUTCH 55 THROTTLE B 99 SUCTION
15 1ST-HOLD CLUTCH 56 THROTTLE B X BLEED
(cont'd)
14-157
Description
Hydraulic Flow 01582 (cont'd)
IE] Position
As the engine turns, the oil pump also starts to operate. Automatic transmission fluid is drawn from (99) and discharged
into ( 1). Then, ATF pressure is controlled by the regulator valve and becomes line pressure ( 1). The torque converter
inlet pressure (92) enters (94) of torque converter through the orífice and discharges into (90).
The torque converter check valve prevents the torque converter pressure from falling.
Under this condition, the hydraulic pressure is not applied to the clutches.
14-158
II] Position
The line pressure ( 1 l becomes the line pressure (4) and 1 st-hold clutch pressure ( 16) as it passes through the manual
valve. Also, the line pressure ( 1) goes to the governor valve and becomes the governor pressure (60). The governor pres-
sure (60) is supplied to the 1-2 and 2-3 shift valves. The shift valves remain on the right side because the governor pres-
sure is lower than the valve spring tention and the throttle A pressure supplied to the left side of the shift valves.
The line pressure (4) becomes the 1 st clutch pressure ( 1 O) via the orífice, then goes to the 1 st clutch. The 1 st clutch
pressure ( 1 O) is also supplied to the servo control valve and 2-1 timing valve to move them to the left side.
The 1 st-hold clutch pressure ( 16) goes to the 1 st-hold clutch via the 1-2 shift valve, orífice and 4th exhaust valve.
In the [Il position, the 1 st clutch and 1 st-hold clutch are engaged.
The line pressure(4) also goes to the servo valve via the servo control valve, and holds on the servo valve in the dríving range.
NOTE:
• When used, "left" and "right" indicates direction on the flowchart.
• SOL-©: Lock-up Control Solenoid Valve A
(cont'd)
14-159
Description
.
Hydraulic
Flow
01582 (cont'd)------------------
[Il Position
The line pressure (1) becomes the line pressure (2), (4), (4'), (25) as it passes through the manual valve. Also, the line
pressure ( 1) goes to the governor valve and becomes the governor pressure (60). The governor pressure (60) is supplied
to the 1-2 and 2-3 shift valves, but the 1-2 and 2-3 shift valves remain on the right side.
The line pressure (25) goes to the 2-3 shift valve .via the 1-2 shift valve and becomes the 2nd clutch pressure (21). The
2nd clutch pressure(21) becomesthe 2nd clutch pressure(20) as it passesthrough the orifice, then goes to the 2nd clutch.
The line pressure (4) becomes the 1 st clutch pressure ( 1 O) and flows to the 1 st clutch, servo control valve and 2-1 timing
valve. The line pressure (4') also holds on the servo valve in the driving range as in the [I] Position.
In the []] position, the 1 st clutch and 2nd clutch are engaged.
NOTE:
14-160
~ or ~ Position
1. 1st speed
The flow of fluid through the torque converter is the same as in the ffiJ position. The line pressure ( 1) becomes the
line pressure (4).The line pressure (4) becomes the 1st clutch pressure (10) as it passes through the orifice. The
1 st clutch pressure ( 1 O) is supplied to the 1 st clutch and, consequently the vehicle will move as the engine power
is transmitted.
The line pressure (1) becomes the governor pressure (60) by the governor valve and travels to each shift valve. But,
all shift valves remain on the right side because the governor pressure (60) is lower than the shift valve spring ten-
sion and the throttle A pressure.
The line pressure ( 1) also flows to the modulator valve and throttle valve B.
In the ~ or ~ position, the line pressure (4') flows to the servo valve and holds it on in the driving range as in the
[TI and 2 position
NOTE:
• When used, "left" or "right" indicates direction on the flowchart.
(cont'd)
14-161
Description
2. 2nd speed
The flow of fluid up to the 1-2 and 2-3 shift valves is the same as the 1 st speed range. As the speed of the car
reachesthe prescribedvalue, the 1-2 shift valve is moved to the left side by the governor pressure (60) and uncovers
the oil port leading to the 2nd clutch; the 2nd clutch is engaged.
Fluid flows by way of:
Une Pressure(41 - CPCValve-line Pressure(4') - 1-2 Shift Valve-line Pressure(5) - 2-3 Shift Valve-2nd Clutch
Pressure (21) - Orifice-2nd Clutch Pressure (20) - 2nd Clutch.
The 2nd clutch pressure (201 is also supplied to the governor cut valve. The governor cut valve is moved to the
left side to cover the oil port of the governor pressure (60) to the 3-4 shift valve. The hydraulic pressure also flows
to the 1 st clutch. However, no power is transmitted by means of the one-way clutch.
NOTE:
14-162
3. 3rd speed
The flow of fluid up to the 1-2, 2-3 and 3-4 shift valves is the same as the 2nd speed range. As the speed of the
car reaches the prescribed value, the 2-3 shift valve is moved to the left side by the governor pressure (60) and
uncovers the oíl port leading to the 3rd clutch. Since the 1-2 shift valve is kept on the left side, and the 3-4 shift
valve is on the right side to uncover the oíl port leading to the 3rd clutch, the 3rd clutch is engaged.
Line Pressure (4) - CPC Valve-Line Pressure (4') - 1-2 Shift Valve-Line Pressure (5) - 2-3 Shift Valve-3rd Clutch
Pressure (31) - 3-4 Shift Valve-3rd Clutch Pressure (30) - Orífice - 3rd Clutch.
The hydraulic pressure also flows to the 1 st clutch. However, no power is transmitted by means of the one-way
clutch as in the 2nd speed.
NOTE:
(cont'd)
14-163
Desription
Hydraulic
Flow
01582 (cont'd)------------------
4. 4th speed
The flow ot fluid up to the 1-2, 2-3 and 3-4 shift valvas is the sama as the 3rd speed ranga. As the speed of the
car reaches the prescribed value, the 3-4 shift valva is moved to the left side by the governor pressure (60) and
uncovers the oil port leading to the 4th clutch. Since the 1-2 and 2-3 shift valves are kept on the left side, the fluid
flows through to the 4th clutch; the power is transmitted through the 4th clutch.
Une Pressure(4) - CPCValve-LinePressure(4') - 1-2 Shift Valve-Line Pressure(5) - 2-3 Shift Valve-3rd Clutch
Pressure (31) - 3-4 Shift Valve-4th Clutch Pressure (41) - Orífice - Manual Valve-4th Clutch Pressure
(40) - 4th Clutch.
clutch as in the 3rd speed. ·
NOTE:
14-164
[ID Position
The flow of fluid through the torque é:onvertercircuit is the same as in the [ffi position. The line pressüre ( 1) becomes
the line pressure (3) as it passes the manual valve. lt then flows through the reverse control valve to the servo valve,
causing the reverse shift fork shaft to be moved to the reverse position. The line pressure (3") from the servo valve
goes to the manual valve and becomesthe 4th clutch pressure (40). Then it goes to the 4th clutch; the power is transmit-
ted through the 4th clutch.
When the [B] position is selected while the vehicle is moving forward at more than a certain speed, the line pressure
rn
(3) is cut by the governor pressure (60) which activates the reverse control valve.
When shifting to [B) from ~. ~' or [!] position, the servo control valve is moved to the left side by 1 st clutch
pressure (10). The servo control valve combines with the reverse shift fork shaft detent system to control movement
of the servo valve.
NOTE:
• When used, "Ieft" and "right" indicates direction on the flowchart.
(cont'd)
14-165
Description
.
[f] Position
The flow of fluid through the torque converter is the same as in theffiJ
position. The line pressure ( 1) becomes the line
pressure (3) as it passesthe manual valve. The line pressure (3) flows through the reverse control valve to the servo
valve, causing the reverse shift fork to be moved to the reverse position as in the [BJ position.
14-166
...- Lock-up System 01582
In [Q;] or []El in 2nd, 3rd and 4th, pressurized fluid is drained from the back of the torque converter through an oil pas-
sage, causing the lock-up piston to be held against the torque converter cover. As this takes place, the mainshaft rotates
at the same speed as the engine crankshaft. Together with hydraulic control, the ECUoptimizes the timing of the lock-up
system. Under certain conditions, the lock-up operation is applied during deceleration, in 2nd, 3rd and 4th speed.
The lock-up shift valve controls the range of lock-up according to vehicle speed and lock-up control solenoid valve A.
When lock-up control solenoid valve A actívate, modulator pressure changes. Lock-up control solenoid valve A is mount-
ed on the torque converter housing and is controlled by the ECU.
LOCK-UP CONTROL ~
SOLENOID VALVE A I
n
= 80
8º 80 X ti
111 ,-""'- X -
H'~
L/C TIMING B VALVE
D- n1 ....n g¡
~~ -
HI
- 81 ¡-,.=,...:::
--- ~r
(!:::""" ...... 11 -
~ 1r
-
(h:::: 'º 1LJ

1111
14
01 b COOLER
COO EA CHECK VALVE

111111
11
1
\ J
(cont'd)
14-167
Description
Lock-up System 01582 (cont'd)
No Lock-up
Pressuredfluid regulated by the modulator works on both ends of the lock-up shift valve and on the left side of the lock-
up control valve. Under this condition, the pressure on both ends of the lock-up shift valve are equal, and the lock-up
shift valve is moved to the right side by the tension ot the valve spring alone. The fluid from the oil purnp will flow through
the left side of the lock-up clutch to the torque converter; i.e., the lock-up clutch is in OFF condition.
OFF
LOCK-UP CONTROL
SOLENOID VALVE A
1111
110
UNE PRESSURE
l BEGYLATOB
.lALll
111 .
Qll
14-168
Lock-up Control Mode
Lock-up Control Solenoid Valve A: ON
The modulator pressure is released by the solenoid valve A, causing the modulator pressure in the left cavity of the lock-
Also, the modulator pressure in the left cavity of the lock-up timing valve is low. However, the governor pressure is still
low at this time, consequently the lock-up timing valve is kept on the right side by the spring force.
As the modulator pressure released, the lock-up control valve is moved somewhat to the left side, causing the back pres-
sure (F2) to lower. This allows a greater amount of the fluid (F1) to work on the lock-up clutch so as to engage the clutch.
The back pressure (F2) which still exists prevents the clutch from engaging fully.

ON
THROTTLE B PRESSURE
l
LOCK-UP CONTROL
SOLENOID VALVE A
1111
H
1: 111111111. IILIE
80 GOVERNOR PRESSURE
Lts===:s:s4-
l UNE PRESSURE
REGYLATPB
.ui.:a
99
(cont'dl
14-169
Description
Lock-up System 01582 {cont'd)
Full Lock-up
Lock-up Control Solenoid Valve A: ON
When the vehicle speed further increases, the governor pressure is increased. The lock-up timing valve overcomes the
spring force and moves to the left side. Also this valve closes the oil port leading to the torque converter check valve.
Under this condition, the throttle B pressure working on the right side of the lock-up control valve becomes greater than
that on the left end (modulator pressure in the left end has already been released by the solenoid valve A); i. e., the lock-
up control valve is moved to the left side. As this happens, the torque converter back pressure is released fully, causing
the lock-up clutch to be engaged fully.
NOTE: When used, "left" or :'right" indicates direction on the flowchart.
ON
THROTTLE B PRESSUAE
!
LOCK·UP CONTROL
SOLENOID VALVE A
LC SKiFT YAUE
~====+--
80 GOVERNOR PRESSUAE
t UNE PRESSURE
REGUI ATAR
.l'.AI..U
11
DIL cooLER
99
14-170
Lock-up Control System D 1626/D 16A8/D 16A 7
Lock-up control
From sensor input signals, the ECUdetects whether to turn the lock-up ON or OFF and activates lock-up control solenoid
val ve A and/or B accordingly.
The combination of driving signaIs to lock-up control solenoid valves A and B is shown in the table below.
\ Solenoid valve
A B
Lock-up condition \
Lock-up OFF OFF OFF
Duty operation
Lock-up, slight ON
OFF - ON
Lock-up, half ON ON
l.ock-up, full ON ON
ON
during deceleration OFF - ON
14-171
Description
HydraulicFlow D1626/D16A8/D16A7 -------------
Line Pressure
Oíl Pump - Regulator Valve - Torque Converter Pressure
Line Pressure
• Regulator Valve Torque Converter Pressure
• Manual Valve To Select Line Pressure
• Modulator Valve Modulator Pressure
• 1-2 Shift Valve

• 2-3 Shift Vavle - Clutch Pressure
• 3-4 Shift Valve
• Throttle Valve A Throttle A Pressure
• Throttle Valve B Throttle B Pressure
• Governor Valve Governor Pressure

1 LINE 16 1 ST-HOLD CLUTCH 57 THROTTLE B
2 LINE 18 LINE 58 THROTTLE B
3 LINE 20 2ND CLUTCH 60 GOVERNOR
3' LINE 21 2ND CLUTCH 61 GOVERNOR
3" LINE 25 LINE 90 TORQUE CONVERTER
4' LINE 31 3RD CLUTCH 92 TORQUE CONVERTER
5 LINE 40 4TH CLUTCH 93 OIL COOLER
5' LINE 41 4TH CLUTCH 94 TORQUE CONVERTER
5" LINE 50 THROTTLE A 95 LUBRICATION
6 MODULATOA 51 THROTTLE A 96 TORQUE CONVERTER
6' MODULATOA 52 THROTTLE A 97 TORQUE CONVERTER
10 1ST CLUTCH 55 THROTTLE B 99 SUCTION
15 1 ST-HOLD CLUTCH 56 THROTTLE B X BLEED
14-172
[filPosition
As the engine turns, the oil pump also starts to operate. Automatic transmission fluid is drawn from (99) and discharged
into ( 1). Then, ATF pressure is controlled by the regulator valve and becomes line pressure ( 1). The torque converter
inlet pressure (92) enters (94) of torque converter through the orífice and discharges into (90).
The torque converter check valve prevents the torque converter pressure from falling.
Under this condition, the hydraulic pressure is not applied to the clutches.
(cont'd)
14-173
Description
Hydraulic Flow D1626/D16A8/D16A7 (cont'd)
[!] Position
The line pressure ( 1) becomes the line pressure (4) and 1 st-hold clutch pressure ( 1 6) as it passes through the manual
valve. Also, the line pressure ( 1) goes to the governor valve and becomes the governor pressure (60). The governor pres-
sure (60) is supplied to the 1-2 and 2-3 shift valves. The shift valves remain on the right side because the governor pres-
sure is lower than the valve spring tention and the throttle A pressure supplied to the left side of the shift valves.
The line pressure (4) becomes the 1 st clutch pressure ( 1 O) vía the orífice, then goes to the 1 st clutch. The 1 st clutch
pressure ( 1 O) is also supplied to the servo control valve and 2-1 timing valve to move them to the left side.
The 1 st-hold clutch pressure ( 16) goes to the 1 st-hold clutch vía the 1-2 shift valve, orífice and 4th exhaust valve.
In the [!] position, the 1 st clutch and 1 st-hold clutch are engaged.
The line pressure(4) also goes to the servo valve vía the servo control valve, and holds on the servo valve in the driving range.
NOTE:
• SOL-@: Lock-up Control Solenoid Valve B
14-174
rn Position
The line pressure ( 1) becomes the line pressure (2), (4), (4'), (25) as it passes through the manual valve. Also, the line
pressure (1) goes to the governor valve and becomes the governor pressure (60). The governor pressure (60) is supplied
to the 1-2 and 2-3 shift valves, but the 1-2 and 2-3 shift valves remain on the right side.
The line pressure (25) goes to the 2-3 shift valve via the 1-2 shift valve and becomes the 2nd clutch pressure (21 ). The
2nd clutch pressure (21) becomesthe 2nd clutch pressure (20) as it passesthrough the orifice, then goes to the 2nd clutch.
The line pressure (4) becomes the 1 st clutch pressure ( 1 O) and flows to the 1 st clutch, servo control valve and 2- 1 timing
valve. The line pressure (4') also holds on the servo valve in the driving range as in the [TI Position.
In the []] position, the 1 st clutch and 2nd clutch are engaged.
NOTE:
(cont'd)
14-175
Description
Hydraulic Flow D 1626/D 16A8/D 16A 7 (cont' d)
~ or ~ Position
1. 1st speed
The flow of fluid through the torque converter is the same as in the I]] position. The line pressure ( 1) becomes the
line pressure (41.The line pressure (4) becomes the 1st clutch pressure (10) as it passes through the orífice. The
1 st clutch pressure ( 1 O) is supplied to the 1 st clutch and, consequently the vehicle will move as the engine power
is transmitted.
The line pressure ( 1) becomes the governor pressure (60) by the governor valve and travels to each shift valve. But,
ali shift valves remain on the right side because the governor pressure (60) is lower than the shift valve spring ten-
sion and the throttle A pressure.
The line pressure ( 1) also flows to the modulator valve and throttle valve B.
In the ~ or ~ position, the line pressure (4') flows to the servo valve and holds it on in the driving range as in the
[Il and rn position
NOTE:
• SOL-@: Lock-up Control Solenoid Valve 8
14-176
2. 2nd speed
The flow of fluid up to the 1-2 and 2-3 shift valves is the same as the 1 st speed range. As the speed of the car
reaches the prescribed value, the 1-2 shift valve is moved to the left side by the governor pressure (60) and uncovers
the oil port leading to the 2nd clutch; the 2nd clutch is engaged.
Line Pressure (4) - CPC Valve-Line Pressure (4') - 1-2 Shift Valve-Line Pressure (5) - 2-3 Shift Valve-2nd Clutch
Pressure (21) - Orifice-2nd Clutch Pressure (20) - 2nd Clutch.
The 2nd clutch pressure (20) is also supplied to the governor cut valve. The governor cut valve is moved to the
left side to cover the oil port of the governor pressure (60) to the 3-4 shift valve. The hydraulic pressure also flows
to the 1 st clutch. However, no power is transmitted by means of the one-way clutch.
NOTE:
(cont'd)
14-177
Description
Hydraulic Flow 01626/016A8/D16A7 (cont'd)
3. 3rd speed
The flow of fluid up to the 1-2, 2-3 and 3-4 shift valves is the sarne as the 2nd speed range. As the speed of the
uncovers the oil port leading to the 3rd clutch. Since the 1-2 shift valve is kept on the left side, and the 3-4 shift
valve is on the right síde to uncover the oil port leading to the 3rd clutch, the 3rd clutch is engaged.
Line Pressure(4) - CPCValve-Line Pressure(4') - 1-2 Shift Valve-Line Pressure(5) - 2-3 Shift Valve-3rd Clutch
Pressure (31) - 3-4 Shift Valve-3rd Clutch Pressure (30) - Orífice - 3rd Clutch.
clutch as in the 2nd speed.
NOTE:
• When used, "left" and "right" índícates direction on the flowchart.
14-178
4. 4th speed
The flow of fluid up to the 1-2, 2-3 and 3-4 shift vatves is the same as the 3rd speed range. As the speed of the
uncovers the oil port leading to the 4th clutch. Since the 1-2 and 2-3 shift valves are kept on the left side, the fluid
flows through to the 4th clutch; the power is transmitted through the 4th clutch.
Line Pressure(4) - CPCValve-LinePressure(4') - 1-2 Shift Valve-LinePressure(5) - 2-3 Shift Valve-3rd Clutch
Pressure (31) - 3-4 Shift Valve-dth Clutch Pressure (41) - Orífice - Manual Valve-4th Clutch Pressure
(40) - 4th Clutch.
clutch as in the 3rd speed.
NOTE:
• When used, "left" or "rlqht" indicates direction on the flowchart.
• SOL-@: l.ock-up Control Solenoid Valve B
(cont'd)
14-179
Description
Hydraulic Flow D1626/D16A8/D16A7 (cont'd)
(ID Position
The flow of fluid through the torque converter circuit is the same as in the [RJ position. The line pressure ( 1 l becomes
the line pressure (3) as it passes the manual valve. lt then flows through the reverse control valve to the servo valve,
causing the reverse shift fork shaft to be moved to the reverse position. The line pressure (3") from the servo valve
goes to the manual valve and becomes the 4th clutch pressure (40). Then it goes to the 4th clutch; the power is transmit-
ted through the 4th clutch.
When the [B] position is selected while the vehicle is moving forward at more than a certain speed. The line pressure
(3) is cut by the governor pressure (60) which activates the reverse control valve.
When shifting to [ID from ~' ~' []] or [TI position, the servo control valve is moved to the left side by 1 st clutch
pressure ( 1 O). The servo control valve combines with the reverse shift fork shaft detent system to control movement
of the servo valve.
NOTE:
14-180
~ Position
The flow of fluid through the torque converter is the same as in the [El position. The line pressure ( 1 l becomes the line
valve, causing the reverse shift fork to be moved to the reverse position as in the [fil position.
14-181
Description
Lock-up System D16Z6/D16A8/D16A7
In ~ or ~ in 2nd, 3rd and 4th, pressurized fluid is drained from the back of the torque converter through an oil pas-
sage, causing the lock-up piston to be held against the torque converter cover. As this takes place, the mainshaft rotates
at the same speed as the engine crankshaft. Together with hydraulic control, the ECUoptimizes the timing of the lock-up
system. Under certain conditions, the lock-up operation is applied during deceleration, in 2nd, 3rd and 4th speed.
The lock-up shift valve controls the range of lock-up according to lock-up control solenoid valves A and B, and the throt-
tle valve. When lock-up control solenoid valves A and B actívate, modulator pressure changes. Lock-up control solenoid
valves A and B are mounted on the torque converter housing and are controlled by the ECU.
lOCK-UP COIITROl lOCK-UP CONTROL

SOL!NOID VALVE A SDLENOID VALVE 8
80
RUiULAIPB
.liJ..U
11
14-182
No Lock-up
Pressuredfluid regulated by the modulator works on both ends of the lock-up shift valve and on the left side of the lock-
up control valve. Under this condition, the pressure on both ends of the lock-up shift valve are equal, and the lock-up
shift valve is moved to the right side by the tension of the valve spring alone. The fluid from the oil pump will flow through
the left side of the lock-up clutch to the torque converter; i.e., the lock-up clutch is OFF.
LOCK·UP CONTROL LOCK-UP CONTROL

SOLENDID VAlVE A SOLENOID VALVE B
OFF OFF
80
LINE PRESSURE
t AfGUl AIOR
.liLll
(cont'd)
14-183
Description
Lock-up System D1626/D16A8/D16A7 (cont'd)
Partial Lock-up
Lock-up Control Solenoid Valve A: ON Lock-up Control Solenoid Valve B: Duty operation (ON ..... OFF)
The ECU switches the solenoid valve A to ON to release the modulator pressure in the left cavity of the lock-up shift
valve. The modulator pressure in the right cavity of the lock-up shift valve overcomes the spring force, thus the lock-up
shift valve is moved to the left side.
The torque converter pressure is separated into two passages:
Torque Converter lnner Pressure: entered into right side-to engage lock-up clutch
Torque Converter Back Pressure: entered into left side-to disengage lock-up clutch
The back pressure (F2) is regulated by the lock-up control valve, whereas the position of the lock-up timing valve is deter-
mined by the governor pressure, tension of the valve spring and pressure regulated by the modulator. Also the position
of the lock-up control valve is determined by the throttle B pressure, torque converter back pressureand torque converter
pressure regulated by the check valve. In low speed range, the throttle B pressure working on the right side of the lock-up
control valve is low, causing the valve to· be moved to the right side. With the lock-up control solenoid valve B to ON
and OFF alternately, the modulator pressure is maintained in the left side of the lock-up control valve; in other words,
the lock-up control valve is moved slightly to the left side. This slight movement of the lock-up control valve causes
the back pressure (F2) to be lowered slightly, resulting in partial lock-up.
LOCll>UP CONTROL LOCK-UP CONTROL
i
SOLENOID VALVE A SOLENOIO VALVE B
Duty operation
OFF ...._... DN
.
THROTnE PRESSURE
. .
u..:::::=-=-
eo GOVERNOR PRESSURE
l
LINE PIIESSURE
••
14-184
Half Lock-up
The modulator pressure is released by the solenoid valve B, causing the modulator pressure in the left cavity of the lock-
Also, the modulator pressure in the left cavity of the lock-up timing valve is low. However, the governor pressure is still
low at this time, consequently the lock-up timing valve is kept on the right side by the spring force.
With the lock-up control solenoid valve B turned ON, the lock-up control valve is moved somewhat to the left side, caus-
ing the back pressure (F2) to lower. This allows a greater amount of the fluid (F1) to work on the lock-up clutch so as
to engage the clutch. The back pressure (F2) which still exists prevents the clutch from engaging fully.
lOCK-UP COUROl LOCK-UP CONTROL

SOLENDID VALVE A SOLENOID VALVE B
ON ON
THRDTILE B PRESSURE
l ee
GOVERNOR PRESSURE
U-!:~=-
80
l llNE PRESSURE
(cont'd)
14-185
Description
Lock-up System 01626/016A8/016A7 (cont'd)
Full Lock-up
Lock-up Control Solenoid Valve A: ON Lock-up Control Solenoid Valve 8: ON
When the vehicle speed further increases, the governor pressure is increased. The lock-up timing valve overcomes the
spring force and moves to the left side. Also this valve closes the oil port leading to the torque converter check valve.
Under this condition, the throttle 8 pressure working on the right side of the lock-up control valve becomes greater than
that on the left end (modulator pressure in the left end has already been released by the solenoid valve B); i. e., the lock-
up control valve is moved to the left side. As this happens, the torque converter back pressure is released fully, causing
LOCK-UP CONTROL LOCK·UP CONTROL

SOLENOIO VALVE A SOLENOIO VALVE B
ON ON
THROTTLE B PRESSURE
l 55
!!:s====-
t UNE PRESSURE
11
14-186
Deceleration Lock-up
Lock-up Control Solenoid Valve A: ON Lock-up Control Solenoid Valve B: Duty Operation (ON <-+ OFF)
The ECU switches the solenoid valve B to ON and OFF alternately at high speeds under certain conditions. The slight
lock-up and half lock-up regions are maintained so as to lock the torque converter properly.
LOCK·UP CONTROL LOCK-UP CONTROL

SOLENOIO VALVE A SOLENOID VALVE 8
Duty operation
ON OFF +--+ DN
THROTILE B PRESSURE
'1:s:====-
f UNE PRESSURE
BEAUI ATAR
~
14-187
Troubleshooting
Electrical Troubleshooting
lf the lock-up control system is suspected to be faulty, do the following:
1. lf the Check Engine Light comes on, check and inspect PGM-FIsystem according to PGM-FI Troubleshooting (See
Section 11 ) .
CHECK ENGINE LIGHT
2. lf the Check Engine Light does not come on or it blinks other than nineteen times, check and inspect according to
the Symptom-to-Component Chart (see page 14-190 thru 193).
3. Check the lock-up control solenoid valve (see page 1 4-1891.
14-188
Lock-up Control Solenoid Valve A/B
Test Replacement
NOTE: 1. Removethe mounting bolts and lock-up control sole-

• Lock-up control solenoid valve must be re- noid valve assembly.
moved/replaced as an assembly.
• D16Z6, D16A8 and D16A7 ·are shown; D1 582 is NOTE: Be sure to remove or replacethe lock-up con-
similar. trol solenoid valve as an assembly.
• Only the D 1 582 engine uses the lock-up control sole-
noid valve A. 2. Check the lock-up control solenoidvalve oil passages
far dust or dirt and replace as an assembly, if
1. Disconnect the connector from the lock-up control necessary.
solenoid valve A/B.
·r· . ,
2. Measure the resistance between the No. 1 terminal
(SOL. V A) of the lock-up control solenoid valve con-
nector and body ground and between the No. 2 ter- 6 x 1.0 mm
12 N•m
minal (SOL. V B) and body ground.
., .z b-ft ,
STANDARD:
. D16Z6/D16A8/D16A7: 14.1-15.5 íl (at 25ºCI
01582: 14.25-15.75 íl (at 25ºCI
\
BASE GASKET
Replace.
View from terminal side. LOCK-UP CONTROL

SOLENOID VALVE
ASSEMBLY
3. Replace the lock-up control solenoid valve assem-

bly if the resistance is out of specification. 3. Clean the mounting surface and oil passagesof the
lock-up control solenoid valve assembly and install
4. Connect the No. 1 terminal of the lock-up control a new base gasket.
solenoid valve connector to the battery positive ter-
minal and body ground. A clicking sound should be 4. Check the connector far rust, dirt or oil and recon-
heard. Connect the No. 2 terminal to the battery nect it securely.
5. lf not, check far continuity between the ECU A 19

or A 17 harness and body ground.
(See Section 11)

bly if there is continuity between the ECU A 1 9 or
A 17 harness and body ground.
(See Section 11 ).
14-189
Hydraulic System
Symptom-to-Component Chart -------------------
SYMPTOM Check these items on the Check these items on the

PROBABLECAUSE LIST NOTESCHART
Engine runs, but car does not move in any gear. 1,6,7,16 K, L, R, S
Car moves in ffil
and rn, but not in [Qi), ~ or [IJ. 8, 29, 44, 48 C,M,O
ffil,
Car moves in [ 03l [ D4l, Í 1 l, but not in [Ij. 9, 30, 49 C, L
Car moves in [Qi], ~, [Ij, [IJ, but not in [[]. 1, 11, 22, 34, 38, 39, C, L, Q
40
Car moves in ~- 1, 8, 9, 1 O, 11, 46, C, D
47
Excessive idle vibration. 5, 17 B, K, L
No engine braking in [11 position. 12 C, D, L
Slips in 1 st gear. 8. 29, 44, 48 C, N,O,U
Fiares on 1 -2 upshift. 3, 15 E, L, V
Harsh shift (up and down s},ifting). 2, 4, 15, 23, 24, 27, A, E, H, l, L, V
47
Harsh shift (1-2). 2, 9 C, D,V
Harsh shift (2-3). 2, 10, 23, 24 C, D, H,L,V
Harsh shift (3-4). 2, 11, 23, 25 C, D, 1, L, V
Harsh shift when manually shifting to ín. 33 L
Axle(s) slips out of trans on turns. 43, 50 L, P, Q
Ratcheting noise when shifting into I Rl. 6, 7, 38, 39, 40 K, L, Q
Loud popping noise when taking off in íITT. 38, 39, 40 L, Q
Ratcheting noise when shifting from ffil to ~ or from 38, 39, 40, 45 L, Q
íITT
to INI.
Noise from trans in all selector lever positions. 6. 17 K, L, Q
Noise from trans only when wheels are rolling. 39. 42 L, Q
Gear whine, rpm related (pitch changes with shifts). 8, 13, 41 K, L, Q
Gear whine, speed related (pitch changes with speed). 38, 42 L, Q
Trans will not shift into 4th gear in [ D4 l. 1,21,28,32 L
Lock-up clutch does not operate properly. 2, 3, 15, 18, 35, 36, E, L, V
37
At disassembly, large particles of metal are found on
magnet.
14-190
PROBABLE CAUSE
1 . Shift cable broken/out of adjustment.
4. Wrong type ATF.
5. /die rpm too low/high.
7. Regulator va/ve stuck.
8. 1 st clutch detective.
9. 2nd c/utch detective.
11 . 4th c/utch detective.
12. 1 st-hold clutch detective.
14. Modulator valve stuck.
16. ATF strainer clogged.
17. Torque convertor detective.
18. Torque convertor check va/ve stuck.
23. Clutch pressure control (CPC)valve stuck.
24. 2-3 orífice control valve stuck.
25. 2/3-4 orífice control valve stuck.
26. 3-2 kick-down valva stuck.
27. 4-3 kick-down valve stuck.
28. 4th exhaust valve stuck.
29. 1 st accumulator detective.
30. 2nd accumulator detective.
31. 3rd accumulator detective.
33. 1 st-hold accumulator detective.
35. Lock-up timing valve stuck.
36. Lock-up shift valve stuck.
37. Lock-up control valve stuck.
38. Shift fork bent.
39. Reverse gears worn/damaged (3 gears).
41. 3rd gears worn/damaged (2 gears).
42. Final gears worn/damaged (2 gears).
43. Differential pinion shaft worn.
44. Feedpipe 0-ring broken.
45. 4th gears worn/damaged (2 gears).
48. One-way (sprag) clutch detective.
49. Sealing rings/guide worn.
50. Axle-inboard joint clip missing.
(cont'd)
14-191
Hydraulic System
Symptom-to-Component Chart (cont'd) --------------

The tollowing symptoms can be caused ltems on the
PROBABLECAUSE DUE
by improper repair or assembly. NOTES CHART
TO IMPROPERREPAIR
Car creeps in rn:J. R1, R2
Car does not move in [lliJ or (Q;]. R4
Trans locks up in ffi]. R3, R12
Noise with wheels moving only. R5
Various shifting problems. R9, R10
Harsh upshifts. R 11

R8. Main seal improperly installed.
14-192
NOTES
B. Set idle rpm in gear to specified idle speed. lf still no good, adjust motor mounts as outlined in engine
section of service manual.
c. . lf the large clutch pistan 0-ring is broken, inspect the pistan groove for rough machining .
D. lf the clutch pack is seized or is excessively worn, inspect the other clutches for wear and check the
orifice control valves and throttle valves for free movement.
G. lf the 1 -2 shift valve is stuck closed, the transmission will not upshift. lf stuck open, the transmission
has no 1st gear.
H. lf the 2 -3 orífice control valve is stuck, inspect the 2nd and 3rd clutch packs for wear.
l. lf the 2/3-4 orífice control valve is stuck, inspect the 3rd and 4th clutch packs for wear.
J. lf the clutch pressure control valve (CPC)is stuck closed, the transmission will not shift out of 1 st gear.
K. lmproper alignment of main valve body and torque convertor housing may cause oíl pump seizure. The
symptoms are mostly an rpm-related tickinq noise or a high pitched squeek.
L. lf the oíl screen is clogged with particles of steel or aluminum, inspect the oil pump and differential
pinion shaft. lf both are OK and no cause for the contamination is found, replace the torque converter.
M. lf the 1 st clutch feedpipe guide in the R. side cover is scored by the mainshaft, inspect the ball bearing
for excessive movement in the transmission housing. lf OK, replace the R. side cover as it is dented.
The 0-ring under the guide is probably worn.
N. Replace the mainshaft if the bushings for the 1 st and 4th feedpipe are loose or damaged. lf the 1 st
feedpipe is damaged or out of round, replace it. lf the 4th feedpipe is damaged or out of round, replace
the R. side cover.
o. A worn or damaged one-way (sprag) clutch is mostly a result of shifting the trans in~ or ~ while
the wheels rotate in reverse, such as rocking the car in snow.
Replaceitems 1, 2, and 4 if worn or damaged. lf trans makes clicking, grinding or whirring noise, also
replace mainshaft 4th gear and reverse idler gear and countershaft 4th gear in addition to 1, 2, 3 or 4.
lf differential pinion shaft is worn, overhaul differential assembly and replace oil screen and thoroughly
clean trans, flush torque converter, cooler and lines.
R. Be very careful not to damage the torque converter housing when replacing the main ball bearing. You
may also damage the oil pump when you torque down the main valve body. This will result in oil purnp
s. lnstall the main seal flush with the torque converter housing. lf you push it into the torque converter
housing until it bottoms out, it will block the oíl return passage and result in damage.
v. Throttle cable adjustment is essential for proper operation of the transmission. Not only does it affect
the shift points if misadjusted, but also the shift quality and lock-up clutch operation.
14-193
Road Test
1. Apply parking brake and block the wheels. Start the engine, then move the selector lever to [!E] position while
2. Repeat same test in ~ position.
3. Shift the selector lever to [!E] position and check that the shift points occur at approximate speeds shown. Also
check for abnorrnal noise and clutch slippage.
01582: ~ or [QiJ Position
• Upshift
Throttle Opening Unit of speed 1st - 2nd 2nd - 3rd 3rd - 4th
Full-closed throttle Km/h 15 - 19 35 -39 49 -53
mph 9 - 12 22 - 24 30 - 33
3/16 throttle Km/h 20 - 24 45 - 49 63 - 69
mph 12 - 15 28 - 30 39 - 43
6/16 throttle Km/h 25 - 33 57 - 69 80 - 92
mph 16 - 21 35 - 43 50 - 57
Full-opened throttle Km/h 49 - 53 92 - 99 146 - 157
mph 30 - 33 57 - 62 91 - 98
• Downshift
Throttle Opening Unit of speed 4th - 3rd 3rd - 2nd 2nd - 1st
Full-closed throttle Km/h -- 29 - 33 9 - 13
mph -- 18 - 21 6 - 8
mph 77 - 84 53 - 57 26 - 29
• Lock-up
(Q;J Position ~ Position

Throttle Opening Unit of speed
Lock-up ON Lock-up OFF Lock-up ON Lock-up OFF
Full-closed throttle Km/h 24 -27 23 -26 97 - 103 92 - 98
mph 15 - 17 14 - 16 60 - 64 57 - 61
6/16 throttle Km/h 107 - 113 87 - 93 107 - 113 92 - 98
mph 66 - 70 54 - 58 66 - 70 57 - 61
Full-opened throttle Km/h 141 - 147 136 - 142 132 - 138 126 - 132
mph 88 - 91 85 - 88 82 - 86 78 - 82
14-194
D16Z6: [Q;J or ~ Position
• Upshift
mph 9 - 12 22 - 24 30 - 33
3/16 throttle Km/h 21 - 25 48 - 52 64 - 70
mph 13 - 16 30 - 32 40 - 43
6/16 throttle Km/h 26 - 34 62 - 74 83 - 95
mph 16 - 21 39 - 46 52 - 59
mph 35 - 39 66 - 70 96 - 103
• Downshift
Full-closed throttle · Km/h -- 29 - 33 9 - 13
mph -- 18 - 21 6-8
mph 83 - 90 58 - 63 25 - 27
• Lock-up
[Q;J Position ~ Position

Full-closed throttle Km/h 24 -27 23 -26 97 - 103 92 - 98
mph 15 - 17 14 - 16 60 - 64 57 - 61
6/16 throttle Km/h 107 - 113 87 - 93 107 - 113 92 - 98
mph 66 - 70 54 - 58 66 - 70 57 - 61
Full-opened throttle Km/h 151 - 157 145 -151 132 - 138 127 - 133
mph 94 - 98 90 - 94 82 - 86 79 - 83
(cont'dl
14-195
Road Test
(cont'd)~~~~~~~~~~~~~~~~~~~~~~~~~~~-
D 16A8: ~ or ~ Position
• Upshift
mph 9 - 12 19 - 22 28 - 30
3/ 1 6 throttle Km/h 18 - 22 42 - 46 59 - 65
mph 11 - 14 26 - 29 37 - 40
6/16 throttle Km/h 26 - 34 54 - 66 77 - 89
mph 16 - 21 34 - 41 48 - 55
Full-opened throttle Km/h 56 - 60 108 - 1.15 159 - 169
mph 35 - 37 67 - 71 99 - 105
• Downshift
Full-closed throttle Km/h -- 13 - 17 10 - 14
mph -- 8 - 11 6-9
mph 89 - 96 60 - 65 27 - 30
• Lock-up
~ Position [Q!l Position

Full-closed throttle Km/h 15 - 19 13 - 17 98 - 102 93 - 97
mph 9 - 12 8 - 11 61 - 63 58 - 60
6/16 throttle Km/h 108 - 112 85 - 89 108 - 112 93 - 97
mph 67 - 70 53 - 55 67 - 70 58 - 60
Full-opened throttle Km/h 158 - 162 153 - 157 132 - 136 128 - 132
mph 98 - 101 95 - 98 82 - 85 80 - 82
14-196
D16A7: ~ or~ Position
• Upshift
Throttle Opening Unit of speed 1st-2nd 2nd--+3rd 3rd-+4th
Full-closed throttle Km/h 15-19 36-40 50-54

mph 9-12 22-25 31-34
3/1 6 throttle Km/h 20-24 46-50 63-69
mph 12-15 29-31 39-43
6/16 throttle Km/h 25-33 58-70 81-93
mph 16-21 36-43 50-58
Full-opened throttle Km/h 50-55 93-101 149-159
mph 31-34 58-63 93-99
• Downshift
Throttle Opening Unit of speed 4th-+3rd 3rd-2nd 2nd-1st
Full-closedthrottle Km/h -- 29-33 9-13

mph -- 18-21 6-8
rnph 79-86 53-58 27-30
• Lock-up
Unit [!E] Position ~ Position

Throttle Opening
of speed
Full-closed throttle Km/h 24-27 23-26 98-104 92-98
mph 15-17 14-16 61-65 57-61
6/16 throttle Km/h 107-114 87-93 107-113 92-98
mph 66-71 54-58 66-70 57-61
Full-opened throttle Km/h 141-147 134-141 132-138 127-133
mph 88-91 83-88 82-86 79-83
4. Accelerate to about 35 mph (57 km/h) so the transmission is in 4th, then shift ~to (1]. The car shoud immediately
begin slowing down from engine braking.
CAUTION: Do not shift from rp:;J or ~to~ or [QJ at speeds over 99 mph (160 km/h); you may damage the
transmission.
[I] ( 1 st Gear) Position

-1. Accelerate frorn a stop at full throttle. Check that there is no abnormal noise or clutch slippage.
-2. Upshifts and downshifts should not occur with the selector in this position.
(1] (2nd Gear) Position

-1. Accelerate frorn a stop at full throttle. Check that there is no abnormal noise or clutch slippage.
-2. Upshifts and downshifts should not occur with the selector in this position.
ffiJ (Reverse)Position
6. Test in [f:] (Parking) Position

Park car on slope (approx. 16°), apply the parking brake, and shift into [El position. Releasethe brake; the car should
not move.
14-197
Stall Speed
Test~~~--~~~~~~~~~~~~~~~~~~~~~~~~~~~~---.
CAUTION:
• To prevent transmission damage, do not test stall speed for more than 1 O seconds at a time.
• Do not shift the lever while raising the engine speed.
1. Engagethe parking brake and block all four wheels.
3. After the engine has warmed up to normal operating temperature, shift into [1) position.
5. Allow 2 minutes for cooling, then repeat same test in[]] [!E] and []] position.
NOTE:
• Stall speed test must be made only for checking the cause of trouble.
• Stall speed in [JE:], [1], [I] and [[] must be same, and must also be within limits.
Stall Speed RPM: rpm

Specification: 2,600 rpm
Service Limit: 2,400-2,800 rpm
TROUBLE PROBABLECAUSE
Stall rpm high in [JE:], [1], O]and [ID position • Low fluid level or oil pump output
• Clogged oil strainer
• Pressureregulator valve stuck closed
• Slipping clutch
Stall rpm high in O] position • Slippage of 1 st clutch, 1 st-hold clutch or 1 st gear one-
way clutch
Stall rpm high in []] position • Slippage of 2nd clutch.
Stall rpm high in [JE:] position • Slippage of 1 st clutch, 1 st gear one-way clutch
Stall rpm high in [BJ position • Slippage of 4th clutch
Stall rpm low in [JE:], [I], [I] and [[] position • Engineoutput low
• Torque converter one-way clutch slipping
14-198
Fluid Level
Checking/Changing~~~~~~~~~~~~~~~~~~~~~~~-,
Checking Changing
1 . Bringthe transmission up to operating temperature
NOTE: Check the fluid level with the engine at nor- by driving the car. Parkthe car on level ground, turn
mal operating temperature. the engine off, then remove drain plug.
1. Park the car on level ground. Shut off the engine. 2. Reinstall the drain plug with a new washer, then
refill the transmission to the upper mark on the
2. Remove the dipstick (yellow loop) from the dipstick.
transmission and wipe it with a clean cloth.
Automatic Transmission Fluid Capacity:
3. lnsert the dipstick into the transmission. 2.7 e (2.8 US qt., 2.4 lmp qt.) at change
5.9 e (6.2 US qt.. 5.2 lmp qt.) after overhaul
AIR INTAKE HOSE
4. Remove the dipstick and check the fluid level. lt

should be between the upper and lower marks.
DRAIN PLUG
14 x 1.5 mm SEALING WASHER
40 N•m Replace.
(4.0 kg-m, 29 lb-ft)
TI~
fü-- UPPER MARK
LOWER MARK
5. lf the level is below the lower mark, add fluid into

the tube to bring it to the upper rnark. Use Honda
Premium Formula Automatic Transmission Fluid or
an equivalent DEXRON® 11 Automatic Transmis-
sion Fluid (ATF) only.
14-199
Pressure Testing
f,SfrMMiN
• While testing, be careful of the rotating front wheels.
4. Start the engine and measure the respective
pressure as follows.
• Make sure lifts, jacks, and safety stands are placed • Line Pressure
properly (see page 1-9 thru 1-11). • Throttle A/Throttle B Pressure
• Clutch Pressure
CAUTION:
• Clutch Low/High Pressure
• Before testing, be sure the transmission fluid is filled
• Governor Pressure
• Warm up the engine before testing.
5. lnstall a new washer and the sealing bo\t in the in-
1. Raisethe car (see page 1-9 thru 1-11). spection hole and tighten to the specified torque.
2. Warm up the engine, then stop the engine and con- TORQUE:18 N·m ( 1 .8 kg-m, 12 lb-ft)
nect a tachometer.
NOTE: Do not reuse old aluminum washers.
3. Connect the oil pressure gauge to each inspection
• Line Pressure
hole(s).
- 1 . Set the parking brake and block both rear
TORQUE:18 N·m (1.8 kg-m, 12 lb-ft)
wheels securely.
CAUTION: Connect the oil pressure gauge secure- -2. Aun the engine at 2,000 rpm.
ly, be sure not to allow dust and other foreign par-
ticles to enter the inspection hole. - 3. Shift the select lever to [fil or [EJ.
A/T OIL PRESSURE -4. Measure line pressure.
A/T OIL PRESSURE GAUGE SET GAUGE HOSE
07406-0020003 ASSEMBLY LINE PRESSURE
(includes pressure hose set 07MAJ-PY40100 INSPECTION HOLE
07406-0020201)
OIL PRESSURE
GAUGE HOSE
07MAJ-PY40110
OIL PRESSURE
JOINT -----..11
el
07MAJ-PY40120
A/T LOW
PRESSURE
GAUGE
07406-0070000
~
NOTE: Use the A/T Oil PressureGauge Set or A/T LOCK-UP CONTROL
Low Pressure Gauge replacing the oil pressure SOLENOID VALVE
ASSEMBLY
gauge hose assembly. The A/T Oil PressureGauge
Hose (07406-0020201) may also be used.

PRESSURE SYMPTOM
Une [[] or [fJ No (or low) Torque con-

01626 850-900 kPa 800 kPa
line pressure verter, oil (8.0 kg/cm2,
D16A8 (8.5-9.0 kg/cm2,
pump 121 -128 psi) 114 psi)
D16A7
pressure
regulator, tor-
800-850 kPa 750 kPa
que converter
01582 (8.0-8.5 kg/cm2, (7.5 kg/cm2,
check valve,
114-121 psi) 107 psi)
oil pump.
NOTE: Higher pressures may be indicated if measurements are made in selector positions other than [[] or [EJ.
14-200
• Throttle A/Throttle B Pressure Measurement
f,f.foj.ijjJINWhile testing, be careful of the

rotating front wheels.
-2. Removethe cable end of the throttle control THROTTLE A PRESSURE

INSPECTION HOLE
cable from the throttle control lever.

-3. Shift the selector lever to ~ or [Qi] posi-

tion.
- 5. Measurefull-closed throttle A/B pressure.
- 6. Move the throttle control lever to full-opened

throttle position.
- 7. Measurefull-opened throttle A/B pressure.
SELECTOR PROBABLE FLUIDPRESSURE

PRESSURE SYMPTOM
Throttle A U@ or ~ Pressuretoo Throttle 0-5 kPa (0-0.05 kg/cm2,
high Valve A 0-0.7 psi)
Modulator throttle ful! closed
No or low valve 515-530 kPa 510 kPa
Throttle A (5.15- 5.3 kg/cm2, (5.1 kg/cm2,
016A 7
pressure 73-75 psi) 73 psi)
throttle ful! opened throttle ful! opened
535-550 kPa 530 kPa
(5.35-5.5 kq/crn''. (5.3 kg/cm2,
D16AB
76- 78 psi) 75 psi)
throttle full opened throttle full opened
505-520 kPa 500 kPa
01582 (5.05-5.2 kg/cm2, (5.0 kg/cm2,
01626 72- 74 psi) 71 psi)
throttle full opened throttle ful! opened
Throttle B Pressuretoo Throttle Valve 0-15 kPa (0-0. 1 5
high B kg/cm2, 0-2 psi)
throttle ful! closed
No or low 800-850 kPa 750 kPa
01626
Throttle B (7.5 kg/cm2,
01 BAB (8.0-8.5 kg/cm2,
pressure 114-121 psi) 107 psi)
1 7
O BA throttle ful! closed throttle ful! opened
850-900 kPa 800 kPa
(8.5-9.0 kg/cm2, (B.O kg/cm2,
01582
1 21 - 1 28 psi) 114 psi)
throttle ful! opened throttle full opened
(cont'd)
14-201
Pressure Testing
(cont'd)
• Clutch PressureMeasurement
f·§f+idMJ While testing, be careful of the rotating front wheels.
- 1. Set the parking brake and block both rear wheels securely.
- 2. Raise the front of the car and support with safety stands.
- 3. Allow the front wheels to rotate freely.
-4. Aun the engine at 2,000 rpm.
-5. Measure each clutch pressure.
1 ST-HOLD CLUTCH PRESSURE

INSPECTION HOLE
4TH CLUTCH PRESSURE

INSPECTION HOLE
2ND CLUTCH PRESSURE
INSECTION HOLE
INSPECTION HOLE
3RD CLUTCH PRESSURE

INSPECTION HOLE
14-202
D 1626/D 1 6A8/D 16A 7
FLUID PRESSURE
SELECTOR
PRESSURE SYMPTOM PROBABLE CAUSE
1 st Clutch [Tior\D41 No or low 1 st 1 st Clutch 850-900 kPa 800 kPa

pressure (8.5-9.0 kq/crn«. (8.0 kg/cm2,
[IJ No or low 1 21 - 1 28 psi) 114 psi)

1 st-hold 1 st-hold Clutch
Clutch 1 st-hold
pressure
2nd Clutch rn No or low
2nd pressure
2nd Clutch
2nd Clutch ~ No or low 2nd Clutch 400 kPa 350 kPa

3rd Clutch No or low 3rd Clutch 57 psi) 50 psi)
3rd pressure (throttle fully (throttle fully
closed) closed)
4th Clutch No or low 4th Clutch 850-900 kPa 800 kPa
4th pressure (8.5-9.0 kq/crn>, (8.0 kg/cm2,
121 -128 psi) 114 psi)
(throttle more than (throttle more than
1 /8 opened) 1 /8 opened)
[ID Servo Valve or 4th 850-900 kPa 800 kPa
Clutch (8.5-9.0 kg/cm2, (8.0 kg/cm2,
1 21 - 1 28 psi) 114 psi)
01582

1 st Clutch [TI or [041 No or low 1 st 1 st Clutch 800-850 kPa 750 kPa
pressure (8.0-8.5 kq/crn", (7.5 kg/cm2,
114-121 psi) 107 psi)
1 st-hold [IJ No or low 1 st-hold Clutch
Clutch 1 st-hold
pressure
2nd Clutch rn No or low
2nd pressure
2nd Clutch
2nd Clutch Uh] No or low 2nd Clutch 400 kPa 350 kPa
3rd Clutch No or low 57 psi) 50 psi)
3rd Clutch
3rd pressure (throttle fully (throttle fully
closed) closed)
4th Clutch No or low 4th Clutch 800-850 kPa 750 kPa
4th pressure (8.0-8.5 kg/cm2, (7.5 kg/cm2,
114-121 psi) 107 psi)
(throttle more than (throttle more than
1 /8 opened) 1 /8 opened)
[ID Servo Valve or 4th 800-850 kPa 750 kPa
Clutch (8.0-8.5 kg/cm2, (7.5 kg/cm2,
114-121 psi) 107 psi)
(cont'd)
14-203
Pressure Testing
(cont'd)-------------------------------------------------------
• Clutch Low/High PressureMeasurement - 7. With the engine idling, lift the throttle control
lever up approximately 1 /2 of its possible
f•\fa.f;j@jd While testing. be careful of the travel and increase the engine rpm until
rotating front wheels. pressure is indicated on the gauge, then
measure the highest pressure reading
- 1 . Allow the front wheels to rotate freely. obtained.
- 2. Remove the cable end of the throttle control -8. Aepeat step 7 for each clutch pressure being
cable from the throttle control lever. inspected.

THROTTLE
CONTROL
LEVER
-3. Start the engine and let it idle.
-4. Shift the select lever to~ position.
- 5. Slowly move the throttle linkage to increase

engine rpm until pressure is indicated on the
oil pressure gauge.
Then releasethe throttle linkage, allowing the
engine to return to an idle, and measure the
pressure reading.
- 6. Repeat step 5 for each clutch pressure being

inspected.
THROTTLE
LINKAGE
14-204
4TH CLUTCH PRESSURE THROTTLE CONTROL
INSPECTION HOLE LEVER
2ND CLUTCH PRESSURE

INSPECTION HOLE
3RD CLUTCH PRESSURE

INSPECTION HOLE
D 1626/D 16A8/D 16A 7

2nd Clutch ~ No or low 2nd 2nd Clutch 400-900 kPa 350 kPa
3rd Clutch No or low 3rd 3rd Clutch 57-128 psi) 50 psi)
pressure varies with throttle with throttle control
opening lever released
4th Clutch No or low 4th 4th Clutch 800 kPa
pressure (8.0 kg/cm2,
114 psi)
with throttle control
lever more than 1 /8
opened
01582

2nd Clutch ~ No or low 2nd 2nd Clutch 400-850 kPa 350 kPa
pressure (4.0-8.5 kq/crn", (3.5 kg/cm2,
3rd Clutch No or low 3rd 3rd Clutch 57-121 psi) 50 psi)
pressure varies with throttle with throttle control
opening lever released
4th Clutch No or low 4th 4th Clutch 750 kPa
pressure (7.5 kg/cm2,
107 psi}
lever more than 1 /8
opened
(cont'd)
14-205
Pressure Testinq
(cont'd)~~~~~~~~~~~~~~~~~~~~~~~~~~----i
• Governor Pressure Measurement
f,\§fl;!Jjj.,j¡ While testing. be careful of the rotating front wheels.
-2. Run the vehicle at 38 mph (60 km/h).
- 3. Measure the governor pressure.
GOVERNOR PRESSURE
INSPECTION HOLE
EXHAUST PIPE

PRESSURE SYMPTOM
Governor [Tu] or [QiJ No or low Governor 01626 180-190 kPa 175 kPa
governor Valve 016A8 (1.8-1.9 kg/cm2, (1.75 kg/cm2.
pressure 01582 26-27 psi) 25 psi)
182-192 kPa 177 kPa
016A7 (1.82-1.92 kg/cm2, (1.77 kg/cm2,
26-27 psi) 25 psi)
14-206
Transmission
Rernoval~~~~~~~~~~~~~~~~~~~~~~~~~~~~~--,
l·\Mi&iihi 4. Remove the transmission ground cable from the
• Make sure lifts, jacks and safety stands are placed
transmission.
rect position on the engine (see pages 1 -9 thru
1-11 ).
under it.
CAUTION: Use fender covers to avoid damaging

painted surfaces.
1. Disconnect the battery negative (-) and positive

(+) cables from the battery.
2. Remove the resonator, air intake hose and air

cleaner case.
5. Disconnect the lock-up control solenoid valve con-

nector and remove the cable clamp from the lockup
control solenoid connector stav.
3. Remove the starter motor cable and cable holder

from the starter motor.
CABLE HOLDER
LOCK-UP CONTROL
SOLENOID VALVE
ASSEMBLY
STARTER MOTOR (cont'd)
14-207
Transmission
Removal (cont'd)
6. Disconnect the speedometer sensor connector. 9. Remove the cotter pins and castle nuts, then
separate the ball joints from the lower arm (see
Section 18).
1 O. Remove the damper fork bolts, then separate the

damper fork and damper.
SPEEDOMETER
SENSOR
CONNECTOR
~
STARTER MOTOR
DAMPER FORK

and rear engine mounting bolt.
REAR ENGINE
MrNTING BOLT
MOUNTING BOLTS
8. Remove the drain plug and drain the automatic

transmission fluid (ATF). Reinstall the drain plug
with a new sealing washer (see page 1 4-199).
14-208
11 . Remove the driveshafts.
• For 01582/015A 7/01626
-1 . Pry the right and left driveshafts out of the

differential.
-2. Pull on the inboard joint and remove the right

-3. Tie plastic bags over the driveshaft ends.
NOTE: Coat all precision finished surfaces with

clean engine oil or grease.
• For 016A8
-1 . Pry the right driveshaft out of the differential.
- 2. Pry the left driveshaft out of the intermediate PLASTIC BAG

shaft.
- 3. Pull on the inboard joint and remove the right

-4. Remove the intermediate shaft.
-5. Tie plastic bags over the driveshaft and in-

termediate shaft ends.
NOTE: Coat all precision finished surfaces with

clean engine oil or grease.
INTERMEDIA TE
SHAFT
016A8 only.
(cont'd)
14-209
Transmission
Removal (cont'd)
12. Removethe splash shield. 14. Remove the shift cable cover, then remove the
shift cable by removing the control lever.
CAUTION: Take care not to bend the shift control

cable while removing it.
SPLASH SHIELD
LOCK WASHER
6 x 1.0 mm BOLT Replace.
CLIP 1 5. Remove the stopper mount, then remove the end
5 pes. of the throttle control cable from the throttle con·
trol lever.
13. Remove the exhaust pipe A. 16. Remove the ATF cooler hoses at the joint pipes.
Turn the ends of the cooler hoses up to prevent
A TF from flowing out, then plug the joint pipes.
NOTE: Check for any signs of leakage at the hose

joints.
THROTTLE
CONTROL
LEVER
SELF·LOCKING
NUTS
Replace.
/
STOPPER MOUNT
ATF COOLER
HOSES
14-210
17. Remove the engine stiffeners and torque converter 20. Place a jack under the transmission and raise the
cover. transrnission just enough to take weight off of the
mounts, then remove the transmission side mount.
NOTE: Only the 01626 and 016A8 engine use a
rear engine stiffener.
18. Remove the 8 drive plate bolts one at a time while TRANSMISSION
MOUNTING NUTS
rotating the crankshaft pulley. SIDEMO~
REAR
ENGINE STIFFENER
NOTE: 01626 and
/ D16A8 only
MOUNTING BOL T
21 . Remove the transmission housing mounting bolts

19. Attach a hoisting bracket to the engine using the and rear engine mounting bolts.
distributor mounting bolt, then lift the engine
slightly. 22. Pull the transmission away from the engine until it
clears the 14 mm dowel pins, then lower it on the
transmission jack.
HOISTING BRACKET
REAR ENGINE
TRANSMISSION
ENGINE JACK
14-211
lllustrated lndex
R. SideCover~~~~~~~~~~~~~~~~~~~~~~~~-
14-212
G) ROLLER @ 1 ST CLUTCH FEED PIPE
@ COLLAR @) 0-RING Replace.
@ O·RING Replace. @ FEED PIPE GUIDE
© FEEO PIPE FLANGE @ CIRCLIP
@ MAINSHAFT LOCKNUT (FLANGE NUT) Replace.
$(J) 0-RING Replace.
CIRCLIP @ 1ST CLUTCH ASSEMBLY
3RO CLUTCH FEED PIPE @ 0-RING Replace.
® COUNTERSHAFT LOCKNUT (FLANGE NUT) Replace. @ THRUST WASHER
® PARKING GEAR @ THRUST NEEDLE BEARING
@) ONE-WAY CLUTCH ASSEMBLY @ NEEDLE BEARING
® COUNTERSHAFT 1 ST GEAR @ MAINSHAFT 1 ST GEAR
@ NEEDLE BEARING @ THRUST WASHER
@ COUNTERSHAFT 1 ST GEAR COLLAR @509 MAINSHAFT 1 ST GEAR COLLAR
@ R. SIDE COVER @) 1ST-HOLD CLUTCH FEED PIPE
@ BREATHER COVER @ 0-RING Replace.
@ BREATHER CHAMBER GASKET Replace. @ FEED PIPE GUIDE
@ BREATHER CHAMBER @) 0-RING Replace.
@ 0-RINGS Replace. @) CIRCLIP
@ R. SIDE COVER GASKET Replace. @) SUBSHAFT LOCKNUT
® DOWEL PINS (FLANGE NUTJ Replace.
® 0-RING Replace. @ SUBSHAFT DISC SPRING Replace.
@ 1ST-HOLD ACCUMULATOR PISTON ® SUBSHAFT 1 ST GEAR
@ 1ST-HOLD ACCUMULATOR SPRING @) LOCK WASHER Replace.
® 0-RING Replace. @) THROTTLE CONTROL LEVER
® 1ST-HOLO ACCUMULATOR COVER @) THROTTLE CONTROL LEVER SPRING
@ CIRCLIP @ OIL SEAL Replace.
® PARKING BRAKE PAWL @) THROTTLE CONTROL CABLE HOLDER
@ PARKING BRAKE PAWL SPRING @)643 SEALING WASHERS Replace.
@ PARKING BRAKE PAWL SHAFT @ ATF COOLER PIPE JOINT BOLT
@ PARKING BRAKE PAWL STOPPER @) ATF COOLER PIPES
® PARKING BRAKE LEVER SPRING @ ATF LEVEL GAUGE
® PARKING BRAKE LEVER @) SPEED SENSOR
® PARKING BRAKE STOPPER @ 0-RING Replace.
@ LOCK WAHSER Replace. @) A TF COOLER PIPE JOING BOLT
® DRAIN PLUG @ SEALING WASHERS Replace.
® SEALING WASHER Replace.
Ref. No. Torque Value Bolt Size Remarks

A 12 N•m (1.2 kg-m, 9 lb-ft) 6 X 1.0 mm
B 14 N·m (1.4 kg-m, 1 O lb-ft) 6 X 1.0 mm Special bolt
e 11 N•m ( 1. 1 kg-m, 8 lb-ft) 6 X 1.0 mm
D 22 N·m (2.2 kg-m, 16 lb-ft) 8 x 1.25 mm
F 8 N•m (0.8 kg-m, 6 lb-ft) 5 X 0.8 mm
G 29 N·m (2.9 kg-m, 21 lb-ft) 12 x 1.25 mm ATF cooler pipe joint bolt
1 40 N•m (4.0 kg-m, 29 lb-ft) 14 X 1.5 mm Drain plug
J 95 N•m (9.5 kg-m, 69 lb-ft) 19 x 1 .25 mm Mainshaft locknut (flange nut):
Left-hand threads
K 140-+0-+140 N·m (14.0-+0-+14.0 kg-m, 23 x 1.25 mm Countershaft locknut
101-0-101 lb-ft) (flange nut)
L 95 N•m (9.5 kg-m, 69 lb-ft) 19 x 1.25 mm Secondary shaft locknut
(flange nut)
14-213
lllustrated lndex
Transmission Housing ------------------
14-214
(D COUNTERSHAFT REVERSE GEAR COLLAR @) MAINSHAFT
@ NEEDLE BEARING @ SEALING RINGS. 35 mm
@ COUNTERSHAFT REVERSE GEAR @) SEALING RING, 29 mm
@) LOCK WASHER Replace. @) NEEDLE BEARING
@6 REVERSE SHIFT FORK @ SET RING
@ REVERSE SELECTOR @ 1ST-HOLD CLUTCH ASSEMBLY
(J) REVERSE SELECTOR HUB @ 0-RINGS Replace.
@ COUNTERSHAFT 4TH GEAR @ THRUST SHIM
@ NEEDLE BEARING @ THRUST NEEDLE BEARING
@) DISTANCE COLLAR. 28 mm @ NEEDLE BEARING
@ COUNTERSHAFT 2ND GEAR @ SUBSHAFT 4TH GEAR
@ COTTERS @ THRUST NEEDLE BEARING
@ THRUST NEEDLE BEARING @ SUBSHAFT 4TH GEAR COLLAR
@ COUNTERSHAFT 3RD GEAR @ SUBSHAFT
@ NEEDLE BEARING @ NEEDLE BEARING
@ THRUST NEEDLE BEARING ® NEEDLE BEARING STOPPER
@ SPLINED WASHER Selective part @) OIL GUIDE CAP
@ 3RD CLUTCH ASSEMBL Y @ REVERSE IDLER GEAR SHAFT/HOLDER
@ 0-RINGS Replace. @ NEEDLE BEARING
@) COUNTERSHAFT @) STEEL BALL
@ CIRCLIP @ REVERSE IDLER GEAR SHAFT SPRING
@ THRUST SHIM ® OIL SEAL Replace.
@ THRUST NEEDLE BEARING @ SET RING, 80 mm Selective part
@ MAINSHAFT 4TH/REVERSE GEAR @) TRANSMISSION HANGER
@ NEEDLE BEARINGS @) TRANSMISSION MOUNT BRACKET
@ 4TH/REVERSE GEAR COLLAR @) REVERSE IDLER GEAR
@ THRUST NEEDLE BEARING @ TRANSMISSION HOUSING GASKET Replace.
@ THRUST SHIM @)643 DOWEL PIN
@ 2ND/4TH CLUTCH ASSEMBL Y @ SNAP RINGS
@) 0-RINGS Replace. @ TRANSMISSION HOUSING SUBSHAFT BEARING
@ THRUST WASHER. 36.5 x 51 mm @) TRANSMISSION HOUSING MAINSHAFT BEARING
Selective part @) TRANSMISSION HOUSING COUNTERSHAFT BEARING
@ THRUST NEEDLE BEARING @) TRANSMISSION HOUSING
@ MAINSHAFT 2ND GEAR @) DIFFERENTIAL ASSEMBL Y
@ NEEOLE BEARING @ OIL SEAL Replace.
A 12 N·m (1.2 kg-m, 9 lb-ft) 6 X 1.0 mm

B 14 N·m ( 1 .4 kg-m, 1 O lb-ft) 6 X 1.0 mm Special bolt
E 34 N°m (3.4 kg-m, 25 lb-ft) 8 x 1.25 mm
H 50 N•m (5.0 kg-m, 36 lb-tt) 12 x 1.25 mm
M 40 N·m (4.0 kg-m, 29 lb-ft) 30 X 1.5 mm Oíl guide cap
14-215
lllustrated lndex
25 ®
A
i\' ®
01 582 only
14-216
G) ATF MAGNET Ctean. @ REGULATOR VALVE BODY
@ ACCUMULATOR COVER @ 0-RING Replace.
@ 0-RING Reptace. @ STATOR SHAFT
© OIL FEED PIPE @ STOPPER SHAFT
ATF MAGNET Clean. @ CHECK BALLS
~ DENTENT BASE @ DOWEL PINS
(!) LOCK WASHERS Replace. @ MAIN VALVE BODY
® OIL FEED PIPE @ OIL FEED PIPE
® BAFFLE PLATE @) OIL FEED PIPE
@) SERVO BODY @ DOWEL PIN
@ SERVO SEPARATOR PLATE @ MAIN SEPARATOR PLATE
@ THROTTLE CONTROL SHAFT @ OIL PUMP ORIVE GEAR
@) E-RING @ OIL PUMP DRIVEN GEAR SHAFT
@ CHECK BALLS @ OIL PUMP DRIVEN GEAR
® SECONDARY VALVE BODY @ CONTROL SHAFT
@ DOWEL PINS @ DETENT SPRING
@ SECONDARY SEPARATOR PLATE @ DETENT ARM SHAFT
@ LOCK WASHERS Replace. @ DETENT ARM
® GOVERNOR BODY @ ATF STRAINER Clean or replace.
@ DOWEL PIN ® TORQUE CONVERTER HOUSING COUNTERSHAFT
® OIL FEED PIPE NEEDLE BEARING
® MODULATOR VALVE BODY @) OIL GUIDE PLATE Replace.
® DOWEL PINS @) TORQUE CONVERTER HOUSING
® MODULATOR SEPARATOR PLATE @ TORQUE CONVERTER HOUSING MAINSHAFT
@ LOCK-UP VALVE BODY BALL BEARING
@ DOWEL PINS @ OIL SEAL Replace.
@ LOCK-UP SEPARATOR PLATE @ LOCK-UP CONTROL SOLENOID VALVE ASSEMBLY
@ TORQUE CONVERTER CHECK VALVE SPRING @581 LOCK-UP CONTROL SOLENOID FILTER/GASKET Replace.
® TORQUE CONVERTER CHECK VALVE @) OIL FEED PIPE
® COOLER CHECK VAL VE SPRING
® COOLER CHECK VALVE

A 12 N•m (1.2 kg-m, 9 lb-ft) 6 X 1.Q mm
14-217
Side Cover
R. 1 .
Remova __ ' with compres sed air.
. olvent or car buretor eI eaner and d y. .
NOTE, 11 parts thornughly m s ' replace the followong.
•• Bfow
Cleanout
a a II passages.
. .
the transmiss ion R. side cove ,
• When removme~gasket
R side cov
• L~ck washers
• 0-ringsh ft locknut
Each s a
. spring
• D1sc_ ashers
Sealmg w
R.SIDE COVER
THROTTLE CONTROL
LEVER
"º'\
6 x 1.0 mm
PARKING BRAKE
PAWL SHAFT
ATF COOLER
PIPE ATF LEVEL GAUGE
14-218
1 . Remove the 16 bolts securing the R. side cover, 5. Pry the lock tabs of the mainshaft and countershaft
then remove the cover. locknuts.
2. Slip the special tool onto the mainshaft. 6. Cut the lock tab of the subshaft locknut using a
chisel as shown. Then remove the locknut from
each shaft.
MAINSHAFT HOLDER
07GAB-PF50101
NOTE:
• Mainshaft locknut has left-hand threads.
• Clean the old countershaft locknut, it is used
when installing to press the press fitting parking
gear on the countershaft.
CAUTION: Keep ali of the chiseled particles out of

the transmission.
CHISEL
SUBSHAFT
LOCKNUT
LOCK TAB
3. Engage the parking brake pawl with the parking 7. Removethe special tool from the mainshaft after
gear. removing the locknut.
4. Align the hole of the subshaft 1 st gear with the 8. Remove the 1 st clutch and mainshaft 1 st gear
hole of the transmission housing, then insert a pin assembly from the mainshaft.
to lock the subshaft while removing the subshaft
locknut. 9. Removethe subshaft 1 st gear.
1 O. Removethe parking brake pawl.
11. Remove the parking gear, one-way clutch and

PIN countershaft 1 st gear assembly. Use a puller for
SUBSHAFT press fitting parking gear as shown.
1ST GEAR
PARKING GEAR
Press fitting type
12. Remove the parking brake lever from the control

shaft.
1 3. Removethe throttle control lever from the throttle

PARKING BRAKE control shaft.
PAWL
14. Removethe ATF cooler pipes.
15. Removethe ATF level gauge.
14-219
Removal
NEEDLE BEARING
REVERSE GEAR
MAINS~
REVERSE SELECTOR
COUNTERSHAFT
14-220
NOTE: 5. Removethe countershaft reverse gear with the col-
• Clean all parts thoroughly in solvent or carburetor lar and needle bearing.
• Blow out all passages. 6. Remove the lock bolt securing the shift fork, then
• When removing the transmission housing, replace remove the fork with the reverse selector from the
the following: countershaft.
• Transmission housing gasket
Lock washer 7. Remove the countershaft and mainshaft sub-
assembly together.
1. Remove the transmission mount bracket.

and hanger.
COUNTERSHAFT

HOUSING PULLER
07HAC-PK40101
8. Remove the differential assembly.
14-221
Removal
MODULATOR VAL VE
OIL FEED BODY
PIPE
ACCUMULA TOR COVER
LOCK-UP VALVE
BODY OIL FEED PIPE
SERVO DETENT
BASE
REGULATOR -------
VALVE BODY
.>
BAFFLE PLA TE
STOPPER
STATOR SHAFT
OIL FEED
PIPES
MAIN VALVE
BODY
AFT STRAINER
·GOVERNOR
BODY
14-222
NOTE: 1 O. Remove the detent spring from the detent arm,
• Clean all parts thoroughly in solvent or carburetor then remove the control shaft from the torque con-
cleaner and dry with compressed air. verter housing.
• When removing the valve body replace the 11 . Remove the detent arm and detent arm shaft from
following: the main valve body.
• 0-rings
• Lock washer 12. Remove the 4 bolts securing the main valve body,
1 . Remove the oil feed pipes from the servo body,
modulator valve body and main valve body.
13. Remove the oíl pump driven gear shaft, then
remove the oil pump gears.
2. Remove the 3 bolts securing the accumulator
cover, then remove the accumulator cover.
14. Remove the 3 bolts securing the governor body,
then remove the governor body.
3. Remove the 3 bolts securing the servo detent base,
then remove the servo detent base and baffle plate.
1 5. Remove the main separator plate with 2 dowel
pins.
4. Remove the 4 bolts securing the modulator valve
body, then remove the modulator valve body and
16. Remove the ATF strainer.
separator plate.

6. Remove the 1 bolts securing the secondary valve

body, then remove the secondary valve body and
separator plate.
7. Remove the 7 bolts securing the lock-up valve

body, then remove the lock-up valve body and
separator plate.
8. Remove the 1 bolt securing the regulator valve

body, then remove the regulator valve body.
9. Remove the stator shaft and stopper shaft.
14-223
Valve Caps
Description
stalled with the flat end toward the spring. end away from the spring.

Toward outside of valva body.
Toward spring. Toward spring.
spring guide.

Toward spring.
Toward spring.
14-224
Valve Body
Repair~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~--.
NOTE: This repair is only necessary if one or more of 5. Removethe #600 paper and thoroughly wash the
bores. You may use this procedure to free the valves in pressed air.
the valve bodies.
6. Coat the valve with ATF then drop it into its bore. lt
1. Soak a sheet of #600 abrasive paper in A TF for should drop to the bottom of the bore under its own
about 30 minutes. weight. lf not, repeat step 4, then retest.


3. lnspect the valve for any scuff rnarks. Usethe ATF-

soaked #600 paper to polish off any burrs that are
on the valve, then wash the valve in solvent and
drv it with compressed air.
4. Roll up half a sheet of A TF-soakedpaper and insert

Twist the paper slightly, so that it unrolls and fits
the bore tightly, then polish the bore by twisting
the paper as you push it in and out.
CAUTION: The valve body is aluminum and

doesn't require much polishing to remove any
burrs.
ATF-soaked 7. Removethe valve and thoroughly clean it and the

#600 abrasive valve body with solvent. Dry all parts with corn-
paper pressed air, then reassemble using ATF as a
lubricant.
14-225
Valve
Assembly
body. Pushthe spring in with a screwdriver, then in-
• lnstall the valve, valve spring and cap in the valve stall the spring seat.
body and secure with the roller.
ROLLER
14-226
• Slide the spring into the hole in the big end of the • lnstall the valve, spring and cap in the valve body.
shift valve. While holding the steel balls with the tips Push the cap, the install the stopper seat.
of your fingers, put the sleeve over the shift valve.
Place the shift spring in the shift valve, then slip ít in-
to the valve body and install the valve cover.
STOPPER SEAT
BALL SPRING
SLEEVE
STEEL
BALL
VALVE
14-227
Main Valve IBody
Disassem bly/lnspection/Reassembly
NOTE:
• Coat all parts with A TF before reassembly.
CAUTION: Do not use a magnet to remove the check balls; it may magnetiza the balls.
VALVE COVER
5 x 0.8 mm
8 N•m VAL VE SLEEVE
(0.8 kg-m, 6 lb-ft)
@/'>
/ DETENT ARM SHAFT
2-3 SHIFT VALVE DETENT ARM
3-2 TIMING
VAL VE
MAIN VALVE
BODV
14-228
@ @ © ®
CHECK BALL
Standard (New)
No. Spring
G) Relief valve spring 1.1 (0.043) 8.6 (0.339) 37.1 (1.461) 13.4
@ 4th exhaust valve spring 0.9 (0.035) 6.6 (0.260) 43.3 ( 1. 705) 22.0
01626/016A 7/
0.9 (0.035) 7.1 (0.280) 64.7 (2.547) 32.1
@ 2-3 shift valve spring 01582
016A8 0.9 (0.035) 7.6 (0.299) 53.4 (2. 102) 28.5
01626/016A 7/
0.4 (0.016) 4.5 (0.177) 14.7 (0.579) 7.3
@ 2-3 shift ball spring 01582
016A8 0.5 (0.020) 4.5 (0.177) 13.2 (0.520) 10.5
01626/016A 7/
0.9 (0.035) 9.6 (0.378) 32.5 (1.280) 10.3
® 3-4 shift valve spring 01582
016A8 0.8 (0.031) 9.6 (0.378) 27.1 (1.067) 7.8
01626/016A 7/
0.5 (0.020) 4.5 (0.177) 11.3 (0.445) 7.4
® 3-4 shift ball spring 01582
016A8 0.45 (0.018) 4.5 (0.177) 13.5 (0.531) 8.2
(j) 3-2 timing valve spring 1.2 (0.047) 8.6 (0.339) 46.9 (1.847) 15.2
01626/016A 7/
0.45 (0.018) 5.1 (0.201) 52.8 (2.079) 29.0
® 1 -2 shift valve spring 01582
016A8 0.5 (0.020) 6.1 (0.240) 52.0 (2.047) 18.8
® 1-2 shift ball spring 0.45 (0.018) 4.5 (0.177) 10.7 (0.421) 12.7
14-229
Oil Pump
lnspection
1. lnstall the pump gears and shaft in the main valve 2. lnstall the oíl pump shaft and measure the side
body. clearance of the drive and driven gears.
Pump Gears Side (Radial) Clearance:

0.210-0.265 mm
(0.0083-0.0104 in)
Driven gear
0.07-0.125 mm
(0.0028-0.0049 in)
ORIVEN GEAR
Grooved and chamfered
ORIVE GEAR
lnspect teeth for
wear or damage.
¿
3. Measure the thrust clearance of the driven gear-to-
ORIVE GEAR main valve body.
DRIVEN O:---
/' Standard (New): 0.03-0.05 mm
(0.001-0.002 in)
,
~ SHAFT
2:~n--------
1 rn. ·:?%1
MAIN VAL VE BOOY
14-230
Disassembly/1 nspection/Reassembly
NOTE:
1 .- Hold the regulator spring cap in place while removing the lock bolt. Once the bolt is removed, release the spring cap
slowly.
2. Reassembly is in the reverse of the disassembly.
NOTE:
• Coat ali parts with ATF.
• Align the hole in the regulator cap with the hole in the valve body, press the spring cap into the body and tighten
the lock bolt.
REGULATOR VALVE
TOROUE CONVERTER
CHECK VALVE
2 pes.
REGULATOR VAL VE
BODY
SPRINGSPECIFICATIONS
Standard (New)
No. Spring
CD Regulator valve spring A D 1 626/D 1 6A8/

1.8 (0.071) 14.7 (0.579) 88.6 (3.488) 16.5
D16A7
01582 1.8 (0.071) 14. 7 (0.579) 86.5 (3.406) 16.5
® Regulator valve spring B 1.8 (0.071) 9.6 (0.378) 44.0 ( 1. 732) 7.5
@ Stator reaction spring 5.5 (0.217) *26.4 (1.039) 30.3(1.193) 2.1
@ Lock-up control valve
spring 0.9 (0.035) 6.6 (0.260) 41.0 (1.614) 23.3
® Cooler check valve
spring 1 . 1 (0.043) 8.4 (0.331) 33.8 (1.331) 12.5
® Torque converter check
valve spring 1 . 1 (0.043) 8.4 (0.331) 33.8 (1.331) 12.5
*: lnside Diameter
14-231
NOTE:
CAUTION: Do not use a magnet to remove the check halls; it may magnetize the balls.
FIL TER CHECK BALLS

Replace. 4 PCS.
1ST ACCUMULATOR CHOKE
SPRING SEAT
1 2-3 ORIFICE CONTROL
VAL VE
~
¡@
~~'
CAP
ROLLER
2-1 TIMING
VAL VE
REVERSE CONTROL
VAL VE
CAP
a
?(~-, ' Gk_ ~
DOWEL PINS
2 pes.
~
CPC VALVE íl
j~ "'STOPPER SEAT
SERVO CONTROL VALVE
14-232
Standard (New)
No. Spring
CD 3-2 kick-down valve spring 1.3 (0.051) 8.6 (0.339) 45.6 (1.795) 17.0
@ 4-3 kick-down valve spring 1.0 (0.039) 6.6 (0.260) 29.9 (1.177) 14.7
@ Governor cut valve spring 0.8 (0.031) 7.6 (0.299) 44.5 (1.752) 17.0
@ 2-3 orífice control valve spring 0.9 (0.035) 6.6 (0.260) 33.2 ( 1 .307) 14.9
® 2-1 timing valve spring 0.7 (0.028) 5.6 (0.220) 33.0 (1.299) 21.7
® Reversecontrol valve spring 0.7 (0.028) 7.1 (0.280) 40.0 (1.575) 20.8
(J) Servo control valve spring 0.9 (0.035) 6.4 (0.252) 34.1 ( 1.343) 17.5
@ CPC (Clutch Pressure Control) valve 0.9 (0.035) 8.4 (0.331) 24.9 (0.980) 9.8
spring
14-233
Servo Body
NOTE:
• Clean ali parts thoroughly in solvent or carburetor cleaner and dry with compressed air.
• Coat ali parts with A TF befare reassembly.
THROTTLE VAL VE A
rV
i¡
4TH ACCUMULATOR PISTON
'-
THROTTLE CAM
1 ST ACCUMULA TOR PISTON

srnm~
6x1.0mm
12 N•m
? >;
(1.2 kg-m. 9 lb-ft) 1(. .
@
Do not remove or
THROTTLE VALVE B
<fÍ
r adjust these nuts.
3RD ACCUMULATOR
PISTON
MODULATOR VALVE SERVO VAL VE/

BODY SHIFT FORK SHAFT
MODULATOR SEPARATOR
PLATE
DOWEL PINS
2 pes.
0-RINGS
Replace.
14-234
Standard (New)
No. Spring
CD 3rd accumulator spring 2.6 (0.102) 17.5 (0.689) 91.8 (3.614) 15.8
@ 2nd accumulator spring 3.5 (0.138) 22.0 (0.866) 75.4 (2.968) 8.7
@ 1 st accumulator spring 2.6 (0.102) 24.3 (0.957) 79.8 (3.142) 8.5
@ 4th accumulator spring 2.6 (0.102) 16.0 (0.630) 89.4 (3.520) 16.2
® 2/3-4 orífice control valve spring 1.0 (0.039) 8.6 (0.339) 51.9 (2.043) 19.8
01626/016A 7/
1.2 (0.047) *7.0 (0.276) 27.2 (1.071) B.O
® Modulator valve spring 01582
D16A8 1.2 (0.047) *7.0 (0.276) 27.6 (1.087) 7.7
Throttle valve A adjusting
{J) 0.8 (0.031) 6.2 (0.244) 27 .o ( 1 .063) 8.5
spring
1.1 (0.043) 8.5 (0.335) 22.3 (0.878) 8.1
01626/016A 7 1.0 (0.039) 8.5 (0.335) 22.2 (0.874) 6.0
01582 1.1 (0.043) 8.5 (0.335) 22.3 (0.878) 7.6
1.0 (0.039) 8.5 (0.335) 22. 1 (0.870) 5.5
® Throttle valve A spring
1.0 (0.039) 8.5 (0.335) 22.2 (0.874) 6.0
1.0 (0.039) 8.5 (0.335) 22.1 (0.870) 5.5
D16A8
1.1 (0.043) 8.5 (0.335) 22.3 (0.878) 8.1
1.0 (0.039) 8.5 (0.335) 22.3 (0.878) 6.2
® Throttle valve B adjusting spring 0.8 (0.031) 6.2 (0.244) 30.0 (1.181) B.O
1.4 (1.653) 8.5 (0.335) 41.5 (1.634) 10.5
@ Throttle valve 8 spring 1.4 (1.653) 8.5 (0.335) 41.5(1.634) 11.2
1.4 (1.653) 8.5 (0.335) 41.6 (1.638) 12.4
*: lnside diameter
14-235
Lock-up Valve Body
Disassembly/lnspection/Reassembly ------------------,
NOTE:
LOCK-UP SHIFT VALVE
LOCK-UP VALVE
BODY
Standard (New)
No. Spring
G) Lock-up shift valve spring 0.9 (0.035) 7.6 (0.299) 73. 7 (2.902) 32.0
D16Z6/D16Z7/
lock-up timing valve 0.8 (0.031) 6.6 (0.260) 61.5 (2.421) 27.6
@ D1582
spring
D16A8 0.7 (0.028) 6.6 (0.260) 64.3 (2.531) 22.4
14-236
Governor Body
NOTE:
• Check that the governor works smoothly; replace it if it does not.
• Coat all parts with A TF befare reassembly.
i
GOVERNOR HOUSING ASSEMBL Y
6x1.0mm
LOCK WASHER 12 N•m (1.2 kg-m, 9 lb-ftl ~OVERNOR VALVE
Replace.~
FILTER i ~
::~:·~~
FILTER
dDoo
o 0 to~~
Do@
O
Replace~o
- .............-PIPE
~ ~
GOVERNOR SHAFT
THRUST WASHER
WOODRUFF KEY, 3 mm
GOVERNOR GEAR
Standard (New)
No. Spring
016Z6/D16A 7/
1.0 (0.039) 18.8 (O. 740) 32.9 (1.295) 4.1
CD Governor spring A 01582
D16A8 1.0 (0.039) 18.8 (0.740) 18.0 (O. 709) 4.0
016Z6/D16A7/ 0.9 (0.035) 11 .8 (0.465) 27.8 (1.094) 6.0
01582 0.9 (0.035) 11 .8 (0.465) 29.1 (1.146) 6.0
@ Governor spring 8 0.8 (0.031) 11 .8 (0.465) 30.0 (1.181) 6.3
D16A8 0.8 (0.031) 11 .8 (0.465) 34.4 (1.354) 6.3
0.8 (0.031) 11.8 (0.465) 30.9 (1.217) 6.0
14-237
1 st-hold Accumulator/R. Side Cover
NOTE:
SNAP RING
COVER
G)1ST-HOLD ACCUMULATOR
,/ SPRING
1
'
1
PISTON
R. SIDE COVER
Standard (Newl
No. Spring
CD 1 st-hold accumulator spring 4.0 (0.157) 21.5 (0.846) 71.7 (2.823) 8.3
14-238
Mainshaft
NOTE:
• Lubricate all parts with ATF during reassembly.
LOCKNUT
19x1.25mm
95N•m
(9.5 kg-m, 69 lb-ft)
~ /
:f;:;:dl~h;~:s
• ASSEMBLY
0-RINGS
~ Replace.
CC, THRUST WASHER
F/'...r~vJ-'1:, .... _. 4TH/REVERSE ~--...;_· THRUST NEEDLE
GEAR
BEARING
NEEDLE BEARING
NEEDLE BEARINGS 1ST GEAR
MAINSHAFT
Check splines for ex-
cessive wear or THRUST WASHER
damage.
Check bearing surface
or excessive wear. / THRUST NEEDLE
~ BEARING
THRUST SHIM
Selective part THRUST NEEDLE

BEARING
2ND GEAR
_,,.,. SEALING RING,
,,,,,.... 35mm NEEDLE BEARING
THRUST NEEDLE
SEALING RING,
~1'IZtrfl~ afii'...,,.__---BEARING
29 mm
NEEDLE BEARING
SET RING
14-239
Mainshaft
lnspection
• Clearance Measurement 3. Torque the mainshaft locknut to 30 N•m (3.0 kg-m,

22 lb-ft).
1. Remove the mainshaft bearing from the transmis-


inspecting.
LOCKNUT
LOCKNUT 30N•m
(3.0 kg-m. 22 lb-ft)
THRUST WASHER 4. Hold the 2nd gear against the 2nd clutch.
Measure the clearance between the 2nd gear and
1 ST GEAR COLLAR the 3rd gear with a feeler gauge.
BEARING NOTE: Take measurements in at least three places
THRUST SHIM
4TH/REVERSE GEAR STANDARD:0.05-0.13 mm (0.002-0.005 in)

COLLAR
r=•=0·~--THRUST SHIM
2ND/4TH CLUTCH
ASSEMBLY 3RD GEAR 2ND GEAR
THRUST WASHER.
36.5 x 51 mm
Selective
2ND GEAR
NEEDLE BEARING
MAINSHAFT
THRUST WASHER.
36.5 x 51 mm
14-240

1 90441-PC9-01 O 3.50 mm (0.138 in)
2 90442-PC9-01 O 3.55 mm (0.140 in)
3 90443-PC9-01 O 3.60 mm (0.142 in)
4 90444-PCS-01 O 3.65 mm (0.144 in!
5 90445-PC9-01 O 3. 70 mm (O. 146 in)
6 90446-PC9-01 O 3. 75 mm (O. 148 in)
7 90447-PC9-01 O 3.80 mm (0.150 in)
8 90448-PCS-01O 3.85 mm (0.152 in)
9 90449-PC9-01 O 3.90 mm (0.154 in)
7. After replacing the thrust wa3her, make sure the

14-241
Countershaft
NOTE:
• Lubricate all parts with ATF befare reassembly.
LOCKNUT
23 x 1.25 mm
140 O ...... 140 N•m
(14.0 O - 14.0 kg-m,
--------101 O ..... 101 lb-ftl
~
~ PARKING GEAR
NEEDLEBEARING
2ND GEAR
COTTERS 'lJll'/ THRUST NEEDLE

"""'""'.AA"'/ BEARING
,.Ciiiji:~
~~~~ /3RD GEAR
~UNTERSHAFT
Check splines for excessive wear or damage.
Check bearing surface for scoring, scratches or
excessive wear.
14-242
• Clearance Measurement 3. Torque the countershaft locknut to 30 N•m (3.0
kg-m, 22 lb-ft).
assembly.
1 . Remove the countershaft bearing from the

transmission housing (see page 14-259).

inspecting.
LOCKNUT
PARKING GEAR/1ST GEAR 4. Measure the clearance between the 4th gear and
ONE-WAY CLUTCH ASSEMBLY the reverse selector hub with a feeler gauge.
NEEDLE BEARING
1 ST GEAR COLLAR and take the average as the actual clearance.
BEARING STANDARD: 0.05-0.13 mm (0.002-0.005 in)
. _/REVERSE SELECTOR HUB
/ _.,......4THGEAR
4TH GEAR REVERSE
NEEDLE BEARING SELECTOR
HUB
I
DISTANCE COLLAR, 28 mm
Selective \
2ND GEAR
.~~~~/ THRUST NEEDLE BEARING
3RD GEAR
NEEDLE BEARING

./ __..,,..- SPLINED WASHER 28 mm
~ Selective
I
\
/ COUNTERSHAFT
DISTANCE COLLAR,
28 mm
4TH GEAR REVERSE

SELECTOR
HUB
(cont'd)
14-243
Countersha1ft
lnspection (cont'd)
from step 4 between the 4th gear and reverse the thickness and/or the width.
selector hub.
-1. Measure the clearance with the 3rd gear recheck.
-2. Measure the clearance with the 3rd gear

pushed towards the 2nd gear. DISTANCE COLLAR 28 mm
and take the average as the actual clearance. 1 90503-PC9-000 39.00 mm (1.535 in)
2 90504-PC9-000 39.10 mm (1.539 in)
-3. Subtract the measurements of step -2. from
step -3 .. and you have the clearance be- 3 90505-PC9-000 39.20 mm (1.543 in)
tween the 3rd gear and 2nd gear. 4 90!507-PC9-000 39.30 mm (1.547 in)
5 90508-PC9-000 39.05 mm (1.537 in)
STANDARD: 0.05-0.13 mm (0.002-0.005 in)
6 90509-PC9-000 39.15 mm (1.541 in)
7 9051 O-PC9-000 39.25 mm (1.545 in)
4TH GEAR 8 90511-PC9-000 38.90 mm (1.531 in)
REVERSE 9 9051 2-PC9-000 38.95 mm (1.533 in)
SELECTOR HUB

recheck.
SPLINEDWASHER 35 x 52 mm
I
1 90411 -PF4-000 3.00 mm (O. 118 in)

3RD CLUTCH
2 90412-PF4-000 3.05 mm (O. 120 in)
ASSEMBLY
3 9041 3-PF4-000 3. 1 O mm (0.122 in)
4 9041 4-PF4-000 3.1 5 mm (0.124 in)
SPLINED WASHER 5 904 1 5-PF4-000 3.20 mm (0.126 in)
6 904 1 6-PF4-000 3.25 mm (0.128 in)
7 904 1 7-PF4-000 3.30 mm (0.130 in)
/
DISTANCE COLLAR,
8
9
904 1 8-PF4-000
9041 9-PF4-000
3.35 mm (0.132 in)
3.40 mm (O. 134 in)
28mm 90411-P24-JOO · 3.45 mm (O. 136 in)
10
11 9041 2-P24-JOO 3.50 mm (0.138 in)

14-244
One-Way Clutch/Parking Gear
Disassemblyand lnspection
1. Separatethe countershaft 1 st gear from the park- lnspect the parts as follows:
shown.
PARKING GEAR
cou¿;;;
1 ST GEAR HAFT \
lnspect ttie one-way
faulty movement.
,
2. Removethe one-way clutch by prying it up with the lnspect the counter-

end of a screwdriver. shaft 1 st gear for wear
or scoring.
COUNTERSHAFT ONE-WAY CLUTCH

1ST GEAR NOTE: lnstall in this
direction.

COUL\
1ST GEAR
14-245
Sub-shaft
NOTE:
• Lubricate all parts with A TF befare reassembly.
1. Remove the oil guide cap.
2. Remove the sub-shaft, 1 st-hofd clutch assembly and 4th gear assembly.
3. Assemble the sub-shaft in the reverse order of removal.
SNAP RING
1ST-HOLD CLUTCH
ASSEMBLY
6 x 1.0 mm----,--~
12 N•m 0-RINGS
(1.2 kg-m, 9 lb-ftl Replace.
THRUST SHIM
/' / THRUST NEEDLE
SUB-SHAFT~::::-::::::~;:;--~~~--..J,;;,;;;;;;.~ / /BEARING
Check splines for excessive
wear or damage.
Check bearing surface for scoring,
scratches or excessive
wear.
30 x 1.5 mm
40 N•m
(4.0 kg-m, 29 lb-ft)
·4TH GEAR COLLAR
NEEDLE BEARING
14-246
Sub-shaft Bearings
Replacement
NOTE: Lubricate all parts with ATF befare reassembly. 4. lnstall the new needle bearing in the transmission
housing using the special tools and a press as
1. To remove the sub-shaft ball bearing from the shown.
transmission housing, expand the snap ring with
snap ring pliers, then push the bearingout using the
special tool and a press as shown.
SNAP RING PLIERS

07LGC-0010100
-.~.--- SNAP RING 07746-0010100
5. Expand the snap ring with snap ring pliers, then

insert the ball bearingpart-way into the housing us-
ing the special tool and a press as described on step
2. Removethe needle bearing stopper. 1 . lnstall the bearing with the groove facing outside
the housing.
3. Removethe needle bearing from the transmission
housing using the special tool. 6. Releasethe pliers, then push the bearing down into
the housing until the snap ring snaps in place
around it.
7. After installing the ball bearing verify the following:

ing grooves.
• The snap ring operates.
• The ring end gap is correct.
END GAP: 0-7 mm

(0-0.28 inl
SNAP RING
14-247
Clutch
lllustrated lndex
1ST CLUTCH
3RD CLUTCH
LUTCH PLA TES .

e d thickness.
Standar (O 079 in)
2.0mm .
14-248
2ND/4TH C LUTCH
CH DISCS
CLUT hickness:
Standard t(O 076 in)
1.94 mm .
CH PLATES
CLUT d thickness:
Standar (O 079 in)
2.0 mm .
/
SNAP RING
·u~
CH DISCS
CLUT thickness:
Standard (O 076 in) /
CIRCLIP SP~RETAINER
1.94 mm .
(cont'd)
14-249
Clutch
lllustrated lndex (cont'd)
1 ST-HOLD CLUTCH
CLU TCH ENO PLATE
CH PLATES
CLUT d thickness:
Standar (O 079 in)
2.0mm .
CH OISCS·
CLUT hickness:
Standard t(O 076 in)
1.94 mm .
14-250
Clutch
Disassembly
1. Removethe snap rings, then remove the clutch end 3. lnstall the special tools as shown.
plate, clutch discs and plates.
CLUTCH SPRING
COMPRESSOR SET CLUTCH SPRING
07LAE- PX40000 COMPRESSOR
ATTACHMENT
07LAE-PX40100
/
SCREWDRIVER
CLUTCH SPRING
COMPRESSOR
ATTACHMENT
---, / 07HAE-PL50100
2. Remove the disc spring.
NOTE: For 1 st-hold, and 2nd clutches
CLUTCH SPRING
COMPRESSOR
BOLT ASSEMBL Y
07GAE- PG40200
CLUTCH SPRING
COMPRESSOR
BOLT ASSEMBL Y
07GAE -PG40200
(cont'd)
14-251
Clutch
Disassembly (cont' d)
CAUTION: lf either end of the compressor attachment 5. Removethe circlip. Then remove the special tools,
damaged.
CIRCLIP
4. Compress the clutch return spring. 6. Wrap a shop towel around the clutch drum and ap-
ply air pressure to the oil passage to remove the
piston. Place a finger tip on the other end while ap-
CLUTCH SPRING plying air pressure.
COMPRESSOR
BOL T ASSEMBL Y
07GAE- PG40200
OIL PASSAGE
\
COMPRESSED AIR
HOSE NOZZLE
14-252
NOTE: 4. lnstall the piston in the clutch drum. Apply pressure
• Clean all parts thoroughly in solvent or carburetor and rotate to ensure proper seating.
• Blow out all passages. NOTE: Lubricate the piston 0-ring with ATF before
• Lubricate all parts with A TF before reassembly. installing.
1. lnspect for a loose check valve. CAUTION: Do not pinch 0-ring by installing the
pistan with force.
CHECK VALVE
2. lnstall a new 0-ring on the clutch piston.
3. Be sure that the disc spring is securely staked.
NOTE: For 1 st, 3rd and 4th clutches. CLUTCHDRUM

RETAINER CIRCLIP
RETURN SPRING
(cont'd)
14-253
Clutch
Reassembly(cont'd)~~~~~~~~~~~~~~~~~~~~~~~
ment is set over an area of the spring retainer
CLUTCH SPRING which is unsupported by the retainer spring, the re-
COMPRESSOR SET tainer may be damaged.
07LAE-PX40000
CLUTCH SPRING
/ COMPRESSOR
/ ATTACHMENT
07LAE-PX40100
CLUTCH SPRING
_..- COMPRESSOR
ATTACHMENT
07HAE-PL50100
CLUTCH SPRING
COMPRESSOR
BOLT ASSEMBL Y
07GAE- PG40200
----~ ....--, CLUTCH SPRING

COMPRESSOR
ATTACHMENT
07HAE-PL50100
CLUTCH SPRING
COMPRESSOR
BOLT ASSEMBL Y
07GAE-PG40200
14-254
8. lnstall the circlip. 11. Soak the clutch discs thoroughly in ATF for a
minimum of 30 minutes.

NOTE: Before installing the plates and discs, make

sure the inside of the clutch drum is free of dirt or
other foreign matter.
CIRCLIP
9. Rerriovethe special tools.
NOTE:
• For 1 st-hold and 2nd clutches. DISCS AND PLATES END PLATE
SCREWDRIVER
1 ST-HOLD CLUTCH (cont'd)
14-255
Clutch
Reassembly (cont'd)
14. Measure the clearance between the clutch end 1 5. lf the clearance is not within the service limits,
end plate moves is the clearance between the NOTE: lf the thickest clutch and plate is installed
clutch end plate and top disc. but the clearanceis still over the standard, replace
NOTE: Measureat three locations.
End Plate-to-Top Disc Clearance: 1ST, 2ND, 3RD and 4TH CLUTCH
Clutch Service Limit Plate No. Part Number Thickness

1 st 0.65-0.85 mm (0.026-0.033 in) 1 22551-PC9-000 2.4 mm (0.094 in)
2nd 0.65-0.85 mm (0.026-0.033 in) 2 22552-PC9-000 2.5 mm (0.098 in}
3rd 0.40-0.60 mm (0.016-0.024 in) 3 22553-PCS-OOO 2.6 mm (0.102 in)
4th 0.40-0.60 mm (0.016-0.024 in) 4 22554-PCS-OOO 2. 7 mm (0.106 in)
1 st-Hold 0.50-0.80 mm (0.020-0.031 in) 5 22555-PCS-OOO 2.8 mm (O. 11 O in)
6 22556-PC9-000 2.9 mm (0.114 in)
7 22557-PC9-000 3.0 mm (0.118 in)
8 22558-PCS-OOO 3.1 mm (0.122 in)
9 22559-PCS-OOO 3.2 mm (0.126 in)
10 22560-PCS-OOO 3.3 mm (0.130 in)
11 22561-PCS-OOO 2. 1 mm (0.082 in)
12 22562-PC9-000 2.2 mm (0.086 in)
13 22563-PCS-OOO 2.3 mm (O.OSO in)
1 ST-HOLD CLUTCH

1 22551-PS5-030 2. 1 mm (0.082 in)
2 22552-PS5-030 2.2 mm (0.086 in)
3 22553-PS5-030 2.3 mm (0.090 in)
4 22554-PS5-030 2.4 mm (0.094 in)
5 22555-PS5-030 2.5 mm (0.098 in)
6 22556-PS5-030 2.6 mm (0.102 in)
7 22557-PSS-030 2.7 mm (0.106 in)
PLATE NUMBER
t l Thick_ness
-< _, r--~'"i-
ENDPLATE
14-256
Mainshaft ~earing Replacement
1. Pull up the mainshaft bearing and oil seal using the 2. Orive in the new mainshaft bearing until it bottoms
special tools as shown. in the housing, using the special tools as shown.
DRIVER
07749-0010000
ADJUSTABLE BEARING 07746-0010500
REMOVERSET
07JAC-PH80000
3. lnstall the new oil seal flush with the housing using
the special tools as shown.
DRIVER
07749-0010000
07746-0010600
14-257
Countershaft Bearing Replacement
1. Remove the countershaft bearing using the special

too l.
2. Replace the oil guide plate.
3. Drive the new bearing into the housing using the

special tools as shown.
DRIVER
07749-0010000
0-0.03 mm
(0.001 inl
OIL GUIDE PLATE

Replace.
14-258
Transmission Housing Bearings
Mainshaft/Countershaft Bearing Replacement ---------------.
1. To remove the mainshaft and countershaft bear- 2. Expandeach snap ring with snap ring pliers, insert
ing out using the special tools and a press as bearing with the groove facing outside the housing.
shown.
NOTE: Coat ali parts with ATF.
SNAP RING PLIERS
07LGC-0010100
PRESS~
DRIVER
07749-0010000
DRIVER ATTACHMENT
/ • MAINSHAFT
07749-0010000~ ~ - ATTACHMENT,
72 x 75 mm
07746-0010600
ATTACHMENT,
/
62 x 68 mm ,.....~ _ _..___..........., • COUNTERSHAFT
GROOVE
07746-0010500 - . ATTACHMENT,
62 x 68 mm
07746-0010500

MAINSHAFT BEARING
DRIVER ing grooves.
07749-0010000 • The snap ring operates.
ATTACHMENT
• MAINSHAFT
ATTACHMENT,
72 x 75 mm END GAP: 0-7 mm
07746-0010600 (0-0.28 in)
_____ _.._.... / • COUNTERSHAFT
ATTACHMENT,
62 x 68 mm
07746-0010500
TRANSMISSION
HOUSING
14-259
Transmission Housing Bearing
Sub-shaft Bearing Replacement
1. To remove the sub-shaft bearing from the transmis- 2. Expand the snap ring with snap ring pliers, insert
sion housing, expand the snap ring with snap ring the new bearing part-way into the housing using
pliers, then push the bearing out using the special the special tools and a press as shown. lnstall the
tools and a press as shown. bearing with the groove facing outside the housing.
NOTE: Do not remove the snap ring unless it's NOTE: Coat all parts with ATF.
necessary to clean the groove in the housing.
3. Releasethe pliers, then push the bearing down into
PRESS~
DRIVER
07749-0010000
ATTACHMENT.
62 x 68 mm
07746-0010500
ATTACHMENT,
62 x 68 mm
07746-0010500

ing grooves.
DRIVER
~07749-0010000
ATTACHMENT, END GAP: O- 7 mm

62 x 68 mm (0-0.28 in)
07746-0010500
l \ TRANSMISSION
HOUSING
SNAP RING
14-260
Reverse ldler Gear
lnstallation -----------------------------
1. Set the spring in the reverse idler shaft. Push the 3. lnstall the reverse idler shaft holder into the
spring in with the steel ball then install the needle transmission housing, then tighten the bolts.
bearing.
NOTE: The steel ball is under spring pressure. 6x1.0mm

Take care not to let it pop out. / 12 N•m (1.2 kg·m. 9 lb-hl
REVERSEIDLER
STEEL BALL GEAR SHAFT
HOLDER ASSEMBL Y
REVERSE IDLER GEAR
2. lnstall the reverse idler gear with the large chamfer

on the shaft bore facing the torque converter
housing.
Sectional View
CHAMFER
Faces toward torque
converter housing.
TRANSMISSION
HOUSING
\
REVERSEIDLER
GEAR
14-261
Transmission/Valve Body
Reassembly
NOTE:
• 0-rings
• Lock washers
• Gaskets
• Locknuts
• Spring washer
• Sealing washers
¡/VVn/ íl'
OIL FEED MODULATOR
PIPE VAL VE BODY 3 Bolts
TORQUE: 12 N•m (1.2 kg-m, 9 lb-ftl AII bolts
/ /4Bolts ACCUMULATOR COVER
7Bolts~~
LOCK-UP VALVE
II ~ OIL FEEO PIPE
BODY ~
~ -cz: _ 3 Bolts
~~ ]v LOCK WASHER
OIL FEED
PIPES
SERVO BODY
SEPARATOR PLATE
2 pes.
DOWEL PINS
2 pes.
SEPARATOR PLATE
~SEPARATOR PLATE
ATF STRAINER i ~3Bolts
~ ~ LOCK WASHER
14-262
1 . lnstall the A TF strainer in the torque converter 4. lnstall the stator shaft and stopper shaft.
housing.
5. lnstall the regulator valve body with one bolt.
2. lnstall the main separator plate with 2 dowel pins
on the torque converter housing. Then install the oil 6. lnstall the lock-up valve body, separator plate and 2
pump drive gear, driven gear and driven gear shaft. dowel pins with 7 bolts.
NOTE: lnstall the oil pump driven gear with its 7. lnstall the secondary valve body, separator plate
grooved and chamfered side facing down. and 2 dowel pins with 1 bolt.
8. lnstall the control shaft in the housing, with the

DRIVEN GEAR
control shaft and manual valve together.
/ 9. lnstall the detent arm and arm shaft in the main

valve body, then hook the detent spring to the de-
tent arm.
~
GRO OVE CHAMFER
O-
SERVO SEPARATOR
PLATE
DRIVEN GEAR
SHAFT
r--"---ir-~--.-~~......,..~......... DRIVEN
¡¡
GEAR
CONTROL SHAFT
side faces separator plate.
3. lnstall the main valve body with 4 bolts. And make DETENT SPRING
sure the pump drive gear rotates smoothly in the
normal operating direction and the pump shaft
moves smoothly in the axial and normal operating
directions. lf the pump gear and pump shaft do not
move freely, loasen the valve body bolts, realign
the shaft, and then retighten to the specified
torque.

ly will result in seized pump gear or pump shaft.
1 O. lnstall the servo body and separator plate with 4
bolts.
11. lnstall the modulator valve body, separator plate

and 2 dowel pins with 4 bolts.
1 2. lnstall the accumulator cover with 3 bolts.
1 3. lnstall the detent base, baffle plate with 3 bolts and

new lock washers.
14. lnstall the governor body with 3 bolts and new lock
washers.
15. lnstall the oil feed pipes.
(cont'd)
14-263
Transmission/Transmission Housing
Reassembly {cont' d)
MAINSHAFT
DIFFERENTIAL
ASSEMBLY
14-264
16. lnstall the sub-shaft assembly in the transmission 21 . lnstall the reverse gear with the collar and needle
housing (page 14-246). bearing on the countershaft.
1 7. lnstall the reverse idler gear and gear shaft holder 22. Align the spring pin with the transmission housing
(page 14-261 ). groove by turning the control shaft.
18. lnstall the differential assembly in the torque con- 23. Placethe transmission housing on the torque con-
verter housing. verter housing with a new gasket and the dowel
pins.
CAUTION: Take care not to damage the governor
body.
SPRING PIN CONTROL SHAFT
19. lnstall the mainshaft and countershaft sub-
assembly together in the torque converter housing.
MAINSHAFT TRANSMISSION
HOUSIN\~~~::::;:;!,t~:!!::~---l:J
?\
20. Turn the shift fork so large chamfered hole facing 24. lnstall the transmission housing bolts and transmis-
fork bolt hole, then install the shift fork with the sion hanger, then torque bolts to 34 N•m (3.4
reverse selector and torque the lock bolt. Bendthe kg-m, 25 lb-ft) in two or more steps as shown.
lock tab against the bolt head.
SHIFT FORK
25. lnstall the transmission mount braket on the

(cont'd)
14-265
Transmission/R. Side Cover
Reassembly (cont'd)
26. Slip the special tool onto the mainshaft. 30. Tighten the old locknut to press the press fitting
parking gear to specified torque, then loosen it.
MAINSHAFT HOLDER
07GAB-PF50101 TOROUE: 140 N•m (14.0 kg-m, 101 lb-ft)
LOCKNUT
PARKING GEAR
Press-fit type "'--.....
31 . lnstall the mainshaft 1 st gear and 1 st clutch

assembly on the mainshaft, and subshaft 1 st gear
27. lnstall the parking brake lever on the control shaft. on the subshaft.
28. lnstall the parking gear, countershaft 1 st gear and 32. Align the hole of the sub-shaft 1 st gear with the
one-way clutch assembly on the countershaft. hole of the transmission housing, then insert a pin
to lock the subshaft while tightening the subshaft
29. lnstall the parking brake pawl in the transmission locknut.
housing, then engage it with the parking gear.
33. lnstall the disc spring on the subshaft, and new
locknuts on each shaft.
CAUTION: Instan the disc spring in the direction

shown.
34. Tighten the locknuts to specified torque.
TORQUE:
• MAINSHAFT 95 N•m (9.5 kg-m, 69 lb-ft)
• COUNTERSHAFT
140 N•m (14.0 kg-m, 101 lb-ft)
• SUB-SHAFT
95 N•m (9.5 kg-m, 69 lb-ft)
NOTE: Mainshaft locknut has left-hand threads.
PIN
14-266
35. Stake each locknut using a 3. 5 mm punch. 36. Set the parking brake lever in the PARK position,
then verify that the parking brake pawl engages to
the parking gear.
37. lf the pawl does not engage fully, check the parking
14-268.
38. Tighten the lock bolt and bend the lock tab.
Point to
be staked.
1.2 mm (0.05 in)
COUNTERSHAFT
LOCKNUT
PAWL
39. lnstall the R. side cover.
TOROUE: 12 N·m (1.2 kg-m, 9 lb-ft)
Points to be staked.
1.2 mm I0.05 in)
~
1.2mm~
(0.05in)~0
SUB-SHAFT
LOCKNUT
40. lnstall the ATF cooler pipes and ATF level gauge.
14-267
I nspection/Adjustment
1. Set the parking brake lever in the Park position.
2. Measurethe distance between the tace of the park-

ing brake pawl shaft and tace of the parking brake
lever roller pin as shown.
STANDARD: 67.;25-68.25 mm (2.65-2.69 in)
ROLLER PIN
PARKING GEAR
PARKING
BRAKE PAWL
3. lf the measurement is out of tolerance, select and

install the appropriate parking brake stopper from
the table below.
PARKING BRAKE
STOPPER
I
-=il,
PARKINGBRAKESTOPPER

11.00 mm 11.00 mm
1 24537-PA9-003
(0.433 in) (0.433 in)
10.80 mm 10.65 mm
2 24538-PA9-003
(0.425 in) (0.419 in)
10.60 mm 10.30 mm
3 24539-PA9-003
(0.417 in) (0.406 in)
4. After replacing the parking brake stopper, make

sure the distance is within torelance.
14-268
Torque Converter
Disassembly ---------------------------
6 x 1.0 mm
12 N•m (1.2 kg-m, 9 lb-ft)
WASHER
Replace.
RING GEAR/
TORQUE CONVERTER
ASSEMBLY
14-269
Transmission
lnstallation ......_ _
housing, then install the 14 mm dowel pins in the
TRANSMISSION SIDE
torque converter housing.
MOUNT~
ST ARTER MOTOR
/
14 x 20 mm
DOWEL PIN
/
Replace/ 12 x 1.25 mm
55 N•m (5.5 kg-m, 40 lb-ftl
TORQUE CONVERTER
5. lnstall the remaining transmission housing moun-
ting bolts and the remaining rear engine mounting
bolt.
REAR ENGINE
2. Placethe transmission on a transmission jack, and MOUNTING BOLT
raise to the engine level. 14 x 1.25 mm
85 N•m (8.5 kg-m,
\
6·1 lb-ftl
3. Attach the transmission to the engine, then install
two transmission housing mounting bolts and two
rear engine mounting bolts.
MOUNTING BOLTS
12 x 1.25 mm
60 N•m (6.0 kg-m, 43 lb-ft)
MOUNTING BOLTS
12 x 1.25 mm
60 N•m (6.0 kg-m, 43 lb-ftl
6. Removethe transmission jack and the hoist from

the engine.
14-270
7. Attach the torque converter to the drive plate with 11 . lnstall the control lever with a new lock washer to
8 bolts and torque to 12 N•m (1.2 kg-m, 9 lb-ft). the control shaft, then install the shift cable cover.
Rotate the crankshaft as necessary to tighten the
bolts to 1 /2 of the specified torque, then final tor- CAUTION: Take care not to bend the shift cable.
que, in a criss-cross pattern.
Check for free rotation after tightening the last
\
· bolt. SHIFT CABLE
8. lnstall the torque converter cover and engine

stiffeners.
NOTE: Only the D16Z6 and D16A8 engine use a

rear engine stiffener.
FRONT ENGINE
STIFFENER
-~
ro x i )~
45 N•m (4.5 kg-m.
33 lb-ft)
8x1.25mm
'
10 x 1.25 mm
45 N•m (4.5 kg-m,
33 lb-ft)
24 N•m (2.4 kg-m. 17 lb-ftl

9. Connect the ATF cooler hoses to the joint pipes.
1 O. Connect the throttle control cable and install the GASKETS

stopper mount.
THROTTLE EXHAUST PIPE

CONTROL A
LEVER
SELF-LOCKING NUTS
10 x 1.25 mm Replace.
39 N•m SÉLF-LOCKING NUTS 8 x 1.25 mm
(3.9 kg-m, 28 lb-ft) 12 x 1.25 mm Replace. 16 N•m
65N•m ( 1.6 kg-m, 12 lb-ft)
8 x 1.25 mm
STOPPER MOUNT (6.5 kg-m, 47 lb-ftl 22 N•m
(2.2 kg-m, 16 lb-ft) (cont'd)
14-271
Transmission
13. lnstall the driveshafts. 14. lnstall the damper fork, then install the ball joint to
the lower arm with a new castle nuts and cotter
NOTE: Turn the right and left steering knuckle fully pins.
10 x 1.25 mm
its spring clip engage the side gear. 44N•m
• For D1582/D15A7/D16Z6 (4.4 •• \. 32 lbr'--ft-~)..,.._._¡
-1. lnstall a new set ring on the end of the each

driveshaft.
- 2. Instati the right and left driveshafts (see Sec-

tion 16).
• For D16A8
-1. lnstall a new set ring on the end of the right 9
/
drive shaft and intermediate shaft.
-2. lnstall the intermediate shaft. SELF-LOCKING NUT

Replace.
COTTER PIN
-3. lnstall the right and left driveshafts (see Sec- 12 x 1.25 mm CASTLE NUT
Replace.
tion 16). 65 N•m 12 x 1.25 mm
(6.5 kg-m, 47 lb-ftl 55 N•m (5.5 kg-m, 40 lb-ft)
10 x 1.25 mm
40 N•m
15. lnstall the splash shield.
INTERMEDIA TE
SHAFT
016AB only
14-272
16. Connect the speedometer sensor connector. 18. Connect the transmission ground cable.
SPEEDOMETER TRANSMISSION
SENSOR CONNECTOR HANGER
TRANSMISSION
GROUND CABLE
17. Connect the lock-up control solenoid connector, 19. Connect the stater motor cable on the stater motor,
and clamp the harness on the lock-up control and install the cable holder.
solenoid connector stay.
B TERMINAL MOUNTING
NUT
9 N·m (0.9 kq-m, 7 lb-ftl
LOCK-UP CONTROL
SOLENOID CONNECTOR
LOCK-UP CONTROL
SOLENOID VALVE
ASSEMBLY
(cont'd)
14-273
Transmission
lnstallation (cont'd) -------
20. lnstall the air cleaner case, air intake hose and
resonator.
AIR CLEANER CASE ASSEMBL Y
- I
AIR INTAKE
/ ~- HOSE
21. Refill the transmission with ATF (see page

14-199).
22. Connect the battery positive (+) and negative (-)

23. Check the ignition timing (see Section 23).
24. Start the engine. Set the parking brake, and shift
the transmission through ali gear three times.
Check far proper shift cable adjustment.
25. Let the engine reach operating temperature with

the transmission in Neutral or Park, then turn it off
and check fluid level.
26. Roadtest as described on pages 14-194 and 197.
14-274
Shift Cable
Removal/lnstallation----------------------------.
f@¡.j;jfliJid Make sure lifts are placed properly (see 3. Remove the shift cable bracket.
page 1 -9 thru 1-111.
1. Removethe center console (see page 20-801.

the cable adjuster.
SHIFT CABLE
BRACKET
/
6 x 1.0 mm
12 N•m
(1.2 kg-m. 9 lb-ftl
4. Removethe shift cable holder.
5. Removethe shift cable cover.
6. Remove the control lever from the control shaft,

then remove the shift cable. Take care not to bend
the cable when removing/installing it.
SHIFT CABLE HOLDER
-, 6x1.0mm
12 N•m
LOCK WASHER. 11 '2 kg-m,
9 lb-ft\
Replace.
7. lnstall the shift cable in the reverse order of

removal.
8. Check the cable adjustment on reassembly, on

page 14-276.
14-275
Shift Cable
Adjustment
f•@·•·fojj.lid Make sure lifts are placed properly (see 4. Check that the hole in the adjuster is perfectly
page 1-9 thru 1-11). aligned with the hole in the shift cable. There are
two holes in the end of the shift cable. They are
NOTE: LHD is shown; RHD is similar. positioned 90° agart to allow cable adjustment in
1 /4 turn increments.
1. Start the engine. Shift to [E] position to see if the
reverse gear engages. lf not, refer to trouble-
shooting on page 14-190 thru 193.
2. With the engine off, remove the center console ADJUSTER

(see page 20-80).
SHIFT CABLE
the cable adjuster.
~~
~~
Cable Cable Exact

TooShort - TooLong Alignment
5. lf not perfectly aligned, loosen the locknut on shift

LOC& 6. Tighten the locknut to 7 N·m (0.7 kg-m, 5 lb-ft).
7. lnstall the lock pin on the adjuster. lf you feel the

out of adjustment and must be readjsuted.
8. Move the select to each gear and verify that the

SHIFT CABLE ADJUSTER
shift position indicator follows the shift position
~ console switch.
9. Start the engine and check the shift lever in all

gears. lf any gear does not work properly.- refer to
troubleshooting on page 14-190 thru 193.
1 O. lnsert the ignition key into the key cylinder on the

shift indicator panel, verify that the shift lock lever
is released.
14-276
Gearshift Selector
Disassembly/Reassembly-----------------------,
NOTE: LHD is shown; RHD is symmetrical.
PUSH K\ ~~\:'i' LEVER
~! Apply non-hardening
thread lock sealant.
SHIFT INDICATOR
PANEL
LEVER COVER
SILICONE
GREASE
CONTROL BRACKET
LOCK PIN ROD
5 N•m (0.5 kg-m, 4 lb-ft)
SHJFT POSITION
SWITCH
Testing, see Section 23
10 N•m (1.0 kg-m, 7 lb-ft)
14-277
Shift lndicator Panel
Adjustment
1. Check that the index mark of the indicator aligns

with the [R) mark of the shift indicator panel with
the transmission in NEUTRAL.
2. lf not aligned,remove the center console. (see page

20-80).
3. Removethe shift indicator panel mounting screws

and adjust by moving the panel.
NOTE: Whenever the shift indicator panel is

removed, reinstall the panel as described above.
INDEX MARK
SHIFT INDICA TOR

PANEL
MOUNTING SCREW
3 N•m (0.3 kg-m, 2 lb-ft)
14-278
lnspection
NOTE: Before inspecting the throttle control cable, 3. Check that there is play in the throttle control lever
make sure; while depressing the accelerator pedal to the full-
throttle position.
• Throttle cable free play is correct (see Section
11 ).
• ldle speed is correct (see Section 11).
peratura (cooling tan comes on).
1. Verify that the throttle control levar is synchronized

with the throttle linkage while depressing and
releasingthe accelerator pedal.
2. lf the throttle control levar is not synchronized with

the throttle linkage, adjust the throttle control
cable.


smoothly.
THROTTLE LINKAGE
(
CABLE END
THROTTLE CONTROL
LEVER
14-279
Adjustment
NOTE: Before inspecting the throttle control cable, 4. Tighten the locknut.
make sure;
• Throttle cable free play is correct (see Section

11).
• ldle speed is correct (see Section 11 ) .
• To warm up the engine to normal operating
temperature (cooling fan comes on).

position.
2. Loosenthe locknut of the throttle control cable at

the throttle linkage.
THROTTLE LINKAGE
LOCKNUTS
5. After tightening the locknuts, inspect the syn-

chronization and throttle control lever movement.
LOCKNUTS
3. Removethe free play of the throttle control cable

with the locknut, while pushing the throttle control
'ever to the full-closed position as shown.
THROTTLE CONTROL
LEVER
14-280
Service Precaution . .. .. .. . . . . . .. . . . . . . . . . . .. . .. . . . . 14-282 Main Valve Body 14-384
Special Tools 14-283 Oil Pump 14-386
Description 14-284 Regulator Valve Body 14-387
Secondary Valve Body 14-388
Electricál System Servo Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-390
Component Location 14-311 Lock-up Valve Body 14-392
Circuit Diagram . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-312 2nd Accumulator Body . . . . . . . . . . . . . . . . . . . . . . . . . . 14-393
Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . 14-314 Mainshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-394
Countershaft 14-397
Electrical Troubleshooting One-way Clutch/Parking Gear . . . . . . . . . . . . . . . . 14-400
Symptom-to-Component Sub-shaft 14-401
Chart 14-316
Troubleshooting Flowchart . . . . . . . . . . . . . . . . . . . . . 14-318 Clutch
A/T Control Unit . . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-343 lllustrated lndex 14-402
NC Speed Sensor 14-343 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-405
Lock-up Control Solenoid Reassembly 14-407
Valve A/B 14-344
Shift Control Solenoid
Mainshaft Bearing Replacement . . . . . . . . . . 14,411
Valve A/B 14-345
Countershaft Bearing Replacement . . . . . 14-412
S Switch . . . . . . . • . • . . . . . . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . 14-346
Transfer Shaft Bearing
LOW Switch .....•.................................. 14-346
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-41 2
Hydraulic System
Hydraulic System
Symptom-to-Component Mainshaft/Countershaft Bearing
Chart . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-348 Replacement ..............................•.. · 14-413
Road Test 14-352 Sub-shaft Bearing
Stall Speed . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . 14-354 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-414
Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-355 Sub-shaft Bearing
Pressure Testing ..................•................ 14-356 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-415
Transmission Transfer Shaft Bearing Outer Race

Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-41 5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-361 Reverse ldler Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-416
Transfer ; 14-417
lllustrated lndex
R. Side Cover 14-366 Transmission
Transmission Housing ..............•........ 14-368 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-434
Torque Converter Housing/ Parking Brake Stopper . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-442
Valve Body 14-370 Torque Converter 14-443
Transfer Housing 14-372 Transmission
R. Side Cover lnstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-444
Removal 14-374 Gearshift Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-449
Transmission Housing Shift Cable

Removal 14-376 · Removal/lnstallation . . . . . . . . . . . . . . . . . . . . . . . . . . 14-450
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-451
Torque Converter Housing/Valve Body Throttle Control Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-452
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-378
Valve Caps 14-380
Valve Body
Repair 14-381
Valve
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-382
Service Precautions
4VVD Disengagernent~~~~~~~~~~~~~~~~~~~~~~~~
• For cars equipped without ABS • For cars equipped with ABS
1. Locate the disengagement plate at the rear of the 1. Locate the orange disengagement bolt at the front
transmission case behind the right front wheel. of the rear differential behind the left rear wheel.
DISENGAGEMENT PLATE
DISENGAGEMENT
PLATE
2. Loasen the lock bolt in the notch on the plate. 2. Loosen the middle bolt fixing the lock plate.
NOTE: For better accessibility, use a socket anda NOTE: For better accessibility, use a socket anda
long extension bar. long extension bar.
CAUTION: Do not loosen the middle bolt more than
CAUTION: Do not loosen the middle bolt more than 5 - 7 turns. Replacement is extremely difficult.
5 - 7tuns. Replacement is extremely difficult.
Unlocked Position Locked Position

(4WD off) (4WD onl ·
Unlocked Locked ..---- MIDDLE BOLT -------.
Position Position
(4WD off) (4WD on)
MIDDLE BOLT
®¿
LOCK PLATE __:r
...._ DISENGAGEMENT ...,
BOLT
10 mm
3. Turn the disengagement bolt counterclockwise un-

3. Turn the middle bolt counterclockwise until the plate
til the disengagement bolt rotates about 180° and
rotates about 1 50° and is stopped by the lock bolt.
is stopped by the lock plate.
4. Tighten the lock bolt.
4. Tighten the middle bolt.
NOTE: After service or towing is completed, return
NOTE: After service or towing is completed, return
the plate to the normal (4WD on) position and tight-
the plate to the normal (4WD on) position and tight-
en the lock bolt.
en the middle bolt.
14-282
Special Tools

G) 07HAC-PK40101 Housing Puller 1 14-377
@ 07 JAC-PH80000 Adjustable bearing Remover Set 1 14-411,412,415
@-1 07JAC-PH80100 Bearing Remover Attachment 1 14-411,412,415
@-2 07JAC-PH80200 Remover Handle Assembly 1 14-411,412,41 5
@-3 07741-0010201 Remover Weight 1 14-411,412,415
@ 07JAJ-PH80100 Orive Gear Gauge 1 14-422,423
@) 07KAJ-PS50100 Driven Gear Dummy Shaft 1 14-421 ,422,423,426
® 07LAE-PX40000 Clutch Spring Compressor Set 1 14-405,408
@-1 07GAE-PG40200 Clutch Spring Compressor Bolt 1 14-405,408
@-2 07HAE-PL50100 Clutch Spring Compressor Attachment 1 14-405,408
@-3 07LAE-PX401 00 Clutch Spring Compressor Attachment 1 14-405,408
® 07LGC-0010100 Snap Ring Pliers 1 14-413,414
(J) 07MAJ-PY40100 A/T Oil PressureGauge Hose Assembly 1 14-356
(J)-1 07MAJ-PY40110 Oil PressureGauge Hose 1 14-356
(J)-2 07MAJ-PY40120 Oil PressureJoint 1 14-356
® 07406-0020300 A/T Oil PressureGauge Set 1 14-356
@-1 07406-0020201 A/T Oil PressureGauge Hose 1 14-356
® 07406-0070000 AT Low Pressure Gauge 1 14-356
@ 07746-0010200 Attachment, 37 x 40 mm 1 14-415
@ 07746-0010400 Attachment, 52 x 55 mm 1 14-421
@ 07746-0010500 Attachment, 62 x 68 mm 1 14-411 ,41 2,41 3,
414,419,421
@ 07746-0010600 Attachment, 72 x 75 mm 1 14-411,412,413
@ 07746-0030100 Driver 40 mm, I.D. 1 14-424,426
® 07746-0030400 Attachment 35 mm, I.D. 1 14-424,426
@ 07749-0010000 Driver 1 14-411 ,412,413,
414,415,419,421,
426
@ 07907-601 0300 Socket Wrench Handle 1 14-419,427
@ 07923-6890202 Mainshaft Holder 1 14-375,438
@) 07926-SD90000 Flange Holder 1 14-419,427
® 07948-SC20200 Oil Seal Driver 1 14-426
1
1
r=•~---2 -3
iW
G) @-1 ~-2
l;}amhmo ~-.®~
~ ~ ._.
~
@-1 @-2 ·@-3
el~ ®
~-
@@@@ @
.r :
@
®
14-283
Description
The Automatic Transmission is a combination of a 3-element torque converter and triple-shaft automatic transmission
which provides 4 speeds forward and 1 speed reverse. The entire unit is positioned in fine with the engine.
Torque Converter, Gears and Clutches

The torque converter consists of a pump, turbine and stator, assembled in a single unit.
The torque converter is connected to the engine crankshaft so they turn together as a unit as the engine tums. Around
the outside of the torque converter is a ring gear which rneshes with the starter pinion when the engine is being started.
The entire torque converter assembly serves as a while transmitting power to the transmission mainshaft.
The transmission has three parallel shafts, the mainshaft, countershaft and sub-shaft. The mainshaft is in line with the
engine crankshaft.
The mainshaft includes the clutches for 1 st, and 2nd/4th, and gears for 3rd, 2nd, 4th, Reverse and 1 st (3rd gear is in-
tegral with the mainshaft, while reverse gear is integral with 4th gear).
The countershaft includes 3rd clutch and gears for 2nd, 3rd, and 4th, Reverse and 1 st.
4th and reverse gears can be locked to the countershaft at its center, providing 4th gear or Reverse, depending on which
way the selector is moved.
The sub-shaft includes the low hold clutch.
The gears on the mainshaft are in constant mesh with those on the countershaft. When certain combinations of gears
in the transmission are engaged by the clutches, power is transmitted frorn the mainshaft to the countershaft to provide
~ t @J , [I] and [fil .
Electronic Control
The electronic control system consists of an automatic control unit, sensors, and 4 solenoid valves. Shifting and lock-up
are electronically controlled for comfortable driving under ali conditions.
The A/T control unit is located under the dashboard.
Hydraulic Control
The valve assembly includes the main valve body, secondary valve body, servo valve body, regulator valve body and
lock-up valve body, through the respective separator plates.
They are bolted to the torque converter case as an assembly.
The main valve body contains the manual valve. 1-2 shift valve,2-3 shift valve, 3-4 shift valve, pressure relief valve,
orífice control valve, cooler relief valve, and oil pump gear.
The secondary valve body includes the CPC valve. servo control valve, modulator valve, 4-2 kick-down valve, 4-3 kick-
down valve, 4th exhaust valve and 2nd orifice control valve.
The servo valve body contains the accumulator pistons. throttle B valve, and the servo valve.
The regulator valve body contains the torque converter check valve, pressure regulator valve and lock-up control valve.
Fluid from the regulator passes through the manual valve to the various control valves.
The lock-up valve body contains a lock-up timing valve and lock-up shift valve.
Shift Control Mechanism

Input from various sensors located throughout the car determines which shift control solenoid valve the A/T control unit
will activate. Activating a shift control solenoid valve changes modulator pressure, causing a shift valve to move. This
pressurizes a line to one of the clutches, engaging that clutch and its corresponding gear.
Lock-up Mechanism
In ~ or [QiJ , in 2nd, 3rd and 4th, pressurized fluid is drained from the back of the torque converter through an oíl
passage, causing the lock-up pistan to be held against the torque converter cover. As this takes place, the mainshaft
rotates at the same speed as the engine crankshaft. Together with hydraulic control, an A/T control unit optimizes the
timing of the lock-up mechanism.
The lock-up shift valve body controls the range of lock-up according to lock-up control solenoid valves A and B , and
throttle valve B. When lock-up control solenoid valves A and B actívate, modulator pressure changes. Lcok-up control
solenoid valves A and B are mounted on the torque converter housing, and are controlled by the A/T control unit.
14-284
Gear Selection
The selector lever has six positions: !E]
PARK, [KI REVERSE,[[] NEUTRAL, ~ 1 st through 4th gear ranges, ~ 1 st
through 3rd gear ranges, and [I] 2nd gear. _
Position Description
[fJ PARK Front wheels locked; parking pawl engaged with parking gear on coun-
tershaft. AII clutches released.
[KI REVERSE Reverse; reverse selector engaged with countershaft reverse gear and 4th
gear clutch locked.
[fil NEUTRAL AII clutches released.
! 04\ ORIVE General driving; starts off in 1 st, shifts automatically to 2nd, 3rd, then 4th,
( 1 through 4) depending on vehicle speed and throttle position. Downshift through 3rd,
2nd and 1 st on deceleration to stop.
The lock-up mechanism comes into operation in ! 04 ! .
(Q;J ORIVE For rapid acceleration at highway speeds and general driving; starts off in
( 1 through 3) 1 st, shifts automatically to 2nd, then 3rd, depending on vehicle speed and
throttle position. Downshifts through 2nd to 1 st on deceleration to stop.
WSECOND For engine braking or better traction starting off on loose or slippery surfaces.
LOW switch: OFF; stays in 2nd gear
LOW switch: ON and below 30 mph (50 km/h approx.); in 1 st gear
LOW switch: ON and above 30 mph (50km/h approx.); in 2nd gear
Starting is possible only in !E] and [fil through the use of a slide-type, neutral-safety switch.
Position lndicator
A position indicator in the instrument panel shows what gear has been selected without having to look down at the console.
14-285
Description
Clutches~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
The tour speed automatic transmission uses hydraulically actuated clutches to engage or disengage the transmission
gears. When clutch pressure is introduced into the clutch drum, the clutch piston is applied. This presses the friction
discs and steel platas together, locking them so they don't slip. Power is then transmitted through the engaged clutch
Likewise, when clutch pressure is bled from the clutch pack, the piston releasesthe friction discs and steel plates, and
ting no power.
[ 1 st Clutchl
The first clutch engages/disengages first gear, and is located at the end of the mainshaft, just behind the R side cover.
[ 1 st-hold Clutch]
The first hold clutch engages/disengages 1 st-hold or 1 position, and is located at the center of the sub-shaft. The 1 st-
hold clutch is supplied clutch pressure by its oil feed pipe within the sub-shaft.
[2nd Clutch]
[3rd Clutch]
The third clutch engagesdisengages third gear, and is located at the end of the countershaft, opposite the R side cover.
The third clutch is supplied clutch pressure by bits oíl feed pipe within the countershaft.
[4th Clutch]
The fourth clutch engagesdisengages fourth gear, as well as reverse gear, and is located at the center of the mai,nshaft.
feed pipe within the mainshaft.
[One-way Clutch]
clutch locks up when power is transmitted frorn the mainshaft first gear to the countershaft first gear.
The first clutch and gears remain engaged in the 1 st, 2nd, 3rd, and 4th gear ranges in the [[J, [Q;] or W position.
However, the one-way clutch disengages when the 2nd, 3rd, or 4th clutches gears are applied in the [QJ, [Q;J or W
range" of the one-way clutch. Thereafter, the one-way clutch free-wheels with the first clutch still engaged.
FREE
PARKING GEAR
14-286
SUB-SHAFT 4TH GEAR
MAINSHAFT
1 ST HOLD CLUTCH
MAINSHAFT 2ND GEAR
3RD GEAR
LOCK-UP CLUTCH
1ST CLUTCH
TORQUE
CONVERTER
MAINSHAFT
3RD CLUTCH
REVERSE SELECTOR
COUNTERSHAFT
FINAL DRIVEN
GEAR ONE-WAY CLUTCH
COUNTERSHAFT REVERSE GEAR
COUNTERSHAFT 2ND GEAR

TRANSFER MECHANISM
(cont'dl
14-287
Description
Clutches (cont'd)-----~--------------------.
Lock-up clutch
1 . Operation (clutch on)
and the converter oil exerts pressurethrough the pistan against the converter cover. As a result, the converter turbine
is locked on the converter cover firmly. The effect is to bypass the converter, there by placing the car in direct drive.
I Power flow I LOCK-UP PISTON DAMPER SPRING
The power flows by way of:

TORQUE CONVERTER
Engine COVER COMP
!
Orive plate
!
!
Lock-up piston OUTLET
! t
Oamper spring
!
Turbine
!
Mainshaft
2. Operation (clutch off)

With the lock-up clutch off, the oil flows in the reverse of CLUTCH ON. As a result, the lock-up piston is moved away
I Power flow I
Engine
!
Orive plate
!
!
Pump
!
Turbine
! INLET
Mainshaft
•
14-288.
Power Flow
Sub-shaft 1 st Gear 4th Reverse Parking

Torque 1 st Gear 2nd Gear 3rd Gear
I~
1 st Gear, Lov, One-way Gear Gear
Converter 1st Clutch 2nd Clutch 3rd clutch Clutch Gear
n Hold Clutch Clutch
~ o X X X X X X X X o
[fil o X X X X X o X o X
[fil o X X X X X X X X X
1 st o X o o X X X X X X
2nd o X *O X o X X X X X
~ 3rd o X *O X X o X X X X
4th o X *O X X X o o X X
1 st o X o o X X X X X X
[füJ 2nd o X *O X o X X X X X
3rd o X *O X X o X X X X
2nd o X *O X o X X X X X
[}] 1 st
Acceleration o o o o X X X X X X
1 st
Oeceleration o o *O X X X X X X X
O: Engaged
x: Not engaged
*· Also the 1 st clutch engaged, power in not transmitted by means of one-way clutch.
2ND MAINSHAFT REVERSE GEAR

CLUTCH SUB-SHAFT 1 ST GEAR
MAINSHAFT
I
OIL PU~':::;~:~AA
¡~~~p
PARKING GEAR
PARKING PAWL
COUNTERSHAFT
SERVO VALVE 1ST GEAR
COUNTERSHAFT
REVERSE GEAR
REVERSE
SELECTOR
14-289
Description
Electronic Control System
Electronic Control System

The electronic control system consists of an automatic transmission (A/T) control unit, sensors, and tour solenoid valves.
Shifting and lock-up are electronically controlled for comfortable driving under all conditions.
The A/T control unit is located under the dashboard.
Shift control
Getting a signa\ from each sensor, the A/T control unit determines the appropriate shift point and activates shift control
solenoid valves A and/or B.
The combination of driving signaIs to shift control solenoid valves A and B is shown in the table below.
'""" Shift control sol. valve

Range (gear) -, A B
~fo;l (1ST) OFF ON

[I)@J@J (2ND) ON ON
[QJ~(3RD) ON OFF
[QJ (4TH) OFF OFF
[I)(1ST) ON ON
[I) (2ND) ON OFF
[fil (REVERSE) OFF OFF
Lock-up control
From sensor input signals, the A/T control unit determines whether to turn the lock-up ON or OFF and activates lock-up
control solenoid valve A and/or B accordingly.
The combination of driving signals to lock-up control solenoid valves A and B is shown in the table below.
1""'Lock-up
- Solenoid valve
condition <,
A B
Lock-up OFF OFF

Lock-up, slight ON OFF
Lock-up, half ON ON
Lock-up, full ON ON
ON
during deceleration OFF .... ON
14-290
A/T CONTROL UNIT
Air Conditioner
Signal
Vehicle Speed Signal
Throttle Angle Shift Control

Signal Solenoid Valva A
Shift Control
Shift Control
Solenoid Valve B
¡¡¡
e:
e,
¡¡; Lock-up Control
e: Solenoid Valva A
o
·,¡::¡
·¡¡; Lock-up
o Control
a..
Lock-up Control
-=:E Solenoid Valva B
vi
S lndicator Light
Brake Light
Switch Signal LOW lndicator Light
Coolant Temperatura
Self-Diagnosis
Signal
lndicator
Engine RPM
(cont'd)
14-291
Description
Electronic Control System (cont'd)
Circuit Diagram and Terminal Location
A/T CONTROL UNIT
82
87
812 84
SHIFT CONTROL
81 SOLENOID VAL VE A
-=- 86
PGM-FI -=-
85
A15
ECU A16
SHIFT CONTROL
SOLENOID VAL VE B
-=-
A17
83
A11
COOLANT TEMP
SENSOR LOCK-UP CONTROL
SPEED PULSEA SOLENOID VALVE A
A6
-=-
+ 12V 88
IGNITION COIL A9
A/C CLUTCH RELAY LOCK-UP CONTROL
A10 SOLENOID VALVE B
-::-
A7
-=- BRAKE LIGHT SWITCH
NC SPEED
A12 SNESOR
A14
A1 A18
'A2 811
A3
~ A4
LOW 0 A5
7 AS
1 SWIÚ
1
-::- S SWITCH 810
...L A13
_¡_
= = LOW INDICATOR
LIGHT
18P CONNECTOR A 12P CONNECTOR B
8 7 6 5 4 3 2 5 4 3 2
18171615 12 11 10 9 12 11 8 7 6
AIT Control Unit Terminal location
14-292
- H y drauI"re FI ow
{Line Pressure
Oil Pump --+ Regulator Valve --+ Torque Converter Pressure
{Line Pressure
• Regulator Valve --+ Torque Converter Pressure
• Manual Valve --+ To Select Une Pressure
• Modulator Valve --+ Modulator Pressure
• 1-2 Shift Valve }

• 2-3 Shift Valve --+ Clutch Pressure
• 3-4 Shift Valve
• Throttle Valve B --+ Throttle B Pressure

1 LINE 10 1ST CLUTCH 90 TORQUE CONVERTER
2 LINE 15 1 ST-HOLD CLUTCH 91 TORQUE CONVERTER
2' LINE 20 2ND CLUTCH 92 TOROUE CONVERTER
3 LINE 21 2ND CLUTCH 93 OIL COOLER
3' LINE 22 2ND CLUTCH 94 TORQUE CONVERTER
3" LINE 30 3RD CLUTCH 95 LUBRICATION
4' LINE 40 4TH CLUTCH 99 SUCTION
5 LINE 41 4TH CLUTCH X BLEED
6 MODULATOR 55 THROTTLE B
6' MODULATOR 55' THROTTLE B
(cont'd)
14-293
Description
Hydraulic Flow (cont'd)
Ui] Position
As the engine turns, the oíl pump also starts to operate.Automatic Transmission Fluid is drained from (99) and discharged
into (1 ). Then, ATF pressure is controlled by the regulator valve and becomes the line pressure ( 1 ). The torque converter
inlet pressure ( 1 l enters (94) of torque converter through the orifice and discharges into (90).
the torque converter check valve prevents the torque converter pressure from raising.
Under this condition, the hydraulic pressure is not applied to the clutches as the manual valve stops line pressure (1 ).
14-294
1 st Gear in (I] Position
The line pressure ( 1 ) becomes the line pressure (2) at the manual valve and passesto the 1 st clutch and 1 st accumula-
tor. The line pressure (2) goes to the 2-3 shift valve. The 2-3 shift valve is moved to the right by the spring force because
the shift control solenoid valves A and B are switched on by the A/T control unit. The valve opens the oíl port leading
to the low hold clutch and the line pressure (2) passes to the low hold clutch. However the power is transmitted only
during deceleration.
Power flows by way of:
Axle Shaft -+ Front Differential -+ Countershaft -+Countershaft 4th Gear -+ Mainshaft 4th Gear -+ Sub Shaft 4th
Gear -+ Low Hold Clutch -+ Sub Shaft -+ Sub Shaft 1 st Gear -+ Mainshaft 1 st Gear -+ Mainshaft -+ Torque Converter
The modulator pressure (6) is supplied to the 1-2, 2-3 and3-4 shift valves.
The line pressure (2) also flows to the throttle valve B.
t.OW H0U> Cll.lTCM
NOTE: When used, "Lef't" or "right" indicates direction on the flow chart.
(cont'd)
14-295
Description
2nd Gear in ~ Position
The flow of fluid up to the 2-3 shift valve is same as in the 1 st gear. As the speed of the vehiele reaches the prescribed-
value, the shift control solenoid valve B is turned off (shiftcontrol solenoid valve A remains on). The 2-3 shift valve is
moved to the left, consequently the low hold clutch pressure (15) becomes the 2nd clutch pressure (20) as it passes
through the 2-3 shift valve, and passes to the 2nd clutch.
The hydraulic pressure also flows to the 1st clutch. However no power will transmit by means of the one way clutch.
lOW HOLOCLUTCH
·-=-~
-ll
NOTE: When used, "left" ar "right" indicates direction on the flow chart.
14-296
1 st Gear in [QJ or [QJ Position
The flow of fluid through the torque converter is the same as in l]J position.
The line pressure ( 1) becomes the line pressure (4) and it becomes the 1 st clutch pressure ( 1 O) through the clutch pres-
sure control valve. The 1st clutch pressure is applied to the 1st clutch and 1st accumulator, consequently the vehicle
will move as the engine power is transmitted.
The line pressure (1) becomes the modulator pressure (6) by the modulator valve and it goes to each shift valve. The
1-2 shiftvalve is moved to the right side because the shift control solenoid valve A is turned off and B is on by the A/T
control unit. This valve stops 2nd clutch pressure and the power is not transmitted to the 2nd clutch.
The line pressure (2) also flows to the servo valve and throttle valve B.
NOTE: When used, "left" or "right" indicates direction of the flow chart.
(cont'd)
14-297
Description
HydraulicFlow
(cont'd)----------------------
2nd Gear in [QJ or ~ Position
The flow of fluid up to the 1-2 and 2-3 shift valves is the sarne as in the 1 st speed. When the vehicle speed is increased
and reaches the prescribed value, the solenoid valve A is turned on by means of the control unit. As a result, the 1-2
shift valve is moved to the left and uncovers the port leading to the 2nd clutch; the 2nd clutch is engaged.
The fluid flows by way of:
- Line Pressure (4) --> Clutch Pressure Control Valve - Clutch Pressure Control Pressure (4') --> 1-2 Shift Valve
- Clutch PressureControl Pressure (5) --> 2-3 Shift Valve - 2nd Clutch Pressure (22) --> Orifica - 2nd Clutch Pres-
sure (20) --> 2nd Clutch.
The hydraulic pressure also flows to the 1 st clutch. However no power will transmit by means of the one-way clutch.
NOTE: When used. "left" or "right" indicates direction on the flow chart.
14-298
3rd Gear in [QJ or [Q;J Position
The flow of fluid up to the 1-2, 2-3 and 3-4 shift valves is the same as in the 2nd speed. As the speed of the car reaches
the prescribed value, the shift control solenoid valve Bis turned off (shift control valve A remains on). The 2-3 shift valve
is then moved to the left, uncovering the oil port leading to the 3rd clutch. Since the 3-4 shift valve is moved to the
right to cover the oil port to the 4th clutch, the 3rd clutch is turned on.
- Line Pressure (4) ...... Clutch Pressure Control Valve - Clutch Pressure Control Pressure (4') ...... 1-2 Shift Valve
- Clutch Pressure Control Pressure (5) -+ 2-3 ShiftValve - 3rd Clutch Pressure (31) -+ 3-4 Shift Valve (not con-
trolled) - 3rd Clutch Pressure (31) ...... 3rd Clutch
The hydraulic pressure also flows to the 1 st clutch. However no power will transmit by means of the one-way clutch
as in the 2nd gear.
(cont'd)
14-299
\
Description
4th Gear in [QJ Position

The flow of fluid up to the 1-2, 2-3 and 3-4 shift valves is the same as in the 3rd speed. When the speed of the car
reaches the prescribed value, the shift control solenoid valve A is turned off (shift control solenoid valve B remains off).
As this takes place, 3-4 shift valve is moved to the left and uncovers the oíl port leading to the 4th clutch. Since the
1-2 and 2-3 shift valves are kept on the left side, the fluid flows through the 4th clutch; the power is transmitted through
the 4th clutch.
Fluid flows by ways of:
-Line Pressure (4) -+ Clutch Pressure Control Valve - Clutch Pressure Control Pressure (4')-+ 1-2 Shift Valve
- Clutch Pressure Control Pressure (5) -+ 2-3 Shift Valve - 3rd Clutch Pressure (31) -+ 3-4 Shift Valve - 3rd
Clutch Pressure (31) -+ 3-4 Shift Valve - 4th Clutch Pressure (42) -+ Manual Valve - 4th Clutch Pressure
(40) -+4th Clutch
The hydraulic pressure also flows to the 1 st clutch. However no power will transmit by means of the one-way clutch
as in 2nd and 3rd gears.
14-300
00 Position
ffiJ.
The flow of fluid through the torque converter circuit is the same as in the The fluid ( 1) from the oil pump flows through
the manual valve and becomes the line pressure (3). lt then flows through the 1-2 shift valve to the servo valve (3),
causing the shift fork shaft to be moved in the reverse direction.
Under this condition, the shift control solenoid valve A on whereas the valve Bis turned off as in 3rd. As a result, the 1-2
shift valve is also moved to the left. The fluid (3)' will flow through the servo valva and manual valve to the 4th clutch;
power is transmitted through the 4th clutch.
Reverse lnhibitor Control

When the [K] position is selected while the vehicle is moving forward at a speed over 1 O km/h, the control unit
outputs 1st signal (A: OFF, B: ON), the 1-2 shift valve is moved to the right. The line pressure (3) is intercepted
by the 1-2 shift valve, consequently the power is not transmitted as the 4th clutch and servo valve are not operated.
When the select lever is moved from the [fil position to the ~, [Q:J or W position, the servo control valve is moved
to the left by the 1 st or 2nd pressure to move the servo valve.
(cont'd)
14-301
Description
~ Position
The flow of fluid through the torque converter is the same in lliJposition.
The line pressure(1) is intercepted by the manual valve, and is not supplied to the clutches. The power is not transmitted.
NOTE: When used, "left" or "right" indicats direction on the flow chart.
14-302
Lock-up System
In ~ or ~ in 2nd, 3rd and 4th, pressurized fluid is drained from the back of the torque converter through an oil
passage, causing the lock-up piston to be held against the torque converter cover. As this takes place, the mainshaft
rotates at the same speed as the engine crankshaft. Together with hydraulic control, the A/T control unit optimizes the
timing of the lock-up system. Under certain conditions, the lock-up operation is applied during deceleration, in Znd, 3rd
and 4th speed.
The lock-up shift valve controls the range of lock-up according to lock-up control solenoid valves A and 8, and the throt-
tle valve. When lock-up control solenoid valves A and B actívate. modulator pressure changes. Lock-up control solenoid
valves A and B are mounted on the torque converter housing and are controlled by the A/t control unit.
OFF
OFF
.LQCK·UP CONTROL LOCK-UP CONTROL

SOLENOID VALVE A SOLENOID VALVE B
rum,,,,,,,,,,,,111{<1
MODULATOR
PRESSURE
90 SS
03 90 X
LOCK-UP TIMING
VALVE B
••
OIL COOLER
(cont'd)
14-303
Description
Lock-up System (cont'd)
Partial Lock-Up
Lock-Up Control Solenoid Valve A: ON Lock-Up Control Solenoid Valve B: OFF
The control unit switches the solenoid valve A to on to releasesthe modulator pressure in the left cavity of the lock-up
shift valve. The modulator pressure in the right cavity of the lock-upshift valve overcomes the spring force, thus the
lock-up shift valve is moved to the left side.
The modulator pressure is separated to the two passages:
Torque Converter lnner Pressure: entered into right side- to engage lock-up clutch
Torque Converter Back Pressure: entered into left side -to disengage lock-up clutch
The back pressure (F2) is regulated by the lock-up control valve whereas the position of the lock-up timing valve B is
determined by the throttle B pressure, tension of the valve spring and pressure regulated by the modulator. Also the
positíon of the lock-up control valve is determined by the throttle valve B pressure, back pressure of the lock-up control
valve and torque converter pressure regulated by the check valve. In low speed range, the throttle B pressure working
on the right side of the lock-up control valve is low, causing the valve to be moved to the right. With the lock-up control
solenoid valve B kept off, the modulator pressure is maintained in the left end of the lock-up control valve; in other words,
the lock-up control valve is moved but slightly to the left side. This slight movement of the lock-up control valve causes
· the back pressure to be lowered slightly, resulting in partial.
OFF
ON
LOCl<-UP CONTROL
SOLENOID VALVE A ~== LOCl<-UP CONTROL
SOLENOID VALVE B
96
_J I
-MOOULATOR
PRESSURE
93 90 X
LOCK-UP TIMING
VALVE B
••
to SUBSHAFT
14-304
Half Lock-Up
Lock-Up Control Solenoid Valve A: ON Lock-Up Control Solenoid Valve B: ON
The modulator pressure is released by the solenoid valve B, causing the modulator pressure in the left cavity of the lock-
Also the modulator pressure in the left cavity of the lock-up timing valve B is low. However the throttle B pressure is
still low at this time, consequently the lock-up timing valve B is kept on the right side by the spring force.
With the lock-up control solenoid valve B turned on, the lock-up control valve is moved somewhat to the left side, caus-
ing the back pressure (F2) to lower. This allows greater amount of the fluid (F 1) to work on the lock-up clutch so as
to engage the clutch. The back pressure (F2) which still exists prevents the clutch to be engaged fully.
ON
ON
LOCK-UP CONTROL LOCK-UP CONTROL

••
_J
.
MODULATOR
PRESSURE
90 55
93 90 X
LOCK-UP TIMING
VALVE B
••
!!::====-··
1
COOLER RELIEF VALVE
••
to SUBSHAFT
14-305
Description
Lock-up System (cont'd)
Full Lock-Up
Lock-Up Control Solenoid Valve A: ON Lock-Up Control Solenoid Valve B: ON
When the vehicle speedfurther increases, the throttle valve B pressureis increasedin accordancewith the throttle opening.
The lock-up timing valve B overcomes the spring force and moves to the left side. Also this valve clases the oil port
leading to the torque converter check valve.
Under this condition, the throttle B pressure working on the right end of the lock-up control valve becomes grater the
lock-up control valve is moved to the left. As this happens, the torque converter back pressure is releasedfully, causing
ON
ON

==::;,
LOCK-UP SHIFT
6 VALVE
Daa....,.....¡11,,1 - THROTTLE
PRESSURE B
- MODULATOR
_ PRESSURE
90 X
LOCK-UP TIMING
VALVE B
OIL COOLER
COOLER RELIEF VALVE
14-306
Deceleration Lock-Up
Lock-Up Control Solenoid Valve A: ON Lock-Up Control Solenoid Valve B: Duty Operation (ON <-+ OFF}
The A/T control unit switches the solenoid valve B to on and off alternatelv in high speed under certain condition. The
slight lock-up and half lock-up regi.ons are maintained so as to lock the torque converter properly.
ON

SOLENOID V AL VE A
=== SOLENOID VALVE B
LOCK-UP SHIFT
O VALVE
••
---------- . . ----~~----
-,
... --o.
_J
l
rr=======::;::::=============::.J
!
MODULA TOA
PRESSl,JRE
93 90 X
LOCK-UP TIMING
VALVE B
--,
1
ss
COOLER RELIEF VALVE
to SUBSHAFT
14-307
Description
Hydraulic Control -------------------------
The valve body ,includes the rnain valve body, the second accurnulator body, the regulator valve body, 'the secondary
valve body, the servo body, and the lock-up valve body.
The oil purnp is driven by splines on the right end of the torque converter which is attached to the engine. Oil flows
through the regulator valve, to rnaintain specified pressure through the rnain valve body to the manual valve, and servo
body, directing pressure to each of the clutches.
SERVO BODY
COOLER RELIEF VALVE

REGULATOR VALVE BODY
TORQUE REGULATOR
CON VERTER VAL VE
MAIN CHECK
VAL VE VAL VE
BODY
SERVO BODY
3-4 LOCK-UP CONTROL

SHIFT VALVE
VAL VE
MANUAL
VALVE
SERVO BODY
1-2 SHIFT
'l..--- LOW-HOLD
ACCUMULATOR
VALVE
ORIFICE
CONTROL VALVE SERVO VALVE
THROTTLE
VALVE B (SHIFT FORK SHAFT)
14-308
Regulator Valve
The regulator valve maintains a constant hydraulic pressure sent from the oil pump to the hydraulic control system, while
also furnishing oil to the lubricating system and torque converter.
Oíl flows through B and B'. The oil which enters through B flows through the vatve orifice to A pushing the regulator
vatve to the right. According to the level of hydraulic pressure through B, the position of the vatve changes, and the
amount of the oíl through B' from D thus changes. This operation is continued, thus maintaining· the line pressure.
ENGINE NOT RUNNING ENGINE RUNNING

to TOROUE CONVERTER
t to RELIEF V AL VE
ST ARTOR SHAFT ARM

from OIL PUMP
REGULA TOR VAL VE SPRING

Hydraulic pressure increase according to torque is performed by the regulator valve using stator torque reaction. The
stator shaft is splined in the stator and its arm end contacts the regutator spring cap. When the car is accelerating or
climbing (Torque Converter Range).stator torque reaction acts on the stator shaft and the stator arm pushes the regula-
tor spring cap -+ direction in proportion to the reaction. The spring compresses and the valve moves to increasethe regu-
lated control pressure or line pressure. Line pressure is maximum when the startor reaction is maximum.
TORQUE CONVERTER
CHECK VALVE
REGULATOR VALVE
STATOR REACTION SPRING
STATOR SHAFT
(cont'd)
14-309
Description
Hydraulic Control {cont'd)
Throttle Valve B
Throttle valve B converts changes in the throttle opening to changes in transrnission hydraulic pressure. The end of throt-
tle valve B contacts the throttle cam which is connected by a cable to the throttle body. The cable pulls the cam which,
in turn, moves the valve. The valve-to-carn engagement is adjustable for shift smoothness and lock-up, Throttle valve
B controls the accumulators, to make smooth changes from one gear to another. An assist function is used to lessen
the throttle load.
Modulator Valve
The rnodulator valve maintains line pressure from the regulator which is supplied to shift control solenoid valves A/8
and lock-up control solenoid valves A/8, thus maintaining accurate shift and lock-up characteristics.
Second Orifice Control Valve

For smooth shifting between second and third, the open pressure on the second gear side is relieved through a fixed
orífice. The valve also moves to equalize pressure differences between second and third gears.
2ND ORIFICE CONTROL

VALVE
55
THROTTLE VALVE B
14-310
Component Location
BRAKE LIGHT
SWITCH
PGM-FI ECU
S SWITCH
SHIFT POSITION
CONSOLE SWITCH
LOCK-UP CONTROL THROTTLE ANGLE SENSOR

SOLENOID VALVE
ASSEMBLY
COOLANT TEMPERATURE (TWI

SENSOR
14-311
Circuit Diaqram
UNDER-HOOD FUSE/RELAY 80X

BATTERY
+ l-~..,..-----Cf"'\....C>---+----WHT/G
No.42(20A)
RN----------.
No.32(7 .5A)
IGNITION COIL
PGM-FI ECU 8RAKE LIGHT
SWITCH
IGNITION
SWITCH
UNDER-DASH
FUSE 80X
8RAKE LIGHT
No.13
(7 .SA)
WHT/8LU GRN/WHT 8LU
BLK/YEL 8LK/YEL
82 87 812 A 12 A10
A/T CONTROL UNIT
810 B 11 A18 A2 A1 A3 A4 AS
RED/Y EL YEL/WHT GRN GRN/RED GRN/BLU
YEL YEL/GRN GRN/BLK GRN/YEL
DIMMING/
CANCEL
CIRCUIT
..,_--+-GRN/BLK -t--+-- .....
--•
i----+-GRN/BLU -t--+-- .....

--+--e
..,_--+-GRN/YEL -t--+-- .....

--+---11-- ...
o.
R
SHIFT POSITION Da
INDICATOR
I
G401
BLK
l
G401
SHIFT POSITION
CONSOLE SWITCH
14-312
PGM-FI ECU
• SPEED SENSOR A/C CLUTCH

• SPEEDOMETER
SERVICE THROTTLE
CHECK
TA
ANGLE
TW
CONNECTOR
SENSOR
SENSOR
SENSOR
YEL/8LU WHT/8LK LT GRN 8LK/RED

8LK/RED BRN RED/WHT 8LK/RED
AS A9 A15 A17 A16 A 11 81 86

A/T CONTROL UNIT
AS A1 3 A14 A7 B3 B8 B4 85
"T'
YEL 8LU/YEL YEL BRN/BLK
BLUr
LOW S 8LU/YEL GRN/WHT
SWITCH SWITCH
A 8 B
NC SPEED
SENSOR LOCK-UP SHIFT
CONTROL CONTROL
SOLENOIDO SOLENOIDO
VAL VE VALVE
G401 Gt01
18P CONNECTOR A 12P CONNECTOR 8
e 7 e s 4 3 2 5 4 3 2
18171615 12 11 10 9 12 11 8 7 6
A/T Control U nit Terminal Location
14-313
TroubleshootingProcedures
When the A/T control unit senses an abnormality in the input or output systems, the [§] indicator light in the gauge
assembly willblink, However, when the Service Check Connector (located under the dash on the passenger side) is con-
nected with a jumperwire, the [§] indicator light will blink the problem code when the ignition switch is turned on.
When the [§] indicator light has been reported on, connect the two termina Is of the Service Check Connector together.
Then turn on the ignition switch and observe the [fil indicator light.
(§] INDICATOR LIGHT 3P CONNECTOR

NOTE:
Do not attach /
-
63~:1
1
1
•
\
1 -
jumper wíre. 1 1
1
1
1
1
2P SERVICE CHECK
CONNECTOR
Problem codes 1 thorough 9 are indicated by individual short blinks, Problem codes 1 O and 11 are indicated by a series
of long and short blinks. One long blink equals 1 O short blinks. Add the long and short blinks together to determine the
problern code. After determining the problem code, refer to the electrical system Symptom-to-Component Chart on pages
14-316 and 31 7.
n
Short
_Jl _____.íl...._ _ ___.íl.__ _ _____.íl....___ See Problem CODE 1
See Problem CODE 2
_] Ul__ _____. Ul__ See Problem CODE 11
1--IW Long Short
14-314
1. Removed the center console (see page 20-80). • A/T control Reset Procedure
2. Remove the 3 bolts securing the A/T control unit,
then remove the A/T control unit. 2. Removethe No. 32 BACK UP fuse (7.5 Al from the
mainrelay box for 1 O seconds to reset the A/T con-
trol unit.
NOTE: Disconnecting the No. 32 BACK UP fuse

also cancels the radio preset stations and the clock
settinq. Make note of the radio presetsbefore remov-
ing the fuse so you reset them.
\
6x1.0mm
12 N·m
(1 .2 kgm,
9 lb-ft)
3. Removethe screw then remove the unit cover from

the A/T control unit.
4. Troubleshoot according to the number of the S FUSE/RELAY

indicatorlight blink(s). BOX
• Final Procedure
NOTE: This procedure must be done after any

troubleshooting.
1. Remove the Jumper Wire from the Service Check-

Connector.
2. Reset the A/T control unit.
3. Set the radio preset stations and clock setting.
/
A/T CONTROL
UNIT
14-315
Symptom-to-Component Chart
Number of []] indicator

light blinkswhile Service
[i] indicator Symptom Probable Cause
Ref.
light page
CheckConnectoris jumped.
• Lock-up clutch does not engage. • Disconnected lock-up control solenoid
• Lock-up clutch does not dis- valve A connector
1 Blinks engage. • Open or short in lock-up control solenoid 14-318
• Frequent engine stalling. valve A wire.
• Low light does not blink. • Faulty lock-up control solenoid valve A
• Lock-up clutch does not engage. • Disconnected lock-up control solenoid
• Low light does not blik. valve B connector
2 Blinks • Open or short in lock-up control solenoid 14-319
valve B wire.
• Faulty lock-up control solenoid valve B
Blinks • Lock-up clutch does not engage. • Disconnected throttle angle sensor con-
or • Low light does not blink. nector
3 14-320
OFF • Open short in throttle angle sensor wire
• Faulty throttle angle sensor
• Lock-up clutch does not engage. • Disconnected speed sensor connector
4 Blinks • Low light does not blink. • Open or short in speed sensor wire 14-321
• Faulty speed sensor
• Fails to shift other than 2nd++4th • Short in shift position console switch wire.
gear. • Faulty shift position console switch
5 Blinks 14-322
• Lock-up clutch does not engage.
• Low light does not blink.
• Fails to shift other than 2nd++4th • Disconnect shift position console switch
gear. connector
• Lock-up clutch does not engage. • Open in shift position consola switch wire
6 OFF 14-324
• Lock-up clutch engages and dis- • Faulty shift position console switch.
engages alternately.
• Low light does not blink.
• Fails to shift other than 1 st++4th, • Disconnected shift control solenoid valve
2nd++4th. or 2nd++3rd gears. A connector
7 Blinks • Fails to shift (stuck in 4th gear). • Open or short in shift control solenoid 14-326
• Low light does not blink. valve A wire
• Faulty shift control solenoid valve A
• Fails to shift (stuck in 1 st gear or • Disconnected shift control solenoid valve
4th gear). B connector
8 Blinks • Low light does not blink. • Open or short in shift control solenoid 14-327
valve B wire
• Faulty shift control solenoid valve B
• Lock-up clutch does not engage. • Disconnected NC speed sensor
9 Blinks • Low light does not blink. • Open or short in NC speed snesor wire 14-328
• Faulty NC speed sensor
• Lock-up clutch does not engage. • Disconnected coolant temperature sensor
• Lock light does not blink. connector
10 Blinks • Open or short in coolant temperature sen- 14-329
sor wire
• Faulty coolant temperatrue sensor
• Lock-up clutch does not engage. • Disconnected ignition coil connector
11 OFF • Low light does not blink. • Open or short in ignition coil wire 14-330
• Faulty ignition coil
NOTE:
• lf a customer describes the symptoms for codes 3, 6 or 11, yet the LEOis not bliking, it will be necessary to recreate
the sy~tom by test driving, and then checking the [[J indicator light with the ignition still ON.
• lf the L-ªJ indicator light display blink 1 2 or more times, the control unit is faulty.
14-316
lf the self-diagnosis ~ indicator light does not blink, perform an inspection according to the table listed below.
Sympton Probable Cause Ref. page

Do not change S mode Check S switch signal 14-331
~ indicator light is on steady whenever the
14-333
ignition switch is ON (S switch is OFF).
[]] indicator light does not come on with the
14-334
ignition switch ON.
Do not change LOW mode Check LOW switch signal. 14-336
LOW indicator light does not come on with the
14-338
ignition switch ON.
LOW indicator light is on steady whenever the
14-340
ignition switch is ON (LOW switch is OFF).
Lock-up clutch does not duty operation Check A/C signal. 14-342
(ON++OFF)
Lock-up clutch does not engage
14-317
Self-diagnosis ~ indicator light

blink once.
\Íiew from terminal side.
1
from the control unit.
1 r®-1
BLK/RED YEL
2
1
7
Measure the voltage between the
83 (YEL) and 81 (8LK/REO) ter-
minals.
Repair short to power

1 source in YEL wire be-
Is there voltage? tween the 83 terminal
~ and the lock-up control
I NO
solenoid valve A.
1
¡®-¡
BLK/RED VEL
Measure the resistance between
the 83 (YEL) and B 1 (BLK/RED) 2
terminals.
7
Check for open in YEL

1 wire between the 83
terminal and the lock-up
Is the resistance 16.2-19.80? ~
(at 25°C) control solenoid valve
A. lf wire is OK, check
the Lock-up Control
I YES Solenoid Valve A.
Oís connect the 2P connector

from the lock-up control solenoid
val ve assembly.
1 r-®l
BLK/RED YEL
83 (YEL) and 81 (BLK/RED) ter-
minals. 2
7
»=
1 Repairshort in YEL wire
between the 83 termi-
Is there continuity?
nal and the lock-up con-
trol solenoid valve A.
I NO

lock-up control solenoid valve as-
sembly.
1
Check for loose control unit con-
nectors. lf necessary, substituta
a known-good control unit and
recheck.
14-318
blinks twice.
View from terminal side.

Disconnect the 1 2P connector

88 (8RN/8LK) and 81 (8LK/RED)
terminals.
Repair short to power source in

YES 8RN/8LK wire between the 88
Is there voltage?
terminal and the lock-up control
solenoid valve 8.
NO

the 88 (8RN/8LK)
(8LK/RED) terminals.
and 81
I BLKJ.._,R,-ED.......,..--,
@ 1 2 3
Check for open in 8RN/8LK wire

NO between the 88 terminal and the
Is the resistance 16.2-19.80? L38LK
(at 25°C) lock-up control solenoid valve B.
lf wire is OK, replace the Lock-up
YES Control Solenoid Valve 8.

the lock-up control solenoid valve
assembly.
I BLK/.... I
Rr-ED-,---,

@ 1 2 3
88 (GRN/8LK) and 81 (8LK/RED)
terminals.
~BLK
Repair short in 8RN/8LK wire be-

YES
Is there continuity? tween the 88 terminal and the
lock-up control solenold valve B.
NO

lock-up control solenoid valve as-
sembly.

nectors. lf necessary. substituta
a known-good control unlt and
recheck.
(cont'd)
14-319
Troubleshooting Flowchart (cont'd)
Self-diagnosis [!) indicator light

blinks three times.
Does Check Enginelight indicates YES lnspect the PGM-FI System (see
any code? (see page 11-208). Section 11 ).
NO

BLK/RED
Disconnect the 18P and 12P con-
nectors from the control unit. 2 3 4 6 7 8 2 3
9 1O 11 12 18 17 18 7 8
Tum the ignition switch ON. WHT/BLK

l__v
A15 (WHT/BLK) and 81
(BLK/RED) terminals.
NO Repair open or short in WHT/BLK

Is the voltage 4. 75-5.25V? wire between the A 15 terminal
and the PGM-FI ECU.
YES
Connect the 18P and 12P connec-

tors to the control unit. BLK/RED
2 3 4 5 8 2 3
Tum the ignition switch ON. 1O 11 12 15 17 16 7
LT GRN
A 16 (LT GRN) and B 1 (BLK/RED)
L@
terminals.
NO Repair open or short in LT GRN

Is the voltage 0.44-0.56V?* wire between the A 16 terminal
and the throttle angle sensor.
YES

nectors. lf necessary, substitute
recheck.
*±10%
14-320
Self-diagnosis [¡] indicator light
blinks four times.
Jack up the tour wheels and sup-

IWHMiihN
• Make sure jacks
port with safety stands. and safety stands
are placed properly
(see paga 1-10
Turn the ignition switch ON and thru 12).
shift transmission to @ • Jack up and sup-
port the front and
Rotate the front wheel and meas-

rear of the car.
r-®-1
YEL/BLU BLK/RED
ure the voltage between the A6
(YEL/BLU)and B 1 (BLK/RED)ter- 2 3 4 5 8
minals.
9 1O 11 12 15 17 18
Doesthe voltage O- 5V appearal- NO

ternately?
YES
Disconnect the 18P and 1 2P con-
nectors from the control unit.
Substitute a known-good control Turn the ignition switch ON.

unit and recheck.
Rotate the front wheei and check

for voltage between the B 1
(BLK/RED) and A6 (YEL/BLU)ter-
minais.
Check for short or open

in VEL/BLU wlre be-
Does the voltage 0-5V appearal- NO tween the A6 terminal
ternately? and the gauge assem-
bly. lf wire is OK, check
YES the Speed Sensor.

recheck.
(cont'd)
14-321
TroubleshootingFlowchart (cont'd) ------------------
Self-diagnosis [i] lndicator light

blinks fiva times.
View frorn terminal side

~~~~~~@>--~~~~~¡
Shift to other than ~ position. GRN/RED BLK/RED
4 5 8
Measure the voltage between the 1 O 11 12 15161718
A 1 (GRN/RED)and 81 (8LK/RED)
terminals.
Check for short in GRN/REDwire

between the A 1 terminal and the
NO shift position consola switch.
Is there battery voltage? lf wire is OK, check for loose con-
YES a known-good control unit and
recheck.
®
Shift to other than ~ and [fJ po- 1
GRN BLK/RED
sition.
Measure the voltage between the 9 11 12 15 16 17 18

A2 (GRN) and 81 (BLK/RED)ter-
minals.
Check for short in GRN wlre be-

tween the A2 terminal and the
NO shift position consola switch. lf
Is there battery voltage? wire is OK, check for loose con-
trol unit connectors. lf necessary,
YES substitute a known-good control
unit and recheck.
Shift to other than @J position. ® 1

GRN/BLK BLK/RED
2 6 8
A3 (GRN/8LK) and 81 (8LK/RED) 1 O 12 15 16 17 18
terminals.
Check for short in GRN/BLK wire

between the A3 terminal and the
NO shift positlon consola switch.
Is there battery voltage? lf wire is OK, check for loose con-
trol unit connectors.
YES lf necessary, substituta a known-
good control unit and recheck.
(To page 14-322)
14-322
(From page 14-322) View from terminal side.
~~~~·@)>--~~~!
Shift to other than ~ position. BLK/RED
2 3 6 7 8
Measure the voltage between the 1O 11 1 5 16 ,17 18

A4 (GRN/BLU)and B 1 (BLK/RED)
terminals.
Check for short in GRN/BLU wire
between the A4 terminal and the
shift position console switch. lf
NO
Is there battery voltage? wire is OK. check for loose con-
trol unit connectors. lf necessary,
unit and recheck.
i-®~
GRN/YEL BLK/RED
Shift to other than [iJ position.
2 3 4 6 7 8
9 10 11 12 16 17 18
A5 (GRN/YEL)and B 1 (BLK/RED)
terminals.
Check for short in GRN/YEL wire

between the AS terminal and the
shlft position console switch. lf
NO
Is there battery voltage? wire is OK, check for loose con-
trol unlt connectors. lf necessary,
unit and recheck.

unit and recheck.
(cont'dl
14-323
Self-diagnosis [fil indicator light

blinks six times.
®
Shift to IB] position. GRN/RED
1
BLK/RED
2 3 4 5 6 7 6
1O 11 12 15 16 17 18
A 1 (GRN/RED)and 81 (8LK/RED)
terminals.
YES Repair open in GRN/RED wire be-

Is there voltage? tween the A 1 terminal and the
shift position console switch.
NO
Shift to ~ or ~ position. 1
® 1
GRN BLK/RED
3 4 5 6 7 8
A2 (GRN) and 81 (BLK/RED) ter- 9 11 12 15 16 17 18
minals.
YES Repair open in GRN wire between

Is there voltage? the A2 terminal and the shlft po-
sltion consola switch.
NO
® 1
Shift to~ position.
1
GRN/BLK BLK/RED
2 4 5 6 7 8
A3 (GRN/BLK) and 81 (BLK/RED) 9 1O 12 15 16 17 18
terminals.
YES Repair open in GRN/BLK wire be-

Is there voltage? tween the A3 terminal and the
shift posltion consola switch.
NO
(To page 14-325)
14-324
(From page 14-324)
Shift to~ position.

® 1
GRN/BLU BLK/RED
A4 (GRN/BLU) and 81 (BLK/RED) 2 5 .7 8
terminals.
9 1O 11 15 18 17 18
YES Repair open in GRN/BLU wire be-

Is there voltage? tween the A4 terminal and the
NO
Shift to~ position:

~©------¡BLK/RED
GRN/VEL
2 8
Measure the voltage between the 9 1O 11 12 18 17 18
A5 (GRN/YEL) and B 1 (BLK/RED)
terminals.
YES Repair open in GRN/YEL wire be-

Is there voltage? tween the AS terminal and the
NO

recheck.
(cont'd)
14-325

blinks seven times.


Measurethe voltage between the r-®-1

BLK/RED BLU/8LK
84 (8LU/8LK) and 81 (8LK/RED)
terminals.
Repair short to power source in 7 8

YES 8LU/8LK wire between the 84 ter-
Is there voltage? minal and the shift control sole-
noid valve A.
NO

¡--® 1
the 84 (8LU/8LK) and 81 8LK/RED BLU/8LK
(8LK/RED)terminals.
2
Check for open in 8LU/8LK wire 7

NO between the 84 terminal and the
Is the resistance 16.2-19.8{}?
shift control solenoid valve A.
(at 25ºC)
lf wire is OK. check the shift con-
YES trol solenoid valve A.
Disconnectthe 2P connector from

the shift control solenoid valve as-
sembly.
Check for continuity between the ~

84 (8LU/8LK) and 81 (BLK/RED) BLK/RED 8LU/BLK
terminals.
2 3
7
YES Repair short in 8LU/BLK wire be-
shift control solenoid valve A.
NO

recheck.
14-326
Self-diagnosls ~ lndlcator light
blinks eight times.

1

1- ---'@--~¡
BLK/RED BLU/WHT
Measurethe voltage between the
85 (8LU/WHT) and B 1 (8LK/RED) 2
terminals.
7 8
Repair short to power source in

YES
Is there voltage? BLU/WHT wire between the 85
terminal and the shift control sole-
NO noid valve B.
.------@1----,,
Measure the resistance between BLK/RED BLU/WHT
the 85 (BLU/WHT) and 81
(8LK/RED) terrninals.
2 3
7 8
Check for open in BLU/WHT wire
NO between the B5 terminal and the
Is the resistance 16.2-19.Bm
shift control solenoid valva B. lf
(at 25ºCl
wire is OK. check the shift control
YES solenoid valve B.
Disconnectthe 2P connector from

the shih control solenoidvalve as-
sembly.
1~ ---,@1---~,
85 (8LU/WHT) and 81 (BLK/RED) BLK/RED BLU/WHT
terminals.
2 3
7 8
YES Repairshort In BLU/WHT wire be-
shift control solenoid valve B.
NO

recheck.
(cont'd)
14-327
Self-diagnosis [!]indicator light

blinks nine times.
Check the state of installation of

the NC speed sensor.
NO
OK? Reinstall and recheck.
YES

the NC speed sensor connector.
Measure the resistance of the NC

speed sensor. 2 3 4 5 6
9 1O 11 12 15 16
ORN
Is the resistance 400-600 O? NO
Replace the NC speed sensor.
(at 20ºC)
YES
Reconnect the NC speed sensor.


A 7 (WHT) and A 14 (ORN) ter-
minals.
Repalr open or short in WHT wire

Is the resistance 400-600 O? NO between A 7 terminal or ORN wire
(at 20ºC) between A14 terminal and NC
speed sensor.
YES
Check for loase control unit con-

nector. lf necessary. substituta a
known-good control unit and
recheck.
14-328
blinks ten times.
Does Check Engine light indicates YES lnspect the PGM-FI System (see
any code? section 11 ).
NO
Turn the ignition switch OFF. View from terminal side.
Disconnect the 18P and 12P con- BLK/RED

2 4 6 1 8 2 3
9 10 11 12 18 17 18 7
WHT/BLK
Measure the voltage between the L__@
A 1 5 (WHT /BLK) and 81 (BLK/
RED) terminals.
NO Repair open or short in WHT/BLK

Is the voltage 4. 75-5.25V? wire between the A 15 terminal
and the PGM-FI ECU.
YES
Connect the 18P and 12P connec-

tors to the control unit.
BLK/RED
Start the engine and warm it up

to normal operating temperature.
2 3 4 s e 1 8 2 3
9 10 11 12 15161718 7 8
Measure the voltage between the RED/WHT

A 11 (RED/WHTI and 81 (BLK/
RED) terminals.
Repair open or short in RED/WHT

NO wire between the A 1 1 terminal
is the voltage 0.50-1.20V?
and the coolant temperatura
YES sensor.

a known-good control unit.
(cont'd)
14-329
Self-diagnosis [!]indicator light

blinks eleven times.
Vlew from terminal slde.
Disconnect the 1 BP and 12P con-

BLK/RED
Start the engine. 3 4 5 7 8 2 3

11 12 15161716 7 8
BLU
A 1 O (BLU) and B 1 (BLK/RED) ter-
minals. '----------, V•J------~

NO BLU wlre between the
A 10 terminal and the
YES ignition coll.

recheck.
14-330
S switch signal test
Is the service check connector YES Disconnect the jumper wire and
jumped? recheck.
NO
Push the S switch OFF.
¡§] INDICATOR LIGHT

Does the [§]
indicator light come NO Test the [§] indicator light.
onfor about 2 seconds? See page 14-334.
YES
Does the [§] indicator light go NO Test the [§] indicator light.
out? See page 14-333.
YES
Push the S switch ON.
Does the [§] indicator light come YES

S switch signal is OK.
on?
NO
(To page 14-332)
(cont'd)
14-331
TroubleshootingFlowchart (cont'd)
(From page 14-3311

Disconnect the 1 SP and 12P con-

BLK/RED
2 3 4 6 7 8
A 13 (BLU/YEL)and B 1 (BLK/RED) 1O 11 12 15181718
terminals while pushing the S
switch ON and OFF. BLU/YEL
l~~~-101-~~~
Is there continuity while pushing Check for open or short in

the S switch ON, and is there no NO BLU/YEL wlre between the A 13
continuity while pushing the S terminal and S switch. lf wlre is
switch OFF? OK, check the S switch.
YES

recheck.
14-332
[¡] indicatorlight is on steady
whenever the ignition switch is
ON. IS switch is OFF.)
Is the service check connector YES Dlsconnect the jumper wire and
jumped? recheck.
NO


Does the [¡]indicator light come YES nectors. lf necessary, substitute
on? a known-good control unit and
recheck.
NO
Check for open or short in

YEL/GRN wire between the 810
terminal and the gauge assembly.
lf wire Is OK, check the shift po-
sition lndicator and ~ lndicator
light bulb.
(cont'd)
14-333
IIJ indicator light does not come

on with the ignition switch ON. (lt
should be come on for about 2
seconds.l
Is the service check connector YES Disconnect the jumper wire and
jumped? recheck.
NO
Push the S switch ON.

Does the [§] indicator light come NO
nectors and S switch. lf neces-
on? sary, substitute a known-good
control unlt and recheck.
YES

nectors from the cotnrol unit.
BLK/RED
2 6
1O 11 12 1 5 18 18
A 1 7 (BRNI and B 1 (BLK/RED) ter- BRN
minals.
YES Repair short in BRN wire between

Is there continuity? the A 17 terminal and the service
check connector.
NO

B 1 (BLK/RED)terminal and body
ground, and between the 86
(BLK/RED) terminal and body
ground.
NO Repair open in BLK/RED wire be-

Is there continuity? tween the B 1 terminal and/or 86
terminal and G 1 O 1 .
YES
(To page 14-3351
14-334
(From page 14-334) r-®-1 View from terminal side
1 8LK/RED 8LK/YEL
1
82 or 87 (8LK/YEL) and 81 or 86
8 LK/RED 8LK/YEL
4>--J
(8LK/RED) terminals.
1
NO Repeir open or short in 8LK/YEL
Is the battery voltage? wire between the 82 and/or 87
I YES
terminal and the fuse box.
Connect jumper wire between the

82 or 87 (8LK/YEL) and 811
(YEL/GRN) terminals.
JUMPER WIRE
1
NO nectors and S switch. lf neces-
Does the ~ indicator light come
on? sary, substituta a known-good
I YES
control unit and recheck.
Check for continuity YEL/GRN

wire between the 811 terminal
and the gauge assembly.
1 Repair open in YEL/GRN wire be-

NO
gauge assembly.
I YES
Check the shift position lndlcator

and []] indicator light bulb. lf the
shift posltlon indicator and []]in-
dicator light bulb are OK, check
for loose control unlt connectors.
unit end recheck.
(cont'd)
14-335
LOW switch signal test.
\ LOW \ 1NDICATOR LIGHT

!
Does the LOW \ indicator light NO !
Test the LOW \ indicator light.
come on for about 2 seconds? See page 14-338.
YES
Does the \ LOW \ indicator light go NO !

Test the LOW \ indicator light.
out? See page 14-339.
YES
Shift to W position.
Push the LOW switch ON.
!
Does the LOW \ indicator light YES
LOW switch signal is OK.
come on?
NO
Check whether the [fil indicator

light blinks.
Does the W indicator light come YES Troubleshoot ~ording to the

number of the L!J indicator light
on? blink(s).
NO
(To page 14-337)
14-336
(From page 14-336) View from terminal side

nectors from the control unit. r®-i
YEL BLK/RED
Check far continuity between the 2 4 5 6 7

AS (YEL) and 81 (BLK/RED) ter- 1O 11 12 15 16 17
minals while pushing the LOW
switch ON and OFF.
Is there continuity while pushing Check for open or short in YEL

the LOW switch ON, and is there NO wire between the AB terminal and
no continuity while pushing the LOW switch. lf wire is OK, check
LOW switch OFF? the LOW switch.
YES

recheck.
(cont'd)
14-337
j LOW l indicator light does not

come on with the ignition switch
ON. (lt should be come on for
about 2 seconds.)
Shift to W position. 1
Pushing the LOW switch ON.

1

!
Does the j LOW indicator light NO nectors and S switch. lf neces-
come on? sary, substitute a known-good
control unit and recheck.
YES
Disconnect the 1 SP and 12P con-


B 1 (BLK/RED)terminal and body
ground, and between the 86
(BLK/RED) terminal and body
ground.
NO Repair open in BLK/REDwire be-

Is there continuity? tween the B 1 terminal and/or 86
terminal and G 1 O 1 .
YES
(To page 14-339)
14-338
(From page 14-338) View from terminal side
1
BLK/RED BL
í-©-i
Turn the ignition switch ON. 1
1
1
1 ¡2
1 6 1 7
Measurethe voltage between the
82 or 87 (8LK/YEL) and 81 or 86
(8LK/RED) terminals. BLK/R~D BLK/YEL
LwJ
1
NO Repalr open or short in BLK/YEL
Is the battery voltage? wire between the 82 and/or 87
I YES
terminal and the fuse box.
Connect jumper wire between the 1 1 2

82 or 87 (8LK/YEL) and 81 O
6 1 7
(RED/YEL) terminals.
1
JUMPER WIRE
1
I
Does the LOW indicator light I NO nectors and LOW switch. lf
come on? necessary, substituta a known-
good control unit and recheck.
I YES
Check for continuity RED/YEL

wire between the 810 terminal
and the gauge assembly.
1
NO Repair open in RED/YELwire be-
Is there continuity? tween the B1 O terminal and the
gauge assembly.
I YES
- Check the shift position indi-

I
cator and LOW indicator lightI
bulb. lf the shift position indi-
I
cator and LOW indicator lightI
bulb are OK, check for loose
control unit connectors.
- Sub'stitute a known-good con-
trol unit and recheck.
(cont'd)
14-339
! LOW ! indicator light is on steady

whenever the ignition switch is
ON. ILOW switch is OFF.)


Does the ! LOW ! indicator light YES nectors. lf necessary, substituta
come on? a known-good control unit and
recheck.
NO
Check for open or short in RED/

YEL wire between the B1 O termi-
nal and the gauge assembly. lf
wire is OK, chec~hift posi-
tion indicator and LOW lndicator
light bulb.
14-340
lnspection of brake light slgnal.
Check the brake lights come on

with the brake pedal pushed.
NO
Are brake lights ON? Faulty brake light circuit.
YES
View from terminal side

Disconnect the 1 2P and 18P con-
BLK/RED
2
A 12 (GRN/WHT) and 81 (BLK/ 7
RED)terminals with the brake pe- V
dal pushed.
5 6 7
1O 11 1 S 16 17 18
GRN/WHT
NO Repairopen in GRN/WHT wire be-

Is there battery voltage? tween A 12 terminal and brake
light switch.
YES
Brake light signal is OK.
(cont'dl
14-341
lnspection of A/C signal.
Start the engine.
Push the A/C switch.
Does A/C compressor clutch)>--N_0 1

See Air Conditioner inspection
engage? (section 22).
'-----------------'
YES
Stop the engine.
Disconnect 1 2P and 1 BP connec-

tor from the control unit.
Start the engine.
Measure the voltage between A9

(BLK/RED)and B 1 (BLK/RED)ter-
minals. (A/C compressor OFF)
NO Repalr open in BLK/REDwire be-

Is there battery voltage? tween A9 terminal and A/C clutch
relay.
YES
A/C signal is OK.
14-342
A/T Control Unit NC Speed Sensor
Replacement Replacement
NOTE: The A/T control unit is located under the 1. Remove the transmission side mount.
dashboard.
2. Remove the transmission mount bracket from the
1. Remove the center console (see page 20-80). transmission housing.
2. Remove the 3 bolts securing the A/T control unit, 12 x 1.25 mm

55 N·m
then remove the A/T control unit. (5.5 kg-m, 40 lb-ft)
\'><"'~""""'- @
TRANSMISSION
SIDE MOUNT
TRANSMISSION
MOUNT BRACKET
12 x 1.25 mm
55 N·m
(5.5 kg-m, 40 lb-ft)
3. Removethe screw then remove the unit cover from
the A/T control unit.
3. Disconnect the NC speed sensor connector.
4. Troubleshoot according to the number of the S indi-
cator light blink(s). 4. lnstall the NC speed sensor in the reverse arder of
the removal.
6 x 1.0 mm
12 N·m
( 1.2 kg-m, 9 lb-ftl
\ N/SENSOR CONNECTOR
A/T CONTROL UNIT
HARNESS GUIDE A TF COOLER PIPE
14-343
Lock-up Control Solenoid Valve A/B
Test Replacement
NOTE: Lock-up control solenoid valves A and B rnust 1. Rernovethe mounting bolts and lock-up control sole-
be removed/replaced as an assembly. noid valve assembly.
1. Disconnect the connector from the lock-up control NOTE: Be sure to remove or replace the lock-up
solenoid valve A/8. control solenoid valves A and B as an assembly.
2. Measure the resistance between the No. 1 terminal 2. Checkthe lock-up control solenoidvalve oil passages
(SOL. VA) of the lock-up control solenoid valve con- for dust or dirt and replace as an assembly, if
nector and body ground and between the No. 2 ter- necessary.
minal (SOL. V B) and body ground.
r···. ,
6 x 1.0 mm
STANDARD: 16.2-19.80 (at 25ºC)
LOCK-UP CONTROL 12 N·m
SOLENOID VALVE (1.2 kg-m.
ASSEMBLY
LOCK-UP CONTROL
SOLENOID VALVE ASSEMBLY

bly if the resistance is out of specification.
4. Connect the No. 1 terminal of the lock-up control Clean the mounting BASE GASKET
solenoid valve connector to the battery positive ter- surface and oil Replace.
minal and body ground. A clicking sound should be passages.
heard. Connect the No. 2 terminal to the battery
5. lf not, check for continuity between the A/T control 3. Clean the mounting surface and oil passagesof the
unit 83 or 88 harness and body ground (page lock-up control solenoid valve assembly and install
14-318, 319). a new base gasket.
6. Replace the lock-up control solenoid valve assem- 4. Check the connector for rust, dirt or oil and recon-
bly if there is continuity between the A/T control unit nect it securely.
83 or 88 harness and body ground (page 14-318,
319).
14-344
Shift Control Solenoid Valve A/8
Test Replacement
NOTE: Shift control solenoid valves A and B must be 1. Remove the mounting bolts and shift control sole-
removed/replaced as an assembly. noid valve assembly.
1. Disconnect the connector from the shift control NOTE: Be sure to remove or replace the shift con-
solenoid valve A/B. trol solenoid valvas A and B asan assembly.
NOTE: Do not remove the shift control solenoid 2. Check the shift control solenoid valve oíl passages
valve A/B stay. for dust or dirt and replace as an assembly, if
necessary.
2. Measure the resistance between the No. 1 terminal
(SOL.V A) of the solenoid valve connector and body
ground and between the No. 2 terminal (SOL. V B)
and body ground.
STANDARD:16.2-19.80 (at 25ºCl
View from
terminal side
)
SHIFT CONTROL
SOLENOID VALVE
BASE GASKET
ASSEMBLY
Replace.
Clean the mounting surface

and oil passages.
3 .. Clean the mounting surface and oíl passagesof the

shift control solenoid valve assembly and install a
new base gasket.
4. Check the connector for rust, dirt or oíl and recon-

SHIFT CONTROL
SOLENOID VAL VE nect it securely.
3. Replacethe shift control solenoid valve assembly if

the resistance is out of specification.
4. Connectthe No. 1 terminal of the solenoidvalve con-

nector to the battery positive terminal and the No.
2 terminal to the battery positive terminal.
A clicking sound should be heard each time the con-
nection is made.
5. lf not, check for continuity between the A/T control

unit 84 or 85 harness and body ground. (page
14-326, 327)
6. Replacethe shift control solenoid valve assembly if

there is continuity between the A/T control unit B4
or 85 harnessand body ground. (page 14-326, 327)
14-345
S Switch LOW Switch
Test Test
1. Remove the center console. (see page 20-80) 1. Remove the console.
2. Disconnect the switch connector. 2. Disconnect the switch connector and remove the
LOW switch.
3. Check for continuity between A and B terminals.
There should be continuity when the switch is 3. Check for continuity between the terminals by press-
pressed. ing and releasingthe switch button according to the
table below.
r-, TERMINAL
e
POSITION -, B A D E
-
,=
o- H)
-
PRE SS
-- =-. --
RELEASE
S SWITCH
LOW SWITCH
A~
lE!jJ
View from
B E
wire side
A e
14-346
Hydraulic System
Symptom-to-Component Chart
Check these items on the Check these items on

SYMPTOM PROBABLECAUSE LIST the NOTESCHART
Engine runs, but car does not move in any gear. 1, 6, 7, 16 K, L, R, S
Car moves in [!] and [I], but not in ~ i
or 04 i 8, 29, 44, 48 C,M,O
Car moves in ~ i
i , [!] ,
, 04 but not in [l] . 9, 30, 49 C, L
Car moves in @iJ , ! 04 i , (1] , but not [!) . 1, 11, 22, 34, 38, 39, 40 C, L, Q
Car moves in [H] . 1, 8, 9, 10, 11, 46, 47 C,D
Excessive idle vibration. 5, 17 B,K, L
No engine braking in [l] position. 12 C, D, L
Slips in 1 st gear. 8, 29, 44, 48 C,N,O,U
Fiares on 1 -2 upshift. 3, 15 E, L, V
Harsh shift (up and down shifting). 2, 4, 15, 23, 24, 27,47 A, E, H, 1, L, V
Harsh shift (1-2). 2, 9 C, D,V
Harsh shift (2-3). 2, 10, 23, 24 C, D, H, L, V
Harsh shift (3-4). 2, 11, 23, 25 C, O, 1, L, V
Harsh shift when manually shifting to [IJ . 33 L
Axle(s) slips out of trans on turns. 43, 50 L, P, Q
Ratcheting noise when shifting into []]. 6, 7, 38, 39,40 K, L, Q
Loud popping noise when taking off in ffiJ. 38, 39, 40 L, O
Ratcheting noise when shifting from [!] to [f] or from []] to 38, 39, 40, 45 L, Q
[[J.
Noise from trans in all selector lever positions. 6, 17 K, L, Q
Noise from trans only when wheels are rolling. 39, 42 L, Q
Gear whine, rpm related (pitch changes with shifts). 8,13, 41 K, L, O
Gear whine, speed related (pitch changes with speed). 38, 42 L, O
Trans will not shift into 4th gear in i 04 ! . 1, 21, 28, 32 L
Lock-up clutch does not operate properly. 2, 3, 1 5, 18, 35, 36, 37 E, L, V
At disassembly, large particles of metal are found on magnet.
14-348
PROBABLE CAUSE
1. Shíft cable broken/out of adiustment.
4. Wrona tvoe ATF.
5. ldle rom too low/hiah.
7. Reaulator valva stuck.
8. 1 st clutch defectiva.
9. 2nd clutch detective.
11. 4th clutch detective
12. 1 st-hold clutch detective.
14. Modulator valva stuck.
16. ATF strainer cloaaed.
17. Toraue convertor detective.
18. Toraue convertor check valve stuck.
19. 1 - 2 shift valve stuck.
20. 2-3 shíft valve stuck.
23. Clutch oressure control (CPC) valve stuck.
24. 2-3 orífice control valve stuck.
25. 2/3-4 orífice control valve stuck.
26. 3- 2 kíck-down valva stuck.
27. 4-3 kíck-down valve stuck.
28. 4th exhaust valva stuck.
29. 1st accumulator defectiva.
30. 2nd accumulator defectíve.
31. 3rd accumulator defectiva.
33. 1 st-hold accumulator detective.
35. Lock-uo tirninu valve stuck.
36. Lock-uo shift valve stuck.
37. Lock-uo control valve stuck.
38. Shíft fork bent.
39. Reverse aears worn/damaaed (3 seers).
41. 3rd aears worn/damaged (2 aears).
42. Final qears worn/damaoed (2 aeers).
43. Differential oinion shaft worn.
44. Feedoíoe 0-rina broken.
45. 4th qeers worn/damaoed (2 qears).
48. One-wav (soraa) clutch detective.
49. Sealinq rinqs/quide worn.
50. Axle-inboard ioint clic rnissinc.
(cont'd)
14-349
Hydraulic System
Symptom-to-Component Chart (cont'd)

The following syrnptorns can be caused lterns on the
PROBABLECAUSE DUE
by irnproper repair or assembly. NOTES CHART
TO IMPROPERREPAIR
Car creeps in [fil. R1, R2
Car does not move in @iJ or [§;]. R4
Trans locks up in [[]. R3, R12
Noise with wheels rnoving only. R5
Various shifting problems. R9, R10
Harsh upshifts. R11

R8. Main seal irnproperly installed.
14-350
NOTES
B. Set idle rpm in gear to specified idle spead. lf still no good, adjust motor mounts as outlinad in engine section of service
manual.
c. lf the large clutch piston 0-ring is broken, inspect the piston groove for rough machining.
D. lf the clutch pack is seized or is excessively worn, inspect the other clutchas for wear and check the orífice control
valves and throttle valvas for free movement.
G. lf the 1 -2 shift valve is stuck closed, the transmission will not upshift. lf stuck open the transmission has no 1 st gear.
H. lf the 2-3 orífice control valve is stuck, inspect the 2nd and 3rd clutch packs for wear.
l. lf tha 2/3-4 orifica control valve is stuck, inspect the 3rd and 4th clutch packs for wear.
J. lf the clutch pressure control valva (CPC) is stuck closed, the transmission will not shift out of 1 st gear.
K. lmproper alignment of main valve body and torqua convertor housing may cause oil pump saizure. Tha symptoms are
mostly an rpm-ralated ticking noise or a high pitched squeek.
L. lf the oíl scraen is clogged with particles of steel or aluminum, inspect the oíl pump and differential pinion shaft. lf both
are OK and no cause for the contamination is found, replace the torque converter.
M. lf the 1st clutch feedpipa guide in the R. side cover is scored by the mainshaft, inspect tha ball bearing for excessiva
movement in the transmission housing. lf OK, replace the R. side covar as it is dentad. The 0-ring under the guide is
probably worn.
N. Replacethe mainshaft if the bushings for the 1 stand 4th feedpipe are loosa or damaged. lf the 1 st feedpipe is damaged
or out of round, replace it. lf the 4th faadpipe is damaged or out of round, replace the R. side cover.
o. A worn or damaged one-way (sprag) clutch is mostly a result of shifting the trans in~ !
or 104 while the wheels
rotate in reverse, such as rocking the car in snow.
Replace items 1, 2 and 4 if worn or damaged. lf trans makes clicking, grinding or whirring noise, also replace
mainshaft 4th gear and reverse idler gear and countershaft 4th gear in addition to 1, 2, 3 or 4.
lf differential pinion shaft is worn, overhaul differential assembly and replace oil screen and throughly clean
trans, flush torque converter, cooler and lines.
R. Be very careful not to damage the torque converter housing when replacing the main ball bearing. You
may also damage the oil pump when you torque down the main val ve body. This will result in oil pump
s. lnstall the main seal flush with the torque converter housing. lf you push it into the torque converter hous-
ing until it bottoms out, it will block the oil return passage and result in damage.
v. Throttle cable adjustment is essential for proper operation of the transmission. Not only does it affect the
shift points if misadjusted, but also the shift quality and lock-up clutch operation.
14-351
Road Test
1. Apply parking brake and block the wheels. Start the engine, them move the selector lever to ~ position while
2. Repeat same test in [QJ position.
3. shift the selector lever to [[J position and check that the shift points occur at approximate speeds shown. Also
check far abnormal noise and clutch slippage.
~ or [QJ Position: Normal mode (S switch OFF)
• Upshift
NOTE: When the coolant temperature is below normal operating temperature, the shift point is higher than specified
vehicle speed.
Throttle Opening Unit of speed 1st --+ 2nd 2nd --+ 3rd 3rd --+ 4th
1 /8 throttle Km/h 18-20 36-39 53-58
mph 11-12 22-24 33-36
1 /2 throttle Km/h 39-42 71-77 95-101
mph 24-26 44-48 59-63
mph 40-44 73-76 104-108
• Downshift
Throttle Opening Unit of speed 4th --+ 3rd 3rd ----> 2nd 2nd--+ 1st
Full-closed throttle Km/h 30-34 10-14 (3rd--+ 1 st) -
mph 19-21 6-9 (3rd ----> 1 st) -
mph 84-88 55-59 27-30
• Lock-up
Lock-up control solenoid Lock-up control solenoid

valve A ON valve BON
1 /8 throttle Km/h 25-29 66-70
mph 16-18 41-43
Full-opened throttle Km/h 147-153 147-153
mph 91-95 91-95
14-352
I l I
104 (or 03 I Position: Sport mode (S switch ON)
• Upshift
Throttle Opening Unit of speed 1st -+ 2nd 2nd -+ 3rd 3rd -+ 4th
1 /8 throttle Km/h 21-23 44-47 78-83
mph 13-14 27-29 48-52
1 /2 throttle Km/h 43-46 82-88 117-123
mph 27-29 51-55 73-76
Full-operiedthrottle Km/h 65-71 117-123 167-173
mph 40-44 73-76 104-108
• Downshift
Throttle Opening Unit of speed 4th -+ 3rd 3rd -+ 2nd 2nd-+ 1st
Full-closed throttle Km/h 30-34 10-14(3rd--+ 1st) -
mph 19-21 6-9 (3rd --+ 1 st) -

mph 84-88 55-59 27-30
• Lock-up
Lock-up control solenoid Lock-up control solenoid

valve A ON valve BON
1 /8 throttle Km/h 38-42 84-88
mph 24-26 52-55
Full-opened throttle Km/h 147-153 147-153
mph 91-95 91-95
4. Accelerate to about 35 mph (57 km/h) so the transmission is in 4th, then shift D4 to I I [fil. The car should immedi-
ately begin slowing down from engine braking.
CAUTION: Do not shift from I D4I or 103I to [fil at speeds over 62.5 mph (100 km/h); you may damage the trans-
mission.
(I] (2nd Gear) Position
-1. Accelerate from a stop at full throttle. Check that there is no abnormal noise or clutch slippage.
- 2. Upshifts and downshifts should not occur with the selector in this position.
[[] (Reverse)Position
6. Test in ~ (Parking) Position

Parkcar on slope (approx. 16º), apply the parking brake, and shift into [fJ position. Releasethe brake; the car should
not move.
14-353
Stall Speed
Test
CAUTION:
• To prevent transmission damage, do not test stall speed for more than 10 seconds ata time.
• Do not shift the lever while raising the engine speed.
1. Engagethe parking brake and block all tour wheels.
3. After the engine has warmed up to normal operating temperature, shift into [IJ position.
5. Allow 2 minutes for cooling, then repeat same test in 104 ! and [[] position.
NOTE:
• Stall speed test must be made only for checking the cause of trouble.
• Stall speed in ~ W
and [[] must be same, and must also be within limits.
Stall Speed RPM:

Specification: 2, 750 min-1 (rpml
Service Limit: 2,300-2,900 min-1 (rpm)
TROUBLE PROBABLECAUSE
Stall rpm high in [füJ. [IJ and [fil position • Low fluid level or oil pump output
• Clogged oil strainer
• Pressure regulator valve stuck closed
• Slipping clutch
Stall rpm high in [I] position • Slippage of 1 st clutch, 1 st-hold clutch or 1 st gear one-
way clutch
Stall rpm high in 1 04 ! position • Slippage of 1 st clutch, 1 st gear one-way clutch
Stall rpm high in []] position • Slippage of 4th clutch
Stall rpm low in [füJ, [1J and !]] position • Engine output low
•Torque converter one-way clutch slipping
14-354
Fluid LeveJ
Checking/Changing
Checking Changing
NOTE: Check the fluid level with the engine at normal 1. Bring the transmission up to operating temperature
operating temperature. by driving the car. Parkthe car on level ground, turn
the engine off, then remove drain plug.
1. Park the car on level ground. Shutt off the engine.
2. Reinstallthe drain plug with a new washer, then refill
2. Remove the dipstick (yellow loop) from the trans- the transmission to the upper mark on the dipstick.
mission and wipe it with a clean cloth.
Automatic TransmissionFluid Capacity:
3. lnsert the dipstick into the transmission. 3.2 e (3.4 US qt., 2.8 lmp qt.) at change
6.4 e (6.8 US qt., 5.6 lmp qt.) after overhaul
DIPSTICK
(YELLOW LOOP)
4. Remove the dipstick and check the fluid level. lt

14 x 1 .5 mm
should be between the upper and lower marks. 40 N·m
(4.0 kg-m. 29 lb-ftl
¡~
fil- UPPERMARK
LOWER MARK
5. lf the level is below the lower mark, add fluid into

the tube to bring it to the upper mark. Use Honda
Premium FormulaAutomatic Transmission Fluid or
an equivalent DEXRON® 11 Automatic Transmission
Fluid (ATF) only.
14-355
Pressure Testing
i·f&+idMN
• While testing, be careful of the rotating front wheels.
4. Start the engine and measure the respective pres-
sure as follows.
• Make sure lifts, jacks, and safety stands are placed • Line Pressure
properly. (see page 1 - 1 O thru 1 - 1 2). • Clutch Pressure
CAUTION: • Clutch Low/High Pressure
• Before testing, be sure the transmission fluid is filled • Throttle B Pressure
• Warm up the engine before testing. 5. lnstall a new washer and the sealing bolt in the in-
spection hole and tighten to the specified torque.
1. Raise the car. (see page 1 -1 O thru 1 -12).
2. Warm up the engine, then stop the engine and con-
nect a tachometer. NOTE: Do not reuse old aluminum washers.
3. Connect the oil pressure gauge to each inspection • Line Pressure

hole(s).
-1 . Set the parking brake and block both rear
TOROUE: 18 N·m (1.8 kg-m, 12 lb-ftl wheels securely.
CAUTION: Connect the oil pressure gauge secure- - 2. Aun the engine at 2,000 min-1 (rpm)
ly, be sure not to allow dust and other foreign parti-
cles to enter the inspection hole. - 3 . Shift the select lever to ffi] or [EJ.
A/T OIL PRESSURE GAUGE SET A/T OIL PRESSURE - 4. Measure line pressure.
GAUGE HOSE
07406-0020003
ASSEMBLV
07MAJ-PV40100 UNE PRESSURE
INSPECTION HOLE
OIL PRESSURE
GAUGE HOSE
07MAJ-PV40110
A/T LOW
PRESSURE
GAUGE
07406-0070000
NOTE: Use the A/T Oil Pressure Gauge Set or A/T

Low PressureGauge replacingthe oil pressuregauge
LOCK-UP CONTROL
hose assembly. The A/T Oil Pressure Gauge Hose
SOLENOID VALVE
(07406-0020201 I may also be used. ASSEMBLV
FLUID PRESSURE
SELECTOR
Une [ill or [IJ No (or low) line Torque converter, oil 850-900 kPa 800 kPa
pressure pump pressure regula- (8.5-9.0 kg/cm2, (8.0 kg&cm2,
tor, torque converter 121-128 psi) 114 psi)
NOTE: Higher pressures may be indicated if measurements are made in selector positions other than ffi] or !E] .
14-356
• Clutch Pressure Measurement
While testing, be careful of the rotating front wheels.
-1.Set the parking brake and block both rear wheels securely.
- 2. Raise the front of the car and support with safety stands.
-3.Allow the front wheels to rotate freely.
-4.Run the engine at 2,000 min-1 (rpm).
- 5. Measure ea ch clutch pressure.
INSPECTION HOLE
4TH CLUTCH PRESSURE

INSPECTION HOLE
2ND CLUTCH PRESSURE

INSPECTION HOLE
3RD CLUTCH PRESSURE

INSPECTION HOLE
FLUID PRESSURE
SELECTOR
PRESSURE SVMPTOM PROBABLE CAUSE Service Limit
POSITION Standard
1 st Clutch O] or l 04 I No or low 1 st 1 st Clutch 850-900 kPa 800 kPa

1 21 - 1 28 psi) 114 psi)
1st-hold O] No or low 1 st- Clutch
Clutch hold pressure
2nd Clutch ~ No or low 2nd 2nd Clutch
pressure
2nd Clutch 104 I No or low 2nd 2nd Clutch 500kPa 450 kPa
pressure (5.0 km/cm2, (4.5 kg/cm2, 61 psi)
71 psi) (throttle fully closed)
No or low 3rd 3rd Clutch (throttle fully closed) 800 kPa
3rd Clutch
850-900 kPa (8.0 kg/cm2, 114
pressure
(8.5-9.0 kg/cm2, psi)
4th Clutch No or low 4th 4th Clutch 121-128psi) (throttle more than
pressure (throttle more than 3/8 openedl
3/8 opened)
[fil Servo Val ve or 4th 850-900 kPa 800 kPa

Clutch (8.5-9.0 kg/cm2 (8.0 kg/cm2
121-128 psi) 114 pai)
(cont'd)
14-357
Pressure T esting
(cont'd)
• Clutch Low/High Pressure Measurement 7. With the engine idling, lift the throttle control lever
up approximately 1 /2 of its possible travel and in-
f,j{frjflifldWhile testing, be careful of the rotating crease the engine rprn until pressure is indicated on
front wheels. the gauge, then measurethe highest pressure read-
ing obtained.
1. Allow the front wheels to rotate freely.
8. Repeat step - 7. far each clutch pressure being in-
2. Remove the cable end of the throttle control cable
spected.
inspected.
NOTE: Do not loasen the locknuts, simply unhook
the cable end.
THROTTLE CONTROL
LEVER THROTTLE
CONTROL
LEVER
3. Shaft the engine and let it idle.
4. I !
Shift the select lever to D4 position.
5. Slowly move the throttle linkage to increase engine

rpm until pressure is indicated on the oil pressure
gauge.
Then release the throttle linkage, allowing the en-
gine to return to an idle, and measure the pressure
reading.
6. Repeat step - 5. far each clutch pressure being in-

spected.
THROTTLE
LINKAGE
14-358
4TH CLUTCH PRESSURE
INSPECTION HOLE
L
---r- 2ND CLUTCH PRESSURE

INSPECTION HOLE
3RD CLUTCH PRESSURE

INSPECTION HOLE

2nd Clutch ! D4! No or low 2nd 2nd Clutch 500-900 kPa 450 kPa
pressure (5.0-9.0 kg/cm2, (4.5 kg/cm2, 61 psi)
3rd Clutch No or low 3rd 3rd Clutch 71-128 psi) with throttle control
pressure varíes with throttle lever released
opening 800 kPa
4th Clutch No or low 4th 4th Clutch (8.0 kg/cm2,
pressure 114 psi)
lever more than 3/8
opened
(cont'd)
14-359
Pressure Testing
(cont'd) -·---------------------------,
• Throttle B Pressure Measurement
f•SWfofiifiN
front wheels.
While testing, be careful of the rotating
1. Allow the front wheels to rotate freely.
2. Remove the cable end of the throttle control cable

NOTE: Do not loasen the locknuts, simply unhook

the cable end.
3. Shift the selector lever to @J or @;J position.
4. Aun the engine at 1 ,000 min-1 (rpm).
5. Measure full-closed throttle B pressure.
6. Move the throttle control lever to full-opened throt-

tle position.
7. Measure full-opened throttle B pressure.
LOCK-UP CONTROL
SOLENOID VALVE
ASSEMBLY
THROTTLE B PRESSURE
INSPECTION HOLE

PRESSURE SYMPTOM
Throttle B ID4 ! or@;J Pressure Throttle O kPa (O kg/cm2, O psi) -
too high Valve B throttle full closed
No or low 850 - 900 kPa 800 kPa
throttle B (8.5 - 9.0 kg/cm2, (8.0 kg/cm2, 114 psi)
pressure 121 - 128 psi) throttle full opened
throttle full opened
14-360
Transmission
Remo val
1%foidMiN 4. Remove the transmission ground cable from the

transmission and disconnect the NC speed sensor
• Make sure lifts, jacks and safety stands are placed connector.
rect position on the engine (see pages 1-6 thru 1-8).
NC SPEED SENSOR
• Apply parking brake and block rear wheels, so car will
not roll off stands and fall on you while working un- CONNECTOR
der it.
CAUTION: Use fender covers to avoid damaging paint-

ed surfaces.
1. Disconnectthe battery negative ( - ) and positive ( + 1

cables from the battery.
2. Removethe resonator, air intake hose and air cleaner

case.
5. Disconnect the lock-up control solenoid valve and

shift control solenoid valve connectors.
SHIFT CONTROL SOLENOID

VAL VE CONNECTOR
3. Remove the starter motor cable and cable holder

from the starter motor.
ST ARTER MOTOR CABLE
LOCK-UP CONTROL
SOLENOID VALVE
CONNECTOR
(cont'd)
14-361
Transmíssion
Removal (cont'd)
6. Disconnect the speedometer sensor connector. 9. Removethe ATF cooler hosesat the joint pipes. Turn
the ends of the cooler hoses up to prevent A TF from
flowing out, then plug the joint pipes.
NOTE: Check for any signs of leakage at the hose

joints.
1 O. Remove the transmission housing mounting bolts

7. Remove the clip from the control pin. and starter motor mounting bolt.
8. Remove the locknut securing the shift cable, then

remove the shih cable from the control cable.
\
ST ARTER MOTOR
ST ARTER MOTOR and

MOUNTING BOL T
MOUNTING BOL TS
11 . Removethe drain plug and drain the automatic trans-

mission fluid (ATF). Reinstall the drain plug with a
new sealing washer (see page 14-355).
14-362
1 2. Remove the cotter pins and castle nuts, then 18. Removethe intermediate shaft.
separate the ball joints from the lower arm (see Sec-
tion 18). 19. The plastic bags over the intermediate shaft end.
1 3. Remove the damper fork bolts, then separate the NOTE: Coat all precision finished surfaces with
damper fork and damper. clean engine oil or grease.
O AMPER PINCH BOLT

Replace
DAMPER FORK
Replace. Replace. INTERMEDIATE SHAFT
14. Pry the right drivershaft out of the differential.

20. Remove the splash shield.
15. Prythe left drivershaft out of the intermediate shaft.
1 6. Pull on the inboard joint and remove the right and

left driveshafts (see Section 16).
17. The plastic bags over the dirveshaft ends.
NOTE: Coat al! precision finished surfaces with

clean engine oil or grese.
BOLT -,
CLIP
{cont'd)
14-363
Transmission
Removal (cont'd)
21. Remove the exhaust pipe A. 23. Remove the stopper mount bolts.
24. Remove the end of the throttle control cable from

the throttle control lever.
GASKET
Replace.
STOPPER MOUNT
SELF-LOCKING NUT
Replace.
THROTTLE CONTROL
CABLE ENO
22. Removethe 4 bolts securingthe propellershaft, then

separate the propeller shaft from the transfer. 25. Remove the engine stiffener and torque converter
cover.
26. Remove the 8 drive plate bolts one at a time while

PROPELLER SHAFT rotating the crankshaft pulley.
ORIVE PLATE BOL T
ORIVE PLATE
~ \
TORQUE CONVERTER
COVER
14-364
27. Attach a hoisting bracket to the engine, then lift the 29. Remove the transmission housing mounting bolts
engine slightly. and rear engine mounting bolts.
30. Pull the transmission away from the engine until it

clears the 14 mm dowel pins, then lower it on the
transmission jack.
MOUNTING BOLTS
28. Place a jack under the transmission and raise the

transmission just enough to take weight off of the
mount, then remove the transmission side mount.
TRANSMISSION SIDE MOUNT
14-365
lllustrated lndex
R. Side Cover~~~~~~~~~~~~~~~~~~~~~~~~~~
14-366
(D R. SIDE COVER @) SUB-SHAFT LOCKNUT Replace.
@ 0-RING Replace. @ SPRING WASHER Replace.
@ R. SIDE COVER GASKET Replace. @ SUB-SHAFT 1 ST GEAR
@ OOWEL PIN @ LOCK BOLT
@ 0-RING Replace. @ LOCK WASHER Replace.
@ NC SPEED SENSOR @ PARKING BRAKE STOPPER
(f) ROLLER @ PARKING BRAKE LEVER
@ WASHER @ PARKING BRAKE SPRING
@ 0-RING Replace. @ PARKING BRAKE PAWL
@ FEED PIPE FLANGE @ PARKING BRAKE PAWL SHAFT SPRING
@ 0-RING Replace. @ PARKING BRAKE PAWL SHAFT
@) SNAP RING @ PARKING BRAKE PAWL STOPPER
@ 3RD CLUTCH FEED PIPE @) DRAIN PLUG
@ COUNTERSHAFT LOCKNUT Replace. @) SEALING WASHER Replace.
@ PARKING GEAR @ LOCK WASHER Replace.
@) ONE-WAY CLUTCH @) THROTTLE CONTROL LEVER
@ COUNTERSHAFT 1 ST GEAR @) THROTTLE CONTROL LEVER SPRING
@) NEEDLE BEARING @) OIL SEAL Replace.
@) COUNTERSHAFT 1 ST GEAR COLLAR @) THROTTLE CONTROL CABLE STA Y
@) 1 ST CLUTCH FEED PIPE @) ATF COOLER PIPE
@ 0-RING Replace. @) JOINT BOL T
@ FEED PIPE FLANGE @ SEALING WASHER Replace.
@ SNAP RING @) SPEED SENSOR ASSEMBL Y
@ MAINSHAFT LOCKNUT Replace. @) 0-RING Replace.
@ 1 ST CLUTCH ASSEMBL Y @ STOPPER MOUNT BRACKET
@ 0-RING Replace. @) TRANSMISSION MOUNT BRACKET
@ THRUST WASHER
@) NEEDLE BEARING
@) MAINHSAFT 1 ST GEAR
@ THRUST WASHER
@ MAINSHAFT 1ST GEAR COLLAR
@ ROLLER
@ WASHER
@ 0-RING Replace.
@ FEED PIPE FLANGE
@ 0-RING Replace.
@ SNAP RING
@ 1ST-HOLD CLUTCH FEED PIPE

A 12 N·m (1.2 kg-m, 9 lb-ft) 6 x 1.0 mm
B 14 N·m ( 1.4 kg-m, 1 O lb-ft) 6 x 1.0 mm Specialbolt
e 22 N·m (2.2 kg-m, 16 lb-ft) 8 x 1.25 mm
F 8 N·m (0.8 kgm, 6 lb-ft) 5 x 0.8 mm
G 29 N·m (2.9 kg-m, 21 lb-ft) 12 x 1.25 mm A TF cooler pipe joint bolt
1 40 N·m (4.0 kg-m, 29 lb-ft) 14 x 1.5 mm Drain plug
J 95 N·m (9.5 kg-m, 69 lb-ft) 19x1.25mm Mainshaft locknut (flange nut):
Left-hand threads
K 140-+0-+ 140 N·m 23 x 1.25 mm Countershaft locknut (flange nut)
( 14.0-+0-+ 14.0 kg-m,
101-+0-+101 lb-ft)
L 95-+0-+95 N·m 19 x 1.25 mm Sub-shaft locknut(flange nut)
(9. 5-+O-+9. 5 kg-m,
69-+0-+69 lb-ft)
p 39 N·m (3.9 kg-m, 28 lb-ft) 10 x 1.25 mm Transmission mount bracket
Q 65 N·m (6.5 kg-m, 47 lb-ft) 12 x 1.25 mm Stopper mount bracket bolt
14-367
d lndex
lllustrate_ . n Housing
Transmisslo
14-368
(D SHIFT CONTROL SOLENOID VALVE ASSEMBLY
@ FIL TER Re place.
@ 0-RING Replace.
@ JOINT COLLAR
@ 0-RING Replace.
@ TRANSMISSION UNDER GUARO
(!) LOCK WASHER Replace. @ NEEDLE BEARING
@ REVERSE SHIFT FORK @ SET RING
@ REVERSE GEAR COLLAR @ 1 ST -HOLD CLUTCH ASSEMBL Y
@ NEEDLE BEARING @ 0-RING Replace.
@ COUNTERSHAFT REVERSE GEAR @ THRUST WASHER
@ REVERSE SELECTOR @ THRUST NEEDLE BEARING
@ REVERSE SELECTOR HUB ® NEEDLE BEARING
@ COUNTERSHAFT 4TH GEAR @) SUB-SHAFT 4TH GEAR
@ NEEDLE BEARING @) THRUST NEEDLE BEARING
@ DIST ANCE COLLAR, 28 mm Selectiva part @ SUB-SHAFT 4TH GEAR COLLAR
@ COUNTERSHAFT 2ND GEAR @ SUB-SHAFT
@ COTTER
@ NEEDLE BEARING
@) THRUST NEEDLE BEARING
@ COUNTERSHAFT 3RD GEAR @ OIL GUIDE PLATE Replace.
@ SNAP RING
@ NEEDLE BEARING
@ THRUST NEEDLE BEARING @) HOLDER BOL T
@ SPLINED WASHER Selectiva part @) WASHER
@ 3RD CLUTCH ASSEMBL Y @ REVERSE IDLER GEAR SHAFT SPRING
@ 0-RING Replace. @) REVERSE IDLER GEAR SHAFT HOLDER
@) REVERSE IDLER GEAR SHAFT
@ COUNTERSHAFT
@ SNAP RING @ STEEL BALL
@ THRUST WASHER @ REVERSE IDLER GEAR SHAFT SPRING
@ THRUST NEEDLE BEARING @) NEEDLE BEARING
@) MAINSHAFT 4TH/REVERSE GEAR ® DOWEL PIN
@ NEEDLE BEARING @) CHANGE COVER GASKET Replace.
@) CHANGE COVER
@ 4TH/REVERSE GEAR COLLAR @) HARNESS CLAMP
@ THRUST WASHER @ TRANSMISSION HANGER
@ 2ND/4TH CLUTCH ASSEMBL Y @ TRANSMISSION HOUSING
@ 0-RING Replace. @ TRANSMISSION HOUSING GASKET Replace.
@ DOWEL PIN
@ THRUST WASHER 36.5 x 51 mm
Select part
@ TRANSMISSION HOUSING SUB-SHAFT BEARING
@ TRANSMISSION HOUSING MAINSHAFT BEARING
@ TRANSMISSION HOUSING COUNTERSHAFT BEARING
@) MAINSHAFT 2ND GEAR
@ SNAP RING
@ NEEDLE BEARING
@ REVERSE IDLER GEAR
@ MAINSHAFT
@) CONTROL LEVER
@ DIFFERENTIAL ASSEMBL Y
@) T APERED BEARING INNER RACE

A 12 N·m ( 1.2 kg-m, 9 lb-ft) 6x 1.0 mm
B 14 N·m (1.4 kg-m, 10 lb-ft) 6x 1.0 mm Special bolt
e 22 N·m (2.2 kg-m, 16 lb-ft) 8 x 1.25 mm
E 55 N-m (5.5 kg-m, 40 lb-ft) 10 x 1.25 mm
H 27 N·m (2.7 kg-m, 20 lb-ft) 10 x 1.25 mm
14-369
lllustrated I
Tor ndex
que Convert er Housing/Valve Body
14-370
(D OIL FEED PIPE @ 2ND ACCUMULATOR BODY
@ DETENT BASE/ACCUMULATOR COVER @DOWEL PIN
@DOWEL PIN @ 2ND ACCUMULATOR SPRING
@ BAFFLE PLATE ® 0-RING Replace.
@MAGNET @ 2ND ACCUMULATOR PISTON
@SERVO BODY @ 0-RING Replace. .
(J) OIL FEED PIPE @ CONTROL SHAFT
@ THROTTLE CONTROL SHAFT @ROLLER PIN
@ E-RING @ROLLER
@) SERVO SEPARATOR PLATE @ROLLER
@SECONDARY VALVE BODY @WASHER
@ OIL FEED PIPE @ COTTER PIN Replace
@DOWEL PIN @ATF STRAINER Clean.
@ SECONDARY SEPARATOR PLATE @ TOROUE CONVERTER HOUSING COUNTERSHAFT NEE-
@LOCK-UP VALVE BODY DLE BEARING
@LOCK-UP SEPARATOR PLATE @OIL GUIDE PLATE Replace.
@ STOPPER @ LOCK-UP CONTROL SOLENOID VALVE ASSEMBLY
@TOROUE CONVERTER CHECK VALVE SPRING @) LOCK-UP CONTROL SOLENOID VALVE FILTER/GASKET
@TOROUE CONVERTER CHECK VALVE Replace.
@DOWEL PIN @ TORQUE CONVERTER HOUSING
@REGULATOR VALVE BODY @) MAINSHAFT BEARING
@ 0-RING Replace. @) OIL SEAL Replace.
@ STATOR SHAFT @ SHIFT CONTROL CABLE STAY
@ STOPPER SHAFT
@ OIL FEED PIPE
@ COOLER RELIEF VAL VE SPRING
@ COOLER RELIEF VAL VE
@ MAIN VALVE BODY
@ OIL PUMP DRIVEN GEAR SHAFT
@) OIL PUMP ORIVE GEAR
@ OIL PUMP DRIVEN GEAR
@MAIN SEPARATOR PLATE
@DOWEL PIN
Re~. No Torque Value Bolt Size Remarks

A 1 2 N•m ( 1. 2 kg-m, 9 lb-ft) 6 X 1.Q mm
e 22 N•m (2.2 kg-m, 16 lb-ft) 8 x 1.25 mm
14-371
lllustrated I n dex
Transfer Housmg
.
14-372
NOTE: The part composition of the transfer differs in the
models without ABS and with ABS.
• Common use: • Model without ABS

Model without ABS and model with ABS @ LOCK BOLT
(D TRANSFER REAR COVER @) LOCK WASHER Replace.
@ BEARING OUTER RACE @) SPECIAL BOL T
@ BEARING INNER RACE @ 2WO .... 4WO SELECTOR LEVER
@ OIL SEAL Replace. @ SELECTOR LEVER STA Y
@ COMPANION FLANGE @ 2WO .... 4WO SELECTOR CAM
@ OUST COVER @ 0-RING Replace.
(Z) OISC SPRING Replace @ TRANSFER SHAFT
@ ORIVEN SHAFT LOCKNUT Replace. @) NEEOLE BEARING Separate type
@ TRANSFER ORIVEN GEAR SHAFT @) TRANSFER SHAFT ORIVEN GEAR
@) BEARING INNER RACE @) SNAP RING
@ BEARING OUTER RACE @ SPRING RETAINER
@ TRANSFER SPACER @) RETURN SPRING
@) 0-RING Replace. @ TRANSFER SHAFT ORIVEN GEAR OIST ANCE COLLAR
@ ORIVEN GEAR THRUST SHIM Selective part @) ORIVE GEAR THRUST SHIM Selectiva part
@ OOWEL PIN @) 2WO 4WO SELECTOR
@ OOWEL PIN @) 2WO 4WO SELECTOR FORK
@ SPECIAL SEAL Replace.
@ TRANSFER HOUSING • Model with ABS
@ TRANSFER ORIVE GEAR
@) BEARING INNER RACE @> TRANSFER SHAFT /ORIVEN GEAR
@ BEARING OUTER RACE
@ 0-RING Replace.
@ TRANSFER THRUST SHIM Selective part
@ TRANSFER L. SIDE COVER
@ L. SIOE COVER PROTECTOR
@ OIL SEAL Replace.
® SET RING. 80 mm Selective part
@ BEARING OUTER RACE
@ BEARING INNER RACE
@:) OIL SEAL Replace.
@ OIL SEAL Replace.
@ NEEOLE BEARING
@ OIFFERENTIAL ASSEMBL Y

A 12 N·m (1.2 kg-m, 9 lb-ft) 6 x 1.0 mm
B 14 N·m (1.4 kg-m, 10 lb-ft) 6 x 1.0 mm Special Bolt
D 26 N·m (2.6 kg-m, 19 lb-ft) 8 x 1.25 mm
N 45 N·m (4.5 kg-m, 33 lb-ft) 10 x 1.25 mm
M 120-230 N·m Driven Gear Shaft Locknut
(12.0-23.0 kg-m, 87-166 lb-ft)
14-373
R. Side Cover
Remo val
NOTE:
• Clean all parts thoroughly in solvent or carburetor cleaner and dry with cornpressed air.
• When removing the transmission R. side cover, replace the following:
• R. side cover gasket
• Lock washers
• 0-rings
• Each shaft locknut
• Sealing washers
• Clean the old countershaft and sub-shaft locknuts, they are used when installing the parking gear and sub-shaft 1 st gear.
í''º'"
6 x 1.0 mm
R. SIDE COVER
1ST CLUTCH
R. SIDE COVER GASKET
MAINSHAFT LOCKNUT
Left-hand threads
PARKING BRAKE LEVER
/ PARKING BRAKE
n~~-- ~ /
/ PAWL COUNTERSHAFT
LOCKNUT
PARKING GEAR
~ ............. COUNTERSHAFT
~ 1STGEAR
SEALING WASHER
14-374
1. Remove the transmission mount bracket and stop- 7. Align the hole of the sub-shaft 1 st gear with the hole
per mount. of the transmission housing, then inserta pin to lock
the sub-shaft while removing the sub-shaft locknut.
2. Removethe 11 bolts securingthe R. side cover, then
remove the cover. 8. Remove the each shaft locknut.
3. Slip the special tool onto the mainshaft.
4. Engagethe parking brake pawl with the parking gear. '~-CHISEL
~LOCKTAB
MAINSHAFT
HOLDER
07923-6890202
9. Remove the special tool from the mainshaft after
removing the locknuts.
1 O. Remove the 1 st clutch, thrust washer, thrust nee-

dle bearing, needle bearing and 1 st gear from the
mainshaft.
11 . Remove the parking brake pawl.

MAINSHAFT
12. Remove the parking gear using a puller from the
countershaft as shown. Then remove the counter-
5. Pry the lock tabs of the mainshaft and countershaft shaft 1 st gear, needle bearing and 1 st gear collar.
locknuts.
13. Remove the sub-shaft 1 st gear using a puller from
NOTE: Cleanthe old countershaft locknut, it is used
the sub-shaft as shown.
when installingto pressthe parking gear on the coun-
tershaft.
6. Cut the lock tab of the sub-shaft lock-nut using a

chisel as shown.
CAUTION: Keep ali of the chiseled particles out of

the transmission.
NOTE: Clean the old sub-shaft locknut, it is used

when installing to press the parking gear on the
sub-shaft.
PARKING GEAR SUB-SHAFT 1 ST GEAR
:
14. Removethe thrust washer and 1 st gear collar from
STOPPER PIN
the mainshaft, and needle bearing and 1 st gear col-
lar from the countershaft.
1 5. Remove the parking brake pawl, spring, shaft, and

stopper from the housing.
1 6. Remove the parking brake lever from the control

shaft.
1 7. Removethe throttle control lever and spring from the

throttle control shaft.
18. Removethe ATF cooler pipes and ATF level gauge.
14-375
Transmlsslon Housing
Rernoval~---~~~~~~~~~~~~~~~~~~~~~~~~~~~
¡NSMISSION UNDERGUARO
CHANGE COVER
i I
CONTROL LEVER
COLLAR
~NEEDLE BEARING
..,....,........_ /SHIFT FORK
'DIFFERENTIAL
ASSEMBLY
14-376
NOTE: 7. Removethe reverse gear collar and needle bearing-
• Clean all parts thoroughly in solvent or carburetor from the countershaft.
• Blow out all passages. 8. Removethe lock bolt securing the shift fork, then
• When removing the transmission housing, replace the remove the fork with the reverse selector from the
following: countershaft.
• Transmission housing gasket
• Change cover gasket 9. Removethe mainshaft and countershaft together.
• Lock washer
1. Remove the transmission under guard.
2. Remove the change cover.
3. Remove the 1 bolt securing the control shaft rod, COUNTERSHAFT

then remove the control lever from the transmission
housing.
4. Remove the transmission housing mounting bolts.


HOUSING PULLER
CLUTCH 07HAC-PK40100
~~--.......íl . 1 O. Remove the differential assembly.
14-377
Torque Converter HousingNalve Body
Removal-
OIL FEED PIPE
íl íl¡
CONTROL SHAFT
/
6 x 1.0 mm
4 BOLTS
ATF STRAINER
14-378
NOTE:
• Clean ali parts thoroughly in solvent or carburetor
• When removing the valve body replace the following:
• 0-rings
• Lock washers
• Filter
• Cotter pin
1. Remove the oil feed pipes.
2. Remove the baffle plate.
3. Remove the 7 bolts securing the servo detent

base/accumulator cover, then remove the servo de-
tente base/accumulator cover.

5. Remove the secondary valve body and separator

plate.
6. Removethe 6 bolts securing the lock-up valve body,

then remove the lock-up valve body and separator
piate.
7. Removethe 1 bolt securing the regulator valve body,

then remove the regulator valva body and stopper.
8. Remove the stator shaft and stopper shaft.
9. Remove the cotter pin from the control shaft.
1 O. Removethe roller pin from the manual valve, then

remove the control shaft.
11. Removethe 3 bolts securing the 2nd accumulator

body, then remove the 2nd accumulator body.
12. Removethe 4 bolts securing the main valve body,

13. Removethe oil pump driven gear shaft, then remove

the oil pump gears.
14. Removethe main separator plate with the 1 dowel

pin.
1 5. Remove the A TF strainer.
14-379
Valve Caps
Description
stalled with the flat end toward the spring. end away from the spring. ·
Towardoutsideof valve body.

Towardoutsideof valvebody.
Towardspring. Towardspring.
spring guide.
Towardoutsideof valve body.
Towardspring.
Towardspring.
14-380
Valve Body
Repair
NOTE: This repair is only necessary if one or more of 5. Removethe # 600 paper and thoroughly wash the
bares. You may use this procedure to free the valves in pressed air.
the valve bodies.
6. Coat the valve with ATF then drop it into its bore.
1. Soak a sheet of # 600 abrasive paper in ATF far lt should drop to the bottom of the bore under its
about 30 minutes. own weight. lf not, repeat step 4, then retest.
r-VALVE

3. lnspect the valve far any scuff marks. use the A TF-
soaked # 600 paper to polish off any burrs that are
on the valve, then wash the valve in solvent and dry
it with compressed air.
4. Roll up half a sheet of ATF-soaked paper and insert

Twist the paper slightly, so that it unrolls and fits
the bore tightly, then polish the bore by twisting the
paper as you push it in and out.
CAUTION: The valve body is aluminum and doesn't

require much polishing to remove any burrs.
7. Remove the valve and thoroughly clean it and the

ATF-soaked valve body with solvent. Dry all parts with com-
# 600 abrasive
paper pressed air, then reassemble using A TF as a
lubricant.
14-381
Valve
Assembly
body. Push the spring in with a screwdriver, then in-
• lnstall the valve, valve spring and cap in the valve body stall the spring seat.
and secure with the roller.
ROLLER
VALVE BODY
14-382
• Set the valve spring in the valve and install it in the • lnstall the manual valve in the direction shown, then
valve body. Push the spring in with a screwdriver, install the spring with the detent rollers.
then install the spring seat.
MANUAL VALVE
lnstall in this direction.
SCREWDRIVER
• Set the spring in the valve and install in the valve

body.
lnstall the spring with a screwdriver, then install the
valve cap with the cutout aligned with the
screwdriver.
SCREWDRIVER
14-383
Main Valve Body
-----------------
NOTE:
• Check ali valves for free movement. lf any fail to slide freely, see Valve Body Repair on page 14-381.
• Coat ali parts with ATF before reassembly.
CAUTION: Do not use a magnet to remove the check halls, it may magnetize the halls.
CHECK BALLS
1-2 SHIFT VALVE 4 Pes.
VALVE CAP
FILTERS
Replace.
ORIFICE CONTROL
VALVE
,..__-.:;::~ 6 X 16
2-3 SHIFT VALVE ROLLER
RELIEF VAL VE
14-384
CHECK BALL
(Sectional View)
®----...
[l
Section C-C
4
SPRING SPECIFICATIONS Unit of length: mm (in)
Standard (New)
No Spring
Wire Dia. 0.D. Free Length No. of Coils
CD 2-3 shift valve spring 0.8 (0.031) 8.6 (0.339) 35.8 (1 .409) 10.6
@ 1 - 2 shift valve spring 0.9 (0.028) 8.6 (0.339) 40.4 (1 .591) 14.5
@ Orífice control valve spring 0.9 (0.028) 6.1 (0.240) 35.9 (1.413) 20.0
@ 3-4 shift valve spring 0.8 (0.031) 7.6 (0.299) 59.7 (2.350) 22.7
® Cooler relief valve spring 1.1 (0.043) 8.4 (0.331) 36.4 (1.433) 12.0
® Relief valve spring 1.0 (0.039) 8.4 (0.331) 52.0 (2.047) 23.0
14-385
Oil Pump
lnspection~~~~~~~~~~~~~~~~~~~~~~~~~~~~~-.
1. lnstall the pump gears and shaft in the main valve 2. lnstall the oil pump shaft and measurethe side clear-
body. ance of the drive and driven gears.
Purnp Gears Sida (Radial) Clearance:

0.240-0.266 mm
(0.009-0.010 in)
Driven gear
0.063-0.088
(0.002-0.003 in)
DRIVEN GEAR
-~Grooved and chamfered

side faces separator
piate.
/
::::::::::.
0--ii
ORIVE GEAR
lnspect teeth for
wear or damage.
3. Measure the thrust clearance of the driven gear·-to-

DRIVEN
¿R
main valve body.
1

SHAFT /
, ----rn ;z¿a
(0.001-0.002 in)
J!811 1 Service Limit: 0.07 mm (0.0028 in)
M A IN VALVE BODY
14-386
NOTE:
• Check ali valves for free movement. lf any fail to slide freely, see Valve Body Repair on page 14-381.
1. Hold the regulator spring cap in place while removing the lock bolt. Once the bolt is removed, release the spring
cap slowly.
2. Reassemblyis in the reverse order of disassembly.
NOTE:
• Align the hale in the regulator cap with the hole in the valve body, press the spring cap into the body and tighten
the lock bolt.
/
REGULATOR VALVE BODY
SLEEVE
SPRINGSPECIFICATIONS Unit of length: mm (in)
Standard (New)
No Spring
G) Regulator valve spring A 1.8 (0.071) 14.7 (0.579) 86. 5 (3.406) 16.5
@ Regulator valve spring B 1.8 (0.0711 9.6(0.378) 44.0 (1.732) 7.5
@ Stator reaction spring 5.5 (0.217) 31.9 (1.256) 30.3 (1.193) 2.1
@) Lock-up control valve spring 0.8 (0.031) 6.6 (0.260) 47.9 (1.886) 25.1
® Torque converter check valve spring 1.1 (0.043) 8.4 (0.331) 36.4 (1.433) 12.0
14-387
NOTE:
• Coat ali parts with A TF before reassembly.
CAUTION: Do not use a magnet to remove the check balls; it may magnetize the balls.
3
4-2 KICK-DOWN
VALVE CPC VALVE SPRING SEAT
CHECK BALLS
SLEEVE
2ND ORIFICE CONTROL

VAL VE
CAP
14-388
©
CHECK BALLS
SPRINGSPECIFICATIONS Unit of length: mm (in)
Standard (New)
No Spring
G) 2nd orífice control valve spring 0.8 (0.031 l 6.6 (0.260) 38.5 (1.516) 28.0
@ 4-2 kick-down valve spring 0.9 (0.035) 6.4 (0.252) 42.7 (1.681) 20.8
@ CPC valve spring 1.4 (0.055) 9.4 (0.370) 31.6 (1.244) 10.9
© Modulator valve spring 0.9 (0.035) 8.6 (0.339) 18.2 (0.717) 5.54
® 4-3 kick-down valve spring 0.9 (0.035) 6.4 (0.252) 42. 7 (1.681 l 20.8
® Servo control valve spring 1.0 (0.039) 8.1 (0.319) 42.0 (1.654) 16.5
(J) 4th exhaust valve spring 0.9 (0.035) 6.6 (0.260) 37 .o ( 1 .457) 18.7
14-389
Servo Body
Disassembly/lnspection/Reassembly-----------------
NOTE:
• Coat all parts with A TF befo re reassembly.
1ST ACCUMULATOR PISTON
1ST ACCUMULATOR PISTON

5 X 0.8 mm
8 N·m
1 ST -HOLD ACCUMULA TOR
(0.8 kg-m, 6 lb-ft)
PISTON
hl_
MAGNET 6 x 1.0 mm
.-/12 N·m
SLEEVE
&iJ (1.2 kg-m. 9 lb-ftl
BAFFLE PLA TE
<> THROTTLE ADJUSTING BOL T
<,
3RD ACCUMULATOR PISTON ~
Do not remove and adjust.
SERVO VALVE/SHIFT FORK

SHAFT
0-RINGS
Replace.
14-390
Standard (New)
No. Spring
CD Throttle valve B spring 1.6 (0.063) 8.5 (0.335) 41.3 (1.6261 13.9
@ Throttle valve B adjusting spring 0.8 (0.031) 6.2 (0.244) 30.0 (1.181) 8.0
@ 4th accumulator spring 3.5 (0.138) 18.6 (O. 732) 77.0 (3.031) 11.0
@ 3rd accumulator spring 2.8 (0.110) 15.5 (0.610) 78. 7 (3.098) 15.0
® 1 st-hold accumulator spring 3.2 (0.126) 24.3 (0.957) 59.5 (2.343) 5.8
® 1 st accumulator spring 2.0 (0.079) 13. 7 (O. 539) 71.3 (2.807) 11.0/8.0
14-391
Lock-up Valve Body
NOTE:
• Clean all parts thoroughly in solvent or carburetor cleaner and drv with compressed air.
• Check all valves for free movement. lf any fail to slide freely, see Valve Body repair on page 14-381.
• Coat all parts with ATF before reassembly.
LOCK-UP SHIFT VALVE
ROLLER
Standard (New)
No. Spring
CD Lock-up shift valve spring 1.1 (0.043) 8.1 (0.319) 51.0 (2.001) 21.3
@ Lock-up timing valve spring 0.9 (0.035) 5.6 (0.220) 43.6 (1.717) 30.1
14-392
2nd Accumulator Body
· Disassembly/lnspection/Reassembly------------------.
NOTE:
• Coat all parts with ATF before reassembly.
2ND ACCUMULATOR BODY
.:
G) 2ND ACCUMULA TOR SPRING
0-RING
Replace.
2ND ACCUMULATOR PISTON
~0-RING
Replace.
Standard (New)
No. Spring
Wire Dia. 1 O.D. I Free Length \ No. of Coils
CD 2nd accumulator spring 2.7 (0.106) 1 16.1 (0.634) 1 88.4 (3.480) 1 16.0
14-393
Mainshaft
NOTE:
• Lubricate all parts with A TF during reassembly.
7
NEEDLE BEARINGS
cessive wear or 4TH/REVERSE

damage. / GEAR COLLAR
Check bearing surface
or excessive wear. / THRUST NEEDLE
>' BEARING
THRUST SHIM
36 x 51 mm
THRUST NEEDLE
Selective part
BEARING
2ND GEAR
__.,... SEALING RING,
~ 35mm NEEDLE BEARING
THRUST NEEDLE
SEALING RING, 'E!'l;llitflt~~~M---- BEARING
29mm
NEEDLE BEARING
SET RING
14-394
lnspection
• Clearance Measurement 3. Torque the mainshaft locknut to 30 N·m (3.0 kg-m,

22 lb-ft).
l. Removethe mainshaft bearingfrom the transmission

housing (see page 14-413).

inspecting.
LOCKNUT
LOCKNUT 30 N•m
(3.0 kg-m, 22 lb-ft)
THRUST WASHER
4. Hold the 2nd gear against the 2nd clutch.
1 ST GEAR COLLAR Measure the clearance between the 2nd gear and
the 3rd gear with a feeler gauge.
BEARING
THRUST SHIM and take the average as the actual clearance.
4TH/REVERSE GEAR
COLLAR STANDARD: 0.05-0.13 mm (0.002-0.005 in)
"""ª""''-~- THRUST SHIM
2ND/4TH CLUTCH
ASSEMBLY 3RD GEAR 2ND GEAR
THRUST WASHER.
36.5 x 51 mm
Selective
2ND GEAR
NEEDLE BEARING
FEELERGAUGE 2ND CLUTCH

MAINSHAFT
THRUST WASHER,
36.5 x 51 mm
~---=~
¡~L-LL..L.
(cont'd)
14-395
Mainshaft
lnspection (cont'd)

1 90441-PC9-01 O 3.50 mm (0.138 in)
2 90442-PC9-01 O 3. 55 mm (O. 140 in)
3 90443-PC9-01 O 3.60 mm (O. 142 in)
4 90444-PC9-01 O 3.65 mm (O. 144 in)
5 90445-PCS-01 O 3. 70 mm (O. 146 in)
6 90446-PC9-01 O 3. 75 mm (O. 148 in)
7 90447-PC9-010 3.80 mm (O. 1 50 in)
8 90448-PC9-01 O 3.85 mm (O. 1 52 in)
9 90449-PC9-01 O 3.90 mm (O. 1 54 in)
7. After replacing the thrust washer, make sure the

14-396
Countershaft
NOTE:
• Lubricate ali parts with A TF before reassembly.
• lnstall thrust needle bearings with unrolled edge ofbearing retainer facing washer.
• lnspect thrust needle and needle bearings for gallingand rough movement.
• Before installing the 0-rings, wrap the shaft splineswith tape to prevent damaging the 0-rings.
LUCKNUT
23 x 1.25 mm
140 - O - 140 N·m
(14.0 - O - 14.0 kg-m.
101 - O - 101 lb-ftl
~=::-!.,d...,...-- REVERSE GEAR PARKING GEAR

COLLAR
i---- NEEDLE BEARING ONE-WAY CLUTCH
ASSEMBLY
REVERSE GEAR
1ST GEAR
REVERSE
SELECTOR HUB
NEEDLE BEARING
4TH GEAR
NEEDLE BEARING
TRANSMISSION
DISTANCE COLLAR. 28 mm HOUSING BEARING
Selective part
2ND GEAR
THRUST NEEDLE
COTTERS BEARING
3RD GEAR
NEEDLE BEARING
SPLINED WASHER
Selective part
0-RINGS
Replace.
COUNTERSHAFT
Check splines for excessive wear or damage.
Check bearing surface for scoring, scratches or
excessive wear.
14-397
Countershaft
lnspection
• Clearance Measurement 3. Torque the countershaft locknut to 30 N·m (3.0 kg-

rn, 221b-ft).
NOTE: Lubricateall parts with ATF during assembly.
1. Removethe countershah bearing from the transmis-

NOTE: Do not assemble the 0-rings while in-

specting.
LOCKNUT
PARKING GEAR/1ST GEAR

/
-""-'"'--/. ONE-WA Y CLUTCH ASSEMBL Y
NEEDLE BEARING 4. Measurethe clearancebetween the 4th gear and the

reverse selector hub with a feeler gauge.
1 ST GEAR COLLAR
REVERSE GEAR o O O~ ~
COLLAR ~ , ~ TRANSMISSION HOUSING NOTE: Take measurements in at least three places
""J BEARING and take the average as the actual clearance.
_/REVERSE SELECTOR HUB STANDARD: 0.05-0.13 mm (0.002-0.005 in)

~ 4TH GEAR
4TH GER REVERSE
NEEDLE BEARING SELECTOR
HUB
\
l.
..-3RD CLUTCH ASSEMBLY
I
DIST ANCE COLLAR,
28mm
4TH GEAR
\ REVERSE
. SELECTOR
HUB
14-398
from step 4 between the 4th gear and reverse the thickness and/or the width.
selector hub.
-1 . Measure the clearance with the 3rd gear recheck.
-2. Measure the clearance with the 3rd gear DISTANCE COLLAR 28 mm
pushed towards the 2nd gear.
NOTE: Take measurements in at least three places 1 90503-PC9-000 39.00 mm (1.535 in)
and take the average as the actual clearance. 2 90504-PC9-000 39.10 mm (1.539 in)
- 3. Subtract the measurements of step 2 from

3 90505-PC9-000 39.20 mm (1.543 in)
step 3 and you have the clearance between 4 90507-PC9-000 39.30 mm (1.547 IN)
the 3rd gear and 2nd gear. 5 90508-PCS-OOO 38.05 mm ( 1. 537 in)
STANDARD: 0.05-0.13 mm (0.002-0.005 in) 6 90509-PC9-000 39.15 mm (1.541 in)

7 90510-PC9-000 39.25 mm (1.545 in)
4TH GEAR 8 90511-PC9-000 38.90 mm (1.531 in)

9 90512-PC9-000 38.95 mm (1.533 in)


recheck.
SPLINEDWASHER35 x 52 mm
I
1 90411-PA9-010 3.00 mm (O. 118 in)
3RD CLUTCH
2 90412-PA9-01 O 3.05 mm (O. 120 in)
ASSEMBLY
3 90413-PA9-010 3.10 mm (0.122 in)
4 90413-PA 19-010 3.10 mm (0.122 in)
SPLINED WASHER 5 90415-PA9-01 O 3.20 mm (0.126 in)
6 90418-PA9-000 3.25 mm (0.128 in)
7 90419-PA9-000 3. 30 mm (O. 1 30 in)
I
DISTANCE COLLAR,
8
9
90420-PA9-000
90421-PA9-000
3.35 mm (0.132 in)
3.40 mm (0.134 in)
28mm 10 90423-PA9-000 2.90 mm (0.114 in)
11 90424-PA9-000 2.95 mm (O. 116 in)

14-399
One-way Clutch/Parking Gear
Disassemblyand lnspection
1. Separate the countershaft 1 st gear from the park- lnspect the parts as follows:
shown.
PARKING GEAR
lnspect tlie one-way

----·r
faulty movement.
lnspect the counter-

2. Remove the one-way clutch by prying it up with the shaft 1 st gear for wear
end of a screwdriver. or scoring.
COUNTERSHAFT ONE-WAY CLUTCH

1ST GEAR NOTE: Instan in this
direction.

PARKING GEAR
14-400
Sub-shaft
NOTE:
• Lubricate all parts with ATF before reassembly.
1. Removethe snap ring and guid plate.
2. Removethe sub-shaft, 1 st-hold clutch assembly and 4th gear assembly.
3. Assemble the sub-shaft in the reverse order of removal.
1ST-HOLD CLUTCH
__.- ASSEMBL Y
SUB-SHAFT
Check splines for excessive
wear or damage.
Check bearing surface for scoring,
scratches or excessive
wear.
NEEDLE BEARING / ~
GUIOE
PLATE/'
SNAP RING
- 4TH GEAR COLLAR
14-401
Clutch
lllustrated lndex
1ST CLUTCH
3RD CLUTCH
t
CLUTCH DRUM
TCH PLATES
CLU d thickness:
Standar (O 079 in)
2.0mm .
14-402
2ND/4TH CLUTCH
CH DISCS
CLUT d thickness:
Standar (O 076 in)
1.94 mm .
RETURN SPRING
H PLATES
CLUTC d thickness:
Standar (O 079 in)
2.0 mm .
/
SNAP RING
'U~
H DISCS
CLUTC hickness: /
Standard t 076 in) CIRCLIP \NG
SPRI RETAINER
1.94 mm (O. (cont'd)
14-403
Clutch
lllustrated I ndex (cont' d)
1ST-HOLD CLUTCH
CLUTCH END PLATE

SNAP RING
TCH PLATES
CLU hickness:
Standard(O
t 079 in)
2.0mm .
LUTCH DISCS .
e d thickness.
Standar (O 076 in)
1.94 mm .
14-404
Clutch
Disassembly
1. Remove the snap rings, then remove the clutch end 3. lnstall the special tools as shown.
plate, clutch discs and plates. CLUTCH SPRING
COMPRESSOR SET
07LAE-PX40000 CLUTCH SPRING
COMPRESSOR
I
ATTACHMENT
07LAE-PX40100
SCREWDRNER
CLUTCH SPRING
COMPRESSOR
ATTACHMENT
-----, / 07HAE-PL50100
2. Bernove the disc spring.
NOTE: For 1 st-hold, and 2nd clutches
CLUTCH SPRING
COMPRESSOR
BOLT ASSEMBLY
07GAE-PG40200
CLUTCH SPRING
COMPRESSOR
/ /ATTACHMENT
," 07HAE-PL50100
CLUTCH SPRING
COMPRESSOR
BOLT ASSEMBL Y
07GAE- PG40200
(cont'd)
14-405
Clutch
Disassembly (cont' d)
CAUTION: lf either end of the compressor attachment 5. Rernovethe circlip. Then remove the special tools,
damaged.
CIRCLIP
4. Compress the clutch return spring. 6. Wrap a shop towel around the clutch drum and ap-
ply air pressure to the oil passage to rernove the
piston. Placea finger tip on the other end while ap-
CLUL TCH SPRING plying air pressure.
COMPRESSOR
BOL T ASSEMBL Y
07GAE-PG40200
COMPRESSED AIR
OIL PASSAGE HOSE NOZZLE
14-406
Reassembly
NOTE: 4. lnstall the pistan in the clutch drum. Apply pressure

• Clean all parts tharoughly in salvent or carburetor and rotate to ensure proper seating.
• Blow out all passages. NOTE: Lubricate the pistan 0-ring with ATF befare
• Lubricate all parts with ATF befare reassembly. installing.
1. lnspect far a loase check valve. CAUTION: Do not pinch 0-ring by installing the
piston with force.
CHECK VALVE
PISTON
2. lnstall a new 0-ring on the clutch pistan.
3. Be sure that the disc spring is securely staked. CLUTCH DRUM
NOTE: Far 1 st. 3rd and 4th clutches.

RETAINER CIRCLIP
RETURN SPRING
(cont'd)
14-407
Clutch
CLUTCH SPRING ment is set over an area of the spring retainer
COMPRESSOR SET which is unsupported by the retainer spring, the re-
07LAE-PX40000 tainer may be damaged.
CLUTCH SPRING
/ COMPRESSOR
/ A TT ACHMENT
07LAE-PX40100
CLUTCH SPRING
.,,,,,,,....-- COMPRESSOR
ATTACHMENT
07HAE-PL50100

CLUTCH SPRING
COMPRESSOR
BOLT ASSEMBL Y
07GAE-PG40200
-~--, ,,,.,.-- CLUTCH SPRING

COMPRESSOR
ATTACHMENT
07HAE-PL50100
CLUTCH SPRING
COMPRESSOR
BOLT ASSEMBL Y
07GAE- PG40200
14-408
8. lnstall the circlip. 11. Soak the clutch discs thoroughly in A TF for a
mínimum of 30 minutes.

NOTE: Befare installing the plates and discs, make

sure the inside of the clutch drum is free of dírt or
other foreígn matter.
CIRCLIP
9. Remove the special tools.
NOTE:
• For 1 st-hold and 2nd clutches. DISCS ANO PLATES END PLATE
SCREWDRIVER
1 ST-HOLD CLUTCH
(cont'd)
14-409
Clutch
Reassembly (contd) --------------------------.
14. Measure the clearance between the clutch end 15. lf the clearance is not within the service limits,
end plate moves is the clearance between the NOTE: lf the thickest clutch and plate is installed,
clutch end plate and top disc. but the clearanceis still over the standard, replace
NOTE: Measure at three locations.
End Plate-to-Top Disc Clearance: 1ST, 2ND, 3RO and 4TH CLUTCH
Clutch Service Limit Plate No. Part Number Thickness

1 st 0.65-0.85 mm (0.026-0.033 in) 1 22551-PC9-000 2.4 mm (0.094 in)
2nd 0.65-0.85 mm (0.026-0.033 in) 2 22552-PC9-000 2.5 mm (0.098 in)
3rd 0.40-0.60 mm (0.016-0.024 in) 3 22553-PC9-000 2.6 mm (0.102 in)
4th 0.40-0.60 mm (0.016-0.024 in) 4 22554-PC9-000 2.7 mm (0.106 in)
1 st-Hold 0.50-0.80 mm (0.020-0.031 in) 5 22555-PC9-000 2.8 mm (0.110 in)
6 22556-PC9-000 2.9 mm (O. 114 in)
7 22557-PC9-000 3.0 mm (0.118 in)
8 22558-PC9-000 3.1 mm (0.122 in)
9 22559-PC9-000 3.2 mm (0.126 in)
10 22560-PC9-000 3.3 mm (0.130 in)
11 22561-PC9-000 2.1 mm (0.082 in)
12 22562-PC9-000 2.2 mm (0.086 in)
13 22563-PC9-000 2.3 mm (0.090 in)
1 ST-HOLD CLUTCH

1 22551-PS5-003 2. 1 mm (0.082 in)
2 22552-PS5-003 2.2 mm (0.086 in)
3 22553-PS5-003 2.3 mm (0.090 in)
4 22554-PS5:-003 2.4 mm (0.094 in)
No Mark 22555-PS5-003 2.5 mm (0.098 in)
6 22556-PS5-003 2.6 mm (0.102 in)
7 22557-PS5-003 2. 7 mm (O. 106 in)
. .~~-----------1
PLATE NUMBER
Thickness
,.., 1 -
t
ENDPLATE
14-410
Mainshaft Bearing Replacement
1. Remove the mainshaft bearing and oil sealusing the 3. lnstatl the new oíl seal flush with the housing using
special tools as shown. the special tools as shown.
DRIVER
07749-0010000
ADJUST ABLE BEARING

REMOVER SET ATTACHMENT, 72 x 75 mm
07 JAC-PHSOOOO 07746-0010600
2. Orive in the new mainshaft bearing until it bottoms

in the housing, using the special tools as shown.
DRIVER
07749-0010000
07746-0010500
14-411
Countershaf'lt Bearing Replacement Transfer Shaft Bearing Replacement
1. Remove the countershaft bearing using the special 1. Remove the transfer shaft bearing.
too l.
ADJUSTABLE BEARING
REMOVER SET
()7JAC-PH80000
2. Replace the oil guide plate.

2. Drive the new bearing flush with the housing.
3. Drive the new bearing into the housing using the spe-
cial tools as shown.
DRIVER
07749-0010000
DRIVER
07749-0010000
0-0.03 mm
(0.001 in)
OIL GUIDE PLATE

Replace.
14-412
Transmission HouslnqBearinqs
Mainshaft/Countershaft Bearing Replacement
1. To remove the mainshaft and countershaft bear- 2. Expand each snap ring with snap ring pliers, insert
ing out using the special tools and a press as bearing with the groove facing outside the housing.
shown.
NOTE: Coat all parts with ATF.
SNAP RING PLIERS

07LGC-0010100
PRESS~
DRIVER
07749-0010000
ATTACHMENT
/ • MAINSHAFT
ATTACHMENT,
72 x 75 mm
07746-0010600
/
r---'---1--__. .......... _, • COUNTERSHAFT
ATTACHMENT,
62 x 68 mm
07746-0010500
COUNTERSHAFT
BEARING

MAINSHAFT BEARING ing grooves.
DRIVER
07749-0010000 • The ring end gap is correct.
ATTACHMENT
• MAINSHAFT
ATTACHMENT,
72 x 75 mm
END GAP: 0-7 mm
07746-0010600
(0-0.28 in)
_ __. __._...../ • COUNTERSHAFT
ATTACHMENT,
62 x 68 mm
07746-0010500
TRANSMISSION
HOUSING
14-413
Sub-shaft Bearing Replacement
1. To remove the sub-shaft bearing from the transmis- 2. Expandthe snap ring with snap ring pliers, insert
sion housing, expand the snap ring with snap ring the new bearing part-way into the housing using
pliers, then push the bearing out using the special the special tools and a press as shown. lnstall the
tools and a press as shown. bearing with the groove facing outside the housing.
NOTE: Do not remove the snap ring unless its NOTE: Coat all parts with ATF.
necessary to clean the groove in the housing.
3. Releasethe pliers, then push the bearing down into
PRESS~
DRIVER
~07749-0010000
ATIACHMENT,
62 x 68 mm
07746-0010500
62 x 68 mm 4. After installing the bearing verify the following:

07746-0010500
ing grooves.
DRIVER
~07749-0010000
ATTACHMENT,
2 x 68 mm
END GAP: O- 7 mm
07746-0010500 (0-0.28 in)
\ TRANSMISSION
HOUSING
SNAP RING
14-414
Transfer Shaft
Sub-shaft Bearing Bearing Outer Race
Replacement ·------------. Replacement-----------,
1. Remove the subshaft bearing 1. Removethe transfer bearing outer race.
ADJUSTABLE
BEARING ADJUSTABLE
REMOVER SET BEARING
07JAC-PH80000 REMOVER SET
07JAC-PH80000
2. Orive in the new bearing until it bottoms in the 2. Orive in the new bearing outer race until it bottoms
housing. in the housing.
NOTE: The bearinginner race and outer race should

be replaced as a pair.
DRIVER
07749-0010000
DRIVER
07749-0010000
ATTACHMENT
37 x 40 mm
07746-0010200
ATTACHMENT
37 x 40 mm
07746-0010200
14-415
Reverse ldler Gear
lnstallation
1. Assemble the reverse id/e bearing holder. 5. Tighten the reverse idler bearing holder bolts.
NOTE: Align the hole in the shaft with the spring. 6. lnstall the spring and the tighten the retaining bolt
and washer.
6 x 1.0 mm
REVERSE IDLER BEARING HOLDER
/
12 N·m 11.2 kg-m, 9 lb-ftl
RETAINING
BOLT IDLER BEARING
27 N ·m (2. 7 kg-m, 20 lb-ftl HOLDER
WASHER
2. lnstall the reverse idler gear.
NOTE: lnstall the reverseidler gear so that the larger

chamfer on the shaft bore faces the torque converter
housing.
STEEL BALL
lnspect teeth for wear.
Chamfered end
3. lnstall the needle bearing into the idle gear.
4. lnstall the reverse idler bearing holder into the trans-

mission housing.
14-416
Transfer
lnspection
1. Shift the disengagement lever to 2WD.
MIDDLE BOLT
4WD DISENGAGED
2. Check the backlash at the companion flange with

a dial indicator; measureas shown, them rotate the
flange 180° and measure again.
Standard: 0.10-0.15 mm (0.004-0.006 in.)
DIAL INDICATOR
Long
Side
COMPANION
FLAN GE
3. lf the backlash is outside the specifications, ad-

just as per the instruction described on page
14-430.
14-417
Transfer
Gear Tooth Contact
1. Shift the disengagement lever to 2WD. 7. lf the tooth contact is correct, reassemble the drive
and driven gear as follows.
2. Removethe transfer drive and driver gear assembly.
ORIVE GEAR NOTE:
• Replacethe 0-ring with a new one.
ORIVE GEAR • Coat the 0-ring with oil.
THRUST SHIM • Apply liquid gasket (P/N OY740-99986) to
threads of L. side cover attaching bolts.
L. SIOE COVER
~
Apply liquid gasket.
(P/N OY740-99986)
f
Replace.
ORIVEN GEAR
L.SIOE COVER THRUST SHIM
PROTECTOR
3. Apply PrussianBlue evenly to the driven gear teeth.
4. Reinstall the gear and tighten the mouting bolts to

the correct torque.
5. Turn the companion flange back and forth severa!

times, then remove the driven gear assembly and in-
spect the pattern on the gear's teeth.
26 N·m (2.6 kg-m. 20 lb-ftl
12 N·m
(1.2 kg-m, 9 lb-ftl
GOOO CONT ACT
6. lf the contact pattern is notas shown, correct it ac-

cording to the instructions on page 14-430.
14-418
L. Side Cover Race Replacement Transfer Orive Gear Disassembly
1. Removethe drive gear bearing race with a bearing 1. Slide the driven gear assembly into the torque con-
puller as shown. verter housing and secure with the six bolts.
26 N·m 12.6 kg-m. 20 lb-ftl
2. Raisethe locknut tab from the groove of the driven

2. lnstall the new race with the specialtools as shown. gear shaft.
3. Hold the companion flange with the specialtool and

remove the locknut with a 32 mm socket.
ATTACHMENT
62 x 68 mm
07746-0010500
TRANSFER
·ORIVEGEAR L. SIDE COVER
BEARING RACE
(O.D. 62 mm)
SOCKET /
WRENCH HANDLE FLANGE HOLDER
07907 - 6010300 07926-5090000
(cont'd)
14-419
Transfer
Transfer Driven Gear Disassembly (cont'd)
4. Removethe driven gear from the transfer rear cover 6. Pry the oil seal off the transfer rear cover.
by tapping the driven gear shaft
DRIVEN GEAR SHAFT
7. Remove the bearing race from the transfer rear

cover.
DRIVEN GEAR
OUTER DRIVEN
5. Removethe inner driven gear bearingfrom the driven
GEAR BEARING RACE
gear shaft. (O.D. 58 mm)
8. Remove the bearing race from the transfer rear

DRIVEN GEAR cover.
SHAFT
INNER DRIVEN
GEAR BEARING
(I.D. 35 mm)
14-420
Driven Gear Pre-load
NOTE: Cleanali tools and parts thoroughly in solvent and 4. Slide the inner driven gear bearing onto the special
dry with compressed air. tools.
lnstall the special tools with bearing into the rear
1. Press the inner driven gear bearing race into the cover.
transfer rear cover with the special tools as shown.
ATTACHMENT
62 x 68 mm
07746-0~IP?':~""7~~,-r.,.,.. TRANSFER REAR

COVER
OUTER DRI~~~
GEARBEAR~
rr=n / COMPANION FANGE
r<i= SPRINGWASHER
2. Press the outer driven gear bearing race into the

transfer rear cover with the special tools as shown.
CJ q:::p\RIVENS SHAFT LOCKNUT
5. lnstall the outer driven gear bearing, companion

flange, spring washer and driven shaft locknut.
NOTE:
ATTACHMENT • Use a new driven shaft locknut.
• Do not assemble the oil seal.
• Take care the spring washer direction.
3. Coat the races with clean oíl.
(cont'dl
14-421
Transfer
Driven Gear Pre-load (cont'd) Adjustment/Reassembly,
(Thrust Shim Selection)
6. lnstall a screw driver into the special tool and then 1. lnsert the threaded shaft/driven gear rear cover as-
torque the locknut to 1 O N·m (1.0 kg-m, 7 lb-ft). sembly into the transfer housing.
NOTE: The pre-load must be properly adjusted be-

DRIVEN GEAR
DUMMY SHAT
fore selecting shims. See page 14-421.
07KAJ-PS50100
SCREW DRIVER 2. Removethe drive gear bearingwith a bearing puller.
....___LOCKNUT ORIVE GEAR

BEARING
1 O N ·m ( 1 .O kg-m, 7 lb-ftl
3. Lubricate the drive gear bearing with clean oil then

7. Measure the driven pinion preload.
install it on the Orive Gear Gauge. Slide the bearing
NOTE: Before measuring the preload, turn the
andqauqe onto the transfer shaft.
threaded shaft severa! times to seat the bearing.
NOTE:
• Do not install the drive gear thrust shim.
Standard: 0.5-0.8 N·m (5.0-8.0 kg-cm,
• Pul!the Rearcover assembly out slightly to allow
4.3-6.9 lb-in)
the drive gear gauge to seat.
TRANSFER
SHAFT
- ----~-~-.
F -
ORIVE GEAR GAUGE
07JAJ-PH80100
ORIVE GEAR BEARING
8. lf the preload is outside the above limits, re-

adjust by turning the locknut.
NOTE: Do not overtighten the locknut.
14-422
6. The correct rear cover shim thickness is determined
by recording the clearancebetween the transfer rear
ORIVE GEAR GAUGE cover and the transfer case, then adding or sub tract-
07JAJ-PH80100
ing the machining tolerance, which is etched in to
the driven gear.
NOTE: The plus ( +) or minus ( - ) number given as
machining tolerance representshundredths of a mil-
limeter.
Example:
• Clearance measured in Step 5: 1.08 mm
(+2)
Corrected driven gear thrust shim thickness:

1.08 + 0.02 mm= 1.10 mm
Example:
• Machining tolerarice etched in the driven gear:
(-3)
Corrected driven gear rear cover shim thickness:

1.08 - 0.03 mm = 1.05 mm
Etched mark
Thicknass mark
4. lnstall L. side cover without the bolts.

5. To determine driven gear thrust shim thickness,
measure the clearance between the transfer rear
cover and transfer case with a feeler gauge, then
record the clearance.
NOTE: The clearance should be taken while press-

ing the dummy shaft ali the way in.
DRIVEN GEAR THRUST SHIM:
Part No. Thickness

29481-PHB-OOO 0.50 mm (0.020 in.)
29482-PH8-000 0.85 mm (0.033 in.)
29483-PHS-000 0.90 mm (0.035 in.)
29484-PHB-OOO 0.95 mm (0.037 in.)
29485-PHS-000 1 .00 mm (0.039 in.)
29486-PHS-OOO 1 .05 mm (0.041 in.)
29487-PHB-OOO 1.10 mm (0.043 in.)
29488-PHB-OOO 1.15 mm (0.045 in.)
29489-PHB-000 1 .20 mm (0.047 in.)
29491 -PH8-000 1 .25 mm (0.049 in.)
29492-PHB-000 1.30 mm (0.051 in.)
FEELER GAUGE
(cont'd)
14-423
Transfer
Adjustment/Reassembly (Thrust Shim Selection) (cont'd)
7. To determine the left side cover shim thickness · TOLERANCE MARK THICKNESS MARK
measurethe clearancebetween the transfer L. side
cover and transter case with a feeler gauge, and
record the clearánce.
NOTE: The clearance should be measured while

pressing the L. side cover ali the way against the
transfer case.
ORIVE GEAR TRANSFER GEAR THRUST

SHIM
TRANSFER GEAR THRUST SHIM:
Part No. Thickness

29461-PS5-000 0.30 mm (0.012 in.)
29462-PS5-000 1.00 mm (0.033 in.)
29463-PS5-000 1.03 mm (0.041 in.)
29464-PS5-000 1.06 mm (0.042 in.)
L. SIDE COVER
29465-PS5-000 1.09 mm (0.043 in.)
29466-PS5-000 1. 12 mm (0.044 in.)
8. The correct shim thickness is determinedby record- 29467-PS5-000 1. 15 mm (0.045 in.)
ing the clearancebetween the transfer caseand the 29468-PS5-000 1.18 mm (0.046 in.)
left side cover, then adding ar subtracting the 29469-PS5-000 1.21 mm (0.048 in.)
machining tolerance, which is etched into the drive 29471-PS5-000 1.24 mm (0.049 in.)
gear. 29472-PS5-000 1.27 mm (0.050 in.)
29473-PS5-000 1.30 mm (0.051 in.)
Example: 29474-PS5-000 1.33 mm (0.052 in.)
• Clearancemeasured in Step 7: 1.04 mm
• Machining tolerance etched on drive gear: ( + 2) 9. Pressthe drive gear bearing on the drive gear.
Corrected transfer thrust shim thickness:
1 .04 + 0.02 mm = 1 .06 mm
Example:
• Clearancemeasured in Step 7: 1.04 mm
• Machining tolerance etched on drive gear: ( - )
Corrected transfer thrust shim thickness: DRIVER 40 mm I.D.
1.04 - 0.01 mm= 1.03 mm 07746-0030100
INNER TAPER
BEARING
14-424
10. lnstall two 1. 75 mm "dummy shim" (P/N 13. Subtract the clearancemeasuredin Step 13 from 3. 5
2941 5- PH8000) on the transfer shaft. mm (2 dummy shims) to obtain the corrected shim
Slide the drive gear onto the transfer shaft. thickness.
Example:
• Clearance measured in Step 1 3:
1.57 mm
• Thickness of dummy shims:
3.5 mm
\
ORIVE GEAR
Corrected drive gear thrust shim:
3.5-1.57 mm
Thickness: 1.93 mm
ORIVE GEAR THRUST SHIM:
Part No. Thickness

29411-PH8-000 0.48 mm (0.019 in.)
29412-PH8-000 1.57 mm (0.062 in.)
29413-PH8-000 1.63 mm (0.064 in.)
29414-PH8-000 1.69 mm (0.067 in.)
29415-PH8-000 1. 75 mm (0.069 in.)
\ TRANSFER THRUST SHIM
29416-PH8-000 1.81 mm (0.071 in.)
29417-PH8-000 1.87 mm (0.074 in.)
L. SIDE COVER
29418-PH8-000 1.93 mm (0.076 in.)
29419-PH8-000 1.99 mm (0.078 in.)
14. Remove "dummy shim" and install L. side cover.

11 . Place the shim selected in Step 7 on the L. side
cover, and install the cover on the transfer case NOTE: After the thrust shim selection check the
without bolt. proper backlash and tooth contact pattern. See
pages 14-429 through 14-431.
12. Measurethe clearancebetween the L. side cover and
transfer case while pushing against the L. side cover.
and record the clearance.
14-425
Transfer
Driven Gear Reassembly
1. Removethe specialtool from the transfer rearcover. 5. Press the inner driven gear bearing on the driven
gear.
DRIVEN GEAR
DUMMY SHAFT
07KAJ-PS50100
DRIVER 40 mm I.D.
07746-0030100
TRANSFER REAR
,COVER INNER TAPER
BEARING
~~ COMPANION FLANGE
...,,,,,_. ~
~ q::=p. - SPRING WASHER
...____ LOCKNUT
2. lnstall the outer driven gear bearing in the transfer

rear cover.
6. lnstall the following parts in the transfer rear cover:

• Driven gear
• Transfer spacer (new spacer)
OUTER DRIVEN • Companion flange
GEAR BEARING
• Spring washer
• Driven gear locknut
NOTE: lnstall the spring washer with the dishedside

toward the companion flange.
3. Press the oil seal into the transfer rear cover.
DRIVER
07749-0010000
DRIVEN GEAR
14-+---TRANSFER
SPACER
OIL SEAL
~ - COMPANION
~ FLAN GE
4. Coat the maín and side sealinglips of the oil seal with
grease.
_ -fiiiim
LOCKNUT
14-426
7. Ternporarily install the driven gear assernbly and 9. Remove the driven gear assembly from the trans-
rnounting bolts in the transfer case. fer case, and measure the preload.
NOTE: Before rneasuring the preload, rotate the

companion flange severa! times to assure normal
bearing contact.
Preload: 0.8-1.1 N·m

(8.0-11.0 kg-cm, 6.9-9.5 lb-in)
IDRIVEN GEAR ASSEMBL Y
8. To measurepreload,tighten the locknut to the speci-

fied torque.
Torque: 120 N·m (12 kg-m, 87 lb-ftl

NOTE: lf the preloadexceeds 1.1 N·m (11.0 kg-cm,
9.5 lb-in), replacethe transfer spacer with a new one
and readjust. Do not try to adjust the preload by
loosening the locknut.
1 O. lf the preload is less than 0.5 N·m (5 kg-cm, 4.3 lb-

in), adjust by turning the lock nut in a little ata time.
NOTE: Replacethe transfer spacer with a new one

if the preload is still outside the above limits when
the lock nut is tightened to 230 Nvrn (23 kg-m, 166
lb-ft)
FLANGE HOLDER
07926- 5090000
SOCKET
WRENCH HANDLE
07907-6010300
14-427
Transfer
Driven/Drive Gear Reassembly
1. Apply liquid gasket to the torque converter housing 3. lnstall the following parts in and on the transfer case
mating surface of the transfer case and install the and shaft:
special seal as shown. Use liquid gasket Part No.
OY740-99986. • Transfer thrust shim
• Drive gear (coat with clean oil)
NOTE: • 0-ring (replace)
• Check that the mating surface are clean and dry • Orive gear thrust shim
before applying liquid gasket. • L. side cover bolts.
Degrease the mating surfaces if necessary.
• Apply liquid gasket evenly, being careful to cover
all the mating surface. ORIVE GEAR THRUST SHIM
• To prevent leakage of all, apply liquid gasket to
inner threads of bolt holes. 0-RING
Replace.
• Do not install the parts 20 minutes or more have
elapsed since applying gasket.
In that case, reapply liquid gasket after remov- TRANSFER THRUST
ing the old residue. SHIM
• Wait at least 30 minutes before filling with oil.

SPECIAL SEAL
45 N·m
(4.5 kg-m, 33 lb-ft)
4. lnstall the following parts:

• Driven gear thrust shim
• Driven gear assembly
• Driven gear assembly bolts
2. lnstall the transfer case on the torque converter

housing.
DRIVEN GEAR
THRUST SHIM
Replace.
26 N·m
(2.6 kg-m, 19
lb-ft)
45 N·m (4.5 kg-m, 33 lb-ftl
14-428
5. Measure the total bearing preload: 7. After the bearing preload has been adjusted proper-
• Rotate the companion flange several times to as- ly, measure the gear backlash.
sure normal bearing contact. • Place the disengagement lever in 2WD.
• Set the disengagement lever in 2WD position.
• Measure the preload with a torque wrench.
The total bearing preload should be O. 7-1.0 N·m

(7 .O- 1 O.O kg-cm, 6. 1 -8. 75 lb-in) greater than the
preload on the driven gear assembly alone (see page MIDDLE BOLT
14-427. step 9).
Example:
lf the preload of the driven gear assembly alone was
0.9 N·m (9 kg-cm, 7.8 lb-in), the total bearing
preload should be between 1 .6 N·m ( 16 kg-cm, 13.9
lb-in), and 1.9 N·m (19 kg-cm, 16.5 lb-in).
• Using a dial indicator, measure the backfash at

the top of the companion flange, then rotate the
companion flange 180° and measure again.
Backlash: 0.09-0.14 mm (0.004-0.006 in.)
DIAL INDICATOR
6. lf the preload is outside the specifications, adjust it

by replacing the transfer thrust shim.
• lf the total bearing preload is less than the specifi-
cation, reduce the size of the transfer thrust shim.
• lf the total bearing preload is more than the Long Side
specification, increase the size of the transfer
thrust shim.
COMPANION FLANGE
(cont'dl
14-429
Transfer
Driven/Drive Gear Reassembly (cont'd)
• lf the backlash is outside the specifications, adjust by • Removethe driven gear assembly from the trans-
changing the driven gear thrust shim. fer case and note the tooth impression on the
gear.
NOTE: Compare the tooth impression the gear

TRANSFER THRUST with the examples below and follow the apropri-
SHIM ate adjustment instructions.
Continue the check/adjustment procedure until
ORIVE GEAR the tooth contact is correct.
THRUST SHIM
I j
I CORRECT TOOTH CONT ACT I
1 1
1
¡~1
1
DRIVEN GEAR
1~,
THRUST SHIM
1 1
L----------------j
IMPROPER TOOTH CONT ACT
TOE CONTACT FLANK CONTACT
~~
8. Check for proper tooth contact after the backlash
J'h
t '1h
adjustment has been completed. Adjust drive Adjust driven 1 ~
9
• Removethe driven gear assembly from the trans- ~::: and driven gear only
fer case, and paint the driven gear teeth evenly
with Prussian Blue.
• Reinstall the driven gear assembly in the transfer
case and tighten the bolts to the specified torque.
Tt
• With the disengagement lever in 2WD, rotate the
companion flange one full turn in both directions.
TOE CONTACT
lf the pattern shows toe contact. use a thicker drive gear

thrust shim for and increase the thickness of the trans-
fer thrust shim an egual amount.
TOE CONTACT
14-430
FACE CONT ACT
TRANSFER
THRUST SHIM To correct tace contact, use a thicker drive gear thrust
ORIVE GEAR shim to move the driven gear away from the drive gear.
THRUST SHIM The backlash should remain within the limits.
lf the backlash cannot be held within the limits (page

14-429), make correction in the same manner as for
HEEL CONTACT.
FACE CONTACT
ORIVEN GEAR
THRUST SHIM
TRANSFER
THRUST SHIM ORIVE GEAR
THRUST SHIM
HEEL CONTACT
lf the pattern shows heel contact. it indicates too much
backlash. To correct, reduce the thickness of the drive
gear thrust shim. The thickness of the transfer thrust
shim must also be reduced by the amount by which the
ORIVEN GEAR
drive gear thrust shim thickness is reduced. THRUST SHIM
NOTE: The driven gear thrust shim will have to be

changed also to compensate for the change in backlash.
HEEL CONT ACT FLANK CONTACT
lf the pattern shows flank contact, move the driven gear

in toward the drive gear by using a thinner shim for the
driven gear.
The backlash must remain within the limits.
ORIVE GEAR
lf the backlash exceeds the limits (page 14-429), make
THRUST SHIM
correction in the same maner as for TOE CONTACT.
FLANK CONT ACT
DRIVEN GEAR
THRUST SHIM
(cont'dl
14-431
Transfer
Driven/Drive Gear Reassembly (cont'd)
1 O. Stake the locknut into the driven gear shaft.
11 . lnstall the thrust shim and 0-ring on the driven gear

assembly, then install the assembly in the transfer
ORIVE GEAR case.
THRUST SHIM
DRIVEN GEAR
THRUST SHIM
9. When gear tooth contact is correct, install the new

special seal, apply liquid gasket to the mating sur-
faces of the torque converter and transfer housing.
Use liquid gasket part No. OY740-99986.
NOTE:
• Check that the mating surface are clean and dry
before applying liquid gasket.
Degrease the mating surfaces if necessary.
• Apply liquid gasket evenly, being careful to cover DRIVEN GEAR
ASSEMBLY 26 N·m
all the mating surface. (2.6 kg-m, 19 lb-ftl
• To prevent leakage of all, apply liquid gasket to
inner threads of bolt holes.
• Do not install the parts 20 minutes or more have
elapsed since applying gasket.
In that case, reapply liquid gasket after remov-
ing the old residue.
• Wait at least 30 minutes before tilling with oíl.
Apply liquid gasket to mating surfaces

of torque converter and transfer
housing.
14-432
12. Slide the drive gear thrust shim and drive gear onto 14. Measure the total bearing preload after assembly.
the transfer shaft.
13. Placethe transfer thrust shim and 0-ring (74.5 x 2.5

mm) on the L. side cover and install the cover on the
transfer case. Tighten the L. side cover attaching
bolts, and then install the L. side cover protector.
NOTE:
• Coat the 0-ring with oil.
• Apply liquid gasket (P/N OY740- 99986) to
threads of L. side cover attaching bolts.

(P/N OY740-99986)
TRANSFER
THRUST SHIM
L. SIDE COVER
ATTACHING BOLTS
45 N·m
(4.5 kg-m,
33 lb-ftl
L. SIDE COVER
45 N·m PROTECTOR
(4.5 kg-m, 33 lb-ft)
12 N·m (1.2 kg-m, 9 lb-ftl
14-433
TransmissionNalve Body
Reassembly ----------------------------
NOTE:
• 0-rings
• Lock washers
• Gaskets
• Locknuts
• Sealing washer
2ND ACCUMULATOR
BODY
OIL FEED PIPE
6 x 1.0 mm 7 Bolts
SERVO DETENT BASE/

ACCUMULATOR COVER
6 x 1.0 mm
4 Bolts
OIL PUMP DRIVEN

GEAR SHAFT
MAIN SEPARATOR
PLATE
14-434
1 . lnstall the ATF strainer in the torque converter 5. lnstall the 2nd accumulator piston and spring in the
housing. 2nd accumulator body, then install the 2nd accumu-
lator body with 1 dowel pin and 3 bolts on the tor-
2. lnstall the main separator plate with 1 dowel pin, que converter housing.
then install the oil pump gears and oil pump driven
gear shaft. 6. lnstall the stator shaft and stopper shaft.
NOTE: lnstall the oil pump driven gear with its 7. lnstall the 2 dowel pins, cooler relief valve and spring
grooved and chamfered side facing down. in the main valve body.
8. lnstall the regulator valve body with 1 bolt with stop-

DRIVEN GEAR per on the main valve body.
/ 9. lnstall the torque converter check valve and spring

in the regulator valve body.
~ 1 O. lnstall the 2 dowel pins and separator plate on the
D-
GROO VE CHAMFER
regulator valve body, then install the lock-up valve
body with 6 bolts.
t
91 V i-- ~=z:·
ORIVE GEAR DRIVEN GEAR
SHAFT 11 . lnstall the secondary separator plate with 2 dowel
l1 pins on the secondary valve body, then install the

secondary valve body on the main valve body.
'(ii ·
G~oved and chamfere~
side faces separator plate.
12. lnstall the servo separator plate and servo body on
the secondary valve body with 6 bolts.
13. lnstall the oil feed pipe in the servo body, then in-
stall the servo detent base/accumulator cover with
3. fnstalf the main valve body with 4 bolts. And make 2 dowel pins and 7 bolts.
sure the pump drive gear rotates smoothly in the nor-
mal operating direction and pump shaft moves 14. lnstall the baffle plate on the servo body with 1 bolt.
smoothly in the axial and normal operating
directions. 1 5. lnstall the control shaft in the torque converter hous-
ing, then install the roller pin through the manual
4. lf the pump gear and pump shaft do not move free- valve.
ly, loosen the valve body bolts, realignthe shaft, and
then retighten to the specified torque. 16. lnstall new cotter pin into the roller pin, then bend
the cotter pin.
ly will result in seized pump gear or pump shaft. 1 7. lnstall 3 oil feed pipes int he servo body, pipe in
the secondary valve body and 2 pipes in the main
valve body.
1 ,=_/
~@'º
DRIVENGE~ ~
DRIVEN
GEAR SHAFT (cont'd)
14-435
Transmission/Transmission Housing
Reassembly ícont'dl -----------------------
CONTROL LEVER
MAINSHAFT
COLLAR
SUB-ASSEMBLY ~
y·NEEDLE BEARING
~
'--~~~ SHIFT FORK
REVERSE SELECTOR
COUNTERSHAFT
SUB-ASSEMBL Y
CONTROL SHAFT ROD
14-436
18. lnstall the sub-shaft assembly in the transmission 23. lnstall the reverse gear, needle bearing and reverse
housing ( 14-401 ) . gear collar on the countershaft.
1 9. lnstall the reverse idler gear and gear shaft holder 24. Align the spring pin with the transmission housing
in the transmission housing (page 14-416). groove by turning the control shaft.
20. lnstall the differential assembly in the torque con- 25. Place the transmission housing on the torque con-
verter housing. verter housing.
21 . lnstall the mainshaft sub-assembly and the counter-

shaft sub-assembly together. SPRING PIN
Align the spring pin with
the transmission housing
groove.
MAINSHAFT
COUNTERSHAFT
22. Turn the shift fork shaft so large chamfered hole fac- 26. lnstall the transmission housing bolts and transmis-
ing fork bolt hole. Then instan the shift fork and tor- sion hanger, then torque bolts to 55 N·m (5.5 kg-
que the lock bolt. Bend the lock tab against the bolt m, 40 lb-ft) in two or more steps as shown.
head.
SHIFT FORK
LOCK WASHER
(cont'd)
14-437
Transmission
Reassembly (cont'd)
27. lnsert the control lever into the control shaft rod 29. Slip the special tool onto the mainshaft.
through the housing,then torque the bolt with a new
lock washer. Bendthe lock tab against the bolt head.
CONTROL SHAFT ROD
MAINSHAFT HOLDER
LOCK WASHER 07923-6890202
MAINSHAFT
CONTROL LEVER
30. lnstall the parking brake lever on the control shaft.
31 . Assemble the one-way clutch and parking gear with

the countershaft 1 st gear.
28. lnstall the change cover.
32. lnstall the 1 st gear collar, needle bearing and park-
ing gear/1st gear assembly on the countershaft.
33. lnstall the parking brake pawl with shaft and spring,
CHANGE COVER GASKET then engage the parking brake pawl to the parking
gear.
CHANGE COVER
6 x 1.0 mm
12 N·m
(1.2 kg-m, 9 lb-ft)
14-438
34. Tighten the old locknut to press the parking gear to 38. lnstall the 1 st gear collar and thrust washer on
specified torque, then loosen it. the mainshaft.
TOROUE: 140 N·m (14.0 kg-m, 101 lb-ft) 39. lnstall new 0-rings on the mainshaft.
COUNTERSHAFT LOCKNUT NOTE: Before installing the 0-rings, wrap the shaft
Old locknut splines with tape to prevent damaging the 0-rings.
40. lnstall the thrust washer, thrust needle bearing, nee-

dle bearing and 1 st gear on the 1 st clutch, then in-
stall them on the mainshaft.
41 . lnstall new disc spring on the sub-shaft and new

locknuts on each shaft.
CAUTION: lnstall the disc spring in the direction

shown.
42. Tighten the locknuts to specified torque.
TOROUE:
Mainshaft 95 N·m (9.5 kg-m, 69 lb-ft)
35. lnstall the 1 st gear on the sub-shaft. Countershaft 140 N·m (14.0 kg-m, 101 lb-ft)
Sub-shaft 95 N·m (9.5 kg-m, 69 lb-ft)
36. Align the hole of the subshaft 1 st gear with the
hold of the transmission housing, then insert a
pin to lock the subshaft while tightening the sub- NOTE: Mainshaft locknut had left-hand threads.
shaft locknut.
37. Tighten the old locknut to press the 1 st gear to

the specified torque, then loosen it.
Left-hand Threads Mark
STOPPER PIN
TORQUE: 95 N·m (9.5 kg-m, 69 lb-ftl
SUB-SHAFT LOCKNUT STOPPER PIN

Old locknut \
SUB-SHAFT
MAINSHAFT
(cont'd)
14-439
Transmission
Reassembly (cont'd)
43. Stake each clocknut using a 3. 5 mm punch. 44. Set the parking breake lever in the PARK position,
then verify that the parking brake pawl engagedsthe
parking gear.
MAINSHAFT
45. lf the pawl does not engage fully, check the parking
14-442.
46. Tighten the lock bolt and bend over the lock tab.
0.7-1.7 mm 1ST CLUTCH

(0.03-0.07 in)
PUNCH
COUNTERSHAFT
3.5 mm (O. 14 in)
Points to be
staked.
PARKING GEAR
PARKING BRAKE
PAWL.
4 7. lnstall the R. side cover.
TORQUE: 12 N -rn ( 1.2 kg-m, 9 lb-ft)
0.7-1.7 mm
(0.03-0.07 in)
SUB-SHAFT
Pointto be staked.
14-440
48. lnstall the throttle control lever with a new lock 52. lnstall the stopper rnount bracket on the transrnis-
washer on the end of the throttle control shaft. Tight- sion housing.
en the lock bolt and bend the lock tab.
TORQUE: 65 N·m (6.5 kg-m, 47 lb-ft)
12 x 1.25 mm
49. lnstall the ATF cooler pipes with new sealing 65 N·m
washers. (6.5 kg-m, 47 lb-ftl
TORQUE: 29 N·m (2.9 kg-m, 21 lb-ftl /

50. lnstall the ATF leve! gauge.
51 . lnstall the transrnission rnount bracket ont he trans-

rnission housing.
TRANSMISSION MOUNT BRACKET

-, STOPPER MOUNT BRACKET
53. lnstall the transmission under guard.
10 x 1.25 mm
10 x 1.25 mm 6x 1.0mm 55 N·m
39 N·m 12 N·m /5.5 kg·m. 40 lb·ftl
(3.9 kg-m, 28 lb-ftl (1.2 kg-m, 9 lb-ft)
1
'\8 x 1.25 mm
22 N·m
14-441
1. Set the parking brake lever in the PARK position.
2. Measurethe distance between the face of the park-

ing brake pawl shaft and face of the parking brake
lever roller pin as shown.
STANDARD: 57.2-58.2 mm (2.25-2.29 in)
ROLLER PIN
PARKING
BRAKE PAWL
3. lf the measurment is out of tolerance, select and in-

stall the appropriate parking brake stopper from the
table below.
PARKING BRAKE
STOPPER
I
L2 -=rl,
PARKING BRAKE STOPPER

11.00 mm 11.00 mm
1 24537-PA9-003
(0.433 in) (0.433 in)
10.80 mm 10.65 mm
2 24538-PA9-003
(0.425 in) (0.419 in)
10.60 mm 10.30 mm
3 24539-PA9-003
(0.417 in) (0.406 in)
4. After replacingthe parking brake stopper, make sure

the distance is within torelance.
14-442
Torque Converter
Disassembly
6 x 1.0 mm
12 N·m (1.2 kg-m, 9 lb-ft)
/
ORIVE PLATE
RING GEAR/
TORQUE CONVERTER
ASSEMBLy
14-443
Transmission
lnstallation
housing, and install the 14 mm dowel pins in the tor-
que converter housing.
SIDEMO\
ST ARTER MOTOR TRANSMISSION
MOUNTING BOL T
45 N·m
0-RING
Replace.
V\
12 x 1.25 mm
55 N·m
2. Placethe transmission on a jack, and raise to the en- (5.5 kg-m, 40 lb-ftl
gine level.
5. lnstall the transmission housing mounting bolts and
3. Attach the transmission on the engine, then instan starter motor mounting bolt.
the transmission housingmounting bolts and rear en-
gine mounting bolts.
REAR ENGINE MOUNTING
BOLTS
TRANSMISSION HOUSING 14 x 1.25 mm
MOUNTING BOL TS 85 N·m
12 x 1.25 mm (8.5 kg-m, 61 lb-ftl
60 N·m
(6.0 kg-m, 43 lb-ft)
\
TRANSMISSION HOUSING/
ST ARTER MOTOR MOUNTING
BOLT
45 N·m
'
MOUNTING BOL TS
12 x 1.25 mm
60 N·m
(4.5 kg-m, 33 lb-ft) (6.0 kg-m, 43 lb-ftl
6. Removethe transmission jack and the hoist from the

engine
14-444
7. Attach the torque converter to the drive plate with 10. lnstall the propeller shaft on the transfer.
8 bolts and torque to 12 N·m (1.2 kg-m, 9 lb-ft). Ro-
tate the crank-shaft as necessary to tighten the bolts
to 1 /2 of the specified torque, then final torque, in
a criss-cross pattern. Check for free rotation after
tightening the last bolt.
8. lnstall the torque converter cover and engine

stiffener.
6 x 1.0 mm
12 N·m
(1.2 kg-m, 9 lb-ftl
SPECIAL NUT
GASKET
10 x 1.25 mm
/
45 N·m
14.5 kg·m,
33 lb-ft)
TOROUE CONVERTER
COVER
8 x 1.25 mm
24N·m EXHAUST
(2.4 kg-m. 17 lb-ft) PIPE A
9. Connect the throttle control cable and install the

stopper mount bolts.
STOPPER MOUNT
10 x 1.25 mm
/ 39 N·m
(3.9 kg-m, SELF-LOCKING NUT
28 lb-ft] Replace.
8 x 1.25 mm
16 N·m
Replace.
8 x 1.25 mm
( 1 .6 kg-m. 12 lb·ft)
22 N·m
(2.2 kg-m. 16 lb-ft)
LOCKNUT
35 N·m
THROTTLE CONTROL
(3.5 kg·m, (cont'dl
CABLE END
25 lb-ft)
14-445
Transmission
1 2. lnstall a new set ring on the end of the right 16. lnstall the splash shield.
driveshaft and intermediate shaft.
13. lnstall the intermediate shaft.
14. lnstall the right and left driveshafts.
NOTE: Turn the right and left steering knuckle fully

its spring clip engage the side gear.
10 x 1.25 mm
40 N·m
(4.0 kg-m, 29 lb-ft)
1 7. Connect the ATF cooler houses to the joint pipes.
1 5. lnstall the damper fork. And install the boll joint to

the lower arm with a new castle nuts and cotter pins.
10 x 1.25 mm
44N·m
(4.4 kg·m, 32 lb-ftl
\
COOLER HOSES
,,,
/
SELF-LOCKING NUT
Replace. COTTER PIN
12 x 1.25 mm CASTLE NUT Replace.
65 N·m Replace.
(6.5 kg-m, 47 lb-ft) 12 x 1.25 mm
55 N·m
15.5 kg-m, 40 lb-ft)
14-446
18. lnstall the shift cable with the control pin to the con- 21. Connect the lock-up control solenoid valve and shift
trol lever, then install the clip. control solenoid valve connectors.
19. lnstall the shift cable on the shift cable stay, then SHIFT CONTROL
ji
torque the locknut to 35 N·rn (3.5 kg-m, 25 lb-ft). SOLENOID VALVE
CONNECTOR
LOCK-UP CONTROL
SOLENOID VAL VE
CONNECTOR
CONTROL PIN \
CONTROL LEVER
22. Connect the transmission ground cable and the NC
speed sensor connector.
20. Connect the speed sensor connector.
!
SPEED SENSOR CONNECTOR
\
TRANSMISSION GROUND
CABLE
(cont'd)
14-447
Transmission
23. Connect the starter motor cable. 25. Refill the transmission with ATF (see page 14-355).
26. Connect the battery positive ( + ) and negative ( - )

27. Start the engine. Set the parking brake, and shift the
transmissionthrough all gearathree times. Check for
proper shift cable adjustment.
28. Let the engine reach operating temperature with the

transmission in Neutral or Park, then turn it off and
check fluid level.
29. Road test as described on page 14-352 and 353.
24. lnstall the air cleaner case, air intake hose and
resonator.
14-448
Gear Shift Selector
WIRE HARNESS
GUIDE
\.) /LOCK PINROD
/
SELECT LEVER BRACKET
SHIFT POSITION
SWITCH
Testing, see section 23.
14-449
Shift Cable
i·W+MMN 4. Remove the shift cable bracket.

ly and hoist brackets are attached to correct positions 5. Remove the grommet.
on the engine.
• Apply parking brake and block rear wheels, so car will 6. Pull the shift cable out from the engine compartment.
not roll off stands and fall on you while working un-
der it.
CAUTION: Take care not to bend the cable when
1. Remove the shift cable by removing the cotter pin, removing it.
control pin, control lever roller and loosening the
locking nut. 7. lnstall the shift cable in the reverse order of removal.
2. Remove the center console (see page 20-80). NOTE: On reassembly, check the cable adjustment
(page 14-449).
3. Remove the lock pin from the cable adjuster, then
remove the shift cable. 6 x 1.0 mm
12 N·m
(1.2 kg-m, 9 lb-ft)
SHIFT CONTROL CABLE
LOCKNUT
35 N·m
(3. 5 kg-m, 25 lb-ft)
CONTROL LEVER Replace.
14-450
Adjustment
1. Start the engine. Shift to reverseto see if the reverse 4. Check that the hole in the adjuster is perfectly
gear engages.lf not, refer to troubleshootingon page alignedwith the hole in the shift cable. There are two
14-348 thru 351. holes in the end of the shift cable. They are posi-
tioned 90° agart to allow cable adjustment in 1 /4
2. With the engine off, remove the center console (see turn increments.
page 20-80).
3. Shift to ill]or [B] position, then remove the lock pin

from the cable adjuster. ADJUSTER
SHIFT CABLE
~~
~~
Cable Cable Exact

Too Short Too Long Alignment
5. lf not perfectly aligned, loosen the locknut on shift

6. Tighten the locknut to 7 N·m (O. 7 kg-m, 5 lb-ft).
7. lnstall the lock pin on the adjuster. lf you feel the

out of adjustment and must be readjusted.
8. Move the select to each gear and verify that the shift
position indicator follows the shift position console
switch.
9. Start the engine and check the shift lever in ali gears.
lf any gear does not work properly, refer to
troubleshooting on page 14-42 thru 45.
ADJUSTER
14-451
lnspection
NOTE: Befareinspecting the throttle control cable,make 3. Check that there is play in the throttle control lever
sure; while depressing the accelerator pedal to the full-
throttle position.
• Throttle calber free play is correct (see page
11-364).
• ldle speed is correct (see page 11-326).
perature (cooling tan comes on).
1. Verify that the throttle control lever is synchronized

with the throttle linkagewhile depressing and releas-
ing the accelerator pedal.
2. lf the throttle control lever is not synchronized with

the throttle linkage, adjust the throttle control cable.


smoothly.
THROTTLE LINKAGE
CABLE END
THROTTLE CONTROL
LEVER
14-452
Adjustment
NOTE: Beforeinspectingthe throttle control cable, make 4. Tighten the locknut.

sure;
• Throttle calber free play is correct (see page ·

11-364).
• ldle speed is correct (see page 11-326).
perature (cooling fan comes on).

position.
2. Loasen the locknut of the throttle control cable at

the throttle linkage.
THROTTLE LINKAGE LOCKNUTS
5. After tightening the locknuts, inspect the synchroni-

zation and throttle control lever movement.
LOCKNUTS
3. Remove the free play of the throttle control cable

with the locknut, while pushing the throttle control
lever to the full-closed position as shown.
14-453
Differential
2WD Manual Transmission

Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5-1
Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5-9
Front Differential . . . . . . . . . . . . . . . . . . . . . . . . . 1 5-1 7
Front Differential . . . . . . . . . . . . . . . . . . . . . . . . . 1 5-25
4WD Rear Differential
(Without Viscus Coupling) 15-33
4WD Rear Differential
(With Viscus Coupling) 15-53
Diff erential
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5-2

Backlash lnspection . . . . . . . . . . . . . . . . . . . . . . . . 1 5-4
Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . 1 5-4
Ring Gear Replacement . . . . . . . . . .. . . . . . . . . 1 5-5
Oil Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5-5
lnstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5-6
Special Tools
Special Tools
G) 07746-0030100 lnner Handle C
® 07946-5090200 Oil Seal Driver
© 07947-6110501 Oil Seal Driver
® 07NAD-P200100 Oil Seal Driver
G)
© ®
15-2
Diff erential
RING GEAR
Replace.
15-3
Differential
Backlash lnspection Bearing Replacement
1. Place differential assembly on V-blocks and install NOTE: Check bearingsfor wear and rough rotation.
both axles. lf bearings are OK, removal is not necessary.
2. Check backlash of both pinion gears. 1. Remove bearings using a standard bearing puller.
BEARING PULLER
/
DIAL
INDICATOR
3. lf the backlash is not within the standard, replace 2. lnstall new bearings.
the differential carrier assembly.
INNER HANDLE C
;7746-0030100
BALL BEARING
15-4
Ring Gear Replacement Oil Seal Removal
1. Remove the ring gear from the differential carrier. 1. Remove the differential assembly.
NOTE: The ring gear bolts has left-hand threads. 2. Removethe snap ring from the transmissionhousing.
Chamfer on inside diameter of SNAP RING
3. Removethe oil seal from the transmission housing.
10 mm BOLT CARRIER
103 N·m (10.3 kg-m, 74 lb-ft)
Left-hand threads.
2. lnstall the ring gear.

4. Remove the oíl seal from the clutch housing.
OIL SEAL
Replace.
15-5
Differential
lnstallation
1. lnstall the differential assembly in the clutch housing. 3. lnstall the transmission housing (see section 13).
NOTE: Do not apply liquid gasket to the mating sur-

4. Tighten the transmission bolts (see section 13).
5. Use special tools to bottom differential assembly in

clutch housing.
INNER HANDLE C
07746-0030100
2. lnstall the thrust shim.
NOTE: lnstall the snap ring that was removed.
6. Measureclearancebetween snap ring and outer race

of bearing in transmission housing.
15-6
7. lf out of limits, select a new snap ring from follow- 8. Remove the bolts and transmission housing.
ing table and install.
9. Replace the snap ring with the one of the correct
Side Clearance: 0-0.10 mm (0.03937 in) thickness selected in stop 6.
72 mm Snap Ring: Except D16Z6, D16Z7. D16A7. 1 O. Reassemble the transmission and install the trans-
D16A8. D16A9.B16A2 mission housing (see section 13).
PART NUMBER THICKNESS 11. 1 nstall the. oil seal in the transmission housing.
41441-PL3-AOO 1.0 mm (0.03937 in)
41442-PL3-AOO 1. 1 mm (0.04331 in)
41 443-PL3-AOO 1.2 mm (0.04724 in)
41444-PL3-AOO 1.3 mm (0.05118 in)
41445-PL3-AOO 1.4 mm (0.05512 in)
41446-PL3-AOO 1.5 mm (0.05906 in)
41447-PL3-AOO 1.6 mm (0.06299 in)
41448-PL3-AOO 1. 7 mm (0.06693 in)
41449-PL3-AOO 1.8 mm (0.07087 in)
41450-PL3-AOO 1 .05 mm (0.04134 in)
41451-PL3-AOO 1. 1 5 mm (0.04528 in)
41452-PL3-AOO 1. 25 mm (0.04921 in)
41453-PL3-AOO 1.35 mm (0.05315 in)
41454-PL3-AOO 1.45 mm (0.05709 in)
41455-PL3-AOO 1.55 mm (0.06102 in)
41456-PL3-AOO 1.65 mm (0.06496 in)
41457-PL3-AOO 1. 75 mm (0.06890 in)
80 mm Snap Ring: D16Z6, D16Z7, D16A7, D16A8,

Except D16Z6, 01627, D16A7, D16A8. 016A9,
D16A9, 816A2
816A2:
41441-PL3-BOO 1.0 mm (0.03937 in) OUTER HANDLE A OIL SEAL DRIVER
41442-PL3-BOO 1.1 mm (0.04331 in) 07749-0010000 ---...._ 07947-6110501
41443-PL3-BOO 1.2 mm (0.04724 in)
41 444- PL3 - 800 1.3 mm (0.05118 in)
41445-PL3-BOO 1.4 mm (0.05512 in)
41446-PL3-BOO 1. 5 mm (0.05906 in)
41447-PL3-BOO 1.6 mm (0.06299 in)
41448 - PL3- 800 1. 7 mm (0.06693 in)
41449-PL3-BOO 1.8 mm (0.07087 in) OIL SEAL
41450-PL3-BOO 1.05 mm (0.04134 in) Replace.
41451-PL3-BOO 1. 1 5 mm (0.04528 in)
41452-PL3-BOO 1. 25 mm (0.04921 in) D16Z6, D16Z7, D16A7. D16A8. D16A9. B16A2:
41453-PL3-BOO 1.35 mm (0.05315 in)
41454-PL3-BOO 1 .45 mm (0.05709 in)
41455-PL3-BOO 1.55 mm (0.06102 in) OUTER HANDLE A---. OIL SEAL DRIVER
41456-PL3-BOO 1.65 mm (0.06496 in) 07749-0010000 07947-5090200
41457-PL3-BOO 1. 75 mm (0.06890 in)
NOTE: lf snap ring-to-bearing outer race clearance mea-

sured in step 6 is less than_ the specification, it is not
necessary to perform steps 8 and 9.
OIL SEAL
Replace. (cont'd)
15-7
Diff erential
1 2. lnstall the oil seal in the clutch housing using the spe-
cial tools.
OUTER DRIVER A
07749-0010000
OIL SEAL
Replace.
15-8
2WD Automatic
Transmission Differential
Special Tools 15-1 O

lllustrated lndex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-11
Backlash lnspection . . . . . . . . . . . . . . . . . . . . . . . . 15-12
Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . 15-12
Carrier Assembly Replacement . . . . . . . . . 1 5-13
Oil Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5-14
Oil Seal lnstallation/Side Clearance . . . 15-14
Special Tools
CD 07JAD-PH80101 Attachment 1 1 5-16

@ 07JAD-PH80200 Pilot, 26 x 30 mm 1 15-16
@ 07NAD-P200100 Attachment, 52 x 55 mm 1 15-16
© 07746-0030100 Driver, 40 mm I.D. 1 1 5-12, 1 4, 1 5
®
®
07749-001 ºººº
07944-SAOOOOO
Driver
Pin Driver, 4.0 mm
1
1
15-16
15-13
0 07947-6110501 or Attachment 1 15-16
07947-6110500
1 []
® ®
15-10
Differential (2WD Automatic Transmission)
lllustrated lndex--------------------------
SNAP RING SPEEDOMETER ORIVE GEAR
i
RING GEAR
lnspect for excessive wear.
~/
SET RING, 80 mm
Select, page 1 5-1 5
l
BALL BEARING
Replacement, page 1 5-1 2
lnspect for faulty movement.
/ o
10 x 1.0 mm
103 N·m (10.3 kg-m, 74 lb-ftl
Left-hand threads.
15-11
Backlash lnspection --------, Bearing Replacement-------,
1. Place differential assembly on V-blocks and install NOTE: Check bearings for wear and rough rotation. lf
both axles. bearings are OK, removal is not necessary.
Standard(New):0.05-0.15 mm (0.002-0.006 in)
SIDE GEAR
BEARING
3. lf backlash is out of tolerance, replace the differen-
tial carrier assembly.
2. lnstall new bearings using the special tool as shown.
BALL BEARING
15-12
Carrier Assembly Replacement---------------------.
1. Remove the ring gear from the carrier. 4. Align snap ring on carrier as shown.
2. Pry snap ring off carrier, then remove speedometer

drive gear and dowel pin using the special tool
(07944-SAOOOOO PIN DRIVER,4.0 mm).
END GAP
SNAP RING
SNAP RING \
o
·I
J l
3. lnstall speedometer drive gear with its chamfer (on
inside diameter) facing carrier and secure with snap 5. lnstall the ring gear.
ring.
CAUTION: The ring gear bolts have left-hand
threads.
Chamfer on inside diameter

of ring gear faces carrier.
~~~-
SPEEDOMETER ORIVE GEAR SNAP RING

10 x 1.0 mm
103 N·m (10.3 kg-m, 74 lb-ftl
Left-hand threads.
6. lnstall the ball bearings ( 1 5-1 2).
15-13
Oil Seal Removal----------. Oil Seal lnstallation/Side Clearance-
1. Re.move the differential assembly. 1. lnstall a 2.50 mm (0.09843 in) set ring in transmis-
sion housing.
2. Removethe oil seal from the transmission housing. Do not install the oil seal yet.
Oll SEAL
Replace. 2. lnstall the differential assembly into the torque con-
3. Remove the oil seal from the torque converter verter housing using the special tool as shown.
housing.
3. Assemble the transmission (See Section 14).

lnstall the transmission housing and tighten the bolts
OIL SEAL
(See Section 14).
Replace.
15-14
4. Tap on transmission housing side of differential as- 5. Measure clearance between the set ring and outer
sembly with driver and attachment to seat the as- race of bearing in transmission housing.
sembly in torque converter housing.
DRIVER, 40 mm I.D.
07746-0030100
lf out of limits, select new set ring from following
table and install:
Side Clearance:
MAX: 0.15 mm (0.006 in)
SET RING 80 mm

90414-689-000 2.50 mm (0.09843 in)
9041 5-689-000 2.60 mm (O. 10236 in)
90416-689-000 2. 70 mm (O. 10630 in)
90417-689-000 2.80 mm (0.11024 in)
90418-689-000 2.90 mm (0.11417 in)
90419-PH8-000 3.00 mm (0.11811 in)
NOTE:lf the set ring-to-bearing outer race clearance

measured in step 5 is less than the specification, it
is not necessary to perform steps 6 and 7.
6. Remove the transmission housing.
7. Replacethe 2.50 mm (0.09843 in) set ring with that

of the correct thickness selected in step 5.
8. lnstall the transmission housing (See Section 1 4).
(cont'd)
15-15
Differential {2WD Automatic Transmission)
Oil Seal lnstallation/Side Clearance
(cont'd)
9. lnstall the oil seal in the transmission housing us-
ing the special tools as shown.
ATTACHMENT
07947-6110500 or
07947-6110501
PILOT,
26 x 30 mm
07JAD-PH80200
1 O. lnstall the oil seal in the torque converter housing

using the special tools as shown.
DRIVER
07749-0010000
PILOT.
26 x 30 mm
or 07JAD-PH80200
ATTACHMENT,
52 x 55 mm
07NAD-P200100
15-16
Front Differential
Special Tools 15-18

lllustrated lndex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-19
Backlash lnspection . . . . .. .. .. .. .. . . .. .. .. .. 15-20
Bearing Replacement .. .. .. . .. .. .. .. .. .. .. . 15-20
Ring Gear Replacement .. .. .. .. .. .. .. .. .. . 15-21
Oil Seal Removal .. .. .. .. .. .. . .. .. .. .. .. . .. .. 1 5-21
lnstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-22
Special Tools
Special Tools
Ref. No. Tool Number Description Qty Remarks
<D 07746-0030100 lnner Handle C

@ 07946- 5090200 Oil Séal Driver
@ 07NAD-P200100 Oil Seal Driver
15-18
Differential
80 mm THRUST SHIM
Selection, Page 1 5-22
BALL BEARING
/
FINAL DRIVEN GEAR
lnspect for wear or
damage.
TRANSFER ORIVE GEAR
lnspect for wear
or damage. BALL BEARING
Replacement, page 1 5-20
15-19
Diff erential
Backlashlnspection -------. BearingReplacement-------,
1. Place differential assembly on V-blocks and install NOTE:Check bearingsfor wear or rough rotation. lf bear-
the both driveshafts. ings are OK, removal is not necessary.
2. Check backlash of both pinion gear. 1. Remove bearings using a standard bearing puller.
. BALL BEARING
2. lnstall new bearings.

3. lf the backlash is without the standard, replace the
differential carrier assembly.
BALL BEARING
15-20
RingGear Replacement-------.. Oil Seal Removal--------
1. Removethe final driven gear and transfer drive gear 1. Remove the differential assembly.
from the differential carrier.
2. Remove the thrust shim from the transmission
NOTE: The ring gear bolts has right-hand thread. housing.
¡
\
DIFFERENTIAL CARRIER
\
-,-------~~ o
~ :::>
3.
"
Removethe oil seal from the transmission housing.
1
10 mm BOLT
103 N·m (10.3 kg-m,
74 lb-ft)
4. Remove the oil seal from the clutch housing.
2. lnstall the final driven gear and transfer drive gear.
15-21
Diff erential
lnstallation-----------------------------
1. lnstall the differential assemblyin the clutch housing. 6. Measure clearance between thrust shim and outer
race of bearing in transmission housing.
2. lnstatl the transmission housing (see section 13).
Side Clearance: O - 0.10 mm (O - 0.0394 in)
NOTE:Do not apply liquid gasket to the mating sur-
3. Tighten the transmission bolts (see section 13).

80 mm THRUST SHIM
4. Use special tools to bottom differential assembly in
clutch housing.
INNER HANDLE C
07'746-0030100
7. lf out of limits, select new thrust shim from follow-

ing table and install.
80 mm thrust shim

90414-689-000 2.5 mm (0.0984 in)
90415-689-000 2.6 mm (0.1024 in)
5. lnstall the thrust shim. 90416-689-000 2. 7 mm (0.1063 in)
90417-689-000 2.8 mm (0.1102 in)
NOTE: lnstall the thrust shim that was removed. 9041 8-689-000 2.9 mm (0.1142 in)
90419-PH8-000 3.0 mm (O. 1181 in)
8. Remove the bolts and transmission housing.
9. Replacethe thrust shim with the one of the correct

thickness selected the step 6.
NOTE: lf the shim -to-bearing clearance calculated

in step 6 is less than the thrust shim.
1 O. Reassemblethe transmission and install the trans-

mission housing.
15-22
11. lnstall the oil seal in the transmission housing. 12. lnstall the oil seal in the clutch housing.
OUTER HANDLE A OUTER HANDLE A

OIL SEAL DRIVER 07749-0010000
0774~ 0794 7 -8090200
OIL SEAL OIL SEAL

Replace. Replace.
15-23
Front Differential
Special Tools 15-26

Backlash lnspection 15-28
Bearing Replacement .. . . . . . . . . .. . . .. .. . . .. 15-28
Carrier Assembly Replacement . . . . . . . . . 15-29
Oil Seal Removal . . . . .. . . . . . . . . .. .. .. . . . . . . . . 1 5-30
Oil Seal lnstallation/Side Clearance . . . 15-31
Special Tools

CD 07JAD-PH80101 Attachment 1 15-31
® 07 JAD-PH80200 Pilot, 26 x 30 mm 1 15-31
@ 07NAD-P200100 Attachment, 52 x 55 mm 1 15-31
@ 07746-0030100 Driver, 40 mm I.D. 1 15-28, 31
® 07749-0010000 Driver 1 15-31
® 07944-SAOOOOO Pin Driver, 4.0 mm 1 15-29
(J) 07947-6110501 or Attachment 1 15-31
07947-6110500
® ®
15-26
Differential {4WD Automatic Transmission)
BALL BEARING
Check for Smooth
rotation.
FINAL DRIVEN GEAR
Check for abnormal

wear.
SNAP RING -----1
BALL BEARING
Check for smooth rotation.
15-27
Backlash lnspection ------ ...... Bearing Replacement
1. Place differential assembly on V-blocks and install NOTE: Check bearings for wear and rough rotation. lf
both axles. bearings are OK, removal is not necessary.
BEARING PULLER
~º!
BALL BEARING
3. lf backlash is out of torelance, replace the differen- 2. lnstall new bearingsusing the special tool as shown.
tial carrier assembly.
7-003-0100
DRIVER 40 mm I.D.
15-28
Carrier Assembly Replacement
1. Removethe final driven gear and transfer drive gear. 3. lnstall speedometer drive gear with its chamfer (on
lnspect teeth for wear or damage. inside diameter) facing carrier and secure with snap
ring.
TRANSFER ORIVE GEAR
SPEEOOMETER ORIVE GEAR

SNAP RING
FINAL ORIVEN GEAR
2. Pry snap ring off carrier, then remove speedometer 4. Align snap ring on carrier as shown.
drive gear and dowel pin using the special tool
(07944-SAOOOOO PIN DRIVER,4.0 mm).
END GAP
SNAP RING
\
SPEEOOMETER SNAP RING
ORIVE GEAR
t ·•
J o 1 (cont'd)
15-29
Carrier Assembly Replacement Oil Seal Removal
(cont'd)
5. lnstall the final driven gear and transfer drive gear. 1. Remove the differential assembly.
2. Removethe oil seal from the transmission housing.

Chamfer on inside
diameter
FINAL DRIVEN
GEAR
TRANSFER
ORIVE
10 mm BOLT GEAR
103 N·m (10.3 kg-m. 74 lb-ft)
OIL SEAL
Replace.
3. Remove the oil seal from the torque converter
housing.
OIL SEAL
Replace.
15-30
Oil Seal lnstallation/Side Clearance
1. lnstall a 2.50 mm (0.09843 in) set ring in transmis- 4. Tap on transmission housing side of differential as-
sion housing. sembly with driver and attachment to seat the as-
Do not install the oil seal yet. sembly in torque converter housing.
DRIVER. 40 mm 1.0.
07746-0030100
2. lnstall the differential assembly into the torque con-
verter housing using the special tool as shown.
3. Assemble the transmission (See Section 14).

lnstall the transmission housingand tighten the bolts
(See Section 14).
(cont'd)
15-31
Oil Seal lnstallation/Side Clearance (cont'd)
5. Measure clearance between the set ring and outer 9. lnstall the oil seal in the transmission housing using
race of bearing in transmission housing. the special tools as shown.
DRIVER
07749-0010000
PILOT.
L~
26 x 30 mm
07JAD-PH80200
lf out of limits, select new set ring from following

table and install:
1 O. lnstall the oil seal in the torque converter housing
using the special tools as shown.
Side Clearance:
MAX: 0.15 mm (0.006 in)
SET RING 80 mm
DRIVER
07749-0010000
90414-689-000 2.50 mm (0.09843 in)
90415-689-000 2.60 mm (0.10236 in)
90416-689-000 2.70 mm (0.10630 in)
90417-689-000 2.80 mm (0.11024 in)
90418-689-000 2.90 mm (0.11417 in)
90419-PH8-000 3.00 mm (0.11811 in)
NOTE: lf the set ring-to-bearing outer race clearance

measured in step 5 is less than the specification, it
is not necessary to perform steps 6 and 7.
6. Remove the transmission housing.
7. Replacethe 2.50 mm (0.09843 in) set ring with that

of the correct thickness selected in step 5.
26 x 30 mm
07JAD-PH80200
8. lnstall the transmission housing (See Section 14). or
ATTACHMENT,
52 x 55 mm
07NAD-P200100
15-32
Differential
(without viscous coupling)
Special Tools 15-34

Service Precautions .. .. .. .. .. .. .. .. .. .. .. .. 15-35
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5-36
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-37
Differential Assembly
Removal/lnstallation . . . . . . . . . . . . . . . . . . . . . 15-37
lllustrated lndex .. .. .. .. . . .. .. . .. .. .. . .. .. . .. 15-38
Differential
Hous1ng Removal ~........................ 15-39
Oil Seal Replacement . .. .. . .. . . .. .. .. . .. 15-39
lnspection .. .. . .. .. . .. .. . .. .. .. .. .. .. . .. .. .. . 15-40
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-41
Differential Carrier
Disassembly /Reassembly . . . . . . . . . . . . . . 1 5-43
Diff erential
Height Adjustment .. .. .. .. .. .. . .. . .. .. . .. 1 5-44
Reassembly . .. .. . .. .. . . . . . . .. .. .. .. . . . . . . .. 15-4 7
Housing lnstallation .. . .. .. .. .. .. .. .. .. .. 15-51
Special Tools
Special Tools
CD 07749-0010000 Outer Handle A

@ 07JAD-PH80100 Oil Seal Driver
@ 07966-SD90000 Differential Carrier Stand
@ 07973-SD90300 Differential Pinion Center Pin
® 07926-SDSOOOO Companion Flange Holder
® 07946-SAOOOOO Pin Driver, 4.0 mm
0 07GAF-SE00300 Driver Attachment
® 07LAD-PW50601 Bearing Driver Attachment
® 07746-0010600 Outer Driver, 72 x 75 mm
@ 07947-5090101 Oil Seal Driver
® 07973-SD90100 Pinion Dummy Shaft
@ 07973-SD90200 Pinion Height Block
@ 07946-MBOOOOO Driver
@ 07974-5800200 Oil Seal Driver
el b;;J) ~
CD
111 l¡ )
@
©
@
® ®
~
(J)
® ®
~
@ @ @ @
15-34
Service Precautions
from 2WD to 4WD automatically when greater traction • When using test appliances;
is needed. To prevent accidents or injuries, the system Speedometer tester, brake tester, chassis dynamo-
must be released before performing any services on the meter, etc.
differential unit.
CAUTION:Apply the parking brake and block the rear
To release 4WD wheels before using a speedometertester. When you
DISENGAGEMENT LEVER
2. Move the lever by turning the lock bolt A counter-

clockwise.
3. Confirm that the lever is in the fully disengaged po-

sition by rocking the cat back and forth while plac-
ing slight counterclockwise pressureon the lock bolt
A. 7
4. Tighten the lock bolt A.

tem disengaged,the rear differential clutch warning
light should come on.
<2WD> <4WD>
J-
~
DISENGAGEMENT LOCK BOLT A

LEVER
15-35
Differential
Troubleshooting
NOTE:
• Most problems in the unit are to be diagnosed by identifying noises from the gears or bearings.
• Care should be taken during diagnosisnot to confuse rear differential noiseswith those from other drive train components.
< Noise symptoms vvill be most prominent when 4WD is engaged. >
Symptom Probable Cause Remedy

Consistent noise during • Lack of oil • Replenish oil
cruising • Foreign matter stuck in gears, etc. • Clean and inspect
• Replace any damaged or faulty
parts
• lmproper tooth contact between ring gear • Adjust or replace
and drive pinion
• Worn or damaged side bearing
• Deformad ring gear or carrier
Gear noises while • Lack of oil • Replenish oil
accelerating •
•
•
Foreign matter stuck in gears, etc.
lmproper drive pinion preload
Chipped or damaged gears
.
• Clean and inspect
Re place
Gear noises while coast- • lmproper drive pinion preload • Adjust or replace
ing of accelerating • Damaged or chipped gears
Bearing noises while • Cracked or damaged drive pinion bearing or • Replace
accelerating or coasting/ side bearing
deceleration
Abnormal noises when • Worn (excessive play) or damaged side • Replace
rounding a curve bearing
• Damaged side gear, pinion, or pinion shaft
Abnormal noises during • Excessive backlash between ring gear and • Adjust
acceleration or when first drive pinion
driving away from a stop
.•
• lmproper ring gear or drive pinion preload
Excessive pinion backlash
Worn differential splines
.• Replace the carrier assembly
Recheck torque or replace
• Loose companion flange nuts and other
fasteners
Oil leak •
•
•
Oil level too high
Clogged breather hole
Loose carrier or inadequate sealing
.•
• Lower to proper level
Clean or replace
Recheck torque or apply
sealant
• Worn or damaged oil seal • Replace
Overheating • Lack of oil • Replenish
• lnsufficient ring gear-to-pinion backlash • Adjust
• Excessive ring gear or drive pinion preload • Adjust or replace
15-36
Maintenance
Transmission Oil--------- Removal/lnstallation1---------,
NOTE: Check the oil at operating temperatura, engine 1. Drain the differential oil.
OFF, and the cot on level ground.
2. Remove the propeller shaft (see section 16).
1. Removethe oil filler plug, then check the level and
condition of the oil. 3. Remove the rear drive shafts (see section 16).
4. Removethe mounting bolts from the rear differen-

tial mount B.
5. Remove the mounting bolts, then remove the

differential and rear differential mount A assembly.
~---'/_ Proper Level.
6. Remove the differential from the mount A.
2. The oil level must be up to the fill hole. lf it is below

the hole, add oil until it runs out, then reinstall the
oil filler plug.
SPECIAL
3. lf the oil is dirty, remove drain plug and drain trans- BOLT
mission.
4. Reinstallthe drain plug with a new washer, and refill

to proper level.
Oil Capacity
2.2 (2.3 U.S. qt.) after drain. REAR DIFFERENTIAL
2.3 (2.4 U.S. qt.) after overhaul. MOUNT B
Use only SEA 1 OW-30 or 1 OW-40, SF or SG grade. REAR DIFFERENTIAL
OIL DRAIN PLUG

45 N·m 14.5 kg-m, 33 lb-ft)
15-37
lllustrated lndex
Refer to the drawing below for the differential disassembly.

Clean ali parts thoroughly in solvent and dry with compressed air.
, Lubricate all parts with oil before reassembly.
NOTE:This differential uses no gaskets between the major housings; use Honda GenuineLiquid Gasket (P/N08718-0001 ).
Assemble the housings within 20 minutes after applying the liquid gasket and allow it to cure at least 30 minutes after
assembly before filling the differential with oil.
10 mm BOLT OIL SEAL

55 N·m (5.5 kg-m, 40 lb-ftl
OIL FILLER BOLT
45 N·m (4.5 kg-m,
OIL SEAL SIOE BEARING 33 lb-ft)
Replace. lnspect for smooth rotation.
mm
T APER BEARING
OIFFERENTIAL
22 mm SPRING WASHER lnspect for smooth rotation.
BEARING CAP
67 rRUST SHIM
COMPANION ({)
FLANGE
lo6)a,,om? (l)
/
~ DOWE~PIN
rfflfN·1~~~~
8 x 1.25 mm
22 N·m (2.2 kg-m,
RING GEAR
lnspect for wear
16 lb-ft) or damage.
22 mm LOCKNUT
PINION SPACER
Replace. SIOE BEARING
Replace.
Removal, page 15-43
OIFFERENTIAL CARRIER
Disassembly/Reassembly, page 15-43
15-38
Differential
Housing
Removal--------, OilSealReplacement--------.
1. Removethe differential carrier housing and dowel 1. Removethe oil seal from the differential housing.
pins.
OIL SEALS
Replace.
DIFFERENTIAL
HOUSING
t
8 x 10 mm
DOWEL PIN
o
DIFFERENTIAL HOUSING
2. Drive the new oil seal in the differential housing.
OIL SEAL DRIVER

07JAD-PH80101
15-39
Diff erential
lnspection~~~~~~~~~~~~~~~~~~~~~~~~~~~~~--,
Ring Gear Backlash Tooth Contact (Ring Gear and Orive Pinion)
1 . Place the differential carrier assembly on the 1 . Thoroughly cleanthe ring gearanddrive pinionteeth,
Differential CarrierStand and check backlashat four and paint the ring gear teeth lightly and evenly with
equally spaced locations around the gear. Prussian Blue.
Standard: 0.11 - 0.16 mm (0.004 - 0.006 in) 2. Rotate the pinion one full turn both forward and
backlash.
GOOO CONTACT PATTERN
OIFFERENTIAL CARRIER STAND

07973-$090300
2. lf out of tolerance, adjust as described on page

15-AV.
Pinion Gear-to-Side Gear Backlash

1. lnstall the pinion center pin in the differential side
gear. Measure the backlash with a dial indicator.
Standard: 0.05 - O. 15 mm (0.002 - 0.006 in)
3. lnspect the contact pattern on the ring gear. lf the

pattern is abnormal, adjust as instructed on page
15-48.
PINION CENTER PIN

07973-$090300
2. lf out of tolerance, replacethe differential carrier as-

sembly.
15-40
1 . Raise the locknut tab from the groove of the shaft. 4. Mark the bearing caps and differential carrier, then
remove bearing caps.
BEARING CAPS
LOCKNUT TAB
2. Hold the companion flange with the Companion

Flange Holder then loose the locknut.
ALIGNING MARKS
5. Removethe differential carrier frorn the differential

carrier housing.
6. Removethe drive pinion from the differential carrier

housing.
COMPANION FLANGE HOLDER

07926-SD90000
3. Removethe locknut, spring washer, and compan-

ion flange.
r
COMPANION FLANGE
ORIVE PINION
Replace.
(cont'd)
15-41
Differential
~isasse~bly (cont'd)~~~~~~~~~~~~~~~~~~~~~~~~
7. Removethe drive pinion oil seal and the taper roller 9. Removethe bearing outer race from the differential
bearing. carrier housing.
DIFFERENTIAL
CARRIER
HOUSING
Replace.
8. Removethe bearing outer race from the differential 1 O. Removethe taper roller bearingfrom the drive pinion.
carrier housing.
BEARING PULLER
BEARING
OUTER RACE
ORIVE PINION
15-42
~isasse~bly/Reasse~bly~~~~~~~~~~~~~~~~~~~~~~
1. Remove the both differential side bearings using a 3. lnstall the ring gear on the differential carrier.
bearing puller.
NOTE: Tighten the bolts in a criss-cross pattern in
2-3 steps.
TAPER ROLLER
BEARING
BEARING PULLER 10 mm BOLT

103 N·m 110.3 kg-m,
74 lb-ft)
2. Removethe ring gear bolts, then remove the final

driven gear from the differential carrier.
4. Orive the taper roller bearing onto the differential
NOTE: carrier.
• The final driven gear bolts has right-handthreads.
• Loosen the bolts in a criss-cross pattern in 2 - 3
steps.
DRIVER
ATTACHMENT
07GAF-SE00300 T APER ROLLER
BEARING
~
15-43
Differential
Height
Adjus1tment------------------------
1. Insta\\ the rear pinion bearing race into the differen- 3. Adjust drive pinion height as follows;
tial carrier housing using the special tools.
NOTE:Clean all parts and tools in solvent thoroughly
OUTER HANDLE A before adjusting the pinion height.
07749-0010000
a. lnstall the taper roller bearing on the Pinion Dum-
DIFFERENTIAL my Shaft, then install the shaft in the differential
CARRIER carrier housing.
/
H07NG
' 22 mm LOCKNUT
SPRING
WASHER lb
\
COMPANION
\=
FLAN GE
PINION DUMMY
SHAFT
07973-8090100
BEARING
OUTER RACE.
2. lnstall the front pinion bearing race into the differen-

tial carrier housing using the special tools.
DIFFERENTIAL
CARRIER T APER ROLLER BEARING
OUTER HANDLE A HOUSING
' 07749-0010000
/ SEAL DRIVER b. Slide the taper roller bearing onto the dummy
shaft.
~(
/ ~~947-$090101
c. lnstall the companion flange, spring washer and

locknut on the dummy shaft.
NOTE:
• Replace the locknut with a new one.
• Do not install the drive pinion oil seals and pinion
spacer at this time.
• lnstall the spring washer with the dished end fac-
DIFFERENTIAL
CARRIER ing the carrier.
------
HOUSING
15-44
d. Hold the dummy shaft by inserting the end of a g. Placethe Pinion Height Block on a surface plate;
screwdriver in its hole, and torque the locknut to set the dial indicator needle to "O".
10 N·m (1.0 kg-m, 8 lb-ft).
NOTE: DIAL INDICATOR

• The locknut has right-hand threads.
• Do not overtighten the locknut.
22 mm LOCKNUT
PINION DUMMY
8HAFT
07973-8090100
8URFACE PLATE
h. Move the pinion height block onto the differen-

tial housing with the indicator needleover the end
of the dummy shaft as shown.
NOTE:lnstall the bearing caps, then tighten the bolts

8CREWDRIVER to 55 N·m (5.5 kg-m, 44 lb-ft) to assure proper tool
contact.
e. Measure drive pinion preload.
i. Remove the bearing caps, and measure the pin-
Standard: 0.9 - 1.2 N·m ion height. Take the least reading to determine
(9.0 - 12.0 kg-cm, 7.8-10.8 lb-in) the pinion height by rotating the pinion height
block on the differential housing.
DIAL INDICATOR
PINION HEIGHT BLOCK
07973-5090200
PINION DUMMY
8HAFT
07973-8090100
f. lf out of tolerance, turn the locknut in or out until

the correct preload is obtained.
(cont'd)
15-45
Differential
Height Adjustment (cont' d)
j. To determinethe proper30mm thrust shim thick- 4. Drive the rear drive pinion and 30 mm thrust shim
ness,subtract the valueetchedon the pinionfrom selected onto the drive pinion.
the value obtained in step 3-i. TAPER ROLLER
DRIVER
IBEARING
¡ eJ
NOTE:Make etched on the pinion are a plus ( +) or 07946-MBOOOOO
minus ( - ) figure representing machining tolerance
in hundredths of a mm.
Example _1:
•
•
Value measured in Step 3-i: 0.85 mm
Mark etched on pinion: + 2
=s-..
= 30 mm THRUST
.. SHIM
Shim Thickness required:
Shim to be selected from chart: 0.84 mm (0.033 in)
Example 2:
• Value measured in Step 3-i: 0.85 mm
• Mark etched on pinion: - 1
Shim Thickness required: 5. lnstall the drive pinion in the carrier.
e. ~- ~
Shim to be selected from chart: 0.87 mm (0.034 in)
22 mm LOCKNUT'-..._
SPRING
WASHER
ce:::JJ-------
__ _.. . ___(( ~ ETCHED
~ MARK
30 mm THRUST SHIM
1 41361-PH8-000 O. 75 mm (0.030 in)

2 41362-PH8-000 0.78 mm (0.031 in)
OIFFERENTIAL
3 41363-PH8-000 0.81 mm (0.032 in)
CARRIER
4 41364-PH8-000 0.84 mm (0.033 in) HOUSING
5 41365-PH8-000 0.87 mm (0.034 in)
6 41366-PH8-000 0.90 mm (0.035 in) 6. lnstall the front drive piruon bearing, companion
7 41367-PHS-OOO 0.93 mm (0.036 in) flange, spring washer, and locknut.
8 41368-PH8-000 0.96 mm (0.037 in)
9 41369-PH8-000 0.99 mm (0.038 in) NOTE:
10 41370-PH8-000 1 .02 mm (0.039 in) • Do not install the drive pinion oil seals and pinion
11 41371-PH8-000 1 .05 mm (0.030 in) spacers.
12 41372-PH8-000 1 .08 mm (0.030 in) • lnstall the spring washer with the dished end fac-
13 41373-PH8-000 1. 11 mm (0.030 in) ing the carrier.
14 41374-PH8-000 1. 14 mm (0.030 in)
15 41375-PH8-000 1. 17 mm (0.030 in)
16 41376-PH8-000 1.20 mm (0.030 in)
15-46
Reassembly
7. Hold the companion flange with the Companion 1. Fit the assembleddifferential case into the carrier.
Flange Holder, and tighten the locknut to about 1 O
N·m (1.0 kg-m, 8 lb-ft). 2. lnsert the one 2. 20 mm (0.087 in) shim between the
side bearing and carrier at the ring gear side, then
push the differential assemblyto move the ring gear
away from the drive pinion. Measurethe clearance
between the side bearingand carrier at the opposite ·
side of the ring gear.
3. To determine the shim thickness, add 2.23 to 2.26

mm to the clearancemeasured (to compensate far
bearing tightening). then divide by 2.
COMPANION FLANGE Example:

HOLDER Clearancemeasured with thickness gauge:
07926-$090000 Allowance far taper bearing
8. Check the drive pinion bearing preload.
3.32 mm 5.58 mm
2.79 mm
NOTE: 2.20 mm 2
• Do not overtighten the locknut. +0.06 mm
• Rotate the pinion severaltimes to assure proper 5.58 mm
bearing contact. lnsert a 2.77 mm shim in each side.
Preload: 0.9 - 1.2 N·m PART NUMBER THICKNESS

(9.0 - 12.0 kg-cm. 0.7 - 0.9 lb-ft)
1 41411-PHB-OOO 2.20 mm (0.087 in)
2 41412-PH8-000 2.23 mm (0.088 in)
3 41413-PH8-000 2.26 mm (0.089 in)
4 41414-PH8-000 2.29 mm (0.090 in)
5 41415-PHB-OOO 2.32 mm (0.091 in)
6 41416-PHB-OOO 2.35 mm (0.093 in)
7 41417-PHB-OOO 2.38 mm (0.094 in)
8 41418-PH8-000 2.41 mm (0.095 in)
9 41419-PH8-000 2.44 mm (0.096 in)
10 41420-PH8-000 2.4 7 mm (0.097 in)
11 41421-PH8-000 2. 50 mm (0.098 in)
12 41422-PH8-000 2. 53 mm (O. 100 in)
13 41423-PH8-000 2.56 mm (0.101 in)
14 41424-PH8-000 2.59 mm (0.101 in)
15 41425-PHB-OOO 2.62 mm (0.103 in)
16 41426-PHB-OOO 2.65 mm (O. 104 in)
17 41427-PH8-000 2.68 mm (0.106 in)
18 41428-PH8-000 2.71 mm (0.107 in)
19 41429-PHB-OOO 2. 74 mm (O. 108 in)
20 41 430- PH8 -000 2. 77 mm (O. 109 in)
21 41431-PH8-000 2.80 mm (O. 11 O in)
22 41432-PHB-OOO 2.83 mm (O. 111 in)
9. lf out of specification, turn the locknut in or out un-
23 41433-PH8-000 2.86 mm (0.113 in)
til the correct preload is obtained.
24 41434-PH8-000 0.50 mm (0.020 in)
(cont'd)
15-47
Differential
4. lnstall the shims selected between the side bearing 7. lf out of tolerance. correct by decreasing the shim
and carrier on both sides. thickness on one side and increasing the thickness
of other shim the same amount.
SHIMS
NOTE:
• The total of both shims must still equal the cal-
culation you made in step 3.
• lf there is too much backlash, move the ring gear
toward the drive pinion. lf there is not enough
backlash, move the ring gear away from the drive
pinion.
8. When you obtain correct backlash, check the total

bearing preload.
Orive pinion preload: 0.9-1.2 N·m (9.0-12.0 kg-m,

7.8-10.4 lb-in)
+
5. Position the bearing caps in place and tighten the Diff housing preload: 0.4-0.6 N·m (4.0-6.0 kg-m,
bolts.
3.4- 5.2 lb-in)
NOTE: Align the marks made during disassembly. lf the preload is not within the limit, change the 67
mm thrust shim on both sides of the differential case.
10 mm BOLT
The backlash must remain within tolerance.
55 N·m (5.5 kg-m. 40 lb-ftl
9. Check the contact between the ring gear and drive
pinion.
NOTE:
• Paint the ring gear teeth lightly and evenly with
Prussian Blue (on both sides of each tooth).
• Rotate the pinion one full turn forward and back-
ward while applying pressure the ring gear.
6. Measure the backlash between the ring gear and

drive pinion.
Backlash: 0.11 - 0.16 mm (0.0043 - 0.0063 in)
15-48
1 ) CORRECT TOOTH CONT ACT 1 O. Remove the differential carrier from the housing.
11. Remove the following parts from the carrier.
• 22 mm locknut
• Spring washer
2) TOE CONT ACT
• Companion flange
• Use a thinner pinion shim to move the drive • Orive pinion
pinion away from the ring gear. • Front drive pinion bearing
~¿_+_0-1 22 mm LOCKNUT
3) HEEL CONTACT
SPRING WASHER ~
• Use a thinner pinion shim to move the drive
pinion toward the ring gear.
-c:::::::::::-•-0
4) FLANK CONTACT
• Use a thinner side bearing shim on the drive
pinion side and a thicker one on the ring gear
side to move the ring gear toward the drive
pinion. The total of both shims must still
equal the calculation you made on page
15-47, step 3.
NOTE:Recheckbacklashafter replacingthe side

bearing shims. lf out of specification, adjust as
described under TOE CONTACT.
DIFFERENTIAL
CARRIER
1 2. lnstall a new pinion spacer onto the drive pinion.
5) FACE CONTACT
/
ORIVE PINION
• Use a thinner side bearing shim on the drive
pinion side and a thinner one on the ring gear
away from the drive pinion. The total of both PINION SPACER
shims must still equal the calculation you Replace.
made on page on 1 5-4 7, step 3.
NOTE: Recheckbacklashafter replacingthe side

bearing shims.
lf out of specification, adjust as described un-
der HEEL CONTACT.
(cont'd)
15-49
Diff erential
1 3. lnstall the drive pinion in the differential carrier 15. lnstall the following parts on the drive pinion.
housing, then install the two thrust washers and
taper roller bearing on the drive pinion. • Companion flange
• Spring washer
• 22 mm Locknut
THRUST ORIVE PINION

WASHERS
SPRING
WASHER
PINION
SPACER
22mm
LOCKNUT
1 6. Hold the companion flange with the Companion

14. Orivethe oil seal into the differential carrier hous- Flange Holder and tighten the 22 mm locknut to
ing using a special tool. 120 - 230 N·m ( 12 - 23 kg-m, 86 - 166 lb-ft).
The preloadshouldbe 1.2 - 1.5 N·m(12.0 - 15.0
kg-m, 1 O - 13 lb-ft).
NOTE:
• lf the preload exceeds 1.5 N·m (15 kg-cm, 13
lb-in), replace the spacer; Do not adjust by
loosening the 22 mm locknut.
• Also replacethe pinion spacer if the preload is
not within the limit even when the locknut is
tightened over 230 N·m (23 kg-m, 166 lb-ft).

07926-8090000 .
SOCKET WRENCH
/
/
/
22 mm LOCKNUT
120 - 230 N·m (12.0 - 23.0 kg-m, 86 - 166 lb-ft)
15-50
Housing lnstallation
17. Check the preload. 1. Apply liquid gasket to the carrier housing mating sur-
face of the differential housing.
NOTE: Befare measuring the preload, rotate the
pinion severa! times to assure proper bearing NOTE: This differential uses no gasket between the
contact. majar housing; use Honda Genuine Liquid Gasket
(P/N 08718-0001). Assemble the housing within
Preload: 1.2 - 1.5 N·m ( 12.0 - 15.0 kg-m. 20 minutes after applying the liquid gasket and al-
10 - 13 lb-in) low it to cure at least 30 minutes after assembly be-
fare filling it with oil.
2. lnstall the carrier on the differential housing.
8 x 10 mm
DOWEL PIN
18. Stake the 22 mm locknut.
DIFFERENTIAL CARRIER
ASSEMBLY
LOCK TAB
19. lnstall the differential assemblyon the carrier (page

15-47).
20. Check the total preload.
Orive Pinion Differential

Preload: Carrier Preload:
1.2 - 1.5 N·m 0.4 - 0.6 N·m
(12.0 - 15.0 kg-cm, + (4.0 - 6.0 kg-cm,
10 - 13 lb-in) 3.4 - 5.2 lb-in)
15-51
Differential
(with viscous coupling)
Special Tools 15-56

Service Precautions . . . . . . . . . . . . . . . . . . . . . . . . 15-56
Differential Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5-5 7
Oil Leak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-58
Viscous Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-59
Differential Clutch
Operation Check (Mechanical) . . . . . . . 15-60
Operation Check (With ALB Checker) 15-61
Operation Check (With Jumper Wire) 15-62
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5-63
Differential
Removal/lnstallation . . . . . . . . . . . . . . . . . . . . . 15-64
lllustrated lndex . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-66
Disassembly • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-68
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5- 78
Dog Clutch Clearance . . . . . . . . . . . . . . . . . . . . . 15-91
Hypoid Pinion Height 15-92
Ring Gear Backlash . . . . . . . . . . . . . . . . . . . . . . . . 15-93
Ring Gear & Hypoid Pinion Tooth
Contact ·...................................... 15-94
Solenoid Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 1 5-94
Solenoid-On-Differential Assembly . . . . 15-95
Stroke Switch
lnpsection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-95
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5-96
Special Tools
Special Tools
CD 07HAJ- SG00602 ALB Checker 07HAJ-SG00601 or

07508-SBOOOOO
@ 07HAJ- SG00400 Frequency Convert Adapter
@ 07KAJ-PS30100 Feeler Gauge Set
@-1 07KAJ-PS30110 Feeler Gauge 0.05 mm
@-2 07KAJ-PS30120 Feeler Gauge 0.25 mm
© 07979-PJ40001 Magnet Stand Base
® 07KAZ-PS30100 Viscous Shaft Adapter
® 07926-SDSOOOO Companion Flange Holder
0 07744-0010400 Pin Driver 5 mm
® 07LGC-0010100 Snap Ring Plier
® 07749-0010000 Outer Handle A
® 07GAD-PG40100 Driver Attachment
® 07KAF-PS30200 lnner Race Remover Base
@ 07JAD-SH30100 Oil Seal Driver
@ 07KAB-PS30100 Dog Piece Holder
@ 07JAC-PH80000 Adjustable Bearing Remover Set
@-1 07JAC-PH80100 Bearing Remover Attachment
@-2 07JAC-PH80200 Remover Handle
@-3 07JAC-PH80300 Amover Weight
¡ o
<; Q)-1 @
G) Q)-2
1
@e5 l..~P
j I
~
@ (J) ®
®
~ ~@
&-@-1
® @ @
~
~·@2 --@-3
@) @
15-54
- Special Toos
® 07KAD-PS30100 Taper Bearing Remover

@) 07746-0030100 lnner Handle C
@ 07746-0030400 lnner Driver 35 mm
@ 07KAF-PS30100 Bearing lnstaller Tool Set
@-1 07JAF-SJ80110 Shaft
@-2 07JAF-SJ80120 Nut
@-3 07KAF-PS30110 Taper Bearing lnstaller
® 07KAF-PS30400 Pinion Oil Seal Driver
® 07KAF-PS30500 lnner Race Driver
® 07 JAD- PNOO 100 Oil Seal Driver
® 07KAJ-PS30200 Height lnspection Gauge
@-1
rrn
fí'3 @
~
6,
'---"
@
s @
~
1
@-2
@-3
@-4
~
@ ®
15-55
Service Precautions
The RealTime4WD systemallowsinstantaneous shift from Operations Requiring 4WD Disengagement

FWD to 4WD automaticallywhen greatertraction is need- • When using test appliances:
ed. To prevent accidentsor injuries, the system must be Speedometertester, braketester, chassisdynamometer,
releasedbefore performing any serviceson the differential etc.
unit.
CAUTION: Apply the parking brake and block the rear
wheels before using a speedometer tester. When you
To ralease 4WD use a chassis dynamometer, fix the car body with a rope
With the engine stopped, turn the shift bolt (painted to prevent it from moving.
orange)as describedbelow.
DISENGAGEMENT
BOLT
1. Loosenthe lock bolt A.
2. Align the mark on the disengagementbolt B with "2"

to disengagethe 4WD system.
3. Align the plate C with the cutout in the disengagement

bolt B and tighten the lock bolt A to the specified
torque.
TORQUE: 17N•m (1.7kg-m, 121b-ft)
NOTE: When the engine starts with the 4WD

system disengaged, the rear differential clutch
warning light should come on.
CAUTION: After servicing, be sure to engage the 4WD

<2WD> <4WD> system (align the alignment mark with "4") and tighten
the lock bolt A securely.
Stop the engine and disconnect the ABS 82 fuse in the
DISENGAGEMENT BOLT B
engine compartment far more than 3 seconds.
The self-diagnosis lamp of the ABS control unit should
stop blinking.
LOCKBOLTA ALIGNMENT MARK
15-56
Differential Oil
Oil Level Check Oil Change
Clutch Housing Clutch Housing

1. Check with oil at operating temperature, engine OFF, 1. Change oil only when disassembling the clutch
and car on level ground. housing.
2. Remove oil filler plug and check level with finger. NOTE: The clutch housing has no drain bolt.
3. Oil level must be up to filler hole, lf it is below the e

Capacity: 0.31 (0.33 US qt., 0.26 Imp. qt.) after
hole, add oil until it runs out, then reinstall plug. overhaul.
Recommended oil: Genuine Honda ATF
Differentlal Carrier
1. Drain with transmission oil at operating temperature,
engine OFF, and car on level ground.
2. Removethe oil filler plug, then remove the drain plug

and drain transmission.
OIL FILLER PLUG 3. Reinstall drain plug with a new washer, and refill to
40 N·m (4.0 kg-m, 29 lb-ft) ---~• proper level.
NOTE: Drain plug and filler plug washers should be

replaced at every oil change.
Oil Capacity
0.~3 e
(1.0 US qt., 0.8 Imp. qt.) after drain.
WASHER
Replace.
1.0 e(1. 1 US qt., 0.9 Imp. qt.) after overhaul.
Recommendedoil: Hypoid gear oil (API Classification GL5
or equivalent)
Viscosity SAE #90 above SºC (41 ºF)
SAE #80 below 5°C (41 ºFl
1. Check with oil at operating temperature, engine OFF,
and car on level ground.
2. Remove oil filler plug and check level with finger. OIL FILLER PLUG
48 N·m (4.8 kg-m, 35 lb-ft)
3. Oil level must be up to filler hole. lf it is below the
hole, add oil until it runs out, then reinstall plug.
OIL FILLER PLUG

48 N•m (4.8 kg-m, 35 lb-ft)
OIL DRAIN PLUG

40 N·m (4.0 kg-m, 29 lb-ftl
WASHER
Replace.
15-57
Oil Leak
lnspection
CAUTION:
• Use Honda Genuine Liquid Gasket (P/N
08718-0001 ).
• Clean the sealing surfaces before inspection.
• Apply sealant evenly to the whole area of the sealing
surfaces.
• lf more than 20 minutes have passed after applying
the sealant. apply it again before assembling.
CD Check the area around the companion flange for oil @ Check the area around the carrier cover for oil leaks
leaks or seepage.lf oul is leaking or seepingout, check or seepage. Remove the carrier cover and apply Hon-
for damaged companion flange oil seal. da Genuine Liquid Gasket (P/N 08718-0001) again,
if necessary.
@ Check the area around 2 - 4 shift column for oil leaks
or seepage. lf oil is leaking or seeping out, check for (J) Check the area around the carrier cover oil seal for oíl
damaged 2 - 4 shift column 0-ring. leaks or seepage. lf oil is leaking or seeping out, check
for damaged carrier cover oil seal.
@ Check the area around the intermediate plate for oil
leaks or seepage. lf oil is leaking or seeping out, re- @ Check the area around the differential carrier side oil
move the intermediate plate and apply Honda Genuine seal for oil leaks or seepage.
Liquid Gasket (P/N 08718-0001) again. Check for damaged differential carrier side oil seal if
necessary.
@) Remove the check bolt and check for oil leaks or
seepage. lf oil is leaking or seeping out, check for ® Check the areas around the oil filler plug and the drain
damaged 2 - 4 shift shaft oil seal. plug for oil leaks or seepage.
Replace the washers if necessary.
® Check the check hole for oil leaks or seepage. lf oil
is leaking or seeping out, check for damaged two- CAUTION: Clean the differential; this will make it easy
liquid separator oil seals. to identify the oil leak/seepage point.
NOTE: Referto "Disassembly" and "Reassembly" of the

differential.
15-58
Viscous Coupling
lnspection
MT AT
1. Raisethe car off the ground and place safety stands 1 . Raisethe car off the ground and place safety stands
under the side sill reinforcement sections. under the side sill reinforcement sections (see left
drawing).
2. Mark either the No. 1 or No. 2 propeller shaft.
2. Start the engine and keep the engine speed at idle. 3. Start the engine and keep the engine speed at idle.
3. Shift into low gear and gradually releasethe clutch. 4. Fix the engine speed at low gear by moving the shift
lever to the 2nd gear range and pressing the LOW
4. Apply the parking brake firmly. switch.
• Viscous coupling is OK if the engine stalls.
• Viscous coupling is faulty if the engine continuas 5. Apply the parking brake firmly and hold the engine
to run. idling for 5 minutes.
NOTE:Both the front and rear wheels should be spin-

ning before the parking brake is applied, while the
rear wheels should lock and the front wheels should
turn slowly when the parking brake is applied.
6. After the engine has idled for 5 minutes, measure

the time during which the marked propeller shaft ro-
tates 1 O times.
• Viscous coupling is OK if the time for 1 O turns
is 18 seconds or more.
• Viscous coupling is faulty if the time for 1 O turns
is less than 18 seconds.
CAUTION: Raleasethe parking brake levar immedi-

ately after measurlng. Otherwise. the temperatura
of the viscous coupling risas causing damage.
15-59
Differential Clutch
Operation Check (Mechanical)
1. Check for operation with the engine OFF. 6. Make sure that the rear wheels can be turned by
hand.
2. Block the front wheels securely. Jack up the rear of
the car and place safety stands under the side sill 7. lf the rear wheels turn in step 4, or if they do not
reinforcement sections. turn in step 6, check the differential for damage.
3. Make sure that the 4WD system is engaged. CAUTION: Do not forget to engage the 4WD sys-
tem after checking the differential clutch for
operation.
DISENGAGEMENT BOLT
SAFETY STAND
4WD ENGAGED
ALIGNMENT MARK
4. Make sure that the rear wheels cannot be turned by

hand.
5. Disengagethe 4WD system.
AT2WD
(4WD DISENGAGEDI
15-60
Operation Check (With ALB Checker)
1. Perform the ABS function test with ALB checker to 7. Start the engine and release the parking brake.
check that there are no problems or abnormalities.
8. Turn the Mode Selector switch to 4 or 5.
2. Turn the ignition switch ON and check that the rear
differential clutch warning light comes on. lf it does 9. Push the Start Test switch.
not come on, go to troubleshooting, page 19-66.
CAUTION: When the test in progress indicator light
3. With the ignition switch OFF, disconnect the 6-P in- is ON, don't turn the Mode Selector switch.
spection connector (ORN)from the connector cover
PULSE SELECTOR
located on the cross-member under the passenger's SWITCH
seat and connect the 6-P inspection connector to the
ALB checker. .sr":
CONNECTOR
COVER
ST ART TEST SWITCH
1 O. Check if the rear wheels can be rotated by hand

while solenoid operating sound is heard.
lf the rear wheels cannot be rotated, there is an open
circuit in the related wire harness or the solenoid is
faulty.
CAUTION: Do not use Mode 6 while testlng.
ew+M@d
ALB CHECKER
07HAJ-SG00601 or Disconnect the ALB checker before
07HAJ-SG00602 or driving the car A collision can result from a reduc-
07508-SBOOOOO and 07HAJ-SG00400 (Adaptar)
tion, or complete loss of braking ability causing se-
vera personal injury or death.
4. Block the front wheels, raise the rear of the car and
support on safety stands.
5. Shift the transmission in neutral for manual trans-

mission models, and in P for automatic transmission
models.
6. Short the brake light switch terminal with a jumper

wire.
NOTE: Although it is acceptable for assistant to

depress the brake pedal instead of performing step
6, the wheels cannot be rotated in step 1 O if the pe-
dal is depressed firmly.
SAFETV ST ANO
15-61
Diff erential Clutch
Operation Check (With Jumper Wire)
CAUTION: To prevent the rear ditferential clutch sole- 4. Turn the ignition switch ON.
noids from damage, do not leave the ignition switch on
for more than 5 minutes and do not ground the RED/YEL 5. Check that the voltmeter shows the battery voltage.
wire (pulling solenoidl for more than 5 seconds while lf it shows OV, the stroke switch circuit is detective
testing. or the dog clutch is faulty (2WD position).
1. With the ignition switch OFF, disconnect the 4-P in- 6. Ground the RED/YELterminal to the body with a
spection connector (ORN)from the connector cover different jumper wire for an instant (less than 5
located on the cross-rnernber under the passenger' s seconds).
seat. Ground the RED/GRNterminal (holding sole-
noid) to the body with a jumper wire and connect
4-P INSPECTION CONNECTOR
the voltmeter between the BLUE/GRNterminal and
body ground.
BLK/VEL RED/GRN
4-P INSPECTION CONNECTOR
BLK/VEL RED/GRN
/ RED/YEL
BLU/GRN
BLU/GRN
View from terminal side. View from terminal side.
2. Block the front wheels, raise the rear of the car and
support on safety stands.
7. Check that the voltmeter shows OV and that the rear
3. Make sure that the selector bolt of the rear differen- wheels can be rotated by hand.
tial is set to 4WD. • lf the rear wheels cannot be rotated, there is an
open circuit in the relatad wire harnessor the sole-
noid is faulty.
• lf the rear wheels can be rotated but the voltmeter
does not show OV, the stroke switch is faulty.
For 4WD
SAFETV STAND
15-62
Troubleshooting
CAUTION: Most problems in the unit are to be diagnosed by identifying noises from the gears or bearings. Care should
be taken during diagnosis not to confuse the differential noises with those from other drive train components.
Symptom Probable Cause Remedy

Consistent noise during • Lack of oil • Replenish oil
cruising
• Foreign matter stuck in gears, etc . • Clean and inspect
• Replace any damaged or faulty
parts
• lmproper tooth contact between ring gear • Adjust or replace
and hypoid pinion
• Worn or damaged side bearing
• Worn or damaged hypoid pinion taper
bearing
• Worn ring gear or hypoid pinion • Replace
• Deformed ring gear or differential carrier
• Damaged gears, etc .
Gear noises while • Lack of oil • Replenish oil
accelerating
• Foreign matter stuck in gears, etc. • Clean and inspect
• Replace damaged parts
• Gears not engaged properly or misadjusted • Clean and inspect
• lmproper hypoid pinion preload • Replace damaged parts
• Chipped or damaged gears • Replace
Gear noises while • lmproper hypoid pinion preload • Adjust or replace
coasting • Chipped or damaged gears
Bearing noises while • Cracked or damaged hypoid pinion taper • Replace
accelerating or coasting/ bearing or side bearing
decelerating
Abnormal noises while • Excessive backlash between ring gear and • Adjust
starting or accelerating hypoid pinion gear
• lmproper ring gear or hypoid pinion preload
• Worn viscous side spline • Replace
Oíl leak • Oil level too high • Lower to proper level
• Clogged breather hale • Clean or replace
• Loose differential carrier or inadequate • Recheck torque or apply
sealing sealant
• Worn or damaged oil seal • Replace
Overheating • Lack of oil • Replenish
• lnsufficient backlash between ring gear and • Adjust
hypoid pinion gear
• Excessive ring gear or hypoid pinion preload • Adjust
Shock noises from the • Excessive backlash between ring gear and • Adjust
rear when starting hypoid pinion gear
Shock noises from rear • Dog clutch out of engagement • Adjust or replace
differential when rouding
a curve in reverse gear
at full speed
15-63
Differential Assembly
Removal/lns1tallation
1. Disconnectthe battery negative ( - ) and positive ( + ) 9. Remove the rear differential mount A from the
cables from the battery. differential assembly.
2. Disconnect the differential harness connectors.
3. Drain oíl from the differential.
4. Remove the breather tube joint. 12 x 1.25 mm

55 N·m (5.5 kg-m, 40 lb-ft)
5. Remove the propeller shaft (see section 16).
6. Remove the driveshafts (see section 16).
7. Remove the mount bolts from the rear differential

mount B.
8. Removethe rear differential mount A attaching bolts,

then remove the differential assembly and mount A.
REAR DIFFERENTIAL
MOUNT B
12 x 1.25 mm
55 N·m (5.5 kg-m, 40 lb-ft)
DIFFERENTIAL
ASSEMBLY
1 O. lnstall the differential assembly in the reverse order

of removal.
NOTE: After installing the rear differential, pour the

specified amount of the ATF oil into the clutch hous-
ing and the gear oíl into the differential carrier (see
page 15-57).
SPECIAL BOL TS
12 x 1.25 mm
49 N·m (4.9 kg-m, 35 lb-ft)
Re place.
15-64
Differential
lllustrated lndex -----------------
CAUTION: Coat the clutch housing side parts with ATF and the differential carrier side parts with hypoid gear oil.
NOTE:
• Clean the parts (except solenoid) thoroughly in cleaning solvent and dry them with compressed air. Blow out all passages.
• Coat the rotating or sliding sections of the parts with oil befare reassembly.
15-66
G) 20 mm LOCKNUT @ SPRING WASHER @ STROKE SWITCH CLAMP
Replace. @ SOCKET BOLT @ 12 mm CHECK BOLT
99 N·m (9.9 kg-m, 72 lb-ftl 24 N·m (2.4 kg-m, 17 lb-ft) 17 N·m (1.7 kg-m, 12 lb-ftl
@ SPRING WASHER @ 14 mm SHIM @) SOLENOID SPACER
@ COMPANION FLANGE Selection, page 1 5-96 @) SOLENOID MOUNTING SPACER
@ 40 x 62 x 8 mm OIL SEAL @) STROKE SWITCH @) 2-4 SOLENOID ASSEMBLY
Replace. 25 N·m (2.5 kg-m, 18 lb-ftl @) 30 mm SHIM
@ BALL BEARING @ SWITCH HARNESS PROTECTOR @) PINION SPACER
@SNAP RING @ 26 mm LOCKNUT ® 72 mm OUTER SPACER
(J) 14 mm FILLER BOLT Replace. @ TAPER ROLLER BEARING
@WASHER @ SPRING WASHER @35 mm SHIM
Replace. @HUB WASHER Selection, page 1 5-92
@ CLUTCH HOUSING @DOG PIECE @ HYPOID PINION
@) BREATHERPLATE @ 39 x 68 x 7 mm OIL SEAL @ 20 mm FILLER BOLT
@ 30 mm WASHER Replace. 48 N·m (4.8 kg-m, 35 lb-ftl
Selection, page 1 5-91 @ 39 x 64 x 7 mm OIL SEAL @WASHER
@ 2-4 INPUT SHAFT Replace. Replace.
@2-4 SLEEVE @ TAPER ROLLER BEARING @ 35 x 66 x 8 mm OIL SEAL
@STEEL BALL @ 62 mm OUTER SPACER Replace.
@ DOG CLUTCH HUB @ 10 x 24 mm DOWEL PIN @) 14 mm DRAIN BOLT
@ 20 x 26 x 17 mm NEEDLE @ SPECIAL PIPE C 40 N·m (4.0 kg-m, 29 lb-ftl
BEARING @ SEALING LOW BOLT @) WASHER
@ INTERMEDIATE PLATE @ 35 x 66 x 8 mm OIL SEAL Replace.
@ 5 x 25 mm SPRING PIN Replace. @) OIL CHAMBER PLATE
Replace. @ 34 mm SEALING BOLT @ HOUSING COVER
@) 2-4 SHIFT FORK @TUBE CLAMP @ OIL GUIDE PLATE
@) 2-4 SHIFT FORK SHAFT @ BREATHERTUBE @68 mm SHIM
@ 2-4 SHIFT SPRING @3-WAY JOINT Selection, page 15-93
@ 2-4 SHIFT SPACER @ BREATHERTUBE JOINT @ TAPER ROLLER BEARING
@ SPRING WASHER @) HARNESS CLAMP @ VISCOUS COUPLING
@ LOCK WASHER @) OIL GUTTER PLATE ASSEMBLY
Replace. ® DIFFERENTIAL HOUSING @ HYPOID RING GEAR
@ 2-4 SHIFT CbLUMN @) BREATHER CHAMBER PLATE @ TAPER ROLLER BEARING
@ 15.8 x 2.4 mm 0-RING @) HARNESS PROTECTOR @66 mm SHIM
Replace. Selection, page 1 5-93
Bolt Size Torque Value

A 6 X 1.0 mm 10 N·m (1.0 kg-m, 7.2 lb-ftl
8 6 X 1.0 mm 11 N·m (1.1 kg-m, 8.0 lb-ft)
e 6 X 1.0 mm 12 N·m ( 1.2 kg-m, 8. 7 lb-ft)
D 8 x 1.25 mm 24 N·m (2.4 kg-m, 17 lb-ft)
E 8 x 1.25 mm 26 N·m (2. 6 kg-m, 1 9 lb-ft)
F 10 x 1.25 mm 103 N·m (10.3 kg-m, 74 lb-ft)
G LOCK BOLT 1 7 N·m ( 1. 7 kg-m, 12 lb-ft)
15-67
Differential
lnspection -------------------------------.
lnspection befare Disassembly 3. Check the tooth contact between the ring gear and
1 . Removethe 14 mm filler plug from the clutch hous- hypoid pinion through the 34 mm sealing bolt hole.
ing. Measurethe dog clutch clearanceusing the feel-
er gauge. NOTE: Paint the ring gear teeth (on both sides of
each tooth) lightly and evenly with PrussianBlue.Ap-
CAUTION: Measure the clearance at tour diagonal- plying load to the ring gear, rotate the companion
ly opposed points. flange one full turn both forward and backward.
Standard: 0.05 mm (0.002 in) feeler gauge can be CAUTION: Check at three equally spaced point.
~ CL7
inserted, while 0.25 mm (0.01 in) cannot.
34 mm SEALING BOL T HOLE
14 mm FILLER
BOLT HOUSING
«. )
Replace.
7
FEELER GAUGE
07KAJ-PS30100
2. Remove the 34 mm sealing bolt from the differen-
GOOD TOOTH CONTACT PATTERN
tial carrier and measure the ring gear backlash.
CAUTION: Measure the backlash at tour diagonally

opposed points.
Standard: 0.10 - 0.15 mm (0.004 - 0.006 in)
NOTE: Measure the backlash by holding the dog

piece and moving the viscous shaft adapter.
15-68
Diff erential
Disassembly-----------------------------,
1. Disconnect the breather tube. 3. Remove the harness clarnps and disconnect the
stroke switch connector.
STROKE SWITCH CONNECTOR HARNESS CLAMP
4. Removethe 8 mm socket bolt and removethe clutch

housing from the differential housing.
2. Removethe flat screws and the harness protector. NOTE:

• Puta pan under the clutch housing and differen-
tial housing when separating them, becauseATF
will flow out.
• Separatethe clutch housing from the differential
housing by tapping lightly on the companion
flange with a plastic hammer.
FLAT SCREWS
(cont'd)
15-69
Differential
Disassembly (cont'd)~~~~~~~~~~~~~~~~~~~~~~~-
Clutch Housing 7. Hold the companion flange with the Companion

5. Remove the stroke switch protector and stroke Flange Holder and loosen the 20 mm locknut.
switch.

07926-5090000
STROKE SWITCH PROTECTOR
8. Removethe 20 mm locknut, 20 mm spring washer,

6. Pry off the staked area of the 20 mm locknut. and the companion flange.
20 mm SPRING
WASHER
i 20 mm LOCKNUT
Replace.
20 mm LOCKNUT
~ COMPANION FLANGE
~o
o
15-70
9. Remove the locknut and lock bolt plate, then pull out 1 l Disassemblethe 2 - 4 input shaft, dog clutch
the 2 - 4 shift column. hub, 2 - 4 sleeve, steel balls, and the 30 mm
shim.
NOTE: Use a pair of pliers to remove the 2 - 4 shift
column. CAUTION: Before disassembly, mark the 2 - 4
input shaft and dog clutch hub to ensure correct
reassembly.
LOCK BOLT
~BOLTP~TE
2 - 4 INPUT SHAFT
SPRING WASHER
2 - 4 SHIFT 0-RING
COLUMN Replace.
STEEL BALLS
1 O. Remove the 2 - 4 input shaft, dog clutch hub, 2 2) Disassemblethe 2 - 4 shift shaft, 2 - 4 shift
- 4 sleeve, steel balls, 30 mm shim, 2 - 4 shift fork, 2 - 4 shift spring, and the 2 - 4 shift
shaft, 2 - 4 shift fork, 2 - 4 shift spring, and the spacer.
2 - 4 shift spacer as a set.
NOTE:
• Put the clutch housing in a pan and remove the
parts with care in order not to loosethe steel balls.
• Remove the parts by tapping lightly on the 2 -
4 input shaft with a plastic hammer. 2 - 4 SHIFT SPRING 2 - 4 SHIFT FORK
»>
PIN DRIVER 5 mm
CLUTCH HOUSING 07744-0010400
SPRING PIN
Replace. 2 - 4 SHIFT SHAFT
(cont'd)
15-71
Differential
Disassembly (cont'd)~~~~~~~~~~~~~~~~~~~~~~~
11. Removethe oil seal. 13. Removethe breather plate.
CAUTION: Do not damage the oil seal surface.
OIL SEAL
Replace.
BREATHER PLATE
lntermediate Plate
14. Remove the bolts and remove the intermediate
plate and solenoid mounting spacer from the
differential housing.
NOTE: Removethe intermediate plate by tapping

it lightly with a plastic hammer.
12. Expandthe snap ring and remove the ball bearing.
SNAP RING PLIERS

07LGC-0010100
OUTER HANDLE A-----.1

07749-0010000
SOLENOID MOUNTING SPACER
DRIVER ATTACHMENT
07GAD-PG40100
BALL BEARING
15-72
15. Screw the 6 mm bolt into the solenoid assembly, 17. Remove the oil seal.
and remove the solenoid assembly and solenoid
spacer from the differential housing. CAUTION: Do not damage the oil seal surface.
CAUTION: Do not remove by pulling the harness.

OIL SEAL
Replace.
SOLENOID SPACER
Carrier Cover 18. Driveout the oil plate, 66.5 mm shim, and the taper
16. Removethe 8 mm flange bolts from the housing bearing outer race using the Oil Seal Driver At-
cover and the housing cover from the differential tachment.
housing.
CAUTION:
NOTE: Remove the housing cover by tapping it • Take care not to damage the carrier cover seal-
lightly with a plastic hammer. ing surface.
• Replace the oil guide plate if it is deformad.
8 mm FLAN GE BOL T
(cont'd)
15-73
Differential
Disasse~bly (cont'd)~~~~~~~~~~~~~~~~~~~~~~~
19. Straighten the staked area, then remove the flat 21. Pull off the taper roller bearing using the press and
screws and oil chamber plate. the lnner Race Remover Base.
FLAT SCREW
Peplace. PRESS
INNER RACE REMOVER
BASE
07KAF- PS30200
/
OIL CHAMBER PLATE
T APER ROLLER BEARING
22. Rernovethe 1 O mm special bolts and the ring gear.

Viscous Differential Assembly
20. Remove the viscous differential assembly, ríng CAUTION:
gear, and the taper bearíng inner from the differen- • Remove the 1 O mm special bolts by loosening
tial housing as an assembly. them in a criss-cross pattern in severa! steps.
• Do not remove the torx bolts from the viscous
coupling.
VISCOUS DIFFE.RENTIAL ASSEMBL Y 10 mm SPECIAL BOLT
DIFFERENTIAL
HOUSING
VISCOUS
ASSEMBLY
15-74
Differential Carrier 25. Removethe 26 mm locknut, 26 mm spring wash-
23. Straighten the staked area of the 26 mm locknut. er, hub washer, and the dog piece.
CAUTION: Make sure the staked area gets corn-

pletely straightened.
24. Attach the Dog Piece Holder to the differential

housing and loosen the 26 mm locknut.
CAUTION: 26. Removethe hypoid pinion, 35 mm shim, taper bear-

• Attach the Dog Piece Holder securely to the ing inner, pinion spacer, and the two 30 mm shims.
• Make sure that the housing cover is installed on
the differential housing.
• Use an appropriate socket wrench that can
reach the locknut.
PINION SPACER
HYPOID PINION
DOG PIECE HOLDER
07KAB-PS30100
(cont'd)
15-75
Differential
Disassembly (cont'd)~~~~~~~~~~~~~~~~~~~~~~~
27. Removethe outer oil seal. 29. Removethe inner oíl seal, then remove the taper
roller bearing.
OIL SEAL
Replace.
TAPER ROLLER
BEARING
28. Remove the sealing low bolt and special pipe C. 30. Removethe bearing outer race and 62 mm outer
spacer using the special tools.
ADJUSTABLE BEARING
REMOVER SET
r:
07JAC-PHSOOOO
BEARING
OUTER RACE
15-76
31. Orive out the taper bearing outer race and 72 mm 33. Orive out the taper bearing outer race and 66 mm
outer spacer using the Outer Driver and Taper Bear- shim using the Oil Seal Driver Attachment.
ing Remover.
CAUTION: To prevent damage to the differential
CAUTION: To prevent damage to the differential housing, place a shop towel or equivalent material
housing, place a shop towel or equivalent material into the differential housing and remove the parts
into the differential housing. with the housing cover mounted on the differen-
tial housing.
PRESS --- ....._-1

OUTER HANDLE A
07749-0010000 OUTER HANDLE A OIL SEAL DRIVER
07749-0010000 07JAD-SH30100
T APER BEARING
REMOVER
07KAD-PS30100
34. Raise the lock tab and remove the bolts, then re-
move the oil gutter plate and breather chamber
plate.
32. Remove the oil seal from the differential housing.
CAUTION: Do not damage the oil surface.

BREATHER CHAMBER PLATE
OIL GUTTER PLATE
(cont'd)
15-77
Diff erential
Disassembly (cont' d) -------, Reassembly....,..._---------
Hypoid Pinion NOTE:

35. Remove the taper roller bearing and 35 mm shim • lf replacement is required, always replace the drive
using a special tool. pinion and ring gear as set.
• lf necessary, check the height adjustment, see page
15-92.
PRE SS
INNER RACE REMOVER BASE /
07KAF -PS30200 SET NUMBER HYPOID PINION
SET NUMBER
RING GEAR
Hypoid Pinion
1. lnstall the 35 mm shim and taper roller bearing.
TAPER ROLLER BEARING
/
35mmSHIM ~
o
Selec,1~~
15-78
2. Drive the taper roller bearing using the special tools. 4. tnstalt the 66 mm shim. Pressthe taper bearing out-
er race into place using the Taper Bearing lnstallers,
Shaft, and Nut.
INNER HANDLE C CAUTION: Do not install the oil seal.

07746-0030100
~ TAPER BEARING INSTALLER
07KAF-PS30130
INNER DRIVER
35mm
07746-0030400
TAPER BEARING
INSTALLER
07KAF-PS30140
NUT
07JAF-SJ80120
66 mm SHIM
Differential Housing Selection.
3. Check A and B of the differential housing for clog-
ging. tnstall the breather chamber plate and oil gut-
ter plate in the differential housing and stake the ends 5. lnstall the 72 mm and 62 mm outer spacers, and
of the plates against the bolts. press the taper bearing outer races simultaneously
into place using the Taper Bearinglnstallers and Nut.
NOTE: lnsert the taper bearing outer races lightly be-

6 mm BOLT
i, N·m ( 1.1 kg-m. 8 lb-ftl fore pressingthem into place using the specialtools.
\ STAKE AGAINST BOLT
TAPER BEARING INSTALLER

07KAF-PS30120
NUT
07JAF-SJ80120
T APER BEARING
DIFFERENTIAL OUTER RACE
HOUSING
T APER BEARING
OUTER RACE
A
(cont'd)
15-79
Differential
Reassembly (cont'd)~~~~~~~~~~~~~~~~~~~~~~-
6. Lubricatethe gear oil to the taper roller bearing and B. lnstall the outer oíl seal using the special tools.
install the bearing, then install the inner oil seal us-
ing the special tools. NOTE:
• Orive the oíl seal in the proper position shown
NOTE: in the drawing.
• Orive the oil seal in the proper position shown in • Note the installation direction of the oíl seal.
the drawing.
• Note the installation direction of the oíl seal. OIL SEAL INNER HANDLE C
Replace. 07746-0030100
INNER HANDLE C
07746-0030100
OIL SEAL DRIVER

07KAF-PS30400
OIL SEAL DRIVER
07KAF-PS30400
7. Instan the special pipe C and sealing low bolt. 9. lnstall the hypoid pinion assembled in step 2, the
pinion spacer, and the 30 mm shims as a set.
NOTE:
• Apply liquid gasket to the clearancebetween the CAUTION: Be sure to replace the pinion spacer .with
pipe C and differential housing. a new one.
• Apply liquid gasket to the threads of the sealing
low bolt.
SEALING LOW BOLT

12 N·m (1.2 kg-m. 9 lb·ft) 30 mm SHIMS
'
15-80
-.
1 O. lnstall the dog piece, hub washer, 26 mm spring DOG PIECE HOLDER
washer, and the 26 mm locknut. 07KAB-PS30100
CAUTION:
• Be sure to replace the 26 mm locknut with a
new one.
• Note the installation direction of the 26 mm
spring washer.
• Lubricate the threads of the locknut and shaft.
26 mm LOCKNUT
Replace. DIFFERENTIAL
HOUSING
/
HUB WASHER
Preload:1.0-1.63 N·m (10.0-16.3 kg-cm, 9-14 lb-in)
DOG PIECE
TOROUE WRENCH
36 mm HEX
SOCKET WRENCH
Viscous Differential Assembly

12. lnstallthe ringgearby tightening the bolts in a criss-
11. Attach the Dog Piece Holder to the differential cross pattern in several steps.
housing Adjust the hypoid pinion preload to
1 O mm SPECIAL BOL T
10.0-16.3 kg-cm by tightening the 26 mm
103 N·m (10.3 kg-m. 74 lb-ftl -
locknut gradually to a torque between 1 5.0 and
30.0 kg-m.
CAUTION:
• lf the hypoid pinion preload exceeds 16.3 kg-
cm when tightening the 26 mm locknut to the
torque of 15.0 kg-m, replace the pinion spacer
(do not adjust the preload by loosening the 26
mm locknut).
• Replacethe spacer if the preload is below the
specification even when tightening the 26 mm
locknut to a torque of more than 30 kg-m.
• Befare measuringthe preload, rotate the hypoid
pinion bearing severa! times to assure proper
bearing contact.
(cont'd)
15-81
Differential
Reassembly {cont'd)~~~~~~~~~~~~~~~~~~~~~~~
13. Press the taper roller bearing into place using the Housing Cover
lnner Driver C and lnner Race Driver. 15. lnstall the oil chamberplate and stake it against the
flat screws.
/PRESS
14. Instan the viscous differential assembly in the

differential housing. 16. Instan the oil guide plate, 68 mm shim, and taper
bearingouter race using the Taper Bearinglnstaller,
NOTE: Lubricate the gear oil to the taper roller Nut, and Shaft.
bearing.
CAUTION: Do not install the oil seal.
VISCOUS DIFFERENTIAL ASSEMBL Y
TAPER BEARING
OUTER RACE 68 mm SHIM
Selection.
DIFFERENTIAL
HOUSING
<,
TAPER BEARING
INSTALLER
07KAF-PS30140
15-82
1 7. Apply liquid gasket to the differential housing 19. Measure the ring gear backlash through the seal-
cover. ing bolt hole.
NOTE: This differential uses no gasket between the NOTE:

major housing; use Honda Genuine liquid gasket • Measure the backlash at four diagonally op-
(P/N 08718-0001 ). Assemble the housing within posed points.
20 minutes after applying the liquid gasket and al- • Measure the backlash by holing the dog piece
low it to cure at least 30 minutes after assembly and moving the viscous shaft adapter.
before filling it with oil.
Standard: O. 10-0. 15 mm (0.004-0.006 in)
MAGNET STAND
20. lf the backlash is out of tolerance, adjust it (see

page 1 5-93).
18. lnstall the differential housing cover. 21 . Check the tooth contact between the ring gear and
hypoid pinion through the sealing bolt hole.
NOTE: Tighten the bolts in a criss-cross pattern in
severa! steps. NOTE:
• Paint the ring gear teeth (on both sides of each
tooth) lightly and evenly with Prussian Blue. Ap-
plying load to the ring gear, rotate the hypoid
pinion one full turn both forward and backward.
• Check at three equally spaced points.
HOUSING COVER
TORQUE
GOOD TOOTH CONTACT PATTERN
WRENCH
VISCOUS SHAFT ADAPTER

07KAZ-PS30100
22. lf the contact pattern shows incorrect contact, ad-

just it (see page 1 5-94).
(cont'd)
15-83
Diff erential
Reassembly (cont'd) -----------------------
23. lf the contact pattern shows incorrect contact, ad- 27. Stake the 26 mm locknut.
just it {see page 15-94).
24. Measure the total preload.
Preload: 1.11 - 1.78N·m (11.1 - 17.Skg-cm,

10 - 15 lb-in)
TORQUE WRENCH
36 mm HEX SOCKET WRENCH
25. lf the total preload is out of tolerance, adjust it by

changing the 66 mm shim and 66. 5 mm shim to 28. Check the solenoid assembly for operation (see
shims of proper thickness. The backlash must re- page 15-94).
main within tolerance (see page 1 5-93).
29. lnstall the solenoid spacer, solenoid assembly, and
26. Attach the Outer Driver A and Oil Seal Driver At- the solenoid mounting spacer in the differential
tachment to the differential housing and housing housing.
cover and press the oil seals into place.
CAUTION:Coat the entire circumference of the lip
CAUTION:Press-f"ltthe oil sealsinto the correct po- with the sealant (Cemedain 366E or equivalent).
sition shown in the drawing.
OUTER HANDLE A
07749-0010000
OIL SEAL DRIVER

07JAD-PN00100
SOLENOID SPACER
SOLENOID MOUNTING SPACER
Replace.
15-84
30. Apply liquid gasket to the differential housing Clutch Housing
cover. 32. Expandthe snap ring and install the ball bearing us-
NOTE: This differential uses no gasket between the
major housing; use Honda Genuine liquid gasket
low it to cure at least 30 minutes after assembly
before filling it with oil.
SNAP RING
PLIER
07LGC-0010100
OUTER HANDLE A ---.~1

07749-0010000
DRIVER
ATTACHMENT
07GAD-PG40100
lntermediate Plate
33. lnstall the oíl seal using the special tools.
31 . lnstall the intermediate plate on the differential
housing. NOTE: Orive the oil seal into the correct position
shown in the drawing.
OIL SEAL DRIVER OUTER HANDLE A

07KAF-PS30400 07749-0010000
8 mm BOLT
24 N·m (2.4 kg-m. 18 lb-ftl
(cont'd).
15-85
Differential
Reassembly (cont'd)~~~~~~~~~~~~~~~~~~~~~~
34. lnstall the breathe plate in the clutch housing. 1) lnstall the 2-4 sleeveover the dog clutch hub
and insertthe steel ballsinto the dog clutch hub.
CAUTION: To prevent the steel balls from drop-

ping out of the dog clutch hub, multi-purpose
grease may be applied to the holas in the hub. Be
sure not to apply more greasa than to the half of
each hola.
BREATHER PLATE
35. Assemble the 2-4 input shaft, steel balls, dog 2) lnsert the 2-4 input shaft into the dog clutch
clutch hub, 2-4 sleeve, and the 30 mm shim. hub until the shaft contacts the steel balls.
CAUTION: Be sure that the alignment mark on the

2-4 input shaft aligns with the alignment mark on
the dog clutch hub.
30 mm SHIM
2-4 SLEEVE
STEEL BALLS
15-86
3) Pull up the 2-4 sleeve. The 2-4 input shaft 6) Pushing the 2-4 input shaft with the palm,
should drop. makesurethat the 2-4 sleevecan be lifted by
little force.
4) Pul! up the 2-4 input shaft.
36. Assemble the 2-4 shift shaft, 2-4 shift fork,

2-4 shift spring, and the 2-4 shift spacer.
2-4 SHIFT SPRING

5) Set the 2-4 sleeve in the 4WD position.
Pushthe 2-4 input shaft firmly with the palm
and make sure that it does not move.
2-4SHI~
~\ SPRING PIN
~ Replace.
PIN DRIVER 5 mm
07744-0010400
(cont'd)
15-87
Diff erential
Reassembly(cont' d)
37. Assemble the 2--4 input shaft and dog clutch hub 39. lnstall the companion flange, 20 mm spring wash-
assembled in step 29 with the 2-4 shift fork and er. and the 20 mm locknut.
2-4 shift shaft assembled in step 30, then install
the assembly in the clutch housing. CAUTION:
• Replace the 20 mm locknut with a new one.
CAUTION: Look if the 2-4 shift spring is on the • Note the installation direction of the 20 mm
2-4 shift spacer. spring washer.
20 mm LOCKNUT
99 N·m (9.9 kg-m, 72 lb-ftl
CLUTCH HOUSING Replace.
20 mm SPRING
WASHER
COMPANION
FLANGE
38. lnstall the 2-4 shift column in the clutch housing.

Check that it shifts smoothly from "4" to "2" and
vice versa. lnstall the lock bolt washer and tighten
the lock bolt. 40. Attach the Companion Flange Holder to the com-
panion flange and tighten the 20 mm locknut.
NOTE: Push the 2-4 shift column into the clutch
__
housing using a pair of pliers or equivalent tool.
,- COMPANION FLANGE HOLDER
L
07926-$090000
2-4 SHIFT COLUMN 0-RING

Replace.
15-88
41 . Apply liquid gasket to the clutch housing. 43. Using the feeler gauge, measure the dog clutch
clearancethrough the 14 mm filler bolt hole in the
NOTE:This differential uses no gasket between the clutch housing.
major housing; use Honda Genuine liquid gasket
(P/N 08718-0001 ). Assemblethe housing within NOTE: Measureat four diagonally opposed points.
low it to cure at least 30 minutes after assembly Standard: 0.05 mm (0.02 in) feeler gaugecan be
before filling it with oil. inserted. while 0.25 mm (0.01 in)
cannot.
r=
FEELER GAUGE
07KAJ-PS30100
42. lnstall the assernbled clutch housing on the

44. lnspect the stroke switch (see page 1 5-95).
45. Adjustment the 14 mm shim (see page 15-96).
NOTE: Tighten the bolts in a crisscross pattern in
several steps.
46. lnstall the stroke switch and stroke switch pro-
tector.
I
-,
STROKE SWITCH
25 N·m (2.5 kg-m. 18 lb-ft)
SOCKET BOLT
STROKE SWITCH PROTECTOR
24 N·m (2.4 kg-m. 18 lb-ftl
8 mm BOLT
26 N·m (2.6 kg-m, 19 lb-ft)
(cont'd)
15-89
Differential
Reassembly (cont'd)
4 7. Stake the 20 mm locknut. 49. lnstall the harness protector.
20 mm LOCKNUT
FLAT SCREW
6 x 1.0 mm
1 O N·m ( 1.0 kg-m. 8 lb-ftl
50. lnstall the breather tube.
48. lnstall the harness clamp and stroke switch con-

nector.
6 mm BOLT
12 N·m ( 1.2 kg-m. 9 lb-ftl
51 . With the solenoid mounted on the differential as-

STROKE SWITCH CONNECTOR
sembly, check the solenoid for operation (see page
HARNESS CLAMP 15-95).
52. After installation, test-drive and make sure that the

ABS warning light does not come on when the ABS
is ON.
15-90
Dog Clutch Clearance
Adjustrnent~~~~~~~~~~~~~~~~~~~~~~~~~~~--.
Dog Clutch Hub Side 3. Calculate the dog clutch clearance from the results
1. Place a straight edge on the clutch housing end as obtained in steps 1 and 2.
shown and measurethe dog clutch hub depth using Dog clutch clearancecan be calculated by subtract-
the calipers. Measure the depth at many points. ing the clearanceto the dog piece ridge from the dog
Dog clutch hub depth is calculated by subtractinq clutch hub depth.
the thickness of the straight edge from the calipers
reading. 4. Select the appropriate 30 mm shim using the table
below.
CAUTION: Be sure that the calculation results ob-

talned at all measuring points are within the
tolerance.
Clearance: 0.05-0.25 mm (0.002-0.01 in)
30 mm SHIM

A 42380-PS3-010 1 .00 mm (0.0394 in)
B 42381-PS3-010 1.20 mm (0.0472 in)
e 42382-PS3-010 1.40 mm (0.0551 in)
D 42383-PS3-010 1.60 mm (0.0630 in)
E 42384-PS3-010 1.80 mm (0.0709 in)
F 42385-PS3-010 2.00 mm (0.0787 in)
Dog Piece Side
2. With the intermediateplate mounted on the differen- G 42386-PS3-010 1.50 mm (0.0591 in)
tial carrier, attach the Height lnspectionGaugeto the H 42387-PS3-000 1. 1 O mm (0.0433 in)
differential carrier. Measurethe clearanceto the dog 1 42388-PS3-000 1.30 mm (0.0512 in)
piece ridge at many points using a feeler gauge.
J 42389- PS3-000 1. 70 mm (0.0670 in)
CAUTION: Make sure that the dog piece inclinatlon K 42390-PS3-000 1.90 mm (0.0748 in)
is within 0.1 mm (0.004 in).
5. Using a feeler gauge, check the dog clutch clearance
Clearanceto the dog piece ridge can be calculated
through the 14 mm filler bolt hole in the clutch
by subtracting the feeler gauge reading from the
housing.
dimension of 19.8 mm (O. 78 in), which is the inner
height of the Height lnspection Gauge.
CAUTION:Checkthe clearanceat tour diagonallyop-
posed points.
HEIGHT INSPECTION GAUGE
07KAJ-PS30200 Standard: 0.05 mm (0.002 in) feeler gauge can be
I insertad. whlle 0.25 mm (0.01 in) cannot.
--- ~1\1~
~~
FEELER GAUGE"----" V//
15-91
Hypoid Pinion Height
Adjustment~~~~~~~~~~~~~~~~~~~~~~~~~~~-,
Adjustment Is Required 2. When the hypoid pinion bearing is replaced. Meas-

1. When the hypoid pinion and ring gear are replaced. ure the thickness of the new and the existing bear-
Calculate the 35 mm shim thickness and select the ing and calculate the difference in thickness between
appropriate shim. the two bearings.
Select the shim whose thickness is equal to the cal-
NOTE: Replacethe hypoid pinion and gear as a set. culated difference in thickness between the two
bearings.
X: Calculated thickness of the replacement shim For selecting the appropriate shim use the table
A: Number on top of the existing hypoid pinion below.
B: Number on top of the replacement hypoid pinion
C: Thickness of the existing shim 35 mm SHIM

A 41361-PS3-010 O. 72 mm (0.0283 in)
NOTE: Number on top of the hypoid pinion is shown B 41362-PS3-010 O. 75 mm (0.0295 in)
in 1 e 41363-PS3-010 O. 78 mm (0.0307 in)
100 mm. D 41364-PS3-010 0.81 mm (0.0319 in)
E 41365-PS3-010 0.84 mm (0.0331 in)
Example 1) X 0.02 ( - 0.02) + 0.84
X 0.04 + 0.84 F 41366-PS3-010 0.87 mm (0.0343 in)
X 0.88 G 41367-PS3-01 O 0.90 mm (0.0354 in)
Use the 35 mm shim which is 0.87 mm in
H 41368-PS3-010 0.93 mm (0.0366 in)
thickness.
1 41369-PS3-010 0.96 mm (0.0378 in)
Number-2
J 41370-PS3-010 0.99 mm (0.0390 in)
K 41371-PS3-010 1.02 mm (0.0402 in)
L 41372-PS3-010 1.05 mm (0.0413 in)
M 41373-PS3-010 1.08 mm (0.0425 in)
N 41374-PS3-010 1. 11 mm (0.0437 in)
o 41375-PS3-010 1. 14 mm (0.0499 in)
e@ 0.84mm X @o.87mm Adjustment Is Not Required

1. When you replace the differential housing, ring gear,
hypoid pinion, and the 35 mm shim as a set.
Example 2) X= 0.02 - 0.04 + 0.84
X = - 0.02 + 0.84 2. When the viscous assembly is replaced.
X = 0.82
Use the 35 mm shim which is 0.81 mm in
thickness.
A B
C © 0.84mm X @ 0.81mm
15-92
Ring Gear Backlash
Adjustment~~~~~~~~~~~~~~~~~~~~~~~~~~~--,
1. Adjust the ring gearbacklashby selectingthe proper 68 mm SHIM

66 mm shim for the differential housingand 68 mm
shim for the housing cover usingthe tables shown. PARTNUMBER THICKNESS
A 41449-PS3-010 1.40 mm (0.0551 in)
CAUTION:
• lf the backlash is excessive, move the ring gear B 41450-PS3-010 1.43 mm (0.0563 in)
toward the hypoid pinion. e 41451-PS3-010 1.46 mm (0.0575 in)
• lf the backlash is too small. move the ring gear
D 41452-PS3-010 1.49 mm (0.0587 in)
away from the hypoid pinion.
• Do not changethe total thickness of the shims. E 41453-PS3-010 1.52 mm (0.0598 in)
F 41454-PS3-010 1.55 mm (0.0610 in)
2. After adjustment, measurethe ring gear backlash
G 41455-PS3-100 1.58 mm (0.0622 in)
through the 34 mm sealing bolt hole.
H 41456-PS3-010 1.61 mm (0.0634 in)
CAUTION: Measure at tour diagonally opposed 1 41457-PS3-010 1.64 mm (0.0646 in)
points.
J 41458-PS3-010 1.67 mm (0.0657 in)
Standard:0.10-0.15 mm (0.004-0.006 in) K 41459-PS3-010 1.70 mm (0.0669 in)
L 41460-PS3-010 1. 73 mm (0.0681 in)
66 mm SHIM
M 41461-PS3-010 1.76 mm (0.0693 in)
PARTNUMBER THICKNESS N 41462-PS3-010 1.79 mm (0.0705 in)
A 41411-PS3-010 1.40 mm (0.0551 in) o 41463-PS3-01 O 1.82 mm (0.0717 in)
B 41412-PS3-010 1.43 mm (0.0563 in) p 41464-PS3-010 1.85 mm (0.0728 in)
e 41413-PS3-010 1.46 mm (0.0575 in) Q 41465-PS3-010 1.88 mm (0.0740 in)
D 41414-PS3-01 O 1.49 mm (0.0587 in) R 41466-PS3-01 O 1.91 mm (0.0752 in)
E 41415-PS3-01 O 1.52 mm (0.0598 in) s 41467-PSJ-010 1.94 mm (0.0764 in)
F 41416-PS3-010 1.55 mm (0.0610 in) T 41468-PS3-010 1.97 mm (0.0776 in)
G 41417-PS3-010 1.58 mm (0.0622 in) u 41469-PS3-010 0.60 mm (0.0236 in)
H 41418-PS3-010 1.61 mm (0.0634 in)
1 41419-PS3-010 1 .64 mm (0.0646 in)
J 41420-PS3-010 1.67 mm (0.0657 in)
K 41421-PS3-010 1.70 mm (0.0669 in)
L 41422-PS3-01 O 1.73 mm (0.0681 in)
M 41423-PS3~010 1.76 mm (0.0693 in)
N 41424-PS3-010 1.79 mm (0.0705 in)
o 41425-PS3-010 1.82 mm (0.0717 in)
p 41426-PS3-010 1.85 mm (0.0728 in)
Q 41427-PS3-010 1.88 mm (0.0740 in)
R 41428-PS3-010 1.91 mm (0.0752 in)
s 41429-PS3-010 1.94 mm (0.0764 in)
T 41430-PS3-010 1 .97 mm (0.0776 in)
u 41431-PS3-010 0.60 mm (0.0236 in)
15-93
Ring Gear & Hypoid Pinion
Tooth Contact Solenoid Assembly
Adjustment lnspection------------
1. TOE CONTACT 1. Connect the A and C terminals of the solenoid as-
sembly 4-P connector to the battery positive ( +)
terminal.
NOTE: Take care not to pinch your finger during in-

• Use a thinner 35 mm shim to spection.
move the drive pinion away from
the ring gear.
2. HEEL CONTACT
• Use a thicker 35 mm shim to

.move the drive pinion toward the
ring gear.
3. FLANK CONTACT
• Adjust within the range of the

standard backlash (movethe ring
gear away from the drive pinion).
• lf adjustment cannot be made wi-
thin the range of the standard
backlash, adjust in the same way
as TOE CONTACT.
2. Connect the B terminal of the 4-P connector to the
4. FACE CONTACT battery negative (-) terminal. Make sure that "P"
is drawn in quickly and does not return when its end
is pushed firmly with a finger.
~ NOTE: Align the end of "P" with the end of the

• Adjust in the range of the stan-
solenoid.
dard backlash (move the ring
gear toward the drive pinion).
CAUTION: Do not connect to the battery far more
• lf adjustment cannot be made in
than 5 seconds. The solenoid could get damaged.
the range of the standard back-
lash, adjust in the same way as
3. Connect the D terminal of the 4-P connector to the
HEEL CONTACT.
battery negative ( - ) terminal. Make sure that "P"
5. After adjusting check the tooth contact between the is kept up in quickly and does not return when its
ring gear and hypoid pinion through the 34 mm seal- end is pushed firmly with a finger.
ing bolt hole.
NOTE: Align the end of "P" with the end of the
NOTE: Paint the ring gear teeth (on both sides of solenoid.
each tooth) lightly and evenly with PrussianBlue. Ap-
plying load to the ring gear, rotate the companion CAUTION: Do not connect to the battery for more
flange one full turn both farward and backward. than 5 minutes. The solenoid could get damaged.
CAUTION: Check at three equally spaced points.
4. lf "P" is not drawn and kept up in quickly in the
6. CORRECTTOOTH CONTACT above steps 2 and 3, check far continuity between
the A and B terminals, and between the C and D ter-
minals of the 4-P connector.
15-94
Solenoid-On-Differential
Assembly Stroke Switch
lnspection-------------. lnspection -------------.
1. Connect the A and C terminals of the solenoid as- Checkfor continuity between the terminals of the stroke
sembly 4-P connector to the battery positive ( + ) switch connector.
terminal.
NOTE: Make sure that the 2-4 shift column is at

"4".
1. There must be continuity between the A and B ter-

minals (with 4WD engaged).
2. Rotate the companionflange by hand. You must feel

resistance.
3. Connect the B and D terminals of the 4-P connector

simultaneously to the battery negative ( - ) terminal,
then immediately disconnect the B terminal.
CAUTION: Do not connect the B terminal of the 4-P

connector to the battery for more than 5 seconds
and the D tenninal for more than 5 minutes. The sole-
noid could get damaged. 2. There must be no continuity between A and B ter-
minals (with 4WD disengaged).
1) Check if the solenoid sound can be heard.
2) Rotate the companion flange by hand and make

sure that it rotates smoothly and lightly.
4. Disconnect the 4-P connector D terminal from the

battery. ~,-·
--_,. L.
1) Check if the solenoid sound can be heard.
2) Rotatethe companionflange by hand. You must

feel resistance.
5. lf the solenoidsound cannot be heardand resistance

is felt while rotating the companion flange by hand
in step 3, check for continuity between the A and
B terminals and between the C and D terminals of
the 4-P connector. lf there is continuity, check each 3. The stroke switch is faulty if there are any abnor-
part in the clutch housing for operation. malities at the above checks 1 and 2.
15-95
Stroke Switch
Adjustment~~~~~~~~~~~~~~~~~~~~~~~~~~~-,
1. Align the mark on the disengagement bolt B with 5. Compare the measuredvalue of E with the table be-
"2" and disengage the dog clutch. low and select the proper 14 mm shim.
2. Turn the companion flange so that the teeth of the 14 mm Shim

dog clutch hub and dog piece touch each at the tips,
then turn the disengagement bolt B. CLEARANCE
E *E
14 mm FILLERBOLT A 40731-PS3-000 1.00mm(0.0394 in) - -
/
40 N•m 14.0 kg·m, CLUTCH HOUSING
B40732-PS3-000 1.85mm(0.0728 in) 1.3mrn 2.3mm
29 lb-ft)
e 40733-PS3-000 1.95mm(0.0768 in) 1.4rnm 2.4mm
o 40734-PS3-000 2.05mm(0.0807 in) 1.5mm 2.5mm
E 40735-PS3-000 2. 15mm(0.0846 in) 1.6mm 2.6mm
F 40736-PS3-000 2.25mm(0.0886 in) 1.7mm 2.7mm
G 40737-PS3-000 2.35mm(0.0925 in) 1.8mm 2.8mm
H 40738-PS3-000 2.45mm(0.0965 in) 1.9mm 2.9mm
1 40739-PS3-000 2. 55mrn(O. 1004 in) 2.0mm 3.0mrn
J 40740-PS3-000 2.65mm(0.1043 in) 2.1mm 3.1mrn
K 40741-PS3-000 2. 75mrn(O. 1083 in) 2.2mm -
*: Use· a shirn together with shim A (1.00 mm).
6. lnstall the 14 mm shim(s) and the stroke switch, turn

the disengagement bolt B, and check the correct
opening and closing of the switch.
3. Check for continuity between the A and the B ter-

minal of the stroke switch.
4. With the shim removed, screw in the stroke switch,

and measure the distance E at with continuity be-
tween terminals A and B will disappear.
15-96

Civic 1992 Eg3, Eg4, Eg5, Eg6, Eg7, Eg8, Eh1, Eh8, Eh9 Non-Usdm Manual-1

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Civic 1992 Eg3, Eg4, Eg5, Eg6, Eg7, Eg8, Eh1, Eh8, Eh9 Non-Usdm Manual-1

Uploaded by

Copyright:

Available Formats

INTRODUCTION *General lnfo

How to UseThls Manuel-----------~

Spectal lnformatlon ------------~

CAUTION: lndicates • posslbility of perM>n•I injury

NOTE: GivH helpful information,

flf&t Eóitlon 9/91 1514 pag,es HONDA MOTOR CO.• LTD.

• SIIIWOMbetow •re in VOlUMli 2,

Chassis and Engine Number 1-2

Manufacturer, Code and Engine Type j___,

Automatic Transmission Number -----~

Transmission Type -------~ 1

Manufacturar, Code and Engine Type J__,

Vehicle ldentification Number (KB) ----- - Manual Transmission Number --------

1 HGEH554* NL700001 820-1 000001

Manufacture r. Code and

MFG., INC. U.S.A. Serial Number ___,

Manufactur er, Code and

Manufacturer, Code and Engine Type !___.

Chassis and Engine Chassis and Engine

A: DRIVER INFORMATION B: MAINTENANCE LID CAUTION

ALWAYS WEAR YOUR SEAT BELT JSRSI CAUTION !

C: MONITOR CAUTION F: UNDER-HOOD WARNING

CAUTION SRS] I WARNING j SRS !

G: SLIP RING CAUTION

COOLING FAN CAUTION

1. Place the lift blocks as shown.

FRONT SUPPORT POINT LIFT BLOCKS REAR SUPPORT POINT

4. Adjust and place the safety stands as shown on

Center the jack

Center the jack

FRONT SUPPORT POINT SAFETY STANDS REAR SUPPORT POINT

For 4WD see also "4WD Disengagement". Front:

Flat-bed Equipment-The operator loads the car on the

Wheel Lift Equipment-The tow truck uses two

Sling-type Equipment- The tow truck uses metal

lf the car cannot be transported by flat-bed, it should be

• Releasethe parking brake.

NOTICE:Trying to lift or tow the car by the bumpers

The 4WD System shifts instantaneously and 4WD Disengagement

3. Move the . lever by turning the middle bolt

NOTE: After service or towing is completad return

Standards and Service Limits 3-2

Com- 250 min-1 (rpm) and Nominal 1,300 ( 13.0, 184)

D16Z6, D16Z7 IN Primary 35.900 (1.4134) --

Com- 250 min - (rpm) and

Com- 250 min-1 (rpm) and Nominal 1,300 ( 1 3.0, 184)

Camshaft End play 0.05-0.15 (0.002-0.006) 0.5 (0.02)

Rocker Arm-to-shaft clearance IN 0.025-0.052 (0.0009-0.0020) 0.08 (0.003)

MEASUREMENT STANDARD (NEW)

MEASUREMENT STANDARD (NEW) 1

sion fluid 2.4 (2.5, 2.1) for fluid change

MARK 3 2.8-2.9 (0.110-0.114)

MARK 3 2.5-2.6 (0.098-,-0.102)

On countershaft 1 st gear 35.000-35.016 (1.3780-1.3786)

MEASUREMENT STANDARD (NEW) SERVICE LIMIT

Clutch Clutch initial clearance 1st, 2nd 0.65-0.85 (0.026-0.033) --

Trans- Diameter of needle bearing contact area

MEASUREMENT STANDARD(NEW) SERVICE LIMIT

Diameter of needle bearing contact area

mission On mainshaft and stator shaft 19.980-19.993 (0.7866-0.7871) Wear or damage

~ 1 erentl,a1 2WD M/T Y21

Final driven Backlash

MEASUREMENT STANDARD(NEW) SERVICE LIMIT