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INTRODUCTION

How to Use This Manual This manualis dividedinto 23 sections. The first pageof each seclionis markedwith a blacktab that linesup with its corresponding thumb indextab on this pageand the backcover. You can quicklyfind the first pageof eachsectionwithout lookingthrougha full tableof contents. The symbolsprintedat the top cornerof each pagecan also be used as a quick re{erence system. Eachsectionincludes: 1. A tableof contents, an exploded or view index showingl . Partsdisassembly sequence. . Bolttorquesand threadsizes. . Pagereferences descriptions text. to in procedures 2. Disassembly/assembly and tools. 3 . Inspefiron. g. 4. Testing/troubleshootin 5. Repair. 6. Adjustments.

S p e c i fi c a ti o n s M a i n te n a n c e

1)ll:{l+'

Safety
Your safety, and the satetyof others,is very important. help To you makeinformeddecisions, have providedsafety we messages, and othersafetyinformation throughoutthis manual. Of course, is not practical possible warn you aboutall the it or to hazards associated with servicing this vehicle. You must use your own good judgment. You will find impoftantsafetyinformationin a varietyof forms including: . SatetyLabels on the vehicle. . Satetv Messages preceded by a salety alert symbol A and one of threesignalwords, DANGEF, WARNING, CAUTION. or Thesesignalwords mean:

Emissions

sR H tmEnEErily;,: i":5*i5"?;rE IousLY uBrir H,ll HURT ir E$EEEE ys,: f#,ff ,:hl:3,:JjERrousLY
tlGtltT]llilll YoucAN b HUBT vou don'tfollow if . lnstructionshowto service vehicle this correctlv safelv. and
All information in contained this manualis basedon the latest productinformation We reserve available the time of printing. at the right to makechanges any time without notice.No part of at this Oublication maVbe reDrodLrced, storedin a retrieval or in system,or transmitted, any form by any means,electronic, photocopying, mechanical, recording, otherwise, or without the priorwritten permission the publisher. o{ This includes text, figures, and tablesAs vou readthis manual,vou will tind information that is preceded a @ by symbol.The purposeof this message is to help preventdamageto your vehicle, other property, the or environment, pages FirstEdition 8/2002 1,168 HONDA MOTOR CO..LTD. All RightsReserved ServicePublication Office Specifications to U.S.A. Canada apply and
As seclion3 with *inclode SRS comoonentsi special precautionsare required when servicing.

*Body

z-tl!
^ t l

*Restraints

Information General
Ghassis and PaintCodes -2002 odel M Chassis and PaintCodes -2003 odel M . . . . . . . . . . . . . 1.-.2 . . . . . . . . . . . . . . .1.-.3 . .

ldentification NumberLocations ........ 1-4 Warning/Caution LabelLocations......1-5 Under-hood Emission ControlLabel ........... .... 1-7

L i f ta n dS u p p o r P o i n t s. . . . . . . . . , . . . . , . . .1 . .8 , . t .- . Towing ......1-9

PaftsMarkingLocations...................... 1-10

GeneralInformation
Model Chassis and PaintCodes- 2OO2
Vehicle ldentffi cationNumber
SHHEP3 5'2 3 U 300001

Engine Number
K2OA3 1700001 a
a. EngineType K20A3: 2.0 0 DOHCVTECSequentialMultiport Fuel-injected engine b. Serial Number

[[tttrtF

c d e f g h

a. Manufacturer, Make and Type of Vehicle S H H ; H O N D A O F T H E . K .M F G . ,L T D .U . K . U v H O N D AP a s s e n g e re h i c l e b. Line, Body and EngineType EP3: CIVIC/K20A3 c. Body Type and Transmission Type Manual 3: 2-door HatchbacUs-speed d. VehicleGrade lSeries) 5:Si {U.S.} 5 ; S i R( C a n a d a ) 6: Si with side airbagsystem (U,S.) 6: SiR with side airbagsystem (Canada) e. CheckDigit l. ModelYear 2i 2002 g. Factory Code n U : H o n d ao f U . K .M a n u f a c t u r i nig S w i n d o n , En gl a n d h. Serial Number U.S,: 00001 3 1-

Transmission Number
NBH3 I

1000001

a
Transmission Type N R H 3 ; s - s D e eM a n u a l d

0
u.s.
Canada

PaintCode
Code

B-92P
NH-578 NH-623M R-81

Y-62P

Color Niqhthawk Black Pearl TaffetaWhite Satin Silver lvletallic M i l a n oR e d E u r oY e l i o wP e a r l

Vhicle ldentif ication Numbo. and Federal Motor Vehicle Safety Standard Certification/ Color Label.

1-2

Chassis and PaintCodes- 2003Model


Vehicle ldentif icationNumber
SHHEP3 5*3 3 U 400001

EngineNumber
K2OA3 2700001

[--t-rlF

c d e fg h

I
a
a. EngineType K20A3: 2.0 0 DOHCVTECSequentialMultiport Fuel-injected engine b. SerialNumber

Manufacturer, Make and Type of Vehicle S H H : H O N D A O F T H E . K .M F G . , T D .U . K . U L HONDAPassenger vehicle Line. Body and EngineType EP3: CIVIC/K20A3 G . Body Type and Transmission Type Manual 3: 2-door HatchbacldS-speed d . Vehicle Grade (Series) 5:Si (U.S.) 5 : S i R( C a n a d a ) 6: Si with side airbagsystem (U.S.) 6: SiRwith side airbagsystem (Canada) Check Digir f. Model Year 3: 2003 Factory Code U: Hondaof U.K. Manufacturing Swindon, in England SerialNumber U.S.:400001 :700001

Transmission Number
NRH3 - 2000001

I
a
Transmission Type N R H 3 : 5 - s p e eM a n u a l d Serial Number

PaintCode
Code

B-92P B-520P
NH-578

NH-623M
R-81

Y-62P

Color Niohthawk Black Pearl V i v i d B l u eP e a r l Taffeta White Satin Silver N4etallic M i l a n oR e d EuroYellow Pearl

U , S . Canada

Vehicleldentification Number and FederalMotor Vehicle Saletv Standard Certif ication/ Color Label.

)_.

1-3

Information General
ldentificationNumber Locations
(

Vehicle ldentif ication Number {vlN}

Vehicle ldentificalion Numbe.lvlN)

0
EngineNumber

t)

1-4

, I O

warning/cautionLabelLocations
NOTE: FRONT PASSENGER AIRBAG WARNING TAG (CHILD is SEAT) installed the glovebox on the U.S. on mooet. Passenger's Compartment:
SRSINFORMATION U.Smodel .
SRS WARNING INFORMATION FRONTPASSENGER MODULE DANGER

Steering Wheel: DRIVER MODULE DANGER CABLEREEL CAUTION

MONITOR NOTICE

!
,/
FRONT SEATBELT TENSIONER CAUTION SIDEMODULE DANGER
SIDEAIRBAG CAUTION Located on driver's ano passen9er s doorjamb(not shown)

..r'
(cont'd)

1-5

General Information
Warning/Caution LabelLocations(cont'dl
SERVICE INFORMATIONLABEL (Undor-hood Emission Control Informationlabl)and ENGINE COOLANTINFORMATION

SRS WARNING LABEL

TIREINFORMATION

RADIATOR CAPCAUTION

BATTERY CAUTION

1-6

Emission ControlLabel Under-hood


ication Groupldentif Emission
2002model Example:

Families: Engine and Evaporative


EngineFamily:

rr-tt--[ t t l
a b c d
2 T TO . V CO T H I S E H I C L E N F O R M S U . S E P A I E R B I N5 APPLICABLE 2002 TO LEVREGULATIONS AND NLEV CARS NEWPASSENGER AND MODEL YEAR TO APPLICABLE 2OO2 REGULATIONS CALIFORNIA CARS. YEAR NEWLEVIi LEVPASSENGER MODEL Example: 2003model

2 HNX V O2.O VBP

c. d. e.

ModelYear 2:2002 3: 2003 Subcode Manulacturer H HNX: ONDA Type Family V: LDV Displacement Sequence Characters V B P2 0 0 2 : X K C2 0 0 3 :

Evaporative Family:

rH/

TO CONFORMS U.S. EPATIER2 BIN 5 THISVEHICLE TO APPLICABLE 2O03 AND NLEVLEVREGULATIONS CARS NEWPASSENGER AND MODEL YEAR TO APPLICABLE 2OO3 REGULATIONS CALIFORNIA CARS, YEAR NEWLEVII LEVPASSENGER MODEL

a b

t[-l=[
c d

2 HNX R OO99 AAH

Model Year 2t 2002 3: 2003 Manufacturer Subcode H N X :H O N D A c. Family Type R: EVAP/ORVR d . Canister Work Capacity e . Sequence Charactets AAH: 2002 AAA: 2003

1-7

General Information
Lift and Support Points
NOTE:If you are going to remove heavycomponents such as suspensionor the fuel tank from the rear of the vehicle,first supportthe front ofthe vehiclewith tall safetystands.When substantialweightis removed from the rear of the vehicle,the centerof gravity can changeand causethe vehicleto tip forward on the hoist.

FloorJack
1. Set the parkingbrake. 2. Blockthe wheels that are not being lifted. 3. When liftingthe rear of the vehicle.put the gearshiftIever in reverse. 4. Positionthe floor jack underthe front jacking bracket(A) or rearjackingbracket(B),centerthe jacking bracketin the jack lift ptatform(C),and jack up the vehiclehigh enoughto fit the safetystands u n d e ri t .

FrameHoist
1. Positionthe hoist lift blocks(A),or safetystands, under the vehicle'sfront support points (B)and rear support points (C).

0
2. Raisethe hoist a few inches,and rock the vehicle gentlyto be sure it is firmly supported. 3. Raisethe hoistto full height,and inspectthe lift pointsfor solid contactwith the lift blocks.

c
Positionthe safetystandsunderthe support points and adjustthem so the vehiclewill tevet. Lower the vehicleonto the stands.

Safety Stands
To supportthe vehicleon safetystands.use the same suppon points (B and C) as for a frame hoist,Always use satetystandswhen working on or under any vehiclethat is supportedonly by a jack.

1- 8

Towing
lf the vehicleneedsto be towed, call a professional towing service.Nevertow the vehiclebehind another vehiclewith just a rope or chain.lt is very dangerous. Towing Emergency m o T h e r ea r et h r e ep o p u l a r e t h o d s f t o w i n g a v e h i c l e . Flat-bedEquipment The operatorloadsthe vehicle on the backof a truck.This is the bestway of transportingthe vehicle. flat-bedequipment.the vehicleis To accommodate with towing hooks(A)and tie down hooks{B). equipped The towing hook can be usedwith a winch to pull the vehicleonto the truck, and the tie down hooks slotscan be used to securethe vehicleto truck. Wheel Lift Equipment The tow truck usestwo pivoting arms that go underthe tires (front or rear)and lifts them off the ground.The other two wheels remain way of towing the on the ground.This is an acceptable vehicle. Sling-typeEquipment The tow truck uses metal T w c a b l e s i t h h o o k so n t h e e n d s . h e s eh o o k sg o a r o u n d parts of the frame or suspensionand the cableslift that T o e n d o f t h e v e h i c l e f f t h e g r o u n d . h ev e h i c l e ' s d i a n d b o d yc a n b e s e r i o u s l y a m a g e d f t h i s suspension method of towing is attemPted. lf the vehiclecannot be transportedby flat-bed,it should be towed with the front wheels off the ground lf due to damage,the vehiclemust be towed with the front wheels on the ground, do the following: . Release parkingbrake. the . s h i f t t h e t r a n s m i s s i o in N e u t r a l . n It is bestto tow the vehicleno farther than 50 miles (80 km), and keepthe speed below 35 mph (55 km/h).

. l m p r o p e r o w i n g p r e p a r a t i ow i l l d a m a g e h e n t t Follow the above procedureexactly.lf transmission. the you cannot shift the transmission, vehicle must on be transDorted a flat-bed. . Trying to lift or tow the vehicle by the bumperswill a d , c a u s es e r i o u s a m a g e T h e b u m p e r s r e n o t designedto supportthe vehicle'sweight.

1-9

GeneralInformation
PartsMarking
To deter vehicletheft, certainmajor componentsare markedwith the vehicleidentification number (VlN).Original partshave self-adhesive labels.Replacement body parts have genericself-adhesive labels.The originalengrneor transmissionVIN plate is transferredlo a replacement engine or transmissionand attachedwith break-offbolts. NOTE:Be careful not to damagethe parts marking labelsduring body repair.Maskthe labelsbefore repairingthe part.

r a

1-10

ra
Specifications

Standards Service and Limits


EnqineElectrical ne

Item

Measurement
Rated voltage F i r i n go r d e r

Oualification

lgnition coil plug Spark

Standard or New

Service Limit

Type
Gap

l g n i t i o nt i m i n g

A t i d l e ( c h e c kr h e

12V 1 3-4 2 N G Kt Z F B 6 K 1 1 : DENSO: SKJ20DR-M11 1 . 0 1 . 1 m m ( 0 . 0 3 9 . 0 4 3n . ) 0 i in neutral: 8t2' ETDC 650150rpm at

1 . 3 m m ( O . OiS 1) n.

Alternator

Output

Coillrotor)resistance
5|lp flng u.u.

Starter

Brushlength Brushspring tension Output Commutator micadepth Commutator tunout Commutator O.D. Brushlength

At 13.5 and V 80A normalengine temperature At 68.F(20'C) 2.2 3.0 A 14.4 mm {0_57 in.) 14.0 mm (0.55 in.) 10.5 mm (0.41 in.l 1.5mm {0.06 in.) 2.9 3.5N (0.30 0.36kgf,0.7-0.8tbs) 0.50 0.80mm (0.020-0.031 in.) 0.20mm 1O.OO8 in.)

o:BlalqryL4i) max
2 8 . 0 m ( 1 . 1 0n . ) m i 14.0 14.5 mm {0.55 0.57in.)

o.o5 (0.002 mm in.)


2 7 . 0 m ( 1 . 0 6n . ) m i 9.0mm {0.35 in.)

Enqtne
Item Measurement Compression Pressure checkat 250rpm with wide openthroftle. (SeeDesignSpecsfor rato,
Oualification Standard or New Service Limit

Minimum Maximum vanatton

930kPa(9.5 kgflcmr, psi) 135 200kPa{2.0kgf/cm',28 psi)

e_

.l
2-2

nder Head
Item Head Measur6ment Warpage Height Endplay
C a m s h a f tt o h o l d e r o i l c l e a r a n c e No.l journal N o . 2 , 3 ,4 , 5 journals

Oualification

Standard or New

Service Limit

in.) 0.05mm {0.002 '103.95104.05 mm (4.093 4.096 in.) in.) 0.05 0.20mm (0.002 0.008 mm 0.030 0.069 in.) {0.001 0.003 mm 0.060 0.099 (0.002-0.004 in.) in.) 0.03mrn (0.001 max. in.) mm (1.3356 33.925 i 2 9 . 6 3m m ( l . 1 6 6 8n . ) 8 mm in.) 34.092 (1.3422 in.) 0.21 0.2smm 10.0080.010 in.) 0.28 0.32mm (0.011 0.013 in.) mm 10.21560.2159 5.475 5.485 in mm (0.2146 0.2150 ) 5.450 5.460 mm (0.0012 0.0022in.| 0.030 0.055 in mm (0.0022 0.0031 ) 0.055 0.080 in.) mm (0.049 0.061 1.25 1.55 in.) 1.25 1.55 mm (0.049 0.061 m 4 0 . 8 -4 1 . 0 m ( 1 . 6 0 6 1 . 6 1 4 i n . ) i m 5 4 . 6 5 4 . 8 m ( 2 . 1 5 02 . 1 5 7n . ) (1.874 in.) 47.61 mm in.) 49.64 mm (1.954 mm 5.515 5.530 |.0.21710.2117 4n.1 m 5.515 5.530 m in.l \0.2111 0.2177 m 1 5 . 2" 1 6 . 2 m ( 0 . 5 9 80 . 6 3 8 i n . ) in.) mm (0.610 0.650 15.5 16.5 mm 0.025 0.052 (0.00'10 in.) 0.0020 mm 0.018 0.056 (0.0007 0.0022 in.)

Camshaft

in.) 0.4mm (0.02 n m 0 . 1 5 m { 0 . 0 0i6 . ) in.) 0.15mm (0.006 in.) 0.04mm {0.002

Totalrunout
Cam lobe height

primary Intake, Intake, Exhaust

(cold) clearance StemO.DS t e m - t o - g L r i dc l e a r a n c e e

lntake

Exhaust
lnlaKe

Exhaust
lntake

height stem installed Valve springs length Free LD.

Exhaust lntake Exhaust lntake Exhaust lntake Exhaust


Intake Exhaust

in.) 5.445 mm (0.214 n 5 . 4 2 m ( 0 . 2 1i3 . ) m in.) 0.08mm (0.003 in.) 0.11mm (0.004 in.) 2.00mm {0.079 in.) 2.00mm {0.079

Valveguides

in.) 5.55mm (0.219 n 5 . 5 5 m { 0 . 2 1i9 . ) m

I n s t a l l e dh e i g h t

lntaKe

Exhaust Rocker arms Arm-to-shaft clearance


lntaKe Exhaust

in.) 0.08mm (0.003 in.) 0.08mm (0.003

lo
2-3

Standardsand ServiceLimits
Enqine n q t n e Block
Item Block

Measurement of I Warpage deck tsore diameter

Oualification

Aori Borll

Standardor New 0.07mm (0.003 max. in.) 86.010 86.020 mm (3.3862 3.3866in.) 86.000 86.010 mm (3.3858 3.3862 in.)

ServiceLimir

foro.. (ulur^^-"1
86.070 mm (3.3886 in.) 86.070 mm (3.3886 in.)
0 . 0 5m m ( 0 . 0 0 2n . J I

R e b o r i n gl r m i t

Piston

SkirtO.D. 11mm (0.4in.)from at bottom of skirt

Piston ring

",";"* lFis,.-"'"

Lo.D.

Ringend gap

0 . 2 5 m ( 00 l i n . ) m 85.980 85.990 mm (3.3850 3.3854 85.930 in.) mm (3.383'l in.) F" LetterB s.980 r"i33846 85.920 mm (3.3827 l-il?0 in.) 0.020 0.040 mm (0 0008 0.0016 in.) 0.05mm {0.002 in.) Top 1.220 1.230 mm (0.0481 0.0484 in.) 1.25 mm 10.049 ) rn Second 1 . 2 2 0 1 . 2 3 0 m ( 0 . 0 4 8 1 0 0 a 8 4 I n . ) 1.25 m mm 10.049 in.) mm (0.0789 0.0797 in.) ?.09rrl9.091lt i 2.005 2.025 ) o.ooza 0.13mm (0.005 ) lo.oora i.'.f fo.o:s o.oto.rn in rn. OOO2 i") 0 . 1 3 m ( 0 . 0 0i5 . ) m n EO3t 0 056 {OJ01r (FEDEHAL 0.025 0.060 Second mm (0.0010 0.0024 in.) 0.13mm (0.005 ) in I\4OGUL) Top 0.20 0.35mm (0.008 0.014 in.) 0.60mm (0.024 in.)

btt"' "' A

Second

OiI(REKEN) OiI(FEDERAL I\4OG L) U pin Piston Pin'to-piston clearance Connecting rod


Pin to-rod clearance Small end bore diameler L a r g e - e n db o r e d i a m e t e r ( N o r m a l )

0.40 0.55mm {0.016 0.022 in.) 0.25 0.65mm (0.010 0.026 in.) 0 20 0.70mm i0.008 0.028 in.)

0.70mm (0.028 in.) 0.75mm (0.030 in.) 0.80mm 10.031 in.)

21.961 21.965 {0.8646 0.8648 2 1 . 9 5 3m m l 0 8 6 4 3 i n mm in.) 0.005-*0.002 ( 0.00020 mm + 0.005 mm (0.0002 in.)

0.00008 in.)
0.005 0.015 mm (0.0002 0.0006 in.) 0 . 0 2 m m l O 0 O O 8n I i 21.970 21.976 mm (0.8650 0.8652 in.) 4 8 . 0 m ( 1 . 8 9n . ) m i 0.15 0.30mm (0.006 0.012 in.) 0 . 4 0 m ( 0 . 0 1i6 . ) m n s4.e84 s5.008 mm (2.1648=16illl

c_

Endplayinslalled crankshaft on
Crankshaft Main journal diameter

No. l journal No.2 journal N o .4 j o u r n a l No.5 journal No.3 journal

5 4 . 9 7 65 5 . 0 0 m m ( 2 . 1 6 4 4 - 1 6 5 4 i n ) 0 2
4 4 . 9 7 6 4 5 . 0 0 0m m ( 1 . 1 7 0 7 1 . 1 7 1 7i n . l

Rodjournal diameter Rod/main

Rod/main out iournal of,round E n dp l a y Runout . . - ' . : - - ' +


Deaflngs M a r n o e a r , n 9 - t o J o u r n a o t t c t e a r a n c e No. l journal t

0.005 mm 10.0002 max. in.) 0.005 mm (0.0002 max. in.) 0.10 0.35mm (0.004 0.0'14 in.) 0.03mm (0.0012 max. in.) 0 . 0 1 7 0 . 0 4 1 m ( 0 . 0 0 0 70 . 0 0 1i6 . ) m n

0.010 mm (0.0004 in.) 0.010 mm (0.0004 in.) 0.45 m10.018.) m in 0.04mm {0.0016 in.) 0.050 mm (0.0020 in.)

No.2 journal No.4 journal


No.5

No.3 journa/ Bodbearing clearance

q0rr034, -rn {O'o010 0-o01r|"tl 0.055 (0.0022 mm in.)


0.021 0.049 mm (0.0008 0.0019 in.) 0.060 mm (0.0024 in.)

2-4

o i

nqlne
|tem

Lubrication
Measurement Capacity Oualificalion ServiceLimil Standerdor New overhaul 5.30 (5.6US qt)for engine filter including 4.20 (4.4US qt)for oil change, withoutfilter 4.00 (4.2US qt)for oil change, in.) in.) 0.20mm (0.008 0.02 0.16mm {0.001 0.006 in.) in.) 0.23mm (0.009 0-15 0.21mm {0.006-0.008 in.) 0.02 0.07mm (0.001 0.003 front No.1 journal, shaft
No 1 journal,rearshaft

Engine oil

Oilpump

lnner-to outerrotorclearance to Pumphousing outerrotor clearance axial Pumphousing-to-rotor clearance journal Balancer shafts, diameter

0.12mm (0.005 in.)

mm (0.784 in.) in.) 19.92 mm 19.938 19.950 10.78500.7854

journal taper Ealancer shafts, shafts, play end Balancer shatts,shaft-to'bear;ng Balancer clearance

in.) in.) mm (0.942 mm (0.9424 0.9429 23.92 23.938 23.950 mm (1.296 in.) in.l mm 11.29121.2911 32.93 frontand 32.949 32.961 No.2 journal, rearshaft in.) 0.005 rnm (0.0002 max. in.) in.) 0.15mm (0.006 mm (0.0028 0.0053 0.070 0.135 Front (0.0028 0.0053 in.) in.) 0.15mm (0.006 mm 0.070 0.135 Rear m n in.) 0 . 1 0 m ( 0 . 0 0i4 . ) mm (0.0020 0.0032 front 0.050 0.082 No. 1 iournal, shaft
N o . 1 J o u r n a l ,r e a r s h a f t N o . 2 j o u r n a l ,f r o n t a n d rear shafl

in.) mm (0.0020 0.0032 0.050 0.082 in.) mm (0.0024 0.0047 0.060-0.120

in.i 0.10mm (0.004 in.) 0.15mm (0.006

LD. shaftbearings, Balancer

a
Thermostat

mm (0.789 in.) in.l mm (0.1814 0.7442 20.03 front 20.000 20.020 No. 1 journal, shaft in.) ir'.) 24.03 mm (0.946 OSa57 ZI.OZO tOSa+emrearshaft Z+.OOO No. 1 iournal, in.) in.) mm {1.303 mm (1.3000 1.3019 33.09 No.2 journal, frontand 33.021 33.069 rearshaft
At idle 7 0 k P a ( 0 . 7k q ? c m , 1 0 p s r )m i n .

R e l i e f v a l v e ,o i l p r e s s u r ew i t h o i l t e m p e r a t u r ea t 1 7 6 ' F ( 8 0 " C )

rpm At 3,000

psi)min. ksf/cm',44 300kPa{3.1

engine, Coolant capacity {includes hoses, reservoir) and heater,

Standardor New 6 . 7L ( 7 . 1 S U US 0.53L (0.56 kqtcm , 14 18psi) 93 123kPa(0.95 1.25 't69 176'F (76 80'C) in.) 8.0mm {0.31 min. TurnsOFF actual ON 5 Subtract 15'F(3 8"C)from

ServiceLimit

OPeningtemPerature

a
2-5

Standardsand ServiceLimits
Fueland Emissions
Item Fuelpressure regulator Fueltank Engine idle Measulement Oualification Pressure with fuel pressure gauge connected Capacity ldlespeed with headlights radiator Neutral and fan off
F a s ti d l e

Standardor New ServiceLimit 320-370kPa13.3-'3.8 kgtcm',47 52psi) 5 04 ( 1 3 . 2 Sg a l i U 750 50 rpm 1,600150 rpm

f
. \

Neutral

Clutch
Item pedal Clutch Mea3uremnl Height fromthe floor Stroke
D i s e n g a g e m e n th e i g h t f r o m t h e f l o o r

Oualification

Clutch disc plate Pressure

Bunout clutch on matingsurface Bivetheaddepth Ihickness Warpage


Heightof diaphragm spring fingers

Measured with specialtool and gauge feeler

Slandardor New 193mm (7.60 in.) 130 140 m15.15.5in.) m 10 16mm (0.39 0.63in.) 1 ' 1 5 m ( 4 . 5 3n . ) i n . m i m 0.05mm 10.002 max. in.) 1.65 2.25mm (0.065 0.089 in.) 8.3 8.9mm (0.33 0.35in.) 0.03mm (0.001 in.)max. 0.6mm (0.02 max. in.)

ServiceLimit

0.15mm (0.006 in.) 0.7mm {0.03 in.) 6.0mm (0.24 in.) 0 . 1 5 m ( 0 . 0 0i1 . ) m n 0.8mm (0-03 in.)

r a

\ < c
2-6

O E

and M/T Differential nualTransmission


Item Masurement Oualification Standardor New 1.5 Forfluidchange: 0 (1.6US qt) F o ro v e r h a u1:. 7 1 1 . 8 Sq t ) l 0 U ' 0 . 1l - 0 . 1 7m m ( 0 . 0 0 40 . 0 0 7 i n . ) in.) 20.80 20.85 mm {0.819 0.821 mm in.) 31.984-32.000 (1.2594 1.2598 n m 2 7 . 9 7 72 7 s 9 0 m \ 1 . 1 0 1 - 1 . 1 0 2i0 . ) 5 mm (1.5348 38.984 39.000 '1.5354 in.) Se.viceLimit

Transmission Capacity fluid Endplav Mainshaft Diameter bushing of surface


D i a m e t e ro f d i s t a n c ec o l l a r

contact area Diameter ballbearing of (clutch housing side) contact Diameter needle of bearing area area Diameter ballbearing of contact (transmission housing side) Runout Mainshaft 3rd, t.D. 4th and sth Endplay gears Thickness Countershaft Diameterof needlebearingcontact side) area(clutch housing of collarcontact Diameter distance alea
D i a m e t e ro f b a l l b e a r i n gc o n t a c t a r e a ( t r a n s m i s s i o nh o u s i n g s i d e )

Adiust 20.75 mm 10.817 in.) 3 ' 1 . 9m m ( 1 . 2 5i7 . ) 3 n n 2 7 . 9 2 m ( 1 . 0 9i9 . ) m 4n.) 38.93 mm (1.533 n 2 7 . 9 3 m { 1 . 1 0i0 . ) m in.) 0.05mm (0.002 44.08 mm (1.735 in.) m n 0 . 2 5 m ( 0 . 0 1i0 . ) 23.80 mm (0.937 in.) in.) 34.95 mm (1.376 39.88 mm (1.570 in.) n 2 9 . 9 7 m ( 1 . 1 8i0 . ) m in.) 0.05mm (0.002 Adjust in.) 52.08 mm (2.050 m in 0.25 m10.010.) 22.87 mm (0.900 in.) mm {2.050 in.} 52.08 4n.) 0.25mm 10.010 in.) 27.87 mm 11.097 mm (1.574 in.) 39.97 mm (l.848in.) 46.94 mm (1.574 in.) 39.97 in.) 46.94 mm (1.848

in.) mm 27.987 28.000 (1.10'191.1024 in.) 0.02mm (0.001 max. mm in.) 44.009 44.025 11.73261.7333 0.06 0.16mm {0.002 0.006;n.) in.) 23.92 23.97 mm (0.94'10.944 '1.3785 in.) mm 35.000-35.015 (1.3780 39.937 39 950mm (1.5723 1.512ain.| n 3 0 . 0 2 0 - 3 0 . 0 m3 ( 1 . 1 8 1 91 . 1 8 2i4 . ) 3m in.) 0.02mm {0.001 max. in.) 0.04 0.10mm (0.0016 0.0039 in.i mm (2.0476-2.0484 52.010 52.029 (0.002 0.006 in.) 0.06 0.16mm -0.904in.) $m 10.902 22.92 22.91 in.) mm 52.010 52.029 (2.0476 2.0484 in.) 0.06 0.16mm (0.002 0.006 mtn \1.099 1.101 in.) 21.92 27.91 in.) mm (1.572a 1.5132 39.95 39.96 in.) mm 1.8504 46.989-47.000 (1.8499in.i mm (0.907-0.909 23.03 23.08 1.5732 in.l mm {1.5728'39.95 39.96 in.) 46.989 47.000 (1.8499 1.8504 mm m 28.03 28.08 m (l.104 1.106in.)

Runout innerrace 35 mm shim-to'bearing

Countershaft

clearance LD.
End play

Thickness Countershaft 2ndgear Countershaft 'lst gear

t.D.
Endplay Thickness LD.

o.D.

collar Length distance Countersha{l l . D . o.o. 2ndgear distance coliar L e n g t h

o
2-7

Standardsand ServiceLimits
ManualTransmission anuatI ransm and Differentialcont'
Item

?
ServiccLimit 3 2 . 0 2 m ( 1 . 2 6i1 . ) m n 38.94 mm (1.533 in.)

Measutemenl

Oualification

Nlainshaft 4th and5thgears

LD.

o.D.
B

distance collar L e n g t h

Standardor New 32.00-32.01 mm (1.2598 1.2602 in.) 38.989 39.000 mm (1.5350 1.5354 in.) 51.95 52.05 mm (2.045 2.049 in.) 24.03 24.08 mm (0.946-0.947 in.)

MBSdistance LD.
Len9th

Reverse idler gear Synchro ring Triple cone

t.D.
G e a r l o r e v e r s eg e a r s h a f i c l e a r a n c e

Bingto'gearclearance Outer synchro ring-to synchro cone clearance Synchro cone-to-gear clearance Outersynchro ring-to-gear cone clearance Finger thickness Forkto-synchro sleeve clearance Finger thinkness
F o r k - t o - r e v e r s ed l e r g e a r c l e a r a n c e i

Ringpushed gear against Ringpushed qear against pushed Ring gear against Ringpushed gear against

(1.102 1.103 28.00 28.01mm in.) 23.95 24.05 mm (0.943 0.947 in.) 20.016 20.043 mm (0.7880 0.7891 in.) 0.036 0.08a mm (0.0014 0.0033 in.) 0.70 1.49 mm (0.028 0 059in ) 0.70- '1.19 {0.028 0.047 mm in.) 0.50 1.04 mm (0.020 0.041 in.) 0.95 1.68 mm (0.037 0.066 in.) 7.4 7.6mm 10.29 0.30in.) 0.35 0.65mm (0.014 0.026 in.i 13.4 13.7 mm (0.527 0.539 in.) 0.20 0.59mm (0.007 0.024 in.) 13.973 '14.000 (0.5501 0.5512 mm in.) 16.9 '17.0 (0.665 0.669 mm in.) 0.2 0.5mm (0.008 0.020 in.) 14.85 '14.95 (0.585 0.589 mm in.) 0.05 0.25mm (0.002 0.010 in.) 15.00 15.10 mm {0.591 0.594 in.) 0.013 0.07mm (0.0005 0.003 in.) 18.010 18.028 (0.7091 0.7098 mm in.) 0.027 0.057 mm (0.0011 0.0022 in.) 28.025 28.045 (1.1033 1.1041 mm in.) 0.05 0.15mm {0.002 0.006 in.) 1 8 . 0 4 21 8 . 0 6m m ( 0 . 7 1 0 30 . 7 1 1 3 i n . ) 6 0.059 0.095 mm (0.0023 0.0037 in.) 0 0.10mm (0 0.0039 in.)

2 8 . 0 2 m ( 1 . 1 0i3 . ) m n 20.90 mm (0.832 in.) 0 . 1 6 m { 0 . 0 0i6 . ) m n 0.4mm (0.016 4n.) 0.3mm (0.012 in.) 0.3mm (0.012 in.) 0.6mm (0.024 in.)

Shift fork Reverse shift fork Shiftarm

1.0mm (0.039 in.) 1.3mm (0.051 in.)

t.D.
S h i f t f o r k d i a m e t e ra t c o n l a c ta r e a S h i f t a r m ' t o - s h i f t l e v e rc l e a r a n c e

0 . 6 2 m ( 0 . 0 2i4 . ) m n 0.50mm (0.020 in.) 0.1mm {0.004 in.) 0.1mm (0.004 in.l

Select lever Shiftlever

Finger width -to-select Shaft leverclearance Groove{to selectlever) Shaftto shiftarm clearance Pinionshaftcontactareal.D.
Carrier-to-pinion haftclearance s

L O

Mfi differential carrier Mfi differential pinionqear 80 mm shim

Driveshaft contactareaLD. Backlash

t.D.
P i n i o ng e a r t o p i n i o n s h a f t c l e a r a n c e

80 mm shim to-bearing outerrace clearance transmission in housing

0.15mm (0.006 in.) Adjust

2-8

o
n

Rotational measured outside at olav loadmeasured outside at Starting


A n g l e o f r a c kg u i d e s c r e w l o o s e n e d

0 10mm (0 0.39in.) 2 9N ( 3 . 0 g f . 6 . 6 l b s ) k

Item W h e e l a l i g n m e nCamber t Caster TotalToe

Measurement

Oualitication Front Rear Front

Standardor New 0'00' 45' 0'45'- 45


1"33' 11"

ServiceLimit

lrytt
Rear
l n s i d ew h e e l

Frontwheel turningangle wheelrunout Aluminum


Wheelbearing

wheel Outside
Axial Radial Front

Endplay

Rear

i 0 - 3 m m ( 0 : : 0 . 1 2n . ) lN 2 ' , mm (0.08"' ,, in.) 37'40'-2' 29'50'(Reference) 0 0.7mm (0 0.03in.) 0 - 0 . 7m m ( 0 0 . 0 3 i n . ) in.) 0 0.05mm (0 0.002 in.) 0 0.05mm (0 0.002

2.0mm (0.08 in.) l.5mm{0.06in.)

a
2-9

Standardsand ServiceLimits
Brakes
Item Parking brake lever pedal Brake Master cylinder Erake disc Masurement Distance traveled when leverpulled with 196N (20kgf, 44 lbs) ol force (carpet Pedal height removed) Freeplay Piston-to-pushrod clearance Thickness Runout
Parallelism

Oualification

Standardor New 7 8 clicks


1 8 4m m ( 7 4 / 1 6i n . )

ServiceLimit

Front Rear Front Rear Frontand rear


Front llear

0 . 4 3 . 0m m ( 00 1 6 0 ' 1 1 8n . ) i 0 0.4mm (0 0.02in.) 2 1 . 0 m ( 0 . 8 3n . ) m i 9.0mm {0.35 in.)

pads Brake

Thickness

10.0 mm (0.39 in.) 9.0mm {0.35 in.)

1 9 . 0 m m ( 0 . 7 5n . ) 0 i 8-0mm (0.31 in.i 0.10mm (0.004 in.) 0.10mm (0.004 in.) 0.015 mm (0.0006 in.) 1 . 6 m ( 0 . 0 6n . ) m i 1 . 6 m ( 0 . 0 6n . ) m i

Air Gonditionin
Item Refrige.ant Refrigerant oil Moasurement Oualilication
Standard or New Service Limit

Tvpe
Capacity system of Type Capacity ofcomponents Condenser Evaporator
Eachline and hose

4 H F C1 3 4 ( B - 1 3a ) a 500 550g 117.6 19.4 oz) S P1 O (P/N 38897-P13-A01AH or 38899-P13-A01 ) 25 m0,15/6fl ozl 45 mA111/2fl ozt 10m0 (1/3 or) fl 130 150 014 /3 5floz) m 1 3.05 3.350 0.35 0.6mm (0.014 0.024 in.) Autotensioner no lneeds adjustment)

Compressor Drivebelt

Startercoil resistance plate Pulley-to-pressure clearance

Compressor At 68"F(20"C)

e-

2-10

Design Specifications

|tem

Measurement
Overalllength

Oualification 4 , 2 1 0 m { 1 6 5 .i8 . ) m n mm 166.7 in.) 1,695 i 1 , 4 4 m m ( 5 6 . 7n . ) 0 n m 2 , 5 7 0 m ( 1 0 1 .i2 . ) mm (57.9 in.) 1,470 '1,470 (57.9 mm in.i in.) 152mm (5.98 four {4) rbs 3,660 1,660 kg

Specilication

DIMENSIONS

Overallwidth
Overallheight

Track Ground clearance


S e a t i n gc a p a c i t y

rront Rear

wEtGt-iT {u.s.A.)
WEIGHT (CANADA)
ENGINE

G r o s s V e h i c l eW e i g h t R a t i n g (GVWR)

Vehicle WeightRating Gross {GVWR) Tvpe arrangement Cylinder Boreand stroke


Displacement

ratio Compression Valve train system Lubrication Oil pumpdisplacement Waterpumpdisplacement F!el required STARTER

At 6,000 engine rpm At 3,400 engine

4 V-ECengin( Watercooled. stroke DOHC 4'cylinder, transverse Inline x 86 x 86 mm (3.39 3.39in.) c 1,99cm'(122uin.) 8 9.8 per 4 VTEC valves cylinder Chain drive.DOHC pumP withtrochoid Forced, sump, wet 54.30 (57.4 qo/minute US 82 0 (87US qt)/minute gasoline number higher with 86 pumpoctane or UNLEADED Gearreduction 12V 30 seconds
C l o c k w i s ea s v i e w e c lf r o m g e a r e n d S i n q l e p l a t ed r y , d i a p h r a g m s p r i n g

Tvpe
Normaloutput
Nominalvoltage

o
CLUTCH

Hourrating Direction rotation of


C l u t c ht v p e

material area Clutch friction surface

Tvpe I\,1AN UAL reduction TRANSMISSIONPrimarv Gearratio

lst 2nd 3rd


4th

Finalreduction

5th Reverse Type Gearratio

1 7 4 m ' { 2 6 . 9s q i n . ) c 7 forward,1 reverse s-speed Svnchronized, D i r e c1 : 1 t 3.062 1.769 1.212 0.921 0.738 3.583 helicalgear Sinole 4.164

o
2-11

DesignSpecifications
cont'
Item STEERING Measuremeni Type Overall ratio Turns,lock to-lock Steering wheeldiameter Type Shock absorber Oualification Specilication Electric, Powerassisted and pinion rack 15.1 3 6 0m m ( 1 4 . 2n ) i
I n d e p e n d e n ts r r u l w i t h s t a b i l i T e rc o i l s p r i n g .

SUSPENSION

Rear Front Rear Front Bear Front


Front

D o u b l ew i s h b o n e

Telescopic, hydraulic. gas-frlled nitrogen Telescopic, hydraulic, gas,filled nitrogen

WHEEL ALIGNMENT

Camber Caster
Totaltoe

0"00'
0.45' 1'33' 0 mm (0 in.)
In2 mm (1/16n.) i P o w e r a s s i s t e ds e l f - a d j u s l i n g e n t i l a t e dd i s c v

BRAKES

Typeof servicebrake Typeof parkingbrake Padfriction surfacearea

Rear Front Bear Front Rear

TIRES AIR CONDITIONING

Sizeoffront and reartires Sizeo{ sparetire Compressor

Type Numberof cylinders Capacity Maximumspeed


L u b r i c a n tc a p a c i t y

Power-assisted self-adjusting disc solid Mechanical actuating, wheels rear 4 5c m ' ( 7 . 0 q i n . ) x 2 s 2 8c m ' ( 4 . 3 q i n . ) 2 s x Pl95/60 81588V T125r0 D1595M Scroll

Condenser Evaporator Blower

Lubricanttype Type

Tvpe
Type Motor type
Speed control

85.7m015.23 in.)/rev. cu 12,000 rpm 130m0 {4 1/3floz) (P/N SP-10 38897'P13-A01AH or38899-P13 A01) Corrugated fin Corrugated fin Siroccofan 220 Wl12 V
4 Speeo

M a x i m u m c a p a c i t y 480m" 116.900 ft)/h cu T e m p e r a t u r ec o n t r o l

Compressor clutch

Tvpe
Electricalpower cons!mptron at 68"F(20.C) Type
Capacity

Airmixtype plate, poly-V Dry,single beltdrive 42W maximum 12V at

Refrigerant

(R-134a) HFC134a 500 550g (17.6 19.4 oz)

../a
2-12

Item ELECTRICAL RATINGS

Measurement

Oualilication

Battery
Starter Alternator Fuses

Under-hood fuse Under'dash Iuse

Specitication 1 2 V 3 6A H / 5 o u r s h 1 2V - . 1 . 1 W ,1 . 2 W k k 12V 95A,90A 80A, 60A, 50A, 40A, 30A, 20A, 15A, 10A, 7.5A A 3 04 , 2 0 a , 1 5A , 1 0A , 7 . 5

Light bulbs

Headlight high beam Headlight low beam Frontturn signal liqhts


Front parlinq lights

'12 60w v.'


12V 55W 12V 21W 12V 5W 1 2 V" 2 1 W

Bear turn signal lights FronVrear side marker lights


Brale/taillighls H i g h m o L r n tb r a k e light

12V 5W
12V 21/5W 12V 5W 12V 21W 12V 5W

Backup lights platelight License Ceiling light


Cargoarea light

'12 v'.8 w

Spotlights
Gauge lights I n d i c a t o rl i g h t s

12V 5W 12V 5W LED 12V 5W

Sideturn signal light

a
2-13

Body Specifications

Unit: mm {in.) 1.555{61.6) (56.71 1,i140

2-14

Maintenance
Lubricants and Fluids Maintenance Schedule Normal for Conditions
Listed by Distance/Time

Maintenance Schedule Severe for Gonditions


Listedby Distance/Time

Maintenance Schedule
Listed Maintenance for Normal by ltem Conditions ................... 3-8 Listedby Maintenance ltem for Severe Conditions ...................3-9

\.4

Lubricants and Fluids

to For detailsof lubricationpoints and type of lubricants be applied,referto the illustratedindex and variouswork i o v e r h a u l . n s t a l l a t i o n .t c . ) o n t a i n e dn e a c hs e c t i o n . l e c ures{such Assem as

NO.
1 Eng ine

LUBBICATION POINTS

LUBBICANT
The Honda Motor Oil (P/N08798-9023). oil container seal shown below. must disolavthe API Cenification E " M a k es u r ei t s a y s" F o r G a s o l i n e n g i n e s . S A E Viscositv:See chart below.

2 3
4

Transmission
ABS line) Brakesvstem (includes C l u t c hl i n e l R e l e a s eo r k ( m a n u a t r a n s m i s s i o n l f Throftlecableend (throttleIink) Shift and selectcable ends (manual transmission) lower panel hole) Throttlecable end (dashboard Brakeboosterclevis CIutchboosterclevis Shift lever pivot Pedalinkage Batteryterminals F u e lf i l l d o o r H o o dh i n g e sa n d h o o d l a t c h H a t c hh i n g e s , a D o o rh i n o e s u o D e r n d l o w e r Caliperpiston boot, caliperpins and boots Air conditionincompressor g

Honda MTF*'(P/N 08798-9016)


HondaDOT 3 BrakeFluid*' (P/N08798-9008) S u p e rH i g hT e m p U r e aG r e a s e P / N0 8 7 9 8 - 9 0 0 2 ) { g Silicone rease

5 6
7 I 9 10 11
1'

grease Multi-purpose

14 16 17 18 19

HondaCaliDer Grease(P/N08C30-80234lvl) ( oH C o m p r e s s o r o i S P - 1 0 P / N3 8 8 9 7 - P 1 3 - A 0 1 A r l: 38899-P'13-A01) a a F o rr e f r i q e r a nH F C ' 1 3 4 ( R - 1 3 4 ) t;

Recommond6dEngineOil f f E n g i n e i l v i s c o s i l yo r a m b e n t t e m p e r a l u r ea n g e s o

-30 -20

-10

t0

20

* 1 : Always use HondaManualTransmission Fluid (MTF).Using motor oii can causestiffershifting becauseit does not containthe Drooeradditives. " 2 : Always use HondaDOT 3 BrakeFluid.Using a non-Hondabrakefluid can causecorrosionand decrease the life of the system.

3-2

t
o o o o o
o@@ a9

3-3

Maintenance Schedule
for Listedby Distance/Time Normal Conditions
Thistwo pagel/lanitenance Schedule outlines minimunrequired the maintenance. Service the indicated at distance time,whichever or comes if in first.use the lvlaintenance Schedule Severe for conditions the vehicle meets anyof the qualifiers the Severe Conditions schedule if the or vehicle normally is driven Canada. in

(cold) (see page6-321r in.) valveclearance. Intake: 0.21-0.25mm (0.008 0.010 Exhaust: in.) 0.28 0.32mm (0.011 0.013 Inspect (NGK) SKJ20DR-M11 (DENSO). plugs.UseIZFR6K'11 Replace or spark 1 . 0 1 . 1m m km/ 120,000 192,000 6 years mi/ page13-3). fluid.UseHonda MTF(see I Replace transmission ! Do items in A,B,alqq.,
/ / Y vcdrs

120,000 192,000 mil (see page106).Capacity: 0 (5.3US qt).UseHonda Season Type 5.0 All Antifreeze/Coolant 2. Beplace coolant andlederal regulations, tailure do the maintenance to itemsmarked with an asterisk will not voidthe customer's According state to {*) interval ensure to long-term warranties, However, Honda recommends all maintenance that services doneat the recommended be emissions reliability.

3-4

Dothe itemsin partsA, B, C, D, andE as required mileage/time for interval listed. A Replace engine oillseepage8-5i. Capacity withoutlilterchange: S (4.2US qt, 3.5lmp qt) 4.0 Rotate tires. Follow pattern the shownin the Owner's Manual Checktire information condition. and B Replace engine filterlseepage8-6). Capacity oil with filterchange: (4.4US qt,3.7lmp qt) 4.20 (see page19 3i. Inspect frontandrearbrakes . Check padsand djscs wear(thickness), for damage, cracks. and ' Check calipers damage, tor leaks, tjghtness mountbolts. and ot parking Check brake adjustment. ShouldbeIullyapplied within7 to I clicks. gearbox, boots{seepage17 5). Inspect rod ends, tie steering and . Check grease steering rack linkage. and . Check grease bootsfor damage and leaking . Chack fluidline{or damage and leaks. lnspectsuspension components. . Chock boltsfor tightness. . Check condition balliointboots deterioration damage. of lor and Inspect driveshaftboots.Checkbootsfor cracksand boot bandsfor tightness(seepage16-3). proponioning Inspct brake hoses ABS). Checkthe andlines{including mastercylinder, valve, control andABSmodulator{or damage andleakage. Check fluidlevels condition tluids; all and ot check leaks. necessary, MTFlseepage13'3), for lf add engioe coolant, brake fluid,and windshield washer fluid. pipeand mufflerfordamage,leaks, tightness system*. L lnspectexhaust Check catalytic converter heatshield, exhaust and {soepage9,8). lnspect linesandconnections*. {uel Check loose for connections, cracks deterioration; and retighten loose connoctions replace and parts(sepage11 146). damaged and l InsDect adiust drivebelt. . Lookfor cracks damage, inspect (needs adjustment). and and autotensioner no page21 39). Replace dustandpollen the lilter(see . Replacethe dustandpollen filterwhenever low lrom the heating cooling airf and system lessthan is normal.

D E

Replace cleaner air element every30,000 miles(48,000 (independent time). km) of

i I Replace brake fluidevery3 years(independent mileage). oI

* According state to andfederal regulations, failure do the maintenance to itemsmarked with asterisk( ) will not voidcustomer's emissions warranties. However, Honda recommends all maintsnance that service doneat the recommended interval ensure longterm reliability. be to

3-5

Maintenance Schedule
for Listedby Distance/Time SevereConditions
or comes first.Usethisschedule the vehicle drivenMAINLY Canada in anyof the Service the indicated at distance time,whichever if is in or (see il in tollowing conditions; onlyOCCASIONALLY driven these conditions, the Normal use Conditions schedule page3-4). SevereDrivingConditions . Driving less than5 miles{8 km) pertrip or, in freezing temperatures, drivingless than 10miles(16km)pertrip . Driving extremely (over hot 90"F/32"C) conditions in . Extensive suchasa taxior a commercial delivery vehicle. idl;ng longperiods stopand go driving, or of . Trailer with a car-top carrier, drivingin mountainous or conditions. towing,driving . Driving muddy, roads on dusty, de'iced or

R e p l a c et r a n s m i s s i o nf l u i d . U s e H o n d a M T F { s e e p a g e 1 3 3 ) .

(seepage6 32):lntake: (cold) in.) in.) 0.28 0.32mm (0.011 0.013 Inspect valveclearance. 0.21 0.25mm (0.008 0.010 Exhaust: 11 11 Replace sparkplugs.Use IZFR6K (NGK)or SKJ20DR'M {DENSO)

km/ 6 years R e p l a c e r a n s m i s s i o nf l u i d . U s e H o n d a M T F ( s e ep a g e 1 3 3 ) . t

mi/ km/ mil 192,000 10years, km/ thenevery60,000 96,000 5 years 5.0 All Antifreeze/coo Type2. lant Replace coolant(seepage10-6). Capacity: 015.3 qt) UseHonda Season US

3-6

Dothe itemsin parts B, C,D, E,F,and G as required mileage/time A, for interval listed. A q Feplace engine oil(seepageS5). Capacity withoutlilter change:4.0 (4.2US qt,3.5lmpqt) I Replace engjne filter(seepageI 6). Capacity oil with filterchange: 0 14.4 qt,3.7lmp qt) 4.2 US Insoect frontand rearbrakes, . Check padsanddiscsforwearlthickness), damage, andcracks. . Check calipers damage, for leaks, tightness mountbolts. and of Lubricate doorlocks, latches hinges and with Honda whitelithiumgrease. Rotate tires,if the vehicle beendriven distance has the listed. Follow pattern the shownin the Owner's Manual-Check inflaronaoo tire condition, (seepage17,5). gearbox, boots Inspecttie ends, rod steering and . Check rackgrease steering linkage. and . Check grease. bootsfor damage and leaking . Checklluid linefordamage leaks. and L Inspect suspensron components . Check boltsfor tightness. . Check condition balljointbootsfor deterioration damage. of and (seepage16-3). Inspect driveshaft boots. Check bootsfor cracks and bootbands tightness for parking Check brake adjustment. Should fullyapplied be within7 to 9 clicks. (including Inspct hoses proportioning brake andlioes. ABS). Check master the cylinder, control valve, andABSmodulator damage for (see and leakage page19-24). (see page13 3),engine Check fluidlevels condition lluids;check leaks. necessary, MTF all and ot for lf add coolant, brake fluid,and windshield washer luid. f (see Inspect pipeand muffler damage, page9 8). exhaust system*. Check catalytic converter heatshield, exhaust for leaks, tightness and Inspect lines fuel andconnections*. for Check looseconnections, cracks deterioration; and retighten loose connections replace and pans(seo page11'146). damaged (see Check alllights. Checkfunction otallinterior andexterior lights, andtheposition ofthe headlights page22-68). Inspect vhicle the underbody. Check paintfor damage, the scratches, stonechippin0, dents. and

L
D

InsDect and adiustdrive belt. . Looktor cracks damage, inspect and and autotensioner no {needs adjustment). Reolace dustand oollen filter.

E
Replace cleaner air element every15,000 miles124,000 in dustvcondition km) ol use Conditions {independent timei otherwise Normal (see scredule page11-162).
F

lReplaceaircleanerelementevery30,000miles(48,000km)(independento{timei(seepagell-162). Replace fluidevery3 years(independent mileagei. brake oJ


H

Replacethe andpollen Iilterevery15,000 dust milesifvehicle drivenmostlywhere hashighconcentration is air olsootfrom industryand dieselpowered vehiclesj replace dustand pollen also the filteranytime aarflow less is thanussal(seepags21-39).
A c c o r d i n gt o s t a t e a n d f e d e r a l r e g u l a t i o n s , a i l u r e t o d o t h e m a i n t e n a n c ei t e m s m a r k e d w i t h a s t e r i s k( * ) w i l l n o t v o i d c u s t o m e r ' s e m i s s i o n s f w a r r a n t i e s .H o w e v e r , H o n d a r e c o m m e n d s t h a t a l l m a i n t e n a n c es e r v i c e sb e d o n e a t t h e r e c o m m e n d e d i n t e r v a lt o e n s u r e l o n g - t e r m r e l i a b i l i t y ,

3-7

Maintenance Schedule
ltem for NormalConditions Listedby Maintenance
on for Conditions the nextpagedo in Schedule Severe if driving conditions specified the lMaintenance Follow NormalSchedule the severe the driving conditions. drivenin severe and if onlyOCCASIONALLY not apply, if is in schedule the vehicle drivenMAINLY Canada. Follow Severe the Conditions ortime, distance Service atthe indicated comes first. whichever milesx 1,000 km x 1,000 months oil Replace engine
R o t a t et i r e s { C h e c kt i r e i n t l a t i o na n d c o n d i t i o n a t l e a s t o n c e p e r m o n t h )

c
70 96 112 48 80 128 90
144

t0 16 12

20 32

30
48

40
64

50 80 3

100
160

110

r20
192

24

60

12

oil Replace engine filter Inspect frontand rearbrakes


C h e c kp a r k i n g b r a k e a d j u s t m e n t

items: inspect following the Visually . Tie-rod gearbox and boots ends,steering . Suspension components . Driveshaft boots . Brake ABSi hoses and lines(including . Allfluidlevels andcondition of{luids . Exhaust system* . Fuellinesandconnections* Inspect adjust drivebelt and filter Replace dustand pollen fluid Reolace transmission intervals Servicethefollowing items at the recommended
R e p l a c ea i r c l e a n e re l e m e n t

a a

km) Every 30,000 (48,000 miles Lm) Every 110,000 (176,000 miles km), adiusl if Inspect 110,000 {176,000 otherwise only noisy. miles every km) Every 160.000 es1256,000 or8 years mr km) 60,000 (96,000 or5 miles km) then At 120,000 (192,000 or 10years, every miles Every years 3

Replace sparkplugs Inspect valveclearance


I n s p e c ti d l e s p e e d * R e p l a c ee n g i n e c o o l a n t

brake fluid Replace

(*) emissions * : According state with asterisk will not voidcustomer's itemsmarked failure do the maintenance to andlederal regulations, to reliabilityinterval ensure to long-term service doneat the recommended be recommends all maintenance that However, Honda warranties.

3-8

Listedby Maintenance ltem for SevereConditions


Usethisschedule the vehicle drivenMAINLY Canada in anvof thefollowina if is in or conditions. NOTE: onlyOCCASIONALLY it drivenin these conditions, the Normal use Conditions schedute. SovereDrivingConditions . Driving less than5 miles(8 km)pertrip or, in lreezing temperatures, drivingless than 10miles(16km)pertrip. 'C)conditions. . Driving extremely over90 "F 132 in hot . Extensive idling, longperiods stop-and-go-driving, as a taxior a commercial or ot such delivery vehicle. . Trailer towing,driving with a cartop carrier, drivingin mountainous or conditions. . Driving muddy, on dusty, de icedroads. or Service the indicated at distance time, or whichever comes first. milesx 1,000 km x 1,000 months Replace engine oil Rotate tires intlation condition leastonce monthi per and {Checktire at
R e p l a c ee n g i n e o i l f i h e r

10 16 12

20

30 48 24

40
64

50
80 36

60 96

70
112

80 128 48

90
144

100 160

110 176 72

120 192

60

Replace 5,000 every miies km)or months 6 18,000

Inspect frontand rearbrakes


L u b r i c a t ea l l l o c k s ,h i n g e s ,a n d l a t c h e s

Visually inspect following the items: . Tie rod ends, gearbox steering and boots . Suspension components ' Driveshaft boots Checlparking braleadjuslment Visually inspect following the items: . Brake hoses and lines ABSi {including . Allfluidlevels condition and oflluids . Exhaust system* . Fuellines andconnections* . Lights andcontrols, vehicle underbody Inspect adjust and drivebeh
R e p l a c ed u s t a n d p o l l e n f i l t e r " o ' t '

a a

a a

Replace transmission lluid Service following items atthe recommended the interuals Replace cleaner air element plugs Replace spark Inspect valveclearance
I n s p e c ti d l e s p e e d '

(24,000 in dusty Every 15,000 miies km) conditions, otheMise normal use schedule. Every 110,000 (176,000 miles km) Inspect 110,000 (176,000 otheMise every miles km), adiust if noisy. only Every 160,000 (256,000 miles km)or8 vears At 120,000 (192,000 of 10years,lhen 60,000 (96,000 miles km) every miles km)or 5 Every years 3

Replace engine coolant Replace brake fluid

* : A c c o r d i n gt o s t a t e a n d f e d e r a l r e g u l a t i o n s , a i l u r e t o d o t h e m a i n t e n a n c ei t e m s m a r k e d w i t h a s t e r i s k1 * ) w i l l n o t v o i d c u s t o m e r ' s e m i s s i o n s f w a r r a n t i e s .H o w e v e r , H o n d a r e c o m m e n d st h a t a l l m a i n t e n a n c es e r v i c eb e d o n e a t t h e r e c o m m e n d e d i n t e r v a lt o e n s u r e l o n g { e r m r e l i a b i l i t v . N O T E 1 : R e p l a c et h e d u s t a n d p o l l e n f i l t e r a t 1 5 , 0 0 0m i l e s / 2 4 , 0 0 0 m i f t h e v e h i c l e i s d r i v e n m o s t l y i n u r b a n a r e a st h a t h a v e h i g h c o n c e n t r a t i o n s k o f s o o t i n t h e a i r f r o m i n d u s t r va n d d i e s e l - D o w e r e d e h i c l e s . v

t,

3-9

EngineElectrical
Engine Electrical
SpecialTools 4-2
4-J

StartingSystem
Comoonent Location Index ............... Circuit Diagram Starter it Circu Troubleshooting ClutchInterlock SwitchTest Starter Solenoid Test .............. StarterPerformance Test Reolacement Starter ............... Starter Overhaul ....................... 4-4 4-5 4-6 4-7 4-8 4-9 4-10

ENGINE

lgnition System
Component Location Index ............... 4-15 Circuit Diagram 4-16 lgnition TimingInspection 4-17 lgnition CoilRemoval/1nsta11ation ....................... 4-18 PlugInspection Spark 4-19

ChargingSystem
Component Location Index .................................. 4-2O Circuit Diagram ........................... 4-21 Charging Troubleshooting ....................... 4-22 Circuit Drive BeltInspection ................... 4-26 Drive BeftReplacement .............. 4-26 Drive BeftAuto-tensioner Inspection .................. 4-27 Drive Beft Auto-tensioner Replacement .............. 4-28 Alternator Reolacement ............. 4-29 Alternator ................ .... 4-30 Overhaul

CruiseControl
Component Location Index .................................. 4-36 Circuit Diagram ........................... 4-37 Troubleshooting Index ....................... 4-38 Symptom Cruise Control UnitlnDut Test ............................. 4-40 MainSwitch TesVReolacement ........................... 4-42 .. SeVResume/Cancel SwitchTesVReplacement 4-42 Cruise Control Actuator Test ......4-43 Cruise Actuator/Cable Replacement 4-44 ...... Control Actuator Cable Adjustment .................................. 4-45 Pedal Clutch Position Switch Test ....................... 4-45
\.

EngineElectrical
SpecialTools
Number

\ C
Tool Number Description Attachment,52 x 55 mm Driver

otv
1 1

07746-0010400 07749-0010000

\(a
4-2

Starting System
ComponentLocationIndex

- l - ar]]]ll -i I

UNDER-DASH FUSE/RELAYBOX

-_rt_.1 -. _-- _. / Itti: : - l t . i t - t! i t !t:!|STARTER CUTRELAY page Test, 22-51

CLUTCH INTERLOCK SWITCH Test,page4-6

\ r \ ' l \'\l I

\r\, l,
/

, . \ \ \ \ / \-

'....",r.v
\:,...)

\ /'\ t l

STARTER page4 5 StanerCircuitTroubleshoot,ng, SolenoidTest,page 4-7 Performance Test,page4-8 page4-9 Replacement, '10 Overhaul,page4

4-3

Starting System
CircuitDiagram
ilo.20lOA) :USA motkl No.2!l50A) : C.nid. model

UiIOEN H@D fUSE/REI.IY BOX

STHOT STA8T in illl

UNDEiOASTI FUST/ifLAY 80x

Y.

cLuTot [{Tr8LocK swtlcH

a
4-4

StarterCircuitTroubleshooting
NOTE: . Airtemperaturemust be between59'and 100'F(15' and 38'C) during this procedure. . After this test, or any subsequent repair,resetthe to enginecontrolemodule (ECM) clear any diagnostlc trouble codes (DTCS) {seepage 11-4). . The batterymust be in good conditionand fully charged. . lf you disconnect the baftery,do the ECM idle learn ( p r o c e d u r es e ep a g e1 1 - 1 3 9 ) . Procedure: Recommended . Use a startersystemtester. . Connectand operatethe equipmentin accordance with the manufacturer'sinstructions. Alternate Procedure 1. Hook up the following equipment: . Ammeter,0 400A . Voltmeter,0 20 V (accurate within 0.1 volt) . Tachometer,0 1200rpm 4. Checkthe batterycondition.Checkelectrical at connections the battery,the negativebaftery cableto body, the engine ground cablesand the and corrosion.Then try starterfor looseness startingthe engine again. Did the statter crank the engine? YES Repairing the looseconnectionfixed the problem.The startingsystem is now OK.! a n N O l f s t a r t e r w i l l o t c r a n k t h e e n g i n e t a l l ,g o t o step 5. lf it cranksthe engine erraticallyor too from the slowly, go to step 7. lf it won't disengage flywheel ring gear when you releasethe key, check for the following until you find the cause. . Solenoidplungerand switch malfunction . Dirty drive gear or damagedoverrunningclutch 5. Make sure the transmissionis in neutral,then 1P disconnect startersubharness connector(A) the 'lP from the enginewire harness connector(B). Connecta jumper wire from the batterypositive 'l terminalto the startersubharness P connector.

2 . Removethe No. 17 (15A)fuse from the under-dash


fuse/relaybox. turn the ignition 3 . With the clutch pedal pressed, switchto start (lll). Did the starter crank the enginenormally? YES-The startingsystem is OK.I YES-Go to step 6. NO-Go to step 4. wire betweenthe starter NO Checkthe BLK,ANHT 1P subharness connectorand the starter.lf wire is OK, removethe starter,and repairor replaceas necessary. Did the starter crank the engine?

L
(cont'd)

4-5

StartingSystem
StarterCircuitTroubleshooting (cont'dl
6. Checkthe following items in the order listeduntil you find the open circuit. . Checkthe BLIVWHT wire and connectors betweenthe under-dash fuse/relaybox and the ignition switch,and betweenthe under-dash fuse/relaybox and the starter. . Checkthe ignition switch {seepage 22-53). . Checkthe clutch interlockswitch and connector. . Checkthe startercut relay (seepage 22-51). . CheckLT GRNwire betweenthe startercut relayl under-dash fuse/relaybox and the clutch interlockswitch. . Checkthe BLKwire betweenthe clutch interlock switch and G501. 7, Checkthe crankingvoltageand currentdraw. ls ctanking voltagegreatet than or equal to 8.7 V and current draw less than or equal to 230 A? YES-Go to step8. NO Replace starter.or remove and the disassemble and checkthese items until you find it, thecause. . Starterarmaturedragging . Shortedarmature winding . E x c e s s i vd r a g i n e n g i n e e 8 . C h e c k h e e n g i n e p e e dw h i l ec r a n k i n g h e e n g i n e . t s t ls the engine speed above 100 tpm? YES Go to step 9. NO-Replace the starter,or remove and disassemble and checkfor the following until it, y o u f i n dt h e c a u s e . . Excessively worn starterbrushes . Open circuit in commutator brushes . Open circuit in starterarmaturecommutator segments . D i r t yo r d a m a g e d e l i c as p l i n e s r d r i v eg e a r h l o . Faultydrive gear clutch 9. Removethe starter,and inspectits drive gear and the flywheel ring gear for damage.Replace any p damaged ans.I
Terminal \ Cl","f ri"t.tf ."tS""*Jrl

ClutchInterlockSwitch Test

1. Disconnect clutchinterlock the switch connector. 2P

2. Removethe clutch interlockswitch (A). Checkfor continuitybetweenthe terminals accordingto the table. . lf the continuityis not as specified,replacethe clutch interlockswitch. . lf OK, installclutch interlockswitch and adjust the pedal height (seepage 12-4l.. 2

PRESSED RELEASED

o--

- --o

4-6

StarterSolenoidTest
from thestarter 1. Disconnect S andlvlconnectors the solenoid.

2. Checkthe hold-incoil for continuitybetweenthe S terminal and the armaturehousing(ground).There should be continuity. . lf there is continuity,goto step 3. . lf there is no continuity,replacethe solenoid,

et

n 3. Checkthe pull-incoil for continuitybetwee the S . t e r m i n a a n d M t e r m i n a l T h e r es h o u l db e l continuity, . lf there is continuity,the solenoidis OK. . lf there is no continuity,replacethe solenoid,

4-7

StartingSystem
Starter Performance Test
1 , Disconnect wires from the S terminal and the M the termrnal. Make a connectionas describedbelow using as heavya wire as possible(preterably equivalentto the wire used for the vehicle). avoid damaging To the starter,never leavethe batteryconnected for more than 10 seconds, Connectthe batteryas shown. Be sure to disconnect the startermotor wire from the solenoid. lf the starterpinion moves out, it is working propefly. 5. Disconnect batteryfrom the starterbody. lfthe the pinion retractsimmediately,it is working properly.

6 . Clampthe starterfirmly in a vise.


7 . Connect the starterto the batteryas describedin the diagram below,and confirm that the motor starts and keepsrotating.

Disconnect batteryfrom the M terminal.lf the the pinion does not retract,the hold-incoil of the solenoidis working properly.

lf the eiectriccurrent and motor speedmeet the specifications when the batteryvoltage is at 11.5V, the staner is working properly, Specifications: 1.1 kw 90 A or less (Electric current), ot more

4-8

Starter Replacement
code for the radio. 1. Make sure you havethe anti-theft for then write down the frequencies the radio's presetbuttons. the 2. Disconnect negativecablefrom the batteryfirst, the positivecable. then disconnect the 3. Disconnect knocksensorconnector. 4. Removethe bolt (A) securingthe harnessbracket, then removethe intakemanifold bracket(B).
A 6x1,0mm 12 N.m {1.2kgf.m, 8.7 tbt.ft)
8 x 1 . 2 5m m 9Nm kgf.m,7 lbl ft) 10.9

the 5. Disconnect startercable (A)from the B terminal wire the BLK,/WHT on the solenoid,then disconnect

{ B )f r o mt h eS t e r m i n a l .
10x 1.25 mm kgf.m,33lblft) 44N.m{a.5

2
S'-12x12smm
6ilNm

{ 6 . 5k g l m , 4 7 l b f f t )

Removethe two bolts holdingthe starter,then removethe starter. mm 8 x 1.25 kgt.m, 22 N,m 12.2 16rbf.ftl 7 . lnstallthe starterin the reverseorder of removal. Make sure the crimped side of the ring terminal (A) is facing out.

I
Connectthe positivecable and negativecableto the batterY.

9 . Start the engineto make sure the starteroperates


propeny.

'10.Enterthe anti-theftcode for the radio,then enter


the customer'sradio stationpresets. 1 1 .Set the clock.

' t 2 .Performthe enginecontrol module (EcM) idle learn


procedure(seepage 1'1- ). 139

4-9

StartingSystem
Starter Overhaul
Disassembly/Reassembly

@ @

STARTERSOLENOID

rw.h \:!@a
,/ 1(-\

,--\

----_2<-

G
SOLENOID LEVER

q
b-.-

- @-A
-z\hsc6

," OVERRUNNING

CLUTCHASSEMBLY

7:- o
S#o

o*"lu*.

V*rN*

\#.
\
,..
END COVER

A*@
ffiA
'!4/ t/ BRUSHHOLDER

c^)* -#""Jli[X:""
a<-4 t^ fr/ / -v

9\:-/ lW ffitr D

\ r
4-10

\
Armature Inspection and Test 1. Removethe starter(seepage 4-9). h a 2 . D i s a s s e m b lte e s t a r t e r s s h o w na t t h e b e g i n n i n g of this procedure. 3. Inspectthe armaturefor wear or damagefrom contactwith the permanentmagnet.lf there is wear or damage,replacethe armature. Commutator Diameter Standard(Newl: 28.0mm (1.10in.l ServiceLimit: 27.0 mm (1.06in.) 5. Checkthe commutatordiameter.lf the diameteris below the servicelimit, replacethe armature.

6 . Measurethe commutator (A) runout. . lf the commutator runout is within the service limit, checkthe commutatorfor carbondust or brasschips betweenthe segments. . lf the commutator runout is not within the service limit, reolacethe armature. Commutator Runout in.) StandardlNew): 0.02mm 10.001 max. in.) ServiceLimit: 0.05mm (0.002

?.-

Checkthe commutator(A) surface.lf the surfaceis with emery cloth or a lathe dirty or burnt, resurface in within the specifications step 5, or recondition with # 500 or # 600 sandpaper(B).

(cont'd)

4-11

StartingSystem
StarterOverhaul(cont'dl
7. Checkthe mica depth (A).lf the mica is too high {B), undercutthe mica with a hacksawbladeto the properdepth.Cut away allthe mica (C)between the commutatorsegments. The undercutshould not be too shallow,too narrow,or V-shaped(D). Commutator Mica Depth Standard(New):0.50-0.80 mm {0.020-0.031in.) ServiceLimit: 0.20 mm (0.008in.) 9. Placethe armature(A) on an armaturetester (B). Hold a hacksawblade (C)on the armaturecore. lf the blade is attracted the core or vibrateswhile to t h e c o r ei s t u r n e d , h e a r m a t u r e s s h o n e d .R e p l a c e t i thearmature.

1 0 ,Checkwith an ohmmeterthat no continuityexists


betweenthe commutator(A) and armaturecoll core (B),and betweenthe commutatorand armatureshaft (C).lf continuityexists,replacethe armature.

Checkfor continuitybetweenthe segmentsof the commutator.lf an open circuitexists betweenany segments,replacethe armature.

M
\

4-12

Starter Brush Inspection 11. lvleasure brush length.lf it is not within the the servicelimit, replacethe brush holder assembly. Brush Length Standard{New): 14.0-14.5 mm (0.55-0.57 in.) 9.0 mm {0.35 in.) Service Limit:

Starter Brush Holder Test 14, Checkthat there is no continuitybetweenthe (+ ) b r u s hh o l d e r{ A )a n d ( ) b r u s hh o l d e r( B } .l f t h e r e is continuity,replacethe brush holder assembly.

Brush Spring Inspection Starter Field Winding Test 12. Checkfor continuitybetweenthe brushes(A).lf there is no continuity.replacethe armature ( housing B). 15. Insen the brush (A) into the brush holder,and bring the brush into contactwith the commutator,then attacha spring scale(B)to the spring (C).Measure the spring tensionat the moment the spring lifts off the brush.lf the springtension is not within replacethe spring. specification, Spring Tension: 13.7-17.7 N {1.40-1.80 kgf, 3.09 3.97lbf)

1 3 .Checkfor continuitybetweeneach brush (A) and


the armaturehousing(B).li there is continuity, replacethe armaturehousing.

(cont'd)

4-13

StartingSystem
StarterOverhaul(cont'dl
Planetary Gear Inspection 1 6 . C h e c k h e p l a n e t a r y e a r s( A )a n d r i n g g e a r{ B ) . g t Replace them if they are worn or damaged. Starter Reassembly 20, Pry backeach brush spring with a screwdriver, then positionthe brush about halfwayout of its holder, a n d r e l e a s eh e s p r i n gt o h o l d i t t h e r e . t NOTE:To seatthe new brushes.slip a strip of #5OO or # 600 sandpaper. with the grit side out, be&veen the commutatorand each brush,and smoothly rotatethe armature.The contactsurfaceof the brusheswill be sandedto the same contouras the commutator.

OverrunningCluich Inspection 17. Slidethe overrunningclutchalong the shaft. Replaceit if it does not slide smoothly. 18. Rotatethe overrunningclutch(A) both ways. Doesit lock in one directionand rotatesmoothly in reverse? it does not lock in eitherdirectionor it lf locksin both directions,replaceit. 21 l n s t a l l t h e r m a t u r en t h e h o u s i n ga n d i n s t a l l t h e a i , brush holder.Next, pry backeach brush spring a g a i n , n d p u s ht h e b r u s hd o w n u n t i li t s e a t s a againstthe commutator,then release the spring againstthe end of the brush.

s
1 9 .lf the starterdrive gear (B) is worn or damaged,
replacethe overrunningclutch assembly; the gear is not availableseparately. Checkthe conditionof the flywheel ring gear. Replaceit if the starterdrive gear teeth are oamageo. Installthe starterend cover to retainthe brush holder.

i.-

4-14

lgnition System
ComponentLocationIndex

SPARK PLUG page Inspection, 4-'19

IGNITION COIL page Timing Inspection, 4-17 lgnition page Removal/lnstallation, 4-18

4-15

lgnition System
Gircuit Diagram
'No.20lOA) :USAmo&l No.A model l50A):Cmrda

UNDEB HOOD FUST/8TIAY M)(

lG1tioT in 0N {ll) rd SIARIilll)

4-16

lgnition Timing Inspection


1 . Connectthe Honda PGM Testerto the data link connector(DTC), and checkfor DTC'S. a DTCis lf present,diagnoseand repairthe causebefore inspectinthe ignitioniming. g t Startthe engine.Holdthe engine at 3,000rpm with no load (in Neutral)until the radiatorfan comes on, then let it idle. C h e c k h e i d l es p e e d( s e ep a g e1 1 - 1 3 8 ) . t
4. Follow the tester'sprompts in the

6. Pointthe light toward the pointer (A) on the cam t c h a i nc a s e . h e c k h e i g n i t i o n i m i n g u n d e rn o l o a d C t conditions:headlights, blower fan. rearwindow defogger,and air conditionerare not operaling.lf the ignitiontiming differsfrom the specification, and there are no enginecontrol module {ECM)DTcs, r e p l a c eh e E C M( s e ep a g e1 1 - 4 ) t lgnition Timing: 8"+2" BTDC{REDmark {B))during idling in neutral A

"SCS" menu

{seethe testeroperator'smanual),

5 . Connectthe timing light to the serviceloop.

7. Turn the ignition switch OFF. a D i s c o n n e c t t hH o n d aP G MT e s t e r n dt h e t i m i n g e light.

4-17

lgnition System
lgnitionCoilRemoval/lnstallation
1. Removethe ignition coil cover (A),then removethe i g n i t i o n o i l s( B ) . c 6x1.0mm
9.8 N.m (1.0kgf.m,7.2lbf ftl

2. Installthe ignition coils in the reverseorder of removal.

--a

4-18

SparkPlug Inspection
1 . Inspectthe electrodes and ceramicinsulator. Burned or worn electrodes may be caused by: . Advancedignitiontiming . Loosespark plug . Plug heat rangetoo hot .Insufficientcooling Fouledplug may be causedby: . Retardedignitiontiming . Oilin combustionhamber c . Incorrect spark plug gap . Plug heat rangetoo cold . Excessive idling/lowspeed running . C l o g g e d i rc l e a n e r l e m e n t a e . Deteriorated ignitioncoils Worn or deformed electrodes 3. Replace the plug at the specifiedinterval,or if the centerelectrodeis rounded{A). Use onlVthe spark plugs listedbelow. Spark Plugs: lZFR6Kl1(NGK) (DENSO) SKJ2ODR-M11

gap f .lmproper I J.Oil-touling . Cs6on deposits 'r- 1I . Cracked center insulator \ electrode

compoundto 4 . Apply a small quantityof anti-seize the plug threads,and screwthe plugs into the Then torque them to cylinder headfinger-tight. 1 8 N m ( 1 . 8k g f . m ,1 3 l b f f t ) .

Do not adjustthe gap of iridium tip plugs (A); replacethe spark plug if the gap is out of specification. Electrode Gap: Standard(New): ServiceLimit:

1.0 1.1 mm {0.039-0.0 in.) 1.3 mm {0.051in.l

4-19

Gharging System
ComponentLocationIndex

CHARGING INDICATOR SYSTEM (ln the gaugeassembly)

q*o

BATTERY page22-50 Test, ALTEBNATOR page Troubleshooting, 4-22 page Replacement, 4-29 page4-30 Overhaul,

DRIVE BELT page4 26 Inspection, page Replacement, 4 26

4-20

CircuitDiagram
'flo. {l0Al :uSAhod.l ilo.20l50Al:C.n.d.mod.l

UNDTR XOOD FUSI/RILAY MX

+--, I fmlil*t"t'
TL

+ilt = l

4-21

Gharging System
Charging CircuitTroubleshooting
lf the chargingsystem indicatordoes not come on or does not go off, or the batteryis dead or low, test these items in the order listedbelow: Battery(seepage 22-50) Chargingsystem indicator Alternatorand regulatorcircuit Alternatorcontrol system 6. Measurethe voltageat the No. 3 terminal of the e n g i n e i r e h a r n e s s P c o n n e c t ow i t h t h e i g n i t i o n w 6 r s w i t c hO N {l l ) .
WIREHARNESS CONNECTOR ENGINE 6P

IBLK/YEL}

Charging SystemIndicator Test


1 . T u r nt h e i g n i t i o n w i t c hO N { l l ) . s Does the chatging system indicator come on? YES Go to step 2. NO Go to step 3. ls there battery voltage? 2. Startthe engine. YES-Go to step 7. Does the charging system indicator go off? YES-Charging system indicatorcircuitis OK. Go to the Alternatorand Regulator circuitTest.t NO-Go to step 3. 7 . Turn the ignition switch OFF. 3. Turn the ignitionswitch OFF. 4. Troubleshoot multiplexcontrol system (see the page 22 172). ls the multiplex control system OK? YES Go to step 5. NO Checkthe multiplexcontrol system as indicatedby the diagnostic trouble code (DTC) (see s t e p8 o n p a g e2 2 - 1 7 2 ) . 1
ACGL WHT/BLU) {

Wiresideof female terminals

N O - C h e c k f o r a b l o w nN o . 4{ 1 0 A ) u s e i n t h e f under-dash fuse/relaybox. lf the fuse is OK, repair open in the wire betweenthe alternatorand the under-dash fuse/relaybox.I

8 . Disconnect enginecontrol module (ECM)connector (24P). B

9 . Checkcontinuitybetweenthe ECMconnector
t e r m i n a lB ' 1 0 n d e n g i n e i r e h a r n e s s Pc o n n e c t o r w a 6 t e r m i n a lN o . 6 .
ECM CONNECTOB A (24P)

5. Disconnect enginewire harness6P connector the from the startersub harness6P connector.
ENGINE IBE W HARNESS 6P

L (WHT/BLUI

W i r e s i d eo f f e m a l e t e r m i n a s

ls there continuity? YES Go to step 10. NO-Repair open in the wire betweenthe a l t e r n a t oa n dt h e E C N 4 . I r

\"4

4-22

'10.

Checkcontinuitybetweenthe ECMconnector t e r m i n a l8 1 0 a n d b o d y g r o u n d . ECMCONNECTOR I24PI S

Alternator and RegulatorCircuitTest


1. Be sure the batteryis sufficientlychargedand in good condition{seepage 22-50), and the connections the fuse box and alternatorare at clean and tight. 2. Raisethe hoist to full height. 3. Hook up the ammeter,0 subharness. 400 A, to the starter

2 3 t 4t 5 8 I 10 ,/1,/ 3 1 1 8 ,N nt,/ 21

6 7 15

23

ACGL(WHT/BLUI t1'

Wire side ol femaleterminals

ls there continuity? YES- Repairshort to ground in the wire between the ECMand the enginewire harness6P connector. t NO-Go to alternatorand regulatortest.

Lower the hoist. Hook up the voltmeter,0 0.1V),toT101. 20 V (accurate within

(cont'd)

4-23

GhargingSystem
(cont'd) Charging CircuitTroubleshooting
6. Startthe engine.Hold the engineat 3,000rpm with no load (in Neutral)until the radiatorfan comes on, then let it idle. 7. Raisethe engine speedto 2,000rpm, and hold it there. 8. Turn the headlights(high beam)on, and measure voltageat the under-hoodfuse/relaybox terminal. ls the voltagebetween 13.9and 15.1v? YES-Go to step 9. NO Repairor replacethe alternatorcomponents (seepage 4-30).1 9. Readthe amperageat '13.5 V.

Alternator Control SystemTest


performthe engine NOTE:After troubleshooting, control module (ECM)idle learn procedure(seepage 11-139). 1. Checkfor proper operationof the electricalload detector(ELD)by checkingthe malfunction i n d i c a t o lra m p ( M l L ) ( s e ep a g e1l - 3 ) .l f a D T Ci s present,diagnoseand repairthe causebefore continuingwith this test. 2. Disconnect enginewire harness6P connector the from the startersub harness6P connector. 3. Start the engine,and turn the headlights(high b e a m )O N , 4. Measurevoltage betweenthe enginewire harness 6P connectorterminal No. 2 and the positive terminal of lhe battery. BATTERY

NOTE:Adjust the voltage by turning the blower motor, rearwindow defogger,brakelights.etc.ON. ls the amperage604 ot morc? YES-Alternator/regulator operationis OK.I NO Repairor replacethe alternatorcomponents (seepage 4-30).1

C {WHT/GRN)

ENGINE WIRE HARNESS CONNECTOR 6P Wiresideof female terminals ls there 1 V or less? YES Go to step 8. N O - G o t o s t e p5 . 5 . T u r nt h e h e a d l i g h t a n d i g n i t i o n w i t c hO F F . s s ECMconnectorB (24P). 6 . Disconnect

\,

4-24

\
7, Checkfor continuitybetweenECMconnector t e r m i n a l8 1 8 a n d b o d y g r o u n d .
ECM CONNECTOR {24PI B

10. Checkfor continuitybetweenECMconnector t e r m i n a l8 1 8 a n d e n g i n e i r e h a r n e s s Pc o n n e c t o r w 6 t e r m i n a lN o . 2 .


ECM CONNECTOR l2,lPI B

1 2 3 t 4t 5

6 1
5

8 9 10 ,/1,/ 3
11o

nt,/21

23

1 2 3 1 4 l 5 l l6l 7 8 9 10 15 t.) 11o 21 23

ACGC {WHT/GRN}

(WHT/GRN) ACGC

o
Wire side ot femaleterminals

o
2 5

C (WHT/GRN)

3
6

ENGINE WIREHARNESS CONNECTOR 6P Wire side oI lemale terminals

ls there continuity? ls therc continuity? YES-Repair short to ground in the wire between the alternatorand the ECM.I NO-Check that the terminalsare firmly seatedat the ECMconnectorB. lf OK, substitutea knowngood ECM,and recheck(seepage 11-6). lf prescribed voltage is now available.replacethe o r i g i n aE C M , I l Turn the headlights and ignition switch OFF. 9 . Disconnect ECMconnectorB (24P). YES Repairor replacethe startersubharness or the alternator(seepage 4-30).I NO Repairopen in the wire betweenthe a l t e r n a t oa n d t h e E C M . I r

4-25

Charging System
DriveBelt Inspection
(A) indicator is withinthe Check the auto-tensioner that (B) range asshown. it is out of thestandard lf standard page4-26). range, replace drivebelt(see the

DriveBelt Replacement
(A) 1, Move the auto-tensioner to relievetensionfrom the drive belt (B).and removethe drive belt.

2. Installthe new belt in the reverseorder of removal.

4-26

DriveBelt Auto-tensioner Inspection


1 . Checkwhether there is a changein the positionof

(seepage 4-28). Removethe auto-tensioner I n s t a ltlh e t e n s i o n e p u l l e y . r (A) 7 . Clampthe auto-tensioner by using two 8 mm bolts (B)and a vise (C)as shown. Do not clamp the auto-tensioner itself.

the auto-tensioner indicatorbeforestartingthe engineand after startingthe engine.lf there is a , c h a n g e n t h e p o s i t i o nr e p l a c eh e a u t o - t e n s i o n e r . i t

C h e c k o r a b n o r m a n o i s ef r o m t h e t e n s i o n e p u l l e y . f l r l f a b n o r m a n o i s ei s h e a r d ,r e p l a c eh e t e n s i o n e r l t pulley.

3 . Removethe drive belt (seepage 4-26).


8 . Set the torque wrench (D)on the pulley bolt. lMove the auto-tensioner within its limit with the belt tension release tool in the directionshown. Checkthat the tensionermoves smoothly and without any abnormal noise.lf the tensionerdoes not move smoothly or there is abnormal noise, replacethe auto-tensioner. 9 . Align the indicator{E)on the tensionerbasewith c e n t e rm a r k( F )o n t h e t e n s i o n e a r m b y u s i n gt h e r torque wrench, and measurethe torque. lf the torque value is out of specification, replacethe auto-tensioner, NOTE;lf the indicatorexceeds the centermark, recheck torque. the Auto-tensioner spring torque: 26.5-36.3 N.m 12.7-3.7 kg.m, 19.5-26.8lbt.ft)

4-27

System Charging
Replacement DriveBelt Auto-tensioner
1. Removethe drive belt (seepage 4'26). t 2 . R e m o v e h e i d l e rp u l l e y .
6xl.0mm 9.8 N.m (1,0kgl.m, 7.2 tbf.ft)

4. Removethe auto-tensioner,

6x1,0mm 12 N.m ('1.2 kgt.m.8.7lbt.ft)

22 N.m

x 1.25mm

{2.2 kgt m, 16 lbf ft} 8 x 1.25mm 22 N.m (2.2kgf.m, 16lbt.ft) 5. lnstall in the reverse order of removal.

3. Removethe tensionerpulley.

\-a

4-28

l\-

AlternatorReplacement
1. Make sure you havethe anti-theft code for the radio, then write down the frequencies the radio's for preset buttons, 2. Disconnect negativecablefrom the batteryfirst, the then disconnect the positivecable. 3. Removethe front bumper (seepage 20-85).
tt.

9 . Removethe alternator. 1 0 . Installthe alternatorand drive belt in the reverse order of removal. 'I 1 . Connectthe positivecable and negativecableto the battery. Enterthe anti-theft code for the radio,then enter the customer'sradio station presets.

4. Removethe right side headlight(seepage 22-79). 5. Removethe reservetank from the bracket. 6. Removethe drive belt (seepage 4-26). 7. Removethe three bolts securingthe alternator.
8 x 1 . 2 5m m 22 N.n 12.2kgl.m,

1 3 .Set the clock. 1 4 . Performthe enginecontrol module {ECM)idle learn


( p r o c e d u r es e ep a g e1 1 - 1 3 9 ) .

Disconnect alternatorconnector(A) and BLK the wire (B)from the alternator.


8 N.m kgf.m,6lbf.ft) 10.8

4-29

ChargingSystem
AlternatorOverhaul
ExplodedView

ROTOR .oy." W|UF., / REARBEARING


\ \

,/

./

FRoNr B BEARING

@b.J.y{=RE+LN'"' I vVFko"-% \ /

qtr*njlv
BRUSH HOLDER \ \ VOLTAGE REGULATOR \

V ( rV , " )
BRUSH HOLOER TNSULATOR \ \\11 -\\ \l } (-

PULLEY / \
PULLEY LOCKNUT

-\: @*F,

/@

v_re*^i
\gP^@'I

\-a

*ffilw9
TERMINAL INSULATOR REARHOUSING ASSEMBLY

INSULATOR BUSHING

4-30

L
Special Tools Required . Driver07749-0010000 . Attachment,52x 55 mm 07746-0010400 NOTE:Referto the ExplodedView as neededduring this procedure. 1, Testthe alternatorand regulatorbeforeyou remove them (see page 4-22l,. 2. Removethe alternator(seepage 4-29). 3. lf the front bearingneedsreplacing,removethe pulley locknutwith a 10 mm wrench (A) and a 22 mm wrench (B).lf necessary, use an impact wrencn. 5 . R e m o v e h e e n d c o v e r( A )a n d d u s t s e a l{ B ) . t

6 . Removethe brush holder (A),voltage regulator(B),


a n dt h e r u b b e rs e a l{ C } .

, (( , t tI ; r _l L t
Removethe harnessbracket(A),insulator(B).three flange nuts (C),and the screw (D),then removethe p l a t et e r m i n a l( E ) .

L1i.21---^

tqLJ
B-"--|.

1!q[-dr,:l

(cont'd)

4-31

ChargingSystem
AlternatorOverhaul(cont'dl
7. Removethe four screws,then removethe rectifier ( A )a n d f o u r i n s u l a t o r ( B ) . s

the and/or 9. lf you arenot replacing frontbearing '16. go the rearbearing, to step Remove rotorfrom the stator driveendhousing.

1 0 .Inspectthe rotor shaftfor scoring,and inspectthe


bearingjournal surfacein the statorhousingfor setzure arks. m Removethe four flange nuts,then removethe rear ( h o u s i n g A )a n dw a s h e r( B ) . . l f e i t h e r t h er o t o r o r s t a t o r h o u s i n g d a m a g e d , is replacethe alternator, . lf both the rotor and the stator housingare OK, g o t o s t e p1 1 . 'l

\"
1 . R e m o v e h e r e a rb e a r i n g s i n ga p u l l e ra s s h o w n . t u

o\

f.r,e
4-32

\1 2 . W i t h a h a m m e ra n d c o m m e r c i a l l a v a i l a b l eo o l s y t shown, installa new rear bearingon the rotor shaft. NOTE:Installthe bearingusing the inner race. 14. Supportthe stator housingin a vise, and drive out the front bearingwith a brassdrift and hammer.

1 5 . W i t h a h a m m e ra n d t h e s p e c i a l t o o l si , s t a l a n e w n l front bearingin the stator housing. 13. Removethe front bearingretainerplate.

f-\ \r-:1 \s---'^/

6 u

s H

q E

e s

07749-0010000

07746-0010400

(cont'd )

4-33

ChargingSystem
AlternatorOverhaul(cont'd)
Rectitier Test 16. Checkfor continuityin each direction,betweenthe B terminal and P terminals,and betweenthe E t e r m i n a a n d P t e r m i n a l s f e a c hd i o d ep a i r . l o A l l d i o d e ss h o u l dh a v ec o n t i n u i t yn o n l y o n e i direction.Because the rectifierdiodes are designed to allow currentto pass in one direction,and the rectifieris made up of eight diodes (four pairs).you musttest each diode in both directionsfor continuitywith an ohmmeterthat has diode checkingcapability: total of 16 checks. a . lf any diode is faulty. replacethe rectifier assembly.{Diodesare not availableseparately.) ' lf all the diodes are OK, go to step 17. Alternator Brush Inspection ( 1 7 . M e a s u r eh e l e n g t ho f b o t h b r u s h e s A ) w i t ha t vernier aliper B). c { . l f e i t h e rb r u s hi s s h o r t e r t h a n t h e e r v i c e i m i t , l s r e p l a c eh e b r u s ha s s e m b l y . t . lf brush length is OK, go to step '18. Alternator Brush Length: Standard(New): 10.5mm (0.41in.) ServiceLimit: 1.5 mm (0.06in.)

/--:',t-L -o \--

. -l'-=

\"
Rotor Slip Bing Test 18. Checkthat there is continuitybetweenthe slip rings {A). B P " . lf there is continuity,go to step 19. . lf there is no continuity,replacethealternator.

P, P. P, P.

1 9 . Checkthat there is no continuitybetweeneach slip ring and the rotor (B) and the rotor shaft (C). . lf there is no continuity,goto step 20. . lf there is continuity,replacethe alternator.

\r'a

4-34

Stator Test 20. Checkthatthereis continuitybetweeneach pair of leads(A). lf there is continuity,go to step 21. lf there is no continuity,replacethe alternator.

'--l-- --i
2 1 .Checkfor no continuitybetweeneach lead and the
coil core (B). . lf there is no continuity,goto step 22. . lfthere is continuity,replacethe alternator.

22. Assemblethe alternatorin reverseorder of


disassembly, and note these items: . Be carefulnot to get any greaseor oil on lhe slip nn g s . . lf you removedlhe pulley,tighten its locknutto 1 1 1N . m ( 1 1 . 3 g f m , 8 1 . 7l b f . f t ) w h e n y o u n s t a l l k i it.

4-35

GruiseControl
ComponentLocationIndex
INDICATOR CRUISE CONTROL (Builtinto gaug6assembly)

CLUTCH PEDAL POSITION swtTcH page 4-45 Test, Pedal Adjustment, Clutch page12-4

CRUISE CONTROL UNIT page lnputTest, 4-40 BRAKE PEDAL POSITION SWITCH Test,page22-84 page'19-6 Pedal Height Adjustment,

t.-

_,-

CRUISE CONTROL ACTUATOR page Test, 4'43 page Replacement, 4-44

ACTUATORCABLE Adjustment,page4-45

\-a

4-36

CircuitDiagram
' fUS'/iILAY IOX UISEF NOOD No.aloAl No.20 itoAl USAnod.l C.md! modrl

-to

ots

BU/YIL

lcl H0Tii0llilll mdSTARTlllll

1 Honilsffroi

1 uNtT cnu6EcoNTnoL

3 l0

PEDAL CTuICII

P0sm0 swtrct

4-37

Cruise Control
Symptom Troubleshooting Index
NOTE: ' The numbersin the table showthetroubleshootingsequence. . Beforetroubleshooting. - checkthe No, 10 (7.5A)and No. 4 (10A)fuses in the under-dash fuse/relaybox. and the No. 7 (15A)fuse in the under-hoodfuse/relaybox, - checkthat the horn sounds. - checkthe tachometerto see if it works properly. - checkthe speedometer see if it works properly. lo

Symptom
Cruisecontrol cannot be set

Diagnostic procedure 1. Checkmain switch (seepage 4-42) 2. CheckSET/RESUME/CANCEL switch (seepage 4-42) 3. Test brakepedal positionswitch (seepage 22-84)and check its adjustment{seepage 19,6) 4. Test clutch pedal positionswitch (seepage 4-45)and check its adjustment(seepage 12-41 5. Checkcruisecontrol unit {seepage 4-40} 6. Checkvehiclespeed sensor(VSS)(seepage 22-65)

. Poorground: G501 . Opencircuit, loose or disconnected t e r mn a l s : i L TG R N , BLI(ORN. GRY/RED, BLU. LTBLU, BLUAA/HT
. Poor ground: G501 . Open circuit, looseor disconnected termrnats: YEL,BLUA/EL

Also check for

Cruisecontrol can be set but indicatorlight does not go on

1. Check cruise controlindicator bulbin gauge assembly {see page 22-631 2. Check cruise controlunit(seepage4-40)

ar, 'i.a

c^aa.l

ic

n o t i c e a b l h i g h e ro r y lower than what was set Excessive overshooting or undershooting when trying to set speed Speedfluctuationon a flat road with cruise control set Vehicledoes not decelerate accelerate or accordingly when SET/ RESUME/CANCEL button is pushed Set speed does not cancel(enginerpm stays h i g h )w h e n c l u t c hp e d a l is pushed Set speeddoes not cancelwhen brakepedal is pushed

1. Checkvehiclespeed sensor(VSS){seepage 22-65) Checkcruisecontrol actuator{seepage 4-43) 2. Checkcruisecontrol unit (seepage 4-40) 1. Checkcruisecontrol actuator(seepage 4-43) 2. Checkvehiclespeed sensor(VSS)(seepage 22-65) Checkcruisecontrol unit (seepage 4-40) 3. 1. Checkvehiclespeedsensor(VSS)(seepage22-65) Checkcruisecontrol actuator(seepage 4-43) 2. Checkcruisecontrol unit (seepage 4-40) 1. CheckSET/RESU ME/CANCEL switch (seepage 4-42) 2. Checkcruisecontrol unit {seepage 4-40)

Open circuit,loose or disconnected terminals: GRY/RED, LT GRN/BLK

1. Testclutch pedal positionswitch (seepage 4-45)and check its adjustment(see page 12-4) 2. Checkcruisecontrol unit (seepage 4-40) '1. 2.

Shortto groundin the LTBLUwire

Test brakepedal positionswitch (seepage 22-84)and check Open circuit,loose its adjustment(seepage 19-6) or disconnected Checkcruisecontrol unit (seepage 4-40) terminals: WHT/BLK

g ,

4-38

svmptom
Set speeddoes not cancelwhen main switch is oushed FF O Set speeddoes not c a n c ew h e n C A N C E L l button is pushed

Diagnosticprocedure 1. Checkmain switch (seepage 4-42) 2. Checkcruisecontrol unit (seepage 4-40) ME/CANCEL switch (seepage 4-42) 1. CheckSET/RESU 2. Checkcruisecontrol unit (seepage 4-40)

Also check for Short to power in the LT GRNwire.

loose Open circuit, or disconnected terminals: GRYiRED, LTGRN/BLK


Open circuit,loose or disconnected terminals: L TG R N / B L K

Set speedwill not resume henRESUME w button is pushed(with main switch on, and set speedtemporarily cancelledby pressingthe brakeDedal)

switch (seepage 4-42) 1. CheckSET/RESU ME/CANCEL 2. Checkcruisecontrol unit {seepage 4-40)

4-39

Cruise Gontrol
CruiseControl Unit Input Test
SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations(seepage 23-'13) and precautions and (seepage 23-14)in the SRSsectionbefore performingrepairsor service. procedures 1. Disconnect 14Pconnectorfrom the control unit. the 2. Inspectthe connectorand socketterminalsto be sure they are all makinggood contact. . lf the terminalsare bent, loose,orcorroded, repairthem as necessary, and recheckthesystem. . lf the terminalslook OK, go to step 3.

Wire sideof femaleterminals

3. With the 14Pconnectordisconnected, make these inDuttests. Cavity

Wire Test condition BRN/WHT Connectbattery


power

Test:Desired result
Checkthe operationof the magneticclutch:Clutch s h o u l dc l i c ka n d o u t p u tl i n k should be locked. Checkfor voltageto ground; There should be 0 V with lhe pedal pressedand battery voltagewith the pedal released.

BLU

lgnitionswitch ON (ll),main swltch ON and brakepedal pressed, then reteaseo

U n d e ra l l c o n d i t i o n s Checkfor continuityto grouno: There should be continuitv BLIVORN l g n i t i o n w i t c hO N s Checkfor voltageto ground: Thereshould be battery flr) vottaqe. WHT/BLK Brakepedal pressed, Checkfor voltageto ground: then released There should be battery voltagewith the pedal pressed,and 0 V with the pedal released.

BLK

Possiblecause is notobtained ifresuh Faultyactuator P o o rg r o u n d( G 3 0 1 ) An open in the wire Shon to ground (arcswhen Doweris connected) . Faultybrakepedal position switch . A n o p e ni n t h e w i r e . Open in cruisecontrol main swrtcn . B l o w nN o . 4 ( 1 0A ) f u s e i n t h e under/dash fuse/relavbox . P o o rg r o u n d( G 5 0 1 ) . An open in the wire ' . . . B l o w nN o . 4 ( 1 0A ) f u s e i n t h e under-dash use/relay f box An oDenin the wire B l o w nN o . 7 { 1 5A ) f u s ei n t h e under-hoodfuse/relaybox Faultybrakepedal position
SWIICN

A n o D e ni n t h e w i r e

4-40

Cavity

Test condition Wire GRYiRED Setbuttonpushed

result Test:Desired
Checkfor voltageto ground: Thereshould be battery voltage, W h e nt e s t i n g e r m i n a lN o . 6 , t there should be no voltageon t e r m i n a lN o . 7 . Checkfor voltageto ground: Thereshould be battery voltage. W h e nt e s t i n g e r m i n a lN o . 7 , t there should be no voltageon t e r m i n a lN o . 6 . Checkthe operationof the actuatormotor: You should be ableto hear the motor.

LT GRN/ BLK

Resume button pusneo

is Possible il result notobtained cause B l o w nN o . 7 ( 1 5A ) f u s e i n t h e under-hoodfuse/relaybox Faultyhorn relay Faultysevresume/cancel swrtch Faultycable reel An open in the wire Shon to ground (horn sounds when button is pressed)

BRN 11

Connectbattery t e r m i n a la n d g r o u n d to the BRNIVEL termrnal lgnitionswitch ON

BRNI/EL power to the BRN

. Faultyactuator . An open in the wire

10

L BLUIVE

0r)

Attachto groundi i r C r u i s e n d i c a t o l i g h ti n t h e g a u g ea s s e m b l y h o u l dc o m e s on. Checkfor voltage between (+) thE BLU/VVHT ANdBLK ( )terminals: T h e r e s h o u l d b e 05 V o r more repeatedly.

Blown No. 10 (7.5A) fuse in fuse/relaybox the under-dash Blown cruise indicatorbulfl g F a u l t y a u g ea s s e m b l y An open in the wire

12

BLU/VVHT lgnitionswitch ON
(ll) and main switch ON; raisethe front of the vehicle,and rotateone wheel s l o w l yw h i l e h o l d i n g the other wheel

Faulty VSS An openin thewire Shortto ground

13

LTGRN

lgnition switchoN { l l )a n dm a i ns w i t c h ON
C l u t c hp e d a l reteaseo

for to Check voltage ground: There shouldbe battery voltage.


Checkfor continuityto grouno: T h e r es h o u l db e c o n t i n u i t y . N O T E : T h e r s h o u l db e n o e continuitywhen the clutch oedal is Dressed.

14

LT BLU

B l o w nN o . 4 ( 1 0A ) f u s e i n t h e fuse/relaybox under-dash Faultymain switch An oDenin the wire Faultyclutch pedal position swtlcn P o o rg r o u n d( G 5 0 1 ) Incorrect clutchswitch adjustment An open in the wire

the system.lf all the input tests prove OK, lf any test indicatesa problem,find and correctthe cause,then recheck cruisecontrol unit may be faulty. Substitutea known-goodcruisecontrol unit and retest.lf the system works the properly,replacethe cruisecontrol unit.

4-41

CruiseControl
Main Switch Test/Replacement
1 . Removethe driver's dashboardlower cover (see page 20-59). 1. Removethe two screws.then removethe switch. Release clips of the main switch and push the the main switch 1A)out of the panel,then disconnect the 5P connector(B)from the main switch.

Set/Resume/Cancel Switch Test/ Replacement

Checkfor continuitybetweenthe terminalsin each switch positionaccordingto the table. . lfthere is continuity,and it matchesthe table, but switchfailure occurredon the cruisecontrol unit input test, checkand repairthe switch circult. . lf there is no continuityin one or both positions, replacethe switch.
\ 1 4 ;"itl* Terminal '\

Checkfor continuitybetweenthe terminalsin each switch positionaccordingto the table. lf the continuityis not as specified,replaceillumination bulbs (C)or the switch.

\-------11v1
Position OFF

2 CF

(9

ON

o @ o \J

sET(ONt
RESUME ION)
CANCEL {ON}

o o

--o

--o

r\--

4-42

CruiseControlActuatorTest
1. Disconnect 4P connector(A) from the cruise the control actuator(B). 6. Checkthe operationof the actuatormotor in each output linkagepositionaccordingto the table.You should be able to hear the motor. power Battery Dolarities Output linkageposition

FUtL FULt MIDDLE OPEN CLOSE PO$TION The The The No.3 No,4 Terminal Terminal motor motor motor runs. runs. stoDs, The The The No.3 N o .4 Terminal Terminal motor motor motor sIoos. runs. runs.
OUTPUTLINKAGE

2. Removethe cover (A),and checkthe output linkage


(B)for smooth movement. ,to

FULLCLOSE

1 . lf the actuatormotor does not operateas specified, replacethe cruisecontrol actuatorassembly,

Connectbatterypower to the No, 2 terminal and g r o u n dt o t h e N o . 1 t e r m i n a l . c s f C h e c k o r a c l i c k i n g o u n df r o m t h e m a g n e t i c l u t c h . The output linkageshould be locked. 5 . lf the output linkageis not locked,replacethe cruisecontrol actuatorassembly,

4-43

Cruise Control
CruiseControlActuator/Cable Replacement
1 . Fully open the cruisecontrol link by hand,then removethe cruisecontrol cable{A) from link. Loosenthe locknut(B),and removethe cablefrom the bracket.

3 . Removethe actuatorcover (A),then removethe


actuatorcable (B)from the cruisecontrol actuator.

2 . Disconnect 4P connector,and removethe three the


bolts securingthe cruisecontrol actuator.

4 . Installin the reverseorder of removal,and adjust the free play at the throttle linkageafter connecting the actuatorcable.

6x1,0mm 12 N.m (1.2kgf.m,8.7lbf.ft)

\rla
4-44

ActuatorCableAdiustment
1. Checkthat the actuatorcable{A) moves smoothly with no binding or sticking.

ClutchPedalPositionSwitch Test
the 1. Disconnect 2P connectorfrom the clutch pedal positionswitch (A), 2P POSITION SWITCH CONNECTOR CLUTCH PEOAL
T e r m i n a l s i do f e m a l et e r m i n a l s

2. Startthe engine. 3. Measurethe amount of movementof the output linkage(B) until the engine speedstartsto increase. At first, the output linkageshould be locatedat the fully closedposition(C).The free play (D)should be i 3 . 7 5 1 0 . 5m m ( 0 . 1 5 1 0 . 0 2n , ) . 4. lf the free play is not within specs,loosenthe locknut(E).and turn the adjustingnut (F)untilthe then retightenthe locknut free play is as specified,

Removethe clutch pedal positionswitch. Checkfor continuitybetweenthe terminals accordingto the table. . lf the continuityis not as specified,replacethe clutch pedal positionswitch. . lf OK, installtheclutch pedal positionswitch and adjustthe pedal height (seepage 12-4). Terminal Cl"t"h P"d"l I PositionSwitch
PRESSED 1

RELEASED

4-45

Engine Assembly
Engine Removal
Special Tools Required FrontsubframeadapterEOS02C00001 1 NOTE: . Usefender coversto avoid damagingpainted surfaces. . To avoid damage,unplug the wiring connectors carefullywhile holdingthe connectorportion. . Mark all wiring and hosesto avoid misconnection. Also, be sure that they do not contactother wiring or hoses,or interferewith other parts. 1. Securethe hood in the wide open position(support rod in the lower hole). 2. Make sure you have the anti-theft code for the radio, then write down the frequencies the radio's for presetbuttons. 3. Disconnect negativecablefrom the batteryfirst, the then disconnect positivecable. the 4. Removethe battery. 5. Removethe intakemanifoldcover. 6. Disconnecttheintakeairtemperature(lAT)sensor connector(A),removethe breatherhose (B)and v a c u u mh o s e( C ) , h e n r e m o v e h e a i r c l e a n e r t t housingcover/intake duct assemblv(D). air

\,

7 . R e m o v e t h e a i r c l e a n e rh o u s i n g .

II

5-2

8. Removethe intakeair duct.

10. Fullv ooen the throttle link and cruisecontrol link by hand,then removethe throttlecable (A) and t c c r u i s ec o n t r o l a b l e( B ) f r o mt h e l i n k s .L o o s e n h e locknuts{C),and removethe cablesfrom the bracket.

9. Removethe batterycables{A) fromthe under-hood fuse/relaybox. then removethe harnessclamp (B) a n d g r o u n dc a b l e( C ) .

( 1 1 . R e l i e v e f u ep r e s s u r e s e ep a g e1 1 - 1 4 4 ) . l t 1 2 . R e m o v eh ef u e ll i n e ( s e e p a g e l l - 1 4 9 ) . canister emission(EVAP) 13. Removethe evaporative hose {A) and brakeboostervacuum hose (B).

(cont'd)

5-3

Engine Assembly
EngineRemoval(cont'dl
1 4 . R e m o v e h e c l u t c hs l a v ec y l i n d e r A )a n d c l u t c h l i n e t { bracketmounting bolt (B). 16. Disconnect engine control module (ECM) the connectors(A) and main wire harnessconnector (B).

..4,

15. Removethe shift cable (A) and selectcable (B).

't7. Remove the harnessclamps (A) and grommet (B),


t h e n p u l l t h ee n g i n e i r e h a r n e s sh r o u g ht h e w t bulkhead.

\l,

5-4

1 8 .Removethe drive belt (seepage 4-26).


t 1 9 .R e m o v e h e l v C l i n e m o u n t i n gb o l t .

sensorconnector the 30. Disconnect air fuel ratio {4,/F) (A) and secondaryheatedoxygen sensor (secondary HO2S)connector(B),then removethe three way catalyticconverter{TWC)assembly{C).

20. Removethe radiatorcap. 2 1 . R a i s e h e h o i s tt o f u l l h e i g h t . t 22. Removethe front tires/wheels. 23. Removethe splashshield. t 3 1 . R e m o v e h e l o w e rh o s e .

o@

d 2 4 . L o o s e n h e d r a i np l u g i n t h e r a d i a t o r t o r a i nt h e t enginecoolant(seepage 10-6). l 2 5 . D r a i nt h e t r a n s m i s s i ofn u i d ( s e ep a g e1 3 ' 3 ) . 26. Drainthe engineoil {seepage8-5). i 2 7 . D i s c o n n e c h e s t a b i l i z el r n k s( s e ep a g e1 8 - 1 8 ) . tt lower arm ball joints the 28. Disconnect suspension ( s e es t e p3 o n p a g e1 8 - 1 9 ) . Coat all 29. Removethe driveshafts {seepage 16-3). p r e c i s i o ni n i s h e d u r f a c e s i t h c l e a ne n g i n e i l . w o f s Tie plasticbags over the driveshaftends.

(cont'd)

5-5

Engine Assembly
(cont'd) Engine Removal
32. Lower hoist. the (B). 33. Remove upperhose(A)andheater the hoses 36. Remove transmission the mountbracket support boltandnuts.

34. Bemovethe radiator(seepage 10-10). 35. Attachthe chain hoist to the engine as shown.

37. Remove upperbracket the mounting andnut. bolt

(.g

\a

5-6

Make sure the hoist brackets are positioned properly.Raisethe hoist to full height.

41. Attach subframe the adapterto frontofthe subframe, thentighten knurled the knob.

39. Removethe rear mount mounting bolts.

Raisethe jack. Line up the slots in the arms with the bolt holeson the corner of the jack base,then attachthe adaDter the iack basewith the bolts. to

40. Remove frontmountbracket the mountinq bolt.

(cont'd)

5-7

Engine Assembly
(cont'd) Engine Removal
43. Use a markerto make alignmentmarks on the referencelines(A) that align with the centersof the r e a rs u b f r a m e o u n t i n gb o l t s( B ) . m 45. Disconnect compressorclutchconnector(A), the then removethe Ay'C compressor(B)without disconnecting A'./C the hoses.

!:_- _l.=

:r

--

---.-','-

ffi4 ffit'"

46. Checkthat the engine/transmission completely is free of vacuum hoses,fuel and coolanthoses,and electrical iring. w 4 7 . S l o w l yl o w e rt h e e n g i n e b o u t1 5 0m m ( 6 i n . ) . a C h e c k n c ea g a i nt h a t a l l h o s e sa n d w i r e sa r e o disconnected trom the engine/transmission. 48. Lowerthe engineall the way. Removethe chain hoistfrom the engine. 4 9 . Removethe enginefrom under the vehicle. 44. Removethe front subframe(C).

5-8

Engine lnstallation
Special Tools Required FrontsubframeadapterEOS02C00001 1 1. lnstallthe accessory brackets, and tighten their bolts and nuts to the specifiedtorques. ENGINE MOUNTBRACKET

1 0x 1 . 2 5m m il4 N.m {4.5kgf.m,33lbl.ft)

A/C COMPRESSOR BRACKET

10 x 1,25mm 44 N.m {4.5kgf.m,33lbt.ft)

(cont'dl

5-9

Engine Assembly
(cont'd) Engine Installation
Positionlhe engine under the vehicle.Attachthe chain hoistto the engine,then lift the engine into p o s i t i o nn t h e v e h i c l e . i

(A). 5. Install subframe Alignthe reference the marks (B)on the subframe withthe center the bolt of h e a d s , e nt i g h t e nh eb o l t s . th t
- - -.'.: --=---=-.-..'tt-

R e i n s t a l l t h e o u n t i n gb o l t s / s u p p o r tu t si n m n the sequencegiven. Failureto follow this sequencemay causeexcessive noiseand vibration,and reducebushinglife. 3. Installthe A,/C compressor(A),and connectthe compressorclutchconnector{B).

---:- -

6r"
6-_-'-

1 4 x 1 . 5m m 103Nm k {10,5 gfm. 76 rbt.ftl Replace.

6. Tightenthe rear mount mounting bolts. 8 x 1.25 mm 22 N.m 12.2 m. 16 lbf.ft) kgf 4. Supportthe subframewith the subframeadapter a n da j a c k .

l 0 x 1 . 2 5m m 59 N.m (6.0 kgf.m, 4:] lbI.ft)

5- 10

7. Looselytightenthe front mount bracketmounting bolt.

10. Tightenthe transmissionmount bracketsupport bolt and nuts. 1 2x 1 . 2 5 m m 54 N m {5.5kgt m, 40 lbf.ft}

8 . Lower the hoist. 9 . Tightenthe upper bracketmounting bolt and nut. 'l '1.

Raisethe hoistto full height.

' t 2 . Tighten the front engine mount bracketmounting bolt. 12x 1.25rnrn 64 N.m{6.5 kgf.m, 47 tbt.ftl

:l

13. Lower the hoist. 1 4 . R e m o v e h e c h a i nh o i s tf r o m t h e e n g i n e . t '15. ( I n s t a l l t h e a d i a t o r s e ep a g e1 0 - 1 0 ) . r '16. R a i s e h e h o i s tt o f u l l h e i g h t . t 17. Installa new set ring on the end of each driveshaft, then installthe driveshafts. Make sure each ring "clicks" into place in the differentialand intermediate shaft. (cont'd)

5-11

Assembly Engine
EngineInstallation{cont'dl
1 8 . Connectthe suspension lower arm ball joints (see s t e p6 o n p a g e1 8 - 1 9 ) . 1 9 . Connectthe stabilizer links (seepage 18-18). 20. Installthe three way catalyticconverter(TWC) assembly(A);use new gaskets(B) and new selflockingnuts {C). 10x 1.25 mm 33 N.m{3.i1kgf.m, 25 tbt.ftl 23. Installthe plash hield. s s

-t-

-- -

-- --r

24. Lower hoist. the e 25. I n s t a l l t hd r i v e e l t . b 26. Installthe linemounting A,/C bolt.
6 x '!.0mm 9.8 N.m (1.0kgf.m, 7.2 tbt.ftl

-d
6\
\

,ry
8 x 1.25 mm 22N.m |.2.2kgl m, 16tbt.ft)

2 1 . Connectthe air fuel ratio (4,/F) sensorconnector(D)


and secondaryheatedoxygen sensor(secondary HO2S)connector(E). Installthe lower radiatorhose.

v
5-12

27. lnstallthe upper radiatorhose {A) and heaterhoses (B).

30. Connectthe ECI\4 connectors(A) and main wire harnessconnector(B).

(ECM) Push engine control module the connectors t h r o u g hh eb u l k h e a t h e ni n s t a l l t hg r o m m e(tA ) . t d, e 3 1 .Installthe throttlecable (seepage 11-164), then
a d j u s t t h e a b l e{ s e ep a g e1 1 - ' 1 6 3 ) . c

3 2 . Installthecruisecontrol cable (seepage 4-44), then


adjustthe cable (seepage 4-45),

33. Installthe brakeboostervacuum hose (A) and the


evaporative emission(EVAP) canisterhose (B).

2 9 . I n s t a l l t h e a r n e s s l a m p s( B ) . h c

3 4 . I n s t a l l t h e u e l l i n e ( s e ep a g e1 1 - 1 5 0 ) . f

(cont'd)

5-13

Assembly Engine
Installation Engine {cont'dl
Installthe selectcable (A) and shift cable(B) using the plasticwashers(C),washers(D),and new cotter p i n s( E ) . 6x1.0mm kgf.m, 9.8N.m(1.0 7.2tbl.ftl 37. Installthe batterycables(A) on the under-hood fuse/relaybox, then installthe harnessclamp (B).

\"

6x1.0mm 12Nm{1.2kgt.m, 8.7rbf.ft)

"-.----->) "------'6
g I n s t a l l t h e r o u n dc a b l e( C ) .

3 9 . I n s t a l l t h en t a k e i r d u c t . i a
( I n s t a ltlh e c l u t c hs l a v ec y l i n d e r A )a n d c l u t c hl i n e bracketmounting bolt (B).
6x1.0mm 9.8 N.m {1.0kgf.m, 7.2 tbt.ft) 6x1.0mm 12Nm{1.2kgf.m, 8.7 tbf.ft)

\-

8 x '1.25 mm 24 N.m (2.4kgl.m,

5-14

4 0 . I n s t a ltlh e a i r c l e a n e r o u s i n q . h
6x1.0mm 12 N m (1.2kgf.m,8.7lbt.ft)

4 3 . I n s t a l l t h en t a k e a n i f o l d o v e r . i m c
6x1.0mm 12Nm11.2kgf.m. 8.7 tbf.ft)

4 1 . I n s t a ltl h e a i r c l e a n e r o u s i n g o v e r( A )a n d h c connectthe intakeair temperature(lAT)sensor connector(B),

44. Installthe battery.Cleanthe batterypostsand c a b l et e r m i n a l s i t h s a n d p a p e r , e n a s s e m b l e w th them and apply greaseto preventcorrosion.


]tE

Checkthat the transmissionshifts into gear smoothly.

46. Inspectfor fuel leaks. Turn the ignition switch ON (ll) {do not operatethe starter)so that the fuel pump runs for about 2 secondsand pressurizes fuel the line. Repeat this operationtwo or three times, then checkfor fuel leakageat any point in the fuel line. 41. R e f i l l t h e n g i n e i t h e n g i n eo i l ( s e ep a g e8 - 5 ) . e w 48. R e f i l t h e t r a n s m i s s i ow i t h f l u i d ( s e ep a g e1 3 - 3 ) . l n 4 9 . Refillthe radiatorwith enginecoolant,and bleed air from the cooling system with the heatervalve o p e n ( s e ep a g e1 0 - 6 ) . 4 2 . I n s t a l l t h e r e a t h e h o s e( C )a n d v a c u u mh o s e1 D ) . b r

5 0 . P e r f o r m h e e n g i n ec o n t r o lm o d u l e( E C M ) d l el e a r n t i
( p r o c e d u r es e ep a g e1 1 - 1 3 9 ) . 5 1 . Inspectthe idle speed (seepage 11-138).

52. I n s p e ctth e i g n i t i o n i m i n g ( s e ep a g e4 - 1 7 ) . t 5 3 . C h e c k h e w h e e la l i g n m e n { s e ep a g e1 8 - 4 ) . t t 54. Enterthe anti-theftcode for the radio,then enter


the customer'sradio station presets. 55. Set the clock.

5-15

EngineMechanical
Cylinder Head
Special Tools 6-2 Comoonent Location Index 6-3 Engine Compression Inspection b-t' VTEC Rocker Arm Test ........... ............ 6-7 VTCActuator Inspection .................... 6-8 Valve Clearance Adjustment ............. 6-9 Crankshaft Pulley Removal Installation and .............. 6-11 C a mC h a i n e m o v a l R . . . . . . . . . . . . . . . . . . . . - 1.2. . . 6 .. . C a mC h a i nn s t a l l a t i o n I . . . . . . . . . . . . . . . .6 .-.1 . . . . .5 Auto-Tensioner Removal/1nsta11ation ......................... 6-19 Chain Case SealInstallation Oil ........ 6-21 Cyf inderHead Removal Cover .......... 6-22 Head Cylinder Removal ..................... 6-23 WC Actuator. Exhaust Camshaft Sorocket R e pa c e m e n t f .........6-24 Head Cylinder Inspection Warpage...................... for 6-25 Rocker Arm Assembly Removal................................. 6-26 Rocker ArmsandShafts Disassembly/Reassembly .............. 6-27 Rocker ArmsandShafts Inspection ............................ 6-28 Camshaft Inspection .......................... 6-29 Valves, Springs, Valve and Seals Removal................ 6-31 Valve Insoection ...................... ........... 6-32 Valve Stem-to-Guide Clearance Insoection ............... 6-32 Valve Reolacement Guide ................. 6-33 Valve SeatReconditioning ................ 6-35 Valves, Springs, Valve and Seals Installation ............ 6-37 Rocker Arm Assemblv Installation .... 6-38 C v l i n d e r e a d n s t a l l a t i o.n . . . . . . . . . . . . . . . . . . . . . . . . . . . . - 3.9. . . . . . . . . H I . 6 .. . Cylinder Head Cover Installation ......6-41

Head Cylinder
SpecialTools
Ref. No. Tool Number

a
Description
R Air Pressure egulator V a l v eG u i d eR e a m e r5 . 5m m , Socket,19 mm H o l d e rH a n d l e HolderAttachment,50 mm Attachment Valve Spring Compressor VTECAir Adapter VTECAlr Stopper Air Joint Adapter m V a l v eGu i d eD r i v e r , 5 . 5 m Attachment,52 x 55 mm Driver

Oty
1 1 1 1 1 1 2 1 1

O .D

o
@ o G) E] O tro @ (D

ozoa I oz..rae-oot

OTAAJ.PNAA'IOO OTHAH-PJ7O1OB

07JAB-0010204 07NAB-0010404 07VAE-001010A OTZAJ.PNAAlOO OTZAJ-PNAA2OO I 07ZAJ-PNAA300 07742-0010100 07746-001o4oo 07749-0010000

--

l-:

,.

'a- ti-',..)-)--'

- -- -i
-

- 1jr-

r-

o ..'.,i2

,-

''

,.-/

,)

a:-t'"

r--\ Lq-,

5'r'
/":

.<:'':'v'' a

l?

a,/'/'

..# ..a:-"
@

-- -'''

't'tY-,l
OD
@

6-2

Component Location lndex

IGNITION COIL COVER

CYLINDER HEAD COVER page Removal, 6-22 page lnstallation, 6-41

CAM CHAIN Bemoval,page6-'12 page6-15 Installation,

frn "p
|]tJ ,
TENSIONER ARM

CAM CHAINGUIDEB

CAM CHAINGUIDEA

VALVE VARIABLE TIMING CONTROL twc) olL soLENotD VALVE

PULLEY CRANKSHAFT R e p l a c e m e np a g e6 1 1 t,

AUTO.TENSIONER page6-'lI Replacement,

O-RING

(cont'd)

6-3

Cylinder Head
ComponentLocationIndex(cont'd)

Y f\ R LI T
F]

F g

CAMSHAFT HOLDER

fr

EEI
g-----

CAMCHAIN B GUIDE

CAMSHAFTPOSITION ICMP}SENSOR

-"-oowetew

TOPDEADCENTER (TDC) SENSOR


EXHAUSTCAMSHAFT SPROCKET page6 24 Removal, page6-25 Installation,

EXHAUSTCAMSHAFT

ROCKER ARM ASSEMBLY page6 27 Overhaul, page 6-28 Inspection,

6-4

EXHAUST VALVE SEAL

.\ ll" --.i
SPRING RETAINER

vALvE

.""or", uo.u,
aFl
d:l.\

>il(

,H
| |

l* I / uo.ur.r","o l l

T1 l l

\ l g g
II
tl Y I I

G\-r_

.--

spntruc

H e ,
EI 1.U _-/

U-

^-'--

vALVE -/ TNTAKE

9E4L Replacement,

6-31 Page

|NTAKE VALVE GUIDE page Replacement, 6-33

,p

2bw
9) \
HEAD CYLINDER Removal,page6'23 page6-25 Inspection, page6-39 Installation, EXHAUSTVALVE page6-31 Removal, page6-37 Installation, INTAKEVALVE Removal,page6 31 page6 37 Installation,

\*""'RArNERcovER wcsrRArNER

HEATSHIELD

CYLINDER HEAD GASKET

6-5

Head Cylinder
EngineCompression Inspection
1 . W a r m u p t h e e n g i n e o n o r m a lo p e r a t i n g t temperature(coolingfan comes on). 2. Turn the ignition switch OFF. 3. Removethe intakemanifoldcover (seestep 1 on page6-22). 4, Disconnect four injectorconnectors. all 5. Startthe engine,and let it run until it stalls. 6 . R e m o v e h e i o u r i g n i t i o n o i l s( s e ep a g e4 - 1 8 ) . t c 7. Removethe four spark plugs. 8. Attachthe compressiongaugeto the spark plug note. Maximum vadation Within 200 kPa (2.0 kgf/cm', 28 psi) 1 1 .lf the compressionis not within specifications, checkthese items,then remeasure the compressron. . . . . Damagedorworn valvesand seats Damagedcylinder head gasket Damagedor worn piston rings Damagedorworn piston and cylinderbore

\ 9 . Open the throttlefully, then crankthe enginewith


the startermotor and measurethe compression. Compression Pressure Above 930 kpa (9.5 kgf/cm', 135 psi)

1 0 .Measurethe compressionon the remaining


cylinders,

\-

V,

6-6

WEC Rocker ArmsTest


Special Tools Required . Air pressureregulator07AAJ-PNAA100 . VTECair adaoter07ZAJ-PNAA100 . WEC air stoDoer 07ZAJ-PNAA200 . Air joint adapter07ZAJ-PNAA300 1. Removethe cylinder headcover (seepage 6-22). (see 2. Set the No. 1 pistonat top dead center(TDC) step 1 on page6-12). 3. Verify that the intakeprimary rockerarm (A) moves of independently the intakesecondaryrockerarm (B). . lf the intakeprimary rockerarm does not move, removethe primary and secondaryrockerarms as an assemblyand checkthat the pistonsin the secondaryand primary rockerarms move smoothly.lf any rockerarm needs replacing, replacethe primary and secondaryrockerarms as an assemblv,and test. . lfthe intakeprimary rockerarm moves freely,go to step 4. Repeatstep 3 on the remainingintakeprimary rockerarms with each piston at TDC.When all the primary rockerarms passthe test, go to step 5. Checkthat the air pressureon the shop air compressorgauge indicatesover 400 kPa (4 kgflcm',57 psi). (seepage 6-9). 6 . Inspectthe valve clearance 7 . Removethe sealingbolt (A)from the relief hole, and installthe VTECair stopper(B).
OTAAJ.PNAAlOO

D OTZAJ-PNAA3OO

OTZAJ.PNAAlOO

Removethe No. 2 and No. 3 camshaftholder bolts, and installthe VTECair adapters(C)finger-tight. Connectthe air joint adapter(D),and air pressure regulatorwith a 0-100psi gauge (E).

(cont'd)

6-7

CylinderHead
WEC RockerArms Test (cont'dl
'10. Loosenthe valve on the regulator,and apply the specifiedair pressure.

VTGActuator Inspection
'11. Removethe cylinder headcover (seepage 6-22lr. (seepage6-19). 2. Removethe auto-tensioner 3. Loosenthe rockerarm adjustingscrewslsee step 2 on page6-26). 4. Removethe camshaftholder (seestep 3 on page 6-

Specified air pressure: 290 kPa 13.0kgt/cm', 42 psi) NOTE:lf the synchronizing piston does not move after applyingair pressure; move the primary or secondaryrockerarm up and down manuallyby rotatingthe crankshaft clockwise. 1 1 . W i t h t h e s p e c i f i e d i r p r e s s u r e p p l i e d m o v et h e a a , p i n t a k e r i m a r yr o c k e r r m ( A ) f o r t h e N o , 1 c y l i n d e r . a The primary rockerarm and secondaryrockerarm ( B )s h o u l dm o v e t o g e t h e r . lf the intakesecondaryrockerarm does not move, removethe primary and secondaryrockerarms as an assembly,and checkthat the pistonsin the primary and secondaryrockerarms move smoothly.lf any rockerarm needsreplacing, replacethe primary and secondaryrockerarms as an assembly,and test.

26t.
5. Removethe intakecamshaft. 6, Checkthat the variablevalve timing control (VTC) actuatoris lockedby turning the VTCactuator clockwiseand counterclockwise. the VTC actuator lf is not locked,replacethe VTCactuator. 7 . S e a lt h e a d v a n c e o l e s( A ) a n dr e t a r dh o l e s( B )i n h the No. 1 camshaftjournal with tape.

Puncha hole through the tape over one of the advanceholes.

1 2 .Removethe specialtools. 1 3 .Tightenthe camshaftholder mounting boltslo


22N m 12.2 kgf.m, 16 lbf.ft). 1 4 . T i g h t e n h e s e a l i n g o l t t o 2 0 N . m ( 2 . 0k g f . m , t b 14 tbf.ft).
t5.

I n s t a l l t h e y l i n d e r e a dc o v e r( s e ep a g e6 - 4 1 ) . c h

6-8

Adiustment ValveGlearance
the lock. 9. Apply air to the advancehole to release NOTE:Adjust the valvesonly when the cylinder head temperatureis lessthan 100'F (38'C). 1. Removethe cylinderhead cover (seepage6-22). The 2. Set the No. 1 piston at top dead center(TDC). punch mark (A) on the variablevalve timing control (VTC)actuatorand the punch mark (B)on the exhaustcamshaftsprocketshould be at the top. Align the TDC marks (C)on the VTC actuatorand exhaustcamshaftsprocket.

1 0 .Checkthat the VTCactuatormoves smoothly.lf the


VTC actuatordoes not move smoothly, replacethe VTC acluator.

{cont'd)

6-9

GylinderHead
ValveClearance Adjustment (cont'd)
3. Select correct the thickness feelergauge the for you'regoingto check. valves Intake: 0.21 0.25mm (0.008-0.010 in.) Exhaust; 0.28 0.32mm (0.011 0.013 in.) Adiustingscrew locations:
EXHAUST
No. 1

\.
5 . l f y o u f e e lt o o m u c h o r t o o l i t t l e d r a g ,l o o s e n t h e locknut(A),and turn the adjustingscrew {B) until the drag on the feelergauge is correct..

N o .2

No.3

N o .4

No. 1

No.4

Tightenthe locknut,and recheck clearance. the Repeatthe adjustmentif necessary 7 . Rotatethe crankshaft180"clockwise(camshaft p u l l e yt u r n s9 0 ' ) .

4. Insertthe feeler gauge {A) betweenthe adjusting

s c r e w( B )a n d t h e e n d o f t h e v a l v es t e m ,a n d s l i d ei t backand forth; you should feel a slight amount of d rag.

t.

\-

8. Checkand, if necessary, adjustthe valve clearance o n N o .3 c y l i n d e r .

6-10

PulleyRemovaland Crankshaft Installation


9. Rotatethe crankshaft180"clockwise(camshaft pullevturns 90'). Special Tools Required . Holder handle07JAB-001020A . Holderattachment, mm 07NAB-001040A 50 . Socket,19 mm 07JAA-001020,4 a commercially or 1 a v a i l a b l e 9m m s o c k e t

Removal
1. Removefront tires/wheels. 2. Removethe splashshield (seestep 23 on page 5-5). ( 3 . H o l dt h e p u l l e yw i t h h o l d e rh a n d l e A )a n d h o l d e r attachment(B). adjustthe valve clearance 1 0 .Checkand, if necessary, on No.4 cylinder. 1 1 .Rotatethe crankshaft180"clockwise(camshaft p u l l e yt u r n s9 0 " ) . B 07NAB-001040A

el
/ f

/ Srroo.oo,oroo (or
commercially available)

Removethe bolt with a 19 mm socket(C)and breakerbar.

adjustthe valve clearance 1 2 .Checkand, if necessary, o n N o .2 c y l i n d e r . Installthe cylinder headcover (seepage 6-41).

(cont'd)

6-11

CylinderHead
Crankshaft PulleyRemovaland (cont'dl Installation
Installation
1. Cleanthe crankshaftpulley (A),crankshaft (B),bolt (C).and washer (D).Lubricateas shown below. . .: Clean O; Lubricate

CamChainRemoval
NOTE:Keepthe cam chain away from magneticfields. 1. Turn the crankshaft pulley so ils top dead center ( T D C ) a r k( A )l i n e su p w i t h t h e p o i n r e r B ) . ( m

t[] rL
-'....-----=a

ll ll

(-,

5U-1J It
t 2 . Removethe front tires/wheels.
I n s t a l l t h e r a n k s h a fp u l l e y , n d h o l dt h e p u l l e y c t a with holder handle(A) and holder attachment{B). B 07NAB-0010iroA

3 . R e m o v e h e s p l a s hs h i e l d . t - , , - - . = . - - - - - _ _ - - _ \

A 07JAB-001020A

4. Removethe drive belt (seepage 4-26). Tightenthe bolt to 245 N.m (25.0kgf.m, 181 tbf.ft) with a torque wrench and 19 mm socket(C).Do not use an impactwrench. I n s t a ltl h e s p l a s h h i e l d( s e es t e p2 0 o n p a g e5 - 1 2 ) . s 5 . Insta front tires/wheels. ll 5. Removethe cylinder headcover (see page6-22). 6 . R e m o v e h e c r a n k s h a fp u l l e y( s e ep a g e6 - 1 1 ) . t t

\-

6-12

position(CKP) sensor 7. Disconnectthe crankshaft connector{A) and variablevalvetiming control {VTC)oil control solenoidvalve connector(B).

1 1 . R e m o v e h e s i d ee n g i n em o u n tb r a c k e t . t

t 1 2 . R e m o v e h e c h a i nc a s e .

Removethe VTC oil control solenoidvalve (see s t e p1 o n p a g e1 1 - 1 2 7 ) . 9 . Supportthe enginewith a iack and wood block u n d e rt h e o i l p a n .

1 0 .Removethe ground cable (A).and removethe


upper bracket(B).

(cont'd)

6-13

CylinderHead
(cont'd) CamChainRemoval
Looselyinstallthe crankshaft pulley. 1 4 . Turn the crankshaft counterclockwise compress to the auto-lensioner, 16. Removethe auto-tensioner.

1 7 . R e m o v e h e c a m c h a i ng u i d eB . t

gffi
llll
t5.

Align the holes on the lock (A) and the autot e n s i o n e ( B ) , h e n i n s e na 1 . 5m m ( 0 . 0 6 n . ) r t i diameterpin (C)into the holes.Turn the crankshaft clockwiseto securethe Din.

U U

\-

6 -14

CamChainInstallation
1 8 . R e m o v e h e c a m c h a i ng u i d eA ( A )a n d t e n s i o n e r t a r m( B ) . t./6. | \ {n$1J; NOTE:Keepthe cam chain away from magneticfields. Align to 1. Set the crankshaft top dead center(TDC). sprocketwith the TDC mark {A) on the crankshaft ( b t h e p o i n t e r B )o n t h e c y l i n d e r l o c k .

,o

g"'1 9 . R e m o v et h e c a m c h a i n .

Setthe camshaftsto TDC.The punch mark (A) on the variablevalve timing control {VTC)actuatorand t t h e p u n c hm a r k( B )o n t h e e x h a u s c a m s h a f t sprocketshould be at the top. Align the TDC marks (C)on the VTC actuatorand exhaustcamshaft sprocKet.

(cont'd )

6-15

Gylinder Head
(cont'dl CamChainInstallation
3. Installthe camchainon the crankshaft sprocket (A) piece aligned with thecolored withthe punch mark(B)on the crankshaft sprocket.
5 . I n s t a l l t h e a m c h a i ng u i d eA ( A )a n d t e n s i o n ea r m c r (B).

6x1.0mm 1 2N . m {1,2kgf.m, 8.7 tbf.ftt

'6I

Installthecam chain on the VTCactuatorand exhaustcamshaftsprocketwith the punch marks (A) alignedwith the two colored pieces(B). B 6. Installthe auto-tensi

8 x 1.25 m m 22 N.m 12.2kgt.m, 16tbf.ft)

a
6x1,0mm 12Nm (1.2kgt.m,8.7 lbf ti)

a
6-16

7 , I n s t a ltlh e c a m c h a i ng u i d eB .

1 0 .Removeold liquid gasketfrom the chain case


8 x 1.25 mm 22 N.m (2.2 kgf.m, 16lbt.ft) bolts,and bolt holes. mating surfaces, 1 1 .Cleanand dry the chain case mating surfaces. evenlyto the Apply liquid gasket.P/N 08718-0009, cylinder block mating surfaceofthe chain caseand o t o t h e i n n e rt h r e a d s f t h e h o l e s .

H4 \ilt
H g
q

8. Removethe Dinfrom the auto-tensioner,

Apply liquid gasket alongthe brokenline.

Apply liquid gasketto the cylinder blockupper surfacecontactareas(A) on the chaincase. evenlyto the 1 4 . Apply liquid gasket,PiN 08718-0009, oil pan mating surfaceof the chain caseand to the innerthreadsof the holes. NOTE:Do not installthe parts it 5 minutesor more have elapsedsinceapplying liquid gasket.lnstead, reapplyliquid gasketafter removing old residue.

9 . Checkthe chain caseoil sealfor damage.lf the oil seal is damaged,replacethe chain case oil seal ( s e ep a g e6 - 2 1 ) .

Apply liquid gasket alongthe brokenline.

(cont'd)

6-17

Gylinder Head
(cont'd) CamChainInstallation
'15. Installthe new O-ring(A) on the chain case.Set the edge of the chain case (B)to the edge of the oil pan ( C ) , h e n i n s t a ltl h e c h a i nc a s eo n t h e c v l i n d e r l o c k t b (D). 1 6 . l n s t a l l t h e i d ee n g i n em o u n t . b r a c k e t . s

NOTE:When installingthe chain case,do not slide the bottom surfaceon the oil pan mounting surface.

rbf.ft)

',.9

17. Installthe upper bracket(A),then tightenthe bolv nuts in the numberedseouence shown.
6 x 1 . 0m m 12 N.m {1.2kgl m, 8.7 lbf ft} 1 2 x 1 . 2m m 5 54 N.m (5.5 kgt m, 40 lbf.ft)

6x1.0mm 1 2N . m (1.2kgt.m.8.7lbf.ft)

6x1.0mm 12Nm (1.2kgf.m,8.7lbf.ft)

1 8 . I n s t a ltl h e g r o u n dc a b l e( B ) .

\-

6-18

Auto-Tensioner RemovaU lnstallation


1 9 . lnstallthe variablevalve timing control (VTC)oil c o n t r o l o l e n o i d a l v e( s e es t e p 1 o n p a g e1 1 ' 1 2 7 ) . s v

Removal:
20. Connectthe crankshaftposition(CKP) sensor
connector{A) and VTC oil control solenoidvalve connector(B). 1 . R e m o v e h e c h a i nc a s ec o v e r . t

pulley (seepage 6-12). 21. Installthe crankshaft h 2 2 . I n s t a l l t h e y l i n d e r e a dc o v e r( s e ep a g e6 - 4 1 ) . c 2 3 . I n s t a l l t h e r i v eb e l t . d 24. Installthe plash hield. s s

to counterclockwise compress Turn the crankshaft the auto-tensroner.

D@

{cont'd)

6-19

GylinderHead
Auto-Tensioner Removal/l nstallation(cont'dl
3. Align the holes on the lock (A) and the autot e n s i o n e ( B ) , h e n i n s e r ta 1 . 5m m ( 0 . 0 6 n . ) r t i diameterpin (C)into the holes.Turn the crankshaft clockwiseto securethe oin.

Installation:
1. Installthe auto-tensioner.

4. Removethe auto-tensioner.

6x1.0mm 12 N.m {1.2kgt.m,8.7 lbt.tt) Remove the pin from the auto-tensioner.

\-

6-20

ChainCase SealInstallation Oil


Removeold liquid gasketfrom the chain casecover mating surfaces, bolts,and bolt holes.
4 . Cleanand dry the chain casecover mating surfaces.

SpecialToolsRequired . Driver07749-0010000 . Attachment,52 x 55 mm 07746-0010400 1 . U s et h e s p e c i atl o o l st o d r i v ea n e w o l l s e a l squarelyinto the chain caseto the specified installed eight. h

Apply liquid gasket,P/N 08718-0009, evenlyto the chain case mating surfaceof the chain casecover and to the innerthreadsof the holes. NOTE:Do not installthe parts if 5 minutesor more have elapsedsinceapplyingliquid gasket.Instead, reapplyliquid gasketafter removing old residue.

07749-0010000

Apply liquid gasket l a l o n gt h e b r o k e n i n e .

2. Measurethe distancebetweenthe chain case ( s u r f a c e A )a n d o i l s e a l1 B ) . Oil Seal InstalledHeight: 3 3 . 0 - 3 3 . 7m m ( 1 . 3 0 -1 . 3 3i n . )

6 . I n s t a l l t h e h a i nc a s ec o v e r . c

6x1.0mm 1 2N . m {1.2kgt.m, 8.7 tbf.ft)

33.0 33.7mm i { 1 . 3 0 1 . 3 3n . l

6-21

Gylinder Head
CylinderHeadCoverRemoval
1. Removethe intakemanifoldcover. 4, Removethe cylinder headcover

V:t :;t 1

|,'.i/
2. Removethe four ignition coils (seepage 4-'18). 3. Removethe dipstick(A) and breatherhose (B).

\-

6-22

GylinderHeadRemoval
NOTE: . Usefender painted covers avoiddamaging to surfaces.
To avoid damage,unplug the wiring connectors carefullywhlle holdingthe connectorportion. To avoid damagingthe cylinderhead,wait until the enginecoolanttemperaturedrops below 100'F(38"C) betore looseningthe cylinder head bolts. Mark all wiring and hosesto avoid misconnection. Also, be sure that they do not contactother wiring or hoses,or interferewith other parts. 8. Removethe enginewire harnessconnectors and wire harnessclampsfrom the cylinder head. . Enginecoolanttemperature(ECT) sensor conneclor . Camshaftposition(Cl\4P) (top dead center(TDC)) sensor B connector . Camshaftposilion (CMP)sensorA connector 9. Removethe upper radiatorhose (A) and heater h o s e( B ) .

' 1 .Drainthe

enginecoolant(seepage 10-6).

2 . Removethe drive belt (seepage 4-26). 3 . Removethe intakemanifold {seepage 9-3).


Removethe air cleanerhousing(seestep 7 on page 5-2t. 5. Removethe water bypasshose (A).

'10.

Removethe harnessholder (A)from the bracket, then removethe connectingpipe mounting boh {B) and brakeboostervacuum line mounting bolts {C).

6 . Removethe exhaustmanifold (seepage9-7) . 7 . Removethe cam chain (seepage 6-12).

11. Removethe water bvpasshose (D).

(cont'd)

6-23

Head Cylinder
CylinderHeadRemoval(cont'd)
Removethe rockerarm assembly(seepage 6-26).
tJ.

VTCActuator, Exhaust Camshaft


SprocketReplacement
Removal:
1 . R e m o v e h e c a m c h a i n( s e ep a g e6 - 1 2 ) . t 2. Hold the camshaftwith an open-endwrench,then loosenthe variablevalve timing control (VTC) actuatormounting bolt and exhaustcamshaft sprocketmounting bolt.

Removethe cylinderhead bolts.To prevent warpage,unscrewthe bolts in sequence1/3turn at u a t i m e ; r e p e a t h e s e q u e n c e n t i la l l b o l t sa r e loosened. HEADBOLTSLOOSENING CYLINDER SEQUENGE:

h 1 4 . R e m o v eh e c y l i n d e r e a d . t
I

Removethe VTC actuatorand exhaustcamshaft sprocket.

I
6-24

Installation:
1. Installthe VTC actuatorand exhaustcamshaft sprocket. 2. Apply engineoil to the th readsof the VTC actuato r mounting bolt and exhaustcamshaftmounting bolt, then installthem. 3. Hold the camshaftwith an open-endwrench,then tighten the bolts. Specified torque: VTC actuator mounting bolt: 1 1 3N . m ( 1 1 . 5 g l . m , 8 3l b l . f t ) k Exhaust camshaft sprocket mounting bolt: 72 N m (7.3 kgf.m, 53 lbf.ft)

CylinderHeadInspection for Warpage


1 , Removethe cylinder head{see page 6-23).

Inspectthe camshaft(seepage 6-29). Checkthe cylinder headfor warpage.Measure along the edges,and three ways acrossthe center. . lf warpage is lessthan 0.05mm (0.002in.) cylinder head resurfacing not required. is . lf warpage is between0.05 mm (0.002in.) and 0.2 mm (0.008in.),resurface cylinder head. the . Maximum resurface limit is 0.2 mm (0.008in,) basedon a height of 104mm (4.09in.). Cylinder Head Height; Standard{New}: 103.95 104.05 mm {4.093 4.096in.}

4 . I n s t a ltl h e c a m c h a i n{ s e ep a g e6 - 1 5 ) .

6-25

CylinderHead
RockerArm AssemblyRemoval
'1. Removethe cam chain (seepage 6-12). 4 . Removethe cam chain guide B, camshaftholders, and camshafts. 5 . Insertthe bolts (A) Into the rockershaft holder,then removethe rockerarm assembly(B).

2 . Loosenthe rockerarm adjustingscrews (A), A

3. Removethe camshaftholder bolts.To Drevent damagingthe camshafts,unscrewthe bolts two pattern. turns at a time, in a crisscross CAMSHAFTHOLDERBOLTS LOOSENING SEOUENCE:

\-

6-26

RockerArms and ShaftsDisassembly/Reassembly


NOTE:
ldentifypartsas they are removedto ensurereinstallation original location. in Inspect the rockershaftsand rockerarms (seepage 6-28). The rockerarms must be installedin the same positionsif reused. When removing or installingthe rockerarm assembly,do not removethe camshaftholder bolts.The bolts will keep the holders,springsand rockerarms on the shaft. Priorto reassembling, cleanall the parts in solvent,dry them, and apply lubricantto any contactpoints. Bundlethe rockerarms with rubber bandsto keeD them tooetheras a set. EXHAUST ROCKER SHAFT EXHAUST ROCKER ARM

wASHEB

\nl I ltnrllln
IJI_J;-L,JLI []1_L^|l]
o
'rl) 70)

Yr

rY

rffin ,ffif-

.;.
..1

t:l P
- l

'l
o

,q

,,_tl

INTAKE ROCKER ARM ASSEMBLY

INTAKEROCKER SHAFT

6-27

CylinderHead
Arms and ShaftsInspection Rocker
1 . Removethe rockerarm assembly(seepage 6-26). 2 . Measurethe diameterof the shaft at the first rocker location. 4. Measurethe insidediameterofthe rockerarm, and condition. checkit for an out-of-round Rocker Arm-to-Shaflt Clearance: Standard lNew): 0.025 0.052 mm lntake: (0.0010 0.0020in.) Exhaust: 0.018 0.056mm (0.0007 0.0022in.) 0.08 mm (0.003in.) Service Limit:

3. Zero the gauge (A)to the shaft diameter.

5. Repeatfor all rockerarms and both shafts.lfthe clearance over the Ilmit. replacethe rockershaft is rockerarms. lf any VTEC and all overtolerance replacethe rocker rockerarm needs replacement, as arms (primaryand secondary) a set. 6. Inspectthe rockerarm pistons{A}.Pusheach p i s t o nm a n u a l l y . lf it does not move smoothly,replacethe rocker arm set. NOTE:Apply oil to the pistonswhen reassembling.

\.

,,,@@

6-28

Gamshaft Inspection
NOTE:Do not rotatethe camshaftduring inspection. 1. Removethe rockerarm assembly(seepage 6-26). and disassemble (seepage6-27). it 2. Putthe rockershaft holders,camshaft,and camshaftholderson the cylinderhead,then tighten the bolts to the specifiedtorque. Specified torque: I mm bolis: 22 N.m {2.2kgt m, 16lbf.ft} 6 mm bolts: 12 N.m {1.2kgf.m,8.7 tbf.ftl 6 mm bolts: @, 0, @ 3. Seatthe camshaftby pushing it away from the c a m s h a f p u l l e ye n d o f t h e c y l i n d e r e a d . t h 4. Zero the dial indicatoragainstthe end of the camshaft,then push the camshaftbackand forth and read the end play. lf the end play is beyondthe servicelimit, replacethe camshafthead and recheck. it is still beyondthe servicelimit, replace lf thecylinder. CamshaftEnd Play: Standard{New}:0.05 0.20 mm (0.002 0.008in.l ServiceLimit: 0.4 mm (0.02in.)

(cont'd)

6-29

Head Cylinder
CamshaftInspection(cont'dl
Unscrewthe camshaftholder boltstwo turns at a pattern.Then removethe time, in a crisscross camshaftholdersfrom the cylinder head. Lift the camshaftsout of the cylinder head,wipe them clean.then inspectthe lift ramps.Replace the camshaftif any lobes are pitted,scored,or worn, excessively i 1 . C l e a n h e c a m s h a fjto u r n a ls u r f a c e sn t h e c y l i n d e r t head,then set the camshaftsbackin place.Placea plastigage strip acrosseachjournal. Installthe camshaftholders,then tighten the bolts to the specified torque as shown in step 2. 9 . Removethe camshaftholders.Measurethe widest portionof plastigage eachjournal. on . lf the camshaft-to-holder clearance within is l i m i t s ,g o t o s t e p 11 . . lf the camshaft-to-holder clearance beyondthe is servicelimit and the camshafthas been replaced, replacethe cylinder head. . lf the camshaft-to-holder clearance beyondthe is servicelimit and the camshafthas not been go replaced, to step 10. Camshaft-to-Holder Oil Clearance: Standard (New): No. 1 Journal: 0.030 0.069 mm No.2,3,4,5 Journals: ServiceLimit: 10. Checkthe total runoutwith the camshaftsupported on V-blocks, . l f t h e t o t a l r u n o u to f t h e c a m s h a f its w i t h i nt h e servicelimit, replacethe cylinder head. . lf the total runout is beyondthe servicelimit, replacethe camshaftand recheck camshaftthe lf to-holderoil clearance. the oil clearanceis still beyondthe servicelimit, replacethe cylinder neao. Camshaft Total Runout: Standard(New):0.03mm (0.001in.) max. ServiceLimit: 0.04mm {0.002in.)

\,

1 1 . M e a s u r e a m l o b eh e i g h t . c Cam Lobe HeiohtStandard(New

in-) {0.001 0.003 mm 0.060*0.099 in.) {0.002 0.004 0 . 1 5 m { 0 . 0 0i6 . ) m n

INTAKE
PRI SEC m 33.925 m ( 1 . 3 3 5 6n . ) i

EXHAUST
34.092mm \1.3422in.l

2 9 . 6 3m m 8 ( 1 . 1 6 6n . ) i8 P R IP r i m a r y : C/C: CamChain

SEC:Secondary

\-

6-30

Valves,Springs,and ValveSealsRemoval
Special Tools Bequired Valvespring compressorattachment07VAE-001010A ldentifythe valvesand valve springsas they are removedso that each item can be reinstalledin its original position. 1. Removethe cylinder head (seepage 6-23). 2. Using an appropriate-sized socket(A) and plastic mallet {B),lightly tap the valve retainerto loosen the valve keepers. 4 . I n s t a l l t h e a l v eg u i d es e a lr e m o v e r . v

5 . Removet h e v a l v es e a l .
\

Installthe spring compressor. Compressthe spring, and removelhe valve keepers.

6-31

Head Gylinder
ValveInspection
1 . R e m o v e h e v a l v e s( s e ep a g e6 - 3 1 ) , t

ValveStem-to-Guide Clearance Inspection


1 . Removethe valves (seepage6-3'1). S l i d et h e v a l v eo u t o f i t s g u i d ea b o u t1 0 m m . t h e n with a dial measurethe guide-to-stem clearance indicatorwhile rockingthe stem in the directionof normal thrust (wobble method). . l f t h e m e a s u r e m e n tx c e e d s t h e e r v i c ei m i t , e s l recheckit using a new valve. . lf the measurementis nowwithin the service limit, reassemble using a new valve. . l f t h e m e a s u r e m e n t w i t a n e w v a l v es t i l l h exceeds the servicelimit, go to step 3. lntake Valve Stem-to-Guide Clearance: StandardlNew): 0.06 0.11 mm {0.002 0.004in.} ServiceLimil: 0.16mm {0.006in.) Exhaust Valve Stem-to-Guide Clearance: S t a n d a r d N e w l : 0 . 1 1- 0 . 1 6 m m l 10.004 0.006in.) in.) ServiceLimit: 0.22 mm 10.009

2 . Measurethe valve in these areas.


lntake Valve Dimensions A StandardlNewl: 34.85 35.15mm i { 1 . 3 7 2 1 . 3 8 4n . l B Standard{Newl: 108.7 109.5mm 14.280-4.311in.) C StandardlNew): 5.475 5.485 mm i9 1 0 . 2 1 5 6 - 0 . 2 1 5n . ) C ServiceLimit: 5.445mm {0.214in.l ExhaustValve Dimensions A Standard(New):29.85-30.15 mm ( 1 . 1 7 5 -1 . 1 8 7 n . ) i (New):108.3 109.1mm B Standard (4.264- 4.295 in.l (New): 5.450 5.460mm C Standard (0.2146 0.2150in.) C Service Limit: 5.42mm (0.213in.)

.<

4,.

3 . Subtractthe O.D.of the valve stem. measuredwith


a micrometer,from the LD. of the valve guide, m e a s u r e d i t h a n i n s i d em i c r o m e t eo r b a l lg a u g e . w r Takethe measurements three placesalong the in v a l v es t e m a n dt h r e ep l a c e s n s i d e h e v a l v eg u i d e . i t The differencebetweenthe largestguide m e a s u r e m e n t n dt h e s m a l l e s s t e m m e a s u r e m e n t a t should not exceedthe servicelimit lntake Valve Stem-to-Guide Clearance: Standard(New):0.030 0.055mm {0.0012 0.0022in.) in.l ServiceLimit; 0.08mm (0.003 ExhaustValve Stem-to-Guide Clearance: Standard{Newl: 0.055 0.080mm (0.0022-0.003rin.l ServiceLimit: 0.11mm (0.004in.)

t-

6-32

ValveGuideReplacement
Special ToolsRequired . Valve guidedriver, mm 07742-0010100 5.5 . Valveguidereamer, mm 07HAH-PJ7o108 5.5
(seepage 61 . Inspectvalve stem-to-guide clearance Working from the camshaftside. usethe driver and an aarhammerto drive the guide about 2 mm (0.1 in.)towardsthe combustionchamber.This will knockoff some of the carbon and make removal easier.Hold the air hammer directlyin line with the valve guide to preventdamagingthe driver. Turn lhe head over, and drive the guide out toward the camshaftside of the head.

32t.
As illustratedbelow, use a commerciallyavailable air-impactvalve guide driver (A) modifiedto fit the diameterof the valve guides.In most cases, the same procedurecan be done usingthe specialtool and a conventional hammer.

-_|Jfillr-.-4fi'11., tT 10.8mm {0.,|2in.)

guides,and chill 3. Selectthe proper replacement lhem in the freezersectionof a refriqerator for about an hour. 4. Use a hot plate or oven to evenly heatthe cylinder headto 300'F (150"C). Monitor the temperature with a cookingthermometer.Do not getthe head hotterthan 300'F (150"C); excessiveheat may loosenthe valve seats. 7 . lf a valve guide won't move, drill it out with a I mm ( 5 / 1 6i n c h )b i t .t h e nt r y a g a i n .D r i l lg u i d e so n l y i n extremecases;youcould damagethe cylinder head if the guide breaks. Removethe new guide(s) from the freezer,one at a time, as vou needthem.

(cont'd)

6-33

Head Cylinder
(cont'dl ValveGuideReplacement
Apply a thin coat of clean engineoil to the outside of the new valve guide. Installthe guide from the camshaftside of the head;usethe specialtool to drive the guide in to the specifiedinstalledheight ( A )o { t h e g u i d e( B ) .l f y o u h a v ea l l 1 6 g u i d e s t od o , you may have to reheatthe head. Valve Guide Installed Height: 15.2 16.2mm (0.598-0.638in.) Intake: Exhaust: 15.5 16.5mm (0.610-0.650in.)

\ 1 0 .Coat both reamerand valve guide with cutting oil.


1 1 .Rotatethe reamerclockwisethe full length of the v a l v eg u i d eb o r e .

O7HAH.PJ7O1OB

' - \

Continueto rotatethe reamerclockwisewhile removing it from the bore. Thoroughlywash the guide in detergentand water to remove any cutting residue. 1 4 . C h e c k h e c l e a r a n c ew i t h a v a l v e( s e ep a g e6 3 2 ) . t s Verifythat a valve slidesin the intakeand exhaust valve guideswithout exening pressure.

6-34

ValveSeat Reconditioning
1. Inspectvalve stem-to-guide clearance(seepage 632).lf the valve guidesare worn, replacethem (see page6-33)beforecuttingthe valve seats. 2 . R e n e w h e v a l v es e a t si n t h e c y l i n d e r e a du s i n ga t h valve seat cutter. 5. Make one more very light passwith the 45" cutter to removeany possibleburrs causedby the other cutters. Valve Seat Width: Standard(New): 1.25 1.55mm {0.049 0.061in.) ServiceLimit: 2.00 mm (0.079in.) 6. After resurfacing seat,inspectfor even valve the s e a t i n gA p p l y P r u s s i a n l u ec o m p o u n d( A )t o t h e : B v a l v ef a c e .I n s e r t h e v a l v ei n i t s o r i g i n a l o c a t i o nn i the head,then lift it and snap it closedagainstthe seat severaltrmes.

3 , C a r e f u l l y u t a 4 5 ' s e a t ,r e m o v i n g n l y e n o u g h c o
materialto ensurea smooth and concentricseat. 4 . Bevelthe upper and lower edgesat the angles shown in the illustration. Checkthe width of the seat and adjustaccordingly. INTAKE:35" EXHAUST:30'
- 45' , { 67.5'

1 . The actualvalve seatingsurface(B),as shown by the blue compound,should be centeredon the seat. . lf it is too high (closer the valve stem),you to must make a secondcut with the 67.5' cutterto move it down, then one more cut with the 45" cutterto restoreseatwidth. . lf it is too low (closeto the valve edge),you must make a secondcut with the 35'cutter (intake sidel or the 30" cutter (exhaustside)to move it up, then make one more cut with the 45" cutterto restoreseatwidth. N O T E T h e f i n a lc u t s h o u l da l w a y sb e m a d ew i t h : the 45'cutter.

(cont'd)

6-35

Head Cylinder
(cont'dl ValveSeat Reconditioning
8 . Insen the intakeand exhaustvalves in the head, and measurevalve stem installedheight (A). Intake Valve Stem Installed Height: Standard{New):40.8 41.0mm ( 1 . 6 0 6 1 . 6 1 4n . ) i Exhaust Valve Stem Installed Height: Standard(New):54.6-54.8 mm -2.157 in.l |'2.150

L lf valve stem installedheight is over the standard, replacethe valve and recheck. it is still over the lf standard,replacethe cylinder head;the valve seat in the head is too deeD.

\-

\-

6-36

Valves,Springs,and Valve SealsInstallation


Special Tools Required Valve spring compressorattachment07VAE-00101 0A 1. Coatthe valve stemswith engine oil. lnstallthe valves in the valve guides. 2. Checkthat the valves move up and down smoothly. Installthespring seatson the cylinder head. Installthe new valve seals(A) usingthe valve guide r s e a li n s t a l l e( B ) . NOTE:The exhaustvalve seal (C)has a blackspring (D),and the intakevalve seal (E)has a white spring (F).They are not interchangeable. l n s t a l l t h e a l v es p r i n g . l a c e h e e n d o f t h e v a l v e v P t spring with closelywound coils toward the cylinder ne a o . 6 . Installthe valve retainer. 7 . Installthevalve spring compressor, Compressthe spring, and installthe valve keepers. Removethe valve spring compressor.

Lightlytap the end of each valve stem two or three times with a plasticmallet (A)to ensureproper Tap the seatingof the valve and valve keepers. valve stem only along its axis so you do not bend the stem.

6-37

Head Cylinder
Arm AssemblyInstallation Rocker
:,ean and dry the No. 5 rockershaft holder mating surfaces. eeassemble rockerarm assembly(seepage 6the 2 1t . Apply liquid gasket,P/N 08718-0009, evenlyto the :ylinder head mating surfaceofthe No. 5 rocker shaft holder. \OTE: Do not lnstallthe partsif 5 minutesor more r a v e e l a p s e d i n c ea p p l y i n g i q u i dg a s k e tI.n s t e a d , l s 'eapply liquid gasketafter removingold residue.

\ 5 . Removethe bolts from the rockershaft holder.


v m 6 . M a k es u r et h e D U n c h a r k so n t h e v a r i a b l e a l v e actuatorand exhaustcamshaft timing control (VTC) sprocketare facing up. then set the camshafts(A) in the holder.

fl
c

Apply liquid gasket alongthe brokenline.

\7 . Set the camshaftholders(B) and cam chain guide B ( C )i n p l a c e . torque. Tightenthe bolts to the specified Specified torque: 8 mm bolts: 22 N.m (2.2 kgf.m, 16 lbl.ft) 6 mm bolts: 12 N.m {1.2kgf.m,8.7 lbf.fil 6 mm bolts: @),@.@

Insertthe bolts (A) into the rockershaft holder,then installthe rockerarm assembly(B)on the cylinder head.

lnstallthe cam chain (seepage 6-15).and adjustthe (seepage 6-9). valve clearance

l-

6-38

CylinderHeadInstallation
Installthe cylinder head in the reverseorder of removat: 1. Cleanthe cylinderhead and blocksurface.
f.f

5. Measurethe diameterof each cylinder head bolt at ooint A and DointB. a 50mm (2.0 in.l
)>-

2. Installthe new cylinder headgasket(A) anddowel pins (B)on the cylinderblock.Always use a new cylinder headgasket.

A '15mm {'1.8 in.) " < > .

i i l f e i t h e rd i a m e t e r s l e s st h a n 1 0 . 6m m { 0 . 4 2 n . ) , replacethe cvlinder head bolt. Align to Set the crankshaft top dead center{TDC). sprocketwith the TDC mark (A) on the crankshaft the pointer(B)on the cylinderblock.

4. Installthe cylinderhead on the block.

( c o n td )

6-39

Cylinder Head
CylinderHeadlnstallation(cont'd)
7 . Apply engine oil to the bolt threadsand under the b o l t h e a d s f a l l t h e c y l i n d e r e a db o l t s . o h 10. Installthe rockerarm assembly{seepage6-38).

8 . Tightenthe cylinder head bolts in sequenceto 39


N.m {4.0 kgf.m,29 lbf.ft).Use a beam-type torque wrench.When using a preset-type torque wrench, be sure to tighten slowly and do not overtighten.lf a bolt makesany noisewhile you are torquing it, loosenthe bolt and retightenit from the first step.

1 ' . Installthe water bypasshose (A). t


---l.-.

B 6x1.0mm 'r2N.m c (1.2 kgl.m,8.7 lbf.ftl 6xl.0mm '12 N,m(1.2 kgt.m,8.7 lbf.ft) 9 . After torquing,tighten all cylinderhead bolts in two steps(90" per step).lf you are using a new cylinder head bolt,tighten the bolt an extra 90..

1 2 .Tightenthe connectingpipe mounting bolt (B)and


brakeboostervacuum line mounting bolts (C),then i n s t a l l t h e a r n e s s o l d e r( D )o n t h e b r a c k e t . h h

't3. Installthe
(B).
FIRSTSTEP

upper radiatorhose {A) and heaterhose

SECOND STEP

6-40

GylinderHeadCoverlnstallation
h 1 4 . I n s t a l l t h e a t e rb v p a s s o s e . w 1. Thoroughlycleanthe headcover gasketand the groove. 2. Installthe head cover gasket(A) in the groove of h t h e c y l i n d e r e a dc o v e r( B ) .

( h 1 5 . I n s t a l l t h e i r c l e a n e r o u s i n g s e es t e p3 7 o n p a g e a 5-15). ( i m 1 6 . I n s t a l l t h en t a k e a n i f o l d s e ep a g e9 - 5 ) . ( m e 1 7 . I n s t a l l t h e x h a u s t a n i f o l d s e ep a g e9 - 7 ) . '18. c I n s t a l l t h e a m c h a i n ( s e ep a g e6 - 1 5 ) . ( 1 9 . A d j u s tt h e v a l v ec l e a r a n c e s e e p a g e 6 - 9 ) . d 2 0 . I n s t a l l t h e r i v eb e l t( s e ep a g e4 - 2 6 ) . 21. Cleanthe batterypostsand cableterminalswith t t, s a n d p a p e r h e n a s s e m b l eh e m a n d a p p l yg r e a s e to preventcorrosion. ch 2 2 . A f t e ri n s t a l l a t i o n , e c k t h a t a ltl u b e s ,h o s e s a n d connectors are installedcorrectly. s . 2 3 . I n s p e c t f o r f u elle a k sT u r nt h e i g n i t i o n w i t c hO N {ll) {do not operatethe starter)so that the fuel pump the runs for about 2 secondsand pressurizes fuel line. Repeatthls operationtwo or three times, then a c h e c k o r f u e l l e a k a g e t a n y p o i n ti n t h e f u e l l i n e . f 24. Refillthe radiatorwith enginecoolant,and bleed air from the cooling systemwith the heatervalve open (seepage 10-6). 2 5 . I n s p e ctth e i d l es p e e d( s e ep a g e1 1 - ' 1 3 8 ) . t 2 6 . I n s p e ctth e i g n i t i o n i m i n g ( s e ep a g e4 - 1 7 ) . Checkthat the mating surfacesare clean and dry. on Apply liquid gasket.P/N 08718-0009, the chain caseand the No.5 rockershaft holder mating areas. NOTE:Do not installthe parts if 5 minutesor more have elapsedsinceapplying liquid gasket.Instead, reapplyliquid gasketafter removing old residue.

(cont'd)

6-41

GylinderHead
CylinderHeadGoverInstallation(cont'd)
Set the spark plug seals(A) on the spark plug tubes. O n c et h e c y l i n d e r e a dc o v e r( B )i s o n t h e c y l i n d e r h head,slide the cover slightly backand forth to seat the head cover gasket. 7. Tightenthe bolts in two or three steps.In the final s t e p , i g h t e na l l b o l t s ,i n s e q u e n c e , 9 . 8 N . m ( 1 . 0 t to kgf.m,7.2 lbf.ft).

( 8 . I n s t a ltlh e d i p s t i c k A )a n d b r e a t h e h o s ei B ) . r

Inspectthe cover washers(C).Replace any washer that is damagedor deteriorated.

\l
6-42

9 . Installthe four ignition coils (seepage 4-'18). 1 0 . Checkthat all tubes, hoses,and connectorsare installedcorrectly. 1 1 .lnstallthe intakemanifoldcover. 6x 1,0 m '12 m kgf m. N.m{1.2 8.7tbf.ftl

wait at least30 minutesbefore 12. After assemblv, w f i l l i n gt h e e n g i n e i t h o i l .

6-43

EngineMechanical
Engine Block
7 . . . . . . . . . . . .-.2 T S o e c i a lo o l s . . In d e x . . . . . . . . . . . . . . . . . . . . . . . . . . .7.-.3 . . . . . . . . . . n L C o m o o n e n to c a t i o End Rod Connecting andCrankshaft Play 7-5 .............. InsDection 7-6 ...................... Replacement MainBearing Crankshaft 7-8 ...................... Replacement Rod Connecting Bearing . . . . . . . .7 . 1 1 .l O i lP a nR e m o v a . . . . . . . . . . . . . . . . . . . . . . . 7-12 ........ Removal and Piston Crankshaft 7-14 ........................ Inspection Crankshaft 7 .. . . I B l o c k n dP i s t o nn s o e c t i o n. . . . . . . . . . . . . . . . . . . . . . . . . . .- 1.5. . . . . . . . a . " . . . . . . . . . . . . .7- . 1.7. ..' . . H C y f i n d e r o n i n g. . . . . . . . . . . . 7-18 .......... Rod Piston, andConnecting Replacement Pin 7 -21 ................... RingReplacement Piston 7-23 ........... .................... Piston lnstallation 7 .......' -24 RodBoltInspection Connecting 7-24 .....................'. lnstallation Crankshaft . . . . . . . . .7-.2 7 . . O i lP a nl n s t a l l a t i o .n . . . . . . . . . . . . . . . . Seal End Transmission Crankshaft ........' -28 7 Car lnstallation-ln ...................

EngineBlock
SpecialTools
Ref.No.

\
Description Oil Seal DriverAttachment96 Attachment,24 x 26 mm Driver Oty 1 1 1

6
@

Tool Number OTZAD-PNAAlOO 07746-0010700 07749,0010000

I
o
\ {

7-2

ComponentLocationIndex
BAFFLEPLATE

BLOCK LOWER

fr "

fi E

-4
MAINBEARINGS pa 7 O i l c l e a r a n c e ,g e - 6 page Selection, 7-6

FLYWHEEL

CRANKSHAFT SEAL. OIL END TRANSMISSION 7-26 Installation, 21on page step

THRUST WASHERS

CRANKSHAFT End play,page7-5 R u n o u t p a g e7 - 1 4 , page7-14 Out-of-Round, page7-12 Removal, page7-24 lnstallation,

(cont'd)

7-3

Engine Block
ComponentLocationIndex(cont'd)

D-><
Y1

/^.,

|
l-"t

nrrucs _,-ersroru Benlacement. 7-21


Page

ffil

rkrej,

rG\ AalQ [= ^oJ l


PISTON page7-'12 Removal, page7-15 Measurement,

CONNECTINGROD End play, page7-5 page7-19 Small end measurement,

f,
6

PISTONPIN page7-18 Removal, p I n s p e c t i o n ,a g e7 - 1 9 page7,20 Installation,

ENGINE BLOCK page7-'15 Cylinderbore inspection, page7-15 Warpageinspection, p C y l i n d e b o r eh o n i n g , a g e1 - 1 1 r Ridgeremovai,step 13 on page7-13 CONNECTING ROD

CONNECTING ROD BOLT page7 24 lnspectaon,

7-4

End PlayInspection Rod and Crankshaft Connecting


page8-9). 1 . Remove oil pump(see the (see plates 1 Remove baffle the step6 on page -12).
3. Measurethe connectingrod end play with a feeler gauge betweenthe connectingrod and crankshaft. ConnectingRod End Play Standard{New):0.15 0.30mm (0.006-0.012in.l 0.40mm (0.016in.l ServiceLimit 5. lnstalla dial indicatoras shown. Pushthe firmly away from the dial indicator,and crankshaft Then zerothe dial againstthe end of the crankshaft. pull the crankshaft firmly backtoward the indicator; the dial readingshould not exceedthe servicelimit. Crankshaft End Plav StandardlNew): 0.10-0.35 mm i { 0 . 0 0 4 - 0 . 0 1 4n . l ServiceLimit: 0.45mm {0.018in.)

4 . lf the connectingrod end play is out-of-tolerance,

lf installa new connectingrod, and recheck. it is (see replacethe crankshaft still out-of-tolerance, page 7 -12],.

replacethe thrust lf the end play is out-of-tolerance, lf washersand recheck. it is still out-of-tolerance, replacethe crankshaft.

7-5

EngineBlock
Crankshaft Main BearingReplacement
MainBearing Clearance Inspection
1. To checkmain bearing-to-jou I oil clearance. rna removethe lower block and bearinghalves(see page 1 -12).. 2 , C l e a n a c hm a i nj o u r n a la n d b e a r i n g a l fw i t h a e h cleanshop towel. 3. Placeone strip of plastigage acrosseach main l o ur n a l . 4 . R e i n s t a l l t h e e a r i n g s n d l o w e rb l o c k t h e nt o r q u e b a , the bolts to 29 N.m {3.0kgf.m,22 lbf.ft) + 56'. NOTE:Do not rotatethe crankshaft during Inspeclton. 5 . R e m o v e h e l o w e rb l o c ka n d b e a r i n g s g a i n , n d t a a measurethe widest part of the plastigage. Main Bearing-to-Journal Clearance Oil N o . 1 , 2 ,4 , 5 J o u r n a l s : Standard(New):0.017 0.041mm Service Limit: No.3 Journal: 6. lf the plastigagemeasures too wide or too narrow, removethe crankshaft. and removethe upper half ofthe bearing.Installa new, completebearingwith the same color code{s), and recheck clearance. the Do not file, shim, or scrapethe bearingsor the caps to adjustclearance. 7. lf the plastigage shows the clearance still is incorrect, the next largeror smaller bearing(the try color listedabove or below that one),and check again.lf the proper clearance cannot be obtained b y u s i n gt h e a p p r o p r i a t ea r g e ro r s m a l l e rb e a r i n g s , l replacethe crankshaft and start over.

10.0007 0.0016 in.l 0.050 mm {0.0020 in.)

Standard{Newl:0.025- 0.049mm (0.0010 0.0019 in.) Service Limit: 0.055 mm (0.0022 in.l

\.

7-6

Main Bearing Selection


Crankshaft Bore Code Location 1. Numbersor lettersor bars have been stampedon the end of the block as a code for the sizeof each of the five main journal bores.Write down the crank bore codes.lf you can't readthe codes becauseof dirt and dust, do not scrub them with accumulated a wire brush or scraper.Cleanthem only with solventor detergent.
No. 5 JOURNAL END) {FLYWHEEL No. 1 JOURNAL END} IPULLEY

Main Journal Code Location 2. The main journal codesa{e stampedon the cran kshaft.

No. 1 JOURNAL

No. 5 JOURNAL

(cont'd)

7-7

Engine Block
Crankshaft Main Bearing (cont'd) Replacement
3. Usethe crank bore codes and crankjournal codes to selectthe appropriatereplacement bearings from the following table. NOTE: . Color code is on the edge of the bearing. . When using bearinghalvesof differentcolors.it does not matterwhich color is used in the top or bottom. Lalgercrankbore 3or c oi__-l C o r l l l D o r t t t It

Connecting RodBearing Replacement


RodBearing Clearance lnspection
1 . R e m o v e h e o i l p u m p ( s e ep a g e8 - 9 ) . t 2. Bemovethe baffle plates(seestep 6 on page7-12). 3. Removethe connectingrod cap and bearinghalf. 4 . C l e a n h e c r a n k s h a frto d j o u r n a la n d b e a r i n g h a l f t with a clean shop towel. 5. Placeplastigage acrossthe rod journal. 6 . R e i n s t a l l t h b e a r i n g a l fa n d c a p ,a n dt o r q u et h e e h b o l t st o 2 0 N . m ( 2 . 0k g f . m ,1 4 l b f . f t ) l 9 0 " . NOTE:Do not rotatethe crankshaft during inspection. 7 . R e m o v e h e r o d c a pa n d b e a r i n g a l f ,a n d m e a s u r e t h the widest part of the plastigage. ConnectingRod Bearing-to-Journal Oil Clearance: Standard{Newl: 0.020 0.050mm --0.0020in.l (0.0008 ServiceLimit: 0.060mm (0.0024 in.)

Main iournsl cooe


1 2

Crank ---=-> bore | 1or code IAorl


--

2ot Borll

--> Smaller bearing {Thickerl

Pink f!1f;* v"rro* c,""n

v"no* f111f;,," c,""" $;;fl


cr""n $ffi ero-n
Creen ; g=jiff;i Brown Black

4 5

;;lT]*Brown

ffi#Tr,.*" i.,""* '---l-'o"*,


Black 6il;

\-

Brack !l;kr
(Thicker)

ar*

7-8

8 . lf the plastigagemeasures wide or too narrow, too


removethe upper half of the bearing,installa new, completebearingwith the same color code(s), and recheck clearance. not file. shim, or scrape Do the the bearingsor the capsto adjustclearance.

RodBearing Selection
1. Inspecteach connectingrod for cracksand heat damage. Connecting Rod Big End Eore Code Locations

9 . lf the plastigage shows the clearance still is


incorrect, the next largeror smaller bearing(the try color listedabove or below that one),and check clearance agaln.lf the properclearance cannot be obtainedby usingthe appropriatelarger or smaller bearing,replacethe crankshaft and stan over. 2 . E a c hr o d h a sa t o l e r a n c ea n g ef r o m 0 0 . 0 2 4 m r m (0.0009 in.) in.),in 0.006mm (0.0002 increments, dependingon the sizeof its big end bore. lt's then w s t a m p e d i t h a n u m b e ro r b a r ( 1 ,2 , 3 o r 4 / 1 l,l , l l l ,o l Y l l l l )i n d i c a t i n gh e r a n g e . o u m a y f i n d a n y t c o m b i n a t i o n f n u m b e r s n d b a r si n a n y e n g i n e . o a ( H a l ft h e n u m b e ro r b a r i s s t a m p e d n t h e b e a r i n g o cap,the other half on the rod.) lf you can't readthe code becauseof an accumulation oil and varnish.do not scrub it of with a wire brush or scraper.Cleanit only with solventor detergent. Normal Bore Size: 48.0 mm 11.89 in.l

(cont'd)

7-9

Block Engine
(cont'dl Rod BearingReplacement Connecting
Connecting Rod Journal Code Location 3. The connectingrod journalcodesare stampedon the crankshaft. Connecting Rod Journal Code Location (Letters or Bars) 4. Use the big end bore codes and rod journalcodes to selectappropriatereplacement bearingsfrom the followingtable. NOTE: . Color code is on the edge of the bearing. . When using bearinghalvesof differentcolors,it does not matter which color is used in the top or bottom. Big end ----------> bore codo
lorl
Rod

Larger end bore big


3 ol lll 4 orllll

2oJll

---------> Smallsrb.aring {Thickerl Pink Pink/ Yollow/ Yellow Grecn Green

Yellow Yellow/ Green Green Brown

Green/ Brown Brown


Black

c
D

Green/ Erown/ Brown Black Brown/ Black Black/ Blue

Blue

\
(Thicker)

No.l JOURNAL No.4 JOURNAL

7-10

OilPanRemoval
1 . Drainthe engineoil (seepage8-5). lf the engine is still in the vehicle,removethe subframe. -1 Attachthe chain hoistto the engine (seestep 35 on page 5-6). -2 Disconnectthe suspension lower arm ball joints (seestep 3 on page 18-19). -3 Removethe rear mounl mounting bolts (see step 39 on page 5-7). -4 Removethe front mount mounting bolt (see step 40 on page 5-7). -5 Use a markerto make alignmentmarks on the referencelinesthat align with the centersof the rear subframemounting bolts.Removethe front subframe(seestep 43 on page 5-8). 6. Removeheoil pan. t Removethe bolts/nutssecuringthe oil pan. Drivean oil pan seal cutter betweenthe oil pan and cylinderblock.

l 5 . C u tt h eo i l p a n s e ab y s t r i k i n g t h e s i d e o f t h e c u t t e r to slidethecutteralong oil pan. the

7-11

EngineBlock
and PistonRemoval Crankshaft
( 1 . R e m o v e h e e n g i n e s s e m b l y s e ep a g e5 - 2 ) . t a t n 2 . R e m o v e h e t r a n s m i s s i o ( s e ep a g e1 3 - 4 ) . 3 . R e m o v e h e o i l p a n ( s e ep a g e7 - 11 ) . t 4. Removethe oil pump {seepage8-9). 5. Removethe cylinderhead (seepage 6-23). 6. Removethe baffle plates.
E

8. Removethe bearingcap bolts.To preventwarpage, unscrewthe bolts in sequence1/3turn at a time: repeatthe sequenceuntil all bolts are loosened.

7. Removethe 8 mm bolts.

L Removethe lower blockand bearings,Keepall bearingsin order.

7-12

1 0 .Removethe rod caps/bearings. Keepall caps/


b e a r i n g sn o r d e r . i 1 1 .Liftthe crankshaft out ofthe engine,being careful n o tt o d a m a g e h ej o u r n a l s . t

14. Use the wooden handleof a hammer (A)to drive out the pistons(B).

1 5 . Reinstall the lower block and bearingson the engine in the proper order,
to.

R e i n s t a l l t h c o n n e c t i n go d b e a r i n g s n d c a p s e r a after removingeach piston/connecting rod assembly.

1 7 .To avoid mixup on reassembly. mark each piston/ connectingrod assemblywith its cylinder number. Removethe upper bearinghalvesfrom the connectingrods.and set them asidewith their respective caps.
t.J.

NOTE:The existingnumber on the connectingrod does not indicateits positionin the engine,it indicates the rod bore size.

lf you can feel a ridge of metal or hard carbon aroundthe top of eachcylinder,remove it with a r i d g er e a m e r A ) .F o l l o w t h er e a m e rm a n u f a c t u r e r ' s { instructions. the ridge is not removed,it may lf damagethe pistonsas they are pushedout.

7-13

EngineBlock
lnspection Crankshaft
Out-ol-Round and Taper 1. Removethe crankshaft from the cylinder block(see page7-121. with pipe 2. Cleanthe crankshaft passages oil cleaners r a suitable rush. o b 3. Cleanthe keywayand threads. 4. Measureout-of round at the middle of each rod and The differencebetween main journal in two places. measurements each journal must not be more on than the serviceIimit. Journal Out-ot-Round Standard(New):0.005mm (0.0002 max. in.) ServiceLimit; 0.010mm (0.0004 in.) . 9 . M e a s u r e u n o u to n a l l m a i nj o u r n a l sR o t a t e h e r t crankshaft two completerevolutlons. The differencebetweenmeasurements eachjournal on must not be more than the servicelimit. Crankshaft Total Runout Standard(New):0.03mm 10.0012 max. in.l ServiceLimit: 0.04mm (0.0016 in.l Straightness 6. Placethe cylinder blockon the surfaceplate. 7 . C l e a n n d i n s t a l l t h e e a r i g n s n t h e N o . 1a n d N o . 5 a b o j o u r n a lo f t h e c y l i n d e r l o c k . b 8. Lowerthe crankshaft into the block.

I_JJ fl
5. Measuretaper at the edgesof each rod and main journal.The differencebetweenmeasurements on eachjournal must not be more than the service limit. JournalTaper in.) StandardlNewl: 0.005mm (0.0002 max. in.) ServiceLimit: 0.010mm {0.0004

7- 14

Blockand PistonInspection
1 . Removethe crankshaft and pistons(see pageT -121. Checkthe pistonfor distortionor cracks, M e a s u r eh e p i s t o nd i a m e t e r t a p o i n t I 1 m m { 0 . 4 t a in.)from the bottom of the skirt.There are two pistons(No Letteror A, and B).The standard-size letteris stampedon the top of the piston.Letters are also stampedon the blockas cylinder bore stzes. Piston Diameter: Standard(Newl: No Letter {or A): 85.980 85.990 mm (3.3850 3.3854in.) B: 85.970-85.980mm (3.3846-3.3850 in.) Service Limit: No Lefter lor A): 85.930mm (3.3831 in.) B: 85.920mm 13.3827 in.) 4. Measurewear and taper in directionX and Y at t h r e el e v e l si n e a c hc y l i n d e r s s h o w n .l f a measurements any cylinder are beyondthe in oversizebore servicelimit. replacethe block.lf the block is to be rebored,referto step 7 after reboring. CylinderBore Size Standard(New): A or l: 86.010 86.020mm 13.3862 3.3866in.) B or ll: 86.000 86.010mm (3.3858 3.3862in.) Service Limit: 86.070 mm (3.3886in.) Oversize: O.25t 96.250 86.260 mm (3.3957 3.3961 in.) Reboringlimit: 0.25mm (0.01in.l max. Bore Taper: Limit: (Differencebetween first and third measurement) 0.05mm (0.002in.)
6 mm {0.2in.} First Measurement Second Measutement Third Measurement 6 mm {0.2in.}

Oversize Piston Diameter: -3.3953 in.l 0.25: 86.230-85.240mm (3.3949

(cont'd)

7-15

EngineBlock
Blockand PistonInspection(cont'd)
Scoredor scratched cylinderbores must be honed. Checkthe top of the blockfor warpage.Measure along the edgesand acrossthe centeras shown. Engine Block Warpage StandardlNew): 0.07mm (0.003in.) max. ServiceLimit: 0.10mm (0.004in.l 7. Calculate differencebetweenthe cylinder bore the diameterand the plstondiameter.lf the clearance is near or exceeds the servicelimit, inspectthe pistonand cvlinder blockfor excessive wear. Piston-to-Cylinder Clearance StandardlNew): 0.020 0.040mm {0.0008 0.0016in.) ServiceLimit: 0.05mm (0.002in.l
PISTON-TO-CYLINDER CLEARANCE

++

PRECISION STRAIGHT EDGE

7-16

Cylinder Honing
Only a scoredor scratched cylinderbore should be noneo. 'L M e a s u r eh e c y l i n d e r o r e s{ s e ep a g e7 - 1 5 ) . t b lf the block is to be reused,hone the cylindersand remeasure the bores. H o n et h e c y l i n d e r o r e sw i t h h o n i n go i l a n d a f i n e b (400grit) stone in a 60 degreecross-hatch pattern (A).Use only a rigid hone with 400 grit or finer stone such as Sunnen,Ammco, or equivalent.Do not use stonesthat are worn or broken.

3 . W h e n h o n i n gi s c o m p l e t et,h o r o u g h l y l e a nt h e c
engine blockof all metal particles. Wash the cylinder boreswith hot soapywater,then dry and oil them immediatelyto preventrusting.Never use solvent,it will only redistribute grit on the the cylinder alls. w lf scoringor scratches still presentin the are cylinderboresafter honing to the servicelimit, reborethe cylinder block.Some light vertical scoringand scratchingis acceptable it is not deep if enoughto catchyour fingernailand does not run the full length of the bore.

7-17

EngineBlock
Piston,Pin,and Connecting Rod Replacement
Disassembly
1. Removethe pistonfrom the cylinderblock (see page7 -12). 2 . A p p l ye n g i n e i l t o t h e p i s t o np i n s n a p r i n g s( A ) , o and turn them in the ring grooves until the end gaps are lined up with the cutoutsin the piston pin b o r e s( B ) . NOTE;Takecare not to damagethe ring grooves. 4 . Heatthe piston and connectingrod assemblyto about 158'F(70"C), then removethe piston pin.

\
Removeboth snap rings (A).Start at the cutout in t h e p i s t o np i n b o r e .R e m o v e h e s n a pr i n g s t carefullyso they do not go flying or get lost.Wear eve protection.

\"

7-18

Inspection
NOTE:Inspectthe piston,piston pin, and connecting rod when they are at room temperature. 1. Measurethe diameterof the piston pin. Piston Pin Diameter Standard(New):21.961 21.965mm (0.8646-0.8648in.) ServiceLimit: 21.953mm 10.8643 in.l

3. Checkthe differencebetweenthe DistonDin d i a m e t e r n d p i s t o np i n h o l ed i a m e t e r n t h e p i s t o n . a i Piston Pin-to-Piston Clearance Standard(Newl: -0.005 to +0.002 mm (-0.00020 to +0.00008 in.) ServiceLimit: 0.005mm (0.0002 in.)

4 . Measurethe piston pin-to-connecting clearance. rod Piston Pin.to-Connecting Rod Clearance Standard(New):0.005 0.015mm {0.0002 0.0006in.} ServiceLimil: 0.02mm (0.0008 in.l

2. Zerc the dial indicatorto the piston pin diameter.

v
(cont'd)

7-19

EngineBlock
(cont'd) RodReplacement Piston, Pin,and Connecting
Reassembly
1 . I n s t a l a p i s t o np i n s n a pr i n g ( A ) . l 4. Installthe piston pin (A).Assemblethe piston (B) and connectingrod (C)with the arrow (D)and the m e m b o s s e d a r k ( E )o n t h e s a m es i d e . -

Coatthe piston pin bore in the piston,the bore in the connectingrod, and the piston pin with engine oil.

3 . Heatthe pistonto about 158"F(70'C).

s 5 . I n s t a ltlh e r e m a i n i n g n a pr i n g ( F ) . 6 . T u r nt h e s n a pr i n g si n t h e r i n gg r o o v e su n t i l t h e end gaps are positionedat the bottom of the piston.

7 -20

PistonRing Replacement
1. Removethe piston{rom the cylinder block(see page 7 -121. 2. Using a ring expander(A),removethe old piston r i n g s( B ) . 4. Using a piston,push a new ring (A) into the c y l i n d e r o r e 1 5 - 2 0 m m { 0 . 6 - 0 . 8 i n . )f r o m t h e b bottom.

15 20 mm (0.6 0.8 in.)

I
B 3. Cleanall ring groovesthoroughlywith a squaredoff brokenring or ring groovecleanerwith a blade to fit the pislon grooves.The top and 2nd ring g r o o v e s r e 1 . 2m m ( 0 . 0 5 n , ) w i d e T h e o i l r i n g a i . groove is 2.0 mm (0.08in.) wide. Filedown a blade lf necessary. not use a wire brush to cleanthe Do ring grooves,or cut the ring groovesdeeperwith t h e c l e a n i n go o l s . t NOTE:lf the piston is to be separated from the connectingrod, do not installnew rings yet. Measurethe piston ring end-gap(B)with a feeler g au g e : . l f t h e g a p i s t o o s m a l l ,c h e c k t os e ei f y o u h a v e t h e p r o p e rr i n g sf o r y o u r e n g i n e . . l f t h e g a p i s t o o l a r g e ,r e c h e c k t h e c y l i n d e ro r e b diameteragainstthe wear limits (seeslep 4 on p a g e7 - 1 5 ) . . l f t h e b o r e i s o v e r t h es e r v i c e i m i t ,t h e c y l i n d e r l block must be rebored. PistonRing End-Gap Top Fing Standard(Newl: 0.20 0.35 mm (0.008 0.014in.l ServiceLimit: 0.60mm (0.024in.. SecondRing Standard(New):0.40-0.55 mm {0.016 0.022in.) ServiceLimit: 0.70mm (0.028in.) Oil Ring REKEN manufacturedring Standard(Newl: 0.25 0.65 mm (0.010 0.026in.l ServiceLimit: 0.75mm (0.030in.) FEDERAL MOGUL manufacturedrino StandardlNew): 0.20 0.70mm {0.008 0.028in.} ServiceLimit: 0.80mm (0.031in.)

(cont'd)

7-21

EngineBlock
(cont'd) PistonRing Replacement
6. Installthe top ring and secondring as shown.The t o p r i n g ( A )h a sa 1 R m a r ko r n o m a r ka n dt h e r s e c o n d i n g ( B )h a sa 2 R m a r ko r 2 N D m a r k .T h e marks must be facing upward. 8. Positionthe ring end gaps as shown:

OIL RINGGAP

About 90' SECOND RINGGAP

About 45"

TOP RINGGAP and SPACER RINGGAP

OIL RINGGAP PISTONPIN

o\,"16. s \

9. After installinga new set of rings,measurethe ring-to-groove clearances:

\5

=:-=2

V" 12-) V
P'ffi+a
\aq*-pogd

Top RingClearance Standard {New}: mm {0.0014-0.0024 in.) 0.035-0.060 ServiceLimit: 0.13mm (0.005in.) SecondRing Clearance StandardlNew): REKENmanutactured ring in.) 0.030-0.055 mm (0.0012-0.0022 FEDERAL MOGUL manulactured ring 0.025-0.060mm (0.001 0-0.0024in.) 0.13 mm (0.005 in.) ServiceLimit:

.ZR, V
Piston Ringoimensions: | | A| | t J o ToPRing{Standardl: A :3 . 1m m { 0 . 1 2n . l i m i B : 1 . 2 m { 0 . 0 5n . ) Socond Ring{Standard): A : 3 . 4 m { 0 . 1 3n . } m i B:'1.2 (0.05 mm in.i

7, Rotatethe rings in their groovesto make sure they do notbind.

7-22

PistonInstallation
lf the crankshaft already is installed
1. Setthe crankshafttobottom dead center(BDC) for e a c hc y l i n d e r . 2. Removethe connectingrod caps,then installthe ring compressor, and checkthat the bearingis securelyin place, 3. Positionthe arrow {A) facingthe cam chain side of r n ee n g t n e .

lf the crankshaft not installed is


1 . Removethe connectingrod caps.then installthe r i n g c o m p r e s s o ra n d c h e c k h a tt h e b e a r i n g s , t i s e c u r e l yn p l a c e . i

2. P o s i t i o nh e a r r o w( A ) f a c i n g h e c a m c h a i ns i d eo f t t
Ineengrne.

\--lno

n\-.--l. ^u

Positionthe piston in the cylinder,and tap it in u s i n gt h e w o o d e nh a n d l e f a h a m m e r( A ) . o N4aintain downward force on the ring compressor (B)to preventthe rings from expandingbefore enteringthe cylinder bore.

Positionthe piston in the cylinder,and tap it in u s i n gt h e w o o d e nh a n d l e f a h a m m e r( A ) , o Maintaindownward force on the ring compressor (B)to preventthe rings from expandingbefore enteringthe cylinder bore.

>-*/zi .,.'_\pf{
Stop afterthe ring compressorpops free, and journal checkthe connectingrod-to-crank alignmentbeforepushingthe piston into place. 6 . Checkthe connectingrod bearingclearance with plastigage(seepage7-8). 7 . lnspectthe connectingrod bolts (seepage 7 241. Apply engine oil to the bolt threads,then installthe rod capswith bearings. Torquethe bolts to 20 N.m {2.0kgf m, 14 lbf ft) + 90'.

wr

(( 'V,/ :

4. Positionall pistonsattop dead center.

7-23

EngineBlock
Rod Bolt Inspection Connecting
1 . Measurethe diameterof each connectinqrod bolt at DointA and ooint B.
35 mm

Installation Crankshaft
Special Tools Bequired . Driver07749-0010000 . Attachment, x 26 mm 07746-0010700 24 . Oil seal driver attachment o7ZAD-PNAAl00 96 1 . I n s t a ltl h e c r a n k s h a fe n d b u s h i n g i t h t h e s p e c i a l w t Drive in the tools when replacingthe crankshaft. c r a n k s h a fe n d b u s h i n gu n t i lt h e s p e c i atl o o l s t bottom aqainstthe crankshaft.

mm

07749-0010000

07746-00'l

Calculate differencein diameterbetweenpoint the A a n d p o i n tB . Point A-Point B = Difference in Diameter Diflerence in Diameter: Specification:0 0.1 mm (0 0.004in.)
I

\-

3 , lf the differencein diameteris out of tolerance,


replacethe connectingrod bolt. r c e C h e c k h e c o n n e c t i n go d b e a r i n g l e a r a n c w i t h t plastigage {seepage7-8). C h e c k h e m a i n b e a r i n g l e a r a n cw i t h p l a s t i g a g e t c e ( s e ep a g e7 - 6 ) .
4 . lnspecttheconnectingrod bolts (seepageT-241.

\-

7-24

5 . I n s t a l l t h e e a r i n g a l v e s n t h e c y l i n d e r l o c ka n d b h i b conneclrngrods. 6 . A p p l ya c o a to f e n g i n eo i l t o t h e m a i n b e a r i n g s n d a rod bearings. 7 . H o l dt h e c r a n k s h a f to r o d j o u r n a lN o . 2 a n d r o d s journal No. 3 are straightup, and lower the crankshaft into the block. ( 8 . l n s t a l l t h e h r u s tw a s h e r s A )i n t h e N o . 4 j o u r n a lo f t the cylinder block.

12. Tightenthe connectingrod bolts to 20 N.m (2.0kgf.m, 14 lbf.ft). 13. Tightenthe connectingrod bolts an additional90". 14. Removeold liquid gasketfrom the lower block mating surfaces, bolts and bolt holes. 15. Cleanand dry the lower block mating surfaces. 16. Apply liquid gasket,P/N 08718-0009, evenlyto the cylinderblock mating surfaceof the lower block a n dt o t h e i n n e r t h r e a d o f t h e b o l t h o l e s . s NOTE:Do not installthe parts if 5 minutesor more have elapsedsinceapplying liquid gasket.Instead, reapplyliquid gasketafter removing old residue.

.\

,i,
\-1

Apply liquid gasket alongthe broken line.

9 . Apply engine oil to the threadsot the connecting rod bolts,

1 0 .Seatthe rod journals into connectingrod No. 1 and


connectingrod No. 4. Line up the mark (B)on the connectingrod and cap,then installthe caps and bolts finger-tight. '11 Rotate . the crankshaft clockwise,and seatthe j o u r n a l s n t oc o n n e c t i n go d N o . 2 a n d c o n n e c t i n g i r rod No. 3. Line up the mark on the connectingrod and cap, then installthe caps and bolts finger-tight.

(cont'd)

7-25

EngineBlock
Installation(cont'd) Crankshaft
'17 . Putthe lower blockon lhe cylinderblock. 1 8 . Tightenthe bearingcap bolts in sequence to 29 N.m (3.0kgf m, 22 lbf.ft). 2'1. Use the specialtoolsto drive a new oil seal squarelyinto the blockto the specifiedinstalled height.

07749-0010000

07zAo-PNAA100 (A) Measurethe distancebetweenthe crankshaft a n d o i l s e a l( B ) . Oil Seal InsialledHeight: 5.5 6.5 mm |10.22 0.26 in.l
5.5-6.5 mm {0.22 0.26in.l

1 9 . Tightenthe bearingcap bolts an additional56". 20. Tightenthe I mm bolts in sequence 22 N.m 12.2 to kgf m, 16 lbf.ft).

7-26

OilPanlnstallation
23. Installthe baffle plates. 6x1.0mm 1 2N . m (1.2ksf m, 8.7lbf ft) 1 . Removeold liquid gasketfrom the oil pan mating surfaces, bolts,and bolt holes. 2 . Cleanand dry the oil pan mating surfaces. 3 . Apply liquid gasket,P/N 08718-0009, evenlyto the cylinderblock mating surfaceof the oil pan and to the innerthreadsof the bolt holes. NOTE:Do not installthe parts if 5 minutesor more have elapsedsinceapplying liquid gasket.Instead, reapplyliquid gasketafter removing old residue.

2 4 . I n s t a l l t h e i l p u m p ( s e ep a g e8 - 1 4 ) . o 25. Installtheoil pan (seepage7-27). 26. Installthecylinderhead (seepage 6-39). 27. Installthetransmission(seepage 13-8). 28. Installtheengine assembly(seepage 5-9).
Apply liquid gasket alongthe brokenline. 4. I n s t a l l t h e i l p a n . o 5. Tightenthe bolts in two or three steps.In the final

to s t e p ,t i g h t e na l l b o l t s ,i n s e q u e n c e , 1 2 N . m ( 1 . 2 kgf m, 8.7 lbf.ft). ( } @

(cont'd)

7-27

Engine Block
Oil PanInstallation(cont'dl
6 . l f t h e e n g i n ei s s t i l l i n t h e v e h i c l e i,n s t a l t h e l subframe, - 1 I n s t a l l t h e u b f r a m eA l i g nt h e r e f e r e n c e n e s s . li on the subframewith the bolt head center,then tighten the bolts (seestep 5 on page 5-10). -2 Tightenthe front mounting bolt (seestep 6 on p a g e5 - 1 0 ) . -3 Tightenthe rear mount mounting bolts (see s t e p7 o n p a g e5 - 1 1 ) . -4 Connectthe suspension lower arm ball joints (seestep 6 on page 18-19). 7. After assembly,wait at least30 minutes before f i l l i n gt h e e n g i n e i t h o i l . w Special Tools Required . Driver07749-0010000 . Oil seal driver attach ment 96 07ZAD-PNAA100 '1. D r y t h e c r a n k s h a f t i l s e a lh o u s i n g . o

Transmission EndGrankshaft Seal Installation In Car

2. Use the specialtools to drive a new oil seal squarelyinto the blockto the specifiedinstalled height. 07749-0010000

tr*W(r -]t fl\


OTZAD.PNAAlOO (A) Measurethe distancebetweenthe crankshaft a n d o i l s e a l( B ) . Oil Seal InstalledHeight: 5.5 6.5 mm 10.22-0.26in.l
5.5 6.5 mm l0.22- O.26in .l

/$rRfr4T

v
7-28

EngineMechanical

r_::::-l

t--l

EngineLubrication
SpecialTools
Ref. No.

\
Descriotion Oil FilterWrench

Tool Number 07HAA-PJ70100

Otv

I
\-

8-2

ComponentLocationIndex
WASHER

DRAINBOLT

OILPAN R e m o v ap , g e 1 1 la 7 page Installataon, 7-27

OILPUMP page OverhaLrl, 8-8

HL]

BAFFLEPLATE

OILPUMP CHAINTENSIONER

OILCONTROL ORIFICE

-&\JrI
ksrarr cKEr

PIPE OIL FILTER FEED page8-7 Replacement,

--t

lN-? dczt$)

N\
\

# 1

OILFILTER page8-6 Replacement, SWITCH OIL PRESSURE SwitchTest,page8 4 test, page8'4 Oil Pressure p, R e p l a c e m e n t a g e8 1 6

OIL PUMP CHAINGUIDE

8-3

EngineLubrication
Oil Pressure Switch Test
1 . R e m o v e h e Y E U R E D i r e ( A ) f r o mt h e e n g i n e i l w t o pressureswitch (B).

Oil Pressure Test


lf the oil pressureindicatorstayson with the engine r u n n i n g c h e c k h e e n g i n e i l l e v e l . f t h e o i l l e v e li s . t o l correct: '1. Connecta tachometer. Removethe engine oil pressureswitch,and install g a n o i l p r e s s u r e a u g e{ A ) .

2. Checkfor continuitybetweenthe positiveterminal


( C )a n d t h e e n g i n e( g r o u n d )T h e r es h o u l db e . continuitywith the engine stopped.There should be no continuitywith the engine running. lf the switch fails to operate,checkthe engineoil l e v e l . f t h e e n g i n eo i l l e v e li s O K .c h e c k h e e n g i n e l t oil pressure. the oil pressureis OK, replacelhe oil lf Dressure switch. Start the engine.Shut it off immediatelyif the gauge registersno oil pressure. Repairlhe problem beforecontinuing. 4. Allow the engineto reachoperatingtemperature (fan comes on at leasttwice),The pressureshould be: EngineOil Temperature: 176'F (80'Cl EngineOil Pressure: At ldle: 70 kPa (0.7kgf/cm', 10 psi) mtntmum At 3,000rpm: 300 kPa (3.1kgf/cm',44 psi) minimum lf the oil pressureis NOT within specifications, inspectthese items: . C h e c kh e o i l s c r e e n f o r c l o g g i n g . t . Checkthe oil pump (seepage8-8). . Checkcrankshaft and connectingrod bearing clearances.

\.

I
8-4

Engine Replacement Oil


1 . Warm up the engine. 2 . R e m o v e h e d r a i nb o l t ( A ) ,a n d d r a i nt h e e n g i n eo i l . t

A 44 N.m {i1.5 kgf.m,33lbf.ft) Donotovertighten.

3 . Reinstall drain bolt with a new washer (B). the


R e f i l l w i t h h e r e c o m m e n d e o i l ( s e ep a g e3 - 2 ) . d t Capacity 4.0 0 (4.2US qt) at oilchange. 4.2 014.4US qt) at oilchange includingfilter. 5.3 015.6US $) after engineoverhaul. 5 . Run the enginefor more than 3 minutes.then check for oil leakage.

8-5

EngineLubrication
Engine FilterReplacement Oil
Special Tool Fequired Oil filter wrench 07HAA-PJ70100 5. lf 4 numbersor marks (1 to 4 or V to VVVV) are printedaroundthe outsideof the filter, usethe following procedure tighten the filter. to . Spin the filter on until its seal lightly seatsagainst t h e b l o c k , n d n o t ew h i c h n u m b e ro r m a r ki s a t a the bottom. . Tightenthe filter by turning it clockwise3 numbersor marksfrom the one you noted.For example,if number 2 is at the bottom when the seal is seated,tightenthe filter until the number 1 comes around the bottom.

Engine Filter(3/4-turn Oil type)


1 . R e m o v e h e o i l f i l t e r w i t h t h e s D e c i ao o l . t tl 2. Inspectthe threads{A) and rubber seal (B)on the new filter. Wipe off the seat on the engine block, then apply a light coat of oil to the filter rubber seal. Use only filterswith a built-inbypasssystem.

Number when rubber seal is seated.

Number aftertightening.

\.. 2 or VV
1

I n s t a l l t h e i l f i l t e rb y h a n d . o After the rubberseal seats,tightenthe oil filter clockwisewith the specialtool. Tighten: Tighteningtorque: 3/4 turn clockwise. 12 N.m (r.2 kgf.m,8.7 lbf.ft)

N u m b eo r r Mark hen w r u b b es e a l s r i
N u m b e ro r Mark after tightening

1 or V
4

3 or VVV 2 or VV

4 or VVVV 3 or VVV

vvvv. v

or

or

6 . A f t e ri n s t a l l a t i o ni,l l t h e e n g i n e w i t ho i l u p t o t h e f specifiedlevel,run the enginefor more than 3 m i n u t e st,h e n c h e c k o r o i l l e a k a g e . f

07HAA-PJ70100

\,

8-6

Oil FilterFeedPipeReplacement
1 . Removethe oilfilter (seepage8-6). Removethe oil filter feed pipe.

3 . l n s t a l l t h e t w o 2 x 1 . 5 m m n u t s ( Ao n t o t h e n e w 0 ) oil filter feed pipe. Holdthe nut with a wrench,then tighten the other nut.

4 4 . T i g h t e n t ho i lf i l t e r f e e p i p e t o t h e l o c k t o 9N . e d b m {5.0kgf.m, lbf ft),thenremove nutsfrom 36 the the oil filterfeedoiDe.

8-7

EngineLubrication
OilPumpOverhaul
ExplodedView
BAFFLE PLATE 6x1.0mm 1 2N . m kgf {1.2 m,8.7lbf.ft)

6x1.0mm 12 N.m kgf.m,8.7 lbt ft) 11.2

P UI I "
EU

Ptr

(2.8kst m, 20 lbt ft) Apply nginoilto e e the boltthreads.

x 1 . 2 5m m 27 N.m

UPPER BALANCER SHAFTHOLDER

$--."Dowetem
DOWEL PIN BALANCER SHAFT BEARINGS

REAR BALANCER SHAFT


/=.---'n

t w

fs/

FRONT BALANCER SHAFT

SEALINGBOLT 39 N.m {4.0kgf.m,29lbf.ftl

LOWER BALANCER HOLDER SHAFT

\-

8-8

Oil PumpRemoval
1. Setthe No. 1 piston attop deadcenter{TDC) {see s t e p1 o n p a g e6 - 1 2 ) . 2 . R e m o v eh e o i l p a n ( s e e p a g e T - 1 1 ) . t 3 . R e m o v e n dd i s c a r dh e o i l p u m p c h a i n t e n s i o n e r . a t

6. Removethe oil pump sprocket(A),then removethe oil pump(B).

4. To hold the rear balancershaft,inserta 6 mm pin driver (A) into the maintenance hole in the lower balancershaft holderand through the rear balancer shaft.

5. Loosenthe oil pump sprocketmounting bolt.

(cont'd)

8-9

Engine Lubrication
Oil PumpOverhaul {cont'dl
Oil PumpInspection
1. Removehe pumphousing. t 3. Checkth e h ousing-to-roto axiaI clearance r between ( t h e r o t o r( A )a n d p u m p h o u s i n g B ) .l f t h e h o u s i n g to-rotoraxial clearance exceeds the servicelimit. r e p l a c eh e o i l p u m p . t Housing"to-Rotor Axial Clearance -0.003 in.l Standard(New):0.02 0.07 mm (0.001 (0.005in.l ServiceLimit: 0.12mm

Checkthe inner-to-outer rotor radialclearance betweenthe inner rotor (A) and outer rotor {B).lf the inner-to-outer rotor radialclearance exceeds the servicelimit, replacethe oil pump. Inner Rotor-to-Outer Botor Radial Clearance -0.006 in.) Standard{New):0.02 0.16mm (0.001 ServiceLimit: 0.20mm (0.008in.,
4 . Checkthe housing-to-outer rotor radialclearance

betweenthe outer rotor (A) and pump housing(B). lf the housing-to-outer rotor radialclearance exceeds the servicelimit, replacethe oil pump. Housing-to-Outer Rotor Radial Clearance StandardlNewl: 0.15 0.21mm (0.006-0.008in.l ServiceLimit; 0.23mm (0.009 in.)

\,

1'[1e-\1.-,-2
1 'a :.: ,-'r'

Inspectboth rotors and the pump housingfor parts if scoringor other damage.Replace necessary.

\-

8- 10

Balancer Shaft Inspection


1 . Seatthe balancershaft by pushingit away from the o i l p u m p s p r o c k ee n d o f t h e o i l p u m p . t

3. Removethe baffle plate (A) and upper balancer shaft holder {with bearings)(B),then removethe front balancershaft (C)and rear balancershaft (D).
9 H
L=] R j/

2 . Zero the dial indicatoragainstthe end of the


balancershaft,then push the balancershaft back and forth and readthe end olav. Balancer Shaft End Play: Fronl Balancer Shaft: Standard{Newl: 0.070 0.135mm {0.0028 0.0053in.} ServiceLimit: 0.15mm (0.006in.) Rear Balancer Shaft: Standard{New):0.070-0.135 mm (0.0028 0.0053in.l ServiceLimit: 0.15mm (0.006in.)

.r

''/

Rfl|] 3 eI ]U U B
+-

(cont'd)

8-11

Engine Lubrication
Oil PumpOverhaul(cont'dl
4. Measure innerdiameter the No. 1 bearing the of for thefrontbalancer shaftholeandthe rearbalancer shafthole. Bearing InnerDiameier: Front: (New): Standard 20.000-20.020 mm (0.7874 0.7882 in.) Service Limit; 20.03 mm (0.789 in.) Rear: Standard(New):24.000-24.020 mm in.) 10.9/t49-0.9457 ServiceLimit: 24.03mm (0.946 in.) Front: 5 . Measurethe diametersof the No. 1 journalson the
front balancershaft and rear balancershaft. NO.1Journal Diameter: Front: StandardlNew): 19.938 19.950 mm (0.7850 0.7854in.) ServiceLimit: 19.92mm {0.784in.) Rear: StandardlNewl: 23.938 23.950mm in.) {0.9424-0.9/129 ServiceLimit: 23.92mm (0.942in.) Front:

a
Rear:

8-12

6. Cleanboth balancershaft No. 2 journalsand bearinghalveswith a cleanshop towel. 7. Placeone strip of plastigage acrosseach No.2 journal.

1 0 . A l i g nt h e p u n c hm a r ko n t h e r e a rb a l a n c es h a f t r with the centerof the two punch marks on the front balancershaft,then install'thebalancershaftsin the lower balancershaft holder

8 . Reinstall bearingsand upper balancershaft the


holder,then torque the bolts. NOTE;Do not rotatethe balancershaft durinq insDection. 9 . Removethe uooer balancershaft holder and bearingsagain,and measurethe widest part of the plastigage. the balancershaft No. 2 journal oil lf is installthe new clearance out-of-tolerance. lf bearings,and recheck. it is still out-of-tolerance, replacethe balancershafts. No. 2 Journal Oil Clearance: StandardlNewl; 0.060 0.120mm ServiceLimit:

(0.0024 0.0047 in.l 0.15mm {0.006 in.)


1 1 .Apply engine oil to the threads of the 8 mm bolts
(A). 6x1.0mm '12N.m (1.2kgt.m,8.7 lbt ft)

1 2 . I n s t a l l t h e p p e rb a l a n c es h a f th o l d e r( B )a n d u r bafile plate (C).

(cont'd)

8-13

Engine Lubrication
Oil PumpOverhaul(cont'd)
p 13. lnstallthe umphousing.

Oil PumpInstallation
1. Make sure the No. 1 piston is at TDC (seestep 1 on p a g e6 - 1 2 ) . 2. Align the dowel pin{A} on the rear balancershaft with the mark (B)on the oil pump.

9%ttrc
6x1,0mm 1 2N . m (1.2kgt.m,8.7lbf.ft)
+:.:4.4 /

o/.-lY\

t\

To hold the rear balancershaft, inserta 6 mm pin driver {A) into the maintenance hole in the lower balancershaft holder and through the rear balancer shaft.

\,-

f,o-;

-rrdv

:aa:'

8- 14

4. Apply engine oil to the threadsof the oil pump sprocketmounting bolt (A).

8. Squeeze the new oil pump chain tensioner(A),then installthe set clip (B)on it as shown. N O T E T h e s e tc l i p i s s u p p l i e d i t h t h e o i l p u m p : w chain tensioner.

A 10x 1.25 mm {4 N.m (a.5kg{ m, 33 rbf.ftl

I
6x1.0mm 12N.m(1.2 kgf.m, 8.7rbf.ft)

9. Installthe oil DumD chain tensioner.

1 0 x1 . 2 5 m m ,l,t N.m {4.5kgf.m, 33 tbt.ftl

8 x 1,25 m m 22N m l2.2kot m.

r6 tbt.fti

, 5 . L o o s e l y n s t a l l t h e i l p u m p( B ) t h e ni n s t a l l t ho i l i o e pump sprocket(C).
Removethe pin driver (D). 7 . Tightenlhe oil pump mounting bolts.

(cont'd)

8-15
I

EngineLubrication
Oil PumpOverhaul(cont'dl
1 0 . R e m o v e h e s e t c l i pf r o m t h e o i l p u m p c h a i n t tensioner.

I
Oif Pressure Switch Replacement
1. Discon nectthe oil pressureswitchconnector, then removethe oil pressureswitch.

1 1 . I n s t a ltl h e o i l p a n ( s e ep a g e T - 2 7 ) .

2. Apply liquid gasketto the oil pressureswitch threads,then installthe oil pressureswitch.

8-16

EngineMechanical
IntakeManifoldand ExhaustSystem
lntake Manifold Removal Installation and ................. 9-2 Exhaust Manifold Removal Installation and .............. 9-7 Exhaust Pipe and Muffler Replacement ..................... 9-8

r-!i!1

System IntakeManifoldand Exhaust


and Installation lntakeManifoldRemoval
Exploded View:

8 x 1,25 m m 22 N.m {2.2kgf.m, 16 lbf ft}

I
INTAKE MANIFOLD or Replace cracked if if mating surfaceis

GASKET Replace.

'e) w)
INTAKE MANIFOLDPLATE if or Replace cracked if matingsurfaceis damaged. 6x1.0mm 1 2N . m {1.2kgf.m,8.7lbf.ft)

k
\ t9 \
8 x 1.255 x . 2 mm 22 ' m 2 2 Nm

'!

ksf kgf.m, 1 6 12.2

8 x 1.25 m m 22 N.m (2.2kgf m. 16 lbt.ft)

\-

9-2

Removal:
'1. Removethe intakemanifoldcover.

3. Disconnecttheintakeairtemperature(lAT)sensor connector(A),and removethe breatherhose (B), then removethe air cleanerhousingcover/intake ( a i r d u c ta s s e m b l y C ) .

2 . Removethe evaporative emission(EVAP) canister


hose (A),brakeboostervacuum hose (B),and vacuum hoses{C). 4. Fully open the throttle link and cruisecontrol link by hand,then removethe throttlecable (A) and cruisecontrol cable(B)from the links.Loosenthe locknuts{C).and removethe cablesfrom the bracket.

(cont'd)

9-3

IntakeManifoldand ExhaustSystem
IntakeManifoldRemovaland Installation(cont'dl
5. Be preparedto catch and clean up spilledcoolant. Removethe water bypasshoses,then plug the water bypasshoses. 9 . Removethe enginewire harnessconnectors and wireharness lamps romthe intake anifold. c f m . . . . Four injectorconnectors ldle air control (lAC)valve connector Throttleposition(TP)sensorconnector fvlanifold absolutepressure{lvlAP) sensor connector . Evaporative purge emission(EVAP)canister valve connector

'1 Removethe bolt securingthe intakemanifoldand 0.


bracket.

l 6 . R e l i e v e f u ep r e s s u r e( s e ep a g e1 1 - ' 1 4 4 ) . 7 . R e m o v eh e f u e ll i n e ( s e e p a g e l l - 1 4 9 ) . t 8. Removethe positivecrankcase ventilation(PCV) hose (A),harnessholder mounting bolt (B)and h a r n e s s l a m pm o u n t i n g o l t ( C ) . c b

1 1 .Removeallthe intakemanifold mounting bolts/ nuts.

1'>

Removethe two stud bolts (A),then removethe ( intake anifold B). m

\-

9-4

1. Installthe intakemanifold (A)with a new gasket(B), then installand tighten the two stud bolts (C).

4 . Installthe PCVhose {A), harnessholder mounting b o l t ( B ) ,a n d h a r n e s s l a m pm o u n t i n gb o l t( C ) . c

w
*& \
8 x 1.25 mm 22 N.m |.2.2k91.m. 16 tbt.ft) 8 x 1.25 mm 22 N.rn (2.2kgf m. 16 lbf.ttl

e-li*h,r

2. Tightenall intakemanifold mountlng bolts/nutsin a


patternin two or three steps,beginning crisscross with the inner bolt.
?

6x1.0mm 12N.m(1.2 kgf.m,8.7 lbf.ft) 5 . I n s t a l l t h e u e l l i n e ( s e ep a g e1 1 - 1 5 0 ) . f 6 . Installthewater bypasshoses.

Tightenthe bolt securingthe intakemanifold and bracket.

8 x 1.25mm 22 N.m (2.2ksf m, 16lbf.ft)

7 . I n s t a ltl h e t h r o t t l ec a b l e( s e ep a g e11 - 1 6 4 ) , e n th a d j u s t h e c a b l e( s e ep a g e1 1 - 1 6 3 ) . 8 . Installthe cruisecontrol cable (seepage 4-44). then adjustthe cable (seepage 4-45).

(cont'd)

9-5

lntake Manifoldand ExhaustSystem


IntakeManifoldRemovaland Installation(cont'd)
a h c 9 . l n s t a l l t h e i r c l e a n e r o u s i n g o v e r( A ) ,a n d connectthe IAT sensorconnector(B). 1 2 . I n s t a l l t h en t a k e a n i f o l d o v e r . i m c
6x1.0mm 1 2N . m l.1.2k91.m, 8.7 tbf.ftl

B hose(C). 1 0 .Installthe breather

C l e a nu p a n y s p i l l e d n g i n e o o l a n t . e c After installation, checkthat all tubes,hoses,and connectors are installedcorrectly. Inspectfor fuel leaks.Turn the ignition switch ON (ll) (do not operatethe starter)so that the fuel pump the runs for about 2 secondsand pressurizes fuel line. Repeat this operationtwo or three times,then checkfor fuel leakageat any point in the fuel line.
to.

hose(A),brake booster 1 1 .lnstallthe EVAP canister ( , h v a c u u m o s e B ) a n dv a c u u m o s e sC ) . h {

\-

Refillthe radiatorwith enginecoolant,and bleed air from the cooling systemwith the heatervalve open (seepage 10-6).

9-6

Exhaust ManifoldRemoval and Installation


1 . Removethe VTECsolenoidvalve (seepage 1'1-128). 2 . Removethe driveshaftheat shield(seepage 16-19). 3 . Removethe cover and exhaustmanifold bracket, then removethe exhaustmanifold.
8x 1.25 m m 22 N.m (2.2 kgf.m, 16lbt.ftl

#'-.GASKET Replace.

SELF-LOCKING NUT 10x 1.25 mm 44 N.m {4.5ksf.m, 33lbt.ftl Beplace.

1 0x 1 . 2 5 m m 44 N.m (4.5kgt.m, 33 lbl ftl Replace.

WASHEB 10x 1.25 mm 14 N.m {4.5kgl.rn, 33lbf.ft)

8 x 1-25 mm 22 N.m (2.2kgI m, 16lbf.ft) Replace. Tighten boltsin steps, the alternating to side. side

Installthe exhaustmanifoldand tighten the bolts/nutsin a crisscross patternin two or three steps,beginningwith the inner bolt. 5 . Installtheother parts in the reverseorder of removal.

9-7

lntake Manifoldand ExhaustSystem


ExhaustPipeand Muffler Replacement
nuts when reassembling. NOTE:Use new gasketsand self-locking

m 8 x 1.25 m 22 N.m (2.2kst.m. 16lbf.ftl Replace. Tightenthe bolts in steps, alternating side'to side. EXHAUST PIPE B HEATSHIELD

\,

6x1.0mm 9.8 N.m {1.0kgt.m,7.2 lbf ft}

GASKET Replace.

NUT SELF-LOCKING 1 0x 1 . 2 5 m m kgf.m, 33N.m{3.4 25 rbf.ft) Beplace.

SECONDARY HEATED OXYGEN SENSOR HO2SI {SECONDARY


il4Nm (4.5 ksf.m,33 lbf.ftl

8 x 1.25mm 22 N.m {2.2kgf m, 16lbf.ft) Replace. Tightenthe bolts in steps, alternating side to-side.

AIR FUELRATIO {A/F) SENSOR 44 N.m (it.s kgf.m, 33 lbf ftl

\-.

9-8

Engine Cooling
CoolingSystem
Component Location Index ......................................... 10-2 Radiator Test ..................... Cap .......... 10-3 RadiatorTest ............. 10-3 FanMotorTest .......... l0-4 Thermostat Test ...................... ........... 10-4 WaterPumpInspection ..................... 10-5 WaterPumpReplacement ................. 10-5 C o o l a nC h e c k. . . . . . . . . . . . . . t . . . . . . . . . . . . . . . .1.0 . .6 . . .- . Coolant Replacement ......................... 10-6 Thermostat Replacement .................. 10-8 WaterPassage Installation ................ 10-9 Water Installation Outlet .................... 10-9 Radiator FanReplacement and ................................... 10-10

FanControls
C o m p o n e n to c a t i oIn d e x . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0.-.1 .1 . . . . . . L n . . . . Symptom Troubleshooting Index ............................... 10-12 Circuit Diagram ......... 10-13 Radiator CircuitTroubleshooting Fan ........................ 10-14 Radiator Switch Fan Circuit Troubleshooting (Open) ........... . . . . . . . .1 0 - 1 6 . Radiator Switch Fan Circuit Troubleshooting (Short)........... . . . . . . . .1 0 - 1 6 . Radiator Switch Fan Test ................... 10-17 Radiator Switch Fan Reolacement .............................. 10-17

CoolingSystem
ComponentLocationIndex
\

WATER OUTLET, pa I n s t a l l a t i o n ,g e ' 1 0 - g

WATER PUMP page Inspection, 10-5 page Replacement. 10-5 PIPE CONNECTING RESERVE TANK WATER PASSAGE page Installation, 10-9

\\f

RADIATOR CAP

THERMOSTAT page 4 10 Test, page Replacement, 108

RAOIATORFAN SWITCH Test,page 10-17 page 10'17 Replacement,

RADIATOR page 10-'l0 Replacement, RADIATORFAN ASSEMgLY p, R e p l a c e m e n ta g e1 0 - 1 0 Fan MotorTest,page 10 4

A/C CONDENSER FAN ASSEMBLY page 10 10 Replacement, Fan Motor Test,page '10-4

\J
10-2

RadiatorCapTest
1. Removethe radiatorcap {A),wet its sealwith engine coolant,then installit on the pressure tester ( B )( c o m m e r c i a l la v a i l a b l e ) . y

RadiatorTest
1 . Wait untilthe engine is cool, then carefullyremove the radiatorcap and fill the radiatorwith engine coolantto the top of the filler neck. Attachthe pressure tester (A) (commercially a v a i l a b l et) t h e r a d i a t o r . o

Apply a pressureof 93 kgf/cm', l4 18 psi).

'123 kPa{0.95 1.25

3 . Checkfor a drop in pressure. 4 . lf the pressuredrops, replacethe cap. 3 . Apply a pressureot 93 '123kPa(0.95 1.25
kgf/cm', '14 18 psi).
4 . I n s p e cfto r e n g i n ec o o l a n t e a k s n d a d r o p i n l a

pressu re. Removethe tester,and reinstallthe radiatorcap.

10-3

CoolingSystem
FanMotor Test
1. Disconnect 2P connectors the from the radiatorfan motor and condenserfan motor.

ThermostatTest
Replace thermostatif it is open at room the remperalure. To test a closedthermostatl 1. Suspendthe thermostat(A) in a containerof water. Do not let the thermometer{B)touch the bottom of t h e h o tc o n t a i n e r .

Testthe motor by connectingbatterypower to the B t e r m i n a a n d g r o u n dt o t h e A t e r m i n a l . l lf the motor fails to run or does not run smoothly, r e p t a c eL r

2. Heatthe water, and checkthe temDerature with a


thermometer.Checkthe temperatureat which the thermostatfirst opens,and at which it is fully open.

\.

3 . Measurethe lift height of the thermostatwhen it is


f u l l vo o e n . STANDARD THERMOSTAT Lift height; above 8.0 mm (0.31in.) Starts opening: 169 176"F(76 80"C) Fullyopen: 194"F{90'Cl

10- 4

Water Pump Inspection


1 . Removethe drive belt (seepage 4-26), 2 . Turn the water pump pulleycounterclockwise. Checkthat it turns freely. Checkfor signs of seal leakage. small amount of A "weeping" from the bleed holes(A) is normal.

Water Pump Replacement


1. Removethe drive belt (seepage 4-26). 2 . D r a i nt h e e n g i n e o o l a n t s e ep a g e1 0 - 6 ) . c { 3 . R e m o v e h e c r a n k s h a fp u l l e y( s e ep a g e6 - 1 1 ) . t t 4. Removethe six bolts securingthe water pump, then removethe water pump (A).

6x1.0mm 1 2 N m { 1 . 2k g t m , 8.7 rbf.ft)

Inspectand cleanthe O-ring groove and mating surfacewith the water passage. I n s t a l l t h e a t e r p u m pw i t h n e w O r i n g si n t h e w reverseorder of removal. 7 . C l e a nu p a n y s p i l l e d n g i n e o o l a n t . e c 8 . I n s t a l l t h e r a n k s h a fp u l l e y( s e ep a g e6 - 1 2 ) . c t L R e f i l t h e r a d i a t ow i t h e n g i n e o o l a n ta n d b l e e d l r c , air from the cooling system with the heatervalve o p e n{ s e ep a g e1 0 - 6 } .

10-5

CoolingSystem
Goolant Check
1. Look at the coolantlevel in the reservetank. Make sure it is betweenthe MAX mark (A) and MIN mark (B),

CoolantReplacement
1 . Startthe engine.Set the heatertemperaturecontrol dial to maximum heat.then turn off the ignition switch.Make surethe engine and radiatorare cool to the touch. Removethe radiatorcap. Removethe splashshield(seestep 23 on page5-5). Loosenthe drain plug (A),and drain the coolant.

lf the coolantlevel in the reservetank is at or below the MIN mark, add coolantto bring it up to the l\4AX mark, and inspectthe cooling system for leaks.

\
Removethe reservetank drain cap (A),and drain the coolant.

\-

10-6

After the coolanthas drained,tighten the radiator and installthe reservetank drain plug securely. drain cap securely. 1 . Fillthe reservetank to the MAX mark (A) with Tvpe 2 HondaAll SeasonAntifreeze/Coolant (P/NO1999-9001).

Type 2 8. Pour HondaAll SeasonAntifreeze/Coolant into the radiatorup to the baseof the filler neck. NOTE: . Always use HondaAll SeasonAntifreeze/Coolant Type 2 {P/N01999-9001). Using a non-Honda c , t c o o l a n t a n r e s u l ti n c o r r o s i o nc a u s i n g h e cooling systemto malfunctionor fail. . HondaAll SeasonAntifreeze/Coolant Type 2 is a water. Premixture of 50% antifreeze and 507o m i x i n gi s n o t r e q u i r e d . EngineCoolant RefillCapacity includingthe reserve tank capacity of 0.53 4 (0.56 US gtl : 5.0 0 (s.3US qt)

r r L I n s t a l l t h e a d i a t o c a pl o o s e l y .

1 0 .Startthe engine,and let it run until it warms up (the


radiatorfan comes on at leasttwice). 1 1 .Turn off the engine.Checkthe level in the radiator, Type and add HondaAll SeasonAntifreeze/Coolant 2 if needed. r t P u tt h e r a d i a t o c a p o n t i g h t l y , h e n r u n t h e e n g i n e f a g a i na n d c h e c k o r l e a k s .
tJ.

lnstallthe splashshield(seestep 22 on page 5-12).

10-7

GoolingSystem
ThermostatReplacement
1 . D r a i nt h e e n g i n e o o l a n t( s e ep a g e1 0 - 6 ) . c 2. Removethe splashshield (seestep 23 on page 5-5). 3. Removethe lower hose,then removethe thermostat. 6x 1.0 m m 9.8N.m (1.0 gf.m,7.2lbf ) k ft

i*
THERMOSTAT LOWER HOSE 4. Installthethermostatwith a new O-ring,then installthe lower hose. 5 . I n s t a l l t h e p l a s h h i e l d( s e es t e p2 2 o n p a g e5 - 1 2 ) . s s 6. Refillthe radiatorwith engine coolant,and bleed air from the cooling systemwith the heatervalve open (seepage 10_6).

\_

10-8

Water Passage Installation


1 . Cleanand dry the water passagemating surfaces. Apply liquid gasketP/N 08718-0009, evenlyto the c y l i n d e r l o c km a t i n gs u r f a c e f t h e w a t e r p a s s a g e b o and to the inner threadsof the bolt holes. NOTE:Do not installthe parts if 5 minutesor more . h a v ee l a p s e d i n c ea p p l y i n g i q u i dg a s k e t I n s t e a d , s l reapplyliquid gasketafter removing old residue.

Water Outlet lnstallation


I n s t a l l t hw a t e r u t l e ( A ) w i t h n e wO - r i n gB ) , e o t a {

1 2 N m ( 1 . 2k g t m , 8 , 7 l b ff t )

( w 3 . I n s t a l l t h e a t e rp a s s a g e A ) w i t ha n e w O - r i n g( B ) .

.t':.:

m 1 0x 1 . 2 5 m 44N m {4.5 m.33 lbf.ft} kgt 4. After assembly,wait at least30 minutes before f i l l i n gt h e e n g i n e i t h o i l . w

10-9

Cooling System
Radiator and FansReplacement
1. Drainthe enginecoolant(seepage 10-6). 2. Removethe front bumper {seepage 20,85). 3. Removethe bulkhead. 4. Removethe upper radiatorhose and lower radiatorhose.
DRAINPLUG UPPER BADIATOR HOSE BADIATOB BAOIATOA FAN ASSEMBLY O.RING RADIATOR CAP

\LOWERCUSHION RADIATOR FAN

swtTcH
24Nm

{ 2 . 1k g l m . 1 7 l b l h l t

LOWER FADIATOR HOSE

RESERVETANK A/C CONDENSER FANASSEMBLY 9 . 8N m { 1 . 0 g f m , 7 . 2l b ff t ) k CONNECTORS RADIATOB FANSWITCH CONNECTOB

5. Disconnect fan motor connectors the and radiatorfan switch connector, then pull the radiatorup and out. 6. Removethe fan shroud assemblies and other partsfrom the radiator. 7 . I n s t a l l t h e a d i a t o r n t h e r e v e r s e r d e ro f r e m o v a l M a k es u r et h e u p p e ra n d l o w e rc u s h i o n s r e s e t s e c u r e l V . r i . o a 8 . I n s t a ltlh e b u l k h e a dn t h e r e v e r s e r d e ro f r e m o v a l A p p l y b o d y p a i n tt o t h e b u l k h e a d o u n t i n gb o l t s . i o . m 9 . F i l lt h e r a d i a t o w i t h e n g i n e o o l a n t n d b l e e dt h e a i r ( s e ep a g e1 0 - 6 ) . r c a

\.

10-10

FanControls
ComponentLocationIndex
UNDER.HOOD FUSE/RELAY BOX

RADIATORFAN RELAY

RADIATOBFAN SWITCH Test,page 10'17 p, R e p l a c e m e n ta g e ' 1 0 - 1 7 CONDENSER FAN ASSEMBLY Motor Test,page 10-4

RADIATORFAN ASSEMBLY Motor Test,page 10 4

10-11

FanControls
Symptom Troubleshooting Index
Beforeperformingany troubleshootingprocedures check: . Fuses . Grounds . Cleanliness and tightnessof all connectors

SYMPTOM
Radiator fan does not run at all Radiator fan does not run for enginecooling, but it runs with A,/CON Radiator fan runs with ignition switch ON (ll),Ay'C OFF, and enginetemperaturebelow 199"F(93"C)

PROCEDURE
(seepage 1O-14). RadiatorFanCircuilTroubleshooting RadiatorFan Switch CircuitTroubleshooting (Open) ( s e ep a g e1 0 - 1 6 ) . (Short) RadiatorFan Switch CircuitTroubleshooting (seepage 10-'16).

\ , 4

\-

10-12

CircuitDiagram
' : No.20loA)USA modd : Cm.de mod.l No.20l50A) UNDEN DASX FUSE/RELAY BOX

BOX UIIDEF HOOD FJSE/NILAY

lG2H0TiiAClill, 0N{lllrndSTABI llll)

10-13

FanGontrols
RadiatorFanCircuitTroubleshooting
1. Checkthe No. 4 (20A)fuse in the under-hood fuse/relaybox, and the No. 14 (10A)fuse in the under-dash fuse/relaybox. ls the tuse (s) OK? YES-Go to step 2. NO- Replace fuse (s) and recheck.l the 2. Removethe radiatorfan relayfrom the under-hood fuse/relaybox, and test it (seepage 22-51). ls the relay OK? YES Go to step 3. NO Replace the radiatorfan relay.t Does the radiatot fan run? 3. Measurethe voltage betweenthe No. 2 terminal of the radiatorfan relay 4P socketand body ground. YES Go to step 5. NO Go to step 6. RADIATOR FAN RELAY SOCKET 4P Disconnect jumper, and turn the ignition switch the ON {ll}. Checkfor voltage betweenthe No. 3 terminal of the radiatorfan relay 4P socketand b o d yg r o u n d . T e r m i n a li d e f I e m a l t e r m i n a l s s o e JUMPER WIRE 4 . C o n n e c t e N o .l a n d N o . 2 t e r m i n a l s o f t h e th radiatorfan relay 4P socketwith a jumper wire.

RADIATORFAN RELAY4P SOCKET

\-

BADIATOB RELAY SOCKET FAN 4P

Terminalside of femaleterminals

ls therebatteryvoltage? YES Goto step4. NO Replace under-hood the fuse/relay I box.


Termlnal of female side terminals

ls there battety voltage? YES-Go to step 9. NO Checkfor an open in the wire betweenthe under-hood fuse/relaybox and under-dash fuse/ relay box.l

\-

10-14

Disconnect radiatorfan motor 2P connector. the 7 . Checkfor continuitybetweenthe No. 1 terminal of the radiatorfan relay 4P socketand the No. 2 terminal of the radiatorfan motor 2P connector.

9 . Reinstall radiatorfan relay. the 1 0 .Disconnect radiatorfan switch 2P connector. the


1 1 .Connectthe No. 1 and No. 2 terminals,of the radiatorfan switch 2P connectorwith a jumper wire.
RAOIATOR SWITCH FAN 2P CONNECTOR

RAOIATOR REI-AY SOCKET FAN 4P

Terminal sideof female terminals

f-;

5\-'fl \ \r--

IJUMPER

I wrRE

Wiresideof female terminals FAN MOTOR2P CONNECTOR RADIATOR

Does the radiator fan run?

ls thete continuity?
YES- Replace radiatorfan switch.l the

YES-Go to step8.
N O - G o t o s t e p1 2 .

the NO Repair openin the wire between underhoodfuse/relay andthe radiator motor2P box fan terminal 2,I No. connector
8. Checkfor continuitybetweenthe No, 1terminal of the radiatorfan motor 2P connectorand bodv g round.
RADIATOR AN MOTOR2P CONNECTOR F

Removethe jumper wire, and measurethe voltage betweenthe No, 2 terminal of the radiatorfan switch connectorand body ground,
RADIATOR FANSWITCH 2P CONNECTOR

rftr

T-

ls there battery voltage? YES Checkfor an open in the wire between radiatorfan switch 2P connectorterminal No. 1 and body ground. lf the wire is OK, checkfor a poor g r o u n da t G 3 0 1 . 1 NO Repairopen in the wire betweenthe radiator fan switchterminal No. 2 and the under-hood fuse/relaybox.l

Wire side of femaleterminals

ls there continuity? YES Replace the radiatorfan motor.l NO Checkfor an open in the wire between radiatorfan motor 2P connectorterminal No. 1 and body ground. lf the wire is OK, checkfor a poor g r o u n da t G 3 0 1 . 1

10-15

FanControls
RadiatorFanSwitch Circuit (Openl Troubleshooting
1. Disconnect radiatorfan switch 2P connector. the 2 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s 3 . M e a s u r e o l t a g eb e t w e e n h e N o . 2 t e r m i n a lo f t h e v t radiatorfan switch 2P connectorand body ground.
RADIATOR FAN SWITCH2P CONNECTOR

RadiatorFanSwitch Circuit (Short) Troubleshooting


NOTE:After troubleshooting, perform the engine ( c o n t r o lm o d u l e( E C M ) i d l ee a r np r o c e d u r es e ep a g e l 11 , 1 3 9 ) . 1 . R e m o v e h e r a d i a t o f a n r e l a yf r o m t h e u n d e r - h o o d t r fuse/relaybox, and test it (seepage 22-51). ls the relay OK? YES Go to step 2. NO Replace radiatorfan relay.I the

2. Removethe radiatorfan switch,and test it (see p a g e1 0 - 1 7. ) Is the radiatot tan switch OK? YES Go to step 3. ls there battety voltage? YES-Go to step 4. NO- Repairopen in the wire betweenthe radiator fan switch 2P connectorterminal No. 2 and underhood fuse/relaybox.l Turn the ignition switch OFF,and checkfor continuitybetweenthe No. '1terminal of the radiatorfan switch 2P connectorand body ground.
RADIATOB FAN SWITCX2P CONNECTOR

NO

Replace radiatorfan switch.I the

Disconnect batterynegativecablefrom the the battery. 4 . Disconnect enginecontrol module {ECM)connector ) B ( 2 4 P a n d t h e u n d e r h o o df u s er e l a yb o x 1 4 P connector. Checkfor continuitybetweenthe No. 2 terminal of the radiatorfan switch 2P connectorand body grouno.
RADIATORFAN SWITCH 2P CONNECTOR

ls there continuity? YES Replace the radiatorfan switch.t NO Checkfor an open in the wire betweenthe radiatorfan switch 2P connectorterminal No. 1 and body ground. lf the wire is OK, checkfor a poor g r o u n da t G 3 0 1 . 1

lstnere continuity? YES Repairshort in the wire betweenthe radiator f a n s w i t c h2 P c o n n e c t otre r m i n a lN o . 2 a n d u n d e r hood fuse/relaybox.l NO Replace under-hoodfuse/relaybox.t the

\-

10-16

RadiatorFanSwitch Test
NOTE:Bleedair from the cooling system after installing the radiatorfan switch (seepage 10-6). 1, Removethe radiatorfan switchfrom the radiator ( s e ep a g e1 0 - 1 7 ) . 2 . S u s p e n dh e r a d i a t ofra n s w i t c h( A )i n a c o n t a i n e r t of water as shown.

RadiatorFanSwitch Replacement
1 . Disconnect radiatorfan switch connector, the then removethe radiatorfan switch (A). A 24 N m (2.4kgt.m,17lbt.ftl

2. Installthe radiatorfan switchwith a new O-ring(B).

3. Heatthe water, and checkthe temperaturewith a thermometer.Do not let the thermometer(B)touch the bottom of the hot conlainer. 4. Measurethe continuitybetweenterminal No. 1 and terminal No. 2 accordingto the table.
\ Operation Termina lTemperature 203'F ON 196" gs"C) (91" swtTcH 5' 15'F {3' 8'C) lowel OFF than the temoerature when it goes on 1

10-17

Fueland Emissions
Fueland Emissions Systems
SpecialTools 1't-2 General Troubleshooting Information I I-J DTC Troubleshooting lndex .... 11-7 Troubleshooting Symptom 1ndex............... 11 - 1 0 Descriptions System ................ 11-12 Howto SetReadiness Codes.. 11-46 F u e P r e s s u r e T e s.t. . . . . . . . . . . . . 1.-.1 4 5 l . 1. . F u e L i n e sn s p e c t i o.n . . . . . . . . .1.1 . 1 4 6 l I . . .FuelLine/Ouick-Connect Fittings Precautions ............. 11-148 FuelLine/Ou ick-Con nect F i t t i n gR e m o v a l. . . . . . . . . . . . .11.-.1 4 9 s .. . FuelLine/Ou ick-Con nect F i t t i n gls s t a l l a t i o.n. . . . . . . . .1.1 . 1 5 0 n . . .FuelPressure Regu lator R e p l a c e m e . .t. . . . . . . . . . . . . . . 1.1.-.1 . . 2 n . . .5 FuelFifter Replacement ........... 11-152 FuelPump/Fuel Gauge Sending . . . t . . . . . . . . 1.1.-.1 5 3 . . UnitReDlacemen . F u e P u l s a t i oD a m o e r l n R e p 1 a c e m e n.t. . . . . . . . . . . . . . 1.1.-.1 . . 4 .. . . .5 1. F u eT a n k e o l a c e m e n.t. . . . . . . . 1 - 1 5 5 l R . F u eG a u g e S e n d i n i t T e s . . . . .1 1 - 1 5 6 l U g .t . 11-158 Low lndicatorTest Fuel .................

PGM-FlSystem
Component Location Index .... 11-49 D T C r o u b l e s h o o t i n.g . . . . . . . . . . . T . . 11-52 MILCircuit Troubleshooting 11-97 ... DLCCircuit Troubleshooting 1 1 - 1 0 9 .. Injector Replacement ............... - 1 1 1 11 A,/F Replacement ......... 1 - 1 1 3 1 Sensor HO2S Secondary Replacement 11-113 ECT Reolacement Sensor ....... 1 - 1 1 4 1 CMPSensor {TDC B Sensor) Replacement 11-114 I A TS e n s oR e p l a c e m e.n t . . . . 1.1 - 1 1 5 r .. . Knock Replacement 1 1 - 1 1 5 .... Sensor CKP Sensor Reolacement ....... 1 - 1 1 6 1

IntakeAir System
I C o m o o n e nL o c a t i o nn d e x . . . . 1 1 - 1 5 9 t T h r o t t l e o d y T e s t . . . . . . . . . . . . . . 1.1.-.1 6 0 B . . Intake Bypass Air Control T h e r m a V a l v eT e s t . . . . . . . . . . .1.1 - 1 6 1 l . . A i r C l e a n e R e o l a c e m e n .t . . . . . .1 1 - 1 6 2 . r A i r C l e a n eE l e m e n t r R e o l a c e m e n.t. . . . . . . . . . . . . . . . . 1.1.-.1 . 2 . . .6 ThrottleCableAdjustment ...... 11-163 ThrottleCable Removal/lnstallation ............1-164 1 Th rottleBody Removal/ Installation .. 11-165 Th rottleBody Disassembly/ R e a s s e m b l v . . . . . . . . . . . . . . . . . .1.1 . . . 6 6 . . .-1 .

VTEC/VTC
Location Index .... 11-117 Comoonent D T C r o u b l e s h o o t i n.g . . . . . . . . .1 . 1 8 T . . 1 .- 1 VTCOil Control Solenoid Valve Removal/Test ............. 11-127 CMPSensor Replacement 11-128 A ... VTEC Valve Solenoid R e m o v a l / l n s o e c t.i . . n. . . . . .11-128 o. ...

ldle ControlSystem
11-129 . . D T CT r o u b l e s h o o t i n g. . . . . . . . . .1.I.- 1 3 0 A,/C SignalCircuit T r o u b l e s h o o t i n.S . . . . . . . . . . . . .I .t.-. t.5 5 . Alternator SignalCircu FR it T r o u b l e s h o o t i n.S . . . . . . . . . . . . . . 1.- 1 3 4 . 1. . EPSSignalCircuit T r o u b l e s h o o t i n.S . . . . . . . . . . . . . .1 .1 3 5 . 1 . -. Brake Pedal Position Switch Signal Troubleshooting .............1 - 1 3 7 Circuit 1 ldle SpeedInspection 11 - 1 3 8 E C Ml d l el e a r nP r o c e d u r e. . . . . . . 1 - 1 3 9 1

CatalyticConverter System
D T C r o u b l e s h o o t i n.g . . . . . . . . .1 . 1 6 7 T . . 1 .-

Location Index Component

PCVSystem
D T CT r o u b l e s h o o t i n g. . . . . . . . . .1. .- 1 6 8 . .1 PCVValveInsDection a n dT e s t . . . . . .11 -1 6 9 P C V a l v eR e o l a c e m e n.t. . . . . . . . .1 - 1 6 9 V 1

EVAPSystem
C o m p o n e nL o c a t i o nn d e x . . . . 1 1 - 1 7 0 t I . . . D T C T r o u b l e s h o o t i n.g. . . . . . . . .1.1 - 1 7 1 EVAPTwo Way ValveTest ......11-186 FuelTank VaoorControl ValveTest ... 11-187 E V A P a n i s t eR e p l a c e m e n.t. . 1 1 - 1 8 9 C r FuelTank VaoorControl V a l v eR e o l a c e m e n.t. . . . . . . . . .1. .- 1 8 9 .1

FuelSupplySystem
ComponentLocationIndex 11 - 1 4 0 Fuel Pump Circuit Troubleshooting 1 1 - 1 4 1 F u e lP r e s s r e R e l i e v i n g . . . . . . . .1.1 - 1 4 4 u . .

Fueland Emissions Systems


SpecialTools
Rel. No. Tool Number

\,
Description V a c u u mP u m p / G a u g e , 3 0 i n . H g 0 Vacuum/Pressure Gauge.0 4 in.Hg Backprobe Set Fuel Pressure GaugeAdapter Pressure GaugeAdapter FuelSenderWrench Hose,Oil Pressure A,/TPressure Hose A,/TLow Pressure GaugeW/Panel A,/TPressure Hose ,2,210 mm A,/TPressure HoseAdapter F u e lP r e s s u r e a u g e G FuelPressure GauoeSet

(L) @

otv
1 1

o o

@ @ @ @-t @-2 O-3 @-4 @ (iD

A973X-041-XXXXX 07JAZ-0010008 07sAz-001000A 07vAJ-0040100 07NAJ-P07010A 07xAA-001010A 07zAJ-S5AA200 07406-0020201 07406-0070300 OTMAJ-PY4O11A 07MAJ-PY40120 07406-004000A 07zAJ-S5A0100

2
1 1 1

I
*.'l)

UtB o

ffi

/'r';-:'-;--' At-''
o
-'-,---=---1,-'.

a=:t=' (F

--1

/6\ l\r
\-,/

)l

\7
@ \-

ut/t
'jt'
o
@ (i)

i-==.
*==-.2'l
-1,40-2, -3,@-4

\\h
\\:

\\d
o
@

\-

11-2

Troubleshooting General Information


Intermittent Failures
The term "intermittentfailure" means a svstem mav have had a failure.but it checksOK now. lf the MalfunctionIndicatorLamp (MlL)on the dash does not come on, checkfor Doorconnections looseterminals or at all connectorsrelatedto the circuitthat Vou are troubleshooting. 2. lf the MIL stayson, connectthe HondaPGM Tester (A) or an OBD ll scantool to the Data Link Connector{DLC)(B) locatedunderthe driver'sside o f t h ed a s h b o a r d .

Opensand Shorts
"Ooen" and "Short" are common electrical terms.An open is a breakin a wire or at a connection. short is A an accidental connectionof a wire to ground or to anotherwire. In simple electronics, this usuallymeans somethingwon't work at all. With complex electronics ( s u c h s E C M s ) t h i s a n s o m e t i m e s e a ns o m e t h i n g a c m works, but not the way it's supposedto.

How to Usethe PGMTesteror a ScanTool


3 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s
lf the MIL {Malfunction Indicator Lamp} has come on '1. S t a r tt h e e n g i n e n d c h e c k h e M I L { A ) . a t N O T E l f t h e i g n i t i o n w i t c hi s t u r n e dO N ( l l ) ,a n d : s the engine is not started, the MIL will stay on for ( 1 5 2 0 s e c o n d s s e ep a g e1 1 - 4 6 ) . Checkthe Diagnostic TroubleCode (DTC) and note it. Also checkthe freezedata.Referto the DTC T r o u b l e s h o o t i nIg d e x , n d b e g i nt h e a p p r o p r i a t e n a procedure. troubleshooting go 5 . lf you do not find any DTCS, to MIL circuit s t r o u b l e s h o o t i n(g e ep a g e1 1 - 9 7 ) . NOTE: . Freeze data indicates the engineconditionswhen the first malfunction,misfire,or fuel trim malfunction was detected. . The scantool and the Honda PGM Testercan readthe DTC,freezedata,currentdata,and other Engine Controll\4odule data. {EClvl) . For specificoperations, referto the user's manual that came with the scantool or HondaPGl\4Tester. lf the MIL did not stay lf the MIL did not come on but there is a driveability problem,referto the Symptom Troubleshooting Index i n t h i ss e c t i o n . lf you can't duplicate the DTC in Some of the troubleshooting this sectionrequires you to resetthe ECM and try to duplicatethe DTC.lf rhe problem is intermittentand you can't duplicatethe code, T d o n o t c o n t i n u eh r o u g ht h e p r o c e d u r e . o d o s o w i l l t , o n l y r e s u l t n c o n f u s i o n n d ,p o s s i b l ya n e e d l e s s l y i a replaced CM. E

;"PN/.- -:::--d V-: ! K->

w:ix&K#

(cont'd)

11-3

Fueland Emissions Systems


Information(cont'dl GeneralTroubleshooting
How to Resetthe ECM
You can resetthe ECM in eitherof two ways: . U s et h e O B Dl l s c a n t o o lo r H o n d aP G M T e s t e r t o resetthe ECM memory. Testeruser's Seethe OBD ll scantool or HondaPGI\4 manualsfor specificinstructions. ' Turn the ignition switch OFF,and removethe No. 6 ECU{ECM}(15A)fuse (A)from the under-hoodfuse/ r e l a vb o x ( B l f o r 1 0 s e c o n d s .

How to Removethe ECMfor Testing


1. Removethe passenger's dashboardlower cover kick panel (see the {seepage 20-63), passenger's page 20-63), and the glove box (seepage 20-63). 2. Removethe ECM mounting bolts (B)and the ECM

(c),

9.8 N.m {1.0kgf.m,7.2lbt.ft} 3 . R e m o v et h e E C M ( B ) .

How to Enda TroubleshootingSession (required afterany troubleshootingl


1. Resetthe ECM as describedabove. ( 2 . D o t h e E C Mi d l e l e a r np r o c e d u r es e ep a g e1 1 - 1 3 9 ) 3. Turn the ignition switch OFF. 4. Disconnectthe OBD ll scantool or Honda PGM Testerfrom the DLC. NOTE:The ECM is part of the immobilizersystem. lf vou replacethe ECM,it will have a different immobilizercode. In order for the engineto start, you must rewritethe immobilizercode with the Honda PGM Tester.

4. Installthe ECM in the reverseorder of removal.

\- ta
11-4

How to TroubleshootCircuitsat the ECM


Special Tools Required . DigitalMultimeterKS-AHM-32-003 or a (1) commerciallyavailabledigital multimeter . Backprobe (2) Set 07SAZ-0010004 1. Connect the backprobe adapters(A) to the stacking patchcords (B),and connectthe cords to a digital multimete(C). r

2 . U s i n gt h e w i r e i n s u l a t i o n s a g u i d ef o r t h e a contouredtip ofthe backprobeadapter,gently slide the tip into the connectorfrom the wire side until it touchesthe end of the wire terminal. 3. lf you cannot get to the wire side of the connector or the wire side is sealed(A),disconnect the connectorand probe the terminals(B)from the terminal side. Do not force the Drobeinto the connector.

Do not puncturethe insulationon a wire. Punctures can causeDooror intermittent electrical connections.

07sAz-001000A

(cont'd)

11-5

Fueland Emissions Systems


(cont'd) Information Troubleshooting General
for ECMUpdatingand Substitution Testing
Special Tools Bequired HondaInterfaceModule (HlM) EOS05435570 Usethis procedurewhen you haveto substitute a procedure. known-goodECM in a troubleshooting does not alreadyhave U pdatethe ECMonly if the ECN4 the latestsoftwareloaded, NOTE; . lMake sure the batteryis fully chargedbeforeyou updatethe ECN4. . To preventECMdamageduring the update,do not turn the ignition switch OFF,and do not use any of the vehicle'selectrical devices(light,horn, radio,etc. ). How to Update the ECM 1. Turn the ignition switch ON (ll).Do not startthe e n gI n e . 2. Connect the HondalnterfaceModule (HlM)to the Data Link Connector{DLC)(A) locatedunderthe s d r i v e r ' s i d eo f d a s h b o a r d . How to Substitute the ECM '1. Removethe ECMf rom the vehicle.

2. Installa known-goodECM in the vehicle. 3 . R e w r i t e h e i m m o b i l i z ec o d ew i t h t h e E C M t r procedurefrom the Honda PGM replacement Tester.lt allows you to startthe engine. 4. After completingyour tests,reinstall the original E C Ma n d r e w r i t e h e i m m o b i l i z ec o d ew i t h t h e r t p E C Mr e p l a c e m e n tr o c e d u r e n t h e H o n d aP G M o Tester gain. a

EOS05A35570

Do the ECM updateprocedureas describedon the HlN4 label and in the ECM updatesystem.

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11-6

DTCTroubleshooting Index
DTC Temporary DTC Detection ltem indication*) {MlL P 0 0 1( 5 6 ) 0 VariableValveTiming Control{VTC)Oil Control P 0 0 1( 5 6 ) 1 P 0 1 0( 3 ) 7 P 0 1 0( 3 ) 8
( P 0 1 1 21 0 ) P001 1 S o l e n o i d a l v eM a l f u n c t i o n V VariableValveTiming Control(WC) System Malfunction Note { s e ep a g e11 ' 11 8 ) ( s e ep a g e1 1 - 1 9 ) 1 ( s e ep a g e1 ' l - 5 2 1

(MAP) Manifold Absolute Pressure Circuit Sensor LowVoltaqe (MAP) Manifold Absolute Pressure Circuit Sensor HiqhVoltaqe
IntakeAir Temperature(lAT)SensorCircuitLow Voltaoe IntakeAir Temperature(lAT)SensorCircuitHigh Voltaoe EnglneCoolantTemperature(ECT) Sensor Range/ Performance Problem

(see age 1-53) p 1


(seepage 11-55) (seepage '11-56) { s e ep a g e1 1 - 5 7 ) ( s e ep a g e1 1 - 5 8 ) { s e ep a g e1 1 - 5 9 ) ( s e eD a q e1 1 - 6 0 ) ( s e ep a q e1 1 - 6 2 ) ( s e eD a q e1 1 - 6 4 ) ( s e ep a g e1 1 - 6 5 ) ( s e ep a g e1 1 - 6 5 ) ( s e ep a g e1 1 - 6 6 ) ( s e ep a g e1 1 - 6 7 ) ( s e ep a g e1 1 - 6 8 ) ( s e ep a q e1 1 - 7 0 ) ( s e eo a o e1 1 - 7 0 ) ( s e ep a g e1 1 - 7 1 )

( P 0 1 r 31 0 )
P 0 1 1 68 6 ) { P 0 1 1 76 ) { P0116

(ECT) Engine Coolant Temperature Sensor Circuit LowVoltaqe


EngineCoolantTemperature(ECT) SensorCircuit Hiqh Voltaqe Throttle Position(TP)SensorCircuitLow Voltaqe Throttle Posltion(TP)SensorCircuitHiqh Voltaoe CoolinqSVStem Malfunction Air Fuel Ratio(Ay'F) Sensor(Sensor1) No Activity Detected SecondaryHeatedOxygen Sensor (Secondary HO2S) (Sensor2) CircuitLow Voltaqe SecondaryHeatedOxygen Sensor (Secondary HO2S) ( S e n s o 2 ) C i r c u i t i q hV o l t a q e r H SecondaryHeatedOxygen Sensor (Secondary H02S) ( S e n s o2 ) S l o w R e s D o n s e r SecondaryHeatedOxygen Sensor(Secondary H02S) (Sensor2) HeaterCircuitMalfunction

P 0 1 1{8 ) 6 P 0 1 2t 7 \ 2 P 0 1 2{ 7 ) 3
( P012887) ( P013441)

P0128

P 0 1 3( 6 3 ) 7
( P013863)

P0137

P0138 P0139

P 0 1 3( 6 3 ) 9
( P014165) ( P017145) PO112 l'45)

PO\11 PO\l2

FuelSvstem Too Lean


FuelSystemToo Rich R a n d o mM i s f i r e

{ s e ep a g e1 1 - 7 2 ) { s e ep a q e11 - 7 2 ) (73) ( s e eo a q e1 1 - 7 2 ) P0303 P0304{74) P0304 N o . 4 C v l nder Misfire {seeDaqe11-72) " ; T h e s e D T C s r e i n d i c a t e d y a b l i n k i n g a l f u n c t i o nn d i c a t o lra m p ( M l L ) w h e nt h e S C Ss e r v i c e i g n a l i n e i s a b m i s jumped with the Honda PGM Tester. P0302(721

P0300 any and of P 0 3 0( 7 1 ) 1 (721 PO302 (73) P0303 (74) P0304 (7'1) P0301

P0300 any and of P0301 P0302 P0303 P0304 P0301 No. 1 Cyl n d e rM i s f i r e P0302 No.2 Cvl n d e rM i s f i r e P0303 N o . 3 C v l nder Misfire

{cont'd)

11-7

Fueland Emissions Systems


Index(cont'd) DTCTroubleshooting
\ (

KnockSensorCircuitN4alfunction Position(CKP) Crankshaft SensorIntermittent CamshaftPosition(CMP)SensorA No CamshaftPosition(CMP)SensorA Intermiftent ( s e ep a g e1 1 - 7 8 ) ( s e e a q e1 1 - 1 2 1 o i s e ep a g e1 1 - 1 2 1 )

PO4i{ ( P045191)
TU45I

Phqse G Yetrgb-le TiTing Velye _controlll/T!)

s e eo a o e1 1 - 1 2 2 CqJalyst SystemElficie-ncy Below Threshold s e eo a q e11 -1 6 7 ( ) F u e lT a n kP r e s s u r eF T PS e n s o r a n g e / P e r f o r m a n c e( s e e p a g e l l 1 7 1 ) R SensorCircuitLow V (FTP) FuelTank Pressure SensorCircuitHigh V Vehicle Deed ensor M S S C i r c u i t a l fu n c t i o n E n g i n e o n t r o M o d u l e( E C N 4 )o w e rS o u r c e i r c u i l C l P C S e r i a C o m m u n i c a t i o L i n kM a l f u n c t i o n l n 11-172

P0452

s e eD a q e1 1 - 1 3 0 ) ( s e ep a g e11 - 8 1 ) Referto the l\4ultiplex ControlSystem Troubleshooting ee {s ( s e ep a g e11 - 8 3 ) ( s e ep a S e11 ' 8 3 ) { s e ep a g e1 1 - 8 3 ) l\."

1 P 1 1 0(6 3 ) 1 P 1 1 0(? 3 P1 08ts' 1 ( P1121 11) P1122 J ll ( i j 1 1 2 85 )


P 11 2 9( 5 ) ( P115748) Pr 158 (48) P 11 5 9( 4 8 ) ( P 1 1 6 36 1 ( P 1 1 6 46 1 ) P 11 6 6( 4 1 ) P't121 Pl122 P11f,.8

(BARO) Barometric Pressure Sensor Range/ P e r f o r m a n Peo b l e m cr


( ) B a r o m e t r i P r e s s u r eB A R O S e n s o r i r c u i t o w c C L ( ) B a r o m e t r i P r e s s u r eB A R O S e n s o r i r c u i t i g h c C H T h r o t t l e o s i t i o n T P iS e n s o r i g n a lL o w e rT h a n P { S ( T h r o t t l e o s i t i o n T P ) e n s o r i g n a lH i g h e r h a n P T S S

(see age 1-63) p 1


tsee page I r-oJ,

( M a n i { o l d b s o l u t e r e s s u r el \ , 4 A P } n s o r i g n a l A P Se S G;tp"s" 1154) Loqer Than Expected ( * " p a S e11 5 4 ) ManifoldAbsolutePreisure (MAP)SeiiioiSgnul H i q h e r h a nE x T ) ( ( s e ep a g e1 1 - 8 4 ) A i r F u e lR a t i o( A V FS e n s o r S e n s o r ) R a n g e / 1 R e r f o r m a n cP r o b l e m e A i r F u e lR a t i o { A " FS e n s o r S e n s o 1 ) A F S T e r m i n a l ( s e ep a g e11 - 8 5 ) ) { r 'l) A i r F u e lR a t i o1 A V F )e n s o r s e n s o r A F S+ T e r m i n a l ( s e ep a g e11 - 8 6 ) S i Air FuelRatio{A,/F) Sensor{SensorI ) Slow Response ( ( s e ep a g e 11 - 8 8 ) A i r F u e lR a t i o( A / F ) e n s o r S e n s o r ) R a n g e / 1 S

( s e ep a g e1 1 - 8 9 ) Air Fuel Ratio(4,/F) Sensor(Sensor1) HeaterCircuit Malfunction p Air Fuel Ratio(A,/F) Sensor(Sensor1) HeaterSystem ( s e e a g e1 1 - 9 1 ) P 11 6 7( 4 1 )' Malfunction " : T h e s eD T C S r e i n d i c a t e d y a b l i n k i n g I L w h e n t h e S C Ss e r v l c e i g n a l i n e i s j u m p e dw i t h t h e H o n d aP G M b M s a Tester. * 1 r' 0 2 m o d e l

\.

11-8

DTC Temporary DTC Detectionltem indication*l {MlL P1259 VTECSystem l\4alfunction t22J P1291t20\ Electrical Load Detector(ELD) CircuitLow Voltaqe (20) P1298 Electrical Load Detector(ELD) CircuitHiqh Voltaqe
( P13618)

Page ( s e eD a q e1 1 - 1 2 3 ) ( s e eD a q el 1 - 9 2 ) ( s e eo a o e1 1 - 9 3 ) ( s e ep a g e1 1 - 9 5 ) ( s e ep a g e1 1 - 9 5 ) ( s e ep a g e1 1 - 1 7 5 ) ( s e ep a g e1 ' l - 1 8 0 ) ( s e eo a q e1 1 - 1 6 8 1 { s e ep a q e1 1 - 1 3 1 ) ( s e ep a g e11 - 9 6 )

P 1 3 6( 8 ) 2 (90) P'r456 ( P 1 4 s 79 0 ) P 1 5 0( 1 0 9 ) 5
( P 1 5 1 91 4 ) ( P1607 ) P1456 P1457 P1505

CamshaftPosition(CMP)SensorB (Top DeadCenter (TDC) Sensor)Intermittent Sional InterruDtion CamshaftPosition(CMP)Sensor B (Top DeadCenter (TDC) ensorNo Siqnal S ) Evaporative Emissions(EVAP) ControlSystem Leakaqe(FuelTank Svstem) Evaporative Emissions(EVAP) ControlSystem Leakaqe(EVAP Canister Svstem) PositiveCrankcase Ventilation(PCV) Leakaqe Air ldle Air Control(lAC)ValveCircuitMalfunction

( E n g i n C o n t r oM o d u l e E C MI)n t e r n a l i r c u i t e l C Malfunction

" : TheseDTCS indicatedby a blinking MIL when the SCSservicesignal line is jumped with the Honda PGM are Tester.

11-9

Systems Fueland Emissions


Index Symptom Troubleshooting
with the scantool. lf there is no trouble code (DTC) When the vehiclehas one of these symptoms,checkthe diagnostic for DTC,do the diagnosticprocedure the symptom, in the sequencelisted,until you find the cause. Svmotom E n g i n e i l l n o t s t ar t w (MlL works OK, no DTCS set) Diaqnostic procedure 1. Testthe battery{seepage 22-50). 2. Testthe starter(seepage 4-8). 3. Troubleshoot fuel pump circult(seepage 11 the 141). '1-97). Also check lor Low compressron No ignition park s lntake irleaks a Locked p engine u t B r o k e n i m i n gc h a i n fuel Contaminated

w E n g i n e i l l n o t s t a r t( M l L comes on and stayson, or n e v e rc o m e so n a t a l l ,n o DTCSset) Enginewill not start (immobilizerindicatorstays on or flashs)

Troubleshoot the l\4lLcircuit(seepage 1

Troubleshoot the immobilizersystem (seepage 22-165).

Hardstarting (MlLworksOK,no DTCS set)


Coldfast idle too low (MlL works OK. no DTCS set) Coldfast idle too high (MlL works OK, no DTCS set)

1. Testthe battery(seepage22-50). ( 2 . C h e c k t h e u e l p r e s s u r e s e ep a g e1 1 - 1 4 5 ) . f

Low compression Intake irleaks a fuel Contaminated

ldle speedfluctuates (MlL works OK, no DTCS set)

After warming up, idle speed with is below specifications no load set) {MlL works OK, no DTCS After warming up, idle speed with is above specifications no toao (MlL works OK. no DTCS set) Low power (MlL works OK, no DTCS set)

( 1 . D o t h e E C Mi d l e l e a r np r o c e d u r es e ep a g e1 1 - 1 3 9 ) . ( s e ep a q e1 1 - 1 3 8 ) . i 2 . C h e c k t h ed l es D e e d ' ] D o t h e E C I \ 4d l e l e a r np r o c e d u r es e ep a g e11 -1 3 9 ) . ( i 2. C h e c k t h e d l es p e e d{ s e ep a g e1 1 - 1 3 8 ) . i '1-'163). the 3 . Inspect/adjust throttlecable (seepage 1 Inspectand test the throttle body {seepage 11-160}. ( a 1 . D o t h e E C Mi d l e l e a r np r o c e d u r es e ep a g e1 1 - ' 1 3 9 ) .I n t a k e i r l e a k s 2 . C h e c k h e i d l es p e e d( s e ep a g e1 1 - 1 3 8 ) . t 3, Inspecvadjust e throttlecable (seepage 11''163). th 4. Insoectand test the throttle bodv (seepaqe 11-160) ( 1 . D o t h e E C I V d l e l e a r np r o c e d u r es e ep a g e11 -1 3 9 ) . Vacuum hose clogged/ iI FRsignalcircuit (see cracked/poor 2. Troubleshootthealternator p a g e1 1 - ' 1 3 4 ) . connectron 3. InsDect and test the throttle bodv {seepaqe 11-160). 1 . D o t h e E C Mi d l e l e a r np r o c e d u r es e ep a g e1 ' j - 1 3 9 ) . { 2 . T r o u b l e s h o o h e a l t e r n a t oF Rs i g n a lc i r c u i t ( s e e tt r p a g e1 1 - 1 3 4 ) . 1 . C h e c kh ef u e lp r e s s u r e ( s e e p a g e l l - 1 4 5 ) . t 2. Inspectand test the th roftle body (seepage 11-160). st c 3 . I n s p e c v a d j u t h e t h r o t t l e a b l e( s e ep a g e1 1 - ' 1 6 3 ) . Low compressron C a m s h a ftti m i n g problem o Engine il level prootem lntake irleaks a h a Faulty arness nd sensorconnections

\-

Engine talls s (MlL works OK. no DTCS set)

1. 2. 3. 4.

( D o t h e E C Mi d l el e a r np r o c e d u r es e ep a g e1 ' l ' 1 3 9 ) . C h e c kh ef u e lp r e s s u r e { s e e p a g e l l - 1 4 5 ) . t C h e c k h e i d l es p e e d( s e ep a g eI 1 - 1 3 8 ) . t Troubleshootthebrakepedal positionswitch signal ( c i r c u i t s e ep a q e1 1 - 1 3 7 ) .

\-

11-10

Symptom
Difficultto refuel (MlL works OK. no DTCS set)

Fueloverflowsduring refueling (No DTCS set)

Diagnosticprocedure 1 . T e s t t h e f u e lt a n kv a p o rc o n t r o l a l v e { s e e p a g e ' l v 1 2. 1471. I n s p e ctth e f u e lt a n kv a p o rc o n t r o l i g n a lt u b e s 3. betweenthe fuel pipe and the fuel tank vapor control valve. 4. Inspectthe fuel tank vapor vent tube betweenthe EVAPcanisterand the fuel tank vapor control valve. Checkthe EVAPcanister. Replace fuel tank vapor control valve (seepage '1 the 1 189).

Also checktor
M a l f u n c t i o n i ng a s g s t a t i o n i l l i n gn o z z l e . f

Malfunctioning gas stationfilling nozzle.

11-11

Systems Fueland Emissions


SystemDescriptions
ElectronicControl System
The functionsof the fuel and emlssioncontrol systemsare managedby the enginecontrol module (ECM). Fail-safeFunction ignoresthat signaland assumesa pre-programmed When an abnormalityoccursin the signalfrom a sensor,the ECI\4 value for that sensorthat allowsthe enqineto continueto run. Back-up Function of When an abnormalityoccursin the ECM,the injectorsare controlledby a back-upcircuitindependent the systemto p e r m i tm i n i m a ld r i v i n g . Self-diagnosis When an abnormalityoccursin the signalfrom a sensor,the ECM suppliesground for the malfunctionindicatorlamp trouble code {DTC)in erasablememory.When the ignition is first turned on, the EClvl {MlL) and storesthe diagnostic for suppliesground to the l\4lL 15 to 20 secondsto checkthe M lL bulb condition. Two Driving Cycle Detection Method functions. the "two driving cycle detectionmethod" is usedfor some self-diagnostic To preventfalse indications, When an abnormalityoccurs,the ECM storesit in its memory. When the same abnormalityrecursafterthe ignition t s w i t c hi s t u r n e dO F Fa n d O N ( l l )a g a i n , h e E C Mt u r n so n t h e M l L .

\.

11-12

ECMData
You can retrievedata from the ECI\4 connectingthe OBD ll scantool or the Honda PGM Testerto the data link by connector(DLC). The items listedin the table below conform to SAE recommendedpractice. The HondaPGM Tester also readsdata beyondthat recommendedby SAEto help you find the causesof intermittentproblems. The "operatingvalues" listedare approximateand may vary dependingon the environmentand the individual vehicle. Unlessnoted otherwise,"at idle speed" means idling with the enginecompletelywarmed up in the neutralposition, and the A,/C and all Diagnostic Trouble Code (DTC} lf the ECM delectsa problem, it will store it as a code consistingof one letterand four numbers.Dependingon the problem,an SAE-defined code (Poxxx) a Honda, or definedcode {P1xxx)will be output to the tester. l f n o p r o b l e mi s detected, there is no ourpul. YES

TheECI\4 computes fromthe signals engine speed sent N e a r l y h e s a m ea s t position (CKP) fromthe crankshaft sensor. Thisdatais tachometerindication for used determining timeandamount injected the fuel. At idle speed; of
The ECMconvertspulsesignalsfrom the vehiclespeed sensor(VSS). Manifold Absolute Pressure (MAP) The absolutepressurecausedin the intakemanifold by e n g i n el o a da n d s p e e d . N e a r l y h e s a m ea s t speedometer indication

Withengine stopped:

YES

Nearlythe same as almospnencpressure. At idle speed:about 20 4'1kPa ( 1 5 0 3 1 0m m H g , 6 - 1 2 i n . H q ) . 0 . 71 . 3V The ECTsensorconvertscoolanttemperatureinto voltage W i t h c o l d e n g i n e : and signalsthe ECM.The sensor is a thermistorwhose S a m ea s a m b i e n t internalresistance changeswith coolanttempetature.The temperatureand IAT ECM usesthe voltagesignalsfrom the ECTsensorto With enginewarmed determinethe amount of injectedfuel. u p ; a b o u t1 1 6 2 ' 1 2 " F The A,/F sensordetectsthe oxygen content in the exhaust 0.0- 1.25 V g a s a n d s e n d sv o l t a g e i g n a l s o t h e E c l v l , a s e d o n t h e s e 8 . 0 1 1 . 0 m A ( P G M s t B signals,the ECMcontrolsthe airlfuel ratio.When the I Tester) oxygen contentis high (that is, when the ratio is leaner At idle speed: than the stoichiometric ratio),the voltagesignal is Iower. about 0.1 0.9 V When the oxygencontent is low (that is, when the ralio is richerthan the stoichiometric ratio).the voltagesignal is higher.The A'lFsensorsignalsare electrical currentthat are indicatedas voltaqe on the The HO2Sdetectsthe oxygen contentin the exhaustgas 0.0 1.25 V a n d s e n d sv o l t a g e i g n a l s o t h e E C M .B a s e d n t h e s e s t At idle speed: o signals,the ECMcontrolsthe airlfuel ratio.When the a b o u t0 . 1 0 . 9V oxygen contentis high (that is, when the ratio is leaner than the stoichiometric ratio),the voltagesignal is lower. When the oxygen content is low (that is, when the ratio is r i c h e r h a nt h e s t o i c h i o m e t r irc t i o ) t h e v o l t a g e i g n a li s t a , s

1 0 0 ' c ) . 0 . 5 - 0 .v 8

Air Fuel Ratio ( A y ' F )e n s o r . S (Sensor1)

Secondary Heated Oxygen Sensor (Secondary H02S, Sensor2)

NO

(cont'd)

11-13

Systems Fueland Emissions


(cont'd) SystemDescriptions
ECMData(cont'd)
Data FuelSystem Status Description "open" or "closed". Fuelsystem statusis indicatedas Sensoroutput,the ECM Closed:Basedon the A,/F determinesthe airlfuel ratio and controlsthe amount of injectedfuel. Sensoroutput,the ECM refersto Open: lgnoringAy'F signalsfrom the throttle position{TP),manifoldabsolute pressure(MAP),intakeair temperature(lAT),barometric pressure(BARO), and enginecoolanttemperature(ECT)) sensorsto controlthe amount of iniectedfuel. for The airlfuel ratio correctioncoefficient correctingthe Short Term amount of injectedfuel when the fuel system status FuelTrim is "closed." When the ratio is leanerthan the short term fuel sloichiometricratio,the ECM increases trim gradually,and the amount of iniectedfuel increases. The airlfuel ratio graduallygets richer,causinga lower the oxygen content in the exhaustgas. Consequently, short term fuel trim is lowered,and the ECM reducesthe amount of injectedfuel. This cvcle keepsthe airlfuelratio closeto the ratio when in closedloop status. stoichiometric Long term fuel trim is computedfrom short term fuel trim LongTerm changesoccurringin the fuel supply system and indicates F u eT r i m l long period. over a l f l o n gt e r m f u e lt r l m i s h i g h e rt h a n 1 . 0 0t,h e a m o u n lo f the lf injectedfuel must be increased. it is lower than 1.00, amount of injectedfuel must be reduced. The IAT sensorconvertsintakeair temperatureinto Intake Air a t Temperature v o l t a g ea n d s i g n a l s h e E C M .W h e n i n t a k e i r ofthe sensor temperatureis low, the internalresistance {IAT) increases, and the voltagesignal is higher. pedal position,the opening Basedon the accelerator Throttle throttlevalve is indicated. anole of the Position lgnitiontiming is the ignition advanceangle set by the lgnition ECM.The ECM matchesignitiontiming to driving Timing conditions. Opera'tingValue At idle speed:closed Freeze Data

r a
YES

o.7 1.5

YES

0.8 1.2

YES

w
W i t h c o l de n g i n e : S a m ea s a m b i e n t a t e m p e r a t u r e n dE C T At idle speed: a b o u t1 0% At idle speed:8" t 5" | ' t u L w n e nr n e > L ) s e r v i c e i g n a l i n ei s s jumped with the Honda PGM Tester At idle speed: 12 34% At 2.500rpm with no toao: 't4- 34%

YES

YES NO

Calculated L o a dV a l u e (cLV)

from IMAP data. cLV is the enoine load calculated

YES

\.,

11-14

J/-\ -1\_/

BEIAY2

A/C CLUTCHRELAY

I
)
RAOIATOR

T
UNDER.HOOD FUSE/RELAY BOX: (8oA) ONo. 19BATTERY (ECM) (15A1 ONo.6 ECU (3)No.20lG {40A1 {Canada:50A} ONo.l4 OPTION {40A1 uP )No.9 BACK (7.5A1 lo)No. HORN, 7 STOP {15A} UNDER.DASH FUSE/RELAY BOX: PUMP ONo. 17FUEL {15A} ,t ACG{10A) @No. (1sA) ONo.1 IGNCOIL q)No.10METER (7.5A) 0)No.14A/C CLUTCH RELAY IlOA) @No.2+B LAF(A/F) (2OA) HEATER

(cont'd)

11-15

Fueland Emissions Systems


(cont'dl SystemDescriptions
ECMElectrical Connections
\

MAPSENSON No. INJECTOR

No,2INJECTOR TPSENSOR

No.3 INJEC]OB

No./tINJECTOF

IATSENSOR

ECTSENSOB

\'

CMP SENSOR B (TDCSENSOSJ

CKPSENSOR

FVERSE LOCK SOLENOIDVAIVE

\-

11-16

A/FSENSOR

EVAPCANISTE6 PURGEVAIVE

EVAPCANISTER VENTSHUTVATVE

A/FSENSOR (sENSOn 1)

sotENotovAtvE

CMP SENSOFA

VIC OIL CONTROL SO!ENOIDVALVE No. 1 IGNITIONCOIL

wEcorl
N o . 2 l G N l l l O NC O I L

PRESSUSE SWTICH

No. 3 IGNITION COIL

VTEC SOLENOID

No. a IGNITIONCOIL

{cont'd)

11-17

Fueland Emissions Systems


(cont'd) SystemDescriptions
ECMElectrical Connections
\

ARAKEPEDAL POStTtON SWTTCH

GAUGEASSEMBLY

IMMOBILPENUN|T

EPSCONTROT UNIT

TERMINALLOCATIONS

\-

11-18

ECMInputsand Outputsat Connector (31P) A

2 1 AFS]TC ]GP2 '10 SG2 22 t1

3 IGPl

^:^ I -:,

6 AFS+

1 CKP

I KS 18 1 9 2A V S S IVAP vcc2

12 ACV

15 T6 TPS AFS_ 26 25 CMPB CMPA(rDc)

vccl

21

23 HTC+ LG2

27 28 29 30 tGPts,lrcPts3 tGPts2GPLS 1

Wire side ol femaleterminals NOTE: Standardbatteryvoltageis 12V. Terminal Who color numbr ELKAVHT forminal name (AIR AFSHTC FUEL RATIO (4./F)SENSOR HEATER CONTROL} (POWEB IGP2 SOURCE) IGPl {POWER SOURCE) Description DrivesAy'F sensorheater Power source the ECM for circuit Power source the ECM for Ground forthe ECMcircuit Ground forthe ECMcircuit Detects sensor Ay'F 1) {sensor signal Detects CKP sensor signal Detects knock sensor siqnal qrounr Sensor qroun( Sensor DrivesIACvalve Detects sensor TP signal Detects sensor !y'F ( s e n s o r) s i g n a l 1 Detects VSSsignal Wath ignition switch (lli andfrontwheels ON rotating: cycles from about0 V to about5 V or Signal Withignit'on switch {ll):battery ON voltage Withfullywarmedup engine runnang:V 0 Withthe ignition switchON 1ll): battery voltage Withthe ionition switchOFF: about0 V Withthe ignition swatch {ll):battery ON voltage Withthe ionition switchOFF: about0 V Less than 1.0V at all times Less than 1.0V at all times

2
3 4 5 6 1 9 10 12

YEUBLK
YEUBLK BLK

18

PG2(POWER GROUND PG1(POWER GROUND AFS+ (AIR FUEL RATIO (A,/F}SENSOR, SENSOR 1 + stDE) 8LU CKP(CRANKSHAFT POSITION SENSOR) BED/BLU ) KS E N S O B ) YEL 2 {SENSOR R O U N D ) ; G 1{ S E N S O R O U N D ) ;R BLIVRED IACV(IDLE CONTROL AIR (IAC)VALVE) RED/BLK TPS(THROTTLE POSITION SENSOR) REDI/EL AFS (AIR FUEL RATIO (4,/F)SENSOR, SENSOB 1 SIDE) WHT/GRN V S S ( V E H I C L E P E E D S

BLK RED

pulses Withengine running: pulses Withenqine knocking: Lessthan 1.0Vat elltimes L e s s t h a 1 . 0 Va t a l l t i m e s n Withengine runningr dutycontrolled Withthrottle fullyopen:about4.8V Withthronle fullvclosed: ahout0-5V

SENSOR)

(cont'd)

11-19

Fueland Emissions Systems


SystemDescriptions {cont'd)
A ECMInputsand Outputsat Connector (31P)

\. il

1 AFS]TC

2 GP2

3 IGPl

4 PG2

12 10 11 SG2 sG1 IACV


22 23 AFS LG2 HTC+

5 6 PG.1 AFS+ '15 1 6 TPS AFS_

1 CKP

I KS

18 1 9 20 V S S IVAP vcc2

vccl

21

26 25 CMPB Ct\.4PA (rDc)

29 30 27 28 IGPLS,I IGPLS4 IGPLS3 IGPLS2

Wire side of femaleterminals voltage 12V. is NOTE: Standard battery [rminal namo Description Jorminal Wirecolor number MAPsensor 19 Detects signal GRN/RED MAP(MANIFOLD PRESSURE ABSOLUTE SENSOR) (SENSOR YEUBLU VCC2 VOLTAGE) P r o v i d e ss e n s o r v o l t a g e 20
Signal With ignitionswitchON (ll):about3 V A t i d l e : a b o u t 1 . 0V ( d e p e n d i n go n e n g i n e s p e e d )

21
22 23 24 25 26

voltage YEURED VCC](SENSOB VOLTAGE) Provides sensor a,/F AFSHTC (AIRFUEL Detects sensorheater (A"iFiSENSOR RATIO voltage + HEATER CONTROL SIDE) BRN?ryE L LG2(LOGIC GROUND roundfor the ECMcircu 1(L roundfor the ECMcircu BRN?ryE L D e t e c t sC M P s e n s o r A BLU,^/VHT CMPA (CAMSHAFT A) stonal POSITION SENSOR Detects 8 GRN CMPB CAMSHAFT CMPsensor (TDc (CMP)SENSOB sensor) POSITION (TOP B (TDC DEAD CENTER SENSORi) I G P L S 4 N o .4 I G N I T I O N DrivesNo, 4 ignitioncoi BRN { WHT/BLU
COILPULSE) I G P L S 3N o . 3 I G N I T I O N { COILPULSE) O r i v e s N o . 3 r g n i t i o nc o i DrivesNo.2 ignitioncoil

With ignition switch {ll):about5 V ON Withionition switch OFF: about0V Withignition switch {ll):about5 V ON With ionition switch OFF: about0V
W i t h i g n ; t i o ns w i t c h O N l l l ) : b a n e r y v o l t a g e

\.
1.0 Lessthan V at alltimes
L e s st h a n '1.0 V at alltimes

pulses Withengine running: pulses Withengine running:

27 28 29

Withignition switch (ll)r ON about0 v pulses running: Withengine

30

IG BLU/RED l G P L S 2 l N o . 2 N I T I O N COIL PTJLSE) (No.1 IGNITION YEUGRN IGPLSI co PlltsF)

Drives No. I ignition coil

\.

11-20

Wire side o{ femaleterminals

NOTE: Standardbafteryvoltageis 12V. Terminal numot 2 3 4 5 6 7 8 9 Wire color [erminal name Description Signal 0 switch (ll): V ON Withignition At idle:dutycontrolled

VTCoilcontrol BLUAvHT VTC+ lVTCOILCONTBOL Drives VALVE +SIDE) SOLENOID lNJa{No.4INJECTOR) Jo.3INJECTORI BL )TOR) R1 lNJl 1No. INJECTOR) I BRN (RAOIATOR FAN FANC GRN CONTROL) LOCK GRN/vVHT RVS(REVERSE VALVE) SOLENOID Drives o. 4 iniector Drives o.3 iniector Drives o . 2 i n i e c t o r No. 1 iniector Drives Drivesradiatorfan relay

10

fan about0 V With radiator running: With radiatorfan stopped:battervvoltaoe speed below9.4mph (15km/h): Drivesreverselocksolenoid Withvehicle batteryvoltage mph (20km/h): V 0 above12.5 Withvehicle speed (ENGINE switch (ll):about0.1 4.8V ON Withthe ignition ECTsensorsignal Detects COOLANT REDAVHT ECT temDerature) ideoendino enoine on coolant TFMPFRATURE SENSOR) speed: about0 . at VTEc pressure Withengine low engine oil Detects OIL BLU/BLK VTPSW(VTEC voltaqe batterv Wirhenoine hiohenoine at soeed: PRFSSTIRF SWITCH) switch sional about0 V swit'ch (ll): ON L L Detects alternator signal With ignition WHT/BLU ALTL(ALTEBNATOR voltaqe Whh enoine runnino: batterv SIGNAI I running: about0 V- 5 V alternator signal Withengine FB FR Detecls WHT/RED ALTF(ALTERNATOR load) on SIG ALI N {deoendinq electrical valve A t i d l e : a b o u t 0 V Drives VIECsolenoid SOLENOID GRN/YEL VTS {VTEC ON With ignition switch {ll):about0.1V 4.8v l.lcnen.iino intake temoerature) on air running: about0 V 5 V Withengine control Sends alternator (.lcocn.lino electrical on ioad) coolant below149'F purge Withengine running, engine Drives EVAPcanister voltage battery valve 165'C): coolant above149'F running, engine Withengine 165"C): controlled dutv W i t h t h e i g n i t i o n s w i t c h O N ( l l ) :0 V VTCoilcontrol OIL BLK/Vr'HT VTC (VTC CONTROL Drives SOIFNOID VALVE SIDE)

'17

18 21

IAT(INTAKE AIR TEMPERATURE SENSOR) WHT/GRN ALTC(ALTERNATOR CONTROL) YEUBLU PCS{EVAPORATIVE EMISSION CANISTER PURGE VALVE)

REDI/EL

IAT signal Detects sensor

23

(confd)

11-21

Fueland Emissions Systems


(cont'dl SystemDescriptions
ECMlnputsand Outputsat Connector (31P} E

1 iMo FPR

sr-{]zsLG3

4 SG3

22 23 24 BKSW K-LINE SEFMJ

6 1 $1025 MRLY HTC 16 14 15 18 FTP ELD EPS ACC LD 21 26 rMo NEP CD

8 AFS HTCR

20 21 Z/VBS VSV

scs

29

30 31 WEN MIL

Wire side of femaleterminals NOTE: Standardbatteryvoltageis '12 V. Terminal Wire color number GRNI/EL 2 ferminal name Description Signal 0Vfor2 seconds afterturningignition switchON {ll).then battervvoltaoe Withthrottle Jully opened from idlewith fully warmedup engine: above 0.6V quickly Withthrottle closed: below0.4V Less than1.0V at all times Less than 1.0V at all times With ignition switch (ll):about5 V ON With ionition switch OFF: about0 V With ignitionswitch ON (ll):bafteryvoltage Wilh fullvwarmedup engine running: dul, controlled Withignition switch (ll): ON about0 V With ignitionswitchOFF:batteryvoltage Withignition swirch {ll):0 V ON
With ignition switch ON (ll): battery voltage With iqnition switch OFF: about 0 V

3 4 5 6

(IMMOBILIZER D r i v e s P G M F l m a i n r e l a y 2 IMOFPR FLJEL PUMP RELAYI (SECONDARY WHT/RED SHO2S Detectssecondary HO2S HEATED OXYGEN SENSOR {sensor signal 2) (SECONDARY HO2S), SENSOR 2r BRN/YEL LG3(LOGIC GROUND) cround forthe ECM/PCM controlcircuit PNK SG3{SENSOR GBOUND) Sensor oround YEUELU VCC3 VOLTAGE) Provides {SENSOR sensorvoltage (SECONDARY Drives BLKATr'HT SO25HTC secondary HO2S HEATED OXYGEN SENSOR heater (SECONDARY H02S) HEATER CONTROL) REDA/EL MRLY(PGM.FI MAIN Drives PGM-Flmain relay1 RELAY} Powersourceforthe DTC ORN AFSHTCR FUEL BATIO Drives fuel ratiosensor {AIR air (Iy'F)SENSOR HEATER heaterrelay CONTROL RELAY)
IGl (IGNITION IGNAL) S D e t e c r si g n i t i o n s i g n a l

1
I

YEUBLK
LT GRN

't4

FIP lFUEL TANK (FTP) PRESSURE SENSOR) GRN/RED ELD(ELECTRICAL LOAD DETECTOF) (ELECIRICAL LTGRN/8LK EPSLD POWEB STEEBING LOAD DETECT) RED

Withignition switch (ll)andfuelfill capopen: ON about2.5V Detects signal ELD Withignition swjtch itt):aOoutO.t l-gV ON V (deDendino electrical on load) DetectsPowersteeringload At idlewith steering wheelin straight ahead srgnal position: about V 0 At idlewith steering wheelatfulllock: momentary Detects sensor FTP signal Withcompressor about0 V ON: With comoressor OFF: battervvoltaoe

'18

ACC(Ay'C CLUTCH RELAY) DrivesP,/C clutch relay

\-

11-22

E ECMInputsand Outputsat Connector (31P)

2 t M o $.c2s FPR

6 1 SFIO2S IVRLY HTC


14 FTP

I AFS HTCR t8

9 tGl

15 ELD 26 NEP

16 EPS LD

21 20 2,4/BS VSV

22 23 24 K BKSW LINESEFMJ

21 lvo CD

scs

29

30 31 WEN MIL

Wire side of femaleterminals

is NOTE: Standard battery voltage 12V. Terminal Wire color 20 21 Terminalname Description Signal voltage Withignition switch (ll):baftery ON
W i t h i g n i l i o n s w i t c h O N ( l l ) :b a t t e r y v o l t a g e

22 23

Drives EVAP bypass (EVAP)BYPASSsolenoid valve EMISSION SOLENOID VALVE) vent Drives EVAP canister LT GRN/RED VSV (EVAPORATIVE shutvalve EI\4ISSION iEVAP) VENT SHUT CANISTEB VALVE) PEDAL Detects brake pedal WHT/BLK BKSW lBRAKE POSITION SWITCH) o o s i t i o ns w i t c h s i o n a l scan LT BLU K-LIN E Sends and receives YEL
SEFMJ C o m m u n i c a t e sw i t h mrltinleYeontrolunit

BLU/RED 2WBS(EVAPORATIVE

pedalreleased: With brake about0 V


With hrake nedal nresse.l: batterv voltaoe

pulses battery or With ignition switch (li)r ON

26 21 29 30

( E N E P E N G I NS P E E D PULSE) RED/BLU \40CDfl\4MOBTLTZER CODE) BRN SCS(SERVICE HECK C

BLU

With ignition switch (ll):about5 V ON Withenoine runnino underload:DUlses pulses pulse Withengine running: Outputs engine speed
D e t e c t si m r n o b i l i z e rs i g n a l

with the PGM check signal shorted O e t e c t ss e r v i c ec h e c k s i g n a l Withthe service Tester: about0 V Wiih rheservice check sional ooened: about5 V
D e t e c t sw r i t e e n a b l e s i g n a l W i t h i g n i t i o n s w i t c h O N ( l l ) :a b o u t 0 V

SIGNAL)

ENABLE RED,A/VHT WEN(WRITE SIGNALi GRN/ORN MIL(MALFUNCTION LAMP) INDICATOR

Drives N4lL

WithMILturnedON:about0 V voltaqe WithMILturnedOFF: batterv

(cont'd)

11-23

Fueland Emissions Systems


(cont'dl SystemDescriptions
VacuumHoseRouting

INTAKEAIR BYPASSCONTROL THERMALVALVE

\*

FRONTOF VEHICLE EVAPORATIVE EMISSION {EVAP}CANISTERPURGEVALVE

\,

11-24

VacuumHoseRouting

1} RATIO SENSOR {SENSOR IA/F) O AIRFUEL HEATED OXYGEN SENSOR O SECONDARY 2} HO2S} {SENSOR ISECONDARY (MAPISENSOR PRESSURE ABSOLUTE O MANIFOLD SENSOR TEMPERATURE COOLANT {ECT) O ENGINE (IAT) AIR O INTAKE TEMPERATURE SENSOR (CKP) SENSOR POSITION O CRANKSHAFT SENSOR O KNOCK (CMPI B POSITION SENSOR O CAMSHAFT SENSOR) CENTER DEAD ITDC) ITOP A SENSOR POSITION O CAMSHAFT ICMPI (IACI VALVE AIR @ IDLE CONTROL BODY O THRONLE .OINJECTOR PULSATION OAMPER @ FUEL FILTER [I FUEL PRESSURE REGULATOR @ FUEL PUMP @ FUEL TANK @ FUEL

@ RESONATOR (9 AIRCLEANER VENTILATION CRANKCASE {PCVIVALVE @ POSITIVE CONVERTER WAYCATALYTIC @ THREE EMISSION CANISTER {EVAPI @ EVAPORATIVE CANISTER EMISSION {EVAP) @ EVAPORATIVE PURGE VALVE (EVAPI CANISTER EMISSION {} EVAPORATIVE VALVE VENTSHUT TWOWAYVALVE EMISSION {EVAP) {' EVAPORATIVE BYPASS EMISSION IEVAPI @ EVAPORATIVE VALVE SOLENOID (FTP) TANKPRESSURE SENSOR @ FUEL VALVE EMISSION IEVAP} @ EVAPORATIVE VALVE CONTROL TANKVAPOR @ FUEL VALVE TANKVAPOR RECIRCULATION FUEL 60) VALVE THERMAL AIR CONTROL O INTAKE BYPASS

(cont'd)

11-25

Fueland Emissions Systems


(cont'd) SystemDescriptions
PGM-FI System
The ProgrammedFuel Injection(PGM-Fl) system is a sequentialmultiport fuel injectionsystem. Air Conditioning {A/C) Compressor Glutch Relay When the ECfM receives demandfor coolingfrom the a Ay'C system,it delaysthe compressorfrom being energized, and enrichesthe mixture to assuresmooth transitionto the AVC mode. Air Fuel Ratio lA/Fl Sensor The Ay'F Sensoroperatesover a wide airlfuel range.The Ay'F Sensoris installedupstreamof the TWC, and sends signalsto the ECMwhich variesthe durationof fuel injectionaccordingly.
SENSOR TERMINALS

Camshaft Position(CMPI SensorB (TopDeadCenter (TDCI Sensor) TheCMP sensor (TDC B sensor) detects position the of the No.1 cylinder a reference sequential as for fuel injection each to cylinder.

MAGNET

ztRcoNta ELEMENT

Crankshaft Position (CKPISensor The CKPsensordetectscrankshaft soeedand determinesignitiontiming and timing for fuel injection of each cylinderas well as detectingengine misfire.

HEATER

HEATER TERMINALS

Barometric Pressure {BAROI Sensor The BAROsensoris insidethe ECM.lt convens atmosphericpressureinto a voltagesignalthat the ECM usesto modify the basicdurationof the fuel injection discharge.

Engine Coolant Temperature (ECT)Sensor The ECTsensoris a temperaturedependentresistor (thermistor). The resistance the thermistordecreases of as the enginecoolanttemperatureincreases.
TERMINAL

\,

11-26

lgnition Timing Control The ECMcontainsthe memory for basicignitiontiming at variousengine speedsand manifold absolute pressure. also adjuststhe timing accordingto engine lt coolanttemperature. Iniector Timing and Duration The ECM containsthe memory for basicdischarge e a d u r a t i o n t v a r i o u s n g i n es p e e d s n d m a n i f o l d a pressures. The basicdischargeduration,after being read out from the memory, is further modified by signalssent from varioussensorsto obtain the final discharge uration. d By monitoring long term fuel trim, the ECMdetectslong in term malfunctions the fuel systemand sets a Trouble Code{DTC). Diagnostic Intake Air Temperature (lAT) Sensor The IAT sensoris a temperaturedependentresistor The resistance the thermistor decreases of {thermistor). increases. as the intakeair temDerature

MalfunctionIndicatorLamp lMlLl Indication{ln relation to ReadinessCodes) "readinesscodes" that are part The vehiclehas certain for of the on-boarddiagnostics the emissionssystems. or lf the vehicle'sbafteryhas been disconnected gone have been cleared,or if the ECM has dead.if the DTCS been reset.these codesare set to incomplete.In some states,part of the emissionstesting is to make sure lf these codes are set to comDlete. all of them are not set to complete,the vehiclemay fail the test and the test cannot be finished. codes are set to complete, To checkif the readiness turn the ignition switch ON (ll). but do not startthe l e n g i n e . T h e M I L w clo m e o n f o r l S 2 0 s e c o n d sf. i t i l codesare set to complete, then goes off, the readiness codes lf it blinksseveraltimes,one or more readiness are not set to comolete.To set each code, drive the i v e h i c l e r r u n t h e e n g i n ea s d e s c r i b e dn t h e o procedures set them in this section(seepage 11-46). to Manifold Absolute Pressure {MAP) Senso] The MAP sensorconvertsmanifoldabsolutepressure s t i n t oe l e c t r i c a li g n a l s o t h e E C M . SENSOR UNIT

Knock Sensor The knockcontrol system adjuststhe ignitiontiming to minimizeknock.

PIEZO CERAMIC

(cont'd)

11-27

Fueland Emissions Systems


(cont'dl SystemDescriptions
Secondary Heated Oxygen Sensor (Secondary HO2S) The secondaryHO2Sdetectsthe oxygen content in the exhaustgas downstreamof the three way catalytic converter(TWC)and sendssignalsto the ECMwhich checksthe efficiencyof the TWC.To stabilizeits output, the sensorhas an internalheater.The secondarvHO2S i s i n s t a l l e dn t h e T W C . i Vehicle Speed Sensor (VSS) The VSS is driven by the differential. generates lt a pulsedsignalfrom an input of 5 volts.The number of pulsesper minute increases/decreases the speed with of the vehicle.
BEARING

ztRcoNta ELEMENT

SENSOR TERMINALS

HEATER TERMINALS

Starting Control When the engine is started,the ECM providesa rich mixture by increasinginjectorduration.

(
Throttle Position ITP)Sensor The TP sensoris a potentiometer connected the to throttlevalve shaft.As the throttle positionchanges, the sensorvariesthe signalvoltageto the ECM.The TP sensoris not replaceable apart from the throftle body.

ELEMENT

BRUSH HOLDER

gRUSH

11-28

wEc/wc
The i-WEC has a VTC (Variable ValveTiming Control)mechanismon the intakecamshaftin additionto the usual VTEC. This mechanismimprovesfuel efficiencyand reducesexhaustemissionsat all Ievelsof engine speed,vehiclespeed. a n d e n g i n el o a d . The VTECmechanismchangesthe valve lift and timing by using more than one cam profile. lt The VTCchangesthe phaseof the intakecamshaftvia oil pressure. changesthe intakevalve timing continuously.
HIGH

LOW<DrivinoCondition Qr Light-load VTC Control B a s eP o s i t i o n

ENGINE SPEED

?l M edium/high-load

AdvanceControl

) High speed

Advance-Base Position

DescriDtion Cam angle is retardedto reducethe entry of exhaust gas into the intakeport and to achievestablefuel c o n s u m D t i o d u r i n ql e a nb ur n . n Cam angle is advancedfor EGReffectand to reduce this pumping loss.The intakevalve is closedquickly to help reducethe entry of airlfuel mixture into the intakeport and improve the chargingeffect. f C a m p h a s ea n g l ei s c o n t r o l l e do r o p t i m u mv a l v e t i m i n qa n d m a x i m u me n o i n eo o w e r .

{cont'd)

11-29

Fueland Emissions Systems


(cont'dl SystemDescriptions
VTC system . The VTC system makescontinuousintakevalvetiming changesbasedon operatingconditions. . Intakevalve timing is optimizedto allow the engineto producemaximum power. 'CamangleisadvancedtoobtaintheEGReffectandreducethepumpingloss.Theintakevalveisclosedquicklyto reducethe entry of the airlfuel mixture into the intakeport and improvethe chargingeffect. . Cam angle is reducedat idle to stabilize combustionand reducesenginespeed. ' l f a m a l f u n c t i o n o c c u r s , t h e V T C s y s t e m c o n t r io l d i s a b l e d n dt h e v a l v et i m i n g i s f i x e da t t h e f u l l y r e t a r d e d o s i t i o n . s a p TDC MAXIMUM VTCADVANCE 50'
MAXIMUM VTC ADVANCE50'

i '+-|l

l(-4

sHoRT oVERLAP LoNG oVERLAP

VTEC system ' The VTECsystemchangesthe cam profileto correspond enginespeed.lt maximizes to torque at low enginespeed and output at high engine speed. . The low lift cam is used at low engine speeds,and the high lift cam is used at high enginespeeds.

LOWSPEED VALVETIMING

HIGHSPEED VALVETIMING

11-30

System Diagram
CMPSENSOR A From No. il ACC{10A)fuse

INTAKE
CAMSHAFT

BRN/YEL
-:-

BLU/WHT BLU/WHT BLK/WHT GRN/YEL BLU/BLK VARIOUS SENSORS

BLK

I t

:5i.T,""

Camshaft Position {CMP}Sensor The CMP sensordetectscamshaftangle positionfor the VTC system.

{cont'd}

11-31

Fueland Emissions Systems


(cont'd) SystemDescriptions
ldle Control System
When the engine is cold, the Ay'C compressoris on, the transmissionis in gear,the brakepedal is pressed. the power steeringload is high, or the alternatoris charging,the ECIM controlscurrentto the ldle Air Control(lAC)valveto maintainthe correctidle speed. Referto the System Diagramto seethe functional layout of the system. Brake Pedal Position Switch The brakepedal positionswitch signalsthe ECMwhen the brakepedal is oressed. Electrical Power Steering (EPS)Senser The EPSsensorsignalsthe ECMwhen the power s t e e r i n go a di s h i g h . l ldle Air Control llACl Valve To maintainthe proper idle speed,the IACvalve changesthe amount of air bypassingthe throttle body in responseto an electrical signalfrom the ECM.
From AIR CLEANER To INTAKE MANIFOLD

FuelSupply System
Fuel Cut-off Control Duringdeceleration with the throttle valve closed, currentto the injectorsis cut off to improve fuel economy at enginespeedsover 1,030rpm. Fuelcut-off actionalso occurswhen enginespeedexceeds 6,900rpm, regardless the positionof the throttle of valve,to protectthe enginefrom over-rewing. When the vehicleis stopped.the ECMcuts the fuel at engine speedsover 6,500rpm. Fuel Pump Control When the ignition is turned on, the ECMgroundsthe PGM-Flmain relay which feeds currentto the fuel pump for 2 secondsto pressurize fuel system,With the the e n g i n er u n n i n gt.h e E C Mg r o u n d s h e P G M - Fm a i n t l relay and feeds currentto the fuel pump. When the engine is not running and the ignition is on, the ECI\4 cuts ground to the PGM-Flmain relaywhich cuts currentto the fuel pump. PGM-FIMain Relay1 and 2 The PGM-Flmain relay consistsof two separaterelays. Relay1 is energized wheneverthe ignition switch is ON (ll)to supply batteryvoltageto the ECM power to the injectors, and power for relay,Relay2 is energized to supply power to the fuel pump for 2 secondswhen the i g n i t i o n w i t c hi s t u r n e dO N ( l l ) ,a n d w h e n t h e e n g i n ei s s runnrng.

IAC VALVE

11-32

IntakeAir System
Referto the SystemDiagramto seethe functional layout of the system. Intake Air Bypass Control Thermal Valve W h e nt h e e n g i n ei s r u n n i n g t h e i n t a k e i r b y p a s s , a controlthermal valve sendsair to the iniectors,

Throttle Body The throttle body is a single-barrel side draft type. lt housesthe TP senserand the IACvalve.The lower portion of the IAC valve is heatedby enginecoolant fromthecylinder ead. h

IACVALVE

INJECTOR

{cont'd)

11-33

Fueland Emissions Systems


(cont'dl SystemDescriptions
GatalyticConverterSystem
ThreeWay CatalyticConverter(TWC) (HC), TheTWCconverts hydrocarbons carbon (NOx) the monoxide and of {CO), oxides nitrogen in (C02), gas (N2), exhaust to carbon dioxide dinitrogen andwatervaDor. {

PositiveCrankcase Ventilation (PCVISystem


The PCVvalve preventsblow-by gassesfrom escaping into the atmosphereby ventingthem into the intake manifold.

BREATHER PIPE

THREE WAY CATALYST

FRONTOF VEHICLE

:: :

BLOW-BY VAPOR FRESH AIR

11-34

(EVAPI Evaporative Emission Control System


Referto the SystemDiagramto see the functional layout of the system. EVAPCanister The EVAPcanistertemporarilystoresfuel vapor from the fuel tank until it can be purged back into the engine a n db u r n e d . EVAP Canister Purge Valve When the enginecoolanttemperatu is below 149'F re (65'C),the ECMturns off the EVAPcanisterpurge valve which cuts vacuum to the EVAPcanister. FuelTank Pressure (FTP)Sensor The FTPsensorconvertsfueltank absolutepressure into an electricalinputto the ECMduring the EVAPleak cnecK. SENSOR UNIT

EVAP Two Way Valve and EVAP Eyp8s Solenoid Valve The EVAPtwo way valve is installedbetweenthe fuel tank and the EVAPcanisterline. The EVAPtwo way valve sendsfuel vapor to the EVAP canistercorresponding the pressureinsidethe tuel to tank. lt also relievesexcessvacuum in the tank by allowingfresh air to be drawn into the tank through the EVAPcanister. The EVAPbypasssolenoidvalve opensto bypassthe two way valve during the EVAPleakcheck.
EVAP BYPASS SOLENOID VALVE

VALVE

To FUELTANK

(cont'd)

11-35

Fueland Emissions Systems


(cont'dl SystemDescriptions
ldle Control System Diagram
The idle speedof the engine is controlledby the ldle Air Control(lAC)varve: 'Aftertheenginestarts,theIACvalveopensforacertainamountoftime.Theamountofairisincreasedtoraisethe i d l es D e e d . . When the engine coolanttemperatureis low, the IACvalve is openedto obtain the properfast idle speed.The amount of bypassedair is controlledin relationto enginecoolanttemperature.
INTAKE MANIFOLD

IACVALVE

AKEAIR DUCT
CLEANER

YEL/BLK ---< BLK/ REO

From PGM.FI MAIN RELAY

THROTTLE AODY

VARIOUS SENSOnS

BLK

IntakeAir SystemDiagram
This systemsuppliesair for engine needs.A resonatorin the intakeair pipe providesadditionalsilencingas air is drawn into the svstem.

THROTTLE AODY

VARIOUS SENSORS

BLK

11-36

(EVAPI Evaporative Emission ControlDiagram


The EVAPcontrolsminimizethe amount of fuel vapor escaping the atmosphere. to Vapor from the fuel tanKrs temporarilystoredin the EVAPcanisteruntil it can be purgedfrom the canisterinto the engine and burneo.

. The EVAPcanisteris purged by drawing fresh air through it and into a port on the intakemanifold. The purgingvacuum is controlledby the EVAPcanisterpurge valve,which operateswheneverengine cootant temperatureis above 149'F(65"C). 'WhenvaporpressureinthefueltankishigherthanthesetvalueoftheEVAPtwowayvalve,thevalveopensan regulates flow of fuel vapor to the EVAPcanister. the ' D u r i n g r e f u e l i n g , t h e f u e l t a n k v a p o r c o n t rv a l v eo p e n sw i t h t h e p r e s s u r en t h e f u e lt a n k ,a n d f e e d st h e f u e lv a D o r ol i to the EVAPcanister.

FUEL TANK VAPOR RECIRCULATION VALVE

FUEL TANK VAPOR SIGNAL TUBE BLU/RED

BLK
FUELFILLCAP

FUELTANK VAPOR RECIRCULATION TUBE

FUELTANK

EVAP + CANISTER VENTSHUT VALVE From BLK/YEL --<No. 4 Acc

A {10 }fuse

EVAP CANISTER EVAPTWOWAY VALVE

(cont'd)

11-37

Systems Fueland Emissions


(cont'd) SystemDescriptions
ECM Circuit Diagram

I
mrrrrn
CONNECTOi

B CMP SENSOR (TDCSENSOn)

I-BRN/YEr-

\,

11-38

wEc solENorD

_YEL/aLU -RED/aLK |-GFN/YEL

__f -----l _l

+
I
Y
I

F=-1 Hi I t_r I I?SCNSOn

L!l

I
croz

ff:l_l *'*"_-ll-t
-KnocK lSENSOn

l
I

-l-

Ll]

wcoLcoNTnoL
SoLENO|OVAIVE

(cont'd)

11-39

Systems Fueland Emissions


(cont'dl SystemDescriptions
ECMCircuitDiagram{cont'd) \

---1t-|

-{ffi]
IATSENSOR

-{Ell -----ECTSENSOS

T_""",,..
I-BFN/YEL

CMPSENSOAA

L-

IJUNCTION I CONNECTOR

ft^--l
,","., J | t- : '
I +
I I REVERSE LocK

soleloto vaLvE

t!j]]

11-40

_1ffi1
-'----1 | | Fahdl
G8N

'--rBLU/

'8r-K-L-|

l -r l
l

J.L9l

HcoNNEcroR
-l .lurcrroru

EVAPCANISTEB

ALK/YEL WHT/ALU WHT/NED


WHI/GRN

JUNCTION CONNECTOR

rrrn

tcM
No.2IGNITION Olt C

PLUG

PLUG No.3IGNITION COIL

(cont'd)

11-41

Fueland Emissions Systems


(cont'd) SystemDescriptions
ECMCircuitDiagramlcont'dl

YEI/BLK
IGP2

VET/BLK

---rF-rl -lF-forl --JliD\l


--t-l
MAIN BETAV2

t_,",
tr

:t r, l-,r'l
-,uI SENSOS

f-"'*'o""

IMMOAIL|zER UNIT

a
11-42

SECONDAFY H02S (sNsoR2l

TPSNSOR

m tlil

'--{=l

-{r

CANISTER VEAIT SHUTVALVE

--lti l
solENorD
EVAP EYPASS ToPS CONTROLUNIT

t-_]

CPU

GAUGE ASSEMBTY

(cont'd)

11-43

Fueland Emissions Systems


(cont'dl SystemDescriptions
(cont'd) ECM Circuit Diagram

UNDER.HOOD FUSE/RELAY9OX CONNCTOF

CONNECTOi

WHI/NED BLK/YET

lalLREllY _l _

a
11-44

CONNECTOR E

""rr"a*J
r''lHr/cnN 1

CONNECTOi K

IGNITIONSWITCH lG2

' I

CONNECTOFJ /GRN

TEST TACHOMETER CONNECTO8

UNDER.HOOD

UNDER.DASH FUSE/FELAYBOX

UNDER.DASH FUSE/RELAY BOX: 4 ACG (1oAt 1 tGN CO|Lt15A) 2 A/F HEATER{2OA) 17 FUELPUMPI15A} 1OMETER {7.5AI 14 A/C CLUTCH RELAY{1OA}

POStTtON SWTTCH

,or"-9J3{51 "_.rl re* _{F


Brake pedal pressed: closed Brake pedal releasedropen

11-45

Fueland Emissions Systems


How to Set Readiness Codes
Lamp(MlL)Indication Malfunction lndicator (ln relationto Readiness Codesl
The vehiclehas certain"readinesscodes" that are part for of the on-boarddiagnostics the emissionssystems. lf the vehicle'sbatteryhas beendisconnected gone or have beencleared,or if the ECM has dead,if the DTCS been reset,these codesare set to incomplete.In some states,part of the emissiontesting is to make sure these codesare set to complete.lf all of them are not set to complete,the vehiclemay fail the emissiontest, or the test cannot be finished. To checkifthe readiness codesare complete,turn the ignitionswitch ON (ll), but do not startthe engine.The MIL will come on for 15 20 seconds.lf it then goes off, the readiness codesare complete.lf it blinksseveral codes are not complete. times, one or more readiness To set readlness codesfrom incompleteto complete. code. do the procedurefor the appropriate

L
Catalytic Converter Monitorand Readiness Code
NOTE: . Do not turn the ignition switch off during the procedure. . All readiness codes are clearedwhen the batteryis disconnected when the ECM is clearedwith the or OBD ll scantool or HondaPGlvlTester. . Low ambienttemperatures excessive or slop-and-go traffic may increase the drive time neededto switch the readiness code from incompleteto complete. ' The readiness code will not switchto com Dleteuntil a l lt h e e n a b l e r i t e r i a r em e t . c a . lf a fault in the secondaryHO2Ssystemcausedthe MIL to come on. the readiness code cannot be set to comDleteuntil vou correctthe fault.

Enable Criteria

. E C Ta t 1 5 8 " F 7 0 ' C ) r h i g h e r . ( o . I n t a k e i r t e m p e r a t u r el A T )a t 2 0 " F( - 7 ' C ) o r h i g h e r . ( a . Vehiclespeed is steady,and vehiclespeedsensor ( V S S ) e a d sm o r et h e n 2 5 m p h ( 1 3 k m / h ) . r

Procedure
1 . C o n n e ctth e s c a nt o o l t o t h e v e h i c l e ' s a t al i n k d , c o n n e c t o( D L C i a n d b r i n gu p t h e t o o l ' sg e n e r i c r O B Dl l m o d e . \ \"

2 . Startthe engine.
the conditions 3 . Test-drive vehicleunder stop-and-go with short periodsof steadycruise.After about 5 miles (3 km),the readiness code should switch from incompleteto complete. lf the readiness check code is still set to incomplete, for a temporary DTC.lf there is no DTC,one or more of the enablecrlteriawere probablynot met;

11-46

Evaporative Emissions(EVAP) Control SystemMonitor and Readiness code


NOTE:
All readiness code are clearedwhen the batterVis disconnected when the ECM is clearedwith the or OBD ll scantool or HondaPGM Tester. The enablecriteriamust be repeatedif the intakeair temperature(lAT)drops lower than 36'F (20"C) from i t s v a l u ea t e n g i n e a n u p . $

Air FuelRatio(A/FlSensorMonitorand Readiness Code


NOTE: . Do not turn the ignitionswitch off during the orocedure. . All readiness codesare clearedwhen the bafteryis disconnected when the ECM is clearedwith the or OBD ll scantool or Honda PGM Tester.

Enable Criteria
At enginestart up, ECTand IAT are higherthan 32'F (0"C), but lower than 95'F (35"C). At enginestart up, the ECTand IAT are within 12'F (7'C)of each other.

Enable Criteria
ECTat 140'F(60"C) higher. or

Procedure
1. Connectthe scantoolto the vehicle'sdata link connector(DLC), and bring up the tool's generic O B Dl l m o d e . 2. Start the engine. 3. Test-drive vehicle under stop-and-go the conditions with short periodsof steadycruise.Duringthe (wirh the throttlefully closed)for drive, decelerate 5 seconds. After about 3.5 miles (2.2km).the readiness code should switch from incomDlete to complete. 4 . l f t h e r e a d i n e s s c o d e i s s t isle tt o i n c o m p l e t e ,h e c k l c for a temporary DTC.lfthere is no DTC,the enable criteriawas probablynot meU repeatthe procedure.

Procedure
1. Connect the scantool to the vehicle'sdata link connector(DLC), and bring up the tool's generic O B Dl l m o d e . 2. Startthe engine. 3. Test-drive vehicleunder stop-and-go the conditions with short periodsof steadycruise.After about 2 . 5m i l e s( 1 . 6k m ) ,t h e r e a d i n e sc o d es h o u l d s switchf rom incompleteto complete. 4. lf the readinesscode isstill setto incomplete, check for a temporaryDTC.lf there is no DTC,one or more of the enablecriteriawere probably not met; repeatthe procedure.

Air/FuelRatio(A/FlSensorHeater Monitor Readiness Code


NOTE;All readiness codes are clearedwhen the battery is disconnected when the ECM is clearedwith the or OBD ll scantool or HondaPGM Tester,

Procedure
'1. Connectthe scantool to the vehicle'sdata link connector{DLC), and bring up the tool's generic O B Dl l m o d e .

2. Startthe engine,and let it idle for 1 minute.The readiness code should switch from incompleteto comDlete. 3. lf the readiness code is still set to incomplete,check for a temporary DTC.lf there is no DTC,repeatthe proceoure.

(cont'd)

11-47

Fueland Emissions Systems


How to Set Readiness Codes(cont'd)
Code MisfireMonitorand Readiness
. This readiness code is alwaysset to available becausemisfiring is continuouslymonitored. . l\4onitoring pauses, and the misfirecounterresets,if the vehicleis driven over a rough road. . Monitoringalso pauses,and the misfire counter holds at its currentvalue.if the throttle position value,or if changesmore than a predetermined driving conditionsfall outsidethe rangeof any relatedenablecriteria,

\-

Code FuelSystemMonitorand Readiness


. This readiness code is always setto available because fuel system is continuouslymonitored the during closedloop operation. . Monitoringpauseswhen the catalyticconverter, EVAPcontrol system,and Ay'F sensor monitorsare active. . Monitoringalso pauseswhen any relatedenable criteriaare not being met. Monitoring resumeswhen lhe enablecriteriais again being met.

Monitorand Component Comprehensive Readiness Code


This readiness code is always set to availablebecause the comprehensive componentmonitor is continuously o r u n n i n g h e n e v e t h e e n g i n ei s c r a n k i n g r r u n n i n g . w r

a
11-48

PGM-FI System
ComponentLocationIndex

CAMSHAFTPOS]TION{CMP)SENSORB (TOPDEAD CENTER(TDC} SENSORI Troubleshootina. oaoe 11-95 p;ge 1-1.1 Replacement, 14

ii'- r'1

.I11---:,I
''.!,i(..,.?:fir-J-

.....,..:--.

ELECTRICAL LOAD DETECTOR {ELDI Troubleshooting, -92 page1'l INTAKE TEMPERATURE AIR {IATISENSOR Troubleshooting, page'l'l-55 page Replacement, 11-'l 15
f \

ENGINE COOLANT TEMPERATURE (ECTI SENSOR page Troubleshooting, 11-57 R e p l a c e m ep a , e 11 1 4 ntg 1 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR page Troubleshooting, 11-52

POSITION CRANKSHAFT ICKPISENSOR page'l1-78 Troubleshooting, page 11-'l16 Beplacement,

THROTTLE POSITION ITP}SENSOR page Troubleshooting, 11-60 KNOCK SENSOR page Troubleshooting, 11-77 B e p l a c e m ep a , e 11 1 5 nt g 1
AIR FUELRATIO{A/F) SENSOR ISENSOR 1} page 11-84 Trorrbleshooting, page 11-113 Replacement,

{cont'd)

11-49

PGM-Fl System
ComponentLocationIndex(cont'd)
\

\.,

v
11-50

'}

DATALINKCONNECTOR IDLCI page 1l 3 General Troubleshooting Information,

PGM.FI MAINRELAY 1 page Troubleshooting, 11-97

ENGINECONTROLMODULE g General Troubleshootin Information, p a g e1 1 3 page I 1-96 Troubleshooting,

11-51

PGM-FI System
DTCTroubleshooting
DTCP0107: MAPSensor Circuit LowVoltage
1 . T u r nt h e i g n i t i o n w i t c hO N ( l l i . s 2. Checkthe MAP with the scantool. ls about 101kPa (760 mmHg,30 in.Hg)or 2.9 V indicated? YES Intermittent failure, system is OK at this time. Checkfor poor connections looseterminalsat or t h e M A Ps e n s o r n d a t t h e E C M . I a N O - G o t o s t e p3 . 3. Turn the ignition switch OFF. YES-Go to step 9. 4. Disconnect MAP sensor3P connector. the NO Replace the lvlAPsensor.l 5 . T u r nt h e i g n i t i o n w i t c hO N ( l l l . s NO Updatethe ECMif it does not havethe latest software,or substitulea known-goodECM,then recheck(seepage 'l1-6).lf the symptom/indication goes away with a known-goodECfvl, replacethe originaECM.I l 8 . Checkthe MAP with the scantool. ls 2 kPa (15 mmHg,0.6 in.Hg) ot lessor 0 V indicated? ls there about 5 V? YES-Repair open in the wire betweenthe Eclvl ( A 2 1 ) a n d h e M A Ps e n s o r . l t

9 . Turn the ignitionswitch OFF.


6. lvleasure voltage betweenMAP sensor3P c o n n e c l o tre r m i n a l s o . 1 a n d N o . 3 . N
MAP SENSOR3P CONNECTOF

'10.Disconnect

ECMconnectorA (31P).

11. Checkfor continuitybetweenMAP sensor


connectorterminal No. 2 and body ground.
MAP SENSON3P CONNECTOA

sGl {GRN/WHTI

Wires de of femaleterminais

ls there about 5 V? YES Go to step8. ls therc continuity? N O - G o t o s t e p7 . 1 . Measurevoltage betweenEClvl connector t e r m i n a l s 1 1 a n d4 2 ' 1 . 4
ECM CONNECTOR 13'IP} A

YES-Repair short in the wire betweenthe ECM ( A 1 9 ) n d t h e M A Ps e n s o r . l a NO Updatethe ECM if it does not have the latest software,or substitute known-goodECM,then a recheck(seepage 11-6). the symptom/indication lf goes away with a known-goodECM,replacethe o r i g i n aE C M . I l

vccr
{YEL/BED)

sGr
{GRN/WHT}

Wire side of female terminals

11-52

MAPSensor CircuitHighVoltage DTCP0108:


'1. Startthe engine.Holdthe engine at 3,000rpm with no load (in neutral)until the radiatorfan comes on, then let it idle.

MAPsensor 9. Measure voltage between 3P No. connector terminals 1 andNo.3.


MAP SENSOR 3PCONNECTOF

2. Checkthe MAP with the scantool. le about 101kPa (780 nmHg, 30 in.Hg)ot highet, or about2.9 V or higher indicated? YES Go to step 3. NO-lntermittent failure,system is OK at this time. or Checkfor poor connections looseterminalsat the MAP sensorand at the ECM.I 3. Turn the ignitionswitch OFF. 4. DisconnecttheMAP sensor3P connector. 5, ConnectMAP sensor3P connectorterminalsNo. 2 and No. 3 with a jumper wire.
MAP SNSOR3P CONNECTOR

vccl { Y E L / Rl El D ) , o cl l . l . r l I lsct d) l{GRN/wHrr

Y
i

I
l

W i r es i d eo f f e m a l el e r m i n a l s

ls there about 5 V? YES Go to step 10. NO Repairopen in the wire betweenthe ECM (A11) and the MAP sensor.I

1 0 .Turn the ignitionswitch OFF.


A 1 1 .C o n n e c E C Mc o n n e c t otre r m i n a l s 1 1 a n d A 1 9 t with a jumper wire.

1 2 3
MAP {GRN/REO}

A ECMCONNECTOR {31PI

SG1(GRN/WHTI

JUMPER WIRE
W JUMPER IAE

Wiresideof female terminals 6. Turn the ignition switch ON (ll).

Wire side of fema e te.minals

s T u r nt h e i g n i t i o n w i t c hO N ( l l ) . 7. Checkthe MAP with the scantool. Checkthe MAP with the scantool. ls about 101kPa (760 mmHg,30 in.Hg) ot higher, or about2.9 V or higher indicated? YES-Go to step 8. NO Replace MAP sensor.I the 8 . R e m o v e h e j u m p e rw i r e . t YES Updatethe ECM if it does not have the lalest software,or substitutea known-goodECM,lhen recheck(seepage 11-6).lf the symptom/indication goes away with a known good ECM,replacethe originaECM.I l NO-Repair open in the wire betlveenthe ECI\il ( A 1 9 ) n dt h e M A P s e n s o r . I a ls about 101kPa (760 mmHg,30 in.Hg)or higher, or about2.9 V ot higher indicated?

11-53

PGM-FI System
(cont'dl DTCTroubleshooting
DTCPl128: MAPSensor Signal Lower Than Expected
1. Turn the ignition switch ON (ll). 2. Checkthe MAP with the scantool. ls 54.1 kPa(406mmHg, 16.0in.Hg),1.6 V, or higher indicated? YES- Intermittent failure.system is OK at this time.I NO Replace the MAP sensor.l

DTCPl129: MAPSensor Higher Signal Than Expected


1. Startthe engine.Hold the engineat 3,000rpm with no load (in neutral)until the radiatorfan comes on, then Iet it idle. 2. Checkthe MAP with the scantoot. ls 36.9 kPa (277 mmHg, 10.9 in.Hg),1.1 V , or less indicated? YES- lntermittentfailure,system is OK at this time.l NO Replace the MAP sensor.l

11-54

DTCP0112: Sensor IAT Circuit LowVoltage


1 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s 2. Checkthe IAT with the scantool. ls 302'F (150'C) or highet (or H-Limit in Honda node of PGM Tester),ot 0 V indicated? VES-Go to step 3. NO Go to step 8.

8. Checkthe temperaturereadingon the scantool. Be aware that if the engine is warm, the reading l. w i l l b e h i g h e r h a na m b i e n t e m p e r a t u r e I t h e t engine is cold, the IAT and ECTwill have the same v al u e . ls the correct ambient temperatureindicated? YES lntermittentfailure,system is OK at this time or Checkfor poor connections looseterminalsat t h e I A Ts e n s o r n d a t t h e E C M . I a NO Replace IAT sensor.l the

Disconnect IAT sensor2P connector. the


4 . Checkthe IAT with the scantool.

ls 302'F(150'C)or higher (or H-Limit in Honda mode of PGM Testet),ot 0 V indicated? YES-Go to step 5. NO- Replace IAT sensor.I the 5 . Turn the ignition switch OFF. ECMconnectorB (24P). 6 . Disconnect 7 . Checkfor continuitybetweenIAT sensor2P c o n n e c t otre r m i n a lN o . 2 a n d b o d y g r o u n d ,
IAT SENSOR2P CONNECTOR

,^\ , l r 2 l
t
-----Tr---

II

l IAT _t{RED/YELI

W i r es i d eo f f e m a l e e r m i n a i s t

ls there continuity? YES Repairshon in the wire betweenthe ECM ( B ' 1 7a n d t h e I A Ts e n s o r . l ) NO Updatethe ECM if it does not have the latest software,or substitutea known-goodECM,then lf recheck(seepage 11-6). the symptom/indication goes away with a known-goodECM,replacethe originaECM.I l

11-55

PGM-FI System
(cont'dl DTCTroubleshooting
DTCP0113: Sensor IAT Circuit HighVoltage
1. Turnthe ignition switch (ll). ON 2. Check IATwith the scan the tool.
YES Go to step 8. 7. Checkthe IAT with the scantool. ls - 4"F ( 20'C) or less(or L-Limitin Honda mode ot PGM Tester) or 5 V indicated?

ls 4'F (-20'C) or less(or L-Limit Honda in modeot PGM Tester)or 5 V indicated?


YES-Go to step 3. NO Intermitent failure,system is OK at this time. Checkfor poor connections looseterminalsat or the IAT sensorand at the ECM.I

NO - Replace IAT sensor.l the 8. Turn the ignition switch OFF. 9 . R e m o v e h e j u m p e rw i r e . t 1 0 . C o n n e c E C Mc o n n e c t otre r m i n a l s 1 0 a n d 8 1 7 t A w i t h a j u m p e rw i r e .
ECM CONNECTORS

3 . Turn the ignitionswitch OFF. 4. Disconnect IAT sensor2P connector. the


ConnectIAT sensor2P connectorterminalsNo. 1 a n d N o . 2 w i t h a j u m p e rw i r e . IATSENSOR CONNECTOR 2P
JUMPERWIRE A (31 P)

B {24 P)

rJ--

:---

\"

l ' l L l
-'_-l--_----r--_

sG2 rAT I {GRN/YEL) IRED/YEL) I L ] WIRE JUMPER Wiresideof female terminals

Wiresideof female terminals 1 1 .T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s 12. Checkthe IAT with the scantool. ls - 4"F ( 20"C) or less (or L-Limitin Honda mode of PGM Tester) or 5 V indicated? YES Updatethe ECMif it does not have the latest software,or substitutea known-goodECI\4 then recheck(seepage 11-6). the symptom/indication lf goes away with a known-goodECM.replacethe originaECM! l . NO Repairopen in the wire betweenthe ECM ( A 1 0 ,8 1 7 )a n dt h e I A Ts e n s o r . I

6 . T u r nt h e i g n i t i o n w i t c hO N { l l ) . s

11-56

ECT DTCP0116: SensorRange/Performance Problem


and/or P0118 are storedat the NOTE:lf DTCP0117 those DTCS first, troubleshoot same time as DTCP0116, for then recheck DTCP0116, 1. Stanthe engine.Hold the engineat 3,000rpm with no load {in neutral)until the radiatorfan comes on, then let it idle. 2. Checkthe ECTwith the scantool. ls 176- 212'F (80 indicated? 100"C)or0.5 0.8V

failure.system is OK at this time. YES Intermittent Checkthe thermostatand the cooling system.l NO-Checkthe thermostatand the cooling system. lf they are OK, replacethe ECTsensor.l

11-57

PGM-FISystem
(cont'dl DTCTroubleshooting
DTCP0117: SensorCircuitLow Voltage ECT
1 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s 2. Checkthe ECTwith the scantool. ls 150'C (302'F)or higher (ot H-Limit in Honda mode of PGM Tester) or 0 V indicated? YES Go to step 3. NO Intermittent failure,system is OK at this time. Checkfor poor connections looseterminalsat or the ECTsensorand at the ECM.t
Wire side of femaleterminals

\
7. Checkfor continuitybetweenthe ECTsensor2P connectorterminal No. 1 and bodv oround. ECTSENSOR CONNECTOR 2P

3. Disconnect ECTsensor2P connector. the 4. Checkthe ECTwith the scantool. ls 150'C (302"F)or higher (ot H-Limit in Honda mode ot PGM Tester) or 0 V indicated? YES-Go to step 5. NO Replace ECTsensor. the ! ls there continuity? YES-Repair short in the wire betweenthe ECM ( B 8 )a n d t h e E C Ts e n s o r . l NO-Update the ECMif it does not havethe latest software,orsubstitute known-goodECM,then a recheck{seepage 11-6). the symptom/indication lf goes away with a known-goodEClvl, replacethe originaECM.I l

5. Turn the ignition switch OFF. 6. Disconnect ECMconnectorB (24P).

11-58

HighVoltage DTCP0118: Sensor ECT Circuit


1 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s 2. Checkthe ECTwith the scantool.

1 . Checkthe ECTwith the scantool. ls 20"C ( 4"F)or less (or L-Limitin Honda mode ot PGM Tester) or 5 V indicated? YES-Go to step 8.

ls 20'C ( 4'F)or less(or L-Limitin Honda mode of PGM Tester) or 5 V indicated? YES Go to step 3. NO lntermittentfailure,system is OK at this time. Checkfor poor connections looseterminalsat or the ECTsensorand at the ECM.I
?

N O R e p l a c eh e E C Ts e n s o r . I t 8 . Turn the ignition switch OFF. t 9 . R e m o v e h e j u m p e rw i r e . 1 0 . ConnectECMconnectorterminalsA10 and Bg with a j u m p e rw i r e .


ECM CONNECTORS

Turn the ignitionswitch OFF. Disconnect ECTsensor2P connector. the

5 . Connectthe ECTsensor2P connectorterminals N o . 1 a n d N o . 2 w i t h a j u m p e rw i r e .


ECTSENSOR2P CONNECTOR

a {31P}

B {24P)

JUMPERWIRE

Ecr (RED/WHT)

lt t .l t l l t -I-l*,
{GRN/YEL)

terminals Wiresideof female s 1 1 .T u r nt h e i g n i t i o n w i t c hO N ( l l ) . 1 2 . Checkthe ECTwith the scantool.

t l WIRE JUMPER wire sideoI Iemale terminals

ls 20"C ( 4"F) or less (or L-Limitin Honda mode of PGM Tester) ot 5 V indicated? s 6 . T u r nt h e l g n i t i o n w i t c hO N ( l l ) . YES- Updatethe ECM if it does not havethe latest then a software,or substitute known-goodECI\4, recheck(seepage 11-6).If the symptom/indication goes away with a known-goodECM,replacethe o r i g i n aE C M . I l NO Repairopen in the wire betweenthe ECM ( A 1 0 ,8 8 ) a n d t h e E C Ts e n s o r . l

11-59

PGM-FI System
(cont'dl DTCTroubleshooting
DTCP0122: Sensor TP CircuitLowVoltage
1 . T u r nt h e i g n i t i o n w i t c ho N ( 1 1 1 . s 2. Checkthe throttle positionwith the scantool. ls there about 10./.or 0.5 V when the thrcttle is fully closed and about 90% or 4.5 V when the throttle is fully opened? YES Intermittent failure,system is OK at this time. Checkfor poor connections looseterminalsat or the TP sensorand at the ECM. t NO Go to step 3. 3. Turn the ignition switch OFF, 4. Disconnect TP sensor3P connector. the 5 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s 6. Measurevoltagebetweenthe TP sensor3P connectorterminals No. 1 and No. 3.
TP SENSOR3P CONNECTOR

8. At the sensorside, measureresistance betweenthe TP sensor3P connectorterminalsNo. 1 and No. 2 with the throttlefully closed.
TP SENSOR CONNECTOR 3P

T e r m i n a li d e f m a l e e r m i n a l s s o t

Is there about 0.5 0.9 kQ ? YES Go to step 9. NO Replace throttle body (theTP sensoris not the a v a i l a b l e e p a r a t e l yI) . s 9 . Measureresistance betweenthe TP sensor3P connectorterminalsNo. 2 and No. 3 with the throttlefully closed. TPSENSOR CONNECTOB 3P

Wire side of femaleterminals

ls thereabout5 V?
Terminal of male side terminals

YES-Go to step7. N O G ot o s t e p1 4 .
1 . Turnthe ignition switch OFF. ls there about 4.5k{l ? YES Go to step 10. NO Replace throttle body (theTP sensoris not the a v a i l a b l e e p a r a t e l yI) . s 1 0 . D i s c o n n e c t C Mc o n n e c t oA ( 3 1 P ) . E r

11-60

for side, check continuity 11. At thewire harness terminal 2 No, TP 3P between sensor connector a n db o d yg r o u n d .
TP SENSOR CONNECTOR 3P

check continuity for side, 13. At thewire harness terminal 2 No. TP 3P between sensor connector a n db o d yg r o u n d .
TP SENSOR CONNECTOR 3P

11 2 1 3
'PS REO /BLKI

1 2 3
TPS (RED/BLX}

Wire sideof female terminals

Wire side ot Iemaleterminals

ls there continuity?

ls thetecontinuity? the YES-Repair shortin the wire between ECM { A 1 5a n dt h eT Ps e n s o r . l l ) N O - G o t o s t e p1 2 . A15to body ECM connector terminal 12. Connect ground with a jumperwire.
A ECMCONNECTOR 131P)

YES-Update the ECM if it does not have the latest software,or substitutea known-goodECM,then lf recheck(seepage 11-6). the symptom/indication goes away with a known-goodECM,replacethe originaECM.I l NO- Repairopen in the wire betweenthe ECM ( A 1 5 ) n dt h e T P s e n s o r . l a voltage betweenECMconnector 14. lvleasure 4 t e r m i n a l s 1 0 a n dA 2 0 .
A ECMCONNECTOB 131P}

9 1 1 2 1 34 5 6 7 19t2021 tc 6 10 1 1 1 1 2 8

23124

28129130

wrne ,tf$,rr*, ];uueen


vcc2
terminals Wire side oJ.female (YEL/8LU)

Wire side of female terminals

ls there about 5 V? YES Repairopen in the wire betlveenthe ECM ( A 2 0 ) n dt h e T P s e n s o r . I a NO Updatethe ECM if it does nor have the latest software,or substilutea known-goodECM,then ( r e c h e c k s e ep a g e11 - 6 ) l.f t h e s y m p l o m i n d i c a t i o n goes away with a known-goodECM.replacelhe originaECM.I l

11-61

PGM-FI System
(cont'd) DTCTroubleshooting
DTCP0123: Sensor TP Circuit HighVoltage
1 . T u r nt h e i g n i t i o n w i t c ho N ( l l ) s 2. Checkthe throttle positionwith the scantool. ls there about 10%or 0.5 V when the throttle is fully closed and about 90% or 4.5 V when the throttle is f ully opened? YES lntermittentfailure.system is OK at this time. Checkfor poor connections looseterminalsat or t h eT Ps e n s o r n da t t h e E C MI a , NO Go to step 3. 3. Turn the ignition switch OFF. Is there about 5 V? 4. Disconnect TP sensor3P connector. the 5 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s 6. At the wire harnessside, measurevoltage between the TP sensor3P connectorterminalsNo. 1 and No.3.
TP SENSOR CONNECTOR 3P

(
7. Measurevoltage betweenECMconnector terminalsA10 and A20.
ECMCONNECTOR 131PI A

Wiresideof female terminals

YES- Repairopen in the wire betweenthe ECM (A10)and the TP sensor. t NO Updatethe ECMif it does not havethe latest soflware,or substitutea known-goodECM,then recheck(seepage 11-6). the symptom/indication lf goes away with a known-goodECM,replacethe o r i g i n aE C M . I l

W;resideof female terminals

ls thete about 5 V? YES-Replace the throttle body (theTP sensor is not availableseparately). I NO Go to step 7.

11-62

TP Lower Than DTCPl121: Sensor Signal Expected


1 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s 2. Checkthe throttle positionwith the scantool. ls 12.9'/.,0.6 V, or higher indicated when the throttle is tully opened? YES- Intermittent failure,system is OK at this time.I NO-Replace the TP sensor(the TP sensor is not availableseparately). I

Higher Than DTCP1122:.fP Sensor Signal Expected


1 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s 2. Checkthe throttle positionwith the scantool. ls 12.9%,0.6 V, or lessindicated when the throttle is f ully closed? failure,system is OK at this YES Intermittent time.l NO Replace TP sensor(theTP sensoris not the availableseparately). I

11-63

PGM-FI System
(cont'dl DTGTroubleshootang
DTCP0128: CoolingSystemMalfunction
NOTE;lf the DTCS listedbelow are stored at the same time as DTCP0128. troubleshootthose DTCS first, then recheck P0128. for P 0 1 0 7P 0 1 0 8P 1 1 2 8P 1 1 2 9N 4 a n i f o la b s o l u t e , , , : d pressure(MAP)sensor P] I06, P1107,P1108:Barometricpressure(BARO) sensor P1259: VTECsystem P0116,P0117, P0118:Enginecoolanttemperature(ECT) sensor P0112,P0113: Intakeair temperature(lAT)sensor P0500: Vehiclespeedsensor{VSS) position(CKP) P0335, P0336: Crankshaft sensor P0300: Randommisfire P 0 3 0 1P 0 3 0 2P 0 3 0 3P 0 3 0 4N o . 1 , N o . 2 , N o . 3 o r N o . 4 , , , : cylinder misfire P0505: ldle control system malfunction P 1 5 1 9l:d l ea i r c o n t r o l( l A C ) v a l v e DTCP0128 can occasionally when the hood is set o p e n e d h i l e t h e e n g i n ei s r u n n i n g . w 1. Checkthe enginecoolant level Is the engine coolantlevel low? VES Refillthe enginecoolant.lf necessary, repair t h e c o o l a n tl e a k a g e . l NO Go to step 2. 2 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) ,a n d m a k es u r et h e s A,/Cis off. 3. Checkthe radiatorfan. Does the tadiator fan keep running? YES Checkthe radiator fan circuit(seepage 1014),the radiatorfan switch circuit(Short)(seepage 10-'16), the radiatorfan switch (seepage 10-17). and Also, inspectthe ECTand IAT circuitsand terminal connections. the circuits, lf the switch,and the connections are OK, updatethe ECI\4 it does not if have the latestsoftware.or substitutea knowngood ECM,then recheck(seepage 11-6).lf the goes away with a known-good symptom/indication E C M ,r e p l a c eh e o r i g i n a E C M . I t l NO Replace thermostat(seepage 10-8).1 the

11-64

1) DTCP0134: Sensor(Sensor No Activity Ay'F Detected


1. Checkthe attachmentstateof the A,/F sensor (Sensor ). 1 ls it slacked f rom the exhaust pipe? YES- Reinstall Ay'F the sensor(Seneor1) (seepage 11-113).t NO-Go to step 2. 2 . R e s e t h e E C M( s e ep a g e11 - 4 ) . 3 . S t a nt h e e n g i n e H o l dt h e e n g i n e p e e da t . s 3,000rpmwith no load (in neutral)until the radiator fan comes on, then let it idle for 2 minute. ls DTC PO134 indicated? YES-Replacethe Ay'F sensor{Seneor1) (seepage 11-113).t failure, sistem is OK at this time. NO - Intermittent or Checkfor poor connections looseterminalsat the Ay'F sensor(Seneor1) and the ECM.I

(Sensor DTCP0137: Secondary HO2S 2) LowVoltage Circuit


1 . R e s e t h e E C M( s e ep a g eI 1 - 4 ) 2. Start the engine.Holdthe engine at 3,000rpm wilh no load (in neutral)until the radiatorfan comes on. 3. Checkthe secondaryHO2S(Sensor2) output voltageat 3,000rpm with the scantool. ls there 0.3 V or less? YES Go to step 4. NO-lntermittent failure,system is OK at this time. or Checkfor poor connections looseterminalsat the secondaryHO2S(Sensor2) and at the ECM.I s 4. T u r nt h e i g n i t i o n w i t c hO F F . the secondaryHO2S(Sensor2) 4P 5 . Disconnect connector. 6 . Turn the ignition switch ON (ll). 7 . Checkthe secondaryHO2S(Sensor2) output voltagewith the scantool. ls there 0.3 V or less? YES Go to step 8. r H N O R e p l a c eh e s e c o n d a r y O 2 S( S e n s o 2 ) . 1 t 8 . Turn the ignition switch OFF. E r 9 . D i s c o n n e c t C Mc o n n e c t oE ( 3 1 P ) .

icont'd)

11-65

PGM-FISystem
(cont'dl DTCTroubleshooting
10. Checkfor continuitybetweenthe secondaryHO2S (Sensor2) 4P connectorterminal No. 2 and body ground. SECONDARY H02S 2) ISENSOR 4PCONNECTOR

a
(Sensor DTCP0138: Secondary HO2S 2) Circuit HighVoltage
1 . R e s e t t h e C M{ s e ep a g e ' 1 1 - 4 ) . E 2. Startthe engine.Hold the engineat 3,000rpm with no load (in neutral)until the radiatorfan comes on. 3. Checkthe secondaryHO2S(Sensor2) output voltageat 3,000rpm with the scantool. ls thete 1.0 V or morc? YES Go to step 4.

Terminalside of male terminals

NO-lntermittent failure,system is OK at this time. Checkfor poor connections looseterminalsat or the secondaryHO2S(Sensor2) and at the ECM.I 4. Turn the ignition switch OFF.

ls there continuity? YES-Repair shon in the wire betweenthe ECM (E2)and the secondaryHO2S(Sensor2).t NO Updatethe ECM if it does not have the latest software,or substitutea known-goodECM,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe originaECM.I| l

5. Disconnect secondaryHO2S(Sensor2) 4P the connector. ConnectsecondaryH02S (Sensor2) 4P connector t e r m i n a l s o . 1 a n d N o . 2 w i t h a j u m p e rw i r e . N


SECONDARY HO2S 2) {SENSOR 4P CONNECTOR JUMPERWIRE

SG3 (PNKI

SHO25(WHT/RED)

T e r m i n as i d eo Jm a l et e r m i n a l s l 7. Turn the ignitionswitch ON (ll).

11-66

8 . Checkthe secondaryH02S (Sensor2) output


voltagewith the scantool, ls there 1.0 V ot mote? YES-Go to step 9. NO Replace secondaryHO2S(Sensor2).1 the

(Sensor Slow HO2S 2l DTCP0139: Secondary Response


E 1 . R e s e t t h e C M( s e ep a g e1 1 - 4 ) . Start the engine.Holdthe engine at 3,000rpm with no load (in neutral)until the radiatorfan comes on.

3 . Checkthe secondaryHO2S(Sensor2) output


9 . Turn the ignitionswitch OFF. 1 0 . ConnectECMconnectorterminalsE2 and E4 with a J U m p ew r r e . r E ECMCONNECTOR 131PI voltageat 3,000rpm with the scantool. ls thete 0.3- 0.8 V, fot 2 minutes? YES Replace secondaryHO2S(Sensor2).! the NO- lntermittentfailure,system is OK at this time. or Checkfor poor connections looseterminaisat the secondaryHO2S(Sensor2) and at the ECM.I

JUMPER WIRE

Wiresideof female terminals 1 1 .Turn the ignition switch ON (ll). 1 2 . Checkthe secondaryHO2S(Sensor2) output voltagewith the scantool. ls there 1.0 V or more? YES Updatethe ECM if it does not have the latest soflware,or substitutea known-goodECM,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM.replacethe originaECM.I l NO Repairopen in the wire betweenthe ECM (E2, E4)and the secondaryHO2S{Sensor2).I

11-67

PGM-FISystem
(cont'dl DTCTroubleshooting
(Sensor DTCP0141: Secondary HO2S 2l Heater Malfunction Circuit
1. Resetthe ECM(seepage 1 l-4) 2. Startthe engine. ls DTC P0141indicated? YES-Go to step 3. NO-lntermittent failure,system is OK at this time. Checkfor poor connections looseterminalsat or the secondaryHO2S(Sensor2) and at the ECM.I 6. Checkfor continuitybetweenbody ground and secondaryH02S (Sensor2) 4P connectorterminals N o . 3 a n d N o .4 i n d i v i d u a l l y . SECONDARY HO2S 21 {SENSOR 4PCONNECTOR

Wire side of femaleterminals

3 . Turn the ignitionswitch OFF.


Disconnect secondaryH02S (Sensor2) 4P the connecror. 5 . At the secondaryHO2S(Sensor2) side, measure resistance betweenH02S 4P connectorterminals N o . 3 a n d N o .4 . (SENSOR 4PCONNECTOR HO2S SECONDARY 21

ls therecontinuity? (Sensor YES- Replace secondary the HO2S 2).1 NO-Go to step7.
7 . Turnthe ignition switch (ll). ON 8 . Measure voltage between secondary H02S4P

connector terminals 3 andNo.4, No.


SECONDARY HO2S (SENSOR ilP CONNECTOR 2l

s02sHTc {BLK/WHTI
Wire side ol lemale terminals

IG1(BLK/ORN}

ls thereabout3.3 Q ? YES Goto step6. (Sensor t NO- Replace secondary the HO2S 2).

T e r m i n a li d e f m a l e e r m i n a l s s o t

ls there battery voltage? YES Go to step 9. NO Go to step 12. 9 . Turn the ignition switch OFF. 1 0 . Disconnect ECMconnectorE {31P)

11-68

11. Check continuity for between ECM connector terminal andbodyground. E6


E ECM CONNECTOR {31PI

1 3 .Turn the ignitionswitch OFF.


1 4 . Reconnect secondaryHO2S(Sensor2) 4P the connector.
t5.

Disconnect ECMconnectorE (31P). Turn the ignition switch ON (ll).

to.

1 7 . Measurevoltage betweenECMconnectorterminal E 6a n d A 5 . ECMCONNECTORS


Wire side o{f Iemaleterminals

A (31 P)

ls therc continuity? YES-Repair short in the wire betweenthe ECM r ( E 6 ) n d t h e s e c o n d a r y O 2 S( S e n s o 2 ) . 1 a H NO-Update the ECM if it does not have the latest soflware,or substitutea known-goodECM,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe o r i g i n aE C M . I l MeasurevoltagebetweensecondaryHO2S (Sensor2) 4P connectorterminal No. 4 and body g round. HO2S 2I SECONDARY {SENSOR 4PCONNECTOR

E {31P}

Wire side ot femaleterminals

Is there 0-1 V or less? YES-Repair open in the wire betweenthe ECM (E6)and the secondaryHO2S(Sensor2).! NO Updatethe ECM if it does not havethe latest software,or substitutea known-goodECM,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe . o r i g i n aE C Ma l

tFff I

l[faJl--ro' 14 |

IBLK/OFN)

Y I
Terminal of male terminals side ls there battety voltage? YES Go to step 13. N O - C h e c k t h e N o . 4 A C G( 1 0 A ) u s ei n t h e u n d e r f dash fuse/relaybox. lf the fuse is OK, repair open in the wire betweenthe secondaryHO2S(Sensor2) f a n d N o . 4 A C G( 1 0 A ) u s e . l

11-69

PGM-FI System
(cont'dl DTCTroubleshooting
Fuel Too Lean DTCP0171: System Too Rich DTCP0172: FuelSystem
listedbelow are storedat NOTE:lf some of the DTCS the same time as DfC PO17'l and/ot PO172, for first, then recheck P0171 troubleshootthose DTCS andlot P0112. . a P 0 1 0 7P 0 1 0 8P 11 2 8 .P 11 2 9 :M a n i f o l d b s o l u t e , ( p r e s s u r eM A P ) e n s o r s P1162.P1166,P 1167:4,,/F sensor(Sensor1) heater r H : P 0 1 3 7P 0 1 3 8S e c o n d a r y O 2 S( S e n s o 2 ) , P014'l: SecondaryHO2S(Sensor2) heater P1259: VTECsystem ( 1 . C h e c k h e f u e l p r e s s u r e s e ep a g e1 1 - ' 1 4 5 ) . t ' ls luel pressure OK? YES Go to step 2. Does it hold vacuum? NO Checkthese items: . lf the pressureis too high, replacethe fuel p r e s s u r e e g u l a t o( s e ep a g e1 1 - 1 5 2 ) . 1 r r . l f t h e p r e s s u r es t o o l o w . c h e c k t h e f u ep u m p , i l the fuel feed pipe,the fuel filter, and replacethe r r f u e l p r e s s u r e e g u l a t o ( s e ep a g e1 1 - 1 5 2 ) . I 2. Startthe engine.Hold the engineat 3,000rpm with no load (in neutral)until the radiatorfan comes on. and adjust YES-Check the enginevalve clearances lf are if necessary, the valve clearances OK, replace ( 1 t h e i n j e c t o r ss e ep a g e11 - 1 1 ) . 1 NO-Replace the EVAPcanisterpurge valve.l A973AX-041-XXXXX 3. Turn the ignition switch OFF. 4. With a vacuum pump, apply vacuum to the emission(EVAP) canisterpurge valve evaporative (A) from the evaporative emission(EVAP) canister side.

11-70

DTCP0300: Random Misfire andAny Combination the Following: of DTCP0301: 1 Cylinder No. Misfire No. Misfire DTCP0302: 2 Cvlinder DTCP0303: 3 Cvlinder No, Misfire DTCP0304: 4 Cvlinder No. Misfire
NOTE: . lfthe misfiring is frequentenoughto trigger detectionof increased driving cycles. emissionsduring two consecutive will be stored. the MIL will come on, and DTCP0300(and some comlrinationof P0301 through P0304) . lf the misfiring is frequentenoughto damagethe catalyst, the MIL will blink wheneverthe misfiring occurs,and OTC P0300(and some combinationof P0301 through P0304) will be stored.When the misfirlng stops,the MIL will remain on. 1. Troubleshoot following DTCsfirst if any of them were stored along with the random misfire DTC(s): the ( p P 0 ' 1 0 7 ,0 1 0 8P 1 1 2 8P 1 1 2 9N 4 a n i f o la b s o l u t e r e s s u r eM A P )s e n s o r P , , r d P0111. P0'172t Fuelsvstem position(CKP) P0335. P0336: Crankshaft sensor P0505: ldle control system sensor P1149,Pl 162,P1163,P1164,P 1165:Air fuel ratio (Ay'F) VTECsystem P1259: P1361, P1362: sensor) Camshaftposition(CMP)sensorB {Top dead center(TDC) P 1 5 1 9l:d l ea i r c o n t r o l( l A C ) a l v e v 2. Test-drive vehicleto verify the symptom. the in 3. Findthesymptom inthechart below, and dothe relatedprocedures the order listeduntil you find the cause. Symptom Random isfire nly m o at low RPMand under load Random isfire nly m o du ring acceleration Randommisfire at h i g h R P M ,u n d e r l o a d ,o r u n d e r random conditions

Procedure(sl
Checkfuel pressure(seepage 11-145).

Also check foi:

. Lowcompressron. . Lowquality fuel. in Malfunction the (see page VTEC system 1' t-123).
Correctenginevalve (seepage 6clearances 91.

Checkfuel pressure(seepage 11-145).

( C h e c k u e l p r e s s u r es e ep a g e1 1 - 1 4 5 ) . f

11-71

PGM-FI System
(cont'dl DTCTroubleshooting
No. Misfire DTCP0301: 1 Cylinder No. Misfire DTCP0302: 2 Cylinder No. Misfire DTCP0303: 3 Cylinder
YES Replace faulty ignitioncoil.! the 1 . Determine which cylinder(s) had the misfire. Does the misf ire occur in the cylinder where the ignition coil was exchanged?

No. Misfire DTCP0304: 4 Cylinder


NO-Go to step 8. 1. After checkingand recordingthe freezedata,reset the ECM (seepage 11-4).lf there is no freezedata of the misfire,just clearthe DTC. 2. Startthe engine,and listenfor a clickingsound from the injectorat the problemcylinder. 8 . Turn the ignition switch OFF. 9 . Exchange spark plug from the problemcylinder the with one from anothercylinder.

1 0 .Test-drive vehiclefor severalminutes in the the


rangeof the freezedata or under various conditionsif there was no freezedata.

Does the injector click? YES-Go to step 3. NO-Go to step 30. 3. Turn the ignition switch OFF. YES Go to step 12. 4. Exchange ignition coil from the problem the cylinderwith one from anothercylinder, the 5. Test-drive vehiclefor severalminutesin the range of the freezedata or under va rious conditionsif there was no freezedata. 6. Checkfor a DTCor a TemporaryDTCwith the scan root. ls DTC or Tempotaty DTC P0301, P0302, P0303 or P0304 ind icated? YES Go to step7. misfire due to poor contactat the NO Intermittent a i g n i t i o n o i l c o n n e c t o r { n o m i s f i r e t t h i st i m e ) . c s are Make sure the coil connections secure.l NO Intermittentmisfiredue to spark plug fouling, e t c .( n o m i s f i r ea t t h i st i m e ) . 1 D e t e r m i n e h i c h c y l i n d e r ( sh a dt h e m i s f i r e . w ) Does the misl ire occur in the cylinder where the spark plug was exchanged? Y E S R e p l a c eh e f a u l t ys p a r kp l u g . l t NO Go to step 13. Turn the ignition switch OFF. 1 4 . Exchange lnjectorfrom the problemcylinder the w i t h o n ef r o m a n o t h e r y l i n d e r . c
t5.

1 1 .Checkfor a DTCor TemporaryDTCwith the scan Tool. ls DTC ot Tempotary DTC P0301, P0302, P0303 or P0304indicated?

L e tt h e e n g i n ei d l ef o r 2 m i n u t e s .

11-72

1 6 .Test-drive vehiclefor severalminutesin the the rangeof the freezedata or under various conditionsif there was no freezedata.

22. Measurevoltage betweenignition coil 3P connectorterminal No. 3 and body ground.


IGNITIONCOIL3P CONNECTOR

't7. Checkfor a DTCor a TemporaryDTCwith the scan


Tool. ls DTC or TemporaryDTC P0301,P0302, P0303 or P0304 indicated? YES Go to step 18. NO lntermittentmisfire due to bad contactat the injectorconnector(no misfireat this time). Make surethe injectorconnectionis secure.Checkfor poor connections looseterminalsat the or injector.l

Wire side ol femaleterminals

ls there battery voltage?

1 8 .Determinewhich cylinder(s) had the misfire.


YES-Go to step 23. Does the misf ire occur in the cylinder where the i njector w as exchanged ? YES- Replace faulty injector.I the NO Repairopen in the wire betweenthe No. 1 I G NC O I L( 1 5 A ) f u s e n dt h e i g n i t i o n o i l . I a c

2 3 . Turn the ignitionswitch OFF.


NO-Go to step19.

24. Checkfor continuitybetweenignitioncoil 3P 1 9 .Turn the ignitionswitch OFF. 20. Disconnect ignitioncoil 3P connectorfrom the the
problemcylinder. Turn the ignition switch ON (ll). connectorterminal No. 2 and body ground. IGNITION COIL3PCONNECTOR

Wire side ot femaleterminals

ls there continuity? YES Go to step 25. NO Repairopen in the wire betweenthe ignition G coiland 101.1 ECMconnectorA {31P) Disconnect

(cont'd)

11-73

PGM-FI System
(cont'dl DTCTroubleshooting
26. Checkfor continuitybetweenbody ground and ECMconnectorterminal (seetable). ECMCONNECTOR {31PI A 28. Checkfor continuitybetweenbody ground and ECMconnectorterminal (seetable).
ECMCONNECTOR {31P} A

PROB IVI LE CYLINDER


N o .1 No.2 No.3 No,4

DTC P0301 P0302 P0303 P0304

ECM WIRE TERMINAL COLOR

PROBLEM CYLINDER
No.1 N o .2 N o .3 N o .4

DTC P0301 P0302 P0303 P0304

430 A.29 428 421

YEUGRN BLU/RED WHT/BLU BRN

ECM WIRE TERI\4INAL COLOR A30 YEL/GRN 429 BLU/RED A.28 WHT/BLU A.21 BRN

ls there continuity? YES Repairshon in the wire betweenthe EClvl a n dt h e i g n i t i o n o i l . l c NO-Go to step 27. 2 7 . C o n n e c itg n i t i o n o i l 3 P c o nn e c t o r e r mi n a l N o . 1 t o c t body ground with a jumper wire (seetable).
IGNITIONCOII 3PCONNECTOR

ls there continuity? YES-Go to step 29. NO Repairopen in the wire betweenthe ECMand the ignition oil.l c 29. Checkthe engine compression

ls the compression OK? YES-Update the ECM if it does not have the latest software,or substitutea known-goodECM,then recheck(seepage 11-6). the symptom/indication lf goes away with a known-goodECM,replacethe originaECI\4.I l

Wire s de of femaleterminals

NO- Repaithe engine.l r

3 0 . Disconnect ECMconnectorB (24P). PROBLEM CYLINDER


No.1 N o .2 N o .3 N o .4

DTC P0301 P0302 P0303 P0304

WIRECOLOR
T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s

YEUGR N BLU/RED WHT/BLU


BRN

11-74

32. fvleasure voltage between bodygroundandECM (see connector terminal table).


ECMCONNECTOR (24P) B

36. Exchange injectorfrom the problemcylinder the


w i t h o n ef r o m a n o t h e r y l i n d e r . c

3 7 . L e t t h ee n g i n ei d l ef o r 2 m i n u t e s . 3 8 . Test-drive vehiclefor severalminutes in the the


r a n g eo I t h e l r e e z e a t ao r u n d e rv a r i o u s d condilionsif there was no freezedata.

39. Checkfor a DTCor TemporaryDTCwith the scan


tool. ls DTC or TemporaryDTC P0301,P0302, P0303, or P0304 indicated?
W i r e s i d e o f f e m a l et e r m r n a l s

YES Go to step 40. PROBLEM CYLINDER No. 1 No.2 No.3 No.4

DTC P0301 P0302 P0303 P0304

EC t\4 TERMINAL B5 B4 B3

WIRE COLOR BRN RED BLU YEL

NO Intermittentmisfiredue to injector malfunction,etc. Make sure the injector connections are secure.Checkfor poor connections or looseterminalsat the injectorconnector.l D e t e r m i n e h i c hc y l i n d e r { sh a d t h e m i s f i r e . w }

ls there battery voltage? YES-Go to step 33, N O G o t o s t e p4 1 . Does the mislirc occur in the cylinder whete the i nj ector w as exchanged ? YES Replace faulty injector.l the NO Updatethe ECM if it does not have the latest software,or substitutea known-goodECM.then recheck(seepage 1'l-6).lf the symptom/indication goes away with a known-goodEClvl, replacethe originaECM.I l

33. Turn the ignitionswitch OFF,and removethe


engine cover.

34. Disconnect injector2P connectorfrom the the


problem ylinder. c

3 5 , Measurethe resistance betweeninjector2P


c o n n e c t otre r m i n a l s o . 1 a n d N o . 2 . N

4 1 .Turn the ignition switch OFF. 42. Removethe enginecover.

INJECTOB CONNECTOR 2P

43. Disconnect injector2P connectorfrom the the


p r o b l e mc y l i n d e r . 4 4 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) s

Terminal side of male terminals

l s t h e r e 1 0Q

13A?

YES-Go to step 36. ( N O R e p l a c eh e i n j e c t o r s e ep a g e11 -1 1I ) .t t (cont'd)

11-75

PGM-FI System
(cont'dl DTCTroubleshooting
45. Measure voltage between injector connector 2P N t e r m i n a l o .1 a n db o d yg r o u n d .
INJECTOR CONNECTOR 2P

48. Connect injector connector 2P terminalNo.2to with a jumper wire {see table). bodyground
INJECTOR2P CONNECTOR

tll-z] -lt,o,,"=rrrr*, o I
Wiresideof female terminals

tll-Z-l -]_r-l_rNJ
IJUMPER

IwrBE
Wire side of {emaleterminals

ls there battery voltage? YES-Go to step 46. NO-Repair open in the wire betweenthe injector l a n d t h e P G M - Fm a i n r e l a yl . l PROBLEM CYLINDER No.1 No.2 N o .3 N o .4

DTC P0301 P0302 P0303 P0304

WIRECOLOR BRN RED BLU YEL

46. Turn the ignitionswitch OFF. 4 7 .Checkfor continuitybetweenbody ground and


ECMconnectorterminal (seetable).
B ECMCONNECTOR {24P)

49. Checkfor continuitybetweenbody ground and ECMconnectorterminal (seetable).


ECM CONNECTOR I24P) B

Wire side oJtemaleterminals t W i r es i d eo f f e m a l e e r m i n a l s

PROBLEM CYLINDER N o .1 No.2 No.3 N o .4

ECM TERMINAL P030'1 B5 B4 P0302 P0303 B3 P0304 82 DTC

WIRE COLOR
BRN

RED BLU YEL

PROBLEM CYLINDER No.1 N o .2 N o .3 N o .4

DTC P0301 P0302 P0303 P0304

ECM TERMINAL B5 B4 B3 82

WIRE COLOR BRN RED BLU YEL

ls therc continuity? ls there continuity? YES Replace injector,then recheck.l the YES-Repair short in the wire betweenthe ECM a n dt h e ; n j e c t o r . I N O - G o t o s t e p4 8 . NO Repairopen in the wire betweenthe ECM and the injector.I

11-76

DTG P0325: Malfunction KnockSensor in Circu it


1 . R e s e t h e E C M( s e ep a g e1 1 - 4 ) . 2. Startthe engine.Hold the engineat 3,000rpm with no load (in neutral)until the radiatorfan comes on, then let it idle. 3. Holdthe engineat 3,000-4,000 rpm for at least 60 seconds. ls DTC P0325 indicated?

7. Connect staner subharness connector 6P terminal r N o .5 t o b o d yg r o u n d i t ha j u m p e w i r e . w


STARTER SUAHARNESS 6P CONNECTOR

l1l213l
l,/l5l6l ._
KS IJUMPER |RED/BLU) IW|RE I Wiresideof female terminals

YES-Go to step 4. NO Intermittent failure,system is OK at this time. Checkfor poor connections looseterminalsat or the knocksensorand at the ECM.I 4. Turn the ignition switch OFF. 5. Disconnect startersubharness connector. the 6P 6. Checkfor continuitybetweenECMconnector terminalAg and body ground. ECMCONNECTOR 131P) A
Wire side of female terminals

8 . Check continuity for between bodygroundand ECM connector terminal A9.


ECMCONNECTOR {31PI A

ls there continuity? YES-Go to step 9. NO Repairopen in the wire betweenthe ECM (A9) and the startersubharness connector.l 6P
Wire side of lemaleterminals

betweenthe 6P 9 . Checkthe startersubharness

ls therecontinuity? YES-Repair shortin thewire between ECM the (A9)andthe starter subharness connector.l 6P NO Goto step7.

connectorand the knocksensorfor an open or short. lf it's OK, substitutea known-goodknock sensorand recheck. ls DTC P0325 indicated? YES Updatethe ECM if it does not have the latest software.or substitutea known-goodECM,then recheck{seepage '11-6). the sym ptomlindication lf goes away with a known good ECM,replacethe originaECM.I l N O R e p l a c eh e o r i g i n a k n o c ks e n s o r n d / o r t l a starter subharness.l

11-77

PGM-FI System
(cont'd) DTCTroubleshooting
DTCP0335: CKPSensorNo Signal CKPSensorIntermittent DTCP0336: Interruption
'1-4). '1. Reset the ECM (seepage 1 2. Start the engine. ls DTC P0335 and/or P0336 indicated? YES Go to step 3.
Wire side of female tefminals

7. Measurevoltage betweenCKPsensor3P connector t e r m i n a lN o , 1 a n d b o d y g r o u n d


CKPSENSOR CONNECTOR 3P

failure,system is OK at this time. NO Intermittent or Checkfor poor connections looseterminalsat t h e C K Ps e n s o r n d a t t h e E C M . I a 3. Turn the ignition switch OFF. 4. Disconnect CKPsensor3P connector. the 5. Turn the ignitionswitch ON {ll). 6. Measurevoltage betweenCKPsensor3P connector t e r m i n a lN o . 3 a n d b o d y g r o u n d .
CKPSENSOR CONNECTOF 3P
IGP

ls thereabout5 V? YES Goto stepL N O G ot o s t e p1 0 . voltage between CKP sensor connector 3P 8. Measure t e r m i n a lN o . 2a n dN o .3 . s
CKPSENSOR 3PCONNECTOR

L " l
LGl {BRN/YELI

,llYtL

1 2 3

(YEL/BLK}

W i r e s i d eo f f e m a l e e r m i n a l s t

Wiresade female of terminals

ls there battery voltage? YES Go to step 9.

Is therebattery voltage? YES- Goto step7. main PGM-Fl NO Repair openln thewire between 1 s r e l a y a n dt h eC K P e n s o r . !
NO Repairopen in the wire betweenthe CKP . s e n s o r n d G1 0 1 I a 9. Substitutea known-goodCKPsensorand recheck. ls DTC P0335 and/or P0336 indicated? YES Updatethe ECM if it does not have the latest software.or substitutea known good ECM,then recheck {seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe originaECM.I l t l N O R e p l a c eh e o r i g i n a C K Ps e n s o r . l

11-78

'10.l\4easure voltage between ECM connector terminal A7 andbodyground,


ECMCONNECTOR 13lPI A

Wiresideot female terminals

ls there about 5 V? YES-Repair open in the wire betweenthe ECM (A7)and the CKPsensor. t N O - G o t o s t e p1 1 . 1 1 .Turn the ignitionswitch OFF. Disconnect ECMconnectorA (31P) 1 3 . Checkfor continuitybetweenECMconnector terminal 47 and body ground.
ECMCONNEfiORA (31P)

Wiresideof female terminals

ls there continuity? YES-Repair short in the wire betweenthe ECM (A7)and the CKPsensor. t NO Updatethe ECM if it does not have the latest software.or substitutea known-goodECI\4, then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe originaECM.t l

11-79

PGM-Fl System
(cont'dl DTCTroubleshooting
DTCP0500: VSSCircuitMalfunction
1. Test-drive vehicle. the 2. Checkthe vehiclespeedwith the scantool. ls the correct speed indicated? YES-lntermiftent failure,system is OK at this time. or Checkfor poor connections looseterminalsat t h e V S Sa n d a t t h e E C M . I NO Go to step 3. 3. Turn the ignition switch OFF. 4. Blockthe rearwheels,and set the parkingbrake. 5. Raisethe front ofthe vehicle,and make sure it is securelysupported, 6 . Turn the ignition switch ON (ll). 1 . Blockthe right front wheel, and slowly rotatethe left front wheel. 8. Measurevoltage betweenECMconnector t e r m i n a l s 1 8a n dA 2 4 . A
A ECMCONNECTOR {31P)

9. Turn the ignitionswitch OFF. 10. Disconnect ECMconnectorA (3'1P). 11 . T u r nt h e i g n i t i o n w i t c hO N { l l } . s 12. Blockthe right front wheel. and slowly rotatethe left front wheel. '!3. lMeasure voltage betweenECMconnector A t e r m i n a l s 1 8a n dA 2 4 .
A ECMCONNECTOR I31PI

Wiresideof female terminals

Does the voltage pulse between 0 V and 5 V ol between0V and battety voltage? YES Updatethe ECM if it does not have the latest software,or substitute known-goodECM,then a recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe origlnaECM.I l NO Checkthese items: . A short or an open in the wire betweenthe ECM ( A 1 8 ) n dt h e V S S . I a . l f t h e w i r e i s O K , t e s t t h e V S S s e ep a g e2 2 7 1 ) . 1 (

Wiresideof female terminals

Does the voltage pulse between 0 V and 5 V or between 0V and battery voltage? YES-Update the ECM if it does not havethe latest software,or substitutea known-goodECM.then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe originaECN4.l l NO Go to step 9.

11-80

DTCP0563: ECMPowerSource Circuit Unexpected Voltage


1 . R e s e t h e E C I \ { s e ep a g el 1 - 4 } . 4 2. Turn the ignitionswitch OFF. 3. Wait 5 seconds. 4 . T u r nt h e i g n i t i o n w i t c hO N { l l l . s ls DTC P0563 indicated? YES Go to step 5. NO-lntermiltent failure,system is OK at this time. Checkfor poor connections looseterminalsat or t h e N o . 6 E C U( E C M ) 1 5A ) f u s ei n t h e u n d e r - h o o d { fuse/relaybox and at the ECM.I Turn the ignitionswitch OFF.

9 . Removethe glove box (seepage20-63). 1 0 .Removethe PGM-FImain relay 1 (A7.

1 1 .Checkfor continuitybetweenECMconnector terminal E7 and body ground.


ECMCONNECTOR 131P) E

6 . Disconnect ECI\4 connectorE {31P). 7 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s 8 . lvleasure voltagebetweenECMconnectorterminal


E7 and body ground.
ECMCONNECTOR {31P} E MRLY

MRLY {RED/YEL)

Wiresideof {emale terminals

ls there continuity? YES-Repair short in the wire betweenthe ECM l a { E 7 ) n d t h e P G M - Fm a i n r e l a y1, I Wiresideol remale terminals
tt.

N O R e p l a c eh e P G M - Fm a i n r e l a y1 . 1 t l Turn the ignition suitchOFF. c o n n e c t oE ( 3 1 P ) . r

ls there battery voltage? YES Go to step 12. NO Go to step 9.

'13.R e c o n n e cE C M t

(conl'd)

11-81

PGM-FISystem
(cont'dl DTCTroubleshooting
14. Measurevoltage betweenECMconnectorterminal E7 and body ground.
ECMCONNECTOR 13lPI E MRLY IBEO/YEL)

1 8 .Removethe glove box (seepage 20-63). 1 9 .Removethe PGM-FImain relay '1{A).

W i r es i d eo f f e m a l e e r m i n a l s t

ls there battery voltage? YES Go to step 15. NO-Update the ECM if it does not have the latest software,or substitutea known-goodEClvl, then recheck(seepage 11-6). the symptom/indication lf goes away with a known-goodECM,replacethe o r i g i n aE C M . I l 1 5 . Disconnect ECI\4 connectorA (31P).
to.

20. Measure voltage

between body ground and ECM connector terminals A3 and A2 individually. ECMCONNECTOR {31PI A IGP2 (YEL/BLK) IGP1 (YEL/BLK)

T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s

1 7 . Measurevoltage betweenbody ground and ECIM c o n n e c t otre r m i n a l s 3 a n d4 2 i n d i v i d u a l l y . 4


ECMCONNECTOR {3.IP) A IGP2 (YEI./BLX) IGP1 (YEL/BLKI

Wiresideof female terminals

I s there battery v oltage? YES Repairshortto power in the wire between ( ) t h e E C I \ 4A 2 . A 3a n d t h e P G M - Fm a i n r e l a y1 . 1 l


W i r es i d eo f f e m a l e e r m i n a l s l

N O R e p l a c e t h e G M F l m a i n r e l a y1 . ! P

ls there battery voltage? YES-Go to step 18. NO Updatethe ECM if it does not havethe latest software,or substitutea known-goodECM,then recheck(seepage 11-6). the symptom/indication lf goes away with a known-goodECM,replacethe originalECM/PCl\4.1

11-82

DTGPl106:BARO SensorRange/Perfomance Problem


1 . R e s e t h e E C M( s e ep a g e1 1 - 4 ) . 2. Startthe engine.Holdthe engineat 3,000rpm with no load (in neutral)until the radiatorfan comes on, then let it idle. Test-drive with the transmissionin 4th gear. Accelerate 5 secondsusingwide open throttle. for Checkfor a TemporaryDTCwith the scantool. Is TemporaryDTC Pl106 indicated? YES-Update the ECM if it does not have the latest software,or substitutea known-goodECM.then recheck(seepage 11-6). the symptom/indication lf goes away with a known-goodECM,replacethe o r i g i n aE C M! l . NO Intermittent failure,system is OK at this time.I

DTCPl107: BARO Sensor Circuit LowVoltage DTCPl108: BARO Circuit High Sensor Voltage
1 . R e s e t h e E C M{ s e ep a g e11 - 4 ) . 2. Turn the ignition switch ON (ll). l s D T C P 1 1 0 7o r P 1 1 0 8 n d i c a t e d ? i YES-Update the ECM if it does not havethe iatest software,or substitutea known-goodECI\4, then recheck(seepage 11-6). the symptom/indication lf goes away with a known-goodECM,replacethe originaECI\4.I l NO- Intermittent failure,system is OK at this trme.l

11-83

PGM-FI System
(cont'dl DTGTroubleshooting
(Sensor Range/ DTC Pl157: Sensor Ay'F 1) Performance Problem
( 1 . R e s e t t h e C I Ms e ep a g e1 1 - 4 ) . E 2. Startthe engine. ls DTC Pl157 indicated? YES-Go to step 3. NO Intermittent failure,system is OK at this time. Checkfor poor connections looseterminalsat or the Ay'F sensor(Sensor1) and at the ECN4.I
Wire side of femaleterminals

L
6. Check continuity for between ECM connector t e r m i n a l4 6 a n dA 1 6 . s
ECMCONNECTOR {3IP) A

3 . Turn the ignitionswitch OFF.


Disconnect Ay'F the sensor(Sensor1) 4P connector a n d E C Mc o n n e c t oA ( 3 1 P ) . r ConnectA,/F sensor(Sensor1) 4P connector t e r m i n a l s o . 1 a n d N o . 2 w i t h a j u m p e rw i r e . N (SENSOR 4PCONNECTOR A/F SENSOR 1) AFS+ {BLU)
A/F SENSOR 1I {SENSOR 4P CONNECTOR

ls therecontinuity? YES Goto step9. NO Goto step7. (Sensor 4Pconnecror 7 . Connect sensor A/F 1) r g t e r m i n a l o .1 t o b o d y r o u n d i t ha j u m p e w i r e . N w (

JUMPER WIRE

Wire side of femaleterminals

Wire side ot femaleterminals

11-84

ECM connector for between 8. Check continuity 46 terminals andbodyground.


A ECMCONNECTOR 131P}

(Sensor AFS1) Ay'F DTCPl158: Sensor Terminal LowVoltage


E 1 . R e s e t t h e C M( s e ep a g e1 1 - 4 ) . 2. Startthe engine. ls DTC P1158 indicated? YES Go to step 3. NO-lntermittent failure,system is OK at this time at or Checkfor poor connections loosetermanals I the Ay'F sensor(Sensor1) and at the ECIM

Wire side ol lemaleterminals

3. Turn the ignition switch OFF. ls there continuity? YES-Repair open in the wire betweenthe Ay'F sensor(Sensor1) and the ECM(416).1 NO-Repair open in the wire betweenthe Ay'F sensor(Sensor1) and the ECM (46).1 sensor(Sensor1) and 9 . Substitutea known-goodAy'F recheck. ls DTC P1157 indicated? YES- Updatethe ECM if it does not have the latest software,or substitutea known-goodECM,then recheck(seepage 11-6).if the symptom/indication goes away with a known-goodECM,replacethe original ECM.! the sensor{Sensor1).! NO- Replace Ay'F ls thete continuity? YES-Repair shon in the wire betweenthe A,/F ( 1 s e n s o r S e n s o r ) a n dt h e E C M( A 1 6 ) . 1 NO Go to step 6. Ay'F sensor(Sensor1) 4P connector, 4, Disconnectthe r a n d E C Mc o n n e c t oA ( 3 1 P ) . 5. Checkfor continuitybetweenECMconnector t e r m i n a 4 1 6 a n d b o d yg r o u n d . l A ECMCONNECTOR (31P)

Wire side oJfemaleterminals

' c o n td )

11-85

PGM-FI System
(cont'd) DTCTroubleshooting
6. Substitutea known-goodAy'F sensor(Sensor1)and recheck. Is DTC P1158 indicated? YES Updatethe ECM if it does not have the latest software,or substitutea known-goodECM,then recheck(seepage 11-6).if the symptom/indication goes away with a known-goodECM,replacethe originaECM.I l NO- Replace Ay'F the sensor(Sensor1).t

DTCPl159:A,/F Sensor(Sensor AFS + 1) Terminal LowVoltage


1 . R e s e t t h e C M( s e ep a g e1 1 - 4 ) . E 2. Start the engine. ls DTC P1159 indicated? YES-Go to step 3. NO-lntermiftent failure.system is OK at this time. Checkfor poor connections looseterminaisat or the A,/F sensor(Sensor1) and at the ECM.I 3. Turn the ignition switch OFF. 4. Disconnect Ay'F the sensor(Sensor1) 4P connector a n d E c M c o n n e c t oA ( 3 1 P ) . r 5. Checkfor continuitybetweenECMconnector terminal 46 and body ground.
ECMCONNECTOR {31PI A

Wire side of femaleterminals

ls therecontinuity? YES-Repair shortin thewire between Ay'F the r ( s e n s o(rS e n s o1 )a n dt h eE C M A O ) . I NO Goto step6.

11-86

6. Substitutea known-goodAy'F sensor(Sensor1i and recnecK. i l s D T C P 1 1 5 9n d i c a t e d ? YES-Update the ECM if it does not have the latest software,or substitutea known-goodECM,then if recheck(seepage 11-6). the symptom/indication goes away with a known-goodECN4, replacethe o r i g i n aE C M . I l ( 1 N O R e p l a c eh e A y ' F e n s o r S e n s o r ) . 1 t s

11-87

PGM-FI System
(cont'dl DTCTroubleshooting
DTCPl163:Ay'F Sensor(Sensor ) Slow 1 Response
NOTE:lf DTCP1162is storedat the same time as DTC P1163. troubleshootDTCP1162 first, then recheckfor D T CP 1 1 6 3 . 1 . R e s e t h e E C M( s e ep a g e11 - 4 ) . 2. Startthe engine.Hold the engine at 3,000rpm with no load (in neutral)until the radiatorfan comes on. 3. Test-driveunderthe following conditions: . 55 mph (89 km/h) steadyspeed ' Transmissionin sth gear ' Until the Ay'F sensorreadiness code or TemporaryDTCPl163 comes on 4. Checkfor a TemporaryDTCwith the scantool. ls Temporary DTC P 1163indicated? YES Replace Ay'F the sensor(Sensor1).I NO Intermittent failure, system is OK at this time. Checkfor poor connections looseterminalsat or the A'lFsensor (Sensor1) and at the ECM.t

(Sensor Circuit DTCPl164: Sensor A,/F 1) Range/Performance Problem


( 1 . R e s e t t h e C I \ 4s e ep a g e1 t - 4 ) . E 2 . S t a r tt h e e n g i n e . o l d t h e e n g i n e a t 3 , 0 0r p m w i t h H 0 no load (in neutral)until the radiatorfan comes on, 3. Test-drive 3rd gear.Startingat 1,600rpm, in accelerate using wide open throttlefor at least 5 seconds. Then decelerate at least5 seconds for with the throttle completelycloseduntil the A,/F sensorreadiness code is set to completeor TemporaryDTCP1164comes on. 4. Checkfor a TemporaryDTCwith the scantool. ls TemporaryDTC P1164indicated? YES- Replace A,,/F the sensor(Sensor1).I NO Intermittent failure,system is OK at this time. Checkfor poor connections looseterminalsat or the Ay'F sensor relay,at the Ay'F sensor(Sensor1), a n da t t h e E c M . l

11-88

(Sensor Heater 1) Ay'F DTCPl166: Sensor Malfunction Circuit


1 . R e s e t t h e C M( s e ep a g e1 1 - 4 ) . E 2. Startthe engine. ls DTC P1166indicated?

Is therc battery voltage? YES-Update the ECM if it does not have the latest a soflware,or substitute known-goodECM.then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe o r i g i n aE C M . I l NO-Go to step 5.

YES-Go to step 3. NO-lntermittent failure,system is OK at this lime. or Checkfor poor connections looseterminalsat sensor(Sensor1),and the Ay'F sensorrelay,the A,/F t h e E c M .! 3. Checkthe following fuse: . No. 14 OPTION(30A)fusein under-hoodfuse/ rerayDox. . No. 2*B LAF (Ay'F) (20A)fuse in underHEATER dash fuse/relaybox. . No. 4 ACG (10A)in underdash fuse/relaybox. Are any of the fuses blown? YES Repairshort in the wire betweenthe Ay'F sensorrelay and the fuses.I NO Go to step 4. 4. MeasurevoltagebetweenECMconnector terminalsA1 and A24. 30 secondsafter the ignition s w i t c hi s t u r n e dO N ( l l ) .
A ECMCONNECTOR I31P) Wire side of femaleterminals

5. MeasurevoltagebetweenECMconnector terminalsA22 and A24.


A ECMCONNECTOR {31P}

ls therebattery voltage? YES Goto step6. N O - G o t o s t e p1 0 . OFF. switch 6. Turnthe ignition E 7. Disconnect connector (31P). ECM s O 8 . T u r nt h ei g n i t i o n w i t c h N{ l l ) .

W i r es r d eo f l e m a l et e r m i n a l s

(cont'd)

11-89

PGM-FI System
(cont'dl DTCTroubleshooting
9. ConnectECMconnectorterminal EStobody ground with a jumper wire, then measurevoltage betweenECMconnectorterminalsA1 and 424. ECMCONNECTORS ls there continuity? YES Repairshort in the wire betweenthe A|/F sensorrelay,A,/F sensor{Sensor1) and ECM lA22J.a NO Go to step 13.
t5.

Turn the ignition switch ON (ll).

1 4 . Measurevoltage betweenECMconnector terminalsE8 and A24.


ECM CONNECTORS

Wire side of femaleterminals

E {31P)

ls there battery voltage? YES- Updatethe ECM if it does not have the latest soflware,or substitutea known-goodECM,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe originaECMt l . NO Repairopen in the wire betweenthe Ay'F ( r s e n s o r S e n s o 1 ) a n d E C M( A 1 ) t. a {31P)

Wiresideof female terminals ls there battety voltage? YES-Repair open in the wire betweenthe ECM (A22)and the IVF sensor(Sensor1).I N O - G o t o s t e p1 5 . Checkfor continuityin the wires betweenthe Ay'F sensorand the fuses. ls there continuity? (SENSOR 4PCONNECTOR A/F SENSOR 1) YES-The wires are OK. Replace A,/F the sensor relay.l NO Repairopen in the wire betweenthe Ay'F sensorrelay and the fuses.l

1 0 .Turn the ignitionswitch OFF. 1 1 .Disconnecl ECfM the connectorA (31P) and the Ay'F
sensor(Sensor1) 4P connector. 1 2 . Checkfor continuitybetweenthe Ay'F sensor ( S e n s o r ) 4 Pc o n n e c t otre r m i n a lN o . 3 a n d b o d y 1 ground.

Wire side ot Iemaleterminals

11-90

(Sensor Heater 1) Ay'F DTCPl167: Sensor Malfunction Circuit


NOTE:lf DTCP1162is storedat the same time as DTC first, then troubleshoot P1167, troubleshootDTCP1162 D T CP 1 1 6 7 . E 4 1 . R e s e t t h e C I \ ( s e ep a g e1 1 - 4 ) 2. Startthe engine.Wait for at least80 seconds. ls DTC P01167 indicated? YES Go to step 3.

6. Checkfor continuitybetweenECMconnector , t e r m i n a l s4 6a n d 4 1 6 . A ECMCONNECTOR {31P) AFS- {RED)

trTzTil,ils l t l

t8

9 2C21
IRED/YEL)

l?rlzsIels
AFS

Wire side of lemale terminals

NO-lntermittent failure,system is OK at this time. or Checkfor poor connections looseterminalsat sensor(Sensor1), the Ay'F sensorrelay,at the Ay'F a n da t t h e E C M . I
?

ls thetecontinuity? r th Y E S - R e p l a c e eA / Fs e n s o(rS e n s o1 ) . 1 the NO-Repairopenin thewire between Ay'F ( r s e n s o(rS e n s o1) a n dt h eE C M 4 6o r A 1 6 ) . I

Turn the ignitionswitch OFF. sensor4P connectorand ECM Disconnect A,/F the connectorA (31P).

sensor(Sensor1) 4P connector 5 . Connectthe Ay'F N t e r m i n a l s o . 2 a n d N o . 1 w i t h a j u m p e rw i r e .


(SENSOR 1) A/F SENSOR 4P CONNECTOR JUMPERWIRE

Wire side of femaleerminals t

11-91

PGM-FI System
(cont'dl DTCTroubleshooting
DTCPl297: ELD Circuit LowVoltage
1 . R e s e t h e E C M{ s e ep a g e1 1 - 4 ) . 2. Startthe engine. 3 . T u r no n t h e h e a d l i g h t s . ls DTC P1297 indicated? YES Go to step 4. NO Intermittent failure,system is OK at this time. Checkfor poor connections looseterminalsat or t h e E L Da n d a t t h e E C M . I 4. Turn the ignition switch and the headlightsOFF. 5. DisconnecttheELD3P connector. 6. Turn the ignition switch ON {ll). ls there continuity? 7. Measurevoltage betweenbody ground and ELD3P connectorterminal No. 3. ELO3P CONNECTOB ELD{GRN/REDI YES-Repair short in the wire betweenthe ECM ( E1 5 )a n d t h e E L D r . NO- U pdatethe ECM if it does not havethe latest software,or substitutea known-goodECM,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe o r i g i n aE C M . I l
Wire side of femaleterminals

I
8. Turn the ignition switch OFF. 9. Disconnect ECMconnectorE {31P). 10. Checkfor continuitybetweenbody ground and E C Mc o n n e c t otre r m i n a lE 1 5 . ECMCONNECTOR 131PI E

I l 2 l 34 5 6 1 7
to ,2 2al2/
td

8 I 21 / 120 31

tA

7\'

ELD (GRN/RED}

Wire side of femaleterminals

ls thereabout5 V? YES Replace ELD. the t NO-Gotostep . 8

11-92

ELD Circuit HighVoltage DTCPl298:


1 . R e s e t t h e C M( s e ep a g e1 1 - 4 ) E 2. Stan the engine.

8. T u r nt h e i g n i t i o n w i t c hO F F . s 9 . ConnectELD3P connectorterminal No. 3 to body g r o u n dw i t h a j u m p e rw i r e .


ELD3P CONNECTOR

3. Turn on the headlights. ls DTC P1298 indicated? YES-Go to step 4. failure.system is OK at this time. NO- Intermittent or Checkfor poor connections looseterminalsat t h e E L Da n d a t t h e E C M . I 4. Turn the ignition switch and headlightsOFF. ELD3P connector. 5. Disconnectthe 6. Turn the ignition switch ON (ll).

---F-------

ELD (GRN/RED)

l 1 l 2: r l
wrRE IJUMPER

Wire side of temaleterminals

1 0 .Disconnect ECMconnectorE (31P). 11. Checkfor continuitybetweenbody ground and


ECMconnectorterminal E15. E ECMCONNECTOR 131PI

7. Measurevoltagebetweenbody ground and ELD3P connectorterminal No. 1. ELD3PCONNECTOR

1 2 1 34 5
IG1IBLK/ORNI
14
L C

o t /

22123 24

I I 6 l / 1 8 2C 21 21./ 2Q 30 J

ELD
i1' IGRN/RED)

Wire side of femaleterminals Wire side ot {emaleterminals

Is thetecontinuity?
ls there battery voltage?

Y E S - G ot o s t e p1 2 .
YES-Go to step 8. i N O - C h e c k t h e N o . 4 A C G ( 1 0 A ) f u s en t h e u n d e r dash fuse/relaybox. lf the fuse is OK, repairopen in the wire betweenthe No. 4 ACG (10A)fuse and the ELD.I

the openin thewire between ECM NO Repair ( E 1 5a n dt h eE L D . )

(cont'd)

11-93

PGM-FI System
(cont'dl DTCTroubleshooting
12, Checkfor continuitybetweenELD3P connector t e r m i n a lN o . 2 a n d b o d y g r o u n d .
E L D 3 PC O N N E C T O R

W i r e s i d eo f f e m a l e e r m i n a l s t

ls there continuity? YES Go to step 13. NO- Repairopen in the wire betweenthe ELDand G 2 0 1I. Reconnect ELD3P connectorand ECM the connectorE (31P). 1 4 . Startthe engineand let it idle.
t5_

While measuringvoltage betweenECMconnector t e r m i n a l s 2 4 a n d E 1 5 , u r nt h e h e a d l i g h to n 4 t s t hi g h ) .


ECM CONNECTORS

W i . e s i d eo f f e m a l et e r m i n a l s

Does the voltage drop? YES-Update the ECM if it does not have the latest software,or substitutea known-goodECM,then recheck{seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe originaECM.I l N O R e p l a c eh e E L D . I t

11-94

(CMP) DTCPl361:Camshaft Position Sensor B (TDC Sensor) Intermittent Interruption (CMP) DTCPl362:Camshaft Position Sensor (TDC B Sensor) Signal No
1 . R e s e t h e E C M( s e ep a g e1 1 - 4 ) . 2. Startthe engine. ls DTC P1361and/or P1362 indicated? YES Go to step 3. NO- Intermittent failure.system is OK at this time. Checkfor poor connections looseterminalsat or t h e C M Ps e n s o r ( T D C e n s o r a n d a t t h e E C M . I B s )

7. l\4easure voltage betweenCMP sensorB {TDC sensor)3P connectorterminal No. 1 and body ground.
CMP SNSOR 8 ITDCSENSOR)3P CONNECTOR

Wlres de ollemaleterminals

ls thereabout5 V? YES-Go to step8.

3 . Turn the ignitionswitch OFF. N O - G o t o s t e p1 0 .


4 . DisconnecttheCMP sensorB (TDCsensor)3P

connector.

voltage Cl\ilP sensor (TDC B 8. Measure between s e n s o r )Pc o n n e c t oe r m i n a lN o .2 a n dN o ,3 . 3 tr s


CMPSENSON llOC SENSOfi) CONNECTOF B 3P

5 . Turn the ignitionswitch ON (ll). 6 . Measurevoltage betweenCMP sensorB (TDC


sensor)3P connectorterminal No. 3 and body grouno. B CMP SENSOR {TDC SENSOR) CONNECTOR 3P
IGP
Wire s de olfema etefminals

1 2 3

{YEL/BLK}

ls there battery voltage? Y E S - G o t o s t e p9 . NO Repairopen in the wire betweenthe CMP s ) s e n s o rB ( T D C e n s o r a n d G 1 0 1 . 1

Wiresideol temale terminals

a 9. Substitute known-goodCMP sensorB (TDC sensor)and recheck. ls DTC P1361and/or P1362 indicated? YES Updatethe ECMif it does not have the latest software,or substitutea known-goodECM,then lf recheck(seepage 11-6). the symptom/indication goes away with a known-goodECM,replacethe originaECM.I l N O R e p l a c eh e o r i g i n a C M P s e n s o r B ( T D C t l sensor).1

ls there battety voltage? YES Go to step 7. NO-Repair open in the wire betweenthe PGM-Fl m a i n r e l a y1 a n dt h e C M Ps e n s o r ( T D C e n s o r ) . I I s

(cont'd)

11-95

PGM-FI System
(cont'd) DTCTroubleshooting
10. Measure voltage between ECI\4 connectorterminal A26andbodyground.
ECM CONNECTOR A (31P)

DTCPl607: Malfunction ECMInternal in Circuit


1. ResettheEC|\il lsee page 11-4). 2 , T u r nt h e i g n i t i o n w i t c hO N ( l l ) ,a n d w a i t f o r s 40 seconds. ls DTC P 1607 indicated? YES Updatethe ECM if it does not have the latest software,or substitutea known-goodECM,then recheck(seepage 11 6). lf the symptom/indication goes away with a known-goodECM,replacethe o r i g i n aE C M . I l NO Intermittent failure,system is OK at this time. A low batterycan causethis problem . Ask the customerif there has been any recenttrouble s t a r t i n gh e e n g i n e . l t

1 2 3 4 5 6 1 7 I 0 1 11 2 1 . / 61,/18 I 2C2l 2324 21m 30


TDC {GRN}

Wire side oI temaleterminals

ls thereabout5 V ? YES Repair openin thewire between ECM the (426) and CMPsensor (TDC B sensor).1 N O - G o t o s t e p1 1 .
1 1 .Turnthe ignition switchOFF. 1 2 . Disconnect ECIM A connector (31P)

Check continuity for between ECM connector terminal 426 andbodyground.


ECMCONNECTOR {31PI A

Wiresideof female terminals

ls there continuity? YES Repairshort in the wire betweenthe ECM (426)and the CMP sensor B (TDCsensor).1 NO Updatethe ECM if it does not have the latest software,or substitutea known-goodECM,then recheck(seepage 11-6). the symptom/indication lf goes away with a known-goodECM,replacethe originaECM.I l

11-96

MIL CircuitTroubleshooting
1. Connectan OBD ll scantool/HondaPGM Tester ( s e ep a g e1 1 - 3 ) . 2. Turn the ignition switch ON (ll) and readthe OBD ll scantool/HondaPGM Tester. Does the OBD ll scan tool/Honda PGM Tester communicatewith the ECM? YES Go to step 3. " NO Go to troubleshooting DLCCircuit T r o u b l e s h o o t i n g ( s e ep a g e1 1 - 1 0 9 ) . " 3. Checkthe OBD ll scantool/HondaPGM Testerfor DTCs. Are any DTCs indicated? Index. YES Go to the DTCTroubleshooting NO-Go to step 4. 4. Turn the ignitionswitch OFF. 5 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) a n dw a t c ht h e s r l M a l f u n c t i oIn d i c a t oL a m p( M l L ) . Does the MIL come on and stay on for more than 20 secondsaftet turning the ignition switch . A l o o s eN o . 1 7 F U E LP U M P( 1 5 A ) f u s en t h e i fuse/relaybox. under-dash . A p o o r c o n n e c t i o n t E C Mt e r m i n a E 3 1 . l a . An intermittentopen in the GRN/ORN wire ) b e t w e e n h e E C M( E 3 1 a n d t h e g a u g ea s s e m b l y . t . An intermittentshort in the wire betweenthe ECM(A21)and the manifold absolutepressure (MAP) ensor. s . An intermittentshort in the wire betweenthe (A20)and the throttle posilion (TPisensor. ECI\4 . An intermittentshort in the wire betweenthe ECM (E5)and the fuel tank pressure(FTP) sensor. 6. Turn the ignition switch OFF. 7 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s ls the low oil pressure light on? YES Go to step 10. N O - G o t o s t e p8 . i N R 8 . I n s p e c t t h e o . 1 0 l \ 4 E T E( 7 . 5 A ) f u s en t h e u n d e r dash fuse/relaybox. ls the luse OK? YES Go to step L N N O R e p a i r h o n i n t h ew i r e b e t w e e n o . 1 0 s ( . M E T E R 7 . 5 A ) f u s e n d t h e g a u g ea s s e m b l yA l s o a r e p l a c e t h e o . 1 0M E T E R7 . 5 Af u s e . l N { ) 50A)fuse in 9. Inspectthe No. 20 lG1 (40A)(Canada: fuse/relaybox. the under-hood ls the f use OK? YES Repairopen in the wire betweenthe No. 20 a l G ( 4 0 A ) C a n a d a5 0 A ) f u s e n d t h e g a u g e { r assembly.lf the wire is OK, test the ignition switch {seepage 22 53). N N O R e p a i r h o r ti n t h e w i r e b e t w e e n o . 2 0 l G s ( 4 0 A ) C a n a d a5 0 A ) f u s e n d t h e u n d e r ' d a s hu s e l f a l : r e l a yb o x .A l s o r e p l a c eh e N o . 2 0 l G ( 4 0 A i t ( C a n a d a5 0 A )f u s e . I :

oN (tr)?
YES lf the MIL alwayscomes on and stayson, go to step 76. But if the lMlLsometimesworks normally,first checkfor these problems. . An intermittentshort in the wire betweenthe ( ) E C I M E 2 9 a n dt h e d a t al i n kc o n n e c t o( D L C ) . r . An intermittentshort in the wire betweenthe ) E C M( E 3 1 a n dt h e g a u g ea s s e m b l y . NO lf the MIL is alwaysoff, go to step 6. But if the lvllLsometimesworks normally,first checkfor these problems. . A l o o s eN o . 1 0 M E T E R 7 . 5 A f u s ei n t h e u n d e r ( ) dash fuse/relaybox. . A l o o s eN o . 2 0 l G ( 4 0 A ) C a n a d a5 0 A ) I u s e n t h e ( : i fuse/relaybox. under-hood . A i o o s eN o . 6 E C U( E C M ) 1 5 A ) u s ei n t h e u n d e r ( f hood fuse/relaybox.

(conr'd)

11-97

PGM-FI System
(cont'dl MIL CircuitTroubleshooting
1 0 .Tryto startthe engine. Doesthe enginestart? Y E S - G ot o s t e p1 1 . N O - G o t o s t e p1 4 .
1 1 .Turnthe ignition switch OFF. 1 7 . Removethe glove box (seepage 20-63) and the P G M ' F I a i n r e l a y1 . m
to.

(154)fuse Removethe blown No. 6 ECU{ECfU) from the under-hood fuse/relaybox.

12. Connect ECM connector terminal to body E31 ground with a jumperwire.
ECMCONNECTOR 13lPI E

l l 2 l 34 5 6 1 7 l1 8I 4 1 5161,/ 118 2( 2t 2' 23 24 z7l/ 129 31


JUMPER MIL (GRN/ORN} WIRE
Wire side of femaleterminals

1 8 . Checkfor continuitybetweenbody ground and P G M - Fm a i n r e l a y1 4 P c o n n e c t otre r m i n a l s o . 2 l N a n d N o .4 i n d i v i d u a l l v .


PGM-FI MAIN RELAY1 4P CONNECTOR

Turn the ignition switch ON (ll). ls the M lL on? YES Updatethe ECM if it does not have the latest software,or substitutea known-goodECM,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECIM, replacethe o r i g i n aE C M . I l NO-Check for an open in the wire betweenthe ) E C M( E 3 1 a n d t h e g a u g ea s s e m b l yA l s o c h e c k o r . f a b l o w nM I L b u l b .l f t h e w i r e sa n d t h e b u l ba r e O K , replacethe gauge assembly.l

f V (wHr/ B v) BLK)( IA
W r r es r d eo l l e m a l e e r m r n a l s t

ls there continuity? Y E S - R e p a i rs h o r ti n t h e w i r e b e t w e e nh e N o . 6 t () E C U( E C l \ 4 1 5 A ) u s ea n d t h e P G M - Fm a i n r e l a y1 . f l ( A l s o r e p l a c eh e N o . 6 E C U( E C M ) 1 5 A ) u s e . l t f N O - G o t o s t e p1 9 .

't4. Turn the ignltion switch OFF,


(15A)fuse in the 1 5 . Inspectthe No. 6 ECU (ECIM) under-hood fuse/relaybox. ls the f use OK? YES-Go to step 22. N O - G o t o s t e p1 6 .

11-98

19. Disconnect each of the componentsor the connectorsbelow, one at a time, and checkfor continuitybetweenPGM-FI main relay 1 4P connectorterminal No. 1 and body ground. . . . . . PGfvl-Fl main relay 2 ECMconnectorA (31P) Eachinjector2P connector ldle air control (lAC)valve3P connector CamshaftPosition(CMP)sensorB (Topdead center(TDC) sensor)3P connector . Crankshaft position(CKP) sensor3P connector PGM-FI MAIN RELAY1 4PCONNECTOR

21. Checkfor continuitybetweenPGM-FI main relay 1 4P connectortermlnal No. 1 and body ground.
PGM-FIMAIN RELAY1 4P CONNECTOR

Wire side of femaleterminals

ls there continuity? YES Repairshort in the wire betweenthe PGM-Fl main relay 1 and each item. Also replacethe No. 6 ( E C U{ E C M ) 1 5 A ) u s e . l f l N O - R e p l a c et h e P G M - Fm a i n r e l a y1 .A l s o r e p l a c e (1 f t h e N o 6 E C U{ E C I M ) 5 A ) u s e . I
Wire side of femaleterminals

( N i 22. I n s p e c t t h e o . 1 7 F U E LP U I \ 4 P1 5 A ) f u s en t h e ls thete continuity? YES Go to step 20. NO- Replace componentthat made continuity the lf to body ground go away when disconnected. the item is the ECM,updatethe ECM if it does not have the latestsoftware.or substitutea known-good ECM,then recheck(seepage 11-6). the symptom/ lf indicationgoes away with a known'good ECM, r e p l a c eh e o r i g i n a E C M . t l Also replacethe No. 6 ECU(ECM)(15 A) fuse, f box. under-dash use/relay ls the tuse OK? YES Go to step 34. NO Go to step 23. f 23. R e m o v e h e b l o w nN o , 1 7 F UE LP U M P( 1 5 A ) u s e t fuse/relaybox. from the under-dash ECfvl connectorE (31P). 2 4 . Disconnect

20. Disconnect connectorsof all these components. the


. . . . . P G M - Fm a i n r e l a y2 l E C Mc o n n e c t oA ( 3 1 P ) r lnjectors ( l d l ea i r c o n t r o l l A C ) v a l v e CamshaftPosition{CMP)sensorB (Top dead center(TDC) sensor) . Crankshaft position(CKP) sensor

(conr'd)

11-99

PGM-FI System
(cont'dl MIL CircuitTroubleshooting
25. Checkfor continuitybetweenECMconnector
terminal E9 and body ground. ECMCONNECTOR (31P) E

27. Check continuity for between ECIVI connector terminal andbodyground. Eg


ECMCONNECTOR 131P) E

Wire side o{ {emaleterminals

Wire side oI Jemale terminals

ls therc continuity? YES-Go to step 26. N O R e p l a cte e N o . l T F U E L P U M P ( 1 5 A ) f u s e , h and updatethe ECM if it does not have the latest software.or substitutea known-goodECM,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM.replacethe originaECM.I l 26. Removethe PGM-Flmain relay 2 (A).

ls there continuity? YES Repairshort in the wire betweenthe No. 17 , F UE LP U M P( 1 5 A ) f u s e n d t h e E C M( E 9 ) o r a betweenthe No. 17 FUELPUMP (15A) fuse and the P G M - Fm a i n r e l a y2 . A l s o r e p l a c eh e N o . 1 7 F U E L I t P U M P( 1 5 A ) f u s e . l NO Go to step 28.

28. Removethe rear seatcushion (seepage 20-80). 29. Removethe accesspanelfrom the floor. 30. Disconnect fuel pump 5P connector. the

11-100

for 31. Check continuity between pump5P fuel connector terminal 5 andbodyground. No.
FUELPUMP5PCONNECTOR

33. Check continuity for between pump5P fuel connector No. terminal 5 andbodyground.
FUELPUMP5P CONNECTOR

=
Wire side ol lemal rerminals

Wire side of temaleterminals

ls there continuity?

ls therc continuity? YES Repair shortin thewire between fuel the p u m pa n dt h eP G M - F l a i nr e l a y .A l s or e p l a c e m 2 ( t h EN O . 7F U E L U M P 1 5 Af)U S E . T 1 P NO-Go to step32. 32. Reinstallthe PGM-Fl mainrelay (A). 2

YES Replace the PGM-Flmain relay 2. Also r e p l a c eh e N o . 1 7 F U E LP U M P( 1 5 A ) u s e . l t f NO Checkthe iuel pump, and replaceil if necessary. Also replacethe No. 17 FUELPUMP (15A)use.! f 34. Disconnect ECMconnectorE (31P). 3 5 . T u r nt h e i g n i t i o n w i r c hO N { 1 1 1 . s 36. Measurevoltage betweenECMconnectorterminal E9 and body ground.
ECfl CON|{CCIORE (3rPt

Wire side ol female lerminals

ls there battery voltage? YES Go to step 37. NO Repairopen in the wire betweenthe No. 17 F U E LP U M P( 1 5 A ) f u s e n d t h e E C M( E 9 ) . 1 a

(cont'd)

11-101

PGM-FI System
(cont'dl MIL CircuitTroubleshooting
37. lvleasure voltage between ECM/PCM connector E t e r m i n a l 7a n db o d yg r o u n d .
ECM CONNECTOR {31PI E MRLY

40. lvleasure voltage betweenPGN4-Fl main relay 1 4P c o n n e c t otre r m i n a lN o . 4 a n d b o d vq r o u n d .


PGM-FIMAIN RELAY1 ilP CONNECTOR

Wire side of femaleterminals Wire side ot lemale terminals

ls there battery voltage? YES Go to step 42. NO Go to step38.

ls there battery voltage? Y E S - G o t o s t e p4 1 . NO Repairopen in the wire betweenthe No. 6 ( E C U( E C M ) 1 5 A ) u s ea n d t h e P G f M - F l a i n r e l a y1 . f m I


4 1 . Checkfor continuitybetweenPGM-FI main relay 1

38. Turn the ignitionswitch OFF. 3 9 . Removethe PGM-FImain relay 1 {A}


-A

4P connectorterminal No. 3 and ECMconnector t e r m i n a lE 7 .


PGM.FIMAIN RELAY1 4P CONNECTOR

(RED/YEL) MRLY
ECMCONNECTOR 131PI E

(RED/YEL) MRLY

Wire side of femaleterminals

ls there continuity? YES-Testthe PGM-Flmain relay 1 (seepage2251). lf the relay is OK, updatethe ECM if it does not have the latestsoftware,or substitute knowna good ECM,then recheck{seepage 11'6).lf the goes away with a known-good symptom/indication E C M ,r e p l a c eh e o r i g i n a E C M . I t l NO*Repair open in the wire betweenthe PGM-FI m a i n r e l a y1 a n d t h e E C M( E 7 ) . 1

11-102

42. Reconnect ECI\4 connectorE {31P). 4 3 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s 44. Measurevoltage betweenbody ground and ECM
connectorterminals42 and 43 individually.
ECMCONNECTOR {31PI A

48. Measure voltage between PGM-FI mainrelay1 4P connector terminal 2 andbodyground. No.
PGM.FIMAIN RELAY1 4PCONNECTOR

Wire side of temaleterminals

ls there battery voltage?


Wire side of femaleterminals

YES Go to step 49. ls there battery voltage? YES Go to step 51. NO Go to step 45. 4 5 . T u r nt h e i g n i t i o n w i t c hO F F . s 46. R e m o v e h e P G M ' F m a i n r e l a y1 {A) l t ,A N O R e p a i r p e ni n t h e w i r e b e t w e e n h e N o . 6 o t ( E C U{ E C M ) 1 5 A } f u s e n d t h e P G M - Fm a i n a l r e l a y1. ! 4 9 . T u r nt h e i g n i t i o n w i t c hO F F . s 5 0 . Checkfor continuitybetweenPGM-Flmain relay 1 4P connectorterminal No. 1 and ECMconnector t e r m i n a l s 2 a n d4 3 i n d i v i d u a l l y . 4
PGM.FI MAIN RELAYI ilP CONNECTOR

IGPl (YEL/BLK)

W i r es i d eo f f e m a l e e r m i n a l s t

4 7 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s

ls there continuity? Y E S R e p l a c eh e P G M - Fm a i n r e l a y1 . 1 t l NO Repairopen in the wire betweenthe PGM-FI '1 m a i n r e l a y a n d t h e E C M( A 2 ,A 3 ) . 1

{cont'd}

11-103

PGM-FI System
(cont'dl MIL CircuitTroubleshooting
51. Measure voltage between bodygroundandECM 44, connector terminals A5,423,and424 individuallv.
ECM CONNECTOR A 131P) (BLK) PG2 PG1 IBLKI

53. Turn the ignitionswitch OFF. 54. Disconnect manifoldabsolutepressure(MAP) the


sensor3P connector. 55. T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s 56. Measurevoltage betweenbody ground and ECM c o n n e c t otre r m i n a A 2 1 . l
ECMCONNECTOR {31P) A

W i r es i d eo f f e m a l e e r m i n a l s t

ls there morc than 1.0 V ? YES Go to step 52. N O - R e p a i r o p e n i n t h e w i r e ( s ) h a t h a d m o r et h a n t 1.0V betweenG 10'l and the ECM (A4,A5, A23, A24l.a Measurevoltagebetweenbody ground and ECM c o n n e c t otre r m i n a 4 2 1 . l
ECMCONNECTOR 131P) A

Wiresideof female terminals ls there about 5 V? YES Replace MAP sensor.l the NO Go to step 57. 5 7 . Turn the ignition switch OFF. 5 8 . D i s c o n n e c t C Mc o n n e c t oA ( 3 1 P ) . E r

Wiresideof female terminals ls there about 5 V? YES-Go to step 60. N O - G o t o s t e p5 3 .

11-104

59. Check continuitv for between ECIM connector t e r m i n a l 2 1a n db o d yg r o u n d . 4


ECM CONNECTOR {3,IPI A

t t,

Turn the ignition switch OFF.

o z , Disconnect throttle position(TP)sensor3P the connector.

6 3 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s 64. Measurevoltage betweenbody ground and ECM


connectorterminal 420,
ECMCONNECTOR 131P) A

Wire side of femaleterminals

ls there continuity? YES*Repair short in the wire betweenthe ECM ( 4 2 1 )a n d t h e M A P s e n s o r . l NO Updatethe ECM it it does not have the latest soflware,or substitutea known-goodECM,then recheck(seepage 1'l-6).lf the symptom/indication goes away with a known-goodECM,replacethe originaECM.I l Wiresideof female terminals ls there about 5 V? YES Replace thronle body (theTP sensoris the not availableseparately). I NO Go to step 65. 65. Turn the ignition switch oFF. 66. Disconnect ECMconnectorA (31P).

6 0 . Measurevoltagebetweenbody ground and ECM


connectorterminal 420.
ECMCONNECTOR {3TP} A

1 1 2 14 5 o t / 3 I 1 0 11112 5 6 / 1189 2t 21 2' 231?4 ? q Tln 29

vcc2

IYEL/ BLU)

W i r e i d e tf e m a l t e r m i n a l s e s o ls there about 5 V? YES-Go to step 68. N O - G o t o s t e p6 1 .

conlo

11-105

PGM-FI System
(cont'd) MIL CircuitTroubleshooting
6 7 . Check continuity for between ECIM connector A t e r m i n a l 2 0a n db o d yg r o u n d .
ECMCONNECTOR (31P) A

68. Measurevoltage betweenbody ground and ECM c o n n e c t otre r m i n a lE 5 . ECMCONNECTOR (31PI E

r l 2 l 3 1 5 4

o t / ta,

10 t1 121,/ 1516 1,/ 22 '3 241 125 26

9 2A21

vcc2

{YEL/ BLU}

Wire side of femaleterminals Wire side of femaleterminals

ls there continuity? YES Repairshon in the wire betweenthe ECN4 {A20)and the TP sensor,or repairshort in the wire betweenthe ECM (A8) and the knocksensor. t NO Updatethe ECM if it does not have the latest software.or substitutea known-goodECM,then recheck(seepage l1-6).lf the symptom/indication goes away with a known-goodECM,replacethe originaECM.t l

Is there about 5 V? YES U pdatethe ECM if it does not have the latest software,or substitutea known-goodECM,then recheck(seepage 11-6). the symptom/indication lf goes away with a known-goodEClvl, replacethe o r i g i n aE C M . t l NO-Go to step 69. 6 9 . Turn the ignition switchOFF.

7 0 . Disconnect fuel tank pressure(FTP) the sensor3P


connector. 1 1 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s

11-106

72. Measure voltage between bodygroundandECM connector terminal E5.


ECMCONNECTOR 131P} E

7 6 . T u r nt h e i g n i t i o n w i t c hO F F . s 7 7 .T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s 7 8 . Measurevoltage betweenECMconnectorterminal
E 2 9a n d b o d y g r o u n d . ECMCONNECTOR (31P) E

r l 2 l 3 1 4 6 1 5
22

23 241 l,/

1 ,/1,/1145 6

8 9 2A21 2930 scstBRN)

Wire side of femaleterminals

ls there about 5 V? Wiresideof female terminals YES Replace the FTPsensor.t NO Go to step 73. ls there about 5 V (or battery voltage)? YES-Go to step 82. NO Go to step 79.

1 3 . Turn the ignitionswitch OFF. 7 4 . Disconnect ECMconnectorE (3'lP). 7 5 .Checkfor continuitybetweenECMconnector


t e r m i n a lE 5 a n d b o d y g r o u n d .

7 9 . Turn the ignitionswitch OFF. 8 0 . Disconnect ECMconnectorE (31P).

ECMCONNECTOR {31PI E

Wire side of femaleterminals

Is there continuity? YES Repairshort in the wire betweenthe ECM ( E 5 ) n dt h e F T Ps e n s o r . l a NO Updatethe ECM if it does not have the latest software,or substitutea known-goodECM,then recheck(seepage 11-6). the symptom/indication lf goes away with a known-goodECM,replacethe originaECM.I l (cont'd)

11-107

PGM-FISystem
(cont'd) MIL GircuitTroubleshooting
81. Checkfor continuitybetweenECMconnector t e r m i n a lE 2 9a n d b o d y g r o u n d . ECMCONNECTOR 131P} E

r l 2 l 34 5
14 t c

22123124

61,/118 2A21 271./ 3031

scs(BRN)

Wire side of femaleterminals

ls there continuity? YES-Repair short in the wire betweenthe data link and the ECM(E29).1 connector(DLC) NO Updatethe ECM if it does not havethe latest software,or substitutea known-goodECM,then recheck(seepage 11-6). the symptom/indication lf goes away with a known-goodECM,replacethe o r i g i n aE C I \ 4 , I l Turn the ignition switch OFF. Disconnect ECMconnectorE (31P). T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s Does the MIL stay on? YES-Repair short in the wire betweenthe gauge a s s e m b l y n dt h e E C M( E 3 1. l f t h e w i r e i s O K , a ) r e p l a c eh e g a u g ea s s e m b l y . l t NO Updatethe ECM if it does not have the latest software,or substitutea known-goodECM,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe originaECM.I l

11-108

DLCCircuitTroubleshooting
lf the ECMdoes not communicatewith the OBD ll scan tool, HondaPGfM Tester,or l/M test equipment,do this procedure. troubleshooting 1. Measurevoltage betweenDLCterminal No. 16 and body ground. DATALINKCONNECTOR {DLCI 3. Measurevoltage betweenDLCterminalsNo. 5 and No. 16. DATALINKCONNECTOR {DLC)

(WHT/RED)

Terminalside of femaleterminals

ls there battery voltage? Terminal of lemale side terminals YES Go to step 4. ls therc battery voltage? YES-Go to step 2. 4 . T u r nt h e i g n i t i o n w i t c hO N { l l ) . s NO-Repair open in the wire betweenDLCterminal N o . 1 6 a n d t h e N o . 9 B A C KU P ( 7 . 5 ) f u s ei n t h e A f under-hood use/relaybox.I Measurevoltage betweenDLCterminalsNo. 4 and No.16.
(DLCI DATA LINK CONNECTOR

NO- Repairopen in the wire betweenDLCterminal N o . 5 a n dt h e E C M( E 3 )t.

5 . M e a s u r e o l t a g eb e t w e e n L Ct e r m i n a l s o . 5 a n d v D N No.7.
DATA LINKCONNECTOR {DLCI

T e r m i n a li d e f l e m a l ee r m i n a l s s o t

Terminal of Jemale side terminals

ls there 8.5 V or more? YES Go to step 10.

Is there battery voltage? NO Go to step 6. YES Go to step 3. 6. Turn the ignition switch OFF. NO Repairopen in the wire betweenDLCterminal N o . 4 a n d b o d yg r o u n d . l

(cont'd)

11-109

PGM-FI System
DLCCircuitTroubleshooting {cont'dl
Make sure the 7. Disconnect EClvl connectorE (31P). O B Dl l s c a nt o o l o r H o n d aP G MT e s t e r s i disconnected from the DLC. 8. Checkfor continuitybetweenDLCterminal No. 7 a n d b o d yg r o u n d . DATALINKCONNECTOR IDLC) ls there continuity? YES U pdatethe ECMif it does not have the latest software,or substitutea known-goodECM,then recheck(seepage 11-6). the symptom/indication lf goes away with a known-goodECM,replacethe originaECI\4.I l NO Repairopen in the wire betweenDLCterminal N o . 7 a n dt h e E C M{ E 2 3 )A f t e rr e p a i r i n gh e w i r e , t . checkthe DTCwith the OBD ll scantool/Honda PGl\4Tester,and go to the DTCTroubleshooting Index.l

1 0 .T u r nt h e i g n i t i o ns w i t c hO F F .
1
Ierminal side of femaleterminals

' I.

l\4ake Disconnect ECI\4 connectorE (31P). sure the O B Dl l s c a nt o o l o r H o n d aP G MT e s t e ri s disconnected from the DLC. T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s

ls there continuity?
tJ.

YES-Repair short to ground in the wire between After DLCterminal No. 7 and the ECM {E23). r e p a i r i n gh e w i r e ,c h e c k h e D T Cw i t h t h e O B Dl l t t scantool/HondaPGM Tester,and go to the DTC Troubleshooting index.I NO Go to step 9.

Measurevoltage betweenDLCterminalsNo. 5 and No.7. DATALINKCONNECTOR {DLC}

9 . Checkfor continuitybetweenDLCterminal No. 7


a n d E C Mt e r m i n a lE 2 3 ,
ECMCONNECTOR {31PI E Terminalside of femaleterminals

K-LINE{LTBLU)
DATA LINK CONNECTOR

Is there 0 V? YES Updatethe ECMif it does not havethe latest then software,or substitutea known-goodECI\4, lf recheck(seepage 11-6). the symptom/indication goes away with a known-goodECM,replacethe originaECM.I l NO Repairshort to power in the wire betweenthe . D L Ct e r m i n a lN o . 7 a n d t h e E C M( E 2 3 )A f t e r repairingthe wire, checkthe DTCwith the OBD ll scantool/HondaPGMTester,and go to the DTC T r o u b l e s h o o t i ni g d e x I n .

Terminalside of femaleterminals

11-110

InjectorReplacement
(see page1l-144). 1 . Relieve pressure fuel (A), 2 . Disconnect connectors the fromthe injectors disconnect ground (C). the cable(B), andremove bracket the

(2.2 kgf.m, l6 lbf.ftl

*\

ffi\t\

3. Disconnect quick-connect the fittings (D). 4 . R e m o v e t h e f u erl a i lm o u n t i n g n u t s ( Ef)r o m t h e f u e l r a i l( F ) t h e nr e m o v e t h e f u e r a i la n d i n j e c t o r s s a n a s s e m b l y . l a 5. Removethe injectorclip (G)from the injector. 6. Removethe injectorfrom the fuel rail.

(cont'd)

11-111

PGM-FI System
(cont'd) InjectorReplacement
7 . C o a t t h e n e w o - r i n g s ( A ) w i t h c l e a n e n g i n e o l l , a n d i n s e r t t h e i n j e c t o ris (tB ) h e f u e lr a i l( C ) . n ot

r 8 , l n s t a ltl h e i n j e c t o c l i p { D ) . 9. Coatthe injectoro-rings(E)with cleanengine oil. 1 0 . I n s t a l l t h en j e c t o r sn t o t h e f u e lr a i l ,t h e n i n s t a l t h e f u e l r a i li n t o t h e i n t a k e m a n i f o l d ( G ) . i i l 1'1. Installthe fuel rail mounting nuts,ground cable.and bracket. 12. Connect the connectors the injectors. to 13. Connect fittings. the quick-connect 1 4 . T u r n t h ei g n i t i o n w i t c hO N ( l l ) ,b u t d o n o t o p e r a t e t h e t a r t e rA f t e r t h e f u e lp u m p r u n sf o r a b o u t2 s e c o n d st,h e s s . fuel pressurein the fuel line rises.Repeat this two or three times. then checkfor fuel leakage.

11-112

A/F SensorReplacement
Special Tools Required O2 sensorwrench,Snap-onYA8875.SPTools 93750, o r e q u i v a l e n t ,o m m e r c i a l l a v a i l a b r e c y 1. Disconnect A,/F the sensor4P connector(A),then removethe A,/F sensor{B).

Secondary HO2SReplacement
Special Tools Fequired 02 sensorwrench,Snap-onYA8875,SP Tools 93750, o r e q u i v a l e n t ,o m m e r c i a l l a v a i l a b l e c V 1. Disconnect secondaryHO2S4P connector(A), the then removethe secondaryH02S (B).

ffi

\I

B 44N.m

InstalltheIVF sensorin the reverseorder of removal.

2 . InstallthesecondaryHO2Sin the reverseorder of


removal.

11-113

PGM-Fl System
ECTSensorReplacement
'1. R e m o v e h e a i r c l e a n e r s e ep a g e1 1 - 1 6 2 ) . t {

CMPSensorB (TDC Sensorl Replacement


' t . R e m o v e h e a i r c l e a n e r s e ep a g e1 1 - 1 6 2 ) . ( t 2. Disconnect CN4P the sensorB (TDCsensor)3P
conneclor. Removethe CMP sensorB (TDCsensor)(A).

2. Disconnect ECTsensor2P connector. the 3. Removethe ECTsensor(A).

{1.2kgt m.8.7 lbt.ft}

---8.7tbf.ftl

r, ".- ,',',., *nr...

i l n s t a l l t h e e n s o r n t h e reverse order of removal s with a new o-ring {B).

4 . lnstallthe sensorin the reverseorder of removal with a new o-ring {B).

11-114

IAT SensorReplacement
1, Dlsconnect IAT sensor2P connector. the 2. Removethe clip (A) and the IAT sensor(B).

KnockSensorReplacement
1. Removethe intakemanifold bracket(A).

3. lnstallthe sensorin the reverseorder of removal.

24Nm (2.4kgt.m,17lbt.ftl

2. Disconnect knocksensor 1Pconnector. the 3 . R e m o v e h e k n o c ks e n s o r( B ) . t


4 . Installthesensorin the reverseorder of removal.

11-115

PGM-FI System
GKPSensorReplacement
sensor connector. 3P 1. Disconnect CKP the 2. Remove CKP the sensor {A).
12 N.m (1.2kgt m. 8.7 tbf.ftl

3. lnstallthe sensorin the reverseorder of removal with a new o-ring (B).

11-116

VTEC/VTC
ComponentLocationIndex

-gl
:1

ia

i@'-;'

r-:
-

--tl
)

lt i..,,

;'l--i

',..

-'

'--'-

tt

VTCOILCONTROL VALVE SOLENOID page Troubleshooting, 11-118 11-'l27 Test,page VALVE VTCSOLENOID page Troubleshooting, 11-123 page Removal/lnspection, 11-128

CAMSHAFTPOSITION A ICMPISENSOR page 11-121 Troubleshooting, Replacement, Pagel'!-128

11-117

VTEC/VTC
DTGTroubleshooting
DTCP0010: WC Oil ControlSolenoid Valve Malfunction
1 . R e s e t t h e C M( s e ep a g e1 1 - 4 ) . E 2. Start the engine.Hold the engineat 3,000rpm with no load (in neutral)until the radiatorfan comes on, t h e nl e t i t i d l e . 3. Test-drive a steadyspeed between20-40mph at (30-60 km/h)for 10 minutes. ls DTC P0010indicated? YES Go to step 4. NO- Intermittent failure,system is OK at this time. Checkfor poor connections looseterminalsat or the VTC oil control solenoidvalve and at the ECM.I 4. Turn the ignition switch OFF. 5. Disconnect ECMconnectorB {24P). the 6. Measureresistance betweenECrU connector terminals 1and 823. B ECMCONNECTOR I24P) B
T e r m i n a s i d 6 o t m a t e t e r m i n as

8. Measureresistance betweenVTCoil control s o l e n o i d a l v e2 Pt e r m i n a l s o . 1 a n d N o . 2 . v N


VTC OIL CONTAOLSOLENOID VAI"VE2P CONNECTOB

ls there 6.75 8.25 Q ? YES-Go to step L NO-Replace the VTC oil control solenoidvalve (seepage 11-1271.a 9 . C o n n e cV T Co i l c o n t r o l o l e n o i d v a l v e 2 P t s connectorterminalsNo. 1 and No. 2 to body g r o u n dw i t h a j u m p e r w i r ei n d i v i d u a l l y . wc otl coNTBoL sotENoto
VALVE 2P CONNECTOR

-4-t t 1
wc I

tBr-K/wHT) | liELU/WHT) JUMPER WTREI IJUMPEnW|RE

2 l lwc*

W i r e s i d eo f 1 6 m a l e e . m i n a t s t

10. Checkfor continuitybetweenECMconnector t e r m i n a l s 1 a n d 8 2 3 a n d b o d y g r o u n di n d i v i d u a l l y . B Wiresideof female terminals

ls there 6.75 8.25 Q ? YES Go to step 11. NO Go to step7. 7. Disconnect VTC oil control solenoidvalve2P the connector. ls there continuity? Y E S G o t o s t e p1 1 . NO- Repairopen in the wire betweenthe ECM (B1, B23)and the VTCoil control solenoidvalve.I

11-118

11. Checkfor continuitybetweenECMconnector B t e r m i n a l s 1 a n d B 2 3a n d b o d y g r o u n di n d i v i d u a l l y .

VTCSystemMalfunction DTCP0011:
(seepage 11-4). 1. Reset the EClvl r H 2 . S t a r tt h e e n g i n e . o l dt h e e n g i n ea t 3 , 0 0 0 p m w i t h r ) n o l o a d ( i n n e u t r a l u n t i lt h e r a d i a t o f a n c o m e so n . 3. Test-drive a steadyspeed between20 40 mph at (30 60 km/h)for 10 minutes. with the scantool 4 . Checkfor TemporaryDTCP0011 ls Tempotaty DTC P0011indicated?

VTC (BtK/WHT)

ls there continuity? YES Go to step 12. NO Updatethe ECM if it does not have the latest software,or substitutea known-goodECM,then lf recheck(seepage 11-6). the symptom/indication goes away with a known-goodECM,replacethe original EClvl. !

YES-Go to step 5. failure, system is OK at this time. NO- Intermittent or Checkfor poor connections loosewires at the v V T Co i l c o n t r o ls o l e n o i d a l v ea n d a t t h e E C M . I Watch the low oil pressurelight with the engine r un n i n g . ls the low oil pressute light on?

12. Disconnect VTC oil control solenoidvalve 2P the connector. 1 3 .Checkfor continuitybetweenECMconnector
B t e r m i n a l s 1 a n d 8 2 3 a n d b o d y g r o u n di n d i v i d u a l l y .

YES- Checkthe oil pressure(seepage 8-4).I N O - G o t o s t e p6 . 6 . Turn the ignition switch OFF. (seepage 4-28). 7 . Removethe auto-tensioner

vfc

(8LK/WHT)

W i r e s i d eo f f e m a l er e r m i n as

ls there continuity? t Y E S - R e p a i rs h o r ti n t h e w i r e b e t w e e n h e E C M( B 1 , B23)and the VTCoil control solenoidvalve.l the NO Replace VTC oil control solenoidvalve (seepage 11-1211.a

(cont'd)

11-119

VTEC/VTC
(cont'dl DTCTroubleshooting
Removethe VTC strainer(A).Checkthe WC s t r a i n ef o r c l o g g i n g . r 13. ConnectECM connectorterminalsA3 and 81 witha j u m p e rw i r e m o m e n t a r i l y . NOTE:Do not jump for more than 1 minute,
ECM CONNECTORS

ls the strainet OK?


Wire side of femaleterminals

YES Go to step g. NO-Clean the VTC strainer, then replacethe e n g i n eo i l f i l t e ra n d t h e e n g i n eo i l . l 9. Checkthe VTCoil control solenoidvalve{seepage 11-127 ). ls the VTC oilcontrol solenoid valve OK? YES Go to step 10. NO Cleanthe ports of the WC oil control solenoid valve,or replacethe VTCoil control solenoidvalve {seepage 11-127).a Did the engine stall or run rough? YES Test-drive a steadyspeedbetween at 20 40 mph (30 60 km/h)for 10 minutes. lf temporaryDTCP00'l is indicated,updatethe 1 ECIVI it does not have the latestsoftware,or if substitute known-goodECM,then recheck(see a page 11-6). the symptom/indication lf goes away with a known-goodECM,replacethe original ECM! . NO Go to step 14. 1 4 . Checkthe VTC actuator(seepage6,8). ls the VTC actuatot OK? (see page 4-281, YES Removethe auto-tensioner and clean or replacethe VTC oil strainer.Update the ECI\4 it does not have the latestsoftware,or if substitutea known-goodECM,then recheck(see page 11-6). the symptom/indication lf goes away with a known-goodECM,replacethe original ECM. T NO Replace VTC actuator.t the

1 0 .InstalltheVTCoil control solenoidvalve. 1 1 .Startthe engine.Hold the engine at 700 1,000rpm.


1 2 . C o n n e c E C Mc o n n e c t otre r m i n a lB 2 3 t o b o d v t g r o u n dw i t h a j u m p e rw i r e .
ECMCONNECTOR {24PI B

213415
8 1

e l1a ,/1,/
181./l l./ 21

6 7 15

23 vTc JUMPER (BLK/WHT} WIRE

Wire side of temaleterminals

11-120

A DTCP0340: CMPSensor No Signal A CMPSensor Intermittent DTGP0344: Interruption


'11-4). 1 . R e s e t h e E C M( s e ep a g e 2. Startthe engine. ls DTC P0340and/or P0344indicated? YES-Go to step 3. failure,system is OK at this time. NO Intermittent or Checkfor poor connections looseterminalsat A t h e C M Ps e n s o r a n d a t t h e E C M . I 3. Turn the ignition switch OFF.

A voltage between CMPsensor 3P 7. Measure No. terminal 1 andbodyground. connector


CMP SENSORA 3P CONNECTOR

W i r e s i d eo l f e m a l e t e r m i n as

ls thercabout5 V? YES-Go to step8. NO-Go to step10.

4. Disconnect CMPsensorA 3P connector. the s 5 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) . 6. Measurevoltage betweenCMPsensorA 3P connectorterminal No. 3 and body ground.
A CMPSENSOR 3P CONNECTOR tG1

A CMPsensor 3P voltage between 8. Measure tr s c o n n e c t oe r m i n a lN o .2 a n dN o .3 .


CMP SENSORA 3P CONNECTOF

;f-;-1 J ,o,,r.*,"r., I l1 l-t ,-or---T--I


{8RN/YEL) ni-

1 2 3

(BLK/YEL}

ls there battety voltage? YES Go to step 9. terminals Wiresideof female NO-Repair open in the wire betweenthe Cl\4P s e n s oA a n dG 1 0 1 . 1 r 9. Substitute known-goodCMPsensorA and a recheck. ls DTC P0340and/ot P0344indicated? YES Updatethe ECM if it does not have the latest software,or substitutea known-goodECM,then lf recheck(seepage 11-6). the symptom/indication goes away with a known-goodECM,replacethe o r i g i n aE C M . I l A t l N O R e p l a c eh e o r i g i n a C M Ps e n s o r { s e ep a g e 11-128).t (cont'd)

ls there battety voltage? YES Go to step 7. f N O C h e c k h e N o . 4 A C G{ 1 0 A ) u s ei n t h e u n d e r t dash fuse/relaybox. lf the fuse is OK, repairopen in sensorA and No. 4 ACG the wire betweenthe CN4P (10A)use.I f

11-121

VTEC/VTC
(cont'd) DTCTroubleshooting
1 0 .Measurevoltage betweenECMconnectorterminal
A25 and body ground.
ECMCONNECTOR 131P) A

DTCP0341: WC Phase Gap


1 . R e s e t t h e C M{ s e ep a g e1 1 - 4 ) . E 2. Startthe engine. ls DTC P0341indicated? YES Go to step 3. NO Intermittent failure,system is OK at this time. Checkfor poor connections looseterminalsat or t h e C M Ps e n s o r a n d a t t h e E C M . I A

Wiresideof female te.minals

3. Checkthe VTC oil control solenoidvalve (seepage 11_127]-. Isthe VTC oil control solenoid valve OK? YES-Go to step 4. NO-CIean the VTCoil control solenoidvalve,or r e p l a c et ( s e ep a g e1 1 - ' l 2 7 l . a i 4. Removethe head cover,and checkthe cam chain {seepage 6-12). ls the cam chain OK? YES Go to slep 5. N O R e p l a c eh e c a m c h a i n( s e ep a g e6 - 1 2 ) . 1 t 5. Checkthe VTC actuator(seepage 6-8). ls the VTC actuator OK? YES- U pdatethe ECM if it does not have the tatest soflware,or substitutea known-goodECI\4, then recheck(seepage 11-6). the symptom/indication lf goes away with a known-goodECM,replacethe originaECM.I l NO- Replace VTC actuator.l the

ls there about 5 V? YES-Repair open in the wire betweenthe ECM ( A 2 5 ) n d C M Ps e n s o r . I a A N O - G o t o s t e p1 1 . 1 1 .Turn the ignition switch OFF. 't2. Disconnect ECMconnectorA (31P) Checkfor continuitybetweenECMconnecror terminal A25 and body ground.
ECMCONNECTON 131P} A

Wiresideof femaleterminals

ls tnere continuity? YES-Repair short in the wire betweenthe ECM (A25)and the CMP sensorA. t NO Updatethe ECt\4 it does not have the latest if software,or substitutea known-goodECM,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe originaECM.I l

11-122

DTCPl259:WEC SystemMalfunction
SpecialToolsRequired . Pressure gaugeadapter07NAJ P07010A . A/T low pressuregaugew/panel 07406-0070300 . A/T pressurehose 07406-0020201 . Av/T pressurehose,2,210mm 07IMAJ-PY4o11A . l"/T pressureadapter07MAJ-PY40120 . Oil pressurehose 07ZAJ-S54,4200 1 . R e s e t h e E C M( s e ep a g e1 1 - 4 ) . a o 2 . C h e c k h e e n g i n e i l l e v e l , n d r e f i l li f n e c e s s a r y . t 3. Startthe engine.Hold the engineat 3,000rpm with no load {in neutral)until the radiatorfan comes on. 4. Roadtestthe vehicle: in Accelerate the 1stgear to an engine speedover lf 4.000rpm. Holdthe speedfor at least2 seconds. DTCP1259is not repeatedduring the first road test, repeatthe test two more times. ls DTC P1259 indicated? YES Go to step 5. NO-lntermittent failure,system is OK at this time Checkthe oil consumptionif oil was added in step or 2. Checkfor poor connections looseterminalsat the VTECsolenoidvalve,the VTECoil pressure I switch,and at the ECI\4. 5, Turn the ignitjon switch OFF.

the 6. Disconnect VTECoil pressureswitch2P connector. 7. Checkfor continuitybetweenVTECoil pressure switch 2P connectorterminals No. 1 and No. 2 SWITCH VTECOILPRESSURE 2PCONNECTOR

T e r m i n as i d eo f m a l et e r m i n a l s l

Is therecontinuity? YES-Go to step8. switch.l oil the NO Replace VTEC pressure s O 8 . T u r nt h ei g n i t i o n w i t c h N( l l ) . switch oil VTEC pressure voltage between 9. Measure No. terminal 1 andbodyground 2Pconnector
SWITCH VTEC PRESSURE OIL 2PCONNECTOR VTPSW /T\ {BLU/BLK}

{.--rr-l'--.l

\rJ

I I

o I
t W i r es i d eo f f e m a l e e r m i n a l s

ls there battety voltage? Y E S G o t o s t e P1 4 . NO-Go to step 10.

(cont'd)

11-123

VTEC/VTC
(cont'd) DTCTroubleshooting
10. Measurevoltage betweenECMconnectorterminal 89 and body ground.
ECMCONNECTOR (24P) B

14. fMeasure voltage between VTEC pressure oil switch 2 Pc o n n e c t oe r m i n a lN o .1 a n dN o .2 , tr s


VTECOILPRESSURE SWITCH 2P CONNECTOR

213415 o 1 8 I a t / t / n 3 15
WPSW {BLU/BLK}

VTPSW (BLU/BLK) (BRN/YELI

Wire side Iemale of terminals ls there battery voltage?

Wire side of Iemaleterminals

ls there battery voltage? YES Repairopen in the wire betweenthe VTECoil pressureswitch and the ECM(89).t N O - G o t o s t e p1 1 . 1 1 .Turn the ignition switch OFF. Turn the ignition switch OFF. Disconnect ECMconnectorB {24P).
to.

Y E S - G o t o s t e p1 5 . NO Repairopen in the wire betweenthe VTECoil p r e s s u r e w i t c ha n d G 1 0 1 . 1 s

Disconnect VTECsolenoidvalve 2P connector. the

Checkfor continuitybetweenECMconnector t e r m i n a lB g a n d b o d y g r o u n d .
ECMCONNECTOR {24P) B

1 7 . Checkfor resistance betweenVTECsolenoidvalve 2 Pc o n n e c t otre r m i n a l s o , 1 a n d N o . 2 . N VTECSOLENOID VALVE 2PCONNECTOR

2 3 415 I 9 ol./ ./ 13

6 7 15

VTPSW {BLU/BLK}

Wrre side of femaleterminals

T e r m i n a li d e f m a l e e r m i n a l s s o t ls there continuity? YES Repairshort in the wire betweenthe VTECoil pressureswitch and the ECM (89).I NO Updatethe ECM if it does not have the latest software.or substitutea known-goodECM,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe originaECN4. l ! ls there 14- 30 Sl ? YES Go to step 18. NO Replace VTECsolenoidvalve (seepage the 11-128).t

11-124

1 8 . Removethe VTECoil pressureswitch (A) and i n s t a l l t h e p e c i a l t o o l a s s h o w n ,t h e n r e i n s t a ltlh e s s switch. VTECoil pressure 07406-0020201 ot 07MAJ-PY,lo11A and 07MAJ-PY40120

23. Turn the ignitionswitch OFF.


the 24. Disconnect VTECsolenoidvalve 2P connector.

25. Aftachthe batterypositiveterminalto VTEC


v s o l e n o i d a l v e2 P c o n n e c t otre r m i n a lN o . 2 .

07406-0070300

\lsl
t:={

26. Startthe engine,then connectthe batterynegative


A 22 N.m l2.2kgt.m, 16rbf.ft)
07NAJ-P07010A

s v t e r m i n a l t oV T E C o l e n o i d a l v e2 P c o n n e c t o r a t t e r m i n a lN o . 1 , a n d c h e c k h e o i l p r e s s u r e t a n engine speedof 3,000rpm. ls the oil pressure above 390 kPa (4.0 kgt/crtf , 57 psi)? YES Go to step 27. NO InspecttheVTECsolenoidvalve (seepage I112Al.a

1 9 .Reconnect VTECsolenoidvalve 2P connector the


and VTECoil pressureswitch 2P connector.

20. Connecta tachometeror OBD ll scantool/Honda


PGM Testerto the DLC.

27. With the batteryterminalsstill connectedtothe VTECsolenoidvalve connector,measurevoltage betweenECMconnectorterminal 89 and bodv oround. B ECMCONNECTOR {24P)

2 1 . Startthe engine.Holdthe engine at 3,000rpm with


no load (in neutral)until the radiatorfan comes on.

22. Checktheoil pressureat enginespeedsof 1,000


and 2.000rpm. Keepthe measuringtime as shon b t t a s p o s s i b l e l e s s h a n 1 m i n u t e ) e c a u s eh e e n g i n e { w is running ith no load. ls the oil ptessure below 49 kPa (0.5 kgf/cnf, 7 psi)? YES Go to step 23. NO Inspectthe VTECsolenoidvalve (seepage 11't28l.a
Wire side of femaleterminals

ls there battery voltageabove 4,000 tpm? YES Go to step 28. NO-Replace the VTECoil pressureswitch (see p a g e1 1 ' 1 2 8 ) . 1

28. Turn the ignitionswitch OFF.


the 29. Disconnect batteryterminalsfrom the VTEC solenoidvalve terminal connector.

(cont'd)

11-125

WEC/VTC
(cont'd) DTCTroubleshooting
30. Disconnect ECMconnector B (24P)
Checkfor continuitybetweenECMconnector t e r m i n a l8 1 5 a n d b o d y g r o u n d .
ECM CONNECTOR {24P) B

32. ConnectVTECsolenoidvalve 2P connector terminal No. 2 to body ground with a jumper wire.
VTEC SOLENOIDVALVL 2P CONNECTOR

r-.'-r.---.1

t 1 t 2 l
JUMPER VtS I WIRE I IGRN/YEL)

Wiresideof female terminals

Wire side of femaleterminals

Checkfor continuitybetweenECMconnector t e r m i n a l8 1 5 a n d b o d y g r o u n d .
ECM CONNECTOR {24PI B

ls therecontinuity? YES-Repair shortin thewire between VTEC the ( s o l e n o iv a l v e n dt h eE C M 8 1 5 ) . 1 d a NO Goto step32.

Wiresideof female terminals ls thete continuity? YES Updatethe ECM if it does not have the latest software,or substitute known-goodECM,then a recheck(seepage 11-6). the symptom/indication lf goes away with a known-goodECM,replacethe originaECM.I l NO Repairopen in the wire betweenthe VTEC v s o l e n o i d a l v ea n dt h e E C M( 8 1 5 ) . I

11-126

ValveRemoval/Test WC OilControlSolenoid
v 1 . R e m o v e h e W C o i l c o n t r o l o l e n o i d a l v e( A ) . t s NOTE:lnstallthe valve in the reverseorder of removalwith a new o-ring (B),then checkthese tlems: Cleanand dry the VTCoil control solenoidvalve mating surface. Coatthe O-ringwith engineoil. Do not installthe VTC oilcontrol solenoidvalve while wearingfibrous gloves, Be carefulnot to contaminate the cylinder head openrng. BATTERY Connectthe batterynegativeterminalto VTC oil s v c o n t r o l o l e n o i d a l v e2 Pc o n n e c t otre r m i n a lN o . 1 , t h e n m a k es u r et h e v a l v e( A )o p e n sf u l l y . Connectthe batterypositiveterminal to VTC oil control solenoidvalve 2P connectorterminal No. 2. VTCOILCONTROL SOLENOID VALVE CONNECTOR 2P

Terminalside oJ m a l et e r m i n a l s

Checkthe VTC oil control solenoidvalve filter for clogging.lf it is clogged,replacethe VTC oil control solenoidvalve. betweenthe port (advance Checkthe clearance (A) side)and the valve.The clearance should be at ( 1 / 8i n . ) . l e a s t2 . 8m m

11-127

VTEC/WC
CMPSensorA Replacement
( 1 . R e m o v e h e a i r c l e a n e r s e ep a g e11 - 1 6 2 ) . t Disconnect CMP sensorA 3P connector. the Removethe CMPsensorA (A). 1 . Disconnect VTECsolenoidvalve 2P connector. the Measureresistance betweenVTECsolenoidvalve c o n n e c t otre r m i n a l s o . 1 a n d N o . 2 . N Resistance:14-30 Q

WEC SolenoidValveRemoval/ Inspection

B-'-----'-l:,",14*
Installthe sensorin the reverseorder of removal with a new o-ring (B). 3. lf the resistance within specifications, is removethe VTECsolenoidvalve assemblv(A)from the cylinder head,and checkthe VTECsolenoidvalve f i l t e r( B ) f o rc l o g g i n g l.f i t i s c l o g g e d r e p l a c eh e , t solenoidvalve filter,the engine oilfilter, and the engine il. o

6x1.0mm 9.8 N.m (1.0kgf.m, 7,2 lbf.ftl

11-128

ldleGontrol System
ComponentLocationIndex

TE'

IDLEAIRCONTROL {IAC)VALVE page Troubleshooting, 11-'131

11-129

ldle ControlSystem
DTCTroubleshooting
DTCP0505: ControlSystemMalfunction ldle
NOTE:lf DTCP1519is storedatthe same time as DTC P0505, troubleshootDTCP1519 first, then recheck for DTCP0505. 1. Startthe engine.Hold the engineat 3,000rpm with no load (in neutral)until the radiatorfan comes on, then let it idle, 2. Checktheengine speedat idle with no,load conditions:headlights, blower fan, rear defogger, radiatorfan, and air conditioneroff. Is the engine running at 750t50 rpm? YES- Intermittent failure,system is OK at this trme.I NO lf the idle speed is lessthan 700 rpm, go to step 3; if it's 800 rpm or higher,go to step 4. 3 . D i s c o n n e c h e i d l ea i r c o n t r o l l A C ) a l v e 3 P tt v { connector. Does the engine speed increase or fluctuate? YES- Checkthe idle speed{seepage 1 1-138). the lf idle will not adjust properly,cleanthe passagein the throttle body, and then adjustthe idle.I N O - R e p l a c eh e I A Cv a l v e . I t 4. Turn the ignition switch OFF. 5. Removethe intakeair duct from the throttle body. 6. Startthe engine,and let it idle. 7 . P u ty o u r f i n g e r s n t h e l o w e rp o n ( A )i n t h e t h r o t t l e o oooy.

Does the enginestall? Y E S C h e c k t h e d l es p e e d( s e ep a g e1 1 - 1 3 8 ) f i t ' s i l. out of specification, replacethe IACvalve.l NO With the throttlevalve completelyclosed, c h e c k o r v a c u u ml e a k sa n d r e p a i ra s n e c e s s a r y . l f ,

11-130

DTCPl519:IACValveCircuitMalfunction
1 . R e s e t t h e C M( s e ep a g e1 1 - 4 ) . E 2. Turn the ignition switch ON (ll) ls DTC P 1519indicated? YES Go to step 3. NO-lntermittent failure,system is OK at this time. or Checkfor poor connections looseterminalsat the IACvalve and at the ECM.I 3. Turn the ignition switch OFF. 4. Disconnect IACvalve 3P connector. the

8, Checkfor continuitybetweenbody ground and IAC v a l v e3 Pc o n n e c t otre r m i n a lN o . 1 . IACVALVE CONNECTOR 3P

PG1{BLK}

a.
Wire side of lemaleterminals

Is there continuity? 5. Turn the ignitionswitch ON (ll). Y E S - G o t o s t e p9 . 6. Measurevoltage betlveenIACvalve 3P connector terminal No. 2 and body ground. IACVALVE3PCONNECTOR NO Repairopen in the wire betweenthe IACvalve a n dG ' 1 0 1 . 1 ECMconnectorA (31P) 9 . Disconnect

1 0 . Checkfor continuitybetweenbody ground and l E C Mc o n n e c t otre r m i n a A 1 2 .


A ECM CONNECTOR 131P)

IGP {YEL/BLK)

r0 1l 12./
Wire side of femaleterminals

s r l 2 l 3 l 45 6 1 7 2C21 / 115 6 ./11819 da 25126 l27ln2930


IACV{BLK/RED}

ls therebattery voltage? YES Goto step7. the NO-Repairopenin thewire between IACvalve 1 m a n dt h eP G M - F l a i nr e l a y . 1 switchOFF. 7 . Turnthe ignition

1,)

terminals WiresideoJJemale ls there continuity? YES-Repair short in the wire betweenthe IAC v a l v ea n dt h e E C M( A 1 2 ) . 1 N O G o t o s t e p 11 .

LCOnIOl

11-131

ldle ControlSystem
(cont'd) DTCTroubleshooting
11. Connect valve3Pconnector IAC terminal No.3to bodyground with a jumperwire.
IACVALVE CONNCTOR 3P 15. Measurevoltagebetweenbody ground and ECM c o n n e c t otre r m i n a A 1 2 . l ECMCONNECTOR 131P} A

r l 2 l 3 1 5 6 1 7 4
IACV IBLK/REO} JUMPER WIRE

t 0 1tl12l,/l/
22

tc

231?4l| 12.

9 6 ,/ 118 2C21 zil28 30

IACVIBLK/RED)

Wire side of femaleterminals Wire side ol femaleterminals

Checkfor continuitybetweenECMconnector t e r m i n a l A l 2 a n d b o d yg r o u n d . ECMCONNECTOR 131P) A

I s there battery voltage? YES-Update the ECI\4 it does not have the latest if software,or substitutea known-goodECM,then recheck(seepage 11-6). the symptom/indication lf goes away with a known-goodECM,replacethe o r i g i n aE C I \ 4 . 1 l N O - R e p l a c et h e I A Cv a l v e . I

Wire side of femaleterminals

ls therecontinuity? YES Goto step13. NO-Repairopenin thewire between IACvalve the a n dr h eE c M( A 1 2 ) . r 1 3 .Reconnect IACvalve3Pconnector. the 1 4 .Turnthe ignition switch (ll). ON

11-132

A/G SignalCircuitTroubleshooting
1 . Turn the ignitionswitch ON (ll). 2 . MomentarilyconnectECMconnectorterminals424 and E18with a jumper wire severaltimes. 6. Momentarilyconnectunder-hoodtuse/relaybox 14Pconnectorterminal No. 10 to body ground with a jumper wire severaltimes. UNDER.HOOD FUSE/RELAY BOX I4P CONNECTOR

1 2 3 1 8 9 10 11

5 6
I J

14

ACC (RED) JUMPERWIRE

terminals Wiresideof female


Wire side of femaleterminals

ls there a clicking noise I rom the NC compressor clutch? YES Go to step 3. NO-Go to step 6. Start the engine. Turn the blower switch ON.

ls there a clicking noise f rom the NC compressor clutch? YES- Repairopen in the wire betweenthe ECM (E'18) and the Ay'C clutch relay.l NO- Checkthe A/C systemfor other symptoms.l

5. Turn the Ay'C switch ON.


Does the NC operate? Y E S - T h e a i r c o n d i t i o n i n s i g n a li s O K . I g NO Updatethe ECM if it does not have the latest software,or substitutea known-goodECM.then recheck(seepage 11-6). the symptom/indication lf goes away with a known-goodECM,replacethe o r i g i n a C M . l l

11-133

ldle GontrolSystem
AlternatorFRSignalCircuitTroubleshooting
' t . Disconnect alternator4P the
alternalor. connectorfrom the '11. Connectalternator4P connector term inal No.4 to body ground with a jumper wire.
ALTERNATOR4P CONNECTOR

2. T u r nt h e i g n i t i o n w i t c hO N { l l ) . s 3 . Measurevoltage betweenECMconnector
4 terminals 24 and813.
ECM CONNECTORS

2
4
ALTFIWHT/RED)
JUMPERWIRE

A l31Pl

1 2 1 3 4 5 6 1 1| 1 . , 'I 10 1 1 1 1 2 , / 5 6 , / r8119l2C 21 23124 28129130


L (BRN/ EL) Y ALTF (WHT /REDI

213 4t5
8

9ltal,/l/

6 1 15

Wiresideof female terminals

1 2 .Checkfor continuitybetweenbody ground and


EClvl connectorterminal 813. ECMCONNECTOB(24PI B

Wire side of femaleterminals

ls there about 5 V? YES Go to step 4. N O - G o t o s t e p1 3 . 4. Turn the ignition switch OFF. the 5. Reconnect alternator4P connector. 6. Slan the engine.Hold the engineat 3,000rpm with no load (in neutral)until the radiatorfan comes on, then let it idle. 7. lvleasure voltagebetweenECMconnector t e r m i n a l s 2 4a n d B1 3 . A Does the voltage decrease when the headlights and rear window defogger arc tutned on? Y E S T h e a l t e r n a t oF Rs i g n a li s O K . l r N O - G o t o s t e p8 . 8. Turn the ignition switch OFF. ECMconnectorB (24P). 9. Disconnect 10. Disconnect alternator4P connector. the
Wire side of femaleterminals

ls there continuity? YES-Testthe alternator(seepage 4-22).1 NO Repairopen in the wire betweenthe ECM ( B1 3 )a n dt h e a l t e r n a t o r . l

1 3 .Turn the ignitionswitch OFF. 't4. Disconnect ECMconnectorB (24P).

11-134

Electrical PowerSteering(EPSI SignalCircuitTroubleshooting


15. Checkfor continuitybetweenbody ground and ECIM connectorterminal 813.
ECM CONNECTOR I24P} B

1 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s 2 . l\4easure voltage betweenECMconnector terminals 24 andE16. 4

Wire side of femaleterminals

ls there continuity?
Wire side of femaleterminals

YES Repairshort in the wire betweenthe ECM ( 8 1 3 )a n dt h e a l t e r n a t o r . l NO Updatethe ECM if it does not have the latest software,or substitutea known-goodECM,then rechecklsee page 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe o r i g i n aE C M . I l

ls there battery voltage? YES Go to step 6. NO Go to step 3.

3 . Startthe engine. 4 . Turn the steeringwheel lo the full lock position. 5 . l\4easure voltage betweenECMconnector
A t e r m i n a l s 2 4a n d E 1 6 . ls there momentatybattery voltage? Y E S T h e E P Ss i g n a li s O K . t N O G o t o s t e p1 0 . s 6 . T u r nt h e i g n i t i o n w i t c hO F F . 7. Disconnect EPScontrol unit 20Pconnector. the 8 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s

(cont'd)

11-135

ldle ControlSystem
(cont'd) Electrical PowerSteering(EPSI SignalCircuitTroubleshooting
9. Measure voltage between control EPS unitterminal N o . l 7a n db o d yg r o u n d .
'13. l\4easure voltagebetweenEPScontrol unitterminal N o . 1 7a n d t h e b o d y g r o u n d .
EPSCONTROL UNIT2OP CONNECTOR

EPSCONTROL UNIT2OP CONNECTOR

Wire side of femaleterminals

Wire side of femaleterminals

ls there battery voltage? ls there battety voltage? YES-Substitute a known-goodEPScontrol unit a n dr e c h e c k . I NO- Repairopen in the wire betweenthe ECM ( E1 6 )a n d t h e E P Sc o n t r o lu n i t . l YES Substitutea known-goodEPScontrol unit andrecheck.l N O - G o t o s t e p1 4 , 1 4 . Turn the ignition switch OFF.
t5_

D i s c o n n e c t t hE C Mc o n n e c t oE { 3 1 P ) . e r

1 0 .Turn the ignitionswitch OFF. I ' I. Disconnect EPScontrol unit 20Pconnector. the 12. Turn the ignitionswitch ON (ll).

1 6 .Checkfor continuitybetweenbody ground and E C I \ c o n n e c t otre r m i n a E 1 6 . 4 l


ECMCONNECTOR {31PI E

1 2 3 4 5 6 1 7 l1 89 5 6 . / 1 8 2A21 22 23 zi ./ 2930 o l

a,
lsthere continuity?

EPSLD {LTGRN/BLK)

Wiresideot Iemale terminals

YES Repairshort in the wire betweenthe ECN4 ( E1 6 )a n d t h e E P Sc o n t r o lu n i t . l NO Updatethe ECM if it does not have the latest software,or substitutea known-goodECM,then recheck(seepage 11-6). the symptom/indication lf goes away with a known-goodECM,replacethe originaECM.I l

11-136

BrakePedalPositionSwitch SignalCircuitTroubleshooting
1. Checkthe brakelights. Are the brake lights on without pressing the brake pedal? YES Inspectthebrakepedal positionswitch ( s e ep a g e1 9 - 6 ) . I NO Go to step 2. 2. Pressthe brakepedal. Do the brake lights come on? YES-Go to step 3. NO Go to step 4. 3. MeasurevoltagebetweenECMconnector terminalsA24 and E22with the brakepedal presseo. 4 . I n s p e ctth e N o . 7 H O R N S T O P( 1 5 A ) u s el n t h e , f under-hoodfuse/relaybox. ls the tuse OK? YES- Repairopen in the wire betweenthe brake pedal positionswitch and the No.7 HORN,STOP ( l5A) fuse, Inspectthe brakepedal positionswitch ( s e ep a g e1 9 - 1 0 ) . 1 NO Repairshort in the wire betweenthe ECM ( E 2 2 ) n dt h e N o . 7 H O R N , T O P 1 5 A ) f u s e . ( a S (15A)fuse.t R e p l a c eh e N o . 7 H O R N S T O P t ,

Wire side of lemaleterminals

ls there battery voltage? YES-The brakepedal positionswitch signal is

oK,I
NO Repairopen in the wire betweenthe Eclvl (E22) and the brakepedal positionswitch.l

11-137

ldle ControlSystem
ldle Speedlnspection
NOTE: ' Leavethe idle air control (lAC)valve connecled. . Beforecheckingthe idle speed,checkthese items: - T h e m a l f u n c t i o nn d i c a t o lra m p ( M l L )h a s n o t b e e n i reportedon. - lgnitioniming t - S p a r kp l u g s - Aircleaner - PCVsystem . P u l l t h ep a r k i n g r a k el e v e ru p . S t a r tt h e e n g i n e a n d b , make sure the headlightsare off. 1. Disconnect evaporative the emission(EVAP) canisterpurge valve 2P connector. 2. Connecta tachometer(A)to the test tachometer connector(B),or connectthe HondaPGM Tester(C) or an OBD ll scantool to the data link connector (DLC)(D) locatedunder the driver'sside of the dashboard.

3 . Startthe engine.Holdthe engineat 3,000rpm with


n o l o a d ( i n n e u t r a l u n t i lt h e r a d i a t ofra n c o m e so n , ) t h e nl e t i t i d l e . 4 . Checkthe idle speedwith no-loadconditions; headlights, blower fan, radiatorfan, and air conditioneroff. ldle speedshould be: 750 t 50 rpm 5 . Let the engine idle for 1 minute with the heaterfan switch on Hl and air conditioneron, then checkthe i d l es p e e d . ldle speedshould be: 750 t 50 rpm NOTE:lf the idle speed is not wilhin specification, go to the Symptom Troubleshooting Index, 6 . Reconnect EVAPcanisterpurgevalve 2P the connector.

11-138

ECMldle LearnProcedure
The idle learn proceduremust be done so the ECMcan learnthe engine idle characteristics. Do the idle learn procedure wheneveryou do any of these actions: . Disconnect battery. the Replace ECMor disconnect connector. the its Resetthe ECM. NOTE:ErasingDTCS with the HondaPGM Tester does not requireyou to do the idle learn procedure. Removethe No.6 ECU{ECM)( 15A)fuse from the under-hood fuse/relaybox. Removethe No.19baftery(80A)fuse from the underhood fuse/relaybox. R e m o v e G M - Fm a i n r e l a y1 . P I Removeany of the wires from the under-hoodfuse/ retayDox. Disconnect any of the connectors from the under hood fuse/relaybox. Disconnect connectorbetweenthe engine the compartmentwire harnessand ECMwire harness. Disconnect G2 terminal from the transmission the h ous r n g . Disconnectthe terminal from the body. G'l D i s c o n n e c t t hG 1 0 1 e r m i n a f r o m t h e c y l i n d e r e a d e t l h cover.

Procedure:
To completethe idle learn procedure, this: do 1. Make sure all electricalitems (Ay'C, audio, rear defogger,l:ghts,etc.,)are off. 2. Startthe engine,and hold it at 3,000rpm with no l o a d{ i n n e u t r a l u n t i lt h e r a d i a t o f a n c o m e so n , o r ) r u n t i lt h e e n g i n e o o l a n t t e m p e r a t u r e a c h e s 9 4 " F c 1

(90'c).

3. Let the engine idle for about 5 minuteswith the throttlefully closed. NOTE:lf the radiatorfan comes on, do not includeits r u n n i n g i m ei n t h e5 m i n u t e s . t

11-139

FuelSupplySystem
ComponentLocationIndex
p T e s t , a g e1 1 - 1 4 1 page 11'153 Fleplacement, FUELFILTER page 11-1 Replacement, 52 FUELGAUGESENDING UNIT p a g e1 1 - 1 5 6 Test, page 11-153 Replacement, FUELPRESSUN REGULATOR page'1 Replacement, 1-'152

PUMP

FUELFILLCAP

FUEL TANK R e p l a c e m ep a , e '1 - 1 5 5 ntg l


FUELTUBE/OUICK.CONNECT FITTINGS page 11-148 Precautions, p a g e1 1 - ' 1 4 9 Removal, page 11-'l50 Installation,

FUELFEED LINE FUELPULSATION DAMPER page Replacement, 11'154

FUELVAPORLINE

PGM.FIMAIN RELAY1

2 PGM.FI MAINRELAY T r o u b l e s h o o t ip a g e ' l ' l - 1 4 1 ng,

11-140

FuelPumpCircuitTroubleshooting
lf you suspecta problemwith the fuel pump, checkthat the fuel pump actuallyruns;when it is on, you will hear some noise if you listento the fuel fill port with the fuel fill cap removed.The fuel pump should run for 2 secondswhen the ignition switch is first turned on. lf the fuel pump does not make noise,checkas follows: 1. Turn the ignition switch OFF. 2. Removethe glove box {seepage 20-63), then removethe PGM-FI main relay 2 (A). 5. N4easure voltage betweenPGM-Flmain relay 2 5P connectorterminal No. 1 and body ground.
PGM.FI MAIN RELAY2 5P CONNECTOR

Wire side oJfemaleterminals

ls there battery voltage? YES Go to step 6. NO Repairopen in the wire betweenthe underd a s hf u s e / r e l a y o x a n d P G M - Fm a i n r e l a y2 . 1 b l 6. Turn the ignition switch OFF.

3 . Turn the ignitionswitch ON {ll).


Measurevoltage betweenPGM-Flmain relay 2 5P connectorlerminal No. 5 and body ground.
PGM.FI MAIN RELAY 2 5P CONNECTOR

7. Disconnect ECMconnectorE (31P). 8. Checkfor continuitybetweenPGM-FI mainrelay2 5P connectorterminal No. 3 and ECMconnector t e r m i n a lE 1 . PGM-FI MAIN RELAY 5PCONNECTOB 2

IGPl (YEL/BLK}

7 -

Ftxm

E2 t

z
IMOFPR (GBN/ YEL) Wiresideof female terminals

ECMCONNECTOR 131P} E

Wire side of femaleterminals

ls there battery voltage?

ls therecontinuity?
YES-Go to step 5.

YES-Go to step9.
NO Repairopen in the wire betweenthe PGM'Fl m a i n r e l a y1 a n dt h e P G M - Fm a i n r e l a y2 . t l

NO-Repairopenin thewire between PGMFl the ( m a i nr e l a y a n dt h eE C M E 1 ) . 1 2

(cont'd)

11-141

FuelSupply System
(cont'dl FuelPumpCircuitTroubleshooting
l L R e i n s t a l l t h P G M - Fm a i n r e l a y2 . e ls there battery voltage? YES U pdatethe ECM if it does not havethe latest so{1ware, substitute known-goodECM.then or a recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe o r i g i n aE C M . I l NO Go to step 15.
t5. to.

1 0 .T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s 1 ' ] .Measurevoltage betweenECI\4/PCM connector


t e r m i n a lE 1a n d b o d y g r o u n d .
ECMCONNECTOB {31P) E

Turn the ignition switch OFF. Removethe rear seat cushion (seepage 20-80).

1 1 . Removethe accesspanelfrom the floor. 1 8 . Measurevoltage betweenfuel pump 5P connector terminal No. 5 and body ground within the first 2 secondsafter the ignition switchwas turned ON (ll).
FUELPUMP5P CONNECTOR

Wiresideof female terminals

ls there battety voltage? YES Go to step 12. l N O - R e p l a c et h e P G M - Fm a i n r e l a y2 . 1

(
Turn the ignition switch OFF. ECMconnectorE (31P). 1 3 .Reconnecl

1 4 .Turn the ignitionswitch ON (ll),and measure


voltagebetweenECMconnectorterminal E1 and body ground within the first 2 secondsafterthe i g n i t i o n w i t c hw a s t u r n e dO N ( l l ) . s
E ECMCONNECTOR (31PI

wire sideoI female terminals

ls there battery voltage? YES Go to step 24. N O - G o t o s t e p1 9 . 1 9 . Turn the ignition switch OFF. 20. R e m o v e h e P G M - Fm a i n r e l a y2 . t l

Wiresideof female terminals

11-142

21. ConnectPGM-Flmain relay 2 5P connector terminalsNo. 1 and No. 2 with a iumDerwire.


PGM.FIMAIN RELAY2 5P CONNECTOR

25. Checkfor continuitybetweenfuel pump 5P connectorterminal No. 4 and body ground.


FUELPUMP5P CONNECTOR

FUEL PUMP (YEL/ GRN) JUMPER WIRE

rcr fv {YEL/BLK) A

tri

FNI

dffi
Wire side of femaleterminals

Wiresideof {emale terminals

22. Turn the ignitionswitch ON (ll). 23. Measurevoltagebetweenfuel pump 5P connector


terminal No. 5 and body ground. FUELPUMP5PCONNECTOR

ls therecontinuity? Y E S R e p l a cte ef u e lp u m p . l h NO-Repairopenin thewire between fuel the p u m p5 Pc o n n e c t o rn dG 5 5 1 . 1 a

Wiresideol female terminals

ls there battery voltage? Y E S R e p l a c e t h e G M - Fm a i n r e l a y 2 . t P l NO-Repair open in the wire betweenthe PGM-Fl main relay 2 and the fuel pump 5P connector.l

24. Turn the ignitionswitch OFF.

11-143

FuelSupply System
Relieving FuelPressure
fuel lines or hoses,relieve Beforedisconnecting pressure from the system by disconnecting fuel the tube/quickconnectfitting in the enginecompartment. 1 . T u r nt h e i g n i t i o n w i t c hO F F , s 2 . R e m o v e h e P G M - Fm a i n r e l a y2 ( A ) . t l 9. Placea rag or shop towel over the quick-connect fitting (A).

fifting (A):Hold the 1 0 .Disconnect quick-connect the the connector(B)with one hand and squeeze retainertabs (C)with the other handto release them from the lockingpawls {D).Pullthe connector off.

3 . S t a r t t h ee n g i n e a n d l e t i t i d l e u n t i li t i s s t a l l s . ,
P0301. P0302, NOTE:The DTCS TemporaryDTCS or P0303, P0304may come on during this procedure. lf any DTCS stored,ignorethem. are
4 . Turn the ignitionswitch OFF.

Removethe fuel fill cap, and relievefuel pressure inthefueltank. 6 . Removethe enginecover. the 7 . Disconnect negativecablefrom the battery. fitting for dirt, and 8 . Checkthe fuel quick-connect cleanit if necessary.

NOTE: . P r e v e ntth e r e m a i n i n gu e l i n t h e f u e lf e e d l i n e o r f hosefrom flowing out with a rag or shop towel. . Be carefulnotto damagethe line (E)or other parts. . Do not use tools. . l f t h e c o n n e c t o r d o e n o t m o v e ,k e e p t h er e t a i n e r s pull and push tabs presseddown, and alternately it comes off easily. the connectoruntil . Do not removethe retainerfrom the line; once removed,the retainermust be replacedwith a new one.

fifting, check 1 1 After disconnecting quick-connect the i t f o r d i r t o r d a m a g e( s e ep a g e11 - 1 4 9 ) .

11-144

FuelPressure Test
Special Tools Required . Fuel pressure gauge 07406-0040004 . Fuel pressuregaugesel 07ZAJ-S5A0100 ( 1 . R e l i e v eh e f u e l p r e s s u r e s e ep a g e1 ' 1 - 1 4 4 ) . t 2. Disconnect quick-connect fitting (A).Aftachthe the fuel pressuregaugeset and fuel pressuregauge.

Startthe engineand let it idle. . lf the enginestarts,goto step 5. . lf the enginedoes not start,goto step 4. Checkto see if the fuel pump is running:listento the fuel fill port with the fuel fill cap removed.The fuel pump should run for 2 secondswhen the ignitionswitch is first turned on. . lf the pump runs,go to step 5. . l f t h e p u m p d o e sn o t r u n ,d o t h e f u e l p u m pc i r c u i t s t r o u b l e s h o o t i n(g e ep a g e11 - 1 1) . 4 5 . Readthe pressuregauge.The pressureshould be 320-370 kpa (3.3-3.8 kgf/cm',a7-52 psi) . lf the pressureis OK, the test is complete. . lf the pressureis out of specification, replacethe fuel pressureregulatorand the fuel filter (see p a g e1 1 - 1 5 2 t h e n r e c h e c kh e f u e l p r e s s u r e . ), t

11-145

FuelSupply System
FuelLineInspection
Checkthe fuel system lines,hoses,and fuel filter for damage,leaks,and deterioration. Replace any damagedparts.

Makesurethe connection is secureand the quick-connect fitting cover is firmly lockedinto place.

11-146

Check clamps all andretighten necessary. if A: Do notdisconnect hosefromthe lineat theseioints. the

Settheboltflange T h e r es h o u l d b e n o

W.W
C l a m pi n t h e m i d d l e . C l a m pi n t h e m i d d l e . t h e f u e l { i l lt u b e , a l i g nt h e m a r k s on the tubeand t h el i n e .

Setthispart

11-147

FuelSupply System
FuelLine/Ouick-Connect FittingsPrecaution
The fuel tube/quick-connect fittings connectthe fuel rail (A)to fuel feed hose (B),the fuel feed hose (B)to the f u e l l i n e( C ) ,a n dt h e f u e l t u b e( D )t o t h e f u e l p u m p ( W a s s e m b l y E ) . h e n r e m o v i n g r i n s t a l l i n gh e f u e l f e e d o t hose,fuel pump assembly,or fuel tank, it is necessary to disconnect connectthe quick-connect or fittings. Pay attentionto the following: . T h e f u e lf e e dh o s e( B ) ,f u e lt u b e ( D ) ,a n d q u i c k connectfittings (F)are not heat-resistanU careful be not to damagethem during welding or other heatgeneralrng proceoures. . T h ef u e l f e e dh o s e( B ) ,f u e l t u b e( D )a n d q u i c k connectfittings (F)are not acid-proof; not touch do them with a shop towel which was used for wiping Replace batteryelectrolyte. them if they came into contactwith electrolyte somethingsimilar. or . When connectingor disconnecting fuel feed hose the (B),fuel tube (D),and quick'connect fittings (F).be carefulnot to bend or twist them excessivelv. ReDlace them it they are damaged. quick-connect A disconnected fitting can be reconnected, the retaineron the mating line cannot but be reusedonce it has been removedfrom the line. Replace retainerwhen the . . . . . . . replacing the fuel rail. r e p l a c i n gh e f u e l l i n e . t replacing the fuel pump. replacing the fuel filter, replacing the fuel gaugesendingunit. it has been removedfrom the line. it isdamaged.

I\4ANUFACTUREB RETAINER COLOR EN GN E I TOKAI GREEN COI\4PARTMENT ( F U EF E E D L HOSE;U L F E LINE IDE) S EN INE TOKAI G BLU COIVIPARTMENT ( F U EF E E D L HOSE:UEL F RAIL IDE) S FUELTANK WHITE SANOH UNIT

PART

11-148

FittingsRemoval FuelLine/Ouick-Gonnect
( 1 . R e l i e v eu e l p r e s s u r e s e ep a g e1 ' l - 1 4 4 ) . f fiftingsfor din, and 2 . Checkthe fuel quick-connect clean if necessary. Hold the connector(A) with one hand and squeeze the retainertabs(B)with the other hand to release them from the lockingpaws (C).Pullthe connector off. NOTE: . B e c a r e f u l o t t o d a m a g e h e l i n ei D ) o r o t h e r t n parts.Do not usetools. . lf the connectordoesnot move, keepthe retainer pull and push tabs presseddown, and alternately the connectoruntil it comes off easily. . Do not removethe retainerfrom the line; once removed,the retainermust be replacedwith a new one. 4. Checkthe contactarea (A) of the line (B)for dirt and d am a g e . . lf the surfaceis dirty, clean it. . if the surfaceis rusty or damaged,replacethe , f u e l p u m p ,f u e l f i l t e r f u e l f e e dl i n e .

=k
To preventdamagedand keepforeign matter out, connectorand line end with cover the disconnected plasticbags (A). NOTE: . The retainercannot be reusedonce it has been f removedromthe line. the Replaced retainerwhen - r e p l a c i n gh e f u e l r a i l . t - r e p l a c i n gh e f u e lf e e dI i n e . t - r e p l a c i n gh e f u e l p u m P . t - replacing the fuel filter. - r e p l a c i n gh e f u e l g a u g es e n d i n g n i t u t - it has been removedfrom the line. - it is damaged.

11-149

FuelSupply System
FuelLine/Ouick-Connect Fittingslnstallation
1. Checkthe contacta rea (A) of the line (B)for dirt and damage,and clean if necessary. 3. Beforeconnectinga new fueltube/quick-connect fitting assembly(A),removethe old retainerfrom t h e m a t i n ol i n e ,

Inserta new retainer(A) into the connector(B) if the retaineris damaged,or after . r e p l a c i n gh e f u e l r a i l . t . replacingthe fuelfeed line. . replacingthe fuel pump. . replacingthe fuel filter. . r e p l a c i n gh e f u e l g a u g es e n d i n g n i t t u . removingthe retainerfrom the line.

11-150

fittingswith the line (A). 4. Align the quick-connect ( B )l o c k i n g a w l sw i t h t h e p a n d a l i g nt h e r e t a i n e r connector{C)grooves.Then pressthe quickconnectfittings onto the line until both retainer p a w l sl o c kw i t h a c l i c k i n g o u n d . s l , N O T E ; f i t i s h a r dt o c o n n e c tp u t a s m a l la m o u n to f n e w e n g i n e i l o n t h e l i n ee n d . o Connectionwith new retainer:

5. lvlake sure the connectionis secureand that the ; v p a w l sa r ef i r m l y l o c k e d n t o p l a c e c h e c k i s u a l l y i and by pullingthe connector.

negativecableto the battery,and 6. Reconnectthe T s t u r n t h e i g n i t i o n w i t c hO N ( l l ) . h e f u e l p u m p w i l l will rise and fuel pressure run for about 2 seconds, Repeat2 or 3 times, and checkthat there are no fuel leaks.

Reconnectionto existing retainer:

11-151

FuelSupply System
FuelPressure Regulator Replacement
1 . R e m o v e h e f u e l p u m p ( s e ep a g e11 - 1 5 3 ) . t 2 . Removethe fuel pressureregulator(A).

FuelFilterReplacement
The fuel filter should be replacedwheneverthe fuel pressuredrops belowthe specifiedvalue {270 320 kpa, 2.8 3.3 kgflcm', 40 47 psi),after makingsure that the fuel pump and the fuel pressureregulatorare OK. 1 . R e m o v e h e f u e lp u m p ( s e e p a g e l l - ' 1 5 3 ) . t 2. Removethe fuel filter (A).

@-to
IJ

e"^
g s
s g
Installthe part in the reverseorder of removalwith a n e w o - r i n g( B ) .

Re
AR
@n-)

^ e

...\

Installin the reverseorder of removalwith a new basegasket(B)and a new o-ring (C),then check these items: ' When connectingthe wire harness, make sure the connectionis secureand the terminal (D) is firmly lockedinto place. . W h e n i n s t a l l i n gh e f u e l g a u g es e n d i n g n i ti E ) , t u make sure the connectionis secureand the connectoris firmly lockedinto place.Be careful not to bend or twist it excessively.

11-152

GaugeSendingUnit Replacement FuelPump/Fuel


SpecialToolsRequired w F u e ls e n d e r r e n c h0 7 X A A - 0 0 1 0 1 0 A ( t 1 . R e l i e v eh e f u e l p r e s s u r es e ep a g e1 1 - 1 4 4 ) . Removethe fuel fill cap. Removethe seat cushion(seepage 20-80). Removethe accesspanel (A)from the floor. t t 8 . R e m o v e h e l o c k n u ( A )a n d t h e f u e lt a n k u n i t .

r tt 5 . D i s c o n n e c h e f u e l p u m p 5 Pc o n n e c t o( B ) . fitting {C)from the the Disconnect quick-connect f u e lt a n ku n i t . t 7 . U s i n gt h e s p e c i atlo o l ,l o o s e n h e f u e lt a n ku n i t locknut(A).

t t { 9 . R e m o v e h e s t o p p e r O ) .R e l e a s eh e h o o k ( P )a n d t r e m o v e h e f u e lf i l t e r( B ) , h e f u e l g a u g es e n d i n g t ( a t t u n i t ( C ) . h e c a s e( D ) , h e w i r e h a r n e s s E ) , n d t h e fuel pressureregulator(F). t 1 0 . W h e nc o n n e c t i n gh e f u e lt a n k u n i t ,m a k es u r et h e f a i c o n n e c t i o ns s e c u r e n d t h e s u c t i o n i l t e r( G )i s t f i r m l y c o n n e c t e do t h e f u e l p u m p ( H ) . o 1 1 . I n s t a ltl h e f u e lt a n ku n i t i n t h e r e v e r s e r d e ro f ( r e m o v a w i t h a n e w b a s eg a s k e t l ) a n dn e w o - r i n g s l ( J ) ,t h e nc h e c k h e s ei t e m s : t . W h e nc o n n e c t i n t h e w i r e h a r n e s sm a k es u r e , g r a i t h e c o n n e c t i o ns s e c u r e n d t h e c o n n e c t o( K )i s i f i r m l y l o c k e d n t ot h e p l a c e . . W h e n i n s t a l l i n gh e f u e l g a u g es e n d i n g n i t , u t make sure the connectionis secureand the i B c o n n e c t oirs f i r m l y l o c k e d n t o p l a c e . e c a r e f u l not to bend or twist the connectorexcessively. . W h e n i n s t a l l i n gh e f u e l t a n ku n i t ,a l i g nt h e m a r k s t ( L )o n t h e f u e lt a n k( M ) a n d t h e f u e lt a n k u n i t( N i

93 N.m kgf.m,69 lbf.ftl 19.5

11-153

FuelSupply System
FuelPulsationDamperReplacement
1 . R e l i e v eh e f u e l p r e s s u r e ( s e e p a g e l l - 1 4 4 ) . t 2. Removethe enginecover. 3. Removethe fuel rail mounting nuts from the fuel rail. 4 . R e m o v e h e g r o u n dc a b l e( G1 0 1 . t 5 . R a i s eh ef u e l r a i l . t 6 . P l a c e w r e n c h( A )o n t h e f u e l r a i l( B ) . a

7 . P l a c e w r e n c h( C )o n t h e f u e l p u l s a t i o n a m p e r( D ) . a d 8. Removethe pulsationdamper. 9. Installthefuel pulsationdamper in lhe reverse order of removalwith new washers. NOTE: . Replace washerswhenever the fuel pulsation all damper is loosenedor removed, . l f t h e d r a i nh o l e( A )o f t h e f u e l p u l s a t i o n d a m p e r cover does not face bottom, reinstallit as shown.

11-154

FuelTank Replacement
( 1 . R e l i e v e t h e f u ep r e s s u r es e ep a g e1 1 - 1 4 4 ) . l f a r . t 2 . D r a i nt h e f u e lt a n k :R e m o v e h e f u e l p u m p ( s e ep a g e11 - 1 5 3 )U s i n ga h a n dp u m p ,h o s e , n d c o n t a i n es u i t a b l eo r gasoline.draw the fuel from the fuel tank.

3 . Jack up the vehicle,and suppon it with safetystands.


fittings. the Removethe fuel pipe cover (A).Disconnect fuel vapor hose and quick-connect backthe clamps (B),then twist the hosesas you pull to avoid damagingthem. the Disconnect hoses.Slide

(}

A 5. Placea jack or other supportunder the tank. s 6 . R e m o v e t h e t r a pb o l t s ,a n d l e t t h e s t r a p( C )h a n g f r e e .

38N.m (3.9 ksf.m,28lbfft)

p i t 7 . R e m o v e h e f u e lt a n k ( D ) .l f i t s t i c k s t o t h eu n d e r c o a t o nt s m o u n t ,c a r e f u l l y r y i t o f f t h e m o u n t 8. Installthe parts in the reverseorder of removal.

11-155

FuelSupply System
FuelGaugeSendingUnit Test
Special Tools Required Fuelsenderwrench 07XAA-001010A NOTE;For the fuel gauge system circuitdiagram,refer to the GaugesCircuitDiagram(see page 22-58||. 1 . C h e c k t h e o . 1 0 f U E T E R . 5 A ) f u s en t h e u n d e r N i {7 dash fuse/relaybox beforetesting. 2. Do the gauge drive circuitcheck(see page 22-56|l. ' lf the fuel gauge needlesweepsfrom minimuni to maximum positionand then returnsto the m i n i m u mp o s i t i o nt.h e g a u g ei s O K .G o t o s t e p3 . . lf the fuel gauge needle does not sweep from m i n i m u mt o m a x i m u mp o s i t i o n o s i t i o n n d p a then returnto the minimum position,replacethe gauge assemblyand retest. 3 . T u r nt h e i g n i t i o n w i t c hO F F . s 4. Removethe rear seat cushion{seepage 20-80). 5. Removethe accesspanel (A)from the floor. Turn the ignition switch OFF.Removethe No. 9 BACKUP (7.5A)fusefrom the under-hoodfuse/ relay box for at least 10 seconds, lhen reinstallit. Installa 2 Q resistorbetweenfuel pump 5P connectorlerminals No. 1 and No. 2, then turn the i g n i t i o n w i t c hO N ( l l ) . s FUELPUMP5P CONNECTOR Wiresideof female terminals FUELPUMP5PCONNECTOR 7. Measurevoltage betweenfuel pump 5P connector terminalsNo. 1 and No. 2 with the ignition switch ON (ll).There should be batteryvoltage. . lf the voltage is as specified, to step 8. go . lfthevoltages notasspecified,checkfor: i - a n o p e n i n t h e Y E U B L K r B L Kw i r e . o - p o o r g r o u n d( G 5 5 1 ) .

-ztr

-VVV{YEL/BLK) {Y 2 9 RESISTOR,

(elrt \

=-a
\

//,

\ 4

5 /

Wire side of femaleterminals

6. Disconnect fuel pump 5P connector{B). the

11-156

p 1 0 . C h e c k t h a t t h e o i n t e r o ft h e f u e lg a u g ei n d i c a t e s "F". . lf the pointerdoes not indicate"F", replacethe g au g e . . lf the pointerindicates"F", inspectthe fuel gauge sendingunit. NOTE: The pointerof the fuel gauge returns to the bottom of the gaugedial when the ignition switch is OFF,regardless the fuel level.of 11. Relieve the fuel pressure(seepage 11-144\. 1 2 . R e m o v e h ef u e l f i l lc a p . t fittingsfrom the fuel 13. Disconnect quick-connect the pump. t 1 4 . U s i n gt h e s p e c i atlo o l ,l o o s e n h e f u e lt a n ku n i t locknut(A).

1 5 . M e a s u r e e s i s t a n cb e t w e e n h e N o . 1 a n d N o . 2 r e t 'l12 terminalswith the float at E (EN4PTY), \HALF F U L L )a n d F { F U L L p o s i t i o n s . , ) lf you do not get the following readings,replacethe f u e l g a u g es e n d i n g n i t{ s e ep a g e1 ' 1 - 1 6 3 ) . u F Float Position Resistance 1 1 {0) to 13

'U2
68,5 to 74.5

LOW

114.4 130 to 126.6 to 132

fuse from NOTE:Removethe No. 9 BACKUP (7.5A) fuse/relaybox for at least 10 the under-hood secondsafter completingtroubleshooting, otherwiseit may take up to 20 minutesfor the fuel gaugeto indicatethe correctfuel level.

A 93Nm {9.5ksf.m,69 lbf.ft}

11-157

FuelSupply System
Low FuelIndicatorTest
1 . Do the fuel gauge sendingunit test (seepage 11, rcol. . lf the system is OK, go to step 2. . lf the system has any malfunction,repair it. Turn the ignition switch OFF.Removethe No. 9 BACKUP (10A)fuse from the under-hoodfuse/ relay box for at least30 seconds, then reinstallit. Turn the ignition switch ON (ll)with the float at the E (EMPry) position. . lf the low fuel indicatoris on, go to step 4. . lf the low fuel indicatoris not on, referto the low fuel indicatorCircuitDiagram(seepage 22-58) and checkthe circuit.
4, Turn the ignition switch OFF.Removethe No. 9

BACKUP (10A)fuse from the under-hood fuse/ relay box for at least30 seconds, then reinstallit. Lift the float above the LOW position. . l f t h e l o w f u e l i n d i c a t o r g o e o f f , t h es y s t e mi s O K . s . lf the low fuel indicatoris still on, referto the low fuel indicatorCircuitDiagram{seepage 22-58), and checkthe circuit.

\,

11-158

IntakeAir System
Component Location Index

l .

INTAKE AIR BYPASSCONTROL THERMALVALVE Test,page 1'1-161

AIR CLEANER p, R e p l a c e m e n t a g e11 ' 1 6 2 ELEMENT AIR CLEANER p, R e p l a c e m e n ta g e11 - 1 6 2

THROTTLEBODY Test,page l'l-160 page 11-165 Removal/lnstallation, page Disassembly/Reassembly, 11 166

THROTTLE CABLE page11-163 Adjustment, R e m o v a l / l n s t a l l ap ao n11 - 1 6 4 t i g e,

11-159

IntakeAir System
Throttle BodyTest
NOTE: . Do not adjustthe throttlestop screw. lt is presetat the factory. . l f t h e m a l f u n c t i o nn d i c a t o lra m p ( M l L )h a sb e e n i reportedon, checkfor diagnostictrouble codes ( D L C S()s e ep a g e1 1 3 ) . 1. With the engine off, checkthe throttle cable movement.The cableshould move without binding or sticking. . lf lhe cable moves OK, goto step 2. . lf the cable binds or sticks,checkit and its routing. . l f t h e c a b l ei s f a u l t y ,r e r o u t e t o r r e p l a c et a n d i i a d j u s ti t ( s e ep a g e1 1 - 1 6 3 ) h e ng o t o s t e p2 . t, 2. l\4ove throttle lever by hand to see if the throftle the valve and/or shaft are too looseor too tight. . lf there is excessive play in the throttlevalve shaft,or any binding in the throttlevalve at the fully closedposition,replacethe throttle body. . l f t h e t h r o t t l e v a l v e n d s h a f ta r e O K ,g o t o s t e p 3 . a 3. Connectthe scantoolto the DLC. T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s 5 . Checkthe throttle positionwith the scantool. The readingshould be about 10%when the throttle is fully closedand about 90% when the throttle is fully openeo. . lf the throttle positionis correct,the throttle body is OK. . lf thethrottle positionis notcorrect,replacethe throttle body.

11-160

Test IntakeAir Bypass GontrolThermalValve


Special Tools Required Vacuum Pump/Gauge,0 30 in. Hg A973X-041-XXXXX 1 . S t a n t h e e n g i n e T h e nl e t i t i d l . . NOTE:The enginecoolanttemperaturemust be b e l o w1 4 9 ' F ( 6 5 ' C ) . 2 . R e m o v e h e v a c u u mh o s e( A ) f r o mt h e i n t a k e i r t a duct, and connecta vacuum pump/gaugeto the nose. checkfor these lf the vacuum readingchanges, proorems: . l\4isrouted, leaking,broken,or cloggedintakeair bypasscontrol systemvacuum lines. . A crackedor damagedintakeair bypasscontrol t h e r m a lv a l v e . , 5 . R a i s e n d l o w e rt h e e n g i n es p e e d a n d m a k es u r e a the vacuum gauge readingdoes not changeas the rpm cnanges.

. 3 . R a i s e n d l o w e r t h ee n g i n es p e e d a n d m a k es u r e a c a t h e v a c u u mg a u g er e a d i n g h a n g e s s t h e e n g i n e speeocnanges. lf the vacuum readingdoes not change,checkfor these problems: . M i s r o u t e dl,e a k i n gb r o k e n o r c l o g g e d n t a k e i r i a , , bypasscontrol system vacuum lines. . A crackedor damagedintakeair bypasscontrol t h e r m a lv a l v e . 4 . H o l dt h e e n g i n e t 3 , 0 0 0 p m w i t h n o l o a d( i n a r neutral)until the radiatorfan comes on, then let it i dl e .

11-161

IntakeAir System
Air Cleaner Replacement
1. Removethe nuts (A) and the stud (B).

Air Cleaner Element Replacement


1 . D i s c o n n e c h e P C Vh o s e1 A ) . tt

{0.3kgf m,2lbf.ft)

2. Removethe air cleaner(C). 3 . Installin the reverseorder of removal.

2 . O p e nt h e a i r c l e a n e r o u s i n g o v e r( B ) . h c ( 3 . R e m o v e h e a i r c l e a n e r C )f r o m t h e a i r c l e a n e r t ( housing D). 4 . Installin the reverseorder of removal.

\,

11-162

Throttle CableAdjustment
1 . Checkcablefree play at the throttle linkage.Cable f r e e p fa v ( A )s h o u l db e 1 0 1 2 m m ( 3 / 8 1 / 2i n . ) .

lf the free play is not within spec (10- 12 mm, t t 3 1 8 - 1 1 2 l n . l , l o o s etn e l o c k n u ( B ) , u r n t h e h adjustingnut (C)untilthe free play is as specified, then retightenthe locknut. With the cable properlyadjusted, checkthe throttle valve to be sure it opens fully when you push the pedalto the floor. Also checkthe accelerator throttlevalve to be sure it returnsto the idle positionwheneveryou releasethe accelerator peoar.

11-163

IntakeAir System
Throttle CableRemoval/lnstallation
1. Fully open the throttlevalve,then removethe throttle cable (A)from the throttle link (B). Installin the reverseorder of removal. 5 . After installing, startthe engine.Holdthe engine at 3,000rpm with no load (in neutral)untilthe radiator fan comes on, then let it idle. H o l dt h e c a b l e ,r e m o v i n g l l s l a c k r o m i t . f a 7 . Set the locknuton the cable bracket{A). Turn the adjustingnut (B)so that its free play is 0 mm.
T h e s h o u l db e no crearance.

(P/N08?98-9002)

2 . R e m o v e h e c a b l eh o u s i n g( C ) f r o mt h e c a b l e t
bracket(D).

('1.0 kgf.m, 7.2 tbf.ftl

3 . Removethe throttlecable (A)from the accelerator


p e d a l( B ) .

!
8 . Removethe cablefrom the cable bracket(A).Set
the adjustingnut on the other side of the throttle bracket, then tightenthe locknut{C}. 9 . With the cable properlyadjusted, checkthe throttle valve to be sure it opensfully when you push the pedalto the floor. Also checkthe accelerator throttlevalveto be sure it returnsto the idle positionwheneveryou release the accelerator Deoat.

SILICONE GREASE B (P/N08798-9002)

11-164

Throttle Body Removal/lnstallation


NOTE: ' Do not adjustthe throttle stop screw. . A f t e r r e a s s e m b l y , a d j u s t t h e t h r o t t l e c a b l e { s e e p a g e l l - 1 6 3 ) h e c r u i s e o n t r o l a b l e( s e ep a g e4 - 4 5 ) . a n dt c c . The throttle position(TP)sensoris not removable.

THROTTLE LEVER
Thereshould be noclearance

THROTTLECABLE MANIFOLD ABSOLUTE PRESSURE {MAP}SENSOR 22Nm (2.2 kgt.m, 16 lbf.ft)

EVAPORATIVE EMISSION{EVAPI CANISTERPURGEVALVE

IDLEAIR CONTROL {IACI VALVE

11-165

IntakeAir System
Throttle Body Disassembly/Reassembly
2 N.m {0.2 kgt m, 1 lbf.ft)

V
MAPSENSOR

EMISSION EVAPORATIVE {EVAP) PURGE VALVE CANISTER

L
TPSENSOR THROTTLE BODY

3.5 N.m (0.35kgf m.2.5lbf ft)

11-166

CatalyticConverterSystem
DTCTroubleshooting
DTCP0420: Catalytic SystemEfficiency Below Threshold
NOTE:lf some of the DTCS listedbelow are storedat the same time as DTCP0420, troubleshootthose DTCS first, then recheck DTCP0420. for P 0 1 3 7P 0 1 3 8S e c o n d a r y e a t e d x y g e nS e n s o r , : H O (secondary HO2S)(Sensor2) r P 0 1 4 1S e c o n d a r y O 2 S( S e n s o 2 ) h e a t e r : H 1 . R e s e t h e E C M{ s e ep a g e1 ' l - 4 }t,h e nc o n t i n u e o t step 2 through 5 to resetthe readiness code. 2. Startthe engine.Hold the engineat 3,000rpm with n o l o a d( i n n e u t r a lu n t i l t h er a d i a t o f a n c o m e so n . ) r D r i v ef o r a b o u t l 0 m i n u t e s i t h o u ts t o p p i n gY o u r w . speeocan vary. 4 . With the transmissionin 4th gear,drive at a steady speed between50 62 mph (80-'100 km/h)for 30 seconds. Repeatstep 4 three times. Betweeneach repetition, closethe throttlecompletelyfor 1 2 seconds.lf the engine is stoppedduring this part of the procedure, repeatsteps3, 4 and 5. Checkfor a TemporaryDTCwith the scantool. Does the scan tool indicate Temporaty DTC P0420? YES Checkthe TWC. lf necessary, replacethe TWC.I N O C h e c k o r r e a d i n e s c o d ec o m p l e t i o nl.f t h e f s readiness complete,it was a interminentfailure, is and the system is OK at this time. lf the readiness code is incomplete,repeatsteps2 through 5.1

11-167

PCVSystem
DTCTroubleshooting
Air PCV Leakage DTCP1505:
1 . R e s e t h e E C M( s e ep a g e1 1 - 4 ) . 2. Startthe engine.Hold the engineat 3,000rpm with r ) n o l o a d( i n n e u t r a l u n t i lt h e r a d i a t o f a n c o m e so n 3. Letthe engineidle tor al least40 secondswith the throttlefully closed. with the scantool 4. Checkfor a DTCP1505 ls DTC P1505 indicated? YES-Check these partsfor vacuum leaks l . . . . . PCVvalve PCVhose EVAPcanisterpurge valve Throttlebody Brakeboosterhose

failure,system is OK at this NO - Intermittent time.l

11-168

PCVValve Inspection and Test


1. Checkthe PCVvalve (A),hoses{B),and connections leaksor restrictions. for

PCVValve Replacement
'L Disconnect PCVhose. the Removethe PCVvalve (A).

2 . At idle, make sure there is a clickingsound from the


PCVvalve when the hose betweenthe PCVvalve a n d i n t a k e a n i f o l d s l i g h t l yp i n c h e d A ) w i t hy o u r m i { fingers r pliers. o lf there is no clickingsound,checkthe PCVvalve grommet for cracksor damage.lf the grommet is the OK. reDlace PCVvalve and recheck.

(4.5 kgf.m,33 lbf.ft) l 3 . I n s t a lthe parts in the reverseorder of removal ( with a n e w g a s k e t B ) .

11-169

EVAPSystem
ComponentLocationIndex

EMISSIONIEVAPI EVAPORATIVE CANISTERPURGEVALVE Troubleshooting, 'l1-175, step 3 on page s t e p1 o n p a g e1 1 - 1 8 0

FUELTANK VAPORCONTROLVALVE Test,page 11'187 p, R e p l a c e m e n t a g e1 1 1 8 9 EMISSION{EVAPI EVAPORATIVE CANISTER Troubleshooting, step 28 on page 11'183 page 11-189 Replacement,

SENSOR FUELTANKPRESSURE T r o u b l e s h o o t ip a g e 1 - 1 7 1 ng, 1


EVAPORATIVE EMISSION{EVAP} BYPASSSOLENOIDVALVE Troubleshooting, 1 ' 1 7 6 , '1 s t e p1 2o n p a g e '10 s t e p o n p a g e1 1 1 8 1

EMISSION{EVAP) EVAPORATIVE CANISTER VENT SHUT VALVE Troubleshooting, step 23 on page 1'l 178, s t e p1 go n p a g el 1 - 1 8 2

EVAPOBATIVE EMISSON{EVAP) VALVE TWO WAY 'l1-'186 Test,page

11-170

DTCTroubleshooting
DTCP0451: SensorRange/Performa FTP nce Problem
SpecialTools Required Vacuum Pump/Gauge, 0-30 in. Hg A973X-041-XXXXX 1 . R e m o v e h e f u e lf i l l c a p . t 2. Turn the ignition switch ON (ll) 3. l\4onitor fuel tank pressure(FTP) sensorvoltage with the HondaPGM Tester,or medsurevoltage betweenECMconnectorterminals and E14. E4
ECMCONNECTOR 131P) E

6. Connecta vacuum pump to the open end of the hose.

7 . Turn the ignition switch ON {ll). 8 . l\4onitor FTPsensorvoltagewith the Honds PGM Tester,or measurevoltage betweenECM E a c o n n e c t otre r m i n a l s 4 a n d E 1 4 , n d c a r e f u l l y s q u e e z eh e v a c u u mp u m p a l i t t l e . t ECMCONNECTOR 13lPI E

W i r e i d e ff e m a l t e r m i n a l s s o e

ls there about 2.5V? YES-Go to step 4. NO Replace FTPsensor.I the 4 . Turn the ignitionswitch OFF. Wiresideof lemale terminals the 5 . Disconnect hose betweenthe EVAPtwo way valve and the FTPsensorat the EVAPtwo way valve end.

9 . The voltageshould smoothly drop from about 2.5 V v t o a b o u t1 . 5V . S t o pa p p l y i n g a c u u mw h e n t h e voltagedrops to about 1.5V or damageto the FTP sensormay occur. Does the voltage drop to about 1.5 V and hold? YES Checkfor misrouted,leaking,or brokenFTP v l s e n s o r a c u u ml i n e s . f t h e v a c u u ml i n e sa r e O K , updatethe ECM if it does not havethe latest software.or substitutea known-goodECM,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe originaECM.I l NO Replace FTPsensor.! the

11-171

EVAP System
(cont'd) DTCTroubleshooting
FTP DTCP0452: SensorCircuitLow Voltage
1. Checkthe vacuum lines at the FTPsensorfor breakage, clogging. or misrouting,leakage. Are the vacuumlines OK? 9. Turn the ignition switch ON (ll) YES Go to step 2. NO Repairor replacevacuum lines as necessary. I 2 . R e s e t h e E C M( s e ep a g e1 1 - 4 ) . t 3 . R e m o v e h e f u e l f i l lc a p . 4. Turn the ignition switch ON (ll) 5. Monitor FTPsensorvoltagewith the HondaPGM Tester,or measurevoltage betweenbody ground and ECMconnectorterminal E14. E ECMCONNECTOR 131PI terminals Wiresideof female VCgl {YEL/BLU} 10. Measurevoltage betweenFTPsensor3P connector terminals o.1 andNo.2. N 3P FUEL TANK PRESSURE SENSOR CONNECTOR 6. Turn the ignition switch OFF. 7 . R e i n s t a l l t h f u e lf i l l c a p . e 8. Disconnect FTPsensor3P connector. the

1 2 t 3 t 45
././114
tc

8 9
ls there about 5 V? '1. YES Go to step 1 NO-Repair open in the wire betweenthe FTP a s e n s o r n dt h e E C M{ E 5 ) . 1

61./18 2C 21
271/ 29 31

22123 241 t

26

TP (LTGRN)

Wire side of femaleterminals

ls thete about2.5 V? failure,system is OK at this time. YES- Intermittent or Checkfor poor connections looseterminalsat the FTPsensorand at the ECrM.l NO Go to step 6.

11-172

11. MeasurevoltagebetweenFTPsensor3P connector t e r m i n a l s o .2 a n d N o . 3 . N


FUELTANKPRESSUBE SENSOR CONNECTOR 3P

DTCP0453: Sensor FTP CircuitHighVoltage


1. Checkthe vacuum lines at the FTPsensorfor misrouting,leakage, breakage, clogging. or Are the vacuumlines OK? Y E S - G o t o s t e p2 . N O R e p a i r r r e p l a c e a c u u ml i n e sa s o v necessary.I

FTP(LT GBN)

W i r e s i d eo f f e m a l e t e r m i n a l s

2 . R e s e t h e E C M{ s e ep a g e1 1 ' 4 ) . 3. Removethe fuel fill cap.

ls there about 5 V? YES- Replace FTPsensor. the t N O - G o t o s t e p1 2 . 4 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s 5. lvlonitorFTPsensorvoltagewith the Honda PGM Tester,or measurevoltage betweenbody ground a n d E C Mc o n n e c t otre r m i n a lE ' 1 4 . ECMCONNECTOR 131PI E

' t 2 .Turn

the ignitionswitch OFF.

1 3 .Disconnect ECMconnectorE (31P), 1 4 .Checkfor continuitybetweenFTPsensor3P


connectorterminal No. 3 and body ground.
FTPSENSOR CONNECTOB 3P

1 1 2 1 34 5 6 7 I 9 5 6 / t18 2C 21 24 2il./ 29 30 31
TP {LTGRN}

Wire side of femaleterminals


FTP (LT GRNI

Is there about 2.5 V? YES Intermittent failure,system is OK at this time. Checkfor poor connections looseterminalsat or t h e F T Ps e n s o r n d a t t h e E C M . I a NO Go to step 6.

W i r es i d eo f f e m a l e l e r m i n a t s

ls there continuity? YES Repairshort in the wire betweenthe FTP s e n s o r n dt h e E C I \ { E 1 4 ) . I a 4 NO-Update the ECM if it does not have the latest software,or substitutea known-goodECM,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodEClvl, replacethe originaECM.I l

{cont'd)

11-173

EVAPSystem
(cont'dl DTCTroubleshooting
6. Turn the ignitionswitch OFF. 7 . R e i n s t a l h e f u e lf i l l c a p . l 8. Disconnect FTPsensor3P connector. the 9 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s '10. l\4easure voltage betweenFTPsensor3P connector N terminals o.1 andNo.2.
FTPSENSOR3P CONNECTOR FTPILT GRN}

11, Measurevoltage betweenFTPsensor3P connector t e r m i n a l N o . 2 a n dN o . 3 . s


FTPSENSOR3P CONNECTOR

(YEL/BLU) VCC3

terminals Wiresideof female ls there about 5 V? YES Replace FTPsensor.l the NO Go to step 12.

Wire side of femaleterminals

l\4easure voltage betweenECMconnector t e r m i n a l s 4 a n d E1 4 , E ECMCONNECTOR (31P) E

ls there about 5 V? Y E S G o t o s t e p1 1 . NO-Repair open in the wire betweenthe FTP sensorand the ECM (E4). !

W i r es i d e f f e m a l t e r m i n a l s o e

ls there about 5 V? YES Repairopen in the wire betweenthe FTP s e n s o r n d t h e E C M( E 1 4 ) . I a NO Updatethe ECM if it does not have the latest then software,or substitutea known-goodECN4. lf recheck(seepage 11-6). the symptom/indication goes away with a known-goodECM,replacethe originaECM.I l

11-174

DTCPl456:EVAP ControlSystemLeakage (Fuel TankSvstem)


The fuel system is designedto allow specified maximum vacuum and pressureconditions.Do not deviatefrom the vacuum and pressure tests as indicatedin these procedures. pressure/ Excessive vacuum would damagethe EVAPcomponentsor cause eventualfuel tank failure. Special Tools Required Vacuum Pump/Gauge, 0-30 in. Hg A973X-041-XXXXX This is a two-trip code. Oncecleared,it cannot be reproducedin one trip. Also, cenain specificdriving and ambientconditionsmust occur beforethe ECMwill completethe systemchecks.Additionaltest drives may still not meet the specificconditionsneededto reproduce the code.

EVAP Canister Purge Valve Test 3. Disconnect vacuum hose from the EVAP the canisterpurge valve (A),and connecta vacuum oumo to the hose.

A973X-041-XXXXX T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s

procedures Follow thesetroubleshooting carefullyto ensurethe integrityof the system and to confirm the causeof the problemor code. NOTE:Freshfuel has a highervolatilitythat creates greaterpressure/vacuum. optimum condltlonfor The testing is fresh fuel, and must be lessthan a full tank. lf possible, assistin leakdetection, to add 1 gallon of fresh fuel to the tank (as long as it will not fill the tank). just beforestartingthese procedures. Fuel Fill Cap Check 1. Checkthe fuel fill cap (the cap must say "lf not tightened3 clickscheckengine light may come o n ") . ls the proper luel till cap installed and properly tightened? YES Go to step 2. NO- Replace tightenthe cap.I or 2. Checkthe fuel fill cap seal. ls the tuel fill cap seal missing or damaged? Y E S - R e p l a c eh e f u e lf i l l c a p . I t N O T h e f u e l f i l lc a p i s O K .G o t o s t e p3 .

5 . Apply vacuum to the hose. Does the valve hold vacuum? YES-The EVAPcanisterpurge valve is OK. Go to s t e p1 1 . NO-Go to step 6. Turn the ignition switch OFF. 7 . Disconnect EVAPcanisterpurge valve 2P the connecror.

{cont'd)

11-175

EVAPSystem
(cont'd) DTCTroubleshooting
purge EVAP canister for between 8. Check continuity No. valve2Pconnenctor terminal 2 andbody grou no.
EVAP CANISTERPURGE VALVE 2P CONNECTOR

EVAP Bypass Solenoid Valve Test 11, Disconnect both vacuum hosesfrom the EVAPtwo way valve (A),and connecta vacuum pump to the canisterport on the EVAPtwo way valve.

A973X-041-XXXXX
Wire side of femaleterminals

F-

ls therecontinuity? YES Goto step9. purge valve.l canister NO Replace EVAP the B ECM connector (24P). 9 . Disconnect purge EVAP canister for between 1 0 . Check continuity terminal 2 andbodyground. No. valve2Pconnector
PURGE EVAPCANISTER VALVE2PCONNECTOR Turn the EVAPbypasssolenoidvalve on with the Honda PGM Tester,or connectECMconnecter terminal E20to body ground with a jumper wire. E ECMCONNECTOR 131P)

1 2 3 4 5 6 1 7 l1 8 9 4 5 6 / 118 2C21 2 2 t 2 ? 24 z7l./29


2WBS (BLU/RED} JUMPER WIRE

1 2
'.\'
PCS {YEL/BLU)

Wiresideof female terminals

1 3 .Turn the ignitionswitch ON (ll).


Wire side of femaleterminals

1 4 .Apply vacuum to the hose.


Does the valve hold vacuum?

ls there continuity? Y E S - G o t o s t e p1 5 , YES Repairshort in the wire betweenthe EVAP 4 c a n i s t e p u r g ev a l v ea n dt h e E C I \ { 8 2 1 ) . 1 r NO Updatethe ECM if it does not have the latest software,or substitutea known-goodECM,then lf recheck(seepage 11-6). the symptom/indication goes away with a known-goodECM,replacethe originaECM.I l NO Go to step 20.

11-176

1 5 . Turn the ignition switch OFF.


to.

'19.

Measurevoltage betweenEVAPbypasssolenoid valve 2P connectorterminal No. 1 and body ground. EVAPBYPASS SOLENOID VALVE CONNECTOR 2P

Disconnect EVAPbypasssolenoidvalve 2P the connecror.

1 7 . Checkfor continuitybetweenEVAPbypass solenoidvalve 2P connectorterminal No. 2 and body ground.


EVAP BYPASSSOLENOID VALVE 2P CONNECTOR tG'l

2
{BLK/ORN)

Wire side ol lemale terminals

Wire side oI Iemaleterminals

ls there continuity? YES Go to step 18. NO-Repair open in the wire bet\iveen EVAP the bypasssolenoidvalve and the ECM (E20).1

'18. u r nt h e i g n i t i o n w i t c hO N ( l l ) . T s
ls there battery voltage? YES Replace EVAPtwo way/bypasssolenoid the v a l v e( A ) . 1 NO-Repair open in the wire betweenthe EVAP bypasssolenoidvalve and the No. 4 ACG (10A) fuse.l

{cont'd)

11-177

EVAPSystem
(cont'dl DTCTroubleshooting
2 0 . P l u gt h e f u e l t a n kp o r t ( A )o f t h e E V A P t w o w a y valve, EVAP Canister Vent Shut Valve Test 22. Disconnect vacuum hosefrom the EVAP the canistervent filter (A),and connecta vacuum pump to the hose.

While monitoring FTPsensorvoltagewith the HondaPGM Tester,or measuringthe voltage E E b e t w e e n C Mc o n n e c t otre r m i n a l s 4a n d E1 4 , slowly pump the vacuum pump until the voitage droDS about 1.5volts. to ECMCONNECTOR {31PI E

T u r nt h e i g n i t l o n w i t c hO N ( l l ) . s Apply vacuum to the hosewith five strokesof the pump. Does the valve hold vacuum? YES Go to step 25. NO The EVAPcanistervent shut valve is OK. Go to step 30.

25. T u r nt h e i g n i t i o n w i t c hO F F . s 26. Disconnect EVAPcanistervent shut valve 2P the


Wiresideof female terminals conneclor. 2 1 . Checkfor continuitybetweenEVAPcanistervent s h u tv a l v e2 Pc o n n e c t otre r m i n a lN o . 2 a n d b o d y ground. EVAPCANISTEB VENTSHUT VALVE CONNECTOR 2P

Does the voltagedtop to 1.5 V and hold fot at Ieast 20 seconds? YES-The EVAPbypasssolenoidvalve/EVAP two way valve is OK. Go to step 22. N O R e p a i r h e l e a kf r o m t h e E V A Pb y p a s s t solenoidvalve, EVAPtwo way valve.or F T Ps e n s o r . l

{LTGRN/REOI

W i r es i d eo f f e m a l e e r m i n a l s t

11-178

VacuumHoses and Connections Test 3 0 . Do the fuel tank vapor control valve test (seepage
11 - 1 8 7 ) . ls the fuel tank vapot control valve OK? Y E S - G o t o s t e p3 1 . v N O R e p l a c eh e f u e l t a n kv a p o rc o n t r o l a l v e . l t
5 t .

Tightenthe fuel cap 3 "clicks", then monitorthe FTPsensor readingswith the Honda PGM Tester. Startthe engine.and let it idle for 5 minutes.

ls thete continuity? Checkthe FTPsensor readings. YES-Go to step 28. NO-Replace the EVAPcanistervent shut valve (A) a n d o - r i n g( B ) . 1

28. Disconnect ECMconnectorE (31P). 29. Checkfor continuitybetweenEVAPcanistervent


s o l e n o i d a l v e2 P c o n n e c t otre r m i n a lN o . 2 a n d v body ground. VENTSHUT EVAPCANISTER VALVE CONNECTOR 2P

ls the reading above 0.5 kpa (4 mm Hg, 0.16 in. Hg) pressure, or about 3 V? YES Updatethe ECM if it does not have the latest software,or substitutea known-goodECM,then recheck{seepage 11-6).lf the symptom/indication goes away with a known-goodECfvl, replacethe originaECM.t l NO Checkthe following partsfor leaks:l ls there continuity? YES-Repair short in the wire betweenthe EVAP c a n i s t e v e n ts h u tv a l v ea n dt h e E C M( E 2 1 ) . 1 r NO Updatethe ECM if it does not have the latest soflware,or substitutea known-goodECM,then lf recheck(seepage 11-6). the symptom/indication goes away with a known-goodECM,replacethe o r i g i n aE C M . I l . . . . . . . . . ( Fueltank A) F u e lf i l l c a p ( B ) F u e lf i l l p i p e ( C ) v F u e l t a n k a p o rc o n t r o l a l v e ( D ) v n F u e l t a n k a p o rr e c i r c u l a t i ov a l v e( E ) v u F u e l t a n k a p o rr e c i r c u l a t i otn b e ( F ) v ( v F u e l t a n k a p o rs i g n a l t u b e G ) v v F u e l t a n k a p o rc o n t r o l e n t t u b e ( H ) FTPsensor(J) - Repair r replace nyleaking arts. p a o

Wire side o{ femaleterminals

11-179

EVAPSystem
(cont'd) DTCTroubleshooting
DTCPl457:EVAP ControlSystemLeakage (EVAP Canister System)
The fuel system is designedto allow specified maximum vacuum and pressureconditions.Do not deviatefrom the vacuum and pressure tests as pressure/ indicatedin these procedures. Excessive vacuum would damagethe EVAPcomponentsor causeeventualfuel tank systemfailure. SpecialToolsRequired Vacuum pump/gauge, 0-30 in.HgA973X-041-XXXXX
W i r e s i d eo f l e m a l et e r m i n a l s

2. Turn the EVAPcanisterpurge valve on with the HondaPGM Tester,or connectECMconnector terminal 821 to body ground with a jumper wire.
ECMCONNECTOR I24P' A

This is a two-trip code.Once cleared,it cannot be reproducedin one trip. Also, certainspecificdriving and ambientconditionsmust occur beforethe ECfM will completethe system checks, Additionaltest drives may still not meet the specificconditionsneededto
16^r^.1' '^6 rh6 ^^.16

Turn the ignition switch ON (ll).


4 . Apply vacuum to the hose.

Does the valve hold vacuum? procedures Followthesetroubleshooting carefullyto ensurethe integrityof the system and to confirm the causeof the problem or code. NOTE:Freshfuel has a highervolatilitylhat creates greaterpressure/vacuum. optimum conditionfor The testing is fresh fuel, and there must be lessthan a full tank. lf possible, assistin leakdetection, to add I gallon of fresh fuel to the tank (as long as it will not fill the tank),just beforestartingthese procedures. EVAPCanister Purge Valve Test 1. Disconnect vacuum hose from the EVAP the canisterpurge valve (A),and connecta vacuum pump to the hose. YES-Go to step 5. NO-The EVAPcanisterpurge valve is OK. Go to step 10. Turn the ignition switch OFF.
b.

Disconnect EVAPcanisterpurge valve 2P the conneclor,

7 . Checkfor continuitybetweenEVAPcanisterpurge valve 2P connectorterminal No. 2 and body ground.


EVAPCANISTEN PURG VALVE CONNECTOR 2P

-4lll2l -fircs
(f])
IYEL/8Lu)

I
W i r e s i d eo f f e m a l e l e r m i n a l s

ls therecontinuity? YES-Goto step8.


4973X-041-XXXXX

NO Repair openin thewire between EVAP the p c a n i s t e ru r g e a l v e n dt h eE C M / P C( 8 2 1 ) . I v a M 8 . T u r nt h ei g n i t i o n w i t c h N( l l ) . s O

11-180

purge voltage between EVAP canister 9. Measure terminal 1 andbodyground. No. valve2Pconnector
PURGE EVAPCANISTER VALVE2PCONNECTOR

EVAP Bypass Solenoid Valve Test both vacuum hosesfrom the EVAPtwo 10. Disconnect way valve {A),and connecta vacuum pump to the canisterport on the two way valve.

Wire side oI lemaleterminals

ls thetebatteryvoltage? purgevalve.l canister the YES- Replace EVAP the NO Repair openin thewire between EVAP purge valveandthe No.4 ACG(10A) canister fuse.I
s 1 1 .T u r nt h e i g n i t i o n w i t c hO N ( l l ) .
'It

Apply vacuum to the hose. Does the valve hold vacuum? YES The EVAPtwo way/bypasssolenoid valveis O K . G o t o s t e p1 8 . N O - G o t o s t e p1 3 . Turn the ignition switch OFF.

the 1 4 . Disconnect EVAPbypasssolenoidvalve 2P connector. Checkfor continuitybetweenEVAPbypass v s o l e n o i d a l v e2 P c o n n e c t otre r m i n a lN o . 2 a n d b o d yg r o u n d .


SOLENOID EVAPBYPASS VALVE2P CONNECTOR

Wire sideof female terminals

(cont'd)

11-181

EVAPSystem
(cont'd) DTCTroubleshooting
EVAP Canisler Vent Shut Valve Test 18. Disconnect vacuum hosefrom the EVAP the canistervent filter (A),and connecta vacuum pump to the hose.

ls there continuity? YES Go to step 16. NO- Replace EVAPtwo waylbypasssolenoid the valve (A).1
to.

Disconnect ECMconnectorE {31P). Checkfor continuitybetweenEVAPbypass solenoidvalve 2P connectorterminal No. 2 and body ground.
EVAPBYPASS SOLENOID VALVE2P CONNECTOR

't7.

19. Turn the EVAPcanistervent shut valve on with the HondaPGM Tester,or connectECMconnector terminal E21to body ground with a jumper wire. ECMCONNECTOR (3TP) E

11213 5 4
1/

l l tl - 2 l I l
2WBS -[BLU/REo) ())

\ ,

1 5tal/la

z3lz4

zil./

8 9 vsv GBN/RED) {LT( 2A21 m 31


JUMPER WIRE

I
Wire side of femaleterminals

Wiresideol lemale terminals

20. Turn the ignitionswitch ON (ll)


ls there continuity?

2 1 .Apply vacuum to the hose.


YES Repairthe short in the wire betweenthe EVAPbypasssolenoidvalve and the ECM{E20). f NO Updatethe ECI\4 it does not havethe latest if software.or substitutea known-goodEClvl, then recheck(seepage 11-6). the symptom/indlcation lf goes away with a known-goodECM,replacethe o r i g i n aE C M . I l Does the valve hold vacuum? YES-The EVAPcanistervent shut valve is OK. Go to step 27. NO Go to step 22.

2 2 . Turn the ignitionswitch OFF. 2 3 . Disconnect EVAPcanistervent shut valve 2P the


connector.

11-182

24. Checkfor continuitybetweenEVAPcanistervent N s h u t v a l v e2 P c o n n e c t o r t e r m i n a lo . 2 a n d b o d y ground.


2P VATVE CONNECTOR

Canister System Leak Test 27. Turn the ignition switch oFF. ( T 2 8 , C o n n e c t t w ot,h r e e - w a y - f i t t i n g sA )i n t o t h e h o s e from the EVAPcanisterto the EVAPtwo way valve. the FTPsensorto one of the T-fittingsand Connect t h e v a c u u mp u m p t o t h e o t h e l

-4l-T_*u l r 2
ILTGFN/REDI

@
wn s de ol lma1e terminals

ls therc continuity? YES Go to step 25. NO Repairopen in the wire betweenthe EVAP ( c a n i s t e v e n ts h u tv a l v ea n dt h e E C I V IE 2 1 ) . 1 r s 25. T u r nt h e i g n i t i o n w i t c ho N ( l l ) .

26. Measurevoltage betweenEVAPcanistervent shut


v a l v e2 P c o n n e c t otre r m i n a lN o . 1 a n d b o d yg r o u n d .
VENTSHUT EVAPCANISTER VALVE 2PCONNECTOR

29. Removethe vent hosefrom the EVAPcanistervent shut valve (A),and cap the port (B)to sealthe fresh air vent of the EVAPcanister.

Wlreside oflem. rerm na s

s 3 0 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) .

ls there battery voltage? the YES Replace EVAPcanistervent shut valve ( A )a n d t h e o - r i n g( B ) . I NO Repairopen in the wire betweenthe EVAP c a n i s t e v e n ts h u tv a l v ea n dt h e N o . 4 A C G ( 1 0 A ) r fuse.I

(cont'd)

11-183

EVAPSystem
(cont'dl DTCTroubleshooting
31. While monitoring FTPsensorvoltagewith the Honda PGM Tester,or measuringvoltage between ECMconnectorterminalsE4 and E14,slowly pump the vacuum oumD. ECMCONNECTOR 13lPI E 37. While monitoringFTPsensorvoltagewith the Honda PGM Tester,or measuringvoltage between E C Mc o n n e c t otre r m i n a l s 4a n d E1 4 ,s l o w l yp u m p E t h e v a c u u mp u m p . ECMCONNECTOR {31PI E

Wire side ot femaleterminals

Wiresideof lemale terminals

32. Continueto pump vacuum until the voltagedrops to about 1.5V. Make sure the enginecoolant temperatureis still above 95'F 135.C) and your v a c u u mp u m p h a s n o l e a k . 33. Monitor the voltagefor 20 seconds. Does the voltage drop 1.5V and hold for at least 20 seconds? YES Inspectthe EVAPcanistervent shut valve l i n ea n d c o n n e c t i o n s . l NO-Go to step 34.

38. Continueto pump vacuum until the voltagedrops


to about 1.5V.Make sure the enginecoolant temperatureis still above95"F (35"C) and your vacuum pump has no leak.

39. Monitor the voltagefor 20 seconds


Does the voltage hold for at least 20 seconds? YES Inspeclthe fuel tank vapor control lineand connections.I NO Go to step 40.

40. T u r nt h e i g n i t i o n w i t c hO F F . s
34. Turn the ignition switch OFF. 35. Discon nectthe quick-con nectfitting (A) fromthe EVAPcanister, and plug the canisterport {B).

4 1 .Disconnect purge line hose {A) from the the


c a n i s t e a t t h e m e t a ll i n e a n d p l u gt h e h o s e( B ) . r

3 6 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s

4 2 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s

11-184

43. While monitoringFTPsensorvoltagewith the Honda PGM Tester,or measuringvoltage between ECMconnectorterminalsE4 and E14,slowly pump t h e v a c u u mp u m p . E ECMCONNECTOR {31P)

terminals Wiresideof female

4 4 . Continueto pump vacuum until the voltagedrops to about 1.5V.Make sure the enginecoolant temperatureis still above 95'F (35'C)and your v a c u u mp u m p h a sn o l e a k .

45. Monitor the voltagecontinuouslyfor 20 seconds.


Does the voltage drop to 1.5 V and hold f or at least 20 seconds? YES Inspectthe EVAPcanisterpurge valve line lf and connections. they are OK, perform the EVAP and the fuel two way valvetest (seepage 11-186) tank vapor controlvalve test (seepage 1'l-187)l NO-Replace the EVAP canister ( s e ep a g e1 1 - 1 8 9 ) . 1

11-185

EVAPSystem
EVAPTwo Way ValveTest
Special Tools Required . V a c u u mp u m p / G a u g e , 0 - 3 0i n . H g A973X-041-XXXXX . Vacuum/Pressure cauge.0-4 in. Hg 07JAZ-0010008 1 . R e m o v e h e f u e l f i l lc a p . t 2. Disconnect vapor line from the EVAPtwo way the valve (A).Connectit to a T-fitting(B)from the v a c u u mg a u g ea n d t h e v a c u u mp u m p a s s h o w n , 4. Move the vacuum pump hosefrom the vacuum fitting to the pressure fitting,and move the vacuum gauge hosefrom the vacuum side to the pressure side (A) as shown.

07JAZ-0010008

Slowly pressurize vapor line while watchingthe the gauge.The pressureshould stabilize momentarilV a b o v e1 . 0k P a( 8 m m H g ,0 . 3i n . H g ) . . lfthe pressuremomentarilystabilizes (valve o p e n s ) b o v e1 . 0k P a( 8 m m H g , 0 . 3i n . H g )t,h e a v a l v ei s O K . . lf the pressurestabilizes below 1.0 kPa(8 mmHg, 0.3 in.Hg),installa new valve and retest.

Apply vacuum slowly and continuouslywhile watchingthe gauge.The vacuum should stabilize m o m e n t a r i l y t 0 . 8 2 . 1 k P a( 6 1 6 m m H g , a 0 , 2 0 . 6i n . H g ) . lf the vacuum stabilizes {valveopens)below 0.8 kpa ( 6 m m H g , 0 . 2i n . H g ) r a b o v e2 . 1k P a( 1 6m m H g , o 0.6 in.Hg),installa new valve and retest.

11-186

VaporControlValveTest FuelTank
ToolsRequired Special 0-30 in. HgA973X-041-XXXXX Pump/Gauge, Vacuum

ValveTest
1 . N 4 a ks u r et h e f u e lt a n ki s l e s st h a n h a l ff u l l e t 2 . R e m o v eh e f u e lf i l l c a p . the 3. Disconnect fuel tank vapor signaltube (A).

FloatTest
1 . M a k es u r et h e f u e lt a n ki s l e s st h a n h a l ff u l l . 2. Removethe fuel fill cap to relievefuel tank pressure, then reinstallthe cap. tube the 3. Disconnect fuel tank vapor recirculation t t { A ) ,a n d c o n n e c a v a c u u mP u m P o i t .

the vacuum hoses(A)from the EVAP 4 . Disconnect canister(B),then plug the ports with plugs (C)

A973X-041-XXXXX P l u gt h e l i n e( B ) . 5 . Apply vacuum to the fuel tank vapor recirculation tuDe. lf the vacuum holds, replacethe fuel tank vapor c o n t r o l a l v e( s e ep a g e1 1 - 1 8 9 ) . v lf the vacuum does not hold, the float is OK. Do the valve test.

A973X-O41-XXXXX the 5. Disconnect vacuum hose (D)from the EVAP canistervent shut valve (E),and connecta vacuum pump to the vacuum hose. 6 . P u m pt h e v a c u u mp u m p 8 0 t i m e s . . l f t h e v a c u u mh o l d s , o t o s t e P . g 7 . l f t h e v a c u u md o e sn o 1h o l d ,g o t o s t e p 1 0 .

(cont'd)

11-187

EVAPSystem
FuelTank VaporControlValve Test (cont'd)
7. Connecta secondvacuum pump to the fuel tank ( v a p o rs i g n a l t u b e A ) . Fill the fuel tank with fuel, then checkfor fuel in the EVAPtwo way valve (A),and fuel tank vapor recirculation hose (B). NOTE: either location, At tiny dropletsof fuel are normal. . lf fuel runs out of th e hosesat either location, replacethe fuel tank vapor control valve. . l f t h e f u e l d o e sn o t r u n o u t o f t h e h o s e s t h e f u e l , tank vapor systemfunction is normal.

8. Apply vacuum (1 pump) to the fuel tank vapor signaltube (A).then checkthe vacuum on the pump in step 6. . lf the vacuum holds,replacethe fueltank vapor c o n t r o l a l v e{ s e ep a g e1 1 - 1 8 9 ) . v . If the vacuum is released, goto step 9.

Checkfor fuel rirnningout.

Checkfor fuel runningout.

1 0 .Disconnect fuel tank vapor quickdisconnect the


from the EVAPcanister, then plug lhe port on the canister.Reapplyvacuum (80 pumps). . lf the vacuum holds,replacethe fuel tank control v a l v e( s e ep a g e11 - 1 8 9 ) . . lf the vacuum does not hold, insDect EVAP the canistervent shut valve o-ring.lf the o-ring is OK, replacethe EVAPcanister, and repeatstep 4.

11-188

EVAPCanisterReplacement
l. Removethe vacuum hoses(A).

FuelTankVapor ControlValve Replacement


t 1 . R e m o v e h e f u e lt a n k ( s e e p a g e l l - 1 5 5 ) . v t 2 . R e m o v e h e f u e l t a n kv a p o rc o n t r o l a l v e ( A )f r o m t h e f u e lt a n k( B ) .

2. Removethe boit (B). 3. Removethe EVAPcanister(C). 4. Installin the reverseorder of removal.

3 . Installthe fuel tank vapor control valve.


'l 4 , Installthe fuel tank (seepage 1 -155).

11-189

Clutch
......... 12-2 Tools Special n .2 .. Lto c a t i oIn d e x . . . . . . . . . . . . . . . . . . . . . . . , .1 . .- 3. . . . . . . Comoonen and Position Switch, Pedal Pedal, Clutch Clutch 12-4 .................... Adiustment Interlock Switch Clutch 12-5 ..................... Rep|acement Cylinder CfutchMaster 12-7 .'........ Replacement Cylinder Slave .....12-9 ................... Replacement Clutch

Clutch
SpecialTools
Ref. No.

a
Description
Clutch lignment isc A D R i n gG e a rH o l d e r Clutch lignment haft A S Remover andle H

(1, @

Tool Number OTJAF-PM7O11A 07LAB-PV001or 07924-PD20003 00 07zAF-PR8A100 07936-3710100

Oty
,l 1 1 1

l _ l

l .

'l-r
o
.{\

'\-'/

.tt./

12-2

ComponentLocationIndex

""*--/ \,L_.Ei

INTERLOCK SWITCH CLUTCH page12-4 Adjustment,

/i (,'.'
RETAININGCLIP Replace.

_,___-,-s\
O-RING Replace. CYLINDER CLUTCH MASTER page Replacement, l2-5
CLUTCHDISC Bemoval,page 12-9 I n s t a l l a t i op a g e ' 1 2 - 1 2 n,

PEDAL CLUTCH POSTTTON SWITCH p, A d j u s t m e n ta g e ' 1 2 - 4

UTCHPEDAL A d j u s t m e n tP a g e1 2 4 ,

PRESSURE PLATE page'12-9 Removal, pa 1 l n s t a l l a t i o n ,g e 2 - 1 2 RELEASE BEARING B e p l a c e m ep a , e 2 - 1 3 nt g 1

FLYWHEEL page'12-1 1 Inspection, page 1 Replacement, 12-1


CLUTCHHOSE CLIP

SLAVECYLINDER page 12-7 Replacement,

\".rr"*"o*

12-3

Clutch
ClutchPedal,ClutchPedalPositionSwitch, and ClutchInterlockSwitch Adjustment
NOTE: . To checkthe clutch pedal positionswitch (seepage 4-45). . To checkthe clutch interlockswitch (seepage 4-6). . Removethe driver's side floor mat beforeadjusting the clutch pedal. . The clutch is self-adjusting compensate wear. to for . lf there is no clearance betweenthe mastercylinder pistonand push rod, the releasebearingwill be held againstthe diaphragmspring.which can resultin clutchslippageor other clutch problems. 1. Loosenthe clutch pedal positionswitch locknut(A), and backoff the clutch pedal positionswitch (B) until it no longertouchesthe clutch pedal (C).
J 9.8 N.m (1.0kgf.m,7.2lbf.ft)

3. Tightenthe clutch push-rodlocknut(D). 4. With the clutch pedal released. turn the clutch pedal positionswitch (B) in until it contactsthe clutch pedal (C). 5. Turn the clutch pedal positionswitch {B) in an additional3/4 to 1 turn. 6. Tightenthe clutch pedal positionswitch locknut(A). 7. Loosenlocknut(J)and the clutch interlockswitch (K). 8. Pressthe clutch pedalto the floor. 9 . R e l e a s t h e c l u t c hp e d a l1 0 ' l 6 m m ( 0 , 3 9 0 . 6 3 i n . ) e from the fully pressedposition,and hold it there. Adjust the positionof the clutchinterlockswitch (K) so that the enginewill startwith the clutch pedal in thls position. 10. Tightenthe clutch interlockswitch locknut(J).

A 9.8 N.m kgf.m,7.2 lbf.ft) 11.0

18 N.m {1.8kgf.m, 13 tbf.ftl

Loosenthe clutch push-rodlocknut(D).and turn the push rod (E)in or out to get the specifiedheight (F),stroke(G).free play (H)and disengagement h e i g h t( l ) a t t h e c l u t c hp e d a l . 130 140 mm ( 5 . 1 2 5 . 5 1i n . l Clutch PedalFreePlay: l0 16 mm (0.39-0.63 in.) Clutch PedalHeight: 193 mm (7.60in.) Disengagement Height: 115 mm (4.53in.) Between Floor And Carpet Height (ApproximateValuel: 38 mm {1.50in.l Clutch PedalStroke:

12-4

ClutchMasterCylinderReplacement
NOTE:Do not spill brakefluid on the vehicle;it may damagethe paint; if brakefluid does contactthe paint, wash it off immediatelV with water. 1 . P r yo u t t h e l o c kp i n ( A ) ,a n d p u l l t h e p e d a lp i n ( B ) out of the yoke. Removethe mastercylinder mounting nuts (C). 6. Disconnect reservoirhose (D)fromtheclutch the mastercylinder reservoir.Plugthe end of the reservoirhose with a shop towel to preventbrake fluid from coming out. 7. Removethe O-ring(E)and the clutch master cylinderseal (F)from the mastercylinder. 8. Installtheclutch mastercylinder in the reverse order of removal.Installa new O-ring. 9. Make sure the hose clamps (A) are positionedon the mastercylinder (B)and reservoir(C)as shown.

UP

R e m o v e h e a i r c l e a n e r o u s i n g o v e ra n dt h e a i r h t c cleanerhousing (seestep 6 on page 5-2).

3 . Removethe brakefluid from the clutch master


cylinder reservoirwith a syringe. Removethe clutchline bracketfrom the frame rail, and removethe clutch line clip. Removethe clutch mastercylinder(A),and pull it toward the middle of the enginecompartment. Removethe retainingclip (B).Disconnect clutch the line (C).Plugthe end of the clutch line with a shop towelto preventbrakefluid from coming out.

g-E

(cont'd)

12-5

Clutch
(cont'd) ClutchMasterCylinderReplacement
10. To preventthe retainingclip (A)from coming off, pry open the tip of the retainingclip (B)with a screwdriver,

1 1 .Tightenthe mastercylindermounting nuts to 13 N m ( 1 . 3k g f m , 9 . 4 l b f . f t ) . Bleedthe clutch masterhydraulicsystem (seestep 11 o n p a g e 1 2 - 8 ) . i N O T ET h e r e s e r v o ifri l l i n gi s c o v e r e d n t h e : bleedingprocedure. h l n s t a l l t h e i r c l e a n e r o u s i n g( s e es t e p3 7 o n p a g e a 5-15).

12-6

SlaveCylinder Replacement
NOTE: . U s ef e n d e rc o v e r s o a v o i dd a m a g i n g a i n t e d p t surfaces. . D o n o t s p i l lb r a k e l u i d o n t h e v e h i c l e i; t m a y d a m a g e f the paint; if brakefluid does contactthe paint,wash it off immediatelywith water. 1. Write down the frequencies the radio's preset for buttons.Disconnect negative( ) cablefirst, the then the positive(+)cable from the battery. Removethe battery. 2. Removethe batterytray. 6. Removethe mounting bolts (A) andtheslave ( cylinder B).

7 . Removethe roll pins (C).Disconnect clutch line the ( D ) ,a n d r e m o v et h e O - r i n g( E ) .P l u gt h e e n d o f t h e clutch line with a shop towel to preventbrakefluid f rom coming out. Installtheslavecylinder in the reverseorder of removal.Installa new O-ring (A).

R e m o v e h e a i r c l e a n e r o u s i n g o v e ra n dt h e a i r t h c ( c l e a n e r o u s i n g s e es t e p6 o n p a g e5 - 2 ) . h
4 . Removethe intakeair duct (seestep 8 on page 5-3).

,,6NJ'
=-#.q!4sEn (P/N 08798-90021

5 . Removethe clutch line bracket(A).

(Brak6 Assembly Lube) a 9 . P u l l t h eb o o t ( B )b a c k , n d a p p l yb r a k ea s s e m b l y l u b et o t h e b o o ta n d s l a v ec y l i n d e r o d ( C ) .R e i n s t a l l the boot.

1 0 .Apply super high temp urea grease(P/N087989 0 0 2 ) o t h e p u s h r o d o f t h e s l a v ec y l i n d e rT i g h t e n t . t h e s l a v ec y l i n d e r o u n t i n gb o l t st o 2 2 N m ( 2 . 2 m kgfm, 16lbf.ft).

(cont'd)

12-7

Clutch
(cont'd) SlaveCylinderReplacement
11. Bleedthe clutch hydraulicsystem. . Aftach a hoseto the bleederscrew (A),and suspendthe hose in a containerof brakefluid. . M a k es u r et h e r ei s a n a d e q u a t e u p p l yo f f l u i d i n s the clutch mastercylinder,then slowly pump the clutch pedal until no more bubblesappearatthe bleederhose. . lt may be necessary llmit the movement of the to releasefork (B)with a blockof wood to remove all the air from the system. . Tightenthe bleedscrewto I N.m (0.8kgf.m,6 lbf ft); do not ovenightenit, . Refillthe clutch mastercylinderwith fluid when done. . Always use only Honda DOT3 brakefluid.

L
12. Installthe intakeair duct (seestep 36 on page 5-14). 1 3 .I n s t a l l t h e i r c l e a n e r o u s i n g( s e es t e p3 7 o n p a g e a h
5-15). 1 4 . Installthe batterytray.
t5.

Installthe battery,connectthe positive(+) cable first, then the negative(- ) cable.

1 6 . Resetthe frequencies the radio stationpreset for buttons,

12-8

ClutchReplacement
Spscial Tools Required . Clutchalignmentdisc 07JAF-PM701 1A . Ringgear holder07LAB-PV00100 or 07924-PD20003 . Clutchalignmentshaft 07ZAF-PR8A100 . Removerhandle07936-3710100 2 . I n s t a l l t h e p e c i atl o o l s . s
A

\-

Pressure Plateand GlutchDiscRemoval


1 . C h e c k h e d i a p h r a g m p r i n gf i n g e r s o r h e i g h t t s f using lhe speciallool and feelergauge.lf the height is more than the servicelimit, replacethe pressure ptate. StandardlNewl: ServiceLimit: 0.6 mm (0.02in.) max. 0.8 mm {0.03in.)

A-.-

\ffim
9fra-I

nl I
tP

|-

07LAB-PV00100 or 07924-PD20003

07zAF-PR8A100 07936-3710100 OTJAF-PM7O11A

plate To prevent warping, unscrew pressure the pattern several mounting bolts(A)in a crisscross in plate(B). steps, then remove pressure the Inspect fingers the diaphragm the of spring(A)for wearat the release bearing contact area.

5. Inspectthe pressureplate 1A)surfaceforwear, cracks.and burning.

(cont'd)

12-9

Clutch
(cont'd) ClutchReplacement
6. Inspeclfor warpage using a straightedge (A) and feeler gauge (B).l\4easure acrossthe pressureplate (C).lf the warpage is more than the servicelimit, replacethe pressureplate. Standard{New): ServiceLimit: 0.03mm (0.001in.) max. 0.15mm (0.006in.) 9. lvleasu th e clutchd isc th ickness. re lfthethickness is lessthan the servicelimit, replacethe clutchdisc. StandardlNew): ServiceLimit: 8.3 8.9 mm (0.33 0.35in.) 6.0 mm {0.24in.)

1 0 .Measurethe rivet depthfrom the clutchdisc lining


7 . R e m o v e h e c l u t c hd i s ca n d s D e c i a l t o o l s . t surface(A) to the rivets(B)on both sides.lf the rivet depth is lessthan the servicelimit, replacethe c l u t c hd i s c . Standard(New): ServiceLimit: 1.65 2.25 mm (0.065 0.089in.) 0.7 mm (0.03in.)

1 d

I n s p e c t t h ei n i n go f t h e c l u t c hd i s cf o r s i g n so f l s l i p p i n g r o i l . l f t h e c l u t c hd i s ci s b u r n e db l a c ko r o oil soaked.reolaceit.

12-10

FlywheelInspection
1. Inspectthe ring gear teeth for wear and damage. 2. Inspectthe clutchdisc mating surfaceon the flywheel for wear, cracks,and burning. 3. Measurethe flywheel (A) runout using a dial indicator(B)through at leasttwo full turns. Push againstthe flywheel eachtime you turn it to take up the crankshaft th rust washerclearance.lf the runout is more than the servicelimit, replacethe flywheel and recheck the runout.Resurfacing the flywheel is not recommended. Standard(New): 0.05mm (0.002in.) max. ServiceLimit: 0.15mm (0.006in.)

FlywheelReplacement
1 . I n s t a l l t h e p e c i atlo o l . s

2 . Removethe flywheel mounting bolts in a crisscross


patternin severalsteps,then removethe tlywheel.

3 . Installtheflywheel on the crankshaft, and install


the mounting bolts fingertight.
4 . I n s t a l l t h e p e c i a l t o o lt,h e nt o r q u et h e f l y w h e e l s

patternin several mounting bolts in a crisscross sreps.

1 2 x 1 . 0m m 103 N.m (10,skst.m. 76 lbf ftl

(cont'd)

12-11

Glutch
(cont'dl ClutchReplacement
PlateInstallation ClutchDiscand Pressure
'L T e m p o r a r i l yn s t a ltl h e c l u t c hd i s co n t o t h e s p l i n e s i of the transmissionmainshaft,Make sure the clutch disc slidesfreely on the mainshaft.

pattern, 5. Torque mounting the boltsin a crisscross Tighten boltsin several steps prevent to the w a r p i n gh ed i a p h r a g mp r i n g . s t PRESSURE PLATE MOUNTING BOLT TOROUE: 25 N.m{2.6kgt.m, lbt.ft) 19

2 . l n s t a l l t h e i n g g e a rh o l d e r . r
O?ZAF.PRSAIOO

\---,

/v

07936-3710100

{P/N08798-9002) 07LAB-PVo0'100 or 0792,1-PD20003

3 . Apply super high temp urea grease(P/N087989002)to lhe splines(A) of the clutch disc (B),then installthe clutchdisc usingthe specialtools. Removethe specialtools. Installthe pressureplate (A) and the mounting ht. bolts (B)finger-tig 1 . Make sure the diaphragmspringfingers are all the s a m eh e i g h t .

12-12

Release Bearing Replacement


'L Removethe releasefork boot (A)from the clutch ( housing B).

4 . Apply super high temp urea grease{P/N087989002)to the releasefork (A),the release fork bolt ( B ) ,t h e r e l e a s e e a r i n g C ) , n d t h e r e l e a s e e a r i n g ( a b b g ui d e ( D )i n t h e s h a d e da r e a s .
1 . 0 1 . 6g 10.04 0.06oz)

\\

l-'..\
\\ \ ) ) / /-/

!ac
Xrl-Rl It\'1
f-l\-._ -A 0 . 4 1 . 0g 10.01 0.04o

{re\
"

I L!),l-*E

0.t 1.09 (0.01 0.04 oz)

2 . Removethe release fork (C)from the clutch


( h o u s i n g B )b y s q u e e z i n t h e r e l e a s eo r k s e ts p r i n g g f ( D ) w i t hp l i e r s R e m o v e h e r e l e a s e e a r i n g E ) . ( . t b With the releasefork slid betweenthe release p b e a r i n g a w l s .i n s t a l l t h e e l e a s e e a r i n g n t h e r b o m a i n s h a fw h i l e i n s e r t i n gh e r e l e a s eo r kt h r o u g h t f t t h e h o l ei n t h e c l u t c hh o u s i n g . 6 . Align the detentof the releasefork with the release fork bolt,lhen pressthe releasefork over the r e l e a s eo r k b o l ts q u a r e l yM a k es u r et h e r e l e a s e f . f o r k s e t s p r i n g( F )i s p r o p e r l y e t . s 7 . I n s t a l l t h e e l e a s eo r k b o o t{ E ) .M a k es u r et h e b o o t r f f s e a l sa r o u n dt h e r e l e a s eo r k a n d c l u t c hh o u s i n g . fork (A) right and left to make 8 . Move the release i t f i t s p r o p e r l y g a i n st h e r e l e a s e e a r i n g a b s u r et h a t ( B )a n d t h a tt h e r e l e a s e e a r i n g l i d e ss m o o t h l y . b s

3 . Checkthe releasebearingfor play and noise by


p s p i n n i n g t b y h a n d .l f t h e r ei s e x c e s s i v e l a yo r i n o i s e , e p l a c eh e r e l e a s e e a r i n g i t h a n e w o n e . r t b w NOTE:The releasebearingis packedwith grease. Do not wash it in solvent.

12-13

ManualTransmission
SpecialTools 13-2 Transmission Inspection Fluid a n dR e o 1 a c e m e n.t. . . . . . . . . . . .|.5-J. - . .. .. Back-Up LightSwitch Test ..........J - 5 t Transmission Removal 13-4 Transmission Installation ........... I J-at Transmission Disassemblv ........ 3 - 1 4 1 Reverse ShiftFork Clearance lnsoection 13-19 Lever Change Clearance lnsoection 13-19 Lever Assembly Change Disassembly/Reassembly 13-20 ....... ShiftForks Clearance Inspection 13-21 ShiftForks Disassembly/Reassembly 13-22 ....... Mainshaft Assemblv Clearance Inspection 13-23 't3-25 Mainshaft Disassembly Mainshaft lnsoection 13-26 Mainshaft Reassembly | 5-2.5 Countershaft Assemblv Clearance Inspection 13-31 Disassembly Countershaft ......... 13-32 Inspection ............. Countershaft 13-33 Reassembly Countershaft .......... 13-34 Synchro Sleeve Hub and Inspection Reassembly 13-39 and .... Synchro RingandGear Insoection ....... 13-39 Mainshaft Bearing OilSeal and R e p l a c e m e n.t. . . . . . . . . . . . . . . . .1.3 . .4 . . . . . . - ,1 Cou ntershaft Bearing ReDlacement .. 13-42 Mainshaft Thrust Clearance Adiustment .....13-43 Transmission ......... 13-46 Reassemblv Gearshift Mechanism R e p l a c e m e n.t. . . . . . . . . . . . . . . . .1.3 . .5 . . . . . . - .1

M/T Differential
Comoonent Location Index ........ 13-52 Backlash Inspection ..................... 13-53 Final Driven Gear/Carrier Replacement .. 13-53 Bearings ... Carrier Replacement 13-54 Oil SealReplacement 13-55 .................. Differential Thrust Clearance Adiustment .....13-56

ManualTransmission
SpecialTools
Ref.No. Description A 2 E n g i n eH a n g e r d a p t e r , . 0t o 2 . 4 L i t e r E n g i n eH a n g e r ral M a i n s h a fH o l d e r t 07GAJ-PG20' ]10 07GAJ-PG20130 M a i n s h a fB a s e t @ 07JAD-P190100 O i l S e a lD r i v e r 07NAD-P20A100 Oil Seal DriverAftachment AdjustableBearingPuller,20-40mm 07736-A01000B ri) Attachment,42 x 47 mm 07746-0010300 Driver,40 mm LD. 07746-0030100 @ Driver,30 mm LD. 07746-0030300 @ Driver 07749-0010000 @ of Mainshaft Inspection o o l S e t .0 7 G A J - P G 2 0 1 0 2 . on T Tool Set, '16 3 S l i d eH a m m e r . M u s t b e u s e dw i t h c o m m e r c i a l la v a i l a b l e / 8 " y

ToolNumber

Oty

(!l ar\

vs802c000015 vs802c000018

o o

l l
,l

Z-'

-4
@

I
\'---'' @

A n r f; D \".,i'i

I rS'D

IN
@

Q)-'' o

-a ,/
@

-4

13-2

Transmission FluidInspection and Replacement


'1. Parkthe vehicleon level ground,and turn the e n g i n eO F F .

Back-UpLight Switch Test


1. Disconnecttheback-uplight switch (A) connector.

2 . R e m o v e h e o i l f i l l e rp l u g ( A )a n d w a s h e r( B ) ,c h e c k t the conditionof the fluid, and make sure the fluid is at the proper level (C).

2 . Checkfor continuitybetweenthe back up light


s w i l c h2 P c o n n e c t o N o . 1 a n d N o . 2 t e r m i n a l s . r There should be continuitywhen the shift lever is in reverse. l f t h e t r a n s m i s s i ofn u i d i s d i n y , r e m o v e h e d r a i n l t p l u g( D )a n d d r a i nt h e f l u i d . replacethe back-uplight switch. 3 . lf necessary, ( a, l A p p l y l i q u i dg a s k e t P / N0 8 7 1 8 - 0 0 0 1 )n d i n s t a l i t o n t h et r a n s m i s s i oh o u s i n g . n

A 44 N.m{4.5kgt.m,

33rbr.ftl

R e i n s t a t lh e d r a i np l u gw i t h a n e w w a s h e r , n d l a refillthe transmission fluid to the proper level. Oil Capacity 1.50 (1.6US (F) at tluid change 1.70 {1.8US qt) at overhaul Always use Honda ManualTransmissionFluid (MTF).Using motor oil can causestiffer shifting and noise becauseit does not containthe proper additives. 5 . R e i n s t a t lh e o i l f i l l e rp l u gw i t h a n e w w a s h e r . l

13-3

ManualTransmission
Transmission Removal
SpecialToolsRequired . E n g i n e a n g e r d a p t e r . 2 . t o 2 . 4l i t e rV S B 0 2 C 0 0 0 0 1 5 h a 0 . E n g i n eh a n g e rV S B 0 2 C 0 0 0 0 1 8 . Enginesupport hanger,A & RedsAAR'T 12566' ' . SubframeadaDter EOS02C000011 * A v a i l a b l eh r o u g ht h e H o n d aT o o l a n d E q u i p m e n t t Program888-424-6857 NOTE:Use fender coversto avoid damaging painted surfaces. 1 . Write down the frequencies the radio'spreset for buttons.Disconnect negative( ) cablefirst, the then the positive( )cable from the battery. Removethe battery. Removethe intakemanifoldcover {seepageg-3). ( R e m o v e h e a i r c l e a n e r o u s i n g s e ep a g e11 - 1 6 2 ) . t h
4 . Removethe intakeair duct {seestep 8 on page 5-3).

8. Removethe cable bracket(A).then disconnect the ( c a b l e s B )f r o m t h e t o p o f t h e t r a n s m i s s i o h o u s i n g . n Carefullyremove both cablesand the bracket togetherso as not to bend the cables.

A i l

@ B

Removethe batterytray (A). 9. Removeheharness lip. t c

D i s c o n n e c h e t r a n s m i s s i o g r o u n dc a b l e( B ) . tt n 7 . Disconnect back-uplight switch connector(A) the ( s c r a n dv e h i c l e p e e ds e n s o r V S S ) o n n e c t o( B ) .

13-4

10. Carefullyremovethe slavecylinderand clutchline bracketso as not to bend the clutch line. Do not operatethe clutch pedalonce the slavecylinder has been removed,

12. Attach the specialtool to the threaded hole in the c y l i n d e rh e a d .

vsB02c00001s

tJ.

1 1 .Removethe enginewire harnesscover (A) by lifting up on the locktab (B),then slidethe harness f o r w a r do f f t h e a i r c l e a n e r o u s i n g o u n t i n g h m bracket{C).

I n s t a l l t h e n g i n eh a n g e r( A ) a n d t h e e n g i n es u p p o r t e hanger {B) to the vehicle,then attachthe hook to the sDeciai tool.

vs802c000015

1 4 . Removethe two upper transmissionmounting bolts.

(cont'd)

13-5

ManualTransmission
(cont'd) Removal Transmission
15. Removethe transmissionmount bracket(A) and t r a n s m i s s i o m o u n t i n gb o l t ( B ) . n

20. Removethe three way catalyticconverter(TWC)


assembly(seestep 30 on page 5-5)

2 1 . Removethe driveshafts(seepage 16-3). 22. Removethe intermediate shaft {seepage 16-19). 23. Removethe front enginemount bracketmounting
bolt.

to.

b t R e m o v e h e a i rc l e a n e r r a c k e{ C ) . t

, 1 7 . R a i s e h e v e h i c l e a n d m a k es u r ei t i s s e c u r e l y t supponed. l 1 8 . D r a i nt h e t r a n s m i s s i o f l u i d .R e i n s t a t lh e d r a i nb o l t n w i t h a n e w w a s h e r( s e ep a g e1 3 - 3 ) . 1 9 .R e m o v eh e s p l a s h h i e l d . t s

24. Removethe three bolts securingthe transmission


r e a rm o u n I .

db-qF

Ds

1 3- 6

25. Supportthe subframewith the subframeadapter and a jack.

27. Removethe clutchcover.

---

EOS02C000011 2 8 . R e m o v e h e f r o n t e n g i n em o u n t . t

marks (A) on the front suspension 26. Make reference subframe(B)and mounting bolts (C).then remove subframe. the front suspension

29. P l a c e h e t r a n s m i s s i oin c ku n d e rt h e t r a n s m i s s i o n , t a
and removethe transmissionmounting bolts.

(cont'd)

13-7

Manual Transmission
Transmission Removal(cont'd)
30. Pullthe transmissionaway from the engine until
the transmissionmainshaftclearsthe clutch pressureplate,then lower the transmissionon the jack. transmission Removethe transmissionrear mount (A) and the transmissionrear mount bracket{B).

Transmission Installation
Special Tools Required . Enginehangeradapter,2.0to 2.4 liter VS802C000015 . En g i n eh a n g e rV S 8 0 2 C 0 0 0 0 1 8 . Enginesupport hanger,A & RedsAAR-T-12566" . subframe adaDterEoS02c000011 * Availablethrough the HondaTool and Equipment Program888-424-6857 1. Checkthe two dowel pins are installedin the clutch h o u sn g . r Apply super high temp urea grease(P/N087989002)to the releasefork (A) and the releasebearing (B).Installthe releasefork and the releasebearing.
g 1.0 '1.6 {0.04 0.06oz)

3 2 . Removethe boot (A),the releasefork {B).and the


( r e l e a s e e a r i n g C )f r o m t h e t r a n s m i s s i o ( D ) . b n

0.4 1.0g {0.01 0.04 ozl 3 . I n s t a l l t h er a n s m i s s i o r e a rm o u n tb r a c k e ( A ) a n d t n t t h e t r a n s m i s s i o r e a rm o u n t( B ) . n 't2x 1 . 2 5 m m 64 N m {6.5kgf.m, 47


1 2x 1 . 2 5 m m 64 N.m {6.5 ksf.m, 47 tbf.ft)

P l a c eh e t r a n s m i s s i oo n t h e t r a n s m i s s i o i a c k . t n n and raiseit to the engine level.

13-8

5 . I n s t a l lt h e t r a n s m i s s i o nm o u n t i n g bolts. 1 2 x 1 . 2 5m m 64 N.m 16.5 m.47 lbt ft) kgf

8. Supportthe subframewith the subframeadapter a n da j a c k .

1 2x 1 . 2 5 m m 64 N.m (6.5kgf.m,47 lbf.ft) 6 . I n s t a l l t h ef r o n t e n g i n e m o u n t .

( f n 9 . I n s t a l l t h er o n t s u s p e n s i o s u b f r a m e A )i n i t s t b o r i g i n a p o s i t i o n y a l i g n i n g h e m a r k s( B )y o u l made in the removal procedure,

12 x 1.25ftrn 64 N.m (6.5 kgf m. 47 lbf.ft)

12x 1.25mm 64 N.m (6.5kst.m,47 lbf ft) 7 . l n s t a l l t h e c l u t c hc o v e r . 1 4x 1 . 5m m

6x1.0mm 12 N.m {1.2kgI.m,9 lbf ftl

(cont'd)

13-9

Manual Transmission
(cont'dl Transmission Installation
'10. Installthethree rear mounting bolls for the transmissionrear mount.

1 5 .Installthe transmissionmount bracket(A) and the


t r a n s m i s s i o m o u n t i n gb o l t{ B ) . n
6x1.0mm 12Nm 1 2x 1 . 2 5 m m 54 N.m {5.5ksf.m, 40lbf.ft) 12x 1.25nn 54 N.m (5.5kgf.m, 40 tbt.ft)

/t':::= -)

12 x 1.25 mm 54 N.m (5.5kgf.m, 40 tbf.ftl

1 6 . Installthe air cleanerbracket(C). 59 N.m(6.0 kgf.m,43 tbf.ft) 1 1 .Looselytighten the front engine mount bracket mounting bolt.
10 x 1.25mm

1 7 . Installthe two uppertransmissionmounting bolts.

12x 1.25 mrn 64 N.m(6.5 kgt.m,47 lbf.ftl

12. Installthe intermediateshaft (seepage 16-24).


t5.

1 8 . R e m o v e h e e n g i n eh a n g e ra n d s p e c i atlo o l f r o m t engrne.

(seepage 16-17). Installthedrivershafts

1 4 . lnstallthe three way catalyticconverter(TWC) assembly(seestep 17 on page 5-12).

13-10

19. Tightenthe front engine mount bracketmounting bolt.


'12x 1.25mm 64 N.m 16.5 kgf.m, il7 lbf.ft)

21. lnstallthe brakeboosterand EVAPline bracket mounting bolts (A).and air cleanerhousing bracket h T t m o u n t i n gb o l t ( B ) . i g h t e n h e a i r c l e a n e r o u s i n g bracketmounting bolt (C),and installthe water pipe mounting bolt (D). A 9.8N.m (1,0 qf k

s 2 0 . I n s t a ltl h e s p l a s h h i e l d .

%,

22N.m l2.2kglm, 16rbt.ft) 9.8Nm (1.0 m. kgf 'B 7.2tbl{rl 22Nm {2.2kgf m, 16 lbf ft)

c e 22. I n s t a l l t h e n g i n eh a r n e s s o v e r .

(cont'd)

13-11

Manual Transmission
(cont'dl Transmission Installation
(P/N08798Applysuperhightemp ureagrease 9002) the endof the slave to cylinder rod.Install the slave cylinder the clutchlinebracket. and Take care
not to bend the clutch line. 8 x 1.25mm 22 N.m (2.2 kgf.m, 16 lbf ft) 6x1.0mm 9.8 N.m (1.0kgf.m, 7.2 tbt.ftl

2 5 . I n s t a l l t h e a b l eb r a c k e ( A )a n d c a b l e s B ) . ( c t

BWZ[i:i'u'T!'*n'-'

#._gEEa9En (P/N08798-9002)

a^_

lPlN 08798-9002)

24. Installthe arness lip. h c

26. Apply a light coat of super high temp urea grease


(P/N08798- 9002)to the cable ends.
t1

Connectthe back-uplight switch connector(A) and (r t h e v e h i c l e p e e ds e n s o r V S S ) c o n n e c t o B ) . s {

13-12

ground cable (A). 28. Connectthe transmission


8 x 1.25mm 22 N.m (2.2kgf.m, 16lbf.ft)

[---.-.---e e

6x1,0mm 9.8 N.m {1.0kgl m. 7 lbf ftl

8x125mm 22Nm kgt 12.2 m, 16lbf ft)

29. lnstallthe batterytray (B). 30. Installthe intakeair duct (seestep 36 on page 5-14).
( h I n s t a l l t h e i r c l e a n e r o u s i n g s e es t e p3 9 o n p a g e a 5-15).

3 2 . Installthe intakemanifoldcover (seestep 41 on


p a g e5 - 1 5 ) .

33. Installthe battery.Connectthepositive(+) cable


first, then the negative(-)cable to the battery. l t 34. R e f l l l t h e r a n s m i s s i ofn u i d ( s e ep a g e1 3 - 3 ) . the 35. Test-drive vehicle.

36. Checkthe clutchoperation. 3 1 .Checkthe front wheel alignment(seepage 18-4). 38. Enterthe anti-theftcode for the radio,then enter
the customer'sradio stationpresets. i 39. D o t h e e n g i n ec o n t r o lm o d u l e( E C M ) d l e l e a r n ( p r o c e d u r e s e ep a g e1 1 - 1 3 9 ) .

13-13

Manual Transmission
Transmission Disassembly
Exploded View-Clutch Housing

,.Y

' r'<__J'.@t / ,, tl j=-X ri ,1.-6

'-==-Yh,_-9
n""

-',ot/u

,tA'

v i6

\? q'/V^

-1 t3l

t4

.!) DIFFERENTTAL ASSEMBLY r2lSHIFTFORK ASSEMBLY 6 a9l mm FLANGEBOLT 1 2 N . m ( 1 . 2k g f m , 9 l b f f t l ..4] BEARINGsET PLATE ASSEMBLY G, COUNTERSHAFT BEARING O NEEDLE C 3 OIL GUIDEPLATE e 14 x 20 mm DOWELPIN MAGNET .9-i i.!! MAINSHAFTASSEMBLY U 28 mm WASHER

i[, 28 mm SPRINGWASHER iO BALLBEARING (l 28 x 43 x 7 mm OIL SEAL Replace. .D REVERSE GEARSHAFT IDLER GEAR 1' REVERSE f lr 6 mm SPECIALBOLT 15 N.m (1.5kgt.m, 11 lbf.ft) (!I REVERSE SHIFTFORK LOCKCAM .4' REVERSE Q-t x 58 x 8 mm OIL SEAL 35 Replace.

?]] BACK-UPLIGHTSWITCH 29 N m (3.0kgf.m,22 lbf ftl .?1 O.RING Replace.

(Vss) VEHICLE SPEEo sENsoR 1!)


.O 8 mm FLANGE BOLT 22 N.m (2.2kgf m, 16lbf.ftl .' CLUTCH HOUSING iI6) TRANSMISSIONHANGER BOLT tl 10 mm FLANGE 44 N.m {4.5kgt.m,33 lbf.ft}

13-14

Housing Exploded View-Transmission


tt-P "=-@
@

z-W :
iq { "
@------

'\b e P\B o,. @\

rai \:/

dd

f /

\ @

O=-rl

F,z

,-1 _\ (g/----------__"^\

\-/r*---------..-,

HOUSING O TRANSMISSION O 10 mm WASHER Replace. @ 10 mm FLANGEBOLT 44 N.m {4.5kgf.m,33lbf.ft) O 8 mm FLANGEBOLT kgf 27 N.m 12.8 m,20lbl.ft) TRANSMISSIONHANGERA .' BOLT O INTERLOCK 39N m (4.0ksf.m,29lbf.ft) PLATEM O OILGUIOE 72 .1 mm SHIM .' OIL GUTTEBPLATE

{i) 80 mm SHIM PIN 0 8 x 14mm DOWEL LEVER ASSEMBLY [A CHANGE a06 mm FLANGE BOLT kgf.m,9lbfft} 12N m {1.2 BOLT O DETENT 22 N.m{2.2 kgf.m, 16lbf.ft) O 12mm waSHER

@)20 mm WASHER Replace. q,]FILLERPLUG 44 N m {4.5kgf.m,33 lbf.ft) @ 40 x 56 x 8 mm OILSEAL Replace. qO14 mm WASHER Replace. q' DRAIN PLUG 39 N.m (4.0kgf.m,29 lbf.ftl @ 32 mm SEALINGCAP 34 N m (3.5 kgf.m, 25 lbf.ft)

ReDlace. (D SPRING [I STEELBALL (D TRANSMISSION B HANGER (9 CLUTCHLINE CLIPBRACKET

(cont'd)

13-15

Transmission Manual
(cont'd) Disassembly Transmission
NOTE:Placethe clutch housingon two piecesof wood thick enoughto keepthe mainshaftfrom hittingthe workbench. 1. Removethe detent bolts (A),springs,steel balls, and back-uplight switch (B). 3, Removethe interlockbolt (A),the changelever ( a a s s e m b l y B ) ,8 x 1 4 m m d o w e lp i n s( C ) , n d t h e t c l u t c hl i n ec l i p b r a c k e{ D ) .

R e m o v e h e d r a i np l u g( A ) ,f i l l e rp l u g( B ) ,a n d t 1 0 m m f l a n g eb o l t ( C ) . Removethe vehiclespeedsensor(VSS)(A) and O - r i n g( B ) .

13-16

5. Removethe 8 mm flange bolts in a crisscross Datternin severalsteos.

10. Removethe reverselock cam.

g t.l Y g

(,

^A

6 . Removethe transmissionhangerA, and t r a n s m i s s i o h a n g e rB . n c 7 . R e m o v e h e 3 2 m m s e a l i n g a p( A ) . t

1 1 .Removethe reverseidler gear {A) and reversegear s h a f t{ B ) .

E x p a n d h e 7 2 m m s n a pr i n g ( B )o n t h e t ball bearing,and remove it from the countershaft groove using a pair of snap ring pliers. ( L R e m o v e h e t r a n s m i s s i o h o u s i n g C )a n d t n 1 4 x 2 0 m m d o w e l p i n s( D ) .

(cont'd)

13-17

ManualTransmission
(cont'd) Transmission Disassembly
12. Removethe reverseshift fork. 15. Removethe differential assembly(A) and magnet ( B) .

t7
I

t1

Apply vinyl tape to the mainshaftsplinesto protect the seal,then removethe mainshaftassembly(A) and countershaft assembly(B)with the shift forks ( { C ) f r o mt h e c l u t c hh o u s i n g D ) .

1 6 . Removethe oil gutter plate (A),72mm shim (B), a n d o i l g u i d ep l a t eM .

1 4 . R e m o v e h e 2 8 m m s p r i n gw a s h e r( E )a n d 2 8 m m t w a s h e r( F ) .

13-18

Reverse Shift ForkClearance Inspection


betweenthe reverseidler 1. Measurethe clearance gear {A) and the reverseshift fork (B)with a feeler gauge (C).lf the clearance more than the service is limit, go to step 2. 0.20-0.59 mm (o.oo7 0.024 in.l Standard: ServiceLimit: r.3 mm {0.051in.)

Inspection ChangeLeverClearance
1 . Measurethe clearancebetweenchangelever (Al and the selectlever (B)with a feelergauge (Cf.lf i l t h e c l e a r a n c es m o r et h a nt h e s e r v i c e i m i t ,g o r o step 2. 0.05 0.25 mm (0.002-0.010in.) Standard: ServiceLimit: 0.50mm {0.020in.)

2. Measurethe groove of the changelever'


Measure the width of the reverseshift fork. . l f d i s t a n c es n o t w i t h i n t h e s t a n d a r d , p l a c e t h e re i reverseshift fork with a new one. . lf distanceis within the standard,replacethe reversegear wrln a new one. Standard: 13.4 13.7mm (0.527 0.539in.l . lf distanceis not within the standard,replacethe c h a n g el e v e rw i t h a n e w o n e . . l f d i s t a n c es w i t h i n t h es t a n d a r dr,e p l a c e t h e i selectlever with a new one. i m Standard: 1 5 . 0 0 1 5 . 1 0 m ( 0 . 5 9 1 - 0 . 5 9 4n . )

qI

,tl

13-19

ManualTransmission
ChangeLeverAssemblyDisassembly/Reassembly
Priorto reassembling, clean all the parts in solvent,dry them, and apply lubricantto any contactsurface. LEVER SELECT Becareful to damage dustseal not the w h e ni n s t a l l i n t . ig DUST COVEB

BREATHER CAP Turnthe arrow toward {ront the and it. o{thevehicle, install

r rrl
I

@).1 l L

I l

7 Fr"irr6-rooa
SHIFTARM COVER

a^^

ROLLER (P/N 08798-9002) 6x1.0mm 12 N.m (1.2kgl.m,8.7 lbf.ft)

\op
(g)'
'^
Fl q )-=^l
WASHER

\r'

E-='1sr/2No !-d
sELEcr

/-r,s \__/

,/

-, OILSEAL
ReDlace.

,.* (A) tace. ix#,,l

sPntruc

INTERLOCK

H\ lV

SHIFT ARM

srx

r
/

-z:-=:l-':

tr7
,/u
SELECTSTOP PLATE 9.8Nm {1.0kgf.m,7.2 lbf.ft)

SELECT SPRING

LOCKCAM REVERSE STRIKER

13-20

Inspection Shift ForksGlearance


NOTE:The synchrosleeveand synchrohub should be replacedas a set. 1. Measure the clearance betweeneach shift fork (A) and its matchingsynchrosleeve(B).lf the exceeds the servicelimit, go to step 2. clearance Standard: 0.35 0.65 mm {0.014 0.026in.1 in.l ServiceLimit: 1.0 mm 10.039 betweenthe shift fork (A) 3. Measurethe clearance exceeds the the shift arm (B).lf the clearance and servicelimit, go to slep 4. 0.2-0.5 mm (0.007 0.020in.) Standard: ServiceLimit: 0.62mm (0.024in.)

4 . Measurethe width of the shift arm. . l f t h e w i d t h o f t h e s h i f t a r mi s n o t w i t h i n t h e standard,replacethe shift arm with a new one. . l f t h e w i d t h o f t h e s h i f ta r m i s w i t h i n t h es t a n d a r d , replacethe shift fork and shift piecewith a new one. Standard: 16.9-17.0 mm (0.665-0.669in.)

2 . l\4easure thicknessof the shift fork fingers. the


. l f t h e t h i c k n e s s otfh e s h i f tf o r k f i n g e ri s n o t within the standard,replacethe shift fork with a new one. . l f t h e t h i c k n e s s otfh e s h i f tf o r k f i n g e ri s w i t h i n the standard,replacethe synchrosleevewith a new one. Standard:7.4 7.6 mm (0.29-0.30 in.)

13-21

ManualTransmission
Shift ForksDisassembly/Reassembly
Priorto reassembling, clean all the parts in solvent,dry them, and apply lubricantto any contactparts.

sTH SHIFTFORK

PINDRIVER, mm 5

13-22

MainshaftAssemblyClearance Inspection
NOTE:lf replacement required,always replacethe is synchrosleeveand hub as a set. 1. Supportthe bearinginner racewith an appropriate sizedsocket(A).and push down on the mainshaft (B). 4. Measurethe clearance between4th gear (A) and ( B )w i t h a d i a l i n d i c a t o ( C ) . thedistance ollar c r . lf the clearance more than the servicelimit, go is to step 5. . lf the clearance within the servicelimit, go to is step 7. Standard: ServiceLimit: 0.06 0.16 mnl (0.002 0.006in.) 0.25mm {0.010in.)

Measurethe clearance bet\iveen 2nd (C)and 3rd (D) gearswith a feelergauge {E). . l f t h e c l e a r a n c i s m o r et h a nt h e s e r v i c e i m i t .g o l e to step 3. . lf the clearance within the servicelimit, go to is step 4. MeasuredistanceO on the distanceco[ar. Standard: ServiceLimit: 0.06 0.16mm {0.002 0.006in.l 0.25 mm (0.010 in.l . lf distance't is notwithin the standard,replace the distancecollarwith a new one. . lf distancee is within the standard,go to step 6. Standard: . l f t h e t h i c k n e s o f 3 r d g e a r i sl e s s t h a n t h e e r v i c e s s l i m i t ,r e p l a c e r d g e a r w i t ha n e w o n e . 3 . l f t h e t h i c k n e s o f 3 r dg e a r i s w i t h i n t h e s e r v i c e s limit, replacethe 3rd/4thsynchrohub with a new one. Standard: ServiceLimit: 23.92-23.97 mm (0.941 0.944in.) 23.80mm (0.937in.)

Measurethe thickness 3rd gear. of

24.03 24.08mm in.} {0.946-0.9/u

(cont'd)

13-23

ManualTransmission
Inspection(cont'd) MainshaftAssemblyClearance
of 6. Measurethe thlckness 4th gear. . l f t h e t h i c k n e s o f 4 t h g e a ri s l e s s t h a n t h e s e r v i c e s limit, replace4th gear with a new one. . l f t h e t h i c k n e s s o4 t h g e a r i s w i t h i nt h e s e r v i c e f limit. replacethe 3rd/4thsynchrohub with a new one. Standard: ServiceLimit: 23.92 23.97mm (0.941 0.944in.) 23.80mm (0.937in.) 8. MeasuredistanceO on the distancecollar. . lf distance is notwithinthestandard, place re O the distancecollar with a new one. ' l f d i s t a n c e Oi s w i t h i n t h es t a n d a r dg o t o s t e p 9 . , Standard:

mm 24.03 24.08 (0.946 0.947 in.)

of 9. Measurethe thickness 5th gear. . l f t h e t h i c k n e s s o5 t h g e a r i s l e s s t h a n t h e s e r v i c e f limit, replace5th gear with a new one. . lf the thickness sth gear iswithin the service of limit. replacethe 5th synchrohub with a new one. Standard: Service Limit:

betweenthe distancecollar 7. l\4easure clearance the ( A )a n d s t h g e a r( B )w i t h a d i a l i n d i c a t o ( C ) . f t h e r l is clearance more than the servicelimit. go to step l i 8 . l f t h e c l e a r a n c es w i t hi n t h e s e r v i c e i m i t ,g o t o steD10. Standard: ServiceLimit: 0.06 0.16mm (0.002-0.006in.) in.) 0.25 mm (0.010

23-92 23.97mm in.l 10.9410.944 in.l 23.80 mm (0.937

13-24

MainshaftDisassembly
'10. M e a s u r eh e t h i c k n e s s f t h e M B S d i s t a n c e o l l a r . t o c . l f t h e t h i c k n e s o f M B S d i s t a n c e o l l a ri s l e s s s c than the standard,replacethe MBS distance c o l l a rw i t h a n e w o n e . Standard: ( 1 . R e m o v e h e a n g u l a r a l l b e a r i n g A )a n d t h e b t ring using a commerciallyavailable taperedcone b e a r i n g e p a r a t o{ B )a n d a c o m m e r c i a l l a v a i l a b l e s r y p s b e a r i n g u l l e r{ C ) .B e s u r et h e b e a r i n g e p a r a t oirs c u n d e rt h e t a p e r e d o n er i n g .

23.95 24.05 mm in.) {0.9(3 0.947

E-f
Support5th gear (A) on steel blocks,and pressthe mainshaftout of the sth synchrohub (B).Use of a jaw-typepuller can damagethe gear teeth.

(cont'd)

13-25

Transmission Manual
(cont'dl MainshaftDisassembly
3. Supportthe 3rd gear (A) on steel blocks,and press the mainshaftout of the 3rd/4thsynchrohub (B). Use of a jaw-type puller can damagethe gear teeth.

Mainshaft Inspection
1. Inspectthe gear surfaceand bearingsurfacefor w e a r a n d d a m a g et,h e n m e a s u r eh e m a i n s h a fa t t t pointsA, B, C, D, and E. lf any part of the mainshaft is lessthan the servicelimit, reDlace with a new it on e . Standard: A Ball bearingsurface(transmission housingside): 27.987 28.000 m (1.1019 1.1024in.) m B Distance collar surtace: 31.984 32.000mm {1.2594 1.2598in.) C Needle bearing surlace: 38.984-39.000mm (1.53/t8 1.5354 in.) D Ball bearingsurface(clutchhousingside): 2 7. 9 7 7 2 7 . 9 9 0m m ( 1 . 1 0 1 5 1 . 1 0 2 0 i n . ) E Bushing surface: 20.80 20.85mm (0.819 0.821in.) ServiceLimit; A : 2 7 . 9 3 m 1 1 . 1 0 i0 . l m n B: 31.93 mm |.1.257 in.l C: 38.93mm 11.533 in.l Di 27.92mm {1.099 in.l E: 20.75mm 10.817 in.l

13-26

2. Inspectthe runout by supponing both ends of the mainshaft.Rotatethe mainshafttwo complete revolutions when measuringthe runout. lf the runout is more than the servicelimit. reolacethe mainshaftwith a new one. Standard: 0.02mm (0.001in.) max. ServiceLimit: 0.05mm (0.002in.)

13-27

ManualTransmission
MainshaftReassembly
Exploded View

QJ'

3RD/4TH SYNCHRO SLEEVE 3RD/4TH


SYNCHRO HUB SYNCHRO SPRING

ANGULAB BALL BEARING Checkfor wear and operation. Note the directionof installation. TAPEBED CONERING MBS DISTANCECOLLAR

frfl Y7

SYNCHROSLEEVE SYNCHRORING

NEEDLE BEARING Check wearandoperation. for

MAINSHAFT

NEEDLE BEARING

Checkfor wear and operation. GEAR 4TH/5TH GEAB DISTANCECOLLAR SYNCHRORING SPRING SYNCHRO

a
13-28

SpecialTools Required . Driver,40 m 1.D.07746-0030100 m . Attachment,30mm l.D.07746-0030300 NOTE:Referto the ExplodedView as neededduring this procedu re. '1. Cleanall the parts in solvent,dry them, and apply lubricantto all contactsurfacesexceptthe 3rd/4th and 5th synchrohubs.

6. Installthe3rd/4thsynchrosleeve(A) by aligning the stops (B)with the 3rd/4thsynchrosleeveand hub. After installing, checkthe operationof the 3rd/ 4th synchrohub set.

@--

2. I n s t a l l t h e e e d l e e a r i n g n d 3 r d g e a ro n t h e n b a
mainshaft. I n s t a l l t h e y n c h r o i n g a n dt h e s y n c h r o p r i n g . s r s
4 . I n s t a l l t h e r d / 4 t h y n c h r o u b ( A )b y a l i g n i n g h e 3 s h t

synchroring fingers (B)with 3rd/4thsynchrohub grooves(C).


-A

7 . I n s t a l l t h e y n c h r o p r i n g( A ) . s s

lnstallthe 3rd/4thsynchrohub {A) usingthe special tool.

I n s t a l l t h e y n c h r or i n g ( B )b y a l i g i n g h e s y n c h r o s t cone fingers (C)with 3rd/4thsynchrohub grooves (D). 9 . I n s t a l l t h e t h g e a r ,n e e d l e e a r i n gd i s t a n c e o l l a r , 4 b , c n e e d l e e a r i n ga n d s t h g e a r . b ,

07746-0030100

(cont'd)

13-29

ManualTransmission
(cont'dl MainshaftReassembly
1 0 . I n s t a l l t h e y n c h r o i n ga n dt h e s y n c h r o p r i n g . s r s 1 '1. I n s t a l l t h e t h s y n c h r oh u b ( A )b y a l i g n i n g h e s t synchrocone fingers (B)with sth synchrohub grooves(C). 1 4 . I n s t a l l t h e y n c h r o p r i n g( A ) . s s

t5.

I n s t a l l t h e y n c h r o i n g ( B )b y a l i g n i n g h e s y n c h r o s r t cone fingers (C)with sth synchrohub grooves(D).

12. I n s t a l l t h e t h s y n c h r oh u b ( A )u s i n gt h e s p e c i a l 5
tools.

1 6 . I n s t a l l t h e B S d i s t a n c e o l l a ra n dt h e t a p e r e d M c c o n er i n g . 1 1 . I n s t a l l t h e e w b a l l b e a r i n g A ) u s i n gt h e s p e c i a l n { t o o l sa n d a p r e s s( B ) .

U
07746-0030100 07746-0030300 07746-0030100

1 3 . I n s t a l l t h e t hs y n c h r o l e e v e . 5 s

\.

13-30

Countershaft AssemblyClearance lnspection


1 . Measurethe clearance betweenthe 1st gear (A) a n dt h e d i s t a n c e o l l a r( B ) w i t ha f e e l e rg a u g e( C ) . c . l f t h e c l e a r a n c es m o r et h a nt h e s e r v i c e i m i t ,g o i l to step 2. . l f t h e c l e a r a n c es w i t h i nt h e s e r v i c e i m i t .g o t o i l step 4. Standard: 0.06 0.16mm 10.002 0.006in.l ServiceLimit: 0.25 mm (0.010 in.l 3. Measure the thicknessof the 1st oear. . l f t h e t h i c k n e s s o lfs t g e a r i s l e s s t h a n t h e e r v i c e s l i m i t ,r e p l a c e s t g e a r w i t h a n e w o n e . l . lf the thicknessof '1st gear is within the service limit, replacethe lst/2nd synchro hub with a new one. 22-92 22.97 mm 10.902 0.904 in.l Standard: ServiceLimit; 22.87mm {0.900in.)

2. fvleasure thickness the distancecollar. the of . l f t h e t h i c k n e s i s n o t w i t h i nt h e s t a n d a r dr,e p l a c e s t h e d i s t a n c e o l l a rw i t h a n e w o n e . c ' lf the thicknessis within the standard,go to

4. Measurethe clearance betweenthe 2nd gear (A)

a n d 3 r d g e a r( B )w i t h a f e e l e rg a u g e( C ) .l f t h e clearance more than the servicelimit, go to is steD5. Standard: 0.06 0.16 mm (0.002 0.006in.) ServiceLimit: 0.25mm {0.010in.l

Standard:

23.03 23.08 mm (0.907 0.909 in.l

(cont'd)

13-31

Transmission Manual
AssemblyClearance Countershaft Inspection(cont'd)
of 5. Measurethe th ickness the distancecollar. . l f t h e t h i c k n e s ss n o t w i t h i nt h e s t a n d a r dr,e p l a c e i the distancecollar with a new one. . l f t h e t h i c k n e s ss w i t h i n t h es t a n d a r dg o t o i , step 6. Standard: 28.03 28.08mm {1.104-1.106in.)

Countershaft Disassembly
1 . Securelyclamp the countershaft assemblyin a benchvlse with wood blocks.

Removethe specialbolt (left-hand threads). Supportthe ball bearing(A) on steel blocks,then use a press (B)and an attachment(C)to pressthe countershaft of the ball bearing. out 6. Measurethe thicknessof the 2nd qear. . l f t h e t h i c k n e s o f 2 n dg e a r i sl e s s t h a n h e t s servicelimit, replace2nd gear with a new one. . l f t h e t h i c k n e s s o2 n d g e a r i s w i t h i n t h e s e r v i c e f synchro hub with a new limit, replacelhe 1sV2nd one. 27-92-21.97 mm|.1.099 1.r01 in.l Standard: in.) ServiceLimit: 27.87mm 11.097

c 4 . R e m o v e h e 3 5 m m s h i m a n dd i s t a n c e o l l a r . t

I
13-32

Countershaftlnspection
5. Support gear(A)on steelblocks, 4th thenusea (B) press andan attachment to press the (C) countershaft out ofthe 5thgear.
1. Inspectthe gear surfaceand bearingsurfacefor w e a r a n d d a m a g e t h e n m e a s u r eh e c o u n t e r s h a f t , t at pointsA, B, and C. lf any part of the countershaft is lessthan the servicelimit, replaceit with a new one. Standard: A Ballbearingsurfaceltransmissionhousingsidel: 3 0 . 0 2 0 3 0 . 0 3 3m m { 1 . 1 8 1 9 1 . 1 8 2 4 i n . ) B Distancecollar surface; 39.937- 39.950mm 11.5723 1.572A in.l C Needlebearingsurface(clutchhousingside): 3 5 . 0 0 0 3 5 . 0 1 5 m { r . 3 7 8 0 - 1 . 3 7 8 5n . ) m i Service Limit: A : 2 9 . 9 7 m { 1 . 1 8 0n . ) m i B: 39.88mm {1.570in.l C: 34.95mm {1.376in.) 6 . Support2nd gear (A) on steel blocks,then use a Dressand an attachment{B}to pressthe (C) countershaft out of the 3rd gear.

2 . lnspectthe runout by supportingboth ends of lhe


countershaft. Rotatethe countershaft two complete revolutionswhen measuringthe runout. lf the runout exceedsthe serviceIimit, replacethe countershaft with a new one. Standard: ServiceLimit: 0.02mm (0.001in.) max. 0.05mm (0.002in.)

13-33

Transmission Manual
Reassembly Countershaft
View Exploded

SPECIAL BOLT Eeplace. ( 1 2k g fm ,8 7l b ff t ) 118 .m N


BALL BEARING Checkfor wear and operation. Note the directionof installation. 35 mm SHIM ANCE COLLAR

REVERSE GEAR 1ST/2ND SYNCHRO HUB


SPRING TRIPLECONESYNCHRO

GEAR 4THGEAR

1ST GEAR

NEEDLE BEARING Check wear for anoopera!on. DISTANCE COLLAR

Check wear and for operation. DISTANCECOLLAR DAMPER FRICTION Checkfor wear and damage.

(
COUNTERSHAFT
TRIPLECONESYNCHRO

SYNCHROSPRING

13-34

ToolsRequired Special . Driver, mm l.D.07746-0030100 40 . Aftachment.30 07746-0030300 mm NOTE: Refer the Exploded to Viewas needed during lhis procedure. 1. Clean partsin solvent, them,andapply all dry lubricantto contact all surfaces.
I n s t a l l t h e i s l a n c e o l l a r , e e d l e e a r i n ga n d 1 s t n d c b , gear onto the countershaft.

6 . I n s t a l l t h e y n c h r o p r i n g( A ) . s s

3 . Installthe triple cone synchroassembly(A) by

'lst gear aligningthe synchrocone fingers (B)with grooves(C),then installthe synchrospring {D). 1 . lnstallthe triple cone synchroassembly(B) by aligningthe synchrocone fingers (C)with the 1sv2ndsynchro hub grooves(D). 8 . Installthedistancecollar (A) and friction damper (B) by aligningthe friction damper fingers (C)with the 1sv2ndsynchro hub grooves(D).

'1st/2nd Installthe s y n c h r o u b ( A )b y a l i g n i n g h e h t synchrocone fingers (B)with 1sV2ndsynchrohub grooves(C).

g r 5. Installtheeverse ear.

(cont'd)

13-35

ManualTransmission
(cont'dl Reassembly Countershaft
9 . I n s t a ltl h e n e e d l e e a r i n g . b l 1 2 . I n s t a ltlh e 4 t h g e a r( A )u s i n gt h e s p e c i a l t o oa n d a press(B).Do not exceedthe maximum pressure. B 14,700 {1,500 N kgt, lbf) 3,307 max. 07746-0030100

L,

1 0 .I n s t a l l t h e n d g e a r( A )b y a l i g n i n g h e s y n c h r o 2 t
cone fingers (B)with znd gear grooves(C).

'l

(A) 1 . Supoortthe countershaft on the steel blocks, g e a r( B )u s i n gt h e s p e c i atlo o l t h e n i n s t a ltl h e 3 r d and a press(C).Do not exceedthe maximum Dressure.
14,700 (1,500 N kgf, 3,307lbflmax.

I n s t a l l t h e t h g e a r( A )u s i n gt h e s p e c i atl o o l a n d a 5 press(B).Do not exceedthe maximum pressure.


kgl, 14,700 (1.500 N 3.307lbf) max. 07746-0030100

07746-0030100

13-36

1 4 . I n s t a ltlh e d i s t a n c e o l l a r( A ) ,3 5 m m s h i m ,a n d o l d c ball bearing(B)using the specialtools and a press

(c).

16. lf the clearance more than the standard, is selecta new shim from the following table. lf the clearance measuredin step 15 is within the standard,replace o n l yt h e b a l lb e a r i n g . 35 mm Shim

c
F

D E

11

K L M
N

o
t5.

R
Measurethe clearance betweenthe old bearing(A) a n dt h e 3 5 m m s h i m ( B )w i t h a f e e l e rg a u g e( C ) . Standard: 0.04 0.10mm 10.002 0.004in.)

PartNumber Thickness n 23981-PPP-0000.87mm (0.0343 . 23981-PPP-9000 . 9 1 m { 0 . 0 3 5 8 , m n 23982-PPP-0000 . 9 5 m ( 0 . 0 3 7 4 . m n 23982-PPP-9000.99mm (0.0390 , n m 23983-PPP-0001 . 0 3 m 1 0 . 0 4 0n , 6 23983-PPP-9001 . 0 7m m ( 0 . 0 4 2 1n . 1 23984-PPP-0001 . 1 m m ( 0 . 0 4 3 7 . n 23984-PPP-9001 . 1 5 m ( 0 . 0 4 5 3 . m n m 23985-PPP-0001 . ' 1 9 m ( 0 . 0 4 6 9n . m n 23985-PPP-9001 . 2 3 m ( 0 . 0 4 8 4 m n 23986-PPP-0001 . 2 7 m ( 0 . 0 5 0 0 . i 23986-PPP-9001 . 3 1m m ( 0 . 0 5 1 6n . i 23987-PPP-0001 . 3 5m m ( 0 . 0 5 3 1n . n 23987-PPP-9001 . 3 9m m ( 0 . 0 5 4 7 . i 23988-PPP-0001 . 4 3m m ( 0 . 0 5 6 3n . i 23988-PPP-9001 . 4 7m m ( 0 . 0 5 7 9n
i 23989-PPP-000 1 . 5 1m m ( 0 . 0 5 9 4n i 23989-PPP-900 1 . 5 5m m ( 0 . 0 6 1 0n

T U X
Y

m n 23990-PPP-0001 . 5 9 m { 0 . 0 6 2i6 . m n 23990-PPP-9001 . 6 3 m { 0 , 0 6 4i2 . i 23991-PPP-0001 . 6 7m m ( 0 , 0 6 5 7n


i 23991-PPP-900 1 . 7 1m m { 0 . 0 6 7 3n i 23992-PPP-0001 . 7 5m m ( 0 . 0 6 8 9n 23992-PPP-9001 . 7 9m m ( 0 . 0 7 0 5n i

AB
AC

AD AE
AF

m n 23993-PPP-0001 . 8 3 m ( 0 . 0 7 2i0 i 23993-PPP-9001 . 8 7m m ( 0 . 0 7 3 6n m i 23994-PPP-000' 1 . 9 1 m ( 0 . 0 7 5 2n


i 23994'PPP-900 1 . 9 5m m ( 0 . 0 7 6 8n . i 23995PPP-000 1 . 9 9m m ( 0 . 0 7 8 3n .

{cont'd)

13-37

ManualTransmission
(cont'd) Countershaft Reassembly
(A) (B), 1 1 . Support ballbearing on steelblocks then (C) (D) usea press andan attachment to press the (E) countershaft out of the ballbearing.
20. Tightenthe new specialbolt (A) (left-hand threads).

'l18 N.m (12kgf.m, 87 tbf.ftl

1 8 . l f n e c e s s a r yn s t a l l t h e 5 m m s h i m s e l e c t e dn i, 3 i step 16,then recheck clearance, the 1 9 . Installthe distancecollar (A).35 mm shim, and new ( b a l l b e a r i n g B )u s i n gt h e s p e c i a l t o o l a n d a p r e s s s

(c).

46-0030r00

13-38

SynchroSleeveand Hub Inspection and Reassembly


1. lnspectthegearteeth on ali synchro hubs and synchrosleevesfor roundedoff corners,which indicatewear. 2. Installeach synchrohub (A) in its mating synchro sleeve(B),and checkfor freedom of movement.Be sure to match the three sets of longerteeth (C)(120 degreesapart)on the synchrosleevewith the three sets of deepergrooves(D) in the synchrohub. Do not installthe synchrosleevewith its longerteeth in the 1sv2ndsynchrohub slots (E)becauseit will t d a m a g e h e s p r i n gr i n g . is NOTE;lf replacement required,always replace the svnchrosleeveand svnchrohub as a set.

SynchroRingand GearInspection
1 . Inspectthe insideof each synchroring (A) for wear. Inspectthe teeth (Bi on each synchro ring for wear (roundedoff).

Exampleof synchroring teeth

I
GOOD

I
WORN

Inspectthe teeth (C)on each synchrosleeveand matchingteeth on each gear for wear (roundedoff).

Exampleof synchro sleeve teeth and gearteeth

t
GOOD WORN

\
(cont'd)

13-39

Manual Transmission
SynchroRing and GearInspection(cont'dl
3. Inspectthe thrust surface{D)on each gear hub for wear. 7. Measurethe clearance betweeneach gear (A) and i t s s y n c h r o i n g ( B )a l l t h ew a y a r o u n d . o l dt h e r H synchroring againstthe gear evenlywhile measuringthe clearance. the clearance less lf is than the servicelimit, replacethe synchro ring and gear. Synchro Ring.to.Gear Clearance Standard: 0.70 1.49mm 10.028 0.059in.) ServiceLimit: 0.4 mm {0.016in.) Triple Cone Synchro-to-Gear Clearance Slandard: O: Outer Synchro Ring {B}to SynchroCone (Cl 0-70 1.19mm (0.028-0.047in.) @: Synchro Cone lC) to cear (A) 0.50- 1.04mm (0.020-0.041in.) O: Outer Synchro Ring (B) to Gear (Al 0.95 1.68mm 10.037 0.066in.) ServiceLimit: O: 0.3 mm (0.012in.) : 0.3 mm (0.012in.) in.l O; 0.6 mm 10.024

Inspectthe cone surface(E)on each gear hub for wear ano rougnness. Inspectthe teeth on all gears(F)for unevenwear, , s c o r i n gg a l l i n g a n d c r a c k s . , Coatthe cone surfaceof each gear (E)with oil, and placeits synchro ring on it. Rotatethe synchroring, m a k i n gs u r et h a t i t d o e sn o t s l i p .

13-40

Bearing Mainshaft and Oil SealReplacement


Special Tools Required . O i l s e a ld r i v e r0 7 J A D - P 1 9 0 1 0 0 . Adjustable earing uller,20 40mm p b 07736-4010008 . Driver07749-0010000 . Attachment,42x 47 mm 07746-0010300 . S l i d eh a m m e r , o m m e r c i a l l a v a i l a b l e c y assembly, 1. Removethe differential ( 2 . R e m o v e h e b a l l b e a r i n g A ) f r o mt h e c l u t c h t ( l h o u s i n g B )u s i n gt h e s p e c i a l t o oa n d a 3 c o m m e r c i a l la v a i l a b l e / 8 " - l 6 s l i d eh a m m e r( C ) . y
4 . Drive the new oil seal in from the transmissionside

using the specialtools.

07749-0010000 07746-0010300

Drivethe new ball bearing(A) in from the t r a n s m i s s i o s i d eu s i n gt h e s p e c i a l t o o l . n

Removethe oil seal (A) from the clutch side. Be carefulwhen removingthe seal so the clutch i h o u s i n g s n o td a m a g e d .

13-41

ManualTransmission
Countershaft BearingReplacement
Special Tools Required . Adiustablebearingpuller,20-40 mm 07736-A0tOOOB . Oil seal driver 07JAD-AP190100 . S l i d eh a m m e r ,c o m m e r c i a l l a v a i l a b l e y 1. Removethe bearingset plate (A)from the clutch h o u s i n g( B ) . 3. Positionthe oil guide plate C and new needle bearing(A) in the bore of the clutchhousing(B).

I n s t a l l t h e e e d l e e a r i n g s i n gt h e s p e c i a l t o o l . n b u Installthe bearingset plate (A)wirh bolts (B). Removethe needlebearing(A) usingthe special tool and a commerciallyavailable3/8" - 16 slide hammer (B),then removethe oil guide plate C. B 6x 1.0 n n 12N.m kgt m, {1.2

8.7 tbf.ft)

07736-A010008

13-42

Adiustment MainshaftThrust Clearance


Special Tools Required . Mainshaftbase07GAJ-PG20130 . M a i n s h a fh o l d e r0 7 G A J - P G 2 0 1 1 0 t 1 . R e m o v e h e 7 2 m m s h i m ( A )a n d o i l g u i d ep l a t eM t from the transmissionhousing(B).

5 . Measuredistance@ betweenthe end of the clutch


( i h o u s i n g A )a n d t h e b e a r i n g n n e rr a c e( B ) w i t ha straightedge and depth gauge.Measureat three locationsand averagethe readings. A

,5---o v/

Shim Selection Formula: Installthe3rd/4thsynchrohub (A),the distance h c t c o l l a r( B ) , h e 5 t h s y n c h r o u b { C ) .d i s t a n c e o l l a r ( ( D ) ,a n d b a l l b e a r i n g E )o n t h e m a i n s h a f(t F ) , h e n t m a i n s t a l l t h e s s e m b l e d a i n s h a fitn t h e t r a n s m i s s i o n ( housing G). 6, Selectthe proper 72 mm shim from the chan. Follow the examplebelow, and use the you made in steps4 and 5: measurements (Basic ormula) F ( ( 0 . 8* 0 . 1 1 ) s h i m t h i c k n e s sm a x i m u m ) = O+@ ( ( 0 . 8+ 0 . 1 7 ) s h i m t h i c k n e s sm i n i m u m ) = + O O . Add distanceO (step5) to distanceO (step4) . 0 . 8m m ( 0 . 0 3 1n ) :S p r i n gw a s h e r , d i m e n s i o nn i a i the installation. . 0 . 1 1m m ( 0 . 0 0 4n ) :l v l i n i m u mh r u s tc l e a r a n c e t i . 0 . 1 7m m ( 0 . 0 0 7n ) :M a x i m u mt h r u s tc l e a r a n c e . i ( F o re x a m p l e ) i 2 . 3 2+ 0 . 1 5- ( 0 . 8+ 0 . 1 1 ) =1 . 5 6m m ( 0 . 0 6 1n . ) i 2 . 3 2+ 0 . 1 5- ( 0 . 8+ 0 . 1 7 ) =1 . 5 0m m ( 0 . 0 5 9n . ) T a k et h e m i d d l ev a l u eo f t h e m i n i m u mv a l u ea n d t h e m a x i m u mv a l u e ,a n d s e l e c t h e 1 . 5 3m m ( 0 . 0 6 0n . )s h i m . i

lnstallthe washer (H) on the mainshaft. MeasuredistanceO betweenthe end of the transmissionhousingand washerwith a straight edge and verniercaliper.Measureat three locationsand averagethe reading.

{cont'd)

13-/li|

ManualTransmission
MainshaftThrust Clearance Adjustment (cont'dl
72 mm Shim

c
F

D E J

L
M N

o
P

o
R

T U
X

z
AB
AC

AD AE
AF AG AH AI AJ

AK
AL

AM
AN

PartNumber Thickness 2 3 9 3 1 - P 2 1 - 0 0 0 . 6 0 m { 0 . 0 2 3i6 . ) 0 m n 23932-P21-000 0.63mm (0.0248 in. 2 3 9 3 3 - P 2 1 - 0 0 0 . 6 6 m ( 0 . 0 2 6i0 . 0 m n 2 3 9 3 4 - P 2 1 - 0 0 0 . 6 9m m ( 0 . 0 2 7 1n . 0 i 23935-P21-000 0 . 7 2 m ( 0 . 0 2 8i3 . m n 23936-P21-000 0 . 7 5 m ( 0 . 0 2 9i5 . m n 23931-P21-000 0 . 7 8 m ( 0 . 0 3 0i7 . m n 23938-P2'l-000 0 . 8 1 m ( 0 . 0 3 1i9 m n 23939-P21-000 0 . 8 4 m ( 0 . 0 3 3i1 m n 23940-P21-000 0 . 8 7m m { 0 . 0 3 4 3n , i 23941-P21-000 0.90 mm (0.0354 in. 23942.P21-000 0.93mm (0.0366 in. 23943-P21-000 0 . 9 6 m ( 0 . 0 3 7i8 . m n .000 23944-P21 0 . 9 9 m ( 0 . 0 3 9i0 . m n 23945-P21-000 1 . 0 2 m ( 0 . 0 4 0i2 . m n 23946-P21-000 1 . 0 5m m ( 0 . 0 4 1 3n . i 23941-P2't-000 'l.08mm (0.0425 in 23948-P2'l-000 ' 11 m m { 0 . 0 4 3i7 . 1 n 23949-P21-000 ' 1 . 1 4 m ( 0 . 0 4 4 9n m i 23950-P21-000 1 . 1 7m m { 0 . 0 4 6 1n . 23951-P21-000 1.20 mm 10.0472. n 23952-P21-000 1.23mm (0.0484n . 23953-P21-000 1 . 2 6 m { 0 . 0 4 9 6 . m n 23954-P21-000 1 . 2 9m m ( 0 . 0 5 0 8n . 23955-P21-000 1 . 3 2 m ( 0 . 0 5 2 0 . m n 23956-P21,000 1 . 3 5 m ( 0 . 0 5 3i1 m n 23957-P21-000 1 . 3 8 m ( 0 . 0 5 4i3 m n 23958-P21-000 1 . 4 1m m ( 0 . 0 5 5 5n 23959-P21-000 1 . 4 4 m ( 0 . 0 5 6 7 . m n 23960-P21-000 1.47mm (0.0579n . 2 3 9 6 1 - P 2 1 - 0 0 0 . 5 0m m ( 0 . 0 5 9 1 . 1 n 23962-P21-OOO 1 . 5 3 m ( 0 . 0 6 0 2 . m n 23963-P21-000 1 5 6 m m ( 0 . 0 6 1 4n . 23964-P21-000 1 . 5 9m m ( 0 . 0 6 2 6n . 23965-P21-000 1 . 6 2m m ( 0 . 0 6 3 8n i 23966-P21-000 1 . 6 5 m ( 0 . 0 6 5i0 m n 23967-P21-000 1 . 6 8 m ( 0 . 0 6 6i1 m n -000 1 . 7 1 m ( 0 . 0 6 7i3 . 23968-P2r m n 23969-P21-000 1 . 7 4 m ( 0 . 0 6 8i5 . m n 2397 0-P21-000 1 . 7 7 m ( 0 . 0 6 9i7 . m n
2 3 9 7 1 - P 2 ' t - O O O . 8 0m m ( 0 . 0 7 0 9n . 1 i

7 . I n s t a l l t h e 2 m m s h i m ( A )s e l e c t e d n d o i l g u i d e 7 a p l a t eM i n t h e t r a n s m i s s i o h o u s i n g B ) . ( n

,6,,-o V

8 . Thoroughlycleanthe spring washer (A) and


washer (B) before installing them on the clutch h o u s i n g i d eb a l l b e a r i n g C ) .N o t et h e i n s t a l l a t i o n s { directionof the spring washer.

9 . l n s t a l l t h e a i n s h a fitn t h e c l u t c hh o u s i n g . m

1 0 .Placethe transmissionhousingover the mainshaft


and onto the clutchhousing. 1 1 .Tightenthe clutchand transmissionhousingswith several8 mm bolts. NOTE:lt is not necessary use sealingagent to betweenthe housings.

AO

12. Tap the mainshaftwith a plastichammer.

13-44

13. Attachthe specialtool to the mainshaftas follows: . B a c k - o ut th e m a i n s h a fh o l d e rb o l t{ A )a n d l o o s e n t the two hex bolts (B). . Fit the holderover the mainshaftso its lip is towards the transmission. . Align the mainshaftholder'slip aroundthe groove at the insideof the mainshaftsplines, then tightenthe hex bolts.

1 6 . Z e r oa d i a l g a u g e{ A )o n t h e e n d o f t h e m a i n s h a f t .

07GAJ-PG20130 stop 1 7 . Turn the mainshaftholder bolt (B)clockwise; turning when the dial gauge (A) has reachedits maximum movement.The readingon the dial gauge is the amount of mainshaftend play NOTE:Do not turn the mainshaftholder bolt more than 60 degreesafter the needleof the dial gauge stops moving,this may damagethe transmission. the 1 8 .lf the readingis within the standard, clearance Threadthe mainshaftholder bolt in until it just contactsthe wide surfaceof the mainshaftbase. is correct.lf the readingis not within the standard, recheck shim thickness. the Standard:0.11-0.17 mm (0.004 0.007in.)

07GAJ-PG20130

1 4 . Seatthe mainshaftfully by tapping its end with a plastic ammer. h

13-45

ManualTransmission
Transmission Reassembly
N O T E : r i o r t or e a s s e m b l i n g , e a na l l t h e p a r t si n P cl solvent,dry them, and apply lubricantto any contact surfaces. 1. Installthe magnet (A) and differential assembly(B). 4. Installthe reverseshift fork.
6x1.0mm 15 N.m (1.5kgf.m,11 lbf.ft)

n-",-o
l;-D

f.)
Installthe reverseidler gear (A) and reversegear s h a f t( B )b y a l i g n i n g h e m a r k{ C ) w i t ht h e r e v e r s e t g e a rs h a f th o l e( D ) .

Installthe 28 mm spring washer (A) and 28 mm washer (B) over the ball bearing(C).Note the installation directionof the spring washer {A).

Apply vinyl tape to the mainshaftsplines(D)to p r o t e c t t h e e a l .I n s t a l l t h e a i n s h a fa n d s m t (E) countershaft into the shift forks {F}.and install themas an assembly.

13-46

l r 6 , l n s t a l l t h e e v e r s eo c kc a m .
z/ --' t - 2 6 x 1 , 0m m / 15 N.m / {1 5 kgf m, 11 tbf.ft) I

Fl g

8. Removethe dirt and oil f rom the tramsmission ( h o u s i n g e a l i n g u r f a c eA p p l y l i q u i dg a s k e t P / N s s . to the sealingsurface.Be sure to seai 08718-0001) of the entirecircumference the bolt holesto preventoil leakage. NOTE:lf 5 minuteshave passedafter applying liquid gasket,reapplyit and assemblethe housings. Allow it to cure at least20 minutesafter assembly with oil. beforefilling the transmission

7 . Selectthe proper size72 mm shim (A) accordingto made during the Mainshaft the measurements '13-43), Adjustment(seepage Thrust Clearance , o I n s t a l l t h e i l g u t t e rp l a t e( B ) ,o i l g u i d e p l a t el \ 4 a n d ( n 7 2 m m s h i m i n t ot h e t r a n s m i s s i o h o u s i n g C ) .

- -

-Liquid gasket

{cont'd)

13-47

Manual Transmission
(cont'dl Transmission Reassembly
9 . I n s t a ltlh e 1 4x 2 0 m m d o w e lp i n s( A ) .
34 N.m (3.5 kgf.m, 25 rbf.ft)

(
11. Lowerthe transmissionhousingthe rest of the way as you expandthe 72 mm snap ring {C).Release the snap ring so it seatsin the groove of the countershaft bearing. 12. Checkthat the 52 mm snap ring is securelyseated in the groove of the countershaft bearing. DimensionO as instalted: 3.3 6.0 mm { 0 . 1 3 0 . 2 4i n . l

1 3 .Apply liquid gasket(P/N08718-0001) the threads to


o f t h e 3 2 m m s e a l i n g a p { D ) ,a n d i n s t a l i t o n t h e c l transmissiohousing, n

't4.

I n s t a ltl h e t r a n s m i s s i o h a n g e r s . a n d B , a n d t h e n A 8 mm flange bolts finger-tight.

\A

e./
./
1 5 . Tightenthe 8 mm flange bolts in a crisscross PatternIn severalsteDs.
8 x 1.25mm 27 N.m (2.8kgf.m. 20 rbf.ft)

1 0 .Set the taperedcone ring (B)as shown. Placethe


transmissionhousingover the clutch housing, being carefulto line up the shafts.

(t

13-48

16. Removethe dirt and oil from the shift iever cover ( s e a l i n g u r f a c eA p p l y l i q u i dg a s k e t P / N0 8 7 1 8 s . 0001)to the sealingsurface. NOTE:lf 5 minuteshave passedafter applylng liquid gasket.reapplyit and assemblethe housings. Allow it to cure at least20 minutesafter assembly b e f o r e i l l i n gt h e t r a n s m i s s i ow i t h o i l . f n

1 9 . I n s t a l l t h e r a i np l u g( A ) ,f i l l e rp l u g ( B ) ,a n d 1 0 m m d f l a n g eb o l t ( C )w i t h n e w w a s h e r s .

@ Ut !?iJl'.'l,''
R\-: \
A 39Nm (4.0 kgf m, 33 tbl.ft)

/..l-.=,'-B g ^

44N.m

-.-t

?0,,.ru ^

44 N m {4.5kgt m,33lbf.ft}

20. Installthedetent bolts (A),spring,and steel balls


with new washers. - -Liquidgasket

1 7 . I n s t a l l t h e x 1 4 m m d o w e lp i n s( A ) .c l u t c hl i n ec l i p 8 ( l b r a c k e ( B ) ,a n d c h a n g e e v e ra s s e m b l y C ) . t

{3.0kgf.m.22lbf.ft)

h 2 1 . A p p l y l i q u i dg a s k e t P / N0 8 7 1 8 - 0 0 0 1 } t o e t h r e a d s { l l o i t h e b a c k - u pi g h ts w i t c h( B ) ,a n d i n s t a l i t i n t h e transmissiohousing. n
6x1.0mm

kgf.m,9lbt ft) 12N.m(1.2

( N 1 8 . A p p l y l i q u i dg a s k e t P i 0 8 7 1 8 - 0 0 0 t o t h e t h r e a d s 1) of the interlockbolt (D),and installit on the transmissiohousing. n

(cont'd)

13-49

Manual Transmission
(cont'dl Transmission Reassembly
22. Installthevehiclespeedsensor(VSS){A)and O - r i n g( B ) .

22 N.m (2.2kgf.m,r6 lbf.ft)

13-50

GearshiftMechanismReplacement
KNOB --SHIFT LEVER 8 N m {0.8ksr.m.5.8lbf.ft}

8 x 1.25mm 22 N.m (2.2 kgf.m, 16 lbt ftl

,.-,'-'

l'/

HOUSING SHIFTLEVER

{P/N 08798-9002}

SHIFT CABLE CLIP Replace.

r-Ll Rotatethe shift cable t o w a r dt h e o p e n i n g .

6x1.0mm 9.8Nm (1.0kgf.m, 7.2 tbf.fr) COTTERPINS {P/N 08798-9002) qrBemovethe shift cable from the shift leverbracket.

13-51

M/T Differential
ComponentLocationIndex
\ (

DRIVENGEAR page 13-53 Beplacement,

\
Backlash Insoection. oaoe 13-53 paoe I 3-5-3 Feplacemeni,

,<-=-

I \c1
\ =

l/

,/

,/BALL BEARING page 13-54 Beplacemenl,

13-52

Backlash lnspection
1 . Placethe differential assemblyon V-blocks(A),and installboth axles.

FinalDrivenGear/Carrier Replacement
1. Removethe bolts (left-hand threads)in a crisscross patternin severalsteps,then removethe final driven gear (A)from the differential carrier{B).

\tt

1 2 1N m (12.3kgf m, 89 rbt.ft)

x t . om m { t o )

M e a s u r eh e b a c k l a s h f b o t h p i n i o ng e a r s( B )w i t h t o a dial indicator(C).lf the backlashis not within the standard,replacethe differential carrier. Standard(New):0.05 0.15mm (0.002 0.006in.) Installthe final driven gear with the chamferon the i n s i d ed i a m e t e f a c i n gt h e c a r r i e rA l i g nt h e m a r k s r . t o n t h e f i n a ld r i v e ng e a ra n d t h e c a r r i e rT i g h t e n h e . patternin severalsteps. bolts in a crisscross

13-53

M/T Differential
CarrierBearingsReplacement
Special Tool Bequired Driver,40 mm l.D.07746-0030100 1. Checkthe carrierbearingsfor wear and rough rotation.lf they rotatesmoothly and their rollers show no signs of wear, the bearingsare OK, 2. Removethe carrierbearing(A) with a p c o m m e r c i a l l y - a v a i l a b le a r i n g u l l e r( B ) . be 3. Installthe new bearings(A)with the specialtool and a press.Presseach bearingon until it bottoms. There should be no clearance betweenthe bearinos and the carrier. NOTE: Turn the sealed(B)side of the bearingaway from the differentialtoinstallit.

077i16-0030100

07746-0030100

13-54

Oil SealReplacement
Special Tools Required . Driver07749-0010000 . Oil seal driver attachment07NAD-P20A100 1. Removethe differential assembly. 2. Removethe oil seal (A) from the transmission ( housing B). 4 . I n s t a l l t h e e w o i l s e a li n t h e t r a n s m i s s i o h o u s i n q n n with the specialtools.

n w 5 . I n s t a l l t h e e w o i l s e a li n t h e c l u t c hh o u s i n g i t h the specialtools.

( 3 . R e m o v e t h e o i s e a l( A )f r o m t h e c l u t c hh o u s i n g B ) . l

13-55

M/T Differential
Differential Thrust Clearance Adjustment
SpecialToolRequired Driver.40 mm LD.07746-0030100 1 . I n s t a la n 8 0 m m s h i m t h a t ' st h e s a m es i z ea s t h e l one you removeo. Installthe transmissionhousingonto the clutch housing,then tightenthe 8 mm flange bolts in a patternin severalsteps(seestep 15 on crisscross page 13-48). 8 x 1 . 2 5m m 27 N m (2.8 kgf'm, 20 lbf.ft) Use the specialtoolto bottom the differential i a s s e m b l yn t h e c l u t c hh o u s i n g .

00746-0030100

2 . Installthe differentialassemblyinto the clutch


housing.

5 . Measurethe clearance betweenthe 80 mm shim a n d b e a r i n g u t e rr a c ei n t h e t r a n s m i s s i o h o u s i n g . o n Standard:0 0.10mm l0 0.004in.)

-i.

w
.t

-- --

..1

:,- -=.

13-56

6. lf the clearanceis more than the standard,selecta n e w s h i m f r o m t h e f o l l o w i n g a b l e .l f t h e c l e a r a n c e t m e a s u r e dn s t e p5 i s w i t h i nt h e s t a n d a r dg o t o i , step 9. 80 mm Shim Part Number

c
F
rt

Thickness 4 1 4 4 1 L 3 - 8 0 0 1 1 . 0m m ( 0 . 0 3 9 4 . P n 41442-PL3-B001 1 mm (0.0433. n 4 1 4 4 3 - P L 3 - 8 0 0 1 1 . 2m m ( 0 . 0 4 7 2 . n


4 1 4 4 4 - P L 3 - B 0 0 1 1 . 3m m { 0 . 0 5 1 2 . n 4 1 4 4 5 - P L 3 - 8 1 0 1 . 4m m 1 0 . 0 5 5 1 . 0 n 4 1 4 4 6 - P L 3 - 8 0 0 1 1 . 5m m { 0 . 0 5 9 1n . 4 1 4 4 7 - P L 3 - 8 0 0 1 . 6m m ( 0 . 0 6 3 0n . 1 4 1 4 4 8 - P L 3 - B 0 0 1 1 . 7m m { 0 . 0 6 6 9n . 4 1 4 4 9 - P L 3 - 8 0 0 1 . 8m m ( 0 . 0 7 0 9n . 41450-PL3-8000 . 0 5m m ( 0 . 0 4 1 3n . ) 1 4 1 4 5 1 - P L 3 - 8 0 0 01. 1 5m m ( 0 . 0 4 5 3n . l 41452-PL3-8000 . 2 5m m ( 0 . 0 4 9 2n . l 1 41453-PL3-8000 1 . 3 5m m ( 0 . 0 5 3 ' ln . ) 41454-PL3-8000 . 4 5m m ( 0 . 0 5 7 1n . l 1 41455-PL3-8000 . 5 5m m ( 0 . 0 6 1 0n . ) 1 41457-PL3-8000 1 . 7 5m m ( 0 . 0 6 8 9n . ) i

D E

tvl
N P

o
R

' 5 41456-PL3-8000 1 . 6m m ( 0 . 0 6 5i0 . ) n

7 . R e m o v e h e b o l t sa n dt r a n s m i s s i o h o u s i n g . t n 8 . Replace thrust shim selectedin step 6, then the recheck clearance. the 9 . R e i n s t at h e t r a n s m i s s i o n . ll

13-57

Driveline/Axle
............. 16-2 SpecialTools ......................... 16-3 Driveshaft Inspection Driveshafts Removal .......................... 16-3 ................... 16-5 Driveshafts Disassembly Dynamic Damper Replacement ........ 16-8 .................... 16-9 Driveshafts Reassembly ...................... 16-17 Driveshafts lnstallation .............. 16-19 lntermediate ShaftRemoval Intermediate ................................. 16-20 ShaftDisassembly lntermediate .................................. 16-22 ShaftReassembly 16-24 lntermediate Shaftlnstallation ....................................

Driveline/Axle
SpecialTools
Ref. No.

L
DescriDtion O i l S e a lD r i v e r B a l l J o i n tR e m o v e r2 8 m m , Half Shaft Base ThreadedAdapter,22 x 1.5mm Attachment,52 x 55 mm u f l v e r ,J 5 m m L U . Driver O i l S e a lD r i v e r

n]
@

o
t9

6)

(D

ToolNumber 07GAD-PH70201 07MAC-S100200 0 7N A F - S R 3 0 1 0 1 07xAc-001010A 07746-0010400 07746-0030400 07749-0010000 07947-S800100

Orv
1 1 1 1 1 1 1 1

t g[]

r?) \J
,0)

\*

16-2

Driveshaft Inspection
1. Checkthe inboardboot (A) andthe outboardboot (B)on the driveshaft(C)for cracks,damage,leaking grease,and loose boot bands (D).lf any damageis found, reDlace boot and boot bands. the

Driveshafts Removal
Special Tool Required B a l l j o i n tr e m o v e r 2 8 m m 0 7 M A C - S 1 0 0 2 0 0 , 1. Loosenthe wheel nuts slightly 2. Raisethe front of the vehicle,and support it with safetystandsin the proper locations(seepage 1-8). 3. Removethe wheel nuts and front wheels.

Turn the driveshaftby hand,and make sure the splines(E)and joint are not excessively loose. Make sure the driveshaftis not twisted or cracked; if it is, replaceit.
4 . Lift up the lockingtab (A) on the spindle nut (B),

then removethe nut. lf the !eft driveshaftor the intermediate shaft is to be removed,drain the transmissionfluid. Reinstall t h e d r a i np l u g u s i n ga n e w w a s h e r( s e ep a g e1 3 - 3 ) . H o l dt h e s t a b i l i z eb a l l j o i n tp i n ( A )w i t h a h e x r wrench {B),and removethe flange nut (C). the front stabilizerlink (D)from the lower Separate ar m .

(cont'd)

16-3

Driveline/Axle
Driveshafts Removal(cont'd)
7 . R e m o v e h e l o c kp i n { A ) f r o mt h e l o w e ra r m b a l l t joint castlenut (B),and removethe nut. NOTE: . T o a v o i dd a m a g i n g h e b a l l j o i n t ,i n s t a l a h e x n u t t l on to the threadsof the ball joint, . Be carefulnot to damagethe balljoint boot when installingthe remover. 10. Left driveshaft: Pry the inboardjoint (A)from the differential casewith a prybar.Rightdriveshaft: Drivethe inboardjoint (A) off of the intermediate shaft with a drift and hammer. Removethe driveshaftas an assembly.Do not pull on the driveshaft(B),because the inboardjoint may come apart.Draw the driveshaftstraightout to avoid d a m a g i n gh e o i l s e a l . t Left driveshaft:

t
07MAC-S100200

w^ 'e

.."8

Separate the ball joint from the lower arm (C)with the specialtool (seestep 3 on page 18-19). Be carefulnot to dislodgethe lower ball joint from the knuckle. 9 . Pullthe knuckleoutward,and removethe driveshaftoutboardjoint from the front wheel hub u s i n ga p l a s t i c a m m e r . h

Right driveshaft:

16-4

Driveshafts Disassembly
Special Tools Required . T h r e a d e d d a D t e r . 2 x 1 . 5m m 0 7 X A C - 0 0 1 0 1 0 A a 2 . S l i d eh a m m e r , o m m e r c i a l l a v a i l a b l e c y . Boot band pincers,commerciallyavailable

Inboard Joint Side:


1. Removethe set rlng from the inboardjoint.

Low Profile Type

Removethe boot bands.Be carefulnot to damage the boot and dynamic damper. . lf the boot band is a welded type (A),cut the boot b a n d( B ) . . lf the boot band is a double loop type (C),lift up t h e b a n db e n d( D ) ,a n d p u s hi t i n t ot h e c l i p ( E ) . . lf the boot band is a low profiletype (F),pinch the b o o t b a n du s i n ga c o m m e r c i a l l a v a i l a b l e o o t y b ( b a n dp i n c e r s G ) . Welded Type

(cont'd)

16-5

Driveline/Axle
Driveshafts Disassembly {cont'd)
j M a k ea m a r k( A )o n e a c hr o l l e r( B )a n d i n b o a r d o i n t (C)to identifythe locationsof rollersand grooves j j i n t h e i n b o a r d o i n t .T h e n r e m o v e h e l n b o a r d o i n t t on the shop towel (D).Be carefulnot to drop the rollerswhen separating them from the inboard Jornt. 8. Wrap the splineson the driveshaft with vinyl tape (A)to preventdamageto the boot.

9 . R e m o v e h e i n b o a r db o o t .B e c a r e f u n o t t o d a m a o e t l the boot. 10. Removethe vinyl tape. N4ake mark (A) on the rollers(B) and spider (C)to a identifythe locationsof rollerson the spider,then removethe rollers.

R e m o v e h e c i r c l i p{ D ) . t

6 . Mark the spider (C)and driveshaft(E)to identifythe


positionof the spider on the shaft, 7 . R e m o v e h e s p i d e r( C ) . t

16-6

OutboardJoint Side:
1 . R e m o v e h e b o o tb a n d s . ec a r e f u n o t t o d a m a g e t B l t h e b o o ta n d d y n a m i c a m p e r . d . l f t h e b o o t b a n di s a n e a r c l a m p t y p e A ) ,l i f t u p ( the three tabs (B)with a screwdriver. Ear Clamp Type

Wipe off the greaseto exposethe driveshaftand j t h e o u t b o a r d o i n t i n n e rr a c e .


4 . Make a mark (A) on the driveshaft(B) at the same

positionof the outboardjoint end {C).

5. Carefullvclamp the driveshaftin a vise.

2 . Slidethe outboardboot (A)to the inboard ioint side.


Be carefulnot to damaoethe boot.

Removethe outboardjoint (A) usingthe special t o o l a n d a c o m m e r c i a l l a v a i l a b l e / 8 " x 1 8s l i d e y 5 h a m m e r( B ) . 7 . Removethe driveshaftfrom the vise.

(cont'd)

16-7

Driveline/Axle
(cont'dl Disassembly Driveshafts
the 8. Remove stopringtromthe driveshaft.

Dynamic DamperReplacement
j 1 . R e m o v e h e i n b o a r d o i n t ( s e ep a g e1 6 - 5 ) . t 2, Removethe dynamic damper bands.Be carefulnot to damagethe dynamic damper (seepage 16-5). . l f t h e b o o l b a n di s a w e l d e d t y p e . c u t t h e o o t b band. . l f t h e b o o t b a n di s a d o u b l el o o p t y p e ,l i f t u p t h e band bend, and push it into the clip. . lfthe boot band is a low profiletype, pinch the b o o t b a n du s i n ga c o m m e r c i a l l a v a i l a b l e o o t y b band pincers. with vinyl tape 3. Wrap the splineson the driveshaft (A)to preventdamageto the dynamic damper.

9 . Wrap the splineson the driveshaftwith vinyl tape (A) to preventdamageto the boot.

Removethe dynamic damper. Be carefulnot to damagehe dynamic amper. t d 5 . Adjust the positionof the new dynamic damper to the figure below. 1 0 . Removethe outboardboot. Be careful not to damagethe boot. 1 1 .Removethe vinyl tape. 296 300mm ( 1 1 . 6 -1 1 . 8 n . ) i Right driveshaft(Directionall: 301 305 mm ( 1 1 . 9 1 2 . 0i n . l Left driveshaft{Directionall:

6 . I n s t a l l t h e y n a m i cd a m p e rb a n d( s e es t e pI o n d p a g e1 6 ' 1 2 ) . j 1 7 . I n s t a ltlh e i n b o a r d o i n t ( s e ep a g e1 6 - 1 ) .

16-8

Driveshafts Reassembly
ExplodedView
'02 model SETRING Replace.

0e
\)

//ROLLER

6)

/''"oH?"'
/ #'g!!a$il

YJ

II t,//>\
Usethe greaseincludedin the inboardboot set.

// /,/7\

.?-// "\

, I

Includedin the Use the greaserr inboardboot set inboard boot set.

\\1lg n r.
.'(9
-< OOUBLE LOOPBAND Replace.

{\

--.-

l>I I

/'..-:'\ .-\
|

DYNAMTC DAMPER ,/

.''

, \ V L/ A

.^-.1 //^\l

r\

// DOUBLE LOOP BAND Replace.

STOP RING Replace.

EAR CLAMP BANDS

JOINT OUTBOARD

Usethe greaseincludedin the outboardboot set,

(cont'd)

16-9

Driveline/Axle
(cont'dl Driveshafts Reassembly
Exploded View
'03 model
SET RING / Replace. INBOARO JOINT ROLLEB CIRCLIP

I
DOUBLE LOOP BAND Replace. (Boot bandreplacement only.)

s l
Usethe greaseincluded in the nboard boot set.

E.
-"-,,,

@(
(^Y \ \_,/

>
Usethe greaseincluded in the inboardboot set.

LOWPROFILE BAND Beplace. DOUBLE LOOPBAND Replace.

(Boot band replacement only.) DYNAMIC DAMPER

OUTBOARDJOINT

BOOT OUTBOARD ITPI

at-

Usethe greaseincludedin the outboardboot set.

16-10

Special Tools Required . Boot band tool, KD-3191 equivalent, or commercially available . Boot band pincers,Kent-Moore J-359'10 equivalent, or commerclallyavailable . Boot band pincers,commercially available NOTE:Referto the ExplodedView as neededduring this procedure.

3. Installthe spider (A) onto the driveshaftby aligning the marks (B)on the spider and the end of the driveshaft.

lnboardJoint Side:
1. Wrap the splineswith vinyl tape (A)to prevent damageto the inboardboot.

4 . Fit the circlip (C)into the driveshaftgroove.Always rotatethe circlip in its groove to make sure it is fully seated.
5

Fit the rollers (A) onto the spider {B)with their high shouldersfacing outward,and note these items: ' Reinstalltherollers in their original positionson the spider by aligningthe marks (C). . Holdthe driveshaftpointed up to preventthe rollersfrom falling off.

Installthe inboardboot onto the driveshaft, then removethe vinyl tape, Be carefulnot to damageI n e inboardboot.

(u
@\

(cont'd)

16-11

Driveline/Axle
(cont'd) Driveshafts Reassembly
jointwith thejointgrease 6 . Pack inboard the included the newdriveshaft in set. quantity Grease Inboard ioint: 130 140g (4.6-4.9oz)
Usethe greaseincludedin the inboardboot set.

I
8 . Make sure the ends of the boot are sealedin the
groovesin the driveshaftand joint, then installthe boot bands. . For the double loop type, go to step 12. (Replacement boot bands only) . For the low profiletype, go to step 9. 9 . Installthe new low profile band {A) onto the boot {B).then hook the tab (C)of the band,

7 . Fit the inboardjoint onto the driveshaft, and note these items: . Reinstall the inboardjoint onto the driveshaftby j a l i g n i n g h e m a r k s( A )o n t h e i n b o a r d o i n ta n d t the rollers. . Hold the driveshaftso the inboardjoint is pointing up to preventit trom falling off.

1 0 .Closethe hook portionof the band (A) with a


commerciallyavailableboot band pincers(B),then hook the tabs of the band.

1 1 .Installthe boot band on the other end of the boot, and reoeatsteos9 and 10.

16-12

Fit the boot ends onto the driveshaftand the inboardjoint, then installthe new double loop band {A) onto the boot.

15. Threadthe free end ofthe band through the nose sectionof the commerciallyavailableboot band or tool KD-3191 equivalent(A),and into the slot on ( t h e w i n d i n gm a n d r e l B ) .

P u l lu p t h e s l a c ki n t h e b a n db y h a n d ( M a r ka p o s i t i o n A )o n t h e b a n d 1 0 - 1 4 m m ( 0 . 4 0 . 6i n . )f r o m t h e c l i p { B ) .

1 6 . Placea wrench on the winding mandrelof the boot band tool, and tightenthe band until the marked spot (C)on the band meetsthe edge of the clip 1 7 . L i f tu Dt h e b o o t b a n dt o o l t o b e n d t h e f r e e e n d o f the the band 90 degreesto the clip. Center-punch t f o l d o v e rt h e r e m a i n i n ga i l o n t ot h e c l i p . c l i o ,t h e n

(cont'd)

16-13

Driveline/Axle
(cont'dl Driveshafts Reassembly
18. Unwind the boot band tool, and cut off the excess free end of the bandto leavea 5- 10 mm (0.2-0.4 in.) tail protrudingfrom the clip 2 ' 1 .I n s t a l l t h e e w s e t r i n g . n

19. Bendthe band end (A) by tapping it down with a nammer. NOTE; . Make sure the band and clip do not interferewith anythingand the band does not move. . Removeany greaseremainingon the surroundingsurfaces

20. Repeatsteps 12through 19 for the band on the other end of the boot.

16-14

Outboard Joint Side:


1. Wrap the splineswith vinyl tape (A) to prevent damageto the outboardboot.

4. Insertthe driveshaft(A) into the outboardjoint (B) until the stop ring (C)is closeto the joint.

n I n s t a l l t h e e w e a r c l a m pb a n d s( B )a n d o u t b o a r d boot,then removethe vinyl tape. Be carefulnot to damagethe outboardboot.

3 . Installthe new stop ring into the driveshaftgroove


(A).

5 . To completelyseatthe outboardjoint, pick up the driveshaftand joint, and drop them from about 10 cm (4 in.) onto a hard surface.Do not use a force may damagethe hammer as excessive Be driveshaft. carefulnot to damagethe threaded section(A) of the outboardjoint.

1 0c m ( 4i n . )

- ..,..,1;,t,:-,;

{cont'd)

16-15

Driveline/Axle
(cont'd) Driveshafts Reassembly
Checkthe alignmentof the paint mark (A)with the j o u t b o a r do i n t e n d ( B ) . 8. Adjust the length of the driveshafts the figure to below,then adjustthe boots to halfwaybetween full compressionand full extension.Make sure the ends of the boots seat in the groovesof the driveshaftand joint. Leftdriveshaft:497 mm (19.6 19.8in.) 502

-tTfi'.D.ilTD
Rightdriveshaft: 475 480 mm {18.7 1 8 . 9i n . l

7. Packthe outboardjoint (A)with the joint grease includedin the new ioint boot set. Grease quantity Outboardioint: 105 115g (3.7 4.1 ozl

/,)r llt -*>


\{(

9 . Fit the boot (A) ends onto the driveshaft(B)and j o u t b o a r do i n l ( C ) .

'., "o o :;,"0'A?g.fff :l:f

16-16

Installataon Driveshafts
10. Closethe ear portion (A) of the band with a commerciallyavailableboot band pincersKentor Moore J-35910 equivalent(B). 1. Installa new set ring onto the set ring groove of the driveshaft{left driveshaft ).

betweenthe closedear portlon 1 1 .Checkthe clearance is lf the clearance not within the of the bands. standard, closethe ear podion of the bandsfarther. in.) 6.0mm 10.24 MAX

Apply 0.5 1.0g {0.02 0.04oz) of specifiedgrease ( s t o t h e w h o l e s p l i n e d u r f a c e A )o f t h e r i g h t After applyinggrease,removethe driveshaft. greasefrom the splinedgroovesat intervalsof 2a 3 s p l i n e s n d f r o m t h e s e t r i n gg r o o v e( B )s o t h a t shaft. air can bleedfrom the intermediate

3.0 mm {0.12in.} MAX

12. R e p e as t e p s1 0 a n d 1 1 f o r t h e b a n do n t h e o t h e r t
end of the boot.

(cont'd)

16-17

Driveline/Axle
Driveshafts Installation(cont'd)
Cleanthe areaswhere the driveshaftcontactsthe differential thoroughlywith solvent,and dry with c o m p r e s s e a i r .I n s e n t h ei n b o a r d n d { A )o f t h e d e driveshaftinto the differential(B)or intermediate shaft {C) until the set ring (D)locks in the groove (E). 5 . W i p e o f f t h e g r e a s e r o m t h e b a l l i o i n ta n d l o w e r f arm taperedsurfaces. Installtheknuckle(A) onto the lower arm {B).Be careful not to damagethe ball joint boot.Wipe off the greasebeforetightening the nut at the ball joint. Torquethe new castlenut (C)to the lower torque specification, then tighten it o n l y f a r e n o u g ht o a l i g nt h e s l o tw i t h t h e b a l lj o i n t p i n h o l e .D o n o t a l i g nt h e n u t b y l o o s e n i n gt . i NOTE:Make sure the ball joint boot is not damage or cracks.

"-'t-

4. Installthe outboardjoint (A) into the front hub (B).


1 2x 1 . 2 5 m m 59 69 N.m -7.0 kgf m, (6.0 43 51 tbt.ftl

I n s t a l l t h e e w l o c kp i n { D )i n t ot h e b a l l j o i n tp i n n hole from the insideto the outsideof the vehicle. 7 . Connectthe front stabilizer link {A)to the lower arm. H o l dt h e s t a b i l i z elr n kb a l l j o i n tp i n ( B )w i t h a h e x i w r e n c h{ C ) ,a n d t i g h t e n h e n e w f l a n g en u t { D ) . t

'10 1.25mm x 39 N.m {4.0kgf.m,29 lbf.ft)

16-18

lntermediateShaft Removal
the nut thentighten nut. a 8. Install newspindle {A), nut the use Aftertightening, a driftto stake spindle the shoulder against driveshaft. {B)
1 . Removethe right driveshaft(seepage 16-3). t 2 . R e m o v e h e h e a ts h i e l d .

108N.m (11.0kgf.m, 80 tbt.ft)

/ o oo e

t 3 . R e m o v e h e f l a n g eb o l t{ A )a n d t w o d o w e l b o l t s ( B ) .
22x 1.5 mm 1 8 1N . m

134lbt.ft) kgf.m, {18.5

.---2"
E J /

9. Cleanthe mating surfacesofthe brakedisc and the front wheel, then installthe front wheel with the wheel nuts. 10. Turn the front wheel by hand,and make sure the betweenthe driveshaftand clearance parts. circumference with recommended 1l. Refillthe transmission fluid (seepage 13-3). transmission 12. Checkthe front wheel alignment,and adjust it if (seepage 18-4). necessary

(cont'd)

16-19

Driveline/Axle
Intermediate Shaft Removal (cont'dl
4. Removethe intermediate shaft (A) from the differential. Hold the intermediate shaft horizontal until it is clear of the differential preventdamage to to the differentialoil seal (B).

Intermediate Shaft Disassembly


Special Tools Required . Oil seal driver 07947-5800100 . Half shaft base07NAF-SR30101 1 . R e m o v e t h e s e r i n g ( A ) ,o u t e r s e a ( B ) ,a n d e x t e r n a l t l s n a pr i n g ( C ) .

Pressthe intermediate shaft (A) out of the intermediate shaft bearing(B) using a press.Be carefulnot to damagethe metal rings (C)on the intermediate shaft during disassembly.
PRESS

16-20

3. Removethe internalsnap ring.

shaft bearing(A) out of the 4. Pressthe intermediate ( b e a r i n g u p p o r t B )u s i n gt h e s p e c i atl o o l sa n d a s oress. 07947-s800100

07NAF-SR30101

16-21

Driveline/Axle
Intermediate Shaft Reassembly
Exploded View

INTERMEDIATE SHAFTRING

FLANGEBOLT 10 x '1.25 mm 39IVm {4.0kgf.m,29lbt.ftl

\^

,tto", *,"o p

\--'+7\ E

BEARING SUPPOBT

Packthe interiorof the outer seal.

16-22

Special Tools Required . Driver07749-0010000 . Attachment,52x 55 mm 07746-0010400 . Attachment,35 mm 1.D.07746-0030400 . Oil seal driver 07GAD-PH70201 NOTE:Referto the ExplodedView as neededduring this procedure. , t d 1 . C l e a n h e d i s a s s e m b l ep a r t sw i t h s o l v e n t a n d d r y air. Do not wash the rubber them with compressed partswith solvent. shaft bearing(A) intothe 2. Pressthe intermediate ( b e a r i n g u p p o r t B )u s i n gt h e s p e c i atl o o l sa n d a s press. ES PR

shaft (A) intotheshaft 4. Pressthe intermediate ( B )u s i n gt h e s p e c i atl o o l a n d a p r e s s . bearing


PRESS

07746-0030400 l I n s t a l lt,h e n s e a tt h e e x t e r n as n a pr i n g { A ) i n t ot h e groove of the intermediate shaft (B). 07746-0010400

l 3 . I n s t a l lt,h e n s e a tt h e i n t e r n as n a pr i n g i n t ot h e groove ofthe bearingsupPort.

(cont'd)

16-23

Driveline/Axle
Intermediate Shaft Reassembly (cont'd)
6 . l n s t a l l t h e u t e rs e a l( A )i n t o t h e b e a r i n g s u p p o r t ( B ) o usingthe specialtool and a press.
PRESS

Intermediate Shaft Installation


1 . U s es o l v e n t r b r a k ec l e a n e t o t h o r o u g h l y l e a n o r c the areaswhere the intermediate shaft {A) contacts the transmission(differential), and dry with compressed air. Insertthe intermediate shaft assemblyinto the differential. Hold the intermediate shaft horizontal preventdamageto to the differential seal (B). oil

Packthe interior ofthe outer seal.

7. Installthe etring. s

2 . I n s t a l l t h el a n g eb o l t( A )a n d t w o d o w e lb o l t s( B l . l
A 10 x 1.25mm 39Nm (4.0kgf.m,29lbf.ft) B l 0 x 1 . 2 5m m 39 N.m (4.0kgf.m, 29 tbf.ftl

16-24

3. Installthe heat shield,and tightenthe three bolts.


8 x 1.25mm 22Nm

12.2

r 4 . I n s t a l l t h e i g h td r i v e s h a f(ts e ep a g e1 6 - 1 7 ) ,

16-25

Steering
Steering
. . . . . . . . . .1 . .- 2 .7 T S p e c i a lo o l s 1.7.-.3 . . . . . . . . n L C o m o o n e n to c a t i oIn d e x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-4 Play WheelRotational Check.....................". Steering 17-4 .......... Power Assist Check.................. 17-5 ................. Inspection Linkage Gearbox and Steering . 7 .. l S t e e r i nW h e e R e m o v a.l . . . . . . . . . . . . . . . . . . . . . . . . , . . . .1 . . - 6. . . . . . . . . . g 17-7 ................ WheelDisassembly/Reassembly Steering 17-8 ............... WheelInstallation Steering 17-9 ...........'... and Removal Installation Steering Column 17-11 .............. Inspection Column Steering 17-'12 .......................................'. Replacement Lock Steering . . . . . " . . . . . . . . '1 . ' . . 3 . 7-1 A Rack uide diustment G

PowerSteering(EPS) Electrical

17-15

Steering
SpecialTools
Ref.No.

Tool Number 07MAA-S100200

Description
LocknulWrench.43 mm

Oty

---<,/ L\2 r

-.tt)-

6Y

.Vo

1 7-2

ComponentLocationIndex

DRIVER'S AIRBAG ASSEMBLY Removal/lnstallation, page 3-113 2

WHEEL STEERING page 17-6 Removal, Disassembly/Reassembly, page 17-7 page 17-8 Installation,

STEERING COLUMN SteeringColumnRemovaland Installation, p a g e1 7 ' 9 SteeringColumn Inspection, p a g e1 7 - 1 ' l SteeringLockReplacement, page 11-12

STEERING GEARBOX page'17-13 Rack Adjustment, Guide

17-3

Steering
SteeringWheelRotationalPlay Check
1. Turn the front wheelsto the straightaheadposition. 2. Measurehow far you can turn the steeringwheel left and right without moving the front wheels. . lf the play is within the limit, the gearboxand l i n k a g e r eO K . a . l f t h e p l a y e x c e e d s t h ei m i t ,a d j u s t t h er a c kg u i d e l '17-13). lf the play is still excessive after {seepage rackguide adjustment,inspectthe steering l i n k a g e n d g e a r b o x s e ep a g e1 7 - 5 ) . a { BOTATIONAL PLAY: 10mm (0-0.39in.l 0

PowerAssistCheck
1 . Startthe engine,and let it idle. Attach a commerciallyavailablespring scaleto the s t e e r i n g h e e l .W i t h t h e e n g i n ei d l i n ga n d t h e w v e h i c l e n a c l e a n , r y f l o o r ,p u l lt h e s c a l ea s o d shown, and read it as soon as the tires begin to turn.

+ :

3 . l f t h e s c a l er e a d sn o m o r e t h a n2 9 N ( 3 . 0k g f , 6 . 6l b f ) , the power assistis OK. lf it readsmore, checkthese items: . . . . Fronttire pressure Steeringlinkage(seepage 17-5) Rackgulde adjustment(seepage 17-13) EPSsystem (seepage 17-18)

17-4

SteeringLinkageand GearboxInspection

BOOT Inspect damage deterioration. Ior and

Checkfor looseness, a n db i n d i n g .

12 mm BOLTS Inspect looseness. for

I
TIE.RODLOCKNUTS Checkfor looseness.

STEERING COLUMN Inspect loose for column mounting hardware STEERING JOINTS Check looseioint bolts, for andloose binding or ioints.
STEERING GEARBOX Inspect loosemounting hardware. for GEARBOXMOUNTING CUSHIONS Inspect deterioration. for

TIE.ROD ENOBALLJOINT lnsoect looseness, tor b i n d i n g ,n dd a m a g e . a

BALLJOINT BOOT Inspect damage deterioration. for and

17-5

Steering
SteeringWheelRemoval
SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations(seepage 23-13), and (seepage 23-14)in the SRS precautions and procedures sectionbeforeperformingrepairsor service. 1. Align the front wheels straightahead,then remove the driver'sairbagfrom the steeringwheel (see p a g e2 3 - 1 1 3 ) . 2. Disconnect cruisecontrol sevresumeswitch the connector(A),and loosenthe steeringwheel nut {B). 3. Installa commerciallyavailablesteeringwheel puller {A) on the steeringwheel (B).Freethe steeringwheel from the steeringcolumn shaft by t u r n i n gt h e p r e s s u r e o l t( C )o f t h e p u l l e r . b Note these items when removing the steering wheel: . Do not tap on the steeringwheel orthesteering column shaft when removingthe steeringwheel. . l f y o u t h r e a dt h e p u l l e rb o l t s( D )i n t o t h e w h e e l hub more than 5 threads,the bolts will hit the cable reel and damageit. To preventthis, install a p a i ro f j a m n u t s5 t h r e a d s p o n e a c hp u l l e rb o l t . u D

i
Bemovethe steeringwheel puller,then removethe steeringwheel nut and steeringwheel from the sleerinocolumn.

17-6

SteeringWheelDisassembly/Reassembly

WHEEL STEERING CONTACTPLATE ACCESSPANELA

HOLDERS CONNECTOR

75*-=offi
MOOULE SETBRACKET REAB STEERING WHEEL COVER

ffi)Y
-f b
CRUISECONTROLSWITCH

,/*

accEss PANEL B

17-7

Steering
WheelInstallation Steering
1 . B e f o r e n s t a l l i n gh e s t e e r i n g h e e l ,m a k es u r et h e i w t front wheels are alignedstraightahead,then center the cable reel (A).Do this by first rotatingthe cable reel clockwiseuntil it stops.Then rotate it counterclockwise about two and a half turns.The a r r o w m a r k( B )o n t h e c a b l er e e ll a b e ls h o u l dp o i n t straightup. 3. Installthe steeringwheel nut (A),and tighten it to the specified torgue. A 39 N.m(4.0 m.29lbt ftl kgf _ B

lr,',,t
;. _,:! '' '1i::..'.'l

Connect the cruisecontrol set/resume switch connector(B).fvlake sure the wire harnessis routed and fastenedproperly. Positionthe two tabs (A) of the turn signal ( c a n c e l i n g l e e v e B )a s s h o w n .I n s t a l l t h e t e e r i n g s s wheel onto the steeringcolumn shaft, makingsure the steerlngwheel hub (C)engagesthe pins (D) of the cable reel and tabs of the cancelingsleeve.Do not tap on the steeringwheel or steeringcolumn shaft when installingthe steeringwheel. I n s t a ltlh e d r i v e r ' s i r b a g a n d c o n f i r mt h a tt h e a , system is operatingproperly{seepage 23-113). C h e c k h e h o r n ,t u r n s i g n a lc a n c e l i n g n d c r u i s e t a control switchesfor proper operation. 7 . Reconnect batteryand do the following: the . D o t h e e n g i n ec o n t r o l o d u l e( E C M ) d l e l e a r n m i ( p r o c e d u r es e ep a g e1 l - 1 3 9 ) , . Powerwindow control unit resettingprocedure \see page 22-1281. . Enterthe anti-theft cord for the radio,then enter the custmer'sradio stationpresets. . Set the clock.

17-8

SteeringColumnRemovaland Installation
SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations(seepage 23-13)and precautions and (seepage 23-14)in the SRSsectionbefore performingrepairsor service. procedures

Removal
1, Recordthe radio stationpresets, and disconnect the battery. 2 . R e m o v e t h e d r i v e r ' s a i r b a g a s s e m b l y ( s e e p a g e 2 3 -a n dt)h e s t e e r i n g h e e l( s e ep a g e1 7 - 6 ) . 113 w p p 3 . R e m o v e t h e r i v e r ' s a s h b o a r do w e r c o v e r ( s e e a g e2 0 - 5 9 a n d u n d e r c o v e r ( s e e a g e2 0 - 6 0 ) . d d l ) 4. Removethe column covers(A:

I x 1.25mm 16 N.m (1.6kgf.m, 12 lbl.fr)

the from the combinationswitch assembly{B). 5 . Disconnect wire harnessconnectors

6 . Removethe combinationswitch assemblyfrom the steeringcolumn shaft by removingthe screw (C)on the top of
the combinationswitch. 7. Disconnect connectors from the ignition switch,and releasethe wire harnessclips from the steeringcolumn. the 8. Disconnect steeringjoint (D),and remove it from the column shaft. the 9. Removethe steeringcolumn {E)by removingthe attachingnuts and bolts.

\
(cont'd)

17-9

Steering
(cont'd) SteeringColumnRemovaland Installation
lnstallation
c 1 . I n s t a ltl h e s t e e r i n g o l u m n ,a n d m a k es u r et h e wires are not caught or pinchedby any parts. Insertthe upper end ofthe steeringjoint onto the steeringshaft {A) (line up the bolt hole (B)with the flat portion (C)on the shaft).

8 x 1 , 2 5m m 28 N.m {2.9 kgf m,

21rbr.ft)
A

Slip the lower end of the steeringjoint onto the pinion shaft {D) (line up the bolt hole with the g r o o v e( E )a r o u n dt h e s h a f t )a n d l o o s e l y n s t a l l t h e l , lower joint bolt. Be sure that the lower joint bolt is securelyin the groove in the pinion shaft. 4 . Pull on the steeringjoint to make sure that the j u . s t e e r i n go i n t i s f u l l y s e a t e dT h e n i n s t a l l t h e p p e r joint bolt, and tighten it to the specifiedtorque. Tightenthe lower joint bolt to the specifiedtorque. and note these items: Finishthe installation, . Make surethe wire harnessis routed and fastenedproperly. . Make sure the connectorsare properlyconnected. . R e i n s t a l l t h s t e e r i n g h e e l( s e ep a g e1 7 - 8 ) . w e . Reconnect battery. the - Do the power window control unitreset procedure{seepage 22-128). - Enterthe anti-theftcode for the radio,then enterthe custmer'sradio stationpresets. - Set the clock. . Verify horn, turn signalswitch,and cruisecontrol switch operation. . Checkwheel alignment,if necessary (seepage 18-4). . D o t h e e n g i n e o n t r o lm o d u l e( E C M ) d l el e a r n i c p r o c e d ue { s e ep a g e' 1 1 - 1 3 9 ) . r

17-10

SteeringColumnInspection
. C h e c k h e s t e e r i n g o l u m nb a l l b e a r i n g ( A a n d t h e s t e e r i n g j o i n t b e a r i n g s ( B ) f o r p l a y a n d p r o p e r m o v e m efn tn y t c ) l a. play, replacethe steeringcolumn as an assembly, bearingis noisy or has excessive ' C h e c k t h e a b s o r b i n g p l a t e s ( C ) , a b s o r b i n g p l a t e g u i d e s ( D ) , s t o p ( E ) , a n d c o a t i n g p l a oe s (i F t o r t i o n n d ft rd s) a breakage. there is distortionor breakage, lf replacethe steeringcolumn as an assembly.

17-11

Steering
SteeringLockReplacement
NOTE:Do not try to re-keya replacement steeringlock. lf necessary, re-keythe other locks. 1 . R e m o v e h e s t e e r i n g o l u m n( s e ep a g e1 7 - 9 ) . t c 2. Centerpunch each ofthe two shear bolts (A),and drill their headsoff with a 5 mm (3i16 in.) drill bit. Be carefulnot to damagethe switch body when removingthe shear bolts, 7. Tightenthe shearbolts (A) untilthe hex heads(B) twist off.
A

:..'-":'

3. Removethe shear bolts from the switch body. 4. Installtheswitch body without the key inserted. 5. Looselytighten the new shear bolts. 6. Insertthe ignition key,and checkfor proper operationof the steeringwheel lock and that the ignition key turns freely.

17-12

RackGuideAdjustment
Special Tool Required Locknutwrench, 43 mm 07MAA-S100200 1. Set the wheels in the straightaheadposition.
j

6. Tighten rackguidescrew(A)ro25 N.m (2.5 the kgf.m, 18lbf.ft). thenloosen it.


5" Max.
i-rrrr-,

2. Removethe heat shield(A).

'-.i. ''

'

9 . 8N . m ( r . 0 k g f . m , 7 . 2 l b t f t ) I 4il N.m

3 . Removethe transmissionmount bracket(seestep


32 on page 13-8). Loosenthe rackguide screw locknut(A)with the specialtool, then removethe rack guide screw (B).
07MAA-S100200

kgf.m,33lbt.ft) {a.5 7 . Retighten the rack guide screw to 6 N.m (0.6kgf m, 4 lbf.ft),then back it off to the specifiedangle. Specified Return Angle: 5' Max. Hold the rack guide screw stationarywith a wrench, and tighten the locknutby hand until it's fully seated. 9 . I n s t a l l t h e p e c i atl o o l o n t h e l o c k n u ( B ) ,a n d h o l d s t the rackguide screw (A) stationarywith a wrench, Tightenthe locknutan additional30" with the specialtool.

1 0 .Reinstall transmissionmount bracketand heat the


s hi el d , Removethe old sealantfrom rackguide screw,and apply new sealantto the middle of the threads(A). Looselyinstallthe rackguide screw on the steering gearDox. 1 1 .Checkfor unusualsteeringeffort through the c o m p l e t e u r n i n gt r a v e l . t

12. Checkthe steeringwheel rotationplay (seepage


17-4)and the power assist(seepage 17-4).

17-13

Electrical PowerSteering(EPSI

SpecialTools . . . . . . . . . .1 . - 1 6 .7 . C o m p o n e n to c a t i oIn d e x . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.-.1.7 . . . . . . L n 1. . . Troubleshooting General Information....................... 17-18 DTC Troubleshooting Index .............. 17-22 Symptom Troubleshooting Index ............................... 17-23 Description System ................. ........... 17-24 Circuit Diagram ......... 17-26 DTC Troubleshooting ............... .......... 17-28 EPS lndicator Circuit Troubleshooting ....................... 17-47 MotorRemoval/lnstallation ............... 17-49 Steering Gearbox Removal ............... 17-51 Steering Gearbox Overhaul ............... 17-55 Steering Gearbox Installation ........... 17-63 EPS Control l/lnsta llation....................... UnitRemova 17-67 Tie-rod JointBootReplacement Ball .......................... 17-67

EPSComponents
SpecialTools
Rel.No. Tool Number (!) 07MAC-S100200 at' 070AD-P0A0100

\ Description
B a l lJ o i n t R e m o v e r2 8 m m , Attachment,42 mm LocknutWrench

otv
'1 1 'l

07zAA-S5A0100

_---1t

,.^G) C\

-)
t t ) \L-,

h5--d-'
u_r-.c_-

a
17-16

ComponentLocationIndex

GAUGE ASSEMBLY UNDER.DASH FUSE/RELAY BOX

UNDER.HOOD FUSE/RELAY BOX

-,'/.,....

'.,i,
X \ ]

DATA LINK CONNECTOR I16P)

TOROUE SENSOR
STEERING GEARBOX SteeringGearboxRemoval,page 17-51 page 17-55 SteeringGearboxOverhaul, page 17-63 SteeringGearboxInstallation,

EPS CONTROL UNIT EPS Control UnitRemoval/lnstallation, page17-67 MOTOR


Removal/lnstallation, page l7-49

17-17

EPSComponents
General Troubleshooting Information
EPSIndicator
Under normal conditions, EPS the indicator comes when on the ignitlon switch turned theON(ll)position, is to thengoes is This off after engine started. indicates thebulband the that itscircuit operating correctly. are lf thereis anytrouble thesystem in after engine started, the is indicator stayon,andthe power will is theEPS assist turned off. WhenEPS indicator comes thecontrol light unit on, memorizes DTC. thiscase, control will not In the the unit system after engine starts again, it activate EPS the the but keeps EPS indicator the on. WhenDTC12,16,17,18or 67 is stored thecontrol in unit, the EPS indicator stayon untiltheDTC erased. will is Whena problem detected the EPS is and indicator comes thereare on, whenthe indicator stays untilthe on ignition switch is cases goes whenthe indicator off turned 0FF,andcases when returns normal. to Even though automatically thesystem thesystem operating is normally, EPS the indicator come will on under following the conditions: '1: Condition . Thevehicle traveling least 12.4 mph(20km/h), was at then . A rapid changein vehiclespeedwas detected, then . Thevehicle thevehicle (or speed sensor signal) for stopped at least seconds 5 ' . T h ee n g i n s p e e d a ss t i l l l , 6 4 0 r p m o r h i g h e r f o r a t l e a s t S w e seconds Condition : 2 (or speed sensor signal) has After vehicle thevehicle the yet for 10 speed wasstill stopped at least seconds, theengine 1,640 or higherfor least seconds. rpm at 20 Condition : 3 When engine is rpm and vehicletraveling is the speed 280 or less, the at (10 for a speed 6,2 of mph km/h) more 3 seconds. or question To determine actual the cause ofthe problem, the the during whichthe problem customer about conditions taking above the conditions consideration. into occured, . TheDTCS memorized theEEPRO| (non-volatile are in memory) therefore memorized the DTCS cannot erased be by disconnecting battery. the Perform specified the procedures clear to DTCS.

a
Self-diagnosis
Self-diagnosis be classifiedinto two categories: can . I n i t i a l d i a g n o s i sp e r f o r m e d i g h ta f t e rt h e e n g i n e : r startsand until the EPSindicatorgoes off. . Regulardiagnosis:performedright after the initial d i a g n o s i s n t i lt h e i g n i t i o n w i t c hi s t u r n e dO F F . u s The EPScontrol unit performsthe following functions when a problem is detectedby self-diagnosis; '1. T u r n so n t h e E P Si n d i c a t o r . 2. Memorizes the DTC. 3. Stops power assistand manual steeringoperation begrns. NOTE: . When DTC23 (a problemwith the circuitfor enginespeedsignal)is detected, the power a s s i s w i l l r e t u r n o n o r m a lw h e n t h e v e h i c l e t t s p e e di s 0 . 6 2m p h ( 1 k m / h )o r a b o v e . . Fot DfCs 22,23, 64, or 66 the EPSindicatorgoes when the system relurnsto off automatically n o r m a l . o ra l l o t h e rc o d e s t h e E P Si n d i c a t o r F , goes off when the system is OK afterthe ignition switch is turned from OFFto ON (ll).

Restriction PowerAssistOperation on
Repeated extremesteeringforce.such as turning the steeringwheel continuouslyback-and-forth with the vehiclestopped,causesan increaseof power consumptionin the EPSmotor. The increase electric of t c u r r e n t a u s e s h e m o t o rt o h e a tu p . B e c a u s eh i s h e a t c t adverselyaffectsthe system,the control unit monitors the electriccurrent of the motor. When the control unit detectsheat build-upin the motor, it reducesthe electriccurrentto the motor graduallyto protectthe system,and it restricts the power assist o p e r a t i o nT h e E P Si n d i c a t o d o e sn o t c o m e o n d u r i n g . r t h i sf u n c t i o n . When steeringtorque is not appliedto the steering wheel, or when the ignition is turned off, and the motor cools,the control unit will restorethe power assist graduallyuntil it's fully restored(afterapproximately15 m i n u t e sm a x i m u m ) .

Diagnostic TroubleCode(DTCI
. lf theCPU EPS indicator cannot activated, itfails,the be or on, is comes butthe DTC notmemorized. . Thememory holdanynumber DTCS. of However, when can thesame DTC detected is morethanonce, mostrecent the is therefore one only DTC written overthe priorDTC, occurrence memorized. is . TheDTCS indicated are repeatedly untiltheignition switch is turned OFF. . lf theDTC not memorized,the indicator is EPS blinks.

17-18

How to TroubleshootEPSDTCs
flowchart procedures assumethat The troubleshooting the causeof the problem is still presentand the EPS indicatoris still on, Followingthe flowchartwhen the EPSindicatordoes not come on can result in incorrect diagnosis. show the female terminal The connectoriliustrations a c o n n e c t o rw i t h a s i n g l eo u t l i n e n d t h e m a l et e r m i n a l s with a double outline. connectors 1. Ouestionthe customeraboutthe conditionswhen the the problem occured,and try to reproduce Find out same conditionsfor troubleshooting. when the EPSindicatorcame on, such as while w a , t u r n i n g . f t e r t u r n i n gw h e n t h e v e h i c l e a s a t a certain speed,etc. 2. When the EPSindicatordoes not come on during is the test drive, but troubleshooting done basedon poor terminal the DTC,checkfor looseconnectors, contact.etc in the affectedcircuit,beforeyou start troubleshooting. clearthe DTCand test-drive 3. After troubleshooting, the vehicle.Be sure the EPSindicatordoes not c o m eo n .

O o 2 . T u r nt h e i g n i t i o n N ( l l ) ,a n d f o l l o wt h e p r o m p t s n on the PGM Testerto displaythe DTC(s) the screen. After determiningthe DTC,referto the DTC Index. Troubleshooting NOTE:See the HondaPGM Testeruser's manual for specificinstructions. ServiceCheckSignalCircuit Method: c 1 . W i t h t h e i g n i t i o n w i t c hO F F , o n n e c t h e H o n d a s ( r P G MT e s t e r A ) t o t h e 1 6 Pd a t al i n kc o n n e c t o( D L C ) (B) locatedunderthe dash on the driver'sside of the vehicle.

How to RetrieveEPSDTCs
Honda PGM Tester Method: 1, With the ignition switch OFF,connectthe Honda PGM Tester(A)to the 16Pdata link connector(DLC) (B) locatedunderthe dash on the driver'sside of thevehicle. Short the SCScircuitto body ground using the Tester. HondaPGN4 s T u r nt h e i g n i t i o n w i t c hO N { l l ) . Recordthe DTC.

(cont'd)

17-19

EPS Components
Troubleshooting General Information(cont'dl
5. The blinkingfrequencyindicates the DTC.DTCS are indicatedby a seriesof long and short blinks.One l o n g b l i n ke q u a l s1 0 s h o r tb l i n k s A d d t h e l o n g a n d . short blinkstogetherto determinethe DTC.After determiningthe DTC,referto the DTC Troubleshooting Index. The system will not indicatethe DTCunlessthese conditionsare met: . Set the front wheels in the straightaheaddriving position. . The ignition switch is turned ON (ll). . The engine is stopped. . The SCScircuit is shortedto body ground before the ignition switch is turned ON (ll).

How to ClearEPSDTCs
Honda PGM Tesler Method: 1. With the ignition switch OFF,connectthe Honda PGM Tester(A)to the 16Pdata link connector(DLC) ( B )l o c a t e d n d e rt h e d a s ho n t h e d r i v e r ' s i d eo f u s the vehicle.

Example DTC23 of

Long blinks Short blinks (two times) (three timesl

Turn the ignition switch ON (ll),and clearthe DTC{s) following the screenpromptson the by PGM Tester. NOTE:Seethe Honda PGMTesteruser'smanual for specificinstructions.

6 . Turn the ignitionswitch OFF.


7 . Disconnect Honda PGM Testerfrom the DLC. the

17-20

Service Check Signal Circuit Method: NOTE:Use this procedure when the PGM Tester softwaredoes not matchthe yearlmodelvehicleyou are working on. 1. With the ignitionswitch OFF,connectthe Honda PGM Tester(A)to the 16Pdata link connector{DLC) (B) locatedunderthe dash on the driver'sside of the vehicle.

1 . Within 4 secondsafter the EPSindicatorgoes off, returnthe steeringwheel to the straightahead driving positionagain and releasethe steering wheel.The EPSindicatorblinkstwice 4 seconds after releasing the steeringwheel, indicatingthat the DTCwas erased. NOTE:If the EPSindicatordoes not blinktwice, an error was made in the procedureand the DTCwas not erased.Turn the ignition switch OFF,and repeatthe operationfrom step 3. Turn the ignition switch OFFafterthe EPSindicator blinkstwice. 9. Disconnect Honda PGM Testerfrom the DLC. the 10. Performthe DTCcode output operation,and be sure that the code has been erased.

With the vehicleon the ground,set the front wheels in the straightaheaddriving position. Short the SCScircuitto body ground using the HondaPGM Tester.
4. Turn the ignition switch ON (ll).The EPSindicator

Within 4 secondsof comes on for about 6 seconds. turning the switch ON, while the EPSindicatoris on, turn the steeringwheel 45 degreesto the left from the straightaheaddriving position,and hold the steeringwheel in that positionuntil the EPS indicatorgoes off. Within 4 secondsafterthe EPSindicatorgoes off, returnthe steeringwheel to the straightahead the steeringwheel. driving positionand release The EPSindicatorcomes on again 4 secondsafter releasing the steeringwheel, Within 4 secondsafter the EPSindicatorcomes on, turn the steeringwheel 45 degreesto the left again and hold it in that position. The EPSindicatorgoes off after 4 seconds.

17-21

EPS Components
DTCTroubleshooting Index
DTC DTC; 12 D T C1 6 :
DTC:17 DTC:18 Detection ltem A problem with voltagefor torque sensorT/SlG A problemwith averageof voltagefor torque sensorVT3 and VT6 Note (seepage 17-28) (seepage 17-29) ( s e ep a g e1 7 - 3 1 ) ( s e ep a g e1 7 - 3 1 ) ( s e ep a g e1 7 - 3 3 ) {seepage 17-33) ( s e ep a g e1 7 - 3 3 ) (seepage 17-35) ( s e ep a g e1 7 3 6 ) (seepage '17-38) ( s e ep a g e1 7 - 4 1 ) (seepage 17-38) { s e ep a g e1 7 - 4 2 ) ( s e ep a g e1 7 - 4 3 ) (seepage 17-43) ( s e ep a g e1 7 - 4 4 ) (seepage 17-44) (seepage 17-44) {seepage 17 45) ( s e ep a g e1 7 ' 4 5 ) {seepage 17-45) ( s e ep a g e1 7 - 4 6 )

A problem with thevoltage torquesensor V powersource 1 for 12 Vcc


A problemwith the voltagefor torque sensor5 V power sourceVcc 2 A problemwith the averagefor vehiclespeedand enginespeed Excessive changeof the vehiclespeed sensorsignal

DfC:22

DTC: 23 DTC: 37
DTC:41 DfC: 42

A problemwith the engine speedsignal circuit A problemwith the circuitfor input motor voltage in the EPScontrol unit A problemwith the motor voltage A problemwith the motor driven current (opencircuitor short to grounol A problem with the motor driven current (shortto power) A problemwith the motor driven current (opencircuitor short to grounol A problemwith the motor relav in the EPScontrol unit A problem with the CPU in the EPScontrol unit

DTC: 43
DTC:45 DfC: 47

DTC: 50
DTC: 1 5

A problem with EEPROM the EPS in controlunlt


Fail-safe relay stuckON A problem with low batteryvoltage Fail-safe relay contactfailure

DTC: 62 DTC: 64

DTC: 66 DTC: 67
DTC:68 DTC:69

A problem with the motor driven voltage A problemwith the torque sensorl/F circuit A problemwith the interlockcircuit (torque) A p r o b l e mw i t h t h e i n t e r l o c k i r c u i t( c u r r e n t ) c

17-22

Index Symptom Troubleshooting


Symptom
EPSindicatordoes not come on EPSindicatordoes not go off and no DTC is stored EPSindicatordoes not stay on, no DTCis stored,and there is no power assist Diagnostic procedure (seepage 17-47) EPSlndicatorCircuitTroubleshooting Also check fo]

(seepage 17-47) EPSIndicatorCircuitTroubleshooting

1. Checkthe motor wires betweenthe EPScontrol unit and the motor for a short to ground. Repairas needed. 2. lf the motor wires are OK, replacethe steeringgearbox {short in the motor).

17-23

EPS Gomponents
SystemDescription
EPS GontrolUnit Inputsand Outputsat Connector (2pl A
EPSCONTROLUNIT CONNECTOR {2P) A

Wire side of femaleterminals Termanal Wire color numbol

Terminalsign (Terminal namel

Description Power source the for actuatormotor Ground forthe actuator

WHT/BLU -' BAT (Plus bafterv)


2 8LK PG

Measurement Conditions lqnitiqr switch ON (lll l Ground Constant Terminals 2-Ground

Voltage
Battery voltage

EPS ControlUnit Inputsand Outputsat Connector (2P) B


EPSCONTROL UNITCONNECTOB {2P} B

Wire side of femaleterminals Terminal Wire colol numDer


1

Terminalsign {Te.mioalname)
M1 (Motor 1

Description Terminals Drives actuator lhe motor


Drives the actuator motor

RED
GRN

Measuremenl Conditions lqnition switch ON llll

Voltage

1-Ground 2'Ground

M2

17-24

C EPS GontrolUnit Inputsand Outputsat Connestor (20P1


EPSCONTROL UNITCONNECTOR (2OP) C

Wire side of femaleterminals

Terminal
numbel 2

Wire color
PNK

Terminalsign name} {Terminel

Descriplion Terminals

Measuremeni Conditions {lqnitionswitch ON {lll)

Voltage

for T/SGND Ground the torque (Torque qround) sensor 3-Ground tarttheenqrne Power source fortorque ORN vccl (Voltaqe common1 and engine Detects torque sensor 5 Ground Startthe YEUBED VT6 (Voltaqe turnthe steerino wheel stonal torque 6) ON Drives EPS the indicator 6 Ground E P S YEUBLU (Warninq lidhr uTltnotcatol lamp) Raise vehicleoff the the Detects vehiclespeed the BLUAVHT VSP ( V e h i c l es p e e d p u l s e i groundandspinthe inputsignal the speed for sensor the ECM(4 pulse/ or BRN SCS siqnal) check {Servjco IG1 1 llqnition Detects servicecheck 8-Ground SCSnot grounded on switch (ll) ON on switch OFF 1'l-Ground tan the enoine
on switch OFF

voltaqe Ba$erv OV About OV voltaqe Banerv Alternating voltage about OV 5V OV-5V Batteryvoltage Battervvoltaqe About5V

10
11

YEL
GRN//EL

Powersourcefor activating 10-Ground Drives torquesensor the Detects torque sensor Detects torque sensor srgnal

vcc2

(Voltaqe common2)

8LU/ORN VT3

(Voltaoe toroue 3)

YEUBLK T/SIG (Torque F/S sensor


1'l

About engine and 13-GroundStartthe trrrnthe steerino wheel 5 - 0 v Momentarily V 5 15-GroundStartthe engine 0-12V engine and l7-Ground Startthe nrrnthe steerino wheel engine, and let 19-GroundStartthe ;t idte 5V 20-Ground PGMTesternot

LT GRN/ B IK

19 20

BLU
GRY

power steering Provides PSW iPowersteerinoswitch) switchsional Detects enginepulse the NEP DIAG-H with Communications HondaPGNI Tester

17-25

EPSComponents
CircuitDiagram
\

SPEDSENSOR 3P CONNECTOR

GAUGEASSEMBLY 22PCONNECTON

@
GAUGEASSEMATY 22PCONNECTOR TOFOUESENSOR 6P CONNECTOR

lli2l3F r;T;T-I (=J_:_LvJ


Wn. !ide ot f.m.l r.fmin.ls

17-26

EPS COI{IFOIUNIT cou{EcToR A (2P) F-l

(T6P) OATA !IN( CONNCTOA

A
EPSCONTNOL UNIT co|lNEcTofi 8 {2P} | l l MOTOF CONNECTOR

vTTrvaEvnrv

wwzna

t2)
Wir. !.le ol l.m.l. t.tman.r.

riTt

T.rmin.l.id.

oll.m.l.r.rmin.l.

17-27

EPSComponents
DTCTroubleshooting
DTC12: TorqueSensor T/SIG
1. Clear he DTC. t 2 . S t a nt h e e n g i n e . 3. Wait at least 10 seconds. Does the EPS indicatot come on? YES Go to step 4. NO Checkfor loosewires or poor connections. lf the connections good, the system is OK at this are time.l 4 . Stop the engine,and verify the DTC. ls DTC12 indicated? I s there battery v oltage? YES Go to slep 5. NO-Perform the appropriate troubleshooting for the code indicated. t YES-Repair short to power in the + circuitwire betweenthe torque sensorand EPScontrol unit.l NO Go to step 9.
Wire side ot lemaleterminals

1 . Turn the ignition switch ON (ll). 8 . Measurethe voltage betweenEPScontrol unit c o n n e c t oC ( 2 0 P ) t e r m i n a l o . 1 5 a n d b o d y g r o u n d . r N EPS CONTROL UNITCONNECTOR(2OP) C

2 3

5 6 1 8
T/SIG {YEL/BLK)

5 . Make sure the ignitionswitch is OFF,then


disconnectEPScontrol unit connectorC (20P) and the torque sensor6P connector. Checkfor continuitybetweenEPScontrol unit c o n n e c t oC ( 2 0 P ) t e r m i n a l o . 1 5 a n d b o d y g r o u n d . r N EPS CONTROL UNITCONNECTOR{2OP) C 9 . Turn the ignition switch OFF. 1 0 . Checkfor continuitybetweenEPScontrol unit connectorC (20P) terminal No. 15 and the torque sensor6P connectorterminal No. 4. EPS CONTROL UNITCONNECTOR(2OPI C

T/SIG (YEL/BLK)

W i r es i d eo f f e m a l e e r m i n a l s t

TOROUE SENSOR 6PCONNECTOR


T/SIG (YEL/BLK) Wire side of femaleterminals Wire side ot femaleterminals

ls therecontinuity? YES- Repair shortto bodygroundin thewire between torque the sensor EPS and control unit.l NO Go to step7.

ls there continuity? YES Go to step 1'1, NO Repairopen in the wire betweenthe torque sensorand the EPScontrol unit.I

17-28

'I 1 . Substitute known-goodEPScontrol unit, and a connectthe all disconnected connectors.

DTC16:Torque Sensor VT3andW6


1. Clear he DTC. t 2. Startthe engine. 3 . W a i t a t l e a s t1 0 s e c o n d s . Does the EPS indicator come on?

1 2 .Start the engine.


Does the EPS indicator come on? YES Go to step 13.

YES Go to step 4. lf NO Checkfor loose EPScontrol unitconnectors. necessary, replacethe EPScontrol unit and retest.l lf NO Checkfor loosewires or poor connnections. the connections are good,the system is OK at this time.l 4. Stop the engine,and verify the DTC. ls DTCl2 indicated? ls DTC16 indicated? YES Checkfor loosetorque sensorconnectors. lf necessary, substitutea known-goodsteering gearboxand recheck.l for NO-Perform the appropriate troubleshooting the code indicated. ! YES-Go to step 5. troubleshooting for NO Performthe appropriate the code indicated. t 5. Make sure the ignition switch is OFF,then and disconnectEPScontrol unit connectorC (20P) the torque sensor6P connector. 6, Checkfor continuitybetweenthe appropriateEPS terminal and body control unit connectorC (20P) ground (seetable). Terminal name Vccl C EPS control connector unit No. terminal

1 3 .Stop the engine,and verify the DTC.

3
11

Vcc2 VT3 VT6


T/S GND

13
5 2

EPS UNITCONNECIOR (2OP) C CONINOT

W re s d oltemalelermi.als

ls there continuity? YES- Repairshort to body ground in the appropriatesensorcircuit betweenthe torque sensorand EPScontrol unit,! NO Go to step7. {cont'd)

17-29

EPSComponents
(cont'd) DTCTroubleshooting
7 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s 8 . Measurethe voltage betweenthe appropriateEPS control unit connectorC (20P) terminal and body ground (seetable). Terminal name Vccl 9 . Turn the ignition switch OFF. 1 0 . Checkfor continuitybetweenthe appropriateEPS control unit connectorC {20P) terminal and the torque sensorterminal (seetable).

EPS control connector unit C t e r m i nNlo . a 3


11

Vcc2 VT3 VT6


T/S GND

13
5

EPSCONTROL UNITCONNECTOR {2OP} C

T e r m i n a l Torque Sensor EPS control name t e r m i n aN o , unitconnector l C t e r m i n aN o . l Vccl 2 3 Vcc2 3 11 'l 't3 VT3 VT6 6 5 6 T/S GND 2
TOROUE SENSOR CONNECTOR 6P Vccz (GRN/YELI
Wire side of femaleerminals t

VT6 {YEL/RED)

T/S GND {PNK) Wire side of femaleterminals

EPSCONTROL UNIT CONNECTOR I2OP) C VT6{YEL/RED}

ls thete battery voltage? YES Repairshon to power in the + circuitwire betweenthe EPScontrol unit and torque sensor.l NO Go to step 9.
Wire side of femaleterminals

ls therecontinuty? Y E S G ot o s t e p1 1 . NO Repair openin the appropriate torque sensor wirecircuitbetween EPS the control unitandthe torque ensor.l s

17-30

1 1 .Substitutea known-goodEPScontrol unit, and reconnect disconnected the connectors.

DTC17: Torque Sensor Vccl DTC18:Torque Sensor Vcc2

't2.

Start the engine. 1. Clear heDTC. t Does the EPS indicator come on? 2 . S t a r tt h e e n g i n e .

YES Go to step 13. 3. Wait at least 10 seconds. NO Checkfor looseor poor connections the at EPScontrol unit and the torque sensorconneclors. lf the connections good, replacethe EPScontrol are u n i ta n d r e c h e c k . I Does the EPS indicator come on? YES Go to step 4. lf NO Checkfor loosewires or poor connections. are good, the system is OK at this the connections time.I
4 . Stop the engine,and verify the DTC.

1 3 .Stop the engine,and verify the DTC.


ls DTC16 indicated? YES Replace steeringgearboxand recheck.l the for NO Performthe appropriate troubleshooting the code indicated.l

Is DTCl7 or DTCl8 indicated? YES Go to step 5. for NO Do the troubleshooting the DTc indicated.I Make sure the ignition switch is OFF,then and disconnectEPScontrol unit connectorC (20P) the torque sensor6P connector. Checkfor continuitybetweenEPScontrol unit N c o n n e c t oC ( 2 0 P ) t e r m i n a l o . 3 a n d b o d y g r o u n d . r UNIT C (2OP) EPS CONTROL CONNECTOR

Wiresideo{ female terminals

ls there continuity? s Y E S R e p a i r h o n t o b o d y g r o u n di n t h e w i r e betweenthe torque sensorand EPScontrol unit.I NO Go to step 7. (cont'd)

17-31

EPS Components
(cont'dl DTCTroubleshooting
7. Checkfor continultybetweenEPScontrol unit ) c o n n e c t oC ( 2 0 P t e r m i n a lN o . 3 a n d t h e t o r q u e r sensor6P connectorterminal No. 2. EPS CONTROL UNITCONNECTORI2OP) C 9. Checkfor continuitybetweenEPScontrol unit connectorC {20P) terminal No. 11 and the torque sensor6P connectorterminal No. 3. EPS CONTROL UNITCONNECTOR(2OP} C

Vcc2(GRN/YEL)

Wire side ol lemale terminals

Wire side of femaleterminals

ls thete continuity? YES Go to step 8. NO Repairopen in the wire betweenthe torque s e n s o r n d E P Sc o n t r o lu n i t . I a

ls therc continuity? YES-Go to step 10. NO Repairopen in the wire betweenthe torque sensorand EPScontrol unit.l

8 . Checkfor continuitybetweenEPScontrol unit


) c o n n e c t oC ( 2 0 P t e r m i n a lN o . 1 1 a n d b o d y g r o u n d . r EPS CONTROL UNITCONNECTOR(2OP) C

1 0 .Substitutea known-goodEPScontrol unit, and


connectall the disconnected connectors. 1 1 .Start the engine. Does the EPS indicator come on?

2 3
lvcc2

5 6 1 8

YES Go to step 12. NO Checkfor looseor poor connections the at EPScontrol unit and the torque sensorconnectors. lf the connections good, replacethe EPScontrol are u n i ta n d r e c h e c k . l

{GRN/YEL)

Wire side of femaleterminals

12. Stop the engine,and verity the DTC.


ls DTC17 or DTC18 indicated?

ls therecontinuity?
YES-Replace the steeringgearboxand recheck.l

YES Repair shortto bodygroundin thewire between torquesensor EPS the and control unit. t NO Goto step9.

NO Performthe appropriate for troubleshooting the code indicated.l

17-32

22: DTC Vehicle Speed Sensor Signal DTC Engine 23: Speed Signal

3 . Blockthe rearwheels and raisethe vehicle,and


make sure it is securelysupported.
4 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s

NOTE: . lf the MIL indicatoris ON, troubleshoot the PGIVI-Fl systemfirst. . Eventhough the system is operatingnormally,the EPSindicatorwill come on underthe following conditions. - Condition : 1 . The vehiclewas travelingat least '12.4 mph (20 km/h),then . A rapld changein vehiclespeedwas detected, then . T h e v e h i c l e o rt h e v e h i c l e p e e ds e n s o r i g n a l ) ( s s and stoppedfor at least5 seconds, . The engine speedwas still 1,640rpm or higherfor at least5 seconds - Condition2: After the vehicle(or the vehiclespeedsensor yetthe signal)has stoppedfor at least10 seconds, w r e n g i n e p e e d a s s t i l l 1 , 6 4 0 p m o r h i g h e rf o r a t s least20 seconds. - Condition3: W h e nt h e v e h i c l e p e e di s 1 0 k m / h ( 6 . 2m p h )o r s a b o v ea n d t h e e n g i n ei s r u n n i n g t 2 8 0 r p m o r a below for 3 seconds. 1. Startthe engineand checkthe tachometer. ls the tachometer working correctly? YES- Go to step 2. N O - G o t o s t e p9 . 2. Test-drive vehicleabove 15 km/h {9.3mph). the ls the speedometerworking correctly? YES Go to step 3. system NO-Perform the speedometer troubleshooting {see page22-651.a

5 . Blockthe right front wheel, and slowly rotatethe left front wheel, and measurethe voltage between N E P Sc o n t r o lu n i tc o n n e c t oC ( 2 0 P ) t e r m i n a l o . 7 r a n d b o d yg r o u n d . EPS CONTROL CONNECTOR UNIT C {2OP)

Wire side of femaleterminals

Does the voltagepulse 0 V and 5 V? YES Go to step 6. NO Repairopen in the wire betweenthe EPS for control unit and the VSS. lf the wire is OK,check at a loose or poor connections the EPScontrol unit. lf necessary, substitutea known-goodEPScontrol u n i t ,a n d r e c h e c k . l

(conr'd)

17-33

EPSGomponents
(cont'dl DTCTroubleshooting
Turn the ignition switch OFF,and disconnect EPS control unit connectorC (20P). 7 . Startthe engine,and let it idle. 8 . Measurethe voltage betweenEPScontrol unit c o n n e c t oC { 2 0 P t e r m i n a lN o . 1 9a n d b o d y g r o u n d . r ) EPS CONTROL UNITCONNECTOR{2OP) C 11. Measurethe voltage betweenEPScontrol unit c o n n e c t oC ( 2 0 P ) t e r m i n a l o . 1 9 a n d b o d y g r o u n d . r N EPSCONTROL UNITCONNECTOR {2OPI C

Wiresideof female terminals

ls there about 6 V at idle? (With the metet set tor trequency, is therc 33 Hz per 1,000 engine rpn?)
Wire side of {emaleterminals

ls there about 6 V at idle? (With the meter set lol t requency,is there 33 Hz per 1,000engine rpm?) YES Checkfor loose EPScontrol unit connectors. lf necessary, substitutea known-goodEPScontrol u n i ta n d r e c h e c k . l NO Repairopen in the wire betweenthe EPS c o n t r o lu n i ta n d t h e E C M . I 9 . Turn the ignition switch OFF,and disconnect EPS control unit connectorC (20P).

YES Checkfor loose EPScontrol unitconnectors. lf necessary, substitutea known-goodEPScontrol u n i ta n d r e c h e c k . I NO Go to step '12.

1 2 .Turn the ignition switch OFF. 1 3 .Disconnect ECMconnectorE (31P)connector. the

1 0 .Startthe engine,and let it idle.

!
17-34

'14. Checkfor continultvbetweenEPScontrol unit c o n n e c t oC ( 2 0 P ) t e r m i n a l o . 1 9 a n d E C M r N connectorE (31P) terminal No. 26. ECM CONNECTOR E {31PI

DTC EPS 37: Control UnitInternal Circuit (lnputCircuit MotorVoltage) For


1 . C l e a rt h e D T C . 2. Startthe engine. several 3. Turn the steeringwheel from lock-to-lock times, and wait 10 secondsor more. Does the EPS indicator come on? YES Go to step 4. lf NO Checkfor loosewires or poor connections. the connections are good,the system is OK at this trme.l

ls thete continuity? YES-Go to step 15. N O - R e p a i ro p e ni n t h e w i r e b e t w e e n h e E P S t c o n t r o lu n i ta n d E C M . I 1 5 . Disconnect gauge assembly22Pconnector. the Checkfor continuitybetweenEPScontrol unit N c o n n e c t oC ( 2 0 P ) t e r m i n a l o . 1 9 a n d b o d y g r o u n d , r EPS CONTROL UNITCONNECTOR(2OP} C

4. Stop the engine,and verify the DTC. ls DTC 37 indicated? YS Checkfor loose EPScontrol unit conneclors. lf necessary, substitutea known-goodEPScontrol u n i ta n d r e c h e c k . l for troubleshooting NO Performthe appropriate the code indicated.l

Wiresideof female terminals

ls there continuity? Y E S R e p a i r h o r t t ob o d y g r o u n di n t h e w i r e s betweenthe EPScontrol unit, the test tachometer the connector, gaugeassembly,and the ECM.I NO Checkfor loose ECMcontrol unit connectors. lf necessary, substitutea known-goodECMcontrol u n i ta n d r e c h e c k . I

17-35

EPSComponents
(cont'dl DTCTroubleshooting
41: For DTC Voltage Motor
1. Clearhe DTC. t 2 . S t a r tt h e e n g i n e . several 3. Turn the steeringwheel from lock-to-lock times, and wait 10 secondsor more, Does the EPS indicator come on? YES-Go to step 4. NO Checkfor loosewires or poor connections. lf are good,the system is OK at this the connections time.l 4. Stop the engine,and verify the DTC. ls DTC 41 indicated? YES Go to step 5. NO Go to step 8. troubleshooting for NO Performthe appropriate t h e c o d ei n d i c a t e d . l 5. Make sure the ignition switch is OFF,then disconnectEPScontrol unit connectorB (2P)and the motor 2P conneclor. 6. Checkfor continuitybetweenEPScontrol unit t c o n n e c t o B ( 2 P ) e r m i n a lN o . 1 a n d b o d y g r o u n d . r
UNIT CONNECTOR {2P} B EPSCONTROL M2 (GRNI

.l
7. Checkfor continuitybetweenEPScontrol unit N c o n n e c t o B ( 2 P ) t e r m i n a l o . 2 a n d b o d yg r o u n d . r EPSCONTROL UNITCONNECTOR I2P) B

Tit M2 {GRN) FJ

o)
I

-r

Wiresideof female terminals

ls there continuity? Y E S - R e p a i rs h o r tt o b o d y g r o u n di n t h e G R Nw i r e betweenthe EPScontrol unit and the motor,l

Checkfor continuitybetweenEPScontrol unit N c o n n e c t oB ( 2 P ) t e r m i n a l o . 1 a n d N o . 2 . r B EPS CONTROL UNITCONNECTOR{2P)

M1 (RED}H

Itr (f))
,L

F---t||

Wiresideof female terminals

ls there continuity? YES Repairshort betweenthe REDand GRN wires in the motor circuit betweenthe EPScontrol u n i t a n dt h e m o t o r . l NO Go to step 9.

Wiresideof female terminals

ls there continuity? YES Repairshort to body ground in the REDwire betweenthe EPScontrol unit and the motor.! N O - G o t o s t e p7 .

17-36

9. Turn the ignition switch ON (ll),and measurethe voltagebetweenEPScontrol unit connectorB (2P) terminal No. 1 and body ground EPSCONTROL UNITCONNECTOR (2P) B

1 1 .T urn the ignition switch is OFF. Substitutea known-goodEPScontrol unit, and connectall the disconnected connectors.

1 3 .Start the engine,and turn the steeringwheel from


lockto lock severaltimes.

M1 IREDIH r-_-1 ||

,<.)\ uL,/ Y

tr

Does the EPS indicator come on? Y E S - G o t o s t e p1 4 . NO-Check for loose or poor connections atthe lfthe EPScontrol unit and the motor connections. connections are good, replacethe EPScontrol unit andrecheck.l 1 4 . S t o pt h e e n g i n e a n d v e r i t yt h e D T C . ,

WiresideoI female terminals

Is there battety voltage? ls DTC 41 indicated? YES Repairshort to power in the + circuitwire betweenthe EPScontrol unit and the motor.I N O - G o t o s t e p1 0 . YES Replace steeringgearboxmotor and the recheck.l NO Performthe appropriate troubleshooting for t h e c o d ei n d i c a t e d . l

1 0 .Measurethe voltagebetweenEPScontrol unit


c o n n e c t oB ( 2 P ) t e r m i n a l o . 2 a n d b o d y g r o u n d . r N EPS CONTROL B UNITCONNECTOR(2P)

raz rcnrrrr l{ I . l-t

I (v)

Y I

Wire side of femaleterminals

ls there battery voltage? YES-Repair shortto power in the - circuitwire betweenthe EPScontrol unit and the motor.! N O G o t o s t e p1 1 .

17-37

EPSComponents
(cont'd) DTCTroubleshooting
DTC42,45: MotorDrivenCurrent
1. Clearthe DTC. 2. Start the engine. 3. Turn the steeringwheel from lock-to-lock several t i m e s ,a n d w a i t 1 0 s e c o n d s r m o r e . o Does the EPS indicator come on? YES- Go to step 4. NO-Check for loosewires or poor connections. lf the connections are good, the system is OK at this time.I Stop the engine,and verify the DTC. ls DTC 42 or 45 indicated? YES-Go to step 5. NO Go to step 8. NO- Performthe appropriate troubleshooting for t h e c o d ei n d i c a t e d . I M a k es u r et h e i g n i t i o n w i t c hi s O F F , h e n s t EPScontrol unit B connector(2P)and disconnect the motor 2P connector. Checkfor continuitybetweenEPScontrol unit c o n n e c t oB ( 2 P ) e r m i n a lN o . 1 a n d N o . 2 . r t EPS CONTROL UNITCONNECTOR{2P) B EPSCONTROL UNITCONNECTOR I2PI B 7. Checkfor continuitybetweenEPScontrol unit l c o n n e c t oB ( 2 P l t e r m i n aN o . 2 a n d b o d y g r o u n d . r

r',rz ll tcnnrt
-](o)
I

Wiresideof female terminals

lsthere continuity? YES Repairshort to body ground in the GRNwire betweenthe EPScontrol unit and the motor.l

6 . Checkfor continuitybetweenEPScontrol unit


c o n n e c t o B ( 2 P ) t e r m i n a l o . 1 a n d b o d yg r o u n d . r N EPS CONTROL UNITCONNECTORI2P) B
M2 {GRN)

M1 IRED}H

I
I

f2-l

W i r es i d eo f f e m a l e e r m i n a l s t

(C))

ls there continuity? YES Repairshort betweenthe REDand GRN wires in the motor circuit betweenthe EPScontrol u n i ta n d t h e m o t o r . l NO Go to step 9.

Wire side of femaleterminals

ls there continuity? YES Repairshort to body ground in the REDwire betweenthe EPScontrol unit and the motor,I N O - G o t o s t e p7 .

17-38

9. Turn the ignition switch ON (ll),and measurethe voltage betweenEPScontrol unit connectorB (2P) t e r m i n a lN o . I a n d b o d y g r o u n d . EPSCONTROL UNITCONNECTOR (2PI B

11. Checkfor continuitybetweenEPScontrol unit connectorB (2P)terminal No. 1 and the motor 2P connectorterminal No. 2. EPSCONTROL UNIT B 12P) CONNECTOR MOTOR CONNECTOR {2PI

M1{RED} H T-----l | |

M1 IRED)
M1 (RED}

(v)
I

lil

I
Wire side of femaleterminals

Wiresideo{ Iemale terminals

ls there battety voltage? YES-Repair short to power in the + circuitwire betweenthe EPScontrol unit and motor.l NO Go to step 10.

ls therecontinuity? YES-Go to step'12. NO-Repairopenin the RED wire between EPS the controlunitandthe motor.l

1 0 .Measurethe voltage betweenEPScontrol unit


c o n n e c t oB { 2 P } t e r m i n a l o . 2 a n d b o d y g r o u n d . r N EPS CONTROL CONNECTOR UNIT B (2P}

mzrcnrur ll-l
A (v)

Y I

W i r es i d eo f f e m a l e e r m i n a l s t

ls there battery voltage? Y E S R e p a i r h o r tt o p o w e ri n t h e + c i r c u i t w i r e s betweenthe EPScontrol unit and the motor.a N O - G o t o s t e p1 1 .

(cont'd)

17-39

EPS Gomponents
(cont'd) DTGTroubleshooting
12. Checkfor continuitybetweenEPScontrol unit c o n n e c t o B ( 2 P ) t e r m i n a l o . 2 a n d t h e m o t o r2 P r N c o n n e c t otre r m i n a lN o . 1 .
EPSCONTROLUNIT CONNECTOR I2PI B

L
15. Stop the engine,and verify the DTC. ls DTC 42 or 45 indicated? YES Replace steeringgearboxmotor and the recheck.l NO Performthe appropriate for troubleshooting the code indicated.l

MOTOR CONNECTOR {2P)

M2 IGRN)

Wire side of femaleterminals

ls there continuity? Y E S - G o t o s t e p1 3 . NO-Repair open in the GRNwire betweenthe EPS control unit and the motor.l Checkfor loosewires or poor connections, the if connections are good. substitutea known-good EPScontrol unit, and connectallthe disconnected connectors. 1 4 . Startthe engine,and turn the steeringwheel from lockto lock severaltimes. Does the EPS indicatot come on? YES Go to step 15. NO Checkfor loose EPScontrol unitconnectors. lf necessary, replacethe EPScontrol unit and recheck. a

17-40

tli|: DTC MotorDriven Current Excessively is Hish


1. Clear he DTC. t 2. Startthe engine. 3. Turn the steeringwheel from lock-to-lock several '10 times, and wait secondsor more. Does the EPS indicator come on? YES Go to step 4. NO-Check for loosewires or poor connections. lf the connections good,the system is OK at this are ttme.I 4. Stop the engine,and verify the DTC. ls DTC 43 indicated? YES Go to step 5. NO-Perform the appropriate troubleshooting for the code indicated.I 5. Make sure the ignition switch is OFF,then disconnect EPScontrol unit connectorB (2P)and the motor 2P connector. 6. Turn the ignition switch ON (ll). 7. Measurethe voltage betweenEPScontrol unit '1 c o n n e c t oB ( 2 P ) t e r m i n a l o . a n d b o d y g r o u n d . r N EPSCONTROL UNITCONNECTOR {2P} B

8. Measurethe voltagebetweenEPScontrol unit c o n n e c t o B ( 2 P ) t e r m i n a l o . 2 a n d b o d yg r o u n d . r N EPS CONTROL CONNECTOR UNIT B I2PI

M2tcRNl F-l
f---1 z I

Til

(v)
I
Y
W i r es i d eo f f e m a l e e r m i n a l s t

ls there battety voltage? YES- Repairshort to power in the - circuitwire betweenthe EPScontorl unit and the motor.! NO-Go to step 9. 9 . Turn the ignition switch OFF. 1 0 . Checkfor continuitybetweenEPScontrol unit c o n n e c t o B ( 2 P ) e r m i n a l s o . 1 a n d N o .2 . r t N EPS CONTROL UNITCONNECTOR{2P) B

M2 {GBN)

M 1 { R E o )H
T------t

It (v)r
T -L

I I

Wire side of femaleterminals

ls there continuity? YES Repairshort betweenthe GRN and RED wires in the motor circuitbetweenthe EPScontrol u n i ta n d t h e m o t o r . l N O G o t o s t e p1 1 .

Wiresideot Iemale terminals

ls therc battery voltage? YES Repairshort to power in the + circuitwire betweenEPScontrol unit and motor.l N O - G o t o s t e p8 . ( c o n td )

17-41

EPSComponents
(cont'dl DTCTroubleshooting
1 1 .Substitutea known-goodEPScontrol unit, and connectall the disconnected connectors.

DTC 47: EPS Control Unitlnternal Circuit (Power Relay)


1. Clearthe DTC. 2. Startthe engine.

1 2 .Start the engine,and turn the steeringwheel from


lockto lock severaltimes. Does the EPS indicator come on?

Does the EPS indicator come on? YES Go to step 13. NO -Check for loose or poor connections the at EPScontrol unit and the motor connections. the lf connections good, replacethe EPScontrol unit are and recheck.l YES-Go to step 3, NO-Check for loosewires or poor connections, lf the connections good, the system is OK at this are time.I 3. Stop the engine,and verify the DTC. ls DTC 47 indicated? YES Checkfor loose EPScontrol unit connectors. lf necessary, substitute known-goodEPScontrol a u n i ta n d r e c h e c k . l NO Performthe appropriate troubleshooting for the code indicated.I

1 3 .Stop the engine,and verity the DTC.


ls DTC 43 indicated? YES-Replacethe steeringgearboxmotor and recheck.tl NO-Perform the appropriate troubleshooting for the code indicated.l

17-42

DTC50: EPS ControlUnit Internal Circuit (CPU Microcomputer) or


1. Clearthe DTC. 2. Start the engine. Does the EPS indicator come on? YES Go to step 3. NO Checkfor loosewires or poor connections. lf the connections good. the system is OK at this are t i m e .t 3. Stop the engine,and verify the DTC. ls DTC 50 indicated? YES-Check for looseor poor connections the at EPScontrol unit connections. the connections lf are good, substitutea known-goodEPScontrol unit. lf goes away, replacethe the symptom/indication original EPScontrol unit.l NO Performthe appropriate troubleshooting for the code indicated. t

DTC 51: EPS Control UnitInternal Circuit (EEPROM)


1. Clear he DTC. t 2. Start the engine. Does the EPS indicatot come on? YES-Go to step 3. NO-Check for loosewires or poor connections. lf the connections good, the system is OK at this are time.I 3. Stop the engine,and verify the DTC. ls DTC 51 indicated? YES-Check for looseor poor connections the at EPScontrol unit connections. the connections lf are good. substitutea known-goodEPScontrol unit. lf goes away, replacethe the symptom/indication original EPScontrol unit.! NO Performthe appropriate troubleshooting for the code indicated. t

17-43

EPSComponents
(cont'dl DTC Troubleshootang
Circuit DTC62: EPS ControlUnit Internal (Fail-safe ON) Relay Stuck
'1. Clearthe DTC. 1. Clear he DTC. t 2. Startthe engine. Does the EPS indicatot come on? YES Go to step 3. lf NO Checkfor loosewires or poor connections. the connections are good,the system is OK at this trme.l 3. Stop the engine,and verify the DTC. ls DTC 64 indicated? YES Go to step 4. for troubleshooting NO Performthe appropriate the code indicated. '18(604) fuse/ 4. Checkthe No. fuse in the under-hood relay box, and reinstallthefuse if it is OK. Is the f use OK? YES Go to step 5. NO Replace fuse and recheck.l the 5. Disconnect EPScontrol unit connectorA (2P). 6. Measurethe voltage betweenEPScontrol unit t c o n n e c t oA ( 2 P ) e r m i n a lN o . 1 a n d b o d y g r o u n d . r

is Low DTC64: Battery Voltage Excessively (Fail-safe Relay Contact Failure Motor and FallOff) Voltage

2. Startthe engine. Does the EPS indicator come on? YES-Go to step 3. lf NO-Check for loosewires or poor connections. are the connections good, the system is OK at this time.I 3. Stop the engine,and verify the DTC. ls DTC 62 indicated? at YES-Check for loose or poor connections the are EPScontrol unit. lf the connections good, substitutea known-goodEPScontrol unit. lf the goes away, replacethe symptom/indication originalEPScontrol unit and recheck.l troubleshooting for NO-Perform the appropriate the code indicated. t

-Blwt{r/Bl.urH l \9

ls there battety voltage? at YES- Checkfor loose or poor connections the and checkfor a poor EPScontrol unit connectors, ground at G 151. lf necessary, a substitute knowngood EPScontrol unit and recheck.l NO Repairopen in the WHT/BLUwire between e c t h e N o . 1 8 ( 6 0 , 4 ) f u sa n d E P S o n t r o lu n i t . l

17-44

DTC 66,68: EPS Control Unitlnternal Circuit


1. Clear he DTC. t 2. Start the engine. 3. Turn the steeringwheel from lock-to-lock several times, and wait 10 secondsor more. Does the EPS indicator come on? YES-Go to step 4. NO-Check for loosewires or poor connections. lf the connections good.the system is OK at this are time.l 4. Stop the engine.and verify the DTC.

DTC67: TorqueSensorl/FCircuit
1. Clearthe DTC. 2 . S t a r tt h e e n g i n e . 3. Turn the steeringwheelfrom lock-to-lock several times, and wait 10 secondsor more. Does the EPS indicator come on? YES-Go to step 4. NO Checkfor loose wires or poor connections.lf the connectionsare good, the system is OK at this time. ! 4. Stop the engine,and verify the DTC. ls DTC 67 indicated?

ls DTC 66 or 68 indicated? YES-Check for looseor poor connections the at EPScontrol unit. lf the conneclionsare good, substitute known-goodEPScontrol unit. lf the a goes away, replacethe symptom/indication original EPScontrol unit and recheck.I NO Performthe appropriate troubleshooting for the code indicated. t YES Checkfor looseor poor connections the at EPScontrol unit. lf the connections are good, substitutea known-goodEPScontrol unit. lf the goes away, replacethe symptom/indication original EPScontrol unit and recheck. ! NO-Perform the appropriate for troubleshooting the code indicated.I

17-45

EPS Components
(cont'd) DTCTroubleshooting
DTC69: EPS ControlUnit Internal Circuit
1. Clear he DTC. t 2. Startthe engine. several 3. Turn the steeringwheel from lock-to-lock times, and wait 10 secondsor more, Does the EPS indicator come on? YES Go to step 4. NO-Check for loosewires or poor connections. lf the connections are good, the system is OK at this time.l 4. Stop the engine,and verify the DTC. ls DTC 69 indicated? YES-Check for loose or poor connections the at are good, EPScontrol unit. lf the connections substitutea known-goodEPScontrol unit. lf the goes away, replacethe symptom/indication original EPScontrol unit and recheck.l troubleshooting for NO- Performthe appropriate the code indicated.l

17-46

EPSIndicatorCircuitTroubleshooting
1 . Turn the ignitionswitch ON (ll),startthe engine, and watch the EPSindicator. Does the EPS indicator come on? 7 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s YES lf the EPSindicatorcomes on and goes off, it's OK. lf the EPSindicatorstayson or blinks.go to s t e p1 2 . NO Go to step 2. Turn the ignition switch OFF,then ON (ll) again, and watch the brakesystem indicator, Does the brake system indicator come on? YES-Go to step 3. NO Repairopen in the indicatorpower source circuit.l . B l o w nN o . 1 0 ( 7 . 5 A ) f u s e . . Open in the wire betweenthe No. 10 (7.5A) fuse and gaugeassembly. . Open circuitinsidethe under-dash fuse/relaybox, . Faultygauge assembly.
s Wire s d oflemale16rmina

5. Turn the ignition switch OFF. EPScontrol u n it connectorC (20P). 6. Disconnect

8. ConnectEPScontrol unit connectorC (20P) terminal No. 6 to body ground with a jumper wire.
EPSCONTBOLUNIT CONNECTOBC {2OP)

Does the EPS indicatot come on? YES Go to step 9. NO Repairopen in the wire betweenthe gauge assemblyand the EPScontrol unit.l

3 . Turn the ignitionswitch OFF, 9 . Turn the ignitionswitch OFF.


4 . Connecta jumper wire betweenthe gauge

assembly22Pconnectorterminal No. 13 and body g r o u n d , h e nt u r n t h e i g n i t i o n w i t c hO N ( l l ) . t s (Blue ASSEMBLY CONNECTOR connector) 22P GAUGE

1 0 .Disconnect EPScontrol unit connectorA (2P), ' l1 .


Checkfor continuitybetweenEPScontrol unit connectorA terminal No. 2 and body ground.
A I2PI EPS CONTROL UNITCONNECTOA

w i r e s d e o f t e m a l et e r m i n a l s

Wiresideof female terminals ls there continuity? Does the EPS indicator come on? YES-Go to step 5. N O I n s p e ctth e E P Si n d i c a t o b u l b ,i f t h e b u l b i s r O K , r e p l a c eh e b u l bc i r c u i tb o a r di n t h e g a u g e t assembly.l YES Checkfor loose or poor connections the at E P Sc o n t r o lu n i t .l f t h e c o n n e c t i o na r e g o o d , s substitutea known-goodEPScontrol unit. lf the goes away, replacethe symptom/indication o r i g i n a E P Sc o n t r o lu n i ta n d r e c h e c k . I l N O R e p a i r p e ni n t h e w i r e o r a b a d g r o u n da t o G151,t (cont'd)

17-47

EPS Components
(cont'dl EPSIndicatorCircuitTroubleshooting
1 2 .Turn the ignitionswitch OFF. 1 3 .Disconnect EPScontrol unit connectorC (20P). 1 4 .Turn the ignitionswitch ON (ll).
Does the EPS indicator come on? YES-Repair short to ground in the YEUBLUwire betweenthe gaugeassemblyand the EPScontrol unit,or replacethe bulb circuit board in the gauge assembly.l NO-Go to step 15. Measurethe voltagebetweenEPScontrol unit c o n n e c t oC ( 2 0 P ) t e r m i n a l o . 1 0 a n d b o d y g r o u n d . r N EPS CONTROL UNITCONNECTORI2OP) C EPS CONTROL UNITCONNECTON A (2P} 16. Measurethe voltagebetweenEPScontrol unit '1 connectorA (2P)terminalNo. and body ground.

+B (WHT/BLUI H

v
-L
YES-Go to step 17.

Itr

Wire side of female terminals

ls there battery voltage?

NO-Check for a blown No. 18 (604)fuse in the under-hood fuse/relaybox or open/shortin the WHT/BLUwire betweenthe under-hoodfuse/relay box and the EPScontrol unit.l 1 7 . Turn the ignition switch OFF. 1 8 , Reconnect EPScontrol unit connectorA (2P). 1 9 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s 20. Measurethe voltage betweenEPScontrol unit connectorC (20P)terminal No. 8 and body ground.
Wire side of femaleterminals

ls therebatteryvoltage? Y E S - G ot o s t e p1 6 . NO-Repairopenin thewire between control EPS unitconnector (20P) the No, 10(7.5A) C and fuse. t

EPS CONTROL CONNECTOR UNIT C (2OP)

Wiresideof female terminals

ls therc about 10 V? YES Checkfor looseor poor connections the at EPScontrol unit. lf the connections good, are substitutea known-goodEPScontrol unit. lf the goes away, replacethe symptom/indication originalEPScontrol unit and recheck.l NO Repairshort to ground in the BRNwire betweenthe data link connectorand the EPS c o n t r o lu n i t . I

17-48

Motor Removal/lnstallation
Bemoval 1. Make sure you havethe anti-theftcode for the radio, then write down the frequencies the preset for buttons. 2. Disconnect negativecablefrom the battery,and the wait 3 minutesbefore beginningwork. 3. Removethe air cleanerassembly(A). 4. Removethe connectorbracket(A) onthegearbox housing,and disconnect the motor 2P connector (B).
9.8 N.m {1.0kgf.m,

5. Removethe motor {A) from the gearboxhousing.

6. Removethe O-ring (B)and discardit.

(cont'd)

17-49

EPSComponents
(cont'dl Motor RemovaUlnstallation
lnsiallation 7. Cleanthe mating surfaceof the motor (A) and gearbox. 8 x '1.25 mm 20 N.m kgt.m,7.2lbl ftl 12.0

r 0 .Installthe motor on the gearboxby engagingthe


motor shaft and worm shaft (D).Note the motor position{directionof motor wires). installation 1 1 .Beforetighteningthe bolts,turn the motor two or three times right and left about 45 degrees.lvlake sure the motor is evenlyseatedon the steering gearboxand that the O-ring is not pinchedbetlveen the mating surfaces.

q
E

1 2 .Installthe removedDartsin the reverseorder of


removal.and note these items: lvlake sure the motor 2P connectoris properly connected. lvlake surethe motor and EPSwires are not caughtor pinchedby any parts. Reconnect negativecableto the battery. the D o t h e e n g i n e o n t r o l o d u l e( E C M ) d l e l e a r n c m i ( p r o c e d u r es e ep a g e1 1 - 1 3 9 ) . Enterthe anti-theft code for the radio station Dresets. Resetthe clock, Do the oower window control unit reset procedure(seepage 22-1241.

c].E@

L==-

Apply a thin coat of siliconegrease(P/N087338070E)tothe new O-ring(B),and carefullyfit it on the motor. 9 . Apply grease{Nippon GreaseWR-S or equivalent steeringgear grease)into the motor shaft (C).

1 3 .After installation, startthe engine,and let it idle.


Turn the steeringwheel from lock-to-lock several times. Checkthat the EPSindicatordoes not come on.

17- 5 0

SteeringGearboxRemoval
Special Tool Required Ball ioint remover,2Smm 0TlvlAC-S100200 1. Raisethe front of vehicle,and make sure it is securelysupponed. 2. Removethe front wheels. a R e m o v eh e d r i v e r ' s i r b a g ( s e e p a g e 2 3 - 1 1 3 ) . t 4 . Removethe steeringwheel (seepage 17-6). 5 . Removethe motor on the steeringgearbox (see p a g el T - 4 9 ) .
l,a.: '/ --L-

8. Removethe cotter pin (A)from the tie-rod balljoint nut {B),and loosenthe nut.

_t\

6 . Removethe driver'sdashboardlower cover (see


page20-59)and under cover {seepage20-60). 7 . Removethe steeringjoint bolts (A),and disconnect the steeringjoint by moving the steeringjoint (B) toward the column.

r0 mm HEXNUT

07MAC-S100200

9 . Separatethe tie-rod balljoint and damper steering


Repeat arm usingthe specialtool (seepage 18-10). on the other side of the vehicle. , 1 0 .G r a s pt h e r i g h ts i d et i e - r o d a n d p u l lt h e r a c ka l l t h e side, way to the passenger's 1 1 . Removethe heat shield (A) mounting bolts from the body stiffener,and let the heat shield lay againstthe exhaust.

'

(cont'd)

17-51

EPS Components
SteeringGearboxRemoval(cont'd)
12. Disconnect EPS the (A), wire harness connector 6P (B) andremove EPS the wire harness andmountino (C). bracket
1 4 . R e m o v e h e e n g i n e i r e h a r n e s s l a m p s{ A ) f r o m t w c the three mounting brackets.

-a--zi
i

F--_1

t5.

Removethe heaterhose {B)from the bracket.

(A) 1 3 . Remove ground the cable terminal fromthe gearbox steering housing.

.,/

..(

ry T,-.lt'^ \
'" \--

a b- \ H

1 6 . Open the heatervalve cableclamp (A),and disconnect heatervalve cable(B).Removethe the heatervalve (C)from the bulkhead, and move jt aside.

_ - 1 . . 1 . - '

17-52

17. Removethe bodv stiffener(A).

19. Removethe steeringstiffenerB from the right side of the steeringgearbox.

i t1-:: .,

1 8 .Removelhe steeringstiffenerA from the left side


of the steeringgearbox.

20. Lower the steeringgearbox,and rotateit so the pinion shaft points upward. 21. Removethe pinion shaft grommet (A)from the top of the torque sensor.

(cont'd)

17-53

EPS Components
SteeringGearboxRemoval{cont'd)
22. Move the steeringgearboxand tie-rod ends as an assemblyto the wheelwellopening on the passenger's side. 23. Carefullyraisethe driver'sside (pinionside)ofthe steeringgearbox(A) and tie-rod (B) until clearsthe mastercylinderand under-hood fuse relay box, then removethe steeringgearbox.Be careful not to damagethe hoses,linesand wtre narnesses.

17-51

SteeringGearboxOverhaul
ExplodedView
mm I x '1.25 ftl 20 N.m(2.0 kgf.m,7.2lbt O.RING Replace. PINION SHAFT GROMMET

CONNECTOR

RACKGUIDE

-@ . WASHEB @'--. DISC g

-sPRrNG
SCREW

' v---\

L)-RACKGUIDE 6

\.oc**u.

6^:,;
BOOT BAND Beplace. '"''/

v \>--. -*\{i#r^i i
.
GUIDE \ SLTDER {^il \J" \

-'t

''

s(./t' J -l
\ \ \ stot *,tttc Renrace

SRACKET

@ I I
rtE-ROD

\ LocKscREw '162

W LOCK ASHER Replace.


54 N m {5.5kgf.m,40lbf ft)

\ BOOTBAND - Replace.

N.m l t o . sr g f m , 1 1 9 l bfft ) Beqtace.

TIE.ROD END

44 N m {4.5 kgf.m, 33 tbt.ft)

(cont'd)

17-55

EPSComponents
SteeringGearboxOverhaul(cont'dl
Special Tools Required . Locknutwrench 07ZAA-S5A0100 . Pincers, Oetiker1098or equivalent, commercially available. NOTE: . Referto the ExplodedView as neededduring this procedure. . Do not allow dust, dirt, or other foreign materialsto enter into the steeringgearbox. Eemoval 1, Removethe steeringgearbox(seepage 17-b1). Disassembly 2. Unbendthe lock washer (A). 4. Removethe stop plate (A).the 12 mm flange bolts (B),the O-rings(C),and the bracket(D)from the sleeringgearbox.

-,'i. . Loosenthe locknut(A),then removethe rack guide screw (B),sprlng (C),disc washer (D),and rack g u i d e( E )f r o m t h e s t e e r i n g e a r b o x . g
i::..:4,. , - -. -

:.--. '

Holdthe bracket(A) with one wrencn, anq unscrew both tie-rod ends (B)with anotherwrench. Remove the lockwashers.

1 7-56

6. Removethe two boot bands (A)from boot (B). Compressthe boot by hand,and apply vinyl tape (C)so the boot ends stay collapsedand pulled back

8. Installthespecialtool (A) on the lock screw (B) securely. then loosenand removethe lock screw from the steeringgearboxhousing.

07zAA-S5A0r00

1 . Attachthe yoke (A) of a universalpullerto the steeringgearboxmounts with bolts.Securely clamp the yoke in a vise as shown. Do not clamp the steeringgearboxhousingin the vise.

Removethe specialtool.

1 0 .Pull on the rackhousing(A)to remove it from the


steeringgearboxhousing,Removethe boot {B) and s l i d e rg u i d e( C )f r o m t h e c y l i n d e r .

(cont'd)

17-57

EPSComponents
SteeringGearboxOverhaul(cont'd)
'll. Checkthe slider guide for damageand cracks. Using verniercalipersto measurethe thicknessof the slider guide. lf the thicknessis lessthan service l i m i t ,r e p l a c eh e s l i d e rg u i d e , t

15. Applymultipurpose grease the indicated part to part)of theoutersurface the rack {shaded of housing. not applyto the dents Do andgrooves.

(fr--', -.---I il ( t t l
f Z,-----:-r-.--------.t.t'E-r

i @ r
25.3mm in.} {0.925

,)))

/i\

I
|

25.3 mm in.l {0.925

12

Remove discard stopring{A)onthe and the cylinder expanding with snapringpliers. by it Remove discard lockscrew{B}. and the

13. Installthe new lock screw on the rack housing. 1 4 . I n s t a l l t h e e w s t o p r i n g i n t h e g r o o v e( C ) o nt h e n cylinderby expandingit with a snap ring pliers.Be carefulnot to scratchor damagethe housing surfacewith the stop ring edges.

I
17-58

16. Set the new boot bands (A) on the band installation groovesof the boot (B) by aligningthe tabs (C)with the holes (D)of the band.Do not closethe ear of the boot band in this step.

'19. Pushthe rack housing(A) into the steeringgearbox housing(B) so the notch (C)is alignedwith the pin (D)on the bottom of the gearboxhousinginside

1 1 . Compressthe boot by hand,and apply vinyl tape (E)to the bellowsso the boot ends stay collapsed and pulled back. Passthe boot over the rack housingso the smaller diameterend of the boot facesthe steering gearboxhousing.

20. Tightenthe lock screw {A) by hand first, then install the specialtool (B)on the lock screw. Lightly tighten the lock screw.Do not tighten the lock screwto the specifiedtorque Yet.

1 8 .Attachthe yoke (A) of a universalpuller to the


gearboxhousingmounts with bolts.then securely clamp the yoke in a vise as shown. Do not clamp the steeringgearboxhousingin a vise.

21. Removethe specialtool.

(cont'd)

17-59

EPSComponents
SteeringGearboxOverhaul(cont'dl
22. Apply multipurposegreaseto the sliding surface and circumference ofthe rackguide (A),and install it onto the gearboxhousing.Wipe the greaseoff the threadedsectionofthe housrno. 25. Centerthesteeringrackwithin its stroke,and align t h e s l i d e rg u i d e( A ) w i t ht h e h o t e s( B )i n t h e b o o t ( C ) . Fit the slider guide to the boot by pressingaround the edgesof the holessecurely

'1

- .- =-1, ...'. ,. ,l
.j

2 3 . I n s t a l l t h e i s cw a s h e r( B ) w i t hi t s c o n v e xs i d e d f a c i n gt h e r a c kg u i d e .I n s t a l l t h e p r i n g( C ) . p p t y s A sealantto the middle of the threadson the rack guide screw (D),then installand tighten it to 25 N m (2.5kgf.m, 18 lbf.ft).Looselyinstatlrhetocknut (E). 24. Apply multipurposegreaseto the sliding surfaceof the slider guide (A).Keepgreaseoff of the rack-toslider guide mating surfacesand the boot-to-slider guide mating surfaces. Slidethe steeringrack all the way to left, and place t h e s l i d e rg u i d eo n t h e s t e e r i n g a c kb y a l i g n i n g h e r t bolt holes (B).

E 25 N.m 12.5 kgt.m,18tbt.ft) 26. Beforeinstallingthe bracket(D),cleanthe mating surfaceofthe 12 mm flange bolts (E)and the bracket. Coatthe new O-rings{F)with multipurpose g r e a s ea n d i n s t a l l t h e m n t h e ' 1 2 m f l a n g eb o l t s . , o m 27. Looselyinstallthe bracketon the steeringrack by tighteningthe 12 mm flange boltsto 25 N.m (2.5 kgf.m, 18lbf.ft). 28. Hold the gearboxhousingusing a yoke,then install the specialtoolon the lock screw (A).Retighten the lock screwto the specified torque values.

A
{ 1 6 . 5k g t . m , 1 1 9 l b f . f t }

29. Removethe specialtool.

17-60

30, Retighten the 12 mm flange bolts (A) to the soecified toroue value.
74 N.m (7.5kgf.m,5irlbf.ft)

t 3 4 . C l o s e h e e a r p o r t i o n( A )o f t h e b a n d s( B ) w i t h p , 1 c o m m e r c i a l l a v a i l a b l e i n c e r sO e t i k e r 0 9 8o r v e q u i v a l e n(tC ) .

5 t .

After tighteningthe 12 mm flange bolts, installa new stop plate (B)over one of the bolt heads.Be surethe tabs (C)of the stop plate are alignedwith of the flat surfaces the bolt head. from the Cleanoff any greaseor contamination o b o o t i n s t a l l a t i og r o o v e s n t h e h o u s i n g . n Expandthe boot (A) by removingthe vinyltape, grooves and fit the boot ends (B) in the installation h o n t h ec y l i n d e r o u s i n g . n 3 5 . I n s t a l l t h e e w l o c kw a s h e r( A )w i t h i t s r a d i u s e d side facing (B)the tie-rod (C),and screwthe tie-rod this stepfor the other on the bracket(D).Repeat of the tie-rod.Hold the bracketwith one side wrench,and tightenthe tie-rodsto the specified torque with anotherwrench.

32,

,,";=-. . . , . , *=,,',

(cont'd)

17-61

EPSComponents
SteeringGearboxOverhaul(cont'dl
36. Bendthe lock washer againstthe flat spots on the bracketwitha Iarge pair of pliers.

37. Adjust the rackguide screw {seepage 17-13).

17-62

SteeringGearboxInstallation
'1. Beforeinstallingthe steeringgearbox,slidethe side (right rack all the way to the passenger's direction). 4. Insertthe pinion shaft up through the bulkhead, then slip the right side of the steeringgearbox housing(A) over the mounting stud (C)on the gearboxmounting bracket.
\--' '.'', i

2 . Passthe right side of the steeringgearboxtogether


with the tie-rodsthrough the wheelwell openingon the passenger's side.Continuemoving the steering gearboxtoward the passenger's side untilthe driver'sside tie-rodend and gearboxclearsthe fuse Ielay box. mastercylinderand under-hood Lower the steeringgearbox.and move it toward g i s t h e d r i v e r ' s i d eu n t i l t h es t e e r i n g e a r b o x s l n Dosition.

:-1

. . . .

Be carefulnot to damagethe hoses,lines and wire harnesses.


10 x '1.25 mm 61 N.m

{62 kgl m, 45 lb{ ftl

Installthe steeringstiffenerB, and lightlytighten the steeringgearboxmounting nuts. Installthe steeringstiffenerA with the gearbox T m o u n t i n gb o l t s . h e nt i g h t e na l l t h e s t e e r i n g gearboxmounting hardwareto the specifiedtorque.
1 0x 1 . 2 5m m 6l N.m (6.2 kgt.m, 45 lbt.ft)

p 3 . I n s t a l l t h e i n i o ns h a f tg r o m m e t( A ) .

: . . --.-{

(cont'd )

17-63

EPSComponents
SteeringGearboxInstallation(cont'd)
(A), 7. Installthe bodystiffener andtorque the mounting bolts the specified to torque.
8 x 1.25mm 29 N.m {3.0kgf.m,22lbf.ftl

9. Reinstall heaterhose (A) on the hose bracket. the

1 0 .Installthe enginewire harnessclamps (B)to the


three harnessbrackets.

L Installthe heatervalve (A) on the bulkhead,and


connectthe heatervalve cableend (B)to the heater valve arm (C).Readjust the heatervalve cable{see page21-46).

' It . Under the steeringgearbox,installthe ground


cableterminal (A) on the steeringgearboxhousing.
9 . 8N . m {1.0kgf.m,7.2lbf.ft)

:.i.t'

L-t

9.8N.m (1.0 m, kgf 7.2tbf.ftl

17-64

(A) EPS wire harness bracket on the 12. lnstallthe (B) gearbox the housing, connect 6Pconnector and propefly.
9.8 N.m {1.0kgt m,7.2 lbt.ftl

1 4 . Centerthe steeringrackwithin its stroke. from lhe ball 1 5 . Wipe off any greasecontamination joint taperedsectionand threads.Then reconnect the tie-rod ends 1A)tothe damper steeringarms. lnstallthe ball joint nut (B) and tighten them.

,-', ''l
: 1 )

h 1 3 . I n s t a l l t h e e a ts h i e l d( A ) .

i N.m {4.4 kgf.m. 32 tbt.ftl

B 10x 1.25 mm

to.

Installthe new cotter pins (C),and bend them as shown.

,.!,..6 ''

(cont'd)

17-65

EPS Components
SteeringGearboxInstallation(cont'dl
1 7 . Installthe motor on the steeringgearbox(seepage 17-49). performthe following checks. 22. After installation, . Performthe front toe inspection. . C h e c k h e s t e e r i n g h e e ls p o k e a n g l el.f s t e e r i n g t w spokeanglesto the right and left are not equal (steering wheel and rackare not centered), correctthe engagementof the joinvpinion shaft serrations, then adjustthe front toe by turning the tie-rods,if necessarv.

1 8 . lnstallthe steeringjoint (A).and reconnect the


steeringshaft (B) and pinion shaft (C).Make sure the steeringjoint is connectedas follows: . I n s e r t t h e p p e r e n do f t h e s t e e r i n go i n t o n t o t h e j u steeringshaft (line up the bolt hole (D)with the flat portion (E)on the shaft). . Slip the lower end of the steeringjoint onto the pinion shaft (line up the bolt hole with the groove (F)around the shaft),and looselyinstallthe lower joint bolt. Be sure that the lower joint bolt is securelyin the groove in the pinion shaft. . Pull on the steeringjoint to make surethat the steeringjoint is fully seated.Then installthe upper joint bolt, and tighten it to the specified torque.Tightenthe lower joint bolt to the specifiedtorque.

\
8 x '1.25 mm 28 N.m {2.9kgf.m, 21 tbt.ft)

1 9 .Installthedriver's dashboardlower cover (see


page 20-59) and under cover (seepage 20-60).

20. lf the steeringwheel was turned,centerthe cable


reel by first rotatingit clockwiseuntil it stops.Then (abouttwo and half rotateit counterclockwise turns) untilthe arrow mark on the label points straightup. Reinstall steeringwheel (seepage the 17-8).
)1

Installthe front wheels.

17-66

EPSControlUnit Removal/ Installation


1. Removethe passenger's under panel. 2. Turn up the floor carpel,removelhe EPScontrol untr.

Tie-rodBallJoint Boot Replacement


Special Tool Required Attachment,42 mm 07OAD-P0A0100 l. Removethe boot from the tie-rod end, and wipe the old greaseoff the ball pin. 2 . P a c k h e l o w e ra r e ao f t h e b a l l p i n ( A ) w i l h f r e s h t mulr purposegrease.

d______i.l+_D

r/\-,

*-4

-6rA

the 3 . Disconnect EPScontrol unit connectors. lnstallthe EPScontrol unit in the reverseorder of removal.
E

3. Packthe interiorof the new boot (B) and lip (C)with fresh multipurposegrease. Note these items when installingnew grease; . Keepgreaseoffthe boot installation section(D) and the taperedsection(E)of the ball pin. . Do not allow dust, dirt, or other foreign materials to enterthe boot. 4. Installthe new boot (A) usingthe specialtool.The boot must not have a gap at the boot installation sections(B).After installingthe boot.checkthe ball pin taperedsectionfor greasecontamination, and wipe it if necessary. 07(lAD-P0A0100

After installation, startthe engine,and let it idle. Turn the steeringwheelfrom lock-to-lock several times. Checkthat the EPSindicatordoes not come on.

17-67

Suspension
Frontand RearSuspension
SpecialTools ............. 18-2 Component Location Index ......................................... 18-3 1. W h e eA l i g n m e n .t . . . . . . . . . . . . . . . . . . . . l . . . . . . . . . .8 - 4 18-8 WheelBearing PlayInspection End ............................ 18-9 WheelRunout Inspection .................. ... 18-10 B a l J o i n tR e m o v a l l

FrontSuspension
Knuckle/H bAVheel BearingReplacement u BallJoint Boot Reolacement.................. Stabilizer Rep|acement.................... Bar Link Removal/lnstallation Stabilizer LowerArm Removal/lnstallation ............... Damper/Spring Replacement

18-1 18-16 18-17 18-18 18-19 18-20

RearSuspension
H u bB e a r i n U n i tR e p l a c e m e . . t . . . . . . . . . . . . . . . . . . 18-26 g n. 18-28 Knuckle Reolacement 18-30 Stabilizer Replacement Bar .................... Link 18-31 Stabilizer Removal/lnstallation .......................... 18-32 Upper Arm Removal/lnstallation ............... Trailing Arm Removal/lnstallation 18-33 Damper/Spring Replacement 18-34

Frontand RearSuspension
SpecialTools
Ref.No.

Tool Number

o
G)

07GAF-SE00100 07MAC-S100200 07746-0010500 07749-0010000 07965-SA50500 07965-SD90100

Description Hub Dis/Assembly Tool B a l lJ o i n t R e m o v e r2 8 m m , Attachment, x 68 mm 62 Driver Front Hub Dis/Assembly Tool Support Base

otv

[]

a6,l

18-2

ComponentLocationIndex
FrontSuspension:
DAMPER/SPRING page Replacement, 18-20 STABILIZER BAR page Replacement, 18-17 STABILIZER LINK page Removal/lnstallation, 18 18
KNUCKLE/HU8/WHEEL BEARING page 18-1 Replacement, 1 Ball Joint Boot page'18-16 Replacement,

LOWEBARM page 18 19 Removal/lnstallation,

Rear Suspension:
STABILIZER BAR page Replacement. 18-30
ARM UPPER Removal/lnstallation, page'18-32

DAMPER/SPRING page'18-34 Replacement,

UNIT HUBBEARING page Replacement, 18'26 KNUCKLE page Replacement, 18-28


TRAILINGARM page 18 33 Removal/lnstallation,

18-3

Frontand RearSuspension
WheelAlignment
The suspension can be adjustedfor front camber,front toe, and reartoe. However,each of these adjustments to are interrelated each other. For example,when you you Therefore, adjustthe toe, the camberchanges. must adjustthe front wheel alignmentwheneveryou adjustthe camberor toe.

Front Casterlnspection
fo U s ec o m m e r c i a l l a v a i l a b l e o m D u t e r i z e d u r w h e e l v c w a l i g n m e ne q u i p m e ntto m e a s u r e h e e la l i g n m e n t t (caster, camber,toe, and turning angle).Follow the instructions. eouiomentmanufacturer's Checkthe casterangle.lf the casterangle is not within the specification, checkfor bent or damaged susoensron comoonents. Front casterangle: 1'40't 1"

Pre-Alignment Checks
For proper inspection and adjustmentof the wheel alignment,do these checks: 1. Release parkingbraketo avoid an incorrect the measurement.

2 . Make sure the suspensionis not modified.


t 3 . C h e c k h e t i r e s i z ea n d t i r e p r e s s u r e Tire size: Front/rear: 195/60R15 Tire pressure: 230 kPa {2.3kgf/cm',33 psil Front: Rear: 210 kPa |'2.1kgf/cm', 30 psi) Checkthe runout of the wheels and tires. Checkthe suspensionball joints. (Holda wheel with your hands,and move it up and down and right and left to checkfor wobbling),

Bouncethe vehicleup and down severaltimes to the stabilize suspension.

18-4

Front CamberInspection
Use commerciallyavailablecomputerized four wheel alignmentequipmentto measurewheel alignment (caster, camber,toe, and turning angle).Follow the equipmentmanufacturer's instructions. Checkthe camberangle.lf the camberangle is not within the specification, adjustthe camber. Front camber angle: 0"30' t 45'

Front CamberAdjustment
The front cambercan be adjustedby exchangingone or both of the damDerDinchbolts with the smaller The differencebetweenthe diameteradjustingbolt(s). adjustingbolt diameterand the pinch bolt hole d i a m e t e r l l o w sa s m a l lr a n g eo f a d j u s t m e n t . a

DamDer PinchBolt:

AdiustingBoh: P/N 90188-55A-000

1 . Raisethe front of the vehicle,and support it with safetystandsin the proper location(seepage 1-8). Removethe front wheels. L o o s e n h e d a m p e rp i n c h n u t sa n d b o l t s( A ) ,a n d t adjustthe camber by moving the bottom of the d a m p e rw i t h i nt h e r a n g eo f t h e d a m p e rp i n c hb o l t free play.

-+

+t

A 1 6 x 1 . 5m m 157 N.m (16.0kgf.m, 116 tbf.ftl

3 . Tightenthe boltsto the specifiedtorque.


4 . Reinstall the front wheels.Lower the front of the

t v e hi c l et o t h e g r o u n d , n d b o u n c e h e v e h i c l e a s e v e r atl i m e st o s t a b i l i z t h e s u s p e n s i o n . e l 5 . C h e c k h e c a m b e ra n g l e . f i t i s w i t h i nt h e t specification, checkthe front toe. lf it is not within go the specification, to step 6. (cont'dl

18-5

Frontand RearSuspension
WheelAlignment (cont'd)
Raisethe front of the vehicle,and support it with safetystandsin the proper location(seepage 1-8). Removethe front wheels. 7 . Replace damper pinch boltswith the adjusting the bolts (A),and adjustthe camber angle. NOTE:The camberangle can be adjustedup to t 15' (centerof tolerance)by replacingone damper pinch bolt with the adjustingbolt. The camber angle can be adjustedup to a 30' by replacingboth upper and lower damper pinch bolts with the adjustingbolts.

RearCamber Inspection
Use commercially-available computerized four wheel alignmentequipmentto measurewheel alignment (caster, camber,toe, and turning angle).Followthe instructions. eouiDmentmanufacturer's l C h e c k h e c a m b e ra n g l e . f l h e c a m b e ra n g l ei s n o t t within the specification, checkfor bent or damaged susDenston comoonenrs. Rearcamberangle: 0 0"55' t 45'

NOn-dEl
Do not loosenthe specialb o l t so n t h e t r a i l i n g r m . a

'rntr
.:r,//
i,iY. a

1 5 x 1 . 5m m 157N.m {16.0kgt.m, 116tbf.ft)

8 . Tightenthe boltsto the specified torque. Reinstall front wheels.Lower the front of the the vehicleto the ground, and bouncethe vehicle severaltimes to stabilize the suspension.

1 0 .Checkthe camber angle.lf it is within the


specification, checkthe front toe. and adjust it if necessary. it is not within the specification, lf readjust,and recheck. the camber anglecannot lJ checkfor bent or be adjustedto the specification, damagedsuspension components.

18-6

Front Toe Inspection/Adjustment


Use commercially-available four wheel computerized a l i g n m e ne q u i p m e ntto m e a s u r e h e e la l i g n m e n t t w (caster, camber,toe, and turning angle).Followthe equipmentmanufacturer's instructions, 1. Centerthe steeringwheel spokes. 2. Checkthetoe.lf it is not with in the specif ication,go to step 3. Front toe-in: 0 t 3 mm {0 t 0.12in.) 3. Loosenthe locknut(A) while holdingthe tie-rod end ( B) .

RearToe Inspection/Adiustment
Use commercially-available computerized four wheel a l i g n m e ne q u i p m e ntto m e a s u r e h e e la l i g n m e n t t w (caster, camber,toe, and turning angle).Followthe equipmentmanufacturer's instructions. 1 , R e l e a s eh e p a r k i n g r a k e . t b go 2. Checkthetoe. lf it is not within the specification. to step 3. Reartoe-in {inspection): 1 1 3 mm (0.04a 0.12 in.) 3. Loosenthe self-locking (A)while holdingthe nut adjustingbolt (B).

1,;

A 1 4 x 1 . 5m m ,14N.m (a.5 kgt m,33 lbt.ftl

Do not loosenlhe specialbolts (C)on the lower arm to adjustthe alignment.

Turn the tie-rod(C)untilthe toe is correct. 5 . After adjusting, tighten the locknutwhile holding the tie-rodend. Make sure the toe settingdoes not change.

4. Replace self-locking with a new one, and nut the l i g h t l yt i g h t e n . nut NOTE: Always use a new self-locking whenever it has been loosened. Turn the adjustingbolt until the toe is correct. Rear toe.in (adiustment): 2 ' , mm {0.08 "' ,. in.} nut Tightenthe self-locking to the specifiedtorque w h i l eh o l d i n g h e a d j u s t i n g o l t . t b

(cont'd )

18-7

Frontand RearSuspension
WheelAlignment (cont'dl
TurningAngleInspection
Use commercially-available computerized four wheel a l i g n m e ne q u i p m e ntto m e a s u r e h e e la l i g n m e n t t w (caster. camber,toe, and turning angle).Followthe equiDmentmanufacturer's instructions. 1 . T u r nt h e s t e e r i n g h e e lf u l l y t o t h e r i g h t a n d l e f t w while applyingthe brake,and checkthe turning anglesof both front wheels, lf the turning angle is not within the specification the inward turning or anglesdiffer betweenthe right and left side,go to steD2. Turning angle: lnward: 34'00'+ 2' Outward: 28'00' {reference)

WheelBearingEnd PlayInspec'tion
1. Raiselhe vehicle,and support it with safetystands in the proper location(seepage 1-8).Removethe wheels. 2. Installsuitable f lat washers (A) and wheel nuts,and tighten the nuts to the specified torque to hold the b r a k ed i s cs e c u r e l y g a i n s t h e h u b . a Front:

108N.m (11.0kgf.m, 80 rbf.ft)

Rear: \

Checkthe toe. lf it is correct,but the turning angle is not within the specification, checkior bent or damagedsuspension components,

108N.m (11.0kgf.m,80 lbf.ft)

3 . S e t u p t h e d i a lg a u g ea g a i n s t h e h u b f l a n g ea s shown, and measurethe bearingend play moving the brakedisc inward and outward. Bearing end play: Standard: Front/rear: 0 0.05 mm {0 0.002in.} 4. lf the bearingend play is more than the standard, replacethe wheel bearing.

18-8

WheelRunoutInspection
1 . Raisethe vehicle,and supportit with safetystands in the proper location(seepage 1-5,. Checkfor a bent or deformedwheel. Set up the dial gauge as shown, and measurethe axial runout by turning the wheel. Front and rear wheel axial runout: Standard: Aluminum wheel: 0-0.7 mm (0-0.03 in.) Servicelimit: 2.0 mm {0.08in.l 4 . R e s e t h e d i a l g a u g e t o t h ep o s i t i o n h o w n ,a n d s measurethe radial runout. Front and rear wheel radial runout: Standard: Aluminum wheel: 0 0.7 mm (0 0.03io.) 1.5 mm {0.06in.} Servicelimit:

lf the wheel runout is not within the specification, checkthe wheel bearingend play (seepage 18-8), and make sure the mating surfaceson the brake disc and the insideof the wheel are clean. lf the bearingend play is within the specification but the wheel runout is more than the servicelimit. replacethe wheel.

18-9

Frontand RearSuspension
BallJointRemoval
Special Tools Required Ball ioint remover.2Smm 07MAC-SL00200 3. Loosenthe pressurebolt (A),and installthe special tool as shown. Insen the jaws carefully,making sure not to damagethe ball joint boot. Adjustthe jaw spacingby turning the adjustingbolt (B). 10 mm HEXNUT

Always use a ball joint removerto disconnect ball a joint. Do not strikethe housingor any other part of the ball joint connectionto disconnectit. '1, I n s t a la h e x n u t ( A ) o n t o t h e t h r e a d s o f t h e b a l l j o i n t l { B ) .M a k es u r et h e n u t i s f l u s hw i t h t h e b a l l j o i n tp i n end to preventdamageto the threadedend of the b a l l i o i n to i n .

07MAC-S100200 After adjustingthe adjustingbolt, make sure the head (C)of the adjustingbolt is in the position shown to allow the jaw to pivot. 5 . With a wrench,tighten the pressurebolt until the a b a l li o i n t p i n p o p sl o o s ef r o m t h e s t e e r i n g r m o r type knuckle.lf necessary. apply penetrating lubricantto loosenthe ball joint pin

2 . Apply greaseto the specialtool on the areasshown


(A).This will easeinstallation the tool and of preventdamageto the pressurebolt {B)threads. NOTE:Do not use pneumaticor electrictools on the pressurebolt.

6 . Removethe tool, then removethe nut from the end


o f t h e b a l l j o i n tp i n ,a n d p u l l t h eb a l l j o i n to u t o f t h e s t e e r i n g r m o r k n u c k l eI.n s p e c t t h e a l l j o i n tb o o t , a b and replaceit if damaged.

18-10

FrontSuspension
Knuckle/Hub/Wheel BearingReplacement
ExplodedView

WHEELBEARING Replace. SNAPRING

5 mm SCREWS Replace.

FLAT SCREWS 6x1.0mm 9.8Nm (1.0 kgf.m,7.2 lbf.ft)

KNUCKLE
Checkfor delormation a n oo a m a g e .

SPLASHGUARD Checkfor corrosion. delormation. and damage. if Replace rusted.

BRAKE DISC
NUT SPINDLE 22 x 1.5mm 181 m N (18.5kgf.m, 134 lbt.ft) Replace.

'--7.l

'tq

I A p p ya s m a la m o u no f e n g i n o i l l t e to theseating surface.

lcont'd)

18-11

FrontSuspension
BearingReplacement Knuckle/Hub/Wheel {cont'dl
Special Tools Required . Hub dis/assembly tool 07GAF-SE00100 . Balljoint remover,2Smm 0TlvlAC-S100200 . Attachment62 x 68 mm 07746-0010500 . Driver07749-0010000 . SuDDort base07965-5D90'100 1. Raisethe front of the vehicle,and support it with safetystandsin the proper location(seepage 1-8). 2. Removethe wheel cap,wheel nuts, and front wheel.
1 0 8N . m (11.0kgf m, 80 rbf.ftl

5. Raisethe stake(A),and removethe spindle nut (B).

' ,

B 22x1.5mm 181 .m N ('18.s kgf.m, 134tbt.ft)

6. Removethe brakedisc retainingflat screws(A).

3. Removethe brakehose bracketmounting bolt (A). A 8 x 1.25 mm 22N.m 12.2ksl.m, 26 tbf.ftl

A 6x1.0mm 9.8 N.m {1.0kgt.m, 7.2 tbl.ttl

B 12 x 1.25mm 108N.m {11.0kgf.m, 80 rbf.ftl

7. Screwtwo 8 x 1.25mm bolts (B)into the discto oush it awav from the hub. Turn each bolt two turns at a time to preventcockingthe disc excessively,

4 . Removethe caliperbracketmounting bolts (B),and removethe caliperassembly(C)from the knuckle. To preventdamageto the caliperassemblyor brakehose,use a short pieceof wire to hang the Do caliperassemblyfrom the undercarriage. not twist the brakehose with force.

18-12

8. Removethe flange bolt {A) andwheel sensor(B) from the knuckle.Do not disconnect wheel the sensorconneclor.
A 5x1.0mm 9.8 N.m (1.0kgl.m, 7.2 tbt.ftl

10. Removethe lock pin (A)from the lower arm ball joint, and removethe castlenut (B). insertthe lock pin into NOTE:During installation, t t h e b a l l j o i n tp i n f r o m t h e l n s i d e o t h e o u t s i d e f o the vehicle.The closedend of the lock Din must be i n t h e r a n g es h o w n .

07MAC-SL00200 'R.

--....-"
12x 1.25 mm 59 69N m
(6.0 7.0 kgl m, 43 -51 lbf tt)

9 . Removethe flange nut (A) while holdingthe joint pin (B)with a hex wrench (C),and disconnect the i s t a b i l i z el r n k{ D )f r o m t h e l o w e ra r m ( E ) .

1 1 .Disconnect lower arm from the knuckleusing the the specialtool (seepage l8-10).

12. Loosenthe damper pinch bolts (A) while holding


the nuts (B),and removethe bolts and nuts.

10 x 1.25mm kgf.m,29lbf.ft) 39 N.m (,1.0

'13.Removethe driveshaftoutboardjoint

{C)fromthe knuckle(D) by tappingthe driveshaftend (E)with a plastichammer while drawing the knuckleoutward, then removethe knuckle. NOTE:Do not Dullthe driveshaftend outward.The driveshaftjoint may come off.

(cont'd)

18-13

FrontSuspension
(cont'd) Knuckle/Hub/Wheel Bearing Replacement
14. Separate the hub (A)from the knuckle(B) usingthe specialtool and a hydraulicpress.Be carefulnotto deform the splashguard. Hold onto the hub to keep it from falling when pressedclear. 07GAF-SE00100 g 1 6 . R e m o v e h e s n a pr i n g ( A )a n dt h e s p l a s h u a r d( B ) t ( fromtheknuckleC).

./

.-''-

.|

a'\s

1 1 . Pressthe wheel bearing(A) out of the knuckle(B usingthe specialtool and a press. 1 5 . Pressthe wheel bearinginner race(A) off of the h u b ( B )u s i n gt h e s p e i i a l t o o l , c o m m e r c i a l l y a a v a i l a b l e e a r i n g e p a r a t o( C ) , n d a p r e s s . b s r a 07GAF-SE00100 \ Pross

+
\

\r

Press

18-14

i a 1 8 . W a s ht h e k n u c k l e n d h u b t h o r o u g h l y n h l g hf l a s h point solventbefore reassembly. 1 9 . Pressa new wheel bearing(A) into the knuckle(B) usingthe old bearing(C),a steel plate {D).the specialtool, and a press.Placethe wheel bearing on the knucklewith the packseal side facing (metal color)toward the inside.Be careful not to damage the sleeveof the packseal.

u 2 2 . P r e s s n e w h u b b e a r i n g n i t{ A )o n t o t h e h u b ( B ) a usingthe specialtools and a press.

"-t-_"*,,''

_,.' . . a-.) ../


..-.

u be k 23. I n s t a l l t h e n u c k l e / h u b / h u b a r i n g n i t i n t h e reverseorder of removal,and notethese items: . B e c a r e f u n o t t o d a m a g e t h e a l l j o i n tb o o t w h e n b l i n s t a l l i n gh e k n u c k l e . t . Tightenall mounting hardwareto the specified v lOrque alues. . Torquethe castlenut to the lower torque then tighten it only far enoughto specification, a l i g nt h e s l o tw i t h t h e b a l lj o i n t p i n h o l e .D o n o t align the castlenut by looseningit. . Installa new look pin on the castlenut after torquing. . U s ea n e w s p i n d l e u t o n r e a s s e m b l y . n . B e f o r e n s t a l l i n gh e s p i n d l e u t ,a p p l ya s m a l l n i t amount of engine oil to the seatingsurfaceof the nut. After tightening,use a drift to stakethe a n s p i n d l e u t s h o u l d e r g a i n st h e d r i v e s h a f t . . B e f o r e n s t a l l l n gh e b r a k ed i s c ,c l e a nt h e m a t i n g i t surfaceof the front hub and the insideof the b r a k ed i s c . . B e f o r e n s t a l l i n gh e w h e e l ,c l e a nt h e m a t i n g t i surfaceof the brakedisc and the insideof the wneet. . Checkthe front wheel alignment,and adjustit if (seepage 18-4). necessary

( i 2 0 . I n s t a ltlh e s n a pr i n g ( A )s e c u r e l yn t h e k n u c k l e B ) .

D kgf.m,4lbf ft) 6 N.m10.6 lnstallthe splashguard (C),and tighten the screws (D)to the specifiedtorque.

18-15

FrontSuspension
BallJoint Boot Replacement
Special Tools Required Front hub dis/assembly tool 07965-5450500 1. Removethe boot. 2. Packthe interiorand lip (A) of a new boot with fresh grease.Keepthe greaseoff of the boot-to-knuckle mating surfaces(B). Pressthe boot with the specialtool until the bottom seatson the knuckle(A) evenly around. pross 07965-SA50500 Instllthe boot onto the ball joint pin, then squeeze it gentlyto force out any air. Do not let dlrt or other foreign materialsget into the boot.

rffi
-

-6r
B

t
6 . After installinga boot,wipe any greaseoff the exposedportion of the ball joint pin.

Wipe the greaseoff the taperedsectionof the pin (C),and packfresh greaseonto the base (D).

18-16

StabilizerBar Replacement
1 . Raisethe front of the vehicle,and support it with safetystandsin the proper location(seepage 1-8). Removethe front wheels. nuts (A)while holdingthe Removethe self-locking joint pin (B)with a hex wrench (C),and disconnect i r t h e s t a b i l i z el r n k s( D ) f r o mt h e s t a b i l i z eb a r ( E )o n the right and left. D bar in the reverseorder of 4. lnstallthe stabilizer removal.and note these itemsl . Use new self-locking nuts on reassembly. . Note the right and left directionof the stabilizer oar. . A l i g nt h e e n d so f t h e p a i n tm a r k s( A )o n t h e bar stabilizer with each end of the bushings(8). . Note the forelaft directionofthe bushing holders. . Referto stabilizerLink Replacement connect to t h e s t a b i l i z eb a r t o t h e l i n k s( s e ep a g e1 8 - 1 8 ) . r

''i] ,.'i i
. i.',.:-l I
_:

,r',' \'r'j-- r-'1

i-ii::;i
;4-llt,-'j--;

i :.. i'

1 0x 1 . 2 5m m 39Nm (4.0 kgf m, 29 tbl,ft)

Removethe flange bolts {A) and bushingholders {B),then removethe bushings(C)and the stabilizer b a r( D ) .

FORWARD
A 1 0x 1 . 2 5m m 39Nm (4.0ksf.m, 29lbl.ftl

18-17

Front Suspension
StabilizerLink Removal/lnstallation
1 . Raisethe front of the vehicle,and support it with safetystandsin the proper location(seepage 1-8). Removethe front wheels. Removethe self-locking (A) and flange nut {B) nut joint pin (C)with a hex while holdingthe respective wrench (D),and removethe stabilizer link (E). 4. Installthe self-locking and flange nut, and nut lightlytighten them. NOTE:Use a new self-locking on reassembly. nut 5. Placethe floor jack under the lower arm balljoint, and raisethe suspension load it with the vehicle's to weaght.

mri-dEl
Do not placethe jack againstthe lower arm balljoint. 6. Tightenthe self-locking (A) and flange nut (B)to nut the specified torque valueswhile holdingthe joint pins (C)with a hex wrench (D). respective
A 10 x 1.25mm 38 N.m (3.9kgf m,28 lbf.ft)

\
3 . l n s t a l l t h e t a b i l i z el r n k( A )o n t h e s t a b i l i z eb a r { B ) s i r and lower arm (C)with the joint pins (D)set at the centerof their rangeof movement.

..,
B 10 x 1.25mm 39 N.m {4.0kgf.m,29lbf.ft}

1 . After 5 minutesof driving, re-tighten self, the lockingnut again to the specified torque.

18-18

Lower Arm Removal/lnstallation


SpecialToolsRequired Balljoint remover,2Smm 07|MAC-S100200 1. Raisethe front of the vehicle,and supportit with safetystandsin the proper location(seepage 1-8). Removethe front wheels. Removethe flange nut (A) while holdingthe joint pin {B)with a hex wrench (C),and disconnect the i s t a b i l i z el r n k( D ) f r o mt h e l o w e ra r m ( E ) . 5. Removethe flange bolts (A),and removethe lower arm {B}.

1 4x 1 . 5m m kgf.m,61 lbf.ft) 83 N.m(8.5 6. Installthe lower arm in the reverseorder of removal,and note these items: . Be carefulnot to damagethe ball joint boot when connectingthe lower arm to the knuckle. ' Tightenall mounting hardwareto the specified torque values, . F i r s t i n s t a la l l t h e c o m p o n e n t s n d l i g h t l y t i g h t e n a l to the bolts and nuts.then raisethe suspension load it with the vehicle'sweight beforefully tighteningit to the specifiedtorques. . Torque the castlenut to the lower torque then tighten it only far enoughto specification, align the slot with the ball joint pin hole. Do not allgn the castlenut by looseningit. . Installa new lock pin on the castlenut after torquing. . Beforeinstallingthe wheel, cleanthe mating surfaceof the brakedisc and the insideof the wneet. . C h e c k h e w h e e la l i g n m e n ta n d a d j u s t i t i f , t (seepage '18-4). necessary

mm 10x 1.25 39 N.m {4.0kgf m, 29 lbt.ft)

3 . Removethe lock pin (A) from the lower arm ball


joint, and removethe castlenut (B). insertthe lock pin into NOTE:During installation, the ball joint pin from the insideto the outsideof the vehicle.The closed end of the lock pin must be i n t h e r a n g es h o w n .

6--__
@a

oTMAc-sloo2oo
1 2x 1 . 2 5 m m 59 69Nm kgt-m, 16.0-7.0 43 51 lbf.ft)

the 4 . Disconnect lower arm from the knuckleusing t h e s p e c i atl o o l ( s e ep a g e1 8 - 1 0 ) .

18-19

Front Suspension
Damper/Spring Replacement
ExplodedView
/.' ^a ta ,/ ,,/ NUT ./ SELF-LOCK|NG 12 x 1.25inm 44 N.m {4.5kgt.m,33lbf.ftl neDtace.

e9 -.-

1, @-:'\--""' lF \-:-./ - ,

MOUNTING - DAMPER BASE checkfor delormation

E9-

DAMPER MOUNTING BEARING

UPPER SPRING MOUNTING CUSHION Check deterioration for anooamage,

DAMPER SPRING for Check lreelength.

DAMPER UNIT Checkfor oil leaks, gas leaks, and smooth operatron.

18-20

ToolsRequired Special mm Balljoint remover,28 07MAC-S100200

5. Removethe damper pinch bolts (A)while holding t h e n u t s( B ) .

Removal
1. Raisethe front of the vehicle,and supportit with safetystandsin the proper location(seepage 1-8). Removethe front wheels. Removethe cotterpin (A) from the tie-rod end ball ioint, and removethe nut (B).

6. Removethe flange nuts (A)from the top ofthe damper, A 'l.25 mm 10x 10 mm HEXNUT 07MAC-S1002000 tie-rodend from the steeringarm Disconnectthe o n t h e d a m p e ru s i n gt h e s p e c i a l t o o(l s e ep a g e1 8 1 0) . 4. Removethe bolts,and removethe wheel sensor harnessbracket{A) and brakehose bracket(B) the from the damper.Do not disconnect wheel sensorconnector. A
6x1.0mm x 1.25nm

7. Lower the lower arm, and removethe damper ( assemblyB).

/.8

(cont'd)

18-21

FrontSuspension
(cont'd) Damper/Spring Replacement
Disassembly/lnspection
1 . C o m p r e s sh e d a m p e rs p r i n gw i t h a c o m m e r c i a l l y t availablestrut spring compressor(A) accordingto the manufacturer's instructions. then removethe s e l f - l o c k i nn u t ( B ) w h i l eh o l d i n g h e d a m p e rs h a f t g t (C)with a hex wrench (D).Do not compressthe spring more than necessary removethe nut, to Reassemble the pans, exceptfor the upper all s p r i n gs e a ta n d s p r i n g .
4. Compress the damper assemblyby hand,and

checkfor smooth operationthrough a full stroke. both compressionand extension. The damper should extend smoothly and constantlywhen compressionis released. it does not, the gas is lf leakingand the damper should be replaced.

Release pressure the from the strut spring compressor, then disassemble damper as the shown in the ExplodedView.

C h e c k o r o i l l e a k s a b n o r m a n o i s e sa n d b i n d i n g f , l , during thesetests.

18-22

FrontSuspension
(cont'dl Damper/Spring Replacement
Right side:

Installation
1. Lower the lower arm, and positionthe damper assemblyin the body, Turn the damper mounting baseso the "AL" or "AR" mark (A)facestoward the outsideof the vehicle. B 10x 1.25 mm ,14 N.m kgt.m,33 lbf.ft) {4.5

Hold the bottom of the damper with your hand,and compressthe spring. Do not compressthe spring excessively.

9 . I n s t a l l t h e 2 m m n u t ( A )o n t h e d a m p e rs h a f t( B ) . 1
Hold the damper shaft with a hex wrench (C),and tighten the 12 mm nut to the specifiedtorque.

,1,6
Looselyinstallthe flange nuts (A) onto the top of the damper.

(4.5 kgt.m, 33 lbf ft)

1 0 .Remove damper the assembly fromthe strutspring compressor.

18-24

, 3 . P o s i t i o nh e d a m p e ro n t h e k n u c k l ea n d i n s t a l l t h e t new damper pinch bolts (A) and nuts (B),and lightlytighten the nuts.

8. Connect the tie-rod end to the steeringarm, and torque. Install tightenthe nut (A)to the specified the cotterpin (B)after tightening,and bend lts end asshown.

B 1 6 x 1 , 5m m 157N.m (16.0kgt m, 116tbt.ftl

4 . P l a c e h e f l o o rj a c ku n d e rt h e l o w e ra r m b a l l j o i n t , t to and raisethe suspension load it with the vehicle's weight.

Do not placethe jack againstthe lower arm balljoint. 5 . Tightenthe flange nuts on the top of the damperto the specifiedtorque. Tightenthe damper pinch nuts to the specified torque. 1 . Installthe brakehose bracket(A) and the wheel sensorharnessbracket(B)onto the damper,and torque. tighten the bolt to the specified 9.8N.m kgf.m, 7.2lbf.ftl 11.0 22N|rl. kgI 12.2 m, 16rbr,ftl

9. Cleanthe mating surfaceofthe brakedisc and the insideof the wheel,then installthe front wheels. t , 1 0 . C h e c k h e w h e e la l i g n m e n ta n d a d j u s t i t i f necessary {seepage 18-4).

18-25

RearSuspension
Hub BearingUnit Replacement
Exploded View

SPLASHGUARD Check deformation. for

x 1.0 mm 9.8 N.m (1.0kgf.m,?1 lbf ftl

Checkfor wear and damage.

',[ ',, / -o ' 0 \

KNUCKLE
Checkfor delormation.

un
Y
HUBBEARING UNIT Check faultymovement for andwear.
6x1.0mm 9,8 N.m {1.0kgf.m,7 lbf.ft} HUB CAP Replace. NUT SPINDLE 22 x 1.5mm 181 N.m {18.5kgt.m, 134lbf.ft} Beplace.

-A

T
Appy a small amount oI engineoil to the seatingsurface.

18-26

1 . Raisethe rear of the vehicle,and support it with 'l-8). safetystandsin the proper location(seepage Removethe wheel cap. wheel nuts, and rearwheel.

Release parkingbrakelever. the 5 . Removethe brakehose mounting bolt (A). B 1 0x 1 . 2 5 m m 55Nm kgf {5.6 m.41lbf.ft}

108N.m(11.0 kgf.m,80 ftl lbf Removethe hub cap (A), raisethe stake(B),and n remove hespindle ut(C). t (2.2 m, 16lbt.ftl kgt Removethe caliperbracketmounting bolts (B),and hang the caliper(C)to one side.To preventdamage to the caliperor brakehose,use a short pieceof f w i r e t o h a n gt h e c a l i p e r r o m t h e u n d e r c a r r i a g e . 7 . Removethe brakedisc retainingscrews(A).

O
\
A

ap
2 2 x 1 , 5m m 1 8 1N . m (18.5kgf.m, 134lbf.ftl

t
\

I A 6x1.0mm 9 . 8N . m (1.0kgf.m,?.2lbf.ftl

Screwtwo 8 x 1.25mm bolts (B) into the disc {C)to oush it awav from the hub. Turn each bolt two turns at a time to preventcockingthe disc excessively. Removethe brakedisc.

(cont'd)

18-27

Rear Suspension
Hub Bearing Unit Replacement (cont'd)
9. Removethe hub bearingunit (A) from the spindle.

Knuckle Replacement
1 . Raisethe rear of the vehicle,and suppon it with safetystandsin the proper location(seepage 1-8). Removethe rear wheels. R e m o v e h e b r a k ed i s ca n d h u b b e a r i n g n i t( s e e t u s t e p 1 o n p a g e1 8 - 2 7 ) . Removethe flange bolts (A) and splashguard (B) from the knuckle.

,=,,,

1 0 .Installthe hub bearingunit in the reverseorder of


removal,and note these items: . Tightenall mounting hardwareto the specified torque values, . Beforeinstallingthe brakedisc,cleanthe mating surfaceot the hub and the insideof the brake disc. . Use a new spindle nut on reassembly. . After tightening,use a drift to stakethe spindle n u t s h o u l d e r g a i n st h e s p i n d l e . a . Use a new hub cap on reassembly. . Beforeinstallingthe wheel, cleanthe mating surfaceof the brakedisc and the insideof the wneel.

kgf.m, lbf ft) 7.2 11.0 4. Removethe wheel sensor(A),braKenose m o u n t i n gb r a c k e ( B ) ,a n d p a r k i n g a b l em o u n t i n g t c bracket(C)from the knuckle.Do not disconnect the wheel sensorconnector.

tt

8 x 1.25 mm 22 N.m kgf {2.2 m, 16lbf ftl

6x1.0mm 9.8 N,m {I.0 kgt.m,7.2lbf ft)

18-28

5. Placethe floor jack underthe trailing arm {A),to support it.

k i o 9 . I n s t a l l t h e n u c k l e n t h e r e v e r s e r d e ro f r e m o v a l , and note these items: . F i r s ti n s t a l a l l t h e s u s p e n s i o c o m p o n e n t s , n d l n a lightlytighten the bolts and nuls,then placea floor jack under the lower a rm, and raisethe suspension load it with the vehicle'sweight to beforefully tighteningthe bolts and nutsto the specified torque values. . Align the cam positionsof the adjustingbolt (A) and adjustingcam (B)with the markedpositions w h e nt i g h t e n i n g . . Use a new self-locking on reassembly. nut . T i g h t e n l l t h e m o u n t i n gh a r d w a r eo t h e t a specifiedtorque values. . U s ea n e w s p i n d l e u t o n r e a s s e m b l y . n . B e f o r e n s t a l l i n gh e s p i n d l e u t ,a p p l ya s m a l l n i t amount of engine oil to the seatingsurfaceof the nut. After tightening,use a drift to stakethe a s p i n d l e u t s h o u l d e r g a i n st h e d r i v e s h a f t . n . Beforeinstallingthe brakedisc,cleanthe mating surfaceof the hub and the insideof the brake drsc. . U s ea n e w h u b c a po n r e a s s e m b l y . . Beforeinstallingthe wheel, cleanthe mating surfaceof the brakedisc and the insideof the wheel. . Checkthe wheel alignment,and adjust it if necessary {seepage 18-4).

Do not placethe jack againstthe plate sectionof the lower arm, Be carefulnot to components. damageany suspension

12x 1.25 mm 59 N.m {6.0ksf.m.43lbf.ft)

the Removethe flange bolt (B),and disconnect upper arm {C)from the knuckle. 1 . Mark the cam positionsof the adjustingbolt (A) and nut adjustingcam (B),the removethe self-locking {C},adjustingcam, and adjustingbolt. Discardthe nut. self-locking

12x 1.25 mm 59 N.m {6.0kgf m,43lbl.ft)

12x 1.25 mm 59Nm(6.0kgf.m, 43 tbI.ftl

8. Remove the flange bolt (D), and remove the k n u c k l e{ E ) .

18-29

RearSuspension
StabilizerBar Replacement
1 . Raisethe rear of the vehicle,and supportit with safetystandsin the proper location(seepage 1-8). Removethe rearwheels. Removethe self-locking nuts (A)while holdingthe joint pins (B)with a hex wrench (C),and disconnect t h e s t a b i l i z el r n k s( D )f r o m t h e s t a b i l i z eb a r { E )o n i r the right and left.
A 1 0 x 1 . 2 5m m 38 N.m (3.9 kgf.m,28 lbf.ft)

4. Inslallthestabilizerbar in the reverseorder of removal,and notethese items: . Use new self-locking nuts on reassembly. . lMake sure the right and left ends of the stabilizer bar are installedon their respective sidesof the vehicle. . Align the ends of the paint marks (A) on the ( s t a b i l i z eb a r w i t h t h e b u s h i n g s B ) . r . Referto StabilizerLink ReDlacement connect to t h e s t a b i l i z eb a rt o t h e l i n k s{ s e ep a g e1 8 - 3 1 ) . r

'..: \.... .

Al
.----'';-r'--\---r-

-tt'.,'t),

Removethe flange bolts (A) and bushing holders (B),then removethe bushings{C)and the stabilizer bar(D).

18-30

StabilizerLink Removal/lnstallation
1. Raisethe rear of the vehicle,and support it with safetystandsin the proper location(seepage 1-8). Removethe rearwheels. 2. Removethe self-locking (A) and flange nut (B) nut joint pin {C)wilh a hex while holdingthe respective wrench (D),and removethe stabilizer link (E). 4. lnstallthe self-locking and flange nut, and nut lightlytighten them. NOTE:Use a new self-locking on reassembly. nut Placea jack under the trailing arm at the knuckle side end. and raisethe suspension load it with lo the vehicle'sweight. Tightenthe selflocking nut (A) and flange nut {B)to the specifiedtorque valueswhile holdingthe joint pins (C)with a hex wrench (D). respective
A 1 0 x 1 . 2 5m m 38 N.m 13.9 kgf.m,28lbf.ftl

\,1 i

i'-r d
*l'',:

3 . I n s t a l l t h e t a b i l i z el r n k( A )o n t h e s t a b i l i z eb a r { B ) s i r a n dt r a i l i n g r m ( C )w i t h t h e j o i n t p i n s( D )s e ta t t h e a centerof each moving range,

7. After 5 minutesof driving, re-tighten selfthe lockingnut again to the specified torque.

18-31

Rear Suspension
UpperArm Removal/lnstallation
1 . Raisethe rear of the vehicle,and supportlt with safetystandsin the proper location(seepage 1-8). Removethe rearwheels. P l a c e f l o o rj a c ku n d e rt h e t r a i l i n ga r m , a n d a supportthe suspensron. Removethe flange bolt (A) and wheel sensor h a r n e s s r a c k e( B ) . b t 5. Installthe upper arm in the reverseorder of renloval,and note these items: . F i r s ti n s t a l a l l t h e s u s p e n s i o c o m p o n e n t s n d l n a lightlytighten the bolts and nuts,then placea j a c ku n d e rt h e t r a i l i n g r m , a n d r a i s e h e a t suspension load it with the vehicle'sweight to beforefully tighteningthe bolts and nuts to the specifiedtorque values. . T i g h t e n l l t h e m o u n t i n g a r d w a r eo t h e a h t specified torque values. ' B e f o r e n s t a l l i n gh e w h e e l ,c l e a nt h e m a t i n g i t surfaceof the brakedisc and the insideof the wheel. . Checkthe wheel alignment,and adjustit if (seepage 18-4). necessary

8 x 1.25 m m 22 N.m(2.2 kgf.m, 16rbf.ft) Removethe flange bolts (A),and removethe upper arm{B).

1 2 x 1 . 2 5m m 59 N.m {6.0kgf.m, ir3 lbf.ft)

1 2x 1 . 2 5 m m 59 N.m 16.0 m, kgf 43 tbf.ft)

18-32

Trailing Arm Removal/lnstallation


1 . Raisethe rear of the vehicle,and suppon it with safetystandsin the proper location(seepage 1,8). Removethe rearwheels. Removethe knuckle(seepage 18-28). 7. Removethe trailing arm rear mounting bolt (A).

Do not loosenthe specialbolts (B)on the t r a i l i n ga r m .


A 12 x 1.25mm

3 . P l a c e h e f l o o rj a c ku n d e rt h e t r a i l i n g r m ( A )t o t a
support it.

59 N.m

-----\':,'.ttg
'.,--1..-r.':1
B 1 0x 1 . 2 5 m m 38Nm (3.9 kgl.m, 28 tbf.ftl

1 2x 1 . 2 5 m m 61N m (6.2 m. kgt 4s tbf,ft)

8 . Lower the jack,and removethe trailing arm. 9 . Installthe trailing arm in the reverseorder of
removal,and note these items: . F i r s ti n s t a l a l l t h e s u s p e n s i o c o m p o n e n t s n d l n a lightly tlghtenthe bolts and nuts,then placea j a c ku n d e rt h e t r a i l i n ga r m , a n d r a i s e h e t suspension load it with the vehicle'sweight to beforefully tighteningthe bolts and nuts to the specified torque values. . Tightenallthe mounting hardwareto the specif torque values. ied . Beforeinstallingthe wheel, cleanthe mating surfaceof the brakedisc and the insideof the wneei. . Checkthe wheel alignment,and adjust it if (seepage'18-4). necessary

Removethe flange nut (B),and disconnect the s t a b i l i z el r n k( C )f r o m t h e t r a i l i n g r m . i a Removethe flange bolt {D),and disconnect the d a m p e r( E )f r o m t h e t r a i l i n g r m . a Removethe trailing arm front mounting bolts (A).

,'a':r
A 12 x 1.25Jnm 108N.m {11.0kgt.m, 80 tbf.ft)

18-33

RearSuspension
Replacement Damper/Spring
ExplodedView

I
NUT SELF-LoCK|NG 10 x 1.25mm 29 N m {3.0kgf.m,22 lbf.ft} Replace.

9-----.---.-. -=\
ItI t=J

DAMPER MOUNlING COLLAR

DUSTCOVER

-tr) \ qnJ/
9...
E Z n \ lt \

BUMP sroP PLArE

/t
SPRING DAMPER Checkfor weakened and damage. compression

\ BUMPSTOP
and damage.

tor Check weakness

OAMPER UNIT for Check oil leaks, gas leaks, and smooth operation,

18-34

Removal
1. Raisethe rear of the vehicle.and support it with safetystandsin the proper location(seepage 1-8). Removethe rearwheels.

5. Removethe damper assemblyfrom the body.

i
2. Removethe flange bolt {A) from the bottom of the damper.

3 . Removethe rear bulkheadcover (seepage 20-51).


Removethe flange nuts (A) from the top of the damper in the trunk.

( c o n td )

18-35

RearSuspension
(cont'dl Damper/Spring Replacement
Disassembly/lnspection
1 . C o m p r e s sh e d a m p e rs p r i n g i t h a c o m m e r c i a l l y t w to availablestrut compressor(A) according the instructions. then removethe selfmanufacturer's l o c k i n g u t ( B ) w h i l eh o l d i n g h e d a m p e rs h a f t( C ) n t with a hex wrench (D).Do not compressthe spring to more than necessarv removethe nut.

Reassembly
1 . I n s t a la l l t h e p a r t s e x c e p t t h e e l f - l o c k i nn u t o n t o l s g the damper unit by referringto the ExplodedView. Align the bottom of the spring {A} and the stepped part of the lower spring seat (B),and align the d a m p e rm o u n t i n gb a s ea s s h o w n ,

,, '161\
from the strut spring Release pressure the then disassemble damper as the compressor, shown ln the ExplodedView.
?

7fi)1,, \3P qY/

"

I n s t a l l t h e a m p e ra s s e m b l y n a c o m m e r c i a l l y o d availablestrut spring compressor(C). C o m p r e s t h e d a m p e rs p r i n gw i t h t h e s p r i n g s compressor. Installthenew self'lockingnut (A) on the damper shaft.

Reassemble the pans, exceptfor the spring. all

4 . Compress the damper assemblyby hand,and

checkfor smooth operationthrough a full stroke, The damper both compressionand extension. should extend smoothly and constantlywhen lf compressionis released. it does not, the gas is leakingand the damper should be replaced.

10 x 1.25mm 29Nm (3.0kgt m,22 lbt.ft)

5. Hold the damper shaft {B)with a hex wrench (C), nut and tighten the self-locking to the specified torque. Checkfor oil leaks,abnormal noises,or binding during thesetests.

18-36

Installation
1. Positionthe damper assemblyin the body. Note the directionof the damper mounting base so that the small hole dot on it is toward the front and insideof the vehicle.

3. Looselyinstallthe flange bolt (A) on the bottom of thedamper.

1 2 x1 . 2 5 m m 45 61N m {6.2 kgf.m. lbf.ft) Raisethe suspension with a floor jack to load the vehicleweight, and tighten the nuts and bolt to the specifiedtorque values. C l e a n h e m a t i n gs u r f a c e f t h e b r a k ed i s ca n d t h e t o i n s i d e f t h e w h e e l ,t h e n i n s t a ltl h e r e a rw h e e l . o Checkthe wheel alignment,and adjust it if (seepage 18-4). necessary

Looselyinstallthe flange nuts (A) onto the top of the damper,

A 1 0 x 1 . 2 5m m 59 N.m 16.0kgt.m, ia lbt ft)

18-37

Brakes
Conventional BrakeComponents
Tools Special ........ l9-2 ... C o m p o n e n to c a t i oIn d e x . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9.-.3 . . . . . . . . L n . . . Brake SystemInspection and Tests............... .......... 19-4 Brake Pedal and Brake PedalPosition Switch Adjustment .............. 19-6 Parking Brake Check and Adjustment .............. 19-7 Brake System Bleeding ...................... 19-8 Brake SystemIndicator Circuit Diagram . . . . . . . . . . . . . . . 9.-.9 1. . Parking Brake Switch Test ................. 19-10 Brake FluidLevel Test ...................................... Switch 19-10 Front Brake Pads lnsoection and Replacement ........... 19-11 Front Brake DiscInspection ............... 19-13 Front Brake Calioer Overhaul...................................... 19-14 Master Replacement Cylinder ........... 19-15 Master Cylinder Inspection ................ 19-16 Brake Booster Pushrod Adjustment................................ Clearance 19-16 Brake BoosterTest ................... .......... 19-18 Brake Booster Reolacement .............. 19-19 Rear Brake Pads Inspection and Reolacement ........... 19-20 Rear Brake DiscInspection ................ 19-22 Rear Brake Caliper Overhaul....................................... 19-23 Brake Hoses Lines and Insoection .... 19-24 Brake Hose Reolacement ................... 19-25 Parking Brake Replacement Cable .............................. 19-26

ABS (Anti-lockBrakeSystem) Gomponents

... 19-29

BrakeComponents Conventional
SpecialTools
Ref.No.

Tool Number
100 07JAG-SD40

DescriDtion PushrodAdiustmentGauoe

Qty 1

19-2

Component Location Index

INDICATOR BrakeSystemIndicatorCircuit D i a g r a mp a g e1 9 - 9 , ParkingBrakeSwitch Test,page 19 10 BrakeFluidLevelSwitch Test,page 19-10

BRAKE CABLE
Parking rake able B C page 19 26 Replacement,

FRONT BRAKES FrontBrakePads,Inspection and page 19-1 Replacement, 1 FrontBrakeDisc page 19'13 Inspection, FrontBrakeCaliper O v e r h a u lp a g e1 9 - 1 4 , BRAKEBOOSTER BrakeBooster Test,page 19-18 BrakeEooster page 19 19 Replacement, BRAKE HOSES and LINES BrakeHosesand Lines page 19 24 Inspection, BrakeHoses page 19 25 Replacement, MASTER CYLINDER MasterCylinder
Fl6^1.^6m6nr ^2^o 1O-18

REARDISCBRAKE RearBrakePads Inspection and page l9-20 Replacement, RearBrakeDisc page 19'22 Inspection, R e a rB r a k e a l i p e O v e r h a u l , C r page 19'23

PARKING BRAKE LEVER Parkino Brake page19-7 Check Adjustment, and BRAKE PEDAL Brake Pedal Erake and Pedal Position Switch pagel9-6 Adjustment,

p M a s t e r y l i n d eIrn s p e c t i o n ,a g e1 9 - 1 6 C BrakeBoosterPushrodClearance p A d j u s t m e n t ,a g e ' 1 9 - 1 6 page 19-8 BrakeSystemBleeding,

19-3

BrakeComponents Gonventional
and Tests BrakeSystemInspection
Component l\4aster Cylinder

Procedure
Look for damageor signs of fluid leakageat; . Reservoir reservoirgrommets or . L i n ej o i n t s . Betweenmastercvlinderand booster Look for damageor signs of fluid leakageat: . Line joints and banjo bolt connections . Hosesand lines.also inspectfor twisting or damaqe Lookfor damageor signs of fluid leakageat: . Pistonseal . Banjo bolt connections . Bleederscrew at: Lookfor damageor signs of fluid leakage . Linejoints . Modulator

Also check for:

Brake Hoses

Bulging,twisted or bent lines.

Caliper

p c Seized r sticking aliper ins. o

ABS l\ilodulator

BrakeSystemTest
Brake pedal sinks/fades when braking 1. Startthe engine,and let it warm up to operatingtemperature. 2. Attacha 2-inchpieceof maskingtape along the bottom of the steeringwheel, and draw a horizontalreference mark acrossit. the 3 . With the transmissionin Neutral,pressand hold the brakepedal lightly,then release parkingbrake. While still holdingthe brakepedal,hook the end of the tape measurebehind it. Then pull the tape up to the mark you made on the maskingtape. steeringwheel, noting where the tape measurelines up with the reference 5 . Apply steadypressureto the brakepedalfor 3 minutes. 6 . Watch the tape measure. . if it moves lessthan 10 mm, the mastercylinderis OK. . if it moves more than 10 mm replacethe mastercylinder.

t-

19-4

Rapid brake pad wear. Vehicle vibration {after a long drivel, or High, hard brake pedal 1 . D r i v et h e v e h i c l e n t i lt h e b r a k e s r a go r u n t i l t h e u d pedal is high and hard.This can take 20 or more brakepedal applications during an extendedtest drive. 2 . W i t h t h e e n g i n er u n n i n g r a i s e h e v e h i c l e n a l i f t , , t o a n d s p i n a l l f o u r w h e e l sb y h a n d . ls there btake drag at any of the wheels?

5. Loosenthe hydrauliclines at the mastercylinder, then spin the wheelsto checkfor brakedrag. ls there brake drag at any of the wheels? YES Go to step 6. NO- Replace mastercylinder.l the 6. Loosenthe bleederscrewsat each caliper,then spin the wheels to checkfor brakedrag. Is there brake drag at any of the wheels?

YES Go to step 3. NO Lookfor other causesof the pad wear, high pedal, r vehicle ibration.I o v 3. Turn the engineoff, pump the brakepedalto depletethe vacuum in the brakebooster,and then spin the wheels againto checkfor brakedrag. ls therc brake dtag at any ot the wheels? YES-Go to step 4. NO Replace brakebooster.I the 4. Without removingthe brakelines,unbolt and separate the mastercylinderfrom the booster,then spin the wheelslo checkfor brakedrag. ls there btake drag at any of the wheels? YES Go to step 5, NO-Check the brakepedal positionswitch adjustmentand pedalfree play.I YES Disassemble and repairthe caliperon the w h e e l ( s w i t h b r a k ed r a g . l ) NO Inspectbrakehose (s)/line(s).

19-5

BrakeComponents Conventional
BrakePedaland BrakePedalPosition SwitchAdjustment
Height Pedal
1 . Disconnect brakepedal positionswitch the connector, turn the brakepedal positionswitch (A) c o u n t e r c l o c k w i sa n d p u l l i t b a c ku n t i li t i s n o e, l o n g e rt o u c h i n g h e b r a k ep e d a l . t Lift up the carpetand the insulatorcutout (B). l\4easure pedal height (C)from the middle of the the left side of the pedal pad (D). StandardPedalHeight (with carpet removed): 184 mm (7 4/16in.)

PedalFreePlay
4. With the engineoff, inspectthe play (A) on the p e d a lp a d ( B )b y p u s h i n g h e p e d a lb y h a n d . t F r e eP l a y :0 . 4 - 3 . 0 m m { 0 . 0 1 6 0 . ' l 1 8 i n . )

lf the pedalfree play is out of specification, adjust the brakepedal positionswitch (C).lf the pedalfree p l a yi s i n s u f f i c i e n itt, m a y r e s u l ti n b r a k ed r a g . 6 . Pushin the brakeoedal oositionswitch until its ( d p l u n g e r s f u l l yp r e s s e d t h r e a d e e n d ( A ) t o u c h i n g i the pad (B)on the pedal arm).Then,turn the switch 45" clockwiseto lock it. The gap betweenthe brake pedal positionswitch and the pad is automatically i t a d j u s t e do 0 . 4t o 3 . 0m m ( 0 . 0 1 6 0 . 1 1 8 n . )b y l o c k i n g h e s w i t c h . a k es u r et h e b r a k el i g h t sg o t M otf when the pedal is released.

Loosenthe pushrodlocknut(A),and screwthe pushrodin or out with pliers until the standard pedal heightfrom the floor is reached. After adjustment, tighten the locknutfirmly. Do not adjustthe pedal heightwith the pushrodpressed.

1 5N . m (1.5kgl m. 11lbl ft)

7 . C h e c k h e b r a k ep e d a lf r e e p l a ya s d e s c r i b e d e l o w . b t

19-6

ParkingBrakeCheckand Adiustment
Check
1. Pullthe parkingbrakelever {A) with 196 N (20 kgf, 44 lbf) of forceto fully apply the parkingbrake.The parkingbrakelever should be lockedwithin the specifiednumber of clicks(B). Leverlockedclicks: 7-8 Removethe rear console{seepage 20-57). Pull the parkingbrakelever up one click,

l2okqf,a4lbl)

if 2. Adjust parking the brake the leverclicks not are withinthe specification.

7, Tightenthe adjustingnut {A} until the parking brakesdrag slightlywhen the rear wheels are t ur n e d . A /

Adjustment
1. Release parkingbrakeleverfully. the Loosenthe parkingbrakeadjustingnut, startthe engine,and pressthe brakepedal severaltimes to set the self-adjusting brakebeforeadjustingthe parkingbrake. Blockthe front wheels,then raisethe rear of the vehicle,and supportit with safetystandsin the proper location(seepage 1-8). Make sure the parkingbrakearm (A) on the rear brakecalipercontacts the brakecaliperpin (B), The parkingbrakearm will only contactthe NOTE: brakecaliperpin when the parkingbrakeadjusting nut is loosened. 8 . Release parkingbrakelever fully, and check the that the parkingbrakesdo not drag when the rear wheels are turned. Readjustif necessary. 9 . Make surethe parkingbrakesare fully applied when the parkingbrakelever is pulled up fully. 1 0 . Reinstall the rear console.

19-7

BrakeComponents Conventional
BrakeSystemBleeding
NOTE: . Do not spill brakefluid on the vehicle;it may damage the painUif brakefluid does contactthe paint.wash it off immediatelywith water. . The reservoiron the mastercylindermust be at the MAX (upper)level mark at the start of the bleeding procedureand checkedafter bleedingeach brake c a l i p e rA d d f l u i da s r e q u i r e d . . . Do not reusethe drainedfluid. . Always use Honda DOT3 brakefluid. Non-Honda brakefluid can causecorrosionand shortenthe life of the system. . Make sure no din or other foreign matter is allowed to contaminate the brakefluid. 1 . M a k es u r et h e b r a k ef l u i d l e v e li n t h e r e s e r v o i irs a t t h e M A X ( u p p e r ) e v e ll i n e( A ) . l Refillthe mastercylinder reservoir the MAX to {upper)level line. FRONTBRAKE: procedurefor eachwheel in the 5. ReDeatthe sequence shown below until air bubblesno longer appearn thefluid. i
BLEEDING SEOUENCE: OFront Right ORe.r Right

O Front Left

ORoar Loft

9 N.m 10.9 kgf.m,7 lbl.ft)

t-

2 . Slide a pieceof clear plastichoseover the flrst


bleed screw,and submergethe other end in a containerof new brakefluid. Havesomeoneslowly pump the brakepedal severaltimes, then apply steadypressure. Startingat the left-front,loosenthe brakebleed screwto allow air to escapefrom the system.Then tighten the bleedscrew securely.

REARBRAKE:
9 N m 10.9kgf.m, 7 lbf ft)

19-8

BrakeSystemIndicatorCircuitDiagram

UNDER.OASH FUSE/FELAYBOX

A Y
BtK

GRN/ORN

EBAKFLUID IEVELSwlICH

(b, 3s1E8,.""",,"
oPEN,Leve,down

,tk
I

,o"","o ""o*.

I -=:

csor

19-9

Conventional Brake Components


ParkingBrakeSwitch Test
1. Removethe rear console,and disconnect the connector(A)from the switch (B).

BrakeFluidLevelSwitch Test
Checkfor continuitybetweenthe terminals(A) with the float in the down positionand the up position. . Removethe brakefluid completelyfrom the reservoir. With the float down, there should be continuity. . F j l l t h er e s e r v o iw i t h b r a k e f l u i d t oM A X ( u p p e r ) e v e l r l (B).With the float up, there should be no continuity.

'dFu !UF\!E

Checkfor continuitybetweenthe switchterminal a n d b o d yg r o u n d : . With the brakelever up, there should be continuity. . With the brakelever down, there should be no continuity.

19-10

and Replacement Front BrakePadsInspection


Replacement
s o F r e q u e nitn h a l a t i o n f b r a k ep a d d u s t ,r e g a r d l e so f o c m a t e r i ac o m p o s i t i o n ,o u l db e h a z a r d o uts y o u r l . Avoid breathingdust particles. . N e v e ru s ea n a i r h o s eo r b r u s ht o c l e a nb r a k e va U a s s e m b l i e s . s ea n O S H A - a p p r o v e d c u u m cleaner. ( 1 . R e m o v e h e b o l t( A ) ,a n d p i v o tt h e c a l i p e r B )u p o u t t of the way. Checkthe hose and pin boots for d a m a g ea n d d e t e r i o r a t i o n .

lnspection
1. Raisethe front of the vehicle,and support it with safetystandsin the proper location{seepage 1'8). Removethe front wheels. of 2. Checkthe thickness the inner pad iA) and outer p a d { B ) .D o n o t i n c l u d e h e t h i c k n e s s f t h e b r a k e t o pad backingplate. Brakepad thickness: 9.5 10.5mm (0.37 0.41 in.l Standard: Servicelimit: 1.6 mm (0.06in.)
Innerpad:

&
\ A
t 2 . R e m o v e h e p a ds h i m i A ) a n d p a d s { B ) .

' . . '
, .a

Outer pad:

.^hv/
lf the brakeDadthicknessis lessthan the service l i m i t ,r e p l a c e l l t h e p a d sa s a s e t . a

\ \ \t J I ."r------B v

(cont'd)

19-11

Conventional BrakeGomponents
Front BrakePadsInspection (cont'dl and Replacement
3. Removethe pad retainers(A),and checkthe caliper pins for free movement. 10. Push in the piston (A) so the caliperwill fitoverthe pads.Checkthe brakefluid level.The brakefluid may overflow if the reservoiris too full. lvlake sure the piston boot is in positionto preventdamagingit when pivotingthe caliperdown

/:-." t-.. . .,.';i.:


i '1=' r

.. a.-

8x1.0mm 34 N.m 3.5 kgt m. 25 tbf.ft)

4. Cleanthe caliperthoroughly;remove any rust,and checkfor groovesand cracks. 5. Checkthebrakedisc for damageand cracks. 6. Apply Dow CorningMolykoteM77 greaseto the retainers their mating surfacesagainstthe on caliperbracket. 7. Installthe pad retainers. Wipe excessgreaseoffthe retainers. Contaminated brakediscsand pads reducestoppingability.Keepgreaseoff the discs andpads. greaseto both sidesof the 8. Apply Molykote l\477 p a d s h i m { A ) ,t h e b a c ko f t h e p a d s( B ) ,a n d t h e o t h e r areasindicatedby the arrows. Wipe excessgreaseoff the shim. Contaminated brakediscsand pads reducestoppingability.Keep greaseoff the discs and pads.

11. Pivotthe caliperdown into position.Beingcareful not to damagethe pin boots,installthe bolt (B),and tighten it to the specified torque. 1 2 . P r e s s h e b r a k ep e d a ls e v e r atli m e s t o m a k e s u r e t the brakeworks,then test drive. N O T E E n g a g e m e n t f t h e b r a k em a y r e q u i r e : o a greaterpedal strokeimmediatelyafter the brake pads have been replacedas a set.Several applications lhe brakepedalwill restorethe of normal pedalstroke. 13. After installation, checkfor leaksat hose and line joantsor connections, and retightenif necessary.

, a .).

Installthe brakepads and pad shim correctly. Installthe padswith the wear indicators(C)on the inside. lf you are reusingthe pads,always reinstall the brakepads in their original positionsto preventa momentary loss of brakingefficiency.

19-12

Front BrakeDisclnspection
Runout
1. Raisethe front of the vehicle,and support it with safetystandsin the proper location(seepage 1-8). Removethe front wheels. 2 . R e m o v e h e b r a k ep a d s( s e ep a g e1 9 - 1 1 ) . t 3. Inspect the disc surfacefor damageand cracks. Cleanthe discthoroughly,and removeall rust 4. lnstallsuitable flat washers(A) andwheel nuts,and torque to hold the tightenthe nuts to the specified brakedisc securelyagainstthe hub.

Thickness Parallelism and


1. Raisethe front of the vehicle,and supportit with safetystandsin the proper location(seepage 1-8). Removethe front wheels. 2. Removethe brakepads (seepage 19-11). 3. Using a micrometer,measurediscthicknessat eight points,approximately45" apart and 10 mm {0.4 in.) in from the outer edge of the disc. Brake Oisc Thickness: Standard:20.9 21.8mm {0.82-0.86 in.} in.) Limit: 19.0mm 10.75 Max. Refinishing in.) Brake Disc Parallelism: 0.015 mm 10.0(X)6 max. NOTE:This is the maximum allowabledifference betweenthe thicknessmeasurements

10 mm lo.itin.l

': . --'t-'"'t , . Set up the dial gaugeagainstthe brakedisc as shown, and measurethe runout at 10 mm (0 4 in.) from the outer edge of the disc. BrakeDiscRunout: in.l ServiceLimit: 0.10mm (0.00tt lf the disc is beyondthe servicelimit, refinishthe brakedisc. Max. RetinishLimit: 19.0mm (0.75in.) NOTE: . l f t h e b r a k e d i s cs b e y o n d t h e s e r v i c le m i t f o r i i 1 i r e f i n i s h i n g , p l a c et ( s e ep a g e1 8 - 1 ) . re . A new disc should be refinishedif its runout is g r e a t e r h a n0 . 1 0m m ( 0 . 0 0 4n . ) . i t

s 4 . l f t h e s m a l l e s m e a s u r e m e ni t l e s st h a nt h e m a x . t refinishinglimit, replacethe brakedisc (seepage 18-11). lf the disc is beyondthe servicelimit for parallelism, refinishthe brakedisc with an on-carbrakelathe. producedby Kwik-way The Kwik-Lathe "Front BrakeDisc Co. and the Manufacturing Lathe" offered by Snap-onTools Co. are approved for this operation.

19-13

Conventional BrakeComponents
Front BrakeCaliperOverhaul
{

Frequentinhalationof brakepad dust, regardless materialcomposition, of could be hazardous your health. to . Avoid breathingdust particles. ' N e v e ru s ea n a i r h o s eo r b r u s ht o c l e a nb r a k ea s s e m b l i e s .s e a n o s H A - a p p r o v e d u v a c u u mc l e a n e r . Remove,disassemble, inspect,reassemble, and installthe caliper,and note these items: ' D o n o t s p i l lb r a k ef l u i d o n t h e v e h i c l e i;t m a y d a m a g et h e p a i n t ;i f b r a k e f l u i d g e t s o n t h e p a i n t , w a s h i t o f f immediatelywith water. . To preventdripping,cover disconnected hose joints with rags or shop towels. . C l e a n a l lp a r t s i n b r a k e f l u i d a n d a i r d r y ; b l o w o u t a lp a s s a g e s w i t c o m p r e s s e d i r . l h a . Beforereassembling, checkthat all parts are free of dust and other foreign particles. . Replacepartswith new ones as specifiedin the illustration. . Make sure no dirt or other foreign matter is allowedto contaminate the brakefluid, ' When reusingpads,always reinstallthemin their original positions to preventloss of brakingefficiency. . Do not reusedrainedbrakefluid. 'AlwaysuseHondaDOT3brakefluid.Non'Hondabrakefluidcancausecorrosionandshortenthelifeofthesvstem. . Do not mix differentbrandsof brakefluid as they may not be compatible. . C o a t t h ep i s t o n , i s t o ns e a lg r o o v e , n d c a l i p e r o r e w i t h c l e a n r a k e f l u i d . p a b b . Make sure no greaseor oil gets on the brakediscs or pads. . Replace rubber partswith new ones wheneverdisassembled. all . After installingthe caliper,checkthe brakehose and line for leaks,interference, and twistinq.
>:@:Honda caliper sreaso tplN 08C30-80234M)

Boors
-ffiFA

3i,l'1.'"
BRAKE HOSE/ / / / / / /
,

isli\ii ^ zswttt
SCREW /8LEEO /eNm (o.s kgr'm. / | itbt.ftl /caLl

/paq\ t l

l l [
3.4N.m kef {3.5 m,
25 lbf ft) ---=-? .===?

-ffi \--l -ffi PINA \:7 CALIPER


\
\ t )/) I I / /

,\L,.'iE/
/ /

(}', >vr

"=;lGoXu";;;lqEty'
/ ,,'

^ *fL-f

l^

t9..-\

^/rkr)
.==f@

*d':ffi
,-o/ vlJ
1 0 8N . m 1 1 1 . 0 g f . m , k 80 tbt.ft)

| (hA \t/

RepracF #.'@ PAD RETATNERS \

//' SEAL|NG WASHEaS WAStrtXS

/7\ !s-

ffi

Es,lry:' E*,e,a ["fif:i#l1t*"_,,. \


tz x t.zsmm

ourEBpaDsHrM

19-14

MasterCylinderReplacement
NOTE:Do not spill brakefluid on the vehicle;it may damagethe paint;if brakefluid does contactthe paint, wash it off immediatelywith water, ( t r 1 , R e m o v eh e a i rc l e a n ea s s e m b l yA ) . r t 3 . R e m o v e h e c l u t c hr e s e r v o i ( B )a n d e n g i n e w i r e harnessclip (C)from the mastercylindermounting b a s e( D ) . 4. Removethe reservoircap and brakefuid from the reservoir. 5. Removethe reservoir(E)on the mastercylinder D mountrng ase. the 6, Disconnect brakelines (F)from the master cylinder (G).To preventspills,cover the hosejoints with rags or shop towels. 7. Removethe mastercylinder mounting nuts {H)and washers. 8. Removethe mastercylinderfrom the brakebooster. Be carefulnot to bend or damagethe brakelines when removingthe mastercylinder. the 2, Disconnect brakefluid level sensorconnector (A). 9. Removethe rod seal (l) from the mastercylinder. 10. Installthe mastercylinder in the reverseorder of removal,and note these items: . Replace the rubber partswith new ones all wheneverthe mastercylinder is removed. . Checkthe pushrodclearance beforeinstallingthe (see mastercylinder.and adjust it if necessary p a g e1 9 - 1 6 ) . . Use a new rod seal on reassemblY . Coatthe inner bore lip and outer circumference of the new rod seal {A) with the recommended seal greasein the mastercylinderset. . I n s t a l l t h e o d s e a lo n t o t h e m a s t e r y l i n d e r i t h w c r its groovedside (B)towardthe mastercylinder. . Checkthe brakepedal height and free play after c , t i n s t a l l i n gh e m a s t e r y l i n d e ra n d a d j u s ti t i f (seepage 19-6). necessary

1 5N . m {1.5kgt.m,11 lbt.ft)

19-15

Conventional BrakeComponents
MasterCylinderInspection
NOTE: . Beforereassembling, checkthat alI partsare f ree of dust and other foreign particles. . D o n o t t r y t o d i s a s s e m b l e t hm a s t e r c y l i n d e r e assembly.Replace the mastercylinder assemblywith a new part if necessary. . Do not allow dirt or foreign matterto contaminate the brake luid. f I
,--l

BrakeBoosterPushrodClearance Adjustment
SpecialToolsRequired Pushrodadjustmentgauge07JAG-SD40100 NOTE:Brakeboosterpushrod-to-piston clearance must be checkedand adjustmentsmade, if necessarV, before installingthe mastercylinder. 1 . S e t t h e s p e c i atlo o l ( A )o n t h e m a s t e r c y l i n d eb o d v r (B),push in the centershaft (C)until the top of it contacts the end of the secondarypiston {D) by t u r n i n gt h e a d j u s t i n g u t ( E ) . n

RESERVOIB CAP unecK otocKage Ior


of vent holes. RESERvOIR SEAL Checklor damaoe and deterioration. STRAINER Removeaccumulated seotment.

RESERVOIR
r ' , , . J \ +

RESERVOIR HOSES Inspecthosesfor damage,leaks, and deterioration.

MASTER CYLINDER Check leaks, for rust,anddamage

Without disturbingthe centershaft'sposition, installthe specialtool(A) backwards the booster. on


1 5N m { r . 5 11tbf.ftl

Installthe mastercylinder nuts (B),and tighten them to the specifiedtorque. Conneclthe boosterin line with a vacuum gauge { C )0 - 1 0 1 k P a{ 0 ' - 7 6 0m m H g ,3 0 i n . H g ) o t h e t booster'senginevacuum supply,and maintainan e n g i n es p e e d h a tw i l l d e l i v e r 6 k P a( 5 0 0m m H g , t 6 20 in.Hg) acuum. v

19-16

5. With a feelergauge (A),measurethe clearance betweenthe gauge body and the adjustingnut (B) as snown, betweenthe gauge body and the lf the clearance adjustingnut is 0.4 mm (0.02in.),the pushrod-topistonclearance 0 mm. However.if the clearance is betweenthe gauge body and the adjustingnut is is clearance 0 4 mm 0 mm, the pushrod-to-piston {0.02in.) or more. Thereforeit must be adjusted and rechecked. Clearance: 0-0./t mm (0-0.02 in.)

l t 9 . C h e c k h e p u s h r o d e n g t h( A )a s s h o w n i f t h e boosteris removed,lf the length is incorrect, loosenthe pushrodlocknut(B),and turn the clevis (C)in or out to adjust. A m i 1 1 6 m { 4 . 6n . )

1 0 x 1 . 0m m 1.5 N'm kgf.m,11 lbf.ftl 11.5

( m c 1 0 . I n s t a l l t h e a s t e r y l i n d e r s e ep a g el 9 - 1 5 )

is lf the clearance incorrect,loosenthe star locknut (A).and turn the adjuster(B)in or out to adjust. . Adjustthe clearance while the specifiedvacuum is appiiedto the booster. . Holdthe clevis(C)while adjusting. A 22N.n in.) 0 0.4mm l0 -0.02

07JAG-SO40100 7. Tightenthe star locknutsecurely. 8. Removethe specialtool (D).

19-17

Gonventional BrakeComponents
Brake Booster Test
Functional Test
1. With the enginestopped,pressthe brakepedal severaltimes to depletethe vacuum reservoir, then pressthe pedal hard, and hold itfor 15 seconds.lf the pedalsinks,eitherthe mastercylinderis bypassinginternally,or the brakesystem (master c y l i n d e rl,i n e s . o d u l a t o ro r c a l i p e r si)s l e a k i n g . m , 2. Startthe enginewith the brakepedal pressed.lf the pedal sinksslightly,the vacuum boosteris working properly.lf the pedal heightdoes not vary, the boosteror checkvalve is faulty. 3. With the engine running,pressthe brakepedal l i g h t l y . f t h e b r a k ep e d a ls i n k sm o r e t h a n 1 Om m l {3/8 in,) in 3 minutes,the mastercylinder is faulty. A slight changein pedal heightwhen the Ay'C compressorcycleson and off is normal.(TheA,/C compressorload changesthe vacuum availableto the booster.) 3. Disconnect brakeboostervacuum hose (check the valve built-in)(A) at the boosterside.

LeakTest
1. Pressthe brakepedalwith the engine running,then stop the engine.lf the pedal height does not vary while pressedfor 30 seconds, vacuum booster the is OK. lf the pedal rises,the boosteris faulty. 2. With the engine stopped,pressthe brakepedal severaltimes using normal pressure. When the pedal is first pressed,it should oe row. On consecutive applications, pedal height the s h o u l dg r a d u a l l y i s e .l f t h e p e d a lp o s i t i o n o e s n o t r d varv, checkthe boostercheckvalve.

4 . Startthe engine,and let it idle.Thereshould be v a c u u ma v a i l a b l el . n o v a c u u mi s a v a i l a b l e , e f th checkvalve is not working properly.Repiace the brakeboostervacuum hose and checkvalve,and relesI. 5 . Reconnect brakeboostervacuum nose. the Startthe engine,and then pinch the brakebooster vacuum hose betweenthe checkvalve and the booster, Turn the ignition switch OFF,and wait 30 seconds, Pressthe brakepedal severaltimes using normal pressu re, When the pedal is first pressed, should be low. it On consecutive applications, pedal height the s h o u l dg r a d u a l l y i s e . r . lf the pedal positiondoes notvary, replacethe brakebooster. . lf the pedal positionvaries,replacethe brake boostervacuum hose/check valve assembly.

19-18

BrakeBoosterReplacement
( c 1 . R e m o v e h e m a s t e r y l i n d e r s e ep a g e1 9 - 1 5 ) . t Removethe mastercylinder brakelines {A) from t h e b r a k el i n ec l i p . t 5 . R e m o v e h e c l i p ( A )a n dt h e j o i n t p i n ( B ) .a n d disconnecttheyoke from the brakepedal.

.,.,....

alu
i '..

' - /

c
6x1.0mm 9.8 N.m (1.0kgf.m, 7.2 tbf.ft)

{'l.3kgf.m,9lbf.ftl Removethe brakeboostermounting nuts (C). 7 . Removethe brakebooster(A)from the engine comparlmenr.

Removethe vacuum hose mounting bracket(B). Disconnect vacuum hose {C)from the brake the booster.

INdAdEI

. Be carefulnot to damagethe booster surfacesand threadsof the boosterstud bolts. . Be carefulnot to bend or damagethe b r a k el i n e s .

lnstallthe brakeboosterin the reverseorder of removal,and note these items: . Adjustthe pushrodclearance beforeinstalling the brakebooster(seepage 19-16). . U s ea n e w c l i pw h e n e v e r n s t a l l i n g . i . After installingthe brakeboosterand master cylinder,fill the reservoirwith new brakefluid, and bleedthe brakesystem (seepage 19-8), adjustthe brakepedal height and free play (see p a g e1 9 - 6 ) ,

19-19

Conventional Brake Components


RearBrakePadsInspection and Replacement
Replacement
Frequentinhalationof brakepad dust, regardless of materialcomposition,could be hazardous your to h e ah h . . Avoid breathingdust particles. . Never use an air hose or brushto clean brake assemblies, Use an OSHA-approved vacuum cleaner. 1. Removethe bolt (A) and brakehose {B}from the mounting bracket.

Inspection
'1. Raisethe rear of the vehicle,and supportjt with safetystandsin the proper location(seepage 1-8). Removethe rearwheels,

2. Checkthe thickness the inner pad (A) andouter of pad (B).Do not includethe thicknessof the brake pad backingplate. Brakepad thickness: Standard: 8.5 9.5 mm {0.33-0.37 in.} Servicelimit: 1.6 mm (0.06in.)

Removethe caliperbolts (C),and removethe caliper(D)from the caliperbracket.

3 . R e m o v e h e p a d s h i m s( A )a n d p a d s( B ) . t

A
B -::-A

t {
\

3 . lf the brakepad thicknessis lessthan the service


l i m i t ,r e p l a c e l l t h e p a d sa s a s e t . a

t I
A

r\
) \

19-20

4. Removethe pad retainers(A).and checkthe caliper pins for free movement.


:.i _ _l

11. Rotatethe caliperpiston clockwiseinto the cylinder, then align the cutout (A) in the pistonwith the tab {B) on the inner pad by turning the piston backso o c t h e c a l i p e r a n b e i n s t a l l e d n t h e p a d .L u b r i c a t e the boot with rubbergreaseto avoid twisting the Distonboot. lf the piston boot is twisted,back it out so it is positionedproperly.

5. Cleanthe caliperthoroughly;remove any rust.and checkfor groovesand cracks. 6, Checkthe brakedisc for damageand cracks. 7 . Apply Dow CorningMolykoteM77 greaseto the retainerson their mating surfacesagainstthe caliperbracket,
.ar

m 8 x 1.25 m 22 N.m l2.2kgt m, 16rbl.ttl

Wipe excessgreaseoffthe 8 . Installthe pad retainers. brakediscs and pads retainers. Contaminated reducestoppingability.Keepgreaseoff the discs a n dp a d s . 9 . Apply Dow CorningMolykotelvl77greaseto both sidesof the pad shims {A),the backof the pads (B), and the other areasindicatedby the arrows.Wipe brake excessgreaseoff the shim. Contaminated discs and pads reducestoppingability.Keep greaseoff the discsand pads.

D mm 8 x 1.25 23Nm kgf.m, {2.3 17rbf.ft)

. .-.

( b I n s t a l l t h e r a k ec a l i p e r C )a n d c a l i p e r o l t s( D ) . b and tighten the boltsto the specifiedtorque. b 1 3 .I n s t a l l t h e r a k eh o s e( E ) . 1 4 . Pressthe brakepedal severaltimes to make sure the brakeworks, then test-drive. of NOTE:Engagement the brakemay requirea greeterpedal strokeimmediatelyafterthe brake pads have been replacedas a set. Several of applications the brakepedalwill restorethe n o r m a lp e d a ls t r o k e , b 1 5 . C h e c k h e p a r k i n g r a k ea d j u s t m e n{ts e ep a g e1 9 - 7 ) . t

1 0 . I n s t a l l t h e r a k ep a d sa n d p a d s h i m sc o r r e c t l y . b p s I n s t a l l t h e a d sw i r h t h e w e a r i n d i c a t o r { C )o n t h e inside. lf you are reusingthe pads,always reinstallthe brakepads in their originalpositionsto preventa momentaryloss of brakingefficiency.

a f ch 1 6 . A f t e ri n s t a l l a t i o n , e c k o r l e a k s t h o s ea n d l i n e joints or connections, and retightenif necessarY.

19-21

Conventional BrakeComponents
RearBrakeDiscInspection
Runout
1. Raisethe rear of the vehicle,and support it with safetystandsin the proper location(seepage 1-8). Removethe rear wheels, 2. Removethe brakepads (seepage 19-20). 3. Inspectthe disc surfacefor damageand cracks. Cleanthe discthoroughly,and remove all rust, 4. lnstallsuitable f lat washers(A) and wheel nuts, and tighten the nuts to the specifiedtorque to hold the brakedisc securelyagainstthe hub.

Thickness Parallelism and


1. Raisethe rear of the vehicle,and supportwith safetystandsin the proper location(seepage l-g). Removethe rearwheels. 2. Removethe brakepads {seepage 19 20). 3, Using a micrometer,measurediscthicknessat , e i g h tp o i n t s a p p r o x i m a t e l4 5 ' a p a r ta n d 1 0 m m y {0.4 in.)from the outer edge of the disc. BrakeDiscThickness: Standard:9.9-10.1 mm (0.389 0.397in.l Max. Retinishing Limit: 9.0 mm (0.35in.) BrakeDiscParallelism: 0.016mm 10.0006 in.) max.

108N.m (11.0 kgf.m,80lbf.ft) Set up the dial gauge againstthe brakedisc as shown. and measurethe runout at 10 mm (0.4in.) from the outer edge of the disc. Brake Disc Runout; ServiceLimit: 0.10mm {0.004in.) lf the disc is beyondthe servicelimit, refinishthe brakedisc. Max. RefinishLimit: 9.0 mm (0.35in.) NOTE: . l f t h e b r a k ed i s ci s b e y o n d t h e s e r v i c le m i t f o r i refinishing,replaceit (seepage 18-26). . A new disc should be refinishedif its runout is g r e a t e r h a n0 . 1 0m m ( 0 . 0 0 4n . ) . t i 4 . lf the smallestmeasurementis lessthan the max. refinishinglimit, replacethe brakedisc (seepage 18-26). lf the disc is beyondthe servicelimit for parallelism, refinishthe brakedisc with an on-carbrakelathe.

19-22

Overhaul RearBrakeCaliper

to of Frequentinhalationof brakepad dust, regardless materialcomposition,could be hazardous your health. ' Avoid breathingdust particles. . Never use an air hose or brushto clean brakeassemblies. vacuum cleaner' Use an OSHA-approved and installthe caliper,and note these items: inspect,reassemble, Remove,disassemble, . D o n o t s p i l lb r a k e l u i d o n t h e v e h i c l e i;t m a y d a m a g e h e p a i n t ;i f b r a k ef l u i d g e t so n t h e p a i n t , a s h i t o f f w t f immediatelywith water. . To preventdripping.cover disconnected hosejoints with rags or shop towels. . C l e a n a l lp a r t s i n b r a k e f l u i d a n d a i r d r y ; b l o w o u t a l l a s s a g e s w i t c o m p r e s s e a i r ' p h d . Beforereassembling, parts are free of dust and other foreign particles checkthat all . Replace pans with new ones as specifiedin the illustration. . Make sure no dirt or other foreign matter contaminates brakefluid. the . When reusingpads,always reinstallthemin their originalpositionsto preventloss of b raking efficie ncy. . Do not reusedrainedbrakefluid. . U s eo n l y c l e a nH o n d aD O T3 b r a k e l u i d .N o n - H o n d a r a k e l u i d c a nc a u s ec o r r o s i o n n d s h o r t e n h e l i f eo f t h e t a b f f system. . Do not mix differentbrandsot brakefluid as they may not be compatible. . C o a t t h ep i s t o n , i s t o ns e a lg r o o v e , n d c a l i p e r o r ew i t h c l e a nb r a k ef l u i d . p b a . Make sure no greaseor oil gets on the brakediscsor pads. . R e p l a c e a lrlu b b e rp a r t sw i t h n e w o n e sw h e n e v e r i s a s s e m b l e d . d . After installingthe caliper,checkthe brakehose and line for leaks,interference. and twisting.
oG , nonau."rip6r qreaslP/N 08c30-aoa4Ml BOLT 3 4 N . m( 3 . 5 g f m , 2 5 l b t f t ) k WASHERS BRAKE HOSE

\-"o, V((rA
a

i,,'IltE" !!;,ff /
.ARKING NUr
27Nm{2.8kgtm,, f.m 20 tbf.ftr

t H\a \l / t,i*t'*" ?,,.t/*"^.,,.:,"", l, /"V4#


,/

",1 ;[.,.JF /;;;;---

ADJUSTING BOLT

olT-J,.o"c.
lii.'i rz.r rgr..

O.RING Beplace.

CUP Beplace.

Gd

ffi

PADSPRING

A,n
INNEBPA'SHIM /

Na

--t\)(*ff '(
.r.:._U
: .:r=,9!q!q}l

l^7k
i*E

',,0,n, \ ,,:,o"\ 7lfl,lif,loffi

''"'t!1'ry#'

":;*" *dF
fr.x{_>@

,,.-"iV

,/q &'"o.,"."""o"^.,

fftt **-->**^'"

,.2>a>-

10 MM FLANGE BOLTS 55 N m (5.6 lgf-m, 4r lbt ft)

19-23

Conventional BrakeComponents
BrakeHosesand LinesInspection
1. Inspectthe brakehosesfordamage,deterioration, leaks,interference, andtwisting. 2. Checkthe brakelinesfor damage,rusting.and leakage. Also checkfor bent brakelines. 3. Checkfor leaksat hose and line joints or connections, and retightenif necessary. 4. Checkthe mastercylinderand ABS modulator unit for damageand leakage. NOTE:Replace the brakehose clip wheneverthe brakehose is serviced.

BRAKE LINE-to-BRAKE HOSE


15 N.m (1.5kgf.m, 11 lbf.ftl

BRAKE HOSE-to-CALIPER lBANJOBOLTI 3il N.m {3.5kgf.m.25lbt'ft) BLEEO SCREW 9 N.m{0.9 kgf.m,7lbf.ftl ABS MODULATOR UNIT-Io-BRAKE LINE 15N.m{1.5 m.11lbf.ftl kgf

t''

/,i'i'
,/ ,l
t t,.. -)

MASTERCYLINDEB-to-BRAKE LINE 15 N m {1.5kgt.m,ll lbf.ft)

BRAKEHOSE.tO-CALIPER {BANJO BOLTI 34 N.m {3.5kgf.m,25 lbl.ft) BLEEDSCBEW 9 N.m 10.9kgf.m, 7 lbf ft)

BRAKE LINE 15N.m11.5 m, 11lbf.ft) kgf


BRAKELINE-Io-BRAKE HOSE 15 N.m (1.5kgf.m,11lbf.ftl

CONTROLVALVE-to-

19-24

BrakeHoseReplacement
NOTE: . Do not spill brakefluid on the vehicle;it may damage the paint;if brakefluid gets on the paint,wash it off immediatelywith water. . To preventdripping,cover disconnected line joints with rags or shop towels. . Beforereassembling, checkthat all parts are free of dust and other foreign particles. . Replace partswith new ones wheneverspecifiedto do so. 1. Replace brakehose (A) if the hose is twisted, the cracked, if it leaks. or 6. Installthe brakehose bracket(A)on the damper with the flange bolt (B)first, then connectthe brake hose (C)to the caliperwith the banjo bolt {D) and ( newsealing ashers E). w

7. lnstallthe hose onto the hose bracketon the bodv with a new hose clip (A).
1 0 x 1 . 0m m 15 N.m (1.5kgf.m, 1t tbt.ftl

i !

Disconnect brakehosefrom the brakeline (B) the using a 10 mm flare nut wrench {C) Removethe flange bolt (A),and removethe brake from the damper. hose brackets

the brakeline to the brakehose. Connect the brakehose,bleedthe brake 9 . After installing system (seepage l9-8).

1 0 .Do the following checks:


I x 1 . 2 5m m

. Checkthe brakehose and line joint for leaks,and tighten if necessary. . Checkthe brakehosesfor interference and twisting.

4. R e m o v e n d d i s c a r d h e h o s ec l i p ( B ) . t a

Removethe banjo bolt (C),and removethe brake h o s e( D ){ r o m t h e c a l i p e r .

19-25

Conventional BrakeComponents
ParkingBrakeCableReplacement
Exploded View

ADJUSTING NUT

PARKING BRAKE swtTcH

L
e
PARKING BRAKE CABLE for Check stiffness, binding, damage. and
8 x 1.25 22 N.m 12.2kgl

19-26

NOTE: . The parkingbrakecablesmust not be bent or distorted.This will leadto stiff operationand prematurefailure. . Referto the ExplodedView as neededduring this proceoure. 1 . R e l e a s t h e p a r k i n g r a k el e v e rf u l l y . e b 2. Removethe rearconsole(seepage 20-57).

7 . l n s t a l l t h e e w c a b l ei n t h e r e v e r s e r d e ro f n o removal.and note these items: . Be careful not to bend or distortthe cable. . M a k es u r et h e p a r k i n g r a k ec a b l ec l i p i s f u l l y b seatedon the cable housing. . Do the parkingbrakecable adjuslment(seepage 1 9 - 7. )

4 . Removethe parkingbrakecableclip (A) from the

b r a k e a b l e( B ) . c

parkingbrakecablefrom the lever Disconnectthe

{c).
6 . Removethe parkingbrakecable mounting hardware, then removethe cable.

19-27

Brakes
BrakeComponents................ 19-1 Conventional ABS (Anti-lockBrakeSystem)Components
C o m o o n e n to c a t i oln d e x . . . . . . . . . . . . . , . . . . . . . . . . . . . 1.9.-.3 . . . . . . . . L n . . .0 Troubleshooting Information ....................... 19-31 General .............. 19-34 DTC Troubleshooting Index 19-35 Symptom Troubleshooting Index ...,........................... ................. ........... 19-36 System Description 19-42 Diagram ......... Circuit .......... 19-45 DTC Troubleshooting ............... 19-52 ABSIndicator ...................... CircuitTroubleshooting Brake System Indicator Circuit T r o u b l e s h o o t i n. . . . . . . . . . . . . . . . . . . . . .g . . . . . .1 9 - 5 5 . ABSModulator-Control Removal Unit and ............. 19-57 lnstallation 19-59 WheelSensor Insoection ................... .............. 19-59 WheelSensor Reolacement

ABSGomponents
Location Component Index
(

RIGHT-REAR WHEEL SENSOR page Inspection, 19-59 page Replacement, 19-59


UNDER.OASH FUSE/RELAY BOX

UNDER.HOOD FUSE/RELAY BOX

\L
LEFT.REAR WHEEL SENSOR page 19-59 Inspection, page 19-59 Replacement, DATA LINKCONNECTOR I16PI RIGHT.FRONT WHEEL SENSOR page 19-59 Inspection, page 19-59 Replacement,

ABSMODULATOR.CONTROL UNIT page Removal Installation, 19'57 and

LEFT-FRONT WHEEL SENSOR page Inspection, 19-59 page Replacement, 1959

19-30

Troubleshooting General Information


ABS Indicator
. lf the system is OK,theABS indicatorgoes off 2 secondsafter turning the ignition switch ON (ll) without startingthe engine,and then comes on again and goes off 2 secondslater after startingthe engine. This occursbecause ABS control unitisturned the on by the lG2 power source. . The ABS indicatorcomes on when the ABS control unit detectsa problem in the system.However,even though the system is operatingproperly,the indicator will come on underthese conditions: - Only the drive wheels rotate - One drive wheel is stuck - The vehiclegoes into a spin - The ABS continuesto operatefor a long time. - The vehicleis subjected an electrical to signal disturbance To determinethe actualcauseof the problem,question the customeraboutthe problem.taking the above condilionsinto consideration. . When a Droblemis detectedand lhe ABS indicator comes on, there are caseswhen the indicatorstays on until the ignition switch is turned OFF,and cases when the when the indicatorgoes off automatically sYstemreturnsto normal. - DTC61: The ABS indicatorgoes off automatically when the system returnsto normal. - D T C1 1 ,1 3 , 1 5 , 1 73 1 , 3 2 , 3 3 ,3 4 ,3 5 ,3 6 ,3 7 ,3 8 ,5 4 , , or 81: The ABS indicatorstayson until the ignition switch is turned OFFwhether or not the system returnsto normal. - D f C 1 2 ,1 4 ,1 6 ,1 a , 2 1 , 5 1 , 5 2o r 5 3 ;T h e A B S , indicatorgoes off when the vehicleis driven again and the system is OK afterthe ignition switch is t u r n e df r o m O F Ft o O N { l l } .

Diagnostic TroubleCode{DTCI
. The memory can hold three DTCS. However,when the same DTCis detectedmore than once,the more recentDTCis written over the earlierone. when the same problem is detected Therefore, repeatedly, is memorizedas a single DTC. it . The DTCsare in the order they occurred,beginning with the most recent. . The DTCS (nonare memorizedin the EEPROM volatile memory).Therefore. the memorizedDTCs the are not clearedwhen the batteryis disconnected, ignition switch is turned off, or the system returnsto to normal. Do the specifiedprocedures clearthe DTCs.

Self-diagnosis
. Self-diagnosis be classifiedinto two categories: can - I n i t i ad i a g n o s i s : l Done right after the enginestarts and until the ABS indicatorgoes off - R e g u l ad i a g n o s i s : r D o n er i g h t a f t e r t h e n i t i a d i a g n o s i s n t i lt h e i l u ignition switch is turned OFF . When a problem is detectedby self-diagnosis, the system does the following: - Turnsthe ABS indicatoron - Memorizes the DTC - StopsABS control

Kickback
The pump motor operateswhen the ABS is functioning, and the fluid in the reservoiris forced out to the master k k c y l i n d e rc a u s i n g i c k b a c a t t h e b r a k ep e d a l . ,

PumpMotor
. The pump motor operates when the ABS is functioning. . The ABS control unit checksthe pump motor operationwhen the vehicleis startedthe first time after the ignition switch is turned ON (ll).You may hearthe motor operateat this time, but it is normal.

(cont'd)

19-31

ABSComponents
Troubleshooting Information(cont'd) General
How to TroubleshootABS DTCs
The troubleshooting flowchartprocedures assumethat the causeof the oroblem is still Dresent and the ABS indicatoris still on. Followingthe flowchartwhen the ABS indicatordoes not come on can resultin incorrect diagnosis. The connectorillustrations show the female terminal connectors with a singleoutline and the male terminal with a double outline. connectors 1. Ouestionthe customeraboutthe conditionswhen the problem occured,and try to reproduce the Find out same conditionsfor troubleshooting. when the ABS indicatorcame on, such as during ABS control,after ABS control,when the vehicle was at a certainspeed,etc. 2. When the ABS indicatordoes not come on during the test-drive, troubleshooting done basedon but is poor terminal the DTC,checkfor looseconnectors. contact,etc.,beforeyou starttroubleshooting. clearthe DTC,disconnect 3. After troubleshooting, the HondaPGM Tester.and test-drive vehicle. the Make sure the ABS indicatordoes not come on. 2 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) ,a n df o l l o wt h e s prompts on the PGM Testerto displaythe DTC{S) on the screen.After determiningthe DTC,referto the DTCTroubleshooting Index. NOTE:Seethe HondaPGM Testeruser'smanual for specificinstructions. Service Check Signal (SCS)Circuit Method: 1. With the ignition switch OFF,connectthe Honda PGM Tester(A)to the 16Pdata link connector(DLC) (BI underthe driver'sside of the dashboard.

How to RetrieveABS DTCs


Honda PGM Tester Method: 1, Wjth the ignition switch OFF,connectthe Honda PGMTester(A)to the 16Pdata link connector(DLC) (B) under the driver'sside of the dashboard. 2. Short the SCScircuitto body ground usingthe HondaPGM Tester. 3. Turn the ignition switch ON (ll).

19-32

4. The blinkingfrequencyindicates the DTC.DTCS are indicatedby a seriesof long and short blinks.One l o n gb l i n ke q u a l s1 0 s h o n b l i n k s A d d t h e l o n g a n d . short blinkstogetherto determinethe DTC.After determiningthe DTC,referto the DTC Troubleshooting dex. In NOTE: . lf the DTCis not memorized, ABS indicator the will go off for 3.6 seconds, and then come back on. . lf the ABS indicatorstayson, troubleshootfor "ABS indicator does not go off" (seestep 1 on page 19-53). Th system will not indicate the DTC unless these conditions are met: . The brakepedal is not pressed. . The ignitionswitch is turned ON {ll). . The SCScircuitis shortedto body ground before t h e i g n i t i o n w i t c hi s t u r n e dO N ( l l ) . s Example DTC ot 15
Long blink Short blinks {five timesl

How to ClearABS DTCs


Honda PGM Tester Method: 1. With the ignition switch OFF,connectthe Honda ( P G MT e s t e r A ) t o t h e l 6 P d a t a l i n kc o n n e c t o ( D L C ) r { B }u n d e rt h e d r i v e r ' s i d eo f t h e d a s h b o a r d . s

T u r nt h e i g n i t i o n w i t c hO N ( l l ) ,a n d c l e a r t h e s DTC(s) following the screenprompts on the by PGM Tester. NOTE:Seethe HondaPGl\4Testeruser's manual for sDeclf instructions. ic Cycling the lgnition Switch Method: C l e a rt h e D T Cb y t u r n i n gt h e i g n i t i o n w i t c hO N ( l l )t h e n s O F Fa t l e a s t2 0 t i m e s .

Examole of DTC 22 Long blinks (two times)

5 . Turn the ignition swltch OFF, Disconnect HondaPGM Testerfrom the DLC. the

19-33

ABSGomponents
Index DTCTroubleshooting
DTC
DTC:11 Detection ltem to to Rioht-front wheel sensor{ooen/short bodv qround/short power) Faultv riqht-frontwheel sensoroulse siqnal to to Left-front wheel sensor{oDen/short bodv qround/short power) Faultvleft-frontwheel sensorDulsesrqnal to to Riqht-rear wheel sensor(oDen/short bodv qround/short power) r r F a u l t v i q h t - r e aw h e e ls e n s o r u l s es i q n a l o to to Left-rear wheel sensor (open/short bodv qround/short power) Faultvleft-rear wheel sensorDulsesiqnal d C o n t i n u o uo D e r a t i o( c h i o D e D u l s e r ) s n Solenoid Solenoid Solenoid Solenoid Solenoid S ol en oi d S ol en o i d n S o l e oi d lvlotor Iocked lvlotor stuck off lMotorstuckon Main relav stuckoff lG2 voltaqe Unit) cPU (CentralProcessinq Note (seeoaoe 19-45) {seeoaoe 19-46) (seeoaqe 19-45) (seepaqe 19-46) (seeDaqe19-45) (seepaqe 19-46) (seeDaoe'19-45) (seeDaqe'19-46) (seepaqe 19-47) (seeDaoe19-48) { s e eD a q e1 9 - 4 8 ) {seeDaoe19'48) lsee oaqe 19-48) (seepaqe 19-48) (seeDaqe19-48) (seeDaqe19-48) (seeDaoe19-48) ( s e eD a q e1 9 - 4 8 ) (seeDaoe19-49) (seeDaoe19-50) ( s e ep a q e1 9 - 5 1 { s e eo a q e1 9 - 5 ' l {seepaqe 19-52)

DTC:12 DTC:13
DTC:14 DTC;15

DTC:16
DTC:17

DTC:18

Drc:2l
DTC:3'l DTC:32 DTC:33 DTC:34 DTC:35 DTC;36 DTC:37 DTC:38
DTC:51

DTC:52 DTC:53
DTC:54 DTC:61

DTC:81

19-34

g Symptom Troubleshootin Index


Symptom ABS indicatordoes nol come on ABS indicatordoes not go off and no ABS DTCis stored Brakesystem indicatordoes nol come on Brakesystem indicatordoes not go off and no ABS DTCis stored Diagnostic procedure (seepage ABS IndicatorCircuitTroubleshooting 19-52) ABS IndicatorCircuitTroubleshooting {seestep 1 on Daqe19-53) BrakeSystem lndicatorCircuitTroubleshooting (seepaqe 19-55) Also check for

Brake Indicator System Circuit Troubleshooting (see steo1 on Daqe 19-55)

19-35

ABS Gomponents
SystemDescription
ABSControlUnit Inputsand Outputsfor 31PConnector

1 2

4 5 6 7 B I

1 6 1 1 1B 1 9

20 ?1/t/t/l/t/

1112

1 41 5

Wire side of temaleterminals

Terminal number

Wire color BLU/ YEL GRN/ YEL BLU

Terminal sign RRS

Description Detects righfrear wneetsensor srgnal


Detects right-front wneetsensor srgnal

Measurement Terminals Conditionsllgnition


switch ON (ll))

Voltage

( R R S+ )
F R S( - )

;a-_-l

V S p i n h e e l a t AC:0.053 or w I turn/second above Wheel Oscilloscope 0.15 p-p r V o above

5
6 7 8 9 11

GRN/ BLK

( F R S+ )
F L S( _ )

BRN/ WHT BLU/ ORN


GRY/ RED

FLS+) {
R L SH

Detects left-front wneet sensor srgnal


Detects left-rear wneetsensor srgnal Communications with Honda PGM rester DTC indication

6-7

8 9

YEU RED LT BLU


BRN

( RLS +) DIAG K
DIAG L

12

19-36

Terminal number 14
t5

Wire color WHT/ BLK BLV ORN BLK WHT/ RED WHT/ GRN BLK BLU/ RED
BRN/ YEL

Terminalsign

Description
Detects brake switch siqnal

Measurement Terminals Conditions {lgnition


I 4 - GN D 15-GND switch oN lll)) pedal Pressed Brake Released

Voltage

STOP

rG2
M-GND + B-MR + B-FSR
GND

16

Power for source activating the svstem Ground the for motor 0umD
Powersource for the oumD motor Powersource for thevalve relav Ground the for modulator assemDtv

Eattery voltaoe Baftery voltage Below V 0.3

16-GN D
17-GND ,18-GND Atalltimes Atalltimes

Battery voltaoe
Battery voltaoe

18

'19

19.GND 20-GND ON
OFF OFF

Below V 0.3 A b o u t 1V 1
Below 1 V

20

ABS

Drives ABS indicator

EBD Drives brake (Electronic brake system indicator distribution)

ABS indicator 2 1 - G N D Brake system indicator

ONfor bulb cnecK

Below V 0.3 8attery voltage

(cont'd )

19-37

ABS Gomponents
(cont'd) SystemDescription
Features
When the brakepedal is pressedduring driving,the wheels can lock beforethe vehiclecomesto a stop. In such an event.the maneuverability the vehicleis reducedif the front wheels are locked,and the stabilityof the vehicleis of reducedif the rearwheels are locked,creatingan extremelyunstablecondition.The ABS precisely controlsthe slip rate of the wheelsto ensuremaximum grip force from the tires,therebyensuringthe maneuverability and stabilityof thevehicle. The ABS calculates slip rate of the wheels basedon the vehiclespeedand the wheel speed,then it controlsthe the to brakefluid pressure reachthe target slip rate. Grip Force of Tire and Road Surface
TARGET SLIPRATE

OF COEFFICIENT FRICTION

SLIPRATE

19-38

ABSControlUnit
Main Control The ABS control unit detectsthe wheel speed basedon the wheel sensorsignal it received, then it calculates the vehiclespeed basedon the detectedwheel speed.The control unit detectsthe vehiclespeedduring deceleration basedon the rate of deceleration. The ABS control unit calculates slip rate of eachwheel and transmitsthe control signalto the modulatorunit the solenoidvalve when the slip rate is high. The pressurereductioncontrol hasthree modes: pressurereducing,pressureretaining,and pressureintensifying.
T---

Function Self-diagnosis 1 . T h e A B S c o n t r o ln i t i s e q u i p p e d w i t h a m a i n C P U a n d a s u b - C P U . E a c h C P U c h e c k s t h e o t h e r f o r p r o b l e m s . u 2. The CPUS checkthe circuitof the system. p l w 3 . T h e A B S c o n t r ou n i t t u r n so n t h e A B S i n di c a t o r h e n t h e u n i t d e t e c t s a r o b l e ma n d t h e u n i ts t o p st h e s y s t e m . 4. The self-diagnosis be classifiedinto thesetwo categories: can . l n i t i a ld i a g n o s i s . R e g u l ad i a g n o s i s r On-boardDiagnosisFunction The ABS can be diagnosedwith the Honda PGM Tester. The ALB Checker cannot be usedwith this system.For air bleedingand checkingwheel sensorsignals.usethe Honda PGM Tester.Seethe Honda PGMTesteruser's manualfor specificoperatinginstructions.

(cont'd)

19-39

ABSComponents
(cont'd) SystemDescription
ABSModulator
The ABS modulatorconsistsof the inlet solenoidvalves,outlet solenoidvalves,reservoir, pump, pump motor, and the damping chamber.The modulator reducesthe caliperfluid pressuredirectly.lt is a circulating-type modulator becausethe rakefluidcirculatesthroughthecaliper,reservoir,andthemastercylinder.Thehydrauliccontrol b has pressureretaining,and pressurereducing. three modes:pressureintensifying, The hydrauliccircuitis an independent f o u r - c h a n n e l t y p e , e c h a n n efl o r e a c hw h e e l . on

Pressure intensifyingmode: Inletvalveopen,outlel valve closed M a s t e r y l i n d e f l u i d i s p u m p e do u t t o t h e c a l i p e r . c r Pressure retainingmode: lnlet valve closed,outlet valve closed Caliperfluid is retainedby the inlet valve and outlet valve. Inletvalve closed,outlet valve open Caliperfluid flows through the outlet valveto the reservoir. When startingthe pressurereducingmode,the pump motor is ON. When stoppingABS operation, the pump motor is OFF. T h e c a l i p e r l u i d i s p u m p e do u t b y t h e p u m p ,t h r o u g ht h e d a m p i n gc h a m b e rt,o t h e f master vlinder. c

Pressure reducingmode:

lvlotoroperationmode:

19-40

t
WheelSensors
type. As the gear pulserteeth rotate pastthe wheel sensor'smagnetic The wheel sensorsare the magneticcontactless with the wheel speed.The ABS control unit The AC frequencychangesin accordance coil, AC current is generated. and therebydetectsthe wheel speed. detectsthe wheel sensorsignalfrequency
GEARPULSER WHEEL SNSOR .r HIGXSPEED
!t LOW SPEED

Wheel Speed and Modulator Control VEJ!q!ESPEEq 8E!EEETqE

PRESSURE

OUTLET VALVE 9p OFF INLET VALVE oN OFF

MoroR
-,. OFF

I
l t l

the When the wheel speeddrops sharplybelow the vehiclespeed,the inlet valve closesand il necessary, outlet valve pressure. The pump motor startsat this time. As the wheel speed is opens momentarilyto reducethe caliperfluid the caliperfluid pressure. and the outlet valve closes,the inlet valve opens momentarilyto increase restored,

19-41

ABSGomponents
CircuitDiagram

"'----G50l

L "*'*" lJ5 Il
I Gu ^ csl

r * *r + t ? l 'l I
lo+-sN LqF**,

19-42

*- :ffrre, *riq.r.srbm r.l I q_ L md/Y4

7--:::

19-43

ABSComponents
(cont'd) CircuitDiagram
UNDER-HOOD FUSE/RELAY CONNECTORS BOX CONNECTOR {12P) CONNECTOR{12P) A CONNECTOR{2P} B BRAKE PEDALPOSITION SWITCH CONNECTOR 4P

UNDER.DASH FUSE/RELAY CONNECTORS BOX CONNECTOR{5P) I CONNECTOR I17P) K

MULTIPLEX CONTROL UNIT13PCONNECTOR

1l2l3l,/15 1 2 3 4
8

5 67 1011121 3 415 1 1 1
CONNECTOR I22PI B

1 2 3

,/ ,/

6 7 8 9 10 11n2 13

GAUGE ASSEMBLY CONNECTORS CONNECTORI22P) A

ABSCONTROL 3IP CONNECTOR UNIT

q,

1 2

4 5 6 7 8 I

16 1 1 1 8 1 9

1112 1 415 20 21/1,/1,/vl,/l

/t,/t/t,/t/

Wire side of femaleterminals

OATA LINK CONNECTOR {16P)

WHEEL SENSOR CONNECTORS 2P FRONT


J --T:-l L t q t t / ) l 'l L_.:-:J r \-r-----Tr'
e:l

Terminalside of femaleterminals

RIGHT.REAR

LEFT-REAR

tslTt?t I tL |

/J 1T-1\ J \t rlzi

T e r m i n as i d eo f m a l el e r m i n a l s l

19-44

DTCTroubleshooting
DTC11,13,15,17:WheelSensor (Open/Short BodyGround/Short Power) to to
the 1. Disconnect ABS control unit 31Pconnector.

the for between appropriate 5. Check continuity (+ andbodyground terminal wheelsensor ) circuit t { s e ea b l e ) . DTC
Appropriate Terminal 11 (Riqht-front)

2. Start the engine. 3. Measurethe voltagebetweenthe appropriate ( w h e e ls e n s o r * ) c i r c u i t t e r m i n a lo f t h e A B S control unit 31Pconnectorand body ground (see table).

( N o .5 : F R S + )
N o . 7 : F L S( * )

13(Left-front) 1 5( R i o h t - r e a r ) 17(Left-rear)

( N o . 2R R S* ) : ( N o . 9R L S + l

ABS CONTROL UNIT31PCONNECTOR

DTC 11(Rioht-front) 13(Left-front)


15 {Riqht-rear} 17 (Left-rear)

ADpropriate Terminal ( N o . 5 :F R S t ) (*) N o ,7 : F L S

( N o .2 : R R S * ) N o . 9R t S( f )

ABS CONTROLUNIT 31P CONNECTOR

FRS+IIGNR/BLK} FLS +I (BLU I { RRS+) { (GNR/YEL)


Wire side W i r es i d eof femaleterminals

ls therecontinuity? YES Goto step6. NO-Go to step7.


terminals Wiresideof female ls thete battery voltage? YES Repairshort to power in the (+) circuitwire unit and the betweenthe ABS modulator-control wheel sensor. I appropriate NO Go to step 4. 4. Turn the ignition switch OFF. Disconnect harness2P connectorfrom the the wheel sensor,then checkfor continuity appropriate o t b e t w e e nh e 1 + ) a n d ( ) t e r m i n a l s f t h e h a r n e s s and body ground. ls there continuity? Y E S - R e p a i rs h o r t t o b o d y g r o u n di n t h e ( + ) o r { ) circuitwire betweenthe ABS modulator-control unit and the wheel sensor.l the NO Repiace wheel sensor.l

(cont'd)

19-45

ABS Components
(cont'dl DTCTroubleshooting
7. Checkthe resistance betweenthe appropriate ( w h e e ls e n s o r + ) a n d ( ) c i r c u i t e r m i n a l s s e e { ta ble).

DTC12,14, 18:Wheel 16, Sensor Putse Signal


NOTE:lf the ABS indicatorcomes on for the reasons describedbelow,the indicatorgoes off when you testd r i v et h e v e h i c l e t 3 1 m p h ( 5 0k m / n l . a . Only the drive wheel rotated . T h ev e h i c l e p u n s . Electrical noise 1 . V i s u a l l y h e c k o r a p p r o p r i a t w h e e ls e n s o r a n d c f e pulserinstallation and condition(seetable).

DTC
11 {Riqht-front)

'13 {Left-front)

1 5( R i o h t - r e a r ) 17 (Left-rear)

Appropriate Terminal *lSide l+) Side No.5: RS*) N o . 4 : F R S ) F ( 1N o .7 : F L S + i N o . 6F L S{ : ( ( No. RBS 2: {+) N o .1 : R B S- ) N o . 9 : L S - N o . 8B L SR 1 : (

ABS CONTROL UNIT31PCONNECTOR

DTC 12
14 18

Appropriate Wheel Sensor Riqht-front Left-front Riqht-rear Left-rear

Ate they installed correctly and not damaged? YES-Go to step 2,


Wire side of femaleterminals

NO Reinstall replacethe appropriate or wheel sensor r pulser,I o Is the rcsistance between 450 2,000 A ?

\\|D

YES Checkfor a looseABS control unit3lP connector.lf necessary. substitutea known-good ABS modulator-control unit, and recheck.l NO Go to step 8.

2. Disconnect ABS control unit 31Pconnector. the 3 . Measurethe resistance betweenthe appropriate
( w h e e ls e n s o r f ) a n d ( ) c i r c u i t e r m i n a l s s e e ( table).

DTC
Disconnect harness2P connectorfrom the the appropriate wheel sensor,and checkthe resistance b e t w e e nh e ( + ) a n d { ) t e r m i n a l s o f h e w h e e l t t sensor. ls the resistance between 450- 2,000 Q ? Y E S - R e p a i ro p e ni n t h e ( + ) o r ( - ) c i r c u i t i r e ,o r w short betweenthe (+) circuitwire and the { ) circuitwire betweenthe ABS modulator-control u n i ta n d t h e w h e e ls e n s o r . l N O R e p l a c eh e w h e e ls e n s o r . l t 12 {Rioht-front) 14 (Left-front) 1 6( R i q h t . r e a r ) 18 (Left-read

Appropriate Terminal l*) Side ) Side N o . 5 : F ( *S B No.4:FBS N o . 7 ; F L*S l No,6:FLS N o . 2 : R( * R S N o1 : B R S . N o . 9B L S : 1 No.8:RLS

ls therc less than 450 Q ? YES Go to step 1. N O - G o t o s t e p4 .

19-46

4. Checkfor continuitybetweenthe appropriate ( a w h e e ls e n s o r + ) c i r c u i t t e r m l n a l n d o t h e r w h e e l ( ( s e n s o r + ) c i r c u i t e r m i n a l s s e et a b l e ) .

(Chipped Operation DTC21:Continuous pulser)


the HondaPGM 1. Clearthe DTC,then disconnect tesler. 2. Test-drive vehicleat 19 mph (30 km/h)or more. the Doesthe ABS indicator come on and is DTC 21 indicated? YES Go to step 3.

DTC Appropiate Terminal 12 No.5: ( FRW*i '14 No.7: FLWIT.) to No.2; RRW(T-) No.9: 18 ( RLW *)
ls there continuity?

Other Terminal No.7 No.5 No.5 No.5 No.2 No.2 No.7 N o .7 No.9 No.9 No.9 No.2

NO The system is OK at this time.l 3. Checkthe pulsergear for a chippedtooth. ls the pulser OK? YES Checkfor a looseABS control unit 31P substitutea known-good connector.lf necessary, unit, and recheck.l ABS modulator-control the NO Replace driveshaftor hub unit (chipped pulser ear).1 g

YES Repairshort in the wires betweenthe wheel sensorand the other wheel appropriate sensor arnesses.l h the Honda PGM NO Clearthe DTC,disconnect the vehicle.lf the ABS Tester,and test-drive indicatorcomes on and the same DTCis indicated, unit.l replacethe ABS modulator-control Disconnect harness2P connectorfrom the the wheel sensorand checkthe resistance appropriate t b e t w e e n h e ( + ) s i d ea n dt h e ( - ) s i d eo f t h e w h e e l sensor. ls there lessthan 450 Q ? the YES Replace wheel sensor. NO- Repairshort to wire betweenthe appropriate ( w h e e ls e n s o r + ) a n d ( - ) c i r c u i t s . l

1g-47

ABSComponents
(cont'd) DTCTroubleshooting
DTC31,32.33,34,35,36,37,38:Solenoid
1. Clear DTC, the thendisconnect Honda the PGN4 Tester. 2. Test-drive vehicle. the Doesthe ABSindicator comeon and are DTCs 31, 32, 33, 34, 35, 36, 37, 38 indicated? YES Replace ABSmodulator-control the unit.t NO Thesystem OKat thistime.t is

DTC51:Motor Locked
'1. C h e c k h e N o . 1 0 ( 4 0 A ) f u s en t h e u n d e r - h o o d f u s e / t i retayDox. ls the tuse OK? YES-Reinstall the fuse, and go to step 2. NO- Replace fuse, and recheck.l the 2. Disconnect ABS control unit 31Pconnector. the 3. Measurethe voltagebetweenthe ABS control unit 3 1 Pc o n n e c t otre r m i n a lN o . 1 7a n d b o d y g r o u n d . ABS CONTROL UNIT31PCONNECTOR

I
Wiresideof female terminals ls thete battery voltage? YES Go to step 4. NO Repairopen in the wire betweenthe N o . 1 0 (40A)fuse and the ABS control unit.l

19-48

4. Checkfor continuitybetweenthe ABS control unit 31P connectorterminal No. 16 and body ground. ABS CONTROL UNIT31PCONNECTOR

DTG52:MotorStuckOFF
u 1 . C h e c t h eN o .1 0 ( 4 0 Af ) s ei n t h eu n d e r - h o o d k box. fuse/relay ls thef useOK?
YES-Reinstall the fuse, and go to step 2. NO-Replace the fuse, and recheck.l| the 2. Disconnect ABS control unit 31Pconnector.

3 . Measurethe voltage betweenthe ABS control unit


Wire side of femaleterminals

3 1 Pc o n n e c t otre r m i n a lN o . 1 7 a n d b o d y g r o u n d UNIT31PCONNECTOR ABSCONTROL

ls there continuity? YES-Go to step 5. NO Repairopen in the wire betweenthe ABS control unit and body ground (G202).1 the Reconnect ABS control unit 31Pconnector. the HondaPGM 6. Clearthe DTC,then disconnect tester. 7 . Test-drive vehicleat 6 mph (10 km/h) or more. the

Wire side of femaleterminals

ls there battery voltage? Doesthe ABSindicator come on, and is DTC 51 indicated? unit.l the YES Replace ABS modulator-control NO The system is OK at this time.l YES-Go to step 4. NO Repairopen in the wire betweenthe N o . 1 0 (40A)fuse and the ABS control unit.l

(cont'di

19-49

ABS Components
(cont'dl DTCTroubleshooting
4. Checkfor continuitvbetweenthe ABS control unit 3 1 Pc o n n e c t otre r m i n a lN o . 1 6 a n db o d y g r o u n d . ABSCONTROL UNIT31PCONNECTOR

DTC53:MotorStuckON
1 . C l e a r h e D T C t h e n d i s c o n n e c t e H o n d ap GM t , th Tester. 2. Test-drive vehicle. the Does the ABS indicatot come on and is DTC 53 indicated? YES -Go to step 3. NO- lntermittentfailure,the system is OK at this trme.l

Wiresideol female terminals

3 . Disconnect ABS control unit 31Pconnector. the


ls there continuity? YES-Check for looseterminalsin the ABS control unit 31Pconnector.lf necessary, substitutea known-goodABS modulator-control unit, and recheck.l NO Repairopen in the wire betweenthe ABS c o n t r o lu n i ta n d b o d y g r o u n d( G 2 0 2 ) . 1 Checkfor continuitybetweenthe ABS control unit 3 1 Pc o n n e c t otre r m i n a lN o , 1 6 a n d b o d y g r o u n d . ABSCONTROL UNIT3,IPCONNECTOR

Wiresideof female terminals

ls therc continuity? YES-Replacethe ABS modulator-control unit.t NO-Repair open in the wire betweenthe ABS c o n t r o lu n i ta n d b o d y g r o u n d( G 2 0 2 ) . I

19-50

Stuck OFF DTC MainRelay 54:


f d 1 . C h e c k t h e o . 8 ( 2 0 A ) u s ei n t h e u n d e r - h o o f u s e / N f r e l a yb o x ,a n d r e i n s t a l l t h eu s ei f i t i s O K . ls the f use OK? YES-Go to step 2.

DTC lG2Voltage 61:


) t N O T E C h e c k h e N o . 1 1 ( 7 . 5 A f u s ei n t h e u n d e r - d a s h : fuse/relaybox beforetroubleshooting. th t t 1 . C l e a r h e D T C , h e n d i s c o n n e c t e H o n d aP G M tesler. 2. Test drive the vehicle.

the NO Replace fuse, and recheck.l the 2. Disconnect ABS control unit 31Pconnector. the 3. l\4easure voltagebetweenthe ABS control unit c o n n e c t otre r m i n a lN o . 1 8 a n d b o d y g r o u n d . ABSCONTROL 31PCONNECIOR UNIT Doesthe ABS indicator come on and is DTC 61 indicated? YES Go to step 3. NO The system is OK at this time.l tt 3 . D i s c o n n e c h e A B S c o n t r o lu n i t 3 l P c o n n e c t o r . 4 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s 5. Measurethe voltage betweenthe ABS control unit N 3 1 Pc o n n e c t o r t e r m i n a l o . 1 5 a n d b o d y g r o u n d . ABSCONTROL 31P UNIT CONNECTOR

Wiresideof female terminals

Is there battety voltage? unit.l YES Replace ABS modulator-control the NO-Repair open in the wire betweenthe ABS fuse/relaybox.I control unit and the under-hood

Wire side of femaleterminals

ls there battery voltage? unit.l the YES Replace ABS modulator-control NO - Repairopen in the wire betweenthe ABS control unit and the under-hood{use/relaybox.l

19-51

ABSComponents
(cont'd) DTCTroubleshooting
DTC CPU(Central 81: Processing Unit)
1. Clearthe DTC,then disconnect the HondaPGM Tester. 2. Test-drive vehicle. the Does the ABS indicator come on and is DTC 81 indicated? YES Replace ABS modulator-control the unit.l NO Go to step 2, NO-The system is OK at this time. t Pull up the parkingbrakelever. Does the btake system indicator come on? YES Go to step 3. NO Repairopen in the indicatorpower source circuit.lf necassary, substitute known-goodABS a modulator-control unit, and recheck. I . Blown No, 10 (7.5A) fuse. . O p e ni n t h e w i r e b e t w e e n h e N o . 1 0 ( 7 . 5 A ) f u s e t a n dl h e g a u g ea s s e m b l y , . Open circuitinsidethe fuse box.

ABS IndicatorGircuit Troubleshooting


ABS indicator does not come on
1 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) ,a n d w a t c ht h e A B S s indicator. Does the ABS indicator come on? YES The system is OK at this time.I

3 . Turn the ignitionswitch OFF.


Disconnect ABS control unit 31Pconnector. the

5. T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s
Does the ABS indicator come on? YES-Check for looseterminalsin the ABS control unit 31Pconnector.lf necessary, substitutea known-goodABS modulator-control unit, and recheck.l NO Go to step 6. 6 . Turn the ignition switch OFF. 7 . Removethe gauge assembly(seepage 22-64).

19-52

the 8 . Disconnect gaugeassemblyconnectorA (22P).

ABS indicator does not go off


fuse/ in 1. Checkthe 8 (20Alfuse the under-hood No. relaybox,andreinstall fuseif it is OK. the ls the fuse OK? YES Goto step2. lf NO-Replace fuse,andrecheck. thefuseis the blown, check a shonto bodygroundin thisfuse for is the ll circuit. thecircuit OK,replace ABS modulator-control I unit.
fuse in the under-dash Checkthe No. 11 (7.5A) fuse/relaybox, and reinstallthe fuse if it is OK.

9 . Checkfor continuitybetweengauge assembly


connectorA {22P) terminal No, 12 and body ground. A ASSEMBLY CONNECTOR(22P) GAUGE

Wire side of femaleterminals

ls the f use OK? ls there continuity? YES- Repairshon to body ground in the wire betweenthe gaugeassemblyand the ABS control unit.l NO Go to step 10. YES Go to step 3. If NO Replace fuse, and recheck. the fuse is the blown, checkfor a shortto body ground in this fuse circuit.lf the circuit is OK, replacethe ABS unit.I modulator-control the 3 . Disconnect ABS control unit 31Pconnector. Measurethe voltage betweenterminal No. l8 and body ground. UNIT3lP CONNECTOR A8S CONTROL B GAUGE ASSEMBLY CONNECTOR(22PI

'10.Disconnect gaugeassemblyconnectorB (22P). the 1 1 .Checkfor continuitybetweengauge assembly


terminal No. 12 and body ground. connectorB (22P)

Wire side of femaleterminals

terminals Wiresideol Iemale ls there battery voltage? ls there continuity? YES-Go to step 5. YES Checkfor looseterminalsin the gauge lf are OK, assemblyconnectors. the connectors replacethe gaugeassembly.l NO Repairopen in the wire betweenthe gauge a s s e m b l y n d b o d y g r o u n d( G 5 0 1 ) . 1 a (cont'd) NO Repairopen in the wire betweenthe No. 8 (20A)fuse and the ABS control unit.l

19-53

ABSComponents
(cont'dl ABS IndicatorCircuitTroubleshooting
5. Turn the ignitionswitch ON (ll). 6 . Measurethe voltage betweenthe ABS control unit
31PconnectorterminaI No. 15 and body ground. ABSCONTROL UNIT3IP CONNECTOR
ABSCONTROL UNIT31PCONNECTOR

10. Connect the ABS control unit3lPconnector t e r m i n a lN o . 2 0 a n d b o d y g r o u n dw i t h a j u m p e r wire.

Wire side of femaleterminats

Wiresideof female terminals Is there battety voltage? YES-Go to step 7. NO-Repair open in the wire betweenthe No. 11 (7.5A) fuse and the ABS control unit.I 1 . Turn the ignition switch OFF. 8 . Checkfor continuitybetweenthe ABS control unit 31Pconnectorterminal No. 19 and body ground. ABSCONTROL UNIT31PCONNECTOB 'l '1.

Does the ABS indicator go off? YES-Check for looseterminalsin the ABS control unil 31Pconnector.lf necessary, substitutea known-goodABS modulator-control unit, and recheck.I NO Go to step 11. Removethe gaugeassembly,and leavethe connectors connected. Connectthe gauge ) a s s e m b l y o n n e c t oA ( 2 2 P t e r m i n a lN o . ' 1 2 n d c r a body ground with a jumper wire. GAUGE ASSEMBLY CONNECTOR(22P) A

Wire side ot Iemaleterminals

Wiresideof female terminals

ls there continuity? YES Go to step 9. NO-Repair open in the wire betweenthe ABS control unit and body ground (G202). t 9 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s

Does the ABS indicator go off? YES-Repair open in the wire betweenthe gauge a s s e m b l y n d t h e A B S c o n t r o lu n i t . I a NO-Check for loosegauge assemblyconnectors. lf the connectorsare OK, replacethe printedcircuit b o a r di n t h e g a u g ea s s e m b l y . l

19-54

BrakeSystemIndicatorGircuitTroubleshooting
Brakesystem indicator does not come on
'1. nectthe m ultiplexcontroI unit l3Pconnector Discon and the ABS control unit 31Pconnector.

Brakesystem indicatordoes not go off


1 . T u r nt h e i g n i t i o n w i t c hO N { l l ) . s t b 2 . R e l e a s eh e p a r k i n g r a k e .

2. Checkfor continuitybetweenthe ABS control unit 3 l P c o n n e c t otre r m i n a lN o , 2 1 a n d b o d y g r o u n d .


UNIT31PCONNECTOR ABS CONTROL

Does the brake system indicatot go ofl after several seconds? YES The system is OK at this time.l NO Go to step 3. 3. Checkthe brakefluid level. ls the level OK? YES Go to step 4.

Wire side of femaleterminals

NO Refillthe brakefluid, and recheck.l 4. Checkthe ABS indicator.

ls there continuity? Does the ABS indicator stay on? YES Repairshort to body ground in the wire betweenthe multiplexcontrol unit and the ABS c o n t r o lu n i t . l NO Go to multiplexcontrol system trou bleshootinglsee page 22''172).a YES Readthe ABS DTC(seestep 1 on page 19-32). for troubleshooting the DTC and do the applicable NO Go to step 5. 5. Turn the ignition switch OFF. tt 6 . D i s c o n n e c h e A B S c o n t r o lu n i t 3 l P c o n n e c t o r . 7 . C o n n e ctth e A B S c o n t r o lu n i t3 1 Pc o n n e c t o r t e r m i n a lN o . 2 1 a n d b o d y g r o u n dw i t h a j u m p e r

ABS CONTROL UNIT31PCONNECTOR

W i r es r d eo f l e m a l el e r m i n a l s

(cont'd )

19-55

ABSComponents
BrakeSystemIndicatorGircuitTroubleshooting (cont'd)
8 . Turn the ignititonswitch ON (ll). 9 . Checkthe brakesystem indicator. Does the brake system indicatot go off? YES-Replace the ABS modulator-control unit.l NO-Go to step 10.

1 0 .Turn the ignitionswitch OFF. 1 1 .Connectthe multiplexcontrol unit 13Pconnector


'l t e r m i n a lN o . a n d b o d y g r o u n dw i t h a j u m p e rw i r e . MULTIPLEX CONTROL UNIT13P CONNECTOR

JUMPER WIRE

\
Wiresideof female terminals

12. Turn the ignitionswitch ON (ll). 1 3 .Checkthe brakesystem indicator.


Does the btake system indicatot go off? YES Repairopen in the wire betweenthe multiplexcontrol unit and the ABS control unit.l NO Go to multiplexcontrol system g troubleshootin (seepage22-17 a 2).

19-56

ABS Modulator-Control Unit Removaland lnstallation


NOTE: . D o n o t s p i l lb r a k e l u i d o n t h e v e h i c l e i;t m a y d a m a g e h e p a i n U f b r a k e f l u i d g e t s o n t h e p a i n t , w a s h i t o f f f t i immediatelywith water. . Becarefulnot to damageor deform the brakelines during removal and installation. . To preventthe brakefluid from flowing, plug and cover the hose ends and joints with a shop towel orequivalent malenal.

Removal
'1. Turn the ignitionswitch OFF.

2 . P u l lu p t h e l o c k ( A )o f t h e A B S c o n t r o u n i t 3 l P c o n n e c t o r ( B ) , t h e n d i s c o n n e c t t h e c o n n e c t o r . l
FLARE NUT l5 N.m (1.5kgt.m,11 lbt.ftl

6)o

CI

I mm NUT 8.8N.m {0.9kgl m.6.5lbfft)

--/Q
\---'

\.

\,
6 mm BOLT 9.8N.m ksf.m,7.2lbf.ft) 11.0

(cont'd)

19-57

ABS Gomponents
ABS Modulator-Control Unit Removaland Installation{cont'dl
3. Disconnectthe brakelines. six 4. Removethe two I mm nuts. 5. Removethe ABS modulator-control unit (C).

Installation
'1. I n s t a l l t h e A B S o d u l a t o r c o n t r o l n i t ,t h e nt i g h t e n h e t w o 8 m m n u t s . m u t

2. Align the connectingsurfaceofthe ABS control unit 3'lP connector. . 3 . P u s h i n t h e l o c k o f t h e A B S c o n t r o l n i t3 1 Pc o n n e c t o u n t i ly o u h e a ri t c l i c ki n t o p l a c e t h e nc o n n e c t h e c o n n e c t o r . u r 4. Connect the six brakeIines. 5. Bleedthe brakesystem,startingwith the front wheels. 6. Connectthe PGMTester,and do the solenoidfunctiontest for each wheel. 7. Bleedthe brakesystem again,staning with the front wheels. 8. Startthe engine,and checkthat the ABS indicatorand brakesystem indicatorgo off. 9. Disconnect Honda PGMTester.Test-drive vehicle,and checkthat the ABS indicatorand brakeqvqtem the the i n d i c a t od o n o t c o m e o n . r

19-58

WheelSensorInspection
1 . Inspectthe front and rear pulsersfor chippedor damagedteeth.

WheelSensorReplacement
NOTE:Inslallthe sensorscarefullyto avoid twisting the wtres. Front:
6 mm BOLT 9.8 N.m {1.0kgf.m,7.2lbf.ftl

2. Measurethe air gap betweenthe wheel sensorand


the pulserall the way around while rotatingthe pulser.Removethe rear brakedisc to measurethe gap on the rearwheel sensor.lf the gap exceeds 1 . 0m m ( 0 . 0 4 n . ) , h e c k o r a b e n ts u s p e n s i o a r m . i f c n Standard: Front; 0.4- 1.0mm (0.02-0.04 in.) Rear: 0.2 1.0mm (0.01 0.04 in.l Front:

0.4 '1.0 mm 10.02 0.0'l in.l

6 mm BOLT 9.8 N.m {1.0kgf.m,7.2lbf.ftl

WHEEL SENSOR

Rear: 6 mmBOLT
9.8 N.m kgf.m,7.2lbf.ft) 11.0 6 mm BOLT 9.8 N.m (1.0kgf'm,

7.2rbr.ft)
Bear:

0.2 1.0mm in.} {0.01 0.04

19-59

Body
Doors
C o m p o n e n to c a t i oIn d e x . . . . . . . . . . . L n 20-2 D o o rP a n eR e m o v a l / l n s t a l l a t i o.n . . , . . . . . .20,4 l . . .... DoorOuterHandle Replacement 20-6 DoorLatchReplacement 20-7 DoorGlassand Regulator Replacement 20-9 . . . . D o o rS a s h r i mR e p l a c e m e n.t. . . . . . . . . . . . . . 2.0 .t.0. T DoorGlassOuterWeatherstrip Replacement 20- 10 Beplacement DoorWeatherstrip 20-11 D o o rG l a s s d j u s t m e n t . . . . . . . . . . . . . . . . . . . . . .20-11. . . . A . ...... D o o rP o s i t i oA d j u s t m e n . . . . . . . . . . . . . . . . . . . .20-12 . . n t ....... D o o rS t r i k eA d i u s t m e n.t. . . . . . . . . . . . . . . . . . . . .2 .0 . . 3. . . . r . .1. L n ....... C o m p o n e n to c a t i o I n d e x . . . . . . . . . . . . . . . . . . .20-14 . P o w e r i r r o r e p l a c e m e n . . . . . . . . . . . . . . . . . .2 0.- 1.5 . M R .t .. .. . M i r r o r o l d e R e p l a c e m e n.t. . . . . . . . . . . . . . . . .20-15. . H r . ...... R e a r v i e w i r r o r e p 1 a c e m e.n t . . . . . . . . . . . . . . 0.-.1.6 M R .. 2. .

Dashboard
Instrument Panel Removal/lnstallation ........ 20-59 Driver's Dashboard LowerCover Removat Installation 20-59 Driver's Dashboard UnderCover Remova Insta llation 20-60 t Oriver's Pocket Removal/lnstallation ............ 20,60 ShiftLever Trim Removal/lnstallation .......... 0 6 1 2 C e n t eP a n eR e m o v a l / l n s t a l l a t i. o.n . . . . . . .20-62 r l . . .... Passenger's Dashboard LowerCover Remova l/lnsta ion llat 20-63 x GloveBox Removal/lnstallation 20-63 Dashboard SideVent R e m o v a l / l n s t a l l a t i. o.n . . . . . . . . . . . . . . . . . . . 2.0.-.6 . . . . . . . . . .4 Beverage HolderRemoval/lnstallation ........ 20-64 Driver'sTray Removal/lnstallation ............... 20-65 Passenger's Removal/lnstallation Tray ........ 65 20 * Dashboard Removal/lnstallation .................. 20-66 S t e e r i" H a n q eB e a mR e o l a c e m e n.t. . . . . . . . 0 - 6 8 nq r . 2. Component Location Index ........................... 20-10 * FrontSeatRemoval/lnstallation ................... 20-11 * FrontSeatDisassembly/ R e a s s e m b l y - D r i v e . . s. . . . . . . . . . . . . . . . . . . 2.0 .-.7 . . . . . .r'. . . .3 * FrontSeatDisassembly/ R e a s s e m b l y - P a s s e n g . .r '.s . . . . . . . . . . . . .2 0.- 7.4 . .e . . .. .. . * F r o n t e a t o v e r e p l a c e m e n . . . . . . . . . . . . . .2 . . .-.7 5 S C R .t .O . R e a r e a tR e m o v a l / 1 n s t a 1 1.a t i o.n . . . . . . . .2 . . - . .0 .... . . 0 .8 S RearSeat-back LatchReplacement .............. 20-81 RearSeat-backStriker Replacement ............ 20-81 RearSeat-back CoverReplacement ............. 20-82 R e a r e a t u s h i o n o v e r e p l a c e m e n . . . . .2 0 . 8 4 R S C C .t .

Mirrors

Glass

Seats

Moonroof

C o m p o n e n to c a t i o I n d e x . . . . . . . . . . . . . . . . . . .2 0. 1.1. . L n .. . . W i n d s h i e lR e p l a c e m e n t d 20-19 .t ...... B e a r i n d o wR e p 1 a c e m e.n . . . . . . . . . . . . . . . . .20-25 . . W R .t ...... O u a r t eG l a s s e p l a c e m e n . . . . . . . . . . . . . . . . . 20-29. . r C o m p o n e n to c a t i o I n d e x . . . . . . . . . . . . . . . . . . .20,35. . L n ...... Index SymptomTroubleshooting 20-36 H t ....... G l a s s e i g hA d j u s t m e n.t. . . . . . . . . . . . . . . . . . . . 20-37. . . R 20-31 Glass eplacement W i n dD e f e c t o r e p 1 a c e m e n.t. . . . . . . . . . . . . . .20-38 l 8 . ....... R D r a i n h a n n e l e p 1 a c e m e.n.t. . . . . . . . . . . . . . .20 . . . . . C . . . . 39 . ...... S u n s h a dR e p l a c e m e n.t. . . . . . . . . . . . . . . . . . . . .20-40. . . . e Motor Replacement 20-41 Frame and DrainTubeReplacement ............ 20,42 A D r a i n h a n n e l l i d e a n dC a b l e s s e m b l y C S r Replacement 20 44 L i m i tS w i t c h d j u s t m e n . . . . . . . . . . . . . . . . . . . . . 20-46. . . A t ....... Closino Force and ODenina DraqCheck ......20,44

Bumpers

lnterioiTrim

F r o n t u m p e R e m o v a l / l n s t a l l a t . o.n. . . . . .20,85 B r i. . ... R e a r u m o e R e m o v a l / l n s t a l l a t.i.o . . . . . . . .20-86 B r .n .... Hood Adjustment 20-47 H o o dS e a l e p l a c e m e n t R 20,88 H o o dI n s u l a t o r e p 1 a c e m e.n.t. . . . . . . . . . . . . . . . . . . . . . R . 20,89

Consoles

L n ...... C o m p o n e n to c a t i oIn d e x . . . . . . . . . . . . . . . . . . .20-49. . Trim Removal/lnstallation DoorArea .......... 50 20 Trim Removal/lnstallation -Rear SideArea 20-51 Trim Removal/lnstallation -Cargo FloorArea 20-52 Trim Removal/lnstallation-Hatch ......... Area 20-53 Headliner Removal/lnstallation 20-54 * C a r p eR e p 1 a c e m e.n.t. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-55 t Frontand Rear Consoles, Remova l/lnsta llation 20-57 FrontConsole Disassembly/Reassembly 20-58 .....

Hatch

FuelFill Door Exterior Trim


Adiustment

Adjustment . . . . . . . . . . . . . .2 0.-. 9 0 .. . H a t c h u p p o n t r u tR e p l a c e m e n.t. . . . . . . . . .2 . .- 9 1 S S . .0 . Hatch WeatherstriD Reo1acement ................. 20-92 . . . . . . . . . . . . . .2 0.-. 9 3 .. .

F r o n t r i l l e e p l a c e m e n.t. . . . . . . . . . . . R . 20-94 G CowlCovers Replac"rn""t .. . ..................... 20-95 A p i l l a r o r n eT r i mR e p l a c e m e n.t. . . . . . . . . .20-96 C r . .... R o o fl M o l d i nR e p l a c e m e n.t. . . . . . . . . . . . . . . . .20-97 . . g . ...... RearLicense Trim Replacement 20,98 H a t c h p o i l e8 e p 1 a c e m e . .t. . . . . . . . . . . . . . . . .20-99 . S r n ....... E m b l e m e p 1 a c e m e.n.t. . . . . . . . . . . . . . . . . . . . . . 0 - 1 0 0 R . 2

Fenderwell
FrontInnerFender Replacement 20-102 F r o n t e n d eF a i r i n g e p l a c e m e n . . . . . . . . . .2.0 . 1 0 3 F r R .t . .FuelPipeProtector Replacement 20-104 R e a r i r O u t l e R e p 1 a c e m e.n.t. . . . . . . . . . . . . . . . . . . . . . A t . 20-'to4

Openers

Frame

n C o m p o n e n to c a t i oIn d e x . . . . . . . . . . . . . . . . . . .2 . . - 1.0.5 L . 0 .. . H o o dO p e n eC a b l e e p l a c e m e n . . . . . . . . . . .2 . .- 1 0 6 R r .t .0 . * F u e F i l lD o o rO p e n eC a b l e l r Replacement 20 107 H o o dL a t c h e p 1 a c e m e . . t. . . . . . . . . . . . . . . . . . .2 0.-.1.0 . . R n .. . . 8 F u e F i l lD o o rO p e n eR e p l a c e m e n.t. . . . . . . . . .0.- 1 0 9 l r . 2. H a t c h a n d l e e p l a c e m e n.t. . . . . . . . . . . . . . . . .2 . . - 1. . . H R . . 0 . .1 0 H a t c h a t c h e p l a c e m e n.t. . . . . . . . . . . . . . . . . . .2 . .- 1.1.0 L R . .0 .. . . H a t c h o c k y l i n d eR e p l a c e m e n.t. . . . . . . . . .20-111 L C r . .... rameReplacement Subf ................................. 20-112 Frame Stiffener, Brace, and Gusset Replacement ............. 20-113
r Fremp RFnrir Chrrr . . . . . . . . . . . . . .2 0 - 1 1 4 ..

Doors
ComponentLocationIndex

a
DOOR TRIM OUTER
DOORSASHTRIM page20-10 Replacement,

DOOR GLASS OUTER WEATHERSTRIP

page20-10 Replacement,

DOOR Adiustment, Position page 20-12

K-p IJ
dq

A'A

W2"'
Ya
\J aita.

t
DOOR WEATHERSTRIP page Replacement, 20-'l'l

POWER WINDOW swtTcH

\
POWER DOOR LOCKSWITCH (Driver's)

20-2

GLASS page20-9 Replacement, Adjustment,page20-11

IMMOBILIZER LABEL

@
REGULATOR page Replacement, 20-9
RETAINER CLIP

LOCK CYLINDER \ LOCKKNOB O


ROO CYLINDER PROTECTOR

OUTER HANDLE PROTECTOR

tt

,-\

v4,,(, E ) i l
- /6X@ ( W
STRIKER Adjustment,page20-13

LATCH page20-7 Replacement, POWERDOOR LOCKACTUATOR

20-3

Doors
Door PanelRemoval/lnstallation
SpecialToolsRequired Trim pad remover,Snap-onA 177Aor equivalent, c o m m e r c i a l la v a i l a b l e . y wrap it NOTE:When prying with a flat-tipscrewdriver, tape around tape, and apply protective with protective the relatedparts.to preventdamage. 1. Removethe mirror mount cover (seepage 20-15). 2. Inserta hex wrench through the hole (A) in the door grip base(B),Pushthe door grip cover (C)out to a r e l e a s eh e h o o k( D )a n d t a b ( E ) , n d p u l l o u t t h e t cover to releasethe tabs (F)and hook (G) by hand, then removethe cover. 3. Removethe armrestcover (A).Takecare not to scratchthe door panel. -1 Pry out the front edge of the cover to release the hooks(B). -2 Pry out the bottom and rear edge of the cover to releasethe hooks(C). -3 Pry out along the top to release tabs (D). the

the tabs (C), 4 . Removethe screws(A, B), and release then removethe door grip base(D).Removethe screw (A) securingthe door panelfrom the armrest portion. Fastgngr Locations A> : Screw,3 B > : Screw,5

20-4

5. Pull out the switch panel (A)to releasethe hook (B), then removethe panelfrom the door panel. Disconnect power window switch connector(C). the

7. Disconnect inner handlecable {A) from the the ( i n n e rh a n d l e B ) ,a n d d i s c o n n e c t t h p o w e rd o o r e lock switch connector(C){driver's). Takecare not to bend the cable.

8. Detachthe harnessclip (A)from the door panel (B). B Release clipsthat hold the door panel (A) with a the commerciallyavailabletrim pad remover (B),then removethe door panel by pulling it upward. Removethe door panelwith as little bendingas possibleto avoid creasingor breakingit,
FastenerLocations 95 mm (3.74 in.l

> : Clip,9

ffi EtA

12 mm r q---------i.0.17in.l r <_--'rlmm in.l {0.04 45 mm {1.77 in.l

9 . Installthe door panel in the reverseorder of removal,and note these items: . Replace any damagedclips. . Make sure the cable is connectedsecurely,and the connectoris plugged in properly. . Checkthe window and power door lock operatrons,

20-5

Doors
Door Outer HandleReplacement
your hands. Put NOTE: on gloves protect to 1, Remove theseitems:
. Door panel (seepage 20-4) . Plasticcover,as necessary (seepage 20-2) 4. Disconnect cylinder rod (A),and release the the retainerclip (B).then removethe lock cylinder(C).

2 . R a i s e h e g l a s sf u l l y . t
5.

Removethe lock rod protector(A). -l Removethe screw. -2 Release protectorfrom the latch protector the (B). -3 Pullthe protectordown to release the hook (C) from the door. Fastener Location ) : Screw,1 Disconnect outer handle rod (A). the Fastenor Locations > : Bolt,2

6x1.0mm 9.8 N.m {1.0kgf.m, 7.2 tbt.ft')

cap (B),and removethe 6 . Removethe maintenance b o l t ss e c u r i n gh e o u t e rh a n d l e( C )w h i l e h o l d i n g t the the handlefrom outside.Release hook (D).then removethe outer handleprotector(E).

20-6

Door LatchReplacement
7. Pull out the outer handle(A),then remove it. NOTE:Put on glovesto protectyour hands. 1. Removethese items: . Door panel (seepage 20-4) . Plasticcover,as necessary (seepage 20-2) Raisethe glassfully.

3 . Removethe lock rod protector(seestep 3 on page


20-6).
4 . Pullthe glass run channel(A) away as necessary,

and removethe bolt, then removethe centerlower channel(B) by pulling il downward Installthe handlein the reverseorder of removal, and note these items: . Make sure each rod is connectedsecurelv. . Make sure the door locksand opens properly. . W h e n i n s t a l l i n t h e l o c kc y l i n d e rl.e a v e t h e o u t e r g door handlebolts looseso the inner protector does not interferewith the lock cylinder installation, then tighten the handle bolts. . Installthe lockcylinder retainingclip on the handle,then installthe lockcylinder.Be sure the i c l i p i s f u l l y s e a t e d n t h e s l o to n t h e l o c kc y l i n d e r . . W h e n r e i n s t a l l i ntg e d o o r p a n e l , a k es u r et h e h m plasticcover is installedproperly,and is sealed aroundthe coversDerimeter. Fastenor Location

1 > : Bolt, IIilE

q
6x1.0mm 8 N.m {0.8 kgf.m, 6 lbf.ftl

(cont'd)

20-7

Doors
(cont'dl Door LatchReplacement
5 . Disconnect cylinder rod (seestep 4 on page 20the 6). 6 . Disconnect outer handle rod (seestep 5 on the page 20-6). 7 . Disconnect actuatorconnectors(A),and release the t h e i n n e rh a n d l e a b l e( B ) f r o mt h e d o o r b y c d e t a c h i n gh e c a b l ec l i p ( C i . t 9. Installthe latch in the reverseorder of removal,and notethese rtems: . [Vlake sure the actuatorconneclorsare pluggedin properly,and that each rod and cable are connectedsecurely. . W h e n r e i n s t a l l i ntg e d o o r p a n e l , a k es u r et h e h m plasticcover is installedproperly,and is sealed aroundthe coversperimeter. . M a k es u r et h e d o o r l o c k sa n d o p e n sp r o p e r l y .

8 . Removethe screws,then removethe latch{A) through the hole in the door. Takecare not to bend the outer handle rod (B),cylinderrod (C),lock rod ( D ) ,a n d i n n e rh a n d l e a b l e( E ) . c Fastener Locations ) : Screw U.#

6x1.0mm 5Nm {0.5kgf.m, 4 tbf.ft)

20-8

Door Glassand RegulatorReplacement


NOTE:Put on glovesto protectyour hands. 1. Removethese items: . Door panel (seepage 20-4) . Plasticcover.as necessary (seepage 20-2) 2 . C a r e f u l l ya i s e h e g l a s s( A )u n t i ly o u c a n s e e t h e r t bolts,then removethem. Carefullypull the glass out through the window slot.Takecare not to drop the glass insidethe door. Fastener Locations ):Boh,2 3. Disconnect and detachthe connector(A) and h a r n e s s l i p ( B )f r o m t h e d o o r . c Fastonor Locations C>: Bolt.1 D>: Bolt,5

6x1.0mm 8 N.m (0.8 kgf.m, 6 rbf.ftl

@
Remove bolts(C), andloosen bolts(D), the then the (E) the remove regulator through holein the the door, grease allthe sliding to Applymultipurpose (A) surfaces the regulator whereshown. of

6x1.0mm 9.8 N m {1.0kgl.m, 7.2 lbf.ftl

Installtheglassand regulatorin the reverseorder of removal,and note these items: . R o l l t h eg l a s su p a n d d o w n t o s e ei f i t m o v e s freely without binding. . Make sure that there is no clearance betweenthe g l a s sa n d g l a s sr u n c h a n n e w h e n t h e g l a s si s l ctoseo. . Adjust the positionof the glassas necessary (see p a g e2 0 - 1 ) . 1 . Checkfor water leaks(seestep 7 on page20-121. . Test-drive and checkfor wind noiseand rattles. . W h e n r e i n s t a l l i ntg e d o o r p a n e l , a k es u r et h e h m plasticcover is installedproperlyand sealed around its perimeter.

20-9

Doors
Door SashTrim Replacement
NOTE: Takecare not to scratchthe door. 1. Removethe door glassouter weatherstrip. (A) 2. Pull backthe door weatherstrip at the rear upper corner,and removethe screw.
Fasten6r Location ) : Screw, I

Door GlassOuterWeatherstrip Replacement


NOTE: . Put on glovesto protectyour hands. . Takecare not to scratchthe door 1 . R e m o v e h e p o w e rm i r r o r( s e ep a g e2 0 - 1 5 ) . t 2. Startingat the front, pry the door glassouter weatherstrip(A) up to detachthe clips (B),and release weatherstrip the from the door sashtrim (C),then removethe weatherstrip.
Fastener Locations

B>:Clip,s

3 . Lift up the door sashtrim {B)to release hooks the


(C),then removethe trim. lnstallthe trim in the reverseorder of removal.

3 . Installthe weatherstripin the reverseorder ot


removal,and replaceany damagedclips.

20-10

Door WeatherstripReplacement
NOTE: . Takecare not to scratchthe door. . Use a clip removerto removethe clips. 1. At the A-pillar,removethe door stop mounting bolt (A). Fastener Locations A > : B o t t ,1 B>:Clip,1 C>:Clip, 8 1

Door GlassAdjustment
NOTE: . Checkthe weatherstrips and glassrun channelfor and replacethem if damageor deterioration, necessary. . Wipe the run channelcleanwith a shop towel. . Lubricate grease the run channelwith Shin-Etsu P/N 08798-9013. 1. Placethe vehicleon a firm, level surface. 2. Removethese items: . Door panel (seepage 20-4) . Plasticcover {see page20'2) 3. Carefullymove the glass (A) until you can seethe glass mounting bolts (B),then loosenthem.

' 14.----' 'r, .,'o-,,tL' .

.rrt
B 6x1.0mm kgf.m, 7.2lbf.ft) 9.8N.m(1.0 Pushthe glassagainstthe channel(C),then tighten the glass mounting bolts. Detachthe clips (8, C),then removethe door (D). weatherstrip in Installthe weatherstrip the reverseorder of removaland note these items: . Replace any damagedclips. . Make sure the weatherstripis installedln the h o l d e r( E )s e c u r e l y . . A p p l y l i q u i dt h r e a dl o c kt o d o o r s t o p m o u n t i n g bolt beforeinstallation. . Checkfor water leaks(seestep 7 on page20-'121. . Test-drive and checkfor wind noase. Checkthat the glassmoves smoothly.

(cont'd)

20-11

Doors
DoorGlass Adiustment {cont'd)
6. Raisethe glassfully, and checkfor gaps.Checkthat the glass(A) contactsthe glass run channel(B) evenrv.

Door PositionAdiustment
NOTE;Checkfor equal gaps betweenthe front, rear, and bottom door edgesand the body. Checkthat the door and body edges are parallel. 1. Placethe vehicleon a firm, levelsurfacewhen adjustingthe door. 2. Adjust at the hinges{A): . Removethe front innerfender (seepage 20-102) and front fenderfairing (seepage 20-103). Loosenthe hinge mounting bolts (B) slightly,and move the door backwardor forward, uD or down as necessary equalize to the gaps. . Placea shop towel (C)on the jack (D)to prevent damageto the door when adjustingthe door.

7 . Checkfor water leaks.Run water over the roof and on the sealingarea as shown, and note these items: . . . . U s ea 1 2 m m ( 1 / 2i n . )d i a m e t e r o s e( A ) . h Adjust the rate of water flow as shown {B). Do not use a nozzle. H o l dt h e h o s ea b o u t3 0 0 m m ( 1 2i n . )a w a y f r o m the door (C).
t, 12mm1112in,l !

\
29 N.m (3.0kgf.m, 22 tbt.trl
8x1.25mm

\e
300mm {12in.l

Attachthe plasticcover,and installthe door panel (seepage 20-4). 9. Test-drive and checkfor wind noise.

20-12

Door StrikerAdjustment
3. Checkthat the door and body edges are parallel.lf necessary, adjustthe door cushions(A)to make the rear of the door flush with the bodv. w M a k es u r et h e d o o r l a t c h e s e c u r e l y i t h o u ts l a m m i n g it. lf necessary, adjustthe striker(A):The strikernuts u c s a r ef i x e d ,b u t t h e s t r i k e r a n b e a d j u s t e d l i g h t l y p o r d o w n ,a n d i n o r o u t . 1. Loosenthe screws(B),rhen inserta shop towel (C) betweenthe body and striker.

Apply body paintto the hinge mounting bolts and a r o u n dt h e h i n g e s . 5 . Checkfor water leaks(seestep 7 on page 20-12). and checkfor wind noise. Test-drive
m 8 x 1.25 m kgf m, 13 lbf.ft) 18 N.m 11.8

Lightlytlghten the screws. Wrap the strikerwith a shop towel, then adjustthe h s t r i k e r y t a p p i n gi t w i t h a p l a s t i c a m m e r( D ) .D o b not tap the strikertoo hard. Loosenthe screws,and removethe shop towel.

5 . Lightlytighten the screws.


6 . Hold the outer handleout, and push the door againstthe body to be sure the strikerallows a flush fit, lf the door latchesproperly,tighten the screwsand recheck.

20-13

Mirrors
ComponentLocationIndex

POWER MIRROR ACTUATOR page Replacement, 22-1'18

.a\ b\.\ | \ \-r<,,/


\.J \.4
\ TWEETER

\\

TWEETER

MIRROR MOUNTCOVER

POWER MIRROR page Replacement, 20-15

MIRROR HOLDER page20 '15 Replacement,

__.Q
-'-'
MOUNT /

REARVIEW MIRROR page Replacement, 20 16

20-14

PowerMirror Replacement
1 . Lower the door glassfully.

Mirror HolderReplacement
p 1 . C a r e f u l l y u l l o u t t h eb o t t o me d g eo f t h e m i r r o r holder (A) by hand.Takecare not to scratchthe mrrror.

2. Carefullypry out the mirror mount cover (A) by


the shown. Disconnect hand in the sequence tweeterconnector(B),and releasethe wire harness (C)from the hook (D). Fastener Location
) : Clip,1

t 3 . R e m o v e h e d o o r p a n e l( s e e p a g e 2 0 - 4 ) . connector(A),and detachthe 4. Disconnectthe W t h a r n e s s l i p ( B ) . h i l eh o l d i n g h e m i r r o r{ C ) , c removethe nuts,then removethe mirror. Takecare not to scratchthe door. Fastener Locrtions O: Nut.3

the mirror holderfrom the actuator(B) by Separate slowly pullingthem apart while detachingthe clips (C).lf equipped,disconnect the mirror defogger from the heaterpad terminals. connectors{D) the mirror defogger lf equipped,reconnect connectors. Reattach clips of the mirror holderto the the then positionthe mirror holderon the actuator, actuator.Carefullypush on the clip portionsof the m i r r o rh o l d e ru n t i l t h em i r r o rh o l d e rl o c k si n t o prace. 5 . Checkthe operationof the actuator

5 . lnstallthe mirror in the reverseorder of removal, and note these items: . Make sure the connectoris plugged in properly. . Attachthe harnessclip.

20-15

Mirrors
RearviewMirror Replacement
1. Turnthe mirrorbase(A)90.in eitherdirection.
4, Fit the mirror base over the mount, and securethe mirror by turning the base90".

2. Slide the rearviewmirror (A) down toward the


bottom of the windshield,then detachit from the spring (B) in the mount (C),and removethe rearviewmirror. Takecare notto scratchthe mirror Dase.

3. lf necessary, removethe spring from the mount.

20-16

Glass
ComponentLocationIndex
FASTENER,2 glassside) {Self-adhesive-type,

PASSENGER'S AIRSAG CAUTION LABEL

DAM SIDERUBBER WINDSHIELD SIDETRIM

4
WINDSHIELD page20-19 Beplacement,

', m-_-==}lny'
S{|---..------'RErA'NER,6

f..N ;\tJ e \ N8*?'


CLIP,4 Blue CLIP RUBBER DAM LOWER DAM,4 UPPER RUBBER
SPOILER 2 FASTENER, (Selt-adhesive-type)

'9>
DAM LOWER RUBBER

(cont'd)

20-17

Glass
ComponentLocationIndex(cont'd)

OUARTER GLASS FRONT SEAL ..,////

- UPPER CLIP tsetl adhesive-typel

\n iT-

/ LowERcLrp

vI
-.,-''

l / Pl l /

/ J l" n

.--"..---.-_
OUARTER GLASS page Beplacement, 20-29
R AR CLIP (Self-adhesive-type)

(Self-adhesive-type)

LEV EMBLEM

('03model) page20-100 Replacement.

20-18

WindshieldReplacement
NOTE: . Puton gloves protect your hands, to . Weareyeprotection whilecutting glass the adhesive with piano wire. . Useseatcovers avoiddamaging seats. to the items: 1. Remove these . Rearview page20-16) mirror(see . Windshield page22-145) wiperarms(see 2. Pullup the sidetrim (A)to release clips(B)from the (C), to the retainers andpullthetrim rearward the release fromthecliD(D)thenremove trim it from eachsideof thewindshield.
Removethe cowl covers(seepage 20-95).
4. Removethe molding (A) from the upper edge of the

cut windshield(B).lf necessary, the molding with a utility knife.

make lf the old windshieldis to be reinstalled, alignmentmarks acrossthe glassand body with a greasepencil. Pull down the front portionof the headliner(see page 20-54). Takecare not to bend the headliner or excessively, you may creaseor breakit. tape along the edge of the 7 . Apply protective dashboardand body. Using an awl, make a hole and dashboard through the rubber dam, adhesive. sealfrom insidethe vehicleat the corner ponion ot the windshield.Pusha pieceof piano wire through the hole, and wrap each end around a pieceof wood.

(cont'd)

20-19

Glass
(cont'd) WindshieldReplacement
W i t h a h e l p e r n t h e o u t s i d e p u l l t h e p i a n ow i r e { A ) o , backand forth in a sawing motion. Hold the piano wire as closeto the windshield(B)as possibleto preventdamageto the body and dashboard. Carefullycut through the rubber dam and adhesive ( C )a r o u n dt h e e n t i r ew i n d s h i e l d .
-A

10. With a knife,scrapethe old adhesivesmooth to a thicknessof about 2 mm (0.08in.) on the bonding surfacearoundthe entirewindshieldopening flange: . Do not scrapedown to the paintedsurfaceofthe body; damagedpaint will interferewith proper bonding. . Removethe rubber dam and fasteners from the oooy. 11. Cleanthe body bonding surfacewith a sponge dampenedin alcohol.After cleaning,keepoil, greaseand water from getting on the cleansurface.

\,

,.-

,,t""""""""',-\ i-..
-1:-, -

-= -.--

12. lf the old windshieldis to be reinstalled, use a puttv knifeto scrapeoff all of the old adhesive, the fastenersand the rubber dam from the windshield. Cleanthe insideface and the edge of the windshieldwith alcoholwhere new adhesiveis to be applied.Make sure the bondingsurfaceis kept free of water, oil, and grease.

20-20

t5.

Glue the side rubber dams (A) and lower rubber dam (B)with adhesive tape (NITTO501M,or equivalent). Glue the fasteners(C)with adhesive tape (3M 4215,or equivalent) the insideface of to t h e w i n d s h i e l d D )a s s h o w n : { . Be sure the rubber dams and fastenersline uD w i t h t h e a l i g n m e n m a r k s( E ) . t . Be carefulnot to touch the windshieldwhere adhesive ill beaoolied. w

t 1 4 . G l u et h e m o l d i n g( A ) w i t ha d h e s i v ea p e{ B ) ( 3 M 4 2 1 2 , r e q u i v a l e n t ) t t h e u p p e re d g eo f t h e o o ( w i n d s h i e l dC ) ; . B e s u r et h e a l i g n m e n m a r k( D )o f t h e m o l d i n g t l i n e su p w i t h t h e a l i g n m e n m a r k( E )o f t h e t windshield. . Be carefulnot to touch the windshieldwhere w adhesive ill beapplied.

t3.

Installthe fasteners(A),retalners(B, C),and clips (D)to lhe body. Fastener Locations A>:Fastener.2 B>:Retainer,2

q\

O C> : R e t a i n e r , 6 > : C l i p , 2

(cont'd)

20-21

Glass
(cont'dl WindshieldReplacement
t o . Set the windshieldin the opening,and centerit.

Make alignmentmarks (A) acrossthe windshield and body with a greasepencilat the four points shown. Be careful not to touch the windshield w h e r ea d h e s i v e i l l b e a p p l i e d . w

18. With a sponge,apply a light coat of glassprimer aroundthe edge of the windshield(A) betweenthe d a m s ( B )a n d m o l d i n g{ C )a s s h o w n ,t h e n l i g h t l y wipe it off with gauzeor cheesecloth: . A p p l yg l a s sp r i m e rt o t h e m o l d i n g . . Do not apply body primer to the windshield,and do not get body and glassprimer spongesmixed

up.
. Nevertouch the primed surfaces with your hands. lf you do, the adhesivemay not bond to the p . w i n d s h i e l d r o p e r l yc a u s i n g l e a ka f t e r t h e a w i n d s h i e l ds i n s t a l l e d . i . Keepwater. dust, and abrasivematerialsaway from the primed surface. 'l',,1rr Applyglassprimerhere.

1 7 . R e m o v eh ew i n d s h i e l d . t

) - ' G1)'r'
B

lnside

,,/ ll\ tl

ol

l l

-A

20-22

19. With a sponge,apply a light coat of body primer to the originaladhesiveremainingaroundthe windshieldopeningflange, Letthe body primer dry for at least 10 minutes: . Do not apply glassprimer to the body, and be carefulnot to mix up glassand body primer sponges. . Nevertouch the primed surfaces with your hands. . l\4ask the dashboardbefore paintingthe off flange. 20 mm (0.79 in.l

21. Packadhesiveinto the cartridgewithout air pockets to ensurecontinuousdelivery.Putthe cartridgein a caulkinggun, and run a bead of adhesive(A) aroundthe edge of the windshield(B) betweenthe d a m s ( C )a n d m o l d i n g( D )a s s h o w n .A p p l yt h e adhesivewithin 30 minutesafter applyingthe glass primer. Make a slightlythickerbead at each corner.

l'1fifr.,1: ?mm
in.l 10.28 A.. )t

n ,..-

$?I.",x1"u.80."., trl
Inside

.,r []\"

- '

20. Beforefilling a cartridge,cut a


( n o z z l e A )a s s h o w n .

"V"

in the end of the

c.. N
2 m m I 'Zn l in.} {0.08 I l
A

\F1
./"

12 mm (0.47in.)

o U s es u c t i o n u p st o h o l dt h e w i n d s h i e l d v e rt h e c t o p e n i n g a l i g ni t w i t h t h e a l i g n m e n m a r k sm a d ei n , step 16,and set it down on the adhesive.Lightly p u s ho n t h e w i n d s h i e l d n t i li t s e d g e sa r ef u l l y u D a s e a t e d n t h e a d h e s i v e l l t h ew a y a r o u n d . o n o t o open or closethe doors until the adhesiveis dry.

7 mm {0.27in.)

(cont'd)

20-23

Glass
(cont'd) WindshieldReplacement
23. Scrapeor wipe the excessadhesiveoff with a putty
knife or towel. To remove adhesivefrom a painted surfaceor the windshield,wipe with a soft shop towel dampensdwith alcohol. 27. On both sidesofthe windshield,installthe side trim (Alto the clip (B),then set the bottom edge of the side trim over the cowl cover (C),and align the c l i p s( D ) w i t ht h e r e t a i n e r ( E ) , n d p u s ho n t h e c l i p s a portionsof the trim until the trim is fully seatedon thewindshield.

24. Let the adhesivedry for at least t hour, then spray


water over the windshieldand checkfor leaks. Mark Ieakingareas,and let the windshielddry, then seal with sealant: . Let the vehiclestand for at least4 hours after windshieldinstallation. the vehiclehas to be lf usedwithin the first 4 hours,it must be driven slowly. . Keepthe windshielddry for the first hour after installation. Reinstallthecowl covers(seepage 20-95). NOTE:Thecowl cover clips may not set properlyif the windshieldadhesiveis too wet. Installthe clips (A, B) on both side trim {C).lf the clip (D) is damaged,replacethe side trim and clips as an assembly. A: Grey B :B l u e

28. R e i n s t a al l l r e m a i n i n g e m o v e dp a r t s .I n s t a l l t h e l r
rearviewmirror afterthe adhesivehas dried thoroughly. NOTE: Advise the customernot to do the following things for 2 to 3 days: . S l a mt h e d o o r sw i t h a l l t h e w i n d o w sr o l l e du p . . Twist the body excessively (suchas when going i n a n d o u t o f d r i v e w a y s t a n a n g l eo r d r i v i n g a over rough, unevenroads).

20-24

RearWindow Replacement
NOTE: . Put on glovesto protectyour hands. . Wear eye protection while cuttingthe glassadhesive w i t h p i a n ow i r e . . Use seatcoversto avoid damagingany surfaces. . Do not damagethe rearwindow defoggergrid lines a n dt e r m i n a l s . 1 . Removethese items: . Hatchlower trim panel (seepage 20-53) . Hatchspoiler(seepage 20-99) Removethese items: . High mount brakelight {seepage 22-821 . Rearwindow wiper motor {see page22-1461 Disconnect rearwindow defoggerconnectors the (A). 6. With a helperon the outside,pull the piano wire (A) backand Jorthin a sawing motion. Holdthe piano wire as closeto the rearwindow (B)as possibleto preventdamageto the hatch,and carefullycut t h r o u g ht h e a d h e s i v e C }a r o u n dt h e e n t i r er e a r {

Cutting positions:

make 4 . lf the old rear window is to be reinstalled, alignmentmarksacrossthe glassand body with a grease encrl, p r 7 . C a r e f u l l ye m o v et h e r e a rw i n d o w . Apply protective tape along the insideand outside U e d g e so f t h e h a t c h . s i n ga n a w l , m a k ea h o l e a f t t h r o u g ht h e a d h e s i v er o m i n s i d e h e v e h i c l e t t h e corner portionof the rearwindow. Pushthe piano w i r e t h r o u g ht h e h o l e ,a n d w r a p e a c he n d a r o u n da pieceof wood,

(cont'd)

20-25

Glass
(cont'd) RearWindow Replacement
With a putty kniie. scrapethe old adhesivesmooth to a thicknessof about 2 mm (0.08in.) on the bonding surfacearoundthe entire rear window openingflange: . Do not scraDe down to the Dainted surfaceof the body; damagedpaint will interferewith proper bonding . Removethe fastenersfrom the tailqate. Cleanthe hatch bonding surfacewith a sponge dampenedin alcohol.After cleaning,keepoil, greaseand water from getting on the surface, ( 1 1 . G l u et h e s i d eu p p e rf a s t e n e r sA )a n d s i d e l o w e r fasteners{B)with adhesivetape {3M 5312,or e q u i v a l e n t G l u et h e u p p e rr u b b e rd a m s ( C ) w i t h ). adhesive tape (NITTO501fM, equivalent) or and glue the lower rubberdam (D)with adhesive tape (3M 4216,or equivalent) the insideface of the to rearwindow (E)as shown. Beforeinstallingthe lower rubber dam, apply primer (3M N-200,or equivalent) the areasbetweenthe alignment to marks {F),then glue the rubber dam on. lf glue the spoilerfasteners(G)with necessary, adhesive tape (3M 5671,or equivalent) the to outsideface of the rearwindow: . Be sure the side upper fasteners, and upper r u b b e rd a m s l i n e u p w i t h a l i g n m e n m a r k s{ H ,l ) . t . Be sure both ends of the lower rubber dam line up with the edge of the glass, . Be sure the spoilerfastenersline up with a l i g n m e n m a r k s{ J ) . t . Be carefulnot to touch the rearwindow where adhesive ill beaDolied. w 1,1,.,1,' : Applyprimerhere. G E

1 0 .lf the old rearwindow is to be reinstalled, a use


putty knifeto scrapeoff all of the old adhesive, the fastenersand the rubberdams from the rear window. Cleanthe insideface and the edge oi the rear window with alcoholwhere new adhesiveis to be applied.Make sure the bonding surfaceis kept free of water, oil and grease.

"6'J1r-,

20-26

12. Glue the side upperfasteners(A) andsidelower fasteners(B)with adhesive tape (3M 5312,or equivalent)tothe hatch as shown. Fastoner Locations A>: Fastener, 2

2 B >: Fastener,

1 5 . W i t h a s p o n g e a p p l ya l i g h tc o a to f g l a s sp r i m e r , along the edge of the rear window (A),upper rubber dams (B),and lower rubberdam (C)as shown, then lightly wipe it off with gauzeor cheesecloth: . With the printeddots (D) on the rearwindow as a guide, apply the glassprimer to both side portionsof the rearwindow. . Do not apply body primer to the rearwindow, and do not get hatchand glass primer sponges m i x e du p . . Nevertouch the primed surfaces with your hands. lf you do, the adhesivemay not bond to the rear window properly.causinga leak afterthe rear w i n d o wi s i n s t a l l e d . . Keepwater, dust, and abrasivematerialsaway from the primed surface. .. : Applyglasspiimer here.

T-8.

ar\\
itf,

cl

t5.

Set the rearwindow in the opening,and centerit. Align the clips (A) of the rearwindow with the holes i n t h e o p e n i n g l a n g e . a k ea l i g n m e n m a r k s( B ) f M t acrossthe rearwindow, hatch,and body with a greasepencilat the four pointsshown. Be careful not to touch the rearwindow where adhesivewill beapplied.

1 4 . R e m o v e h e r e a rw i n d o w . t

(cont'd)

20-27

Glass
(cont'd) RearWindow Replacement
1 6 .With a sponge,apply a light coat of body primer to
t h e o r i g i n a a d h e s i v e e m a i n i n g r o u n dt h e r e a r l r a window openingflange. Letthe body primer dry for at least 10 minutes; . Do not apply glassprimer to the body, and be carefulnot to mix up glassand body primer sponges. . Nevertouch the primed surfaces with your hands. ',,,,,': Applybodyprimer he.e. 18. Packadhesiveinto the cartridgewithout air pockets to ensurecontinuousdelivery.Putthe cartridgein a caulkinggun, and run a bead of adhesive(A) aroundthe edge of the rearwindow (B)as shown. With the glassprimer (C)you appliedin step 15 as a guide,apply the adhesive both side portionsof to the rearwindow. Apply the adhesivewithin 30 minutesafter applyingthe glassprimer. fMake slightlythicker a bead at each corner.
12 mm r, in.) 10.47 ,\

ii'(0.28

in.l

20 mm in.l 10.79
2mm {0.08in.)

aru'.1{-----"

1 7 . Beforefilling a cartridge,cut a nozzle as shown. {A}

"V" in the end ofthe

7 mm (0.27in.)

20-28

OuarterGlassReplacement
19. Use suctioncups to hold the rearwindow over the opening.align it with the alignmentmarks you '13, made in step and set it down on the adhesive. Lightlypush on the rearwindow until its edgesare fully seatedon the adhesiveall the way around.Do not open or closethe doors until the adhesiveis dry. 20. Scrapeor wipe the excessadhesiveoff with a putty knife or towel. To removeadhesivefrom a painted surfaceor the rearwindow, use a soft shop towel dampenedwith alcohol. 21. Letthe adhesivedry for at least 'l hour,thenspray water over the rear window and checkfor leaks. Mark the leakingareas,let the rear window dry, then sealwith sealant.Let the vehiclestandfor at least4 hours after rearwindow installation, the lf vehiclehas to be used within the first 4 hours,it must be driven slowly. p 2 2 . R e i n s t a l l a lrle m a i n i n g e m o v e d a r t s . r NOTE: Advise the customernot to do the following things for 2 to 3 days: . S l a mt h e d o o r sw i t h a l l t h e w i n d o w sr o l l e du p . . Twist the body excessively (suchas when going i n a n d o u t o f d r i v e w a y s t a n a n g l eo r d r i v i n g a over rough, unevenroads). NOTE: . Put on glovesto protectyour hands. . Wear eye protectionwhile cuftingthe glassadhesive with piano wire, . Use seatcoversto avoid damagingany surfaces. 1 . R e m o v e h e C - p i l l atrr i m ( s e ep a g e2 0 - 5 1 ) . t lf necessary, removethe rear side trim panel (see page 20-51 and B-pillarupper trim (seepage 20) 50). 2. Removethe front seal {A) from the front edge of the glass (B).lf necessary, the seal with a utility cut knife.

(cont'd)

20-29

Glass
(cont'dl OuarterGlassReplacement
3 . Apply protectivetape to along the insideand
outsideedgesof the body. Using an awl, make a hole through the adhesive from insidethe vehicle. Pusha pieceof piano wire through the hole, and wrap each end around a pieceof wood. With a helperon the outside,pull the piano wire (A) backand forth in a sawing motion. Holdthe piano wire as closeto the quarterglass(B) as possibleto preventdamageto the body, and carefullycut through the adhesive(C)aroundthe entirequarter grass.

6 . With a putty knife,scrapethe old adhesivesmooth


to a thickness about 2 mm (0.08in.) on the of bonding surfacearoundthe entirequaner glass f openinglange: . Do not scrapedown to the paintedsurfaceof the body; damagedpaint will interferewith proper bonding . Removethe clips from the body. 7 . Cleanthe body bondingsurfacewith a sponge d a m p e n e dn a l c o h o lA f t e rc l e a n i n gk e e po i l , i . . greaseand water from getting on the surface. use a lf the old quarter glassis to be reinstalled, putty knifeto scrapeoff all of the old adhesiveand the rubberdam from the glass.Cleanthe inside face and the edge of the glasswith alcoholwhere new adhesiveis to be applied.Make sure the bonding surfaceis keptfree of water, oil, and grease.

Cuttingpositions:

5. Carefullyremovethe quarterglass.

20-30

9. Set the quarterglass(A) in the opening,and center i t . F r o mi n s i d e h e v e h i c l e m a k ea n a l i g n m e n m a r k t , t (B)to the quarterglasswhere the rear clip will be installedwith a greasepencil.Be careful not to w l o u c ht h e g l a s sw h e r ea d h e s i v e i l l b e a p p l i e d .

11 . A l i g nt h e u p p e rc l i p { A )a n d l o w e rc l i p ( B )w i t h t h e edge of the quarter glass(C),then anachthem with adhesive tape (NITTO571,or equivalent) the to insideface of the quarter glass,and align the center of the rearclip (D)with the alignmentmark (E)you made in step 9, and attach it with adhesivetape (3 M 4215,or equivalent) the insideface of the to quarterglassas shown. Be carefulnot to touch the glasswhere the adhesive tape will be applied.
25.5mm { 1 . 0i n . )

10. Removethe quarterglass.

(cont'd)

20-31

Glass
(cont'dl OuarterGlassReplacement
Firstglue the front seal (A)with adhesive tape {31\4 4 2 1 3 , r e q u i v a l e n t a.n d g l u et h e r u b b e rd a m ( B ) o ) with adhesive tape (NITTO501M,or equivalent) to the insldeface of the quarterglass(C)as shown. Beforeinstalling the front seal and rubber dam, a p p l yp r i m e r( 3 M N - 2 0 0 o r e q u i v a l e n t ) t t h e i n s i d e , o tace of the glass.then glue the seal on: . Be sure the front seal lines upwiththe bottom and front edgesof the glass. . Be careful not to touch the glasswhere adhesive will beaoolied. .,1.,,/:/| Apply prlJnerhete. '13. With a sponge,apply a light coat of glassprimer along the edge of the rubber dam (A) and front seal (B)as shown, then lightly wipe it off with gauzeor cheesecloth: With the printeddots (C)on the quarterglass(D) as a guide, apply the glass primer to the upper and lower corner ponions of the quarterglass. Do not apply body primer to the quaner glass, and do not get body and glassprimer sponges m r x e du p . Nevertouch the primed surfaces with your hands. lf you do, the adhesivemay not bond to the quarterglassproperly,causinga leak afterthe quarterglassis inslalled. Keepwater, dust, and abrasivematerialsaway from the primed surface.

-"-c

30 mm n 1 1 . 1i8 . l 50 mm I {1.97in.1 /

\ t

nL

v - -

i--l
'100 mm {3.9i1in.)
45 mm i { 1 . 7 7n . } 6 mm (0.24in.) 3.5 mm {0.r4 in.l

1 1m m lo.i(} in.)

20-32

14, With a sponge.apply a light coat of body primer to t h e o r i g i n a a d h e s i v e e m a i n i n g r o u n dt h e q u a r t e r l r a glassopeningflange.Let the body primer dry for at least 10 minutes: . Do not apply glass primer to the body, and be carefulnot to mix up glassand body primer sponges. . Nevertouch the primed surfaces with your hands. )'/ii,/ii. I Apply bodv prime. here, (0.08 in.l
mm

16. Packadhesiveinto the cartridgewithout air pockets to ensurecontinuousdelivery.Putthe cartridgein a caulkinggun, and run a bead of adhesive(A) around the edge of the rubber dam (B) as shown. W i t h t h e g l a s sp r i m e r( C ) y o ua p p l i e d n s t e p 1 3 o n i the quarterglass (D)as a guide. apply the adhesive to the upper and lower corner portionsof the quarterglass.Apply the adhesivewithin 30 minutesafter applyingthe glass primer. lvlake a slightlythickerbead at each corner.

20 mm (0.79 in.)
2mm {0.08in.)

l.:J611, ;\
7mm {0.28in.)
3mm { 0 . ' 1 2i n . }

20 mm in.) {0.79

t5.

Beforefilling a cartridge, a "V" in the end ofthe cut nozzle(A) as shown.

'10mm (0.39in.)

7 mm 10.27 in.)

( c o n l ' d)

20-33

Glass
(cont'd) OuarterGlassReplacement
17. Use suctioncups (A)to hold the quarterglassover the opening.align it with the clips (B)and set it down on the adhesive.Lightly push on the quarter glass until its edges are fully seatedon the adhesiveall the way around.Do not open or close the doors untilthe adhesiveis drv.

18. Scrapeor wipe the excessadhesiveoff with a putty from a painted knife or towel. To remove adhesive surfaceor the quarterglass,use a soft shop towel dampenedwith alcohol. 19. Let the adhesivedry for at least t hour,thenspray water over the quarterglassand checkfor leaks, Mark the leakingareas,let the quarterglassdry, then sealwith sealant.Let the vehiclestand for at lf least4 hours after quarterglassinstallation. the vehiclehasto be usedwithin the first 4 hours.it must be driven slowlv. 20. Reinstall remainingremoved parts. all NOTE:Advisethe customernot to do the following things for 2 to 3 days: . Slam the doors with all the windows rolled up. . Twist the body excessively (suchas when going in and out of drivewaysat an angle or driving over rough, unevenroads).

20-34

Moonroof
ComponentLocationIndex

GLASS HeightAdjustment,page 20 37 paqe 20-37 Replacement, F C l o s i n o o r c e n dO o e n i n o r a o a " D Check;page20-48 DRAINCHANNEL page20-39 Replacement,

COVER /,BR^CKEI

,5

?a<&, _-""-\\q @
..t'- ? .@ -@c I
WIND DEFLECTOR page20-38 Replacement,
E @

_a

LIMITSWITCH (AUTO.STOP SWITCH) page 20-46 Adjustment, E R

CABLE TUBE REAR BRACKET

E STOP

.a'
CABLEASSEMBLY page20-44 Beplacement, page20'41 Replacement, gJ -.- REARDRA'N TUBE

*\
MOONROOF CONTROL UNIT

)
REARDRAIN VAI-VE FRAME page 20-42 Replacement,

20-35

Moonroof
Index Symptom Troubleshooting
Symptom Water leaks '1. Diagnosticprocedure Checkfor a cloggeddrain tube. and the roof 2. Checkfor a gap betweenthe glassweatherstrip panel. 3. Checkfor a defectiveor an improperlyinstalledglass w e a t h e r s t r i o r d r a i nc h a n n e l . p 4. Checkfor a gap betweenthe drain seal and the roof panel. Also check for Gl a s sh e i g h t adJustment

W i n dn o l s e
Deflector noise

1. Checkfor excessive clearancebetweenthe glassweatherstrip G l a s sh e i g h t panel. adjustment and the root betweendeflectorseal and 1. Checkfor a imDrooerclearance roof panel. deflectorextension. 2, Checkfor a insufficient 3. Checkfor a deformeddeflector. 1. Checkfor a loose motor. 2 . C h e c k o r a w o r n g e a ro r b e a r i n g . f 3. Checkfor a deformedcable assembly. Checkclosingforce

Motor noise

g f Glassdoes not move, 1 . C h e c k o r a d e f e c t i v e e a ro r i n n e rc a b l e . 2. Checkfor foreign matter stuck betweenthe guide rail and the but motor turns r slide . f 3 . C h e c k o r a l o o s ei n n e rc a b l e . 4. l\,4ake sure the cableassemblyis attachedproperly. Glassdoes not move and motor does nol c t u r n( g l a s s a n b e moved with moonroofwrench) 1. 2. 3. 4. 5. 6. Checkfor a blown fuse. Checkfor a faulty moonroof switch. Checkthe limit switch. Checkfor a run down battery. Checkfor a defectivemotor. Checkfor a faulty relay.

20-36

GlassHeightAdjustment
The roof panel (A) should be even with the glass weatherstrip(B).to within 2*0.5/ 1 mm (0.08+0.02l 0.04 in.) all the way around.lf not, make the following adjustment: B
2 + 0.5/ 1mm {0.08+ 0.02/-0.0i1in.}

GlassReplacement
'L C l o s e h e g l a s sf u l l y . t S l i d et h e s u n s h a d e l l t h e w a y b a c k . a Removethe screws (A),then remove both bracket covers (B).Removethe nuts (C)and shims {D)from both glassbrackets(E). Fastengr Locations
A } : Screw, 2

c O ,Nut.

il

@
E

\o
1 , Removethe bracketcover from each side.

2. L o o s e n h e n u t s{ A ) ,a n d i n s t a l l t h e h i m s( B ) t s
betweenthe glassframe (C)and glass bracket(D) on each side. Shim ihickness: Front and rear max. 2 mm 10.08 in.l 6x1.0mm 9 N.m {0.9kgf.m,7 lbf.ft} 4. Removethe glass{A) by lifting it up. Do not damagethe roof panel.

B \

Forward

A 6x1.0mm I N.m(0.9 kgf.m,7lbt.ft) 3. lf necessary, repeaton the oppositeside. 5. Installthe glassin the reverseorder of the removal, a n d a d j u s t h e g l a s sh e i g h ta l i g n m e n t . 6. Checkfor water leaks.Use free-flowingwater from a hose without a nozzle. not use high-pressure Do water.

20-37

Moonroof
Wind DeflectorReplacement
1 . O p e nt h e g l a s sf u l l y . 3. Installthedeflector(A) in the reverseorder of removal,and checkthat lhe deflectorarm base (B) and deflectorlink pivot base (C)line up with the s a m ea l i g n m e n lti n e s( D ) .l f n e c e s s a r y ,d j u s t h e m a forward or backwardso the edge of the deflector seal (E)touchesthe roof panel (F)evenly.Each base must be moved the same amount for adjustment.lf the deflectorseal and roof panel make a rubbing sound, move the deflector backwardas necessary positionit properly. to
4il mm (1.7n.) i
_ l

2 . Removethe screws(A, B), and releasethe hooks


(C),then removethe wind deflector(D).
Fastener Locations

A>:Screw,2B>:

Screw, 2

'a- ' -

20-38

DrainChannel Replacement
1 . Removethe moonroof glass(seepage 20-37). 2 . With the moonroofwrench,move both glass (A) brackets to the positionwhere the moonroof normally pivots down, and removethe screws s e c u r i n gh e d r a i nc h a n n e ( B ) . t l Fastener Locations ) : Screw,2 4 . R e m o v e h e d r a i nc h a n n e ( A ) . t l

I n s t a l l t h e h a n n e il n t h e r e v e r s e r d e ro f r e m o v a l , o c and notethese items: P u s ht h e d r a i nc h a n n e o n t ot h e h o o k su n t i la l faint click is heard. Checkthe glass height adjustment(seepage 2031). Checkfor water leaks.Letthe water run freely from Do a hose without a nozzle. not use a high-pressure spray.

Release drain channel(A)from both hooks{B) the o f t h e d r a i nc h a n n e s l i d e rb y p u l l i n g h e d r a i n l t channelforward,

20-39

Moonroof
Replacement Sunshade
1 . R e m o v e h e d r a i nc h a n n e l . t Slidethe sunshade(A) until you can see both ( s u n s h a d e l i d e rs p a c e r s B ) . s Fastener Locations > : Screw,4 4. While liftingthe front portionofthe sunshade(A), move the sunshadeforward until you can see both s u n s h a d e e a rh o o k s( B ) .D o n o t d a m a g e h e r t s u n s h a d e n dh o o k s . a Fastener Locations ) : Screw,4

tF

(F

3. Removethe screws,then remove both spacers.

5. Removethe screws,then remove both hooks.

20-40

Motor Replacement
6. Removethe sunshade(A), 1 . Removethe headliner(seepage 20-54). Put on glovesto protectyour hands.Disconnecl the connector(A),and removethe bolts,then remove the motor (B). Fastener Locations >:Bolt,2 A

::lll' =r'"'------.-.. --.,

\
?

'l'i
,

@@

..
7 . Removeboth front sunshadebasesliders (A) and ( b o t h r e a rs u n s h a d e a s es l i d e r s B ) b kgf.m. {0.9 7 rbf.ftl
t'-^'

Installthe motor in the reverseorder of removal, and note these items: . lvlake surethe connectoris plugged in properly. . Checkthe motor operation.

' a {

s i o 8 . I n s t a l l t h e u n s h a d en t h e r e v e r s e r d e ro f r e m o v a l , and checkthe glassheight adjustment(seepage 20-37). 9 . Checkfor water leaks.Let the water run freely from Do a hose without a nozzle. not use a high-pressure spray.

20-41

Moonroof
Frame and DrainTubeReplacement
1 . Removethese items: . Headliner(seepage 20-54) . Moonroof glass(seepage20-37)

2. Put on glovesto protectyou r hands.Disconnect motor connector(A),open/close-tilt/close the switch connector


{B),moonroof control unit connector{C),auto-stopswitch connector(D),and the drain tubes (Ei,and removethe

(F). moonroof relays


FastenorLocations

10 > : Bolt,

{um

irl
/^

6x1.0mm 9.8N.m (1.0 kgf.m,7.2lbf ft) Removethe interiorharness(G) by detaching the harnessclips (H).
4 . With an assistant holdingthe frame (l). removethe bolts,startingat the rear,and release the rear hooks (J) by

moving the f rame forward,then removethe frame. 5 . With the help of an assistant, carefullyremovethe frame through the passenger's door opening.Takecare not to scratchthe interiortrim and body, or tear the seat covers.

20-42

6. To removea front drain valve (A)from the body, removethe kick panel,left or right (seepage 20-50). Tie a string to the end of the drain tube, then pull the front drain tube (B)down out of the front pillar.

f o 8 . I n s t a l l t h er a m ea n d d r a i nt u b e i n t h e r e v e r s e r d e r of removal,and note these items: . B e f o r e n s t a l l i n gh e f r a m e ,c l e a rt h e d r a i nt u b e s i t air. and drain valves using compressed . Checkthe frame seal. . Cleanhesurface fthe frame. t o . When installingthe frame, first attachthe rear hooks into the body holes. . Make sure the connectors are plugged in properly. . When connectingthe drain tube, slide it overthe i f r a m en o z z l e t l e a s t1 0 m m ( 0 . 3 9 n . ) . a . I n s t a l l t h e t u b e c l i p ( A ) t h e d r a i n u b e( B )a s t on shown.

1 . To remove a rear drain valve (A)from the cargo compartment,removethe rear side trim panel (see p a g e2 0 - 5 1 ) . D e t a t h e c l i p s( B ) , h e n r e m o v e h e t t ch d r a i nt u b e ( C ) , B

Upward

t I
I
B 9 . Checkfor water leaks.Let the water run freely from Do a hosewithout a nozzle. not use a high-pressure spray.

20-43

Moonroof
DrainChannel Sliderand Cable Assembly Replacement
1. Removethe frame (seepage 20-42). 2. Removethese partsfrom the frame: . Sunshade(seepage 20-40) . Moonroof motor (seepage 20-41) 3. Put on glovesto protectyour hands,Removethe screws(A, B),then removethe slide stops (C)and (D).Removethe bolts (E) cabletube rear brackets from the cabletube side bracket(F)and the cable tube mounting screws(G)from both sidesof the f r a m e( H ) . Fastener Locations A> rScrew.2 B): Screw,2 E > : B o l t , 2 g 5 . P i v o t t h e l a s sb r a c k e ( A )d o w n b y s l i d i n g h e l i n k t t lifter (B) back,then slide both glassbracketsback with the link lifter.

@
r):
Screw 6\-'1

@
( S l i d et h e c a b l ea s s e m b l y A )a n d b o t hg l a s s brackets(B) back,then removethem from the f r a m e( C ) .

Position switch side: 6x1.0mm g , aN . m c A

No switch sidel

o
B

6x1.0mm 9.8 N.m kgf.m,7.2 lbf.ft) 11.0

Detachthe onen switch connectorclip {l)from the frame.

20-44

f l 7 . R e m o v e h e d r a i nc h a n n e s l i d e r ( A ) r o m t h e g l a s s t bracket(B).

i s 8 . I n s t a l l t h e l i d e ra n d c a b l ea s s e m b l yn t h e r e v e r s e , o r d e ro f r e m o v a l a n d n o t et h e s ei t e m s ; . D a m a g e d a r t ss h o u l db e r e p l a c e d . p ' Apply multipurposegreaseto the glassbracket ( A )a n d g u i d er a i lp o r t i o no f t h e f r a m e ( B ) indicatedby the arrows. . Beforereinstalling the motor, make sure both , l i n kl i f t e r s r e p a r a l l e la n d i n t h e f u l l y c l o s e d a position. . Beforereinstalling the motor, installtheframe , t a n d g l a s s t h e nc h e c k h e o p e n i n gd r a g ( s e ep a g e 20-481.

B \

\ ----lll

---':rdrt'Irrt fl u,t La/J' I ll l$=-r:-

20-45

Moonroof
Limit Switch Adjustment
1. Removethe headliner(seepage 20-54).

Fullyclosedpositionadiustment
2. With the moonroof wrench,closethe glass(A) fully: . Make sure both link lifters(B)are parallel,and in the positionshown. . Checkthe g lassfit to the roof panel and the glass height (seepage 20-37).

5x0.8mm 5 N.m {0.5kgf.m,4lbf.ft)

3 . W i t h a n o p e n - e n d r e n c h ,l o o s e n h e l i m i ts w i t c hm o u n t i n gb o l t s( C ) . w t 4. Adjust the limit switch (D): ' Move the switch plate (E)a little at a time, then secureit atthe positionwhere you hear a faint clickwhen the switch cam (F) pushesthe positionswitch (open/close). . Checkthat the switch plate contacts the switch bracket(G).

20-46

Auto-stop position adiustment


5. With the moonroofwrench.operatethe glass(A)to the auto-stopposition.

/--:.!Jtr+rtl

. ,
G

\_-_:_t+#1 <F / \ / \
i! .. I

5 N.m {0.5kgt.m,4 lbt ft)

With an open-endwrench, loosenthe auto-stopswitch m o u n t i n g b o l t s ( C ) . switch (D): 7 . Adjustthe auto-stop . N 4 o v e t h s w i t c hp l a t e( E )a l i t t l e a t a t i m e , t h e n s e c u r e i t a t t h e p o s i t i o n w h e r e y o u h e a r a f a i n t c l i c k w h e n t h e e switch cam (F)pushesthe switch (auto-stop). . Checkthat the switch platecontactsthe switch bracket(G). 8 . Checkthe operationof the glassby operatingthe moonroof switch:From the tilt-up positionto the fully closed position,from the fully open positionto the auto-stopposition,from the auto-stoppositionto the fully closed posltron. spray Do L Checkfor water leaks.Letthe water run fleely from a hosewithout a nozzle. not use a high-pressure

20-41

Moonroof
Closing Force and Opening DragCheck
1 . R e m o v e h e h e a d l i n e( s e ep a g e2 0 - 5 4 ) . t r 2. Closingforce check: . With a shop towel {A) on the leadingedge of the g l a s s( B ) ,a f t a c h s p r i n gs c a l e( C )a s s h o w n . a . Havean assistanthold the switchto closethe glasswhile you measurethe force requiredto stop it. . Readthe force as soon as the glassstops moving, then immediatelyrelease the switch and spring scale. Closing Force; 200 290 N (20 30 kgf,44 66 tbl) 4. Openingdrag check:Protectthe leadingedge of the glasswith a shop towel (A).Measurethe effort requiredto open the glass using a spring scale(B) as shown.

5 . lf the load is over 40 N (4 kgf,9 lbf),check; . The side clearance and glass heightadjustment (seepage 20'37), . F o r b r o k e n r d a m a g e d l i d i n gp a r t s . f a n y o s l s l i d i n gp a r t sa r e d a m a g e d r e p l a c eh e m . , t

lf the force in not within specification, removethe moonroof motor (seepage 20-41), then check: . The gear portion and the inner cablefor breakage and damage.lf the gear portion is broken, r e p l a c eh e m o t o r .l f t h e i n n e rc a b l ei s d a m a g e d , t removethe frame (seepage 20-42), and replace the cable assembly(seepage20-44). ' T h e m o o n r o o fm o t o r ( s e ep a g e2 2 - 1 1 2 ) . t h e If motor fails to run or doesn'ttu rn smoothlv. replaceit (seepage 20-41), . The opening drag. Go to step 4.

20-48

InteriorTrim
ComponentLocationIndex

TRIM PANEL LOWER HATCH oaoe 20-53 HATCH SIDETRIM page 53 20 TRIM C-PILLAR page 20'51
B.PILLARUPPEBTRIM page20-50 TRIM DOOROPENING page20-50

TRIM A.PILLAR page20-50


R e m o v a l / l n s t a l l a t ip a g e2 0 5 4 on, KICKPANEL page20 50 Replacement, page20-55

DOORSILLTRIM page20-50

CARGOAREA FLOOR page20-52 REAR SIDESHELF page20 5l SHELF CENTER REAR page20-51 REARSIDETRIM PANEL page20-51 CARGOFLOORMAT page20-52 TRIM PANEL REAR page 20-52

20-49

InteriorTrim
Trim Removal/lnstallation Door Area
NOTE: . Put on glovesto protectyour hands. . When prying with a flat-tipscrewdriver, wrap it with protective tape to preventdamage. . Takecare not to bend or scratchthe trim and panels. 1 . R e m o v e h e t r i m a s s h o w n . o r e m o v et h e d o o r s i l l t r i m a n d B - p i l l a u p p e rt r i m , r e m o v et h e r e a rs i d et r i m p a n e l t T r (seepage 20-51). as necessary 2. Installthetrim in the reverseorder of removal,and note these items: . Replace nydamaged lips. a c . Apply liquid thread lockto the anchor bolts before reinstallatior,. . Beforeinstallingthe anchorbolts, make sure there are no twists or kinks in the belts. Fastener Locations

A>: Clip,2 B > r C l i p , 3 C > : C l i p , ?


(Black) {White)

2ffi Tl|t

,"lF \r{

FRONT SEAT BELT UPPER ANCHOR BOLT 7/16-20 UNF 32 N m (3.3 m,24 lbf.ft) kgf A-PILLAR TRIM

il-::7
KICKPANEL

ao-----

LowER ANcHoR cAP

FRONTSEAT BELTLOWER ANCHOR BOLT 7/16-20UNF (3.3kgt.m,24lbl.ftl 32 N.m REARSIDETRIM PANEL

20-50

Trim Removal/lnstallation RearSideArea


NOTE: . Put on glovesto protectyour hands. . When prying with a flat-tipscrewdriver, wrap it with protective tape to preventdamage. . Takecare not to bend or scratchthe trim and panels. '1. To removethe rear side trim panel,removethese items: . Rearseat cushionand rear seat-back (seepage20-80) . Cargofloor mat and cargo areafloor (seepage 20-52) . R e a r r i m p a n e l{ s e ep a g e 2 0 - 5 2 ) t 2 . Removethe trim as shown. On the right side,disconnect cargo compartmentlight connector. the

3 . Installthetrim in the reverseorder of removal,and note these items:


. Replace nydamaged lips. a c . Make sure the cargo compartmentlight connectoris pluggedin properly. . l f t h e t h r e a d s o n t h e r e a r s i d e t r i m p a n e l o u n t i n g e l f - t a p p i nE Ts c r e w sa r ew o r n o u t , u s ea n o v e r s i z e s e l f d m s g o t a p p i n gE T s c r e w( P / N9 0 1 3 7 - S 1 A - E1 )1 a d es p e c i f i c a l lfy r t h i s a p p l i c a t i o n . om . W h e n i n s t a l l i n gh e r e a rs i d es h e l f ,s l i pt h e r e a rs e a tb e l tt h r o u g ht h e s l i t i n t h e t r i m . t ' A p p l y i i q u i dt h r e a dl o c k t ot h e a n c h o rb o l t sb e f o r er e i n s t a l l a t i o n . . Beforeinstallingthe anchorbolts,make sure there are no twists or kinks in the belt.
Fastenr Locations A>:Clip,11 B> rClip,2

c>rClap,l -..:.:'
TRIM S I D ES H E L F

SEATSELT REAR
SIDETRIM PANEL SEAT

STRIKER CAP

S I L LT R I M SELF-TAI

scREws
5x0.8mm { 0 . 4k g f m , 3 l b f . f t )

.. F . -\ *: :- . n\ : :
,/\
R E A RB U L K H E A O COVER REARSPEAKERCOVER

,/

\*J

FRONTSEAT AELT LOWERANCHORBOLT REARSEAT BELTLOWER \ 7/16-20UNF ANCHOF BOLT \ 32 N.m 7/16-20UNF \ { 3 . 3k g f m , 2 4 l b t . t t ) 32 N m (3.3 kgf m, 24 lbf ft, \ LOWER ANCHORCAP

20-51

Trim lnterior
- CargoFloorArea Trim Removal/lnstallation
NOTE: . Put on glovesto protectyour hands. tape to preventdamage' . When jrying with a flat-tipscrewdriver, wrap it with protective panels. . Takecare notto bend or scratchthe trim and ( s e ep a g e2 3 - 1 1 ) ' t r t 1 . T o r e m o v e h e r e a rt r i m p a n e l , e m o v e h e c h i l ds e a tt e t h e ra n c h o r 2. Removethe trim as shown. c a , o t 3 . I n s t a l l t h er i m i n t h e r e v e r s e r d e ro f r e m o v a l a n d r e p l a c e n y d a m a g e d l i p s '
Fastener Locations

A > :C l i p , 3 B > : C l i p . 4
j-= E T r

\t

FLOORMAT

COVER REAR SEAT-BACK

-t

CARGOAREA FLO

7
To rearsade trim panel.

To rearsidetrim panel.

REAR TBIM PANEL

20-52

Trim Removal/lnstallation HatchArea


NOTE: . Put on glovesto protectyour hands. . When prying with a flat-tipscrewdriver, wrap it with protective tape to preventdamage. . Takecare not to bend or scratchthe trim and panels. 1. Removethe trim in the sequenceshown. . . . . Hatchuppertrim panel Left hatchside trim Righthatchside trim Hatchlower trim panel

c 2 . I n s t a l l t h er i m i n t h e r e v e r s e r d e ro f r e m o v a l a n d r e p l a c e n y d a m a g e d l i p s . t o , a
Fastener Locations

o> A>;crip,a B>:crip,2 .>,l,l,Jil,l3

3il;1,

E>:crip.2

"-{q .1. \

Y,]

n g g l f nl t

itr^

HATCH LOWER TRIMPANEL

LowER TRrM O HATCH PANEL

t7,
f.

a- ,,) I

=- -1

->

HATCH UPPER TRIM PANEL

.D HATCHUPPER TRIM PANEL

HATCHSIDETRIM

20-53

InteriorTrim
Headliner RemovaUlnstallation
NOTE: . When prying with a flat-tip screwdriver, wrap itwith protective tape to preventdamage. . Takecare not to bend and scratchthe headliner. . Be carefulnot to damagethe dashboardand other interiortrim. 1. Removethese items: . A-pillartrim, both sides(seepage 20-50) . B - p i l l a u p p e r t r i m ,b o t h s i d e s( s e ep a g e2 0 - 5 0 ) r . Hatchweatherstrip, necessary as {seepage 2092\ . C - p i l l atrr i m , b o t hs i d e s( s e ep a g e2 0 - 5 1 ) . Moonroof switch (seepage22-'112) . Spotlights(seepage 22-961 . Ceilinglight (seepage 22-96) Removethe sunvisor{A) and holder {B)from both srdes. -1 -2 -3 -4 Removethe caps {C). Removethe screws. Removethe sunvisorfrom the body and holder. Using a flat-tipscrewdriver,push the hook (D), a n d t u r n t h e h o l d e r9 0 ' . t h e n p u l l i t o u t .
5x0.8mm 4 N.m {0.4 kgf.m, 3 lbf.ft}

3. From both rear passenger's, removethe caps (A), removethe screws,then removethe grab and ( handlesB). Fastener Locations > : Screw,4 t , t;---iJ

)e

Fastener Locations > : Screw,4

r(\'-r \)*

5x0.8mm 5 N.m {0.5kst m.4lbf ft}

20-54

CarpetReplacement
4. Removethe headliner. -1 Removethe socketplug (A). - 2 R e m o v e h e r e m a i n i n g o o ro p e n i n g r i m { B } t d t from each roof portion. -3 Detach the clips (C),and releasethe fasteners ( D )b y p u l l i n g h e f r o n t p o r t i o no f t h e h e a d l i n e r t (E)down. -4 With the help of an assislant, release the clips (F)of the headlinerfrom the moonroof frame ( G ) ,a n d r e l e a s eh e h e a d l i n efrr o m t h e c l i p s( H ) t by slidingthe headlinerforward, and lowering the headliner. -5 Removethe headlinerthrough the passenger's opening. Fastener Locations
C>:Clip,3

SRScomponentsare locatedin this area.Reviewthe and the SRScomponentlocations(seepage 23-13) (seepage23-14)in the SRS precautions and procedures sectionbefore performingrepairsor service. NOTE: . Put on glovesto protectyour hands. . Takecare not to damage,wrinkle. or twist the carpet. . Be carefulnot to damagethe dashboardor other interiortrim pieces. 1. Removethese items: . Frontseats,both sides(seepage 20-111 . Driver'sdashboardunder cover (seepage 20-60) . Passenger's dashboardIower cover (seepage 20-631 . Rearseatcushion(seepage 20-80) . Kick panels,both sides(seepage 20-50) . Door silltrim, both sides(seepage 20-50) . Consoles, front and rear (seepage20-57) 2 . R e m o v e h e n u t ( A ) ,a n d u s i n ga h e xw r e n c h , t release the clip (B),then removethe footrest(C). Fastener Locations Aa:Nut,1 B):Clip,'l
--'1 I

F>:Clip,2

H>:Clip,2

tj I =\-/
5 . Installthe headlinerin the reverseorder of removal, and note these items: . W h e n r e i n s t a l l i ntg e h e a d l i n etrh r o u g ht h e h passenger's door opening,be carefulnot to fold or bend it, Also, be carefulnot to scratchthe DOOy. . C h e c k h a t b o t hs i d e so f t h e h e a d l i n ea r e t r securelyattached the trim. to . R e p l a c e n y c l i p st h a t r e m a i ni n t h e r o o f d u r i n g a r e m o v a l R e i n s t a l l t h c l i p sb a c ki n t h e h e a d l i n e r . e before installation.

--\

;tt4f
l[il

-JrL

A 6x1.0mm 9.8Nm kgf m,7.2 lbf.ft) 11.0

-o

(cont'd)

20-55

InteriorTrim
(cont'dl CarpetReplacement
Using a utility knife,cut the carpet(A) underthe heaterareas(B),and cut out the parkingbrakelever area (C)as shown, then pull backthe carpet. A B 5. Installthecarpetin the reverseorder of removal, and note these items: . T a k ec a r en o t t o d a m a g e w r i n k l e , r t w i s t t h e , o carpeL . Make sure the seat harnesses routed are correctly. . S l i pt h e c a r p e tu n d e rt h e r e a rs i d et r i m p a n e lo n each side properly. . R e p l a c eh e c l i p i f i t ' sd a m a g e d . t . Reattach cut areasunder the heateraround the the parkingbrakelever with a wire tie. . When installingnew carpet,cut the carpet(A) underthe heaterareas(B),and around the parkingbrakelever (C).After installingthe new carpet,slip the carpetfrom the driver's and passenger's side through the spacebetweenthe heaterunit and body, and reattach the cut area {C)around the parkingbrakeleverwith wire ties.

4 . Removethe clip (A),and release the fasteners(B). Pullthe carpetout from both rear side trim panels (D),then removethe carpet(C). Fastener Location A >: Clip.1
&z

tr

20-56

Consoles
Frontand RearRemoval/lnstallation Console,
NOTE:Takecare not to scratchthe front seal, dashboard, and relatedparts. ( 1 . R e m o v e h e r e a rc o n s o l e A ) . t -1 Slidethe front seatforward fully on each side. -2 Removethe screws{B)from the rear portionof the rearconsole, -3 Slidethe front seat rearwardfully on each side. - 4 P u l l t h ef r o n t p o r t i o no f t h e r e a rc o n s o l e p t o u detachthe clips (C)and hooks (D),then release the rearconsolefrom the front console(E). - 5 S t a r t i n g t t h e r e a r ,p u l l t h e r e a rc o n s o l e p , a u then remove it. Fastener Locations C >: Clip, 2 B >:Screw,2 2. Removethe front console(A). - 1 P u l lo u t t h e d a s h b o a r d e n t e rl o w e rc o v e r{ B ) c to detachthe clips (C). -2 Dlsconnect accessory power socket the c o n n e c t o( D ) . r b 3 R e m o v eh e c o n s o l e o x m a t( E ) . t - 4 R e m o v e h e b o l t s( F ) , c r e w s( G ) ,a n d c l i p s( H ) . t s -5 Gently pull out the front consoleto release the h o o k s( l ) a n dp i n s ( J ) . Locations Fastener C > : C l i p , 3 F > i B o l t , 2 G > : S c r e w . 2H ) : C l i p , 2

..4-* q ' 4!-- L } * fF-\ . / -,-('E9'/ * ' J J d

98Nm (1.0 kgt.m,7.2lbf.ft) Installthe consolein the reverseorder of removal, and note these ltems: . R e p l a c e n yd a m a g e d l i p s . a c . Make sure the accessory power socketconnector i s p l u g g e di n p r o p e r l y . . P u s ht h e c l i p si n t o p l a c es e c u r e l y .

6x1.0mm

20-57

Consoles
Front ConsoleDisassembly/Reassembly
NOTE;Takecare not to scratchthe consoleand relatedparts.

Fastener Locations ):Screw,8

C*
FRONTCONSOLE

\
BEVERAGE HOLDER ASSEMBLY

',/ BOX CONSOLE

,/

20-58

Dashboard
InstrumentPanelRemoval/ Installation
NOTE: . When prying with a flat-tipscrewdriver, wrap it with protective tape, and apply protective tape aroundthe relatedparts,to preventdamage. . Takecare not to scratchthe dashboardand related parts. 1. Tilt the steeringcolumn down. 2. Removethe steeringcolumn upper cover {seepage 17,9). Removethe instrumentpanel (A). -1 Gently pull out along the bottom to release the c l i p s( B )a n d h o o k s( C ) . -2 Gently pull out the upper portionto release the c l i p s( D )a n d h o o k s( E ) .
FastenerLocations

Driver'sDashboard Lower Cover Removal/lnstallation


NOTE:Takecare not to scratchthe dashboardand relatedParts. 1. Removethe driver'sdashboardlower cover (A). -1 Turn the lock knob (B)90". -2 Gently pull out the left side to release the h o o k s( C ) , -3 Pull out the panelto release the hooks (D).

B> : c l i p . 2

D D:,C l i p , 2 ^*,
Installthecover in the reverseorder of removal, and push the hook portions into placesecurely.

4 . Installthe panel in the reverseorder of removal, and push the clip and hook portionsinto place securery.

20-59

Dashboard
Driver'sDashboard UnderCover Removal/lnstallation
NOTE:Takecare not to scratchthe dashboardand relatedparts. 1. Removethe driver'sdashboardunder cover (A). - 1 T u r nt h e l o c kk n o b( B )9 0 ' . -2 Gentlypull down the rear edgeto releasethe clip(C). -3 Pullthe cover away to releaseit from the clip {D). Fastener Locations C >: Clip.1

Driver'sPocketRemoval/ lnstallation
NOTE: . Put on glovesto protectyour hands. . Takecare not to scratchthe dashboardand related p an s . 1. Removethe driver's pocket(A) -1 Removethe driver'sdashboardunder cover. -2 Removethe screws(B). -3 From behindthe dashboard, push the pocket b a c kb y h a n dt o r e l e a s eh e c l i p s( C ) . t 4 R e l e a s eh e h o o k( D ) . t Fastener Locations B):Screw,2 C>: Clip,2
','"\5

;;t='

Installthecover in the reverseorder of removal, and push the clip portion into placesecurely.

2 . Installthe pocketin the reverseorder of removal, and push the clip portionsinto placesecurely.

20-60

Shift LeverTrim Removal/lnstallation


NOTE: . Takecare not to scratchthe dashboardand related parts. . Put on glovesto protectyour hands. 1. Removethe glove box (seepage20-63). 2. Removethe shift knob. 4. Pull outthe shift levertrim (A) by hand to release t h e r e m a i n i n g l l p s( 8 , C ) a n d h o o k s( D ) ,a n d c disconnect the hazardwarning switch connector(El, then removethe trim. Fastener Locations B >:Clip,1 C > : C l ; p1 ,

D>: Hook,3

,,.;w,

, ,

U s i n ga r a t c h ew r e n c ha n d a n 1 1 i n c he x t e n s i o n t (A)wrapped with a shop towel (B),carefullyinsert the extensionthrough the glove box opening,and push the shift levertrim (C)from underthe trim to releasethe clips (D)and hooks (E)of the left side.
Fastener Locations

Installthe trim in the reverseorder of removal,and note these rtems. . Make sure the hazardwarning switch connectot is plugged in properly. . Pushthe clip and hook portionsinto place securely,

D>clip, 2 i:F \V

E> H o o k , 2

.-a7 \rt1

20-61

Dashboard
CenterPanelRemoval/lnstallation Dashboard
NOTE: . Put on glovesto protectyour hands. . When prying with a flat-tipscrewdriver, wrap it with protective tape around the tape, and apply protective relatedparts,to preventdamage. . Takecare not to scratchthe dashboardand related parts. code for the radio, 1. Make sure you have the anti-theft for the write down the frequencies the preset buttons. the clips (B) 4. Pull out the centerpanel (A)to release and hooks (C),and removethe harnessholder (D) from the bracket(E).Disconnect audio unit the connector(F),antennalead (G),heaterswitch connector(H)and heatercontrol unit connectors(l). Fastener Locations B ): Clip, 8

*4
, F

2 . Removethese items:
. Driver'sdashboardlower cover (seepage20-59) . Passenger's dashboardlower cover (seepage 20-63). . Glove box (seepage20-63). . Shift levertrim {seepage20-61). From the glove box and driver'sdashboardIower cover openings,loosenthe bolts (A) securingthe centerpanel (B).
Fastener Locations A): Bolt,2 x 0.8 mm 5Nm

Installthe panel in the reverseorder of removal, and note these items: Make sure eachconnectoris pluggedin properly, and antennalead is connectedproperly. Pushthe clip portionsinto placesecurely. Reconnect the negativecableto the battery. idle Do the ECN4/PCt\4 learn procedure{seepage 1l-139). Enterthe anti-theft code for the radio.then enter the customer'sradio stationpresets. Resetthe clock.

;.'

20-62

Passenger's Dashboard Lower CoverRemoval/lnstallation


NOTE: Takecare not to scratchthe dashboardand relatedparts. 1. Removethe passenger's dashboardlower cover (A). -1 Gently pull down the rear edge to release the c t i p s( B ) . -2 Pullthe cover away to releasethe pins (C)from ( the holders D). Fastener Locations B>: Clip,3

GloveBox Removal/lnstallation
SRScomponentsare locatedin this area.Reviewthe ( S R Sc o m p o n e n lto c a t i o n ss e ep a g e2 3 - 1 3 a n d t h e ) p r e c a u t i o na n d p r o c e d u r e ( s e ep a g e2 3 1 4 )i n t h e S R S s s sectionbeforeperformingrepairsor service. NOTE:Takecare not to scratchthe dashboardand relatedparts. 1. Removethe passenger's dashboardlower cover. 2. While holding the glove box (A),removethe glove box stop (B)on each side. Fastener Localions >Boh.2 .-6\

I jl

{Ill fir-"b .-<,/


B

tJ

r-3t.oi,t-'
kgf m, 10.5 4 tbf.ft)

Installthe under cover in the reverseorder of removal,and push the clip ponions into place securety.

Removethe bolts,then removethe glove box. g 4 . l n s t a l l t h e l o v eb o x i n t h e r e v e r s e r d e ro f o removal.

20-63

Dashboard
Dashboard Side Vent RemovaU Installation
NOTE: . Takecare not to scratchthe dashboard. . Put on glovesto protectyour hands. 1. Removethe dashboard(seepage 20-66). 2. Removethe steeringhangerbeam from the dashboard(seepage 20-68). 3. Removethe screws,then removethe air duct (A) ( f r o m t h e d a s h b o a r dB ) . Locations Fastener
):Screw, 7

Beverage HolderRemoval/ lnstallation


NOTE: . Takecare not to scratchthe dashboard, . Put on glovesto protectyour hands. 1. Removethe dashboard(seepage20-66). 2. Removethe screws,then removethe beverage h o l d e r( A ) . Fastener Locations ):Screw.2

6hD
t

4 . Remove the screws, lhen remove the slde vent (A). Fastener Locations ):Screw,4

3 . Installthe beverageholder in the reverseorder of


removat.

o 5 . l n s t a l l t h e i d ev e n t i n t h e r e v e r s e r d e ro f r e m o v a l . s

20-64

Driver'sTray Removal/lnstallation
NOTE: . Takecare not to scratchthe dashboard. . Put on glovesto protectyour hands. 1. Removethe dashboard(seepage 20-66). 2. Removethe beverageholder(seepage 20-64). 3. Removethe screws,then removethe driver'stray (A). Fastener Locations ):Screw.3

Passenger's Tray Removal/ Installation


NOTE: . Take carenotto scratch dashboard. the . Puton gloves protect yourhands. to
1 . Removethe dashboard(seepage 20-66), 2 . Removethe steeringhanger beam from the dashboard(seepage 20-68).

3 . Removethe air duct (seestep 3 on page20-64).


4 . Removethe screws,then removethe passenger's

tray(A). Fastener Locations ):Screw, 8

4, lnstallthe tray in the reverseorder of removal.

5. lnstallthe trav in the reverseorder of removal.

20-65

Dashboard
Dashboard Removal/lnstallation
SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations(seepage23-13)and the (seepage23-14)in the SRS precautions and procedures sectionbeforeperformingrepairsor service. NOTE: . When prying with a flat-tipscrewdriver, wrap it with protective tape aroundthe tape, and apply protective relatedpartsto preventdamage. . Havean assistant help you when removing and r i n s t a l l i n gh e d a s h b o ad . t . Takecare not to scratchthe dashboard, body, and other relatedparts. . Put on glovesto protectyour hands. code for the radio, 1. Make sure you have the anti-theft for then write down the frequencies the preset buttons. the Disconnect negativecablefrom the battery,and wait at leastthree minutesbefore beginningwork. Removethese items: . Driver'sdashboardlower cover (seepage 20-59) . Driver'sdashboardunder cover (seepage 20-60) . Passenger's dashboardlower cover (seepage 20-63) . Glove box (seepage 20-63) . Consoles, front and rear (seepage 20-57) . Shift levertrim {seepage 20-61) . Centerpanel (seepage 20-62) . Kick panels,both sides(seepage 20-50) . A-pillartrim. both sides(seepage 20-50) . Steeringcolumn (seepage 17-9) Removethe shift lever (seepage 13-51). door, gently pull From outsideof the passenger's out along the edge of the dashboardside cover (A) the upper to release the hooks (B),then release (C),to removethe cover. hook 4. From the centerpanelopening,removethe screws, then removethe centerbracket(A).
FastenerLocations ):Screw,2

20-66

Driver's side: 7. From underthe dash,disconnect the interiorwire harnessconnector(A),driver'sdoor wire harness (B),side turn signallight connector(C). connectors roof antennaconnector(D),antennalead (E).clutch (F), switch connectors and brakeswitch connector (G),and disconnect floor wire harness the connectors(H)and engine compartmentwire (l)from the under-dash harnessconnectors fuse/ r e l a vb o x ( J ) .

Middle portion: 8. Disconnect floor wire harnessconnectors(A) the a n d c o m b i n a t i o n u b h a r n e sc o n n e c t o ( B ) . s s r

Passenger's side: 9. From under the dash,disconnect the dashboard (A),EPSsubharness wire harnessconnectors connectors(B),enginecompartmentwire harness connectors(C),A,/C subharness connectors(D), passenger's door wire harnessconnectors {E),and s i d et u r n s i g n a l i g h tc o n n e c t o( F ) . r

1 0 . D e t a c h l l o f t h e h a r n e s s n d c o n n e c t oc l i p s . a a r

(cont'd)

20-67

Dashboard
Dashboard Removal/lnstallation (cont'd)
11. From outsidethe driver'sdoor, removethe caps (A), then removethe bolts (8, C, D),and lift up on the dashboard(E)to releaseit from the guide pins (F.G) on the body. Fastener Locations B>rBolt.3 C>: Bolt,2 D>: Bolt,2

Steering Hanger Beam Replacement


NOTE:Put on glovesto protectyour hands. 1, Removethe dashboard(seepage 20-66). 2. Removethese items from the dashboard: . . . . lnstrumentpanel (seepage 20-59) Driver'spocket(seepage20-60) ( G a u g e s s e m b l y s e ep a g e2 2 - 6 4 ) a Passenger's airbag(seepage 23-'l14)

m6[-,,,,",",,-,F6't---'' ffi'!-v{/-

Kr*

w-

Remove screws, thenremove glovebox the the (A). striker


FasteneaLocations ):Screw,4

^/761:
/ , {2.2kgf m, 16lbf.ftl

$7:

mm ,. r:; 8 x 1.25 22Nm (2.2 kgf.m, 16lbf.ft)

through the front Carefullyremovethe dashboard d o o ro p e n i n g .

1 3 .lnstallthe dashboardin the reverseorder of


removal,and note these items: . Make sure the dashboardfits onto the guide pins correctly. . A p p l y l i q u i dt h r e a dl o c kt o t h e d a s h b o a r d mounting bolts of the middle portion before reinstallation. . Beforetighteningthe bolts,make sure eachwire harnessand control cablesare not pinched. . Make sure the connectorsare plugged in properly,and the antennalead is connected propeny. . Reconnect negativecableto the battery. the . Enterthe anti-theftcode for the radio,then enter the customer'sradio stationpresets. . Resetthe clock. . D o t h e E C M / P C Md l el e a r np r o c e d u r es e ep a g e i i '1-139). 1

20-68

4. Removethe bolts (A) and screws(B)securingthe ( d a s h b o a r dC )a n d s t e e r i n g a n g e rb e a m( D ) ,a n d h disconnect the power mirror switch connector(E) and cruisecontrol main switchconnector(F). S e p a r a t eh e d a s h b o a r d n d s t e e r i n g a n g e rb e a m . t a h Faslener Locations A>rBolt,4 B>:Screw,9

5 . I n s t a l l t h e e a mi n t h e r e v e r s e r d e ro f r e m o v a l , b o and note these items: . N 4 a ks u r et h e d a s h b o a r d i r e h a r n e s s G ) i s n o t ( e w pinched. . Make sure the connectorsare plugged in properly.

5 N.m {0.5kgf m,4lbf,ftl

20-69

Seats
ComponentLocationIndex

REAR SEAT page20-80 Removal/lnstallation, LatchReplacement, Seat-back page20-81 Seat-back StrikerReplacement, page20-81 Seat'back CoverReplacement, page 20-82 SeatCushionCoverReplacement, page20-84

FRONTSEAT page20-i 1 Removal/lnstallation, page Disassembly/Reassembly-Driver's, 20 73 page Disassembly/Reassembly-Passenger's, 20-74 page20-75 SeatCoverReplacement,

20-70

Front Seat Removal/lnstallation


For some models:SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations(seepage (seepage 23-'13) the precautions and and procedures 23-14)in the SRSsectionbefore performingrepairsor service. NOTE . When prying with a flat-tipscrewdriver, wrap it with protective tape to preventdamage. . Takecare not to scratchthe body or tear the seat covers. . Put on glovesto protectyour hands. 1, Make sure you have the anti-theft code for the radio, then write down the frequencies the preset for butlons. Disconnect negativecablefrom the battery,and the wait at least3 minutesbefore beginningwork. 4. Removethe bolts securingthe front seat. Fastener Locations

> : Bolt,

3 . Removethe seattrackend covers(A)from the back


of both seattracks. Outef:
1 0 x 1 . 2 5m m

lnner:

(cont'd)

20-71

Seats
(cont'dl FrontSeatRemoval/lnstallation
Lift up the front seat,then detachthe harnessclip (A).and disconnect the seat belt switch connector ( B )a n d s e a tb e l tb u c k l e e n s i o n ec o n n e c t o( C ) .l f t r r th w , e q u i p p e d i t h a s i d ea i r b a g d i s c o n n e c t e s i d e s a i r b a g o n n e c t o ( D ) ,a n d o n t h e p a s s e n g e r 's e a t , c r r T th d i s c o n n e c t e O P D Su n i tc o n n e c t o( E ) . h e p a s s e n g e r 's e a ti s s h o w n ,t h e d r i v e r ' s e a ti s s s e x c e p ti t h a sn o O P D Su n i tc o n n e c t o r . similar

carefullyremovethe 6 . With the help of an assistant, front seatth rough the front door opening. o , s 7 . I n s t a l l t h e e a ti n t h e r e v e r s e r d e ro f r e m o v a l a n d notethese rtems: . l\4ake sure each connectoris plugged in properly. . A p p l y l i q u i dt h r e a dl o c kt o t h e s e a tm o u n t i n g bolts before reinstallatlon. . Reconnect negativecableto the battery. the . Enterthe anti-theft code for the radio,then enter the customer'sradio stationpresets. . Resetthe clock. . Do the ECM/PCM idle learn procedure(seepage 11 - 1 3 9 ) .

20-72

- Driver's FrontSeat Disassembly/Reassembly


For some models:SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations(seepage 23-13) (seepage 23-14)in the SRSsectionbefore performingrepairsor service. and the precautions and procedures NOTE: . Takecare not to tear the seamsor damagethe seatcovers, . Put on glovesto protectyour hands. . When prying with a flat-tipscrewdriver. wrap it with protective tape to preventdamage. ' Apply multipurposegreasetothe moving portion of the seattrack. . To preventwrinklesin the seat cushioncover,stretchthe materialevenlyoverthe pad.
Release seatcushion the coverfrom the cushion f r a m es p r i n g .

SEAT-BACK

10 x 'l.25mm 47 N.m {4.8kgf.m, 35 rbt.ft)

WIRETIE

RECLINE COVER

RECLINE KNOB

20-73

Seats
- Passenger's FrontSeat Disassembly/Reassembly
For some models:SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations(seepage23-'13) (seepage 23-14)beforedoing repairsor service. and procedures and the precautions NOTE; . Takecare not to tear the seamsor damagethe seatcovers . Put on glovesto protectyour hands. . When prying with a flat-tipscrewdriver, tape to preventdamage wrap it with protective . Apply multipurposegreaseto the moving portion of the seattrack . To Drevent wrinklesin the seat cushioncover,stretchthe materialevenlyover the pad. . lvlake cable is connectedproperlyon each side sure the rear seat access . Replace any damagedclips,and replacethe wire ties with new ones SEAT"BACK
SIDEAIRBAG HARNESS Release seatcushion the coverfrom the cushion f r a m es p r i n g .

10 x 1.25mm 47 N.m (4.8kgf.m, 3s rbf.ft) OPDSHARNESS HANGER SPRING

COVER CENTEB WIRETIE CUSHION SEAT FRAME/SEAT TRACKS

/
REAR SEAT CABLE ACCSS
,/CLIP

*r(".o, ACCESSKNOB

,/

/-

N
/

v/

I
SLIDE LEVER

/ H o o K RECLINE KNOB
RECLINE COVER

20-74

Front SeatCoverReplacement
For some models:SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations(seepage (seepage 23 13)and the precautions and procedures 23-'14) the SRSsectionbeforeperforming repairsor in service, NOTE: . Takecare not to tear the seamsor damagethe seat covers, . On the passenger's seatwith side airbag,do not pad, and keep touch the OPDSsensorin the seat-back it away from oil. Oil can corrodethe sensorcausingit to fail. . Puton glovesto protectyour hands. forward. 3 . Foldthe seat-back t 4 . R e l e a s eh e h o o k s( A ) ,a n d u n z i p h e s e a t - b a c k t c o v e r( B ) .

Cover Seat-back
'L Removethe front seat isee page 20-71).

F 2. W i t h s i d ea i r b a g : r o mu n d e rt h e s e a tc u s h i o n , detachthe side airbagconnectorclip (A),and on seat,detachthe OPDSunit the passenger's ( e c o n n e c t oc l i p ( B ) .R e l e a s t h e h o o ks p r i n g s C ) r f f r o m t h e s e a tc u s h i o n r a m es p r i n g{ D ) ,t h e n p u l l the guide cover (E)back,and removethe wire ties (F).The passenger's seat is shown, the driver'sseat is svmmetricalexceptit has no OPDSunit connector.

(cont'd)

20-75

8 . Using a flat-tipscrewdriverwrappedwith
protective tape, insert it into the hook portions ( s e v e n l a c e so f t h e h e a d r e srte a rt r i m i A ) f r o m t h e p ) headrest front trim side. Prv up the hooks (B)to front trim (Di release labs (C)of the headrest the p u l l i n g h e h e a d r e sftr o n tt r i m f o r w a r d , n d a t while removethe tflm. D /

cover 9. Unzipthe headrestportionof the seat-back ( A ) ,t h e n r e m o v et h e z i p p e r B ) ,a n d r e m o v et h e i cover.

1 0 .installthe cover in the reverseorder of removal,


and note these items: . Fit all the hooksof the headrest front trim into the t h o l e si n t h e h e a d r e sr e a rt r i m ,t h e n p u s ho n t h e h e a d r e sttr i m u n t i lt h e h o o k ss n a pi n t o p l a c e . . To preventwrinkleswhen installinga seat back cover, make sure the materialis stretchedevenly over the pad beforesecuringthe clips, hooks, a n d h o o ks p r i n g s . . M a k es u r et h e s i d ea i r b a gh a r n e s sO P D S , seat).and rear seataccess harness{passenger's seati are routed properly. cable(passenger's . lf necessary, reinitialize OPDScontrol unit the ( s e ep a g e2 3 - 1 2 4 ) .

(cont'd)

20-77

Seats
Front Seat CoverReplacement {cont'd)
SeatCushion Cover
1. Removethe front seat (seepage 20,71). 2. Removethese items from the front seat: . Reclinecover,driver's seat (seepage 20-73) passenger's seat {seepage 20-7 4l . Frontseat belt buckle{seestep 4 on page 23-6) 3. From underthe seat cushion,detachthe side airbagconnectorclip, and on the passenger's seat, detachthe OPDSunit connectorclip. Release the hook springsfrom the seatcushionframe spring, then pull the guide cover back,and removethe wire ties. 4. Release hooks(A). the Inside: Release seat-back the cover (A)from the cushion frame spring (B),and release the hooks(C)from u n d e rt h e s e a tc u s h i o n .

Outside:

20-78

c 6 . R e m o v e h e s e a tc u s h i o n o v e r( A )w i t h t h e s e a t t cushion pad from the seat cushionframe.

8. Installthecover in the reverseorder of removal, and note these items; . To preventwrinkleswhen installlnga seat cushioncover, make sure the materialis stretchedevenlyover the pad beforesecuring t h e c l i p sa n d h o o k s . . Make sure the side airbag harnessand OPDS seat)are routed properly. harness(passenger's . Replace any clips you removedwith new ones ( A ) .I n s t a l l t h e m i t h c o m m e r c i a l l a v a i l a b l e w y upholsteryring pliers (B).

1 . Pull backthe edge of the seatcushioncover all the the clips {A),then remove way around.and release the seat cushioncover (B).

r
: r * F +

{,
r ?

20-79

Seats
RearSeat Removal/lnstallation
NOTE: Takecare not to scratchthe body or tear the seatcovers. '1. Removethe rear seat as shown.To removethe seat-back, removethe front portion of the cargofloor mar lsee page 20-52).

2. Installthe seat in the reverseorder of removal,and note these items: 'Beforeinstallingthecenteranchorboltsontheseat-backwiththecentershoulderbelt,makesurethereareno twists or kinksin the belt. . Make sure the seat-backs lock securelv.
Fastener Locations

A > : B o l t , 2 B > r B o l t 1 C > : B o t t1 , ,


/-<.{\.-K\| J ] . P F.i\-- H A P t-

D >: Clip, 2 lltl agr f ( 1

r_r+*.

VtSEAT.BACK CENTER HINGE


BUSHING

8 x 1.25mm 22 N.m 12.2 m, 16lbf.ft) kgt

CENTER PIVOTBOLT 8 x 1.25 mm 22 N.m


{2.2kgf.m, 16lbf.ftl RIGHTSEAT-BACK

\'7

LEFT SEAT.BACK

CENTER BELT

PIVOTBUSHING

PIVOT BUSHING

CENTER ANCHOR BOLT 7/16-20UNF 32Nm (3.3kgf m.24 lbt ftl

SEATBELTBUCKLE

6x1.0mm 9.8Nm {1.0kgf.m,7.2lbf.ft)

HOOK SEAT CUSHION

20-80

LatchReplacement RearSeat-back
(seepage 20-80). 1 . Removethe seat-back cover (seepage 20-82). Removethe seat-back pad {A) from the seat-back Removethe seat-back with centershoulder frame (B).On right seat-back belt,passthe centerbelt (C)through the hole in the pad. seat-back

Striker Replacement RearSeat-back


NOTE: Takecare not to scratchthe interiortrim. 1 . R e m o v e h e r e a rs i d et r i m p a n e l( s e ep a g e2 0 - 5 ' l ) . t 2. Removethe bolts,then removethe seat-back striker(A). Fastener Locations ) : Bolt,2

,-;1
8 x 1.25mm 22 N m 12.2kgl rn, 16 tbf.ft)

latch Removethe bolts,then removethe seat-back (A)from the seat-back frame (B),and releasethe pivot pin {C)of the latch lever (D)from the seat' backf rame. Fastener Locations

i o s 3 . l n s t a l l t h e t r i k e r n t h e r e v e r s e r d e ro f r e m o v a l , and move the striker(A) up or down until it is latch {B). centeredin the seat-back

lnstallthe latch in the reverseorder of removal,and locksand unlocksproperly. make sure the seat-back

20-81

Seats
RearSeat-back CoverReplacement
NOTE: . Takecare not to tear the seamsor damagethe seat covers. . Put on glovesto protectyour hands. '1. (seepage 20-80). Removethe seat-back Removethe headrest. Pull up the latchcover (A)to teleasethe clips.then remove it.
Fastener Locations ) : Clip,4

5. On right seat-backi Using a Torx T30 bit, remove the bolts,then removethe belt holdertrim (A),and removethe trim from the centerbelt (B). Fastener Locations ) : Bolt, A*\./6x1.0mm 9.8Nm (1.0kgf.m,7.2lbf.ft)

1W
Release hook (A),and unzipthe seat-back the cover (B).The right seat-back shown. the left seat-back is i ss i m i l a r .

4 . Pull up the outsideedge of the latch lever cover (A)

to releasethe clips, and release the cover from the p i v o tp i n s( B )o f t h e l a t c hl e v e r{ C )w h i l e p u l l j n g h e t


latch lever. Fastener Locations D : Clip,2 i\r*

rJ

20-82

cover (A),and 7. Pull backthe edge of the seat-back r e l e a s eh e c l i p s{ B ) . t

cover (A)from the seat-back 9. Removethe seat-back pad (B).On right seat-back with centershoulder belt, passthe centerbelt (C)through the hole in the cover. seat-bacl(

cover,and pull Pull backthe edge of the seat-back pad frame {A) from the seat-back out the seat-back t { B ) ,t h e n p u l l o u t t h e h e a d r e sg u i d e( C )w h i l e , p i n c h i n g h e e n d o f t h e g u i d e s a n d r e m o v et h e m . t

1 0 ,lnstallthe cover in the reverseorder of removal,


and note these items: . To preventwrinkleswhen installinga seat-back cover, make sure the materialis stretchedevenly over the pad beforesecuringthe hooksand clips . On right seat-back: When installingthe seat-back frame to the pad, slip the centerbeltthrough the cover and pad. hole in the seat-back . Replace you removedwith new ones. any clips y I n s t a ltlh e m w i t h c o m m e r c i a l l a v a i l a b l e upholsteryring pliers.

20-83

Seats
RearSeat CushionCoverReplacement
'1. Removethe rear seat cushion (seepage 2O-80). Release the clips (A)from under the seat all c u s h i o n a n d f o l d b a c kt h e s e a tc u s h i o n o v e r( B ) . , c 4. Installthecover in the reverseorder of removal, and note these items; . To preventwrinkles,make surethe materialis stretchedevenlyover the pad beforesecuring t h ec l i p s . . Replace any clips {A) you removedwith new o n e s .I n s t a ltlh e m w i t h c o m m e r c i a l l a v a i l a b l e y u p h o l s t e r yi n g p l i e r s( B ) . r

B Pull backthe edge of the seatcushioncover all the way around,and release the clips (A),then remove the seatcushioncover.

\
iw F 1., 1L +. ts+'

l-,+

,+

r
l

20-84

Bumpers
Front BumperRemovaUlnstallation
NOTE: . H a v ea n a s s i s t a nh e l py o u w h e n r e m o v i n g n d i n s t a l l i n gh e f r o n t b u m p e r . a t t . Takecare not to scratchthe front bumper and body. . Puton glovesto protectyour hands. 'L Removethe front bumper as shown.

, o 2 . I n s t a l l t h e u m p e ri n t h e r e v e r s e r d e ro f r e m o v a l a n d n o t et h e s ei t e m s : b . Make sure both front side markerlight connectors are plugged in properly. . Make sure the front bumper engagesthe hooksof the side spacersand upper beamson both sidessecurely. . Replace nydamaged lips. a c Fastener Locations
A ) , Screw, 2

B >: Screw,2

C>:Bolt.4

D>:Clip,7

E>:Clip,2

{D[]

k/- '

*S

=$
t

ABSORBER

SIDESPACER UPPER BEAM LEFTFRONT SIDEMARKER LIGHT CONNECTOR

' * D BUMPER

e 3

INNER FRONT FENDER BUMPER FEONT


C l

ti-\
I
A E

AIR SPOILER FRONT SPOILER PLATE AIR SPOILER PLATE 6 x 1 . 0m m 9.8 N.m (1.0kgt.m,7.2lbf.ft)

20-85

Bumpers
RearBumperRemovaUlnstallation
NOTE: ' Havean assistanthelp you when removingand installingthe rear bumper. . Takecare not to scratchthe rear bumper and body. . When prying with a flat-tipscrewdriver, wrap it with protective tape to preventdamage. . Put on glovesto protectyour hands. L R e m o v e h e r e a rb u m D e r s s h o w n . t a 2. Installthe bumper in the reverseorder of removal,and note these items: . Make sure both rear side marker light connectorsare pluggedin properly. 'Makesuretherearbumperengagesthehooksofthesidespacers,sidebrackets,andupperbracketsonboth sidessecurely. . Make sure the upper spacersof the rear bumper engagethe clips on the body securely. . Replace nydamaged lips. a c
Fastener Locations

A>:Bolt,2

B)

: Screw, 2

c >: Screw, 2
XJ

) : Clip,

/h-

\-P-

ffiI"ut ^*

\s
I

? ri)

SIDEBRACKET

UPPER BRACKET

m , 6x 1 . 0 m / 9.eN.n kgl ,/ 11.0 m, 1.2tbt.ttl ./


SIDESPACER

a
'\

:r
LEFTREARSIDEMARKER LIGHTCONNECTOR

A CAP

A
UPPER SPACER

REAR BUMPER

20-86

Hood
Adjustment
'1. Slightly looseneach hood hinge bolt, 2 . Adjustthe hood (A) alignmentin this sequence. . A d j u s t t h e h o o d r i g h t a n d l e f t , a s w e al s f o r w a r da n d r e a r w a r db y u s i n gt h e e l o n g a t e d o l e so n t h e h o o dh i n g e h , l (B). . Turn the hood edge cushions(C),as necessary, makethe hood iit flush with the body at the front and side to edges.

6x1.0mm 9.8 N.m {1.0kgl.m,7.2 lbf.ftl

6x1.0mm 9.8 N.m {1.0kgf.m,7.2lbf.ft}

3 . Adjustthe hood latch (D)to obtainthe proper height at the forward edge,and move the hood latch right or left until the striker(E)is centeredin the hood latch. Tighteneach bolt securely.

(contd)

20-87

Hood
Adjustment(cont'd)
5. Checkthat the hood opens properlyand locks securely. 6. Apply body paint to the hinge mounting bolts and a r o u n dt h e h i n g e s . 7. Apply multipurposegreaseto each locationof the hood latch and hood hinge as indicatedby the arrows.

HoodSealReplacement
1 . Using a clip remover,detachthe clips,then remove the hood seal (A).Takecare not to scratchthe hood. Fastener Locations

I n s t a l l t h e e a li n t h e r e v e r s e r d e ro f r e m o v a l a n d s o , note these items: . Replace nydamaged lips. a c . P u s ht h e c l i p si n t o p l a c es e c u r e l y .

. :I

20-88

Replacement HoodInsulator
w 1 . D i s c o n n e c h e w i n d s h i e l d a s h e rt u b e s( A ) . tt Fastener Locations : Clip,'10 )

t*'-&

,2V..=-'
( \

the Using a clip remover,detachthe clips. Release t r T h o o k s( B ) , h e n r e m o v e h e h o o di n s u l a t o ( C ) . a k e t care not to scratchthe hood. i o I n s t a l l t h en s u l a t o irn t h e r e v e r s e r d e ro f r e m o v a l , and note these items: . R e p l a c e n yd a m a g e d l i p s . a c . Pushthe clips into placesecurely.

20-89

Hatch
Adjustment
1. Removethe support strut from each side (seepage 20-91). 2 . R e m o v e t h e C - p i l l a r t r i m f r o m e a c h s i d e ( s e e p a g e 2 0 - 5 ' l ) ,d o w n t h l r e a r p o n i o n o f t h e h e a d l i n e r ( s e e andpule page20-54). Takecare not to bend the headlinerexcessively. 3. Removethe reartrim panel (seepage 20-52). 4, Slightly looseneach bolt and nut. 5 . A d j u s t t h eh a t c h( A )a l i g n m e n i n t h e f o l l o w i n g e q u e n c e . t s . Adjustthe hatch hinges(B) right and left, as well as forward and rearward,using th e elongatedholes. 'Turnthehatchedgecushions(C),inoroutasnecessary,tomakethehatch(D).fitflushwiththebodyattheside edges. . Adjustthe fit betweenthe hatch and hatchopening by moving the striker(D).

8 x 1.25 mm 22 N.m {2.2kgf.m,16lbf.ft}

8 x 1.25mm 18 N.m 11.8 kgf.m, 13 lbf.ft)

20-90

HatchSupportStrut Replacement
Tighteneach bolt and nut securely. 7 . Checkthat the hatchopens properlyand locks securery. Reinstall supportstruts securely. the l r 9 . R e i n s t a la l l r e m a i n i n g e m o v e dp a r t s . 1 . With the help of an assistant, use a flat-tip screwdriver(A)to pry the supportstrut clips (B) from each end of the supportstrut (C)at the hatch and body, then release the supportstrut from the pivot bolts (D).Do not removethe clips from the supportstrut.

1 0 .Apply multipurposegreaseto the pivot portion of


the hatch hinges{A) as indicatedby the arrows.

D 8 x 1.25 mm 22 N.m(2.2 kgf.m, lbf ft) 16 2 . Set the clips (A) to the original position,then reattach the supportstrut (B)on the pivot bolts (C) pushingon the supportstrut. by

20-91

Hatch
HatchWeatherstripReplacement
p 1 . R e m o v e h e h a t c hw e a t h e r s t r i{ A ) b y p u l l i n g o u t t on it.

a t 2 . L o c a t eh e p a i n t e d l i g n m e n m a r k{ B )o n t h e h a t c h t Allgn the paintedmark with the weatherstrip. alignmenttab in the the centerof the hatchopening, p l a n d i n s t a l t h e h a t c hw e a t h e r s t r i a l l t h ew a y around in the directionshown. Make surethere are no wrinklesin the weatherstrip. 3. Checkfor water leaks.

20-92

FuelFill Door
Adjustment
1. Removethe nut (A),and removethe fuel fill door o p e ns p r i n g{ B ) . 7. Apply multipurposegreaseto each location indicatedby the arrows.

5x0.8mm 1.8Nm (0.18kgf.m, 1.3rbf.ft) >t=r'

8 . Apply body paint to the hinge mounting bolts and around the hinges,

2 . S l i g h t l y o o s e n h e h i n g em o u n t i n gb o l t s( A ) . l t 3 . A d j u s tt h e f u e lf i l l d o o r ( B )i n o r o u t u n t i li t ' sf l u s h
with the body, and up or down as necessary to
a^rr.li7a tha n.nc

T i g h t e n h e h i n g em o u n t i n gb o l t s . t 5 . R e i n s t a l l t h f u e lf i l l d o o r s p r i n g . e 6 . Checkthat the fuel f ill door opens properlyand lockssecurely, and checkthat the rear of the door is flush with the body.

20-93

Exterior Trim
FrontGrille Replacement
1 . Removethe front bumper (seepage 20-85).

2 . Removethe front grille (A),Takecare not to scratch


the front bumper (B). -1 -2 -3 -4 Removethe screws (C). Removethe clips (D). Release bottom hooks(E)ofthe grille, the Pull out the boftom of the grille to release the u p p e rh o o k s( F ) . - 5 P u l lo u t t h e g r i l l et o r e l e a s eh e s l i t s( G ) f r o m t the ribs {H),then removethe grille.
FastqnErLocations C >:Screw.4 D ) : Clip, 4 ll

-S---:
F

i")

g o 3 . I n s t a l l t h e r i l l ei n t h e r e v e r s e r d e ro f r e m o v a l , a n d r e p l a c e n yd a m a g e d l i p s . a c Reinstall front bumper. the

20-94

Cowl CoversReplacement
1 . R e m o v e h e w i n d s h i e l d i p e r a r m s ( s e ep a g e2 2 - 1 4 5 ) . t w 2. Removethe windshieldsidetrim from both sides(seestep 2 on page 20-19). 3. Pullthe hood rear seal (A) away from the cowl covers,then remove it, and using a clip remover,detachthe clips (B)from the cowl covers.Takecare not to scratchthe cowl covers. Fastener Locations B> rClip,3 C>:Clip,8

:- :::: = - --::;-:

4 . Detachthe clips (C)by carefullypulling the passenger's cowl cover {D) upward,to release the hooks{E),and pull out the cover forward to release the hooks(F),then removethe cover.Takecare not to scratchthe body, Detachthe clips (C)by carefullypulling the driver'scowl cover (G) upward.and pull out the cover forward to releasethe hooks(H),then removethe cover.Takecare not to scratchthe body. Installthecovers in the reverseorder of removal,and note these items: . Replace nydamaged lips. a c . Pushthe clip portionsinto placesecurely. . Reinstallboth windshieldside trim properly(seestep 26 on page 20-24).

20-95

Trim Exterior
A-Pillar Corner Trim Replacement
1 . Open the door. Wrap a flat-tipscrewdriverwith protective tape, tape aroundlhe body to and apply protective preventdamage.Carefullyinserta flat-tip screwdrivernext to the upper clip, and detachthe c l i p b y p r y i n go n t h e A - p i l l a r o r n e rt r i m ( A ) .T a k e c care not to scratchthe body and relatedparts. Location Fastener 5 . R e p l a c e n yd a m a g e d l i p s . a c H o l dt h e t r i m u p , a n df i t t h e u p p e rc l i p a n d l o w e r c l i p si n t ot h e h o l e si n t h e b o d y ,t h e n p u s ho n t h e t r i m u n t i lt h e c l i p ss n a pi n t op i a c e .

3 . Closethe door half-way.


Pullthe A-pillercornertrim (A) out to detachthe lower clips,then removethe trim. Fastener Locations

20-96

RoofMolding Replacement
1 . Apply protective tape to the body (A).Using a flat-tipscrewdriver wrapped with protective tape (B),pry up on the roof molding (C).Takecare not to scratchthe bodv. 4, Pull up and release the rear bracket(A)from the pin (B),then removethe roof molding (C).

..:.::.l. g

5 . Installthe molding in the reverseorder of removal, and note these items: . T a k ec a r en o t t o d a m a g e h e w i n d s h i e l d o l d i n g . t m . Make sure the roof molding is installedsecurely. Pull up and slidethe roof molding to release the front bracket(D)from the pin (E). Pull up the front portion of roof molding.

20-97

Exterior Trim
RearLicense Trim Replacement
NOTE:Put on glovesto protectyour hands. 1. Removethe hatch lower trim panel (seepage 20r 3 . F r o mi n s i d e h e h a t c h , e l e a s eh e c l i p s( A , B ) w h i l e t t h o l d i n g h e r e a rl i c e n s er i m ( C ) , h e n r e m o v e h e t t t l trim, Takecare not to scratchthe hatch. Fastener Locations 2. On insidethe hatch.removethe bolts securingthe ( r e a rl i c e n s er i m ( A )a n d h a t c hl o c kc y l i n d e r B ) . t Fastener Locations > : Bolt,2 A>:Clip,2 B>:Clip.2

cHl

:t+

\ ! -

-)

4 . I n s t a l l t h er i m i n t h e r e v e r s e r d e ro f r e m o v a l a n d , t o

note these rtems: . Replace any damagedclips. . Pushthe clip portionsinto placesecurely.

6x1.0mm 9.8 N.m (1.0kgf.m,7.2lbf.ftl

20-98

HatchSpoilerReplacement
NOTE:Put on glovesto protectyour hands. 'l. Removethe hatch upper trim (seepage 20-53). 4 . F r o mi n s i d e h e h a t c h , e l e a s eh e c l i p s , h i l e t r t w ( p u l l i n g h e h a t c hs p o i l e r A )a w a y ,a n d r e l e a s eh e t t fasteners(B),then removethe spoiler.Takecare not to scratchthe body. Fastener Locations . > : C l i p2 3. From insidethe hatch,removethe bolts {A} and n u t s( B ) .
Fastener Locaiions

2. Removethe high mount brakelight (seepage2282).

A>: Bolt,2 Bar Nut,

fi'f$t-uLt*

/,fl v_/

$A .
5 . I n s t a l l t h e p o i l e ri n t h e r e v e r s e r d e ro f r e m o v a l , s o and note these items:
5x1.0mm 9.8Nm (1.0kgf.m.7.2lbf.ft)

Replace nydamaged lips. a c Replace any damagedfasteners. Before installingthe fastenerto the spoiler,cleanthe spoilerbonding surfacewith a sponge d a m p e n e dn a l c o h o l G l u et h e f a s t e n e w i t h i r . a d h e s i v ea p e( 3 M 5 6 7 1 , r e q u i v a l e n t ) t t h e t o o spoiler. Pushthe clip and fastenerportions into place securely.

20-99

Trim Exterior
EmblemReplacement
NOTE: When removingthe emblem,take care not to scratchthe body. 1. To removethe front "H" emblem and front type emblem, removethe front bumper (seepage 20-85)

2. Cleanthe bonding surfacewith a spongedampenedin alcohol.After cleaning,keepoil, grease,and water from getting on the surface. w 3 . A p p l yt h e e m b l e m , h e r es h o w n . . W h e n i n s t a l l i n gh e s i d ei - V T E C m b l e mo n t h e b o d y ,a l i g nt h e a p p l i c a t i otn p ew i t h t h e e d g eo f t h e w h e e la r c h , e a t tape. then pressthe emblem into place,and removethe application . ' 0 3 m o d e l : h e n i n s t a l l i n gh e L E Ve m b l e mo n t h e q u a r t e r l a s s , l i g nt h e a p p l i c a t i o t a p ew i t h t h e e d g eo f t h e g a n W t , g , t b l a c kc e r a m i c n d a l i g n m e n m a r ko n t h e q u a r t e r l a s s t h e n p r e s s h e e m b l e mi n t o p l a c e a n d r e m o v et h e a t a p p l i c a t i ot a p e . n

FRONT TYPEEMBLEM

FBONT"H" EMBLEM FRONT"H" EMBLEMBASE FBONTGRILLE SCREWS

FRONT EMBLEMPLATE Si NUTS PUSH

PINS FRONT GRILLE FRONT GRILLE

20-100

REARCIVICEMBLEM

LEVEMBLEM (Left sideonly) ('03model)


REAR VERSION EMBLEM SIDE|-VTEC EMBLEM

"H" REAR EMBLEM


Unit: mm {in.l Adhesive tape: 3M 4213E, equivalent o. Thickness:0.8 mm (0.03in.) "H'' EMBLEM REAR APPLICATION TAPE Edoeol the blackceramic.

Align. HATCHLINE REARLICENSE TRIM REAR EMBLEM si

LEVEMBLEM Ontoinside face


REARSiR EMBLEM (Canada)

of the guarterglass.

34 11.3)
, ilg

(1.93)

=-t

I
50 {'!,9?)

.,!!ll,'nt (1.s31

CIVICEMBLEM

E d g eo f t h e hatch.

ADHESIVE TAPE i.WEC SIDE EMBLEM


Right Side:

Edge of the hatch.

SIDEi-VTECEMBLEM
Left Side: . 114(4.49)

63 (2.5)

F.l^6

^l

rh-

wheelarch.

.=4,
BODY LINE

y' Li.Est
BODY LINE TAPE

112

Edgeof the wheel arch.

APPLICATION TAPE

o"f,r,ao.o"

(5'5s)

4. After installingthe front "H" enblem and front type emblem, reinstallthe front bumper.

20-101

Fenderwell
Replacement FrontInnerFender
NOTE:Takecare not to scratchthe body. 1, Removethe front inner fender (A). -1 On the backofthe wheel arch,removethe screws(B). - 2 F r o mu n d e r t h e f r o n tb u m p e r ( C )r e m o v e t h e s c r e w B )s e c u i n gt h e f r o n t b u m p e r . p l a s h h i e l d( D ) ,a n d f r o n t ( r s s , fender,and removethe clip (E)securingthe front air spoiler,front bumper,and front inner fender. inner - 3 F r o m t h e w h e e la r c h ,r e m o v e h e c l i p s{ F ,G ) s e c u r i n gh e f r o n t i n n e rf e n d e r( a n ds p l a s h h i e l d ) n t h e b o d y . o t t s - 4 R e l e a s t h e h o o k( H )o f t h e s p l a s h h i e l d , t h e n e m o v e t h e f r o n i n n e r f e n d e r . r t e s Locations Fastener B):Screw,4 E>:Clip,1

F > : C l i p ,1

0*

,ws

G):Clip,8

2. Installthe inner fender in the reverseorder of removal,and note these items:


. R e p l a c e n yd a m a g e d l i p s . a c . P u s ht h e c l i p si n t o p l a c es e c u r e l y .

20-102

Front FenderFairingReplacement
(see 1 . Removethe front inner fender as necessary p a g e2 0 - 1 O 2 1 . Open the front door. From outsidethe door, t r e m o v e h e u p p e rc l i p ( A ) ,a n d f r o m i n s i d e h e d o o r , t removethe lower clip (A) securingthe front fender f a i r i n g( B )a n d f r o n tf e n d e r( C ) . Fastener Locations 3. From the wheel arch, removethe clip (A),and releasethe clip (B),then removethe front fender f a i r i n g( C ) . Locations Fastener A > : C l i p1 , B > : C l i p1 ,

J*.' -@

A>:Clip,2

J<a-'

4 . Installthe fender fairing in the reverseorder of

removal,and note these items: . Replace nydamaged lips. a c . R o u t e h e s i d et u r n s i g n a l i g h t h a r n e s s ( A ) t through the slit (B)of the front fender fairing (C). . B e f o r ei n s t a l l i n gh e c l i p so f t h e d o o r u p p e ra n d t lower ponions, installthe front fender fairing (A) to the front fender (B) properlyas shown. . Pushthe clips into placesecurely.

o --____--

20-103

Fenderwell
FuelPipeProtectorReplacement
1 . R e m o v e h e c l i p s , h e n r e m o v et h e f u e l p i p e t t

RearAir Outlet Replacement


1 . R e m o v e h e r e a rb u m p e r( s e ep a g e2 0 - 8 6 ) . t r n e r e a ra t r the body.

protector(A).Takecare not to scratchthe body.


Fastener Locations > : Clip,4

p I n s t a l l t h e r o t e c t o irn t h e r e v e r s e r d e ro f r e m o v a l , o and note these items: . R e p l a c e n yd a m a g e d l i p s . a c . P u s ht h e c l i p si n t o p l a c es e c u r e l v .

I n s t a l l t h e i ro u t l e t s y p u s h i n g n t h e h o o k a b o p o r t i o n s n t i l t h eh o o k ss n a pi n t o p l a c e . u

20-104

Openers
ComponentLocationIndex

HATCH LOCK CYLINDER page Replacement, 20-1'l 1 HATCH HANDLE Replacement, page 0-110 2
HATCHLATCH page20'110 Replacement,

FUELFILLDOORLATCH page 20-107

FUELFILLDOOROPENEB CABLE page 20-107 Replacement, FUELFILLDOOROPENER page20-109 Replacement, I{OOD RELEASE HANDLE page20-'106 HOODOPENERCABLE page20-106 Replacement,

z)-105

Openers
Hood OpenerCableReplacement
NOTE: . Put on glovesto protectyour hands. . Takecare not to scratchthe body and relatedparts. l. Removethese items: . Front bumper (seepage 20-85) . F r o n ti n n e rf e n d e r , e f t s i d e ( s e e p a g e 2 0 - 1 0 2 ) l . Kick panel,left side (seepage 20-50) 2. Disconnect hood openercable(A) from the hood latch {B) (seepage20-108), the and removethe bolts (C),then removethe hood releasehandle(D)from the body. Fastener Locations C>:Bolt,2 E >:Clip,3
6x1.0mm 9,8 N.m kgl.m, 7.2 lbl.ft) 11.0

@m

l,.t'.

W:"

Using a clip remover,detachthe clips (E),and removethe grommet (F)from the body, then removethe hood openercablefrom the vehicle.Takecare not to bend the cable. 4 . I n s t a l l t h e a b l ei n t h e r e v e r s e r d e ro f r e m o v a l a n d r e p l a c e n y d a m a g e d l i p s . c o , a c

20-106

FuelFill Door OpenerCableReplacement


and the precautions SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations(seepage 23-13) (seepage 23-14)in the SRSsectionbeforeperformingrepairsor service. and procedures NOTE; . Put on glovesto protectyour hands. . Takecare notto scratchthe body and relatedparts. 1. Removethese items from the left side of the vehicle: . D o o rs i l l t r i m { s e ep a g e2 0 - 5 0 ) . R e a rs i d et r i m p a n e l( s e ep a g e2 0 - 5 1 ) (seepage 20-55). 2 . Pullthe carpetbackas necessary
5.

Disconnect fuel fill door openercable (A)from the opener(B) (seestep 3 on page 20-109). the Fastener Locations 1 C >:Cushiontape, , D > : C l i p1

2 E > : Clip,

( g l R 4 . K C m o d e l : e m o v e t h e e f tm i d d l ef l o o rc r o s s - m e m b e ru s s e t s e ep a g e2 0 - 1 1 3 ) . a t t 5 . R e m o v e h e c u s h i o n a p e{ C ) , n d r e l e a s eh e c a b l ef r o m t h e c l i p s( D ,E ) . t 6 . R e m o v e t h e f u efli l l d o o r l a t c h( F ) f r o m t h eb o d y b y t u r n i n gi t 9 0 ' . 7. Removethe fuel fill door openercablefrom the vehicle.Takecare not to bend the cable 8 . I n s t a lt lh e o p e n e r c a b l e i n t h e r e v e r s e o r d e r o f r e m o v a l , r e p l a c e t h e c u s h i o n t a p e , a n d r e p l a c e t h e c l i p i f i t i s oamageo.

20-107

Openers
Hood LatchReplacement
NOTE: . Put on glovesto protectyour hands. . Takecare not to scratchthe body. 1. Removethe bolts,then removethe hood latch (A) from the body. Fastener Locations > i Bolt,3 Installthe hood latch in the reverseorder of removal,and note these items: . Apply multipurposegreaseto each locationof the hood latch indicatedby the arrows. . Make sure the hood openercable is connected properly. . Make sure the cableactuates the latch beforeyou closethe hood, . Adjustthe hood latchalignment(seestep 3 on page 20-87). . M a k es u r et h e h o o do p e n sp r o p e r l y n d l o c k s a securely.

--------------'
6x1.0mm 9.8 N.m (1.0kgf.m,7.2lbf.ft)

Disconnect hood openercable (B)from the the hood latch.Takecare not to bend the cable.

20-108

Replacement FuelFillDoorOpener
1 . Using a flat-tipscrewdriverwrapped with protective tape, detachthe hooks(A) by prying the front side cap (B),then remove it from the left door a t t s i l l t r i m ( C ) , n d l o o s e n h e b o l t ( D )s e c u r i n gh e f u e lf i l l d o o r o p e n e r . 4. Disconnect fuel fill door openercable (A),then the removethe openeriB). Takecare not to bend the c ao t e .

6x1.0mm 9.8 N.m kgf 11.0 m,7.2 lbf.ft)

5 . Installthe opener in the reverseorder of removal, and note these items: lMake sure the openercable is connected properly. lvlake sure the fuel fill door opens properlyand lockssecurely.

2. Removethe left door sill trim (seepage 20-50i. 3 . R e m o v e h e o p e n e r( A l f r o m t h e b o l t{ B ) . t

20-109

Openers
HatchHandleReplacement
NOTE:Put on glovesto protectyour hands. 1. Removethese items: . Hatchlower trim panel (seepage 20-53) . Rear licensetrim panel (seepage 20-98) 2. Removethe rearwindow wiper motor (seepage 22-1461. 3. Disconnect hatch o p e n e rc a b l e1 A ) f r o m h e the t ( h a t c hh a n d l e B ) ,a n d removethe nuts.
Fastener Locations

HatchLatchReplacement
NOTE:Put on glovesto protectyour hands. '1. Removethe hatch lowertrim panel (seepage 2053).

2. Disconnect hatch openercable (A),cylinder rod the (B).hatchactuatorconnector(C).and hatch latch switch connector{D).and detachthe hatch actuator connectorand hatch latch switch connectorfrom the hatch. Faslener Locations ) : Bolt,3

a : Nut,

6x1.0mm 9.8N.m

(1.0 kg{.m,7 2 tbt.{t\

ttb

()rI
a
,t.

4. Pull outthe hatch handle(A),then remove it.

i-'-3;li9#k 1 1 , 0 g tm , 7 . 2 l bfft l

R e m o v e h e b o l t s , h e n p u l l t h eh a t c hl a t c h( E )o u t , t t then remove it. I n s t a l l t h ea t c hi n t h e r e v e r s e r d e ro f r e m o v a l a n d l o , notethese items: . Make sure each connectoris plugged in properly, and the rod and cableare connectedproperly. . l\4ake sure the cable actuates the latch beforeyou c l o s et h e h a t c h . . Make sure the hatch opens properlyand locks securely. I n s t a l l t h e a n d l ei n t h e r e v e r s e r d e ro f r e m o v a l . h o and note these items:

lMake surethe hatch opener cableis connected securely. p M a k e u r e h eh a t c h p e n s r o p e r l y . s t o

20-110

HatchLockCylinderReplacement
NOTE;Put on glovesto protectyour hands. '1. Removethese items: . Hatchlower trim panel (seepage 20-53). . Rearlicensetrim (seepage 20-98). 2. Disconnect cylinder rod (A) the 4. Installthe lock cylinder in the reverseorder of removal,and note these items: . Make sure the rod is connectedproperly. . Make sure the hatchopens properlyand locks securely.

- . .

From outsidethe hatch,removethe bolt securing the lock cylinder{A}.From insidethe hatch,pull the g o l o c kc y l i n d e r u t b y r e l e a s i n t h e h o o k( B ) .
Fastener Location 6x 1.0 m m 9.8Nm (1.0kgf m,7.2lbt.ftl

> : Bolt,1

rS'l-. u-ar

*/t

20-111

Frame
SubframeReplacement
SubframeTorque
NOTE: After looseningthe subframemounting bolts,be sureto replacethem with new ones.

Reference holesalignment:

SUBFRAME

REFERENCE HOLE (Body ide) S

INSTALLATION REFERENCE HOLE (Subframe side)

INSTALLATION REFERENCE HOLE

SCREWDRIVER or TAPERED PUNCH

FRONTSUSPENSION To body. INSTALLATION REFERENCE HOLE

To body. I

n E
SPECIALBOLTS ' 1 4 1 . 5m m x 103 N.m (10.5kgf.m,75lbf.ft) Replace.

20-112

FrameStiffener,Brace, and GussetReplacement


Torque Frame Stiffener, Brace, and Gusset
torque the mounting hardwarein the NOTE:When installingthe middle floor cross member braceor gussets, to following sequence avoid damageto the quarterpanel.

MIDDLE FLOOR CROSS-MEMgER BRACE/GUSSET


SIDEFRAME STIFFENER

m 8 x 1.25 m 29 N.m (3.0kgf m,22 lbf ft)

To body.
U.S.model: 1 0x 1 . 2 5 m m 38 N.m (3.9kgf.m.28lbf.ftl

model: Canada

MIODLE FLOOR CROSS-MEMBER BRACE

MIDDLE FLOOR CROSS.MEMBER GUSSET

..

__!:::-| -

1 0 x 1 . 2 5m m 38 N m (3.9 kgt.m, 28 lbf.ftl

1 0 x 1 . 2 5m m 38Nm (3.9kgf.m,28 lbl.ftl

20-113

Frame
FrameRepairChart
Top view

Unit:mm {in.} o: Inner diametel

a b1 b2 b3 cl c2 c3

Forsublrame o1510.59) Forengine mount e13 (0.511 Forengine mount o13 (0.51) Forengine mount rl3 (0.51) Formanual transmission mouoto13{0.5' Formanual transmission mounto13 10.5' Formanual t.ansmission mo!nt d13{0.51)

o I g h

Fordampermounts11.5{0.45} For damper centero78 (3.07) Fordampermounts11.5(0.451 Fordampeimountd11.5 10.45) Forsubframe o15 {0.591 Localinghole s25 {0.98} Locating holee50 (1.97)

VEFTICAL UNE

20-114

m n p q

Locatinghole d25 (0.981 Fortrailing.rm rl3 10.51) Locatinghole o25 (0.981 Locatinghole s20 (0.79) Trailingarm center Reardampercenter Forupperarm o13 (0.51)

t1, t2

x1 x2

Fortrailingarm d13 (0.511 For upper arm bracketcenterrl5 {0.59) Locating holes13 (0.51) Foruppe.arm o13{0.511 For rear lower arm centr holes50 (1.97) Locating Locatinghole s20 (0.79) Locatinghole o25 (0.981

(cont'd)

20-115

Frame
FrameRepair Chart(cont'dl
Sideview

I
o e I Fordampermounto11.5 {0.45) For damper centerr78 {3.07} (0.45) Fordampermounto11.5 Fordampermountr11.5{0./t5l Forsubtrame el5 10.591 Locatinghole o25 (0.98) Locatinghole s 11.97)

Unitrmm {in.) o: InnerdiameteJ

a b1 b2 b3 cl c2 c3

For subframe015 {0.59} Forengine mount o13 (0.511 Forengine mount 01310.51) Forengine mount 113(0.511 Formanual transmission mount 013{0.51) Formanual trensmission mount 613{0.51} Formanual trrnsmission mounro13{0.51}

s
h i

SECTIOiI AA

BASE UNE

trr2xt.6

VERTICAI LINE

20-116

Frame
FrameRepair Chart(cont'dl
Sideview

I
o e I Fordampermounto11.5 {0.45) For damper centerr78 {3.07} (0.45) Fordampermounto11.5 Fordampermountr11.5{0./t5l Forsubtrame el5 10.591 Locatinghole o25 (0.98) Locatinghole s 11.97)

Unitrmm {in.) o: InnerdiameteJ

a b1 b2 b3 cl c2 c3

For subframe015 {0.59} Forengine mount o13 (0.511 Forengine mount 01310.51) Forengine mount 113(0.511 Formanual transmission mount 013{0.51) Formanual trensmission mount 613{0.51} Formanual trrnsmission mounro13{0.51}

s
h i

SECTIOiI AA

BASE UNE

trr2xt.6

VERTICAI LINE

20-116

m p q

Locatinghole o25 {0.98) Fortrailingarm 613 {0.511 Locatinghole d25 {0.98} Locatinghole r20 {0.79) Trailingarm center Reardamper centel Forupperarm o13 (0.51)

11,t2

xl x2

Fortrailingarm s13 {0.51} For upper arm bracketcenter o15 {0.591 Locating holeo13{0.51} Forupperarm d13{0.51) For rear lower arm centei Locating holeo50{1.97} Locatinghole a20 {0.79} Locetinghole s25 (0.98)

20-117

(Heating, HVAC Ventilation, Air Gonditioningl and


Heating andAir Conditioning
21-2 SpecialTools z Comoonent Location lndex ........ t-'5 A/CService Tiosand Precautions z t-o A,/C Refrigerant Oil ReDlacement z t-o Troubleshooting General lnformation 21-8 Troubleshooting Index ....... 21-9 DTC Symptom Troubleshooting 1ndex.............. 21-10 Description ..................... 21-11 System Circuit Diagram 21-14 D T C r o u b l e s h o o t i n.g. . . . . . . . . .z. . . .t . T . . t- o Recirculation Motor Control .......... CircuitTroubleshooting 21-25 Power Heater Control andGround Troubleshooting ........ 21-27 Circuits Condenser Circuit Fan Troubleshooting ...................... 21-28 Fans Radiator Condenser and Circuit Common ...................... 21-29 Troubfeshooting Compressor Clutch Circuit T r o u b l e s h o o t i n.g . . . . . . . . . . . . 2.1.-.3 . . . . . .0 A,/C Pressure SwitchCircuit ...................... 21-32 Troubleshooting Motor Air Mix Control ............. 21-34 TestandReolacement ModeControl Motor ............. 21-35 TestandReplacement Motor Recirculation Control ............. 21-36 TestandReolacement Evaporator Temperature Sensor and 21-31 Reolacement Test ............. Test ................. 21-38 Power Transistor Heater Panel and Control Push Switch Assemblv ........ 21-38 Removal Installation and DustandPollen Filter Reolacement ..21-39 Blower UnitRemoval and ......21-39 lnstallation Blower UnitComoonents R e D l a c e m e . . t. . . . . . . . . . . . . . . . .2.1 . . . 1. . n . .-4 . Evaporator Core ..21-42 Reolacement *Heater Unit/Core ..21-43 ReDlacement Heater Valve Cable .....21-46 Adjustment .......... CompressorReplacement 21-47 21-48 Check .......... Comoressor Clutch Comoressor Clutch Overhaul.....21-49 Thermal Protector Compressor . . .-5 . R e o 1 a c e m e.n .t . . . . . . . . . . . . . . . .2.1 . . . 1. . Relief Valve Comoressor R e o l a c e m e n.t. . . . . . . . . . . . . . . . .2.1 . . . 1. . . . .-5 . ............ 21-52 Reolacement Condenser Recovery .................. 21-53 Refrigerant ...................... 21-54 Evacuation System 21-55 ......................... CharginS System 21-56 LeakTest.................. Refrigerant 21-57 Tests ........................ A,/C Svstem

HVAC{Heating, Ventilation, and Air Conditioning)


SpecialTools
Ret.No.

Tool Number

DescriDtion Backprobe Set

07sAz-001000A

Otv 2

att-,,/'Tt e^t"'

---2
"-t--'

KCe

T
21-2

Heating and Air Gonditioning


ComponentLocationIndex

VALVE SERVICE {LOW.PRESSUBE SIDEI

EVAPORATOR CORE (Built-in heater the unit) B e p l a c e m ep a , e 1 4 2 nt g 2

SERVICE VALVE {HIGH-PRESSURE SIDEI

RECEIVER/DRYER

COMPRESSOR page21 47 Beplacement, CONOENSEB ClutchCheck,page21-48 page 21-52 Replacement, C l u t c h v e r h a u lp a g e2 1 - 4 9 O , page21-48 ThermalProtector Check, page21 51 ThermalProtector Replacement, p, R e l i eV a l v eR e p l a c e m e n ta g e2 1 5 1 f

Heating and Air Conditioning


ComponentLocationIndex(cont'dl

RADIATOR FAN RELAY Test,page22-51


Tesl, page 22-51

CLUTCH RELAY

Test, page 22-5I

MOTOR RELAY

'-t

t_]]l

BOX UNDER.HOOD FUSE/RELAY

/l

-::--

l-

-l

FAN CONDENSER Test, page 22-51

.\\ -

... A/C PRESSURE SWITCH

RADIATORFAN FAN CONOENSER

21-4

HEATER UNIT/CORE page Beplacement, 21-43

BLOWEN UNIT page Removal Installation, 21-39 and BLOWER UNITCOMPONENTS page Replacement, 21-41

HEATER VALVECABLE page Adjustment, 21-46

DUSTAND POLLEN FILTER page Replacement, 21'39 RECIRCULATION CONTROL MOTOR page Test, 21-36 page Replacement, 21-36
MODE CONTROLMOTOR Test,page21-35 page21-35 Replacement, POWERTRANSISTOR Test,page 21-38

AIR MIX CONTROL MOTOR page Test, 21'34 page Replacement, 21'34
EVAPORATOR TEMPERATURE SENSOR page 21-37 Replacement, Test,page21-37 PUSH SWITCHASSEMBLY page21'38 Removaland Installation,

HEATERCONTROLPANEL page21 38 RemovalandInstallation,

21-5

Heating Air Conditioning and


A/C ServiceTips and Precautions A/C Refrigerant Replacement Oll
R e c o m m e n d eP A Go i l : K E I H I N P 1 0 : d S forms a Compressed mixed with R-134a air c o m b u s t i b l ea p o r . v T h e v a p o rc a n b u r n o r e x p l o d e a u s i n g e r i o u s c s injury. Never use compressedair to pressure test R - 1 3 4 a e r v i c e q u i p m e no r v e h i c l e i r s e t a conditioninsystems. g '120 . P/N38897-P l3-A01AH: m0 i4 fl oz) . P/N38899-P13'A01: m0 i1 1/3fl oz) 40 Add the recommendedrefrigerantoil in the amount listedif you replaceany of the following parts. . T o a v o i dc o n t a m i n a t i o n .o n o t r e t u r n h e o i l t o t h e d t c o n t a i n eo n c ed i s p e n s e d , n d n e v e rm i x i t w i t h o t h e r r a refrigerant oils. . l m m e d i a t e l a f ' t e u s i n gt h e o i l , r e i n s t a l l t h e a po n y r c the container,and seal it to avoid moisture aosorpron. . D o n o t s p i l lt h e r e f r i g e r a no i l o n t h e v e h i c l e i;t m a y t damagethe paint. lf it gets on the paint,wash it off immediately. m t , C o n d e n s e r. . . . . . . . . . . 2 5A\ 5 1 6 l . o z 0 . 9l m p . o z ) '1.4 E v a p o r a t o r . . . . . . . .4 5 m 0 ( 1 1 1 3 I l . o z , l m p . o z ) . .. '10 l L i n eo r h o s e . . . . . . . . . m 0 { 1 / 3f l . o z , 0 . 4m p . o z ) '10 R e c e i v e r / D r y e.r . . m 0 ( ' 1 1f3. o z , 0 . 4m p . o z ) . l l Leakage repair ....25 m0,1516 oz,0.9 lmp.oz) Il . . r C o m p r e s s o r . . . . . . F.o rc o m p r e s s or e p l a c e m e n l , s u b t r a ctth e v o l u m eo f o i l d r a i n e d from the removedcompressorfrom , 1 3 0m 0 ( 4 1 / 3 f l . o z4 . 6 l m p . o z )a n d , d r a i nt h e c a l c u l a t e v o l u m eo f o i l d '130 f rom the new compressor: m0 l i . 4 1 1 f l . o z , 4 . 6m p . o z ) V o l u m eo f 3 removedcompressor= Volume to d r a i nf r o m n e w c o m p r e s s o r . NOTE:Evenif no oil is drainedfrom the removedcompressor, don't d rain more than 50 m0 \1 2/3 fl.oz, ' 1 . 8m p l o z ) f r o mt h e n e w compressor. REMOVED COMPBESSOR NEW COMPRESSOR

t A i r c o n d i t i o n i n ge f r i g e r a no r l u b r i c a nv a p o r r t can irritateyour eyes,nose,or throat. Be carefulwhen connectingserviceequipment. Do not breatherefrigerant vapor. or R T h e a i r c o n d i t i o n i n s y s t e mu s e sH F C - 1 3 4(a - 1 3 4 a ) g P r t r e fr i g e r a n a n d p o l y a l k y l e n e g l y c(o l A G ) e fr i g e r a n o i l , t ( ) w w h i c h a r e n o t c o m p a t i b l e i t h C F C ' 1 2 R - 1 2r e f r i g e r a n t r t l a n d m i n e r a o i l . D o n o t u s e R - ' 1 2e f r i g e r a no r m i n e r a l oil in this system,and do not aftemptto use R 12 t s e r v i c i n g q u i p m e n td a m a g e o t h e a i r c o n d i t i o n i n g e ; e t s y s t e mo r y o u r s e r v i c i n g q u i p m e nw i l l r e s u l t . e d U s eo n l y s e r v i c e q u i p m e ntth a t i s U . L . - l i s t ea n d i s of certifiedto meet the requirements SAE J2210to f r e m o v eR - 1 3 4 ar o m t h e a i r c o n d i t i o n i n s y s t e m . g lf accidental system dischargeoccurs,ventilatethe s w o r k a r e ab e f o r er e s u m i n g e r v i c e . e t a R - 1 3 4 a e r v i c e q u i p m e no r v e h i c l e i r c o n d i t i o n i n g s tested or leaktested systemsshould not be pressure withcompressed ir. a m A d d i t i o n ah e a l t h n d s a f e t yi n f o r m a t i o n a y b e l a obtainedfrom the refrigerantand lubricant manufacturers. . Always disconnect the negativecablefrom the p w a b a t t e r y h e n e v e r e p l a c i n g i rc o n d i t i o n i n g a r t s . . Keepmoistureand dirt out of the system.When p d i s c o n n e c t i na n y l i n e s , l u go r c a pt h e f i t t i n g s g don't removethe caps or plugs until immediately; iust be{oreyou reconnecteach line. ' B e f o r e o n n e c t i n g n y h o s eo r l i n e ,a p p l ya f e w d r o p s c a of relrigerantoil to the O-ring. . W h e nt i g h t e n i n g r l o o s e n i n g f i t t i n g ,u s ea s e c o n d o a wrench to supportthe matchingfitting. . W h e n d i s c h a r g i ntg e s y s t e m u s ea R - ' 1 3 4 a h , station;don't refrigerantrecovery/recycling/charging releaserefrigerantinto the atmosphere.

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A: 130 m0 {4 l/3 tl.oz,4.6lmp.oz)

21-6

RECEIVER A LINE

RECEIVER/DRYER
CONDENSER LINE

Discharge hoseto the compressor x 1.0 mm) : 9.8 N.m {1.0kgf.m,7.2 lbl.ft} {6 (5 Discharge hoseto the condenser x 1.0mml : 9.8 N.m {1.0kgt.m,7.2 lbf ft) (6 x 1.0mm) : 9.8 N.m {1.0kgf,m,7.2 lbt.ft} Condenser line to the condenser Condenserine to the receiver/dryer x 1.0mm} :