Escolar Documentos
Profissional Documentos
Cultura Documentos
com
www.emanualpro.com
Generallnformation
1-2
Chassis
andPaintCodes.......................
1-10
NumberLocations.........
ldentification
Warning/Caution
LabelLocations.......1-11
Under-hoodEmissionsControl
. . . . . . . . . . . . . .1
. .-.1. .5. .
L a b e l. . . . . . . . . .
Lift and SupportPoints
1-19
LiftandSafetyStands.......................
FloorJack
.......................
1-20
.........1-21
Towing
ServicePrecautions
1-22
PaftsMarkingLocations..,.................
for Real-time4WD
Precautions
(Four-wheel
Drivel.........
.................
1-23
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Chassisand PaintCodes
U.S. 1997Model
VehicleldentificationNumber
JHLRD184*VC000001
JHL: HONDAMOTORCO.,LTD
HONDA,Multipurpose
Passenger
Vehicle(MPV)
line, Body and Engine Type
RDl: CR V/82084
Body Type and TransmissionType
8: 5-door/4-soeed
Automatic
Vehicle Grade (Series)
4: LX
5: LX (with ABS)
CheckDigit
Model Year
Vt 1997
C: SaitamaFactoryin Japan(Sayama)
B-84P
NH-552M
NH-592P
R-94
Vehicleldentification Number
and FederalMotor Vehicle
SupermarineBlue Pearl
CypressGreenPearl
SebringSilverMetallic
FlamencoBlackPearl
San MarinoRed
(o
COLORLABEL
INT.COLOR
WPEF
EXT.COLOR
B-84P
KA S2BA1 C
to
www.emanualpro.com
1-2
U.S.1998Model
JHLRD174*WC000001
B20B4t2.01 DOHCSequentialMultiport
Fuel-injected
engine
JHL: HONDAMOTORCO.,LTD
HONDA.Multipurpose
Passenger
Vehicle(MPV)
Line, Body and EngineType
RD1:CR-V/82084
RD2:CR'V/82084
Body Type and TransmissionType
7: 5-door/s-soeed
Manual
8; 5-door/4-soeed
Automatic
MDLA: 4-speedAutomatic
M4TA: 4-speedAutomatic
S B X M : s - s p e eM
danual
MDLA,SBXM:1000001M4TA: 3000001C: SaitamaFactoryin Japan(Sayama)
B-84P
G-82P
NH-552M
NH-592P
R-94
VehicleldentificationNumber
and CanadianMotor Vehicle
SupermarineBlue Pearl
CypressGreen Pearl
SebringSilverMetallic
FlamencoBlackPearl
San MarinoRed
COLORLABEL
INT.COLOR
TYPEF
EXT.
COLOR
8.84P
KA S2BA1 C
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1-3
Chassisand PaintCodes
U.S. 1999Model
Vehicle ldentification Number
JHLRDIT4*XC000001
B2OZ2:2.0
| DOHCSequentialMultiport
Fuel-injected
engine
JHL: HONDAMOTORCO.,LTD
HONDA.Multipurpose
RDlt CR-vlB20Z2
RD2t CR-V1B2OZ2
Body Type and TransmissionType
7: 5-door/5-speed
Manual
8: 5-door/4-spsed
Automatic
MDLA: 4-speedAutomatic
MDMA:4-speedAutomatic
SBXM: s-speedManual
4: LX
6:Ex
Chock Digit
Model Year
X: 1999
MDLA:2000001MDMA:1000001SBXM:2000001-
C: SaitamaFactoryin Japan(Sayama)
B-84P
B-92P
G.95P
NH-578
NH-552M
R,81
SupermarineBlue Pearl
NighthawkBlackPearl
CloverGreenPearl
TaffetaWhite
SebringSilverMetallic
MilanoRed
COLORLABEL
INT.COLOR
TYPEF
EXT.
COLOR
B.84P
KA S2BA1 C
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1-4
Model
U.S.2000
J H L R D 1 7 4 *Y C 0 0 0 0 0 1
B20Z2t2.0I DOHCSeouentialMultiDort
Fuel-injected
engine
JHL: HONDAMOTORCO.,LTD
HONDA,Multipurpose
Vehicle(MPV)
Passenger
Line. Body and EngineType
RDlt CR-V/82022
RD2iCR-v/BzOz2
Body Type and TransmissionType
Manual
7: 5-door/s-speed
8: 5 door/4-soeed
Automatic
MDLA; 4-speedAutomatic
MDMA:4-speedAutomatic
SBXM: s-speedManual
MDLA:3000001MDHA:2000001SBXM:2000001CrSaitamaFactoryin Japan(Sayama)
B-92P
B-95P
G-95P
NH-578
NH-552M
R-81
NighthawkBlackPearl
ElectronBluePearl
CloverGreenPearl
Taffeta White
SebringSilverMetallic
M i l a n oR e d
COLORLABEL
INT.COLOR
TYPEF
EXT,
COLOR
8.92P
KA S2BA1 C
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1-5
Chassisand PaintCodes
Canada1997Model
J H L R D 1 8 5 *V C 8 0 0 0 0 1
B20g4t2.0| DOHCSeouentialMultiDort
Fuel-injected
engine
HONDAMOTORCO.,LTD
HONDA,Multipurpose
Passenger
Vehicle(MPV)
Line, Body and EngineType
RDl: CR-V/B2084
Body Typ and TransmissionTyp
8: s-door/4-soeedAutomatic
MDMA- 1000001
MDMA:4-speedAutomatic
SDMA: 4-speedAutomatic
C: SaitamaFactoryin Japan(Sayama)
B-84P
G-82P
NH-552M
NH-592P
R-94
SupermarineBluePearl
CypressGreen Pearl
SebringSilverMetallic
FlamencoBlackPearl
San MarinoRed
COLORLABEL
INT.COLOR
TYPEF
EXT.COLOR
B-84P
KCS2BC2 C
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1-6
Canada1998Model
J H LR D 17 4 * W C 8 0 0 0 0 1
JHL:HONDAMOTORCO.,LTD
HONDA,Multipurpose
Vehicle(MPV)
Passenger
Lino, Body and EngineType
RD1:CR-V/82084
Body Type and TransmissionType
Manual
7: 5-door/s-speed
Automatic
8: 5-door/4-speed
M4TA: 4-speedAutomatic
SBXM:5-speedManual
SBXM:1000001M4TA: 3000001*
C: SaitamaFactoryin Japan(Sayama)
B-84P
G-82P
NH-552M
NH-592P
R-94
SupermarineBIuePearl
CypressGreen Pearl
SebringSilverMetallic
FlamencoBlackPearl
San MarinoRed
COLORLABEL
INT.COLOR
TYPEF
EXT.COLOR
8.84P
KCS2BC2 C
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1-7
Chassisand PaintCodes
Canada1999Model
Vehicle ldentification Number
J H LR D l T 4 * X C 8 0 0 0 0 1
B20Z2i2.0I DOHCSequentialMultiport
Fuel-injected
engine
JHL:HONDAMOTORCO.,LTD
HONDA,Multipurpose
Passen0er
Vehicle{MPV)
Line, Body and Engin6Type
RD1:CB-Y/B2OZ2
Eody Typ6 and Transmi$ion Type
7: 5-door/5-speed
Manual
8: s-door/4-speedAutomatic
4: LX
5: EX
ChockDigit
Model Yeal
X: 1999
MDMA:4-speedAutomatic
SBXM: s-speedManual
C: SaitamaFactoryin Japan{Sayama)
B-84P
a-92P
G.95P
NH.552M
R-81
VehicloldentificationNumber
and CanadianMotor Vehicle
Safety Standard Certification.
SupermarineBluePearl
NighthawkBlackPearl
CloverGreenPearl
SebringSilverMetallic
MilanoRed
COLORLABEL
INT.COLOR
TYPEF
EXT.
COLOR
B-84P
KCS2BC2 C
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1-8
J H LR D l7 4 * Y C8 0 0 0 0 1
Manulacturer, Make and
Type of Vehicle
JHL:HONDAMOTORCO.,LTD
HONDA,Multipurpose
Passenger
Vehicle(MPV)
Line, Body and EngineType
RDlt CR-VlB2oZ2
Body Type and TransmissionType
Manual
7: 5-door/s-soeed
Automatic
8: 5-door/4-sDeed
Vehicle Grade (Seriesl
4: LX
5: EX
8 2022:2.0| DOHCSequentialMultiport
engine
Fuel-injected
MDMA:4-speedAutomatic
SBXM: s-speedManual
Check Digit
Model Year
Yr 2000
FactoryCode
C: SaitamaFactoryin Japan(Sayama)
Serial Number
B-96P
B-92P
G-95P
NH-552M
R-81
YR-524M
EternalBlue Pearl
NighthawkBlackPearl
CloverGreenPearl
SebringSilverMetallic
MilanoRed
NaplesGold lVetallic
OOLORLABEL
tNrcoL0R
TYPEF
COLOR
EXT.
B-92P
KCS2BC2 C
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1-9
ldentificationNumberLocations
VehicleldentificationNumber lVlNl
TransmissionNumb6r lManudl)
www.emanualpro.com
1-10
TransmissionNumbor {Aulomaticl
EngineNumbel
Warning/CautionLabelLocations
A: CABLEREELCAUTION
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C: DRIVERMODULEWARNING
A WARNING
T H E A I R E A GI N F L A T O RI S E X P L O S I V EA N D , I F
ACCIDENTALLYDEPLOYED,CAN SERIOUSLYHURT
OR KILLYOU.
TEST EOUIPMENTOR
. DO NOT USE ELECTRICAL
PROBINGDEVICES.
THEYCAN CAUSEACCIDENTALDEPLOYMENT.
. N O S E R V T C E A B LP
EA R T S l N S l D E . D O N O T
DISASSEMBLE.
. PLACEAIRBAGUPRIGHTWHEN REMOVED
. F O L L O WS E R V I C EM A N U A L I N S T R U C T I O N S
CAREFULLY.
(cont'd)
1-11
Warning/CautionLabelLocations
(cont'dl
(U.S.A.modelonlyl
{U.S.A.modolonlyl
o: SRSWARNING{HOOD}
SUPPLEMENTAL
RESTRAINT
SYSTEM{SRSI
THIS VEHICLEIS EOUIPPEDWITH DRIVERAND FRONT
SEATPASSENGER
AIRBAGS,
ALL SRS ELECTRICAL
WIRINGAND CONNECTORS
ARE
COLOREDYELLOW.
T A M P E R I N G W I T H , D I S C O N N E C T I N GO R U S I N G
ELECTRICAL
TEST EOUIPMENTON THE SRS WIRINGCAN
MAKETHESYSTEMINOPERATIVE
OR CAUSEACCIDENTAL
FIRINGOF THEINFLATOR.
A WARNING
T H E A I R B A G I N F L A T O R I S E X P L O S I V EA N D . I F
ACCIDENTALLYDEPLOYED,CAN SEBIOUSLYHURT YOU.
FOLLOWSERVICEMANUAL INSTRUCTIONS
CAREFULLY.
www.emanualpro.com
1-12
E: STEERINGCOLUMNNOTTCE
tHOODI
NOTICE
TO PREVENTSRS DAMAGE, REMOVESTEERINGWHEEL
BEFOREREMOVINGSTEERING
SHAFTCONNECTING
BOLT.
F: MONITORNOTICE
NOTICE
. NO SERVICEABLE
PARTStNStoE.
. REFER TO SERVICEMANUAL FoR DETAILED
rNsrRucTtoNs.
AIRBAGMODULEDANGEN
G: FRONTSEATPASSENGER
A DANGER
EXPLOSIVE/FLAMMABLE
CONTACTWITH ACID,WATER.OR I{EAVY METALSSUCH
HARMFUL
T.EAD.
OR MERCURYMAY PRODUCE
AS COPPER.
AND IRRITATINGGASESOR EXPLOSIVECOMPOUNDS.
MUST NOT EXCEED2OO"F
STORAGETEMPERATURES
I l O O ' C ) . F O R P R O P E RH A N D L I N G ,S T O R A G E ,A N D
REFERTO THESERVICEMANUAL,
DISPOSALPROCEDURES
SRSSUPPLEMENT.
POTSON
SODIUM AZIDEANO POTASSIUM
CONTAINSPOTSONOUS
NITRATE.
FIRSTAID
IF CONTENTSARE SWALLOWED,INDUCEVOMITING.FOR
E Y E C O N T A C T ,F L U S H E Y E S W I T H W A T E R F O R 1 5
MINUTES. IF GASES (FROM ACID OR WATEN CONTACT)
ARE INHALEO.SEEKFRESHAIR. IN EVERYCASE,GET
PROMPTMEDICALATTENTION.
KEEPOUTOF REACHOFCHILDREN.
A WARNING
T H E A I R B A G I N F L A T O R I S E X P L O S I V EA N D , I F
CAN SERIOUSLYHURT OR
DEPLOYED,
ACCIDENTALLY
KILLYOU.
L E S T E O U I P M E N TO R
. D O N O T U S E E L E C T R I C AT
PROBINGDEVICES,
DEPLOYMENT.
THEYCAN CAUSEACCIDENTAL
. NO SERVICEABI-E
PARTSlNSlDE.DO NOT DISASSEMBII.
. PLACEAIRBAGUPRIGHTWHENREMOVEO.
. FOLLOWSERVICMANUAL INSTRUCTIONSCAREFULLY
INFORMATIONlU S.A. modell
H: PASSENGER
{U.S.A.'97model}
AIEBAGSEEOTHERSIDE,
lU.S.A.'98- 00 models)
WARNING
DEATHOR SERIOUSINJURYCAN OCCUR'
. CHILDREN12 ANO UNDERCAN BE KILLEDBY THE
AIRBAG.
. THE BACKSEATlS THESAFESTPLACEFORCHILDREN.
C H I L DS E A T l N T H E
. N E V E RP U T A R E A R - F A C I N G
FRONT.
o SIT AS FARBACKAS POSSIBLEFROMTHEAIRBAG
. ALWAYSUSESEATBELTSAND CHll-DRESTRAINTS.
TEN YEAnS AFTERlT lS
. THE SRSMUST BE TNSPECTED
INSTALLED.
. T H E O A T EO F I N S T A L L A T I O Nl S S H O W N O N T H E
DRIVER'SDOORJAMB.
AIRBAGWARNING
J: FRONTPASSENGER
lU.S.A.'98- 00 models)
WARNING
C H I L D R E NC A N B E K I L L E D O R I N J U R E D 8 Y T H E
AIRBAG.
PASSENGER
THE BACKSEAT IS THE SAFESTPLACEFORCI{ILDREN12
AND UNDER.
MAKE SURE ALL CHILDRENUSE SEAT BELTSOR CHILD
SEATS.
WARNING
K: FRONTSEATBELTTENSIONER
WABNING
EXPLOSIVEMATERIALINSIDE
HURTOR BURNED,
YOU CAN BE SERIOUSLY
. DO NOT TAMPEROR DISASSEMBLE
PARTSINSIDE.
NO SERVICEABLE
. REFERTO SERVICEMANUAL FORCOMPLETE
INSTRUCTIONS.
{U.S.A.'98- 00 modelsl
AIRBAGWARNING
FLIPVISOROVER.
l: SRSINFORMATION
model
lU.s.A.'97
i
'97
lcanada - 00modlsI
CAUTION
TO AVOIDSERIOUSINJURY:
lN ALL TYPESOF
. FORMAXIMUM SAFEW PROTECTION
CRASHES,YOU MUST ALWAYS WEAR YOUR SAFETY
8ELT.
CHILOSEATSlN
o OO NOT INSTALLREARWARD-FACING
SEATPOSITION.
ANY FRONTPASSENGER
CLOSETO THE
. DO NOT SIT OR LEAN UNNECESSARILY
AIRBAG.
. DO NOT PLACE ANY OBJECTSOVERTHE AIRBAGOR
BETWEENTHEAIRBAGAND YOURSELF.
. SEE THE OWNER'S MANUAL FOR FURTHER
INFORMATIONAND EXPLANATIONS
TEN YEARSAFTERlT lS
. THE SRS MUST BE INSPECTED
INSTALLED.
. T H E D A T E O F I N S T A L L A T I O Nl S S H O W N O N T H E
DRIVER'SDOORJAMB.
(cont'd)
www.emanualpro.com
1-13
Warning/CautionLabelLocations
(cont'd)
VACUUM HOSEROUTING
DIAGRAMlUndor-hood
EmissionsControl Lrb6ll
ENGINECOOLANT
INFORMATION
SERVICE
INFORMANON
{Under-hood
Emission3
Control l.rbell
STEERING
COLUMNNOTICE
(sepage 1-12)
(Canadamodel)
RAOIATORCAP
CAUTION
www.emanualpro.com
1-14
AIR CONDITIONING
INFORMATION
Under-hoodEmissionsControlLabel
EmissionGroupldentification
(1997modell
Example:
VACUUMHOSEROUTINGDIAGRAM
INFORIMATION
VEHICLE
Ii/PORTANT
VHN2
OIJCrcK
ENGINE
FAMILY
OLITER
DISPIACEMENT'2
VNNl0778YMBP
VEf AM]LY
EVAPORAT
CATALYST
NFORMATON.
REfERTOSEBVICEMANUALfORAODITIONAL
I-]P
TUNT
CONDITIONS
TEMPERATURE,
ATNORI\,!AL
OPERATNG
ENGINE
FANOIF
OFFCOOLING
ESTL]RNED
ALLACCESSOR
NNEUTRAL
TRANSM1SSION
ADJUSTMENIS
NEEDED
NOOTHEB
ap'
ND\. 61FL r
TO U.S EPAREGUI.ATIONS
TNISVENICLE
CONFORMS
TO I99] MODET
YEARNWL GNI DUTYTRACKS
APPICASLE
E n g i n eF a m i l y :
Year
Model
v:1s97
l JGKE
vHN2.o
T_fT
I I
| L
Manufaqturer
H N :H o n d a
Displacement
Class
1: Light DutyVehicle
Fuol Systom ,nd Numbr of valves
J: ElectronicSequentialMultiport
Injection(threeor more valvesper
cylinder)
Fuel Type
G: Gasoline
Standard
F: 49 or 50 StatesTier 1
K: 49 or 50 StatesTier 1
1: CaliforniaTier 1
2: CaliforniaTLEV
3: CaliforniaLEV
4: CaliforniaULEV
Catalyst
E, F, G, H: ThreeWay Catalyst
i
I
OBD
K - T: OBDEquipped
ONCONTROL'EOLJIPPED
OSVEORTRACT
fOUBWHEEL
OFPERMANENT
LOADED
IM TEST]NG
ZED
ON A IOUR WHEELDRVE SPEEOSYNCHRON
VEHTCLES
MUST BE CONDUCTED
ANONLOADEDTESTPBO(EOUBEMUSIBEPERFORMEO
www.emanualpro.com
Families
Engineand Evaporative
Evaporative Family:
"r0",
V
HNlOTTBYMBP
T|
"*,
V: 1997
Manufacturer
HN: Honda
Storago System
1: Canister
CanistorWorking Capacity (gramsl
CanisterConfigulation
A: PlasticHousing(ClosedBottom)
B: PlasticHousing(OPenBottom)
Fusl System
Y: FuelInjection
FuelTank
M: Metal
Standard
A: CurrentEvap
B: EnhancedEvap
Wild C.rd
1 - 15
Under-hoodEmissionsControlLabel
EmissionGroupldentification
(1998modell
Engineand EvaporativeFamilies
EngineFamily:
Example:
DwlF\AIo|NG
oBcha\GtftcI + cootr\r -smsoru1or or FoNoA-IEaoTTxD-ibl
a\D wATfB.
M w r or_ut-ir coolqNt,oR-l;ir,FEaFEf1'v!Lrff EzEcoo-aN'
ENGINE
MAY
BESEflIOUSLYSIONTENEO.
DSEPLACI
CoOTANT
AnEs85 itNlgsloF@ MILIS
l@0 rnl, wHrcHEvEs
coMEs
Modl Year
W: 1998
ManufacturerSubcods
HNX:HONDA
TNEREAFTR,
REPLACE
EvEny
fmAFSlm m
M[Esi@ kml,wHcHrvEB
coMEs
DCHEC(ONADOCOOLqNTATTHE
RSSEFVETANX.
NOTTHE
iAD]ATOR.
DFOR
FUFTNEfr
INFO8MATION
ONINCOOT]NC
SYSIEM
NEAD
THE
OWNEN'S
MANUAL,
. CHECK
W|TH
YOUR
NONDA
OEALEF.
FamilyTypo
V: LDV
T: LDT
IMPORTANT
VEHICLE
INFORMATION
THISVEHICLE
CONFOEMS
TOI], S.EPA
FEGIJLAIIONSAPPLICASLE
TO1993MOOEL
YAFNEWLIGHTDUIYTNUCXS.
CATALYST
rwqHozst2l/sFt/osD
l cERI|FtEO
vAlvttAsH lrr0.l010.02nm
icolo)
EX:01310.02mm
SPAS(
PIUGGAP I.O IINM
686,13G96
lDLlSPTED
750I 50rym
PROCEOURESI
2.0L
TlNt UPCoND/ToNS:
ENGINE
ATNOiM
IEMPETAIURT,ALLACCESSORIESTUNNI
fANOFf.TRAI1SMISSON
INNEUTMI
NOOIIIERAOJUSTI\TFIIS
IIEEOED.
GD
www.emanualpro.com
1-16
W HNX T O2.OUF1
Displacomsnt
SoquncoCharaciors
Evaporative Fami
Family:
Model Yeat
W:1998
Manufastu16rSubcode
HNX:HONDA
Family Type
E: EVAP
R; EVAP/ORVR
CanisterWork Capacity
SgquoncoCharaqtsrs
W HNXEOOSOAAB
EmissionGroupldentification
(1999model)
Example:
U-ECo-q.NOEDI
USE
THE
COOLANT.
NGORCNANGINC
@SOLU I ONOfFONOA
'.WNEN
AOO
0FTNE
LIFE
THE
CooLANT,0RTHE
oILLJTE
mcrtniuvcoourr mo wlttt NEVEF
coMEs
lmo rhl,wNrcHEVEn
"Eifil:$o""niii?i,THffiffi'"R@ MLEs
os@
i'lrt^torrrr,^,r*a, rurr"*
coMEs
MLEs
1@ kmrwNICHEVER
TAN(NOTIHENADIATOS
ATTHERESER!'E
}CNECK
ORADDCOOLANT
MANUAL'
READ
THEOWNER'S
NCSYSTEM
ONTHECOOL
DFOfifWTHEFNFORMATION
' CHECK
HONOA
OEALER.
WIIHYOUS
INFORMATION
VEHICLE
IMPORTANT
S EPANLEV
CONFOAMSTOU.
THISVEHICLE
TO1999MODL
APPLICCBLI
FEGULANONS
YEA8NEWTIEVLIGHTDUTY]nUCKSAND
IO 19S9
APPLICASLE
REGULATIONS
CALIFORNIA
YEARNEWTLEVLIGHTDUTYIFIJCKS,
MOOEL
CATALYST
mm
IASN lN:010r0.02
VALVE
E X0 1 3 1 0 0m
2m
lCoLDj
PLUG
GAP 10- l l nm
SPA8K
rPm
130
t
5{
IDLE
SPEED
NOB
I]PCONDIIIONS
INGINEAT
TUNE
ESTLJRN
ATLACCESSOS
TEI\'PERATUR
NNEL]TML
FANOFf IRANSMSSION
NEEOEO.
ADJUSTMTNTS
NOOINER
EngineFamily:
,|
F
--'-
Ll:.-.-,1
I
rFrll
\=#_H*
JL
SPEED
MUsT
BE
coMoufitooNArounwNEElDslvE
Iooro nr tist rc orn svtncrE
MU
sT8EPfRrouRE
DrEsrPRoCE
iitriunor mo ovuvo uenn orr EnwsEaNoN.loaDE
X HNXT02,OUA2
Model Year
X:1999
Manutao{urerSubcode
HNX:HONDA
FamilyType
V: LDV
T: LDT
Displacoment
SaquenceCharactors
EvaporativeFamily:
OBDIICERT]ATD
201
Engineand EvaporativeFamilies
X HNXEOO8OAAB
Model Yoal
X:1999
ManutacturarSubcode
HNX:HONDA
Family Typo
E: EVAP
R: EVAP/ORVR
Canbter Work Capacity
SquonceChartsters
GD
50 state TLEV + NLEV {Unrestricted}
T H I S V E H I C L EC O N F O R M ST O U . S . E P A N L E V
E O 1 9 9 9 M O D E LY E A R
R E G U L A T I O NA
SP P L I C A B L T
T
R
U
C K SA N O C A L I F O R N I A
N E W T L E V L I G H TD U T Y
T
O 1 9 9 9 M O D E LY E A R
A
P
P
L
I
C
A
B
L
E
REGULATIONS
NEWLIGHTDUTYTRUCKS.
www.emanualpro.com
1-17
Under-hoodEmissionsControlLabel
EmissionGroupldentification
(2000model)
EngineFamily:
Example:
DWFEN
aDDr,tc0RChA\CtN!
rlt cooraN.ust MsoLU- oNor fioNpAq-af6MrNp-ol
\rvEn
u u'r+-E
coo|-d',r
os-Fiiiiifi-'
lfi ;!,."5:P!$t:1t9ffilf
1
DREpf
cEcoolaNrAFTEBt3tlomistoR@MtLEs
r@km),wH ctlEvrscoMEs
T|E8EAFTER,
BEprAcE
EVEny
ErdFstoB@ MttEs
lmr,t,
ffitcHEVER
coMEs
DCIIICXOF ADDCOOLA\I I'-FE
":3lliJ#fl
s,5TEM
8r!D
TrE
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"lj,9lx6L;T&Iji(0or|]\G
IMPORTANT
VEHICLE
INFORMATION
IHIS\/IHICLECONFONMS
TOU.S.EPANLEV
SEGULATIONS
APPIJCq3LE
TO2OOO
IVOOEL
YEAFNEWT!!V LIGHTDUTYTBUCKS
AND
CALIFONNIA
SEGULATIONS
APPLICASLE
TO2OOO
MOOLYIAA NEWTLEVLIGHT.OUTY
TFIJCKS.
vALvtLA5h tN:0,10r0.02
mm
{C0t0l
E l : 0 . 1 3 ! 0 0m2h
S P A n ( P L U G G A1P. 0 - 1 1 m m O8OCENTFIED
l D l ES P E E o
734150lpm
?.0t
TUNIUPCoNDIToNS:
ENGINE
ATNORM
TTMPERAIURE
ATLACCESSORIES
fu BNI
TANOFFTiANSMISS
ONINNUTRAL
NOOTHER
AD.ILJSTMENIS
NEEDEO.
.l-L
gt couolorooN,{raua.wxEtt
|oAoEDr/MTESTNG
oFTHsvtHrctE
uLrst
onuspreo
syNoiRoN
zEoDvNAMoMETER.
olrEiwsE.ANoN.LoAoEo
rEsrpBocEounr
uust sr pair
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Y HNX TO2.OUA2
Model Yar
Y: 2000
ManufaqturerSubcodo
HNX:HONDA
FamilyType
V: LDV
T: LDT
Displacement
SaquencoCharasters
Evaporative Family:
CATALYST
1-18
Engineand EvaporativeFamilies
Modol Yea.
Y: 2000
ManufacturerSubcode
HNX:HONDA
Family Type
E: EVAP
R: EVAP/ORVR
CanisterWork Capacity
SoquencaCharactet3
Y HNXEOOSOAAB
FRONTSUPPORTPOINT
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LIFTBLOCKS
REARSUPPORTPOIMT
1-19
Front:
JACK LIFTPLATFORM
Rsar:
Centerthe iack
bracketin the middle
of the iack lift platform.
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1-20
Towing
l f t h e v e h i c l en e e d st o b e t o w e d , c a l l a p r o f e s s i o n a l
towing service.Never tow the vehicle behind another
vehjclewith just a rope or chain.lt is very dangerous.
EmergencyTowing
Thereare three popularmethodsof towing a vehicle.
Flat-bedEquipment- The operator loads the vehicle on
the
the backof a truck.Thisis the bestway of transporting
vehicle.
Wheel Lift Equipment- The tow truck usestlvo pivoting
armsthat go underthe tires lfront or rear)and liftsthem
o f f t h e g r o u n d .T h e o t h e r t w o t i r e s r e m a i no n t h e
g r o u n d . T h e v e h i c l e ' ss u s p e n s i o na n d b o d y c a n b e
seriouslydamagedif this methodof towing is attempted.
Sling-typeEquipment- The tow truck usesmetalcables
with hookson the ends.Thesehooksgo aroundpartsof
the frame or suspensionand the cableslift that end of
the vehicleoff the ground.The vehicle'ssuspensionand
body can be seriouslydamagedif thjs methodof towing
i s a t t e m p t e d .T h i s m e t h e d o f t o w i n g t h e C R - Vi s
unaccePtable.
The onlv recommendedway of towing the CR-Vis on a
f l a t - b e dt r u c k . T w o w h e e l d r i v e C R - V ' sm a y a l s o b e
towed with all four wheelson the ground.
Front:
lOwlNG HOOKS.nd
TIE DOWN BRACKETS
Rear:
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1-21
ServicePrecautions
PartsMarkingLocations
To deter vehicletheft, cenain major componentsare markedwith the vehicleidentificationnumber
{VlN).Originalparts
will have self-adhesivelabelsor labelsattachedwith a break-offbolt. Replacementbody parts will have self-adhesive
labels,and replacement
engineand transmissionpartswill be stampedwith a codetor spareparts.
NOTE:
. Be carefulnottodamagethe partsmarkinglabelsduringbody repairs.Maskthe labelsbeforerepainting.
' Labellocationletterswithout parenthesisindicateoriginalparts.Letterswith parenthesisindicate
replacement
pans.
A, (A): Engine
B, (B): Transmission
C, (C): FrontBumoer
D, (D); Hood
E, (E): Tailgate
F, (F): RearBumper
G, (G):FrontFenders(Lefrand Right)
H, {H): FrontDoors(Leftand Right}
l, (l): RearDoors(Leftand Right)
J, (J): OuterSide Panel(Leftand Right)
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1-22
for Real-time4WD(Four-wheelDrivel
Precautions
U n d e r n o r m a l c o n d i t i o n s t, h e v e h i c l ei s i n 2 W D ( f r o n t - w h e edl r i v e ) .H o w e v e r ,t h e s y s t e m w i l l i n s t a n t l yt r a n s m i t
appropriatedrivingforceto the rearwheels{dependingon the drivingforceof the front wheelsand the road conditons)
The Real-time4WD-DualPump Systemdoes not have a manual switch to disablethe 4WD system.Wheneverservice
work requiresspinningthe front or rearwheelswith the engine,alwayslift up and supportthe vehicleso all lour wheels
are off the ground (seepage1-19).
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1-23
Specifications
2-2
Standardsand ServiceLimits...............
..........
2-12
DesignSpecifications
..................
..........2-14
BodySpecifications
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Standardsand ServiceLimits
EngineElectrical- Section4
MEASUREMENT
lgnitioncoil
R a t e dv o l t a g e V
P r i m a r y w i n d i n g r e s i s t a n c e0 a t 6 8 ' F ( 2 0 ' C )
lgnition wire
Besistance
at 68"F(20 C) ktl
Firingorder
Sparkplug
STANDAFDINEWI
1 3
l g n i t i o nt i m i n g
Type
Gap
At idle
Alternator belt*r
D e f l e c t i o nw i t h 9 8 N { 1 0 k g f , 2 2 l b f )
Alternator
Belttension N {kgf,lbt)
Measuredwith bek tensiongauge
OutputA (at 13.5V, hot and 6,000alternatorrpm
4-2
See Section 4
1 . 0 - 1 . 1 ( 0 . 0 3 9- 0 . 0 4 3 )
BTDC
AII
M/I
Brushlength
Staningmotor
SERVICELIMIT
12
0.63 0.77
25 max.
A/f
Mfi
Output kW
Micadepth
Commutatorrunout
CommutatorO.D.
Brushlength
Brushspringtension N (kgf,lbf)
1 6 12 { R e d )
8 . 5 1 1 . 5 1 0 . 3 30 . 4 5 ) w i t h
u s e db e l t
5.5- 8.0 (0.22- 0.31)with new belt
340- 490{35- 50,77 110)with usedbelt
690 880(70 90, 150- 200iwith new belt
95
90
1 0 . 5( 0 . 4 1 )
1.5(0.06i
1.1
1.0
0.5- 0.8{0.02- 0.03)
0,0.02 (0 0.0008)
2 7 . 9 2 8 . 0( 1 . 0 9 8 41 . 1 0 2 4 )
14.0 14.5(0.55 0.57)
- 3.97)
13.7- 17.7(1.40- 1.80,3.09
0.2 (0.008)
0.0s(0.002)
2 7 . 0( 1 . 0 6 )
9.0 (0.35)
' 1 W h e n u s i n g a n e w b e l t , d d i u s t d e f l e c t i o nt o n e w v a l u e . R u n t h e e n g i n e f o r 5 m i n u t e s t h e n t u r n i t o f { . B e a d i u s t d e f l e c t i o nt o u s e d b e l t v a l u e .
CylinderHead/ValveTrain - Section6
MEASUREMENT
Compression
250rpm and
wide openthrottle
,
kPa(kgflcm' psi)
Cylinderhead
Warpage
Height
E n dp l a y
Camshaft
STANDARD{NEW}
Totalrunout
Cam lobe height
'97,'98models
'99,'00models
(Cold)*
Valveclearance
ValvestemO.D.
Stem'to-guide
clearance
width
Steminstalledheight
lN
EX
lN
EX
lN
EX
lN
EX
lN
EX
tN
EX
lN
EX
Valve spring
Freelength
lN
EX
Valve guide
I,D,
IN
EX
tN
EX
Installedheight
*: Measuredbetweenthe camshaftand rockerarm,
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2-2
SERVICELIMIT
Nominal
1,230i'12.5, 11Al
Minimum
930(9.s,135)
Maximumvariation 20012.0,2al
1 3 1 . 9-5 1 3 2 . 0{55 . 1 9 -5 5 . 1 9 9 )
0.05 0.1s(0.002 0.006)
- 0.0027)
0.030- 0.069(0.0012
0 . 0 3{ 0 . 0 0 1 ) m a x .
33.204\1.30721
33.528{1.3200)
33.116 \1.3214)
33.528{'1.3200)
0.08- 0.12(0.003 0.005)
0.16 0.20(0.006- 0.008)
6.580- 6.590(0.2591 0.2594)
6.550- 6.560(0.2579 0.2s83)
0.02- 0.05{0.00t 0.002)
0.05- 0.08(0.002 0.003)
1.25- 1.55(0.049- 0.061)
1 . 2 5 1 . 5 5( 0 . 0 4 -9 0 . 0 6 1 )
40.765- 41.235{1.6049 1.6234)
- 1.70221
42.765- 43.235i'1.6837
42.36(1.668i
44.32t1.1451
- 0.261)
6.61 6.6310.260
6.61 6.63{0.260- 0.261i
1 3 . 7 -5 1 4 . 2 5
1 0 . 5 4 10 . 5 6 1 i
15.75- 16.25{0.620 0.640i
0.05{0.002)
0.5(0.02)
0.15(0.006)
0.04(0.002)
u* to.rutt
6.52lO.257l
0.08{0.003i
0.'1t(0.004)
2.0 (0.08)
2.0 (0.08)
41.485{1.6333}
43.485{1.7120i
6.6510.2621
6.65(0.262i
STANDARD(NEWI
MEASUREMENT
Cylinder block
Piston
Pistonring
clearance
Ring-to'groove
Ringend gap
PistonPin
0.07(0.003)max.
84.00- 84.02(3.307 3.308)
Top
Second
oil
ToP
Second
ToP
Second
oil
o.D.
Pin-to-piston
clearance
Pin-to-rodinterference
Smallend borediameter
Nominal
Largeend borediameter
Endplayinstalledon crankshaft
Mainjournaldiameter
Crankshaft
N o .1 , 2 , 4 a n d5 i o u r n a l s
No.3 journal
Rodiournaldiameter
Taper
Out ol round
Endplay
Bunout
Main bearing-to-iournal
oil clearance
Bearing
N o .1 ,2 , 4 a n d 5 i o u r n a l s
No.3 journal
oil clearance
Rodbearing-to-,ournal
*1: '97,'98models15 mm (0.6in)
'99,'00models20 mm (0.8ini
rod
Connecting
EngineBlock- Section7
SERVICELIMIT
0.10(0.004)
84.07(3.310)
0.05(0.002)
83.97(3.306)
0.05{0.002)
1.26(0.0s0)
1.25(0.049)
2.44lo.112l
0.13(0.005)
0.13(0.005)
0.60(0.024)
0.70(0.028)
0.70(0.028)
oroto.oroi
- 2.1654)
54.976- 55.000(2.' l644
- 2.1651)
54.970 54.994(2.1642
- 1.71111
44.976- 45.000/.1.1707
0.005(0.0002)max.
max.
0.005(0.0002)
0.10- 0.35(0.004- 0.0r 4)
0.03(0.001)max.
0.010(0.00041
0.010(0.0004)
0.45(0.0r8)
0.04(0.002)
- 0.042
0.024
10.00090.0017)
- 0.048(0.0012
- 0.0019)
0.030
0.020- 0.038(0.0008 0.0015)
0.06(0.002)
0.06(0.002)
0.05(0.002)
o
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2-3
StandardsandServiceLimits
EngineLubrication
Section8
MEASUREMENT
Engineoil
Capacity
f (US qt, lmp qt)
Oilpump
Inner-to-outer
rotorclearance
Pumphousing-to-outer
rotorclearance
Pumphousing-torotoraxialclearance
Pressure
settingat engineoil temp. 176'F(80'C)
kPa(kgt/cm,,psi)
At ldle
At 3,000rpm
R e l i e fv a l v e
Cooling
Radiatorcap
Thermostat
Coolingfan
70 (0.7,10)min.
3 4 0{ 3 . 5 , 5 0m
) in.
Section 10
MEASUREMENT
Radiator
STANDARO{NEWI
SERVICELIMIT
4.6(4.9,4.0)Iorengineoverhaul
3 . 8{ 4 . 0 , 3 . 3 ) f oori l c h a n g ei n
, c l u d i nfgi l t e r
3.5 (3.7,3.1)for oil change,withoutIilter
0.04- 0.16(0.002- 0.006)
0.20(0.008)
0 . 1 0- 0 . 1 9 ( 0 . 0 0-4 0 . 0 0 7 )
0.20(0.008)
0.02-0.07 (0.001- 0.003i
0.15(0.006)
Fueland Emissions
M/T
STANDAROINEW}
5.9{6.2,5.2}toroverhaul
3.9(4.1,3.4ifor coolantchange
6.0(6.3,5.3ifor overhaul
4.0(4.2,3.5)for coolantchange
9 3 - 1 2 3( 0 . 9 5- 1 . 2 5 1, 4 1 8 )
169- 176(76- 80)
194(90)
8 . 0( 0 . 3 1 i m i n .
196- 203 (91- 95)
Subtract5 - 14 (3 - 8) trom actual"ON" temperature
Section 11
MEASUREMENT
STANDARDINEW}
ldle CO %
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2-4
'97 model
'98 model
'99,'00 models
750r 50
7301 50
1,5001200
1,600r 200
0.1max.
AT {E or E position)
750t 50
750r 50
7 3 0 15 0
1 , 5 0 0 12 0 0
1 , 5 0 0 12 0 0
1,600r 200
Clutch
Section 12
MEASUREMENT
Clutchpedal
Pedalheight
Stroke
Freeplay
Pedalplay
Disengagement
height
Clutchsurfacerunout
to floor
to floor
Clutchdisc
plate
Pressure
Warpage
Diaphragmspringfingeralignment
SERVICELIMIT
STANDARDINEWI
183(7.20)
1 3 5 - 1 4 5 1 5 . 3- 15 . 7 1 )
7 - 2210.24- 0.41J
1-9 (0.04-0.35)
7 2 1 2 . 8 3m) i n .
max.
0.05(0.002)
0.r5(0.006)
1 . 2- 1 . 7 1 0 . 0 50-. 0 7 )
8 . 4 9 . 1( 0 . 3 3 , 0 . 3 6 )
0 . 0 3( 0 . 0 0 1 ) m a x .
0.6 (0.02)max.
0.2(0.01)
6.0i0.24)
0.15(0.006)
0.8 (0.03)
ManualTransmission Section 13
Transmission
fluid
Mainshaft
STANDARDINEW}
MEASUREMNT
Capacity f (USqt, lmp qti
SERVICEI-IMIT
1 . 71 1 . 8 1
, . 4 ) f o ro i l c h a n g e
2 . 1 ( 2 . 2 ,1 . 8 ) { o r o v e r h a u l
Endplay
Diameterof ball bearingcontactarea(clutchside)
Diameterof needlebearingcontactarea
Diameterof ball bearingcontactarea
(transmission
housingside)
Runout
Adjust
2 7 . 9 4( 1 . 1 0 0 )
37.93(1.493)
- 1.1024)
27.987- 28.000(1.1018
0.02(0.0011max.
43.009- 43.02511.6933- 1.6939)
0.06- 0.21 (0.002- 0.008)
- 1.377)
34.92 34.9711.375
31.42- 31.4'711.237, 1.2391
Mainshaftsth
gear
LD.
Endplay
Thickness
Countershaft
Diameterol needlebearingcontactarea
DiameteroI ball bearingand needlebearingcontact
27.94(1.100)
0.05{0.002)
43.08011.6961)
0.3 (0.01)
34.811.37)
31.311.23)
- 43.02511.6933
1.6939) 43.08011.6961)
43.009
- 0.008)
0 . 3( 0 . 0 1 )
0.06- 0.21(0.002
- 1.219)
- 30.97
3 0 . 8( 1 . 2 1 )
30.92
{1.217
36.000 36.015{1.4173 1.4179) 3s.95(1.415)
(0.982)
24.94
24.987- 25.000(0.9837- 0.9843)
-1.4567)
36.984- 37.00011.4561
0.02(0.001)max.
(1.4s4)
36.93
0.0s(0.002)
LD.
Endplay
Thickness
t.D.
Endplay
Thickness
- 43.025
(1.69331.6939)
43.009
- 0.007i
0.06- 0.18(0.002
- 1.063)
(1.061
26.9s,27.00
- 47.025
- 1.8514)
(1.8507
47.009
,0.006)
0.07- 0.1410.003
2As2- 2a.97l 1.139-1.1411
43.08(1.696)
0.2310.009)
3 1 . 0 6( 1 . 2 2 3 )
37.94(1.494)
Mainshatt3rd and
4th gears
countershatt1st
gear
Countershaft2nd
gear
LD.
Endplay
Thickness
3rd gear
4th gear
47.08{1.854)
0.18(0.007)
Spacercollar
(Mainshaft
4th
and 5th gears)
t.D.
o.D.
Reverseidlergear
t.D.
gearshaftclearance
Gear-to-reverse
R i n g - t o - g e a rc l e a r a n c e ( r i n g p u s h e d a g a i n s l g e a r )
0.85- r.10(0.0330.043)
0.4 (0.02)
(ringpushedagainstgear)
Clearance
Outersynchroring to synchrocone
Synchrocone-to-gear
Outersynchroring-to-gear
Fingerthickness
3rdl4thshiftlork
Exceptabove
Fork-to-synchrosleeveclearance
0.3(0.01)
0 . 3( 0 . 0 1 )
0.6(0.02)
Synchroring
Dualcone
Shift fork
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Length
l' les
26.01t1.0241
20.09(0.7909)
0.16010.0063)
't, torag)
Standardsand ServiceLimits
ManualTransmission{cont'd}- Section 13
MEASUREMENT
Raverseshift Iork
STANDAROINEW)
'13.0
- 13.3(0.5' -j 0.52)
0.5- 1.1(0.02- 0.04)
7.O5- 7.25 i.0.21
4 - 0.2451
7.4-7.7 t0.29 0.301
at A
atB
Fork-to-5th/reverse
shift shaft clearance*'
PinionshaftcontactareaLD.
Carrier-to-pinion
shaftclearance
Driveshaft,intermediateshatt contact area LD,
Carrier-to-driveshaft
clearance
Carrierto-interrnediateshaft clearance
Backlash
t.D.
Piniongearto-pinion
shaftclearance
- 0.006)
0.05-0.r5{0.002
- 18.066
- 0.7113)
(0.7103
18.042
- 0.0037)
0.059- 0.09510.0023
oru ro.ooor
Adjust
33.93(1.336)
27.92 (1.O99)
39.95(1.573)
34.95(1.376)
26.92(1.060)
Adjust
Adjust
Shift arm A
Shiftarm C
Selectlever
o.D.
Transmission
housingclearance
Shift lever
o.D.
Shift arm cover clearance
Differential
carner
Differential
piniongear
Ditferential
taperedrollrbesringpreloac
Staningtorque N.m (kgf.cm,lbl.ini
Transter
11:fuleasuring
points
Diameterof rollerbearingcontactarea
Translershaft {driven gear side}
Translorshaft {middle of shaft)
Transterdrive gear
Translordrivengearshaft{drivengearside)
Transterdrivengearshaft(splinedside)
Trans{ergear backlash
TotalstartingtorqueN.m (kgicm,lbiin)
A
'Ay"
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2-6
18 (0.07)
at B'
Selectarm
SERVICELIMIT
*2: Measuringpoints
0.5{0.02)
1.0(0.04)
0.6{0.024i
0.1 (0.004)
0 . 1 2{ 0 . 0 0 5 i
0 . 1 5( 0 . 0 0 6 i
A'
-l-...
_{-P)
U n i t o f l e n g t h :m m ( i n )
MEASUREMENT
Transmission
fluid
4WD
2WD
Hydraulic
pressure
kPa
(kgflcm', psi)
1st,2nd,3rd,4th
'1st-hold
2nd,3rd, 4th
1st,1st-hold
Mark1
Mark2
Mark3
Mark4
Mark5
Mark6
Mark7
Mark8
MarkI
Mark 10
Clutchend platethickness
{2nd,4th)
Mark6
Mark7
Mark8
Mark9
M a r k1 0
M a r k1 1
lvlark12
M a r k1 3
M a r k1 4
M a r k1 5
M a r k1 6
Mark17
Clutchend platethickness
{3rdi
Mark8
MarkI
M a r k1 0
M a r k1 1
M a r k1 2
M a r k1 3
M a r k1 4
M a r k1 5
M a r k1 6
M a r k1 7
Mark1
M a r k2
Mark3
Clutchend platethickness
( 1 s th o l d )
No mark
Mark6
Mark7
SERVICELIMIT
6.8(7.2,6.0)for overhaul
2.9(3.1,2.6)for fluid change
5.9{6.2,5.2)foroverhaul
2.7{2.9,2.4}forfluid change
830- 880(8.5- 9.0,120 130)
780(8.0,1' t0)
760t7.7,1101
2,550
0.65- 0.85(0.026-0.033)
0.40- 0.60(0.016- 0.024)
0.5- 0.8(0.020- 0.031)
31.1 11.22)
3 4 . 6( 1 . 3 6 )
1.88- 2.00(0.074- 0.079)
'r.95- 2.05
{0.077 0.081)
'1.55-1.65(0.061- 0.065)
2.05- 2.r0 (0.081- 0.083)
2.15 2.20(0.085- 0.0871
2.25 2.30(0.089,0.091)
2.35 2.40{0.093- 0.094}
2.45- 2.50{0.096-0.098}
2.55- 2.60(0.100- 0.102)
2.65- 2.70(0.104- 0.106)
2.75 2.80i0.108- 0.110)
2 . 8 5- 2 . 9 0 1 0 1. r2 0 . 1 1 4 )
2 . 9 5- 3 . 0 0 1 0 . 1 1 6
0.118)
- 0.102)
2.55 2.6010.100
2.65 2.70(0.104,0.106)
2.75- 2.80(0.108 0.110)
2 . 8 5- 2 . 9 0( 0 . 1 1-20 . r r 4 )
2 . 9 5 3 . 0 0( 0 . 1 1 6 - 0 . 1 1 8 )
3 . 0 5- 3 . 1 0( 0 . 1 2-0 0 . 1 2 2 )
3 . 1 5 3 . 2 0( 0 . 1 2 4 - 0 . 1 2 6 )
3.25- 3.30(0.128 0.130)
3.35- 3.40(0.r32- 0.134)
3.45- 3.50(0.136- 0.138)
3 . 5 5 3 . 6 0( 0 . 1 4 -0 0 . 1 4 2 )
3.65- 3.70(0.144- 0.146)
2 . 7 5- 2 . 8 0( 0 . 1 0 8 0 . 1 1 0 )
2 . 8 5 -2 . 9 0( 0 . 1 1-2 0 . 1 1 4 )
2 . 9 5- 3 . 0 0( 0 . 1 1 -6 0 . 1 ' j 8 )
3.05 3.10(0.120- 0.122)
3 . 1 5 - 3 . 2 0{ 0 . 1 2 4 0 . 1 2 6 )
3.25- 3.30(0.128- 0.r30)
3.35- 3.40(0.132- 0.r34i
3.45- 3.50(0.136- 0.138)
3.55- 3.60{0.140- 0.142)
3.65- 3.70{0.144- 0.r46)
2.05 2.10(0.081- 0.0831
2.r5 2.20(0.085- 0.087)
2.25- 2.30{0.089- 0.091}
- 0.094i
2.35- 2.4010.093
2.45- 2.50(0.096-0.098i
2.55- 2.60(0.r00- 0.102)
2.65- 2.70(0.r04- 0.106)
2,400,2,700
2 9 . 1( 1 . 1 5 )
32.6(r.28)
Untilgroovesworn out
Discoloration
Discoloration
Discoloration
Discoloration
Discoloration
Discoloration
Discoloration
Discoloration
(cont'd)
www.emanualpro.com
2-7
Standardsand ServiceLimits
Automatic Transmission (cont'd)- Section 14
MEASUBEMENT
Transmission
Diameterof needlebearingcontactarea
On mainshaftstatorshaftbearing
On mainshaft2nd gear
On mainshaft4th gearcollar
On mainshaft1stgearcollar
(torqueconverterhousingside)
On countershatt
On countershaft
3rd gear
4th gear
On countershaft
On countershaft
reversegearcollar
1stgearcollar
On countershaft
housingsidei
On sub-shaft{transmission
On sub shaft4th gearcollar
On reverseidlergearshaft
Insidediameterof needlebearingcontactarea
On mainshaft1stgear
On mainshaft2nd gear
On mainshaft4th gear
1stgear
On countershaft
3rd gear
On countershaft
4th gear
On countershaft
reversegear
On countershaft
On sub-shaft4th gear
On reverseidlergear
fleverseidlergearshaftholderl.D.
Endplay
Mainshaft1stgear
Mainshaft2nd gear
Mainshaft4th gear
Countershaft
1stgear
Countershaft
3rd gear
Countershaft4th gear
Sub-shaft4th gear
Reverseidlergear
Countershaftreversegear
Selectorhub O.D.
Mainshaft4th gearcollarlength
Mainshaft4th gearcollarflangethickness
Mainshaft1stgearcollarlength
Countershaft
distancecollarlength
Countershaft
3rd gearcollarlength
reversegearcollarlength
Countershaft
Countershaft
reversegearcollarflange
thickness
1stgearcollarlength
Countershaft
lst gearcollarflangethickness
Countershaft
Sub-shaft4th gearcollarlength
Sub shatt4th gearcollarflangethickness
www.emanualpro.com
2-8
STANDARD{NEW}
SERVICELIMIT
Wearor damage
Wearor damage
il*=lo'.d"'.n"n"
Wearor damage
Wearor damage
Wearor damage
Wearor damage
MEASUREMENT
Transmission
Thrustwasherthickness
l'rainshaftballbearingleftside
Mainshaft1stgear
Countershaft
3rd gearsplinedwasher
Sub-shaft4th gear thrust washer
ATFpump
One-wayclutchcontactareaLD.
1stgear
Countershaft
Parkinggear
Mainshaftfeed pipeA, O.D.(at 15 mm trom end)
Mainshaftfeed pipe B, O.D.(at 30 mm from end)
teed pipeO.D.lat 15 mm from end)
Countershaft
Sub-shaft
feed pipeO.D.(at 15 mm from end)
Mainshattsealingring thickness
(29mm and 35 mm)
MainshaftbushingI.D.
Mainshaftbushingl.D.
Countershaft
bushingl.D.
Sub shattbushingLD.
Mainshaftsealingring groovewidth
ATFpump gearsideclearance
ATFpump gear'tobody clearance
Drive
Driven
ATFpump drivengearLD.
ATFpump drivengearshaftO.D.
Regulator
valve body
Stator shaft
Shiftingdeviceand
parkingbrakecon'
trol
Servo body
Differential
carrier
Differential
prnrongear
o
www.emanualpro.com
- 0.157)
4.0010.156
4.05{0.158- 0.159)
4.1010.160 .161)
4 . 1 5( 0 . 1 6-2 0 . 1 6 3 )
4.20(0.164 0.165)
- 0.167)
4.2510.166
4.30(0.168- 0.169)
4 . 3 5( 0 . 1 7 0 - 0 . 1 7 1 )
4.40(0.172 0.173)
4.45(0.174- 0.r75)
2.95
2.434.9s2 . 9 3-
3 . 0 5( 0 . 1 1 6 0 . 1 2 0 )
2.50(0.096- 0.098)
5.00(0.195- 0.197)
3 . 0 0( 0 . 1 1 -5 0 . 1 1 8 1
Wearor damage
Wearor damage
Wearor damage
8.95(0.352)
5.95(0.234)
7.95(0.313)
7.95{0.313)
1.42$.O72)
- 0.2374)
6.018- 6.030(0.2369
- 0.3549)
9.000- 9.015(0.3543
8.000- 8.022(0.3150-0.3158)
8.000- 8.022(0.3150 0.3158)
2.025- 2.075(0.0797 0.0811)
0.03- 0.05(0.001- 0.002)
0.1050 0.1325(0.004,0.005)
- 0.002)
0.0350- 0.062510.001
14.016*14.034(0.5518 0.5525)
13.980- 13.990{0.5504 0.5508)
- 1.3782)
35.000 35.025{1.3780
5.045(0.2380)
9.03(0.356)
8.03(0.316)
8.03(0.316)
2.095(0.082)
Wearor damage
Wearor damage
5.40(0.213)
5.90- 6.00{0.232,0.236)
I
I
Wearor damage
I
Wearor damage
0.0710.003)
Wearor damage
Wearor damage
35.050(1.3799)
lWear
or otherdefect
Carrierto driveshaltclearance
Carrier-to-intermediate
shaftclearance
- 0.5516)
14.000- 14.010(0.55' l2
- 1.4582)
37.000- 37.039(1.4567
'18.010
- 18.02810.709
- 0.710)
0.023- 0.057{0.001- 0.002}
- 1.0254)
26.025- 26.045(1.0246
28.025- 28.045(1.103- 1.104)
0.045- 0.08610.0020.003)
0.075- 0.11110.003-0.004)
Backlash
t.D.
Piniongear'to-pinion
shaftclearance
- 0.006)
0.05- 0.15(0.002
- 18.066
- 0.7113)
(0.7103
18.062
- 0.0037)
otu to.oout
0.055- 0.09510.0022
PinionshaftcontactareaLD.
Carrierto-pinion
shaftclearance
Driveshafvintermediate
shaftcontactare l.D.
S e t r i n g - t o - b e a r i n go u t e r r a c e c l e a r a n c e
Transfer
SERVICELIMIT
3.974.024 . 0 74 . 1 24.17
4.224.274.32
4.374.42-
Diameterof rollerbearingcontactarea
Transfershaft(transfergearside)
Transfershaft(middleof shaft)
Transferdrive gear
Transferdrivengearshaft{drivengearside)
Transferdrivengearshaft{splinedside)
Transfergearbacklash
TotalstartingtorqueN.m (kgf.cm,lbf.in)
2WD
4WD
37.045(1.4585)
0.r {0.004)
0.12(0.005)
0.15(0.006)
0 0.15(0- 0.006)
Adjust
3 8 . 4 3( 1 . 5 1 3 )
27.92(1.099)
39.95(1.573)
34.95(1.376)
26.92(1.060)
Adiust
Adiust
(cont'd)
2-9
Standardsand ServiceLimits
Automatic Transmission(cont'dl - Section 14
STANDAROINEWI
MEASUREMENT
Wire Dia.
Springs
Regulator
valvespringA
Regulator
valvespringB
Statorreactionspring
Modulatorvalvespring
Torqueconvenercheckvalvespring
'97 model
'98 - 00 models
Coolerreliefvalvespring
Reliefvalvespring
2nd orilicecontrolvalvespring
1-2shittvalvespring
2 3 shiftvalvespring
3-4shiftvalvespring
1staccumulator
spring
4th accumulator
springB
4th accumulator
springA
2nd accumulator
springA
3rd accumulator
springA
2nd accumulator
springB
3rd accumulator
springI
3rd sub accumulator
spring
2nd accumulator
springC
Lock-upshiftvalvespring
Lock-uptiming valvespring
Lock'upcontrolvalvespring
3'4 orificecontrolvalvespring
Servocontrolvalvespring
CPBvalvespring
4th exhaustvalvespring
o.D.
Fiee Length
1 . 81 0 . 0 7 1 )
1 . 8i 0 . 0 7 1 )
4 . 5( 0 . 1 7 7 )
1.4{0.055)
14.7(0.579)
9.6 (0.378)
35.4{1.394}
9.4 (0.370)
87.8(3.457)
44.011.1321
30.31r.193)
35.0{1.378)
1.1(0.043)
1.2(0.047)
1.0(0.039)
1 . 1( 0 . 0 4 3 )
0.7 (0.028)
0.9 (0.035)
0.9 (0.035)
0.9 (0.03s1
2.1 (0.083)
2.3 (0.091)
2.6 (0.102)
2.410.094)
2 . 8( 0 . 1 1 0 )
1.6(0.063)
2.1(0.083)
2.7{0.r06)
2.2lO.OA7)
0.9 (0.035)
0.9 (0.035)
0.7 (0.028)
0.6 (0.024)
1.0(0.039)
0.9 (0.035)
0.9 (0.035)
8.4 (0.331)
8.4 (0.331)
8.4 (0.331)
8.6(0.3391
6.6(0.260i
7.6{0.299}
7.6{0.299)
7.6{0.299)
16.0(0.630)
10.2to.402l
17.0(0.669)
29.0\1.1421
'r7.510.689)
9.0 (0.354)
3 1 . 0( 1 . 2 2 0 )
17.0(0.669)
14.510.571)
7.610.299i
8 . 1{ 0 . 3 1 9 }
6.6(0.260)
6.6(0.260i
8.1(0.319)
8.1{0.319)
6.t (0.240)
36.4{1.433)
32.4tl.216J
3 3 . 8{ r . 3 3 1 )
3 7 . 1( 1 . 4 6 1 )
34.8(1.370)
41.3(1.626)
57.0 (2.2441
57.0 12.2441
89.1(3.508)
5 1 . 6( 2 . 0 3 1 )
88.4(3.480)
39.011.s35)
94.313.713)
20.710.8r5)
38.2(1.504)
39.0(1.535)
68.0(2.677)
73.7 12.902)
8 r . 4( 3 . 2 0 5 )
38.0fl.496)
37.9(1.492)
5 2 . 1( 2 . 0 5 1 )
41.2 t\ .A5Al
36.4(1.4331
STANOABD{NEW'
1 . 2( 1 . 3 1, . 1 )a t o v e r h a u l
1 . 0( 1 . 10, . 9 1a t f l u i dc h a n g e
Steering
Section 17
STANDARD
INEWI
MEASUREMENT
Steeringwheel
Gearbox
Pump
playat steeringwheelcircumference
Rotational
Staningloadat steeringwheelcircumference
N {kgf,lbl)
Enginerunning
Angleof rack$uide-screw
loosenedlrom lockedposition
'97, '98 models
'99, '00 models
Pumppressurewith shut off valveclosed
kPa (kgvcm,,psi)
Powersteering
fluid
Recommended
tluid
Fluidcapacity
I {USqt, lmp q0
Powersteering
belt*
Deflection
with 98 N {1Okgl,22lht)
betweenpulleys
Belttension N {kgt,lbf}
Measuredwith belttensiongauge
0 - 1 0( 0- 0 . 3 9 )
29 (3.0,6.6)
10"1 5"
20" MAX.
6,900- 7,800(70 80,995 1,138)
Hondapowersteeringfluid.
For overhaul 0.85(0.90,0.75)
For reservoir 0.4{0.42,0.35)
11.0 14.5(0.43 0.57)withusedbelt
7.5- 10.0(0.30 0.40)with new belt
390- 540(40- 55,88 - 121)with usedbelt
740-880 (75 90, 165 198)withnew belt
* When usinga new belt,adjustdeflectionor tensionto new values.Runthe enginefor 5 minutesthen turn it off.
Readjustdellectionor tensionto usedbeltvalues.
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2-10
No. of Coils
r 1.0
1.9
10.9
12.O
12.7
8.2
13.4
22.0
26.4
26.8
13.8
14.2
2.9
15.9
2.6
6.3
32.0
47.A
20.8
'18.3
'19.5
Suspension Section18
STANDARD{NEW)
MEASUREMENT
Wheelalignment
Front
Rear
Front
Front
near
Inwardwheel
Outwardwheel
Camber
Caster
Totaltoe
Frontwheelturningangle
Wheelbearing
E n dp l a y
Rim runout
Front
Rear
Aluminumwheel
Axial
Badial
Axial
Radial
Steelwheel
0"00'1 1'
- 1"00'1 1'
2"10'! 1"
0J3(011/8)
r N2 r i ( 1 / 1 6 11 / r 6 )
37"00'! 2
31'30'(Referencei
0 - 0.05{0- 0.002}
0 - 0.05(0 0.002i
STANOARD(NEW)
0 - 0.7 (0
0 , 0 . 7 ( 00 1.0(0 0 - 1.0{0 -
0.03)
0.03)
0.04)
0.04)
SERVICELIMIT
2.0(0.08)
'r.5
{0.06)
2.0{0.08)
1.s(0.06)
Brakes Sec'tion 19
STANDARDINEWI
MEASUREMENT
Parkingbrake
lever
Footbrakepedal
Mastercylinder
Discbrake
tl o
Piston-to-pushrod
clearance
Front
Discthickness
Front
Front
Front
Discrunout
Discparallelism
Padthickness
Rearbrakedrum
'97,'98 models
'99,'00 models
LD.
Liningthickness
Air Conditioning
155(6 1/8)
1 6 1( 6 5 / 1 6 )
1 5 (1/16- 3/16)
0 - 0.4(0- 0.02)
STANDARD{NEW'
22.9- 23.1(0.902- 0.909)
23.6 23.8(0.929- 0.937)
10.5- 11.5(0.4' t 0.45)
2r9.9 220.0(8.657- 8.661)
3 . 9- 4 . 5( 0 . 1 5- 0 . 1 8 )
Compressor
(KEIHIN)
Compressor
belt*
221.O8.7011
2.0(0.08)
Section 22
STANDARD
{NEWI
MEASUREMENT
Air conditioning
SERVICE LIMIT
21.0(0.83)
21.0(0.83)
0.10{0.004)
0.015(0.0006)
1.6(0.06)
Lubricanttype:
KEIHINSP 10 (P/N38897- Pl3 - A01AHor 38899P l 3- A 0 1 )
Condenser
Lubricantcapacity
Evaporator
mf {floz, lmp oz)
Lineor hose
Receiver
25 (5/6,0.9)
40 {1 1/3,1.4)
1 0{ 1 / 3 , 0 . 4 )
10(.]/3,0.4)
Lubricant
type:SP 10
Lubricantcapacity ml ({l 02,lmp oz}
Stator coil resistanceat 68'F (20"C)O
plate clearance
Pulley-to-pressuae
Deflection
with 98 N (10kgl,22lbli
betweenpulleys
Belttension N (kgf,lbf)
Measuredwith belttensiongauge
130'3'{41fi'3o,4.6;"}
3.05- 3.35
0.51 0.15(0.021 0.006)
7.5- 10.5{0.30- 0.41)with usedbelt
5.0- 7.0(0.20- 0.28)with new belt
3 9 0- 5 4 0( 4 0 5 5 , 8 8 - 1 2 0 ) w i t h u s e d b e l t
740- 880 {75 90, 170- 200)with new belt
* When usinga new belt,adjustdeflectionor tensionto new values.Runthe enginefor 5 minutesthen turn it off.
Readjustdeflectionor tensionto usedbeltvalues.
o
www.emanualpro.com
2-11
DesignSpecifications
ITEM
DIMENSIONS
WEIGHT(USA)
WEIGHT(CANADA)
ENGINE
METRIC
Overalllength
Overallwidth
Overallheight
Wheelbase
Track
Front
Rear
Seatingcapacity
Grossvehicleweightrating(GVWR)
Grossvehicleweightrating(GVWR)
Type
Cylinderarrangement
Bore and stroke
Displacement
Compression
ratio
'97,'98mooers
'99,'00 models
Lubricationsystem
Oil pump displacement
at 6,000enginerpm
Waterpump displacement
at 7,600enginerpm
Fuelrequired
Type
Normaloutput
Nominalvohage
Hourrating
Directionof rotation
Weight
CLUTCH
Clutchtype
MIT
Clutchlacingarea
Transmission
type
MIT
TRANSMISSION
MIT
PrimaryredLrction
Type
1st
2nd
3rd
4th
5th
Reverse
Finalreduction
Geartype
Gearratao
Transfer
Type
Transfer
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2-12
3.500
1.956
1.344
1.071
0.812
3.000*,.3.461*'
Single helicalgear
4.562
0.434
Reardifferential
Finalreduction
4 , 1 6 5t b s
|
1,900kg
Water-cooled,4-strokeDOHC
gasolineengine
Inline4-cylinder,
transverse
84.0x 89.0mm
3.31x 3.50in
.1,973
cm3(m{)
1 2 0c u - i n
9.2
9.6
Beltdriven,DOHC
4 valvesper cylinder
Forcedandwet sump,trochoidpump
501 (53 US qt,44 lmp qt)/minute
1401(148US qt, 123lmp qt)/minute
gasoljnewith 86
UNLEADED
PumpOctaneNumberor Higher
gearreduction
Planetary
A/T:1.1kW
M/T: 1.0kW
12V
30 seconds
Clockwiseas viewedfrom gearend
3.7kg
8.2 lbs
Singleplatedry, diaphragmspring
Torqueconverter
203cm,
31.5sq-in
Synchronizeds-speedtorward, 1 reverse
Electronically
controlled
4-speedautomatic,1 reverse
Direct I : 1
Approx.
Manualtransmission
Gearratio
Gearratio
NOTES
1 7 7 . 6i n
68.9in
63.3in
1 0 3 . 2i n
60.4in
60.4in
5lf
Valvetrain
STARTER
ENGLISH
4 , 5 1 0m m
1,750mm
1,608mm
2,622mrn
1,533mm
1,534mm
1st
2nd
3rd
4th
Reverse
Geartype
Gearratio
2.533
Automatictransmission
2.722
1.079
0.711
1.955
Singlehelicalgear
4.357
0.393
ITEM
AIR CONDITIONING
Compressor
-Condenser
Evaporator
Blower
METRIC
Cooling capacity
Type/manutacturer
No. of cylinder
CaPacity
Max.speed
Lubricantcapacity
Lubricanttype
Type
Type
Type
Motor input
Speedcontrol
Max.capacity
ENGLISH
NOTES
j
14,000BTU/h
3,520Kcal/h
Scroll/KElHlN
85.7mf/rev
| 5.23cu'in/rev
10,000rpm
algIloz
130mf
1
sP-10
fin
Corrugated
Corrugated
fin
Siroccofan
200w 112v
4-Speeo
15,500 cu fvh
440 m3/h
Temperature
control
Compressor
clutch
Befrigerant
Type
Powerconsumption
Type
Ouantity
STEERING
SYSTEM Type
Overallratio
Turns, lock to lock
Steeringwheeldiameter
SUSPENSION
Type
Front
Bear
Shockabsorber
WHEEL
ALIGNMENT Camber
Tvpe
Front
hear
Front
Front
Rear
Front
Rear
Front
Rear
Tvpe
Caster
Totaltoe
BRAKESYSTEM
TIRE
ELECTRICAL
Frontand Rear
Sizeand pressure
Baftery
Starter
Alternator
In under-dash
fuse/relaybox
In under hood fuse/relaybox
In underhoodABSfuse/relay
box
Headlights
Frontturn signallights
Frontparkinglights
Frontsidemarkerlights
Rearsidemarkerlights
Rearturn signallights
Erake/parkinglights
Back-uplights
Ceilinglights{fronvrear)
Licenseplatelight
Spotlights
Highmountbrakelight
lgnitionkey light
Ashtraylight
Gaugelights
Indicatorlights
lllLrmination
and pilotIights
Heaterilluminationlights
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Dry,singleplate,poly-V-belt
drive
40 W max./12V
HFC-134a
1R-134a)
24j anoz
zoo o' g
Powerassisted,rackand pinion
At 68'F (20 C)
Independent
doublewishbone,coil spring
with stabilizer
Independent
doublewishbone,coil spring
with stabilizer
hydraulicnitrogengas tilled
Telescopic,
0'
- r"00'
2.10'
0mm
0in
l n 1 / 1 6i n
ln2mm
Power-assisted
selt-ad,usting
ventilateddisc
Power assistedself-adiustingdrum
49 cm, x 2
7.6sq-inx 2
7 3 c m ,x 2
1 1 . 3s q - i nx 2
reartwo wheelbrakes
Mechanical
actuating,
Seetire inlormationlabel.
Drum brake
12V, 36 AH/sHR
1 2 V 1 . 0 ,1 . 1k W
12V 100A
7.5A, 10A, 15A, 20 A
7.5A, 10A, 15A, 20 A, 30 A, 40 A
'100A
7 . 54 , 2 0 A . 4 0A
12V 60/55W
12V- 21 W ('97model),
1 2V - 2 7W ( ' 9 8 - 0 0m o d e l s )
12V 5 W {'97model),3CP('98- 00 models)
12V-8W
1 2V , 3 C P
12V-21W
12V 2115W
1 2 V 2 1C P( 1 8W )
12V-8W
12V-8W
12V-5W
1 2 V- 2 1 W
1 2V - 1 . 4W
1 2 V 1 . 4W
1 2V 1 . 4W , 3 W , 3 . 4W
1 2 V - 0 . 8 4 W ,1 . 1 2W , 1 . 4W , 3 W , L E D
12V - 0.84W, 1.4W, LED
1 2V , 1 . 4W
2-13
Body Specifications
U n i t :m m ( i n )
www.emanualpro.com
2-14
Maintenance
............3-2
Points
Lubrication
MaintenanceSchedulefor 1997Model
(NormalConditions)
...".3-4
Schedulefor 1997Model
Maintenance
(SevereConditions)
."...3-6
Schedulefor 1998- 2000Models
Maintenance
(NormalConditionsl
..'."3-8
Schedulefor 1998- 2000Models
Maintenance
(severeConditionsl
'....'3-10
I
www.emanualpro.com
LubricationPoints
Forthe detailsof lubricationpointsand type of lubricantsto be applied.referto the illustratedindexand variouswork procedures(suchas Assembly/Reassembly,
Replacement,
Overhaul,Installation,
etc.)containedin eachsection.
NO.
LUBRICATION
POINTS
Engine
Transmission
Manual
Automatic
Reardifferential
Brakeline(includesABS line)
ClutchLine
Release
fork (Manualtransmission)
10
l1
12
14
16
17
18
19
20
21
22
23
24
GenuineHondaMTF*1
GenuineHondaPremiumFormulaAutomaticTransmission
Fluid
(ATF)*'
GenuineHondaCVTFluid
4
5
LUBRICANT
gradeoil.The oil
APIServiceGrade:UseSJ "EnergyConserving"
containermay alsodisplaythe APICertitication
sealshown
"For
below.Makesure it says
GasolineEngines."SAEvjscosity:
Seechartbelow.
Power steeringgearbox
GenuineHondaDOT3 BrakeFluid*3
Brakefluid DOT3 or DOT4*3
Greasewith molybdenumdisultide
- PYs- 305
LJrea
GreaseUM264P/N4'1211
SteeringgreaseP/N 08733- B070E
T h r o t t l e c a b l e e n d { D a s h b o a r dl o w e r p a n e l h o l e l
Siliconegrease
Throttlecableend (Throttlelink)
Brakemastercylinderpushrod
Pedallinkage
Batteryterminals
F u e l f i l ll i d
Clutchmastercylinderpushrod
Hoodhingesand hood lock
Tailgatehinges
Hatchglasshinges
Doorhinges,upperand lower
Dooropeningdetent
Caliper Pistonseal,Dustseal,
Caliperpin, Piston
Shiltcableand selectcable{Manualtransmission)
Brakeline ioints(Frontand rearwheelhouse)
Powersteeringsystem
Air conditioningcompressor
25
API SERVICELABEL
/,.*-G\
/.'z-\e\
t / 6 A
E \ l
l-;-1 5w-30/---l
SEAL
API CERTIFICATION
ffi
Multi purposegrease
HondaWhiteLithiumGrease
Silicone grease
Rustpreventives
GenuineHondaPowerSteeringFluid-.
Compressor
oil: SP 10 lP/N38897- P13- A0lAH or
38899-P13-A01)
For Refrigerant:
HFC134a(R,134a)
Recomm6ndedEngine Oil
Engine
oilviscosity
for ambient
temperature
ranges
-20
20
100'F
10 20 30 40'c
0
r1: Always use GenuineHonda Manual TransmissionFluid {MTF).Using motor oil can causestiffer shifting becauseit
does not containthe orooeradditives.
*2: Always use GenuineHondaPremiumFormulaAutomaticTransmissionFluid(ATF).Usinga non-HondaATF can affect
shift qualitv.
+3rAlways use GenuineHondaDOT3 BrakeFluid.Using a non-Hondabrakefluid can causecorrosionand decreasethe
life of the system.
*4: Always use GenuineHondaPowerSteeringFluid.Usingany other type of power steeringfluid or automatictransmission fluid can causedincreasedwear and poor steeringin cold weather.
www.emanualpro.com
3-2
www.emanualpro.com
3-3
Maintenance
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3-10
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3-11
EngineElectrical
4-2
ChargingSystem
.............
SpeciafTools
4-22
ComponentLocationIndex ............
Starting System
4-23
....................,...........
Diagram
4-3
Circuit
ComponentLocationIndex ............
4-24
Troubleshooting..............................
4-4
CircuitDiagram................................
4-30
..........,.......
AlternatorReplacement
...........
4-5
StarterTest
4-31
AlternatorOverhaul.......,,................
4'5
StarterSolenoidTest ......................
.........4-32
RectifierTest
4-7
StarterReplacement.......................
...........
4-32
Inspection
Alternator Brush
4-7
FieldWindingTest ...........................
4-33
4-8
RotorSlip RingTest ........................
StarterOverhaul............................,.
4-33
.............
Stator Test
4-9
BrushInspection...........................,.,
Alternator Belt Inspectionand
OverrunningGlutchInspection ......4-9
........4-34
Adiustment
Armaturelnspectionand Test ........4-10
GruiseControl
4-12
BrushHolderTest ............................
4-36
ComponentLocationIndex .,,,........
4-12
StarterReassemb|y.........................
4-37
CircuitDiagram................................
4-13
PerformanceTest .............................
4-38
ControlUnit InputTest ...................
lgnition System
Main Switch Test/Replacement.....4-40
4-14
ComponentLocationIndex ............
Set/ResumeSwitch Test/
4-15
CircuitDiagram................................
4'40
Replacement.......................,........
lgnition Timing Inspectionand
....,,.,
4-41
Actuator Test
4-16
Setting ..........................................
4-42
Actuator Replacement...............,....
4-17
........,........
DistributorReplacement
4-43
Actuator CableAdiustment ............
4-18
DistributorOverhaul.............,,.........
4-43
ClutchSwitchTest ..........................
lgnition Control Module (lCM)Input
4-44
..........
SwitchTest ..................
T e s t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , .4.-. 1
. .9. . . . . . . . .Brake
..
...,.
4-44
Test
..............
Actuator Solenoid
4-2O
fgnitionCoilTest ..............................
4-45
ActuatorDisassembly.....................
lgnition Wire Inspectionand
4-20
Test ...............................................
4-21
SparkPlugInspection.....................
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ENGINE
SpecialTools
Ref. No.
Tool Number
o
-o
o
Description
Oty
VacuumPump/Gauge,
0 30 in.Hg.
BeltTensionGauge
SCSServiceConnector
* Includedin the BeltTensionGaugeSet,T/N 07JGG- 0010004
PageReference
4-41
434
4-16
o
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4-2
StartingSystem
ComponentLocationIndex
CLUTCHINTERLOCK
swtTcH{M/T)
BATTERY
Test,section23
I
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Test,page 4-43
Switchpositionadiustment,
section12
A/T GEARPOSITIONSWITCH{A/T}
Test,section14
Reolacement.
section14
Test,page4 5
SolenoidTest,page4-6
Replacement,page 4-7
Overhaul,page4 8
page4-12
Reassembly,
PerformanceTest,Page4-13
4-3
StartingSystem
CircuitDiagram
IGNTION
SWITCH
UNDER.HOOD
FUSE/RELAY
8OX
N0.41(100A)
N0.42(40A)
-+o
/ BAI
\i7
cf-.|
BLKMHT
II
I
ELKMHT
BLK'WHT
IGNITIONCONTROL
MOoULE
( CM)
STARTEF
CUl RELAY
-.1
GRY
BLKRED
GRN
I
PosrroN!
I A/TGEAR
(A/T) |
i swrTcH
ll \/ o N E o r N \ |
!--
p . s i t o n/
:
-_
--___J
f';--"-l
I TNTERLooK I
fYl""yl, I
8LK
STARTEB
(Fieldwndnglype)
Gl0l
www.emanualpro.com
4-4
StartingSystem
Starter Test
NOTE: The air temperaturemust be between 59 and
'100'F(15and 38"C)beforetesting.
RecommendedProcedure:
.
.
.
Usea stanersystemtester.
Conneca
t n d o p e r a t et h e e q u i p m e n ti n a c c o r d a n c e
instructions.
with the manufacturer's
Testand troubleshootas described.
Alte.nate Procedure:
.
Usethe followingequipment:
- Ammeter,0 - 400A
- Voltmeter,0 - 20 V (accurate
within 0.1volt)
T a c h o m e t e r ,-01 , 2 0 0r p m
Hookup a voltmeterand ammeteras shown.
NEGATIVETERMINAL
.
.
l f t h e s t a r t e rs t i l l d o e s n o t c r a n k t h e e n g i n e ,
removeit, and diagnoseits internalproblem.
lf the startercranksthe engine,go to step6.
www.emanualpro.com
6 . Checkthe ignitionswitch(seesection23).
7 . Checkthe startercut relay{seesection23}.
8. Checkthe IVT gear position switch (A/T)or the clutch
interlockswitch (M[).
Checkfor an open in the wire betweenthe ignition
switchand starter.
(cont'd)
4-5
StartingSystem
StarterTest (cont'dl
1.
B TERMINAL
MOUNTINGNUT
9 N.m 10.9kgtm,
7 tbtftl
www.emanualpro.com
4-6
TERMINAL
ARMATURE
HOUSING
(GROUND}
BLK/WHT
WIRE
2.
StarterReplacement
t.
STARTER
ERUSHES
7 rbtftl
RE
l0 x 1.25mm
4,1N.m {4.5 kgf.m,
33 tbt.ftl
5.
R e m o v et h e t w o b o l t s h o l d i n g t h e s t a r t e r .t h e n
remove the starter.
4.
I n s t a l l i n t h e r e v e r s eo r d e r o f r e m o v a l . W h e n
i n s t a l l i n gt h e s t a r t e r c a b l e , m a k e s u r e t h a t t h e
crimpedside ofthe ring terminal is facing out,
Crimpedside of ring
terminal
TERMINAL
o
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4-7
Starting System
Starter Overhaul
STARTERSOLENOID
STARTER
SOLENOID
Test,page4 6
OVEBRUNNING
CLUTCH
w
ARUSH
-6^l
MOLYBDENUM
DISULFIDE
SPRINGCLIP
Replace.
BBUSHHOLDER
Test,page4-12
GEARHOUSING
ARMATURE
HOUSING
ARMATURE
Inspection
and Test.page4-10
ENDCOVER
BAUSH
InsPeclon,page4-9
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4-A
..'...:|@{
MOLYBDENUM
DISULFIDE
BrushInspection
ClutchInspection
Overrunning
1.
2.
Brush Lsngth
Standard{Newl:14.0- I'1.5mm (0.55- 0.57inl
ServicoLimit: 9.0 mm (0.35in)
BRUSH
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3.
4-9
StartingSystem
ArmatureInspectionand Test
1.
I n s p e c t h e a r m a t u r ef o r w e a r o r d a m a g ed u e t o
contact with the field winding. lf there is wear or
damage.replacethe armature.
3.
C h e c kt h e c o m m u t a t o rd i a m e t e r .l f c o m m u t a t o r
d i a m e t e r i s b e l o w t h e s e r v i c el i m i t , r e o l a c et h e
armalure.
Commutator Diameter
Standard(Newl:27.9- 28.0mm (1.09- 1.10in)
ServiceLimilr 27.0mm (1.06inl
lnspectfor damage.
4.
Measurethe commutatorrunout.
l f t h e c o m m u t a t o r u n o u ti s w i t h i n t h e s e r v i c e
limit, checkthe commutatorfor carbon dust or
brasschipsbetweenthe segments.
lf the commutator runout is not within the service limit, replacethe armature.
CommutatorRunout
Standard(Newl:0 - 0.02mm (0 - 0.0008in)
ServiceLimit: 0.05mm {0,002inl
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4-10
5.
7.
NOT GOOD
MICA DEPTI{
COMMUTATOR
cotLcoRE
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4-11
StartingSystem
Starter Reassembly
O BRUSHHOLDER
2.
@ BRUSHHOLDER
E ^
F*4#-@
6t ta
al
la
tl l l
ft
SPRINGSCALE
3.
SpringTension:13.7- 17.7N
(1.40- 1.80kgf, 3.09- 4.00lbf)
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4-12
I n s t a ltlh e e n dcovero n t h e b r u s hh o l d e r .
,r
Test
Performance
1.
Disconnect
the wire from terminalN4.
5.
6.
7.
8,
M a k e a c o n n e c t i o na s d e s c r i b e db e l o w u s i n g a s
heavy a wire as possible(preferablyequivalentto
the wire usedfor the vehicle).
3.
12V
BATTERY
ie
Specifications:
Maker
DENSO
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Electriccurrent
90 A or less
Motor speed
3,000rpm or
more
4-13
lgnition System
ComponentLocationIndex
IGNITIONTIMINGCONTROLSYSTEM
. ldle speedInspection/Adjustment,
section11
. Inspectionand Sening.page4-16
SERVICECHECKCONNECTOR(2P)
lwi.c colo6: BRNrnd BLKI
TESTTACHOMETER
SPARKPLUGS
page4-21
Inspection,
DISTRIBUTOR
page4-17
Replacement,
Overhaul,page4-18
lgnitionCoilTest,page4,20
lgnitionControlModule CM)
InputTest,page4,19
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4-14
WIRES
Inspection
and Test,page4-20
CircuitDiagram
IGNITON
SWTCH
UNDEF.HOOD
FUSE/RELAY
8OX
UNDEF,DASH
FUSEiRELAYBOX
6\
l;;l
i{Hr6-(-\9-'-'*'.--EII
Eci,.pcM
' i Vl
BLK/YEL
l^
IGNITION
cotL
IGN]TION
CONTROL
MODULE
(CM)
/ Hasbuil-if\
I no|se
l
TDCTopdeadcenler
poslion
CKP Cran[shan
C Y PC y l n d epro s r l o n
TDC/CKP/CYP
SENSOR
l-- r
IGNTION
W]BES
i l ' i - - ,l
l
i f r
BLU
IJltfi
--cMFcr,r
SPARK
PLUGS
BLU BLU
l l / ' i
|
|
I
I I
resr
TACHOMETER
tott"to*
LTTCHoMEIEB
'97-'98 models
I
I l:
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'99- 00models
Gt01
4-15
lgnition System
lgnition Timing Inspectionand Setting
1.
2.
6.
C h e c kt h e i g n i t i o nt i m i n g i n n o l o a d c o n d i t i o n s :
headlights,blower fan, rear window defogger,and
air conditionerare not operating.
lgnitionTiming:
M/T: 16"12" BTDC(RED)idling in neutral
AlTt'16"!2" BTDC(RED)idling in E or E
MOUNTING
BOLTS
24 N.m{2.4kgfm, 17lbtft}
7 . Tightenthe distributormountingbolts,and recheck
t h e i g n i t i o nt i m i n g .
8.
CRANKSHAFT
PULLEY
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4-16
DistributorReplacement
Removal:
e
o
5.
1.
Disconnect
the connectorfrom the distributor.
2.
3.
R e m o v et h e m o u n t i n gb o l t s f r o m t h e d i s t r i b u t o r ,
then removethe distributorfrom the cylinderhead.
I'
CAMSHAFT
END
No. 1
CYLINDER
MARK
6.
7.
8.
BOLTS
MOUNTING
8 x 1.25mm
17lbfftl
2,1N.m{2.,1kgrf.m,
lnstallation:
1.
2.
3.
4.
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4-17
lgnition System
Distributor Overhaul
LEAK COVEN
CAPSEAL
Checkfor damage.
DISTRIBUTOR
IGNITIONIDII ROTOR
IGNITION{DII CAP
OISTRIBUTOR
Checkfor cracks,wear,
damage,and to!ling.
Cleanor replace.
IGI{ITIONIDOHOUSING
OISTBIBUTOR
forcracks
anddamage.
Check
O.RING
Replace.
IGNITIONCOIL
Test, page 4 20
@_
IGNITIONCONTROL
MODULE{ICMI
InputTest,page4-19
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4-18.
lgnitionControlModule(lCMlInputTest
NOTE:
. See section11 when the malfunctionindicatorlamp
( M l L )c o m e so n .
. Performan input test for the ignitioncontrol module
( l C M )a f t e r f i n i s h i n gt h e f u n d a m e n t atl e s t sf o r t h e
ignitionsystemand the fuel and emissionssystems.
. '97 -'98 models:The tachometershouldoperatenorm a l l yi f t h e I C Mi s O K .
T u r n t h e i g n i t i o ns w i t c hO N ( l l ) .C h e c kf o r v o l t a g e
betweenthe WHT/BLUwire and body ground.There
shouldbe batteryvoltage.
2.
Disconnect
the wiresfrom the lCM.
8LU WIRE
'98 models}
{'97 -
lf thereis no batteryvoltage,check:
- ignitioncoil.
- WHT/BLUwire betweenthe ICM and ignition
corl.
. lf thereis batteryvoltage,go to step5,
'97 model: Disconnectthe ECM/PCM
connectorA
(32P)C
. h e c kf o r c o n t i n u i t yo n t h e Y E L / G R Nw i r e
betweenthe ICM and ECM/PCM.There should be
continuity.
'98 - 00 models: Disconnectthe ECM,PCM
connector
B (25P).Checkfor continuityon the YEUGRNwire
betweenthe ICM and ECM/PCM.There should be
continuity.
Checkfor continuityon the YEUGRNwire to body
ground.Thereshouldbe no continuity.
7 . Reconnect
the ECM/PClvl
connector.
'97 -'98 models:
Checkfor continuityon the BLU
wire betweenthe test tachometerconnectorand the
lCM.Thereshouldbe continuity.
9 . ' 9 7 - ' 9 8 m o d e l s :C h e c kf o r c o n t i n u i t yo n t h e B L U
wire to body ground.Thereshouldbe no continuity.
'10. lf all the
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4-19
lgnition System
lgnitionCoilTest
1 . C a r e f u l l yr e m o v et h e i g n i t i o nw i r e s b y p u l l i n go n
the rubber boots.Do not bendthe wires;you might
breakthem inside.
IGNITIONWIRE
TERMINALA {+l
IGNITIONWIRE
4.
4-20
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SparkPlugInspection
Inspectthe electrodesand ceramicinsulatorfor:
2.
Checkthe electrodegaP.
.
ElectrodeGap
.
.
.
.
lmpropergap
Oil-fouling
Carbondeposits
Crackedcenter
electrodeinsulator
in)
1.1 3 ' mm (0.043Loo.
Standard
,--,
(--/
Burned or worn electrodesmay be causedby:
. Advancedignitiontiming
. Loosesparkplug
. Plugheat rangetoo hot
. Insufficientcooling
Fouledplug may be causedby:
. Retardedignitiontiming
. O i l i n c o m b u s t i o cnh a m b e r
. Incorrectsparkplug gap
. Plug heatrangetoo cold
. Excessive
idling/lowspeedrunnang
. C l o g g e da i r c l e a n eer l e m e n t
. Deteriorated
ignitionwires
| |
/
r--'--'--r
-.-l-:=---:1
:
Spark Plugs
'97 - '98 modsls:
Z F R 5 F - 1(1N G K )
(D
KJ16CR-11
1E N S O )
'99 - 00 models;
NGK)
Z F R 6 F - 1( 1
(DENSO)
KJ2OCR-111
Apply a small quantity of anti-seizecompound to
the plug threads,and screwthe plugs into the cylinder head finger-tight.Then torque them to 18 N'm
(1.8kgf.m.13lbf.ft).
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4-21
ChargingSystem
ComponentLocationIndex
CHARGINGSYSTEMLIGHT
(ln the gaugeassembly)
Test, page 4-24
BATTERY
Test,
ALTERNATOR
Troubleshooting,
page4-24
Replacement,
page4-30
Overhaul,page4-31
RectifjerTest,page 4,32
4-22
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ALTERNATOR
BELT
Inspection
and Adjustment,page4 34
CircuitDiagram
BOX
FUSUFtAY
UNDES.HOOD
BATTERY
(1Cr0A)
N0.41
,-a\
(40A)
N0.42
WHT/8tK
l.
( tot,o, )
IGNITON
SWITCH
8LI(YEL
GRN/RED
ECM/PCM
V
I
WHT/RED
ALTERNATOR
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4-23
GhargingSystem
Troubleshooting
lf the chargingsystemlight does not come on or does not go off, or the batteryis dead or low, test the followingitems in
the order listedbelow:
1. Battery(seesection23)
2. Chargingsystemlight
3. Voltage
4. Alternatorcontrolsystem(U.S.A.model)
5. Alternator/regulator
ChargingSystem Light Test
ChsrgingSystomLight Check:
Turn the ignition switch ON {ll),
and makesure the chargingsys
tem lightcomeson.
Doesthe chargingsystem
lightcome on?
Doesthe chargingsystem
light go offf
ALTERNATOR
4P CONNECTOR
{U.S,A.modell
Voltage Check:
Measurethe voltageat the No. I
lNo.2iterminalof the 4P [3Plconnectorwith the ignitionswitch ON
(BLK/YEL)
Wiresadeof
femaleterminals
{ ).
ALTERNATOR
3P CONNECTOR
lCanedamodel'
Iemale terminals
[ ] : C a n a d am o d e l
4-24
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(Frompreviouspage)
in
Ch6ckthe L circuil:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe 4P [3P] connectorfrom the alternator.
3. Turnthe ignitionswitchON (ll).
[ ]: Canadamodel
www.emanualpro.com
(cont'd)
4-25
ChargingSystem
Troubleshooting(cont'dl
'97 modol:
{WHT/GRNI
ALTEFNATOR
4P CONNECTOR
Wiresideof
femaleterminals
ECM/PCMCONNECTOR
A I32PI
,/1./
lstherelVorless?
1
t4
./ l./
26 27
Check for an open in the wire
(ALTClinel:
1 . T u r n t h e h e a d l i g hat n d i g n i tion switchOFF.
2. Disconnectthe 32P connector
from the ECN4/PCM.
3. Checktor continuitybetween
the EcM/PcM 32P connector
terminalNo.30 and alternator
4P connectorterminalNo.2-
ls therecontinuity?
4-26
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2A 29 30
Wire side of
femaleterminals
femaleterminals
21
32
] ALTC
I tWHT/cRNl
tl
WHT/GRN)
ALTERNATOR
irP CONNECTOR
ls therecontinuity?
10
1 6 1 7 1 8 t9 20 21
ECM/PCMCONNECTOR
A {32P}
4
,/ ,/
,/1,/
14
6
8
1 6 l 7 t 8 '19 20 21
10
27
:t2
2A 2S 30
Wire side of
femaleterminals
Subslitute a known-good ECM/
PCM,and recheck.
It prescribedvoha96 b now available, replacethe original ECM/
PCM.
23 21
I ALTC
{WHT/GRNI
f)
'oR
c
IWHT/GRN)
Wire sideol
femaleterminals
ALTERNATOR
4P CONNECTOR
l s t h e r e1 V o r l e s s ?
ECM,/PCM
CONNECTOR
c {31P)
Wire sideol
temaleterminals
C {31P}
ECM/PCMCONNECTOR
ALTC
IWHT/GBNI
Chack lor a rhort in tho wire
{ALTClincl:
' ! . T u r n t h e h e a d l i g hat n d i g n i '
tion switchOFF.
the 31Pconnector
2. Disconnect
Irom the ECM/PCM.
3. Ch6ckfor continuitybetween
the ECM/PCM31P connector
terminalNo. 2 and body
ground.
lu
rcM.
Rcpair rhort in thc wire b.twcon
th. ahGrn.tol.nd the EcM/PcM.
www.emanualpro.com
(cont'd)
4-27
GhargingSystem
(cont'd)
Troubleshooting
Alternator/RegulatorTest
NOTE:Makesurethe batteryis sufficientlycharged(seesection23).
Alternator/RegulatorTest:
1 . C o n n e c ta S u n V A T - 4 0( o r
e q u r v a l e ntte s t e r ) ,a n d t u r n
the selectorswitchto position
1{sraning).
2. Shift to neutral(A/T in E or
, n d s t a r tt h e
N) positiona
e n g a n eH. o l d t h e e n g i n ea t
3,000rpm with no load until
t h e r a d i a t o rf a n c o m e s o n ,
then let it idle.
3 . R a i s et h e e n g i n es p e e dt o
2,000rpm, and hold it there.
l s t h e v o l t a g e o v e r 1 5 . 1V ?
(BED)
FIELD
SELECTOR
TEST
NEGATIVE
TESTER
CABI.E{BLKI
swtTcH
Ahernator/Regulator
Test (cont'd)l
I Releasethe accelerator
pedal,
and let the engineidle.
2 Makesure all accessories
are
turned off. Turn the selector
switchto posjtion2 (charging).
3 Removethe inductivepickup,
and zerothe ammeter.
{ P l a c et h e i n d u c t i v ep i c k - u p
over the batterygroundcable
so that the arrow pointsto the
bafterynegativeterminal.
5 . R a i s et h e e n g i n es p e e dt o
2 000rpm, and hold ir there.
VOLTMEIER
POSmVE
INDUCTIVE
PICK.UP
{GRN)
TESTER
CABLEIREDI
WHTWIRE
l s t h e v o l t a g e l e s st h a n 1 3 . 5V ?
To next page
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4-28
Frompreviouspage
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4-29
ChargingSystem
AlternatorReplacement
l
I
' t . Disconnect
the batterynegativeterminalfirst, then
the positiveterminal.
N
ir
T
n
THROUGH
BOLT
WHT WIRE
MOUNTINGNUT
10x 1.25mm
44 N.m 14.5kgf.m.
33 tbtftt
LOCKNUT
8 x 1.25 mm
24 N.m (2.4kgt m, 17 lbl.ft,
4-30
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'll
AlternatorOverhaul
PULLEY
,T
PULLEYLOCKNUT
111N.m (11.3kgf.m,81.7lbf.ft)
BEARINGINSULATOR
FRONTBEARING
PULLEY
"'^.^t%
BRUSHHOLDER
INSULATOB
THROUGHBOLT
RECTIFIER
ASSY
Test.page4 32
PULLEYLOCKNUT
111N.m {11.3kgf.m,81.7lbf,ft)
REARHOUSING
COVER
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4-31
ChargingSystem
RectifierTest
AlternatorBrushInspection
1.
2.
M e a s u r et h e l e n g t ho f t h e b r u s h e sw i t h a v e r n i e r
calrper.
'l.
VERNIERCALIPER
2.
4-32
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Stator Test
RotorSlip RingTest
1.
1.
ROTORSHAFT
corLcoRE
SLIPRINGS
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4-33
ChargingSystem
AlternatorBelt Inspectionand Adjustment
NOTE:When usinga new belt,first adjustthe deflection
or tensionto the valuesfor the new belt, then readjust
the deflectionor tensionto the valuesfor the used belt
afterrunningenginefor five minutes.
Deflection methodi
A p p l ya f o r c eo f 9 8 N ( 1 0 k g t , 2 2 l b l l , a n d m e a s u r et h e
deflectionbetweenthe alternatorand crankshaftpulley.
Detlection:
UsedBelt:8.5- 11.5mm (0.33- 0.45inl
New Beft: 5.5 - 8.0 mm 10.22- 0.31 inl
NOTErlf the belt is worn or damaged,replaceit.
Measurehere
4-34
www.emanualpro.com
lf adjustment is necessary:
1.
2.
Move the alternatorto obtain the proper belt tension,then retightenthe nuts.
LOCKNUT
8 x 1 . 2 5m m
24 N.m (2.4kgtm,'17lbf ft)
NUT
MOUNTING
10x 1.25mm
14N.m{4.5kgl.m.33lbf.ft)
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4-35
GruiseControl
ComponentLocationIndex
CRUISEINDICATORLIGHT
(Builtinto gaugeassembly)
BulbLocations.
section23
BA
SET/RESUMESWITCH
Test,page 4 40
Beplacement,
page4-40
CRUISECONTROLUNIT
Input Test,page 4 38
swtTcH
Test, page 4-44
CLUTCHINTERLOCK
swrTcH{M/T)
PedalHeightAdjustment,
section19.
Test,page 4-43
Switchposkionadjustment,
section12
ACTUATOfiASSEMBLY
and VACUUMTANK
Test,page4 41
SolenoidTest,page4 44
A/T GEABPOSITION
swlTcH (A/Tl
'14
Test,section
www.emanualpro.com
+36
ACTUATORCAELE
Adjustment,page4-43
GircuitDiagram
IGNITON
SWITCH
FUSEi
RELAY
BOX
UNDER.HOOD
FUSARELAYBOX
UNDER.OASH
COMEINATON
L GH'I SWITCH
No41(100A) No42(404)
f7
I
RED/BLK
INDICATOR
LIGHT
(0.84W)
lP
IOSET
BRAK
LGHTS
2
1
6
1
7
1
2
C R U I SCEO N T R OUTN L T
1
1
3
10
CRUISE
PNK
CONTROL
ACTUATOR
BLK
It
4F\ /lr,mcern
t'
BLK
*: '98 00 modelswith
AutomaticTransmission.
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n:
G202
BLK
L_ll
I I
Y{"^i?tr'.flffi'JF
)l
t
rereasedl
/l
loN: Pedar
8LK
BLK
G101
G401
I
4-37
CruiseControl
ControlUnit Input Test
and proceduresin the SRS
SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations.precautions,
section(241beforeperformingrepairsor seryice.
'1. Removethe driver'sdashboardlowercoverand kneebolster{seesection20).
'l4P
connectorfrom the controlunit.
2.
Disconnect
the
3.
*: '98- 00 modelswith
AutomaticTransmission.
4-38
www.emanualpro.com
Wire
BRNAr'VHT
BRN
11
BRN/BLK
GRY
BLK
GRNMHT
LT GRN/
RED
7
LT GRN/
BLK
lgnitionswitch ON (ll),
main switch ON and
brakepedaldepressed,
then released
. Faultybrakeswitch
. An openin the wire
Setbuttonpushed
l4
PNK
B l o w nN o . 5 21 ' 1 A
5 lfuse inthe
under-hoodfuse/relaybox
Faultybrakeswitch
An open in the wire
Attach to ground:
Cruiseindicatorlight in the gauge
assemblyshould come on.
E l o w nb u l b
Blown No. 25 (7.5A) tuse in the
under-dashfuse/relaybox
Faultydimming circuit in the gauge
assembly
An open in the wire
Faultyvehiclespeed sensor(VSS)
An open in the wire
lgnitionswitch ON {ll}
and main switch ON
A'/T:Shift leverin E, E
otE
lvl/T:Clutchpedal
releaseo
Resumebuttonpushed
RED/BLU
LT GRN
Faultyactuatorsolenoid
Poorground(G202)
An openin the wire
lgnitjonswitch ON {ll}
and main switch ON;
raisethe front of the
ELU^r'r'HT
vehicle,block one wheel
and rotatethe other
wheel slowly.
r3
lgnitionswitch ON lll)
10
Test: Desiredresult
Test condition
fi{/r)
P o o rg r o u n d( G 1 0 1 )
An open in the wire
BLU
. Faultycruisecontrol unit
. Shod to ground
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4-39
CruiseControl
Main Switch Test/Replacement
1 . Carefullypry the switchout of the instrumentpanel.
Disconnect
the 6P connectorfrom the switch,
Set/ResumeSwitch
Test/Replacement
1 . Disconnectthe bafterynegativecable,then disconnectthe positivecable,and wait at leastthree minutes.
Terminal
sideof male
rermtnats
Disconnect
the driver'sairbagand front passenger's
airbagconnectors(seesection24).
6P CONNECTOR
Disconnect
the 6P connectorbetweenthe cablereel
sub harnessand the main wire harness.
BULES{0.84Wt
Checkfor continuitvbetweenthe terminalsin each
switchpositionaccordingto the table.
Terminal
-_\
5
;;;
OFF
G-
@o
ON
(9 ,{)
-o o- @ -o
Terminal
;;;
--_l
o-
S E T( O N )
(ON)
RESUME
Cf-
-o
c
4-40
www.emanualpro.com
ActuatorTest
6. Removethe two screws.then removethe switch.
nn-
1 . Disconnect
the actuatorcabletrom the actuatorrod
and the 4Pconnector.
SET/RESUME
,s
t*,r*
SETION)
(ON)
RESUME
.
.
1e
to
---o
oo- ---o
Terminalside
ot
maleterminals
The actuatorrod shouldpull in completely.lf the rod
pulls in only part-wayor not at all, checkfor a leaking vacuumIineor defectivesolenoid.
ACTUATOBROD
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4-41
CruiseGontrol
ActuatorTest (cont'dl
5.
ActuatorReplacement
' t . Pullbackthe boot.
and loosenthe locknut.Then dis-
Ar
1.
.J.
8.
9.
4-42
www.emanualpro.com
3.
Disconnect
the 4Pconnectorfrom the actuator.
4.
Disconnect
the vacuumhosefrom the vacuumtank.
Pullout the vent hose.
Removethe three mounting bolts and the actuator
with the bracket.
ACTUATOR
CABLE
I
4.
ACTUATOR
6.
lf necessary,
disconnectthe cableend from the linkage over the acceleratorpedal,then turn the grommet 90' in the bulkhead.and removethe cable.
7.
ActuatorCableAdiustment
ClutchSwitch Test
'1.
1.
CLUTCHSWITCH2P CONNECTOR
Terminalsideof
maleterminals
ACTUATORROD
LOCKNUTFREEPLAY:11 t 1.0 mm
10.43r 0.04 in)
2.
Removethe clutchswitch,
5.
Terminal
Clutch Switch
OEPRESSED
RELEASED
st
te
www.emanualpro.com
4-43
CruiseControl
ActuatorSolenoidTest
BrakeSwitch Test
1.
Disconnect
the 4Pconnectorfrom the switch,
2.
Removethe brakeswitch.
1.
ACTUATOR
{P CONNECTOR
of
Terminalside
maleterminals
Checkfor resistancebetweenthe terminalsaccording to the table.
il',",""*(t)
_\
o- - o
VENTSOLENOID
40-600
Check for continuity between the terminals according to the table.
Terminal
;;;;-t
RELEASED
PUSHED
O-
---o
o- -o
Terminal
Terminalsideof male
termtnals
VACUUM
SOLENOID
SAFEWSOLENOID
40-600
---o
30-500
---o
o-
To VACUUM
TANK
4-44
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ActuatorDisassembly
ACTUATORCABLE
ACTUATORERACKET
VACUUM
TANK
)rd'
!l
l
VALVES
Test, page 4-44
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4-45
E ngine
EngineRemovaUlnstallation
................
5-1
CylinderHead/Valve
Train ...................
6-1
E n g i n eB f o c k. . . . . . . . . .
...........7-1
EngineLubrication
...........8-1
IntakeManifold/Exhaust
System ........
9-1
Cooling
.........
10-1
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EngineRemovaUlnstallation
EngineRemoval/lnstallation
. . . . . . . . . . . . . . . . . . .5. -. .2. . .
Removal
.....................5-12
lnstallation
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EngineRemovaUlnstallation
Removal
@
4.
BATTERY
BASE
NOTEI
. U s e f e n d e rc o v e r st o a v o i d d a m a g i n gp a i n t e ds u r faces.
o To avoid damage.unplugthe wiring connectorscarefully while holdingthe connectorportion.
lvlarkall wiring and hosesto avoid misconnection.
Also, be surethat they do not contactother wiring or
hoses,or interferewith otherparts.
1.
2.
Disconnect
the batterynegativeterminalfirst,thenthe
positiveterminal.
I x 1.25mm
24 N.m (2.4kgf.m,
17 tbnft)
-t'.-e
F
F
Y
5.
INTAKE AIB
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6.
7.
6.
Disconnect
the enginecontrolmodule(ECM)/powerfrom the ECM/
traincontrolmodule(PCM)connectors
PCM.
7.
Disconnect
the main wire harnessconnector.
CONNECTOR
GROMMET
(cont'd)
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5-3
EngineRemoval/lnstallation
Removal(cont'dl
1 0 . Removethe cruisecontrolactuator(seesection4).
1 t . R e m o v et h e m o u n t i n g b o l t a n d l o c k b o l t , t h e n
removethe P/Spump belt and pump.
MOUNNNG BOLT
8 x 1.25mm
2a N.m 12.4kg{.m, 17 lbtftl
P/S PUMP
BELT
2s tbf.ft)
LOCKBOLT
I x 1.25mm
24 N.m {2.4kgtm, '17lbf.ftl
5-4
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,%l
*ryft
'fltr
\'t,f
EVAPCC
CANISTERHOSE
he
'.n
!d
BRAKEBOOSTER
VACUUM HOSE
'ol
FUELRETURN
HOSE
99 - 00 modob:
'99 - 00 modob:
BRAKEBOOSTER
VACUUM HOSE
THROTTLE
CABLE
LOCKNUT
ADJUSTING
NUT
(cont'd)
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5-5
EngineRemoval/lnstallation
Removal(cont'd)
17. Disconnect
the powersteeringpressure{psp} switch
connector,and removethe wire harnessclamo.
19. Disconnect
the transmissiongroundcable(M/T).
GROUNDCABI."E
(Mrr).
NOTE:
. Do not disconnectthe pipe/hoseassembly.
. Do not operatethe clutch pedal once the slave
cylinderhas beenremoved.
. Takecarenot to bendthe pipe/hoseassembly.
R e m o v et h e c o t t e r p i n s , t h e n r e m o v e t h e s t e e l
washers,plasticwashers,shiftcable,and selectcable
from the levers(M/T).
sElEcr
CABI."E
21. Removethe cable bracketfrom the clutch housing
(M/T).
5-6
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PRIMARYHO2S
CONNECTOR
SPLASH
GASKET
Replace.
NUT
SELF-LOCKING
8 x 1.25mm
NUT
22 N.m 12.2kgf.m,
8 x 1.25mm
16 lbf.ftl
16 N.m {1.6 kgf.m.
Replace.
12 tbt.ftl
Replace.
6x1.0mm
NUT
SELF.LOCKING
10x 1.25mm
54 N.m 15.5kgf.m,
.() tbf.frl
Replace.
8 x 1.25mm
2,1N.m {2.4 kgf,m, 17 lbl ft)
BAR
9.8N.m{1.0kgf.m, GUARD
7.2tbf.rr)
26. L o o s e nt h e d r a i n p l u g i n t h e r a d i a t o r .D r a i n t h e
enginecoolant(seepage10-51.
the drain
oil or fluid. Reinstall
2 7 . Drainthe transmission
plug using a new washer lsee section 13 (M/T)or section 14 (ly'T)].
28. Drainthe engineoil. Reinstallthe drain bolt using a
new washer{seepage8-4).
29. Bemovethe A,/Ccompressor.Do not disconnectthe
!y'C hoses.
ER
lC
EB
GASKET
Replace.
SELF.LOCKING
8 x 'l.25mm
22 N.m (2.2kgf m,
16 rbf.ftl
Replace.
NUT
SELF.LOCKING
8 x 1.25mm
16 N.m 11.6kgf.m,
12 tbt fr)
Replace.
10 x 1.25mm
54 N.m 15.5kgt.m,
40 rbt.ftl
Replace.
{cont'd)
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5-7
EngineRemovaUlnstallation
Removal(cont'dl
31. Removethe shift cable.Take care not to bend the
cablewhen removingit. Always replaceany kinked
cablewith new one (Afl-).
OOI{TROLPI
SNAPPIN
sHtFTCABtt
OOVEB
8 x 1.25mm
t2 N.m 12.2lgtr'l'',,
16tbf.ftl
5-8
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rd
te
n-
3 8 . R e m o v et h e u p p e r a n d l o w e r r a d i a t o rh o s e sa n d
heaterhoses.
4 1 . Removethe radiator(seepage10"4).
42. Removethe IVC hoseclamp.
A/C HOSE
rt,
BT
3 9 . R e m o v et h e t r a n s m i s s i o ng r o u n dc a b l ea n d h o s e
clamp(A,/T).
9.8 'm lt.o klt m,
l.2tutal
GBOUI{DCABLE
6 x l1,0
6x
,0m
mm
m
11 N.m 11.1lof'm,
I tbf.ftl
40. Remove the ATF cooler hoses, then plug the ATF
cooler hoses and, n"" lAfI).
(cont'd)
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5-9
EngineRemovaUlnstallation
Removal(cont'dl
43. Attachthe chainhoistto the engine.
5-10
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UPPER
Replace.
M/T:
TRANSMISSION
Alf I
MOUNTBMCKET
REABMOUNT
is completelyfree
Checkthat the engine^ransmission
hoses,
and electriand
coolant
hoses,
fuel
of vacuum
calwiring.
150mm (6 in)'
49. Slowlyraisethe engineapproximately
wires
are disconhoses
and
Checkonce again that all
nectedfrom the enginenransmission.
50. Raisethe engineall the way, and removeit from the
vehicle.
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5 - 11
Engine Removal/lnstallation
Installation
Bracket Bolts Torque Specifications:
P/S PUMP
BRACKET
SIDEEIIGII{E
i'OUT{T BRACKET
t t 1.25m.D
2a 'tn (2,4 kgt ft,
17 tbtftl
10 x 1.25mm
54 t$m 15.5tgfm,
iO lbflrl
10 x 125 mm
il,a t*m {4.5 tgt'm,
d, tbtft)
ALTERI{ATOR
BNACKET
A/C @MPRESSOR
BRACIGT
t0 r 125 ]nm
a,l t+Jnll.5 lgf-rn,
3 tbf{tl
8 r 1.25mm
24 N.m 12.4kg{.m;
17tbtfrl
5- 12
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10 x 1.25mrn
,L il.tn {1.5 tgt m, :|:l lbf'ft}
2.
EngineInstallation:
lnstallthe enginein the reverseorderof removal.
Reinstall
the mount bolts/nutsin the followingsequence
Failureto follow these proceduresmay causeexcessrve
noiseand vibration.and reducebushinglife.
1 . 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 a n d b r a c k e t t. h e n
tighten the bolts on the frame side. Do not tighten
the bolts/nutson the transmissionside.
O 12 x 1.25mm
7a N.m {7.5kgf'm,
54 tbf.trl
A 12r1.25mm
7il N.m 17.5kgl'm,
5,r lbt.ft)
A/T:
TM'{SMISSION
MOUNT
12x 1.25mm
6,aN.m16.5kgtr.m,
47 tbt f0
R
R
3.
TRANSMISSION
MOUNT BRACKEY
M/T:
TRANSMISSION
MOUNT
12x 1.25mm
64 N.m {6.5kgt.m,
47 tbl.ft)
!, m,
MOUNN G BOLT
Replace.
(cont'd)
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5-13
EngineRemovaUlnstallation
(cont'd)
Installation
4.
T i g h t e nt h e b o l t / n u t so n t h e t r a n s m i s s i o nm o u n t
bracketin the numberedsequence.
5.
AIT:
@ 12 x 1.25mm
?4 N.m {t.5 kgt.h,
5,4lbf.ftl
O 12x 1.25mm
6l .m (6.5kgtm,
47 tbt{r}
M/T:
i?. 12 x 1.25mm
74 N.m {7.5kgf'm.
s/rtbr.ftl
,,.....\.L}
@'...,'..4:
a1l12 x 1.25mm
64 N.m {6.5kgf.m,
47 lbf.ft)
5 - 14
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12 x 1.25mm
59 N.m {6.0 lgl'm, ait lbf.ftl
Replace.
6.
then tightenthe
Installthe rightfront mounvbracket,
boltsin the numberedsequence.
7.
A/T:
Loosen th is nut,
i! 12x 1.25mm
g N.m {6.5 kgf.m, 47 lbf.ftl
Replace.
(D to x t.zs mm
44 N.m{4.5kgfm, 33 lbf.ft)
O 12 x 1.25mm
59 N.m 16.0kgt ln, , lbfttl
Replace.
@ lo x 1.25mm
a,aN.m14.5kgf.m,
33 tbf.trl
M/T:
Loosenthis nut.
O 10x r.25mm
4/tN.m14.5kgt.m,33lbf.ft)
O 12 x 1.25mm
64 N.m 16.5kgf.m.47 lbf.ft)
Replace.
{cont'd)
www.emanualpro.com
5-15
EngineRemoval/lnstallo
cton
Installation(cont'd)
8.
59 .m 16.0tgt m, (l lbfftl
Replace.
MlTi
12 x'1.25mm
59 N.m 16,0kgt m, /(} lbt ttl
Reolace.
5-16
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9.
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5-17
CylinderHead/ValveTrain
.............6-2 Camshafts
SpeciafTools
..............6-22
lnspection
ValveClearance
Valves,Valve Springsand Valve Seals
............6-3
Adiustment
................,
6-23
Removal
ValveSeals
.............
6-29
lnstallation
Replacement(cylinderhead
6-5
removalnot requiredl.................
Valve Guides
CrankshaftPulleyand PulleyBolt
6-25
ValveMovement............,,,,.,............
.........6-7
Replacement
.........6-25
Replacement
Timing Belt
.................6-27
Reaming
6-8
Illustratedlndex ...............................
Valve Seats
.............,
6-9
Inspection
......6-28
Reconditioning
6-9
TensionAdjustment........................
...........,.....
6-10
Removal
.............6-11
lnstallation
(CKFI
Fluctuation
Speed
Crankshaft
Sensor
.........6-13
Replacement
CylinderHead
6-14
lllustratedlndex ...............................
.................6-16
Removal
................6-27
Warpage
.............
6-30
lnstallation
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SpecialTools
Ref. No.
Tool Number
07JAA- 001020A
07JAB- 00'10204
OTMAB_ PY3O1OA
07757- PJ1010A
07942- 6570100
07984- 657010D
,61
A)
a!)
a!)
c--E-rr------------
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6-2
Description
Socket,19 mm
H o l d e rH a n d l e
PulleyHolderAttachment,50mm, Offset
ValveSpringCompressorAnachment
ValveGuideDriver,6.6 mm
ValveGuideReamer,6.6 mm
(Xy
1
1
r
1
1
'l
PageRefereflce
6-1
6-7
I 6-7
I
|
6-23,29
6-25,26
6-27
ValveClearance
Adiustment
Adjustthe valvesonly when the cylinderheadtemperature is lessthan 100"F(38"C).
1.
Removethe cylinderheadcover.
Removethe middlecover(seepage6-11).
"UP" mark on the
Set the No. 1 pistonat TDC.The
pulleysshouldbe at the top, and the TDC markson
the pulleysshouldalignwith the pointerson the back
LOCI(NUT
9 x 0.75m.n
25 N.m 12.5kgf.m, 18lbf.ft)
POINTER
POINTER
No.4
No.3
No.2
No. 1
EXHAUST
(cont'd)
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6-3
ValveClearance
Adjustment(cont'dl
6.
to brinq
8. Rotatethe crankshaft180"counterclockwise
No. 4 pistonto TDC.
The "UP" marksshould be pointingstraightdown.
Adjustthe valveson No. 4 cylinder.
"UP" MARKS
GAUGE
7.
(camshaft
Rotatethe crankshaft180"counterclockwise
pulleyturns90').
The "UP" marksshouldbe on the exhaustside.Adjust
the valveson No.3 cylinder.
.UP" MARKS
to brino
Rotatethe crankshaft180'counterclockwise
No.2 pistonto TDC.
The "UP" marksshouldbe on the intakeside.Adiust
the valveson No. 2 cylinder.
"UP" MARKS
1 0 . Installthe cylinderheadcover(seepage6-32).
1 1 . Retorquethe crankshaftpulleybolt (seepage6-7).
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ValveSeals
Replacement(cylinderhead removal not required)
The procedureshown below applieswhen usingthe inc a r v a l v e s p r i n g c o m p r e s s o r( S n a p - o nY A 8 8 4 5w i t h
YA8845-2A7/8" auachment). Use approved eye protection.
1. Turn the crankshaftso that the No. 1 and the No. 4
pistonsare at top deadcenter(TDC).
2.
Removethe cylinderheadcover.
3.
Removethe distributor.
4.
L o o s e na n d d i s c o n n e c t h e t i m i n g b e l t f r o m t h e
camshaftpulleys.
5.
at.
Selectthe 7/8 in. diameterlong compressorattachment,and fastenthe attachmentto the front hole of
the leverarm with the speedpin supplied.
OIL PASSAGES
't1. Position
the lever arm under the crossshaft so the
lever is perpendicular
to the shaft and the compressor attachmentrests on top of the retainerfor the
spring being compressed.Usethe rear positionslot
on the leveras shown,
(cont'd)
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6-5
ValveSeals
Replacement(cylinderheadremovalnot requiredl(cont'dl
12. Usingan upwardmotionon the leverarm,compress
the valve spring and removethe keepersfrom the
valvestem.Slowlyreleasepressureon the spring.
24. Using a downward motion on the lever arm, compressthe valvespringand removethe keepersfrom
t h e v a l v e s t e m . S l o w l y r e l e a s ep r e s s u r eo n t h e
spring.
Repeatstep24 for the othervalvein that cylinder.
Removethe valveseals(seepage6-24).
2 1 . Installthe valveseals(seepage6-29).
28. Installthe springs,the retainersand the keepersin
reverseorderof removal.
29. Repeatsteps21 to 28 on the otherthreecylinders.
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o-o
CrankshaftPulleyand PulleyBolt
Replacement
When installingand tighteningthe pulley,follow the procedurebelow.
Clean,removeany oil, and lubricatepointsshown below.
C: Clean
x I Removeany oil
a: Lubricate
CRANKSHAFT
PULLEY
WASHER
CRANKSHAFT
X
X
o
oooo o
o
o
- oooo o
X
X
^ oooo o
o
o
o
6r.
R
o".
HOLDERATTACHMENT.
50 mm, OFFSET
OTMAB- PY3OlOA
SOCKET,19 mm
07JAA- 001020A
available}
{or Commercially
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6-7
TimingBelt
lllustratedIndex
HEAD
CYLINDER
COVER
Referto page6-32
when installing.
HEADCOVERGASKET
Replacewhen leaking,
damagedor deteriorated.
Apply liquidgasketat
the eightcornersof the
\
@
Cl
WASHER
Replaceif damaged
or deteriorated,
k6
TIMING BELT
page6-9
Inspection,
Adjustment,page6-9
Removal,page6-10
page6-11
Installation,
SEAL
RUEBER
Replaceil damaged
ot detetiorated.
8 x 1.25mm
37 N.m (3.8kst.m,27lbf ftl
MIDOLECOVER
6x1.0mm
9.8N.m {1.0kgf.m,
1.2lbt.ftl
SEALS
RUBBER
when damaged
Replace
or deteriorated,
LOWERCOVER
ADJUSTINGBOLT
10 x 1.25mm
54 N.m (5.5kgl.m, 40 lbf.ft)
TIMINGBELT
ORIVEPULLEY
PULLEY
CNANKSHAFT
page6-7
neplacement,
R e p l a c e m e n t ,p a g e 6 ' 7
lnstallwith concave
surfacefacingout,
Removeany oaland clean,
SPEEO
CRANKSHAFT
FLUCTUATIONICKF}
SENSOR
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6x1.0mfi
1 1N . m{ 1 . 1k g t m ,
8.0 rbtft)
6x1.0mm
9.8Nm(1.0kgl.m,
7.2 tbl.ft)
BOLT
14 x 1.25mm
177N.m (18.0kgf'm,
130 tbf.fr)
Replacement,
Page6-7
Do not usean impact
wrenchwhen installing.
Inspection
TensionAdjustment
1 . Removethe cylinderheadcover.
NOTE:
. Alwaysadjustthe timing belt tensionwith the engine
coto.
. Always rotatethe crankshaftcounterclockwise
when
v i e w e df r o m t h e p u l l e ys i d e . R o t a t i n gi t c l o c k w i s e
m a y r e s u l ti n i m p r o p e ra d i u s t m e not f t h e b e l t t e n sion.
2.
lnspectthis
areafor wear.
2.
3.
4.
5.
ADJUSTINGBOLT
5,4N.m (5.5 kgf.m,
40 tbtftl
For adiustmentonly,
rotation,
Rotatethe crankshaftcounterclockwise
three teeth
on the camshaftpulley.
3.
7.
8.
9.
Installthecylinderheadcover(seepage6-32).
Installthe cylinderheadcover(seepage6-32).
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6-9
Timing Belt
Removal
Replacethe timing belt at 105,000miles (168,000km)
accordingto the maintenanceschedule{normalconditions/severe
conditions).lf the vehicleis regularlydriven
in eitherof the following conditions,replacethe timing
belt at 60,000miles(U.S.A.l100.000km (Canada).
- ln very high temperatures(over 110'F,43"C).
- In very low temperatures(under-20"F.-29"C).
5.
,l
6.
Removethe cruisecontrolactuator(seesection4).
7.
S u p p o r tt h e e n g i n ew i t h a j a c k ,t h e n r e m o v et h e
u p p e r b r a c k e t .M a k e s u r e t o p l a c e a c u s h i o n
betweenthe oil Danand the iack.
12 x 1.25mm
74 N.m (7.5kgf m, 54 lbtftl
24 N.m 12.4kgf.m, lt lbf.ftl
BRACKET
4.
6-10
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Installation
8. Removethe cylinderheadcover.
1.
9 . Removethe crankshaftpulley(seepage6-7).
GROOVE
POINTER
6x1.0mm
9.8N.m {1.0kgt m,
DRIVEPULLEY
Clean.
LOWER
COVER
2.
9.8N.m(1.0kgt.m,7.2lbf.ftl
CAMSHAFT
PULLEY
Clean.
r-t
AINUSTING BOLT
54 N.m (5,5 kgt m,
.(} tbf.rrl
1 3 . R e m o v et h e t i m i n gb e l t .
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POINTER
(cont'd)
6-11
Timing Belt
Installation(cont'd)
3.
POINTERON
4.
5.
C l e a n .t h e n i n s t a l l t h e l o w e r c o v e r a n d m i d d l e
cover.
Installthe crankshaftpulley,then tightenthe pulley
bolt (seepage6-7).
1.
POINTER
6-12
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CKFSensor
Replacement
1.
4.
L o o s e nt h e l o c k b o l t a n d m o u n t i n g b o l t , t h e n
removethe P/Spump belt.
MOUNTING
BOLT
8 x 1.25mm
24 N.m (2.{ kgf.m, 17 lbf.ttl
PUMP
10 x 1.25 mm
a4 N.m (4.5kgt m, 33 lbtft)
BELT
BELT
E
Removethe cylinderheadcover.
6.
Removethe crankshaftpulley(seepage6-7).
7.
aJ.
CKFSENSOR
6x1.0mm
11 N.m {1.r kgnm,8.0lbfft)
|o|'ln PUUCYBMCKETSOLI
l0 r 1.25mm
14 .m 14.5kgl.m,3:'lbtftl
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9.
6-13
GylinderHead
lllustratedIndex
To avoiddamage,wait until the enginecoolanttemperaturedropsbelow 100'F(38'C)beforeremovingthe cylinderhead.
6x1.0mm
9.8 N.m (1.0kgI.m, 7.2 lbf.ft)
WASHER
Replace
when damaged
or deteriorated,
CYLINDERHEAD
COVEB
Reterto page6 32 when
installingcylinderheadcover.
HEAOCOVERGASKET
Beplacewhen leaking,
damagedor deteriorated.
Apply liquidgasketat
the eightcornersof the
RUBEER
SEAL
R e p l a c ei f
or deteriorated,
8 x 1.25mm
24 N.m (2.4
17 tbtft)
6x1.0mm
9.8N.m (1.0kgf.m.
7.2 tbf.fo
Applyengineoil to the
threads.
Seesection4.
CYLINDEB
HEADPLUG
Replace-
---..-@
CAMSHAFT
HOLDER
0+---.."...s<--
KEY
DOWEL
PIN
OIL SEAL
Replace.
CAMSHAFT
PULLEY
8 x 1.25mm
37 N.m {3.8kgf.m,
27 tbtft)
OILSEAL
Replace.
6x1.0mm
9.8 N.m (1.0kgl.m,7.2lbtftl
6-1 4
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gasket.
VALVEKEEPERS
CYLINDERHEADBOLT
1 1x 1 . 5m m
85 N.m {8.7kgf.m,6:} lbf.ft)
Tightening,page6'30.
Applyengineoilto the threads.
END PIVOTBOLT
63 N.m 16.4kgl m, 46 lbf.ft)
SPRINGBETAINER
EXHAUSTVALVE
SPRING
INTAKEVALVE
SPRING
INTAKEVALVESEAL
Replace.
EXHAUSY
VALVE
SEAL
Replace.
VALVESPRING
SEAT
EXHAUSTVALVE
GUIDE
page6-25
Inspection,
page6-25
Replacem6nt,
Reaming,page6-27
INTAKEVALVE
GUIDE
HEAD
Removal,page6-16
Warpage,page6 27
Valveseatreconditioning,
page6 28
page6-30
Installation,
EXHAUST
VALVE
INTAKEVALVE
Removal,page6-23
page6-29
Installation,
CYLINDERHEAO
GASKET
Replace.
OIL CONTROL
ORIFICE
Clean.
10x 1.25mm
4,0N.m {i1.5kgf.m.
33 rbf.ft)
O.RING
Replace.
DOWELPIN
8 x 1.25mm
24 N.m (2.4kgf.m,
17 tbf.ft)
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6-15
GylinderHead
Removal
Engineremovalis not required
for thisprocedure.
6.
l!@
LOCKNUT
8 x 1.25mm
24 N.m (2.4 kgf.m, 17 lbt.ftl
2.
10x 1.25mm
44 N.m (4.5kgt.m. 33 lbf.ft)
BELT
Removethe intakeair duct and air cleanerhousing
(seepage5-2).
4.
R e m o v et h e m o u n t i n gb o l t a n d l o c k b o l t , t h e n
r e m o v et h e p o w e r s t e e r i n g( P / S )p u m p b e l t a n d
pump (seepage5-4).
5.
7.
Removethe P/SOUmobracket.
ADJUSTINGBOLT
LOCKNUT
8 x 1 . 2 5m m
24 N m {2.4ksf.m, 17 lbttt}
l0 x 1.25mm
44 N.m (4.5kgf.m,
33 rbf.ft)
IOLERPULLEYBBACKETBOLT
10 x 1.25mm
44 N.m {4.5 kgtm, 33 lbf ft)
tt\
aA
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o-Io
8.
9. Relievefuel pressure(seesection11).
Do not smoke while working on the
@
fuel systom. Kop opon flame or sparks away from
ths work area. Drain fuol only into an approved
containgr.
'10, Removethe evaporativeemission (EVAP)control
canisterhoseand fuel feed hose.
'!X, - 00 modob:
CANISTERHOSE
{cont'd)
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6-17
GylinderHead
Removal(cont'dl
'11. Removethe brakeboostervacuumhose.fuel return
hose,and vacuumhose.
'97 - 98 modsls:
BRAKEBOOSTER
PCVHOSE
BREATHEB
HOSE
VACUUM
HOSE
'99 - 00 models:
BREATHER
HOSE
BRAKEBOOSTEB
VACUUM HOSE
PCVHOSE
6-18
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WATERBYPASS
UPPEB
RADIATOR
HOSE
HEATER
HOSE
R e m o v et h e e n g i n ew i r e h a r n e s sc o n n e c t o r sa n d
wire harnessclampsfrom the cylinderheadand the
intakemanifold.
o Fourfuel injectorconnectors
. E n g i n ec o o l a n tt e m p e r a t u r e( E C T )s e n s o rc o n neclor
. Radiatorfan switchconnector
. Coolanttemperaturegaugesendlngunlt connector
. Throttlepositionsensorconnector
. Manifold absolute pressure{MAP) sensor connector
Primary heatedoxygen sensor (primary HO2S)
connector
a ldle air control(lAC)valveconnector
Distributorconnector
u p p e r b r a c k e t .M a k e s u r e t o p l a c e a c u s h i o n
betweenthe oil pan and the iack(seepage6-10).
(cont'd)
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6-19
CylinderHead
Removal(cont'dl
Removethe timing belt (seepage6-10).
EXHAUSTMANIFOLD
BRACKET
'r
10 x 1.25mm
44 N.m 14.5kgf,m,
33 rbf.ft)
SELF.LOCKING
NUT
54 N.m {5.5kgf.m, .{) lbf.ftl
Replace.
'97 98 U.S. models {Excepi Calitornia}:
'99 0O modeb:
BACKCOVER
GASKETS
Replace.
SELF.LOCKING
NUT
10 x 1.25mm
54 N.m {5.5kgt.m, 40 lbtft}
Replace.
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6-20
10 x 1.25mm
4il N.m (4.5kgf.m,
33 tbf.ftl
2 3 . R e m o v et h e i n t a k em a n i f o l dm o u n t i n gb o l t s a n d
water bvDasshose.
ROCKERARM
8 x 1.25mm
2,1N.m 12.4kgt.m,
17 tbf.ft)
CYLINDERHEADBOLTSLOOSENINGSEOUENCE:
24. Loosen the locknuts and adjusting screws,
INTAKE
No. 4
No.3
No.2
N o .1
No.3
No.2
N o .1
EXHAUST
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6-21
Camshafts
Inspection
1 . Loosenthe adjustingscrews.
Removethe camshaftholders.
Camshatt-toHoldGrOil Clearance:
Standard {Newl: 0.030- 0.069mm
{0.0012- 0.0027in}
ServicoLimit: 0.15 mm (0.006in)
Rotat6camshatt
while measuring.
6-22
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Valves,Valve Springs
and ValveSeals
Removal
13. Measurethe cam lobe height.
Cam Lobe Height Standard (Newl
'97 - 98 models:
INTAKE: 33.20,1mm(1.3072in)
EXHAUST:33.528mm (1.3200inl
'99 - 00 models:
INTAKE: 33.716mm 11.327t1in)
mm (1.3200in)
EXHAUST:33.528
l d e n t i f yt h e v a l v e s a n d v a l v e s p r i n g sa s t h e y a r e
removedso that eachitem can be reinstalledin its original Dosition.
1.
socketand plasticmallet.
Usingan appropriate-sized
retainer
to loosenthe valvekeeP
lightlytap the valve
ers beforeinstallingthe valvespringcompressor'
2.
VALVESPRINGCOMPRESSOR
KD No. 3&!. whh *'5 JAW o.
VALVESPRINGCOMPRESSOR
ATTACHMEUT
07757- PJ1010A
(cont'd)
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6-23
VALVEGUIDESEALREMOVER
LISLEP/N 57900or KD3350or equivalent
(Commerciallv
available)
Removethe valveseal.
6-24
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- 1.226inl
11.21s
- 10/t.10
103.80
mm
{i[.087- 4.098in)
6.580- 6.590mm
(0.2591- 0.2594in)
6.55 mm (0.258inl
1.35- 1.65mm
(0.053- 0.05s in)
1.15mm (0.045in)
ValveGuides
ValveMovement
Replacement
c l e a r a n c ew i t h a d i a l
1 . M e a s u r et h e g u i d e - t o - s t e m
in the directionof
the
stem
indicatorwhile rocking
normalthrust(wobblemethod),
1.
VALVEGUIDEDRIVER
(Commerciallv
available)
6.4 mm
ExhaustValve Stem-to-GuideClearance:
Standard{Newl:0.10- 0.16mm
(0.004- 0.006inl
ServiceLimit: 0,22mm (0.009inl
(0.25inl
_,1-r
,_T-_
*]-'
sz mm
l2.21inl
l r l
'11.3mm
(0.{,r in}
or
VALVEGUIDEDRIVER,
6.6mm
0t9a:I- G5t01q)
l f t h e m e a s u r e m e net x c e e d st h e s e r v i c el i m i t ,
recheckusinga new valve.
2.
3.
stillexceedsthe limit,subtractthe
lf the measurement
O.D.of the valvestem,measuredwith a micrometer,
from the l.D. of the valve guide, measuredwith an
insidemicrometeror ballgauge.
T a k et h e m e a s u r e m e n tisn t h r e e p l a c e sa l o n g t h e
valvestem and three placesinsidethe valveguide
The differencebetweenthe largestguide measurem e n t a n d t h e s m a l l e s st t e m m e a s u r e m e nsth o u l d
not exceedthe servicelimit.
lntake Valve Stem-to-GuideClearance:
Standard (New): 0.02- 0.05 mm
{0.001- 0.002in)
ServiceLimit: 0.08 mm (0.003in)
2.
S e l e c tt h e p r o p e r r e p l a c e m e n gt u i d e s .a n d c h i l l
t h e m i n t h e f r e e z e rs e c t i o n o f a r e f r i g e r a t o rf o r
aboutan hour.
3.
ExhaustValve Stem-to-GuideClearance:
Standard(New):0.05- 0.08mm
(0.002- 0.003in)
ServiceLimit: 0.11mm (0.004in)
(cont'd)
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6-25
ValveGuides
(cont'dl
Replacement
Workingfrom the camshaftside,use the driver and
a n a i r h a m m e rt o d r i v et h e g u i d ea b o u t2 m m ( O . l
i n ) t o w a r d s t h e c o m b u s t i o nc h a m b e r .T h i s w i l l
k n o c ko f f s o m e o f t h e c a r b o na n d m a k e r e m o v a l
easier.Hold the air hammerdirectlyin line with the
valveguideto preventdamagingthe driver.
8.
Turn the head over and drive the guide out toward
the camshaftside of the head.
ATTACHMENT
'o C'
6.
7.
6-26
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CylinderHead
Reaming
Warpage
oil clearances(seepageG22)
NOTE: lf camshaft-to-holder
the head cannot be resurare not within specification,
faced.
3.
C o n t i n u et o r o t a t e t h e r e a m e r c l o c k w i s ew h i l e
removingit from the bore.
4.
5.
Checkclearancewith a valve(seepage6-25).
REAMERHANDLE
mm
vALvE GUIDEREAMER,6.6
0798i1- 657010O
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6-27
Valve Seats
Reconditioning
lf the guidesare worn (seepage6-25),replacethem (see
pagee25) beforereconditioning
the valveseats.
1.
5.
VALVE
SEAT
o
PRUSSIAN
C a r e f u l l yc u t a 4 5 os e a t , r e m o v i n g o n l y e n o u g h
materialtoensurea smoothand concentricseat.
Bevelthe upperedge of the seatwith the 30. cutter
and the lower edge of the seatwith the 60" cutter.
Checkwidth of seatand adjustacco.dingly.
f-]
VALVESTEM
INSTALLEDHEIGHT
8.
6-28
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VALVESPRINGCOMPRESSOR
lComm6rciallyavailable)
KD No. 383,with *35 JAw or
BLACK
SPRING
EXHAUSTVALVESEAL
VALVEGUIDE
SEALINSTALLER
lCommerciallyavailable)
KO3372or equivalnt
ot
07GAD- PH70100
VALVESPRIT{G
OOMPfiESSOR
ATTACHMENT
0775'- PJ1010A
7.
PLASTE
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6-29
CylinderHead
Installation
Installthecylinderheadin the reverseorderof removal:
1.
2.
CYLII{DER
HEAD
GASKET
Rplace.
4.
CYLINDER
HEADBOLTSTOROUESEOUENCE:
DOWELPIN
O.RING
Roplace.
DOWEL
PIN
T i g h t e nt h e i n t a k em a n i f o l dm o u n t i n gb o l t s ( s e e
page6-21).
OIL CONTBOL
ORIFICE
Clean.
6 -30
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7.
I?,ITAKE
No. I
EXHAUST
EXHAUST
II{TAKE
(cont'd)
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6-31
CylinderHead
Installation(cont'dl
' 1 3 .A l i g n
t h e m a r k so n t h e c y l i n d e rh e a d p l u g t o t h e
cylinder head upper surface,then installthe cylin
d e r h e a dp l u gi n t h e e n d o f t h e c y l i n d e hr e a d .
CYLINOER
HEAD
1 9 . T h o r o u g h l yc l e a nt h e h e a d c o v e r g a s k e ta n d t h e
groove.
PLUG
Replace.
'18. Adjust
the valveclearance(seepage6-3).
1 4 . lnstallthebackcover.
I x 1.25mm
37 N m (3.8*gl.m, 27 lbt.tr)
6x1.0mm
9.8N.m(1.0kgtm,
7.2|hrftl
Pushthe camshaftpulleysonto the camshafts.then
tightenthe retainingboltsto the torquespecified.
6-32
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NOTE:
. Do not installthe parts if five minutesor more
h a v e e l a p s e ds i n c e a p p l y i n g l i q u i d g a s k e t .
Instead,reapplyliquid gasketafter removingold
residue.
. After assembly.wait at least 30 minutes before
filling the enginewith oil.
to
Applyliquidgasket
areas.
theshaded
26. C h e c kt h a t a l l t u b e s , h o s e s a n d c o n n e c t o r sa r e
installedcorrectly.
www.emanualpro.com
6-33
En g i n eB loc k
.............7-2 CylinderBlock
SpeciafTools
lllustratedlndex ...................................
7-3
Inspection
..............7-13
Flywheeland Drive Plate
PistonPins
Replacement
..,.,....7-5
Removal
..,.......,,.....
7-14
ConnectingRod and Grankshaft
Installation
.............
7-15
E n dP l a y
. . . . . . . . . . . . . . . . . 7 - 6 Inspection
..............
7-16
MainBearings
ConnectingRods
-7
-14
Cfearance
...............7
Selection
................7
................7-8 PistonRings
Selection
-17
ConnectingRod Bearings
End Gap
.................7
Clearance
...............7-8
Ring-to-GrooveClearance...............
7 -17
................7-9
Replacement
.........7-18
Selection
Pistonsand Crankshaft
Alignment
..............
7-18
Removal
.................7-9 CrankshaftOil Seal
Crankshaft
lnstallation
.............
7-19
Inspection
..............
7-11
Crankshaft
Pistons
lnstalfation
.............7-20
fnspection
..............7-12 Oil Seals
fnstaflation
.............7-20
fnstalfation
....,..,.....7-23
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tl
SpecialTools
Ref, No.
Tool Numbor
07GAF- PH60300
07HAF- P120102
07LAB- PV00100
07LAD- PT30101
07LAF- PR30100
07948- S800101
07749- 0010000
07973- PE00310
07973- PE00320
07973- 6570500
07973- 6570600
@
@
/6
@
@
@
@
Oty
Description
PageReterence
,l
PistonPin Baselnsert
PistonBaseHead
RingGearHolder
SealDriver
PilotCollar
SealDriverAttachment.76 x 80 mm
Driver
PistonPin DriverShaft
PistonPin DriverHead
Piston Base
PistonBaseSpring
7-14,15
1-'t4,15
1-5
1-23
7-14,15
7-'t9,24
7 -'t9, 24
1-14,15
7-14,15
7-'t4,15
7-14,15
1
I
I
1
1
1
1
1
1
1
eE
E
g
0
o
7-2
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lllustratedlndex
Applyliquidgasketto the matingsurfacesof the right side coverand oil pump casebeforeinstallingthem.
Jse liquidgasket,PartNo. 08718- 0001or 08718- 0003.
:lean the oil pan gasketmatingsurfacesbeforeinstallingthe oil pan.
WASHER
Replace.
76 x 1.0 mm
y'
9
t:n-
l.zxstm, 8.7lblftl
oIL PAN
to page1-22
when installing
OIL PAN GASKET
Replace.
1 1 x 1 . 5m m
76 N.m {7.8kgl.m, 56 lbf.ft}
Appiyengineoilto the bolt
threaos.
NOTE:Afterlorquing
eachcap,turn the crankshaft
to checkfor binding.
6x1.0mm
9,8N.m (1,0kgf.m,
7.2 tbt.lrl
BEARINGCAP
BAFFI.f PLATE
OOWELPIN
MAIN BEARINGS
page7 8
Selection,
NOTE:New main bearingsmust
be selectedby matchingthe crank
and blockidentification
markings.
otL
6 x ' 1 . 0m m
9.8 N.m {1.0kgtm,
7.2 tbf.ftl
GASKET
Replace.
6x1.0mm
9.8N.m 11.0kgt m,
7.2tbt+tl
CRANKSHAFT
OIL SEAL
Installation,
page7-19
1 2x 1 . 0m m
Replace.
/ , 7 1 N n 1 7. 5
ks{ m 5a lbtft) {a/Tl
&it
ln
OIL PUMP
Overhaul,page8-8
Removal/lnspection,
page8-9
Applyliquidgasket
to mating surface.
WASHERIA/T}
ORIVEPLATEIA/T)
Checkfor cracks.
6x1.0mm
9.8 N.m 11.0kgt.m,7.2lbtft)
8 x 1.25mm
2a N.m(2.akgt.m,---\6/
RIGHTSIDECOVER
Apply liquidgasket
to matingsurface,
CRANIGHAFTSEAL
page8-10
Installation,
Replace-
6x1.0mm
9.8 N.m l'1.0kgf.m,7.2 lbf.ft)
O.RING
Replace.
THRUSTWASHERS
Groovedsides face outlvard,
NOTE:Thrustwasherthickness
is lixed and must not be changed
by grindingor shimming.
(cont'd)
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7-3
lllustratedIndex(cont'd)
NOTE:New rod bearingsmust be selectedby matchingconnectingrod assemblyand crankshaftidentificationmarkings
(seepages7-91.
DIRECTION:
INSTALLANON
PISTON
parts
with
engine
oil
Lubricateall internal
EXHAUST
during reassembly.
l1\AAtr\
\9q9Q9e/
INTAKE
PISTON PIN
Removal,page7-14
page7-15
Installation,
Inspection.page7-16
PISTONRINGS
Replacement.page 7-18
page7-17
Measurdment,
Alignmnt,page7-18
PISTON
page7-12
Inspection,
ENGINCBLOCK
Cylinderbore inspection.pago 7-13
Warpage inspoction,Page7-'13
CONNECTING
End play, page 7-6
page7-14
Selection,
COiINECI'ING ROD
BEARINGS
Clearance,page 7-8
Solection.page7-9
RODBEARINGCAP
CONNECTING
page7-20
lnstallation,
NOTE:Installthe capsso the
bearingrecessis on the
samesideasthe recess
in the rod.
RODCAPNUT
CONNECTING
8 x 0.75mm
31 N.m {3.2kgl.m.
23 tbf.ftl
Apply engine oil to the bolt threads.
NOTE:Aftertorquingeachbearing
to checkfor
cap,rotatethe crankshaft
binding.
7-4
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ENGINE
BLOCK
12 x 1.0mm
103 N.m 110.5kgf.m,
76 lbf.ft)
RINGGEAR
Inspectring gear
teethfor wear or damage,
RI G GEARHOTDER
07LAB - PV001|X)
AutomaticTransmission:
Removethe eight drive plate bolts, then separatethe
drive platefrom the crankshaftflange.After installation,
tightenthe bolts in the sequenceshown.
/ AzXi{'jA\Ao
12 x 1.0mm
7a N.m
(7.5 kgt.m,5a lbf.ftl
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7-5,
3.
2.
SCREWORIVER
CrankshaftEnd Play:
Stand.rd (New):0.10- 0,35mm
(0.004- 0.014inl
0.45
mm (0.018inl
ServiceLimit:
4.
7-6
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MainBearings
Clearance
lf the plastigagemeasurestoo wide or too narrow,
( r e m o v et h e e n g i n e i f i t ' s s t i l l i n t h e v e h i c l e ) ,
removethe crankshaft,and removethe upper half
of the bearing.Installa new, completebearingwith
the same color code (selectthe color as shown on
the next page).and recheckthe clearance,Do not
f i l e , s h i m , o r s c r a p et h e b e a r i n g so r t h e c a p s t o
adjustthe clearance.
1 . T o c h e c k m a i n b e a r i n g - t o - j o u r n aoli l c l e a r a n c e ,
C l e a ne a c h m a i n j o u r n a l a n d b e a r i n gh a l f w i t h a
cleanshoptowel.
3.
4.
7.
lf the plastjgageshows the clearanceis still incorrect,try the ne)dlargeror smallerbearing{the color
listedabove or below that one),and checkagain.lf
the proper clearancecannot be obtained by using
the appropriatelarger or smaller bearings,replace
the crankshaftand startover.
R e i n s t a ltlh e b e a r i n g sa n d c a p s ,t h e n t o r q u e t h e
bolts,
1st step:25 N'm (2.5kgf.m,18lbf.ft)
Final siep: 76 N'm 17.8kgl.m, 56 lbf.ftl
NOTE:Do not rotatethe crankshaftduring inspectron.
R e m o v et h e b e a r i n gc a p a g a i n ,a n d m e a s u r et h e
widestpart of the plastigage.
Main Bearing.to.JournalOil Clearance:
Stand8.d {New):
N o .1 , 2 , 4 , 5 J o u r n s l s :
0.02i1- 0.0i12mm (0.0009- 0.0017inl
No. 3 Journal:
0.030- 0.0i18mm (0.0012- 0.0019inl
ServiceLimit: 0.06 mm 10.002in)
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7-7
ConnectingRod Bearings
Main Bearings
Selection
Clearance
1.
""""""""
Smallerbearing(rhicker)
Green
Green
Elacl
7- 8
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Alue
7.
Pistonsand
Crankshaft
Selection
Removal
1.
Numbershave been stampedon the side of each connectingrod as a code for the size of the big end. Use
lhem, and the lettersstampedon the crankshaft(codes
for rod journalsize),to choosethe correctbearings.
lf the codesare indeciDherable
becauseof an accumulat i o n o f d i r t a n d d u s t ,d o n o t s c r u bt h e m w i t h a w i r e
brushor scraper.Cleanthem only with solventor detergent.
Half of numberis
stampedon beanng
cap and the othel
half is stampedon
rod.
2
---------------r.
l l A o r tl l
l l B o ' l l l
l l c o t r l ll l
I l-.. ilril I
t - l
Smaller
'od
Red
OIL PUMP
Pink
Pink
Green
Brown
Green
Brown
Black
Elack
Blue
Green
Green
Brown
5.
Removethe baffleplate.
Smaller
beanng
(thicker)
(cont'd)
www.emanualpro.com
7-9
Pistonsand Crankshaft
Removal(cont'dl
6.
7.
7-10
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Crankshaft
Inspection
1.
2.
Out-of-Roundand TaDer
4.
Alignment
3.
M e a s u r et h e r u n o u to n a l l m a i n j o u r n a l st o m a k e
sure the crank is not bent. The differencebetween
m e a s u r e m e n tosn e a c hj o u r n a lm u s t n o t b e m o r e
thanthe servicelimit.
CrankshaftTotal IndicatedRunout:
StandardlNew):0.03mm (0.001in) max.
ServiceLimit:
0.04 mm {0.002in)
Measureout-ol'
roundat middle.
DIAL INDICATOR
Rotate two complete
revolut|ons.
Measuretaper
at edges.
5.
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7-11
Pistons
Inspection
L
3.
Piston Diameter:
Standard (New): 8:1.980- txl.990mm
(3.3063- 3.3067inl
Limit:
83.970
mm {3.3059inl
Service
SKIRTDIAMETER
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7-12
CylinderBlock
Inspection
M e a s u r ew e a r a n d t a p e r i n d i r e c t i o n sX a n d Y a t
three levelsin eachcylinder.lf the measurements
in
any cylinderare beyond the ServiceLimjt, replace
the block.
2.
SURFACESTO BE MEASURED
PRECISION
STRAIGHTEDGE
CvlinderBole Size:
Standard{Newl:84.00- 84.02mm
{3.307- 3.308inl
ServiceLimit: 84,07mm (3.310inl
Bore TaDer:
Limit: {Difterencebetween first and third measurement) 0.05mm {0.002in)
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7-13
PistonPins
ConnectingRods
Removal
Selection
PISTONBASEHEAO
07HAF -PL20102
PISTONPIN BASEINSERT
07GAF- PH60300
CONNECTINGROD BORE
REFENENCE
NUMBER
Half of numberis stampedon
bearingcap, the other half on
connectno roo.
PISTONBASE
07973- 6570500
R
Ir1
nT--u
ffi-"""-
PISTONPIN DRIVERSHAFT
07973- PEt0310
u_ll
3.
PILOTCOLLAR
07LAF- PR30100
Embossodmarkfacingup.
7-14
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PistonPins
lnstallation
otL Hor.E
1.
PISTONPIN DRIVERSHAFT
0t973 - Pqxtlo
ffi*r,"ron'nl
PILOT COLLAR
OTLAF- PF3O1(x'
PISTONPIN BASEINSERT
07GAF- PH6o3ttO
PISTONBASE HEAD
OTHAF- PL2O102
PISTON BASE
07973 - 6670500
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7-15
PistonPins
Inspection
1.
3.
Oversize:
{0.8266- 0.8268in}
20.998- 21.002mm
(0.8267- 0.8268in)
4.
2.
M e a s u r et h e p i s t o np i n t o p i s t o nc l e a r a n c el .f t h e
p i s t o n p i n c l e a r a n c ei s g r e a t e rt h a n 0 . 0 2 4m m
(0.0009inL remeasureusingan oversizedpistonpin.
7-16
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PistonRings
Glearance
Ring-to-Groove
EndGap
1.
U s i n ga p i s t o n ,p u s h a n e w r i n g i n t o t h e c y l i n d e r
bore 15 - 20 mm (0.6 0.8 in) from the bottom
2.
M e a s u r et h e p i s t o nr i n g e n d - g a pw i t h a f e e l e r
g au g e :
. lf the gap is too small,checkto see if you have
the properringsfor your engine.
. lf the gap is too large,recheckthe cylinderbore
'13.
diameteragainstthe wear limits on page7
PistonRingEnd-Gap:
Top Ring
Standard(Newl:0.20- 0.30mm
- 0.012inl
10.008
ServiceLimit: 0.60 mm {0.024inl
SecondRing
Standard lNew): 0.i10- 0.55 mm
{0.016- 0.022inl
ServiceLimit: 0.70mm (0.028in)
Oil Ring
Standard(Newl:0.20- 0.50mm
- 0.020in)
10.008
ServiceLimit: 0.70 mm (0.028in)
PISTONRING
--:4
ll
ENDGAP-1f-
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7-17
PistonRings
Replacement
Alignment
l.
2.
Installtheringsas shown.
C l e a n a l l t h e r i n g g r o o v e st h o r o u g h l yw i t h a
squared-offbroken ring or a ring gtoove cleaner
with a bladeto fit the pistongrooves.
TOP RING
'97 - 98 models:
I n s t a l lt h e n e w r i n g s i n t h e p r o p e rs e q u e n c ea n d
position(shownin the right column).
'99 - O0modls:
l-;
RING EXPANDER
|-
T f
+-
' 1
A
Top Ring {standard}:
A: 3.1 mm (0.12in)
B: 1.2mm 10.05inl
SecondRing (standard):
A: 3.'1mm (0.f 3 in)
B: 1.2mm (0.05in)
N O T E : T h e m a n u f a c t u r i n gm a r k s m u s t b e t a c i n g
upward.
MARK
ropnrNG+S
z:-\
SECONDRING+
,A-\
o**^o(
ffi+-sPAcER
\zu-\
7-18
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CrankshaftOil Seal
lnstallation
Rotatethe rings in their groovesto make sure they
do not bind.
Positionthe ring end gaps as shownl
SECONDRINGGAP
1.
DRIVER
Appror.90"
Appror.
90'
TOP RI.IIGGAP
DO NOT position any ring gap
in linewith the pistonpin hole.
OIL RING
GAP
SPACERGAP
lnstallsealwith the
part numberside
facingout.
OIL RINGGAP
0.5-0.8 mm
{O.02 0.03 in)
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7-19
Pistons
Crankshaft
Installation
Installation
1.
1.
3.
4.
NUISIO:
31 N.m (3.2kgf.m,23tbf.ft)
Apply engineoil to the bolt threads.
lf the crankshaft is not installed:
2. Removethe rod caps and bearings,and installthe
flng compressor.
3 . P o s i t i o nt h e p i s t o n i n t h e c y l i n d e r ,a n d t a p i t i n
u s i n gt h e w o o d e n h a n d l eo f a h a m m e r .M a i n t a i n
downwardforce on the ring compressorto prevent
rings from expandingbefore enteringthe cylinder
oore,
4. Positionall the pistonsat top deadcenter.
5.
6.
CONNECTING
ROO
OIL HOLE
outward.
Rotatethe crankshaftclockwise,and seat the jour
n a l s i n t o c o n n e c t i n gr o d s N o . 1 a n d N o . 4 , I n s t a l l
the rod caps and nuts finger-tight.Installthe caps
s o t h e b e a r i n gr e c e s si s o n t h e s a m e s i d e a s t h e
recessanthe rod.
C h e c kt h e r o d b e a r i n gc l e a r a n c ew i t h p l a s t i g a g e
(seepage7 8). then lorque the capnuts.
Torque:
3l N.m 13.2kgf.m, 23 lbt.ftl
Apply engine oil to the bolt thleads.
7.
I n s t a ltl h e t h r u s tw a s h e r so n t h e N o . 4 j o u r n a l .
RUBBERHOSES
\\
7 -20
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RIGHTSIDE
6x1.0mm
9.EN.m {1.0 kgt m,
7.2 tbf.ft)
OOWELPINS
NOTE:
. Do not install the parts if five minutes or more
h a v e e l a p s e ds i n c ea p p l y i n gt h e l i q u i d g a s k e t .
Instead,reapplyliquid gasketafter removingthe
old residue.
. After assembly,wait at least 30 minutes before
f i l l i n gt h e e n g i n ew i t h o i l .
(cont'dl
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7-21
Crankshaft
(cont'd)
Installation
1 2 . Apply liquid gasketto the oil pump mating surface
of the block.
1 3 . Apply a light coat of oil to the crankshaft,the lip of
the seal,and the O-rings.
Applyliquidgsket
to thesepornts.
17. Installthe oil pan gasketand oil pan. Wait no
than five minutesafterapplyingliquidgasket.
{
^
6x1,0mm
9.8 N.m {1.0 kg{.m,
,.2 tbf.ftl
OILPAN
"[z
(..6
GASKET
Replace.
6x1.0mm
9,8 N.m 11.0kg{.m,
7.2lbt.trl
,'t
./o,
DowEL PtN
//
O-RING
Replace.
OIL PUMP
7 -22
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OIL PAN
|
8 x 1.25mm
24 N.m {2.4 kgf.m,
17 tbt.ftl
GASKET
Replace.
Oil Seals
lnstallation
18. Tightenthe boltsand nutsfingertight at six points.
1.
SEALDRIVER
OTLAD- PT3O1OA
lnstallsealwiththe
partsnumberside
facingout.
(cont'd)
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7-23
Oil Seals
(cont'dl
Installation
4.
<:
DRIVER
ATTACHMENT
76x80mm
07948- 5800101
I n s t a lsl e a l w i t ht h e
n u m b e rs i d ef a c i n g
out,
7 -24
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EngineLubrication
...".""'8-2
S p e c i aTf o o l s . . . . . . . . . .
.'...8-3
l l l u s t r a t e dI n d e x. . . . . . . . . . .
E n g i n eO i l
. . . . . . . . . . . . ' . . ' . .8. -' .4. '
Inspection
. .-.4. . . . . . . .
R e p l a c e m e n. .t. . . . . . . . . . . . . . . . . . . . . . . . . . ' 8
OilFilter
R e p 1 a c e m e n t . . . . . . . . . . . . . . . . . . . . . . . . . .8. .-.5. . . . . . . . . . .
Oil PressureSwitch
".....8-7
Testing
Oil Pressure
....'.'8-7
Testing
OilPump
. . . . . . . . . . . , . . . .8. .-.8. .
Overhaul.....
....'.'8-9
Removal/lnspection/lnstallation
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SpecialTools
Ret. No.
8-2
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I
I
Tool Number
OTLAD_ PT3O1OA
0 7 9 ' 1-2 6 1 1 0 0 0 1
Description
SealDriver
Oil FilterWrench
Oty
1
1
Pagc Roforance
8-10
8-6
lllustratedIndex
OIL CONTROL
ORIFICE
'--
/o-RrNG
\
,/
\^
O-RING
OILPUMP
Overhaul,page8-8
page8 I
Removal/lnspection,
Apply liquidgasketto
matingsurfaceof engineblock.
./
v,/
Reptace.
'99 - 00 models:
KNOCKSENSOR
31 N.m {3.2 kgf.m.23 lbl.ft)
ENGINEOIL PRESSURE
SWITCH
18 N.m {1.8kgtm, 13lbl.ft)
1/8in. BSPT(BritishStandard
PipeTaper)28 Threads/inch.
Useproperliquidsealant.
DOWELPIN
6x1.0mm
9.8 N.m (1.0kgf.m,
7.2 tbl.ft)
8 x 1.25mm
24 N.m 12.4kgf.m,
17 tbf.ft)
BAFFLEPLATE
6x1.0mm
9.8 N.rn{1.0kgtm,7.2 lbtftl
OIL PAN
GASKET
Replace.
Replace.
OILPAN
Befertopage7 22
w h e ni n s t a l l i n g .
6x1.0mm
9.8 N.m 11.0kgf m,
7.2 tbf.ftl
SCREEN
WASHEB
Replace.
6x1.0mm
12 N.m 11.2kglm,8.7 lblftl
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DRAINBOLT
4,1N.m{,1.5kgf'm,33lbf ft)
Do not overtighten.
8-3
EngineOil
Inspection
Replacement
2.
2.
Make certainthat the oil level indicatedon the dipstick is betweenthe upper and lower marks.Insert
the dipstickcarefullyto avoid bendingit.
1 . W a r mu p t h e e n g i n e .
D r a i nt h e e n g i n eo i l .
l f t h e l e v e l h a s d r o p p e dc l o s et o t h e l o w e r m a r k ,
add oil until it reachesthe uppermark.
ORAINBOL
4il N.m {4.5kgtm,33 lbf.ft)
Do not overtighten.
3.
WASHER
Rplace.
3 . 5{ ( 3 . 7U S q t , 3 . 1l m p q t )
at oil change.
3 . 8/ ( 4 . 0U S q t , 3 . 3l m p q r )
at oil changeincludingfilter.
4.6{ (4.9US qt, 4.0 lmp qt)
afterengineoverhaul.
Change
Inlerval
Every7,500miles(12,000km) or
12 months(Normalconditions)
Every3,750miles(6,000km) or 6
months(Severeconditions).
N O T E : U n d e r n o r m a l c o n d i t i o n s t, h e o i l f i l t e r
shouldbe replacedat everyother oil change.Under
severeconditions,the oil filter should be replaced
a t e a c ho i l c h a n g e .
8-4
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Oil Filter
Replacement
The numbersin the middle of the API Servicelabeltell
you the oil's SAE viscosityor weighl. Selectthe oil for
your vehicleaccordingto this chart:
AmbientTemperature
1 . R e m o v et h e o i l f i l t e r w i t h t h e s p e c i a lo i l f i l t e r
wrench.
lnsoectthe threadsand rubbersealon the new filter.
Wipe off the seaton the engine block,then apply a
light coatof oil to the filter rubberseal.
1 0 0F
-30
-20
-10
40c
A n o i l w i t h a v i s c o s i t yo f 5 W - 3 0 i s p r e f e r r e df o r
i m p r o v e df u e l e c o n o m ya n d y e a r - r o u n dp r o t e c t i o ni n
the vehicle.You may usea 10 W - 30 oil if the climatein
your area is limited to the temperaturerangeshown on
the chart.
-G
oil to rubberseal
Deroreinstalling.
API SERVICELABEL
4.
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R u n t h e e n g i n et o r m o r e t h a n three minutes,then
checkfor oil leakage.
(cont'd)
8-5
Oil Filter
Replacement(cont'd)
Installtheoil filter by hand.
A f t e r t h e r u b b e r s e a l s e a t s ,t i g h t e n r h e o i l f i l t e r
clockwisewith the specialtool.
l) Makea markon the cylinderblockunderthe number that showsat the bottomof the filterwhenthe
rubbersealis seated.
2) Tighten the filter by turning it clockwiseseven
numbersfrom the makespoint.For example,if a
mark is made underthe number2 when the rubber seal is seated,the filter should be tightened
untilthe number1 comesup to the markedpoint.
OIL FILTERWRENCH
07912-61 10001
MARK
Numberwhen rubber
seal is seated.
Numberafter tightening.
5
8
6 7
IJ
6 7
8-6
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Oil PressureSwitch
Testing
Testing
L
Oil Pressure
Connecta tachometer.
2.
ENGINE
OILPRESSURE
SWTTCH
MOUNNNG
HOt-E
PRESSURE
SWTCH
18 N.m {1.8kgf.m,
13 tbr.ftl
Apply liquidsealant
to the threads,
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8-7
Oil Pu mp
Overhaul
OUTERROTOR
pages8-9,1O
Inspection,
6x1.0mm
5 N.m {0.5kgt m. 4lbtft}
DOWELPIN
6xl.0mm
9.8 N m (1.0kg,tm, 7.2 lbf ftl
PUMPCOVER
pages8-9,10
lnspection,
Apply liquidgasket
to the matingsurfaceof
the cylinderblock
when anstalling.
REI-IEFVALVE
Valvemust slidefreely
in the housingbore.
Replace
the valveif it is scored.
8 x 1.25mm
2{ N.m (2.4 kgf m,
17 tbf.fi)
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8 -8
RemovaUlnspection/lnstallation
1.
D r a i nt h e e n g i n eo i l .
R e m o v et h e c r a n k s h a f tp u l l e y , a n d r e m o v e t h e
lowercover.
6.
7.
8.
9.
rotor clearance
the pump rotor. lf the inner-to-outer
e x c e e d st h e s e r v i c el i m i t . r e p l a c et h e i n n e r a n d
outer rotors.
lnner Rotor-to Outar Rotor RadialClearance
Standard{Newl:0.04- 0.16mm
{0.002- 0.006inl
ServiceLimit: 0.20 mm (0.008in)
orL
PUMP
OLRING
Replace.
OIL SCREEN
HOUSING
(cont'd)
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8-9
Oil Pump
Removal/lnspection/lnstallation(cont'd)
1 3 . Checkthe housing-to-outer
rotor radialclearance.lf
the housing-to-outer
rotor radialclearanceexceeds
the servicelimit, reDlacethe set of inner and outer
rotorsand/orthe pump housing,
Housing-to-OuterRotor RadialClearance
StandardlNewl: 0.10- 0.19mm
{0.004- 0.007in}
ServiceLimit: 0.20 mm {0.008inl
1 7 . R e a s s e m b lteh e o i l p u m p , a p p l y i n gl i q u i dt h r e a d
lockto the pump housingscrews.
1 8 . Checkthat the oil pump turnsfreely.
1 9 . Apply a light coatot oil to the seallip.
NOTE:
.
8-10
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8 x 1.25mm
24 N.m 12.4kgf.m,
'17tbf.ft)
O-RING
Applyengineoil
Replace.
DOWEL
PIN
6x1.0mm
9.8 N.m {1.0kgf.m,
1.2lbfitl
OIL PUMP
6x1.0mm
9.8Nm(1.0kgf.m,
7.2 tbt ft)
6x1.0mm
9.8N.m (1.0kgf.m.
7.2 tbtftl
OIL SCBEEN
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8-11
IntakeManifold/ExhaustSystem
IntakeManifold
Rep1acement
.......................................
9-2
ExhaustManifold
Replacement
.......................................
9-4
ExhaustPipeand Muffler
Replacement
.......................................
9-6
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IntakeManifold
Replacement
NOTE:
. Use new O-ringsand gasketswhen reassembling.
. Checkfor folds or scratcheson the surfaceof the gasket.
. Replacewith a new gasketif damaged.
'97 - 98 models:
INTAK MANIFOLD
R e p l a c ei f c r a c k e d o r
i f m a t i n g s u r f a c e sa r e
oamageo,
INTAKEAIR
TEMPERATURE
{IATISENSOR
22 N.n 12.2kgl.m,
16 rbf.ftl
8 x 1.25mm
22 N.m 12.2kgtm.
't6 tbf ft)
8 x 1.25mm
22 N.m |.2.2kgl.rn,
'16tbt ftl
I x 1 . 2 5m m
24 N m 12.4kgf m.
17 tbf.ft)
INTAK
BRAC}
INTAKEMANIFOLO
BRACKETB ('98 modell
I x 1.25mm
24 N.m 12.4kgf.m,
17 tbf.ft)
8 x 1.25mm
24 N.m (2.4kgf.m,
17 tbf.ft)
9-2
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8 x 1.25mm
23 N m (2.3kgt m,
17 tbf.ftl
'99 - O0modol3:
6x1.0mm
9.8 N.m 11.0kg{.m,
7.2 tbtltl
NESONATOR
6x1.0mm
9.8 N.m {1.0 kgf.m,
7.2 rbr.ftt
RESONATOR
CHAMBER
BRACKET
O-RING
Replace.
Applyoil to O-RING
betoreinstalling.
GASKET
Replace.
IATSENSOR
2:2N.ml2.2kgl.n,
16tbtftl
l
("\"-\
W\qu
N,1\J
K\*}Gt
'n\
.a,,-\\J "
\ G)s
INTAKEMANIFOLD
Replaceit crackedor
if matingsurfacesare
oamageo.
O.RING
Replace.
O.RING
Replace.
8 x 1.25mm
22 N.m 12.2kgl.m,
16 rbf.ftt
IAC VALVE
8 x 1.25mm
23 N.m (2.3 kgf.m,
17 tbf.ft,
8 x 1.25mm
24 N.m 12.4kgt m,
17 tbt frl
INTAKEMANIFOLD
22 N.m 12,2kgl.m,
16 rbfftl
BRACKET
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9-3
ExhaustManifold
Replacement
NOTE:
. Use new gasketsand self-lockingnutswhen reassembling.
. Checkfor folds or scratcheson the surfaceof the gasket.
. Replacewith a new gasketif damaged.
'97 - 98 U.S. models (Calilornia):
8 x 1.25mm
31 N.m (3.2kgf.m, 23 lbtft)
Replace.
I x 1.25mm
24 N.m (2.4kgl.m,
1? tbf.ft)
8 x 1.25mm
24 N.m (2.i1kgt.m,
17 lbf.ftl
NN
EXHAUST
MANIFOLO
10 x 1.25mm
44 N.m 14.5kgf.m, 33 lbf.ft)
NUT
SELF.LOCKING
8 x 1.25mm
31 N m 13.2kgt.m, 23 lbt'ft)
Replace.
EXHAUSTMANIFOLD
BRACKET
10 x 1.25mm
44Nm{4.5kg{.m.
33 lbf.ftl
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9-4
8 x '1.25mm
31 N.m {3.2kgl.m,23lbl.ft)
Beplace.
COVER
(v/\
NL-]
\\ r-------.
'r
\\'
\F=
\\/ ,l
8 x 1.25mm
31 N.m {3.2 kgf.m.23 lbf.ft)
Replace.
MANIFOLD
BRACKET
6x1.0mm
9.8 N m 11.0kgf.m, 7.2 lbf.ft)
44 N.m {4.5kgf.m, 33 lbtftl
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9-5
ExhaustPipeand Muffler
Replacement
NOTE:Use new gasketsand self-lockingnutswhen reassembling.
7 - 98 U.S. models (Calitornial:
MUFFLER
GASKET
Replace.
NUT
SELF.LOCKING
I x 1.25mm
22 N.m (2.2 kg{.m, 16lbt'ftl
Replace.
Tightenthe nuts in stePs,
alternatingside-to-side.
NUT
SELF.LOCKING
10 x 1.25mm
33 N.m {3.4kgt m, 24 lbl.ft)
Replace.
SECONDARY
HO2S
4il N.m lil.5 kgtm,
33 tbf.ft)
PRIMARYHO2S
44 N.m {{.5 kgl.m,
33 tbt.ft)
GASKET
Replace.
S*S:--t-..-_
TWC
Inspection,
seesection1 l
GASKET
Replace.
EXHAUST
PIPEA
NUT
10 x 1.25mm
54 N.m 15.5kgi.m,40lbf'tt)
Replace.
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NUT
SELF.LOCKING
8 x 1.25mm
16 N.m {1.6kgt.m,
12 tbt fr)
Replace.
NUT
SELF.LOCKING
8 x 1.25mm
22 N.m (2.2 kgf.m,
r 6 tbt.ft)
Replace.
Tightenthe nuts in
steps,a'ternating
side-to-side.
6x1.0mm
9.8N.m (1.0kgf.m,
7.2 tbt.ltl
GASKET
Replace.
MUFFLER
SELF.LOCKING
NUT
8 x 1.25mm
22 N.m (2.2kgf.m, 16 lbl.ft)
Replace.
Tightenthe nuts in steps,
alternatingsideto side.
NUT
SELF.LOCXING
l0 x 1.25mm
33 N.m 13.4kgl.m, 24 lbtft)
Replace.
SECONDARY
HEATED
OXYGENSENSOR
HO2SI
{SECONDARY
4il N.m 14.5kgl.m,
33 tbf.ftl
PRIMABYHEATED
OXYGENSENSOR
(PRTMARY
HO2S)
44 N.m (4.5 kgf.m,
33 tbf.ftl
THREEWAYCATALYTIC
(TWCI
CONVERTER
GASKETS
Replace.
NUT
10x 1.25mm
5a N.m (5.5kgl.m,40 lbf ftl
Replace.
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l n s p e c t i o n ,s e e s e c t i o n 1 1
SELF-LOCKING
NUT
8 x 1.25mm
16 N.m 11.6kgf.m,
12 tbf.ftt
Replace.
NUT
SELF.LOCKING
8 x 1.25mm
22 N,m 12,2kgi'm,
16 tbf.ftl
Replace.
Tightenthe nuts in
steps,alternating
side-to-sade.
x 1.0mm
9.8 N.m {1.0kgf.m,
7.2 rbf.ft)
Cooling
ff f u s t r a t e dI n d e x. . . . . . . . . . .
. . . . .1 O - 2
Radiator
R e p | a c e m e n.t. . . . . . . . . . , . . . . , . . . . . . . . . . . .1. 0
. .-. 4. . . . . .
EngineCoolantRefillingand
Bleeding
. . , . , . . . . . . . . . . . .1. .0.-. 5
.
C a pT e s t i n g
. . . . . . . . . . . . . . .1. .0. .-.7
Testing
......10-7
Thermostat
R e p | a c e m e n.t. . . . . . . . . . . . . . . . . . . . . . . . . . . .1. 0
. .-. 8. . . . . .
Testing
......10-9
Water Pump
l l l u s t r a t e dl n d e x . . . . , . . . . .
.. 10-10
Inspection
. 10-11
R e p l a c e m e n.t. . . . . . . . . . . . . . . . . . . . . . . . . . . .1. 0
. .-. 1.1. . , . .
FanGontrol
ComponentLocationIndex ...............
10-12
C i r c u i tD i a g r a m
. . . . . . . . . .1
. .0. - 1 3
FanMotor Testing
.........10-14
RadiatorFanSwitch Testing .............
10-14
CoolantTemperatureGauge
G a u g eT e s t i n g
. . . . . . . . . . . .1. .0.- 1 5
CoolanttemperatureSending
UnitTesting
. . . . . . . . , . . . .1.0. .- 1 5
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lllustratedIndex
l f a n y e n g i n ec o o l a n ts p i l l so n t h e paintedportionsof the
body, rinse it off immediately.
C h e c k a l l c o o l i n g s y s t e m h o s e s f o r d a m a g e ,l e a k so r
deterioration and replace if necessar,.
Check all hose clamps and retighten if necessary.
RADIATOR
Enginecoolantrefillingand bleeding,
page10-5
Leaktest,page10 7
Inspectsolderedjointsand
seamsfor leaks.
Blow out din from between
corefins with compressed
air.
lf insects,etc.,are clogging
radiator,wash them off with
RADIATORCAP
low pressurewater.
Pressuretest, page 10-7
ATF COOLER
HOSE
Relerto section14
when installing.
LOWER
cusHroN
FAN MOTOR
6x1.0mm
7 N.m (0.7kgf.m, 5 lbf ftl
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10-2
EngineHoseConnections:
FASTIDLETHERMO
VALVE(A/T onlyl
IDLEAIR CONTROL
IIAC}VALVE
TEF BYPASS
HOSE
THERMOSTAT
HOUSING
CONNECTING
PIPE
VALVE
HOSES
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10-3
Radiator
Replacement
1.
D r a i nt h e e n g i n ec o o l a n t .
5.
R e m o v et h e f a n s h r o u da s s e m b l i easn d o t h e rp a r t s
from the radiator.
2.
R e m o v et h e u p p e r a n d l o w e r r a d i a t o rh o s e s ,a n d
ATFcoolerhoses.
6.
3.
Disconnect
the fan motor connector.
4.
NOTE:
. Setthe upperand lower cushionssecurely.
. Fillthe radiatorwith enginecooiantand bleedthe air.
RADIATORCAP
RADIATOR
6x1.0mm
7 N.m (0.?kgd.m,5 lbl.ftl
UPPERMDIATOR HOSE
rriItriiii
Relerto section14
when installing.
LOWERCUSHION
CONDENSER
FAN,/SHROUD
ASSEMBLY
DRAINPLUG
RADIATOR
ASSEMBLY
6x1.0mm
7 N.|n 10.7kgt.m,
5 tbt.ftl
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10-4
LOWER
TOR HOSE
EngineCoolantRefillingand Bleeding
1.
2.
Removethe radiatorcaP.
3.
L o o s e nt h e d r a i np l u g ,a n dd r a i nt h e c o o l a n t .
7.
DRAINPLUG
4.
DRAINBOLT
78 N.m {8.0ksl.m, 58 lbtft}
(cont'd)
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10-5
Radiator
EngineCoolantRefillingand Bleeding(cont'dl
M i x t h e r e c o m m e n d e da n t i f r e e z ew i t h a n e q u a l
amountof water in a cleancontainer.
NOTE:
. Always use GenuineHonda Antifreeze/Coolant.
Using a non-Hondacoolantcan result in corros\on, ca\rsng t\e coo\\ng sys\em \o ma\lunct\on
o. fail.
For best corrosion protection,the coolant conc e n t r a t i o nm u s t b e m a i n t a i n e dy e a r - r o u n da t
50% minimum.Coolantconcentrations
lessthan
50%may not providesufficientprotectionagainst
c o r r o s i o no r f r e e z i n g .C o o l a n tc o n c e n t r a t i o n s
greaterthan 60% will impair cooling efficiency
and are not recommended.
Do not use additionalrust inhibitorsor anti-rust
products;they may not be compatiblewith the
coolant.
10-6
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Testing
CapTesting
1.
2.
3.
1.
2.
3.
4.
5.
t n d / o rc o o l a n it n
C h e c kf o r e n g i n eo i l i n t h e c o o l a n a
t h e e n g i n eo i l .
TESTER
RADIATORPNESSURE
available)
lCommercially
RADIATOR
RAOIATOR
PRESSURE
TESTER
(Commercially
available)
ADAPTOR
(for 32 mm neck,
low profile)
ADAPTOR
(for 32 mm neck,low Profile)
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10-7
Thermostat
Replacement
THERMOSTAT
HOUSING
RUBBERSEAL
Replace.
THERMOSTAT
COVER
THERMOSTA
Installwith pin up.
RADIATOBFAN
swtTcH
24 N.m {2.4kgtm, l7 lbt.ftl
10-8
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6 x '1.0mm
12 N.m (1.2kgl.m,
8.7 tbtftl
Testing
Replacethe thermostatif it is open at room temperature.
To test a closedthermostat:
1.
THERMOMETER
THERMOSTAT
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10-9
Water Pump
lllustrated Index
ENGINECOOLANT
TEMPERATURE
IECTI
SENSOR
18 N.m 11,8kgt.m,
13tbt.ftl
COOLANT
TEMPERATURE
GAUGE
UNIT
9 N.m {0.3kgf.m,
7 tbf.ftt
Applyliquidgasket
to the threads.
6x1.0mm
9.8 N'm (1.0 kgf.m,
7.2 tbt frl
WATEROUTLET
COVER
Apply liquidgaskerpart No.
- 0001or 08718- 0003
087'18
to the mating surface.
RADIATORFAN SWITCH
2il N.m (2.i1kgl.m,
17 tbfft)
WATERPUMP
page10-11
lnspection,
O-RING
Replac.
CONNECTING
PIPE
6x1.0mm
12 N.m 11.2kgf.m,
8.7 tbtftl
10-10
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6xl,0mm
12N.tnn.2 lgl.rn,
8.7 tbf'ft)
Replacement
Inspection
1.
1.
2.
2.
3,
-<o
@-
II
Replace.
6x1.0mm
't2 N.m 112 kgf m.
8.7 tbf.ftl
4.
BIIED HOLE
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1 0 - 11
FanControl
ComponentLocationIndex
ftflEffltrl
t lrt
UNDEB.HOOD
FUSE/RELAY
BOX
r-1 a-l
@u!lfl]l
RADIATORFAN RELAY
Test,seesection23
BADIATORFAN
Removal,page 10-10
Test, page 10-14
BADIATORFAN MOTOR
Removal, page 10-2
CONDENSER
FAN MOTOR
10-1 2
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CircuitDiagram
IGNITIONSWITCH
No.41{100A) N0.42140A)
UNDER
OASH
FUSEiRELAY
BOX
6;\
E;';l
wHTsLka
rtF',*",El-l
I
IL^,^,.,
BLK/RED
T*'
I
B LK
oro,
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RAOIATOR
FAN
SWITCH
f C l o s e d: A b o v e )
{ 9 3 0 CJ)
L 199oF
FanControl
FanMotor Testing
1 . D i s c o n n e ct ht e 2 Pc o n n e c t o r .
RADIATORFAN MOTOR
Terminalside
of
maleterminals
Test the motor by connectingbatterypower to the
N o .2 t e r m i n aal n d g r o u n dt o t h e N o . 1 t e r m i n a l .
lf the motor fails to run or does not run smoothly,
reptacert.
1.
2.
S u s p e n dt h e r a d i a t o rf a n s w i t c h i n a c o n t a i n e ro f
water as shown.
Tr"ip".a*" \.
op".*i-
196- 203"F
{91- 95.C)
5 - 14"F(3 - 8.C)
SWITCH
lower than the temOFF
p e r a t ur e w h e n i t
goeson
ON
B
o- --o
10-1 4
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Gauge
GoolantTemperature
GaugeTesting
CoolantTemperatureSendingUnit
1 . C h e c kt h e N o . 2 5 ( 7 . 5A ) f u s e i n t h e u n d e r - d a s h
fuse/relaybox beforetestin9.
1.
2.
Testing
Make sure the ignition switch is OFF,then disconnect the YEL/GRNwire from the coolant temperat u r es e n d i n gu n i t .a n dg r o u n di t w i t h a j u m p e rw i r e .
COOLANTTEMPERATURE
POSITIVE
TERMINAL
WIRE
YEL/GRN
(Covered
with
insulation)
YEL/GRN
WIRE
2.
T u r n t h e i g n i t i o ns w i t c hO N { l l ) .C h e c kt h a t t h e
p o i n t e ro f t h e c o o l a n tt e m p e r a t u r eg a u g e s t a r t s
" H " m a r k .T u r n t h e i g n i t i o n
movingtoward the
"H" on the
switch OFF beforethe pointer reaches
g a u g ed i a l .F a i l u r e
t o d o s o m a y d a m a g et h e g a u g e .
l f t h e p o i n t e ro f t h e g a u g e d o e s n o t m o v e a t a l l ,
wire.
checkfor an open in the YEL/GRN
5.
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3.
Temperature
133.F(56'C)
(8s- 100'c)
Resistance
(0)
137
46-30
10-15
Fueland Emissions
......................
11-2
SpecialTools
Component Locations
. . . . , . .1. .1 - 3
l n d e x. . . . . . . . . . . . . . . . . . . . . .
Svstem Description
V a c u u mC o n n e c t i o n .s. . . . . . . . . . , . . . . , . , . . . . . .1.1. .-.9. . . . . . .
. .5. . . . .
E l e c t r i c aClo n n e c t i o n.s. . . . . . . . . . . . . . . . . . . . . . . 1. .1. -. 1
S y s t e mC o n n e c t o r .s, . , , . , . . . . . . . . . . . . . . . . . . . .1.1. .-.3. .6. . , . , .
Troubleshooting
T r o u b l e s h o o t i nPgr o c e d u r e s , . , . . . . . . . . . . . .1. .1. -. .6. 0. . .
Conttol
EngineControlModule/Powertrain
11-67
ModuleTerminalArrangement..............,
1t-75
DiagnosticTroubleCodeChart ....................
I 1-79
How to ReadFlowcharts.......,.....,.,...............
PGM-FlSystem
11-80
SystemDescription.................,.,.,,,...............
Flowcharts
Troubleshooting
EngineControlModule/Powertrain
........11-52
ControlModule
11-90
ManifoldAbsolutePressureSensor.............
11-95
IntakeAir TemperatureSensor ....................
11-99
EngineCoolantTemperatureSensor.,..,.,....
I 1'103
ThrottlePositionSensor ...........,.....,.,.,..,......
PrimaryHeatedOrygenSensor(Sensor1) ... 11-110
SecondaryHeatedOxygen Sensor
. . . . . . . . . . . . .1. 1
. .-.1. 1 7
{ S e n s o2r l
11-121
HeatedOxygenSensorHeater .....................
......11-124
FuefSupplySystem
11-126
,....,.,.....
RandomMisfire
11-128
MistireDetectedin One Cylinder .....-...........
. . . . . . . . . . . .1. 1
. .-. 1 3 0
K n o c kS e n s o r
C K P / T D C / C YSPe n s o r. . . . . . . . . . . . . . . . . . . . . . . . .1. 1. .-.1. .3. .1. . .
....
V e h i c l eS p e e dS e n s o r. . . . . . . . . . . . . . . . . . . . . . . . .1.1. .-.1. .3, 5
11-137
BarometricPressureSensor .....,...,...,.,,........
11-138
ElectricalLoadDetector...,.,..........................
'11-112
................,.,,
CKFSensor
11'117
ECM/PCMlnternafCircuit .............................
.,.,.,.11-148
HO2SReplacement
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FuelSupply System
. . . . . . . . . . . . . . . . . . . .1. 1. .-.1. .7. .1
F u e lL i n e s
11-175
Fittings.....................
FuefTube/Ouick-Conneci
............
11-178
SystemDescription
. . . . . . . . . . . . . . . .1. 1
. .-.1. .7 8
F u e lP r e s s u r g
................,.....
11-179
FuelIniectors
, .1. . . ,
e e 9 u 1 a t o. r. . . . . . . . . . . . . . . . . . . . . . . . .f .1. .- ,1. 8
F u e lP r e s s u rR
....,.,.,.,,,,.,............11-142
FuefFifter
. . . . . . . . . . . . . . . . . . .1. .1. -. .1.8. .3
F u e lP u m p
. . . . . . . . . . . . . . . . . . 1. .1. .-.1. .8.4
F u e lG a u g e
. .8. .5. . .
F u e lG a u g eS e n d i n gU n i t . . . . . . . . . . . . . . . . . . . . . . . .I. .1. -. 1
11-185
Low FuelIndicatorSystem ...........,.,..,...............
. . . . . . . . . .1. .1.- 1 8 7
P G M - FM
I a i nR e l a y
. . . . . . . . . .1. .1.- 1 9 1
Fue|Tank................
IntakeAir System
SystemDescription
AirCleanel
ThrottleCable
T h r o t t l eB o d y . . . . . . . .
............
11-193
, . , . , . . . . . . . . . . . . . 1. .1. .-.1. .9.4
.....................
11-194
. . . . . . . . . . 1. .1. .- 1 9 6
EmissionControl System
...,....,.,.
11-199
SystemD$cription
11-199
...............
TailpipeEmission
11-199
ThreeWay CatalyticConverter..................,.,...,,
11-2O1
PositiveCrankcaseVentilationSystem .,.,,,,.,..,
11-203
EvaporativeEmissionControls.........,.,.,............
SpecialTools
SpecialTools
Tool Number
Ref.No.
q
t3'
, 3 ) l
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11-2
Description
Oty
A 9 7 3 X _ 0 4 1_ X X X X X
V a c u u mP u m p / G a u g e -, 03 0 i n . H g
07JAZ 0010008
07PAZ, 0010100
Vacuum/Pressure
Gauge,0 4 in.Hg
SCSServiceConnector
1
1
07sAz - 001000A
07405- 0040001
BackprobeSet
FuelPressureGauge
2
1
PageReference
'11-201
. 208,214,
2 1 5 , 2 ' t 6 , 2 1, 27 2 0 ,
221, 222,223,224
11 207, 224
11-60,83,88, 1 16,
128,200,205
11-62
1 1 - 1 7 81 ,8 1
ComponentLocations
lndex
'97 - 98 models:
MANIFOLDABSOLUTE
PRESSURE
IMAP} SENSOR
Troubleshooting,
Page11-90
THROTTLEPOSITION(TP}
SENSOR
page11-103
Troubleshooting,
toLEAtRCONTROL
llAcl VAI-VE
page11-152
Troubleshooting,
INTAKEAIRTEMPERATURE
IIATISENSOR
page1'l-95
Troubleshooting.
EMISSION(EVAP)
EVAPORATIVE
CONTROLCANISTERVENT SHUT
VALVE t'98 modll
page11'213
Troubleshooting,
POWERSTEERINGPRESSURE
ELECTRICAL
LOAD
DETECTOR
IELD)(USA modol)
page11-138
Troubleshooting,
lPsPlswtrcH
page11-162
Troubloshooting,
VEHICLESPEED
SENSOR(VSS)
Troubleshooting,
p a g e1 1 ' 1 3 5
CRANKSHAFT
POSTTtON/
TOP OEADCENTER/
CYLINDER
POStTtON
SENSOR
{CKP/TDC/CYP}
(Builtinto the distributor)
page1l-131
Troubleshooting,
ENGINECOOLANT
TEMPERATURE
IECTISENSOR
page11 99
Troubleshooting,
CMNKSHAFT SPEED
FLUCTUATION
ICKF}SENSOR
page1'!-142
Troubleshooting.
EVAPORATIVE
IVAP)PURGECONTROL
SOLENOIDVALVE
Troubfeshooting,page 11'2o5,213
(cont'd)
www.emanualpro.com
11-3
ComponentLocations
Index (cont'dl
39 - 00 models:
MANIFOLDABSOLUTE
PRESSURE
IMAPISENSOR
page11-90
Troubleshooting,
THROTTLEPOSITION{TP)
SENSOR
page11-103
Troubleshooting,
IDLEAIR CONTROLOACIVALVE
page11-152
Troubleshooting,
EVAPORATIVE
EMISSION
(EVAPIPURGECONTROISOLENOIDVALVE
page11-2'13
Troubleshootang,
EVAPOBATIVE
EMISSION{EVAPI
CONTROLCANISTERVENTSHUT
VALVE
page11-213
Troubleshooting,
INTAKEAIR TEMPERATURE
(IAT)SENSOR
page11 95
Troubleshooting,
ELECTRICAL
LOAO
OETECTOR
{ELD)IUSA modet)
Troubleshooting,
page I 1-138
POWEBSTEERING
PRESSURE
tPsPtswtTcH
page11162
Troubleshooting,
VEHICLESPEED
SENSORIVSSI
Troubleshooting,
p a g e1 1 ' 1 3 5
CRANKSHAFT
POSTTTON/
TOP OEADCENTER/
CYLINDER
POStTtON
SENSOR
{CKP/TDC/CYP)
(Builtinto the distributor)
page11 131
Troubleshooting,
ENGINECOOLANT
TEMPERATURE
{ECT)SENSOR
Troubleshooting,
page11 99
11-4
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CRANKSHAFT
SPEED
FLUCTUATION
ICKN SENSOR
page11-142
Troubleshooting,
SENSOR
page'11130
Troubleshooting,
DATA LINKCONNECTOR
{DLC)I16P}
page11'60
Troubleshooting
Procedures,
PRIMARYHEATEDOXYGENSENSOR
1)
HO2SI{SENSOR
{PRIMARY
page11 110
Troubleshooling,
PGM-FI
MAIN RELAY
RelayTesting,page11-l87
Troubleshooting.
page1'1188
,a'=_-_
WAY CATALYTIC
HEATEDOXYGEN
SECONDARY
SENSOR
HO2S){SENSOR2)
{SECONDARY
page11-117
Troubleshooting,
'97 - 98 models:
AIR CLEANER
page11'194
Replacement,
SERVICECHECKCONNECTOR
{2PI
page11-60
Troubleshooting
Procedures,
page1'l-200
Troubleshooting,
POWERTRAIN
CONTROLMODULE
(PCM)(A/TI
page11-60
Troubleshooting
Procedures,
page11'82
Troubleshooting.
THROTTLEBODY(TB)
page11 196
Inspection,
Removal,page11-197
page11-'198
Disassembly,
THROTTLECABLE
page11-194
Inspection/Adjustment,
page11-195
Installation,
VENTILATION(PCV)VALVE
page11-201
Inspection,
FASTIDLE
VALVE (A/T}
I n s p e c t i o n ,p a g e 11 - 1 6 8
(cont'd)
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11 - 5
ComponentLocations
Index{cont'd)
39 - q, models:
THROTTLEBODYITB)
page11-196
Inspection,
Removal,page11-197
page11 198
Disassembly,
THROTTLECABLE
page11 194
Inspectaon/Adjustment,
page I l'195
Installation,
AIR CLEANER
page11-194
Rplacomenl,
CRANKCASE
VENTILATIONIFCVIVALVE
page11 201
lnspection,
FASTIDLETHERMOVALVEIA/T)
page11'168
Inspection,
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11 - 6
FUELPRESSURE
REGULATOR
T e s t i n gp, a g e1 1 - 1 8 1
page11 181
Replacement,
'97 model:
FUELPUMP
Testing,page11 183
page11 183
Replacement,
FUELGAUGESENDINGUNIT
page11 185
FUELVAPORPIPE Testing,
FUELFEEDPIPE
FUELFILTER
page11 182
Replacement,
FUELFILL
CAP
FUELPULSATIONDAMPER
EVAPORATIVE
EMISSION
IEVAP)CONTROLCANISTER
page1'l-205
Troubleshooting.
EVAPORATIVE
EMISSION
IEVAPITWO WAY VALVE
Testing,page11 224
TANK
R e p l a c e m e n t ,p a g e 1 1 1 9 1
-CONNECT
FUEL
FITTINGS
page11-175
Precautions,
page11 175
Disconnection,
page11-176
Connection,
FUELINJECTORS
page11-179
Replacement,
'98 model:
FUELFEEDPIPE
FUELFILTER
page11 182
Replacement,
FUELVAPORPIPE
FUEI-TANK
FUELPUMP
Replacement,
Testing,page11 183
p a g e1 l 1 9 1
page11 183
Replacement,
FUELGAUGESENDINGUNIT
Testing,page1l'185
FUELPULSATIONDAMPER
FUELFILLCAP
EVAPORATIVE
EMTSSTON
IEVAPI
CONTROL
CANISTER
VENT
SHUTVALVE
Troubleshooting,
p a g e1 1 ' 2 1 3
FUELTANK PRESSURE
SENSOR
page1l-209
Troubleshooting,
EVAPORATIVE
EMISSION
IEVAPICONTROLCANISTER
page11-213
Troubieshooting,
FUELRAIL
FUEL
FUELTUBE/OUICK.CONNECT
FITTINGS
page11 '175
Precautions,
page11 175
Disconnection,
page11 176
Connection,
page11-179
Feplacement,
FUELPRESSURE
NEGULATOR
Testing,page11-181
Replacement,
Page11 181
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EVAPORATIVE
EMISSION
{EVAP)EYPASS
SOLENOIDVALVE
page11'213
Troubleshooting,
VAPORATIVE
EMISSION
{EVAP)TWO WAY VALVE
Testing,page11 224
(cont'd)
GomponentLocations
Indexlcont'd)
'99 - (X)modols:
FUELTANK
Replacement,
p a g e1 1 - 1 9 1
FUELVAPORPIPE
FUELPUMP
'11
Testing,page 183
page11_183
Replacement,
FUELGAUGESENDINGUNIT
Testing,page11-185
FUEL FEEDPIPE
FUELFILTER
page11 182
Replacement,
EVAPORATIVE
EMtSStON
IEVAP)
CONTROL
CANISTER
VENT
FUELFILLCAP
SHUTVALVE
Troubleshooting,
p a g e1 1 - 2 1 3
FUELTANK PRESSURE
SENSOR
page1'l'208
Troubleshooting,
EMISSION
EVAPORATIVE
IEVAP)CONTROL
page11-213
Troubleshooting,
FUELPULSATIONDAMPER
FUELRAIL
FUEL
page11-179
Replacement,
FUEL PRESSURE
REGULATOR
Testing,page11-181
page11 181
Replacement,
www.emanualpro.com
EVAPORATIVE
EMISSION
{EVAP)TWO WAY VALVE
Testing,page11-224
,CONNECT
FITTINGS
page11-175
PrecaLrtions,
page11-175
Disconnection,
page176
Connection,
EVAPORATIVE
EMISSION
{EVAPIBYPASS
SOLENOIDVALVE
page11 213
Troubleshooting,
FUEL
VacuumGonnections
'97 model:
To EVAPORATIVE
EMISSIONIEVAPI
TWO WAY VALVE
EVAPOBAIIVE
EMtSStON
IEVAPI
CONTROL
CANISTER
EVAPORATIVE
EMtSStON
tvaP)
PURGECONTROL
VALVE
SOLENOID
FRONTOF
VEHICLE
PBESSURE
REGULATOR
{cont'd)
www.emanualpro.com
11-9
System Description
(cont'dl
VacuumConnections
'97 model:
ENGINE
COOLANT
IT
r|ll
HEATED
oxYGENsENsoR{PRIMARY
Ho2s,
O PRIMARY
SENSOR
lt
HEATED
oxYGENsENsoR{SECoNDARY
O SECONDARY
HO2S.SENSOR
2l
(MAPISENSOR
ABSOLUTE
PRESSURE
) MANIFOLD
cooLANTTEMPERATURE
@ ENGINE
{EcT}sENsoR
(IAI} sENsoR
AIRTEMPERATURE
O INTAKE
SPEED
FLUCTUATION
@ CRANKSHAFT
ICKFISENSOR
O |DLEArRcoNTRoL{tAc)vALvE
@ FASTIDLETHERMovALvE
EoDYITB)
O THRoTTLE
@ FUELINJEcTon
oAMPER
O FUELPULSATIoN
@ FUELFILTEn
(} FUELPRESSURE
REGULATOR
11 - 1 0
www.emanualpro.com
@ FUELPUMP
(D FUELTANK
(D FUELTANK EVAPORATIVEEMISSION(EVAPIVALVE
o AIRCLEANER
@ RESONATOR
(} POSITIVECRANKCASEVENTILATION{PCVIVALVE
EMISSION{EVAP}PURGECONTROL
@ EVAPORATIVE
SOI.'ENOID
VALVE
EMISSION{EVAP)CONTROLCANISTER
@ EVAPORATIVE
EMISSION{EVAPITWO WAY VALVE
@ EVAPORATIVE
(TWC)
@ THREEWAY CATALYTICCONVERTER
'98 model:
To EVAP THREE
WAY VALVE
To EVAP
TWO WAY VALVE
EVAP
PURGE
CONTROL
SOLENOID
VALVE
FRONTOF
VEHICLE
(cont'd)
www.emanualpro.com
11-11
System Description
VacuumConnections(cont'dl
'98 model:
-i*'";-t
G/T only)
f\
COOLANTJ
C PRIMARYHEATEOOXYGENSENSOR(PRIMARYHO2S,
SENSOR1)
(, SECONDARY
HEATEOOXYGENSENSORISECONDARY
HO2S,SENSOR2)
(!)\\\\ss\SNBSS\\\ETRESS\RE\\NQ\SE\SSR
(ECT)SENSOR
G) ENGINECOOLANTTEMPERATUBE
{IAT}SENSOR
O INTAKEAIRTEMPERATURE
(CKFISENSOR
SPEEDFLUCTUATION
@ CRANKSHAFT
O IDLEAIR CONTROL(IAC)VALVE
@ FASTIDLETHERMOVALVE(A/T)
O THROTTLEBODY(TBI
(0) FUELINJECTOR
.1' FUELPULSATIONDAMPER
.14 FUELFILTER
(i FUELPRESSURE
REGULATOR
14 FUELPUMP
(D FUELTANK
EMISSION{EVAPIVALVE
@ FUELTANK EVAPORATIVE
www.emanualpro.com
11-12
C] AIR CLEANER
(O RESONATOR
1iC POSITIVECRANKCASEVENTILATION (PCV)VALVE
6 \$REE$IN\ gN\ NL$\C CON\ER\ER (TNC\
ti\ q\ rpos,xr\tE qN\rssros \E\ aP\ cqN\RoLcaNtsrR
EMISSIONIEVAP)PURGECONTROL
@ EVAPORATIVE
SOLENOIDVALVE
q3 EVAPORATIVE
EMISSTON
IEVAP}CONTROLCANISTER
VENT SHUTVALVE
EMISSION(EVAP)TWO WAY VALVE
@ EVAPORATIVE
EMISSION{EVAP)BYPASSSOLENOID
i EVAPORATIVE
VALVE
SENSOR
9 FUELTANK PRESSURE
EMISSION{EVAP)THREEWAY VALVE
Oi EVAPORATIVE
Qd PURGEJOINT
'99 - 00 models:
To EVAPTHREE
WAY VALVE
To EVAP
TWO WAY VALVE
EVAP
PURGE
CONTROL
SOLENOID
VALVE
FUEL
PRESSURE
REGULATOR
FRONTOF
VEHICLE
(cont'd)
www.emanualpro.com
11 - 1 3
System Description
VacuumConnections(cont'dl
'99 - q) models:
ENGINE
COOLANT
o PRIMARYHEATEDOXYGENSENSORIPRIMARYHO2S,
SENSOR1l
o SECONDARYHEATEDOXYGENSENSOR{SECONDARY
HO2S.SENSOR2l
o MANIFOLDABSOLUTEPRESSURE(MAPISENSOR
IECN SENSOR
@ ENGINECOOLANTTEMPERATURE
@
@
@
@
@
@
@
@
@
(t
INTAKEAIR TEMPERATURE
IIATI SENSOR
SPEEDFLUCTUATION
CRANKSHAFT
{CKF)SENSOR
KNOCKSENSOR(KS}
IDLEAIR CONTROLIIACIVALVE
FASTIDLETHERMOVALVE{A/T}
THROTTLEBODY(TB}
FUELINJECTOR
FUELPULSATIONDAMPER
FUELFILTER
FUELPRESSURE
REGULATOR
FUELPUMP
FUELTANK
FUELTANK EVAPORATIVE
EMISSION(EVAPIVALVE
www.emanualpro.com
11-14
@
@
@
@
@
@
@
@
@
@
@
@
AIR CLEANER
RESONATOR
POSITIVECRANKCASE
VENTILATION(PCV}VALVE
THREEWAY CATALYTICCONVERTERITWCI
EVAPORATIVE
EMISSION{EVAPICONTROLCANISTER
EVAPORATIVE
EMISSIONIEVAPIPURGECONTROL
SOLENOIDVALVE
EVAPORATIVE
EMISSION{EVAPICONTROLCANISTEF
VENTSHUTVALVE
EVAPORATIVE
EMISSIONIEVAPITWO WAY VALVE
EVAPONANVEEMISSION{EVAPIAYPASSSOLENOID
VALVE
FUELTANK PRESSURE
SENSOB
EVAPORATIVE
EMISSIONIEVAPITHREEWAY VALVE
PURGEJOINT
-'97 Model
Electrical
Connections
--- --- -t
f_
l-1r
n l no 3wrcx
(.J
Htl
T:
I
4
-'tl
-'o.:\
-lla^^^
l-
tirr
-]lrL
Dl"ii
I-6,
' ^li lGPl
f----;;l
t l
t l
oa 9I3
ctovEu
A' lGI
aztL@,
FUELll'tlEcToes
aEt30F
|NJ2 3
TDC
3ErcON
catDcP
ctP
SErAOi
Gt ct(iP?
Xo.2
[{J3 A2
cra Tltcl
er2cxP{
CKF
3EN30F
cfl ct(Ftr
TOEIIF-
Dta ELtr
||tL
c|| v!]3
f1
uNx
coi||lEctoh
TL
T'
^cc^r?
^ca 6
c. K.uirE
__-l db
SERVICE
Cl|ECK
@ NEqroi
rtT
qr 3c3
ALTF CI'
t'-
bI. ATPfi
Ei. ATPI
Att lE
FOgn ON
3wltc
6u
I
t *l f
TPDI
GAIXIE
ASSEIBLY
gi7 alP:l
I
I
)r^ l
B2aAtPtX
E'
ila
rt: usA
EII ATPI{P
D{NDtir
:
FUSES
(DBACKuP (RADro)(7.sr0.
@ "o^n ttot (tuo)'
*
(DBATfERY(IOOA)
(4oA)*
rcl
o
(DFt E/ flsA).
@ No.13 FUELPU P ('l5A)
O No. 2s METER(7.5A)
(D NO.'I5 ALTERNATORSP SENSOB(7.5A)*
O No. 3i STABTERSIGNAL (7.5A)
*: In lhc und?r.lrood tu$/rclay bor
(cont'd)
www.emanualpro.com
11 - 1 5
SystemDescription
-'97 Model(cont'dl
Electrical
Connections
VALVE
EVAPPUFGECONIROI SOLENOIO
SPEOSENSOR
COUNERSHAFI
SPEEDSENSOF
PFESSUhECOI{TFOL
sotENotDvALvE
IERi'INAL LOCATIONS
11 - 1 6
www.emanualpro.com
YEL/BLU
FED/BI(
(SErOR
r)
HO2S
l-
(cont'd)
www.emanualpro.com
11-17
System Description
-'97 Model(cont'dl
Electrical
Connections
No.2 FUELIIUECIOF
cl09
11-18
www.emanualpro.com
BLK,TELJflI
BLU rdHT , -----L+
alx
Frrt\rFEl
L-fJl
||
l-
CONDENSERFANFELAY
*1 : USA
(cont'd)
www.emanualpro.com
11 - 1 9
SystemDescription
-'97 Model(cont'dl
Electrical
Connections
-Fc
h- -FE
rF
ARN
B R N :BLK
eLKr
BLKj
BLxj
8Rt,l,'BLxj
ARN,'BI.K.
c113
11-20
www.emanualpro.com
cat.,auxt
LT GAN
BLVBLU
RED
GRN
BLU,
an12
GAUGEASSEI'BLY
I
enr2-{
I
I
A,ryGEABPOSINONSWITCH
*".r".o'-
) Inor.".o"*
CONTROL UNIT
(cont'd)
www.emanualpro.com
11-21
SystemDescription
-'97 Model lcont'd)
ElectricalGonnections
t,l
/8LU l
|l
,J
I
IVTII/BLU -
WHT/LU
l
wltT/BLr(.
(c352
WHT/BLK
rcl ({0A}
HOiXsIOf 05A)
wltT/GRt{
CRN/FEO
GRI{/FO
BLU/ORN
ALU/'IVHT
UNOER]IOOD
fUSE,/FEIAY 8OX
T"*,,*.
".*_f
Btur,tvrr
I-.'|
r'tc3rsrAaIES
SG|I|^L 05 )
BLU/W8T
,ato"nL
;rfi
""r _g!:f
BLK/FED
'I_
FUSE/BELAY BOX
11-22
www.emanualpro.com
*2: USA
(Fromp!9.1r-221
ca32
**r2",-*J-1
YEVGRN
YEvErK --
___-I
BLU?'I'HT
-GRN,/YEL
I
YEVGnN--
"*
--1
PGII.FI
UAIN RELAY
C56-2
trru^n --
_BLK
I
dL
www.emanualpro.com
-]
i\
//--\
- \_-,/ , /
FUELPUMP
11-23
SystemDescription
-'98 - 00 Models
Electrical
Connections
lg il
T
t ( 1 1
BATTERY
\
ffi
\
t.
ro3Ecl,|{r
/
STAFIEF
F
q,t
REL Y
FUEL IUECIONA
att
OAT'OE
alsErELY"
tr
POSll|O|l
S TClt
ovEi-odYE
*1: A/T
'2: USA
*3: '98 modol
*il: '!X) - 00 model!
www.emanualpro.com
(DEAGKuP (RADlo)(75A).
@ HoB sroP (rsAr
(tood'
O BATTERY
(Drci (4oa)'
O Fl E/trl(lsA)r
(ONo.13FUELPUmP(l5A)
O No.2s HETERO.5a)
(DNo.15AITERNATOB
SPSENSoR(7.5A)'
@r.ro.3l STAnTERstcNAL (7.5A)
t: in tha und!..hoodfule/irl.y box
TESTTACHOiIETER
coNr{EctoB
lo CRUISECoNTEOLUNIT+r
TANK
PRESSUFE
SENSOF
SOIENOIDVAIVE
EVAPPURGECONTROL
EVAPCONIFOLCANISTEFVETITSHUTVALVE
sp:rosENsoF*1
COUNIERSHAFT
SPEEDSENSOR'T
coNlRo! solENotDvALvEA*1
H02S
(SENSOF1)
COI'TIFOLUNIT*!
TOINTEFLOCK
rcrocrsgrson*'
TERI/lINALLOCATIONS
(cont'd)
www.emanualpro.com
11-25
SystemDescription
ElectricalConnections- '98 - 00 Models (cont'dl
G]
- l
ct sEt{goh
' c14t
I J/C
llo23 (SEltgOi O
l!to2srfic
11-26
www.emanualpro.com
SECOiD hY
HO2a (aE toh 2)
Iil
I I
Y sExsoF
I
t1 t r- : r E
I
ll
Y s . n s oI R
l |
IL|
. - ac x P I
Y sErsonl
tl
ll
I f-=-r
'""
ILfr l-
I
I|
FI
t q l
r-__:__-)
{o.l
FUELIIUECIOF
r - l
l _ , I
(cont'd)
www.emanualpro.com
11-27
SystemDescription
-'98 - 00 Modelslcont,dl
Electrical
Connections
l M
l--
+
_
8rk
_{lr]]]]]]]
F >rt
i
-4.
w;i-nu-
" l---r
' a
r q - v--J
t_.1
CONOEflSERFANRELAY
rlrA/T
.2: USA
*4: '99 - 00 models
11-28
www.emanualpro.com
elrcvrlJ-l
".o"*'-{l -- 3 |
CONTROI
soLENOroVALV
ca6l
,o""r"*Jffil
"."** {H
I
tT GFtt/wxt
sotEtrolo vALvE
'.,r".u-fffil
,.YGRN'-I
f+<-l
GR/8LX'-11-
FUEI TAIIX
PRESSUBE
SENSOF
To CRt ISE
coNtFol u|{lt
*1 : A/T
(cont'd)
www.emanualpro.com
11-29
SystemDescription
-'98 - 00 Models(cont'dl
ElectricalConneetions
fJ-
F
l
fJ
fJ
f:t
!l T
9RN/
BRN/
BRN/ gLxl
aLKl
atx'
F]
Tl
BLKt
BRN/
aLKl
c121
r=r
BRN/
eLxr
STNFT
@NTFOL
SOICNOIDVALVE
c115
IIAINSIIAFI SPEEDSENSOF
c119
clll
--l
A/t cLulctl
PFESSURE
COIiTTHOL
SOIENOID
VALVE
11-30
www.emanualpro.com
n"t,lonrJ
1"r.]
L : ]
-*"{
r-YEL.cRN--_l
l--
- GRN/BLK
I-
LTGRN1
-BIK/BLU
REO
BtuT
]
-.,]
r.I=
-*i-
]
-::'",1
*I : A/T
+3: '98 model
(cont'd)
www.emanualpro.com
11 - 3 1
SystemDescription
-'98 - 00 Models(cont,dl
Electrical
Connections
OVE&ORVEOFF
[{DtcatoR LlfP
C UqEAASEr|ELY
*tnzaeo'
) ,r*ear_oo,
@lillFo|. ur{tT
* 1 :N f
*4: '99 - 00 modets
11 -3 2
www.emanualpro.com
c$3 c.r'
L*_"."{h
cl/I
crxl
I *,,,,".u:][
-*^;1n-;"*,
u
wF /BLx__1
c35lI
,-wnrzEr-x{
8uc{rHr --l
-!"'*
clfz
u|,|oEF-ftooD
BOI
FUAE/NEIAY
=-
B ITEFY
r-t
Lh-v
BMIG STITCH
E|.UflTT'
YEVORN
cal7
9q/wHr
Et&{lll
BLX/WFI
YEL
{cont'd)
www.emanualpro.com
11-33
SystemDescription
-'98 - 00 Models(cont'dl
Electrical
Connections
PGU.FI
MAII{BEIAY
-YEL/GBN-BLx--
_L
cssr
11-3 4
www.emanualpro.com
cs6-2
,z-_\
p \
-f
l- \
./
"---.,
FUELPUI{P
SystemDescription
SystemGonnectors[EngineCompartmentl-'97 Model
MAIN WIRE
HARNESS
UNOER.HOOD
FUSE/RELAY
..'.'.'
80x
ct21
cl11
cl16
11 - 3 6
www.emanualpro.com
cl15
cl11
I 3 l . l
f,_rr'Hr-lwHr'-------
--l
Ft RE!'wr
lll
ft'-cRN/sLK,
t l
2 l
l r , r l
c 6
eFr
1 1 2 l
cl.t7
r-r=l r 2 l
T!-Isrf,-*--/r*".er*
I]]ll
-;-BLi'uF
c129
.__1-..']..-r
1 1 2 3 l
ffl.E*-------lO
stx,YEL
TtlBru/"Nr----
c35l
c354.'
l4;i;1_s;:a
'-{-l-r
riiiltTf,n
fd,sLK rHr-----l
t-rlBL(
19
cFNnEo
*2: USA
(cont'd)
www.emanualpro.com
11-37
SystemDescription
SystemGonnectors[EngineCompartment]-'97 Model {cont'd)
MAIN WIRE
HARNESS
ENGINE
WIBE
HARNESS
www.emanualpro.com
cr03
c105
tusAl
r__F2
1 1
-+
l l 2 l
cr07
c105
r#-r
l r , 2 3 l
cr08
rfjl
1 1 2 l
l l . 2 l
l 3 l . l
I T'*--film----t
[--1;N,/ruo; l]]l]
t,Id&Yr
|.-T;s,,. -
cltxt
l';FELM
.
.
www.emanualpro.com
r--=
lr 2l
u)
----l
li
e@;----
lEl*",]!
N O T E :.
t F l
tl
tildK"ri
t
ltlB$jrma -
t0
r--q
ll 2 l
lEl;.
titna.
{ ' )
\:)
t.;ERN,f
Ttl;Eor-L
-_-]l
-
o
I
D i f f e r e n tw i r e s w i t h t h e s a m e c o l o r h a v e b e e n g i v e n a n u m b e r s u f f i x t o d i s t i n g u i s ht h e m ( f o r e x a m p l e ,
YEUBLK1
and YEUBLK'are not the same).
O: Relatedto Fueland EmissionsSvstem.
- Connectorwith maleterminals(doubleoutline):View from terminalside
- Connectorwith femaleterminals{singleoutline):View from wire side
11 - 3 9
System Description
SystemGonnectorslDashand Floor]-'97 Model
DASHBOARDWIRE
HANNESS
MAIN WIRE
HARNESS
REARHEATEDOXYGEN
SENSOR
SUAHARNESS
WIREHARNESS
www.emanualpro.com
cat2
titT T)l
t]l
filsl].Mr
FT-I
l5l'ri":'*l]]l
,t\./
9 t0 1'l
r\.2
18 t,/
20
1ol,/ /
1 3 1 a 1 1 5 16 ./
ta
lolZmlvv{-l -l
l@is',t'A' t-l
f.Tt.-f f
r$r
l t 4 . l' l
riTLiGN--]]l
I111
rtTa*
lo-6dN'!Hnl .]l
[tltu/cs
c426
rrFr-r
| 1 1 23 l . l
t';l;Kvi-l
fol**"---
NOTE: o Different wires with the same color have been given a number suffix to distinguish them (for example.
www.emanualpro.com
(cont'd)
11-41
SystemDescription
SystemGonnectors[Dashand Floor]-'97 Model (cont'dl
DASHEOARDWIRE
HARNESS
MAIN WIRE
HARNESS
11-42
www.emanualpro.com
1 t 12 13
9 to
5
l6
'11
l 8 l9
-t
i
(}
NOTE: o Differentwires with the same color have been given a number suffix to distinguish them (for example,
www.emanualpro.com
(cont'd)
11-43
S)stern Dessr\ptron
SystemConnectorslDashand Floor]-'97 Model {cont'd)
MAIN WIRE
HARNESS
ENGINE
WIRE
HARNESS
//l
tao,
c1z2
(PCM.AI
{PCM.D}
www.emanualpro.com
11-44
c124 (PCM,B)
ct23 {PCM-Al
1 2 \ 3 1 5 6 1 8
1 1 1 2 1 3 r a 1 5 1 6 '11 l 8
iJq
.t
,,
cr26 tPicM-ol
cr25 tPCM-Cl
1
2 3 a 5 X
r r l 1 2 13 l a t 5 t 6
9 1 0
1 1 t 8 19 20
ii)
!t
o
n
n
lit
1 1 1 1 2 t 3 !il
6
'16 I t
9 1 0
't8 t9 20
NOTE:o D i f f e r e n w
t i r e s w i t h t h e s a m e c o l o r h a v e b e e n g i v e n a n u m b e rs u f f i x t o d i s t i n g u i s ht h e m ( f o r e x a m p i e ,
YEUBLKT
and YEUBLK2
are not the same).
O: Relatedto Fueland EmissionsSvstem.
- Connectorwith maleterminals(doubleoutline):View from terminalside
- Connectorwith femaleterminals(singleoutline):View from wire side
www.emanualpro.com
11-45
System Description
SystemConnectorslEngineGompartment]-'98 Model
MAIN WIRE
HARNESS
UNDER.HOOD
FUSE/RELAY
BOX
ENGINE
w|RE
HARNESS
*2: USA
11-46
www.emanualpro.com
ctt5
t'ltl
[.1.1
lSlwHr
-------
lo GnNAUC I
TdTBLx/YEL-----1
fdBtx vNP
fr
\,v
tdTiaotfi-----l
---l
IETcRll,aLX'
ct10
fr
fr
fr
I6rc;iEiF--l- ll
IltIYEr,
ffi
ct19
fr
f'Ttfrl
-'l
l6lcnN'
lo eLU'
tdFLxr-----l
SLKI
L4.lrl
LrsLU
cRY
I O BL|^EL
l6l6tu/rJHr'
I
-
c354*'
NOTE;.
.
.
-1|
fr
16T816rr-----l
lol "."
I
lO
tsTYE'Jrr
G361
r'ft]
GF&aEp
ldTcRN/BrF----lO iEo/BL(
www.emanualpro.com
11-47
System Description
SystemConnectorslEngineCompartmentl-'98 Model (cont'd)
MAIN WIRE
ENGINE
WIRE
HARNESS
www.emanualpro.com
c t5
{usa)
r'ftr
t'ltl
I'l.l
Ttlrsrtsu
ftT,,tHr/FEpi
IET$'rmc' -- I
ftlarxrEl-l
ftlwn/srt
l
NOTE: o Differentwires with the same color have been given a number suffix to distinguish them (for example,
www.emanualpro.com
11 - 4 9
SystemDescription
SystemGonnectorslEngineCompartment]-'99 - 00 Models
MAIN WIRE
HAENESS
UNDER.HOOO
FUSE/RELAY
BOX
ENGINE
WIRE
HARNESS
www.emanualpro.com
cl11
ffir
lilrl
t-lwHn-----t
I ' IGRNtsLI'
f"l".*,.
15
c114
ft
ffi
,g
1lI
c116
cl17
c118
ffi
ffi
Effi-ffiffi
rdTnEDlllHr-----l6lcRN/Buc
-
----
ffi
trhlx,l/vH?
c121
c129
ffi
f'ftf
'1)
c135
Gt51
t6-tBrK
-----_l
l lBrxrEr
lShLU^,/Nrr
l]l I
Gt52
ElzTt)
IiTYvnED-----l
TdTcFN/rHr, FfREp/cFr
l
Gt54.'
-Ell 1 l 23 l
ldTBLxr'rtvii-----l
TitlBL.
I o cFN/Frp
l
*2:USA
NOTE:o Differentwireswith the samecolor havebeengivena numbersuffixto distinguishthem (for example,YEUBLK1
and YEUBLK,are not the same).
a O: Relatsdto Fueland EmissionsSystem,
a - Connectorwith maleterminals{doubleoutline):View from terminalside
- Connectorwith femaleterminals(singleoutline):View from wire side
(cont'd)
www.emanualpro.com
11-51
System Description
SystemGonnectors[EngineCompartment]-'99 - 00 Models{cont'dl
MAIN WIRE
HARNESS
11-52
www.emanualpro.com
c105
(usA)
c104
c103
Ir zl
lslrl
----
f -T;iE;;n
tll
lrlBR,r
FIrt
l1 2l
I '
WNT]FEDI
filBLKry.L ll]I
fu-,wHrcn[ l]l
ftl-wNr/sr't ---l
TaTtNanEc!
c105
{Canadal
c108
c107
r'fifl
-'-l
fi'Iw|r/nE D. -_-l
T'TBt(ryEL
t]l
t lnrtsrr
ffi
ffi
|iTYEULX'
--
-rfnri-r
FfBLK//EL---l-l
l -IREor/Ar
c134
c109
c133
10
ffi
ffi
---l
l-!. IYEUBLK.
c137
c303
----l
FEp/Bru
N O T E :.
.
.
www.emanualpro.com
riaF.\rjrr. - l]l I
ttInEoYEr,
fil
Differenw
t i r e s w i t h t h e s a m e c o l o r h a v e b e e n g i v e n a n u m b e rs u f f i x t o d i s t i n g u i s ht h e m ( f o r e x a m p l e .
YEUBLK'and YEUBLK'are not the same).
O: Relatedto Fueland EmissionsSvstem.
- Connectorwith maleterminals(doubleoutline):View from terminalside
- Connectorwith femaleterminals{singleoutline):View from wire side
11 - 5 3
System Description
SystemConnectors[Dashand Floorl-'98 - 00 Models
DASHBOARD
WIRE
HART{ESS
Ita|l{ wtRE
HARIIIESS
REARHEATEDOXYGEN
SENSOR
SUBHAR ESS
LEFTSIDE
WIREHAR ESS
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1 1 -5 4
c4r2
ll,Vt'll
6fswYv-ii----
E-r-
F lwir,L(
--
-l
!E!E!t
LT GRN
/l/lt
rolrr
tHrBLt
l/
r . l , / za
/te
tol./ /llEl1.lt6
r . l/
tl
-ftr
rdT6iffi---l
ET----- ---l
l.T--
r'TfifiI
I'X.l
l ' l . l
l-i'f iifiN
ftTGRY
fdlGiffil
fdlw{rcftr
-----l
----
TdliL,,rw{r----1
I
l @ c R M/ H r '
lO wt{r D' ---l I
TofuLr/,txl-
NOTE:o Differentwires with the same color have been given a number suffix to distinguish them (for example,
YEVBLK1
and YEUBLK' arenot the same).
a O: Relatedto Fueland EmissionsSystem.
a - Connectorwith maleterminals(doubleoutline):View from terminalside
(cont'd)
- Connectorwith femaleterminals(singleoutline):View from wire side
www.emanualpro.com
11 - 5 5
SystemDescription
SystemConnectorslDashand Floorl-'98 - 00 Models(cont'd]
c510
DASHBOARDWIRE
HARNESS
MAINWIEE
HARNESS
11 - 5 6
www.emanualpro.com
rE0
c508
2 3 a
1 l 12 13
6
E 9 10
1 5 1 6 1 1 1 8 1 9 20
|l!
.,
1-t""'
-----l
lo lLrcRN,
I O IsLKM/Hr
l r l
I t lYErrLU
T-ilcirrlLrr
I
t
rdTYEcii-----lll
I
ETGRN/Brxi - lll
fSliaGFNr-
mJv
, - + , ,
lrl2l3l1l
l.f.T'-]
F6EFN-----
ftTcll-l
t 2 l
''l
ftTYEUsr.
t
TstYEr
*4:'99 -00 models
IO IBLK
ftTwHr/BL(---'1
f.ft1.
(for example,
Different wires with the same color have been given a number suffix to distinguish them
www.emanualpro.com
YEL
I
l]l I
c76t*.
c760
NOTE: .
\:9
vl5l6l
l--l
I a l Y E U c n NftTYEL'BrK
a.a
r,'ffijt
trLtzl
|.-l.T'|
ffi
rcrBr.
c546
c580
c552
(cont'd)
11-57
System Description
SystemConneetorslDashand Floorl-'98 - 00 Models(cont'dl
DASHBOARD
WIREHARNESS
MAIN WIB
HARNESS
ENGINE
WIRE
HARNESS
n
lno,
c,47
(ECM/PCM.A}
c121
(ECM/PCM-8)
(PCM.D}
www.emanualpro.com
cl25 tECM/PCM-C)
c124 {ECM/PCM.B}
c't22
1 I
2 3 a
12 t 3 l t a 't5 t 0 1 1 t 8 t 9
tt
c126 (PCM-O)*,
c127'.
c121*3
c132
C,r47(ECM/PCM-Al
ot33
6
3
1 t 12 l 3
10
l 6 17 la t9
*1:4,/T
*3: '98model
'4:'99- 00models
NOTE:.
.
.
www.emanualpro.com
'1all
Differentwires with the same color have been given a number suffix to distinguish them {for example,
and YEUBLK' arenot the same).
YEUBLK1
O: Relatedto Fueland EmissionsSvstem.
- Connectorwith maleterminals(doubleoutline):View from terminalside
- Connectorwith femaleterminals(singleoutline):View from wire side
11-59
Troubleshooting
TroubleshootingProcedures
How To BeginTroubleshooting
When the MalfunctionindicatorLamp(MlLl has beenreportedon, or there is a driveabilityproblem,usethe appropriate procedurebelowto diagnoseand repairthe problem.
A. Whenthe MIL hascome on:
1. Connectthe Honda PGM Testeror an OBD Il scantool to the 16PData Link Connector(DLC)locatedbehindthe
right sideof the centerconsole.
Turn the ignitionswitchON (ll).
Checkthe DTCand note it. Also checkand note
the freezeframe data.
Referto the DiagnosticTroubleCode Chart and
begintroubleshooting.
NOTE:
. SeetheOBDll scantool or HondaPGMTesteruser'smanualsfor specificoperatinginstructions.
. The scantool or testercan read the DiagnosticTroubleCodes(DTC),freezeframe data,currentdata,and other
EngineControlModule(ECM}/Powertrain
ControlModule(PCM)data.
. Freezeframe data indicatesthe engineconditionswhen the first malfunction,misfireor fuel trim malfunctionwas
detected.lt can be usefulinformationwhen troubleshootino.
B. Whenthe MIL has not come on, but there is a driveabilityproblem,referto the SymptomCharton page 11-64.
C. DTCswill be indicatedby the blinkingof the MalfunctionIndicatorLamp{MlL)with the SCSserviceconnectorconnected.
Connectthe SCS serviceconnectorto ServiceCheckConnectoras shown. {The 2P ServiceCheckConnecrorrs
locatedbehindthe right side of the centerconsole.)Turn the ignitionswitchON 0l).
DATA LINKCONNECTOR
I16PI
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11 - 6 0
ll.
ControlModule{PCM)ResetProcedure
EngineControtModule(EcM)/Powertrain
Eitherof the followingactionswill resetthe ECM/PCM.
.
. Turn the ignitionswitchoFF. Removethe BACKUP (RADIO)(7.5A) fuse from the under-hoodfuse/relaybox for
seconos.
10
FUSE/RELAYBOX
(cont'd)
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11 - 6 1
Troubleshooting
TroubleshootingProcedures(cont'd)
lf the inspectionfor a particularcode requiresvoltageor resistance
checksat the EcM/pcM connectors,removethe right
kick panel.Unboltthe EcM/PcM.and connectthe backprobesetsand a digitalmultimeteras describedbelow,
checkthe
systemaccordingto the proceduredescribedfor the appropriatecode(s)listedon the followingpages.
@@)@)c,
Backp.oboAdapto.
BACKPROBE
SET
o'SAZ - (xtlqDA lTwo requir.dl
11-6 2
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DIGITAI.MULTIMETER
(Commarci.llyrvrilabl.l or
KS-AHM-32-@3
CAUTION:
. Puncturingthe insulation on a wile can causepoor ot intelmittent electricalconneciions.
. Bring the tester probe into contact with th terminal from the terminal side of wire htrness Gonnectorsin the engine
probe.
comoartment. Fol temale connectols,iust touch lightly whh the tester probe and do not insgrt lhe
(cont'd)
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11 - 6 3
Troubleshooting
Troubleshooting Procedures(cont'dl
Symptom Chart
Listedbeloware symptomsand probablecausesfor problemsthat DO NOTcausethe MalfunctionIndicator
Lamp(MlL)to
come on. lf the MIL was reportedon, go to page 11-60.
Troubleshooteachprobablecausein the order listed(from leftto right)until the symptomis eliminated,
The probablecauseand troubleshooting
pagereferencecan be found below.
SYMPTOM
PROBABLECAUSE
4 , 2 , 3 , 5 , 2 0 ,' t 5 ,1
2, 4, 12,17,14, 't9
7 ,a , 9 ,6 , 1 7
7,8,9,11,10
9 , 7 , 8 ,' t 1 ,1 0
LOl/\/power
E n g i n es t a l l s
OtherProbableCausesfor an enginethat will not start:
- Compression
- Intakeair leakage
- Enginelockedup
- Timing belt
- Startingsystem
- Overheating
- Battery
ProbableCauseList (Forthe DTCCh8rt, see page ll-75.)
ProbableCause
'I
Page
Engine
(ecvtffi
controtruoaute
I 1-178
Fueloressure
PGM-Flmain relav
11-187
5
Section4
't1-'t31,146
6
7
I 't-95
11-152
1'l-168
10
12
11-196
11-'194
'1'l-90
14
11- 103
11-137
11-169
'11
15
16
17
18
'19
20
11 -6 4
www.emanualpro.com
System
11-42
Section14
11- 166
r1-194
11 , 1 9 9
11-203
lgnitionsystem
positionsensorcircuit
Crankshatt
Position/Top
DeadCenter/Cylinder
IntakeAir Temperature(lAT)sensorctrculr
ldleAir Control(lAC)Vatve
Fastidle thermo valve
ldle speedadjustment
Throttle body
Throftlecable
ManifoldAbsoluteP."""rr"ffi
ThroftlePosition(TP)sensor
Barometricpressur"(gnnoAy'Tgear positionsignal
Brakeswitchsignal
Air Cleaner
Three Way CatalyticConverter(TWC)
Evaporative
emission(EVAP)control
Contaminated
fuel
ECM/PCMData
By connectingthe OBD ll scan tool or the Honda PGM Testerto the 16Pdata link connector(OLC),variousdata can be
The itemslistedin the table belowconformto the SAErecommendedpractice
retrievedfrom the ECM/PCM.
The HondaPGMTesteralso readsdata beyondthat recommendedby SAE.
understandingthis datawill help to find the causesof intermittentfailuresor engineproblems.
NOTE:
The ',operatingvalues" given below are approximatevaluesand may be differentdependingon the environmentand
the individualvehicle.
"at
Unlessnotedotherwise. idle speed" meansidlingwith the enginecompletelywarmed up, transmissionin position
turnedotf.
the
A,./C
and all accessories
Parkor neutraland
Data
Diagnostic
TroubleCode
(DTC)
EngineSpeed
VehicleSpeed
Desc.iption
lf no problemis detected,
lf the ECM/PCMdetectsa problem,it will storeit as a
there is no output.
codeconsistingof one letterand tour numbers
code (Poxxx)
Dependingon the problem,an SAE-defined
(P'lxxx)
will be outputto the
code
or a Honda-defined
tester.
Nearlythe sameas
computesenginespeedfrom the signals
The ECN4/PCN4
tachometerindication
sentfrom the CrankshaftPositionsensor.
This data is usedfor determiningthe time and amountof At idle speed:
'97 - 98 models:
fuel iniection.
750t 50 rpm
'99 - 00 models:
730f 50 rpm
The ECM/PCMconvertspulsesignalsfrom the Vehicle
SpeedSensor(VSSIinto speeddata.
FreezeData
YES
YES
Nearlythe sameas
speedometerindication
YES
With engin6stopped:
Nearlythe sameas atmosphericpressure
At idle speed:
2a - 41 kPa{210- 310
m m H g ,8 . 3- 1 2 . 2i n H g )
YES
Oprating Valuo
YES
NO
(cont'd)
www.emanualpro.com
11 - 6 5
Troubleshooting
TroubleshootingProcedures(cont'd)
Data
HO2S
Feedback
Loop Status
ShortTerm
F u e lT r i m
Descliption
Loop statusis indicatedas "open" or "closed".
Closed:Basedon the HO2Soutput,the ECM/pCMdeterminesthe airlfuelratioand controlsthe amountof
injectedfuel.
Open:ignoringHO2Soutput,the ECM/pCiM
refersto sig,
nalsfrom the TP, MAP,and ECTsensorsto controlthe
amountof injectedfuel.
Operating Value
Freezo Data
At idle speed:closed
YES
YES
LongTerm
F u e lT r i m
! 20%
I n t a k eA i r
Temperature
(IAT)
Throttle
Position
At idle speed:
approx.10%
lgnition
Timing
A t i d l es p e e d 1
: 6'1 4.
BTDCwith the SCSservtceconnectorconnected.
NO
Calculated
LoadValue
(cLV)
At idle speed:
2A- 410/o
At 2,500rpm with no load:
13 - 260/o
YES
www.emanualpro.com
11 _ 6 6
YES
PowertrainControlModuleTerminalArrangement-'97 Model
Wire
color
YEL
NOTE:Standardbatteryvoltageis 12V.
Telminal
nama
lNJ4(No.4 FUEL
INJECTOR)
10
l N J 3( N o . 3F U E L
INJECTOR)
l N J 2{ N o . 2F U E L
RED
INJECTOR)
l N J l ( N o .l F U E L
BRN
INJECTOR)
SO2SHIC(SECONDARY
OXYGENSEN
BLK WHT
HEATED
CONTROL)
SORHEATER
(PRIMARY
PO2SHTC
HEATEDOXYGEN
BLKAr'YHT
SENSORHEATER
CONTROL}
8RN/BLK LGl (LOGICGROUND}
PG1lPOWERGROUND}
BLK
l1
YEUELK
12
BLI(BLU
6
I
BLU
REDryEL
16
GRN/VEL
IGPl lPOWERSOURCE}
IACV{IDLEAIR
CONTROLVALVE}
PCS(EVAPPURGE
CONTFOL
SOLENOID
VALVE)
FLR(FUELPUMPRELAY)
19*
ACC (A,/CCLUTCH
RELAY}
MIL (MALFUNCTION
GRN/ORN INDICATORLAMP}
ALTC(ALTERNATOR
WHT/GRN CONTROL}
20
YEUGRN
22
23
BRN/BLK
BLK
24
YEUBLK
27
GRN
11
18
8LI(RED
Description
Drives No. 4 {uel injector.
Signal
With enginerunning:duty controlled
ICM(IGNITION
CONTROL Sendsignitionpulse.
MODULE)
Groundtor the PCMcontrolcircuit.
LG2(LOGICGROUND}
GROUND}
Groundlor the PCMpowercircuit.
PG2{POWER
Power sourcefor the PCMcontrol
IGP2{POWER
SOURCE}
circuit.
FAN
Drives radiator{an relay.
FANC(RADIATOR
CONTROL)
*: USA
{cont'd)
www.emanualpro.com
11-67
Troubleshooting
PowertrainControlModuleTerminalArrangement-'97 Model (cont'dl
PCMCONNECTOR
B I25PI
color
RED
8LU//EL
GRN/BLK
YEL
PNK
11
GRN/VVHT
12
WHT/BED
GRN/BLK
RED
16
Oescription
Signal
LS 1A/TCLUTCH
PRESSURE
CONTROL
SOLENOID
VALVE-)
DrivesA,/Tclutch pressurecontrol
solenoidvalve
LS + (A"/TCLUTCH
PRESSURE
CONTROL
VALVE+)
SOLENOID
CONTROL
SHA(SHIFT
SOLENOID
VALVEA)
DrivesA,/Tclutch pressurecontrol
solenoidvalve
LCB (LOCK-UP
CONTFOL
VALVEB)
SOLENOID
LCA (LOCK.UP
CONTROL
VALVEA)
SOLENOID
ATPD3(Ay'T
GEAR
POSITION
SWITCH}
SHB(SHIFTCONTROL
VALVE8}
SOLENOID
ILU(INTERLOCK
CONTROL
UNITi
D4IND(04 INDICATOR
LIGHT}
NMSG (MAINSHAFT
Groundtor mainshaftspeedsensor.
S P E E DS E N S O RG R O U N D }
14
1'l
BLU
18
BRN
22
GBN
23
BLU
24
YEL
25
LT GRN
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NOTE:Standardbatteryvoltageis l2 V.
Terminal
name
11 - 6 8
NM (MAINSHAFT
SPEED
SENSOR)
ATPR(A"/TGEAR
POSITION
SWITCH)
ATP2(A./TGEAR
POSITION
SWITCH)
ATP1(4,,/TGEAR
POSTTTON
SWTTCH)
NCSG(COUNTERSHAFT
SPEEDSENSOR
GROUND)
NC (COUNTERSHAFT
SPEEDSENSOR)
ATPD4(M GEAR
POSITION
SWITCH)
ATPNP{A/TGEAR
POSITION
SWITCH)
Detectsmainshaftspeedsensor
srgnal,
With enginerunning:pulses
InRposition:0V
In any otherposition:batteryvoltage
In 2nd position:0 V
In any otherposition:batteryvoltage
ln lst position:0 V
In any otherposition:batteryvoltage
C (31PI
PCMCONNECTOR
C {31PI
PCMCONNECTOR
ferminal
number
't
2
3
4
5
Wire
color
NOTE:Standardbatteryvoltageis 12 V.
Terminal
name
P
CKFP(CKFSENSOR
SIDE)
P
CKPP(CKPSENSOR
BLU
SIDE)
P
TDCP(TDCSENSOR
GRN
SIDE)
P
CYPP(CYPSENSOR
YEL
SIDE)
ACS(A/CSWTTCH
BLU,frED SIGNAL)
SWITCH
STS(STARTER
BLU/ORN SIGNAL)
BLUiRED
BRN
LT BLU
CHECK
SCS(SERVICE
SIGNAL)
K-LINE
10
BACK
VBU(VOLTAGE
WHT/BLU U P )
11
(CKFSENSORM
WHT/RED CKFM
Doscription
Signal
DetectsCKFsensor.
: ulses
W i t h e n g i n er u n n i n g p
Detects
CKPsensor.
DetectsTDCsensor.
DetectscYP sensor.
DetectsA,/Cswitchsignal.
With AJCswitchON:0 V
With A,/CswitchOFF:batteryvoltage
With starterswitchON (lll): baftery
voltage
With stanerswitchOFF:0 V
Detectsstarterswitchsignal.
Detectsservicecheckconnector
signal(thesignalcausinga DTC
indication)
Sendsand receivesscantool
srgnal.
Powersourcetor the PCM
controlcircuit.Powersourcefor
the DTCmemory
SIDE)
12
WHT
13
RED
14
BLK
swtTcH)
16
GRN
17
WHT/RED
18
SPEED
VSS(VEHICLE
BLUA/VHT SENSOR)
FR
ALTF(ALTERNATOR
SIGNAL)
FRsignal.
Detects
alternator
VSSsignal.
Detects
(cont'd)
www.emanualpro.com
Troubleshooting
PowertrainGontrolModuleTerminalArrangement-'97 Model (cont'd)
O {16PI
PCMCONNECTOR
PCM CONNECTOR
D (I6P)
f.rminal
Wir! color
numbcr
1
RED/BLK
Trminal nam6
TPS ffHROTTLE
POSITION
SENSOR}
Wiresideof f6maleterminals
RED,4/VHT TEMPERATURE
SENSOR
MAP(MANIFOLD
DetectsMAP sensorsignal.
RED/GRN ABSOLUTE
PRESSURE
SENSOR)
VCCl (SENSOR
YEURED
VOLTAGE)
E
GRN/WHT
Signal
With throttlefullv oDen:about4.8V
With throttlefullv closed:about0.5V
With ignitionswitchON {ll):about
0.1- 4.8V (dependingon engine
coolanttemperature)
With ignitionswitchON (ll):about3 V
At idle;about 1.0V
(dependingon enginespeed)
BKSW(BRAKE
SWITCH)
Detectsbrakeswitch signal.
With brakepedalreleased:0V
With brake pedal depressed:battery
voltage
(PRIMARY
PHO2S
HEATED
OXYGEN
SENSOR
1)
SENSOR
Detectsheatedprimary oxygen
sensor(sensor1) signal.
IAT (INTAKEAIRTEM.
PERATURE
SENSOR)
WHT
RED//EL
10
YEUBLU
VCC2(SENSOR
VOLTAGEI
Providessensor voltage.
11
GRN/BLK
SG2(SENSOR
GROUND)
Sensorground.
12
GRN/WHT
SGl (SENSOR
GROUND)
13
14
SHO2SSG
(SECONDARY
HEATED
RED/YEL
OXYGENSENSOR,
SENSOR2 GROUND)
SHO2S(SECONDARY
HEATEDOXYGEN
WHT/RED
SENSOR,
SENSOR2)
Groundfor secondaryheated
orygen sensor(sensor2).
Detectssecondaryheated
orygen sensor(sensor2)
signal,
0.4v
EL (ELD)
16*
GRN/RED
1 -7 0
www.emanualpro.com
DetectsELDsignal.
ControlModuleTerminalArrangement- 38 - 00 Models
Engine/Powertrain
A (32P}
ECM/PCMCONNECTOR
5
sca
,/./
t5
,/
It
sTs
l,/
n
2l
s!u
CI
A {32P)
ECM/FCMCONNECTOR
NOTE:Standardbafteryvoltageis
D93cription
BLU
LT GRNMHT
5',
BLU
RED/YEL
ELIOWHT
10
BRN
l4'r
GRN/8LK
GRNI/EL
17
AL|(/RED
18
GRN/ORN
19
BLU
2WBS{EVAPBYPASS
S O L E N O IV
DA L V E )
W i t h i g n i r i o n s w i t c h O N { l l ) rb a t t e r y v o l t a g e
VSV {EVAPCONTROLCANIS
TEBVENTSHUTVALVE)
EO N T R OSL I G '
C R S( C R U I SC
NAL)
PCS(EVAPPURGECONTROL
SOLENOIDVALVE)
D.ivesEVAPcontrolcanislervent shut
ShiftOownsignalinputfrcmcruisecon
W h e nc r u i s ec o n t r o il s u s e d :p u l s e s
S O 2 S H T (CS E C O N D A R V
HEATEDOXYGENSENSOR
HEATERCONTROL)
SCS(SERVICE
CHECXSIGNAL)
Drivessacondaryheatedoxygen sensor
w i t h r h el e r m i n a cl o n n e c t e d :v0
W i t ht h e r e r m i n a l d i s c o n n e c t e d r a b5ovu to r
D 4 I N D( D 4 I N D I C A T O R ) + 3
D I N D( D I N D I C A T O R T I
DrivesD4*3.Dr'indicaior light.
W , r h0 4 ' , O " i n d r c a t ol ri g h tt u r n e dO \ b a t t e r ,
F L R( F U E LP U M PR E L A Y )
0 V f o r i w o s e c o n d sa f t e r r u ' n i n 9 i g n ' l i o n s w i l c h
ON lll), then banery voltage
ACC(I/C CLUTCHRELAY}
INDICA.
MIL (MALFUNCTION
TORLIGHT)
EPEED
N E P( E N G I N S
PULSE)
DrivsMlL.
W i t hc o m p r e s s oOr N r 0V
With compressorOFF:batteryvoltage
W i t h M l L t u r n e dO N : 0 V
With MIL turned OFF:batteryvoltage
: ulses
W i t hs n g i n er u n n i n 9 p
FANC{RADIATOR
FANCON
TROL)
Drivesr6diatorfan rslay.
S e n d sa n d r e c e i v ssc a nt o o l s i g n a l .
Detectssecondaryhatdoxygensensor
20
GRN
21
8LU/t/EL
K-LINE
23
WHT/RED
SHO2S(SECONDARY
HEATED
SENSOR2i
OXYGENSENSOR.
21
BLU/WHT
GBN
2f
BLU/BEO
2A'\
WHT/NED
29
Signal
W i t h D 4 * 3D
, * . i n d i c a t olri g h tt u r n e dO F F r 0V
16
26
'12V.
LT GRN
Outputsenginespsed pulse.
SWITCHSIG,
STS (STARTER
NAL}
Dotoctssrarterswitch signal.
PSPSW{P/SPsESSUFE
SWITCHSIGNAL)
ACS (Ir'C SWTCH SIGNAL}
DetecrsPSPswitch signal.
SLU {INTERLOCK
CONTROL
UNIT)
P T A N K( F U E LT A N KP R E S '
S U R ES E N S O R )
E L( E L D }
Detoctsfueltank pressuresensorsignal.
W i t h a g n i t i o ns w i t c h O N ( l l ) a n d f u e l f i l l c a p
opensd; about 2.5 v
DetectsELDsignal.
W i r hp a a i n gr i g h t s t u m eodn a t i d l e : a b o u2t. 5- 3 . 5V
W i t h l o w b e a mh e a d l i g h ttsu m e do n a t i d l e :
a b o u t1 . 5 - 2 . 5 V
BKSW(BRAKESWTTCH)
W i r h b r a k e p e d a l r e l e a s e d : 0V
With brake pedal depressed: battery vollage
GBN/FED
GRN/WHT
W i t h r a d a a t of ar n r u n n i n g : 0V
With radaatorfanstopped:batteryvollage
With ignition switch ON (ll): p'rlses
www.emanualpro.com
(cont'd)
11-71
Troubleshooting
'98 - 00 Models
Engine/Powertrain
ControlModuleTerminalArrangement(cont'd)
B {25PI
ECM/PCMCONNECTOR
ECM/PCMCONNECTORB I25PI
Ierminal
Wire color
numbt
1
YEUBLK
BLK
RED
BLU
YEL
Wiresideof femaleterminals
NOTE:Standardbafteryvoltageis l2
Terminsl name
Description
IGPl(POWER
SOURCE) Powersourcefor the ECM/PClvl with ignitionswitchON (ll):batteryvoltage
controlcircuit.
with ignitionswitchOFF:0V
RR O U N D } Ground for the ECM/PClvlcontrol Lessthan 1.0V at all times
P G 1( P O W EG
circuit.
roR)
YEUBLK
10
BLK
PG2(POWER
GROUND} Ground for the ECM/PCMcontrol
'
BRN
l N J l ( N o . 1 F U E LI N J E C
TOR)
crrcurt.
DrivesNo. l tuel injector.
RED
PNK
19*.
20
BRN/BLK
A,/Tclutchpressurecontrol
solenoidvalvepowersupply
positiveterminal
Drives OVER-DRIVE
OFF
indicatorlight.
LG1(LOGIC
GROUND)
BRN/BLK
LG2(LOGIC
GROUND)
23
BLVBLU
IACV{IDLEAIR CON.
TROLVALVE)
11-72
LS+(A,,IT
CLUTCHPRES
SURECONTROL
SOLENOIDVALVE+ SIDE)
ODIND(OVER-DRIVE
OFFINDICATOR}
22
www.emanualpro.com
Sendsignition pulse.
VBU (VOLTAGE
BACK
WHT/BLU U P )
*2t MlT
*3: '98 model
"4: '99 - 00 models
rcM {rGNrTroN
coN-
YEUGRN TROL
MODULE)
17*1
WHT
8*1
Signal
With OVER-DRIVE
OFFindicatorlight
turned ON: 0 V
OFFindicatorlight
With OVER-DRIVE
turned OFF:battery voltage
ECM/PCMCONNECTOFC (31PI
C (31P)
ECM/PCMCONNECTOR
Termidal
NOTE:Standardbatteryvoltageis 12V.
D.3cription
8LI(WHT
Signal
HEATED
POzSHTC{PRIII4ABY
OXYGENSENSORHEATER
CONTROL)
CON,
ALTC(ALTERNATOR
TROL)
Sondsalternalorcontrol signsl.
2"
WHT/GBN
3'1
FED/8LU
K S( K N O C K
SENSOR)
DstectsKS signal.
WHT/RED
FRSIGALTF(ALTERNATOR
NAL}
DetectsalternatorFRsignal.
W t h f u l l y w a r m e du p n g i n er u n n i n g : 0V - b a t t e r y
voltag{dpendingon slsctricalload)
GRN,4trHT
R8 0 U N D }
S G 1( S E N S O 6
CKPP(CKPSENSOFP SIDE)
DatclsCKPs6nsor.
W i t h n g i n r u n n i n gpr u l s s
CKPI.,I|
{CKPSENSOFM SIDE)
Groundfor CKPsnsor.
15
PHO2S{PRIMARYHEATED
SENSOR1)
OXYGENSENSOR,
Detoctspfimary he6t6doxygenssnsor
{sonso1
r )signal.
D6tectsMAP snsorsign6l.
W i t h i g n i t i o ns w i t c hO N ( l l ) : a b o u3t V
A t i d l s :a b o u l1 . 0V { d s p s n d i n o
g n e n g i n es p e e d )
VCCl {SENSORVOLTAGE)
BLU
17
RED/GRN
MAP (MANIFOLDABSOLUTE
P R E S S U RSEE N S O R )
18
GRN/BLK
B NOUNDi
S G 2( S E N S O G
19
YEUBED
20
GRN
TDCP{TDCSENSORP SIDE)
DerecisTDCsensor.
2l
RED
Groundfor TDCsensor.
22
BLU/RED
PSIDE)
C K F P( C K FS E N S O R
DstsctsCKFsnsor.
23
BLU/WHT
VSS (VEHICLE
SPEEDSEN-
vss signal.
Dstscrs
25
RED//EL
DetactsIAT sensorsignal.
W i t h i g n i t i o ns w i t c hO N ( l l ) a n df r o n tw h e e l s
rotaringrcyclss0 v- 6bout 5 V or banryvoltage
With igniiion switch ON (ll):about 0.1 - 4.8 V
(dpndingon iniate air tmpraturc)
26
REO/WHT
ECT{ENCINECOOLANT
TEMPERATURE
SENSOR)
oetsctsECTsensorsignal.
27
RED/BLK
TPS (THROTTLE
POSITION
SENSOR)
DotectsTP sensorsignrl.
2A
YEUBLU
VCC2lSENSOR
VOLTAG}
Providssnsorvoltage.
29
YEL
CYPPICYPSENSO8P SIDE)
CYPM(CYPSENSORM SIDE)
DsrsctsCYPsensor.
Groundfor CYPsansor.
30
BLK
soR)
WHT/RED
CKFM{CKFSENSORM SIDE)
11.AfT 13. '94 model
'2:M/T 14:'99- 0omodsls
.5: USA
31
(cont'd)
www.emanualpro.com
11-73
Troubleshooting
Powertrain Control Module Terminal Arrangement -'98
- 00 Models (cont'dl
ECM/PCMCONNECTOR
D {16P}
NOTE:Standardbatteryvoltageis 12V.
Ds4ription
Orivslock'up conrrolsolenoidvalve A.
S H B( S H I F T
CONTROL
SOLENOIO
VALVEB)
GRN/BLK
LC 8 (LOCK,UP
CONTROL
SOLENOIDVALVEB}
Driveslock up controlsolenoidvalve B.
BLK/YEL
VBSOL(BATTERY
VOLTAGE
F O RS O L E N O IV
DA L V E }
Powrsourceof solenoidvalvs.
ATPR{AI GEAEPOSITION
SWITCH)
SHA (SHIFTCONTROL
SOLENOIDVALVEA)
Drivesshift conrrolsolenoidvalvp A.
ATPD3(AT GEARPOSITION
DetectsA,/Tgar poshionswirchsign6l.
I n D 3 p o s i t i o n : 0V
h any other posiiion:banryvoltage
YEL
GBN,M/HT
2+1
Sign!l
LCA {LOCK,UPCONTBOL
SOLENOIDVALVEA)
BLU,ryEL
PNK
swrTcH)
O D S W( O V E R . D B I V
SE
W I T C H ) DetectsOVEF-DRIVE
swirch sagnal.
PNK
9''
YEL
10.,
BLU
RED
I n D 4 r 3O
, * . p o s i t i o n : 0V
In any other posilion:batteryvoltage
Detsctscounlrshaftspeedsensor
N M I I V A I N S H A FSTP E E D
SENSOB)
Detectsmainshaftspeedsensorsign6ls.
W i l h e n g i n er u n n i n gp: u l s e s
N M S G{ M A I N S H A F T S P E E D Groundfor mainshaftspeedsensorSENSOB
GBOUND)
'13*1
LT GRN
8LU
BRN
15.'
t6''
i1:A/T
'2: M/T
GRN
*3:'98 model
*4:'99
00 models
11-74
www.emanualpro.com
ATPNP(AT GEARPOSITION
swtTcH)
ATP2(AT GEARPOSFION
swrTcH)
ATP1{AT GEARPOSITION
swrTcH)
N C S G{ C O U N T E R S H A F T
SPEED
SENSOR
GROUND}
I n p a r ko r n u t r a l : 0V
h any other posilion:about 5 V
Detection ltem
ProbableCause
Pago
P0107
(3)
ManifoldAbsolute
Pressu.eCircuit
Low Input
't'l-90
P0108
{3)
ManifoldAbsolute
PressureCircuit
H i g hI n p u t
11-92
P 0 11 1 * 3
(10)
IntakeAir
TemperatureCircuit
Range/Performance
Problem
P0112
(10)
lntakeAir
TemperatureCircuit
Low Input
11-96
P0113
(10)
lntakeAir
TemperatureCircuit
H i g hl n p u t
Open in IATsensorcircuit
IAT sensor
ECM/PCM
'I 1-97
P0116
(86)
EngineCoolant
TemperatureCircuit
Range/Performance
Problem
ECTsensor
Coolingsystem
P0117
(6)
EngineCoolant
TemperatureCircuit
Low Input
P0118
(6)
EngineCoolant
TemperatureCircuit
H i g hI n p u t
Shortin ECTsensorcircuit
ECTsensor
ECM/PCM
Openin ECTsensorcircujt
ECTsensor
ECM/PCM
P0122
\11
ThrottlePosition
Circuit
Low Input
11-103
P0123
l7l
ThroftlePosition
Circuit
H i g hI n p u t
Openin TPsensorcircuit
TPsensor
ECM/PCM
11-107
PrimaryHeatedOxygenSensor
Circuit Low Voltage
(Sensor1)
P0131
(1)
P0132
(1)
PrimaryHeatedOrygen Sensor
CircuitHighVoltage
(Sensor1)
P0133
(61)
(41)
PrimaryHeatedOxygenSensor
Heater
CircuitMalfunction
{Sensor1)
P0135
. IATsensor
11-95
Short in PrimaryHO2S{Sensor1)
circuit
PrimaryHO2S(Sensor1)
Fuelsupplysystem
ECM/PCM
Openin PrimaryHO2S(Sensor1) circuit
PrimaryHO25(Sensor1)
ECM/PCM
. PrimaryHO2S(Sensor1)
. Exhaustsystem
. Openor short in PrimaryHO2S(Sensor
'l) heatercircuit
. ECM/PCM
11-99
11 - 1 0 0
11-101
11-110
' 1 11 1 3
11 'I16
11-12'l
www.emanualpro.com
11-75
Troubleshooting
DiagnosticTrouble Code (DTCIChart (cont'd)
DTC
Detectionhem
lMlL indicationl
P0137
(63)
P0138
(63)
S e c o n d a r yH e a t e dO x y g e nS e n s o r
C i r c u i tH i g h V o l t a g e
P0139
{63)
SecondaryHeatedOxygenSensor
Probable Caus.
Shon in Secondary
HO2S(Sensor2) circuat
Secondary
HO2S(Sensor
2)
ECM/PCM
Openin Secondary
HO2S(Sensor
2)circuit
HO2S(Sensor2)
Secondary
EC|\il/PCM
HO2S(Sensor
2)
Secondary
Page
'n-1t7
1 11 1 8
11-120
lSensor2i
P0141
P0r71
(65)
Openorshonin Secondary
HO2S(Sensor
2)
heatercircuit
EC|V/PCtu
(45)
Contaminated fuel
't2l
11
1 1124
E x h a u s tl e a k a g e
System Too Rich
P0112
(45)
Fuelsupplvsystem
PrimaryHO2S(Sensor
1)
11124
Contaminated
fuel
Random Mistire
and
Po3ol
P0302
P0303
P0304
ltr \
112|
173i
\74t
P0301
P0302
P0303
P0304
/71 \
112|
173|
\74l
P0325*5
{23)
P033s
{4}
P0336
P0420
P0441*3
I A Cv a l v e
C o n t a m i n a t e df u e l
L a c ko f f u e l
11-126
C y l i n d e r1
C y l i n d e r2
C y l i n d e r3
- C y l i n d e r4
Misfire Detected
F u e li n j e c t o r
Fuel injector circuit
lgnition system
11-130
Crankshaft
Position
SensorCircuit
11-131
(4)
11,131
{67)
Evaporative Emission
ControlSystem
Insulficient Purge Flow
'It 205
F u e l T a n kP r e s s u r eS e n s o rC i r c u i t
Bange/Performance
FuelTank PressureSensor
ECM/PCM
t't-208
(91i
{91)
F u e l T a n kP r e s s u r eS e n s o rC i r c u i t
HighInput
OpsnorShortin FuelTankPressure
Sensorcircuit
FuelTankPressureSensor
ECM/PCt\4
Openin FuelTankPressureSensorcircuit
FuelTankPressure
Sensor
ECt /PCt\.1
(92)
P0451*5
P0453*r.5
lgnition system
Fuel supply system
't't 127
't1-200
11-209
11-211
11-76
www.emanualpro.com
DTC
(MlLindicationl
Dotection ltom
P0500
t17)*,
VehicleSpeed
SensorCircuit
Malfunction
P0501
l17J*1
VehicleSpeed
SensorCircuit
Malfunction
P0505
(14)
P0700
P0715
PO720
P0730
P0740
P0753
P0758
ldle Control
System
Malfunction
Automatic
Transaxle
ProbableCause
VehicleSpeedSensor
VehicleSpeedSensorcircuit
ECtVI
VehicleSpeedSensor
VehicleSpeedSensorcircuit
PCM
IACvalve
ThrottleBody
Fastidlethermovalve*1
Page
11 - 1 3 5
11-135
' ]1 150
Section l4
P1106
(13)
P1107
(13)
P1108
(13)
P1121
(7)
P1122
(7)
P112a
(5)
P1129
Barometric
Pressure
Circuit
Range/Performance
Problem
Barometric
Pressure
Circuit
LowInPut
Barometric
Pressure
Circuit
HighInpur
(Barosensor)
ECM/PCM
11-137
. ECM/PCM
{Barosensor)
11-137
ECM/PCM
{Barosensor)
11,137
Throttle Position
Lower Than
Expected
. TPsensor
ThrottlePosition
H i g h eTr h a n
Expected
ManifoldAbsolute
PressureLowerThan
Expected
' TP sensor
(5)
ManifoldAbsolute
PressureHiqherThan
Expected
' MAPsensor
P1297
(20)
Electrical Load
DetectorCircuit
Low Input
ElectricalLoadDetector
ElectricalLoadDetectorcircuit
ECM/PCM
11 -1 3 8
P1298
(20)
Electrical
Load
Detector
Circuit
HighInput
ElectricalLoad Detector
ElectricalLoad Detectorcircuit
ECM/PCM
11-140
Random lvlisfire
lgnitionsystem
Fuelsupplysystem
MAPsensor
IACvalve
fuel
Contaminated
Lackoffuel
11-126
P1300'3
P0301
P0302
P0303
P0304
7l
72
13
14
11-109
11-'109
. MAPsensor
11-94
1l-94
{cont'd)
www.emanualpro.com
11-77
Troubleshooting
DiagnosticTroubleCode(DTCIGhart(cont'd)
DTC
{MlLindication}
Detection ltem
ProbableCause
154)
Crankshaft
Speed
Fluctuation
Sensor
Intermittent
Interruption
. CKFsensor
P1336
P1337
i54)
Crankshaft Speed
FluctuationSensor
No Signal
P1359
(8)
CKFsensor
CKFsensorcircuit
ECM,FCM
' CKP/TDC/CYP
sensorcircuit
P1361
(8)
P1362
(8)
P1381
(9)
P1382
(9)
CrankshaftPosition/TooDead
CenterSensorrcylinder
Position
ConnectorDisconnection
Top DeadCenter
SensorIntermittent
Interruption
Top Dead Center
SensorNo Signal
CylinderPositionSensor
Intermittent
Interruption
Cylinder
PositionSensor
No Signal
Evaporative
Emission
ControlSystemLeakDetected
(FuelTank
System)
P1456n.*
{90}
Evaporative
Emission
ControlSystemLeakDetected
(EVAPControlCanister
Svstem)
Pr457n.s
{90)
P1508
(14)
ldleAir Control
ValveCircuit
Failure
Pr607
(-)
EngineControlModule,Powertrain
ControlModule InternalCircuit
FailureA
Pagc
11-142
11-142
11-146
11-131
TDCsensor
TDCsensorcircuit
ECM/PCM
. CYPsensor
CYPsensor
CYPsensorcircuit
ECM/PCM
F u e l f i lcl a p
Vacuumconnection
Fueltank
Fueltankprossure
sensor
EVAPbypasssolenoidvalve
EVAPtwo way valve
EVAPcontrolcanistervent shut valve
EVAPcontrolcanister
EVAPpurgecontrolsolenoid
valve
Vacuumconnection
EVAPcontrolcanister
Fueltankpressure
sensor
EVAPbypasssolenoidvalve
EVAPtwo way valve
EVAPcontrolcanister
ventshutvalve
Fueltank
EVAPpurgecontrolsolenoid
valve
IACvalve
IACvalvecircuit
ECM/PCM
. ECM,FCM
11-131
11-131
11-131
11-213
11-219
11-152
11-147
P1705
Automatic
P1706
Transaxle
P1753
Section'14
P1758
P1768
r: TheseDTCSwill be indicatedby the blinkingoJ the MalfunctionIndicatorLamp (MlL)with the SCSserviceconnector
connected.
**: The Di (E)*5 indicatorlight and the MalfunctiontndicatorLamp (MlL)may come on simultaneously.
*1: A[f
*3;'97 model *5: '99 - 00 models
*21M/f *4: '98 model
11-7 8
www.emanualpro.com
How to ReadFlowcharts
A flowchartis designedto be usedfrom startto final repair.lt's likea map showingyou the shortestdistance.But beware:
lf you go off the "map" anywherebut a "stop" symbol,you can easilyget lost.
brARn
tw"t
t.-OotO
FcTloNl
@
fS-OPl
(boldtype)
Describes
the conditionsor situationto starta troubleshooting
flowchart.
Asksyou to do something;performa test,set up a conditionetc.
Asksyou aboutthe resultof an action,then sendsyou in the appropriatetroubleshooting
direction.
The end of a seriesof actionsand decisions,describesa final repairactionand sometimesdirectsyou to
an earlierpart of the flowchartto confirmyour repair.
NOTE:
. The term "lntermittentFailure"is used in thesecharts.lt simply meansa systemmay have had a failure,but it checks
out OK at this time. lf the MalfunctionIndicatorLamp (MlL)on the dash does not come on, checkfor poor connections
or loosewires at all connectorsrelatedto the circuitthat you are troubleshooting(seeillustrationbelow).
. Most of the troubleshootingflowchartshave you resetthe EngineControlModule (EcM)/Powertrain
ControlModule
(PCM)and try to duplicatethe DiagnosticTroubleCode(DTC).lf the problemis intermittentand you can't duplicatethe
code,do not continuethoughthe flowchart.To do so will only resultin confusionand, possibly,a needlesslyreplaced
ECM/PCM,
o "Open" and "Short" are common electricalterms.An open is a breakin a wire or at a connection.A short is an accidental connectionof a wire to ground or to anotherwire. ln simple electronics,this usuallymeanssomethingwon't
work at all. In complexelectronics(likeECM'S/PCM'S),
this can sometimesmeansomethingworks,but not the way it's
suooosedto.
LOOSE
www.emanualpro.com
11-79
PGM-FISystem
SystemDescription
INPUTS
CKP/TDC/CYP
Sensor
CKFSensor
MAP Sensor
ECTSensor
IAT Sensor
TP Sensor
PrimaryHO2S
SecondaryH02S
vss
KS*5
BAROSensor
ELD*6
StarterSignal
ALT FRSignal
Air ConditioningSignal
Ay'TGearPositionSignal*1
BafteryVoltage(lGN.1)
BrakeSwitchSignal
PSPSwitchSignal
*5
FuelTankPressuae
Sensor*4.
ENGINECONTROL
MODULE(ECM)/
POWERTRAIN
MODULE(PCM)
CONTROL
OUTPUTS
FuelInjectors
PGM-FlMain Relay(FuelPump)
MIL
IACValve
Ay'CCompressorClutchRelay
RadiatorFanRelay
CondenserFanRelay
ALT
tcM
Et*-.nt"tdt"cont.orl
to,r*,c;;trffi;]
.
l.----.---:.
Lrgnrnon|lmrngLonrrorI
B*k',p Fr""il]
Ecir/PcM
m;"t-ll-r*'io*l
Countershaft
SpeedSensor*1
MainshaftSpeedSensor*r
OVER-DRIVE
SwitchSignal*s
EVAPPurgeControlSolenoid
Valve
PrimaryHO2SHeater
SecondaryH02S Heater
EVAPBypassSolenoidValve*a*5
EVAPControlCanisterVent Shut
DLC
Lock-upControlSolenoidValve*l
Shift ControlSolenoidValve*1
Ay'TClutch PressureControl
SolenoidValve*1
D4 IndicatorLight'1*3,*a
D IndicatorLight,l *5
OVER-DRIVE
OFFIndicator
Lighl*t *:
* 1 :A / T
'2: M/f
{ 3 : ' 9 7m o d e l
+4:'98 model
*5: '99 - 00 models
"6: USA
PGM-FlSystem
The PGM-Flsystemon this model is a sequentialmultiportfuel injectionsystem.
Fuel iniecior Timing and Duration
The ECM/PCMcontainsmemoriesfor the basicdischargedurationsat variousenginespeedsand manifoldpressure.The
basicdischargeduration,after being read out from the memory,is further modifiedby signalssentfrom varioussensors
to obtainthe final dischargeduration.
ldle Air Control
ldle Air ControlValve(lACValve)
When the engineis cold,the Ay'Ccompressoris on, the transmissionis in gear,the brakepedalis depressed,
the P/Sload
is high,or the alternatoris charging,the ECM/PCM
controlscurrentto the IACValveto maintainthe correctidle speed.
lgnition Timing Control
o The ECM/PCMcontains memoriesfor basic ionition timing at various engine speedsand manifold air flow rates.
lgnitiontiming is alsoadjustedfor enginecoolanttemperature.
. A knockcontrolsystemwas adoptedwhich setsthe idealignitiontiming for the octaneratingof the gasolineused.*s
Other Control Funstions
1. StartingControl
Whenthe engineis started.the ECM/PCMprovidesa rich mixtureby increasingfuel injectorduration.
2. FuelPumpControl
. When the ignition switch is initiallyturned on (ll). the ECMiPCMsupplisground to the PGM-FImain relay that
suppliescurrentto the fuel pump for two secondsto pressurize
the fuel system.
. When the engineis running,the ECM/PCMsuppliesground to the PGM-FImain relaythat suppliescurrentto the
fuel oumo.
. When the engineis not runningand the ignitionis on, the ECM/PCMcuts groundto the PGM-FImain relaywhich
cuts currentto the fuel pump.
11 - 8 0
www.emanualpro.com
5.
PCMFail-safe/Back-upFunctions
1. Fail-safe
Function
When an abnormalityoccursin a signalfrom a sensor,the ECM/PCMignoresthat signal and assumesa pre-pre
grammedvaluefor that sensorthat allowsthe engineto continueto run.
2. Back-upFunction
When an abnormalityoccursin the ECM/PCMitself,the fuel injectorsare controlledby a back-upcircuitindependent
of the systemin orderto permitminimaldriving.
3. Self-diagnosis
FunctionIMalfunctionIndicatorLamp (MlL)l
When an abnormalityoccursin a signalfrom a sensor,the ECM/PCMsuppliesgroundfor the MIL and storesthe DTC
in erasablememory.When the ignition is initiallyturned on {ll),the ECM/PCMsuppliesground for the MIL for two
secondsto checkthe MIL bulb condition.
4. Two Trio DetectionMethod
To preventfalseindications,
fuel metering-related.
idle control
the Two Trip DetectionMethodis usedfor the HO2S*1,
system,ECTsensorand EVAPcontrol systemself-diagnostic
functions.When an abnormalityoccurs,the ECM/PCM
storesit in its memory.When the same abnormalityrecursafter the ignitionswitch is turned OFFand ON (ll) again,
the ECM/PCMinforms the driver by lighting the MlL. However,to ease troubleshooting,this function is cancelled
when you jump the servicecheckconnector,The MIL will then blink immediatelywhen an abnormalityoccurs.
5. Two (or Three)DrivingCycleDetectionMethod{'97 model)
A "DrivingCycle"consistsof startingthe engine,beginningclosedloop operation,and stoppingthe engine.lf misfiring that increasesemissions or EVAPcontrol system malfunction is detected during two consecutivedriving cycles.
or TWC deteriorationis detectedduringthreeconsecutivedrivingcycles,the ECM/PCMturnsthe MIL on. However,to
easetroubleshooting,
this functionis cancelledwhen you jump the servicecheckconnector.The MIL will then blink
immediatelywhen an abnormalityoccurs.
*1: '97 - 98 models
*2: '99 - 00 models
www.emanualpro.com
PGM-FISystem
Powertrain Control Module {PCM}-'97
The Malfunction lndicator LamD
(MlL) nev6r comes on {evenlor
two seconds) after ignition is
turned on (lll, or it's on dimly
and flickers.
Model
Doesthe enginestart?
ls thorelssthan 1.0V?
l s t h e M I Lo n ?
-
11-42
www.emanualpro.com
A {32PI
PCMCONNECTOR
NOTE:
. Whenthereis no Diagnostic
TroubleCode(DTC)stored,the MIL will stay on if the SCS
serviceconnectoris connected
andthe ignitionswitchis on.
. lf this svmotomis intermittent,
checkfor:
- A looseFl E/M(15Aifuse in the underdashtuse/relay
box
- A looseNo. 13 FUELPUMP{15A) fuse in the under-dash
fuse/relay
box
- An intermittentshort in the wire betweenthe PCM(C7)and the servicecheckcon-
Go to troubleshootingprocedures
(spage11501.
NOTE:An openor shortin the wire betweenthe PCM(C8)and the DLCwill keepthe
with the PCM.You shouldioterpret
scantool or HondaPGMTesterlrom communicating
this as no DTCSare indicated.
Doesthe enginestart?
C h e c kt o r a s h o r t i n t h e w i r e
{SCSline):
1. Turn the ignition switch OFF
a n d t u r n t h e i g n i t i o ns w i t c h
oN flt).
2. Measurevoltagebetweenthe
P C M c o n n e c t o rt e r m i n a lC 7
and body ground.
ls thereapprox.5 V?
(To page1'l-84)
www.emanualpro.com
(cont'dl
11-83
PowertrainControlModule (PCM)-'97
Model (cont'dl
( F r o mp a g e 1 1 8 3 )
lsthe MILON?
InspectNo. 13 FUELPUMP(15Ai
fuse in the underdashfuse/relay
( T op a g e1 1 - 8 5 )
1 1 -8 4
www.emanualpro.com
ReplaceNo. 13 FUELPUMP
115A) fuse.
(Frompage 11-84)
D (16PI
PCMCONNECTOR
VCCl NEL/RED}
Wiresideof femaleterminals
Repair shorl lo body ground
in the wile between the PCM
{D4}and the MAP sensor.
Repairshort to body ground in
th wire between the PCM
lol0l and the TPsensor.
PCMCONNECTOR
A (32PI
l s t h e r e l e s st h a n 1 . 0 V ?
R e p a i ro p e n i n t h e w i r e ( s l
boiween the PCM 1A11,A24)
and the PGM-Flmain relav.
Chck lor poor connections
or loose wires at ihe PGM-FI
main relay.
Tesi lhe PGM-FImain relav
{seep.g6 1l-1871.
www.emanualpro.com
11 - 8 5
PGM-FISystem
Engine
Module/PowertrainControlModule(ECM/PCM)
'98 - 00Gontrol
Models
Tho Maltunction Indicator Lamo
(MlL) n6Yor como3 on leven lor
two laconds) rft6r tho ignhion is
turnod ON {lll.
NOTE:
. lf this symptom is intermittent,checktor:
- A looseFl E/M{15A) fuse in the under-hood
fuse/relay
box
- A looseNo. 25 METER{7.5A) fusein the under-dash
fuse/relay
box
- A looseNo. 13FUELPUMP(15Alfuse in the underdashfuse/rolay
box
- An intermiftentshort in the wire betweenthe ECM/PCM
(A18)and the gaugeassem-
Wiresideof femaleterminals
Turnthe ignitionswitchOFF.
Inspectthe Fl E/M 115A) tuse
in the undeFhoodfuse/relay
box.
I n s p e c t h e N o . 1 3 F U E LP U M P
(15A) fuse in the under-dash
fuse/relaybox.
-
(Topage11-871
www.emanualpro.com
(Frompage11-86)
ECM/FCMCONNECTOR
A {25PI
IGPl
(YEL/BLK)
10
20
vXv)iiP2
rELlBLK)
't3
11
17
23
21
ls there batteryvoltage?
2
I
19
lstherelessthan1.0V?
ls thereapprox.5V?
2 i 3
s /
't6 1 7 1 8 1 9 20 21\22
26 27 2el E 30 31
vcc2
kt
(YEL/BLUI
vccl
(YEL/RED)
Wire sideof
lemaleterminals
. TP sensor
. Fueltankpressuresensor
ls there approx. 5 V?
Sub3lhuio . known-good ECM/
PCM .nd rcch6ck. lf tymptom/
indic.tion go.3 away, rapl.ce
th. original ECM/PCM.
R e p l e c et h e r o n s o r t h t t h a d
approx. 5 V.
lcont'd)
www.emanualpro.com
11-47
PGM-FISystem
EngineControlModule/Poweftrain
ControlModule(ECM/PCM)
NOTE:
. When there is no DiagnosticTrouble Code IDTC)stored,the MIL will stay on iI the SCS
serviceconnectoris connectedand the ignitionswitch is ON (ll).
. lf this symptom is intermittent,checkfor:
- An intermittentshort in the wire betweenthe ECM/PCM(A10)and the servicecheck
connoctor
- An intermittentshort in the wire between the ECM/PCM(At8l and the gauge
assemDty
. See the OgD ll scantool or HondaPGMTesteruser'smanualsfor specificoperating
rnstructions.
Go to troublGhooting procadura.
(3c prg l lS0l
Doesthe enginestan?
o N{ ) .
2- Measurevoltage between
body groundand the ECM/
PCi, conneclorterminalA10.
lTo page1l-89)
11-88
www.emanualpro.com
(Frompage11-88)
www.emanualpro.com
1-89
PGM-FISystem
ManifoldAbsolutePressure(MAPISensor
The scan tool indicatesDiagnosticTrouble Code (DTC)POl07:A low input (high vacuum) problem in the
ManifoldAbsolutePressure(MAP)sensor,
The MAP sensorconvensmanifoldabsolutepressureinto electricalsignalsand inputsthe ECM/pCM.
OUTPUI
VOLTAGE
tvl3.s
3.0
2.5
2.O
1.5
1.0
0.5
r o - 1 5 ^ 1 o 25
30 lin.H9) GAUGE
.5
READIT{G
100 200 300 a00 5oo 6fi, 7d)
lmmHgl
Problomverification:
1. Turn the ignitionswitchON lll).
2. Checkthe lvlAPwith the scan
root.
ls approx.101kPa(760mmHg,
30 in.Hg),2.9
V indicated?
ls thereapprox.5 V?
(Topage11-91)
11-90
www.emanualpro.com
vccl
(YEL/RED}
{Frompage11-90)
ls approx.2 kPa(15mmHg,
V or lessindi0.6in.Hg),0.1
cated?
(C131I
MAP SENSOR3P CONNECTOR
(cont'd)
www.emanualpro.com
11 - 9 1
PGM-FISystem
Manifold Absolute Pressure(MAP)Sensor (cont'd)
The scan tool indicatesDiagnosticTrouble Code (DTC)P0108:A high voltage (low vacuum) problem in the
[tn,t
|jg nn-] ManifoldAbsolutePressure(MAP)
sensor.
The MIL has boen reportedon.
DTCm108 is slored.
Problemveritication:
1 . S t a r tt h e e n g i n e .H o l d t h e
engine at 3,000rpm with no
load (in Parkor neutral)until
the radiatorfan comeson, then
letit idle.
2. Checkthe MAP with the scan
tool.
ls 101kPa{760mmHg,30in.Hg),
2.9V or higherindicated?
tcRN/wHrll
IIRED/GRN|
vccl
IYEL/RED}
D I16PI
PCMCONNECTOR
JUMPERWIRE
sGl
IGRN/WHTI
Wire side of lemale termin6ls
(To page11,93)
': '98- 00 models
1 1-92
www.emanualpro.com
(Frompage11-92)
I
Check for an open in the wire
{MAPlinel:
1. Turnthe ignitionswitchOFF.
2 . I n s t a l la j u m P e rw i r e o n t h e
ECM/PCMconnectorsbetlveen
C7andC17.
3. Turnthe ignitionswitchON (ll)
4. Checkthe MAP with the scan
tool.
ls 101kPa(760mmHg,30in.Hg),
2.9V or higherindicated?
(cont'd)
www.emanualpro.com
11-93
PGM-FISystem
ManifoldAbsolutePressure(MAP)Sensor(cont'dl
The scan tool indicatesDiagnosticTroubleCode (DTC)P1128:ManifoldAbsolutepressure(MAp) lower than
exoected.
-
Problomverification:
1. Turnthe ignitionswitchON1lli.
2. Checkthe MAP with the scan
tool,
ls 54.1kPa(406mmHg,16.0in.Hg),
1.61V or higherindicated?
Problemveritication:
1 . S t a r tt h e e n g i n e .H o l d t h e
engine at 3,000rpm with no
load lin Parkor neutral)until
t h e r a d i a t o rf a n c o m e s o n ,
then Iet it idle.
2. Checkthe MAP with the scan
tool,
ls 43.3kPa(325mmHg,12.8in.Hg),
'1.32
V or lessindicated?
www.emanualpro.com
11 -9 4
IntakeAir Temperature(lAT)Sensor
problemin
The scantool indicatesDiagnosticTroublecode (DTC)P0111:A ranoe/performance
1P0111
| ('97model)the lntakeAir TemDerature(lAT)Sensorcircuit.
RESISTANCE
IKOI
Problemvetification:
1. Turnthe ignitionswitchOFF.
the IAT sensor2P
2. Disconnect
connector,
3. Removethe IATsensor.
4. Reconnectthe IAT sensor2P
connector,
5. Leavethe IATsensoretposed
to ambienttemPerature.
6 . T u r n t h e i g n i t i o ns w i t c hO N
INTAKEAIB TEMPERATURE
flr).
(cont'd)
www.emanualpro.com
11 - 9 5
PGM-FISystem
IntakeAir Temperature(lAT)Sensor(cont'dl
The scantool indicatesDiagnosticTroublecode (DTC)P0112:A low voltage(hightemperature)problem
in the
IntakeAir Temperature0AT)sensorcircuit.
The IAT Sensoris a temperaturedependantresistor(thermistor).
The resistance
of tho thermistordecreasesas the intake
air temperatureincreasesas shown below.
-
RESISTANCE
IKO)
Problemvsrification:
1. Turnthe ignitionswitchON flt).
2. Checkthe IAT with the scan
tool.
-. 32 aa rorr 1?a 2ra 2aa f.el
-m 0 20 rto ao i0 too l2ofcl
INTAKEAIR TEMPERATUR
ls 302"F{150"C)or higher{or
H - L i m i ti n H o n d am o d e o f
PGMTester)or 0 V indicated?
'
A
9)
)
/
tAr
(RED/YEU
-L
Wi16sideof femsleterminals
Repairshort in the wi.o botween
th6 ECM/rcM {D8,C25*l and th6
IAT 3ensor.
Substitute a known-good ECM/
PCM and recheck. lf normel IAT
is indicaled, replace the original
ECM/PCM,
*: '98- 00 models
11 - 9 6
www.emanualpro.com
Problemvrification:
1. Turnthe ignitionswitchON (ll).
2. Checkthe IAT with the scan
tool,
sG2
{GRN/BIIO
ICl33I
IAT SENSOR2P CONNECTOR
JUMPENWNE
IAT IRED/YELI
Wire side ol female terminals
YES
_!!7rqd9ll_____FCM CONNECTOR
O IT6PI
IAT IRED/YEL)
sG2
IGRN/BLK}
JUMPER
w|BE
ls -4"F {-20"C)or Iess(or Llimit
in Hondamodeot PGMTester)or
5 V indicated?
Wiresideof female
terminals
(cont'd)
(Topage11-98)
www.emanualpro.com
11-97
PGM-FISystem
IntakeAir Temperature(lATl Sensor(cont'd)
(Frompage11,97)
ECM/PCMCINNECTORC t3lPl
2
./
23
5
7
I I
16 1 7 1 8 19 20 21 22
4 Wp,
IAT{RED/YELI
29 c) 31
sG2{GRN/BLK)
JUMPERWIRE
Wire sideof fernaleterminals
Repsir opn in the wirca batween
the ECM/PCM1C18,C25l and the
IAT snsor.
'l
11 - 9 8
www.emanualpro.com
(ECTISensor
EngineGoolantTemperature
problem in the Engine
The scan tool indicatesDiagnosticTrouble Code (DTC)P0116:A range/performance
CoolantTemperature(ECT)Sensorcircuit.
as the engine
of the thermistordecreases
The resistance
The ECTSensoris a temperaturedependantresistor(thermistor).
coolanttemperatureincreasesas shown below
RESISTANCE
tk0l
- 4 3 2 6 8 r 0 a r a 0 1 7 62 1 22 a E{ ' r )
-2O O 20 ito tO .o ! t2O I c)
THERMISTON
NOTE:lf DTC P0117and/or P0118are stored at the same time as DTC P0116,troubleshootthose DTCSfirst, then troubleshootDTCP0116.
PossibleCause
a ECTsensordeterioration
. Malfunctionin the thermostatand coolingsystem
Troubleshooting Flowchart
-
Probl6mverification:
1 . S t a r t t h e e n g i n e .H o l d t h e
engine at 3,000 rpm with no
load (in Parkor neutral)until
t h e r a d i a t o rf a n c o m e s o n ,
then let it idle.
2. With the scan tool, checkthe
ECT.
(cont'd)
www.emanualpro.com
11 - 9 9
PGM-FISystem
EngineCoolantTemperature(ECTISensor{cont'd)
:[F011'
-
Problemverification:
1. Turn the ignitionswitchON {ll).
2. Checkthe ECTwith the scan
tool,
ls 302"F(150'C)or higher(or
H Limitin Hondamodeot
PGMTester)or 0 V indicated?
'1. Disconnect
the ECTsensor2P
connefior,
2. Checkthe ECTwith the scan
tool.
ls 302"F(150"C)orhigher(or
H-Limitin Hondamodeof
PGMTester)or 0 V indicated?
ECTSENSOR2P CONNECTOR
{C114I
C h e c kf o r r s h o r l i n t h e w i r s
(EgTlinel:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe ECM/PCMconnectorD (16P),(C(31P)*1.
3. Checktor continuitybetween
the ECTsensor2Pconnectorter
minalNo.1 and bodyground.
Wire sideof femaleterminals
ls therecontinuity?
1-1
www.emanualpro.com
Problemverification:
1. Turnthe ignitionswitchON {ll).
2. Checkthe EcT with the scan
tool-
Intermiftent tailu.,3ystem is OK
at this time, Checl foJ poor connction3 or loose wires et C1'14
(ECT ren3or) and at the ECM/
PCM.
ECTSENSOR2P CONNECTOB(C11ill
ECT
(ncD/wlrT)
1. Disconnect
the ECTsensor2P
connector.
2 . C o n n e c tt h e E C Ts e n s o r2 P
connectorterminalsNo. 1 and
No.2 with a jumperwire.
3. Checkthe ECTwith the scan
tool.
JUi,IPEBWNE
sG2
(GRN/8LKI
('97model)
D {T6PI
PCMCONNECTOR
JUMPERWIRE
ECT
IREDAAIHT)
IGRN/BLX}
(To page11-102)
(cont'd)
www.emanualpro.com
11 - 1 0 1
PGM-FISystem
EngineGoolantTemperature(ECTISensor(cont'dl
( F r o mp a g e1 1 1 0 1 )
ECM/PCMOONNECTOR
C 13lPI
1
7
I 9
't8 '19
,/ 16 1 7
20 n
ECTIRED/WHTI
sG2(GRN/BLK)
JUMPERWIRE
Wiresideof temaleterminals
11-102
www.emanualpro.com
ThrottlePosition(TPlSensor
The scan tool indicatesDiagnosticTroubleCode (DTC)P0122:A low input (voltage)problem in the Throttle
Position(TP)sensorcircuit.
lt is connoctedto the throttlevalve shaft.As the throttle positionchanges,the throftle
The TP Sensoris a potentiometer.
positionsensorvariesthe voltagesignalto the ECM/PCM.
'97
BRUSH
HOI,I'ER
mod6l:
-
Problemvorificalion:
1 . S t a r tt h e e n g i n e .H o l d t h e
engine at 3,000rpm with no
load (in Parkor neutralluntil
t h e r a d i a t o rf a n c o m e s o n ,
then turn the ignition switch
OFF.
2. Turn the ignitionswitchON (ll).
3 . C h e c kt h e t h r o t t l e p o s i t i o n
with the scantool.
3
2
1
0
THROITLE
OPCNIiIG
FUTI
IHROTTI"E
TP SENSOR3P CONNECTOR
{Cl3OI
ls there approx. 10%when the
throttle is fully closedand
approx.90%when the throttle
is fully opened?
vcc2
IYEL/BLUI
D I16PI
PCMCONNECTOR
ls thereapprox.5V?
ls thereapprox.5 V?
(GRN/BLX)
Wiresideof femaleterminals
Repairopen in the wirc between
PCM{D10}and TP 3ensor.
( T op a g e1 1 - 1 0 4 )
Terminalsideof maleterminals
www.emanualpro.com
(cont'd)
11 - 1 0 3
PGM-FISystem
ThrottlePosition(TP)Sensor(cont'd)
(Frompage11 103)
TP SENSOR3P CONNECTOR
ls thereapprox.0.5- 0.9kO?
TPS IREO/
BLK)
SG2 (GRN/BLKI
Wiresideol femaleterminals
ls thereapprox.0.5V whenthe
throftle is fully closedand
approx.4.5V when the throttle
is fullyopened?
11-104
www.emanualpro.com
'98 - 00 model3:
The MIL has boon reDortod on.
DTCm122 b rtorod.
P.oblom veiification:
1. Start the engine.Hold the
engine at 3,000rpm with no
load (in Parkor neutral)until
t h e r a d i a t o rt a n c o m e s o n ,
then turn the ignition switch
OFF.
2. Turnthe ignitionswitchON lll).
3 . C h e c kt h e t h r o t t l e p o s i t i o n
with the scantool.
TP SENSOR3P CONNECTOR
{C130}
ls thereapprox.10%whenthe
throttle is fully closedand
approx.90%when the throttle
is fully opened?
vcc2
sG2
IGRN/BLKI
IYEUBLUI
C (31P}
ECM/PCMCONNECTOR
sG2IGRN/BLKI
1
a
,l -
18 sl./|
ls thereapprox.5 V?
/ 1 6 17
gJ lzgi3osrI
T ^
vccz {YEL/8LUl
23
Checklor an opon in wiro IVCC2
linel:
Measurevoltage betweenECM/
rcM connectorterminalsC'18and
zzl
lrs]zolzr
25
27)
c2a.
Chockfor en opn or Bhort in TP
3an30r:
1. Turnthe ignitionswitchOFF.
2. At the sensor side, measure
r e s i s t a n c eb e t w e e nt h e T P
sensor3P conneclorterminals
No. 1 and No. 2 with the throttle fullyclosed.
(To page11-106)
ls lherapprox.5 V?
(cont'd)
www.emanualpro.com
11 - 1 0 5
PGM-FISystem
ThrottlePosition(TPlSensor(cont'dl
(Fromp6ge11-105)
TP SENSOR3P CONNECTOR
ls there approx. 0.5 - 0.9 kO?
ECM/PCMCONNECTOR
C {31P}
7 l
la
1 6 17 t 8 1 9 l m
23
27 t l
TPS IRED/BLK)
l 2 e30 31
Lle (GRN/BLKI
{9}
11 - 1 0 6
www.emanualpro.com
Pioblom vorificltion:
1 . S t a r t t h e o n g i n 6 .H o l d t h
ongine at 3,000rpm with no
load {in Parkor neutral)until
t h 6 r a d i a t o rf a n c o m e s o n .
then turn the ignition switch
OFF,
2. Turn the ignitionswitchON (ll).
3 . C h e c kt h e t h r o t t l e p o s i t i o n
with the scantool.
sG2
(GnN/Br.Xl
Choct toJ an opcn in th6 TP s6n3t']:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe TP sensor3P
connectol,
3. Turn the ignitionswitchON (ll).
4. At the wir6 harnossside, measuro voltage betweonthg TP
sensor 3P connectortrminals
No. 1 and No.3.
vocr
tYEt/8LU)
ls thereapprox.5V?
('97model)
PCMCON'{ECTOFD I16PI
Chack for an oDan in tha wira
(SG2linel:
M6asu16voltage b6tween PCM
connctorterminalsDl0 and D'!1.
{GBIT/BLKI
ls there approx. 5 V?
(Topage11-108)
(cont'd)
www.emanualpro.com
11-107
PGM-FISystem
ThrottlePosition(TP)Sensor(cont'dl
(Frompage11-107)
ECM/PCMCONNECTOR
C {31PI
ls thereapprox.5 V?
11 - 1 0 8
www.emanualpro.com
Problemveritication:
1. Turnthe ignitionswitchON (ll).
2 . C h e c kt h e t h r o t t l e p o s i t i o n
with the scantool.
ls 14.1%(12.97.)*
or higher
indicatedwhen the throttleis
fullyopened?
Problemverification:
1. Turnthe ignitionswitchON lll).
2 . C h e c kt h e t h r o t t l e p o s i t i o n
with the scantool.
(16.9%)'or less
ls'17.670
indicatedwhen the throftle is
lully closed?
*:'99 - 00 models
www.emanualpro.com
1-109
PGM-FISystem
PrimaryHeatedOxygenSensor(PrimaryHO2S)(Sensor1)
In operation,
The HeatedOxygenSensors(HO2S)detectthe oxygencontentin the exhaustgas and signalthe ECM/PCM.
the ECM/PCMreceivesthe signalsfrom the sensorand variesthe durationduring which fuel is iniected.To stabilizethe
sensor'soutput,the sensorhasan internalheater.The PrimaryHO2S(Sensor1) is installedin exhaustpipeA.
sNsoR
HO2S:
TERMINALS
VOLTAGEIVI
ztRcoNtA
EI.IMENT
HEATER
HEATEB
TERMINALS
The scan tool indicatesDiagnosticTroubleCode (DTC)P0131:A low voltage problem in the PrimaryHeated
OxygenSensor(HO2S){Sensor1} circuit,
37 - 98 models:
The MIL has been reoorted on.
DTC P0131 is stoied.
Problemverification:
1. Do the ECM/PCMResetProceoure.
S t a r t t h e e n g i n e .H o l d t h e
engine at 3,000rpm with no
load (in Parkor neutral)until
the radiatorfan comeson.
Test-drivewith the A/T in E
position(M/T in 4th gear)
Check the Primary HO2S
{Sensor1} output voltagewith
the scantool during acceleration usingwide openthrottle.
Intermittent f.ilure, system is OK
at this time. Check fo. poor connections or loose wirer at C111
(Primary HO2S,SeGor 1) and at
rh ECM/FCM.
Checkthe fuel pressure(seepage
11-178).
{ T op a g e1 1 ' 1 1 1 }
1 1 - 11 0
www.emanualpro.com
{ F r o mp a g e1 1 - 1 1 0 }
Replacethe HO2S{Sensor1).
(Cl111
PRIMARYHO2Sls.n.or 'l I 4P CONNECTOR
PHO2S ---'t
rwHTr T-T-l
T-1 1 2l
6 t lr___J_J
r rl
Y
(cont'd)
www.emanualpro.com
11-111
PGM-FISystem
PrimaryHeatedOxygenSensor(PrimaryHO2SI(Sensor1l (cont'd)
'99 - 00 models:
-
Problemve fication:
1. Do the ECM/PCMReset Procedure,
2. Start the engine. Hold the
engine at 3,000rpm with no
load {in Parkor neutral)until
lhe radiatortan comeson.
3. Check the Primary HO2S
(Sensor1) oltput voltage with
the scantool during acceleration usingwide opnthrottle.
Doesthe voltage stay at 0.5 V
or less?
PRIMARYHO2S(Son.or 1l aP CONNECTOR
|C111)
PHO2S T--1
rwHTr f-T---]
--1 1 2l
I
t---
t6)lslrl
v L__r__J
_L
www.emanualpro.com
11-112
The scan tool indicatesDiagnosticTroubleCode (DTC)P0132:A high voltage problemin the PrimaryHeated
OxygenSensor{PrimaryHO2S)(Sensor1) circuit.
'97 - 98 models:
Problemverification:
1. Do the ECM/PCMResotPro,
ceoute,
2. Start the engine.Hold the
engine at 3,000rpm with no
load (in Parkor neutral)until
the radiatorfan comeson.
3. Test-drive with the Ay'Tin E
position(M/Tin 4th gear).
4. Check the Primary H02S
{Sensor1}outputvoltagewith
the scantool duringdeceleration using completelyclosed
throttle.
Does the voltage stay at 1.0 V
sG2
PHO2S
IWHTI
IGRN/
BLK}
ls there1.0V or more?
{'97 model}
PCMCONNECTOR
D {16PI
JUMPERWIRE
PHO2SIWHTI
SG2 IGRN/BLK}
{ T op a g e1 1 - 1 1 4 )
www.emanualpro.com
I
(cont'dl
11-113
PGM-FISystem
PrimaryHeatedOxygenSensorlPrimaryHO2S){Sensor1} {cont'dl
( F r o mp a g e ' 1 1 - l 1 3 )
ECM/PCMCONNECTOR
C {31PI
11-114
www.emanualpro.com
'99 - 00 modols:
Th6 Mll has bon reDortodon.
DTCml32 is itorod.
Problemvorification:
'1. Do the ECi!4/PCM
ResetPro
cedure,
Start the ongine.Hold the
engine at 3,000rpm with no
load (in Parkor neutral)until
the radiatorfan comeson.
Check the Primary HO2S
lSensor1) outputvoltagewith
the scan tool during decelelation using completelyclosed
throftle.
PRIMARYHOzS (S6n!or 1l aP
CoNNECTORlcltl)
Pt()2s
IWHTI
sG2
{GRN/
BTJ(I
ECM/PCMCONNECTOR
C (31P}
2
23
7
8 9
't8
1912A
0 22
/ 1 6 17
E
29 g) 31
PHO2S{WHTI
ls there1.5V or more?
sG2IGRN/BLKI
JUMPERWIRE
Wire sideol temalet6rmin6ls
(cont'd)
1 1- 11 5
PGM-FISystem
Primary Heated Oxygen Sensor (PrimaryHO2S)lSensor 1) (cont'd)
scantool indicatesDiagnosticTroubleCode(DTC)P0133:A slow responseproblemin the PrimaryHeated
tFO133
\ lhe
:
Oxysen Sensor (Primarv HO2S\ (Sensor 1) circuit.
Description
By controllingthe airlfuelratiowith a PrimaryHO2S(Sensor1) and a SecondaryHO2S(Sensor2), the deteriorationof the
PrimaryHO2S(Sensor1) can be evaluatedby its feedbackperiod.When the feedbackperiodof the HO2Sexceedsa cer
tain valueduringstabledrivingconditions,the sensorwill be judgedas deteriorated.
When deteriorationhas beendetectedduringtwo consecutive
trips,the MIL comeson and DTCP0133will be stored.
NOTE: lf DTCP0131,P0132and/or P0135are storedat the same time as DTCP0133.troubleshootthose DTCSfirst, then
troubleshootDTCP0133.
PossibleCause
. PrimaryHO2S(Sensor1) Deterioration
. PrimaryHO2SHeater(Sensor1) Deterioration
. Exhaustsystemleakage
Troubleshooting Flowchart
-
ProblemVerilication:
'1. Do the ECM/PCMResetPro
cedure.
2. Connectthe scantool.
3. Start the engine.Hold the
engine at 3,000rpm with no
load lin Parkor neutraliuntil
the radiatorfan comeson.
4. Connectthe SCSservicecon
nector.
5. Test-driveunderthe following
condations,
55 mph (89 km/h) steady
speed
- M in @ position(E posi
tion and Over DriveON)*,
(M/Tin sth gear)
- Until readinesscode comes
1 1 - 11 6
www.emanualpro.com
SecondaryHeatedOxygenSensor(SecondaryHO2S)(Sensor2)
The scantool indicatesDiagnosticTroublecode (DTC)P0137:A low voltageproblemin the secondaryHeated
OxygenSensor(SecondaryHO2S)(Sensor2) circuit.
The MIL hrs been reported on.
DTC P0137 is stored.
Problemveritication:
1. Do the ECM/PCMResetPro'
cedure.
2 . S t a r tt h e e n g i n e .H o l d t h e
engine at 3,000rpm wilh no
load (in Parkor neutral)untal
the radiator{an comeson,
3 . C h e c kt h e S e c o n d a r yH 0 2 S
l S e n s o r2 ) o u t p u tv o l t a g ea t
3,000rpm with the scantool.
HO2Sls.nlor 2)
SECONDARY
4P CONNECTOBlC721l
C h e c kl o r a s h o r t i n t h e w i r e
(SHO2Slinel:
1. Turnthe ignitionswitchOFF.
2 . D i s c on n e c t t h e E C M / P C M
connector{D (16P},A (32P}').
3. Check for continuity between
the SecondaryHO2S(Sensor
2i 4PconnectorterminalNo. 1
and bodyground.
(cont'd)
*: '98 - 00 modeis
www.emanualpro.com
11-117
PGM-FISystem
SecondaryHeatedOxygenSensor(SecondaryHO2SI(Sensor2l (cont'dl
The scantool indicatesDiagnosticTroubleCode(DTC)P0138:A high voltageproblemin the SecondaryHeated
OxygenSensor(SecondaryHO2S)(Sensor2) circuit.
The MIL hra bon Eported on,
OTCm138 b stor.d.
PJoblcmv6dtic.tion:
1. Do the ECM/PCMResotProcedure,
S t a r t t h e e n g i n e .H o l d t h e
engine at 3,000rpm with no
load (in Parkor neutral)trntil
the radiatorlan comeson.
Check the Secondary HO2S
(Sensor2) outpl.rtvoltage at
3,000rpm with the scantool.
Int.rmitto
tailurc, syst.m b OK
rt ihi! timo. Chack fo. poo. oonnoctioni or looaa wiiaa at C127
lloc.ted on EcM/PcM br.cket),
C721 (Second!ry llO2S, Sonlol
2).nd at th. ECM/PCM.
SECONDABYHO2S (Sonror 2)
1P CONNECTORrC721l
sHo2s
{WHT/REDI
sH()2sG
IGFN/WHTI
ls there0.6V or more?
('97model)
Ch6ck for an open in thg wiro3
(SH()2S,SG2 line3l:
1. Turnthe ignitionswitchOFF.
2. ConnectrcM connectorterminals 014 and D13 with a
J!mper wite.
3. Turnthe ignitionswitchON (ll).
4 . C h e c kt h e S c o n d a r yH O 2 S
( S n s o r2 ) o u t p u t v o l t a g e
with the scantool.
lsthere0.6V or more?
{ T op a g e1 1 - 1 1 9 )
www.emanualpro.com
1 1 - 11 8
PCMCOI{NECTOR
D {16PI
sHo2sG
(RED/YELI
JUMPERWIRE
( F r o mp a g e1 1 - 1 1 8 )
('98- 00 models)
ECM/PCMCONNECTORS
A l32Pl
Check for an open in tha wire
ISH()2Slinel:
1. Turnth ignitionswitchOFF.
2. ConnectECM/PCMconnector
terminalsA23 and C18with a
iumperware.
3. Turnthe ignitionswitchON (ll).
4. Checkthe Secondary HO2S
(Sensor2) output voltage with
the scantool.
SHO2SW}iT/RED)| JUMpERW;RE
(cont'd)
www.emanualpro.com
1 1 - 11 9
PGM-FISystem
SecondaryHeatedOxygenSensor(secondaryHO2SI(sensor2l (cont,d)
-lTol3al
-
Problmve.itication:
1. Do the ECM/PCMResetPro
cedure,
S t a r tt h e e n g i n e .H o l d t h e
engine at 3,000rpm with no
load (in Parkor neutral)until
the radiatorfan comeson.
C h e c kt h e S e c o n d a r yH O 2 S
(Sonsor2) output at 3,000rpm
with the scantool.
Doesthe voltagestaywithin
0.3- 0.6V for two minutes?
1 1 -1 2 0
www.emanualpro.com
HeatedOxygenSensor(HO2S|Heater
scantool indicatosDiagnosticTroubleCode
Fol3slThe
{PrimarvHO2S)(Sensor1) Heatercircuit.
indicatesDiagnosticTrouble Code
F o 1 1 t The
l scantoolHO2S)
(Secondary
(Sensor2) Heatercircuit.
-
Probl.m verification:
1. Do the ECM/PCMResotProcedure,
2. Startthe engine.
PBIMARYHO2Sls.n.or ll 4P
CONNECTOR(CI 11I, SECONDARY
HO2Sls.n.o.2l aP CONNECTOR
lc721l.
Terminalsideof maletrminals
ls there10- 40 0?
C h e c kf o r c o n t i n u i t y b e t w e e n
body ground and the HO2S 4P
c o n n e c t o rt e r m i n a l sN o . 3 a n d
No. 4 individually.
PRIMARYHO2Slson.o. 1l aP
CONNECTOR{Cl 11}, SECONDARY
HO2Sls.nror 214P CONNECTOR
tcr21l.
Checktor an op6n or 3hort in the
wires IPO2SHTC, SO2SHTC'
linel:
1. Turnthe ignitionswhchON {ll).
2. Moasurevoltage between the
HO2S4P connectorterminals
N o . 3a n dN o . 4 .
('97model:To page'11-122)
('98- 00 models:To page11-'123)
so2sHTc
tBLK/WHn.
PO2SHTC
(BLK/
WHTI
tGl
IBLKAAIHTI'
('97model:To page'11-122)
1'98- 00 modelslTo page11-123)
(cont'd)
*: P0141
www.emanualpro.com
11-121
PGM-FISystem
HeatedOxygenSensorIHO2S)Heater(cont'd)
{'97model)
PRIMARYHO2S(S.nsor 1) ap CONNECTOR
{cl111
| 1 1 2|
|.i-l
1 3. l
'ot X(9
tErK/
Reprir op6n or 3hort in thc wirc
betwo.n th No. 15 ALTERNATOR SP SENSOR(7.5 Al fu!. rnd
tho HO2S(Primary.Socond.ry*).
-L
Wiresideof femaleterminals
SECONDARY
HO2S
ISENSOR214P CONNECTOR
lcr21l,
ls thero0.1V or less?
YELI
IGl IBLK/WHTI
( F r o mp a g el 1 - 1 2 1 )
So2HTCIALK/WHTI*PO2SHTCIBLK/WHTI
11-1 2 2
www.emanualpro.com
('98- 00 models)
HO2S{S.n3or 1l aPCONNECTOR
PRIMARY
lc111l
Check for an open in the witoa
(lGP,lGl'lino):
Mgasurevoitage betweenthe primary HO2S4P connectorterminal
No. 3 (secondaryHO2S:No. 4) and
body ground.
1 1 2 l
r--T -
lL-.IJ------J
3 t . l
Wiresideof femaleterminals
HO2S
SECONDARY
{SENSOR2} 4P CONNECTOR
(c7211'
lcl /5'
tErK/ g,
YELI I
IGl IBLK/WHT}
ECM/FCMCONNECTORS
PGl (BLK}
lFrom page11-12'!)
www.emanualpro.com
11-123
PGM-FISystem
Fuel Supply System
[POliil
The"""ntool indicatesDiagnosticTroubteCode(DTC)p0'171:Thefuet
systemistoo lean.
[Fo17ZJ rh""""ntool
indicatesDiagnosticTroubtecode {DTc)p0172:Thefuelsvstemistoorich.
Description
By monitoringthe LongTerm Fuelrrim, long term malfunctionsin the fuel systemwill be detected.
lf a malfunctionhas beendetectedduringtwo consecutive
trips,the MIL will come on and DTc p0171and/orpol72 will be
stored.
NOTE: lf someof the DTCSlistedbeloware storedatthesametimeas DTCP017'land/orp0172,troubleshootthose DTcs
first,then troubleshootDTCP0171and/orPO1i2.
P0107,P0108,P1128,P'1129:
MAP Sensor
P0135:PrimaryHO2S(Sensor1)Heater
P0137,P0138:SecondaryHO2S{Sensor2)
P0141:SecondaryH02S (Sensor2) Heater
P0441*r:EVAPSystemlnsufficientPurgeFtow
P1456*,,P'l457*?i EVAPSystem Insufficientpurge Ftow
* 1 : ' 9 7m o d e l
*2: '98 - 00 models
PossibleCause
DTCP0171
too lean
FuelPumpinsufficientflow/pressure
FuelFeedLineclogged.leaking
FuelPressureRegulatorstuckopen
FuelFilterclogged
FuelInjectorclogged,air leakage
Gasolinedoesn'tmeet Owner'sManualspec.
PrimaryHO2S(Sensor1) deteriorated
ValveClearance
Exhaustleak
DTCP0172
FuelPressureRegulatorclogged,stuckclosed
FuelReturnPipeclogged
FuelInjectorleaking
Gasolinedoesn'tmeetOwner'sManualspec.
PrimaryH02S (Sensor1) deteriorated
EVAPPurgeControlSolenoidValveleaking,stuckopened
ValveClearance
flch
11 -1 2 4
www.emanualpro.com
TroubleshootingFlowchart
-
Doesit holdvacuum?
www.emanualpro.com
PGM-FISystem
RandomMisfire
lF()gool",tftod-'
andsome
orlpiogolthroughTo3otiP0300*,,P1300*1and someof po30t-
Descriotion
Misfiredetectionis accomplishedby monitoringthe crankshaftspeedwith the crankshaft
speedfluctuation(cKF)sensor
which is attachedto the crankshaft.
lfmisfiring strongenoughto damagethe catalystis detected,the MIL will blinkduring
the time of its occurrence,
and DTc
P0300*' P1300*1
,
and some of DTCsP03olthrough P0304will be stored.Then,after misfirehasceased,
the MtL will come
on,
lf misfiringthat increasesemissionsis detectedduring two consecutivedriving
cycles,the MIL will come on, and DTc
and some of DTCSp0301through p0304wi be stored.
NOTE:lf some of the DTCSlistedbeloware storedat the sametime as a misfireDTc,
troubleshootthose DTcsfirst. then
troubleshootthe misfireDTC.
P0106,P]128,P1'129;
MAp sensor
P0171.P0172;Fuetmetering
P0505:ldle Control Svstem
P1336,P1337;CKFsensor
P1361,P1362:TDCsensor
Pl381.Pl382:CYPsensor
*1:,97 model
P1508:IACvalve
*2: '98 - 00 models
PossibloCaus
. Fuelpump insufficientfuel pressure,amountofflow
. Fuelline clogging.blockage,leakage
. Fuelfilter clogging
a Fuelpressureregulatorstuckopen
. Distributormalfunction
. lgnitioncoil wire open,leakage
. lgnitioncontrolmodulemalfunction
. Valvescarbondeposit
a Compressionlow
a Fueldoes not meetOwner'sManualspec.,lackoffuel
Troubleshooting
By test-driving,determinethe conditionsduring which misfireoccurs.Depending
on these conditions,test in the order
describedin the table below.
\
[
Possible
cause
-....
;;;;-
Condition
Only low rpm and load
Crankshaft
speedfluctuation
sensor
Fuel
pressure
Distributorand
lgnitionwires
tcM
section6
11-178
section 23
section 23
,6)
Valve
Clearance
section 6
Only accelerating
,a'
Not specification
G\
11-1 2 6
www.emanualpro.com
MisfireDetectedin OneCylinder
Ipffi1]
ThescantootindicatesDiagnosticTroubleCode(DTC)P0301:Cylinder1 misfiredetected.
(cont'd)
www.emanualpro.com
11-127
PGM-FISystem
MisfireDetestedin OneCylinder(cont'dl
Troubl93hootingFlowchart
-
Problom vorification:
1. Atter chackingthe lrezedata,
do the ECM/PCMReset Procedure.
2. Exchange
the sparkplug from
the problemcylinderwith one
ol anothercylinder.
3. Connectthe SCS service connector.
4. Tost-drivethe vohicleseveral
times in the rangool the freeze
data.
(Topage'11-129)
1 1 -1 2 8
www.emanualpro.com
NOTE:
.lf there is no freezedata ol misfiring,
just clearthe DTC.
.lf there is no freezedata ot misfiring,
test drives under various conditions
are necessary,
( F r o mp a g e1 1 - 1 2 8 )
ls DTCP0301,P0302,P0303,
or P0304indicated?
ls DTCP0301,P0302,P0303,
or P0304indicated?
Checkfollowing items
- Valvo clearance
- Cvlinderlak-down
- Compression
- Crsnkshaft Speed Fluctuation
ICKF)sensol
www.emanualpro.com
11-129
PGM-FISystem
KnockSensor{KSl
('99- 00 models)The scantool indicatesDiagnosticTroubloCode(DTC)P0325:A malfunctionin the circuitof
the KnockSensor(KS).
-
Problemverification:
1. Do the ECM/PCir,ResetPro
cedure,
2 . S t a r t t h e e n g i n e .H o l d t h e
engine at 3,000rpm with no
load (in Parkor neutral)until
t h e r a d i a t o rt a n c o m e s o n ,
then let it idle.
3 . H o l d t h e e n g i n e a t 3 , 0 0 04,000 rpm for at least 60 seconds,
Intermittent lailu.e, 3ystom is OK
at thi3 tim. (te3t drive m.y be
nacalLrYr.
Chock to. poor connsctions ol
loora wiros rt C137 lknock aon.o. (KS))and ar the ECM/FCM.
Chck tor a short in the wir6 {KS
linel:
1. Turnthe ignitionswitchOFF.
2, Disconnectthe knock sensor
lP connector.
3. Checklor continuitybetween
E C M / P C Mc o n n e c t o rt e r m i
nalsC3and body ground.
ECM/PCMCONNECTOR
C 131P}
Wiresideof femaleterminals
KS 1P CONNECTOR
IC13?'
KS
IRED/BLU)
Wire side ol female
termtnals
ls therecont;nuity?
Substitutea known-goodknock
sensorand recheck.
ls DTCP0325indicated?
ECM/PCMCONNECTOR
KS
c (31P)
(BED/BLU)
11 - 1 3 0
www.emanualpro.com
Sensor
Position(CKP/TDC/CYPI
CrankshaftPosition/TopDeadGenter/Gylinder
scantool indicatesDiagnosticTroubleCode
tro-rslThe
sensorcircuit,
1Tffi61 Position{CKP)sensorcircuit.
The
scan
tF136t(TDC)
sensorcircuit.
The scan
fPfa6r-1
ci.cuit.
The scan
tF138tl(CYP)
sensorcircuit.
I-Pi382lcircuit.
Description
The CKPSensordeterminestiming for fuel injectionand ignitionof eachcylinderand also detectsenginespeed.The TDC
Sensordeterminesignitiontiming at start-up{cranking)and when crankangle is abnormal.The CYPSensordetectsthe
Sensoris built into the distribupositionof No. 't cylinderfor sequentialfuel injectionto eachcylinder.The CKP/TDC/CYP
ror.
NOTE:lf DTCP1359is storedatthesametimeas DTCP0335,P0336,Pl361,P1362,P1381and/orP1382,troubleshootDTC
P1359first,then troubleshootthose DTCS.
'97 model:
-
lOP
DISTRIBUTOR
CoNNECTOR(Cl211
TDCPIGRNI
CYPPIYELI
Problemverific.tion:
1. Do the PCMResetProcedure.
2. Startthe engine.
ls DTCP0335,P0336,P1361,P1362,
P1381and/orP1382indicated?
CYPM(BLKI
TIrcMIREOI
Terminalsideof
maleterminals
S E N S O E DTC
SENSOB
WIRE
PCM
E R M I N A I COLOR
P0335
P0336
CKP
c2
c12
TDC
P1361
P1352
P' I381
P1342
3
't0
CYP
8LU
GRN
c13
c4
c14
RED
YEL
BLK
{cont'd)
(To page11-132)
www.emanualpro.com
11-131
PGM-FISystem
Grankshaft
Position/Top
DeadCenter/Cylinder
Position(CKP/TDC/CYPI
(cont'd)
Sensor
DISTRIBUTOR
10PCONNECTOR
tCl2l)
{ F r o mp a g e 1 ' 1 - 1 3 1 )
CKP P
IBLUI
TDCP {GRNI
ls therecontinuity?
ls there350- 7000?
Terminalsideof
maleterminals
PCMCONNECTORS
C I31P)
CKPP TDCP CYPP
IBLU) IGRNI IYEL}
ls therecontinuity?
www.emanualpro.com
{WHT)
IREDI IBLK)
Wiresideof
female
terminals
CKPP
TDCP
CYPP
'98 model:
1OP
DISTRIBUTOR
CoNNECTOR(C121)
TDCP(GRN)
CYPP(YEL}
'98 - 00 models:
'99 - 00 modelr:
8P
DISTRIBUTOR
coNNECTOR{C121)
TDCP (GNN}
CYPP IYEL}
TDCM(REDI
CYPMIBLKI
Terminalsideof maleterminals
Intermittant tailure, svstom is OK
at this time. Check for poor connections or loose wirgs al C121
{distributo.l .nd at the ECM/
PCM.
CYPM IBLKI
TDCM (RED}
sideof maleterminals
Terminal
S E N S O R DTC
SENSOR
ECM/PCM WIRE
ERMINAT
I E R M I N A I COLOR
):'99mode
P0335
P0336
8 (6)
c8
c9
BLU
CKP
P1361
Pl362
2 (3)
c20
GBN
TDC
9 (7)
c21
RED
3 (4)
c29
YEL
1 0{ 8 )
c30
BLK
CYP
P]381
P]382
1 t2)
ls there350 7000?
'98
modeli
TDCP {GRNI
ls there350 700O?
C {31P)
ECM/PCMCONNECTOFS
CKP P
{BLU)
TOCP
IGRNI
CYPP
(YEL)
(Topage11-134)
femaleterminals
www.emanualpro.com
CKPM
IWHT)
(RED)
CYPM
(BLKI
(cont'd)
11 - 1 3 3
PGM-FISystem
GrankshaftPosition/TopDeadCenter/CylinderPosition(CKP/TDC/CYPI
Sensor{cont'd}
(Frompage11 133)
C {3IPI
ECM/PCMCONNECTOR
11 -1 3 4
www.emanualpro.com
'97 modol:
FCM CONNECTORS
A t32Pl
LG1
(BRN/BLK)
Problomverificetion:
1. Test'drivethe vohicle.
2. Checkthe vehiclespeedwith
the scantool,
ls the correctspeedindicated?
N O T E :D o n o t u s e t h e e n g i n et o t u r n t h o
front wheels with th6 rear wheels on the
ground. The 4WD system will engage and
the vehiclewill suddenlvIurchforward.
Wire side ot femaleterminals
{BRN/BLKI
Checkfor a .hort in the PCM:
L Turnthe ignitionswitchOFF.
2 . D i s c o n n e c tt h e P C M c o n '
nectorC (31P).
3. Turnthe ignitionswitchON (ll).
4 . E l o c kt h e r i g h t f r o n t w h e e l
and slowly rotate the left front
5. MeasurevohagebetweenPCM
connectorterminalsC18 and
A9.
Doesthevoltagepulse0 V
and 5 V or batteryvoltage?
www.emanualpro.com
rhevss.
f wire is OK. tost lho VSS l3oo
soction 231.
(cont'd)
11-135
PGM-FISystem
VehicleSpeedSensor(VSSI{cont'd}
'98 - 00 models:
-
ECM/PCMCONNECTORS
B t25Pl
Probl6mverification:
1. Test-drive
the vehicle.
2. Checkthe vehiclespeedwith
the scantool,
Wiresideof femaleterminals
6. Measurevoltage between
E C M / P C Mc o n n e c t o rt e r m i nals820 and C23.
Doesthe voltage pulse between
0 V and 5 V or battery voltage?
B (25P)
*2:Mft
11 - 1 3 6
www.emanualpro.com
BarometricPressure(BARO)Sensor
problemin the Barometric
The scantool indicatesDiagnosticTroubleCode(DTC)P1106:A range/performsnce
Pressure{BARO)Sensorcircuit.
The MIL has been reDortedon.
OTCPl106b slored.
Problemve.ification:
1. Oo the ECM/PCMreset pro'
ceoure.
2. Start the engine.Hold the
engine at 3,000rpm with no
load (;n Parkor neutral)until
the radiatorlan comeson, then
letit idle.
3. Connectthe SCSserviceconnector,
4. Test'drivewith the A/T in E
position,M/T in 4th gear.
5. AccelerateIor five seconds
usingwide openthrottle.
ls DTCP1106indicated?
Problomveritic.lion:
L Do the ECM/PCMResetProcedure.
2. Turnthe ignitionswitchON (lli.
ls DTCP1107or P1108indicated?
www.emanualpro.com
PGM-FISystem
ElestricalLoadDetector(ELDI(USAModell
The scan tool indictesDiagnosticTrouble Code (DTC)P1297:A low voltage problem in the ElectricalLoad
Detector(ELD)circuit.
'97 model:
Problemvsriticltion:
1. Do the PCMFesetProcedure.
2. Startthe engine.
3. Turn on the headlights.
ls DTCP1297indicated?
--+l 1 L 2 l 3 l
lerO) tcnrulaeot
ls thereapprox.4.5V?
PCMCONNECTOR
D I16P)
11 - 1 3 8
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98 - 00 mod6l3:
-
OTCPl17 is 3tored.
Problcm vcrificrtion:
1. Do the ECM/PCMResetProcedure,
2. Startthe engine.
3. Turn on the headlights.
ls DTCP1297indicated?
ELD3PCONNECTOR
ICAs4I
-I
f 2_ l l 3, l
l---r'.
&)
iGRN/RED)
ECM/PCMCONNECTOR
A I32P)
Chcck lor a 3horl in tho wiio (EL
linol:
1. Turnthe ignitionswitchOFF.
2 . D i s c o n n e c tE C M / P C Mc o n nectorA (32P).
3. Check for continuity between
body ground and ECM/PCM
connctortrminalA30.
Wire sid6of femaleterminals
Ropairshon in thc wira botwocn
tho PcM (A301rnd rho ELD.
(cont'd)
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1 1- 1 3 9
PGM-FISystem
ElectricalLoadDetestor(ELDI(USAModel)(cont'dl
The scan tool indicatesDiagnosticTrouble Code {DTC)Pl298; A high voltage problem in the ElectricalLoad
Detector(ELD)circuit.
97 modsl:
ELD3P CONNECTOR
{C35,'I
Problamverification:
1. Do the PCMResetProcedure.
2. Startthe engine.
3. Turn on the headlights.
Intermittent tailuro, systcm is OK
.t this time. Chack for ooor connoction! or looro wire3 at C127
{locaied on PCM brackot), C35{
{ELDIand .t tho PCM.
Chack for an opan in tho wile
llGl linol:
1 . T u r n t h g i g n i t i o na n d h e a d lightsOFF.
2. Disconnectthe ELD3P connector.
3. Turn the ignitionswitchON {ll).
4. M6asurevoltage btwen
body ground and the ELD 3P
connoctorterminalNo. 1.
WiresidooI lemaleterminals
rlzlrl
--T_ow
/6\ IBLKI
Y
Repail opn in th. wire btwsn
t h o N o . 1 5 A L T E R N A T O RS P
S E N S O R1 7 . 5 A ) t u s e i n t h e
under-dlrh fuso/r.lay box and
th6 ELD.
EL {GRN/NEDI
Doesthe voltagedrop?
1 1 -1 4 0
www.emanualpro.com
38 - 00 modeb:
Problemverification:
1. Do the ECM/PCMResetPro
ceoure.
2. Stanthe engine.
3- Turn on the headlights.
ls DTCP1298indicated?
ELO3PCONNECTOR
{c35/rl
ELD3P CONNECTOR
{C35,lt
Wiresideof femaleterminals
EL IGRN/RED}
Wire sideof female
termrnars
Repairopn in tha wile botwecn
the EcM/PCM lA30l .nd rhe ELD.
ECM/PCMCONNECTORS
A l32P)
11-141
PGM-FISystem
GrankshaftSpeedFluctuation(CKF)Sensor
Tj":""l.tool indicatesDiagnosticTroubleCode(DTCIP1336:Intermittentinterruptioninthe Crankshaft
Speed
fF13361l
:
Fluctuation(CKF)sensorcircuit.
The scan tool indicatesDiagnosticTrouble Code (DTC)P1337:No signal in the CrankshaftSpeedFluctuation(CKF)
sensorcircuit.
Description
The diagnosticsystemhas a pulserrotor on the crankshaftand a pulsepick-upsensoron the engineblock.The ECM/PCM
monitorsthe crankshaftspeedfluctuationbasedon the CKFsensorsignal,and judgesthat an enginemisfireoccurredif
the fluctuationgoes beyonda predetermined
limit.
37 mod.l:
-
Problemverificrtion:
1. Do the PCMResetProcedure.
2. Startthe engine.
CKFSENSOR
Intermittent {ailure,systom is OK
.l thia timo. Ch6ck tor poor connections or loose wir$ at Clorl
ICKFsonsorl .nd at tho PCM.
Chocktor an opon in th6 CKF.en'
30r:
1. Turn the ignitionswitchOFF.
2. Disconnect
the CKFsensor2P
connector,
3, Measure the resistance
b e t w e e nt h e C K Fs e n s o r2 P
connectorterminalsNo. 'l and
No.2.
ls there1.6-3.2 kO?
CKFSENSOR2P CONNECTOR
IClO4I
T:]
l-r'r Lll
l' 1' z' L' l
CKFP
I lcKFM
talu/aeotfdJ twxrneor
\-7
(Topage11-113)
1 1 -1 4 2
www.emanualpro.com
{ F r o mp a g e1 1 - 1 4 2 )
PCMCONNECTOR
C 13lPI
Chock to. an open in the wires
(CKFlin06l:
1. Reconnect
the CKFsensor2P
connector,
2. D;sconnectthe PCM connect o rC ( 3 1 P ) .
3. Measureresistancebetween
PCM connectorterminalsC1
a n dC l 1 .
Wire sideof lemaleterminals
ls there1.6- 3.2k0?
(cont'd)
www.emanualpro.com
11-143
PGM-FISystem
GrankshaftSpeedFluetuation(CKFISensor(cont'dl
.98 - 00 modols:
-
ProblGmverification:
1. Do the ECM/PCMResetProcedure,
2. Stanthe engine.
Inte.mittant failuro, 3y*om b OK
at thb tima. Chack lor ooor connections or looso wirea at C10a
{ C K Fs e n s o r la n d . t t h e E C M /
PCM,
Chgckforun open in tho CKFsonsori
1. Turnthe ignitionswitchOFF.
2. Disconnectthe CKFsensor 2P
connector.
3. Measure the resistance
between the CKF sensor 2P
connectorterminalsNo. 1 and
No.2.
IClO'I
CKFSENSOR2P CONNECTOR
r-:-i-_l
tr_-
l, 1, -2 l' l
CKFP
ICKFM
tsLuneotTOl
wlrrneo)
\7
lsthere1.6- 3.2kO?
Terminalsideof maleterminals
Checkfor a short in the CKFsenC h e c kl o r c o n t i n u i t y b e t w e e n
body groundand the CKFsensor
2P connectorterminalsNo. 1 and
No.2 individually.
r:l
t !E l
.KFPXA"*."
\:f
talurneor
(Topage11'1451
11-144
www.emanualpro.com
rwxvneor
C (31P)
ECM/PCMCONNECTOR
CKFP
IBLU/REDI
ls there1.6- 3.2kO?
1 2
,/ 2s
7
8
1 6 1 7 1 6 't9 20 21 22
26 27 28
29 3() 3 l
__l (oI
-l
T
M
CKFM
(WHT/BEOI
Wi16sideof l6maleterminals
Repairopon in the wir6 botwoon
the ECM/PCM1C22,glll lnd th6
CKFs6n3or.
( F r o mp a g e1 1 - 1 4 4 )
C (31PI
ECM/PCMCONNECTOR
CKFP
{BLU/RED)
ls therecontinuity?
www.emanualpro.com
11-145
PGM-FISystem
Sensor
CrankshaftPosition/TopDeadCenter/CylinderPosition(CKP/TDC/CYP)
The scantool indicatesDiagnosticTroubleCode (DTC)P 1 3 5 9A: problemin the CrankshaftPosition/TopDead
sensor circuit.
Center/CvlinderPosition tCKP/TDC/CYP)
-
Problemverific.tion:
1. Do the ECM/PCM
ResetProcedure.
2. Startthe engine.lf the engine
won't start, crank it continuouslyforat least15seconds.
ls DTCP1359indicated?
C h e c kf o r p o o r c o n n e c t i o n so r
loosewires betweenthe distribu'
tor andthe EcM/PcM.
1 1 -1 4 6
www.emanualpro.com
ECM/PCMInternalCircuit
lFi6oil
-
Problomveritication:
1. Do the ECM/PCMResetPro
2. Turnthe ignitionswitchON (ll).
3, Waitthreeseconds,
ls DTCP1607indicated?
www.emanualpro.com
11-147
PGM-FISystem
HO2SReplacement
1.
Disconnect
the HO2S4P connector,and removethe
HO2S.
PRIMARYH02S:
PRIMARYHO2S
4P CONNECTOR
02 SENSOR
WRENCH
PRIMARY
HO2S
44 N.m
{4.5kgt m,33lbf.ftl
SECONDARY HO2S:
SECONDARY
HO2S
4,0N.m (4.5 kg{.ft, 33 lbtftl
2.
11-1 4 8
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FromPGM'FI
TMAIN RELAY
VARIOUS
SENSORS
IAC VALVE
INTAKEMANIFOLD
After the enginestarts,the IACvalve opensfor a certaintime. The amountof air is increasedto raisethe idle speed
about 150- 300 rpm.
when the cootanttemperaturets row, the lAc valve is openedto obtain the proper fast idle speed The amount o{
bvoassedair is thus controlledin relationto the enginecoolanttemperature
and the scantool does not indicateDiagnosticTroubleCode(DTC)P0505
When the idle speedis out o{ specification
items:
or P1508,checkthe following
. Adjustthe idle speed(seepage11-169,170)
. A i r c o n d i t i o n i nsgi g n a (l s e e p a g e l l - 1 5 5 1
. A L TF Rs i g n a (l s e ep a g e1 l - 1 5 9 )
. Starterswitchsignal(seepage11-16'1)
. A,/Tgear positionsignal(seesection14)
. P S Ps w i t c hs i g n a (l s e e p a g e l l - 1 6 2 )
. Brakeswitchsignal(seepage11-165)
. F a s ti d l e t h e r m o v a l v (es e ep a g e ' 1 11 6 8 )
. Hosesand connecttons
. IACvalveand its mountingO-rings
4.
www.emanualpro.com
11-149
Problemverificationi
1. Start the engine.Hold the
engine at 3,000rpm with no
load (in Parkor neutral)until
the radiatorIan comeson, then
let it idle.
2. With the scan tool, checkthe
lollowingitems.
- Throttleposition should be
approx. 10%with the throttle {ully closed.
- E n g i n ec o o l a n tt e m p e r a
ture shorJldbe 194- 205'F
(90- 96"C).
lf they are not within the
spec.,repairthe faultysensor circuit.
3 C h e c kt h e e n g i n e s p e e d a t
idle with no-loadconditions:
headlights,blower fan. rear
defogger,radiatorlan, and air
conditionerare not operaling,
ls it 750{730)*i 50 rpm?
ls il 700(680)'rpm or less?
l:'99 - 00 models
{ T op a g e1 1 - 1 5 1 )
www.emanualpro.com
( T op a g e1 ' l - 1 5 1 )
(Frompage11-150)
Doesthe enginespeeddroP
or the enginestall?
UPPER
{ F r o mp a g e1 1 - 1 5 0 }
THERMOVALVE
(A/Tonlyl
Doesthe enginespeeddrop?
Doesthe enginespeeddroP?
www.emanualpro.com
37 model;
The MIL has beon .eportd on.
OIC Pl508 is sto.ed.
Problemveiification:
1. Do the PCMResetProcedure.
2. Startthe engine,and warm it
up to normal operatingtemperature.
ls DTCPl508indicated?
,f\
rcp'
IYEL/BI.(I
I- 2df -) 1
Y
Wir side of female terminals
{ T op a g e1 l - 1 5 3 )
www.emanualpro.com
tacv
IBLK/
BLU)
Wire sideof femaleterminals
( F r o mp a g e1 1 - 1 5 2 )
ls therebafteryvoltage?
www.emanualpro.com
1-153
Problemveritication:
L Do the ECM/PCMResetProcedure.
2. Startthe engine,and warm it
up to normal operatingtemperature.
ls DTCP1508indicated?
rcpt
F\
*l
tYELrBLxl
I2/'-
rf)
Y
9
19
2
'to
5
1l
21 22
20
13
t7
23
tAcv
(BLK/BLUI
Wiresideof femaletorminals
ls there batteryvoltage?
PG1
{BLKI
1
2 |
t 3 4 5
9 1 0
1 1 13
19
20 | 121)22
8
17
tAcv
(BLK/
BLU)
JUMPERWIRE
Air ConditioningSignal
This signalsthe EcM/PcMwhen there is a demandfor coolingfrom the air conditioningsystem.
'97 modol:
Wiresideof lemaleterminals
C (31PI
PCMCONNECTOR
ACS IBLU/RED)
Check for . .hon in the wire IAGS
linel:
1. Turnthe ignitionswitchOFF.
2. DisconnectPCM connectorC
(31P).
3. Check for continuity between
body ground and PCM connectortorminalC5.
Wiresideof femaleterminals
(To page11-156)
A (:TIPI
PCMCONNECTOR
JUMPERWIRE
(cont'd)
www.emanualpro.com
1 1 - 15 5
ldle GontrolSystem
Air ConditioningSignal(cont'dl
(Frompage11-'155)
ls therea cl;ckingnoisefrom
the 4!/Ccompressorclutch?
ls therea clickingnoisefrom
the 4!/Ccompressorclutch?
UNOER.HOOD
FUSE/RELAY
BOX 9P CONNECTOR
tqt52)
1
JUMPER
WIRE
ACC IBLK/REDI
IBLK/R
Wire sideof female
termrnats
A t32Pl
C t3rp)
Doesthe A,/Coperate?
www.emanualpro.com
'98 - 00 models:
ECM/PCMCONNECTORS
A {32P1
A (32PI
ECM/PCMCONNECTOR
ls there batteryvoltage?
Wiresideof femaleterminals
ls therecontinuitv?
ECM/PCMCONNECTORS
Check for an open in the wire
(ACCline):
'1. Turnthe ignitionswitchOFF.
2. Reconnectthe A/C Pressure
switch2Pconneclor.
3. Turn the ignitionswitchON (ll).
4 . M o m e n t a r i l yc o n n e c tE C M /
PCMconnectorterminalsA17
a n d 8 2 0 w i t h a j u m P e rw i r e
severalllmes,
A (32P1
ACC(BLK/REOI
(BRN/BLKI
JUMPERWIRE LG1
{cont'd)
www.emanualpro.com
11-157
ldle ControlSystem
Air Gonditioning
Signal(cont'd)
(Frompage'11,157)
ls therea clickingnoiselrom
the y'y'Ccompressorclutch?
ls therea clickingnoisefrom
tho A,/Ccomprossorclutch?
UNDER-HOOD
FUSE/RELAY
BOX9PCONNECTOR
{G'52I
JUMPER
WIRE
3 a
(BLK/R
ACC(BLK/RED'
Wire side otfemale
ot
terminals
ECM/PCMCONNECTORS
Wiresidof femaletorminals
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Alternator(ALT)FRSignal
This signalsthe ECM/PCMwhen the Alternator(ALTIis charging.
PCMGONNECTORS
,97 modet:
Inspectionot ALT FRSignal.
C h e c kl o r a s h o r t i n t h e w i r e
{ALT F line}:
1. Disconnectthe 4P 13Pi*con
nectorfrom the ALT.
2. Turnthe ignitionswitchON (ll)
3, Measurevoltage between
PCMconnectorterminalsC17
and A9.
ls thereapprox.5 V?
c (31P|
Check for a short in the wire
(ALT F linel:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe negativebat'
tery cable from the battery.
3. DisconnectPCM connectorC
(31P).
4. Checkfor continuitybetween
b o d y g r o u n da n d P C Mc o n
nectorterminalC17.
lll2llw|{frREDl
-| 3 . r - ' l
wne
lruueen
JUMPER
WIRE
3Pr
ALT F IWHT/REDI
Repair open wi.e between the
PCMlCl7l and the ALT.
Wire sideof femaleterminals
www.emanualpro.com
11 - 1 5 9
ldle GontrolSystem
Alternator(ALT)FRSignal(cont'dl
'98 - 00 modols:
ECM/PCMCONNECTORS
B (25P)
AI.T F IWHT/REDI
Check fo. a shon in th. wire {ALT
F linel:
1. Disconn6ctthe 4P (3P)*connectorfrom the ALT.
2. Turnthe ignitionswitchON {ll).
3. MeasurevoltagebetweenECM/
PCM connectorterminalsC5
and 820.
ls thereapprox.5 V7
ECM/PCMCONNECTOR
C {31PI
rH] Arr F
l'l'ltwHr/REo)
l3laF1
WIRE
I JUMPER
+
JUMPER
WIRE
ECM/PCMCONNECTOR
C {31P}
ALT F {WHT/REDI
Rsprir opan wiro batw.en tho
ECM/PCMlcsl .nd th. ALT.
11 - 1 6 0
www.emanualpro.com
c t31P)
A {32P}
Checkfor an opan ot short in the
wire (STSlinel:
Measurevoltage between PCM
c o n n e c t o tre r m i n a l sC 6 a n d A g
w i t h t h e i g n i t i o ns w i t c h i n t h e
start(lll)position.
LGl
(BBN/BLK)
STS(BLU/ORNI
ls there batteryvoltage?
Reoair short in the wire between the PCM lc6l and th.
No. 31 STARTERSIGNAL175
A) tuse ot the PGM-FImain
reray.
Reolacethe No. 31 STARTER
SIGNALt7.5Altu.e.
'98 - 00 models:
NOTE:
. M/T:Clutchpedalmustbedepressed.
. A/T:Transmission
in E orE position
A (32P)
ECM/PCMCONI{ECTORS
ls therebatteryvoltage?
SIG
Inspectthe No. 31 STARTER
NAL(7.5A){usein the under-dash
11 - 1 6 1
ldle GontrolSystem
PowerSteeringPressure(PSP)Switch Signal
This signalsthe ECM/PCM
when the power steeringload is high.
'97 model:
Inspectionot PSPswitch signal.
ls therelessthan 1.0V?
PSPSWTTCH
2P CONNECTOR
1C135)
PSPSW (GRN)
JUMPERT_7
vnRE t--f
r)
GNDIBLK}
Wire3id6of femaleterminals
-
ls therelessthan 1.0V?
ls there batteryvoltage?
www.emanualpro.com
(To page11-163)
Ropsir open in the wi.e betwoon the PCM lcl6l and the
PSPswitch.
Ropdir open in BLK wire between the PSP switch and
G101.
{ F r o mp a g e 1 1 1 6 2 )
PCMCONNECTORS
C h e c kf o r a s h o r t i n t h e P S P
swilch:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe 2P connector
from the PSPswitch.
3. Turnthe ignitionswitchON (ll).
4 . l l e a s ur e v o l t a g e b e t w e e n
PCMconnectorterminalsC16
and A9.
c t3lPl
(cont'd)
www.emanualpro.com
1 1- 1 6 3
ldle ControlSystem
PowerSteeringPressure(PSP)Switch Signal(cont'dl
'98 - 00 models:
ECM/FCMCONNECTORS
ls therelessthan 1.0V?
Wiresideof femaleterminals
PSPSwlTCH 2P CONNECTOR
ICl35}
PSPSW IGRNI
JUMpER f-7
wtRE L-5 rl
5. MeasurevoltagebetweenECM/
PCM connectorterminals 426
and 820.
GND (3LX}
Wire sideof lemaleterminals
-
lstherelessthan 1.0V?
ls there batteryvoltage?
www.emanualpro.com
11-164
(Topage 11-165)
{Frompage11 164i
ECM/PCMCONNECTORS
C h e c kf o r a s h o r t i n t h e P S P
switch:
1. Turnthe ignitionswitchOFF.
2, Disconnectthe 2P connector
from the PSPswitch.
3. Turnthe ignitionswitchON (ll).
4. MeasurevoltagebetlveenECM/
PCMconnectorterminalsA26
and 820.
Wiresideof femaleterminals
A l32Pl
www.emanualpro.com
11 - 1 6 5
ldle ControlSystem
BrakeSwitch Signal
This signalsthe ECM/PCM
when the brakepedalis depressed.
Inspctionof Brak. Switch Signal.
Inspectthe HORN,STOP{15 A)
fuse in the undeFhoodluse/ relay
box.
'-
('97model)
-_-
Il
a t32P)
PCMCONNECTORS
BKSW
(GRN/WHT)
(Topage11-167)
11 - 1 6 6
www.emanualpro.com
D ll6Pl
(Frompage11-166)
ECM/FCMOONNECTORS
www.emanualpro.com
11-167
ldle ControlSystem
Fastldle ThermoValvelA/T)
Description
To preventerraticrunningwhen the engine is warming
up, it is necessaryto raisethe idle speed.The fast idle
t h e r m o v a l v e i s c o n t r o l l e db y a t h e r m o w a xp l u n g e r .
When the engine is cold, the engine coolantsurrounding the thermowaxcontractsthe plunger,allowingadditional air to be bvDassedinto the intakemanifoldso that
the engineidlesfaster.Whenthe enginereachesoperating temperature.the valve closes,reducingthe amount
of air bypassinginto the intakemanifold.
IDLE
ADJUSTING
Inspgction
NOTE:The fast idle thermo valve is factoryadjusted;it
shouldnot be disassembled.
1.
2.
Startthe engine,
3.
O-RINGS
Replace.
11.0kgfl.m,7.2 lbl.ftl
11-168
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Inspoction/Adiustmont
37 modsl:
IDLE
NOTE:
. Before setting the idle speed, check the following
items:
- The MIL has not beenreportsdon.
- l g n i t i o nt i m i n g
- Sparkplugs
- Air cleaner
- PCVsystem
. lcanada) Pull the parking brake lever up. Stan the
engine,then checkthat the headlightsare off.
1.
www.emanualpro.com
11 - 1 6 9
ldleControlSystem
ldle Speed Setting (cont'd)
38 - 0Omod6l3:
NOTE: Beforesettingthe idle speed,checkthe following items:
- The MIL has not beenreportedon.
- lgnitiontiming
- Sparkplugs
- Air cleaner
- PCVsystem
1.
CONTROL
SOLENOIDVALVE
VALVE
SOLENOID
lf the enginestalls,restartthe enginewith the accelerato. pedal slightly depressed.Stabilizethe rpm at
1,000,then slowly releasethe pedaluntil the engine
idles.
Chekthe idle in no-loadconditions:headlights,blower fan, rear defogger,radiatorfan, and air conditioner
are not operating,
ldle speed should bo:
480 t 50 rpm {in PErkor noutrall
11-170
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FuelSupplySystem
FuelLines
Check fuel system lines, hoses, fuel filter, and other components for damage, leaks or det6rioration, and rplace it neces-
sary.
'97 model:
33N.m
(3.4kg(.m,2s lbf.ftl
27 N.m
12.8kg{.m,21 lbf.ft)
'98 model:
27 N.rn
(2.8 kgl.m, 21 lbf.ft)
www.emanualpro.com
(cont'd)
11-171
33 N.m
(3.4kgl.m.25lbtftl
11-172
www.emanualpro.com
'97 model:
Checkall hoseclamps,and retightenif necessary.
{"2
/\
FUEL
FILTER
,"1
<,,
___--tJ
FUELTUBE/
OUICK-CONNECT
FITTINGS
' ^ s
,4\-') |
EVAPORATIVE
EMISSION{EVAP}
CONTBOL
CANISTER
ft\
q'l
/'------/
,
To FUEL
PRESSURE
REGULATOR
(cont'd)
10-14mm
(0.39- 0.55 inl
www.emanualpro.com
11-173
FUEL
FILTER
To FUEL
PRESSURE
REGULATOR
C l a m pi n t h e m i d d l e
10-14mm
(0.39- 0.ssin)
11-174
www.emanualpro.com
Fittings
FuelTube/Ouick-Gonnect
Procautions
Disconnection
1.
Disconnect
the batterynegativecable.
2.
3.
4.
5.
NOTE:
. Be carefulnot to damagethe pipeor other parts.
Do not usetools,
. lf the connectordoes not move,keepthe retainer
tabs presseddown, and alternatelypull and push
the connectoruntil it comesoff easily.
. Do not removethe retainerfrom the pipe; once
removed,the retainermust be replacedwith a
new one.
. Whenconnectingor disconnecting
the fuel tube/quickconnectfittings assembly,be carefulnot to bend or
twist it excessively,Replaceit if damaged,
A disconnectedquick-connectfittings can be reconnected,
but the retaineron the mating pipe cannot be reusedonce
it has been removed from the pipe. Replacetha retainer
.
.
.
.
LOCKII{G PAWL
RETANENTAB
@NNCCTOR
Pressdown.
6.
RCTAINER
FUELTUBE
CONTACTANEA
CONNECTOR
CONNECTOR
RETAINER
{cont'd}
www.emanualpro.com
11-175
FuelSupplySystem
FuelTube/Ouick-Connect
Fittings{cont'd)
7.
Connection
Do not smoke white working on the fuel
E!@
system. Keepoper flamss away flom your work atea.
1.
COiITACT AiEA
PL TSnCEAGS
AASE
GASKET
Beplace.
11-176
www.emanualpro.com
3.
with the
tabs pulled
apart, remove
and discard
the retarner
4.
Ncw FUELTUBE/
OUICK.CONNECT
FI?TINGASSEMBLY
www.emanualpro.com
5.
6.
FuelSupplySystem
SystemDescription
The fuel supply system consistsof a fuel tank, in-tank
high-pressure
fuel pump. PGM-Flmain relay,fuel filter,
fuel pressureregulator,fuel injectors,and fuel delivery
and return lines.This system deliverspressure-regulated fuel to the fuel injectorsand cuts the fuel delivery
when the engineis not running.
FuelPressure
Inspection
1,
2.
Relievefuel pressure.
Removethe 12 mm banjobolt on the fuel filterwhile
holding the fuel filter with anotherwrench.Attach
the 12 mm fuel pressureadapterbolt and the special
tool.
FUEL
PRESSURE
GAUGE
07406- 0040001
FUELPRESSURE
REGULATON
Relieving
Beforedisconnectingfuel pipes or hoses,releasepressure from the system by looseningthe 12 mm banjo
bolt on the too of the fuel filter.
SHOPTOWEL
NOTE: Replacethe washers whenever the 12 mm
baniobolt is loosenedor removed.
www.emanualpro.com
11-178
The illustration
shows
'97 - 98 models,
'99 - 00 modelsare similar.
FuelInjectors
R6placomoni
1. Relievethe fuel pressure(seepage 11-178).
2. Removethe resonato.chamber('99- 00 models).
S
O.RING
Beplace.
Disconnectthe connectorsfrom the fuel injectors, and disconnectthe IAT sensor 2P connector ('97 - 98 models) and
EVAPpurge control solenoid valve 2P connctor ('97 - 98 models),
Disconnectthe PCVvalve and the vacuum hose from the fuel pressureregulator.
Placea shop towel overthe fuel returnhose,then disconnectit from the fuel pressureregulator.
Removethe retainernuts on the fuel rail.
Disconnect
the fuel rail.
7, Removethe fuel injectorsfrom the intake manifold.
'97 - 98 model3:
EVAPPURGE
CONTROL
SOLENOID
VALVE2PCONNECTOR
FUELPULSATION
IAT SENSOR
2P CONNECTOR
12 N.m
{1.2 kgt'm,
8.7 tbtft)
FUEL
PRESSURE
REGULATOR
O.RING
CUSHION
Replace.
SEAL
RING
Replace.
www.emanualpro.com
FUEL
PRESSURE
REGULATOR
O.RING
Replace.
CUSHION
RING
Replace.
SEAL
RING
Replace.
11-179
FuelSupplySystem
FuelInjectors{cont'dl
8. Slidenew cushionringsonto the fuel injectors.
9 , C o a tn e w O - r i n g s w i t ch l e a ne n g i n eo i l , a n dp u t t h e mo n t h e f u e li n i e c t o r s .
'10. lnsertthe fuel injectorsinto the fuel rail first.
p r e s st h e m i n t ot h e i n t a k em a n i f o l d
nngineoil,and
1 1 . C o a t n e w s e arl i n g s w i t h c l e a e
12. To preventdamageto the O-rings,installthe fuel injectorsin the fuel rail first, then installthem in the intakemanifold.
FUELRAIL
The ill!strationshows
'97 -98 models,'99- 00 models
are similar.
11 - 1 8 0
www.emanualpro.com
FuelPressureRegulator
Replacement
Tesiing
1.
'1. Placea shop towel under the fuel pressureregulator, then relievefuel pressure(seepage 11-1781.
2.
Startthe engine.
2.
Disconnect
the vacuumhoseand fuel returnhose.
Prasgureshould be:
'97 - 98 models;
260- 310 kPa (2.7- 3.2 kgl/cm' ,38 -,16 psi)
'9!t - 00 models:
27O- 32o kPa l2-8- 3.3 kgf/cm', 40 - /l7 psil
(with the lugl pressure rsgulator vacuum hose disconnestedand pinched)
3.
12 N.m
(1.2kgf.m,
8.7 tbf.ft)
FUEL
PRESSURE
GAUGE
07406 - 0040001
CLAMP
Replace.
FUELPRESSURE
NEGULATOR
shows
Theillustration
'97- 98models,'99
-00 models
aresimilar.
shows
Theillustration
'99 00models
'97- 98models,
similar.
are
l f t h e f u e l p r e s s u r ed i d n o t r i s e , r e p l a c et h e f u e l
pressureregulator.
www.emanualpro.com
11 - 1 8 1
FuelSupplySystem
FuelFilter
Replacamont
.
.
The fuel filter should be replacedwheneverthe fuel Dressure drops belowthe specifiedvalue*with the fuel pressure regulatorvacuum hose disconnected
and pinchedl
after makingsure that the fuel pump and the fuel pressure regulatorare OK.
12 mm
SEAUNG
BOLT
33 hl.m
l3.a kgt m,
25 lbt frl
2.
3.
4.
11 -1 8 2
www.emanualpro.com
9.8 N.|n
11.0kgf'm,
t.2 tbt.ftl
FuelPump
Testing
Raplac6mont
1.
2.
3,
4.
5.
6.
7.
8.
I n s t a l lt h e f u e l p u m p i n t h e r e v e r s eo r d e r o f
removal.
1.
2,
3.
Make sure the ignition switch is OFF,then disconnectthe fuel pumP5P connector.
4.
I'TtlJil
-r'-r
t f
l . l 5 l 5 1 7 l
,frTt-
, a t \.
tcl tyEL/cRNl
FUELpUMp LrrYEL/cRNl I
I
Wirsideof
JUMPER
femaleterminals
WIRE
5.
FUELPUMP
(YEL/GRNI
wire sideof
femaleterminals
l f b a t t e r yv o l t a g e i s a v a i l a b l e ,c h e c kt h e f u e l
pump ground. lf the ground is OK, replacethe
fuel oumo.
lf there is no voltage,checkthe wire harness(see
p a g e1 1 - 1 8 8 ) .
www.emanualpro.com
11-183
FuelSupplySystem
FuelGauge
Tssting
Turnthe ignitionswitchOFF.
2.
3.
4.
Disconnect
the 5Pconnectorfrom the fuel pump.
5.
FUELPUMP
5P CONNECTOR
tc56al
1 1 -1 8 4
www.emanualpro.com
FuelGaugeSendingUnit
Tgsting
Do not smoke while working on tho fuel
@
systom. Keop open flamo 8waYfrom your work araa.
1.
2.
Removethe accesspanel.
3.
4.
5.
Disconnect
the fuel lines.
6.
7.
www.emanualpro.com
11-185
FuelSupplySystem
Low Fuel Indicator System
Indicator Light Testing
8.
oK.
Do not smoke while working on the
@
fuel system. Keep open flame away trom the work
aroa. Drain fuel only into an approved container.
D r a i n t h e f u e l i n t o a n a o D r o v e dc o n t a i n e r T
. hen
installthe drain bolt with a new washer.
Add lessthan 8 f (2.1U.S.Gal. 1.8lmp. Gal)of fuel,
and turn the ignitionswitchON {ll).The low fuel indicatorlightshouldcome on within four minutes.
INDICATONLIGHT
7.
Removethe seatcushion(seesection20).
Removethe fuel tank accesspanel from the floor,
and disconnectthe 5Pconnectorfrom the fuel pump,
Connectthe No. 1 and No. 2 terminalswith a jumper
wire.
.
.
l f t h e l i g h t c o m e s o nc, h e c k t h es e n d i n gu n i t .
lf the light does not come on, checkfor:
- a n o p e n i n t h e G R N / y E Lw i r e b e t w e e nt h e
fuel unit and fuel gaugeassembly.
- blown bulb.
- poor ground (G552).
(C562)
FUEI-PUMP5PCONNECTOR
WIRE
JUMPER
IGRN/YEL}
Wiresidol temleterminals
1 1 - 18 6
www.emanualpro.com
PGM-FIMain Relay
Description
The PGM-Flmain relav actuallvcontainstwo individual
relays.This relay is locatedat the passengerside of the
cowl. One relay is energizedwheneverthe ignitionis on
w h i c h s u p p l i e st h e b a t t e r yv o l t a g et o t h e E C M / P C M ,
power to the fuel injectors,and power for the second
relay. The second relay is energizedfor two seconds
when the ignition is switchedon, and when the engine
is running,to supplypowerto the fuel pump
PGM.FI
MAIN RELAY
Belay Testing
N O T E :l f t h e e n g i n es t a r t sa n d c o n t i n u e st o r u n , t h e
PGM-FImain relayis OK.
1.
2.
3.
No.5 No.5
To lGN.1
To GROUND
To ST. SWITCH
To ECM/PCM
CONNECTOR
TERMINAL
A16
(FLR)
To BAT O
To FUELPUMP
To ECM/PCM
CONNECTOR
TERMINAL
(411and A24,
Bl .nd Bgal
(IGP)
To FUELPUMP
98- 00 models
Attachthe battervDositiveterminalto the No. 5 terminal and the batterynegativeterminalto the No. 3
termjnalof the PGM-Flmain relay.Then checkthat
there is continuitybetweenthe No. 7 terminal and
No. 6 terminalof the PGM-FImain relay.
. lf there is continuity,go on to step 4.
. lf there is nocontinuity,replacethePGM-Flmain
relayand retest.
5 . Attachthe battervoositiveterminalto the No.6 terminal and the batterynegativeterminalto the No. 1
terminalof the PGM-Flmain relay.Then checkthat
there is continuitvbetweenthe No. 5 terminal and
No. 4 terminalof the PGM-Flmain relay.
. lf thereis continuity,the PGM-Flmain relayis OK.
P G M - Fm
I ain
. l f t h e r ei s n o c o n t i n u i t yr,e p l a c e t h e
(cont'd)
relayand retest.
www.emanualpro.com
11-147
FuelSupplySystem
PGM-FIMain Relay(cont'dl
Troubleshooting
-
trTr]--Flq
FI,Til'I A
('97model:To page11-189)
('98 00models:Tp
o a g e1 l 1 9 0 )
11 - 1 8 8
www.emanualpro.com
lFrompage11 188)
-t
('97model)
(C432I
PGM.FIMAIN RELAY7P CONNECTOR
FLR
IGRN/YELI
IGP2
(YEL/BLK)
ls therebatteryvoltage?
-
ls there'1.0V or less?
(cont'd)
C h e c k t h e P G M - F lm . i n . e l a V
(seepage11-187).
_l
www.emanualpro.com
1 1 - 18 9
FuelSupplySystem
PGM-FIMain Relay(cont'dl
(Frompage11,188)
('98- 00 models)
-l
ECM/PCMCONNECTOR
B I25PI
Dde"Jt;;li
L-F-T-PGl
(BLK}
3
s l 1 0
IGP2
(YEL/BLKI 1 9
20
11
13
21 22
8
17
ECM/PCMCONNECTORS
Chock for an open in the ECM/
PCM:
1. Turnthe ignitionswitchOFF.
2, Measurevoltage between
ECM/PCMconnectorterminals
416 and 82 when the ignition
switch is first turned ON (tl) for
ls there1.0V or less?
a t32Pl
11 - 1 9 0
www.emanualpro.com
FuelTank
Replacement
Do not smoke while working on fuol systam Keep open flame away from your work area'
@
1.
2.
3.
4.
5.
6.
7.
8.
g.
them.
10. Placea jack,or othersuppon,underthe tank
11. Removethe strapnuts,and let the strapsfall free
12. Removethe fuel tank.lf it stickson the u ndercoatappliedto its mount,carefully pry it off the mount,
'13. lnstallthedrain bolt with a new washer,then coatthe drain bolt with Noxrust1248'
Allow the Noxrustto dry for 20 minutes.
14. Installpartsin the reverseorderof removal.
'97 modol:
AOCESSPANEL
CONNECTOR
DRAINEOLT
49 N.m
15.0kgf'm,
36 rbt frl
www.emanualpro.com
(cont'd)
11 - 1 9 1
FuelSupplySystem
FuelTank (cont'd)
,98 - 00 models:
5P CONNECTOR
6P CONNECTOR
38 N.m
(3.9ksf.m,28lbtftl
11-192
www.emanualpro.com
YEL| BLK
Fiom PGM'FI
MAIN RELAY
vaRtous
SENSORS
IDLE
THERMO
INTAKEMANIFOLD
lJ-_iuo'u'j"'
FESONATON
THROTTLE
BODY(TB)
INTAKE
AIR DUCT
www.emanualpro.com
11 - 1 9 3
IntakeAir System
Air Cleaner
ThrottleCable
Inrpection/Adiustmcnt
1.
2.
3.
'97 - 98 modols:
CABLE
BRACKET
m
DEFLECTION
10-12mm
BIA- 112i^l
LOCKNUT
'99 0O modsls:
DEFLECTION
l0-12mft
Bla - 112inl
AIR CLEANERELEMENT
No.mal conditions:
Replaceair cleanerelementevery
30,000miles{48,000km) or 24
monthswhichevercomesfirst.
Severecondition3:
Replaceair cleanerelementevery
15,000miles124,000
km) or 12
monthswhichevercomestirst.
NUT
lf deflectionis not within specs,loosenthe locknut,
turn the adjustingnut untilthe deflectionis as specified,then retightenthe locknut.
With the cableproperlyadjusted.checkthe throttle
valve to be sure it opens fully when you push the
acceleratorpedal to the floor. Also check the throttle valve to be sure it returns to the idle position
whenever you releasethe acceleratorpedal.
11-194
www.emanualpro.com
'97 - 98 modals:
lnstellation
1.
lhere shouldbe
no clearance.
97 - 98 modols:
CABLE
LINKAGE
THRoTTLE
AD.'USTINGNUT
9.8 N.m
(1.0 kg{.m,
7.2lbllrl
'99 - 00 modeb:
LOCKNUT
INNERCABLE
CABLE
BRACKET
BRACKET
2.
www.emanualpro.com
9.8 N.m
l'1.0kgt'm,
7.2 tbr.ft)
IntakeAir System
ThrottleBody
Doscription
The throttle body is a single-barrelside-drafttype. The
lower portion of the throttle valve is heatedby engine
coolantfrom the cylinderhead.The idle adjustingscrew
which regulatesthe bypassair is locatedon the top of
the throttlebodv.
lnspection
Checkthat the throttlecableoperatessmoothlywithout
bindingor sticking.
lf thereare any abnormalities,
checkfor:
. Excessive
wear or play in the throftlevalveshaft.
. Sticky or binding throttle lever at the fully closed positton.
. Clearancebetweenthrottle stop screw and throttle
leverat the fully closedposition.
97 - 98 models:
THROTTLE
LINKAGE
The illustration
shows
'97 - 98 models,'9900 rnodels
are similar.
THROTTLELINKAGE
11 - 1 9 6
www.emanualpro.com
Removal
'97 - 98 models:
GASKET
MAP SENSOR
R \ t
,:4W)
TP SENSOR
FASTIDLETHERMO
VALVE(A/T onlyl
'99 - O0models:
TP SENSOR
F(
\g-.-'
22 N.m
12.2kgl m,
16 tbtft)
NOTE:
. Do not adjustthe throttlestop screw.
. After reassembly,
adjustthe throftlecable(seepage11-194).
. The TP sensoris not removable.
www.emanualpro.com
FASTIDLETHERMO
VALVElA/T only)
(cont'd)
11-197
IntakeAir System
ThrottleBody (cont'd)
Disassembly
O-RING{A/l only)
Replace.
ADJUSTING
SCREW
IDLETHERMO
VALVE (A/T only)
9.8 N.m
(1.0kgl.m,7.2lbf.ftl
The illustration
shows'97- 98
models,'99 00 modelsare similar.
11 - 1 9 8
www.emanualpro.com
EmissionControlSystem
SystemDescription
ThreeWayCatalyticConverter(TWCI
T h e e m i s s i o nc o n t r o l s y s t e m i n c l u d e s ,a T h r e eW a y
CatalyticConverter{TWC),PositiveCrankcaseVentilation
(PCV)svstem and EvaporativeEmission(VAP)Control
system.The emissioncontrol system is designedto meet
federaland stateemissionstandards.
DsscriDtion
TailpipeEmission
Inspsction
Do not smoke during this procsdura. Keep
!@
any open tlame away from your work area.
1.
4.
{cont'd)
www.emanualpro.com
11 - 1 9 9
EmissionControlSystem
ThreeWay CatalyticConverter{TWCI(cont'd}
1P0420 Thescantool indicatesDiagnosticTroubleCode(DTC)P0420:Catalystsystemefficiencybelowthreshold.
DescriDtion
This systemevaluatesthe catalyst'scapacityby meansof the HO2S(Primaryand Secondary)outputduring stabledriving
hasbeendetectedduringthreeconsecutive
drivingcycles,the MILcomeson and DTCP0420will
conditions.lf deterioration
be stored.
NOTE:lf some of the DTCSlistedbelow are storedat the same time as DTCP0420,troubleshootthose DTCSfirst. then
troubleshootDTCP0420.
P0137,P0138:SecondaryHO2S(Sensor2)
P0141:SecondaryHO2S(Sensor2) Heater
PossibleCause
. IWC Deterioration
. Exhaustsystemleakage
Troubleshooting Flowchart
-
Problemverification:
1. Do the ECM/PCM
ResetProce
dure,
2 . S t a r tt h e e n g i n e .H o l d t h e
engine at 3,000rpm with no
load (in Parkor neutraliuntil
the radiatorfan comeson.
3. Connectthe SCSservicecon
nector.
4. Test-drive40 - 55 mph (64- 88
km/h)for approx.lwo minutes.
Then deceleratefor at least3
secondswith the throftlecom
p l e t e l yc l o s e d .T h e n r e d u c e
t h e v e h i c l es p e e dt o 3 5 m p h
1 5 6k m / h ) ,a n d t r y t o h o l d i t
u n t i l t h e r e a d i n e s sc o d e
ls DTCP0420indicated?
11-200
www.emanualpro.com
PositiveGrankcase
Ventilation(PGVISystem
Description
Inspoction
T h e P o s i t i v eC r a n k c a s eV e n t i l a t i o n( P C V )s v s t e m i s
designed to prevent blow-by gas from escaping to the
atmosphere.The PCVvalve contains a spring-loaded
plunger,When the enginestarts,the plungerin the PCV
valve is lifted in proportionto intakemanitoldvacuum and
the blow-by gas is drawn directlyinto the intakemanifold.
1.
'97 - 98 models:
'99 - (X)
models:
i/lAlrllFOLD
-: BLOW.BY VAPOR
-: FRESHAIR
BREATHER
HOSE
(cont'd)
www.emanualpro.com
11-201
EmissionControlSystem
PositiveCrankcase
Ventilation(PCV)System(cont'dl
2.
'97 - 98 models:
'99 - 00 modelsi
Gentlypinchhere.
11-202
www.emanualpro.com
Evaporative
Emission(EVAP)Controls
Description:
The evaporativeemissioncontrolsare designedto minimizethe amount of fuel vapor escapingto the atmosphere.The
systemconsistsof the followingcomponents:
A.
EvaporativeEmission(EVAPIControl Canister
An EVAPcontrolcanisteris usedfor the temporarystorageof fuel vapor until the luel vapor can be purgedfrom the
EVAPcontrolcanisterinto the enqineand burned.
B. Vapor PurgeConirolSystem
EVAPcontrolcanisterpurgingis accomplishedby drawingfreshair throughthe EVAPcontrolcanisterand into a pon
on the intakemanifold.The purgingvacuumis controlledby the EVAPpurgecontrolsolenoidvalve.
E V A P P U R G EC O N T R O LS O L E N O I DV A L V E D U T Y C O N T R O L L E D
AFTER
S T A R T I NE
GN G I N E
ENGINECOOLANTTEMPERATURE
ABOVE154"F(68'C)
C.
VALVE
BLK/
YEL
VARIOUS
SENSOR
FEESHAIF
BLK
FUEI-TANK
INTAKEMANIFOLD
(cont'd)
www.emanualpro.com
11-203
EmissionGontrolSystem
EvaporativeEmission(EVAP)Controls(cont'dl
'98 - 0Omodels:
EVAP
THREEWAY
VALVE
EVAP
CONTROL
CANISTER
VENTSHUT
VALVE
Frofi
< NO.15
BLK/WHT
'EL/BLU
._^_-:.*,"..
GRN/BLK
<3|ltAIS"o[..^,
1inthe under-dash
tuse/relay
box)
BLU
L
VARIOUS
SENSOR
LT GRN/WHT ,
RED/YEL
EVAP
TWOWAY
VALVE
EVAP
BYPASS
SOLENOID
EVAPPURGE
CONTROL
SoLENOtO
VALVE
SLK
VALVE
FUELTANK
MANIFOLD
11-204
www.emanualpro.com
'97 model:
The scan tool indicatesDiagnosticTrouble Code (DTC)P0441:EvaporativeEmission(EVAP)control system
insufficientpurgeflow.
Description
By monitoringthe purge line vacuumwith the MAP sensor,the PCM can detectinsufficientEVAPcontrol system purge
flow.
PossibloCause
. EVAPPurgeControlSolenoidValve
. EVAPPurgeControlSolenoidValveCircuit
. EVAPControlCanister
. VacuumLines
. PCM
TroubleshootingFlowchart
Th MIL has ben reooited on.
DTCP0441is .tored.
Problemverificationl
1 . S t a r tt h e e n g i n e .H o l d t h e
engine at 3,000rpm with no
load (in Parkor neut.al)until
the radiatorfan comeson.
2. Do the PCMResetProcedure.
3. Connectthe SCSserviceconnector,
4. Test drive underfollowingcon'
ditionson the road.
- without any electricalload
- Transmission
in @ or @
position
- Engine speed between
- 2,4OO
1,2OO
rpfi.
- Decelerate
from 50 mph (80
km/h)to15mph (24km/h)
ls DTCP0441indicated?
EVAPPURGECONTROL
SO1TNOIDVALVE2P
CoNNECTOR(C108)
(v)
YL
(To page11'206)
(cont'd)
www.emanualpro.com
11-205
EmissionControl System
EvaporativeEmission(EVAP)Controls(cont'dl
(Frompage11-205)
PCMCONNECTOR
A (32PI
PG1(BLKI
PCSIRED/YELI
JUMPERwlRE
ls there batteryvoltage?
(Topago11'207)
11-206
www.emanualpro.com
(Frompage11-206)
<\
VACUUM
PUMPI
GAUGE,
0-30 in.Hg
4973X 0il1 -
xxxxx
Doesit hold vacuum?
JUMPEFWIRE
wire side of femaleterminals
{cont'd)
www.emanualpro.com
1 1-207
EmissionControlSystem
EvaporativeEmission(EVAP)Controls(cont'd)
99 - 00 models:
The scan tool indicatesDiagnosticTrouble Code {DTC)P0451:The Fuel Tank Pressuresensor circuit range/
oerformanceDroblem.
-
ECM/PCMCONNECTORS
a t32Pl
Check lor th6 tu6l tank prssure
len30r:
1. Do the ECM/PCM
ResetProce,
oure.
2. Removethe fuelfill cap.
3. Turnthe ignitionswitchON (ll).
4. Monitor the FTPSensorvolt
a g e w i t h t h e H o n d aP G M
T e s t e r ,o r m e a s u r ev o l t a g e
between ECM/PCMconnector
terminalsA29 and C18.
ls thereapprox.2.5V?
PTANKILT GRNI
SG2 {GRN/BLK)
Wire sideof {emaleterminals
Chock tho vacuum lin6s tor
rGlriction o. blockago repair as
necessary.lf OK, roplacethe fuel
tank Drer3ursentor.
FUELTANK
PRESSURE
SENSOR
VACUUM
-30 in.H9
PUMP/GAUGE.0
A973X- 041 XXXXX
WAYVALVE
Doesthe voltage drop to approx.
1 . 5V a n dh o l d ?
11-208
www.emanualpro.com
'98 - 00 modls:
The scantool indicatesDiagnosticTroubleCode(DTC)P0452:A low voltageproblemin the FuelTank Pressure
sensof.
The fuel tank Dressuresensorconvertsfuel tank absolutepressureinto electricalsignalsand inputsthe ECM/PCM.
OUTPUT
VOLTAGE
tvl
{.5
0,5
-? KPA
(-50 mmHg,
-2 in.Hgl
+7 kPr
l5OmmHg,
2 in.Hgl
PRESSURE
FUELTANK
PRESSURE
SENSOR
3PCONNECTOR
tc6a6l
voc2
(YEL/BLUI
(cont'd)
YES
( T op a g e1 1 - 2 1 0 )
www.emanualpro.com
11-209
EmissionControlSystem
EvaporativeEmission(EVAP)Controls(cont'dl
(Frompagel1'209)
FUELTANK
PRESSUNE
SENSOR
3PCONNECTOR
tc646l
ls thereapprox.5V?
Wire side of female terminals
Check for a short in the wire
(PTANKline):
1. Turnthe ignitionswitchOFF.
2 . D i s c on n e c t t h e E C M / P C M
connectorA {32P).
3. Checkfor continuity between
the fuel tank pressuresensor
3P connectorNo. 3 terminals
and bodyground.
11 -2 1 0
www.emanualpro.com
'98 - 00 modals:
The scantool indicatesDiagnosticTroubleCode(DTC)P0453:A high voltageproblemin the FuelTankPressure
sensor.
Thc MIL has b6on ropottcd on.
DTCmia53is dorcd.
A {32PI
ECM/PCMCONNECTOR
trminals
Wire sidoot fema16
{[).
ls thereapprox.2.5V?
ls thereapprox.5 V?
FUELTANX
Pf,ESSUBESENSOR
3p CONNECTOR{C6,a6l
vcc2
IYEL/BLUI
sG2
(GRN/BLK}
Replir opn in th. wi.c b{ween
tha fuel tank Dio'sute sansot and
tho EC|,/PCM {Cl8}.
sG2
IGRN/BLKI
3
PTANK
ILT GRNI
ls thereapprox.5 V?
(cont'd)
\To page 11-212)
www.emanualpro.com
11-211
EmissionControlSystem
EvaporativeEmission(EVAP)Controls(cont'dl
( F r o mp a g e1 1 , 2 1 1 )
ECM/PCMCONNECTORS
Check fo. an open in the wire
(PTANKlinel:
Measurevoltage betweenECM/
PCMconnectorterminalsA29 and
c18.
PTANK {LT GRNI
ls thereapprox.5V?
11-2 1 2
www.emanualpro.com
'98 - 00 models:
Emission(EVAP)controlsystemleak
The scantool indicatesDiagnosticTroublecode (DTC)P1456:Evaporative
detected{fueltank system).
Troubleshooting Flowchart
-
' : ' 9 9 - 0 0m o d e l s
(cont'd)
www.emanualpro.com
11-213
EmissionControlSystem
EvaporativeEmission(EVAPIControls(contd)
lP14s6l("ont,a)
Fueltank pros3uresensortost.
(Thecontinuetion of DTCPl456
t.oubls3hooting.,
ECM/PCMCONNECTORS
11-2 1 4
www.emanualpro.com
FUEI-TANK
PRESSURE
SENSOR
VACUUM
- 30in.Hg
PUMP/GAUGE,0
A973X - ill -
xxxxx
EVAP TWO
WAY VALVE
VACUUM
- 30 in.Hg
PUMP/GAUGE,0
A973X- 041 -
xxxxx
EVAP
CONTROL
CANISTER
Wiresideof
female
terminals
ls there continuity?
(cont'd)
www.emanualpro.com
1 1-215
EmissionControlSystem
EvaporativeEmission(EVAPIControls(cont,dl
(conro)
1T1456I
EVAPbypa3ssolenoid valve test.
(The continuation ot DTC P1456
troubleshooting.l
VAP
BYPASS
SoLENOtO
VALVE
ECM/PCMCONNECTOR
A I32P)
2WBS (BLU}
/ 3
4l
o /
7,x , /
1 6 1 7 1 8 't9 2 0 2 1 1 /
26 27
2A 29 solT
VACUUM
PUMP/
GAUGE.
0 -30 in.Hg
A373X041 -
to
z3
32
JUMPERWIRE
Wiresideof femaleterminals
xxxxx
2WBS
(BLU}
Wire sideof
female
termrnats
Repairopen in the wire between
the EVAP bypass solenoid valv.
and ECM/PCMlA3).
tGl
IBLK/WHT}
1 1 -2 1 6
www.emanualpro.com
-/
VACUUM
- 30 in.Hg
PUMP/GAUGE,0
A973X- 041 XXXXX
VALVE
EVAP
CONTROL
CANISTER
EVAPCONTROL
CANISTERVENT SHUT
IC361)
VALVE2P CONNECTOR
r+
l 1
f
t 2 l
1 VSV
(o) tLTcnrulwxrt
1
Wire sideof femaleterminals
EVAP
CONTROL
CANISTER
VENT
SHUT
VALVE
O.RING
Replace.
ILT GRN/WHT)
(cont'd)
www.emanualpro.com
1 1- 2 1 7
EmissionControlSystem
EvaporativeEmissionIEVAPIControls(cont'd)
lTi,t56l ("onto)
Vacuum hoses and connections
telit.
C h e c kt h e v a c u u m h o 3 e s a n d
connect|ons:
C h e c kt h e f o l l o w i n g p a r t s f o r
l e a k sa t a t m o s p h e r i cp r e s s ur e
{seepage11-204).
. Fueltank
. Fuelfill cap
. F u e l f i l pl i p e
. EVAPtwo way valve
. Fueltankpressuresensor
1 1 -2 1 8
www.emanualpro.com
'98 - 00 modls:
Emission(EVAP)Controlsystemleak
The scantool indicatesDiagnosticTroublecode (DTc)P1457:Evaporative
detected(EVAPcontrolcanistersystem).
Troubl6shootingFlowchart
-
_]
ls the {ueltankpressuresensorOK?
(cont'dl
www.emanualpro.com
11-219
EmissionControlSystem
EvaporativeEmission(EVAP)Controls(cont,dl
iTl457l ("ont'or
- The MIL has been reportedon.
- DTCP1457is stored.
{EVAP purge control solenoid
valve test.l*
VACUUM
PUMP/GAUGE,
O-30 iN.Hg
A973X- 0rl -
xxxxx
'\)
AP
CONTROL
CANISTER
1 -220
www.emanualpro.com
4
5
8 /
,/3
't6 1 7 1 8 l 9 20
,,/ 14 ,/
,/ 26
29 30
't0
24
JUMPER
WIRE
ls therecontinuity?
ECM/PCMCONNECTOR
A {32P}
PCS(RED/YELI
EVAPPURGECONTROLSOI.ENOID
VALVE2P CONNECTOR
(Cl08)
PCS
IRED/YELI
female
termanals
EVAP
BYPASS
SOLENOID
VALVE
EVAPbypasssolenoidvalv test.
{The continuation of DTC P1457
troubleshooting.l
FUELTANK
SENSOR
PRESSUBE
EVAPTWOWAY
VALVE
1. Disconnectthe vacuLlmhose
from the EVAPtwo way valve,
and conned a vacuumPUmP
to the hose.
2. Turnthe ignitionswitchON (ll).
3. Applyvacuumto the hose
xxxxx
t.'-+l
t1t?l
| 2wBs
(d1terul
Y-L
ReDlacethe EVAPbypass 3olenoid
valveand O-rings.
C h e c kf o r a s h o r t i n l h e w i r e
{2WBSlinel:
connec
ECM/PCM
1. Disconnect
tor A (32P).
2. Checklor continuity betlveen
t h e E V A P b y p a s s s o l e n oi d
valve 2P connectortermrnal
No.2 and body ground.
ls therecontinuitY?
Wire sideof
female
terminals
2WBS
(BLU}
@)
(cont'd)
www.emanualpro.com
11-221
EmissionControlSystem
EvaporativeEmission(EVAP)Controls(cont,dl
lT145il ("ont'o)
VACUUM
- 30 in.Hs
PUMP/GAUGE,0
A973X- 041 -
xxxxx
ECM/PCMCONNECTOR
A {32PI
vsv
{LTGRN/WHT)
l 4 / 1 6 1 7 l 8 't9 20 2l
26 27
2a 29 30
EVAP
THREE
10
23
JUMPER
WIRE
VATVE
\
Wiresideof femaleterminals
't
EVAP
CONTROL
CANISTER
EVAP control crni3ter v6nt shut
velve b OK. Do the canistsr syslern loak test {3eepage 11-2231.
EVAPCONTROL
CANISTERVENT SHUT
VALVE2P CONNECTOR
{C361}
riEr
r+J
I vsv
Y
I
Wiresideof femaleterminals
EVAP
CONTROL
CANISTEF
VENT
SHUT
VALVE
(}BING
Replace.
11-222
www.emanualpro.com
ffil r c r
e
(BLK/wHr)
24
EVAP
CONTROL
Canbter system leak test
{Thecontinuation of DTCP1457
trouble3hootin9.)
Doesthevoltagedrop to 1.5V
and holdsat least20 seconds?
EVAP
FUELTANK
BYPASS
SENSOR
SOLENOID
EVAPTWOWAY
VALVE
VALVE
EVAP
THREE
VALVE
EVAP
CONTROL
CANISTER
ttrrL
t a
VACUUM
PUMP/
GAUGE,
0 - 30 in.Hg
A973X041 XXXXX
FITTINGS
ECM/PCMCONNECTORS
A {32P)
PTANKILT GRN)
Check the EVAP Pu.ge control
solenoidvalve line and connections:
1. Turnthe ignitionswitchOFF.
2 . D i s c o n n e ctth e P u r g e l a n e
hose from the EVAPcontrol
canisterand Plugthe Port
3. Turnthe ignitionswitchON (lli.
4. While monitoringthe FTP
Sensorvoltagewith the Honda
P G M T e s t e r ,o r m e a s u r i n g
v o l t a g e b e t w e e nE C M / P C M
connectorterminalsA29 and
Cl8 slowly PumPthe vacuum
pump using a strokeevery 1 2 seconds.
5 . C o n t i n u et o p u m p v a c u u m
u n t i l t h a t v o l t a g ed r o P st o
approx.1-5V.
N O T E :M a k e s u r e t h a t t h e
e n g i n ec o o l a n tt e m P e r a t u r e
andYour
stillabove95'F(35"C)
vacuumpumphasno leak6 . M o n i t o r t h a t v o l t a g et o r 2 0
seconds.
www.emanualpro.com
VENT
SHUT
VALVE
c (31Pt
SG2 {GRN/BLK)
Wiresideof femaleterminals
{cont'd)
11-223
EmissionControlSystem
EvaporativeEmission(EVAP)Controls(cont,dl
EvaporativeEmission (EVAP)Two Way Valve Testing
'97 model:
1.
2.
1.
2.
R e m o v et h e v a p o r I i n e f r o m t h e E V A Pt w o w a y
valve on the fuel tank, and connectit to a T_fitting
f r o m a v a c u u mg a u g ea n d a v a c u u m p u m p a s
shown.
VACUUM
PUMP/GAUGE,
0 - 30 in.Hg
A973X-041-XXXXX
.98 -
0Omodels:
Removethe fuel fill cap.
R e m o v et h e v a p o r l i n e f r o m t h e E V A Pt w o w a y
valve{locatedabovethe EVAPcontrolcanister).and
c o n n e c ti t t o a T - f i t t i n gf r o m v a c u u mg a u g e a n d
vacuumpump as shown.
VACUUM/PRESSUFE
VACUUM,/
PRESSURE
GAUGE
otJAz - 001rDoB
T-FITTING
VACUUM PUMP/
GAUGE,0- 30 in.Hg
A973X- 041 -
xxxxx
T-FITTING
T-FITTING
3 . A p p l y v a c u u m s l o w l y a n d c o n t i n u o u s l vw h i l e
watching the gauge.The vacuum should stabilize
momentarilyat 0.7- 2.0 kpa (5 - 1SmmHg,0.2_ 0.6
in.Hg).
l f t h e v a c u u m s t a b i l i z e s( v a l v e o p e n s ) b e l o w
0 . 7 k P a ( 5 m m H g , 0 . 2 i n , H g )o r a b o v e 2 . 0 k p a
(15 mmHg,0.6 in.Hg),installa new valveand retest.
4.
A p p l y v a c u u m s l o w l y a n d c o n t i n u o u s l yw h i l e
watchingthe gauge.
The vacuum should stabilizemomentarilyat O.g_
2.1 kPa(6 - 16 mmHg,0.2- 0.6 in.Hg).
l f t h e v a c u u m s t a b i l i z e s( v a l v e o p e n s ) b e l o w
0 . 8 k P a ( 6 m m H g , 0 . 2 i n . H g )o r a b o v e 2 . 1 k p a
(16 mmHg,0.6 in.Hg),installa new valveand retest.
Move the vacuum pump hosefrom the vacuumfitting to the pressurefitting. and move the vacuum
gauge hose from the vacuum side to the pressure
side as shown.
PiESSURE
SIDE
5.
Slowly pressurize
the vapor line while watchingthe
gauge.The pressureshouldstabilizeat 1.3- 4.7 kpa
( 0 - 3 5 m m H g ,0 . 4- 1 . 4i n . H g ) .
. l f t h e p r e s s u r em o m e n t a r i l ys t a b i l i z e s( v a l v e
opens)at 1.3- 4.7 kpa (10 - 35 mmHg, 0.4 _ 1.4
in. Hg),the valveis OK.
. lf th6 pressurestabilizes
below 1.3kpa fio mmHg,
0.4 inrHg)or above4.7 kpa (35 mmHg, 1.4 in.Hg),
installa new valve and retest.
11-224
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5.
Transaxle
...........12-1
Clutch
. . . . . . . . . . . . . . . . . . . . .1. .3. -. 1
...
M a n u a lT r a n s m i s s i o n
. 4-1
A u t o m a t i cT r a n s m i s s i o .n. . . . . . . . . . . ..........1
... 15-1
Differential
... 16-1
Driveshafts
www.emanualpro.com
Clutch
12-2
..........'
Tools....,.....
Speciaf
.'." 12'3
lllustratedlndex...........
ClutchPedal
........."."."".12-4
Adjustment
ClutchMasterCylinder
'." 12'5
RemovaUlnstallation
SlaveCylinder
.'.. 12-6
Removal/lnstallation
PressurePlate
..'." 12-7
RemovaUlnspection
ClutchDisc
."'.. 12-8
Removal/lnspection
Flywheel
12-9
......................
Inspection
12-9
.......................................
Replacement
ClutchDisc,PressurePlate
12-10
....................'
lnstallation
ReleaseBearing
......12'11
Removal/lnspection
12-12
.....................
lnstaflation
www.emanualpro.com
SpecialTools
Rel.No.
a
IA
@
!c,
Lo,
Tool Number
OTJAF- PM70,I1A
07NAF- PR30l00
07LAB- PV00100
or
07924- PD20003
07746 0010100
07749- 0010000
07936- 3710100
Description
ClutchAlignmentDisc
ClutchAlignmentShaft
R i n gG e a rH o l d e r
1
1
1
Attachment,32 x 35 mm
Driver
H an dl e
b)
2-2
www.emanualpro.com
Oty
1
1
PageReference
|
I
I
t2-7
12-7, A, ' t0,11
1 2 - ,79 , 1 0 ,1 ' l
12-10
12-10
1 2 - 7, a , 1 0 , 1 1
lllustratedIndex
NOTE:
. Wheneverthe transmissionis removed,cleanand greasethe releasebearingslidingsurface
.lfthepansmarked*areremoved,theclutchhydraulicsystemmustbebled(seepage12-6).
and twisting.
. Inspectthe hosesfor damage.leaks.interference,
LOCKPIN
*CLUTCHLINE
19 N.m (1.9kgj.m,
14 tbtft)
PEDALPIN
.RESEFVOIR
HOSE
8 x 1.25mm
13 N.m {1.3kgf m,9.4lbtft)
*RESERVOIR
TANK
.o-.9r
CLUTCHPEDAL
Adjustment,page12-4
*CI-UTCHMASTERCYLINDER
page12-5
Femoval/lnstallation,
WM\,".0-ffi-P"8Nmlloks{m'
6x1.0mm
9.8 N.m (1.0kgf.m,
7.2 tbf.ft)
*CLUTCHLINE
15 N.m (1.5kgt m,
11 tbr.ft)
CLUTCHDISC
page 12-8
Removal/lnspection,
page12,13
Installation,
*CLUTCHLINE
24 N.m {2.4 kgf.m,
17 tbf.ft)
8 x 1.25mm
25 N.m {2.6kgt m,
19rbf.ftt
FLYWHEEL
page12I
Inspection,
page12-9
Repiacement,
1 2x 1 . 0m m
103N.m (10.5kgtm,75.9lbf ftl
PLATE
PRESSURE
page'12-7
Removal/lnspection,
page'1213
Installation,
RELEASEBEARING
page12-1'!
Removal/lnspection,
page12-12
Installation,
*CLUTCHLINE
15 N.m (1.5kgt m,
11 tbf.ft)
www.emanualpro.com
I x 1.25mm
22 N.m 12.2kgl'm, 16lbfft)
12-3
ClutchPedal
Adiustment
NOTE:
. T o c h e c k t h e c l u t c h i n t e r l o c ks w i t c h a n d c l u t c h
switch,seesection23.
. The clutchis self-adjusting
to compensatefor wear.
CAUTION:lf there is no clearancebstwan the master cylinder piston and push rod, ths roloasebearing
is held againsi the diaphragm spring, which can
resuh in clutch slippageor other clutch probloms.
1.
2.
3.
TightenlocknutC.
4.
1 0 .TightenlocknutB.
LOCKNUT B
9.8 N.m 11.0kgf.m, 7.2 lbf.ftl
CLUTCHINTERLOCK
SWITCH
CLUTCHSWTTCH
{or ADJUSTINGBOLTI
L(rcKNUT A
9.8 N.m {1.0kg{.m,7.2 lbf.ftl
CLUTCHMASTERCYLINDER
PUSHROD
Pedal in contact with swhch
LOCKNUTC
18 N.m (1.8kgf.m,13lbtftl
a_-_--/
@
@
@
o
12-4
www.emanualpro.com
GlutchMasterCylinder
Removal/lnstallation
CAUTION:
. Do not spill brake fluid on the vehicle; it may damage
the paint; if brake tluid does contact the paint. wash
it off immediately with water.
. Plug the end ol the clutch line and leservoir hose
with a shop towel to prevent brake tluid trom coming
out.
4.
Prv out the lock pin, and pull the pedal pin out of
the voke.Removethe nuts.
NUTS
I x 1.25mm
13 N.m t1.3kgt.m,g.illbtft)
9.8N.m11.0kst m,
7.2tbf.ftl
5,
Removethe clutchmastercylinder.
CLUTCHLINE
19 N'm 119 kgJm'
14 lbf.frl
MASTER
CLUTCH
CYLINDEF
I n s t a l lt h e c l u t c h m a s t e rc y l i n d e r i n t h e r e v e r s e
orderof removal.
NOTE:Bleedthe clutchhydraulicsystem{seepage
12-61.
www.emanualpro.com
12-5
SlaveCylinder
RemovaUlnstallation
CAUTION:
. Do nol spill braketluid on the vehicle;itmaydamage
the paint; if brake fluid dos contast the paint, wash
it off immediately with water.
. Plug the end of the clutch line with a shop towel to
prevcnt brake tluid from coming out.
3.
I n s t a l lt h e s l a v ec y l i n d e ri n t h e r e v e r s eo r d e r o t
removal.
NOTErMake sure the boot is installedon the slave
cylinder.
CLUTCH
LINE
15N.m(i.Skgf.m,lt tbf.ftl
.6|l,Super
1.
SLAVECYLINDER
Disconnect
the clutchline from the slavecvlinder.
.-lG
(P/N08798- 90021
E x 1.25mm
22 N.m (2.2kgt.m,
16 tbtft)
(BrakeAssembly
Lube)
Bleed the clutch hydraulic system.
2.
BLEEDER
SCREW
7.8 N.m (0.8 kgf.m.5.8 lbt.ft)
12-6
www.emanualpro.com
PressurePlate
Removal/lnspection
1 . Checkthe diaphragmspringfingersfor heightusing
the specialtools and a feelergauge.
StandardlNewl: 0.6 mm {0.02in) max.
ServiceLimit: 0.8 mm (0.03in)
4.
5.
HANDLE
07936- 3710100
CLUTCHALIGNMENTDISC
- PM7O11A
OTJAF
CI.UTCHALIGNMENTSHAFT
07NAF- PR30100
FEELER
GAUGE
PRESSURE
PLATE
6.
l n s t a l lt h e s D e c i a l l o o l sa s s h o w n .
PLATE
PRESSURE
RINGGEARHOLDER ADJUSTERNUT
ADJUSTER
BOLT
ENGINEBLOCK
GAUGE
FEELER
BOLT
NUT
WASHER
T o p r e v e n tw a r p i n g ,u n s c r e wt h e p r e s s u r ep l a t e
mounting bolts in a crisscrosspattern in several
steps.then removethe pressureplate.
www.emanualpro.com
12-7
GlutchDisc
Removal/lnspection
'1. Removethe
clutchdiscand specialtools.
4.
CLUTCHDISC
Inspectthe lining of the clutchdisc for signsof slipping or oil. lf the clutch disc is burned blackor oil
soaked,replaceit.
Measurethe clutchdiscthickness.
Standard(New):8.,1-9.1 mm (0.33- 0.36in)
ServiceLimh: 6.0 mm (0.2,1in)
LINI G SURFACE
CLUTCHDISC
l f t h e r i v e t d e p t h i s l e s s t h a n t h e s e r v i c el i m i t ,
replacethe clutchdisc.
12-8
www.emanualpro.com
Flywheel
Replacement
Inspection
L
Installthespecialtool as shown.
2.
2.
3.
MOUNNNG
BOLTS
N O T E :T h e r u n o u tc a n b e m e a s u r e dw i t h e n g i n e
installed.
Standard (Newl: 0.05 mm (0.002in) max.
ServiceLimit: 0.15mm {0.006inl
lf the runout is more than the servicelimit, replace
the flywheeland recheckthe runout
FLYWHEEL
FLYWHEEL
RINGGEARHOLDER
07LAB- PV00r00
ol
07924 - PD20003
3.
RINGGEAR
FLYWHEEL
BALLBEARING
(cont'd)
www.emanualpro.com
12-9
Flywheel
Replacement(cont'dl
Drive the new bearing into the flywheel using the
specialtools.
HANOLEDRIVER
07749-
Clutch Disc,PressurePlate
Installation
1.
ATTACHMET{T32x35mm
07746-O010100
FLYWHECI-
CLUTCHDISC
RINGGEARHOLDER
07LAB_ pvoot(x)or
07924_ PD20003
Torque:
12x 1.0mm
r03 N.m(10.5kgl.ln,
75.9tbtftl
lnstallthe pressureplate.
PRESSURE
PLATE
12-10
www.emanualpro.com
ReleaseBearing
Removal/lnspection
4.
1.
8 x 1.25mm
25 N.m (2.6kgf.m,19lbfft)
RELEASE
FORK
BOOT
RELEASEFORK
Removethe specialtools.
6.
www.emanualpro.com
12-11
ReleaseBearing
lnstallation
NOTE: Use only Super High Temp Urea Grease(P/N
08798- 9002).
3.
-6.l
(P/N08798-
r iz]))
(P/N08798
9002)
| (,4\1t1t
/\[w
RELEASE
FORK
BOOT
4.
(P/N08798 9002)
1 . 0- 1 . 6g
{0.0,1- 0,06 ozl
12-12
www.emanualpro.com
ManualTransmission
Diffrential
l n d e x. . . . . . . . . . . . . . . . . . . . . .
. . . . . . .1. .3 - 3 8
BacklashInspestion..,....,.,.....................,......,
13-38
FinalDrivenGearReplacement....................
13-39
TaperedRoller Bearing
Replacement
.............
13-39
BearingOuterRaceReplacement......,.,........
13-i10
TaperedRoller Bearing Preload
Adiustment
...............
13-il1
Oil SealReolacement....................................
13-/l:}
TransferAssembly
lllustratedIndex
.............
13-il4
Inspection
..,....,.,......,......
13-46
Disassembly
...................
13-47
Transfer Drive Gear Bearing
Replacement
...,..................,.......................
13-ilg
Transfer Driven Gear Shaft Bearing
Replacement..............................................
13-ilg
TransferShaft Disassembly/
Reassembly
..............
13-50
Transler Cover A Bearing Outer Race
Rep1acement.........,.,.,..........,....,...,.........,.,
13-50
Transter Housing Bearing Outer Race
R e D 1 a c e m e n t . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. 3. .-.5. .1. . . . . . . . . . . .
Reassembly
13-52
..-............,...
Mainshaft Bearing/OilSeal
Beplacement
..................
13-62
CountershaftBearing
Replacement.,,.,.,.,
..,......
13-63
Mainshaft Thrust Clearance
Adiustment
....................
13-6,1
TransmissionAssembly
Reassembly
13-67
.,.,.,.,..,.,....,.,
fnstaffation
13-72
.,.,.............,...
Gearshift Mechanism
O v e r h a u.l. . . . . . . . . . . . . . .
.........13-17
www.emanualpro.com
SpecialTools
SpecialTools
Ref. No.
o
o
Dsscription
1
1
1
'l
@
@
DriverAttachment
MainshaftHolder
MainshaftBase
PreloadInspectionTool
AdjustableBearingRemoverSet
Driver Attachment
Pilot,28 x 30 mm
Attachment,40 x 50 mm
CompanionFlangeHolder
Attachment,32x 35 mm
Attachment,42 x 47 mm
Attachment,52 x 55 mm
Attachment,62 x 68 mm
@
@
07746- 0010600
07746- 0030100
Attachment,72 x 75 mm
Driver,40 mm l.D.
1
1
@
@
@
07746- 0030300
07746- 0030400
07749- 0010000
Attachment.30 mm l.D.
Attachment,35 mm l.D.
Handle
@
@
07947- SD90200
07979- PJ40001
@
-o
\9'
a
@
6r
,d,
I A
a5-z
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1
1
Page Roterence
13-43
13-66
13-66
13-41
13-62.63
13-43,53
13-43
13-39,49
13-48,54,57,58
13-18,68
13-27,34,62
13-40.51
't3-40,50.51,61,
oz, oJ
13-40
13-27,34,35, 49,
tJ-5C
13-66
ta\
o@(9
1
1
1
1
1
1
'I
13-27,34
13-14,27.34,40,
43, 49, 50, 51, 53,
61,62,63,68
'13-49
Attachment
MagnetStandBase
* Must be usedwith commerciallyavailable3/8" - 16SlideHammer.
. A
Oty
07GAD- PG40100
07GAJ- PG20110
07GAJ- PG20130
07HAJ - PK40201
07JAC- PH80000
07JAD- PH80101
07JAD - PH80400
07LAD- PW50601
07RAB- 0020000
07746- 0010100
07746- 0010300
07746- 0010400
07746- 0010500
,6)
ll
Tool Number
G)
(oo@(9(}
Back-upLight Switch
Maintenance
Fluid
Transmission
Test/Replacement
1.
1.
R e m o v et h e f i l l e r p l u g . t h e n c h e c kt h e l e v e l a n d
conditionof the fluid.
PLUG
FILLER
44 N.m{4.5kgf.m.33 lbfftl
\
TerminalsideoI
malelerminals
PtopetLevel
ll
/
\--ril
HllllllTl /
Hllllrlll
/
_rf-F{--rno."."
l l
| |
BACK.UP LIGHTSWTTCH
r 25 N.m 12.5kgt m, 18 lbf.ftl
Replaco.
WASHER
Replace.
lf necessary,replacethe switch.
DRAINPLUG
39 N m (4.0 kgf.m,29 lbf'ft)
WASHER
Replace.
R e i n s t a ltl h e d r a i n p l u g w i t h a n e w w a s h e r .a n d
refillthe transmissionfluid to the properlevel.
NOTE:The drain plug washershouldbe replacedat
everyfluid change.
Reinstallthe filler plug with a new washer.
Fluid Capacity
1.7/ {1.8US qt, 1.5lmp qtl at oil change
2.1 ! 12.2US qt, 1.Almp qtl at overhaul
Alwavs use GenuineHonda Manual Transmission
Fluid (MTF).Using motor oil can causestiffershiftind becauseit doesnot containthe properadditives.
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13-3
TransferAssembly
lnspection
Make sure tifts, iacks, and satety stands
@
are placed properly (seesection 1).
L
2.
3.
Shiftto neutraloosition.
4.
6.
COMPAf{IONFI-ANGE
1.
8 x 1.25mm
32N.m(3.3kg{.m.
24 rbf.ftl
Replace.
5.
S e p a r a t et h e p r o p e l l e r s h a f t f r o m t h e t r a n s f e r
assemDty.
13-4
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Removal
Make sure the lifts, i8cks. and safety stands
!@@
properly
placed
are
{seesection 1}.
1.
2.
3.
D r a i nt h e m a n u a lt r a n s m i s s i o fnl u i d R e i n s t a ltlh e
drain plug with a new sealingwasher.
4.
6.
Replace.
7.
S e p a r a t et h e p r o p e l l e r s h a f t f r o m t h e t r a n s f e r
assemblyflanges,
Removethe rear stiffener, then remove the transfer
assembly.
SELF.L(rcKNG
NUT
Replace.
SELF-LOCKI'{G
NUT
Replac.
5.
RemoveexhaustoipeA.
Replace.
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13-5
TransferAssembly
lnstallation
1.
6.
Installthe exhaustpipeA,
10 x 1.25mm
44 N.m (4.5 kgJ.m,
GASKET
EXHAUSTPIPEA
HO2SCONNECTOR
DOWELPIN
TRANSFEB
ASSEMBLY
Replace.
2.
10 x 1.25 mm
54 N.m (5.5 kgt m,
40 tbtftt
Replace.
SELF.LOCKING
NUT
8 x 1.25mm
16 N.m {1.6kgf.m,
12 tbt.ft)
Replace.
8 x 1.25mm
zzN.m l2.2kg!-m,
16rbf.trt
Replace.
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REFERENCE
MARKS
7.
Connectthe heatedoxygensensor(HO2S)connector.
8.
9.
TransmissionAssemblY
Removal
@
FMak.
sw. iack" and safety stands are placed propelly, and hoist bracketsare attached to collect position
on the engine,
. Apply parking brake and block rear wheels so vehicle
will not roll off stands and lall on you while working
under it.
4.
D i s c o n n e c t h e s t a r t e r c a b l e sa n d t r a n s m i s s i o n
groundcable.
2.
3.
TRANSMISSION
GROUNDCABLE
WIREHARNESSCLAMP
(cont'd)
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13-7
TransmissionAssembly
Removal(cont'dl
6.
R e m o v et h e c o t t e r p i n s , t h e n r e m o v e t h e s t e e l
w a s h e r s ,p l a s t i cw a s h e r s .s h i f t c a b l e ,a n d s e l e c t
cablefrom the levers.
9 . R e m o v et h e f o u r u p p e r t r a n s m i s s i o nm o un t i n g
bolts.
MOUNNNG BOLTS
8.
Disconnectthe vehiclespeedsensor(VSS)connector.
-------------.2
13-8
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15. Removethe cotter pins,and castlenuts.then separate the ball iointsfrom the lower arm (seesectlon
18).
OAMPERPINCHBOLT
GASKET
Replace.
HO2SCONNECTOR
CASTLENUT
NUT
Replace.
NUT
Replace.
DAMPERFORK
FOFK
EOLT
Replace.
EXHAUST
SELF.LOCKING
Replace.
GASKET
Replace.
MABKS
REFERENCE
8 x 1.25mm
Replace.
1 4 . S e p a r a t et h e p r o p e l l e r s h a f t f r o m t h e t r a n s f e r
assemDly.
www.emanualpro.com
{cont'd}
13-9
TransmissionAssembly
Removal(cont'd)
20. Removethe intermediate
shaft.
2 1 . Tie plasticbagsoverthe both endsof the intermediate shaft. Coat all precisionfinished surfaceswith
cleanengineoil.
Removethe rear engine stiffene.and clutch housIng cover.
RIGHTFRONT
MOUNT/BRACKET
P l a c ea j a c k u n d e r t h e t r a n s m i s s i o nr,a i s e i t j u s t
enough to take it off of the mounts, then remove
the transmissionmount bracketand transmission
mount.
TRANSMISSIONMOUNT
MOUNT BRACKET
13-10
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REARENGINEMOUNTINGBOLTS
Replace.
TRANSMISSION
STARTER
MOTOR
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1 3 - 11
TransmissionAssembly
lllustrated Index
Referto the drawingbelowfor the transmissiondisassembly/reassembly.
Cleanall the pans thoroughlyin solvent,and drv with comoressedair.
I
NOTE:
t This transmissionusesno gasketsbetweenthe major housings;use liquid gasket(p/N
0g718- 0001or oE7l8 - 0003)
(seepage 13-69,71).
. Alwayscleanthe magnet@ wheneverthe transmissjonhousingis disassembled.
. Inspectall the bearingsfor wear and operation.
C) sHrFr FoRKASSEMBLY
. I n d e xp a g e l, 3 - 2 1
(a MAINSHAFTASSEMBLY
. I n d e xp a g e 1
, 3-23
(9 28 mm WASHER
) 28 mm SPRTNG
WASHER
O BALLBEARING
a6)OIL SEALReDlace.
(D 14 x 20 mm DOWELptN
G) couNTERSHAFTASSEMBLY
.lndex page,13-28
13 -1 2
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@ NEEDLEBEARING
o OILGUIOEC PLATE
@ MAGNET
@ DIFFERENTIAL
ASSEMBLY
.lndex page,13-38
(DO-nlNGBeplace.
i9 TRANSFERASSEMBLY
'13,44
.Index page,
@ OILSEALReplace.
@ VEHICLESPEEDSENSOR
@ CLUTCHHOUSING
(9 REVERSELOCKCAM
@ REVEESESHIFTHOLDER
@ REVERSEIDLEGEAR
@ REVERSEGEARSHAFT
e3THRUSTWASHER,20x 36 x 2
@ COLLER,15 x 20 x 20
C) TRANSMISSIONHANGER
BOLT
O INTERLOCK
O 32 mm SEALINGBOLT
@ STEELBALL{5/16 in.)
26.1mm {1.03in.l
) SPRING
@ wasHER Replace.
O sET BALLscREw
@ WASHERReplace.
) FLANGEBOLT
@ oll SEALReplace.
@ DRAINPLUG
@ WASHERReplace.
@ FILLERPLUG
@ WASHERReplace.
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(9 10 x 12 mm DOWELPIN
(D SPRING
in.l
25.6mm 11.01
' THRUSTWASHER
@} SHIFTARM C
(3 CONICALSPRINGWASHER
BOLT
@ SPECTAL
8] SHIFTARM COVER
@ OILSEALReplace.
! SHIFTLEVER
CAP
@I BREATHER
(2! SHIFTARM SHAFTASSEMBLY
PINReplace.
@ SPRING
O SELECTARM
!} THRUSTWASHER
SELECT
@ sTH/REVERSE
RETURNSPRING
@ SELECTRETURNSPRING
) OIL GUTTERPLATE
@ 78 mm SHIM
@ OIL GUIOEM PLATE
@ SELECTSPRINGBOLT
@ OILSEALReplace.
@ SELECTLEVER
O BACK.UPLIGHTSWITCH
@ WASHERReplace.
HOUSING
OOTRANSMISSION
13-13
TransmissionAssembly
Disassembly
1.
Removethe transferassemblv.
3.
Removethe interlockbolt.
SELECTARM
O-RING
Replace.
SHIFTARMSHAFT
Turn the selectlevercounterclockwise,
then remove
the shift arm A finger from the groove of the shift
forks.
T u r n t h e s h i f t a r m s h a f t c o u n t e r c l o c k w i s ea n d
removethe selectarm fingerfrom the grooveof the
shift arm A. then removethe shift arm shaft assemblv.
6.
Removethe vehiclespeedsensor(VSS).
SHIFTARM COVERASSEMBLY
10x 12 mm DOWELptN
13-14
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7.
STEELBALL
D. 5/16 in
LIGHTSWITCH
8.
FILLERPLUG
DRAINPLUG
WASHER
Replace.
WASHER
Replace.
FLANGEBOLT
' It . Expandthe snap ring on the countershaftball bearing, and removeit from the groove using a pair of
snap ring plier.
Separatethe transmissionhousingfrom the clutch
housing.
R e m o v et h e d o w e l p i n s ,a n d w i p e i t c l e a no f t h e
sealant.
(cont'd)
www.emanualpro.com
13-15
TransmissionAssembly
Disassembly(cont'dl
1 4 . R e m o v et h e o i l g u t t e rp l a t e ,7 8 m m s h i m , a n d o i l
guide M plate.
OIL GUTTERPLATE
PIN PUNCH,5.0 mm
Replace.
OIL GUIDEM PLATE
SELCTLEVER
SELECTSPRINGBOLT
OIL SEAL
Replace.
THRUSTWASHER
SELECTARM
13-16
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COUNTEBSHAFT
ASSEMBLY
WASHER
SPRINGWASHER
HOUSING
HOLOER
www.emanualpro.com
13-17
5.
HANOLE
07749- 0010000
ATTACHMENT,
32x35mm
077a6- 0010100
BREATHER
CAP
OIL SEAL
Replace.
STEELBALL
D. 5/16 in,
SPRING
L,25.6mm (1.01in.l
T BALLSCREW
22 N.m 12.2kgtm, 16lbf.ftl
Remove the special bolt and conical spring washers.
6.
Reassemble
the shift arm cover in the reve.seorder
of disassembly.
SHIFTARMA
SHIFT
ARM
COVER
SPCCIALBOLT
8x1.0mm
29 N.m (3.0kgf.m,
22IbI.ftI
CONICALSPRING
SHIFTLEVER
SHIFTARM SHAFT
THRUSTWASHER
SHIFI ARM C
WASHER
8x1.0mft
29 N.m13.0kg{.m,
z2 tbt.ftl
R e m o v et h e s h i f t l e v e r , s h i f t a r m C , a n d t h r u s t
washerfrom the shift arm cover.
SPECIALBOLT
8x1.0mm
29 N.m {3.0kgf.m,22 lbtft}
13-18
www.emanualpro.com
SPRING
WASHER
2.
3.
InsPection
Clearance
1.
3.
SELECTARM
SHIFT ARM A
2.
SHIFTARM B
l f t h e c l e a r a n c ea r e m o r e t h a n t h e s e r v i c el i m i t ,
measurethe diameterof the selectarm pln
l f t h e c l e a r a n c ea r e m o r e t h a n t h e s e r v i c el i m i t ,
measurethe diameterof the shift arm C.
SHIFTARM C
SELECT
ARM
lf the diameterof the selectarm pin is lessthan
the service limit, replacethe select arm wrtn a
new one.
lf the diameterof the selectarm pin is within the
servicelimit, replacethe shift arm A with a new
one.
www.emanualpro.com
13-19
ReverseShift Holder
ClearanceInspection
1.
3.
PIECEPIN
2.
l f t h e c l e a r a n c ea
s r e m o r e t h a n t h e s e r v i c el i m i t .
measurethe widths of the groove in the reverse
shift holder.
Standard:A: 7.05- 7.25 mm {0.278- 0.285inl
B: 7.4- 7.7 mm (0.29- 0.30inl
lf the clearanceis more than the servicelimit. measurethe width ot the reverseshift holder.
Standard:13.0- 13.3mm (0.512-0521inl
REVERSE
SHIFTHOLDER
13-20
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Shift ForkAssembly
Disassembly/ReassemblY
I
cleanall the pans in solvent,dry them, and apply lubricantto any contactparts
erior,o reassembling,
3RD/,|THSHIFTFoRK
1ST/2NDSHIFTFORK
5TH/REVERSE
SHIFTPIECE
PIN PUNCH,5.0 mm
www.emanualpro.com
13-21
Shift ForkAssembly
ClearanceInspection
NOTE:The synchrosleeveand synchrohub should be
reolacedas a set.
1.
3.
Standard:
0.35- 0.65 mm 10.01/t- 0.026inl
ServiceLimit: 1,0 mm {0.039inl
sTH/REVERSE
SHIFTPIECE
ran,rru
lST/2ND
SI{IFTFORK
SHIFTFORK
2.
- 0.512inl
Standard:12.9- 13.0mm 10.508
Standard:
3rd/4th shift fork
1sv2ndshiftfork
5th shift fork
7 . 4- 7 . 6m m
(0.29- 0.30in)
6 . 2- 6 . 4m m
(0.24- 0.25in)
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MainshaftAssembly
lndex
Notethe Iollowingduringreassembly:
. The 3rd/4th,and 5th synchrohubs,and the ball bearingare installedwith a press.
. Installtheangularball bearingwith the thin-edgedouter racefacingthe stop ring
prior to reassembling,
clean all the parts in solvent,dry them, and apply lubricantto any contactsurfaces.The
hubs,however,shouldbe installedwith a pressbeforelubricatingthem'
5th
svnchro
3rd/4thand
SYNCHRORING
page l3 37
Inspection,
ANGULAREALLBEARING
Checkfor wear and operation.
Note the direction
of installation.
SYOPRING
SYNCHROHUB
page13-36
lnspection,
SYNCHROSLEEVE
page13 36
Inspection,
TAPERRING
BEARING
CheckIor wear and operataon.
COLLAR
SPRING
RING
page13-37
Inspection,
SYNCHRO
SYNCHROSPRING
Inspection,
page13-37
SYNCHROHUB
page13_36
Inspection,
3RDGEAR
Inspeclton,
page13 24,37
SYNCHROSLEEVE
page13 36
Inspection,
SPFING
BEARING
RING
page13_37
Inspection,
Checkfor wear
ano operalton.
GEAR
page13_25,
37
Inspection,
page13 26
Inspection,
COLLAR
page13-24,25
Inspection,
NEEDLEBEARING
Checkfor wear and operat,on.
GEAR
I n s p e c t i o n ,p a g e 1 3 2 4 , 3 7
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13-23
MainshaftAssembly
ClearanceInspection
NOTE; lf replacementis required,always replacethe
synchrosleeveand hub as a set.
L
2.
4.
Siandard:
0.06- 0.21 mm 10.002- 0.008in)
ServicaLimit: 0.3 mm (0.01in)
lf the clearanceis more than the servicelimit, measure distance@ on the spacercollar,
Standard:
26.03- 26.08mm {1.025- 1.027inl
ServiceLimit: 26.01mm {1.02,[in]
o[-l:-g;;em
lf the clearanceis more than the servicelimit, measurethe thicknessof 3rd gear.
Standard: 34.92- 34.97mm {1.375- 1.377in)
ServiceLimit 34.8 mm (1.37in)
3RD GEAR
fp-rro.ERcoLLAR
6.
lf the thicknessof 3rd gear is lessthan the service limit, replace3rd gearwith a new one.
lf the thicknessof 3rd gear is within the service
limit, replacethe 3rd/4thsynchrohub with a new
one.
13-24
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lf the thickness of 4th gear is less than the service limit, replace 4th gear with a new one.
lf the thickness of 4th gear is within the service
limit, replace the 3rd/4th synchro hub with a new
one,
Disassembly
7.
1.
S u p p o r t5 t h g e a r o n s t e e l b l o c k s ,a n d p r e s st h e
mainshaftout of the 5th synchrohub, as shown.Do
not use a jaw-type puller, becauseit can damage
the gearteeth.
PRESS
MAINSHAFT
I
ACHMENT
SPACERCOLLAR
SOCKET
8.
5TH GEAR
5TH GEAR
SIDE
9.
gt
r--\
,,srH GEAR
Fq
I- l.J'-----!--\--J
lf the thicknessof 5th gear is less than the service limit, replace5th gearwith a new one.
li the thicknessof sth gear is within the service
l i m i t , r e p l a c et h e s t h s y n c h r oh u b w i t h a n e w
one.
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BLOCKS
MainshaftAssembly
Inspection
1.
I n s p e c t h e g e a r s u r f a c ea n d b e a r i n gs u r f a c ef o r
wear and damage,then measurethe mainshaftat
pointsA, B, and C.
Standard:
A (Ballbearingsurface): 27.987- 28.000mm
1 1 . 1 0 1- 81 . 1 0 2 4i n l
B (Needlebearing surfacel:37.984- 38.000mm
- 1.4961inl
(1.4954
C {Baflbearingsurfacel: 27.977-27.990 mm
( 1 . 1 0 1-5 1 . 1 0 2 0
inl
ServiceLimit:A:27.94mm (1.100in)
B: 37.93mm (1.'193
inl
C: 27.94mm 11.100
inl
2.
Inspectfor runout.
Standard: 0.02mm (0.0008in) max.
ServiceLimit: 0.05 mm 10.002inl
N O T E : S u p p o r tt h e m a i n s h a f a
t t both ends
shown.
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Reassembly
sequence.
NOTE:Referto page13-23for reassembly
1.
3.
I n s t a l lt h e a n g u l a rb a l l b e a r i n gu s i n g t h e s p e c i a l
tools and a oress.Notethe directionof installation.
PRESS
3RD/4TH
SYNCHROHUB
HANDLE
07749- 0010000
I
DRIVER,,l(} mm l.O.
07746 - 0030'100
ATTACHMENT,
/Vl x a7 mm
077a6- 0011x100
BALLBEARING
Notethe diredion
o{ installation.
2NO GEAR
2.
I
DRlvER,40mm l.D.
077{6 - 00301(x)
ATTACHMENT,
35 mm l.D.
077i16- lx)3ollx)
sTH SYNCHBOHUB
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13-27
CountershaftAssembly
Index
NOTE:The 3rd, 4th.and sth gearare installedwith a press.
Priorto reassembling,
cleanall the partsin solvent,dry them, and apply lubricantto any contactsurfaces.The 3rd,
4th,and sth gears,however.shouldbe installedwith a pressbeforelubricatingthem.
LOCKNUTReplace.
127-o-127N.m
113-0- 13kstmi
9.trbtft/
\94-0WASHER
IST/2ND SYNCHROHUB
page13 36
Inspection,
DAMPER
Checklor wear and
damage.
AEARING
Checkfor wear and ooeration.
BEARING
Checkfor wear and
operation.
GEAR
SPNING
4TH GEAR
DOUBI.f CONE
page13-37
Inspection,
3RD GEAR
1STGEAR
page13 29,37
Inspection,
BEARING
Checktor wear and operation.
THRUSTWASHER
page13-29
Inspection,
GEAR
page13-30,37
Inspection,
NEEDLEBEARING
Checkfor wear and oPeration
SPACER
page13-30
Selection,
DAMPER
C h e c kf o r w e a r a n d d a m a g e .
DOUBLECONE
page13-37
Inspection,
SPRING
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ClearanceInspection
NOTE: lf replacementus required,always replacethe
synchrosleeveand hub as a set.
1.
M e a s u r et h e c l e a r a n c eb e t w e e nt h e l s t o e a r a n d
thrustwasher.
3.
THRUST WASHER
2.
lf the clearanceis more than the servicelimit, measurethe thicknessof the thrustwasher.
Standsrd:1.95- 1.97mm (0.077- 0.078in)
{cont'd}
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13-29
CountershaftAssembly
Clearance
Inspection(cont'dl
4.
6.
FEET.ER
GAUGE
. -]
lf the thicknessof 2nd gear is lessthan the standard,replace2nd gearwith a new one.
lf the thicknessof lst gear is within the standard,
replace1sv2ndsynchrohub with a new one.
lf the clearanceis more than the servicelimit. measurethe thicknessof the spacer.
Standard:29.07- 29.09mm (l.14il- 1.145inl
13-30
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Disassembly
1.
S e c u r e l yc l a m p t h e c o u n t e r s h a f ta s s e m b l yi n a
benchvisewith wood blocks.
4.
CHISEL
SPRIiIGWASHEF
BETICH
vtsE
W(X)DBLOCKS
2.
FRICTIONDAMPER
Inspectlor wear and damage.
Raisethe locknuttab from the groove in the countershaft,then remove the locknut and the spring
washer.
Removethe ball bearingusinga pressas shown.
5.
S u p p o r t l s t g e a r o n s t e e l b l o c k s ,a n d p r e s st h e
out of 3rd gear.
countershaft
PRESS
3RD GEAR
1STGEAR
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13-31
CountershaftAssembly
Inspection
1.
I n s p e c t h e g e a r s u r f a c ea n d b e a r i n gs u r f a c eI o r
wear and damage,then measurethe countershaft
at pointsA, B, and C.
A: 36.000- 36.015mm
- f.ill79 inl
11.,1173
B: 36.98/t- 37.000mm
{r.4561- 1.4567inl
C: 24.987- 25.000mm
- 0.9843inl
{0.98:17
Limit:
Servics
A:35,95mm (1.'115
in)
B: 36.93mm (1.454in)
C: 24.94mm (0.982in)
2.
Inspectfor runout.
Standard:
0.02 mm 10.0008inl max.
ServiceLimit: 0.05 mm {0.002inl
Standa.d:
N O T E :S u p p o r tt h e c o u n t e r s h a fat t b o t h e n d s a s
shown.
Rotatetwo completerevolutions.
lf anv part of the countershaftis lessthan the service limit.reolaceit with a new one.
13-32
www.emanualpro.com
Reassembly
Notetheseitemsduring reassembly:
. Pressthe 3rd, 4th, and sth gear on the countershaft
without lubrication.
. When installingthe 3rd, 4th. and sth gears,suppon
the shaft on steelblocksand installthe gearsusinga
press.
. Referto page 13-28for reassemblysequence.
1.
2.
OUTER
----.-4O)
orn,leen
rnrcrroru
lST GEAR
NEEDLEBEARING
3.
THRUSTSHIM
lST/2ND
(cont'd)
www.emanualpro.com
13-33
CountershaftAssembly
(cont'dl
Reassembly
4.
Reassembly
the frictiondamperon the spacerusing
the sDecialtoolsand a Dress.
6.
PRESS
ATTACHMENT,
U2t 47 mfi
07716- 0010300
3ROGEAR
FRICTIONDAMPER
Inspectfor wear and
damage.
7.
PRESS
ATTACHMENT,
35 mm LD.
07746- 0030,100
GROOVE
13-34
www.emanualpro.com
8.
PRESS
DRIVER,40 mm l.D.
07715- 0030300
DRIVER.40 mm LD.
07746- 0030100
ATTACHMENT,
30 mm LD.
077a6- 0030300
ATTACHMENT,
30 mm LD.
077,16- 0030300
I n s t a l lt h e n e e d l eb e a r i n gu s i n g t h e s p e c i a tl o o l s
and a press,then installthebearingouter race
PRESS
1 1 .S e c u r e l yc l a m p t h e c o u n t e r s h a f ta s s e m b l yi n
benchvisewith wood blocks.
LOCKNUT
Replace.
I
DRIVER.40 mm l.D.
077{6 - 0030100
ATTACHMENT,
30 mm l.D.
07746- 0030300
NEEDLE
BEASING
wooD slocKs
12. Installthe springwasher.
Installthe new locknutto the correcttorque, then
stakethe locknuttab into the groove.
Torque:127+ 0 + 127N.m 113- 0 +13 kgf.m,
94+0-94|bf.ft)
www.emanualpro.com
13-35
SynchroSleeve,SynchroHub
Inspection
1.
Installation
I n s t a l le a c h s y n c h r oh u b i n i t s m a t i n gs y n c h r o
sleeve,and checkfor freedomof movement.
N O T E :l f r e p l a c e m e ni ts r e q u i r e d a, l w a y sr e p l a c e
the synchrosleeveand synchrohub as a set.
SYNCHRO
SLEEVE
SYNCHRO
SYNCHBO
HUB
SYNCHBO
SI.EEVE
13-36
www.emanualpro.com
LONGER?EETH
SynchroRing,Gear
Inspection
1.
SYNCHROSPRING
SYNCHRO
CC
GOOOWORN
teeth
and matching
sleeve
Cr Inspectthe synchro
teethon the geartor wear (roundedoff).
,,\n
(-l
u
WORN
GOOO
D: Inspectthe gear hub thrustsurfacefor wear.
E: Inspectthe conesurfacelor wear and roughness.
F: Inspectthe teeth on all gearsfor unevenwear,
scoring,galling,and cracks.
2.
OUTERSYNCHRORING
www.emanualpro.com
13-37
Differential
lndex
BacklashInspection
1.
*THRUSTSHIM
Adiustment,Page13'41
P l a c e t h e d i f f e r e n t i a l a s s e m b l yo n V - b l o c k sa n d
install both axles.
PINIONGEARS
+BEARINGOUTERRACE
page13 40
Beplacement,
Inspectfor wear and damage.
*TAPEREDROLLER
BEARING
pagel3-39
Replacement,
Inspectfor wear and damage.
1 0x 1 . 0m m
103N.m {10.5kgf m, 75.9lbf.ft}
Left-handthreads
CARRIER
page13 38
Backlash
inspection,
lnspectfor cracks.
V-BLOCK
FINALDRIVENGEAR
page13-39
Replacement,
Inspectfor wear and damage
TRANSFERDRIVENGEAR
page13-39
Replacement,
Inspect{or wear and damage.
,,4\
W-
*TAPEREDROLLERBEARING
page13'39
Beplacement,
Inspectfor wear and damage.
IEEARINGOUTERRACE
page13-40
Replacement,
Inspectfor wear and damage.
.75 mm SHIM
13-38
www.emanualpro.com
2.
FinalDrivenGearRePlacement
L
TaperedRollerBearing
Replacement
Notetheseitems:
. T h e t a p e r e dr o l l e r b e a r i n ga n d b e a r i n go u t e r r a c e
shouldbe replacedas a set.
. Inspectand adiustthe taperedroller bearingpreload
wheneverthe taperedrollerbearingis replaced'
. Checkthe taperedrollerbearingsfor wear and rough
rotation.lf the taperedrollerbearingsare OK, removal is not necessary.
1.
1 0x 1 . 0m m
103N.m (10.5kgf m,75.9lbf'ftl
Left'handthreads
BEARING
BEARING
SEPAFATOB
{Commercially
FINALDRIVENGEAR
lnsoect{or weal and damage
TRANSFERORIVENGEAR
Inspectfor wear and damage.
www.emanualpro.com
IJ
ATTACHMENT,
,10x 50 mm
07LAD - PWs060l
13-39
Differential
BearingOuter RaceReplacement
Notetheseitems:
. The bearing outer race and tapered roller bearing
shouldbe replacedas a set.
. lnspectand adjustthe taperedroller bearingpreload
wheneverthe taperedrollerbearingis replaced.
'1.
2.
3.
Notetheseitemsduringbearingreplacement:
. Installthe bearingouter racesquarely.
. Check that there is no clearancebetween the
bearingouter race,thrust shim or 75 mm shim
and housing.
TRANSMISSION
HOUSING:
HANDI-E
07749 - 00 xxto
TRANSMISSION
HOUSING:
ATTACHMENT,
62x68mm
077ir6- 0010500
ATTACHMENT
52x55mm
07746- 0010400
THRUSTSHIM
BEARING
OUTERRACE
BEARING
OUIER RACE
THRUSTSHIM
CLUTCH
HOUSING:
HANDLE
07749 - 001tXX)o
CLUTCH
HOUSING:
ATTACHMENT.
72xt5mm
07745 - 00106{x)
OUTERRACE
75 mm SHIM
4,
13-40
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lnstalltheoil seal(seepage13-43).
TaperedRollerBearingPreloadAdiustment
After installingthe thrust shim, installthe bearing
outer race in the transmissionhousing (see page
13-40).
the tapered
lf any oJthe itemslistedbelowwere replaced,
be
adjusted.
preload
must
rollerbearing
.
.
.
o
.
.
Transmissionhousing
Clutchhousing
carrier
Differential
Taperedrollerbearingand bearingouter race
Thrustshim
75mm sham
1.
W i t h t h e m a i n s h a f ta n d c o u n t e r s h a f tr e m o v e d ,
i n s t a l lt h e d i f f e r e n t i a al s s e m b l y ,a n d t o r q u e t h e
clutchhousingand transmissionhousing.
NOTE:lt is not necessaryto use sealingagent betweenthe housings.
R e m o v et h e b e a r i n go u t e r r a c e a n d t h r u s t s h i m
from the transmissionhousing(seepage 13-40)'
NOTE:
. Do not reusethe thrust shim if the bearingouter
racewas drivenout.
. Let the transmissioncool to room temperatureil
the bearingouter race was removedby heating
the clutchhousing.
2.
4.
THRUSTSHIM
/A
07HAJ- PK4020'1
(cont'd)
www.emanualpro.com
13-41
Differential
TaperedRollerBearingPreloadAdjustment(cont'd)
7.
9.
THRUSTSHIM
Part Numbe.
41381- PX5 000
Thickness
1 . 9 0m m ( 0 . 0 7 4 i8n )
41383-PX5-000
1 . 9 3m m { 0 . 0 7 6 i0n )
'1.96mm (0.0772
in)
41384-PX5-000
1 . 9 9m m ( 0 . 0 7 8 i3n )
41385-PX5-000
2 . 0 2m m ( 0 . 0 7 9 i5n )
41386-PXs-000
2.05mm (0.0807in)
41387-PXs-000
2 . 0 8m m ( 0 . 0 8 1 i9n )
41388-PX5-000
2 . 1 1m m ( 0 . 0 8 3 i1n )
41389-PX5-000
2 . 1 4m m ( 0 . 0 8 4 i3n )
41390-PXs-000
2.'17mm (0,0854in)
2.20mm (0.0866in)
4'1392-PX5-000
2.23mm (0.0878in)
41393-PX5-000
2.26mm (0.0890in)
41394-PX5-000
2.29mm (0.0902in)
4 1 3 9 5P
, X s- 0 0 0
2.32mm (0.09'13
in)
41396-PX5-000
2.35mm (0.0925in)
41397-PX5-000
2.38mm (0.0937in)
4' t398-PXs-000
2.41mm (0.0949in)
41399-PXs-000
2.44mm (0.0961in)
41400-PXs-000
2.47mm (0.0972in)
41873-P16-000
1 . 6 6m m ( 0 . 0 6 5 i4n )
AC
41874-Pl6-000
41875 P16- 000
1 . 6 9m m ( 0 , 0 6 6 i5n )
'1.72mm (0.0677
in)
AD
41876-P16-000
1 . 7 5m m ( 0 . 0 6 8 i9n )
AE
41877-P16-000
1 . 7 8m m ( 0 . 0 7 0 1i n )
AF
41878-P16-000
41879-P16-000
3)
1 . 8 1m m ( 0 . 0 7 ' 1i n
'1.84
mm (0.0724in)
41880-P16-000
1.87mm {0.0736in)
AB
AH
8.
Recheckthe taperedrollerbearingpreload.
13-42
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TransmissionHousing:
1.
1.
OIL SEAL
Replace.
jn)
NOTE:Installoil sealup to i0.5 mm (10.02 from
transmissionhousingend surface.
CLUTCH
HOUSING
TRANSMISSION
HOUSING
PRESS
PRESS
HANOLE
- @1OCIO0
.--.'/'01119
DRIVERATTACHMENT
- PG4()r00
OIL SEAL
Replace.
PILOT,28x 30 mm
07JAO- PH80400
www.emanualpro.com
HANDLE
07749 - tx)l(xxto
DRIVERATTACHMENT
OTJAD- PHM1Ol
PILOT,28 x 30 mm
07JAD - PH8oaU)
13-43
TransferAssembly
lllustrated Index
ea/
g B
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,AC
O TRANSFERHOUSING
@ O-RINGReplace.
O DAMPERHUB
G) NEEDLEBEARING
G) TRANSFERDRIVENGEAR
G) TRANSFERSHAFT
O TAPEREDROLLERBEARINGOUTERRACE
@ TAPEREDROLLERBEARING
) TRANSFERSHAFTCOLLAR
@ THRUSTSHIM,25 mm selectivepart
6D TRANSFERDRIVEGEAR(HYPOIDGEAR)
@ CONICALSPRINGWASHERRePlace
SHAFTLOCKNUT.22x 1.25mm Left-handthreads,replace'
GDTRANSFER
BEARING
ROLLER
TAPERED
E)
BEARINGOUTERRACE
ROLLER
TAPERED
@
@ THRUSTsHlM. 68 mm selectivepart
O o.RlNG Replace.
@ TRANSFERCOVERA
GDTRANSFERCOVERB
@ O-RINGReplace.
) TRANSFERDRIVENGEARSHAFT(HYPOIDGEAR}
@ THRUSTSHIM,35 mm SelectivePart
@ TAPEREDROLLERBEARING
@ TRANSFEBSPACEBRepIace.
@ TAPEREDROLLERBEARINGOUTERRACE
@ TAPEREDROLLERBEARINGOUTERRACE
@)TAPEREDROLLERBEARING
@ olL SEALReplace.
@ COMPANIONFLANGE
@ O-RINGReplace.
@ BACK-UPRING
@ coNtcAL SPRINGWASHEBReplace.
(o TRANSFERDRIVENGEARSHAFTLOCKNUT,22x 1.25mm Replace.
TOROUESPECIFICATIONS
Boh/Nut No.
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Torque Value
Size
6A
8C
22L
12 N.m (1.2kgf.m.8.7lbf.ft)
24 N.m {2.4kgf.m,17 lbf'ft)
118N.m (12.0kgf.m,86.8lbf'ftl
6x1.0mm
8 x 1 . 2 5m m
2 2 x 1, 2 5m m
22H
1 3 2- 2 1 6N . m( 1 3 . 5- 2 2 . 0k g f ' m ,
97.6- 159lbf.ft)
2 2 x 1. 2 5m m
Remarks
Transfershaftlocknut:
Lett-handthreads
Transferdriven gear shaft locknut
Tighteningtorque:dePendingon
TotalStartingTorquevaiue
13-45
TransferAssembly
Inspection
N O T E : T o p r e v e n t d a m a g e t o t h e t r a n s f e rh o u s i n g ,
always use soft jaws or equivalentmaterialsbetween
the transferhousingand the vise.
S e t a d i a l i n d i c a t o ro n t h e c o m p a n i o nf l a n g e a s
shown.
DIALINDICATOR
TRANSFERDRIVEGEAR
COMPANIONFLANGE
2.
7.
4.
M e a s u r et h e s t a r t i n gt o r q u e ( c o m p a n i o nf l a n g e
side)usinga torquewrench.
STANDARD:
2.68- 3.47 N.m
{27.3- 35.4 kgf.cm.23.7- 30.7 tbt.in)
lf the measurementsor the tooth contact Dattern
are not within the standard.disassemblethe transfer assembly,replaceworn or damagedparts,and
reassembleit.
1 3 -4 6
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Disassembly
1.
3.
TRANSFER
TRANSFEF
Replace.
14 mm ALLENWRENCH
TAPEREDROLLER
BEARING
TRANSFERSHAFT
COLLAR
THRUSTSHIM,
25 mm
pan
Selective
TRANSFERDRIVE
GEAR
LOCKNUT
LOCKTAB
(cont'd)
www.emanualpro.com
13-47
TransferAssembly
Disassembly(cont'd)
Secure the transfer housing in a bench vise with
soft jaws.
COMPANION
FLANGE
HOLDER
07RAA-
7.
TRANSFER
ORIVEN
GEARSHAFT
I n s t a l lt h e s p e c i a lt o o l o n t h e c o m p a n i o nf l a n g e ,
then loosenthe transferdrivengearshaft locknut.
Removethe transferdrivengear shaft locknut,conical spring washer, back-upring, O-ring,and compsnionflange.
OIL SEAL
Replace.
TAPEREOROLIIR
AEARING
TRANSFERHOUSING
TRANSFERDRIVEN
GEARSHAFTLOCKNUT
Reolace,
13-4 8
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Replacement
TransferDrivenGearShaft
BearingReplacement
TransferDriveGearBearing
1.
1.
ATTACHMENT,
37x/Omm
07746- 0010200
SEPARATOR,
BEARING
o - 1112"
GEAR
SEPARATOR,
BEARING
0 - 1112'
available)
lCommercially
{ C o m m e r c i a l l ya v a i l a b l e )
ATTACHMENT,
40x50mm
07LAD - PW5lr601
www.emanualpro.com
13-49
TransferAssembly
TransferShaft Disassembly/
Reassembly
1.
TransferGoverA BearingOuter
RaceReplacement
BEARINGOUTERRACE
2.
BEARINGOUTERRACE
TRANSFERCOVERA
ATTACXMCNT,
52x68mft
07746- tD,t0500
13-50
www.emanualpro.com
TransferHousingBearingOuterRaceReplacement
NOTE:Coatall partswith MTFduring reassembly.
1.
ATTACHMENT,
62x68mm
07746- 0010500
ATTACHMENT,
62x68mm
07?a6- 0010500
ATTACHMENT,
52x55mm
07715- 0010400
TBANSFERHOUSING
I n s t a l lt h e n e w t a p e r e dr o l l e r b e a r i n go u t e r r a c e
usingthe specialtools and a press
DRIVER
07749- 0o1(xD0
J
i=
\ l
TRANSFERHOUSING
DRIVERATTACHMENT
www.emanualpro.com
BEARINGOUTER
RACE
13-51
TransferAssembly
Reassembly
Notetheseitemsduring reassembly:
. While reassembling
the transferassembly:
- Checkand adjustthe transfergeartooth contact.
- Measureand adjustthe transfergear backlash.
- Checkand adjustthe taperedroller bearingstartIng rorque.
. Coatall partswith MTFduring reassembly.
. R e p l a c et h e t a p e r e dr o l l e rb e a r i n ga n d t h e b e a r i n g
outer raceas a set if eitherpart is replaced.
. Replacethe transferdrive gear and the transferdriven gear shaftas a set if eitherpart is replaced,
EXAMPLE:
C: EXISTING35 mm
THRUSTSHIM
Thicknoss:C=1.05mm
X: REPLACEMET{T35
mm
THRUSTSHIM
Thickness:X=??mm
Number: A=+2
Number: B-l
Outlineof Assembly
1.
Selectthe 35 mm thrustshim.
Performthis procedureif the transler driven gear
shaft or the tapered roller bearingon the transfer
drivengearshaft is replaced.
2.
Preassemble
the parts to checkand adjust transfer
gear backlashand transfergeartooth contact.
3.
4.
5.
6.
A: EXISTINGTRANSFER
DRIVENGEARSHAFT
B: REPLACEMENT
TRANSFER
DRIVENGEAFSHAFT
C a l c u l a t teh e t h i c k n e s so f t h e 3 5 m m t h r u s ts h i m
usingthe formulabelow.
ronrvruu:fi--fr-+c=x
A: Numberon the existingtransferdrivengearshaft
B: Numberon the replacement
transferdriven gear
shaft
C: Thicknessofthe existing35 mm thrustshim
X : T h i c k n e s sn e e d e df o r t h e r e p l a c e m e n3t 5 m m
thrustshim
Shim No.
c
E
F
n
N O T E : T h e n u m b e r o n t h e t r a n s f e rd r i v e n g e a r
shaft is shown in 1/100mm.
13-52
www.emanualpro.com
Part Number
41361- PS3- 000
41362-PS3-000
41363-PS3-000
41364-PS3-000
Thickness
0.72 mm (0.028in)
0.75 mm (0.030in)
0.78 mm (0.031in)
0.81 mm (0.032in)
41365-PS3-000
0.84 mm (0.033in)
4 r 3 6 6 - P S 3 - 0 0 0 0.87 mm (0.034in)
41367-PS3-000
0.90 mm (0.035in)
4 1 3 6 8 - P S 3 - 0 0 0 0.93 mm (0.037in)
4 1 3 6 9 - P S 3 - 0 0 0 0.96 mm {0.038in)
4 1 3 7 0 - P S 3 - 0 0 0 0.99 mm (0.039in)
41371- PS3- 000
1.02mm (0.040in)
4 1 3 7 2 - P S 3 - 0 0 0 1 . 0 5m m ( 0 . 0 4 1i n )
4 1 3 7 3 - P S 3 - 0 0 0 1.08mm (0.043in)
41374-PS3-000
1 . 1 1m m ( 0 . 0 4 4i n )
5.
2.
TRANSFER
HOUSING
6,
DRIVEN
TRANSFER
GARSHAFT
Installthecompanionflange.conicalspringwasher,
and locknut on the transfer driven gear shaft. Do
n o t i n s t a l lt h e O - r i n ga n d t h e b a c k - u pr i n g o n t h e
transfergearshaft in this step.
TRANSFERHOUSING
3.
DRIVER
077/tg - 001qt00
OIL SEALDRIVER
ATTACHMENT
07JAD- PH80101
CONICALSPRING
WASHER
direction.
COMPANION
FLANGE
Replace.
TAPEREDROLLER
BEARING
I n s t a l lt h e n e w o i l s e a l o n t h e t r a n s f e r h o u s i n g
usingthe specialtools.
www.emanualpro.com
(cont'd)
13-53
TransferAssembly
(cont'd)
Reassembly
7.
S e c u r et h e t r a n s f e rh o u s i n gi n a b e n c hv i s e w i t h
soft jaws, then installthe specialtool on the companion flange. To preventdamageto the transfer
housing,alwaysuse soft jaws or equivalentmaterials betweenthe transferhousingand the vise.
COMPANION
FLANGE
HOLDER
07RAB- 0020000
9.
TRANSFER
WRENCH
8.
T i g h t e nt h e l o c k n u tw h i l e m e a s u r i n gt h e s t a r t i n g
torque so the starting torque is within 0.98 - 1.39
N.m {10.0- 14.2kgf.cm.8.68- 12.3lbf.in).
THRUSTSHIM.
25 mm
Selectivepart
COLLAR
NOTE:
. C o a t t h e t h r e a d so f t h e l o c k n u t ,a n d t h e s h a f t
with MTFbeforeinstallingthe locknut.
. Do not stakethe locknutin this step.
STARTINGTOROUE:
0.98- 1.39N.m
(10.0- 14.2kgf.cm,8.68- 12.3lbf.in)
www.emanualpro.com
TRANSFERDRIVE
GEAR
Replace.
CONICALSPRING
WASHER
Replace.
'14.
FLANGE
COMPANION
lil mm ALLENWRENCH
NOTE:
. The transfershaft locknuthasleft-handthreads,
. Do not stakethe locknutin this step.
l f t h e m e a s u r e m e n ti s n o t w i t h i n t h e s t a n d a r d ,
removethe transfershaft locknutand replacethe 25
m m t h r u s t s h i m . S e l e c ta n d i n s t a l la n e w 2 5 m m
Do not
thrust shim. then recheckthe measurement.
use more than one 25 mm thrust shim to adjustthe
transfergear backlash,
THRUSTSHlM,25mm
1 1 .Tightenthe transfershaftlocknut.
rl0ustNG
Shim No.
Thickness
29416-PlC-000
2
3
7
8
'10
11
TRANSFERCOVERA
Part Numbel
in
2 9 4 1 r- P 1 C- 0 0 0 1.70mm 10.067
'L73
mm (0.068in
29412-PlC-000
2 9 4 1 3 - P 1 C - 0 0 0 1.76mm (0.069in
2 9 4 1 4 - P l C - 0 0 0 1.79mm (0.070in
2 9 4 1 5 - P 1 C - 0 0 0 1.82mm (0.072in
12
13
l4
16
17
'18
19
1.85mm (0.073in
2 9 4 ' 1 7 - P r C - 0 0 0 1.88mm (0.074in
2 9 4 ' 1 8 - P 1 C - 0 0 01 . 9 1m m ( 0 . 0 7 5i n )
2 9 4 1 9 - P l C - 0 0 0 1.94mm (0.076in)
2 9 4 2 0 - P 1 C - 0 0 0 1.97mm 10.078in)
29421- P1C- 000 2.00mm (0.079in)
29422-P1C - 000 2.03mm (0.080in)
2 9 4 2 3 - P 1 C - 0 0 0 2.06mm (0.081in)
2 9 4 2 4 - P 1 C - 0 0 0 2.09 mm (0.082in)
29425-P'tC-000 2 . 1 2m m ( 0 . 0 8 3i n )
2 9 4 2 6 - P 1 C - 0 0 0 2 . 1 5m m ( 0 . 0 8 5i n )
29427-P1C-000
2 . 1 8m m { 0 . 0 8 6i n )
2 9 4 2 8 - P 1 C - 0 0 0 2.21 mm {0.087in)
2 9 4 2 9 - P 1 C - 0 0 0 2.24 mm 10.088in)
8xL25mm
24 N.m (2.4kgt.m. 17 lbnftl
(cont'd)
www.emanualpro.com
13-55
TransferAssembly
(cont'dl
Reassembly
16. Apply PrussianBlue to both sides of the transfer
gearteeth lightlyand evenly.
TRANSFERDRIVEGEAR
INCORRECT
IOOTH CONTACTPATTERN
TOECONTACT
Toe Contact
U s e a t h i c k e r3 5 m m t h r u s t s h i m t o m o v e t h e
transferdriven gear shaft toward the transferdrive
gear. Becausethis movement causesthe transfer
gear backlashto change,move the transfer drive
gear away from the transfer driven gear shaft to
adjustthe transfergearbacklash
asiollows;
. I n c r e a s et h e t h i c k n e s so f t h e 2 5 m m t h r u s t
shim.
. R e d u c et h e t h i c k n e s so f t h e 6 8 m m t h r u s t
shim bv the amount of increasedthicknessof
the 25 mm thrustshim.
Heol Contact
Use a thinner 35 mm thrust shim to move the
transfer driven gear shaft away from the transfer
drive gear. Becausethis movement causesthe
transfer gear backlashto change,move the transfer drive gear toward the transferdriven gear shaft
to adjustthe transfergear backlashas follows:
. R e d u c et h e t h i c k n e s so f t h e 2 5 m m t h r u s t
s hi m .
a I n c r e a s et h e t h i c k n e s so f t h e 6 8 m m t h r u s t
shim by the amount of reducedthicknessof
t h e 2 5 m m t h r u s ts h i m .
HEELCONTACT
FLANKCONTACT
FACECONTACT
13-56
www.emanualpro.com
Flank Contact
Use a thinner thrust shim to move the transfer
drive gear toward the transferdriven gear shaft.
Flankcontactmust be adtustedwithin the limits
o f t h e t r a n s f e rg e a r b a c k l a s h l. f t h e b a c k l a s h
e x c e e d st h e l i m i t s , a d j u s t a s d e s c r i b e du n d e r
HeelContact.
FaceContsct
Use a thickerthrust shim to move the transfer
drive gear away from the transfer driven gear
shaft. Facecontactmust be adjustedwithin the
limits of the transjergear backlash.lf the backl a s h e x c e e d st h e l i m i t s , a d j u s t a s d e s c r i b e d
underToe Contact.
TRANSFERDRIVEN
TRANSFERHOUSING GEARSHAFT
TRANSFERSPACER
Installin this direction.
TRANSFER
TAPEREDROLLER
BEARING
TRANSFERSHAFT
COLLAR
TMNSFER DRIVE
GEAR
THRUSTSHIM,25 mm
Selectivepart
CONICALSPRING
WASHER
Replace.
LOCKNUT
Replace.
Transter Driven Gear Shaft Starting Torque Inspection
and Adlustment
21. Securethe transfer housing in a bench vise with
soft iaws.
COMPANIONFLANGEHOLDER
O.RING
COMPANION
FLANGE
CONICALSPRING
WASHER
Replace.
BACK.UP
22. I n s t a l lt h e s p e c i a lt o o l o n t h e c o m p a n i o nf l a n g ,
LOCKNUT
Replace.
www.emanualpro.com
13-57
TransferAssembly
(cont'dl
Reassembly
26. Securethe transfer housing in a bench vise with
soft jaws.
COMPANION
FLANGE
HOLDER
07RAB- 002tD00
0.7- 1.2mm
(0.03- 0.05 inl
PUNCH
3 . 0 - 3 . 5m m
- 0.1ainl
10.12
Point to be
staked.
NOTE:
. Coatthe threadsof the locknutand transfershaft
with MTFbeforeinstallingthe locknut.
. lnstallthe conicalspringwasher in the direction
snown.
STARTINGTOROUE:
0.98- 1.39N.m
{10.0- 1i1.2kgf.cm,8.68- 12.3lbf in}
TIGHTENINGTOROUE:
132- 216 N.m
(13.5- 22.0kgf.m,97.6- 159lbf.ft)
NOTE:
. R o t a t et h e c o m p a n i o nf l a n g e s e v e r a lt i m e s t o
seatthe taperedrollerbearing,then measurethe
startrngtorque.
. l f t h e s t a r t i n gt o r q u e e x c e e d s1 . 3 9 N . m ( 1 4 . 2
kgf.cm, 12.3 lbf.in), .eplacethe transfer spacer
a n d r e a s s e m b l et h e p a r t s . D o n o t a d j u s t t h e
torquewith the locknutloose.
. l f t h e t i g h t e n i n gt o r q u ee x c e e d s2 1 6 N . m ( 2 2 . 0
kgf.m,159 lbf'ft),replacethe transferspacerand
reassemble
the parts.
. W r i t e d o w n t h e m e a s u r e m e no
t f the starting
torque: it is used to measurethe total starting
torque.
TMNSFER SHAFT
ASSEMBLY
TRANSFERHOUSING
TAPEREDROLLER
BEARING
TRANSFERSHAFT
COLLAR
TRANSFERDRIVE
GEAR
THRUSTSHIM,25 mm
Selectivepart
CONICALSPRING
WASHEB
Replace.
LOCKNUT
Replace.
www.emanualpro.com
TOROUE:118N.m (12.0kgt'm,86.8lbf'ft)
TRANSFERCOVERA
l E
/Eh
v
14 mm ALLENWRENCH
5t.
/E\
\g
8 x 1.25 mm
24 N.m (2.4kg{ m, 17 lbtftl
PUNCH
3.0- 3.5 mm
{0.12- 0.14inl
TOROUEWRNCH
(cont'd)
www.emanualpro.com
13-59
TransferAssembly
(cont'd)
Reassembly
3 5 . RemovetransfercoverA.
THRUSTSHIM,68 mm
Shim No.
Part Number
Thickne3s
zv
23914-P1C-020
zw
23975-P1C-020
23916 PlC -020
23917-P1C-O20
1.41mm (0.056in)
'1.44mm
in)
10.057
'1.47mm (0.058in)
1.50mm (0.059in)
1.53mm (0.060in)
zx
ZI
zz
23978-PlC-020
23941- PW5 000
1.56mm {0.061in)
1.59mm (0.063in)
2 3 9 4 3 - P W 5 - 0 0 0 't.62mm (0.064in)
23944 PW5- 000
1.65mm (0.065in)
2 3 9 4 5 - P W s - 0 0 0 1.68mm (0.066in)
23946-PW5-000
23947-PW5-000
23942-PWs-000
c
D
HEAT GUN
1.71mm 10.067
in)
'1.74mm
in)
10.069
23948-PWs-000
1.77mm (0.070in)
2 3 9 4 9 - P W s - 0 0 0 1.80mm (0.071in)
2 3 9 s 0 - P W 5 - 0 0 0 1.83mm (0.072in)
23951- PW5- 000
1.86mm (0.073in)
23952-PWs-000
COVERA
1.89mm {0.074in)
2 3 9 s 3 - P W s - 0 0 0 1.92mm {0.076ini
N
23954-PW5-000
23955-PW5-000
23956- PW5, 000
o
R
T
U
2.01mm (0.079in)
2 3 9 5 7 - P W s - 0 0 0 2.04mm (0.080in)
2 3 9 5 8 - P W s - 0 0 0 2.07mm (0.081in)
23959-PW5-000
BEARINGOUTERRACE
1.95mm (0.077in)
1.98mm (0.078in)
23960-PW5-000
23961- PW5- 000
23962-PW5-000
2.10mm (0.083in)
2.13mm (0.084in)
2.16mm (0.085in)
2.19mm (0.086n)
2 3 9 6 3 - P W s - 0 0 0 2.22 mm (0.087 n)
X
23964-PWs-000
2.25mm (0.089n)
2 3 9 6 5 , P W s - 0 0 0 2.28mm 10.090n )
23966-PW5-000
2.31mm {0.091in)
2 3 9 6 7 - P W s - 0 0 0 2.34mm (0.092in)
23968-PWs-000
AC
AD
2 3 9 6 9 - P W s - 0 0 0 2.40mm {0.094in}
M
BZ
cz
13-60
www.emanualpro.com
2.37mm (0.093in)
AB
23970-PW5-000
23941- PW8- 000
23942-PW8-000
DZ
23943-PW8-000
23944-PW8-000
EZ
23945-PW8-000
2.43mm (0.096in)
2.46mm {0.097'n}
2.49mm (0.098in)
2.52mm {0.099ini
2.55mm (0.100in)
2 . 5 8m m ( 0 . 1 0 i2n i
3 8 . I n s t a l lt h e 6 8 m m t h r u s t s h i m u s i n g t h e s p e c i a l
tools.
DRIVER
077 - 001(xno
4 0 . C o a t t h e n e w O - r i n g sw i t h M T F , i n s t a l lt h e m o n
transfercoversA and B, then installthe coverson
the transferhousing.
6x1.0mm
12 N.m 11.2kgf.m,
8.7 tbt.ft)
TRANSFERCOVERB
TRANSFER
THRUSTS1{IM,
68 mm
Selectivepart
BEARINGOUTERBACE
ATTACHMENT.
62x68mm
077a6 - (x)10500
O.RING
Replace.
O.BING
Replace.
TRANSFER
COVERA
8 r 1.25mm
2,r N.m (2.4 kgl.m. 17 lbtft)
www.emanualpro.com
13-61
MainshaftBearing/OilSeal
Replacement
1.
3.
ATTACHMENT,
12x 17 .nfi
07746- 0010300
- ,10mm
PULLER.25
07736- A01000A
ATTACHMENT.
62x68mm
07746- 0010500
BALLBEARING
13-62
www.emanualpro.com
GountershaftBearing
Replacement
1.
Replace.
CLUTCHHOUSING
HETAININGPLATE
ATTACHMENT,
62x88mm
07746- 0t!105q)
NEEDII AEARING
CLUTCHTIOUSING
^'
ADJUSTABI.fBEARING
PULLER,25- 40 mm
07736- A01(x)04
6x1.0mm
12 N.m (1.2 kgt m,8.7 lbtftl
NEEDLEBEARING
www.emanualpro.com
13-63
MainshaftThrustClearance
Adjustment
l.
5,
78 mm SHIM
END ot CLUTCHHOUSING
BEARING
NOTE:
. Usea straightedgeand verniercaliper.
. Measureat three locationsand averagethe readIng.
ENDot
TRANSMISSION
MAINSHAFT
-3. Takethis number and compareit to the availableshim sizesin the chart.
WASHER
(Forexample)
3RD/4THSYNCHROHUB
SPACERCOLLAR
sTH SYNCHROHUB
SPACER
BALLBEARING
13-64
www.emanualpro.com
A: 2.39
+ Bi O.22
2.61
- 0.93
= 1.68
2.61
7,
78 mm SHIM
c
u
F
G
H
K
L
M
N
X
z
AB
AD
AE
AH
AI
AJ
AK
AN
Part Numbor
23941- P16- 000
23942-P16-000
23943-P16-000
23944-Pt6-000
23945-P16-000
2 3 9 4 6 -P 1 6- 0 0 0
23947-P16-000
23948-P16-000
23949-P16-000
23950-P16-000
23951- P16- 000
23952-Pl6-000
23953-P16-000
23954-P16-000
23955-P15-000
23956- P16- 000
23957-P16-000
2 3 9 5 8 -P 1 6- 0 0 0
23959-P16-000
23960-P16-000
23961- P16- 000
23962-P16-000
23963-P16-000
23964-P16-000
23965-P16-000
23966-Pl6-000
23967-Pl6-000
23968-P16-000
23969-Pl6-000
2 3 9 7 -0 P l 6 - 0 0 0
23971- P16- 000
23972-P16-000
23973-P16-000
23974-P16-000
23975-P16-000
23976-Pl6-000
23977-P16-000
23978-Pl6-000
23979-Pl6-000
23980-P16-000
Thickness
1.20mm (0.0472in)
1.23mm (0.0484in)
'1.26mm (0.0496in)
in)
1.29mm (0.0508
1.32mm (0.0520n )
1.35mm (0.0531n )
1.38mm {0.0543n )
1.41mm (0.0555n )
1.44mm (0.0567in)
1.47mm (0.0579in)
N O T E : M e a s u r e m e nst h o u l d b e m a d e a t n o r m a l
room temperature.
-1. Installthe 78 mm shim selectedand oil guide
platein the transmissionhousing.
78 mm SHIM
OIL GUIDEPLATE
1.50mm {0.0591in}
in)
1.53mm (0.0602
1.56mm (0.0614in)
1.59mm (0.0626in)
in)
1.62mm (0.0638
1.65mm (0.0650in)
1.68mm (0.066'tin)
1 . 7 1m m ( 0 . 0 6 7 i3n )
- 2 . I n s t a l lt h e s p r i n g w a s h e ra n d w a s h e ro n t h e
1.74mm {0.0685in)
1.77mm {0.0697inl
ball bearing.
in)
1.80mm (0.0709
in)
1.83mm (0.0720
'1.86mm (0.0732
in)
NOTE:
. Cleanthe spring washer,washerand thrust
shim thoroughlybeforeinstallation.
. Installthe spring washer,washerand thrust
shim properly.
1.89mm (0.0744in)
1.92mm (0.0756in)
1.95mm (0.0768in)
in)
1.98mm (0.0780
in)
2.01mm (0.0791
in)
2.04mm (0.0803
n)
2 . 0 7m m { 0 . 0 8 1i 5
2.10 mm {0.0827in}
in)
2.13mm (0.0839
WASHER
SPRTNG*ASHER
,-g
2.16 mm (0.0850in)
in)
2.19mm (0.0862
4 inl
2.22mm 10.087
in}
2.25mm {0.0886
2.28mm {0.0898
in)
in)
2.31mm (0.0909
2.34mm (0.0921
in)
2.37mm (0.0933
in)
www.emanualpro.com
13-65
MainshaftThrustClearance
Adjustment(cont'dl
-7. Slidethe mainshaftbaseoverthe mainshaft.
DIALGAUGE
07GAJ- PG20130
t--E-H
lf\f,A\
l\.
xex
l"\y
I aors
t____=__)"n-____"8
\
MAINSHAFT
HOLDER
07GAJ- PG20110
MAINSHAFT
EASE
07GAJ- PG20130
-9. Seatthe mainshaftfully by tappingits end with
a plastichammer.
-10. Threadthe mainshaftholder bolt in until it just
c o n t a c t st h e w i d e s u r f a c eo f t h e m a i n s h a f t
base.
- 1 1 . Z e r oa d i a lg a u g eo n t h e e n d o f t h e m a i n s h a i t .
www.emanualpro.com
MAINSHAFTHOLDER
07cru - PG20110
TransmissionAssembly
Reassembly
1.
4.
ASSEMBLY
DIFFERENTIAL
model
THRUSTWASHER
COLLER
5x1.0mm
15 N'm 11.5kgt.m, 11 lbf.ftl
Tapethe mainshatt
splines.
REVERSE
SHIFTHOLDER
(cont'd)
www.emanualpro.com
13-67
TransmissionAssembly
Reassembly(cont'dl
6.
10. Apply liquid gasket (P/N 08718- 0001 or 087180003)to the selectspring bolt threads,then install
the selectspringbolt.
SELECTSPRINGBOLT
39 N.m la.o kgf'm,29lbtft)
LOCKCAM
REVERSE
7.
l n s t a ltl h e o i l s e a l .
HANDLE
07749- 001mO
ATTACHMENT,
32x35mm
07745- 0010100
'I1. I n s t a l tl h e o i l g u i d e M p l a t e . 7 8m m s h i m ,
and oil
guner platein the transmissionhousing.
N O T E : S e l e c tt h e 7 8 m m s h i m a c c o r d i n gt o t h e
measurements
madeon page13-64,
OIL SEAL
Replace.
SELECTBETURN
SPRING
5TH/REVERSE
SELECTRETURN
SPRINGPIN
Replace.
SELECT
ARM
9.
Installthe
s e l e ca
t r m a n ds p r i n gp i n .
13-68
www.emanualpro.com
12. Apply liquid gasketto the surfaceof the transmission housingas shown.
Notetheseitems:
. Use liquid gasket(P/N 08718- 0001 or 087180003).
. Removethe dirty fluid from the sealingsurface.
. Sealthe entirecircumterence
of the bolt holesto
preventfluid leakage.
. lf 20 minutes have passedafter applying liquid
gasket,reapplyit and assemblethe housings.
a Allow it to cure at least20 minutesafter assembly betorefillingthe transmissionwith MTF.
SNAPRINGPLIERS
DOWELPINS
SNAPRING
vk..*,
SHIFTFORK
Align point
www.emanualpro.com
13-69
TransmissionAssembly
Reassembly
lcont'd)
18. Installtransmission
hanger,then tightenthe bolts in
a crisscrosspatternin severalstepsas shown.
8 x 1.25mm bolis: 27 N.m 12.8kgf.m,20 lbf'ft}
2 0 . I n s t a l lt h e s t e e l b a l l s ,s p r i n g s .w a s h e r s ,s e t b a l l
screws,back-uplight switch.
WASHER
Replace.
STEELBALL
D,5/16 in
TRANSMISSION
HANGER
SPRINGL.26.1mm 11.03inl
VEHICI."ESPEEDSENSOR
DRAINPLUG
39 N.m {4.0kg{.m,29lbtftl
WASHER
Replace.
13-70
www.emanualpro.com
8 x 1.25mm
22 N.m 12.2kgl.m, 16 lbt.ftl
WASHER
22. Turn the selectlever and shift arm shaft counterclockwise,then insertthe shift arm shaft.
EOLT
INTERLOCK
39 N.m (4.0kqt ft, 29 lbf ft)
SELECTARM
SHIFTARM COVERASSEMBLY
-->.-
10 x 12 mft DOWELPIN
SHIFTARM A
I x 1.25mm
27 N m 12.8kgtm,20 lbf'ft)
SHIFTARM SHAFT
t1
Installthe transferassemblY.
N O T E : L u b r i c a t eM T F t o t h e O - r i n g a n d c o n t a c t
areas.
10x 1.25mm
44 N.m 14.5kgf.m,33 lbl.ftl
www.emanualpro.com
13-71
TransmissionAssembly
Installation
1.
5.
P l a c et h e t r a n s m i s s i o no n t h e t r a n s m i s s i o nj a c k ,
and raiseit to the enginelevel.
6.
TRANSMISSION
MOUNTINGEOLT
12x 1.25mn
64 N.m {6.5
47 tbt.ft)
REARENGINEMOUNNNG BOLTS
Replace.
Itl x 1.5mm
8:l N.m 18.5kgt m, 61 lbf.ft)
RELEASE
BEARING
(P/N 087989002)
7.
RELEASE
FORK
BOOT
(P/N08798- 9002)
'1.0
- 1.6g {0.0,10.06o2l
?
10x 1.25mm
4{ N'm (4.5 kgf.m,
32 tbf.ftl
13-72
www.emanualpro.com
8.
RIGHTFRONT
MOUNT/BBACKET
10r 1.25mm
39 ttm 14.0kgf.m,
29 tbt ftl
SETRING
Replace.
10 x 1.25mm
4,aN.m (4.5kgf m,
33 tbf ftl
Install the clutch housing cover and rear engine
stiffener.
SHAFT
INTERMEOIATE
1 2 . l n s t a l l t h e d r i v e s h a f t s( s e e s e c t i o n 1 8 ) . W h i l e
in the differential,be sure
installingthe driveshaft(s)
not to allow dust and otherforeignpaniclesto enter
the transmission.
DRIVESHAFT
6xl0mm
12 N.m 11.2kgt.m.
8.7 tbf.ft)
HOUSING
'12x 1.25mm
29 N.m 13.0kgf.m.22 lbf'ft)
8 x 1.25mm
24 N.m {2.5 kgf'm'
18 tbl.ft)
SET RING
Replace.
10 x 'l .25 mm
44 N.m {4.5kgf m,33 lbf ftl
(cont'd)
www.emanualpro.com
13-73
TransmissionAssembly
Installation(cont'dl
13. Installthe balljoints onto the lower arms.
DAMPERPINCHBOLT
10 x 1.25mm
43 N.m {a.a kgf.m,
32 rbfft)
GASKETS
Replace.
HO2SCONNECTOR
SELF.LOCKINGNUT
'12x 1.25|nm
6il N'm 16.5kgtin, 47 lbtftl
Reolace.
Replace.
10 x 1.25mm
5,1N.m15.5kgtm.
() tbt fil
Replace.
12x 1.25mm
,19- 59 N.m
(5.0- 6.0kgi.m,36 - lbfttl
SELF.LOCKING
8 x 1.25rr|ln
22 N.m (2.2 tgf.m, 16 lbl.ftl
Replac6.
NUT
SELF.LOCKING
8 x 1.25mm
16 N.rn 11.6kg{.m,
12lbtfr)
Replace.
GASKET
Replace.
'17.
REFERENCEMARKS
E x 1.25mr'|
SPLASHSHIEI.I)
I x 1.25mm
24 N.m l2.a kgf.m.
17 tbtft)
GUARDBAR
6x1.0mm
9.8 N.m (1.0 kgf.m,7.2 lbf.ft)
PROPELI"ER
SHAFT
13-74
www.emanualpro.com
TRANSFER
8 x 1.25mm
27 N.m (2.8 kgt'm. 20 lbtftl
COTTERPIN
Rplace.
STEEL
WASHER
COTTENPIN
Replace.
STEEL
WASHER
PLASTIC
WASHER
12 x 1.25mm
6it N.m 16.5kgf m,
il7 lbf.ftl
SELECT
CABLE
------------,-
VSS CONNECTOR
HARNESSCLAMP
(cont'd)
www.emanualpro.com
13-75
TransmissionAssembly
(cont'dl
Installation
24. Connectthe startercablesand transmissionground
caore.
6x1.0mm
9.8 N.m (1.0kg{.m,
7.2 tbt.ttl
TRANSMISSION
GROUND
CABLE
2 7 . I n s t a l lt h e i n t a k ea i r d u c t a n d a i r c l e a n e rh o u s i n g
(seesection5),
28. Connectthe positive(+) cablefirst. then the negative (-) cableto the battery.
8 x 1.25mm
22 N.m 12.2kgi-m,
16 tbr.f0
CI-UTCHHOSE
BRACKET
6x1.0mm
9.8 N.m {1.0kgf.m,
7.2 rbf.ftt
_G1
13-76
www.emanualpro.com
GearshiftMechanism
Overhaul
Notetheseitemsl
. InsDectrubberpartsfor wear and damagewhen disassembling'
. Checkthat the new cotterpin is seatedfirmly.
. Be carelulnot to damagethe guide pipe when removingthe cables'
CHANGELEVERKNOS
8 N.m (0.8kgl.m, 5.8 lbf.ft)
COTTEFPIN
CABLE
SELECT
PLATES
Replace.
WASHEB
(PlN
I
I
curur
I
\ \"1I a,I
?-@ -.4'
-(
I
Guidepipe in the
\
GUIDEPIPES
DOOI,
SHIFTCABLE
PLASTICWASHER
6 x 'l.0mm
9.8 N.m {1.0 kgf.m, 7.2 lbf.ftl
(stLlcoNE
GREASEI
LEVERASSEMBLY
8 x 1.25mm
13 N.m 11.3kgt'm,9.4lbfft)
FLOATING
COLLAR
www.emanualpro.com
13-77
AutomaticTransmission
14'2
.
S p e c i a lT o o l s
Oescription
. .... 143
G e n e r aO
l peration
'14_6
.
. ..
Power Flow
.
.
.
1
4
_15
.
.
.
.
.
.
S
y
s
t
e
m
E l e c t r o n iC
control
.. 14 24
H y d r a u l i cC o n t r o l
..
.. . 14_29
H y d r a u l i cF l o w . . . . - . . . . . . . . . . . .
.'t4'39
..
Lock'upSyslem
Electrical System
14 45
ComponenlLocdlrons
P C M C i r c u i l D r a g r a m( A / T C o n t r o l S v s t e m )
'97
.14-46
- . ...
M o d e l . . . . . . . . . . . . . . . . . . . . . ... . .
' 9 8 M o d e .l . . . . . . . . . . . . .. . . . . . .
.1450
.. ..
'99 00Models.... ....
1452
.
.
.
P C M T e r m i n a l V o l t a g e / M e a s u r i n gC o n d i t i o n s
..14'48
......
A"/T
C o n t r oSl y s t e m - ' 9 7 M o d e l
14 54
00 Models . . .. . .
A , / TC o n t r o l S y s t e m - ' 9 8
... - 14_56
.....
T r o u b l e s h o o t i nPgr o c e d u r e s. .
Svmotom to comoonent Charl
14 60
.
E i e c t r , c aS
l yslem -'97 Model .
14_62
E l e c t r i c aS
l y s t e m - ' 9 8 - O OM o d e l s . . . . .
E l e c t r i c aTl r o u b l e s h o o t i n g( ' 9 7 M o d e l )
T r o u b l e s h o o t i nFgl o w a h a r t s. . . . . . . . . . . . . . 1 4 _ 6 4
E l e c t r i c aT
l r o u b l e s h o o t i n g( ' 9 8 - 0 0 M o d e l s )
T r o u b l e s h o o t i nFql o w c l t " n " . . . . . . . . . - . . 1 4 - 9 3
ElectricalTroublesliooting('99 00Models)
T r o u b l e s h o o t i n oF l o w c h a r t
14 131
O / D O F F I n d i c a t o rL i g h t D o e s N o t C o m e O n
O / D O F F I n d i c a t o rL i a h t O n C o n s t a n t l Y . . . . 1 ! - 1 3 2
O / D O F F I n d i c a t o rL i g h t D o e s N o t C o m e O n
EvenThough O/D Switch ls Pressed . .... - 14_133
L o c k u p C o n t r o l S o l e n o i dV a l v e A , / BA s s e m b l y
. .14-135
Test....................-.........
.ll_135
.
Replacement
S h i f r C o n t r o l S o l e n o i dV a l v e A y ' BA s s e m b l ,
. .. 14-136
T e s t. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .14'136
Replacement..............L i n e a rS o l e n o i dA s s e m b l Y
T e s t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . . . .. .. .. .. . . . . .. . . .1 4 _ 1 3 7
14138
..
.
Replacement
M a r n s h a f t l c o u n t e r s h a fSl p e e d S e n s o r s
14_138
...-...
Replacement
A/T Gear Position Switch
. .. 14-139
T e s t. . . . . . . . . . . . . . . . . . . . . . . . . . - . . .
. . . . . . . . . . . .1. .4. .- .1. 4 0
Replacement
A/T Gear Position l n d i c a t o r
'97 ..
9 8 M o d e l s . . . . . . . . . . . . . . . _ . . . . . . .t.4. .1. .4. 2
Input Test'99 0 0 M o d e l s . . . . . . . . . . . . . . . . . . . . . . . .1. .4. -. 1. .4. .3. .
Input Test
I n t e r l o c kS y s t e m
I n t e r l o cC
k o n t r o l U n i tl n p u t T e s t .- . . . . . - . . . . . . . - 1 4 1 4 4
* K e y I n t e r l o c kS o l e n o i dT e s t . - . . . . . - . . . . . . . . 1 4 _ 1 4 6
* S h i f t L o c k S o l e n o i dT e s t . . . . . . . . . . . . . . -. ..-... . . . . . . . 1 4 1 4 7
* S h i f t L o c k S o l e n o i d R e p l a c e m e n t . . . . .. . . . . . 1 4 1 4 8
* park pin Switch Test
. . . . . . . .1. 4 1 1 9
' Park Pin Switch Replacement
- '97 - 98 Models
. . . . . . .1 4 - 1 5 0
* Park Pin Swirch/Over Drive (O/Di Switch
'99-00Models
14_151
. ..
Replacemenl
o v e r - D r i v e ( O / D )S w i t c h { ' 9 9 0 0 [ 4 o d e l s ]
.......14-152
Test........_.....................
Hydr.ulic System
Symptom to-Component Chart
H y d r a u l i cS y s t e m . . . . . . . . . . . . . . .
14 157
R o a d T e s t . . . . . . . . . . . . . -. . . . . . . .
StallSpeed
T e s t. . . . . _ . . . . . . . . . . . . . . . . . . . . . . . .
FluidLevel
Checking
. . . . .1
. .4 - 1 5 9
. . . . . . _ . . . . . . . . . . .1. .4. '.1. .6. 0.
Transmigrion
www.emanualpro.com
14 164
I n s p e c l r o n. . . . ..,. . . . . . . . . .
T r a n s f e rA s s e m b l y
14-165
Remova1,.,,,..............,
14,167
l n s t a l l a l i o n. . . . . . . . . . . . .
Transmission
14-169
Removal ...,
l l l u s t r a t e dI n d e x ( 4 W D )
14'174
.
End Cover/Transmissio
... .. . . .... .. 14-176
T r a n s m i s s i oH
n o u s i n g. . . .
T o r q u e C o n v e r t e rH o u s i n g l y ' a l v eB o d y . . - . . . - . 1 4 1 7 8
lllustrated lndex (2WD)
. . . . . . .1 4 1 8 0
End Cover/Transmissio
T r a n s m i s s i oH
n ousing . . ... . .. .... ... 14'182
14-184
T o r q u eC o n v e n e rH o u s i n g / r ' a l vBeo d y . . . . . . End Covef
. . . . . .1. 4 ' 1 8 6
R e m o v a t. . . . . . . . . . . . . . . . . . . . . .
T r a n s m i s s i o nH o u s i n g
..
14_188
R e m o v a l. . . . . . . . . . . . . . . . . . . . . .
Torque Convener HousingA/alve BodY
. - . . . .1. 4 - 1 9 0
R e m o v a t. . . . . . . . . . . . . . . . - . . . . .
ValveEody
n e p a i r. . . . . . . . . . . . . . . . . . . . . . ........... ... .. . . - . . . . . . 1 4 1 9 2
.. 1{_193
A s s e m b l .y. . . . . . . . . . . . . . . . . . .
ValveCaps
D e s c i i p t i o n . . . . - . . . . . . . . . . . . . . . . . . . . .. .. .. .. . . 1 4 1 9 4
. . 1 4 1' 9 5
...................
tnspeition
ValveBody
N4ain
- ...... .. 14_196
Disassembly/lnspection/Reassemblv
ValveBodY
Secondarv
14 198
.. .
Disassemblv4nspectron/ReassemblY
Reoulator
ValveBodv
. 14199
bisassembtv,lnspiction/Reassemblv
ServoEodv
....14'200
...
Disassembly/lnspection/Reassembly
Lock'uoValveBodY
. 14_201
....
Dis;ssembly/lnspection/Reassembly
Mainshaft
.. .. .. ..14'202
Disassembly/lnspection/Reassembly
..11_203
I n s p e c t i o.n. . . - . . . . . . . . . . . . . .
SealingRings
...... ..... . 14'204
Reilaceient
Countershaft
.. . . . . . 11-205
Disassembly/lnspection/Reassembly
D i s a s s e m b l y / R e a s s e. .m.b. .|.y. . . . . . . . . . . . . 1 4 _ 2 0 6
1 42 0 7
.... .
I n s p e d r o .n. . . . . . . . . . . . . . .
Onewav Clutch
11_209
Disassembly/lnspection/ReassemblY...
Sub-shaft
... . .. . 14-210
Disassembly/lnspection/Reassembly
o i s a s s e m b l y / R e 6 s s e.m b. l.y. . . - . . . . . . . . . . 1 4 - 2 1 1
Bearings
Sub-shaft
.......14'212
Replacement
Clutch
. . .14-213
Index..........
llfustrated
.... .. .....14-216
Disassembly
.... . .. .. . 14'218
Reassembfy
Differential
14-222
"
llfustratedIndex
. ..... .14'223
Inspection
Backlash
.. 11-223
BearingRepiacement
.. .. . . . .. ..11-2?4
CarrierReplacement
Differe-ntial
. .. 14'225
OifSealReplacement.
lnspection. . - .. ... . - ....... .. 11'226
SideClearance
HousingBearings
Transmission
Eearings
MainshaJVCountershaft
.......14221
Repfacement
. . . . . . . . . ..11'224
Sub'siraltEearingReplacement
HousingBearings
ToroueConverter
.. l4229
.
MainshattEearing/OilSe6lReplacement
Bfet a ; i n R
g e p l a c e m e n t..... . . . . . 1 4 - 2 3 0
Countersha
ControlLeverAssembly
. . . . . . . .1. .4 - 2 3 0
R 6 p l a c e m e n t. . . . . . , . ,
R e v e r s el d l e r G e a r
...............
1 n s t a 1 | a t.i .o. n
ParkStop
Inspeclion/Adjustmenl
TransferAssemblY
lllustrated lndex
.........
Disessembly
T r a n s f e rD r i v e G e a r B e a r i n g
Replacement
T r a n s { e rD r i v e n G e s f S h a f t B e a r i n g
Replacement
T r a n s f e rH o u s i n g R o l l e r B e a r i n g
Replacement
T r a n s f e rC o v r A B e a r i n gO u t e r R a c e
Replacement
T r a n s f e r H o u s i n g B e a r i n gO u t e r R a c e
R e p l a c e m e n t. . . . . . - . . , , , , , . . . . .
1 42 3 1
11-231
.......14.232
...........
14-235
11-237
11-237
14-238
$-234
11-239
14-240
Reassemblv
Transmassaon
...-.. .... .14250
Beassembly
C o n v e r i e r / D rPi vl a
e t e. . - . . . . . . . . . . . . . . . . 1 4 _ 2 5 8
Torque
Transmission
.......14'259
..................
lnstatlation
. . ......11-261
C o o l eFr l u s h i n g
ATFCoolerHoses
.......14-266
Connection..................
I Shift Lever
. .. 14'261
Removal/lnstallation
- '97 - 98 Models . . 14_264
Disassemblv/Reassemblv
-'99 00 Models.
14-269
Disassembli/Reassemblv
(O/D)SwitchWire
Over'Orive
C l e a r a n c e A d j u s t m -e n.t... . . . . . . . . 1 4 ' 2 7 0
... .14'271
D e t e nSt p r i n R
g e p l s c e m e. n .t - . .
*ShiftCable
14'272
.......
Adiustment
. 11'273
Repfacement..............
Ref.No.
^
Tool Number
Description
Oty I
BackprobeSet
lVT Oil PressureGaugeSetw/Panel
A,/TLow PressureGaugew/Panel
AdjustableBearingPuller,25 - 40 mm
2
1
'l
@
@
@
@
07GAB- PF50101
or
07GAB- PF50100
07GAE- PG40200
or
_ PG4O2OA
OTGAE
07HAC- PK40102
07JAB- 001020A
07JAD- PH80101
07LAD- PW50601
07LAE- PX40100
OTMAJ- PY4O114
07MAJ- PY40120
07PAZ- 0010100
07RAB- TB4010Aor
07RAB.TB40lOB
07sAz - 001000A
07406- 0020400
07406- 0070300
07736- 4010008or
07736- A010004
07746- 0010100
07746- 0010200
07746- 0010400
07746- 0010500
Anachment,32 x 35 mm
Attachment,37 x 40 mm
Attachment.52 x 55 mm
Attachment.62 x 68 mm
I
1
1
1
@
@
@
@
07746077460774607749-
Attachment,72 x 75 mm
Driver40 mm l.D.
Attachment,35 mm LD.
Driver
1
1
1
I
07947- SD90200
tl)
@
*rar
@
@
,-o
@
@
@
@
@
@
.--@
0010600
0030100
0030400
0010000
MainshaftHolder
PagoReferonc
14-181, 254
ClutchSpringCompressorBoltAssembly
14-216,219
HousingPuller
HolderHandle
Oil SealDriverAftachment
Attachment,40 x 50 mm
ClutchSpringCompressorAttachment
Ay'TPressureHose,2210mm
IVT PressureHoseAdapter
SCSServiceConnector
CompanionFlangeHolder
1
1
1
,l
14-189
't4-236,242,245,246
't 4-225,
241
14-237
14-216,2't9
14-161
1 4 -1 6 1
14-57
14-236,242,245,246
1
I
SealDriverAftachment
lf the top arm is too short,replaceit with 07SAC- pOZ01OO1.
07HAE- PL50101may be usedto substituteone of thesetools.
Must be usedwith commerciallyavailable3/8"-16slide hammer.
14-58,157
14-161
14-161
'14-229,230
14-211,
2't2
14-231
14-239
14-212,227, 228,229,230, 238,
14-239,249
14-221,229
't 4-207
, 223,226, 237, 241
14-237,241
1+21 1, 2't2, 225,227, 228, 229,
14-230,237, 238, 239,24't, 249
't4-225
E----G
tvj
@@@@@
14-2
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\r'
@)
Description
GeneralOperation
controlledunit which provides4
The Automatictransmissionis a 3-elementtorqueconverterand triple-shaftelectronically
positioned
with
the
engine'
in
line
is
The
unit
speedsforwardand 1 reversespeed
('97- 00)' and the front-wheel
Thereare two tvoes of automatictransmissionon CR-V;the four-wheeldrive (4WD)model
drive (2WD)model ('98- 00).
Toroue Converter,Gars,and Clutches
The torqueconverterconsistsof a pump.turbine.and statorassemblyin a singleunit.The torqueconverteris connectedto
Thesepartsturn togetheras a unit as the engineturns.Aroundthe outsideof the torqueconverteris
the enginecrankshatt.
a ring gearwhich mesheswith the starterpinionwhen the engineis started.The torqueconverterassemblyservesas a flywheelwhile transmittingpowerto the transmissionmainshaft.
The mainshaftis in line with
and the sub-shaft.
The transmissionhasthree parallelshafts:the mainshaft.the countershaft,
reverseand 1st
gears
lor
3rd,2nd,4th.
and
4th
clutches,
1st,
2nd.
and
the
includes
The
mainshaft
crankshaft.
the engine
the 3rd
gear).
includes
The countershaft
(3rdgear is integralwith the mainshaft,while reversegear is integralwith the 4th
at
its cencountershaft
gears
locked
to
the
be
4th
can
clutchand gearsfor 3rd,2nd,4th, reverse,1st,and park.Reverseand
the
lst-hold
includes
The
sub-shaft
is
moved.
way
the
selector
which
ter, providing4th gear or reverse,dependingon
clutchand gearsfor lst and 4th.
Whencertaincombinations
and sub-shaft.
The gearson the mainshaftare in constantmeshwith thoseon the countershaft
to provideE, D!, tr, tr,
of gearsare engagedby the ctutches,power is transmittedfrom the mainshaftto the countershaft
('99
position
models)'
00
and E position('97 98 models).and E. E, E, and E
Electlonic Control
The electroniccontrot system consistsof the PowenrainControl Module (PCM),sensors,a linear solenoid,and four
controlledfor comfortabledrivingunderall conditions.The PCMis
solenoidvalves.Shiftingand lock-upare electronically
panel
side.
on the passenger's
locatedbelowthe dashboard,underthe kick
HydraulicControl
The valve bodiesincludethe main valve body, the secondaryvalve body, the regulatorvalve body, the servo body, and
the lock up valve body.They are boltedto the torque converterhousing.The main valvebody containsthe manualvalve,
the 1-2 shift valve,the 2nd orificecontrolvalve.the CPB{ClutchPressureBack-up)valve,the modulatorvalve,the servo
controlvalve.the reliefvalve,and ATF pump gears.The secondaryvalve body containsthe 2-3 shift valve,the 3-4 shift
valve,the 3,4 orificecontrolvalve.the 4th exhaustvalveand the CPC(ClutchPressureControl)valve.The regulatorvalve
bodv containsthe pressureregulatorvalve,the torque convertercheckvalve,the coolerreliefvalve,and the lock-upcontrol valve.The servo body containsthe servovalvewhich is integratedwith the reverseshift tork, and the accumulators
The lock-upvalve body containsthe lock-upshift valveand the lock-uptiming valve.The linearsolenoidand the shift control solenoidvalveAy'Bare boltedto the outsideof the transmissionhousing,and the lock-upcontrolsolenoidvalveAy'Bis
boltedto the outsideof the torque converterhousing.Fluid trom the regulatorpassesthrough the manualvalve to the
feed pipesor internalhydrauliccircuit
variouscontrolvalves.The clutchesreceivefluid from their respective
ShiftControl Mechanism
input from varioussensorslocatedthroughoutthe vehicledetermineswhich shift controlsolenoidvalvethe PCMwill actipressurizes
vate.Activatinga shift controlsolenoidvalvechangesmodulatorpressure,causinga shiftvalveto move.This
A
and B are
valves
gear.
solenoid
The
shift
control
a lineto one of the clutches.engagingthat clutchand its corresponding
controlledby the PCM.
Lock-up Mechanism
('97- 98
tn E! position(,97- 98 modets)and in E position('99 - O0models),in 3rd and 4th, and in Delpositionin 3rd
('99
pressurized
models),
00
(by
in
3rd
(O/D)
pressing
O/D
switchl
rhe
is OFF
models)and in El positionwith Over,Drive
fluid is drainedfrom the back of the torque converterthrough a fluid passage,causingthe lock-uppiston to be held
againstthe torque convertercover,As this takesplace,the mainshaftrotatesat the same speedas the enginecrankshaft.
Togetherwith hydrauliccontrol,the PcM optimizesthe timing of the lock-upmechanismThe lock-upvalvescontrolthe
range of lock-upaccordingto lock-upcontrol solenoidvalves A and B, and the linear solenoid.When lock-upcontrol
solenoidvalvesA and B activate,the modulatorpressurechanges.The lock-upcontrol solenoidvalvesA and B and the
linearsolenoidare controlledby the PCM.
{cont'd)
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14-3
Description
GeneralOperation(cont'dl
Gsar Selection
'97 - 98 Models
The shift lever has sevenpositions;El PARK,ts REVERSE,
N NEUTRAL,Ell 1st through 4th ranges,lpq 1stth.ough 3rd
ranges,P 2nd gear,and [ 1stgear
'99 - 00 Models
,lst through
The shitt lever has six positions;El PARK,E REVERSE,
4th ranges,and 1st through 3rd
E NEUTRAL.E
(whenOver-Drive(O/D)is OFF)ranges.@ 2nd gear,and E 1stgear.
Position
Description
tll PARK
t!!l l|EvEn>E
E NEUTRAL
Allclutches released.
('97- sB)
Ell DRrvE
('ss- oo)
E DRrvE
(1stthrough
4th)
E DRrvE
{'97- s8)
with overO DRTVE
Drive(O/D)
isOFF
('99- 00)
used for rapid ccelerationat highway speeds and general driving; stans off in 1st, shifts automaticallyto
2nd_then
3rd, dejending on vehiclespeedand throttleposition.Downshiftsthroughlower gearson decelerationto stop.The lock-upmechanismcomesinto operationin 3rd gear.
E SECOND
Driving in 2nd_gear;stays in 2nd gear,does not shift up and down. For engine brakingor bettertrac_
tion startingoff on loose or slipperysurfaces.
E FIRST
Driving in 1st gear;stays in 1st gear,does not shift up. For engine braking.
(1stthrough3rd)
14-4
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3rd Clutch
oppositethe end cover.The 3rd
3rd gear,and is locatedat the end of the countershaft,
The 3rd clutchengages/disengages
clutchis suppliedhydraulicpressureby its ATFfeed pipewithin the countershaft.
ilth Clutch
4th gear,as well as reversegear,and is locatedat the middleof the mainshaft.The 4th
The 4th clutchengages/disengages
joined
clutch.The 4th clutchis suppliedhydraulicpressureby its ATFfeed pipewithin the
to
the
2nd
back-to-back
clutchis
mainshaft.
One-way Clutch
The one-wayclutchis positionedbetweenthe parkgear and the countershaft1stgear,with the parkgear splinedto the countershaft.The countershaft1st gear providesthe outer race surface,and the park gear providesthe inner racesurface The
one,way clutch locks up when power is transmittedfrom the mainshaftlst gear to the countershaft1st gear. The 1st
pt, E, or E position The one-way
clutchand gearsremainengagedin the 1st,2nd, 3rd, and 4th gear rangesin the lo],
in
the
or E position'
applied
are
[d,
E,
or
4th
clutches/gears
lor,
clutchdisengageswhen the 2nd, 3rd,
the locking"speedrange" of the
gears
over-ride
on
the
countershaft
of
the
rotational
speed
increased
because
the
This is
one-wavclutch.The one-wavclutchfree-wheelswhen the lst clutchis engaged
2NOCLUTCH
lST.HOLD
CLUTCH
4TH CLUTCH
1STCLUTCH
MAINSHAFT
3RDCLUTCH
COUNTERSHAFT
TRANSFER
SHAFTDRIVE
GEAR
ONE.WAYCLUTCH
TRANSFER
ASSEMBLY
OUTSIDEOF ONE.WAY
CLUTCH
INSIDEOF ONE.WAY
CLUTCH
Splined with countershaft
N O T E :T h e i l l u s t r a t i o ns h o w s t h e 4 W D
a u t o m a t i ct r a n s m i s s i o n{ s e c t i o n avl i e w )
t h e 2 W D t r a n s m i s s i o nd o e s n o t h a v e a
transferassemblyand transfershaft drive
gear on the differentialassembly.
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LOCKINGCONDITION
OVER.RIOING
LOCKINGSPEEDCONOITION
14-5,
Description
PowerFlow
*N
E
E
N
1ST
Fi
2ND
or
3RD
4TH
tr
TOROUE
1ST.
4TH
REVERSE PARK
coNHOLD
1ST
2ND
3RD
GEAR
VERTER CLUTCH CLUTCH CLUTCH CLUTCH GEAR CLUTCH
o
o
o
o
o
o
o
o*,
o*,
o
o
o*1
o*1
'tsT
o"
2ND
OverDrive
(o/D) 3RD
is OFF
o*1
o*r
o
o
o*r
or
tr
tr
o
o
o
O: Operates,
x: Doesn'toperate.
* 1:Althoughthe 1stclutchengages,drivingpower
is not transmittedas the one_wayclutchslips.
*2: The one-wayclutchengageswhen accelerating.
and slipswhen deceleraung.
NOTE:p! and Ipj positionsare on the '97 - '98 models;El positionis on the ,99- OOmodels.
14-6
www.emanualpro.com
E Po3ition
Hydraulicpressureis not appliedto the clutches.Poweris not transmittedto the countershaft.
The countershaft
is lockedby the parkpawl interlockingthe parkgear,
E Position
Enginepower transmittedfrom the torque converterdrivesthe mainshaft.but hydraulicpressureis not appliedto the
The countershaft4th gear is engagedwith the reverseselectorhub
clutches.Poweris not transmittedto the countershaft.
and the countershaftby the reverseselector,when the shift lever is shiftedin E positionfrom E or E position.The
countershaftreversegear is engagedwhen shiftedfrom E position.
NOTE;The illustrationshows the 4WD automatictransmission;oower flow of the 2WD automatictransmissionis identical to the 4WD exceDtfor oarts relatedto the transfer assemblv.
PARKGEAR
SELECTOR
COUNTERSHAFT
REVEBSEGEAR
(cont'd)
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14-7
Description
Power Flow (cont'dl
E Position
In E position,hydraulicpressureis appliedto the lst clutchand the lst-holdclutch.
The powerflow when accelerating
is as follows:
1. Hydraulicpressureis appliedto the lst clutchon the mainshaft,and power is transmittedvia the 1stclutchto the mainshaft 1stgear.
Hydraulicpressureis also appliedto the lst-hold clutchon the sub-shaft.Powertransmittedto the mainshaft1st gear
is conveyedvia the countershaft1st gear to the one-wayclutch,and via the sub-shaft1st gear to the 1st-holdclutch.
The one-wayclutchis usedto drivethe countershaft,
and the 1st-holdclutchdrivesthe countershaft
via the 4th gears.
Poweris transmittedto the final drive gear,which drivesthe final drivengear,and the transfershaftdrive gear (4WD),
4. The transfershaftdrive geardrivesthe transfershaftand the transferdrivengearshaft(4WD).
SUB.SHAFT4TH GEAR
SU8-SHAFT1STGEAR
lST.HOLDCLUTCH
SUB.SHAFT
1STGEAR
lST CLUTCH
COUNTERSHAFT
ONE.WAYCLUTCH
FINALDRIVE
GEAR
PARKGEAB
COUNTERSHAFT
4TH GEAR
FINALDRIVENGEAR
TRANSFERSHAFTORIVEGEAR{4WD}
TRANSFERSHAFT{4WD}
14-8
www.emanualpro.com
TRANSFERDRIVENGEARSHAFT{4WD)
E Position
is as follows:
The powerflow when decelerating
trom the road surfacegoesthroughthe tront wheels(and rearwheels:4WD)to the final drive gear.
L Rollingresistance
then to the sub-shaftlst gearvia the 4th gear.and 1st-holdclutchwhich is appliedduringdeceleration.
2 . The one-wayclutchis free becausethe applicationof torque is reversed.
J.
The counterforceconveyedto the countershaft4th gear turns the sub-shaft4th gear via the mainshaft4th gear.Since
hydraulicpressureis also appliedto the 1st clutch.counterforceis also transmittedto the mainshaft.As a result,
enginebrakingcan be obtainedwith'lst gear.
powerflow of the 2WDautomatictransmissionis identiNOTE:The illustrationshowsthe 4WDautomatictransmission;
cal to the 4WD excepttor parts relatedto the transfer assembly.
lST.HOLDCLUTCH
SUB.SHAFT1STGEAR
TOROUECONVERTER
SUB.SHAFT
{TH GEAR
MAINSHAFT
lST GEAR
lST CLUTCH
MAINSHAFT
COUNTERSHAFT
FINALDRIVEGEAR
HUB
SELECTOR
REVERSE
SELECTOR
REVERSE
COUNTERSHAFT
IITHGEAR
FINALORIVENGEAR
TRANSFERSHAFTDRIVEGEAR{4WDI
TRANSFEBSHAFT{{WD)
{cont'd}
TRANSFERDRIVENGEARSHAFT{,lWDl
www.emanualpro.com
14-9
Description
PowerFlow lcont'd)
lst Gear(8. E or E positionl
In E, E, or D position,
the optimumgearis selected
from 1st,2nd,3rd,and4thgears,according
to conditions
suchas
the balancebetweenthrottle opening (engineload) and vehicle speed.
1. Hydraulicpressureis appliedto the 1st clutch,which rotatestogetherwith the mainshaft,and the mainshaft1st gear
rotates.
2. Poweris transmittedto the countershaft1stgear.which drivesthe countershaft
via the one-wayclutch.
3. Poweris transmittedto the final drive gear.whichdrivesthe final drivengearand the transfershaftdrive gear (4WD).
4. The transfershaftdrive geardrivesthe transfershaftand the transferdrivengearshaft(4WD).
NOTE:
o In @, @, @, or E position.hydraulicpressureis not appliedto the 1st-holdclutch.
. The illustrationshowsthe 4WD automatictransmission;power flow of the 2WD automatictransmissionis identical
to the 4WD exceptfor parts relatedto the transfer assembly.
CONVERTER
MAIiISHAFT
1ST
CLUTCH
MAINSHAFT
COUNTERSHAFT
FINALOBIVEGEAR
ONE.WAYCLUTCH
PARKGEAR
FINALDRIVENGEAR
TRANSFERSHAFTDRIVEGEAR{4WD}
14-10
www.emanualpro.com
TOROUE
COUNTERSHAFT
FINALORIVEGEAR
2NO GEAR
FINALDRIVENGEAF
TRANSFERSHAFTDBIVEGEAR{4WD}
TRANSFERSHAFT{4WDI
(cont'd)
TMNSFER DRIVENGEARSHAFT(4WD)
www.emanualpro.com
14-11
Description
PowerFlow (cont'd)
3rd Gear {8. @, or @ position)
1. Hydraulicpressureis appliedto the 3rd clutch.Powerfrom the mainshaft3rd gear is transmittedto the countershaft
3rd gear.
2. Poweris transmiftedto the final d rive gear,wh ich d rivesthe f inal drivengearand the transfershaftdrive gear(4WD).
3, The transfershaftdrive geardrivesthe transtershaftand the transferdrivengearshaft (4WD).
NOTE:
. Hydraulicpressureis also appliedto the 1stclutch,but sincethe rotationspeedof 3rd gear exceedsthat of 1stgear,
powerfrom lst gear is cut off at the one-wayclutch.
. The illustrationshowsthe 4WD automatictransmission;Dowerflow of the 2WD automatictransmissionis identical
to the 4WDexceptfor partsrelatedto the transferassembly.
CONVERTEF
MAINSHAFT3RDGEAR
COUNTERSHAFT
COUNTERSHAFT
3ROGEAR
3RDCLUTCH
DRIVENGEAR
SHAFTDRIVEGEAR(4WO)
TRANSFERSHAFT(,lwDl
TRANSFERORIVENGEANSHAFT(4WD)
14-12
www.emanualpro.com
TOROUE
CONVERTER
.TH CLUTCH
COU'{TERSHAFT
HUB
SELECTOR
REVERSE
REVERSE
SELECTOR
FINALDRIVENGEAR
TRANSFEBSHAFT DRIVEGEAB I'WD)
TNANSFERSHAFTI4WDI
{cont'd)
TMNSFER DRIVENGEARSHAFT(4WDI
www.emanualpro.com
14-13
Description
PowerFlow (cont'dl
E position
1. Hydraulicpressureis switched by the manual valve to the servo valve, which movss the reverseshift fork to the
reverseposition,The reverseshift fork engageswith the reverseselector,the reverseselectorhub, and the countershaft reversegear.
2. Hydraulicpressureis also appliedto the 4th clutch. Power is transmittedfrom the mainshaftreversegear via the
reverseidler gear to the countershaftreversegear.
3. Rotationaldirectionofthe countershaftreversegear ischangedviathe reverseidlergear.
4. Poweris transmittedto the final drivegear,whichdrivesthefinald rivengear and the transfershaftdrive gesr (4WD).
5. The transfershaftdrive geardrivesthe transfershaftand the transferdrivengearshaft (4WD).
NOTE:The illustrationshows the 4WD automatic.transmission;
power flow of the 2wD automatictransmissionis identical
to the 4WD exceptfor partsrelatedto the transferassembly.
REVERSE
MAINSHAFT
TOROUECONVERTER
COUNTERSHAFT
REVERSE
IDLER
GEAR
FINALORIVE
COUNTERSHAFT
REVERSE
GEAR
REVERSESEITCTOR
HUB
REVERSESELECTOR
FINALOBIVENGEAR
REVEBSC
SHIFT
FORK
TRANSFERSHAFTDRIVEGEAR
{4WD)
TRANSFERSHAFT{4WD)
TRANSFERDRIVENGEARSHAFTI4WD}
14-14
www.emanualpro.com
SERVOVAI-VE
ElectronicControlSystem
The electroniccontrolsvstemconsistsof a PowertrainControlModule(PCM),sensors,a linearsolenoid,and four solenoid
valves.Shiftingand lock-upare electronically
controlledfor comfortabledriving under all conditions.The PCMis located
side.
belowthe dashboard,underthe kickpanelon the passenger's
'97 - 98 Modls
VehicleSp.ed Sensor
Signal
PGM.FI
Control Sy3t6m
EnginoCoolantTampereture
SonsorSignrl
ServiceCheckconnector
Shift Control
Solenoidvalve A
Shift Cont.ol
Shift Control
SolenoidValve B
N
Linear Solenoid
Dr
Ds
Lock-upControl
Lock-upConirol
Sol6noidvalvo B
M.inshaft SpoedSensor
Signel
Selt-Oiagnosbsignel
Lock-upControl
SolenoidValve A
Il -
Sell-Diagnosis
Function
CountrahaftSpeed
sensorSignel
{cont'd)
www.emanualpro.com
14-15
Description
ElectronicGontrolSystem(cont'd)
'99 - 00 Models
PCM
Throttle Position Sensor
Signel
VehicleSpeedSensor
Signal
PGM.FI
Control System
EnginCoolsnt Tomperature
Sen30rSignal
Shift Conlrol
SolenoidValve A
Shift Control
Shift Control
SolenoidValve B
N
Linear Solenoid
D
2
Lock-upControl
Lock-upControl
SolenoidValve B
Over-Drive
Switch Signal
Mainshaft SpeedSensor
Signal
E Indicator Light
Selt-OiagnosisSignd
Lock-upControl
Solenoidvalve A
Self-Diagnosis
Func{ion
CountershaftSpeed
SensorSigntl
O/D OFF
Indicetor Light
14-16
www.emanualpro.com
Shift Control
The PCMdetermineswhich gear should be selectedby varioussignalssent from sensors,and actuatesthe shift control
solenoidvalvesA and B to controlshifting.Also.a GradeLogicControlSystemhas beenadoptedto controlshiftingin E
anOE ('gZ- gg),and E ('99- 00) positionwhile the vehicleis ascendingor descendinga slope,or reducingspeeo.
Position
E, E, Or
E
E orE
tr
Gear
'Ist
OFF
ON
2nd
ON
ON
3rd
ON
OFF
4th
OFF
OFF
2nd
ON
ON
1st
OFF
ON
Reverse
ON
E*See page 14-37for reverseinhibitorcontroldescription.
OFF
Lock-upControl
From sensor input signals,the PCM determineswhether to turn the lock-upON or OFF,and activateslock-upcontrol
solenoidvalveA and/orB accordingly.Lock-updoes not occur until the engineis warm. The combinationof driving signalsto lock-upcontrolsolenoidvalvesA and B and the linearsolenoidpressureis shown in the table below.
Lock-upControl
Solonoid Valve A
Lock-upControl
Solenoid Valve B
LinearSolenoid
Pressuro
LOCK-Up
\Jrr
OFF
OFF
High
Lock-up,Half
ON
Dutyoperation
OFF- ON
Lock-up,Full
ON
ON
Hish
Lock-up
duringdeceleration
ON
Dutyoperation
OFF- ON
Low
Lock-upConditions
(cont'd)
www.emanualpro.com
14-17
Description
ElectronicControlSystem(cont'dl
Grade Logic Control System
How it works:
The PCMcomparesactualdrivingconditionswith memorizeddrivingconditions,basedon the inputfrom the vehiclespeed
sensor,the throttlepositionsensor,the barometricpressuresensor('98model).the enginecoolanttemperaturesensor,the
brakeswitch signal,and the shift lever positionsignal,to controlshiftingwhile the vehicleis ascendingor descendinga
slope,or reducingspeed.
SIGNALSDETECTED
.
.
.
.
14-14
www.emanualpro.com
ASCENoINGMODE:UFhift Sch.dulc
3RD - tlTH
. FLATROADMODE
-----------. : GRADUAL
ASCENDING
MODE
o 5 l )
- - - - - : STEEPASCENDING
MODE
SHIFTINGCHARACTERISTICS
FN1NS : 2ND-3RD
CONTROLAREA
SHIFTINGCHARACTER|SnCS
7,.,.7a | 3RD-aTH
CONTROLAREA
62 mph
1100km/h)
Vehicle .o..d
ASCENDINGMODE:Up.hift Sch.dul.
8 5 0
: 2ND-3RDSXImNG CHARACTERISTICS
GoNTRoLAREA
VVVVVZ:IRD-ITHSHIFnNGCHARACTERISTICS
cot{TRoL AREA
NN
-
6:l mph
11fl)km/hl
Vahicl. sDctd
(cont'd)
www.emanualpro.com
14-19
Description
ElectronicControlSystem(cont'd)
DescendingControl
When the PCMdeterminesthat the vehicleis going down a hill in E and @ positions('97- 98 models).and in @ position {'99 - 00 models),the shitt-upspeedfrom 3rd to 4th gear and from 2nd to 3rd (whenthe throttleis closed)becomes
fasterthan the set speedfor flat road drivingto widen the 3rd gear and 2nd gear drivingareas.This, in combinationwith
engine brakingfrom the decelerationlock-up,achievessmooth drivingwhen the vehicleis descending.Thereare three
descendingmodeswith different3rd gear drivingareasand 2nd geardrivingareasaccordingto the magnitudeof a gradient storedin the PCM.When the vehicleis in 4th gear,and you are decelerating
when you are applyingthe brakeson a
steep hill, the transmissionwill downshiftto 3rd gear,When you accelerate,
the transmissionwill then returnto higher
gear.
2ND - 3RD
3RD- 4TH
DESCENDING
MODE:Downshift Schodule
: FLATROADMODE
----'-----' I GRADUALDESCENDING
MODE
o 5 0
- - - - - : MEDIUMOESCNOING
MODE
.
62mph
km/hl
1100
... : STEEPDESCENDING
MODE
Vehiclesped
DecelerationControl
When the vehiclegoes arounda corner,and needsto deceleratefirst and then accelerate,
the PCMsetsthe datafor deceleration
control to reducethe number of times the transmissionshifts.When the vehicle is deceleratingfrom speedsabove 27 mph
(4i| km,ih),the PCMshiftsthe transmissionfrom 4th to 2nd earlierthan normalto cope with upcomingacceleration,
14-20
www.emanualpro.com
CircuitDiagramand TerminalLocationsr9TModel
IGNITIONSWITCH
LOC( UPCONTROL
LOCK UPCONTROL
B
SOLEITOIDVALVE
sf Frc0|lltF0L
SOLENOIDVALVE
A
sHrFr
c0r{TnoL
VALVEB
SOLEI{OID
UNEASSOLINOID
www.emanualpro.com
14-21
Description
ElectronicControl System (cont'd)
CircuitDiagramand TerminalLocationsrgS
Model
GNTIONSWITCN
LOCK-UPCONIFOL
SOLEIIO
D VALVEA
LOCK-UPCONTSOL
SOLEI.IO
0 vALvEB
SBIFICONTROL
A
SOLEIDVALVE
SHFTCONTFOL
SOLEiDIDVALVE8
LINAASOLiDID
GNIION
SWTCH
tGr
14-22
www.emanualpro.com
GN'IONSWITCN
pG2
LOC(UPC,ONTROL
SOLEIDD VALVEA
IGPI
IGP2
vcc2
LOCK.UPCON'IFO!
SOLENOIOVALVE
B
SNIFTCONTAOT
VALVEA
SOLNOID
SH]FTCONTROL
vArvE
B
solEtiroro
L NEAFSOLEI{OIO
rGNloNSWrlCH
GI
www.emanualpro.com
14-23
Description
HydraulicControl
The hydrauliccontrolsystemis controlledby the ATF pump,valves,accumulators,
and electronically
controlledsolenoids.
The ATF pump is driven by splineson the end of the torqueconverterwhich is aftachedto the engine.Fluidfrom the ATF
pump flows throughthe regulatorvalveto maintainspecifiedpressure,throughthe main valve body,to the manualvalve,
directingpressureto each clutch.The valve body includesthe main valve body, the regulatorvalve body, the lock-up
valve body,the secondaryvalve body,the servo body,the linearsolenoid,the shift controlsolenoidvalveAy'Bassembly,
a n d t h e l o c k - u pc o n t r o ls o l e n o i dv a l v e A / B a s s e m b l yT. h e s h i f t c o n t r o ls o l e n o i dv a l v eA , / Ba s s e m b l ya n d t h e l i n e a r
solenoidare boltedon the outsideof the transmissionhousing.The lock-upcontrolsolenoidvalveA,/Bassemblyis bolted
on the outsideof the torqueconverterhousing.
SHIFTCONTROL
SOLENOIDVALVEA/B
ASSEMBLY
LINEAR
REGULATOR
VALVEBOOY
VALVE
SECONDARY
BODY
VALVEBODY
SOLENOIDVALVEA/B
ASSEMELY
14-24
www.emanualpro.com
ATF PUMPGEARS
2ND ORIFICE
CONTROL
VALVE
MODULATORVALVE
1-2 SHIFTVALVE
RELIEFVALVE
MANUAL VALVE
MAIN VALVE
BOOY
SERVOCONTROIVALVE
Secondaryvalve Body
The secondaryvalve body is locatedon the main valvebody,The secondaryvalvebody housesthe 2-3 shift valve,the 3-4
shiftvalve,the 3-4 orificecontrolvalve,the 4th exhaustvalve,and the CPCvalve'
3.' SHIFTVALVE
2.3 SHIFTVALVE
.TH EXHAUSTVALVE
CPCVAL
3naORIFICECONTROL
VALVE
VALVE
(cont'd)
www.emanualpro.com
14-25
Description
HydraulicControl(cont'd)
RegulatorValve Body
The regulatorvalve body is locatedon the main valve body.The regulatorvalve body consistsof the regulatorvatve,the
torqueconvertercheckvalve.the coolerreliefvalve,and the lock-upcontrolvalve.
COOLERRELIEFVALVE
Lock-upValve Body
The lock-upvalvebody,with lock-upshift valveand lock-uptiming valve,is locatedon the regulatorvalvebody.
LOCK.UPSHIFTVALVE
NMINGVALVE
14-26
www.emanualpro.com
RegulatorValve
The regulatorvalve maintainsconstanthydraulicpressurefrom the ATF pump to the hydraullccontrolsystem,while also
furnishingfluid to the lubricatingsystemand torque converter.Fluid from the ATF pump flows through B and B'. Fluid
enteringfrom B flows throughthe valveorificeto the A cavity.This pressureof the A cavitypushesthe regulatorvalveto
the right side. and this movementof the regulatorvalve uncoversthe fluid port to the torque converterand the relief
valve. The fluid flows out to the torque converterand the relief valve, and the regulatorvalve moves to the left side.
Accordingto the levelof the hydraulicpressurethrough B, the positionof the regulatorvalvechangesand the amountof
fluid from B,throughthe torqueconverteralsochanges.This operationis continued,maintainingthe line pressure.
"|eft" or "right" indicatesdirectionon the illustrationbelow.
NOTE;When used,
ENGINERUNNING
ENGINENOT RUNNING
To TOROUECONVERTER Lubtication
STATORSHAFTABM
STATORREACTION
TOR SPRINGCAP
STATON
www.emanualpro.com
STA
SHAFT
ATOF SHAFTARM
(cont'd)
14-27
Description
HydraulicControl(cont'd)
Servo Body
The servo body is locatedon the secondaryvalve body.The servobody containsthe servovalve(whichis integratedwith
the reverseshiftfork),and the accumulators.
2ND ACCUMULATOR
3RDSUB
ACCUMULATOR
SERVOBODY
1STACCUMULATOR
SERVOVALVE/SHIFT
FORKSHAFT
14-28
www.emanualpro.com
HydraulicFlow
GeneralChart of Hydraulic Pressure
RegulatorValve -a
ATFpump -
ModulatorPressureClutchPressure
ToroueConverterPressure
Pressure
LUbrication
LinePressure
|
LL
5
-
LinearSolenoid
ManualValve
To selectLinePressure -
ModulatorValve
ModulatorPressure --
.
.
.
--1-2ShiftValve
2-3 ShiftValve -t-I
3-4 Shift Valve
ClutchPressure
't'
2
3
3'
3"
MODULATE
(SHIFT
SOLENOIO
CONTROL
MODULATE
VALVEA)
(SHIFT
SOLENOID
CONTROL
MODULATE
VALVEB)
(LOCK.UP
SOLENOID
CONTROL
IVODULATE
VALVEA)
(LOCK-UP
SOLENOID
CONTROL
MODUTATE
VALVEB)
(LOCK-UP
SOLENOID
CONTROL
MODULATE
VALVEB)
91
92
TOROUECONVERTER
93
ATF COOLER
94
TOROUECONVERTER
95
LUBRICATION
LIN E
97
LINE/CPC
LINE
1STCLUTCH
99
LINE
LINE
LINE
LINE
LINE
LINE
LINE
LINE
LINE
LINE
6D'
7
8
I
10
PORTNO,
15
17
18
20
20A
30
40
41
90
5
6A
---- ShiftControlSolenoidValves
Lock-upControlSolenoidvalves
fL
LinearSolenoid
OFPRESSURE
DESCRIPTION
CLUTCH
lST-HOLD
CLUTCH
1ST-HOLD
CLUTCH
1ST-HOLD
1ST-HOLDCLUTCH
2ND CLUTCH
2ND ACCUMULATOR
3RDCLUTCH
4TH CLUTCH
4THCLUTCH
SOLENOID
LINEAR
TOROUECONVERTER
TOROUECONVERTER
OFPRESSURE
DESCRIPTION
PORTNO,
1
ClutchPressure
TOROUECONVERTER
TOROUECONVERTER
SUCTION
DRAIN
HIX
HIGHPOSITIONDRAIN
{cont'd)
www.emanualpro.com
14-29
Description
HydraulicFlow (cont'dl
lll Position
As the engine turns, the ATF pump starts to operate.Automatictransmissionfluid (ATF)is drawn from (99) and dischargedinto (1).Then,ATF flowing from the ATF pump becomesline pressure('l). Line pressure(1) js regulatedby the
regulatorvalve.Torqueconverterinlet pressure{92)enters(94)of the torqueconveTter
throughthe lock-upshift valveand
dischargesinto (90) The torque convertercheckvalve preventstorque converterpressurefrom rising.Underthis condition, hydraulicpressureis not appliedto the clutches.
NOTE;
. When used."|eft" o. "right" indicatesdirectionon the hvdrauliccircutt.
. The hydrauliccircuitshowsthe '97 - 98 models{7 positions};the '99 - 00 models(6 positions)is similar.
'lF'.j.l
14-30
www.emanualpro.com
B Position
pressure(1) changesto line pressure(4) and
Line pressure{1) flows to the manualvalve and the modulatorvalve,Line
pressure
at the modulatorvalve Modulatorpres1st-holdclutchpressureat the manualvalve,and changesto modulator
shift
controlsolenoidvalveA is turned oFF
because
sure {6)flows to the left ends of the 1-2shift valve and 3-4 shift valve
Line pressure(4) becomes1st clutch
side.
right
to
the
moved
are
by the PcM. The 1-2 shift valve and the 3-4 shift valve
1st clutchis engaged lstpressure(10)at the 1-2 shift valve.1st clutchpressure(10)is appliedto the 1st clutch,and the
Poweris transmitted
valve
shift
1-2
hold clutchpressure(18)flows to the lst-hol; clutchvia the 3-4 shift valve and the
throughthe 1st-holdclutch.
only duringdeceleration
NOTE:
"right" indicatesdirectionon the hydrauliccircuit'
. When used,"left" or
'99 - O0models(6 positions)is similar'
. The hvdrauliccircuitshowsthe'97 - 98 models(7 positions);the
(cont'd)
www.emanualpro.com
14-31
Description
HydraulicFlow (cont'dl
l?JPosition
Line pressure{1) flows to the manualvalve and the modulatorvalve.Line pressure(1} changesto line pressure(4) at the
manualvalve,and changesto modulatorpressureat the modulatorvalve.But modulatorpressure{6} does not flow to
eachshift valvebecauseshift controlsolenoidvalvesA and B are turnedON by the PCM.Linepressure(4) passesthrough
the CPBvalveand the CPCvalve,and changesto line pressure(5),then flows to the 'l-2shift valve.Line pressure(5)from
the 1-2shift valvechangesto 2nd clutchpressure(20)at the 2-3 shift valve.The 2nd clutchpressure(20)is appliedto the
2nd clutch,and the 2nd clutchis engaged,Line pressure(4)passesthroughthe 1-2shiftvalveand the orifice,and changes
to lst clutchpressure.The 1stclutchpressure{10)also flows to the 1stclutch.However,no power is transmittedbecause
of the one-wayclutch.
NOTE:
. When used,"left" or "right" indicatesdirectionon the hvdrauliccircuit.
. The hydrauliccircuitshowsthe '97 - 98 models(7 positions);the '99 - OOmodels(6 positions)issimilar.
14-32
www.emanualpro.com
lst Gear
Fluidflow throughthe torque convertercircuitis the same as in E] position.Line pressureflows to the manualvalve
pressure
and the modulatorvalve.Line pressurechangesto modulatorpressure(6) at the modulatorvalveand to line
3-4
shift
valve
and
the
1-2
shift
valve
(6)
of
the
left
end
pressure
flows
to
the
{4) at the manual valve. Modulator
is
moved
to
valve
The
1-2
shift
PcM.
oN
by
the
B
is
turned
and
is
turned
oFF
valve
A
solenoid
becauseshift control
'lst clutchpressure(10}at the 1-2shift valveand the orifice The 1stclutch
the right side.Line pressure{4)changesto
the vehiclewill move as the enginepower is transpressure(10)is appliedto the 1stclutchand the 1st accumulator;
mitted.
NOTE:
. When used,"left" or "right" indicatesdirectionon the hydrauliccircuit.
'97 - 98 models(7 positions);
the '99 - 00 models{6 positions)issimilar.
. The hvdraulic circuitshowsth e
(cont'dl
www.emanualpro.com
14-33
Description
HydraulicFlow (cont'dl
2nd Gsar
As the speed of the vehiclereachesthe prescribedvalue.shift control solenoidvalve A is turned ON by the pCM.
Modulatorpressure(6A) in the left end of the 1-2shift valveis releasedby turning shift controlsolenoidvalveA ON.
The 1-2shift valve is movedto the left side and uncoversthe port to allow line pressure(5)to the 2-3 shift vatve.Line
pressure(5) changesto 2nd clutch pressure(20)at the 2-3 shift valve,The 2nd clutch pressure
{20)is applidto the
2nd clutch.and the 2nd clutchis engaged.
Fluidflows by way of:
- LinePressure(4)+ CPBValve- Line Pressure(5)* 1-2ShiftValveLinepressure(S)* 2-3 ShiftValve
- 2nd ClutchPressure(20)- 2nd Clutch
The hydraulicpressurealsoflows to the lst clutch.However,no power is transmittedbecauseof the one-wav
ctutch.
NOTE:
. When used,"|eft" or "right" indicatesdirectionon the hydrauliccircurr_
' The hydrauliccircuitshowsthe'97 - 98 models(7 positions);the '99 - 00 models(6 positions)
is similar,
14-34
www.emanualpro.com
3.
3rd Gear
As the speedof the vehiclereachesthe prescribedvalue.shift control solenoidvalve B is turned OFF by the PCM.
Shift controlsolenoidvalveA remainsON. Modulatorpressure(6)flows to the right end of the 1-2shift valveand the
(68) The 2-3 shift
left end of the 2-3 shift valve.The 2-3 shift valve is movedto the right side by modulatorpressure
2-3 shift valve
as
the
(5)
shift
valve
the
3-4
and
uncovers
prsssure
2nd
clutch.
to
the
valvecoversthe port to stop line
(30)
The
3rd clutch
valve.
pressure
3-4
shift
(5)
at
the
pressure
3rd
clutch
becomes
side,
Line
is moved to the right
pressure(30)is appliedto the 3rd clutch,and the 3rd clutchis engaged.
Fluidflows by way of:
- Line pressure(4)- CPBValve- LinePressure(5)* 1-2Shift Vaiv- LinePressure(5)* 2-3 ShiftValve
- Line Pressure(5)* 3-4 ShiftValve- 3rd ClutchPressure(30)* 3rd Clutch
The hvdraulicDressurealsoflows to the 1stclutch.However,no power is trsnsmittedbecauseof the one-wayclutch.
NOTE:
. When used,"|eft" or "right" indicatesdirectionon ths hydrauliccircuit.
. The hvdrauliccircuitshowsthe '97 - 98 models(7 positions);the'99 - 00 models(6 positions)is similar.
(cont'd)
www.emanualpro.com
14-35
Description
HydraulicFlow (cont'd)
4th Gear llQ! or E Posirion)
As the speedof the vehiclereaches the prescribedvalue.shift controlsolenoidvalve A is turned OFF by the pCM,
Shift controlsolenoidvalve B remainsOFF.Modulatorpressure(6)flows to the left end of the 1-2shift valveand the
left end of the 3-4 shift valve.Modulatorpressure(64) in the left end of the 1-2shift valveequalsmodulatorpressure
(68)in the right end of the 1-2shift valve.The 1-2shift valveremainsat left side by the tensionof the valvespring.
The 3-4 shiftvalve is movedto the right side by modulatorpressure(6A).The 3-4 shift valvecoversthe pon to the 3rd
clutch and uncoversthe port to the 4th clutchas this valve is moved to the right side,The 4th clutch pressure(41)
from the 3-4 shift valve becomes4th clutchpressure(40)at the manualvalve.The 4th clutchpressure(40)is applied
to the 4th clutch,and the 4th clutchis engaged.
Fluidflows by way of:
- Linepressure(4)+ CPBValve- Line Pressure(5)+ l-2 ShiftValve- LinePressure * 2-3
{5)
Shift Valve
- LinePressure(5)+ 3-4 ShiftValve- 4th ClutchPressure(41)+ ManualValve- 4th ClutchPressure(40)
+ 4th Clutch
The hydraulicpressurealsoflows to the lst clutch.However,no power is transmittedbecauseof the one-wavclutch.
NOTE:
. When used,"lelt" or " tight" indicatesdirectionon the hydrauliccircuit.
. The hydraulic circuitshowsthe '97 - 98 models(7 positions);the '99 - 0Omodels(6 oositions)issimilar.
14-36
www.emanualpro.com
E Position
(3)
Fluidflow throughthe torque convertercircuitis the same as in N position.Line pressure(1)changesto line pressure
(3')
servo
and
flows
to
the
pressure
1-2
shift
valve
(3)
at
the
and flows to the 1-2shift valve.Line pressure changesto line
(3")
vaive.The servovalveis movedto the right side (Reverserangeposition)and uncoversthe port to allow line pressure
valve
and
manual
valve
to
the
(3')
through
the
servo
valve
flows
pressure
1-2
shift
from
the
Line
manual
valve.
to the
changesto 4th clutchpressure(40).The 4th clutchpressure(40)is appliedto the 4th clutch,and the 4th clutchis engaged.
RverseInhibitor Control
Whenthe @ positionis selectedwhile the vehicleis movingforwardat speedsover 6 mph (10 km/h),the PCMoutputsthe
1stspeedsignalto shiftcontrolsolenoidvalvesA and B; shift controlsolenoidvalveA is turnedOFF,shift controlsolenoid
(3')
valve B is turned ON. The 1-2 shift valve is moved to the right side and coversthe port to stop line pressure to the
(40}
to
the 4th
pressure
is
not
applied
4th
clutch
and
valve,
pressure
to
the
servo
servo valve. Line
{3') is not applied
power
direction.
the
reverse
not
transmitted
to
is
clutch,as a result,
NOTE:
. When used,"lelt" ot " right" indicatesdirectionon the hydrauliccircuit.
'97 - 98 models(7 positions);the '99 - 00 models(6 positions)is similar'
. The hvdrauliccircuitshowsthe
(cont'd)
www.emanualpro.com
14-37
Description
HydraulicFlow (cont'dl
E Position
Fluidflow throughthe torqueconvertercircuitis the same as in fl position.Linepressure( 1)changesto line pressure(3)
and flows to the 1-2shift valve.Line pressure(3) changesto line pressure{3') at the 1-2shift valveand flows to the servo
valve.The servovalveis movedto the right side (Reverserangeposition)and uncoversthe port to allow line pressure(3")
to the manualvalveas in E position.Linepressure(3") from the servovalveis interceptedby the manualvalve.Hydraulic
pressureis not suppliedto the clutches,and power is not transmitted.
NOTE:
. When used,"left" or "right" indicatesdirectionon the hydrauliccircuit.
. The hydrauliccircuitshowsthe '97 - 98 models(7 positions);the '99 - 00 models(6 positions)issimilar.
14-38
www.emanualpro.com
Lock-upSystem
In E position('97- 98 models)and in E position('99OOmodels)(3rdand 4th),and E position('97- 98 models) and in E positionwith Over-Drive(O/D)is OFF(by
pressingthe O/Dswitch)('99- 00 models)(3rd),pressurizedfluid is drainedfrom the backof the torque converter througha fluid passage,causingthe lock-uppistonto
be held againstthe torqueconvertercover,As this takes
Dlace,the mainshaftrotatesat the same speed as th8
engine crankshaft.Togetherwith the hydrauliccontrol,
the PCM optimizesthe timing of the lock-up system.
Under certaincondltions.the lock-upclutch is applid
in 3rd and 4th gear.
duringdeceleration,
CONVERTER
TOROUE
LOCK.UPCONTROL
' VALVE
LOCK.UPCONTROL
SOLENOIDVALVE
A
Linaal
Solenoid
Prgssuls
OFF
OFF
High
Lock-up,Half
ON
Dutyoperation
OFF- ON
Low
MAINSHAFT
Lock-up,Full
ON
ON
High
COUNTERSHAFT
Lock-up
during
deceleration
ON
Duty operation
OFF- ON
Lock-up
Conditions
A
Lock-upOFF
MODULATOR
Pf,ESSURE
RELIEFVALVE
LOCK'UPTIMING
VALVE
SUB.SHAFT
LINEARSOLENOIDPRESSURE
COOLERRELIEFVALVE
ATF PUMP
ATF COOLER
ATF STRAINER
(cont'd)
www.emanualpro.com
14-39
Description
Lock-upSystem(cont'dl
Lock-upClutch
L
Ooeration(clutchon)
With the lock-upclutch on, the fluid in the chamber betweenthe torque convenercover and the lock-uDoiston is drained
off, and the converterfluid exertspressurethrough the piston againstthe torque convertercover,As a result,the convener turbine is lockedto the convertercover.This bipassesthe converter,placingthe vehiclein directdrive.
LOCK,UPPISTON
IOROUE
COVER
Drive plate
Torque convertercover
I
Lock-uppiston
t
Damperspring
{
Turbine
Mainshaft
MAIf{SHAFT
Operation(clutchoff)
With the lock-upclutch off, the fluid flows in the reverseof "clutch on." As a result,the lock-uppiston moves away from
the convertercover,and the torque converterlock-upis released.
TOROUE
Engine
COVER
I
Driveplate
{
Torqueconvertercover
{
Pump
I
Turbine
{
Mainshaft
{(1
\\
n1
Jtl
ort
MAII{SHAFT
14-40
www.emanualpro.com
To ATF cooler
INLET
No Lock-up
.
.
.
TOROUECONVERTER
Lock-upControlSolenoidValveA: OFF
Lock-upControlSolenoidValveB: OFF
High
LinearSolenoidPressure:
The pressurized
fluid regulatedby the modulatorworks
on both endsof the lock-upshift valve.Underthis condition, the pressuresworking on both ends of the lock-up
s h i f t v a l v e a r e e q u a l . a n d t h e l o c k - u ps h i f t v a l v e i s
m o v e d t o t h e r i g h t s i d e b y t h e t e n s i o no f t h e v a l v e
spring. Fluid trom the ATF pump will flow through the
left side of the lock-upclutchto the torqueconverter;the
lock-upclutchis OFF.
"|eft" and "right" indicatesdirection
NOTE:When usd,
on the hydrauliccircuit.
LOCK.UPCONTROL
SOI-ENOIDVALVE
MOOULATOR
PRESSURE
MAINSHAFT
RELIEFVALVE
COUNTERSHAFT
TIMING
LOCK-UP
VALVE
LINEARSOLENOIDPRESSURE
i COOLERRELIEFVALVE
ATFPUMP
ATF COOLER
ATF STRAINER
(cont'd)
www.emanualpro.com
14-41
Description
Lock-upSystem(cont'dl
HalfLock-up
a Lock-upControlSolenoidValveA: ON
a Lock-upControlSolenoidValveB: DutyOperation
OFF- ON
LinearSolenoidPressure:
Low
TOFOUECONVERTER
L(rcK.UPCONTROL
SOLENOID
VALVE
A
RELIEFVALVE
MODULATOR
PNESSURE
MAINSHAFT
The PCMswitchessolenoidvalveA on to releasemodulator pressurein the left cavityof the lock-upshift valve.
Modulator pressure in the right cavity of the lock-up
shift valve overcomesthe spring force,and the lock-up
shiftvalveis movedto the left side.
Line pressureis then separatedinto the two passagesto
the torque converter;torque converterinner pressure
entersinto right side to engagethe lock-upclutch,and
torque convener back Dressureenters into left side to
disengagethe lock-upclutch.
Back pressure(F2) is regulatedby the lock-upcontrol
valve,whereasthe positionof the lock-uptiming valve
is determinedby linearsolenoidpressureand tensionof
the valvespring.Also the positionof the lock-upcontrol
valve is determinedby the back pressureof the lock-up
control valve.torque converterpressure(regulatedby
the torque convertercheckvalve),and modulatorpressure (determinedby the lock-upcontrol solenoidvalve
B). The PCM switcheslock-upcontrol solenoidvalve B
on and off rapidly(duty operation),undercertajnconditions,to regulatebackpressur(F2)and lockthe torque
convertef.
NOTE:When used,"left" and "right" indicatesdirection
on the hvdrauliccircuit.
COUNIERSHAFT
L(rcK-UP
TIMING
VALVE
LINEARSOLENOIDPRESSURE
COOLERRELIEFVALVE
ATFPUMP
ATFCOOLER
14-42
www.emanualpro.com
ATF STRAINER
FullLock-up
.
.
.
TOROUECONVEFTER
LOCK-UPCONTROL
SOLENOIDVALVE
Lock-upControlSolenoidValveA: ON
Lock-upControlSolenoidValveB: ON
LinearSolenoidPressure:High
W h e n t h e v e h i c l e s p e e d f u r t h e r i n c r e a s e s l,i n e a r
solenoidpressureincreasesto high in accordancewith
the linearsolenoidwhich is controlledby the PCM.
T h e l o c k u p t i m i n g v a l v e o v e r c o m e st h e s p r i n gf o r c e
and moves to the left side. Also, this valve closesthe
fluid port leadingto the left side of the lock-upcontrol
valve.
Underthis condition,modulatorpressurein the left side
of the lock-upcontrol valve had alreadybeen released
by the lock-upcontrolsolenoidvalve B; the lock-upcontrol valve is moved to the left side. As this takes place,
torqueconverterbackpressureis releasedfully, causing
the lock-upclutchto be engagedfully.
NOTE:When used."left" and "right" indicatesdirection
on the hydrauliccircuit.
MODULATOR
PRESSURE
MAINSHAFT
RELIEF
VALVE
COUNTERSHAFT
TIMING
LOCK.UP
VALVE
SUB-SHAFT
+
BELIEF
VALVE
COOLER
LINEARSOLENOIOPRESSURE
ATFPUMP
ATF COOLER
ATF STRAINER
(cont'd)
www.emanualpro.com
14-43
Description
Lock-up System (cont'dl
DecelelationLock-up
a Lock-upControlSolenoidValveA: ON
a Lock-upControlSolenoidValveB; DutyOperation
OFF- ON
LinearSolenoidPressure:
Low
The PCM switchessolenoidvalve B on and off rapidly
u n d e r c e r t a i nc o n d i t i o n sT
. h e s l i g h t l o c k - u pa n d h a l f
lock-upregionsare maintainedto lock the torque convener propeny.
TOROUECONVERTER
MOOULATOR
PRESSURE
MAINSHAFT
RELIEFVALVE
COUNTERSHAFT
LOCK.UPTIMING
VALVE
SUB.SHAFT
LINEARSOLENOIDPRESSURE
COOLERRELIEFVALVE
ATFPUMP
ATF COOLER
www.emanualpro.com
14-44
ATF STBAINER
ComponentLocations
CONTBOLUN]T
POWERTRAIN
CONTROL
MODULE{PCMI
ASSEMBLY
COUNTERSHAFT
SPEEDSENSOR
AUTOMAIIC TRANSAXI.E
(A/T} GEAR POSITION
swtTcH
\
SHIFTCONTROL
SOLEM)IDVALVE
ASSEMBLY
www.emanualpro.com
SPEEDSCNSOR
14-45
PCMCircuitDiagram(A/T ControlSystem)
'97 Model
FUSAFELAY
BOX
UNDER.I]OOD
EATTEFY
_YEL_
IGNITON
SWITCH
UNDEF
OASN
FUSAFELAYSOX
T-l ,
-T Tl
t_
-:
G101
oowEa-qar.
MooLrE
cor.lForpcMr
*1F
ATP
NP
&
r*--'l_____O_=_
IO!
lrNo
,ATP
lR
. A T D, A - P , A - P , A - P
101 103 12 ll
UNDER
DASN
M 25(7.54)
'Fr-r.04
_a TMEALOC(
BrKru-<< calTFoL
P- r.-or..u
L
P_ *+rr
F- onmrx
f-"".>
CFUISE
CONTFOL
UNIT
pw
F_
P_ eLu
F-- enN
I l,[-l; ,
III
Ar'TGEAR
POS]TION
swtcN
14-46
www.emanualpro.com
["'"]
INTEFLOC(
CONIFOL
UNIT
KEYLCICI(
ACCPUSNSWSOLEIJOIO IGI
SHIFILOCX
SOLEIOD
PPNSW
LI]
ATPF
GND
]'
I
YEI]BLK
-[I
l
YEITILX
t,
I
l-f?
POSrn0N
PPOsITION
SEr!5OR
II
ENGINE
CooL,ANT
TEMPERATURE
SENSOF
tr h.
nf
I1",, II r
I
l"
8nN
II
H
I
SEFVICECHECK
CONNECTON
BLX
{
G101
www.emanualpro.com
PGMTerminal Voltage/MeasuringConditions
A/T ControlSystem-'97 Model
The PCMterminalvoltageand measuringconditionsare shownfor the connectorterminalsthat are relatedto the Ay'Tcontrol system.The other PCMterminalvoltageand measuringconditionsare describedin section11.
PCMTerminalLocations
A {32P}Connector
B (25P1Connectol
C {31PIConnector
D {16P}Connector
PCMCONNECTOR
A {32P}
Torminal Numbcr
Signsl
A9
LG1
G r o u n d( G 1 0 1 )
A10
PG1
G r o u n d{ G 1 0 1 )
At1
IGPl
422
Description
MeasuringConditions/TerminalVohage
Ground
Ground
424
IGP2
Description
Terminal Number
Signal
B1
LSM
Linearsolenoidpowersupply
negativeelectrode
lgnitionswitchON (ll):Pulsingsigna
82
LSP
Linearsolenoidpower supply
positive electrode
B3
SHA
Shift controlsolenoidvalveA
control
B4
LCB
Lock-upcontrolsolenoidvalve B
control
B5
LCA
Lock-upcontrolsolenoidvalveA
control
86 to 87
B8
89 to 810
14-48
www.emanualpro.com
Measuring Conditions/TerminalVohage
Not used
ATPD3
In E position:0V
In otherthan E position:Batteryvoltage
PCMCONNECTORB (25P)lcont'd)
Signal
811
SHB
Shift controlsolenoidvalveB
control
812
ILU
lnterlockcontrol
B13
D 4I N D
D4 Indicatorlight control
814
NMSG
Mainshaftspeedsensorground
815
NM
Mainshaftspeedsensorsignal
InpuI
Dependingon enginespeed:Pulsingsignal
When engineis stopped:0 V
816
ATP R
I n E p o s i t i o nO; V
In otherthan E position:Batteryvoltage
817
ATP2
InEposition:0V
In otherthan E position:Batteryvoltage
B18
ATP 1
InEposition:0V
In otherthan E position:Batteryvoltage
NCSG
Countershaft
speedsensorground
NC
Countershaft
speedsensorsignal
Inpur
Dependingon vehiclespeed:Pulsingsignal
when vehicleis stooped:0 V
824
ATP D4
I n E p o s i t i o n0: V
In other than lgalposition: Bafteryvoltage
825
ATP NP
0V
In E andE positions:
V
Inotherthan
@ andffi positions:5
8 1 9t o 8 2 1
B22
Description
voltage
MeasuringConditions/Terminal
TerminalNumbel
Not used
PCMCONNECTOR
C {31PI
TerminalNumber
c10
Signal
Description
Measuring Conditions/TerminalVoltage
SCS
Servicechecksignal
VBU
Back-uppower system
(under-hoodFuse47)
Alwaysbatteryvoltage
Signal
STOPSW
www.emanualpro.com
Description
Brakeswitchsignalinput
Measuring Conditions/TerminalVoltage
BrakepedalpressedrBatteryvoltage
Brakepedalreleased:0 V
14-49
PCMCircuitDiagram(A/T GontrolSystem)
'98 Model
FUSAFELAY
sox
UNOEF-HOOO
_YEL_
rGD2
I ocr
ATP
NP
I oG2
IDl
lrND
,ATP
lR
I CAs
, A T P, A - P , A T P, A _ P
lD4 lD3 12 ll
PNK BLU
rronr
F_
GFNTBLX
*,',,,)83Hf'L
f-'r'------}-'er'
F_
cRN_______]_f-
F_
gnN
PN(
*'-> 3111"?"
1*[-l
l
l
,I I
sr{rTat
14-50
I SIOPSW
09 lD0 lDl,llDl5
UNOEF-DASH
FUSE/BELAYBOX
www.emanualpro.com
| V8 S0.
Gro]
NIEFIOCX
T
CONTAOLI]N
KEYLOCX
ACCPUSN
SW SOLEIOLO 6]
SHFILOCK
SOLENO1O
PPINSW
ILU
YEUBLX
WNI/8LI< V
ATPP
GNO
II '
I
BLl(BLU
It_
___L
T-T
l
l
YEL]BLK
PosrTroN
VI
PPOSITON
WHTELK
l , l
,T
q**
IH
lF I
l:$"."
-T-
SPEED
SENSOR
I s"'nLocr erx
tJFj
gLUA|/H'I
lS0LEN00 |
4
vrL
__t
;,
,l
Tl'
BLU/YELGFNAiI/N]
COTJNIEFSHAfI
SPEEDSENSOA
LNEAFSOLEID
l*
BFN
-T-
--l
t*l
I
t ? t L
SERVCECHECX
CONNECTOF
I SNFTCONTFOL
I SOLENOIDVALVE
AssEM4Y
I
I-:
BLK
I
BqNLK
I
Gr01
www.emanualpro.com
PCMCircuitDiagram(A/T ControlSystem)
'99- 00 Models
IJNOER'HOOD
FUSE/FELAY
EoX
EATTERY
-]-
8LKryEL
l .
]T
BLX,'YEL
AIP,O,0,ATP,ArPlO/D
04 t5w t2
tr
tN0
D 9 1 0 0 | 0 r 4| D r t I B t g
IJNOER
DASII
FUS'/FELAYBOX
GAUGEASSEMELY
LTGRN
BLKtsLU
Fffi[t**
L'om
{--1
sr&BrLr
l-
F-lwr-i
FED
|--FED----.1
YEL
8LU
|-BFN-LI BLU
f-
Lr sLrJ-l
,-rI ,
G401
)
{
:-\
G4o1
POS]IION
!r'TGEAF
www.emanualpro.com
14-52
NIEFLOCX
UNIT
CONTROL
.'1"
.l'
I
XEYLOCX
ACCP1JSHSW
SOLENOID 61
SHFILOCX
SOLENO
D
PPNSW
YEU8L(
T--[T
?
I
YEUBLK
t,
rt--r
| tr-r I
t9il
LJA
LOCK
1SNTFl
D
SOTENO
L
YEL
LL]
A'PP
GND
l6
I
SLTBL!
Posti0N
SPEEO
SENSOn
YL
I
iJrl
I
(PCM)
POWEFTFALN
CONTROL
MODIJLE
0rr
012
i"']*
lDro
BFN
BLU/IEL
8FN
BLI]IEL
I t
-tl
Trt
SERVCE
CHECK
CONNECIOF
f7
nx^*
ltfJ: I o
coNNEcroR
LOC(,I]PCON'IBOL
SOLENOIDVALVE
BLK
G10r
www.emanualpro.com
PCMTerminalVoltage/MeasuringConditions
A/T ControlSystem-'98 - 00 Models
The PCMterminalvoltageand measuringconditionsare shownfor the connectorterminalsthat are relatedto the A"/Tcontrol system.The other PCMterminalvoltageand measuringconditionsare describedin section11.
FCM ConnectorTerminalLocalions
o (16Pt
T6rminal Number
Signal
A5
CRS
Downshiftsignalinput from
cruisecontrolunit
Whencruisecontrolis used;Pulsingsignal
A10
scs
A14
('98 model)
D4 IND
D4 indicatorlight control
{Voltagefrom PCMturns D4 light
Description
oN)
A14
('99- 00 models)
D IND
D indicatorlight control
(Voltagefrom PCMturns D light
oN)
428
ILU
A.32
STOPSW
MeasuringConditions/TerminalVoltage
Interlockcontrol
(Voltagefrom PCM)
Brakeswitchsignalinput
Brakepedalpressed;Batteryvoltage
Brakepedalreleased:0 V
Signal
B1
IGPl
Powersupplycircuitfrom main
relayvia under-hoodFuse44
82
PG1
G r o u n d( G 1 0 1 )
B8
LSM
Linearsolenoidpower supply
negativeelectrode
IGP2
Powersupplycircuitfrom main
relay
PG2
G r o u n d( G 1 0 1 )
810
B17
819
('99- 00 models)
O/DIND
s20
MeasuringConditions/TerminalVoltage
With ignitionswitchON {ll):Batteryvoltage
With ignitionswitchOFF:0 V
Linearsolenoidpower supply
positiveelectrode
Over-Drive(O/D)OFFindicator
light control
G r o u n d( G 1 0 1 )
B21
VBU
Back-uppowersupply
(under-hoodFuse47)
B22
LG2
G r o u n d( G 1 0 1 )
14-54
www.emanualpro.com
Description
PCMCONNECTORD (16P)
Signal
D1
LCA
Lock-upcontrolsolenoidvalveA
control
Duringlock-upconditions:Bafteryvoltage
Duringno lock-upcondition:0 V
D2
SHB
ShiftcontrolsolenoidvalveB
control
Batteryvoltagein followingpositions:
. E, E and positions
. E, -ql, and E positionsin lst and 2nd gear
0 V in followingpositions:
. E, E;, and E positionsin 3rd gear
. E and E positionsin 4th gear
. E, El, and El positions
D3
LCB
Lock-upcontrolsolenoidvalveB
control
Duringfull lock-upconditions:Batteryvoltage
Duringhalf lock-upconditions;Pulsingsignal
D4
Not used
Powersupplyfor solenoidvalves
(Under-hoodFuse15)
ATP R
In E position:OV
In otherthan E position:Bafteryvoltage
SHA
Shift controlsolenoidvalveA
control
Batteryvoltagein followingpositions:
. E position
. E, E, and E positionsin 2nd and 3rd gear
. E position
0 V in followingpositions:
. E position
. E. E, and E positionsin lst gear
. Erl and E positionsin 4th gear
.EandEpositions
ATPD3
In E position:
0V
voltage
Baftery
In otherthanE position:
O/DSW
Over-Drive(O/D)switch signal
input
D9
ATP D4
I n E p o s i t i o n0: V
In otherthan E position:5 V
D10
NC
Countershaft
sDeedsensorinout
Dependingon vehiclespeed:Pulsingsignal
when vehicleis stopped:Approx.0 V
Dl1
NM
Mainshaftspeedsensorinput
Dependingon vehiclespeed:Pulsingsignal
When engineis stopped:Approx.0 V
D12
NMSG
Mainshaftspeedsensorground
D13
ATP NP
I n E a n d E p o s i t i o n s 0: V
In otherthan E and m position:5 V
D14
AlP 2
I n E p o s i t i o n0 ;V
Battery
voltage
In otherthanE position:
D15
ATP 1
D16
NCSG
D5
VB SOL
D6
D7
D8
{'98model}
D8
('99- 00 models)
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Description
Measuring Conditions/TerminalVoltage
Terminal Numbor
InEposition:0V
ln otherthan El position:Batteryvoltage
Countershaft
speedsensor
grouno
14-55
TroubleshootingProcedures
DATA LINKCONNECTOR
{16PI
[ -=.r,
ili
,i
/i,
v,.,
i
HONDAPGMTESTER
ol
OBDII SCANTOOL
2.
3.
4.
5.
6.
7.
8.
Connectthe OBD ll ScanTool (conformingto SAEJ1978)or HondaPGMTesterto the 16PDLC.(Seethe OBD ll Scan
Tool or HondaPGMTesteruser'smanualfor specificinstructions.lf you are usingthe HondaPGMTester,makesure
it is set to the SAE DTCWpe).
Turn the ignitionswitchON (ll),and observethe DTCon the screen
Recordallfuel and emissionDTCS,
A,,/T
DTCS,and freezedata.
lf there is a fuel and emissionsDTC,first checkthe fuel and emissionssystemas indicatedby the DTC(exceptfor DTC
P0700).DTCP0700meansthere is one or more Ay'TDTC,and no Droblemswere detectedin the fuel and emissions
circuitof the PCM.
Wire down the radio station presets.
Resetthe memorywith the PGMTestero. by removingthe BACKUP fuse in the under-hoodfuse/relaybox for more
than 10seconds.
Drive the vehicle for several minutes at speeds over 30 mph (50 km/hr), and then recheckfor DTCS.lf the A/T DTC
returns,9o to the Symptom-toComponentCharton pages14-60and 14-61for the '97 models,and pages14-62and
14-63for '98 - 00 models.lf the OTCdoes not return,there was an intermittentproblemwithin the circuit.Makesure
all pinsand terminalsin the circuitare tight, and then go to step8.
Resetthe radioDresetstations,and setthe clock.
1 4 -5 6
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.AUGE
AssEMaLY
'99 - O0models
$1,"^f:tT"'ff,
SCSSERVICECONNECTOR
07PAz- (x!l0100
'97 - 98 models
Sr. DTC1
S.. DTC2
Long blink
Sc. DTC 15
(cont'd)
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14-57
TroubleshootingProcedures
(cont'dl
L
2.
KICK PANEL
BACKPROBE
EACKPROBE
SET
07sAz- 001000a
{tworequired)
DIGITALMULTIMETER
(Commercially.v.ilablel
KS-AHM-32-003
ot oquivalont
14-58
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PCMResetProcedure
'1. Turn the ignitionswitchoff
2.
Removethe BACKUP fuse (7.5A) from the under-hoodfuse/relaybox for 10 secondsto resetthe PCM.
NOTE:
. Disconnecting
the BACKUp fuse also cancelsthe radio presetstationsand clock setting Make note of the radio
presetsbeforeremovingthe fuse so you can resetthem
. The PCMmemorvcan also be clearedby usingthe OBD ll ScanTool or HondaPGMTester'
BACKUP IRADIO}{7.5AI FUSE
UNDER.HOOD
BOX
FUSE/RELAY
Final Proceduro
This proceduremust be done after any troubleshooting.
1. Turn the ignitionswitchOFF.
2.
Resetthe PCM.
3.
4.
5,
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(48 km/h).
14-59
Symptom-to-Component
Chart
ElectricalSystem-'97
Model
DTC*
E Indicatol
Light
MIL
P1753
(1)
Blinks
ON
Lock up controlsolenoidvalveA
(seepage 14-64)
P1758
\21
Bl i n k s
ON
Lock-upcontrolsolenoidvalve B
(seepage14-66)
P1 7 0 5
(5)
Blinks
ON
(seepage14-68)
P1706
(6)
OFF
ON
A,/Tgear positionswitch{open)
(seepage14-70)
P0753
\11
Bl i n k s
ON
Shift controlsolenoidvalveA
(seepage 14-72)
P0758
(8)
Blinks
ON
Shift controlsolenoidvalveB
(seepage14-74)
P0720
(9)
Blinks
ON
Countershaft
speedsensor
{seepage14-76)
P0715
(15)
Bl i n k s
ON
Mainshaftspeedsensor
(seepage l4-78)
P1768
(1 6 )
Blinks
ON
Linearsolenoid
(seepage 14-80)
P0740
{40)
OFF
ON
Lock-upcontrolsystem
(seepage14-82)
P0730
(41)
OFF
ON
Shift controlsystem
(seepage 14-84)
Detection ltem
14-60
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Page
Inspection
Ref.page
14-86
't 4-41
Checkshift locksystem
14-89
CheckkeYinterlocksystem
14-91
NOTE: lf a customer describesthe symptom for code P1706(6), it will be necessaryto recreatethe symptom by test-driving, then recheckthe OTC.
www.emanualpro.com
14-61
Symptom-to-Component
Chart
ElectricalSystem-'98 - 00 Models
Et Indicatol
Lighr (98)
E Indicator
Light ('99 - 00)
MIL
P1753
(1)
Blinks
ON
Lock-upcontrolsolenoidvalveA
{seepage14-93)
P1758
(21
Blinks
ON
Lock-upcontrolsolenoidvalveB
(seepage 14-96)
P1705
(5)
Blinks
ON
(seepage14-99)
P1706
(6)
OFF
ON
A,/Tgear positionswitch(open)
(seepage 14-103)
P0753
(71
Blinks
ON
ShiftcontrolsolenoidvalveA
(seepage14-106)
P0758
(8)
Blinks
ON
Shift controlsolenoidvalveB
(seepage14-109)
P0720
(9)
Blinks
ON
Countershaft
speedsensor
{ s e ep a g e1 4 - 1 1 2 )
P0715
{15)
Blinks
ON
Mainshaftspeedsensor
( s e ep a g e1 4 - 1 1 4 )
P1768
(16)
Blinks
ON
Linearsolenoid
( s e ep a g e1 4 - 1 1 7 )
POl40
(40)
OFF
ON
Lock-upcontrol system
(seepage 14-119)
P0730
(41)
OFF
ON
Shiftcontrolsystem
( s e ep a g e1 4 - 1 2 1 )
DTC*
Detestion ltom
Page
14-62
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Inspection
14-123
14-125
Checkshift locksystem
14-'t26
Checkkey interlocksystem
14-129
Ref.page
14-131
14-132
CheckOver-Drive{O/D}
switchcircuit
14-133
(6), it will be necessaryto recreatethe symptom by test-drivNOTE: lf a customer describesthe symptom for code P17OO
ing.then recheckthe DTC.
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14-63
ElectricalTroubleshooting('97 Model)
TroubleshootingFlowchart- Lock-upControlSolenoidValveA
. OBD ll ScanTool indicatesCode
P1753.
. S e l f - d i a g n o s i si @ i n d i c a t o r
light blinksonce.
PossibleCause
. Disconnectedlock-up control
solenoid valve A/B assembly
. Short or open in lock-up control
solenoidvalveA wire
. Faulty lock-up control solenoid
P e r f o r mt h e l o c k , u p c o n t r o l
s o l e n o i dv a l v eA t e s t u s i n gt h e
HondaPGMTester.
NO
PCMCONNECTORS
Checkfor a Short to Power:
r. I urn rne tgntUonswttchut-f.
2. Disconnecr
the A (32P)and B
( 25 P ) c o n n e c t o r sf r o m t h e
PCM.
3. Turnthe ignitionswitchON (ll).
4. Measurethe voltagebetween
t h e 8 5 a n d A 9 o r A 2 2t e r m i
nals.
Wiresideof femaleterminals
ls there voltage?
ls the resistance
12 25 ()?
To page14 65
14-64
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PCMCONNECTORS
Check Lock-up Control Sol6noid
Valve A tor a Short Circuit:
1 . D i s c o n n e ct ht e 2 P c o n n e c t o r
from the lock-upcontrolsole
noidvalve4!/Bassembly.
2. Checkfor continuitybetween
the 85 andA9 or A22termi
nals.
Wiresideof femaleterminals
LOCK.UPCONTROLSOLENOID
VALVEA/B ASSEMBLYCONNECTOR
----E-
lFr]
.=-A LcA IYELI
(nJ
Y
Terminalsideof maleterminals
12- 25 O?
ls the resistance
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14-65
ElectricalTroubleshooting('97Model)
TroubleshootingFlowchart- Lock-upControlSolenoidValveB
. OBOll ScanTool indicatesCode
P1758.
. Self-diagnosispr- indicatorlight
blink3twice.
PossibleCauso
. Disconnoctedlock-up control
solnoid valve A/B assembly
. Short or opn in lock-upcontrol
3olenoidvrlve B wi.e
. Faulty lock-up control solenoid
valve B
lem verification.
PCMCONNECTORS
l s t h e r e s i s t a n c e1 2 2 5 O ?
To page14-67
14-66
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Frompage14 66
PCMCONNECTORS
Wiresideof femaleterminals
LOCK-UPCONTROLSOLENOID
VAI-VEA/B ASSEMBLYCONNECTOR
Me6aureLock-upControl Sole_
noid Valve B Resistanceat the
SolenoidValve Connector:
Measurethe resistancebetween
the No. 1 terminalof the connector and body ground.
12- 25 0?
ls the resistance
LC B (GRN/BLK)
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14-67
ElectricalTroubleshooting{'97Model}
TroubfeshootingFlowchart- AIT GearPositionSwitch (Short)
. OBOll ScanTool indicatsCode
P1705.
' Selt-diagnosisp1- indicatortight
blinb Iive times.
Po$ible Cause
' Short in A/T gear position switch
. Faulty A/T gear position switch
NOTE:Code P1705(5) is causedwhen
t h e P C M r e c e i v e st w o g e a r p o s i t i o n
anputsat the sametime.
Doesany indicatorstayon
when the shift leveris not in
that position?
Do allgear positionindicators
go out?
PCMCONNECTORS
MeasureATP R Voltago:
1. Shittto all positionsotherthan
tr.
2. lMeasure
the voltagebetween
the 816 and Ag or A22 terminals.
MeasureATP NP Voltage:
1. Shiftto all positionsotherthan
NorE.
2. Measurethe vohagebetween
lhe 825 and Ag or A22 terminals.
To page14-69
14-6 8
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Frompage14-68
MeasureATP D4 Voltage:
1. Shiftto all positionsotherthan
Eil
ls thereapprox.5 V?
MasureATP D3 Voltage:
L Shiftto all positionsotherthan
tr.
2. Measurethe voltagebetween
the 88 and A9 or A22 termi
nats.
ls there bafteryvoltage?
MeasurATP 2 Vohage:
1. Shiftto all positionsotherthan
l;
2. Measurethe voltagebetween
the 817 and Ag or A22 termi'
nals.
Check for short in the wire
bstwen the 817 terminal and the
A/T gear posilion switch or A/T
gear position indicator. lf wire is
OK, checklor looseterminal fit in
th6 PCM connctoF. lf necssaty,
substitute a known-good PCM
and recheck.
Mersure ATP 1 Volt.ge:
1. Shiftto all positionsotherthan
El.
2. Measurethe voltagebetween
t h e 8 1 8 t e r m i n a la n d A 9 o r
A22terminals.
ls there batteryvoltage?
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14-69
ElectricalTroubleshooting('97Model)
TroubleshootingFlowchart- A/T GearpositionSwitch (Openl
. OBD ll ScanTool indicat6 Code
P1706.
. Setf-diagnGb Dl indicatortight
blinks six tim$.
Po$iblo C.u3e
. DisconnectedA/T gear position
switch connectol
. Open in A/T goar position switch
. Faulty A/T goar position switch
Measu.eATP R Voltage:
'1. Turnthe ignition
switchON (ll).
2. Shiftto E position.
3. Measurethe voltagebetween
the 816 and Ag or A22 terminals.
MeasureATP NP Voltage:
1. Shiftto E or E position.
2. Measurethe voltagebetween
the 825 and A9 or A22 termin al s ,
ATP NP ILT GRNI
Repai. open in th6 wir6 bctwoan
the 825 terminal and tho A/T gear
polition indicltor or tho A/T gea.
Doshionswhch.
MoasureATP 04 Voltage:
1. Shiftto E position.
2. Measurethe voltage between
the 824 and A9 or A22 terminars,
To page14-71
14-70
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Frompage14-70
FCM CONNECTORS
MeasureATP D3 Vohag:
1. Shiftto E position.
2. Nleasurethe voltagebetween
the 88 and Ag or A22 termi
nals,
Wire sideof femaleterminals
MsasureATP2Volttg6:
'1. Shiftto position.
E
2. Measurethe voltage between
the 817 and A9 or A22 termi'
nals.
MoasureATP1Voltage:
1. Shiftto A position.
2. Measurethe voltagebetween
the 818 and Ag or A22 terminats,
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ElectricalTroubleshooting('97 Model)
TroubleshootingFlowchart- Shift ControlSolenoidValveA
. OBD ll ScanTool indicatesCode
P0753.
. Self-diagnoskE indicator light
blinks seventims.
PossibleCauso
. Disconnectedshift control solenoid
valve A/8 a$embly connector
. Short or open in shift control solenoid valve A wire
shift controlsolenoidvalveA
I
Performthe shiftcontrolsolenoid
v a l v eA t e s t u s i n gt h e H o n d a
PGMTester.
PCMCONNECTORS
Checktor a Short to Power:
1. Turnthe ignitionswitchOFF.
2. Disconnect
the A (32P)and B
( 25 P ) c o n n e c t o r sf r o m t h e
PCM.
3. Turnthe ignitionswitchON lll).
4. Measurethe voltagebetween
the 83 and Ag or A22terminals.
ls the resistance
12 25 {)?
To page l4-73
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14-72
Frompage14-72
C h e c kS h i f t C o n o l S o l e n o i d
Valve A for a Short Circuit:
1. Disconnectthe 2P connector
from the shiftcontrolsolenoid
valve Ay'Bassembly.
2. Checkfor continuitybetween
the 83 andA9 orA22terminals.
SHIFTCONTROLSOI.ENOID
VALVEA/B ASSEMALYCONNEC1OR
MeasureShift Control Solenoid
Valv6 A Resistanceat the Solenoid
Valve Connector:
Measurethe resistancebetween
the No. 1 terminalof the connec
tor and bodyground.
lffil
SHA IBLU/YELIl-(o)
T
I
Terminalsideof maleterminals
ls the resistance
12- 25 0?
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14-73
ElectricalTroubleshooting('97Model)
TroubleshootingFlowchart- Shift ControlSolenoidValveB
. OBOll ScanToot indicrt8 Codo
P0758.
. Setf-diagnGisE indicatorlight
blinks oight tim93.
Po33iblaCrusa
. Disconnec{edshift cont.ol solenoid
valve A/B dssomblyconnector
. Short or open in shift conlrol solenoid valvg B wire
' Faultvshift comrol 3olenoidvalvo B
PCMCONNECTORS
Chocktor a Sho.t to Power:
1. Turnthe ignitionswitchOFF.
2. Disconnect
the A (32P)and B
{25P)connectorsIrom the PCM.
3. Turnthe ignitionswitchON (ll).
4. Measurothe voltage botveen
the 811 and Ag or A22 terminats.
Wiresideot femaleterminals
R.p.ir 3hort to power in the wire
botwon the 811 iormin.l and
tho shift control sol.noid valve B.
ls the resistance
12- 25 O?
To page14-75
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14-74
Frompage14-74
PCMCONNECTORS
C h e c kS h i f t C o n t r o l S o l e n o i d
Valvo B tor a Short Circuil:
1. Disconnectthe 2P connector
from the shift control solenoid
valvey'y'8assembly.
2. Checkfor continuitybetween
the 811 and Ag or A22 terminals,
Wire side of female terminals
ti;Tll
I sH B |GRN/W{T|
oY
I
Terminalsideof maleterminals
ls the resistance
12- 25 O?
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14-75
ElectricalTroubleshooting('97 Model)
TroubleshootingFlowchart- CountershaftSpeedSensor
. OBO ll Scan Tool indicatesCode
m720.
' solt-diagnosis iD!' indicator light
blink3 nine tim6s.
PossibleCause
. Looseor faulty connectionbetween
ih PCMand vehicleharness
. Disconnected countershaft spoed
sensorconneclor
. Short or open in countershaftspeed
. FaultycounteBhaft speedlensor
I
Connectthe Honda PGM Tester,
a n d t e s t - d r i v et h e v e h i c l ew i t h
the tester in Data Link or snap'
Shot mode,Makesure the countershaftspeed sensor readsthe
sameas the vehiclespeedsensor
lVSS).
The countershaftsooed sensor is
OK sr this time. Veritv that all
c o n n e c l o a si n t h e c i r c u i t a r e
making good contacl.
C h e c kt h e c o u n t e r s h a f ts p e e d
sensor installation,and check it
for damage.
ls the countershaft
speedsensor installedproperly,and not
damaged?
ll-'T,ll
-rT
ral
YL__lI
Terminalsideof maleterminals
ls the resistance400- 600 o?
To page14-77
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14-76
B I25PI
PCMCONNECTOR
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14-77
ElectricalTroubleshooting{'97Model)
TroubleshootingFlowchart- MainshaftSpeedSensor
. OBD ll Scan Tool indic.t6 Code
m715.
. Self-diagnosisE indic.tor light
indicatagCode 15.
Po$ible Cau3o
. Disconnocted mainshaft speod sensot connectot
. Short or open in mainsh.ft sp6ed
' Faulty meinshaftspoedsensor
N O T E : C o d e P 0 7 1 5 1 1 5o)n t h e P C M
doesn'talwaysmeanthere'san electrical
problemin the mainshaftor counlersharl
speedsensorcircuit;code P0715(15)
may
problemin the
also indicatea mechanical
transmission.
Checkthe freezedata with
a Honda PGM Tester. lf the mainshaft
speed sensor rpm was 0, proceedwith
this troubleshooting.
lf not, the probable
problomwithinthe
causeis a mechanical
transmission,
MAINSHAFTSPEEO
SENSORCONNECTOR
_ E _
MeaaureMaiNhatt SpoedSen3or
R6sist!nce at the Sensor Connecaor:
1. Disconnectthe 2P connector
from the mainshaftspeedsensor connector.
2. lreasurethe resistance
of the
mainshaftspeedsensor.
ItiT,ll
-F=r
9t
LJ
Terminalsideof maleterminals
ls the resistance
400- 600O?
B {25P'
PCMCONNECTOR
To pagel4-79
14-78
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Frompage14'78
PCMCONNECTOR
B {25P}
MoasuroMrin3haft SpoedSanlor
Resktanco:
1. Connectthe mainshaftspeed
sensor2P connector,
2, Measure the resistance
betweenthe 815 and 814 terminals,
Wir sideof femaleterminals
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14-79
ElectricalTroubleshooting('97Modell
TroubleshootingFlowchart- LinearSolenoid
. OBD ll Scan Tool indicatesCode
P1768.
. S.lt-diagnosis E indicator light
indicat* Code 16.
PossibleCaus
. Disconnoctedlinear solenoid con. Short or oDen in linear solenoid
. Fsultv linear solenoid
LINEARSOLENOIDCONNECTOR
t-TTI t]]lt
t-T
lI ?rr l
Mssurc Linear Solanoid Re3istance ei th SolonoidConnoctor:
1. Disconnectthe 2P connector
from the linear solenoidconnector,
2, Measurethe resistance
ol the
linearsolenoid.
at
l
L_l
Terminalsideot maleterminals
ls the resistance
about5.0O?
B I25PI
PCMCONNECTOR
LSM {WHTI
LSP{RED)
CheckLinearSolenoid{or a Short
Cileuit:
1. Disconnect
the B (25P)connec
tor from the PCM.
2. Checkfor continuitybetween
t h e b o d y g r o u n da n d t h e B 1
terminaland 82 terminalindi
vidually.
Wiresideof lemaleterminals
Rooairshort in the wires between
the Bl end 82 terminek .nd the
linearsolenoid.
To page14-81
www.emanualpro.com
ChckGround Lin:
1 . D i s c o n n e ct th e A ( 3 2 P )c o n nectorfrom the PCM.
2. Checklor continuitybetween
t e r m i n a l sA g a n d A 1 0 a n d
b e t w e e nt e r m i n a l sA 2 2 a n d
A.23.
PGl IBLKI
PG2(ALKI
Wiresideof temaleterminals
Repair loose terminal or opon in
th wires between terminals A9,
A10,A22 and A23 and g.ound,and
repairpoor ground lG101,G4011.
ls the resistance
about5.00?
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14-81
ElectricalTroubleshooting('97Model)
TroubleshootingFlowchart- Lock-upControlSystem
. OBD ll ScanTool indicrt6 Cod6
P0740.
. Self-diagno3bE indicatorlight
indicatos Codc 40.
PossibloCause
Faulty Lock-upcontrol sy3t6m
* Even if yotl cannot reproducecode P0740.test the line pressure,test the clutch
pressures,
replacethe lock-upcontrolsolenoidvalveassembly
and i{ necessary,
R6pairtho hydraulicaystm as
necessary{seepage 14-162}.
ls eachclutchpressurewithin
the servicelimit?
To page14-83
1 4-82
www.emanualpro.com
Repairthe hydraulicsystem ds
necessary {see pago 14-152rnd
14-163).
From page14 82
R e p l a c et h e L o c k - u p C o n t r o l
S o l e n o i dV a l v e A s s e m b l ya n d
Recheck:
1 . R e p l a c et h e l o c k - u pc o n t r o l
solenoidvalve A/B assembly
(seepage14-'135).
2 . T u r n t h e i g n i t i o ns w i t c hO F F
and reset the PCM by removing the BACKuP (7.5A) fuse
in the under-hoodfuse/relay
box for morethan 10seconds.
3. lJsingthe scantool, checkto
be surethatthe enginecoolant
is 176"F180'C)or
temperature
above,
4 . D r i v et h e v e h i c l ea t 5 5 m p h
(88 km/h)constantlyfor more
tnan one mrnute.
5. Recheck
for code P0740(40).
R e p l a c et h e L i n e a r S o l n o i d
A$embly and Recheck:
' 1 . B e p l a c et h e l i n e a r s o l e n o i d
assembly{seepage14-138).
2. Turn the ignition switch OFF
and resetthe PCMmemory by
removingthe BACKUP (7.5A)
fuse in the underhood fuse/
r e l a yb o x f o r m o r e t h a n 1 0
seconds.
3. Usingthe scantool, checkto
be surethatthe enginecoolant
temperature
is 176"F(80'C)or
above.
4. Drivethe vehicleat 55 mph (88
km/h)constantlyfor more than
oneminute,
5. Recheck
for codeP0740{40).
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ElectricalTroubleshooting('97Model)
TroubleshootingFlowchart- Shift ControlSystem
. OBD ll ScanTool indicatesCode
P0730.
. S e l t - d i a g n o s i sE , l i n d i c a t o r
light indicatesCode41.
PossibleCause
F""lty "t lft ".tttr"l "y"t..
ls eachclutchpressurewithin
the servicelimit?
To page 14-85
www.emanualpro.com
P e r t o r mt h e T r o u b l e s h o o t i n g
Flowchart for the indicated
Codels). Do not conlinu with
t h i s t r o u b l e s h o o t i n gu n t i l t h e
causesof anv other DTCShave
been corrected.Recheckfor code
P0730 {41)after troubloshooting.
+ E v e n i t y o u c a n n o t r e p r o d u c ec o d e
P0730,test drive the vehicle,test the
c l u t c h p r e s s u r e sa, n d i f n e c e s s a r y ,
replacethe shiftcontrolsolenoidvalve
Repairthe hydraulicsvstem as
necessary lsee page 1,1-162and
r4-1631.
Frompage14-84
Doesthe OBDllscantool
indicatecode P0730or does
the Di indicatorlightindicatecode 41?
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14-85
ElectricalTroubleshooting('97Modell
TroubleshootingFlowchart- E IndicatorLight On Constantly
The E indicator light is on constantly {not blinking) whenever
the ignitionswitch b ON (lll.
B I25PI
PCMCONNECTOR
IGRN/8LKI
Maa3ureATP D4 Voltage:
1. Turnthe ignitionswitchOFF.
2. Connectthe B (25P)connector
to the PCM.
3. Turn the ignitionswitchON (ll).
4. Shiftto any positionother than
E.
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Checkthe SorviceCheckConnectori
Make sure the specialtool 1SCS
ServiceConnector)is not connected tothe servicecheckconnector,
ls the specialtool(SCSService
Connectorlconnected
to the servicecheckconnector?
LGl IBRN/BLKI
Checkthe Ground Circuit:
1. Turnthe ignitionswitchOFF.
2. Disconnect
the A {32P)connector from the PCM.
3. Check for continuity between
the A9 terminal and body
ground and tho A22 terminal
and body ground.
LG2(BRN/BLKI
To page14-88
(cont'd)
www.emanualpro.com
14-87
ElectricalTroubleshooting('97Modell
TroubleshootingFlowchart- E IndicatorLight DoesNot GomeOn (cont'dl
Frompage14-87
IYEL/BLK)
Measure Power Supply circuit
Voltage:
1. Turnthe ignitionswatch
ON (ll).
2. Measurethe voltagebetween
t e r m i n a lA
s g a n dA 1 1 a n d
b e t w e e nt e r m i n a l sA 2 2 a n d
A24.
ls therebaReryvoltageT
IGP2IYEL/BLK)
MeasurDil INOVoltag6:
L Turnlhe ignitionswitchOFF.
2. Connectthe A 132P)
connector
to the PCM.
3. Connecta digital multimeter
to the 813 and A9 or A22 ter
mtnals,
4 . T u r n t h e i g n i t i o ns w i t c hO N
(ll),and makesurethat voltage
is available
for two seconds.
Check for an opn in the wire
between the 913 terminal and
the gauge assembly. lf wire is
OK. check tor a faulty E indicator lighl bulb or a taulty gauge
a$embly printed circuil bo.rd.
14-88
www.emanualpro.com
ChockBrakeLight Operation:
Pressthe brakepedal.
MasureSTOPSW voltage:
l Turnthe ignitionswitchOFF.
2 . D i s c o n n e ctth e A ( 3 2 P )a n d
D (16P)connectorslrom the
PCM.
3. Measlre the voltagebetween
the D5 and Ag or A22 terma
nals with the brake Pedal
pressed,
Wire sideof lem6letermanals
ls there batteryvoltage?
ILU IWHT/REDI
(cont'd)
To page14 90
www.emanualpro.com
14-89
ElectricalTroubleshooting('97 Model)
TroubleshootingFlowchart- InterlockSystem- Shift LockSystem(cont'd)
Frompage14.89
INTERLOCK
CONTROLUNIT
CONNECTOR
{8P)
Measu.eATP P Voltage:
Measurethe voltage betweenthe
N o . 6 t e r m i n a lo f t h e i n t e r l o c k
controlunit and body ground.
NOTE:Shiftlevermust be in E.
ATPP IBLK/BLU'
Repai. open in the wir6 betwoen
tho No.6 termin.l olthe intorlock
control unit and the A/T geal
po.ition rwitch.
SHIFTLOCKIYEL/BLK}
1
2
5
7 8
o
SHIFT LOCK
LOCK!SOLENOID
CONNECTOR
YEL/BLK
Wiresideof femaleterminals
Rapair opon in the wiro bstwcen
tho No. 3 torminal and tho shift
lock solenoid.
SHIFTL@K SOI.ENOID
CONNECTOB
ldir.sily on .olrnoidl
Terminalsidoof maleterminals
Doesthe shift locksolenoid
oprateproperly?
www.emanualpro.com
Doesthe keyinterlock
solenoidoperateproperly?
To page14 92
www.emanualpro.com
KEYLOCKSOL
{WHT/BLU)
ACCPUSHSW (WHT/YELI
KEYLOCKSOL
(WHT/BLUI
(cont'd)
14-91
ElectricalTroubleshooting{'97 Model)
TroubleshootingFlowchart- InterlockSystem- KeyInterlockSystemlcont'dl
F r o mp a g e1 4 - 9 1
INTERLOCK
CONTROLUNIT CONNECIOR{8PI
Check Key Interlock Solenoid for
a Short Circuit:
1. Disconnectthe interlockcontrol
unitconnector.
2. Checkfor continuitybetween
t h e N o . l t e r m i n a la n d b o d y
groundand betweenthe No.5
terminalandbodygroundindividually.
KEYLOCKSOL {WHT/8I-UI
ACCPUSHSW IWHTI
ls therecontinuity?
ls therecontinuity?
Measu16ATP P Voltage:
1. Turnthe ignitionswitchON lll).
2. Measurethe vohagebetween
the No.6 terminaa
l nd body
ground.
Shiftlevermust be in E.
ATP P (BLK/BLU)
14-92
www.emanualpro.com
ElectricalTroubleshooting('98- 00 Models)
Troubleshooting Flowchart - Lock-up Control Solenoid Valve A
.OBD ll Scan Tool indicates
Code Pl753.
. Self-di.gnosis E or E indicator light blinks once.
Poslible Cause
.
.
.
'
l f t h e P G M T e s t e ri s a v a i l a b l e ,
retrievethe M FreezeData,then
clearthe PCM.
A t32Pl
i
I
r rrilt
l,1 I
I
ltDrste,0n,,
2 .t 3 r B ' r ! 5 1 r .
A {32P)
LGI|BRN/BLK) LG2IBRN/BLK)
12- 25 o?
ls the resistance
To page 14 95
To page14-94
(cont'd)
www.emanualpro.com
14-93
ElectricalTroubleshooting('98- 00 Models)
TroubleshootingFlowchart- Lock-upControlSolenoidValveA (cont'dl
Frompage14-93
FCM CONNECTORS
a t32P)
B {25P}
D l16Pl
C t31Pl
a l32Pl
c t3lPl
LGlIARN/ALKI LG2IBRN/BLKI
LOCK-UPCONTROLSOLENOID
VALVEA/B ASSEMBLYCONNECTOR
Mersurg Lock-up Co|ttrol Solonoid
Valvo A Rolktanco at tho Solonoid
Connoctor:
Measure the resistancobetween
the No. 2 terminalof the lock,up
control soleno;d valve A/B
a s s e m b l yc o n n e c t o ra o d b o d y
ground.
tFttl
._T=
A
(o)
Y
LCA (YELI
Terminalsideof maleterminals
ls the resistance
12- 25 0?
14-94
www.emanualpro.com
R e p l a c et h e l o c k - u p c o n t r o l
solonoid vrlve A/B a$ambly,
PCMCONNECTORS
Moa3uraVB SOLVoltago:
1. Turnthe ignitionswitchON (ll)
2. lreasure the voltage between
the D5 and 820 or 822 terminats.
a t32Pl
B (25P1
c (31P1
D {16P1
www.emanualpro.com
14-95
ElectricalTroubleshooting('98- 00 Models)
TroubleshootingFlowchart- Lock-upControlSotenoidValveB
.OBD ll Scan Tool indicates
Code P'l758.
. Sell-diagnosis Dl or E indicator light blinkstwic.
PossiblCause
.
.
.
.
l f t h e P G M T e s t e ri s a v a i l a b l e ,
relrievethe A,/TFreezeData,then
clearthe PCM-
PCMCONNECTORS
LC B {GRN/8LKI
LG1{BRN/BLK}I-G2{BRN/BLK)
Wire sideof femaleterminals
MeasureLock-upControlSolanoid
ValveB Resistanc:
1. Turnthe ignitionswitchOFF.
2. Measure the resistance
between the D3 and 820 or
822terminals.
ls the resistance
12- 25 O?
To page 14-97
www.emanualpro.com
A {32P1
To page14 98
Frompage14-96
PCMCONNECTORS
c (31P1
B (25Pt
CheckIor continuity betlveenthe
B2Oterminal and body ground,
a n d b e t w e e nt h e 8 2 2 t e r m i n a l
and body ground.
D (16P1
{BRN/BLKI
rc1rBRN/BLKk'
c$G2
t
ls therecontinuity?
A {32P1
SO1TNOID
L(rcK.UPCONTROL
CONNECTOR
VALVEA/B ASSEMBLY
Measure Lock-up Control Solenoid
valve B Resistanceat the solenoid
Connedo
Measurethe resistancebetween
the No. 1 terminalof the lock_up
control solenoid valve A/B
a s s e m b l yc o n n e c t o ra n d b o d Y
ground.
12- 25 O?
ls the resistance
LC B IGRN/BLK)
R e p l a c et h e l o c k _ u p c o n i r o l
solenoidvalve A/8 a$embly.
(cont'd)
www.emanualpro.com
14-97
ElectricalTroubleshooting('98- 00 Modelsl
TroubleshootingFlowchart- Lock-upControlSolenoidValveB (cont,d)
Frompage14 96
PCM CONNECTORS
MeasuroVB SOLVoltago:
1. Turnthe ignitionswitchON llt).
2. Measurethe voltage betlveen
the D5 and 820 or 822 termi
nals,
VB SOL (BLK/YEL}
A l32P)
LG1 (BBN/8LKI
LG2 (BRN/BLKI
14-9 8
www.emanualpro.com
PCMCONNECTORS
A (32P1
Moasu.eATP R Voltage:
1 . S h i f t t o a l l p o s i t i o n so t h e r
than E.
2. Measurethe voltage between
the D6 and 820 or 822 terminals,
To page'14-100
(cont'd)
www.emanualpro.com
14-99
ElectricalTroubleshooting('98- 00 Modelsl
TroubleshootingFlowchart- A/T Gearpositionswitch (short) (cont'dl
From page 14-99
FCM CONNECTORS
A t32Pl
Measur. ATP NP Voltago:
1 . S h i f t t o a l l p o s i t i o n so t h e r
than E or E.
2. Measurethe voltage belween
the 013 and 820 or 822 terminats.
B t25Pl
c (31P)
LGl {BRN/BLK)
a t32Pl
LGl IERN/BLK}
To page14-101
14-100
www.emanualpro.com
PCMCONNECTORS
B (2sP)
c (31P}
D t16P)
' t d. , lll;
;l';nl, :if
ls therebatteryvoltage?
LGl (BRN/BLK}
ATPD3
{PNK)
A (32P1
Mearure ATP 2 voltage:
1 . S h i f t t o a l l p o s i t i o n so t h e r
than E.
2. Measurethe voltagebetween
the D14and 820 or 822 termi
nals.
LG2IBRN/BLK)
B l25Pl
c (31P1
D {16P1
LGl IBRN/BLKI
To page14-102
(cont'd)
www.emanualpro.com
14-101
ElectricalTroubleshooting('gg- 00 Modelsl
TroubleshootingFlowchart- A/T Gearpositionswitch {short) (cont,d)
Frompage14 101
MeasureATP 1 Voltag:
1 . S h i f t t o a l l p o s i t i o n so t h e r
than E.
2. Measurethe voltagebetween
the D15and 820 ot 822 tetminals.
PCM CONNECTORS
B t25Pt
c t3lPl
LGl {BRN/BLK)
www.emanualpro.com
D {16P1
P,CMCONNECTORS
MeasureATP R Vohago:
1. Turnthe ignitionswitchON (ll).
2. Shittto E position.
3. Measureihe voltage between
the D6 and 820 ot 822 tetfii
nals,
LGT(BNN/BLKI LG2IBRN/BLK)
Wire sideof femaleterminals
c l31P)
A {32P)
MeasureATP NP Volt.g:
1. Shiftto Elor E position.
2. Measurethe voltagebetween
the D13and 820 or 822termi
nals,
LGl {SRN/BLK)
ATP NP (LTGRN}
To page14-104
www.emanualpro.com
{cont'd)
14-103
ElectricalTroubleshooting('98- 00 Model)
TroubleshootingFlowchart- A/T GearPositionSwitch (Open)(cont'd)
Frompage14-103
PCMCONNECTORS
Me.sure ATP D4 Vohrge:
1. Shift to E 1'98)or E ('9900) position.
2. Measurethe voltage between
the Dg and 820 or 822 terminats.
B {25Pt
c (31P|
LGl IERN/BLKI
LGl {BRN/BLKI
MeasuroATP 2 Voltage:
1. Shilt to E position.
2. Measurethe voltage between
the D14and 820 or 822termi
nats.
LGl {BRN/ELXI
To page 14 105
www.emanualpro.com
Frompage14-104
FCM CONNECTORS
B t25Pl
MeasureATP 1 Voliag:
1. Shiftto E position.
2, Measurethe voltagebetween
the D15and 820 or B22terminals.
c t3lPt
D tl6Pl
LGl IBRN/BLKI
ls therecontinuity?
A (32P1
B (2sP)
c (31P|
LGl (BRN/BLKI
www.emanualpro.com
14-105
ElectricalTroubleshooting('98- 00 Models)
TroubleshootingFlowchart- Shift ControlSolenoidValveA
. OBD ll Scan Tool indicates
Code P0753.
. Self-diagnosisEl or E indicator light blihk5 ievon times.
Po$ible Caus
'
. Short or open in shift control solenoid valve A wire
. Faulty3hift control 3olenoidvalvo A
. Ooen in VB SOL wire
8 {2sPl
A t32P)
Ct3lPt
LG1IBRN/BLKI LG2IBRN/BLK}
Wi16sideof femaleterminals
A (:l2Pl
a t25Pl
LGl
ls the resistance
l2 - 25 0?
To page14-107
14-106
www.emanualpro.com
To page 14-108
c {31P}
ll Dll6Pt
F r o mp a g e1 4 - 1 0 6
A l32Pl
Checkfor continuity between the
8 2 0 t e r m i n a la n d b o d y g r o u n d .
a n d b e t w e e nt h e 8 2 2 t e r m i n a l
and body ground.
PCMCONNECTORS
(31
B (25P1
cC (31P)
LGl IERN/BLKI
D {16P)
LG2 {BRN/BLK)
Wiresideof femaleterminals
C h e c kS h i l t C o n t r o l S o l e n o i d
Valve A for . Short Circuit:
1. Disconnectthe 2P connector
from the shiftcontrolsolenoid
valve !y'B assembly.
2. Checktor continuitybetween
the D7 and B2Oot 822 tetminals.
ls therecontinuity?
SHIFTCONTROISOLENOID
VALVEA/B ASSEMBLYCONNECTOR
Measure Shift Control Solenoid
Valve A Resistanceat ihe
SolenoidConnector:
Measurethe resistancebetween
t h e N o . I t e r m i n a lo f t h e s h i f t
c o n t r o l s o l e n o i d v al v e A / B
a s s e m b l yc o n n e c t o ra n d b o d y
ground,
IiiE-]
"*otrau/"aalF
I
Termanal
sideof maleterminals
l s t h e r e s i s t a n c e1 2 2 5 Q ?
(cont'd)
www.emanualpro.com
14-107
ElectricalTroubleshooting('98- 00 Models)
TroubleshootingFlowchart- Shift ControlSolenoidValveA (cont'd)
Frompage14-106
MoasureVB SOLVoftago:
1 . T u r n t h e i g n i t i o ns w i t c hO N
flr).
2. Measurethe voltagebetween
the D5 and 820 or 822 terminals,
VB SOL IBLK/YEL)
ls therebatteryvohage?
14-108
www.emanualpro.com
Po3sibleC.us
.Dt
. Short or oDenin shift control solenoidvalve B wira
' F.ulW shitt cont.ol solonoidvalvc B
. Opon in VB SOLwir6
PCMCONNECTOBS
a l32Pl
B {2sPl
c t3tP}
LG2 {BRN/BLK}
LGl {BRN/BLKI
c (31P1
LGI {8RN/BLKI
ls the resistanc
12- 25 O?
LG2IBRN/BLKI
T o p a g e1 4 - 1 1 1
(cont'd)
To page14-110
www.emanualpro.com
ElectricalTroubleshooting('98- 00 Models)
TroubleshootingFlowchart- Shift ControlSolenoidValveB {cont'd)
Frompage14-109
PCMCONNECTORS
A (32P1
a {25P)
cC 13lPl
t31
D tl6Pl
C h e c kS h i l t C o n t r o l S o l e n o i d
Valve B for a Sho.t Circuit:
1, Disconnectthe 2P connector
from the shiftcontrolsolenoid
valve !VB assembly.
2. Checktor continuitybetween
the D2 and B2Oo( 822 tetminals,
a t32Pt
c {31P1
LG1IBRN/BLKI
LG2IBRN/BLKI
R e p a i rs h o r t t o g r o u n d i n t h e
wir btwe6n th D2 terminal
and the shift control solenoid
valve B.
SHIFTCONTROLSOLENOID
VALVEA/B ASSEMBLYCONNECTOR
lF-E]
I
SH B IGRN/WHTI
(ol
Y
I
Terminalsideof maleterminals
12 25 O?
ls the resistance
www.emanualpro.com
1 4 -1 1 0
Frompage14-109
PCMCONNECTORS
M6r3ure vB SOLvoltage:
1. Turn ihe ignition switch ON
flr).
2. Measurethe voltage between
the D5 and B20or B22terminals.
A l32Pl
B (25Pt
C (31P1
o (16P)
www.emanualpro.com
14-111
ElectricalTroubleshooting('98- 00 Models)
Po$ibl Csuse
.
.
.
.
C h e c kt h e c o u n t e r s h a f ts p e e d
sensor installation.and check it
for damage.
ls the countershaftspeedsensor
installedproperly.and not damaged?
T o p a g e1 4 - 1 1 3
14-1 1 2
www.emanualpro.com
COUNTERSHAFT
SPEED
SNSORCONNECIOR
ttt'l
-T-TrY oI l
LI
Terminalsideof maleterminals
F r o mp a g e1 4 ' 1 1 2
NCIBLUI
PCMCONNECTORS
A t32Pl
B (25P1
D {16P1
c l31P)
ial,tu]g
NCSGIGRNI
M e a s u r eC o u n t e r s h a t tS p e e d
S6n3orCircuit to. an Open:
1 , C on n e c t t h e c o u n t e r s h a f t
speeosensorconnector,
2 . M e a s ur e t h e r e s i s t a n c e
betweenthe D10and D16termrnals,
a l32Pl
B (25P1
c (31PI
NCSGIGRN}
www.emanualpro.com
14-113
ElectricalTroubleshooting('98- 00 Modelsl
TroubleshootingFlowchart- MainshaftSpeedSensor
. OBD ll ScanTool indicat$ Code
m715.
. Slf-diagnosi3E or @ indicator light indicatosCode 15.
l f t h e P G M T e s t e ri s a v a i l a b l e ,
retrievethe A/f FreezeData,then
clearthe PCM.
PorsibleCruse
. Disconnsctdmsinsh.ft 3pood3gnlor conncctol
. Short or open in mainshaft 3poedsensorwire
. Faultv mainshrtt speedsonsot
NOTE:Codo P0715(15)on the PCM doesn'talwaysmoan there'san electrical
problemin the mainshaftor countershaft
(15)
speedsensorcircuit;code P07'15
problemin the transmission.
may also indicatea mechanical
Any problemcausing irregularcountershaftto mainshaftspoeddifferencecan causethis codo;this
can sometimesbe seen in A'/TFree2eData.FreezeDatacan also indicatean electrical problemin the sensorcircuits;f one of the sensorsreads0 mph duringa
test dnve.
MoasureMainshattSpedSenror
Rsirtancoat ths Snsol Connoctor:
1. Disconnectthe 2P connector
from the mainshaftspeedsen
sor.
2. Measuremainshattspeedsensor resrstanceat the sensor
connefior.
To page14-115
14-1 1 4
www.emanualpro.com
MAINSHAFTSPEED
SENSORCONNECTOR
Terminalsideof maleterminals
Frompage14-114
PCMCONNECTORS
Check Mainshaft Speed Sensor
for a Short Circuit:
1 . D i s c o n n e ct th e D ( 1 6 P )c o n nectortrom the PCM.
2- Chcktor continuity between
body groundand the D11terminal and Dl2 terminal indi
vidually.
D t16Pt
c t3lPl
A {32P}
-'lTZ
NMSG
v v v v v l.t1lLtLt?!/]|,1tut
larrlrllllpr=r
tavtq tptntatEElt [1!]t! pl
NM (RCD| (O)
(o)Y
Y =
MoasureMainshaftSp6dSonsor
Rosi3tancei
1. Connectthe mainshaftspeed
sensorconn6ctor.
2. Measure the resistance
betweenthe Dl1 and D12termrnals,
B l25Pt
c {31P1
-1-\ 2_1 |1 -1 -,s/ / 1
st/
v,1zzfififinffiiFr
F/l,6t FFF| LrLrEll
2. Checkfor continuitybetween
the D11terminalandthe No.2
terminal of the mainshaft
speeosensorconnector,
NM {REDI
MAINSHAFTSPEEO
SENSORCONNECTOR
To page'14-1'16
www.emanualpro.com
(cont'd)
14-115
ElectricalTroubleshooting('98 - 00 Models)
TroubleshootingFlowchart- MainshaftSpeedSensor(cont'd)
Frompage14 115
PCMCONNECTORS
ls therecontinuity?
14-1 1 6
www.emanualpro.com
Po$ible Cau3e
'
.
.
.
.
l f t h e P G M T e s t e ri s a v a i l a b l e .
retrievethe A/T FreezeData,then
clearthe PCM.
t-rtt
(9l
t t
Terminalsideol maleterminals
ls the resistance
about5 O?
A l32Pt
B {2sP)
LSP(REDI
ls therecontinuity?
T o p a g e1 4 - 1 1 8
(cont'd)
www.emanualpro.com
14-117
('98- 00 Models)
ElectricalTroubleshooting
Troubleshooting Flowchaft - Linear Solenoid (cont'dl
F r o mp a g e1 4 - 1 1 7
MeasureLinea. SolenoidResistance:
1 . C o n n e c t h e l i n e a rs o l e n o i d
connector,
2. Measure the resistance
betweenthe 88 and 817 ter
mrnals,
a t32Pl
c t3lPl
LSP(REO)
Wire sideof femaleterminals
ls the resistance
about5 O?
MeasureVB SOLVoltago:
1. Turnthe ignitionswitchOFF.
2 . D i s c o n n e ct th e D 1 1 6 Pc) o n nectortrom the PCM.
3. Turnthe ignitionswitchON (ll).
4. Measurethe voltagebetween
the D5 and 920 ot B22 tetminals.
ls therebafteryvoltsge?
a l32Pl
ls therecontinuity?
1 4 -1 1 8
www.emanualpro.com
B l2sP)
LGl IBRN/BLK}
c 13lPl
LG2{BRN/BLKI
D l16P)
TroubleshootingFlowchart- Lock-upControlSystem
. OBD ll Scan Tool indicates
Code P07,10.
. selt-diagnGis El or E indicator light indicatesCode40.
PossibleCaus6
Faultylock-up control system
l f t h e P G M T e s t e ri s a v a i l a b l e ,
retrievethe A/T FreezeData,then
clearthe PCM.
P e r f o r mt h o T r o u b l e s h o o t i n g
Flowchart for lh6 indicated
Codolll. Rechocktor code P0740
(,lO)after troubleshooting.
N O T E :D o n o t c o n t i n u et h i s t r o u b l e s h o o t i n gu n t i l t h e c a u s e so f a n y
other DTCShave beencorrected.
T o p a g e1 4 - 1 2 0
www.emanualpro.com
(cont'd)
14-119
ElectricalTroubleshooting('98 - 00 Models)
TroubleshootingFlowchart- Lock-upControlSystem(cont'd)
F r o mp a g e1 4 - 1 1 9
R e p l a c et h e L o c k - u p C o n t r o l
Solenoid Valve A/B Assombly
and Recheck:
1 . R e p l a c et h e l o c k - u pc o n t r o l
solenoidvalve A,/Bassembly
(seepage14-!35).
2. Turn the ignition switch OFF
and resetthe PCMmemoryby
removingthe BACKUP (7.5A)
f u s e i n t h e u n d e F d a s hf u s e /
relaybox for more than 10
seconds.
3. Usingthe scantool, checkto
be surethatthe enginecoolant
temperature
is 176"F{80'C)or
above.
4 . D r i v et h e v e h i c l ea t 5 5 m p h
(88 km/h)constantlytor more
than one minute.
5. Recheck
{or code P0740(40i.
14-120
www.emanualpro.com
PossibleCause
Faultvshift control sYstem
Didthe codereturn?
P e r l o r mt h e T r o u b l e s h o o t i n g
Flowchart for the indicaled
Codets).Recheckfor code P0730
{4116ft6r troubleshooting.
N O T E :D o n o t c o n t i n u et h a s t r o u
b l e s h o o t i n gu n t i l t h e c a u s e so f a n y
otherDTCShavebeencorrected.
MeasureEachClutch Pressure:
M e a s u r et h e 1 s t ,2 n d , 3 r d , a n d
4th clutchPressure(seePage14
1 6 1t h r u1 4 1 6 3 ) .
l s e a ch c l u t c h P r e s s u r e
withinthe servicelimit?
Repairthe hydraulicsYstem as
necessary (se page 14-162and
14-163).
(cont'd)
T o p a g e1 4 - 1 2 2
www.emanualpro.com
14-121
ElectricalTroubleshooting{'gB- 00 Models}
TroubleshootingFlowchart- Shift ControlSystem(cont,d)
Frompage14 121
www.emanualpro.com
A l32Pl
Checkthe Gtound Circuil:
1. Turnthe ignitionswitchOFF.
2 . D i s c o n n e ctth e B ( 2 5 P )c o n nectorfrom the PCM.
3. Checkfor continuitYbetween
l ndbody
t h e 8 2 0t e r m i n a a
ground,and betweenthe 822
terminaland body ground.
PCMCONNECTORS
(31
c (31P)
B t2sPl
f -t l r p r i
i r r
6
3 r o l , :
11/ / l//|
$fe?0?r/a)1 e 'oI 13
I ,
rrr
ltelx ?r2? r,/
i - T _
D (16P)
l*f4tr8-
LG2 (BRN/BL()
LG1 {8RN/BI-KI I
I
@
@
I
+
Wiresideof lemaleterminals
ls therecontinuity?
c (31P)
Measure Power Supply Circuit
Voltage:
1. Turnthe ignitionswitchON 1ll).
2. Measurethe voltagebetween
terminalsB1 and 822 and
betweenterminalsBg and 820.
YES
(cont'd)
To page14-124
www.emanualpro.com
14-123
ElectricalTroubleshooting('98- 00 Modelsl
Troubleshooting
Flowchart- E or @ IndicatorLightDoesNot come on
(cont'd)
F r o mp a g e1 4 - 1 2 3
PCMCONNECTORS
B {25P}
MeasureD4IND or D lNDVoh.ge:
'L Turn
the ignitionswitchOFF.
2. Connectthe B (25Plconnector
to the PCM.
3. Connecta djgital multimeter
to the A14 and 820 or B22ter
minals,
4 . T u r n t h e i g n i t i o ns w i t c hO N
(ll),and makesurethatvoltage
is availablefor two seconds.
(3
cC (31P)
D (16P1
n f,-ff n
t f,Fjrti.trnn
mflnr
LG2 (BRN/BLKI
D {16P)
CheckD4 IND or D IND for a
Short Circuiti
Checkfor continuitybetweenthe
A14terminaland body ground.
D4 IND or D IND
14-124
www.emanualpro.com
B (25P)
c (3'tP)
D lr6Pl
1 1
t r .
/ / a
t tonl /1! /1/ /llt /
F't!4[r
t',lxr uu?lLrfr4
D4 IND or D IND {GRN/BLKI
Wiresideof femaleterminals
A l32Pl
t rl3l/ 5/,
MeasuroATP D4 voltage:
1. Turnthe ignitionswitchOFF
2. Connectthe A (32P)connector to the PCM.
3. Turn the ignitionswitchON (ll)
4 . S h i { t t o a n y p o s i t i o no t h e r
than E or E.
5. Measurethe voltagebetween
t h e D 9 t e r m i n a la n d b o d y
ground.
ls thereapprox.5V?
c t3lPl
_ = - - - r - : =? e- V
t\ r?V
t/l,4lzulErt!t!!j!t!u3t
ll]]lll1lglt]|
r.i
b AE A.W6l ld$!'lLM.l1t I
ATPD' (YEL)I
I
O)
T6st the A/T g.ar Po3ition indicator at the gauge e$embly con_
'98
nectorc (se P.go 1,1-139lor
'99 - 00
for
14-140
model .nd
modelsl, f the A/f gear Poshion
indicator is OK, replacethe FCM.
www.emanualpro.com
14-125,
ElectricalTroubleshooting('98- 00 Modelsl
TroubleshootingFlowchart- InterlockSystem- Shift LockSystem
Shift levor cannot be mov6d
llom the E po3ition when th6
blako pedal is pre3sed.
ChckBJakeLight Oporation:
Pressthe brakepedal.
PCM CONNECTORS
a (25P1
Me.sure ILU Voltage:
1. Turn the ignitionswitchON (ll1,
andshifttoE position.
2 . P r e s st h e b r a k e p e d a l ,a n d
releasethe acceleratorpedal.
3. Measurethe voltage between
t h e A 2 8 t e r m i n a la n d b o d y
grouno.
c l3lPl
D {16P1
1 tttt/
5t/ 1 a t /tlt
1 t\/t
,
. I 3 rholr1t?
/ VVV tl t ttj,r\1e\10l211n
m@-@Effilil"
c t3lPt
ls there batteryvoltage?
fo page 14-121
14-126
www.emanualpro.com
D (lCPl
wE
LGl {8RN/ALKI
Frompage14-126
FCII CONNECTOFS
MeasureTPSVoltage:
1. Reconnectthe A (32P)and B
(25P)connectors
to the PCM
2. Turnthe ignitionswitchON (ll)
3. Measurethe voltagebetween
the C27 and B20ot 822 te(mi'
nats.
c (31P)
B {25P1
A t32Pl
LG1 (BRN/BLKI
ls thereapprox.0.5V?
To page'14-128
LG2IBRN/BIXI
LGl IBRN/BIXI
THROTTTIPOSMON
SENSORCONNECTOR
SG2IGRN/BLK}
rL2l3t
Wiresideof femaleterminals
ls therecontinuity?
B {25P1
D (16P1
n l,I-il n
FFFTI,T';T;I
EFML"|
LGl IBRN/BLKI
ls therecontinuity?
c l3lPl
SG2 {GRN/BLK}
(cont'd)
www.emanualpro.com
14-127
ElectricalTroubleshooting('98 - 00 Modelsl
TroubleshootingFlowchaft- InterlockSystem- Shift LockSystem{cont'dl
Frompage14-127
INTERLOCK
CONTROL
UNTTCONNECTOR
ISPI
SHIFTLOCK{YEL/BLKI
IYEL/BLX
o
SHIFTLOCKSOLENOID
t
CONNECTOR
YEL/BLK
1 2
ls therecontinuity?
ls therebatteryvoltage?
Doesthe shiftlocksolenoid
operateproperly?
14-128
www.emanualpro.com
YEL]
(v)
!
Wiresideof femaleterminsls
SHIFTLOCKSOLENOIO
CONNECTOR
(dir.ctly on $lenoidl
Terminalsideof maleterminals
Roplacethe shift lock solenoid.
IGNITIONSWITCH6P CONNECTOR
KEYLOCKSOL
IWHT/BLU)
ACCPUSHSW (WHT/YEL}
Doesthe keyinterlock
solenoidoperateProPerlY?
Doesthe keyinterlock
solenoidoperateProperly?
KEYLOCKSOL
IWHT/BLUI
+B KEY LOCK
(WHT/GRN)
To page14-130
(cont'd)
www.emanualpro.com
14-129
ElectricalTroubleshooting('98 - 00 Models)
TroubleshootingFlowchart- InterlockSystem- KeyInterlockSystem(cont,dl
Frompage14'129
INTERLOCK
CONTROLUNITCONNECTOR
{8PI
KEYLOCKSOL (WHT/BI-U}
ACCPUSHSW {WHT)
ls therecontinuity?
ls therecontinujty?
MoasureATP P Voftegel
1. Turnthe ignitionswitchON (lli.
2. Measurethe voltagebetween
the No. 6 terminal and body
ground.
Shiftlevermust be in E.
ATP P IBLK/BLUI
14-130
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ElectricalTroubleshooting('99 - 00 Modelsl
TroubleshootingFlowchart- o/D oFF IndicatorLight DoesNot GomeOn
The O/D OFFindicator light doos
not come on when the ignition
switch i3 tiBt tulned ON {lll. {lt
should come on lor about two
secondsand then go outl
C h e c kt h e O / D O F FI n d i c a t o l
Light:
1. Turnthe ignitionswitchON (ll).
2. Shiftto E position,and Press
the Over-Drive(O/D)switch.
B t25Pl
GAUGEASSEMBLY
CONNECTOR
I14P)
(31
cc (3rPt
ls therecontinuitY?
a
www.emanualpro.com
14-131
ElectricalTroubleshooting('gg - 00 Modelsl
Troubleshooting
Flowchart- O/D OFFIndicatorLightOn Constantly
The O/D OFFindicator light is on
constanllv whenever the ignition
switch is ON {ll),
C h e c kt h e O / D O F F I n d i c a t o r
Lighti
'1.
Turn the ignitionswitchOFF.
2 . D i s c o n n e ctth e B ( 2 5 P )c o n nectorfrom the PCM.
3. Turnthe ignitionswitchoN flt).
14-132
www.emanualpro.com
PARKPIN/O/D SWITCHCONNECTOR
Terminalsideof maleterminals
ls therecontinuitywhile
pressingthe switch, and no
continuitywhen releasedit?
PCMCONNECTORS
A {32P1
B l25Pl
c (31P)
O/D SW (PNKI
PARKPIN/
o/D swtTcH
CONNECTOR
Wire sideof femaletermanals
To page14-134
www.emanualpro.com
(cont'd)
14-133
ElectricalTroubleshooting('gg - 00 Modelsl
TroubleshootingFlowchart- o/D oFF lndicatorLight DoesNot come on
EvenThoughO/D Switch ls pressed(contd)
Frompage14-133
PCMCONNECTORS
O/D SW{PNKI
Wiresideof femaleterminals
ls therecontinuity?
PAFKPIN/O/D SWITCHCONNECTOR
Wiresideot femaleterminals
14-134
www.emanualpro.com
Lock-upControlSolenoidValveA/B Assembly
Test
Replacement
2.
1.
6 x 1.0mm
12N.m11.2kgf.m,8.7lbf.ft)
12 - 25 o
STANDARD:
CONTROL
LOCK.UP
VALVE
SOLENOIO
A/B ASSEMBLY
LOCK-UP
CONTROL
VALVE
SOLENOID
CONNECTOR
I2P)
oa
Terminalsideof
maleterminals
Replace.
2.
LOCK.UPCONTROL
Cleanthe mountingsurface
and fluid passages.
and
Cleanthe mountingsurfaceand fluid passages,
valve
IVB
with
solenoid
lock-up
control
installa new
a new filter/gasket.
Checkthe connectorfor rust,dirt, or oi!, and reconnectit securely.
R e p l a c et h e l o c k - u pc o n t r o l s o l e n o i d v a l v e A / B
is out of specification
assemblyif the resistance
lf the resistanceis within the standard,connectthe
No. 1 terminal of the connectorto the batterypositive
terminal.A clickingsound shouldbe heard Connect
the No. 2 terminal to the battery positiveterminal. A
clickingsound shouldbe heard.Replacethe lock-up
control solenoidvalve Ay'Bassemblyif no clicking
sound is heardwhen eitherterminalis connectedto
terminal.
the banervDositive
Checkthe lock-upcontrol solenoidvalve fluid passagesfor dust or debris,and replaceas an assem
bly, if necessary.
www.emanualpro.com
14-135
Replacement
Removethe shiftcontrolsolenoidcover.
2.
6x1.0mm
12 N.m
{1.2k9 .m,8.7lbtft}
CLAMPARACKET
\--
qK
Terminalsade
of
maleterminals
-!t'">,,
SHIFTCONTROL
SoLENO|OCOVEn
SHIFTCONTROL
SOLENOIDVALVEA/B
ASSEMBLY
FILTER/GASKET
Replace.
Cleanthe mounlingsurface
and fluid passages.
STANDARD:12 - 25 O
Replacethe shift controlsolenoidvalveA,/Bassembly if the resistanceis out of specification.
lf the resistanceis within the standard.connectthe
N o , I t e r m i n a lo f t h e s h i f t c o n t r o ls o l e n o i dv a l v e
connectorto the batterypositiveterminal.A clicking
sound should be heard.Connectthe No. 2 terminal
to the battery positive te.minal. A clicking sound
should be heard.Replacethe shift control solenoid
v a l v e A / B a s s e m b l yi f n o c l i c k i n gs o u n d i s h e a r d
w h e n e i t h e rt e r m i n a li s c o n n e c t e dt o t h e b a t t e r v
positiveterminal.
www.emanualpro.com
14-136
LinearSolenoidAssembly
Test
1.
Disconnect
the linearsolenoidconnector.
1.
VALVE
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14-137
LinearSolenoidAssembly
Mainshaft/Countershaft
SpeedSensors
Replacement
Replacement
'1. Remove
the mountingbolts and the linearsolenoid
assemblY.
1.
surface
Cleanthemounting
and fluid passages.
6x1.0mm
12 N.m (1.2kg{.m.
8.7tbtftl
5x1.0mm
12 N.m 11.2kgf.m,
8.7 rbf.frl
COUNTERSHAFT
SPEEDSENSOR
@
@
O.RING
Replace.
GASKET
6x1.0mm
12N'm 11.2kgl.m,
8.7tbf.ftl
R e m o v et h e 6 m m b o l t a n d t h e m a i n s h a f st p e e d
sensorfrom the transmissionhousing.
14-138
www.emanualpro.com
A/T GearPositionSwitch
Test
1. Removethe A,/Tgear position switch connsctorfrom the connectorbracket,then disconnectthe IVT gear position
switchconnector(10P).
2. Checkfor continuitybetweenthe terminalsin eachswitchpositionaccordingto the table below.
A/T GEARPOSITION
SWITCHCONNECTOR
(10P1
\_-__l"'ry1
'l
Position
tr
tr
t!l!l
E
E
E
E
ooo-o_
o_
oo-
10
-o
-----o
---o
----o
-----o
---o
----o
'99 - O0Models
\______lg,-r4
Position
tr
tr
E
E
E
E
oc\ooo
o_
.'
l0
---o
---o
----o
- o
o
----c
NOTE:TerminalNo.3: Neutraloositionswitch
www.emanualpro.com
14-139
A/T GearPositionSwitch
Replacement
Make 3ure lifts, iacks, and safety stands
@
ar placod properly lsoo soction 1).
1.
2.
3.
Shiftto E position.
6.
R e m o v et h e h a r n e s sc l a m p f r o m t h e e n d c o v e r ,
then remove the Aff gear position switch cover and
Ay'Tgear position switch.
A/T GEAFPOSITION
swrTcHcovER
6x1.0mm
12 N.m 11.2kgt m.
8.7 lbf.ftl
6x1.0mm
12 N.m
{1.2 kg{.m,8.7 lbtftl
1.
5x1.0mm
12Nm11.2kgf.m,
8.7 tbf.ftt
BRACIGT
POSmON
swlTcH
14-140
www.emanualpro.com
12, Start the engine. Move the shift lever through all
gears.and verifythe following:
.
.
.
A/TGEARPOSMON
INDICATOR
'99 - 00 MODELS
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A/T GEARPOSITION
INDICATOR
'97 - 98 MOOELS
14-141
A/T GearPositionIndicator
fnput Test-'97 - 98 Models
1 . Removethe gauge assemblyfrom the dashboard(seesection20).and disconnectthe 14Pconnectorfrom the gauge
assemblv(seesection23),
Inspectthe connectorand socketterminalsto be surethey are all makinggood contact.
.
.
Wirs
Color
Cavity
Test Condition
Test: DesirdResult
lgnitionswitchON (ll)
Combinationlight
Checkfor voltagebetweenNo. 2
a n d N o .3 t e r m i n a l s ;
Thereshouldbe batteryvoltage.
YEL
BLU
Shift leverin E
BRN
Shift leverin E
YEL
Shift leverin @
BLK
Underall conditions
lgnitionswitchON {ll)
and shift leverin any
GRN/BLK position except E
10
GRN
PossibleCause
{lf rosult is not obtainod)
1'l
RED
Shift leverin E
Shift leverin @
12
WHT
Shift leverin E
Shift leverin E
. Poorground{G401)
. An open in the wire
' FaultyPCM
. An open in the wire
. FaultyPCM
. An open in the wire
14
LT GRN
lgnitionswitchON {ll)
and shift leverin any
positionexceptE and
14-142
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InputTest-'99 - 00 Models
L Removethe gaugeassemblyfrom the dashboard{seesection20), and disconnectthe 14Pconnectorfrom the gauge
assembly(seesection23).
Inspectthe connectorand socketterminalsto be surethey are all makinggood contact.
a lf the terminalsare bent.loose,or corroded.repairthem as necessary.
and recheckthe system.
. lf the terminalslook OK, makethe followinginput testsat the 14Pconnector.
- lf a test indicatesa problem,find and correctthe cause,then recheckthe system.
- lf all the input testsproveOK, but the indicatoris faulty,replacethe printedcircuitboard.
GAUGEASSEMBLY14PCONNECTOR
Cavity
Wire
Color
YEL
7
'10
Test Condition
Combinationlight
RED/BLK switchON and dash
lightsbrightnesscontrol dial on full bright
RED
Checkfor voltagebetweenNo. 2
a n dN o . 3 t e r m i n a l s :
Thereshouldbe batteryvoltage.
BRN
Shift leverin E
YEL
Shift leverin E
BLU
Shift leverin E
BLK
FaultyO/Dswitch
FaultyA/T gear positionswitch
FaultyPCM
An open in the wire
. Poorground(G401)
. An open in the wire
. FaultyPCM
. An open in the wire
lgnitionswitchON (ll)
and shift leverin any
positionexceptE
. FaultyPCM
. An open in the wire
a:FI\|/Et| ta
11
RED
Shift leverin S
12
WHT
Shift leverin E
Shift leverin E
LT GRN
Underall conditions
14
PossibleCaus6
{lf resutt is not obtainod)
lgnitionswitchON (ll)
lgnitionswitchON (ll),
shift leverin E. and
LT BLU
Over-Driveis OFFby
pressingO/Dswitch.
8
Test: DesiredResuh
lgnitionswitchON (ll)
and shift leverin any
positionexceptE and
E
www.emanualpro.com
14-143
InterlockSystem
InterlockControlUnit Input Test
and proceduresin the SRS
SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations,precautions,
section(24)beforeperformingrepairsor service.
'1. Removethe instrumentpanellower cover(seesection20).
the 8P connectorfrom the interlockcontrolunit.
2. Disconnect
3. Inspectthe connectorand connectorterminalsto be surethey are all makinggood contact.
.
.
NOTE: lf the shift locksolenoidclickswhen the ignition switchis tu rned ON (ll)while pressingthe brakepedalwiththe
shift lever in E position,the shift lock system is OK. lf the shift lever cannot be shiftedfrom E position.test the A/T
gear positionswitch.
14-144
www.emanualpro.com
1
4
Wiresideof femaleterminals
Cavity
Wire
Color
Test Condhion
lgnitionswitchON (ll)
lgnitionswitchON (ll)
Underall conditions
lgnitionswitchturned
to ACC(l), ignitionkey
pushedall the way in
Shift leverin E
Faultyparkpin switch
Shon to ground
WHT/BLU
YEUBLK
BLK
WHT
BLI(BLU
PossibleCause
(lf result is not obtainedl
lgnitionswitchturned
to ACC(l), ignitionkey
pushedall the way in
YEL
Tost: DesiredRosult
. Poorground(G401)
. An open in the wire
Reconnect
the interlockcontrolunit 8P connector.
lgnition switch ON (ll)
and brake pedal
presseo
www.emanualpro.com
Faulty brakeswitch
Faultythrottleposition(TP)
sensor
Faulty PCM
An open in the wire
Faultyinterlockcontrolunit
14-145
lnterlock System
KeyInterlockSolenoidTest
SRScomoonentsare locatedin this area. Reviewthe SRS
and proceduresin the
componentlocations,precautions.
SRSsection(24)before pertorming repairsor service.
1.
2.
3.
IGNITIONSWITCH6P CONNECTOR
\____________r{r4
Position
lgnition Key pushedin
switch
Key released
ACC0)
---'o
o- ---o
6P CONNECTOR
14-146
www.emanualpro.com
Shift LockSolenoidTest
SRScomponentsare locatedin this area.Reviewthe SRS
component locations,precautions,and proceduresin the
SRSsection(24)before performingrepairsor service,
6.
7.
Removethe steeringcolumncovers(seesection17).
3.
Disconnect
the shift locksolenoid2P connector.
Connectthe No. 1 terminalof the shift locksolenoid
connectorto the batterypositivetgrminal,and connect the No. 2 terminalto the batterynogativetermrnal.
Checkthat the shift levercan be moved from the E
o o s i t i o n .R e l e a s et h e b a t t e r vt e r m i n a l sf r o m t h e
shift lock solenoidconnector.Move the shift lever
backto the E position,and makesure it locks.
NOTE:Do not connectpower to the No. 2 (-) terminal {reversepolarity)or you will damagethe diode
insidethe solenoid.
2P CONNECTOR SHIFTLOCK
www.emanualpro.com
14-147
InterlockSystem
Shift LockSolenoidReplacement
SRScomponentsare locatedin this area.Reviewthe SRS
and proceduresin the
componentlocations,precautions,
SRSsection(24)beforeperformingrepairsor service.
'L
2.
3.
B e m o v et h e f l a n g e n u t s a n d b o l t s s e c u r i n gt h e
steeringcolumn,then lowerthe steeringcolumn.
4.
14-148
www.emanualpro.com
ParkPinSwitch Test
SRScomponentsare locatedin this area. Reviewthe SRS
compongnt locations,precautions,and proceduresin the
SRSsection(24)before performingrepairsor service,
1.
PAR( PIN
'99 00 MODELS:
PARKPIN SWITCH/
oVER-DRTVE
{O/D) SWTTCH
CONNECTOR
.qI
www.emanualpro.com
14-149
InterlockSystem
ParkPinSwitch Replacement-'97 - 98 Models
SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations,precautions,
and proceduresin the SRS
section(24)beforeperformingrepairsor service.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
PARKPIN SWITCH
PARKPIN
SWITCHCONNECTOR
scnEw
2.5 N m 10.25kgt.m, 1.8 lbtftl
CONTROLCHECKER
14-150
www.emanualpro.com
-'99 - 00 Models
ParkPin Switch - Over-Drive(O/DlSwitch Replacement
and proceduresin the SRS
SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations,precautions,
performing
repairs
or
service.
section{24)before
NOTE:lf replacement
of the parkpin switchor the O/Dswitchis required.replacethem as a set.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Removethe instrumentpanellowercover(seesection20).
Removethe upperand lowersteeringcolumncovers(seesection17).
Removethe flangenuts securingthe steeringcolumn.then lowerthe steeringcolumn.
Disconnect
the shift locksolenoidand the parkpin switch- O/Dswitchconnectors
Removethe harnessclamp bracket.
Removethe boltssecuringthe shift leverassembly,then removethe shift leverassembly.
Removethe screwssecuringthe shift locksolenoid,then removethe shift locksolenoid.
Cutthe O/Dswitchwires (REDandBLK),thenremovethe connectorfrom the shift levercontrolbracket
Removethe controlcheckerfrom theshift levercontrolbracket
Removethe oarkoin switchfrom the controlchecker.
Removethe shift leverknobfrom the shift lever,then removethe O/Dswitchfrom the shift leverknob.
SCREW
2.5 N.m 10.25kgtm, 1.8lbf,ft)
SHIFTLEVERCONTROL
BRACKET
PARKPIN SWITCH-
o/DswlTcH
CONNECTOR
SHIFTLEVER
HABNESSCLAMPBRACKET
o/o swlTcH
SHIFTLEVERKNOB
6-12N,m
{0.6- 1.2kgt.m.4- 8.7 lbf ftl
12. Routethe new O/D switchwires through the shift lever knob,shift lever,and shift lever control bracket,then install
the knob on the shift lever,and installthe switchin the knob.
13. Installthe new parkpin switchon the controlchecker,then installthe controlcheckeron the shift levercontrolbracket.
14. Routetheparkpin switchharnessthroughthecutoutoftheshiftlevercontrolbracket.
15. Installthe O/D switchwire terminalsin the connectorcavitiessecurely.The wire terminalscan be installedin cavity
N o .1 o r N o . 2 .
16, Installthe connectorand the harnessclampon the bracket.
17. tnstallthe shift locksolenoidby aligningthe joint ot the shift locksolenoidplunger with the tip of the shift lockextension,then securethe shift locksolenoidwith the screws,
18. lnstallthe shift leverassemblvinthe reverseorderof removal.
19. Adjustthe clearancebetweenthe O/Dswitchwires and the edgeof the shift levercontrolbracket(seepage 14-270).
20. Checkthe shift leveroperationand shift lockoperation.
www.emanualpro.com
14-151
4.
PARKPINSWITCH
14-152
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Chart
Symptom-to-Component
HydraulicSystem
Dl ('97 - 98) or Lq ('99 - 00) indicator
Beforetroubleshootinga problemon Hydraulicsystem, checkthe self-diagnosis
perform
the
electricaltroubleshootingaccordingto
code,
a
trouble
light indication.lf the El or E indicatorlight indicates
a troublecode and failureis not
not
indicate
does
light
or
indicator
lf
the
Chart.
Ol
E
the ElectricalSystem-to-Component
followingthe chart.
performthe hydraulictroubleshooting
found on the electricaltroubleshooting,
Checktheseitemson the
CAUSEList
PROBABLE
SYMPTOM
Engineruns,but vehicledoes not move in any gear.
1 r 2 F A t ? 8 2 ?
Checktheseitemson
the NOTESList
K,L.R,S
c,M,o
a l
4 , 6 ,1 4 ,1 5
'l4, '16,2A,32, 33, 34
10, 12, 13,
1,2, 18,3'1,35,44, 46,41
c,L.o
4 ,0
1,2,3,6,37
K,L,R
6 ,8 , 1 0
C,D
B,K,L
c,D
14
17,31,44,46,47
No shift
G,L
21, 48
2 1 , 2 24, 7
Erraticupshifting
fz
ffi
il
3-4 upshift
Harshupshift('l-2)
57
20,47
21, 4A
22, 47
12,18, 19,2A,49,50,56,57
13,1A,19,23,26,28,49,50,56,57
C,D.E,H,L
14,1A,19,24,27,28,49,50,56. 57
C , D ,E ,I , L
18,19,23,42,53,56,51
1 2 ,1 8 , 1 9 , 2 4 , 4 1 , 4 25 ,4 .5 6 ,5 7 ,5 8
C, D, E, I
13,1A,19,23,26,50
1 4 ,1 A ,1 9 , 2 4 , 2 7 , 5 0
13. '18,19, 23, 26, 42,49, 50, 51
E,L,N
Excessive
shockon 3-4 upshift
14,1A,19,24,27, 42,49,50,51
10,29
E,L,N
4,14,20,51
2,36
K,L.O
Harshupshift(2-3)
Harshupshift{3-4)
Harshdownshitt(2-1)
Harshdownshift(3-2)
Harshdownshift(4-3)
E.L.N
M
11
(cont'd)
www.emanualpro.com
14-153
Symptom-to-Component
Chart
HydraulicSystem (cont'd)
Checktheseitemson the
PROBABLE
CAUSEList
SYMPTOM
Shift leverdoes not operatesmoothly.
Failsto shift;stuckin 4th gear.
Transmission
will not shiftintoparkin E position.
Stallrpm high;all clutchpressuresare in specification.
Lock-upclutchdoes not disengage.
Lock-upclutchdoes not operatesmoothly.
Lock-upclutchdoes not engage.
Vibrationin all positions.
No enginebrakingin I position.
Shift positionindicatordoes not indicateanv position,
Checktheseitemson
the NOTESLisr
P
o, Jd
14, 41, 48
6, 38,61
40
18, 43,44,45, 46,49,50,57
14, 40, 43, 44, 45, 46, 49, 50. 57
't8,
40, 43, 44, 45, 46, 49,50, 56, 57
P
D,K,O
59
6. 38, 60
PROBABLE
CAUSE
ATF pump worn or binding
33
34
7
I
10
11
't2
t5
14
tc
16
17
18
'19
20
21
26
27
2a
29
30
31
32
14-154
www.emanualpro.com
Servovalvestuck
Mainshaftworn/damaged
Shiftcablebroken/outof adjustment
Finalgearsworn/damaged
One-way(sprag)clutchworn/damaged
1stgearsworn/damaged{2 gears)
lst clutch defective
2nd gearsworn/damaged(2 gears)
2nd clutch defective
3rd clutchdefective
4th clutch defective
Reversegearsworn/damaged(3 gears)
ExcessiveATF
Torque converter one-way clutch defective
Linearsolenoidassemblvdefective(,98- OO
models)
CPCvalvestuck
l-2 shift valvestuck
2-3 shiftvalvestuck
3-4 shift valve stuck
2nd accumulatordefective
3rd accumulatordefective
4th accumulatordefective
2nd orificecontrolvalvestuck
3-4orificecontrolvalvestuck
Foreignmaterialin main orifice
Foreignmaterialin lst orifice
Foreignmaterialin reverseorifice
Engineoutput low
Needlebearingworn/damaged
5tt
Torqueconverterhousingor transmission
housingbearingworn/damaged
ATF strainer clogged
38
39
Modulatorvalvestuck
Torque converter checkvalve stuck
Foreignmaterialin separatorplate
CPBvalve stuck
Lock-uptiming valvestuck
Lock-upshift valvestuck
Lock-upcontrolvalvestuck
Lock-upclutch Distondefective
Shift control solenoid valve A defecttve
Shift control solenoid valve B dsfectrve
Lock-upcontrol solenoid valve A defective
Lock-upcontrol solenoid valve B deleqtve
Servocontrolvalvestuck
lst accumulatordefective
Foreignmaterialin 2nd exhaustorifice
Foreignmaterialin 3rd exhaustorifice
Foreignmaterialin 4th exhaustorifice
Mainshaftspeedsensordefective
Countershaft
speedsensordefective
3rd sub accumulatordefective
lst-holdclutchdefective
A/T gear position switch defectiveor out of
adjustment
40
41
43
44
46
47
48
49
51
52
53
54
56
58
59
60
61
Parkgear mechanismdefective
Checktheseitems
Vehiclecreepsin N position.
. lmproperclutchclearance
. lmpropergearclearance
or E
Vehicledoes not move in E, [D.lj,
position.
Transmissionlocksup in E position.
One-way(sprag)clutchinstalledupsidedown
drag in transmission.
Excessive
Parkleverinstalledupsidedown
Shiftfork bolt not installed
ATF pump bindingand seizure
Usepropertools when replacingthe ATF pump gears,and be carefulnot
to damagethe ATF pump when torquedown the main valvebody.
Checkthat the shiftfork bolt is installedon the shiftfork shaft
vibration,rpm related.
Excessive
Reverseselectorhub installedupsidedown
Variousshiftingproblems.
. Springsimproperlyinstalled
. Valvesimproperlyinstalled
Harshupshift.
Checkvalveballsnot installed
Mainshaftoil sealimproperlyinstalled
lnstallthemainshaftoil sealtlushwith the torqueconverterhousing lf
the mainshaftoil sealis installedinto the torqueconverterhousinguntil
it bottoms.it will blockthe fluid returnpassageand resultin damage
(cont'd)
www.emanualpro.com
4-15 5
ponentChart
Symptom-to-Com
HydraulicSystem(cont'd)
NOTES
Seeflushingprocedure,page l4-264and 265,
B
Set idle rpm in gearto specifiedidle speed.lf still no good,adjustmotor mountsas outlinedin engine
sectionof this manual.
J
K
L
M
www.emanualpro.com
Installthe main sealflush with the torqueconverterhousing.lf you push it into the torqueconverter
housinguntil it bottomsout, it will blockthe fluid returnpassageand resultin damage.
RoadTest
NOTE:Warm up the engineto normaloperatingtemperature(the radiatortan comeson).
1.
2.
Apply the parkingbrakeand blockthe wheels.start the engine,then shift to E {'97 98) or E {'gg 00) position
not
stall.
pedaland releaseit suddenly.The engineshould
while pressingthe brakepedal.Pressthe accelerator
3.
4.
Test-drivethe vehicle on a flat road in the E or E position. Checkthat the shift points occur at approximate speeds
shownon a flat road.Also checkfor abnormalnoiseand clutchslippage.
Throttlepositionsensorvoltagerepresentsthe throttleopening.Monitorit with the HondaPGMTesteror as follows:
a. Unboltthe PCMfor roadtesting;reJerto page14-58.
b. Setthe digitalmultimeterto checkthrottlepositionsensorvoltagebetweentheseterminalson the PCM:
. '97 Model:BetweenterminalsD'! (+)and A9 (-) or A22 {-}
. '98 - OOModels; Betweenterminals C27 (+) and 820 (-) or 822 {-)
BACKPROBE
ADAPTER
SET
BACKPROBE
orsAz- 001moA
(two roquircdl
STACKINGPATCH
CORD
DIGiTALMULTIMETER
{CommrcirllY.vailablc}
KS-AHM-32-003,
or equival.nt
'97 Model:
PCMCONNECTORS
'.
o a 2r
//B
l'o ti
t-'a:IM-&E
, jl. t
-Llfiffi-fl)\"".'E
1 3 / 10n v
'98 - 0OModels:
PCMCONNECTORS
A l32Pt
B {25Pt
c l31P}
(cont'd)
LGl (BRN/BLK)
www.emanualpro.com
14-157
RoadTest
(cont'd)
lgrror E Position:
Upshift
Throftle Opsning
Throttlepositionsensor
voltage:0.75V
Throttlepositionsensor
voltage;2.25V
Fully-opened
throttle,
Throttlepositionsensor
voltage:4.5V
Unit of spsd
lsi + 2nd
2nd * 3rd
3rd + ilth
mph
9-12
20-23
28-33
Lock-up ON
km/h
15-19
mph
22-26
43-49
km/h
35-41
69-79
mph
37-43
k-/h
60-69
Unit ot speed
Lock-upOFF
i{th + 3rd
mpn
19-23
1 A- 2 ' l
6 - 10 {3rd- 1st)
km/h
5t-5D
29-34
1 0- 1 5( 3 r d* 1 s t )
mph
88-99
86-96
57-64
26-32
km/h
142- 't59
1 3 8- 1 5 4
9 2- 1 0 3
42-51
111- 124
45-53
34-40
oz - ott
9 9- 1 0 8
68-74
1 0 9- 1 1 8
1 0 1- 1 1 1
9 0- 1 0 1
1 6 3- 1 7 9
1 4 5- 1 6 3
Downshift
Throttle Opening
Fully-closed
throttle,
Throttlepositionsensor
voltage;0.5V
Fully-opened
throttle,
Throttlepositionsensor
voltage:4,5V
3rd * 2nd
znd + lst
NOTE:
. Lock-upON:Thelock-upcontrolsolenoidvalveA turns ON.
. Lock-upOFF:The lock-upcontrolsolenoidvalveA turns OFF.
4.
Accelerateto about 35 mph (57 km/h)so the transmissionis in 4th. then shift from
E
The vehicleshouldimmediatelybeginslowingdown from enginebraking.
5.
or E positionto E position.
E {1stGear)Position
Accelerate
from a stop at full throttle,Makesurethere is no abnormalnoiseor clutchslippage.
Upshiftsshouldnot occurwith the shift leverin this position.
E (2ndcear) Position
Accelerate
from a stop at fuI throttre.Makesurethere is no abnormarnoiseor crutchsrippage.
Upshiftsand downshiftsshouldnot occurwith the shift leverin this position.
Position
E (Reverse)
Accelerate
from a stop at full throttle.and checkfor abnormalnoiseand clutchslippage.
6.
Testin E (Park)Position
Parkthe vehicleon slope(approx.16"),applythe parkingbrake,and shift into position.Release
E
the brake;the vehicle shouldnot move.
14-158
www.emanualpro.com
Stall Speed
Test
CAUTION:
. To prevent transmission damage,do not te3t stall speedfor mors than 10 sondsat a time'
. Do not shift the lever while raising th engine spsed.
. Be sure to remove tho pressurogauge bofore testing stall speed,
1. Beforetesting,checkthe transmissionfluid level,sepage 14-160.
2. Engagethe parkingbrakeand blockall four wheels
3. Connectthe tachometer,and startthe engane.
4. Make sure the Ay'Cswitch is OFF
position.
5. Afterthe enginehaswarmedupto normaloperatingtemperature(the radiatorfan comeson),shiftinto@
for 6 to 8 seconds,and noteenginespeed'
6. Fullypressthe brakepedaland accelerator
j. A|ow 2 minutesfor cooling,then repeatthe test in E, E ('97- 98).E {'99- 00},and E positions.Stallspeedshould
be the samein E, E, E, tr. and E positions
Stall Speedrpm:
Specitication:2,550rpm
SrviceLimit: ?,400- 2.700rpm
PROBAELECAUSE
TROUBLE
www.emanualpro.com
14-159
FluidLevel
Checking
NOTE: Keep all foreign particlesout of the transmisston,
1.
7.
FRONT
-'-Y'
Insrallthe dipstickwithin
DIPSTICK
R e m o v et h e d i p s t i c ka n d c h e c kt h e f l u i d l e v e l .l t
shouldbe betweenthe upperand lower marKs.
lt
UPPERMARK
MARK
El--
lf the level is below the lower mark. pour the recommendedfluid into the filler holeto bring it to the upper
mark,Alwaysuse GenuineHondaPremiumFormula
AutomaticTransmissionFluid (ATF).Using a nonHondaATFcan affectshift oualitv.
14-160
www.emanualpro.com
PressureTesting
Changing
NOTE: Keep all foreign particlesout of the transmission.
1.
B e f o r et e s t i n g ,b e s u r e t h e t r a n s m i s s i o nf l u i d i s
filledto the proPerlevel.
2.
4WD:
Raisethe vehicle(seesection11.
2WD:
Raisethe front of the vehicle,and make sure it is
securelysupported.Setthe parkingbrake,and block
both rearwheelssecurely.
TRANSMISSION
END COVER
DRAIN
1 8x 1 . 5m m
SEALINGWASHEB
Replace.
49 N.m{5.0kgt.m,36 lbf.tl)
/4\
\-J--
HOS,
A/T PRESSURE
2210mm
07MAJ - PYiOllA
{4 Requircd}
,4
\r+..\.-.\-'-\
'/"' ,a
W'
HOSE
A/T PRESSURE
ADAPTER
07MAJ - PYt0120
(il Rcquiledl
6.
Measurethe followingPressure:
..........,14-162
. L i n eP r e s s u r e
. 1 s t .1 s t - h o l C
d l u t c hP r e s s u r .e. . . . . . . . . . . . '1. 4 - 1 6 2
. 2 n d , 3 r da n d 4 t h C l u t c hP r e s s u r .e. . . . . . . .1. 4 - 1 6 3
7.
www.emanualpro.com
(cont'd)
14-161
PressureTesting
(cont'd)
Line Proslure, lst Clutch, lst.hold Clutch prsssuro Measuromont
1.
2.
4.
LOCK.UPCONTROL
SOLENOIDVALVE
A/B ASSEMBLY
PRESSURE
Line
1stClutch
SHIFTLEVER
POSmON
Eor@
14-162
www.emanualpro.com
tr
FLUIDPRESSURE
PROBABLECAUSE
Standald
No (or low)
line pressure
E ('se- oo)
lst-hold
Clutch
SYMPTOM
Torque converter.
ATF pump,pressure regulator,
torque converter
checkvalve
lst Clurch
pressure
No or low lsthold pressure
1st-holdClutch
ServiceLimit
780 kPa
'l10 psi)
{8.0kgf/cm,,
'99 - 00 Models:
1.
2.
R u n t h e e n g i n e a t 2 , 0 0 0r p m . t h e n m e a s u r e2 n d
clutchpressure.
3.
3.
4.
4.
5.
5.
6.
4TH CLUTCHPRESSURE
HOLE
INSPECTION
2ND CLUTCHPRESSURE
HOLE
INSPECTION
"..#
'"r.,-ur""
HOLE
INSPECTION
--t"1'-.
3RDCLUTCHPRESSURE
HOLE
INSPECTION
PRESSURE
2nd Clutch
3rd Clutch
4th clutch
SHIFTLEVER
POSmON
PROBABLECAUSE
tr
No or low 2nd
pres$ure
2nd Clutch
E (97 - s8)
Elwith OverDriveis OFF
(99 - 00)
E (97,98)
E (99 - oo)
No or low 3rd
pressure
3rd clutch
No or low 4th
pressure
4th Clutch
www.emanualpro.com
FLUIDPRESSURE
SYMPTOM
Standard
800 - 850 kPa
\A.2- 8.1 kgtlcm2,
'120- '124psil
Servico Limit
760 kPa
(7.7kgf/cm' ,110psi)
ServoValveor 4th
Clutch
14-163
Transfer
Inspection
Mako suro lifts, jacks, and safety stands
@E
are placod properly lsoe section t).
1.
2.
COMPANIONFLANGE
Shift to E position.
4.
14-164
www.emanualpro.com
TransferAssembly
Removal
Make sure the lifts, iacks, and safety
@
stands are placed properly (seesection 11.
1.
2.
5.
SELF-LOCKING
NUT
Beplace.
SEI-F.LOCKING
NUT
Replace.
NUT
Replace
DRAINPLUG
'18x'1.5rnm
49 N.m 15.0kgf.m, 36 lbl.ftl
7.
4.
GUARD8AR
www.emanualpro.com
(cont'd)
14-165
TransferAssembly
Removal(cont'dl
9, Make referencemarks across the prooeller shaft
and the transferassemblyflanges.
1 0 . S e p a r a t et h e p r o p e l l e r s h a f t f r o m t h e t r a n s f e r
assemblyflanges.
REFERENCE
MANKS
PROPELLER
SHAFT
'l
assembly.
NOTE: While servicingthe transfer assembly,do
not allow dust or otherforeignparticlesto enterthe
transmission.
REARSTIFFENER
14-166
www.emanualpro.com
lnstallation
1.
5.
REFERENCE
MARKS
8 r 1.25mm
24 N.m {2.4 kgf m,
r7 bl.ftl
10 x'l.25 mm
araN.m 14.5kgtm,
33 tbf trl
8 xl,25]nm
32 N.m(3.3kgl.m,
2a tbf.ftl
Replace.
I n s t a l lt h e s h i f t c a b l e w i t h t h e c o n t r o l p i n , t h e n
secureit with the snap pin. Do not bend the shift
cableexcessively.
7.
lnstalltheshift cablecover.
SHIFTCABLE
O.RING
TNANSFER
ASSEMALY
8 xl.25 mm
22 N.m 12.2kd-m,
16 tbt.ftl
(cont'd)
www.emanualpro.com
14-167
TransferAssembly
Installation(cont'dl
Installthe exhaustpipe A.
'I 'I.
Connectthe primaryheatedoxygensensor(Primary
H02S) connector,
GASKET
EXHAUSTPIPEA
Replace.
SELF.LOCKING
NUT
10 x 1.25mm
54 N.m {5.5kgf.m,
40 rbf.ft)
Replace.
SELF-LOCKING
NUT
8 x 1.25mm
22 N.m (2.2kgl.m,
16 rbr.ftt
Replace.
-LOCKING
NUT
8 x 1.25mm
16Nm11.6kgf.m,
12 lbf.fO
Replace.
10. Installthe
s p l a s hs h i e l da n dt h e g u a r db a r .
6x1.0mm
9.8N.m {1.0kgt.m,
7.2 tbt.ftt
14-168
www.emanualpro.com
p e r a t u r e( t h e r a d i a t o r f a n c o m e s o n ) , T u r n t h e
engineoff and checkATF level.
Transmission
Removal
@
6.
Disconnect
the vehiclespeedsensor(VSS),the countershaft speed sensor, and the A/T gear position
switch connectors.
A/T GEARPOSITION
SWITCHCONNECTOR
VEHICLESPEED
SENSOR|VSS'
7.
STARTER
CABLES
R e m o v et h e t r a n s m i s s i o ng r o u n d c a b l et e r m i n a l
and the radiatorhose clamp lrom the transmission
hanger.
5.
RADIATORHOSE
CLAMP
MOUNTINGBOLTS
CONTROL
SOLENOIDVALVE
CONNECTOR
www.emanualpro.com
(cont'd)
14-169
Transmission
Removal(cont'd)
8.
SENSORCONNECTOR
R e m o v et h e d r a i n p l u g . a n d d r a i n t h e a u t o m a t i c
t r a n s m i s s i o nf l u i d { A T F ) .R e i n s t a ltlh e d r a i n p l u g
with a new sealingwasher.
1 1 . Removethe cotter pins and castlenuts, then separatethe ball joints from the lower arms (seesection
18).
DAMPERPINCHBOLT
DRAIN
1 8x 1 . 5m m
4eN.mrs.oksr.m.
36rbrft)
;:i:$:
*o"*."
SELF.LOCKING
NUT
Replace.
14-170
www.emanualpro.com
OAMPERFORK
CASII.E NUT
DAMPERFORK
BOLT
Replace.
ORIVESHAFT
Replace.
't7. RemoveexhaustpipeA.
GASKET
Replace.
2WD:
Removethe control lever, then separatethe shift
cablefrom the control shaft. Do not bend the shift
cableexcessivelv.
SHIFT CAELE
EXHAUST
Replace.
www.emanualpro.com
14-171
Transmission
Removal(cont'dl
Make referencemarks across the transfer assemblv
and propellershaftflanges.(4WD)
2 1 . S e p a r a t et h e p r o p e l l e r s h a f t f r o m t h e t r a n s f e r
assembly.(4WD)
REFERENCE
MARKS
I x 1.25mm
Replace.
RIGHTFRONT
MOUNT/BRACKET
2 2 . Removethe intermediateshaft,
Tie plasticbagsover the both ends of the intermediate shaft. Coat all precisionfinished surfaceswith
cleanengineoil.
R e m o v et h e r e a r s t i f f e n e ra n d t o r q u e c o n v e r t e r
cover.
COVER
14-172
www.emanualpro.com
REARENGINEMOUNTINGBOLTS
www.emanualpro.com
14-173
lllustratedIndex(4WDl
EndCover/Transmission
www.emanualpro.com
O
O
O
@
ENDCOVER
olL SEAL Replace.
BALLBEARING
A/T GEARPoSITIoN swITcH coVER
) A/TGEAnPosrloNswrrcH
@ ROLLER
O coLLAR
G) o-RING Replace.
{9) FEEDPIPEFLANGE
@ O-RINGReplace.
O SNAPRING
@ 3RDCLUTCHFEEDPIPE
(D CoUNTERSHAFT
LOCKNUT23 x 1.25mm Replace.
(} coNtcAL SPR|NGWASHER Reptace.
@ PARKGEAR
@ ONE.WAYCLUTCH
(, COUNTENSHAFT
lST GEAR
(D NEEOLEBEARING
(O COUNTERSHAFT
lST GEARCOLLAR
@ o-RING Reptace.
@ lST CLUTCHFEEDPIPE
@ O-RINGReptace.
@} FEEOPIPEFLANGE
@ SNAPRING
@ DOWELPIN
@ ENDcoVER GASKET Feplace.
@ PARKPAWLSToP
@ PARKPAWL
@ PARKPAWLSPRING
@ PARKPAWLSHAFT
O} A/T GEARPOSITIONSWITCHHARNESSCLAMP
@ PARKLEVER
@ LOCKWASHER Replace.
@ PARKSTOP Selectivepart
@ PARKLEVERSPRING
@ DRAINPLUG
O SEALINGWASHER Reptace.
@) MAINSHAFTLOCKNUT2l x 1.25mm Replace.
@ CONICALSPRINGWASHER Replace.
@ lST CLUTCHASSEMBLY
TOROUE SPECIFICATIONS
Bolt/Nut No.
Torque Valuo
Size
6B
8A
12J
18D
19S
21M
23C
'12N'm ('1.2kgf.m,8.7lbf.ft)
14 N.m (1.4kgf.m,10lb{.ft}
22 N.m 12.2kgf.m, 16 lbf.ft)
28 N'm (2.9kgf.m,21lbf.ft)
49 N.m (5.0kgf.m,36lbf'ft)
93 N'm {9,5ksim.69 lbf.ft)
78 N.m {8.0kgnm,58lbf.ft)
103* 0- 103N{n {10.5* 0+ 10.5kgfn,
75.9-0-75.9 lbf{t)
6 x 1 . 0m m
6x1.0mm
8 x 1 . 2 5m m
1 2x 1 . 2 5m m
1 8x 1 . 5m m
1 9x 1 . 2 5m m
2 1 x 1 . 2 5m m
2 3 x 1 . 2 5m m
www.emanualpro.com
Remarks
Linebolt
Drainplug
Sub-shaftlocknut
Mainshaftlocknut:Left-handthreads
Countershaft
locknut:Left-hand
threads
14-175
lllustratedIndex(4WD)
Transmission
Housing
{;
www.emanualpro.com
r] REVERSE
IDLERGEARSHAFT/HOLDER
'A NEDLEBEARING
..] TRANSMISSIONHOUSING
al TRANSMISSIONHOUSINGOIL SEAL Replace.
g SETBING.80mm Selecrive
part
GEARCOLLAB
O REVERSE
GEAB
E couNTERSHAFTREVERSE
.9,]NEEDLEBEARING
i9 LOCKWASHER Replace.
.1!i REVERSE
SHIFTFORK
O REVERSE
SELECToR
HUB
SELECTOR
iJ. REVERSE
4TH GEAR
ii' COUNTERSHAFT
.14 NEEDLEBEARING
iD D|STANCEcoLLAR,28 mm Selectivepart
(i3 COUNTERSHAFT
2NO GEAB
i7-]THRUSTNEEDLEBEARING
(10COUNTERSHAFT
3RDGEAR
(9 NEEDLEBEARING
E9 COUNTERSHAFI3RDGEABCOLLAR
.li THRUSTNEEDLEBEARING
.?) SPLINEOWASHER
,,O 3RDCLUTCHASSEMBLY
1 O-RINGBeplace.
i23 COUNTERSHAFT
4i SHIFTCONTROLSOLENOIDCOVER
?Z]HARNESSCLAMPBRACKET
?9]SHIFTCONTROLSOLENOIDVALVEA/B ASSEMBLY
8 HARNESSCLAMPBRACKET
GI SHIFTCONTROLSOLENOIDVALVEFILTER/GASKET
ReplaceSNAPRING
THRUSTWASHEB
THRUSTNEEDLEBEARING
04MAINSHAFT4TH GEAR
NEEDLEBEARINGS
@ THRUSTNEEDLEBEARING
MAINSHAFT4TH GEABCOLLAR
@ 2NO/4THCLUTCHASSEMBLY
@ O-RINGReplace.
:.ro)THRUSTWASHER,36.5
part
x 55 mm Selective
ai THRUSTNEEOLEBEARING
(4 MAINSHAFT2ND GEAR
i49 NEEDLEBEARING
BEARING
@ THRUSTNEEDLE
(49 MAINSHAFT
@r SEAL|NGR|NG,35mm
O SEALINGRING,29mm
@ NEEDLEBEARING
.49SET RING
) lST.HOLDCLUTCHASSEMBLY
O o-RING Replace.
6E THRUSTWASHER
9 THRUSTNEEDLEBEARING
6' NEEDLEEEARING
ir SUB-SHAFT4TH GEAR
6 THRUSTNEEDLEBEARING
@ SUB.SHAFT4TH GEARCOLLAR
@ sUB-sHAFf
6I NEEDI-EBARINGSTOP
@ NEEDLEBEARING
(6t ATF GUIDECAP Replace.
(64TRANSMISSIONHANGEB
CAP
@ BREATHER
i@ MAINSHAFTSPEEDSENSOR
6i O-RINGReplace.
IDLERGEAR
6D REVERSE
@r DOWELPlN, 14 x 25 mm
.6d SNAPRINGS
QlI SUB.SHAFTTRANSMISSIONHOUSINGBEARING
E) MAINSHAFTTRANSMISSIONHOUSINGBEABING
.2, COUNTERSHAFITRANSMISSIONHOUSING
BEARING
DOWELPlN, 14 x 25 mm
BRACKET
@ CONNECTOR
[E ATF MAGNET
DOWELPlN, 14 x 20 mm
TRANSMISSIONHOUSINGGASKET Replace.
ASSEMBLY
t, DIFFERENTIAL
n9DOWELPlN,10x 12 mm
t0 O-RINGReplace.
@)TRANSFERASSEMBLY
@)TOROUECONVERTERHOUSINGOIL SEAL Replace.
,lDTOROUECONVERTERHOUSING
TOROUESPECIFICATIONS
Bolt/Nut No.
6A
6B
10A
www.emanualpro.com
Torque Value
1 2 N . m( 1 . 2k g f . m , 8 . 7l b f . f t )
1 4 N . m( 1 . 4k g f . m 1
, 0l b i f t )
44 N.m (4.5kgf.m,33lbf.ft)
Size
Rgmarks
6 x 1 . 0m m
6 x 1 . 0m m
1 0x 1 . 2 5m m
14-177
lllustratedIndex(4WDl
TorqueConverterHousing/ValveBody
37-94
6A
a^\
www.emanualpro.com
14-178
ATFFEEDPIPE,8x 145mm
o
a;\
@ MAIN SEPARATORPLATE
@ DOWELPIN
@ ATF PUMPDRIVEGEAR
@ SUCTIONPIPECOLLAR
TOROUECONVERTER
HOUSING
@ COUNTERSHAFT
@ ATF GUIDEPLATE
@ LOCKWASHER Replace.
@ CONTROLLEVERASSEMBLY
@ TOROUECONVERTERHOUSING
@ CHANGESHAFT
@ OIL SEAL Reolace.
@ MAINSHAFTOIL SEAL Reolace.
@ MAINSHAFTTOROUECONVERTRHOUSING
ATF STRAINER
,6 SERVOBODY
G)SERVOSEPARATORPLATE
VALVEEODY
!o, SECONDARY
DOWELPIN
PLATE
SECONDARY
SEPARATOR
@ SERVODETENTBASE('97- 98 model3 onlyl
,6 ATF FEEDPIP,8 x 145 mm
@ ATFFEEDPIPE,8x 40 mm
ATF FEEDPIPE.8 x 62 mm
ATFFEEDPIPE.8x 112mm
@ ATF FEEDPIPE,8 x 192.5mm
(} ATF FEEOPIPE.I x 105.8mm
STOPSHAFTBRACKET
@ ATF LUBRICATIONPLATE
ATF FEEOPIPE
@ DOWELPIN
@ LOCK-UPVALVEEODY
@ LOCK-UPSEPARATORPLATE
@ REGULATORVALVEBODY
@ DOWELPIN
@ COOLERRELIEFVALVESPRING
@ COOLERRELIEFVALVE
CHECKVALVESPRING
6 TOROUECONVERTER
CHECKVALVE
@ TOROUECONVERTER
@)CONTROLSHAFT
@ OETENTARM SPRING
@ OETENTARM
@ DETENTARM SHAFT
@ FILTERReplace.
@ CHECKBALLS
@ lST ACCUMULATORCHOKE
@ O"RING Replace.
@ STATORSHAFT
@ STOPSHAFT
@ ATF FEEDPIPE,I x 112 mm
@ MAIN VALVE BOOY
@ ATF PUMPDRIVENGEARSHAFT
@ ATF PUMPDRIVENGEAR
o
(a
a
BEARING
BEARING
@ LOCK.UPCONTROLSOLENOIDVALVEA/B
FILTER/GASKETReplace.
@ LOCK.UPCONTROLSOLENOIDVALVEA/B
ASSEMBLY
TOROUESPECIFICATIONS
Bolt/Nut No.
Torque Valug
Size
64
6B
12 N'm (1.2kgf.m,8.7lbf.ft)
14 N.m (1.4kgf.m,10 lbf.ft)
6x1.0mm
6x1.0mm
www.emanualpro.com
Romarks
14-179
lllustratedIndex(2WDl
EndCover/Transmission
www.emanualpro.com
O ENDCOVER
iLl OILSEAL Beplace.
O BALLBEARING
i.) A/T GEARPOSITIONSWITCHCOVER
i5] A/T GEARPOSITIONSWITCH
aq)RoLLER
? COLLAB
i0 o-BtNG Replace.
) FEEDPIPEFLANGE
f,o)o-RING Replace.
1' SNAPRING
1A 3RDCLUTCHFEEDPIPE
23 x 1.25mm Replace.
LOCKNUT
O COUNTERSHAFT
WASHERReplace.
[} coNtcal SPRING
iO PARKGEAR
(!I ONE.WAYCLUTCH
lST GEAR
E COUNTERSHAFT
@ NEEDLEBEARING
1STGEARCOLLAR
@ COUNTERSHAFT
Or o-RtNGS Reptace.
?] lST CLUTCHFEEDPIPE
@ o-RING Replace.
e3 FEEDPIPEFLANGE
4I SNAPRING
i DOWELPIN
i?0 END COVERGASKET Replace.
?7)PARKPAWLSTOP
E9 PARKPAWL
C9 PARKPAWLSPRING
D PARKPAWLSHAFT
OI A/T GEARPOSITIONSWITCHHARNESSCIAMP
@ PARKLEVER
3 LoCK WASHER Replace.
04 PARKsToP Selectivepart
(!' PARKLEVERSPRING
@ DRAINPLUG
Ot SEALINGWASHER Replace.
LocKNuT 21 x 1.25mm Replace.
60 MA|NSHAFT
(9 CONICALSPRINGWASHER Replace.
@ lST CLUTCHASSEMBLY
,!4!O-RING Replace.
@I THRUSTWASHER
BEARING
@ THRUSTNEEDLE
i.!' NEEDLEBEARING
i MAINSHAFTlST GEAR
@i MAINSHAFT1STGEARCOLLAR
!r, O-RINGReplace.
SPEEDSENSOR
iO COUNTERSHAFT
E ROLLER
@, coLLAR
Ct o-RING Replace.
5.] FEEDPIPEFLANGE
09 o-RING Replace.
6A SNAPRING
5' IST.HOLDCLUTCHFEEDPIPE
@-]SUB-SHAFTLOCKNUT19 x 1.25mm Replace.
WASHERReplace.
SPRING
!t CONICAL
6i' SUB-SHAFTlST GEAR
G) LINEARSOLENOIDASSEMBLY
(6!)LINEARSOLENOIDASSEMBLYGASKET Replace
G] HARNESSBRACKET
6a SEALINGWASHERSReplace.
C' ATF COOLERLINE
@ L|NEBoLT
GI ATF DIPSTICK
GI ATF COOLERLINE
O LINEBOLT
@ SEALINGwasHERs Replace.
aooVEHICI.ESPEEDSENSORIVSS)
f,E O-RING Replace.
TOROUE SPECIFICATIONS
Bolt/Nut No.
6A
6B
8A
12J
'18D
195
21M
www.emanualpro.com
Torque Value
Size
12 N.m (1.2kgf.m,8.7lbf.ft)
14 N.m (1.4kgf.m,10lbf.ft)
22 N.m 12.2kgim, 16lbf.ft)
28 N.m (2.9kgim,21 lbf.ft)
49 N'm (5.0kgim,36 lbf.ft)
93 N.m (9.5kgf.m,69lbf.ft)
78 N.m (8.0kgf.m,58lbf.ft)
103+ 0+ 103N{n (10.5+ 0+ 10.5kSfm,
75.9' 0 - 75.9lbfft)
6x1.0mm
6x1.0mm
8 x 1 . 2 5m m
1 2x 1. 2 5m m
1 8x 1 . 5m m
1 9x 1 . 2 5m m
2 1 x 1 . 2 5m m
2 3 x 1 . 2 5m m
Remarks
Line bolt
D r a i np l u g
Sub-shaftlocknut
Mainshaftlocknut:Left-handthreads
locknut:Left-hand
Countershaft
threads
14-181
lllustratedIndex(2WDl
TransmissionHousing
6A
Lt--"
&""--
www.emanualpro.com
o REVERSEIDLERGEARSHAFT,/HOLDER
atl
,6
NEEOLEBEARING
TRANSMISSIONHOUSING
@ TRANSMISSIONHOUSINGOIL SEAL Rplace.
part
!., SETRING,80mm Selective
REVERSE
GEARCOLLAR
COUNTERSHAFT
REVERSE
GEAR
NEEDLEBEARING
6l LOCKWASHER Replace.
@ REVERSESHIFTFORK
REVERSE
SELECTOR
HUB
@ REVERSESELECTOR
4TH GEAR
@ COUNTERSHAFT
@ NEEDLEBEARING
@ DISTANCECOLLAR,28mm Selectivepan
2ND GEAR
@ COUNTERSIIAFT
THRUSTNEEDLEBEARING
3RDGEAR
@ COUNTERSHAFT
@ NEEDLEAEARING
3RDGEARCOLLAR
@)COUNTERSHAFT
@ THRUSTNEEOLEBEARING
@ SPLINEOWASHER
@ 3RDCLUTCHASSEMBLY
@ O-RINGSReplace.
@ COUNTERSHAFT
@ SHIFTCONTROLSOLENOIDCOVER
@ HARNESSCLAMPBRACKET
@ SHIFTCONTROLSOLENOIDVALVEA/B ASSEMBLY
@ HARNESSCLAMPBRACKET
@)SHIFTCONTROLSOLENOIDVALVEFILTER/GASKET
Replace.
@ SNAPRING
@ THRUSTWASHER
@ THRUSTNEEDLEBEARING
@)MAINSHAF ,ITH GEAR
@ NEEDLEBEARINGS
@ THRUSTNEEDLEBEARING
@ MAINSHAFT4TH GEARCOLLAR
@ 2ND/4THCLUTCHASSEMBLY
@ O-RINGS ReDlace.
@ THRUSTWASHER,36.5x 55 mm Selectivepart
@ THRUSTNEEDLEBEARING
a
o
o
@ MAINSHAFT2ND GEAR
@ NEEDLEBEARING
@ THRUSTNEEOLEBEARING
@ MAINSHAFT
@ SEALINGRINGS,35mm
@ SEALINGRING.29 mm
@ NEEDLEBEARING
@ SETRING
@ lST-HOLDCLUTCHASSEMSLY
@ O-RINGSReplace.
@ THRUSTWASHER
@ THRUSTNEEDLEBEARING
@ NEEDLEBEARING
@ SUB.SHAFT4TH GEAR
@ THRUSTNEEDLEBEARING
@ SU&SHAFT,ITHGEARCOLLAR
@ SUB.SHAFT
@ NEEDLEBEARINGSTOP
@ NEEDLEBEARING
@ ATF GUIDECAP Replace.
@ TRANSMISSIONHANGER
CAP
@ BREATHER
@)MAINSHAFTSPEEDSENSOR
@ O-RING Reolace.
@ REVERSEIDI.fR GEAR
@ DOWELPlN, lil x 25 mm
@ SNAPRINGS
@ SU&SHAFTTRANSMISSIONHOUSINGAEARING
@ MAINSHAFTTRANSMISSIONHOUSINGBEARING
TNANSMISSIONHOUSING
@ COUNTERSHAFT
@
@
@
@
@
@
@
BEABING
DOWELPlN, 14 x 25 mrn
CONNECTORBRACKET
DOWELPlN, 14 x 20 mm
TRANSMISSIONHOUSINGGASKET Replace.
DIFFERENTIAL
ASSEMBLY
TOROUEOONVERTER
HOUSINGOIL SEAL Replace.
HOUSING
TOROUECONVERTER
TOROUESPECIFICATIONS
Boli/Nut No.
6B
10A
www.emanualpro.com
Torque Value
Size
12 N.m (1.2kgf.m,8.7lbf.ft)
'14N.m (1.4kgim, 10 lbf'ft)
44 N.m (4.5 kgim, 33 lbf.ft)
6 x 1 . 0m m
6x1.0mm
mm
1 0x ' 1 . 2 5
Remarks
14-1A3
lllustratedIndex(2WD)
TorqueConverterHousing/ValveBody
to\
I
@
www.emanualpro.com
ai_lATF FEEDPIPE,I
a2',
ATF STRAINER
PLATE
i4ll MAIN SEPARATOR
(4dDOWELPIN
@ ATF PUMP DRIVEGEAR
@ SUCTIONPIPECOLLAR
.!!l COUNTEBSHAFT
HOUSING
TOROUECONVERTER
x 145 mm
SERVOBODY
(41 SERVOSEPARATOB
PLATE
/4. SECONDABY
VALVE BOOY
:4.
DOWELPIN
PLATE
SEPARATOR
\7) SECONDARY
SERVODETENTBASE('98 model onlvl
ATFFEEDPIPE,8 x 145mm
1.0)ATFFEEDPIPE.8x 40 mm
tl ATFFEEDPIPE,8x 62 mm
ATFFEEDPIPE,I x 112mm
(3] ATFFEEDPIPE,8 x 192.5mm
ATFFEEDPIPE,8 x 105.8mm
t9 STOPSHAFTBRACKET
PLATE
.1qATF LUERICATION
ATF FEEDPIPE
DOWELPIN
ID LOCK-UPVALVEBODY
@,LOCK-UPSEPARATORPLATE
VALVEBOOY
8! REGULATOR
Itt\ DOWELPIN
,29 COOLERRELIEFVALVESPRING
4 COOLERBELIEFVALVE
CHECKVALVESPRING
TOROUECONVERTER
69 TOROUECONVERTERCHECKVALVE
CONTNOLSHAFT
aaDETENTARM SPRING
.21DETENTARM
60 DETENTARM SHAFT
0t FILTERReplace.
CHECKBALLS
CHOKE
1STACCUMULATOR
04O-RINGReplace.
STATORSHAFT
6!)STOPSHAFT
ATFFEEDPIPE.8 x 112mm
t0 MAIN VALVE BODY
0t ATF PUMPDRIVENGEARSHAFT
.@ ATFPUMPDRIVENGEAR
o
o,
BEARING
art)ATF GUIDEPLATE
@ ATF MAGNET
HOUSING
@ TOBOUECONVERTER
@ OILSEAL Beplace.
OILSEAL Replace.
@ MAINSHAFT
li]t MAINSHAFTTOROUECONVERTER
HOUSING
BEARING
LOCK.UPCONTROLSOLENOIDVALVEA/B
FILTER/GASKETReplace.
LOCK-UPCONTROLSOLENOIDVALVEA/B
ASSEMELY
oa
en
TOROUESPECIFICATIONS
Bolt/Nut No.
www.emanualpro.com
Torque Value
Size
6x1.0mm
Remarks
14-185
End Cover
Removal
NOTE:
o The illustrationshowsthe 4WDautomatictransmission;
the 2WD is similar.
. cleanall partsthoroughlyin solventor carburetorcleaner,and drythem with compressedair.
. Blow out all passages.
. When removingthe transmissionend cover,replacethe following:
- End cover gasket
- Lockwasher
- O-rings
6 x 1.0 rhm EOLTS
- Shaftlocknuts
- Conicalspringwashers
- Sealingwashers
A/T GEARPOSMON
SwlTCH COVER
A/T GEARPOSITION
ENDCOVERGASKET
A/T GEARPOSMON
SW|TCH HARNESSCLAMP
MAINSHAFTLOCKNUT
CONICALSPRINGWASHER
1STCLUTCHASSEMBLY
THRUSTWASHER
THRUSTNEEDLEAEARING
NEEDI.TBEARING
SUB.SHAFTLOCKNUT
PARKPAWL
PAWL
O.RINGS
lt1/ sroe
Y plwl
L/'SPRING
Locx wASHER
7//
?ARKsrop
9/
couNTERsHAFr
o-- Ay'
LOCKNUT
LocKNUr
G-
PAwL
'sHAFr
CONICALSPRING
WASHER
!\
-l!'
SUB.SHAFT1STGEAR
MAINSHAF?'ST GEAR
I"EVER
SPRING
MAINSHAFT1ST
GEARCOLLAR
..t,"o,
"oo
CONICALSPRING
WASHCR
PARKGEAR
Y CLUTCH
SEALINGWASHERS
lST GEAR
NEEDLEBEARING
LINEAOLT
COUNTERSHAFT
lST GEARCOLLAR
14-186
www.emanualpro.com
SEALINGWASHERS
1.
R e m o v et h e A / T g e a r p o s i t i o n s w i t c h h a r n e s s
cramp.
Removethe y'VTgear position switch cover.
Removethe bolt securingthe ly'T gear positionswitch
harnessclamp on the end cover,then removethe A/T
gear positionswitch.
Removethe 12 bolts securingthe end cover.then
removethe cover.
Slip the specialtool onto the mainshaftas shown.
PIN
8 mm pin,
commercially
SUB-SHAFT
LOCKNUT
Replace.
MAINSHAFT
LOCKNUT
Replace.
COUNTERSHAFT
LOCKNUT
2\
Replace.
Irot)
CONICALSPNINGWASHERS
Replace.
6.
7.
M=tt"
www.emanualpro.com
1SYGEAR
Removethe needlebearingand countershaft1stgear
co ar.
1 1 . Removethe ATFcoolerlines,
14-187
Transmission
Housing
Removal
NOTE:
. The illustrationshowsthe 4WDautomatictransmission;
the 2WD is similar,
. Cleanallpartsthoroughlyin solventor carburetorcleaner.and drythemwith compressedair.
. Blow out all passages.
. When removingthe transmissionhousing,replacethe lollowing:
- Transmissionhousinggasket
- Lockwasher
- O-rings
TRANSMISSIONHOUSINGMOUNTINGEOLT
TRANSMISSIONHANGER
TRANSMISSIONHOUSING
REVERSE
GEANCOLLAR
REVERSE
GEAR
CONNECTOR
BRACKET
LOCKWASHER
MAINSHAFTSPEED
SENSOR
REVERSE
SHIFT
MAINSHAFT
SUB.ASSEMBLY
TRANSMISSIONHOUSING
GASKET
DIFFERENTIAL
ASSEMBLY
TOROUECONVERTER
HOUSING
O-RING
t4wDl
TRANSFERASSEMBLY
t4wDt
10 x 1.25mm BOLTS
l4wo)
14 -18 8
www.emanualpro.com
Removethe countershaftreversegearcollar,needle
bearing, and countershaftrevsrse gear from the
countershaft,
7.
8.
9.
SPRINGPIN
I n s t a l lt h e s p e c i a lt o o l o v e r t h e m a i n s h a f t .t h e n
removethe transmissionhousingas shown.
www.emanualpro.com
14-189
TorqueConverterHousing/ValveBody
Removal
NOTE:
. The illustrationshowsthe 4WDautomatictransmission;
the 2WD is similar.
' cleanall partsthoroughryin sorventor carburetorcreaner,and drythem with
compressedair.
. Blow out all passages.
. When removingthe valvebodies,replacethe following:
- Lockwasher
- O-ring
ATF FEEDPIPE
SERVODETENT
BASE
137 - 98 models only)
DOWELPIN
6x1.0mm
'97 - 98 models:
LOCK.UPVALVE
BOOY
2 Bolts
'99 - 00 modeb: 1
Bolt
LOCK.UPSEPARA
PLATE
ATF
STRAINER
REGULAIORVALVE
BOOY
DOWELPIN
6x1.0mm
37 - 98 models:
7 Bolts
'gg - 0Omodels:
8 Bolts
COOLERRELIEFVALVE
TOROUECONVERTER
CHECK
VALVE
SERVOBODY
137 - 98 modelsl
STATOR SHAFT
O.RING
SERVO
SEPARATOR
PLATE
5x1.0mfi
3 Bolts
6x 1.0
5 Bolts
SECONDARY
VALVEBODY
MAIN VALVEBODY
DOWELPIN
ATF PUMPORIVEN
GEARSHAFT
ATF PUMPDRIVEN
GEAR
14-190
www.emanualpro.com
\
CONTROL
LEVER
MOUNTINGBOLT
{awD)
SECONDARY
SEPARATOR
PLATE
14, Cleanthe inlet opening of the ATF strainer thoroughly with compressedair, then checkthat it is in
good condition,and the inletopeningis not clogged
or damaged.
INLET OPENING
www.emanualpro.com
14-191
Valve Body
Repair
NOTE:This repair is only necessaryif one or more of
the valvesin a valve body do not slidesmoothlyin their
bores.Usethis procedureto free the varves.
'1.
5.
S o a k a s h e e t o f # 6 0 0 a b r a s i v ep a p e r i n A T F f o r
about30 minutes.
2.
,l
Inspectthe valve for any scutf marks.Use the ATFsoaked#600 paper to polish off any burrs that are
on the valve,then wash the valvein solventand dry
it with compressedair.
4.
N O T E :T h e v a l v e b o d y i s a l u m i n u ma n d d o e s n , t
requiremuch polishingto removeany ourrs.
1.
14-192
www.emanualpro.com
R e m o v et h e # 6 0 0 p a p e r . T h o r o u g h l y w a s h t h e
entire valve body in solvent,then dry it with compressedar.
Valve
Assembly
NOTE;
Coatall partswith ATF beforeassembly.
.
l n s t a l tl h e v a l v e ,v a l v es p r i n g ,a n d c a p i n t h e v a l v e
body.and securewith the roller.
SEAT
u>o
VALVE EODY
VALVE BODY
VALVE
CAP
www.emanualpro.com
14-193
ValveGaps
Description
C a p s w i t h o n e p r o j e c t e dt i p a n d o n e f l a t e n d a r e
i n s t a l l e dw i t h t h e f l a t e n d t o w a r d t h e i n s i d eo f t h e
valvebody.
Capswith a projectedtip on each end are installed
w i t h t h e s m a l l e rt i p t o w a r d t h e i n s i d eo f t h e v a l v e
b o d y .T h es m a l lt i p i s a s p r i n gg u i d e .
TOWARDOUTSIDEOFVALVEAODY
TOWAROOUTSIDEOFVALVEBODY
EEEE
TOWARDINSIDEOF VALVEBODY
C a p sw i t h o n e p r o j e c t e dt i p a n d a h o l l o w e n d a r e
installedwith the tip toward the inside of the valve
body.The tip is a springguide.
Capswith one projectedtip and flat end are installed
with the tip toward the insideof the valve bodv. The
tip is a spring guide. The groove is a valve cao clio
g ui d e .
TOWARDI'{SIDEOF VALVEEOOY
14-194
www.emanualpro.com
TOWARDOUTSIOOFVAIVE BODY
TOWARDINSIDEOF VALVEBOOY
ATFPump
Inspection
1.
I n s t a l tl h e A T F p u m p g e a r sa n d A T F p u m p d r i v e n
g e a r s h a f t i n t h e m a i n v a l v e b o d y L u b r i c a t ea l l
p a r t sw i t h A T F , a n d i n s t a l lt h e A T F p u m p d r i v e n
gearwith its groovedand chamferedsidefacingup
2.
MAIN VAI-VEBOOY
fl
L /
ATF PUMP
DRIVEGEAR
ATF PUMP
DRIVENGEAR
Inspeclteeth{or wear and damage
I n s p e c tt e e t h f o r w e a r a n d d a m a g e ,
3.
ATF PUMP
ORIVENGEAR
www.emanualpro.com
14-195
I-2 SHIFTVALVE
VALVECAPCLIP
2ND ORIFICE
CONTROLVALVE
SPRINGSEAT
@
U K
BALLS,8
ACCUMULATOR
CHOKE
VAI-VE
FELIFVALVE
MAIN VALVEBOOY
Inspectfor wear, scratches,
and sconng.
sERVOCONInOL
:,/\^._.^,
14-196
www.emanualpro.com
CHECKBALL
i)L )
CHECKBALLS
lo
lST ACCUMULATOR
CHOKE
CHECKEALL
MAIN VALVEBODY
(Sectionalview)
SPRINGSPECIFICATIONS
U n i t :m m ( i n )
Standard {New)
No.
o
@
@
@
www.emanualpro.com
Springs
Reliefvalvespring
Modulatorvalvespring
CPBvalvespring
1-2shift valvespring
2nd orificecontrolvalvespring
Servo control valve sPring
Wire Dia.
1 . 1( 0 . 0 4 3 )
1.4(0.055)
0.9 (0.03s)
0.9 (0.035)
0.7 (0.028)
1.0t0.039)
o.D.
8.6 (0.339)
9.4 (0.370)
8 . 1( 0 . 3 1 9 )
7.6 (0.299)
6.6 (0.260)
8 . 1{ 0 . 3 1 9 )
FroeLength
3 7 . 1( 1 . 4 6 1 )
35.0(1.3781
41.2 \1.8581
4 1 . 3( 1 . 6 2 6 )
34.8(1.370)
5 2 . 1( 2 . 0 5 1 )
No. of Coils
'13.4
10.9
20.8
14-197
SecondaryValve Body
Disassembly/lnspection/Reassembly
NOTE:
' clean all partsthoroughlyin solventor carburetorcleaner.and dry them with compressed
air. Blow out aUpassages,
. Replacethe valvebody as an assemblyif any partsare worn or damaged.
t checkall valvesfor free movement.rf anyfair to sridefreery.seevarveBody Repair page
on
14-192.
. Coatall partswith ATFduring reassembly.
. The CPCvalveis installedin the secondaryvalve body,held in placeby the lock
bolt.
t*-1
VALVECAP
2.3 SHIFTVALVE
@,..t'tr.,
,rr'^'//u
"/
./
3-' SHIFTVALVE
ilTH EXHAUSTVALVE
SECONOARY
VALVEBODY
Inspectfor wear, scratches,and
scorang.
N"*,"o"*
3.4 ORIFICECONTROLVAL
VALVESLEEVE
ROLLER
SPRINGSPEC!FICATIONS
U n i t :m m ( i n )
No.
o
@
Standald {Nswl
Springs
3 4 shiftvalvespring
2-3shift valvespring
4th exhaustvalvespring
3-4 orificecontrolvalvespring
14-198
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Wire Dia.
o.D.
0.9 (0.035)
0.9 (0.035)
0.9{0.035)
0.6 {0.024}
7.6 (0.299)
7.6 (0.299)
6.1 (0.240t
6.6 (0.2601
FreeLength
57.Oi.2.2441
57.O12.244J
3 6 . 4( 1 . 4 3 3 )
37.9(1.492)
No. of Coils
26.A
26.8
19.5
31.6
RegulatorValve Body
Disassembly/lnspection/Reassembly
NOTE:
o Cleanall parts thoroughlyin solventor carburetorcleaner,and dry them with compressedair. Blow out all passages.
. Replacethe valvebody as an assemblyif any partsare worn or damaged.
. Checkallvalvesforfreemovement.lf anyfail toslidefreely,seeValveBody Repairon page l4-192.
'1. Holdthe regulatorspringcap in placewhile removingthe stop bolt. The regulatorspringcap is spring loaded Once
the stop bolt is removed,releasethe springcap slowly so it does not pop out.
is the reverseorderof disassembly.
Reassembly
2.
NOTE:
. Coatall partswith ATF during reassembly.
. Align the hole in the regulatorspringcap with the hole in the valve body,then pressthe spring cap into the valve
body,and tightenthe stop bolt.
SPSING
CAP
REGULATOR
STOPBOLT
6x1.0mm
12N.m11.2
8.? tbt.fil
REGULATOR
VALVEBODY
lnspectfor wear,scratches,
ano scoflng.
REGULATOR
VALVE
Standard {New}
No,
o
@
@
,6
a,
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Springs
wire Dia.
RegulatorvalvespringA
Regulatorvalvespring B
Statorreactionspring
Coolerreliefvalvespring
Torque convertercheckvalve spring
'97 Model
'98 - 00 Models
Lock-upcontrolvalvespring
o.D.
F ee Length
1 . 8( 0 . 0 7 1 )
1 . 8( 0 . 0 7 1 )
4 . 5( 0 . 1 7 7 )
1.0{0.039)
14.7(0.579)
9.6 (0.378)
35.4(1.394)
8 . 4{ 0 . 3 3 1 )
87.8(3.457)
44.0t1.7321
3 0 . 3( 1 . 1 9 3 )
3 3 . 8( 1 . 3 3 1 )
1.1(0.043)
1.2lO.O47l
0.7 t0.028)
8 . 4( 0 . 3 3 1 )
8 . 4( 0 . 3 3 1 )
6.6 (0.260)
36.4(1.433)
32.4 11.2761
38.0(1.496)
No. ot Coils
'11.0
1.9
't2.0
12.7
14.'l
14-199
ServoBody
Disassembly/lnspection/Reassembly
NOTE:
' cleanall partsthoroughly in solventor carburetorcleaner,and dry them with compressedair, Blow
out all passages.
. Replacethe valve body as an assemblyif any partsare worn or damaged.
. Coatall partswith ATF during reassembly.
ACCUMULATOR
COVER
3ROSUBACCUMULATOR
O-RING
Feplace.
1STACCUMULATOR
PISTON
@"-.t
SPR|NGRETATNER
-tP
l@
fi,
il
,/
3RDACCUMULATOR
\_)
SERVO
RVOVAL\VE/SHIFT
IRKSHAFT
FORK
S
O.RING
Replace.
SNAPRING
SNAPRING
SPRINGSPECIFICATIONS
U n i t :m m { i n )
No.
Standard lNewl
Springs
Wire Dia,
o
@
J6
@
.A
\o,
o
@
@
1staccumuiatorspring
4th accumulatorspringA
4th accumulatorspring B
3rd accumulatorspringA
3rd accumulatorspringB
2nd accumulatorspringC
2nd accumulatorspringA
2nd accumulatorspringB
3rd sub accumulatorspring
14-200
www.emanualpro.com
2.1 (0.083)
2.6 {0.102)
2 . 3( 0 . 0 9 1 )
2 . 8( 0 . 1 1 0 )
2.1 (0.083)
2.2 (0.087l2.4 (0.094)
r.6 (0.063)
2 . 7{ 0 . 1 0 6 )
o.D.
16.0(0.6301
17.0(0.669)
't0.2
t0.402]
17.5(0.689)
3 1 . 0( 1 . 2 2 0 )
1 4 . 5{ 0 . 5 7 1 )
29.0 11.1421
9.0 (0.354)
17.0(0.669)
FreeLongth
89.r (3.508)
88.4(3.480)
5 1 . 6( 2 . 0 3 1 )
94.3(3.713)
38.2(1.504)
68.0{2.677)
39.0fi.535)
20.7(0.815)
39.0(1.535)
No. of Coil3
14.2
13.8
15.9
2.6
13.9
2.9
o.l
6.3
Lock-upValve Body
bly
Disassembly/lnspection/Reassem
NOTE:
. Cleanall partsthoroughlyin solventor carburetorcleaner,and dry them with compressedair. Blow out all passages.
. Replacethe valvebody as an assemblyif any partsare worn or damaged.
. C h e c k a lvl a l v e s f o r f r e em o v e m e n tl .f a n y f a i l t os l i d ef r e e l y s, e e V a l v eB o d yR e p a i r o np a g e1 4 - 1 9 2 .
. Coatall partswith ATF duringreassembly.
LOCK.UPSHIFTVALVE
'\
\
,^
\-.xlO
@-tr
\"o...*
,As'.
LOCK-UPVALVEEODY
Inspectlor wear,scratches,
and scoring.
VALVECAP
LOCK-UPTIMINGVAL
\uo.*"or".,,
SPRINGSPECIFICATIONS
Unit:mm (in)
Standard lNewl
No.
O
(
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Springs
Lockup shiftvalvespring
Lock-uptiming valvespring
Wire Dia.
0.9(0.035)
0.9(0.035)
o.D.
7.6 (0.299)
8 . 1( 0 . 3 1 9 )
Fle Length
73.1 t2.902),
8 1 . 4( 3 . 2 0 5 )
No. of Coils
32.0
47.8
14-201
Mainshaft
Disassembly/lnspection/Reassembly
NOTE:
. Lubricateall partswith ATFduring reassembly.
.Inspectthethrustneedlebearingsandtheneedlebearingsforgallingandroughmovement,
. Beforeinstallingthe O-rings.wrap the shaftsplineswith tapeto preventdamagingthe O-rings.
. Locknuthas left-handthreads.
. Installthe conicalspringwasherin the directionshown.
. Inspectconditionof the sealingrings.lf the sealingrings are worn, distorted,ordamaged,replacethem (seepage 142041.
LOCKNUTIFLANGENUT)
19 x 1.25mm
78 N.m {8.O kgf.m,58 lbl.ftl
Replace.
Left-hand threads
CONICAL SPRINGWASHER
Replace.
lST CIUTCH
ASSEMBI.Y
SNAP RING
o-Rtt{Gs
THRUSTNEEDLE
BARING
THRUST
WASHEB
Replace.
THRUST WASHCR
4TH GEAR
THRUST NEEOI
BEARIl{G
I{EEDLEBEARIIIG
MAINSI{AFT
Check splinesfor excessive
wear ano damage.
Check bearingsurfacetor scoring,
scratchesand excessivewear.
BEARII{GS
rST GEAR
COLLAR
TXBUST 1{EEDLE
BEARIl{G
4TH GEAR COLLAR
2ND/4TH CLUTCX
o-Brr{Gs
THRUSTWASHER,36.5 r 55 mm
Selective part
THRUSTNEEDLE
SEARING
2NO GEAR
SEALINGRltrlG,
29 mm
NEEDLEEEARING
THRUST NEEDI-E
BEARING
Install the sealing ring
mating faces as shown
NEEDLEEEARING
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14-202
SET RING
lST GEAR
TnANSMtSSIOt{
HOUSII{GBEARII{G
Inspection
Clearance
Measurement
1.
2.
3.
CONICALSPRINGWASHER
2'{D GEAR
2[{D/4TH CLUTCH
ASSEMALY
THRUST WASHER
.5r55mm
Selective part
THBUST IIEEDLE
EEARII{G
2ND GAR
EEARIt{G
TI{RUST NEEOLE
BEARII{G
FEELERGAUGC
THRUSTWASHER.
36.5 x 55 mm
MAII{SHAFT
(cont'd)
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14-203
SealingRings
Mainshaft
Inspection(cont'dl
Replacement
I t t h e c l e a r a n c ei s o u t o f s t a n d a r d ,r e m o v e t h e
thrustwasherand measureits thickness.
Part Number
Thickness
9 0 4 4 1- P G 4 , 0 1 0
4 . 0 0m m ( 0 . 1 5 7
in)
90442-PG4-010
4 . 0 5m m ( 0 . 1 5 9
in)
90443-PG4-010
4 . 1 0m m { 0 . 1 6 1i n )
90444-PG4-010
4 . 1 5m m { 0 . 1 6 3i n )
90445-PG4-010
4 . 2 0m m ( 0 . ' 1 6i5n )
90446-PG4-010
4 . 2 5m m { 0 . 1 6 7i n )
90447-PG4-010
4 . 3 0m m ( 0 . 1 6 9i n )
90448-PG4-010
4 . 3 5m m ( 0 . 1 7 1i n )
90449-PG4-010
4 . 4 0m m ( 0 . 1 7 3i n )
10
90450-PG4-000
4 . 4 5m m ( 0 . 1 7 5i n l
SEALINGRING
Installthe sealingring
matingfacesas shown.
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14-204
Countershaft
Disassembly/lnspection/Reassembly
NOTE:
. Lubricateall pans with ATF beforereassembly.
.Inspectthethrustneedlebearingsandtheneedlebearingsforgallingandroughmovement.
. Beforeinstallingthe O-rings,wrap the shaftspllneswith tapeto preventdamagingthe O-rings.
. Locknuthas left-handthreads.
. Installthe conicalspringwasherin the directionshown.
RVERSEGEAR
LOCKNUTIFLANGENUTI
23 x 1.25mm
103-0-103N.m
t 1 0 . 5- 0 - 10.5 kgl.m,
7 5 . 9- 0 - 75.9 lbt.lr)
CONICAL SPRING
WASHER
Replace.
Replace.
Lelt.hand threads
NEEOLEBEARING
REVERSE
SELECTOR
REVERSE
SELECTOR
HUB
lST GEAR
COUNTERSHAFT
Check splinesfor excessive
wear and damage.
Check bearingsurfacefor scoring,
scratchesand excessivewear.
4TH GEAR
NEEDLEEEARING
I{EEDLEBEARING
OISTANCECOLLAR.
28 mm
Selective part
lST GEARCOLLAR
2NO GEAR
TRANSn SSTON
HOUSI G BEARING
3RD GEAR
NEEDLEBEARING
3RD GEARCOLLAR
THRUSTNEEOLEBEARING
SPLINEDWASHER
3RO CLUTCHASSMBLY
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14-205
Gountershaft
Disassembly/Reassembly
1.
2.
{ C o m m e r c i a l l ya v a i l a b l e )
4TH GEAR
BEARI'{G
DISTANCECOLLAR, 28 mm
Selectiveoart
REVERSE
SELECTOR
HUB
GEAR
THRUST ]{EEOLAEARIIIG
SEARII{G
.TH GEAR
GEAR COLLAR
THRUST I{EEDLEEEARII{G
WASHER
3RO CLUTCH ASSEMBLY
O-RINGS
Replace.
14-206
www.emanualpro.com
Inspection
3.
DRIVERto mm l.D.
07746- 0030100
ClearanceMeasurement
NOTE: Lubricateall partswith ATF duringassembly.
1.
2.
RVERSSELECTOR
HUB
GEAR
NEEDLEBEARING
REVERSE
SEI.ICTOR
HUB
DISTANCECOLLAR, 28 mm
Selective part
2NO GEAR
COUNTERSHAFT
SU&ASSEMBLY
THRUST NEEDLEBEARING
GEAR
NEEOLEBEARING
GEAR COLIAR
THRUSTNEEDLEBEARING
WASHER
CLUTCHASSEMBLY
(cont'd)
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14-207
Countershaft
Inspection(cont'd)
3.
I n s t a l lt h e c o u n t e r s h a fst u b - a s s e m b lpy a r t s ,t h e n
i n s t a l l t h ep a r kg e a ru s i n ga p r e s sa n da c o l l a r .
4.
5.
LOCKNUT
Le{t-hand
threads
2NO GEAR
OISTANCECOLLAR,
28 mm
CONICALSPRING
WASHER
PABKGEAR/ONE.WAY
CLUTCH/1STGEAR
ASSEMBLY
NEEDLEBEANING
lST GEARCOLLAR
TRANSMISSIONHOUSING
AEARING
REVERSE
GEAR
COLLAR
COUNTERSHAFT
SUB.ASSEMBLY
6.
FEELER
GAUGE
lf the clearanceis out ot standard,removethe distancecollar,and measureits width.
7.
DISTANCECOLLAR,28mm
No.
8.
14-208
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Part Number
widrh
90503-PCg-000
3 9 . 0 0m m ( ' 1 . 5 3i5n )
90504-PCg-000
3 9 . ' 1m
0 m ( 1 . 5 3 9i n )
90505-PCg-000
3 9 . 2 0m m { 1 . 5 4 3i n )
90507-PCg-000
3 9 . 3 0m m ( l . 5 4 7i n )
90508*PCg-000
3 9 . 0 5m m ( l . 5 3 7i n )
90509-PCg-000
3 9 . 1 5m m ( l . 5 4 1i n )
90510-PCg-000
3 9 . 2 5m m { 1 . 5 4 5i n )
90511-PCg-000
3 8 . 9 0m m { L 5 3 1i n )
90512-PCg-000
3 8 . 9 5m m ( 1 . 5 3 3i n )
One-way Glutch
Disassembly/lnspection/Reassem
bly
1.
3.
PARKGEAR
COUNTERSHAFT
lST GEAR
2.
ONE.WAYCLUTCH
Inspectfor damage
and taultymovement,
COUNTERSHAFT
IST GEAR
ONE.WAYCLUTCH
Installin this direction.
lST GEAR
Inspectfor wear
and scortng.
4.
ONE.WAYCLUTCH
lST GEAR
,ISTGEAR
COUNTERSHAFT
SCREWDRIVER
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14-209
Sub-shaft
Disassembly/lnspection/Reassembly
NOTE:
. Lubricateall partswith ATF beforereassembly.
. Inspectthe thrust needlebearingsand the needlebearingsfor gallingand rough movement.
. Beforeinstallingthe O-rings,wrap the shaftsplineswith tapeto preventdamagingthe O-rings.
TRAi{SMTSStONtl()UStNG
IST.HOLOCLUTCH
ASSEMBLY
6 x 1.0 mrr
12 1{.m
ll.2 ksl.m, 8.7 lbt.ftl
o,Rtl{GS
Replace.
TI{RUST WASI{ER
SUB.SHAFT
Check splines tor excessive
wear ano damage,
Check bearing surlace for scoring,
scralches and excessive wear-
THFUST TEEOLC
BEARI G
I{EEDLE BARI G
t{EEDLEBEARING
STOP
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14-210
Disassembly/Reassembly
1.
ATTACHMENT,
32x35mm
07746- 0010t00
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14-211
Sub-shaftBearings
Replacement
NOTE:Lubricateall partswith ATF beforereassembly.
1.
4.
E x p a n dt h e s n a p r i n g w i t h s n a p r i n g p l i e r s .t h e n
push the bearing out of the transmissionhousing
usingthe specialtools and a pressas shown.
c
I
32x35mm
077/46- qt10t(x,
ATTACHMENT,
ai:lx 68 mm
07746 - 00105q)
E x p a n dt h e s n a p r i n g w i t h s n a p r i n g p l i e r s ,t h e n
insert the ball bearing part-way into the housing
using the specialtools and a pressas describedin
step 1. Installthe bearingwith the groove facing
outsidethe housing.
Removethe needlebearingstop.
Removethe needlebearingfrom the transmission
housingusinga drift.
ENDGAP:0-7mm
l0 - 0.28 inl
SNAPRING
14-212
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Glutch
lllustratedlndex
3RDCLUTCH
CLUTCHPISTON
RETURNSPRING
NETAINER CLUTCHPLATES
Standardthicknoss:
RING
2.00 mm 10.079inl
CLUTCHDISCS
Standardthickne$:
1.94mm (0 0?6 inl
SNAPFING
lST CLUTCH
CLUTCHDISCS
Standardthicknca3:
inl
1.9amm 10.076
SNAPRING
CLUTCHDRUM
CHECKVALVE
(cont'd)
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14-213
Clutch
lllustratedIndex(cont'dl
2ND/4THCLUTCH
CLUTCHPLATES
Stendardthickness:
OISCSPRING 2.00
mm {0.079in)
[*
CLUTCH
2ND CLUTCH
CLUTCHPISTON
sPl
Repl6ce.
uoavEnr"
CLUTCHPLATES
Standardthicknesai
2.00 mm {0.079inl
SNAPRING
14-214
www.emanualpro.com
lST-HOLDCLUTCH
thickness:
RETURNSPRING
cLUTCHPISTON
O.RINGS
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14-215
Clutch
Disassembly
l.
3.
I n s t a ltlh e s p e c i atlo o l sa s s h o w n .
CLUTCHSPNING
COMPRESSOR
ATTACHMENT
07LAE- PX40100
SCREWORIVER
SNAP RING
-'=*.=:--
'..p
2.
Removethe discspring.
CLUTCHSPRING
COMPRESSOR
ATTACHMENT
07LAE- PX4010Oor
07HAE- PL50100
CLUTCHSPRING
COMPRESSOR
ATTACHMENT
07LAE- PX40t00
CLUTCHDBUM
3RDCLUTCH:
DISCSPRING
CLUTCHSPRING
COMPRESSOR
ATTACHMENT
07LAE- PX4010Oor
07HAE- PL50100
CLUTCHSPRING
COMPRESSOR
BOLTASSEMBLY
07GAE- PG0200 or
OTGAE- PG4O2OA
14-216
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5.
SPRIlIG RETAINER
4.
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Compressthe returnspring.
14-217
Glutch
Reassembly
NOTE:
. Clean all parts thoroughly in solvent or carburetor
cleaner,and dry them with compressedair.
. Blow out all passages.
o Lubricateall parts with ATF before reassembly.
1.
3.
CLUTCH DRUM
CHECK VALVE
2.
4.
SI{AP RING
SPAI'{G RETAIIIER
REIURN SPRING
CLUTCH DRUM
PtsTot{
14-218
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5.
CLUTCHSPRING
COMPRESSOR
ATTACHMENT
07LAE- PX40100
CLUTCHSPRING
COMPRESSOR
BOLTASSEMALY
07GAE- PG{0200or
OTGAE- PG|(IMA
Do notsethere.
TOOL
SPECIAL
CLUTCHSPRING
COMPRESSOR
ATTACHMENT
07LAE- PXaOI0o
CLUTCHSPRING
COMPBESSOR
AOL| ASSEMALY
07GAE- PG/9t200ot
OTGAE- PG/(,20A
Set here.
CLUTCHSPRING
COMPRESSOR
ATTACHMENT
07LAE- PX40100or
O?HAE- PL5O1OO
SPRINGRETAINER
6.
Compressthe returnspring.
CLUTCHSPRING
COMPRESSOR
ATTACHMENT
07LAE- PX4010O
ol
07HAE- PL50100
(cont'd)
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14-219
Clutch
(cont'd)
Reassembly
7.
Installthe
s n a pr i n g .
m u m o f 3 0 m i n u t e s . B e f o r ei n s t a l l i n gt h e p l a t e s
and discs,make sure the insideof the clutchdrum
is free of din or otherforeignmatter
' t 1 . Starting
CLUTCHEI{D PI.ATE
Installin this directior.
S AP RIIG
8.
Removethe specialtools.
9,
otsc sPfitl{c
CLUTCH
CLUTCHEI{D PLATE
SCREWDRIVER
3RD CLUTCH:
Dlsc sPRrrtc
CIUTCH ORUM
14-220
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2 2 5 5 1 P 5 6- N 0 0
22552-P56-N00
22553 - P56 N00
22554-P56-NOo
2 2 5 5 5 P 5 6- N 0 0
2 2 5 5 9- P 5 6 N 0 0
10
6
7
ServiceLimit
0.650.400.400.400.50-
0.033in)
0.024in)
0.024in)
0.024in)
0.031in)
Mark
Parl Number
Thickness
22558-P56-N00
10
22559-P56-N00
2 2 5 6 0- P 5 6 N 0 0
in)
2 . 9m m ( 0 . 1 1 4
3 . 0m m ( 0 . 1 1 8i n )
3 . 1m m ( 0 . 1 2 2i n l
000
000
000
000
3 . 2m m { 0 . 1 2i6n )
3 . 3m m ( 0 . 1 3i 0n )
3 . 4 m m ( 0 . 1 3 4i n )
2 2 5 6 5 P D M- 0 0 0
22566 PDM- 000
3 . 5m m ( 0 . 1 3i8n )
3 . 6m m 1 0 . 1 4i n2 )
22567-PDM-000
in)
3 . 7m m ( 0 . 1 4 6
3RDCLUTCHEND PLATES
Part Number
2 2 5 5 8 P 5 6- N 0 0
2 2 5 5 9 P 5 6- N 0 0
10
11
12
t3
- PDM 000
22562
'14
22564-PDN4-000
22565-PD[,l-000
22566 PDM- 000
- PoM- 000
22567
't1
2 . 9r n m ( 0 . 1 1 4i n )
3 . 0m m ( 0 . 1 1 8i n )
15
--l----T
2 . 7 m m ( 0 . 1 0 6i n )
2 . 8m m ( 0 . 1 1 0i n )
22556-P56-N00
22557 P56- N00
Mark
MARK
2 . 5 m m { 0 . 0 9 8i n )
2 6 m m ( 0 . 1 0 2i n )
17
2 3 m m ( 0 . 0 9 1i n )
2 . 4 m m ( 0 . 0 9 4i n )
2 . 6m m ( 0 . 1 0i2n )
2 . 7m m ( 0 . 1 0i6n )
2 . 8m m ( 0 . 1 1i0n )
12
13
2 . 1m m ( 0 . 0 8i3n )
in)
2.2mm (0.087
'11
SNAPRING
Thicknass
Mark
22563-PDM-000
Thiclness
2 . 8m m ( 0 . 1 1 0i n l
2 . 9m m ( 0 . 1 1 4i n )
3 . 0m m ( 0 . 1 1i 8n )
3 . 1m m ( 0 . 1 2i2n )
in)
3.2mm (0.126
3 . 3m m ( 0 . 1 3i0n )
3 . 4m m ( 0 . 1 3 4i n )
3 . 5 m m ( 0 . 1 3 8i n )
3 . 6m m ( 0 . 1 4 2i n )
3 . 7m m { 0 . 1 4 6i n )
lST-HOLDCLUTCHEND PLATES
Thickness
2255r-PS5-003
2 . 1 m m ( 0 . 0 8 3i n )
2 2 5 5 2- P S 5 - 0 0 3
2 . 2 m m { 0 . 0 8 7i n )
in)
2.3mm (0.091
2 . 4 m m ( 0 . 0 9 4i n )
2 . 5 m m ( 0 . 0 9 8i n )
2 2 5 5 4 , P S 5- 0 0 3
2 2 5 5 5 P S 5- 0 0 3
2 2 5 5 6 P S 5- 0 0 3
rnictness
2 . 6m m { 0 . 1 0 2i n )
2 . 7m m ( 0 . 1 0 6i n )
CLUTCHEND PLATE
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14-221
Differential
lllustratedIndex
'lWD:
2WDl
SETRING,80 mm
part
Selective
SETnlNG,80 mm
Sel6ctive part
10x 1.0mm
103N.m (10.5kgt.m,
?5.9 tbtftl
FINALORIVENGEAR
lnspectfor excessivewear,
Installin this direction.
A
,U
1 0x 1 . 0m m
103N.m {10.5kg[.m,
75.9 tbt.ftl
Left-handthreads
,gBc
FINALORIVENGEAR
Inspectfor excessivewear,
Installin thls direction.
BALLBEABING
Inspectfor rough
BALLBEARING
Inspectfor rough
DIFFERENTIAI.
CARRIER
Inspectfor cracks.
DIFFERENTIAI.
CARRIER
lnspectfor cracks.
TRANSFERSHAET
DNlvE GEAR
Inspectfor excessive
ROLLER,5
x 10 mm
SPEEDOMETER
DRIVEGEAR
Installin this
direction.
SPEEDOMETER
DRIVEGEAR
Installin this
direction.
SNAPRING
Installin this
direction.
BALLBEARING
SNAPRING
Installin this
direction.
BALLBEARING
Inspectfor rough movement,
14 -2 2 2
www.emanualpro.com
BacklashInspection
1.
BearingReplacement
1.
ASSEMBLY
OIFFEBENNAL
l n s t a l l n e w b e a r i n g s u s i n g t h e s P e c i a lt o o l
snown.
PRESS
www.emanualpro.com
14-223
Differential
DifferentialCarrierReplacement
NOTE:The illustrationshows the 4WD automatictransmissiondifferential;
the 2WDdifferentialis similar.
1.
Installthe final drivengearon a new differentialcarrier with its chamferedside facing the carrier and
the transferdrive gear (4WD),
FINALDRIVENGEAR
TRANSFERSHAFT
RoI I FP
5 x 15 mm (/tWD)
{4WDl
5 x 10mm {2WDl
Installthe speedometerdrive gear with its chamfered side facingthe carrier.Align the cutout on the
bore of the speedometerdrive gear with the 5 x 15
mm roller(4WD)or 5 x 10 mm roller(2WD).
7.
A l i g n t h e h o o k e de n d o f t h e s n a p r i n g w i t h t h e
spring pin in the pinion shaft.then installthe snao
ring in the differentialcarriergroove
SNAP RING
Installin this direction.
Hookedend
PINIONSHAFT
14-224
www.emanualpro.com
SPRINGPIN
GROOVE
Oil SealReplacement
1.
3.
DRIVER
077a9- 0010000
OIL SEAL
Replace.
ATTACHMEMT
079r?- slx[ax)
R e m o v et h e o i l s e a l f r o m t h e t o r q u e c o n v e r t e r
housing.
4.
-.].
OIL SEAL
Replace.
www.emanualpro.com
TOROUECONVERTER
HOUSING
14-225
Differential
Side ClearanceInspection
1.
4.
FEEI..ER
GAUGE
lf the clearanceis out of standard,removerne set
ring and measurs its thickness.
7.
Installthe transmissionhousingon the torque converter housing,and tighten the transmissionhousing mountingbolts (seepages14-252and t4-253).
90414-689-000
90415-689-000
90416-689-000
90417-689-000
90418-689-000
90419-PH8-000
Thicknoss
2.50mm (0.098in)
2.60mm (0.102in)
2.70mm (0.106inl
2 . 8 0m m ( 0 . 1 1 0
in)
2 . 9 0m m ( 0 . 1 1 4i n )
3.00mm (0.t'18inl
14-226
www.emanualpro.com
HousingBearings
Transmission
Mainshaft/CountershaftBearingsReplacement
1.
R e l e a s et h e p l i e r s ,t h e n p u s h t h e b e a r i n g sd o w n
i n t o t h e h o u s i n gu n t i l t h e r i n g s s n a p i n p l a c e
a r o u n dt h e m .
077/49- 0010000
ATTACHMENT
. Mainshaft BearingInstallation:
x 75 mm
ATTACHMENT,72
07746- 0010600
. CountershaftBearing Instsllation:
ATTACHMENT,52 x 68 mm
077'16- 0010500
MAINSHAFTBEARING
DFIVER
077a9- 001(xx)o
ATTACHMENT
4.
ENDGAP:0-7rnm
l0 - 0.28in)
ATTACHMENT
. Mainshaft Bearing Romoval:
ATTACHMENT,72 x 75 mm
077/16- 0010600
. CountqrshaftBearing Removal:
ATTACHMENT,62 x 68 mm
07746- 0010500
www.emanualpro.com
SNAPRING
14-227
TransmissionHousingBearings
Sub-shaftBearingReplacement
1.
E x p a n dt h e s n a p r i n g w i t h s n a p r i n g p l i e r s ,t h e n
coat the new bearingwith ATF and insert it partway into the housingusing the specialtools and a
pressas shown. lnstallthe bearingwith the groove
facingoutsidethe housing.
DRIVER
07743- 0010mo
ATTACHMENT,
{i:l x 68 mm
07746- 0010500
GROOVE
SNAP RI]TG
.
.
.
DRIVER
07749- tDl(xx)o
ENDGAP:0-7mm
ATTACHMENT,
6:l x 68 mm
077a6- (X,r0500
SNAPRING
14-228
www.emanualpro.com
TorqueGonverterHousingBearings
MainshaftBearing/OilSeal Replacement
1.
R e m o v et h e m a i n s h a f b
t e a r i n ga n d o i l s e a l u s i n g
the soecialtool.
3.
07749- 0010000
SLIDEHAMMER,
3/8" - 16
(Commercially
available)
ATTACHMENT,
ADJUSTABLEEEARING
- 40 mm
PULLER,25
07736- A010008or
07736- A01000A
07?46- 0010m0
ATTACHMENT,
62x68mm
07746- 0010500
www.emanualpro.com
14-229
TorqueGonverterHousing
Bearings
GontrolLeverAssembly
CountershaftBearingReplacement
Replacement
1.
SLIOEHAMMER,
3la" -16
(Commercially
available)
ADJUSTABLE
BEARING
- 40mm
PULLER,25
07736- A0100OB
ol
07736- A01m0A
1.
2.
3.
4.
COUNTERSHAFT
BEARING
DRIVER
077i19- 001m00
LOCKWASHER
Replace.
ATF GUIDEPLATE
14-230
www.emanualpro.com
ParkStop
Reverseldler Gear
ustment
Inspection/Adi
lnstallation
1.
',.A\
Measuring
\t/
PARKSTOP
PARKPAWLSHAFT
PARKSTOP
Mark
1
Part Number
Lt
L2
2 4 5 3 7 - P A g - 0 0 3 1 1 . 0 0m m
(0.433in)
11.00
mm
(0.433in)
2 4 5 3 8 - P A g - 0 0 3 1 0 . 8 0m m
(0.425in)
10.65mm
(0.419
in)
2 4 5 3 9 - P A g - 0 0 3 1 0 . 6 0m m
(0.417
in)
1 0 . 3m
0m
(0.406
in)
After replacingthe park stop. make sure the distanceis within standard.
www.emanualpro.com
14-231
TransferAssembly
lllustrated Index
www.emanualpro.com
O TRANSFERHOUSING
O o-RINGReplace.
O TRANSFERHOUSINGROLLERBEARING
@ TRANSFERSHAFT
O TAPEREDROLLERBEARINGOUTERRACE
@ TAPEREDROLLERBEARING
O TRANSFERSHAFTCOLLAR
@ THRUSTSHIM,25 mm Selectivepart
) TRANSFERDRtvE GEAR(HYPoIDGEAR}
@ coNtcAL SPRtNGWASHERReptace,
SHAFTLOCKNUT,22x 1.25mm Left-handrhreads,replace.
@ TRANSFER
(D TAPEREDROLLEREEARING
@ TAPEREDROLLEREEARINGOUTERRACE
(} THRUSTSHIM,68 mm Selectivepart
@ O-RINGReplace.
coVER A
@ TRANSFER
(} TRANSFERCOVERB
@ o-RINGReplace.
(9 TRANSFERDRIVENGEARSHAFT(HYPOIDGEAR)
@ THRUSTSHIM,35 mm Selectivepart
@ TAPEREDROLLERBEARING
SPACERReptace.
@ TRANSFER
OUTERRACE
@ TAPEREDRoLLERBEARTNG
@ TAPEREDROLLERBEARINGOUTERRACE
@ TAPEREDBOLLERBEARTNG
@ olL SEALReplace.
FLANGE
@ COMPANION
@ o-RINGReplace.
@ BACK-UPRING
@ coNtcAL SPRtNGWASHERReptace.
DRIVENGEARSHAFTLOCKNUT,22x 1.25mm Replace.
@ TRANSFER
TOROUESPECIFICATIONS
Boh/Nut No.
www.emanualpro.com
Torque Value
Size
6A
8C
22L
1 2 N ' m ( 1 . 2k g f . m , 8 . 7l b f . f t )
24 N.m (2.4kgf.m,17 lbnft)
1 1 8N . m( 1 2 . 0k g i m , 8 7 I b i f t )
6x1.0mm
8 x 1 . 2 5m m
22 x 'l.25mm
22H
2 2 x 1 . 2 5m m
Remarks
Transfershaft locknut:
Left handthreads
Transferdriven gear shaft locknut
Tighteningtorque:dependingon
Total StartingTorquevalue
14-233
TransferAssembly
Inspection
N O T E : T o p r e v e n td a m a g et o t h e t r a n s f e rh o u s i n g ,
always use soft jaws or equivalentmaterialsbetween
the transferhousingand the vise.
1 . S e t a d i a l i n d i c a t o ro n t h e c o m p a n i o nf l a n g e a s
snown.
2.
TRANSFERDRIVEGAR
6.
7.
8.
COMPANIONFLANGE
4.
M e a s u r et h e s t a r t i n gt o r q u e ( c o m p a n i o nf l a n g e
side)usinga torquewrenchas shown,
STANDARD:
2.68- 3.,17N.m
(27.3- 35.,1kgf.cm,23.7- 30.7 lbf.inl
TRANSFER
SHAFT
14-234
www.emanualpro.com
Disassembly
1.
P u t a 1 4 m m A l l e nw r e n c hi n t h e g e a r s i d e o f t h e
transfer shaft, then secure the Allen wrench in a
benchvise.
1a mm ALLENWRENCH
5.
2.
LOCKTAB
THRUSTSHIM,
25 mrn
Selectivepart
CONICALSPRING
WASHER
Replace.
(cont'd)
www.emanualpro.com
14-235
TransferAssembly
Disassembly(cont'd)
Securethe transfer housing in a bench vise with
soft iaws. To preventdamageto the transferhousing, always use soft jaws or equivalentmaterials
betweenthe transferhousingand the vise.
7.
I n s t a l lt h e s p e c i a lt o o l o n t h e c o m p a n i o nf l a n g e ,
then loosenthe transferdrivengearshaft locknut.
TRANSFER
DRIVEN
GEAR
SHAFT
COMPANION
FLANGE
HOI.DER
07RAB- TB4lll0A or
OTRAB- TB&TOB
HOLDER
HAITDI..E
07JAB_ (x)1020a
Removethe transferdrivengear shaft locknut,conical spring washer, back-upring, O-ring.and companionflange.
OILSEAL
Feplace-
O.RING
Replace.
TAPEREOROLLER
BEARING
BACK-UP
RING
CONICAL
SPRINGWASHEN
Replace.
TRANSFERHOUSING
GEARSHAFTLOCKNUT
Replace.
14-236
www.emanualpro.com
TransferDriveGearBearing
Replacement
TransferDrivenGearShaft
BearingReplacement
1.
1.
BANf{GSEPARATO
0 - 1112'
(Comm6rcially
availablel
(Commercially
available)
Installthe new taperedroller bearingin the transfer
drivegear usingthe specialtoolsand a press.
2.
3,
ATTACHMENT,
l()x50mm
07LAD- PWSo6o1
n
GEAR
www.emanualpro.com
DRIVERiO mm l.D.
0t7a5 - 00:I)100
ru
ATTACHMENT.
35 mm l.D.
0t715 - 0030400
14-237
TransferAssembly
TransferHousingRollerBearing
Replacement
TransferCoverA BearingOuter
1.
1.
RaceReplacement
Removethe taperedroller bearingouter racefrom
t r a n s f e rc o v e r A b y h e a t i n gt h e c o v e r t o a l m o s t
212"F llOO"Clusing a heat gun. Do not heat the
coverover 212"F(100"C).
ATTACHMENT,
62x68mm
07746- 0010500
TRANSFERHOUSING
14-238
www.emanualpro.com
TransferHousingBearingOuterRaceReplacement
NOTE: Coat all parts with ATF during reassembly.
1.
ATTACHMENT,
62x68mm
077a5- @105dt
ATTACHI'E'{T,
{i:l x 6t mm
07746 - rDl05rr0
ATTACHMENT,
52x55mm
07t46 - dtroa{x,
TRANSFERHOUSING
DRIVER
077$ - 0010(ro0
www.emanualpro.com
14-239
TransferAssembly
Reassembly
NOTE:
. While reassembling
the transferassembly:
. Checkand adjustthe transfergeartooth contact.
. Measureand adjustthe transfergear backlash.
. Checkand adjustthe taperedroller bearingstaning torque.
. Coatall pans with ATFduring reassembly.
. R e p l a c et h e t a p e r e dr o l l e rb e a r i n ga n d t h e b e a r i n g
outer raceas a set if eitherpart is replaced.
. Replacethe transferdrive gear and the transferdriven gearshaftas a set if eitherpart is replaced.
EXAMPLE:
C: EXISTING35 mm
THRUSTSHIM
Thickness:
C=1.05mm
X: REPLACEMENT
35 mm
THRUSTSHIM
Thickness:X=??mm
Number: A=+2
Numbe.: B=-'l
Outline of Assembly
1 . Selectthe 35 mm thrusi shim.
Psrtorm this procedute if the transter driven gar
shaft or the tapered roller bearing on the transfer
driven gear shaft is replaced.
2.
5.
6.
F o R M U L A :-+* - + c = x
A: Numberon the existingtransferdrivengear shaft
B; Numberon the replacementtransferdriven gear
shaft
C: Thicknessofthe existing35 mm thrustshim
X : T h i c k n e s sn e e d e df o r t h e r e p l a c e m e n3t 5 m m
t h r u s ts h i m
N O T E : T h e n u m b e r o n t h e t r a n s f e rd r i v e n o e a r
shaftis shown in 'll100mm.
14-240
www.emanualpro.com
Ar EXISTINGTRANSFER
DRIVENGEARSHAFT
B: REPLACEMENT
TRANSFER
DRIVENGEARSHAFT
c
D
F
H
Part Number
0.75 mm {0.030in}
0.78 mm (0.03'1in)
0.81 mm (0.032in)
0.84mm (0.033an)
0.87 mm (0.034in)
4 1 3 6 7 - P S 3 - 0 0 0 0.90 mm (0.035in)
4 1 3 6 8 - P S 3 - 0 0 0 0.93 mm (0.037in)
41366-PS3-000
41369-PS3-000
41370-PS3-000
4 r371- PS3- 000
41372-PS3-000
41373-PS3-000
41374-PS3-000
Thickness
0 . 7 2m m ( 0 . 0 2i8n )
0.96mm 10.038
in)
0.99 mm (0.039in)
1 . 0 2m m ( 0 . 0 4 0i n
1 . 0 5m m ( 0 . 0 4 1i n
1.08mm (0.043in
'1.11
m m 1 0 . 0 4 i4n
5.
TRANSFER
DRIVER{0 mm LD.
- 0030100
077146
TRANSFER
DRTVEN
GEARSHAFT
6.
Installthe companionflange,conicalspringwasher,
and locknut on the transfer driven gear shaft. Do
not install the O-ring and the back-upring on the
transfergear shaftin this step.
TRANSFERHOUSING
I n s t a l lt h e n e w o i l s e a l o n t h e t r a n s f e r h o u s i n g
usingthe specialtools.
OIL SEALDRIVER
ATTACHMENT
07JAD- PH80101
COMPANION
FLANGE
{cont'd)
www.emanualpro.com
14-241
TransferAssembly
(cont'd)
Reassembly
7.
9.
I n s t a l lt h e t r a n s f e rs h a f t i n t h e t r a n s f e rh o u s i n g ,
then installthe taperedrollerbearing,transfershaft
collar.25mm thrust shim, transferdrive gear,conical springwasher,and locknuton the transfershaft.
NOTE:
. Coat the threads of the locknut. and the shaft
with ATF beforeinstallingthe locknut.
. Do not stakethe locknutin this step.
NOTE:
Coat the threads of the locknut, and the shaft
with ATF beforeinstallingthe locknut.
Do not stakethe locknutin this step.
STARTINGTOROUE:
0.98- 1.39N.m
{10.0- 14.2kgrf.cm,8.68- 12.3lbf'inl
TRANSFER
COMPANION
FLANGE
HOLDER
THRUSTSXIM,
25 mm
Selectivepan
TRANSFERDRIVE
GEAR
CONICALSPRING
WASHER
Replace.
07JAB- @1020A
14-242
www.emanualpro.com
1 1 . Tightenthe transfershaftlocknut.
NOTE:
. The transfershaftlocknuthas left-handthreads.
. Do not stakethe locknutin this step.
FLANGE
COMPANION
1 5 . l f t h e m e a s u r e m e n ti s n o t w i t h i n t h e s t a n d a r d .
removethe transfershaft locknutand replacethe 25
m m t h r u s t s h i m . S e l e c ta n d i n s t a l la n e w 2 5 m m
thrust shim. then recheckthe measurement.
Do not
use more than two 25 mm thrust shims to adiust
the transfergear backlash.
THRUSTSHIM,25 mm
Shim No.
2
4
6
7
11
14
tt
g 9-r'r.ru-g
2.00 mm (0.079in)
2 9 4 2 2 - P 1 C - 0 0 0 2.03mm 10.080
in)
2 9 4 2 3 - P ' 1 C - 0 0 0 2.06 mm (0.081in)
29424-P1C-000 2.09mm 10.082
in)
2 9 4 2 5 - P 1 C - 0 0 0 2 . 1 2m m ( 0 . 0 8 i3n )
2.'15mm (0.085in)
16
29426-P1C-000
17
18
29427- P1C-O00
2 . 1 8m m ( 0 . 0 8 6i n )
29428-PlC-000
2.21 mm (0.087in)
2 9 4 2 9 - P 1 C - 0 0 0 2.24mm {0.088in)
19
el
1.88mm (0.074in)
10
TRANSFERCOVERA
/Fr
E
29417-PlC-000
2 9 4 1 8 - P 1 C - 0 0 0 1 . 9 1m m { 0 . 0 7 5i n )
2 9 4 1 9 - P 1 C - 0 0 0 1.94mm (0.076in)
2 9 4 2 0 - P t C - 0 0 0 1 . 9 7m m ( 0 . 0 7 i8n )
Part Numbor
Thickness
2 9 4 1 1 - P 1 C - 0 0 0 1.70mm (0.067in)
2 9 4 1 2 - P 1 C - 0 0 0 1.73mm (0.068in)
2 9 4 1 3 - P 1 C - 0 0 0 1.76mm (0.069in)
2 9 4 1 4 - P 1 C - 0 0 0 1.79mm (0.070in)
2 9 4 1 5 - P l C - 0 0 0 1.82mm (0.072in)
2 9 4 1 6 - P 1 C - 0 0 0 1.85mm (0.073ini
N.m 12.4
24 N.m
24
12.4|kgt.m, 17 lbf.ftl
(cont'd)
www.emanualpro.com
14-243
TransferAssembly
(cont'dl
Reassembly
16. Apply PrussianBlue to both sides of the transfer
gearteethlightlyand evenly.
CORRECT
TOOTHCONTACT
PATTERN
NCONRECTTOOTH CONTACTPATTERN
TOE CONTACT
HEELCONTACT
FLANKCONTACT
FACECONTACT
14-244
www.emanualpro.com
Toe Contact
U s e a t h i c k e r3 5 m m t h r u s t s h i m t o m o v e t h e
transferdriven gear shaft toward the transferdrive
gear. Becausethis movement causesthe transfer
gear backlashto change,move the transferdrive
gear away from the transferdriven gear shaft to
adjustthe transfergear backlashas follows:
. I n c r e a s et h e t h i c k n e s so f t h e 2 5 m m t h r u s t
shrm.
. R e d u c et h e t h i c k n e s so f t h e 6 8 m m t h r u s t
shim by the amount of increasedthicknessof
the 25 mm thrustshim.
Heel Contact
U s e a t h i n n e r3 5 m m t h r u s t s h i m t o m o v e t h e
transfer driven gear shaft away from the transfer
d r i v e g e a r .B e c a u s et h j s m o v e m e n tc a u s e st h e
transfer gear backlashto change,move the transfer drive gear toward the transferdriven gear shaft
to adjustthe transfergearbacklash
asfollows:
. R e d u c et h e t h i c k n e s so f t h e 2 5 m m t h r u s t
shim.
. I n c r e a s et h e t h i c k n e s so f t h e 6 8 m m t h r u s t
shim by the amount of reducedthicknessof
t h e 2 5 m m t h r u s ts h i m .
Flank Contaqt
Use a thinner thrust shim to move the transfer
drive gear toward the transferdriven gear shaft.
Flankcontactmust be adjustedwithin the limits
o f t h e t r a n s f e rg e a r b a c k l a s h l. f t h e b a c k l a s h
e x c e e d st h e l i m i t s ,a d j u s t a s d e s c r i b e du n d e r
Heel Contact.
FaceContaqt
Use a thickerthrust shim to move the transfer
drive gear away from the transfer driven gear
shaft. Facecontactmust be adjustedwithin the
limits of the transfergear backlash.lf the backl a s h e x c e e d st h e l i m i t s , a d j u s t a s d e s c r i b e d
underToe Contact.
TRANSFERHOUSING
TAPEFEDROLLER
BEARNG
TFANSFERSPACER
lnstallin this direction.
Replace.
TRANSFER
COLLAR
THRUSTSHIM,25 mm
Selectivepan
TRANSFERDRIVE
GEAR
CONICALSPRING
WASHER
Replace.
Replace.
COMPANION
FLANGE
HOLDER
07RAB- TB,010Aol
07RAB- TB,010B
TRANSFERHOUSING
O.RING
Replace.
CONICALSPRING
WASHER
Replace.
BACK.UPRING
LOCKNUT
Replace.
(cont'd)
www.emanualpro.com
14-245
TransferAssembly
(cont'd)
Reassembly
Secure the transfer housing in a bench vise with
soft jaws. To preventdamage,alwaysuse soft jaws
or equivalentmaterialsbetweenthe transferhousing and the vise.
27. I n s t a l lt h e s p e c i a lt o o l o n t h e c o m p a n i o nf l a n g e ,
then tighten the transferdriven gear shaft locknut
while measuringthe startingtorque of the transfer
drivengearshaft.
STARTINGTOROUE:
0.s8- 1.39N.m
{10.0- 14.2kgf.cm,8.68- 12.3lbf.in)
TIGHTENINGTOROUE:
132- 216 N.m
{13.5- 22.0 kgf.m, 98 - 159 lbf.ft)
NOTE;
. Rotatethe companion flange several times to
seatthe taperedrollerbearing,then measurethe
startingtorque,
. l f t h e s t a r t i n gt o r q u e e x c e e d s1 . 3 9 N . m ( 1 4 , 2
kgf.cm, 12.3 lbf.in), replacethe transfer spacer
a n d r e a s s e m b l et h e p a r t s . D o n o t a d j u s t t h e
torquewith the locknutloose.
. lf the tightening torque exceeds216 N.m (22.0
kgf.m,159 lbf'ft),replacethe transferspacerand
reassemble
the parts.
. W r i t e d o w n t h e m e a s u r e m e no
t f the starting
torque: it is used to measurethe total starting
rorque.
0.7- 1.2mm
{0.03- 0.05 inl
PUNCH
3.0- 3.5 mm
1 0 . 1-2 0 . 1 {i n l
.,.,.,\
t)
--/./
Point to be
staked.
COi'PANIOI{FLANGE
HOLDER
07MB - TBi(tloA ot
O'RAB - TB,.|}IOB
TRANSFERHOUSII{G
THRUSTSHIM.25 mrt|
Selectivepart
TOFOUE
WRENCH
HOLDERHANDLE
07JAB- 001020A
CONICALSPRING
WASHER
Replace.
Replace.
14-246
www.emanualpro.com
HOUSING
TMNSFER COVERA
v
E-
8x1.25mm
r? bt'ftl
24 N'm {2.i1kgt'm,
14 mm ALI-ENWRENGH
5J.
al
0.7- 1.2.nm
{0.0:1-0.C5in}
PU CH
3.0 - 3.5 rnm
TOTALSTARTINGTOROUE:
1.70- 2.08N.m {17.3- 21.2kgl.cm,15.0- 18.i1lbf.in}
+ Transler Driven Gear Sh8ft Starting Torque Value
lwroto down in step 27).
(cont'd)
www.emanualpro.com
14-247
TransferAssembly
Reassembly(cont'dl
35. RemovetaansfercoverA.
ZY
zz
c
23942-PWs-000
23943- PWs 000
23944-PW5-000
F
G
23948-PW5-000
23949 PW5 000
J
K
L
1.92mm (0.076in
1.95mm (0.077in
23957-PW5-000
23958,PWs 000
23959-PW5-000
23960 PW5- 000
2396'1 PW5- 000
AC
AD
M
BZ
cz
DZ
EZ
14-248
1.74mm (0.069ini
1.77mm (0.070ini
1 . 8 0m m ( 0 . 0 7 i1n ,
AB
1.65mm {0.065in}
1.68mm (0.066in)
1.71mm (0.067in)
1.86mm (0.073in
1.89mm (0.074in
T
U
1.53mm 10.060
in)
'1.56mm
{0.061in)
1.59mm 10.063
in)
1.62mm (0.064in)
1.50mm (0.059in)
2 3 9 5 0 - P W s - 0 0 0 1.83mm {0.072ini
www.emanualpro.com
Thickness
2 3 9 7 4 - P 1 C - O 2 0 1.41mm (0.056in)
2 3 9 7 5 - P 1 C - O 2 0 1.44mm (0.057in)
'1.47mm (0.058in)
23976-P1C-020
HEATGUN
Part Number
zv
zw
zx
1.98mm (0.078in
2.01mm (0.079in
2.04mm (0.080in
2.07mm (0.081in
2.10mm (0.083in
2 . 1 3m m ( 0 . 0 8 i4n
2 . 1 6m m ( 0 . 0 8 i5n
2 . 1 9m m ( 0 . 0 8 i6n
2.22mm (0.087in
2.25mm (0.089in
2.28mm (0.090in
2.31mm (0.091in
2.34mm (0.092in
2.37mm (0.093in)
2 3 9 6 9 - P W s - 0 0 0 2.40mm (0.094in)
23970-PW5-000
2.43mm (0.096in)
23941 PW8 000
2.46mm (0.097in)
23968-PWs-000
23942-PW8-000
23943- PW8 000
23944 PW8- 000
23945-PW8-000
2.49mm (0.098in)
2.52mm (0.099in)
2 . 5 5m m ( 0 . 1 0 i0n )
2 . 5 8m m ( 0 . 1 0 i2n )
3 8 . I n s t a l lt h e 6 8 m m t h r u s t s h i m u s i n g t h e s p e c i a l
tools.
PRESS
DRIVER
07743- 0010000
6x1.0mm
12 N.m 11.2kgt.D,
8.7 rbf.ftl
TRANSFENCOVERB
Replace.
O.RING
AEARINGOUTERRACE
Replace.
ATTACHMENT,
62x68mrr|
077a6- (x)10500
www.emanualpro.com
8 r 1.25rnm
24 N.m 12.4kgl.m, 17 lbf'ftl
Transmission
Reassembly
NOTE:
. The illustrationshowsthe 4WDautomatictransmission;the 2WDis similar.
. Cleanall partswith ATF.
. Replacethe followingparts:
- O-rings
- Lockwashers
- Gaskets
- Sealingwashers
- Locknutsand conicalspringwashersof eachshaft
SERVO
DETENT
6x1.0mm
ATF FEEDPIPE
ATF LUBRICATION
PLATE
DOWELPIN
2 Bolts
'99 - 00 models: 1 Bolts
LOCK.UPVALVE
BODY
ATF
STRAINER
ATF FEEOPIPE
LOCK.UPSEPARATOR
PLATE
40 mm
'-\t
REGULATOR
VALVE
BODY
DOWELPIN
coNrRoL
SHAFT
VALVESPRING
COOLERBELIEFVALVE
TOROUECONVERTER
CHECKVALVE
6x1,0mm
'97 - 98 models:
'112mmll,
6x1.0mm
18olts
DETENT
ARM
SHAFT
r l T
7 Bolts
'99- 00 models:8Bolts
SERVOBODY
('97- 98 models)
STATORSHAFT
O.RING
STOPSHAFT
CHECKBALLS18'
SERVO
SEPARATOR
PLATE
6x1.0mm
3 Bolts
ATF FEEDPIPE
1 1 2m m
STOPSHAFT
BRACKET
6x1.0mm
5 Eolts
105.8
SECONDARY
VALVEBODY
/,,!.,::
MAIN VALVEEOOY
(./
,/
afF FEEO
ptpEs
ATF PUMPDRIVEN
d---.-
OOWELPIN
8x40mm
SECONDARY
SEPARATOR
PLATE
--.CONTROLI.EVERMOUNTINGBOLT
6x1.0ftm
14 N.m (1.4 kgt.m, 10 tbf.ft)
(4WD)
SERVO
BODY
('99- 00models)
EP,--!ir{+*a\
x*hi
ATF PUMP
DRIVEGEAR
DOWELPIN
14-250
www.emanualpro.com
fpffi4i
MAIN SEPARATOR
PLATE
_ \zl
TOBOUE
HOUSING
ATF PUi'P
ORIVENGEAR
Grooved and chamtered
side faces separator
plate.
MAIN SPAR/ATOR
PLATE
5.
o.
7.
ATF PUMP
DRIVEGEAR
ATF
DBIVENGEAR
GEAR
SHAFT
DETENTARM
SHAFT
CONTROL
SHAFT
OETENTARM
OETENTARM SPRING
MANUAL VAIVE
www.emanualpro.com
14-251
Transmission
(cont'd)
Reassembly
TRANSMISSION
HOUSINGMOUNNNG BOLT
10 x L25
4,1N.m {/
4WD: 19
2WD: 18
TRANSMISSIONHANGER
f,
6xl.0mm
12 N.m (1.2 kgl.m,
8.7rbt.ft)
llf,
g
il /
MAINSHAFTSPEED
SENSOB
COUNTERSHAFT
BEVERSEGEAB
LOCKWASHER
MAINSHAFT
SUB.ASSEMBLY
REVERSE
SHIFT
FORK
DOWELPIN
14x 20 rnm
NEEDLEBEARING
REVERSE
SELECTOR
OOWELPIN
14x25mm
TRANSMISSIONHOUSING
GASKET
DOWELPIN
14x25mm
COUNTERSHAFT
SUB.ASSEMBLY
DIFFERENTIAL
ASSEMBLY
TRANSFESASSEMBLY
(4wDl
14-252
www.emanualpro.com
COUNTERSHAFT
SUB-ASSEMBLY
TRANSMISSION
HOUSING
25. Placethe transmissionhousingon the torque conv e r t e r h o u s i n gw i t h a n e w g a s k e ta n d t h e t h r e e
dowel pins,
Make sure that the mainshaftspeed sensor is not
i n s t a l l e do n t h e t r a n s m i s s i o nh o u s i n g b e f o r e
h o u s i n go n t h e t o r q u e
i n s t a l l i n gt h e t r a n s m i s s i o n
converterhousing.
2 6 . I n s t a l lt h e t r a n s m i s s i o nh o u s i n g m o u n t i n g b o l t s
alongwith the transmissionhangerand the connector bracket,then torque the bolts in two or more
steosin the seouenceshown.
SHIFI FORK
LOCK WASHER
Beplace.
'l.O mm
6 r
4 N.m
(1.4 ksl.m. 1O lbt.ft)
{cont'd)
www.emanualpro.com
14-253
Transmission
(cont'd)
Reassembly
Install the mainshaft speed ssnsor (with new Oring)on the transmissionhousing.
28. I n s t a l lt h e p a r k l e v e r o n t h e c o n t r o l s h a f t , t h e n
installthe lock bolt with a new lock washer.Do not
bend the lock tab of the lock washer in this step;
bend it after checkingthe park pawl engagementin
step45.
33. Install the old locknut and the old conical spring
washeron ths countershaft.
Tightenthe old locknut
to seat the park gear to the specifiedtorque,then
remove th washer and locknut. The locknut has
left-handthreads. Do not use an impact wrench.
Always usea torquewrenchto tightenthe locknut.
TOROUE:103 N.m {10.5kgf.m, 75.9 lbnft)
3 1 . Installthe countershaft1st gear collar,needlebearing, and the countershaft1st gear/parkgear assembly on the countershaft.
Installthe park pawl shaft. pawl spring, pawl. and
p a w l s t o p o n t h e t r a n s m i s s i o nh o u s i n g ,t h e n
engagethe pawl with th parkgear.
PARKGEAR
PARXGEAR
ONE.WAYCLUTCH
PAWL STOP
I
I
LOCK BOLT
PAWLSHAFT
BEARING
COUNIERSHAFT
COUNTERSHAFT
lST GEARCOLLAR
14-254
www.emanualpro.com
MAINSHAFT
07GAB- PF50101or
07GAB- PF501q)
5C.
4 1 . T i g h t e nt h e l o c k n u t st o t h e s p e c i f i e dt o r q u e .
Mainshaftand countershaftlocknutshave left-hand
threads.Do not use an impactwrench.Always use
a torquewrenchto tightenthe locknuts.
LOCKNUTTOROUE:
78 N.m (8.0 kgf'm, 58 lbf'ft)
MAINSHAFT:
103 N.m (10.5kgf.m, 75.9 lbf'ft)
COUNTERSHAFT:
93
N.m {9.5 kgf'm, 69 lbf'ft|
SUB-SHAFT:
lST CLUTCH
ASSEMELY
SUB.SHAFT
lST GEAR
.A/.b"'
"wt
O.RINGS
THRUSTWASHER
IHRUST NEEDLE
BEANING
NEEDLEBEARING
MAINSHAFT
1ST GEAR
CONICALSPBINGWASHRS
lnstallin this directionMAINSHAFT
1STGEAR
COLLAB
39. A l i g n t h e h o l e o f t h e s u b - s h a f tl s t g e a r w i t h t h e
hole of the transmissionhousing,then insert an 8
mm pin to hold the sub-shaftwhile tighteningthe
sub-shaftlocknut.
0.7- 1.2mm
{0.03- 0.05inl
PUNCH
3.0- 3.5mm
- 0.1ilinl
10.12
40. Install new conical spring washers and new locknuts on each shaft.Installthe washersin the direction shown.
LOCKNUT
Pointto be
staked.
(cont'd)
www.emanualpro.com
14-255
Transmission
Reassembly
lcont'd)
Set the parklever in @ position,then verifythat the
parkpawl engagesthe parkgear.
6 r 1 . Om m
1o tbf'frl
6x1.0mm
14 N.m 11.4kg{.m,
10 tbf.ftl
PARKGEAR
PARKPAWL
CONTROL
LEVER
ASSEMBLY
6 x 1.0mm EOLTHOLE
{Usedin step50.)
END COVER
A/T GEARFOSMON SWNCH
14-256
www.emanualpro.com
,.
((,,,
l( *
O.RING
Replace-
$*\.t+-
'gtt - 00 MoDELS
{6 position3}
50. I n s t a l lt h e A / T g e a r p o s i t i o n s w i t c h c o v e r , t h e n
installthe harnessclamps of the AviTgear position
switch harnesson the end cover and the transmiss i o nh o u s i n g .
6x1.0mm
12 N.m 11.2kgt.m,
8.7 tbf.ftl
10 r 1.25mm
a,aN'm 14.5kgt'm, 33 lbf'ftl
6xl.0mm
12 N.m 11.2kgf'm,
8,7
HARNESSCLAMP
HARNESSCLAMP
TRANSMISSION
www.emanualpro.com
14-257
TorqueConverter/DrivePlate
6 x 1.0 rnin
12 N..t| {1.2 kgt.m, 8.7 lbt.frl
12 x 1.0mm
74 .m (7.5 lgt.m, 54 tbt.ft)
Torque in I crisscross oattern.
o
0o
DBIVCPTATE
14-258
www.emanualpro.com
Transmission
lnstallation
1.
6.
14 mm DOWELPIN
7.
t@
P l a c et h e t r a n s m i s s i o no n a j a c k , a n d r a i s e i t t o
enginelevel.
Anach the transmissionto the engine,then install
the rear engine mounting bolts and the transmission housingmountingbolt (rearsidel.
TRANSMISSIONMOUNT
BRACKET
REARENGINEMOUNTINGBOLTS
la x 1.5mm
8:l N.m (8.5 kgf.m, 61 lbf.ftl
12 x 1.25 mm
74 N.m (7.5 kgf.m,
s{ tbtftl
MOUNTINGBOLT{REARSIDEI
12x 1.25mm
6il N.m 16.5kgd.m,47 tbt.ttl
www.emanualpro.com
TBANSMISSIONMOUNT
(cont'd)
14-259
Transmission
Installation(cont'dl
8. Installthe transmissionhousingmountingbolts.
1 3 . C o n n e c t h e A T F c o o l e r h o s e st o t h e A T F c o o l e r
lines(seepage14-266).
.
ATF COOLER
LINE
'i'l'r
' , : , . )-
10 x 1.25mm
44 N.m (4.5kgf.m,
33 tbtftl
TRANSMISSION
HOUSING
MOUNTING
BOLTS
12x 1.25mm
54N.m16,5kgf.m,a7lbtftl
FRotrtT
MOUNT/ARACKET
't4. Install
the rightfront mounvbracket.
9. Removethe transmissionjack.
10. Attach the torque convenerto the drive plate with
eight bolts. Rotatethe crankshaftas necessarvto
tightenthe bolts to 'll2 of the specifiedtorque,then
to the final torque, in a crisscrosspattern. After
tightening the last bolt. check that the crankshaft
rotatesfreelv.
6x1.0mln
12 N.m (1.2tgt m,
8.t lbf.frl
CLAMP
12x 1.25mm
64 N.m 16.5kg{.m,
a7 tbt.ftl
DRIVEPLATE
8 x 1.25mm
2a N.m 12.5kgf'm,
18 tbt.ftl
6x1.0mm
12 N.m {1.219{.m,
8.7 tbtft,
STIFFENER
12 x t.25 mm
34 N.m 13.5kgf.rn,25 lbf.ft)
14-260
www.emanualpro.com
l0 x 1.25mm
39 N.m 14.0kgt.n,
29 tbf.ftl
SETRING
Replace.
INTERMEDIATE
SHAFT
8 x 1.25mm
32 N.m (3.3 kgt'm,2ir blft)
Feplace.
\
@_
DAMPERPINCHBOLT
10 x 1.25mm
43 N.m 14.{kgf.m,
32 rbr.ftl
SHAFT
PROPELLER
20. lnstallthe shift cable.
4WD:
I n s t a l lt h e s h i f t c a b l e w i t h t h e c o n t r o l p i n , t h e n
secureit with the snap Din. Do not bend the shift
cableexcessivelv.
DAMPER
FORX
SELF.LOCKING
NUT
12 x 1,25mm
6/t N m (6.5kg{.m,a7 lbtft)
Replace.
Replace.
CONTROL
LEVER
CASTLE
12 x 1.25mm
49 - 59 N.m
15.0- 6.0 kgl m, 36 - {3 lbtftl
SHIFTCAALE
COVER
www.emanualpro.com
8 x 1.25mm
22 N.m 12.2l'glm,
16 rbt.ftl
(cont'd)
14-261
Transmission
Installation(cont'dl
2WD:
Installthe controlleverwith a new lockwasherto the
controlshaft.Donot bendtheshiftcableexcessivelv.
SHIFTCABLE
8 r 1.25mm
22 N.m
|'2.2 kgt.m,
16 rbf.ft)
8 x 1.25
24 N.m {2.akgl.m,
17 tbt.ftl
SI{IFT CAELE
COVER
LOCKWASHER
Replace.
6 x 1.0 mm
14 N.m 11.4kgt.m,
10 tbr.frl
6r1.0|r|m
9.8N.ml1.0lgf.m,7.2tbtftl
22. Installexhaustpipe A.
SHIFTCONTROLSOLENOID
VALVECONNECTOR
GASKETS
Replace.
SELF.LOCKING
8 x 1.25mm
22 N.m {2,2kgt.m, l5 lbt.ftl
14-262
www.emanualpro.com
GUAROBAR
lnstalltheshift cablecover.
10 x 1.25m.n
5r N.m {5.5 kgf.m,
40 tbtftl
Replace.
SPLASHSHIELD
SELF-LOCKING
NUT
8 ! 1.25mm
16 N.m {1.6kgf.m,
12 lbf.ftt
Replace.
26. Connectthe vehiclespeed sensor(VSS).the countershaft speed sensor. and the A,/Tgear position
switch connectors,
VEHICLESPEEO
STARTEB
CABLE
SPEED
SENSOA
CO'{NECTOR
STARTER
CAAtf,
30. I n s t a l lt h e a i r c l e a n e rh o u s i n ga s s e m b l ya n d t h e
intakeair duct.
t o r , t h e n i n s t a l lt h e h a r n e s sc l a m p o n t h e c l a m p
bracket.
HARNESSCI-AMP
RADIATORHOSE
CLAMP
TRANSMISSION
GROUNDCAB1I
TERMINAL
LOCK-UPOONTROL
SOLENOIDVALVE
CONNECTOR
6x1.0mm
12 N'm (1.2kgi.m,
8.? tbtftl
www.emanualpro.com
14-263
Transmission
CoolerFlushing
To prevent in;ury to face and eyos, atways
@@
wear safety glassesot a face shield when using the
tlansmission flusher.
2.
Air lp Water
TnAI{SrfiSStoN coot"R
FLUSHER
{Comm.rcidly.v.il.bt.l
K.r -Moor. J38,t{15.A
or aquival.nt
14-264
www.emanualpro.com
to.
TOOL MAINTENANCE
1.
mpty and rinse the flusher after each use. Fill the
flusherwith water and pressurizeit, then flush the
dischargelineto ensurethat the unit is clean.
1 8 . R e m o v et h e d r a i n h o s e ,a n d r e c o n n e ctth e c o o l e r
returnhoseto the transmission(seepage14-266).
2.
3.
FILLERCAP
FILTER
COUPLING
NUT
I
- 0 - - D -@q
I
II
\
ORIFICE
O.RING
www.emanualpro.com
4.
5.
6.
Reassemble
all parts.
14-265
ATFCoolerHoses
Gonnection
'1. Connectthe ATF
2. Facethe tabs of the clips of the transmissionside toward the radiator,and facethe tabs of the ATF coolerside downward.
CLIP
F a c et a b s t o w a r d r a d i a t o r .
ATF COOLERLINE
ATF COOLERLINE
TRANSMISSION
6-8mm
(0.2- 0.3 inl
ATF COOLER
HOSECLAMP
2-rlmm
10.1- 0.2inl
CLIP
Facetabs downward.
14-266
www.emanualpro.com
Shift Lever
Removal/lnstallation
SRS componentsare located in this area. Reviewthe
SRS componentlocations,precautions,and procedures
in the SRSsection(24)beforeperformingrepairsor servrce.
R e m o v et h e f l a n g e n u t s a n d b o l t s s e c u r i n gt h e
steeringcolumn,then lowerthe steeringcolumn.
1.
2.
3.
ADJUSTERROD
SHIFTCABLE
NUTS
FLANGE
16N m (1.6kgl m, 12lbt'ftl
Disconnectthe shift lock solenoidand the park pin
switchconnector.
Removethe bolts securingthe shift leverassembly,
then removethe shift leverassembly.
7.
www.emanualpro.com
14-267
Shift Lever
-'97 - 98 Models
Disassembly/Reassembly
SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations.precautions.and proceduresin the SRS
section(24)beforeperformingrepairsor service.
Apply siliconegreaseto theseparts'
. Movablepartsof the shift lever,
. Movablepartsof the shift lock mechanism.
. Slidingsurfaceson the detentof the controlcheckerand detentguide.
SHIFTLOCKSOLENOID
SPRING
SCREW
2.5 N.m {0.25kgtm, 1.8 lbtftl
SHIFTLOCK
SHIFTLOCKSOLENOID
PLUNGER
SCREW
2.5 N.m {0.25kg{.m,
1.8rbf.ft)
SHIFTLOCK
EXTENSION
DETENTSPFING
STOP
SHIFTLEVER
CONTROLBRACKET
DETENTGUIDE
9.3 N.m 10.95kgtm,
6.8 tbrft)
PARKPIN SWITCH
CONNECTOR
SHIFTLOCK
RELEASELEVER
SPRING
9.3 N.m {0.95kgf.m,
6.8 tbf.ftl
SHIFTLEVER
LINK
9.3 N.m (0.95kgt.m,
6.8 tbf.ftl
SHIFTCAALE
14-268
www.emanualpro.com
KNOB
I N.m 10.9kgt.m,
7 rbf.ftl
-'99 - 00 Models
Disassembly/Reassembly
SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations,precautions,and proceduresin the SRS
section(24)beforeperformingrepairsor service.
Apply siliconegreaseto theseparts:
. Movablepartsof the shift lever.
. Movablepartsof the shift lockmechanism.
. Slidingsurfaceson the detentof the controlcheckerand detentguide.
NOTE:Adjustthe clearancebetweenthe O/Dswitchwires and the edge ofthe shift levercontrolbracketafter reassembly
(seepage 14-270).
SHIFTLOCK
RELEASE
LEVER
SHIFTLOCKSOLENOID
SHIFTLOCKSOLENOID
SPRING
SCREW
2.5 N.m {0.25kgf.m,1.8lbtft)
SHIFTLOCKSOLENOIO
PLUNGER
SCREW
2.5 N.m (0.25kgl.m, 1.8 lbl.ft)
DETENTSPRING
SHIFTLOCKEXTENSION
SHIFTLEVERCONTROL
BRACKET
STOP
PARKPIN SWITCH_
DETENTGUIDE
o/DswtTcH
CONNECTOB
SHIFTLOCKBELEASE
LEVERSPRING
PARK PIN
swrTcH
SCREW
2.5 N.m {0.25kgf.m,
1.8 tbl.f0
9.3 N.m 10.95kgtm,
6.9 tbf.ft)
CONTROLCHECKER
LOCKNUT
7 N.m {0.7kgl.m,
5 tbf.ftl
SHIFTLEVER
BUSHING
SHIFTLEVERKNOB
6 - 1 2N . m
{0.6- 1.2 kgt'm,
4 - 8.7 tbnft)
o/DswtTcH
www.emanualpro.com
14-269
Shift Lever
Over-Drive(O/DlSwitch Wire Clearance
Adjustment-'99 - 00 Models
NOTE: Be sure to adjust the clearancebetween the O/D
switch wires and the shift lever control bracket after
replacingthe O/D switch and park pin switch,and after
reassemblingthe shift lever. lf there is the slack in the
wires or the wires are kept tight, the wires may have
Dreaks.
1.
2.
SHIFTLEVERBRACKET
14-270
www.emanualpro.com
DetentSpringReplacement
1.
4.
'97 - 98 Modeb:
SPRING
DETENT
SHIFI LEVER
GAPGAUGE
SCREW
2.5 N.m 10.25kgl.m, 1.8lbtftl
www.emanualpro.com
14-271
Shift Gable
Adjustment
SRScomponentsare locatedin this area.Reviewthe SRS
componentlocations,precautions,
and proceduresin the
SRSsection(241beforeperformingrepairsor service.
1.
Release
the steeringtilt lever.
2.
CABLEADJUSTER
LOCKPIN
AOJUSTING
noo
K\ffi
6-,>
/*
1
snenrftc Y
TILTLEVER
Cabls
Too Short
Cable
Too Long
Exact
Alignment
ACCESSCOVER
ADJUSTER
7 N.m(0.7kg{.m,
5 tbf.ft)
3.
Tightenthe locknut.
7 . Installthe lock pin on the adjuster.lf you feel the
lock pin bindingas you reinstallit, the cable is still
out of adjustmentand must be readjusted.
M a k e s u r e t h e l o c k p i n i s s e a t e ds e c u r e l yi n t h e
a d j u s t e r .R e p l a c et h e l o c k p i n i f i t d o e s n o t s n a p
over the cableadjustersecurely.
a
1 0 . S t a r t t h e e n g i n e ,a n d c h e c kt h e s h i f t l e v e r i n a l l
gears.lf any gear does not work properly,refer to
troubleshooting
on page 14-'153
thru 14-156.
' l1 . Insertthe ignition key into
the key cylinderon the
upper column cover, and verify that the shift lock
teverreteases.
14-2 7 2
www.emanualpro.com
Replacement
SRScomponentsare locatedin this area.Reviewthe SRS
componentlocations,precautions,
and proceduresin the
SRSsection{24}before performing repairsor service.
1.
4WD:
Removethe snap pin and control pin,then separate
the shiftcablefrom the controllever.
2.
Removethe shiftcable.
CONTROLPIN
CABLEADJUSTER
SHIFTCABLE
LOCKPIN
LOCKNUT
29 N.m {3.0 kgl.m,
2j2lbf.trl
ADJUSTING
SHIFTCABLE ROO
BRACKET
L o o s e nt h e l o c k n u t ,t h e n r e m o v et h e s h i f t c a b l e
from the shift cablebracket.
SHIFT
COVER
t r 1.25mm
22 N.n 12.2*glrn.
16tbf.trl
2WDi
Removethe control lever, then separatethe shift
cablefrom the controlshaft.
R e m o v et h e n u t s e c u r i n gt h e s h i f t c a b l e h o l d e r ,
then removethe shiftcable.
SHIFT CABI-E
CONTROL
SHAFT
STUOBOLT
8 x 1.25mm
22 N.m
12.2 kgl-m,
16 tbf.frl
6x1.0mm
12 N.m {1.2 kgf.m,
8.7tbtfrl
SHIFTCABLE
COVER
LOCKWASHER
6x LOmm
14 N.m {1.4kgf.m,
10 tbt.lrl
www.emanualpro.com
(cont'd)
14-273
Shift Gable
Replacement(cont'd)
7.
STUDBOLT
SHIFTCABLE
f-'
6x 1.0mm
12 N.m 11.2kgtm,
8.7 tbf.ftl
I n s t a l lt h e s h i f t c a b l e l n t h e
removat.
NOTE:
. Do not bent the shift cable excessivelywhen
installingit.
. Make sure the lock pin is seatedsecurelyin the
cableadjuster.
. Replacethe lock pin if it does not snap over the
cableadjustersecurely.
Checkthe cableadjustmentafterinstallingit.
14-274
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Differential
Rear Differential
S p e c i aT
l o o l s. . . . . . . . . .
...........15-2
Description
R e a rD i f f e r e n t i a .l . . . . . . . . . . . . . . . . . . . . . . . 1
. .5. .-.4. . . .
H y d r a u l i cF l o w . . . . . . . . . . . .
, . .1 5 - 6
Real-time4WD-DualPump System
T r o u b | e s h o o t i n .9. . . . . . . . . . . . . . . . . . . . . . . 1
. .5. .-.1. .0. .
RearDifferentialAssembly
T r o u b l e s h o o t i n .g. . . . . . . . . . . . . . . . . . . . . . . 1
. .5. .-.1. .3. .
Maintenance
D i f f e r e n t i aFl l u i d . . . . . . . . . . .
. 15-14
Rear DifferentialAssembly
l l l u s t r a t e dI n d e x . . . . . . . . . .
.. 15-15
Removal/lnstallation
....15-16
DifferentialCarrierAssembly
L e a kR e p a i r
. . . . . . . . . . . . . . .1
. .5. .-.1 8
OilSeals
R e p l a c e m e n.t. . , . . . . . . . . . . . . . . . . . . . . . . . . .1. 5
. .-.1. .9. . . .
RearDifferentialAssembly
Disassembly
. . . . . . . . . . , . . . .1. 5. .-,2 0
Reassembly
. . . . . . . . . . . . . . .1. .5. .-.2 3
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SpecialTools
Ret. No.
o
@
aa
@
/il
tol
Tool Number
J - 38592
07GAD- PH7020'1
07JAB- 0010204
OTRA_
BT B 4 0 l O B
07749 0010000
07965- 6920101
otv
Oescription
TransferCaseOil Seallnstaller
SealDriver
H o l d e rH a n d l e
F l a n g eH o l d e r
Driver
Hub Dis/Assembly
Tool
1
1
1
1
1
1
6\
15-2
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PageRelernce
15-20
15-19
tc-zt, z9
15-21,25
15-19
15-19
www.emanualpro.com
15-3
Description
RearDifferential
Outline
The Real-time4WD-DualPump Systemmodel has a hydraulicclutchand a differentialmechanismin the rear differential
assembly.Under normalconditions,the vehicleis driven by the front wheels.However,dependingon to the drivingforce
of the front wheels and the road conditions.the systeminstantlytransmitsappropriatedrivingforce to the rear wheels
without requiringthe driverto switchbetween2WD (trontwheel drive)and 4WD(fourwheel drive).The switchingmechanism between2WD and 4WDis integratedinto the reardifferentialassemblyto makethe systemlight and compact.
forcewhen brakingin a forwardgear.This allowsthe
ln addition,the dual-pumpsystemswitchesoff the rear-wheel-drive
brakingsystemto work properlyon modelsequippedwith an Anti-lockBrakingSystem(ABS).
Construction
The rear differentialassemblyconsistsof the torque control differentialcase assemblyand the rear differentialcarrier
assembly.The torque control differentialcase assemblyconsistsof the differentialclutch assembly,the companion
flange,and the oil pump body assembly.The reardifferentialcarrierassemblyconsistsof the differentialmechanism.The
differentialdrive and drivengearsare hypoidgears.
The oil pump body assemblyconsistsof the front oil pump, the rear oil pump,the hydrauliccontrolmechanism,and the
clutch piston.The clutch piston has a disc spring that constantlyprovidesthe differentialclutchassemblywith a preset
torqueto Dreventabnormalsound.
The clutchguide in the differentialclutchassemblyis connectedto the propellershaft via the companionflange,and it
receivesthe drivingforce lrom the transferassembly.The clutchguide rotatesthe clutchplate and the front oil pump in
the oil pump body.
The clutchhub in the differentialclutchassemblyhas a clutchdisc that is splinedwith the hypoid drive pinion gear.The
hypoiddrivegear drivesthe rearoil pump.
The front and rearoil pumpsare trochoidalpumps.The rearoil pump capacityis 2.5 percentlargerthat the front oil pump
to handlethe rotationdifferencebetweenthe front and rear wheelscausedby worn front tires and tight corner braking.
The oil pumps are designedso the fluid intakeworks as a fluid dischargewhen the oil pumps rotatein reverse.Genuine
HondaCVTfluid is usedinsteadof differentialfluid.
Operation
Whenthere is a differencein rotationspeedbetweenthe front wheels(clutchguide)and rearwheels(hypoiddrivengear),
hydraulicpressurefrom the front and rear oil pumps engagesthe differentialclutch,and drive force from the transler
assemblyis appliedto the rearwheels.
The hydraulicpressurecontrolmechanismin the oil pump body selects4WD mode when the vehicleis startedabruptly,
or when acceleratingin a forward or reversegear (causingrotationdifferencebetweenthe front and rear wheels).or
when brakingin reversegear {whendecelerating).
lt switchesto 2WD modewhen the vehicleis drivenat a constantspeed
in forwar! or reversegear (whenthere is no rotationdifferencebetweenthe front and rearwheels),or when brakingin a
fo rward gear (whendecelerating).
To protectthe system,the differentialclutchassemblyis lubricatedby hydraulicpressuregeneratedby the oil pumps in
both 4WDand 2WD modes.Also,the thermalswitchrelievesthe hydraulicpressureon the clutchpistonand cancels4WD
mode if the temDerature
of the differentialfluid risesabovenormal.
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REARDIFFERENTIAL
ASSEMBLY
TOROUECONTROLOIFFERENTIAL
OIFFERENTIAL
CARRIER
OILPUMPBODY
HYPOIDDRIVE
PINIONGEAR
OIFFERENTIAL
CLUTCH
ASSEMBLY
DIFFERENTIAL
CLUTCHGUIDE
HYPOIDRINGGEAR
COMPANIONFLANG
CLUTCHHUB
REAROIL PUMP
CLUTCHPLATE
FRONTOIL PUMP
HOUSING
DIFFERENTIAICLUTCHDISC
HYDRAULICCONTROLSYSTEM
DISCSPRING
CLUTCHPISTON
FRONTOIL PUMP
REAROII- PUMP
DIFFEREMT|AL
CLUTCH
ASSEMBI-Y
THERMALSWITCH
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RELIEFVALVE
OIL STRAINER
15-5
Description
HydraulicFlow
Forward Start and Accelerationl4WD)
Duringa forwardstartand forwardacceleration,
the dual pump systemcan engagefour wheeldrive.
lf the front wheelsspin fasterthan the rearwheels,the front oil pump spinsfasterthan the rearoil pump.The front pump
draws fluid through checkvalve B and dischargesit. Some of the dischargedfluid is drawn in the by the rear oil pump.
The remainingfluid will passthroughcheckvalve E into the clutchpiston.There,hydraulicpressureis regulatedby two
orifices.
The regulatedhydraulicpressureat the clutchpistonpushesthe platesand discsof the clutchtogetherto form a connection. The engagedclutchthen passesdrivingforcefrom the transferassemblyto the rearwheels,producing4WD.
oRrFtcEs
FRONTOIL PUMP
REAROILPUMP
FRONTOIL PUMP
15-6
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Forward Decelerationl2WDl
the dual pump systemfunctionsin two wheeldrive mode.
Duringforwarddeceleration,
the speedof the rearwheels may exceedthe speedol the front wheelsduring decelerBecauseof brakingcharacteristics,
ation.lf so, the rearoil pump spinsfasterthan the front oil pump.
d .e c a u s teh e r ei s n o
F l u i dd i s c h a r g ebdy t h e r e a ro i l p u m p i s s i m p l yd r a w n i n a g a i nb y t h e r e a rp u m p a n d r e c i r c u l a t e B
pressurebuilt up at the clutch piston.the clutch piston does not engage,and the vehicleremainsin 2WD (front wheel
drive).
REAROILPUMP
oRtFtcEs
FRONTOIL PUMP
{cont'd)
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15-7
Description
HydraulicFlow (cont'dl
ReverseDriving at Constant Speed l2WD)
when driving in reverseat a constantspeed,the dual pump systemfunctionsin two wheeldrive mode.
The rotationspeedof the front and rearwheelsis the same,so the speedof the front and rearpumps is alsothe same,
Fluiddischargedby the front oil pump is drawn in by the rearoil pump and is circulatedthroughthe system.But,because
the there is a differencein the capacitybetweenthe two pumps,fluid flows through checkvalve E, and then through oriIices.This fluid lubricatesand coolsthe clutchassemblyand bearings.
ls this condition,only a low pressureis built up at the clutchpiston.Thereforethe clutchdoes not engage,and the vehicle
remainsin 2WD (frontwheeldrive).
ReverseDecelerationl/tWDl
Duringreversedeceleration,
the dual pump systemcan engagefour wheeldrive.
When deceleratingin reversedirection,the speedof the rear wheels may exceedthe speedof the front wheels (due to
enginebraking).In this condition,the rearoil pump drawsfluid throughcheckvalvesB and C. Fluid dischargedfrom the
rearoil pump then flows throughcheckvalveE to the clutchpiston.There,pressureis regulatedby two orifices.
The regulatedhydraulicpressureat the clutchpiston may forcethe platesand discsof the clutchtogetherto form a con,
nection.The engagedclutchpassesdrivingforcefrom the transferassemblyto the rearwheels,producing4WD.
oRtFtcEs
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REAROIL PUMP
THERMALSWITCH
RELIEFVALVE
RelietValve Operation
When the fluid pressuregoes higherthan the reliefvalvespringforce,checkvalve R opens.Pressureappliedat the clutch
pistonis held constant.This featureadds stabilityby preventingthe rearwheeldrive systemfrom experiencingexcessive
to rque.
RELIEFVALVE
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15-9
Real-time4WD-DualPumpSystem
(AutomaticTransmissionl
Troubleshooting
When starting and accelerating in forward gesrs {4WD
model
1.
L i f t u p t h e v e h i c l es o a l l f o u r w h e e l sa r e o f f t h e
ground (seesection1).
1.
2.
PROPELLER
SHAFT
L i f t u p t h e v e h i c l es o a l l f o u r w h e e l s a r e o f f t h e
ground (seesection1).
A p p l y t h e p a r k i n gb r a k ef i r m l y . a n d m e a s u r et h e
time it takesthe propellershaftto rotate10 times.
. lf the measuredtime is more than 10 seconds,
the 4WDsystemis normal.
. l f t h e t i m e i s l e s st h a n 1 0 s e c o n d s t, h e r e i s a
problem in 4WD system. Checkthe differential
f l u i d . l f t h e d i f f e r e n t i af l u i d i s n o r m a l ,r e p l a c e
the torquecontroldifferentialcasekit.
A p p l y t h e p a r k i n gb r a k ef i r m l y , a n d m e a s u r et h e
time it takesthe proDellershaftto rotate10times,
. lf the measuredtime is more than 10 seconds,
the 4WDsystemjs normal.
. l f t h e t i m e i s l e s st h a n 1 0 s e c o n d s t, h e r e i s a
problem in 4WD system. Checkthe differential
fluid. lf the differentialfluid is normal, reolace
the torquecontroldifferentialcasekit.
15-10
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(ManualTransmissionl
Troubleshooting
When starting and acceleratingin forward gears (4WD
mode)
1.
L i f t u p t h e v e h i c l es o a l l f o u r w h e e l s a r e o f f t h e
ground{seesection1)
2.
3.
W i t h t h e e n g i n ea t i d l e , s h i f t i n t o 1 s t g e a r a n d
releasethe clutch.
Applythe parkingbrakefirmlY
.
.
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L i f t u p t h e v e h i c l es o a l l f o u r w h e e l s a r e o f f t h e
ground (seesection1).
Real-time4WD-DualPumpSystem
Troubleshooting(AutomaticTransmission/Manual
Transmission)
Whon d6c6l6ratingin a torward gear {2WD mode}
1.
1.
WHEELCHOCKS
15-12
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WHEELCHOCKS
RearDifferentialAssemblY
Troubleshooting
Most problemsin the unit are to be diagnosedby identifyingnoisesfrom the gearsor bear'ngs'
components'
care shouldbe takenduringdiagnosisnot to confusedifferentialnoiseswith thosefrom otherdrivetra'n
Symptom
Remedy
ProbableCause
. Fluidleveltoo low
. Incorrectfluid type
. Add fluid
. Replace
Incorrectfluid type
Gearor bearingnoises
Overheating
F l u i dl e a k
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Fluidleveltoo low
Incorrectfluid type
Damagedor chippedgears
. Fluidleveltoo low
. Incorrectfluid type
Fluidleveltoo high
Cloggedbreatherhose
Worn or damagedoil seal
Damagedsealingwasher
Loosemountingboltsor inadequatesealing
Add fluid
Drain and fill the differential
Replacethe differential carrier
assemory
. Add fluid
. Drain and fill the differential
Lowerto properlevel
Cleanor replace
Replace
Replace
torqueor aPPIYsealant
Recheck
15-13
Maintenance
DifferentialFluid
!@
section 1).
1.
2.
C l e a nt h e d r a i n p l u g , t h e n r e i n s t a l il t w i t h a n e w
washer, and refill the differentialwith the recommendedfluid to the properlevel.
NOTErlf you disassembly
the differential,
checkthe
fluid levelagain after the 4WD systemcheckis finished.Add fluid if necessary.
Reinstallthe oil filler plug with a new washer.
Proper Level
Fluid Capacity
1.0/ {1.1US $, 0.9 lmp qt) at tluid change
1.2/ {1.3US $, 1.1lmp qt) at oyerhaul
Recommended
fluid:
GenuineHondaCVT Fluid
T h e f l u i d l e v e lm u s t b e u p r o t h e f i l l h o l e .l f i t i s
below the hole, add the recommendedfluid until it
runs out, then reinstallthe oil filler plug with a new
wasner.
4.
l f t h e d i f f e r e n t i atll u i d i s d i r t y , r e m o v et h e d r a i n
p l u g ,a n d d r a i nt h e f l u i d .
DMIN PLUG
a7 N.m 14.8kgl.m, 35 lbt.ftl
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1 5 -1 4
RearDifferentialAssembly
lllustratedIndex
6xl.0m
12 N.m (1.2 kgf m,8.7 lbt'ftl
DOWELPINS
COMPANIONFLANGE
O.RING
Replace.
BACK-UPRING
LOCKNUT,24 mm
Replace.
118N.m (12.0kgtm.
87 rbt ft)
6x1.0mm
12 N.m 11.2kgt'm,8.7 lbf'ft|
OIL SEAL
Replace.
PRESSURE
PLATE
CLUTCHHUB/PLATES/DISCS
CLUTCH
DIFFERENNAL
ASSEMBLY
OIL PUMPDRIVESHAFT
THBUSTNEEDLE
AEARING
""t",at\(
'd'
CLUTCHGUIDE
OILPUMP
PIN
e
MAGNET
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OIL STRAINER
15-15
RearDifferentialAssembly
Removal/lnstallation
Make sure tifts are ptaced property lsee
l!!@
section 11.
1.
2.
5,
COMPA'{IONFLANGE
12 POtt'lT BOLI
8 x 1.25mm
32 N.m 13.3tgf.m. 2a lbtft,
Mark
12x 1.25mm
5,1N.m 15,5kgf.m, iO tbf.fO
15-16
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7.
DIFFERENTIAL
REANDFFERENTI,AL
ASSEMBLY
8.
Notetheseitemsduringreassembly
. lnstallthe breathertube to the breathertube joint
properly.
. Duringthe propellershaft installation,align the
m a r k s o n t h e p r o p e l l e rs h a f t a n d c o m p a n i o n
flange.
. Reiillthe rear differentialwith the recommended
fluidto the properlevel{seepage15-14).
DRIVESHAFT
BOLTS
MOUNTING
'10x 1.25mm
,19N'm (5 0 kgf m, 36 lbtftl
Lower the rear differentialassemblyon the transmissionjack,then removethe reardriveshaftsfrom
the rear difterentialassembly.
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15-17
DifferentialCarrierAssembly
LeakRepair
'1. Remove
t h e b o l t s i n a c r i s s c r o s so a t t e r n .t h e n
removethe differentialhousing.
I x 1.25mm
22 N.m 12.2kgl.m, 16 tbtftl
2.
I n s t a ltlh e o i l s e a l s( s e ep a g e1 5 - 1 9 ) .
DIFFERENTIAL
HOUSING
15-18
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Oil Seals
Replacement
1.
2.
Right side:
Rightside:Installationdepth of the oil seal is 9 mm
(0.35in) belowthe edgeof the differentialhousing.
OILSEAL
HUB DIS/ASSEMBLYTOOL
07965- 6920101
OIL SEAL
Left side:
OIL SEAL
(cont'd)
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15-19
Oil Seals
RearDifferentialAssembly
Replacement(cont'd)
Disassembly
3.
1.
BREATHER
TUBE
OIL FILI.IRPLUG
DRAIT{PLUG
L(rcKNUT,24 mm
Replace.
15-20
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3.
7.
R e m o v et h e l o c k n u t ,t h e d i s c s p r i n gw a s h e r ,t h e
back-upring,the O-ringand the companionflange.
HOIIIER HANDTI
o'JAB - OO102nA
@r/
v-.,.
LOCKNUT,24 mm
Feplace.
DISCSPRINGWASHER,24 mm
ao/
BACX.UPRING
rA*..-
O.N|NG
Replace.
zzft
h\@fr\
COMPANIONFLANGE
8 x 1.25mm
8.
5.
6.
LOCKNUT.2,1mm
Tab
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(cont'd)
Rear DifferentialAssembly
Disassembly(cont'dl
9 . R e m o v et h e s h i ma n dt h e c l u t c hq u i d e .
1 1 . R e m o v et h e t h r u s tn e e d l eb e a r i n ga n d t h e o i l p u m p
driveshaft.
d"HIM'30mm
CLUTCHGUIDE
OIL PUMPBODYASSEMBLY
CLUTCHHUB/PLATES/OISCS
ffi
-:*
_zz
PRESSURE
PLArE
MAGNET
@-
OIL PUMPPIN
OIL STRAINER
Inspectfor damage
or clogging.
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15-22
Reassembly
1.
3.
4.
MAGNET
THRUSTNEEDLEBEABING
-n
OIL PUMPPIN
lnstallin thisdirection.
Projection
CWfluid
6x1.0mm
12 N.m 11.2kg{.m,8.7 lbl.ft}
DIFFERE]TTIALCARRIER
ASSEMBLY
2.
5.
OILPUMP
DRIVESHAFT
( c o n t ' d)
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15-23
RearDifferentialAssembly
(cont'dl
Reassembly
7.
sHlM, 30 mm
,/
.A-\,/r
\-7
CLUTCHGUIDE
CLUTCHHUA/PLATES/
Dtscs
8.
Installthe
c l u t c hg u i d ea n dt h e 3 0 m m s h i m .
9.
A p p l y l i q u i d g a s k e tt o t h e s e a l i n gs u r f a c eo f t h e
t o r q u e c o n t r o l d i f f e r e n t i a lc a s e ,a n d n o t e t h e s e
rlems:
. Use liquidgasket(P/N08718- 0001).
. Removeany dirt or fluid from the sealing surface.
. lf 20 minutes have passedafter applying liquid
gasket,reapplyit beforeyou assemblethe housings. Allow it to cure at least 30 minutes after
assemblybeforefilling differentialwith fluid.
TOBOUE CONTROL
DIFFERENNAL
@+-_alcr-upnwc
/r-
K@#/
COMPANIONFLAI{GE
---
15-24
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Apply liquidgaskot
1 2 . I n s t a l tl h e s p e c i a tl o o l s t o t h e c o m p a n i o nf l a n g e ,
then tightenthe locknutto specifiedtorque.
TOROUE:118N.m (12.0kgf-m,87lbf'ft)
BREATHER
TUAE
HOLDEBHANDLE
07JAB- @1020A
OIL FILI..ERPLUG
47 N.m 14.8kgf.m,
35 tbt frl
WASHENS
Replace.
DRAIN PLUG
4? N'm l4.E tgf.m, 35 lbf'ftl
I x I .25 mm
32 N'm (3.3kgt m, 24 lbtftl
t5.
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Driveshafts
Special
Tools..........
...........
16-2
Driveshafts
Inspection
......................
l6-3
FrontDriveshafts
Removal
....16-3
Disassembly
...................
16-5
Reassembly
....................
16-g
Installation
.....................
16-17
IntermediateShaft
Removal
....16-19
Disassembly
...................
16-19
Reassembly
....................
16-20
Installation
.....................
16-21
RearDriveshafts
Removal
.... 16-22
Disassembfy
...................
16-22
Reassembfy
....................
16-24
Installation
.....................
16-29
PropellerShaft
Inspection
. 16-29
RemovaUlnstallation
....16-30
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Rf. No.
o
@
\D'
o
@
@
Tool Number
07JAF- SH20400
07LAD- PW50601
07MAC- S100200
07746- 0010300
07746- 0010400
07746- 0030400
07749- 0010000
07965- SD90100
07xAc - 0010200
Dscription
Attachment
Attachment,40x 50 mm LD.
B a l lJ o i n tR e m o v e r , 2 m
8m
Attachment,42 x 47 mm
Attachment,52 x 55 mm
Attachment,35 mm l.D.
Driver
Suppon Base
T h r e a d e dA d a p t e r , 2 4
x 1 . 5m m
arl
!.,
o)
16-2
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Otv
1
'l
1
1
1
1
,l
'I
1
PageRolsrenca
16-16
16-18
16-4
16-16
1 6 - 1 71, 8
16-17
1 7 ,1 8
16-16
16-7
Driveshafts
Front Driveshafts
Inspection
Removal
Boot Damago
Check the boots on the driveshaft for cracks, damago,
leakinggrease,and loose boot bands.lf any damagsis
found, replacethe boot and boot bands.
Looso Splines
Turn the driveshaftby hand,and make sure th splins
and joint are not excessivelyloose.lf damageis found,
replacethe inboardjoint.
Twisting or Crscking
Make sure the driveshaftis not twisted or crackod.
Replaceit if necessary.
DRIVESHAFT
SPINDLENUT
24 x 1.5mm
Replace.
FRONTWHEEL
Removethe self-locking
nut and flangebolt,
FLANGEBOLT
10 x 1.25mm
SELF"LOCKING
NUT
12 x 1.25mm
Replace.
7.
(cont'd)
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16-3
Front Driveshafts
Removal (cont'd)
Removethe cotterpin from the lower arm ball ioint
castlenut, and removethe nut.
07MAC- SLm2m
Installa 12 mm hex nut on the ball joint. Makesure
the hex nut is flush with the balljoint pin end,or the
threadedsectionof the ball joint pin might be damaged by the specialtool.
i0. Usethe specialtool as shown in section'18to separate the ball joint and lower arm, Be caretulnot to
apply pendamagethe ball joint boot, lf necessary,
etratingtype lubricantto loosenthe ball joint,
1 l . Pry out the driveshaftassemblywith a pry bar, as
shown, to force the set ring at the driveshaftend
past the groove. Be careful not to damagethe oil
sealswhen prying.
PRY BAR
16-4
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Left driveshaft:
Removethe left driveshaftfrom the bearingsuppon
by tapping on the inboard joint of the driveshaft
with a olastichammer.
BEARINGSUPPORT
Disassembly
13, Pullthe knuckleoutward,and removethe driveshaft
inboard joint from the differentialcase or bearing
suoDort.
InboardJoint Sid:
1,
2.
KNUCKLE
Locking Tab
DRIVESHAFT
PLASTICHAMMER
SET BING
Replace.
Welded
DRIVESHAFT
{cont'd)
www.emanualpro.com
16-5
Front Driveshafts
Disassembly(cont'd)
Double Loop
4,
DRIVESHAFT
DRIVESHAFT
Mark
Removethe circlip,
Mark the spider and driveshaft to identify the position ofthe spideron the shaft.
7.
Mark each roller and inboard joint to identify the
locationsof the rollersand groovesin the inboard
joint. Thon remove the inboard ioint on the shop
towel. Be careful not to drop the rollers when separatingthem from the inboardjoint.
INBOARDBOOT
INBOARDJOINT
Checksplinesfor wearor damage.
Checkinside bore for wear.
Inspectfor cracks.
DRIVESHAFT
DYNAMICDAMPER
16-6
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DRIVESHAFT
L i f t u p t h e t h r e e t a b s w i t h a s c r e w d r i v e r ,t h e n
remove the boot bands,Take care not to damage
the boot.
NOTE:
. lf the boot band is a double loop type, lift up the
bandbend.
. lf the boot band is a welded type, cut the boot
band.
. l f t h e b o o t b a n di s a l o c k i n g t a b s t y p ep.r y u p t h e
tabswith a screwdriver,and lift up the end of the
oano.
PAINTMARK
5,
EarClamp
TAB
2.
Slidehammc..5/8'x lS Throad
(Commerically,
available)
o.
7.
8.
DRIVESHAFT
STOPRING
Replace.
www.emanualpro.com
Front Driveshafts
Reassembly
Notetheseitemsduringreassembly
. Cleanthe disassembledparts with solvent,and dry them thoroughlywith compressedair. Do not wash the rubber
partswith solvent.
:Thoroughlypackthe inboardand outboardjoints and both joint bootswith the joint greaseincludedin the
new driveshaftset.
The'98 Canadamodel andall '99 - 00 modelsusea TPE(Thermoplastic
PolyesterElastomer)outboardjoint boot.
Usethe ear clamptype boot band in the outboardboot set.
o *4@]
.
Greasequantity:
Inboard Joint: All models 120- 130 g (i1.2- 4.6 oz)
Left inboard joint splines (Al: 0.5 - 1.0 g (0.018- 0.035oz)
Outboard Joint: '97 model and'98 USA model 130- 140 g (4.6-,1.9 oz)
'98 Canadamodel and all '99 - 0Omodels 140150 g 14.9- 5.3 oz)
SETRING
Replace.
INBOARO
JOINT
LEFTINBOARO
JOINT
SPIOER
INBOARDBOOT
-6r
(Al
SPLINES:
P a c kc a v i t y w i t h g r e a s e .
wtn grease.
BANDS
DYNAMICDAMPER
STOPRING
Replace.
OUTBOARDBOOTITPE)*I
-611
-/
DOUELE
BAND+'
Replace.
Replace.
__G1
P a c k c a v i t y wrtn grease.
OUTBOARDBOOT*'
(RUBBERI
-Grj
Pack cavity wtrn grease.
16-8
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5.
DRIVESHAFT
,..',NYL rAPE
uu.oa.Dsoo.
V6
,",^_Y,C@
I n s t a l lt h e i n b o a r d b o o t t o t h e d r i v e s h a f t ,t h e n
removethe vinyl tape.Takecare not to damagethe
boot.
Installthe spideronto the driveshaftby aligningthe
markon the spiderand the end of the driveshaft.
@+-crncr-rr
4.
(cont'd)
www.emanualpro.com
16-9
Front Driveshafts
Reassembly
{cont'd)
7.
/,?:..{
t
Sptine
airection
lffi
t Y l
:\
ROLLERHOLDER
-flm+dm@
/\
9.
Adjustthe lengthof the driveshaftsto the specifications shown. then adjustthe boots to halfway
betweenfull compressionand full e)dension.Make
surethe endsof the bootsseat in the groovesof the
driveshaftand Ioint.
OUTBOAROJOINT
www.emanualpro.com
16-10
10. Set the double loop band onto the boot or dynamic
damper with the band end toward the front of the
vehicle.
OOUBLELOOPBAND
BOOTBANDTOOL
(KD-3191
or equivalentl
Markon band.
WINDING
MANDREL
HAMMER
(cont'd)
www.emanualpro.com
1 6 - 11
Front Driveshafts
(cont'd)
Reassembly
16. Unwind the boot band tool. and cut off the excess
free end of the band to leavea 5 - 10 mm (0.2- 0.4
in) tail protrudingfrom the clip.
5 - 1 0m m
10.2- 0.4 in,
OUTBOARDBOOT
VINYLTAPE
2,
I n s t a l lt h e b o o t b a n d a n d o u t b o a r d b o o t , t h e n
removethe vinyl tape.Takecare not to damagethe
boot.
3.
DRIVESHAFT
16 -1 2
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4.
6.
DRIVESHAFT
DRIVESHAFT
1.
To completelyseat the outboardjoint, pick up the
driveshaftand joint. and drop them from about 10
cm (4 to 5 inches)onto a hard surface,Do not use a
hammeras excessiveforce may damagethe driveshaft.
DRIVESHAFT
i/,,,t|:l,r;;:,:.'i,,1;'/l
(cont'd)
www.emanualpro.com
1 6 - 13
Front Driveshafts
Reassembly(cont'd)
8. Fit the boot ends onto the driveshaftand outboard
lornt.
OUTBOARDBOOTfiPE)
OUTBOARD
BOOT
OUTBOARDBOOT
BOOTBAND PINCERS
KENT.MOORE
J-35910
or equivalent
OUTBOARD
JOINT
Installthe boot bands,
. F o r a l l ' 9 7 m o d e l sa n d ' 9 8 USA models, go to
step 13.
. For'98 Canadamodelsand all '99 - 00 models,
go to step 10.
10. Set the ear clamp band by threadingthe tab into the
holesof the band.
EARPORTION
16 -1 4
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13. Fit the boot ends onto the driveshaftand the outboardjoint.
CLIP
Mark spot.
(cont'd)
www.emanualpro.com
16-15
Front Driveshafts
(cont'dl
Reassembly
1 8 . Placea wrenchon the winding mandrelof the boot
b a n d t o o l , a n d t i g h t e nt h e b a n d u n t i l t h e m a r k e d
spot on the band meetsthe edgeof the clip.
1 9 . Lift up the boot band tool to bend the free end of
the band90" to the clip. Center-punch
the clip,then
fold over the remainingtail onto the clip.
CLIP
20. 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.
16-16
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Front Driveshafts
lnstallation
1.
4.
KNUCKLE
INBOARDJOINT
Replace.
OUTBOARDJOINT
5.
SET RING
CASTLENUT
12 x 1.25mm
49-59Nm
(5.0- 6.0 kgl'm,
36 - 4:l lbl.ft)
COTTERPIN
Replace.
On reassembly,
bendthe cotterpin
(cont'd)
www.emanualpro.com
16-17
Front Driveshafts
Installation{cont'd}
Installthe damperfork over the driveshaftand onto
t h e l o w e r a r m . I n s t a l lt h e d a m p e r i n t h e d a m p e r
fork so the aligning tab is alignedwith the slot in
the damperfork.
FLANGE
BOLT
10x 1.25mm
N.m{4.i1kst.n,32lbf.ftl
ALtcNtNGTAB
IntermediateShaft
Removal
1 . Drainthe transmissionoil or fluid (seesection13 or
14).
Removethe left driveshaft(seepage16-3).
Removethe threedowel bolts.
12x 1.25mm
64 N.m {6.5 kgf.m, 47 lbf.ftl
Replace.
7. Loosely install the flange bolts and the new selflocking nut.
8. Apply oil to the seating surface of the new spindle nut.
FRONTWHEEL
WHEELNUT 12 x 1.5mm
108N.m (11.0kgf.m,80lbf.ftl
INTERMEDIATE
SHAFT
SPINDLENUT
24 x 1.5mm
245 N.m
{25.0ksf.m, 181 lbf.ft)
NOTE:Attertightening.
usea driftto
stakethespindle
nutshoulder
against
thedriveshaft.
9. Installa new spindlenut,then tightenthe nut.
10. Cleanthe mating surfacesof the brakedisc and the
wheel. then install the front wheel with the wheel
nuts,
1'1. Tighten the flange bolts and the new setf-locking
nut with the vehicle'sweight on the damper.
12. Refillthe transmissionwith recommendedfluid (see
section13or 14).
13. Checkthe front wheel alignment.and adjust if necessary(seesection 18).
16-18
www.emanualpro.com
Disassembly
NOTE:Be carefulnot to damagethe metal rings on the
intermediateshaftduringdisassembly.
6.
ORIVER
07749- 001q)00
FLOATINGRUBBER
DAMPER
Checkfor deterioration
ano oamage,
SEAL
OUTER
RePlace
ATTACHMENT,
tl2x 17 mm
07745- 0010300
SET RING
Replace.
INTERNALCIRCLIP
ATTACHMENT
o?JAF_ SH20it00
SHAFT
INTERMEDIATE
Checklor damage.
5.
www.emanualpro.com
16-19
IntermediateShaft
Reassembly
Notetheseitemsduring reassembly:
. Cleanthe disassembledparts with solvent,and dry them thoroughlywith compressedair. Do not wash the rubber
partswith solvent.
. Be carefulnot to damagethe metal ringson the intermediate
shaftduring reassembly.
DOWELEOLT
10 x 1.25mm
39 N.m 14.0kg'tm, 29lbf.ft)
BEARINGSUPPORTRING
EXTERNALCIRCLIP
Packthe interior
of the outerseal.
2.0-3.5 g {0.07-0.r2 oz}
INTERMEDIATE
SHAFTRING
INTERNALCIRCLIP
BEARINGSUPPORT
'L
OUTERSEAReplace.
W-L!
SHAFT
INTERMEDIATE
ATTACHMENT,
52x55mm
07746- 0010400
ATTACHMENT.35
mm l.D.
07746- 0030400
Pressthe intermediateshaft into the shaft bearing
usingthe specialtools and a press.
16-20
www.emanualpro.com
lnstallation
Seatthe externalcirclip in the groove of the intermediateshaft.
4.
1.
Press
+
Packthe interior
of the outerseal.
2.0- 3.59 {0.07- 0.12oz)
DRNER
07749- 0010000
INTERMEOIATE
SHAFT
ATTACHMENT,
52x55mm
07746- 0010400
OUTERSEAL
EXTERNAL
CIRCLIP
ATTACHMENT.
40 x 50 mm l.D.
07LAD- PW50601
www.emanualpro.com
shaft
I n s t a l lt h e n e w s e t r i n g i n t h e i n t e r m e d i a t e
groove.
2.
OOWELBOLTS
10x 1.25mm
39 N.m {4.0kgf.m,29 lbtftl
16-21
RearDriveshafts
Removal
Disassembly
NOTE:
a Due to the amount of work requiredto replaceone
damaged boot, it is best to replace both boots at the
sametime.
. Theseinstructionsare for the inboardjoint.The same
procedureappliesto the outboardjoint.
1,
SPINDLENUT
22 x 1.5mm
Replace.
WHEELNUT
1 2x 1 . 5m m
INBOARDJOINT
2.
4.
L i f t u p t h e l o c k i n gt a b o n t h e s p i n d l e n u t . t h e n
removethe nut.
Remove the rear driveshaftsfrom the rear differential assembly(seesection15),
Removethe rear driveshaft outboard joint from the
trailingarm and rear hub usinga plastichammeror
a puller if necessary.
OUTBOARDJOINT
16-22
www.emanualpro.com
TRAILINGARM
DOUSLELOOPBAND
Replace.
3.
RING
DRIVESHAFT
INEOARDBOOT
Inspectfor cracking,
splittingand wear.
M.rks
DRIVE
SHOPTOWEL
Marks
Remove the boot band and boot from the driveshaft. Take care not to damagethe boot.
DRIVESHAFT
0\
tI
Mark
CIRCLIP
Removethe circlip.
Mark the spider and driveshaftto identifythe position of the spideron the shaft.
7.
www.emanualpro.com
16-23
RearDriveshafts
Reassembly
Notetheseitemsduring reassembly:
. Cleanthe disassembledparts with solvent,and dry them thoroughlywith compressedair. Do not wash the rubber
partswith solvent,
o r''..@El:
Thoroughlypackthe inboardjoint and both joint bootswith the joint greaseincludedin the new driveshaft
set.
Greasequantity:
fnboard Joint/Outboard Joint: 80 - 90 g 12.8- 3.2 ozl
SETRING
Replace.
LEFTINBOARDJOINT
(withsmalldriveshaftring)
\@
CIRCLIP
BOOTBANOS
Beplace.
DRIVESHAFT
RINGS
DRIVESHAFT
RIGHTINBOARDJOINT
(withlargedriveshaftring)
Packcavity with grease.
BOOTBANOS
Replace.
ROLI.ER
.6{
16-24
www.emanualpro.com
OUTBOARDJOINT
6.
ROLLER
VINYLTAPE
7.
lnstalla new circlip into the end g.oove on the driveshaft. Rotatethe circlip in its groove to make sure its
fullv seated.
(cont'd)
www.emanualpro.com
16-25
RearDriveshafts
(cont'd)
Reassembly
8.
9.
10. Set the double loop band onto the boot with the
bandend towardthe front of the vehicle,
12. M a k ea m a r ko n t h e b a n d 1 0 - 1 4 m m ( 0 . 4- 0 . 6 i n )
from the clip.
CLIP
16-26
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BOOTBANDTOOL
(KD-3191
or equivalent)
16. Unwind the boot band tool, and cut off the excess
free end of the band to leavea 5 - 10 mm (0.2- 0.4
in) tail protrudingfrom the clip.
5-10mm
(0.2- 0.4in)
Markon band.
WINDING
MANDREL
HAMMER
(cont'd)
www.emanualpro.com
16-27
RearDriveshafts
(cont'd)
Reassembly
lnstallation
'1. lnstall
the outboardjoint into the trailingarm.
SETRING
Replace.
ICI
SET RINGGROOVE
SPINDLE
NUT22 x 1.5mm
181 N.m (18.5kgf.m, 134lbl.ftl Replace.
16-2A
www.emanualpro.com
PropellerShaft
Inspection
UnivarsalJoint and Boots
PropellorShaft Runout
1.
6.
2.
7.
3.
No.1 PROPET_LER
SHAFT
Checkthe universaljoint boots for damageand deterioration.lt the boots are damagedor deteriorated,
replacethe propellershaftassembly.
www.emanualpro.com
16-29
PropellerShaft
RemovaUlnstallation
1,
Removethe propellershaftprotectors.
4,
Removethe centersupportbearingmountingbolts.
No. 1 PROPELLER
SHAFT
SHAFT
PROPELLER
PROTECTOR
FLANGEBOLT
I x 1.25 mm
22 N.m (2.2kg{.m. 16lbl'ft)
SHAFT
No. 2 PROPELLER
FLANGEBOLT
8 x 1.25mm
22 N.m 12.2kgf.m, 16lbf.ft)
SELF-LOCK|NG
BOLT
10x 1.25mm
39N'm14.0kg{.rn,29lbtftl
Replace.
PNOPELLER
SHAFT
PROTECTOR
2.
uErrrEnDurrr.r'rI I'EAnrNu
No.2 PROPELLER
SHAFT
12.POINTBOLT
8 x 1.25mm
32 N.m 13.3kst m, 24 lbtftl
12.POINTBOLT
8 x 1.25mm
32 N.m 13.3kgt'm, 2,1lbf.ft)
7.
REARDIFFERENTIAL
16-30
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TRANSFER
ASSEMBLY
Steering
SpecialToofs
.............
17-2 *SteeringColumn
ComponentLocations
Removal/lnstallation
................
.......17-2O
Index................
.......17-3
lnspection
..............
17-21
Troubleshooting
SteeringLock Replacement............
17-22
GeneralTroubleshooting................
17-4
Power Steering Hoses,Lines
Noiseand Vibration.........................
17-8
FfuidLeakageInspection.................
17-23
FluidLeaks
.............
17-10
Repfacement
..........17-23
Inspection and Adiustment
Power SteeringPump
SteeringOperation..........................
17-12
Repfacement
..........17-24
Power Assist Check
Disassembly
...........17-25
With VehicleParked....................
17-12
fnspection
..............
17-26
SteeringLinkageand Gearbox .......17-13
Reassembly
............
17-28
Pump Belt
17-14 Power Steering Gearbox
RackGuideAdjustment...................
l7-15
Removal
.................
17-31
FluidRep|acement...................,,.,....
17-15
Disassembly
...........17-34
PumpPressure
Check.................,,...
17-16
Reassembly
............
17-40
*SteeringWheel
Ball Joint Boot Replacement..........17-50
Removal
.................
17-18
Installation
.............
17-51
Disassembly/Reassembly...............
17-18
4'%/b
.......... -r'-7--a/
To avoid rendering the SRS inoperative, which could lead to peFonal iniury or death in the event of a sevore trontal
collision. allSRS servicework must be performod by an authorized Honda dealer.
lmproper service procedurgs, including incorrect removal and installalion of the SRS, could lead to personal iniury
causedby unintontional deployment of th airbags {'97 - 00 models),and seat belt tensioners ('98 - 00 modelsl.
Do not bump the SRS unit. Otherwise, the system may lail in case ot a collision, or the airbags may deploy when the
ignition switch is ON (lll.
SRS electricalwiring harnessesare identitied by yellow colof coding. Ralatedcomponents are located in the steering
column, front console,dashboard,dashboard lower panel, and in the dashboardabove the glove box. Do not use electrical test equipment on these cilcuits,
www.emanualpro.com
Ret. No,
o
o
Tool Numbel
07GAF- PH70100
07HAG- SF10100
07GAG- SD40200or
- SD4O2OA
OTGAG
07JGG 001010A
07MAC- S100200
OTNAD_ SR3O2OA
07NAG SR30900or
07NAG, SR3OgOA
07RAK- 5040110
07RAK- 5040120
07406- 0010001or
07406- 0010004
07725- 0030000
0 7 7 4 6- 0 0 1 0 1 0 0
07749- 0010000
07916- SA50001
07974- SA50200or
07974- SA5050A
07974- SA50800
-@
r
o
@
rol
o
@
@
(}
@
Description
fty
'l
PilotCollar
PistonSealRingGuide
PistonSealRingSizingTool
1
1
11-39
17-44
11-44
BeltTensionGauge
B a l lJ o i n tR e m o v e r , 2 m
3m
CylinderEndSealRemoverAttachment
ValveSealRingSizingTool
1
1
1
1
1 7- 1 4
't]-31
17-37
't7-4'l
P/SJoint Adaptor(Pump)
P/SJoint Adaptor(Hose)
P/SPressureGauge
1
1
1
1 7 - ' t 61, 7
1 7 - 1 61, 7
11-16,17
UniversalHolder
Attachment,32 x 35 mm
Driver
LocknutWrench,40 mm
SleeveSealRingSizingTool
1
1
1
,l
17-26,30
't]-42,43
't1-42,
43
11-15
't]-42
11-42,50
,l-
=tt
,/:\
\J
PageReference
aA)
l:I
o
www.emanualpro.com
17-2
(D
/\L----.--.--------_
(9
ComponentLocations
lndex
Notetheseitemsduringdisassembly:
' lf an intactairbagassemblyhas been removedfrom a scrappedvehicleor has beenfound
defectiveor damagedduring transit,storageor service.it shouldbe deployed(seesection24),
a Beforeremovingthe gearbox,removethe driver.sairbagassemblyand steeringwheel.
. After installingthe gearbox,checkthe wheelalignmentand adjustif necessary.
SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations,precautions,and proceduresanthe
SRs
section(24)beforeperformingrepairsor servrce.
STEERINGWHEEL
Removal,page17,18
Disassembly/Reassembly,
page1?,18
page17-19
Installation,
DRIVER'SAIRBAGASSEMBLY
Removal/lnstallation,
see section24
STEERINGGEARBOX
RackGuideAdjustment,page17-15
Removal,page17-31
page17-34
Disassembly,
page17,40
Reassembly,
page17,51
Installation,
VALVEBODYUNIT
Overhaul,page17-38
STEERINGCOLUMN
page17-20
Removal/lnstallation.
pagel7 21
Inspection,
page17 22
SteeringLockReplacement,
CABLEREEL
Removal/lnstallation,
see section24
tcNrnoNswtTcH
See sction23
STEERINGHOSES,LINES
Replacement.page l7-23
RESERVOIR
page17 15
FluidR6placement.
Fluid Leakagelnspection,page 17-23
END BALLJOINT
BallJointBootReplacement,
page17-50
PumpBeltInspection
and
Adjustment, pag t7-14
PumpPressure
Check,page17-16ot 17-1j
Replacemont,
page17-24
Disassembly,pa96 17,25
Inspection,page 17-26
Reassembly.page17-28
www.emanualpro.com
17-3
Troubleshooting
g
GeneralTroubleshootin
Checkthe followingbeforeyou begin:
. Hasthe suspensionbeenmodifiedin a way that would affectsteering?
. Are tire sizes,tire varietyand air pressurecorrect?
. ls the steeringwheeloriginalequipmentor equivalent?
. ls the power steeringpump belt properlyadjusted?
. ls steeringfluid reservoirfilledto properlevel?
. ls the engineidle speedcorrectand steady?
HardSteering(Checkthe powerassist,see page17-12.lf the forceis over 29 N (3.0kgl 6.6 lbfl, proceedwith this troubleshooting.i
C h e c kt h e p u m p f l u i d p r e s s u r e
(seepage17-16or 17-17).
Measuresteadystate lluid pressure at idle with the pressurecontrol valve and the shut-offvalve (it
so equipped)
fullyopen.
The fluid pressureshould be 1,500
psi)orless.
kPa(15kgf/cm,,213
Abnormalthiid
pressure(Iluid
pressureis too
high)
Normallineand hose
Normal
Faultyvalvebody unit
C h e c kt h e p u m p f l u i d p r e s s u r e
(seepage17-16or l7-17).
Measurepump reliefpressureat
i d l e w i t h t h e p r e s s u r ec o n t r o l
valve and the shut'off valve lil so
equipped)
fullyclosed.
The fluid pressureshould be 6,900
7,800kPa (70- 80 kgflcm,, 1,000
- 1,140psi).
Reliefpressure
too low
Normalreliefpressure
Go to page 17 5
1 7 -4
www.emanualpro.com
Abnormal
Faultypump assembly
Abnormal
Deformed
Not deformed
Faultycylinderlines
Readjust
the rackguide
(seepage17-15)
AdjustmentOK
Normal
Bent
Faultysteeringgearbox
(cont'd)
www.emanualpro.com
17-5
Troubleshooting
(cont'dl
GeneralTroubleshooting
Assist(excessively
lightsteering)at
high speed.
Adjustthe rackguide.
Rackguideis adiustedproperly.
C h e c kt h e b e l t f o r s l i p p a g ea n d
(seepage17-14).
adjustas necessary
A a n d B c y l i n d e rl i n e sa r e n o r
mal, checkwheel alignment(see
section18).
W h e e l a l i g n m e n ti s a b n o r m a l ,
adjustas needed.
Wheelalignmentis normal.
Checkthe steeringwheel operation and power assistcheck(see
page 17-121.
l f t h e m e a s u r e m e n tasr e o u t o f
s p e c i f a c a t i o n as d
, j u s tt h e r a c k
guade.
www.emanualpro.com
Unevenor roughsteering.
Ad,usttherackguide(seepage17-15).
Beltslippingon pulley.
Adjustthe belttension.Replacethe
belt,if necessary(seepage17-14).
ldlespeedlow or erratic.
l f t h e e n g i n es t a l l sw h e n t h e
wheel is turnedwhile the vehicle
is stopped or moving at low
speed,adjustthe idle speed(see
section111.
Steeringwheel kicksback
duringwide turns.
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P u m p b e l t s l i p p i n go n p u l l e y
(pumpstopsmomentarily).
7-7
Troubleshooting
NoiseandVibration
NOTE:Pumpnoisein first 2 - 3 minutesafterstartingin cold weatheris normal.
Humming
Rattleor chattering
lf equippedwith automatictransm i s s i o n ,t h e h u m c o u l d b e t h e
torqueconverteror pump noase.
Feedhose (high-pressure)
touching the frame.
Loosesteeringshaft connector,
tie-rod,or balljoint.
C h e c ka n d t i g h t e n , o r r e p l a c e
parts as necessary,
Columnshaftwobbling.
Roplacethe columnassembly.
Adjust,if necessary.
Rattlingsound and feeling when turning the steeringwheel right and left with th
engineOFFis normal.
Pump noise,though not loud,from the valvebody unit can be heardwhen turning the steeringwheelto full lockin eitherdirection.This is normal.Do not hold
the steeringwheelat full locklor morethan five secondswhen inspecting.
17 -8
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Pumpnoise
Gratingnois
trom pump
Pumpnoise
Raftleor chattering
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17-9
Troubleshooting
FluidLeaks
Checkthe gearboxassemblyfor oil leakscarefully.Oil can leakout ot variouspoints,dependingon locationof the faulty
oil seals/seal
rings.Checkthe followingbeforeremovingthe gearboxfrom the frame.
SteeringGearbox
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17 -1 0
R e p l a c et h e v a l v e b o d y u n i t .
Leakingfrom cylinderlineA or B
(attlarenut).
connections
L e a k i n gc a u s e db y a d a m a g e d
cylinderlineA or B.
Replace
cylinderlineA or B.
B e p l a c et h e h o u s i n g O - r i n g s .
if the housing still leaks, replace
the pump.
is overfilled.
Reservoir
P u l l o f f t h e h o s e a n d d r a i nt h e
reservoirto the properlevel.
PumpoLrtlethose
(high-pressure)
Pumpinlet hose
(low pressure)
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L e a k i n ga t t h e t h r e a d e d f i f t i n g .
Replace
the pump outlethose.
Leakingbecauseof damage,dete'
rioration,
or improperassembly,
Replace
or repairas necessary.
17-1
Inspectionand Adjustment
Steering Operation
PowerAssistCheckwith
VehicleParked
1.
Checkthe power steeringfluid level (see page 1715)and pump belttension(seepage 17-14).
2.
Startthe engine,allow it to idle, and turn the steering wheel from lock-toiockseveraltimes to warm
u p t h ef l u i d .
3.
ROTANONALPLAY
+i r
f::1-t
SPRING
SCALE
(Commercially
available)
17-12
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SteeringLinkageand Gearbox
PINIONSHAFTGROMMET
Inspoctfor damageand deterioration.
STEERINGJOINTS
Checkfor loosejoint bolts.
NE-RODLOCKNUT
CheckIor loose locknut.
BALLJONT AOOT
Inspoctlor damageand deterioration.
Se page 17-50for replacemont.
BOOT
lnspectfor damaganddterioration.
END AAtL JOINT
Inspectfor faulty movement
ano oamag.
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17-13
Inspectionand Adjustment
PumpBelt
When using a new belt.first adjustthe deflectionor tension to the values for the new belt, then readjustthe
deflectionor tensionto the valuesfor the used belt after
runningenginefor five minutes.
Inspection
Deflection:
UsedBelt:11.0- 1i1.5mm {0.'(l - 0.57in)
New Belt: 7.5 - 10.0mm {0.30- 0.39 in)
Notetheseitemsduring inspection:
a lf there are cracksor any damageevidenton the belt,
replaceit with a new one.
. Followthe manufacturer's
instructionslor the tension
gauge.
'1. Remove
the P/Sreservoirfrom the bracket,and set
it aside.
2.
Measurehere.
Tension:
Used Belt:
New Belt:
Adiustment
'1.
L o o s e nt h e p o w e r s t e e r i n gp u m p m o u n t i n g b o l t
and pump lockbolt.
PUMPMOUNNNG
BOLT
24 N'm(2.4kgf'm,17lbfftl
PUMPLOCKBOLT
24N.m12.4kgf.m,17lbf.ftl
PULLEY
CRANKSHAFT
Adjust the belt tensionby moving the power steering pump with a 1/2" drive breakerbar to obtainthe
p r o p e rb e l t t e n s i o n ,t h e n r e t i g h t e nt h e m o u n t i n g
bolt and lockbolt.
Start the engine and turn the steeringwheel from
lock-to-lock
severaltimes,then stop the engineand
recheckthe deflectionof the belt.
17 -1 4
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RackGuide Adjustment
Fluid Replacement
RACKGUIDESCREW
UPPENLEVELLINE
LOWERLEVELLINE
LOCKNUT
25 N.m
12.5kgt m, 18lbtftl
5.
4.
3.
T i g h t e nt h e l o c k n u tw h i l e h o l d i n gt h e r a c k g u i d e
screw.
6.
7.
Performfollowinginspections:
. Steeringoperation(seepage17-12).
. Powerassistwith vehicleparked
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4.
5.
6.
7.
Connecta hose of suitablediameterto the disconnectedreturn hose,and put the hose end in a suitablecontainer.
Stan the engine.let it run at idle,and turn the steering wheel from lock-to-lockseveral times. When
f l u i d s t o p s r u n n i n go u t o f t h e h o s e ,s h u t o f f t h e
engine.Discardthe fluid.
Beinstallthereturnhoseon the reservoar.
Fillthe reservoirto the upperlevelline,
Startthe engineand run it at fast idle.then turn the
severaltimes to bleedair
steeringfrom lock-to-lock
from the system.
Recheckthe fluid leveland add some if necessary.
Do not fill the reservoirbeyondthe upperlevelline.
lnspectionand Adjustment
PumpPressureGheckWith T/N 07406- 0010001
Checkthe fluid pressureas follows to determinewhether
the troubleis in the pump orgearbox.
1.
2.
6 x 1.0mm BOLT
{Partoftool)
FEEDHOSEFITTING
PUMPOUTLETHOSE
6. Fullyopenthe pressurecontrolvatve.
7. Startthe engineand let it idle.
8. Turn the steeringwheel from lock-to-lockseveral
times to warm the fluid to operating temperature.
9, Measuresteady-statefluid pressurewhile the engine
is idling. lf the pump is in good condition,the gauge
should read lessthan 1,500kPa(15 kgf/cmr,213 psi).
lf it reads high, checkthe outlet hose or valve bodv
unit (seeGeneralTroubleshooting).
10. Close the pressure control valve, then close the
shut-off valve gradually until the pressuregauge
nsedle is stable.Readthe pressure.
CAUTION: Do not kap tha prca3un control valvo
clorod mo.c thon 5 srconds or thc pump cluld bo
damEgodby ovor-hoating.
Connectthe P/Sjoint adapter (hose)to the p/S pressure gauge,then connectthe pump outlet hose to
the P/Sioint adspter(hose).
I n s t a l l t h e P / S p r e s s u r eg a u g e t o t h e p / S j o i n t
adapter(pump),
17-1 6
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Checkthe power steeringtluid level (see page 17151,and pump belttension(seepage 17-14).
2.
PRESSURE
CONTROLVALVE
6 x 1.0mm BOLT
(Partoftool)
FEEDHOSEHfNNG
PUMPOUTLETHOSE
1 0 . lmmediatelyopenthe pressurecontrolvalvefully.
Connectthe P/Sjoint adapter (hose)to the P/S pressure gauge,then connectthe outlet hoseto the P/S
joint adapter(hose).
I n s t a l l t h e P / S p r e s s u r eg a u g e t o t h e P / S j o i n t
adapter(pumpl.
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17-17
SteeringWheel
Removal
SRS componentsare located in this area. Reviewthe
SRScomponentlocations,precautions,and procedures
in the SRSsection(24)beforeperformingrepairsor service.
1.
2.
3.
CONTROL
SWITCHESCONNECTOR
STEERINGWHEELEOLT
Disassembly/Reassembly
STEERINGWHEEL
EOSSCOVERPLATE
WHEELBODYCOVER
_^M
@,
"\
BODY
COVERCAP
ACCESSPANEL
17- 1 8
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lnstallation
1.
2.
CABLEREEL
ARROWMARK
HOLE
Installthe steeringwheel bolt, and tighten it to 39
N.m (4.0 kgf.m, 29 lbf.ft).
Connectthe horn connectorand the cruisecontrol
switchconnectors,
Installthe driver's airbag assembly,and confirm
propersystemoperation(seesection24).
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17-19
SteeringColumn
Removal/lnstallation
SRS componentsare located in this area. Review the
SRScomponentlocations,precautions,and procedures
in the SRSsection(24)beforeperformingrepairsor service.
1.
Removethe columncovers.
With A"/T,move the shift lever to the E position,
and removethe shift cable from the column. and
set it aside(seesection14).
Remove the combinationswitchassemblyfrom the
steeringcolumn shaft by disconnecting
the connectors, and removing the two screws.
FULLSTROKE:
23 mm 10.9in)
MAXIMUMUPPER
POSTTTON
8 mm (5/16)
7.
MAXIMUM LOWER
POSTTTON
R e m o v et h e s t e e r i n g c o l u m n b y r e m o v i n g t h e
attachingnuts and bolts.
TILT LEVER
SHAFTCENTER
1 1 1m m
1 0 0m m
JOINT COVER
5mm
UPPER
COLUMNCOVER
COMAINANONSWITCHASSEMBLY
BOOTBAND
JOINT
COLUMNBMCKET
LOWERATTACHINGBOLTS
39 N.m lir,o kgf.m, 29 lbf.ft)
UPPERATTACHINGNUTS
16 N.m lr.6 kgf.m, 12 lbf.ftl
17-20
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LOWERCOLUMNCOVER
8.
SIEERING JOIMT
UPPERJOINT BOLT
Bolt must IineuP
with fl6t on shaft.
Flatponion.
JOINT
STECRING
LOWER
JOINTBOLT
Boltmustlineupwith
groovearoundon shaft,
Inspection
Checkthe steeringcolumn ball bearingand the steering joint bearingsfor play and proper movement.lf
there is noisyor if there is excessiveplay,replacethe
steeringcolumn as an assemblY
Checkthe retainingcollar for damage.lf it is damaged,replacethe retainingcollar.
PLASl'tC
INJECTIONS
ABSOBBING
PLATE
FETAININGCOLLAR
SHIFT I.EVER
Seesection 14.
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ABSORBING
PLATEGUIDE
|GNMON SWTTCH
See section23.
(cont'd)
17-21
SteeringColumn
Inspection(cont'dl
SteeringLockReplacement
b , R e m o v et h e 6 m m l o c k b o l t . a n d r e m o v e t h e
stop. Be carefulnot to loosenthe tilt leverwhen
installingthe stop or tighteningthe 6 mm lock
bolt.
NLT LOCKBOLT
Tighten the lock bolt with
the tilt leverraised.
SPRINGSCALE
SHEARBOLT
Replace.
L-_
6 mm LOCKBOLT
7 N.m(0,7kgf.m,S tbtftl
Adjustthe preloadby turningthe tilt lockbolt left
or ri9ht.
I n s e r t t h e i g n i t i o n k e y t o t h e n e w s t e e r i n gl o c k
body,and turn it to "1".
7 . Push the lock pin down, and insen the steering lock
body into the steeringcolumn until it clicksinto place.
8 . Looselyinstallthenew shearbolt.
SHEARBOLT
1 7- 2 2
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PowerSteeringHoses,Lines
Fluid LeakageInspection
HOSESand LINES
. lnspecthosesfor damage.leaks.interferenceand twisting
. Inspectfluid linesfor damage,rustingand leakage.
. Checkfor leaksat hoseand line joints and connections.
FEEDHOSE
37N.m13.8kgf.m,27lbtft)
RETURNLINEJOINT
28 N.m (2.9kgf.m.21 lbf.ftl
CYLINDERLINES
17 N.m (1.7kgf.m. 12 lbf.ftl
FOWERSTEERINGPRESSURE
SWITCH
12 N.m (1.2kgf.m,8.7 lbtft)
GEARBOX.nd VALVEBODYUNll
Checkfor leaksat the mating surface
and flare nut connections.
CYLINDER
26 N.m (2.7 kgf.m, 20 lbf.ft)
FEEDHOSE
11 N.m
('1.1kgt.m, 8 lbf.ftl
SUCTIONHOSE
PUMPASSEMBLY
Checkfor leaksatthe pump
seal.inletand outletfittings.
Replacement
Notetheseitemsduring installation:
. Connecteachhoseto the correspondingline securely
until it contactsthe stop on the line. Installthe clamp
or adjustableclampat the specifieddistancefrom the
hoseend as shown.
. Checkall clamDsfor deteriorationor deformation;
replacewith the clampsnew onesif necessary.
. Add the recommendedpower steering fluid to the
specifiedlevelon the reservoirand checkfor leaks.
ADJUSTABLEHOSECLAMP:la)
. P o s i t i o nt h e a d j u s t a b l eh o s e c l a m p s a t t h e p o i n t s
indicatedby (a) in the drawingabove.
. Slidethe hoseoverthe line until it contactsthe stop.
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2.0 - 4.0 mm
- 0.16inl
10.08
HOSECLAMP:lbl
. Positionthe hose clamps at the points indicatsdby
(b) in the drawingabove.
. Slidethe hoseoverthe line until it contactsthe stop,
2.5- 5.5mm
{0.01- 0.22 in}
17 -23
PowerSteeringPump
Replacement
1.
PUMPMOUNNNG
BOI.T
24 N.m12.4kgtm, 17lbl.ftl
FOWERSTEER G EELT
PUTrlY
't7-151..
PUMPLOCKBOLT
24 N.m(2.4kg{.m,1, tbfttl
Cover the IVC compressorwith several shop towels
to protectit from spilledpowersteeringfluid.
Disconnectthe pump inlet hose and pump outlet
hose from the pump, and plug them. Takecare not
to spill the lluid on the body or parts.Wipe off any
spilledfluid at once.
R e m o v et h e p u m p m o u n t i n gb o l t a n d p u m p l o c k
bolt, then removethe pump. Do not turn the steering wheelwith the pump removed.
Coverthe openingof the pump with a pieceof tape
to preventforeignmaterialfromenteringthe pump.
17-24
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Disassembly
Notetheseitemsduringdisassembly:
. The powersteeringcomponentsare madeof aluminum,Avoid damagingthe componentsduringassembly.
partswith a solvent,and dry them with compressedair. Do not dip the rubber parts in a sol. Cleanthe disassembled
vent.
. Always replacethe O-ringsand rubbersealswith new ones beforeassembly.
. Apply recommendedpower steeringfluid to the partsindicatedin the assemblyprocedures.
. Do not allow dust,dirt, or otherforeignmaterialsto enterthe power steeringsystem.
. Replacethe pump as an assemblyifthe partsindicatedwith asterisk(*)areworn ordamaged.
FLANGEBOLTS
20 N.m 12.0kgt'm,
1a tbf,ft)
.PUMP COVER
ROLLER
PUMPCOVERSEAL
*OUTERSIDEPLATE
.PUMP CAM RING
*PUMPHOUSING
5l x 2.4 mm O-RING
Repiace.
PULI.-EY
NUT
fl N.m (6.5kgf.m,
/r7 lbf.ftl
(cont'd)
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17 -25
PowerSteeringPump
Disassembly(cont'dl
1 . Drainthe fluid from the pump.
Inspection
Flow Control Valve
1.
UNIVERSAL
HOLDER
07725- 0030000
Checkfor
damageto edges.
'98 - 0Omodls:
FLOWCONTBOL
VALVE
Checkfor damage
to edges.
L o o s e nt h e f l o w c o n t r o l v a l v e c a p w i t h a h e x
wrench,and removeit.
CONTROLVALVE
17-26
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HOSE
5.
Submergethe valve in a containerof power steering fluid or solvent,and blow in the hose.lf air bubbles leakthroughthe valve at lessthan 98 kPa
(1.0kgflcm' ,14.2psi),repairit as follows('97model).
For'98 - 00 models,the flow control valve cannot
replacethe pump as an assembly
be disassembled;
Ball Bearing:
'1. Inspectthe ball bearingby rotatingthe outer race
slowly. lf any play or roughnessis felt, replacethe
b a l lb e a r i n g .
AIR PRESSURE
BALLEEARING
POWERSTEENING
FLUIDor SOLVENT
6.
2.
RELIEF ALVE
RELIEFCHECKBALL
{w@r
Remove
lnstall
Press
I
Press
SEAT
9 N.m
(0.9kgf.m, 6.5 lbfft)
RELIEFVALVE
SPRING
Hold this end with
a open eno wrencn.
7.
FLOWCONTBOLVALVE
C l e a na l l t h e p a r t s i n s o l v e n t ,d r y t h e m o t f , t h e n
reassembleand retestthe valve.
T h e r e l i e f p r e s s u r ei s a d j u s t e da t t h e f a c t o r y b y
addingshims underthe checkball seat lf you found
shims in your valve,be sure you reinstallas many
as you took out.
8,
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lnstallwith the
r e d s h a e l d e ds i d e
facing down.
NOTErSuPPortthe innerrace
with the tool securelY-
17-27
PowerSteeringPump
Reassembly
'1.
5.
OIL PASSAG
Alignthe pin of
ROLLERSET HOLES
OUTERSIDEPLATE
#q
;1..*
5 mrh ROLLER
PUMPHOUSING
SNAP RING
Installthe new pump seal(with its groovedside facing in) into the pump housingby hand,then install
the pump sealspacer.
PUMPCOVER
H
go
29 mm SOCKET
,O mm CIRCLIP
un.t SHAFT
BALLBEARfNG /=\ PUMPDRIVE
grlu,e
1 /\
t\v4
t/\ Y
ry^\i- d
#
ROLLERSET HOLES
/ffi\
PUMP
SEALSPAC,ER
@.--#$i":*'
ROLLERS
PUMPHOUSING
4,
17 -2A
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7.
Set the pump cam ring over the two rollerswith the
"' " markon the cam ring upward.
12. Coatthe O-ringwith power steeringfluid, and position it into the pump housing.
FLANGEBOI-TS
20 N.m (2.0kgt m,
14 tbf.ft)
PUMPROTOR
51 x 2.4 mm O-RING
Replace.
1 0 . C o a t t h e O - r i n g w i t h p o w e r s t e e r i n gf l u i d , a n d
installit into the groovesin the side plate.
Eg
SPRING
SII'E PLATE
Gfooves.
SETHOTT
FLOW CONTBOL
VALVE
l'98 - 0Omodeltl
FLOW CONTROL
VALVE CAP
49 N.m (5.0kgl.m,
36 tbf.ft)
BOLI-ERS
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17-29
PowerSteeringPump
Reassembly(cont'dl
'18.
C o a t t h e O - r i n g w j t h p o w e r s t e e r i n gf l u i d , a n d
installit into the groovesin the inletjoint.
FLANGEBOLTS
11 N.m 11.1kgf.m,
8 rbf.ft)
'13x '1.9
Replace.
r
17-30
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PowerSteeringGearbox
Removal
Notetheseitemsduring removal:
. Using solventand a brush,wash any oil and dirt off
the valve body unit its lines,and the end if the gearbox. Blow dry with compressedair.
. Be sure to removethe steeringwheel beforedisconnectingthe steeringjoint. Damageto the cable reel
can occur.
. With 4WD.tilt the enginewith a jack to expandthe
clearancebetween the transfer assembly and rear
beam when removingthe steeringgearboxfrom the
rearoeam.
Do not removethe steeringgearboxby removingthe
transferassemblyfrom the transmission.
1.
COTTER
PIN
Replace.
Installthe 10 mm hex nut on the ball joint. Be sure
that the 10 mm hex nut is flush with the ball joint
pin end, or the threadedsectionof the ball joint pin
might be damagedby the specialtool. Referto section 18 for ball joint removerusageinstruction,Be
carefulnot to damagingthe ball joint boot.
UPPERJOINT BOLT
LOWERJOINT BOLT
(cont'd)
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17-31
PowerSteeringGearbox
Removal(cont'dl
1 4 . L o o s e nt h e 1 4 m m f l a r e nut, and disconnectthe
pump outlethose.
AN'USTABLEHOSECLAMP
4WD:Stepr 18-22
18. Removetherighttront mount,then applyvinyl tape
to the sideframe to protectit from the transmission
coverand stop bolt.
12 x 1.25 fiiA
Replace.
x 1,25mm
RIGHTFRONTMOUNT
NUT
14mm FLARE
15. Loosenthe adjustablehose clamp and disconnect
the returnhose,
SIDEFRAME
Vinyltapeor
equivalgntmaterial.
'19. Remove the left front mount, then apply vinyl tape
to the side frame to protect it from the stop bolt.
10x 1.25mm
Vinyltapor
equivalntm6terial.
STOPBOLT
17 -32
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approximately
.Lower
'40 mm (1.57in)
REARMOUNT BRACKET
12 x 1.25mm
Replace.
14x 1.5mm
Replaco.
ASSEMBLY
2 1 . P l a c ea j a c k u n d e r t h e e n g i n e b l o c k i n t h e a r e a
shown,
Removethe stiffenerolate.
NOTE:Somestiffenerplatemountingbolts a.e also
used as gearboxmounting bolts.The gearboxwill
tilt to the sidewhen theseboltsare removed.
STIFFENER
PLATE
?*
JACK.UPPOINT
(cont'd)
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17-33
PowerSteeringGearbox
Removal(cont'dl
Disassembly
Steering RackDisassembly
Notetheseitemswhen disassembling:
. Beforedisassemblingthe gearbox,wash it off with
solventand a brush.
. Do not dip sealsand O-ringsin solvent.
1.
2.
MOUNTINGBRACKETS
AIR TUBE
4.
STEEBINGGEARBOX
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17 -3 4
5.
Hold the steeringrackwith a wrench {'98- 00 models: left end onlv), and unscrewthe rack end with
anotherwrench,Be carefulnot to damagethe rack
surfacewith the wrench,
LOCKWASHER
LINEA
CYLINDER
9 . Drain the fluid from the cylinderfittings by slowly
movingthe steeringrackbackand {orth.
6.
L o o s e nt h e l o c k n u t ,t h e n r e m o v et h e r a c k g u i d e
screwand O-ring('97model).
RACKGUIDE
FLANGEBOLT
LOCKNUT
1.
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17-35
PowerSteeringGearbox
Disassembly{cont'd}
12. Drill a 3 mm (0.12in) diameterhole approximately
2.5 - 3.0 mm (0.10- 0.12in) in depth in the staked
point on the cylinder.Do not allow metal shavings
to enter the cylinder housing.After removing the
cylinderend, removeany burrsat the stakedpoint.
- 0.12inl
D.oth: 2.5- 3.0mm 10.10
CYUNOER
'12
14, Assemblea 12 x 1.25mm flangenut onto a
x 175
mm grade 10 flangebolt as shown,Wrap the flange
portion of the bolt with vinyl tape to protect the
cvlinder,
12mmFLANGENUT
VINYLTAP tp/N90177- SLO- OOOI
1 5 . Installthe flange bolt into the end of the steering
r a c k u n t i l i t b o t t o m s i n t h e h o l e .t h e n b a c kt h e
flange bolt out 1/4 turn. Hold the flange bolt, and
tightenthe flangenut againstthe rackby hand.
Installthe bearingseparatoron the gearbox housing
as snown.
BEARINGSEPARATOR
0- 1112'
(Commercially
available)
STEERINGRACK
CYLINDERND
17-36
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22. Carelully pry the piston sesl ring and O-ring off the
piston rack.Be carefulnot to damagethe insideof
seal ring groove and piston edgeswhen removing
the sealring.
Replace.
II
CI
20. lnsert a 24" long,3/8" drive extension and the special tool into the cvlinderfrom the left side. Make
sure that the specialtool is securelypositionedon
the backup ring edges. Be careful not damage to
innersurfaceof the cylinderwith the specialtool.
Replaco.
Prass
24 'LONG 3/8' DRIVEEXTENSION
(Commerciallv
available)
BACKUPRING
CYLINDEREND SEAL
CYLINDERENDSEAL
REMOVERATTACHMENT
07NAD- SR3020A
2 1 . Set the gearboxin a press,then pressout the cylinder end sealand backupring from the gearbox.
Note these items when pressingthe cylinder end
seat:
. K e e pt h e t o o l s t r a i g h tt o a v o i d d a m a g i n gt h e
cylinderwall.Checkthe tool angle,and correctit if
necessary,
when removingthe cylinderend seal.
. Use a pressto removethe cylinderend seal.Do
not try to removethe seal by strikingthe tool. lt
will breakthe backupring, and the cylinderend
sealwill remainin the gearbox.
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(cont'dl
17-37
PowerSteeringGearbox
Disassembly(cont'd)
Valve Body Unit Dbassembly
23. Beforeremovingthe valvehousing,applyvinyltape
to solinesof the Dinionshaft.
VALVEHOUSING
2 6 . C h e c kf o r w e a r , b u r r s a n d o t h e r d a m a g et o t h e
edgesof the groovesin the sleeve.
NOTE:The pinion shaft and sleeveare a precision
m a t c h e ds e t . l f e i t h e r t h e o i n i o n s h a f t o r s l e e v e
must be replaced,replaceboth partsas a set.
SLEEVESEALRINGS
Checkfor Deeloff or
17-38
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SLEEVE
3 0 . R e m o v et h e v a l v e o i l s e a l a n d b a c k u pr i n g ( ' 9 7
model)or wave washer ('98 - 00 models)from the
pinionshaft.
Notetheseitemsduringdisassembly:
. Inspectthe ball bearingby rotatingthe outer race
slowly. lf there is any excessiveplay, replacethe
pinionshaftand sleeveas an assembly.
. The pinion shaft and sleeveare a precisefit; do
n o t i n t e r m i xo l d a n d n e w D i n i o ns h a f t sa n d
sreeves,
BALLBEARING
WAVE WASHER
l'98 - 0Omodelsl
PINION SHAFT
BACKUPRING
{'97 modell
VALVEOIL SEAL
Replace.
3 1 . Pressthe valveoil sealand roller bearingout of the
valve housing using a hydraulicpress and special
tool shown below.
Cuftingslot position.
PILOTCOLLAR
ROLLERSEARING
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PowerSteeringGearbox
Reassembly
Notetheseitemsduring reassembly
. Cleanthe disassembled
partswith a solvent,and dry them with compressedair. Do not dip the rubberparts in a solvent.
. Always replacethe O-ringsand rubbersealswith new ones beforeassembly.
. Apply the recommendedpowersteeringfluid to the partsindicatedin the assemblyprocedures.
. Do not allow dust.dirt, or othertoreignmaterialsto enterthe power steeringsystem.
. Usethe appropriatespecialtoolswhere necessary.
FLANGE
BOLTS
20N.m(2.0kgl.m,14lbtftl
CYLINDERLINE A
FLARENUTS
17 N.m 11.7
12 rbl.ftl
VALVEHOUSING
VALVEOIL SEAL
Beplace.
ROLLERBEARING
CYLINDEREND SEAL
Replace.
CIRCLIP
Replace.
BA.KUP RING
BACKUPRING
Replace.
97 model:
WAVEWASHER
HOUSING
VALVESEALRING
Replace.
\/^"
O.RING
Replace.
32 mm SHIMS
'97 mod6l only:
RACKGUIDESCREW
@---r-ocxr'rur
'97 model:
O-RING
Replace.
'9? model only:
END
CYLINDER
69 N.m (7.0 kgf.m, 51 lbf.ft)
PISTONSEALRING
Replace.
www.emanualpro.com
17-40
STEERINGRACK
'98 model:
'99 - 0Omod6ls:
Apply vinyl tape to the steppedportion of the pinion shaft,and coat the surfaceof the vinyl tape with
the power steeringfluid.
VALVEOIL SEAL
Vinyl tape
(Stopp6d portion)
Replace.
Makesurethe springis
seatedin the oil seal.
Serling
E
PINIONSHAFT
BACKUPRING
137 modell
\ /
WAVEWASHER
{'98- 00modelsl
Installthe backupring {'97 model)or wave washer
('98- 00 models).
Coat the inside surface of the new valve oil seal
with powersteeringfluid.
Installthe valveoil sealwith its groovedside facing
oppositethe bearing,then slide the valve oil seal
over the pinion shaft, being carefulnot to damage
t h e s e a l i n gl i p .
Apply vinyl tape to the splinesand steppedponion
of the shaft, and coat the surfaceof the vinyl tape
with the power steeringfluid.
PINIONSHAFT
tffifrE-r
r.] r\-''] 7
Vinyl trp
12. Turn the specialtool over,and set the smallerdiameter end of the specisltool over the valveseal ring.
Move the specialtool up and down severaltimes to
m a k et h e v a l v e s e a l r i n g f i t s n u g l yi n t h e p i n i o n
shaft.
O.RING
Replace.
Do not twist.
www.emanualpro.com
(cont'd)
17-41
PowerSteeringGearbox
(cont'd)
Reassembly
1 3 . Apply power steeringfluid to the surfaceof the specialtool. Set the new sealrings overthe specialtool
f r o m t h e s m a l l e r d i a m e t e re n d o f t h e t o o l . a n d
e x p a n dt h e s e a l r i n g s .I n s t a l lt w o r i n g s a t a t i m e
Jromeachend ofthe sleeve.
18. Apply power steeringfluid to the surfaceof the pinion shaft.Assemblethe sleeveover the Dinionshaft
b y a l i g n i n gt h e l o c a t i n gp i n o n t h e i n s i d eo f t h e
sleevewith the cutout in the shaft.Then installthe
new circlipsecurelyin the pinionshaftgroove.
Notetheseitemsduring reassembly:
. B e c a r e t u l n o t t o d a m a g et h e v a l v e s e a l r i n g
when insertingthe sleeve.
. Installthe circlipwith its radiusedsidefacingout.
CIRCLIP
ATTACHMENT,
32x35mm
077i16- (x)10100
SLEEVESEALRING
SIZINGTOOL
07974- SA502O0or
07974- SA5020A
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VALVEOIL SEAL
Replace.
Makesurethe
springis in the
oilseal.
2 4 . P r e s st h e p i n i o n s h a f t / s l e e v eu s i n g a h y d r a u l i c
p r e s s . C h e c kt h a t t h e p i n i o n s h a f t / s l e e v et u r n s
smoothlyby turningthe pinionshaft,
DRIVER
ATTACHMENT,
32x35mm
07746- 0010100
ROLLERBEARING
Letterstampedface
21. Apply vinyl tape to the pinion shaft, then coat the
vinyltape with powersteeringfluid.
Sealinglip tace.
VALVEOIL SEAL
VALVEHOUSING
PINIONSHAFT
E
SLEEVESEAL
8e surethat the
sealringsare not
turnedup,then
install.
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17-43
PowerSteeringGearbox
(cont'dl
Reassembly
Stecring RackR8assembly
25. Coatthe pistonseal ring guide with power steering
fluid,then slideit onto the rack,big end first.
PISTON
24. Coatthe pistonseal ring and the insideof the specialtool with power steeringfluid.
PISTON
Replace
E
07GAG- SO4O200
or
- SD'()2OA
OTGAG
Carefullyslide the tool onto the rack and over the
pistonsealring.
30. Move the specialtool backand fonh severaltimes
to makethe pistonseal ring fit snugly in the piston.
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17-44
12 x'175 mm FLANGEBOLT
lP/N 90177- SLo- 0001
12 mm FLANGENUT
to.
GEARBOXHOUSING
CYLINDERENDSEAL
Replace.
R e m o v et h e f l a n g e b o l t , a n d c e n t e rt h e s t e e r i n g
rack.
40. W r a p v i n y l t a p e a r o u n dt h e r a c k e n d e d g e s ,a n d
coatthe surfaceof the tape with the power steering
fluid. Makesurethat the vinyl tape is wrappedcarefully so that there is no steppedportion.
(cont'dl
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17-45
PowerSteeringGearbox
(cont'dl
Reassembly
4l. Coatthe insidesurfaceof the new cvlinderend seal
with powersteeringfluid.
CYLINDEBENOSEAL
Replace.
Makesurethe spring
is in the cylinderend seal.
Staked
posrtron.
4.0mm {0.16in)
Groovedside.
43. P u s h i n t h e c y l i n d e r e n d s e a l w i t h y o u r f i n g e r .
When installingthe cylinderend seal,be carefulnot
damagethe sealingfaceof the sealwith the threads
a n d b u r r s a t t h e s t a k e dp o s i t i o n o f t h e c y l i n d e r
housing.
44. Removethe vinyl tape from the steeringrack,then
removeany residuefrom the tape adhesive.
45. Holdthe gearboxusinga C-clampas shown.
C.CLAMP
GEARBOX
BUSHING
CYLINDEREND
69 N.m (7.0kgf.m,51 lbtft)
-tG
8e carefulnot to damage
the bushingwhen inserting
the cylinderend.
17-46
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5 0 . I n s t a l lt h e v a l v e b o d y u n i t o n t h e g e a r b o x .a n d
tightenthe flangeboltsto the specifiedtorque.
VALVEBODY
FLANGE
BOLT
20 N.m12.0kgt.m,14lbtft)
Example:
Measurementis 0.28mm (0.011in);
0 . 7 0 - 0 . 2 8 = 0 . 4 2m m ( 0 . 0 2 8 - 0 . 0 1=1 0 . 0 1 7i n )
T h e s e l e c t e ds h i m s s h o u l db e 0 , 2 5m m ( 0 . 0 1 0i n l a n d
0.15mm (0.006in) in thickness.
lf the required shim thicknessis 0.10 mm or less, no
shrmsare necessary.
53. Set the selected32 mm shims on the bearingsurfaceof the gearboxhousing.
SHIM SET
(fourshims)
VALVEBODYUNIT
FLANGEBOLT
20 N.m (2.0 kgf.m, la lbl.frl
a)
E?
ct.
O.RING
Replace.
-6{
GAUGE
NEEDLEBEARING
-6lr
54. Coatthe new O-ringwith grease,and carefullyfit it
on the valvehousing.
Apply greaseto the needlebearingin the gearbox
housing.
D e t e r m i n et h e r e q u i r e dt h i c k n e s so f t h e 3 2 m m
shims by subtractingthe clearanceobtainedin the
step "c" from the total thicknessof the four shims.
( T o t a lt h i c k n e s so f t h e 4 s h i m s ) - ( C l e a r a n c e=)
Reouiredthicknessof the shims
(cont'd)
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17-47
PowerSteeringGearbox
(cont'dl
Reassembly
6 3 . I n s t a l lt h e n e w l o c k w a s h e ri n t h e g r o o v e i n t h e
steering rack.
LOCKWASHER
Replace.
STEERINGRACKENO
54 N.m (5.5kgf.m,40 lbtftl
17 N.m 11.7kgd.m,12lbf.ttl
STEERING
CYLINDEF
LINEA
Greasethe sliding surface of the rack guide, and
installit onto the gear housing.
Hold the steering rack with a wrench ('98 - 00 models: left end only), and tighten the rack ends. Be
careful not to damage the rack surface with the
wrench.
After tighteningthe rack ends, stakethe four sections of lockwasherwitha drift and a mallet.
.
.
.
-6r
O-RING
17-48
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STEERINGRACK
WOODENBLOCK
RIGHTBOOT
(Viewedtrom the
rightside)
ro
''rT.a'.
Front
, tri"
\,'tAr-
{,1@}tr
)Fr1
RACKENDGROOVE
.={@
GREASE
SILICONE
68. A p p l y a l i g h t c o a t o f s i l i c o n eg r e a s et o t h e b o o t
grooveson the rackends.
69. lnstall the boots in the rack end with the tie-rod
clips.
NOTE:Installthe bootswith the rackin the straight
ahead position (right and left tie-rodsare equal in
length).
RACK ENO
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17-49
PowerSteeringGearbox
Reassembly(cont'd)
7 4 . C o n n e c tt h e a i r t u b e b e t w e e nt h e r i g h t a n d l e f t
boot,
CYLINDER
LINEA
sEclroN
Wipe off the grease.
BOOT INSTALLATION
SECTION
Wipe offthe grease.
DUSTCOVER
Vinyl Tsp
VALVEOIL SEAL
VALVEBODYUNIT
ADJUSTINGBOLT
Adiustthe depth
by turningthe bolt.
77. P a c kt h e i n t e r i o r o f t h e d u s t c o v e r a n d l i o w i t h
grease,then installdustcoveron the valvebodv unit.
Removethe vinyl tapef.om the pinionshaft.
17-50
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SET RING
lnstallation
1.
2.
3.
5.
I n s t a l lt h e s t i f f e n e rp l a t e w i t h t h e t w o g e a r b o x
mounting bolts and stiffenerplate attachingbolts.
Be sure the air tube is not caught or pinched by
stiffener plate. Installthe bolts loosely first. then
tightenthem securely.
NOTE:With 2WDcontinueto step 11.
PLATE
STIFFENER
MOUNTINGBOLTS
38 N.m
:/
STEERINGGEARBOX
I n s t a l lt h e m o u n t i n g b r a c k e to v e r t h e m o u n t i n g
c u s h i o n .t h e n i n s t a l lt h e t w o g e a r b o xm o u n t i n g
b o l t s .P o s i t i o nt h e s p l i t p o r t i o no f t h e m o u n t i n g
cushionas shown.
MOUNTINGBBACKETS
1.
l n s t a l lt h e r e a r m o u n t a n d r e a r m o u n t b r a c k e t .
Tightenthe mountingbolts in order:A, B and C.
8.12 x 1,25mm
59 N.m
(6.0 kgt.m. *l lb{'ftl
Replace.
10 x 1.25mm
6,aN.m
16.5kst.m, 47 lbl'ft)
Rplace.
) \ ^
o
GEARBOXMOUNTING
BOLTS
39 N.m
14.0kgf.m, 29 lbf.ft)
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17-51
PowerSteeringGearbox
Installation(cont'd)
8,
LEFTFRONTMOUNT
B-12x 1,25mm
59Nm
(6.0 kgtm,, lbl.ftl
Replaca.
AD.'USTAB[THOSECLAMP
(Forinstallation
reterto page 17,23)
RETURNHOSEJOINT:
16 mm FLARENUT
28 N.m
12.9kg{.m.21 lbt{t)
A-10x 1.25mm
4,1N.m
la.s kgt m, 33 lbf.ft)
9.
B-12x 1.25mm
59 N.m
16.0ks[.m, ,|:| lbf.ftl
Replace.
14 mm FLARENUT
37 N.m
(3.8 ksf.m, 27 lbl'frl
A-10x 1.25mm
a,aN.m
17-52
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HEXNUT
l'g!t - 00 modeb)
il:l N.m
JOINT
STEERING
CAST1TNUT
(9t - 98
modol!)
39 - iU N'm
lil.o - 4.8 kgl.m,
29 - 35 tbf.ftl
14.4ksl.m,
32 tbf.f0
'99 - lD modeb:
COLUMN
SHAFT
UPPERJOINT BOLT
Bolt must line up
with tlat on shatt.
LOWERJOINT BOLT
Bolt must lineup with
groove around on shaft.
PINION
SHAFT
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PIN
COTTER
RePlace.
bend
on reassembly,
thecotterPinasshown.
LOWERJOINTBOLT
22 N.m
12.2kgf.m,16lbtftl
.
.
S t a r t t h e e n g i n e ,a l l o w i t t o i d l e , a n d t u r n t h e
steering wheel from lock-to-lockseveraltimes to
warm up the fluid. Checkthe gearboxfor leaks
(seepage17-23).
Adjustthe front toe (sesection18).
Checkthe steeringwheel spokeangl.Adjust by
turning the right and left tie-rodsequally,if necessary.
17-53
Suspension
.............
18-2
SpecialTools
ComponentLocations
......18-3
lndex ................
WheelAlignment
18-4
Servicelnformation......................,..
..................
18-4
Camber
......18-5
Caster...............
Front Toe Inspection/
........18-5
Adiustment
RearToe Inspection/
........18-6
Adiustment
Turning Angle Inspection/
........18-6
Adiustment
Wheel/HubInspection
18-7
BearingEnd Play .......................,......
.......18-7
WheelRunout
Front Suspension
SuspensionArms Replacement.....18-8
18-9
Knuckle/Hub
Replacement.............
LowerBallJoint Replacement.......18-15
18-16
BallJoint Boot Replacement..........
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Front Damper
18-16
.................
Removal
18-17
..................
Disassembly/lnspection
18-18
...........
Reassembly
18-18
.............
lnstallation
RearSuspension
SuspensionArms Replacement.....18-19
Hub BearingUnit Replacement......18-20
Upper Arm Bushing
.....18-23
Replacement
RearDamper
18-23
.................
Removal
18-24
..................
Disassembly/1nspection
18-25
...........
Reassembly
.............
18-25
lnstallation
S p e ci a l T ools
Ref.No.
Tool Number
07GAF- SE00l00
07GAG- SD40700
07JAF- SH20200
0 7 L A D- S M 4 0 1 0 0
07MAC- S100200
07746- 0010200
07749- 0010000
07947- 6340400
07965- SA50100
07965- 5400600
07965- S800100
07965- S800200
07965- SD90100
07974- SA50700
/a
@
/6
lol
o
@
6r
@
@
@
Hub Dis/Assembly
Tool
B a l lJ o i n tB o o tC l i pG u i d e
BallJoint RemoverBase
DriverAttachment,60 mm
B a l lJ o i n tR e m o v e r , 2 m
3m
DriverAttachment,3Tx 40 mm
Driver
DriverAttachment,62 x 64 mm
Hub Dis/Assembly
Tool
DriverAttachment
BallJoint Remover/lnstaller
BallJoint InstallerBase
SupportBase
BallJoint BootClip Guide
1
1
1
1
1
1
1
1
'l
I
1
1
I
1
f1
U
o,o
18-2
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.4.@
@,@,@,@
c0
r 8-'13
' 1 81 6
18-15
1A-22
1a-1't,12
1a-21
1 8 - 1 31, 4 , 2 1 , 2 2
18-13
1a-22
1 8 -1 4
1 8 -1 5
18-15
l8-14
18-16
ComponentLocations
FrontSuspension:
BAR
STABILIZER
LOWERARM
Rear Suspension:
REAROAMPER
BAR
STABILIZER
ARM
UPPER
LOWERARM
COMPENSATOB
ARM
TRAILING ARM
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18-3
WheelAlignment
Caster
Camber
Inspection
U s e c o m m e r c i a l l y - a v a i l a bcloem p u t e r i z e ldo u r w h e e l
alagnment
equipmentto measurewheel alignment(cast,
e r , c a m b e r ,t o e , a n d t u r n i n ga n g l e ) .F o l l o wt h e e q u i p ,
ment manufacturer's
instructions.
1 . C h e c kt h e c a m b e ra n g l e .
Camberangle:
Front: 0'00' 1 1"
Rear:- 1' :! 1"
2.
Inspection
U s e c o m m e r c i a l l y - a v a i l a bcloem p u t e r i z e fdo u r w h e e l
a l i g n m e net q u i p m e nt to m e a s u r ew h e e la l i g n m e n(tc a s t e r , c a m b e r ,t o e , a n d t u r n i n ga n g l e ) .F o l l o wt h e e q u i p ment manufacturer's
instructions.
1.
18-4
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FrontToe Inspection/Adjustment
RearToe Inspection/Adjustment
U s e c o m m e r c i a l l y - a v a i l a bcloem p u t e r i z e fdo u r w h e e l
alignmentequipmentto measurewheelalignment(caster,
camber,toe, and turning angle).Follow the equipment
instructions,
manufacturer's
U s e c o m m e r c i a l l y - a v a i l a bcloem p u t e r i z e fdo u r w h e e l
alignmentequipmentto measurewheelalignment(caster,
camber.toe, and turning angle).Follow the equipment
manufacturer'sinstructions.
1.
1.
C h e c kt h e t o e w i t h t h e w h e e l s p o i n t e d s t r a i g h t
ahead.
Loosenthe adjustingbolts, and slide the compensatorarm in or out. as shown,to adiustthe toe.
FLANGEBOLT
'10x 1.5mm
6a N.m 16.5kgf.m, 47 lbf'ftl
ARM
COMPENSATOR
5.
A f t e r a d j u s t i n g t, i g h t e n t h e t i e - r o d l o c k n u t sa n d
repositionthe tie-rod boots if they are twisted or
displaced.
5.
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18-5
WheelAlignment
TurningAngle Inspection
U s e c o m m e r c i a l l y - a v a i l a bcloem p u t e r i z e fdo u r w h e e l
alignmentequipmentto measurewheelalignment(caster,
c a m b e r t, o e , a n d t u r n i n ga n g l e ) F
. o l l o wt h e e q u i p m e n t
manufacturer's
instructions.
1.
Turningangle:
Inwardwheel:37.00'
Outwardwheel lreference):
31.30'
2.
18-6
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Wheel/Hublnspection
BearingEndPlay
WheelRunout
1.
Front/Rear;
Standard:0 - 0.05 mm (0 - 0.002in)
Rear:
108 N.m
{11.0kgf.m, q} lbf.ftl
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18-7
FrontSuspension
Suspension
ArmsReplacement
Notetheseitemsduring replacement:
. Replacethe self-lockingnuts afterremoval.
. The vehicleshouldbe on the ground beforeany boltsor nuts connectedto rubbermountsor bushingsare tightened.
. Beforetighteningthe upper and lower mountingnuts on the stabilizerlink,adjusrthe locationof the link with the susp e n s i o nu n d e rv e h i c l el o a d .
. After installing the suspensionarm, checkthe front wheel alignment,and adjustif necessary(seepage 18-4|.
FLANGEEOLTS
10x 1.25mm
54 N.m (5.5kgf.m,
40 tbf.ft)
STABILIZER
BAR
Alignthe stabilizermark
with end of stabilizer
bushing.
STAEILIZER
STABILIZER
Checkfor bendingand damage.
UPPER
ARM
Checkthe bushingfor deterioration
and damage.
BALLJOINT BOOT
. Checkfor deter'oration
ano oamage,
Seepage18 16for boot
replacement.
FLANGEBOLT
1 { x 1 . 5m m
103N.m {10.5kgf.m,
76 tbf.ft)
LOWERARM
RUBBER
BUSHING
Checkfor deterioration
and damage.
..'.{l@3
GREASE
SILICONE
RUBBER
BUSHINGS
SELF-LOCKING
NUT
10 x 1.25rr|m 29 N.m (3.0kgf.m,22 lbf.ft)
Feplace.
Holdthe ballioint pin usinga hex wrenct
BOOT
Checkfor deterioration
ano oamage,
18-8
o\
SELF.LOCKING
NUT
1 4x 1 . 5m m
Replace.
83 N.m (8.5 kgt.m,61 lbt.ftl
FLANGEBOLT
1 4x 1 . 5m m
89 N.m (9.'l kgl.m, 66 tbf.ft)
DAMPERFOBK
Checkfor damage.
AOLT
10x 1.25mm
!$ N.m (4.4 kgt.m,
32 rbf.ftl
STABILIZER
LINK
Checkfor daftage.
FLANGEBOLT
8 x 1.25mm
22 N.m {2.2kg{.m,
16 tbf.ftl
DAMPERFORK
RUBBER
BUSHING
Checkfor deterioration
and damage.
SELF.LOCKING
NUT
12 x 1.25mm
Beplace.
64 N.m (6.5kgt.m, 47 lbf.ft)
Knuckle/HubReplacement
Notetheseitemsduring replacement:
. Replacethe selt-lockingnuts afterremoval.
. The vehicleshouldbe on the ground beforeany boltsor nutsconnectedto rubbermountsor bushingsare tightened.
. Torquethe castlenuts to the lowertorquespecifications,
then tightenthem only far enoughto alignthe slotswith each
pin hole.Do not alignthe nuts by loosening.
o Use only genuineHondawheel weightsfor aluminumwheels.Non'genuinewheel weights may corrodeand damage
t h e a l u m i n u mw h e e l s .
. Onthealuminumwheels,removethe centercap from the insideof the wheelafter removingthe wheel.
. Beforeinstallingthe brakedisc,cleanthe matingsurfacesof the front hub and brakedisc.
. Beforeinstallingthe wheel.cleanthe matingsurfacesofthe brakediscand wheel.
. Wipe off the greasebeforetighteningthe nuts at the balljoints.
CALIPERMOUNTINGBOLT
1 2x 1 . 2 5m m
108N.m (11.0kgtm.80 lbt.ftl
CASTLENUT
1 0x 1 . 2 5m m
39 - 47 N.m (i1.0- 4.8 kgf.m,29 - 35 lbf.ftl
COTTERPIN
Replace.
WHEELBEARING
Beplace.
page18-13
Replacement,
CIRCLIP
SPLASHGUARD
SCREW
5x0.8mm
4.9N.m {0.5kgf.m,3.6lbf.ft)
LOWERBALLJOINT
Inspectfor faulty
movementand wear,
page'1815
Replacement,
F R O N TH U B
C h e c kf o r d a m a g e a n d
SETRING
Replacement,
page 18 10
BALLJOINTBOOT
Checkfor deterioration
ano oamage.
COTTERPIN
Replace.
CASTLENUT
12x 1.25fim
49 - 59 N.m 15.0- 6.0 kgt.m.36 - lbf.ft)
BRAKEDISC
Checkfor wear and
rust.
R e p l a c e m e n t ,p a g e 1 8 - 1 0
I n s p e c t i o n ,s e c t i o n 1 9 .
SPINOLENUT
24 x 1.5mm
245 N.m {25.0kgI.m, 181 lbtft}
Replace.
. Beforeinstallingthe spindlenut,apply
engineoil to the seatingsurfaceof the nut.
. Aftertightening,usea driftto stakethe
spindlenut shoulderagainstthe spindle.
WHEELNUT
1 2x 1 . 5m m
108N.m
{11.0kgt m,
80 tbf.ftl
6 mm BRAKEDISCRETAININGSCREW
9.8 N.m (1.0kgtm, 7.2 lbtftl
(cont'd)
www.emanualpro.com
18-9
FrontSuspension
(cont'dl
Replacement
Knuckle/Hub
1 . Loosenthe wheel nuts slightly.
8 x 1.25mm BOLTS
8. Screwtwo 8 x 1.25mm bolts into the discto push it
awav from the hub. Turn each bolt two turns at a
time to prevent cockingthe disc excessively,
NUT
SPINDLE
24x 1,5mm
245N.m(25.0kgf.m,181lbtft)
Replace.
Raisethe lockingtab on the spindle nut, then remove
the nut.
Removethe brakehosemountingbolts.
BRAKEHOSEMOUNTINGBOLT
8 x 1.25mm
22 N.m {2.2kgt m, 16 lbtft)
9.8 N.m
(1.0 kgf.m,
7.2 tbttrl
CALIPER
MOUNTING
BOLTS
12x 1.25mm
108N.m(11.0kgl.m,80 lbl.ft)
18-10
MOUNTING
BOLTS
9.8 N.m
lr.0 kgf.m, ?.2lbf.ftl
ADJUSTINGBOLT
tc.
HEX NUT
10x 1.25mm
('99 modcll
43 N.m
lit.a kgl.m.
32 tbtft)
6:)
CASTLENUT
10x '1.25mm
l'97 - 98 modcls)
39 - 47 N.m
{4.0- 4.8
29- 3s rbtftt
COTTER
Replace.
37 -98 models:
Onre6ssmbly,
bendthe cofterpin
16. Install the special tool as shown. Insert the jaws
carefully,makingsure you do not damagethe ball
joint boot. Adiust the jaw spacing by turning the
pressurebolt. lf necessary,apply penetratingtype
lubricantto loosenthe ball ioint.
www.emanualpro.com
(cont'dl
1 8 - 11
FrontSuspension
Knuckle/HubReplacement(cont'd)
20. Removethe cotterpin from the lower arm ball joint
castlenut, and removethe nut.
23. Removethe cotterpin from the upper ball joint castle nut, and removethe nut.
COTTERPIN
Replace.
On reassembly,bend
the cotterpin as shown.
COTTERPIN
Replace.
On ra6ssembly,
bend the cofter pin
CASTI.ENUT
12 x 1.25mm
ilg - 59 N.m (5.0 - 6.0 kgf.m, 36 - a3 lbf.ftl
CASTLENUT
10 x 1.25mm
39 - 47 N.m
14.0- ,4.8kgt m,
29 - 35 tbt.ftl
10 mm
nEMOVER,
28 mm
07MAC_ SLtD2(xl
24. Installthe 10 mm hex nut on the ball joint.
Makesurethe hex nut is flush with the ball joint pin
end, or the threaded section of the ball joint pin
might be damagedby the balljoint remover.
25. Usethe specialtool as shown on page 18-11to separatethe ball joint and knuckle.lf necessary,apply
penetratingtype lubricantto loosenthe ball joint.
CASTLENUT
12 x 1.25mm
COITER PIN
Replace.
BALLJOINTREMOVER,
28 mm
07MAC- Sl(xr2(x,
www.emanualpro.com
18-12
DRIVER
077,19- 0010000
HUBDIS/ASSEMELY
TOOL
07GAF- 5800100
ORIVER
ATTACHMENT,
62x64mm
07947- 6340400
FRONTHUB
SETTING
POINT
HU8OIS/ASSEMBLY
TOOL
07GAF- SE00100
EEARING
SEPARATOR
O-1112in.
(Commercially
available)
{cont'd}
www.emanualpro.com
18-13
Front Suspension
Knuckle/HubReplacement(cont'dl
3 1 . Wash the knuckleand hub thoroughlyin high flash
point solvent before reassembly,
Pressa new wheel bearinginto the knuckleusing
t h e o l d b 6 a r i n g ,a p l a t e .t h e s p e c i a lt o o l , a n d a
press.Placethe wheel bearingon the knucklewith
the pack seal side facing (metal color) toward the
inside.Be careful not to damagethe sleeveof the
Dackseal.
ORIVER
077irg- 0010000
DOUBLELIPSEAL
IBLACKCOLORI
SPLASHGUARO
BASE
SUPPORT
0?965- SD90t00
scREws
CIRCLIP
www.emanualpro.com
18-14
8.
Installthe ball joint boot and set ring usingthe specialtool {seepage18-16}.
BAII JOINTBEMOVER
BASE
07JAF- SH2oe00
P o s i t i o nt h e s p e c i a lt o o l s o v e r t h e b a l l j o i n t a s
shown. then set the assemblyin a vise. Pressthe
ball joint out of the knuckle.
Placethe ball joint in positionby hand.
7.
BALLJOINT HOUSINGSURFACE
www.emanualpro.com
18-15
Front Damper
FrontSuspension
BallJoint Boot Replacement
Removal
1,
2.
DAMPERFORK
BALL PIT{TAPEFEOSCTION
DAMPER
PINCH
BOLT
'10x 1.25
B{rcYHSI
SECTIO
BOOT|NST
SECTION
AD'USN G BOLT
Adjustth6 depthby
turningthe bolt.
UPPERBAI.I
Jott'trBoor:
07GAG - SO407q)
LOWEF BATI
JOIIYI EOOTI
0t97il - SA507lXl
18-16
www.emanualpro.com
SELF.LOCKING
NUT
12x 1.25fifi
Replace.
Removethe damper fork bolt and self-lockingnut
from the bottom of the damper fork, then remove
the damperfork.
Removethe damperby removingthe two nuts.
DAMPER
Disassembly/
Inspection
Disass.mbly
1 . C o m p r e s st h e d a m p e rs p r i n gw i t h a s p r i n g c o m pressor accordingto the manufacturer'sinstructions,then removethe self-lockingnut. Do not compressthe spring more than necessary
to removethe
nur.
SELF-LOCKING
NUT
10 x 1.25mm
29 N.m (3.0kgl.m,22lbtftl
Replace.
DAMPERMOUNTINGWASHER
DAMPERMOUNTING
RUBBER
Check
for
10 mm SELFLOCKING
Replace.
ano oamage.
DAMPERMOUAMNGCOLLAR
DAMPERMOUNTING
BASE
STRUT
DAMPERMOUNTING
RUBBER
Checkfor detrioration
ano oamage.
COMPRESSOR:
lComm6rciallyavailablo)
BRANICK@T/N MST-580A
or Mod6l 7200
or equivalent
Reassemble
all parts,exceptfor the spring.
2.
SPRINGMOUNTING
BUMPSTOPPLATE
..rg
BUMPSTOP g
DUST
weaknessand
www.emanualpro.com
Front Damper
lnstallation
Reassembly
1.
.46
-
10 x 1.25mm
59 N.m {5.0 kgt m, 43 tbf.ftl
-__---a-"-
g*-
| -,./
./
--...
-4
ADAMPER
ASSEMBLY
SPRINGLOWERSEAT
ALIGNING
TAB
10x 1.25mm
il3 l+m
{4.4kgf'm,
Compressthe damperspring,
Installthe dampermountingrubber,dampermounting washer,and a new 10 mm self-lockingnut.
NUT
SELF-LOCKING
10x 1.25mm
Zt N.m 13.0kgf.m, 22 lbf.ft)
Replace.
DAMPER
MOUNfING WASHER
www.emanualpro.com
18-18
Replace.
RearSuspension
Suspension
ArmsReplacement
when the suspensionarms are to be removed, plsce additional weight in lhe trunk beto.o hoisting. when
@
substantial weight is removed from the rear of the vehicle, the center ot grsvity m8y chango causing the vehicle to tip
forward.
Notetheseitemsduring replacement:
. Replacethe self-locking
nuts afterremoval.
. Any boltsor nuts connectedto rubbermountsor bushingsshouldbe tightenedwith the vehicleon the ground.
. Makesurethe toe adjustingboltson the compensatorarm are installedin the samedirection,
. After installingthe suspensionarm, checkthe rearwheelalignment,and adjustif necessa
ry (seepage 18-4),
FLANGEEOLT
10 x 1.25mm
64 N.m 16.5kgf.m,47 lbf.ft)
FLANGEBOLT
10 x 1.25mm
54 N.m (5.5kgt.m,
40 lbf.ftt.
--1/
\A1(\
t
\
BAR
STABILIZER
Checkfor bending
or oamage.
STABILIZER
8AR
\a'v..:r
UPPERARM BUSHING
Checkfor deterioration
and damage.
il ,
FLANGEBOLT
'l0 r 1.25mm
54 N.m (5.5 kgf.m,
8 mm EOLTS
22 N.m {2.2 kgf.m, 16 bl.ftl
40rbtft)
stLtcoNE
TRAILINGARM
Checkfor bending
'anooamage.
UPPERARM BUSHING
-6l
FLANGEBOLTS
10 x 1.25mm
39 N.m 14.0kgf.m, 29 lbf.ft)
stLtcoNE
.@i
COMPENSATOR
ARMBUSHING
UPPERARM
Checklor bendingor damage.
//
^/
COMPENSATOR
ARM BUSHING
FLANGENUT
10 x 1.25mm
29 N.m {3.0kg{.fl,22 lbf.ft}
Beforetighteningthe flangenut,
positionthe balljoint pin
in the middleof its rangeof
travel,with the suspension
under
vehicleload.
FLANGEBOLT
10 x 1.25mm
54 N.m {5.5 kgf.m, 40 lbf.ft}
www.emanualpro.com
,/ FLANGEBOLT
10 x 1.25mm
s4 N.m 15.5kst'm, 40 lbf ftl
Checktor damage.
LOWERARM BUSHING
Checkfor deterioration
and damage.
LOWENARM BUSHING
-6il
stLrcoNE
RearSuspension
HubBearingUnit Replacement
Notetheseitemsduring replacement:
. Use only genuineHondawheel weightsfor aluminumwheels.Non-genuinewheel weights may corrodeand damage
t h e a l u m i n u mw h e e l s .
. Beforeinstallingthe brakedrum, cleanthe matingsurfacesof the rearhub and the brakedrum.
. Beforeinstallingthe wheel,cleanthe matingsurfacesof the brakedrum and wheel.
FLANGEBOLI
12x 1,25mm
103N.m 110.5kgf.m,
76 tbtfr)
BACKINGPLATE
SPINDI-ENUT
2 2 x ' 1 . 5m m
181 N.m {18.5kgf.m, 134 lbf.ftl
Replace.
NOTE:Altertightening,usea drift
punchto lockthe spindlenut shoulder
intothe spindle.
BRAKESHOE
TRAILINGARM
Check{or cracking
ano oamage.
FLANGEBOLT
10x 1.25mm
64 N'm 16.5kgf.m, 4? lbt.ft)
Checkfor cracking
ano oamage.
BRAKEDRUM
Checkfor wear
ano oamage,
WHEELNUT
1 2x 1 . 5m m
108N.m {11.0kgt m,80lbtftl
www.emanualpro.com
1A-20
7 . Disconnect
the brakeline from the wheelcylinder.
securelysupponed.
6.
Removethe rearwheel.
Removethe brakedrum from the hub by threading
8 x,r.25 mm bolts into the drum to push it away
from the hub bearingunit. Turn each bolt two turns
at a time to preventcockingthe drum excessively.
8 x 1.25mm BOLTS
i+/3
',1
"@,1
/
-->-
\ . ' - - 7J
SPINDLENUT
r81 N.m t18.5kgt m, 134lbt'ftl
Replace.
WHEELNUT
12 x 1.5 mm
108N m 111.0kgf'm, 80 lbf ftl
4.
R a i s et h e l o c k i n gt a b o n t h e s p i n d l en u t , t h e n
removethe nut.
5.
Removethe brakeshoes.
6.
PULLER
available)
lCommercially
BACKINGPLATE
DRIVERATTACHMENT,
37 x ilo mm
07746- 0010200
PARKINGARAKECABLE
(cont'd)
www.emanualpro.com
1a-21
RearSuspension
Hub BearingUnit Replacement(cont'd)
12, Pressthe wheel bearing inner race from the hub
usingthe tools,a bearingseparator,and a press.
HUB DIS/ASSEMBLYTOOL
07965- SA50100
BEARING
SEPARATOR
mml
0 -,t 1/2 in {0 - 11i1.3
qvailable)
(Commercially
Prcss
DRIVER
07749- 0010000
BEARING
HUB BEARINGUN]T
REARHUB
O.RING
1 8 . I n s t a l l t h e b a c k i n g p l a t e / h u b b e a r i n gu n i t o n t h e
trailing arm.
FLANGEBOLTS
12 x 1.25mm
103N.m 110.5kgf'm,75lbfft)
1 4 . R e m o v et h e h u b b e a r i n g u n i t f r o m t h e b a c k i n g
plate.
15. Installa new O-ringon the hub bearingunit.
FLANGEBOLTS
10x 1.25mm
64 N.m (6.5kgf.m, 47 lbf.ftl
www.emanualpro.com
18-22
RearDamper
UpperArm BushingReplacement
1.
R e m o v et h e u p p e r a r m b u s h i n g a n d u p p e r a r m
innerbushingas shown.
UPPER
ARM INNERBUSHING
Removal
't. Removethe rearwheels(seepage '18-21),
Removethe damper accesspanel and the damper
cap.
UPPER
ARM AUSHIT{G
5.
OAMPERCAP
REARUPPERARM
Mark a scribeline on the upper arm inner bushing
so it is in linewith the bolt mountingsurface.
4.
Removethe flangebolts.
BOLT MOUNTII{G
SURFACE
www.emanualpro.com
1a-23
RearDamper
Disassembly/lnspection
Disassembly
L
Compressthe damper spring with the spring comp r e s s o ra c c o r d i n gt o t h e m a n u f a c t u r e r 'isn s t r u c tions,then removethe self-lockingnut. Do not compressthe spring more than necessary
to removethe
self-locking
nut.
SELF-LOCKING
NUT
10 x 1.25mm
Replace.
OAMPER
MOUNTING
WASHER
SELF-LOCKING
NUT
10x 1.25mm
29 N.m {3.0kgf.m,22 lbf.ft)
Beplace.
OAMPERMOUNTING
RUBBER
C h e c kf o r
deterioration
ano oamage.
DAMPERMOUNTING
COLLAR
DAMPER
MOUNTINGBASE
DAMPERMOUNTING
RUBBER
Checkfor
deterioration
ano oamage.
STRUTSPRING
COMPRESSOR:
lCommercirlly avaihblo)
BRANICKO
I/N MSI-580A
or Mod6l/7200or equivalent
2.
Inspection
1.
2.
DAMPER
Checkfor weakness,
compressron
'"dd"^.s"'
//F,
DUSTCOVERPLATE
SPRINGMOUNTING
RUBBER
CheckIor deterioration
and damage.
BUMP STOP
Checkfor weakness
ano oamage.
BUMP STOPPLATE
Reassemble
all parts,exceptthe spring.
Pushon the damperas shown.
DUSTCOVER
Checkfor bending
and damage.
DUSTCOVENBOOT
Checkfor deterioralion
ano oamage.
WOODENELOCK
DAMPER
3.
4.
www.emanualpro.com
lnstallation
Reassembly
1.
I n s t a ltlh e d a m p e ru n i to n a s p r i n gc o m p r e s s o r ,
1.
L o w e r t h e r e a r s u s p e n s t o n a, n d p o s i t i o n t h e
d a m p e r .T h e s p r i n g s t o p o n t h e r i g h t d a m p e r
should face rearward,and the s p r a n gs t o p o n t h e
left dampershouldfaceforward.
2.
2 . Assemblethe reardamperin reverseorderof disassembly except the damper mounting washer and
self-lockingnut. Align the bottom of the damper
springand the springlower seatas shown.
DAMPERMOUNNNG
STRUTSPBINGCOMPRESSOR:
(Commorcislly!v.ilablel
BRANICKCT/N MST.s8OA
SPRINGSTOP
FLANGENUTS
10x 1.25mm
. .:
{9 N.m 15.0kgf.m,36 lbtft}-----.-*
:',,rigf't"n if'"""_nrr. in
qla^ 7
Step7.
3.
3.
Looselyinstallthe flangebolt.
FLANGEEOLT
10 x 1.25mm
54 N.m 15.5kgt.m,
40 tbI.ft)
NUT
SELF.LOCKING
10x 1.25mm
29 N.m (3.0
Replace.
www.emanualpro.com
6.
7.
8.
18-25
Brakes
. . . . . . . . .1. .9 - 1
Anti-lockBrakeSystem (ABS) .............
19-25
www.emanualpro.com
Brakes
19-2
.............
SpecialTools
ComponentLocations
......19-3
lndex ................
Inspectionand Adlustment
BrakeSystem RubberParts
19-4
and BrakeBooster..........,,,..........
............
19-5
BrakePedal
........19-6
ParkingBrake
19'7
.................
Bleeding
19-8
BrakeSystemIndicator...................
Front BrakePads
Inspectionand Replacement..........19-9
Front BrakeDisc
19-11
DiscRunoutInspection...................
DiscThicknessand
19-11
Parallelism
Inspection........,........
Front BrakeCaliper
...............
19-12
Disassembly/Reassembly
www.emanualpro.com
MasterCylinder/BrakeBooster
19-13
.......................
Removal/lnstallation
Master Cylinder
..............
19-14
Inspection/Disassembly
PushrodClearanceAdiustment ......19-14
19-15
BrakeBoosterInspection...,.,,,,.......
RearDrum Brakes
19-15
..............
Inspection
BrakeShoes
.....19-r8
Replacement
Wheel CylinderReplacement.........19-20
BrakeHoses/Lines
Specifications... 19-21
Inspection/Torque
..,,,19-22
....,...,.............
HoseReplacement
ParkingBrakeCable
Inspectionand Replacement..........19-23
SpecialTools
Ref. No.
(,
19-2
www.emanualpro.com
Tool Number
|
07JAG. SD40100
Description
|
PushrodAdiustmentcauge
psge Reference
ety
I
tg_rt
Gomponent Locations
lndex
ERAKESYSTEMINOICATOR
CircuitDiagram,page't9-8
PARKINGBRAKE
Adjustment,page19-6
'19-8
ParkingBrakeSwitchTest, page
PARKINGBRAKECABI..E
and Replacement,
Inspection
page19-23
BRAKEBOOSTER
page19-15
BrakeBoosterInspection,
page19 13
Removal/lnstallation,
)i't
' -"''
/'"''t,'..,
,
1...,.
\,,,.
'a.,
i ,.'
I
.)
^fl)
..)
REARDRUM BRAKE
pago19-16
Inspection,
BrakeShoesReplacement,
page19-18
WheelCylinder
page19-20
Replacement,
MASTERCYLINDER
page19-13
Removal/lnstallation,
lnspection/Disassembly.
p a g e1 9 - 1 4
PushrodClearance
Adjustment,
p a g e1 9 l d
BrakeFluidLevelSwitchTest,
page19-8
www.emanualpro.com
Inspection/TorqueSpecification,pag'19-21
Hose Replacement,Page19-22
FrontBrakePads,page19-9
FrontBrakeDisc.page19-11
FrontBrakeCaliper,page19-12
19-3
Inspectionand Adjustment
BrakeSystemRubberPartsand BrakeBooster
@-BrakeBooster
Checkbrakeoperationby applyingthe brakes.
lf the brakesdo not work properly,checkthe brake
booster.Replacethe brakeboosteras an assemblyif
it does not work properlyor if thereare signsof leakage.
@-Piston Cup and PressureCup Inspection
. Checkbrakeoperationby applyingthe brakes.
Visuallycheckfor damageor signs of tluid leakage.
R e p l a c et h e m a s t e rc y l i n d e ra s a n a s s e m b l yi f t h e
pedaldoes not work properlyor if there is damageor
signsof fluid leakage.
.
19-4
www.emanualpro.com
(9-BrakeHoses
Visuallycheckfor damageor signsof fluid leakage.
Replacethe brake hose with a new one if it is dama g e do r l e a k i n g .
O-Caliper Piston Sal and Piston Boots
Checkbrakeoperationby applyingthe brakes.
Visuallycheckfor damageor signsof fluid leakage.lf
the pedaldoes not operateproperly,the brakesdrag,
or there is damageor signs of fluid leakage,disass e m b l ea n d i n s p e c t h e b r a k ec a l i p e r .R e p l a c et h e
boots and sealswith new ones wheneverthe brake
caliperis disassembled.
@-WheelCylinder Piston Cup and Dust Cover
Checkbrakeoperationby applyingthe brakes.
Visuallycheckfor damageor signsof fluid leakage.lf
the pedaldoes not operateproperly,the brakesdrag,
or there is damageor signs of fluid leakage,replace
the wheelcvlinder.
Brake Pedal
Pedal Hoight
1. Disconnectthe brakeswitch connector,loosenthe
brake switch locknut, and back off the brake switch
until it is no longertouchingthe brakepedal.
2.
4.
5.
Checkthebrakepedalfreeplay as describedbelow
ERAKESWITCH
Pedal FreePlay
1. With the engine off. inspect the free play on the
pedalpad by pushingthe pedalby handStandard Pedal Height (with floor m8i removed):
A/T: 161mm (5 5/16 in)
M/T: 155 mm {6 U8 in}
adiust
lf the pedalfree play is out of specification,
the brake switch. lf the pedal free play is insufficient,it may resultin brakedrag.
swtTcH
PEOALPAD
PUSHRODLOCKNUT
15 N.m
11.5kgj m, 11 lbf ftl
www.emanualpro.com
PEDALFREEPLAY
19-5
Inspectionand Adjustment
ParkingBrake
Inspeqtion
1.
3.
Releasethe parkingbrakelever.
2.
Adiustment
1.
@@
2.
Removethe parkingbrakecover
PARKINGBRAKECOVER
19-6
www.emanualpro.com
Installtheparkingbrakecover.
Bleeding
CAUNON:
. Do not spill brake tluid on the vehicle. it may damage
the paint; if brake fluid does contaqt th paint, wash
it otf immodiately with water.
. Maks sure no dirt oy other forsign matter is allowsd
to contaminate the brake fluid.
FRONT:
NOTE:
. Do not reusethe drainedfluid.
. Always use GenuineHondaDOT3 BrakeFluid.Using
a n o n - H o n d ab r a k ef l u i d c a n c a u s ec o r r o s i o na n d
decreasethe life of the svstem.
. The reservoiron the mastercylindermust be at the
MAX (upper)level mark at the start of bleedingprocedureand checkedafter bleedingeach brakecaliper
and wheelcylinder.Add fluid as required.
1,
MAX {UPPER)LEVEL
LINE
RESERVOIR
MASTERCYLINDER
2.
3.
4.
BLEEO
SCREW
7 N.m(0.?kgf.m,5 lbf.ftl
ALEEDINGSEOUENCE:
O Front Right
Gt RearRight
O Front Lefl
O Rear Left
www.emanualpro.com
19-7
Inspectionand Adjustment
BrakeSystemIndicator
Circuit Diagram
lNuLR.HorJD
UNDEB.DASH
FUSE]NEtAY
BOI
GNrT0ll
St!ITCH
r l l A N l ]4 2 4 ! A
GBNiBEO
o\
t uEU0 r E V E9r! 1I ( N
lt j I ERAK
P A FN
KCB R A ( E
S\I'ICH
|
BIK
o P t ^ r ' f ., r' 1
-o:
G401
1.
Removethe parkingbrakecover,
1.
2.
R e m o v et h e r e s e r v o i rc a p . C h e c kt h a t t h e f l o a t
movesup and down freely;if it doesn't,replacethe
reservoircap assembly.
2.
3.
Terminal
LeverPosition \
Positive
Terminal
\ Body Ground
--o
LeverUp
r9''r
Position
FLOATUP
FLOATDOWN
Lever Down
RESERVOIR
CAP
GROUND
19-8
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Front BrakePads
Inspectionand Replacement
4.
Nsvgr u9e an air hose or dry brush to clean brake
assemblies.
Use an OSHA approved vacuum cleaner to avoid
broathing brake dust.
1.
U s i n g v e r n i e rc a l i p e r s ,m e a s u r et h e t h i c k n e s so f
each brake pad lining.The measurementdoes not
includethe pad backingplatethickness.
Brake PadThickness:
- 0.45in)
Standard: 10.5- 11.5mm {0.,11
Servics Limit: 1.6 mm (0.06in)
i)n.
CALIPER
BOLT
3.
EACKINGPLATE
CALIPERBODY
INNEBPADSHIMS
Checkfor weakness.
7.
'.'..i
#
I
OUTERPADSHIM
Checkfor weakness.
PAD RETAINERS
(cont'd)
www.emanualpro.com
19-9
Front BrakePads
(cont'dl
Inspection
and Replacement
9 . A p p l y M o l y k o t e M 7 7 g r e a s e o r D a i k a l u b5 2 8 D
greaseto both sidesof the pad shims and the back
of the pads.Wipe excessgreaseoff the shims.
ApplyMolykote
M77
INOICATOR
Apply MolykoteM77
or 0aikalub528D
to both sidesof shim.
INNERPAD
OUTERPAD
1 0 . l n s t a l lt h e b r a k e p a d s a n d p a d s h i m s c o r r e c t l y .
Installthe pad with the wear indicatoron the inside.
19-10
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N O T E : E n g a g e m e n ot f t h e b r a k e m a y r e q u i r e a
greater pedal stroke immediately after the brake
pads have been replaced as a set. Several applications of the brake pedal will restore the normal
pedal stroke.
1 4 . After installation, check for leaks at hose and line
joints and connections,and retighten if necessary.
Front BrakeDisc
DiscRunoutInspection
l.
DiscThicknessand Parallelism
Inspection
1.
BrakeDi3c Runout:
ServiceLimit: 0.10 mm {0.00,0in)
NUTAND
WHEEL
PLAINWASHER
108N.m{11kg{m, 80 lbf.ft)
lf the disc is beyond the servicelimit, refinishthe
brake disc with an on-car brake lathe. The KwikLathe produced by Kwik-way ManufacturingCo.
and the "Front Brake Disc Lathe" offered by Snapon ToolsCo. are approvedfor this operation.
M8x. RofinishLimit: 21.0 mm l0.8il in)
NOTE:A new disc shouldbs refinishedif its runout
is greaterthan 0.10mm (0.004in).
Brake DiscThickness:
Standard:
'97 - 98 modsls:
22.9 -23.1mm {0.90- 0.91 inl
'99 - 00 modls:
23.6- 23.8 mm {0.93- 0.94 in}
Max. RefinishingLimit:21.0 mm (o.txlin)
Brake Disc Parallelism:0.015mm {0.0006in} max.
NOTE:This is the maximum allowabledifference
betweenthe thicknessmeasurements,
lf the disc is beyondthe servicelimit for parallelism,
refinishthe brake disc with an on-car brake lathe.
The Kwik-Latheproduced by Kwik-WayManufacturing Co. and the "Front BrakeDiscLathe" offered
by Snap-on Tools Co. are approved for this operatron.
NOTE:Seesection18for brakedisc replacement.
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1 9 - 11
Front BrakeCaliper
Disassembly/Reassembly
. Never use an air hose or dry brush to clean brake assemblies.
. Usean OSHAapprovedvacuumcleanerto avoidbreathingbrakedust.
. Contaminatedbrake discs or pads reducestopping ability.
. When reusingthe pads,alwaysreinstallthebrakepadsin their originalpositionsto preventlossol brakingefficiency.
CAUTION:
. Do not spill brakefluid on the vehicle;it may damagethe paint; if brakefluid does contactthe paint,wash it off immediatelYwith water.
NOTEI
. To preventspills,coverthe hosejointswith ragsor shoptowels.
. C l e a na l l p a n si n b r a k ef l u i da n d a i r d r y ;b l o wo u t a l l p a s s a g ews i t h c o m p r e s s eadi r .
. Beforereassembling,
checkthat all partsare free of dust and otherforeignparticles.
. Replacepartswith new oneswheneverspecifiedto do so.
. Makesure no dirt or otherforeignmatteris allowedto contaminatethe brakefluid.
. D o n o t r e u s et h e d r a i n e df l u i d .
. A l w a y su s e G e n u i n eH o n d aD O T3 B r a k eF l u i d .U s i n ga n o n - H o n d ba r a k ef l u i d c a n c a u s ec o r r o s i o na n d d e c r e a s teh e
life of the system.
. C o a t h e p i s t o np, i s t o ns e a l ,a n dc a l i p e b
r o r ew i t h c l e a nb r a k ef l u i d .
. ReDlace
all rubberoartswith new oneswheneverdisassembled.
. After installingthe front brakecaliperdo the following.
- Checkfor leaksat hoseand linejointsand connections,
and retightenif necessary.
- Checkthe brakehosesfor interference
and twistinq.
t".:jil
,,.'.1!!!!9!il: Rubber grease (Use recommended
--6,
I N N E RS H I M
I N N E RS H I M B
12 mm FLANGEBOLTS
113N.m (11.5kgtm,83lbf.ftl
WEABINDICATOR
.@
irf"i:;;T::fl,-J'I",0
\
i
ft
i l 1
#
PIN B
OUTERPAOSHIM
EANJO BOLT
34 N.m {3.5kgf m,25 lblftl
SEALING
WASHERS
Replace.
PIN BOOT
-Cr
4dd*
ERAKEPADS
'f,-rre
PADSPRING
>
6-
PIN A
/ tto*l "o"\
/
\
sLreo6cnew
-6,
I
'
\
AFACKET
CALIPER
BOOY
I N m 10.9kStm, 6.5lbnft)
\
CALIPEREOLTS
49 N.m {5.0kgl.m, 36lbf.ftl
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19-1 2
PISTONSEAL
Replace.
PADRETAINERS
PISTONAOOT
Replace.
"..-a=a-.
PISTON ..,--"sEqri
Master Cylinder/BrakeBooster
Removal/lnstallation
1,
2.
3.
4.
5.
6.
Disconnect
the brakefluid levelswitchconnectors.
Removethe reservoircap from the mastercylinder.
R e m o v et h e b r a k ef l u i d f r o m t h e m a s t e rc v l i n d e r
reservoirwith a syringe.
Disconnect
the brakelinesfrom the mastercylinder.
To preventspills,cover the line joints with rags or
shop towels.
R e m o v et h e m a s t e rc y l i n d e rm o u n t i n g n u t s a n d
wasners.
Removethe mastercylinderfrom the brakebooster.
Disconnect
the vacuumhosefrom the brakebooster.
Removethe cotterpin and clevispin from the clevis.
Do not disconnectthe clevis by removing it from
the operatingrod of the brakebooster.lf the clevis
i s l o o s e n e d ,a d j u s t t h e p u s h r o d l e n g t h b e f o r e
installingthe brakebooster(seepage 19-15).
1 3 . F i l l t h e m a s t e rc y l i n d e rr e s e r v o i r a
, n d b l e e dt h e
brakesystem(seepage 19-7).
1 4 . After installation,checkthe brakepedal height and
brakepedalfree play (seepage 19-5),and adjust if
necessary.
vAcuuM HosE
|
BRAKE
FLUTD
LEvEL
|
15N.m{1.5kgtm,
r r rbf.ft)
/
To FrontCaliper(WithoutABS)
/l
I
r o R e awr h e ect y l i n d e r s/
l,/--
To MasterCylinder
(WithoutABS)
To ModulatorUnit
(with ABs)
swrrcHcoNNEcroRs
h ./-'''
*s
/. I
/
|
COTTERPIN
neotace
I
(.S I /r:
Yli
//
@-\
-#q
CLEVISPIN
\
^
To FrontCaliper
:-,/
9i
\.
13 N.m 11.3kg{.m,
I rbf.ft)
PROPORTIONING
CONTROLVALVE
MASTERCYLINDER
BRAXEBOOSTER
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Master Cylinder
Inspection/Disassembly
PushrodClearance
Adjustment
NOTE:Mastercylinderpushrod-to-piston
clearancemust
be checkedand adjustments made, if necessary.before
installingthe mastercylinder.
NOTE:
. Beforereassembling,
checkthat all parts are free of
dust and otherforeignparticles.
. Do not try to disassemble
the mastercylinderassembly. Replacethe mastercylinderassemblywith a new
pan it necessary,
. Make sure no dirt or other foreign matter is allowed
to contaminatethe brakefluid.
1.
RESERVOIR
SEAL
Checkfor damaoeand
deterioration,
MASTERCYLINDER
ADJUSTINGNUT
Without disturbingthe center shaft's position, installthe specialtool upsidedown on the booster.
RESERVOIR
Checkfor damage.
RODSEAL
Checkfor damage
and deterioration.
--1
SILICONEGREASE
MASTERCYLINOER
Checkborefor wear,rustand damage.
MASTERCYLINDERNUT
15 N.m 11.5kgt m, 11 lbt.ftl
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19-14
BrakeBoosterInspection
l f t h e c l e a r a n c eb e t w e e nt h e g a u g e b o d y a n d
adjusting nut is 0.4 mm (0.02in), the pushrod-topistonclearanceis 0 mm. However.if the clearance
betweenthe gaugebody and adjustingnut is 0 mm,
the pushrod-to-piston
clearanceis 0.4 mm (0.02in)
o r m o r e . T h e r e f o r ei t m u s t b e a d j u s t e da n d
recheckd.
6. lf clearanceis incorrect,loosenthe star locknut,and
turn the adjusterin or out to adjust.
.
.
FunctionalTest
1. With the enginestopped,pressthe brakepedalseve r a l t i m e s t o d e p l e t et h e v a c u u m r e s e r v o i rt.h e n
pressthe pedal hard, and hold it for 15 seconds.lf
t h e p e d a l s i n k s ,e i t h e r t h e m a s t e r c y l i n d e r i s
bypassinginternally,or the brake system (master
cylinder,lines, modulator,proportioningvalve. or
caliper)is leaking.
2.
3.
With the enginerunning,pressthe brakepedallightly. Apply just enough pressureto hold back automatic transmissioncreep. lf the brake pedal sinks
morethan 10 mm (3/8in.) in threeminutes,the master cylinderis faulty.A slightchangein pedalheight
when the Ay'Ccompressor cycles on and off is normal. (TheAy'Ccompressorloadchangesthe vacuum
availableto the booster.)
Leak Test
1 . Pressthe brakepedalwith the enginerunning,then
stop the engine. lf the pedal height does not vary
while pressedfor 30 seconds,the vacuum booster is
OK. lf the pedal rises,the booster is faulty.
With the engine stopped, press the brake pedal severaltimes using normalpressure.Whenthe pedalis
first pressed.it shouldbe low, On consecutive
applications,the pedalheightshouldgraduallyrise.lf the
pedal position does not vary. check the booster
checkvalve.
2.
PUSHROD
LOCKNUT
1.5N.m11.5kgf.m.'11lbtfl)
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RearDrum Brakes
Inspection
a
a
rl
a
1.
Blockthe front wheels,loosenthe rear wheel nuts slightly,then raisethe vehicle,and make sure it is securelysupponed.Removethe rearwheels.
2.
Release
the parkingbrake,and removethe rearbrakedrum.
I N.m {0.9kgl.m,5.5rbr.ft)
\
\
BACKINGPLATE
Markedleftand right.
\
196
@
PARKINGEBAKE I-EVER
Markedleft and right.
ADJUSTERBOLT
Checkratchetteeth
for wearand damage.
UPPERRETURN
SPRING
Checkfor weakness
and damage.
CLEVISB
CLEVISA
\L;
'l-'-'
I
t /
64 N.m 16.5kgl.m,
47 lbt.ftl
BRAKESHOE
Inspection,
see page19 17
lf brakeshoesareto be
reused,markand reassemble
in sameposition.
Inspectfor leakage.
Replacement,
see
page19-20
SPRING
C h e c kf o r w e a k n e s s
ano oamage.
LOWERRETURN
SPRING
Checkfor weakness
a n oo a m a g e .
RETAINER
SPRING
Installsecurelyon
l e n s r o np r n .
19-16
Replace.
6d/
WHEEL
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u-cllP
BrakeLining Thicknoss:
Standard:
3.9-,1.5 mm {0.15- 0.18inl
SorviceLimil: 2.0 mm {0.08in}
WHEELCYLINOER
BRAKEDRUM
LININGS
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Checkthe bearingsin the hub unit for smooth operation; if the bearingrequireservicing.referto section18.
19-17
RearDrum Brakes
BrakeShoesReplacement
1.
l@
7.
\
\
w
\n
RETAINER
SPRING
BRAKESHOE
BRAKESPRINGWBENCH
available)
{Commerciallv
TENSIONPIN
o.
19-18
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UPPERRETURNSPRING
lnstall the wave washer with its convex side facIng our.
Pinchthe U-clipsecurelyto preventthe pivot pin
from comingout of the brakeshoe.
U-CLIP
Replace.
WAVE WASHER
Replace.
1 0 . C o n n e c tt h e p a r k i n g b r a k e c a b l e t o t h e p a r k i n g
brakelever,
1 1 , Cleanthe threadedportionsof clevisesA and B.
Coat the threads of the cleviseswith grease.To
shortenthe clevises,turn the adiusterbolt.
UPPERRETURNSPRING
..4
S l r d r n sgu r f a c e
Apply rubbergrease
to slidingsurface.
1 4 . Installthelower returnspring.
(cont'd)
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RearDrum Brakes
(cont'd)
BrakeShoesReplacement
WheelCylinderReplacement
CAUTION:
. Do not spill brake fluid on th6 vehicle; it may damage
the paint; if brako fluid doos contact tho paint, wash
it off immedialely whh water.
. To pr6v6ni 3pills, cov6r th6 hose ioinls with rags ol
shop lowels,
. Use only a genuine Honda whoel cylinder spocial
bolt.
Disconnect
the brakeline,
SEALANT
BACKINGPLATE
15 N,m 11.5kgt m,
11 tbf.ftl
WHEELCYLINDER
TENSIONPINS
9 N.m 10,9kgf'm.
6.5 rbtft)
Apply sealant betweenthe wheel cylinder and backing plate,and installthe wheelcylinder.
adjustingbrake.
Adjustthe parkingbrako(seepage 19-6).
www.emanualpro.com
19-20
BrakeHoses/Lines
Specifications
Inspection/Torque
and twisting
leaks,interference,
1. Inspectthe brakehosesfor damage,deterioration,
2. Checkthe brakeIinesfor damage,rusting,and leakage.Also checkfor bent brakelines.
and retightenif necessary.
3. Checkfor leaksat hoseand line jointsand connections,
4. Checkthemastercylinder,proportioningcontrolvalve.and ABS modulatorunit for damageand leakage.
NOTE:Replacethe brakehoseclip wheneverthe brakehoseis serviced.
LINE
MASTERCYLINOER.Io.BRAKE
15 N.m 11.5kgt m, 11 lbnftl
PROPORTIONING
CONTROLVALVE.
Io-BRAKELINE
15 N.m (1.5 kgf.m. 11 lbl.ftl
HOSE
BRAKELINE-Io-BRAKE
15 N.m 11.5kgd.m,11 lbf'ft)
BRAKEHOSE-to-CALIPER
{8ANJO BOLTI
34 N.m (3.5kgf.m,25 lbf.ftl
BLEEDSCREW
9 N.m 10.9kgf.m, 6.5 lbf.ftl
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CYLINDER
15 N.m 11.5kgf.m, 11 lbf.ft)
BLEEDSCREW
7 N.m 10.7kgf.m, 5 lbt.ftt
with ABS:
19-21
BrakeHoses/Lines
HoseReplacement
CAUTION: Do not spill brak fluid on the vehicl;it m8y
damage th paint; if brak lluid doos contact tho paint,
wash it off immediately with water.
NOTE:
. Beforereassembling,
checkthat all pans are free of
dust and otherforeignparticles.
. Replaceparts with new ones wheneverspecifiedto
qo so,
'1.
6. Installthe brakehose on the knucklefirst, then connectthe brakehoseto the caliperwith the banjobolt
and new sealingwashers.
6 mm HOSEBRACKET
EOLTS
9.8Nm
(1.0kgf.m,7 lbf.ftl
BRAKEHOSE
BANJO BOLT
34 N.m
13.5kgf.m, 25 lbl.ftl
WASHERS
SEALING
Heplace.
BRAKEHOSE
1 tbtftl
F
)
/
BRAKE
HOSEARACKET
8. Connectthe brakelineto the brakehose.
9 . After installingthe brakehose,bleedthe brakesys'19-7).
tem (seepage
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19-22
Performthe followingchecks;
. Checkthe brakehoseand line joint for leaks,and
tighten if necessary.
. Checkthe brake hoses for interferenceand twistIng
ParkingBrakeCable
Inspectionand Replacement
Inspection
The parkingbrakecablesmust not be bent or distorted,This will leadto stiff operationand prematurecablefailure.
Replacoment
l.
Disconnect
the parkingbrakeswitchconnector.
2.
3,
Bemovethe parkingbrakeleverassembly.
4.
Removethe parkingbrakeshoes{seepage
5.
6.
'19-18).
PARKINGBRAKECABI-E
BRACKET
PABKINGARAKECABLE
or corroston,
Checktor
PARKINGBRAKELEVER
Checkfor smooth
operation,
,"u/n*UM
-6l
(Slidingsurface)
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19-23
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DTC1r - 18:
Wheel Sensor
.... 19-45
DTC31 38:
Solenoid
.............
19-47
DTC51 53:
ABS PumpMotor .........................
19-49
DTC 54:
Main Relay
.........
19-52
DTC61:
lgnitionVoltage ...........................
19-54
DTC81:
CentralProcessingUnit (CPU).... 19-55
Modulator Unit
Removal/lnstallation
.......................
19-56
ABS Control Unit
Replacement
..,......19-57
Pulsers/WheelSensors
Inspection
..............
19-57
Wheel SensorReplacement............
19-58
S p e ci a l Tools
Rel. No.
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19-26
Tool Number
07PAZ- 0010100
Description
SCSServiceConnector
Oty
1
PageRelerence
19-38
ComponentLocations
NOTE:The illustrations
show the '97 - 98 models.The '99 - 00 modelsare similar.
SERVICECHECKCONNECTOR
{2PI
ABS CONTROLUNIT
RIGHT-REAR
WHEELSENSOR
UNDER.HOOD
ABS
FUSE/RELAYBOX
RIGHT.FRONT
WHEEL
SENSORCONNECTOR
RIGHT-FRONT
WHEELSENSOR
WHEEL
RIGHT-REAB
SENSORCONNECTOR
MODULATORUNIT
WHEEL
LEFT.FRONT
SENSOECONNECTOR
GAUGEASSEMBLY
8OX
UNDER.DASHFUSE,/RELAY
LEFT.FRONT
WHEELSENSOB
FUSE/RELAYAOX
UNDER.HOOO
D!
trtrtr
[r D!
ABS INDICATOR
UNDER-DASH
FUSE/NELAYBOX
METER{7.5AI FUSE
HOBN/STOPI15 AI FUSE
UNDER.HOODABS FUSE/RELAYBOX
ABS +B 120Al FUSE
PUMPMOTOR('II AI FUSE
MOTORRELAY
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19-27
TARGETSLIPRATE
RADIAL
OIRECTION
OF THE
ROTATIONAL
DIRECTION
SLIPRATE
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19-24
ABS Control
The ABS control unit detectsthe wheel speedbasedon the wheel sensorsignalit received,then it calculatesthe vehicle
speed basedon the detectedwheel speed.The control unit detectsthe vehiclespeed during decelerationbasedon the
rateof deceleration.
The ABS control unit calculatesthe slip rate of each wheel, and it transmitsthe control signal to the modulator unit
solenoidvalvewhen the slip rateis high
The pressurereductioncontrolhasthree modes:pressurereducing,pressureretaining,and pressureintensi{yingmodes.
ABS CONTROLI-INIT
Self-diagnosisFunction
The ABS controlunit is equippedwith a main cPU and a sub cPU, that checkeachotherfor problems.
The CPUscheckthe circuitof the system.
"systemdown mode" or the "controlinhibitionmode".
Whenthe CPUSdetectfailure,they shiftto the
SOLENOID
VALVE
LIGHT
ABSINDICATOR
MAIN
RELAY
SYSTEM
DOWN
ON
No
operatron
Drive
inhibition
CONTROL
INHIBITION
ON
No
operaton
Drive
inhibition
MODE
Restancondition
DTC
lgnition
- oN (ll) Memory
Operation*r switch OFF
Operation
Automatic
lVemory
*1: ExceptCPUfailure
can be classitiedinto thesefour categories:
The self-diagnosis
O : I n i t i adl i a g n o s i s
O: ExceptABS control
O; DuringABS control
@ : D u r i n gw a r n i n g
On-boardDiagnosisFunction
The ABS systemcan be diagnosedwith the HondaPGMTester.
The ALB Checkercannot be used with this system.For air bleeding.and checkingwheel sensorsignals,use the Honda
PGIMTester.Seethe HondaPGMTesteruser'smanualsfor specificoperatinginstructions.
(cont'd)
www.emanualpro.com
19-29
Anti-lockBrakeSystem(ABS)
(cont'd)
Features/Gonstruction
ABS Modulator
The ABS modulatorconsistsof the inlet solenoidvalve, outlet solenoidvalve, reservoir,pump, pump motor and the
d a m p j n gc h a m b e r .
The modulatorreducesthe caliperfluid pressuredirectly.lt is a circulating-type
modulatorbecausethe brakefluid circulates
throughthe caliper,reservoirandthe mastercylinder.
The hydrauliccontrolhasthree modes:pressurereduction,pressureretainingand pressureintensifyingmodes.
The hydrauliccircuitis the independent
four channel-type,
one channelfor eachwheel.
SOLENOIDVALVE
PUMP MOTOR
t-
Pressureintensifyingmode:Inletvalveopen,outletvalveclosed,
Mastercylinderfluid is pumpedout to the caliper.
Pressureretainingmode: Inletvalveclosed,outletvalveclosed.
Caliperfluid is retainedby the inletvalveand outletvalve.
Pressurereductionmode: Inletvalveclosed,outletvalveooen
Caliperfluid flows throughthe outletvalveto the reservoir.
Motor operationmode:
Whenstartingthe pressurereductionmode.the pump motor is ON.
WhenstoppingABS operation,the pump motor is OFF.
The reservoirfluid is pumpedout by the pump,throughthe dampingchamber,to the master
cylinder.
19-30
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Wheel Sensor
The wheel sensorsare the magneticcontactlesstype. As the gear pulserteeth rotatepast the wheel sensor'smagnetic
with the wheel speed.The ABS controlunit detects
The AC frequencychangesin accordance
coil,AC currentis generated.
the
wheel
speed
the wheelsensorsignalfrequencyand therebydetects
GEARPULSER
at LOW SPEED
F
VEHICLS
EPEED
VEHICLESPEED
WHEELSPEED
PRESSU
OUTLET
VALVE
ON
OFF
INLET
VALVE
ON
OFF
MOTOR
ON
OFF
When the wheel speeddrops sharplybelow the vehiclespeed,the outlet valve opens momentarilyto reducethe caliper
fluid pressure.The pump motor startsat this time. As the wheel speedis restored.the inlet valve opens momentarilyto
increasethe caliDerfluid oressure.
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19-31
CircuitDiagram
UNDFS
I]OODFISAFELAY
8OX
Cbsod:&rrc ped. deprelled
-tjF
wHT/GrN
GFrlrr'vril
GNITION
*oJG\'*"
\F*,-
UNDER-HOOD
A8S FUSE/FELAY
BOX
(O number)
3P CONNECTOR
t_--t
l-|
l l ' " 1
UNDER.HOOO
A8S FUSE/RELAY
BOX
2P CONNECTOF(! numbor)
UNDER,DASH
FUSFJRELAY
BOX
20PCONNECTOR(O number)
3
5 6
1 0 1 1 12 1 3 ,/ 115 ,/
8 9
19
s a'l
fLr--'--.----1
3 4
5 6
'12 1 3 | i 4
9 10
/
PUMP MOTORCONNECTOR
number)
(tr
19-32
7 18
ASSEMBLY5P CONNECTOR
----.4-
l1)/l3l/l5l
Wiresideol femalelerminals
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ll3 2ir I
{tT6TsF}
!]q:]j_1,
UNDER-DASH
FUSE/RELAY
BOX
(E number)
18PCONNECTOR
1 2
EFIAKESWITCHCONNECTOR
l-4
| 1t x l 2 |
M-OD
ULATORUNIT CONNECTOR
ATi)
Terminal
sideoJlemaleterminals
Gil
I.]NII {NBK)
ABSCONTROL
STOP
[m;]t
ra
-[rf$-n*'"
SEFVCE
CHEC(
l'? g,l
,ln
,BFN+BsN-,|
.
G2
Y
WIT/BLIJ
,r-,,..J
|;
Br(
--o-
:
G101cr02
A ^ l 0 l T AL M
'r6P)
i trr cor'hrEcroF
8LK
c1013,402
tG2,
rlr*r"t_._*h
-----r;c,
r"-!cc
Lffi_--
PMR,
-.^
t!94
PCOM,
.,._
Pf:
-tL
t=
J*
,,-:g
GRN/8I(
t-
LT
GFNmL---l
-r
l,'2
-14
=l------5o
ril|
,
/
,
i7
19
- ) 1. 2 2 1
INK
QAIA.L
coNNE
croR (16P)
mtTl
#
|
T?'--"r""""./ 6 ,/ 8\
F{ c7
,z
Wiresideof lemaleterminals
www.emanualpro.com
, f
I'
ABScoNTRoL
-- uNrr22pcoNNEcroR
i-;;i,;;)
t,*---;Tr
I
)ECHECK
9E-FY!!
coNNF
:CTOR(2P)
Ilcrom.
IRE^R
-l
BLr(
eli -.1
BtK-L
,-ry
pliirn
:C,
4iq!A
ABscoNTRoL
-- uNrr26pcoNNEcroR
(o;fib;;;
HEELSENSOR
CONNECTOR
'98-99models
'97 model
FRONT/ REAR FRONTIRIG-HT-REAR
iTtl\
/Jr lz !\
Termnal sideol
mateterminals
Terminalsideol
maleterminals
LEFT.REAR
/nf'\
1./ 1F
r .4-;1
V L:J
Terminalsideol
lemaleterminals
19-33
ABSControlUnit TerminalArrangement
ABS CONTROLUNIT26PCONNECTOR
Teiminal
numbel
Wiie
color
Terminal3ign
Teiminalnamgl
Voltrge
Description
Condhions
(lgnition Switch ON llll)
tdminals
PCOM
GRNn/VHT (Primary
common)
1-GND
RRO
BLUA/EL (Rear-right
0)
GRY
RLO
(Rear-left
0)
GRN
FRO
(Fronr-right0)
STOP
{Stop)
OFF
AC:3-6V
OFF
theSCSseNice]
lConnect
connector
\
I
A p p r o x . 3V
53mVor aboveon
Detectsleft-rearwheelsensor
srgnat.
6-19
8-21
(AC
digitaltester
Whenthe wheelis
range)
{Beference)
turnedat 1 turn/second.
150mvtrp or above
on oscilloscope
Stops
Brakepedalpressed.
Detects
bfakeswitchsignal.
(Prevents
unnecessary
ABSoperation) 9-GND
FLO
BRN^/VHT(Front-left
0)
OV
BatteryVoltage
BrakeDedalreleased.
Detectsleft-frontwheelsensor
srgnal.
10
ON
ON
SCOM
Power sourcefor the solenoid
BLI(WHT (Secondary
2-GND
common)
Detectsignitionswitch2
BLVBLU (lgnition
2)
signal.(Systemactivate
signal) 3-GND
10-23
Stops
YEL
13
14
16
't7
19
23
RL-oUT Drivesleft-rearoutletsolenoid
12.GND
(Rearleft
outlet)
RR.IN
RED^/vHT (Rear-right
inlet)
B1
WHT/GRN (Baftery
1)
82
(Battery2)
GND2
BLK
(Ground2)
RR1
GRN/YEL(Rear-right
1)
R
L
1
LT BLU (Rearieft
1)
FR1
GRN/BLK(Front-right
1)
FL1
GBN/ORN
{Front-left1}
Drivesright-rear
inletsolenoid
13.GND
14.GND
15-GND
Detectsleft-frontwheelsensor
sagnal.
ON
26
19-34
www.emanualpro.com
BLK
GND3
(Gtound
3)
AC:3-6V
53 mV or above
on digitaltester
(AC range)
(Reference)150
mVp-p or above
on oscilloscope
Stops
Approx.2.5V
21-8
26-GND
Approx.3 V
BatteryVoltage
't7-4
25,GND
OFF
Below0.3V
ON
RLIN
(Rear-left
inlet)
OV
16-GND
23-10
53mVorabove
on
digitaltester
lAC
(Reference)
range)
150mvpporabove
onoscilloscope
ADprox. 2.5 V
Everytime
19-6
Approx.2.5
V
BatteryVoltage
OV
ON
OFF
the
lConnect SCSservice\
connector I
\
RED
Output voltago
ON
-9
OFF
the
/Connect SCSservice]
conneclor
\
I
OV
AC:3-6V
Approx.3 V
Below0.3V
Wire
color
Terminal 3i9n
Terminal name
Description
Conditions
(lgnition Switch ON (ll)l
tominals
Drivesright-frontinlet
solenoidvalve.
ON
FR-IN
1
1-GND
RED/BLU (Front-right
BRN
10
l'l
BLU/RED (Warning
ramp)
YEUBLK
FL-OUT
(Frontieft
outlet)
FL-IN
RED/BLK (Front-left
inlet)
DrivesABS indicator{The indicator goes off when ABS control unit outputs battery voltage).
Drives left-front outlet
solenoidvalve.
17
LT BLU
(Datalink
connectod
ot
4.GND
Communicateswith Honda
PGM Tester.
PMR
YEURED (Pumpmotor
reray,
BLK
www.emanualpro.com
GND2
(Ground2)
AC:3-6V
SCSserviceconnector
connected.
SCS service connector
disconnected.
A p p r o x . 3V
OV
Approx.S V
Approx.2 V
lndicatorON
7.GND
BatteryVoltage
lndicatorOFF
1O-GND
ON
ON
OV
OFF
AC:3-6V
OFF
theSCSservicq
lconnect
connector l
\
12-GND
Pump
1 7 - G N D motor
relay
19.GND
outlet
Drivesright-rear
solenoidvalve.
cl)
22.GND
'a)
ON
Battery Vollage
OFF
OV
6
I
ON
OV
OFF
AC:3-6V
OFF
ponnecl
theSCSservice]
connector I
\
ON
21.GND
A p p r o x . 3V
Approx.5 V
14-GND
ON
RR-OUT
(Rear-right
outlet)
OFF
11-GND
DetectsPumPmotor drive
MCK
BRN/YEL(Motorcheck) signal.
BLU
OV
OFF
servicel
theSCS
lconnect
connedor l
\
ON
Drivesleft-frontinlet solenoid
Drivesright-frontoutlet
FR-OUT
YEUBLU (Front-right solenoidvalve.
outlet)
14
.9
ur
inlet)
Output voltage
Pump ON
moror
rcray OFF
OFF
lconnecttheSCSservice]
connector l
\
A p p r o x . 3V
OV
AC:3 6V
A p p r o x . 3V
Below0.3V
19-35
TroubleshootingPrecautions
ABS lndicalor
1 lf the systemis oK, the ABS indicatorgoes off two secondsafter turning the ignitionswitch oN
1l) wathoutstaning
the engine,and then comes on again and goes off after two seconds.This occursbecausethe ABS control unit
is
turnedon by the lG2 powersource.
2. The ABS indicatorcomeson when the ABS control unit detectsa problemin the system.However,even
thouoh the
systemis operatingproperly,the ABs indicatorwill come on too, underthe followingconditions:
. Signaldisturbance
. W h e e ls p i n
. Only drivewheelsrotate
. Batteryvoltagefluctuates
To determinethe actualcauseof the problem,questionthe customeraboutthe problem,takingtheseconditions
into
consideration:
3 When a problem is detectedand the ABS indicatorcomes on, the indicatorcan stay on until the ignition
switch is
turnedOFF,or it can automatically
go off, dependingon the mode.
. Indicatorstayson untilthe ignitionswitchis turnedoff: Whenthe systemis in the systemdown
mode.
. Indicatorautomatically
goesoff: Whenthe systemis in the controlinhibitionmode.
4 The ABS indicatorstayson when the systemis reactivatedwithout erasingthe DTC,but it goes off after starting
the
vehicle.
When the wheel sensorsystem is faulty and the ABS indicatorcomeson. the algorithmof the systemautomatically
turns
off the ABS indicatorafterthe wheelspeedsignalreturnsto the normalspeed.Also,when the DTc is erased,the
cpu is
resetandthe ABS indicatorgoesoff whenthe systemcheckedout normalby the initialdiagnosis.
Therefore,test-drivethe vehicleafterservicingthe wheel sensorsystem.and be surethat the ABS indicator
does not
c o m eo n .
5 When the ABS controlunit outputsbatteryvoltageto the gaugeassembly,the ABS indicatorooesoff.
DiagnosticTrouble Code (DTCI
1. The diagnostictroublecode (DTc)is memorizedwhen a problemis detectedand the ABS indicator
does not go off,
or when the ABS indicatorcomeson.
The DTc is not memorizedwhen the ABS indicatorcomeson unressthe cpu is activated,
2 The memorycan hold any numberof DTCs.However,when the same DTc is detectedtwice or more,
the taterone is
writtenover the old one.
Therefore,when the same problemis detectedrepeatedly,
it is recordedas one DTC.
3. The DTCsare indicatedin the orderof ascendingnumber,not in the orderthey occur.
4. The DTCSare memorizedin the EEPROM(non-volatile
memorv).
Therefore,the memorizedDTcscannotbe canceledby disconnecting
the battery.performthe specifiedproceduresto
erasethe DTCS.
Self-diagnosis
1. Self-diagnosis
can be classifiedinto thesefour categories:
' Initialdiagnosis: Performedright afterthe engine startsand untirtheABS indicatorgoes
off.
. ExceptABS control:Performedwhen the ABS is not functioning.
. DuringABS control:Performedwhen the ABS is functioning.
. Duringwarning:
Performedwhen the ABS indicatoris ON.
2. The systemperformsthe fo|owing controrswhen a probremis detectedby the serf-diagnosis:
. ABS indicatorON
. Memorvof DTC
. Mode changetothe "systemdown mode,,or the ,,controlinhibitionmode,,.
MODE
ABS INDICATOR
MAIN
RELAY
SOLENOID
VALVE
CPU
SYSTEM
DOWN
ON
No
operation
Drive
inhibition
Operation*r
CONTROL
INHIBITION
ON
No
operal|on
Drive
inhibition
Operation
Restartcondition
lgnition
switch
DTC
oFF- ON l) Memory
Automatic
lMemory
*1: ExceptCPUfailure
19-36
www.emanualpro.com
Kickback
'1. The motor operateswhen the ABS is functioning.and the fluid in the reservoiris forcedout to the mastercylinder,
causingkickbackat the brakepedal.
2.
The ABS controlunit operatesthe solenoidvalvewhen the brakepedalis releasedafterthe initialdiagnosisYou may
hearthe solenoidvalveoperateat this time, but it is normal
PumoMotol
1. The pump motor operateswhen the ABS is functioning
2.
Bleeding
BrakeFluidReplacement/Ail
and air bleedingproceduresare the sameas for vehicleswithout ABS To easebleeding,start
L Brakefluid replacement
with the front wheels.
Troubleshooting
flowchartproceduresassumethat the causeof the problemis still presentand the ABS indicator
1. The troubleshooting
is still on. Followingthe flowchartwhen the ABS indicatordoes not come on can resultin incorrectdiagnosis.
2.
Ouestionthe customerabout the conditionswhen the problemoccurred,and try to reproducethe same conditions
for troubleshooting.
is made at varioustimes such as the initialdiagnosis,exceptABS control,during ABS control,during
Self-diagnosis
during the specifiedvehiclespeed,etc. Therefore,the symptom canngt be checkedunlessthe check
acceleration,
conditionsmatchwith the problemconditjons
3.
When the ABS jndicatordoes not come on duringthe test-drive.but troubleshootingis performedbasedon the DTC,
checklor looseconnectors,poor contactof the terminals,etc.,beforeyou starttroubleshooting.
4.
erasethe DTCand test-drivethe vehicle.Be surethe ABS indicatordoes not come on.
Aftertroubleshooting,
5.
www.emanualpro.com
19-37
DiagnosticTroubleCode(DTC)
DiagnosticTroubleGodeIDTCIIndication
NOTE:This operationcan also be donewith the HondapGM Tester.
1.
Connectthe SCS service connector to the service check connector (2P) located on the passenger'sside of the center
consote.
2.
4.
5.
Erasethe DTC.
u.s.A.
GAUGEASSEMBLY
@
CANADA
A8S II{DEATOR
19-38
www.emanualpro.com
DTCErasure
NOTE:This operationcan also be done with the HondaPGMTester.
1.
2.
Pressthe brakeoedal.
3.
Turnthe ignitionswitchON (ll)while keepingthe brakepedalpressed.The ABS indicatorgoes off aftertwo seconds.
4.
5.
After the indicatorcomeson, pressthe brakepedalagain.The indicatorgoes off againafterfour seconds (the brake
oedalis still Dressed.)
6.
7.
8.
0.3sec.
ON
ABSINDICATOR
OFF
within3sc. I
within3 sc.
within3 sec.
0.3sec.
DEPRESSED
BRAKEPEDAL
RELEASED
lonitionswitch
dN (r)
www.emanualpro.com
19-39
DiagnosticTroubleCode(DTC)
TroubleshootingIndex
This operationcan also be done with the HondapGM Teste..
DETECTION
TIMING
DTC
3
R
< Y
DIAGNOSIS/SYMPTOM
ct
8
< i
< = E E2E 2 =
3 eB28 ET
6 3
E
X
zd 9
gl
REFER
TO
PAGE
(J
19,4'l
ON
19-43
oN*
't1
't5
PROBLEM
LOCATION
OFF
No
DTC
13
4,,
to
< J
FR
o o o o
17
FL
RR
19-45
RL
12
't4
FR
oN*
(chippedpulsergearlelectrical
Wheelsensor/Pulser
notse,
o o o
FL
RR
18
RL
31
FR-IN
32
FR-OUT
19-45
FL.IN
34
ON
Solenoid(open/short
to body ground/shortto
power/stuck)
o o o
FL-OUT
RB-IN
36
RR-OUT
37
RL-IN
38
19-47
RL.OUT
ON
Motor lock
ON
Motor stuckOFF
53
ON
Motor stuckON
54
ON
Main relaystuckOFF
6l
ON
lgnitionvoltage(low voltage/highvoltage)
81
ON
o o
o o
o
o o o
o o o o
o o o o
19-49
19-49
19-49
ia_at
'19-54
19-55
*: lf DTcs 11-18
{wheelsensorcodes)were detectedthe last time the vehiclewas driven,the ABs indicatorwi stav on
untilthe ignitionswitchis turnedON (ll),and the controlunit confirmsthat the wheelsensorsare OK,
19-4 0
www.emanualpro.com
Troubleshooting
ABS lndicator Does Not Come On
The ABS indicator does not
come on when ignition switch is
turnodON lll).
GAUGEASSEMBLY5P CONNECTOR
ls there batteryvoltageT
(cont'd)
www.emanualpro.com
19-41
Troubleshooting
ABS IndicatorDoesNot ComeOn (cont'd)
(Frompage19'41)
---g-
l1 t/l3_l/ |5|
JUMPER
I GNDIBLK}
wrBE
Doesthe ABSindicatorcomeon?
19-42
www.emanualpro.com
L
Reolacethe ABS indicator drive
circuit in the gaug assmbly.
Wiresideof femaleterminals
oK.
IG2IBLK/BLU)
Checkfor sn open in the lG2 circuit:
1. Turnthe ignitionswitchON {ll).
2. Measurethe voltage between
the ABS controlunit 26Pconn e c t o rt e r m i n a lN o . 3 a n d
body ground.
{WHT/GRNI
(Topage19 44)
www.emanualpro.com
(cont'd)
19-43
Troubleshooting
ABS IndicatorDoesNot Go Off (No DTC)(cont'dl
(Frompage19,43)
WALP{BLU/REDI
ls there batteryvoltage?
JUMPCR GND2IBLKI
WIRE
Wiresadeof femaleterminals
WALPIBLU/FEDI
ls there batteryvoltage?
19-44
www.emanualpro.com
DTC11- 18:WheelSensor
NOTE:The ABS indicatorcomeson only when the drive wheelsare turning and signaldisturbanceis detected,Therefore,testdrive the car at a speedof 12 mph (20 km/h)or more afterturning the ignition switchfrom OFFto ON l), and if the ABS indicator does not come on, the svstemis OK.
-
ls the resistanceOK?
/Fronr:750 r,050o (20"C,68"F\
-'1,450O (20"C,68'F,
950
\Rear:
DTC
Appropriate
Terminal
{0}srDE ( 1 ) S | D E
RRO
IBLU/YEL}
FLO
(BRN/WHTI
1 1 ,l 2 l R i g h t - f r o n t ) No.8: Fno N o . 2 1 F
: R1
13, 14 (Left-front)
No.10rFLo No. 23: FLl
15, 16 (Rightread
No.4: RRo N o . 1 7 :R R 1
17,l8 (Lsft-rear)
. Ropairopn in th. {01o. lll circuit wire, oa short to the (01circuit wire in the lll circuit wiro
betweon the ABS control unit
and th. appropriatewhasl sensot.
. Roplacethe rpp.opriatc whe6l
Sensor.
RRTIGRN/YELI
RLl (LT BLUI
FLl IGFN/ORN}
FRl IGRN/BLKI
NO
NOTE:
. Normalvoltage:
Approx.2 V
.0 V: Replace
the ABScontrolunit.
. 4 V or more indicatesa shon to power.
Checkfor a short to body ground
in the whoal s.n3or cilcuit:
1. Disconnectthe ABS control
unit 26Pconnector.
2. Checklor cont;nuitybetween
the ABS controlunit 26Pconnector appropriatewheel sens o r { 0 ) c i r c u i t t e r m i n a la n d
body ground{se6table).
NO
(cont'dl
19-45
Troubleshooting
DTC11- 18:WheelSensor(cont'd)
C h e c kf o r c h i p p e d p u l s e r g e a r .
19-46
www.emanualpro.com
DTC31 - 38:Solenoid
-
DTC
31:FR'lN
32:FROUT
3 3 :F L l N
ls there baReryvoltage?
34:FLOUT
35:RR-lN
36:RR-OUT
Appropraate
Connector Terminal
22P
No. 1
22P
No. 12
22P
N o .1 1
22P
No.10
26P
No.13
22P
No.21
37: RLIN
26P
No.25
38:RL-OUT
26P
No. 12
RL.OUT{YELI
R p a i rs h o r t t o p o w e r i n t h e
approp.iato solenoid circuit wire
betwen the ABS control unit
and the modulator unh.
ls therecontinuity?
DTC
Checkthe ABS control unit:
1. Turnthe ignitionswitchOFF.
2. Connectthe ABS controlunit
22Pand 26Pconnectors.
3. Connectthe SCSserviceconnector.
4. Turnthe ignitionswitchON (ll).
5, Measurethe voltage between
the appropriateABS control
unit 26PconnectorCOMcircuit
terminaland body ground (see
table).
ls thereapprox.3 V7
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Wiresideof femaleterminals
FL.OUTIYEL/BLKI
Appropriate
Terminal
3 1 :F R l N
No. 2i SCOM
32:FR-OUT
No. 2: SCOM
33: FLIN
No.1:PCOM
34:FL-OUT
No. 1:PCOM
35:RRIN
No. 1: PCON4
36: RR-OUT
No. 1: PCON4
37rRL-lN
No. 2: SCOM
3a:RL-OUT
No. 2: SCOM
RL.OUT{YELI
19-47
Troubleshooting
DTC31 - 38: Solenoid(cont'dl
A8S CONTROLUNIT 22PCONNECTOR
FL.OUTIYEL/BLK}
DTC
3 1 :F R I N
32:FR-OUT
33: FL-IN
ls thereapprox.3 V?
34:FL OUT
35:RRIN
36:RR-OUT
37:RLIN
38:RL-OUT
Connector
22P
22P
22P
22P
No. 1
26P
No.13
22P
No.21
26P
N o .2 5
No.12
No.11
No.10
No. 12
www.emanualpro.com
19-4 8
c h e c k t h e M T R c H E c K ( 7 . 5A i
luse in the under-hoodABS
tuse/relaybox, and reinstallthe
luse if it is OK.
(cont'di
(To page19 50)
www.emanualpro.com
19-49
Troubleshooting
DTC51 - 53:ABS PumpMotor (cont'dl
UNDR-HOOO
ABS
FUSE/REI-AY
BOX
(Frompage19 49)
JUMPERWIRE
Chockthe pump motor ci.cuit:
1. Removethe pump motor relay.
2. Turn the ignitionswitchON {ll).
3. Connectthe pump motor relay
connector+B and MOTORterminalswith a jumporwire for
a moment,
TERMINAL
PUMPMOTORCONNECTOB
MOTOR+B {WHTI
Fr
12 lF-
(v)
v
{Topage19-51)
www.emanualpro.com
Terminalsideof femaleterminals
Bepair opon in the wire botween
the under-hoodABS fuse/relav
bor and the pump motor.
MOTOR+B IREDI
Check the pump motor operation:
Connectthe battery(+)terminalto
the pump motor connectorterminal No. 1, and the (-) terminalto
the terminalNo. 2 for a moment.
TERMINAL
MOTORGNDIBLKI
Terminal
sideof
male
terminals
(Frompage19-50)
ls thereapprox.3V?
tr
) l--l
r"r
ls thereapprox.3 V?
ls there batteryvoltage?
www.emanualpro.com
MCK IBRN,/YEL}
t0 1 1
Troubleshooting
DTG54:MainRelay
-
oK.
FeDlacethe tu3e and recheck.
AAS CONTROLUNIT 26PCONNECTON
IWHT/GRNI
(To page19-53)
www.emanualpro.com
Wiresideof femaleterminals
PCOM
scoM
IGRN/WHTI {BLK/WHTI
www.emanualpro.com
SCOM
Wiresideof temaleterminals
Troubleshooting
DTC61:lgnitionVoltage
-
Problom vorification:
1. Erasethe DTC.
2. Start the engine.
www.emanualpro.com
DTC81:CentralProcessingUnit (CPUI
-
Problemvorific.tion:
L Eraserne u t L.
2. Test-drive
the vehicle.
www.emanualpro.com
19-55
ModulatorUnit
Removal/lnstallation
NOTE:
. Do not spill brakefluid on the vehicle;it may damagethe painu if brakefluid does contactthe paint,wash it off immediatelywith water.
a Takecarenot to damageor deformthe brakelinesduring removaland installation.
. To preventthe brakefluidfromflowing,plug and coverthe hoseends and jointswith a shop towel or equivalentmaterial,
Romoval
1.
2.
Disconnect
the brakelines,then removethe modulatorunit.
lnstallation
1.
Installthe modulatoru nit.then connectthe brakelines.Tightenthe flare nutsto 15 N.m (1.5kgf.m,11 lbf.ft).
2.
3.
4.
5.
PUMPMOTOR
CONNECTOR
MODULATONUNIT
\ * \
,@
TORXEOLT
9.8N,m(1.0kgf.m.7.2lbf
ftl
www.emanualpro.com
19-56
ABS ControlUnit
Replacement
L
Removethe passenger's
side kickpanel.
Pulsers/Wheel
Sensors
Inspection
1 . Checkthe front and rear pulserfor chippedor damagedteeth.
Disconnect
the ABS controlunit connectors.
ABS CONTROLUNIT
0.4- 1.0mm
(0.02- 0.04 inl
CONNECTORS
www.emanualpro.com
19-57
Sensors
Pulsers/Wheel
WheelSensorReplacement
NOTE;
. Be carefulwheninstallingthe sensorsto avoidtwistingthe wires.
. The torquevalueof the boltsis 9.8 N.m ( 1.0kgf.m,7 Ibf.ft).
Front
\all
6 mm BOLT
9.8 N.m {1.0kgtm. ?.2lbf'ft)
WHEELSENSOR
Rgar
1. Removethe hub bearingunit (seesection18).
2. Removethe tour backingplatebolts.
to disconnectthe
3, Pullthe backingplateaway from the trailingarm, then removethe wheel sensor.lt is not necessary
brakeline.
'97 - 98 models,The '99 - 00 modelsare similar.
NOTE:This illustrationshowsthe
6 mm BOLT
9,8 N.m 11.0kgf.m, 7.2lbf.ft)
WHEELSENSOR
www.emanualpro.com
19-58
Body
RearWheelwellProtectol
.....20-90
Replacement
.........20-72
FuelPipeProtectorReplacement...20-90
RearAir Outlet Replacement..........20-91
.........20-74 *FrameRepairChart ..............................
20-106
Front Grille
lnstrument PanelRemovaland
.........20-77
Repfacement
.........20-47
lnstallation
Glass
Driver'sDashboardLower Coverand
20-29
ComponentLocationIndex ............
KneeBolsterRemovaland
Hood
Installation
.........20-48
......,,,20-75
Replacement
Glove Box Removaland
............20-76
Adjustment
lnstallation
.........20-49
*lnterior
Trim
CenterPocketRemovaland
.........20-49
lnstallation
20-40
ComponentLocationIndex ............
Center Dashboard Lower Cover
Mirrors
20-50
Removaland lnstallation ............
20-26
ComponentLocationIndex .........,,,
CenterPanelRemovaland
Moldings
.........20-50
lnstallation
20-84
Roof Molding Replacement............
Power Window Switch Removaland
20-85
Door MoldingsReplacement..........
lnstallation
.........20-51
Openers
CenterAir Vent Removaland
20-92
ComponentLocationIndex ............
lnstallation
.........20-51
RearHatchGlass
Side Air Vent Removaland
.........20-52
fnstallation
.........20-74
Replacement
Side DefoggerTrim Removaland
Disassemblyand Reassembly........20-79
fnstallation
.........20-52
............20-81
Adiustment
DashboardRemovaland
RearWeatherstripReplacement....20-83
.........20-53
lnstallation
Seats
DashboardFrameReplacement.....20-55
20-56
ComponentLocationIndex ............
Doors
Side Sill Panel
Component Location Index
.........20-87
Repfacement
FrontDoor
,,...,,,,20-2
SpareTire Cover
...........20-4
RearDoor
20-88
EmblemInstallation........................
TailgateDoor ................................
20-6
..................20-104
Sub-frame
Fenderwell
Wiper/Washer
Front Wheelwell Protector
20-97
ComponentLocationlndex ,,,,,.......
Replacement
.....20-89
Bumpers
Front Bumper Removaland
fnstaflation
RearBumper Removaland
fnstaflation
'Dashboard
Inner FenderReplacement.,.....,.,....
20-89
www.emanualpro.com
Doors
ComponentLocationIndex
Front Door:
NOTE:Refertothe 1997SeriesHondaCR-VBody RepairManual(P/N61S1030)
forfrontdoor removat.
OOORCHANNELTAPE
INNER
WATHERSTRIP
OUTERMOLDING
v
MIRRORMOUNT
COVER
PLASTIC
COVER
----s
-re
,\//. r =::rR
ffi
*Y
l
POWERDOORLOCK
CONTROLUNIT
HINGE
fl
"\-,-.*
FRONTDOOR
PositionAdjustment,
page 20-22
t\q
efl-Nr2
/ *-8
ARMREST
FRONTDOORPANEL
Removaland lnstallation,
page20,7
www.emanualpro.com
20-2
GLASSRUN
CHANNEL
REAR LOWER
CHANNEL
\ f \i \ \ \ \
t\\\
\\II
za\\l
@'-ua$
REGULATOR
page20-10
Replacement,
k'"""'
POWERWINDOW
MOTOR
CYLINDEB
PROTECTOR
OUTERHANOLE
page20-8
Replacement,
INNERHANOLE
@,
LATCH
PROTECTOR
,;@
I
POWEN
POWEF
ACTUATOB
wtNDow
swtTcH
(cont'd)
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20-3
Doors
GomponentLocationIndex(cont'dl
Rear Door:
NOTE: Refertothe 1997 Series Honda CR-V Bodv RepairManual (P/N 6151030)for rear door removal.
DOORCHANNELTAPE
INNERWEATHERSTRIP
OUTERMOLOING
DOORPROTECTION
D \FR,
\a)Ei
tu4
PositionAdiustment,
page 20-22
ARMREST
ARMREST
BRACKET
HINGE
REARDOORPANEL
1'99- 00 models)
Removaland Installation,
page20 '11
dP
@
REARDOOR
('97-98 models)
Bemovaland Installation,
page20-11
('99- 00 models)
20-4
www.emanualpro.com
OUARTER
SEAL
OUARTER
GLASS
Replacement,
page20-13
GLASSRUN
CHANNEL
REARCHANNEL-\ -.-----_----_-""
UPPERCOLLAR
trw
-flHiili^'i--_Fffi
,6S
FRONTLOWER
CHANNEL
POWERWINDOW
MOTOR
REGULATOR
page20'13
Replacement,
STRIKER
Adjustment,page20 2L
l
I
W*
LATCH
Replacement,
page20'13
INNRHANDLE
s /*
eoweawrruoow
sYtfcH
M-q/
-\<SU
fl
LOCKROD
PROTECTOR
CItr'
6,1-
POWEBDOOR
LOCKACTUATOB
LATCH
PROTECTOB
iI
LOCK
CRANK
(cont'd)
www.emanualpro.com
20-5
Doors
Component Location Index (cont'dl
Tailgate Door:
NOTE: Referto the 1997SeriesHondaCR-VBody RepairManual{P/N61S1030)
for tailgatedoor removal.
TAILGATEOOOR
PositionAdjustment,page20-23
HINGE
COVER
\
LICENSEPLATE
TRIM
page20-16
Replacement,
TAILGATEDOOR
WEATHERSTRIP
HINGE
illt
REARHATCHGLASSLATCH
page20 18
Replacement,
SUPPORTSTRUT
REARHATCHGLASS
ACTUATOR
page20-19
Replacement,
lVr
d
d+-BA^cKEr
LATCHSTOP
page20-17
Replacement,
REARHATCHGLASS
\A
Replacement,
page20'19
TAILGATEDOORLATCH
page20-17
Replacement,
TAILGATEDOOR
HANDLE
page20-16
Replacement,
TAILGATEDOOR
STRIKER
Adjustment,page20-25
k @ /
-6
%
\
TAILGATEDOORWEDGE
Adiustment,page 20-25
d\
FLEXIBLECARGO
HOOK
TAILGATEDOORPANEL
page20-15
Removaland Installation,
www.emanualpro.com
20-6
Removethe innerhandle(seepage20-3).
2.
eF**I
>:Clip locttions
g>,3
A>, 1
f- fwi l.$ ; ^ r * l
ttv
il
F:I
3
>: Scrwlocations,
FRONTOOORPANEL
SPEAKER
COVER
TRIM PAD
REMOVER
(Commercially
avaalable)
Snap-on
*4177,ol
equivalent
{0.04in.) r
'..4'
,mm+,----ZY"
-i
F
45 mm
{1.77in.}
www.emanualpro.com
20-7
Doors
FrontDoorOuterHandleReplacement
CAUTION: Put on gloves to protect your hands.
4.
NOTE;Raisethe glassfully.
NOTE:
. To easereassembly,
note location@ ofthe outer
handlerod on the joint beforedisconnecting
it.
. Takecare not to bendthe outer handlerod.
. Use a shop towel to protectthe opening in the
door.
1 . Removel
. Door panel(seepage20-7)
. Plasticcover{seepage2O-2)
2.
LOCK
CYLINDER
5.
RETAINEB
CLIP
OUTEB
HANDLE
5.
HANDLE
www.emanualpro.com
20-8
FrontDoor LatchReplacement
CAUTION: Put on gloves to protect your hands,
NOTErRaisethe glassfully.
'1. Remove:
. Door panel(seepage20-7)
. Plasticcover (see page 20-21
. O u t e rh a n d l e
2.
3.
6x1.0mm
6 N.m 10.6kgt m,
4 tbf.ft)
CYLINDER
ROD
6xl.0mm
8 N.m (0.8kgf m,
6 tbf ft)
OUTER
HANDLE
ROD
LOCKROD
PROTECTOR
CONNECTOR
HARNESS
CLIP
www.emanualpro.com
20-9
Doors
FrontDoorGlassand RegulatorReplacement
CAUTION: Put on gloves to protect your hands,
1.
2.
Remove;
. Door panel(seepage20-7)
. Plasticcover (see page 20-21
Carefullymove the glassuntil you can seethe bolts,
then loosenthem. Slidethe guide to the front, then
removethe glassfrom the guide.Carefullypull the
glassout throughthe window slot.
NOTE:Takecare not to drop the glassinsidethe door.
3.
Roaru/ard
GLASS
Loosen,
REGULATOR
www.emanualpro.com
20-10
RearDoor PanelRemovaland
lnstallation
4.
RGULATOF
Removethe innerhandle(seepage20-5).
'99 - 00
Removethe screwsfrom the armrest.On
models,removethe screwfrom the beverageportion. Releasethe clipsthat hold the door panel,then
removethe door panelby pullingit upward.
NOTE:Removethe door panel with as little bending as possibleto avoidcreasingor breakingit.
TBIM PAD
REMOVER
(Commercially
available)
Snap-on
t_
#4177,or
lmm
equivalent
{0.04in.)
T r-----
/t5 mm I
11.77in.)
POWERWINOOWMOTOR
REGULATOR
DOOBPANEL
ARMREST
EEVERAGE
HOLDEN
('99 00modelsi
^mi
A
A
'99 - 00 models:
www.emanualpro.com
\
(,1
3.
20-11
Doors
RearDoorOuter HandleReplacement
CAUTION: Put on gloves to protect your hands.
4,
NOTE:Raisethe glassfully.
1.
2.
Remove:
. Door panel(seepage20-11)
. Plasticcover(seepage20-4)
Remove the lock crank. then remove the screws
securing the latch.
>: Screw locations
A>.3
OUTERHANDLE
ROD
B>,'l
6x1.0mm
6 N.m 10.6kgf.m.
4 tbf.ft)
PCtlTn-i
LOCKROD
PROTECTOR
Move the latch down, and remove the bolts securing the outer handle,
SHOPTOWEL
5.
20-12
www.emanualpro.com
RearDoorGlass,OuarterGlassand
RegulatorReplacement
2.
Removel
. Door panel(seepage20-11)
. Plasticcover(seepage20-4)
. Outerhandle(seepage20-121
D i s c o n n e ctth e c o n n e c t o ra n d h a r n e s sc l i p , t h e n
removethe latchthroughthe hole in the door.
1.
Remove:
o Door panel(seepage20-11)
. Plasticcover(seepage20-4)
2.
6x1.0mm
9.8N.m (1.0kgtm,
7.2 tb{ft)
GLASS
3.
NOTE:
. Makesuretheouterhandlerod andinnerhandle
properly.
rodareconnected
. Makesurethedoorlocksandopensproperly.
(cont'd)
www.emanualpro.com
20-13
Doors
RearDoorGlass,OuarterGlassand RegulatorReplacement(cont'd)
3.
C a r e f u l l yl o w e r t h e g l a s s .R e m o v et h e b o l t s a n d
s c r e w f r o m t h e r e a r c h a n n e l ,t h e n p u l l t h e r e a r
channelup as shown. Removethe glass from the
r e a rc h a n n e lC
. a r e f u l l yp u l l t h e g l a s so u t t h r o u g h
the window slot.
4.
Removethe quarterglass.
WPU
f\
'^S\\\-.-
W)+
-6 x 1.0 mm
I N m i o . 8 k sm
f,
6 tbf.ftt
c>,1
CLIP
REGULATOR
www.emanualpro.com
20-14
''
TailgateDoor PanelRemovaland
lnstallation
6.
N O T E :T a k e c a r e n o t t o s c r a t c ht h e d o o r p a n e l a n d
other parts.
1.
REGULATOR
SECTORGEAB
FLEXIBLECARGO
HOOKBASE
@t"
COVER
POWER
wtNDow
MOTOR
FLEXIBLE
CARGOHOOK
POWERWINDOWMOTOR
2.
>: Screwlocations.2
?11 |
HPI
,4|
REGULATOR
7.
TAILGATE
DOORLIO
3.
www.emanualpro.com
20-15
Doors
LicensePlateTrim Removaland
Installation
TailgateDoorHandleReplacement
CAUTION; Put on gloves to protecl your hands,
1.
Remove:
. Tailgatedoor panel(seepage20,15)
. Licenseplate
. Licenseplatetrim
2.
'1. Remove
the licenseolate.
2.
3.
Disconnectthe handlerod. Removethe nuts securing the tailgatedoor handle,then removethe tailgatedoor handleby pullingit out.
a: Nut loc.lions.4
5x0.8mm
1.8Nm(0.18kgt.m.
1.3 rbf.ft)
TAILGATEDOOR
6x1.0mm
9.8 N.m {1.0kgtm,
7.2 rbtft)
,Is
TAILGATE
DOOR
HANDLE
Installationis the reverseof the removalprocedure.
NOTE:
. Makesurethe handlerod is connectedproperly.
. Makesurethe tailgatedoor openspropedy.
4.
www.emanualpro.com
20-16
2.
Disconnect
the handlerod. Removethe bolts securing the latchstop and screwssecuringthe latch.
>: Bolt,screwlocations
A>,3
3.
Move the latch stop and latch down, then pry the
latchstop rod out of its joint usingdiagonalcutters.
Removethe latchstop and latchthroughthe hole in
the tailgatedoor.
NOTE:
. To easereassembly,note location@ of the latch
stop rod on the joint beforedisconnecting
it.
. Takecare not to bend the latch stop rod.
B>,3
6x1.0mm
''-t.-N
gta
-\S/r
BUSHING
(cont'd)
www.emanualpro.com
20-17
Doors
TailgateDoor Latchand LatchStop
Replacement(cont'd)
4.
RearHatchGlassLatch
Replacement
NOTE: Takecare not to scratchthe tailgatedoor.
' 1 . R e m o v et h e t a i l g a t ed o o r p a n e (l s e e p a g e 2 0 - 1 5 ) .
2.
LATCHSTOP
KNOE
3.
www.emanualpro.com
20-18
RearHatchGlassLockCylinder
Replacement
RearHatchGlassActuator
Replacement
1.
2.
1.
Remove;
o Tailgatedoor panel(seepage20-'15)
. Rearhatchglasslockcylinder
2.
>: Boltlocation.1
6x1.0mm
9.8N.m {1.0kg .m,
7.2 tbt.lll
REARHATCHGLASS
CONNECTOR
CONNECTOR
J.
REARHATCH
GLASS
ACTUATOR
JOINT
-6{
www.emanualpro.com
20-19
Doors
TailgateDoorWeatherstrip
Replacement
Frontand RearDoorGlass
Adjustment
asshown.
Installthetailgatedoorweatherstrip
NOTE;
. Cleanthetailgate
witha sponge
doorbondingsurface
in alcohol.
dampened
NOTE:
. Placethe vehicleon a firm, levelsurfacewhen adjusting the glass.
. Checkthe weatherstripsand glassrun channelfor damage or deterioration,and replacethem if necessary,
1.
Remove:
. D o o rp a n e l( s e ep a g e s 2 0 - 7l l,l
. Plasticcover(seepages2O-2,41
2.
Adjustthe glass.
i-t]
/[L
|
I oouere-rrceo
ll 1T
I Thickness:
lE
lll
rAPE
I aDHEsrvE
I
Front:
r.2mmlo.o5
in.)
lM
/L)
DOUBLE.FACED
ADHESIVETAPE
Thickne$:
1.2mm 10.05in.)
g\
GLASSRUN
CHANNEL
BUTYL
SEALANT
Sealantarea,
ROLLER
GUIDEBOLTS
6x1.0mm
8 N.m{0.8kgf.m,
5 tbffi)
Tightenthe rollerguide bolts.
Loosenthe front channelbolt.
www.emanualpro.com
20-20
e.
Lowerthe glass.
l.
Loosenthe rearchannelmountingbolts,
f.
Lowerthe glass.
Push the rear channelagainstthe glass,then
tightenthe mountingbolts.
>: Bohlocationt2
5x1.0mm
8 N.m(0.8kgtm.6lbtft)
GLASS
6x1.0mm
8 N'm108 kg{m'
6 tbf.ftl
a,
Raisethe glassfully.
o.
Loosenthe regulatormountingbolts.
c.
Pushthe glassforward.
o.
Tightenthe regulatormountingbolts.
il
>: Bohlocations,
6x1.0mm
8 N.m(0.8kgf.m,6 lbf.ft)
GLASS
3.
4.
5.
Checkthe glassoperation.
NOTE:Checkthat the glass contactsthe glass run
channelevenly.
www.emanualpro.com
20-21
Doors
Frontand RearDoorGlass
Adiustment(cont'dl
6.
,'r)"f
(r\
"1
tl
-"'*r"i
12 mm {0.47in.l
Frontand RearDoorPosition
Adjustment
0.5 m (1.6ftl
HOSE
DOORMOUNTING
BOLTS
I x 1.25mm
21 lbI.ftl
28 N.m12.9kgtr.m,
Loosenthe doormountingbolrsslighrly
to movethedoorlN or OUTuntil
it'sflushwith the bodv.lf necessary,
youcaninstallashimbehindone
hingeto makethedooredges
PARALLEL with the bodv.
300mm 111.8in.)
HINGEMOUNTINGBOLTS
8 x 1.25mm
28 N,m 12.9kgt.m. 21 lbl.ftl
Removethe innerfender,
loosenthe hingemounting
bolts,and movethe door
BACKWARDor FORWARD,
UP or DOWNas necessary
to equalizethe gaps.
Lowerthe glass.
7.
20-22
www.emanualpro.com
..-
TailgateDoor PositionAdjustment
The door and body edges should be parallel.lf necessary,adjustthe door cushion.
ry.
oooRcusHroNs
DOOR
CUSHION
Checkfor water leaks.
HINGEMOUNYING
BOLTS
8 x 1.25mm
25 N.m 12.6kgt m,
19 rbf.ftl
TAILGATE
DOOR
MOUNTINGsOLTS
8 x 1.25mm
25 N.m {2.6 kgf.m,
19 tbf.ft)
8x1.0mm
22 N'rrl 12.2kgl.m,
16 tbt.ftl
6xl.0mm
9.8N.m {1.0kgt m,
1.2 tbl.ltl
(cont'd)
www.emanualpro.com
20-23
Doors
TailgateDoor PositionAdiustment
Frontand RearDoorStriker
Adjustment
(cont'd)
1.
STRIKER
Inserta shoptowel
betweenthe body and
scREws
8 x 1.25 mm
18 N.m (1.8kgt.m,
13 rbf.ft)
-*4
l2 mm (0.47in.)
.*1:]*
d3
"1
,'r)"C
II
0.5m {1.6ft}
2.
J.
HOSE
Lightlytightenthe screws.
Wrap the strikerwith a shop towel, then adjustthe
strikerby tappingit with a plastichammer.
CAUTION: Do not tap the striksr loo hard.
300 mm {11.8in.l
20-24
www.emanualpro.com
4.
5.
Lightlytightenthe screws.
6.
TailgateDoorStrikerAdjustment
TailgateDoorWedgeAdjustment
1.
1.
2.
L o o s e nt h e s c r e w s ,t h e n i n s e r t a s h o p t o w e l
betweenthe body and striker.
STRIKER
Insen a shoptowel
between the body and
Forward
TAILGATEOOOR
8 x 1.25mm
18 N.m (1.8kgf.m,
r 3 tbf.ft)
Lightlytightenthe screws.
4.
Holdthe tailgatedoor handleout, and push the tailgate door againstthe body to be sure the tailgate
door wedge allows a flush fit. lf the tailgate door
latchesproperly,tightenthe boltsand recheck.
1.
www.emanualpro.com
20-25
Mirrors
ComponentLocationIndex
MIRRORMOUNT
COVEB
POWERMIRBOR
page20 27
Replacement,
,//
MIRRORHOLDER
page20-27
Beplacement,
@
DAMPER
w
REARVIEWMIRROR
page20-28
Replacement,
q
COVER
www.emanualpro.com
20-26
PowerMirror Replacement
PowerMirror HolderReplacement
1.
2.
1,
HOOK
C a r e f u l l yp u l l o u t t h e b o t t o m e d g e o f t h e m i r r o r
holderbv hand.
ADHESIVE
MIRROR
www.emanualpro.com
20-27
Mirrors
RearviewMirror Replacement
CAUTION: When prying with a flat-tip screwdrivor,
wrap it whh a shop towel to prevent damage.
NOTE: Take care not to scratchthe cover or tear the
headliner.
1.
HOOKS
Removethe rubberdamper.
>: Screwlocations,3
www.emanualpro.com
20-28
Glass
ComponentLocationIndex
NOTE:The numbersafterthe part namesshow the quantitiesof the pans used.
Windshield:
MOLOING
U P P E RS E A L , 2
UPPERRUBBERDAM
1'00model)
UPPERFASTENER
('97- 99 models,and requiredfor
replacement
or reinstallation
on '00 model)
FASTENER,2
(Self'adhesive
type,glassside)
('97- 99 models,and requiredfor
replacement
or reinstallation
o n ' 0 0m o d e l )
WINDSHIELD
page20-30
Replacement,
FASTENER,2
(Self-adhesive-type,
body side)
('97- 99 models,and
requiredlor replacement
or reinstallation
on
'00 model)
tE-r
*@
LOWERRUBBERDAM
('00model)
Ouarter Glass:
LOWERRUBBERDAM
l'97 99 models,and requiredfor reDlacement
or reinstallation
on'00 modeli
SIDERUBBERDAM, 2
{'97-99 models,and
requiredfor replacement
or reinstallation
on
'00 model)
OUABTERGLASS
page20-35
Replacement,
FASTENER,
1
(Clip-type,
body side)
\,o,,.,.*,,,
( S e l f a d h e s i v e - t y p e ,g l a s s s i d e )
www.emanualpro.com
Glass
WindshieldReplacement
CAUTION:
. Put on gloves to protect your hands.
. Use seat coversto avoid damaging any surfaces.
1.
2.
4.
Apply protective tape along the edge ot the dashboard and body as shown. Using an awl, make a
hole through the rubber dam and adhesivefrom
inside the vehicle. Push a piece of piano wire
through the hole, and wrap each end around a
piece of wood.
PROTECTIVE
TAPE
PIANO
WIRE
RUBBER
UPPER
WINDSHIELD
PROTECTIVE
TAPE
PIANO
WINDSHIELO
MOLDING
PROTECTIVE
TAPE
DASHBOARD
WINDSHIELD
ADHESIVE
LOWERRUBBER
DAM
CAUTION: Hold the piano wire as closeto the windshield as possibleto prevent damageto the body
and dashboard.
3.
5.
W i t h a h e l p e ro n t h e o u t s i d e ,p u l l t h e p i a n o w i r e
backand fo(h in a sawingmotion,and carefullycut
through the rubber dams and adhesivearoundthe
e n t i r ew i n d s h i e l d .
6.
C a r e f u l lrye m o v et h e w i n d s h i e l d .
P u l l d o w n t h e f r o n t D o r t i o no f t h e h e a d l i n e r( s e e
page20-44).
CAUTION: Take care not to bend the headliner
excessivsly,or you may break it.
www.emanualpro.com
20-30
7.
8.
\,@,--
w,{,.
'>Yl
14mm
0.55in.l
-'-
\l
ALIGNMENT
MARKS
1 3m m
(0.51in.)
--r-r
ALIGNMENT
MARKS
1 3m m
in.)
10.51
NOTE:Cleanthe shadowedarea.
*ffi
ALIGNMENT
MARKS
1 2m m
(0.47in.l
WINDSHIELD
(cont'd)
www.emanualpro.com
20-31
Glass
WindshieldReplacement(cont'dl
1 1 . G l u et h e m o l d i n gs i d es e a la n d m o l d i n gu p p e rs e a l
to the moldingon eachside.
1 2 . A l i g na n d g l u et h e m o l d i n gt o t h e e d g eo f t h e w i n d shield.
N O T E : B e c a r e f u ln o t t o t o u c h t h e w i n d s h i e l d
w h e r ea d h e s i v w
e illbeapplied.
a. With a brush,apply a light coat of primer (3lvlN200,or equivalent)to the edge ot the windshield
as shown,
b. Gluethe adhesivetapes l3M 4212,or equivalent)
to both bottomedgesof the windshield.
c . A l i g nt h e a l i g n m e n m
t a r ko n t h e m o l d i n gt o t h e
alignmentmarkof the windshield.
d. Gluethe moldingto the edgeof the windshield.
100mm {3.9in.l
100mm {3.9in.}
ADHESIVETAPE
Thic*ness:1.2mm (0.05in.)
W i d t h4
r m m ( 0 . 1 6i n . )
r0 mm (1.6in.l
www.emanualpro.com
20-32
2
>: Fastener
locations,
NOTE:
Do not apply body primerto the windshield,and
do not get body and glassprimerspongesmixed
up.
N e v e r t o u c h t h e p r i m e d s u r f a c e sw i t h y o u r
hands.lf you do, the adhesivemay not bond to
the windshieldproperly,causinga leakafter the
windshieldis installed.
. Keep water, dust, and abrasivematerialsaway
from the primedsurface.
R-
//fu
: Applyglassptimar hea.
Applyglassprimer
WINDSHIELD
Applyglassprimer
to the molding.
1 0 m m RUBBERDAM
{0.4in.}
WINDSHIELD
WINDSHIELD
GLASS
BRACKETS
NOTE: Adjust the glass bracketsto centerthe windshieldin
the opening,then tightenthe
www.emanualpro.com
MOLDING
12 mm 10.5in.)
(cont'd)
20-33
Glass
(cont'dl
WindshieldReplacement
17. With a sponge,apply a light coat of body primerto
t h e o r i g i n a la d h e s i v er e m a i n i n ga r o u n dt h e w i n d shield openingflange,Let the body primer dry for
at least10 minutes.
NOTE:
. Do not apply glassprimerto the body, and be careful not to mix up glassand bodyprjmersponges.
. Nevertouch the primed surfaceswith your hands.
. Maskoff the dashboardbeforepaintingthe flange.
///////l
, apptvaoav primorhere.
16 mm {0.63in.l
12mm (0.47in.)
Ff oo*tt'u'
Makea slightlythicker
beadat eachcorner.
8 mm {0.31in.l
7.8mm 10.30in.)
8mm
16 mm
10.fi in.) (0.31in.)
FASTENER
14.6mm
(0.57in.l
16 mm
{0.63in.)
WINOSHIELD
adhesiveand hardenertogether
on a glassor metalplatewith a putty knife.
NOTE:
. Cleanthe platewith a spongeand alcoholbefore
mixing.
. Followthe instructionsthat come with the adhesive.
'19. Beforefilling a
as shown.
WINDSHIELO
Cut nozzleend
10 mm {0.39in.)
RUBBER
DAM
3mm
{0.1in.l
7 mm {0.27in,}
20-34
www.emanualpro.com
OuarterGlassReplacement
2 1 . U s e s u c t i o nc u p s t o h o l d t h e w i n d s h i e l do v e r t h e
opening,align it with the alignmentmarksmade in
s t e p 1 4 , a n d s e t i t d o w n o n t h e a d h e s i v eL. j g h t l y
push on the windshielduntil its edge is fully seated
on the adhesiveall the way around.
NOTErDo not open or closethe doors until adhesive is dry.
SUCTTON
ALIGNMENTMARK
CAUTION:
. Put on gloves to protct your hands.
. Use seat covers to avoid damaging any surfaces.
1. To removethe quarterglass,first removethe:
. Rearseat(seepage20-63)
. Cargofloor lid and cargo storagebin (seepage
20 431
. R e a rt r i m p a n e l a n d r e a r s i d e t r i m p a n e l ( s e e
page 20-421
. Rearhatchglasssupportstrut (seepage20-78)
. Ouarterpillartrim panel(seepage20-421
. Taillight(seesection23)
NOTE:With the rear hatch glass support strut
removed,you will need to support the rear hatch
glassby hand.
2.
L e t t h e a d h e s i v ed r y f o r a t l e a s t o n e h o u r , t h e n
s p r a y w a t e r o v e r t h e w i n d s h i e l da n d c h e c k f o r
l e a k s .m a r k l e a k i n ga r e a s ,a n d l e t t h e w i n d s h i e l d
dry, then sealwith sealant.
NOTE:
. Let the vehiclestandfor at leastfour hours after
w i n d s h i e l di n s t a l l a t i o nl f. t h e v e h i c l eh a s t o b e
usedwithin the first four hours,it must be driven
.
.
2 4 . Reinstallall remainingremovedparts.
NOTE:
. Installthe rearviewmirror rubber damper after
t h ea d h e s i vh
e a sd r i e dt h o r o u g h l , .
. A d v i s e t h e c u s t o m e rn o t t o d o t h e f o l l o w i n g
thingsfor two to threedays:
- S l a m t 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 d
up.
- Twist the body excess,vely{such as when
going in and out of drivewaysat an angle or
drivingover rough.unevenroads).
www.emanualpro.com
(cont'd)
20-35
Glass
Ouarter Glass Replacement(cont'd)
lnside:
v\//,
/6\ /l
ADHESIVE
3.
Carefullyremovethe quarterglass.
NOTEj Checkthe molding for damage,replacethe
qua.terglassif necessary.
20-36
www.emanualpro.com
7.
NOTE:
. Be carefulnot to touch the quarterglasswhere
adhesivewill be aDplied.
. Do not peelthe separatoroff the butyl tape.
| Bttryl taee locationsl3M 8628,or equivalent)
Thickness:3.2
mm 10.13in.l
/'/.////
Width:5.4mm 10.25
in.)
BUTYLTAPE
I
wmr
> t \
/
GLASS
>: Fastenoalocation, I
MOLDING
FASTENER
1l mm
(0.43in.)
GLASS
MOLDING
ALIGNMENTMANK
400 mm (15.75in.)
8.
r lass.
1 0 . R e m o v et h e q u a r t e g
(cont'd)
www.emanualpro.com
20-37
Glass
(cont'd)
OuarterGlassReplacement
11. With a sponge,apply a light coat of glassprimer to
the insideface of the quaner glass,as shown,then
lightlywipe it off with gauzeor cheesecloth.
NOTE:
. Do not apply body primer to the quarter glass,
a n d d o n o t g e t b o d y a n d g l a s sp r i m e rs p o n g e s
m r x e du p .
. Nevertouchthe primedsurfaceswith your hands.
It you do, the adhesivemay not bondto the quarter glass properly.causinga leak after the quar
ter glassis installed.
. Keep water, dust, and abrasivematerialsaway
from the primedsurface.
7///f
: Applybody primerhere.
' aeerysra$primerhere.
1 0m m
{0.39in.)
BUTYLTAPE
'13.
BUTYLTAPE
1 4 . Beforefilling a cartridge,cut the end of the nozzle
MOLOING
23 mm
10.90in.) 10 mm 10.39in.)
as snown.
Cutnozzleend
10 mm {0.39in.)
GLASS
7 mm {0.27in.)
20-38
www.emanualpro.com
i:.8T".,1,/:AoHEsrvE
I rnm
(0.31in.)
BUTYL
TAPE
SUCTIONCUPS
1 9 . Reinstallall remainingremovedparts.
NOTE:Advisethe customernot to do the following
thingsfor two to threedays:
.
.
www.emanualpro.com
20-39
lnteriorTrim
ComponentLocationIndex
SRScomponentsare locatedin the areasmarkedwith an asterisk(*). Reviewthe SRScomponentlocations,precautions,
and proceduresin the SRSsection(24)beforeperformingrepairsor service.
CENTERPILLAR
FRONTPILLAR
UPPER
TRIM
TRIM
(seepage20 41)
(seepage20-41)
CENTERPILLAR
FRONTSIDE
LOWERTRIM PANEL
TRIM
(seepage20 41)
(seepage20-41)
BEARSIDE
TEIM
(seepage20'41)
HEADLINER
Removaland lnstallation,
page 20-44
OUARTERPILLAR
TRIM PANEL
(seepage20 42)
*CARPET
Replacement,
page20 45
CENTERCONSOLEIM/T}
Replacement,
page20-47
CENTENTABLE
(seepage20-45)
PARKINGBRAKE
COVER
(seepage 20-45)
CARGOFRONT
SPACER
(seepage20 43)
TRIM
20-40
www.emanualpro.com
TRUNKFLOOR
EXTENSION
(seepage20 43)
Removaland Installation
CAUTION:
. Put on gloves to protect your hands,
. When prying with a tlat-tip screwdrivel, wrap it with protective tape to prevent damage.
. When removing the support strut of the rear hatch glass,you will need to open or closethe rear hatch glass by hand.
NOTE:Takecarenot to bendor scratchthe trim and panels.
>: Cliolocations
a>,5
B> , 8
c>,1
e>,2
o>.2
'rrl
sl
elElw"lel
I
l_lss-l
REARDOOR
TRIM
FRONTSEATBELT
UPPER
BOLT
7/16- 20 UNF
32 N.m {3.3 kgf.m,
24 rbt.ft)
Apply liquidthread
PILLAR
CENTER
LOWERTRIM PANEL
REARSIDE
LOWER
ANCHOB
COVER
('98 00 models)
FRONTSEATBEL
LOWERANCHOR
BOLT
7/15- 20 UNF
32Nm(3.3kgf.m,
24 tbt.ftl
REARSIDETRIM
tlemovethe rearseat
(seepage20 63).
ANCHOR
CAP
('97model)
{cont'd)
www.emanualpro.com
20-41
InteriorTrim
Removaland Installation(cont'd)
>i Clip loc.tions
a>,21
B>,4
c>,1
D > ,1
E>.!
F> , 3
@wt
we@M
REANSEATBELT
UPPERANCHORBOLT
7/16-20UNF
32 N.m {3.3kgt.m,
24 rbt.ft)
OUARTERPILLAR
TNIM PANEL
Removethe rear hatch glass
supportstrut (seepage
20-741.
REARDOOR
REARSIOE
TRIM PANEL
Removethe reat seat
(seepage20-63).
REAR
Disconnectthe accessory
socketconnectors,
F
CONNECTOR
5x1.0mm
9.8N.m (1.0kgf.m,
1.2lbt-lrl
TIEDOWN
HOOK
ffi
TIE
oowN
HOOK
6x1.0mm
9.8N.m (1.0kgt m,
7.2 tbf.ft)
STRIKER
REARTRIM PANEL
Removethe cargo areafloor
and cargosloragebin.
20-42
www.emanualpro.com
6x1.0mm
9.8 N.m (1.0kgtm,
7.2 tbf ftl
O\A
D
REARSEATBELT
LOWERANCHOREOLT
7/16- 20 UNF
32 N.m {3.3kgt.m,
24 tbl.frl
rr.
m)b
-</
0>,2
c>,2
6xl.Omm
tbr.rrl
At
Nmr1.o
ksnm.l
D
GlrrIIITTpl
-<_/lbe.8
0pE
7.2
B>,r
A>,8
|I
.\
tl1|r' t
l| w
|I
r-
l--Tr@HP
I v
l'---llH-
-E
TRUNK MAT
LOCKASSEMBLY
BUSHING
l V^
> '%L
i l
v
"ro"*i*
TRUNKFLOOR
EXTENSIONS
CARGOAREAFLOOR
FLOOR
SrO
LID
l*,hl
CARGOSTORAGEBIN
FLOORSIDEFRAME
CARGO
FRONT
TRIM
Insta,lationis the reverseof the removalprocedure.
NOTE:
. lf necessary,
replaceany damagedclips.
r Beforeinstallingthe anchorbolts,makesurethereare no twistsor kinksin the seatbelts.
www.emanualpro.com
20-43
lnteriorTrim
Headliner
Removaland Installation
CAUTION: When prying with a tlat-tip screwdriver,
wrap it with protective tape to prevent damage.
3.
NOTE:
. Takecarenot to bendand scratchthe headliner.
o Be careful not to damagethe dashboardand other
interiortrim.
1.
2.
Remove:
. Frontand reardoor sidetrim (seepage20-41)
. F r o n tp i l l a r t r i m( s e ep a g e2 0 - 4 1 )
. Centerpillarlowertrim panel(seepage20-41)
. Centerpillaruppertrim (seepage20 41)
. Rearseat(oneside,seepage20-63)
. Cargoareafloor and cargostoragebin
{seepage20-43)
. Reartrim panel (see page 20-421
. Rearsidetrim panel(oneside,see page20-42l,
. R e a rh a t c hg l a s ss u p p o r ts t r u t ( o n e s i d e , s e e
page20-78)
. Ouanerpillar trim panel {one side, see page 2042)
. Ceilinglight,interiorlight and trunk light
(seesection23)
. Rearviewmirror (seepage20-28)
ry_l
COVER
4.
A\"rYr*
I
|
||
Pullout. OUARTER
TRIM
PANEL
suNvtsoR
5.
6.
20-44
www.emanualpro.com
Carpet Replacement
are locatedin this area.Reviewthe SRS
SRScomDonents
and proceduresin the
componentlocations,precautions,
SRSsection{24)beforeperformingrepairsor service.
4.
a: Nut locations,4
8 x 1.25mm
22N.m l2.2kgl.n,
16 tbt ft)
8 x 1.25mm
22 N.m 12.2kgf.m,
16 tbtfrl
i l l
, l
CENTERTABLE
2.
Removethe footrest.
Forwaad
>: Eoltlocaiions,2
6x1.0mm
9.8N.m {1.0kgf.m,
7.2 tbt.ttt
FOOTREST
3.
Removethe parkingbrakecover.
>: Screwlocations,2
"
6bo" I
COVER
TABLEFRAME
BRACKET
{cont'd)
www.emanualpro.com
20-45
lnteriorTrim
(cont'dl
CarpetReplacement
5.
Removethe centerlowercover(M/Tmodel).
8.
>: Cliplocations,2
-ffi]
lN'
>: Cliplocations.3
FASTENER
COVER
6.
.dL I
tEu( |
- qf
SNSUNIT
FASTENER
('98- 00 models)
cARPET
COVER
7.
20-46
www.emanualpro.com
NOTE:
. Take care not to damage. wrinkle or twist the
carper.
. Makesurethe seatharnessis routedcorrectly.
. lf necessary,
replaceany damagedclips.
. Reaftachthe cut areas@ and @ ('97 model)or
cut area @ ('98 - OOmodels)in the carpetwith
wire ties.
Dashboard
GenterConsoleReplacement
lnstrumentPanelRemovaland
Installation
M/T model:
NOTE;Takecare not to scratchthe dashboardand related
parts,
1,
CAUTION:
. When prying with a flat-tip screwdriver.wrap it with
protestive tape, and apply prolestive tape around the
related parts, to provont damago,
a Put on glovss to protect your hands.
NOTE: Takecare not to scratchthe dashboardand related
pans.
*K/
6-Emmmn>
| #\
arl
l
r#sr\
= -, l
|
]
3.
3.
www.emanualpro.com
20-47
Dashboard
Driver'sDashboardLowerCoverand KneeBolsterRemovaland Installation
SRScomponentsare locatedin this area.Reviewthe SRS
componentlocations,precautions,
and proceduresin the
SRSsection(24)beforeperformingrepairsor service.
2.
GAUTION:
. When prying with a tlat-tip screwdriver,wrap h with
proteqtive tape, and apply protective tape around the
relatd parts, to prevent damage,
. Put on glovgsto protect your hands.
6x1.0mm
9.8N.m ('1.0kgtm.
7.2 tbtftl
R e m o v et h e s c r e w s ,a n d d e t a c h t h e c l i p s , t h e n
removethe driver'sdashboardlower cover.Disconnectthe rearhatchglassopenerswitchconnector.
>: Screw locations,2
I
GlTtrrrb
I
. - l
>: Cliplocations
A>,3
B > ,1
rr.- |
lr, l
@,
r ' "| {l
|'l
1
REARHATCHGLASS
OPENERSWITCH
CONNECTOR
KNEEBOLSTEF
3.
20-48
www.emanualpro.com
Installation
CenterPocketRemovaland
Installation
CAUTION:
. When prying with a flat-tip 3crewdriver,wrap it with
protective tape, and apply protoqtivetape around ths
related parts, to prgveni damage.
. Put on glovegto protect your hands.
1.
A/T model:
1.
GLOVEBOX
STOPS
6F@''
Il
-
elsl
GLOVEBOX
3.
www.emanualpro.com
Installation
is the reverseof the removalorocedure.
20-49
Dashboard
CenterDashboardLowerGover
Removaland Installation
CenterPanelRemovaland
lnstallation
CAUTION:
. Whn prying with a flat-tip screwdrivet,wrap it with
protective tap, and apply proteclive tape around the
rslated parts to prevenl damage.
. Put on glovgsto protect your hands.
NOTE:Takecare not to scratchthe dashboardand related
oarts.
1.
Remove:
. Driver'sdashboardlowercover(seepage20-48)
. Glovebox (seepage20-49)
. Centerpocket(AVTmodel.seepage20-49)
. Centerconsole (M/f model, see page 20-41l,
. Centerupperpocket(M/Tmodel,see page2O-47J
2.
R e m o v et h e s c r e w s ,a n d d e t a c h t h e c l i p s . t h e n
r e m o v e t h e c e n t e r d a s h b o a r dl o w e r c o v e r .
the connectors.
Disconnect
>: Screw locationa,.a
6br"
- Il
CAUTION:
. When prying with a flat-tip screwdriver,wrap it with
protective tape, and apply protectivetape around the
relatgd parts to prevent damage.
. Put on glovesto protect your hands.
NOTE:Takecare not to scratchthe dashboardand related
parts.
1.
Remove:
. Driver'sdashboardlowercover(seepage20-48)
. Glovebox (seepage20-49)
. Centerpocket(A,/Tmodel,seepage20-49)
. Centerconsole(M/Tmodel,see page20-47)
. Centerupperpocket{M/Tmodel,see page20-47)
. Centerdashboardlowercover
2.
(8NEDL
l
I5
\"P
I AccEssoRy
I socKET
CENTERPANEL
3.
3.
www.emanualpro.com
20-5 0
>: Cliplocation3
A> , 4
B>,2
.t !^
\lJS>,,
I is
tt
u .
\>ry
I r-,/'
AUOIOUNIT
CLIMATE
CONTBOL
UNITCONNECTORS
Installationis the reverseof the removalprocedure.
NOTE:Make sure the connectorsand antennalead
are connectedproPerly.
CAUTION:
. When prying with a flat.tip screwdriver,wrap it with
protective tape, and apply protective tape around th
related parts to ptavgnt damage.
. Put on glovesto protect your hands.
CAUTION:
. When prying with a flat.tip screwdriver,wrap h with
protective tape, and apply proteqtivetape around the
rolated parts to prevont damage.
. Put on gloves to protect your hands.
Installation
'L
2.
>: Cliplocations,
4
>:Cliplocations.,l
1.
R e m o v et h e c e n t e ra i r v e n t . t h e n d i s c o n n e c t h e
connector.
ffil
CENTERAIB VENT
POWER
WTNOOW
SWITCH
Installationis the reverseof the removalprocedure.
Installationis the reverseof the removalprocedure,
NOTE;Make surethe connectoris connectedpropN O T E : M a k e s u r e t h e c o n n e c t o r sa r e c o n n e c t e d
properly.
www.emanualpro.com
20-51
Dashboard
Side Air Vent Removaland
lnstallation
CAUTION:
. When prying with a flat-tip screwdriver,wrap it with
protec'tivetape, and apply protcctive tape around the
related parts to provent damage.
. Put on glovsto protect your hands.
CAUTION:
. when prying whh a flat-tip sctewdriver, wrap it with
protective tape, and apply protectiv tape around the
relatgd parts to prevent damagg.
. Put on gloves to protect your hands.
1.
1.
2.
2.
>: Cliplocations
B > ,1
A>,2
f f- it l
sl4
POWERMIRROR
SWITCHCONNECTOR
TRIM
SIDEAIB VENT
3.
3.
Installation
is the reverseofthe removalprocedure.
www.emanualpro.com
20-52
DashboardRemovaland Installation
SRScomponentsare locatedin this area.Reviewthe SRS
componentlocations,precautions,
and proceduresin the
SRSsection{24)beforepreformingrepairsor service.
5.
CAUTION:
. When prying with a flat-tip screwdriver,wrap h with
protective tap, and apply protective tape around the
related parts to prevgnt damage.
. Put on glovesto protct your hands.
r t t l
sl l l l
NOTE:
. An assistantis helpfulwhen removingand installing
the dashboard.
. T a k ec a r e n o t t o s c r a t c ht h e d a s h b o a r db, o d v a n d
other relatedparts.
ANTENNA
LEAD
HARNESS
SRSMAIN
HARNESS
1 . M a k e s u r e y o u h a v e t h e a n t i - t h e f tc o d e f o r t h e
r a d i o , t h e n w r i t e d o w n t h e f r e q u e n c i e sf o r t h e
radio'spresetbuttons.
2.
UNDER.DASH
FUSE/RELAY
BOX
OASHBOARD
SIDECOVER
Removei
a Driver'sdashboardlower cover and knee bolster
(seepage20-48)
. Glovebox (seepage20-49)
. L o w e r c o n s o l ec o v e r a n d c e n t e r p o c k e t ( A / T
model,seepage20-49)
. C e n t e rc o n s o l ea n d c e n t e ru p p e r p o c k e t( M / T
model,see page20-47)
. Centerdashboardlower cover(seepage20-50)
. Powerwindow switch(seepage20-51)
. Driver'sside air vent (seepage20-52)
. Driver'sside defoggertrim (seepage20-52)
Disconnect
the driver'sairbagconnector,and lower
the steeringcolumn(seesection17)
6x1.0mm
DASHBOARD9 . 8 N m 1 1 . 0 k g f . m ,
FFAME
7.2tbt.ftl
CONNECTOR
HOLDER
6.
Removethe passenger's
dashboardlowercover.
>: Scrw location, 1
I
SF:oo
lI
D: Clip locations,
-$t- I
ssj
PASSENGER'S
DASHBOARD
LOWERCOVER
I
{cont'd)
www.emanualpro.com
Dashboard
DashboardRemovaland Installation(cont'd)
7.
Disconnect
the connectorsand harnesscliDS.
>: Boli loc.lions
B>,1
a>,5
c>,1
^5\h'.'_.
4fl\',r,' r$\'rmTrr':j,1.ff,ry-r,.,".
\fl)Prtu'
tltbt.ttl
W/*
W)-
OASHBOARD
GUIDEPIN
c)-
CONNECIORS
CONNECTOR
20-54
www.emanualpro.com
DashboardFrameReplacement
CAUTION: Put on gloves to prolect your hands.
NOTE:Takecarenot to scratchthe dashboardand relatedparts.
a: Nut locations,3
6x1.0mm
9.8 N.rn 11.0kgf.m,
7.2 tbt.ftl
>i Screwlocations
A>,16
INSTRUMENT
PANEL
(seepage20 47)
\,.\
/ ,.-------f,\
lu
GAUGE
CENTERPANEL
{seepage20 50)
/A
\,r*
B>,2
^
S@t'
-
1l
c >,2
I
0" @ ll
D>.a
DASHBOARD
wlRE HARNESS
0- F ll
DASHBOARD
FRAME
.dr
-wr I
Ihll'rifi-
FRONTPASSENGER'S
www.emanualpro.com
Seats
ComponentLocationIndex
REARSEAIS
page20 63
Removaland lnstallation,
page20 65
Disassembly
and Reassembly,
page20-67
and Reassembly,
SeatLinkageDisassembly
page20-69
ArmrestReplacement,
page20-69
SeatCoverReplacement,
Removaland Installation,
page20 57
Disassembly
page2O-58
and Reassembly,
SeatLinkageDisassembly
page20-60
and Reassembly,
ArmrestFleplacement,
page20 61
SeatCoverReplacernent,
page20 61
www.emanualpro.com
20 -5 6
2.
B > ,1
10x 1.25mm
37 N.m
13.8kgt.m,
27 tbt.ftl
SEATBELTSW]TCH
CONNECTOR
Carefullyremove the front seat through the door
opening.
NOTE:An assistantis helpful when removingthe
front seat.
Installationis the reverseof the removalprocedure.
NOTE:Make sure the seat belt switch connectoris
connectedproperly(driver'sfront seat).
www.emanualpro.com
20-57
Seats
and Reassembly
FrontSeatDisassembly
CAUTION: When prying with a flat-tip screwdriver,wrap it with protsqtive tape to prevent damage.
NOTE:Takecarenot to scratchthe bodv or tear the seatcovers.
Driver's seat lmanually adiustablewith manual height adiustmentl:
removal:
barremoval:
Torsionbar
Torsion
>: Cliolocations
HOOK
SEATCUSHION
10x 1.25mm
,17N.m (,1.8kgt m,
35 tbt.ft)
PIVOTNUT
8 x 1.25mm
22 N.n 12.2kgl.m,
16 rbI.ft)
10 x 1.25mm
47 N.m (4.8 kgf.m,
35 tbtfr)
HOOKS
10 x 1.25mm
47 N.m {,1.8kgl.m.
35 rbt.ft)
www.emanualpro.com
20-5 8
Passenger's
seat (manuallyadiustablel:
>: Clip locations
HOOK
HEADREST
SEAT.BACK
PIVOTWASHER
PIVOTNUT
8 x 1.25mm
22 N.m 12.2kgl..n,
16 tbt.ftl
SEATCUSHION
CENTERCOVER
BUSHING
1 0x 1 . 2 5m m
,U N.m 14.8
35 rbt.ft)
'10x 1.25mm
47 N.m {4.8 kgf m,
35 rbl.ft)
UNDER-SEAT
TRAYGUIDE
1 0x 1 . 2 5m m
17 N.m {4.8kgl.m,
HOOKS 35 tbf.ft)
COVER
Reassembly
in the reverseorderof disassembly.
NOTE:
. Makesurethe bushingand pivotwasherare installedproperly.
. To preventwrinkleswhen installingthe seat-back
cover,makesurethe materialis stretchedevenlyover the pad.
. Greasethe movingportion.
www.emanualpro.com
Seats
and Reassembly
FrontSeatLinkageDisassembly
CAUTION: Put on gloves to protect your hands.
RECUNEADJUSTER
8 x 1.25 mm
22 N.m 12.2kgl.m,
16 tbf.fi)
8 x 1.25mm
22 N.m 12.2kd-m,
16 tbtf0
CROSSBRACE
8 x 1.25mm
22 N.m 12.2kgl.m,
16 tbf.f0
INNERSLIDE
ADJUSTER
cRoss
BRACE
CONNECTING
WIRE
To connect,twist 180".
OUTERSLIDE
AOJUSTER
8 x 1.25mm
22 N.rn l.2.2kgl-m,
16 rbr.ft)
www.emanualpro.com
20-6 0
FrontSeatArmrestReplacement
FrontSeatCoverReplacement
>: Boltlocations.2
6r1.0mm
9.8N,m ll.0 kgl.m,
7,2 tbf.ft)
Seat-backcover:
'1. Slide the front seatforward,and fold the
seat-back
forward.
2.
3.
Release
the hook,and fold backthe seat-backcover.
SEAT-BACK
1 0x 1 . 2 5m m
kgf,m,
47 N.m 1,1.8
35 tbt{t)
4.
cover on
'00
model)
(cont'd)
www.emanualpro.com
20-61
Seats
FrontSeatCoverReplacement(cont'dl
Removethe headrestguide,then removethe seatDacxcover.
3.
COVER
6.
(padside)
NOTE:
. To preventwrinkleswhen installinga seatcushion cover. make sure the material is stretched
evenlyoverthe pad beforesecuringthe clips.
. Replacethe releasedclipswith new ones.
Removethe seatcushion(seepages20-58,59).
Removethe clipsfrom underthe seatcushion.then
loosenthe seatcushioncover.
RINGPLIERS
UPHOLSTERY
available)
lCommercially
CLIP
NEWCUP
SEAT FRAME
SEAT
CUSHION
COVER
www.emanualpro.com
20-62
with tilt:
NOTE:Beforeremovingthe rearseat,tilt it.
LOWERHINGE
covERs
LOWERHINGE
COVER
(cont'd)
www.emanualpro.com
20-63
Seats
RearSeat Removaland Installation(cont'dl
2.
5.
removethe striker.
With tilt: lf necessary,
A>, 1
B>, 4
8 x 1.25mm
22 N.m {2.2 kgf.rn,
16 rbtft)
a: Nut loc.iion,
@ t
'l
8 x 1.25mm
22 N<n 12.2kglrn,
16 rbtftl
BASEFRAME
SEATBELTBUCKTES
(CENTERBELTTONGUEI
SEATCUSHION
Removethe headrest.
4.
www.emanualpro.com
20-64
and Reassembly
RearSeat Disassembly
CAUTION: When prying with a flat-tip screwdriver,wrap it with protective tape to prevent damage.
NOTE:Takecarenot to scratchthe body or tearthe seatcovers.
Without till:
SEAT-BACK
SEAT.AACK
RECLINEROD
PIVOT
COVER
PIVOTNUT
8 x 1.25mm
20 N.m 12.0kg{.m.
14 tbf.ftl
WASHER
HOOKS
SEATCUSHION
LATCH
SEAT
CUSHION
SEATCUSHION
STRAP
5x1.0mm
9.8 N'm (1.0kgf.m,
7.2 tbl.ltl
SEATLINKAGE
(cont'd)
www.emanualpro.com
20-65
Seats
(cont'd)
RearSeat Disassembly
and Reassembly
with tilr:
SEAT-BACK
SEAT.BACK
RECLINEROO
PIVOTNUT
x 1.25mm
20 N{n (2.0kgt.m,
14 tbt-fr)
10 x 1.25mm
47 N.m {4.8kgfn,
35 tbtft)
I-ATCH
COVER
SEATCUSHION
LATCH
SEAT
CUSHION
SEATLINKAGE
T;LT
KNOB
CLIP
Reassemble
in the reverseorderof disassembly.
NOTE:
. Makesurethe bushingand pivot washerare installedproperly.
. Greasethe moving portion.
20-66
www.emanualpro.com
6x1.0mm
9.8 N.m {1.0kgf.m,
7.2 tbf.ftl
SEATCUSHION
STRAP
and Reassembly
RearSeat LinkageDisassembly
CAUTION: Put on glovesto protect your hands'
Without tilt:
REABSEAT
FOOT
CENTER
COVER
6x1.0mm
9.8 N{n 11.0kgt'm,
7.2 tbt ftl
N
HINGE PIN
E-CLIPS
Replace.
BASEFRAME
I
I
b
HINGEBRACKET
(cont'd)
www.emanualpro.com
20-67
Seats
RearSeat LinkageDisassemblyand Reassembly(cont'd)
with tilt:
NOTE:Referto section24 for the rearseatbelt bucklesand centerbelttongue removal
TILTCONTFOL
CABLE
CENTEBARM
COVER
1 0x 1 . 2 5m m
47 N.m {i1.8kgt.m,
35 tbf.ft)
6x1.0mm
9.8 N.m n.0 kgt.m,
7.2 tbt.tll
n
/
8 r 1.25mm
16 N.m (1.6kgf.m,
12 tbt.ftl
//-)
ASE FRAME
DAMPER
6x1.0mm
9.8 N.m 11.0kgtm,
7.2 tbttr)
TILTCONTROLROD
A
@
SPRING
UPPERHINGE
TILT
CONTROL
CABLE
Replace.
BUSHING
H I N G EP I N
E.CLIP
Reptace.
Reassemble
in the reverseorderof disassembly.
NOTE:
. Greasethe moving ponion.
. lf necessary,
adjustthe tilt controlcable.
20-64
www.emanualpro.com
RearSeatArmrestReplacement
RearSeatCoverReplacement
SEAT.BACK
COLLAR
Removethe seat-back{seepage20-65).
2.
Remove:
a Armrest
. Headrest
. Seat-back
reclinerod (seepage20-65)
COLLAR
6x1.0mm
9.8 N.m {1.0kgf.m,
7.2rbr.ft)
WASHER
NYLON
WASHER
VE
WASHER
ARMREST
'
ARMREST
PIVOTBOLT
6x1.0mm
9.8 N.m (1.0kgt.m,
7.2lbllll
4.
(cont'd)
www.emanualpro.com
20-69
Seats
RearSeatCoverReplacement(cont'dl
Removethe headrestguide and latch knob collar,
then removethe seat-back
frame.
SEAT.BACK
FRAME
i
Removethe seatcushion(seepage20-65).
2.
R e m o v et h e s e a t c u s h i o nl a t c h a n d s e a t c u s h i o n
strap(seepage20-66).
3.
P u l l b a c kt h e e d g e o f t h e s e a tc u s h i o nm a t , t h e n
releaseall of the clips.
SEATCUSHION
MAT
--t)c/
l@
I
pio
t-t
t l
L]
HEADREST
GUroE
LATCHKNOB
COLLAR
CLIPS
( L e a t h e rs e a t - b a c k
coveron '00model)
1.
WIRE
(Padside,leatherseat,back
coveron ,00model)
20-70
www.emanualpro.com
COVER
5.
FING PUERS
UPHOLSTERY
(ComE|erciallY
available)
PAD
WIRE
(Padside)
www.emanualpro.com
20-71
Bumpers
FrontBumperRemovaland Installation
CAUTION: Put on gloves to protec,tyour hands.
NOTE:
. An assistantis helpfulwhen removingthe front bumper.
. Takecarenot to scratchthe front grille,lront bumperand body.
o Firstremovethe front grille (seepage20-77).
. lf necessary,
removethe front licenseplatebaseand front licenseplatelower bracket.
>: Boli screw locations
A>,3
6x1.0mm
9.8 N.m (1.0kgf.m,
7.2 tbt t0
FRONTGRILLE
(seepage20-77)
>: Cliplocations,5
B > ,4
C>,4
<
S))PF
| ffi)m>l
v
Y./
I
FRONTGRILLE
EMBLEMCOVER
(seepage20-77)
.r.,
w
l
w
FENDER
tx\ \{_:
I
B
FRONTBUMPER
20-72
www.emanualpro.com
c>.6
V.2
E>,6
D>,2
Gfu @p;i,li',ll-"-'
>: Clip locations
B>.3
A>, 5
10 x 1.25mm
38 N.rn {3.9 kgf.m,
28 rbl.ftl
@,,2
n l n - n l z n Ir
dE6
I #\Er+
;lHl=|
=.=r |
t:Wl
TIE DOWN
HOOK
Yl-r
{to/
BEAM
TIE.DOWN
HOOK
v1
www.emanualpro.com
FRONTBUMPEB
20-73
Bumpers
RearBumperRemovaland Installation
CAUTION: Put on gloves to proteqt your hands.
NOTE:
. An assistantis helpfulwhen removingthe rearbumper.
. Takecarenot to scratchthe rearbumDerand bodv.
>: Boli,screwlocations
a>,2
.f-.'
0f'"I trl
c>, 10
B>,4
Y)f
l
l
BEARBUMPER
STEP
SIOEMARKER
LIGHTCONNECTOF
REARSPLASH
Disconnect.
GUARD
To body
To body
SIDE
MARKER
LIGHT
To body
To body
REARBUMPER
LIGHT
20-74
www.emanualpro.com
Hood
Replacement
NOTE:
. An assistantis helpfulwhen removingand installingthe hood.
a Takecarenot to damagethe hood and body
. When removingthe clips,usea clip remover.
>: Bolt locations,4
6x1.0mm
9.8N.m {1.0kgt.m,
7.2tbtfr)
HOOD
WINDSHIELD
WASHERNOZZLES
(seepage20-100)
G
{
\
WINDSHIELD
WASHER
TUBE
(seepage20-100)
HOOD
HINGE
www.emanualpro.com
20-75
Hood
Adjustment
NOTE: Beforeadjustingthe hood,looseneachbolt slightly.
to make
Turnthe hood edgecushions,as necessary,
the hood fit flushwith the bodv at front and sideedges.
f
sz
14--+ik-
HOODEDGE
CUSHION
6x1.0mm
9.8N.m (1.0kgtm,
7.2 tbt.ttl
HOODHINGE
HOODHINGE
?-9.8N.m (1.0kgf m,
7.2 rbf.ftl
20-76
www.emanualpro.com
HOODLATCH
HOOD
LATCH
Front Grille
Replacement
CAUTION: When prying with a flat-tip screwdriver,
wrap it with protective tape, and apply protective tape
around the related parts to prevent damage.
NOTE:Takecare not to scratchthe front orille and front
oumper.
1.
@-l@,"l
N O T E : I n s e r t a P h i l l i p ss c r e w d r i v e rt h r o u g h t h e
holes in the front grille,then loosen the screws.
2.
www.emanualpro.com
20-77
RearHatchGlass
Replacement
CAUTION:
. Put on glovesto protecl your hands.
. Use seal coversto avoid damaging any surfaces.
. Do not damage the rear window delogger grid lines
and terminals.
Harnosswiring locations:
REARWINDOWWIPER
MOTORCONNECTOR
Removethe rearwiper lower
cover(seepage20-99i.
@i!iff*-"REARSPOILER
.;=-
8 x 1.25mm
22 N-m l'2.2kgl.m,
'16tbt fr)
8 x 1.25mm
22N.m l.2.2*ql.m,
16 tbf.ft|
Installation is the reverse of the removal orocedure.
NOTE:
. Adjustthe rearhatchglassalignment.
. Makesurethe connector,terminalsand washertube are connectedproperly.
. Adjustthe aim of the rearwindow washernozzle(seepage20-103).
20-78
www.emanualpro.com
HARNESS'
TRIM
Disassembly
and Reassembly
NOTE:
. Takecarenot to scratchthe rearhatchglass.
. lf necessary,
replaceany damagedspacersand seals.
. Referto page20-99fortherearwindowwiper motor removaland section23 for the high mount brakelight removal.
HINGEPLATE
('00model)
HINGESPACEN
('97- 99 models)
HINGESPACERS
REARSPOILEB
SPACER
{'99 00 models)
HARNESS
TRIM
HARNESS
TRIM
6x1.0mm
9.8 N.m {1.0kgl.m,
7.2 tbt.ft)
WASHER
STBIKER
REARSPOILER
SPACER
('97- 98 models)
RAFWINDOW
WIPERMOTOR
BASEPLATE
SEAL
REARWINDOW
WIPERUPPER
COVER
CAUTION
LABEL
MOTORBASE
PLATESEAL
/=
PIVOTNUT
{cont'd)
www.emanualpro.com
20-79
RearHatchGlass
(cont'dl
Disassembly
and Reassembly
NOTE:Beforeinstallingthe rear spoilerspacer,harnesstrim. cautionlabel,real time 4WD emblem and glass protector,
cleanthe rearhatchglassbondingsurfacewith a spongedampenedin alcohol.
>: Alignment mark locatioos
A>
_\
l
|
r\,
ALIGNMENT
MARK
w
l
:
f \
ALIGNMENT HARNESS
MARK
TRIM
lnside:
Center line
REARSPOILERSPACER
Centorline
Outside:
o o o
REARSPOILER
SPACER
{'97 98 models)
REAR
SPACERS
{'99 00 models)
20- 8 0
www.emanualpro.com
SPOILER
SPACEBS
('99 00 models)
Adjustment
NOTE:
. After adjustingthe tailgatedoor,adjustthe rearhatchglass.
. Loosenthe strikermountingboltsslightly.
. Removethe rearspoiler,and removethe supportstrutfrom body side.
1. Loosenthe rearhatchglassmountingnuts.
2. Adjustthe rearhatchglassso thereare equalgaps betweenthe rearhatchglass,the taillights,and the tailgatedoor.
NOTE:lf necessary,loosenthe rear hatchglasshinge mountingnuts and move the rear hatchglassbackwardor forward to fit the rearweatherstripand tailgatedoor weatherstrip.
REARHATCI{
GLASSHINGES
REARHATCHGLASSHINGE
MOUNTINGNUT
6x1.0mm
9.8 N.m (1.0kgf.m,
7.2 tbt f
Removethe rearedge
otthe headliner
(seepage20-44).
MOUNTINGNUT
6x1.0mm
9.8N.m 11.0kgtm,
7.2 rbf.ftt
Taillight side:
NOTE:Adjustfor equalgaps
betweenthe right and left.
About
7mm
1o.27in.l
REARH ATCHGLASS
(cont'd)
www.emanualpro.com
20-81
RearHatchGlass
Adjustment(cont'dl
3 . After adjustingthe rearhatchglass,tightenthe rear hatchglassmountingnuts,and installthesupportstrut.
4 . Adjustthe strikeralignment.
NOTE:
. Move the strikerfore or aft to makethe rearhatchglassfit flush with the tailgatedoor'
. Move the strikerright or left until it's centeredin the rearhatchglasslatchas shown.
REARHATCH
GLASS LATCH
REARHATCHGLASS
STRIKER
6x1.0mm
9.8 N.m (1.0kgt'm,
7.2tbl.ftl
NOTE:When equalizing
the gap between
the tailgatedoor and rear hatch glass,do not
dglorm the rear hatch glass.
TAILGATEDOOR
5. Tightenthe strikermountingbolts.
6. Recheckthe rearhatchglassalignment.and makesurethe glassopensproperly,and lockssecurely.
7. Installtherearspoiler.and adjustit.
NOTE:Adjustthe rearspoilerso
thereare four equalgaps
betweenthe rearspoilerand
the body.
REARSPOILER
REARHATCHGLASS
www.emanualpro.com
20-82
RearWeatherstripReplacement
W h e n i n s t a l l i n gt h e r e a rw e a t h e r s t r i pa,l i g n t h e a l i g n ment mark of the rear weatherstripto the body flange
notch.
'98 - 00 modols:
NOTE:
. Makesurethereare no wrinklesin the weatherstrio.
. T h e s t e e l c o r e i n t h e r e a r w e a t h e r s t r i pc a n n o t b e
restoredto it originalshapeonce it is bend. Replace
the rearweatherstripwhen the steelcore is bent.
. Apply sealantto the areasindicatedby arrows.
. Checkfor water leaks.
Sealant: CemedineP/N 08712- 000i1,or equivalont
SEALANT
WEATHERSTRIP
'97 model:
area.
Sealing
Sealingarea.
BODY
FLANGE
REAR
WEATHERSTRIP
WEATHERSTRIP
www.emanualpro.com
Moldings
RoofMoldingReplacement
CAUTION:
. Put on glovgsto protect your hands.
. Whn prying with a {lat-tip screwdriver,wrap it whh protective tape to prevent damage
NOTE:
. Takecarenot to scratchthe body.
. The steelcore in the roof moldingcannotbe restoredto it originalshapeonce it is bend.Replacethe roof moldingwhen
the steelcoreis bent.
. Startingat the front, carefullypry off the roof molding.
>: Clip locations
A>,2
B>,3
www.emanualpro.com
20-84
ROOFMOLDING
STEELCORE
DoorMoldingsReplacement
CAUTION:
. Put on gloves to protect your hands.
. When prying with a flat-tip scrowdriver,wrap it with protstive tape to provent damag.
NOTE:
. Takecarenot to scratchthe body.
. Be carefulnot to damagethe front and reardoor moldings.
t
Adhesive aleas,
Adhesivearea. FRONTDOOR
MOLDING
REARDOOB
MOLDING
a: Plasticnut location, 1
(cont'd)
www.emanualpro.com
20-85
Moldings
Door MoldingsReplacement(cont'd)
7 . G l u e t h e n e w a d h e s i v et a p e t o t h e m o l d i n g sa s
snown,
: Adlesivetapelocations
instructions.
NOTE:Followthemanufacturer's
Forwerd
Materials:(Reference)
. Striperemover
3M 08907
. Stripeadhesiveremover
3M 08908
. Adhesivetape
3M SuperAutomotiveAttachmentTape
Tools:
. Protectivetape
. Knifeor Cutter
. Spongeor Shoptowel
. Infrareddryer
.
.
.
45 mm
( 1 . 8i n . l
125mm 30 mm
{4.92in.) { 1 . 2i n . }
G l u eo n t h e r i b
area,
26 mm (1.0in.) 440mm 117.3in.l
FRONT
MOLDING
Film
Plasticputty knife
Alcohol
200 mm
(7.87in.)
35 mm 125mm
{1.4in.) {4.92in.)
2.
3.
25 mm {0.98in.l
8 2 0 m m 1 3 2 . 3i n . )
REARDOOR
MOLDING
(Front/rear end)
Width:5 mm
NOTE: Use care when heatingto preventdeformation of the body and molding.
4.
t'.
all removedparts.
1 0 . Reassemble
www.emanualpro.com
>: Screwlocations,4
A>.7
SIDE CLIP
S I O ES I L L P A N E L
Remove the lower clips,
then remove the side sill panel
by sliding it forwatd.
To installthe side sill panel,removethe sideclipsfrom the body,installthem on the side sill panel,then installthe sidesill
Danelon the vehicle.
NOTE:
. Takecarenot to twist the sidesill panel.
. lf necessary,
replaceany damagedclips.
www.emanualpro.com
20-47
SpareTire Gover
EmblemInstallation
Hard spare tire cover {for some models}:
Apply the emblemwhere shown.
NOTE:
. Beforeapplying,cleanthe sparetire coversurfacewith a spongedampenedin alcohol.
. After cleaning,keepoil, greaseand water from gettingon the surface
Attachment Point lRferencel:
U n i t :m m ( i n . )
Honda/CR-vemblem:
APPLICATION
TAPE
HONDAEMBLEM
CR.VEMBLEM
SPARETIRECOVEB
www.emanualpro.com
20-88
Fenderwell
FrontWheelwellProtector
Replacement
InnerFenderReplacement
NOTE: Takecare not to scratchthe body.
NOTE:
a Take care not to scratchthe front wheelwell protector
and body.
. Use a T30 Torx bit to remove the Torx screw.
,,-C\
ffi
A\
>: Screwlocations
a >,3
B > ,1
s))pp>
Y]
6'thp
I sv.l/) D
Y/
6x1.0mm
9.8Nm(1.0kgf.m,
7.2 tbf.ft)
)fl(
l#
:rl
A I
4t
wt
I
a l
INNER FENDER
www.emanualpro.com
20-89
Fenderwell
RearWheelwellProtector
FuelPipeProtectorReplacement
Replacement
NOTE: Take care not to scratchthe body.
NOTE:
. Take care not to scratch the rear wheelwell protector
and body.
. Use a T30 Torx bit to remove the Torx screw.
/ll
I ,.{\
6x1.0mm
N.m {1.0kgl.m.
6him"
l FY-./),@ 9.8
7.2 rbtft)
Y/
qK
1l
A> , 5
B > ,1
YnTn
/'d)Ul | +['Tl+l
\=lHl | -_H_l
tlrflJ
-
|
|
removinsthe
INoTE:Before
thescrew
lclip.remove
from the rearbumperand
lowerthe rearbumper,
20-90
www.emanualpro.com
>: Cliplocations,
4
Tt-
A\
-T[-r
Installation
is the reverseof the removalDrocedure.
www.emanualpro.com
20-91
Openers
ComponentLocationIndex
FUELFILLOOORLATCH
page20'96
Replacement,
HOODRELEASEHANDLE
page20'95
Replacement,
HOODLATCH
page20'95
Replacement,
DOOROPENER
FUEL
CABLE
Replacement,
Page20 94
HOODOPENERCABLE
page20'93
Replacement,
www.emanualpro.com
20-92
FUELFILLOOOROPENER
Replacement,
Page20_96
HoodOpenerCableReplacement
NOTE:
. When removingthe clips,usea clip remover.
. Takecarenot to bendthe openercable.
Remove:
. Frontwheelwellprotectorand innerfender{leftside,seepage20 89}
. Frontgrille(seepage20-77)
. Kickpanel(leftside.seepage20-411
>: Clip locations,3
'.--)r
@l
HOODLATCH
(seepage20-95)
t"
HOODRELEASE
HANDLE
(seepage20 95)
Routethe opener
cablethroughthe
hole in the body.
www.emanualpro.com
Openers
FuelFillDoorOpenerCableReplacement
NOTE:
. When removingthe clips,usea clip remover.
. Takecare not to bendthe openercable.
Removethe followingparts,then pull the carpetback,as necessary(seepage20-45),
a Kickpanel(leftside.see page20-41)
c>,1
@lRlg
FUELFILLOOORLATCH
(seepage20-96)
FUELFILLDOOROPENER
{seepage 20-96)
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Hood ReleaseHandleReplacement
HoodLatchReplacement
>: Eoltlocations.2
>: Boltlocations,3
6x1.0mm
9.8 N.m {1.0kgl.m,
7.2 tbl.tll
6x1.0mm
9.8 N.m {1.0kgf.m,
7.2 tbt.ftl
HOODOPENER
CABLE
{seepage20-93)
HOOOLATCH
NOTE;
. Greaseeachlocationofthe hoodlatchas indicated
by the arrows.
. Makesurethe openercableis connectedproperly.
. Makesurethe hood locksproperly.
. Adjust the hood latchalignment(seepage20-76).
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20-95
Openers
FuelFillDoorOpenerReplacement
>: Boltlocstions.2
>: Boh locdions, 2
5x1.0mm
9.8N.m (1.0kgf.m,
7.2 tbt.ftl
6x1.0mm
9.8 N.m (1.0 kgf.m,
7.2 tbf.ft)
FUELFILLDOORLATCH
FUELFILLDOOR
OPENERCABLE
(seepage 20-94)
FUELFILLDOOR
After installing,
checkfor
a flushfit with the body.
DOOROPENER
FUEL
CAELE
(seePage20,94)
LATCH
Removethe fuel fill door latch
by turningit 90'
FUEL FILL
Installation
is the reverseof the removalprocedure.
NOTE:
. Makesurethe openercableis connectedproperly.
. Makesurethe fuel fill door opensproperly,
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20-9 6
Wiper/Washer
ComponentLocationIndex
WIPERARMS
WINOSHIELD
and LINKAGE
page20-98
Replacement,
Adiustment,Page20-103
WASHERRESERVOIN
page20 99
Replacement,
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REARWINDOWWIPER
ARM and MOTOR
page20 99
Replacement,
Adiustment,page20 103
TUBE
WASHER
page20-100
Replacement,
20-97
Wiper/Washer
WindshieldWiperArmsand LinkageReplacement
CAUTION: Put on gloves to protoct your hands.
3.
1.
2.
6x1.0mm
9.8 N.m (1.0kglm,
7.2 tbt.fr)
>: Cliplocations
A>.9
a. Pryout the annerclip.
INNERCLIP
b. Removethe clip.
/G
SHOP
TOWEL
"rr/ &
(Cowlcoverside)
4.
S e p a r a t et h e w i n d s h i e l dw i p e r l i n k a g ea n d w i n d shieldwiper motor.
B>.8
NOTE:Scribea line acrossthe link and windshield
wiper linkageto show the originaladjustment.
ql
>: Bohlocations,
3
6x1.0mm
8 N.m 10.8kgf.m,
5.8 lbf.ftl
WINDSHIELD
WIPERARMS
NUTS
'10x 1.25mm
18 N.m 11.8kgf.m.
13 tbf.ftl
s}@
1ffi,
/Y{
' L|NK
/
WINDSHIELD
WIPERLIN(AGE
5.
COVER
2 0- 9 8
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NUT
10 x 1.25mm
18 N.m 11.8kgf.m,
13 tbf.ftl
SPRING
WASHER
WIPERMOTOR
RearWindowWiperArm and
Motor Replacement
WasherReservoirReplacement
GAUTION: Put on glovesto protect your hands.
Remove:
. Frontgrille (seepage20-771
. Front bumper (see page 20-721
. Frontwheel{leftside,seesection18)
. Frontwheelwellprotector(leftside,see page2089)
. Innerfender(leftside,see page20-89)
. Headlight(leftside,seesection23)
2.
D i s c o n n e ctth e w a s h e rt u b e s a n d w a s h e r m o t o r
connectors.
>: Boltlocations,
3
REARWIPER
COVER
>: Scaowlocationa,2
@rrc
REARWINDOW
WIPERMOIOR
6x1.0mm
9,8 N.m 11.0kgt.m,
7.2 tbt.ftl
SPECIALNUT
18 x 1.0mm
9 N.m 10.9kgt m,
5.r tbt.ftl
Routethe washertubes
to the washerteservoir
WASHER
RESERVOIR
WINOSHIELO
WASHERMOTON
CONNECTORS
REAR
WIPERARM
NUT
6x 1.0mm
9.8 N.m {1.0 kgt.m,
?.2 tbfftl
HARNESS
cLrP
\ - S(ilq
l' wrsHER
s{J
D i s c o n n e ctth e c o n n e c t o r t, h e n r e m o v et h e r e a r
window wiper motor.
3.
4.
NOTE:
. Makesurethe connectoris connectedproperly.
. Installthe rea. window wiper arm as described
on page20-103.
. Checkthe rearwindow wiper motor operation.
. Greasethe movingparts.
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/ t
C-(fu
NOTE:
a M a k e s u r e t h e w a s h e r m o t o r c o n n e c t o r sa n d
washertubes are connectedproperly.
. Checkthe washermotor operation.
20-99
Wiper/Washer
WindshieldWasherTubeReplacement
'97
NOTE:
. Takecarenot to scratchthe relatedpartsand body.
. When removingthe clips,use a clip remover.
'fr{------63
ax--\J
Removethe followingparts.
. Leftfront wheelwellprotector(seepage20-89)
. Left innerfender(seepage20-89)
>: Clip locations
A >,2
,.&--
\7
B>,1
c>,1
D>,1
WINDSHIELO
WASHERNOZZLES
Y-JOINT
\
Boutethe w6shertubes
to the washerreservoir
lnstallation
is the reverseof the removalprocedure.
NOTE:
. Takecare not to pinchthe washertubes.
. lf necessary,
replaceany damagedclips.
. Afterinstalling,
(seepage20-103).
adjustthe aim ofthe washernozzles
20-100
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model:
RearWindow WasherTubeReplacement
NOTE:
. Takecarenot to scratchthe relatedpartsand body.
. When removingthe clips,usea clip remover.
Removethe followingpartsfrom the left side of the vehicle,then pull the carpetbackas necessary(seepage20-45)
.
.
.
.
.
.
a
Frontwheelwellprotector(seepage20-89)
Innertender(seepage20-89)
Kickpanel(seepage20-4't)
Centerpillarlowertrim panel(seepage20-41)
Frontsidetrim (seepage20-41)
Rearseat(seepage20-63)
Cargoareafloor and cargostoragebin (seepage2043)
>: Clip,harnesscu3hionlocation3
c>,3
A > ,1
B > ,1
D>,12
GROMMET
el4
@s_l
GROMMET
Routethe washert!be
underthe wire harness
WINDSHIELD
WASHEBTUBE
Routethe washertubes
to the washerreservoir
wasnerno2zre.
WASHEB
RESERVOIR
wrNoow
TUBE
WASHER
REARWINDOW
WASHERMOTOR
(cont'd)
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20-101
Wiper/Washer
RearWindow WasherTubeReplacement(cont'dl
REARWINDOW
WASHERNOZZLE
GSOMMET
"'..--a
i;r.
REARWINDOW
WASHERTUBE
Routethe washertube
undorthe wire harness,
20-102
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Wind3hieldWipor/Washer:
1,
Distance
'_\ from center
ltne
ru"rrr."i.
2 7 m m ( 1 . 1i n . )
from black
ceramicedge
88 mm (3.5in.)
GLASS
sPo[.-ER
C.nlar lino
L
2.
^,J;-ll\
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from black
ceramicedge
A and A'
B and B'
20-103
Sub-frame
Sub-frameTo.que Sequence:
CAUTION: After loo3eningthe sub-framemounting bolts, be sure to replacethem with now ones.
REANCROSS
BEAM
10 r 1.25mm
49 N.m 15.0kg{.m, 12 x 1.25mm
36 tbt.ftl
74 N.m (7.5kgtm.
54 tbf.ft)
SNFFENER
BOLTS
1 l x 1 . 5m m
89 N.m 19,1kgt m,
66 tbt ftl
Replace.
20-104
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FrameRepairChart
Top view:
U n i t :m m ( i n . )
0: Innerdiameter
{4.021 t1.19}
lm
302
tr.rr!9$I
POtt{T
POINT'
POINT hl
SECTIONDD
20-106
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2&2 t111.11
I
POINTn
258,1{10r.7}
32A7 1129.11
(cont'd)
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20-107
FrameRepairChart
(cont'd)
Sideview:
U n i t :m m ( i n . )
0: Innerdiamete.
POINTd3
o15 {0.591For TrensmissionMount
d15 10.591
For Trrnsmi3don
Mount
POINTd1
t13 10.5'llFor Transmb3ion
Mount
POINTel
613 10.51)For Transmirsion
Mouni
130
POINTh1
.25
POINT
,1710.67)
Fof Re.r Beam
o16 10.631
LocateHole
o12 (0.,171
For Right Front Stop
POINTc1
612 {0.47}For Left Front Stoo
b2
t12 {0.47}For Right Front Stop
POINTc2
r12 {0.47)For Left Front StoD
o11 (0.{31For EngineMount
20-108
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Damper
Lower Bushing
Point
POINT
t17 10.671
Fo. R..r
r'17 10.671
For Rcar Bo.m
POlNTx.y /
'sad
POINTm3, m4
FuelTank Strap Poinr
2700.5(106.32)
SECTIONBB
RearDamoer Center
Upper Arm
M12 x P1.25
POINTn
I
FOINT
\ql
ol
.df
o2010.8|Locate Hole
rg (0.3)Fuel T
Strap Center
For RearCros3Beam
LocateHole
271,1(10,6.9)
POINTw
POINT 3, s1
ForTrailingAim
o14 {0.551
POINT v
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20-109
...........21
......'..'..
Air Conditioning
'.'22'1
SYSTEM(SRS}
RESTRAINT
SUPPLEMENTAL
airbagin the dashboard
This model has an SRSwhich includesa driver'sairbagin the steeringwheel hub, a passenger's
abovethe glove box ('97,00 models).and seat belt tensionersin the seat belt retractors('98- 00 models).Information
necessaryto safelyservicethe SRSis includedin this ServiceManual.ltems markedwith an asterisk(*) on the contents
or replacingtheseitemswill requirespecial
pageinclude.or are locatednear,SRScomponents.Servicing,disassembling
precautionsand tools,and shouldonly be done by an authorizedHondadealer.
@
. To avoid rendering the SRS inoperative, which could lead to personal iniury or death in the event of 8 severe frontal
collision, all SRSservicework must be performed by an authotized Honda dealer.
lmproper service procedures, including incorrect removal and installation of the SRS, could lead to personal iniury
causedby unintentional deployment of the airbags ('97 - 00 models),and seat belt tensioners 138 - 00 models).
Do not bump the SRS unit. Otherwise, the system may fail in case of a collision, or the airbags may deploy when the
ignitionswitch is ON {lll.
SRS eleqtricalwiring harnessesare identified by yellow color coding. Relatedcomponents are located in the steering
column, front console,dashboard,dashboardlower panel, and in the dashboard above the glove box. Do not use electricaltest equipment on thes cilcuils.
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Air Conditioning
Heater Control Panel
Reofacement
,.,...,,.,..,.,.,,22-46
Blower Unit
Replacement
..................
22-46
Overhaul...........,,,.,
.......-.22-17
Evaporalor
ReDlacement
...,.,.,..,......,22-4A
Overhaul................
.........22-19
A/C Filter
Replacement
..................22-50
*HeaterUnit
ReDfacement
..................22-50
Overhaul..,.,..,.,...,..
.........22-52
TemperatureControl
Adiustment
....................22-53
A/C ServiceTips and Precauiions............-....-....
22-54
A/C SystemTorqueSpecifications
....................
22-55
A/C System Service
Performance
Test
......,...22-56
PressureTestChart
.-.....22-5a
Recovery..............,.
...-.-...22-59
Evacuation
-...........-........22-60
Charging................
.......-.22-61
LeakTest
........................22-61
Compressor
Repfacement
..........-.......22-62
flfustratedIndex
.....,.......22-64
Cfutchfnspection
.........,.22-65
CfutchOverhaul
............22-66
ThermafProtectorRep|acement...................
22-68
RefiefValveReplacement..............................
22-68
A/C ComoressorBelt
Adiustment
....................
22-69
Condenser
Repfacement
.,.....,,.,..,.,..22-70
'Read SRSprecautionsbetore working in this area.
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SpecialTools
Rel. No.
.o
Tool Number
Oty
Description
0 7 J G G- 0 0 1 0 1 0 A
07sAz - 001000A
07947- 6340300
07965- 6920500
1
2
1
1
BeltTensionGauge
BackprobeSet
DriverAttachment
@
Hub AssemblyGuideAttachment
@
* Includedin the BeltTensionGaugeSet,T/N 07TGG- 001000A
6,
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22-2
PageRelerence
22-69
22-33,36,37
22-66
22-61
ComponentLocation
lndex
EVAPORATOR
Replacement,page 22-48
Overhaul,page22-49
SERVICE
VALVE
ILOW-PRESSURE
SIDE}
A/C PRESSURE
SWTTCH
When the refrigorantpressureis below 200 kPa12.0kglc.r|r,
28 psi) or abov 3,200kPa(32 kgflcmr,455 psi),the AJCpressure
switch opensthe circuit to the Ay'Cswitch and stops the air
conditioningto protectthe compressor.
,
[\,
-il
CONDENSER
Replacement,page 22-70
SERVICEVALVE
IHIGH-PRESSURE
SIDEI
Replacement,page 22-62
Clutch Inspection,page 22-65
ClutchOverhaul,pago22-66
Thermal ProtectorReplacement,page 22-68
ReliefValve Replacemnt.page 22-68
(cont'd)
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ComponentLocation
lndex (cont'dl
SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations,precautions,and proceduresin the SRS
section(24)beforeperformingrepairsor service.
BLOWERUNIT
page22-46
Replacement,
Ovethaul,page22 47
ruoronl
/alowen
page
\Test,
22-16 /
RECIRCULATION
CONTROLMOTOR
page22 42
Replacement,
EVAPORATOR
Feplacement,
page22-48
Overhaul,page22,49
lest, pag.e22 42
HEATER
UNIT
page2250
Replacement,
page2252
Overhaul,
A/C FILIER
Replacement.page 22-50
RECIRCULATION
CONTROLSWITCH
VALVECABLE
Adjustment,page 22-53
a/c swtTcH
REARWINDOW
DEFOGGER
SwlTCH
See section23
MODE
MOTOR
page22-41
Replacement,
Test,page 22-41
MODECONTROL
DIAL
HEATERCONTROL
PANEL
Replacement,page 22 46
CONTROL
swtTcH
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22-4
SLOWERMOTORRELAY,
RADIATORFAN RELAY.
CONDENSER
FAN REI-AY,
COMPRESSOR
CLUTCHRELAY
(Locatedin the undeFhoodfuse/relay
box)
Test. page 22-45
CONDENSER
FAN 2P CONNECTOB
RADIATORFAN
2P CONNECTOR
A/C PRESSURE
SWITCH
2P CONNECTOR
COMPARTMENT
WIREHARNESS
1PCONNECTOR
{cont'd)
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22-5
Component Location
Index(cont'dl
and proceduresin the SRS
SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations,precautions,
section(24)beforeperformingrepairsor service.
BECIRCULATION
CONTROLMOTOR
4P CONNECTOR
TEMPERATURE
SENSOR
EVAPORATOR
Tesl, page 22-44
POWERTRANSISTOR
3P CONNECTOR
BLOWERMOTOB
2P CONNECTOR
BLOWERMOTORHIGHRELAY
Test, page 22-45
HEATERSUB.HARNESS
7P CONNECTOR
DASHBOARDWIREHARNESS
HEATERCONTROLPANEL
8P AND 2OPCONNECYORS
www.emanualpro.com
22-6
Description
High-temperature/
h i g h - p r e s s u r lei q u i d
r r a p so e o n s ,
and removes
motsture
Radiationof heat
IlcoMpREssoR
necetve
coruoerusenl*
Lessmoisturized
low-pressurevapor
High-temperature/
h i g h - p r e s srue l i qu i d
More liquidified
row-pressurevapor
Absorption of heat
EVAPoRAToR
(-l
EXPANSToN
vAL
EVAPORAYOR
SUCTIONLINE
tLow-PRESSURES|OEt
LIOUIDLINE
CONDENSER
DISCHARGE
LINE
IHIGH.PRESSURE
SIDEI
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22-7
CircuitDiagram
BOX
FUSE/RELAY
HOOD
UNDEB
IGNITON SWITCH
+
wHTBLK
**f
/6'^'\
,o+trrffl-
UNDER.DASH
FUSEiRELAY
BOX
F;t"^i I
eLK/YEI
f
\_-./
COMPRESSOF
CLUTCH
RELAY
RED
I,
m
BLK
BLU'ryVHT
I d I CoMPRESSOR
I I I CLUTCH
LIl
G401
G402
BLK/RED
GRN
WHT
IL^"^,Y**t,|
I,^,^,",
I
CONDENSER
T*.'1
Y
l
l
l
MOTOR
r t l
BLK
BLK
BLK
l l l
-
G201
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22-8
G101
G202
,JC
PRESSURE
SWITCN
1
2 /:\
-{.-!}Btu/yvHT
Btu/RED
\,-/
POWER
TRANSISTOR
ORNMHT
EVAPONATOR
TEMPERATURE
SENSOR
cnNj@_snN
Fg"{
GRY
PNK/BLK
s5v
AMD P
NED/8LU
REO/YEL
"'"fi3'.Hfi|$l#i9D>
DASH
LTGHTS
_/4
EE|GHTNESS
< -! l_
CONTROLLER
REAR
RED
s coM
A I RM I X
CONTROL
MOTOB
HOT
BRN
YEL/RED
VENT
GRN/YEL
B/L
8LU/8LK
YEL
YEL/BLU
H/D
I/lODE
CONT8OL
l\r10T0R
M
DEF
8RN/WHT
(l
fllf$!S,*
RELAY
aLurrL
GRNI/VHT
GRN/RED
8LK
O:8P coNNEcToR
n :20Pc0NNCToR
HEATER
CONTROL
PANEI-
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c401
c402
22-9
Troubleshooting
SymptomGhart
function (see next
system,reterto selt-diagnosjs
For electricalmalfunctionswhich are indicatedby the self-diagnostic
page).
a symptom.
Notetheseitemsbeforetroubleshooting
. Checkthe enginecoolantlevel,and allow the engineto warm up beforetroubleshooting.
. Anv abnormalitymust be correctedbeforecontinuingthe test.
. Becauseof the precisemeasurementsneeded,use a digital multimeterwith an output of 1 mA or less at the 20 kO
rangewhen testing.
procedurescheck:
. Beforeperformingany troubleshooting
- FusesNo. 47 17.5AJ,No. 55 (40A), No. 56 (20A), No. 57 (20A) in the under-hoodfuse/relaybox, and No. 17 {7.5A) in
fuse/relaybox.
the under-dash
._ GroundsNo. G101,G201,G202,G401,G4O2
- Cleanliness
and tightnessof all connectors
Symptom
Sse pags
22-24
Condenserfan does not run at all {but radiatorfan runswith the Ay'Con).
Bothfans (radiatorand condenser)do not run for enginecooling.but they both run with the A,/C
on.
22-29
22-33
22-34
22-39
22-10
www.emanualpro.com
22-37
Self-diagnosis
Function
The heatercontrolpanelhasa self-diagnosis
function.
Runningthe Self-diagnosisFunction
'97 modl:
Turn the ignitionswitchON {ll),then set the mode controldial to the Vent position,and the recirculation
controtswitchto
Recirculate
indicatorlightcomeson).Pressand holdthe recirculation
{recirculation
controlswitchto Fresh(recirculation
indicatorlight goes off).Continueto hold the switch;the recirculation
indicatorlight will come on for two seconds.then it will
blink the DiagnosticTroubleCode(DTC)to indicatea iaulty component.lf no DTC'Sare found,the indicatorliqht will not
blinkatterthe initialtwo secondlight.
'98 - 00 models:
Set the mode controldial to the Vent position,and turn the ignitionswitchON (ll).Withinsix secondsafterturningthe ignition switchon, pressthe recirculation
controlswitchthe requirednumberof times dependingon the recirculation
indicator
lightstatus:
. l f t h e i n d i c a t o r l i g h t i s O N , p r e s s t h e r e c i r c u l a t i o n c osnw
t riot cl hf i v et i m e s .
. l f t h e i n d i c a t o r l i g h t i s O F F , p r e s s t h e r e c i r c u l a t i o n c osnwt irtoclhs i xI | m e s .
The recirculation
indicatorlight will come on for two seconds,then blinkthe DiagnosticTroubleCode(DTC)to indicatea
faultycomponent.lf no DTC'Sarefound,the indicatorlightwill not blinkafterthe initialtwo secondliqht.
DTCIndicaiion Pattern{SeeDTC3}:
Rocirculation
indicator
light on
Recirculrtion
indicator
lighi off
'97 model:
,r*
1.5 aaa
/
0.3 aac
RECIRCULANON
INDICATORLIGHT
MODECONTROLOIAL
Diagnostic
trouble
code {DTCI
'l
R6circulation
indicator light
Possiblo causc
See page
22-12
O n eb l i n k
Openor shortcircuit,obstructed
door,
faultymotor
Two blinks
Elower motor
Three blinks
Evaporator
temperature
sensor
22-14,16
22-20
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Troubleshooting
Air Mix ControlMotor
Recirculation
indicatorlight indicatesDiagnosticTroubleCode(DTC)1:A problemin the air mix controlmotor circuit.
The air mix controlmotor regulatesthe mixtureof cool/hotair accordingto outputsfrom the heatercontrolpanel.
Selt-diagnosiscircuit check indicates a Droblem in the air mix
control motor circuil.
HEATERCONTROLPANEL2OPCONNECTOR
PNK/BLK
CheckIor a short in the wires:
1 - R e m o v et h e h e a t e rc o n t r o l
panel(seepage22-46).
2. Checktor continuitybetween
body ground and the heater
control panel 20P connector
terminalsNo. 1, 6, 9, 17 and
18 individually.
RED/BLU
Wiresideof femaleterminals
Ropairany short in the wire(s)
betwoon th. heater co.rtrol panel
and the air mix conlrol motor.
To page22-13
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HEATERCONTROLPANEL2OPCONNECTOR
RED/YEL
RED/YEL
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Troubleshooting
BlowerMotor Speed
indicatorlight indicatesDiagnosticTroubleCode(DTC)2: A problemin the blowermotor circuit
Recirculation
The speedof the blowermotor is controlledby signalssentfrom the heatercontrolpanel
Blower motol only runs on high
spood position; h does not run in
any othe. speodpositions.
3P CONNECTOR
POWERTRANSISTOR
Self-diagnosis
circuitcheck indic a t e sa p r o b l e mi n t h e b l o w e r
motor circuit,
1
2 ) 3
BLK
ls therecontinuity?
JUMPER
WIRE
,/1,/
't1 12 1 3
1ia
22-14
10
o
LT GBN/BLK
www.emanualpro.com
LI GRN/BLK
10 page22-15
't5 1 6 1 1 1 8 1 9 20
From page22-14
HEATERCONTROLPANEL2OPCONNECTOR
2
11
,/1,/l/
10
12 1 3 1 a 1 5 1 6 1 7 1 8 1 9 20
LT GRN/BLK
o
R.p.ir short in the wire betwoen
th. herter control Denel snd the
oowor tranSastor.
Checkto. an open in the wire:
1. Turnthe ignitionswilchON (ll).
2. Measurethe voltage between
t h e N o . I t e r m i n a lo f t h e
heatercontrol panel 8P connectorand body ground.
HEATERCONTROLPANEL8P CONNECTOR
1
4
8
BLU/8LK
ls there batteryvoltage?
www.emanualpro.com
22-15
Troubleshooting
BlowerMotor
Recirculation
indicatorlight indicatesDiagnosticTroubleCode(DTC)2: A problemin the blowermotor circuit.
The speedof the blowermotor is controlledby signalssentfrom the heatercontrolpanel,
Blower motor do.3 not run at all.
circuitcheck indiSelt-diagnosis
c a t e sa p r o b l e m i n t h e b l o w e r
motor circuit,
BLOWERMOTOR 2P CONNECTOR
Check tho blowe. motor input
and output cilcuh:
1. Connectthe No. 2 terminalof
the blower motor 2P connector to body ground with a
jumperwrre.
2. Turnthe ignitionswitchON (ll).
fo page 22-19
22-16
www.emanualpro.com
JUMPEF
w|RE
fo page 22-11
Frompage22-16
BLOWERMOTORHIGHBELAYitP CONNECTOR
BLU/BLK
rF
r
.--1 1 2 )
l | _ #
. r u u eI e l"3 1 i
wrRE
I
ls there batteryvoltage?
To page22-18
www.emanualpro.com
(cont'd)
Troubleshooting
BlowerMotor (cont'd)
Ftom page 22-17
BI-OWERMOTORI{IGHRELAY4P CONNECTOR
Wire sideof femaleterminals
Checkfor an open in the wiro:
1 . F e m o v e t h e h e a t e rc o n t r o l
panel(seepage22-46).
2. Checklor continuitybetween
t h e N o . 8 t e r m i n a lo I t h e
heatercontrol panel 8P connectorand the No. 1 terminal
of the blower motor high
relay4P connector.
ls therecontinuhy?
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HEATERCONTROLPANEL8P CONNECTOR
Wiresideof femaleterminsls
I{EATERCONTROLPANEL2OPCONNECTOR
Wirc sideot femaleterminals
ls thore batteryvoltage?
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22-19
Troubleshooting
EvaporatorTemperatureSensor
Recirculationindicatorlight indicatesDiagnosticTroublecode (OTC)3: A problemin the evaporatortemperaturesensorcircuit.
The evaporatortemperaturesensor is a temperaturedependentresistor{thermistor}.The resistanceof the thermistor
decreases
as the evaporatoroutletair temperatureincreases.
Self-diagnosiscircuit check indi
cates a problem in the avaporator tempeleture ssnsor circuit,
EVAPORATOR
TEMPEMTURESENSOR
Terminalsideof malterminals
86'F
30"c
ls the resistance
withinthe speci,
ficationsshownon the 9raph.
HEATERCONTROLPANEL2OPCONNECTOR
Wiresideof fema16
terminals
fo page22.21
www.emanualpro.com
From page22-20
HEATERCONTROLPANEL2OPCONNECTOR
Wire sideol femaleterminals
Chocktor an oDenin th wire:
Checkfor continuity betlveenthe
No. 2 terminalof the heatercontrol oanel 20P connector and the
No.2 terminaloI the evaporator
temperaturesensor2P connoctor.
10
11 1 2 1 3 1 a 1 5 1 6 't7 1 8 1 9 20
GIIN
Fopair open in the wiro between
tho heato. control penel and the
evaporatortempetatule sensor.
TEMPERATURE
EVAPORATOB
SENSOR
2P CONNECTOR
Wire sideoI temaleterminals
'tl
o
+
li-L:t
Ropairopen in tho wire betwegn
the heater control oanel and the
evaporatortgmpcrature sen3or.
www.emanualpro.com
,/ l,/
2
8 9 t0
6
1 2 1 3 l a t 1 5 1 6 '17 1 8 't9 20
Troubleshooting
Mode ControlMotor
Mode control motol does not run.
or ono or more modesare inoDaa-
BLK/YEL
Wiresideof femaleterminals
HEATERCONTROLPANEL2OPCONNECTOR
2
1 1 12
l,/1,/
NO
To page22-23
[E!r!
Ii
Wiresideof femaleterminals
www.emanualpro.com
10
YEL/RED
BLU
ls therecontinuity?
1 3 t a 1 5 1 6 1 7 r 8 1 3 20
BRN/WHT
From page22-22
HEATERCONTROLPANEL2OPCONNECTOR
' V VL g l
't1 1 2
r s l r r l r s l 1r7e1 8
BRN/WHT
:L/BLU
10
1 9 20
8LU/BLX
,/1,/l/
10
1 1 1 2 1 3 t 1 4 t 1 51 5 1 1 1 8 1 9 20
YEL/BLU
BRN/WHT
BLU/BL
Kt I I
GRi|/YELI
I
I
YEL/REDI
t
YEL/BLUI
;f;T;T;
YEL
BLU/BLK
GRN/ItEL
BRN/WHT
YI:L/FED
MODECONTROI-MOTOR7P CONNECTOR
Wire sideol temaleterminals
R.pair any opon in tho wilols)
betwaen th6 modg cortrol motor
and th. heatar control p.nsl.
www.emanualpro.com
22-23
Troubleshooting
Recirculation
GontrolMotor
Rocirculation control door do6s
noi chango botwen Fresh and
Reci.culate.
REORCULATION
CONTROL
MOTOR
,rPCONNESTOR
q?
T---
V-l
l 1 l, r l / l 1 l
I BI.IUYEL
(v)
Wiresideof femaleterminals
YES
To page22-25
Do the recirculation
controllink
age and door move smoothly?
www.emanualpro.com
Ftom page22-24
HEATERCONTROLPANEL8P CONNECTOR
ls thereany voltage?
GRN/REO
---1
T
' l F I2 1 3
i r l 5 1 6 I ;T;
4P:
8P:
N o . 2- N o . 4
No.3- No.2
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ffi
I V I 4 I
GRN/WHT
CONTROLMOTOR
RECIRCULATION
,lP CONNECTOR
wire sideot femaleterminals
22-25
Troubleshooting
RadiatorFan
Radiator tan doos not run at sll
(but condonserfsn runs with the
A/C onl.
Chockthe radiatortan:
Connectthe No. 1 and No.2 tr
minals of the radiatorfan relay
4P socketwith a iumperwire.
fo page22-28
www.emanualpro.com
fo page22-21
Ftom page22-26
BLK/RED
3. Checkfor continuitybeNveen
the No. l terminalo{the radiator fan relay 4P socketand the
N o . 2 t e r m i n a lo f t h e r a d i a '
tor fan 2P connector-
RADIATORFAN 2P CONNECTOR
Wire sideof lemaleterminals
ls therecontinuity?
(cont'd)
www.emanualpro.com
Troubleshooting
Radiator Fan (cont'dl
From page 22-26
1
2
a
BLK/YEL
ls there batteryvoltage?
22-28
www.emanualpro.com
Fan
Condenser
Condenserlan does not run at all
lbut radiator fan runs with the
A/C on).
Checkthe under-hoodluso/relay
box:
Measurethe voltage betweenthe
No.2terminalof the condenserfan
relay4Psocketand body ground.
page22-30
To page22 31
(cont'd)
www.emanualpro.com
22-29
Troubleshooting
CondenserFan{cont'd)
CONDENSER
FAN RELAY4P SOCKET
ls therecontinuity?
r---------t wHT
lr_f__l
1
2 |
fT;.]
|I
/Or
\j/
CONDENSER
FAN 2P CONNECTOR
Wire sideol temaletorminals
Chechtor an open in the wire:
Checkfor continuitybetweenthe
No. I terminal of the condenser
fan 2P connector and body
ground.
-r+-,.
1 2
TBtK
Check for an open in thg wire
between the condenser fan and
body ground. lf the wiro is OK.
checktor poor ground .t G202.
www.emanualpro.com
22-30
@
!
R e p a i ro p e n i n t h e G R N w i r o
b6tw6en the cond.nser lan relay
and rhe PcM/EcM,
www.emanualpro.com
22-31
'.r
GRN
ls therecontinuity?
ls the coolingsystemOK?
www.emanualpro.com
Wiresideof femaleterminals
Both Fans
2
1
BLK/YEL
PCMCONNECTOR
A I32PI
1
12
t5 t6 17 18 r9
10
22
23
11
21
GRN
PCM/ECMCONNECTOR
A (32PI
'98 - 0Omod6ls:
www.emanualpro.com
22-33
Troubleshooting
R e m o v et h e c o m p r e s s ocr l u t c h
relay,and test it (seepage 22 45).
Checkthe under-hoodfuse/relay
DOX:
Chacklhe complessorclutch:
Connectthe No. 1 and No. 2 terminalsofthe comoressorclutchrelav
4Psocketwith a jumper wire.
Doesthe comprossorclutchclick?
To page22-36
22-34
www.emanualpro.com
To page22-35
tr-=--l
I.TT
@
i
$"f
1
I
\
__---.1
1___J.RED
COMPRESSOR
CLUYCHlP CONNECTOR
Wire sideof lemaleterminals
Repairopen in the wire between
the comp.e3sor clutch relay and
the comprsssorclutch.
RED
-_-l
.lwww.emanualpro.com
(cont'd)
Troubleshooting
Compressor(cont'dl
Frcm page22-34
COMPRESSOR
CLUTCHRELAY
4P SOCKET
2
3
BLK/YEL
Repairop.n in the wire between
the No. l7 fu3e and the compressor clutch ielay.
A I32P)
PCMCONNECTOB
'97 model:
12
2
15 1 6 1 7
6
'18 1 S
10
22
23
11
21
BLK/RED
Wiresideof femaleterminals
A {32P}
PCM/ECMCONNECTOR
38 - 00 models:
22-36
www.emanualpro.com
A/C System
A/C aystem does not come on
{both fans and comDrossor).
A/C PRESSURE
SWITCH2P CONNECTOR
Ch6cklor .n open in the wire:
1. Disconnectthe A,/Cpressure
switch2P connector.
2. Turnthe ignitionswitchON (ll).
3. Measurethe voltagebetween
t h e N o . 2 t e r m i n a la n d b o d y
ground.
ls thereapprox.5 volts?
fo page 22-38
C (31PI
PCMCONNECTOR
'97 modol:
PCM/ECMCONNECTOR
A I32P'
38 - 00 modeb:
ls thereapprox.5volts?
www.emanualpro.com
(cont'd)
22-37
Troubleshooting
A/G System {cont'd)
Frompage22-37
SWITCH
A/C PRESSURE
Checkfor properAy'Csystempressure.
HEATERCONTROLPANEL2OPCONNECTOR
Chocklor an opgn in thg wire:
1. Feconnectthe A/C pressure
switch 2P connector,
2 . R e m o v et h e h e a t e rc o n t r o l
panel(seepage22-46).
3. Turn the ignitionswitch ON llli.
4. Measurethe voltage between
t h e N o . 1 0 t e r m i n a lo f t h e
heatercontrolpanel20P connectorand body ground.
22-38'
www.emanualpro.com
HEATERCONTROLPANEL8P CONNECTOR
ls thero batteryvoltage?
Wiresideot femaleterminals
A,/1,/
WHT/BLU
Repsil opon in tha wi.a batwcan
th. No. 47 tur. and tho hoitor
contlol panol.
Wiresideof femaleterminals
3
8
BLK
Check for an opon in tho wira
b6{woon tho hoatar control p.nol
and body ground. It the wir. i3
OK, chsck for poor ground rt
GlOl lnd Glo2.
www.emanualpro.com
10
1 t 1 2 1 3 1 a 1 5 1 5 1 7 1 8 1 9 20
HEATERCONTROLPANEL2OPCONNECTOR
Troubleshooting
HeaterControl PanelInput/OutputSignals
HEATERCONTROLPANELCONNECTORS
2OPCONNECTOR
8P CONNECTOR
8P CONNECTOR
Cavity
lrvire colol
'l
BLK/TEL
Cavity
Signal
I G 2( P O W E R )
Wire colol
INPUT
RED
GRN/RED RECIRCULATE
INPUT
RED/BLK
GRN/VVHT F R E S H
INPUT
CUTPUT
BLUI/EL
REARWINDOW
RELAY
DEFOGGER
Signal
DASHLIGHTSERIGHTNESSCONTROLLER
LIGHT
COMBINATION
SWITCH(ViaNo. 30 (7.5A)
fuse)
CUTPUT
INPUT
GROUND
OUTPUT
BLU/BLK BLOWERFEEDBACK
INPUT
BLK
20PCONNECTOR
Cavity
Cavity
Signal
Wire color
GRY
+5V
AIR MIX POTENTIAL
GRN
TEMPERA.
EVAPORATOR
OUTPUT
T U R ES E N S O R
PNI(BLK
OUTPUT
INPUT
7
8
BLOWERMOTORHIGH
ORNrur'HT
RELAY
BRN
10
22-40
SENSOR
GROUND
SWITCH
BLU,ryVHTA"/CPRESSURE
www.emanualpro.com
INPUT
INPUT
INPUT
'll
12
Signal
Wire color
YEL
MODEHEAT/DEF
INPUT
INPUT
13
BLU/BLK MODEHEAT
INPUT
14
GRN/YEL MODEHEAT/VENT
INPUT
I C
YEURED M O D EV E N T
INPUT
to
YEUBLU MODEDEF
INPUT
17
RED/BLU A I RM I X C O O L
OUTPUI
18
RED/VEL
OUTPUI
'19
MOTORGROUND
BRNA/VHT IVIODE
INPUT
20
BASE CUTPUT
T GRN/BLKPOWERTRANSISTOR
Mode ControlMotor
Replacement
Test
1.
Disconnect
the 7P connectorfrom the mode control
motor. Removethe rod from the arm of the mode
control motor, Remove the self-tapping screws and
the mode controlmotor.
7P CONNECTOR
MODECONTROLMOTOR
MODECONTROLMOTOR
2.
Installin the reveGeorderof removal.After installation, make sure the mode control motor runs
smoothlv.
U s i n g a j u m p e r w i r e . c o n n e c tt h e N o . 7 t e r m i n a l
i n d i v i d u a l ltyo t h e N o , 2 , 3 , 4 , 5 a n d 6 t e r m i n a l si n
that order. Eachtime the connectionis made. the
mode controlmotor shouldrun smoothlyand stop.
lf the mode control motor does not run when jumping the first terminal,jump that terminalagain after
j u m p i n g t h e o t h e r t e r m i n a l s .T h e m o d e c o n t r o l
motor is OK it it runs when jumping the first terminal again.
lf the mode control motor does not run in step 3,
removeit, then checkthe mode control linkageand
doorsfor smoothmovement.lf they move smoothly,
reDlacethe mode control motor.
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RecirculationControl Motor
Replacement
Test
1.
{P CONNECTOR
RECIRCULANON
CONTROLMOTOR
Disconnect
the No. 2 or No. 4 terminalsfrom ground;
control motor shouldstop at Fresh
the recirculation
Don't cvcle the recirculationcontrol
or Recirculate.
motor for a long time.
4.
22-42
www.emanualpro.com
Test
1.
1.
Disconnectthe 5P connectorfrom the air mix control motor. Remove the self-tapping screws, the air
mix controlmotor and the flangecollar.
5P CONNECTOR
6
AIR MIX
CONTROL
MOTOR
Installin the reverseorderof removal.After installation. makesure the air mix control motor runs
smoothlv.
Measurethe resistance
betweenthe No. 2 and No. 3
terminals.lt shouldbe approximately6 kOt 20%.
4.
Measurethe resistance
betweenthe No. 2 and No, 4
terminals,lt shouldbe approximately
4.8kO:t 20%at
MAX HOT and approximately '1.2kO t 20% at lilAx
cooL.
www.emanualpro.com
22-43
EvaporatorTemperature
Sensor
Power Transistor
Test
Test
1 2 V1 . 2 - 3 . 1 W
EVAPOBATOR
TEMPERATURE
SENSOB
No. 2 ILT GRN/BLK)
Terminalsideol maleterminals
RESISTANCE
ko
t0
50
10
68
20
86.F
30'c
No.I IBLU/BLK)
www.emanualpro.com
22-44
Relays
Test
Thereshouldbe continuitybetweenthe No. 1 and No.3
terminalswhen power and ground are connectedto the
No. 2 and No. 4 terminals,and thereshouldbe no continuity when power is disconnected.
,I
In
t)
P
.I
tI r I
o Blowermotor relay
a Rsdiatorfan relay
Condenserfan relay
a Compressor
clutchrelay
F)'"
,2-4.._.
www.emanualpro.com
22-45
HeaterControlPanel
Blower Unit
Replacement
Replacement
6x1.0mm
9.EN.m 11.0kgf.m,7.2lbtftl
CENTERPANEL
www.emanualpro.com
22-46
Overhaul
Notetheseitemswhen overhaulingthe blower unit.
. The recirculationcontfol motor. the power transistor,the blower motor high relay, and the blower motor can be
replacedwithout removingthe blowerunit.
. Betorereassembly,
makesurethattherecirculation
controldoorand linkagemove smoothlywithout binding.
o After reassembly,
makesurethe recirculation
controlmotor runs smoothly(sepage22-42).
o Makesurethat there is no air leakage.
RECIBCULATION
CONTBOLMOTOR
page22-42
Replacement.
m
POWEBTMNSISTOR
Test. page 22'44
BLOWER
Tost, page 22-45
www.emanualpro.com
22-47
Evaporator
Replacement
1 . Recoverthe refrigerantwith a recovery/recycling/
chargingstation(seepage22-59).
6.
Removethe battery.
Removeeach bolt, then disconnectthe suctionand
receiverlinesfrom the evaporator.Plug or cap the
them to avoid
linesimmediatelyafter disconnecting
moistureand dust contamination,
5xl,0mm
9.8 N.m {1.0kgf.m, 7.2 lbf.ftl
II
RECEIVERLINE
-l: "
..
\
EVAPORATOR
6x1.0mm
9.8 N.m (1.0kgtm,7.2lbf.ftl
6x1.0mm
9.8N'm(1.0kgfm,
7.2 tbl.ttl
(see
glove
Removethe
box
section20).
Removethe self-tappingscrewand the passenger's
dashboardlower cover,then removethe bolts and
the glove box frametogetherwith the kneebolster.
KNEE
GLOVEBOX FRAME
www.emanualpro.com
22-44
7.
} -
Overhaul
1.
6.
Remove the filter lid. then pull out the A/C filter
assembly.
TAPE
ELECTRICAL
Replace.
Makesure there is no foreign matter stuck between
the capillarytube and outletline.
CAPILLARY
TUAE
;
EXPANSIONVALVE
TEMPERATURE
SENSOR
lest, page 22-41
,m
\!{
FILTERLID
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I-OWERHOUSING
A/C FILTERASSEMBLY
22-49
A/C Filter
Replacement
1.
A/C FILTERASSEMELY
HeaterUnit
Replacement
SRS componentsare located in this area. Reviewthe
SRS componentlocations,precautions,and procedures
in the SRSsection{24)beforeperformingrepairsor ser-
1.
Disconnect
the negativecablefrom the battery.
2.
HEATERVALVE ARM
R e m o v et h e A / C f i l t e r f r o m t h e f i l t e r h o u s i n g .
Replacethe Ay'Cfilter accordingto the maintenance
schedulein the owner'smanual.
HEATER
VALVECABLE
22-50
www.emanualpro.com
4.
Removethe dashboard(seesection20).
7.
ll.
HEATERHOSE
IOUTLETSIDE)
Removethe evaporator(seepage22-48).
Disconnectthe connectorsfrom the mode control
motor and the air mix control motor, and removethe
wire harnessclips and wire harnessfrom the heater
unit. Remove the clip from the heater duct, then
removethe mountingnutsand the heaterunit
6x1.0mm
9,8N.m (1.0kgt m,7.2lblft)
HEATER
UNIT
CLAMPS
13 N.m 11.3kg{.m,9.4lbtftl
www.emanualpro.com
22-51
HeaterUnit
Overhaul
1.
Reassemble
the heaterunit in the reverseorder of
disassemblv.
HEATERCORECOVER
HEATERCORE
22-52
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TemperatureControl
Adjustment
l.
5.
HEATERVALVE ARM
HEATERVALVECABLE
VALVECABLE
HEATER
www.emanualpro.com
22-53
(R-134a)
refrigerantand polyalkyleneglycol
The air conditionersystemusesHFC-'134a
{PAG)refrigerantoil*, which are not
(R-12)
refrigerantand mineraloil. Do not use R-12refrigerantor mineraloil in this system,and do
compatiblewith CFC-12
not attempt to use R-12servicingequipmenudamageto the air conditionersystem or your servicingequipmentwill
resutr.
*KEIHINSP-10:
. P/N 38897- Pl3 - A01AH:120m{ (4 fl.oz,il.2 lmp.oz)
. P/N 38899- Pl3 - A01:40 mf 11113tl.oz,1.4
lmp.oz)
Use only serviceequipmentthat is U.L.-listedand is certifiedto meet the requirementsof SAE J2210to removeR-134a
from the air conditionersystem,
CAUTION: Exposureto air conditioner refrigerant and lubricant vapor or misl can irritats eyes, nose and throat. Avoid
breathingthe air conditionerrefrigerantand lubricantvaporor mist,
lf accidentalsystemdischargeoccurs,ventilatework areabeforeresumingservice.
R 134aserviceequipmentor vehicleair conditionersystemsshouldnot be pressuretestedor leaktestedwith compressed
air.
Some mixtures of air and R-13,1ahave been shown to be combustible at elevatd pressuresand can result
E@
in fire or explosion causing iniury or property damage. Never use complessed air to pressuretest R-l3,[a service equipment or vehicle air conditioner systems.
Additionalhealthand safetyinformationmay be obtainedfrom the refrigerantand lubricantmanufacturers.
1.
2.
3.
4.
5.
6.
r.sr-o.o.t
rsom r rr:0.o.,
www.emanualpro.com
22-54
A/C SystemTorqueSpecifications
EVAPORATOR
SUCTIONLINE
SUCTIONHOSE
RECEIVERLINE A
RECEIVENLINE B
RECEIVER/ORYER
22-55
Recovory/Recycling/chargingstation
22-56
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LOW.PRESSURE
SIDE
5.
To comDletethe charts:
. Markthe deliverytemperaturealongthe verticalline'
. Markthe intaketemperature{ambientair temperature)alongthe bottom line'
. Drawa line straightup from the air temperatureto the humidity'
. Marka point 10%aboveand 10%belowthe humiditylevel'
a Fromeachpoint,draw a horizontalline acrossthe deliverytemperature'
. The delivervtemperatureshouldfall betweenthe two lines'
. Completethe low-sidepressuretest and high-sidepressuretest in the sameway'
outsidethe line may indicatethe needfor furtherinspection
. Anv measurements
kPa
{kst/cm')
Ipsil
29r,0
t30t
l,a0l
HUMIDITY
LEVEI-
2500
(251
t3601
2000 l
l20l I
t28ol |
I
1s00'l
{15} |
DELIVERY r21or
I
PRESSURE
980 j
rlol
kp.
{ksf/cmz}"F
lcsil
Pcl
,l0oI
85 -l
(4} |
(301
t57lI
3oo-.J
{31 I
"r1
I
l25lI
200
t2) |
68 J
(2otI
r14ol r13l
I
-lL
r28r
I
I
-.1
100
TNTAKElli' I
PRESSURE
80v.
80vo
HUMIOITY
LEVEL
HUMIDITY
LEVEL
I
ss l
(15r
I
|
50 -l
,to,
I
DELIVERY
TEMPEBATURE.t
I
:.] _
rsl -ll
fl
6g
t2o)
j7
l25l
*
(30)
95
(351
104
(ro)
fct
INTAKETEMPERATURE
www.emanualpro.com
22-57
Dischargepressure
abnormallylow
Suction pressure
abnormallyhigh
Suctionand dischargepressure
abnormallylow
Refrigerant
leaks
www.emanualpro.com
Relatadsymptoms
After stoppingcompressor,pressure
dropsto about200 kPa12.0kgtlcm,,
28 psi)quickly,and then lalls gradualty.
Prcbablecaus
Air in system
No bubblesin sightglasswhen
condenseris cooledby water
Reducedor no air flow through
condenser
Excessiverefrigerantin system
. Cloggedcondenseror radiator fins
. Condenser
or radiatorfan
not wo.king properly
Remody
Discharge,
evacuate,
and recharge
with specifiedamount.
Evacuation:
seepage22-60
Charging:
seepage22-61
Discharge,
evacuate,
and recharge
with speciliedamount.
Clean
Checkvoltageand fan rpm.
Checkfan direction.
Restrictedflow of relrigerantin
sy$em
Festrictedlines
Excessive
bubblesin sightglass;
condenseris not hot.
Highand low pressures
are balanced
soon after stopping compressor.Low
sideis higherthan normal.
Outlet ot expansionvalve is not
frosted, low-pressuregauge indicates
Insufficientretrigerantin
Checkfor leak.
Chargesystem.
Replacethe comprossor.
. Faultycompressordischarge
. Faultycompressorseal
' Faultyexpansionvalve
. Moisture in system
Excessive
bubblesin sightglass;
condenseris not hot.
Insufficiontrelrigerantin
' Frozenexpansionvalve
lMoisture in system)
. Faultyexpansionvalve
Frozenevaporator
Expansionvalve is frosted.
Feceiver/dryeroutlet is cool, and inlot
rsw6rm (shouldbe warm during
operation).
Cloggedexpansionvalve
Cloggedreceiver/dryer
. Expansionvalveopentoo long
. Looseexpansioncapillary
tube
Excessiverefrigerantin system
No bubblesin sightglasswhen
condenseris cooledby waler
Low-pressure
hoseand motalend
areasare cooterlhan evaporator.
Temperature
aroundexpansionvalve
rstoo low comparedwith that around
Faultygasket
Faultyhigh-pressure
valve
Foreignpaniclestuckin high. Cloggedcondenseror
radiatortins
. Condenser
or radiatorfan
not workingproperly
Excessiverefrigerantjn system
Cloggedor kinkedlowpressurehose pans
Cloggedhigh-pressure
line
. Replace
. Discharge,evacuate,and
rechargewith specifiedamount.
Repairthe leaks.
Discharge,
evacuate,
and
rechargewith specifiedamount.
Chargeas rquired.
. Discharge,evacuate,and
rechargewith specitiedamount.
. Replaceth expansionvalve.
Run the fan with compressoroff,
then checkevaporatortempera,
ture sensor.
Cleanor replace.
Replace
Repairor roplace.
Discharge,
evacuate,
and recharge
wathspecifiedamount.
Replace
the compressor.
Clean
Checkvoltageand fan rpm.
CheckIan direction.
Discharge,
evacuate,
and recharge
with specifiedamount.
Repairor replace.
Repairor replace.
Compressor
clutchis diny.
Compressor
boltls)are dirty.
Compressor
shaftsealleaking
Leakingaroundbolt(s)
Replace
the compressor.
Tighton bolt{s)or replace
compressor.
Gasketleaking
Replacethe compressor,
Recovery
and is cerUseonly serviceequipmentthat is U.L.-listed
tifiedto meetthe requirementsof SAEJ2210to remove
(R-134a)
from the air conditionersystem.
HFC-134a
Station
Recovery/Recycling/Charging
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22-59
22-60
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Recovery/Recycling/Charging
Station
Charging
LeakTest
Connecta R-'134a
refrigerantrecovery/recycling/charging
stationto the vehicle,as shown.followingthe equipment
manufacturer'sinstructions.
Station
Rcovery/Recycling/Charging
HIGH-PRESSURE
SIDE
Add the same amount of new refrigerantoil to system
t h a t w a s r e m o v e d d u r i n g r e c o v e r y .U s e o n l y S P - ' 1 0
refrigerantoil.
C h a r g et h e s y s t e m w i t h R e q u i r e da m o u n t o f R - 1 3 4 a
refrigerant.Do not overchargethe system;the compressor will be damaged.
S e l e c tt h e a p p r o p r i a t eu n i t o f m e a s u r ef o r y o u r
chargingstation.
ll-
Refrigerantcapacity:700 to 750 g
0.70to 0.?5k9
1.5to 1.6lbs.
21.7 to 26.5 oz.
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5.
22-61
Compressor
Replacement
'L
2.
Disconnect
the negativecablefrom the battery.
5.
CONDENSER
FAN
CONNECTOR
6x1.0mm
7 N.m 10.7kg{.m,5 lbl.ftl
LINE
LINE
DISCHARGE
6.
7.
10x 1.25mm
/t4 N.m (4.5kgl.m,33 lbtftl
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tFT
FRONT
MOUltlT
COMPRESSOR
BELI
8.
1 0 . C h e c kt h e i d l e r p u l l e yb e a r i n gf o r p l a y a n d d r a g ,
and replaceit with a new one if it's noisy or has
excessiveplay or drag.
IDLERPULLEY
kgtm,33lbfftl
+r N.m14.5
E x 1.25mm
l7 lbl.ft)
2aN.m(2.,1kgf.m,
BBACKET
q
.
.
.
10x 1,25mm
art N.m (4.5 kgf'm, 33 lbfftl
www.emanualpro.com
PIVOTBOLT
10x 1.25mm
ir4 N.m{4.5kgt m, 33 lbl'ft}
drainall the
lf you'reinstallinga new compressor,
reJrigerantoil from the removed compressor,and
m e a s u r ei t s v o l u m e . S u b t r a c tt h e v o l u m e o f
drainedoil trom 130 m/ 14 U3 fl'o2,4.6lmp'oz);
the result is the amount of oil you should drain
lrom the new compressor(throughthe suctionfittrngl.
Replacethe O-ringswith new ones at each fitt i n g , a n d a p p l y a t h i n c o a t o { r e f r i g e r a n to i l
before installingthem. Be sure to use the right
(R-134a)
to avoid leakage.
O-ringsfor HFC-134a
(SP-10)
for R-134aKEIHINspiUse refrigerantoil
ral type compressorsonly.
To avoid contamination,do not returnthe oil to
the containeronce dispensed,and never mix it
with other refrigerantoils.
lmmediatelyafter using the oil, replacethe cap
on the container.and seal it to avoid moisture
aDsorprlon.
Do not spill the refrigerantoil on the vehicle;it
may damagethe paint; if the retrigerantoil contacts the Daint,wash it off immediately.
Adjust the Ay'Ccompr'essorblt (see psge 22-69)
and the power steeringpump belt {see section
17t.
and test its
Chargethe system (seepage 22-611,
performance(seepage 22-56]-.
Gompressor
lllustratedIndex
CENTER
NUT
Replace.
ARMATUREPLATE
Inspection,page 22-65
sHtM{s)
Replace.
SNAPRINGB
Replace.
ROTORPULLEY
Inspection.page 22-65
SNAPRINGA
Replace.
FIELDCOIL
Inspection,page 22-65
THERMALPROTECTOR
Replace.
Inspection,page 22-55
Replacement,
page22-68
---------------coMPRESSOR
(Donotdisassemble.)
O.RING
Roplace.
RELIEFVALVE
Replacement,page 22-68
RELIEFVALVECOVER
('97modelonly.)
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22-64
ClutchInspection
Checkthe plated parts of the armature plate for color
changes,peelingor other damage.lf there is damage,replacethe clutchset.
Checkthe rotor pulley bearing play and drag by rotating the rotor pulley by hand. Replacethe clutch set
with a new one if it is noisy or has excessiveplay/drag.
ROTOR
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22-65
Compressor
GlutchOverhaul
1.
2.
sHtMls)
Replace.
za:s
(i@,
22-66
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3.
SNAPRINGB
R6place.
l5.
6.
+
Press
FIELDCOIL
CLAMP
HUB ASSEMBLY
GUIDEATTACHMENT
07966 - 6920500
ROTOR
PULLEY
HOLDER
GROUND
TERMINAL
7,a N.m
10.75kgt'm,
5 tbt ftl
7.
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Compressor
ThermalProtectorReplacement
1.
Removethe bolt,the groundterminaland the holder. Disconnectthe field coil connector.then remove
the thermalDrotector.
ReliefValveReplacement
l.
O.RING
Replace.
RELIEF
VALVE
9.8 N.m {1.0hgf.m,
7.2 rbr.ftl
Cleanthe matingsurfaces.
ReDlace
the thermal protectorwith a new one, and
apply siliconesealantto the bottom of the thermal
orotector,
Replace
the O-ringwith a new one at the reliefvalve,
a n d a p p l y a t h i n c o a t o f r e f r i g e r a n to i l b e f o r e
installingit.
Removethe plug. and installand tighten the relief
valve.
Put the cover on the relief valve so that the arrow
d i r e c t sd o w n w a r d s a s s h o w n i n t h e i l l u s t r a t i o n
above('97 model).
7.
SILICONESEALANT
3.
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22-68
A/C CompressorBelt
Adjustment
Detlection Method
1.
BELTTENSIONGAUGE
07JGG- 00't010A
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22-69
Gondenser
Replacement
't. Recoverthe refrigerantwith a recovery/recycling/
6.
chargingststion(seepage22-59)
Removethe front grille (seesection20).
Removethe coolant reservoii,but do not disconnect the reservoirhose Jrom the coolant reservoir
and the radiator.
Removethe bolts and the suction line bracketas
s h o w n . R e m o v et h e b o l t s a n d t h e u p p e r m o u n t
brscketsfrom the radiator.
6xl.0mm
9,8 N.m 11.0kgf'm' 7.2lbf'ft)
1,0mm
MOUNT
UPPER
BRACKETS
Remove each bolt, then disconnectthe discharge
and condenserlines from the condenser,Plug or
them
cap the lines immediatelyafter disconnecting
to avoid moistureand dust contamination.
6x1.0mm
9.8 N.m 11,0kgf.m,7.2 lbfttl
t\,
6x1.0mm
7.
l/
a
it--:
.
.
i..
LINE
DISCHARGE
CONDENSRLINE
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22-70
Body Electrical
SpeciafToofs
,...,..,.............-.23-2
Troubleshooting
Tips and Precautions......,.,..........,..................
23-3
Five-stepTroubleshooting........,.,.,...,,.,.........
23-5
Wire ColorCodes
...,....,..
23-5
Relay and Control Unit Locations
EngineCompartment..,.,......,.........................
23-6
Dashboard
,.,.,..............-.23-7
Door.......................
.........23-10
Index to Cilcuits and Sysiems
AccessorySocket..
,....,.,..,.,.
23-95
*Airbags................
.,....,.Sestion24
Air Conditioning
,.,.,....
Section22
Alternator
...................
Section4
Anti-lockBrakeSystem{ABSI ...................
Section19
'A/T GearPositionIndicator.......................
Section1,1
AutomaticTransmission
System ...........,..
Section14
B a t t e r y. . . . . . . . . . . . . . . . . . .
..............23-50
BlowerControls
.,...,.,,
Section22
ChargingSystem
.......Seqtionil
Clock-'98 Model
................
23-98
Connectorldentification and Wire Harness
R o u t i n g. . . . . . . . . . . . . . . . . .
. . . . . . .2. .3 . 1 1
CruiseControl
............
Ssction4
DashLightsBrightnessContlo||er.....................
23-90
FanConlrols
...,......,....
Section10
FuelPump
,..,.,...,....,....
Section11
Fuses......................
.,,.,.,.,.,,.,23-40
*Gauges
CircuitDiagram
......-....-..23-58
FuelGauge
.....,.,.....
Section11
Speedometer
..,..........,...
23-56
GroundDistribution
,....,.,...23-46
HatchGlsssODenor.........................,.,.,.,.,..,.,.,.,,.
23-121
HeaterControls
.-........
Soction21
*Horns.,...,..,.,.,.......
................23"104
*fgnitionSwitch
,,.,.,..,.,.,,.,.,.,23-51
lgnitionKey Light System-'97 Mod6l ..............
23.88
+
BODY
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SpecialTools
Ret. No.
Description
Tool Numbel
OTLAJ PT3O2OA
23-2
PageReference
23-62,63
TestHarness
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Oty
Troubleshooting
Tips and Precautions
Before Troubleshooting
. Checkapplicablefuses in the appropriatefuse/relay
box.
. Checkthe batteryfor damage,state of charge,and
clean.and tight connections.
. Checkthe alternatorbelttension.
N e v e r t r y t o d i s c o n n e c ct o n n e c t o r sb y p u l l i n g o n
their wires;pull on the connectorhalvesinstead.
Alwavsreinstallolasticcovers.
CAUTION:
. Do not quick-chargea battery unless the battery
ground cable has been disconnected,otherwise you
will damage the alternator diodes.
. Do not attempt to crank thc engins wilh the battery
ground cable loosely connected or you will severely
damagethe wiring.
Handling Connestors
. Makesurethe connectorsare cleanand haveno loose
wire terminals,
. N4ake
sure multiplecavityconnectorsare packedwith
grease(exceptwater-tightconnectors).
. All connectorshavepush-downreleasetype locks.
LOCKINGTAB
.
S o m e c o n n e c t o r sh a v e a c l i p o n t h e i r s i d e u s e d t o
attach them to a mount bracketon the body or on
anothercomponent.This clip hasa pull type lock.
Some mounted connectorscannot be disconnected
unlessyou first releasethe lock and removethe connectorfrom its mount bracket.
RETAINER
T h e b a c k s o f s o m e c o n n e c t o r sa r e o a c k e d w i t h
grease.Add greaseif necessary.
lf the greaseis con
taminated.reolaceit.
LOCKING
PAWLON
OTHER
Pullto
HALFOF
disengage
CONNECTOR
BRACKET
{cont'd}
www.emanualpro.com
23-3
Troubleshooting
Tips and Precautions(cont'dl
Insen the connectorall the way and make sure it is
securelyIocked.
Positionwires so that the open end of the coverfaces
down.
Slip pliers under the clip base and through the hole at
an angle,then squeezethe expansiontabs to releasethe
clrD.
NOT GOOD
Face
openend
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lr
-M/
lr*
Five-stepTroubleshooting
1.
VerifyThe Complaint
Turn on all the componentsin the problemcircuitto
verify the customercomplaint.Note the symptoms.
Do not begin disassemblyor testinguntil you have
narroweddown the problemarea.
AnalyzeThe Schematic
L o o k u p t h e s c h e m a t i fco r t h e p r o b l e mc i r c u i t .
Determinehow the circuit is supposedto work by
t r a c i n gt h e c u r r e n tp a t h sf r o m t h e p o w e r f e e d
throughthe circuitcomponentsto ground.lf several
circuitsfail at the sametime, the fuse or ground is a
likelycause,
Basedon the symptomsand your understandingof
the circuitoperation,identifyone or more possible
causesof the problem.
3.
4.
O
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Wire ColorCodes
T h e f o l l o w i n ga b b r e v i a t i o nasr e u s e d t o i d e n t i f yw i r e
colorsin the circuitschematics:
W H T . . . . . . . . . . . . . . . . . . . .W
. . .h. i. t. e. . .
Y E L , . . . . . . . . . . . . . . . . . . . .Y. .e. .l .l o
. .w
...
B L K . . . . . . . . . . , . . . . . . . . . .B. .l.a. .c.k. . .
B L U . . . . . . . . . . . . . . . . . . . . .B. .l.u. .e. . . .
GRN.............................Green
R E D. . . . . . . . . . . . . . . . . . . . .R. .e. .d. . . . .
ORN.............................Oran9e
P N K . . . . . , . . . . . . . . . . . . . . .P. .i n
. .k. . . . .
B R N. . . . . . . . . . . . . . . . . . . . .B. .r.o. .w. .n. .
G R Y. . . . . . . . . . . . . . . . . . . . .G
. .r. a. .y. . . .
P U R. . . . . . . . . , . . . . . . . . . . .P. .u. .r .p. l. e. .
L T B L U. . . . . . . . . . . . . . . . . .L, i.g. .h. .tB. l u e
L T G R N . . . . . . . . . . . . . . . . .L. .i .g.h. .tG
. reen
T h e w i r e i n s u l a t i o nh a s o n e c o l o r o r o n e c o l o r w i t h
anothercolor stripe.The secondcolor is the stripe.
WHT/BLK
UNIT
UNDER.HOOD
FUSE/RELAY
BOX
t:
tr
tr ;
tr BLOWER
MOTOR
RELAY
A/C COMPRESSOR
CLUTCHRELAY
UNDER.HOOD
ABS FUSE/RELAY
BOX
''r@
l--\ r rr r
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23-6
RADIATOR
FAN EELAY
Dashboard
PGM.FIMAIN RELAY
MOTORHIGHRELAY
BLOWER
lwir. colorc:BLK/YEL,
I
ORN/WHT,.ndBLKI
LBLU/BLK,
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23-7
HEATERCONTROLPANEL
RELAY
REARWINDOWDEFOGGER
-rj,r1
Iu
/-\,r1
lJ-JlJ
r*t
WINDOWRELAY
CONTROLUNIT
INTEGRATEO
23-8
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TURNSIGNAL/HAZARDRELAY
DAYTIMEBUNNINGLIGHTS
CONTROLUNIT (Canrda){'98 - (X)modok)
IGNITIONKEYLIGHT
CONTROLUNIT l7 model)
OAYTIMERUNNINGLIGHTS
CONTROLUNIT lcanad!l l'97 modell
CRUISECONTNOLUNIT
HORNBELAY137 modell
Iwiro color3:WHT/GRN,
I
GRY,andBLU/REDI
IWHT/GBN,
{cont'd)
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23-9
REARACCESSORY
SOCKETRELAY
I Wire colors:YEL/GRN,
J
IWHT/BLK.BLK,.nd YEL/BLUl
REVERSE
RELAY
{A/TI
I WirecolonrYEI-/RED,
I
IYEL/RED,YEL,.nd GRN/BLKI
REARWINDOWWIPER
CONTROLUNIT 137 mod.ll
INTERLOCX
CONTROLUNIT
KEYIISS/POWER
DOORL(rcK
CONTROL
UNIT
23-10
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EngineCompartmsnt
Startercable
T 1 ,T 2 a n d@
Batterygroundcable
G 1 a n dO
Enginegroundcable
T3
groundcable
Transmission
T4
G3
Enginewire harness
C 1 0 1t h r o u g hC 1 3 7
T 1 0 1a n dT 1 0 2
G101
Enginecompartmentwareharness
C201throughC218
G201and G202
Under-hoodABS fuse/relaybox
wire harness
t5ano9
C301throughC309
C351throughC361
Dashboardwire harness
Dashboard
C401throughC447
G401and G402
C501throughC524(C525)
G501
Leftsidewire harness
C551throughC581
G551,G552and G553
Rightsidewire harness
C601throughC605
lnteriorwire harness
C701throughC703
Rearbumperwire harness
C641throughC643
Heatersub-harness
C731throughC740
C721through C722
Secondaryheatedoxygensensor
sub-harness
Combinationswitchsub-harness
C751throughC760
C661throughC667
C6Tl throughC676
C681throughC684
C69'lthroughC694
Rearwire harness
C611throughC520
Tailgatewire harness
C631throughC634
G631
SRSmain harness
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C801throughC808
G801
C651throughC653
Fueltank oressuresensorsub-harness
C645throughC647
Starter Cables
Connoctoror
Terminal
Number of
Cavities
T1
Location
Connectsto
r2
Rightside of enginecompartment
Rightside of enginecompartment
Under-hoodfuse/relaybox
Starter motor
Battery
Batterypositiveterminal
Notes
Numberof
Cavities
GI
Location
Conneqtslo
Rightfront shocktower
Bodyground,via batteryground
cable
Battery
Batterynegativeterminal
Notes
EngineGroundCable
Connectoror
Terminal
Numb6r ol
Cavities
T3
Location
Connectsto
Leftsideof engine
Powersteeringpump bracket
Leftside of enginecompartment
Bodyground.via engineground
caote
Notes
TransmissionGround Cable
Connsstor o.
Terminal
Number of
Cavities
T4
Location
Connectsto
Rightside of enginecompartment
Transmission
Notes
Numberof
Cavities
Location
Connoctsto
tc
Rightside of enginecompartment
Under-hoodABS tuse/relavbox
Battery
88tterypositiveterminal
23-12
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Notos
STARTERCABLE
ABS FUSE/RELAY
UNDER-HOOD
BOX WIREHARNESS
@
EATTERY
GROUND
CABLE
ENGINEGROUND
CABLE
TRANSMISSIONGROUND
CABLE
www.emanualpro.com
23-13
EnginoWire Harness
Connecto; or
Terminal
c101
c102
c103
c104
c105
c105
c106
c 107
c 108
Number of
Cavities
10
6
c 109
c]10
c1l'l
c112
c113
c ' t1 4
cl16
cl16
c117
c118
c119
c120
c121
c't22
c't23
c't25
cl26
cl27
cr28
cl29
c130
c131
c132
c 133
c134
c134
c135
c 136
Location
Conneqtsto
Leftside of enginecompartment
Leftside of enginecompartment
Middleof engine
Middleof engine
Leftsideof enginecompartment
Leftsideof enginecompartment
Middleof engine
Middleof engine
Middleof engine
Middleof engine
Middleof engine
M i d d l eo f e n g i n e
1
10
20
31
16
22
l0
l0
'14
Middleof engine
Middleof engine
Middleof engine
Middleof engine
Middleof engine
Middleof engine
Middleof engine
Middleof engine
Middleof engine
Rightsideof engine
Middleof engine
Behindright kickpanel
Underright side of dash
Underright side of dash
Underright side of dash
Underright sideof dash
Underright sideof dash
Rightsideof engine
Rightsideof engine
Middleof engine
Middleof engine
Middleof engine
Middleof engine
Middleof engine
Middleof engine
14
1
G101
Middle of engine
23-14
A/r
USA
Canada
Alr
AlT
M/'r
Afi
'97 mooel
'97 model
'98 - 00
mooets
T101
r102
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Notos
'99 - 00
models
c1733
clsl gra,
c103
c137
T101
c104
c112
ENGINEWIREHARNESS
cl13
cl' l1
23-15
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lrffiltEfinl,
Number of
Cavities
c20'l
c202
c203
c204
c205
c206
c207
c208
c209
c210
14
c212
c213
c2't4
c215
c216
2
2
1
'l
c217
c21A
c218
G201
G202
www.emanualpro.com
23-16
10
Location
Connectsto
Notes
Optional
'97 - 98
models
'99 - 00
mooets
ENGINECOMPARTMENT
WIREHARNESS
c212
c211
www.emanualpro.com
23-17
Number ot
Cavities
c301
c303
c304
c305
2
10
c306
c307
c308
c309
c356
c357
c358
c359
c360
LJO
G35l
23-18
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Conneqtsto
Leftside of enginecompartment
Leftsideof enginecompartment
Leftside of enginecompartment
Leftside of enginecompanment
Leftside of enginecompartment
Windshieldwiper motor
Daytimerunninglightsresistor
Test techometerconnector
Enginewire harness(C10])
Enginewire harness(C102):'97 - 98
models
Left front ABS wheel sensor
Enginecompartmentwire harness(C201)
Brakefluid level switch {-)
Brakefluid levelswitch(+)
Under-hoodfuse/relaybox (C908)
Under-hoodfuse/relaybox (C906)
Under-hoodfuse/relaybox (C905)
Under-hoodfuse/relaybox (C907)
ABS modulatorunit
ABS pump motor
Enginecompartmentwire harness(C218)
Leftside of enginecompartment
Leftside of enginecompartment
Leftsideof enginecompartment
Leftside of enginecompartment
Rightsideof enginecompartment
Rightsideof enginecompartment
Rightsideof enginecompartment
Rightsideof enginecompartment
Rightsideof enginecompartment
Rightsideof enginecompartment
Rightsideof enginecompartment
10
Rightside of enginecompartment
'14
1
1
t1
c352
c354
Location
3
10
Rightsideof enginecompartment
Rightsideof enginecompartment
Rightsideof enginecompartment
Rightsideof enginecompartment
Rightside of enginecompartment
Nots
Canada
ABS
USA
ABS
ABS
'97 - 98
models
Enginecompartmentwire harness(C218) '99 - 00
mooets
Rightfront ABS wheelsensor
ABS
Under-hoodABS fuse/retaybox (C931) ABS
Under-hoodABS fuse/relaybox (C9321 ABS
'98 Evaporative
emission(EVAP)contro
00
canistervent shutvalve
mooets
Bodyground,via main wire harness
ABS
UNDEB.HOOD
FUSE/RELAY
BOX
MAIN WIREHARNESS
branch)
G351
MAIN WIREHARNESS
{left branch}
www.emanualpro.com
23-19
c401
c402
c403
c404
c404
c405
c406
c407
c408
c409
c410
c410
c411
c412
c413
5
20
20
24
't4
8
5
3
12
Behindleft kickpanel
Behindleft kickpanel
Behindleft kickpanel
Behindleft kickpanel
Behindleft kickpanel
Startercut relay
Horn relay
Leftsidewire harness(C558)
Leftsidewire harness(C559)
Leftsidewire harness(C559)
Cruisecontrolunit
Daytimerunninglightscontrolunit
Daytimerunninglightscontrolunit
lgnitionkey light controlunit
Interiorwire harness{C701)
Cablereel
Cablereel
c413
c414
c415
c416
c416
c417
c418
c419
c420
10
'1
18
20
'18
10
c420
c421
c422
c423
c424
c425
c42A
c426
15
1
4
8
5
5
c437
c438
22
c438
c439
c440
c441
c442
23-20
www.emanualpro.com
'97 model
'98 - 00
mooets
Canada
Canada
'97 model
'97 model
'98 00
models
lgnitionkey switch
lgnitionkey switch
'97 Combinationswitchsub-harness
{C753)
98
models
Combinationswitchsub-harness
(C753) '99 - 00
moqets
SRSmain harness(C803)
Dashboardwire harness(C503)
Dashboardwire harness(C501)
Dashboardwire harness{C501)
Under-dash
fuse/relaybox (C922)
Under-dash
fuse/relaybox (C920)
'97 model
Under-dash
fuse/relaybox (C919)
'98 - 00
lntegratedcontrolunit
mooets
Integratedcontrolunit
Optional
Frontfog lightsswitch
Brakeswitch
Interlockcontrolunit
Reverserelay
Rearaccessorysocketrelay
Rearaccessorysocketrelay
Rearheatedoxygensensorsubharness(C722)
Optional
Securitycontrolunit
Optional
Securitystarter cut relay (for security
alarmsystem)
Junctionconnector(for interlocksystem) Optional
Securitywire harness
Optional
'97 model
Securitywire harness
Rearwindow wiper controlunit
Combinationswitchsub-harness(C760) '97 - 98
mooels
Combinationswitch sub-harness(C760) '99 - 00
models
Securltyindicator
Optional
Securityvalet switch
Optional
Clutchinterlockswitch
Mfi
Clutchswitch(forcruisecontrol)
Mlr
Bodyground,via main wire harness
MAIN WIREHARNESS
dn' cntt
I
--r F -'L-1al 1l}a]
a
UNDER-DASH
FUSE/BELAYBOX
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-n-rrr---rrr
-:/l
-
Number ol
Cavities
c427
25
Frontpassenger's
door
c428
c429
c430
c431
c432
c433
c434
c435
c436
c436
Behindright kickpanel
Behindright kickpanel
Behindright kickpanel
Behindright kickpanel
Underright side of dash
Under.ight side of dash
Undermiddleof dash
U n d e rm i d d l eo f d a s h
Undermiddleof dash
Undermiddleof dash
Frontpassenger's
door wire harness
(c671)
Rightsidewire harness{C601)
ABS controlunit
ABS controlunit
Enginewire harness(C127)
PGM-Flmain relay
JUnotronconnector
Tailgateopen relay
Headlightsf lasherrelay
(C731)
Heatersub-harness
(C731)
Heatersub-harness
c447
Behindright kickpanel
ECM/PCM
G402
23-22
www.emanualpro.com
26
22
7
20
5
7
Location
Connectsto
Notes
ABS
ABS
Optional
Optional
'97 model
'98 00
models
'98 00
mooets
MAIN WIREHARNESS
www.emanualpro.com
23-23
Numbr of
Cavities
c501
c501
c502
c503
c504
c505
10
1
20
c506
c507
c508
c509
c510
c511
c512
c514
14
16
Above under-dashfuse/relaybox
Leftsidewire harness(C556)
Dashlightsbrightnesscont.oller
Cruisemain switch
Junctionconnector
Gaugeassembly
Gaugeassembly
Gaugeassembly
Gaugeassembly
Gaugeassembly
Hazardwarningswitch
Audio unit
Heatercontrol panel
Heatercontrol panel
Datalink connector
Servicecheckconnector
Front accessorysocketconnector
Ashtraylight
Heatersub-harness(C733)
Heatersub-harness
{C740}
Heatersub-harness(C740)
Behindgauges
Uppermiddleof dash
Gaugeassembly
Clock
Behindmiddleof dash
6
20
13
5
t6
14
10
20
16
2
24
2
1
c524
G501
www.emanualpro.com
23-24
Conngctsto
Above under-dashfuse/relaybox
Above under-dashfuse/relaybox
Above under-dashfusehelaybox
Above under-dashfuse/relaybox
Behinddashboardlower panel
Above under-dashfuse/relaybox
to
c518
c519
c520
c521
Location
Notes
Mir
'97 - 98
models
'99 - 00
models
A/r
'97model
'98- 00
mooets
'98- 00
models
DASHBOARD
wlRE HART{ESS
www.emanualpro.com
23-25
Number of
Cavities
c551
c552
8
16
10
14
'I
Locaiion
Connectsto
14
Behindunder-dash
fuse/relay
box
Behindunder-dash
fuse/relay
box
Left side of steeringwheel
Left side of steeringwheel
Left side of steeringwheel
Above under-dashfuse/relaybox
fuse/relaybox (C921)
Under-dash
fuse/relaybox (C923)
Under-dash
Powermirror switch
Powerwindow masterswitch
Powerwindow masterswitch
Dashboardwire harness{C505)
16
Above under-dashfuse/relaybox
Dashboardwire harness1C505)
c558
c559
c559
20
20
24
Driver'sdoor
Behindleftkickpanel
Behindleftkickpanel
Behindleftkickpanel
c560
)
1
5
1
1
Leftquarter panel
Leftquarter panel
Leftquarter panel
Leftquarter panel
Leftquarter panel
Leftquarter panel
On left half of rearcrossbeam
Rightquarterpanel
Rightquarterpanel
Leftquarter pillar
Leftside of floor
Left B-piller
Left B-piller
Behindleftkickpanel
c554
c556
Not6s
'97 - 98
mooets
'99 - 00
models
'97 model
'98 - 00
models
c562
c563
c563
'97 model
'98 - 00
models
c564
c565
c566
c578
Underleftsideof dash
Rearaccessorysocketconnector{+}
Rearaccessorysocketconnector (-)
Rearbumperwire harness1C641)
Trailerlightingconnector
Tailgatedoor latchswitch
Left rear speaker
RightrearABS wheelsensor
Rearwire harness(C611)
Rightrea. door switch
Lefttaillight
Parkingbrakeswitch
Leftreardoor wire harness(C681)
Driver's door switch
Selectunlockrelay(for securityalarm
system)
Junctionconnector(for power door
locks)
SRSmain harness(C807)
c579
LeftB-piller
Driver'sseat belttensioner
c580
Fueltank
c581
Leftside of steeringwheel
Fueltank pressuresensorsub-harness
(c645)
Power window master switch
G551
Behindleftkickpanel
Left side ot floor
Leftquarterpiller
c568
c569
c570
c572
c573
c574
c575
c576
6
1
2
14
1
1
6
1
G553
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23-26
Behindleftkickpanel
Optional
'98 - 00
mooets
'98 - 00
models
'98 - 00
mooets
'99 - 00
mooets
www.emanualpro.com
23-27
Numberof
Cavities
c601
c602
c603
c604
6
'1
Location
Conneststo
Behindright kickpanel
RightB-piller
Rightreardoor
Undermiddleof dash
R i g h tB - p i l l e r
seatbelttensioner
Frontpassenger's
Notes
'98 - 00
mooets
'98 - 00
models
c641
c642
c643
Number ot
Cavities
4
2
2
Location
Leftquarterpanel
Behindrearbumper
Behindrearbumper
Number ot
Cavities
c645
c646
c647
Connoctsto
Notes
Leftsidewire harness(C566)
Leftrearside markerlight
Rightrearside markerlight
'98 Model
Location
Fueltank
Leftside of fuel tank
Leftside of fuel tank
Connectsto
Not63
Leftsidewire harness(C580)
Fueltank pressuresensor
emission(EVAP)bypass
Evaporative
solenoidvalve
Number of
Cavities
c651
c652
c653
www.emanualpro.com
23-28
1
1
Location
Top of hatchglass
Top of hatchglass
Top of hatchglass
Connec-tsto
High mount brakelight
Rearwire harness(C617)
Rearwire harness(C618)
Notes
HIGHMOUNT BRAKELIGHT
SUB-HARNESS
RIGHTSIDEWIBEHARNESS
FULTANK PRESSURE
SENSORSUB.HARNESS
REARBUMPERWIREHANNESS
www.emanualpro.com
23-29
RearWiro Harness
Connectoror
Terminal
Number of
Cavities
Location
Connectsto
c61l
c612
c613
c614
14
2
c617
r anel
R i g h tq u a r t e p
r anel
R i g h tq u a r t e p
r anel
R i g h tq u a r t e p
R i g h tq u a n e rp i l l e r
Rightside of hatchglass
Middleof hatchglass
Top of hatchglass
c618
'I
Top of hatchglass
c619
c620
Leftside of hatchglass
Roofarea
Leftsidewire harness(C57'l)
Rightrearspeaker
Tailgatewire harness(C631)
Rightaillight
Rearwindow defogger(+)
Rearwindow wiper motor
High mount brakelight sub-harness
(c652)
Hjgh mount brakelight sub-harness
{c653)
Rearwindow defogger(-)
R e a rc e i l i n gl i g h t
r iller
R i g h tq u a r t e p
6
1
G611
Notes
c633
c634
23-30
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Numberof
Cavities
2
2
1
Location
Connectsto
Rightquarterpanel
Middleof tailgatedoor
Leftsideof tailgatedoor
Middleof tailgatedoor
Rearwire harness(C613)
Hatchglassopenersolenoid
Licenseplatelight
Hatchglasslatchswitch
I/iddle of tailgatedoor
Noles
TAILGATEWIREHARNESS
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23-31
Number of
Cavities
25
4
c664
at
c667
18
Location
Driver'sdoor
Driver'sdoor
Driver's door
Driver's door
Driver's door
Driver's door
Driver's door
Connoctsto
Notes
Leftsidewire harness{C557)
Left front speaker
Driver'spowerwindow motor
Driver's door lock actuator
Driver's door lock switch
Driver's power mirror actuator
Keyless/power
door lockcontroluni
c671
c612
Number ot
Cavities
2^
c674
c675
I
Location
Frontpassenger's
door
Frontpassenger's
door
Frontpassenger's
door
Frontpassenger's
door
Frontpassenger's
door
Frontpassenger's
door
Connectsto
Main wire harness(C4271
Rightfront door speaker
Front passenger'spower window motor
Frontpassenger's
door lockactuator
Front passenger'spower window switch
Front passenger'spower mirror actuator
DBIVEB'SDOORWIRE
HARNESS
6tt
23-32
www.emanualpro.com
inliiioint""
Notes
o,-
c681
c6a2
c683
c684
Numbor of
Cavities
2
5
Location
Left rear door
Leftreardoor
Left rear door
Left rear door
Connectsto
Notos
Leftsidewire harness{C575)
Leftrearoowerwindow motor
Left rear door lock actuator
Left rear oower window switch
c691
c692
c694
Number of
Cavitios
Locstion
Rightreardoor
Rightreardoor
Rightreardoor
Rightreardoor
LEFTREARDOOR
WIRE HARNESS
www.emanualpro.com
Conneststo
Rightsidewire harness(C603)
Rightrearpowerwindow motor
Rightreardoor lockactuator
Rightrearpowerwindow switch
Notos
Numbr of
Cavities
Location
Underleft sideof dash
Roofarea
Roofarea
c701
c702
c703
Connoct3lo
Notes
Numbor ot
Cavities
Location
c721
Undermiddleof dash
c722
Undermiddleof dash
23-34
www.emanualpro.com
Connectsto
Secondaryheatedoxygensensor
{SecondaryH02S)(Sensor2)
Main wire harness(C426)
Notos
OXYGENSENSOR
SUE.HARNESS
www.emanualpro.com
23-35
Hoat6rSub-harness
Connectoror
Tgrminal
Numbsrot
Cavities
c73']
c731
5
7
Undermiddleof dash
Undermiddleof dash
c732
c733
c734
c735
c736
c737
c738
c739
c740
7
24
Behindmiddleof dash
Behindmiddleof dash
Behindglove box
Behindglove box
Behindglove box
Behindglove box
Behindglove box
Behindglove box
Behindmiddleof dash
Modecontrolmotor
Dashboardwire harness(C522)
Air mix controlmotor
Evaporatortemperaturesensor
Blowermotor high relay
Blower motor
Powertransistor
controlmotor
Recirculation
Dashboardwire harness(C523)
c740
Behindmiddleof dash
Dashboardwire harness(C523)
Localion
Connectsto
Notes
'97 model
'98 - 00
modsls
'97 model
'98- 00
mooels
c751
c753
c754
c755
c756
c757
c758
Number of
Cavities
Location
6
7
12
Above under-dashfuse/relaybox
Above under-dashfuse/relaybox
Underleft side of dash
fuse/relaybox (C914)
Under-dash
fuse/relaybox {C915)
Under-dash
Main wire harness(C413)
10
Behindsteeringcolumn
Behindsteeringcolumn
Behindsteeringcolumn
Behindsteeringcolumn
Behindsteeringcolumn
Behindsteeringcolumn
Underleft side of dash
Shift locksolenoid
Parkingpin switch
Combinationlight switch
Combinationlight switch
Wiper/washerswitch
Wiper/washerswitch
Main wire harness(C442)
7
6
8
c760
c760
23-36
www.emanualpro.com
Conneststo
Notos
'97 - 98
mod6ls
'99 - 00
models
'97 - 98
models
'99 - 00
models
Ol-
f-
www.emanualpro.com
ConnGtoro1
Terminal
Numbor of
Cavities
c801
Location
Connectsto
fuse/relaybox (C911)
Under-dash
Leftside of under-dash
fuse/relaybox
Top of under-dashfuse/relay
box
Underleft sideof dash
Underleft sideof dash
Behindglove box
Middleof floor
Underleft sideof dash
c808
Undermiddleof dash
Rightsidewire harness(C604)
G801
Middleof floor
c802
c803
c804
c805
c806
c807
23-38
www.emanualpro.com
18
Notes
Memoryerasesignal{MES)connector
'98 - 00
mooets
'98 - 00
mooets
SRSMAINHARNESS
D\
n
ll-
www.emanualpro.com
23-39
Fuses
Under-hoodFuse/RelayBox
ALTERNATOR
lTo engine wire harness{T102)l
BATTERY
lTo slarter cableslTlll
DEn
r-'l
tr
tr
tr
IJ
11
IJ
r'1
51
LI
r-'l
56
IJ
r-'l
57
LJ
cro1
c903
lTo radiator ten relavl
.: Not used
c306
fTo main wiro hamose(C352ll
c305
lTo mainwiie harnes lc353ll
23-40
www.emanualpro.com
Under-dashFuse/RelayBox
c912
wire harness{C502ll
lTo dashboard
c914
lTo
c911
lToSRSmainharness{C801)l
switchsub-harness
{C751ll
c915
switchsub-harness
lTo combinatioo
1C752)l
r'=G@6
T"r r-1 T't r't r-l r-r r't r;l Fl T1 r-l r-l
23
21
25
21
26
28
29
30
31
33
32
rr Ll tJ tJ LJ Ll lJ LJ t-J LJ u Ll
1a
16
t5
11 1a 19
20
21 22
a; Canada
c9r6
[Topowe.windowrelay]
LI I.J LI LJ tJ LJ IJ LI I.J IJ IJ tJ
c924
lTo integraledconttolunitl
c922
1C417)l
lTomainwireharness
(css1)l
c919
lTo mainwire herness1C419)l
c920
lTo main wire harness1C418)l
www.emanualpro.com
Fuses
Under-hoodABS Fuse/RelayBox
c931
c933
c932
www.emanualpro.com
23-42
PowerDistribution
Index(numericalsequence)
Fuse-to-Gomponent(sl
Under-hood Fuse/RolayBox:
Capacity
wiro Color
43
'100A
40A
7 . 5A
WHT/BLK
WHT/RED
44
1 5A
WHT/BLK
46
47
40A
7 . 5A
WHT/BLU
WHT/BLU
48
30A
WHT
204
204
WHT/GRN
WHT/GRN
52
1 5A
WHT/GRN
53
54
10A
40A
WHT/BLK
WHT/RED
50
40A
204
BLU/WHT
WHT
RED
BLK/RED
Fuse
41
49
50
20A
Circuit(s)Protcted
A
lgnitionswitch(BAT)
lntegratedcontrolunit
Ceilinglights
Spotlights
PGM-Flmain relay
Not used
No. 7, 8, 10,11fuse in the under-dashfuse/relaybox
A u d i ou n i t
Clock{'98- 00 models)
Datalinkconnector('98- 00 models)
ECM(VBU){'98- 00 models:M/T)
Heatercontrolpanel
PCM (VBU)(A./T)
Combinationlight switch(via under-dashfuse/relaybox)
No. 20,33 fuse in the under-dashfuss/relaybox
Not used
Rearwindow defogger(viarelay)
Door lockcontrolunit
Hatchglassopenersolenoid
Keylessdoor lockcontrolunit ('98- 00 models)
Horn relay
Horns(via relay)
via brakeswitch:
ABS controlunit
Brakelights
Cruisecontrolunit
ECM ('98 - 00 models: M/T)
Highmount brakeiight
PCM(4./T)
Trailerlightingconnector
relay(viaswitch)
Turn signal/hazard
Optionconnector(+B)
No. 6 fuse in the under-dashfuse/relaybox
Blowermotor (viarelay)
Condenserfan motor (viarelay)
Ay'Ccompressorclutch (via relay)
Radiatorfan motor (viarelay)
Capacity
61
40A
204
7 . 5A
Wire Color
Circuitls) Protoct
WHT
WHT/GRN
BRN/YEL
{cont'd)
www.emanualpro.com
23-43
PowerDistribution
Fuse-to-Component(sl
Index(numericalsequencel(cont'dl
Under-dashFuse/RelayBox:
Fuse
Capacity
Wire Color
1 0A
"^
1 0A
RED/B
LU
1 0A
RED/GRN
6
7
I
9
10
11
1 0A
20A
204
15A
204
204
WHT/BLK
RED/VVHT
YEUBLK
RED
GRN/BLK
BLU/BLK
12
13
7 . 5A
'15A
14
7 . 5A
YEVBLK
YEUGRN
RED
BLK/YEL
7 . 5A
BLK/VVHT
7 . 5A
7 . 5A
BLVBLU
17
BLKA/EL
18
19
7.54
7.54
YEUBLK
YEVRED
l0A
1 0A
BLKAr'YHT
RED/VHT
RED/YE
L
20
22
23-44
www.emanualpro.com
Circuit{s)Protected
Not used
Not used
Rearwindow washermotor (viaswitch)
Rearwindow wiper controlunit ('97 model)
Rearwindow wiper motor
Daytimerunningrightsresister{Canada)
R i g h th e a d l i g h{tH i g hb e a m }
Daytimerunningrights resister(Canada)
High beam indjcatorlight
Left headlight(Highbeam)
Rearaccessorysocket(viarelay)
Left rearpowerwindow motor (viaswitch)
Rightrear powerwindow motor (viaswitch)
Distributor(ignitioncontrolmodule)
powerwindow motor (viaswitch)
Frontpassenger's
Driver'spowerwindow motor {viaswitch)
Powerwindow masterswitch(powerwindow controlunit)
Turn signal/hazard
relay(viaswitch)
PGM-FImain relay
SRSunit (VA)
Cruisecontrolunit (viaswitch)
Cruisemain switchindicatorlight
Alternator
Chargingsystemlight
E L Du n i t( U S A )
EVAPbypasssolenoidvalve('98- 00 models)
EVAPcontrolcanistervent shutvalve('98- 00 models)
EVAPpurgecontrolsolenoidvalve
PrimaryHO2S
SecondaryH02S
VSS
ABS controlunit
Optionconnector(lG2)
Ay'Ccompressorclutch relay
Blowermotor high relay
Blowermotor relay
Condenserfan relay
Heatercontrolpanel
Left power mirroractuators(viaswitch)
Mode controlmotor
Radiatorfan relay
Recirculation
controlmotor
Rightpower mirror actuators(viaswitch)
Daytimerunninglightscontrolunit (Canada)
Back-uplights
Reverserelay (A"/T)
Daytimerunninglightscontrolunit (Canada)
R i g h th e a d l i g h(tL o wb e a m )
Left headlight(Low beam)
under-dash Fuse/RelayBox:
Fuse
Capacity
wir6 Color
PNK
25
1 0A
7 . 5A
7 . 5A
204
GRN/BLK
10A
28
YEUGRN
10A
YEURED
29
30
7.5A
a, olrL"
7 . 5A
BLU,ryVHT
www.emanualpro.com
7 . 5A
RED/GRN
7 . 5A
WHT/GRN
Circuit(sl Protocted
SRSunit (VB)
Powerwindow relay
IntegratedControlUnit
ABS indicatorlight
A/T gear positionindicatorlight
Clock('98- 00 models)
Cruiseindicatorlight
Gaugeassembly
Interlockcontrolunit (A,/T)
Keylessdoor lockcontrolunit ('98- 00 models)
Powerdoor lockcontrolunit
Shift locksolenoid(lVT)
SRSindicatorlight
Integratedcontrolunit ('98- 00 models)
Integratedcontrolunit (viawindshieldwiper switch)
Windshieldwashermotor (viaswitch)
Windshieldwiper motor
Front accessorysocket
Rearaccessorysocket relay
Optionconnector(ACC)
Audio unit
Not used
Optionconnector(dashlights)
Integratedcontrolunit
Ashtraylight
A,/Tgear positionindicatorlight
Audio univclock('97model)
Audio unit ('98- 00 models)
Clock('98- 00 models)
Cruiseindicatorlight
Cruisemain switchlight
Dashlightsbrightnesscontrolunit
Gaugelights
Hazardwarningswitchlight
Heatercontrolpanel
Powerwindow masterswitchlight ('99- 00 models)
Integratedcontrolunit
ECM('98- 00 models:M/T)
PCM (4./T)
PGM-Flmain relay
Leftfront pa.kinglight
Leftfront side markerlight
Left rearside markerlight
Lefttaillight
Licenseplatelight
Rightfront parkinglight
Rightfront side markerlight
Rightrearside markerlight
Rightaillight
Trailerlightingconnector
lgnitionkey light
lgnitionkey light controlunit ('97model)
Interlockcontrolunit (via ignitionswitch)
Key interlocksolenoid
23-45
GroundDistribution
Ground-to-Component(sl
Index
Ground
Wire Color
G2
G3
G1 0 ' l
BLIVRED
BRN
BLK
BLK
BRN/BLK
G201
BLK
G202
BLK
G351
BLK
www.emanualpro.com
23-46
Ground
Wir Color
G401
BLK
G402
BLK
{cont'd)
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23-47
GroundDistribution
Ground-to-Component(sl
Index(cont'dl
Ground
Wire Color
G501
BLK
BLK
G552
BLK
BLK
BLK
BLK
G801
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23-48
BLK
Box
Fuse/Relay
Under-dash
Removal/lnstallation
S R Sc o m p o n e n t sa r e l o c a t e di n t h i s a r e a .R e v i e wt h e
SRS componentlocations,precautions,and procedures
in the SRSsection(241beforeperformingrepairsor service.
Installation:
1.
C o n n e c t h e c o n n e c t o r st o t h e u n d e r - d a s hf u s e /
relay box (seesection24 for the SRSmain harness
connector),then install the under-dashlusehelay
box in the reverseorderof removal.
2.
3.
4.
5.
Removal:
1.
2.
3.
4.
D i s c o n n e ctth e c o n n e c t o r sf r o m t h e u n d e r - d a s h
fuse/relaybox (seesection24 for the SRSmain harnessconnector),and take out the under-dashfuse/
relayoox.
www.emanualpro.com
23-49
Battery
Test
@M
. Battery fluid (eleqtrolyte)contains sulturic acid. lt may couse sevore
.
.
CheckIndicatorEYEColor
lf the indicatorshows low electrolyte,
add distilled
water if possible.
EYEIndicatesOK
Test LoadCapacity(#1)
. Apply 300amp load for 15 secondsto removesurface
charge.
. Allow 15 secondsrecoveryperiod.
. Apply test load (seeTest LoadChart).
. Recordvoltageat the end of 15 seconos.
Voltagestaysabove9.6
volts;batteryis OK.
www.emanualpro.com
23- 5 0
(},
Voltagestaysabove9.6volts;
battery is OK.
Voltagedropsbelow9.6volts;
batteryis no-good,
J-
TESTLOAD CHART
Usethe test load or use 1/2the cold crankingamps (CCA)printedon
the labelon the top of the battery.lf neitheris indicated.usethe informationbelow:
BATTERY
CODE
55
COLDCRANKING
AMPS (CCA)
TESTLOAD
{amps)
410
200
BATTERYCODE
i
5582{LtS)-MF
www.emanualpro.com
J
23-51
PowerRelays
RelayTest
NOTE:See page23-86for turn signal/hazard
relay input
IESI.
Normally-opontype:
'1.
.
.
Blowermotor relay
Rearwindow defoggerrelay
type 1:
Terminal
t"""r f*r
t*i__\
Disconnected
Connected
o
type 2i
Itrrz-Hl
llHrrUll
Y:F,
' , 3
ffi
23-52
www.emanualpro.com
a l
Normally-opentype:
Normally-opentype:
1.
Terminal
t.*", ^"-
t*f
1.
tl**^-*
Powerwindow relay
Radiatorfan relay
Condenserfan relay
A,/Ccompressorclutchrelay
Reverserelay (A/f)
Horn relay
Rearaccessorysocketrelay {A,/T)
a Startercut relay
\K,
www.emanualpro.com
-_\
Disconnected
Drsconnected
a
a
a
a
a
Terminal
Connected
Connected
o- ---o
lgnition Switch
Test
ElectricalSwitch Replacement
S R Sc o m p o n e n t sa r e l o c a t e di n t h i s a r e a .R e v i e wt h e
SRScomponentlocations,precautions,and procedures
in the SRSsection{24}beforeperformingrepairsor ser
vtce.
L l M a k es u r e y o u h a v e t h e a n t i - t h e f tc o d e f o r t h e
r a d i o , t h e n w r i t e d o w n t h e f r e q u e n c i e sf o r t h e
radio'spresetbuttons(wilh anti-theftfeature).
2. Disconnect
the batterynegativecable.
3. Removethe driver'sdashboardlower coverand the
kneebolster{seesection20).
4. Disconnectthe 5P connectorfrom the under-dash
fuse/relaybox and the 3P connectorfrom the main
wtre narness,
3P CONNECTOR
1.
M a k e s u r e y o u h a v e t h e a n t i - t h e t tc o d e f o r t h e
r a d i o , t h e n w r i t e d o w n t h e f r e q u e n c i e sf o r t h e
radio'spresetbuttons(with anti-theftfeature).
2.
Disconnect
the batterynegativecable.
3.
4.
7.
5P CONNECTOR
Wiresideof
temaleterminals
Checktor continuitybetweenthe terminalsin each
switchpositionaccordingto the table.
rernrnal I
\
ros[ron
I3l
I1l
swrTcH
lsrl
LOCKCYLINDER
0 (LocK)
r(Accl
o- -o
fl (oN)
III(START)
o-
_o
-.o
{ I | 3Pconnector
7.
www.emanualpro.com
23-54
GaugeAssembly
ComponentLocationIndex
and proceduresin the SRS
SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations,precautions,
section{24}beforeperformingrepairsor service.
I x 1.25mm
24 N.m {2.4
VEHICLESPEEDSENSOF{VSS'
page23-62
Troubleshooting,
GAUGEASSEMBLY
Gauge/lndicator/Terminal
LocationIndex,page 23-56
page23-57
BulbLocations,
Removal,page23-61
FUELGAUGESENDINGUNIT
Seesection1l
J-
PARKINGBRAKESWITCH
GAUGE
COOLANTTEMPERATURE
SENDINGUNIT
BRAKEFLUIDLEVELSWITCH
SWITCH
ENGINEOIL PRESSURE
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GaugeAssembly
Gauge/lndicator/TerminalLocationIndex
"A"
CONNECTOR
{A/T GEABPOSITIONINDICATOR)
a1___-__-____>816
cl--------->cl3
JilililIJililil1
JililtHililL
..
"""^
t)1- --->t)5
u e
E1- - -->E5
"DCONNECTOR
{ABS INDICATOR)
"E"
CONNECTOR
{CBUISEINDICATOR'
SPEEDOMETER:
Indicates
60 km/hat 637 rpm or
60 mph at 1,026rpm ofthe
vehiclespeedsensor(VSS).
oo/
TACHOMETER:
lndicates100rpm at
200pulsesper minute
of the ignitioncontrol
module(lCM).
www.emanualpro.com
23- 5 6
\oo
o u
Fl---->F5
"F"
CONNECTOR
{SRSINDICATOR}
l-
Bulb Locations
TAILGATEINDICATOR
LIGHT(,I.4W)
CHARGING
SYSTEMLIGHT(1.4WI
GAUGELIGHT{1.4WI
SEATBELT
REMINDERLIGHT{1.' W'
GAUGELIGHTI1,4WI
BRAKESYSTEM
LTGHT
11.4Wl
HIGHBEAM
INDICATORLIGHT
{ 1 . 4W l
LOW FUELINOICATOB
LIGHT13WI
LEFTTURN SIGNAL
INDICATORLIGHT{1,4W}
RIGHTTURNSIGNAL
INDICATORLIGHTI1.' WI
GAUGELIGHT
t3wl
1,.
f-=\
GAUGELIGHTS13WI
A/T GEARPOSITION
INDICATOR
{1.12x 7}
(Onthe printed
GAUGELIGHT{3.' W}
circuitboard)
(1,4W)
ABSINDICATOR
lOn the printedcircuitboard)
F -
SRSINDICATOR('1./tW)
(Onthe printedcircuitboard)
w)
cRutsEtNDtcAToR
11.r2
(On the printed circuit board)
www.emanualpro.com
23-57
GaugeAssembly
CircuitDiagram
U N O E R . I I O OFDU S E / R E L8AOYX
BATTERY
@*"
UNOER_DASH
FUSEiNELAY
BOX
N o . 4 1( 1 0 0 A ) N o . 4 2( 4 0 A )
YEL
E5
'''
l-
CRUISE
CONTROL
UNIT
ABS
CONTROL
UNIT
G401
G4A2
23-58
www.emanualpro.com
-I
-I
DASHLIGHTS
BRIGHTNESS
CONTROLLER
| 0l
8LK BLU/RED
RED
ALTERNATOR
ASSEMSLY
GAUGE
SRSUNIT
(}-.
tI -,
I
I T
rJr--------11-.----..1'\-J
BLK/YEL
I BLUMHT
BLKMHTJ 'i-
| g
l t Y
YEL_
TURN
SIGNAU
HAZARD
WARNING
swrTcH
No.si10A) .--......_
FUSE
LEFT
RIGHT
Y Y Y
IGNITION
CONTROL
I/lODULE
IcM)
f7
I
1.,
BLU
MALFUNCTION
INDICATOR
tA[rP([,{tL)
{1.4W1
l.,
CRN/ORN
PCM
COOLANT
TEII,4PERATURE
SENDING
UNIT
BLK
T
G401
G402
www.emanualpro.com
G552
(cont'd)
23-59
GaugeAssembly
CircuitDiagram(cont'd)
GAUGE
ASSEMBLY
PREVIOUS
PAGE
SEAT
BELT
REMINDER
LIGHT
(1.4W)
BRAKE
SYSTEM
LIGHT
l1.4Wl
a1 \
\
./
\J
TAILGATE
INDICATOR
LIGHT
{1.4W}
'
\
\
B6
Gnru;neo
f7
BED'BLU
I INTEGRATED
I coNTRoL
I UN|T
i oo,,#, i
I
I
l
L__c_o!l!g_yI'__l
rcanada)
t\
-l
R U I \ N | N0GG H T S
l v
REAR
CEILING
LIGHT
It tI
r-
REDIBLU
A
I Jl
FLUIO
I SRAKE
I LEVET
SWITCH
. Floaldown)
I fCLOSED
. Floal
up J
lLoPEN
BLK
ABS
CONTROL
UNIT
+
G401
G402
23-60
www.emanualpro.com
BLK
T
tlsA)-
G552
I Glass
open I
rCLOSED
closed
toPEN : Glass
I
TAILGATE
LATCH
swtTcH
rTailsate
openI
fCLoSED
I0PEN iTailsateclosed.J
Removal
'1. Remove
the two screwsfrom the instrumentpanel.
2.
3.
4,
5.
6.
7,
Removethe gaugeassembly.
GAUGEASSEMELY
INSTRUMENT
PANEL
www.emanualpro.com
23-61
VehicleSpeedSensor(VSSI
Troubleshooting
Beforetesting,inspectthe No. 15 (7.5A) fuse in the underdashfuse/relaybox.
T6st tho BLK wirei
1. Disconnectthe 3P connector
from the vehiclespeedsensor
{VSS).
2. Connect the test harness
{07LAJ- PT3020A)only to the
enginewire harness.
3. Connectthe FEDtest harness
clip to the positiveprobe of an
ohmmeter,
4. Checkfor continuitybetween
the REDtest harnessclip and
body ground.
TESTHARNESS
OTLAJ- PT3O2OA
REDTESTHARNESS
PROTECTIVE
TAPE
GRNTESTHARNESS
CLIP
T.st the BLK/YELwire:
1. Connectthe WHT test harness
clip to the positive probe of a
vohmeter,and connectthe RED
test harnessclip to the negative
probe.
2. Turnthe ignitionswitchON (ll).
TESTHARNESS
OTLAJ- PT3O2OA
REO
CLIP
WHT TESTHARNESSCLIP
ls there batteryvoltage?
ls thereabout5 V or more?
23-62
www.emanualpro.com
TAPE
HARNESS
o-.
(Frompreviouspage)
WHT TESTHARNESS
CLIP
TESTHARNESS
OTLAJ_ PT3O2OA
BEDTESTHARNESS
ct-tP
GRNTESTHARNESS
PROTECTIVE
TAPE
oN r).
Spoodom6torT6st:
1, Disconnect
the 16Pconnector
" B " f r o m t h e g a u g ea s s e m
2. Toucha probeto the BLUMHT
wire. and connect it to body
groundthrougha voltmeter.
3. Slowly rotate one wheel with
the otherwheel blocked.
www.emanualpro.com
'BGAUGEASSEMBLY16PCONNECTOR
Wire sideof
femaletermin6ls
BLU/WHT
I
(v)
It
23-63
Model
tGNITtON
SWlCrl
UNDER.HOOD
FUSEiRELAY8OX
BATTEFY
cr*"
I N o . 4 {' ' 0 0 4 )
l__*l;;T
\0.d2'40A) |
+!v_T
w_T
ELK
H-uTr.r--i=r-
BLKryEL
WINDSHIELD
WIPER/
WASHEF
9WTTCH
,
OFF/INT INT
lo
,,.h\ WINDSHIELD
( il) WASHEB
SWITCH
tt
l
l
G F NBi L K
l-I
a
g
WHTiBLK
YEL
3
BEMINDEB
LIGHT
(r 4w)
WHT]BLKWINDSHIELD
WASHER
I
MOTOB
I
NTERMITTENT
WIPERRELAYCIRCUlT
KEY.IN/SEAT
BELT
andLIGHTS-ON
BEMINDER
CIRCUIT
RED/BLU
BLUMHT
BLK
DRIVER'S
SEAT
BELT
swtTcH
r Unbuckled
f CLOSED
)
(OPEN :Buckled -.1
WINDSHIELD
WIPER
MOTOR
(As)
BL(
-tr
-l
G401
23-64
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G552
<
ELK/WHT
COMBINATON
LIGHTSWITCH
S'TARTEB
CUT
RELAY
\-/
RED/GRN
A,/rGEAR
POSrr
0NSWTTCH
(CLOSED
:lnpostion
Eor N)
1,,,,,"
Yilei'r
GRN/RED
.l-
. BNAKEFLUIO
LEVELSWITCH
. P A R K I NE
GR A K E
(usA)
swrTcH
NTEGRATED
CONTROLUNIT
A8
BULB
BRAKE
CHECKCIFCUT
KEY.IN]SEAT
BELTandLIGHTS'ON
R E M I N D ECRR C UT
B1o
PowER
I
LOCK
BLU/RED DOOR
CONTFOL
UNT
I
J
F r,r'tro
RED
BLUi
/rh
v
no*
llon.
155,1'*
I a C L O S E DK e y l n s e d e d
LTGRN/RED
"l\
u/
\oPEN
|
8LK
POWER
DOOR
LOCK
CONTROL
UNIT
Keyrcmoved
LTGRN/RED
d[)
!s-l
I FFONT
I
I PASSENGEBS
I
I DOOR
|
oDen) lSwlTcH
I
: oootooer ) |
dosedJ J f C-OSED
( ooE\ Dootdosed,r
|
|
_L
:
LT
LEFT
REAB
00OR
SWITCH
: Door
opel
f CLOSED
\oPEN Doo'closed
-._
-
G40r
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23-65
IntegratedControlUnit
CircuitDiagram-'98 - 00 Models
FUSE/BELAY
UNOER,HOOD
8OX
EATTERY
N0.41(100A)
@*"
N0.42(40A)
-....+
WHT/BLK
WHT
WHT/RED
IJNDERDASHFUSEiBELAYBOX
GRN/BLK
WINDSH
ELDWPER/
REAS
WINDOW
/.Fn WINDSHIELDWIPER
( il) WASHEF
MOTOR
lo
gsHERlIrTcH
.
OFF/NT
f7
tt
t
INT
SWITCH
f7
l
WHT/BLK
-9
I
LTGRN
BLU/BLKYEUBLU
INTEGFATED
coNTsoLUNIT I 85
WINDSHIELD
WASHEF
MOTOR
t,,
I 83
INTERIT,IITTENT
WIPER
RELAY
CIRCUIT
8LK
G401
G402
23-6 6
www.emanualpro.com
f7
NEAFWINDOWINTERMITTENT
WIPERRELAY
CIRCUIT
WHT/BLK
COMBlNATION
LIGHTSWIlCH
\-7
REO/GFN
GRY
GRN
I
rql)
Y4-orot
POSTT1ON
(A/T)
SWTTCH
I
I . (cLosEDInposrlion
Eor NI
I CLUTCN
INTERLOCK
I
I swrTcH(M,T)
:Clulch
I /CLOSED
Dedal\
\lullydeprsssed I
|
-"'-},,,,,"
YEL
SEATEELT
REMNDER
LIGHT
(1.4W)
Y l1eff
E
II
g
v**JT"
8LK
Gl01(A,T)
f;iillrvrr
' BFAKEFLUID
LEVELSWITCH
'PARKINB
GR A K E
(usA)
swrTcH
A6
INTEGRATED
CONTROL
UNIT
A8
\-
i
KEY]N/SEAT
BELTandLIGHTS.ON
REMINDER
CLRCUIT
I
:
*,
RED/BLU
/BLU RED/BLU
FEO/BLU
dF)
Y*
lsE
DRIVER'S
SEAT
BELT
swrTcH
13fr
rcLosED
,,,[:ltrh::ffIxl,,'.l'"
l*,*,J I
B L UB/ E D
A
Y
I cvro\
Y*,u,.,
| Bft_oi|l
(3!?i".
sl:$P)l
lHfi.#'
)
Hrtrff"%
l(3
l
(OPEN
BtK
4
www.emanualpro.com
:
G40t
G402
KEYLESS/POWER
DOOB
LOCK
CONTROL
UNlT
GFN/nED+-]
LTGRN/RD
d['\
\s.i
EF's l*'n
LTGRN/RED
4P'\
IFF^I'
13fft"Doo'open) l39P*
:Door
oper) | fCLOSED.
ooe.)
| fCLO#D.Door
. Door
dosd, \oPE\
I
l--
. 000'closed, \oPE\
|
l --
Door
ciosed,
IntegratedGontrol Unit
Input Test -'97 Model
SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations,precautions,
and proceduresin the SRS
section{24)beforeperformingrepairsor service.
'1. Removethe driver'sdashboardlowercoverand
the kneebolster(seesection20).
2.
Disconnect
the 'l0Pconnectorfrom the inteoratedcontrolunit.
3.
4.
INTEGRATEO
CONTROLUNIT
rOPCONNECTOR
femaleterminals
23-6 8
www.emanualpro.com
All Systems:
Cavity
Test condition
Wire
414
Test: Desiredrsult
Underall conditions
lgnitionswitchON (ll)
A9
A6
B1
Wire
Tost condition
lgnitionswitchON (ll),
and windshieldwiper
BLU/BLK switchat OFF/lNT
lgnitionswitchON (ll)
82
BLUrur'HT
Test: Desiredresult
Checkfor voltageto ground:
Thereshouldbe batteryvoltage.
Anopeninthewire
B3
B4
YEVBLU
lgnitionswitchON (ll),
and windshieldwipe.
switch at INT
lgnitionswitchON (ll),
and windshieldwasher
WHT/BLK
switchON
(cont'd)
www.emanualpro.com
23-69
lntegratedControlUnit
InputTest-'97 Model(cont'd)
At----------+A7
Cavity
A8
B7
RED/BLU
B9
GRN
8 1 0 BLU/RED
Test condition
Test: Desiredrosult
C o m b i n a t i olni g h t
switchON
lgnitionswitchON {lll.
and driver'sseatbelt
switchunbuckled
lgnitionswitchON (ll),
and driver'sseatbelt
switchbuckled
Driver'sdoor open
Driver'sdoor closed
lgnitionkey insened
into the ignitionkey
switch
lgnitionkey removed
trom the ignitionkey
swrtch
Poorground(G401,G,[02)
Faultyignitionkey switch
An open in the wire
Wire
A4
A13
23-70
www.emanualpro.com
Test condition
lgnitionswitchON {ll),
brakefluid reservoir
full, and parkingbrake
teveroown
Connectto ground:Brakesystem
l i g h ts h o u l dc o m eo n .
lgnitionswitchat
START(lll),and
A/T gear position
switchE or E
InputTest-'98 - 00 Models
and proceduresin the SRS
SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations,precautions,
section(24)beforeperformingrepairsor service.
L
2.
'l5P
Disconnect
the
connectorfrom the inteqratedcontrolunit.
3.
4.
UNDER-DASH
FUSE/RELAY
BOX
A8<------A14
INTEGRATED
CONTROLUNIT
YEL/BLU
15PCONNECTOR
www.emanualpro.com
LT GRN
WHT/BLK
www.emanualpro.com
www.emanualpro.com
IntegratedControl Unit
InputTest-'98 - 00 Models(cont'dl
YEL/BLU
A 1- - - - - - - - >
A7
LT GRN
WHT/BLK
GRN/BLK
LT GRN/REO
Wiresideof
femaleterminals
A8------->A14
WHT/BLK
BLU/RED
Wire
A8
RED/BLU
814
B8
GRN
BLU/RED
Test condition
Test: Desiredresult
Combinationlight
switch ON
lgnitionswitchON (ll),
and driver'sseatbelt
switchunbuckled
lgnitionswitchON (ll),
and driver'sseat belt
switchbuckled
Poorground{G552)
Faulty seat belt switch
Blownseatbelt reminderlight
b ul b
An open in the wire
Driver'sdoor open
Driver'sdoor closed
lgnitionkey inserted
into the ignitionkey
swrtch
lgnitionkey removed
from the ignitionkey
switch
. Faultydriver'sdoor switch
. An open in the wire
Poorground(G401,G402)
Faultyignitionkey switch
An open in the wire
Wire
A4
A13
23-74
www.emanualpro.com
Test condition
Test: Desiredresult
lgnitionswitchON (ll),
brakefluid reservoir
full, and parkingbrake
leverdown
lgnitionswitchat
START(lll),and
A,/Tgear position
switchE or E
Connectto ground:Brakesystem
l i g h ts h o u l dc o m eo n .
LightingSystem
l-.
ComponentLocationIndex
I{IGHBEAM INOICATORI-IGHT
DAYNMERUNNINGLIGHTS
REslsToi lCan!drl
Test,page23-80
COMBINATIONLIGHTSWTCH
Test,page 23-78
DAYTIMERUNNINGLIGHTS
CONTROLUNIT lCanadal
Input Test, page23-79
Replacment,Page23-80
Adjustment,Page23-81
FRONTTURNSIGNALLIGHT/
FRONTSIDEMARKERLIGHT
page23-80
Replacemont,
HIGHMOUNT BRAKELIGHT
Replacement,page23-84
LIGHT
BRAKE/PARKING
Replacement,page 23-82
BACK.UPLIGHT
Replacement,page 23-82
www.emanualpro.com
23-75
LightingSystem
CircuitDiagram(USAI
BATTERY
UNOER_HOOD
FUSE/RELAY
8OX
@**'
Td
UNDER-DASH
FUSEiREIAY
BOX
I
No.5
tl0Al
i,"dii
Zt'"olli
No.4
{10A)
N0.30
17.5A)
RED/BLU
li':,.^i
I
RED'BLK
lt
HIGHSEAI\4
INDICATOR
LIGHT
BLK
G40l
G4a2
23-76
www.emanualpro.com
' DASHLIGHTS
, PARKING
LIGHTS
. DASHLIGHTS
. SIDEMARKRLIGHTS
BRIGHTNESS,TAILLIGHTS
. LICENSE
COIVTROLLER
PLATETIGHT
BLK
.&
G202
O,-
CircuitDiagram(Canada)
80X
FUSEiRELAY
UNDERHOOD
BATTEBY
@*"
+WHT
WHT/BLK
UGHTSWITCH
c0t\48rNATroN
l = o ), : . , o F F
4
RED
U N D E RD
- A S HF U S E / R E L8AO
YX
BBAXE
SYSTEM
LIGHT
ABSCONTROL
UNIT
I
GRN/RED
NEO/CRN
T,
HIGHBEAM
INOICATOR
LIGHT
8LK
BLK
I I
G401
c402
www.emanualpro.com
G202
BLK
G20
8LK
8LK
-L
-::
d
--
G40l
G402
G401
G402
23-77
LightingSystem
CombinationLight Switch Test
'1. Remove
the driver'sdashboardlower coverand the kneebolster(seesection20).
2. Removethe steeringcolumncovers(seesection'17).
3. Disconnect
the 4Pand 7P connectorfrom the switch.
4. Removethe screws,and slidethe switchtowardthe driver,sdoor,
5. Inspectthe connectorand socketterminalsto be surethey are all makinggood contact.
4P CONNECTOR
2
5
Terminal
1
Position
o-
----o
o- _--_o_----o
OFF
:m:
Headlightswitch
L0w
=D
HIGH
Passingswitch
OFF
ON
r : Canada
23-78
www.emanualpro.com
o_ ----o
o-- ----o
o_ ----o
o_ ---o
DAYTIMERUNNINGLIGHTS
CONTBOLUNIT
8P CONNECTOR
YEL/BLK
GRN/RED
BLK/WHT
RED/GRN
Tst condition
Cavity
B1
BLK
Underall conditions
Underall conditions
A2
82
A4
A1
R'I
B6
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BLK,4iVHT
Combinationlight
"
"
switchin =D Posiuon
Combinationlight
switchOFF;connecta
jumperwire between
WHT/RED
the 82 and 41 terminals,then turn the ignition switchON (ll)
lgnitionswitchON (ll),
brakefluid reservoir
GRN/RED
full. and parkingbrake
leverdown
8EDlGRN
lgnitionswitchoN (ll)
YEUBLK
RED
Tost: Desiredresult
Parkingbrakeleverup
Headlights(highbeam)should
come on, (andhigh beam
indicatorshouldcome on).
Poorground (G201.G202,G401,
G402)
Blown headlightbulbs
Faultydaytimerunninglights
resrslor
An open in the wire
LightingSystem
Dafime RunningLightsResistor
Test (Canada)
Disconnect
the 3P connectorfrom the resistor.
Headlights
Replacement
CAUTION: Halogen headlights bGcomevery hot in use;
do not touch them or the attaching hardware immediately after they have been turned oft.
1.
2.
Removethe mountingbolts.
3.
HEADLIGHTASSEMELY
23-80
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HEADLIGHT:60/55 W
TURN SIGNAL/SIDEMARKERLIGHT:
2118W {37 model}
2718W ('98 - 00 modelsl
PARKINGLIGHT:5W l'97 modell
3CP{'98 - 00 modelsl
Adjustment
Bstore adiusting the headlights:
. Parkthe vehicleon levelground
. Makesurethe fuel tank is tull
. The driver or someonewho weighsthe same should
sit in the driver'sseat.
. Loadthe trunk with the itemsyou usuallycarry'
. Push down on the front and rear bumpers several
timesto makesurethe vehicleis sittingnormally'
CAUTION: Halogen headlights become very hot in use;
do not touch them or the atiaching hardware immediately after they have been turned off.
1.
ODenthe hood.
2.
3.
indicator.
adjustment
Checkthehorizontal
"0"
indicatorgear should
the
horizontal
markon
The
be alignedwith the mark.
5.
"0" mark as
lf eitherindicatoris not alignedwith its
describedleft column,an adjustmentcan be made
by usinga Phillipsscrewdriver.
Adjustthe headlightsto localrequirementsby turning the adjusters.
NOTE:
. As the outer lensesare made of an acrylicoated,
material,do not cover the headpolycarbonated
lightswhen they areturnedon
. When making horizontaladiustments,slide the
horizontalindicatorgear rearward.
After horizontaladjustment,put back the horizontalindicatorgear.
HORIZONTAL
INDICATOR
GEAR
"0" MARK
olwww.emanualpro.com
23-A1
RearSide MarkerLights/
LicensePlateLight
Taillights
Replacement
Replacement
1.
Openthe hatchglass.
1.
2.
Disconnect
the 6P connectorfrom the taillight.
3.
2.
Disconnect
the 2P connectorfrom the light.
RETAINING
HOUSING
LicensPlate Light:
1.
2.
LIGHT(8 WI
23-A2
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Back-upLights
CircuitDiagram
FUSE/RELAY
BOX
UNDEN-HOOD
_*,,@_ "*"
*"_,,.
]__ _..'
iu.Er.w
-r-
(M/r)
I
I
BACK,UP
LIGHT
swtTcH
/0n1he \
I lransmisson
J
\no!s{
/
: Inposilion
Rl
lolosed
GRN/BLK
LEFI
BACK,UP
LIGHT
2 1 C P( 1 8 W )
T
BLK
www.emanualpro.com
A,/IGEAR
Posrl0N
swtTcH
/Back'up \
RIGHT
BACK,UP
LGHT
2 1 C P0 8 W )
\lhl swilch ,/
: Inposilion
ICLOSED
[8ll
8LK
G101
BrakeLights
GircuitDiagram
BATTENY
/,i\
UNDER.HOOD
FUSE/RELAY
BOX
1.
No.s2
{15A) |
\Y*-I=f*-'o*T*'no"l
|
P u s ht h e c l i p s , a n d r e m o v e t h e c o v e r f r o m t h e
housing.
HOUSING
HORNSYSTEM
T:,^-,
*",*"",
i.t53l|
GRNA,VHT
-.1
GBNMHT
. ABSCONTFOL
UNIT
' ECM/PCM
. CRUISE
CONTROL
UNIT
2.
Disconnect
the connectors.
Removethe two nuts and the housing.
GRNAVHT
GRNWH
t
l
A[$^Jlr
A
(2rw)
LEFI
BFAKE
LIGHT
Yi,?'il
Y
BLK
BLK
lr
BLK
ll
BLK
G553
23-84
www.emanualpro.com
d
oi,,
RIGHT
EFAKE
LIGHT
(21w)
Turn SignallHazardFlasherSystem
O
-.
CircuitDiagram
UNDER.OASH
FUSE/RELAY
BOX
IGNT]ONSWITCH
BOX
FUSE/NELAY
HOOD
UNDEF
BATTEFY
No12(7.sA)
@**'
N0.30(7.54)
FUSE
YEUBLK
WHTiELK
REO/BLK
l,
\ l----r-l-----i-F--
10
HAZARD
WARNING
swtTcH
GRN/ORN
q-
--------_
3
GRNAVHT
tI '
FqD
GRN/ORN
.+
DASHLIGHTS
BSIGHTNESS
CONTROLLER
INDICATOR
(1.4W)
INDICATOR
TFAILER
LIGHTING
CONNECTOR
BLK
BtK
G553
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G401
G402
:i1r'97model
*2 :'98-00models
23-85
Turn SignallHazardFlasherSystem
Turn Signal/HazardRelayInput Test
S R Sc o m p o n e n t sa r e l o c a t e di n t h i s a r e a .R e v i e wt h e
SRScomponent/ocations,precautions,ano proceoures
in the SRSsection(24)beforeperformingrepairsor service.
Removethe turn signal/hazard
relayfrom the underdashfuse/relaybox.
1.
'
IF\_-'l
- ]
$ o{+ll
/ll
FUSE/RCLAY
BOX
SOCKET
Cavity
2
Test condition
Tesl: Desiredresults
Underall conditions
l g n i t i o ns w i t c h O N ( l l l
HazardwarningswitchON
Hazardwarningswitch
ON;connectthe No. 1
terminalto the No. 3
terminal.
Hazardlightsshouldcome on.
Poorground(G201.c202, c401,
G 4 0 2G
, 5 5 3G
, 6 1 1 c, 6 3 1 )
Faultyhazardwarningswitch
An open in the wire
l g n i t i o ns w i t c hO N ( l l )a n d
t u r n s i g n a sl w i t c hi n r i g h t
or left;connectthe No. 'l
t e r m i n atlo t h e N o . 3
terminal.
R i g h to r l e f t t u r n s i g n a ll i g h t ss h o u l d
come on.
23-86
www.emanualpro.com
. Faultyturn signalswitch
HazardWarningSwitch Test
1.
Removethe centerpanel{seesection20).
2.
lNol usd)
HAZARD
swtTcH
Checkfor continuitvbetweenthe terminalsin each
switchpositionaccordingto the table.
Checkfor continuitybetweenthe terminalsin each
switchpositionaccordingto the table.
Terminal
2 3
7 8 10
t**--\
Terminal
OFF
Position
RIGHT
Neutral
tlwww.emanualpro.com
LEFT
o-
ON
(9 U
(_)
o @o o o
o- --o
23-87
Model
CircuitDiagram
IJNDER-HOOD
FUSE/HELAY
BOX
BATEBY
l-Noj',roo{ l;;f
tF*-'--ff::f-*"-l
.l-----
| ; )"tli|illsx"r
I
WHT/CRN
,k ,0r,,o,u
( P I KEYLGHT
{14w)
WHT/BLK
WNT/GRN
ORVER'S
000R
9!rl9rl^
^
ULU5EU:UOOrOpen
I
I
(OPEN :DoordosedJ
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IGNITIONKEYLIGHT
CONTROLUNIT
5P CONNECTOR
))
Cavity
Wire
BLK
'I
WHT/BLK
Test: Desiredresult
Underall conditions
lgnitionswitchON (ll)
Driver'sdoor open
Driver'sdoor closed
Underall conditions
Connectto ground:lgnitionkey
light shouldcome on.
WHT/GRN
GRN
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Test condition
23-89
DashLightsBrightnessController
CircuitDiagram
G401
23-9 0
www.emanualpro.com
ControllerInput test
NOTE:The controlunit is built into the dashlightsbrightnesscontroller.
Carefullypry the controllerout of the dashboard.
1.
Disconnect
the 3P connectortrom the controller,
Inspectthe connectorterminalsto be sure they are
all makinggood contact.
.
OASHLIGHTS
BRIGHTNESS
CONTROLLER
Wire sideof
lemaleterminals
Csvity
Wire
RED/BLK
BLK
RED
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Tst condhion
Tsst: Desiredresuli
Combinationlight
switch ON
Underall conditions
Combinationlight
switchON
Connectto ground:
Dashlightsshouldcome on full
bright.
23-91
InteriorLights
ComponentLocationIndex
FRONTCEILINGLIGHT
Test,page 23-94
SPOTLIGHTS
Test, page
FRONTPASSENGER'S
DOORSWITCH
REARCCILINGLIGI{T
Test, page 23-94
RIGHTREAR
swtTcH
DRIVER'SDOORSWITCH
HATCHGLASS
LATCHSWITCH
LEFTREAR
oooRswtTcH
TAILGATE
LATCHSwlTCH
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23-92
I J
CircuitDiagram
FUSERELIY
UNOER.I]OOO
BOX
BA--FqY
[t..*;;;;l
\:/-*-.........-='_Fn-'.,,
o-,
INDCATOF
!ICH'I
f7
I
II
BLU/EL(
rJ----r
I| Y|
l^,,o.orro
| coNthoL
I F#l*'
FI
t_*
d,*^*
"r**I
r"$$i,,,,,*,,
l J
www.emanualpro.com
I
l
Iii{il''
t
LTG
/f\
\9/
I FRoNT
I PASSENGEF'S
| 0@R
) | swrlcN
D@'
J lTcLosED
.-"
Iuffi**
l!oPEN:D@'
23-93
InteriorLights
CeilingLaghtTest
SpotlightTest
1.
2.
2.
3.
3.
4.
Disconnect
the 3P connectorfrom the housing.
4.
Disconnect
the 3P connectorfrom the housing.
aULB(5Wx2l
trmtnar 1
\
Position
or
1'
ON
23-94
www.emanualpro.com
t"",rr"
2'
3'
o-
Pd'l
/=\
oo-
/a\
\:/
-o
-o
-o
2
1
ol
2'
\
ON
OFF
MIDDLE
Terminal
R
OFF
ON
L
OFF
oo
oo-
--o
/-\
\:./
o
--o
/a
\:./
(9
--o
AccessorySocket
o-.
Circuit Diagram
UNDER_HOOO
FUSE/RELAY
8OX
IGNITIONSWITCH
txt
Fffi^-.rr-.rrl wHT'BrK
6\
+*HT-137F
wHr
BLK
t-'**1*fffiT
-*T]
REO/GRN
i ll%ti
) No.6
i{10A)
UNDER-DASH
i l9:,'3FUSE/RELAY
BOX
T
Y E LGRN
/BLK
l-
YEL/GRN
J-i,_,
l
''l '"*'
l ft-
l333iEi.''
,*1.I
t l
ir*?:r"$
|
BLK
l J
www.emanualpro.com
YEL/GflN
YEL,
8LK
RED/BLK
t l
t l
$Ni*"
t-*rt
8LK
8LK
-:a
-:
tl t l lt l l
-
G553
G40t
G4A2
G401
G4A2
G40t
G4A2
23-95
AccessorySocket
AccessorySocketTest/Replacement
5.
Front AccessorySocket:
1.
2.
Disconnect
the 2Pconnectorfrom the front accessory
socket.
PBOTECTOB
FACEPANEL
ACCESSORY
SOCKET
Thereshouldbe batteryvoltage.
lf there is no batteryvoltage,checkfor:
- b l o w n N o . 2 7 ( 1 0A ) f u s e i n t h e u n d e r - d a s h
fuse/relaybox.
- p o o rg r o u n d( G 4 0 1G
, 402).
- a n o p e ni n t h e w i r e .
23-96
www.emanualpro.com
5.
RearAccessorySocket:
'1. Removethe left rear side trim panel
{see section
20t.
Disconnect
the connectors.
2.
3.
l f t h e t e r m i n a l sa r e b e n t ,l o o s eo r c o r r o d e d ,
repairthem as necessary,and recheckthe sys
tem.
l f t h e t e r m i n a l lso o kO K ,g o t o s t e p4 .
ACCESSORY
SOCKET
COVER
THEEMAL
PROTECTOR
T$
THERMOFUSE
HOUSING
SOCKET
A (YEL/8LUI
ry
\
4.
www.emanualpro.com
I IBLK}
23-97
Glock-'98 - 00 Models
CircuitDiagram
UNDEE,HOOD
FUSE/RELAY
BOX
BATTERY
@-*"
-l
IGNTIONSWlTCH
No.41(1004) N0.42140A)
N0.47(7.54)
UNOEN.DASH
FUSgFELAY
8ox
G40t
G402
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23-9 8
Terminals
Removal
1.
2,
Disconnect
the 4Pconnector.
3.
CLOCK
Connectsto
I
WHT/BLU
YEL
RED/BLK
BLK
Constantpower (time
memory)
lG1 (mainclockpowersupply)
Lights-onsignal
G r o u n d{ G 4 0 1G
, 402}
CENTERAIR
VENT
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23-99
StereoSoundSystem
ComponentLocationIndex
AI{TENNA MAST
Replacement,page 23'103
AUDIOUNIT
page23-'102
Replacement.
page23-102
Terminals,
SUB ANTENNALEAD
FROI'ITSPEAKERS
page23-103
Replacement,
REAR
Beplacement,pago 23-103
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23-100
E
t
CircuitDiagram
-T
UNOEB,DASH
FIJSE/RELAY
BOX
IGNITIONSWITCH
FUSE/FELAY
BOX
UNDER.HOOO
l-^*"-l
T'5
1
WHT,tsLK
I
II
II
(7.5A)
No.30
FUSE
a,-,
YEURED
AUOIO
UNIT
o o
o o
s tr4 | 1l7l
1 sl 1 6 l |7 [ 6 1
BRN/BLK
GHY,ryVHT
LEFTREAR
SPEAKER
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RIGHTBEAR
SPEAKER
LEFI FRONT
D O O FS P E A K E R
RIGHTFBONT
DOOBSPEAKER
23-101
StereoSound System
Audio Unit Removal
AudioUnit Terminals
1 . M a k e s u r e y o u h a v e t h e a n t i - t h e f tc o d e f o r t h e
r a d i o , t h e n w r i t e d o w n t h e f r e q u e n c i e sf o r t h e
radio's presetbuttons (with anti-theftfeature).
Removethe centerpanel(seesection201,
Removethe four mountingbolts,and pull the audio
unit out.
D i s c o n n e c t h e ' l 6 P c o n n e c t o ra n d s u b a n t e n n a
lead,then removethe audio unit.
AUDIOUNIT
CENTEBPANEL
Cavrty
Wire
Connoct3 to
1{7)
RED/GRN
2 {8}
BLU
3 {9)
RED/BLK
Lights-onsignal
4 (10)
WHT/BLU
Constantpower (tuning
memory)
5 (2)
YEURED
7 (6)
BLU/YEL
8 (s)
RED/VEL
Rightrearspeaker@
9 (17)
BRN/BLK
1 0( 1 8 )
GRY/BLK
1 2( 1 9 )
RED
Dashlightsbrightnesscontroller
14 (20)
BLK
G r o u n d( G 5 0 1 )
1 5( 1 6 )
GRYMHT
1 6( 1 5 )
BRN^ll/HT
Rightresr speakerO
T e r m i n aN
l o . 6 , 1 1 ,a n d 1 3 :N o t u s e d
( T e r m i n aNl o . 1 , 3 ,4 , ' 1 1 , 1 21, 3 ,a n d ' 1 4N o t u s 6 d )
{ ): '99 - 00 models
www.emanualpro.com
23-102
SpeakerReplacement
1.
Removethe speakercover.
2.
3.
Mast AntennaReplacement
NOTE:To remove the antennalead, it is necessaryto
removethe dashboard(seesection20).
1.
Disconnect
the antennaleadfrom the audio unit.
2.
Front speaker:
MOUNTINGSCREWS
FRONTSPEAKER
Rearspeaker:
/a--=-
2P CONNECTOR
llwww.emanualpro.com
SPEAKER
COVER
23-103
Horns
ComponentLocationIndex
SRScomponentsare locatedin this area,Reviewthe SRScomponentlocations,precautions,
and proceduresin the SRS
section(24)beforeperformingrepairsor service.
HORN
Test,page23-105
HORNSW|TCHES
Test,page 23-106
m
/\
HORNRELAY
Test. page23-53
23-104
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CAELEREEL
R e p l a c e m e n t ,s e c t i o n 2 4
HornTest
CircuitDiagram
1.
2.
3,
Removethe horn.
HORN
2P CONNECTOR
} -
BLU/FED
fl"'
KEYLESSi
POWEF
DOOR
LOCK
CONTROL
UNIT
B L UFi E O
t
l
5.
BLU/RED
g)iirrN I
BLK
4.
LOW
HORN
BLK
BLK
I
I
G201
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23-105
Horns
Switch Test
1 . Disconnectthe batterynegativecable,then disconnect
the positivecable,and wait at ieastthreeminutes.
Disconnect
the driver'sairbagand front passenger's
airbagconnectors(seesection24).
Removethe drive.'sdashboardlower coverand the
kneebolster(seesection20).
CABI.I REEL
SUB.HARNESS
3P or 6P
CONNECTOR
MAIN WIRE
HARNESS
3P o. 6P
CONNECTOR
HORNCONNECTOR
37 modol
,98- 0Omodots
Terminal
sideof
maleterminals
'98 - (X)modols:
operatron:
Terminalsideof
.
.
Terminalsideof
www.emanualpro.com
23-106
Turn the ignitionswitch ON (ll);the SRS indicator light should come on for about six seconds
and then go off.
Makesure both horn buttonswork.
PowerMirrors
CircuitDiagram
IGNITION
SWITCH
FUSURELAY
BOX
UNDER.HOOD
@"*'
N0.41(100A)
N0.42(40A)
+WHT
WHT/8LK
lBAI
\
l
.Y^rc2l
YEL
-t----t
UNDER,DASH
FUSE/RELAY
B0x
I lu.'xI
I
BLKIryEL
POWEN
MIRRON
SWTCH
3
YEURED
BLK
BLUMHT
+l
vHT
GRN
l,-
-:
[ ]:
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'9&00rnodels
G551
23-107
PowerMirrors
FunctionTest
1.
.
-.t-..------'-
Both inoperative:
4.
Checkfor voltage between the No. 2 (BLVYEL)terminal and body groundwith the ignitionswitch ON
flr).
5.
Thereshouldbe bafteryvoltage,
. lf there is no voltage,checkfor:
- blown No. 17 (7.5 A) fuse in the under-dash
fuse/relaybox.
- an open in the BLK,/YEL
wire.
. lf there is battery voltage, go to step 2.
Checkfor continuitybetweenthe No. 4 {BLK)terminal and body ground.
Thereshouldbe continuity.
lf there is no continuity,checkfor;
. an open in the BLKwire.
. poor ground (c551).
23-108
www.emanualpro.com
Actuator Test
Switch Test
1.
2.
Teminal
t*t*
2.
\
UP
DOWN
L
LEFT
RIGHT
UP
DOWN
R
J-
1.
RIGHT
o ooo
oo oo
o .o o o
o oo o
o oo
oo o
oo o
o oo
o
o
o
o
Checkactuator operation by connecting power and
groundaccordingto the table.
Terminal
-\
;;,i".
8
@
TILTUP
@
TILTDOWN
SWINGLEFT
SWINGRIGHT
POWERMIRROR
swtTcH
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23-109
RearWindow Defogger
GomponentLocationIndex
rr^ja}
aia\
al I
rl
REABWINDOWDEFOGGER
SWTTCH
InputTest,p89e23-113
FUSE/RELAY
BOX
REARWINDOW
DEFOGGER
FunctionTest.page23-112
DetoggerWreRepair,page23-112
23-110
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a-
EI
CircuitDiagram
IGNITION
SWTCH
BOX
FUSE/REI-AY
UNDER-HOOD
BATTERY
@-*"
N 0 . 4 1{ 1 0 0 A )
N 0 . 4 2( 4 0 4 )
+WHT
WHT/8LK
-f
"r?h
\_--,'
I
II
l-
DEFOGGER
SWITCH
REAsWINDOW
panel)
control
B1 {iniheheater
l"
8LK
I J
www.emanualpro.com
G401
G402
23-111
RearWindow Defogger
FunctionTest
DefoggerWire Repair
1.
lf there is no voltage.checkfor:
- faultydefoggerrelay.
- faultydefoggerswitch.
- an open ,n the BLK/BLU,WHT/GRN,BLU/YEL,
or BLKwire.
lf there is batteryvoltage,go to step 2.
1.
2.
POSITIVETERMINAL
CELLOPHANE
TAPE
Mix the conductivepaint thoroughly.Using a small
brush, apply a heavy coat of the conductivepaint
extending about 1/8" on both sides of the break.
Allow 30 minutesto dry.
oK.
.
23-112
www.emanualpro.com
Removethe centerpanel{seesection20).
SWITCH
REARWINOOWDEFOGGER
lin the heatercontroloanel)
CENTERPANEL
lessthan 0.4V
ON
baftery voltage
Olwww.emanualpro.com
23-113
Wipers/Washers
ComponentLocationIndex
SRScomponentsare locatedin this area.Reviewthe SRs componentlocations,precautions,and procedures
in the s6s
section(24)beforeperformingrepairsor service.
REABWINDOWWIPERMOTOB
Tst,page23-120
WPSR/WASHER SWITCH
Test.page 23-l't9
REARWINDOW
WIPER
CONTROL
UNlT137mod.ll
Inputtest.page23-118
WINDSHIELD
WIPERMOTOR
Tost,page23-119
n
t ff
UNDER.DASHFUSE/RELA BOX
INTERMITTENT
W|PENRELAY
CIBCUIT,REARWINDOWINTERMTNENT
wlPER RELAYCIBCUITl'98 - 0Omod.t.l
(ln the integratedcontrol unit)
Input test, page 23-68
23-114
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l -
CircuitDiagram{Windshieldl
@*"
N0.41(1004)
UNDEB,DASH
BOX
FUSENELAY
IGNITONSWITCH
BOX
FUSE/NELAY
UNDEB.HOOD
N0.42{40A)
BLUiBLK
YEUBLU
WHTiBLK
INTEGEATED
CONTFOL
UNIT
/ Hasbui[-in
\
I inlermiltenl
I
relay
\ wiper
/
l-
BLK
8LK
BLK
II
_L
G401
G402
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G401
G402
G401
G402
23-115
Wipers/Washers
CircuitDiagram(RearWindow)-'97 Model
UNDER.HOOD
FUSE/RELAY
BOX
@**'
N0.41(100A)
N0.42(40A)
WHT/BLK
+WHT
, 7 ! i s - - - - - - -- - - -
JiJ frT
BLK
d-l
G401
G4A2
23-116
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t'
8LK
G202
G611
G631
CircuitDiagram(RearWindowl-'98 - 00 Models
80X
FUSEi
RELAY
UNDER.HOOD
BATTERY
@*,'
N 0 . 4 (11 0 0 A )
N 0 . 4 (24 0 A )
+WHT
WHT/BLK
GNITON
SWTCH
UNDEF-DASH
FTJSE/RELAY
BOX
REAR
WINDOW
WPERMOTOR
J D L
I
OFF
GRN/BLK
INTEGRATED
CONTROLUNT
/Has boll-inre wndow\
w perrelay ]
t nlermillenl
OtI
vil8t8E
BLK
BLK
BLK
.L
n-
n_
-:
G202
G611
G631
G40l
G402
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A n',$s".,,,
23-117
Wipers/Washers
RearWindow WiperGontrolUnit lnput Test-'97 Model
1 . Removethe driver'sdashboardlower cover and the
kneebolster{seesection20).
Disconnect
the 8P connectorfrom the controlunit.
8P CONNECTOF
LT GRN/BLK
T GRN/RED\ LT
2
GRN/BLK
Cavity
4
Test condhion
BLK
LT GRN/
RED
lgnitionswitchON (lll
lgnitionswitchON (ll),
and rearwindow
wiper/washerswitch
ON
lgnitionswitchON (lll
lgnitionswitchON (ll)
B l o w nN o . 3 { 1 0A ) f u s ei n t h e
under-dashfuse/relaybox
Faultyrgarwindow wiper motor
An open in the wire
B l o w nN o . 3 ( 1 0A ) f u s ei n t h e
under-dashfuse/relaybox
Faultyrearwindow wiper/washer
switch
An open in the wire
LT GRN/
BLK
LT GRN
lgnitionswitchON lll),
and rearwindow
GRN/BLK wiper/washerswitch at
washerposition
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23-118
Underall conditions
GRN
'l
Test Desirdr93uh
. Poorground(G401,c402)
. An open in the wire
Wiper/WasherSwitch Test
WindshieldWiperMotor Test
Windshield/ReErWindow Wiper/WasherSwitch:
1.
1.
2.
Removethe steeringcolumncovers{seesection17)
3.
D i s c o n n e c t h e 8 P a n d 6 P c o n n e c t o r sf r o m t h e
switch, remove the two screws, and pull out the
switch.
\ lind3hi.ld:
tilt-rltl
IEZIA
RaarWindow:
1 12 3
I t-7 al
J-
o
o
o
o
o
P*tOFF
oo
INT
LO
o
o
HI
"0N"
Mistswhch
switch"0N"
Washer
o
o
o
o
-l
Terminal
;fi;"
LOW SPEED
H I G HS P E E D
ti'"
ll www.emanualpro.com
---\Teminal
Washer
switch'0N'
(wiperswitchoFFl
OFF
ON
"ON'
Washer
switch
"0N"1
(Wiper
switch
-o
-o
o
-o
-o
-o
23-11 9
Wipers/Washers
RearWindow WiperMotor Test
WasherMotor Test
1.
REARWINDOW
WASHERMOTOR
4P CONNECTOR
Pushtab
to release,
4.
5.
WIPEB
LOWERCOVEn
L_Iq'.r91
Reconnect
the 4P connectorto the wiper motor.
Disconnected
Connected
oN.
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23-120
,l
Battery
@
f l u i d i s p u m p e d ,c h e c kf o r a d i s c o n n e c t e do r
blockedwasherhose,or a cloggedpump outletin
the motor.
HatchGlassOpener
Switch Test
CircuitDiagram
1.
2.
Disconnect
the 2Pconnectorfrom the switch.
3.
R e m o v et h e s w i t c h f r o m t h e d a s h b o a r d l o w e r
cover.
FUSE/RELAY
BOX
UNDER.H@D
BATTEFY
@*"
|-*;rr^!...',r,*;l
.......1<\o<\r+l
I
I
WHT/GRN
DASHBOAND
LOWER COVER
WHT/GRN
II
WHT/GBN
rt
KEYLESSi
POWEF
DOOB
LOCK
CONTROL
UNIT
V
II
HATCHGLASS
OPENERSWITCH
YEL
J
T
I
HATCH
GLASS
OPENER
soLENOr0
BLK
Otwww.emanualpro.com
out,
G631
23-121
HatchGlassOpener
SolenoidReplacement
Solenoid Test
1.
2.
Disconnect
the 2Pconnectorfrom the solenoid.
Disconnect
the 2P connector.
SOLENOID
Terminalsade
of
maletermtnals
4.
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23-122
DOORL(rcK SWITCH
DRIVER'S
Test,page23-129
LOCKBUTTON
HATCHGLASS BUTTON
RIGT{TREARDOORLOCK
ACTUATOR
Test,page 23-129
Replacement,section20
PA rc AUTTO]II
HATCHGLASSOPENERSOLENOIO
fesl, page 23-122
Replacemnt.pago 23-122
FRONTPASSENGER'S
DOORLOCKACTUATOR
Test, page 23-129
soction20
R6Dlacement,
LEFTBEARDOORLOCK
ACTUATOB
Tesr,page23-129
Beplacement,
section20
. DRIVEB'SDOORLOCK
KNOB SW|TCH
Tesr,pag623-128
. DRIVER'SDOORLOCK
ACTUATOR
T6st,psge 23-128
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23-123
GNTIONSWTCH
UNDERDASH
FUSE/RELAY
BOX
EATTEFY
@*n'
YEL
WHT/GFN
8
UNLOCK
nrrenu@
ITEYLES--l
I TRANSMIT]ER
I
Lr-------HORN
RELAY
f7
II-
LOCK
GRY
HATCH
OPENER
swlTcH
FRONT
CEILING
LGHT
KEYLESS
DOOsLOCK
C O N T R OULN I T
f7
Y_o*,,.,,,0I
. PASSENGENS
DOORSWITCHES
. ]NTEGRATED
CONTROL
UNIT
5
I
I
.,ufrro
,Y,
I
F",'*-{
YEL
fIl
l B
INTEGRATED
CoNTROL
UNT
HATCH
GLASS
OPENER
SOLENO
D
+
l
BL(
G61l
G63l
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23-124
L
rthg#,i."J
8!?i"'[:lll',fffi)
BLK
BLK
DRIVER'S
DOOFLOCK
swrTcH
8LK
G401
G402
G551
G551
I--
CircuitDiagram{WithoutKeylessEntrySystem)
UNDER.HOOD
FUSEi
RELAY
8OX
BATTEBY
+wqr-t_twrr3-K
@**'
UNDER-DASH
FUSE/RELAYBOX
IGNTIONSWITCH
6\
tr.*;l
vEL
BLKYEL
ffr
l-J';
t
|
I
HORN
RELAY
KNOB
oBtvERs
DOOn
LOCK
ACTUATOR
V
(Nolused)
LOCK
HATCH
GLASS
OPENER
SWTCH
FRONT
CEILING
TIGHT
POWER
DOOR
LOCK
CONTROL
UNIT
f7
l_
I
r-
EIGHT
REAR
00oRLocK
ACTUATOR
INTEGRATED
CONTROL
UNIT
V
I
YEL
BLU/RED
l-
8Lr
BLU/RED
t / |Iupl
::iii^
tFl
BLK
G6l1
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'tl
II
,#. L?Vno'
( li: ) swrTcH
YAil''"',4,.'{yrcLosED
tottt
l'
YEURED
-Tq.
GRNORN
GRNWHT
s l-lLocx^l
, |
-=tGJ--
Locx
l,
I
I
DRIVER'S
D00RLOC(
SWITCN
BLK
BLK
I':
I:
G()1
G402
G551
II
II
23-125
PowerDoor Locks
GontrolUnit Input Test
1. Removethe driver'sdoor panel(seesection20).
2. Disconnect
the 18Pconnectorfrom the controlunit.
3. lnspectthe connectorand socketterminalsto be surethey are all markinggood contact.
.
.
18PCONNECTON
BLU
GRN/BED
GRY
10
1t
,/
1 21 1 3
GRN/WHT I
14
LT
femaleterminals
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23-126
5
16
17
1E
Wire
11
8LK
BLU
Test condition
Underall conditions
Connectthe No. 7 termi'
nalto the No. 8 terminal,
and the No.6 terminalto
the No. 17terminal
momentarily.
Underall conditions
Tost: Dcsiredresult
Checkfor continuityto ground:
Thershouldbe continuity.
Checkdoor lock operation:
Driver'sdoor shouldunlock.
Connectto ground:
Hornshouldsound,
GRY
YEURED
BLU/RED
Connectan ohmmeter
betweenthe No. 9 terminal and the No. l7 terminal.Driver'sdoor lock
knobin UNLOCK
Faultyactuator
An openin the wire
BlownNo.51 (20A)fuse in the underhood fuse/relaybox
Checkdoor lockoperationl
All doorsshouldlock.
Faultyactuator
An openin the wire
BlownNo. 51 {20A) fusein ihe underhood fuse/relaybox
Checkfor conlinuity:
Thereshouldbe continuity.
Wir6
Test condition
Driver'sdoor lockknob in
Faultydriver'sdoor lockactuator
Poorground(G551)
An openin the wire
Faultyignitionkeyswitch
Poorground(G401,G402)
An openin the wire
BlownNo. 25 (7.5A) fusein the underdashfuse/relay
box
An openin the wire
10
BLUAVHT LOCK
13
Connectthe No. 5
terminalto the No.I terminalmomentarily
. F a ( l l t yd o o r s w i t c h
. An open in the wire
14
LT
Passengor's
door open
GRN,NED
GRN/RD
12
'
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lgnitionswitchON (ll)
YEL
YEL
WHT/GRN
Tost: Dsirodresult
Underall conditions
Faultylront ceilinglight
An openin the wire
Faultydriver's door lock switch
Poorground{G551)
An openin the wire
23-127
Driver'sDoorLockActuatorTest
1.
1,
2.
2.
6P CONNECTOR
6P CONNECTOR
Terminalsideot
maleterfiinals
Terminalsideof
maleterminals
\
Position
\
LOCK
UNLOCK
o- -o
o- --o
Terminal
F*'',1."
__l
LOCK
UNLOCK
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23-128
o
@
DoorLockActuatorTest
Passenger's
1 . Removethe passenger's
door panel(seesection20).
Disconnect
the 2P connectorfrom the actuator.
Removethe innerhandle{seesection20).
Disconnectthe 3P connector.then removethe two
mountingscrewsand driver'sdoor lockswitch.
\
Position
\
LOCK
OFF
UNLOCK
Terminal
sideof
maleterminals
o- --o
o- -_o
Terminal
;;il;--r
,l
LOCK
UNLOCK
4.
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@
@
23-129
PowerDoor Locks
TransmitterTest (With KeylessEntrySysteml
NOTE:
. The ceilinglight (in middleposition)comeson within 30 secondswhen you unlockthe doorswith the transmitter.
. The doorsdo not lockor unlockwith the transmitterif the ignitionkey is in the ignitionswitch.
. lf any door is open,you cannotlockthe doorswith thetransmitter.
o lf you unlockthe doorswith the transmitter,but do not open any of the doorswithin 30 seconds,the doors relockautomatically.
. For hatchglassbuttonoperation,hold the buttonfor morethan two seconds.
. lf you pressthe PANICbuttonfor more than two seconds,the horn soundsfor about 30 seconds,and the transmitter
LEDcomeson. (The panic mode will not be activatedif the ignition key is in the ignitionswitch.)The panic mode is
cancelledby pressingany of the transmitterbuftons.
. The horn soundsonly the first time you press a transmitterbutton,(Pressingrepeatedlydoes not activatethe horn
again.)
Doors cannot bo locked or
unlockedwhh lhe transmitter.
BATTERY
{cR20251
R e w r i t et h e t r a n s m i t t e rc o d e ,
then try to locldunlockthe doors
{seepage23-131}.
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23-130
TransmitterProgramming
Storingtransmittercodes:
The codesof up to three transmitterscan be read into
the kevlessreceiverunit memory (lf a fourth code is
stored.the codewhich was inDUtfirstwill be erased.)
N O T E : l t i s i m p o r t a n tt o m a i n t a i nt h e t i m e l i m i t s
betweenthe steps.
1 . Turn the ignitionswitchON (ll).
Within 1 to 4 sec.,push the transmitterlock or unlock
buttonwith the transmitteraimed at the vehicle.
Within 1 to 4 sec.,turn the ignitionswitchOFF.
Within 1 to 4 sec.,turn the ignitionswitchON (ll).
W i t h i n 1 t o 4 s e c . . p u s h t h e t r a n s m i t t e rl o c k o r
u n l o c k b u t t o n w i t h t h e t r a n s m i t t e ra i m e d a t t h e
vehicle.
o.
1 3 .W i t h i n 8 s e c . ,a i m t h e t r a n s m i t t e r s( u p t o t h r e e )
whose codes you want to store at the receiver,and
pressthe transmitterlockor unlockbuttons.
Confirm that you can hear the sound of the door
lock actuatorsafter each transmitter code is stored.
1 4 . Turn the ignitionswitchOFF,and pull out the key.
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23-131
PowerWindows
ComponentLocationIndex
t
L--JIJJ'JJL
t
J
- -------------) ------------
1J
15-
t_.1
POWERWINDOWMASTER
SWITCH
(Hasbuilt in controlunit)
Input Test,page 23-'134
Test,page 23-135
FRONTPASSCNGER'S
WINDOWMOTOR
Test,page23-137
FBOI{TPASSENGER'S
WI{DOW SWTTCH
Test,page23-138
LEFTREANWWDOW
SwlTCH
Test,page23-137
LEFTREARWINDOW
MOTOR
Test,page23-'t38
--.-\-.--t
DRIVER'SWINDOW
MOTOR
Test, page 23-137
\-
RIGHTREARWINDOW
MOTOB
Test. page 23-138
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23-132
RIGHT
wtNDowswTcH
T6sr,page23-137
GircuitDiagram
L]NDEFH@O FISETRELAY
BOX
@-*'
V
I
PASSENGEAS
FFONTPASSENGEFS
www.emanualpro.com
23-133
Power Windows
MasterSwitch Input Test
NOTE:The controlunit is built into the powerwindow masterswitchand only controlsdriver'sdoor window operations.
1. Removethe masterswitch,and disconnectthe 14P,2?and 1Pconnectorsfrom the masterswitch.
2. Inspectthe connectorand socketterminalsto be surethey are all makinggood contact.
.
.
lf the terminals are bent, loose or corroded, repair them as necessary,and recheckthe system,
lf the terminalslook OK, makethe followinginput testsat the connector.
- lf a test indicatesa problem, find and correctthe cause,then recheckthe system.
- lf all the input tests prove OK, the power window maser switch must be faulty; replaceit.
lirP CONNECTOR
1P CONNECTOR
BLU/ORN
RED/BLU
BLU/YEL \ RED/YEL
YEL/BLK
GRN/YEL
GRN
WiresideoI
femaleterminals
GRN/BLK aLu/BLK
Wire side of
femaleterminals
POWERWINDOWMASTEBSWITCH
RED/BLK
www.emanualpro.com
23-134
Cavity
Wi1
A11
Test condition
Tesi: Dssiredrosult
Underall conditions
lgnitionswitchON (ll)
BLK
B1
A 1 0 BLU/BLK
A9
GRN/BLK
A6
YEUBLK
412 RED/WHT
A4
A3
. Faultydriver'swindow motor
. An open in the wire
oN flr).
A1
A2
A14
A8
window
Faultyfront passenger's
motor
Faultyfront passenger'swindow
switch
An open in the wire
Check
the leftrearmotor:
,t shouldrun {thewindowmoves
down),
Faultyleft rearwindowmotor
Faulty,eftrearwindowsrrvitch
An openin thewire
Faultypulser
Faultydriver'swindow motor
An open in the wire
Combinationlight
switch ON
Combinationlight
switch ON
Connectto ground:
Dashlightsshouldcome on full
bright.
oN flr).
YEL
GRN
oN flr).
A5
*cl
BLU
RED/BLK
RED
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PowerWindows
MasterSwitch Test
1 . Removethe switch (seesection 20).
F.ont Passongsr'sSwitch:
Disconnect
the 14P,2P and 1P connectorsfrom the
power window masterswitch.
swrTcH
'**[ffi
ON
rermrnal
OFF
FRONT
PASSENGER'S
UP
swncH
A1
oo- --o
ON
G-
OFF
o-
ON
DOWN
A2
OFF
oo-
A9
B1
-_o
--o
C
--o
--o
Right RearSwitch:
B \\N
7-.i::,,,
Terminal
'".'*l-$j[\
ON
OFF
\\'. )),,
UP
OFF
ON
OFF
ON
DOWN
OFF
A14
413
A6
B1
--o
oo* --o
--o
o--o
oo-- --o
o- --o
I F---T-----r-----r----r-----T---------T-----'r
I
l l a l l A 2l A 3 l A { l A 5l A 6 l A 7l a B l l
e*Li*l$[\
l Fa #
l
e
ll
l A 1 0 l l A 1 1 l A 1 2 llt-t___Jl
A13lal.ll
ON
I r________r_____J
fr---r-l
Terminal
OFF
OFF
r---- -------r
I t-------l
-ll
ll 'lr 8 1 ll ll l l c 1 |I c 2 ll lr
UP
L--:J
ON
OFF
ON
DOWN
Dliver's Switch:
The driver'sswitchis combinedwith the control unit so
you cannot isolatethe switchto test it. Instad,run th6
masterswitchinputtest procedureson page23-134.
lf the tests are normal.the drive/s switch is faulty.
www.emanualpro.com
23-136
OFF
A12
A8
ooo-- --o
o- --o
oo-
A7
B1
o --o
--o
-_o
--o
Terminal
ti.*----_\
Underallconditions
o-
-o
ILED)
Motor Test:
1.
2.
Terminalsideof
maleterminals
Terminal
-\
\
;;b"
Terminal
__\
1
\
;"rL-
UP
o-
OFF
DOWN
www.emanualpro.com
o-
-o
-o o- -o
-o
4.
UP
(!r
DOWN
PulserTest:
5.
6.
23-137
PowerWindows
Passenger's
Window Motor Test
Front:
l.
2.
3.
UP
DOWN
UP
DOWN
Rar:
I
;*r*
Terminal
-l\
Rear:
1.
Removethe passenger's
doo. panel,and disconnect
allthe connectors(seesection20).
2.
23-138
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I J
Restraints
.....24-1
SeatBelts
SupplementalRestraintSYstem
(sRSl......'.'.
""'.""".""""24-13
f,
l www.emanualpro.com
SeatBelts
24'2
ComponentLocationIndex.'."..'..'-'.'
'......"'..24-3
FrontSeatBeltReplacement
'.' 24-6
......'.".
RearSeatBeltReplacement
.....""""""""' 24-9
lnspection
ChildSeatTetherAnchor
lnstallation-'97 - 99 Models."'."24-10
ChildSeatTetherAnchor
Removal/lnstallation
-'00 Model ....'......'.'....'.'.."-'-'."'
24'11
Seat Belts
ComponentLocationIndex
SRScomponentsare locatedin the partsareasmarkedwith an asterisk{*). Reviewthe SRScomponentlocauons,precautions,and proceduresin this section(24)beforeperformingrepairsor service(,98_ 00 models).
CHILDSEATTETHENANCHOR
-'97
lnstallation
99 models,page24-10
- '00 model,page24-11
Removal/lnstallation
CHILDSEATTETHER
ANCHORCOVER('00 modtl
REARSEATBELTBUCKLE/
CENTERBELTTONGUE
(seepage24-7)
.FRONTSEATBELT
page24 3
Replacement,
page24-9
Inspection,
BELTEUCKLES
(seepage24 5)
24-2
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2.
3.
4.
5.
M a k e s u r e y o u h a v e t h e a n t i - t h e f tc o d e f o r t h e
radio,then write down the frequenciesfor the preset buttons.
Disconnectthe negativebatterycable,and wait at
leastthree minutesbeforebeginningwork.
Slidethe front seatforwardfully.
Bemove(seesection20):
. Centerpillarlowertrim Pane
. Kickoanel
. Frontsidetrim
'97 model:Removethe upper anchorcover and the
lower anchorcaP.
'98 - oO models: Removethe upper anchor cover
and pull the lower anchorcoverback.
UPPENANCHORBOLT
7/1&20UNF
32 N.m (3.3kgt'm.
24 tbf.ft)
Applyliquidthread
lock.
UPPER
COVER
SEATBELT
TENSIONER
REARSIDE
7 . R e m o v et h e u D D e ra n d l o w e r a n c h o r b o i t s , t h e
retractor bolt, the retractor mounting bolt, and
remove the front seat belt and retractor.
8. Removethe centerpillaruppertrim (seesection20).
9 . Removethe shoulderanchoradjuster.
I x 1.25mm
23 N.m 12.3kgt.m,
1? tbf.ft)
ANCHOR
CAP
('97 modell
LOWERANCHORBOLT
?,/1&20UNF
32 N.m {3.3 kgf.m,2,1lbf.ftl
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SHOULDER
ANCHOR
ADJUSTER
ANCHOR
COVER
l'98- 00models)
RETRACTORBOLT
7/1&20UNF
32 N.m 13.3kgt m,
24 tbt.ft)
SHOULDER
ANCHOR
ADJUSTER
{'98 - 0o modols)
RETRACTOR
MOUNTINGBOLTZ,,
./
Gx1.0mm
9.8N.m (1.0kgt.m,
?.2 tbtft)
o.
(cont'd)
24-3
Seat Belts
FrontSeat Belt Replacement
{cont'dl
Uppgr anchorboh construqtion:
Rtractorbolt construqtion:
UPPEBAI{CHOR
aolT
Apply liquidthread
tock.
T(X)THED
LOCI(WASHCR
RETNACTOR
BOLT
bwd
RETBACTOR
24-4
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2.
Removethe centercover(seesection20).
3.
TOOTHED
LOCKWASHER
WAVE
WASHER
CENTER
ANCHOR
BOLT
>: Cliplocations
SPRING
WASHER
5.
WASHER
CENTER
ANCHOR
To seat belt
buckle.
SEATBELT
swlTcH
CONNECTOR
4.
CENTERANCHORBOLT
7/1&20UNF
32 N.m {3.3kg{ m, 24 lbf ftl
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SEATBLT
SwlTCH
HARNESS
24-5
Seat Belts
RearSeat Belt Replacement
CAUTION:Checkthe rear sat belts for damage,and
replacelhem if necessa.y.Be caretul not to damage
them during temoval and installation.
Rearseat belt:
1,
Removethe rearseat{seesection20}.
2.
6.
UPPERANCHORBOLT
7/16-20UNF
32 N.m 13.3kg{.m,
24 tbt.ft)
UPPERANCHOR
TOOTHEO
LOCKWASHER
A
\tt
REARSEAT
BELT
RETRACTOR
UPPER
ANCHOR
COVER
LOWER
ANCHOR
COVER
ANCHOR
COLLAF
SPRING
WASHEB
RETRACTOB
MOUNTINGBOLT
6x1.0mm
9.8N.m (1.0kgt.m.
7.2 rbf.ftl
RETRACIOREOLT
7/16-20UNF
32 N.m {3,3kgf.m,
24 rbr.ft)
3.
TOOTHED
LOCI(WASHER
LOWERANCHOFBOLT
7/1S20UNF
32 N.m 13.3kgl.m, 2/r lbf.ftl
BUSHING
WASHERS
COLLAR
LOWERANCHOR
4.
Remove(seesection20):
. Cargoareafloor and cargostoragebin
. Reartrim paneland rearsidetrim panel
/\
f/F\-.
P \v*\
/
T(X)THED
LOCKWASHER
24-6
www.emanualpro.com
r>--->.
(t--nnnllH \
\
RETRACTOR
\
RETMCTOR
BOLT
) J
Seat belt buckles/Centerbelt tongue:
with tilt:
without tilt:
1.
2.
1.
2.
SEAT.BACK
CENTERBELTYONGUE
CENTFRANCHORBOLTS
7/16-20UNF
32 N.m (3.3kgf.m,
2a rbtftt
CEiITER AT{CHORBOLTS
7/1e20 UNF
32 N.m {3.3kgt m,
2r bf.frl
SEATBELT
BUCKLE
SEATBELT
BUCKITS
\\
lnstallationis the reverseof the removalprocedure.
NOTE:When reinstallingthe rear seats.make sure
there are no twists or kinksin the centerbelt tongue
and seatbelt buckle.
(cont'd)
www.emanualpro.com
Seat Belts
RearSeat Belt Replacement(cont'dl
5.
TOOTHED
LOCKWASHER
ANCHOR
24-8
www.emanualpro.com
Inspection
Rear:
40.
/A
*1ix
\|
_t-. \ /
page2+231.
L =
ls
Rgtlastor Insgection
RETRACTOR
1.
2.
Make sure that the seat belt does not lock when the
retractoris leanedslowlyup to 15'from the mounted
Dosition.The seat belt should lock when the retractor
is leanedover 40".
CAUTION: Do not attsmpt to dbassemble ths relrac'
tor.
Forwerd
Forwerd
3.
Front:
'97 modol:
lnsida
.: Mounted Position
RETRACTOR
lnside
Forward -
'98 - 00 modcls:
www.emanualpro.com
24-9
Seat Belts
ChifdSeat TetherAnchor Installation-,97 - 99 Models
Canadamodel:
Attachmentpointsare providedfor a rear searmounted
childrestraintsystemwhich usesa top tether.The attach_
ment pointsare locatedon both rearcornersof the head_
liner,just behindthe rear seat-back.
When using a child
seatwith a top tether,installthe child seattetheranchor
securelv.
NOTE:
. Do not removethe toothedwasherfrom the childseat
tether anchor.Use the seat anchorwith the toothed
washerattachedto it.
. When installinga child seat on the rear seat,follow
the instructionsof the manufacturer
of the childseat.
. Additionalanchorsare available.
ATTACHMENT
POINTS
PLUGCOVERS
CHILOSEAT
TETHER
ANCHOR
TOOTHEDWASHER
24-10
www.emanualpro.com
l r
-'00
Child Seat TetherAnchor Removal/lnstallation
Model
AttachmentDointsare providedfor a rear seat mountedchild restraintsystemwhich usesa top tether'The attachment
pointsare locatedon both rear cornersof the headliner,just behindthe rear seat-backThe child seattether anchorsare
installedinto eachattachmentpoint.Eachchild seattetheranchoris coveredwith a childseattetheranchorcover.
NOTE:
. Do not removethe toothedwasherfrom the child seattetheranchor.Usethe anchorwith the toothedwasherattached
to it.
. When installinga childseaton the rearseat,follow the instructionsof the manufacturerof the childseat.
U n i t im m ( i n . )
HEADLINER
TOOTHEOWASHEB
CHILDSEAT
TETHERANCHOR
I x '1.25mm
22 N.m (2.2kgf m,
16 rbf.ft)
www.emanualpro.com
24-11
SupplementalRestraintSystem (SRS)
\
)
<D
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SpecialTools
Ref. No.
Tool Number
o"'
07HAz- SG00500
07PM- 0010100
07sAz- TB40114
07TAZ- SZ50114
o7TAZ - OO1O20A
@-,
/a\
@
rA*,
Description
Oty
DeploymentTool
SCSServiceConnector
SRSInflatorSimulator
SRSSimulatorLeadC
BackprobeAdapter,l7 mm
1
1
'1
I
2
/n
24-14
www.emanualpro.com
PageReference
24-91
24-21
24-50
24-50
24-43
Component/WiringLocationsIndex-'97 model
To CRUISECONTROL
SET
DASHBOABDw|RE HARNESS
LIGHTin
to SBS INDICATOR
GAUGEASSEMBLY
5P
MAIN WIREHABNESS
to DASHBOABDwlRE HARNESS
21P
DRIVER'SAIBMG
Replacement,
page 21-87
Disposal,page 24-97
To DRIVERSAnBAG
FRONTPASSEITGER'SAIRBAG
Replacement,pago 24{9
Disposal,page 24-97
GOf$ECrOn PPI
lBLr( 8R t
SRSMAIN HABNESS
to UNOEB-DASH
FUSE/BELAYBOX
2P CONNECTOR
SRSMAIN HARNESS
to MAIN
WIRE HARNESS
3P OONNECTOR
MEMORYERASESIGNAL
IMES) CONNECTORI2PI
[GRY. GRYI or twHT, BLr.l
www.emanualpro.com
sBsitAr[ ] nNEss
to FROI|T PASSEiIGEB.S
ANBAG
2P
sns ut{fT
GROUND
SES MAIN HAR]GSS
tosnsU n
ItP OOIIITECTOR
24-15
Gomponent/WiringLocationsIndex-'98 - 00 models
CABLEREEL
Replacement,
page24-91
To HORNSWITCH
To CRUISECONTROL
SET/RESUMESWTCH
To DRIVER'SAIRBAG
DASHBOARDWIREHARNESS
to SRS INDICATORLIGHf in
GAUGEASSEMBLY
5P CONNECTOR
ORIVER'SAIRBAG
Replacement,
page 24-87
Disposal,page 24-97
FRONTPASSENGER'S
AIRBAG
page24-89
Replacement,
Disposal,page24 97
SRSMAIN HARNESS
to FROI{TPASSENGER,S
AIRBAG
2P CONiIECTOR
SRSMAIN HARNESS
ro CABLEREEL
2PCONNECTOR
MAIN VYIREHARNESS
to DASHBOARDWIREHARNESS
24PCONNECTOR
SRSMAIN HARNESSto
LEFTSIDEWIREHARNESS
2P CONNECTOR
SRSMAIN HARNESS
to MAIN WIREHARNESS
3P CONNECTOB
RIGHTSIDEWIREHARNESSto
SEAI BELTTENSIONER
2P CONNECTOR
SRSUNIT
(lncludingsafingsensor
and impactsensor)
page24-95
Replacement,
SRSMAIN HARNESSto
RIGHTSIDEWIREHARNESS
2P CONNECTOR
SERVICECHECK
CONNECTOR
I2PI
IBLK BRNI
SRSMAIN
to UNDER-DASH
BOX
FUSE/RELAY
2PCONNECTOR
MEMORYERASESIGNAL
(MES)CONNECTOR
I2PI
IGRN,GRNIor IWHT,BLKI
SEATBELTTENSIONER
page24 3
Replacement,
Disposal,page 24-97
ORIVER'SSEATBELT
Replacement,page 24-3
page24-97
Disposal,
LEFTSIDEWIREHARNESSto
SEATBELTTENSIONER
2P CONNECTOR
www.emanualpro.com
24-16
Description
)
J
The SRSis a safetydevicewhich,when used in conjunctionwith the seat belt,is designedto help protectthe driver and
front passengerin a frontalimpactexceedinga certainset limit.The systemconsistsof the SRSunit (includingsafingsenairbag.
sor and impactsensor),the cablereel,the driver'sairbagand front passenger's
Seat Bolt Tensioner {'98 - 00 models}
of the seat belt. In a front-end
The seatbelt tensioneris linkedwith the SRSairbagsto further increasethe effectiveness
seats
in
their
the
occupants
firmly
to
secure
collision,the tensionerinstantlyretractsthe belt
DRIVER'SAIRBAG
FRONTPASSENGER'S
AIREAG
FRONTPASSENGER'S
SEATBELTTENSIONER
{'98 - 00 modelsl
SRSUNIT
DRIVER'SSEATBELT
TENSIONERl'98 - 0Omodeb)
Operation
ignitesthe intlatorcharges.lf bat
The main circuitin the SRSunit sensesand judgesthe forceof impactand, if necessary,
voltage
regulator
and the back-uppower circuit
impact,
the
power
to
the
is disconnecteddue
tery voltageis too low or
will keepvoltageat a constantlevel.
respectively
For the SRSto operate:
(1) The impactsensormust activate,and sendelectricsignalsto the microprocessor.
(2) The microprocessor
must computethe signals,and sendthem to the airbaginflators(andseatbelttensioners).
(3) The inflatorsmust igniteand deploythe airbags(andactivatethe tensioners).
---__-l
TENSTO1En
I
I
_-___J
1 9 8- 00 N4odes)
Selt-diagnosisSystem
A self-diagnosis
circuitis built into the SRSuniUwhen the ignitionswitchis turned ON (ll),the SRSindicatorIight comes
on and goesoff afteraboutsix secondsif the systemis operatingnormally.
lf the light does not come on, does not go off aftersix seconds,or it comeson while driving,it indicatesan abnormalityin
the system.The systemmust be inspectedand repairedas soon as possible.
For batteryserviceability,
the memorywill storethe causeof the malfunction,and the data link circuitpasseson the infor
mationfrom the memoryto the data link connector(DLC).This informationcan be readwith the HondaPGMTesterconnectedto the DLC{16P).
www.emanualpro.com
24-17
CircuitDiagram
IGNITIONSWITCH
-'WHT/BLK
WHT
UNDER.DASH
FUSE/RELAY
BOX
YEUGRN
SFS INDICATOR
CIRCUIT
(lnlhegaugeassembly)
SRS NDICATOR
L G H T{ r . 4 W )
Shillloc*soenoid
FRONT
PASSENGER'S
ALRBAG
INFLAlOR
P G MF I
mamrelay
DRIVEB'S
AIRBAG
NFLATOR
t l
BLK
GRY
(GFN)
GFY
(GRN)
12
BLU
#+
tl . /t
t lI
GRY
GRY
(GRN) (GRN)
1
4
GR\
3
11
16
17
GRN
(BLU/PNK)
15
GFY
GRY
FRONT
PASSENGERS
SEATBELT
TENSIONEF
G401
DRIVER'S
SEATEELT
TENSIONER
r-?
BRN
t
?
BRN
GNY
(GlN)
lcFNt
I
LTBLU
t
18
DATA
LINX PCM/ECMSERVICE MEMORY
ERASE
CONNECTOR
CHECK
S GNAL(MES)
(Drc)(r6P)
CONNECTOB
CONNECTOR
(2P)
S8S UNT TERMINALS
('98- 00M o d e l s )
3
10 11
14 15
17 18
T e r m i n a sl i d eo f m a l et e r m i n a l s
www.emanualpro.com
24-18
GRY
Precautions/Procedures
GeneralPrecautions
Airbags
Cablereel
SRSunit
Seatbelttensioners
Airbag/SeatBeltTensioner
Handlingand Storage
Do not try to disassemblean airbag or a seat belt tensioner.They have no serviceableparts.Once an airbag
or a seatbelttensionerhavebeendeployed.they cannot
be repairedor reused.
For temporarystorageof an airbag or a seat belt tensioner during service,pleaseobservethe following precautons:
.
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AIRBAGCONNECTORS
Precautions/Procedures
SRSUnit Precautions
Takeextracarewhen paintingor doing body work in
the area belowthe dashboard.Avoid directexposure
of the SRS unit or wiring to heat guns, welding, or
sprayingequipment.
Disconnectthe driver's/frontpassenger'sairbagconnectors and seat belt tensioner connectorsbefore
working belowthe dashboardnearthe SRSunit.
After any degreeof frontal body damage,or after a
collisionwithout airbagdeployment,inspectthe SRS
unit for physicaldamage.lf it is dented,cracked,or
detormed,reolaceit,
InspectionAfter Deployment
After a collision in which the airbags were deployed.
replacethe SRSunit,and inspectthe following:
1.
2.
3.
rD
www.emanualpro.com
24-20
Wiring Precautions
.
Spring-loadedLock Connestorwith
Built-in Short Gontact
SHORTCONTACT
CABIf REELCONNECTOR
M a k e s u r e a l l S R Sg r o u n d l o c a t i o n sa r e c l e a na n d
groundsare securelyfastenedfor optimum metal-tometalcontact.Poorgroundingcan causeintermittent
problemsthat are difficultto diagnose.
CONTACT
CONTACT
www.emanualpro.com
24-21
Precautions/Procedures
Spring-loadedLockConnectors
BackprobingSpring-loadedLock
Connectors
lock.
SomeSRSsystemconnectorshavea spring-loaded
.
Disconnecting
To releasethe lock,pull the spring-loaded
sleevetoward
the stop while holdingthe oppositehalt of the connector.
Then pull the connectorhalvesapart.Be sure to pull on
the sleeveand not on the connectorhalf.
SPRING-LOADED
SLEEVE
RETAINER
*Discardafter removal.
Connecting
1.
RETAINEN
www.emanualpro.com
24-22
RETAINER
) 1 ,
andthe SeatBeltTensionerConnectors
Disconnecting
the AirbagGonnectors
Beforeremovingthe airbagor SRSrelateddevices(the SRSunit,the cablereeland the seatbelttensionerconnector),disconnectingconnectorsfrom relateddevices,or removingthe dashboardor the steeringcolumn, disconnectthe airbag
connectorsand seatbelttensionerconnectorsto Dreventaccidentaldeployment
Turn the ignition switch oFF and disconnect ths nogative cable from the battery, and wait at least ihree
@
minutes before beginning the tollowing proceduresA and B. lprocedure B follows the procedureA.l
Beforedisconnecting
the SRSmain harnessfrom the SRSunit,disconnectboth airbags(C,D) and both seatbelttensioners
(F,H) {'98- 00 models).
the cablereel2P connector(B),disconnectthe driver'sairbagconnector(C).
Beforedisconnecting
the left side wire harness2P connector(E).disconnectthe driver'sseat belt tensioner2P connector
Beforedisconnecting
(F)('98- 00 models).
seatbelttensioner2P
Beforedisconnecting
the right side wire harness2P connector(G),disconnectthe tront passenger's
(H)
('98
connector
00 models).
SRSMA1NHARNESS
i---
Jl
Jl
----l
l*",r*
I I
LEFTSIDE
WIREHARNESS
{cont'd)
www.emanualpro.com
24-23
Precautions/Procedures
Disconneeting
the AirbagConnectorsand the Seat BeltTensioner
Connectors(cont'd)
1.
CLIPS
ACCESSPANEL
DRIVER'S
AIRBAG
2PCONNECTOR
Front Passsng/sAirtag:
. Disconnectthe 2P connectorbetweenthe front
passenger's
airbagand SRSmain harness.When
disconnected.
the airbagconnectoris automaticallYshorted.
DRIVER'SSIDE:LEFTSloE WIREHARNESS
SIDE:RIGHTSIDEWIRE
FRONTPASSENGER'S
HARNESS
24-24
www.emanualpro.com
Steering-related
Precautions
Stooring Whel and Csble Re6lAlignmnt
T o a v o i d m i s a l i g n m e n to f t h e s t e e r i n gw h e e l o n
reassembly,make sure the wheels are turned straight
aheadbeJoreremovingthe steeringwheel.
NOTE:
. Whenthe airbagand cabler6elare disconnected,
and
the batteryis reconnectedand the ignition switch is
turned ON (ll),the SRSunit will storethis as an open
in the driver'sairbag inflator,and the SRS indicator
light will come on, In such a case,makesure to confirm the DTC,then clearthe SRSunit memory.
. For disconnectingthe spring-loadedlock type connector, refer to page24-22.
'97
model:
SRSMAIN HARNESS
2P CONNECTOR
CABLEREEL
2P CONNECTOR
'98 - 00 models:
LABEL
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UNDER-DASH
FUSE/RELAY
BOX
Do not replacethe originalsteeringwheelwith any other
d e s i g nb e c a u s ei t w i l l m a k e i t i m p o s s i b l et o p r o p e r l y
installthe airbag(use only genuineHondareplacement
partsl.
After reassemblv,confirm the wheels are still turned
straightaheadand that the steeringwheel spokeangle
is correct.lf minor spokeangleadjustmentis necessary,
do so only by adjustingthe tie-rods,not by removing
and repositioning
the steeringwhee .
24-25
Troubleshooting
Self-diagnostic
Procedures
The self-diagnosticfunction of the SRSsystem allows it to locatethe causesof system problems and to store this information in memory,For easiertroubleshooting,
this datacan be retrievedvia a data linkcircuit.
When you turn the ignitionswitchON (ll).the SRSindicatorwill come on. lf it goes off aftersix seconds,the systemis
normal.
. lf there is 8n abnormality,the system locatesand definesthe problem.storesthis informationin memory,and turns
the SRSindicatorlight on. The datawill remainin the memoryevenwhen the ignitionswitchis turned off or if the batterv is disconnected.
. When you connectthe SCSserviceconnectorto the servicecheckconnector(2P),and turn the ignitionswitchON (ll),
the SRSindicatorlight will indicatethe diagnostictroublecode (DTC)by the numberof blinks.
. After readingand recordingthe DTC,proceedwith the troubleshooting
forthis code.
.
Precsutions
. Useonly a digitalmultimeterto checkthe system.lf it's not a Hondamultimeter.makesure its outputis 10 mA (0.01A)
or lesswhen switchedto the smallestvalue in the ohmmeterrange.A testerwith a higheroutput could damagethe
airbagcircuitor causeaccidentalairbagdeploymentand possibleinjury.
. Wheneverthe ignitionswitchisON (ll).or has beenturnedOFFfor lessthan three minutes,be carefulnottobumpthe
SRSunit;the airbagscouldaccidentally
deployand causedamageor injuries.
. Beforeyou removethe SRSmain harness,disconnectthe airbagand tensionerconnectors(seepage24-23).
. Make sure the battery is sufficiently charged (see section 23). lf the battery is dead or low, measuringvalues won't be
correct.
. Do not touch a testerprobeto the terminalsin the SRSunit or harnessconnectors,and do not connectthe terminals
with a jumperwire. Use only the backprobeset and the SCSserviceconnector.
For backprobingspring-loadedlock type connectors,.efet to page 24-22.
Readingthe DTC
Whenthe SRSindicatorlight is on, readthe DTCusingone of thesemethods;
A.
Connectthe HondaPGM Testerto the 16PData Link Connector{DLC),and follow the tester'sprompts.lf the tester
indicatesno DTC,DTC9-1 and DTC9-2,double-check
by jumping the servicecheckconnector(2P)and watchingthe
SRSindicatorlight (seenext page).
DATA LINKCONNECIOR{DLCI{16P)
HONDAPGM TESTER
24-26
www.emanualpro.com
)
B . The SRSindicatorlight can also indicatethe DTCby the numberoJ blinkswhen the SCSserviceconnectoris connecred to the servicecheckconnector(2P).
1 . Turn the ignitionswitchOFF,and wait for ten seconds.Then connectthe SCSserviceconnectorto the servicecheck
connector{2P).lf you do not wait ten seconds.the SRSunit will not be completelyresetand will not outputDTCS.
SEBVICECHECKCONNECTOR
I2PI
IALK,BRNI
SEBVICECONNECTOR
07PAZ- 0010100
2.
3.
4.
Turn the ignitionswitchON (ll).The SRSindicatorlight comeson for aboutsix secondsand then goesoff. Then it will
indicatethe DTC:
- The DTCconsistsof a main code and a sub-code.
- Includingthe most recentproblem,up to threedifferentmalfunctionscan be indicated.
- In caseof a continuousfailure.the DTCwill be indicatedrepeatedly(seeexample1 below).
- In caseof an intermittent
failure,the SRSindicatorlightwill indicatethe DTCone time,then it will stayon (seeexarnpte2 below).
- lf both a continuousand an intermittentfailureoccur,both DTCSwill be indicatedas continuousfailures.
- In casethe systemis normal {no DTC),the SRSindicatorlight will stay on (seeexample3).
Readthe DTC.
Turn the ignitionswitchOFF.and wait for ten seconds.Then disconnectthe SCSserviceconnectorJromthe service
checkconnector(2P).
Examplesof DTCIndications:
1.
Continuousfailure,SRSIndicatorLight is:
0.3s
--1 M.h@de
r-
-r f-
DTC21
Mo6t r.@nl p.oblem
2.
--l fl-!
Sub-code (2)
D T Cr . 2
-l
--l F
Sub-cod6ltl
otc I r
Third.mGr .oconl
Intermittentfailure,SRSIndicatorLight is:
DTC5,1
3.
www.emanualpro.com
24-27
Troubleshooting
Erasingthe DTCMemory
To erase the DTC{S)from the SRS unit, use a Honda
P G M T e s t e r( s e et h e H o n d aP G M T e s t e rS R SV e h i c l e
SystemSupplement)or the followingprocedure.
1.
2.
TroubleshootingIntermittent
Failures
lf there was a malfunction.but it doesn'trecur,it will be
storedin the memory as an intermittentfailure,and the
SRSindicatorlight comeson.
After checkingthe DTC,troubleshoot as follows:
Readthe DTC(see"Readingthe DTC").
1.
E r a s et h e D T C m e m o r y ( s e e " E r a s i n g t h e D T C
Memory").
With the shift leverin neutral,turn the ignitionswitch
ON (ll),and let the engineidle.
3.
4 . The SRSindicatorljght comeson for about six seconds and then goesoff.
MEMORYERASE
SIGNAL(MES}CONNECTOR
I2PI
IGRY,GRYIor IGRN,GRNI
SCSSERVICE
CONNECTOR
07PAZ- 0010100
3.
4.
5.
6.
7.
L
ON
t*F
l
--- _l
-+t
6!.c
l.-
,l sec or less
Problemrecurs,light stayson.
SRSindicator
liqtfi
OFF
MES
connac'lol
terminals
CONNECTED
6.
OISCONNECTEO
:-
24-28
www.emanualpro.com
DiagnosticTroubleCode(DTG)Ghart-'97 model
SRS indicator light
doesn'tcome on
DTC
none
(doesn't
come on)
none*'
(doesn't
go off)
Corroctiveaction
Slc pago
FaultySRSindicatorlight circuit
Troubleshooting
24-34
FaultySRSindicatorlight circuit,internal
tailureof SRSunit,faultySBS powersupply
Troubleshooting
24-37
Pos3iblscause
24-50
in the driver'sairbag
Increasedresistance
inflator
24-50
doesn't go off
www.emanualpro.com
24-52
24-54
24-56
airbaginflator
Open in the passenger's
24-58
airbag
Increasedresistancein the passenger's
inflator
24-54
Troubleshooting
Troubleshooting
24-60
2-4
airbag
Shortto power in the passenger's
inflator
24-62
2-5
airbag
Shon to ground in the passengar's
inflator
24-64
(cont'd)
24-29
Troubleshooting
DiagnosticTroubleCode(DTC)Chart-'97 model (cont'dl
SRS indicator light
DTC
Possiblecause
Correstiveaction
See page
SRSunit replacement
24-96
SRSunit replacement
24-96
SRSunit replacement
24-96
SRSunit replacemenr
24-96
Troubleshooting
24-82
SRSunit replacemenr
24-96
9-2
FaultySRSpowersupply(VBline)
Troubleshooting
24-84
'101
SRSairbagsdeployed(SRSunit must be
replaced)
SRSunit replacement
24-96
5-3
5-4
5-5
o-l
6-2
6-4
doesn'tgo off
7-2
7-3
8-1
a-2
8-5
8-6
24-30
www.emanualpro.com
l*
TroubleCode(DTCIChart-'98 - 00 models
Diagnostic
SRSindicator light
doesnt come on
DTC
none
(doesn't
come on)
none*3
{doesn't
go off)
Correctivaagtion
See page
FaultySRSindicatorlight circuit
Troubleshooting
24-34
FaultySRSindicatorlight circuit.internal
failureof SRSunit,faulty SRSpower supply
( V Bl i n e )
Troubleshooting
24-42
Troubleshooting
24-47
Possiblscause
No DTC
(lightcomes
FaultySRSpower supply(VA line)
on afterselfdiagnosis)
Open in the driver'sairbaginflator
1-1
24-50
in the driver'sairbag
lncreasedresistance
inflator
1-3
1-4
1-5
2-1
2,4
3-1
3-2
3-4
4-1
4-3
4-4
4-5
www.emanualpro.com
Troubleshooting
24-52
24-54
airbaginflator
Open in the passenger's
airbag
in the passenger's
Increasedresistance
inflator
24-54
24-50
24-56
24-58
Troubleshooting
24-60
airbag
Shortto power in the passenger's
inflator
24-62
arrbag
Shortto ground in the passenger's
inflator
24-64
24-66
24-66
24-72
seatbelttensioner
Open in the passenger's
seat
in the passenger's
Increasedresistance
belttensioner
seat
Shortto anotherwire in the passenger's
belttensioner
Short to power in the passenger'sseat belt tensroner
seatbelt
Shon to groundin the passenger's
tensroner
24-14
24-64
24-10
24-74
Troubleshooting
24-76
24-74
24-AO
(cont'd)
24-31
Troubleshooting
l*-
DiagnosticTroubleCode(DTC)Chart-'98 - 00 modets(cont,dl
SRSindicator light
DTC
Po$ibla cause
Corroctivelction
Sec pag
SRSunit replacement
24-96
SRSunit replacement
24-96
SRSunit replacement
24-96
SRSunit replacement
24-96
SRSunit.eplacement
24-96
SRSunit replacement
code (SRSunit must not
be usedany longer)
SRSunit replacement
24-96
5-l
5-4
6-1
6-3
6-4
doesn'tgo off
8-1
8-2
8-3
8-4
8-6
9_2*2*3
10-1
1,.-
NOTE:
*1: In caseof an intermittentfailureDTCg-1,
it meanstherewas an internalfailureof the SRSunit or a faulw SRSindicator light circuit.Do the troubleshooting
for intermittentfailures(seepage2,+_2g),
*2: In caseof an intermiuentfairureDTc
9-2, it meansthere was an internarfairureof the power suppry(vB rine).Do the
troubleshooting
for intermittentfailures(seepage24-29).
*3: DTCcannotbe readwith a HondaPGM
Tester;checkby jumpingthe SCSservicconnector.
NOTE: Before troubleshooting DTCS5-1 through g-6. check battery/systemvoltage. lf voltage is low, repair the charg_
ing systembeforetroubleshooting
the SRSsystem.
\f
24-32
www.emanualpro.com
..
SRSIndicatorLightWireConnections
SRS Indicator Light Power Circuit
WIREHARNESS
DASHBOARD
YEL
BLK
To UNDER-DASH
FUSE/RELAYBOX <_
20PCONNECTOR
csog
To GAUGE
assEMBLy
SRSMAIN HARNESS
MAIN WIREHARNESS
V A I V B
I
t
To UNDER-DASH
FUSE/BELAYBOX
2P CONNECTOR
c414
c415
c502
c503
c509
c801
c803
c806
www.emanualpro.com
WIREHARNESS2OPCONNECTOR
DASHBOARD
WIREHARNESS24PCONNECTOR
OASHBOARD
DASHBOABDWIREHARNESS5P CONNECTOR
SRSMAIN HARNESS2P CONNECTOR
SRSMAIN HARNESST8PCONNECTOR
24-33
Troubleshooting
The SRSIndicatorLight Doesn'tComeOn
lr-
NO
Checkthe bulb:
Replacethe No.25 (7.5 A) fuse, and checkthat the
SRSindicatorlightcomeson.
Doesthe SRSindicator liqht come on?
YES
NO
END
Checkthe wire h.rnesi kwen fus.nd gauge .3sembly:
Checkfor an open in the wire harnessbetween fuse
No. 25 (7.5Al and the gaugeassembly,and repair.Check
that lhe SRSindicato.lighi
Doesthe SRSindic.tor liqht com6 on?
YES
NO
END
Checkthe SRSindicator light bulb:
1. Turnthe ignitionswitchOFF.
2. Removethe gaugeassembly.
3. Checklor blown SRSindicatortightbulb.
ls the SRSindicator tight bulb OK?
YES
NO
I YEs
No
:ND
(A)To page24-35
24-34
www.emanualpro.com
(B)To page24 35
lu
Jt
Frompage24 34
(A)
DASHBOARDWIREHARNESS
5P CONNECTOR
YES
NO
DASHBOARDWIREHARI{ESS
5P CONI{ECTOR
c509
MAIN WIREHARNESS
YES
NO
WIRE
DASHBOARO
HARNESS24P
CONNECfOR
Terminalsideof maleterminals
To page 24-36
(cont'd)
www.emanualpro.com
24-35
Troubleshooting
The SRSIndicatorLight Doesn'tComeOn (cont,dl
From page 24-35
MAIN WIREHARNESS
3P CONNECTOR
UNDER.DASH
FUSE/RELAY
BOX
'98 -
'97 modol:
SRSMAIN HARNSS
3P CONNECTOR
00 models:
MAIN WIREHARNESS
3P CONNECTOR
SRSMAIN HARNESS
3P CONNECTOR
SRSMAIN HARNESS
3P COI{NECTOB
c803
Checkth wire hahess of th6 SRSindicator ci.cuit {31:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe battery negative cable, then the positive
cable,and wait threeminutes.
3. Disconnectthe driver's and front passenger,sairbag connectors{anddisconnectthe seatbelt tensionerconnectors}
(seepage24-23).
4. Disconnectthe SRS main harness18p connectorfrom
5. Reconnectthe battery positive cable, then reconnectthe
negativecable.
6. Connecta voltmeterbetweenthe No. 6 terminal (+) of
the SRSmain harness'l8Pconnectorand ground.
7. Turnthe ignitionswitchON (ll),and measurevoltage.There
shouldbe 0.5V or less.
SRSMAIN HARNESS
18PCONNECTOR
24-36
www.emanualpro.com
FUSE/RELAY
BOX
NO
YES
YES
UNOER.DASH
FUSE/RELAYBOX
YES
SRSUNIT
NO
ENO
SRSMAIN HARNESS
r8P CONNECTOR
NO
(cont'd)
(A)
To page24 38
www.emanualpro.com
24-37
Troubleshooting
The SRSIndicatorLight Doesn'tGo Off - '97 model (cont,d)
Frompage24 37
(A)
Checkthe SRSunit:
Connectthe SRSmain harness18PconnectorterminalsNo.
6 and No.7 with a jumperwire and backprobe
SRSMAIN HARNESS18PCONNECTOR
JUMPERWIRE
(B)
To page24'39
Check for a short to ground in the SRS indicator tight circutl:
1. Turnthe ignitlonswitchoFF.
2, Disconnectthe dashboardwire harness5p connector
from the gaugeassembly.
3. Checkresistance
betweenthe No. 1 terminalofthe dash
board wire harness5P connectorand ground. There
shouldbe 1 MOor more.
Wlresidoot tomaleterminsls
)
DASHBOARDWIREHARNESS
5P CONNECTOR
(c)
To page 24-40
Shon to ground in th6 gaugo assembly;replacothe gau96
DASHBOANDWIRE HARI{ESS
5P CONNECTOR
c509
T
243a
www.emanualpro.com
Frompage24-38
{B)
DASHBOARDWIREHARNESS
5P CONNECTOR
DASHBOARDWIREHARNESS
5P CONI{ECTOR
Y;yfivvcsos
ffi
BLU
I
IYEL
JUMPERWIRE
Wir6.sideof female
lormrna|s
{D)
To page24-41
1E)
To page24-41
DASHBOARDWIREHARNESS
5P COI{NECTOR
(cont'd)
www.emanualpro.com
24-39
Troubleshooting
The SRSIndicatorLight Doesnt Go Off -'97 model {cont'dl
Frompage24-38
1C)
i,
MAIN WIRE
HARNESS24PCONNECTOR
OASHBOARD
WIRE
HARNESS
24PCONNECTOR
BLU
SRSMAIN HARNESS
3P CONNECTOR
UNDER.OASH
FUSE/RELAYBOX
SRSMAII{ HARI{ESS
3P CONNECTOR
cao3
Short to ground in tho main wire harnesr; ,opair th6
main wire hamoss.
24-40
www.emanualpro.com
)
DASHBOARDwlRE hARNESS
5P CONNECTON
From page24-39
(D)
YES
NO
DASHBOAROWIREHARI{ESS
5P CONI{EC'OR
c509
ness.
Frompage24-39
iE)
YES
NO
Terminalsideof malelerminals
NO
SRSMAIN HABNSS
3P CONNECTOR
www.emanualpro.com
24-41
Troubleshooting
tl-
NO
YES
NO
FUSE/RELAY
BOX
NO
END
SRSMAIN HARNESS18PCONNECTOR
NO
|
(A)
To page24 43
24-42
www.emanualpro.com
)
Ftom page 24-42
(A)
SRSUNIT
SRSMAIN HARNESS
Checkthe SRSunit:
Connectthe SRSmain harness18PconnectorterminalsNo.
3 and No.6 with a iumperwire and backprobe
Doesthe SRSindicator light go otf?
SRSMAIN HARNESS18PCONNECTOR
Did tuseNo. 23 {10A} blow?
JUMPERWIRE
1B)
fo page24-44
Wiresideof lemalelerminals
DASHBOAEDWIREHARNESS
5P CONNECTOR
(c)
To page24-45
Short to ground in the gauge assembly;replacethe gauge
DASHEOARDWIREHARNESS
5P CONNECTOR
c509
(cont'd)
www.emanualpro.com
24-43
Troubleshooting
The SRSIndicatorLight Doesn'tGo Off -'99 - 00 models(cont,d)
Frompage24,43
(B)
DASHBOARDWIREHARNESS
5P CONNECTOR
NO
YES
DASHBOARDWIREHANNESS
5P CONNECTOR
liTv;Tv;1c5i0s
#
lsru
lYEr
JUMPERw|RE
Wiresadeol lernale
rerminats
SRSMAIN HARNESS
18PCONNECTOR
NO
Wirsideot lemaleieminals
(D)
To page24-46
(E)
To page24-46
DASHBOARDWIREHARNESS
5P CONNECTOR
J
24-44
www.emanualpro.com
J
From page 24-43
1C)
MAIN WIRE
HABNESS2,lP CONNECTOR
WIRE
OASHBOARD
HARNESS
2,rP CONNECTOR
BLU
MAIN WIRE
3P CONNECTOR
Chcckfor a short to ground in the SRSmain harnoss:
1. Disconnectthe SRS main hart\ess3P connector{rom the
main wire harness,
2. Checkresistancebetween the No. 1 terminal of the SRS
main harness3P connectorand ground.Thereshouldbe
1 MOor more.
cToR
BOX
FUSE/RELAY
SRSMAIN HARNESS
3P CONIIECTOR
c803
Short to ground in the mlin wire harnoss; .epair lh
mlin wira harness.
)
(cont'd)
www.emanualpro.com
24-45
Troubleshooting
The SRSIndicatorLight Doesn'tGo Off -,99 - 00 models(cont,d)
Frcm page 24-44
{D)
J)
DASHBOARDWIREHARNESS
YES
NO
c5ott
Wiresideof lemale
terminals
Ftom lage24-44
(E)
NO
Torminalsideol maletermtnal
SRSMAIN HARNESS
18PCONNECTOR
c806
YES
NO
ca03
Open in the BLU wir6 of th6 main wire hernos3;reori.
the main wire hamess,
Open in the SRS main harness;rplacethe SRS main ha.noss.
24-46
www.emanualpro.com
SRSMAIN HARNESS
3P CONNECTOR
No DTC
CAUTION:Wheneverthe ignition switch is ON {lll, ol
has been tulned OFF for less than three minutes, bs
careful not to bump the SRS unit; the airbags could
accideniallydeploy and causedamago or iniuries.
Chckthe fuse:
1. Turnthe ignitionswitchOFF.
2. Checkfor blown No. 13 ('15A) fuse in the under-dash
Iuse/relay
box.
b th fuse OK?
YEs
NO
1A)To page24 48
Replacethe fuse.Turn the ignitionswitchON {ll),and check
that the luse doesn'tblow.
UNDER-DASH
FUSE/RELAYBOX
NO
SBSMAIN HARNESS
18PCONNECTOR
NO
SRSMAIN HARNESS18PCONNECTOR
(B)
To page24-48
www.emanualpro.com
(cont'd)
24-47
Troubleshooting
No DTC(cont'dl
1
ltofi
page 24-47
(B)
Chockfor short to ground in the SRSmain harne3s:
1. Disconnect
the SRSmain harness2P connectorlrom the
underdashfuse/relay
box.
2. Checkresrstance
betwoenthe No.7 terminalof the SRS
main harness18Pconnectorand ground.There should
be 1.0M0 or more.
k the ro3irtancc as specifid?
YES
NO
FUSE/RELAYBOX
J
(A)Frompage24-47
SRSMAIN HARNESS18PCONNECTOR
SRSMAIN HARNESS18PCONNECTOR
Poor conlact .t the SRS main harness l8P connesto.:
checkth6 connector,
. It the connector is OK, substitute a known-good SRS
unit, and rgcheck.
. It lhe problem ii still p.es6nt, rcplace the SRS mlin
hamess.
To page24-49
24-48
www.emanualpro.com
J 3
)
Frompage24-48
YES
NO
UNDER-DASH
BOX
FUSE/RELAY
c801
SRSMAIN HARNESS
2P CONNECTOR
www.emanualpro.com
24-49
Troubleshooting
DTC1-1and DTC1-2
J
DRIVEF'SAIRBAG
2P CONNECTOR
CABLEREEL
2P CONNECTOR
YES
NO
YES
SRSSIMULATOR
LEADC
07TAZ- SZ5011A
and SRSINFLATOR
SIMULATOR
t2 0 JACKI
07saz - TB40r1A
'98 - 00 models:
'97 modol:
CABLEREEL
2P CONNECTOR
NO
SRSMAIN
HARNESS2P
CONNECTOR
To page24'51
24-50
www.emanualpro.com
SRSSIMULATOR
LEADC
07TAZ- SZ5011A
and SRSINFLATOR
SIMULATOR
120 JACKI
07sAz - TB4011A
)
Frompage24 50
NO
SRSMAIN HARNESS
18PCONNECTOR
YES
NO
www.emanualpro.com
24-51
Troubleshooting
DTC1-3
J
YES
2P CONNECTOR
NO
SRSSIMULATOR
tfAD c
0?TAZ- SZ5olrA
and SRSINFLATOR
/SIMULATOR
/ Q a JACKI
07s,A-TB411A
/'
ffi
'97 model:
,98 - 00 models:
CABLE
REEL
2PCONNECTOR
NO
To pago 24-53
24-52
www.emanualpro.com
SRSSIMULATOR
LEADC
07TAZ- SZ50114
and SnS INFLATOR
SIMULATOR
{2 0 JACK}
07sAz - TB{011A
Frompage24-52
NO
YES
SRSUNIT
b th rsciitlnce
SRSMAIN HABNESS
18PCONNECTOR
a3 sDecifi6d?
YES
NO
( . ,L z l3 l l
Faulty SRSunit; rspl.c. th6 SRSunit l.co p.sc 2a-95,,
c806
15
18
Wiresideot
tormrnats
Shori in the SRS m.in h.rn.e!; ropbce the SRS main htrne33.
www.emanualpro.com
24-53
Troubleshooting
DTC1-4
ial
YES
REEL
2P CONNECTOR
NO
SIMULATOR
LEAD C
07TAZ- SZ5011A
.rd SRSINFIATOR
/SIMULATOR
./ ea JA0KI
1(
ffi
otstz-terore
ltl
'97 model:
'98 - 00 models:
CABLE
REEL
NO
SIMULATOR
I-EADC
07TAZ- SZ5011A
and SRSINFLATOR
SIMULATOR
(2 0 JACKT
07sAz - lB4011A
To page 24-55
!
24-54
www.emanualpro.com
Ftom page24-54
YES
NO
SRSMAIN HARNESS
18PCONNECTOR
NO
www.emanualpro.com
24-55
Troubleshooting
O'-
DTCl-s
CAUTION: Whenever tho igniiion switch is ON {ll), or
has been lurned OFF for loss lhan thrse minules, be
caretul not to bump the SRS unit; the airbags could
accidentallydeploy and causedamage or iniuries.
DRIVER'SAIRBAG
2P CONNECTOR
CAALEREEL
2P CONNECTOR
YES
NO
NO
ar
h /
ffi
'97 model:
SRSSIMULATOR
LEADC
07TAZ- SZ50r1A
.nd SRSINFLATOR
SIMULATOR
{2 0 JACK)
07sAz - TBaolrA
'98 - 0Omodels:
CABLE
REEL
2PCONNECTOR
SRSSIMULATOR
LEAOC
07TAZ- SZ5011A
and SRSINFLATOR
SIMULATOR
t2 0 JACKI
07sAz - TB{01rA
To page24-57
J..
24-56
www.emanualpro.com
)
Frompage24 56
YES
NO
SRSMAIN HARNESS
18PCONNECTOR
NO
www.emanualpro.com
24-57
Troubleshooting
DTC2-1 and DTC2-2
!a
SRSMAIN HARNESS
To page 24'59
24-58
www.emanualpro.com
y'
ffi
SIMULATOR
I-EADC
07TAZ- SZ5tt11A
and SRSINFLATOR
/StMULATOR
/ Q A JACKI
07slz-TA411A
)
Frompage24 58
sRsUNIT
NO
18PCONNECTOR
hatnesli,
www.emanualpro.com
24-59
Troubleshooting
DTC2-3
{J
SRSMAIN HARNESS
YES
NO
NO
Short to another wir6 or decaea3draktance in the oassenger's airbag intlatoi; replac the passenger'sairbag
{see pago 24-8t1.
To page24 61
24-60
www.emanualpro.com
y'
ffi
SIMULATOR
LEAD C
07TAZ- SZ50I1A
and SRSINFLATOR
/STMULATOR
/ I2n JACKI
07sAz-fB1011A
)
Frompage24 60
in
Ch6cktor a short to another wire or decreasodaGsistance
lh SRSmain harness:
1. Disconnectthe batterynegativecable,then disconnect
the positivecable,and wait for threeminutes.
2. Disconnectthe driver'sairbag2P connector(anddisconnect
both seatbelttensionerconnectors).
'18Pconnectorfrom
3. Disconnectthe SRS main harness
the specialtool (2 O).
the SRSunit.Do not disconnect
4. Checkresistance
betweenthe No. 10terminaland No. 14
terminalof the SRS main harness18Pconnector.There
shouldbe aoorox.2.0- 3.00.
ls the rosistanc6 as specified?
YES
NO
SRSMAIN HARNESS
18PCONNECTOR
www.emanualpro.com
24-61
Troubleshooting
Ot-
DTC2-4
GAUTION: Whnever tho ignition switch is ON 0t). or
has been turned OFF for less than threo minutes, bo
careful not to bump the SRS unit; the airbags could
accidentallydeploy and causedamaga or iniuriss.
SRSMAIN HARNESS
NO
YES
NO
To page24-63
24-62
www.emanualpro.com
SIMULAYOR
LEAD C
//
ffi
07TAZ- SZ5011A
.nd SRSINFLATOR
/stMU|_ATOR
/ t2 tr JAoKI
olsAz-Tsn11A
Frcm page24-62
Checklor a short to power in the SRSmain harness:
1. Disconnectthe batterynegativecable,then disconnect
the positivecable,and wait for threeminutes.
2. Disconnectthe drive/s airbag2P connector(anddisconnect
both seatbelttensionerconnectors).
3. Disconnectthe SRS main harness18Pconnectortrom
the SRSunit.
4. Removethe specialtool(2 0) from the SRSmain harness
2P connector,
5. Reconnectthe batterv positive cable,then reconnectthe
negativecable.
6. Connecta voltmeterbetweenthe No. 10 (+) terminalof
SRSmain harness18Pconnectorand ground.
7. Turn the ignition switch ON (ll). and measurevoltage
Thereshouldbe 0.5V or less.
8. Connecta voltmeterbetweenthe No. 141+)terminalof
the SRS main harness18Pconnectorand ground,and
measurevoltage.Thereshouldbe 0.5V or less.
sRs
.I8PCONNECTOR
NO
www.emanualpro.com
24-63
Troubleshooting
DTC2-5
tl
YES
NO
NO
To page24 65
24-64
www.emanualpro.com
ffi
SIMULATOR
LEAOC
07TAZ- SZ5011A
.nd SRSINFLATOR
/StMULATOR
/ t2 a JACKI
07saz-fB&11^
J
Frompage24'64
YES
NO
sRs
Faultv SRSuniu replacethe SRSunit {seepaqe 24-951.
18PCONNECTOF
www.emanualpro.com
24-65
Troubleshooting
DTC3-1and DTC3-2
DRIVER'S
SEATBELTTENSIONER
2P CONNECTOR
LEFTSIOEWIRE
HARNESS
2P CONNECTOR
NO
NO
Open or increasedresistancein the d.iver's seat belt tensioner; replacethe driver's seat belt {seepage 2il-91).
To page24 67
www.emanualpro.com
24-66
SRSSIMULA
LEADC
07TAZ- SZ501rA
andSRSINFLATOR
STMULAToR I
t2 0JACKI
I
oTsaz- TB4otlA t
)
Frompage24-66
YES
NO
LEFTSIDEWIRE
HARNESS
2P CONNECTOR
SRSMAIN
HARNESS
2P CONNECTOR
art
00
SRSSIMULATOR
LEADC
07TAZ- SZ5011A
and SRSINFLATOR
{2 0 JACKI
07sAz - T84011A
YES
NO
sRsUNIT
SRSMAIN HARNESS
.I8PCONNECTOR
)
terminals
www.emanualpro.com
24-67
Troubleshooting
DTC3-3
ra
ORIVER'S
SEATEELTTENSIONER
2P CONNECTOR
YES
NO
YES
NO
24-64
www.emanualpro.com
SRSSIMULATOR
LEAOC
07TAZ-525011A
and SRSINFLATOR
srMULAroR I
t2 0 JACK|
t
ozsAz- ls{orra !
LEFTSIDEWIRE
HARNESS
2P CONNECTOB
\.p
Frompage24-68
NO
LEFTSIDEWIRE
HARNESS
2P CONNECTOR
SRSMAIN
HANNESS
2P CONNECTOR
0a
I J
SRSSIMULATOR
LEADC
07TAZ- SZ5011A
and SRSINFLAToR
SIMULATOR
{2 0 JACK}
07sAz - TB4011A
YES
NO
SRSUNIT
SRSMAIN HARNESS
18PCONNECTOR
I J
lerminals.
www.emanualpro.com
24-69
Troubleshooting
DTC3-4
DRIVER'S
SEATBELTTENSIONER
2P CONNECTOR
YES
NO
YES
NO
To page24'71
24-70
www.emanualpro.com
SRSSIMULATOR
LEADC
07TAZ- SZ5011A
and SRSINFLATOR
SIMULATOR I
{2 o JACK}
I
ozsaz- tamrrl i
LEFTSIDEWIRE
HARNESS
2P CONNECIOR
)
Frompage24-70
Chocktor a short lo power in the sid wi.e harness:
1. Disconnect
the left sidewire harness2P connectorfrom
the SRSmain harness2P connector.
2. Connectthe sDecialtool {2 O) to the SRS maanharness
2P connector,
3. Erasothe DTCmemory.
4. Readthe DTC.
b DTC3-4 indiclted?
YES
NO
SRSMAIN
HARNESS
2P CONNECTOR
00
SRSSIMULATOR
LEAOC
07TAZ- SZ5011A
and SRSINFLATOR
YES
LEFTSIDEWIRE
HARNESS
2P CONNECTOR
(2 0 JACKI
07SAZ- TB/t011A
NO
SRSMAIN HARNESS
18PCONNECTOR
www.emanualpro.com
24-71
Troubleshooting
DTC3-5
*r
DRIVER'S
SEATBELTTENSIONER
YES
NO
YES
NO
To page2a-73
24-72
www.emanualpro.com
SRSSIMULATOR
LEADC
07TAZ-S25011A
and SRSINFLATOR
SIMULATOR
\
(2 0 JACK'
I
ozsnz-teronl t
)
Frcm page24-12
\r
LEFTSIDEwlRE
HARNESS
2P CONNECTOR
SRSMAIN
HARNESS
2P CONNECTOR
00
/
I
SRSSIMULATOR
LEADC
07TAZ- SZ5011A
and SRSINFLATOR
SIMULATOR
/ (2 o JACK)
07sAz - TB4o11A
SRSMAIN HABNESS
18PCONNECTOR
www.emanualpro.com
24-73
Troubleshooting
DTC4-1and DTC4-2
!|
FRONT
PASSENGER'S
RIGH1SIDEWIRE
HARNESS
2P CONNECTOR
NO
YES
NO
fo page24-75
24-74
www.emanualpro.com
SRSSIMULATOR
LEADC
07TAZ- SZ5n11A
andSRsINFLATOR
SIMULATOR
/izo.ncri
-
ozsAz T8.011A
)
Ftom page 2!-7a
YES
NO
"r$
YES
RIGHTSIDEWIRE
HARNESS
2P CONNECTOR
SRSMAIN HARNESS
2P CONNECTOR
SRSSIMULATOR
LEADC
07TAZ- SZ5011A
.nd SRSINFLATOR
SIMULATOR
(2 0 JACK)
07sAz - TB4011A
NO
SRSMAIN HABNESS
18PCONNECTOR
)
le.minals.
www.emanualpro.com
24-75
Troubleshooting
DTC4-3
FRONT
PASSENGER'S
RIGHTSIDEWIRE
HARNESS
2P CONNECTOR
NO
YES
NO
To page24-77
24-76
www.emanualpro.com
SRSSIMULATOR
LEADC
07TM - SZ5011A
and SRSINFLATOR
SIMULATOR
/2 o JACKI
l07sAz - TB4011A
tt2s>,-ar'
na
--\>
Frompage24-76
RIGHTSIOEWIRE
HARNESS
2P CONNECTOR
NO
SRSMAIN
2P CONNECTOR
SRSSIMULATOR
LEADC
07TAZ- SZ50114
and SRSINFLATOR
SIMULATOR
{2 0 JACK)
07saz - Ta1ol1A
YES
NO
SBSMAIN HARNESS
18PCONNECTOR
l;
www.emanualpro.com
c806
15
iid of {6male
terminals,
24-77
I
Troubleshooting
DTC4-4
CAUTION:Wheneverthe ignition switch is ON (ll), or
has been turned OFF tor less than thlee minutes. be
careful nol to bump the SRS unit; the airbags could
accidontallydeploy and causedamage or iniuries.
RIGHTSIDEWIRE
HARNESS
2P
FRONT
PASSENGER'S
vEs
NO
YES
NO
Short to power in the front passong6r'3seat belt tensioner; replacethe front passongar'3sat beh {see page
21-31.
To page24'79
24-78.
www.emanualpro.com
SRSSIMULATOR
LEADC
07TAZ- SZ5011A
and SRSINFLATOR
,StMULATOR
/(2 o JACK)
t _07SAZTBiro11A
)
Ftom page24 78
NO
) J
RIGHTSIDEWIRE
HARNESS
2P CONNECTOR
SRSMAIN
2P CONNECTOR
SBSSIMULATOR
LEADC
07TAZ- SZ5011A
and SRSINFLATOR
SIMULATOR
\
(2 0 JACK)
\
07sAz-T84011A
NO
www.emanualpro.com
24-79
Troubleshooting
DTC4-5
RIGXTSIOEWIRE
HARNESS
2P
FRONT
PASSENGR'S
YES
NO
YES
NO
Short to ground in the Lont passengc.'33rt boh tonsioner; replacetho from p.rlenger's sort beh lsa page
21-3t.
To page24-81
24-80
www.emanualpro.com
SRSSIMULATOR
LEADC
07lAz - s25011A
and SRSINFLATOR
SIMULATOR
t2 0 JACKT
o?saz- Taaol1A
Frompage24'80
YES
NO
RIGHTSIDEWIRE
HARNESS
2P CONNECTOR
SRSMAIN HARNESS
2P CONNECTOR
SRSSIMULATOR
LEADC
07TAz- SZ5011A
and SRSINFLATOR
SIMULATOR
\
{2 0 JACK}
\
07SAZ-TB,O114
ffi
4. Disconnect
the specialtool (2 0) from the SRSmain harness2Pconnector.
5. Checkresistancebetweenthe No. 5 terminal oI the SRS
m a i n h a r n e s s1 8 Pc o n n e c t o ra n d b o d y g r o u n d ,a n d
betweenthe No. 12 terminalof the SRS main harness
18Pconnectorand body ground.Thereshouldbe 1 M0
or more,
b th re3i3tance as specified?
YES
NO
www.emanualpro.com
24-81
Troubleshooting
DTC8-6 -'97
model
\
YES
NO
NO
To page 24-83(A)
24-82
www.emanualpro.com
18PCONNECTOR
)
Frompage24-82iA)
YES
NO
www.emanualpro.com
24-83
Troubleshooting
DTC9-2-'97 model
\
CAUTION: Whenever the ignition switch is ON flll, or
has been turned OFF tor loss than thrse minute3, bs
careful not to bump the SRS unit; lhe airbags could
accidentallydoploy and causodamage or iniuriss.
Ch6ckthe tuso:
1. Turnthe ignitionswitchOFF.
2. Checktor blown No. 23 (10 A) fuse in the !nder-dash
Iuse/relaybox.
(A)To page24-85
Replacethe fuse.Turn the ignitionswitchON {ll},and chck
thatthe fusedoesnt blow.
sRs
18PCONNECTOR
To page 24-85
24-84
www.emanualpro.com
YES
NO
FUSE/RELAY
BOX
SRSMAIN HARNESS
18P CONI{ECTOR
To page 24'86
www.emanualpro.com
(cont'd)
24-85
Troubleshooting
DTC9-2-'97
model lcont'dl
Frompage24-85
NO
UNDER.OASH
FUSE/RELAY
BOX
SRSMAII{ HARI{ESS
2P CONNECTOR
24-86
www.emanualpro.com
Driver'sAirbag
Replacement
After a collisionin which the airbagswere deployed,the
airbags,the seat belt tensioners(if so equipped),and
the SRSunit must be replaced.
Store a removed airbag with the pad su.@
tacs up, lf th airbag is improperly stored face down.
accidental deployment could propal the unit with
enough forc io causgseriouginiury.
3.
DRIVER'S
CAUTION:
. Always disconnoct the drivor's airbag connector
when the SRSmain harnessis disconnactod.
. Do not disassembleor tamper with ihe airbag.
NOTE:
Do not install used SRSparts from anothervehicle,
When repairing,useonly new SRSparts.
Carefullyinspectthe airbag beforeyou install it. Do
not install an airbag that shows signs of being
droppedor improperlyhandled,suchas dents,cracks
or deformation.
1 . Disconnectthe batterynegativecable,then disconnect the positive cable from the battery, and wait at
leastthree minutes.
Remove the access panel from the steering wheel.
then disconnectthe 2P connector between the drivthe
er'6 airbag and cable reel.When disconnected.
shorted.
airbagconnectoris automatically
ACCESSPANEL
2P CONNECTON
(cont'd)
www.emanualpro.com
24-87
Driver'sAirbag
Replacementlcont'd)
CAUTION: 8. sure to instattthe SRSwiring so that it is
not plnched or inlerfsring with other parts.
4.
5.
P l a c et h e n e w d r i v e r ' s a i r b a g i n t o t h e s t e e r i n g
wheel, and secure it with new Torx bolts.
C o n n e c tt h e d r i v e r ' sa i r b s g 2 p c o n n e c t o rt o t h e
c a b l e r e e l 2 P c o n n e c t o r ,t h e n i n s t a l l t h e a c c e s s
panelon the steeringwheel.
TORXEOLTS
9.8N,m11.0kgl.m,7.2tbf,ftl
Feplace.
2PCONNECTOR
24-88,
www.emanualpro.com
Airbag
Front Passenger's
Replacement
After a collisionin which the airbagswere deployed,the
airbags,the seat belt tensioners(if so equipped),and
the SRSunit must be reolaced.
store a rsmovod airbag with lhe pad sur@
face up, It the airbag is improporly stor6d face down,
accidental doploymnl could propsl ths unit with
gnough forco to causeserious iniury.
CAUTION:
. Always disconnsqt the front pa3s6ng6r'3airbag connoctor when tho SRSmain harnessis disconnocted,
. Do not disassambl6or tamper with tho airbag,
FRONTPASSENGER'S
NOTE:
. Do not install us6d SRSparts from anothervehicle.
When repairing,useonly new SRSparts.
. Carefullyinspectthe airbag beforeyou install it. Do
not install an airbag that shows signs of being
droppedor improperlyhandled,suchas dents,cracks
or deformation.
1.
Disconnectthe battery negative cable, then disconnect the positive cable from the battery. and wait at
leastthree minutes.
Removethe glove box (seesection 20).
Disconnect
the 2P connectorbetweenthe front Dassenger'sairbag and SRS main harness,When disconnected,the airbag connector is automatically
shorted.
FRONT
PASSENGER'S
FRONTPASSENGER'S
AIRBAG
MOUNNNG NUTS
(cont'd)
www.emanualpro.com
24-49
Front Passenger's
Airbag
Replacement(cont'd)
GAUTION: Be sure to installthe SRSwiring so that it is
not pinched or interfering with olher parts.
6.
7.
P l a c et h e n e w f r o n t p a s s e n g e r ' sa i r b a g i n t o t h e
d a s h b o a r dT. i g h t e nt h e f r o n t p a s s e n g e r ,as i r b a g
mountrngnuts.
FRONTPASSENGER'S
FRONTPASSENGER'S
FRONTPASSENGER'S
AIRBAGMOUNTINGNUTS
9.8 N.m {1.0kgJ.m,7.2lbf ft)
Replace.
24-90
www.emanualpro.com
CableReel
Replacement
CAUTION:
. Always disconnect the airbag connector whgn the
SRS msin harnessis disconnoctod.
. Do not disassembloor tamper with the airbag.
TORXBOLTS
Use a Torx T30 bit.
DRIVER'S
DRIVER'SDASHBOARDLOWERCOVER
5.
*f
www.emanualpro.com
(cont'd)
24-91
GableReel
Replacement(cont'dl
6,
Disconnect
the connectorsfrom the horn and cruise
control sevresumeswitches.
8. Removethe columncovers,
cRursE
coNtRoL
SET/RESUME
SWITCHCONNECTOR
2P CONNECTOR
COVER
1.
STEERING
STEERINGWHEELBOLT
39 N.m 14.0kgf.m.29 lbf.ftl
CAALEREELSU8
HARNESS
3P l6PlCONNECTOR
[ ]:,98_00modets
10. Remove the cable reelfrom the cotumn,
24-92
www.emanualpro.com
)o
NOTE:
. Before installing the steering wheel, the front
wheelsshouldbe alignedstraightahead.
. Be sure to installthe harnesswires so that they
are not pinchedor interfering with other parts.
. After reassemblv,confirm that the wheels are
still turned straightaheadand that the steering
wheel spokeangle is correct(roadtest).lf minor
do so only
spokeangleadjustmentis necessary,
by adjustingthe tie-rods,not by removing and
repositioning
the steeringwheel,
1 3 . Installthe steeringcolumncovers.
1 4 . lf necessary,center the cable reel. {New replacement cable reels come centered,lDo this by first
rotating the csble reel clockwise until it stops, Then
rotate it counterclockwise(approximatelytwo and a
half turns) until the arrow mark on the cable reel
labelpointsstraightup.
VERIC AL
PR(NECNONS
)...0
t5.
I l: 38 - 00 models
't2. Carefullyinstallthe cable reel on the steeringcolumn shaft. Then connectthe 3P t6Pl connectorto
the cablereel sub harness,and connectthe 2P connectorto the SRSmain harness.
(cont'd)
www.emanualpro.com
24-93
CableReel
(cont'dl
Replacement
1 6 . T i g h t e nt h e s t e e r i n gw h e e l b o l t t o t h e s p e c i f i e d
torque,and connectthe horn connectorto the steer
ing wheel.Then installthe driver'sairbag.
TORXBOLTS
9.8N.m(1.0kgd.m,7.2
lbnftl
Replace.
DRIVER'S
Turn the ignitionswitch ON (ll);the SRS indicator light should come on for about six seconds
and then go off.
a Makesure both horn buttonswork.
. Go for a test drive.and makesurethe cruisecontrol switcheswork.
STEERING
WHEELBOLT
38 N.m (3.9kgl.m,28lbf.ftl
Replace.
BOLSTER
l'98 - 00 modalsl
DRIVER'SDASHEOARDLOWERCOVER
24-94
www.emanualpro.com
SRSUnit
).0
Replacement
CAUTION:
. Before disconnecting any part of the SRS wire harnesg,disconnectthe airbag connoctors (and soat beh
tensioner connectorsl.
. During installation or replacament,do not bump
(impact wrench, hammer etc.) the area near the SRS
unit.
Do not damage the SFS unit terminalg or connsclors.
Do not disassemblethe SRS unit it has no saryiceable parts,
a Store the SRS unit in a clean,dry area.
a Do not use any SRS unit which has been subiected
to water damage or shows signs ot being dropped or
improperly handlgd, such as dents, cracks or deformation.
'1.
2.
Disconnect
the airbagconnectors(andseatbeltten(Whendisconnected,
sionerconnectors).
the airbag
and seat belt tensionerconnectorsare automatically shorted.)
3.
SRSUNIT
TORX
AOLTS
Use a Torx
T30 bir.
COVER
Driver's Side:
. R e m o v e t h e a c c e s sp a n e l f r o m t h e s t e e r i n g
w h e e l , t h e n d i s c o n n e c tt h e 2 P c o n n e c t o r
betweenthe driver's airbag and cable reel (see
page 24-231.
Front Passenger'sSide:
. Disconnectthe 2P connectorbetweenthe front
passenger'sairbag and SRS main harness(see
page 24-231.
Soat Beh Tensionor('98 - 00 modelsr:
. Removethe left and right centerpillar lowertrim
panels(seesection20).
. Disconnect
the seat belt tensioner2P connectors
from the left sidewire harness(driver'sside)and
the right wire harness(front passenger'sside)
(seepage24'231.
sRs
HARNESS
18PCONNECTOR
TORX
BOLTS
Us a Torx
T30 bir.
stoE
COVER
) o
www.emanualpro.com
24-95
SRSUnit
(cont'dl
Replacement
6.
l n s t a l lt h e n e w S R S u n i t . l f t h e T o r x b o l t s y o u
r e m o v e di n t h e p r e v i o u ss t e p h a v e r e d t h r e a d s ,
replacethe Torx bolts.
TORXBOLTS
9.8 N.m {1.0 kgf.m,?.2
Use . Torx T30 bh,
SRSUNIT
TORXBOLTS
9.8N.m11.0
kgf.m,7.2
lbtft)
Usoa TorxT30bit.
7.
8.
24-96
www.emanualpro.com
Airbag/SeatBelt Tensioner
)
Disposal
Beforescrappingany airbags{and seat belt tansioners)
(includingthose in a whole vehicleto be scrappedl.the
airbags(and seat belt tensioners)must be deployed.lf
the vehicleis still within the warrantvoeriodthe Honda
District ServiceManager must give approval and/or special instructions,
beforeyou deploythe airbags(andseat
belttensioners).
Only afterthe airbags{andseat belttensioners)havebeendeployed(asthe resultof vehiclecollision,for example),canthey be scrapped.
lf the airbags (and seat belt tensioners)appear intact
(not deployed),treatthem with extremecaution.
Followthis procedure:
6.
DRIVER'S
AIBBAG
FRONTPASSENGER'S
AIRBAG
1.
AI.IIGATOR
cuPs
lY6llowl
At lcast
thirty feot
110motersl
(cont'd)
www.emanualpro.com
24-97
Airbag/SeatBelt Tensioner
Disposal(cont'dl
1.
It the green light on the tool comes on, the airbag ignitercircuitis defectiveand cannotdeploy
t h e a i r b a g .G o t o D a m a g e dA i r b a g S p e c i a l
Procedure.
. l f t h e r e d l i g h t o n t h e t o o lc o m e so n ,t h ea i r b a gi s
readyto be deployed.
P u s h t h e t o o l ' s d e p l o y m e n ts w i t c h . T h e a i r b a g
should deploy (deploymentis both highly audible
and visible;a loud noise and rapid inflationof the
bag,followedby slow deflation).
.
.
'L
2.
3.
CAUTION:
. Wear a faco shield and gloves when handling a
deployedairbag.
. Wash your hands and rinse them well with
water after handling a deployed airbag.
5.
DeploymentTool: CheckProcedure
l.
www.emanualpro.com
24-98