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com

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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
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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

Vehicle ldentification Number


and CanadianMotor Vehicle

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

Safety Standard Certification.


lrl ..V

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

Vehicle ldentification Number


and Canadian Motor Vehicle
Safety Standard Certification.

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

8208 4:2.0| DOHCSequentialMultiport


engine
Fuel-injected

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

Vohicle ldentification Number


and Canadian Motor Vohicle

EternalBlue Pearl
NighthawkBlackPearl
CloverGreenPearl
SebringSilverMetallic
MilanoRed
NaplesGold lVetallic

OOLORLABEL

tNrcoL0R

TYPEF

COLOR
EXT.

B-92P

KCS2BC2 C

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1-9

ldentificationNumberLocations

Vehiclldentific.tion Number tvtNl

VehicleldentificationNumber lVlNl

TransmissionNumb6r lManudl)

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1-10

TransmissionNumbor {Aulomaticl

EngineNumbel

Warning/CautionLabelLocations

A: CABLEREELCAUTION

OF THE SRSCABLEREELIS CRITICAL


TNSTALLATION
TO THE PBOPEROPERATIONOF THE SRS SYSTEM.
REFERTO THE SERVICEMANUAL FOR DETAILED
INSTALLATIONINSTRUCTIONS.
B: DRIVERMODULEDANGER
A DANGER
EXPLOSIVE/FLAMMABLE
CONTACTWITH ACID, WATEROR HEAVY METALS
S U C H A S C O P P E R ,L E A D O R M E R C U R YM A Y
PRODUCEHARMFULAND IRRITATINGGASESOR
EXPLOSIVECOMPOUNDS.STOMGE TEMPERATURES
M U S T N O T E X C E E D2 O O " F{ 1 O O ' C }F. O R P R O P E R
HANDUNG,STORAGE,AND DISPOSALPROCEDURES.
REFERTO SERVICEMANUAI- SRSSUPPI.EMENT,
POTSON
C O N T A I N S P O I S O N O U SS O D I U M A Z I D E A N D
POTASSIUMNITRATE.
FIRSTAID
tF CONTENTS ARE SWALLOWED, INDUCE
VOMITING.FOR EYE CONTACT,FLUSH EYESWITH
WATERFOR 15 MINUTES.IF GASES IFROMACID
OR WATER CONTACTIARE INHALED,SEEK FRESH
A I R . I N E V E R YC A S E , G E T P R O M P T M E D I C A L
ATTENTION.
KEEPOUT OF REACHOF CHILDREN

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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.

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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)

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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

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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'

| \6( Zror '.

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

50ST (50 Statesl:


TO U.S.EPAAND STATEOF
CONFOBMS
THISVEHICLE
C A L I F O R N IR
A E G U L A T I O NASP P L I C A B LTEO 1 9 9 7
MODELYEARNEWLIGHTDUTYTRUCKS.
49ST{49 Statos/Federall:
TO U.S.EPA REGULATIONS
CONFORMS
THISVEHICLE
YEARNEW LIGHTDUTY
TO 1997IVIODEL
APPLICABLE
TRUCKS.
CAL (Calitornial:
TO U.S.EPAAND STATEOF
CONFORMS
THISVEHICLE
TO '1997
APPLICABLE
I
A
R
E
G
U
L
A
T
I
ONS
CALIFORN
M O D E LY E A R N E W T L E V L I G H T D U T Y T R U C K S
THAT THISVEHICLEIS ONLY INTRODUCED
PROVIDED
I N T O C O M M E R C EF O R S A L E I N T H E S T A T E O F
CALIFORNIA.

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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

50ST {50 States}:


THISVEHICLE
CONFORMS
TO U.S.EPAAND STATEOF
C A L I F O R N I AR E G U L A T I O N S
APPLICABLE
TO 1998
MODELYEARNEWLIGHTDUTYTRUCKS,
/$ST (itg Statos/Fodsrsll:
THISVEHICLE
CONFORMS
TO U.S.EPA REGULATIONS
APPLICABLE
TO 1998MODELYEARNEW LIGHTDUTY
TRUCKS.
CAL {California}:
THISVEHICLE
CONFORMS
TO U.S.EPAAND STATEOF
C A L I F O R N I AR E G U L A T T O NASP P L I C A B L E
TO 1998
M O D E LY E A R N E W T L E V L I G H T D U T Y T R U C K S
PROVIDED
THATTHIS VEHICLEIS ONLY INTRODUCED
I N T O C O M M E R C EF O R S A L E I N T H E S T A T E O F
CALIFORNIA.

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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

AISIRVI TAI{I\.NOI THEMDIAIOR

s,5TEM
8r!D
TrE
owrEp
sMA\u.r.
"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

50 State TLEV + NLEV (Unrestricied,


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
R E G U L A T I O NA
SP P L I C A B L T
EO 2 O O O
M O D E LY E A R
N E W T L E V L I G H TD U T Y T R U C K SA N D C A L I F O R N I A
REGULATIONA
S P P L I C A B LT
EO 2 O O O
M O D E LY E A R
NEWLIGHTDUTYTRUCKS.

www.emanualpro.com

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

Lift and SupportPoints


Lift and SafetyStands
place
ffi
When heaw rear components such as suspension,Iuel tank, spare tire and tailgate are to b lemoved,
vehicle,
the
!iiii-'rn"t r""igtrt in the trunk before hoisting. When substantial weight is removed flom the lear ot the
center of gravity may change and can causethe vehicle to tip fotward on the hoist'
NOTE:Sinceeachtire/wheelassemblyweighsapproximately30 lbs (14 kg),placingthe front wheelsin the cargoareacan
assistwith weight distribution.
1. Placethe lift blocksas shown.
and rockthe vehicleto be sure it is firmly supported.
2. Raisethe hoista few inches(centimeters),
3. Raisethe hoistto full height,and inspectthe lift pointsfor solidsupport'
NOTE:Usethe samesuppon pointsto supportthe vehicleon safetystands'

FRONTSUPPORTPOINT

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LIFTBLOCKS

REARSUPPORTPOIMT

1-19

Lift and SupportPoints


FloorJack
1 . Blockthe rear wheelswhen raisingthe front of the
vehicle;blockthe front wheelswhen raisingthe rear
of the vehicle.
Placethe blocksbehindand aheadof the wheels,
Raisethe vehicle high enough to insert the safety
stanos.

Always usg safety standg when working on or under


any vehicle that is supported by only a iack.
Nevor attempt to use a bumper jack for tifting or
supporting ths vehicl.

Adjust and place the safety stands so the vehicle


will be approximatelylevel,then lower the vehicle
onto them.

Front:

Center the jack

bracketin the middle


of the jack lift platform.

JACK LIFTPLATFORM

Rsar:

Centerthe iack
bracketin the middle
of the iack lift platform.
www.emanualpro.com

1-20

JACK LIFT PLATFORM

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:

Towing the four-wheel dlive CR-v with only two


wheels on the ground will damage parts of the 4wD
system. It this vehicle is damaged, it should be towed
on a flat-bed truck ol trailel.
It the 2 wheel drive CR-v is towed wiih all tour wheels
on the ground, do the following:
Manual Transmission
. Release
the parkingbrake.
. Shiftthe transmissionin Neutral
Automatic Transmission
. Releasethe parkingbrake.
. Start the engine.
. Shiftto lD.lposition.then E position.
. Turn off the engine.
TIEDOWNBRACKET
lmproper towing preparation will damage the
transmission.Follow the above procedure exactly. lf
you cannot shift the transmission or start the engine,
the vehicle must be transported on a flat-bed truck.
lf the vchicle is towed with four wheels on the ground,
il is best to tow the vehicle no larther than 50 miles (80
km), and keep the speed below 35 mph {55 km/h).
Trying to lift or tow the vehicle by ihe bumpers will
cause serious damage. The bumpers ale not dosigned
to support the vehicle's weight.

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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}

Camshaft to hoider oil clearance

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,

www.emanualpro.com

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

Warpageof deck surface


Borediameter
Boretaper
bottomof skart
SkirtO.D.*1trom
in cylinder
Clearance
Groovewidth {Forringi

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

Unit of length: mm (in)

EngineBlock- Section7

83.98- 83.99(3.306- 3.307)


- 0.00161
0.01- 0.04(0.0004
- 0.0492)
1.240- 1.250{0.0488
- 0.0484)
1.220 1.230{0.0480
2 . 8 0 5 2 . 8 2 51 0 . 1 1 0- 40 . 1 1 1 2 )
0.055- 0.080(0.0022 0.0031)
- 0.0024)
0.035 0.060(0.0014
0.20 0.30(0.008- 0.012)
0.40- 0.55(0.016 0.022)
0.20- 0.50(0.008- 0.020)
- 0.8268i
20.996- 21.000(0.8266
- 0.0007)
0.010- 0.017(0.0004
- 0.0013)
0.015- 0.032(0.0006
-0.8260)
20.968-20.98110.8255
48.0(1.89)
0.15- 0.30{0.006- 0.012i

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
www.emanualpro.com

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)

Coolantcapacity , (USq1,lmp qt)


llncludingengine,heater,I
lineand reservoirl
Lcooling
Reservoir
capacity:
0 . 6 1 ( 0 . 6 3U S q t , 0 . 5 3 l m pq t )
psi)
Openingpressure kPa(kgf/cm?,
Startsto open 'F 1"C)
Fullyopen 'F ("C)
Valvelift at tully open
"ON" temperature "F
Thermoswitch
{'C)
"OFF"temperature 'F ('C)
Thermoswitch

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}

Pressureregulator Pressurewith regulatorvacuum hose disconnected


'97,'98models
,
kPa(kgflcm' psi)
'99, '00 rnodels
Fueltank
(US
gal,
Capacity /
lmp gal)
En g i n e
ldle speedwith headlights
and coolingfan off rpm
'97 model
'98 model
'99,'00 models
Fastidle rpm

ldle CO %

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2-4

'97 model
'98 model
'99,'00 models

260- 31012.7 3.2,38- 46)


270-32012.8 3.3,40- 471
5 8 ( 1 5 . 31, 2 . 8 )
MT

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

Unitof length:mm lin)

Section 12
MEASUREMENT

Clutchpedal

Pedalheight
Stroke
Freeplay
Pedalplay
Disengagement
height
Clutchsurfacerunout

to floor

to floor

Clutchdisc

Rivet head depth


Thickness

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

0.'11- 0.18(0.004- 0.007)


- 1.1020)
27.977- 27.990(1.1015
37.984- 38.000(1.4954-1.4961)

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)

Diametero{ 1st gear contactarea


Runout

-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

31.002- 31.O1211.2205, 1.2205)


37.989- 38.000(1.4956 1.4961)
56.45- 56.55Q.222- 2.2261
26.03,26.08(1.025- 1.027)
20.01
6 - 20.043(0.7880,0.7891)
- 0.0033)
0.036- 0.084(0.0014

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

0.5 1.0(0.02 0.04)


- 0.04)
0.5- 1.0(0.02
- 0.066)
0.95- 1.68(0.037
- 0.30)
7.4- 7.6(0.29
6.2- 6.4(0.24-0.2s)
- 0.026)
0.35- 0.65(0.0't4

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

Pawl groove width


Fork-to-reverseidler gear clearance
Groovewidth*l

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

1.4 2.5i'14 26,12-231

Adjust

33.984- 34.000(1.337- 1.339)


21.977- 27.99011.1011.1021
- 1.576)
40.002- 40.01811.575
- 1.379)
35.002- 35.01811.378
26.975,26.988(1.062 1.063)
0.06- 0.16{0.002 0.006)
2.64 3.41
\21.3,35.4,23.1 30.t|

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

Shift fork diameter at contact area


Shift arm A-to-shitt tork shaft clearance

Shiftarm C

Shiftarm C'to-shiftarm B clearance


Diameterof shift arm B contactarea
Selectarm'to-shift arm A clearance
Diameterof shiftarm A contactarea

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)

0.05- 0.35(0.002- 0.014)


0.4,0.8 (0.02 0.03)
12.9- 13.0(0.508- 0.512)
0.2- 0.5 (0.008-0.020)
0.05 0.25(0.002 0.01)
r2.9- 13.0(0.508- 0.512)
0.05- 0.25(0.002 0.01)
7 . 9- 8 . 0( 0 . 3 1-1 0 . 3 1 s )
- 0.6287)
15.94r- 15.968(0.6276
- 0.0034)
0.032- 0.086(0.0013
- 0.6287)
r5.941- 15.968(0.6276
- 0.0050)
0.032- 0.127(0.0013
- 0.7098)
18.010 18.028(0.7091
- 0.0022)
0.027- 0.057(0.0011
28.005- 28.025(1.1026,1.1033)
0.025- 0.066(0.0010,0.0026)
- 0.0036)
0.055- 0.09110.0022

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 )

Automatic Transmission Section 14


STANDAROINEW}

MEASUREMENT
Transmission
fluid

Capacity I {US qt, lmp q0

4WD
2WD

Hydraulic
pressure
kPa
(kgflcm', psi)

Linepressureat 2,000rpm in LII or El position


1slclutchpressureat 2,000rpm in Da position
1st-holdclutchpressureat 2,000rpm In l position

2nd clutchpressureat 2,000rpm in El position


3rd clutchpressureat 2,000rpm in E position('97,
'98 models),or positionwith O/DOFFindicator
E
light ON ('99,'00models)
4th clutchpressureat 2,000rpm in gl position('97,
'98 models),or
E positionwith O/DOFFindicator
lightoFF ('99,'00models)
Stallspeedrpm (Checkwith vehicleon levelground)
1st
Clutchinitialclearance
2nd,3rd,4th
'lst-hold
Clutchreturnspringfree length
Clutchdiscthickness
Clutchplatethickness
Clutchend platethickness
(lsti

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)

800- 850(8.2 4.7,120 1241

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)

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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

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2-8

STANDARD{NEW}

SERVICELIMIT

- 0.9446) Wearor damage


23.980-23.993(0.9441
35.975 35.99'!(1.4163 1.4169)
( 1 . 2 5 8 91 . 2 5 9 5 i
3 1 . 9 7 53 1 . 9 9 1
- 1.2201l'
30.975- 30.99111.2195
- 1.4180)
36.004- 36.017(1.4175
35.980 35.996(1.4165 1.4172)
( 1 . 1 0 1-61 . 1 0 2 1 i
2 7 . 9 8-0 2 7 . 9 9 3
( 1 . 2 5 8-9' j . 2 5 9 5 i
3 1 . 9 7 5 -3 1 . 9 9 1
( 1 . 2 5 8-91 . 2 5 9 5 )
3 1 . 9 7 53
- 1.991
- 1.0236)
25.991- 26.000(1.0233
- 23.006s(0.9053 0.9058)
22.9935
- 0.5512) Wearor damage
13.990- r4.000(0.5508
35.000 35.016(1.3780 1.3786)
4 1 . 0 0-0 4 1 . 0 1 (61 . 6 1 4-21 . 6 1 4 8 )
-' 1.4967)
38.000- 38.016(1.4961
- 1.4967)
38.000- 38.016(1.496'1
4 1 . 0 0 0 4 1 . 0 1 (61 . 6 1 4 21 . 6 1 4 8 )
33.000- 33.016(1.2992 1.2998)
- 1.4967)
38.000- 38.016(1.4961
- 1.2605)
32.000- 32.016(1.2598
- 0.7094)
18.007- 18.020(0.7089
14.416 14.434(0.5676 0.5683)
0.05- 0.16{0.002- 0.006)
0.05- 0.13(0.002- 0.005)
0.05,0.'16(0.002 0.006)
0.1 0.5(0.004 0.020)
0.05 0.17{0.002 0.007)
0.10 0.18(0.004 0.007)
0.0s 0.17(0.002- 0.007)
0.05- 0.18(0.002- 0.007)
0 . 1 0 , 0 . 2 5 ( 0 . 0 0 40 . 0 1 0 )
51.87- 51.90(2.042- 2.043)
- |.9508)
49.50- 49.55(1.9488
4 . 4 3 5 4 . 5 2 5( 0 . 1 7 4 6 - 0 . 1 7 8 1 )
2 7 . 0 0 , 2 7 . 0{51 . 0 6 3 ' 1 . 0 6 5 i
38.97- 39.00(1.534- 1.535)
39.02 39.05(1.536, 1.537)
39.07 39.10(1.538 1.539)
3 9 . 1 2- 3 9 . 1 5( 1 . 5 4-0 1 . 5 4 1 )
39.17- 39.20(1.542* 1.543)
- 1.545)
39.22- 39.2511.544
- 1.547i
39.27 39.301'1.546
38.87 38.90{1.530 1.531)
38.92 38.95(1.s32 1.533)
21.15- 21.20rc.4327- 0.4346)
14.5, 14.6(0.57't, 0.575)
2.4- 2.6(0.094- 0.102)
14.5- 14.6(0.571- 0.575)
2.4- 2.6(0.094- 0.102)
24.0 24.1(0.945 0.949)
2 . 9 5- 3 . 1 0( 0 . 1 1 -6 0 . 1 2 2 )

Wearor damage

Wearor damage

il*=lo'.d"'.n"n"
Wearor damage

Wearor damage
Wearor damage
Wearor damage

Unit of length:mm (in)

Automatic Transmission - Section 14


(NEWI
STANDARD

MEASUREMENT
Transmission

Mainshaft 2nd gear thrust washer thickness

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

Sealing ring contact area l.D,

Stator shaft

Insideof diameteroI bearingcontactarea


On torqueconvenerside
On ATFpump side
Reverseshittfork fingerthickness
Parkingbrakepawl
Parkinggear
Shiftfork shattborel.D.
Shiftfork shattvalvebore l.D.

Shiftingdeviceand
parkingbrakecon'
trol
Servo body
Differential
carrier

Differential
prnrongear

o
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- 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

83.339 83.365(3.2810 3.2821)


- 2.6259)
66.685- 66.698(2.6254
8.97- 8.98 (0.353- 0.354)
5.97 5.98{0.2350- 0.2354)
- 0.3142)
7.97- 7.98(0.3138
- 0.3142)
7.97,7.98 (0.3138
1.87- 1.97(0.074-0.078)

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)

2't.o00 27.021I '1.063, 1.064)


2 9 . 0 0-0 2 9 . 0 1 3 1 1 . r 4 117. 1 4 2 2 )

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

38.485 38.500(1.515- 1.516)


- 1.102)
27.917- 21.990 |.1.101
40.002- 40.018(1.575- 1.576)
35.002 35.018(1.378- 1.379)
26.975 26.988(1.062-' l.063)
0.060 0.160(0.002- 0.006)
2.64- 3.41
- 35.4,23.1 30.71
127.3

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

Differential (4WDl * Section 15


MEASUREMENT

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

Capacity f (US qt, lmp ql)

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.

www.emanualpro.com

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

Unit of length:mm {in)

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

To be lockedwhen Dulled:2 - 6 notches

Playin strokeat 196N (20kgf,44lbf)


leverforce
Pedalheight(withtloor mat removed)
NT
Freeplay

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
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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

*1: '97- 99 models


*2: '00 model

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

Pad surface area


Lining surfacearea
P a r k i n gb r a k e

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 )

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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
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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

Shift lever pivots (Manual transmission)

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

-30 -20 .10

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

NOTE:Lubricateall hinges,latches,and locksoncea year.


In corrosiveareas,more frequentlubricationis necessary.
We recommendHondaWhite LithiumGrease.

www.emanualpro.com

3-3

Maintenance
Schedule(for 1997Model)
Normal Conditions
>
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www.emanualpro.com

3-4

'5

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www.emanualpro.com

E #

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3-5

Maintenance
Schedule(for 1997Modell

SevereConditions

z
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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

A973X- 041 XXXXX


0 7 J G G- 0 0 1 0 1 0 A
07PAZ- 0010100

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

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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.

4. Unplug the connector(BLK /VHTwire and solenoid


terminal)from the starter.
5 . Connecta jumper wire from the bafterypositive(+)
terminalto the solenoidterminal.
The startershouldcrankthe engine.

Alte.nate Procedure:
.

Checkthe battery, battery positivecable, ground.


stanercut relay,and the wire connectionsfor loosenessand corrosion.Testagain.
lf the staner still does not crank the engine,go to
step 4.

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

NOTE: After this test, or any subsequentrepair. reset


the ECM/PCM
to clearany codes(seesection11).

.
.

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.

Checkthe Starter Engagement:


'1. Removethe No. 44 (15A) fuse from the under-hood
fuse/relaybox.
2.

Turn the ignitionswitchto START(lll)with the shift


lever in E or E position (A/T) or with the clutch
pedaldepressed{M/T).The startershouldcrankthe
e n gi n e .
.
.

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lf the starter does not crank the engine, go to


step3.
lf it cranksthe engineerraticallyor too slowly,go
t o " C h e c kf o r W e a r a n d D a m a g e "o n t h e n e x t
page.

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

Starter Solenoid Test

Checklor Wear and D8mage


T h e s t a r t e rs h o u l dc r a n kt h e e n g i n es m o o t h l ya n d
s t e a d i l y l.f t h e s t a n e re n g a g e s b, u t c r a n k st h e e n g i n e
erratically,removeit, and inspectthe starterdrive gear
and torque converterring gear or flywheelring gear for
oamage.

1.

Checkthe drive gear overrunningclutchfor binding or


s l i p p i n gw h e n t h e a r m a t u r ei s r o t a t e dw i t h t h e d r i v e
gear held.lf damaged,replacethe gears.

Checkthe hold-incoil for continuitybetweenthe S


t e r m i n a la n d l h e a r m a t u r eh o u s i n g( g r o u n d )T. h e
coil is OK if thereis continuity.
STARTER

B TERMINAL
MOUNTINGNUT
9 N.m 10.9kgtm,
7 tbtftl

CheckCrankingVoltage and Current Draw


Crankingvoltageshouldbe no lessthan 8.7 volts on Ay'T
models,and 8.0volts on M/T moders.
Currentdraw should be no more than 230 ampereson
A,/Tmodels,and 200ampereson M/T models.
lf crankingvoltageis too low, or currentdraw too high,
checkfor:
. deador low battery.
a o p e n c i r c u i t i n s t a r t e ra r m a t u r ec o m m u t a t o rs e g ,
ments.
. starterarmaturedragging.
. shortedarmaturewinding.
. excessivedrag in engine.
CheckCrankingrpm
Enginespeedduringcrankingshouldbe above 100rpm.
lf speedis too low, checkfor:
a loosebafteryor starterterminals.
. excesslvely
worn stanerbrushes
. opencircuitin commutatorsegments.
. dirty or damagedhelicalsplinesor drivegear.
a defectivedrive gearoverrunningclutch.
CheckStarter Disengagement
With the shift lever in @ or @ position(A,iT)or with the
clutchpedaldepressed{M/T).turn the ignitionswitchto
START(lll).and releaseto ON (ll).
The starterdrive gear shoulddisengagefrom the torque
c o n v e r t e rr i n g g e a r o r f l y w h e e l r i n g g e a r w h e n y o u
releasethe key.
lf the drive gear hangs up on the torque converterring
gearor flywheelring gear,checkfor
. solenoidplungerand switchmalfunction.
. dirty drive gear assemblyor damaged overrunning
clutch.

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4-6

TERMINAL

ARMATURE
HOUSING
(GROUND}

BLK/WHT
WIRE
2.

Checkthe pull in coil for continuitybetweenthe S


and M terminals.The coil is OK if thereis continuity.

StarterReplacement

Field Winding Test

1 . Disconnectthe battery negativecable.

t.

Disconnectthe startercablefrom the B terminalon


the solenoid. then disconnectthe BLK/WHTwire
from the S terminal.
B TERMINAL
MOUNNNG NUT
I N.m (0.9kgl.m,

Checkfor continuitybetweenthe brushes.lf there's


no continuity,replacethe armaturehousing,
Checkfor continuity between each brush and the
a r m a t u r eh o u s i n g{ g r o u n d ) l. f t h e r e i s c o n t i n u i t y .
replacethe armaturehousing.

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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Connectthe batterypositivecableand negativecable


to the batterv.

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

Measurethe brush length.lf it is not within the service


limit, replacethe brush(or brushholderassembly).

1.

2.
Brush Lsngth
Standard{Newl:14.0- I'1.5mm (0.55- 0.57inl
ServicoLimit: 9.0 mm (0.35in)

Slidethe overrunningclutchalongthe shaft.Doesit


move freely?lf not, replaceit.
Rotatethe overrunningclutch both ways. Does it
l o c k i n o n e d i r e c t i o na n d r o t a t e s m o o t h l y i n
reverse?lf it does not lock in either directionor it
locksin both directions,reDlaceit.

BRUSH

NOTE:To seat new brushesafterinstallingthem in their


holders.slip a strip of #500or #600sandpaper,with the
grit side up, over the commutatorand smoothly rotate
the armature.The contactsurfaceof the brusheswill be
sandedto the samecontouras the commutator.

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3.

lf the starterdrive gear is worn or damaged,replace


t h e o v e r r u n n i n gc l u t c ha s s e m b l yt;h e g e a r i s n o t
availableseparately.
Checkthe conditionof the torqueconverterring gear
or the flywheel ring gear if the starter drive gear
teethare damaged.

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.

Checkthe commutatorsurface.lf the surfaceis dirty


or burnt,resurfacewith emery cloth or a lathewithor reconditionwith
in the tollowing specifications,
#500or #600sandDaoer.

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.

Checkthe mica depth. lf necessary,undercutthe


mica with a hacksawbladeto achieveproperdepth.
l f t h e s e r v i c el i m i t c a n n o tb e m a i n t a i n e dr,e D l a c e
the armature.

7.

Placethe armature on an armaturetester. Hold a


hacksawbladeon the armaturecore.

NOT GOOD

MICA DEPTI{

Commutator Mica Depth


Standard (Nsw): 0.5 - 0.8 mm 10.02- 0.03 inl
ServicoLimit: 0.2 mm (0.008in)
6.

Checkfor continuitybetweenthe segmentsof the


commutator.lf an open circuit exists betweenany
segments.replacethe armature.

lf the bladeis attractedto the core or vibrateswhile


the core is turned.the armatureis shorted.Replace
the armature.
8.

COMMUTATOR

With an ohmmeter,checkthat no continuityexists


betweenthe commutator and armature coil core,
and betweenthe commutatorand armatureshaft.lf
there is continuity.replacethe armature,

cotLcoRE

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4-11

StartingSystem
Starter Reassembly

Brush Holder Test


1.

Checkthat there is no continuitybetweenthe O and


O brush holders.lf there is continuitv,replacethe
brushholderassembly.

O BRUSHHOLDER

NOTE:Use the illustrationon page 4I as referencefor


reassemDty.
1.

Pry backeachbrushspringwith a screwdriver,


then
positionthe brush about halfwayout ol its holder,
and releasethe springto hold it there.

2.

Installthe armaturein the housing.Next, pry back


each brush spring again,and push the brush down
until it seatsagainstthe commutator,then release
the springagainstthe end of the brush.

@ BRUSHHOLDER

Insertthe brushinto the brushholder,and bring the


brush into contactwith the commutator,then attach
a springscaleto the spring.Measurethe springtension at the momentthe spring liftsoff the brush.

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.

Disconnectthe battery also from the body. lf the


pinion retractsimmediately,it is working properly,
To avoiddamagingthe starter,do not leavethe batterv connectedfor more than 10 seconds.

6.

Clampthe starterfirmly in a vise.

7.

Connectthe starter to the battery as describedin


t h e d i a g r a m b e l o w ,a n d c o n f i r mt h a t t h e m o t o r
starts and keepsrotating.

8,

lf the electric current and motor soeed meet the


when the batteryvoltageis at 11.5V,
specifications
the starteris workingproperly.

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.

Connectthe batteryas shown. lf the starterpinion


pops out. it is working properly.To avoid damaging
the starter,do not leavethe batteryconnectedfor
more than 10 seconds.

12V
BATTERY

ie

Disconnectthe batteryfrom the M terminal. lf the


pinion does not retract,the hold-in coil is working
p r o p e r l y .T o a v o i d d a m a g i n gt h e s t a r t e r ,d o n o t
leavethe batteryconnectedfor more than 10 sec
onds.

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.

Checkthe idle speed,and adjustit if necessary(see


section11).

2.

Pull out the servicecheckconnector2P (BRN and


BLKwires)from the connectorholderlocatedunder
the dash on the front passengerside,then connect
to
the scs serviceconnector(P/N07PAz- 0010100)
it.

6.

lf necessary,adjust the ignition timing as follows.


Loosenthe distributormountingbolts,and turn the
to
distributorignition(Dl)housingcounterclockwise
advancethe timing or clockwiseto retardthe timtn o ,
To RETARD

Startthe engine.Holdthe engineat 3,000rpm with


no load (A/T in N or E, Mff in neutral)until the
radiatorfan comeson, then let it idle.
Connectthe timing light to the No. I ignitionwire,
then point the light towardthe pointeron the timing
belt cover.
5.

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

Disconnectthe SCSserviceconnectorfrom the servicecheckconnector.

DistributorReplacement
Removal:
e
o

5.

1.

Disconnect
the connectorfrom the distributor.

2.

Disconnectthe ignition wires from the distributor


i g n i t i o n( D l )c a p .

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.

Connectthe ignitionwires to the distributorignition


(Dl)cap as shown,

I'

CAMSHAFT
END

No. 1
CYLINDER
MARK

6.

Connectthe connectorto the distributor.

7.

Setthe ignitiontiming (seepreviouspage).

8.

After settingthe ignitiontiming, tightenthe mounting bolts.

BOLTS
MOUNTING
8 x 1.25mm
17lbfftl
2,1N.m{2.,1kgrf.m,

lnstallation:
1.

Bringthe No. 1 pistonto compressionstrokeTDC.

2.

Coata new O-ringwith engineoil, then installit.

3.

Align the lug on the end of the distributorand its


mating grooves in the camshaftend, then slip the
distributorinto position.
NOTE:The lug on the end of the distributorand its
mating groovesin the camshaftend are both offset
to eliminatethe possibilityof installingthe distributor 180oout of time.

4.

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Installthemountingbolts,and tightenthem lightly.

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 .

Turn the ignition switch ON {ll). Checkfor voltage


betweenthe BLK,^/EL
wire and body ground.There
shouldbe batteryvoltage.
.
.

lf there is no batteryvoltage,checkthe BLK/rEL


wire betlveenthe ignitionswitchand the lclvl.
lf there is bafteryvoltage, go to step 4.

Removethe distributorignition(Dl)cap,the distributor ignition(Dl)rotor,and the leakcover.

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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testsare normal,replacethe lCM.

4-19

lgnition System
lgnitionCoilTest

lgnition Wire Inspectionand Test

Using an ohmmeter, measureresistancebetweenthe


terminals.lf the resistanceis not within sDecifications,
replacethe ignitioncoil.

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.

NOTE: Resistancewill vary with the coil temperature;


specifications
are at 68"F(20'C).

Checkthe conditionof the ignitionwire terminals.lf


any terminalis corroded,cleanit, and if it is broken
or distorted,replacethe ignitionwire.

Plimary Winding Resistance


{Betweenthe A and B terminals):
0.6it- 0.77 0
SecondaryWinding Resistance
{Betweenthe A and secondarywinding terminals):
12.8- 19.2kO

IGNITIONWIRE

Connectthe ohmmeter probesand measureresistance.

lgnition Wire Resistance:


25 kO max. at 68'F 120'Cl

TERMINALA {+l

IGNITIONWIRE
4.

4-20

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lf the resistance exceeds 25 kO, replace the ignition


wire.

SparkPlugInspection
Inspectthe electrodesand ceramicinsulatorfor:

2.

Checkthe electrodegaP.
.

Adjustthe gap with a suitablegappingtool.

ElectrodeGap

.
.
.
.

lmpropergap
Oil-fouling
Carbondeposits
Crackedcenter
electrodeinsulator

in)
1.1 3 ' mm (0.043Loo.

Standard

the plug if the centerelectrodeis rounded


Replace
as shownbelow:
ROUNDEO
ELECTRODE

,--,
(--/
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?

Check for a blown No. 15 17.5Al


fuse and a blown charging system light bulb. lf the tusa .nd
bulb are OK, repair th open in
th WHT/BLUwire.

Charging System Light Check


{com'd}:
Startthe engine.

Doesthe chargingsystem
light go offf

Perform the Alte.nator/Regulator


Test lsee page +281.

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

{ ).

ls there battery voltage?

Ropair the open in the BLK/YEL


wiae betwoen the altemator and
under-da3hluso/relay box.

ALTERNATOR
3P CONNECTOR
lCanedamodel'

Iemale terminals

(To next page)

[ ] : C a n a d am o d e l

4-24

www.emanualpro.com

(Frompreviouspage)

in

Ch6ckthe L circuil:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe 4P [3P] connectorfrom the alternator.
3. Turnthe ignitionswitchON (ll).

Doesthe charging system


lightcomeon?

Repairthe short to ground in the


WHT/BLUwire.

[ ]: Canadamodel

www.emanualpro.com

(cont'd)

4-25

ChargingSystem
Troubleshooting(cont'dl
'97 modol:

Alternator Control System Test {U.S.A.model)

NOTE:Beforetesting,checkproperoperationofthe ELDby checkingfor a DTC(seesection.11).


BATTERY
Chockfor a short in the circuit
IALTCline):
1. Disconnectthe 4P connector
from the alternator.
2. Startthe engine,and turn the
headlights
thigh beamiON.
3. Me8surevoltage between the
4 P c o n n e c t o tre r m i n a lN o . 2
and the positiveterminal of
the battery.

CAUTION: Be sure to use a voltmeter


with ils positive terminal connectedto
battery positive and hs negative terminalto the 4P connectorterminal No. 2.

{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?

Rprir short in the wire between


the altornator and the ECM/PCM.

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

Repairopen in the wi.e betwoen


the atternatorand ECM/PCM.

ls therecontinuity?

Check for a shorl in the wiro


IALTCline):
1 . T u r n t h e h e a d l i g hat n d i g n ; ,
I|on swrtcnUFF
2. Disconnect
the 32Pconnector
from the EcM/PcM.
3. Checktor continuitybetween
the ECM/PCN4
32P connector
t e r m i n a lN o . 3 0 a n d b o d y
ground.

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)

'98 -'9O modols: Alternator Contlol SYstemTe3t (U.S.A'model)


NOTE:Beforetesting,checkproperoperationof the ELDby checkingfor a DTC(seesection11)
EATTERY

'oR

Chock tor . short in tha circuit


IALTClino):
1. Disconnoctthe 4P connector
Irom the alternator.
2. Startthe engine,and turn the
headlights(highbeam)ON.
3. Measurevoltage between the
4P connectorterminal No. 2
and the positive terminal oI
the battsry.

CAUTION: Be surc to uso a voltmetor


with its oo3itive torminel connccted to
battery po3hivo tnd its negativo teami'
nal to the 4P connectortorminal No 2.

c
IWHT/GRN)
Wire sideol
femaleterminals

ALTERNATOR
4P CONNECTOR

l s t h e r e1 V o r l e s s ?

Check for an opon in the wire


IALTCline):
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. Disconnect
the 31Pconnector
from the ECM/PCM.
3. Checktor continuitybetween
th6 ECM/PCM31P connector
terminalNo. 2 and alternator
4PconnectorterminalNo. 2.

ECM,/PCM
CONNECTOR
c {31P)
Wire sideol
temaleterminals

Ropairopen in the wiro between


the ahornrtor and ECM/PCM.

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

Substituto . known-good ECM/


PCM,.nd rochock.
lf prdcdbd voltage b now av.ilable, repl.ce the original ECM/

rcM.
Rcpair rhort in thc wire b.twcon
th. ahGrn.tol.nd the EcM/PcM.

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(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 ?

Altarnator/Regulator Test (cont'd:


Apply a load with a VAT-40 until
the battery voltage drops to
b e t w e e n 1 2 - 1 3 . 5V .

To next page

www.emanualpro.com

4-28

Frompreviouspage

ls the amperage65 A or more?

Aharnator/Regulator Tesl (cont'd):


W i t h t h e e n g i n e s p e e ds t i l l a t
2.000rom,fulllield the alternator.

The charging sy3tem b OK.


CAUTION:The voh.ge will tise quickly whon th. ahornato. is tull-li.lded Do not allow
the voltage to exceod18 V; it mry damagothe .loctrictl 3yaiGm.
into the tull field
NOTE: Attach a probe to a VAT-40Iull tield test lead,and inseft the probe
"A
lGround)"posiaccessholeat the backof the altemator'Switchthe fieldselectorto the
and checkthe amperagereadrng.
tion momentarily.
REGULATOR
(Locatedinside
the ond coverl
FULLFIELD
ACCESSHOLE

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4-29

ChargingSystem
AlternatorReplacement

l
I

' t . Disconnect
the batterynegativeterminalfirst, then

the positiveterminal.

Removethe adjustingbolt and mounting nut, then


removethe alternatorbelt.

N
ir

Disconnectthe 4P (or 3P) connectorand WHT wire


from the alternator.

Pullout the throughbolt,then removethe alternator.

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,

Installthe alternatorin reverseorderof removal.


o.

4-30

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'll

Adjust the alternatorbelt tension after installation


(seepage4-34).

AlternatorOverhaul

PULLEY

NOTE:Do not removethe pulley unlessthe front bearing needsreplacement.


To loosenthe pulley locknut,use the tools as shown. lf
necessary,
usean impactwrench.

,T
PULLEYLOCKNUT
111N.m (11.3kgf.m,81.7lbf.ft)

BEARINGINSULATOR

FRONTBEARING

PULLEY

CAUTION: Do not get grease


or oil on the slip rings.

"'^.^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

NOTE:The diodesare designedto allow currentto pass


in one directionwhile blockingit in the oppositedirec
t i o n . S i n c et h e a l t e r n a t o r e c t i f i e ri s m a d e u p o f e i g h t
diodes(four pairs),each diode must be testedfor conti
nuity in both directionswith an ohmmeterthat hasdiode
checkingcapability;a total of 16 checks.

1.

Removethe end cover,thentakeout the brushholder


by removing its two screws.

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.

Checkfor continuityin eachdirectionbetween


- t h e B a n dPt e r m i n a l s .
- E ( g r o u n da) n d P t e r m i n a l s .
A l l d i o d e ss h o u l dh a v ec o n t i n u i t iyn o n l y o n e d i r e c tion.

Alternator Brush Length:


Standard(Newl:10.5mm 10.41inl
ServiceLimit: 1.5mm {0.06in)

VERNIERCALIPER

2.

lf any of the diodesfails,replacethe rectifierassembly. (Diodesare not availableseparatelv.)

4-32

www.emanualpro.com

lf the brushesare lessthan the servicelimit, replace


the alternatorbrushassemblv.

Stator Test

RotorSlip RingTest
1.

betweenthe slip rings.


Checkthe resistance
Thereshouldbe 1.8- 3.0ohms.
go to step2
. lf resistance
meetsthe specification,
. l f r e s i s t a n c ed o e s n o t m e e t t h e s p e c i f i c a t i o n ,
replacethe alternator.

1.

Checkthat there is continuitybetweeneach pair of


leads.
LEADS

ROTORSHAFT

corLcoRE
SLIPRINGS

Checkthat there is no continuitybetweeneach lead


and the coil core.
It the coil fails either continuitycheck,replacethe
alternator.

Checkthat there is no continuity betweenthe slip


ringsand the rotoror rotor shaft.
lf the rotor fails eithercontinuitycheck,replacethe
alternator.

www.emanualpro.com

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

Belt tension gauge m6thod:


Attachthe belttensiongaugeto the beltand measurethe
tension.Followthe gaugemanufacturer's
instructions.
Tension:
Used Belt:340 - /0 N (35 - 50 kgf, 77 - 1r0 tbf)
New Belt: 690 - 880 N (70 - 90 kgf, 150- 200 tbt)
NOTE:lfthe belt is worn or damaged,replaceit.

lf adjustment is necessary:
1.

Loosenthe mountingnut and the locknut.

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)

Recheckthe deflectionor tensionof the belt.


NOTE: For the power steeringpump belt and A,/C
referto section17 and
compressorbelt adjustments,
section22.

www.emanualpro.com

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.

www.emanualpro.com

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.

Inspectthe connectorand socketterminalsto be surethey are all makinggood contact


and recheckthe system.
lf the terminalsare bent,loose,or corroded,repairthem as necessary,
lf the terminalslook OK, makethe followinginput testsat the connector.
- lf any test indicatesa problem.find and correctthe cause,then recheckthe system.
- lf all the input testsproveOK,the controlunit must be faulty;replaceit.

*: '98- 00 modelswith
AutomaticTransmission.

4-38

www.emanualpro.com

Wire sideol femaleterminals

Disconnestthe lilP connectorfrom the control unit.


Csvity

Wire
BRNAr'VHT

BRN

11

BRN/BLK

GRY

BLK

GRNMHT

LT GRN/
RED
7

LT GRN/
BLK

Under all conditions

Checkfor resistanceto groundl


There should be 40 - 60 0.

Under all conditions

Checkfor resistanceto ground:


There should be 70 - 110 O.

lgnitionswitch ON (ll),
main switch ON and
brakepedaldepressed,
then released

Checkfor voltageto ground:


There should be 0 V with the pedal
depressedand batteryvoltagewith
the pedal released.

. Faultybrakeswitch
. An openin the wire

Under all conditions

Checkfor continuityto ground:


There should be continuity.

. Poor ground (G401)


. An open in the wire

Brakepedaldepressed, Checkfor voltageto ground:


thenreleased
There should be batteryvoltagewith
the pedal depressed,and 0 V with
the pedal released.

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

Checkfor voltageto ground:


There should be batteryvoltage.

BlownNo.52 {'15A} fusein the


under-hood
fuse/relay
box
Faultyhornrelay
Faultysevresume
switch
Faultycablereel
An openin 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

Check for voltage between the


ELUA/VHT
@ and BLK O terminalsl
There should be 0 - 5 V or more
-0 - 5 V or more repeatedly.

Faultyvehiclespeed sensor(VSS)
An open in the wire

lgnitionswitch ON {ll}
and main switch ON

Checkfor voltageto ground:


There should be batteryvoltage.

Blown No. 14 (7.5A) fuse in the


under-dashfuse/relaybox
Faultymain switch
An open in the wire

A'/T:Shift leverin E, E
otE
lvl/T:Clutchpedal
releaseo

Checkfor continuityto ground:


There should be continuity.
NOTE: There should be no continuity when the shift lever is in other
positionsor when the clutch pedal is
oepresseo.

Faulty A/f gear position switch 1A,/Tl


Faultyor misadjustedclutch switch

Resumebuttonpushed

RED/BLU

LT GRN

Faultyactuatorsolenoid
Poorground(G202)
An openin the wire

Checkfor resistanceto groundl


There should be 80 - 120 o.

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

Possiblecause it result is not obtained

Under all conditions

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

Rconncttho 14PconnGctorto the control unit.

BLU

Start tho engine.turn


the main switch ON, and
drive the vehicleover 25
mph (40 km/h)with the
crursecontrol set

Checkfor voltageto ground:


There should be approx.5 V

. Faultycruisecontrol unit
. Shod to ground

*: '98 - 00 modelswith AutomaticTransmission.

www.emanualpro.com

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

Removethe dashboardlowercoverand kneebolster.


4.

Disconnect
the 6P connectorbetweenthe cablereel
sub harnessand the main wire harness.

BULES{0.84Wt
Checkfor continuitvbetweenthe terminalsin each
switchpositionaccordingto the table.
Terminal
-_\
5

Wire sideof temaleterminals

;;;
OFF

G-

@o

ON

(9 ,{)

-o o- @ -o

lf there is no continuity,replacethe switch.

Checkfor continuity betweenthe terminalsof the


6P connectorin each switch position accordingto
the table.
\

Terminal

;;;

--_l

o-

S E T( O N )
(ON)
RESUME

Cf-

-o
c

lf there is continuity.and it matchesthe table,


the switchis OK.
a lf there is no continuityin one or both positions,
go to step 6.

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

Connect battery power to the No. 4 terminal and


groundto the No. 1, No. 2 and No. 3 terminals,

,s

Connecta vacuumpump to the vacuumhose.Then


applyvacuumto the actuator.
r.
VACUUMPUMPGAUGE
0-30 in.Hg.
A973X-041-XXXXX

7 . Checkfor continuitybetweenthe terminalsin each


switchpositionaccordingto the table.
Terminal
-__\

t*,r*
SETION)
(ON)
RESUME
.
.

1e
to

---o
oo- ---o

lf there is continuity,and it matchesthe table,


replacethe cablereel.
lf there is no continuityin one or both positions,
replacethe switch.

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

lf all tests prove OK, reconnectthe cable reel subharnessconnector.


9 . Reconnectthe driver'sairbagand front passenger's
airbagconnectors,and reinstallthe accesspanelon
the steeringwheel.

1 0 . Reconnectthe batterypositivecable.then the negative cable.


1 1 . A f t e r c o n n e c t i n gt h e a i r b a gc o n n e c t o r sc, o n f i r m

proper system operation:Turn the ignition switch ON


(ll);the SRSindicatorlight shouldcome on for about
six secondsand then go off.
(cont'd)

www.emanualpro.com

4-41

CruiseGontrol
ActuatorTest (cont'dl
5.

With voltageand vacuumstill applied,try to pull the


actuatorrod out by hand.You shouldnot be able to
pull it out. lf you can.it is defectrve.

ActuatorReplacement
' t . Pullbackthe boot.
and loosenthe locknut.Then dis-

Ar
1.

connectthe cablefrom the bracket.


Disconnect
the cableend from the actuatorrod.

.J.

groundfrom the No. 3 terminal.The actuDisconnect


ator rod should return.lf it does not return,but the
vent hose and filter are not plugged,the solenoid
valve assemblyis defective.
7.

Repeatsteps 2 through 5. and disconnectground


from the No. l terminal. The actuator rod should
return. lf it does not return,but the vent hose and
filter are not plugged,the solenoidvalve assembly
is defective.

8.

lf you replacethe solenoidvalveassembly,be sure


to use new O-ringson eachsolenoid.

9.

powerand groundfrom the 4Pconnector.


Disconnect
Disconnectthe vent hose from the actuator.Connect
a vacuumpump to the actuatorvent hose port, and
applyvacuum.The actuatorrod shouldpull in comp l e t e l y .l f n o t , t h e v a c u u m v a l v e i s s t u c k o p e n .
Replace
the actuator,

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.

Installin the reverseorder of removal,and adjust


free play at the actuator rod after connectingthe
cable(seepage4-43).

ActuatorCableAdiustment

ClutchSwitch Test

'1.

1.

Checkthat the actuator cable operatessmoothly


with no bindingor sticking.
Startthe engine.Hold the engineat 3,000rpm with
no load (A,/Tin E or E position, M/T in neutral)
untilthe radiatorfan comeson, then let it idle.

Disconngctths 2P connector from the clutch switch.

CLUTCHSWITCH2P CONNECTOR
Terminalsideof
maleterminals

Measurethe amount of movementof the actuator


rod until ths cable pulls on the acceleratorlever
(enginespeed startsto increase).Free play should
b e 1 1t 1 . 0m m ( 0 . 4 3i 0 . 0 4i n ) .

ACTUATORROD

LOCKNUTFREEPLAY:11 t 1.0 mm
10.43r 0.04 in)

2.

Removethe clutchswitch,

5.

Checkfor continuitybetweenthe terminalsaccording to the table.

lf free play is not within specs,loosenthe locknut,


and turn the adjustingnut as requirsd,
NOTE: lf necessary,check the throttl cable frso
play (sesection11),then recheckthe actuatorrod
free play.

Terminal

Clutch Switch

OEPRESSED

RELEASED

Retightenthe locknut,and recheckthe free play.


4.

lf necessary,replacethe switch or adjustthe pedal


height(seesectiont2).

st
te

www.emanualpro.com

4-43

CruiseControl
ActuatorSolenoidTest

BrakeSwitch Test
1.

Disconnect
the 4Pconnectorfrom the switch,

2.

Removethe brakeswitch.

1.

the 4P connectorfrom the actuator.


Disconnect

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-

NOTE: Resistancewill vary slightly with temperais at 68"F(20"C).


ture;specifiedresistance

lf necessary,replacethe switch or adjust pedal height


(seesection19).
VACUUM VALVE

To VACUUM
TANK

4-44

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ActuatorDisassembly

ACTUATORCABLE

ACTUATORERACKET

VACUUM
TANK

)rd'

!l
l

VALVES
Test, page 4-44

www.emanualpro.com

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.

a Make sure iacks and safety stands are placedproperly


and hoist brackets are attached to the correct oositions on the engine.
. Make sure the vehicle will not roll oft stands and fall
while you are working under it.

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.

Securethe hood in the open position.

2.

Disconnect
the batterynegativeterminalfirst,thenthe
positiveterminal.

Removethe battervand battervbase.

I x 1.25mm
24 N.m (2.4kgf.m,
17 tbnft)
-t'.-e

F
F
Y

Disconnectthe batterycablesfrom the under-hood


fuse/relaybox and batterypositiveterminal.

5.

Removethe intakeair duct and air cleanerhousino.

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.

Disconnectthe enginewire harnessconnectorson


the left sideof the enginecompartment.
ENGINEWIRE
HARNESSCONNECTORS

CONNECTOR

Removethe grommetand wire harnessclamps,then


pull out the EcM/Pclvlconnectors.
6x1.0mm
11 N.m 11.1kgl.m,8lbf.ftl

GROMMET

(cont'd)

www.emanualpro.com

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

13. Relievefuel pressure{seesection11).


Do not 3mok6 whil working on th6
@
tugl systsm. Koep open flam or spark away from
the work area. Drain fuel only inlo an approved
container.
14. Removethe evaporativeemission (EVAP)control
canisterhoseand tuel feed hose.
33 N.m (3.4kgt.m,

2s tbf.ft)

LOCKBOLT
I x 1.25mm
24 N.m {2.4kgtm, '17lbf.ftl

1 2 . Loosenthe idler pulley bracketbolt and adjusting


bolt, then remove the air conditioning(A,/C)compressorbelt.
ADJUSTINGBOLT
LOCKNUT
8 x 1.25mm
24 N.m {2.4kgf.m, 17 lbf.ftl

ID1TR PULI.f,Y ARACKETBOLT


10r 1.25mm
a{ N.m 14.5lgtm,33 lbf.ft)

5-4

www.emanualpro.com

,%l
*ryft
'fltr
\'t,f
EVAPCC
CANISTERHOSE

he
'.n

'15. Removethe brakeboostervacuumhose,fuel return


hoseand vacuumhose.
'97 - 98 modals:

!d

BRAKEBOOSTER
VACUUM HOSE
'ol

'16. Removethe throttlecableby looseningthe locknut,


then slip the cable end out of the acceleratorlinkage.Take care not to bend the cablewhen removing it. Always replaceany kinkedcablewith a new
one.
97 - 98 modeb:

FUELRETURN
HOSE

99 - 00 modob:
'99 - 00 modob:
BRAKEBOOSTER
VACUUM HOSE

THROTTLE
CABLE

LOCKNUT
ADJUSTING
NUT

(cont'd)

www.emanualpro.com

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

1 8 . Removethe slavecylinderand clutch hose bracket

(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

www.emanualpro.com

30. Disconnectthe primary heatedoxygen sensor(prlthen removeexhaustpipeA


mary HO2S)connector.

22. Removethe radiatorcaP.


use care when removing the radiatol
!@
cap to avoid scalding by hot coolani or steam.

'97 - 98 U.S. models (Cslifornia):

23. Raisethe hoistto full height


24. Removethe front tires/wheels.
25. Removethe guardbar and splashshield.

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.

'97 - 98 U.S. modls {ExceptCalifornia):


'99 - 00 models:
PRIMARYHO2S
CONNECTOR
GASKETS
Replace.

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)

www.emanualpro.com

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-).

Make marks on the transfercompanionflange and


propellershaftas shown.Usethesemarksto set the
propeller shaft in the proper position when reinstalling(4WD).

OOI{TROLPI

Removethe four bolts securingthe propellershaft,


then separatethe propellershaft from the transfer
companionflange(4WD).

SNAPPIN

sHtFTCABtt
OOVEB

8 x 1.25mm
t2 N.m 12.2lgtr'l'',,
16tbf.ftl

Removethe right damperfork (seesection18).


Disconnect
the suspensionlowerarm balljoints(see
section18),

34. Removethe driveshafts(see section t6). Coat all


precision-finished
surfacewith cleanengineoil. Tie
plasticbagsover the driveshaftends.
E x 1.25mm

32 N.m 13.3lgt.m, 24 lbt'ftl


Replce.
37. Lowerthe hoist,

5-8

www.emanualpro.com

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)

www.emanualpro.com

5-9

EngineRemovaUlnstallation
Removal(cont'dl
43. Attachthe chainhoistto the engine.

5-10

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44. Removethe left and right front mounts and brackets

46. Removethe uDperbracket.

UPPER

Replace.

M/T:

47. Removethe transmissionmount bracket,then remove


the transmissionmount.
MOUNT/BRACKET

TRANSMISSION

Alf I

45. Removethe rearmount bracketmountingbolt.

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}

Installthe upper bracket,then tightenthe nuts in the


numberedseauence.

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.

Installthe rear mount bracketmountingbolt. Do not


tightenthe bolt.

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.

Tightenthe rear mount bracketmountingbolt.

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.

Installthe leftfront mount,then tightenthe bolts/nut


in the numberedseouence.
O t2 r 1.25mm
8il N.m18.5kgt.m,el |bfftl

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)

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5-15

EngineRemoval/lnstallo
cton
Installation(cont'd)
8.

Tightenthe nut on the right front mount.


AlTi

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.

Performthe followingchecksand adjustments:


. Checkthat the springclip on the endsof the driveshaftand intermediate
shaftclicksinto place.Use
new springclips.
. Adjustthe shiftcable(seesectionl4).
. Adjustthe throttlecable(seesection11).
. Refillthe enginewith engineoil (seepageg-4).
. Refillthe transmissionwith oil or fluid (seesect i o n 1 3o r 1 4 ) .
. Refillthe radiatorwith enginecoolant(seepage
10_5).
. B l e e da i r f r o m t h e c o o l i n g s y s t e mw i t h t h e
heatervalveopen (seepage l0-5).
. Cleanthe batterypostsand cableterminalswith
sandpaper,assemblethem, then apply greaseto
Dreventcorrosron.
. Inspectfor fuel leakage(seesection1l).
After assemblingfuel line pans,turn on the ignition switch (do not operatethe starter)so that
the fuel pump operatesfor approximatelytwo
secondsand the fuel Iine pressurizes.
R e p e a t h i s o p e r a t i o nt w o o r t h r e e t i m e s ,a n d
checkfor fuel leakageat any point in the fuel line.

Mount and Brackst Bolts/Nuts Torqus Value Specitications:


A: '10x 1.25mm
64 N.m 16.5kgI.m, 47 lb{.ftl
B: 12 x 1.25mm
59 N.m 16.0kgf.m, 43 lblft)
Replace.
C : 1 4x 1 . 5m m
8:l N.m (8.5kgt.m, 6r lbl'ft)
Replace.
D: 10x 1,25mm
,t4 N.m (4.5 kgf'm,33 lbIft)
Er 12x 1.25mm
83 N.m 18.5kgf.m, 61 lbl.ftl

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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

Adjustthe valveson No. 1 cylinder.


Intake: 0.08- 0.12mm (0.003- 0.005inl
Exhaust:0.16- 0.20 mm (0.006- 0.008in)
Loosenthe locknut,and turn the adiustmentscrew
until the feeler gauge slides back and forth with a
slightamountof drag.

LOCI(NUT
9 x 0.75m.n
25 N.m 12.5kgf.m, 18lbf.ft)

POINTER

POINTER

Adiusting Screw Locations:


INTAKE

No.4

No.3

No.2

No. 1

EXHAUST

(cont'd)

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6-3

ValveClearance
Adjustment(cont'dl
6.

Tightenthe locknut,and checkthe clearanceagajn.


Repeatthe adjustmentif necessary.

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.

9 . Positionthe pistonat TDC,and insen an air adaptor


into the spark plug hole. Pump air into the cylinder
t o k e e p t h e v a l v e c l o s e dw h i l e c o m p r e s s i n gt h e
springsand removingthe valvekeepers.
10. Put shop towels over the oil passagesto prevent
t h e v a l v e k e e p e r sf r o m f a l l i n g i n t o t h e c y l i n d e r
head.
OIL PASSAGE

Removethe camshaftholderbolts.then removethe


camshaftholders,the camshaftsand rockerarms.

lntake Valve Seals


6. Usingthe 6 mm boltssuppliedwith the tool, mount
t h e t w o u p r i g h t st o t h e c y l i n d e rh e a d a t t h e e n d
camshaftholders.The uprightsfit as shown.
7.

Insertthe cross shaft through the top hole of the


two uprights,

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.

22. Put shop towels over the oil passagesto prevent


t h e v a l v e k e e p e r sf r o m f a l l i n g i n t o t h e c y l i n d e r
neao.

1 3 . Repeatstep 11 for the othervalvein that cylinder.


1 4 . Removethe valveseals(seepage6-24).
1 5 . Installthevalveseals(seepage6-29).
1 6 . lnstallthe springs,the retainersand the keepersin
reverseorderof removal.
'17. Repeatsteps9 to 16 for the otherthreecylinders.
Exhaustvalve Seals
18. Usingthe 5 mm bolts suppliedwith the tool, mount
t h e t w o u p r i g h t st o t h e c y l i n d e rh e a d a t t h e e n d
camshaftholders.The uprightsfit as shown.
19. Insert the cross shaft through the bottom hole of
the two uprights.

20. Selectthe 7/8 in. diametershort compressorattach


ment,and fastenthe attachmentto the No. 4 hole of
the leverarm with the speedpin supplied.
t1

Positionthe pistonat TDC,and insertan air adaptor


into the spark plug hole. Pump air into the cylinder
t o k e e p t h e v a l v e c l o s e dw h i l e c o m p r e s s i n gt h e
springsand removingthe valvekeepers.

23. Positionthe lever arm underthe crossshaft so the


leveris perpendicular
to the shaftand the compressor attachmentrests on top of the retainerfor the
spring being compressed.Usethe rear positionslot
on the leveras shown.

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".

Crankshaftpulley bolt size and torque value:


14 x 1.25mm
177N'm (18.0kgf.m,130lbt.ftl
NOTE:Do not use an impactwrenchwhen installing.

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.

kgf.m, 7.2 tbtft)

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.

lnspectthe timing belt for c.acksand oil or coolant


s o a k i n g .R e p l a c et h e b e l t i f i t i s o i l o r c o o l a n t
soaked.Removeany oil or solventthat gets on the
belt.

'1. Removethe cylinderheadcover

lnspectthis
areafor wear.

2.

Set the No. 1 pistonat TDC(seepage.6-12).

3.

Rotatethe crankshaftfive or six revolutionsto set


the belt.

4.

Set the No. 1 pistonat TDC.

5.

Loosenthe adjustingbolt 1/2turn (180')only.

ADJUSTINGBOLT
5,4N.m (5.5 kgf.m,
40 tbtftl
For adiustmentonly,

rotation,

Rotatethe crankshaftcounterclockwise
three teeth
on the camshaftpulley.
3.

After inspecting,retorquethe crankshaftpulleybolt


to 177N.m (18.0kgnm,130lbf.ft).

7.

Tightenthe adjustingbolt to the specifiedtorque.

8.

After adjusting,retorquethe crankshaftpulleybolt to


177N.m (18.0kgf.m,130lbf.ft).

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.

Loosenthe mountingnut and locknut,then remove


the altefnatorbelt.
LOCKNUT
I x 1.25mm
2a N.m 12.4kgt m, 17 lblftl

1 . Turn the crankshaftpu\ley so the No. 1 piston is at


top deadcenter(TDC).
2.

Removethe guard bar and splashshield (seepage


5-7).

,l

Loosenthe mountingbolt and lockbolt.then remove


the power steering(P/S)pump belt.
MOUNNNGBOLT
8 x 1.25rnm
24 N.m {2.4 kgt.m, 17 lbf.ftl
10 x 1,25mm
4,1N.m (,1.5kgt m, 33 lbtftl
AELT

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.

Loosenthe idler pulley bracketbolt and adjusting


bolt,then removethe air conditioning(lVC)compres
sor belt(seepage5-4).

6-10

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Installation
8. Removethe cylinderheadcover.

Installthe timing belt in the reverseorderof removal;


Only key pointsare describedhere,

NOTE:Referto page6-32when installingthe cylinder headcover.

1.

9 . Removethe crankshaftpulley(seepage6-7).

GROOVE

POINTER

1 0 . Removethe middle cover and lower cover. Do not


usethesecoversto storeremoveditems.
MTDDLE
COVER

Setthetiming beltdrivepulleyso thatthe No. 1 piston


is at top dead center (TDC).Align the groove on the
timingbeltdrivepulleyto the pointeron the oil pump.

6x1.0mm
9.8N.m {1.0kgt m,

DRIVEPULLEY
Clean.
LOWER
COVER

2.
9.8N.m(1.0kgt.m,7.2lbf.ftl

Set the camshaftpulleysso that the No. I piston is at


TDC.Alignthe TDCmarkson the camshaftpulleysto
the pointerson the backcover.

1 1 . Markthe directionof rotationon the timing belt.

CAMSHAFT
PULLEY
Clean.

12. Loosenthe adjustingbolt 180'.Pushthe tensionerto


removetensionfrom the timing belt, then retighten
the adiustingbolt.

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.

Installthe timing belttightlyin the sequenceshown.


J @ AdjustO Timing belt drive pulley(crankshaft)
ing pulley =r @ Water pump pulley r @ Exhaust
camshaftpulley--)@ Intakecamshaftpulley.

9. Checkthat the crankshaftpulley and camshaftpulleys


are both at TDC.

POINTERON

NOTE: Make sure the timing belt drive pulley and


camshaftpulleysare at TDC.

4.

Loosenand retightenthe adjustingbolt to tension


the timing belt.

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.

Rotatethe crankshaftpulleyabout five or six turns


counterclockwiseso that the timing belt positions
on the pulleys.
Adjustthe timing belttension{seepage6-9).

POINTER

1 0 . lf the camshaftpulleys are not positionedat TDC,


removethe timing belt.adjustthe positionfollowing
the procedureon page6-11.then reinstallthe timing
belt.
1 1 . Installthecylinderheadcover(seepage6-32).
1 2 . After installation,
adjustthe tensionon eachbelt.
. See section4 for alternatorbelt tension adjustmenr.
. See section22 for NC compressorbelt tension
adjustment.
. See section17 for P/Spump belt tensionadjustment.

6-12

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CKFSensor
Replacement
1.

Removethe guard bar and splashshield (seepage


5-7t.

4.

Loosenthe locknutand mountingnut, then remove


the alternatorbelt.
LOCKNUT
8 x 1.25mm
24 N.m (2.4 kgl.m, 17 lbtftl

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.

Removethe middlecoverand the lowercover.

aJ.

Disconnectthe CKFsensorconnector,then remove


the CKFsensor.

24 N.m 12.4lgf.m, 17 lbl.ftl

Loosenthe adjustingbolt and idler pulley bracket


bolt,then removethe Ay'CcomDressorbelt.
ADJUSTINGBOLT
LOCKNUT
8 x 1.25mm
24 N.m {2.4 kgf.m, 17 lbf.ft)

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.

Install the CKF sensor in reverse order of removal.

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

www.emanualpro.com

gasket.

takecarenot to fold it or damagethe contactsurface.


a metal
-?Ehandling
Priorto reassembling,
cleanall the partsin solvent,dry them and apply lubricantto any contactparts.

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)

www.emanualpro.com

6-15

GylinderHead
Removal
Engineremovalis not required
for thisprocedure.

6.

Loosenthe locknutand mountingnut, then remove


the alternatorbelt.

Make sure iacks and safety stands are

l!@

LOCKNUT
8 x 1.25mm
24 N.m (2.4 kgf.m, 17 lbt.ftl

placed properly, and hoist blackels ale attachgd to the


correctposition on the engine.
NOTE:
o 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.
. To avoid damagingthe cylinderhead,wait until the
enginecoolanttemperaturedrops below 100"F(38'C)
beforelooseningthe retainingbolts.
. Markall wiring and hosesto avoid misconnection.
Also, be surethat they do not contactother wiring or
hoses,or interferewith other parts.
1 . Disconnect
the negativeterminalfrom the battery.

2.

Drain the engine coolant (see page 10-5).Remove


the radiatorcapto speeddraining.

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.

Loosenthe idler pulley bracketbolt and adjusting


bolt, then remove the air conditioning(A,/C)com,
pressorbelt.
ADJUSTING
BOLT

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.

Removethe throttlecableby looseningthe locknut,


then slip the cable end out of the throttle linkage.
Take care not to bend the cablewhen removingit.
Always replaceany kinkedcablewith a new one.
'97 - 98 modols:

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)

www.emanualpro.com

6-17

GylinderHead
Removal(cont'dl
'11. Removethe brakeboostervacuumhose.fuel return
hose,and vacuumhose.
'97 - 98 modsls:

12. Removethe breatherhose and oositivecrankcase


ventilation(PCV)hose,
'97 98 models:

BRAKEBOOSTER

PCVHOSE
BREATHEB
HOSE

VACUUM
HOSE

'99 - 00 models:

BREATHER
HOSE
BRAKEBOOSTEB
VACUUM HOSE

PCVHOSE

6-18

www.emanualpro.com

13. Removethe upper radiatorhose, heaterhose and


water bypasshose.

18. Removethe cylinderheadcover.


CYLINDER

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

19. Inspectthe timing belt (seepage6-9).

Removethe sparkplug capsand distributorfrom the


cylinderhead.
Removethe cruisecontrolactuator(seesection4).
1 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 pan and the iack(seepage6-10).

(cont'd)

www.emanualpro.com

6-19

CylinderHead
Removal(cont'dl
Removethe timing belt (seepage6-10).

2' t. Removethe camshaftpulleysand backcover.

22. Bemove the exhaust manifold bracket and self-locking nuts.


'97 - 98 U.S. modsls (Californial:
GASKET
Replace.

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.

www.emanualpro.com

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.

25. Removethe camshaftholderbolts,then removethe


camshaftholdersand rockerarms.Makenote of the
rockerarm Dositions.

ROCKERARM

26. Remove the cylinder head bolts. To prevent


warpage,unscrewthe bolts in sequence1/3turn at a
time; repeatthe sequenceuntil all bolts are loosened.

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

27. Removethe cylinderhead.

www.emanualpro.com

6-21

Camshafts
Inspection
1 . Loosenthe adjustingscrews.

11. Removethe camshaftholders.Measurethe widest


portionof plastigageon eachjournal.

Removethe camshaftholders.
Camshatt-toHoldGrOil Clearance:
Standard {Newl: 0.030- 0.069mm
{0.0012- 0.0027in}
ServicoLimit: 0.15 mm (0.006in)

Markthe rockerarms,then removethem.


4. R e i n s t a l tl h e c a m s h a f ta n d h o l d e r s .T i g h t e nt h e

camshaftholderbolts in a crisscrosspattern,beginning with the innerbolts.


9.8 N.m (1.0kgf.m.7.2lbf.ft)
Seatthe camshaftsby pushingthem toward the distributorend of the headwith a screwdriver.
Z e r o t h e d i a l i n d i c a t o ra g a i n s tt h e e n d o f t h e
camshaft, push the camshaft back and forth and
readthe end play.
CamshaftEnd Play:
StandardlNewl: 0.05- 0.15mm
10.002- 0.005in)
ServiceLimit: 0.5 mm (0.02in)
12. lf camshaft-to-holder
oil clearanceis out of tolerance:
. A n d t h e c a m s h a f th a s a l r e a d yb e e n r e p l a c e d ,
you must replacethe cylinderhead.
. lf the camshafthas not beenreplaced,first check
total runout with the camshaftsuoDortedon Vblocks.
CamshaftTotal Runout:
Standard (N6w): 0.03 mm (0.001in) max.
ServiceLimit
0.04 mm (0.(X)2in)

7 . Unscrewthe camshaftholder bolts two turns at a


t i m e , i n a c r i s s c r o s sp a t t e r n ,T h e n r e m o v e t h e
camshaftholderboltsfrom the cvlinderhead.
8. L i f t t h e c a m s h a f t so u t o f t h e c y l i n d e rh e a d .w i p e
them clean,then inspectthe lift ramps,Replacethe
camshaftif any lobes are pitted, scored,or excessivelyworn.

Rotat6camshatt
while measuring.

Cleanthe camshaftjournal surfacesin the cylinder


head,then set the camshaftback in Dlace.Placea
plastigagestrip acrosseachjournal.

1 0 . Installthe camshaftholders.and torquethe boltsto


the valuesand in the sequenceshownon page6-31.

lf the total runout of the camshaftsis within tolerance,replacethe cylinderhead

lf the total runout is out of tolerance,replacethe


camshaftsand recheck.lf the oil clearanceis still
out of tolerance,replacethe cylinderhead.

NOTE: Do not rotatethe camshaftsduring inspection.

6-22

www.emanualpro.com

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.

Installthe spring compressor.Compressthe spring


and removethe valvekeeper.

Inspectthis arealor wear.

VALVESPRINGCOMPRESSOR
KD No. 3&!. whh *'5 JAW o.

VALVESPRINGCOMPRESSOR
ATTACHMEUT
07757- PJ1010A
(cont'd)

www.emanualpro.com

6-23

Valves,Valve Springs and Valve Seals


Removal(cont'dl
3.

Installthe valveguide sealremover.

VALVEGUIDESEALREMOVER
LISLEP/N 57900or KD3350or equivalent
(Commerciallv
available)

Intake Valve Dimensions


A Standard{New}: 30.85- 31.15mm
B Standard (New):
G Standard {Newl:
C ServiceLimiti
D StandardlNewl:
D Service Limit:
4.

Removethe valveseal.

6-24

www.emanualpro.com

- 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)

Exhausi Valv Dimensions


A Standard(Newl: 27.85- 28.15mm
1 1 . 0 9-61 . 1 0 8i n )
B Standard (Newl:
10,1.00- 10,1.30mm
(il.09i[- it.l06 in)
C Standard {New):
6.550- 6.560mm
10.2579- 0.2583inl
C ServiceLimit:
6.52mm (0.257inl
D StandardlNewl:
1.65- 1.95mm
- 0.077in)
10.065
D Service Limit:
1.45mm (0.057inl

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.

lntake Valve Stem-to-GuideClearance:


Standard(Newl:0.04- 0.10mm
(0.002- 0.004in)
0.16mm (0.006in)
ServiceLimit

As illustratedbelow, use a commerciallyavailable


air-impactvalve guide driver attachmentmodified
t o f i t t h e d i a m e t e ro f t h e v a l v e g u i d e s . I n m o s t
cases,the same procedurecan be done using the
sDecialtool and a conventionalhammer.

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.

lf the measurementis now within the servicelimit,


reassembleusinga new valve.

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.

Use a hot plate or oven to evenlyheat the cylinder


headto 300"F(150"C).Monitorthe temperaturewith
a cookingthermometer.Do not get the head hofter
than 300'F (150"C);excessiveheat may loosenthe
valveseaIs.

CAUTION: To avoid burns, uss heavy gloves when


handling the heated cylinder head.

ExhaustValve Stem-to-GuideClearance:
Standard(New):0.05- 0.08mm
(0.002- 0.003in)
ServiceLimit: 0.11mm (0.004in)
(cont'd)

www.emanualpro.com

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.

Apply a thin coat of cleanengineoil to the outside


of the new valve guide. Installthe guide from the
camshaftside of the head; use the specialtool to
drive the guide in to the specifiedinstalledheight.lf
you have all 16 guidesto do, you mav have to
reheatthe head.

CAUTION: Always wear satety goggles or a face


shield when driving valve guidss.
5.

Turn the head over and drive the guide out toward
the camshaftside of the head.

ATTACHMENT

Valve Guide Installed Height:


Intake: 13.75- 1i1.25
mm
{0.5,[1- 0.561in)
Exhaust:15.75- 16.25mm
(0.620- 0.640inl

'o C'
6.

li a valve guide won't move, drill it out with a 8.0


mm (5/16in) bit, then try again.Drittguidesonty in
extremecases;you could damagethe cylinderhead
if the guide breaks.

7.

Removethe new guide(s)from the freezer,one at a


tlme, as you needthem.

6-26

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CylinderHead
Reaming

Warpage

NOTE:For new valveguidesonly.

oil clearances(seepageG22)
NOTE: lf camshaft-to-holder
the head cannot be resurare not within specification,
faced.

1. Coatthe reamerand the valveguidewith cuttingoil.


2.

Rotatethe reamer clockwisethe full length of the


valveguide bore.

oil clearancesare within specificalf camshaft-to-holder


tions, checkthe head for warpage.Measurealong the
edges,and threeways acrossthe center.

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.

Thoroughlywash the guide in detergentand water


to removeanYcuttingresidue.

5.

Checkclearancewith a valve(seepage6-25).

6 . Verifythat the valvesslidein the intakeand exhaust


valveguideswithout exertingpressure.

if warpage is less than 0.05 mm (0.002in) cylinder


headresurfacingis not required
lf warpageis between0.05mm (0.002in) and 0.2 mm
(0.008in), resurfacecylinderhead.
Maximum resurfacelimit is 0.2 mm (0.008in) based
on a heightof 132.0mm (5.20in).
PRECISION
STRAIGHTEDGE

REAMERHANDLE

mm
vALvE GUIDEREAMER,6.6
0798i1- 657010O

Cylindr Hesd Height:


Standard{New}:131.95- 132.05mm
- 5.199inl
15.195

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6-27

Valve Seats
Reconditioning
lf the guidesare worn (seepage6-25),replacethem (see
pagee25) beforereconditioning
the valveseats.
1.

5.

Renewthe valve seatsin the cylinderhead using a


valve seat cutter.

After resurfacingthe seat, inspect for even valve


seating:Apply PrussianBluecompoundto the valve
face, and insertthe valve in its original locationin
the head,then lift it and snap it closedagainstthe
seatseveraltimes.
ACTUAL
SEATING
SURFACE

VALVE
SEAT
o

PRUSSIAN

The actualvalve seatingsurface,as shown by the


bluecompound,shouldbe centeredon the seat.
. lf it is too high (closerto the valve stem), you
must make a second cut with the 60" cutter to
move it down, then one more cut with the 45"
cutter to restore seat width.
. lf it is too low (closer to the valve edge), you
must make a second cut with the 30. cutter to
move it up, then one more cut with the 45. cutter
to restoreseat width.

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.

NOTE:The final cut shouldalwavsbe madewith


the 45" cutter,
7.

Makeone more very light passwith the 45ocutterto


removeany possibleburrs causedbv the other cutters.

Insert the intake and exhaust valves in the head,


and measurevalvestem installedheioht.
Intake Vslve Siem Instslted Height:
Standard {Newl: it0.765- 41.235mm
- 1.6234inl
11.6049
SarvicoLimit: itl.il85 mm (1.6333in)
ExhaustValve Stem Installed H6ight:
Standard {New}: 42.755- .235 mm
11.61137- 1.7022 inl
/(|.,185
ServicoLimit:
mm (1.7120in)

Valve Seat Width (lntake and Exhaust):


Standard {N.w}: 1.25- 1.55mm (0.049- 0.051in)
ServicaLimit: 2.0 mm (0.08in)

f-]
VALVESTEM
INSTALLEDHEIGHT

8.

6-28

www.emanualpro.com

lf valve stem installed height is over the service


limit. replacethe valve and recheck.lf it is still over
t h e s e r v i c el i m i t . r e p l a c et h e c y l i n d e r h e a d ;t h e
valveseatin the headis too deeo.

Valves,Valve Springsand Valve Seals


lnstallation
1.

Installthe valvespring and valve retainer.Placethe


end of the valve spring with closely wound coils
towardthe cylinderhead,

Coatthe valve stemswith oil. Insertthe valvesinto


the valveguides.
Checkthat the valvesmove up and down smoothly.

Installthe valve spring compressor.Compressthe


spring,and installthe valvekeepers.

Installthe springseatson the cylinderhead.

VALVESPRINGCOMPRESSOR
lComm6rciallyavailable)
KD No. 383,with *35 JAw or

Installthe valvesealsusingthe specialtool.


NOTE:Exhaustand intakevalvesealsare not interchangeable.
WHITE
SPRING

INTAKE VALVE SEAL

BLACK
SPRING

EXHAUSTVALVESEAL
VALVEGUIDE
SEALINSTALLER
lCommerciallyavailable)
KO3372or equivalnt
ot
07GAD- PH70100

VALVESPRIT{G
OOMPfiESSOR
ATTACHMENT
0775'- PJ1010A
7.

Lightlytap the end of eachvalve stem two or three


times with a plasticmalletto ensureproperseating
of the valve and valve keepers,Tap the valve stem
only along its axisso you do not bendthe stem.

PLASTE

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6-29

CylinderHead
Installation
Installthecylinderheadin the reverseorderof removal:
1.

Cleanthe cylinderheadand blocksurfaces.

2.

Cleanthe oil controlorifice.Installthe cylinderhead


gasket,dowel pins and the oil controlorificeon the
cylinderblock.Always use a new cylinderheadgasket.

CYLII{DER
HEAD
GASKET
Rplace.

4.

Tightenthe cylinderhead bolts in two steps.In the


first step tighten all bolts, in sequence,to about 29
N.m {3.0kgf.m,22 lbf.ft);in the finat step,tighten in
the samesequence
to 85 N.m(8.7kgf.m,63lbf.ft).
Usea beam-typetorque wrench.When usinga preset-typetorque wrench, be sure to tighten slowly
and do not overtighten.
lf a bolt makesany noisewhile you are torquing it,
loosenthe bolt, and retightenit from the 1ststep.

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.

Apply clean engine oil to the bolt threads and under


the bolt heads.

6 -30

www.emanualpro.com

Installthe exhaustmanifoldbracket.and tightenthe


new self-locking
nuts (seepage6-20).

7.

Placethe rockerarms on the pivots and the valve


s t e m s .P u t t h e r o c k e ra r m s i n t h e i r o r i g i n a lp o s i lrons.
lnstallthe camshafts,then installthe oil sealswith
the open side (spring)facing in. Make sure that the
keywayson the camshaftsare facingup and the No.
1 pistonis at TDC.

'10. lnstallthe camshaftholders.


NOTE:
o " 1 " o r " E ' m a r k sa r e s t a m p e do n t h e c a m s h a f t
holders.
. T h e a r r o w s m a r k e d o n t h e c a m s h a f th o l d e r s
shouldpoint at the timing belt.

't't, Tighten each bolt in two steps to ensure that the


rockersdo not bind on the valves.
Wipe off the excessliquid gasketfrom the No. 1 and
No. 6 camshaftholderswith a shop towel,
Specifiedtorque:
9.8 N.m (1.0 kgf.m, 7.2 lbf.ft)
Apply engine oil to the bolt ihreads.

Clean and dry the cylinder head mating surfaces.


Apply liquid gasket (P/N 08718- 0001 or 087180OO3)
to the head mating surfacesof the No. 1 and
N o . 6 c a m s h a f th o l d e r s o n b o t h t h e i n t a k e a n d
exhaustside.

I?,ITAKE

No. I

EXHAUST
EXHAUST

II{TAKE

Apply liquidgasketto th shadedareas.

(cont'd)

www.emanualpro.com

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 .

1 7 . Installthe timing belt (seepage6-11).

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).

lnstall the head cover gasket in the groove of the


cylinderhead cover. Seatthe head cover gasketin
the recessesfor the camshaftfirst, then work it into
the groovearoundthe outsideedges.Makesurethe
head cover gasket is seated securely in the corners
of the recesses
with no gap.

1 4 . lnstallthebackcover.

To set the camshaftsat TDC positionfor the No. l


p i s t o n ,a l i g n t h e h o l e s i n t h e c a m s h a f t sw i t h t h e
holes in the No. l camshaftholdersand insert 5.0
mm pin punchesin the holes.Installthe keys into
the camshaftgrooves.
KEYS

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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2 1 . Checkthat the matingsurfacesare cleanand dry.


2 2 . Apply liquid gasket,part No. 08718- 0001or 08718
- 0003,to the headcovergasketat the eight corners
of the recesses.

25. Tightenthe nuts in tvvo or three steps.In the final


step, tighten all nuts, in sequence.to 9.8 N.m (1.0
kgf.m,7.2 lbf.ft).

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.

23. Holdthe headcovergasketin the grooveby placing


your fingerson the camshaftholdercontactingsurfaces(top of the semicirclesl.
O n c e t h e c y l i n d e rh e a d c o v e r i s o n t h e c y l i n d e r
head, slide the cover slightly back and forth to seat
the headcovergasket.
24. Inspectthe coverwashers.Replaceany washerthat
is damaged or dete(iorated.

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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

Luori""t" "tl internalpartswith engineoil during reassembly.

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)

www.emanualpro.com

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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Inspectthe top ot each cylinder bore


for carbonbuild up or a ridge
beloreremovingthe piston.
page7-10
Removethe ridgeif necessary,

Flywheeland Drive Plate


Replacement
ManualTransmission:
Removethe eight flywheelbolts,then separatethe flyflange.After installation,
tightwheelfrom the crankshaft
en the bolts in the sequenceshown.

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,

ConnectingRod and Crankshaft


EndPlay
1.

Measurethe connectingrod end play with a feeler


gauge.

3.

ConnectingRod End Play:


Stsndard(Nsw):0.15- 0.30mm
{0.006- 0.012in)
in)
ServiceLimit: 0./t0mm 10.016

2.

SCREWORIVER

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


installa new connectingrod.
lf it is still out-of-tolerance,
replacethe crankshaft
{seepages7-9 and 7-20).

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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Pushthe crankshaftfirmly away from the dial indic a t o r ,a n d z e r o t h e d i a l a g a i n s t h e e n d o f t h e


c r a n k s h a f tT. h e n p u l l t h e c r a n k s h a f ft i r m l y b a c k
t o w a r d t h e i n d i c a t o rt;h e d i a l r e a d i n gs h o u l d n o t
exceedthe servicelimit.

lf end play is excessive,inspectthe thrust washers


Reolaceoans as
and thrustsurfaceon the crankshaft.
n e c e s s a r yT. h r u s t w a s h e r t h i c k n e s si s f i x e d a n d
m u s t n o t b e c h a n g e de i t h e rb y g r i n d i n go r s h i m mrng.

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 ,

removethe main capsand bearinghalves.


2.

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.

Placea strip of plastigageacrosseachmain journal.


NOTE:lf the engineis still in the vehiclewhen you
b o l t t h e m a i n c a p d o w n t o c h e c kc l e a r a n c et,h e
weight of the crankshaftand flywheel will flatten
the plastigagefurther than just the torque on the
cap bolt, and give you an incorrectreading.For an
a c c u r a l er e a d i n g ,s u p p o r t t h e c r a n k w i t h a j a c k
underthe counterweights
and checkonly one bearI n ga I a I r m e .

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

Crankshaft Bore Code Location

1.

Removethe connectingrod cap and bearinghalf.


Cleanthe crankshaftrod journal and bearing half
with a cleanshop towel.

Lettershave been stamDedon the end of the blockas a


codeJorthe sizeof eachof the 5 main journalbores.
U s e t h e m , a n d t h e n u m b e r so r b a r s s t a m p e do n t h e
crank(codesfor main journalsize),to choosethe correct
beanngs.
lf the codesare indecipherable
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
brush or sc.aper.Cleanthem only with solventor detergent.

Placethe plastigageacrossthe rod journal.


Reinstallthe bearing half and cap, and torque the
nuts.
Torqus: 31 N.m (3.2 kgf.m. 23 lbf.ft)
NOTE:Do not rotatethe crankshaftduring inspection.
Removethe rod cap and bearinghalf,and measure
the widestpart of the plastigage.
ConnestingRod Bearing-to-JournalOil Clearancc:
Standard {Newl: 0.020- 0.038mm
{0.0008- 0.0015in)
ServiceLimit: 0.05 mm {0.002inl
PLASTIGAGE

Main Journ.l Cod. Locrtions lNumbcB oi Bar3l

lf the plastigagemeasurestoo wide or too narrow,


removethe upper half of the bearing,installa new.
completebearingwith the same color code {select
the color as shown on the next page),and recheck
the clearance.Do not file, shim, or sc.apethe bearings or the capsto adjustthe clearance.

Bearing ld.ntif icrtion


Color code is
on the edge of
the bearing.
I

""""""""

Smallerbearing(rhicker)
Green
Green

Elacl

7- 8

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Alue

7.

lf the plastigageshows the clearanceis still incor


rect,try the next largeror smallerbearing{thecolor
listed above or below that one). and check cleara n c e a g a i n .l f t h e p r o p e rc l e a r a n c ec a n n o t b e
obtainedby usingthe appropriatelargeror smaller
bearings.replacethe crankshaftand startover.

Pistonsand
Crankshaft
Selection

Removal

Connecting Rod Code Location

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.

Removethe oil pan assembly.


Removethe right sidecover.

Half of numberis
stampedon beanng
cap and the othel
half is stampedon
rod.

Removethe oil screen.


Removethe oil pump.
Connecting Rod Journal Code Locations {Lettersl
OIL SCREEN

8aring ldentif ication


aolor code is on the
edge ol
tne Deanng.

Larger big end bore

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

sma er bearino {thicker)

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.

Removethe bolts.To preventwarpage,unscrewthe


b o l t s i n s e q u e n c e1 / 3 t u r n a t a t i m e ; r e p e a tt h e
sequenceuntil all boltsare loosened.

9 . Removethe upper bearinghalvesfrom the connecting


rods,and set them asidewith their respectivecaps.
1 0 . Reinstallthe main caps and bearingson the engine
in properorder.
1 1 . lf you can feel a ridge of metalor hard carbon

around the top of each cvlinder,remove it with a


r i d g e r e a m e r .F o l l o w t h e r e a m e rm a n u f a c t u r e r ' s
i n s t r u c t i o n sl.f t h e r i d g e i s n o t r e m o v e d ,i t m a y
damagethe pistonsas they 8re pushedout.

7.

and main caps/bearRemovethe rod caps/bearings


in order
ings,Keepall caps/bearings

12. Use the wooden handle of a hammer to drive the


pistonsout.

Lift the crankshaftout of the engine.being careful


not to damagethe journals.

1 3 . Reinstallthe connectingrod bearingsand capsafter


rod assembly.
removingeachpiston/connecting
1 4 . To avoid mixup on reassembly,mark each piston/
connectingrod assemblywith its cylindernumber.
NOTE:The existingnumber on the connectingrod
does not indicateits positionin the engine,it indicatesthe rod bore size.

7-10

www.emanualpro.com

Crankshaft
Inspection
1.

Cleanthe crankshaftoil passageswith pipe cleaners


or a suitablebrush.

2.

Checkthe keywayand threads.

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.

Measureout-of-roundat the middleof each rod and


main journal in two places.The differencebetween
m e a s u r e m e n tosn e a c hl o u r n a lm u s t n o t b e m o r e
than the servicelimit.
JournalOut-of-Round:
Standard(Newl:0.005mm 10.0002
inl max.
ServiceLimit: 0.010mm (0.000i1in)

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.

Suppon with lathelype tool or V-blocks.

5.

Measuretaper at the edges of each rod and main


journal.The differencebetweenmeasurementson
e a c h i o u r n a lm u s t n o t b e m o r e t h a n t h e s e r v i c e
limit.
JournalTaperi
Standard{Newl:0.005mm 10.0002
inl max.
ServiceLimit: 0.010mm (0.0004inl

www.emanualpro.com

7-11

Pistons

Inspection
L

Checkeachpistonfor distortionor cracks.


Measurethe pistondiameterat distanceA from the
bottom of the skirt.
A: '97 - 98 models15 mm 10.5inl
'99 - 00 models 20 mm 10.8inl

3.

Calculatethe differencebetweenthe cylinder bore


diameter(seepage7-13)and the pistondiameter.
Piston-to-CylinderClearance:
Standard{New):0.010- 0.040mm
{0.0004- 0.0016inl
Limit:
0.05
mm {0.002in}
Service

Piston Diameter:
Standard (New): 8:1.980- txl.990mm
(3.3063- 3.3067inl
Limit:
83.970
mm {3.3059inl
Service

SKIRTDIAMETER

lf the clearanceis near or exceedsthe servicelimit,


inspectthe piston and cylinderblock for excessive
wear.

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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.

Checkthe top of the blockfor warpage.


Measurealong the edgesand acrossthe centeras
shown.

SURFACESTO BE MEASURED

Engine Block Warpage:


Standard(New):0.07mm (0.003in) max.
ServiceLimit: 0.10mm {0.004inl

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

1 . Assemble the Piston Pin Tools as shown.

Eachrod falls into one of four toleranceranges(from 0


to + 0.024mm {0 to + 0.0009in). in 0.006mm (0.0002in)
increments)dependingon the size of its big end bore.
lt's then stampedwith a number 1.1.2,3,or 4) indicating
the range.
Y o u m a y f i n d a n y c o m b i n a t i o no t 1 , 2 , 3 , o r 4 i n a n y
engrne.

PISTONBASEHEAO
07HAF -PL20102
PISTONPIN BASEINSERT
07GAF- PH60300

Normal Bore Size:,18.0mm (1.89in)


Inspectthe connectingrod for cracksand heatdamage.

CONNECTINGROD BORE
REFENENCE
NUMBER
Half of numberis stampedon
bearingcap, the other half on
connectno roo.

PISTONBASE
07973- 6570500

Adjustthe lengthA of the pistonpin dflver.


A: 49.70mm 11.957
in)
PISTONPINDRIVER
HEAI
07973- PE00320

R
Ir1

nT--u
ffi-"""-

PISTONPIN DRIVERSHAFT
07973- PEt0310

u_ll

3.

PILOTCOLLAR
07LAF- PR30100
Embossodmarkfacingup.

Placethe piston on the piston base,and pressthe


pin out with a hydraulicpress.Make sure that the
recessedportion of the piston aligns with the lips
o n t h ec o l l a r .

7-14

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PistonPins
lnstallation

The arrow must face the


timing belt sideot the
engineandthe connecting
rod oil hole must face the
rearof the engine.
ROO
CONNECTING

otL Hor.E

1.

Adjust the length B of the piston pin driver and shaft.


B: 49.70mm (1.957in)

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

Placethe piston on the piston base and pressthe


p i n i n w i t h a h y d r a u l i cpress. Make sure that the
recessedportion of the piston alignswith the lugs
on the pistonbasehead.

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7-15

PistonPins
Inspection
1.

lMeasurethe diameter of the piston pin.

3.

Piston Pin Diameter:


Standard lNewl: 20.996- 21.000 mm

Oversize:

{0.8266- 0.8268in}
20.998- 21.002mm
(0.8267- 0.8268in)

pistonpins are oversize.


NOIE: All replacement
Piston Pin-to-PistonClearance:
StandardlNewl: 0.010- 0.017mm
- 0.0007in)
10.0004

4.

2.

Zeto the dial indicatorto the pistonpin diameter.

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.

Checkthe differencebetlveenthe pistonpin diameter and the connectingrod smallend diameter.


Piston Pin-to-ConnectingRod Interference:
Standard(New):0.015- 0.032mm
(0.0006- 0.0013inl

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

After installinga new set of rings, measurethe ring-togrooveclearances:

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

Top Ring Clearance:


Standard {New}: 0.055- 0.080mm
- 0.0031inl
10.0022
Service Limit: 0.13 mm 10,005inl

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)

Second Ring Clearance:


Standard{Newl:0.035- 0.060mm
{0.001'l- 0.0024inl
Service Limit: 0,13 mm 10.005inl

PISTONRING

--:4

ll
ENDGAP-1f-

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7-17

PistonRings
Replacement

Alignment

1 . Usinga ring expander,removethe old pistonrings.

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

The top ring groove is 1.2 mm (0.042in) wide, rhe


secondring groove is 1.2 mm (0.042in) wide, and
t h e o i l r i n g g r o o v e i s 2 . 8 m m ( 0 . 1 1i n ) w i d e . F i l e
down a bladeif necessary.

'97 - 98 models:

Do not use a wire brush to clean ring lands,or cut


ring landsdeeperwith cleaningtool.
3.

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-;

NOTE: lfthe pistonis to be separatedfrom the connectingrod, do not installnew ringsyet.

RING EXPANDER

Piston Ring Dimensions:

|-

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.

The sealmatingsurfaceon the blockshouldbe dry


Apply a light coat of oil to the crankshaftand to the
l i p o f t h es e a l .
Drivethe crankshaftoil seal squarelyinto the right
sroecover.

DO NOTpositionany ring gap


at piston thrust surfaces,

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

is equalall the way around


Confirmthatthe clearance
with a feelergauge.
- 0.8 mm {0.02- 0.03inl
Clearance:0.5

0.5-0.8 mm
{O.02 0.03 in)

NOTE| Referto pages7 23 and 8-10for installation


of the oil oumDsidecrankshaitoil seal.

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7-19

Pistons

Crankshaft

Installation

Installation

1.

1.

Apply a coat of engine oil to the ring groovesand


cylinderbores.

It the crankshaftis alreadyinstalled.


2. Setthe crankshattto BDCfor eachcylinder.
3. Removethe connectingrod caps,and slip shortsec
tions of rubber hose over the threadedends of the
connectingrod bolts.
4. lnstallthe ring compressor,
and checkthat the bearangis securelyin place.
5. Positionthe pistonin the cylinder,and tap it in using
t h e w o o d e nh a n d l eo f a h a m m e r .M a i n t a i nd o w n ward force on the ring compressorto preventrings
trom expandingbeforeenteringthe cylinderbore.
6. Stop afterthe ring compressorpops free,and check
t h e c o n n e c t i n gr o d - t o - c r a n jko u r n a la l i g n m e n t
beforepushingpistoninto place.
7. Installthe rod caps with bearings,and torque the

Apply a coat of engineoil to the main bearingsand


rod bearings.
I n s e r t h e b e a r i n gh a l v e si n t h e c y l i n d e rb l o c ka n d
connect|ngrods.

3.

Holdthe crankshaftso the rod journalsfor cylinders


N o . 2 a n d N o .3 a r es t r a i g hdt o w n .

4.

Lowerthe crankshaftinto the block,seatingthe rod


j o u r n a l si n t o c o n n e c t i n gr o d s N o . 2 a n d N o . 3 .
Installthe rod capsand nutsfinger tight.

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.

The arrow must face


the timing belt side
of the engine.

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

Line up the mark when


installing connecting rod
cap.

\\

7 -20

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Coat the thrust washer surtacesand bolt threads


with oil.
Installthemain bearingcaps.
Checkclearancewith plastigage(seepage7-7),then
tightenthe bearingcap bolts in 2 steps.

1 0 . Cleanand dry the right sidecover matingsurfaces.


1 1 , Apply liquid gasket,part No. 08718- 0001or 08718
- 0003,evenly to the block mating surfaceof the
right side cover and to the innerthreadsof the bolt
holes.Installit on the cylindrblock

25 N.m {2.5 kgf'm, 18 lbf'ft}


First slsp:
Sscond step: 76 N'm (7.8 kgf'm. 56 lbf'ft)
SEOUENCE
MAIN BEARINGCAPBOLTSTIGHTENING

RIGHTSIDE

NOTE:Wheneverany crankshaftor connectingrod


bearingis replaced,it is necessaryafter reassembly
t o r u n t h e e n g i n ea t i d l i n g s p e e du n t i l i t r e a c h e s
normaloperatingtemperature,then continueto run
15 minutes.
it for approximatelY

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.

1 6 . Apply liquid gasketon the oil pump and right side


covermatrngareas.
CYLINDER
BLOCK

1 4 . Apply greaseto the lips of the oil seals.

Apply liquid gasket


to these pornts,

Align the innerrotor with the crankshaft,


then install
the oil pump.When the pump is in place,cleanany
excessgreaseoff the crankshaft,
then checkthat the
oil seallips are not distoned.

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.

Dry the crankshaftoil sealhousing.


Apply a light coat of greaseto the crankshsftand to
the lips of the seals.
Usingthe specialtool, drive in the timing pulley-end
sealuntilthe driverbottomsagainstthe oil pump.
When the seal is in place,clean any excessgrease
off the crankshaftand checkthat the oil seal lip is
not distorted,

SEALDRIVER
OTLAD- PT3O1OA
lnstallsealwiththe
partsnumberside
facingout.

1 9 . Tighten all bolts and nuts, startingfrom nut O. clocktighteningcan cause


wise in three steps.Excessive
distortionot the oil pangasketand oil leakage.
Torque: 12 N.m (1.2 kgt.m,8.7 lbtft)

(cont'd)

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7-23

Oil Seals
(cont'dl
Installation
4.

l/easurethe flywheel-endsealthicknessand the oil


seal housingdepth.Usingthe specialtool, drive the
flywheel end seal into the rear cover to the point
where the clearancebetweenthe bottom of the oil
seal and the right side cover is 0.5 - 0.8 mm (0.020.03in) (seepage 7-19).Align the hole in the driver
attachmentwith the pin on the crankshaft.

<:
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

1 . Parkthe vehicle on level ground, and turn off the


e n g i n e .A l l o w t h e o i l a f e w m i n u t e st o d r a i n b a c k
into the oil pan so the dipstickwill show the actual
levet,

CAUTION:Removethe drain plug caretuly white the


engino is hot; the hot oil may causescalding.

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.

Reinstallthe drain bolt with a new washer,and refill


with the recommendedoil.
Requirement API ServiceGrade:Use "Energy
" SJ "Energy
Conserving
or
Conservingll" SH gradeoil. SAE
5W - 30 preferred:You can also
usean oil that bearsthe API
CERTIFICATION
mark.
Capacity

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:

CAUTION: After the engine has been tun, ths exhaust


pipes will be hot; be carelul when working around the
exhaust manitold.

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

NOTE:Useonly filterswith a built-inbypasssystem.

Inspect threads and

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.

Some filtershave eight numbers(1 to 8) printedon


the surfaceof the filter.

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.

The followingexplainsthe procedurefor tightening


filtersusingthesenumbers.

Tighten: 7/8 turn clockwise


Tighteningtorque:22N.m (2.2kgt'm 16lbt.ft)

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.

N u m b e rw h e n r u b ber sealis seated


Numberaftertightening
5.

5
8

6 7

IJ

6 7

After installation.fill the engine with oil up to the


specifiedlevel,run the enginefor more than three
minutes,then checkfor oil leakageand oil level.
GAUTION: Installation using other than the above
procedurecould result in serious engine damage
due to oil leakage.

8-6

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Oil PressureSwitch

Testing

Testing
L

Oil Pressure

wire from the engineoil presRemovethe YEL/RED


sureswrtcn.
Checkfor continuitybetweenthe positiveterminal
and the engine{ground).Thereshouldbe continuity
with the enginestopped.Thereshould be no continuity with the enginerunning.

lf the oil pressurewarning light stayson with the engine


running,checkthe engineoil level.lf the oil levelis correct:
L

Connecta tachometer.

2.

Remove the engine oil pressure switch. and install


an oil pressure gauge.
GAUGE
OILPRESSURE
ADAPTER
(1/8" - 28, BSTP)
available)
{Commercially
(Commercially
available)

ENGINE
OILPRESSURE
SWTTCH
MOUNNNG
HOt-E

PRESSURE
SWTCH
18 N.m {1.8kgf.m,
13 tbr.ftl
Apply liquidsealant
to the threads,

lf the switch fails to operate,checkthe engine oil


level.lf the engineoil level is OK, checkthe engine
orl pressure.

Startthe engine.Shut it off immedjatelyif the gauge


registersno oil pressure.Repairthe problembefore
continuing.
4.

Allow the engineto reachoperatingtemperature(fan


comeson at leasttwice).The pressureshouldbe:
Engino Oil Temperature:176'F (80'C)
Engine Oil Pressure:
At ldle:
70 kPa (0.7 kgt/cm', 10 psil
minimum
Ai 3,000rpm: 3/r0 kPa {3.5 kgt/cm', 50 psi)
minimum
lf oil pressurein not within specifications,inspectthe
oil pump (seepage8-9).

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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.

1 0 . Removethe screwsfrom the pump housing,then


separatethe housingand cover.

D r a i nt h e e n g i n eo i l .

2. Turn the crankshaft,and align the white groove on


the crankshaftpulleywith the pointeron the lower
cover.

3. Removethe cylinderheadcoverand middlecover.


Removethe power steering pump belt, air conditioner belt and the alternatorbelt.
5.

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.

Removethe timing belt.

7.

Removethe drive pulley.

8.

Removethe oil pan and oil screen.

9.

Removethe oil pump.

l l . Checkthe inner-to-outerrotor radial clearanceon

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.

Checkthe housing-to-rotoraxial clearanceon the


pump rotor. lf the housing-to-rotoraxial clearance
exceedsthe service limit. replacethe set of inner
and outer rotorsand/orthe pump housing.
Housing-to-RotorAxial Clearance
Standard {New): 0.02- 0.07 mm
{0.001- 0.003in)
So|' ice Limit: 0.15mm (0.006inl

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.

20. Cleanand dry the oil pump matingsurfaces.


2 1 . Installthe two dowel pins and a new O-ringon the
cylinderblock.
Apply liquid gasket,part No. 08718-0001
or 087180003,to the cylinderblockmating surfaceof the oil
pump. Apply the liquid gasketevenly,in a narrow
beadcenteredon the mating surface.Do not apply
liquidgasketto the O-ringgrooves.
Apply liquid gasketto the inner threadsof the bolt
noles.
Apply liquid
gasket alongthe
brokenline.

1 4 . Inspectboth rotorsand the pump housingfor scoring or otherdamage.Replacepans if necessary.


1 5 . Removethe old oil sealfrom the oil pump.
PUMPHOUSING

1 6 . Gentlytap in the new crankshaftoil seal until the


specialtool bottomson the pump.

NOTE:
.

Do not installthe pans if five minutesor more have


elapsedsinceapplyingliquid gasket.Instead,reapply
liquidgasketafter removingold residue.
. After assembly,wait at least30 minutesbetorefilling
the enginewith oil.

8-10

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24. Apply greaseto the lip of the oil pump seal.


Installthe oil pump onto the crankshaft.When the
pump is in place,clean any excessgreaseoff the
crankshaftand checkthat the oil seal lip is not distorted.
lnstallthe oil screen.

2't. Installthe oil pan {seepage7-22).

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

'97 - 98 U.S. models


{ExceptCalifornia):
'99 - 00 models:

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

'97 - 98 U.S. models (ExceptCalifornial:


'99 - 00 models:

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

CAUTION:The system is under high pressurewhen the


engineis hot. To avoid dangerol releasingscaldingengine
coolant,removethe cap only when the engineis cool.
Total Cooling System Capacityfincluding 0.6 I (0.63 US
qt, 0.53 lmp qt) for heater and reservoirl:
A/T: 5.9{ {6.2US qt, 5.2 lmp qt)
M/T: 6.0f (6.3US $, 5.3 lmp qt)
6x1.0mm
9.8 N.m 11.0kgf.m.
1.2 tbl.ftl

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.

lnstallthe radiatorin the reverseorderof removal.

3.

Disconnect
the fan motor connector.

4.

Removethe radiatorupper bracket,then pull up the


raotalor,
6x1.0mm
9.8 N.m 11.0kgf.m,
7.2 tbl.trl

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

www.emanualpro.com

10-4

LOWER

TOR HOSE

EngineCoolantRefillingand Bleeding
1.

Slidethe heaterlemperaturecontrol lever to maxi


mum heat.
Make sure the engine and radiatorare cooi to the
touch.

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 .

Apply liquid gasketto the drain bolt threads,then


reinstallthe bolt with a new washer and tighten it
securely.
6.

Tightenthe radiatordrain plug securely.

7.

Remove,drain and reinstallthe reservoir'Fill the


tank halfwayto the MAX mark with water,then up
to the MAX markwith antitreeze.

DRAINPLUG

4.

Removethe drainbolt from the cylinderblock.

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.

9. Pour coolantinto the radiatoruD to the baseof the


filler neck.When pouringenginecoolant.do not let
coolantspill on any electricalpans or the paint. lf
any coolantspills,rinseit oft immediately.

Engine Coolant Refill CapacityIincluding 0.6 / 10.63


US $, 0.53 lmp qtl for hoater and ressrvoirl:
A/T: 3.9 f {4.1 US $, 3.4 lmp qtl
M/T: 1.Ot 14.2US $, 3.5 lmp qrl

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


radiator fan comes on at leasttwice).
1 1 .Turn off the engine.Checkthe level in the radiator,
add coolantif needed.
1 2 . Put the radiatorcap on tightly.then run the engine
againand checkfor leaks.

10-6

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Testing

CapTesting
1.

Removethe radiatorcap, wet its seal with engine


coolant,then installit on the pressuretester.

2.

Applya pressureof 93 - 123kPa(0.95- 1.25kgflcm' ,


1 4- 1 8p s i ) .

3.

1.

Wait until the engineis cool, then carefullyremove


t h e r a d i a t o rc a p a n d f i l l t h e r a d i a t o rw i t h e n g i n e
c o o l a ntto t h e t o p o I t h e f i l l e rn e c k .

2.

Attachthe pressuretesterto the radiator,and apply


a pressureof 93 - 123kPa (0.95- 1,25kgf/cm' ,14 1 8p s i ) .

3.

Inspectfor enginecoolantleaksand a drop in pressure.

4.

Removethe tester,and reinstallthe radiatorcap.

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 .

Checkfor a drop in pressure.


lf the pressuredrops,repiacethe cap.

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.

Suspendthe thermostatin a containerof water. Do


not let the thermometertouch the bottom of the hot
container.

THERMOMETER

THERMOSTAT

Heat the water, and checkthe temperaturewith a


thermometer.Checkthe temperatureat which the
thermostatfirst opens,and at which it is fully open.
Measurethe lift heightof the thermostatwhen fully
open.
STANDARDTHERMOSTAT
above8.0 mm (0.31in)
Lift height:
169- 176'F(76- 80'C)
opening:
Starts
194'F(90'C)
Fullyopen:

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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

www.emanualpro.com

6xl,0mm
12N.tnn.2 lgl.rn,
8.7 tbf'ft)

Replacement

Inspection
1.

Removethe timing belt (seesection6)

1.

Removethe timing belt (seesection6).

2.

Turn the water pump pulley counterclockwise.


Checkthat it turnsfreely.

2.

Removethe water pump by removingfive bolts

3,

Inspect,repairand cleanthe O-ringgroove and the


matingsurfacewith the cylinderblock.

Checkfor signsof sealleakage.


NOTE:A smallamountol
holeis normal.

"weeping"from the bleed

-<o

@-

II

Replace.

6x1.0mm
't2 N.m 112 kgf m.
8.7 tbf.ftl
4.

lnstall the water pump in the reverse order of removal.

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

Radiator Fan Switch Testing

1 . D i s c o n n e ct ht e 2 Pc o n n e c t o r .

Removingthe radiator fan switch while


E@
the engine is hot can causethe coolant to spray out, seriously scalding you. Always let the enginc and radiator
cool down before removing the radiator fan switch.

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.

Removethe radiatorfan switchfrom the thermostat


housing(seepage10 '10).

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.

Heat the water, and checkthe temperaturewith a


thermometer.Do not let the thermometertouch the
bottomof the hot container.
Measurethe continuitybetweenthe A and B terminalsaccordingto the table.
Terminal

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

Bleedthe air from the coolingsystemafterinstalling


the radiatorfan switch(seepage10-5).

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 .

the YEUGRNwire from the coolanttem


Disconnect
peraturesendingunit.
COOLANTTEMPERATURE

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.

lf the wires are OK, replacethe coolanttemperature


gauge.
l f t h e c o o l a n tt e m p e r a t u r eg a u g ew o r k s ,t e s t t h e
coolanttemperaturesendingunit.

www.emanualpro.com

3.

Using an ohmmeter,measurethe change in resistance betweenthe positiveterminaland the engine


( g r o u n dw
) i t h t h e e n g i n ec o l d a n d w i t h t h e e n g i n e
at operatingtemPerature.
1A5- 212F

Temperature

133.F(56'C)

(8s- 100'c)

Resistance
(0)

137

46-30

lf the readingsare substantiallydifferentfrom the


speciticationsabove, inspectthe coolant level and
t h e c o o l i n gs y s t e m .l f t h e c o o l i n g s y s t e m i s O K ,
replacethe sendingunit.

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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ldle Control System


............
11-149
SystemDescription
TroubleshootingFlowcharts
......11-150
ldle ControlSystem
11-152
fdleAir ControlValve ......................,.............
A i r C o n d i t i o n i nSgi g n a l. . . . . . . . . . . . . . . . . . . . . . .I. 1. .-.1. .5. .5. .
. .5. .9. . . .
A l t e r n a t oFr RS i g n a l. . . . . . . . . . . . . . . . . . . . . . . . . . 1. .1. -. 1
t l-161
StarterSwitch Si9na1....................................
PowerSteeringPressureSwitch Signal......11-162
. .6. . . .
B r a k eS w i t c hS i 9 n a 1. . . . . . . . . . . . . . . . . . . . . . . . . .1. .1. .-.1. 6
. .6, .8, . , .
F a s tl d l eT h e r m oV a l v e. , . , . . . . . . . . . . . . . . . . . . . . . . .1. .1. -. 1
..............
11-169
ldle speed setting

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

to l/C CLUTCfl BELAY


to i^Ol^toh F tl REI Y,
@III'C|{AEi FA'I iEL Y

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

CONTNOL SOIENOID VALVE A

PFESSUhECOI{TFOL

sotENotDvALvE

Tor lEiLocK coNtFol UNlt

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

lo ^/c clwclr hEL Y


lo iADIAIORFAl{iEt Y,
coittct{3F F l{ FCLAY
Yo|/C all'lc8

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

No. 3 FUE! IiUECIOn

r - l
l _ , I

(cont'd)

www.emanualpro.com

11-27

SystemDescription
-'98 - 00 Modelslcont,dl
Electrical
Connections

l M

l--

sL( yEL JJ{FiE-l


sLUwnf li,"+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

A/I GEAA PO3MON SWITCH

*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

NOTE:o Differentwireswith the samecolor havebeengivena numbersuffixto distinguishthem {for example,YEUBLKl


and YEUBLK,are not the same).
O: Relatedto Fueland EmissionsSystem.
- Connectorwith maleterminals(doubleoutline):View from terminalside
- Connectorwith femaleterminals(singleoutline):View from wire side

(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

lwittost crui.! comrol)


3

,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.

YEUBLKland YEUBLK'are not the same).


a O: Relatedto Fueland EmissionsSvstem.

www.emanualpro.com

Connectorwith maleterminals(doubleoutline):View from terminalside


Connectorwith femaleterminals(singleoutline):View from wire side

(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,

YEUBLKIand YEUBLK'are not the same).


a O: Relatedto Fueland EmissionsSvstem.
a - Connectorwith maleterminals(doubleoutline):View from terminalside

www.emanualpro.com

Connectorwith femaleterminals(singleoutline);View from wire side

(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(

lSTLr GRr/wHr--F ]ilwH----I

Differentwireswith the samecolor havebeengivena numbersuffixto distinguishthem (for example,YEUBLK1


and YEUBLK,are not the s8me).
O: Relatedto Fueland EmissionsSystem.
- Connectorwith maleterminals(doubleoutline);View from terminalside
- Connectorwith femaleterminals(singleoutlinel:View from wire side
(cont'dl

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,

YEUBLKland YEUBLK,are not the same).


o: Relatedto Fueland EmissionsSvstem,
a - Connectorwith maleterminals(doubleoutline):Viow from terminalside
- Connectorwith femaleterminals{singleoutline):View from wire side
(cont'd)

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,

1 " 1 " " '-

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

www.emanualpro.com

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

lwlrhot|t crub. 6.trroll

-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

'4: '99 - 00 models

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

and YEUBLK'are not the samol.


YEUBLKT
O: Relatedto Fueland EmissionsSystem
a - Connectorwith maleterminals{doubleoutline):View from terminalside
- Connectorwith femaleterminals{singleoutline);View from wire side

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

www.emanualpro.com

11 - 6 0

ll.

ControlModule{PCM)ResetProcedure
EngineControtModule(EcM)/Powertrain
Eitherof the followingactionswill resetthe ECM/PCM.
.

(see the oBD ll scan tool or


s
use the oBD ll scantool or Honda PGM Testerto clear the ECM' s/PCM'memory.
instructions
)
operating
specific
for
manuals
Tester
user's
HondaPGM

. Turn the ignitionswitchoFF. Removethe BACKUP (RADIO)(7.5A) fuse from the under-hoodfuse/relaybox for
seconos.

10

BACKUP {RADIOII7,5 AI FUSE

FUSE/RELAYBOX

lll. FinalProcedure{this proceduremust be done afterany troubleshooting)


and there are no
1. Removethe SCSServiceConnectorif it is connected.lf the SCSserviceconnectoris connected.
(ll).
oN
is
turnsd
switch
ignition
when
the
on
will
stay
the MIL
DTCSstoredin the ECM/PCM,
2. Do the ECM/PCMResetProcedure.
3. Turn the ignitionswitchOFF
(
the OBD ll scantool orHonda PGMTesterfrom the DataLinkConnector16P)'
4. Disconnect

(cont'd)

www.emanualpro.com

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,

How to Us6 tho BackprobeS6ts


connectthe backprobeadaptersto the stackingpatchcords.and connectthe cordsto a multimeter.
Usingthe wire insulation as a guide for the contouredtip of the backprobeadapter,gently slidethe tip into the connector
from the wire side
until it comesin contactwith the terminalend of the wire.

Backp.oboAdapto.

BACKPROBE
SET
o'SAZ - (xtlqDA lTwo requir.dl

11-6 2

www.emanualpro.com

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)

www.emanualpro.com

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

Enginewill not start


Hardstarting

4 , 2 , 3 , 5 , 2 0 ,' t 5 ,1
2, 4, 12,17,14, 't9

Coldfast idletoo low


Coldfast idle too high
ldle speedfluctuates

7 ,a , 9 ,6 , 1 7
7,8,9,11,10
9 , 7 , 8 ,' t 1 ,1 0

Misfireor rough running

Troubleshootfor misfire on pages '11-126,1|21


2, 10,11,13,'17,18,20
2 , 4 , 1 2 , 1 , 2 0 , 9 , 5 ',t 6

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.

The absolutepressurecausedin the intakemanifoldby


Manifold
engineload and speed.
Absolute
Pressure(MAP)

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

With cold engine:


Sameas ambienttemPeratureand IAT
With enginewarmed uP:
approx.163- 2'12'F
(73- 100"c)
0 . 0- 1 . 2 5V
The HeatedOxygenSensordetectsthe oxygencontentin
At idle speed:
to
the
gas
voltage
signals
sends
exhaust
and
the
controls about0.1- 0.9
Basedon thesesignals,the ECM/PCM
ECMiPCM.
the airlfuelratio.Whenthe oxygencontentis high (thatis.
ratio),the
when the ratiois leanerthan the stoichiometric
is
lower.
voltagesignal
Whenthe orygen contentis low (thatis, when the ratio
ratio),the voltagesignal
is richerthan the stoichiometric
is higher.

EngineCoolant The ECTsensorconvertscoolanttemperatureinto voltThe sensoris a thermistor


age and signalsthe ECM/PCM.
Temperature
changeswith coolanttemperawhose internalresistance
{ECT)
ture.The ECM/PCMusesthe voltagesignalsfrom the
ECTsensorto determinethe amountof injectedfuel
HeatedOxygen
Sensor(HO25)
(Primary,
Sensor1)
(Secondary
Sensor2)

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

The airlfuelratiocorrectioncoefficientfor correctingthe


t:20y"
amountof injectedfuel when HO2Sfeedbackis in the
closedloop status.Whenthe signalfrom the HO2Sis
weak,shortterm fuel trim gets higher,and the ECM/PCM
increases
the amountof injectedfuel.The airlfuelratio
graduallygets richer,causinga higherHO2Soutput.
Consequently.
the shortterm fuel trim is lowered.and
the ECM/PCMreducesthe amountof injectedfuel.
This cyclekeepsthe airfuel ratiocloseto the stoichiometricratiowhen in closedlooDstatus.

YES

LongTerm
F u e lT r i m

Longterm fuel trim is computedfrom shon term fuel


trim and indicateschangesoccuringin the fuel supply
systemover a long period.
lf long term fuel trim is higherthan 1,00.the amountof
injectedfuel must be increased.lf it is lowerthan L00.
the amountof injectedfuel must be reduced.

! 20%

I n t a k eA i r
Temperature
(IAT)

The IAT sensorconvertsintakeair temperatureinto voltage and signalsthe ECrU/PCM.


When intakeair temperature is low, the internalresistance
of the sensor
increases,
and the voltagesignalis higher.

With cold engine:


Sameas ambienttemperatureand ECT

Throttle
Position

Basedon the accelerator


pedalposition,the opening
angleof the throttlevalveis indicateo.

At idle speed:
approx.10%

lgnition
Timing

lgnitiontiming is the ignitionadvanceangleset by the


ECM/PCM.
The ECM/PCMmatchesignitiontiming to the
drivingconditions.

A t i d l es p e e d 1
: 6'1 4.
BTDCwith the SCSservtceconnectorconnected.

NO

Calculated
LoadValue
(cLV)

CLVis the engineload calculatedfrom the MAp data.

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 sideof lemaleterminals

FCM CONNECTORA (32P)


frminal
numlreJ

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

DrivesNo. 3luel injector.


DrivesNo.2 tuel injector.
DrivesNo. 1 fuel injector.
D ves secondaryheatedoxygen
sensorheater.
Drivesprimary heatedoxygen
sensor heater,

Groundforthe PCMcontrol circuit.


Ground for the PCMpower circuit.
Power sourcefor the PCMcontrol
circuit.
Drives IACV.
Drives EVAPpurge control
solenoidvalve.

DrivesIuel pump relay.


DrivesAy'Cclutch relay.
DrivesMlL.
Sendsalternatorcontrolsignal.

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)

With ignition switch ON {ll): batteryvoltage


Withfully warmedup enginorunning:duty
controlled
With ignition switch ON lll): batteryvoltage
with fully warmed up enginerunning:duty
controll6d
Lessthan 1.0V at all times
With ignition switch ON (ll): batteryvoltage
With ignition switch OFF:0 V
With nginerunning:duty controlled
With enginerunning,enginecoolant
below 154'F(68"C):battery voltage
With enginerunning,enginecoolant
above 154"F(68"C):duty controlled
0 V for two secondsafter turning ignition
switch ON lll), then batteryvoltage
With comoressorON: 0 V
With compressorOFF:bafteryvoltage
With MIL turned ON: 0 V
With MIL turned OFF:bafteryvoltage
With tully warmed-upenginerunning:
battery voltage
load:0'
Duringdrivingwith smallelectrical
With ignition switch ON (ll): bafteryvoltage
With enginerunning:pulses
Lessthan 1.0V at alltimes
With ignition switch ON (ll): batteryvoltage
With engineswitchOFF:0 V
With radiatorfan running:0 V
With radiatorfan stopped:bafteryvoltage

*: USA

{cont'd)

www.emanualpro.com

11-67

Troubleshooting
PowertrainControlModuleTerminalArrangement-'97 Model (cont'dl
PCMCONNECTOR
B I25PI

Wire sideof femaleterminals

PCM CONNECTORB I25P}


Terminel
number

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

With ignitionswitchON (ll):duty controlled

LS + (A"/TCLUTCH
PRESSURE
CONTROL
VALVE+)
SOLENOID
CONTROL
SHA(SHIFT
SOLENOID
VALVEA)

DrivesA,/Tclutch pressurecontrol
solenoidvalve

With ignitionswitchON (ll)rduty con


trolled

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}

In 2nd,R position.in 2nd and 3rd gearin


D4, D3 position: Batteryvoltage
In lst gearin D4,D3 position,in 4th gear
in D4 position:0 V
Driveslock-upcontrolsolenoid
With full lock-up;Bafteryvoltage
valveB,
With half lock-up:duty controlled
With lock'upON:batteryvoltage
Driveslock-upcontrolsolenoid
With lock-upOFF:0V
gear
position
DetectsA/T
switch In D3 position:0V
ln any otherposition:batteryvoltage
signal._
DrivesshiftcontrolsolenoidvalveB. In 1st,2nd position,in 1st and 2nd gearin
D4,D3 position:Batteryvoltage
In R position,;n 3rd gearin 04, D3,in 4th
gearin D4 position:0 V
Detectsinterlockcontrolunh signal. With ignitionswitchON (ll)and brake
pedaldepressed:battery voltage
With D4 indicatorlightturnedON:battery
DrivesDl indicatorlight.
voltage
With D4 indicatorlightturnedOFF:0 V
D r i v e ss h i f t c o n t r o l s o l e n o i dv a l v e A .

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

www.emanualpro.com

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

Detects A/T gear position switch


srgnal.

InRposition:0V
In any otherposition:batteryvoltage
In 2nd position:0 V
In any otherposition:batteryvoltage
ln lst position:0 V
In any otherposition:batteryvoltage

DetectsA/T gear position switch


s r gn a l ,
DetectsA/T gear position switch
s r gn a l ,
Groundtor countershaft
speed
sensor,
Detectscountershaftspeedsensor
srgnal.
DetectsA,/Tgear positionswitch
srgnal.
DetectsA/T gear positionswitch
signal.

With agnitionswitchON (ll),and lront


wheelsrotating:pulses
In D4 positionr0 V
In any otherposition:batteryvoltage
In parkor neutral:0V
In any otherposition:about5 V

C (31PI
PCMCONNECTOR

Wire sideof femaieterminals

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.

With engine running: pulses

DetectsTDCsensor.

With engine running: pulses

DetectscYP sensor.

With engine running: pulses

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

With the connectorconnected:0 V


With the connectordisconnected:about
5 V or battery voltage

With ignitionswitchON (ll):pulses


Batteryvoltage at all times

Ground for CKFsensorsignal.

SIDE)

12

WHT

13

RED

14

BLK

I\4 Groundlor CKPsensorsignal.


CKPM(CKPSENSOR
SIDE)
M
TDCM(TDCSENSOR
Groundfor TDCsensorsignal.
SIDE}
M
Groundfor CYPsensorsignal.
CYPM(CKPSENSOR
SIDE}
PSPSW(P/SPRESSURE DetectsPSPswitch signal.

swtTcH)

16

GRN

17

WHT/RED

18

SPEED
VSS(VEHICLE
BLUA/VHT SENSOR)

FR
ALTF(ALTERNATOR
SIGNAL)

FRsignal.
Detects
alternator
VSSsignal.
Detects

At idle with steeringwheel in straight


ahead position:0 V
At idle with steeringwheel at full lock:
battery voltage
With fully warmed up engine running:
0 V-batteryvoltage {dependingon
electricalload)
Wirh ignitionswitch ON (ll) and front
wheels rotating:cycles0 V - 5 V or battery voltage

(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

NOTE: Standard battery voltage is 12 V.


Description
DetectsTP sensor signal.

ECT(ENGINECOOLANT DetectsECTsensor signal.

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)

Powrsourcefor MAP sensor.

With ignitionswitchON (ll):about 5 V


With ignitionswitchOFF:0 V

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.

With throttlefully openedfrom idlewith


fully warmed up engine:above0.6V
With throttlequicklyclosed:below
0.4v

IAT (INTAKEAIRTEM.
PERATURE
SENSOR)

DetectsIAT sensor signal.

With ignitionswitchON lll): about


0.1- 4.8V (dependingon intakeair
temperaturel

WHT

RED//EL

10

YEUBLU

VCC2(SENSOR
VOLTAGEI

Providessensor voltage.

With ignitionswitchON (ll):about5 V


With ignitionswitchOFF:0 V

11

GRN/BLK

SG2(SENSOR
GROUND)

Sensorground.

Lessthan 1.0V at all times

12

GRN/WHT

SGl (SENSOR
GROUND)

Groundfor MAP sensor.

Lessthan 1.0V at all times

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,

With throttlefully openedfrom idlewith


fully warmed up engine;above0.6V
With throttlequicklyclosed:below

0.4v
EL (ELD)
16*

GRN/RED

1 -7 0

www.emanualpro.com

DetectsELDsignal.

With parkinglightsturnedon at idle


about2.5- 3.5V
With low beamheadlightsturnedon
a t i d l e :a b o u t1 . 5- 2 . 5 V

ControlModuleTerminalArrangement- 38 - 00 Models
Engine/Powertrain
A (32P}
ECM/PCMCONNECTOR
5

sca

,/./
t5

,/

It

sTs

l,/
n

2l
s!u

CI

Wire sideot femaleterminals

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 )

Drives EVAP bvoass solonoid valve.

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

With ig^ition switch ON (ll): battery voltage

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

Drives EVAP purge controlsolonoid valve.

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 e n g i n sr u n n i n ge, n g i n ec o o l a n tb, e l o w1 5 4 ' F


(68'C)rbatteryvoltage
W i t h e n g i n er u n n i n ge, n g i n ec o o l a n ta, b o v e1 5 4 " F
{6a'C}rduty conl.olled
With ignitionswitch ON (ll): baneryvoltage
W i t h f u l l yw a r m e du p e n g i n er u n n i n gd: u t y

Detects seNics check conneclor signal


(he signalcausinga DTC indicatjon)

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 )

Drivssfusl pump relay.

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}

Drivesl,/C clurch rclay.

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.

With throttlefully openedfrom idle wilh fully


w a l m e du p e n g i n ea: b o v e0 . 6V
with rhrottlequicklyclosed:below 0-4V
Whh staner switch ON (lll): batlery voltage
With srarterswitch OFF:0 V

SWITCHSIG,
STS (STARTER
NAL}

Dotoctssrarterswitch signal.

PSPSW{P/SPsESSUFE
SWITCHSIGNAL)
ACS (Ir'C SWTCH SIGNAL}

DetecrsPSPswitch signal.

At idle with steeing whel in stBighl aheadposition:0 V


At idls with nee ng wheel al full lockr banory voltage

Dtectsly'C switch signal.

With Ay'Cswitch ON:0 V


With l/C swilh OFF:about 5 V

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 }

Orives interlock control unil.

With ignilion switch ON (ll)and brakepedal


depressed: battery vohage

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)

Dstcts brake switch signal.

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

13: '98 modsl


15: USA

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.

l N J 2( N o .2 F U E LI N J E C - DrivesNo. 2 Iuel injector.

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

With ignition switch ON (ll): battery


voltage
With engine running: pulses
With ignition switch ON (ll):duty
controlled

A,/Tclutchpressurecontrol
solenoidvalvepowersupply
positiveterminal
Drives OVER-DRIVE
OFF
indicatorlight.

LG1(LOGIC
GROUND)

control Lessthan 1.0V at all times


Groundfor the ECM/PCM
circuit.
Powersourcefor the ECM/PCM Batteryvoltage at all times
controlcircuit.
PowersourcefortheDTCmemory.

BRN/BLK

LG2(LOGIC
GROUND)

23

BLVBLU

IACV{IDLEAIR CON.
TROLVALVE)

11-72

With engine running:duty controlled

LS+(A,,IT
CLUTCHPRES
SURECONTROL
SOLENOIDVALVE+ SIDE)
ODIND(OVER-DRIVE
OFFINDICATOR}

22

www.emanualpro.com

With ignition switch ON (lll: baftery


voltage
With ignition switch OFF:0 V
'1.0
Lessthan
V at all times

Sendsignition pulse.

VBU (VOLTAGE
BACK
WHT/BLU U P )

*2t MlT
*3: '98 model
"4: '99 - 00 models

With ignition switch ON (ll):duty


controlled

rcM {rGNrTroN
coN-

YEUGRN TROL
MODULE)

17*1

With engine running:duty controlled

l N J 31 N o .3 F U E LI N J E C - DrivesNo. 3Iuel jnjector.


TOR)
l N J 4{ N o . 4 F U E LI N J E C - DrivesNo. 4 fuel injector.
TOR)

LS- (A"/TCLUTCHPRES. A,/Tclutchpressurecontrol


SURECONTROL
SOLE, solenoidvalvepowersupply
_ SIDE)
NOIDVALVE
negative
terminal.
IGP2IPOWERSOURCE) Powersourcefor the ECN,I/PCM
controlcircuit.

WHT

8*1

Signal

Ground for the ECN4/PCM


control
ctrcutt,
DrivesIAC valve.

With OVER-DRIVE
OFFindicatorlight
turned ON: 0 V
OFFindicatorlight
With OVER-DRIVE
turned OFF:battery voltage

Lessthan 1.0V at all times


With engine running: duty controlled

ECM/PCMCONNECTOFC (31PI

C (31P)
ECM/PCMCONNECTOR

Wire sideo{ femaleterminal

Termidal

NOTE:Standardbatteryvoltageis 12V.
D.3cription

8LI(WHT

Signal

HEATED
POzSHTC{PRIII4ABY
OXYGENSENSORHEATER
CONTROL)

Drivssprim6ry h$ted oxygsn sensor

Wilh ignition switch ON (ll): baneryvoltsge


With ftrllywarmsd up ngine runnang:duty

CON,
ALTC(ALTERNATOR
TROL)

Sondsalternalorcontrol signsl.

With fully wafmod up ngine rnningrbanry


voltago
Du ng driving with small elsctricallo6d:0 v

2"

WHT/GBN

3'1

FED/8LU

K S( K N O C K
SENSOR)

DstectsKS signal.

With engine knockang:pulses

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

Groundfor l/tAP sensor.

Lssthan 1.0v 6t all times

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.

with ihfottls fully openedfrom idle with fully,


walm6d up engins:above0.6 V
With throttloquicklyclossd:below 0.4 v

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)

Power soufce to MAP snsor.

With ignition switch ON (ll): about 5 V


With ignition switch OFF:0V
W i t h e n g i n ef u n n i n g P
: ulses

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

Lsssthan 1.0V at all tims

20

GRN

TDCP{TDCSENSORP SIDE)

DerecisTDCsensor.

2l

RED

TDCM ITDCSENSORM SID)

Groundfor TDCsensor.

22

BLU/RED

PSIDE)
C K F P( C K FS E N S O R

DstsctsCKFsnsor.

With sngins running: pulsss

23

BLU/WHT

VSS (VEHICLE
SPEEDSEN-

vss signal.
Dstscrs

25

RED//EL

IAT (INTAKEAIR TEMPERA'


T U R ES E N S O B )

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.

With ignition switch ON (ll): about 0.1 4.8 V


{dopondingon 6ngincoolanllemper6tu16)

27

RED/BLK

TPS (THROTTLE
POSITION
SENSOR)

DotectsTP sensorsignrl.

with rhrottls fully opn: aboui 4.8 v


with throtrl6fullyclosed: about 0.5 v

2A

YEUBLU

VCC2lSENSOR
VOLTAG}

Providssnsorvoltage.

With ignilion switch ON (ll):about 5 V


Whh ignitionswitch OFF:0 V

29

YEL

CYPPICYPSENSO8P SIDE)
CYPM(CYPSENSORM SIDE)

DsrsctsCYPsensor.

With ngins runningrpulsss

Groundfor CYPsansor.

30

BLK

soR)

WHT/RED
CKFM{CKFSENSORM SIDE)
11.AfT 13. '94 model
'2:M/T 14:'99- 0omodsls
.5: USA
31

6.ound lof CKFssnsorsignal.

(cont'd)

www.emanualpro.com

11-73

Troubleshooting
Powertrain Control Module Terminal Arrangement -'98

- 00 Models (cont'dl

ECM/PCMCONNECTOR
D {16P}

PCM CONNECTORD (16P)

Wire sideof lemaleterminals

NOTE:Standardbatteryvoltageis 12V.
Ds4ription
Orivslock'up conrrolsolenoidvalve A.

With lock-upON: b6tteryvoltags


W i t h l o c k - u pO F F : 0V

S H B( S H I F T
CONTROL
SOLENOIO
VALVEB)

Drivesshift controlsolenoid valve B.

In 1st,2nd position,in lst and 2nd gear anD4, D3


(D)11position:batteryvohag
In P, R, N position,in 3rd geaf in D1, D3 (D)*.
position,in 4th gear in D4 (D)*rpositionr0V

GRN/BLK

LC 8 (LOCK,UP
CONTROL
SOLENOIDVALVEB}

Driveslock up controlsolenoidvalve B.

With full lock-up:8atteryvoitage


With half lock'uprdutycontrolled

BLK/YEL

VBSOL(BATTERY
VOLTAGE
F O RS O L E N O IV
DA L V E }

Powrsourceof solenoidvalvs.

With ignition switch ON (ll): batteryvoltage


With ignition switch OFF|0 V

ATPR{AI GEAEPOSITION
SWITCH)

DelsclsA/T gear posrtionswirch srgnal.

SHA (SHIFTCONTROL
SOLENOIDVALVEA)

Drivesshift conrrolsolenoidvalvp A.

In 2nd, R position,an2nd and 3rd ge6r in D4, D3


(D)r' posilion:batleryvoltage
In 1st gear in 04, 03 {D)}. position,in 4th gear in
D 4 ( D ) * .p o s i t i o ni,n P , N p o s i t i o n : 0V

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

In any other positjon:battsryvoltage

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

With Ovor Drivs OFF(O/DOFFindicatorlight


t u r n e dO N ) :0 V
Wilh Ovsr Drivs ON (O/DOFFindicrto.lasht
turned OFF):about 5 V

ATPDI}3,O}I {AT GEAR


POStTtONSWTTCH)
NC (COUNIERSHAFT
SPEED
SENSOR)

DotctsA/T gar positionswirch signal.

I n D 4 r 3O
, * . p o s i t i o n : 0V
In any other posilion:batteryvoltage

Detsctscounlrshaftspeedsensor

With ignition switch ON (ll), and ffonr wheels

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

DelectsA,/Tgear positionswitch signat.

swtTcH)
ATP2(AT GEARPOSFION

DstectsA,/Tgear positionswitch signal.

swrTcH)
ATP1{AT GEARPOSITION

h any othsr position:batteryvoltsgs


DetsctsA/T gear positionswitch signal.

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

In any other position:htteryvoltage


Grouodfor counterchaftspedsnsor.

DiagnosticTrouble Code (DTCIChart


DTC
(MlLindication*l

Detection ltem

ProbableCause

Pago

P0107

(3)

ManifoldAbsolute
Pressu.eCircuit
Low Input

Openor short in MAP sensorcircuit


MAP sensor
ECMiPCM

't'l-90

P0108

{3)

ManifoldAbsolute
PressureCircuit
H i g hI n p u t

Open in MAP sensorcircuit


MAP sensor
ECM/PCM

11-92

P 0 11 1 * 3

(10)

IntakeAir
TemperatureCircuit
Range/Performance
Problem

P0112

(10)

lntakeAir
TemperatureCircuit
Low Input

Short in IAT sensorcircuit


IAT sensor
ECM/PCM

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

Openor short in TP sensorcircuit


TP sensor
ECM/PCM

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)

Primary HeatedOxygen Sensor


Slow Response
(Sensor1)

(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

*: TheseDTCSwill be indicatedby the blinkingof the MalfunctionIndicatorLamp (MlL)with the SCSserviceconnector


connected.
**: The E (E)*u indicatortightand the MalfunctionIndicatorLamp(MlL)may come on simultaneously.
*1' AIT *3 '97 model +5;'99 - 00 models
*2: MlT *4:'98 model
{cont'd)

www.emanualpro.com

11-75

Troubleshooting
DiagnosticTrouble Code (DTCIChart (cont'd)
DTC

Detectionhem

lMlL indicationl
P0137

(63)

Secondary Heated Oxygen Sensor


Circuit Low Voltage
{ S e n s o r2 )

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)

Second6ry Heated Oxygen Sensor Heater


C i r c u i tM a l f u n c t i o n
( S e n s o r2 )

Openorshonin Secondary
HO2S(Sensor
2)
heatercircuit
EC|V/PCtu

System Too Lean

Fuel supply system


P r i m a r yH O z S( S e n s o r1 )

(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

Knock Sensor {KS) Circuit Malfunction

Open or shon in Knock Sensor (KS) circuit


K n o c kS e n s o r( K S )
ECM/PCt\4

11-130

Crankshaft
Position
SensorCircuit

Crankshaft Position Sensor


Crankshaft PositaonSensor circuit
ECl\,l/PCl\,'!

11-131

(4)

Crankshaft Position Sensor


Range/Performance

Crankshaft Position Sensor


Timing belt skipped teeth

11,131

{67)

Catalyst System Efficiency Below


Threshold

Three Way Catalytic convener


Secondary HO2S {Sensor 2)

Evaporative Emission
ControlSystem
Insulficient Purge Flow

EVAP Purge Control Solenoid valve


EVAP Purge Control Solenoid valve circuit
Throttle gody (purge port)
Tubing
PCM

'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

Fuel Tank PressureSensor


Circlit Low Input

{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

*: TheseDTCSwill be indicatedby the blinkingo{ the MalfunctionIndicatorLamp (MlL)with the SCSserviceconnector


connected.
**: The E (El*s indicatorlight and the MalfunctionIndicatorLamp{MlL)may come on simultaneously,
*1; A/T *3: '97 model *5: '99 - 00 models
*2: MlT *4: '98 model

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

*: TheseDTCSwill be indicatedby the blinkingof the MalfunctionIndicatorLamp {MlL}with the SCSserviceconnector


connected.
**:The E (E])+sindicatorlight and the MalfunctionIndicatorLamp(MlL)may come on simultaneously.
*1:A,./T "3: '97 model +5:'99 - 00 models
*2: M/T *4:'98 model

{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

|iuel 1"j""- Th,rhg""d Drrafr";-l

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.

Fuel Cut-off Control


. Duringdeceleration
with the throttlevalveclosed,currentto the fuel injectorsiscutoffto improvefueleconomyat
speedsover 970 rpm ('97- 98 models),920 rpm ('99- 00 modelsl.
. Fuelcut-offactionalso takes placewhen enginespeedexceeds6,500rpm ('97 - 98 models),6900rpm ('99 - 00
models),regardlessof the positionof the throttlevalve,to protectthe enginefrom over-rewing.
With Ay'Tmodel.the PCMcutsthe fuel at enginespeedsover 5,000rpm when the vehicleis not moving.*'
4,./CComoressorClutch Relav
When the ECM/PCMreceivesa demandfor coolingfrom the air conditioningsystem,it delaysthe compressorfrom
beingenergized,
and enrichesthe mixtureto assurea smoothtransitionto the Ay'Cmode.
Evaporative
Emission(EVAP)PurgeControlSolenoidValve
Whenthe enginecoolanttemperatureis above 154"F(68'C),the ECM/PCMcontrolsthe EVAPpurgecontrolsolenoid
valvewhich controlsvacuumto the EVAPpurgecontrolcanister,
Alternator Control
The systemcontrolsthe voltagegeneratedat the alternatorin accordancewith the electricalload and driving mode.
which reducesthe engineloadto improvethe fuel economy.

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

NOTE:lf this symptomis intermiftent,


checkfor a loosefuse No.25 METER(7.5A) in the
underdashf{rse/relay
box, a poor connectionat PCMterminalA18, or an intermittent
openin the GRN/ORN
wire betweenthe PCM(A18)and the gaugeassembly.

Turnthe ignitionswitchON {ll}.


ls the chargingsystemlighton?
-

Rep.ir short or opon in tho


wire batween No. 25 METER
(7.5Alfuso and gauge a$mbty.
R6pl.cNo. 25 METER17.5Al
fus.

PCM OON ECTORA {32P}


PGl IBLKI

Try to stan the engine.

Doesthe enginestart?

Chocktor.n open in th6 wire3


{PG1,PG2linesl:
1. Turn the ignitionswitchON (ll).
2. Measurevoltage between
body ground and PCM connectorterminalsA10 and A23
individually.
Check for an opn in the wir6 or
bulb (MlL linl:
1. Turn the ignitionswitchOFF.
2. Connectthe PCM connector
terminalA18 to body ground
with a iumperwire.
3. Turnthe ignitionswitchON {ll).

ls thorelssthan 1.0V?

Substituto . known-good PCM


and rcheck.ll symptom/indication goss away, rcplacathe original PCM.

l s t h e M I Lo n ?
-

Substitut6 a known-good PCM


and rocheck.ll 3ymptom/indication goes away, replacethe o.igin.l PCM.

11-42

www.emanualpro.com

Wire side of female terminals

npeir open in tho wirelsl


hwoon PCM and Glol (loc!t.d
at thc tha.mo3tat houling thrt
htd moro th.n 1.0V.

A {32PI
PCMCONNECTOR

R6pai. open in th. wilei


belwoon rcM lAl8l dnd g.uge
a3rombly.
Roolacthe MIL bulb.
Wire sideot temaleterminals

The Malfunciion lndicator Lamo


{MlL) stavs on o. comes on aftel
two seconds,

Check the Oiegnosiic Trouble


Code(DTC):
1 . C o n n e cat n O B D l l s c a nt o o l
or HondaPGMTester.
2. Turnthe ignitionswitchON 1lli.
3. Read the DTC with the scan
tool or HondaPGII Tester.

Are any DTCIs)indicated?

Ch6cklh6 DTCby MIL indication:


1. Turnthe ignitionswitchOFF.
2. Connectthe SCSserviceconn e c t o rt o t h e s e r v i c ec h e c k
connector.
3. Turnthe ignitionswitchON (ll).

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-

An intermittentshortin the wire betweenthe PCM(A18)and the gaugeassembly


An intermittentshon in the wire betlveenthe PCM(D4)and the MAP sensor
An intermiftentshortin the wire betweenthe PCM{D10)and the TP sensor.
PGM-Flmain relay.
'See the OBD ll scantool or HondaPGM Testeruser'smanualslor specilicoperating
instructions,

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 MIL indicateany DTc?

Repair opon or short in wi.6


between the PCM (C8) and
Data Link Connector.
Go to troubloshooting procedurs {3eepage 11-601.
PCMCONNECTOR
c l3lPl
scs .BRNI

Try to startthe engine.

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

lTo page11 84)

Wire sid6of fmaleterminalg

Repairshort to body ground in


the wire between PCM lCTl and
servicecheck connector.

(cont'dl

11-83

PowertrainControlModule (PCM)-'97

Model (cont'dl

( F r o mp a g e 1 1 8 3 )

Checkfor a short in the wire (MlL


line):
1. Turnthe ignitionswitchOFF.
2. Disconnect
the PCMconnector
A {32P).
3. Turnthe ignitionswitchON (ll).

lsthe MILON?

Repairshort to body ground in


the wire between the PCM {418}
and MlL.

Substitute a known-good PCM


and recheck. lf symptom/indication goes away. replace the original PCM.

InspectFl E/M (15 A) fuse in the


undeFhoodfuse/relaybox.
-

Reoair shod in the wire


between Fl E/M {15 A} fuse
and PGM-FImain relav.
ReplaceFIE/M 115A)fuse.

InspectNo. 13 FUELPUMP(15Ai
fuse in the underdashfuse/relay

CheckloJ a short in a sensor:


1. Turnthe ignit;onswitchON (ll).
2. Disconnectthe 3P connector
of eachsensorone at time:
. MAPsensor

( T op a g e1 1 - 8 5 )

1 1 -8 4

www.emanualpro.com

Repair short in lh wire


bolween No. 13 FUEL PUMP
115A) Iuse and PGM-FImain

ReplaceNo. 13 FUELPUMP
115A) fuse.

(Frompage 11-84)

Does the MIL go off.,

Reolacethe Sensor that caused


the lighl lo go out.

Check for a short in the wires


lvCC linesl:
1. Turnthe ignitionswitchoFF.
2. Disconnectthe PCM connec
tor D (16P).
3. Checkfor continuitybetween
bodygroundand PCMconnec
tor terminalsD4 and Dl0 indi
vidually.

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

Check tor an open in the wires


llGPline3l:
1 . D i s c o n n e ctth e f u e l i n j e c t o r
connectorsand IAC valve con
2. Turnthe ignitionswitchON (lli.
3 . [ , 4 e a s u r ev o l t a g e b e t w e e n
b o d y g r o u n d a n d P C Mc o n '
nectorterminalsA'11and A24
individually.

Checkfor an open in the wires


{LGlinesl:
1. Turnthe ignitionswitchOFF.
2, Reconnect
all sensorconnectors,
3. Reconnectthe PCMconnector
D (16P).
4. Turnthe ignitionswitchON (ll).
5 , M e a s ur e v o l t a g e b e t w e e n
b o d y g r o u n d a n d P C Mc o n
nectorterminalsAg a^d 422
individually.

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.

Wire side of lemale terminals

R6pair open in the wire{sl


between the PCM {A9. A22l and
G101 {located at the thetmostat
housing)that had morethan 1.0V.

Substituto a known-good PCM


and rechck.It symptom/indication goos away, replacethe original PCM.

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.

Turnth6 ignitionswitchON (ll).

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-

(C19)and the MAPsensor


An intrmiftent
shortin the wire betweenthe ECM/PCM
An intermiftentshort in the wire betweenrhe ECM/PCM(C28),the TP sensor,the
EGRvalvelift sensorand/or{ueltank Dressure
sensor
A laulty PGM-FImain relay

ls the low oil pressurelighton?


-

Repair lhort or opcn in tho


wire between the No. 25
METER17.5Al fu3e snd the
gaugeassembly.
Repl.co the No. 25 METER
17.5Al fus.
ECM/PCMCONNECTOR
A (32P}

Try to start the engine.


Chockfor an opsn in th wiro or
bulb {MlL line,:
1. Turnthe ignitionswitchOFF.
2. Connectthe ECM/PCMconnectorterminal A18 to body
groundwith a iumperwire.
3. Turn the ignitionswitch ON (ll).

Wiresideof femaleterminals

ls th6 MIL on?

Turnthe ignitionswitchOFF.
Inspectthe Fl E/M 115A) tuse
in the undeFhoodfuse/relay
box.

Substitute a known-good ECM/


PCM and rochock. lf rymptom/
indication goes eway, replace
tho o gind ECM/PCM.

Repair short in the wire


between lhe Fl E/M (15 Al
f u s G a n d t h e P G M - F lm . i n
.slay.
R o p l s c et h F l E / M ( 1 5 A l
fu3.

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

Repair short in th6 wire


between tho No. 13 FUEL
P U M P 1 1 5A ) l u s e a n d t h e
PGM-FImain .elay.
R e D l a c et h o N o . 1 3 F U E L
PUMP115Al tuse.

Rep.ir open in the wi.os


botween the ECM/FCM lA18l
and the gaugo rasombly.
Roplecethe MIL bulb.

(Frompage11-86)
ECM/FCMCONNECTOR
A {25PI
IGPl
(YEL/BLK)

Chck tor rn opon in tha wiioa


(lGPlino.):
1. Disconnectthefuel injctorand
IACvalveconnectors.
2. Turn the ignitionswitchON {ll}.
3. Measurevoltage between
body ground and ECM/PCM
connctorterminals B'l and
89 individually.

10

20

vXv)iiP2
rELlBLK)

't3

11

17

23

21

Wire sideof lemaleterminals


-

ls there batteryvoltage?

2
I
19

Repaii opon in th6 wirc{3l


betw.6n tho ECM/PCM (B1.
B g l l n d t h o P G M - F Im a i n
roby.
Chock for poor connactions
or loo3 wiJo3 at the PGM-FI
main ralry.
T.st the PGM-FImtin r.lay
(soop.ge 11-1871.

Chack for an opon in tho wire3


{PG,LG lino3l:
1 . R e c o n n e ctth e l u e l i n i e c t o r
and IACvalveconnectors.
2. Measurevoltage between
body ground and ECM/PCM
connectorterminals82, 810,
820 and 822 individually.

lstherelessthan1.0V?

Chock for a shon in the wira3


{VCCI, VCC2lin..l:
Measurevoltage betweenbody
ground and ECM/PCN4
connector
terminalsC19and C28individuallv.

ls thereapprox.5V?

B.pair open in the wiroltl


b.twocn tho ECM/PCM .nd
G101 lloc.t6d rt th. thormoiat
houingl that had mo.e than 1.0 V.
ECM/PCMCONNECTOR
C {3'IP}
|

Chock lor a short in r snsor:


While measuring voltage
betwoen body ground and ECM/
P C M c o n n e c t o rt e r m i n a l s C 1 9
and C28 individually,disconnecl
the 3P connector ol each sensor
one at time:

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.

Rooairahort in tho wire btwoen


tho MAP sen3or.TP sensor, Fuel
tank DreaaureSonsor and the
ECM/PCMtC19,C28).

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)

'98 - 00 Models (cont'dl


The Malfunction lndicator Lamo
lMlll 3lays on or comes on after
two 3econds.

Check the Dirgnostic Troublo


Cod (DTCI:
'1.
Connecta scantool or Honda
PGMTester.
2. Turnthe ignitionswitchON (ll).
3. Readthe DTC with the scan
tool or HondaPGMTester.

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

check tho DTc by MIL indication:


1. Turnthe ignitionswitchOFF.
2. Connectthe SCS serviceconnector to the service check
connector,
3. Turnthe ignitionswitchON (ll).

Doesthe MIL indicateany DTC?

Ropair op.n ol Bhort in wiro


b.twe.n thc ECM/FCtrl (A21)
and D.i. Link Connoctor.
Go to troublo3hootlng procdur6. lt o pag. 11.6lrl

Try to start the engine.

Doesthe enginestan?

Sub3titute r known"good ECM/


PCM .nd roch.ck. lt .ymptom/
indic.tion gooa awsy, repl.co
the origin.l ECM/PCM.
ECM/FCMCONNECTOFA {32P)

Check tor a 3hort in the wire


ISCSlinel:
1. Turn the ignition switch OFF
and turn the ignition switch

o N{ ) .

2- Measurevoltage between
body groundand the ECM/
PCi, conneclorterminalA10.

Ropria ahort to body ground in


tho wi.c Mwe.n tho ECM/PCM
lA10l and aarvic. check connsctor.

lTo page1l-89)

11-88

www.emanualpro.com

Wire sideof femslet6rminals

(Frompage11-88)

Checktor a short in the wire (MlL


linel:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe ECM/PCMcon
nectorA (32P).
3. Turnthe ignitionswitchON (lli.
Repairshort to body ground in
the wire btwe.n the ECM/PCM
lA18) and tho MlL.
Substituto a known-good ECM/
PCM .nd recheck. lf symptom/
indication goo3 .way, replace
th original ECM/PCM.

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

Th6 MIL has ben reoorted on.


DTCP0107is 3tored.

Problomverification:
1. Turn the ignitionswitchON lll).
2. Checkthe lvlAPwith the scan
root.

ls approx.101kPa(760mmHg,
30 in.Hg),2.9
V indicated?

lrtormittem tailu.e, lystam b OK


at thb timo. Checktor poor connoctions or loosa wird at C131
(MAP rensor) and rt the ECM/
PCM.

Check for an op6n in wi.o IVCC1


linel:
1. Turn the ignitionswitchOFF.
2. Disconnectthe MAP sensor
connector,
3. Turn the ignitionswitch ON {ll}.
4. Measurevoltage between the
MAP sensorconnectorNo. 1
termanal
and No. 2 terminal.

ls thereapprox.5 V?

(Topage11-91)

11-90

www.emanualpro.com

MAP SENSOR3P CONNECTOR


IC131I

vccl

(YEL/RED}

Roprir opn in the wir6 bstween


tho ECM/PCM(D4,C19*l and the
MAP sensor.

Wiro side ol temale terminals

{Frompage11-90)

Chocktor .n open or short in the


MAP 3n30r:
C h e c kt h e M A P w i t h t h e s c a n
tool.

ls approx.2 kPa(15mmHg,
V or lessindi0.6in.Hg),0.1
cated?

(C131I
MAP SENSOR3P CONNECTOR

Chock for a lhort in the wire


(MAPlinol:
1. Turnthe ignitionswitchOFF.
2 . D i s c o n n e c tt h e E C M / P C M
connectorD (16P),(C131P))*.
3. Checkfor continuitybetween
the MAP sensorconnectorNo.3
terminaland body ground.

Rp.ir 3hort in the wire bstwcen


tho ECM/PCM(D3,C17') rnd tho
MAP 3rnsoi.

Wire sideof lgmaleterminals

Sub3lilut. . known-good ECM/


PCM and rocheck. lf normal MAP
k indic.tcd, r.pl.co thc originrl
ECM/PCM.

(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?

Intermittent tailuro, system i3 OK


at this time. Checktor ooor connections or loose wires at C131
IMAPs6nsor)snd the ECM/rcM.
MAP SENSOR3P CONNECTOR
IC131I

Check Ior an open in the MAP


sensor:
1. Turnthe ignitionswitchOFF.
2 . D i s c o n n e ctth e M A P s e n s o r
3P connector.
3. lnstall a jumper wire between
the MAP sensor3P connector
terminals
No.3 and No.2.
4. Turnthe ignitionswitchON {ll).
5. Checkthe MAP with the scan
tool.

tcRN/wHrll

IIRED/GRN|

Wire side of female terminals


ls 10'lkPa(760mmHg,30in.Hg),
2.9V or higherindicated?

vccl
IYEL/RED}

Check for an open in wire (SGl


liDel:
1. Removethe jumperwire.
2. Measurevoltagebetweenthe
MAP sensor 3P connectorterminalsNo. 1 and No-2.
ls thereapprox.5 V?
YES

R6p.ir open in the wire betwoen


the ECM/PCM(D12,CTrl and the
MAP sensor.

Check for an open in the wire


(MAPline):
1. Turnthe ignitionswitchOFF.
2. lnstall a iumper wire on the
PCMconnectorsbetweenD3
and D12.
3. Turnthe ignitionswitchON (ll).
4. Checkthe MAP wirh the scan
tool.
ls 101kPa1760mmHg,30 in.Hg),
2.9V or higherindicated?

D I16PI
PCMCONNECTOR
JUMPERWIRE

Ropair opon in the wire between


the PCM {D3, .nd the MAP son3('t.

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?

Bopairopn in the wi.es between


the ECM/PCM(c1?l and the MAP
5en30t.

Substitute a known'good ECM/


PCMand recheck.lf normal MAP
k indicated, replace the o.iginal
ECM/PCM,

(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.
-

The MIL has be6n rportedon.


DTCPl128 is stored.

Problomverification:
1. Turnthe ignitionswitchON1lli.
2. Checkthe MAP with the scan
tool,

ls 54.1kPa(406mmHg,16.0in.Hg),
1.61V or higherindicated?

I to.mittent failure, 3ydom i! OK


al thbtimc,

The scan tool indicatesDiagnosticTroubleCode (DTC)P'l129:ManifoldAbsolutePressure(MAP)higherthan


expected.
-

The MIL has boenreportodon.


DTCPl129 is stored.

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

Intarmittani fuilure, systom i3 OK


at this time.

IntakeAir Temperature(lAT)Sensor
problemin
The scantool indicatesDiagnosticTroublecode (DTC)P0111:A ranoe/performance

1P0111
| ('97model)the lntakeAir TemDerature(lAT)Sensorcircuit.

of the thermistordecreasesas the intake


The resistance
The IAT Sensoris a temperaturedependantresistor(thermistor).
air temDeratureincreasesas shown below
-

The MIL has beenreportedon.


DTCP0111is stored.
Or lrom ProbableCauseList.

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

. 3' aa ro. r?a arl ,.t r.fl


20 0 to ao ao aa ioo t2otocl

INTAKEAIB TEMPERATURE

flr).

7. check the IAT with the scan


tool-

Rplacethe IAT son3or.

Checkthe IAT sensor output:


1. Warm the IAT sensor with a
hair dryer.
2. Checkthe IAT with the scan
tool.

Did the IATrise2.0'F(1.0'C)


or morefrom the ambient
temperature?

Intermittent f.ilure, aY3temis OK


ai this tim6.

Replacethe IAT sensor.

(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)

The MIL has been reDonedon.


OTCm112 is stored,
Or from ProbableCausList.

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 a m o d e o f
PGMTesterior 0 V indicated?
ls the correctambienttemperatureindicated,,?

Beplocetho IAT sensor.


It the engineis warm,it will b higher than ambienttemperature.

Check for a short in the IAT sensot:


1. Disconnect
the IAT sensor2p

Intermittent failure, system i3 OK


at this time. Ch6ckfor poor connectiona o. loose wires rt C133
{lAT snsorl and rt th6 ECM/pCtr4.

2. Checkthe IAT with the scan


tool.

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?

Raplacethe lAT aensor.


IAT SENSOR2P CONNCCTOR
(C'33I

Chckfor a short in the wir6 llAt


linel:
1. Turn the ignitionswitchOFF.
2. Disconnectthe ECM/PCMconnector{D (16P},
C (31P)').
3. Checkfor continuitybetween
the IATsensor2P connectorter
minalNo.2andbodyground.

'

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

The scantool indicatesDiagnosticTroubleCode(DTC)P0113:A high voltage(low temperature)problemin the


IntakeAir Temperature(lAT)sensorcircuit.

The MIL has beenreportedon.


OTCP0113is stored.

Problemvrification:
1. Turnthe ignitionswitchON (ll).
2. Checkthe IAT with the scan
tool,

ls -4'F (-20"C)or less(or L Limit


in Hondamode of PGMTester)or
5 V indicated?

Intermiftent failure, syatem is OK


at this time. Ch.ck for Door connections or loose wires at c133
llAT s6nsorland at the ECM/
PCM.

sG2
{GRN/BIIO

Checklor an open in the IAT sensor:


1. Disconnectthe IAT sensor2P
connector,
2. Connectthe IATsensor2P con
n e c t o r t e r m i n a l sN o . 1 a n d
No.2 with a ,umperwire.
3. Checkthe intakeair tempera'
ture with the scantool.

ls -4'F (-20"C)or less(or L-Limit


in HondamodeoI PGMTester)or
5 V indicated?

ICl33I
IAT SENSOR2P CONNECTOR

JUMPENWNE
IAT IRED/YELI
Wire side ol female terminals

Replacethe IAT sensor.

YES

_!!7rqd9ll_____FCM CONNECTOR
O IT6PI

Checklor en opan in the wires


llAT, SG2 lines):
1. Turnthe ignitionswitchOFF.
2. ConnectPCM connectorterm i n a l sD 8 a n d D 1 1w i t h a
3. Turnthe ignitionswitchON lll).
4. Checkthe IAT with the scan
tool.

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?

Rgpairopen in the wires btween


the PcM (D8. D11) and rhe IAT
3en30r,

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

Checkfor an open in the wires


{lAT,SG2lines):
1. Turnthe ignitionswitchOFF.
2. ConnectECM/PCMconnector
terminalsC18and C25with a
jumperwire.
3. Turnthe ignitionswitchON (ll).
4. Checkthe IAT with the scan
tool.
ls -4'F 1-20"C)or less(or L limit
in Hondamodeof PGMTesterior
5 V indicated?

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.

Substitute a known-good ECM/


PCM rnd recheck, lf normal IAT
is indicated, leplaco the originsl
ECM/PCM.

'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

ENGINE COOLANT TEMPERATURE

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
-

The MIL has benroportedon.


DTCP01'16is stored.

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.

ls 176- 200'F(80- 93"C)or


0.4-0.TVindicated?

Intermittent failure, sYstemb OK


at this tim6. Check lhe thermostat and the cooling 5y3tom.

Check the thermostat and the


cooling system. It thy are OK,
reolacethe ECTseNor.

(cont'd)

www.emanualpro.com

11 - 9 9

PGM-FISystem
EngineCoolantTemperature(ECTISensor{cont'd)
:[F011'
-

The.scantool indicatesDiagnosticTroubleCode(DTC)P0117:A low voltage(hightemperature)problemin the


EngineCoolantTemperature(ECT)sensorcircuit.

The MIL has been rooortodon.


DTCml17 is sto.od.

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?

Intermittont f.ilure, sysiom is OK


at thk time. Checkfor poor connections or loo3e wire3 at C1lil
(ECT sensorl and et the ECM/
PCM.

Checkfor a Bhort in the ECTsen301:

'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?

Substitute a known-good ECM/


PCM and recheck.It normal ECT
i! indicatod, replaco the oiiginal
ECM/PCM.
*:'98 - 00 models

1-1

www.emanualpro.com

Repairshort in the wir between


the ECM/FCM(D2,C26rl ,nd th6
ECTsenaor.

The scantool indicatesDiagnosticTroubleCode{DTC)P0118:A high voltage{low temperature)problemin the


EngineCoolantTemperature(ECT)sensorcircuit.
The MIL has benreportedon.
DTCP01'18is stord.

Problemverification:
1. Turnthe ignitionswitchON {ll).
2. Checkthe EcT with the scan
tool-

ls -4"F (-20'C)or less(or L-Limit


in Hondamodeot PGMTester)or
5 V indicated?

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

Checkfor an open in the ECTsen-

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

Wirc side of lemale terminals

ls -4'F (-20'C) or less (or L'Limit


in Hondamodeof PGMTester)or
5 V indicated?

('97model)
D {T6PI
PCMCONNECTOR
JUMPERWIRE

ECT
IREDAAIHT)

Checkfor an open in the wiies


{ECT,SG2 lines):
1. Turnthe ignitionswitchOFF.
2. ConnectPCM connectorter
m i n a l sD 2 a n d D 1 1 w i t h a
iumperwire.
3. Turnthe ignitionswitchON {ll}.
4. Checkthe ECTwith the scan
tool,

ls -4"F (-20'C)or less(or L-Limit


in Hondamodeof PGMTesterior
5 V indicated?

IGRN/BLX}

Wire sideoI femaleterminals

Repairopen in th6 wire! botwen


the PCM lD2, D'l1l and the ECT
3n30t.

(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 )

Chacklor an open in the wires


(ECT,SG2 lines):
1. Turnthe ignitionswitchOFF.
2. ConnectECM/PCMconnector
terminalsC18 and C26with a

ECM/PCMOONNECTOR
C 13lPI
1

3. Turnthe ignitionswitchON (ll).


4. Checkthe ECTwith the scan
tool.

7
I 9
't8 '19
,/ 16 1 7
20 n

ECTIRED/WHTI

sG2(GRN/BLK)

JUMPERWIRE
Wiresideof temaleterminals

ls -4"F (-20"C)or less(or L-Limit


in Hondamodeof PGMTesterlor
5 V indicated?

Substitute a known-good ECM/


PCM and rech.ck. lf normal ECT
is indicrted, replace ths originsl
ECM/PCM.

11-102

www.emanualpro.com

Ralpairopen in tho wir6s b6twen


tho ECM/PCM1C18,c26l 6nd tho
ECTsensor.

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:
-

The MIL h.3 been reoorted on.


OTC m122 b 3tored.

OUTPUT VOLTAGE IVI


5
4

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?

Intormittent feilu?e, 3y3tem is OK


at thb iime. Checktor poor connodiona or loose wiros at C130
tTPloNorl .nd rt th PCM.

Check tor an open in the wire


{vOC2linel:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe TP sensor3P
connector,
3. Turnthe ignitionswitchON lll).
il. Measure voltage between
the TP sensor3P connectorterminalsNo.1 andNo.3.

vcc2
IYEL/BLUI

Wi.6 6ide ot fgmaleterminsls

D I16PI
PCMCONNECTOR

ls thereapprox.5V?

Checkto. an open in wir6 {VCC2


linel:
Measurevoltage between PCM
connector
terminals010 and D11.
Ch6ckto. an opon or shon in TP
sonaol:
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 connectorterminals
No. 1 and No. 2 with the throttle fullyclosed.

ls thereapprox.5 V?

(GRN/BLX)

Wiresideof femaleterminals
Repairopen in the wirc between
PCM{D10}and TP 3ensor.

Sub3tituto . known-good PCM


and rechock. It proscribed voltag. b now availablo.rcplacoth6
originsl PCM,

( 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?

Chockfor an open or short in the


TP sensor:
Measureresistancebetweenthe
T P s e n s o r3 P c o n n e c t otre r m i n n a l sN o . 2 a n d N o . 3 w i t h t h e
throttlet!lly closed.
Terminalsideof maleterminals
ls thereapprox.4.5kO?
PCMCONNECTOR
D I16PI
Check to. an open in the PCM
(TPSlinell
1 . R e c o n n e ct th e T P s e n s o r3 P
connector.
2. Turnthe ignitionswitchON (ll).
3. Measurevoltage between
PCMconnectorD (16P)termin a l sD 1a n dD 1 l .

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?

Substitute a known-good PCM


and recheck. It orescribod voltage is now available,roplacothe
o.iginal PCM.

Repairshort in the wire bstween


the PCMlDl)snd the TP ssnso..

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?

Intarmittent failure. system is OK


at thia time. Checkfor poor connctions or loolo wires rt C130
ITPs.nsorl and.t the ECM/FCM.

Checkfor an opon or short in tho


wire {VCC2linel:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe TP sensor3P
connedor,
3. Turn the ignitionswitchON (ll).
4 . M e a s !r e v o l t a g e b e t w e e n
the TP snsor3P connectorterminalsNo. 1 andNo.3.

vcc2

sG2
IGRN/BLKI

IYEUBLUI

Wire side oI Iemale lerminals

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)

Wire sid6of temaleterminals

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?

B.psir opon in the wire b{woon


tho ECM/PCM {C281and th6 TP
3en!xtt.

Subslitute e known-good ECM/


PCM .nd r.chock. lf pro3cribed
voltrge iB now rYrilablo, replaca
th. originll ECM/PCM.
Terminalsideof maletorminals

(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?

Chockfor rn opn or 3hort in tho


TP sonsor
Measure resistancebetween the
TP sensor 3P connectorterminals
No. 2 and No. 3 with the throttle
fully closed.
Terminalside of mal6 terminals
ls thre approx. 4.5 k0?

ECM/PCMCONNECTOR
C {31P}

Check lor an open in the ECM/


PCM ITPSlinel:
1. Reconnect
the TP sensorcon'
nector.
2. Turn the ignitionswitchON {ll).
3. Measurevoltage between
ECM/PCMconnectorC (31P)
terminalsC18and C27.

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}

Wire sideol temaletorminals


ls thgre6pprox.0.5V when the
throttle is Iully closedand
approx.4.5V when the throttle
is lully opened?

Raoai. ahort in th wira lrltw.an


the ECM/PCM (C181lnd th TP
3n3rot.

11 - 1 0 6

www.emanualpro.com

Subrtituto . known-good ECM/


PCM rnd rocheok. lI pro.cribed
voltaga ia now rvailablc, rcpl.ce
th. o.igln.l ECM/PCM.

The scantool indicatesDiagnosticTroubleCode(DTC)P0123:A high voltageproblemin the ThrottlePosition


(TP)sensorcircuit.
The MIL hlr brn r.9ort.d on.
DTCP0123ir stored.

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.

ls therespprox. 1oyowhen tho


throttle is Iully closedand
approx.90%when the throttle
is tully opend?

Intarmittant tailuro, ryrtern b OK


at this timo. Chocklor poor connections or loo3o wir3 at C130
ITP 3orcorl .nd at tho ECM/FCM.

TP SENSOR3P @]{NECTOR IC13O}

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)

Wiro side of fom.le terminals

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?

R.pai. opcn in tha wira botwcon


tho PcM {o111rnd the TP 3en3('t,

Wire side ot femaleterhinals

(Topage11-108)

(cont'd)

www.emanualpro.com

11-107

PGM-FISystem
ThrottlePosition(TP)Sensor(cont'dl
(Frompage11-107)

ECM/PCMCONNECTOR
C {31PI

Check lor an open in the wirc


(SG2line):
Measurevoltage betweenECM/
PCMconnectorC (31P)terminals
C18and C28.

ls thereapprox.5 V?

Ropairopen in th wire betweon


rhe ECM/PCM(Cl81.nd the TP
56nSOl,

Substitute a known-good ECM/


PCM and rocheck.lf pre3cribed
voltago is now avaibble, replace
tho origin.l ECM/PCM,

11 - 1 0 8

www.emanualpro.com

Wire sideof temaleterminals

Pl121 lThescantool indicatesDiagnosticTroubleCode{DTC)Pl121;ThrottlePosition(TP)lowerthanexpected.


-

The MIL has been reportedon.


DTCPl121 is stored,

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?

Intormittent failur6, systom is OK


at this lime.

I Pl122 | The scantool indicatesDiagnosticTroubleCode(DTC)P1122:ThrottlePosition(TP)higherthanexpected.


-

The MIL has benreoortedon.


OTCP1122is dored.

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?

IntermitteDt tailu.o, system is OK


at thb time.

*:'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

RICH- AIR. . LEAN


FUEL
NATO

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).

Repairthe fuel supply system.

{ 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 }

Checktor a shorl in the HO2S:


1. Turnthe ignitionswitchOFF.
the PrimaryHO2S
2. Disconnect
(Sensor'1i
4Pconnector.
3. Startthe engineand let it idle.
4. Check the Primary HO2S
(Sensor1)outputvoltagewith
the scantool.

Doesit stay at 0.1 V or less?

Replacethe HO2S{Sensor1).
(Cl111
PRIMARYHO2Sls.n.or 'l I 4P CONNECTOR

Check for a short in the wir


(PH02Slinel:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe ECM/PCMconnector(D (16P),C (31P)*).
3. Checktor continuitybetween
the PrimaryHO2S{Sensor1)
4 P c o n n e c t o tre r m i n a lN o . 1
and body ground.

PHO2S ---'t
rwHTr T-T-l
T-1 1 2l

6 t lr___J_J
r rl
Y

Wire sideof temaleterminals


Repairshort in tho wire botwesn
the ECM/PCMlD7, C16*) .nd th6
Prim.ry HO2S(Snsor11.

Substituto a known-good ECM/


PCM and recheck. ll 3ympiom/
indicationgoes away. raplaceth.
origin.l ECM/PCM.

(cont'd)

www.emanualpro.com

11-111

PGM-FISystem
PrimaryHeatedOxygenSensor(PrimaryHO2SI(Sensor1l (cont'd)
'99 - 00 models:
-

The MIL has bsen reported on.


DTCP0131ir storod.

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?

Inl.rmittant failura, 3yrtam i! OK


at thb tim.. Ch.ck tor poor connectiona oa looaa wlraa al C111
{Pri|n.ry HO2S,Son3or 1l .nd .t
tho ECM/FCM,

Checktho fuel pressure(seepago


1r,178).

R.p.ir th. ful lupply ry!t.m.

Chocklor a short in tho HO2S:


1. Turnthe ignitionswitchOFF.
2. Disconnectthe Primary HO2S
(Sensor1) 4Pconnector.
3. St6rtthe engineand lot it idle.
4. Check the Primary HO2S
(Sensor1) output voltage with
the scantool,

Does it stay 6t 0.5 V or less?

Chock for a short in tho wirc


(PHO2Slino):
1. Turnthe ignitionswitchOFF.
2. Disconnectthe ECM/PCMconnectorC (31P).
3. Check tor continlity between
the PrimaryHO2S{Sensor'l}
4P connectorterminal No. I
and body ground.

Rephc. th6 HO2S(S.n3or 11.

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

Wire sideol femaleterminals


Ragah rhort in tha wira balwoan
t h . E C M / P C M{ C l 6 1 r n d t h c
Prirn.ry HO2S(S.n3or 11.
Substltut6 a known-good ECM/
PCM and recheck. lf rymptom/
indicrtion 00os away, raplaco thc
original ECM/PCM.

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

Intormittent l.ilure, 3ystem ia OK


at thb timo. Chcck fo. poor connections01 looso wi.es at C111
{Prim!ry HO2S, Sensor 1} and
ECM/PCM.

Checkfor an open in th6 Primary


H()2S:
1. Turnthe ignitionswitchOFF.
2. Disconnect
the PrimaryHO2S
(Sensor1)connector3 . C o n n e c tt h e P r i m a r yH O 2 5
lSensor1) 4P connector
termin a l sN o . 1 a n d N o . 2 w i t h a
jumperwire.
4. Turnthe ignitionswitchON (ll).
5. Check the Primary HO2S
(Sensor1) output voltagewith
the scantool,

sG2

PHO2S
IWHTI

IGRN/
BLK}

Wire sideot femaleterminals

ls there1.0V or more?

{'97 model}

Chck for an opon in the wires


(PHO2S,SG2linesl:
1. Turnthe ignitionswitchOFF.
2. ConnectPCM connectorterm i n a l sD 7 a n d D l 1 w i t h a

PCMCONNECTOR
D {16PI
JUMPERWIRE
PHO2SIWHTI

SG2 IGRN/BLK}

3. Turnthe ignitionswitchON (ll).


4. Check the Primary HO2S
{Sensor1) output voltagewith
the scantool.
ls there1.0V or more?

{ T op a g e1 1 - 1 1 4 )

www.emanualpro.com

Roprir opon in the wire betweon


tho PCM {D7 01 D11l and the
Primsry HO2S{S6nsor1).

Wire sideof temaleterminals

I
(cont'dl

11-113

PGM-FISystem
PrimaryHeatedOxygenSensorlPrimaryHO2S){Sensor1} {cont'dl
( F r o mp a g e ' 1 1 - l 1 3 )

Ch.ck for an open in the wire


(PHO2Slinel:
1. Turnthe ignitionswitchOFF.
2. ConnectECM/PCMconnector
terminalsC16and C18with a

ECM/PCMCONNECTOR
C {31PI

3. Turnthe ignitionswitchON {ll).


4. Checkthe Primarly H02S
(Sensor1) outputvoltagewith
the scantool.
ls there1,0V or more?

Substitute a known-good ECM/


PCM and rachck.lt 3ymptom/
indication goos away, replace
the origin.l ECM/PCM.

11-114

www.emanualpro.com

Rp.ir open in the wire bqtwen


t h e E C M / P C M ( C 1 6 1a n d t h
PrimaryHO2S(Sen.or'l).

'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.

Doos the voitage stay at 1.5 V


or more?

Int.rmitt .fi tailuro, syltom b OK


at thit tima. Checkfor poor connactiona oi loo3a wirar !t Cltl
(Primrry HO2S,S.nror 1) .nd .t
th. ECM/FCM.

PRIMARYHOzS (S6n!or 1l aP
CoNNECTORlcltl)

Pt()2s
IWHTI

Checkfor an opsn in the Prlmary


HO2S:
1. Turnthe ignitionswitchOFF.
2. Disconnect
the PrimaryHO2S
(Sensor1)connector.
3 . C o n n e c tt h e P r i m a r yH O 2 S
(Sensor1) 4P connectort6rmin a l sN o . 1 a n d N o . 2 w i t h a
iumperwire.
4. Turn the ignitionswitchON (ll).
5, Check the Primsry H02S
(Sensor1) output voltagewith
the scantool,

sG2
{GRN/
BTJ(I

Wire side of tem6leterminsls

lsthere 1.5V or more?

Check for an op6n in th6 wiro


{PHO2Sline):
1. Turntho ignitionswitchOFF.
2. Connect ECM/PCMconnector
terminalsC16 and C18with a
iumperwire.
3. Turnthe ignitionswitchON lll).
4. Check the Primary HO2S
(Sensor1) outputvoltagewith
the scantool.

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?

Ropair opon in thc wire bc{w.cn


t h e E C M / P C M{ C l 6 } . n d t h e
PrimaryHO2S{Snror 1}.

sG2IGRN/BLKI

JUMPERWIRE
Wire sideol temalet6rmin6ls

Substituto a known-good ECM/


PCM snd rochock.lf 3ymptom/
indicetion goa awry, roplaca tho
origin.l ECM/PCM.
www.emanualpro.com

(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
-

The MIL has b6n reoortedon.


DTCP0133is stored.

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

Intermittent failure, system is OK


at this time. Checktor poor connectionsor loose wires at C111
(Primary HO2S,Sensor 1) and al
the ECM/PCM.
Replacethe Primary HO2S {Sensor 11.

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.

Doesthe voltage stay at 0.3 V


or less?

lnlermittent failure, 3ystem i5 OK


at this time. Checktor Poor con'
noction3 or loose wires at C127
{locatod on ECM/PCM bracket},
C721 (Secondary HO2S, Sensor
2l and at the ECM/PCM.

Checkfor a short in the Secondary


HO2S:
1. Turnthe ignitionswitchOFF.
2 . D i s c o n n e c tt h e S e c o n d a r y
HO2SlSensor2) 4Pconnector.
3. Startthe engine.
4 . C h e c kt h e S e c o n d a r yH O 2 5
(Sensor2) outputwith the scan
tool.

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.

Wire sideof lemaleterminals


Reoairshort in the wire btwoen
rhe ECM/PCM|D14, 423*l and
the SecondaryHO2S{Sensor2).

Substitute a known-good ECM/


PCM and rocheck.lf symptom/
indication goes away, replace
the original ECM/PCM.

(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.

Doesthe voltage stay at 0.6 V


or more?

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.

Chockfor an opon in the Socondary


HO2S:
1. Turn the ignitionswitchOFF.
2 . D i s c o n n e c tt h e S e c o n d a r y
HO2S(Sensor2) 4P connector.
3. Connectthe SocondaryHO2S
(Sensor2) 4P connectorterminalsNo. 1 and No. 2 with a

SECONDABYHO2S (Sonror 2)
1P CONNECTORrC721l

sHo2s
{WHT/REDI

4. Turn the ignitionswitchON {ll}.


5 . C h e c kt h e S e c o n d a r yH O 2 S
{Sensor2) output voltagewith
the scantool.

sH()2sG
IGFN/WHTI

Wire side of female terminals

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

Rapair op6n in tho wir. b{woan


tho PcM lDla or Dl3l .nd tho
S.condlry HO2S{Senlor 21.

Wirc sideol lemaleterminals

( 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.

ls there 0.6 V or more?


L _._._ _

SHO2SW}iT/RED)| JUMpERW;RE

Repairopon in tho wire botwaen


t h e E C M / P C Ml A 2 3 l a n d t h e
Second.ry HO2S(Sonsot21.

Wire sideof fomaleterminals


I

Substitute a known.good ECM/


PCM .nd recheck. It symptom/
indication goes rway, replace
the origin.l ECM/PCM.

(cont'd)

www.emanualpro.com

1 1 - 11 9

PGM-FISystem
SecondaryHeatedOxygenSensor(secondaryHO2SI(sensor2l (cont,d)
-lTol3al
-

The scantool indicatesDiagnostic


TroubleCode(DTC)P0139:A slow responseprobtemin the SecondaryHeated
UxygenSensor(HO2S)(Sensor2l circuit.

The MIL has ben reoortedon.


DTCP0139is storad.

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

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lntehittont failure, 3ystem is OK


at this time. Chock for poor connections o. loose wi.es at C127
(located on ECM/PCM brackt),
C721{SecondaryHO2S,Sensor2l
and at the EcM/PcM.

HeatedOxygenSensor(HO2S|Heater
scantool indicatosDiagnosticTroubleCode
Fol3slThe
{PrimarvHO2S)(Sensor1) Heatercircuit.
indicatesDiagnosticTrouble Code
F o 1 1 t The
l scantoolHO2S)
(Secondary
(Sensor2) Heatercircuit.
-

(DTC)P0135:A problemin the PrimaryHeatedOxygenSensor

(DTC)P0141:A problem in the SecondaryHeatedOxygen Sensor

Th6 MIL h.. bocn roponod on.


DTC P0135,and/oi mlal are
stored.

Probl.m verification:
1. Do the ECM/PCMResotProcedure,
2. Startthe engine.

Int.rrnittaii frilurc, awtom ir OK


at thi3 time. Chocklor poor conn.ctiona or loosa wiro3 !t C111
lPrim.ry HO2S, Sen3o. 11.C12?
llocatcd on ECM/PCM br.ck.t),
C721 lsocond.ry Ho2s, s.n3or
2r and at tho ECM/PCM.

Ch.ck ior an opon or shoYt in the


HO2S:
1. Turnthe ignitionswitchOFF.
2. Disconnoctthe Ho2s (Primary
or Secondary*)(Sensor1 or
Sensor2)4P conneclor.
3 . A t t h e H O 2 Ss i d e , m e a s u r e
resistancebetween the HO2S
4P connectorterminalsNo. 3
a n dN o . 4 .

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'

Wire sid of lemale terminals

('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

Chockfor en open or lhort in the


wire (lG1 line):
M e a s u r ev o l t a g e b e t w e e nt h e
HO2S4P connectorterminalNo.
3 ( s e c o n d a r yN: o . 4 ) a n d b o d y
ground,

| 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*).

Chck for an open in the wire


(PO2SHTC,
SO2SHTC.lin):
1. Turnthe ignitionswitchOFF.
2. Reconnectthe HO2S4P con-

-L

Wiresideof femaleterminals

SECONDARY
HO2S
ISENSOR214P CONNECTOR

lcr21l,

3. Disconnectthe PCM connector A (32P).


4. Turnthe ignitionswitchON (ll).
5 . M e a s u r ev o l t a g e b e t w e e n
PCM connectortrminals46
andA10(A5andA10)*.

ls thero0.1V or less?

YELI

IGl IBLK/WHTI

Bepair opon in the wiro botwoon


the PcM (A6. A5lr and tho Ho2s
{Prim.ry, Socond!ryr}.

Wire sideol femaleterminals

Substitute a lnown-good PCM


and recheck. lt 3ymptom/indication goes away, .oplacothe original PCM.

( F r o mp a g el 1 - 1 2 1 )

Wire sideof femaleterminals


Check fo. a ahort in the wire
SO2SHTC.lins):
IPO2SHTC,
1. Turn the ignirionswitchOFF.
2 . D i s c o n n e c tt h e P C M c o n nector A {32P).
3. Checklor continuily between
the PCM connectorterminal
46 (A5)*and body ground.

So2HTCIALK/WHTI*PO2SHTCIBLK/WHTI

Bopair short in the wire lrotwsen


tho PC{r4{A6, A5rl and the HO2S
lPiimary, Scondary.l.
Substitute a known-good PCM
and .echgck. lf 3ymptom/indication gos awry. repl.cethe original PCM.

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

Bepair opan or short in tho wilo


bdtween th6 nlo. 15 ALTERNATOR
SP SENSOR17.5Al fu$ .nd th6
HO2S{Primrry, Scondtrytl.

Wiresideof femaleterminals
HO2S
SECONDARY
{SENSOR2} 4P CONNECTOR
(c7211'

Chock lor sn opon in the wires


SO2SHTC'lincl:
IPO2SHTC,
1. Turnthe ignitionswitchOFF.
2. Reconnectthe HO2S4P connector.
3. Disconnectthe ECM/PCMconnector C (31P)(ECM/PCMconneaor A (32P))*.
4. Turnthe ignitionswitchON (ll).
5. Moasurevoltage between
ECM/PCMconnectorterminals
82 andCl (82andA8)*.
ls there0.1V or less?

lcl /5'
tErK/ g,
YELI I

IGl IBLK/WHT}

Wire sideof femaleterminals


Repsir opsn in tha wire between
tho ECM/PCM(C1, A8.) .nd the
HO2SlPrimsry,Socond.ry*}.

ECM/FCMCONNECTORS
PGl (BLK}

Sub.titute a known-good ECM/


PCM and rocheck. lf iymptom/
indicrtion goes away, repbce
the original ECM/PCM.

lFrom page11-12'!)

Chock lor a short in the wi.es


(PO2SHTC,
SO2SHTC'linol:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe EcM/PcM connector C {31P)lECM/PCMconnectorA (32P))*.
3. Check for continuity between
ECM/PCMconnectorterminal
Cl (A8)*and bodyground.
ls therecontinuity?

Roolir 3hort in th. wiro betwoon


the ECM/PCMlC1, A8'l and the
HO2S(Primary,S6condary*).

Sub3tituie s known-good ECM/


PCM and rech6ck. It symptom/
indicaiion goes away. lgplaco
th6 origin.l ECM/PCM.
: P0'14'l

www.emanualpro.com

Wire sideof lemaleterminals

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

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TroubleshootingFlowchart
-

The MIL has beenrePortedon


DTC P0171 andlot P0172 are
stored,

ls the lLrelpressuretoo high


Checklhe Primaty HO2S:
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 Parkot neutral)until
the radiatorfan comeson
2 . C h e c kt h e P r i m a r yH O 2 S
( S e n s o r1 ) o u t P u tw i t h t h e
scantool.

Doesit stayat lessthan0.3V


or morethan 0.6V?

Checkfor a sticking or leaking


EVAPpurge control solenoid
vacu
With a vacuumpump,aPPIY
u m t o t h e E V A PP u r g ec o n t r o l
s o l e n o i dv a l v e f r o m t h e i n t a k e
manifoldside.

Doesit holdvacuum?

Checkth6 valve clearancsand


adjust il necessary. It the valv
clearancesare OK, replace the
fuel iniectors.

www.emanualpro.com

Checklh fuel pumP. fuel faed


pipe. fuel fiher, and luel Prossurc
.eguhior.

Checkthe lu6l pressuroregulator


and tusl relum PiPe.

PGM-FISystem
RandomMisfire
lF()gool",tftod-'

The scantool indicatesDiagnosticTroubleCode (DTC)


pO3O4;
Random
misfire.

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

Only high rpm and load

,a'

Not specification

G\

NOTE:lf misfiredoesn'trecur,some possiblecausesare fuel that doesn'tmeet owner'smanual


spec,lackof fuel, carbon
deposits on spark plu9, etc.

11-1 2 6

www.emanualpro.com

MisfireDetectedin OneCylinder
Ipffi1]

ThescantootindicatesDiagnosticTroubleCode(DTC)P0301:Cylinder1 misfiredetected.

lF03O2l 16".""n toot indicatesDiagnosticTroubleCode(DTC)P0302;Cylinder2 misfiredetected.


I P0303 | fne scantool indicatesDiagnosticTroubleCode(DTC)P0303:Cylinder3misfiredetected.
Cylinder4 misfiredetected
lF0il04l 16" ""un tool indicatesDiagnosticTroubleCode(DTC)PO3O4:
Description
(CKF)sensor
Misfiredetectionis accomplishedby monitoringthe crankshaftspeedwith the crankshaftspeedfluctuation
which is attachedto the crankshaft.
and DTC
lf misiiringstrongenoughto damagethe catalystis detected,the MIL will blinkduringthe time of its occurrence.
on.
MIL
will
come
the
has
ceased,
misfire
after
the
Then,
will
be
stored.
P0304
and/or
P0303
P0301,P0302,
DTc
lf misfiringthat increasesemissionsis detectedduring two consecutivedriving cycles.the MIL will come on, and
P0301,P0302,P0303and/orP0304will be stored.
first,then
NOTE:lJ some of the DTcs listedbelow are storedat the sametime as a misfireDTc, troubleshootthose DTcs
troubleshootthe misfireDTC.
P0107,P0108,P'n2a,P1129tMAP sensor
'l P0112tFuel suPP|Ysystem
Po'17
,
P0441:EVAPinsufficientPurgeflow
P1336,P1337:CKFsensor
P1359,Pl361,P1362:TDCsensor
Pl381,P1382:CYPsensor
PossibleCause
. Fuelinjectorclogging,fuel leakage,air leakage
. Fuelinjectorcircuitopen or shorted
. Sparkplug carbondeposits,fouling,malfunction
. lgnitionwires open,leaking
. Distributormalfunction
. Compressionlow
. Valveclearanceout of specification

(cont'd)

www.emanualpro.com

11-127

PGM-FISystem
MisfireDetestedin OneCylinder(cont'dl
Troubl93hootingFlowchart
-

Th. MILh!3 b6onr.portod on.


DTCm30r, P0302,m303. or
P0304is indicated.

Ch.ck tho fuol inicctor tunction:


Startthe engino,and listenfor I
clickingsoundat the fuol injector
in the problmcylinder.

The illustration shows


'97 - 98 models,'9900 models
are similar.
Checkfor an open or short in the
harnessbetweenthe ECM/PCM
and the luel injector.

Boprir opan or 3hort in tha wlre.

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

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Roplacoth. tuel inioctor.


Substitut. . known-good
E C M / P C M. n d r o c h o c k .I t
3ym ptom/ indicati on go.3
a w . y , r e p l a c et h e o l i g i n a l
ECM/PCM.

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?

ooesthe misfireoccurin the


othercylinder?

Check lor fuel iniector maltunct|on:


1 . E x c h a n g et h e f u e l i n j e c t o r
f r o m t h e p r o b l e mc y l i n d e r
with one from anothercylinder.
2. Letthe engineidlefor two min
utes.
3. Test'drivethe vehicleseveral
times in the rangeof the freeze
data,

ls DTCP0301,P0302,P0303,
or P0304indicated?

Doesthe misfireoccurin the


othercylinder?

lntormittent misfire due lo spark


plug fouling, etc. (no mislire at
this tim).

Replacethe faulty spark Plug.

NOTE:lf there is no freezedata of mis


firing, test drives under variouscondi_
tionsare necessary.

lntermittent misfiro due lo bad


contrct in the fuel iniector connector {no misfire at this time).

Replacelhe faulty luel inlector.

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).
-

The MIL has been rooortedon.


DTCm325 is storod.

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}

Replil rhort in the n irg b6{wocn


tho ECM/PCMlc:ll and the knock
sngr1.
Check fo..n open in the wire
{KSline):
C h e c kf o r c o n t i n u i t y b e t w e e n
ECM/PCMconnector terminal C3
and knocksensorconnectorter,
m i n a lN o .1 .

Wiresideof femaleterminals

KS 1P CONNECTOR
IC13?'

KS
IRED/BLU)
Wire side ol female
termtnals

ls therecont;nuity?

B.pair opon in the wirc lrotween


lho ECM/PCMlctl and thc knock
acnsor.

Substitutea known-goodknock
sensorand recheck.

NOTE: Torquethe knocks6nsorto


31 N.m (3.2kgl.m, 23 lbf.ft).

ls DTCP0325indicated?

Bcpl.ce the originalknock 3nsor,

ECM/PCMCONNECTOR

KS
c (31P)
(BED/BLU)

Wire sideot femaleterminals

Substituto a known-good ECM/


PCM and .echeck. lf 3ymptom/
indication goes away, replace
the original ECM/PCM.

11 - 1 3 0

www.emanualpro.com

Sensor
Position(CKP/TDC/CYPI
CrankshaftPosition/TopDeadGenter/Gylinder
scantool indicatesDiagnosticTroubleCode
tro-rslThe
sensorcircuit,

(DTC)P0335;A malfunctionin the CrankshaftPosition(CKP)

problemin the Crankshaft


The scantool indicatesDiagnosticTroubleCode(DTC)P0336:A range/performance

1Tffi61 Position{CKP)sensorcircuit.
The

tool indicatesDiagnosticTroubleCode {DTC)P1361:Intermittentinterruptionin the Top DeadCenter

scan
tF136t(TDC)
sensorcircuit.
The scan
fPfa6r-1
ci.cuit.

tool indicatesDiagnosticTroubleCode (DTC)P1362:No signalin the Top DeadCenter(TDC)sensor

tool indicatesDiagnosticTroubleCode(DTC)P1381:Intermittentinterruptionin the CylinderPosition

The scan
tF138tl(CYP)
sensorcircuit.

The scantoot indicatesDiagnosticTroubleCode {DTC)P1382:No signalin the CylinderPosition(CYP}sensor

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:
-

The MIL has ben reportedon.


DTC P0335, P0336, P136' 1,
P1362,Pl341 and/oi P1382are
stored.

lOP
DISTRIBUTOR
CoNNECTOR(Cl211
TDCPIGRNI

CYPPIYELI

Problemverific.tion:
1. Do the PCMResetProcedure.
2. Startthe engine.
ls DTCP0335,P0336,P1361,P1362,
P1381and/orP1382indicated?

Ch.ck for an open in tho CKP/


TDC/CYPsensor:
1. Turn the ignitionswitchOFF.
the distributor10P
2. Disconnect
connector.
3. Measureresistancebetween
the terminalsof the indicated
sensor(seetable).
ls there 350 - 700 o?

Intermittent lailure, 3yd6m i3 OK


at thb tims. Chcck tor poor connections ol looso wire3 si C12'l
ldistributor) .nd .t the PCM.

CYPM(BLKI
TIrcMIREOI

Terminalsideof
maleterminals
S E N S O E DTC

Replacetho distributor ignition


housing {sea3ection41.

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

Check for a short in the CKP/


TDC/CYPsensor:
C h e c kf o r c o n t i n u i t yt o b o d y
ground on both terminalsof the
indicatedsensorindividually(see
t a b l eo n p a g e1 l 1 3 1 ) .

ls therecontinuity?

Rplacthe distributor ignition


housing {seesection4}.

Chckfo. an open in the wires


lines):
{CKP/TDC/CYP
'1. Reconnect
the distributor10P
connector.
2. DisconnectPCMconnectorC
(31P).
3. Measureresistancebetween
the terminalsof the indicated
sensoron the PCMconnector
o n p a g e1 l 1 3 1 ) .
lseetable

ls there350- 7000?

Terminalsideof
maleterminals

Repairopen in the indicated sensor wires {se6 table on page 11131).

PCMCONNECTORS
C I31P)
CKPP TDCP CYPP
IBLU) IGRNI IYEL}

Check tor a short in the wires


linesll
{CKP/TDC/CYP
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 groundand PCMconnector
terminalsC2,C3and/orC4 individ-

ls therecontinuity?

Substitute a known-good PCM,


and recheck.lf symptom/indication goes away, rplacelhe original PCM.

www.emanualpro.com

RDairshort in the indicatodsensor wires lsee table on page 1113rI.

{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}

The MIL ha3beenreoortedon.


DTC P0335. P0336, P1361,
P1362.P1381andlor P13V are
stord,
Problemverification:
1. Do the ECM/PCMResetPro
cedure.
2. Startthe engine.

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.

ls DTCP0$5, m$6, Pl361,P1362,


P1381and/orPl382 indicated?

Check for an open in th6 CKP/


TDC/CYPsensor:
1. Turnthe ignitionswitchOFF.
2. Disconnect
the distributor10P
(8P)*connector.
3, Measureresistancebetween
the terminalsof the indicated
sensor{seetable).

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)

Rephce the distributor ignition


houaing l3e93oction4).

ls there350 7000?
'98

modeli

TDCP {GRNI

Check for a short in the CKP/


TDC/CYPsnsor:
C h e c kf o r c o n t i n u i t yt o b o d y
ground on both terminalsof the
indicatedsensorindividually(see
table).

Replacotho distributor ignition


housing lsee soction tll.

Check for an opn in th6 wires


linesl:
ICKP/TDC/CYP
1. Reconnect
the distributor10P
(8P)*connector.
2. Disconnect
ECM/PCM
connector C (31P).
3. Measureresistancebetween
the terminalsof the indicated
sensoron the ECM/PCMcon
nector(seetable).

ls there350 700O?

C {31P)
ECM/PCMCONNECTOFS

CKP P
{BLU)

Repairopen in the indicated sensor wires lsee t.ble).


':'99 - 00 models

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

Chock lor r 3hon in tho wirer


lin6):
ICKP/TDC/CYP
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 groundand ECM/PCMconnectorterminalsC8, C20 and/or
C29individually.

Rep.ir lhort in ths indicatedsonaor wiroa 136otable on prge 11133).


Substituto r known-good ECM/
PCM, and .6chock. tf 3ymptom/
indication goe3 swey, replrce
tho original ECM/PCM.

11 -1 3 4

www.emanualpro.com

Wire sideof femaleterminals

Vehicle Speed Sensor (VSSI


|posoll-'
lPosoo-]-'.

The scantool indicatesDiagnosticTroubleCode{DTC}P0500*' orP0501*r:A range/perfor* I ; A/T


mancein the VehicleSpeedSensor(VSS)circuit.
*2i Mfi

'97 modol:
FCM CONNECTORS

The MIL hes boen roported on.


DTCm501 is 3tord.

A t32Pl
LG1

(BRN/BLK)
Problomverificetion:
1. Test'drivethe vohicle.
2. Checkthe vehiclespeedwith
the scantool,

ls the correctspeedindicated?

Chockfor an open in tho PiCM:


1. Turnthe ignitionswitchOFF.
2. Block the rear wheels and set
the parkingbrake.
3. Jack up the lront of the vehicle
and support it with salety
stands.
4. Turn the ignitionswitchON (ll).
5. Elockthe right front wheel and
slowly rotate the left tront
wheel by hand.
6. Measurevoltage between
PCMconnectorterminalsC18
and A9.
Doesthevoltagepulse0 V
and 5 V or batteryvoltage?

lntormittent tailure, rystom b OK


at thia timo. Chocktor poor connection3 or 10o3owires rt C129
lvss) .nd rr rhe Pcfr4,

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

Substitulc a known-good PCM


and .och6ck. It symptom/indicd.
tion go.a away, .cplacotho originel FCM.
LGl

{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

Substituto e known-good PCM


and rochock. f rymptom/indication goos rwry, roplsc. tho originalFCM.

Repair short in the wire


between the PCM lC18l,
cruise control unit, speodometer, and VSS,
Repair opon in the wire
between the PCM {C181.nd

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

The MIL ha3 beenreDonedon.


DTC P0500" or P0501*1i3
3torod.

B t25Pl

Probl6mverification:
1. Test-drive
the vehicle.
2. Checkthe vehiclespeedwith
the scantool,

ls the correctspeed indicated?

Checkfor rn open in the ECM/


PCM:
l Turnthe ignitionswitchOFF.
2. Elockthe rearwheelsand set
the parkingbrake.
3. Jack up the front oI the vehicle
and support it with satety
stands.
4. Turn the ignitionswitchON {ll}.
5. Blockthe right front whoel and
slowly rotate the lett front

Intermittont failu.e, svstem is OK


at thk time. Check for poor connection! or loose wiros at C129
lvss) .nd ar the EcM/PcM.

NOTE(4WD):Do not use the engineto turn


the front wheelswith the rearwheelson the
ground. The 4WD system will engage and
the vehiclewill suddenlylurchforward.

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?

Substitute a known-good ECM/


PCM and rochock. ll symptom/
indicetion 9063 away, .oplace th
origin.l ECM/PCM.

B (25P)

Check for a short in the ECM/


PCMI
1. Turn the ignitionswitchOFF.
2 . D i s c o n n e c tE C M / P C Mc o n
nectorC 131P).
3. Turn the ignitionswilch ON {ll).
4 . B l o c kt h e r i g h t f r o n t w h e e l
and slowly rotatethe left front
5. MoasurevoltagebetweenECM/
PCMconnectorterminals820
and C23.

Doesthe voltage pulse betlveen


0 V and 5 V or battery voltage?

R.pair short in the wiro


betwen the ECM/PCMlC23)
.nd tho VSS.
Roprir open in th6 wire
botweon the ECM/PCMlc23l
and th6 vss.
It wirc is OK, te3t ihe VSS
(!e soetion23).

*2:Mft

11 - 1 3 6

www.emanualpro.com

Sub.titute a known-good ECM/


PCM and rschock. It rymptom/
indication goos .w.y. replece
rhe original ECM/PCM.

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?

Intermittent fsilure, sy3tom i5 OK


at this time.

Substitute a known-good ECM/


PCM .nd recheck.It symptom/
indication goes away, replacethe
origioal ECM/PCM.

fTiloz l The scantool indicatesDiagnosticTroubleCode(DTC)P1107:A low voltageproblemin the Barosensorcircuit.


The scan tool indicatesDiagnosticTrouble Code
tP11o8l
circuit.
-

(DTC)Pl108: A high voltage problem in the Baro sensor

The MIL h.3 ben roportdon.


OTCPl10?or Pl108i3 stored.

Problomveritic.lion:
L Do the ECM/PCMResetProcedure.
2. Turnthe ignitionswitchON (lli.

ls DTCP1107or P1108indicated?

Sub3tituto a known-good ECM/


PCM and rcch6ck. ll symptom/
indication 9oo3 away. .oplaco
rho o.igin.l ECM/PCM.

www.emanualpro.com

Intarmittoni failure, lystom b OK


at thb time.

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?

Intormittent lailuic, 3vstom k OK


at thk time. Ch.ck tor poor connections or loose wiro3 at C127
(loc.ted on PCM b.sckot), C354
{ELO,.nd at tho FCM.
ELD3P CONNECTOR
{C354I

Ch.ck for 3hort in lho ELD:


Measurevoltage between body
groundand the ELD3P connector
t e r m i n aNl o . 3 .

--+l 1 L 2 l 3 l
lerO) tcnrulaeot

ls thereapprox.4.5V?

Wire sideot femaleterminals

PCMCONNECTOR
D I16P)

Checkfor a short in tho wire IEL


linel:
1. Turnthe ignitionswitchOFF.
2. DisconnectPCM connector D
(16P).
3. Checkfor continuitybetween
body ground and PCMconnec
tor terminalD16.

Wire sideof femaleterminals


Rcpair 3hort in tho $rire botwon
the PcM lDl6l and tho ELD.

Substituto a known-good PCM


and rocheck. lf 3ymptom/indic.tion goos !w!y, repl.ce the original PCM.

11 - 1 3 8

www.emanualpro.com

98 - 00 mod6l3:
-

OTCPl17 is 3tored.

Problcm vcrificrtion:
1. Do the ECM/PCMResetProcedure,
2. Startthe engine.
3. Turn on the headlights.

ls DTCP1297indicated?

Intcrmittent tailuro, ryrtom ir OK


!t thi3 timo. Ch.ck tor poor connectiont or looao wire! at CXl54
IELD)rnd at rh6 ECM/PCM,

Chockfor 3hort in tho ELD:


Measurevoltage between body
groundand the ELD3P connector
terminalNo.3.

ELD3PCONNECTOR
ICAs4I

-I

f 2_ l l 3, l

l---r'.
&)

iGRN/RED)

Wire sideof temaleterminals

ls there approx. 4.5 V?

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.

Sub.tituto a known.good ECM/


PCM .nd rocheck. ll lymptom/
indication gocs .w!y. replsce
th6 o.iginal ECM/PCM,

(cont'd)

www.emanualpro.com

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

Chock lol !n open in the wire


IGND linel:
'1. Turn the ignition switch and
headlights
OFF.
2. Disconnectthe ELD 3P con
neqor,
3. Check for continuity between
body ground and the ELD3P
connectorterminalNo.2.
Ropairopon in th6 wi.e betweon
th. ELDconnectorrnd GiO2,

Wire sideof lemaleterminals


PCMCONNECTORS

Ch.ck lo. an open in th wiro (EL


line):
Checkfor continuity between the
ELD3P connectorterminalNo. 3
and PCMconnectorterminal016.
ls therecontinuityT

R6pafuop6n in tho wire between


the PCM{D161sndth6 ELD.
Subltituto . known-good PCM
and rachock, f symptom/indic.tion goes awry, ropl.ce the origin.l PCM.

Chock for . malfunction in the


ELD:
1 . R e c o n n e ctth e E L D 3 P c o n neclor,
2. Start the engineand allow it
to idle.
3. While measuring voltage
betweenPCM connectorter
m i n a l s0 1 6 a n d A 9 . t u r n t h e
headlights
on (low).

Doesthe voltagedrop?

Wire sideof lemaleterminals

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?

Check lor an open in the wire


(lG1line):
' 1 . T u r n t h e i g n i t i o na n d h e a d lightsOFF.
2. Disconnectthe ELD3P connector.
3. Turnthe ignitionswitchON (ll).
4 , M e a s ur e v o l t a g e b e t w e e n
body ground and the ELD3P
'1.
connectorterminalNo.

ELO3PCONNECTOR
{c35/rl

Intermittent feilure, sysl.m is OK


at this time. Checkfor ooor connections or loose wires at C354
(ELDIand at the ECM/PCM.

Wire sideot temaleterminals

ELD3P CONNECTOR
{C35,lt

Reprir open or short in th6 wire


botweon the No. 15 ALTERNATOR SP SENSOR{7.5 Al fuse in
the under-drah fuse/relay box
and the ELD.

Wiresideof femaleterminals

Check tor an opon in tho wire


{GNDline}:
1. Turn the ignition switch and
headlights
OFF.
2. Disconnectthe ELD 3P con
nector.
3. Check for continuity between
body ground and the ELD 3P
connectorterminalNo.2,
Repairopon in the wire between
the ELDconneclor and GilO2.

Ched(fo. an opn in the wir (ELlinel:


Checkfor continuity between the
ELD3P connectorterminalNo. 3
and ECM/PCMconnectorterminalA30.

EL IGRN/RED}
Wire sideof female
termrnars
Repairopn in tha wile botwecn
the EcM/PCM lA30l .nd rhe ELD.

ECM/PCMCONNECTORS
A l32P)

Checkfor s malfunction in lhe ELD:


1 . R e c o n n e ctth e E L D 3 P c o n nector.
2. Start the engine and allow it
to idle.
3 . W h i l e m e a s u r i n gv o l t a g e
between ECM/PCMconnector
terminalsA30 and 820, turn
the headlightson (low).

Wire sideof femaleterminals


Substiiute a known-good ECM/
PCM and recheck. It symptom/
indication goos away, replace
the original ECM/PCM.
www.emanualpro.com

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:
-

Tho MIL ha3been reportedon.


DTC P1336and/or P1337are
stored.

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

Checkfo. a short in the CKF3ensot:


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 groundand the CKFsensor
2P connectorterminalsNo. 1 and
No.2 individually.

(Topage11-113)

1 1 -1 4 2

www.emanualpro.com

Terminal side of male terminals

{ 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?

Ropair open in the wire betwoon


tho PCM lcl, Cl1l and th6 CKF
!6naor.
CKFP
IELU/REDI

Chock tor a short in the wires


(CKFlino3):
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 PCMconnector
terminalCl.

Rcoair short in thc wire btween


the PCM{Cl I and the CKF.en!o..

Subsiituto r known-good PCM


and r6chock. lf symptom/indication goe3away, roplacothe origin.l rcM.

(cont'd)

www.emanualpro.com

11-143

PGM-FISystem
GrankshaftSpeedFluetuation(CKFISensor(cont'dl
.98 - 00 modols:
-

The MIL has boon reportedon.


DTC P1336and/or P1337are
stored.

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

Check for an open in the wires


ICKFlinca):
1. Feconnectthe CKFsensor2P
connector.
2. DisconnectECM/PCMconnect o rC ( 3 1 P ) .
3. Measureresistancebetween
E C M / P C Mc o n n e c t o rt e r m i '
nalsC22and C31.

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)

Check for a shorl in the wires


(CKFlines):
C h e c kl o r c o n t i n u i t y b e t w e e n
body ground and ECM/PCMcon
nectorterminalC22.

ls therecontinuity?

Repairshort in tho wire between


the ECM/PCM{C221and rh. CKF

Wire sideof femaleterminals

Substitute a known-good ECM/


PCM and recheck. lf svmptom/
indication goes away. replace
the original ECM/PCM.

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)
-

The MIL has been reoortedon.


DTCP1359is stored.

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.

Substitute a known-good ECM/


PCM, and recheck. ll symplom/
indication goes away, replacethe
original ECM/PCM.

1 1 -1 4 6

www.emanualpro.com

Intermitteni lailure, system is OK.


Check for ooor connectionsor
loos wires al C121 {distributor}
and at the ECM/PCM.

ECM/PCMInternalCircuit
lFi6oil
-

Th" """n tool indicatesDiagnosticTroubleCode{DTC)P1607:An ECM/PCMInternalCircuitProblem.

The MIL has been reoortedon.


DTCPlmT is slor6d.

Problomveritication:
1. Do the ECM/PCMResetPro
2. Turnthe ignitionswitchON (ll).
3, Waitthreeseconds,

ls DTCP1607indicated?

Sub3tiiut a known-good ECM/


PCM and recheck.lf symptom/
indicationgoes away, replacethe
originalECM/rcM.

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.

Installthe HO2Sin reverseorderof removal.

11-1 4 8

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ldle Control System


SystemDescription
The idle speedof the engjneis controlledby the ldle Air Control(lAC)Valve'
The valvechangesthe amount of air bypassinginto the intakemanifoldin responseto electriccurrentcontrolledby the
Whenthe lAc valve is activated,the valveopensto maintainthe properidle speed.
ECM/PCM.
YEL/
BLK

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.

lf the aboveitemsare normat,suDslitutea known-goodIACvalveand readjustthe idle speed{seepage 11-169,170)


lf the idle speedstill cannot be adjustedto specification(and the scantool does not indicateDTC P0505or Pl508)
after IAC valve reolacement,substitutea known-goodECM/PCMand recheck lf symptom goes away' replacethe
originalECM/PCM.

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11-149

ldle Control System


ldle ControlSystem
I P0505 | The scantool indicatesDiagnosticT.oubleCode(DTCIPO5O5:
ldlecontrolsvstemmattunction.
NOTE:lf DTCP1508is storedat the sametime as DTCP0505,troubleshootDTCP1508first.then troubleshootDTCp0505.
PossiblsCause
. IACvalvemechanicalmalfunction
. Throttlebody cloggedport,improperadlustment
. Intakemanifoldgasketleakaging
. Intakeair hoselooseleakaging
. Vacuumhose leakaging
a ECTsensorincorrectoutput
. ThrottlePositionsensorincorrectoutput
TroubleshootingFlowchart
The MIL has been reDortedon.
DTCP0505is sto.ed.

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?

Inte.mittent failure. syltem is OK


at this time.

ls il 700(680)'rpm or less?

l:'99 - 00 models

{ T op a g e1 1 - 1 5 1 )

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( T op a g e1 ' l - 1 5 1 )

(Frompage11-150)

Checkthe IAC valve:


the 2P connectorfrom
Disconnect
the IACvalve.

Doesthe enginespeeddroP
or the enginestall?

Adiust the (basel idl speed lsee


page11-169,1t0).Itihe ba3eidle
speed cannot be adiustd, clean
the Dorts in the throttle body.

UPPER

{ F r o mp a g e1 1 - 1 5 0 }

Checkthe tast idle lhermo valve:


1. Turnthe ignitionswitchOFF.
2 . R e m o v et h e i n t a k ea i r d u c t
from the throttle body.
3. Startthe engineand let it idle.
4. Put your finger on the lower
pon in the throttlebody.

THERMOVALVE
(A/Tonlyl
Doesthe enginespeeddrop?

Checkenginecool.nt leveland for


air in the cooling sy3lem. lf OK,
reolacethe f.st idle thermo valve.

Putyour Iingeron the uPPerPort


in the throttlebody.

Doesthe enginespeeddroP?

Adjust the idle spoed lsee Page


11-169.1701.lf the adiustment
does not correct lhe problem,
r.olace the IAC valve.

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Check for vacuum leaks, make


sure the throttle valve is com'
pletely clo3ed.and repair as nec-

ldle Control System


ldle Air ControlllAC)Valve
The scan tool indicatesDiagnosticTrouble Code (DTC)Pl508: A probtem in the ldle Air ControtflAC)varve
circuit.
The IACValvechangesthe amountof air bypassingthe throttlebody in responseto a currentsignalfrom the ECM/PCMin
orderto maintainthe properidle speed.
From AIR To INTAKE
CLEANER MANIFOLD

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?

Inte.mittent failure, systcm b OK


at thi3 time. Checktor poo. connections or loose wircs at C132
(lAC v.lvel and at the PCM.
IAC VALVE2P CONNECTOR
{C132}

Check lor an open in the wir6


{lGPl lins}:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe IAC valve 2P
connector.
3. Turn the ignitionswitchON {ll).
4. Measurevoltagebetweenbody
ground and the IAC valve 2P
connectorterminal No.2.

,f\

rcp'
IYEL/BI.(I

I- 2df -) 1

Y
Wir side of female terminals

Repairopen in the wire trctwoon


tha IAC v!lv6 and the PGM-Fl
main relly.
PCMCONNECTOR
A I32PI
Chockfor an opan o. short in tho
wi.e (lACv linel:
1. Turn the ignition switch OFF
and reconnectthe IAC valve
2P connector.
2. Disconnectthe PCMconneclor
A (32P).
3. Turn the ignitionswitchON {ll).
4 , M e a s u r ev o l t a g e b e t w e e n
body ground and PCM connectorterminalA12.

{ T op a g e1 l - 1 5 3 )

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tacv
IBLK/
BLU)
Wire sideof femaleterminals

( F r o mp a g e1 1 - 1 5 2 )

ls therebafteryvoltage?

Bepair opn or short in the wire


betweon th PCM {A121and the
IAC vrlve.

Checkthe IAC valve function:


Momentarilyconnect PCM con'
n e c t o rt e r m i n a l sA 1 2 a n d A 1 0
with a iumoerwire severaltimes,
Wire sideof femaleterminals
Doesthe IACvalveclick?

Substitute . known-good PCM


and rcheck, lt 3ymptom/indication goes away, replacothe origi_
nalPCM,

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1-153

ldle Air Control(lAC)Valve{cont'd}


'98 - 00 models:
The MIL has boen r.ported on.
DIC Pl 508 b 3tored.

Problemveritication:
L Do the ECM/PCMResetProcedure.
2. Startthe engine,and warm it
up to normal operatingtemperature.

ls DTCP1508indicated?

Intrmittent failure, systom is OK


al lhis timo. Check lor poor connections or looro wirca at C132
(lAc vrlvel and .t rho EcM/PcM.
IAC VALVE2P CONNECTOR
{C132I

Chock tor an open in the wir6


llGPl linel:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe IAC valve 2P
connector,
3. Turnthe ignitionswitchON (ll).
4. Measurevoltagebetweenbody
ground and the IAC valve 2P
connectorterminaI No, 2.

rcpt

F\

*l
tYELrBLxl
I2/'-

rf)
Y

Wire side ot fem.le terminals


Repairopon in the wira botwoon
the IAC valve and tho PGM-FI
main aalay.
B (25PI
ECM/PCMCONNECTOR

Checktor an open or short in the


wire (IACVlinel:
1. Turn the ignition switch OFF
and reconnectthe IAC valve
2P connector.
2 . D i s c o n n e c tE C M / P C Mc o n nectorB {25P).
3. Turn the ignitionswitchON {ll}.
4. Measurevoltage between
body ground and ECM/PCM
connectorterminal823.

9
19

2
'to

5
1l

21 22

20

13

t7

23

tAcv
(BLK/BLUI

Wiresideof femaletorminals
ls there batteryvoltage?

Checkthe IAC valve func,tion:


Momentarilyconnect ECM/PCM
connectorterminals823 and 82
with a jumperwire severaltimes.

Ropair open or short in thg wire


between tho ECM/FCMlB23l and
the IACvalve.

PG1
{BLKI
1

2 |

t 3 4 5

9 1 0
1 1 13
19
20 | 121)22

8
17

tAcv
(BLK/
BLU)

Does the IACvalve click?

Subslitute . known-good ECM/


PCM .nd rechock.lf symptom/
indication goes aw.y, replac.
th original ECM/PCM.
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JUMPERWIRE

Air ConditioningSignal
This signalsthe EcM/PcMwhen there is a demandfor coolingfrom the air conditioningsystem.
'97 modol:

Chock for a shorl in thc wiro


(ACSlinol:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe A/C pressure
switch2Pconneclor.
3. Turnthe ignitionswitchON (ll).
, 1 . [ I e a s ur e v o l t a g e b e t w e e n
PCM connectorterminalsC5
andA9.

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

Reoaii short in tho wire btwoen


rh6 PCM (Csl and the A/C pres3urc 3witch.

Check tor an opon in the wite


(ACClino):
1. TLrrnthe ignitionswitchOFF.
2. Roconnectthe A/C pressure
switch2Pconnector.
3. Turn the ignitionswitchON (ll).
4 . M o m e n t ar i l y c o n n e c t P C M
c o n n e c t o tr e r m i n a l sA 9 a n d
417 with a iumper wire sev'
eraltimes,

(To page11-156)

Subcdtrte a known{ood PCM


and recheck. lf pr6actibed voltage is now av{ilable, roplace
the origind PCM,
Soethe eir conditionorin3pclion lsee soction221.

A (:TIPI
PCMCONNECTOR
JUMPERWIRE

Wire sideoI Iemaleterminals

(cont'd)

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1 1 - 15 5

ldle GontrolSystem
Air ConditioningSignal(cont'dl
(Frompage11-'155)

Ch6ck for an open in th wire


(ACClinel:
Momentarilyconnectthe underhood fuse/relaybox 9P connector
t e r m i n a lN o . 5 t o b o d y g r o u n d
with a jumperwire severaltimes.

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

See air condiiioner inspection


{seesection221.

Repai. op6n in the wire betwoen


the PcM (A17) and tho A/C
clutch relay.
PCMCONNECTORS

A t32Pl

C t3rp)

Checkthe A/C operation:


1. Startthe engine.
2. Turnthe blowerswitchON.
3. Turn the A"/Cswitch ON.

Wire sideol lemaleterminals

Doesthe A,/Coperate?

Check for an open in the wire


(ACSline):
Measurevoltage between PCM
connectorterminalsAg and C5.

Air conditioningsignal is OK.


ls therelessthan 1.0V?

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Subqtitute a known-good FCM


.nd rch6ck.lt 3ymptom/indication goes awav, replece the
originalrcM.
Soe th eir conditioner in3pection (s6aec.tion22).

Repair open in the wire between


the PCMlCSland the A/C awitch.

'98 - 00 models:

ECM/PCMCONNECTORS
A {32P1

Check for a shott in the wire


{ACSlinel:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe A/C Pressure
switch2Pconnector.
3. Turnthe ignitionswitchON (ll)
4. Measurevoltage between
E C M / P C Mc o n n e c t o rt e r m l
nalsA27 and 820.

A (32PI
ECM/PCMCONNECTOR

ls there batteryvoltage?

Checktor . short in the wire IACS


linel:
1. Turnthe ignitionswitchOFF.
2. DisconnectECM/PCMconnector A (32P).
3. Checkfor continuitybetween
body ground and ECM/PCM
connectorterminalA27.

Wiresideof femaleterminals

ls therecontinuitv?

R.oak short in the wile between


rhe ECM/PCM(A271and the A/C
Dressureswitch.

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,

{To page11 158)

Sub6titute a known{ood ECM/


rcM and recheck. lf pte6cribed
voltage i3 now available,re'
pl.ce the origioalECM/rcM.
Seeih6 air conditionerinspection (s6esection221.

A (32P1

ACC(BLK/REOI

(BRN/BLKI
JUMPERWIRE LG1

{cont'd)

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11-157

ldle ControlSystem
Air Gonditioning
Signal(cont'd)
(Frompage'11,157)

ls therea clickingnoiselrom
the y'y'Ccompressorclutch?

Check Ior dn opon in the wiro


IACClinel:
Momentarilyconnectthe underhood fuse/relaybox 9P connector
t e r m i n a lN o . 5 t o b o d y g r o u n d
with a jumperwire severaltimes.

ls therea clickingnoisefrom
tho A,/Ccomprossorclutch?

Repai. open in th6 wiro lrtwlan


the ECM/PCMlAl7l .nd tho A/C
clutch rolay.

UNDER-HOOD
FUSE/RELAY
BOX9PCONNECTOR
{G'52I

JUMPER
WIRE

3 a

(BLK/R
ACC(BLK/RED'
Wire side otfemale
ot
terminals

Sae rir conditional in3paction


lroa saction 221.

ECM/PCMCONNECTORS

Check tho op.ration of tho A/C:


1. Stan the engine.
2. Turnthe blowerswitchON.
3. Turn the Ay'Cswitch ON.

Doesthe !y'C operate?

ChGGkfor an open in the wi.e


IACS linel:
Measurevoltage betweonECM/
P C M c o n n e c t o rt e r m i n a l sA 2 7
and 820.

Wiresidof femaletorminals

Air conditioning 3ignal i3 OK.


ls voltagelessthan 1.0V?

Sub6lftna a known{ood ECM/


PCM and rechock. lf symptom/indicetion goes away.
roplacethe originalECM/rcM.
See the ah conditionor inspoction {3esection 22},

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Rap.ir opon in the wir6 bdtunaan


rh. Ecil/FcM lA27l rnd rh. A/c
rwitch.

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?

Checkth ope.ation of the ALT:


1. Turnthe ignitionswitchOFF
2. Reconnectthe ALT 4P {3Pi*
connectorto the ALT.
3. 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 rf a n c o m e s o n ,
then let it idle.
4. Measurevoltage between
PCMconnectorterminalsC17
and A9.
when
Doesthe voltagedecrease
headlights
and reardefoggerare
turnedon?

Chd( for an opn in tho wire IALT


F linel:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe negativebattery cablelrom the battery.
3. DisconnectPCMconnectorC
(31P).
4. Disconnectthe 4P (3P)*connectorlrom the ALT.
5. Connectthe ALT 4P (3P)* connectorterminalNo. 4 (No. 1)*
to body groundwith a iumper

wire sideof femaleterminals

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.

Ropeirshort in the wir6 betweon


the PCM lC17l and the ALT.

Substitut. a known-good PCM


and recheck. lf prescribed voltage is now availablo,replacethe
originalPCM.

ALT FRsignal b OK.


(C1O5I
ALT CONNECTOR
lP
ALT F
r-F-

lll2llw|{frREDl
-| 3 . r - ' l

wne
lruueen

JUMPER
WIRE

wire side ol fmale terminals


C I31P)
PCMCONNECTOR

6. Check for continuity between


body ground and PCN4con'
nectorterminalCl7.
ls therecontinuity?

3Pr

ALT F IWHT/REDI
Repair open wi.e between the
PCMlCl7l and the ALT.
Wire sideof femaleterminals

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11 - 1 5 9

ldle GontrolSystem
Alternator(ALT)FRSignal(cont'dl
'98 - 00 modols:

ECM/PCMCONNECTORS

B (25P)

Inspctionof ALT FRSignsl.

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

Checkthe opcration of the ALT:


1. Turnthe ignitiooswitchOFF.
2. Reconnectrhe ALT 4P (3P)*
connectorto the ALT.
3. 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 rl a n c o m e s o n ,
then let it idle.
4. MeasurevoltagebetweenECM/
PCM connectorterminalsC5
and 820.

Doesthe voltage decreasewhen


headlights
and reardefoggerare
turnedon?

Wire sideof femaleterminals

Chck for a sho.t in iho wirc lAlT


F lino):
1. Turnthe ignitionswitchOFF.
2. Disconneclthe negativebat,
tery cablefrom the battery.
3. DisconnectECM,PCMconnect o r C( 3 1 P ) .
4. Checkfor continuitybetwoen
body ground and ECM/PCM
connectorterminalc5.

ECM/PCMCONNECTOR
C {31PI

Wire sideof femaleterminals


Roprir lhort in tho wirc bstween
tho ECM/PCM{Csl and the ALT.

Substitut. r known-good ECM/


PCM and roch.ck. It Droscrib.d
voltage b now lvrilabls, .eplacc
th. o.igin!l ECM/PCM.

ALT FR3ignol is OK,


(C1I}5I
ALT CONNECTOR
4P

Chocklor an opon in tha wire (ALT


F linel:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe negativebattery cablefrom the battery.
3 . D i s c o n n e c tE C M / P C Mc o n nectorC (31P).
4. Disconnectthe 4P 13P)*con,
nector from the ALT.
5. Connectthe ALT 4P {3P)*connectorterminalNo. 4 1No.1)*
to body groundwith a jumper

rH] Arr F
l'l'ltwHr/REo)

l3laF1
WIRE
I JUMPER
+

Wire sideof femaleterminals

6. Check for continuity betwen


body ground and ECM/PCM
connectorterminalC5.
ls therecontinuity?

JUMPER
WIRE

ECM/PCMCONNECTOR
C {31P}
ALT F {WHT/REDI
Rsprir opan wiro batw.en tho
ECM/PCMlcsl .nd th. ALT.

Wire sideot Iemaleterminals


": Canada

11 - 1 6 0

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Starter Switch Signal


when the engineis cranking.
This signalsthe ECM/PCM
'97 model:
in E or E position.
Transmission
PCMCONNECTORS

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

Wire sideof femaleterminals

ls there batteryvoltage?

lnspectthe No. 31 STARTERSIGNAL (7.5A)Illse in the under'dash

Starter swiich signal i3 OK.


-

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.

Repairopon in the wire betweon


rh6 PCM lc6l and the No 31
STARTERSIGNAL17.5A)fuse.

'98 - 00 models:
NOTE:
. M/T:Clutchpedalmustbedepressed.
. A/T:Transmission
in E orE position
A (32P)

ECM/PCMCONI{ECTORS

Checktor an open or short in the


wir (STSline):
Measurevoltage betweenECM/
P C M c o n n e c t o rt e r m i n a l sA 2 4
and 820 with the ignitionswitch
in the startposition(lll).

ls therebatteryvoltage?

SIG
Inspectthe No. 31 STARTER
NAL(7.5A){usein the under-dash

Wire sideoI femaleterminals


-

Starter switch 3ignal is OK.


-

Reoair shorl in the wire


betwen the ECM/PCMlA2,fl
and the No, 31 STARTERSIGNAL t7.5 Al tu3 ot the PGM'
Fl main rclay.
Repl.c. tho No. 31 STARTER
SIGNAL17.5Al fu3e.

Repairopon in tho wire between


the ECM/PCM{A241and the No
31 STARTERSIGNAL(7.5A) tu3e
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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.

Checkfor an open in the wire {PSP


SYVline):
1. Turnthe ignitionswitchON (ll).
2. Measurevoltage between
PCN4
connectorterminalsC16
and A9.

ls therelessthan 1.0V?

Wire sideof femaleterminals


Checktor an open in lhe wire (PSP
SW linel:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe PSPswitch 2P
connecror,
3. Turnthe ignitionswitchON (ll).
4. At the harnessside, connect
the PSPswitch 2P connector
t e r m i n a l sN o . 1 a n d N o . 2
with a jumperwire.
5, Measutevoltage between
PCMconnectorterminalsC16
and A9.

PSPSWTTCH
2P CONNECTOR
1C135)
PSPSW (GRN)
JUMPERT_7

vnRE t--f

r)

GNDIBLK}
Wire3id6of femaleterminals
-

Check the operation oI lhe PSP


switch:
1. Stanthe engine
2. Turnthe steeringwheelto the
full lockposition*.
3. MeasurevoltagebetweenPCM
connectorterminalsC16 and
A9.

ls therelessthan 1.0V?

ls there batteryvoltage?

PSPswitch signal is OK.


*: Do not hold the steeringwheel
at tull
lock for more than five seconds,

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(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.

Wire sideof femaleterminals

c t3lPl

Checktor a short in the wire (PSP


SW linol:
1. Turnthe ignitionswitchOFF.
2. DisconnectPCMconnectorC
(31P).
3. Checkfor continuitybetween
body ground and PCMconnector terminalC16.

Reoairshort in the wire betwoon


rhe PCM {C16)and the PSP
3witch.

Substitute a known-good PCM


and rocheck.lf proscribodvoltage b now available,replacethe
original PCM.

(cont'd)

www.emanualpro.com

1 1- 1 6 3

ldle ControlSystem
PowerSteeringPressure(PSP)Switch Signal(cont'dl
'98 - 00 models:
ECM/FCMCONNECTORS

Inspectionof PSPswilch 3ignal.

Chcktor rn opon in the wire (PSP


SW line):
1. Turnthe ignitionswitchON {ll).
2. MeasurevoltagebetlveenECM/
PCMconnectorterminals426
and 820.

ls therelessthan 1.0V?

Chockfor an open in the wire IPSP


SW lin):
1. Turnthe ignitionswitchOFF.
2. Disconnect
the PSPswitch2P
connector,
3. Turnthe ignitionswitchON (ll).
4. At the wire side.connectthe
PSPswitch 2P connectorter
m i n a l sN o . 1 a n d N o . 2 w i t h a

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
-

Check the opration of the PSP


switch:
1. Stanthe engine
2. Turn steeringwheelto the full
lockposition*.
3. MeasurevoltagebtweenECM/
PCMconnectorterminalsA26
and 820.

lstherelessthan 1.0V?

ls there batteryvoltage?

PSPswitch signal is OK.


*: Do not holdthe steeringwheelat lull
lockfor morethan five seconds.

www.emanualpro.com

11-164

(Topage 11-165)

Ropai. open in the wire betweon th6 ECM/PCM (A26)


and th6 PSP.witch.
R6p.ir open in BLK wire between tho PSP 3witch and
G1 0 1 ,

{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

Checklor e 3hort in the wire IPSP


SW linell
1. Turnthe ignitionswitchOFF.
2 . D i s c o n n e c tE C M / P C Mc o n nectorA (32P).
3. Checkfor continuitybetween
b o d y g r o u n da n d E C M / P C M
connectorterminalA26.
Wiresideof femaleterminals

ReDairshort in the wir bstween


the ECM/PCM(A26)and the PSP
switch.

Substitute a known-good ECM/


PCM and rechock. It Drescribod
voltago is now available,roplace
the origin.l ECM/PCM,

www.emanualpro.com

11 - 1 6 5

ldle ControlSystem
BrakeSwitch Signal
This signalsthe ECM/PCM
when the brakepedalis depressed.
Inspctionof Brak. Switch Signal.

Are the brakelightson without


pressingthe brakepedal?

Inspectthe HORN,STOP{15 A)
fuse in the undeFhoodluse/ relay
box.

Do the brakelightscome on?

Reoair short in the wire between th b.ake switch and


th6 HoRN, STOP{15 A)luso,
Replacothe HoRN, STOP (15
Al fuse.

'-

('97model)
-_-

Check tol .n open in the wire


{BXSWlinel:
1. Pressthe brakepedal.
2. MeasurevoltagebetweenrcM
connectorterminaisD5 and Ag
with the brakepedal pressed.

Il

Repair op6n in the wir between the brake switch and


tho HORN,STOP(15 Allus6.
Inspect the brrke switch (see
aection l9l.

a t32P)

PCMCONNECTORS

BKSW
(GRN/WHT)

Wire sideof femaleterminals


Reprir open in the wire between
the PcM lD5l rnd the brake
switch.

(Topage11-167)

11 - 1 6 6

www.emanualpro.com

D ll6Pl

(Frompage11-166)

ECM/FCMOONNECTORS

Chock for en open in the wire


(BKSWline):
1. Pressthe brakepedal.
2. MeasurevohagebetweenECM/
PCM connectorterminals A32
and 820 with the brakepedal
pressed.

Ropairopon in tha wire bstwson


r h e E C M / P C Ml A 3 2 l r n d t h e
brako switch.
Wiresideof femaloterminals

Brakeswitch signd b OK.

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.

Removethe intakeair ductfrom the throttlebody.

2.

Startthe engine,

3.

Put your finger over the lower port in throttlebody,


and makesurethat there is air flow with the engine
cold (enginecoolanttemperaturebelow 86"F,30'C).

lf there is no air flow, replacethe fast idle thermo


valveand retest,
IDLE
THERMO
VALVE

O-RINGS
Replace.

AIR BYPASS VALVE

11.0kgfl.m,7.2 lbl.ftl

Startthe engine.Holdthe engineat 3,000rpm with no


load (in Parkor neutral)until the radiatorfan comes
on, then let it idle.
Checkthat the valve is completelyclosed.lf the valve
is leaking,the idle speedwill drop when you coverthe
lowerpon. Checkthe enginecoolantleveland for air
in the enginecoolingsystem{seesection10).lf the
cooling system is OK, replacethe fast idle thermo
valveand recheck.

11-168

www.emanualpro.com

ldle Speed Setting


Adjust the idle sp6ed,if necessary,by turning the
idle adjustingscrew.

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.

Startthe engine.Hold the engineat 3,000rpm with


no load (in Park or neutral) until the radiator fan
comeson, then let it idle.
Connecta tachometeror a HondaPGMTester.
Disconnectthe 2P connectorfrom the ldle Air Control (lAC)valve.
Turn the ignitionswitchOFF.
IAC VALVE

7 . Reconnectthe 2P connector to the IAC valve, then


remove the BACK UP (RAD|Ol(7.5 Al fuse in the
under-hood fuse/rslav box for 10 seconds to reset
the PCM.
Restartand let the engine idle with no-loadconditions for one minute,then checkthe idle speed.
NOTE: (CanadalPullthe parkingbrakelever up. Stan
the engine,then checkthat the headlightsare off.

lf the enginestalls,restartthe enginewith the accelerator pedal slightly depr6ss6d,Stabilizethe rpm at


1,000,then slowly releasethe pedaluntil the engine
idles.
C h e c k i d l i n g i n n o - l o a d c o n d i t i o n s :h s a d l i g h t s ,
blowerfan, rear dfogger,radiatorfan, and air conditionerare not operating.
ldle spood should b.:
{80 t 50 rpm {in Park or noutr.ll

ldlo Epedrhould be:


75Ot 50 rpm (in P.rk or noutr.ll
Let the engine idl6 for one minute with the headlights(Low)ON, and checkth idl speed.
ldle lpcod 3hould bo:
750 t 50 ]pm (in Park or nautlal)
Turn the headlights off. Let th engine idle for one
minute with the headlights (Low) ON, heater fan
switch at Hl and air conditioneron. then checkthe idle
sDeeo.
ldl. specd should b6:
7d) 1 50 rpm {in Park or nautral}
see the
lf the idle speed is not within specification,
(cont'd)
symptomcharton page11-64.

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.

lf necessary,adjust the idle speed,by turning the


idle adjustingscrew.
After adjustingthe idle speed,recheckthe ignition
timing (seesection4). lf it is out of spec,go backto
steo 4.
tDt.E
ADJUSTING

Startthe engine.Holdthe engineat 3.000rpm with


no load (in Park or neutral) until the radiator fan
comeson, then let it idle.
Connecta tachometer.
Disconnectthe IACvalve 2P connectorand the EVAP
purge control solenoid valve 2P connector.

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

www.emanualpro.com

6. Turn the ignitionswitchOFF.


7. Reconnectthe 2P connectorsto the IAC valve and
the EVAPpurgecontrol solenoidvalve,then do the
ECM/PCMreset procedure.
8. Restartand idle the enginewith no-loadconditions
for one minute,then checkthe idle speed.
ldle speod should be:
,98 model:
750 t 50 rpm tin Park or neutral)
'9!l - 00 modsls:
730 i 50 lpm lin Psrk or neutral)
NOTE:lf the idle speed increasesto 780 t 50 rpm
(770 1 50 rpml*, this means the EVAPsystem is
purgingthe canister.To stop the purgingtemporarily, raisethe enginespeedabove 1,000rpm with the
pedal,then slowly releasethe pedal.
accelerator
*: '99 - 00 models
9. Let the engine idle for one minute with the headlights(Low)ON, and checkthe idle speed.
ldle speed should be:
38 mod6l:
750 f 50 rpm (in Palk or neutrall
'99 - 00 modols:
730 t 50 rpm (in Palk or neutral)
10. Turn the headlightsoff. Let the engine idle for one
minutewith the heaterfan switchat Hl and air conditioneron, then checkthe idle speed.
ldls spqed should be:
'98 model:
780 t 50 rpm (in Park or neutrall
'99 - 00 modls:
7701 50 rpm lin Park or neutral)
lf the idle speed is not within specification.
see the
SymptomCharton page11-64.

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

Fuel Supply System


FuelLines(cont'dl
'99 - 00 models:

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

Clampin the middle

(cont'd)
10-14mm
(0.39- 0.55 inl
www.emanualpro.com

11-173

Fuel Supply System


Fuel Lines (confd)
'98 - (X)models:
Checkall hoseclamps,and retightenif necessary.
SASE
GASKET
Replace.

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

Do not smoke whils working on the fuel


@
syst6m, Koop open flames away from your work ar9a.

Do not smoke while working on the fuel


!@
syst6m. Keep open flames away from your work area.

The fuel tube/quick-connect


fittings assemblyconnects
the in-tankfuel pump with the fuel feed pipe.For removing or installingthe fuel pump and fuel tank, it is necesfittings.
saryto disconnector connectthe quick-connect
Payattentionto following;

1.

Disconnect
the batterynegativecable.

2.

Removethe fuel fill cap to relievefuel pressurein


the tank.

3.

Relievefuel pressure(seepage 11-178).

4.

Checkthe fuel quick-connectfittings for dirt, and


cleanif necessary.

5.

Hold the connectorwith one hand and pressdown


the retainertabs with the other hand.then pull the
connectoroff.

fittings assemblyis not


The fuel tube/quick-connect
heat-resistant;
be carefulnot to damageit duringweldprocedures.
ing or otherheat-generating
The fuel tube/quick-connect
fittings assemblyis not
acid-proof;do not touch it with a shop towel which
was used for wiping batteryelectrolyte.Rplacethe
fittings assemblyif it came
fuel tube/quick-connect
into contactwith electrolyteor somethinosimilar.

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

replacingthe fuel pump.


replacingthe fuelfeed pipe,
it has beenremovedfrom the Dioe,
it is damaged.

RETANENTAB

@NNCCTOR
Pressdown.

6.

Checkthe contactareaof the pipe for dirt and damage.


. lf the surfaceis dirW,cleanit
. lf the surfaceis rusty or damaged,replacethe fuel
pump or fuelfeedpipe,

RCTAINER

FUELTUBE

CONTACTANEA
CONNECTOR
CONNECTOR
RETAINER

{cont'd}

www.emanualpro.com

11-175

FuelSupplySystem
FuelTube/Ouick-Connect
Fittings{cont'd)
7.

To prevent damage and keep out foreign matter.


coverthe disconnected
connectorand oioe end with
plasticbags.

Connection
Do not smoke white working on the fuel
E!@
system. Keepoper flamss away flom your work atea.
1.

Checkthe pipe contact area for din and damage,


and cleanif necessary.

COiITACT AiEA

PL TSnCEAGS

Insena new retainerintothe connectorif the retainer


is damaged,or after
. replacingthe fuel pump.
. replacingthe fuel feed pipe.
. removingthe retainerfrom the pipe.

AASE
GASKET
Beplace.

11-176

www.emanualpro.com

3.

Beforeconnectinga new fuel tube/quick-connect


fitt i n g a s s e m b l y ,r e m o v et h e o l d r e t a i n e rf r o m t h e
mating pipe.

with the
tabs pulled
apart, remove
and discard
the retarner

4.

Ncw FUELTUBE/
OUICK.CONNECT
FI?TINGASSEMBLY

Align the quick-connectfittings with the pipe. and


align the retainerlockingpawls with the connector
grooves.Then pressthe quick-connect
fittingsonto
the pipe until both retainerpawls lock with a clickI n gs o u n d .
NOTE:lf it is hardto connect,put a smallamountof
n e w e n g i n eo i l o n t h e p i p ee n d .

www.emanualpro.com

5.

Makesure the connectionis secureand that the pawls


are firmly lockedinto place;checkvisually and by
pullingthe connector.

6.

Reconnectthe batterynegativecable,and turn the


i g n i t i o ns w i t c hO N ( l l ) .T h e f u e l p u m p w i l l r u n f o r
abouttwo seconds,andfuel pressurewill rise.Repeat
two or threetimes,and checkthat thereis no leakage
in the fuelsupplysystem.

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.

Do not smoke while working on the fuel system.


Kep open flames or sparks away from your work
area,
Be sure to relieve fuel pressurewhile the ignition
switch is off.
1.

Write down the frequenciesfor the radio's preset


buttons.
Disconnectthe batterynegativecablefrom the battery negativeterminal.
Removethe fuel fill cap.
Use a box end wrench on the 12 mm banjo bolt at
the fuel filter while holdingthe fuel filter with another wrench.
Placea rag or shoptoweloverthe '12mm banjo bolt.
Slowly loosenthe 12 mm banjo bolt one complete
rurn
12mm BANJo
BOLT

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.

Startthe engine.Measurethe fuel pressurewith the


engineidling and the vacuumhose of the fuel pressure regulatordisconnectedfrom the fuel pressure
regulatorand pinched.lf the enginewill not start,
turn the ignitionswitchon (ll),wait for two seconds,
turn it off, then back on again and read the fuel
pressure.
Pressureshould be:
'97 - 98 modls:
260 -31O kPa 12.7- 3.2 kgf/cm,, 38 - 46 psil
'99 - 0Omodels:
270 - 32OkPa Q.A - 3.2 kgf/cm', ifo - /U psil
Reconnectvacuumhoseto the fuel pressureregulator.
Prgs3ureshould be:
'97 - 98 models:
210 - 25OkPa 12.1- 2.6 kgf/cm', 30 - 37 psi)
'99 - 00 models:
22O-26iJ kPa 12.2- 2.7 kgt/cm', 31 - 38 psi)
lf the fuel pressureis not as specified,first checkthe
fuel pump (seepage 11-183).lf the fuel pump is OK,
checkthe following:
. l f t h e f u e l p r e s s u r ei s h i g h e r t h a n s p e c i f i e d ,
inspectfor:
- Pinchedor cloggedfuel returnhoseor line.
- Faultyfuel pressureregulator(see page 11181).
. lf the fuel pressureis lower than specified.inspect
for:
- Cloggedfuel filter.
- Faulty fuel pressureregulator(see page 111811.
- Fuelline leakage.

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.

13. lnstalland tightenthe retainernuts.


14. Connectthe vacuumhosesand fuel returnhoseto the fuel pressureregulator.
15. Connectthe PCVvalve.
16. Connectthe connectorsto the fuel injectors,the IAT sensor('97 - 98 models),and the EVAPpurge controlsolenoid
valve{'97- 98 models).
1 1 . Coata new O-ringwith cleanengineoil, and installthe resonatorchamber('99- 00 models).
1 8 . Turn the ignition switch ON (ll), but do not operatethe starter.After the fuel pump runs for approximatelytwo seconds,
the fuef pressurein the fuel linerises.Repeatthis two or threetimes,thencheckwhetherthereis any fuel leakage.

11 - 1 8 0

www.emanualpro.com

FuelPressureRegulator
Replacement

Tesiing
1.

Attachthe specialtool and the 12 mm fuel pressure


adapterbolt to the fuel filter (seepage 1l-178)

'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.

Removethe two 6 mm retainerbolts and the fuel


pressurereguralor.

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.

Reconnectthe vacuum hose to the fuel pressure


regulalor.
4.

Checkthat the fuel pressureriseswhen the vacuum


hosefrom the fuel pressureregulatoris disconnected agarn.

shows
Theillustration
'99 00models
'97- 98models,
similar.
are

Apply cleanengineoil to a new O-ring.and carefully


installit into its properposition.
Install the fuel pressure regulator in the reverse
orderof removal,

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

.
.

Do not smoke whilo working on tuol syslom,


Keepopen flame away from your work area.
While rsplscingths fuolfihor. bo carefulto kop a safe
distanca betweon baftsry tarminals and any tools,

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

i: '97 - 98 modelsi 260 - 310 kPa


12.7- 3.2 kgllcm2,3g 46 psil
'99 - 00 mod6fs:
270 - 320 kP8 12.8- 3.2 kgilcm2, 40 il7psi)
1,

Placea shop towel underand aroundthe fuel filter.

2.

Relievefuel pressure(seepage l1-l7B).

3.

Removethe enginewire harnessbracketand power


steeringfeed hoseclamp.

4.

Removethe banjo bolt and the fuel feed pipe while


supportingthe fuel filter with another wrench. as
snown.
Removethe fuelfilter clampand fuel filter,
Install the new fuel filter in the reverse orde. of
removal,and notetheseitems:
.
.

Whenassembling,use new washersas shown.


C l e a nt h e f l a r e d j o i n t o f h i g h p r e s s u r en o s e s
thoroughlybeforereconnecting
them.

11 -1 8 2

www.emanualpro.com

9.8 N.|n
11.0kgf'm,
t.2 tbt.ftl

FuelPump
Testing

Raplac6mont

lf you suspect a problem with the fuel pump, checkthat


the fuel pump actuallyruns;when it is oN (ll),you will
hearsome noiseif you hold your ear to the fuel fill port
with the fuel fill cap removed.The fuel pump shouldrun
for two secondswhen ignition switch is first turned ON (ll).
lf the fuel pump does not make noise,checkit as follows:

1.

Foldthe left rear seatcushionforward,and remove


the baseframe cover(seesection20).

2.

Removethe accesspanelfrom the floor.

3,

Relievethe fuel pressure(seepage 11-178).

4.

the fuel lines.


Disconnect

5.

the 5Pconnectorfrom the fuel pump.


Disconnect

6.

Removethe fuel pump mountingnuts.

7.

Removethe fuel pump from the fuel tank.

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.

Foldthe left rear seat cushionforward,and remove


the baseframe cover (seesection 20).

2,

Removethe accesspanelfrom the floor.

3.

Make sure the ignition switch is OFF,then disconnectthe fuel pumP5P connector.

4.

Connectthe PGM-FImain relay7P connectortermrnal No. 4 and No, 5 with a jumperwire.


PGM.FIMAIN
(Cit:}2l
RELAY7P CONNECTOR

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.

Checkthat battery voltage is available between the


fuel pump 5P connectorterminal No. 4 and body
groundwhen the ignitionswitchis turnedON (ll).
{C562}
FUELPUMP5PCONNECTOR
2

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.

NOTE:Referto section23 for the fuel gaugesystemcircuit diagram.


'1.

Checkthe No. 25 METER(7.5A) fuse in the underdash fuse/relaybox before testing.

2.

Foldthe left rear seatcushionforward,and remove


the baseframe cover{seesection20).

3.

Removethe accesspanelfrom the floor.

4.

Disconnect
the 5Pconnectorfrom the fuel pump.

5.

Measurevoltage betweenthe 5P connectorterminalsNo.2 and No. 5 with the ignitionswitchON ( ).


Thereshouldbe between5 and 8 V.

FUELPUMP
5P CONNECTOR

tc56al

Wire side of female trminals

a lf the voltageis as specified,


go to step 6.
a lf the voltageis not as specified,
checkfor:

an open in the YEUBLKor BLKwrre.


poor ground (c552).

1 1 -1 8 4

www.emanualpro.com

7 . Attach a jumper wire betweenthe No. 2 and No. 5


terminals,then turn the ignitionswitchON fll).
Checkthat the pointerof the fuel gaugestartsmoving toward the "F" mark. Turn the ignition switch
OFF before the pointer reaches"F" on the gauge
dial. Failureto do so may damagethe luel gauge.
NOTE:The fuel gaugeis a bobbin (cross-coil)
type,
hencethe fuel level is continuouslyindicatedeven
w h e n t h e i g n i t i o ns w i t c h i s O F F ,a n d t h e p o i n t e r
movesmore slowlythan that of a bimetaltype.
.
.

lf the pointerof the fuel gaugedoes not move at


all. replacethe gauge.
lf the gauge is OK, inspectthe fuel gauge sendingunit.

FuelGaugeSendingUnit
Tgsting
Do not smoke while working on tho fuel
@
systom. Keop open flamo 8waYfrom your work araa.
1.

Foldthe left rearseat cushionforward,and remove


the baseframe cover(seesection20).

2.

Removethe accesspanel.

3.

With the ignitionswitchOFF.disconnectthe 5P connectorfrom the fuel pump.

4.

Relievefuel pressure(seepage 11-178).

5.

Disconnect
the fuel lines.

6.

Removethe fuel pump,

7.

Measurethe resistancebetweenthe No. 2 and No. 5


terminalsat E (EMPTY),1/2(HALFFULL)and F (FULL)
by movingthe float.

lf you do not get the above readings,replacethe


fuel pump.

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11-185

FuelSupplySystem
Low Fuel Indicator System
Indicator Light Testing

8.

NOTE:Referto section23forthe lowfuel lndicatorcircuit


clragram.
1.
2.

Checkthe No. 25 METER(7.5A) fuse in the underdash fuse/relaybox before testing.


Parkthe vehicleon levelground.

Add 4 / of fuel (1.1U.S.Gal,0.9 lmp. Gal).The light


shouldgo off within four minutes.
.

lJ the light does not go off, checkfor:


- a short in the GRNA/ELwire between the fuel
gaugesendingunit and fuel gaugeassembly.
- faultygaugeassembly.
. lf the light goes off, the low fuel indicatorlight is

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

lf the light comes on within four minutes,go to


step8.
lf the lightdoesnot comeon withinfour minutes. go to step 5.

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

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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.

R e m o v et h e g l o v e b o xa n d t h e p a s s e n g e r 'ds a s h boardlowercover (seesection20).


Removethe PGM-FImain relay
Aftachthe batterypositiveterminalto the No. 2 terminal and the batterynegativeterminalto the No. 1
terminal of the PGM-Flmain relay.Then checkfor
continuitybetweenthe No. 5 terminaland No. 4 terminal of the PGM-FImain relay
. lfthere is continuity,go on to step3.
. lf there is nocontinuity,replacethePGM-Flmain
relavand retest.
No.2

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
-

Enginewill not start.


InsDection ol PGM-FI main
relay and relay harness,
PGM.FIMAIN RELAY7P CONNECTOR
lc(}21
GND

Check fo. an open in the wire


IGNDlinol:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe PGM Fl main
relay7P connector.
3. Checkfor continuitybetween
the PGM'FImain relay7P connectorterminalNo.3 and body
ground.

trTr]--Flq
FI,Til'I A

Wire sideot femaleterminals


Repairopcn in th wire between
the PGM-FImain relavand G101.

Checktor an open or short in the


wiro (BATline):
M e a s u r ev o l t a g e b e t w e e nt h e
PGM'FImain relay 7P connector
terminalNo.7 and bodyground.
ls there bafteryvoltage?
-

Repai. open or short in lhe


wir6 belween the PGM-FI
main relay and the Fl E/M (15
Al fu3e.
Replace
th6 FIE/M (15Altus6
in th under-hood fuse/.6lay

Checklor an open or short in the


wire (lGl line):
L Turn the ignitionswitch ON (ll).
2. Measurethe voltage between
the PGM-FImain relay7P con
nectorterminalNo. 5 and body
ground.
-

Checkfor an open or short in the


wire {STSline):
1. Turnthe ignitionswitchto the
START(lll)position.
NOTE:
. M/T: Clutch pedal must be
depressed.
. A/T: Transmissionin E or
Elposition.
2. Measurethe voltage between
t h e P G M - F lm a i n r e t a y7 P
connectorterminalNo. 2 and
body ground.

('97model:To page11-189)
('98 00models:Tp
o a g e1 l 1 9 0 )

11 - 1 8 8

www.emanualpro.com

Repair open or shorl in the


wire between the FGM-FImain
relayand the No. 13 FUEL
PUMP115A) tuse.
Replacothe No. 13RJELPUMP
115A) luse in the und6.-d$h
fuso/ relav box.

Repair open or short in the


wire betwen the PIGM-FIm.in
rclay and th No. 31 STARTER
SlGllAL 17.5A) tuse.
Repl.ce the No. 31 STARTER
SIGNAL 17.5Al tuse in the
under-dashtuse/relaybox.

lFrompage11 188)

-t

('97model)
(C432I
PGM.FIMAIN RELAY7P CONNECTOR
FLR
IGRN/YELI

Ch6ck lor an open in the wir


{FLRline):
1. Turnthe ignitionswitchOFF.
2. Disconnectthe PCM connector A (32P).
3. Checkfor continuitybetween
the PGM-FImain relay 7P connectorterminal No. 1 and PCM
terminalA16.
connector
Wire sideof lemaleterminals
Repairopen in the wire be{weon
the PCM lAl6l and the PGM-FI
main relay.

Checkfor an open in the wirs


{lGP1,lGP2lins):
'1. Reconnect
the PCMconnector
A (32P).
2 . R e c o n n e ct th e P G M ' F lm a i n
relayconnector.
3. Turnthe ignitionswitchON (lli.
4. MeasurevoltagebetweenPCM
connectorterminalsA11 and
A 1 0 , a n d b e t w e e nA 2 4 a n d
A10.

IGP2
(YEL/BLK)

ls therebatteryvoltage?
-

Repair open in the wir bet'


ween th PCM {A11,A2ia}end
the PGM-FImain relay.
Reolscethe PGM-FImain rolaY.

Checktor an open in the PCM:


1. Turnthe ignitionswitchOFF.
2 , M e a s ur e v o l t a g e b e t w e e n
PCMconnectorterminalsA16
a n d A 1 0w h e nt h e i g n i t i o n
switch is first turned ON {ll) for

ls there'1.0V or less?

Substitute a known-good PCM


and recheck. lf ptesctibed volttge
is now available,roplacotho orig'
in.lPCM.

(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

PGM.FIMAIN RELAY7P CONNECTOF(C2)


Check lor an open in the wire
(FLRline):
1. Turn the ignitionswitchOFF.
2. Disconnectthe ECM/PCMcon
nectorA (32P1.
3. Checkfor continuitybetween
the PGM-FImain relay7P connectorterminalNo. '1and ECM/
PCMconnectorterminal416.
Wiresidof femaleterminals
Repaiaopen in the wire between
the EcM/PcM lAl5l .nd the
PGM-FIm.in relay.

Check for an open in the wires


llcPl,lGP2linos):
1. Reconnectthe ECM/PCN4
connector I (25P).
2. Reconnectthe PGM Fl main
retayconnector.
3. Turn the ignitionswitchON l).
4, Measurevoltage between
ECM/PCMconnectorterminals
B1 and 82, and between 89
and 82.

ECM/PCMCONNECTOR
B I25PI

Dde"Jt;;li
L-F-T-PGl
(BLK}
3

s l 1 0

IGP2
(YEL/BLKI 1 9

Ropai. open in tho wire b6twen th. ECM/PCM lBt, Btl


.nd the FGM-FImain rd.y.
Rplacth6 FGM+| main retay,

20

11

13
21 22

8
17

Wire side of female terminals

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

Subrtitute e known-good ECM/


PCM and recheck. lf prescribsd
voltage b now ovrihble, replaco
the originelECM/PCM.
Wiresideof fmaleterminsls

Check the PGM-FI main.elav


(s6epage 11-1871.

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.

Relievethe fuel pressure(seepage11-178).


Foldthe left rearseatcushionforward,and removethe baseframecover{seesection20).
Removethe accesspanelfrom the floor.
and 6P connector(C580)('98-00 models)'
the 5Pconnector1C562)
Disconnect
fittings{seepage 11-175}
Disconnect
the fuel returnhoseand quick-connect
jackstands.
Jackup the vehicle,and supportit with
Removethe middlefloor beam.
Removethe drain bolt, and drainthe fuel into an approvedcontaaner.
the hoses(seepage 11-173,174).slide backthe clamps.then twist hosesas you pull, to avoid damaging
Disconnect

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

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Intake Air System


SystemDescription
The systemsuppliesair for all engine needs.lt consistsof the intakeair pipe,Air Cleaner,intakeair duct, ThrottleBody
(TB),ldle Air Control(lAC)Valve,fast idle thermo valve,and intakemanifold.A resonatorin the intakeair pipe provides
additionalsilencingas air is drawn into the system.

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

Air CleanerEloment Rsplacomsnt

Inrpection/Adiustmcnt

NOTE:Do not cleanthe air cleanerelementby blowing


it off with compressedair,

1.

Stan the engine.Hold the engineat 3,000rpm with no


load (in Parkor neutral) until the radiatorfan comes
on, then let it idle.

2.

Checkthat the throttlecableoperatessmoothlywith


no bindingor sticking.Repairas necessary,

3.

Checkcable free play at the throttle linkage.Cabte


deflectionshouldbe 10- 12 mm (3/8- 1l2in.l.

'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.

Openthe throttlevalvefully,then installthe throttle


cable in the throttle linkage,and install the cable
housingin the cablebracket.

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

'99 - (Xl modols:


ADJUSTING

BRACKET
2.

Sta.t the engine.Hold the engineat 3.000rpm with


no load (in Park or neutral) until the radiator fan
comeson, then let it idle.
Hold the cable sheath,removingall slackfrom the
cable.
Set the locknut on the cable bracket.
Adiustthe adjustingnut so that its free play is 0 mm.
Rimove the cable sheath from the throttle bracket,
resetthe adjustingnut and tightenthe locknut.

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

Replacethe throttle body if there is excessiveplay in the


throttlevalveshaftor if the shaft is bindingor sticking.

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

Three Way Catalytic Convertsr lTwcl:


The Three wav CatalvticConverter (TWC) is used to
converthydrocarbons(HC),carbonmonoxide(CO),and
oxides of nitrogen(NOx) in the exhaustgas to carbon
dioxide(COr),dinitrogen(Nr)and water vapor,

Inspsction
Do not smoke during this procsdura. Keep
!@
any open tlame away from your work area.
1.

Startthe engine.Hold the engineat 3,000rpm with


n o l o a d ( i n P a r ko r n e u t r a l )u n t i l t h e r a d i a t o rf a n
comeson, then let it idle,
Connecta tachometer.
adjustthe idle speed,(see
Checkand, if necessary,
p a g e1 1 - 1 6 91, 7 0 ) .

4.

Warm up and calibratethe CO meteraccordingto the


instructions.
metermanufacturer's
heaterblower,rear
Checkidle COwith the headlights,
off.
windowdefogger,coolingfan,and air conditioner
(Canada)Pull the parkingbrake lever up. Start the
engine,then checkthat the headlightsare off.
0 . 1 %m a x i m u m .
C Om e t e rs h o u l di n d i c a t e

{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
-

The MIL has been reDoriedon.


DTCP0420is stored.

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?

Checkthe TWC (seesection 9).


lI nocessary,replacethe TwC.

11-200

www.emanualpro.com

Intermittent tailure. system is OK


at this time.

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.

Checkthe PCVhosesand connectionsfor leaksand


clogging.

'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.

At idle,makesurethere is a clickingsoundfrom the


PCVvalve when the hose betweenthe PCVvalve
and intakemanifoldis lightly pinchedwith your fingers or pliers.

'97 - 98 models:

Gently pinch here.

'99 - 00 modelsi

Gentlypinchhere.

lf there is no clickingsound, checkthe PCVvalve


grocrmet for cracksor damage,lf the grommet is
OK, reDlacethe PCVvalveand recheck.

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.

FuelTank Vapor Control System


Whenfuel vapor pressurein the fuel tank is higherthan the set valueof the EVAPtwo way valve,the valveopensand
regulatesthe flow ot fuel vaporto the EVAPcontrolcanister.
'97 model:
EVAP
PURGE
CONTROL
From
No. 15
/ALTERNATOR
I sP SENSORr7.sAt
(in the under-dash
fuse/relaybox)

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?

Intermittent trilure, sydern is OK


at this time. Checkfor Door connections or loose wir3 at C108
IEVAP purge control solonoid
valvol .nd at the PCM.

Checktor an open in the wire (lcl


linel:
1. Turnthe ignitionswitchOFF.
2 . D i s c o n n e ctth e E V A Pp u r g e
controlsolenoidvalve2P connector.
3. Turnthe ignitionswitchON (ll).
4. Measurevoltagebetweenbody
ground and the EVAPpurge
control solenoidvalve 2P connectorterminalNo. '1,
ls there batlery voltage?

EVAPPURGECONTROL
SO1TNOIDVALVE2P
CoNNECTOR(C108)

(v)
YL

Wire side of female


termrnals
Rpafuopen in thc wir6 btwen
thG EVAP purge control solenoid
valve and the No. 15 ALTEBNATORSP SENSOR(7.5A)fuse.

(To page11'206)

(cont'd)

www.emanualpro.com

11-205

EmissionControl System
EvaporativeEmission(EVAP)Controls(cont'dl
(Frompage11-205)

PCMCONNECTOR
A (32PI
PG1(BLKI

Chsck th6 EVAP purgo control


solonoidvalve:
' L R e c o n n e ctth e E V A Pp u r g e
controlsolenoidvalve2P connector.
2. ConnectPCMconnectortermi
nals 415 and A10 with a

Does the solenoid valve click


when the jumper is connected?

PCSIRED/YELI
JUMPERwlRE

Wire side of femaleterminais

Chscl to. an op6n or 3hort in th


wiro (PCSlin6):
Measurevoltage between PCM
connectorterminalA15 and body
grouno,

ls there batteryvoltage?

Chockfor . .hort in tho wiJe IPCS


line):
1. Turnthe ignitionswitchOFF.
2. Disconnectthe PCMconnector A (32P).
3. Disconnectthe EVAP purge
controlsolenoidvalve2P connector,
4. Checkfor continuitybetween
body ground and PCM connectorterminalA15.

Rooair short in tho wir6 bctween


the EVAP purge control 3olenoid
valvo and tho PCM(A151.

Checkthe vacuum lin6:


Checkthe vacuum linesof EVAP
systemtor misrouting,leakage,
brsakagoand clogging.

Are the vacuumlinesOK?

(Topago11'207)

11-206

www.emanualpro.com

Ropair open in the wir6 betwoon


the EVAP pu]go control .olonoid
v.lve end the PCM(A15).

(Frompage11-206)

<\

Chack iho EVAP purge control


solenoidvalve:
1. Disconnectthe vacuum hose
trom the EVAPcontrolcanister.
2, Connectthe vacuumpump to
the hoseand applyvacuum,
EVAPCONTNOL
CANISTER

VACUUM
PUMPI
GAUGE,
0-30 in.Hg
4973X 0il1 -

xxxxx
Doesit hold vacuum?

Chgckthg EVAPcontrol csnbter:


1. Reconnectthe vacuum hoseto
the EVAPcontrolcanister.
2. Connecta vac!um gauge to
the purge air hose.
3. ConnectPCM connectorter
m i n a l sA 1 5 a n d 4 1 0 w i t h a
jumperwire.
4. Stanthe engine.
5. Checkthe vacuum.

JUMPEFWIRE
wire side of femaleterminals

Checkthe EVAPtwo way valve


(seepage11'224).

Doesthe EVAPtwo way valve


work properly?

Rapbcethe EVAPtwo wey valve.


VACUUM/PRESSURE
GAUGE
0-4 in.Hg
07JA2 - ml(x)o8

Substitute a known-good PCM


and rechock. It symptom/indication gocs away, roplacgtho originrl rcM.

{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.
-

The MIL har been rooortdon.


DTCP0451b storod.

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?

Check for the fuel tank piessure


Sensot:
L Disconnectthe hose between
the EVAPtwo way valve and
the fuel tank pressuresensorat
the EVAPtwo way valveend.
2 . C o n n e c ta v a c u u mp u m p t o
the openend ofthat hose.
3. Turn the ignitionswitchON (lll.
4. Monitor the FTPSnsorvoltage with the Honda PGM
T e s t e r ,o r m e a s u r ev o l t a g e
between ECNI/PCNI
connector
t e r m i n a l sA 2 9 a n d C 1 8 ,a n d
carefullyappiyvacuumon the
hose one strokeat a time.
5. The voltageshould smoothly
dropfrom the staningapprox.
2.5 V down to approx. 1.5 V.
STOPapplyingvacuumwhen
the voltage drops to approx.
1 . 5 V o r d a m a g et o t h e t u e l
t a n k p r e s s u r es e n s o r m a y

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 ?

Intermittent tailuro. sv3tem is OK


at this tim. Chack to. poor connction6 or 10036hose at fu6l
tank pres3ure ionsor and fuel
trnk.

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

Th. MIL has been reoortedon.


DTCm452 is stored.
Checkthe vacuum lin6:
Checkthe vacuumlinesof the fuel
tank pressuresensorfor misrout
ing, leakage,breakageand clogging.

0,5
-? KPA
(-50 mmHg,
-2 in.Hgl

+7 kPr
l5OmmHg,
2 in.Hgl
PRESSURE

Are the vacuumlinesOK?


A (32P)
ECM/PCMCONNECTOR
Problemveriticstion:
1. Do the ECM/PCM Reset
Procedure2. Removethe luelfillcap.
3 . T u r n t h e i g n i t i o ns w i t c hO N
flr).
4. Monitor the FTPSensorvolt'
age with the Honda PGM
T e s t e r ,o r m e a s u r ev o l t a g e
b e t w e e nb o d y g r o u n d a n d
ECM/PCM
terminalA29.
ls lhereapprox.2.5V?

Intermittent failuro, system is OK


at this lima. Chacklor Door connections or loose wi.es at C580
llocrted rt access panell, C646
lluel tank Daessuresensor) and
at the ECM/PCM.

Checklor an open in wir lVeC2


line):
1. Turnthe ignitionswitchOFF.
2. Reinstallthe
fuel fill cap.
3. Disconnectthe fuel tank pressuresensor3P connector,
4. Turnthe ignitionswitchON (ll).
5- Measurevoltage betweenthe
fLreltank pressuresensor3P
connectorNo. 1 terminaland
N o . 2t e r m i n a l .
ls thereapprox.5 V?

Wire sideot femaleterminals

FUELTANK
PRESSURE
SENSOR
3PCONNECTOR
tc6a6l

voc2
(YEL/BLUI

Wire sideol fsmaleterminals


Replir opon in the wire btwen
th6 tuel tank pressurelensot and
the ECM/PCM{A29).

(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

Check lor a short in the wire


IPTANKIine}:
Measurevoltagebetlveenthe fuel
tank pressuresensor3P connector
No.3terminaland No.2terminal.

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.

Repairshort in the wira betwgon


the fuel trnk prossures6nsorand
tho ECM/PCMlA29).

Sub.tituto a known-good ECM/


PCM and rcheck. lf 3ymptom/
indication goer !way. replace
th6 original ECM/PCM.

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.

Ch6cktho vacuum linos:


C h e c kt h e v a c u u m l i n e s o f t h e
fueltank pressuresensorlor misrouting, leakage,breakageand
cloggrng.

A {32PI
ECM/PCMCONNECTOR

Are the vacuumlinesOK?


PTANK ILT GRN)
Problornverification:
1. Do the ECM/PCM Reset
Procedute.
2. Removethe fuel fill cap.
3. Turn the ignition switch ON

trminals
Wire sidoot fema16

{[).

4. Monitor the FTPSensorvoltage with the Honda PGM


Tester, or measure voltage
b e t w e e nb o d y g r o u n d a n d
terminal429.
ECM,PCM

ls thereapprox.2.5V?

Intarmittent tailuro, sv3iom b OK


at this timo. Chock for poor connection3 or loo$ wire3 at C580
(locstod .t .cc$r p.nell, C6a6
(fucl tank pros3ure son3orl and
.t the ECM/FCM.

Check lor an open in tho wiro


lSG2lin6l:
1. Turnthe ignitionswitchOFF.
Iuel fill cap.
2. R6installthe
3. Disconnectthe Iu6l tank pres_
suresensor3P connector,
4. Turn the ignitionswitchON (ll).
5. Masurevoltago between the
tuel tank pressuresensor3P
'!
connectorterminalsNo. and
No.2.

ls thereapprox.5 V?

Chck for an opon in tho wiro


(PTANKlinel:
M e a s u r ev o l t a g e b e t w e e nt h e
fuel tank pressuresensor3P connectorNo. 3 terminaland No. 2
terminal.

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}.

Wire sideot femaleterminals

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?

Ropairopen in the wire betweon


the ECM/PCM{A291and tho fuol
tank pressule3ensor.

Substitute a known-good ECM/


PCM and recheck. lf symptom/
indication goes away, rplace
tho originrl ECM/PCM.
SG2 (GRN/BLK}
Wire sideof temaleterminals

11-2 1 2

www.emanualpro.com

'98 - 00 models:
Emission(EVAP)controlsystemleak
The scantool indicatesDiagnosticTroublecode (DTC)P1456:Evaporative
detected{fueltank system).
Troubleshooting Flowchart
-

The MIL has been reported on.


DTC P1456 is stored.

Check the fuel fill cap:


Checkthe fuel fill cap (the caP
must be a gray OEM cap and be
"clicks"
to
t i g h t e n e d a t l e a s tt h r e e
p r o p e r l y s e a lt h e s y s t e m ) -

ls the properfuel fill cap installed


and properlytightened?

Replaceor tighton the cap.

Checkthe lueltill cap seal:


Checkthe fuel fill capseal.

ls the tuel fillerpipedamaged?

Fuel till caD is OK. Do the luel


tank pressureSensortest (see
page 11-2111.(EVAP Purge control solenoid valve tsl (seePage
11-2151.1r

Replacethe luelfiller pipe.

' : ' 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

Chockthe tusl trnk pr3suresensor:


1. Removethe fuel fill csp.
2. Turn the ignitionswitchON fll).
3. Monitor the FTPSensorvohage with th Honda PGM
T e s t e r ,o r m e a s u r ev o l t a g e
between ECM/PCMconnctor
terminalsA29and C18.
SG2 IGRN/BLKI
ls there approx. 2.5 V?

Checkthe fuel t nk pressuae3ensor:


1. Turnthe ignitionswitchOFF.
2. Disconnectthe hose between
the EVAPtwo way valve and
the tueltank pressuresensorat
the EVAPtwo way valveend.
3 . C o n n e c ta v a c u u mp u m p t o
the openend ofthat hose.
4. Turn the ignitionswitchON 0l).
5. Monitor the FTPSensorvoltage with the Honda PGM
Testet, or measure voltage
between ECM/PCMconnector
t e r m i n a l s4 2 9 a n d C 1 8 ,a n d
carefullyapplyvacuumon the
hose one strokeat a lime.
6. The voltageshould smoothty
drop from the staning approx.
2.5 V down to approx. 1.5 V.
Stop applyingvacuum when
the voltagedrops to approx.
1 . 5 V o r d a m a g et o t h e f u e l
t a n k p r e s s u r es e n s o r f i a y
occur,

Doesthe voltage drop to approx.


1.5V and hold?

11-2 1 4

www.emanualpro.com

Choct ths vacuum linsr for


ra3triction o. blockago ropair a!
nect*rary. It OK, replaca the fu6l
tank praituJc sentot.

Wire sideoI femaleterminals

FUEI-TANK
PRESSURE
SENSOR

VACUUM
- 30in.Hg
PUMP/GAUGE,0

A973X - ill -

xxxxx

EVAP TWO
WAY VALVE

Fu.l tank pressu.c anlor b OK.


Oo thc EVAP pulge control
solenoid valve toat (3prgo 112151.

EVAP purge control 3olnoid


valve test.
{Tho continu.tion of DTC Plil56
trouble3hootin9.)

VACUUM
- 30 in.Hg
PUMP/GAUGE,0
A973X- 041 -

xxxxx

Check the EVAP purge control


solenoidvalve:
1. Disconnectthe vacuum hose
trom the EVAPcontrolcanist e r , a n d c o n n e c ta v a c u u m
pumpto the hose.
2. Turnthe ignitionswitchON (ll).
3. Applyvacuumto the hose.

Doesthe valvehold vacuum?

EVAP
CONTROL
CANISTER

EVAP purge contlol solenoid


v.lvo is OK. Do the EVAP bypai3
solenoid valve test (see Page 112161
EVAPPURGECONTROLSOLENOID
(Cl08}
VALVE2P CONNECTOR

Check tho EVAP purge control


solenoidvalve:
't. Turnthe ignitionswitchOFF.
2 . D i s c o n n e ctth e E V A PP u r g e
controlsolenoidvalve2P connector,
3. Checkfor continuity between
t h e E V A P p ur g e c o n t r o l
solenoidvalve 2P connector
t e r m i n a lN o . 2 a n d b o d Y
ground,

Wiresideof
female
terminals

Check for s short in the wire


{PCSlinel:
1 . D i s c o nn e c t t h e E C M / P C M
connectorA {32P).
2. Checkfor continuitybetween
the EVAP purge control
solenoidvalve 2P connector
terminalNo. 2 and body
ground.

ls there continuity?

neprir short in tho wite bot$reon


the ECM/FCMlAGl and thc EVAP
purge control 3olenoidvalve.

Substitut a known-good ECM/


PCM and recheck. lf symptom/
indication goe3 away. repl.ce
thc originsl ECM/PCM.

(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

Checkthe EVAP bypasssotenoid


1. Disconnectthe vacuum hose
from the EVAPtwo way valve,
and connecta vscuum pump
to the hose,
2 . C o n n e c t h e E C M / P C Mc o n nectorterminal 43 to the body
groundwith a jurnperwire.
3. Turnthe ignitionswitchON 0t).
4. Applyvacuumto the hose.

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

Doesthe valvehold vacuurn?

EVAP bypass solenoid valve/


EVAP two way valve is OK. Do
th6 EVAP control crnister vent
shut vafvele3t lso page 11-2'111.
EVAPBYPASSSOLENOID
VALVE2P CONNECTOR
lcorlTl

Check for an opn in the wir


(2WBSline):
1. Turnthe ignitionswitchOFF.
2. Disconnectthe EVAPbypass
solenoidvalve2P connector.
3. Checkfor continuity between
t h e E V A P b y p a s s s ot e n oi d
v a l v e2 P c o n n e c t o tre r m i n a l
No.2 and body ground.

2WBS
(BLU}

Wire sideof
female
termrnats
Repairopen in the wire between
the EVAP bypass solenoid valv.
and ECM/PCMlA3).
tGl
IBLK/WHT}

Chack tor an op6n in the wire


llcl line):
1. Turnthe ignitionswitchON l).
2. Measurevoltagebetweenthe
EVAPbypasssolenoidvalve
2 P c o n n e c t o tre r m i n a lN o . l
and body ground.

Replacethe EVAP byps.,s solonoid


vatus and O-ring3.

Ropairo,penin the wire botwoen


th6 EVAP bypa$ sotenoid vatvo
a n d N o . 1 5 A L T E R N A T O RS p
SENSOR(7.5Altuso.

1 1 -2 1 6

www.emanualpro.com

-/

VACUUM
- 30 in.Hg
PUMP/GAUGE,0
A973X- 041 XXXXX

EVAP control canister vent shut


valvelst,
lThe conlinualion ot DTC P1456
troubleshooting.)
EVAP
THREE
Check the EVAP control cankter
vent 3hut valve:
1. Disconnectthe vacuum hose
from the EVAPthreeway valve,
and connecta vacuumPUmP
to the hose.
2. Turnthe ignitionswitchON (ll).
3. Applyvacuumto the hose

Doesthe valvehold vacuum?

VALVE

EVAP control crnisier vent lhul


valve is OK. Do the v.cuum
hoses and connections te3l lsee
page11-218).

EVAP
CONTROL
CANISTER

EVAPCONTROL
CANISTERVENT SHUT
IC361)
VALVE2P CONNECTOR

r+
l 1
f

Chock the EVAP control canbtel


vent shul valvo:
1. Turn the ignitionsw;tchOFF.
2. Disconnectthe EVAPcontrol
c a n i s t e rv e n t s h u t v a l v e 2 P
connector.
3. Checkfor continuitybetlveen
the EVAPcontrol canistervent
shutvalve2Pconnectorterminal No. 1 snd body ground.

t 2 l

1 VSV

(o) tLTcnrulwxrt

1
Wire sideof femaleterminals

Roplacthe EVAPcontlol canbt]


venl shut valve and O-ring.

Chock lor a short in the wire


(VSV lino)r
1 . D i s c on n e c t t h e E c M / P C N 4
connoctorA (32P).
2. Checkfor continuitybetween
the EVAPcontrol canistervent
shutvalve2Pconnectorterminal No. 1 and body ground.

EVAP
CONTROL
CANISTER
VENT
SHUT
VALVE
O.RING
Replace.

Reorir 3hort in tho wiro bgtweon


the EC1I/I/PCMlAal .nd the EVAP
codrol canbtor vent shut valv6.

Substitute a known.good ECM/


PCM and recheck. lf symptom/
indicrtion goes awaY, replace
the original ECM/PCM.

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.

(The continuarion of DTC P1456


troubleshooiing.l

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

Repairor replacothe parts.

Substitute a known-good ECM/


PCM and recheck.lf symptom/
indication goes away, replac
the original ECM/PCM.

1 1 -2 1 8

www.emanualpro.com

'98 - 00 modls:
Emission(EVAP)Controlsystemleak
The scantool indicatesDiagnosticTroublecode (DTc)P1457:Evaporative
detected(EVAPcontrolcanistersystem).
Troubl6shootingFlowchart
-

('98 model only)

_]

The MIL has been rePortedon.


DTCP1,157is storod.

Do the fuel tank Pressuresensor


test {seepage11-214).

ls the {ueltankpressuresensorOK?

Do the EVAP Purge contlol


solenoid valve test lsea Page 1l_
220t.

(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*

Check the EVAP purge conrrol


30lenoidvelve:
L Disconnectthe vacuum hose
from the EVAPconlrol canis,
t e r , a n d c o n n e c ta v a c u u m
pump to the hose.
2 . C o n n e c t h e E C M / P C Mc o n
nectorterminalA6 to the body
groundwith a jumperwire.
3. Turnthe ignitionswitchON (tl).
4. Applyvacuumto the hose.

Doesthe valvehold vacuum?

VACUUM
PUMP/GAUGE,
O-30 iN.Hg
A973X- 0rl -

xxxxx
'\)

AP
CONTROL
CANISTER

Check for an open in the wire


(lGl line):
1. Turnthe ignitionswitchON t).
2. Measurevoltage between the
EVAPbypasssolenoidvalve2p
coonectorterminalNo. 1 and
body ground.

ls there battery voltage?

Repah open in lhe wir6 betwoen


the EVAP pu.ge cont.ol solonoid
vdlvo and No. 15 ALTERNATOR
SP SENSOR{7.5Al fu!.
*: Continuedfrr '98 model

1 -220

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4
5
8 /
,/3
't6 1 7 1 8 l 9 20
,,/ 14 ,/
,/ 26
29 30

't0
24

JUMPER
WIRE

Wire sideof lemaleterminals


EVAPpurge control solenoid
valve is OK. Oo the EVAPbypass
solenoid valve t3t {see psge 1l221t.

Check for an open in the wire


(PCSline):
1. Turnthe ignitionswitchOFF.
2 . D i s c o n n e ctth e E V A Pp u r g e
controlsolenoidvalve2P con
nector,
3. Checkfor continuitybetween
t h e E V A P p ur g e c o n t r o l
solenoidvalve 2P connector
t e r m i n a lN o . 2 a n d b o d y
grouno,

ls therecontinuity?

ECM/PCMCONNECTOR
A {32P}
PCS(RED/YELI

EVAPPURGECONTROLSOI.ENOID
VALVE2P CONNECTOR
(Cl08)
PCS
IRED/YELI

female
termanals

Ropairopn in th6 wire between


the EVAP purge control 3olenoid
velve and ths ECM/PCM(A61.

EVAP
BYPASS
SOLENOID
VALVE

EVAPbypasssolenoidvalv test.
{The continuation of DTC P1457
troubleshooting.l

FUELTANK
SENSOR
PRESSUBE
EVAPTWOWAY
VALVE

Checkthe EVAP bypass 3olenoid


VACUUM
PUMP/
GAUGE,
0-30 in.Hg
A973X041 -

1. Disconnectthe vacuLlmhose
from the EVAPtwo way valve,
and conned a vacuumPUmP
to the hose.
2. Turnthe ignitionswitchON (ll).
3. Applyvacuumto the hose

Does the valve hold vacuum?

xxxxx

EVAP bvpas3 30lsnoid vrlvo/


EVAPtwo way v.lve is OK. Do
the EVAP control canisler vent
3hut v.lve te3l (seePsge11'2221.
EVAPAYPASSSOLENOID
(C647}
VALVE2P CONNECTOR

Ch6ckthe EVAP byp.ss solenoid


'1. Turnthe ignitionswitchOFF
2. Disconnectthe EVAPbypass
solenoidvalve2P connector.
3. Check{or continuitybetween
t h e E V A P b y p a s s s o l e n oi d
v a l v e 2 P c o n n e c t o tre r m l n a l
No.2 and body ground

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}

@)

Rcpsir short in th. wire bgtwoen


the EcM/PCtrl lA3l lnd the EVAP
bypa$ solenoidvalvo.

Sub3tiiute . known'good ECM/


PCM End recheck.lI sYmptom/
indication goe3 away, tePlace
the originalECM/PCM.

(cont'd)

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11-221

EmissionControlSystem
EvaporativeEmission(EVAP)Controls(cont,dl
lT145il ("ont'o)

VACUUM
- 30 in.Hs
PUMP/GAUGE,0
A973X- 041 -

EVAP control canistor vent shut


valve t6t.
(The continuation of DTC p1457
troublahooting.)

xxxxx

ECM/PCMCONNECTOR
A {32PI

vsv
{LTGRN/WHT)

Chcck the EVAP control c.nirt6l


vent ahut vrlve:
1. Disconnectthe vacuum hose
trom the EVAPthreway valve,
and connecta vacuum pump
to the hose.
2. Connectthe ECM,PCMconn6c,
t o r t e r m i n a lA 4 t o t h e b o d y
groundwith a jumper wire.
3. Turn the ignitionswitchON fil).
4. Applyvacuumto the hose.

Doesthe valvehold vacuum?

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

Check for an open in the wire


IVSV linGll
1. Turnthe ignitionswjtchOFF.
2. Disconnectthe EVAPcontrol
c a n i s t e rv e n t s h u t v a l v e 2 p
connector.
3. Check for continuity between
the EVAPcontrol canistervent
shul valve 2P connectorterminal No. l and body ground.

/A\ {Lr GRN/WHT|

Y
I

Wiresideof femaleterminals

EVAP
CONTROL
CANISTEF
VENT
SHUT
VALVE

Ropril op6n in tho wire botweon


the EVAP control canister v6nt
shut v.lve and the ECM/PCM
(A41.

(}BING
Replace.

Check tor an open in the wire


(lGl line):
1. Turn the ignitionswitch ON l).
2. Measurevoltage between the
EVAPcontrolcanistervent shut
valve 2P connectorterrninal
No. 1 and body ground.

RoplacethG EVAP cont.ol canister Yentshut velve and O-ring.

Repai. opon in the wire betwoen


th6 EVAP control canister vont
shut valve .nd No. 15 ALTERNATOB SP SENSORt?.5 Alfus6.

11-222

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ffil r c r
e

(BLK/wHr)

24

EVAP
CONTROL
Canbter system leak test
{Thecontinuation of DTCP1457
trouble3hootin9.)

Chock the EVAP control canister


vent shut valve line and connoc'
tonS:
1. Turnthe ignitionswitchOFF
2. Connectto three'waytee fit_
tings into the hose from the
EVAPcontrol canisterto the
EVAPtwo way valve. Connect
the fuel tank pressuresensor
to one of the tee fittings and
the vacuum PumPto the other'
3. Removethe vent hose from
the EVAPcontrol canistervent
shut valveand cap the Pon to
sealthe fresh air vent Ior the
EVAPcontrol canister.
4. Turnthe ignitionswitchON (ll).
5. While monitoring the FTP
Sensorvoltagewith the Honda
P G M T e s t e r ,o r m e a s u r a n g
v o l t a g e b e t w e e nE C M / P C M
connectorterminalsA29 and
C18slowly PumPthe vacuum
pump using a strokeevery 1 2 seconds.
6 . 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
stillabove95'F(35'ClandYour
vacuumPumPhasno leak
7 . M o n i t o r t h a t v o l t a g ef o r 2 0
seconds.

Doesthevoltagedrop to 1.5V
and holdsat least20 seconds?

lGpct the EVAPcontrol cani3tel


vent 3hut valvo line and connec_
tion5.

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.

Does the voltage drop to 1.5V


and holds at least 20 seconds?

Reolacethe EVAPconirol canister.

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VENT
SHUT
VALVE

c (31Pt

SG2 {GRN/BLK)
Wiresideof femaleterminals

Inlpect tho EVAP Putge control


solenoid valvo line and connec'
tion3. It th6y lro OK, do the EVAP
two way valve te3t (seo page 112211.

{cont'd)

11-223

EmissionControlSystem
EvaporativeEmission(EVAP)Controls(cont,dl
EvaporativeEmission (EVAP)Two Way Valve Testing
'97 model:

1.
2.

1.

Removethe fuelfill cap.

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.

Move the vacuum pump hosefrom the vacuumfit_


ting 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

www.emanualpro.com

5.

Slowly pressurizethe vapor line while watchingthe


gauge.
The pressureshould stabilizemomentarilvabove
1 . 0k P a( 8 m m H g ,0 . 3i n . H g ) .
a 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
o p e n s )a b o v e 1 . 0 k P a ( 8 m m H g .0 . 3 i n . H g ) t, h e
valveis OK.
. lf the pressurestabilizesbelow ,|.0kpa {g mmHg.
0.3 in.Hg),installa new valveand retest.

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

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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

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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

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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.

LoosenlocknutA, and backoff the clutchswitch(or


sdjustingbolt) until it no longertouchesthe clutch
peoar.

2.

LoosenlocknutC, and turn the push rod in or out to


get the specifiedstroke (@) and height (@) at the
clutchoedal.

3.

TightenlocknutC.

4.

Thread in the clutchswirch (or adjustingbolt) until


it contactsthe clutchoedal.

5 . Turn the clutchswitch{or adjustingbolt} in an additional3/4to 1 full turn.


TightenlocknutA.
7 . LoosenlocknutB on the clutchinterlockswitch.
8 . Measurethe clearancebetweenthe floor board and
clutchpedalwiththe clutchpedalfully depressed.
q

Releasethe clutchpedal 15 - 20 mm (0.59- 0.79in)


from the fully depressedpositionand hold it there,
Adjustthe positionof the clutchinterlockswitch so
that the engine will start with the clutch pedal in
this position.

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

at PEDAL):135- 1itsmm (5.31- 5.71in}


{STROKE
(TOTALCLUTCHPEDALFREEPLAY)i7-22mm (0.28-0.87in) inctudethe pedatptay 1 - 9 mm (0.0it- 0.35inl
(GLUTC,H
PEDALHE|GHTI:ltxt mm (7.20inl ro rhe ftoor
(CLUTCHPEDALDTSENGAGEMENT
HEtcHTl: 72 mm {2.txtinl minimum to the floor

12-4

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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)

' t . The brakefluid may be suckedout through the top


of the mastercylinderreservoirwith a syringe.
Disconnectthe clutch line and reservoirhose from
the clutchmastercylinder,

9.8N.m11.0kst m,
7.2tbf.ftl

5,

Removethe clutchmastercylinder.

CLUTCHLINE
19 N'm 119 kgJm'
14 lbf.frl

Remove the reservoir from the engine compartment


bulkhead.

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.

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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

High Temp Urea crease (p/N 087989002).


: BrakeAssemblyLube or equivalentrubber
grease.

.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.

Removethe slavecylinderfrom the clutchhousing.

Attacha hoseto the bleederscrew,and suspend


the hosein a containerof brakefluid.
Makesurethere is an adequatesupplyof fluid at
the clutchmastercylinder,then slowly pump the
clutchpedaluntil no more bubblesappearat the
bleederhose.
Refillthe clutch mastercylinderwith fluid when
qone.
A l w a y s u s e G e n u i n eH o n d aD O T 3B r a k eF l u i d .
Using a non Hondabrakefluid can causecorrosion and decreasethe life of the system.
Confirm clutch operation,and checkfor leaking
fluid.

BLEEDER
SCREW
7.8 N.m (0.8 kgf.m.5.8 lbt.ft)

12-6

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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.

Inspectthe pressureplate surfacefor wear, cracks,


a n db u r n i n g .

5.

Inspectthe fingersof the diaphragmspringfor wear


at the releasebearingcontactarea.

HANDLE
07936- 3710100
CLUTCHALIGNMENTDISC
- PM7O11A
OTJAF
CI.UTCHALIGNMENTSHAFT
07NAF- PR30100

FEELER
GAUGE

PRESSURE
PLATE

lf the height is more than the servicelimit, replace


the pressurePlate.
2.

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 .

Inspectfor warpageusinga straightedge and feeler


gauge.Measureacrossthe pressureplate.
in) max.
StandardlNew):0.03mm 10.001
ServiceLimit: 0.15mm (0.006inl

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.

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lf the warpage is more than the service limit,


replace the pressure plate.

12-7

GlutchDisc
Removal/lnspection
'1. Removethe
clutchdiscand specialtools.

4.

Measurethe rivet depth from the lining surfaceto


the rivets,on both sides.
Standard(New):1.2- 1.7mm 10.05- 0.07in) min.
Service Limit:
0.2 mm {0.008inl

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.

lf the thicknessis lessthan the servicelimit, reDlace


the clutchdisc.

12-8

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Flywheel
Replacement

Inspection
L

lnspectthe ring gearteethfor wear and damage.

Installthespecialtool as shown.

2.

Inspectthe clutch disc mating surfaceon the flywheelfor wear,cracks,and burning

2.

Removethe flywheelmountingbolts in a crisscross


patternin severalsteps,and removethe flywheel.

3.

Measurethe flywheel runout using a dial indicator


through at leasttwo full turns. Pushagainstthe flywheel each time you turn it to take up the crankshaftthrustwasherclearance.

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.

Removethe ball bearingfrom the flywheel.

RINGGEAR

Turnthe innerraceot the flywheelbearingwith your


finger.The bearingshould turn smoothly and quietly. Checkthat the bearingouter racefits tightly in
the tlywheel.lf the racedoes not turn smoothly,quietly,or fit tight in the flywheel,replacethe bearing.

FLYWHEEL

BALLBEARING

(cont'd)

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12-9

Flywheel
Replacement(cont'dl
Drive the new bearing into the flywheel using the
specialtools.
HANOLEDRIVER
07749-

Clutch Disc,PressurePlate
Installation
1.

Installthe ring gear holder.


CLUTCHALIGNMENTSHAFT
07NAF- PR30100

ATTACHMET{T32x35mm
07746-O010100

FLYWHECI-

CLUTCHDISC

RINGGEARHOLDER
07LAB_ pvoot(x)or
07924_ PD20003

Align the hole in the flywheel with the crankshaft


d o w e l p i n , a n d i n s t a l lt h e f l y w h e e l .I n s t a l lt h e
mountingboltsfinger-tight.
I n s t a l lt h e s p e c i a lt o o l , t h e n t o r q u e t h e f l y w h e e l
mounting bolts in a crisscrosspattern in several
stepsas shown.

Apply greaseto the spline of the clutch disc,then


installthe clutchdisc usingthe specialtools.
N O T E :U s e o n l y S u p e rH i g h T e m p U r e aG r e a s e
(P/N08798- 9002).

Torque:
12x 1.0mm
r03 N.m(10.5kgl.ln,
75.9tbtftl

lnstallthe pressureplate.

PRESSURE
PLATE

12-10

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ReleaseBearing
Removal/lnspection
4.

Torquethe mountingbolts in a crisscrosspatternas


shown.Tightenthe bolts in severalstepsto prevent
warpingthe diaphragmspring.

1.

Removethe releasefork boot from the clutchhousIng.


RELEASE
BEABING

8 x 1.25mm
25 N.m (2.6kgf.m,19lbfft)
RELEASE
FORK
BOOT

RELEASEFORK

Removethe releasefork and releasebearingfrom


the clutchhousing.
Checkthe releasebearingfor play by spinningit by
h an d .
NOTE:The releasebearingis packedwith grease.
Do not wash it in solvent.
5.

Removethe specialtools.

6.

Checkthe diaphragmspring fingersfor height (see


page 12-7]'.

lf there is excessiveplay, replacethe releasebearing with a new one.

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12-11

ReleaseBearing
lnstallation
NOTE: Use only Super High Temp Urea Grease(P/N
08798- 9002).

3.

Move the releaselork right and left to make sure


that it tits properly againstthe releasebear'rng.and
that the releasebearingslidessmoothlY.

the releasebear1. With the releasefork slid bet\iveen


ing pawls. installthe releasebearingon the mains h a f tw h i l e i n s e r t i n gt h e r e l e a s et o r k t h r o u g ht h e
hole in the clutchhousing.

-6.l

(P/N08798-

r iz]))

lPlN 08798- 9002)


0.,1-1.0I (0.01- 0 04 ozl

(P/N08798
9002)

| (,4\1t1t

/\[w

RELEASE
FORK
BOOT

4.

(P/N08798 9002)
1 . 0- 1 . 6g
{0.0,1- 0,06 ozl

Align the detentof the releasefork with the release


f o r k b o l t , t h e n p r e s s t h e r e l e a s ef o r k o v e r t h e
releasefork bolt sequarelv.

12-12

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Install the releasetork boot; make sure the boot


sealsaroundthe releasefork and clutchhousing.

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

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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

NOTE:Checkthe fluid with the engineOFFand vehicle


on levelground.

1.

1.

the connectorsfrom the switch.


Disconnect

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.

The fluid level must be up to the filler hole. lf it is


belowthe hole,add fluid until it runs out. then reinstallthe tiller plug with a new washer.

WASHER
Replace.

lf the transmissionfluid is diny, removethe drain


plug and drainthe fluid.
PLUG
FILLEB
a,aN.m 14.5kgf..n.33 lbt'ftl

Checkfor continuity betweenthe No. 1 and No. 2


terminals.
There should be continuitywhen the shift lever
tnto reverse.
. T h e r e s h o u l d b e n o c o n t i n u i t yw h e n t h e s h i f t
leverin positionexceptreverse,

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

Raisethe front of the vehicle,and support it with


safetystands(seesection1).

2.

Set the parkingbrake,and block both rear wheels


securely.

3.

Shiftto neutraloosition.

4.

Make a referencemark acrossthe DroDellershaft


and the transferassemblyflanges,
REFERENCE

6.

STANDARD:0.06- 0.16 mm (0.002- 0.006in)

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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Set a dial indicatoron the transferassemblyflange,


then measurethe transfergear backlash.

lf the measurementis out of specification,


remove
the transferassemblyand adjusttransfergear backlash(seepage13-44thru '13-61).
C h e c kt h e t r a n s f e ro i l s e a l f o r d a m a g ea n d f l u i d
teaKs.
lf oil sealreplacement
is required,removethe transfer assembly,replacethe oil seal, and adjust the
total startingtorque (seepage 13-44thru 13-61).
NOTE:Do not replacethe oil sealwhen the transfer
assemblyis installedon the transmission.

Removal
Make sure the lifts, i8cks. and safety stands
!@@
properly
placed
are
{seesection 1}.
1.

Raisethe front of the vehicle,and support it with


safety stands (seesection 1).

2.

Set the parkingbrake,and block both rear wheels


securely.

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.

Disconnectthe heatedoxygen sensor (HO2S)connector.

6.

Make referencemarks across the propeller shaft


and the transferassemblyflanges'
REFEREI{CEi'ARKS

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.

NOTE: While servicingthe transfer assembly,do


not allow dust or otherforeignparticlesto enterthe
transmission.

RemoveexhaustoipeA.

Replace.

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13-5

TransferAssembly
lnstallation
1.

Installa new O-ringon the transferassembly.


8 x 1.25mm
24 N.m (2.4 kgt m,
17 rbt.ftl

6.

Installthe exhaustpipeA,

10 x 1.25mm
44 N.m (4.5 kgJ.m,
GASKET

EXHAUSTPIPEA

HO2SCONNECTOR

DOWELPIN

TRANSFEB
ASSEMBLY

Replace.

2.

Cleanthe areaswhere the transferassemblycon


tacts the transmissionwith solvent or carburetor
cleaner,and dry with compressedair. Then apply
MTFto the contactareas.

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.

Installthetransferassemblyon the transmission.


N O T E :W h i l e i n s t a l l i n gt h e t r a n s f e ra s s e m b l yo n
the transmission,do not allow dust or other foreign
particlesto enterthe transmission.
lnstallthe rearstiffener.
Installthe propellershaft to the transferassembly
by aligningthe referencemarks,
8 x1.25mm
32 N.m 13.3kg{.m,
24 tbf.ftl

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REFERENCE
MARKS

7.

Connectthe heatedoxygensensor(HO2S)connector.

8.

Relillthe transmissionwith MTF(seepage 13-3).

9.

Startthe engine,and run it to normaloperatingtemp e r a t u r e( t h e r a d i a t o r t a n c o m e s o n ) . T u r n t h e


engineoff. and checkfluid level.

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.

CAUTION:Use fender coversto avoid damaging painted


surfaces.
1.

the negative{-) cablefirst,then the posDisconnect


itive(+)cablefrom the batterY.

2.

Removethe intakeair duct and air cleanerhouslng


(seesection5).

3.

Removethe slavecylinderand clutchhosebracket'


NOTE:
. Do not operatethe clutch pedal once lhe slave
cvlinderhas beenremoved.
. Takecarenot to bendthe clutchline.

TRANSMISSION
GROUNDCABLE

Disconnectthe back-uplight switch connectorand


wire harnessclamP.

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

1 0 . Draintransmissionfluid (seepage '13-3).


1.

Removethe cablebracketfrom the clutchhousing.

8.

Disconnectthe vehiclespeedsensor(VSS)connector.
-------------.2

13-8

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1 1 . Removethe guardbar and the splashshield.

12. Disconnectthe heatedoxygen sensor(HO2S)connector,then removethe exhaustpipe A.

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.

Mark referencemarks on the joint of the transfer


and the propellershaft.

1 6 . Removethe right damper tork bolt, then separate


right damperfork and damPer.
1 7 . Pry the right driveshaftout of the differential,and
pry the left driveshaftout of the intermediateshaft
(seesection18).
1 8 . Pull out the inboardioint, and removethe right and
left driveshaft(seesection18).
1 9 . Tie plastic bags over the driveshattends. Coat all
precisionfinishedsurfaceswith cleanengineoil

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.

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{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.

23. Removethe right front mounvbracket.

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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25. Removethe transmissionmounting bolts and the


rearenginemountingbolts.

REARENGINEMOUNTINGBOLTS
Replace.

28. Removethe releasetork boot. releasebearing,and


releasefork from the clutchhousing
RELEASE
BEANING

TRANSMISSION

Pull the transmissionaway from the engine until it


clearsthe mainshaft,then lower it on the transmission jack.
NOTE:Takecarenot to bendthe clutchline.
Removethe startermotor and hose clampfrom the
transmissionhousing.

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

LuUri""r"uttthe partswith MTFbeforereassembly.

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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aol NEEDLESET PLATE

@ 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.

Removethe shift arm cover assembly,and wiDe it


cleanof the sealant.
5.

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.

Removethe set ball screws,washers,springs,steel


balls.and back-uPlight switch.

9. Removethe transmissionhousing mounting bolts


in a crisscrosspauernin severalsteps.

STEELBALL
D. 5/16 in

LIGHTSWITCH

8.

Removethe flangebolt. drainplug, and filler plug

10. Removethe 32 mm sealingbolt

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)

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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.

1 6 . Removethe spring pin using the pin punch and a


pair of diagonalcutters.

OIL GUTTERPLATE

PIN PUNCH,5.0 mm

Replace.
OIL GUIDEM PLATE

17. Removethe selectlever,springs,washer,and select


arm.
15. Removethe selectspringbolt.

SELCTLEVER

SELECTSPRINGBOLT

OIL SEAL
Replace.

THRUSTWASHER

SELECTARM

18. Removethe oil seal.

13-16

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23. Removethe mainshaftand countershaftassemblies


with the shiftforksfrom the clutchhousing.

19. Removethe reverselockcam.

NOTE;Beforeremovingthe mainshaftand countershaft assemblies,tape the mainshaftsplineto protect it.

COUNTEBSHAFT
ASSEMBLY

20. lf necessary,checkthe clearanceof the reverseshift


holder(seepage13-20).

2 ' t . Removethe reverseshift holder.


Tapethe main'
shaftsplines.

WASHER

SPRINGWASHER

HOUSING

HOLOER

24. Removethe differential asssmbly.

22. '97 - 99 models: Removethe reversegear shaft and


the reverseidler gear.
'00 model: Remove the reverse gear shaft, reverse
idler gear,thrustwasherand the coller.

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13-17

Shift Arm Cover/ShiftArm Shaft Assembly


Disassembly/Reassembly
Shift Arm CoverAssmbly
1.

5.

Installthe oil seal in to the shift arm coverusinothe


sDecialtools.

Removethe breathercap and set ball screw,washer,


spring.and steelball.

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.

Shift Arm Shaft Assembly


1.

Removethe specialbolts and conicalspring washers.

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}

Removethe oil seal.


NOTE: lnstallthe thrust washerwith the alloy surfacetoward shift arm cover.

13-18

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SPRING
WASHER

2.

Remove the interlock, shift arm A, and shift arm B


from the shift arm shaft.

3.

Installin the reverseorderof removal.

InsPection
Clearance
1.

Measurethe clearancebetweenthe shift arm A and


selectarm.
0.05- 0 25 mm (0.002- 0'01 inl
Standard:
ServiceLimit:0.5mm (0.02in)

3.

Measurethe clearancebetweenthe shift arm B and


shift arm c.
0.05- 0.25 mm (0.002- 0.01 inl
Standard:
SeryiceLimit:0,5mm (0.02inl
SHIFTARM C

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.

Standard:7.9- 8.0 mm (0.311- 0.315in)

Standard:12.9- 13.0mm (0 508- 0.512in)

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.

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lf the diameterof the shift arm C is lessthan the


servicelimit, replacethe shift arm C with a new
one.
l f t h e d i a m e t e ro f r h e s h i f t a r m C i s w i t h i n t h e
servicelimit, replacethe shift arm B with a new
on e .

13-19

ReverseShift Holder
ClearanceInspection
1.

Measurethe clearancesbetweenthe reverseshift


holderand sth/reverse
shift DieceDin.
A: 0.05- 0.35mm (0.002- 0.014in)
8: 0.4 - 0.8 mm 10.02- 0.03 inl
ServiceLimit:A: 0.5 mm (0.02in)
B: 1.0mm 10.0,[
in]
Standard:

3.

Measure the clearancebetween the reverseidler


gearand reverseshift holder.
Standard: 0.5- 1.1mm {0.02- 0.0i1in}
ServiceLimit: 1.8mm (0.07in)
REVERSE
IDLER
GEAR

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

lf the widths of the grooves are not within the


standard,replacethe reverseshift holderwith a
new one.
lf the widths of the groovesare within the standard, replacethe sth/reverseshift piece with a
new one.

13-20

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It the width is not within the standard,replace


the reverseshift holderwith a new one.
lf the width is within the standard,reolacethe
reverseidler gearwith a new one.

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

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13-21

Shift ForkAssembly
ClearanceInspection
NOTE:The synchrosleeveand synchrohub should be
reolacedas a set.
1.

3.

Measurethe clearancebetweenthe shift fork and


the shift arm A.

Measurethe clearancebetweeneach shift fork and


its matchingsynchrosleeve.

Standard; 0.2- 0.5 mm (0.008-0.020


in)
ServiceLimit: 0.6 mm (0.02i1in)

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

lf the clearanceexceedsthe servicelimit, measure


the width of the shift arm A.

SHIFTFORK

2.

lf the clearanceexceedsthe servicelimit. measure


the thicknessof the shiftfork fingers.

- 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)

lf the thicknessof the shift fork finger is lessthan


the standard,replacethe shift fork with a new
one.
lf the thicknessof the shift fork tinger is within
the standard,replacethe synchrosleevewith a
new one.

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lf the width of the shift arm A is less than the


standard,reDlace
the shift arm A with a new one.
lf the width of the shift arm A is within the standard, replacethe shift fork or shift piecewith a
new ones.

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

Support the bearing inner race with a socket.and


Dushdown on the mainshaft.

2.

Measurethe clearancebetween2nd and 3rd oears.

4.

Measurethe clearancebetween 4th gear and the


spacercoIar,
Standard:
0.06- 0.21 mm {0.002- 0.008in)
ServicLimit: 0.3 mm {0.01inl

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.

tf distance@ is lessthan the servicelimit, replace


the sDacercollarwith a new one.
lf distance@ is within the service limit. measure
the thicknessof 4th gear.
- L239 inl
Standard: 31.42- 31.'17mm 11.237
SarviccLimit:31.3mm {1.23in)

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.

Measurethe clearancebetweenthe spacer collar


and 5th gear.
0.06- 0.21 mm {0.002- 0.008in)
Standard:
ServiceLimit: 0.3 mm {0.01in)

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

lf the clearanceis more than the servicelimit, measuredistance@ on the spacercollar


26.03- 26.08mm 11.025- 1.027in)
Standard:
SrvicoLimit: 26.01mm (1.024in)
SPACER
COLLAR

In the same manneras above,supportthe 3rd gear


on steel blocks.and pressthe mainshaftout of the
3rd/4thsvnchrohub, as shown.
PRESS

5TH GEAR
SIDE

9.

lf distance@ is lessthan the servicelimit, replace


the spacercollarwith a new one.
lf distance@ is within the service limit, measure
the thicknessof sth gear.
Standard: 30.92- 30.97mm (1.217- 1.219in)
ServiceLimit:30.8mm (1.21in)

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.

lf the runout is more than the servicelimit, reDlace


the mainshaftwith a new one.
I n s p e c t o i l p a s s a g e sI o r c l o g g i n g .

lf anv oart of the mainshaftis lessthan the service


limit. reolaceit with a new one.

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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.

Suppon 2nd gear on steel blocks as shown, then


i n s t a l lt h e 3 r d / 4 t hs y n c h r oh u b u s i n g t h e s p e c i a l
tools and a pressas shown.

PRESS

NOTE:After installing,inspectthe operationof the


3rd/ 4th synchrohub set.
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.

Installthe sth synchro hub using the specialtools


and a press.
PRESS

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.

lf the thicknessis lessthan the standard,reDlacethe


thrust washer with a new one. lf the thicknessis
w i t h i n t h e s e r v i c el i m i t , m e a s u r et h e t h i c k n e s so f
t h e 1 s tg e a r .
Standard:26.95- 27.00mm (1.061- 1.063inl

Standard: 0.06- 0.18mm (0.@2- 0.007in)


ServicaLimit:0.23 mm {0.009in)

THRUST WASHER

2.

lf the thicknessof 1st gear is lessthan the standard,replace1stgearwith 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 thrustwasher.
Standsrd:1.95- 1.97mm (0.077- 0.078in)

{cont'd}

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13-29

CountershaftAssembly
Clearance
Inspection(cont'dl
4.

Measurethe clearancebetweenthe 2nd qear and


3rd gear.
Standard: 0.07- 0.1,1mm (0.003- 0.006inl
ServiceLimit:0.18mm (0.007inl

6.

lf the thicknessis lessthan the standard,reDlacethe


spacerwrln a new one.
lf the thicknessis within the standard,measurethe
thicknessof the 2nd gear.
Standald:28.92- 28.97mm (1.139- 1.141in)

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.

Removethe Jrictiondamperfrom the spacerusinga


pressand a socket.
PRESS

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 the runout exceedsthe servicelimit, reDlacethe


with a new one.
countershaft
lnspectfor wear and damage.

lf anv part of the countershaftis lessthan the service limit.reolaceit with a new one.

13-32

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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.

Installthe doublecone synchro.

OUTER

Installthe thrustshim, needlebearing,1stgear,and


frictiondamper.
NOTE: Reassemblythe friction damper on the lst
gearbeforeinstallation.

----.-4O)
orn,leen
rnrcrroru
lST GEAR

NEEDLEBEARING

3.

Installthe 1sv2ndsynchrohub by align the friction


damperfingerswith 1svzndsynchrohub grooves.

THRUSTSHIM

lST/2ND

(cont'd)

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13-33

CountershaftAssembly
(cont'dl
Reassembly
4.

Reassembly
the frictiondamperon the spacerusing
the sDecialtoolsand a Dress.

6.

Supportthe countershafton a steel blockas shown


and install 3rd gear using the specialtools and a
press.
PRESS

PRESS

ATTACHMENT,
U2t 47 mfi
07716- 0010300

3ROGEAR
FRICTIONDAMPER
Inspectfor wear and
damage.

7.

lnstall4th gear usingthe specialtools and a press.

Install the 2nd gear by align the synchrocone the


fingers with 2nd gear grooves.

PRESS

ATTACHMENT,
35 mm LD.
07746- 0030,100
GROOVE

13-34

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Installsth gear usingthe specialtools and a press.

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

10. Installthe ball bearingusingthe specialtools and a


press.
PRESS

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)

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13-35

SynchroSleeve,SynchroHub
Inspection
1.

Installation

Inspectgear teeth on all synchrohubs and synchro


s l e e v e sf o r r o u n d e d o f f c o r n e r s ,w h i c h i n d i c a t e

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.

When assemblingthe synchrosleeveand synchrohub,


b e s u r e t o m a t c h t h e t h r e e s e t s o f l o n g e rt e e t h ( ' 1 2 0
degreesapart)on the synchrosleevewith the three sets
of deepergroovesin the synchrohub. Do not installthe
synchrosleevewith its longerteeth in the lsv2nd synchro hub slotsbecauseit will damagethe springring.

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

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LONGER?EETH

SynchroRing,Gear
Inspection
1.

SYNCHROSPRING

Inspectthe synchroring and gear.


Ar lnspectthe insideof the synchroring for wear.
B: lnspectthe synchro sleeveteeth and matching
teeth on the synchroring for wear (roundedof0.

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.

Coatthe cone surfaceof the gearwith oil, and place


the synchro ring on the matchinggear. Rotatethe
synchroring, makingsurethat it does not slip.
Measurethe clearancebetween the synchro ring
a n dg e a ra l l t h ew a y a r o u n d .
NOTE:Holdthe synchroring againstthe gearevenly while measuringthe clearance.
Synchro Ring-to-GearClearance
0.85- 1.10mm (0.033- 0.0,lil in)
Standard:
ServiceLimit: 0.,1mm 10.02inl
Double Cone Synchro-lo-GoarClearance
Standard:
@: {Outer Synchro Ring to Synchto Conel
0.5- 1.0mm (0.02- 0.04in)
): {synchro cone to Geal)
0.5- 1.0mm (0.02- 0.0i1inl
@: louter Synchro Ring to Gearl
0.95- 1.68mm (0.037- 0.056inl
ServiceLimit:
@: 0.3 mm (0.01inl
@: 0.3 mm {0.01in}
@: 0.6 mm {0.02in)

OUTERSYNCHRORING

lf the clearanceis lessthan the servicelimit, replace


the synchroring and synchrocone.

www.emanualpro.com

13-37

Differential
lndex

BacklashInspection

NOTE: lf the * mark parts were replaced,the tapered


roller bearing preloadmust be adjusted(see page 1341).

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.

Measurethe backlashot both piniongears.


Standard(Newl:0.05- 0.15mm (0.002- 0.006inl
lf the backlashis not within the standard,reolace
the differentialcarrier.

FinalDrivenGearRePlacement
L

Removethe bolts in a crisscrosspatternin several


steps,and removethe final drivengearfrom the differentialcarrier.
NOTE: The final driven gear bolts have left-hand
threads.

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

Removethe taperedroller bearingsusing a bearing


pullerand a bearingseparatoras shown.

BEARING
BEARING
SEPAFATOB
{Commercially

FINALDRIVENGEAR
lnsoect{or weal and damage

TRANSFERORIVENGEAR
Inspectfor wear and damage.

Installnew taperedroller bearingsusingthe special


tool as shown.
N O T E :D r i v et h e t a p e r e dr o l l e r b e a r i n g so n u n t i l
they bottomagainstthe differentialcarrter.
PRESS

Installthe final driven gear by tighteningthe bolts


in a crisscrosspatternin severalsteps.

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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.

Removethe oil sealsfrom the transmissionhousing


and clutchhousing(seepagej3-43).
Drivethe bearingouter raceand thrust shim out of
the transmissionhousing, or remove the bearing
outer raceand 75 mm shim from the clutchhousing
b y h e a t i n gt h e c l u t c h h o u s i n gt o a b o u t 2 1 2 " F
(100"C)with a heat gun. Do not reuse the thrust
shim if the outer racewas drivenout.

Installthe thrust shim or 75 mm shim and the beari n g o u t e r r a c e i n t h e t r a n s m i s s i o nh o u s i n g a n d


clutchhousingusingthe specialtools.

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.

Do not use more than one thrust shim to adjustthe


t a p e r e db e a r i n gp r e l o a d .F i r s tt r y t h e s a m e s i z e
thrust shim that was removed.There are no shims
usedon the clutchhousingside

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.

TOBOUE;8 x 1.25mm: 27 N'm


(2.8kgf'm, 20 lbt'ftl
5.

Rotatethe differentialassemblyin both directions


to seatthe taperedrollerbearings.
Measurethe taperedroller bearingpreloadat normal room temperature.Measurethe startingtorque
of the differentialassemblyin both directionswith
the specialtool and a torquewrench.
STANDAFD:1.4- 2.5 N'm
{1/r- 26 kgf'cm, 12 - 23 lbf in)

THRUSTSHIM

/A

07HAJ- PK4020'1

(cont'd)

www.emanualpro.com

13-41

Differential
TaperedRollerBearingPreloadAdjustment(cont'd)
7.

lf the tapered roller bearing preload is not within


the standard,selectthe thrust shim which will give
the correcttaperedroller bearingpreloadfrom the
followingtable.
N O T E :C h a n g i n gt h e t h r u s t s h i m t o t h e n e x l s i z e
w i l l i n c r e a s eo r d e c r e a s et a p e r e d r o l l e r b e a r i n g
p r e l o a da b o u t 0 . 3 - 0 . 4 N . m ( 3 - 4 k g f . c m ,2 . 6 3.5 lbf.in).

9.

How to selectthe correctthrustshim:


- 1 ) C o m p a r et h e t a p e r e dr o l l e r b e a r i n gp r e l o a d
you get with the thrustshim that was removed,
w i t h t h e s p e c i f i e dp r e l o a do f 1 . 4 - 2 . 5 N . m
(14-- 26 kgfcm, 12-23lbtinl.
-2) lf your measuredtaperedrollerbearingpreload
is less than specified.subtractyours from the
specified,
l f y o u r s i s m o r e t h a n s p e c i f i e ds, u b t r a c tt h e
specifiedfrom your measurement.

THRUSTSHIM
Part Numbe.
41381- PX5 000

Thickness
1 . 9 0m m ( 0 . 0 7 4 i8n )

41382- PX5 000

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)

41391- PX5- 000

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

www.emanualpro.com

For examplewith a 2.17 mm (0.0854in) thrust


shiml
2.5 N.m (26 kgf.cm,23lbiin)
@ specified
- you measure0.6 N.m (6 kgf.cm,5lbf.in)
1.9N.m(20kgicm, 18 tbt.in)tess
@ you measure3.3 N.m (34 kgf.cm,30lbf.in)
- specified
2.5 N.m (26 kgncm,23lbf.in)
0.8 N.m (8 kgf.cm,7lbt.in)more
E a c hs h i m s i z e u p o r d o w n f r o m s t a n d a r d
m a k e sa b o u t 0 . 3 - 0 . 4 N . . ( 3 - 4 k g f ' c m ,
2.6- 3.5 lbf.in)differencein taperedrollerbearingpreload.
I n e x a m p l e@ , y o u r m e a s u r e dt a p e r e dr o l l e r
b e a r i n gp r e l o a dw a s 1 . 9 N . m ( 2 0 k g f . c m ,
1 8 l b f . i n ) l e s s t h a n s t a n d a r ds o y o u n e e d a
thrust shim five sizesthickerthan standard{try
t h e 2 . 3 2 m m ( 0 . 0 9 1 3i n ) t h r u s r s h i m . a n d
recheck).
ln example@, your measurementwas 0,8 N.m
{8 kgf.cm,7 lbf.in)more than standard,so you
need a thrust shim two sizesthinner (try the
2.1'l mm {0.0831in) thrustshim,and recheck).

Oil Seal Replacement


Clutch Housing:

TransmissionHousing:
1.

Removethe oil sealfrom the transmissionhousing

1.

Removethe oil sealfrom the clutchhousing.

OIL SEAL

Replace.

lnstallthe new oil seal into the clutchhousingusing


the specialtools.
2.

lnstallthe new oil seal into the transmissionhousing usingthe specialtools.

NOTE:Installoil seal up to t0.5 mm (t0.02 in) from


transmissionhousingend surface

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

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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.

TransferGear lHypoid gearl Tooth Contaqt Inspction


5.

Transter Gaar (Hypoid goar) BacklsshMasurement


1.

Removetransfercover B, then apply PrussianBlue


to both sides of the translergear teeth lightly and
evenlv.

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.

Rotatethe companionflangein both directionsuntil


the transfergear rotatesone full tuln in both directions.

Measurethe transfergear backlash.


STANDARD:0.06- 0.16 mm {0.002- 0.006in}

7.

Checkthe transfer gear tooth contact pattern.

Total Sta.ting Torquo Msasuremont


3.

Rotatethe companionflange severaltimes to seat


the taperedrollerbearing.

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.

Removethe transfercoversA and B.

Hold the transfershaft with a 14 mm Allen wrench


clampedin a benchvise.

TRANSFER

TRANSFEF

Replace.

14 mm ALLENWRENCH

Loosenthe transter shaft locknut.The transfer shaft


locknuthaslett-handthreads.
Removethe transfershaft assembly,transferdrive
gear,25 mm thrust shim. transfershaft collar.and
taperedrollerbearingfrom the transferhousing.
TRANSFERSHAFT
ASSEMBLY

Cutthe locktabsofthe locknutusinga chisel.Keepa t l


of the chiseledparticlesout of the transferhousing

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.

9. Removethe transferdrivengear shaft,then remove


the transfer spacer from the transfer driven gear
shaft.

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.

Removethe oil seal and the taperedroller bearing


from the transferhousing,

OIL SEAL
Replace.

TAPEREOROLIIR
AEARING

TRANSFERHOUSING

TRANSFERDRIVEN
GEARSHAFTLOCKNUT
Reolace,

13-4 8

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Replacement

TransferDrivenGearShaft
BearingReplacement

NOTE:Coatall partswith MTFduring reassembly.

NOTE:Coatall partswith MTFduring reassembly.

TransferDriveGearBearing

1.

Removethe taperedrollerbearingfrom the transfer


drive gear usingthe specialtools and a press.

1.

Removethe taDeredrollerbearingfrom the transfer


drivengear shaftusinga pressand a collar.

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 )

Installthe new taperedrollerbearingin the transfer


drive gear usingthe specialtools and a press

lnstallthe 35 mm thrust shim on the transterdriven


gear shaft.
Installthe new taperedrollerbearingon the transfer
drivengearshaftusingthe specialtoolsand a press.
NOTE:Use old transferspacerfor bearinginstallation, then discardit.
DRIVER40 mm l.D.
07746- 0030r00

ATTACHMENT,
40x50mm
07LAD - PW5lr601

www.emanualpro.com

13-49

TransferAssembly
TransferShaft Disassembly/
Reassembly
1.

Support the transfer driven gear on steel blocks,


then pressthe transfershaftout of damperhub,

TransferGoverA BearingOuter
RaceReplacement

NOTE:Coatall partswith MTFduring reassembly.


1.

Bemovethe 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
2 1 2 " F( 1 0 0 o Cu) s i n g a h e a t g u n . D o n o t h e a t t h e
coverover 212"F(100'C),

BEARINGOUTERRACE

2.

Installthe 68 mm thrustshim in transfercoverA.

Align the damper hub groovesand transferdriven


gear teeth,and reassemble
the damperhub. needle
bearing,and transferdrivengear.
Installthe transfershaftusinga press.

BEARINGOUTERRACE
TRANSFERCOVERA
ATTACXMCNT,
52x68mft
07746- tD,t0500

Install the tapered roller bearing outer race u sI n g


the special tools and a press.

13-50

www.emanualpro.com

TransferHousingBearingOuterRaceReplacement
NOTE:Coatall partswith MTFduring reassembly.
1.

Bealing Outer RaceLocations


and SpecialTool APP|ications

Removethe taperedroller bearingouter racefrom


the transferhousing.
HOUSING
TRANSFER
SectionalView

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.

Disassemblethe parts,then assemblethe transfer


drivengear shaftand its relatedparts.

4.

Measureand adjustthe staningtorque of the transfer drivengear shafttaperedrollerbearing.

5.

Assemblethe transfershaftand jts relatedparts.

6.

Measureand adjustthe total startingtorque.

35 mm Thrust Shim Seleqtion


1.

Selectthe 35 mm thrust shim if the transferdriven


gearshaftor the taperedrollerbearingon the transfer drivengear shaft is replaced.

A: EXISTINGTRANSFER
DRIVENGEARSHAFT

B: REPLACEMENT
TRANSFER
DRIVENGEAFSHAFT

'x- = A - B - .100 100


2 - 1
'100 100
= 0.02+ 0.01+ 1.05
-'1.08(mm)
S e l e c t3 5 m m t h r u s t s h i m t h i c k n e s so t ' 1 . 0 8m m
(0.043in). lf the taperedrollerbearingon the transfer
drivengear shaftis replaced.
M e a s u r et h e t h i c k n e s so f t h e r e p l a c e m e nbt e a r i n g
and the existingbearing,and calculatethe difference
of the bearingthickness.Adjust the thicknessof the
existing35 mm thrust shim by the amount of differencein bearingthickness.and selectthe replacement
35 mm thrustshim. Do not use more than one 35 mm
thrustshim to adjustthe transfergear backlash,
THRUSTSHIM.35 mm

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 )

TransterGear BacklashInspectionand TransferGear


Tooth Contaqt Inspection

5.

Installthe transferdriven gear shaft in the transfer


housing. Do not install the transfer spacer on the
transferdrivengear shaftin this step.

lnstallthe 35 mm thrust shim on the transferdriven


g e a r s h a f t ,t h e n i n s t a l lt h e t a p e r e dr o l l e r b e a r i n g
usingthe specialtools and a press.

2.

TRANSFER
HOUSING

NOTE:Use old lransferspacerfor bearinginstallation, then discardit.

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.

Installthe bearingouter race,then the taperedbeari n g o n t h e c o m p a n i o nf l a n g e s i d e o t t h e t r a n s f e r


housing.

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.

Installthe transfer shaft assembly in the transfer


h o u s i n g ,t h e n i n s t a l lt h e t a p e r e dr o l l e r b e a r i n g ,
t r a n s f e rs h a f t c o l l a r , 2 5m m t h r u s t s h i m , t r a n s f e r
drive gear, conical spring washer, and locknut on
the transfershaft.
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.
TRANSFERSHAFT
ASSEMBLY

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.

Rotatethe companionflange severaltimes to seat


the taperedrollerbearing.

10. Hold the transfershaft with a 14 mm Allen wrench


clampedin a benchvise.
TOROUEWRENCH

'14.

Set a dial indicatoron the companionflange,then


measurethe transfergear backlash.
- 0.006in)
STANDARD:
0.06- 0.15mm 10.002
DIALINDICATOR

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,

TOROUE:118 N.m (12.0kgf.m,86.8 lbf.ft)

THRUSTSHlM,25mm

1 1 .Tightenthe transfershaftlocknut.

Temporarilyinstallthe transfercover A without the


O-ring.

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.

19. lf the transfergear tooth contactis incorrect,adjust


the transfergear tooth contactwith a 35 mm or 25
m m t h r u s ts h i m .
NOTE:
. To selecta 35 mm thrust shim, referto page '13.

Do not use more than one 35 mm shim to adjust


the transfergeartooth contact.
. To selectthe 25 mm thrust shim, refer to page
13-55.
a Do not use more than one 25 mm shim to adjust
the transfergeartooth contact.

TRANSFERDRIVEGEAR

1 7 . Rotatethe companionflangein both directionsuntil


the transfergear rotatesone full turn in both directions.
1 8 . Checkthe transfergeartooth contactpattern.
CORREST
TOOTHCONTACT
PATTERN

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.

20. Removethe partson the transfershaft,and remove


the transfershattfrom the transferhousinq.
TRANSFERSHAFT

Removethe transterdrivengear shaftand the companionflange.


Installthe new transferspaceron the transferdriv e n g e a r s h a f t ,t h e n i n s t a l lt h e m i n t h e t r a n s f e r
housing.

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

25. Installthe companionflange,O-ring,back-upring,


conical spring washer and locknut on the transfer
drivengear shaft.
NOTE:
. Coatthe threadsof the locknut,O-ringand transfer shaftwith MTFbeforeinstallingthe locknut.
. Installthe conicalspring washer in the direction
shown.
TRANSFER
HOUSING

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.

then removethe transferdriven gear shaft locknut


and the conicalspringwasher.
(cont'd)

www.emanualpro.com

13-57

TransferAssembly
(cont'dl
Reassembly
26. Securethe transfer housing in a bench vise with
soft jaws.

28. Stakethe locknutinto the transferdriven oear shaft


u s i n ga 3 . 5m m p u n c h .

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.

29. Installthe transfer shaft assemblv in the transfer


h o u s i n g ,t h e n i n s t a l lt h e t a p e r e dr o l l e r b e a r i n g ,
transfer shaft collar, 25 mm thrust shim, transfer
drive gear,conicalspringwasher,and transfershaft
locknuton the transfershaft.
2 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 tighten the transferdriven gear shaft locknut
while measuringthe startingtorque of the transfer
drivengearshaft.

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

30. Hold the transfershaft with a 14 mm Allen wrench


clamDedin a benchvise.
NOTE:The locknuthas left-handthreads.

Totsl Starting Torquo Inspoctionand Adiustment


32. Temoorarilvinstalltransfercover A without the Oring.
TRANSFER
HOUSING

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

Securethe transfer housing in a bench vise with


soft jaws. then rotatethe companionflange several
times to fit the taperedrollerbearing,

31. Stakethe locknuton the transfershaft using a 3.5


mm Dunch.

PUNCH
3.0- 3.5 mm
{0.12- 0.14inl

TOROUEWRNCH

34. Measurethe total startingtorque.


TOTALSTARNNGTOROUE:
- 21.2kgf.cm,15.0- 18.i1lbf inl
1.70- 2.08N.m 117.3
+ Transter Driven Gear Shaft Starting Torque Value
(wrot down in step 27).

(cont'd)

www.emanualpro.com

13-59

TransferAssembly
(cont'd)
Reassembly
3 5 . RemovetransfercoverA.

37. Selectthe 68 mm thrustshim.

36. lf the measurementis out of specification,remove


t h e 6 8 m m t h r u s t s h i m f r o m 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 rt o a l m o s t2 1 2 ' F( 1 0 0 ' C )u s i n ga
heat gun. Do not heat the cover higher than 212F
( 1 0 0 " C )L. e t t h e c o v e r c o o l t o r o o m t e m p e r a t u r e
beforeadjustingthe startingtorque.
go to
lI the measurementis within the specification,
step 40.

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.

39. After replacingthe 68 mm thrust shim, recheckand


m a k e s u r e t h e t o t a l s t a r t i n gt o r q u e i s w i t h i n t h e
soecification.

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.

Removethe ball bearingusingthe specialtool.

3.

Drivethe new oil seal in from the transmissionside


usingthe specialtools.

3/8" -16 SLIDEHAMMER


(Commercially
available)

ATTACHMENT,
12x 17 .nfi

07746- 0010300

- ,10mm
PULLER.25
07736- A01000A

Drivethe new bali bearingin from the transmission


side usingthe specialtools.
2.

Removethe oil sealfrom the clutchhousing.

ATTACHMENT.
62x68mm
07746- 0010500

BALLBEARING

13-62

www.emanualpro.com

GountershaftBearing
Replacement
1.

Removethe retainingplatefrom the clutchhousing.

Positionthe oil guide plate.


Drivethe needlebearingusingthe specialtools.

Replace.

CLUTCHHOUSING
HETAININGPLATE

Removethe needlebearingusing the specialtool,


then removethe oil guide plate.

3/8" -16 SLIDEHAMMER


(Commercially
available)

ATTACHMENT,
62x88mm
07746- 0t!105q)

NEEDII AEARING

CLUTCHTIOUSING

Installthe retainingplate,and stakethe bolt heads


into the groovein the retainingplate

^'

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.

Removethe 78 mm shim and oil guide plate from


the transmissionhousing.

5,

Measuredistance@ betweenthe end of the clutch


housingand bearinginner race.
NOTE:
. Usea straightedgeand depthgauge.
. Measureat three locationsand avoragethe readIngs.

78 mm SHIM

END ot CLUTCHHOUSING

BEARING

Installthe 3rd/4th synchro hub, spacer collar, sth


synchrohub, spacer,and ball bearingon the mainshaft.then installthe above assemblyin the transmissionhousing.
lnstallthewasheron the mainshaft.
4.

Measuredistance@ betweenthe end of the transmissionhousingand washer,

Selectthe proper 78 mm shim from the chan by


usingthe formulabelow.
Shim Slection Formula:

NOTE:
. Usea straightedgeand verniercaliper.
. Measureat three locationsand averagethe readIng.

you made in steps4 and 5:


Fromthe measurements
-1. Add distance@ (step5) to distance@ (step4).
-2. From this number. subtract0.93 (which is the
midpointof the flex rangeof the clutchhousing
bearingspringwasher).

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

Try the 1.68mm (0.0661in) shim.

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

Checkthe thrust clearancein the mannerdescribed


Delow.

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)

Installthe mainshaftin the clutchhousing.


Placethe transmissionhousingover the mainshaftand onto the clutchhousing.
- 5 . Tightenthe clutch and transmissionhousings
with several8 mm bolts.
NOTE:lt is not necessaryto use sealingagent
betweenthe housings.
Tap the mainshaftwith a plastichammer.
(cont'd)

www.emanualpro.com

13-65

MainshaftThrustClearance
Adjustment(cont'dl
-7. Slidethe mainshaftbaseoverthe mainshaft.

-12. Turn the mainshaftholder bolt clockwise;stop


t u r n i n gw h e n t h e d i a l g a u g e h a s r e a c h e di t s
maximum movement,The readingon the dial
gaugeis the amountof mainshaftend play.
NOTE:Turningthe mainshaftholderbolt more
t h a n 6 0 d e g r e e sa f t e r t h e n e e d l eo f t h e d i a l
gaugestopsmoving may damagethe transmission.
MAGNETSTANDAASE
07979- PJ40001

DIALGAUGE

07GAJ- PG20130

-8. Attachthe mainshaftholderto the mainshaftas


follows:
NOTE:
. B a c k - o u t h e m a i n s h a f th o l d e r b o l t a n d
loosenthe two hex bolts.
. Fit the holderover the mainshaftso its lip is
towardsthe transmission.
. Align the mainshaftholder'slip around the
groove at the insideof the mainshaft
splines,then tightenthe hex bolts.
HOLDER
MAINSHAFT
BOLT

-13. lf the readingis within the standard,the clearancers correct.


l f t h e r e a d i n gi s n o t w i t h i n t h e s t a n d a r d ,
recheckthe shim thickness.
Standard:0.11- 0.18mm (0.00i1-0.007inl

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 .

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MAINSHAFTHOLDER
07cru - PG20110

TransmissionAssembly
Reassembly
1.

Installthe differentialassemblyin the clutch housIng.

4.

ASSEMBLY
DIFFERENTIAL

'97 - 99 models: Installthe reverseidle gaar and


reverse gear shaft in the clutch
housing.
'00 model: Installthe coller,thrust washer,reverse
idler gear and the reversegear shaft in
the clutchhousing.

model

THRUSTWASHER

Installthe springwasherand washerwith the angle


againstthe clutchhousingas shown.

COLLER

Tape the mainshaft splines. insert the mainshaft


and countershaft into the shift forks, and install
them as an assemblv.

NOTE:Installthe reversegear shaft ('00 model) in


the directionshown.
5.

Installthe reverseshift holderin the clutch housing


with the sth/reverseshift piecepin positionedin the
slot of the reverseshift fork.

5x1.0mm
15 N'm 11.5kgt.m, 11 lbf.ftl

Tapethe mainshatt
splines.

REVERSE
SHIFTHOLDER

(cont'd)

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13-67

TransmissionAssembly
Reassembly(cont'dl
6.

Installthereverselockcam on the clutchhousing.


6x1.0mm
15 N.m (1.5kgf.m, 11 lbf.ftl

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.

Installthe selectlever,spring washer,and springs


on the selectarm.
SELECT
LEVER

SELECTBETURN
SPRING
5TH/REVERSE
SELECTRETURN

SPRINGPIN
Replace.

OIL GUIDEM PLATE

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.

15. Lowerthe transmissionhousingwith the snap ring


pliers.and set the snap ring into the groove of the
countershaftbearing.

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

r3. Installthe 14 x 20 mm dowel pins.


1 4 . Set the stopperring as shown. Placethe transmis-

sion housingover the clutchhousing,being careful


to line up the shafts.Be sure to align the stop ring
with the 5th shift fork fingertip.
TRANSMISSIONHOUSING

1 6 . Checkthat the snap ring is securelyseatedin the


grooveof the countershaftbearing.
DimensionA as installod:3.6 - 6.3 mm
(0.142- 0.2/8 in)
32 mm SEALINGBOLT
25 N m 12.5kgf.m, 18 lbf.ftl

SNAPRING

vk..*,
SHIFTFORK
Align point

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1 7 . A p p l y l i q u i d g a s k e t( P / N0 8 7 1 8- 0 0 0 1o r 0 8 7 1 80003)to the 32 mm sealingbolt threads,then install


(cont'd)
the 32 mm sealingbolt.

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

1 9 . Install flange bolt, w a s h e r s d


, rainplug.and filler
plug.
21. Installthevehiclespeedsensor(VSS).
FILLERPLUG
4,r N.m (a.5 kgl.m,33lbtftl

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)

26. Installthe shift arm coverassembly.

SELECTARM
SHIFTARM COVERASSEMBLY

-->.-

10 x 12 mft DOWELPIN
SHIFTARM A

I x 1.25mm
27 N m 12.8kgtm,20 lbf'ft)

SHIFTARM SHAFT

23. Align the shift arm A groove and selectarm finger


by turn the shift arm shaft and select lever clockwise.then installtheshift arm shaftassembly.
Apply liquid gasket (P/N 08718- 0001 or 08718
bolt'
interlock
to the threads,then installthe
OO03)

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.

Apply liquid gasketto the surfaceof the shift arm


coveras snown.
Notetheseitems:
. Use liquid gasket(P/N 08718- 0001 or 087180003).
. Removethe dirtv oilfrom the sealingsurface.
of the bolt holesto
. Sealthe entirecircumference
preventoil 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.

10x 1.25mm
44 N.m 14.5kgf.m,33 lbl.ftl

www.emanualpro.com

13-71

TransmissionAssembly
Installation
1.

Checkthat the dowel pins are installedin the clutch


housing.

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.

Apply greaseto the releasefork and releasebearing.

6.

Installthe transmissionmountingboltsand the rear


enginemountingbolts.

{P/N 08798- 90021

{P/N 08798- 9002)


0.{ - 1.0g
{0.0'l- 0.04ozl

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
?

Installthe releasebearing,releasefork, and release


fork boot to the clutchhousing.
Installthe startermotor and hoseclamp.
HOSE

10x 1.25mm
4{ N'm (4.5 kgf.m,
32 tbf.ftl

13-72

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Risethe transmission,then installthe transmission


mount bracketand transmissionmount.
T o r q u et h e m o u n t i n g b o l t s a n d n u t s i n t h e
sequenceshown.
. Checkthat the bushingare not twistedor offset.
O . @ : 1 2x 1 . 2 5m m
64 N.m (6.5 kgf.m, 47 lbf'ft)
Temporarytightening
O:
1 2x 1 . 2 5m m
@:
74 N.m (7.5kgf'm,54lbf.ft)

8.

Installtheright front mounvbracket.


12 x 1.25mm
64 N.m (6.5 kgf'm,
47 tbf.ftl
Replace.

10. Pourtransmissionfluid of 1 literfrom the driveshaft


insertedhole.
11. lnstallthe intermediateshaft {seesection18).While
installingthe intermediateshaft in the differential.
be sure not to allow dust and other foreignparticles
to enterthe transmission.

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.

Installthe exhaustpipe A, then connectthe heated


oxygensensor(HO2S)connector.

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.

1 4 . Installthe right damperfork bolt.


1 5 . Installthe propellershaft to the transferassembly
by aligningthe referencemarks.

'17.

Installthe guard bar and the splash shield.

REFERENCEMARKS

E x 1.25mr'|

32 N.m 13.3kst m, 2a lbf.ftl

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

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TRANSFER

1 8 . Refillthe transmissionfluid (seepage 13-3)

21, Installthe cablebracketfrom the clutchhousing.

1 9 . Installthe four uppertransmissionmountingbolts.

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

20. Connectthe vehiclespeedsensor(VSS)connector.

SELECT
CABLE

22. lnstallthe shift cableand selectcableto the levers,


then installplasticwashers,steelwashers,and cotter prns,
)a

------------,-

Connectthe back-up light switch connector.and


installthe wire harnessclamP.
6x1.0mm
9.8N.m{1.0kgf.m,

VSS CONNECTOR

HARNESSCLAMP

(cont'd)

www.emanualpro.com

13-75

TransmissionAssembly
(cont'dl
Installation
24. Connectthe startercablesand transmissionground
caore.

26. Turn the breathercap so that the "F" mark pointsat


the right side of the vehicleas shown.

6x1.0mm
9.8 N.m (1.0kg{.m,
7.2 tbt.ttl

TRANSMISSION
GROUND
CABLE

Apply greaseto the push rod on the slavecylinder,


then installthe slavecylinderand clutchhosebracket,

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),

NOTE:Use only SuperHigh Temp Urea Grease


{P/N08798- 9002).

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

29. Checkthe levelof the transmissionf luid.


30. Checkthe clutchoperation.
31. Shift the transmissionand checkfor smooth operation.
32. Checkthe front wheelalignment(seesectionl8).

6x1.0mm
9.8 N.m {1.0kgf.m,
7.2 rbf.ftt

_G1

(P/N 08798- 9002)

13-76

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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

www.emanualpro.com

\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)

www.emanualpro.com

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

Reverse;reverseselectorengagedwith countershaftreversegear and 4th clutch locked.

E NEUTRAL

Allclutches released.

('97- sB)
Ell DRrvE
('ss- oo)
E DRrvE
(1stthrough
4th)

Generaldriving;startsoff in 1st,shifts automaticallyto 2nd, 3rd, then 4th, dependingon vehiclespeed


and throftle position.Downshiftsthrough 3rd,2nd, and lst on decelerationto stop.
The lock-upmechanismoperates;n3rd and 4th gear.

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)

Startingis possibleonly in @ and @ positions.usinga slide-type.neutral-safety


switch.
Automatic Transaxle(A/T) Gear Position Indicator
This indicatorin the instrumentpanelshowswhich gear has beenselected.
Transler Mochanism {4WD}
The transfermechanismconsistsof the transfershaftdrivegear.the transfershaft.the transferdrivegear,the transferdriven gear shaft,and the companionflange,The transfermechanismassemblyis on the rearside ot the transmission.
beside
the differential.
The transfershaftdrivegearon the final drivengeardrivesthe transfershaftdrivenqear.poweris transmitted to the reardifferentialvia the transfershaftand the Drooellershaft.
Clutches
The four-speedautomatictransmissionuses hydraulically-actuated
clutchesto engageor disengagethe transmissiongears.
When the hydraulicpressureis introducedinto the clutch drum, the clutch piston moves.This pressesthe friction discs and
steel platestogether,lockingthem so they don't slip. Power is then transmiftedthrough the engagedclutch pack to its hu$
mountedgear.When hydraulicpressureis bled from the clutchpack,the piston releasesthe friction discsand steelplates,and
they are free to slide pasteachother.This allowsthe gearto spin independentlyon its shaft,transmittingno power.
lst Clutch
The 1stclutchengages/disengages
lst gear,and is locatedat the end ofthe mainshaft,just behindthe end cover.
The 1stclutchis suppliedhydraulicpressureby its ATFfeed pipewithin the mainshaft.
lst-hold Clutch
The 1st-holdclutchengages/disengages
1st-holdor E position,and is locatedat the middleof the sub-shaft.The 1st-hold
clutchis suppliedhydraulicpressureby its ATF feed pipewithin the sub-shaft.
2nd Clutch
The znd ciutchengages/disengages
2nd gear,and is locatedat the middleof the mainshaft.The 2nd clutchis joined backto-backto the 4th clutch.The 2nd clutchis suppliedhydraulicpressurethroughthe mainshaftby a circuitconnectedto the
internalhydrauliccircuit.

14-4

www.emanualpro.com

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.
www.emanualpro.com

LOCKINGCONDITION

The sprags engage/


disengage outside
and inside of the

OVER.RIOING
LOCKINGSPEEDCONOITION

14-5,

Description
PowerFlow

*N
E
E
N
1ST

Fi

2ND

or

3RD

4TH

tr

TOROUE

1ST.

1STGEAR 2ND GEAR 3RDGEAR

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)

www.emanualpro.com

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).

NOTE;The illustrationshowsthe 4WDautomatictransmissjon;


powerflow ot the 2WDautomatictransmissionis identical to the 4WDexceptfor partsrelatedto the transferassembly.
TOROUE
CONVERTER

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

2nd cesr (8, E. E, or E positionl


1. Hydraulicpressureis appliedto the 2nd clutch,which rotatestogetherwith the mainshaft,and the mainshaft2nd gear
rotales.
2. Power is transmitted to the countershaft2nd gear, which drives the countershaft
3. power is transmittedto the final drive gear,which drivesthefinald rivengearand the transfershaftdrive gear (4WD)
4. The transfershaftdrive gear drivesthe transfershaftand the transferdrivengearshaft(4WD).
NOTE:
. Hvdraulicpressureis also appliedto the 1stclutch,but sincethe rotationspeedof 2nd gear exceedsthat of lst gear.
powerfrom 1stgear is cut off at the one-wayclutch.
. The illustrationshowsthe 4WD automatictransmission;power flow of the 2WD automatictransmissionis identical
to the 4WD exceptfor parts relatedto the transfer assembly.
CLUICH

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

4th Goar (E or D positionl


1. Hydraulicpressureis appliedto the 4th clutch,which rotatestogetherwith the mainshaft,and the mainshaft4th gear
rotates,
2. Poweris transmittedto the countershaft4th gear,which drivesthe countershaft.
3. Poweris transmiftedto the f inal d rive gear,which drivesthe finaI drivengearand the transfershaftdrive gear (4WD).
4. The transfershaftdrive gear drivesthe transfershaftand the transferdrivengearshaft {4WD).
NOTE:
. Hydraulicpressureis also appliedto the 1stclutch,but sincethe rotationspeedof 4th gear exceedsthat of 1stgear,
powerfrom 1stgear is cut off at the one-wayclutch,
. The illustrationshowsthe 4WOautomatictransmission;power flow of the 2WD automatictransmissionis identical
to the 4WD except for parts relatedto the transfer assembly.
ilTH GEAR

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

Throttl Poshion Sensor


Signal

VehicleSp.ed Sensor
Signal
PGM.FI
Control Sy3t6m

EnginoCoolantTampereture
SonsorSignrl

ServiceCheckconnector

A/T Control Sy3tem


INTERLOCK
CONTROLUNIT

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

-D! Indicator Light

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

Service Chck Connectol

A/T Control Svstem


INTERLOCK
CONTROLUNIT

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

Shift Control Solenoid


Valve A

Shift Control Solonoid


Valve B

'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

Judgemont ot Controlling Aroa


Driving Rcsisl.nce

.
.
.
.

14-14

www.emanualpro.com

Normal Modo {Flrt ro.d mode}


AscendingMode
DeacendingMode
DecelerationMode

AscendingControl {37 Modol}


When the PCMdeterminesthat the vehicleis climbinga hill in E] and E positions,the systemextendsthe engagement
area of 2nd gar and 3rd gear to preventthe transmissionfrom frequentlyshifting between2nd and 3rd gears,and
between 3rd and 4th gears,so the vehicle can run smooth and have more power when needed.
NOTE:
. Shift schedulesstored in ths PCM between 2nd and 3rd gears, and between 3rd and 4th gears. enable the PCM'sfuzzy
logicto automaticallyselectthe most suitablegearaccordingto the magnitudeof 8 gradient.
t Fuzzylogic is a form of artificialintslligencethat lets computersrespondto changingconditionsmuch like a human
mind would.
2ND- 3RD

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

AscondingConirol ('98 - 00 Mod.ls)


When the PCMdeterminesthat the vohicleis climbinga hill in E] and E positions('98 model),and in E] position('9900 models),the system extendsthe engagementsrea of 2nd gear and 3rd gear to prevent the transmissionfrom frequently shifting between 2nd and 3rd gears, and between 3rd and 4th gears, so the vehicle can run smooth and have more
power when needed.
NOTE: Shift schedulssstored in the PCM between2nd and 3rd gears, and between3rd and 4th gears,enable to selsct the
most suitablegear accordingto th6 magnitudeof a gradint.
2ND + 3RD 3RD+ 4TH

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

Circuil Diagram and Terminal Locations-'gg- 00 Models

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

PCM Connclor Tehrial Loaabm

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

Main Valve Sody


The main valve body housesthe manualvalve,the 1-2shift valve.the 2nd orificecontrolvalve.the CPBvalve,the modulator valve.the servo controlvalve.and the reliefvalve.The primaryfunctionsof the main valve body are to switchfluid
pressureon and off, and to controlthe hydraulicpressuregoing to the hydrauliccontrolsystem.
CP8 VALVE

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

Stator ReactionHydraulic PressursControl


in hydraulicpressureaccordingto torqueare performedby the regulatorvalve usingstatortorque reaction.The
Increases
statorshaft is splinedto the stator in the torque converter,and its arm end contactsthe regulatorspring cap When the
or climbing(TorqueConverterRange),statortorque reactionactson the statorshaft,and the stator
vehicleis accelerating
pushes
springcap in the directionof the arrow in proportionto the reaction.The statorreactionspring
regulator
the
arm
and the regulatorvalve movesto increasethe line pressure.Line pressurereachesits maximum when the
compresses,
statortorque reactionreachesits maximum.
TOROUECONVERTER
VALVE
REGULATON

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

Distribution ol Hydraulic Pressure


. RegulatorValve
-"- TorqueConverterPressure
LLubricationPressure
I
To regulateLinePressure
.

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

E] or E Position ('97 - 98 Models), and D Position ('99 - 00 Modelsl


1.

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

The lock-upsystemcontrolsthe rangeof lock-upsccording to lock-upcontrol solenoidvalvesA and B, and ths


linearsolenoid.When lock-upcontrol solenoidvalvesA
and B activate.modulator pressurechanges.Lock-up
controlsolenoidvalvesA and B are mountedon the outs i d e o f t h e t o r q u e c o n v e r t e rh o u s i n g ,a n d t h e l i n e a r
solenoidis mountedon the transmissionhousing.They
are controlledbv the PCM.
The table belowshowsthe lock-upconditionsfor lock-up
controlsolenoidvalvesand linearsolenoidpressure.
Lock-upConirol
Solenoid valve

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

The power flows by way of:


Engine

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

NOTE:When used,"left" and "right" indicatesdirection


on the hydrauliccircuit.

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

Power supply system


With ignitionswitchON (ll):Batteryvoltage
(under-hoodFuse44 via main relav) With ignitionswitchOFF:0 V

422

Description

MeasuringConditions/TerminalVohage

Ground
Ground

424

IGP2

Power supply system


With ignitionswitchON (ll):Batteryvoltage
(under-hood
Fuse44via main relav) With ignitionswitchOFF:0 V

FCM CONNECTORB (25P)

Description

Terminal Number

Signal

B1

LSM

Linearsolenoidpowersupply
negativeelectrode

lgnitionswitchON (ll):Pulsingsigna

82

LSP

Linearsolenoidpower supply
positive electrode

lgnitionswitchON (lll: Pulsingsigna

B3

SHA

Shift controlsolenoidvalveA
control

In @, @ position,in 2nd and 3rd gear in E,


E position:Batteryvoltage
In 1stgear in E. F! position,in 4th gear in E
position:0 V

B4

LCB

Lock-upcontrolsolenoidvalve B
control

With full lock-up:Batteryvoltage


With half lock-up:Pulsingsignal
With no lock-up:0 V

B5

LCA

Lock-upcontrolsolenoidvalveA
control

When lock-upis ON: Bafteryvoltage


With no lock-up:0 V

86 to 87
B8
89 to 810

14-48

www.emanualpro.com

Measuring Conditions/TerminalVohage

Not used

ATPD3

,VT gear position switch E position signalinput


Not used

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

Ay'Tgear position switch E


positionsignalinput

I n E p o s i t i o nO; V
In otherthan E position:Batteryvoltage

817

ATP2

Ay'Tgear position switch E position signalinput

InEposition:0V
In otherthan E position:Batteryvoltage

B18

ATP 1

A/T gear positionswitchEl posit i o n s i g n a il n p u t

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

A/T gear position switch iql position signalinput

I n E p o s i t i o n0: V
In other than lgalposition: Bafteryvoltage

825

ATP NP

Ay'Tgear positionswitchE and


N positionsignalsinput

0V
In E andE positions:
V
Inotherthan
@ andffi positions:5

8 1 9t o 8 2 1

B22

Description

voltage
MeasuringConditions/Terminal

TerminalNumbel

In E, E position,in 1stand 2nd gear in -q,


Er position:Batteryvoltage
In B position,in 3rd gear in qd, q:l,inatn
gear in D. position:0 V
When ignitionswitchis ON (ll),brakepedal
deDressed
and accelerator
oedalreleased:0V
When ignitionswitchis first turnedON (ll):6 V
or more for tlvo seconds
In lDllposition:6V or more

Not used

PCMCONNECTOR
C {31PI
TerminalNumber

c10

Signal

Description

Measuring Conditions/TerminalVoltage

SCS

Servicechecksignal

With ignitionswitchON (ll) and servicecheck


connectoropen: 5 V
With ignitionswitchON (ll) and servicecheck
connectorconnectedwith specialtool: 0 V

VBU

Back-uppower system
(under-hoodFuse47)

Alwaysbatteryvoltage

PCM CONNECTORD II6PI


Terminal Number

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

l ' l ' I'

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

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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

NOTE:819 and C3terminals


are appliedto'99 - 00 models.

o (16Pt

T6rminal Number

Signal

A5

CRS

Downshiftsignalinput from
cruisecontrolunit

Whencruisecontrolis used;Pulsingsignal

A10

scs

Timing and adjustmentservice


checksignal(5 V from PCM)

With ignitionswitchON (ll)and servicecheck


connectoropen:5 V
With ignitionswitchON (ll) and servicecheck
connectorjumpedwith specialtool: 0 V

A14
('98 model)

D4 IND

D4 indicatorlight control
{Voltagefrom PCMturns D4 light

When ignitionswitchis firstturnedON (ll):


Batteryvoltage for two seconds
In E position: Batteryvoltage

Description

oN)
A14
('99- 00 models)

D IND

D indicatorlight control
(Voltagefrom PCMturns D light

oN)
428

ILU

A.32

STOPSW

MeasuringConditions/TerminalVoltage

When ignitionswitchis firstturnedON (ll):


Bafteryvoltage for two seconds
ln E position:Batteryvoltage

Interlockcontrol
(Voltagefrom PCM)

When ignitionswitchON {ll),brakepedal


pedalreleased:
depressed,
and accelerator
Batteryvoltage

Brakeswitchsignalinput

Brakepedalpressed;Batteryvoltage
Brakepedalreleased:0 V

FCM CONNECTORB I25P}


Terminal Number

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

With ignitionswitchON (ll):Bafteryvoltage


With ignitionswitchOFF:0 V

Linearsolenoidpower supply
positiveelectrode

With ignitionswitchON (ll):Pulsingsignal

Over-Drive(O/D)OFFindicator
light control

When ignitionswitchis first turnedON (ll):


0 V for two seconds
O/DOFFindicatorlight ON:0 V
O/DOFFindicatorlight OFF:Batteryvoltage

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

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Description

Always battery voltage

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)

With ignitionswitchON (ll);Batteryvoltage


With ignitionswitchOFF:0 V

ATP R

Ay'Tgear position switch


B positioninput

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

Ay'Tgear position switch


E positioninput

In E position:
0V
voltage
Baftery
In otherthanE position:

O/DSW

Over-Drive(O/D)switch signal
input

When Over-Drive{O/D)is OFF(O/DOFF


indicatorlight is ON):0 V
When Over-Drive{O/D)is ON {O/DOFF
indicatorlight is oFF):Batteryvoltage

D9

ATP D4

A/f gear position switch


E positioninput

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

A,/Tgear position switch E and


El positionsinput

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

A/T gear position switch


El positioninput
A,/Tgear position switch
E positioninput

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

Checkingths DiagnosticTrouble Code (DTC)


with an O8D ll Scan tool or Honda PGM Tsster
Whenthe PCMsensesan abnormalityin the input or outputsystems,the El ('97- 98) or E ('99- O0)indicatorlight in the
gaugeassmblywill blink.When the 16PData Link Connector(DLC){locatedunderthe dash on the passenger'sside) is
connectedto the OBD ll ScanTool or Honda PGM Testeras shown, the scan tool or testerwill indicatethe Diagnostic
TroubleCode(DTC)when the ignitionswitchis turnedON(ll).

DATA LINKCONNECTOR
{16PI

[ -=.r,
ili

,i

/i,
v,.,
i

HONDAPGMTESTER
ol
OBDII SCANTOOL

lf the E or E indicatorlight or the MIL has been reportedon, or if a driveabilityproblemis suspected,


follow this procedure:
1.

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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Checkingthe DiagnosticTrouble Code IDTCI


with the ServicCheckConnestoland SpecialTool
('97- 98) or E (gS - OO)indicatorlight in the
when the PcM sensesan abnormalityin the input or outputsystems'the E
gaugeassemblymay blink.
the specialtool
When the ServiceCheckConnector(2P)(locatedunderthe dash on the passengerside)is connectedwith
is turned ON
(DTC)
switch
the
ignition
when
Trouble
Code
as shown,the E or E indicatorlight will blinkthe Diagnostic
{ ).
(2P)to the specialtool
when the E or E indicatorlight has beenreponedon, connectthe servicecheckconnector
light'
Thenturn ON (ll)the ignitionswitchand observethe E or E indicator

.AUGE
AssEMaLY

'99 - O0models

$1,"^f:tT"'ff,

SCSSERVICECONNECTOR
07PAz- (x!l0100

'97 - 98 models

long and short


codes 1 through9 are indicatedby individualshort blinks.codes 1o and aboveare indicatedby a seriesof
After detercode.
the
to
determine
together
blinks
short
long
and
Add
the
blinks.
blinks.one long blink equals1o short
'97 model,
for
the
pages
and
14-61
14-60
on
chart
symptom-to-component
system
electrical
refer
to
the
code,
miningthe
'98- 00 models.
and pages14-62and 14-63tor the

Short blinl lonc.)

Sr. DTC1

S.. DTC2
Long blink

Shori blink! {fiv. timt

Sc. DTC 15

(cont'd)

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14-57

TroubleshootingProcedures
(cont'dl
L

Removethe kickpanelon the passenger's


side (seesection2O),

2.

Removethe PCM,and turn it over.

KICK PANEL

Inspectthe circuiton the PCMaccordingto the troubleshooting


flowchartwith the specialtools and a digitalmultimeter.
How to Use the BackplobeSet
Connectthe backprobeadaptersto the stackingpatchcords,and connectthe cordsto a multimeter.Usingthe wire
insulationas a guide for the contouredtip of the backprobeadapter,gentlyslidethe tip into the connectorfrom the
wire side until it comesin contactwith the terminalend of the wire.

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.

the OBD ll ScanTool or HondaPGMTesterfrom the DataLinkConnector(16P),or removethe specialtool


Disconnect
from the ServiceCheckConnector(2P).

4.

Turnthe ignitionswitchON (ll),and set the radio presetsand clocksetting'

5,

To verifythat the problemis repaired.test-drivethe vehiclefor severalminutesat speedsover 30 mph

www.emanualpro.com

(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

A,/Tgear positionswitch(shortto ground)

(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

DTC*:The DTc in parentheses


is the codethe loaindicatorrightindicateswhen the DataLink
Connectoris connectedto the HondapGM Tester.

14-60

www.emanualpro.com

Page

NOTE:When the OBD ll ScanTool or HondaPGMTesterindicateDTC(s)for the automatictransmissioncontrolsystem'


code P07oomeansa detectionof some automatictransmisthe scantool or testerindicatescode P0700simultaneously.
sion problemin the PGM-Flcontrolsystem
lf the self-diagnostic
E indicatorlight does not blink,performan inspectionaccordingto the table below.
Symptom
E indicatorlight is on constantly(not blinking)wheneverthe ignition
switchis ON (ll).
E indicatorlight does not come on for two secondsafterignition
switchis first turnedON (ll).
Shift levercannotbe movedfrom @ positionwith the brakepedal
Dressed,
lgnitionkey cannotbe movedfrom ACC(l) positionto LOCK{0) posi
tion with the shift leverin E position.

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

A,/Tgear positionswitch(shonto grounol

(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

DTC*;The DTCin the parentheses


is the codethe E or E indicatorlight indicateswhen the DataLink
Connectoris connectedto the HondapGM Tester.

14-62

www.emanualpro.com

for the automatictransmissioncontrolsystem,


NOTE:When the OBD ll ScanTool or HondaPGMTesterindicateDTC(S)
means
a detectionof some automatictransmisP0700
Code
P0700
simultaneously.
code
indicates
the scantool or tester
sion problemin the PGM-Flcontrolsystem.
lf the self-diagnostic
E or E indicatorlight does not blink,performan inspectionaccordingto the table below.
Symptom
E or E indicatorlight does not come on for two secondsafterignition
switchis first turnedON (ll).
E or E] indicatorlight is on constantly(not blinking)wheneverthe
ignitionswitchis oN {ll).
Shift levercannotbe movedfrom E positionwith the brakepedal
presseo.
lgnitionkey cannotbe movedfrom ACC(l) positionto LOCK(0)position with the shift leverin E position.

Inspection

14-123
14-125
Checkshift locksystem

14-'t26

Checkkey interlocksystem

14-129

O/DOFFindicatorlight does not come on for two secondsafter ignition


switchis first turnedON (ll).('99- 00 models)
The O/DOFFindicatorlight is on constantlywheneverthe ignition
switchis ON (ll).('99- 00 models)
The O/DOFFindicatorlight does not come on eventhoughthe OverDrive(O/Dlswitchis pressedin E position.('99- 00 models)

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

Checkand recordthe freezedata


rn caseit is neededlaterfor problem verification.
lf the Honda PGM
Tester is available:

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.

Did the solenoid pass the test?

The solenoidis OK at this time.


Verify that all connectors in the
circuil are making good contact,

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?

Repairshort to power in the wire


between the 85 terminal and the
lock-upcontrol solenoidvalveA.

Measure Lock-upControl Solenoid Valve A Resistance:


1. Turnthe ignitionswitchOFF.
2. Measure the resistance
betweenthe 85 and A9 or A22

ls the resistance
12 25 ()?

To page14 65

14-64

www.emanualpro.com

Checkfor loose terminal fit in the


PCM connectors, ll necessary,
substitulea known-goodsolenoid
valve assembly or PCM and
recheck,

From page 14-64

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

Reprir short to ground in the wire


between the 85 terrninal and the
lock-uDcontiol solenoidvalveA.

LOCK.UPCONTROLSOLENOID
VALVEA/B ASSEMBLYCONNECTOR

----E-

MeasuroLock-upControl Solenoid Valve A Resistanceat the


solenoid valve Connector:
Measurethe resistancebetween
the No. 2 terminalof the connector and body ground.

lFr]
.=-A LcA IYELI
(nJ
Y

Terminalsideof maleterminals

12- 25 O?
ls the resistance

Check for open in the wire


belwen the 85 teiminal and the
lock-uocontrol solenoidvalve A

Replacethe lock-np control solenoid valve A/B assembly.

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14-65

ElectricalTroubleshooting('97Model)
TroubleshootingFlowchart- Lock-upControlSolenoidValveB
. OBOll ScanTool indicatesCode
P1758.
. Self-diagnosispr- indicatorlight
blink3twice.

Check and record the {reeze data


jn case it is needed later for prob,

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.

Did the code return?

The system is OK at this time.


Verify thet dll connectors in the
circuit are makinggood contact.

PCMCONNECTORS

Checktor a Short to Powerl


1. Turnthe ignitionswitchOFF.
2. Disconnect
the A (32P)and B
( 2 5 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
the 84 and Ag ot A22 tetmi
nals,

Wire sideof femaleterminals


Repairshort to power in tho wire
bstween the 84 terminal and the
lock-upcontrol rolenoid valve B.

MeasureLock-upControl Solenoid Valve B Resistance:


1. Turnthe ignitionswitchOFF.
2. Measure the resistance
b e t w e e nt h e 8 4 a n d A g o r
A22terminals.

l s t h e r e s i s t a n c e1 2 2 5 O ?

To page14-67

14-66

www.emanualpro.com

Checktor looseterminal tit in the


PCM connectors, It necessary,
subslitute a known-good solenoid valve assemblyo. PCM and
rechck.

Frompage14 66

Check Lock-up Control Solenoid


Valve B lor a Short Circuit:
1. Disconnectthe 2P connector
from the lock-upcontrolsole
noid valveA/8 assembly.
2. Checkfor continuitybetween
the 84 and A9 or A22 lermi_
nals-

PCMCONNECTORS

Wiresideof femaleterminals

Repairshort to ground in the wire


between the 84 lerminal and the
lock-upconlrol solenoidvalve B.

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)

Check lor open in the wire


bctween the 84 terminal and the
lock-upcontrol solenoidvolva B.

Replacethe lock-up conttol solenoid valve A/B ass6mbly.

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14-67

ElectricalTroubleshooting{'97Model}
TroubfeshootingFlowchart- AIT GearPositionSwitch (Short)
. OBOll ScanTool indicatsCode
P1705.
' Selt-diagnosisp1- indicatortight
blinb Iive times.

Checkand record the freeze data


in caseit is neededlaterfor problem verification.

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.

Observethe A/T Gar Po3ition


Indicator:
1. Turnthe ignitionswitchON lll).
2. Observethe A./Tgear position
i n d i c a t o r ,a n d s h i l t t o e a c h
positionseparately.

Doesany indicatorstayon
when the shift leveris not in
that position?

The system is OK .t this time.


Ch6ck ihe wii6 harnessfor dam490,

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.

Check tor 3hort in the wire


betwaenthe 816torminal and tho
A/T gear pGilion switch or A/T
gsar posiiion indicator. ff wire is
OK, checkfor 10036torminal flt in
lhe PICMconnectoB. It necessary,
substitute a known-9ood PCM
and recheck.

Wire sideof femaleterminals

MeasureATP NP Voltage:
1. Shiftto all positionsotherthan

NorE.
2. Measurethe vohagebetween
lhe 825 and Ag or A22 terminals.

ls there battery vohage?

To page14-69

14-6 8

www.emanualpro.com

Chock for ahort in the wire


betwentho 825 torminal end the
A/T 96.r pGition indicstor, or a
sho.t in tha wiro! btween the
A/T gear po3ition indicator and
the A/T gar position lwitch. lf
wircs ar OK, ch6ck for loos terminal fit in the PCMconnectors.It
nece3sary,substitute a knowngood PCMand recheck.

ATP NP {LT GRNI

Frompage14-68

MeasureATP D4 Voltage:
1. Shiftto all positionsotherthan

Eil

2. [/leasurethe voltage between


the 824 and Ag or A22 terminals.

ls thereapprox.5 V?

MasureATP D3 Voltage:
L Shiftto all positionsotherthan

Check tor short in the wire


betweenthe 824 terminal and the
A/T geai position indicator. or a
3hort in the wir6s between the
A/T gear position indicttor and
the A/T gear position switch. lf
wires are OK, checklor loose ter'
minal fit in the PCMconneclo.s.lf
necessary,substitute a known'
good PrCMand recheck.

Wire side of female terminals

tr.

2. Measurethe voltagebetween
the 88 and A9 or A22 termi
nats.

ls there bafteryvoltage?

Check for short in the wi.e


between the 88 torminal and the
A/T gear position switch or A/T
gear position indicator. lf wire i3
OK,checklor looseterminaltit in
the PCM connectors. lf necessarY,3ubslitute a known'good
PCMand recheck.

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?

Check lor short in the wire


betw.en the 818 torminal and
the A/T gear position switch or
A/T gear position indicator. lI
wiro is OK. check for loose terminal fii in the PCM connectorc. lf
necessary.substitute a known'
good PCMand recheck.

Checkfor loose terminalfit in the


PCM connectors, lf neces3aty,
substitute e known-good PCM
end rocheck.

www.emanualpro.com

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

Checkand recordthe freezedata


in caseit is neededlaterfor problem verilication.

Test the A,/Tgear position switch


{ s e ep a g e1 4 1 3 9 ) .

Measu.eATP R Voltage:
'1. Turnthe ignition
switchON (ll).
2. Shiftto E position.
3. Measurethe voltagebetween
the 816 and Ag or A22 terminals.

Repeir opn in the wire botween


the 816trminaland the A/T g.r
po3itionswitch.

Wire sideot temaleterminals

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,

Ropai. opcn in tho wiro betwoen


the B24torminal .nd the A/T gcar
Dosition switch.

To page14-71

14-70

www.emanualpro.com

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

Repairopen in the wirg bstween


the 88 tolminal and tho A/l gear
oo3ition 3witch.

MsasureATP2Volttg6:
'1. Shiftto position.
E
2. Measurethe voltage between
the 817 and A9 or A22 termi'
nals.

Repairopen in lhe wire between


the 817 terminaland tho A/T
gear position switch.

MoasureATP1Voltage:
1. Shiftto A position.
2. Measurethe voltagebetween
the 818 and Ag or A22 terminats,

Rpairopon in the wiro between


the 818 terminll and the A/T
goar poshion switch.

Checktor looso terminal fit in the


PCM connectors. lf necossarY,
substitute a known-good PCM
and rechock.

www.emanualpro.com

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

Checkand record the freezedata


in caseit is neededlaterfor prob
lem verification.
lf the Honda PGM
Tester is available:

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.

Did the solenoidpassthe test?

The solnoid is OK at this time.


Verify that all connectors in the
circuit are making good contact.

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.

Wire sideof femaletermin6ls


Repairshort to power in the wire
between the 83 terminal and the
shift control solenoid valve A.

Measure Shift Control Solenoid


Valve A Resistanco:
1. Turn the ignitionswitchOFF.
2, Measure the resistance
betweenthe 83 and A9 or A22
termrnals,

ls the resistance
12 25 {)?

To page l4-73

www.emanualpro.com

14-72

Checktor loose terminal tit in the


PCM connectors, lf necessaay,
subslituie e known-good solenoid valve assemblvor PCM and
rechck.

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.

Wire sideof femaleterminals

Repai.short to ground in the wire


belwen th6 83 terminal and the
shift cont.ol solenoidvalveA.

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?

Check lor ooen in the wire


between the 83 terminal and the
shift control solnoidvalve A.

Replace the shift control solenoid


valve A/B assemblv.

www.emanualpro.com

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

Checkand rcord the lreere data


in case it is neededlater for prob
lem verilication.
lf the HondaPGM
Tsteris available:
Test solenoid valve B with the
Honda PGM Tester in the FLrnc
tion test mode.

Did the solenoidDassthe test?

The 3olonoid is OK at this time.


Verifv that all connoctors in the
circuit are making good contlct.

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.

M.6sure Shift Control Solonoid


Valve B Reaistanco:
1. Turnthe ignitionswitchOFF.
2. Measure the rsistance
b e t w e e nt h e 8 1 1 a n d A 9 o r
A22terminals.

ls the resistance
12- 25 O?

To page14-75

www.emanualpro.com

14-74

Checl lor loosc terminal fil in the


PCM connactors. It nocessarv,
substitute a known-good aolenoid vllvo asssmbly or PCM and
r6chsck,

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

Ropairshort to ground in the wire


b64wntho 811 torminal and lhg
shift control solenoidvalvo B.
SHIFTCONTROLSOLENOID
VALVE A/B ASSEi'BLY CONNECTOR

Meesure Shift Control Solenoid


Valve B Rosistanceat lh Solenoid Vrlve Connector:
Measurethe resistancebetween
the No. 2 terminalol the connec
tor and bodyground.

ti;Tll
I sH B |GRN/W{T|

oY
I

Terminalsideof maleterminals

ls the resistance
12- 25 O?

Check tor open in the wire


bdtweonthe 811 torminal and the
shift control solnoidvalv6 B.

Reolacethe shift control solenoid


valve A/B asJembly,

www.emanualpro.com

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

Checkand recordthe freezedata


in case it is neededlater for prob
lem verification.
lf the Honda PGM
Tester is available:

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?

neinstall or roDlacoand recheck.


SPEEDSENSOR
COUNTERSHAFT
CONNECTOR

MeasuroCountoBhaftSpeedSensor Relbtance at the Sensor Connector:


1. Disconnectthe 2P connector
from the countershaftspeed
sensorconnector.
2. Measurethe resistance
of the
countershaft
speedsensor.

ll-'T,ll
-rT
ral

YL__lI

Terminalsideof maleterminals
ls the resistance400- 600 o?

To page14-77

www.emanualpro.com

14-76

B I25PI
PCMCONNECTOR

Chck CounteGh!ft Spocd Sonsoi


for a Short Cirruit:
1 . D i s c o n n e ctth e B 1 2 5 P c) o n '
nectorlrom the PCM.
2. Checkfor continuity botween
the body ground and the B23
t e r m i n a la n d 8 2 2 t e r mi n aI
individually.
Repair short in tho wirgs btwoen
tho 823 ,nd 822 te.minals and
thc countaBhaft spd senso..

Wire sideof lemaleterminals

Mersuro Countorrhrtt Spoed Sonsor qrcuit tor an Open:


'1.Connect the countershaft
speedsensor2Pconnector,
2, Measure the resistance
betweenthe 823 and 822 ter
mrnals.

ls the resistance400- 600 0?

Rapair loor t.rminll or opon in


tho wircs betwoon tho 823 .nd
822 terminrl! .nd th. countaF
shaft specd san3or.

Checkfor loo3eterminsl fit in the


PCM connecto13.It necess!ry,
sub3titulg s known-good PCM
and rochock.

www.emanualpro.com

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

Checkand record the freeze data


in case it is neededlater {or prob,
lem verification.

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,

Checkthe mainshaftand countershaft speed sensor installation,


and checkthesensorsfor damage.

Are the mainshaftand countershaft speedsensorsinstalled


properly,and not damaged?

Reingtallor reolaceand recheck.

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

Check MainahaftSpeed Sensor


tor a Short Circuit:
1. Disconnect
the B (25P)connector lrom the PCM.
2. Checkfor continuitybetlveen
bodygroundand 815terminal
and the 814 terminalindividu-

Wire side of female terminals

ReDairshort in the wir6 bt\ reen


the 815 and 814 torminals and
the mainsh!ft sped sensor.

To pagel4-79

14-78

www.emanualpro.com

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

ls the resistance400- 600 O?

Run the Electricrl Troubloshooting


Flowchs tor codo m72O l9l.
Chockfor loo3etorminal fh in the
PCM conn6cto.s. It necessarY,
substitute a known-good PCM
and rochgck.
MAINSHAFTSPEEDSENSOR
CONNECTOR

CheckNM Wiro Continuity:


1. Disconnectthe 2P connector
from the mainshaftspeedsensor connector.
2. Checkfor continuitybetween
t h e 8 1 5t e r m i n a l a ntdh e N o . 2
terminal of the mainshaft
speeosensorconneoor.

Ropairopen in the wir6 betwon


the 815 terminal and the mainshaft sDood$nsoa.

CheckNMSG Wire Continuity:


Checkfor continuity between the
814 terminaland the No. 1 terminal of the mainshaftspeedsensor
connector.

Rpai. opon in the wi.o between


the Bltl terminal and tho main'
3haft sDedsensoa,

Ch.ck lor loos. t6rminallit in the


PCM connecto13,lf neca3sary,
substitute a known-good PCM
and rochock.

www.emanualpro.com

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

Checkand record the freezedata


in case it is neededlater for prob
lem verification.

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.

Measure Linear Solenoid R*istance:


1. Connectthe linearsolenoid2P
connector.
2. Measure the resistance
betweenthe 81 and 82 termi
nals,

ls the resistance
about5.00?

Ropair loos terminal or op6n in


the wiles between th 81 and 82
l6rminals and the linear solenoid.

Chocklor loose tarminalfit in the


PCM connectors. lf necosaarv,
subsiituto a known-good PCM
and recheck.

www.emanualpro.com

14-81

ElectricalTroubleshooting('97Model)
TroubleshootingFlowchart- Lock-upControlSystem
. OBD ll ScanTool indicrt6 Cod6
P0740.
. Self-diagno3bE indicatorlight
indicatos Codc 40.

PossibloCause
Faulty Lock-upcontrol sy3t6m

Checkand recordthe freezedata


in caseit is neededlaterlor problem verification

Checktor Another Code:


C h e c kw h e t h e rt h e O B D l l s c a n
t o o l o r t h e E i n d i c a t o rl i g h t
indicatesanothercode.

Doesthe OBDll scantool or


the E indicatorlight indicate
anothercode?

Perlorm the Troubleshooting


Flowchart lor th indicatd
Codo{s).Rochecktor code P0740
{ilol after troubl$hooting.
NOTE:Do not continuewith this troubleshootinguntil the causesof any other
DTCShave beencorrected.

Tesl Line Pressure:


M e a s u r et h e l i n e p r e s s u r e( s e e
p a g e1 4 - 1 6a1n d 1 4 - 1 6 2 ) .

ls the line pressurewithinthe


servicelimit?

* 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}.

Test lst, 2nd, 3rd, and 4th Clutch


Pressure:
Measurethe 1st,2nd,3rd,and 4th
clutch pressure(seepage 14161
thru 14''163).

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).

Doesthe OBDll scantool indicate


codePO74O
or doesthe El indica
tor light indicatecode40?

The svstem is OK ai this time.

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).

Does the OBD ll scan tool


i n d i c a t e c o d e P 0 7 4 0o r d o e s
the E indicator light indi
cate code 40?

Replacethe transmission and


torque convertorassembly.

www.emanualpro.com

The svsteo is OK at this tim.

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..

Check and record the freeze data


in case it is needed later for problem verification.

Checktor Another Code:


C h e c kw h e t h e rt h e O B D l l s c a n
t o o l o r t h e P l l i n d i c a t o rl i g h t
indicatesanothercode,

Doesthe OBDll scantool or


the E indicatorlight indicateanothercode?

Test lst. 2nd, 3rd. and 4th Clutch


Pressure:
M e a s u r et h e 1 s t ,2 n d , 3 r d , a n d
4th clutchpressure(seepage 141 6 1t h r u 1 4 - 1 6 3 ) .

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

ReplaceShift Control Solenoid


vslve Assemblyand Recheck:
1. Replacethe shift control
solenoidvalve A/B assembly
(seepage'14136).
2. Turn the ignitionswitch OFF
and resetthe PCMmemoryby
removingthe BACKUP (7.5A)
fuse in the under-hoodfuse/
relaybox for more than 10
seconds.
3 . D r i v et h e v e h i c l ea t o v e r 1 2
mph (20km/h)in 1st,2nd,3rd,
and 4th qear for more than 30
secondsin E position.
for codeP0730(41).
4. Recheck

Doesthe OBDll scantool


indicatecodeP0730or does
the E indicatorlight indi
catecode41?

The svstem is OK at this time.

ReplaceLinea. Solenoid Assmbly


and Recheck:
1 . R e p l a c et h e l i n e a r s o l e n o i d
assemblylseepage14-138).
2 . T u r n t h e i g n i t i o ns w i t c hO F F
and resetthe PcM memory by
removingthe BACKUP 17.5A)
fuse in the underhood fuse/
relayboxtor morethan 10sec'
onos.
'12
3 . D r i v et h e v e h i c l ea t o v e r
mph {20km/h)in 1st,2nd,3rd,
and 4th geal for more than 30
secondsin -Daposition.
4. Recheck
for codeP0730(41).

Doesthe OBDllscantool
indicatecode P0730or does
the Di indicatorlightindicatecode 41?

www.emanualpro.com

The syslem is OK at this time.

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

MeasureD4 IND Voltage:


'1. Turnthe ignitionswitchOFF.
2 . Disconnect
the I (25P)connector lrom the PCM.
3. Turnthe ignitionswitchON lll).
4. Measurethe voltagebetween
the 813 terminaland body
grouno,

IGRN/8LKI

Wire sideof temaleterminals


Ropairshort to powor in the wire
betwean tho B13 terminal and
tho gauge assembly.

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.

5. Measurethe voltage between


the 824 terminaland body
ground.

Test the lVT gear position switch


(seepage'14139).

Check lor a short to g.ound in


the wire betwoen tho B2rlte.mi
nal and A/T gear position switch.
It wira i3 OK, substitute a knowngood PCMand rcheck.

www.emanualpro.com

TroubleshootingFlowchart- E IndicatorLight DoesNot ComeOn


The E indicator light doos not
como on whon the ignition switch
is first turned ON {lll. (lt should
come on lor about two aaclnd!.I

Checkthe SorviceCheckConnectori
Make sure the specialtool 1SCS
ServiceConnector)is not connected tothe servicecheckconnector,

ls the specialtool(SCSService
Connectorlconnected
to the servicecheckconnector?

Di3connectthe spccial tool trom


the servica chock connoctor and
rechsck.

chock th. El IndicatorLight:


Shift to E position.

Ch6ckfor looie terminal fit in the


PCM connoctors. ll nocesssry,
sub.titule a known-good PCM
and rechock.
PCM CONNECTORA {32PI

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

Wire sideot temaleterminals

Rpair opon in the wire3 between


the Ag or A22torrninab and G101.
Repairthe body ground (G1011.

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)

Repair open or short in the wire


botwon the A11 and/or A24 terminals, the PGM-FImain relav,
and ih6 fuse box.

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.

CheckD4IND tor a Short Circuit:


Checkfor continuitybetweenthe
813terminaland body ground.

Ropairshort in the wiro between


the 813 lerminal and the gauge
assembly.

Checktor looseterminal frt in the


PCM connector3. Chock the A/T
gear position switch. ll necessary,
substitute a known-good PCM
and recheck.

14-88

www.emanualpro.com

Wire sideof femaleterminals

TroubleshootingFlowchart- InterlockSystem- Shift LockSystem


Shift lever cannot be moved from
E] position with the brake Pdel
preiseo.

ChockBrakeLight Operation:
Pressthe brakepedal.

Are the brakelightsON?

Repsirfauhy brake switch circuit


{seosction231.
PCMCONNECTORS

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

Repair opon in the wi.e be{w.en


the D5 terminal and the br.ke
switd!.
CONTROLUNIT
INTERLOCK
CONNECTOR
I8P)
MeasurILU vohage:
1 . C o n n e c tt h e A { 3 2 P )a n d D
to the PCM.
connectors
116P)
2. Disconnectthe 8P connector
from the interlockcontrol unit
3. Turnthe ignitionswitchON (ll).
4. Measurethe voltage between
the No.7 terminaloftheinter
lockcontrol unit and body
ground with the brake Pedal
pressed,

ls there batteryvoltage?

ILU IWHT/REDI

Chckfor an opon or thon in the


wire Mwoon tho No. 7 terminrl
of the inte ock control unit and
the 812 termin.l of the PcM. ll
the wirs is OK, check tor loo3e
terminal fit in the PCM connec_
to13. ll nece3sary,3ubstitutea
known-good PCM and rechock.

(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.

Chock Shitt Lock Solenoid lor .n


Opon Circuit:
1. Turn the ignitionswitchOFF.
2. Disconnect
the shift locksole
notoconnoctor.
3. Checkfor continuitybetween
the No. 3 terminal of the interlock contrcl unit and the No. 2
terminal ot the shift lock solenoid connector.

Wire sideot femaleterminals

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.

Check Shift Lock Solenoid Operation:


'1.
Connectthe No. 1 terminalof
the shiftlocksolenoidconnector to the battery positive ter
minal. and connectthe No. 2
terminalto the batterynegative terminal.
2. Chockthe shift lock solenoid
operation.

NOTE:Do not connectthe No. 2 terminalto


t h e b a t t e r yp o s i t i v et e r m i n a l o r y o u w i l l
damagethe diode insidethe shift lock solenoid.

SHIFTL@K SOI.ENOID
CONNECTOB
ldir.sily on .olrnoidl

Terminalsidoof maleterminals
Doesthe shift locksolenoid
oprateproperly?

Check tor looso terminal frt in th6


interlock cont.ol unit connectoB.
ll ngcara,lary,sutEtitut a knowngood interlockcontrol unit and
rocheck.

www.emanualpro.com

Replsctho .hift lock solonoid.

TroubleshootingFlowchart- Interlocksystem KeyInterlocksystem


lgnition key cannot be moved
Irom ACC (l) pGition to LOCK(0)
positionwhile Pushingthe ignition kev with the shift lever in lll
posifio;, and the shift lever button rcleased.
IGNITIONSW]TCH6P CONNECTOR
C h e c k K e y I n t e r l o c kS o l e n o i d
Opration:
the ignitionswitch
1. Disconnect
connector(6P).
2. Connectthe No. 4 terminalof
the ignitionswitch6P connector to the battery Positiveter
minal, and connectthe No. 3
terminalto the batterynega
tiveterminal.
3. Checkthe key interlocksole
n o i d o p e r a t i o nA c l i c k i n g
so!nd sho!ld be heard.

Doesthe keyinterlock
solenoidoperateproperly?

Check Key Interlock Switch OPer'


adon:
1. Connectthe No. 5 terminalof
the ignitionswitch connector
to the batteryPositivetermi
nal,and connectthe No 3 ter
minal to the bafterynegative
termrnal,
2 . T u r n t h e i g n i t i o ns w i t c h t o
ACC(l),then pushrt.
3. Checkthe key interlocksole'
n o i d o p e r a t i o n .A c l i c k i n g
sound shouldbe heardwhile
pushingthe ignitionkey.

Doesthe key interlock


solenoidoperateProPerlY?

To page14 92

www.emanualpro.com

KEYLOCKSOL
{WHT/BLU)

ACCPUSHSW (WHT/YELI

Wire sideoI femaleterminals

Faulty koy interlock solenoid.


Replacethe ignition key cylinder/
steedng lock as36mbly

KEYLOCKSOL
(WHT/BLUI

Faulty key inte.lock switch


Replacothe ignition key cylindor/
stoering lock a3r.mblY.

(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

Wire sideof femaleterminals

ls therecontinuity?

Repairshort in the wire between


the No. 1 or No. 5 terminal and
the ignition switch 6P connector.

CheckParkPin Switch ODeration:


Checkfor continuitybetweenthe
No. I terminaland body ground.

ls therecontinuity?

Measu16ATP P Voltage:
1. Turnthe ignitionswitchON lll).
2. Measurethe vohagebetween
the No.6 terminaa
l nd body
ground.

Check tor shori in the wire


betwon the No. 8 terminal ot
the interlock control unit and the
park pin switch. lf wire is OK,
ch6ckthe park pin switch.

Shiftlevermust be in E.

ATP P (BLK/BLU)

R6pei. open in the wire between


the No. 6 irminal and the A/T
gea. position switch.

Checkfor looseterminalfit in the


interlock control unil connectors.
lf necessery,substitute a knowngood interlockcontrol unit and
r6check.

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
.
.
.
'

Dbconnectedlock-up control solenoidvalve A/B assemblYconnector


Short or open in lock-up control solenoid valve A wire
Faulty lock-upcontrol solenoid valve A
Open in vB SOLwire

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.

Test-drivethe vehicle under the


same conditionsthe FreezeData

Did the code return?

Checkfor a Short to Power:


'1. Turnthe ignitionswitchOFF.
the B (25P)and D
2. Disconnect
( 1 6 P )c o n n e c t o r st r o m t h e
PCM,
3. Turnthe ignitionswitchON (ll).
4. Measlre the voltagebetween
the D1 and 820 or 822 terminals,

lntermittent failul.. The system is


OK at this time. Check the fit of
the Din3in all connectorsaffected
by thb code.

A t32Pl
i
I

r rrilt
l,1 I
I

ltDrste,0n,,
2 .t 3 r B ' r ! 5 1 r .

LGl IBRN/BLKI LG2 (BRN/BLKI


Wire sideof femaleterminals
npair short lo power in the wire
betwn the Dl terminal and the
lock-upcontrol solenoidvalve A

Mg.sure Lock-up Control Solenoid


Valve A Rssistance:
1. Turnthe ignitionswitchOFF.
2 . M e a s ur e t h e r e s i s t a n c e
b e t w e e nt h e D 1 a n d 8 2 0 o r
822 terminals.

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

Checktor continuity between the


B20 terminal 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.

Wire sideot femaleterminals


Ropair open in the wire3
btweon tha 820 and 822 terminalsand groundlG101l.

Ch6ck Lock-up Control Solonoid


Valv6 A tor a Short Ci.cuit:
'1. Disconnect
the 2P connector
from the lock up control
solenoidvalveA/B assembly.
2. Checkfor continuitybetween
the Dt and B2Oor 822 te(mi
nals.

a l32Pl

c t3lPl

LGlIARN/ALKI LG2IBRN/BLKI

Ropai.lhort to g.ound in the wire


btwen the Dl terminal and the
lock-upcontrol solonoidvslvg A.

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?

Chsck for open in th wirc


bctwen tho Dl terminal lnd th6
lock-up cont.ol solonoid v.lve A.

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

Wire side of lemalo terminals


Chockfor blown No. 15 (7.5 Al
luse in tho undor-dr.h lusa/lel.Y
box. lf tho fulo i! oK, roprir opn
in the wiro betw6on th. D5 tor'
minal and the und.r_dtah
tuao/rohY box.

Chockfor looto torminrl fit in the


PCM connectoJr. ll nocot3a.Y,
rubstitut. . known-good PCM
and rschock.

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
.
.
.
.

Disconnectedlock-up control solenoidvalve A/8 assemblyconnector


Short or open in lock-upcontrol solenoidvalve B wire
Fauhy lock-upcontrol solenoidvalve B
Open in VB SOL wir

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-

Test-drivethe vehicle under the


same conditionsthe FreezeData

Did the codereturn?

Intermittant tailure.The lystem is


OK at this time. Check the tii ot
tho pin3 in all connectorsathed
by this code.

PCMCONNECTORS

Checkfor a Short to Powr:


1. Turnthe ignitionswitchOFF.
2. Disconnect
the B 125P)and D
( 1 6 P )c o nn e c t o r sl r o m t h e
PCM.
3. Turnthe ignitionswitchON 1ll).
4. Measurethe voltage betlveen
the D3 and 820 or 822 terminals.

LC B {GRN/8LKI

LG1{BRN/BLK}I-G2{BRN/BLK)
Wire sideof femaleterminals

Repairshon to power in the wire


between tho D3 terminal and the
look-upcontrol solenoidvalve B.

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

Wire sideol femaleterminals


Bepair open in the wirea
between the 820 and 822 te.minalsand ground(G1011.

Check Lock-up Control Solenoid


Valve I fo. a Short Circuit:
1. Disconnectthe 2P connector
f r o m t h e l o c k _ pu c o n t r o l
solenoidvalveA,/Bassembly
2. Checkfor continuitybetween
the D3 and 820 or 822 termi
nats.

ls therecontinuity?

A {32P1

Rep.ir short to ground in the wiie


between the D3 terminal and the
lock-uDcontrol solenoidvalve B.

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.

Check for open in the wiro


betwoen the D3 terminal and the
lock-upcontrol solenoidvalve B.

(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

Wire sideof Iomaleterminals

ls there battery voltage?

Checkfor loose terminal lit in the


PCM connectors. ll nces3a.y,
substitute a known-good pCM
and .check.

14-9 8

www.emanualpro.com

Check tor blown No. t5 (7.5 Al


fuse in the underdash fu36/.elay
box. lf th6 fuse is OK, ..pair open
in the wire betwooo tho D5 t.rminel and thg underdash two/relay
Itox.

TroubleshootingFfowchart' O8O ll ScanTool indicatasCode


P1705.
. self-diagnGi3 E or El indica'
tor light blinks five time3

AIT GearPositionSwitch {Short)


PossibleCau3e
. short in A/T gear position switch wire
. FaultyA/T gear pGition switch

NOTE:Code 1705(5) is set when the PCMreceivestwo gear positioninputsat


the sametime,

Obsrvethe A/T Goar Position


lndicalor:
1. Turnthe ignitionswitchON (ll).
2. Observethe A/T gearPosition
indicator,and shift eachPosi'
tion seParatelY.

Doesany indicatorstayon when


the shiftleveris not in that
position?

The system is OK at lhis time.


Checkthe wir harne3sfot dam'
age.

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,

LGl IBRN/BLK) LG2 (BRN/BLK)


Wire sideof femaleterminals

Check for short in the wire


betwoon thc DSterminal and tho
A/T gear position switch or A/T
gear porition indicatol, and
check for open in the wires
batween the 820 and 822 t6lmi'
lf
nals and body ground 1G1011.
wires are OK, checklor loos ir_
minel fit in the PCM connectors.
lf necBsarv, substittlle a known'
good PCMand recheck.

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)

Wire sideof lemaleterminals

Check for short in the wir6


b.twoen tha Dl3 terminal and
the A/T go.r polition 3witch,
and in th6 El and E poiition signal wir.! betwoen the A/T garr
po3ition indicetor and the A/T
garr position switch. lf wi.6s are
OK, checkfor loole torminal fit in
tho PCM connccto.s, lf neccasary, lubstituto a known-good
PCMand rocheck.

Mcrsure ATP D4 Vohrg6:


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 {'98)or El ('99 - oo).
2. Measurethe voltage between
the Dg and 820 or 822 terminals.

a t32Pl

LGl IERN/BLK}

Check tor Bhort in the wi..


bctw6cn thg Dg torminal and the
A/T ge.r position .witch or A/T
geor poaition indicator. lf wiaaa
are OK, ch.ck lor loose torminal
fit in the PICMconn.cto6. lf nce3sary, subgthute r lnown-good
rcM and roch6d(.

To page14-101

14-100

www.emanualpro.com

ATP NP ILT GRNI

From page 14 100

PCMCONNECTORS

B (2sP)

c (31P}

D t16P)

' t d. , lll;

;l';nl, :if

Measure ATP D3 Vollage l'98


model):
1 . S h i f t t o a l l p o s i t i o n so t h e r
t h a nE .
2, Measurethe voltagebetween
the D8 and 820 or 822 terminals-

ls therebatteryvoltage?

LGl (BRN/BLK}

ATPD3
{PNK)

Wire sideof femaleterminals

Check for shott in the wire


belween lh6 08 terminal and the
A/T gear posilion switch or A/T
gear position indicator ('98) lf
wires are OK, checklor loose terminal tit in rhe PCM connectors.
ff necessary,substitute a known_
good PCMand recheck.

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

Check for short in the wire


between tho D1{ terminal and
the A/T gear posilion switch or
A/T gear position indicalor. lf
wiles are OK, checkfor loose tr'
minal fit in the PCM connectors.
It necessarv,substitute a knowngood PCMand recheck.

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)

Wire sideof femaleterminals

Chock lor short in the wire


between the D15 terminal and
the A/T gear position switch or
A/T gear position indicator. lf
wires a.e OK, ch6ckfor loos t6rminal fil in tho PCM connectorc.
ll neco$ary, substiiute a knowngood PCMand rechsck.

Chockfor loose terminalfit in the


PCM connectors. lf nocessary,
sub3titut s known-good PCM
and recheck.
The system 3hould be OK at this
point. lf any indicators stay on
when the shift lever is not in ihe
selectdposition, pertorm this
troubleshootingtlowchart again.

www.emanualpro.com

D {16P1

TroubleshootingFlowchart- A/T GearPositionSwitch (Open)


Po$iblg Cause

. OBD ll Scan Tool indicates


Codo Pl706.
. Self-diagnosisFl or E indicato. lighl blinks six times.

. DbconnectedA/T gear position switch connoctor


. Open in A/T gear po3ition switch wiro
. Faulty A/T gar position switch

Are any ofthe gearpositionindi


catorsnot workingwhen you
shiftthem?

The systemis OK.tthis time.


Checkfor oth6r problms such
as harne3sdamage.

Test the A/T gear position switch


(seepage14-139).

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

Repairopen in tho wiro betwoen


the D6 terminal and the A/T gear
oosition switch.

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}

Repairopen in the wiro between


t h D l 3 t e r m i n a la n d t h A / T
gesr posilion awitch.

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

Wire side of female terminals

Repairopon in th6 wire between


tho m tarminal and the A/T geal
position swhch.

Me..ure ATP 03 Vohage l'98


modell:
1. Shiftto E position.
2. Measurethe voltage between
the DB and 820 or 822 tetminals,

LGl {BRN/BLKI

Repairopen in the wire botwoon


th6 08 terminal .nd the A/T geat
position switch (381.

MeasuroATP 2 Voltage:
1. Shilt to E position.
2. Measurethe voltage between
the D14and 820 or 822termi
nats.

LGl {BRN/ELXI

Repairopon in the wire between


the D14 t.minal end the A,/T
gear po3ition switch,

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

Wire sideof femaleterminals

Repairopen in the wire between


t h e D 1 5t e r m i n a l a n d t h e A / T
gear poaition switch.

Check LG Wire tor an Open


Circuit:
'1. Turnthe ignitionswitchOFF.
2. Checklor continuitybetween
t h e 8 2 0 t e r m i n a la n d b o d y
ground,and betweenthe 822
terminaland body ground.

ls therecontinuity?

A (32P1

B (2sP)

c (31P|

LGl (BRN/BLKI

Repair open in th. wires


between the B20 and 822 tarminals and body ground. and repair
poor ground{G101).

Checktor loose terminaltit in the


PCM connectors. lf n6cassary,
substitute d known-good PCM
and recheck.

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

It the PGM Tester is available,


retrievethe A"/TFreezeData,then
clearth PCM.

Test drive the vehicle under the


sameconditionsthe FreezeData

Did the code return?

Ch6ckfor a Short 1o Power:


1. Turnthe ignitionswitchOFF.
2. Disconnect
the B (25P)and D
( 1 6 P i c o n n e c t o r sf r o m t h e
PCM,
3. Turnthe ignitionswitchON (ll).
4. Measurethe voltagebetween
the D7 and 820 or 822 termi
nals.

Intermittent tailure. The system


b OX at this timo. Check the fit
o{ the pins in all connectora
.ttected by this code.

8 {2sPl

A t32P)

Ct3lPt

LG1IBRN/BLKI LG2IBRN/BLK}
Wi16sideof femaleterminals

Repairshort to power in the wire


betwoen tho D7 terminal and the
shift control solenoid valve A.

Moasure Shift Control Solenoid


Valv6 A Resistanco:
1. Turnthe ignitionswitchOFF.
2 . [ r e a s ur e t h e r e s i s t a n c e
between the D7 and 820 or
822terminals.

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}

(BRN/BLKI LG2 (BRN/BLKI

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

Ropairopen in the wir.s betweon


the 820 and 822 terminal3 and
ground(G1011.

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?

LGl IBRN/BLK} LG2 (BRN/BLK}

Repairshort to ground in the wire


be{wenthe D7 terminal and the
3hift control solonoidvalvo A.

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 ?

Replacethe shrft control solenoid


valve A/B assembly.

Check for op.n in the wire


betwoon tho D7 terminal and the
shift control solenoidvalve A.

(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)

Wire sideof femaleterminals

ls therebatteryvohage?

Checkfor loose terminalfit in the


PCM connectors. lf necessary,
subltitute a known-good PCM
and recheck.

14-108

www.emanualpro.com

Checklor blown No. 15 (7.5 Al


fuse in the under-dashfuse/relay
box. lf the tuse is OK, repair open
in the wi.e between the D5 terminal and the under-dashfuse/
relay box.

TroubleshootingFlowchart- Shift ControlSolenoidValveB


. OBD ll ScanTool indicatosCode
P0758.
. Self-di.gnosis E or E indicalor lighf blinb 6ight times.

Po3sibleC.us
.Dt
. Short or oDenin shift control solenoidvalve B wira
' F.ulW shitt cont.ol solonoidvalvc B
. Opon in VB SOLwir6

lf the PGM Tester is available.


retrievethe A/f FreezeData,then
clearthe PCM.

Test-drivethe vehicle under the


same conditionsthe FreezeData

Did the code return?

Checklol o Short to Power:


1. Turnthe ignitionswitchOFF.
2. Disconnect
the B 125P)and D
( 1 6 P )c o n n e c t o r sf r o m t h e
PCM,
3 . T u r n t h e i g n i t i o ns w i t c hO N
0ll.
4. Measu.ethe voltagebetween
the D2 and 820 or 822 terminals.

Intermittent failu16. Tha 3yltgm


is OK at thi3 time. Check the fit
of the Dins in all connectors
affocted by this codo.

PCMCONNECTOBS

a l32Pl

B {2sPl

c t3tP}

LG2 {BRN/BLK}

LGl {BRN/BLKI

Wire side of lemale terminals

Ropairshort to powor in lhe wire


betwoon the D2 termin.l .nd tho
shift cont.ol solenoid vslv6 B.

Measuro Shift Control Solonoid


Valve I Rosbtance:
1. Turnthe ignitionswitchOFF.
2 . M e a s ur e t h e r e s i s t a n c e
between tho D2 and 820 or
822terminals.

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

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.

Wire sideof l6maleterminals


Repairopen in the wire! btwoen
th6 B20 and 822 terminals and
groundlG101l.

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

Measu.e Shift Control Solenoid


Valve B Rasistanceat tha Solonoid Connector:
Measurethe resistancebetween
the No.2 terminalof the shiftcon
trol solenoidvalve NB assemblv
connectorand body ground.

lF-E]
I

SH B IGRN/WHTI

(ol

Y
I

Terminalsideof maleterminals
12 25 O?
ls the resistance

Check for oDen in the wire


btwoen ths D2 torminal and the
shift control 3olenoidvalve 8.

www.emanualpro.com

1 4 -1 1 0

ReDlac.the shift control solenoid valve A/B r$embly.

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)

Wire sideof femaleterminals

Ch6cktor blown No. '15{7.5 Al


fuse in tho undo.-dashtuso/telay
box. It the fu3s is OK, tepair open
in the wire bctweon the D5 terminal and the under-dash fose/
rolaYbox.

Chackto. loo3ete.minal fit in lho


PCM connectols. lf nccoa3ary,
substituto a known-good PCM
snd rechock.

www.emanualpro.com

14-111

ElectricalTroubleshooting('98- 00 Models)

. OgD ll Sc.n Tool indicat* Code


m720.
' selt-diagnosis E or E indicator light blinks nin6 time3.

Po$ibl Csuse
.
.
.
.

Loo3or tauhy connctionbatween the PCMand vehicle harness


Diaconnectedcountetshaft3Deodsensorconnectoa
Short or opon in countershaltspegdsensorwiro
Faulty countershattspoedsensol

It the PGM Tester is available,


retrievethe A"/TFreezeData,then
clearthe PCM.

Test-drivethe vehicle under the


same conditionsthe FreezeData

Intormittent failuro. The systom


is OK .t thb time. Checkthe Iit of
the pins in rll connsctors .fLctod
bv thi! code.

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?

Measure Countershaft Sp6d


SonsoaRsistsncat the Senlor
Connector:
1. Disconnectthe 2P connector
from the countershaftspeed
2. Measurecountershaftspeed
sensorresrstanceat the sensor
connector.

ls the resistance400 - 600 0?

T o p a g e1 4 - 1 1 3

14-1 1 2

www.emanualpro.com

Reinstallor replaceand rechcck.

COUNTERSHAFT
SPEED
SNSORCONNECIOR

ttt'l
-T-TrY oI l
LI

Terminalsideof maleterminals

F r o mp a g e1 4 ' 1 1 2

Check Countershaft 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
nectorfrom the PCM.
2. Checklor continuitybetween
body groundand the D10term i n a la n d D l 6 t e r m i n a il n d i vidually.

NCIBLUI

PCMCONNECTORS

A t32Pl

B (25P1

D {16P1

c l31P)

ial,tu]g
NCSGIGRNI

Wire sideol femaleterminals

Repairshort in the wire3 botweon


the Dl0 and D16 terminals and
the countershaft 3Dedsensor.

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}

ls the resistance400- 600 0?

Repair loose terminal or open in


the wiies between the D10 and
O16 terminals and th. countetshaft sDedsensor.

Checktor loos. terminal fit in the


PCM connctoas.It necessary,
substitute a known-good PCM
and recheck.

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.

Test-drivethe vehicle under the


sameconditionsthe FreereData

Did the code return?

Intermittont tailuro. Tha sy3tem


b OK at this tims. Checkthefit of
tho pins in .ll connoctoB alt6cted
bv this code.

Checkthe mainshaftand countershaft speedsensorsinstallation,


and checkthem for damage.

Are the mainshaftand countershaft speedsensorsinstalled


properly,and not damaged?

MoasureMainshattSpedSenror
Rsirtancoat ths Snsol Connoctor:
1. Disconnectthe 2P connector
from the mainshaftspeedsen
sor.
2. Measuremainshattspeedsensor resrstanceat the sensor
connefior.

ls the resistance400 600 0?

To page14-115

14-1 1 4

www.emanualpro.com

Reinstallor ropllce and rochock.

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

lit4'l Fl l'1tilFTil ,'l unr

v v v v v l.t1lLtLt?!/]|,1tut
larrlrllllpr=r
tavtq tptntatEElt [1!]t! pl
NM (RCD| (O)

(o)Y
Y =

wire sideol femaleterminals

ReDairshort in tho wiros botwen


th Dl1 and D12 torminal3.nd
tho main3haft 3Doedaonlor.

MoasureMainshaftSp6dSonsor
Rosi3tancei
1. Connectthe mainshaftspeed
sensorconn6ctor.
2. Measure the resistance
betweenthe Dl1 and D12termrnals,

ls the resistance400- 600 0?

B l25Pt

Run the Eloctricl Troubldhooting


Flowdrrrt for co& F0720(codo 91.
Chocklor loo3otorminrl fit in the
PCM connectors. It necos3ary,
substitute r known-good PCM
and rchck.

c {31P1
-1-\ 2_1 |1 -1 -,s/ / 1

ChockNM Wire Continuity:


1. Disconnectthe 2P connector
trom the m6inshaftspeedsen-

st/

v,1zzfififinffiiFr
F/l,6t FFF| LrLrEll

2. Checkfor continuitybetween
the D11terminalandthe No.2
terminal of the mainshaft
speeosensorconnector,

NM {REDI

MAINSHAFTSPEEO
SENSORCONNECTOR

Wire sideof temaleterminals


Rcpair opon in tho wire betw.en
th6 Dll tarminal and the mainshaft lpood sonsor.

To page'14-1'16

www.emanualpro.com

(cont'd)

14-115

ElectricalTroubleshooting('98 - 00 Models)
TroubleshootingFlowchart- MainshaftSpeedSensor(cont'd)
Frompage14 115

PCMCONNECTORS

Ch6ckNMSG Wire Continuitv:


Chockfor continuity between the
Dl2 terminaland the No. 1 terminal of the mainshaftspeedsensor connctot.
MAINSHAFTSPEED
SENSORCONNECTOR
Wire sideof femaleterminals

ls therecontinuity?

Checkfor looso terminal fit in the


PCM connoctorc. lf necessary,
substitute a known-good PCM
and aech6ck.

14-1 1 6

www.emanualpro.com

Ropai. opn in the wi.e hn eon


the D12 terminal and the mainshaft sDeedlensor,

. OBD ll ScanTool indic{t.. Cods


P1768.
. selt-diagnosis El or E indicator light indicrt.. Codo 16.

Po$ible Cau3e
'
.
.
.
.

Disconnectsdlinoar solenoid conneclol


Short or open in linear solenoidwire
Faulty linear3olenoid
Open in VB SOL wire
Open in PGI and PG2wires or poot g.ound {G101).

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.

Test drive the vehicleunder the


same conditionsthe FreezeData

Did the code return?

Inlermittont tailure, The 3yrtom


is OK at thb time. Checkthe tit ot
lhe oins in all connectoE affoctod
by this code.
LINEARSOLENOIDCOiINECTOR

Meaaure Linear Solenoid Rsistanc at the SolenoidConnector:


1. Disconnectthe 2P connector
from the linearsolenoid2. Measurelinearsolenoidresistanceat the solenoidconnec
tor.

t-rtt
(9l
t t
Terminalsideol maleterminals

ls the resistance
about5 O?

Chock Lino.r Sol.noid to. a


Short Circuh:
1 . D i s c o n n e ctth e B ( 2 5 P )c o n nectorlrom the PCM.
2. Checktor continuity between
body ground and the 88 terminal and the 817 terminal
individually.

A l32Pt

B {2sP)

LSP(REDI

wire sideoI temaleterminals

ls therecontinuity?

Repair 3ho to ground in the


wires belween the 88 rnd B17
terminalsand tho linaar3olenoid.

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?

Repair loose torminal oi open in


the wires between rhe 88 and
817 terminalsand the linear
solenoid.

a l32Pl

Checkfor blown No. 15 17.5Al


fuse in the under-da3htus/relay
box. lI the fuse is OK, rap.ir open
in the wire betwen the D5 terminal and th under-dash tuso/
relav box.
A (32P1

Check LG Wire for.n Open


Circuit:
1. Turnthe ignitionswitchOFF.
2. Checkfor continuitybetween
t h e 8 2 0 t e r m i n a la n d b o d y
ground,and betweenthe 822
terminaland body ground.

ls therecontinuity?

Chacktor loose terminel fit in the


PCM connecto13.It nocosaary,
substitute a known-good PCM
.nd recheck,

1 4 -1 1 8

www.emanualpro.com

B l2sP)

LGl IBRN/BLK}

Repair op6n in the wiros


betwen the 820 and 822 terminals and body ground, and repair
poor g.oundiG101).

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.

Test-drivethe vehicle under the


same conditionsthe FreezeData

Did the codereturn?

lntermittent failur6. The system


is OK at this time, Check the fil
ol the pins in all connectors
affectedbv lhis code.

Checkfor Another Codc:


Checkwhetherthe OBDll scantool
or rhe E or E]indicatorlightindi
catesanothercode,

Doesthe OBD ll scan tool


or the @ or E indicator
light indicateanothercode?

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.

Test Lin Pres3uro:


Measurethe line pressure(see
page14'161and 14-162i.

ls the line pressurewithin


the servicelimit?

T o p a g e1 4 - 1 2 0

www.emanualpro.com

Repairth6 hyd.aulic system as


necessary {see page 14-161and
14-152).

(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.

Doesthe OBDll scantool indicate


code P0740or does the [9i] or E
indicatorlightindicatecode40?

14-120

www.emanualpro.com

The system is OK at this time.

TroubleshootingFlowchart- Shift ControlSystem


. OBD ll Scan Tool indicates
Code P0730.
. Self-diagnosisJir or E indicator light indicatesCode41.

PossibleCause
Faultvshift control sYstem

lf the PGM Tester is available,


retrieve the AJ.I Freeze Data, then
clear the PCM.

Test-drivethe vehicle under the


same conditionsthe FreezeData

Didthe codereturn?

lntermittent failure. The system


is OK at this time. Chck the fit
of the pins in all connectors
atfectedby this code.

Checkfor Another Code:


C h e c kw h e t h e rt h e O B D l l s c a n
tool or the l-Drlor E] indicator
light indicatesanothercode.

Doesthe OBD ll scan tool


or the Da or E indicator
lighlindicateanothercode?

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

ReplaceShilt Cont.ol Solenoid


Valve A$ambly and Recheck:
'1. Replace
the shift control
solenoidvalve A/B assembly
(seepage 14-136)and the lin,
e a r s o l e n o i da s s e m b l y( s e e
p a g e1 4 1 3 8 ) .
2. Turn the ignition switch OFF
and resetthe PCMmemory by
removingthe BACKUP (7.5A)
tuse in the !nder-hood luse/
r e l a yb o x f o r m o r e t h a n 1 0
seconos.
3. Drive the vehicle at over '12
mph (20km,/ti)
in lst,2nd,3rd,
and 4th gear tor more than 30
secondsin E position.
4. Recheck
for codeP0730(41).

Doesthe OBD ll scantool


indicatecodeP0730or does
the E orE indicatorlight
indicatecode41?

www.emanualpro.com

Tho system is OK .l this tim.

TroubleshootingFlowchart- Df or @ IndicatorLight DoesNot ComeOn


The E or El indicator light doe3
not cofie on when the ignitaon
switch is first turned ON {ll). {lt
should como on for about two
s.cond3 and ihen go out.l
Check ths Service Check Conneclor:
Make sure the specialtool (SCS
S e r v i c eC o n n e c t o r i)s n o t c o n
nectedto the servicecheckcon
nector.
ls the specialtool (SCSService
Connector)connectedto the ser_
vice checkconnector?

Disconneclthe special lool lrom


tha service check connoctor and
recheck.

check the E or E Indicator


Ught:
Shiftto E or E position.
Doesthe E or P indicator lightcome on?

Checkfor loo3et6lminal tit in the


PCM connectors. lf necessary.
substitute a known-good PCM
and recheck.

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?

Repairopen in the wires between


the 820 and 822 terminals and
ground {G1011,and rPair Poor
ground(G101).

c (31P)
Measure Power Supply Circuit
Voltage:
1. Turnthe ignitionswitchON 1ll).
2. Measurethe voltagebetween
terminalsB1 and 822 and
betweenterminalsBg and 820.

ls there battery voltage?

YES

Repairopen or short in tho wi.e


between the 81 and/or Bg torminals and the PGM-FImain rlay,
.nd between tho PGM-FImain
relay and the under-hoodtuse/
relay box.

(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

D4 INOor D IND IGRN/BLKI

Wire sideof femaleterminals

Check lor open in the wire


btweenthe Al/t terminal .nd the
geugo a$eftbly. lf wi.a is OK.
check tor a fautty E or E indicator light bulb or a faulty gauge
assmbly p.inted circuit board.

D {16P)
CheckD4 IND or D IND for a
Short Circuiti
Checkfor continuitybetweenthe
A14terminaland body ground.

D4 IND or D IND

Ropairshort in tha wiro btwesn


the A14 termin.l and th gaugo
.ssemblv.

Checktor looso telminal tit in the


PCM connoctors. Chock the A/T
gear position swiich. It neces3ary, substitute a known-good
PCMand rechck.

14-124

www.emanualpro.com

TroubleshootingFlowchart- E or E IndicatorLight On Gonstantly


The E or E indicator light is on
constantly(not blinkingl whenevr lhe ignition switch is ON
0.
PCMCONNECTORS
A {32P)
Me.3rtreD4IND o. D INDVottage:
1. Turnthe ignitionswitchOFF.
2 . D i s c o n n e ct th e A ( 3 2 P )c o n nectorfrom the PCM.
3. Turnthe ignitionswitchON (ll)
4. Measurethe voltagebetween
t h e A 1 4 t e r m i n a la n d b o d y
ground.

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

Repairshort to power in the wire


biween th A14 terminal and
the gaugea$.mbly.

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.

Test the A/T gear position switch


(seepage14-139i.

Checkfor r 3hofi to ground in the


wire betweon tho IXI teYminal and
A/T gear position switch. lf wire is
OK subBtihrte a known-good PCM
and recheck.

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.

NOTE:li the MIL is on, ropairthe PGM-FIcontrotsystem


{seesection11),and recheck.

ChckBJakeLight Oporation:
Pressthe brakepedal.

Are the brakelightsON?

B6pair tlutty brrko 3whch circuit


l..e rection 231.

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"

Wire side of femalelerminals

Chock tor an open or short in the


wi.o botwoen tha A28 t6rminrl
and thc intorlod( control unit, rnd
check tor loose torminrl fit in the
intorlock conftol unh connoctor. lf
nocassaryraubstitute a knowngood intollock control unit rnd
roch6d(

c t3lPt

Mor3uro STOPSW vohsgo:


1. Turnthe ignitionswitchOFF.
2. Disconnect
the A (32P1and B
( 2 5 P )c o n n e c t o r s{ r o m t h e
PCM.
3. Measurethe voltage between
the A32 and 820 or 822 terminals,

ls there batteryvoltage?

fo page 14-121

14-126

www.emanualpro.com

D (lCPl

| 2ttt/ ;t /n) ).tt)/ 1 21:/ t


vvvvv nnvl.lnl2\n I r r ero 12

wE

gp]P] polr EI!l!!i r.

LGl {8RN/ALKI

Repairop6n in tho wir betwsen


the A32 t6.minal and th6 brake
3witch.

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

wire sideof femaleterminals

ls thereapprox.0.5V?

Check Throttlo Position Sensol


Ground Line:
'1. Turnthe ignitionswitchOFF
2. Disconnectthe throftleposition
sensorconnector.
3. Checktor continuitybetween
t h o N o . 1 t e r m i n a lo f t h e
throttle positionsensorconnector and the 820 and 822
terminslof the PCM.

To page'14-128

LG2IBRN/BIXI

LGl IBRN/BIXI

THROTTTIPOSMON
SENSORCONNECTOR

SG2IGRN/BLK}

rL2l3t

Wiresideof femaleterminals

ls therecontinuity?

Checktor continuity betlveenthe


C18and 820 or 822terminals

B {25P1

D (16P1

n l,I-il n
FFFTI,T';T;I
EFML"|
LGl IBRN/BLKI

ls therecontinuity?

c l3lPl

SG2 {GRN/BLK}

Rgpsir opan in lhe wire botween


the Cl8 torminal .nd the throttle
gosiiion Sensor.

Checklor looss tetminalfit in the


PCM connctoia. It nece3sarY,
subslituta a known-good PCM
and .echock.

(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

Check Shift Lock Solenoid tor an


Open Ci.cuit:
1 . D i s c o n n e c tt h e s h i l t l o c k
solenoidconnector,
2. Checkfor continuitybetween
the No. 2 terminalof the shift
l o c k s o l e n o i dc o n n e c t o a
r nd
the No. 3 terminalof the inter
lockcontrolunit connector,

o
SHIFTLOCKSOLENOID
t
CONNECTOR

YEL/BLK

1 2
ls therecontinuity?

Repairopen in the wir6 between


th No. 2 termin.l oI ihe interlock control unit and ahift lock
solenoid.

Measu.e Shift Lock Solenoid


Voltage:
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 No. 1 terminal and body
ground.

ls therebatteryvoltage?

Check Shift Lock Solenoid


Operrtion:
1. Connectthe No. 1 terminalof
t h e s h i t t l o c k s o l e n o i dc o n
nector to the battery positive
terminal,and connectthe No,
2 terminal to the battery neg,
ativeterminal.
2. Check that the shift lock
solenoidoperates.

Doesthe shiftlocksolenoid
operateproperly?

Checktor looso torminal tit in th6


interlock control unit connector.
lf necessary,substitute a knowngood intrlockcontrol unil and
recheck.

14-128

www.emanualpro.com

Wire side of female termtnals

SHIFT LOCK SOI.ENOID


CONNECTOR
"-irr- l

Checklor blown No.25 {7.5 Al


fuse in the underdash fuse/relay
box. It the tuse i3 OK, repair opon
or short in lhe wire betwen the
No. 1 terminal of tho shift lock
solenoid connector rnd the
under-dashfuso/rlaybox,

NOTE:Do not connectthe No. 2 terminalto


t h e b a t t e r yp o s i t i v et e r m i n a l ,o r y o u w i l l
d a m a g et h e d i o d e i n s i d et h e s h i f t r o c K
solenoid.

YEL]

(v)
!

Wiresideof femaleterminsls

SHIFTLOCKSOLENOIO
CONNECTOR
(dir.ctly on $lenoidl

Terminalsideof maleterminals
Roplacethe shift lock solenoid.

TroubleshootingFlowchart- Interlocksystem - Key Interlocksystem


lgnition ksy cannot be moved
from ACC (l) pGition to LOCK(01
position while Pushing it with
the shift lever in E PGition.

Check Key lntorlock Solenoid


Operation:
the ignitionswitch
1. Disconnect
connector(6P).
2. Connectthe No. 4 terminalof
the ignitionswitch6P connector to the battery Posativeter_
minal, and connectthe No. 3
terminalto the batterynega
tiveterminal.
3. Checkthe key interlocksolen oi d o p e r a t i o n A
. clicking
soundshouldbe heard.

IGNITIONSWITCH6P CONNECTOR

KEYLOCKSOL
IWHT/BLU)

ACCPUSHSW (WHT/YEL}

Wire sideot femaleterminals

Doesthe keyinterlock
solenoidoperateProPerlY?

Chck Key |motlock Switch OPer'


etion:
1. Connectthe No. 5 terminalof
th ignitionswitch connector
to the batteryPositiveterminal,and connecttheNo.3 teF
minal to the bafterynegative
termrnal,
2 . T L r r nt h e i g n i t i o n s w i t c h t o
ACC(l),then PUshit.
3. Checkthe key interlocksolen o i d o p e r a t i o n .A c l i c k i n g
sound should be heardwhile
pushingthe ignitionkev.

Doesthe keyinterlock
solenoidoperateProperly?

F.ulty key interlock solenoid.


Replacetho ignition key cylinder/
steering lock asembly.

KEYLOCKSOL
IWHT/BLUI

+B KEY LOCK
(WHT/GRN)

Faulty key interlock 3witch.


Roplacothe ignidon key cylinder/
steoring lock tssamblY.

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}

Check Key Intorlock Solonoid tol


a Short Circuit:
1. Disconnectthe interlockcontrol
unit connector,
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
terminaland bodygroundindi
vidually.

ACCPUSHSW {WHT)

Wire sideof femaleterminals

ls therecontinuity?

Repairshon in thc wire betweon


the No. 1 or No. 5 terminal and
th ignhion switch 6P connector.

Check Park Pin Switch Operation:


Checkfor continuity between the
No.I terminaland body ground.

ls therecontinujty?

MoasureATP P Voftegel
1. Turnthe ignitionswitchON (lli.
2. Measurethe voltagebetween
the No. 6 terminal and body
ground.

Check for short in the wir6


between the No. 8 terminal of
the intrlock control unit and tho
park pin switch. ll wire is OK,
ch6ckthe park pin switch.

Shiftlevermust be in E.

ATP P IBLK/BLUI

Repairopen in the wiro between


the No. 6 termin.l and the A/T
gear position 3witch.

Checkfor looseterminal fit in th


interlock control unit connoctors.
lf necosssry,substitute t knowngood interlock control unit and
recheck.

14-130

www.emanualpro.com

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.

Does the O/D OFF indicator


lightcome on?

Chocklor looaet.rmin.l tit in tho


PCM connoctor3. lf nocesstrY,
substitute a known'good PCM
and r.chock.
PCMCONNECTORS
A (32Pt

Chck O/O IND lor an OPen Circuit:


1. Turnthe ignitionswitchOFF
2. Disconnectthe B (25P)con'
nectorIrom the PCM.
the 14Pconnector
3. Disconnect
from the gaugeassemblY.
4. Check {or continuity between
the 819 terminaland the No.
6 terminal of the gauge
assembly14Pconnector.

B t25Pl

GAUGEASSEMBLY
CONNECTOR
I14P)

(31
cc (3rPt

O,/DIND ILT BLU}

Wire sideoI lemaleterminals

ls therecontinuitY?

Replir open in the wiro botween


the 819 terminal and gauge
.ssemblY | 4P connector.

Check for a fauhv O/o OFF indi'


cator light bulb or . laulty gluge
a3semblyprinted circuit bo.rd.

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).

Doesthe O/D OFFindicator


lightcomeon?

Fepair short to ground in lhe


wire between the B'19terminal
a n d t h e g a u g e a a s o m b l y1 4 p
GOnnectot,

14-132

www.emanualpro.com

Flowchart- O/D OFFIndicatorLightDoesNot ComeOn


Troubleshooting
EvenThoughO/D Switch ls Pressed
The O/D OFFindicator light does
not come on evn though the
Over-Driv6 lO/Dl 3witch is
pre$ed in E position. lThe o/o
OFF indicatol light come on
wh6n the ignition switch is fir3t
turned on tor two seconds,then
9o out.l

Checkthe Over-Drivs {O/D) Switch


al lhe Switch Connector:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe park pin/O/D
swrtchconnector.
3. Checkfor continuitybetween
t h e N o .1 a n dN o . 2 t e r m i n a l s
of the switchconnectorwhale
p r e s si n g t h e s w i t c h , a n d
when releasedat.

PARKPIN/O/D SWITCHCONNECTOR

Terminalsideof maleterminals
ls therecontinuitywhile
pressingthe switch, and no
continuitywhen releasedit?

CheckO/D Switch fol an Opsn


Circuit:
1 . D i s c o n n e ctth e D ( 1 6 P )c o n
nectorfrom the PCM.
2. Checkfor continuitybetween
the D8 terminaland the No. 1
terminalo{ the switchconnec'
tor,

Checklor loose torminallit in the


O/O switch connestor. lf termin a 1 3a r e O K , r e p l a c et h e O / D
switch and pa]k pin switch as a
se.tlseep.go l+1511.

PCMCONNECTORS
A {32P1

B l25Pl

c (31P)

O/D SW (PNKI
PARKPIN/

o/D swtTcH
CONNECTOR
Wire sideof femaletermanals

Ropairopen in the wire batwean


the D8 te.minal and the park
pin/O/D Bwhchconnocto..

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

Check O/D Switch Ior a Sho.t


Circuit:
Checkfor continuitybetweenthe
D8terminaland body ground.

PCMCONNECTORS

O/D SW{PNKI

Wiresideof femaleterminals

ls therecontinuity?

Repair short to ground in the


wire betweon the D8 terminal
and the park pin/O/D.witch
connectoa,

PAFKPIN/O/D SWITCHCONNECTOR

Chck O/D Switch G.ound Circuit:


Checklor continuitybetweenthe
No. 2 terminalof the switchconnectorand body ground.

Wiresideot femaleterminals

Repairopon in the wire btween


th No. 2 terminal of the park
pinlO/D 3witch connector snd
ground 1G401.c402), or rep.ir
poor ground (G401,4021.

14-134

www.emanualpro.com

Lock-upControlSolenoidValveA/B Assembly
Test

Replacement

1 . Disconnectthe 2P connectorfrom the lock-upcon'


trol solenoidvalveA'lBassembly.

NOTE:Lock-upcontrolsolenoidvalvesA and B must be


as an assembly.
removed/replaced

2.

Measurethe resistancebetweenthe No. 2 terminal


( s o l e n o i dv a l v e A ) o f t h e c o n n e c t o ra n d b o d y
ground. and bet\iveenthe No. 1 terminal (solenoid
valveB) and body ground.

1.

Removethe mountingbolts and the lock-upcontrol


assembly.
solenoidvalveA,,/B

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

Shift ControlSolenoidValveA/B Assembly


Test
'1.

Replacement

Disconnectthe 2P connectorfrom the shift control


solenoidvalveAy'Bassembly.

NOTE: Shift control solenoid valves A and B must be


removed/replaced
as an assembly.
1.

Removethe shiftcontrolsolenoidcover.

2.

Removethe mountingbolts,the clamp and the shift


controlsolenoidvalveAy'Bassembly,
then disconnect
the connector.

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

Measurethe resistancebetweenthe No. 1 terminal


(solenoidvalveA) of the shift controlsolenoidvalve
connectorand body ground,and betweenthe No. 2
terminal(solenoidvalveB) and body ground.

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

Cleanthe mountingsurfaceand fluid passages.


and
installa new shift controlsolenoidvalveAy'Bassembly with the clampand a new filter/gasket.
Installthe shiftcontrolsolenoidcover.
Checkthe connectorfor rust,dirt. or oil, and reconnectit securely.

LinearSolenoidAssembly
Test
1.

lf a clickingsound is not heard,removethe linear


solenoidassembly.

Disconnect
the linearsolenoidconnector.

Checkthe linear solenoidfluid passagefor dust or


orn.
LINEARSOLENOIO

1.

Connectthe No. 1 terminalof the connectorto the


batterypositiveterminaland the No. 2 te.minal to
the battery negativeterminal. Make sure that the
valvemoves.
Disconnect
the negativebatteryterminal.and make
sure the valve releases.You can see valve movem e n t t h r o u g h t h e f l u i d p a s s a g ei n t h e m o u n t i n g
surfaceof the linearsolenoidassembly.
LINEAR
SOLENOID

Measurethe resistancebetweenthe No, 1 and the


No. 2 terminals.
STANDARD:About 5.0 o
lf the resistanceis out of specification,replacethe
linearsolenoidassembly.
Connectthe No. 1 terminalof the connectorto the
batterypositiveterminal and the No. 2 terminalto
t h e b a t t e r y n e g a t i v et e r m i n a l ,A c l i c k i n gs o u n d
shouldbe heard.

VALVE

lf the valvebinds,or movessluggishly.


or if the linear
solenoiddoesnot operate,replacethe linearsolenoid
assemotv.

www.emanualpro.com

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

Removethe 6 mm bolt and the countershaftsDeed


sensorfrom the end cover.

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

Cleanthe mountingsurfaceand fluid passageof the


linearsolenoidassemblyand transmissionhousing.

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.

Installa new linear solenoidassemblvwith a new


gasket.Do not pinch the gasketduring installation,
and makesure it is installedproperlyin the mounting grooveof the linearsolenoid.

Replacethe O-ringwith a new one beforeinstalling


the countershaftspeedsensoror the mainshaftspeed
sensor,

Checkthe linearsolenoidconnectorfor rust.dirt, or


oil, then connectit securelv.

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

Wire side oI female terminals

A/T Gear PGition Swhch Coniinuity Ch6ck


'97 - 98 Models

\_-__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.

Raisethe front of the vehicle,and support it with


safety stands (see section 1).

2.

Set the parking brake,and block both rear wheels


securely.

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

Remove the A/T gear position switch connector


from the connectorbracket,then disconnectit.
Removethe AfI gear position switch harnessclamp.

6x1.0mm
12 N.m
{1.2 kg{.m,8.7 lbtftl

1.

5x1.0mm
12Nm11.2kgf.m,
8.7 tbf.ftt

Set the IVT gear position switch to E position. The


AfI gear position switch clicks in E position.

BRACIGT

POSmON

swlTcH

14-140

www.emanualpro.com

8. Set the control shaft to E] position.then installthe


A,/Tgear position switch on it.
SHAFT
CONTROL

12, Start the engine. Move the shift lever through all
gears.and verifythe following:
.
.
.

The shift lever cannot be moved to E] position


from E positionunlessthe shift leveris pulled.
The engine will not start in any position other
than E or E.
The back-uplightscome on when the shift lever
is in El position.

9 . Installthe Ay'Tgear positionswitch cover and harnessclampon the end cover.


1 0 . Connect the A,/Tgear position switch connector.
then installit on the connectorbracket.
1 1 . Turn the ignitionswitchON (ll).Move the shift lever
through all gears,and checkthe AfI gesr position
switch synchronizationwith the A/T gear position
indicator.

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.
.
.

lf the terminalsare bent,loose,or corroded,repairthemas necessary,


and recheckthe system.
lf the terminalslook OK, makethe following inputtestsat the 14Pconnector.
- lf I test indicatesa problem,find and correctthe cause,then recheckthe system.
- lf all the input testsproveOK, but the indicatoris faulty.replacethe printedcircuitboard,
GAUGEASSEMBLY14PCONNECTOR

Wire sideof femaleterminals

Wirs
Color

Cavity

Test Condition

Test: DesirdResult

lgnitionswitchON (ll)

Checkfor voltageto ground:


Thereshouldbe batteryvoltage,

. Blown No. 25 (7.5A) fuse in the


under-dashfuse/relaybox
. An open in the wire

Combinationlight

Checkfor voltagebetweenNo. 2
a n d N o .3 t e r m i n a l s ;
Thereshouldbe batteryvoltage.

Blown No. 47 (7.5A) fuse in the


under-dashfuse/relaybox
FaultycombinationIightswitch
Faultydash iight brightness
controller
An open in the wire

YEL

RED/BLK switchON and dash


lightsbrightnesscontrol dial on full bright
RED

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

' Faulty Ay'Tgear position switch


Checkfor continuityto ground:
. An open in the wire
Thereshouldbe continuity.
NOTE:Thereshouldbe no continuity in any other shift lever position.
Checkfor continuityto ground:
Thereshouldbe continuity
Checkfor voltageto ground:
Thereshouldbe batteryvoltage
for two secondsafterthe ignition
switchis turned ON {ll),and less
than 1 V two secondslater,

. Poorground{G401)
. An open in the wire
' FaultyPCM
. An open in the wire

Checkfor continuityto ground:


Thereshouldbe continuity.
NOTE:Thereshouldbe no continuity in any othershift leverposiUOn.

. Faulty A,ff gear position switch


. An open in the wire

Checkfor voltageto ground:


Thereshouldbe about5 V.

. FaultyPCM
. An open in the wire

BLVBLU NOTE:Do not push


the brakepedal.

14

LT GRN

lgnitionswitchON {ll)
and shift leverin any
positionexceptE and

14-142

www.emanualpro.com

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

Wire sideof femaleterminals

Cavity

Wire
Color

YEL

7
'10

Test Condition

Checkfor voltageto ground:


Thereshouldbe batteryvoltage.

. Blown No.25 (7.5A) fuse in the


under-dashfuse/relaybox
. An open in the wire

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.

Blown No. 47 {7.5A) fuse in the


under-dashfuse/relaybox
Faultycombinationlight switch
Faultydash light brightness
controller
An open in the wire

BRN

Shift leverin E

YEL

Shift leverin E

BLU

Shift leverin E

BLK

Checkfor continuityto ground:


Thereshouldbe continuity.

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

Checkfor continuityto ground:


Thereshouldbe continuity

lgnitionswitchON (ll)
and shift leverin any
positionexceptE

Checkfor voltageto groundl


Thereshouldbe batteryvoltage
for two secondsafterthe ignition
switchis turnedON (ll).and less
than 1 V two secondslater.
Checkfor continuityto ground:
Thereshouldbe continuity.
NOTE:Thereshouldbe no continuity in any other shift leverposiIton.

. FaultyA/T gear positionswitch


. An open in the wire

Check for voltage to groundl


There should be about 5 V,

. FaultyPCM
. An open in the wire

a:FI\|/Et| ta

11

RED

Shift leverin S

12

WHT

Shift leverin E
Shift leverin E

BLI(BLU NOTE:Do not push


the brakepedal.

LT GRN

. FaultyA/T gear positionswitch


Checkfor continuityto ground:
. An open in the wire
Thereshouldbe continuity.
NOTE:Thereshouldbe no continuity in any othershiftleverposition.

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
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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.
.
.

and recheckthe system


lf the terminalsare bent,loose,or corroded,repairthem as necessary,
lf the terminalslook OK, makethe followinginputtestsat the connector.
- lf a test indicatesa problem,find and correctthe cause,then recheckthe system
- lf all the input tests prove OK, substitutea known-goodcontrolunit, and recheckthe system.lf the checkis OK,
the controlunit must be faulty;replaceit.

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

Checkfor voltageto ground:


There should be battery voltage.

Blown No. 48 {30A} fuse in the


under-hoodfuse/relaybox
Blown No.33 (7.5A) fuse in the
under-dashfuse/relaybox
Faultysteeringlockassembly
{keyinterlocksolenoid)
An open in the wire

lgnitionswitchON (ll)

Checkfor voltageto ground:


Thereshouldbe batteryvoltage.

Blown No.25 (7.5A) fuse in the


under-dashfuse/relaybox
An open in the wire

lgnitionswitchON (ll)

Checkfor voltageto ground:


There should be baftery voltage.

Blown No. 25 (7.5A) fuse in the


under-dashfuse/relaybox
Faultyshift locksolenoid
An open in the wire

Underall conditions

Checkfor continuityto ground:


Thereshouldbe continuity.

lgnitionswitchturned
to ACC(l), ignitionkey
pushedall the way in

Checkfor voltageto ground:


There should be battery voltage.

Blown No.48 (30A) fuse in the


under-hoodfuse/relaybox
Blown No. 33 (7.5A) fuse in the
under-dashfuse/relaybox
Faultysteeringlockassembly
(keyinterlockswitch)
An open in the wire

Shift leverin E

Checkfor continuityto ground:


Thereshouldbe continuity,

Faulty Ay'Tgear position switch


Poorground(G101)
An open in the wire

Checkfor continuityto ground:


Thereshouldbe continuity.

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

Shift leverin @ and


pulled toward steering
wneel
WHT/BLK
Shift leverin E

. Poorground(G401)
. An open in the wire

Checkfor continuityto ground:


Thereshouldbe no continuity.

Reconnect
the interlockcontrolunit 8P connector.
lgnition switch ON (ll)
and brake pedal
presseo

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WHT/RED lgnitionswitchON (lll,


brakepedal and acceleratorpedal pressedat
the sametime

Checkfor voltage to ground:


Thereshouldbe 1 V or less.
Check for voltage to ground:
There should be baftery voltage,

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.

Checkfor continuitvbetweenthe terminalsin each


key positionaccordingto the table.

Removethe instrumentpanel lower cover (seesection 20).

IGNITIONSWITCH6P CONNECTOR

Disconnectthe ignition switch 6P connectorat the


connectorholder.

\____________r{r4
Position
lgnition Key pushedin
switch
Key released
ACC0)

---'o

o- ---o

Check that the key cannot be removed with power


connectedto the No. 5 terminaland ground connected
to the No. 3 terminal.
lf the key cannot be removed.the key interiock
solenoidis OK.
lf the key can be removed,replacethe steering
lock assembly(the key interlocksolenoidis not
availableseparately).

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.

Checkthat the shift lock releaseswhen the release


lever is pushed,and checkthat it locks when the
releaseleveris released,

7.

lf the solenoiddoes not work, replaceit.

'1. Removethe instrumentpanel lower cover (seesection 20).


2.

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

Removethe instrumentpanel lower cover (seesection 20).

2.

Removethe upper and lower steeringcolumn covers (seesection17).

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.

Disconnectthe shift lock solenoidand the park pin


switchconnectors.
Removethe bolts securingthe shift leverassembly,
then removethe shift leverassemblv.
Removethe screwssecuringthe shift locksolenoid,
then removethe shift locksolenoid.

2.5 N.m {0.25kgl.m,1.8lbf.ft}

14-148

www.emanualpro.com

7 . Installthe new shift lock solenoid by aligning the


joint of the shift lock solenoidplungerwith the tip
of the shift lockextension
Securethe shift locksolenoidwith the screws,
9 . Installthe shift lever assemblyin the reverseorder
of the removal.
1 0 Checkthe operationof the shift lever and the shift
lock.

ParkPinSwitch Test
SRScomponentsare locatedin this area. Reviewthe SRS
compongnt locations,precautions,and proceduresin the
SRSsection(24)before performingrepairsor service,
1.

Removetho instrumentpanel lower cover (seesection 20).

Shiftthe shift leverout of the E position,and check


for continuity betweenthe terminalsas in step 4.
Thsreshouldbe no continuity.
lf the parkpin switchis faulty,replaceit.

Removethe upper and lower steeringcolumn covers (seesection 17).


Disconnect
the parkpin switchconnector.
Shift the shift lever into E position,then checkfor
continuitybetwsgntheseconngctorterminals:
. '97 - 98 models;No. 1 and No, 3 terminalsof the
parkpin switchconnector.
. ' 9 9 - 0 0 m o d e l sN
: o .3 a n d N o . 4 t e r m i n a l s o tf h e
park pin switch/Over-Drive{O/D) switch connector.
Thereshouldbe continuity,
37 - 98 MODELS:

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.

Removethe instrumentDanellower cover(seesection20).


Removethe upperand lowersteeringcolumncovers(seesectionli,.
Removethe flangenutsand boltssecuringthe steeringcolumn.then lowerthe steeringcolumn.
Disconnect
the shift locksolenoidand the park pin switchconnectors.
Removethe harnessclamp bracket.
Removethe boltssecuring the shift leverassembly,then removetheshiftleverassembly.
Removethe screwssecuringthe shift locksolenoid.then removethe shift locksolenoid,
Removethe parkpin switchconnectorfrom the shift levercontrolbracket.
Removethe control checkerfrom the shift lever control bracket.
Removethe parkDinswitchfrom the controlchecker.

PARKPIN SWITCH
PARKPIN
SWITCHCONNECTOR

scnEw
2.5 N m 10.25kgt.m, 1.8 lbtftl

9.3 N.m 10.95kgf.m, 6.9 lbl.ft)


BRACKET

CONTROLCHECKER

11. Installthe new DarkDinswitchon the controlchecker.


12. lnstallthe controlcheckeron the shift levercontrolbracket.
13. Routetheparkpin switchharnessthroughthecutoutofthe shift levercontrolbracket,then installthe parkpin switch
connectoron the bracket.
14. Installthe shift locksolenoidby aligningthe joint of the shift locksolenoidplunger with the tip of the shift lock extension.
15. Securethe shift locksolenoidwith the screws.
15. Installthe shift leverassemblyin the reverseorderof the removal.
'17.
Checkthe operationof the shift leverand the shift lock.

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

2.5 N.m (0.25kgt m,


1.8 tbf.fr)

SHIFTLEVER

HABNESSCLAMPBRACKET

9.3 N.m 10.95kgl.m.


6.9 tbf ft)

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

Over-Drive(O/Dl Switch ('99- 00 Modelsl


Test
SRS componentsare located in this area. Review the
SRScomponentlocations,precautions,and procedures
in the SRSsection(24)beforepertormingrepairsor servtce.
1.

Removethe instrumentpanel lower cover (seesection 20).


Removethe upper and lower steeringcolumn covers (seesection17).
Disconnectthe park pin switch - O/D switch connector.

4.

Checkfor continuity betweenthe No, 1 and No. 2


t e r m i n a l sw h i l e p r e s s i n ga n d h o l d i n gt h e O / D
switch,and when it's released.
Thereshouldbe continuitywhile pressingand holding the switch,and no continuitywhen it's released.

PARKPINSWITCH

lf the O/D switch is faulty, replaceit and the park pin


switchas a set (seepage14-1511.

14-152

www.emanualpro.com

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 ?

movesinEl. @, butnotin lE. E, E, or E, position 6, 8, 9, 10,29, 52


Vehicle
movesin [D!.E, E. E, E, butnotinE] position.
Vehicle
Vehiclemovesin .&1,E. E, E, E, but not in E position
Vehiclemovesin E position.
idle vibration
Excessive
flareson startingoff in E, Di position
Pooracceleration;
or E position

Stallrpm hishin El, El, E, E, E Position


Stallrpmhiqhin E, E, E, E position

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

Stall rpm high in E position


Stallrpm high in hl position

14

Stall rpm low

17,31,44,46,47

No shift

18, 19,39, 47,48

G,L

Failsto shift in Pr, E positionor E position;from 1stto


3rd gear
Failsto shift in EJ, E positionor E position;from 1stto
4th gear

21, 48
2 1 , 2 24, 7

Erraticupshifting
fz

upshlft. ,3 ripshlft, 3r. up+ilft

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

13,'1A,19,25, 41, 42,55,56,57

C, D, E, I

Flareson 2-3 upshift

13,1A,19,23,26,50

Flareson 3-4 upshift


Excessive
shockon 2-3 upshift

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)

Lateshiftfrom N positionto ld or Erl position.or to E


position
Lateshift from E positionto E position
Noisefrom transmissionin all shift leverpositions
more than 3l mph (50 km/h).
Vehicledoes not accelerate

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

Regulatorvalve stuck or regulator valve


spflng worn

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

Thrust washer worn/damaged


Clutchclearanceincorrect
Drive plate delective or transmission mtsassembled

5tt

Torqueconverterhousingor transmission
housingbearingworn/damaged
ATF strainer clogged

38

Shift cableis worn where it attachesto the


transmissionor at the body mounts

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

The followingsymptomcan be caused


by improperrepairor assemblY

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

Torqueconverternot fully seatedin ATF pump

Noiseonly with wheelsmoving.


Mainshaftoil sealpo9s out.

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.

lf the largeclutchpistonO-ringis broken,inspectthe pistongroovefor rough machining.

lf the clutchpackis seizedor is excessively


worn. inspectthe other clutchesfot wear,and checkthe orifice
controlvalves,CPCvalve,and linearsolenoidfor free movement.
lf the linearsolenoidis stuck,inspectthe clutchesfor wear.
lf the 1-2shift valveis stuckclosed.the transmissionwill not upshift.lf stuckopen,the transmissionhas
no lst gear.

lf the 2nd orificecontrolvalveis stuck,inspectthe 2nd and 3rd clutchDacksfor wear.


lf the 3-4 orificecontrolvalveis stuck,inspectthe 3rd and 4th clutchpacksfor wear.

J
K
L
M

lf the clutchpressurecontrolvalveis stuckclosed.the transmissionwill not shift out of lst gear.


lmproperalignmentof main valve body and torqueconverterhousingmay causeATF pump seizure.The
symptomsare mostlyan rpm-relatedtickingnoiseor a high-pitchedsqueak.
lf the ATF straineris cloggedwith particlesof steelor aluminum,inspectthe ATF pump and differential
pinionshaft.lf both are OK and no causefor the contaminationis found,replacethe torqueconverter.
lf the lst clutchfeed pipe guide in the end cover is scoredby the mainshaft.inspectthe ball bearingfor
excessivemovementin the transmissionhousing.lf oK, replacethe end coveras it is dented.The o-rino
underthe guide is probablyworn.
' Replace
the mainshaftif the bushingfor the 4th feedpipeis looseor damaged,lf the 4th feed pipeis darrF
agedor out of round.replacethe end cover.
' Replace
the mainshaftif the bushingfor the l st feedpipe is looseor damaged.lf the 1stfeedpipeis damagedor out of round,replaceit.

A worn or damagedspragclutchis mostlya resultof shiftingthe transmissionin E!. E, or E position


while the wheelsrotatein reverse.suchas rockingthe vehiclein snow.

Inspectthe framefor collisiondamage.


lnspectfor damageand wear:
l. Reverseselectorgearteethchamfers.
2. Engagement
teethchamfersof countershaft
4th and reversegear.
3. Shift fork for scuff marksin center.
4. Differentialpinionshaftfor wear underpiniongears.
5. Bottomof 3rd clutchfor swirl marks.
Replaceitems1,2, 3. and 4 if worn or damaged.lf transmission
makesa clicking,grinding,or whirringnoise,
alsoreplacemainshaft4th gear,reverseidlergear,and countershaft
4th gearin additionto 1,2, 3, or 4.
lf differentialpinion shaft is worn, overhauldifferentialassembly,replaceATF strainer,and thoroughlycjean
transmission,
flushtorqueconverter.
cooler,and lines,
lf bottom of 3rd clutch is swirled and transmissionmakesgear noise.replacethe countershaftand final driven
oear,
Be very carefulnot to damagethe torqueconverterhousingwhen replacingthe main ball bearing.you
may also damagethe ATF pump when you torquedown the main valvebody.This will resultin ATF pump
seizureif not detected.Usethe Drooertools.

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.

Beforetesting,checkthe transmissionfluid level,see page14-160.

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.

Repeatsametest in E position('97- 98 models).

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

11111t1.t nait la t1 t213tr / t6t, tl / / / /

1 3 / 10n v

Wire sideof femaleterminals

'98 - 0OModels:
PCMCONNECTORS

A l32Pt

B {25Pt

c l31P}

(cont'd)
LGl (BRN/BLK)

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Wire sideot femaletermanals

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.

Checkfor abnormalnoiseand clutchslippagein the followingpositions.

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

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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

Stallrpm highin El, E, E, E andE


positions

Stallrpm high in E position


Stallrpm high in E position

Slippageof 1stclutch,1st-holdclutch,or 1stgearone-wayclutch

stall rpm high in E! or E position


Stallrpm high in E position

Slippageof 1stclutchor 1stgearone-wayclutch

Stallrpmlow in [dd,E. E, E, anaE


positions

www.emanualpro.com

ATF pump outputis low


CloggedATFstrainer
Pressureregulatorvalvestuckclosed
Slippingclutch
Slippageof 2nd clutch
Slippageof 4th clutch
. Engineoutput low
. Torqueconverterone-wayclutchslipping

14-159

FluidLevel
Checking
NOTE: Keep all foreign particlesout of the transmisston,
1.

7.

Insertthe dipstickback into the transmissionin the


directionshown.

Warm up the engineto normal operatingtemperature (the radiatorfan comeson)


Parkthe vehicle on level ground. Turn off the
engine.

FRONT

Removethe dipstick(yellow loop) from the transmission,and wipe it with a cleancloth.


Insertthe dipstickinto the transmission.
DIPSTICK

-'-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.

Bringthe transmissionup to operatingtemperature


(the radiatorfan comes on) by driving the vehicle.
P a r kt h e v e h i c l eo n l e v e lg r o u n d .t u r n t h e e n g a n e
off. then removethe drain Plug.
NOTE: lf a cooler flusher is to be used, see page
14-264and 14-265.

a Wlrile testing, be careful of the rotaling wheols.


a Mako sure lifts, iacks, and safety stands ar placed

properly (seescction 11.


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

Allow all four wheels {4WD)or front wheels (2wD}


to rotate freely.
Warm up the engine (the radiatorfan comes on),
then stop it and connectthe tachometer.
5.

Connectthe oil pressuregaugesto each inspection


holesecurely,and do not allow dust or otherforeign
particlesto enterthe inspectionholes.
TOROUE:18 N'm ll.8 kgf'm, 13 lbf'ft)

DRAIN
1 8x 1 . 5m m

SEALINGWASHEB
Replace.

49 N.m{5.0kgt.m,36 lbf.tl)

Reinstallthe drain plug with a new sealingwasher,


then refill the transmissionwith the recommended
fluid to the uDpermark on the dipstick.Always use
G e n u i n eH o n d a P r e m i u m F o r m u l aA u t o m a t i c
TransmissionFluid (ATF) Using a non-HondaATF
can affectshiftquality.
Automatic TransmissionFluid Capacity:
4WD;
2.9 { (3.1 US qt. 2.6 lmp qt) 8t change
5.8 ? {7.2 US $, 6.0 lmp qt} at ovethaul
2WD:
2.7 | l2.SUS qt,2.1lmp qtl ai change
5.9 ? {6.2 US $, 5.2 lmp qtl at ovolhaul

A/T OIL PRESSURE


GAUGESETW/PANEL
07{06 - 0020400

/4\

\-J--

HOS,
A/T PRESSURE
2210mm
07MAJ - PYiOllA
{4 Requircd}

,4

\r+..\.-.\-'-\

A/T LOW PBESSURE


GAUGEw/PANEL
07406 - 0070300

'/"' ,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.

Installnew sealingwashersand the sealingbolts in


the inspectionholes, and tighten to the specified
toroue.
TOROUE:18 N'm 11.8kgf'm, 13 lbf'ft)

www.emanualpro.com

(cont'd)

14-161

PressureTesting
(cont'd)
Line Proslure, lst Clutch, lst.hold Clutch prsssuro Measuromont
1.

Startthe engine,and shiftto E or @ position.

2.

Run the engine at 2,000rpm, then measureline pressure.Higherpressuremay be indicatedif measurements


are
madein shift leverpositionsotherthan E or @ position.
shift to E ('97- 98) or E ('99- oo) positionand holdthe engineat 2.ooorpm, then measure1stclutchpressure.

4.

Shiftto E positionand hold the engineat 2,000rpm, then measurelst-hotdctutchDressure.

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 (97 - 98) No or low 1st

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

830 - 880 kPa


(8.5* 9.0 kgflcm,,
120- '130psi)

ServiceLimit
780 kPa
'l10 psi)
{8.0kgf/cm,,

'99 - 00 Models:

znd, 3rd, and ,lth Clutch PressursMeasuremenl


'97 - 98 Modols:
1.
2.

1.

Startthe engine,and shiftto El position.

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.

Shift to E position,and turn the Over-Drive(O/D)


OFF by pressing the O/D switch (O/O OFF indicator
light comeson).

Stan the engine,and shiftto E position.


R u n t h e e n g i n ea t 2 , 0 0 0r p m , t h e n m e a s u r e2 n d
clutchpressure.

3.

Shift to E position,and hold the engine at 2'000


rpm, then measure3rd clutchpressure.

4.

Shift to E position,and hold the engine at 2,000


rpm, then measure4th clutchpressure.

4.

Hold the engine at 2,000 rpm, then measure 3rd


clutchPressure.

5.

Shift to @ position,and hold the engine at 2,000


rpm, then measure4th clutchpressure.

5.

Turn the Over-DriveON by pressingthe O/D switch


( O / DO F F i n d i c a t o rl i g h t g o e s o u t ) , a n d h o l d t h e
engineat 2,000rpm, then measure4th clutch pressure.

6.

Shift to E position,and hold the engine at 2,000


rpm, then measure4th clutchprgssure

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

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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.

Raisethe front of the vehicle,and make sure it is


supported securely.

2.

Set the parkingbrake,and block both rear wheels


securely.

6. Set a dial indicatoron the transferassemblyflange.


then measurethe transfergear backlash.
STANDARD:0.06- 0.16 mm (0.002- 0.006inl

COMPANIONFLANGE

Shift to E position.
4.

Make a referencemark acrossthe propeller shaft


and the transferassemblyflanges.
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.

7. lf the measurementis out of standard,removethe


transferassemblyand adjusttransfergear backlash
'14-232
{see page
thru 14-2491.
8. Checkfor fluid leaks betweenthe mating faces of
transfer cover A and cover B.
9. lf there is a fluid leak,removethe cover,and reDlace
the O-ring.
'10.
8 x 1.25mm
32 N.m 13.3kgl,m,
24 lbf.ftl
Replace.

Checkfor fluid leaks betweenthe mating face of the


transferassemblyand transmission.

11. lf there is a fluid lak, removethe transfrassembly, and replacethe O-ring,


1 2 . C h e c kt h e t r a n s f e ro i l s e a l f o r d a m a g ea n d f l u i d
le8ks.
13, lf oil sealreplacementis required.removethe transfer assembly,replacethe oil seal, and adjust the
total starting torque (see page 1+232 thtu ]'4-249||.
NOTE:Do not replacethe oil seal with the transfer
assemblyon the transmission.

14-164

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TransferAssembly
Removal
Make sure the lifts, iacks, and safety
@
stands are placed properly (seesection 11.
1.

Raisethe front of the vehicle,and make sure it is


supportedsecurely.

2.

Set the parkingbrake,and block both rear wheels


securelv.

Drainthe automatictransmissionfluid (ATF).


Reinstallthe drain plug with a new sealingwasher'

5.

Disconnect he primary heatedoxygen sensor


{PrimaryHO2S)connector.
RemoveexhaustpipeA.

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.

Removethe guard bar and the splashshield.

GUARD8AR

www.emanualpro.com

Removethe shift cablecover.


Removethe snap pin and controlpin, then separate
the shift cablefrom the control lever.Do not bend
the shift cableexcessively.

(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

l. Removethe rear stiffener.then removethe transfer

assembly.
NOTE: While servicingthe transfer assembly,do
not allow dust or otherforeignparticlesto enterthe
transmission.
REARSTIFFENER

14-166

www.emanualpro.com

lnstallation
1.

Installa new O-ringon ths transferassembly.

5.

Installthe propellershaft to the transferassembly


by aligningthe referencemarks

Clsan the areaswhere the transferassemblycontacts the transmissionwith solvent or carburetor


cleaner,and dry with compressedair. Then apply
ATF to the contact areas.

REFERENCE
MARKS

Installthe transterassemblyon the transmission.


PROPELLER
SHAFT

NOTE: while installingthe transfer assembly,do


not allow dust or other foreignparticlesto enterthe
transmission.
lnstallthe rearstiffener.

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,

12. Startthe engine,and run it to normaloperatingtem-

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

Refillthetransmissionwith ATF (seepage14-161).

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.

Make sure lifts. iacks, and safety stands aro placed


properly, and hoist brackets are attached to the colrest position on the engine lsee section 11.
Apply th parking brake and block the rar wheels,
so vehicls will noi roll off the stands and fall on you
while working under it.

Disconnect
the vehiclespeedsensor(VSS),the countershaft speed sensor, and the A/T gear position
switch connectors.

A/T GEARPOSITION
SWITCHCONNECTOR

VEHICLESPEED
SENSOR|VSS'

NOTE: Use fender covers to avoid damaging painted


surfaces.
' 1 . Disconnectthe negativeterminal,then disconnect
the positiveterminalfrom the battery.
2.

Removethe intakeair duct and the air cleanerhousing assembly,


R e m o v et h e s t a r t e rc a b l e s .R e m o v et h e h a r n e s s
clampfrom the clampbracket.
CLAMP
CONNECTOR
BfiACKET
SPEEDSENSOR
CONNECTOR

7.

Remove the transmission housing mounting bolts.

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.

Disconnectthe lock-upcontrol solenoidvalve connector,then remove the harnessclamp from the


clamp bracket.
HARNESS
CLAMP

RADIATORHOSE
CLAMP

MOUNTINGBOLTS

CONTROL
SOLENOIDVALVE
CONNECTOR

www.emanualpro.com

(cont'd)

14-169

Transmission
Removal(cont'd)
8.

Disconnectthe mainshaftsped sensor, the shift


controlsolenoidvalve,and the linearsolenoidconnecrors,

10. Removethe guard bar and the splashshield.

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).

12. Removethe right damper fork bolt, then separate


right damperfork and damper.

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.

1 3 . Pry the right driveshaftout of the differential.and


orv the left driveshaft out of the intermediate shaft
{seesection16).
1 4 . Pull out the inboardjoint, and removethe right and
left driveshaft(seesection18).
Tie plastic bags over the driveshaftends. Coat all
finishedsurfaceswith cleanengineoil.
Drecision

1 8 . Removethe shift cablecover.


1 9 . Removethe shift cable.
ilWD:
Removethe snap pin and controlpin, then separate
the shift cable from the control lever. Do not bend
the shift cableexcessively.

ORIVESHAFT

Replace.

16. Disconnect he primary heatedoxygen sensor


(PrimaryHO2S)connector.

'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)

2 4 . Removethe right front mounvbracket.


Remove the ATF cooler hoses at the ATF cooler
lines.Turn the ends of the cooler hosesuo to orevent ATF from flowing out, then plug the linesand
hoses.Checkfor any sign of leakageat the hose
ioints.

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.

27. Removethe eight drive plate bolts, one at a time.


while rotatingthe crankshaftpulley.
DRIVE PLATE

COVER

14-172

www.emanualpro.com

28. Place a jack under the transmission,raise it just


enough to take it off of the mounts, then remove
the transmissionmount bracket.

30. Rmovethe rear side transmissionhousingmounting bolt and the rearenginemountingbolts.

REARENGINEMOUNTINGBOLTS

3 1 . Pull the transmissionaway from the engine until it


29. Removethe front sidetransmissionhousinomounting bolt.

clearsthe dowel pins,then lower it on the transmissionjack.


Remove thg torque converter assemblyfrom the
transmission.
Removethe starterfrom the transmissionhousing.

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

i!, O-RING Replace.


@ THRUSTWASHER
@ THRUSTNEEDLEBEARING
@ NEEDLEBEARING
@ MAINSHAFI 1STGEAR
@ MAINSHAFT1sT GEARcoLLAR
@ o-RING Replace.
SPEEDSENSOR
6!, COUNTERSHAFT
@ ROLLER
@) COLLAR
@ o-RtNG Replace.
6A FEEoPIPEFLANGE
@ o-RtNG Reptace.
@ SNAPR|NG
@ IST.HOLDcLUTcH FEEDPIPE
LOCKNUT
19 x 1,25mm Reptace.
@ SUB-SHAFT
O coNtCALSPR|NGWASHERReptace.
E! SUB.SHAFTlST GEAR
} LINEARSOLENOIDASSEMBLY
soLENotD aSSEMBLyGASKET Reptace.
@ LTNEAR
@ HARNESSBBACKET
WASHERSFeptace.
@ SEALING
@ ATF COOLERLINE
@ LIN BoLT
@ ATF DIPSTICK
@ ATF COOLERLINE
@ LINEBoLT
@ SEALINGWASHERSReptace.
@ VEHICLESPEEDsENsoR (vss)
@ o-RtNG Beptace.

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
@

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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.

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Torque Value

Size

12 N.m (1.2kgim,8.7 lbf'tt)

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

ATF COOI.fB LINES


LINEBOLT

14-186

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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.

Engagethe parkpawlwith the parkgear.


Cut the locktabsof eachshaft locknutusing a chiselas
shown. Keepall chiseledparticlesout of the transmisston.

M=tt"

9. Removethe lock pin that was installedto hold the


sub-shaft.
10. Removethe specialtool from the mainshaft.
11. Removethe 1stclutch,mainshaft1stgearassembly,
and mainshaft1stgearcollar.
'12. Removethe sub-shaft1stgear.
13. Removethe park pawl, pawl spring,pawl shaft.and
pawl stoP.
14. Removethe park leverfrom the controlshaft.
15. Using a universaltwo jaw puller, removethe park
g e a r , o n e - w a yc l u t c h ,a n d c o u n t e r s h a f 1t s t g e a l
assemblv.
PULLER
available)
{Commercially

Align the hole of the sub-shaft1st gear with the hole


of the transmissionhousing.then insert a pin to lock
the sub-shaftwhile removingthe sub-shaftlocknut.
Removethe locknutsand conicalspring washersfrom
eachshaft.
NOTE:
Mainshaftand countershaftlocknuts have lefthandthreads.
Cleanthe old countershaftlocknut.lt is used to
installthe pressfit parkgear on the countershaft.

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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

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Removethe countershaftreversegearcollar,needle
bearing, and countershaftrevsrse gear from the
countershaft,

1 . Removethe transferassemblyfrom the torque converterhousing.(4WD)


Removethe mainshaftspeedsensorfrom the transmissionhousing.

7.

Removethe lock bolt securingtho reverseshift fork,


t h e n r e m o v e t h e r e v e r s es h i f t f o r k a n d r e v e r s e
selectortogether.

8.

Removethe countershaftsub-assemblvand maintogether,


shaftsub-assembly

9.

Removethe differential assembly.

Removethe transmissionhousing mounting bolts,


transmissionhanger,and connectorbracket.
4.

Align the spring pin on the control shaft with the


transmissionhousinggrooveby turningthe control
shaft.

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.

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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

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\
CONTROL
LEVER
MOUNTINGBOLT
{awD)

SECONDARY
SEPARATOR
PLATE

1 . Removethe control lever mounting bolt trom the


torque converterside of the torque converterhousing. (4WD)

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.

Removethe ATF feed pipes from the servo body,


secondaryvalvebody,lock-upvalvebody,and main
valvebody.
For'97 - 98 models:
Removethe two boltssecuringthe ATF strainerand
servodetentbase,then removethe strainerand the
base.
For'99 - 00 models;
Removethe ATFstrainer{one bolt).
4. For'97 - 98 models:
Removethe seven bolts securingthe servo body,
then remove the servo body and separatorplate'
For'99 - 00 models:
Removethe eight bolts securingthe servo body,
then removethe servobody and separatorplate'
5 . B e m o v et h e t h r e e b o l t s s e c u r i n gt h e s e c o n d a r y
valve body, then remove the secondaryvalve body'
stop shaft bracket,and separatorplate.
6. Removethe eight bolts securingthe ATF lubrication
plate and lock-upvalve body, then removethe ATF
lubricationplate,lock-upvalve body' and separator
plate.

INLET OPENING

1 5 . Test the ATF strainer by pouring clean ATF through


the inlet opening,and replaceit if it is clogged or
damaged.

7. Removethe one bolt securingthe regulatorvalve


body,then removethe regulatorvalvebody'
8. Removethe stator shaft and stop shaft.
9. Removethe detentspringfrom the detentarm, then
remove the control shaft from the torque converter
houslng.
10. Removethe detentarm and detentarm shaft from
the main valvebody.
1 1 . R e m o v et h e f i v e b o l t s s e c u r i n gt h e m a i n v a l v e
body,then removethe main valvebody.
When removingthe main valve body, do not let the
eight checkballsfall out.
1 2 . R e m o v et h e A T F p u m p d r i v e n g e a r s h a f t , t h e n
removethe ATF PumPgears.
13. Removethe main separatorplate with two dowel
prns.

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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.

Carelullytap the valve body so the stickingvalve


drops out of its bore. lt may be necessaryto use a
small screwdriverto pry the valve free. Be careful
not to scratchthe bore with the screwdriver.

,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.

Roll up half a sheet of ATF-soaked


#600 paper and
insertit in the valve bore of the stickingvalve.
Twist the paper slightly,so that it unrolls and fits
the bore tightly,then polishthe bore by twistingthe
paperas you push it in and out.

Coatthe valvewith ATF,then drop it into its bore, lt


shoulddrop to the bottomof the bore underits own
weight. lf not, repeatstep 4, then retest.lf the valve
still sticks,replacethe valvebody.

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

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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.

Removethe valve.and thoroughlyclean it and the


valve body with solvent. DrV all parts with compressedair,then reassemble
usingATFas a lubricant.

Valve
Assembly
NOTE;
Coatall partswith ATF beforeassembly.
.

Set the spring in the valve,and installit in the valve


b o d y . P u s ht h e s p r i n g i n w i t h a s c r e w d r i v e rt,h e n
installthe springseat.

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

Installthe valve,spring,and cap in the valve body.


Pushthe caD,then installthe cliP.

VALVE BODY

VALVE

CAP

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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

Capswith hollow ends are installedwith the hollow


end awayfrom the insideof the valveooov.
Capswith notchedends are installedwith the notch
towardthe insideof the valvebodv.
Capswith flat ends and a holethroughthe centerare
installedwith the smaller hole toward the inside of
the valvebody.

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 .

TOWARD OUTSID OF VALVE BOOY

TOWARDI'{SIDEOF VALVEEOOY

14-194

www.emanualpro.com

TOWAROINSII'C OF VALVE BODY

Capswith flat ends and a groovearoundthe cap are


installedwith the groovedside toward the outsideof
the valvebody.

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

Measurethe side clearanceof the ATF pump drive


and drivengears.

2.

ATF Pump Gears Side {Radial}Cloarance:


Standard (Newl:
ATF Pump Drive Gear
0.105- 0.1325mm {0.004- 0.005in}
ATF Pumo Driven Gear
0.035- 0.0625mm {0.0014- 0.0025in)

ATF PUMP ORIVE

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.

MAIN VALVE AOOY

Removethe ATF pump driven gear shaft Measure


the thrust clearanceof the ATF pump driven gearto-valvebody.
ATF Pumo Drive/DrivenGearThrust (AxiallClearance:
Standard (Nw): 0.03- 0.05 mm {0'001- 0 002 inl
ServiceLimit: 0.07 mm 10.003in)

ATF PUMP
ORIVENGEAR

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14-195

Main Valve Body


Disassembly/lnspection/Reassembly
NOTE:
. Do not usea magnetto removethe checkballs;it may magnetizethe balls.
t clean all partsthoroughlyin solventor carburetorcleaner,and dry them with compressed
ai.. Blow out all passages.
. Replacethe valvebody as an assemblyif any partsare worn or damageo.
. 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 o s l i d e f r e e l y , s e e V a l v e B o d y R e p a i r o n p a g e . t 4 _ 1 9 2 .
. Coatall partswith ATF during reassembly.

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
@
@
@

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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

www.emanualpro.com

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,

www.emanualpro.com

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
(

www.emanualpro.com

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
www.emanualpro.com

14-202

SET RING

lST GEAR

TnANSMtSSIOt{
HOUSII{GBEARII{G

Inspection
Clearance
Measurement
1.

2.

3.

Removethe mainshaftbearingfrom the transmission housing lsee page 14-227l..

Tightenthe mainshaftlocknutto 29 N.m (3.0kgf.m,


22 tbf.ft).
The mainshaftlocknuthas left-handthreads.

Assemblethe mainshaftparts,but do not installthe


O-rings,

CONICALSPRINGWASHER

29 N.m (3.Okst.m, 22 lbt.frl


lST CLUTCHASSEMELY
THRUST WASHER
1ST GEAB COLLAR
TRAI{SMISSION
HOUSIf{G BEARING
SNAP RII{G
THRUST WASI{ER
GEAR COLLAR

Hold 2nd gear againstthe 2nd clutch,then measure


the clearancebetween2nd gear and 3rd gearwith a
feelergauge. Take measurementsin at leastthree
places,and usethe averageas the actualclearance.
STANDARD:0.05- 0.13 mm (0.002- 0.005in)
3RD GEAR

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)

www.emanualpro.com

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.

The sealingrings(35 mm and 29 mm) are syntheticresin


with chamferedends.Checkthe conditionof the sealing
rings,and replacethem only if they are worn, distorted,
or oamageo.
NOTE:Apply ATFto all partsduringassembly.
1.

For a better fit, squeezethe sealing ring together


slightlybeforeinstallingthem.

Selectand install a new washer,then recheckthe


clearance,
and makesure it is within standard.
THRUSTWASHER36.5 x 55 mm
No.

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

Installnew sealingrings on the mainshaft.


After installingthe sealingrings, verify the following:
.
.
.

The sealingringsare fully seatedin the groove.


The sealingringsare not twisted.
T h e c h a m f e r e de n d s o f t h e s e a l i n g r i n g s a r e
properlyjoined.

SEALINGRING
Installthe sealingring
matingfacesas shown.

www.emanualpro.com

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

www.emanualpro.com

14-205

Gountershaft
Disassembly/Reassembly
1.

Removethe reverseselectorhub and countershaft


4th gear using a universaltwo-jaw lor three-jaw)
puller as shown. Placea shaft protector between
t h e p u l l e ra n d c o u n t e r s h a ftto p r e v e n td a m a g i n g
the countershaft.

2.

Assemblethe parts on the countershaftas shown


below.
NOTE;
. Lubricateall partswith ATF during reassembly.
. B e f o r e i n s t a l l i n gt h e O - r i n g s .w r a p t h e s h a f t
s p l i n e sw i t h t a p e t o p r e v e n td a m a g i n gt h e O rings.

{ 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.

Installthe reverseselectorhub on the countershaft


sub-assembly,
and pressthe hub using the special
tool and a pressas shown.

DRIVERto mm l.D.
07746- 0030100

ClearanceMeasurement
NOTE: Lubricateall partswith ATF duringassembly.
1.

Removethe countershaftbearing from the transmissionhousinglsee page14-227).

2.

Assemblethe countershaftparts using the special


tool and a pressas describedon this page. Do not
installthe O-ringsduring inspection.

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)

www.emanualpro.com

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.

Tightenthe locknutto 29 N.m (3.0 kgf.m,22 lbf.ft).


The countershaftlocknuthasleft-handthreads.

Measurethe clearancebetweenthe 2nd gear and


the 28 mm distancecollarwith a feelergauge.

5.

NOTE:Takemeasurementsin at leastthree places,


and usethe averageas the actualclearance.
0.10- 0.18mm (0.004- 0.007in)
STANDARD:

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.

Selectand installa new distancecollar,then recheck.

DISTANCECOLLAR,28mm
No.

8.

14-208

www.emanualpro.com

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 )

After selectinga new distancecollar. recheckthe


clearance
and makesureit is within standard.

One-way Glutch
Disassembly/lnspection/Reassem
bly
1.

Separatecountershaft1st gear from the park gear


by turningthe parkgear in the directionshown.

3.

Inspectthe oartsas follows;


PARKGEAR
InspectIor wear
andsconng.

PARKGEAR

COUNTERSHAFT
lST GEAR

2.

ONE.WAYCLUTCH
Inspectfor damage
and taultymovement,

Removethe one-wayclutchby prying it up with the


tip of a screwdriver.

COUNTERSHAFT
IST GEAR

ONE.WAYCLUTCH
Installin this direction.
lST GEAR
Inspectfor wear
and scortng.

4.

After the parts are assembled, hold countershaft lst


gear. and turn the park gear in the direction shown
to be sure it turns freely. Also make sure the park
gear does not turn in the opposite direction.

ONE.WAYCLUTCH
lST GEAR

,ISTGEAR
COUNTERSHAFT
SCREWDRIVER

www.emanualpro.com

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

www.emanualpro.com

14-210

Disassembly/Reassembly
1.

Removethe ATF guidecap by pushingthe sub-shaft


insidethe transmissionhousing.
R e m o v et h e 1 s t - h o l dc l u t c ha s s e m b l yb y p u l l i n g ,
then removingthe sub-shaft.
Installnew O-ringson the sub-shaft.
NOTE:Wrap the shaft splineswith tape to prevent
damagingthe O-rings.
P l a c et h e s u b - s h a f ti n t h e t r a n s m i s s i o nh o u s i n g ,
and installthe'lst-holdclutchassembly,
I n s t a l lt h e n e w A T F g u i d e c a p u s i n g t h e s p e c i a l
tools.Installit in the directionshown.

ATTACHMENT,
32x35mm
07746- 0010t00

www.emanualpro.com

14-211

Sub-shaftBearings
Replacement
NOTE:Lubricateall partswith ATF beforereassembly.
1.

4.

Installa new needle bearing in the housing using


the sOecialtools and a oressas shown.

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.

Releasethe pliers,then push the bearingdown into


t h e h o u s i n gu n t i l t h e s n a p r i n g s n a p si n p l a c e
aroundit.
7.

After installingthe ball bearingverifythe fottowing:


.
.

The snap ring is seatedin the bearingand housIng grooves.


The ring end gap is correct.

ENDGAP:0-7mm
l0 - 0.28 inl

SNAPRING

14-212

www.emanualpro.com

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)

www.emanualpro.com

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

www.emanualpro.com

14-215

Clutch
Disassembly
l.

Removethe snap ring, then removethe clutch end


plate,clutchdiscsand plates.

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

1ST,2ND, 4TH lST-HOLDCLUTCH:


DISCSPRING
CLUTCH
COMPRESSOR
AOLTASSEMBLY
07GAE- FGao2OO
or
OTGAE. PG4O2OA

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

www.emanualpro.com

CAUTION: lf either end ot the specialtool issetover an


area of the spring retainer which is unsupported by the
return spring, the retainer may be damaged. B sure the
specialtool is adiusted to have lull contact with the
spring retainer.

Do not s6t h6re.

5.

Removethe snap ring, Then removethe specialtools,


springretainerand returnspring.

SPRIlIG RETAINER

Wrap a shop rag aroundthe clutchdrum, and apply


air pressureto the ATF passageto removethe piston.
Placea finger tip on the other end while applying
arr pressure.
OSHA.APPROVED
SPRINGRETAINER

4.

www.emanualpro.com

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.

Installth pistonin the clutchdrum. Apply pressure


and rotate it to ensure proper seating, Lubricatethe
pistonO-ringwith ATF betoreinsta ing the piston.
NOTE:Oo not pinchthe O-ringby installingthe pis_
ton with too muchforce.

Inspectthe checkvalve;if it's loose,replacethe pis_


ton.

CLUTCH DRUM

CHECK VALVE

2.

4.

Installnew O-ringson the clutchpiston.

Installthe return spring, and spring retainer,then


positionthe snap ring on the retainer.

SI{AP RING

SPAI'{G RETAIIIER

REIURN SPRING

CLUTCH DRUM

PtsTot{

14-218

www.emanualpro.com

5.

CAUTION:It sither end of the spscial tool is sot


over an area of the spring retainl which is unsup'
ported by the return spring, the retainer may be
damaged. Be sure the specialtool is adiusted to
have full contaqt with th spring ratainel.

Installthe specialtoolsas shown

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)

www.emanualpro.com

14-219

Clutch
(cont'd)
Reassembly
7.

Installthe
s n a pr i n g .

1 0 . Soakthe clutchdiscsthoroughlyin ATF for a mini_

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

with a clutch plate, alternatelvinstall the


clutch platesand discs.Installthe clutch end plate
with its flat sidetowardthe disc.

CLUTCHEI{D PI.ATE
Installin this directior.

S AP RIIG
8.

Removethe specialtools.

9,

Installthe discspring in the directionshown.

1ST,2ND, 4TH, lST-HOLDCLUTCH:

otsc sPfitl{c

CLUTCH

CLUTCHEI{D PLATE

12. Installthe snap ring.

SCREWDRIVER
3RD CLUTCH:

Dlsc sPRrrtc

CIUTCH ORUM

14-220

www.emanualpro.com

13. Measurethe clearancebetweenthe clutchend plate


and top disc with a dial indicator.Zerothe dial indicatorwith the clutchend platelowered,and lift it up
to the snap ring. The distancethat the clutch end
plate movesis the clearancebetweenit and the top
dtsc.
NOTE:Takemeasurementsin at leastthree places'
and usethe averageas the actualclearance.

lST CLUTCHEND PLATES


'I

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

22556 P56- N00


22557 - P56 N00
2 2 5 5 8- P 5 6 N 0 0

2 2 5 5 9- P 5 6 N 0 0

10

22s60- P56 N00

6
7

Clutch End Ptate-to-TopDisc Clearance:


Clutch
'l st
2nd
3rd
4th
lst-hold

ServiceLimit
0.650.400.400.400.50-

0.85mm (0.0260.60mm (0.0160.60mm (0.0160.60mm (0.0160.80mm (0.020-

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 )

22561 PDM22562- PDM22563 PDM22564 PDM-

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

22560 P56- N00

11

22561 PD[4 - 000

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

NOTE: lf the thickestclutch end plate is installed,


but the clearanceis still over the standard,replace
the clutchdiscsand clutchplates.

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

1 4 . lf the clearanceis not within the servicelimits,select


a new clutchend platefrom the followingtable

2 . 1m m ( 0 . 0 8i3n )
in)
2.2mm (0.087

2ND and 4TH CLUTCHEND PLATES

'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 )

22553 PS5- 003

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

22557- PSs 003

rnictness

2 . 6m m { 0 . 1 0 2i n )
2 . 7m m ( 0 . 1 0 6i n )

CLUTCHEND PLATE

www.emanualpro.com

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

Placethe differentialassemblyon V-blocks.

NOTE:Checkbearingsfor wear and rough movement.


lf bearingsare OK, removalis not required.

lnstallthe driveshaftand intermediateshaft on the


differentialassemblY.

1.

Checkthe backlashof both piniongears.

Removethe bearingsusinga bearingpuller.


PULLER
BEARING
(Commercially
available)

STANDARD:0.05- 0.15 mm (0.002- 0.006in)


DIALINDICATOR

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

It the backlashis out of standard, replacethe difterentialcarrier.

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),

Removethe snap ring from the differentialcarrier.

Tightenthe boltsto the specifiedtorque.


N O T E : T h e 2 W D d i f f e r e n t i a tb o l t h a s l e f t - h a n d
threads,
1 0x 1 . 0m m
103N.m 110.5
kd.m,
7s.9 rbr.ft)

FINALDRIVENGEAR

Removethe 5 x 15 mm roller (4WD)or 5 x 10 mm


roller(2WDland the speedometerdrive gear.
SPEEDOMETER
DRIVEGEAR

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

Removethe bolts securingthe final drivengear and


the transfershaft drive gear (4WD),then replacethe
differentialcarrier.

14-224

www.emanualpro.com

SPRINGPIN

GROOVE

Oil SealReplacement
1.

Removethe oil sealfrom the transmissionhousing.

3.

lnstallthe oil seal in the transmissionhousingusing


the specialtools as shown.

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.

Installthe oil seal in the torque converterhousing


usingthe specialtoolsas shown.

-.].
OIL SEAL
Replace.

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TOROUECONVERTER
HOUSING

14-225

Differential
Side ClearanceInspection
1.

Instsllthe 80 mm set ring in the transmissionhousIng,

4.

Tap on the transmissionhousingside of the diffsr


entialassemblywith the specialtool to seatthe differentialassemblv.
DBIVERilo m.n LO.
0t746 - 0030100

SET RING,80 mrn

Measurethe clearancsbetweenthe 80 mm set ring


and the bearingouter racewith a feelergauge,
Installthe differentialassemblyin the torque converterhousingusingthe specialtool.

STANDARD:0 - 0.15 mm (0 - 0.006inl

FEEI..ER
GAUGE
lf the clearanceis out of standard,removerne set
ring and measurs its thickness.
7.

Selectand instslla new 80 mm set ring.


SETRING,80 mm
Part Numbor

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

TOROUE:4a N.m l/r.5 kgf.m, 33 tbt.ftl


Recheckthe clearance,and make sure it is within
standard.

14-226

www.emanualpro.com

HousingBearings
Transmission
Mainshaft/CountershaftBearingsReplacement
1.

Expandeach snap ring with snap ring pliers,then


coat the new bearingswith ATF and insert them
part-way into the housing using the specialtools
and a pressas shown. Installthe bearingswith the
groovefacingoutsidethe housing.

Expandeach snap ring with snap ring pliers,then


push the bearingsout of the transmissionhousing
usingthe specialtools and a pressas shown.
Do not removethe snap rings unlessit's necessary
to cleanthe groovesin the housing.

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.

After installingthe bearings,verifythe following:


T h e s n a p r i n g s a r e s e a t e di n t h e b e a r i n ga n d
housrnggrooves.
. The snap ringsdo not bind.
. The ring end gapsare correct,
.

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.

Expand the snap ring with snap ring pliers, then


push the bearingout of the transmissionhousing
usingthe specialtools and a pressas shown.

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.

Do not removethe snap ring unlessit,s necessary


to cleanthe groovein the housing.

Releasethe pliers,then push the bearingdown into


the housinguntilthe ring snapsin placearoundit.

DRIVER
07743- 0010mo

ATTACHMENT,
{i:l x 68 mm
07746- 0010500
GROOVE

After installingthe bearing,verifythe following:


ATTACHMEI{T,
5:l x 68 mm
07r{5 - @10500

SNAP RI]TG

.
.
.

DRIVER
07749- tDl(xx)o

The snap rjng is seatedin the bearingand hous_


ing grooves.
The snap ring does not bind.
The ring end gap is correct,

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.

Installa new oil sealflush with the torqueconverter


housing.

07749- 0010000
SLIDEHAMMER,
3/8" - 16
(Commercially
available)

ATTACHMENT,
ADJUSTABLEEEARING
- 40 mm
PULLER,25
07736- A010008or
07736- A01000A

07?46- 0010m0

Installa new mainshaftbearinguntil it bottoms in


the torqueconverterhousing.

ATTACHMENT,
62x68mm
07746- 0010500

www.emanualpro.com

14-229

TorqueGonverterHousing
Bearings

GontrolLeverAssembly

CountershaftBearingReplacement

Replacement

1.

Checkthe conditionand movementof the control lever


assembly,lf the control lever assemblybinds or does
not move smoothly.replaceit.

Removethe countershaftbearingusing the special


tool.

SLIOEHAMMER,
3la" -16
(Commercially
available)

ADJUSTABLE
BEARING
- 40mm
PULLER,25
07736- A0100OB
ol
07736- A01m0A

1.

Removethe 6 x 1.0mm bolt and lockwasher.

2.

Removethe changeshafttrom the torqueconverter


housing.

3.

Removethe controlleverassemblyfrom the control


shaft.

4.

Installthe new controlleverassemblyin the reverse


order of disassembly,until it bottoms in the torque
converterhousing.

COUNTERSHAFT
BEARING

Installthe ATF guide ptate.


I n s t a l la n e w c o u n t e r s h a fbt e a r i n g i n t h e t o r q u e
converterhousing.

DRIVER
077i19- 001m00

LOCKWASHER
Replace.

ATF GUIDEPLATE

14-230

www.emanualpro.com

ParkStop

Reverseldler Gear

ustment
Inspection/Adi

lnstallation
1.

't. Setthe parkleverin the E position.

lnstallthe reverseidler gear'

Measurethe distancebetweenthe park pawl shaft


and the parkleverrollerpin as shown.
72.9- 73.9mm {2.87- 2.91in)
STANDARD:

',.A\
Measuring

\t/

PARKSTOP

lnstallthereverseidler gear shaftholderand needle


bearinginto the transmissionhousing,then tighten
the bolts.
6 x 1.0 mm
12 N.ft ll.2 kgl']n,
a.7 rbl.frl

PARKPAWLSHAFT

lf the measurementis out of standard,selectand


i n s t a l lt h e a p p r o p r i a t ep a r k s t o p f r o m t h e t a b l e
below.
PARKSTOP

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.

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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

132 216 N.m (13.5 22.0kgf.m,


98 - 159lbift)

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.

TransferGear (Hypoid gear) Tooth Contact Inspection


5,

Trsnsfer Gear (Hypoid gear) Backl8shMasuremnt

Removetransfercover B, then apply PrussianBlue


to both sides of the transfergear teeth lightly and

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.

Measurethe transfergear backlash.


STANDARD:0.06 - 0.16 mm {0.02- 0.06 in)
DIALINDICATOR

TRANSFERDRIVEGAR

6.

Rotatethe companionflangein both directionsuntil


the transfergear rotatesone full turn in both directions.

7.

Checkthe transfergear tooth contact pattern.The


pattern should be centered on the gear tseth as
snown.

8.

lf the statrting torque measurementor the tooth


contact pattern are not correct, disassemblethe
transferassembly,replaceworn or damagedparts,
and reassembleit.

COMPANIONFLANGE

Total Starting Torque Meagurgmnt


3,

Rotatethe companionflange severaltimes to seat


the taperedrollerbearing.

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.

Removethe transfercoversA and B.

Removethe transfershaft locknut and the conical


spring washer.The transfershaft locknut has left
handthreads.

1a mm ALLENWRENCH

5.

Removethe transfer shaft, transfer drive gear, 25


mm thrust shim, transfershaft collar,and tapered
rollerbearingfrom the transferhousing.
TRANSFERSHAFT

2.

Cutthe locktabs of the locknutusinoa chisel.

LOCKTAB

THRUSTSHIM,
25 mrn
Selectivepart

CONICALSPRING
WASHER
Replace.

(cont'd)

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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.

9. Removethe transferdriven gear shaft,then remove


the transfer spacer from the transfer driven gear
shaft.

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.

1 0 . Removethe oil seal and the taperedroller bearing


from the transferhousing.

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

NOTE:Coatall partswith ATFduring reassembly.

NOTE: Coat all parts with ATF during reassembly.

1.

1.

Removethe taperedrollerbearingfrom the transfer


drive gear usingthe specialtools and a press.

Removethe taperedrollerbearingfrom the transfer


drivengearshaft usinga pressand a collar.

BANf{GSEPARATO
0 - 1112'
(Comm6rcially
availablel

(Commercially
available)
Installthe new taperedroller bearingin the transfer
drivegear usingthe specialtoolsand a press.

2.

Installthe 35 mm thrust shim on the transferdriven


gear shaft,

3,

Installthe new taperedrollerbearingon the transfer


d r i v e n g e a r s h a f t u s i n g t h e s p e c i a lt o o l s a n d a
press.
PNESS

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

NOTE;Coatall partswith ATF du.ing reassembly.

NOTE:Coatall partswith ATF during reassembly.

1.

1.

Removethe roller bearingfrom the transferhous


Ing.

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).

Installthe 68 mm thrustshim in transfercoverA.


Installthe new roller bearingusingthe specialtools
and a press.

ATTACHMENT,
62x68mm
07746- 0010500

TRANSFERHOUSING

14-238

www.emanualpro.com

Installthe tapered roller bearing outer race using


the specialtools and a p.ess.

TransferHousingBearingOuterRaceReplacement
NOTE: Coat all parts with ATF during reassembly.
1.

Bearing Outer Rac6Locations


and SpecialTool Applications

Removethe taperedroller bearingouter racefrom


the transferhousing.
HOUSING
TRANSTER
vi.w
Sacttonal

ATTACHMENT,
62x68mm
077a5- @105dt

ATTACHI'E'{T,
{i:l x 6t mm
07746 - rDl05rr0
ATTACHMENT,
52x55mm
07t46 - dtroa{x,

TRANSFERHOUSING

Install th new tapered roller bearing outer race


usingthe specialtoolsand a press.

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.

Prea$emble the parts to check and adiust transtel


gear backlashand transfer gear tooth contact.

3 . Disassemblethe parts, then assemble the transler


driven gsar shaft and its related pans.
4.

Measure and adjust the starting torque oI the


transfer driven gear shaft tapered roller bearing.

5.

Assemblethe transfer shaft and its related parts.

6.

Measureand adiust the total starting torque.

35 mm Thrust Shim Selection


L

Selectthe 35 mm thrust shim if the transferdriven


gearshaftor the taperedrollerbearingon the transfer drivengearshaft is replaced.
Calculate
t h e t h i c k n e s so f t h e 3 5 m m t h r u s t s h i m
usingthe formula below.

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

"x = A - B . c100 100


2 - 1
'100 100
= 0.02+ 0.0'l+ 1.05
=1.08{mm)
S e l e c t3 5 m m t h r u s t s h i m t h i c k n e s so f l 0 8 m m
(0.043in). lf the taperedroller bearingon the transfer
drivengear shaftis replaced.
M e a s u r et h e t h i c k n e s so f t h e r e p l a c e m e nbt e a r i n g
and the existingbearing,and calculatethe difference
of the bearjngthickness.Adjust the thicknessof the
existing35 mm thrust shim by the amount of difference in bearingthickness,and selectthe replacement
3 5 m m t h r u s ts h i m .
THRUSTSHIM,35 mm
Shim No.

c
D
F
H

Part Number

41361- PS3- 000


41362-PS3-000
41363-PS3-000
41364-PS3-000
41365-PS3-000

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

Transfer Gear BscklashInspectionand TransferGear


Tooth Contact Inspection
2.

5.

Installthe transferdriven gear shaft in the transfer


housing.Do not install the transfer spaceron the
transferdrivengearshaft in this step.

Installthe 35 mm thrust shim on the transferdriven


g e a r s h a f t ,t h e n i n s t a l lt h e t a p e r e dr o l l e r b e a r i n g
usingthe specialtools and a press.

TRANSFER

DRIVER{0 mm LD.
- 0030100
077146

TRANSFER
DRTVEN
GEARSHAFT

;;. 745- 0O304O0


u,

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.

Placethe taperedrollerbearingon the bearingouter


race of the companionflange side of the transfer
housrng.

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.

Securethe transfer housing in a bench vise with


soft jaws, then installthe specialtool on the companion flange. To preventdamageto the transfer
housing,alwaysuse soft jaws or equivalentmaterials betweenthe transferhousingand the vise.
Tighten the locknut while measuringthe starting
'1.39
torque so the startingtorque is within 0.98N.m (10.0- 14.2kgf.cm,8.68 12.3lbnin).

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 0 . Put a 14 mm Allen wrench in the gear side of the


transfer shaft, then secure the Allen wrench in a
benchvise.

1 3 . Rotatethe companionflange severaltimes to seat


the taperedrollerbearing.
1 4 . Set a dial indicatoron the companionflange,then

1 1 . Tightenthe transfershaftlocknut.
NOTE:
. The transfershaftlocknuthas left-handthreads.
. Do not stakethe locknutin this step.

measurethe transfergear backlash.


STANDARD:
0.06- 0.16mm {0.02- 0.06inl
DIAL INOICATOR

TOROUE:118 N'm 112.0kgf.m, 87 lbf.ftl


TOROUEWRENCH

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.

1 2 . Temporarilyinstallthe transfercoverA without t h e


O-ring.
TRANSFERHOUSING

2
4
6
7

11

29421- P1C- 000

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.

19. lf the transfergear tooth contactis incorrect,adjust


the transfergear tooth contactwith a 35 mm or 25
m m t hr u s ts h i m .
NOTE:
. To selecta 35 mm thrust shim, referto page 14,
240.
. D o n o t u s e m o r e t h a n t w o 3 5 m m s h i m st o
adjustthe transfergeartooth contact.
. To selectthe 25 mm thrust shim, refer to page
14-243.
. D o n o t u s e m o r e t h a n t w o 2 5 m m s h i m st o
adjustthe transfergeartooth contact.

1 7 . Rotatethe companionflangein both directionsuntil


the transfergear rotatesone full turn in both directions.
1 8 . Checkthe transfergeartooth contactpattern.

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.

20. Removethe partson the transfershaft,and remove


the transfershaftfrom the transferhousinq.
TRANSFERSHAFT

TRANSFERHOUSING

23. Removethe transterdrivengear shaftand the companionflange,


24. Installthe new transferspaceron the transferdriv e n g e a r s h a f t ,t h e n i n s t a l lt h e m i n t h e t r a n s f e r
housrng.
TRANSFERDRIVEN
GEARSHAFT

TAPEFEDROLLER
BEARNG

TFANSFERSPACER
lnstallin this direction.
Replace.

TRANSFER
COLLAR
THRUSTSHIM,25 mm
Selectivepan

TRANSFERDRIVE
GEAR

CONICALSPRING
WASHER
Replace.

Replace.

Transfr Driven Gear Shaft Starting Torque Inspsction


and Adjustment

25. Installthe companionflange, O-ring,back-upring.


21. Secure the transfer housing in a bench vise with
soft jaws, To preventdamage,alwaysuse soft jaws
or equivalentmaterialsbetweenthe transferhousing and the vise.
2 2 . 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 removethe transferdriven oear shaft locknut
and the conicalspringwasher.

conical spring washer and locknut on the transfer


drivengear shaft.
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 r a n s f e r
shaftwith ATF beforeinstallingthe locknut.
. Installthe conicalspring washerin the direction
shown,

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.

28. Stakethe locknutinto the transferdriven gear shaft


usinga 3,5 mm punchas shown.

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.

29. Install the transfer shaft in the transfer housing,


then installthe taperedroller bearing,transfershaft
collar,25 mm thrust shim,transterdrive gear,conical springwasher,and transfershaft locknuton the
transfer shaft,
NOTE:
. Coatthe threadsof the locknutand translershaft
with ATF beforeinstallingthe locknut.
. Installthe conicalspring washer in the direction
snown.
TRANSFERSHAFT

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

30. Put a 14 mm Allen wrench in the gear side of the


transfer shaft. then secure the Allen wrench in a
benchvise. Tightenthe transfershaft locknut.{The
locknuthas left-handthreads,)

Total Starting Tolqu Inspctionand Adiustment


32. TemDorarilvinstalltranstercover A without the Oflng.

HOUSING

TOROUE:118 N.m (12.0kgf.m, 87 lbt.ft)

TMNSFER COVERA

v
E-

8x1.25mm
r? bt'ftl
24 N'm {2.i1kgt'm,

14 mm ALI-ENWRENGH
5J.

al

Stakethe locknuton the transfershaft using a 3.5


mm ounch.

Securethe transfer housing in a bench vise with


soft jaws, then rotatethe companionflangeseveral
times to fit the tapered roller bearing.To prevent
damage,alwaysuse soft jaws or equivalentmaterials betlveenthe transferhousingand the vise.

34. Measurethe total startingtorque.

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.

36. lf the measurementis out of specification,remove


t h e 6 8 m m t h r u s t s h i m f r o m 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 rt o a l m o s t2 1 2 " F( 1 0 0 " Cu) s i n ga
heat gun. Do not heat the cover higher than 212"F
( 1 0 0 ' C ) .L e t t h e c o v e r c o o l t o r o o m t e m p e r a t u r e
beforeadjustingthe startingtorque,
go to
lf the measurementis within the specification,
step 40.

37. Selectthe 68 mm thrustshim.


THRUSTSHIM,58 mm
Shim No.

ZY

23977- P1C- O20


23978-P1C-020
23941 PW5- 000

zz
c

23942-PWs-000
23943- PWs 000

23944-PW5-000

23945 PWs- 000


23946 PWs- 000
23947 PWs- 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

23962 PWs 000


X

23963- PW5 000


23964- PW5 000
23965 PW5- 000

23966 PWs 000


23967-PWs-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 ,

23953 PWs- 000

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)

23951- PWs- 000


23952 PW5- 000

1.50mm (0.059in)

2 3 9 5 0 - P W s - 0 0 0 1.83mm {0.072ini

23954 PW5- 000


23955 PW5 000
23956- PWs 000

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

40. Installthe new O-ringson transfercoversA and B,


then installthecoverson the transferhousing

6x1.0mm
12 N.m 11.2kgt.D,
8.7 rbf.ftl

TRANSFENCOVERB

Replace.

O.RING
AEARINGOUTERRACE

Replace.

ATTACHMENT,
62x68mrr|
077a6- (x)10500

39. After replacingthe 68 mm thrust shim. recheckand


m a k e s u r e t h e t o t a l s t a r t i n gt o r q u e i s w i t h i n t h e
specification.

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

ATF FEEDPIPES BASE


(37 -98 modebonlyl
1 4 5m m
6x1.0mm

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

(./
,/

ATF PUMP DRIVEN


GEARSHAFT

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

1 . Installthe suction pipe collar and the ATF magnet


{2WD)in the torque converter housing, if necessary.
lnstallthe main seDaratorDlateand the two dowel
pins on the torqueconverterhousing,
Installthe ATF pump drive gear.ATF pump driven
gear,and ATF pump drivengear shafton the torque
converterhousing.InstalltheATF pump drivengear
with its groovedand chamferedsidefacingdown.
ATF PUMP
GEAR

ATF PUMP D{IVEf{


GEARSHAFT

8. Installthe servo body and separatorplate on the


secondaryvalve body ('97 - 98 models: seven bolts,
'99 - 00 models:eight bolts).
9 . lnstallthe servo detentbase ('97- 98 modelsonly)
and the ATF strainer('97 - 98 models:two bolts,'99 00 models:one boltl.

1 0 . Tightenthe five bolts on the main valve body to 12


N'm (1.2kgf.m,8.7 lbf.ft).
1 l . Makesure the ATF pump drive gear and ATF pump
d r i v e n g e a r s h a f t m o v e s m o o t h l y .l f t h e y d o n ' t ,
loosenthe bolts on the main valve body,and disassemblethe valve bodies.Realignthe ATFpump driven gear shaft and reassemblethe valve bodies,then
retightenthe boltsto 12 N.m (1.2kgim, 8.7 lbf.ft).
CAUTION: Failureto align the ATF pump driven
gear shaft corroctly will rosult in a seizsd ATF pump
drive gear or ATF pump drivon gear shaft.

ATF PUi'P
ORIVENGEAR
Grooved and chamtered
side faces separator
plate.

MAIN SPAR/ATOR
PLATE

Loosely install the main valve body with five bolts.


Makesurethe ATFpump drivegearrotatessmoothly
in the normaloperatingdirection,and the ATF pump
driven gear shaft moves smoothly in the axial and
normal operatingdirections.
Installthe secondaryvalve body, separatorplate,
and two dowel pins on the main valve body. Do not
installthebolts.

5.

o.

Installthe control shaft in the housing along with


the manualvalve.

7.

lnstall the detent arm and arm shaft in the main


valve body, then hook the detentarm spring to the
detentarm.
SEBVOSEPARATOR
PLATE

ATF PUMP
DRIVEGEAR

ATF
DBIVENGEAR

GEAR
SHAFT

Installthe stator shaft and stop shaft

1 3 . Installthe bolts and the stop shaft bracketon the


secondaryvalve body, then tighten the bolts (three
bolts).
1 4 . Installthe torqueconvertercheckvalve,coolerrelief

valve,and valvespringsin the regulatorvalve body,


then install the regulatorvalve body on the main
valvebody {one boltl.
1 5 . Installthe lock-upvalve body, separatorplate,two
dowel pins and lubricationplate(eightbolts).

DETENTARM
SHAFT

CONTROL
SHAFT

OETENTARM
OETENTARM SPRING

MANUAL VAIVE

www.emanualpro.com

1 6 . Installtheone ATFfeed pipe in the main valvebody,


the three ATF feed pipes in the secondaryvalve, the
three ATF feed pipes in the servo body and the one
ATF feed pipe in the lock-upvalve body.
NOTE:lnstallthe 105.8mm ATF feed pipe with its
filter side away from the secondaryvalve body; the
filter is on the 105.8mm ATF feed pipe, which is
(cont'd)
onlv on the '98 - 00 models,

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

1 7 . Installthe sub-shaftassemblyin the transmission


housing(seepage 14-210and 14-2'111.
1 8 . lnstall the ATF magnet (4WD) in the transmission
housing,if necessary.

Installthe reversegear with the collar and needle


bearingon the countershatt.
2 4 . Align the spring pin on the control shaft with the
transmissionhousinggroove by turningthe control
shaft.
SHAFT
CONTROL
SPRING
PIN
PIN
SPRING

1 9 . Installthe reverseidler gear and gear shaft holder


(seepage 14-231).
20. Installthe differentialassemblyin the torque converterhousing.

21. A s s e m b l et h e m a i n s h a f ta n d c o u n t e r s h a f ts u b then install


assembly(seepage 14-206and 14 207],,
them togetherin the torqueconverterhouslng.

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.

Turn the shift fork so the large chamferedhole is


facing the fork bolt hole. then installthe shift fork
with the reverseselectorand torque the lock bolt.
Bendthe locktab againstthe bolt head.

NOTE:The illustrationshows the 4WD automatic


transmission.The 4WD has 19 transmissionhousing mountingbolts;the 2WD has 18 bolts.
TOROUE:44 N.m {,[.5kgf.m, 33 lbf'ft)
TNANSMISSION

SHIFI FORK
LOCK WASHER
Beplace.
'l.O mm
6 r
4 N.m
(1.4 ksl.m. 1O lbt.ft)

Large chamfered hole

{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)

Assemblethe one-wayclutchand the park gear on


the countershaft1stgear(seepage l4-2Og).
Lubricatethese pans with ATF:
. Countershaft
threads
. Old locknutthreadsand flat end
. Old conicalspringwasher
. Park gear contact area with conical spring
wasner

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

34. Slip the specialtoolontothe mainshaft.

LOCK BOLT

PAWLSHAFT

BEARING
COUNIERSHAFT
COUNTERSHAFT
lST GEARCOLLAR

14-254

www.emanualpro.com

MAINSHAFT
07GAB- PF50101or
07GAB- PF501q)

5C.

Installthe sub-shaftlst gear on the sub-shaft.

36. Installthe mainshaft1st gear collar, mainshaft1st


gear,needlebearing,thrust needlebearing,and the
thrustwasheron the mainshaft.
Wrap the shaft splineswith tape to preventO-ring
damage,then installnew O-ringson the mainshaft
,te

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:

lnstallthe1stclutchassemblvon the mainshaft


MAINSHAFT
SU8-SHAFT LOCKNUT
LOCXNUT Left-handthreads
PIN
COUNTENSHAFT
8 mm pin,
LOCKNUT
commercially
threads
Left-hand
available

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.

42. Stake each locknut using a 3.5 mm punch.

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.

47. Install the control lever assemblv on the control


shaft. (4WDl

44. lf the pawl does not engagefully, checkthe distance


b e t w e e nt h e p a r k p a w l s h a f t a n d t h e p a r k l e v e r
rollerpin (seepage 14-231).
Tightenthe lockbolt and bendthe locktab.

6 r 1 . Om m

1o tbf'frl

6x1.0mm
14 N.m 11.4kg{.m,
10 tbf.ftl
PARKGEAR
PARKPAWL

46. Installthe end coverwith two dowel pins and a new


gasket {twelve bolts).
TOROUE:12 N.m (1.2 kgf.m, 8.7 tbf.ft)

CONTROL
LEVER
ASSEMBLY

48. Set the A/f gear position switch to E] position.


NOTE: The Aff gear position switch cticks in N]
position,

6 x 1.0mm EOLTHOLE
{Usedin step50.)

END COVER
A/T GEARFOSMON SWNCH

14-256

www.emanualpro.com

49. Set the control shaft to E position,and installthe


A,/Tgear positionswitchon it.
CONTROLSHAFT

Installthe transferassemblywith a new O-ring.Do


not allow dust or otherforeignparticlesto enterthe
transmission.
{4WD)

,.
((,,,
l( *

Cleanthe areaswhere the transferassemblycontacts the transmissionwith solvent or carburetor


cleaner,dry with compressedair, then coatthe contact areaswith ATF. (4WD)

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

lnstallthe cooler lineswith the line bolts and new


sealingwashers.

6xl.0mm
12 N.m 11.2kgf'm,
8,7

TOROUE:28 N.m 12.9kgif'm.21 lbf'ft)


54. Installthe ATF dipstick.
CONTROLSHAFT

55. lnstallthe breathercap on the breatherpipe so its


arrow pointsto the transmissionhanger.

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.

Flushthe ATF cooler as describedon page 14-264


and 14-265.
Installthe torque converterassemblyon the mainshaftwith a new O-ring.
lnstallthe starteron the transmissionhousing,and
installthe 14 mm dowel pins in the torqueconverter
housing.

6.

Install the transmission housing mounting bolt


(front side).
TRANSMISSIONHOUSINGMOUNNNG BOLT
{FRONTSIDE)
12x 1.25mm
6,1N m (6 5 kgl m, 47 lbf'ftl

44 N.m {{.5 kgf.m,


33 rbf.f0

14 mm DOWELPIN

7.

Installthe transmissionmount bracket.Tightenthe


bolt loosely,then tighten the nuts to the specified
torque,and tightenthe bolt to the specifiedtorque.
12 x 1,25mm
6,aN.ft (6.5kgtm,47 rbf.ft)

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

1 5 . Installnew set rings on the ends of the intermediate


shaftand the driveshaft.
1 6 . Cleanthe areaswhere the intermediateshaft con_
tacts the transmission{differential)with solvent or
carburetorcleaner,and dry with compressedair.
Then installthe intermediateshaft in the differen_
tial, While installingthe intermediateshaft,be sure
not to allow dust or other foreign paniclesto enter
the transmission.

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)

44 N.rn (4.5kgt m, 33 lbtftl

1 1 . Installthe torque convenercover and the rear stiff_


ener.
1 2 . Tightenthe crankshaftpulleybolt as necessary(see
section5).

14-260

www.emanualpro.com

l0 x 1.25mm
39 N.m 14.0kgt.n,
29 tbf.ftl

SETRING
Replace.

INTERMEDIATE
SHAFT

17. Installthe right and left driveshafts(seesection18).


While installingthe right driveshaftin the differential, be sure not to allow dust or other foreignparticlesto enterthe transmission.
NOTE:
. Cleanthe areaswhere the right driveshaftcontacts the transmission(differential)with solvent
or carburetorcleaner,and dry with compressed
air.
. Turn the right and left steeringknucklefully outward, and slide the right driveshaftinto the differentialuntil you feel its spring clip engagethe
side gear. Slidethe left driveshaftinto the intermediateshaft until you feel the spring clip of the
intermediate
shaftengagethe left driveshaft,

19, Installthe propellershaft to the transferassembly


by aligningthe referencemarks(4WD).
MARKS
REFERENCE

8 x 1.25mm
32 N.m (3.3 kgt'm,2ir blft)
Feplace.
\

@_

18. Installright damper fork, then installthe right and


left ball joints on each lower arm with the castle
nutsand new cotterpins (seesection18).

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.

24. Installthesplashshieldand guard bar,

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

25. Connectthe mainshaftspeedsensor,the shift con-

22. Installexhaustpipe A.

23. Connectthe primaryheatedorygen sensor(primary


HO2S) connector.

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

trol solenoidvalve,and the linearsolenoidconnec_


tors,

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

28. Instailthe transmissionground cable terminal on


t h e t r a n s m i s s i o nh a n g e r ,a n d i n s t a l lt h e r a d i a t o r
hoseclampon the transmissionhanger,
29. Connectthe startercablesto the starter,and install
the harnessclamDon the clamDbracket.Makesure
the crimpedside of the startercablering terminalis
facingout.
CLAMPBRACKET

STARTEB
CABLE

SPEED
SENSOA
CO'{NECTOR
STARTER
CAAtf,

2 7 . Connectthe lock-upcontrol solenoidvalve connec-

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.

3 1 . Refillthe transmissionwith ATF (seepage 14-161).

HARNESSCI-AMP
RADIATORHOSE
CLAMP

Connectthe batterypositiveterminaland negative


terminal.
Setthe parkingbrake,Startthe engine,and shift the
transmissionthroughall gearsthreetimes.

34. Checkthe shift cable adjustment (see page 14-271]-.


C h e c kt h e t r o n t w h e e l a l i g n m e n ta n d a d j u s t i t i f
needed(seesection18).

TRANSMISSION
GROUNDCAB1I
TERMINAL

LOCK-UPOONTROL
SOLENOIDVALVE
CONNECTOR

Let the engine reachnormal operatingtemperature


(the radiatorfan comeson) with the transmissionin
E or N position,then turn it off and checkthe ATF
level{seepage14-160).
37. Performa roadtest (seepage 14-157and 14-158).

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.

7. With the water and air valvesoff, attachthe water and


air suppliesto the flusher.(Hotwaterif available.)

This procedureshould be performedbeforereinstalling


the transmission.
L

Checkequipmentfor wear and cracksbeforeusing.


Replaceany worn or crackedcomponents.

2.

Usingthe measuringcup.fill the tankwith 21 ounces


{approximately213lull) ol biodegradableflushing
fluid (J35944- 20). Do not substitutewith any other
f l u i d . F o l l o wt h e h a n d l i n gp r o c e d u r eo n t h e f l u i d
contaaner.
S e c u r et h e f l u s h e r f i l l e r c a p , a n d p r e s s u r i z et h e
flusherwith compressedair to 550 - 829 kpa (5.6_
8 . 4 5 k g f / c m , ,8 0 - 1 2 0 p s i )T. h e a i r l i n e s h o u l d b e
equippedwith a water trap to ensurea dry air system.

8 . Turn on the water valve for 1Oseconds.lf water


does not flow through the cooler, it is completely
plugged,cannotbe flushed,and must be replaced.

Hangthe flusherunderthe vehicle.


5.

Attachthe flusherdischargehose to the return line


of the transmissioncoolerusinga clamp.
Connectthe drain hoseto the inlet line on the transmissioncoolerusinga clamp.
IMPORTANT:
Securelyclampthe oppositeend ofthe drainhoseto a
bucketor floor drain.

Depressthe triggerto mix the flushingfluid into the


water flow. Usethe wire clip to hold the trigger down.
1 0 . While flushingwith the water and flushingfluid for
two minutes,turn the air valve on for five seconds
every 15- 20 secondsto createa surgingaction.
AIR PRESSURE:
MAX 845 kpa(8.45kgf/cmr,t20 psi)
1' I. Turn the water valve off. Releasethe trigger,then
reversethe hosesto the cooler so you can flush in
the oppositedirection.Repeatsteps8 through 10.

12. Releasethe trigger,and rinsethe coolerwith wate.


for one minute.
1 3 . Turn the water valve off, and the water supplyoff.
DISCHARGE
HOSE

1 4 . Turn the air valve on for two minutes,or until no

moistureis visibleleavingthe drain hose.Residual


m o i s t u r e i n t h e c o o l e r o r l i n e s c a n d a m a g et h e
transmission.
Removethe flusherfrom the cooler line.Attachthe
drain hoseto a container.

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.

Installthe transmission,and leave the drain hose


attachedto the coolerline.

1 7 . Makesurethe transmissionis in E position.


F i l l t h e t r a n s m i s s i ow
n i t h A T F ,a n d r u n t h e e n g i n e
for 30 secondsor until approximately0.951 {1.0US
qt., 0.8 lmp qt.) is discharged.

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.

lf dischargeliquiddoes not foam, the orificemay be


blocked.

1 9 . Refillthe transmissionwith ATF to the proper level


( s e ep a g el 4 ' 1 6 1) .

3.

To clean,disconnectthe largecouplingnut from the


flusher.

FILLERCAP

FILTER

COUPLING
NUT

I
- 0 - - D -@q
I

II

\
ORIFICE

O.RING

www.emanualpro.com

4.

Removethe in-linefilterfrom the dischargesideand


cleanit if necessary.

5.

The fluid orificeis locatedbehindthe filter.


Clean it with the pick stored in the bottom of the
tank handle,or blow it cleanwith air.

6.

Reassemble
all parts.

14-265

ATFCoolerHoses
Gonnection
'1. Connectthe ATF

coolerhosesto the ATF coolerlines.then securethem with the cliDs.

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.

22 N.m (2.2kgf.m, 16 lbt.ftl

1.

Removethe instrumentpanel lower cover and the


columncovers(seesection171.

2.

Shift to N position,then removethe lock pin from


the cableadjuster.

3.

Separatethe shift cablefrom the cableadjuster,Do


not bendthe shift cableexcessively.

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.

lnstallthe shift lever assemblyin the reverseorder


of removal.
NOTE;
. Make sure the lock pin is seatedsecurelyin the
cableadjuster.
. Replacethe lock pin if it does not snap over the
cableadjustersecurely.
Checkthe cableadjustmentafter installingthe shift
lever(seepage14-27'l).

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

7 N.m {0.7 kgf.m.5 tbt.fr}

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

9.3 N.m {0.95kgf.m, 6.9 lbl.ftl


SCREW
2.5 N.m {0.25kgt m,
1.8 tbf.ftl

SHIFTLOCKBELEASE
LEVERSPRING
PARK PIN

9.3 N.m {0.95kgl.m,


6.9 lbtfr)
HARNESSCLAMP
ERACKET

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.

Shiftthe shift leverinto E positron.

2.

Pull or push the wires to adjust the clearance


betweenthe wires and the edge of the shift lever
controlbracketto 13 mm (0.5in).

Securethe wireswith the harnessclamp.


Move the shift leverto eachposition,and verifythat
there is a clearancebetweenthe wires and bracket
in eachposition.
lf the wires are kept tight in any position,read.iust
the clearance.
Installthe shift lever assemblyon the steeringcolumn.
7.

SHIFTLEVERBRACKET

14-270

www.emanualpro.com

Move the shift lever to each position, and make


sure that the wires are kept away from any parts
suchas the steeringcolumn.

DetentSpringReplacement
1.

Installthe detent spring on th shift lever control


bracket,and installthescrewloosely.

4.

Put the detent spring roller in E position on the


detentguide,then tightenthe screwto the specified
torque,

Shift the shift lever to E position.


lnssrt a 0.5 mm (0.02 in) wire gap gauge between
the control chockerdetent and the shift lever,then
hold the shift lever againstthe El position in the
controlchecker.

'97 - 98 Modeb:
SPRING
DETENT

SHIFI LEVER

2.5 N.m 10.25kgf.m, 1.8lbl.ftl

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.

Removethe accesscover from the lower column


cover.

4. Checkthat the hole in the cable adjusteris aligned


with the hole in the adjusting rod. There are two
holes in the cableadjuster.They are positioned90"
apart to allow cable adjustmentsln l/4 turn increments.

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.

lf not perfectlyaligned, loosenthe locknut on the


shittcable.and adjustas required.

Shift to E position.then removethe lock pin from


the cableadjuster.

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

Move the shift leverto eachgear,and verifythat the


A/T gear position indicator follows the A"/Tgear
position switch.

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.

Removethe shift cablecover.

1.

Removethe instrumentpanel lower cover and the


columncovers(seesection17).

4WD:
Removethe snap pin and control pin,then separate
the shiftcablefrom the controllever.

2.

Shift to E position,then removethe lock pin from


the cableadiuster.

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.

Removethe nuts securingthe shift cable holder,


then removethe shiftcable.
GROMMET

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

www.emanualpro.com

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

Forward Driving at Constant Speed lzWD)


When drivingforwardat a constantspeed(cruising),
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.
Fluid dischargedby the front oil pump is drawn in by the rear oil pump and is circulatedthrough the system.Because
there is no pressurebuilt up at the clutchpiston,the clutchdoes not engage,and the vehicleremainsin 2WD (frontwheel
drive).

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

ReverseStart and Acceleration(4WD)


the dual pump systemcan engagefour wheeldrive.
Duringreversestartand reverseacceleration,
lf the front wheelsspin fasterthan the rear wheels,the front oil pump spinsfasterthan the rear oil pump. The front oil
pump drawsin fluid throughcheckvalveA and dischargesit. {Notethat in reverse,the directionof the pumps is the opposite of that duringforwarddriving.)
Some of the fluid that is dischargedby the front oil pump is drawn in by the rear oil pump. The remainingfluid passes
throughcheckvalveF into the cylinderof the clutchpiston,where it is regulatedby two orifices.
The regulatedhydraulicpressureat the clutchpistonmay forcethe platesand discsof the clutchtogetherto form a connectlon.The engagedclutchpassesdrivingforcefrom the transferassemblyto the rearwheels,producing4WD.

oRtFtcEs

FRONTOIL PUMP

{cont'd)

www.emanualpro.com

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

www.emanualpro.com

REAROIL PUMP

Thermal Switch Operation l2WD)


fluid is in contactwith the clutchpistonand the thermalswitch.
During4WDoperation,pressure-regulated
lf the temperatureof the fluid in the differentialgoes too high, the thermalswitch pushesopen the reliefvalve R. This
causesthe pressurein the clutchpistonto drop, and 4WD mode is disengaged.

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

When starting and accelerating in revGrsggear {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.

Makea mark on eitherNo. ' I o r N o . 2 p r o p e l l e r


shaft.

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).

Makea mark on eitherNo. 1 or No. 2 propeller


shaft.
PROPELLER
SHAFT

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


radiatorfan comeson at leasttwice).

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


radiatorfan comeson at leasttwicei.

With the engineat idle.shiftto the E position.

With the engineat idle,shift to the E position.

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

www.emanualpro.com

(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.

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


radiatorfan comeson at leasttwlce).

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
.
.

www.emanualpro.com

lf the enginestalls,the 4WDsystemis normal.


lf the enginecontinuesrunning,there is a problem in 4WDsystem.Checkthe differentialfluid. lf
the differentialfluid is normal,replacethe torque
controlditferentialcasekit.

When starting and acceleratingin reversegear (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 s a r e o f f t h e
ground (seesection1).

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


radiatorfan comeson at leasttwice)
3.

With the engine at idle, shift into reversegear and


releasethe clutch.
Apply the parkingbrakefirmlY
.
.

lf the enginestalls,the 4WDsystemis normal.


lf the enginecontinuesrunning,there is a problem in 4WD system.Checkthe differentialfluid lf
the differentialfluid is normal,replacethe torque
controldifferentialcasekit.

Real-time4WD-DualPumpSystem
Troubleshooting(AutomaticTransmission/Manual
Transmission)
Whon d6c6l6ratingin a torward gear {2WD mode}

When deceleratingin reversegear (4WD mod)

1.

1.

Blockthe front wheels,raisethe left rearwheel.and


supportit with a safetystandas shown.

WHEELCHOCKS

Hold the tire and turn it counterclockwise


continuouslvfor more than one rotation.

lf the rotation of the wheel does not gradually


feel heavywhile rotating,the 2WD systemwhen
decelerating
in a forwardgear is normal.
lf the rotationof the wheelgraduallyfeelsheavy,
there is a problem in the system.Checkthe differentialfluid, lf the fluid is normal,reDlacethe
torouecontroldifferentialcasekit.

15-12

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Blockthe front wheels.raisethe left rearwheel,and


suppo( it with a safetystandas shown.

WHEELCHOCKS

Hold the tire and turn it clockwisecontinuouslvfor


more than one rotation.

lf the rotation of the wheel gradually feels heaw.


the 4WD systemwhen deceleratingin reversegear
is normal,
lf the rotationof the wheeldoes not graduallyfeel
heavy,there is a problem in the system.Check
t h e d i f f e r e n t i afl l u i d . l f t h e f l u i d i s n o r m a l .
reolacethe torquecontroldifferentialcasekit,

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

Will not go into 4WD mode

. Fluidleveltoo low
. Incorrectfluid type

. Add fluid
. Replace

Will not returnto 2WD mode

Incorrectfluid type

Drainand fill the differential

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.

Make sure lifts are placed properly lsee

With the vehicleon levelground,inspectdifferential


f l u i dw i t h e n g i n eO F F .
Removethe oil filler plug, then checkthe leveland
conditionof the fluid.

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

o|I FII.IIR PI-UG


4t N.m la.8kgl.m,35 lbl.ftl

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.

Drainthe differentialflujd (seepage 15-14).

2.

Mark the propellershaft and companionflange of


the rear differentialassemblyso they can be reinstalledin theiroriginalpositions.
PROPELLERSHAFT

5,

Placea transmissionjack underthe rear differential


assembly,then removethe right mountingbracketB
andthe left mountingbracket8.

COMPA'{IONFLANGE

12 POtt'lT BOLI
8 x 1.25mm
32 N.m 13.3tgf.m. 2a lbtft,

Mark

Removethe breathertube from the breathertube


fitting.
BREATHER
TUBEflTNNG

Removethe propellershaftfrom the reardifferential


assemory.
Removethe reardifferentialdamper.

12x 1.25mm
5,1N.m 15,5kgf.m, iO tbf.fO

15-16

www.emanualpro.com

7.

Insertthe edge of the screwdriverinto the groove


locatedunder the differentialhousing Pry out the
driveshaftinboardiointwith a screwdraver.
NOTE:Take care not to damagethe differentialoil
sealand differentialring when prying out the differentialinboardjoint.

DIFFERENTIAL

10. Remove the rear difterentialmounting bracketA


from the reardifferentialassembly.
12 x 1.25 fifi

N.m {7.0 lgf.m. 5l lbl.tt)


REARDIFFERENTIAL
MOUNTINGBRACKETA

REANDFFERENTI,AL
ASSEMBLY

1 1 .Installthe rear differentialassemblyin the reverse


orderof removal.

8.

Removethe mountingboltsand the washers.

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

Apply liquid gasketto the sealingsurfaceof the ditferentialhousing,and notetheseitems:


. Use liquidgasket(P/N08718- 000'1).
. R e m o v ea n y d i r t o r f l u i d f r o m t h e s e a l i n gs u r lace.
. lf 20 minutes have passedafter applying liquid
gasket,reapplyit beforeyou assemblethe housings. Allow it to cure at least 30 minutes after
assemblybeforefilling differentialwith ftuid.
DIFFERENTIAL
HOUSING

15-18

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Installthe differentialhousing.then torquethe bolts


in a crisscrosspatternin severalsteps.

Oil Seals
Replacement
1.

Removethe oil sealsfrom the differentialhousing.

2.

Installthe oil sealssquarelyusingthe specialtools.


Be carelulnot to damagethe lip ol the oil seals.

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:

Left side: Installthe oil seal flush with the edge of


the differentialcarrierassembly.

OIL SEAL

(cont'd)

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15-19

Oil Seals

RearDifferentialAssembly

Replacement(cont'd)

Disassembly

3.

1.

Removethe oil seal from the toroue control differentialcase.

Removethe breathertube,the drain plug and the oil


f i l l e rp l u g .

BREATHER
TUBE

OIL FILI.IRPLUG

DRAIT{PLUG

Installthe oil sealsquarelyusingthe specialtool.


carefulnot to damagethe lip of the oil seal.
Raisethe locknuttab from the groove of the clutch
guide, making sure that the tab completelvclears
the grooveto preventdamagingthe clutchguide.

L(rcKNUT,24 mm
Replace.

15-20

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3.

Installthespeclaltoolson the companionflange,

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

32 N m {33 tgt m,24lbf ftl


so that its tab
Loosenthe locknutcounterclockwise
comesout from the groovein the clutchguide.
LOCKNUT,24 mm

8.

5.

Tightenthe locknuttill its tab alignswith the groove.

6.

Removeany dirt from inside of the groove in the


clutchguide,then loosenthe locknut.

Removethe torque controldifferentialcaseand the


dowel pins.

LOCKNUT.2,1mm

Tab

www.emanualpro.com

(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

and the pressure


1 0 . Removethe clutchhub/plates/discs
prare.

1 2 . Removethe oil pump body assembly,the oil pump


pin,the magnet,and the oil strainer.

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.

Apply CVTfluid to the rubberof the oil strainer,then


installthe oil strainer,the magnet,and the oil pump
pin to the differential
carrier.

3.

Tightenthe oil pump body assemblymounting


bolts.

4.

I n s t a l lt h e o i l p u m p d r i v e s h a f tb y a l i g n i n g t h e p r o jection of the oil pump driveshaftwith the groove of


the front oil pump in the oil pump body assembly.

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.

Alignthe oil pump pin with the grooveof the rearoil


pump in the pump body assembly,
then installthe oil
pump body assemblyto the differential
carrierassemoty.
OIL PUMP BODYASSEMBLY

5.

Installthe thrust needlebearing.


Installthe pressureplate assemblyby aligningthe
projectionof the pressureplate with the groove of
the oil pump driveshaft.
PRESSURE
PLATE

OILPUMP
DRIVESHAFT

( c o n t ' d)

www.emanualpro.com

15-23

RearDifferentialAssembly
(cont'dl
Reassembly
7.

then alignthe proInstallthe clutchhub/plates/discs,


jectionof the plateswith the discs.

sHlM, 30 mm
,/
.A-\,/r
\-7

10. lnstallthe dowel pins and toroue controldifferential


case.
TOROUECONTNOL
6x1.0mm
12 N.m 11.2tgf m,8.7lbt.ftl

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.

11. Installthe companionflange,O-ring,back-upring,


discspringwasher,and the locknut.
NOTE:Apply CW fluid to the O-ring.
,24mm
DISCSPRINGWASHER,
2a mm

TOBOUE CONTROL
DIFFERENNAL

@+-_alcr-upnwc

/r-

lnstallin this direction.

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.

14. lnstallthe breathertube.

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.

Stakethe locknuttab into the groove in the clutch


guide.

www.emanualpro.com

Installthedrain plug and the oilfiller plug with


wasners.

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.

1 . Loosenthe wheel nutsslightly.

Looso Splines
Turn the driveshaftby hand,and make sure th splins
and joint are not excessivelyloose.lf damageis found,
replacethe inboardjoint.

Raisethe front of the vehicle,and suppon it with


safetystandsin the properlocations(seesection1).
Removethe wheel nuts and front wheels.

Twisting or Crscking
Make sure the driveshaftis not twisted or crackod.
Replaceit if necessary.
DRIVESHAFT
SPINDLENUT
24 x 1.5mm
Replace.

FRONTWHEEL

lf the right driveshaftis to be removed, drain the


transmission
fluid {seesction13or 14).lt is not necessaryto drain the transmissionfluid when the left
driveshaftis removed.
Lift up locking tab on the spindle nut, then remove
the nut,
6.

Removethe self-locking
nut and flangebolt,
FLANGEBOLT
10 x 1.25mm

SELF"LOCKING
NUT
12 x 1.25mm
Replace.
7.

Remove the damper fork,

(cont'd)

www.emanualpro.com

16-3

Front Driveshafts
Removal (cont'd)
Removethe cotterpin from the lower arm ball ioint
castlenut, and removethe nut.

12. Pull on the inboardjoint, and removethe driveshaft


from the differentialcase or bearingsupportas an
assembly.Do not pull on the driveshaft,the inboard
joint may come apart. Pull the driveshaftstraight
out to avoid damagingthe differentialoil sealor the
intermediate
shaftouter seal.

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,

Carefullyclamp the driveshaftin a vise with soft


jaws, then remove the set ring from the inboard
joint.

2.

Removethe boot bands.Take care not to damage


the boot,
. lf the boot band is a lockingtab type, pry up the
lockingtabs with a screwdriver,and lift up the
end of the band.
. l f t h e b o o t b a n di s a w e l d e dt y p e o r a l o w p r o f i l e
type, carefullycut the boot band with a pair of
diagonalcutters.
. lf the boot band is a double loop type. lift up the
band bend.

KNUCKLE

Locking Tab

DRIVESHAFT

1 4 . Removethe driveshaftoutboardjoint from the front


wheel hub usinga plastichammer.

PLASTICHAMMER

SET BING
Replace.
Welded

DRIVESHAFT

{cont'd)

www.emanualpro.com

16-5

Front Driveshafts
Disassembly(cont'd)
Double Loop

4,

Mark the rollersand spiderto identifythe locstions


of the rollerson the sDider,then removethe rollers.
BEARING
REMOVER
(Commercially
available)

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.

Removethe spiderusinga bearingremover,


Wrap the splines on the driveshaftwith vinyl tape to
preventdamageto the bootsand dynsmicdamper,

INBOARDBOOT
INBOARDJOINT
Checksplinesfor wearor damage.
Checkinside bore for wear.
Inspectfor cracks.

DRIVESHAFT

DYNAMICDAMPER

16-6

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Rsmove the inboard boot and dvnamic d a m p e r .


Take care not to damage the boot and d y n a m i c
damDer.

DRIVESHAFT

Outboard Joint Side:


1.

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,

CarefullvclamDthe driveshaftin a vise.


THREADED
AOAPTER,2iIx 1.5 mm
07xAc - 0010200

EarClamp
TAB

EAR CLAMP BAND


Replace.

2.

Slidethe outboardboot to the inboardioint side.

Slidehammc..5/8'x lS Throad
(Commerically,
available)
o.

Removethe outboardjoint using a specialtool as


shown.

7.

Removethe driveshatttrom the vise

8.

Removethe stop ring from the driveshaft.

DRIVESHAFT

Wipe off the greaseto exposethe driveshaftand


the outboardjoint innerrace.
Markthe driveshaftat the same positionof the outboardjoint end with paint.

STOPRING
Replace.

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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.

Pack cavity with grease.


EARCLAMPBAND*1

Replace.

__G1
P a c k c a v i t y wrtn grease.

OUTBOARDBOOT*'
(RUBBERI

-Grj
Pack cavity wtrn grease.

16-8

www.emanualpro.com

*l: '98 Canadamodels,all '99-00models


*2: '97- 98 models(except'98Canadamodel)

Inboard Joint Side:


1.

5.

Wrap the splineswith vinyl tape to preventdamage


to the boot and dynamicdamper.

DRIVESHAFT

Fit the rollersto the spider.


NOTE:
. Reinstallthe rollersto their originalpositionson
the spiderby aligningthe marks.
. Hold the driveshaft pointed up to prevent the
rollersfrom fallingoff.

,..',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.

Packthe inboardjoint with the joint greaseincluded


in the new driveshaftset,
Greasequantity: 120- 130 g {4.2- 4.6 oz)
Left inboad ioint splines@:0.5 - 1.0 g (0.018- 0.m5
ozl

F i t t h e c i r c l i p i n t o the driveshaft groove. Always


rotatethe circlipin its grooveto makesure it is fully
seated.

(cont'd)

www.emanualpro.com

16-9

Front Driveshafts
Reassembly
{cont'd)
7.

Left: 508 - 513 mm 120- 2O.2inl

Fit the inboard joint onto the driveshaft,and note


theseitems:
Reinstallthe inboardjoint onto the driveshaftby
aligningths markson the inboardjoint with the
markson the rollers.
Holdthe driveshaftso the inboardjoint pointsup
to prevent it from falling off.

Right: AT model 520 - 525 mm {20.5- 20.7 in)


MT mod6l 515 - 520 mm (20.3- 20.5 inl

/,?:..{
t

Sptine
airection

lffi
t Y l
:\

ROLLERHOLDER

-flm+dm@

/\

9.

Positionthe dynamic damper to the specifications


as snown.
Left:299.5t 2 mm 111.8r O.l inl
Right:299.5t 2 mm 111.810.1inl

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

1 3 . Threadthe free end of the band through the nose


sectionof a commerciallyavailableboot band tool
(KD-3191
o r e q u i v a l e n t )a. n d i n t o t h e s l o t o n t h e
winding mandrel.
'14. Place wrench
a
on 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.

BOOTBANDTOOL
(KD-3191
or equivalentl

Markon band.

WINDING
MANDREL

11. Pull up the slackin the band by hand.


12. Make a mark on the band 10 - 14 mm (0.4- 0.6 in)
from the clip.
CLIP

1 5 . Lift up the boot band tool to bend the free end of


the band 90 degreesto the clip, Center-punchthe
clip,then fold over the remainingtail onto the clip.

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.

Outbosrd Joint Sids:


1.

Wrap the splineswith vinyl tape to preventdamage


to the boot.

5 - 1 0m m
10.2- 0.4 in,

OUTBOARDBOOT

VINYLTAPE

1 7 . Bendthe band end by tappingit down with a hammer,


NOTE;
. Makesurethe band does not move,
. Removeany greaseremainingon the surrounding surfaces.

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.

Installthe stop ring into the driveshaftgroove.

DRIVESHAFT

18, Installthe new set ring.

16 -1 2

www.emanualpro.com

4.

lnsertthe driveshaftinto the outboardioint until the


stop ring is closeon the joint.

6.

DRIVESHAFT

Checkthe alignmentof the paint markwith the outboardjoint end.

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.

Packthe outboardjoint with the joint greaseincluded


in the new joint boot set.
Greasequantity:
Outboard ioini: '97 model and '98 USA model
130- 140 g {,1.6- ,0.9oz}
'98 C8n8d8modsl 8ndall '99- 00 models
ll0 - tso g {i1.9- 5.3 ozl

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)

11. Closethe ear portion of the band with a commercially


availableboot band pincersKENT-MOORE
J-35910or
equivalent.

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

12. Checkthe clearancebetween the closed ear Dortion


of the band, lf the clearanceis not within the standard,closethe ear portionof the bandfurther.

6.0 mm 10.24in) MAX

3.0mm {0.12in} MAX

16 -1 4

www.emanualpro.com

13. Fit the boot ends onto the driveshaftand the outboardjoint.

1 5 . Pull up the slackin the band by hand.


1 6 . Mark a positionon the band 10 - 14 mm (0.4- 0.6
in.)from the clip.

CLIP

14. Fit the doublelooDboot bandsonto the boot ends


1 7 . Threadthe free end of the band through the nose
sectionof a commerciallyavailableboot band tool
(KD-3191
o r e q u i v a l e n t la, n d i n t o t h e s l o t o n t h e
winding mandrel.
BOOTBANDTOOL
(Commercially
available)
or equivalent
KD-3191

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.

21, Bendthe bandby tappingit down with a hammer.


N O T E :M a k e s u r e t h e b a n d a n d t h e c l i p d o e s n o t
i n t e r f e r ew i t h a n y t h i n g ,a n d t h e b a n d d o e s n o t
m o v e , R e m o v ea n y g r e a s er e m a i n i n go n t h e s u r roundingsurfaces.
BAND END

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

www.emanualpro.com

Front Driveshafts
lnstallation
1.

Installthe outboardioint into the knuckle.

4.

KNUCKLE

Cleanthe areaswhere the driveshaftcontactsthe


differentialthoroughly with solvent or carburetor
c l e a n e r ,a n d d r y w i t h c o m p r e s s e da i r . I n s e r tt h e
inboardend of the driveshaftinto the differentialor
i n t e r m e d i a t es h a f t u n t i l t h e s e t r i n g l o c k s i n t h e
groove.
INBOARD
JOINT

INBOARDJOINT

Replace.

OUTBOARDJOINT

Apply0.5- 1.0g (0,02- 0.04oz)of specifiedgreaseto


the whole sDlinedsurfaceof the intermediateshaft.
After applyinggrease.removethe greasefrom the
splinedgroovesat intervalsof 2 - 3 splinesand from
the set ring groove so air can bleed from the inboard
ioint.
SETRING
Replace.

5.

lnstallthe knuckleon the lower arm. Be careful not to


damagethe ball joint boot. Wipe off the greasebefore
tighteningthe nut at the ball joint.Torquethe castle
then tightenit
nut to the lower torque specification.
only far enoughto alignthe slot with the pin hole.Do
lnstalla new cotterpin.
not alignthe nut by loosening.

SET RING

Installa new set ring onto the driveshaftor intermediateshaftgroove.

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

Removethe intermediateshaft from the differential.


Holdthe intermediateshaft horizontaluntil it is clearof
the differentialtopreventdamageto the differentialoil
seal.

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.

shaft bearingout of the bearPressthe intermediate


ing supportusingthe specialtoolsand a press

'1. Removethe set ring.

ORIVER
07749- 001q)00
FLOATINGRUBBER
DAMPER
Checkfor deterioration
ano oamage,

SEAL
OUTER
RePlace

ATTACHMENT,
tl2x 17 mm
07745- 0010300

SET RING
Replace.

Removethe intermediateshatt outer seal from the


bearingsupport.
Removethe e)dernalcirclip.
4.

Pressthe intermediateshaft out of the shaft bearing


usingthe specialtoolsand a press.
Press

INTERNALCIRCLIP

ATTACHMENT
o?JAF_ SH20it00

SHAFT
INTERMEDIATE
Checklor damage.
5.

www.emanualpro.com

Remove the internal circlip.

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

Pressthe intermediateshaft bearinginto the bearing supportusingthe specialtools and a press.


Prcss

OUTERSEAReplace.

Seat the internal circlip in the groove of the bearing


support.
Press

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

Cleanthe areaswhere the intermediateshaft conthoroughlywith


tactsthe transmission(differential)
solvent or carburetorcleaner,and dry with compressedair. Insen the intermediateshaft assembly
into the differential.Holdthe intermediateshaft horizontalto preventdamageto the differentialoil seal.

INTERMEOIATE
SHAFT

ATTACHMENT,
52x55mm
07746- 0010400

OUTERSEAL

EXTERNAL
CIRCLIP

ATTACHMENT.
40 x 50 mm l.D.
07LAD- PW50601

Installthe outer seal into the bearingsupportusing


the specialtools. The seal should be flush with the
bearingsupport.
6.

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.

Installthe three dowel bolts,then torquethem.

OOWELBOLTS
10x 1.25mm
39 N.m {4.0kgf.m,29 lbtftl

16-21

RearDriveshafts
Removal

Disassembly

't. Loosenthe rear


whel nuts slightly.
Raisethe rear of the vehicle,and support it with
safety stands in the proper locations(seesection 1),
Removethe wheel nuts and rearwheets.

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,

Removethe set ring from the inboardjoint,


BOOTBAND
Replace.

SPINDLENUT
22 x 1.5mm
Replace.

WHEELNUT
1 2x 1 . 5m m

INBOARDJOINT

2.

Removethe boot band.


-

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

lf the boot band is a double loop type, raisethe


band bendas shown,

DOUSLELOOPBAND
Replace.

3.

Mark each roller and inboard joint to identify the


locationsof rollersand groovesin the inboardjoint.
Then removethe inboardjoint on the shop towel.
INBOARDJOINT
Checksplinesand driveshaftring
for wearor damage,
Checkinsideborefor wear.
Inspect{or cracks,

RING
DRIVESHAFT

8. Wrap the splineson the driveshaftwith vinyl tapeto


preventdamageto the boots.

INEOARDBOOT
Inspectfor cracking,
splittingand wear.

M.rks

DRIVE
SHOPTOWEL
Marks

Markthe rollersand spiderto identifythe locations


of the rollerson the sgider,then removethe rollers,

Remove the boot band and boot from the driveshaft. Take care not to damagethe boot.

1 0 . Removethe vinyl tape.


ROLLER

DRIVESHAFT

'11. Inspectthe driveshaftfor damageand otherfaults.

0\

tI

Mark

CIRCLIP

Removethe circlip.
Mark the spider and driveshaftto identifythe position of the spideron the shaft.
7.

Removethe spiderusinga bearingremover.

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{

Pack cavity with grease.

16-24

www.emanualpro.com

OUTBOARDJOINT

'1. Wrap the splineswith vinyl tape to preventdamage


to the boots.

6.

Reinstallthe rollersto their originalpositionson the


spider by aligning the marks.After installation,make
sure to hold the driveshaftpointed straight up to prevent the rollersfrom fallingoff.

ROLLER

VINYLTAPE

lnstallthe boots onto the driveshaft,and seat the


smallend of the bootsinto the grooveson the driveshaft,lf the smallendsof the bootsare not seatedin
t h e g r o o v e s ,t h e b o o t l e n g t h a d i u s t m e n tw i l l b e
rncorrect.
Removethe vinyl tapefrom the end of the driveshaft.

7.

Packthe joint and the boot with the joint grease


includedwith the new boot.
Greasequantity: 80 - 90 s {2.8- 3.2 o2)

Installthe spideronto the driveshaftby aligningthe


mark on the spiderwith the mark on the end of the
driveshaft.

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.

Installthe joint by holdjngthe driveshaftstraightup


and aligningthe markson the joint with the marks
on the rollers,

9.

Adjustthe positionof the jointsto the specifications


shown. then adjustthe boots halfwaybetweenfull
compressionand full extension.Makesurethe ends
of the bootsare seatedin the groovesin the joints.

10. Set the double loop band onto the boot with the
bandend towardthe front of the vehicle,

1 1 . Pull up the slackin the band by hand.


Inboard ioint lngth:
153- 157mm {6.02- 6.18inl

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

Outboard ioint l6ngth:


l/l:' - 147 mm {5.63- 5.37 in}

16-26

www.emanualpro.com

1 3 . Threadthe free end of the band through the nose


sectionof a commerciallvavailableboot band tool
(KD-3191
o r e q u i v a l e n t )a, n d i n t o t h e s l o t o n t h e
winding mandrel,
1 4 . Placea wrench on the winding mandrelof the boot
band tool, and tighten the band until the marked
spot on the band meetsthe edgeof the clip.

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

Lift up the boot band tool to bend the free end of


the band 90 degreesto the clip, Center-punchthe
clip,then fold overthe remainingtail onto the clip.

HAMMER

17. Bendthe band end by tapping it down with a hammer.


NOTE:
. Makesurethe banddoes not move.
. R e m o v ea n y g r e a s er e m a i n i n go n t h e s u r r o u n d i n g
surfaces.

(cont'd)

www.emanualpro.com

16-27

RearDriveshafts
(cont'd)
Reassembly

lnstallation

18. Installthe new set ring into the driveshaftgroove.

'1. lnstall
the outboardjoint into the trailingarm.

SETRING
Replace.

ICI
SET RINGGROOVE

Installthe rear driveshaftsinto the rear differential


assembly(seesection15).
Apply a small amount of engine oil to the seating
surfaceof the new spindlenut.

WHEELNUT 12x 1.5mm


108N.m (11.0kgt.m,80lbtftl

SPINDLE
NUT22 x 1.5mm
181 N.m (18.5kgf.m, 134lbl.ftl Replace.

Installa new spindlenut, then torquethe nut. After


tightening,usea driftto stakethe spindlenut shoulder
againstthe driveshaft.
Cleanthe mating surfacesof the brakedisc and the
wheel, then install the rear wheel, and torque the
wheel nuts.

16-2A

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PropellerShaft
Inspection
UnivarsalJoint and Boots

PropellorShaft Runout

1.

Shiftthe transmissionto Neutral.

6.

Installa dial indicatorwith its needleon the centerof


No, 1 or No.2 propellershaft.

2.

Raisethe vehicleoff the ground,and supportit with


safetystandsin the properlocations(seesection1).

7.

Turn the other propellershaft slowly and checkthe


runout.Repeatthis procedurefor the other propeller
shaft.

3.

Checkthe cente.supportbearingfor excessiveplay


or rattle.It the centersupporthas excessiveplay or
raftle,replacethe propellershaftassembly.

No. 1 PropellerShaft Runout:


ServiceLimit: t.5 mm (0.06in)

No.1 PROPET_LER
SHAFT
Checkthe universaljoint boots for damageand deterioration.lt the boots are damagedor deteriorated,
replacethe propellershaftassembly.

No. 2 PropellerShaft Runout:


ServiceLimit: 1.5 mm {0.06inl

Checkthe universaljoints for excessiveplay or rattle.


lf the universaljoints have excessiveplay or rattle,
replacethe propellershaftassembly.

lf the runout on either oroDellershaft exceedsthe


servicelimit, replacthe 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.

Mark the No. I propellershaft and transferassembly acrosstheir jointsas shown.


o.

PNOPELLER
SHAFT
PROTECTOR
2.

uErrrEnDurrr.r'rI I'EAnrNu

Mark the No. 2 propellershaft and rear differsntial


acrosstheirjointsas shown.

Removethe four 12-pointbolts, and remove the No.


1 propellershaft from the transferassembly,

No. 'l PROPELLER


SHAFT

Removethe four 12-pointbolts. and remove the No.


2 propellershaft from the rear differential.

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

www.emanualpro.com

TRANSFER
ASSEMBLY

Installthe propellershafts in the reverseorder of


removal.Make sure to align the marks on the propller shafts with the marks on the rear differential
and the transferassemblv.

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/

SUPPLEN\EN\AL RES\RA(N\ SYSTES{\(SRS\


This model has an SRSwhich includesa driver'sairbagin the steeringwheel hub. a passenger's
airbagin the dashboard
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
pageinclude,or are locatednear,SBScomponents.Servicing.disassembling
or replacingtheseitemswill requirespecial
precautionsand tools,and shouldonly be done by an authorizedHondaoearer.

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

BallJoint BootClip Guide


@
* Includedin the BeltTensionGaugeSet 07TGG- 001000,4

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)

Checkthe teed and return circuit lines and hose


betweenthe gearbox and pump for clogging and
deformation.

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

Checkthe flow controlvalve(seepage17 26).


. Checkthe valvlor smooth movementin the housing.
. Checkthe relief valve for leaks.

Normalreliefpressure

Go to page 17 5

1 7 -4

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Abnormal

Faultypump assembly

Faultyflow control valve

Checkthe force requiredto turn


the wheellseepage17 12).
Startthe engineand measurethe
force requiredto turn the wheel
to the right and left.Difference
of
t h e f o r c e r e q u i r e dt o t u r n t h e
wheel to the right and to the left
shouldbe 2.9 N (0.3 kgf,0.7 lbt)
or less,

Abnormal

Deformed

Not deformed

Faultycylinderlines

Readjust
the rackguide
(seepage17-15)

AdjustmentOK
Normal
Bent

Faultysteeringgearbox

Compairthe steeringto another


alikevehicle.

(cont'd)

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17-5

Troubleshooting
(cont'dl
GeneralTroubleshooting
Assist(excessively
lightsteering)at
high speed.

Checkthe rack guide for proper


adjustment(seepage17-15).

Shockor vibrationwhen wheelis


turnedto full lock.

Checkthe rack guide for proper


adjustment(seepage17'15).

lf the problemis not correctedby


adjustingthe rack guide, adjust
t h e f r o n t w h e e l a l i g n m e n t( s e e
section18).

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

lf the problemis not correctedby


adjustingthe rack guide,replace
the gearbox.

Steeringwheelwill not return


smoothly.

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.

lf the problemis not correctedby


adjustingthe rackguide,replace
the gearbox,

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Unevenor roughsteering.

Ad,usttherackguide(seepage17-15).

ll the problemis not correctedby


adjustingthe rack guide,replace
the gearbox.

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.

Air in reservoir,or check power


steeringtluid level.

Checkpower steeringlluid level.lf


the level is excessivelylow check
for leaks in the system.Add fluid
to the specifiedlevel.

lf fluid levelis OK, checkO-rings


a n d s e a l so n b o t h e n d s o f t h e
p u m p i n l e t h o s e ,a n d t h e P / S
p u m p h o u s i n gm a t i n gs u r l a c e s
and drive shaft oil seal for suc
tion leaks.Checkthe reservoirfor
cracks,Replaceparts as neces-

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).

Adjustthe belt tension(seepage


17-14)
or replace
belt.

Installthe power steeringpressure gauge, Closethe pressure


control valve and shut off valve (if
so equipped)fully and measure
the pump pressure(seepage 17-16
ot 17 17).

Checkif pump pressureis normal


and the gauge needletravel is 500
k P a ( 5 k g l / c m , ,7 1 p s i ) o r l e s s .
Checkthe flow controlvalve if the
needletravelexceeds500 kPa (5
kgflcm',71 psi). lI the flow control
valve is normal, replacethe pump
as an assembly,

7-7

Troubleshooting
NoiseandVibration
NOTE:Pumpnoisein first 2 - 3 minutesafterstartingin cold weatheris normal.

Humming

Rattleor chattering

Humming due to pulsationof fluid is normal, particularlywhen the wheel is


turnedwith the vehiclestooDed.

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.

Confirm by temporarily removing


the pump belt.

Feedhose (high-pressure)
touching the frame.

Beposition the feed hose.

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.

Checkthe rack guide for proper


adjustment(seepage17-15).

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

Cavitationcausedby air bubbles


in the fluid.

Checkthe fluid lev1.


l t l o w , f i l l t h e r e s e r v o i rt o t h e
properlevel.and checkfor leaks.
Tightenor roplaceas necessary,

Checkfor a crushedinlet hoseor


a loose hose clamp allowing air
into the suctionside of the sys
t e m . C h e c kt h e r e s e r v o i rf o r
cracks.Tighten or replaceas nec-

Checkthe driveshaftoil seal.

Pumpnoise

Raftleor chattering

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Pump noise up to 2 - 3 minutes


after starting in cold weather is
normal,Comparepump noiseat
operatrngtemperatureto another
vehicle.

ll pump noiseis abnormallyloud,


removeand inspectthe pump for
wear and damage(see page 17251.

Tightenor replacethe pulley.


l I s h a f t i s l o o s e , r e p l a c et h e
pump.

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

Leakingfrom the oil seal on the


top of the valvehousing.

Replace the valve oil seal from


the valve housing.

Leakingfrom cylinder end into


left tie rod boot.

Replace the valve oil seal from


the pinion shaft.

Replacethe cylinderend seal on


the valvebody unit side.

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17 -1 0

Leakingfrom cylinder end into


right tie-rod boot.

Replacethe cylinderend seal on


the cylinderend side.

Leakinglrom the shaftupperend


sectionor pin engagementsection of the pinionshaft.

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

Tightenthe connector.It it's still


leaking,replacethe line,cylinder
or valvehousing.

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.

Leakingfrom pump outlet hose


and returnlinejoint fittingon the
valvebody unit {attlarenut}.

Tightenthe connector.ll it's still


leaking,replacethe line,joint fitting or valvehousing,

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.

Air leakin suctionsideof the system (reservoir,pump inlet hose,


front pump seal).

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 .

Tightenthe fifting. lf it's still leaking, replacethe O-ringor pump


outlethose,

Leakingat the swagedjoint.

Replace
the pump outlethose.

Leakingbecauseof damage,dete'
rioration,
or improperassembly,

Replace
or repairas necessary.

17-1

Inspectionand Adjustment
Steering Operation

PowerAssistCheckwith
VehicleParked

Placethe front wheels in the straight ahead position.


and measurethe distancethe steering wheel can be
turnedwithout movingthe front wheels.

1.

Checkthe power steeringfluid level (see page 1715)and pump belttension(seepage 17-14).

ROTATIONALPLAY:0 - 10 mm (0 - 0.39 inl

2.

lf the play exceedsthe limit, perform rack guide adjustment (seepage17-15).


lf the play is still excessiveafter rackguide adjustment,
inspectthe steeringlinkageand gearbox as described
on the nextpage.

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.

Aftacha springscaleto the steeringwheel,With the


engine idling and the vehicleon a clean.dry floor,
pull the scaleas shown and read it as soon as the
tires beginto turn.

ROTANONALPLAY

+i r

f::1-t

SPRING
SCALE
(Commercially
available)

The scaleshould read no more than 29 N (3.0 kgf,


6 . 6 l b f l . l f i t r e a d sm o r e , c h e c kt h e g e a r b o xa n d
oumo.

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.

Inspectfor loose mounting bolts.


GEARBOXMOUNTINGCUSHIONS
lnsp6ctfor dgterioration.

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.

Measurementwithout Belt Tension Gauge:


Apply a force ot 98 N (10 kgf,22 lbt) and measurethe
deflectionbetweenthe power steering pump and the
crankshaftoullevs.

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.

Attach the belt tension gauge to the belt with the


gaugefacetowardthe engine,and measurethe tension of the belt.
Removethe belt tension gauge carefullyto avoid
hittingthe gaugeresetlever.
PULLEY
CRANKSHAFT

Tension:
Used Belt:
New Belt:

390 - 540 N {40 - 55 kgf, 88 - 121 lbf)


7,[0- 840 N (75 - 90 kgf, 165- 198 lbf)

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

1 . Setthe wheelsin the straightaheadposition.

Checkthe reseryoirat regularintervals,and add the recommendedfluid as necessary.


CAUTION: Always use Gsnuine Honda Power Steering
Fluid-V or S. Using any other type of power steering
tluid or automatic transmissionfluid can causeincreassd
wear and poor steering in cold w3athel.
SYSTEMCAPACITY:
0.85 liter {0.90US. qt. 0.75 lmp.qtl
at disasssmbly
CAPACITY:
RESERVOIR
0.,1liter (0.42US. gt, 0.35 lmp.qi)

Loosenthe rack guide screw locknutwith the specialtool,then loosenthe rackguidescrew.


For'98 - 00 models,removethe rack guide screw.
R e m o v et h e o l d s e a l a n tf r o m r a c k g u i d e s c r e w
threadedsection,and apply new sealantto the first
three threads.Looselyinstallthe rack guide screw
on the steeringgearbox.

RACKGUIDESCREW
UPPENLEVELLINE

LOWERLEVELLINE

1 . Raisethe reservoir.then disconnectthe returnhose


to drainthe reservoir.Takecare not to spill the fluid
on the body and parts.Wipe off any spilledfluid at
once.

LOCKNUT
25 N.m
12.5kgt m, 18lbtftl

5.

4.

Tightenthe rack guide screwto 25 N.m (2.5 kgf'm,


18 lbf.ft),then loosenit.
R e t i g h t e nt h e r a c k g u i d e s c r e w t o 3 . 9 N ' m ( 0 . 4
kgf.m, 2.9 lbf.ft),then back it off to specifiedangle.
2,
SpecifiedReturn Anglo:
10 r 5"
37 model:
'98 - 00 modeb: 20' Max

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.

Checkfor tight or loose steeringthrough the completeturningtravel.

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.

Checkthe powsr steeringfluid level (see page 1715),and pump belttension(seepage17-14).

2.

Disconnectthe pump outlet hose from the pump


outlet with care so as not to spill the powr steering
iluid on the frame and other pans. thon installthe
P/Sjoint adapter(pumplon the pump outlet.

5. Fully open the shut-off valve.


PRESSURE
CONTROLVALVE

6 x 1.0mm BOLT
{Partoftool)
FEEDHOSEFITTING

PUMPOUTLETHOSE

11 N.m ll.1 kgl.m, E lbf.ftl


P/S PRESSURE
GAUGE
07('6 - 0010001
6 x t.0 mm BOLT
{Partoftool)
11 N.m
(1.1kgt m, 8 lbf.tr)

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),

11. lmmodiatelyopenthe pressurecontrolvalvefullv.


lf the pump is in good condition,the gaugeshould
read at least 6,900- 7,800 kpa (70 - 80 kgflcmr,
'1,000- 1.140psi).
A low readingmeanspump output is too low for full assist.Repairor replacethe
DUMD.

17-1 6

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PumpPressureCheckWith T/N 07406- 001000A


Checkthe fluid pressureas follows to determinewhether
the troubleis in the pump or gearbox.
1.

Checkthe power steeringtluid level (see page 17151,and pump belttension(seepage 17-14).

2.

Disconnectthe pump outlet hose from the pump


outletwith careso as not to spill the power steering
fluid on the frame and other parts,then installthe
P/Sjoint adapter(pump)on the pump outlet.

5. Open the pressure controlvalve fully.

PRESSURE
CONTROLVALVE

6 x 1.0mm BOLT
(Partoftool)

FEEDHOSEHfNNG

PUMPOUTLETHOSE

1'l N.m 11.1kgf.m,8lbfft)


GAUGE
P/S PRESSURE
07406- 001000A
6 x 1.0 mm BOLT
(Partol tool)
11 N.m
(1.r kg{.m,8lbf'ft|

Startthe engineand let it idle.


7 . Turn the steering wheel from lock-to-lockseveral
timesto warm the tluid to operatingtemperature.
Measuresteady-statefluid pressurewhile the engine
is idling.It the pump is in good condition,the gauge
shouldread1,500kPa(15koflcm' ,213psi).lf it reads
high. checkthe outlet hose or valve body unit {see
GeneralTroubleshooting),
Closethe-pressurecontrolvalve graduallyand read
the oressure.
CAUTION: Do not keep the pressurs control valve
closed more then 5 seconds or the pump could bo
damaged by overheating.

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).

lf the pump is in good condition,the gauge should


read at least 6,900 - 7;800 kPa (70 - 80 kgflcm' ,
1,000- 1.140psi), A low readingmeanspump outDut is too low for {ull assist.Repairor replacethe
oumo.

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.

Align the front wheelsstraightahead.then remove


the driver's airbag assembly(seesection24) from
the steeringwheel.

2.

Disconnectthe horn connectorand cruise control


switch connectors.

3.

Loosenthe steeringwheel bolt, then install a steering


wheelpulleron the steeringwheeland removeit.
Notetheseitemswhen removingthe steeringwheel:
. Do not tap on the steeringwheel or the steering
columnshaftwhen removingthe steeringwheel.
. lf you threadthe puller bolts into the wheel hub
morethan five threads,the boltswill hit the cable
reel and damageit. To preventthis, installa pair
of jam nutsfive threadsup on eachpullerbolt.
STEERINGWHEELBOLT
39 N.m 14.0kgt.m,29 lbtftl

CONTROL
SWITCHESCONNECTOR

STEERINGWHEELEOLT

Disassembly/Reassembly
STEERINGWHEEL

EOSSCOVERPLATE

WHEELBODYCOVER

_^M
@,

"\

BODY
COVERCAP
ACCESSPANEL

17- 1 8

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lnstallation
1.

Beforeinstallingthe steeringwheel, make sure the


front wheelsare alignedstraightahead,then center
the cablereel.Do this by first rotatingthe cablereel
clockwise until it stops. Then rotate it counterclockwise approximatelytwo turns. The arrow mark on
the cablereel labelshouldpoint straightup.

2.

Installthe steeringwheel on to the steeringcolumn


shaft,makingsurethe steeringwheel shaftengages
the cable reel and cancelingsleeve.Do not tap on
the steeringwheel or steeringcolumn shatt when
instailingthe steeringwheel

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.

Remove the driver's side dashboard lower cover


and kneebolster(seesection20),

Notetheseitemswhen removingthe steeringcolumn:


. Before removing the steering column, remove the
driver'sairbag assemblyand cable reel (seesection
24).
. Beforeremovingor installing,set the columnshaft in
the neutralpositionby pullingup the steeringcolumn
to uppermostposition,then lower it 8 mm (5/16in).
Tightentilt lever.

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

Disconnectthe steeringjoint from the enginecompanment.

8 mm (5/16)

7.

MAXIMUM LOWER
POSTTTON

Removethe steeringwheel (seepage 17-18).

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

9,8 N.m l r .0 kgf.m,7 lbf.fO


JOINT DUSTSEAL
22 N.m (2.2kgl.m, 16lbtftl

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

22 N.m (2.2 kgf.m, 16lbt.ftl

8.

is the reverseofthe removalprocedure.


Installation
Notetheseitemsduring installation:
. Be sure the wires are not caught or pinchedby
any partswhen installingthe column.
a Make sure the wire harnessis routed and fastened properly.
. Make sure the connectorsare properlyconnected.
. Make sure the steeringjoint is connectedas follows:
a. lnsertthe uDperend of the steeringjoint onto
the steeringshaft (line up the bolt hole with
the flat ot the shaft).
b. Slip the lower end of the steeringioint onto
the Dinionshaft (lins up the bolt holewith the
groovearoundthe shaft).and installthelower
ioint bolt. Be sure that the lower joint bolt is
securelyin the groovein the pinionshaft'
c. Pullon the steeringjoint to makesurethat the
steeringjoint is JullYseated.
Then installthe upperjoint bolt and tightenit.

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

Checkthe absorbingplates,absorbingplate guides


and slidingcapsulesJordistortionand breakage.
ReDlacethe column as an assemblyif they are distorted or broken.
SLIDINGCAPSUII
This part is attached
to the column bracket
with the plastic 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

1 . Move the tilt lever from the loose position to the


l o c k p o s i t i o n3 t o 5 t i m e s ; t h e n m e a s u r et h e t i l t
lever preload10 mm (0.4in) from the end of the tilt
rever.
Preload:70 - 90 N (7 - 9 kgf, 15 - 20 lbf)
l f t h e m e a s u r e m e n ti s o u t o f t h e s p e c i f i c a t i o n .
adjustthe preloadusingthe tollowingprocedures.
a. Loosenthe tilt lever,and set the steeringcolumn
in the neutralposition.

1 . Bemovethe steering column (see page 17-20).


Centerpunchthe shearbolt, and drill bolt head off
with a 5 mm (3/16in) drill bit.
Removethe shear bolt from the switch body. Be
carefulnot to damagethe switchbody when removing the shearbolt.
Insertthe ignitionkey and turn it to "1".
Push the lock pin down, and pull out the steering
lockbody from the steeringcolumn.

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.

d . Pull up the tilt lever to the uppermostposition.

and installthe stop. Checkthe preloadagain. lf


t h e m e a s u r e m e n its s t i l l o u t o f s p e c i f i c a t i o n ,
r e p e a tt h e a b o v e p r o c e d u r e sa . t h r o u g h c . t o
adjust.

Checktor proper operation of the steeringwheel


lock,and that the ignitionkeyturns freely.
1 0 . Tightenthe shearbolt untilthe hex headtwistsoff.
TWIST.OFF
PORNON

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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10.01- 0.22 in)

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.

Placea suitablecontainerunderthe vehicle.

7 . Connectthe pump inlet hoseand pump outlethose.


Tightenthe pump fittingssecurely.

Drainthe powersteeringfluid from the reservoir.

Looselyinstallthe pump in the pump bracketwith


the mountingbolt and lockbolt.

Removethe belt by looseningthe pump mounting


bolt and pump lock bolt.

Installthe pump belt.


PUMPOU'I.TT HOSE

PUMPMOUNNNG
BOI.T
24 N.m12.4kgtm, 17lbl.ftl

11 N.m (1.1 kgf.m,


E rbf.ti)

Notetheseitemsdu.ing belt instsllation:


. Make sure that the power steering belt is properly positionedon the pulleys.
. Do not get power steering fluid or greaseon the
power steering belt or pulley faces,Cleanoff any
fluid or greasebeforeinstallation

FOWERSTEER G EELT
PUTrlY

1 0 . Adiustthe pump belt (seepage17-141.


'l

l. Fill the reservoirto the upper level line (see page

'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.

13x 1.9mm O-RING


Replace.
PUMPSEALSPACER
INLETJOINT
PUMPDRIVESHAFT
FLANGEBOLTS
11 N.m 11.1kgt m,
8 tbf.ft)

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.

Hold the steering pump in a vise with soft jaws.


hold the pulley with the specialtool, and remove
the pulleynut and pulley.Be carefulnot to damage
the pump housingwith the jaws of the vise.

Inspection
Flow Control Valve
1.

Checkthe flow control valve for wear, burrs, and


other damageto the edges of the grooves in the
valve.
'97
model:
FLOW
CONTROLVALVE

UNIVERSAL
HOLDER
07725- 0030000

Checkfor
damageto edges.

'98 - 0Omodls:
FLOWCONTBOL
VALVE

Checkfor damage
to edges.

Inspd the bore of the flow controlvalvetor scratches


or wear.
Slip the valve back in the pump, and checkthat it
moves in and out smoothly.lf OK, go to step 4; if
not, replacethe pump as an assembly.The flow
controlvalveis not availableseparately.

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

Removethe O,ring,flow controlvalveand spring.


Removethe inletjoint and O-ring.
Removethe pump coverand pump coverseal.
7 . Removethe outer side plate,pump cam ring, pump
rotor,pump vanes,side plateand O-rings.
4.
Removethe snap ring, then removethe sub-valve
from the pump housing.

Attacha hoseto the end of the valveas shown.


FLOWCONTROL
VALVE

9 . Removethe circlip, then remove the pump drive


shaft by tappingthe shaft end with the ptastichammer.
1 0 . Removethe pump sealspacerand pump seal.

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.

For'97 model only, hold the bottom end of the


valvewith a open end wrench.Unscrewthe seatin
the top end of the valve,and removeany shims,the
relielcheckball,reliefvalveand reliefvalvespring.

2.

Replacethe ball bearingusinga press.

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-

lf the flow control valve tests OK, reinstallit in the


pump. It the flow controlvalvestill leaksair, replace
the pump as an assembly.The flow controlvalve is
not availableseparately.

17-27

PowerSteeringPump
Reassembly
'1.

Align the pin of the sub-valvewith the oil passage


in pump housing,and push down the sub-valve.
Installthe snsp ring properly.

5.

Coatthe pump coversealwith power steeringfluid,


and installit into the groovein the pump cover.

OIL PASSAG
Alignthe pin of

ROLLERSET HOLES

the oil passage.

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

Positionthe pump drive shaft in the pump housing,


then drive it in usinga 29 mm socketas shown,

H
go

29 mm SOCKET

lnstallthe oute. side plateoverthe two rollers.


PUMPCAMRING

,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,

Installthe 40 mm circlipwith its radiusedside facIng out.

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.

8. Asssmble pump rotor to the pump cover,


9. Set the 10 vanes in the groovesin the rotor, Make
surethat the round ends of the vanesare in contact
with the slidingsurfaceof the cam ring.

FLANGEBOI-TS
20 N.m (2.0kgt m,
14 tbf.ft)

PUMPROTOR

51 x 2.4 mm O-RING
Replace.

1 3 . lnstallthe pump cover assemblyin the pump housing.

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.

1 4 . Coat the tlow control valve with power steering


fluid.
FLOWCONTROL
VALVE
137modol)

Eg

SPRING

SII'E PLATE

15.2x 2.4 mm O.RING


('97 modell
16.7x'1.8mm O-RING

15.2 x 2-1 ftm GRING


Replace.
ROL1IR SET HOI,E

Gfooves.

SETHOTT

FLOW CONTBOL
VALVE
l'98 - 0Omodeltl
FLOW CONTROL
VALVE CAP
49 N.m (5.0kgl.m,
36 tbf.ft)

BOLI-ERS

'15. Installthe flow controlvalveand springin the pump


housing.
1 6 . 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 on the flow controlvalvecap.

1 1 . Installthe side plateon the cam ring by aligningthe

rollerset holesin the side Dlatewith the rollers.

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1 7 . Installthe flow controlvalvecap on the pump hous(cont'd)


ing,and tightenit.

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

1 9 . Installthe inletjoint on the pump housing.


20. I n s t a l lt h e p u l l e y a s s h o w n b e l o w . t h e n l o o s e l y
installthe pulley nut. Hold the steeringpump in a
vise with soft jaws. Be careful not to damagethe
pump housingwith the jaws of the vise.

17-30

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21. Holdthe pulleywith the speciattoot, and tightenthe


p u l l e yn u t .

Checkthat the pump turns smoothlyby turning the


pulleyby hand.

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.

7. Removethe cotterpin from the nut, and removethe


castle nut {'97 - 98 models) or hex nut ('99 - 00
models).

Drainthe power steeringfluid as describedon page


'17-15.
Raisethe vehicle,and suppon it on safetystandsin
the properlocations(seesection1).
Removethe front wheels,
Removethe drive/s airbagassembly{seesection24).
Removethe steeringwheel{seepage 17-18).
Removethe steeringjoint bolts, then disconnectthe
steeringjoint by moving the joint toward the column.

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

Separatethe tie-rodball joint and knuckleusingthe


specialtool.

1 0 . Removethe right and left tie-rodends,then extend


the rackall the way to the right.
1 1 . Removethe TWC(seesection9).
Disconnectthe shift linkagefrom the transmission
(M/T:see section 13,A/T: see section 14).

1 3 . With 4WD. separatethe propeller shaft and transfer


assembly(seesection161.

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.

16. Loosenthe 16 mm flare nut, and removethe return


hosejoint.
17. After disconnecting
the hosesand lines,plug or seal
them with a pieceof tape or equivalentto prevent
foreign maisrialsfrom enteringthe valve body unit.
NOTE:
. Do not loosenthe cylinderline A and B between
the valvebody unit and cylinder.
. With 2WD, continue to step 23.

10x 1.25mm

Vinyltapor
equivalntm6terial.
STOPBOLT

17 -32

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20. Removethe rearmount bracketand rear mount.


REARMOUNT
12x 1.25mm
Replace.

22. Jack up the engineand tilt the enginebackuntil the


transferassemblyis loweredapproximately40 mm
(1.57
in).
Notetheseitemswhen tiltingthe engine:
. Checkthat the wire harnesses,hosesand pipes
are not caughtby any surroundingparts.
. Do not tilt the enginemore than necessary.

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

24. Removethe mountingbrackets.

Steering RackDisassembly
Notetheseitemswhen disassembling:
. Beforedisassemblingthe gearbox,wash it off with
solventand a brush.
. Do not dip sealsand O-ringsin solvent.
1.

Removethe steeringgearbox(seepage 17-31).

2.

Removeairtube and clips.

MOUNTINGBRACKETS
AIR TUBE

25. lvlovethe steeringgearboxto the right so the left


rack end clearsthe rear beam, then placethe left
rackend belowthe rearbeam.
3.

Removethe boot bandsand tie-clips.

4.

Pullthe bootsawayfrom the endsof the gearbox.

STEEBINGGEARBOX

Move the steeringgearboxto the left, and tilt the


left sidedown to removeit.
With 4WD. remove the steering gearbox through
the clearancebetweenthe transfer assemblyand
propellershaft.

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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,

8. RemovecylinderlinesA and B from the gearbox,

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).

Removethe two tlangebolts,then removethe valve


body unit from the gearbox. (See page 17-38for
valvebody unit disassembly.)
DUSTCOVER
VINYLTAPE

RACKGUIDE
FLANGEBOLT

LOCKNUT

1 1 . Apply vinyl tape to stepped portion of the pinion

1.

Removethe spring and the rack guide from the gearDOX.

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shaft,and removethe dust cover.


(cont'd)

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)

13. Hold the gearboxusing using a C-clampas shown,


Loosenand removethe cvlinderend.

STEERINGRACK
CYLINDERND

1 7 . Set the gearbox in a press so the lelt side points


upward,then pressthe cylinderend seal and steering rack out of the gearbox.Hold the steeringrack
to keep it from fallingwhen pressedclear.Be caref u l n o t d a m a g et o i n n e r s u r f a c eo f t h e c y l i n d e r
housingwith the flangebolt.

17-36

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18. Removethe 12 mm bolt and nut trom the stsering


rack,
19. Remove the cylinder end seal from the steering
racK.

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

Separatethe valve housingfrom the pinion shafv


valveusinga press.
Checkthe innerwall of the valve housingwhere the
seal ring slideswith your finger.lf there is a step in
t h e w a l l , t h e v a l v e h o u s i n gi s w o r n . R e p l a c et h e
valve housing.
Notetheseitemsduringinspection:
o There may be the sliding marks from the seal
ring on the wall of the valve housing. Replace
the valvehousingonly if the wall is stepped.
. When the valve housingis replaced,installnew
shim{s)on the bearingsurfaceof the housingto
adiustthe thickness.
C h e c kt h e i n s i d e o f v a l v e h o u s i n g
for a step in the wall.

17-38

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27. Removethe circlipand sleevefrom the pinionshaft.

28. Usinga cutte. or an equivalenttool, cut and remove


the four seal ringsfrom the sleeve.Be carefulnot to
damagethe edgesot the sleevegroovesand outer
surfacewhen removingthe sealrings.

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

29. Using a cutter or an equivalenttool. cut the valve


s e a l r i n g a n d O - r i n ga t t h e g r o o v e i n t h e p i n i o n
shaft. Removethe valve seal ring and O-ring. Be
carefulnot to damagethe edgesof the pinion shaft
grooveand outer surfacewhen removingthe valve
sealrjng and O-ring.

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

www.emanualpro.com

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)

'98 - (x) models:

PISTONSEALRING
Replace.

www.emanualpro.com

17-40

STEERINGRACK

'98 model:
'99 - 0Omod6ls:

Valve Body Unh Roa$embly


1.

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.

8. Apply power steering fluid to the surface of the


v a l v e s e a l r i n g t h a t w a s i n s t a l l e do n t h e p i n i o n
shaft.
Apply power steeringfluid to the insideof the special tool. Set the largerdiameterend of the special
tool overthe valvesealring.
VALVESEALRING
SIZNG TOOL
07NAG - SR309q'
ot
07NAG - SR3oltoA

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

Usgth6 largr diameter


end of the special
toollirst to make
th valve seal ring
tit in the pinion
shaft.

Mak the valve seal ring


fit snuglyin the pinion
shatt using th6 other end
{smallerdiameterend)ot
the specialtool.

Vinyl trp

1 0 . Move the specialtool up and down severaltimes to


makethe valvesealring fit in the pinionshaft,
1 1 . Removethe soecialtool.

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.

RplaceDo not over-expand.

Fit the new O-ringin the grooveof the pinion shaft.


Then slide the new valve seal ring over the shaft
and in the grooveon the pinionshaft,
7 . Removethe vinyl tape from the pinionshaft.

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.

Notetheseitemswhen installingthe sealring:


. Do not over-expand
the sealring. Installthe resin
seal rings with care so as not to damagethem.
A f t e r i n s t a l l a t i o nb, e s u r e t o c o n t r a c t h e s e a l
ringsusingthe specialtool{sizingtool).
. There are two types of sleeveseal rings: black
and brown. Do not mix the different types of
sleevesealringsas they are not compatible.

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

1 4 . Align the specialtool with each groove in the sleeve,


and slide a sleeveseal ring into each groove.After
installation,compressthe seal rings with your fingerstemporarily.
BALLJOINT BOOTCLIPGUIDE
07974- SA508q)
SLEEVE

1 9 . Apply power steeringfluid to the seal ring lip of the


valveoil seal.then installthe seal in the valvehousing using a hydraulicpressand specialtools. Install
the valve oil sealwith its groovedside facingthe tool.

1 5 . Apply power steeringfluid to the seal rings on the


sleeve,and to the ehtireinsidesurfaceof the special
tool.

ATTACHMENT,
32x35mm
077i16- (x)10100

SLEEVESEALRING
SIZINGTOOL
07974- SA502O0or
07974- SA5020A

1 6 . Insertthe sleeveinto the specialtool slowly.

't1. Move the sleeve each direction several times to


makethe seal rings snuglyfit in the sleeve.Be sure
that the seal ringsare not turned up,

www.emanualpro.com

VALVEOIL SEAL
Replace.
Makesurethe
springis in the
oilseal.

20. Pressthe new bearinginto the valve housingwith


the stampedletterfacingup usinga hydraulicpress
and soecialtool.

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.

22, Insertthe pinion shaft into the valve housing. Be


carefulnot to damagethe valvesealrings.
23. Removethe vinyl tape from the pinion shaft,then
removeany residuefrom the tape adhesive.
(cont'd)

www.emanualpro.com

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.

31. Wrap vinyl tape aroundthe rackteeth and rack end


edges,then coat the surface of the tape with the
power steeringfluid. Make sure that the vinyl tape
is wrappedcarefullyso that there is no steppedportion.

26. Positionthe new O-ringand new pistonseal ring on


the sDecialtool, then slide them down toward the
big end of the tool.
Notetheseitemsduring reassembly:
a Do not over expandthe resin seal rings. Install
the resin seal rings with care so as not to damage them. After installation,be sure to contract
the sealring usingthe specialtool (sizingtool).
a Replacethe piston'sO-ringand sealring as a set.
27. Pull rhe O-ringoff into the pistongroove,then pull
the pistonsealring off into the pistongrooveon top
of the O-ring.

Coatthe insidesurfaceof the new cvlinderend


with powersteeringfluid.

PISTON

Installthe cylinderend seal onto the steeringrack


w i t h i t s g r o o v e d s i d e t o w a r d t h e p i s t o n .W h e n
installingthe cylinderend seal,be carefulnot damagethe sealinglip faceof the sealwith the edgesor
teethof the steeringrack.
CYLINDER
ENDSEAL

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.

www.emanualpro.com

17-44

Make sure the


spring is in lhe cylinder
eno seal

Removethe vinyl tape from the steeringrack,then


removeany residuefrom the tape adhesive.

35. Install the new backup ring on the steering rack,


then placethe cylinderend sealagainstthe piston.
BACKUPRING
Replace.

37. Installthe flange bolt into the end of the steering


f 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
f l a n g eb o l t o u t 1 / 4 t u r n . H o l d t h e f l a n g eb o l t a n d
tightenthe flangenut againstthe rackby hand.
Prers

12 x'175 mm FLANGEBOLT
lP/N 90177- SLo- 0001
12 mm FLANGENUT

to.

Greasethe steeringrackteeth,then insertthe steering rack into the gearboxhousing,Be carefulnot to


damageto inner surfaceof the cylinder wall with
the rackedges.

GEARBOXHOUSING

CYLINDERENDSEAL
Replace.

38. Installthe cylinderend seal into the bottom of the


cylinderby pressingon the bolt with a press,Do not
p u s h o n t h e b o l t w i t h e x c e s s i v ef o r c e a s i t m a y
damagethe cylinderend seal.
ia

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

www.emanualpro.com

17-45

PowerSteeringGearbox
(cont'dl
Reassembly
4l. Coatthe insidesurfaceof the new cvlinderend seal
with powersteeringfluid.
CYLINDEBENOSEAL
Replace.
Makesurethe spring
is in the cylinderend seal.

46. Greasethe insidesurtaceof the cylinderend, then


installthe cylinderend by screwingit into the cylinder.
41. Removethe C-clampfrom the gearbox.
48. After tighteningthe cylinderend, stakethe point of
the cylindershown below.Stakethe cylinderin the
position oppositefrom where the stakewas removed
duringdisassembly,
NOTE:For '98- 00 models,go to step54.
Stake point, Depth: 1,0 mm (0.04inl

Staked

posrtron.
4.0mm {0.16in)
Groovedside.

42. Installthe cylinderend seal onto the steeringrack


with its groovedsidetowardthe piston.

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.

49. Selectthe 32 mm shim(s)('97 modelonlv).


N O T E :O n l y r e i n s t a l tl h e o r i g i n a l3 2 m m s h i m ( s )
when the steeringgearboxis reassembledwithout
replacingthe pinionshaft.valve housing,and gearbox housingwith new ones.
l f t h e p i n i o n s h a f t , v a l v e h o u s i n g ,a n d g e a r b o x
housingare replaced,selectthe new shim{s)as follows.
Shim selection:
Set the four 32 mm shims on the bearingsurfaceof the
g e a r b o x h o u s i n g .T o t a l t h i c k n e s so f t h e f o u r s h i m s
shouldequalno more than 0.70mm.
Shim set: four 32 mm shims (Thickness:
0.10 mm, 0.15
mm, 0.20mm, 0.25mm respectively)
N O T E :T h e f o u r 3 2 m m s h i m s d o n o t h a v et h i c k n e s s
identification
marks.Measurethe thicknessof eachshim
usinga micrometer,and markthe shim for identification.

17-46

www.emanualpro.com

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{

Measurethe clearancebetween the gearbox and


valve body unit using a feelergauge.Measurethe
c l e a r a n c ea t t h e p o i n l m i d w a y b e t w e e nt h e t w o
mountingbolts.

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

56. Installthe valve body unit on the gearboxhousing


by engaging the gears. Note the valve body unit
installationposition(directionof line connection).
5 7 . Tightenthe flangeboltsto the specifiedtorque.

Selectthe shims so that the total thicknessis close


to, but lessthan,the requiredthickness.

(cont'd)

www.emanualpro.com

17-47

PowerSteeringGearbox
(cont'dl
Reassembly

58. InstallthecylinderlinesA and B


Notetheseitemsduring reassembly:
. C l e a nt h e j o i n t s o f t h e c y l i n d e rl i n e sA a n d B
thoroughly.The joints must be free of foreign
material,
. lnstall the cylinder lines A and B by tightening
the flare nuts by handfirst,then tightenthe flare
nutsto the soecifiedtorque.

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

26 N.m {2.7 kgl.m, 20

STEERING

64. Screwthe rackends into the rack.

CYLINDEF
LINEA
Greasethe sliding surface of the rack guide, and
installit onto the gear housing.

60. For'97 model,applya thin coatof greaseto the new


O-ring,and installit on the rackguidescrew.
For'98 - 00 models.removethe old sealantfrom
the threadsof the rackguide screw.then apply new
sealantto the first threethreads.
RACKGUIOE

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.
.

.
.

Placethe wood blockon the presstable,then set


the lock washer section of the rack end on the
wood block securely.
Be sure the tool is aligned with the flat sections
of the steering rack end before pressing.
Stake the lock washer in the center of the flat
section of the steering rack end,
ROLLPIN PUNCH
lCommorcially.Y.il.blel
Snap-OnNo. PPR8or oquival.nt.

-6r

O-RING

nlcr cutDE R"Pl""u'


SCREW
LOCKNUT
37 model:
38 model:

NOTE: This drift has a flat


shoulderto prevent
puncturingof metalwasher.
ot.

Installthe spring, rack guide screw and locknuton


the gear housing.
Adjustthe rack guide screw (seepage 17,15).After
adjusting,checkthat the rack moves smoothly by
slidingthe rackright and left.

17-48

www.emanualpro.com

STEERINGRACK

WOODENBLOCK

67. Apply greaseto the circumferenceof the rack end


housing.

70. Adiust the air hose fitting positionof the boots by


turning it as shown below.
LEFTBOOT
{Viewedfromthe
leftside)

RIGHTBOOT
(Viewedtrom the
rightside)

ro

''rT.a'.
Front

, tri"

\,'tAr-

{,1@}tr
)Fr1

RACKENDGROOVE
.={@
GREASE
SILICONE

BOOT AIR HOSEFITTING


FIT'I'ING

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).

71. Installnew boot bandson the boot, and bend both


setsof lockingtabs.
CAUTION: Stake the band locking tabs firmly.

RACK ENO

NOTE: Wipe the greaseoff


the threadsection.

Lightlytap on the doubled-overportionsto reduce


their height.
Slide the rack right and left to be cenain that the
bootsare not deformedor twisted.
(cont'd)
TIE.RODCLIP

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17-49

PowerSteeringGearbox
Reassembly(cont'd)

BallJoint Boot Replacement

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,

't. Removethe boot set ring


and the boot.
CAUTION:Do not contaminatethe boot inslallation section with graase.

CYLINDER
LINEA

Packthe interiorof the boot and lip with grease.


Wipe the greaseoff the sliding surfaceof the ball
pin.then packthe lower areawith freshgrease.
CAUTION:
. Keep greaseoff the boot installation section and
the tapered section of th ball pin.
. Do not allow dust, dirt, or other to.eign materials to enter the boot.
EALLPIN TAPERED
SECTION
Wipe olf the grease.
CYLINDERLINE

75. Installthe clips on the cylinderlines,then clampthe


air tube with the clips.
B(X)T IT{STALLATION

76. Apply vinyl tape to around the pinion shaft, and


coat the surfaceof the tape with grease.

sEclroN
Wipe off the grease.

BOOT INSTALLATION
SECTION
Wipe offthe grease.

Installthe boot in the grooveof the boot installation


sectionsecurely.then bleedair.

DUSTCOVER
Vinyl Tsp

VALVEOIL SEAL

Adjust the specialtool with the adjustingbott until


the end of the tool aligns with the groove on the
boot. Slidethe set ring over the tool and into posiI|on.
CAUTION: After installing the boot, chock the batl
pin lapered section for grease contamination and
wipe it it ncessary.

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

www.emanualpro.com

SET RING

lnstallation
1.

Beforeinstallingthe gearbox,extendthe rackall the


waYto right.

2.

lnstallthe mounting cushion on the steerlnggearbox.

3.

Passthe right side of the steeringgearbox above


and throughthe right sideof the rearbeam.Be careful not to bend or damagethe two power steering

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.

With 4WD,lower the iack,and returnthe engineto


the originalPosition.

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)

www.emanualpro.com

17-51

PowerSteeringGearbox
Installation(cont'd)
8,

Installthe left front mount. Tighten the mounting


boltsin order:A and B.

LEFTFRONTMOUNT

B-12x 1,25mm
59Nm
(6.0 kgtm,, lbl.ftl
Replaca.

11. Installthereturnhosejoint by tighteningthe 16 mm


flare nut.

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.

Instsllthe right front mount, Tightenthe mounting


bolts in order:A and B.

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

't2. Connectthe return


hose securely.and tighten the
adjustablehoseclamp.

1 3 . Connectthe pump outlet hose, and tighten the l4


mm flare nut.
NOTE: Makesure that there is no interference
betweenthe fluid lines,the rear beam or any other
parts.

10. Removethe vinyl type from the side frame (both


sides).

17-52

www.emanualpro.com

't4. Centerthe steeringrackwithin its stroke.


1 5 . Installthe steeringjoint, and reconnectthe steering
shaftand pinionshaft.
NOTE:Make surethe steeringjoint is connectedas
follows.

17. Wipe off any greasecontaminationtrom the ball


joint taperedsectionand threadsthen reconnectthe
tie-rod ends to the steeringknuckles.For'97 - 98
models;torque the castle nut to the lower torque
s p e c i f i c a t i o nt,h e n t i g h t e n i t o n l y f a r e n o u g h t o
alignthe slot with the pin hole.Do not align the nut
by loosening.Installnew cotterpins.
TIE.ROOEND

a. Insenthe upperend of the steeringjoint onto the


steeringshaft (line up the bolt hole with the flat
on the shaft).
JOINTBOLT
UPPER
22 N.m
12.2kgf.m,16lbl.ft,

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

b, Slip the lower end of the steeringioint onto the


pinionshaft.
c. Installthe lower joint bolt (line up the bolt hole
with ths groove around the shaft).Be sure that
the lower joint bolt is securelyin the groove in
the pinionshaft.
d. Pull on the steeringjoint to make sure that the
steeringjoint is fully seated.
e, Installthe upperjoint bolt,
1 6 . Reinstallthe steeringwheel{seepage'17-19).

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PIN
COTTER
RePlace.
bend
on reassembly,
thecotterPinasshown.

LOWERJOINTBOLT
22 N.m
12.2kgf.m,16lbtftl

1 8 . With 4WD,connectthe propellershaft and transfer


assembly(seesection16).
1 9 . Connectthe shift linkageto the transmission(M/T:
see section 13,A,/T;see section 14).
20. InstalltheTwc (seesection91.
2 1 . lnstallthe front wheels,
22. Fill the systemwith power steeringfluid, and bleed
air from the system(seepage 17-15).

23. After installation.performthe followingchecks.


.

.
.

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

F o r p r o p e ri n s p e c t i o n / a d j u s t m eonf tt h e w h e e l a l i g n ment, checkand adjustthese items beforecheckinqthe


alignment:

Inspection

. Checkthat the suspensionis not modified.


. Checkthe tire sizeand tire pressure.
. Checkth( runoutof the wheelsand t;res,
. Checkthe suspensionball joints.(Hold a wheel with
your hands,and move it up and down and right and
leftto checkfor wobbling.)

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.

Check the caster angle.


Caster angle: 2'10':t 1"
l f o u t o f s p e c i f i c a t i o n c, h e c k f o r b e n t o r d a m a g e d
s u s p e n s i o nc o m p o n e n t s .

18-4

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lf out of specification,checkfor bent or damaged


suspensron
components.

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.

Checkthe tire pressure.

1.

1.

Releaseparking brake to avoid an incorrectmeasurement.

Centerthe steeringwheel spokes.


Checkthe toe.
3.

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.

Ro8rtoe-in:2 :1 mm {lN l/16:t 1/16 in,

Fronttoe-in:0 i 3 mm {0 t 1/8 inl

lf adjustmentis required,go to step2.

lf adjustmentis required,go on to step 4.

lf no adiustmentis required.remove alignment


equrpmenr.

lf no adjustmentis required,remove alignment


equipment.

Beforeadjustment,note the locationsof adjusting


boltson the right and left compensatorarms.

Loosenthe tie-rod locknuts,and turn both tie-rods


i n t h e s a m e d i r e c t i o nu n t i l t h e f r o n t w h e e l s a r e
pointingstraightahead.

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

sir N m (5.5kgJ.m,'O lbf.ft)

ARM
COMPENSATOR

5.

Turn both tie-rodsequally until the toe readingon


the wheel alignmentcomputeris correct.

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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Example:After the reartoe inspection,the wheel is 2


mm (0.08in) out of the specification.
M o v e t h e a r m s o t h e a d j u s t i n gb o l t m o v e s 2 m m
{0.08in) inwardfrom the positionrecordedbeforethe
adjustment.
The distancethe adjustingbolt is moved should be
equalto the amountout-of-specification.
Tightenthe adjustingbolts.

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.

Turn the wheel right and left while applying the


brake, and measure the turning angle of both
wneets.

Turningangle:
Inwardwheel:37.00'
Outwardwheel lreference):
31.30'

2.

l f t h e t u r n i n ga n g l eis not within the specifications,


c h e c kf o r b en t o r d a m a g e ds u s p e n s i o nc o m p o nenIs.

18-6

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Wheel/Hublnspection
BearingEndPlay

WheelRunout

1 . Raisethe vehicleoff the ground,and makesure it is


securelysupported.

1.

Raisethe vehicleoff the ground,and makesure it is


securelysupported,

Removethe wheels,then reinstallthe wheel nuts.

Checkfor bent or deformedwheels.

Attachthe dial gaugeas shown.

Attachthe dial gaugeas shown.

Measurethe bearingend play by movingthe discor


drum inwardor outward.

Measurethe wheel runoutby turningthe wheel.

Front/Rear;
Standard:0 - 0.05 mm (0 - 0.002in)

Front and RearWhoel Axial Runout:


Standard:
Steel Wheel:
0 - 1.0 mm {0 - 0.0i[ in]
AluminumWheel:0 - 0.7 mm l0 - 0.03in)
ServiceLimit:
2.0 mm 10.08inl

Measureend play at the


hub flange.

Front and RearWheel Radial Runout:


Standard:
Steel Whoal:
0 - 1.0 mm (0 - 0.04 inl
Aluminum Whoel: 0 - 0.7 mm {0 - 0.03 in}
1.5mm (0.06inl
Servics Limit:

Rear:

Measureend play at centerof


the hub flange.

108 N.m
{11.0kgf.m, q} lbf.ftl

It the bearingend play measurementis more than


the standard,replacethe wheelbearing.

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lf the wheel runout is more than the servicelimit,


reolacethe wheel.

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.

29 N.m {3.0 kgl.m, 2.2 lbf.ftl


Beforetighteningthe llangenut,
positionthe balliointpin
in the middleof its rangeof travel,
with the suspensionundervehicleload.
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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)

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18-9

FrontSuspension
(cont'dl
Replacement
Knuckle/Hub
1 . Loosenthe wheel nuts slightly.

7. Removethe 6 mm brakedisc retainingscrews,

Raisethe front of the vehicle,and make sure it is


secu.elysupported.
Removethe wheel nuts and wheel.
6 mm BRAKEDISC
RETAININGSCREWS
9.8 N.m
(1.0 kgl.m,7.2 lbf.ftl

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 brakediscfrom the knuckle.


Checkthe front hub for damageand cracks.
1 1 . R e m o v et h e w h e e l s e n s o rf r o m t h e k n u c k l e( f o r
vehicleswith ABS). Do not disconnectthe wheel
sensor connector.

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)

Removethe caliper mounting bolts, and hang the


caliperassemblyto ona side.To preventdamaggto
t h e c a l i p e ra s s e m b l yo r b r a k e h o s e , u s e a s h o r t
pieceof wire to hangthe caliperfrom the undercarriage.
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18-10

MOUNTING
BOLTS
9.8 N.m
lr.0 kgf.m, ?.2lbf.ftl

12. Cleanany dirt or greaseoff the ball joint.


1 3 . Removethe cotter pin from the steeringarm, and
removethe nut.

17. Oncethe specialtool is in place,turn the adjusting


bolt as necessaryto make the jaws parallel.Then
h a n d - t i g h t e nt h e p r e s s u r eb o l t , a n d r e c h e c kt h e
jaws to makesurethey are still parallel.

14. Apply greaseto the specialtool on the areasshown.

This will ease installationof the tool and prevent


damageto the pressurebolt threads.
PRESSURE
BOLT

ADJUSTINGBOLT

tc.

lnstalla 10 mm hex nut on the ball joint. Makesure


the hex nut is flush with the ball joint pin end to
prevent damage to the threaded end of the ball
joint.
28 mm
BALLJOINTREMOVER,
07MAC- SL(x)2(x)
HEXNUT

HEX NUT
10x 1.25mm
('99 modcll
43 N.m
lit.a kgl.m.
32 tbtft)
6:)

After makingthe adjustmentto the adjustingbolt,


make sure the head of the adjustingbolt is in this
positionto allow the jaw to pivot.
1 8 . With a wrench, tighten the pressurebolt until the
ball joint shaft pops loosefrom the steeringarm.
wear eye protection. The balt ioint
@
can break loose suddenly and scatter dirt or other
dsbris in your eys.
1(|

Removethe tool, then removethe nut from the end


of the ball joint, and pull the ball joint out of the
steering/suspensionarm. Inspectthe ball joint boot.
and replaceit if damaged.

CASTLENUT
10x '1.25mm
l'97 - 98 modcls)
39 - 47 N.m
{4.0- 4.8

29- 3s rbtftt

COTTER
Replace.

37 -98 models:

'99 -00 modol:

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.

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(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,

26. Pull the knuckleoutward, and remove the driveshaft


outboardjoint from the knuckleby tapping the driv+
shaft end with a pl8stichammer,then removethe
knuckle.
KNUCKI.E
Checklor damage.

Installa 12 mm hex nut on the ball joint. Make sure


the hex nut is flush with the balljoint pin end,or the
threadedsectionof the ball joint pin might be damaged by the balljoint remover.
Usethe specialtool as shown on page 18-11to sepa r a t et h e b a l l j o i n t a n d l o w e r a r m . l f n e c e s s a r y ,
apply penetratingtype lubricantto loosenthe ball
joint.

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18-12

27. Separatethe hub from the knuckleusingthe special


tool and a hydraulicpress.Takecare not to distort
the splashguard.Hold on to the hub to keepit from
fallingwhen pressedclear.

29. Pressthe wheel bea.ingoutofthe knuckleusingthe


soecialtoolsand a Dress.

DRIVER
077,19- 0010000

HUBDIS/ASSEMELY
TOOL
07GAF- 5800100

ORIVER
ATTACHMENT,
62x64mm
07947- 6340400

FRONTHUB

SETTING
POINT

28. Removethe circlip and the splashguard from the


knuckle.
30. Pressthe wheel bearing inner race from the hub
using the specialtool, a bearing separator,and a
press.
Checkfor bendingand damage.

HU8OIS/ASSEMBLY
TOOL
07GAF- SE00100
EEARING
SEPARATOR
O-1112in.
(Commercially
available)

{cont'd}

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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.

35. lnstallthe hub on the knuckleusingthe specialtools


shown and a hydraulicpress.Be carefulnot to distort the splashguard.

ORIVER
077irg- 0010000

DOUBLELIPSEAL
IBLACKCOLORI

SPLASHGUARO

BASE
SUPPORT
0?965- SD90t00

33. Installthe circlip securelyin the knucklegroove.

scREws

5 N.m 10.5kgl m, 4 lbl'tt)

CIRCLIP

34. Installthe splashguard and tightnthe screws.

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18-14

lnstall the knuckle in the reverse order of removal,


and pay particular attention to the following items:
Be careful not to damage the ball joint boots
when installing the knuckle.
r Torque a\\ mount\ng hardv{are to ths speci{ied
torquevalues,
o Torque the castle nuts to the lower torque speci
fications, then tighten them only iat enough to
align the slots with each pin hole. Do not align
the castlenut by loosening.
a lnstall new cotter pins on the castle nuts or hex
nut aftertorquing.
. Avoid twisting the sensorwires when installing
the wheel sensor.
. Before installing the brake disc, clean the mating
surfacesof the front hub and the inside of the
brakedisc.
. Beforeinstallingthe spindle nut, apply a small
amount of engine oil to the seatingsurfaceoJthe
nut. After tightening, use a drift to stakethe spindle nut shoulderagainstthe driveshaft.
. Beforeinstallingthe wheel.cleanthe matingsurfaceof the brakediscand the insideof the wheel.
. Checkthe front wheel alignment,and adjust it if
necessary
{seepage 18-4).

Lower BallJoint Replacement


'1.

Removethe knuckle(seepage 18-10).

8.

Installthe ball joint boot and set ring usingthe specialtool {seepage18-16}.

Installthe knucklein the reverseorder of removal.


and pay particularattentionto the followingitems:

Removethe boot by prying the set ring off.


Checkthe boot for deteriorationand damage.and
replaceit if necessary.
lnstallthe specialtools on the ball joint, and tighten
the castlenut.
8AI.I JOINT REMOVEN/INSTALLER

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.

Installthe specialtools over the ball joint as shown,


then pressthe balljoint in.
BAII JOINT INSTAL1IR BASE

BALLJOINT HOUSINGSURFACE

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Be careful not to damage the ball joint boots


when installingthe knuckle.
. Torque all mounting hardwareto the specified
torouevalues.
a Torquethe castlenuts to the lower torque specifications,then tighten them only far enough to
align the slot with the pin hole. Do not align the
castlenut by loosening.
. Install new cotter pins on the castle nuts after
IOrqurng.
Avoid twisting the sensorwires when installing
the wheelsensor.
Beforeinstallingthe brakedisc,cleanthe mating
surfacesof the front hub and the inside of the
brakedisc.
Beforeinstallingthe wheel.cleanthe matingsurfaceof the brakediscand the insideof the wheel.
Checkthe front wheel alignment,and adjust it if
necessary(seepage18-4).
.

18-15

Front Damper

FrontSuspension
BallJoint Boot Replacement

Removal

1 . Removethe set ring and the boot.

1,

Removethe front wheels(seepage 18-10).

2.

Removethe damper pinch bolt from the top of the


damperfork.

Packthe interiorof the boot and lip with grease.Do


not contaminatethe boot installationsectionwith
grease.

DAMPERFORK

BALL PIT{TAPEFEOSCTION

DAMPER
PINCH
BOLT
'10x 1.25

B{rcYHSI

SECTIO

wip6 off tho gr6aso.

BOOT|NST

SECTION

Wipo otf th6 grors.

Wipe the greaseoff the sliding surfaceof the ball


pin, and pack it with fresh greass. Keep grease off
the boot installation section and the taoered section
of the ball pin.
Do not allow dust, dirt, or other foreign materialsto
enter the boot.
Installthe boot in the grooveof the boot installation
sectionsecurelv,then bleedair.
Installthe upper and lower ball joint boot set rings
usingthe specialtools as follows:
Lower ball joint: Adjust the special tool with the
adjustingbolt until the end of the tool alignswith
the groove on the boot. Slidethe set ring over the
tool and into oosition.
Upper ball joint: Hold the tool over the ball joint,
then slidethe set ring overthe tool and into position.
EAII JOINT
B(X)TCUP
GUttrE

AD'USN G BOLT
Adjustth6 depthby
turningthe bolt.

UPPERBAI.I

Jott'trBoor:

07GAG - SO407q)
LOWEF BATI
JOIIYI EOOTI
0t97il - SA507lXl

After installing the boot, check the ball pin tapered


section for greasecontamination,and wipe it if necgssary.

18-16

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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

Releasethe pressurefrom the spring compressor,


then disassemblethe damperas shown in the next
cotumn.
Inspection
1.

Reassemble
all parts,exceptfor the spring.

2.

Pushon the damperassemblyas shown.

SPRINGMOUNTING

BUMPSTOPPLATE

..rg

BUMPSTOP g

DUST

weaknessand

C h e c k for bendingand damage. damage,

Checkfor smooth operationthrough a full stroke,


b o t h c o m p r e s s i o na n d e x t e n s i o n .T h e d a m p e r
should move smoothly.lf it does not (no compress i o n o r n o e x t e n s i o n )t ,h e g a s i s l e a k i n g a
, nd the
dampershouldbe replaced.
Checkfor oil leaks,abnormalnoises,or bindingduring these tests.

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Front Damper
lnstallation

Reassembly
1.

Installthe damperunit on a springcompressor.


STRUTSPflNG COMPBESSOR:
lcomm.rcillly .vrilrble)
BRANICKCT/N MST.sEOA
or Mod.l 7200
or oquivtla

1 . Loosely install the damper on the frame with the


a l i g n i n gt a b f a c i n ginside,then loosely install tne
two flangenuts.
NUT
FLANGE

.46
-

10 x 1.25mm
59 N.m {5.0 kgt m, 43 tbf.ftl

-__---a-"-

g*-

| -,./

./

--...
-4

ADAMPER
ASSEMBLY

SPRINGLOWERSEAT

Assemblethe damper in reverseorder of removal


exceptthe damper mountingwasherand self locking nut. Align the bottom of the damperspring and
the springlower seatas shown.

ALIGNING
TAB

Positionthe damper mountingbaseon the damper


unit as shown.
2, 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 f r o n t d a m p e r i n t h e
damperfork so the aligningtab is alignedwith the
slot in the damDerfork,

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

Hold the dampershaft,and tightenthe 10 mm selflockingnut.

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18-18

Replace.

3. Looselyinstallthe damper pinch bolt on the top of


the damperfork.
4. Looselvinstallthe damperfork bolt and a new selflockingnut on the bottom of the damperfork.
5. Raisethe knucklewith a floor iack until the vehiclejust
lifts off the safetvstand.
The lloor iack must b socurely positioned or personal iniury may result.
6. Tightenthe damperpinch bolt.
7. Tightenthe damperfork bolt and self-lockingnut.
8. Tightenthe flangenuts on top of the damper.
9. Installthe brakehose mounts with the brake hose
mountingbolts.
10. Installthefront wheel.

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}

64 N.m 16.5kgf.m, 47 lbtftl


SELF.LOCKING
NUT
10 x 1.25mm 29 N.m (3.0kgl.m, 22 tbf.ft)
Replace.
Holdthe ballioint pin usinga hexwrenct,,
and tightenthe self-locking
nut.
STABILIZER
LINK
. Checkfor bendingand damage.
. Checkthe bushingtor deterioration
and
damage.

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,/ 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

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1A-20

't. Raisethe rear of the vehicle,and make


sure it is

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.

Removethe wheel sensorfrom the backing plate


( f o r v e h i c l e sw i t h A B S ) . D o n o t d i s c o n n e c t h e
wheelsensorconnector.
Removethe 12 mm flangebolts.

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.

Removethe parking brakecable from the backing


plateusinga 12 mm offsetwrenchas shown.

PULLER
available)
lCommercially

1 0 . 4WD; Removethe backing plate/hubbearing unit


from the rearaxlewith a pullerif necessary.

BACKINGPLATE

1 1 . Separatethe rear hub from the hub bearing unit

usingthe specialtoolsand a press.


Notethe followingitemsduring disassembly:
. Takecare not to distort the backing plate.
. Hold on to the hub to keep it from falling when

DRIVERATTACHMENT,
37 x ilo mm
07746- 0010200

PARKINGARAKECABLE

(cont'd)

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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

't7. Installthe hub bearingunit onto the rear hub using


the specialtools and a press.
DRIVER
ATTACHMENT,
60 mm
07LAO- SM40100

Prcss

DRIVER
07749- 0010000

BEARING

13. Removethe 12 mm flangebolts.

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

16. Installthe hub bearingunit on the backingplate.

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18-22

19. Installthe hub bearingunit in the reverseorder of


removal,and pay particularattentionto the following items:
. Before installingthe spindle nut, apply a small
amountof engineoil to the seatingsurfaceof the
nut, After tightening, use a drift to stakethe spindle nut shoulderagainstthe driveshaft.
. Avoid twisting the sensorwires when installing
the wheelsensor,
. Fill the brakereservoirand bleed the brakesystem {seesection19).
. Adjustthe parkingbrake(seesection191.
. Checkthe rear wheel alignment,and adjust it if
necessary(seepage 18-4).

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.

Removethe two flange nuts.


ACCESSPANEL

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

Makea mark on the upperarm at two pointsso the


marks are in line and at a right angle with the arm
as shown in the drawing.
Drive in the upper arm inner bushingwith the
marks aligned until the leadingedge is flush with
the uoDerarm.
L o w e r t h e r e a r s u s p e n s i o n ,a n d r e m o v e t h e
damper.

Drive the upper arm bushing into the upper arm


untilthe leadingedge is flush with the upperarm.

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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.

Releasethe pressurefrom the spring compressor,


then disassemble
the damperas shown on page 1825.

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.

Checkfor smooth operationthrough a full stroke,


b o t h c o m p r e s s i o na n d e x t e n s i o nT. h e d a m p e r
should move smoothly.lf it does not (no compress i o n o r n o e x t e n s i o n )t ,h e g a s i s l e a k i n g a, n d t h e
dampershouldbe replaced.
Checkfor oil leaks,abnormalnoises,or bindingdurino thesetests.

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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.

Loosely install the two flange nuts.

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.

Positionthe dampermountingbase on the damper


u n i ta s s h o w n .

FLANGEEOLT
10 x 1.25mm
54 N.m 15.5kgt.m,
40 tbI.ft)

Compressthe damper spring with the spring compressor.


I n s t a l lt h e d a m p e rm o u n t i n gw a s h e r ,a n d l o o s e l y
nut.
installa new self-locking

Raisethe rear suspensionwith a floor jack until the


vehiclejust lifts off the safetystand.

NUT
SELF.LOCKING
10x 1.25mm
29 N.m (3.0
Replace.

The floor iack must be securely posi@


iioned or personal iniury may result.
Tightenthe flangebolt.

Holdthe dampershaftwith a hex wrench,and tightnut.


en the self-locking

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6.

Tighten the two flange nuts on the top of the


damperto the specifiedtorque.

7.

Installthe dampercap and accesspanel.

8.

Checkthe rearwheelalignment.and adjustif necessary (seepage 18-4).

18-25

Brakes
. . . . . . . . .1. .9 - 1
Anti-lockBrakeSystem (ABS) .............
19-25

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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

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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

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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

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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.
.

Checkfor a differencein brakepedalstrokebetween


q u i c ka n d s l o w b r a k ea p p l i c a t i o n R
s .e p l a c e
the mas-.
ter cylinderif there is a differencein pedalstroke.

19-4

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(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.

Screw in the brakeswitch until its plunger is fully


p r e s s e d( t h r e a d e de n d t o u c h i n g t h e p a d o n t h e
pedal arm), Then back otf the switch 1/4 turn to
make 0.3 mm (0.01 in) of clearancebetween the
threadedend and pad. Tighten the locknutfirmly.
Connectthe brake switch connecto.. Make sure that
the brakelights90 off when the pedalis released

5.

Checkthebrakepedalfreeplay as describedbelow

Lift up the carpet,At the insulatorcutout,measure


the pedalheightfrom the middleof the right side of
the oedalpad.
BRAKESWITCH

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}

FreePlay:1 - 5 mm (1/16- 3/16 in)


2.

Loosenthe pushrodlocknut,and screwthe pushrod


in or out with pliersuntil the standardpedal height
from the floor is reached.Do not adjustthe pedal
heightwith the pushrodpressed.After adiustment,
tightenthe locknutfirmly.

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

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PEDALFREEPLAY

19-5

Inspectionand Adjustment
ParkingBrake
Inspeqtion
1.

3.

Releasethe parkingbrakelever.

Pull the parkingbrake lever with 196 N (20 kqf, 44


lbfl forceto fully applythe parkingbrake.
The parkingbrakelevershould be lockedwithin the
specifiednumberof clicks.
L.var LockodClicks:2 - 6

Adjust the parking brake by turning the adjusting


nut.
Checkthat the parkingbrakesdo not drag when the
rearwheelsare turned.Readjustif necessary.

2.

Adjustthe parkingbrakeif the leverclicksare out of


specification.

Adiustment
1.

Raisethe rear wheels off the ground. and support


the vehicle on safety stands.

@@

Bbck tho front whots betore iacking

up the rear ot tho vohicle.

2.

Removethe parkingbrakecover
PARKINGBRAKECOVER

19-6

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Makesurethe parkingbrakesare fully appliedwhen


the parkingbrakeleveris pulledup fully.
7.

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,

Makesure the brakefluid levelin the reservoiris at


levelline.
the MAX (uDDer)

MAX {UPPER)LEVEL
LINE
RESERVOIR
MASTERCYLINDER

2.
3.

4.

Havesomeoneslowly pump the brakepedalseveral


times,then applysteadypressu.e.
Loosenthe brakebleedscrewto allow air to escape
f r o m t h e s y s t e m .T h e n t i g h t e n t h e b l e e d s c r e w
securely.
Repeatthe procedurefor eachwheelin the sequence
shown below until air bubblesno longer appearin
the tluid.
Refill the reservoir on the master cvlinder to the
MAX (upper)levelline.

BLEEO
SCREW
7 N.m(0.?kgf.m,5 lbf.ftl

ALEEDINGSEOUENCE:
O Front Right

Gt RearRight

O Front Lefl

O Rear Left

NOTE:Bleedthe front calipersfirst in the bleeding


procedure.

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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

Parking BrakeSwitch Test

Brake Fluid Level Switch Test

1.

Removethe parkingbrakecover,

1.

2.

Disconnectthe connectorfrom the parking brake


switch.

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.

Checkfor continuitybetweenthe terminaland body


ground in eachpositionaccordingto the table.

Checkfor continuitybetweenthe terminalsin each


switchpositionaccordingto the table.

Terminal

LeverPosition \

Positive
Terminal

\ Body Ground

--o

LeverUp

r9''r

Position
FLOATUP
FLOATDOWN

Lever Down

RESERVOIR
CAP

GROUND

NOTE(Canada):lf the parking brakeswitch is OK, but


the brake system indicatordoes not function, perform
the input test for the daytimerunninglightscontrol unit
(seesection23).

19-8

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Switch contacts open at


proper fluid level.

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)

Loosenthe front wheel nuts slightly,then raisethe


v e h i c l e ,a n d m a k e s u r e i t i s s e c u r e l ys u p p o r t e d .
Removethe front wheels.
Removethe caliper bolt, and pivot the caliper up
out of the way. Checkthe hosesand pin boots for
damageand deterioration.

i)n.
CALIPER
BOLT
3.

EACKINGPLATE

lf the brake pad thicknessis less than the service


limit. replacethe front padsand shimstogetheras a
set.

CALIPERBODY

Remove the pads, pad shims, and pad retainers.

Cleanthe caliperthoroughly;removeany rust, and


checkfor groovesand cracks.

INNEBPADSHIMS
Checkfor weakness.

7.

Checkthe brakediscfor damageand cracks.

Installthe pad retainers.

'.'..i

#
I

OUTERPADSHIM
Checkfor weakness.

PAD RETAINERS

(cont'd)

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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

'11. Pushin the piston


so that the caliperwillfit over the
pads. Make sure the piston boot is in position to
p r e v e n td a m a g i n g i t w h e n p i v o t i n g t h e c a l i p e r
down.
CALIPER
BOLT
49 N.m(5.0kgf.m,36 lbf.ftl

to both sides of shims.

INOICATOR
Apply MolykoteM77
or 0aikalub528D
to both sidesof shim.

INNERPAD

OUTERPAD

Pivot the caliperdown into position,being careful


not to damagethe pin boot. Installthe caliperbolt
and tightenit,
1 3 . Pressthe brake pedal severaltimes to make sure
the brakeswork, then test-drive.

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.

When reusing the pads, always reinstall the


brakepads in their originalpositionsto prevent
loss of braking efficiency.
. Contaminatedbrake discs or pads reducestopping ability.Keepgreaseoff the discsand pads.

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.

Loosenthe front wheel nuts slightly,then raisethe


v e h i c l e ,a n d m a k e s u r e i t i s s e c u r e l ys u p p o r t e d .
Removethe front wheels.
Removethe brakepads{seepage 19-9).
I n s p e c t h e d i s c s u r f a c ef o r d a m a g ea n d c r a c k s .
Cleanthe discthoroughly,and removeall .ust.
Use wheel nuts and suitableplain washersto hold
the disc securelyagainstthe hub, then mount a dial
i n d i c a t o ra s s h o w n , a n d m a a s u r et h e r u n o u t a t
10 mm (0.4in) from the outer edgeof the disc.

DiscThicknessand Parallelism
Inspection
1.

Loosenthe front wheel nuts slightly,then raisethe


vehicle, and make sure it is securely supported.
Removethe front wheels.
Removethe brakepads(seepage 19-9).
Usinga micromater,measurediscthicknessat eight
points,approximately45'apan and 10 mm (0.4 in)
in from the outeredgeof the disc.Replacethe brake
disc if the smallest measurementis less than the
max. refinishinglimit.

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

grease in the caliper set)

Siliconegrease(use recommendedsealgreaseand p,n greasein the caliperset)

--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.

9. Removethe four boostermountingnuts.


' 1 0 .P u l l t h e b r a k eb o o s t e rf o r w a r d u n t i l t h e c l e v i si s
clearof the bulkhead.
1 1 . R e m o v et h e b r a k eb o o s t e rf r o m t h e e n q i n ec o m panment.
12. Installthe brakeboosterand mastercylinderin the
reverseorderof removal,and notetheseitems:
. When connectingthe brakelines,makesure that
there is no interferencebetweenthe brake lines
and other parts.
. Be carefulnot to bend or damagethe brakelines
when installingthe mastercylinder.
. lf replacingthe mastercylinderor brakebooster,
checkand adjust the pushrod clearancebefore
installingthe mastercylinder(seepage19-14).

CAUTION: Be careful not to bend or damagethe


brakelineswhen removingthe mastercylinder.
Do not spill brake fluid on the vehicle; it may dam.
age the paint; it brake fluid does cont.ct the paint,
wash it oft immediately with water.
7.
8.

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

15 N.m (1.5kgf.m,11 lbl.ftl

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Master Cylinder
Inspection/Disassembly

PushrodClearance
Adjustment

CAUTION: Do not spill brake fluid onthe vehicle;it may


damsge the paint; il brake fluid does contact th6 paint.
wash it off immodiately with water.

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.

Set the specialtool on the master cylinder body;


push in the centershaft until the top ot it contacts
the end of the secondarypiston by turning the adjustingnut.
PUSHRODADJUSTMENTGAUGE
07JAG- SD{o100
SECONDARY

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.

Installthe mastercylindernuts,and tightenthem to


the sDecifiedtoroue.
Connectthe boosteriniine with a vacuumgauge0 101 kPa (0 - 760 mmHg, 30 in Hg) to the booster's
e n g i n e v a c u u m s u p p l y , a n d m a i n t a i na n e n g i n e
speedthat will deliver66 kPa(500mmH9,20 in Hg)
vacuum.
With a feeler gauge, measurethe clearancebetween
the gaugebody and the adiustingnut as shown.

--1
SILICONEGREASE
MASTERCYLINOER
Checkborefor wear,rustand damage.

Clearanco:0 - 0.4 mm (0 - 0.02 inl


VACUUM GAUGE
lCommo.cidly 6vailablcl
0 - 101 kPt
l0 - 760 mm Hg, 30 in Hgl

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.

Startthe enginewith the pedalpressed.lf the pedal


sinksslightly.the vacuumboosteris operatingnormally.lf the pedalheightdoes not vary,the booster
or checkvalveis faultv.

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.)

Adjustthe clearancewhile the specifiedvacuum


is appliedto the booster.
Holdthe cleviswhile adjusting.

7 . Tightenthe star locknutsecurely.


8. Removethe specialtool.
0 - 0.4mm (0- 0.02inl
STARLOCKNUT
22 N.m
12.2kgt m. 16 lbtftl

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.

9 . Adjust the pushrodlength as shown if the booster


is removed,
1 1 6 1 0 . 5m m
{4.6 t 0.02 inl

Boostor ChockValve Test


1.

Disconnectthe brake boostervacuum hose at the


booster.

2.

Startthe engine,and let it idle.Thereshouldbe vacuum. lf no vacuum is available,the checkvalve is


not working properly. Replacethe brake booster
vacuumhoseand checkvalve.and retest.
ERAKEBOOSTER
VACUUM HOSE
(Checkvalveis built-in)

PUSHROD
LOCKNUT
1.5N.m11.5kgf.m.'11lbtfl)

1 0 . Install the master cylinder (see page 19-13).

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RearDrum Brakes
Inspection
a
a
rl
a

Never use an air hose or dry brush to clgan brake assemblies,


Use an OSHA approved vacuum cleanerto avoid breathing brake dust.
Contaminatedbrake linings or drums reduce stopping ability.
Block the front wheels betore iacking up lhe rear ot the vehicle,

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

Checkthe wheelcylinderfor leakage.


Checkthe brakeliningsfor cracking,glazing,wear,
and contamination.
Measurethe brake lining thickness.Measurement
does not includebrakoshoethickness.

8. Measure the inside diameter of the brake drum


with insideverniercalioers,
Drum Insido Diamoter:
219.9- 220.0mm (8.657- 8.661in)
Standard:
ServiceLimit: 221.0mm {8.700inl

BrakeLining Thicknoss:
Standard:
3.9-,1.5 mm {0.15- 0.18inl
SorviceLimil: 2.0 mm {0.08in}

WHEELCYLINOER

BRAKEDRUM

LININGS

lf the inside diameter of the brake drum is more


than the servicelimit, replacathe brakedrum.

1 0 . Check the brake drum for scoring, grooves, and


cracKs.
lf the brakelining thicknessis lessthan the service
limit, replacethe brakeshoesas a set.
7.

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Checkthe bearingsin the hub unit for smooth operation; if the bearingrequireservicing.referto section18.

19-17

RearDrum Brakes
BrakeShoesReplacement
1.

Removethe upperreturnspringwith the tool.

l@

war eye protestionwhen using the

7.

Removethe wave washer,parkingbrakelever.and


pivot pin from the brakeshoe by removingthe UcliD.

brske spring wrench.


U.CLIP
Replace.

\
\

w
\n

RETAINER
SPRING

BRAKESHOE

BRAKESPRINGWBENCH
available)
{Commerciallv

TENSIONPIN

Removethe tension pins by pushing the retainer


s p r i n ga n dt u r n i n gt h e m .
Lower the brake shoe assembly,and remove the
lower return spring, Make sure not to damagethe
dust coveron the wheel cylinder,
Disconnect
the parkingbrakecablefrom the parking
brakelever.
5.

Removethe brakeshoe assembly,

o.

Removethe upper returnspring,self-adjuster


lever,
and self-adjusterspring, and separatethe brake
shoes.
LEVER
SELF.ADJUSTER

19-18

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UPPERRETURNSPRING

Apply brakecylindergrease(P/N:08733- 80202)or


equivalentrubber greaseto the sliding surfaceof
the pivot pin, 8nd insertthe pin into the brakeshoe.
Installthe parkingbrakelever and wave washeron
the pivot pin, and securethem with a new U-clip.
.
.

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.

15. Apply greaseon each sliding surface.Keepgrease


or oil off the brakelinings.Wipe any excessgrease
off the parts.
.

Apply brakecylindergrease(P/N:08733- 8020E)


o r e q u i v a l e nrt u b b e rg r e a s et o t h e s l i d i n gs u r facesas shown.

UPPERRETURNSPRING

..4

S l r d r n sgu r f a c e

Apply rubbergrease
to slidingsurface.

1 2 . Hook the self-adjusterspring to the self-adjuster


leverfirst,then to the brakeshoe,
Installthe clevisesand upper return spring noting
the installationdirection.Be carefulnot to damage
the wheelcylinderdust covers.

Apply Molykote 44MA to the brake shoe ends


and oppositeedgesof the shoesas shown.

.. a Oppositeedgeof the shoe


.: a) Brakeshoeends
(Shoesideendsand backing
platecontactsurface)

1 4 . Installthelower returnspring.

(cont'd)

www.emanualpro.com

RearDrum Brakes
(cont'd)
BrakeShoesReplacement

WheelCylinderReplacement

16. Installthe brake shoes onto the backingplate. Be


carefulnot to damagethe wheel cylinderdust covers.

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.

17. Installthe tensionpins and the retainersprings.

1 . Removethe brakeshoes{seepage '19-18).


UPPERRETURNSPRING

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)

18. Hookthe upperreturnspringwith the tool.


wsar eye proieclion whon using tho
@
brtko spring wronch.
1 9 . lnstallthebrakedrum.

Removethe bolt and the wheel cylinder from the


backingplate.

20. lf the wheel cylinder has been removed,bleed the


brakesystem (see page 19-7).

Apply sealant betweenthe wheel cylinder and backing plate,and installthe wheelcylinder.

21. Pressthe brake pedal several times to set the self-

Install the removed parts in the reverseorder of


removal.

adjustingbrake.
Adjustthe parkingbrako(seepage 19-6).

Fill the brakereservoirup. and bleedthe brakesystem {seepage 19-7).


7.

www.emanualpro.com

19-20

After installation.checkfor a leak at the line joint.


and retighten if necessary.

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

www.emanualpro.com

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

Replacethe brakehose ifthe hose is twisted,cracked.


or if it leaks.
Disconnect
the brakehosefrom the brakeline using
a 10 mm flarenut wrench.
FLARENUT
WRENCH
(Commercially
available)

BANJO BOLT
34 N.m
13.5kgf.m, 25 lbl.ftl

WASHERS
SEALING
Heplace.
BRAKEHOSE

Removeand discardthe brake hose cliD from the


brakehose.

7. Installthe brakehose on the upper brakehose bracket


with a new b.akehoseclip.
Replace.

1 tbtftl

F
)
/
BRAKE
HOSEARACKET
8. Connectthe brakelineto the brakehose.
9 . After installingthe brakehose,bleedthe brakesys'19-7).
tem (seepage

Removethe banjo bolt, and disconnectthe brake


hosefrom the calioer.
5.

Removethe brakehosefrom the knuckle.

www.emanualpro.com

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.

Releasethe parkingbrakelever.and disconnectthe


parkingbrakecable.

3,

Bemovethe parkingbrakeleverassembly.

4.

Removethe parkingbrakeshoes{seepage

5.

Removethe parkingbrake cable from the backing


plateusinga '12mm offsetwrenchas shown.

6.

Installthecablein the reverseorderof removal.

'19-18).

PARKINGBRAKECABI-E

BRACKET
PABKINGARAKECABLE
or corroston,
Checktor
PARKINGBRAKELEVER
Checkfor smooth
operation,

,"u/n*UM
-6l

(Slidingsurface)

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19-23

Anti-lockBrakeSystem (ABSI,'97- 00 Models


SpecialTools
.............
19-26
ComponentLocations.........................
19-27
Anti-lockBrakeSystem (ABS)
Features/Construction.............
......,19-2A
CircuitDiagram
.........
19-32
ABS Control Unit Terminal
Arrangement
.........
19-34
TroubleshootingPrecautions.............
19-36
DiagnosticTroubleGode(DTC)
DiagnosticTroubleCode (DTC)
Indication(SCSModel ................
19-38
DTGErasure(MESMode) ...............
19-39
Troubleshooting
lndex ....................
19-40
Troubleshooting
ABS IndicatorLight DoesNot
ComeOn
............
19-41
ABS IndicatorLight DoesNot
Go Off (No DTC)...........................
19-43

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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.

www.emanualpro.com

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

IGl I(, AI FUSE

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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ABS {7.5AI FUSE

MTR CHECK17.5AI FUSE

19-27

Anti-lock Brake System (ABS)


Features/Construction
When the brakepedalis pressedduring driving,the wheelscan lock beforethe vehiclecomesto a stop. In suchan event,
of the vehicleis reducedif the front wheelsare locked,and the stabilityof the vehicleis reducedif the
the maneuverability
rearwheelsare locked,creatingan extremelyunstablecondition.The ABS preciselycontrolsthe slip rate of the wheelsto
and stabilityof the vehicle.
ensuremaximumgrip forcefrom the tires,and it therebyensuresmaneuverbility
The ABS calculates
the slip rate of the wheelsbasedon the vehiclespeedand the wheel speed,then it controlsthe brake
fluid pressureto attainthe targetslip rate.

Grip Force of Tire and Road Surlace


COEFFICIENT
OF
FRICTION

TARGETSLIPRATE

RADIAL
OIRECTION
OF THE
ROTATIONAL
DIRECTION
SLIPRATE

www.emanualpro.com

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

www.emanualpro.com

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

wheel Spod and Modulatot Control

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.

www.emanualpro.com

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

www.emanualpro.com

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)

lr z :ltl,/ a ,18 e tol/ 12li3l


p91
|ffi| 4 15 16)17
V I1sV l2'VIIU)4

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

Wire sideof femaleterminals

Teiminal
numbel

Wiie
color

Terminal3ign
Teiminalnamgl

Voltrge
Description

Condhions
(lgnition Switch ON llll)

tdminals

PCOM
GRNn/VHT (Primary
common)

Power sourcefor the solenoid


valve and pump motor.

1-GND

RRO
BLUA/EL (Rear-right

0)

GRY

RLO
(Rear-left
0)

GRN

FRO
(Fronr-right0)

STOP
{Stop)

Detocts right-rear wheel


sensorsrgnat.

OFF

AC:3-6V

OFF
theSCSseNice]
lConnect
connector
\
I

A p p r o x . 3V

53mVor aboveon

Detectsleft-rearwheelsensor
srgnat.

6-19

Detects right-front wheel


sensorsignal.

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

When the wheel is


turned at 1 turn/
second.

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

Powersourcefor the solenoid


valveandpumpmotor.

14.GND

Power sourcefor the solenoid


valve and pump motor.

15-GND

Groundfor the ABScontrol


unit.
Detectsright-rearwheel
sensorsignal.
Detectsleft-rearwheelsensor
signal.
Detects right-front wheel
sensorsrgnat.

Detectsleft-frontwheelsensor
sagnal.

ON

26

19-34

www.emanualpro.com

BLK

GND3
(Gtound
3)

AC:3-6V

When the wheel is turned


at l turn/second,

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

Groundtor the ABScontrol


untI.

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
\

Drives left-rearinlet solenoid

RED

Output voltago

ON

-9

OFF
the
/Connect SCSservice]
conneclor
\
I

OV
AC:3-6V
Approx.3 V
Below0.3V

ABS CONTROLUNIT 22PCONNECIOR

Wire side ol lemale terminals


Voltage
Terminal
numDer

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

Detects service check signal


(Diagnostictrouble code
(Servicecheck
indication)
signal)

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.

Ground for the ABS control


unit.

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
\

Drivespump motor relay.


19

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.

You may hearthe motor operateat this


The ABS control unit checksthe pump motor operationduring acceleration.
time, but it is normal.

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.

The connectorillustratjonsshow the femaleterminalswith a singleoutlineand the maleterminalswith a doubleoutl ne.

ABS Function Test


To simulateABS operationand activatethe solenoidvalvesand pump, usethe HondaPGMTester.
Connectthe PGMTesterto the 16PDataLinkConnector(DLC).Whenthe SystemSelectmenu is displayed,selectthe ABS
TestMode menu,and follow the tester'sprompts.

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.

Turn the ignitionswitchON (ll).


NOTE; Do not pressthe brakepedalwhenturningthe ignitionswitch.

Recordthe blinkingfrequencyof the ABS indicator.The brinkingfrequencyindicatesthe DTc.

4.

Turn the ignition switch OFF.and remove the SCSserviceconnector.


NOTE:The MalfunctionIndicatorLamp (MlL) will stay on after the engine is startsdif the SCSseryicaconnecrorrs
connected.

5.

Erasethe DTC.

Conditions for DTCindication


. The vehicleis stopped.
. The SCSserviceconnector is connectedbefore the ignition switch is turned ON flt).
. The brakepedalis released.
. The SCSserviceconnectorremainsconnectedduringthis procedure.
The DTC indication stops and the ABS control unit axecutostha softwaro lunction if at least one of tho following conditions i3 satisfiod:
. The vehicleis not stoooed.
. The ABS controlunit receivesthe normalsignal(whichis for the ABS controlunit)from a HondapGM Tesrer.
. The SCSserviceconnectoris disconnectod
duringthis procedure.
NQTE:The illustrationof gaugeassemblyshowsthe '97 - 98 models.The '99 - oo modelsare similar.
SEFVICECHECK
CONNESTORI2P}

u.s.A.
GAUGEASSEMBLY

@
CANADA

A8S II{DEATOR

19-38

www.emanualpro.com

DTCErasure
NOTE:This operationcan also be done with the HondaPGMTester.
1.

Connectthe SCSserviceconnectorto the servicecheckconnector(2P)locatedon the passenger'sside of the center


console.

2.

Pressthe brakeoedal.

3.

Turnthe ignitionswitchON (ll)while keepingthe brakepedalpressed.The ABS indicatorgoes off aftertwo seconds.

4.

Afterthe indicatorgoes off, releasethe brakepedal.The indicatorcomeson afterfour seconds.

5.

After the indicatorcomeson, pressthe brakepedalagain.The indicatorgoes off againafterfour seconds (the brake
oedalis still Dressed.)

6.

Afterthe indicatorgoesoff, releasethe brakepedalagain.

7.

Afterfour seconds.the indicatorblinkstwice for 0.3secondand the DTCis erased.

8.

Confirmthe DTCindication,and checkthat the DTCwas erased.

NOTE:Always maintainthese steps.lf you disconnectthe SCSserviceconnectorand/orfail to operatethe brakepedal


accordingto the indicatorindication,the DTCwill not be erased.
Conditions for DTCerasure
. The vehicleis stopped.
. The SCSserviceconnectoris connectedbeforethe ignitionswitchis turnedON (ll)
. The brakepedalis pressedbeforethe ignitionswitchis turnedON (ll).
. The SCSserviceconnectorremainsconnectedduringthis procedure.
The DTCerasurestops and the ABS control unit executesthe software funqtion it at least one of the following conditions
b satisfied:
. The vehicleis not stopped.
. The SCSserviceconnectoris disconnected
duringthis service.
. TheABScontrolunit receivesthe normalsignal(whichis for the ABS controlunit)from a HondaPGMTester.
. The brakepedalis not operatedaccordingto the indicatorindication
. The DTCerasureis finished.

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

ABS indicatordoes not come on.

19,4'l

ON

ABS indicatordoes not go off. (No DTC)

19-43

oN*

Wheelsensor{open/shortto body ground/shortto


power)

'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).

checkthe METER{7.5A} fuse in


t h e u n d e r C a s hf u s e / r e l a yb o x ,
and reinstaltthefuse if it is OK.

Reolacethe tuse and recheck.

Checkfor an open in the lcl chcuil:


1. Disconnect
the gaugeassembly 5P connector.
2. Turnthe ignitionswitchON (ll).
3. Measurethe voltagebetween
the gauge assembly5P conn e c t o rt e r m i n a lN o . 5 a n d
body ground.

ls there battery voltage?

GAUGEASSEMBLY5P CONNECTOR

. Repairopen in the wire between


lhe METER{7.5 A) luse and tho
gaugeassembly.
. Reolecethe under-dashfuse/
relay box. (Oponcircuit inside
the box.)

Wire sideof femaleterminals

Checkthe ABS indicatorbulb in


the gaugeassembly.

Replacethe ABS indicator bulb.

Checkfor a short to power in the


WALPcircuit:
Measurethe voltagebetweenthe
g a u g e a s s e m b l y5 P c o n n e c t o r
terminalNo. 1 and bodyground.

ls there batteryvoltageT

Sepair short to power in the wite


btweenthe gaugassembly
and the ABS control unil.

(To page 19 42)

(cont'd)

www.emanualpro.com

19-41

Troubleshooting
ABS IndicatorDoesNot ComeOn (cont'd)
(Frompage19'41)

Checkthe gruge essembly:


1. Turnthe ignitionswitchOFF.
2. Connectthe gauge assembly
5Pconnector,
3. Connectthe terminalNo. 3 to
b o d y g r o u n dw i t h a j u m p e r

GAUG ASSEMBLY5P CONNECTOR

---g-

l1 t/l3_l/ |5|
JUMPER
I GNDIBLK}

wrBE

4. Turnthe ignitionswitchON (ll).

Doesthe ABSindicatorcomeon?

.Repair open in the wire


between the gauge assembly
and body ground.
. Repair poor ground {G401,
c102l-

19-42

www.emanualpro.com

L
Reolacethe ABS indicator drive
circuit in the gaug assmbly.

Wiresideof femaleterminals

ABS IndicatorDoesNot Go Off (No DTGI


-

With engine running, the ABS


indicsior is ON.
With the SCS serviceconnector conncted (s page 19381,
no DTCis indicated.

Checkthe ABS {7.5A) fuse in the


undeFdashfuse/relaybox, and
reinstallthe fuse if it is OK.

ReDlacelhe tuse and recheck.

Checkthe ABS +B (20 A) fuse in


t h e u n d e r h o o dA B S f u s e / r e l a y
box, and reinstallthe fuse if it is

oK.

Replacethe fuse and rocheck.


A8S CONTROLUNIT 26PCONNECTOR

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.

Wire sideof femaleterminals

Repairopen in tho wire between


the ABS {7.5A} fu3e .nd the ABS
control unit,
ABS CONTROLU N 26P CONf{ECTOR
Check for an open in the 81 and
82 circuit:
M e a s u r et h e v o l t a g e b e t w e e n
bodygroundandterminalsNo. 14
and No. 15individually.

is there battery voltage?

{WHT/GRNI

Ropairopen in tho wi.e between


rhe ABS +B {20 A) fuse and the
ABS control unit.
Wire side of female terminals

(Topage19 44)

www.emanualpro.com

(cont'd)

19-43

Troubleshooting
ABS IndicatorDoesNot Go Off (No DTC)(cont'dl
(Frompage19,43)

ABS CONTROLUNIT 22PCONNECTOR

Check tor a short to body ground


in the WALPcircuil:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe ABS control
unit 22Pand gaugeassembly
5P connectors.
3. Checklor continuity between
the ABS controlunit 22Pconn e c t o rt e r m i n a lN o . 7 a n d
body ground.

WALP{BLU/REDI

Wire side of female terminals

Repair short to body ground in


the wire between the ABS cont.ol unh and the gaugeassembly.

Checkthe ABS control unit:


1. Connectthe ABS control unit
22Pconnector.
2. Turnthe ignitionswitchON (ll).
3. Measurethe voltage between
the ABS controlunit 22Pconn e c t o rt e r m i n a lN o . 7 a n d
body ground.

ls there batteryvoltage?

Check tor an open in the GND2


circuit:
1. Connectthe ABS controlunit
26Pconnecto.terminalNo. 16
to body groundwith a jumper
2. Measurethe voltage between
the ABS controlunit 22Pconn e c t o rt e r m i n a lN o . 7 a n d
body ground.

ABS CONTROLUNIT 26PCONNECTOR

JUMPCR GND2IBLKI
WIRE
Wiresadeof femaleterminals

. Repeir op6n in th6 wire ttetween


the ABS control unit and body
ground.
. Rep.ir poor ground {G401,
G4021.

Check tor an open in the WALP


circuit:
Measurethe voltagebetweenthe
g a u g e a s s e m b l y5 P c o n n e c t o r
terminalNo. 1 and body ground.

Check lor loose ABS control unh


connectors. lf necesssry,substituie e lnown-good ABS control
unit and recheck.
GAUGEASSEMBLY5P CONNECTOF

WALPIBLU/FEDI

ls there batteryvoltage?

Replacothe ABS indicator drive


circuit in the gauge assembly.

19-44

www.emanualpro.com

Repairop6n in the wi.e botwen


the ABS control unit and th
gau9e assmbly.

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.
-

With ths ignition switch ON


llll, the ABS indicatol does
not go ott.
Atte. driving, the ABS indicalot comason.
With the SCS serviceconnector connocted (s page 19.381,
DTGr 11 - 18 sre indbated.

Checkthe whcol sensorcircuit:


1. Disconnectthe ABS control
unit 26Pconnector.
2, Nleasure the resistance
betweenthe appropriatewheel
sensorl0) and 1'l)circuitterminals{seetable).

ls the resistanceOK?
/Fronr:750 r,050o (20"C,68"F\
-'1,450O (20"C,68'F,
950
\Rear:

Chocklor a short 10 power in the


wheel sensoaciacuil:
1. Reconnectthe ABScontrolunit
26Pconnector.
2. Startthe engine.
3. Measurethe voltage betlveen
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(seetable).
ls there4 V or more?

ABS CONTNOLUNIT 26PCONNECTOR

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)

No.6: RLo N o . 1 9R: L 1

. 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

Wire sideof femaleterminals

NOTE:Judgementvalue for short

Ropair lhort to pow.r in the l0l


ot 11)circuit wiro between the
ABS control unit and the appropriate whool sen6or.

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

. Ropairshort to body g.ound in


th6 {01 or {1} circuit wire
botweon th6 ABS cont.ol unit
and tho appropriatowheol sonaot.
. Roplacetho appropriate wheel
sensot.

(cont'dl

(To page 19-46)


www.emanualpro.com

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 .

Rcplacs thc drive3haft or hub


unh. (Chippedpulsor goar.l

DTC 11, 13, 15. 17: Replacothe


ABS control unit.
OfC 12, 11, 16, 18: Th6 ABS control unit may have dstected dgn.l disturbsnc.

19-46

www.emanualpro.com

DTC31 - 38:Solenoid
-

With the ignition switch ON


{lD, tho ABS indicator does
not go off, or the ABS indic.lor comes on whil6 ABS is
tunctioning.
With th SCS service connoctor connoctcd {sce page 1$381,
DTCa31 - 38 ars indicatsd.

ABS CONTROLUNIT 22PCONNECTOR


FL.OUTIYEL/8LKI

DTC
31:FR'lN

32:FROUT
3 3 :F L l N

Checkfor a 3hori to power in th


solenoidci.cuit:
1 . D i s c o n n e ctth e A B S c o n t r o l
untrtlr ano zbr connectors_
2. Startthe engine.
3. Measurethe voltage between
the appropriateABS control
unit connectorsolenoidcircuit
terminal and body ground (see
table).

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

ABS CONTROLUNIT 26PCONNECTOR

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.

Chockfor a short to body ground


in the solnoid circuit:
Checkfor continuity betweenthe
appropriatesolenoidcircuit terminalandbodyground(seetable).

ls therecontinuity?

Wire sadeof femaleterminals


. Ropair short to body ground in
the appropriatosolenoid circuit
wire betwoon the ABS control
unit and the modulator unit.
. Replacethe modulator unit.

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

(To page l9-48)

www.emanualpro.com

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

Checktor loose ABS control unit


connectors. ll nece$ary, substitut a known-good ABS control
unit and recheck.
PCOM
{GRN/WHTI

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

Checkfor an open in the solenoid


circuit:
Measurethe voltage betweenthe
ABS controlunit con
appropriate
nector solenoidcircuit terminal
and bodyground{seetable).

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

. Repair open in the appropriate


COM circuit wire botween the
ABS control unit and th modulator unit.
. Repair open in the appropriate
solenoid circuit wire betwon
lhe ABS control unit and the
modulator unit.
. Replaceih modulator unit.

Wire sideof femaleterminals

ABS CONTROLUNIT 26PCONNECTOR


RI-.OUT{YEL)

Checkfor loos ABS control unil


connctors. lf nece$ary, substitute a known-good ABS control
unit and rechock.
Wire sideof femaletermanals

www.emanualpro.com

19-4 8

DTC51 - 53:ABS PumpMotor


-

Wilh the ignition switch ON


{ll), the ABS indicator does
not go ott.
With the SCS seruicoconnector connoctod {sce page 19381,
DTCa51 - 53 .re indicated.

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.

ABS CONTROLUNIT 22PCONNECTOR


Rsplacethe fuse and rech6ck.
N O T E : S h o r t t h e P M R t e r m i n a lt o b o d y
groundfor a moment,and rochockthe tuse.
lf the fuse is blown,checklor a shon to body
groundin the MCKcircuit.
check the PUMP MOTOR(40 A)
fuse in the under-hoodABS fuse/
relay box, and reinstallthe fuse if
it is oK.

Wire side of female terminals

Roolacelhe tusg and rocheck.


N O T E : S h o r t t h e P M R t e r m i n a lt o b o d y
groundfor a moment,and recheckthe fuse,
lf the tuse is blown, checktor a short to body
ground in the wire betweenthe underhood
ABSfuse/relay
box 6nd the pump motor.

Feplacethe pump motor r6ley.

Check the pump motor powel


sourccircuit:
Turn the ignitionswitchON (ll).

Doesthe pump motoroperate?

Ch6ckfo. a short to oowd in th6


pump motor power sourca circuit:
Removethe pump motor relay.

Doesthe pump motor operateT

Repairrhort to power in the wire


bclweon the under-hood ABS
fuse/.6lay box and ihe ABS
pump motor.

Ch6cktor loos6 ABS control unit


connectors. lf necotsary, 3ubstitute . known-good ABS control
unit and rocheck.

(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,

Doesthe pump motor operate?

Check for an open in the pump


motor +B circuit:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe pump motor
3. Turnthe ignitionswitchON (ll).
4. Connectthe pump motorrelay
connector+B and MOTORter
minalswith a iumperwire.
5. Measurethe voltage beaveen
the pump motor connector
terminal No. l and body
ground.

ls there battery voltage?

TERMINAL

PUMPMOTORCONNECTOB
MOTOR+B {WHTI
Fr
12 lF-

(v)
v

Doesthe pump motoroperate?

Ch6ckfor a short to body ground


in the PMRcircuit:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe ABS control
unit 22Pconnector.
3. Checktor continuity between
t e r m i n a lN o . 1 9 a n d b o d y
ground.

Repairopen in the wire bstween


the pump motor and body ground,
or poo. ground {G3511.

Repairshort to body ground in


the wir6 botweenthe underhood ABS tuse/rclay box and th
ABS contlol unit.

{Topage19-51)

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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

Reolacethe modulator unit.


lFaulty pump moto.l

ABS CONTROLUNIT 22PCONNECTOR

Wire sideof femaleterminals

(Frompage19-50)

Chcck for .n opsn in the PCOM


circuit:
1. Turnthe ignitionswitchOFF.
2 . R e c o n n e ct h e A B S c o n t r o l
unit 22Pconnector.
3. Connectthe SCS serviceconnector.
4. Turn the ignitionswitchON {ll).
5. Measurethe voltage between
t h e p u m p m o t o r r e l a yc o n n e c t o r P C O Mt e r m i n a l a n d
body ground.

ls thereapprox.3V?

tr

) l--l

r"r

Repairopon in the wire betwoen


the under-hoodABS fuse/relay
box and tho ABS conlrol unh.
ABS CONTROLUNIT 22PCO NECTOR

Checkfor an open in tho PMRcircuh:


Measurethe voltage betweenthe
ABS control unit 22P connector
terminalNo. 19and bodyground.

ls thereapprox.3 V?

Ropairopen in tho wir6 botwagn


tho undcr-hood ABS fuse/rolay
box .nd the ABS control unit.

Ch.ck tor an opon in the MCK


ci.cuit:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe SCS service
connector.
3. Turn the ignitionswitchON (ll).
4. Measurethe voltage between
the ABS controlunit 22Pcon
n e c t o rt e r m i n a l N o . 1 7 a n d
body ground while connecting the pump motor relay
connector+B and MOTORterminal with a jumper wire tor
moment,

ls there batteryvoltage?

Chockfor loose ABS control unit


connectoas,It necsssary,substitule a known-good ABS control
unit and aocheck.

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Wire sideof femaleterminals

MCK IBRN,/YEL}

Repairopen in the wiro bdtween


the under-hood ABS fus6/telay
box .nd the ABS control unit.

t0 1 1

Troubleshooting
DTG54:MainRelay
-

With the ignition switch ON


(lll, the ABS indicator does
not go off.
With the SCS serviceconnector connected {see page 19-381,
DTC54 is indicatod.

Checkthe ABS +B 120A) fuse in


the under-hoodABS luse/relay
box, and reinstallthe fuse if it is

oK.
FeDlacethe tu3e and recheck.
AAS CONTROLUNIT 26PCONNECTON

Chck tor an open in the 81, 82


circuit:
M e a s u r et h e v o l t a g e b e t w e e n
body groundand the ABS control
unit26Pconnector
terminalNo. 14
and No. 15individually.
ls there batteryvoltage?

IWHT/GRNI

Repairopen in the wiro bstweon


th6 ABS conirol unit and the
under-hoodABS fuse/rolay box,

Checkfor a short to body ground


in the PMRcircuit:
L Turnthe ignitionswitchOFF.
2. Removethe pump motor relay.
3 . D i s c o n n e ctth e A B S c o n t r o l
unit 22Pconnector.
4. Checklor continuitybetween
t e r m i n a lN o . 1 9 a n d b o d y
grouno.

ABS COf{TROLUN]T 22PCONNECTOR

Repair short to body ground in


the wire betweon the underhood ABS lGe/r.lay box and the
ABS control unit.
Checkfor a short to body ground
in the PCOM,SCOMcilcuit:
1 . D i s c o n n e ctth e A B S c o n t r o l
unit 26Pconnector.
2. Checktor continuitybetween
body ground and the ABS cont r o l u n i t 2 6 Pt e r m i n a l sN o - 1
and No.2 individually.
ls therecontinuity?

(To page19-53)

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Wire sideof femaleterminals

Wiresideof femaleterminals

PCOM
scoM
IGRN/WHTI {BLK/WHTI

. Rpair short to body ground in


th P1COM
circuit wire between
the ABS control unit and the
und6r-hoodABS tuse/r6lay
oox.
. R6p.ir short to body ground in
the PCOMor SCOMcircuit wire
betweon th6 ABS control unit
and lhe mod!lator unit.
. R . D l e c et h o m o d u l r t o r u n i t .
(Short circuit inside the unitl

ABS CONTROLUNIT 26PCONNECTOR


PCOM
(GRN/WHTI
Checkfo. a short to power in tha
PCOM,SCOMcircuhi
1. Startthe engine.
2. Measurethe voltage between
body ground and ABS control
unit 26P connectorterminals
No. I and No.2 individually.
ls there8 V or more?

Tu.n tho ignhion switch OFFand


connect thc SCS 3orviceconnector. Then turn thc ignition switch
ON (lll and measuretha voltago
botween the PCOM .nd SCOM
tsrminal3 and body gJound. It
ther6 is 0 V, .eplecotho ABS control unit.

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'Repair short to powor in ths


FCOM circuit wiro botwoon th
ABS control unit and the underhood ABS tuse/r.lay box.
. Repeir 3hort to power in tho
PCOM or SCOM circuit wire
betwegn tho ABS control unii
and ths modulator unh,
. R.placo tha modulatoi unit.
(Shon to power in.ido th6 unitl
NOTE:8 V or more indicatesa shortto

SCOM

Wiresideof temaleterminals

Troubleshooting
DTC61:lgnitionVoltage
-

Whh the .ngine running. the


ABS indicator b ON,
With the SCS servicc connae
tor connoctod {sao prgo 1998},
DTC61 b indi)atod.

Problom vorification:
1. Erasethe DTC.
2. Start the engine.

Doesthe ABS indicatorcome on


and is DTC61 indicated?

Tho ryrtom i. OK rt thb timo.

Ch.ck the lG2 circuit:


Measurethe voltage betweonthe
ABS control unit 26P connector
terminalNo.3 and body ground.
Wiresideof temaletermioals
ls there18V or above?

lf the volt gc b 0 V, ch6d( to. an


oDn in lhe lG2 circuh.
I thole ir 12 - 17 V, subatilui. !
known-good ABS control unit .nd
rd|eck.

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DTC81:CentralProcessingUnit (CPUI
-

with the ignition 3witch ON


{ll}. the ABS indicator does
not go off.
Whh the SCS sewice connector connectod {see page 1938),
DTC81 b indicatod.

Problemvorific.tion:
L Eraserne u t L.
2. Test-drive
the vehicle.

Doesthe ABS indicatorcome on


and is DTC81 indicated?

Rplaceth. ABS control unit.

The system is OK at this time.

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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.

the modulatorunit and Dumpmotor connectors.


Disconnect

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.

Connectthe modulatorunit and oumo motor connectors.

3.

Bleedthe brakesystem,staningwith the front wheels.

4.

Startthe engine,and checkthat the ABS indicatorgoesoff.

5.

Test-drivethe vehicle,and checkthat the ABS indicatordoes not come on,


'97 - 98 models.The'99 - 00 modelsare similar.
NOTE:This illustrationshowsthe

PUMPMOTOR
CONNECTOR

MODULATONUNIT

\ * \

,@
TORXEOLT
9.8N,m(1.0kgf.m.7.2lbf
ftl

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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

Measurethe air gap betweenthe wheel sensorand


pulserall the way aroundwhile rotatingthe pulser.
lf the gap exceeds1.0mm (0.04in),checkfor a bent
susDension
arm.
Standard:o.il - 1.0 mm 10.02- 0.04 inl
Front/Rear
Removethe rear brakedrum to insDectthe rear wheol
sensorair gap,

0.4- 1.0mm
(0.02- 0.04 inl

CONNECTORS

Removethe ABS controlunit.


Installthe ABS control unit in the reverseorder of
removat.

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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

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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
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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

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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

(Left side only,


'97 - 98 models)

('99- 00 models)

20-4

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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)

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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

Front Door PanelRemovaland Installation


NOTE:Takecarenot to scratchthe door paneland other
pans.
L

Removethe innerhandle(seepage20-3).

2.

Removethe speakercover,then removethe screws.

>: Screw location3,3

eF**I

>:Clip locttions
g>,3
A>, 1

f- fwi l.$ ; ^ r * l
ttv
il
F:I

3
>: Scrwlocations,

FRONTOOORPANEL

SPEAKER
COVER

Removethe screwsfrom the armrest.Releasethe


clipsthat hold the door panel,then removethe door
panel by pulling it upward.Disconnectthe speaker
connector.
NOTE:Removethe door panel with as little bending as possibleto avoidcreasingor breakingit.

lnstallationis the reverseof the removalprocedure.

TRIM PAD
REMOVER
(Commercially
avaalable)
Snap-on
*4177,ol
equivalent
{0.04in.) r

'..4'

,mm+,----ZY"
-i
F
45 mm

NOTE:Makesurethe connectoris pluggedin propefly.

{1.77in.}

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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.

Disconnectthe cylinder rod. Removethe retainer


clip,then removethe lockcylinder.

LOCK
CYLINDER

5.

Pull out the outer handle,Pry the outer handlerod


out of its joint usingdiagonalcutters.

RETAINEB
CLIP

Removethe bolts securingthe o u t e r h a n d l e , t h e n


remove the cylinder protector.

>: Eolt locations,2


6 x ' 1 . 0m m
I N.m {0.9kgt.m,
7 rbf.ftl

OUTEB
HANDLE

5.

Installationis the reverseof the removalprocedure.


NOTE:
. Makesureeachrod is connectedsecurely.
. Makesurethe door locksand opensproperly.

HANDLE

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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.

Disconnectthe connector,and detachthe harness


clip from the door. Removethe screws,and remove
t h e l a t c ht h r o u g ht h e h o l ei n t h e d o o r .
NOTE:Takecarenot to bendany of the rods.
>: Screw locations,3

6x1.0mm
6 N.m 10.6kgt m,
4 tbf.ft)

Removethe bolt,then move the rear lower channel


forward.

CYLINDER
ROD

>: Bolt location, 1

6xl.0mm
8 N.m (0.8kgf m,
6 tbf ft)

OUTER
HANDLE
ROD
LOCKROD
PROTECTOR

CONNECTOR

HARNESS
CLIP

Installationis the reverseof the removalprocedure.


NOTE:
. Make sure the connectoris pluggedin properly,
and eachrod is connectedsecurely.
a Makesurethe door locksand opensproperly.

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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.

Disconnectthe connector,and detachthe harness


clip,then removethe regulatorthrough the hole in
the door.
NOTE:
. Scribea line aroundthe rear roller guide bolt to
show the originaladjustment.
. When installingthe regulator,align the hole of
the rollerguidetowardth rear.

>: Bolt locations,6


6x1.0mm
8 N.m {0.8kgt.m,
6 rbtft)

>: Bolt locations,2


6xl.0mm
9.8Nm(1.0kgt.m.
7.2 tbt.ftl

Roaru/ard

GLASS

Loosen,
REGULATOR

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20-10

RearDoor PanelRemovaland
lnstallation
4.

Greaseall the slidingsurfacesof the regulatorwhere


shown.
NOTE:lf it is necessaryto removethe power wrndow motor from the regulator,scribea line across
the sectorgear and regulatorbeforeyou removethe
power window motor.

NOTE:Takecarenot to scratchthe door paneland other


parts.
1.
2.

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-----

>: Boh locations,3


6x1.0mm
7 N.m lo.t kgf.m,
5 tbf.ftl

/t5 mm I
11.77in.)

>i Clip locations,6

>: Screw locelions


'97 - 98 models.3
'99 - 00 modols,4

POWERWINOOWMOTOR
REGULATOR

DOOBPANEL
ARMREST

EEVERAGE
HOLDEN
('99 00modelsi

^mi
A

A
'99 - 00 models:

Installationis the reverseof the removalprocedure.


NOTEi Rollthe glassup and down to see if it moves
freelywithout binding.Also make sure that there is
no clearancebetlveenthe glassand glassrun chan
nel when the glassis closed.Adjust the positionof
(seepage20-20).
the glassas necessary

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\
(,1

3.

Installationis the reverseof the removalprocedure.

20-11

Doors
RearDoorOuter HandleReplacement
CAUTION: Put on gloves to protect your hands.

4,

NOTE:Raisethe glassfully.
1.

2.

Pull out the outer handle.Pry the outer handlerod


out of its joint usingdiagonalcutters.
NOTE;
o To easereassembly,
note location@ of the outer
handlerod on the joint beforedisconnecting
it.
. Takecarenot to bendthe outer handlerod.
. Use a shop towel to protectthe opening in the
door.

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

>: Bolt locations.


2
6x1.0mm
9.8 N.m {1.0 kgf.m,
7.2 rbf.ft)

5.

Installationis the reverseofthe removalprocedure.


NOTE:
a Makesurethe door locksand opensproperly.
. M a k e s u r e t h e o u t e . h a n d l er o d i s c o n n e c t e d
properly.

20-12

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Rear Door Latch Replacement

RearDoorGlass,OuarterGlassand
RegulatorReplacement

CAUTION: Put on gloves to protect your hands,


CAUTION: Put on gloves to protect your hands.
NOTE:Raisethe glassfully.
1.

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.

Carefullymove the glassuntil you can seethe bolts,


then loosenthem. Slide the guide to the rear,then
removethe glassfrom the guide.
NOTE:Takecarenotto dropthe glassinsidethe door.

NOTE: Takecare not to bend any of the rods.


>: Boll locations,2

6x1.0mm
9.8N.m (1.0kgtm,
7.2 tb{ft)

GLASS

3.

Installation is the reverse of the removal procedure.

NOTE:
. Makesuretheouterhandlerod andinnerhandle
properly.
rodareconnected
. Makesurethedoorlocksandopensproperly.

(cont'd)

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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.

NOTE:Takecare not to drop the glassinsidethe door.


>: Bolt,screwlocations
A>, t
B>,1
-4
rTmtl-larR

WPU

f\
'^S\\\-.-

W)+

-6 x 1.0 mm

I N m i o . 8 k sm
f,
6 tbf.ftt

c>,1

CLIP

Disconnectthe connector.and detachthe harness


clip, then removethe regulatorthrough the hole in
the door.
>: Bolt localions,4
6x1.0mm
8 N.m 10,8kgf.m,
6 tbtftl

REGULATOR

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20-14

''

TailgateDoor PanelRemovaland
lnstallation
6.

Greaseall the slidingsurfacesof the regulatorwhere


shown.
NOTE:lf it is necessaryto removethe power window motor from the regulator,scribea line across
the sectorgear and regulatorbeforeyou removethe
powerwindow motor.

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.

R e m o v et h e c o v e r ,and remove the flexible cargo


hook and base.
>: Screwlocations.2

REGULATOR
SECTORGEAB

FLEXIBLECARGO
HOOKBASE

@t"
COVER

POWER

wtNDow
MOTOR

>: Bolt locations.3


6x1.0mm
7 N.m 10.7kgf.m,
5 rbnftl

FLEXIBLE
CARGOHOOK

POWERWINDOWMOTOR

2.

Removethe tailgatedoor lid,then removethe screws.


>: CliP locations.

>: Screwlocations.2

?11 |

HPI

,4|

REGULATOR

7.

lnstallationis the reverseof the removalprocedure.


NOTErRollthe glassup and down to seeif it moves
freelywithout binding.Also make sure that there is
no clearancebetweenthe glassand glassrun channel when the glassis closed.Adjustthe positionof
the glassas necessary
{seepage20 20).

TAILGATE
DOORLIO
3.

Releasethe clips that hold the tailgatedoor panel,


then removethe tailgatedoor panel.
Installationis the reverseof the removalprocedure.
replaceany damagedclips.
NOTE:lf necessary,

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20-15

Doors
LicensePlateTrim Removaland
Installation

TailgateDoorHandleReplacement
CAUTION; Put on gloves to protecl your hands,

CAUTION: Put on gloves to prolest your hands.


NOTE:Takecarenot to scratchthe tailgatedoor.
NOTE: Take care not to scratchthe licenseplate trim
and tailgatedoor.

1.

Remove:
. Tailgatedoor panel(seepage20,15)
. Licenseplate
. Licenseplatetrim

2.

'1. Remove
the licenseolate.
2.

Removethe tailgatedoor panel(seepage20-15).

3.

Removethe nuts, detachthe clip, then removethe


licenseolatetrim.

Disconnectthe handlerod. Removethe nuts securing the tailgatedoor handle,then removethe tailgatedoor handleby pullingit out.

NOTE: Take care not to drop the nuts inside the


tailgatedoor.

NOTE:Takecarenot to bendthe handlerod.


a: Nut locations,2

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.

Installationis the reverseof the removalprocedure.


NOTE:lf the clip is damaged,replaceit.

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20-16

TailgateDoor Latchand LatchStop Replacement


CAUTION: Put on gloves to protect your hands.
NOTE:Takecarenotto scratchthe tailgatedoor.
'1.

Removethe tailgatedoor panel(seepage20-15).

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)

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20-17

Doors
TailgateDoor Latchand LatchStop
Replacement(cont'd)
4.

lnstallationis the reverseof the removalorocedure.


NOTE:
. Makesure the handlerod and latchstop rod are
connectedproperly.
a Make sure the tailgatedoor locks and opens propenv.
. After installingthe latch stop and tailgate door
latch,makesure that there is about 1 mm {0.039
in.l betweenthe linkA and link B of the latchstop.
Adjust the joint position of the latch stop rod as
needed,then checkthe latchstop operation.(Pull
the tailgatedoor handlewhile you push on the
l a t c h s t o p k n o b ; t h e t a i l g a t ed o o r s h o u l d n o t
oDen.)

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.

Disconnectthe connector.Removethe bolts securing the latch,then removethe latch.


>: Boh locations,3
6x1.0mm
9.8N.m {1.0kgI.m,
7.2 tbl.Itl
REARHATCH
GLASSLATCH

LATCHSTOP
KNOE

3.

Installationis the reverseof the removalprocedure.


N O T E : M a k e s u r e t h e r e a r h a t c h g l a s s l o c k sa n d
opensproperly.

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20-18

RearHatchGlassLockCylinder
Replacement

RearHatchGlassActuator
Replacement

NOTE:Takecarenot to scratchthe tailgatedoor.

CAUTION: Put on gloves to protsct your hands.

1.

Removethe tailgatedoor panel(seepage20-15).

NOTE:Takecarenot to scratchthe tailgatedoor.

2.

Removethe bolt securingthe lock cylinder. Turn


and pull out the lock cylinder,and disconnectthe
cylinderrod,

1.

Remove;
o Tailgatedoor panel(seepage20-'15)
. Rearhatchglasslockcylinder

NOTE:Takecarenot to bendthe cylinderrod.

2.

Disconnectthe connectorand the connectorclip.


R e m o v et h e b o l t s s e c u r i n gt h e a c t u a t o r ,t h e n
removethe actuator.

>: Boltlocation.1
6x1.0mm
9.8N.m {1.0kg .m,
7.2 tbt.lll

NOTE: Take care not to bend the cylinder rod or


damagethe joint.
>: Boltlocations,
3
6x1.0mm
9.8N.m 11.0kgt.m,
7.2 tbt.ft)

REARHATCHGLASS

CONNECTOR
CONNECTOR

J.

Installationis the reverseof the removalprocedure.


NOTE:
. Makesurethe cylinderrod is connectedproperly.
. Makesurethe rearhatchglassopensproperly.

REARHATCH
GLASS
ACTUATOR

JOINT

-6{

Installationis the reverseof the removalprocedure.


NOTE:
. M a k e s u r e t h e c y l i n d e rr o d a n d c o n n e c t o ra r e
connectedproperly.
. Greasethe joint of the cylinderrod.
. Makesurethe rearhatchglassopensproperly.

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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,

a Makesurethereare no wrinklesin the weatherstrip.


a Checkfor water leaks.

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.

> : Clip locations,2

i-t]
/[L

|
I oouere-rrceo

ll 1T

I Thickness:

lE
lll

rAPE
I aDHEsrvE
I

Front:

r.2mmlo.o5
in.)

Raisethe glassas far up as possible.and hold


it againstthe glassrun channel.

lM
/L)

Loosenthe roller guide bolts, and adjust the


glassso it is parallelwith the glassrun channel.

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.

Pushthe front channelagainstthe glass,then


tightenthe tront channelbolt.

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.

Checkthat the glassmovessmoothly.

4.

Raisethe glassfully and checkfor gaps.

5.

Checkthe glassoperation.
NOTE:Checkthat the glass contactsthe glass run
channelevenly.

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20-21

Doors
Frontand RearDoorGlass
Adiustment(cont'dl
6.

NOTE: Placethe vehicleon a firm, level surfacewhen


adiustingthe doors.

Checkfor water leaks.


Spray water over the roof and on the sealingarea
as snown.
NOTE:
. Adjustthe water pressureas shown.
. Do not soueezethe tio of the hose.

,'r)"f

(r\
"1

tl

After instailingthe door, checkfor a flush fit with the


body,then checklor equal gaps betweenthe front, rear.
a n d b o t t o m d o o r e d g e sa n d t h e b o d y . T h e d o o r a n d
body edgesshouldalso be parallel.Adjustat the hinges
as shown.
CAUTION:Placaa shop towel on the iack to prevent
damageto the door when loosening the door and hinge
mounting bolts lor adiustment.

-"'*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.

Attachthe plasticcover,then installthe door panel


(seepages20-7,'l 1),

20-22

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..-

TailgateDoor PositionAdjustment
The door and body edges should be parallel.lf necessary,adjustthe door cushion.

NOTE: Placethe vehicleon a firm, level surfacewhen


adjustingthe tailgatedoor.
A f t e r i n s t a l l i n gt h e t a i l g a t ed o o r . c h e c kf o r a f l u s h f i t
with the body, then checkfor equal gaps betweenthe
tailgatedoor edgesand the body.The tailgatedoor and
body edgesshouldalso be parallel.Adjust at the hinges
assnown.
CAUTION:Placea shop towel on the iack lo prevent
damage to the tailgale door when loosningthe tailgate door and hinge mounting bolts for adiustment.

ry.

oooRcusHroNs

DOOR
CUSHION
Checkfor water leaks.

NOTE:Do not squeezethe tip ofthe hose.

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)

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20-23

Doors
TailgateDoor PositionAdiustment

Frontand RearDoorStriker
Adjustment

The door and body edgesshouldbe parallel.

Make sure the door latchessecurelywithout slamming


it, lf necessary,adjust the striker:The striker nuts are
fixed. The strikercan be adjustedslightly up or down,
a n di n o r o u t .

(cont'd)

1.

Loosenthe screws,then insert a shop towel between


the body and striker.

STRIKER
Inserta shoptowel
betweenthe body and

Checkfor water leaks.


Spray water over the tailgatedoor and on the sealing
areaas shown.
NOTE:
. Adjustthe water pressureas shown.
. Do not squeezethe tip ofthe hose.

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.

Loosenthe screws.and removethe shop towel.

5.

Lightlytightenthe screws.

6.

Holdthe outer handleout, and pushthe door against


the body to be sure the strikerallows a flush fit, lf the
door latchesproperly.tightenthe screwsand recheck.

TailgateDoorStrikerAdjustment

TailgateDoorWedgeAdjustment

Make sure the door latchessecurely without slamming


it. lf necessary,adjust the striker:The striker nuts are
fixed. The strikercan be adjustedslightly up or down,
a n di n o r o u t .

1.

1.

Removethe tailgatedoor wedge.

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.

Loosenthe bolts,and move the tailgatedoor wedge


UP or DOWNto align it with the tailgatedoor wedge
striker.Move the tailgatedoor wedge lN or OUT to
centerit. Then lightlytightenthe bolts.

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.

Wrap the strikerwith a shop towel, then adjustthe


strikerby tappingit with a plastichammer.
CAUTION: Do not tap the striker too hard.
Loosenlhe screws,and removethe shoptowel.
Lightlytightenthe screws.

1.

Hold the tailgatedoor outer handle out, and push


t h e t a i l g a t ed o o r a g a i n s t h e b o d y t o b e s u r e t h e
strikerallows a flush fit. lf the tailgatedoor latches
properly,tightenthe screwsand recheck.
Installthe tailgatedoor wedge,and adjustit.

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

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20-26

PowerMirror Replacement

PowerMirror HolderReplacement

NOTE:Takocarenot to scratchthe mirror,mirror mount


cover and door.

CAUTION: Put on glovss to protest you. hands.


NOTE:Takecarenot to scratchthe mirror.

1.

Lowerthe door glassfully.

2.

Carefullypry out the mirror mount coverby hand,

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

Disconnectthe connector.then remove the mirror


mountingboltswhile supponingthe mirror,
>: Bohlocations,
3

MIRROR

Separatethe mirror holder from the actuator bv


slowly pullingthem apart.
Reattachthe hooks of the mirror holder to the actuator, then Dositionthe mirror holder on the actuator. Carefullypush the clip portions of the mirror
holderuntilthe mirror holderlocksinto place.
Checkthe actuatorooeration.

Installationis the reverseof the removalprocedure,


NOTE:Make sure the connectoris connectedpropefly.

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.

Removethe cover usingthe end of a flat-tipscrewdrtver.

HOOKS

Removethe rubberdamper.
>: Screwlocations,3

Remove the screws, then remove the rearview mirror.


Installationis the reverseof the removalprocedure.

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 )

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Glass
WindshieldReplacement
CAUTION:
. Put on gloves to protect your hands.
. Use seat coversto avoid damaging any surfaces.
1.

2.

4.

To removethe windshield,first removethe:


. Rearviewmirror (seepage20-28)
. Sunvisorsand holders(seepage20-44l'
. Ceilinglight (seesection23)
. Grabhandle(seepage20-44)
. Frontdoor trim (seepage20-41)
. F r o n tp i l l a rt r i m ( s e ep a g e2 0 - 4 1 )
. Windshieldwiper arms and cowl cover (seepage
20-98)

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

Removethe moldingand glassbrackets.


ADHESIVE

NOTE:lf removingthe molding is difficult,cut the


moldlngwith a utility knife.

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.

Using a knife,scrapethe old adhesivesmooth to a


thicknessof about 2 mm (0.08in.) on the bonding
surfacearoundthe entirewindshieldopeningflange.
NOTE:
a Do not scrapedown to the paintedsurfaceof the
body; damaged paint will interferewith proper
bonding.
. Removethe rubberdams and fastenersfrom the
oooy,
. Maskoff surroundingsurfacesbeforepainting.

8.

Cleanthe body bondingsurfacewith a spongedampenedin alcohol.

10. Glue the rubber dams and fastenersto the inside


faceof the windshieldas shown
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
where adhesivewill be applied,
>r Fastenerlocrtions. 2
FASTENEB

\,@,--

w,{,.
'>Yl
14mm
0.55in.l

-'-

\l
ALIGNMENT
MARKS
1 3m m
(0.51in.)

NOTE: After cleaning,keep oil, grease and water


from gettingon the surface.
9.

--r-r

lf the old windshieldis to be reinstalled,


use a putty
knjfeto scrapeoff all tracesof old adhesiveand the
r u b b e r d a m s , t h e n c l e a nt h e w i n d s h i e l ds u r f a c e
with alcoholwhere new adhesiveis to be applied.

ALIGNMENT
MARKS

NOTE:Make sure the bonding surfaceis kept free


of water,oil and grease.
1 3m m
(0.51in.l

CAUTION:Avoid setting tho windshieldon its edges;


small chips m8y later devolopinto cracks.

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.

>: Alignment mark locations


ALIGNMENT
Applyprimer
MARK
here.
\
ln3ide , /

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

'13. Installthe glass bracketsand fastenersto the body


as shown.

16. With a sponge, apply a light coat of glass primer


around the edge of the windshieldas shown, then
lightlywipe it off with gauzeor cheesecloth.

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

14. Set the windshieldon the glassbrackets.then cen


ter it in the opening.Make alignmentmarks across
the windshieldand body with a greasepencilat the
four pointsshown.

: Applyglassptimar hea.

Applyglassprimer
WINDSHIELD

NOTE|Be carefulnot to touch the windshieldwhere


adhesivewill be applied.
ALIGNMENT
MABK

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

15. Removethe windshield.

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.

20, Packadhesiveinto the cartridgewithout air pockets


to ensurecontinuousdelivery.Putthe cartridgein a
c a u l k i n gg u n , a n d r u n a b e a do f a d h e s i v ea r o u n d
the edgeof the windshieldas shown.

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.

NOTE:Apply the adhesivewithin 30 minutesafter


applyingthe glassprimer.

///////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

't8, Thoroughlymix the

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

cartridge,cut the end of the nozzle

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.

22. Scrapeor wipe the excessadhesiveoff with a putty


knifeor towel.
NOTE:To removeadhesivefrom a paintedsurface
o r t h e w i n d s h i e l d ,w i p e w i t h a s o f t s h o p t o w e l
dampenedwith alcohol.

From insidethe vehicle,use a knife to cut through


the quarterglassadhesiveall the way around.
NOTE:
. lf the quaner glassis to be reinstalled,
take care
not to damagethe molding.
. lf the molding is damaged.replacethe quarter
glass,molding,and clipsas an assembly.
. The quarter glasscan be reinstalledusing butyl
tape.

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
.
.

Keep the windshielddry for the first hour after


installation.
Checkthat the ends of the side molding are set
underthe cowl cover.

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:

Using a knife,scrapethe old adhesivesmooth to a


thicknessof about 2 mm (0.08in.) on the bonding
s u r f a c ea r o u n dt h e e n t i r e q u a r t e rg l a s s o p e n i n g
flange.
NOTE:
. Do not scrapedown to the paintedsurfaceof the
body; damaged paint will interferewith proper
b o n di n g .
. lf any of the clips are broken.removelhem trom
the body.
. Mask off surroundingsurfacesbefore applying
pnmer.

v\//,

/6\ /l

Cleanthe body bondingsurfacewith a spongedampenedin alcohol.


NOTE:After cleaning,keep oil, grease and water
from gettingon the surface.
l f t h e o l d q u a r t e rg l a s si s t o b e r e i n s t a l l e du, s e a
putty knife to scrapeoff all tracesof old adhesive,
t h e n c l e a nt h e q u a r t e rg l a s ss u r f a c ew i t h a l c o h o l
where adhesiveis to be applied.
NOTE:Make sure the bonding surfaceis kept free
of water,oil and grease.
CAUTION: Avoid setting the quarter glass on its
edges;the molding can be permanently detormed.
NOTE:Cleanthe shadowedarea.

ADHESIVE

3.

Carefullyremovethe quarterglass.
NOTEj Checkthe molding for damage,replacethe
qua.terglassif necessary.

20-36

www.emanualpro.com

7.

Gluethe fastenerto the insideface of quarterglass


as shown.lf the old quarterglassis to be reinstalled,
applya lightcoatof primer(3M C-100,or equivalent),
then applybutyltapeto the quanerglassas shown.

9. lf the old quarterglassis to be reinstalled,


sealthe
body holewith pieceof urethanetape,Set the quar
ter glassuprightin the openingand makealignment
m a r k s a c r o s st h e q u a r t e rg l a s s a n d b o d y w i t h a
greasepencilat the threepointsshown.

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.

lnstallthe fastenerto the bodv as shown.


>: Fastenerlocation, 1

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

With a sponge,apply a light coat of body primerto


the originaladhesiveremainingaroundthe quaner
glassopeningflange.Let the body primer dry for at
least10 minutes.
NOTE:
. Do not apply glass primer to the body, and be
c a r e f u ln o t t o m i x u p g l a s s a n d b o d y p r i m e r
sponges.
. Nevertouchthe primedsurfaceswith your hands.
'/fu,

: Applybody primerhere.

' aeerysra$primerhere.
1 0m m
{0.39in.)

BUTYLTAPE

'13.

Thoroughlymix the adhesiveand hardenertogether


on a glassor metalplatewith a putty knife.
NOTE:
. Cleanthe platewith a spongeand alcoholbefore
mi x i n g .
. Followthe instructionsthat came with the adheslve.

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

15. Packadhesiveinto the cartridgewithout air pockets


to ensurecontinuousdelivery,Putthe canridgein a
c a u l k i n gg u n , a n d r u n a b e a do f a d h e s i v ea r o u n d
the edgeof the quarterglassas shown.
NOTE:
. lf the old quarterglass is to be reinstalled,peel
the separatoroff the butyltape afterapplyingthe
adhesive.
. Apply the adhesivewithin 30 minutesafterapplying the glassprimer.

16. Use suctioncups to hold the quarterglassover the


opening,alignthe clipsor the alignmentmarksmade
in step 9, and set it down on the adhesive.Lightly
push on the quaner glass until its edges are fully
seatedon the adhesiveall the way around.
N O T E :D o n o t o p e n o r c l o s et h e d o o r s u n t i l t h e
adhesiveis drv.
AUGNMENT

i:.8T".,1,/:AoHEsrvE
I rnm
(0.31in.)

BUTYL
TAPE

SUCTIONCUPS

1 1 . Scrapeor wipe the excessadhesiveoff with a putty


knifeor towel,
NOTE:To removeadhesivefrom a paintedsurface
or the quarter glass,wipe with a soft shop towel
dampenedwith alcohol.
1 8 . 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
spray water over the quarter glass and check for
leaks.Mark the leakingareas,let the quarterglass
dry, then sealwith sealant.
NOTE:Let the vehiclestand for at leastfour hours
after quarterglass installation.lf the vehiclehas to
be usedwithin the first four hours,it must be driven
slowly.
GLASS

1 9 . Reinstallall remainingremovedparts.
NOTE:Advisethe customernot to do the following
thingsfor two to threedays:
.
.

www.emanualpro.com

Slamthe doorswith all the windows rolledup.


Twist the body excessively(suchas when going
i n a n d o u t o f d r i v e w a y sa t a n a n g l eo r d r i v i n g
over rough,unevenroads).

20-39

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

o: Nut locations,2 >: Clip locations

>: Bolt, screw locations


a>,3
B>,4
/\

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.

>r Screw locations,6

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)

R e m o v et h e g r a b h a n d l e sf r o m the front and rear


passenger's
sides.

ry_l

COVER

4.

Removethe clips,then removethe headliner.


NOTE:An assistantis helpful when removing the
headliner.
>: Clip locations,9

Removethe sunvisorand holderfrom eachside.


HEADLINER
>: Scaew location3, 4

A\"rYr*

I
|
||

Pullout. OUARTER
TRIM
PANEL

suNvtsoR
5.

Removethe headlinerthrough the rear hatch glass


openrng.

6.

Installationis the reverseof the removalprocedure.


NOTE:
. W h e n r e i n s t a l l i ntgh e h e a d l i n etrh r o u g ht h e r e a r
h a t c h g l a s so p e n i n g ,b e c a r e f u ln o t t o f o l d o r
bend it, Also, be carefulnot to scratchthe body.
. C h e c kt h a t b o t h s i d e s o f t h e h e a d l i n e ra r e
securelyattachedto the trim.

20-44

www.emanualpro.com

Carpet Replacement
are locatedin this area.Reviewthe SRS
SRScomDonents
and proceduresin the
componentlocations,precautions,
SRSsection{24)beforeperformingrepairsor service.

4.

Removethe centertable and tableframe bracket.


>: Bolt locations,4

CAUTION: Put on glovesto protect your hands.


' 1 . Remove:
. Frontseat(seepage20-571
. Rearseat(seepage20 63)
. Kickpanel(seepage20-41)
. C e n t ep
r i l l a rl o w e rt r i m p a n e l( s e ep a g e2 0 4 1 )
. Frontsidetrim {seepage20-41)
. Lowerconsolecover1A,/T
model,see page20-49)
. Centerconsole(lM/Tmodel,see page2o-47)

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

>: Clip locations,4

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.

Removethe clips, and releasethe fasteners.then


removethe carpet.

>: Cliplocations,2

-ffi]

NOTE:Takecarenot to damage,wrinkleor twist the


carpet.

lN'

>: Cliplocations.3

FASTENER

COVER

6.

lnstallationis the reverseof the removalprocedure.

Removethe SRSunit covers.


>: Clip locations,2

.dL I
tEu( |
- qf

SNSUNIT

FASTENER
('98- 00 models)

cARPET

COVER

7.

'97 model: Cut areas and


@
@ in the carpet,then
pullthe carpetback.
'98 - 00 models:Releasethe fastenerand cut area
@ in the carpet,then pull the carpetback.

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,

Removethe shift lever knob.screwsand clips.then


removethe centerconsole.
>: Screw location3,4

>: Clip locations.2

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>
| #\

1. Tilt the steeringcolumndown.


2.

Removethe screws,and detachthe clips,then carefullv removethe instrumentoanel.


>: Screw locations,2

arl
l

>: Clip locations,2

r#sr\

= -, l

|
]

Remove the screws, then removethe centerupper


pocket.
>: Screw locations,4
PANEL

3.

3.

Installationis the reverseof the removalprocedure.

Installationis the reverseof the removalprocedure.


NOTE:lf necessary,
replaceany damagedclips.

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.

Removethe bolts.then removethe kneebolster.


>: Boh locations,3

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

NOTE:Takecare not to scratchthe dashboardand related


pans.
1.

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.

Installationis the reverseof the removalprocedure.


NOTE:Make surethe connectoris connectedproperly.

20-48

www.emanualpro.com

Glove Box Removaland

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.

CAUTION: When prying with a tlat-tip screwdriver,


wrap it with protestive tape, and apply protective tape
around the related parts to prevent damage.

NOTE: Takecare not to scratchthe dashboardand related


oarts.

NOTE:Takecare not to scratchthe dashboardand related


oans.

1.

Removethe glove box stopsfrom eachside.

A/T model:

1.

Remove the lower console cover.


>: Scrgw locations,6

GLOVEBOX
STOPS

6F@''
Il
-

>: Clip locations


A>,2
B>,2

elsl

GLOVEBOX

Removethe bolts,then removethe glove box.


>i Boltlocations,2
COVER

Removethe screws,then carefullyinsert a flat-tip


screwdriverand push down on the top of the hook.
Removethe centerpocketwith the beverageholder,
Separatethe center pocket, beverageholder and
beverageholderbracket.

3.

Installationis the reverseof the removalprocedure.


4.

www.emanualpro.com

Installation
is the reverseof the removalorocedure.

20-49

Dashboard
CenterDashboardLowerGover
Removaland Installation

CenterPanelRemovaland
lnstallation

SRScomponentsare locatedin this area.Reviewthe SRS


and proceduresin the
componentlocations,precautions,
SRSsection{24)beforeperformingrepairsor service

SRScomponentsare locatedin this area.Reviewthe SRS


and proceduresin the
comDonentlocations,precautions,
(24)
performing
repairsor servace.
before
SRSsection

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.

Removethe bolts, and releasethe clips. then pull


the connectorsand
out the centerpanel.Disconnect
antennalead.then removethe centerpanel.
>: Bolt locations,2

>: Clip loc.tion6,3

(8NEDL
l

I5

\"P

I AccEssoRy
I socKET

CENTERPANEL

3.

3.

Installationis the reverseof the removalprocedureN 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

20-5 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.

Power Window Switch Removal


and Installation

CenterAir Vent Removaland

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.

NOTE:Takecare not to scratchthe dashboardand related


parts.

NOTE:Takecare not to scratchthe dashboardand related


pans.

Installation

'L

Removethe driver's dashboard lower cover (see


page20-48).

2.

Gentlypush out the powerwindow switchfrom the


dashboard lower cover opening by hand.
Disconnect
the connectors.

NOTE:Carefullvinsen a flat-tio screwdriverunder


the clips,then pull out the centerair vent while prying up the clips.

>: 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

Side DefoggerTrim Removal and


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.

NOTE:Takecare not to scratchthe dashboardand related


parts.

NOTE:Takecare not to scratchthe dashboardand related


oarts.

1.

Driver'sside:Removethe Dowerwindow switch.

1.

Driver'sside:Removethe sideair vent.

2.

Driver'sside:Closethe vent, and gentlypushout the


c l i p s f r o m t h e p o w e r w i n d o w s w i t c h o p e n i n gb y
the
hand,then pull out the side air vent. Disconnect
connector.
Passenger'sside:Carefullyinsert a flat-tip screwdriver
underthe clips.then pull out the side air vent while
pryingup the clips.

2.

Driver'sside:Gentlypush out the clipsfrom side air


vent openingby hand,then pull out the side defogger trim. Disconnect
the connector.
Passenger'sside: Carefullyinsert a flat-tip screwdriver underthe clips,then pull out the side defogger trim while prying up the clips.
>: Clip locations,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

Installationis the reverseof the removalprocedure.

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.

Removethe dashboardside cover. Disconnect


the
dashboardwire harnessconnectors,
removethe nuts,
then move the under-dashfuse/relaybox. Disconnect
t h e a n t e n n al e a d , a n d d e t a c ht h e h a r n e s sc l i p s .
Removethe connectorholder from the dashboard
frame. Unbolt the control unit/relay bracketfrom
behindthe middleof the dashboard.
>: Clip locations.

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

Disconnectthe negativebatterycable.and wait at


leastthree minutesbeforebeginningwork.

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

NOTE:To preventdamageto the steeringcolumn,


wrap it with a shop towel.

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

Removethe bolts.then lift and removethe dashboard.


CAUTION: Use protective iape on the botlom of ths tront pillar trim.
lnstallationis the reverseof the removalprocedure.
NOTE:
. Makesurethe dashboardfits onto the guide pinscorrectly.
. Beforetighteningthe bolts,makesurethe dashboardwire harnessesare not pinched.
. Makesurethe connectorsand antennalead are connectedproperly.

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

>: Clip localions.2

.dr
-wr I

Ihll'rifi-

FRONTPASSENGER'S

Installationis the reverseoI the removalorocedure.


NOTE:
. Makesurethe dashboardwire harnessesare not Dinched.
. Makesurethe connectorsand antennaleadare connectedproperly.

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

Front Seat Removaland Installation


CAUTION: When prying whh a tlat-tip screwdrivor,wrap
it with proteqtivetape to prevent damage.
NOTE:Takecare not to scratchthe bodv or tear the seat
covers.
1.

2.

Lift up the driver's front seat,then disconnectthe


seatbeltswitchconnectorand harnessclips.
>: Hrrnosscliploc.lions

Removethe seat track end cover, and removethe


bolts.
>: Bolt loc.tions
A>.3
I x 1.25mm
22 N.m
i'2.2 kgl.m,
16 rbf.ftl

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)

in the reverseorderof disassembly.


Reassembly
NOTE:Greasethe moving portions.

www.emanualpro.com

20-6 0

FrontSeatArmrestReplacement

FrontSeatCoverReplacement

NOTE:Takecare not to tear the seamsor damagethe


seatcoverS.

CAUTION: Put on gloves to protect your hands.


NOTE:Take care not to tear the seamsor damagethe
seatcovers.

>: 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.

Removethe armrestfrom the driver'sseat.

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.

Releaseall insidesprings,then fold backthe seatbackcover.and removethe clios.


WIRE
{Padsidei

Installationis the reverseof the removalprocedure.

(Seatback frame sjde)

cover on

'00

model)

(cont'd)

www.emanualpro.com

20-61

Seats
FrontSeatCoverReplacement(cont'dl
Removethe headrestguide,then removethe seatDacxcover.

3.

Pull backthe edge of the seat cushioncover all the


way around,then releasethe clips.and removethe
seatcushioncover.

COVER

6.

(padside)

is the reverseof the removalprocedure.


Installation

lnstallationis the reverseof the removalprocedure.

NOTE: To preventwrinkleswhen installinga seatbackcover,makesure the materialis stretchedevenly


over the pad before securingthe hook and inside
springs.

NOTE:
. To preventwrinkleswhen installinga seatcushion cover. make sure the material is stretched
evenlyoverthe pad beforesecuringthe clips.
. Replacethe releasedclipswith new ones.

Seat cushion cover:


1.

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

RearSeat Removaland lnstallation


CAUTION: When prying with a llat-tip screwdrivsr,
wrap it with protectivetape to prevent damage.

with tilt:
NOTE:Beforeremovingthe rearseat,tilt it.

NOTE: Takecare not to scratchthe seatcoversand bodv.


l

Removethe lower hinge covers,then remove the


bolts.

>: Boh locations.2


8 r 1.25mm
2 N.m 12.2kgl,n,
16 tbf ttl

LOWERHINGE

covERs

LOWERHINGE
COVER

(cont'd)

www.emanualpro.com

20-63

Seats
RearSeat Removaland Installation(cont'dl
2.

Foldthe seatcushionforward,and removethe base


framecover,then removethe boltsand nut.

5.

removethe striker.
With tilt: lf necessary,

NOTE:The rear seat without tilt is shown,the rear


seatwith tilt is the same manner.
>i Boh screw locetions

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

lnstallationis the reverseof the removalprocedure.


N O T E :M a k e s u r e t h e r e a r s e a t b e l t b u c k l e sa n d
centerbelttongueare routedproperly(withouttilt).

SEATBELTBUCKTES
(CENTERBELTTONGUEI
SEATCUSHION

Removethe headrest.

4.

Carefullyremovethe rear seatthrough the door opening.


NOTE:An assistantis helptulwhen removingthe rear
seaI.

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

NOTE:Take care not to tear the seamsor damagethe


seat covers.

CAUTION: Put on gloves to protect your hands.

SEAT.BACK

NOTE:Takecare not to tear the seamsor damagethe


sealcovers.
Seal-backcover:

COLLAR

Removethe seat-back{seepage20-65).

2.

Remove:
a Armrest
. Headrest
. Seat-back
reclinerod (seepage20-65)

COLLAR

Removethe seat cushionstrap bolt and strap bolt


trim, then removethe seat-backmat.

6x1.0mm
9.8 N.m {1.0kgf.m,

7.2rbr.ft)
WASHER

NYLON
WASHER
VE
WASHER

ARMREST

"'---.' t.-r"t-- i,': ""

'

ARMREST
PIVOTBOLT
6x1.0mm
9.8 N.m (1.0kgt.m,
7.2lbllll

4.

Removeall the clips.

lnstallationis the reverseof the removalprocedure.

(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

Soat cushion cover:


'1.

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

Pull backthe edgeof the seat-back


coverall the way
around.releasethe clips,and removethe seat-back
cover.
CUSHION
COVER
Pull backthe edge of the seat cushioncover all the
way around,releasethe clips,and removethe seat
cushtoncover.
CLIPS

CLIPS
( L e a t h e rs e a t - b a c k

coveron '00model)
1.

WIRE
(Padside,leatherseat,back

coveron ,00model)

Installationis the reverseof the removalprocedure.


NOTE:
o To preventwrinkleswhen installinga seat_back
cover,makesure the materialis stretchedevenly
over the pad beforesecuringthe hook and clips.
. Replacethe releasedclipswith new ones.

20-70

www.emanualpro.com

COVER

5.

Installationis the reverseof the removalprocedure.


NOTE:
o To preventwrinkleswhen installinga seatcushi o n c o v e r ,m a k e s u r e t h e m a t e r i a li s s t r e t c h e d
evenlyover the pad beforesecuringthe clips.
. Replacethe releasedclipswith new ones.

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

removethe front bumperbeam,front bumperupperbeamand guard bar.


lf necessary,
>: Bohlocations
A>,5

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

Installationis the reverseot the removalprocedure.


NOTE:
. M a k e s u r e t h e f r o n t b u m p e re n g a g e st h e f r o n t
bumperupperbeamsecurely.
. It necessary,adjust the front bumper upper beam
to obtainthe propergap.
. lf necessary,
replaceany damagedclips.

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

rgfi\\* ffi\\-. 3il;l-'lln*n,..,


t.2tbtftl
WJ/*

>: Clip locelions, 7

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

Installationis the reverseof the removalprocedure.


NOTE:
. lf necessary,
replaceany damagedclips.
. Makesurethe side markerlight connectorsare pluggedin properly.
. Makesurethe rearbumperengagesthe sideclipson eachsidesecurely.

20-74

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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

Installationis the reverseof the removalprocedure


NOTE:
. Makesurethe hood opensproperlyand lockssecurely.
. Adjustthe hood alignment.
. Adjustthe aim of the windshieldwashernozzles(seepage20-102)

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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.

Adjustthe hood right and left,as well as fore and aft,


by usingthe elongatedholeson the hood hinge

f
sz

14--+ik-

HOODEDGE
CUSHION

6x1.0mm
9.8N.m (1.0kgtm,
7.2 tbt.ttl

HOODHINGE

HOODHINGE

Adiustthe hood latchto obtainthe properheightat the forwardedge'


Move the hood latchrightor left untilthe strikeris centeredin the hood latchas shown

?-9.8N.m (1.0kgf m,
7.2 rbf.ftl

20-76

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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.

Removethe front grille emblem cover. Loosenand


removethe grille mountingscrews.and removethe
front grille by pullingit forward.
>: Screwlocations
a>,5
s>,2

@-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

Installationis the reverseof the removalprocedure.

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.

NOTE:An assistantis helpful when removingthe rear


hatchglass.
a: Nul locations
Aa.4
Ba.4

@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

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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

FEAR TIME 4WD


EMBLEM
GLASSPROTECTOR

{cont'd)

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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

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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.

Tailgate door side:

About
7mm
1o.27in.l

REARH ATCHGLASS

(cont'd)

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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

8. Checkfor water leaks.


NOTE: Do not squeezethe tip of the hose.

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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

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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

Installationis the reverseof the removalprocedure.


NOTE:
. Takecarenot to damagethe windshieldmolding.
. Makesurethe roof moldingis installedsecurely.

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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

>: Clip locations,14

REARDOOB
MOLDING

a: Plasticnut location, 1

(cont'd)

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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,

It the old molding is to be reinstalled:


The following materialsand tools are requiredto repair
t h em o l d i n g .

: 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.)

replaceany damagedclipson the moldlf necessary,


ang.

2.

Apply the striperemoverevenlyto the bondingsurfaceof the body and molding.

3.

Coverthe bondingsurfaceof the body and molding


with a film, then heatto 104- 122"F(40- 50'C)for 5
- 10 minuteswith an infrareddryer.

25 mm {0.98in.l

8 2 0 m m 1 3 2 . 3i n . )

CAUTION: Put on gloves to protect your hands,


1.

REARDOOR
MOLDING
(Front/rear end)

Width:5 mm

NOTE: Use care when heatingto preventdeformation of the body and molding.
4.

Carefullyscrape the adhesivetape with a plastic


putty knife.
For removalof adhesivetape residue,follow-upwith
stripe adhesiveremover,then scrapethe adhesive
tape with a plastic putty knife.
Removethe protectivetape,then cleanthe bonding
surfacewith a spongedampenedin alcohol.
NOTE:Makesurethe bondingsurfaceis keptfree or
water,oil and grease.

t'.

Heatthe bonding surfaceof the door and molding


with an infrareddryer.
Door:
104- 140'F(40- 60'C)
Molding:68 - 86'F (20- 30'C)
NOTE:Use carewhen heatingto preventdeformation of the molding.
A l i g n t h e m o l d i n gw i t h t h e c l i p l o c a t i o n sa, n d s e t
the molding. Lightly push on the molding until its
edgeis fully seatedon the adhesivetape.
NOTE: Oo not spray water on the molding within
the first 24 hoursafterinstallation.

all removedparts.
1 0 . Reassemble

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Side Sill Panel


Replacement
NOTE:Takecarenot to scratchthe body.
>: Cliplocations

>: Screwlocations,4

A>.7

NOTE: Loosenthe screw,


then removethe lowerclip
usinga clip remover,

Remove the side clips from the body


by turning them 45'

SIDE CLIP

NOTE:When removingthe side


sill panel,the sideclipswill
stay in the body.

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.

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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

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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\

>: Screw locations,4

>: Clip locations,

ffi

A\

>: Screwlocations
a >,3
B > ,1

Removethe front wheelwell protector,

s))pp>
Y]

6'thp
I sv.l/) D
Y/

6x1.0mm
9.8Nm(1.0kgf.m,
7.2 tbf.ft)

)fl(

l#

:rl

>: Clip locations,

A I

4t

wt
I
a l

NOTE: Beforetemoving the


remove
frontwheelwellProtector,
the screwfrom the front
bumperand lowerthe front
bumper.

INNER FENDER

Installationis the reverseof the removalprocedure.


NOTE;lf necessary,
replaceany damagedclips.

Installationis the reverseof the removalDrocedure.


NOTE:lf necessary,
replaceany damagedclips.

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.

Removethe rearwheel (seesection18).


>: Cliplocations,3

/ll

>: Screw locations


B>,I
a>,3

I ,.{\
6x1.0mm
N.m {1.0kgl.m.
6him"
l FY-./),@ 9.8
7.2 rbtft)
Y/

qK
1l

>: Clip locations

A> , 5

B > ,1
YnTn

/'d)Ul | +['Tl+l
\=lHl | -_H_l
tlrflJ
-

|
|

removinsthe
INoTE:Before
thescrew
lclip.remove
from the rearbumperand
lowerthe rearbumper,

lnstallationis the reverseof the removalDrocedure.


replaceany damagedclips.
NOTE:lf necessary.

lnstallationis the reverseof the removalprocedure.


NOTE:lf necessary,
replaceany damagedclips.

20-90

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RearAir Outlet Replacement


NOTE:Takecarenot to scratchthe body.
Removethe rearbumper(seepage20-74).

>: 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.

Installationis the reverseof the removalprocedure.


NOTE:
. lf necessary.
replaceany damagedclips.
. Makesurethe hood openercableis routedand connectedproperly.
. Makesurethe hood opensproperly.

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)

Centerpillar lower trim panel (left side,see page 2041)


Frontsidetrim (leftside,seepage20-41)
Rearseat(leftside,seepage20-63)
>: Clip locations
B>,1
A>,6

Cargoareafloor and cargostoragebin (seepage 2043)


a Reartrim panel{seepage20-42)
Rearsidetrim panel(leftside,see page20-421
a Rearsidetrim (leftside,see page20-41)

c>,1

@lRlg
FUELFILLOOORLATCH
(seepage20-96)

FUELFILLDOOROPENER
{seepage 20-96)

Installationis the reverseof the removalprocedure.


NOTE:
. lf necessary,
replaceany damagedclips.
r Makesurefuel fill door openercableis routedand connectedproperly.
. Makesurethe fuel fill dooropens properly.

www.emanualpro.com

Hood ReleaseHandleReplacement

HoodLatchReplacement

NOTE:Takecarenot to bendthe openercable.

NOTE:Takecarenot to bendthe openercable.

Removethe left kickpanel(seepages20-41).

Removethe front grille (seepage20-77).

>: 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

Installationis the reverseof the removalprocedure.

Installationis the reverseof the removalprocedure.

NOTE;
. Greaseeachlocationofthe hoodlatchas indicated
by the arrows.
. Makesurethe openercableis connectedproperly.
. Makesurethe hood locksproperly.
. Adjust the hood latchalignment(seepage20-76).

NOTE:Makesurethe hood opensproperly.

www.emanualpro.com

20-95

Openers
FuelFillDoorOpenerReplacement

Fuel Fill Door Latch Reolacement

NOTE:Takecarenot to bendthe openercable.

NOTE:Takecarenot to bendthe openercable.

Removethe leftfront sidetrim (seepage20-41).

Removethe rear speakercover and rear speakerfrom


the left rearsidetrim panel(seepage20-42).

>: 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,

www.emanualpro.com

20-9 6

Installationis the reverseof the removalprocedure.


NOTE:Make sure the fuel fill door opens properly
and lockssecurely.

Wiper/Washer
ComponentLocationIndex

WIPERARMS
WINOSHIELD
and LINKAGE
page20-98
Replacement,
Adiustment,Page20-103

WASHERRESERVOIN
page20 99
Replacement,

www.emanualpro.com

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.

NOTE:Takecarenot to scratchthe hood and body.

Disconnectthe connector,remove the bolts, then


removethe windshieldwiper linkageassembly.
>: Bohlocations,3

1.

Removethe windshieldwiper arms.

2.

Removethe clips,then removethe cowl cover.

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

www.emanualpro.com

NUT
10 x 1.25mm
18 N.m 11.8kgf.m,
13 tbf.ftl
SPRING
WASHER

WIPERMOTOR

Installationis the reverseof the removalprocedure.


NOTE:
. Makesurethe connectoris connectedproperly.
. lf necessary.
replaceany damagedclips.
. I n s t a l lt h e w i n d s h i e l dw i p e r a r m s a s d e s c r i b e d
on page20-103.
. Checkthe windshieldwiper motor operation.
. Greasethe moving parts.

RearWindowWiperArm and
Motor Replacement

WasherReservoirReplacement
GAUTION: Put on glovesto protect your hands.

CAUTION:Put on gloves to protect your hands.


1.

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

NOTE;Takecarenot to damagethe rear hatchglass.


1.

Removethe rearwindow wiper arm.


a: Nut loc.tion!, 3
6x1.0mm
9.8 N.m 11.0kgt'm,
7.2 tbf.ftl

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

Removethe rearwiper lowercover.

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.

Removethe bolts, then remove the washer reservotr,

Installationis the reverseof the removalprocedure.

4.

Installationis the reverseof the removalprocedure.

NOTE:
. Makesurethe connectoris connectedproperly.
. Installthe rea. window wiper arm as described
on page20-103.
. Checkthe rearwindow wiper motor operation.
. Greasethe movingparts.

www.emanualpro.com

/ 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

Reartrim paneland rearsidetrim panel(seepage2042J


. Rearsidetrim (seepage20-41)
. Rear hatch glass support strut (body side, see page
20-7Al
. Ouarterpillartrim panel(seepage20-421
o Cargoarealight (seesection23)
. Headliner(rearedge,seepage20-44)
.

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,

Installationis the reverseof the removalDrocedure.


NOTE;
. Takecarenot to pinchthe washertubes.
. lf necessary,
replaceany damagedclips.
. After installing,adjustthe aim of the washernozzle(seepage20-103).

20-102

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WiperArms and WasherNozzlesAdiustmenl


RearWindow wipor/Washer:

Wind3hieldWipor/Washer:
1,

Adiust the wiper arms so that their park positions


matchthe illustration.

Distance
'_\ from center
ltne
ru"rrr."i.
2 7 m m ( 1 . 1i n . )

Viow from flont io roar

from black
ceramicedge
88 mm (3.5in.)

GLASS

Vi6w trom roar to lront


REAR

sPo[.-ER

C.nlar lino
L

2.

Insert a tack into the washer nozzles.and adjust


them so that they aim at positionsA, A', B, and B'
shown in the illustration.
Distance from center
line

^,J;-ll\

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Alignto the rearwindow


defoggergrid line.

from black
ceramicedge

A and A'

3,$ mm (13.5in.) 287mm (11.3in.)

B and B'

122mm (4.80in.) 352mm (13.9in.)

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

t13 {0,511For Engin6 Mount


M10 x Pl.25
t13 10.51)For Uppcr Arm

.25
POINT
,1710.67)
Fof Re.r Beam

t5011.97| Locrt. Hol.

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

For ReerCross Beam

271,1(10,6.9)
POINTw

POINT 3, s1

ForTrailingAim
o14 {0.551
POINT v

Bear Damper Lower


Bushing Point

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20-109

Heaterand Air Conditioning


Heater

...........21

NOTE:Section21 ("Heater")is includedin section22.

......'..'..
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

AIR MIX CONTROLMOTOR


page22-43
Replacement,
lest, page 22-13

BLOWERMOTOB
2P CONNECTOR

BLOWERMOTORHIGHRELAY
Test, page 22-45
HEATERSUB.HARNESS

7P CONNECTOR

DASHBOARDWIREHARNESS
HEATERCONTROLPANEL
8P AND 2OPCONNECYORS

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22-6

Description

The air conditionersystemremovesheatfrom the passengercompartmentby circulatingrefrigerantthroughthe system


as shown below.
High'temperature/
h i g h - p r e s s u rgea s
Suction and compression

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

This vehicleusesHFC-I34a(R-l34a)refrigerantwhich does not containchlorofluorocarbons.


Pay attentionto the following serviceitems:
.
.
.
.
.
.

Do not mix refrigerantsCFC-12(R-12)and HFC-l34a(R-134a).


They are not compatible.
(PAG)refrigerantoil (SP-10)designedfor the R-134acompressor.
Use only the recommendedpolyalkyleneglycol
Intermixingthe recommended(PAG)refrigerantoil with any other refrigerantoil will resultin compressorfailure.
Afl Ay'Csystemparts(compressor,
dischargeline.suctionline,evaporator,condenser.receiver/dryer,
expansionvalve,
O-ringsfor joints)haveto be properfor refrigerantR-134a.Do not confusewith R-12parts.
Usea halogengas leakdetectordesignedfor refrigerantR-134a.
R-12and R-134arefrigerantservicingequipmentare not interchangeable.
Use only a recovery/recycling/charging
station
that is U.L.iistedand is certifiedto meetthe requirements
of SAEJ2210to serviceR-134a
air conditioning
system.
Always recover the refrigerant R-134awith an approved recovery/recycling/charging
station before disconnectingany
lVC fitting.

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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
www.emanualpro.com

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

Mode controlmotor does not run, or one or more modesare inoperative.


controldoor doesnot changebetweenFreshand Recirculate.
Recirculation
Radiatorfan does not run at all (but condenserfan runswith the AVCon).

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

Both fans do not run with the Ay'Con

22-33

Compressorclutchdoes not engage.


AJCsvstemdoes not come on (bothfans and compressor).

22-34

Both heaterand A/Cdo not work,

22-39

22-10

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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*

P.essand hold th6 recircul.tion


control switch
'98 - 00 modek:
Within six second3 atter the
ignition switch b turned ON (lll.
Prassthe rocirculationcontrol
switch the required number ol
times dependingon the r6circulation indicator light striu3

1.5 aaa

/
0.3 aac
RECIRCULANON
INDICATORLIGHT

MODECONTROLOIAL
Diagnostic
trouble
code {DTCI
'l

R6circulation
indicator light

Component with problsm

Possiblo causc

See page

22-12

O n eb l i n k

Air mix control molor

Openor shortcircuit,obstructed
door,
faultymotor

Two blinks

Elower motor

Open or short circuit,faultv motor

Three blinks

Evaporator
temperature
sensor

Opon or short circuit,faulty sensor

22-14,16
22-20

In caseof multipleproblems,the recirculation


indicatorlight indicateonly one DTCthat is the leastnumberof blinks.
Resetiing the Solf.diagnosisFunqtion
Turningthe ignitionswitchOFFwill cancelthe self-diagnosis
function.After servicework, run the self-diaqnosis
function
onceagainto checkthat there is no other Droblem.

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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.

Chockthe air mix control moior:


1. Disconnect
the air mix control
motor 5P connector,
2, Testthe air mix controlmotor
(seepage22-43).

ls the air mix controlmotorOK?

Checkthe air mix control linkago


and doors:
1 . R e m o v et h e a i r m i x c o n t r o l
motor (seepage22'43).
2. Checkthe air mix controllink
age and doors for smooth

Do the air mix controllinkageand


doorsmovesmoothly?

Reolacelheair mix conlrol motor.

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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Ftom page 22.12

HEATERCONTROLPANEL2OPCONNECTOR

Checktor a short to poweri


C h e c kt h e s a m e t e r m i n a l s f o r
voltage.
REO/8LU

RED/YEL

Wire sideol femaleterminals

Repairshon lo power in the wi.e


between the heater control panel
and the air mix control motor,
(Thisdamagesthe heater control
Danel.l

Checktor an open in the wires:


Checkfor continuity between foll o w i n g t e r m i n a l so f t h e h e a t e r
control panel20P connectorand
the air mix controlmotor 5P connector,
zOPi
5P:
N o .1 No.3
No.6 _
N o .4
No.g _
No.2
N o .1 7 _
No.5
N o .1 8 _
N o .1

RED/YEL

Repair any open in the wire{s)


betweon the heatercontrol panel
and air mix control motor.
Check toa loos wir63 or poor
connectionsrl the heater control
panel 20P connector and st the
air mix control motor 5P connsctor. lJ the connections aro good,
substitute a known-good hoater
control panel, and rechock.I the
symptom/indication goes away,
..pl.ce the original heater control panel.

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AIR MIX CONTROLMOTOR


5P CONNECTOR
Wire sideof femaleterminals

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.

NOTE: lf the blower motor does


run at all,referto page22-16.

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

Chacklor.n open in the wire:


1. Disconnectthe power transistor 3P connector.
2. Checkfor continuitybetween
the No.3 terminaa
l nd body
gro(1nd.

ls therecontinuity?

Wire side of femaleterminals

Chock for.n op.n in thc wiro


botween ihe powa. transistor
rnd body ground, It tho wir. is
OK, check for poor ground at
G,O1 .nd G4o2.

JUMPER
WIRE

Chsckfor an opon in the wire:


'1. Connectthe No. 1 and No. 3
trminals of the power trans i s t o r 3 P c o n n e c t o rw i t h a
jumperware.
2. Turn the ignitionswitch ON {ll).

Repairop6n in the wiro betwoon


tho Dower transi3tol and the
blowor motor.
HEATERCONIROLPANEL2OPCONNECTOR
Wire sideoI fgmaletrminals
Checktor an open in tho wire:
1. Turnthe ignitionswitchOFF.
2. Disconnect
the iumperwire.
3 . R e m o v et h e h e a t e rc o n t r o l
panel (seepage 22-46).
4. Check for continuity botween
the No. 20 terminal of the
heatercontrolpanel20Pconnectorand the No.2 terminal
o f t h e p o w e r t r a n s i s t o r3 P
connectof,

,/1,/

't1 12 1 3

1ia

22-14

10

o
LT GBN/BLK

www.emanualpro.com

LI GRN/BLK

Rpairopon in tho wire betwoen


th6 oowor ttan3i3tor and th6
hoatar control oanel.

10 page22-15

't5 1 6 1 1 1 8 1 9 20

From page22-14

Chockfor a short in the wire:


Checktor continuity between the
No. 20 terminal of the heatercon'
trol panel20Pconnectorand body
ground,

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.

Wire sideof femaleterminals

HEATERCONTROLPANEL8P CONNECTOR
1
4

8
BLU/8LK

Wire sideof femaleterminals

ls there batteryvoltage?

Repairopan in the wire betwaen


tho heatsr cont.ol o.nel and the
blower motor.

Chockth6 power iransistor:


1. Turnthe ignitionswitchOFF.
2. Reconnectthe heatercontrol
panel8P and 20Pconnectors.
3. Test the power transistor (see
page 22 44).

ls the power transistorOK?

Chec* for loo3e wires or Door oonneclions at the heater control


panel 8P and 20P connoctorsand
at lhe power tran3istor 3P connector. lf lhe connectiorc are good,
substituta , known-good hoater
contrcl pan6l, and rcheck.ll the
symptom/indication goes away.
replecgth6 originalheater control
oanel.

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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,

check rhe No. 55 (40 A) {use in


the under-hoodfuse/relaybox,
and the No. 17 (7.5A) fuse in the
under-dashfuse/relaybox.

Replaceth6 fuse(s),and rechalck.

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).

Doesthe blowermotor run?

Chockthe blower moto.:


1 . D i s c o n n e ctth e j u m p e r w i r e
and the blowermotor 2P connector.
2. Measurethe voltage between
the No. l terminal and body
ground.

Checktho blower motor rolay:


1. Turnthe ignitionswitchOFF.
2 . R o m o v et h e b l o w e r m o t o r
relayfrom the under-hood
fuse/relaybox, and test it (see
page 22 45l'.

fo page 22-19

22-16

www.emanualpro.com

JUMPEF
w|RE
fo page 22-11

Wire side of lemale terminals

Frompage22-16

Check lhe blower motor high


telay:
1. Turn the ignitionswitchOFF,
and disconnecthe jumper
2 . R e m o v et h e b l o w e r m o t o r
h i g h r e l a y ,a n d t e s t i t { s e e
page22-45).

BLOWERMOTORHIGHBELAYitP CONNECTOR

BLU/BLK
rF
r
.--1 1 2 )
l | _ #

Checkfor rn opon in the wire:


l. Connectthe No. 1 terminalof
the blower motor high relay
4P connectorto body ground
with a iumperwire.
2. Turn the ignitionswitchON (ll).

. r u u eI e l"3 1 i
wrRE
I

Wire side of female terminals


Doesthe blowermotor run?

R6pairopcn in the wire botwoen


the blower motor and the blower
motoi high relry.

Checktor an opon in the wire:


'1. Turn the ignitionswitch OFF,
and disconnect he iumper
2. Turn the ignitionswitchON {ll).
3. Meas0rethe voltage between
t h e N o . 2 t e r m i n a lo f t h e
blower motor high relay 4P
connectorand body ground.

ls there batteryvoltage?

Repairopon in the wiro betweon


the No. 17 fuse and tho blowel
motor high relay.

Checktor an open in the wire:


'1. Turnthe ignitionswitchOFF.
2. Checklor continuity between
t h e N o . 3 t e r m i n a lo t t h e
b l o w e r m o t o r h i g h r e l a y4 P
connectorand body ground.
Check for an open in the wire
between the blowar motor high
rel.y and body ground.lf the wiro
i3 OK, check fo. poor ground at
G{Ol .nd Gt|()2,

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.

Ropairop6n in th wira between


tho heater control panol and tho
blowgr motor high relay.

Checklor an op6n in the wire:


Checklor continuity between the
No. 8 terminaloI the heatercon
trol panel20Pconnectorand the
N o . 4 t e r m i n a lo f t h e b l o w e r
motor high relay4Pconnector.

ls therecontinuhy?

Check fo. looso wiles or oool


connoctionsat the haateacontrol
Danel8P .nd 20Pconnectorsand
at the blower motor high relay
4P connoctor. ll the connctions
are good, substitutg a knowngood h.at.r control panol, and
r.check. lf the symptom/indicetion goes away, replacethg original heater contrcl panel.

www.emanualpro.com

HEATERCONTROLPANEL8P CONNECTOR
Wiresideof femaleterminsls

I{EATERCONTROLPANEL2OPCONNECTOR
Wirc sideot femaleterminals

Repairopen in the wire botweon


the heater control Daneland the
blowel motor high r6lay.

Frcm page 22-16

Rcpbcc tho blower motor rolay.


BLOWERMOTORRELAY4P SOCKET
Ch.ck th. under-hoodtu.o/rolay
box:
Measur6the voltage betweenthe
No. 3 terminalofthe blowermotor
relay4P socketand body ground.

Chacktor an open in the wilo:


1. Turnthe ignitionswitchON (ll).
2. Measurethe voltage between
the No. 4 terminal of the
blower motor relav ,[P socket
and body ground.

ls thore batteryvoltage?

Ropairopon in the wirs botwoon


th. No. 17 fu3o and th. blow6r
motol lolay.

Chacktor an opon in tho wilo:


1. Turnthe ignitionswitchOFF.
2. Checkfor continuity between
the No. 2 terminal ot the
blower motor relay 4P socket
and body ground.
Chock tor !n opan in the wile
bstween tha blowar motor ralaY
.nd body ground. It tho wilc is
OK, chock fol poor ground at
G/Ol and G402.
Ropair opon in th. BLU/WHT
wira batwaan lho blowor motol
rohy and tho blowe. motor.

www.emanualpro.com

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

Chck the ev.porato. temperature sensor:


1. Disconnecthe evaporator
temperaturesensor 2P conRESISTANCE
ko

2. Measure the resistance


betweenthe No. 1 and No. 2
t o r m i n a l so f t h e e v a p o r a t o r
temperature
sensor.

86'F

30"c
ls the resistance
withinthe speci,
ficationsshownon the 9raph.

HEATERCONTROLPANEL2OPCONNECTOR

Checklor a short in the wire:


l R e m o v et h e h e a t e r c o n t r o l
panel(seepage22-46).
2. Checktor continuitybetween
the No.2 terminao
l l the
heatercontrolpanel20Pcon,
nectorand body ground.

Wiresideof fema16
terminals

Repai. short in the wir6 betwan


lhe hoater control Danoland the
evaporatoatampereturc senSoa.

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

Checkfor rn opsn in tha wiJe:


Checkfor continuity between the
No. 9 terminalof the heatercon
trol oanel 20P connector and the
No. 'l terminalot the evaporator
temperaturesensor2P connector,

o
+

li-L:t
Ropairopen in tho wire betwegn
the heater control oanel and the
evaporatortgmpcrature sen3or.

Chgck fol loose wiros or pool


connectronsat the hoator control
oan6l 20P connector and at the
eveporator temperatura Sensol
2P connector. It the connections
are good, substitute a knowngood he.tel contlol panel, and
rechck. ll thg symptom/indication 90o3rwey, roplscethe original heatercontrol oanel.

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-

Checkthe No. 17 {7.5A) Iuse in


the under-dashfuse/relaybox.

Replacethe tus, snd iecheck.


MODECONTROLMOTOR7P CONNECTOR
Chocktor an open in th wi.6:
1. Disconnectthe mode control
motor 7P connector.
2. Turn the ignitionswitch ON (ll).
3. Measurethe voltagebetween
the No. l terminal and body
ground.

BLK/YEL

Wiresideof femaleterminals

Repairopon in the wire betwoon


tho No. 17 luse and tho mode
control motor.
Checkthe mode control motor:
1. Turnthe ignitionswitchOFF.
2. Test the mode control motor
.
Gee page 22 41')

ls lhe modecontrolmotor OK?

Chock th mode cont.ol link.ge


and doors:
1 . R e m o v et h e m o d e c o n t r o l
motor (seepage22-41).
2. Checkthe modecontrollinkage
and doors for smooth movement,

Do the mode control linkage


and doors move smoothly?

Replece the inod6 control motor.

Chockfor s shon in the wirs:


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. Checkfor continuitybetween
the No. 12,13,14,15,16and 19
terminalsol the heater control
panel20Pconnectorand body
groundindividuaily.

HEATERCONTROLPANEL2OPCONNECTOR

2
1 1 12

l,/1,/

NO
To page22-23

[E!r!

Repairany short in the wire(sl


between the mode control rnotoa
and the h6ater control Danel.

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

Chgckfor a short to power:


Checkth6 same wires lor voltage.

' V VL g l

't1 1 2

r s l r r l r s l 1r7e1 8

BRN/WHT

:L/BLU

Ropairlhort to powor in the wiio


betw6an tho mode comrol motor
end thc hoat.r cont.ol pan.l.
(ThisdamagF tha hator Gontrol
pancl.l

10

1 9 20

8LU/BLX

Wire sideot femaleterminals

Chackfor an opon in tha wiles:


Checklor continuity between the
followingterminalsoI the mode
control motor 7P connectorand
the heatercontrolpanol20Pconnector.
7P.
20Pt
N o .1 2- N o .3
No. '13- No. 4
N o .1 4 - N o . 5
N o .1 5- N o .6
No. t6 - No. 2
N o .1 9- N o .7

,/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.

Chock fo. loose wiret or pool


connections at the heat6r control
pancl 20P connector and tt the
modo control motor 7P connoctor. lf tho connactions sre good,
substitute a known-good hortcr
control pan6l, and tech.ck. lf the
symptom/indication goes awayt
roplacotho original hcater @nttol
p3nel.

www.emanualpro.com

22-23

Troubleshooting
Recirculation
GontrolMotor
Rocirculation control door do6s
noi chango botwen Fresh and
Reci.culate.

Checkthe No. 17{7.5A)tuse in the


under-dashf use/relaybox.

Roplacethe fu36,and rechock.

REORCULATION
CONTROL
MOTOR
,rPCONNESTOR

q?

Checkfor .n open in the wire:


1. Disconnectthe recirculation
control motor 4P connector.
2. Turn the ignitionswitchON (ll).
3. Measurethe voltage betlveen
the No. l terminal and body
ground.

T---

V-l

l 1 l, r l / l 1 l
I BI.IUYEL

(v)

Repairop6n in the wire bdtween


the No. 17 fuse and thc recirculetion control motor.

Wiresideof femaleterminals

Check the rocirculation control


moior:
1. Turnthe ignitionswitchOFF.
2. Test the recirculationcontrol
motor (seepage22-42).

YES

Chock ths r.circulation control


linkag. end doori
1. Removethe recirculation
control motor (see page 22,42).
2. Checkthe recirculationcontrol
linkageand door for smooth

To page22-25
Do the recirculation
controllink
age and door move smoothly?

www.emanualpro.com

Boprir the recirculrtion control


linkag. or dooJ,

Ftom page22-24
HEATERCONTROLPANEL8P CONNECTOR

Checktol a short in the wit6:


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. Checkfor continuitybetween
of
the No.2 andNo.3terminals
the heatercontrolpanel8Pcon
nectorand body ground individually.
Wire sideof femaleterminals
Reoaii short in tfte wir{s) birvn
the redrc{lstion conttol motor and
ihe hedter control panel.

Checkfor a shon to power:


Checkthe samewireslor voltage.

ls thereany voltage?

Repairshort to power in the wite


between the rocirculationcontrol
motor and lh heator control
panel. (This demsges the heater
conlrolpanel.l

Chcktor an open in the wires:


Checkfor continuity betweenthe
followingterminalsol the recircu'
lation control motor 4P connector
and the heatercontrol panel 8P

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

Ropairopen in the wile(sl between


the recirculalioncontrol motor
and the heeter cortrol Pan|.

Check for loose wires or pool


connections at the heatr control
Danel8P connoctor and .t the
rocirculation control motor 4P
connector.lf lhe connec{ionsare
good, substitule a known-good
hester control oanel, and rochock.
lI the symptom/indication goes
away, .eplace the otiginal heater
control pan|.

www.emanualpro.com

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.

Checkrhe No.57 (20Alfuse in the


underhood fuse/relaybox, and
t h e N o . 1 7 1 7 . 5A ) l u s e i n t h e
0nder-dashfuserelay box.

R.pl.c. th. fur|.l, .nd r.chack.

Remove the radiator fan r6lay,


and test it {seepage22-45).

R.pllco tha r.diator frn rehy.

MDIATOR FAN RELAY4P SOCKET


Check the und.r-hood fus./r.l.y
box:
Measurethe voltage betweenthe
No. 2 terminalol the .adiatortan
relay 4P socketand body ground.

Chockthe radiatortan:
Connectthe No. 1 and No.2 tr
minals of the radiatorfan relay
4P socketwith a iumperwire.

Doesth6 radiatorfan run?

fo page22-28

www.emanualpro.com

fo page22-21

Ftom page22-26

RADIATORFAN REI-AY4P SOCKET


Ch6ckfor an open in the wire:
1. Disconnect
the jumperwire.
the radiatorfan 2P
2. Disconnect

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

Repai. open in the wira between


the radiatorfan .olay ,nd the radi'
atorfan.

Checklor an open in the wi.e:


Checkfor continuity betweenthe
No. 1 terminaloI the radiatorfan
2P connectorand body ground.

ls therecontinuity?

Check lor an open in the wir.


bturosn the radi.tor fan and body
ground. lf ihe wire b OK, check fol
poor ground .t G2()l.

Replacethe radiator tan motor.

(cont'd)

www.emanualpro.com

Troubleshooting
Radiator Fan (cont'dl
From page 22-26

RADIATORFAN RELAY4P SOCKET


Chockfor an open in the wire:
'1. Disconnect jurnper
the
wire.
2. Turn the ignitionswitchON (ll).
3. lleasure the voltage between
the No.4terrninalof the radiat o r f a n r e l a y 4 P s o c k e ta n d
bodyground.

1
2

a
BLK/YEL

ls there batteryvoltage?

Rep.ir open in the GRN wire


botwen lhe radiator tan relay
and the PCM/ECM.

22-28

www.emanualpro.com

Rpairopen in th6 wire botwoon


the No. 17 fuso and the radiatol
fan .elsy.

Fan
Condenser
Condenserlan does not run at all
lbut radiator fan runs with the
A/C on).

Checkthe No. 56 (20A) fuse in the


under hoodfuse/relaybox, and the
No. 17 {7.5A) fuse in the underdashfuse/relaybox.

Replacethe luse(s),and .echeck.

Removethe condenserfan relay,


and test it (seepage22-45).

Replacethe condenserfan rlay.

FAN RELAY4P SOCKET


CONDENSER

Checkthe under-hoodluso/relay
box:
Measurethe voltage betweenthe
No.2terminalof the condenserfan
relay4Psocketand body ground.

Checkthe condensff fan:


Connectthe No. 1 and No. 2 ter
minals of the condenserlan rclay
4Psocketwith a jumperwire.

Doesthe condenserfan run?

page22-30

To page22 31

(cont'd)

www.emanualpro.com

22-29

Troubleshooting
CondenserFan{cont'd)

CONDENSER
FAN RELAY4P SOCKET

Chockfor an open in the wire:


'1. Disconnect
the iumperwire.
2. Disconnect
the condenserfan
2P connector.
3. Checkfor continuitybetween
the No. 1 terminalof the con,
denserfan relay 4P socketand
the No. 2 terminalof the condenserfan 2P connector.

ls therecontinuity?

r---------t wHT

lr_f__l
1

2 |

fT;.]

|I

/Or
\j/

Ropairopen in the wire betwoen


th condenserfan rslay and the
condensertan.

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.

Replacetho condensertan motor.

www.emanualpro.com

22-30

@
!

Ftorn page 22-29


FAN RELAY4P SOCKET
CONDENSER

Chockfor an open in the wiro:


1. Disconnect
the iumperwire.
2. Turn the ignitionswitchON (ll).
3. Measurethe voltage between
the No. 4 terminaloI the condenserfan relay 4P socketand
body ground.

Repairopcn in tho wire betwoon


the No. 17 tuse and the condenseafan relay,

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

Radiator Fan Switch


Both tans (radiatorand condenser)
do not run fo. enginecooling,but
they both run with the A/C on.

Checklor rn open in the wire:


1 . D i s c o n n e ctth e r a d i a t o rf a n
switch2P connector.
2. Turnthe ignitionswitchON lll).
3, Measurethe voltage betlveen
the No.2 terminaa
l nd body
ground.

RADIATOBFAN SWITCH2P CONNECTOR

'.r
GRN

ls there battery voltage?

Repairopen in the wire between


the radiator tan relay, the condensei lan .elay and the radiaior
tan swhch.

Chockfor an open in the wire:


1. Turn the ignitionswitchOFF.
2. Checkfor continuitybetween
the No. 1 terminalof the radiator fan switch 2P connector
and body ground.

ls therecontinuity?

ls the coolingsystemOK?

Replscethe radialor fan switch.

www.emanualpro.com

Check for an open in the wire


between the .adialor fan switch
and body glound. I ths wire is OF;
choc*tor poor g.ound at G'101.

Wiresideof femaleterminals

Both Fans

Checkthe No. 17 (7.5 A) tuse in


the under-dash
fuse/relay
box.

Reolacethe tuse. and recheck.

RADIATORFAN RELAY'P SOCKET

Checkfor an opn in the wire:


1. Removethe radiatorfan relay.
2. TLrrnthe ignitionswitchON (ll).
3. Measurethe voltagebetween
the No.4 terminaloftheradia
t o r f a n r e l a y 4 P s o c k e ta n d
bodyground.

2
1

BLK/YEL

Repairopen in the wire between


lhe No. 17 luse and the radiator
tan relay.
'9? model:

PCMCONNECTOR
A I32PI
1

12

Checkfor an open in the wire:


1. Make sure the A/C switch is
OFF.
2. Using a *BackprobeSet {T/N
0 7 S A Z- 0 0 1 0 0 0 A )m
, easure
the voltagebetweenthe No. 27
I20l terminalol the PCM/ECM
connectorA (32P)and body
groundwith the PCM/ECMconnectorsconnected.
'98- 00 models
[ ]:

t5 t6 17 18 r9

10
22

23

11
21

GRN

Wire sideoI femaleterminals

PCM/ECMCONNECTOR
A (32PI
'98 - 0Omod6ls:

Repairopen in the wire btween


the.adiator fan ralav, the condenser tan rolay and the PCM/
ECM.

Checktor loosewires or poor connodions at the PCM/ECMconnoctor A (32P1.lf the connectionsarc


good, substitute a known-good
PCM/ECM,and recheck. It the
symptom/indicalion goes away,
r.plrce the originalPCM/ECM.

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Wire sideof femaleterminals

* How to use the BackprobeSets


Connectthe backprobeadaptersto the stackingpatchcords,and connectthe cordsto a multi
meter.Usingthe wire insulationas a guide for the contouredtip of the backprobeadapter,
gentlyslidethe tip into the connectorfrom the wire side until it comesin contactwith the ter
minalend ofthe ware{seesectionl1).

22-33

Troubleshooting

Checkthe No. 56 (20 A) fuse in the


underhood fuse/relaybox, and the
No. 17 (7.5A) fuse in the under
dashluso/rglaybox.

Replacethe fuso(sl,and r6check.

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:

Measurethe voltage betweenthe


No. 2 terminalof the compressor
clutch relay 4P socketand body
ground,

Chacklhe complessorclutch:
Connectthe No. 1 and No. 2 terminalsofthe comoressorclutchrelav
4Psocketwith a jumper wire.

Doesthe comprossorclutchclick?

To page22-36

22-34

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To page22-35

Ftom page 22-34


COMPRESSOR
CLUTCHRELAY
ilP SOCKET
Checkfor an open in the wire:
1. Disconnect
the jumperwire.
2 . D i s c o n n e ctth e c o m p r e s s o r
clutch 1Pconnoctor.
3. Checkfor continuity between
the No. 1 terminalof the compressorclutch relay 4P socket
and the terminalol the compressorclutch1Pconnector.

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

Inspect tha compreslor clutch


clearanco,the thormal protector,
and ths comDrg$or clutch tiold
coil lsee page 22-65).

.lwww.emanualpro.com

(cont'd)

Troubleshooting
Compressor(cont'dl
Frcm page22-34

COMPRESSOR
CLUTCHRELAY
4P SOCKET

Ch6ckfor an open in the wire:


1. Disconnect
the jumperwire.
2. Turnthe ignitionswitchON (ll).
3, Measurethe voltage between
the No. 4 terminalot the com'
pressorclutchrelay4P socket
and body ground.

2
3

BLK/YEL
Repairop.n in the wire between
the No. l7 fu3e and the compressor clutch ielay.

Checkfor an opon in the wire:


1. Turn the ignitionswitch OFF,
then reinstallthe compressor
clutchrelay.
2. Make sure the A"/Cswitch is
O F F ,t h e n t u r n t h e i g n i t i o n
switchON (ll).
3. Using a *BackprobeSet (T/N
07SAZ - 001000A),measure
the voltage betweenthe No.
17 terminal ol the PCM/ECM
connectorA (32P)and body
g r o u n d w i t h t h e P CM / E C M
connected,
connectors

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:

Wire sideof {em6leterminals


Repairopen in lhe wire betwoon
the compressor clutch r6lay and
the PCM/ECM.

Check tor loose wires or Door


connections at the PCM,/ECM
connecto. A {32P1.lf the connections are good, sub3titute a
k n o w n - g o o d P C M / E C M ,a n d
rocheck. lf the symptom/indication goas away, replacthe original PCM/ECM.

22-36

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* How to use the BackDrobeSets


Connectthe backprobeadaptersto the stackingpatchcords,and connectthe cordsto a multimeter.Usingthe wire insulationas a guide for the contouredtip ot the backprobeadapter,
gentlyslidethe tip into the connectortrom the wire sideuntil it comesin contactwith the teF
minalendo{the wire {seesectionl1).

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

check tho PcM/EcM:


U s i n g a * B a c k p r o b eS e t ( T / N
07SAZ 0010004).measurethe
v o l t a g eb e t w e e nt h e N o . 5 t 2 7 l
terminalof the PCM/ECM
connec,
t o r C ( 3 1 P )[ A 1 3 2 P )al n d b o d y
ground with the PCM/ECMconnectorsconnected,
'98 - 00 models
I l:

'97 modol:

Wire sideof femaleterminals

PCM/ECMCONNECTOR
A I32P'
38 - 00 modeb:

Wire sideof femaleterminals

ls thereapprox.5volts?

Check tor loo3e wires or Door


connections at the PCM/ECM
connoctorC l3lPl lA (32Pll.It the
connections arg good, 3ubdtitut
a known-good PCM/ECM,and
recheck. ll the 3ymptom/indication go.. eway, rplaco thG original PCM/ECM,
'98 -00 models
[ ]:

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Rop.ir open in th6 wire botweon


the A/C Dr*sure switch and the
PCM/ECM.

* How to use the BackprobeSets


Connectthe backprobeadaptersto the stackingpatchcords,and connectthe cordsto a multimeter.Usingthe wire insulationas a guide for the contouredtip ol the backprobeadapter,
gentlyslidethe tip into the connectorfrom the wire side until it comesin contactwith the ter.
minalondolthe wire (seesection11).

(cont'd)

22-37

Troubleshooting
A/G System {cont'd)
Frompage22-37

SWITCH
A/C PRESSURE

Checkth A/C pressureswitch:


1. Turnthe ignitionswitchOFF.
2. Checklor continuitybgtween
t h e N o .1 a n dN o . 2 t e r m i n a l s
ofthe A,/Cpressureswitch.

Checkfor properAy'Csystempressure.

Roplecetha A/C prssureswitch.

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.

ls there approx. 5 volts?

Check lor loos6 wiras or pool


connectionsat the heater control
Danel 20P connoctor and at the
A/C pr.ssule switch 2P connsctor. lf the connectionsere good,
substitute a known-good heatar
co trol pangl, end recheck.lf the
symptom/indication goes away,
replacethe original heaterconlrol
panel.

22-38'

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Wire sideol femaleterminals

Repairopen in the wir. botwcen


the A/C pres3urswitch and the
heater control oanel.

Both heater and A/C do not work.

Checkthe No. 17(7.5A)fusein the


under-dashfuse/relaybox, and the
No. 47 (7.5A) fuse in the underhoodluse/relaybox.

nophcc ih. fur.l.l, .nd r.check.

HEATERCONTROLPANEL8P CONNECTOR

Checktor rn open in the wiro:


1 . R e m o v et h e h e a t e rc o n t r o l
panellseepage22 46).
2. Turnthe ignitionswitchON (ll).
3. Measurethe voltage between
the No. 1 terminal of the
heatercontrol panel 8P connectorand body ground.

ls thero batteryvoltage?

Wiresideot femaleterminals

R.pair opan in lha wlra batw.cn


the No. 1? fuaa and tha h.ltcr
control panal.

Chgckfor an opan in th wirg:


1. Turnthe ignitionswitchOFF.
2. Measurethe voltage between
t h e N o . l l t e r m i n a lo f t h o
heatercontrolpanel20Pconnoctorand body ground.

ls there battery voltags?

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.

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10

1 t 1 2 1 3 1 a 1 5 1 5 1 7 1 8 1 9 20

Checkfor an opon in the wire:


Ch6cklor continuity betwoen the
No. 7 terminalof the heatercontrol panel8P connectorand body
ground.

Check for loose wire3 or oooa


connection3at the haater control
prnol 8P and 20P connoctors. It
thc conncction3are good, substituta a known-good hater control prnol, and rechecft.lf the
symptom/indic.lion go.3 ewry,
repl.cg the original ha.ter contlol oancl.

HEATERCONTROLPANEL2OPCONNECTOR

Troubleshooting
HeaterControl PanelInput/OutputSignals
HEATERCONTROLPANELCONNECTORS
2OPCONNECTOR

8P CONNECTOR

Wire sideof femaleterminals

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

AIR MIX POTENTIAL

OUTPUT

INPUT

7
8

BLOWERMOTORHIGH

ORNrur'HT
RELAY
BRN

10

22-40

SENSOR
GROUND

SWITCH
BLU,ryVHTA"/CPRESSURE

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INPUT
INPUT
INPUT

'll

12

Signal

Wire color

WHT/BLU BACKPU (POWER)

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

AIR MIX HOT

OUTPUI

'19

MOTORGROUND
BRNA/VHT IVIODE

INPUT

20

BASE CUTPUT
T GRN/BLKPOWERTRANSISTOR

Mode ControlMotor
Replacement

Test

1.

1 . Disconnectthe 7P connectorfrom the mode control


motor.

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

Connectbattery power to the No. 1 terminal, and


ground the No. 7 terminal.To avoid damagingthe
mode control motor, do not reverse power and
grouno.

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.

1 . Disconnectthe 4P connectorfrom the recirculation


controlmotor.

Oisconnectthe 4P connectorand the wire harness


clio from the recirculationcontrol motor. Remove
the self-tappingscrewsand the recirculation
control
motor,

Connectbattery power to the No. 1 terminal, and


groundthe No. 2 and No. 4 terminals;the recirculation control motor should run smoothly.To avoid
damaging the recirculationcontrol motor. do not
reversepower and ground.

{P CONNECTOR

RECIRCULANON
CONTROLMOTOR

lnstall in the reverseorder of removal.After installacontrolmotor runs


tion, make sure the recirculation
smoothlv.

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

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lf the recirculationcontrol motor does not run in step


2, remove it, then checkthe recirculationcontrol linkage and door for smooth movement.lf they move
smoothly, replacethe recirculationcontrol motor.

Air Mix GontrolMotor


Replacement

Test

1.

1.

Disconnectthe 5P connectorfrom the air mix control motor. Remove the self-tapping screws, the air
mix controlmotor and the flangecollar.

Disconnectthe 5P connectorfrom the air mix control motor.


Connect battery power to the No. I terminal of the
air mix control moto., and ground the No, 5 terminal; the air mix control moto. should run, and stop
at MAX HOT. lf it doesn't, reversethe connections;
the air mix control motor should run, and stoo at
MAX COOL.

5P CONNECTOR

lf the air mix controlmotor does not run, remove


i t , t h e n c h e c kt h e a i r m i x c o n t r o l l i n k a g ea n d
doors for smooth movement.
lf they move smoothly,replacethe air mix control motor.

AIR MIX CONTROLMOTOR

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.

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22-43

EvaporatorTemperature
Sensor

Power Transistor

Test

Test

Dip the sensorin ice water, and measurethe resistance


with a digital multimeter.Then pour hot water on the
sensor,and checklor changein resistance.

1 . Disconnectthe 3P connectorfrom the oower transt$or.

Compare the resistancereading between the No. | 8nd


No. 2 terminals of the evaporatortemperaturesensor
with the specificationsshown in the following graph;
resistance
shouldbe within the specifications.

Carefullyreleasethe locktab on the No. 2 terminalin


the 3P connector,then removethe terminal and insulate it from body ground.

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)

Connecta 1.2- 3.4 W bulb betweenthe No, 1 and


the No,2 cavityon the 3P connectol
Reconnect
the 3Pconnectorto the powertransistor.
Turn the ignitionswitch ON (ll). and checkthat the
blowermotor runs.
a lf the blower motor runs at half soeed the oower
transistoris OK, replacethe heatercontrolpanel.
. lf ths blower motor does not run at half soeed,
reDlacathe Dowertransistor.

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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

Thereshould be continuitybetweenthe No. 1 and No. 2


terminalswhen power and ground are connectedto the
No. 3 and No. 4 terminals,and there shouldbe no continuitv when oower is disconnected.

t)
P

.I

tI r I

o Blowermotor relay

a Rsdiatorfan relay

Condenserfan relay
a Compressor
clutchrelay

Blowermotor high relay

F)'"

,2-4.._.

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22-45

HeaterControlPanel

Blower Unit

Replacement

Replacement

'1. Removethe center panel togetherwith the heater


controlpaneland the audio unit (seesection20).

1 . Bemovethe evaporator (see page 22-48),

Removethe self-tappingscrewsand the heatercontrol panelfrom the centerpanel.

Disconnectthe connectors from the blower motor,


the blower motor high relay, the power transistor
and the recirculationcontrol motor. Remove the
w i r e h a r n e s sc l i o f r o m t h e r e c i r c u l a t i o nc o n t r o l
motor,and releasethe wire harnessfrom the clamp
on the blower unit. Removethe mountingbolts,the
mountingnut and the blower unit.
6x1.0mm
9.8 N.m (r,0 kgf.m, 7.2 lbl.ftl

6x1.0mm
9.EN.m 11.0kgf.m,7.2lbtftl
CENTERPANEL

lnstall in the reverseorder of removal. Make sure


that there is no air leakage.
3.

lnstallin the reverseorderof removal.

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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

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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,

Disconnectthe connectorfrom the evaooratortemoeraturesensor.and removethe wire harnessfrom


the evaporator.Removethe self-tappingscrews,the
mounting bolt and the mounting nut. Disconnect
the drain hose,then removethe evaporator.

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

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22-44

7.

Installin the reverseorder of removal,and note of


theseitems.
.

lf you're installinga new evaporator,add refrigerantoil (SP.10)(seepage22-541.


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 f r e f r i g e r a n to i l
before installingthem. Be su.e to use the right
(R-134altoavoid leakage.
O-ringsfor HFC-134a
a Apply sealantto the grommets.
a Makesurethat there is no air Ieakage.
a Charge the system (see page 22-6'll, and test its
performance(see page 22-56]-,

} -

Overhaul
1.

6.

Remove the filter lid. then pull out the A/C filter
assembly.

the O-ringswith new onesat eachfitting,


Replace
and apply a thin coat of refrigerantoil before
installingthem. Be sure to use the right O-rings
(R-134a)
to avoid leakage.
for HFC-'134a
. Installthe expansionvalve capillary tube with
the capillarytube in contactwith the outlet line
directly,and wrap it with electricaltape.
. Reinstallthe evaporatortemperaturesensor to
its originallocation.
. Makesurethat there is no air leakage.

Pull out the evaporatortemperaturesensor from


the evaporatorfins.
R e m o v et h e s e l f - t a p p i n gs c r e w sa n d t h e c l a m p s
from the housings.
4.

the evaporatorin the reverseorder of


Reassemble
Makenoteof theseitems.
disassembly.

Carefullyseparatethe housings,then remove the


evaporator.
lf necessary,remove the expansion valve When
looseningthe nuts of the expansionvalve,use a second wrench to hold the expansionvalve or the evaporator line.Otherwise,they can be damaged.

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.

Removethe glove box (seesection20).


Removethe glove box frame {see page 22-4A).
Releasethe wire harnessfrom the clamps on the
evaporator.Removethe filter lid, then pull out the
,VCfilter assemblyfrom the evaporatorhousing.

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.

Fromunderthe hood,openthe cableclamp,then disconnectthe heatervalve cable from the heatervalve


arm. Turn the heatervalve arm to the fullv ooened
oositionasshown.

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

When the engine is cool, drain the engine coolant


from the radiator(seesection10).
Do not remove the rldiator cap when
@
the engine is hot; the engine coolant is under pressure and could sevo.ely scald you.

Installin the reverseorder of removal.Make sure


that there is no air leakage.

22-50

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4.

Disconnectthe heater hosesfrom the heater unit.


Enginecoolantwill run out when the hosesare disconnected;drain in into a cleandrip pan.
CAUTION:Enginocoolantwill damagep8int. Ouickly
rinse any spilld engine coolant Itom painted surfaces.

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

Remove the mounting nut from the heater unit.


Takecare not to damageor bend the fuel lines,the
brake lines.etc.
q

Installin the reverseorderof removal.Make note of


the followingitems.
a Apply sealantto the grommets.
a Do not interchangethe inlet and outlet heater

hoses.Makesurethat the clampsare secure.


Refill the cooling system with engine coolant
{seesection10).
a Adiustthe heatervalvecable(seepage22-53).
a Makesurethat there is no air leakage.

13 N.m 11.3kg{.m,9.4lbtftl

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22-51

HeaterUnit
Overhaul
1.

Removethe self-tappingscrews and the heater core


cover.

Pull out the heate.core. Be carefulnot to bend the


inletand outlet pipesduring heatercore removal.

Pullout the grommetfrom the heatercore pipes.

Reassemble
the heaterunit in the reverseorder of
disassemblv.

Removethe self-tappingscrewand the pipe clamp.

HEATERCORECOVER

HEATERCORE

22-52

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TemperatureControl
Adjustment
l.

From under the hood, open the cable clamp, then


disconnectthe heatervalve cable from the heater
vatvearm.
HEATERVALVE ARM

5.

From underthe hood.turn the heatervalve arm to


t h e f u l l v c l o s e d p o s i t i o na s s h o w n , a n d h o l d i t .
Attach the heater valve cable to the heater valve
arm, and gently pull on the heatervalvecablehousing to takeup any slack,then installthe heate.valve
cablehousinginto the cableclamp.

HEATERVALVE ARM

HEATERVALVECABLE

From under the dash, disconnectthe heatervalve


cablehousingfrom the cableclamp.and disconnect
the heatervalvecablefrom the air mix contlol arm

VALVECABLE
HEATER

Setthe temperaturecontroldial on MAX COOLwith


the ignitionswitchON (ll).
Attachthe heatervalve cableto the air mix control
arm as shown above. Hold the end of the heater
valvecablehousingagainstthe stop,then snap the
heatervalvecablehousinginto the cableclamp.

www.emanualpro.com

22-53

A/C ServiceTips and Precautions

(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.

Alwaysdisconnectthe negativecablefrom the batterywheneverreplacingair conditioningparts.


Keepmoistureand dust out of the system.When disconnecting
any lines,plug or cap the fittings immediately;don't
removethe capsor plugs untiljust beforeyou reconnecteachline.
Beforeconnectingany hoseor line.applya few dropsof refrigerantoilto the O-ring,
Whentighteningor looseninga fitting,usea secondwrenchto supportthe matchingfitting.
When dischargingthe system,use a R l34a refrigerantrecovery/recycling/charging
station;don't releaserefrigerant
into the atmosphere.
Add refrigerantoil afterreplacingthe followingparts.
Notetheseitemswhen handlingrefrigerantoil:
o To avoidcontamination,
do not returnthe oil to the containeroncedispensed,and nevermix it with other refrigera n to i l s .
. lmmediatelyafter usingthe oil, replacethe cap on the container,and sealit to avoid moistureabsorption.
. Do not spill the refrigerantoil on the vehicle;it may damagethe painu if the refrigerantoil contactsthe paint,wash
it off immediately.
Condenser
. 25 ml (5/6 tl.oz, 0.9 lmp.oz)
Evaporator.,................................40
m/ 11113ll.oz,l.4lmp.ozl
Lineor hose...........
10 ml (1/3fl.oz,0.4 lmp.oz)
Receiver/Dryer.......
10 ml (1/3fl.oz,0.4 lmp.oz)
Leakagerepair............................
25 m/ (5/6ll.oz,0.9 lmp.oz)
Compressor.......,...,
For compressor replacement,subtract the volumg ol oil drained from the removed
compressorfrom 130 m{ (4 113tl.oz, 1,6lmp.ozl, and drain the calculatsd volume of
oif from the now comprossor:130 ml (,1113tl,oz, 1.6lmp'ozl - Volume of removed
compressor= Volume to drain from new compressor.
NOTE:Evenif no oil is drainedtrom the removedcompressor,don't drain more than
5 0 m t 1 12 1 3 l l , o z , 1 .l m
8 p . o zf)r o m t h e n e w c o m p r e s s o r .

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

O Dischargehos to the compressor{6 x 1.0 mml

....9.8 N.m 11.0kgrf.m.7.2lbtftl

@ Condenserline to the condenser(6 x 1.0 mm)


9.8 N.m {1.0 kgf.m, 7.2 lbt.ft)
@ Condensorline to the receiver/dryer{6 x 1.0 mm) ........
9.8 N.m {1.0kgf.m.7.2lbf.ft}
(6
...................
....
mm)
......
O Receiverline A to the receivor/dryer x 1.0
A
receive.
line
B
to
th
Receiver
line
@
O Rceivertine C to the receivorline B
9.8 N'm (1.0kgf.m,7.2lbtftl
@ Recoiverline C to the evaporator (6 x 1'0 mml
O Sustion line to the evaporatot 16x 1.0 mml
......31 N.m (3.2kgl.m, 23 lbf.ft)
@ Sustion line to the suction hose
.....'...'9 8 N'm (1 0 kgt'm, 7'2 lbf'ftI
@ Sucion hose to the qompressor(6 x 1.0 mm)
.. 24 N.m l2.il kgf'm, 17 lbf'ft}
@ Compressorto the compressorbracket {8 x 1.25mm) .
il,t N'm (4.5kgt'm, 33 lbf'ft)
.........
(10
1.25
mm)
................
x
@ Compressorbracket to the cylindsr block
,14N.m (/r.5kgf'm,33 lbf'ft)
(10
.....................
1.25
mm)
x
pulley
bracket
to
the
compressor
bracket
@ ldler
24 N'm (2./tkgt'm, 17 lbf'ft)
.........................
bracket
to
the
compressor
sdiusting
boh
Lock
nut
of
the
@
@|d|erpu||eytotheid|orpu||eybracket.....'..........................'.....'.....'........'....44N.m(4.5kg'
59 N'm (6.0kgt'm,/l:| lbf'ft1
@ compressorbracketto the left front mount (12x 1.25mml ................... ............................
www.emanualpro.com

22-55

A/G System Service


Performance
Test
The performancetest will helDdetermineif the air conditionersystemis operatingwithin specifications.

Recovory/Recycling/chargingstation

Useonly serviceequipmentthat is U.L.-listed


and is certified to meet the requirementsof SAEJ2210to remove
(R-134a)
HFC-134a
from the air conditionersvstem.
CAUTION: Exposure to air condiiioner rtrigerant and
lubricant vapor or mist can irritate yes, nose and
throat. Avoid bre8thing the air conditioner retrige.ant
and lubricant vapor or mist,
lf accidentalsystem dischargeoccurs.ventilate work
areabeforeresumingservice.
R-134aserviceequipmento. vehicleair conditionersystems should not be pressuretested or leak tested with
comDressed
air.
some mixturs ol air and R-134ahave becn
@
shown to be combuslible at olsvated pressuresand can
result in lire or explosion causing iniury or property
damage. Never use compressed air to prgssure test R13i[a service equipment or vehicle air conditioner sys.
tems.
Additional health and safety information may be obtained
from the refrigerant
and lubricantmanufacturers.
1 . C o n n e c ta R - 1 3 4 ar e f r i g e r a n tr e c o v e r / r e c y c l i n g /
chargingstationto the vehicle,as shown.following
instructions,
the equipmentmanufacturer's
2.

Insen a thermometerin the centerair vent. Determine


the relativehumidityand airtemperature.
Testconditions:
. Avoid directsunlight.
o Openhood.
. open front doors.
. Set the temperaturecontrol dial on MAX COOL,
the mode controldial on VENTand the reci.culation controlswitchon RECIRCULATE.
. Turn the A,/Cswitch on and the fan switch on
MAX.
. Runthe engineat 1,500rpm.
. No driveror passengers
in vehicle
After running the air conditioningfor 10 minutes
under the above test conditions,read the deliverv
temperaturefrom the thermometerin the dashvent
and the high and low systempressurefrom the Ay'C
gauges.

22-56

www.emanualpro.com

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

A/C System Service


PressureTestChart
NOTE: PerformanceTest is on page 22-56.
Test results
(high)
Discharge
pressure6bnormally
hagh

Dischargepressure
abnormallylow

Suction {low) pros,


sureabnormally

Suction pressure
abnormallyhigh

Slction and dis,


charge pressutes
abnormallyhigh

Suctionand dischargepressure
abnormallylow

Refrigerant
leaks

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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.

Line to condensoris excossivelvhot.

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

Expansionvalve is not frosted, and


low-pressure
lineis not cold.Lowpressuregaugeindicates
vacuum.
Dischargetemperatureis low, and the
air llow trom vents is restricted.

' Frozenexpansionvalve
lMoisture in system)
. Faultyexpansionvalve
Frozenevaporator

Expansionvalve is frosted.
Feceiver/dryeroutlet is cool, and inlot
rsw6rm (shouldbe warm during
operation).

Cloggedexpansionvalve
Cloggedreceiver/dryer

Low-pressurehose and checkjoint are


coolerthan tho temperature
around
evaporator.
Suction pressureis loworedwhen
condenseris cooledby water.
Highand low-pressure
are equalized
as soonas tho compressoris stopped,
and both gaugestluctuatewhile
running.
Reducedair flow throughcondensr,

. 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.

gasketis wet with oil.


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

CAUTION: Exposure to air conditioner refrigerant and


lubricant vapor or mist can irritate eyes, nose and
throat. Avoid brqathing the air conditioner retrigerant
and lubricant vapor or mist.
systemdischargeoccurs,ventilatework area
lf accidental
beforeresumingservice.
R-134aserviceequipmentor vehicleair conditionersystems should not be pressuretested or leak testedwith
compressedarr.
some mixtures of air and R-134ahave been
@@
shown to be combustible at elevated plessures and can
result in fire or explosioncausinginiury or property damage. Never use compressed air to pressure tect R-134a
serviceequipment or vehicleair conditionersystems.
Additionalhealthand safetyintormationmay be obtained
and lubricantmanufacturers.
from the refrigerant
' 1 . C o n n e c ta R - 1 3 4 ar e f r i g e r a n rt e c o v er y l r e c y c l i n g /
chargingstationto the vehicle,as shown,following
instructions
the equipmentmanufacturer's
2.

www.emanualpro.com

Measurethe amountof refrigerantoil removedtrom


the A,/Csystem after the recoveryprocessis comoleted.Be sure to installthe same amount of new
refrigerantoil backinto the AVCsystembeforecharginq.

22-59

A/C System Service


Evacuation
Use only serviceequipmentthat is U.L.-listed
and is certified to meet the requirementsof SAE J2210to remove
HFC-134a
{R-134a)from
the air conditionersystem.
CAUTION: Exposure to air conditioner refrigerant and
lubricant vapor or mist can irrhate eyes,noso and throat.
Avoid breathing the air condhioner retrigerant and lubricant vapor or mist.
lf accidentalsystem dischargeoccu.s. ventilate work
areabeforeresumingservice.
R 134aserviceequipmentor vehicleair conditionersystems should not be pressuretested or leaktested with
compressedarr.
some mixtures of air and R-134ahsvo been
!@
shown to be combustible at elevatedpressuresand can
result in tire or explosion causing iniury ot property
damage. Never use compressed air to pressure test R134a service equipment or vehicle air conditioner svstems.
Additionalhealthand safetyinformationmay be obtained
from the refrigerant
and lubricantmanufacturers.
1, When an A,/CSystemhas beenopenedto the atmosphere,such as during installationor repair,it must
be evacuatedusing a R-l34a refrigerantrecovery/
recycling/charging
station.{lf the system has been
open for severaldays,the receiver/dryer
should be
replaced,and the system should be evacuatedfor
severalhours.)
Connect a R-134arefrigerant recovery/recyclin
g/
chargingstationto the vehicle,as shown,following
t h e e q u i p m e n t m a n u f a c t u r e r ' si n s t r u c t i o n s .
Evacuatethe system,
lf the low-pressuredoes not reach more than 93.3
kPa (700 mmHg,27.6 in.Hg)in 15 minutes,there is
probablya leak in the system.partiallychargethe
system,and checkfor leaks(seeLeakTest).

22-60

www.emanualpro.com

Recovery/Recycling/Charging
Station

Charging

LeakTest

and is cerUseonly serviceequipmentthat is U.L.-listed


tified to meetthe requirementsof SAEJ2210to remove
(R-134a)
HFC-134a
from the air conditionersystem.

and is cerUse only serviceequipmentthat is U.L.-listed


tified to meetthe requirementsof SAE J2210to remove
(R-134a)
HFC-134a
from the air conditionersystem.

CAUTION:Exposureto air conditionerrefrigerantand


lubricant vapor or mist can irritate eyes, nose and
throat. Avoid breathingth air conditionerrefrigerant
and lubricant vapor or mist.

CAUTION: Exposure to air conditionor refrigerant and


lubricantvapor or mist can irritate eyes,nose and throat.
Avoid breathing the air conditioner retrigerantand lubricant vapor or mist.

lf accidentalsystem dischargeoccurs,ventilate work


a r e a b e f o r er e s u m i n gs e r v i c e .A d d i t i o n a lh e a l t ha n d
safetyinformationmay be obtainedfrom the relrigerant
and lubricantmanufacturers.

lf accidentalsystem dischargeoccurs,ventilate work


areabeforeresumingservice.

Connecta R-'134a
refrigerantrecovery/recycling/charging
stationto the vehicle,as shown.followingthe equipment
manufacturer'sinstructions.
Station
Rcovery/Recycling/Charging

R-134aserviceequipmentor vehicleajr conditionersystems should not be pressuretested or leak testedwith


compressedarr.
some mixturos of air and R-1348 have
!@
been shown to be combustible at olovatod pres3uras
and can result in fire or explosion causing iniury or
property damage.Never use comprelisedair to pressure
test R-13ilaservice equipment or vehicle air conditioner
systems.
Additionalhealthand safetyinformationmay be obtained
from the refrigerantand lubricantmanufacturers.
1 . Connect a R-134arefrigerant recoverylrecycling/
chargingstationto the vehicle,as shown in the previous column,followingthe equipmentmanufacturer's instructions.
2.

Open the high-pressure


valve to chargethe system
t o t h e s p e c i f i e dc a p a c i t y ,t h e n c l o s e t h e s u p p l y
valve,and removethe chargingsystemcouplers.
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.
Refrigerantcapacity:700 to 750 g
0.70to 0.75kg
1.5to 1.6lbs.
21.7 to 26.5 oz.

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.

Checkthe systemfor leaksusing a R-134arefrigerant leak detectorwith an accuracyof 14 g (0.5 ozl


per year or better.

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.

lf you find leaksthat requirethe systemto be opened


(to repair or replacehoses,fittings, etc.), recoverthe
system accordingto the RecoveryProcedureon page
22-59.

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.

www.emanualpro.com

5.

After checkingand repairing leaks,the system must


be evacuated(seeSystemEvacuationon page22-601.

22-61

Compressor
Replacement
'L

lf the compressoris marginally operable.run the


e n g i n e a t i d i e s p e e d ,a n d l e t t h e a i r c o n d i t i o n e r
work for a few minutes.then shut the engineoff.

2.

Disconnect
the negativecablefrom the battery.

5.

Removeeach bolt, then disconnectthe suctionand


dischargelines from the compressor.Plug or cap
the lines immediatelyafter disconnectingthem to
avoid moistureand dust contamination,
6x1.0mm
9.8 N.m 11.0kgf.m,7.2 lbf.ft)

Recoverthe refrigerantwith a recovery/recycling/


chargingstation(seepage22-59).
Disconnectthe condenserfan connector.Remove
the compressorclutch connectorand the wire harness clip from the condenserfan shroud,then disconnectthe compressorclutch connector.Remove
the mountingbolts and the condenserfan shroud,

CONDENSER
FAN
CONNECTOR

6x1.0mm
7 N.m 10.7kg{.m,5 lbl.ftl

LINE

LINE
DISCHARGE

6.

Removethe power steeringpump belt (seesection


17t.

7.

Loosenthe pivot bolt of the idler pulleybracketand


the adiusting bolt, then remove the Ay'Ccompressor
b e l t f r o m t h e p u l l e y s .l f n e c e s s a r y r, e m o v e t h e
mountingbolts from the left front mount,then
remove the A,/Ccompressorbelt through the gap
betweenthe bodv and the left front mount.
PIVOTBOLT
10 x 1.25mm
AIUUSTING 4,t N.m (4.5 kgf.m, 33 tbf.ftl

10x 1.25mm
/t4 N.m (4.5kgl.m,33 lbtftl

www.emanualpro.com

tFT
FRONT
MOUltlT

COMPRESSOR
BELI

8.

Removethe mountingboltsand the compressor.

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

lf necessary,remove the compressor bracket as follows.


.

Remove the nut and the washer from the left


front mount. When tighteningthe nut to the left
front mount,makesurethe washeris set properly on the leftfront mount as shown.

1 1 . lnstallin the reverseorderof removal.Make note of


the followingitems,
.

Removethe mountingbolts and the compressor


12 x 1.25mm
bracket.
59 N.m (6.0 kgt'm,

.
.

.
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.)

www.emanualpro.com

22-64

ClutchInspection
Checkthe plated parts of the armature plate for color
changes,peelingor other damage.lf there is damage,replacethe clutchset.

Releasethe field coil connectorfrom the holder,then


disconnectit. Checkthe thermal protectorfor continuity, lf there is no continuity, replacethe thermal
prorecror.

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

Measurethe clearancebetweenthe rotor pulley and


the armature plate all the way around. lf the clearanceis not within specifiedlimits,the armatureplate
must be removed and shims added or removed as
required,following the procedureon page 22-66.
Cloarance:0.5 t 0.15 mm {0.020t 0.q)6 in)

NOTE:The thermal protectorwill have no continuity


above 251.6to 262.4"F1122to 128"C).When the temperaturedrops below 240.8to 219.8"F(116to 104'C),
the thermalprotectorwill havecontinuity.
Checkresistance
of the field coil.
Field Coil Resistance:3.2 i 0.15 ohms at 68"F {20'C)
lf resistanceis not within specifications,
replacethe
field coil.

NOTE:The shims are availablein four thicknesses:


0.1 mm. 0.2 mm. 0.4 mm and 0.5 mm
ABMATUBE

www.emanualpro.com

22-65

Compressor
GlutchOverhaul
1.

Removethe centernut while holdingthe armature


platewith the tool.
CENTERNUT
17.6N.m ('1.8kgf.m, 13lbfft)
A,/CCLUTCHHOLOER
Reolace.
\
lCommerciallY.vailable)
Robinair:P/N 1020,0
Ked-Mooro: P/N J37872
i

2.

Removethe armatureplateby pullingit up by hand.


ARMATUREPLATE

sHtMls)
Replace.

za:s
(i@,

22-66

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3.

Removethe snap ring B with snap ring pliers. Be


careful not to d8mage the rotor pulley and compressor.

SNAPRINGB
R6place.

Remove the rotor pulley from the shaft with the


tools.Be surethe clawsot the pullerare on the back
of the rotor pulley,not on the belt area;otherwise
the rotor pulleycan be damaged.

l5.

Removethe bolt and holder,and screw and clamp.


then disconnectthe field coil connector.Remove
the snap ring A with snap ring pliers,then remove
the field coil. Be carefulnot to damagethe field coil
and comoressor.

6.

Positionthe rotor pulleysquarelyover the field coil.


Pressthe rotor pulley onto the compressor boss
with the specialtool. lf the rotor pulley does not
press on straight, remove it, and check the rotor
pulleyand compressorbossfor burrsor damage.
CAUTION: Maximum pre3s load: 39,200 kPa
(400kgf/cm,, 5,690psi)

+
Press

FIELDCOIL
CLAMP

HUB ASSEMBLY
GUIDEATTACHMENT
07966 - 6920500
ROTOR
PULLEY

HOLDER

GROUND
TERMINAL
7,a N.m
10.75kgt'm,
5 tbt ftl

7.

Reassemblethe comDressorclutch in the reverse


order of disassembly.Make note of the following
rrems.
Installthe field coil with the wire side facing down,
and alignthe bosson the tield coilwith the holein
the compressor.
C l e a nt h e r o t o r p u l l e ya n d c o m p r e s s o sr l i d i n g
surfaceswith non-oetroleum
solvent.
a lnstallnew snap ringsA and B.
a Make sure the snap rings are fully seatedin the
groove.
Make sure that the rotor pulley turns smoothly
afterit's reassembled.
Routeand clamp the wires properlyor they can
be damagedby the rotor pulley.

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Compressor
ThermalProtectorReplacement
1.

Removethe bolt,the groundterminaland the holder. Disconnectthe field coil connector.then remove
the thermalDrotector.

ReliefValveReplacement
l.

Recoverthe refrigerant with a Recovery/Recycling/


ChargingSystem(seepage22-59).
Removethe reliefvalvecover ('97 model),the relief
valve and the O-ring.Plug the openingto keepforeign matterfrom enteringthe systemand the compressoroil from runningout.

7.4 N.m (0.75kgrf.m,5lbfftl


GROUND
TERMINAL

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.

lnstallin the reverseorderof removal.

www.emanualpro.com

22-68

Chargethe system (see page 22-61),and test its


performance(seepage 22-561r.

A/C CompressorBelt
Adjustment
Detlection Method
1.

Apply a force of 98 N (10 kgf, 22 lbfl, and measure


the deflectionbetweenthe A,/CcomDressorand the
crankshaftpulley.
A/C CompressorEelt
UsedBeh:7.5- 10.5mm (0.30- 0.41inl
New Belt: 5.0 - 7.0 mm (0.20- 0.28 in)
Notetheseitemswhen adjustingbelttension:
. lf there are cracksor any damageevidenton the
belt,replaceit with a new one.
. "Used belt" means a belt which has been used
for five minutesor more.
. "New belt" means a belt which has been used
for lessthan five minutes.

Loosenthe pivot bolt of the idler pulleybracketand


the locknutofthe adjustingbolt.
Turn the adjustingbolt to get properbelttension,
Retightenthe pivot bolt of the idler pulley bracketand
the locknutofthe adiustingbolt.

Tension Gauge Method


1.

Attachthe specialtool to the Ay'Ccompressorbelt as


shown below,and measurethe tensionof the belt.
A/C ComoressorBelt
Used Belt; 390 - 540 N (40 - 55 kgf, 88 - 120 lbtl
New Belt: 740 - 880 N (75 - 90 kgf, 170- 200 lbt)
Notetheseitemswhen adjustingbelttension:
. F o l l o wt h e m a n u f a c t u r e r 'isn s t r u c t i o n fso r t h e
belttensiongauge.
. lf there are cracksor any damageevidenton the
belt,replaceit with a new one.
. "Used belt" means a belt which has been used
for five minutesor more.
. "New belt" means a belt which has been used
for lessthan five minutes.

BELTTENSIONGAUGE
07JGG- 00't010A

Loosenthe pivot bolt of the idler pulley bracketand


the locknutofthe adjustingbolt.
Turn the adjustingbolt to get properbelttension.

Recheckthe deflectionof the A,/Ccompressorbelt,


Retightenthe pivot bolt of the idler pulley bracketand
the locknutofthe adjustingbolt.
Recheck
the tensionof the A,/Ccompressorbelt.

www.emanualpro.com

22-69

Gondenser
Replacement
't. Recoverthe refrigerantwith a recovery/recycling/

6.

chargingststion(seepage22-59)
Removethe front grille (seesection20).

Removethe mounting bolts,then removethe condenserby lifting it up as shown. Be carefulnot to


d a m a g e t h e r a d i a t o r a n d c o n d e n s e rf i n s w h e n
removingthe condenser.

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.

Installin the reverseorderof removal.Make note of


the followingitems.
.
o

l/

a
it--:

.
.

i..

LINE
DISCHARGE

CONDENSRLINE

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22-70

lf you'reinstallinga new condenser,add refrigerant oil (sP-10)(see page 22-54]..


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 f 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
Be careful not to damagethe radiatorand condenserfins when installingthe condenser.
Be sure to install the lower mount cushionsof
condensersecurelyinto the holes,
Chargethe system(seepage 22-61),and test its
performance(seepage22-56).

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.

Beforeconnectingconnectors,make sure the terminalsare in placeand not bent.

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.

Checkfor looseretainersand rubberseals.

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.

After installingharnessclips, make sure the harness


doesn'tinterferewith any moving pans.
Keep wire harnessesaway from exhaustpipes and
other hot parts, trom sharp edges of bracketsand
holes.and from exoosdscrewsand bolts.

Seatgrommetsin their groovesproperly.

NOT GOOD

Face
openend

Handling Wires and Harnesges


. Securewires and wire harnessesto the frame with
wire ties at the designatedlocations.
their respective
. Removeclipscarefully;don't damagetheir locks.

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lr

-M/

lr*

Tsting and Repairs


. Do not usewires or harnesses
with brokeninsulation.
Replacethem or repairthem by wrappingthe break
with electricaltape.
. A f t e r i n s t a l l i n gp a r t s ,m a k e s u r e t h a t n o w i r e s a r e
pinchedunderthem.
. W h e n u s i n g e l e c t r i c a tl e s t e q u i p m e n t ,f o l l o w t h e
manufacturer'sinstructionsand those describedin
t h i sm a n u a l .
. lf possible,insert the probe of the tester from the
wire side (exceptwaterproofconnector).

Usea probewith a taperedtip.

Referto the instructionsin the HondaTerminalKit for


i d e n t i f i c a t i o an n d r e p l a c e m e not f c o n n e c t o rt e r m i nals.

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.

lsolateThe ProblemBy TestingThe Circuit


Make circuitteststo checkthe diagnosisyou made
in step 2. Keepjn mind that a logical,simple procedure is the key to efficienttroubleshooting.
Test for
the most likely cause of failure first. Try to make
testsat pointsthat are easilyaccessible,
FixThe Problem
Once the specificproblem is identified,make the
repair.Be sure to use propertools and safe procedures.
MakeSureThe CircuitWorks
Turn on all componentsin the repairedcircuitin all
modes to make sure you've fixed the entire problem. lf the problem was a blown fuse, be sure to
test all of the circuitson the fuse.lvlakesure no new
problemsturn up and the originalproblemdoes nol
recur.

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

Relayand ControlUnit Locations


EngineCompartment
ELECTRICAL
LOADDETECTOR
IELDI

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

www.emanualpro.com

23-6

RADIATOR
FAN EELAY

Dashboard

PGM.FIMAIN RELAY

MOTORHIGHRELAY
BLOWER
lwir. colorc:BLK/YEL,
I
ORN/WHT,.ndBLKI
LBLU/BLK,

www.emanualpro.com

23-7

Relayand GontrolUnit Locations


Dashboard(cont'd)

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,

STARTERCUT RELAY{'98 - 00 modelsl


IWir6 color3:BLK/WHT,BLK^ UHT,I
STARTEnCUTRELAYl7 modll
I
lGRY,.nd BLx/nED
lwire colors:BLK/WHT,BLK/WHY,l
I
IGRY,and BLK/RED
HORNFELAYl'98 - 00 modcb)
lwire coloF: WHT/GRN,
l
LWHT/GRN,GRY,and BLU/REDI

{cont'd)

www.emanualpro.com

23-9

Relayand ControlUnit Locations


Dashboard(cont'd)and Door

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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Gonnectorldentificationand Wire HarnessRouting

How to ldentity Connectors:


"C" for connectors.
The numberis precededby the letter
numbershavebeenassignedto all connectors,
ldentification
"G" for groundterminalsor "T" for non-groundterminals.
Location
Harness

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

Main wire harness

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

Driver'sdoor wire harness

C661throughC667

door wire harness


Frontpassenger's

C6Tl throughC676

Left reardoor wire harness

C681throughC684

Rightreardoor wire harness

C69'lthroughC694

Rearwire harness

C611throughC520

Tailgatewire harness

C631throughC634
G631

SRSmain harness

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Others lFloor, Door,


8oof, Tailgate)

C801throughC808
G801

High mount brakelight sub-harness

C651throughC653

Fueltank oressuresensorsub-harness

C645throughC647

Connectorldentificationand Wire HarnessRouting

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

Battery Ground Cable


Connoctoror
Terminal

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

Rightside of front frame

Body ground,via transmission


groundcable

Notes

Under-hoodABS Fuse/RelayBox Wire Harnsss


Conn6storor
Terminal

Numberof
Cavities

Location

Connoctsto

tc

Rightside of enginecompartment

Under-hoodABS tuse/relavbox

Battery

88tterypositiveterminal

23-12

www.emanualpro.com

Notos

STARTERCABLE
ABS FUSE/RELAY
UNDER-HOOD
BOX WIREHARNESS
@

EATTERY
GROUND
CABLE

ENGINEGROUND
CABLE
TRANSMISSIONGROUND
CABLE

www.emanualpro.com

23-13

Connectorldentificationand Wire HarnessRouting

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

Main wire harness(C304)


- 98 models
Mainwire harness(C305):'97
No. 1 fuel injector
Crankshaftspeedfluctuation(CKF)sensor
Alternator
Alternator
Engineoil pressureswitch
No.2 fuel injector
Evaporative
emission(EVAP)purge
controlsolenoidvalve
No. 3 fuel injector
No. 4 fuel injector
Primaryheatedoxygensensor
(PrimaryHO2S)(sensor1)
Radiatorfan switch
Coolanttemperaturesendingunit
Enginecoolanttemperature(ECT)sensor
Mainshaftspeedsensor
Lock-upcontrolsolenoidvalve
Back-uplight switch
Shift controlsolenoidvalve
Linearsolenoidvalve
Countershaftspeedsesnsor
Startersolenoid
Distributor
Junctionconnector
PCM
ECIWPCM
ECM/PCM
ECM/PCM
Main wire harness(C,|:}1)
IVT gear positionswitch
Vehiclespeedsensor(VSS)
Throttleposition(TP)sensor
MAP sensor
ldleair control(lAC)valve
lntakeair temperature(lAT)sensor
Junctionconnector
Junctionconnector

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

Leftsideof en0inecompanment Alternator


Rightsideof enginecompartment Under-hoodfuse/relaybox

G101

Middle of engine

23-14

A/r
USA
Canada

Alr
AlT

M/'r
Afi

'97 mooel

'97 model
'98 - 00
mooets

Leftsideof enginecompartment Powersteeringpressure(PSP)switch


Middleof engine
Junctionconnector
Middleof engine
Knocksensor(KS)

T101
r102

www.emanualpro.com

Notos

Engineground,via enginewire harness

'99 - 00
models

c1733
clsl gra,

c103
c137
T101

c104

c112
ENGINEWIREHARNESS

cl13

cl' l1

23-15

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lrffiltEfinl,

Gonnectorldentificationand Wire HarnessRouting

EngineCompartment Wire Harness


Connectorol
Terminal

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

Leftside of enginecompartment Main wire harness(C307)


Leftside of enginecompartment Cruiseactuator
Behindfront bumper
Rearwindow washermotor
Behindright headlight
Leftfront turn signal/sidemarkerlights
Behindfront bumper
Windshieldwashermotor
Behindright headlight
Leftfront parkinglight
Leftsideof enginecompartment Condenserfan motor
Leftsideof enginecompartment Frontfog lights
Leftsideof enginecompartment IVC compressorclutch
Behindleft headlight
Left headlight
Leftsideof enginecompartment IVC pressureswitch
Behindfront bumper
Left horn
Behindfront bumper
Righthorn
Rightside of enginecompartment Radiatorfan motor
Behindright headlight
Rightheadlight
Behindright headlight
Rightfront turn signal/sidemarker
lights
B e h i n dr i g h th e a d l i g h t
Rightfront parkinglight
Rightsideof enginecompartment Main wire harness1C357)
Rightsideof enginecompadment Main wire harness(C357)
Rightsideof enginecompanment Bodyground,via enginecompartment
wire harness
Leftside of enginecompartment
Bodyground,via enginecompartment
wire harness

Notes

Optional

'97 - 98
models
'99 - 00
mooets

ENGINECOMPARTMENT
WIREHARNESS

c212

c211

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23-17

Gonnectorldentificationand Wire HarnessRouting


Main Wire HarnesslEngine compartmont left and right branches)
Connectot ol
Terminal

Number ot
Cavities

c301

c303
c304
c305

2
10

c306
c307
c308
c309

c356
c357

c358
c359
c360
LJO

G35l

23-18

www.emanualpro.com

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}

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23-19

Connectorldentificationand Wire HarnessRouting


Main Wire Harnss(left side of dash and floor branchesl{cont,dl

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)

Underleft side of dash


Underleft side of dash
Underleft sideof dash
Underleft side of dash
Underleft side of dash
Underleft side of dash
Underleft sideof dash

Cruisecontrolunit
Daytimerunninglightscontrolunit
Daytimerunninglightscontrolunit
lgnitionkey light controlunit
Interiorwire harness{C701)
Cablereel
Cablereel

Underleft side of dash


Underleft side of dash
Underleft sideof dash

c413

Underleft side of dash

c414
c415
c416
c416
c417
c418
c419
c420

Underleft side of dash


Underleft side of dash
Underleft side of dash
Underleft sideof dash
Underleft side of dash
Underleft side of dash
Underleft sideof dash
Underleft side of dash

10
'1
18
20
'18
10

c420
c421
c422
c423
c424
c425
c42A
c426

15
1
4
8
5
5

Underleft side of dash


Underleft sideof dash
Underleft side of dash
Undermiddleof dash
Undermiddleof dash
Undermiddleof dash
Undermiddleof dash
Undermiddleof dash

c437
c438

22

Underleft side of dash


Underleft side of dash

c438
c439
c440
c441
c442

Underleft side of dash


Underleft side of dash
Underleft sideof dash
Underleft sideof dash
Underleft side of dash
Underleft side of dash
Underleft side of dash
Underleft sideof dash
Underleft side of dash
Underleft side of dash
Underleft side of dash

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

c115 cla6 c+to


"n,

dn' cntt

I
--r F -'L-1al 1l}a]
a

UNDER-DASH
FUSE/BELAYBOX

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-n-rrr---rrr

-:/l
-

Connectorldentificationand Wire HarnessRouting

Main Wire Harness{Right side of dash and floor branchesl{cont,dl


Connector or
Tsrminal

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

Underright side of dash

Body ground,via main wire harness

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

Connectorldentificationand Wire HarnessRouting


DashboardWire Harness
Connectorol
Terminal

Numbr of
Cavities

c501
c501
c502
c503
c504
c505

10
1
20

c506
c507
c508
c509
c510
c511
c512
c514

14

Main wire harness(C416)


Main wire harness(C416)
Under-dashfuse/relaybox 1C912)
Main wire harness(C415)
Hatchglassopenerswitch
Left side wire harness(C556)

16

Above under-dashfuse/relaybox

Leftsidewire harness(C556)

Left side of steering wheel


Left side of steering wheel
Underleft side of dash
Behindgauges
Behindgauges
Behindgauges
Behindgauges
Behindgauges
Rightside of gauges
Behindmiddleof dash
Behindmiddleof dash
Behindmiddleof dash
Undermiddleof dash
Undermiddleof dash
Behindmiddleof dash
Behindmiddleof dash
Behindmiddleof dash
Behindmiddleof dash
Behindmiddleof dash

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

Bodyground,via dashboardwire harness

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

Connectorldentificationand Wire HarnessRouting

Left Side Wire Harness


ConnectoroI
Terminal

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

Driver'sdoor wire harness(C661)


Main wire harness(C403)
Main wire harness(C404)
Main wire harness(C404)

c560

)
1
5

Left side offloor


Leftquanerpanel
Fueltank
On left half of rearcrossbeam
On left half of rearcrossbeam

Driver's seat belt switch


Left rear door switch
F u e lu n i t
Left rearABS wheelsensor
Left rearABS wheelsensor

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

Bodyground,via left sidewire harness


Bodyground,via left sidewire harness
Body ground,via left sidewire harness

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

c553 c5:6 c5J5

C561 C565 C566


LEFTSIDEWIREHARNESS

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23-27

Gonnectorldentificationand Wire HarnessRouting

Right Side Wire Harness


Connec{oror
Tsrminal

Numberof
Cavities

c601
c602
c603
c604

6
'1

Location

Conneststo

Behindright kickpanel
RightB-piller
Rightreardoor
Undermiddleof dash

Main wire harness(C428)


door switch
Frontpassenger's
Rightreardoor wire harness(C691)
SRSmain harness{C808)

R i g h tB - p i l l e r

seatbelttensioner
Frontpassenger's

Notes

'98 - 00
mooets
'98 - 00
models

Rear Bumper Wire Harness


Connectorol
Terminal

c641
c642
c643

Number ot
Cavities
4
2
2

Location
Leftquarterpanel
Behindrearbumper
Behindrearbumper

FuelTank PressureSensor Sub-harnessConnectoror


Terminal

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

High Mount Brake Light Sub-harnoss


Conneslor or
Terminal

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

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23-29

Gonnectorldentificationand Wire HarnessRouting

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

Bodyground,via rearwire harness

6
1

G611

Notes

Tailgate wire Harness


Connestoror
Terminal

c633
c634

23-30

www.emanualpro.com

Numberof
Cavities

2
2
1

Location

Connectsto

Rightquarterpanel
Middleof tailgatedoor
Leftsideof tailgatedoor
Middleof tailgatedoor

Rearwire harness(C613)
Hatchglassopenersolenoid
Licenseplatelight
Hatchglasslatchswitch

I/iddle of tailgatedoor

Body ground,via tailgatewire harness

Noles

TAILGATEWIREHARNESS

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23-31

Connectorldentificationand Wire HarnessRouting

Drivsr's Door Wire Harness


Connectoror
Terminal

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

Front Pa$enger's Door Wire Harnsss


Connectoror
T6rminal

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,-

Left Rear Door Wile Harness


Conneclor or
Trminal

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

Right Real Door Wire Harness


Connectoror
Terminal

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

Connectorldentificationand Wire HarnessRouting

lntglior Wire Harness


Connectoror
Terminal

Numbr of
Cavities

Location
Underleft sideof dash
Roofarea
Roofarea

c701
c702
c703

Connoct3lo

Notes

Main wire harness(C409)


Frontceilinglight
Spotlights

SocondaryHeatedOxygen Sensor Sub-harflss


Connoqto. ol
Tarminal

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

Connectorldentificationand Wire HarnessRouting

Hoat6rSub-harness
Connectoror
Tgrminal

Numbsrot
Cavities

c73']
c731

5
7

Undermiddleof dash
Undermiddleof dash

Main wire harness{C436)


Main wire harness(C436)

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

Combination Switch Sub-harness


Conneqtor ol
Terminal

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

Underleft sideof dash

Main wire harness(C413)

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)

Underleft side of dash

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

Connectorldentificationand Wire HarnessRouting

SRS Main Haln93s

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

Main wire harness{C414)


Cablereel
Frontpassenger's
airbag
SRSunit
Leftsidewire harness(C578)

c808

Undermiddleof dash

Rightsidewire harness(C604)

G801

Middleof floor

Bodyground,via SRSmain harness

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-

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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

lTo blower motor releyl

lTo condensrtan .slayl

c903
lTo radiator ten relavl

.: Not used

NOTE:View from the backsideof the under-hoodfuse/relaybox.

c306
fTo main wiro hamose(C352ll

c305
lTo mainwiie harnes lc353ll

lTo main wirc harness1C354)l

23-40

www.emanualpro.com

lTo main wire harnesslC351ll

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

- r-l n rT n Tl r-l ri n Fl r-'l r-l


12 13

1a

16

t5

11 1a 19

20

21 22

L-] [J LI LI I.J I.J tJ tJ TJ LI LI IJ


- Fn Fl F1 r-'l T1 r;l r-l r-t r;l |-] r-l
|

a; Canada

c9r6
[Topowe.windowrelay]

LI I.J LI LJ tJ LJ IJ LI I.J IJ IJ tJ

i -': C927loption {ACCll


C928lOption (lG2)l
141:

lTo rear window defoggerrelayl

NOTEr View from the backside of the under-dash tuse/relay box.

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

lTo under-hoodABS fus6/r6lay box wire harnessl

c931

c933

lTo main wire harness1C359)l

lTo ABS pump moto. relayl

c932

lTo main wire harness(C360)l

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)

Under-hoodABS Fuss/nehy Box:


Fusg

Capacity

61

40A
204
7 . 5A

Wire Color

Circuitls) Protoct

WHT
WHT/GRN
BRN/YEL

ABS pump motor {via relay}


ABS controlunit
ABS controlunit

{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

Component or Circuits Grounded


Battery
ValveCover
Transmissionhousing
A,/Tgear position switch
ECM(PG1,PG2)('98- 00 models:M/T)
PCM(PG1,PG2l(Avrr)
PGM-FImain relay
Powersteeringpressure(PSP)switch
Radiatorfan switch
VSS
Datalinkconnector
ECM(1G1,LG2)('98- 00 models:M/T)
PCM(LGI, LG2)(IVT)
Shielding:
between ECM ('98 - 00 models: M/T) or PCM (Ay'T)and CKFsensor
betweenECM{'98- 00 modets:M/T}or pCM (Ay'T)
and CKpsensor
between ECM ('98 - 00 models: M/T) or PCM (rVT)and CYPsensor
betweenECM ('98 - 00 models: M/T) or PCM (Ay'T)and TDC sensor
between ECM {'98 - 00 models: M/T) or PCM (ly'T)and countershaftspeed sensor (Ay'T)
between ECM ('98 - 00 models: M/T) or PCM{A,,/T)
and mainshaftsped sensor {!VT)
between ECM ('98 - 00 models: M/T) or PCM(A,/T)and primary HO2S
between ECM ('98 - 00 models: M/T) or PCM(Ay'T)and secondaryHO2S
H o r n( H i g h )
Horn {Low}
Radiatorfan motor
R i g h th e a d l i g h t
Rightfront parkinglight
Rightfront side markerlight
Rightfront turn signallight
Condenserfan motor
Cruiseactuator
Leftfront parkinglight
Leftfront side markerlight
Leftfront turn signallight
Leftheadlight
Rearwindow washermotor
Windshieldwashermotor
ABS pump motor

Ground

Wir Color

G401

BLK

G402

BLK

Component or Circuits Grounded


ABS indicatorcircuit
ABS controlunit
Ashtraylight
A/T gear positionindicatordimmingcircuit
Brakefluid levelswitch
Clock('98- 00 models)
Clutchinrerlockswitch(M/T)
Clutchswitch(Mff)
Cruisemain switch
Cruiseindicatorcircuit
Cruisecontrolunit
Dashlightsbrightnesscontroller
Dataiink connector
Daytimerunningrightscontrolunit (Canada)
Front accessarysocket
Gaugeand indicators
Heatercontrolpanel
lgnitionkey light controlunit ('97model)
lgnitionkey switch
Integratedcontrolunit
Interlockcontrol unit (Ay'T)
Parkingpin switch{A,/T)
Powerwindow relay
socketrelay
Rearaccessary
Bearwindow defoggerrelay
Rearwindow wiper controlunit ('97model)
Servicecheckconnector
Spotlights
SRSindicatorcircuit
relay
Turn signal/hazard
Windshieldwiper motor
Windshieldwiper/washerswitch
- plus everythinggroundedthrough G402
ABS controlunit
Blowermotor relay
Blowermotor high relay
E L Du n i t( U S A )
Powertransistor
- plus everythinggroundedthroughG401

{cont'd)

www.emanualpro.com

23-47

GroundDistribution
Ground-to-Component(sl
Index(cont'dl
Ground

Wire Color

G501

BLK
BLK

G552

BLK

BLK

BLK

BLK
G801

www.emanualpro.com

23-48

BLK

Component or Circuits Grounded


Audio unit
Driver'sdoor lockactuator(doorlockknob switch)
Driver'sdoor lockswitch
Driver'spowerwindow motor
Keylessdoor lockcontrolunit ('98- 00 models)
Powerdoor lockcontrolunit
Powermirror switch
Powerwindow masterswitch
Driver's seat belt switch
F u e lg a u g es e n d i n gu n i t
Fuelpump (FP)
Leftrearside markerlight
Lefttaillight
Rearaccessary
socket
Rightrearside markerlight
Trailerlightingconnector
High mount brakelight
Rearwindow defogger
Rearwindow wiper motor
Rjghtaillight
- plus eveMhing groundedthroughG631
Hatchglassopenersolenoid
Licenseplatelight
- plus eveMhing groundedthroughG6l1
SRSunit

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.

lnstallthe knee bolsterand the driver'sdashboard


lower cover(seesection20).

3.

Connectthe batterypositivecable,then connectthe


negativecable.

4.

Enterthe anti-theftcodefor the radio,then enterthe


customer'sradiostationpresets(with anti-thettfeature).

5.

Confirmthat all systemswork properly

Removal:
1.

Makesureyou havethe anti-theftcode for the radio,


then write down the frequenciesfor the radio'spreset buttons(with anti-theftfeature).

2.

Disconnectthe batterynegativecable,then disconnectthe positivecable,and wait at leastthree minutes.

3.

4.

Removethe driver'sdashboardlower cover and the


kneebolster(seesection20).
Removethe two mountingnuts,and pull the underdashfuse/relaybox out from underthe dash

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
.
.

burns if it gets on your skin or in your eyes. Wear


protective clothing and a fac6 shield.
- lf elestrolyte gets on your skin o. clothos, rinse it otf with wator immdiately.
- lf leqtrolyte gets in your eyes.tlush it out by splashing water in your syes for at least 15 minutes;
call a physician
immediately.
A battery gives off hydrogon gas. lf ignited, the hydrogen will xplode and could crack the battery case and splattr
acid on you. Kgop sparks.flamss, and cigarettesaway from the battry,
Overchargingwill raise the tomperatute of the electrolyte.This may torcs electrolyto to spray out of the battEry vents,
Follow the charger manutacturer'sinstructions, and chargethe battery at a proper ral,

Use eithera JCI or BearARBSTtester,and follow the manufacturer's


procedures.lf you don't have one of tnesecomputerizedtesters,follow this conventionaltest procedure:
To get accurateresults,the temperatureofthe electrolytemust be between70.F(21.c)and loo"F (38"c).

lf the caseis crackedor the terminalsare roose.


replacethe batterv.

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

(},

Chargeon High Setting(40amps)


Chargeuntil EYEshowschargeis OK,plus an additional30 minutesto
assureJullcharge.
to bypass
NOTE:lf the batterychargeis very low, it may be necessary
the charger'spolarityprotectioncircuitry.
lf the EYEdoes not show chargeis OK within three hours,the batteryis
no-good;replaceit. Writedown how long the batterywas charged.

Test Load Capacity(#2)


.
.
.
.

Apply 300amp load for 15 secondsto removesurfacecharge.


Allow 15 Secondsrecoveryperiod,
Applytest load (seeTest LoadChart).
Recordvoltageat the end ot 15 seconds.

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:

Checkfor continuitybetweenthe terminats.


. Thereshouldbe continuitybetweenthe No. I and
No. 3 terminalswhen power and groundare connectedto the No. 2 and No. 4 terminals.
. Thereshouldbe no continuitybetweenthe No. 1
and No. 3 terminalswhen power is disconnected.

Terminal

t"""r f*r

t*i__\

Disconnected
Connected

o
type 2i

a Blowermotor high relay


a Rearaccessory
socketrelay(M/T)
a l

Itrrz-Hl
llHrrUll
Y:F,

' , 3

ffi
23-52

www.emanualpro.com

a l

Normally-opentype:

Normally-opentype:
1.

Checkfor continuitybetweenthe terminals.


. Thereshouldbe continuitybetweenthe No. 1 and
No. 2 terminalswhen power and groundare con
nectedto the No.3 and No. 4 terminals
. Thereshouldbe no continuitvbetweenthe No. 1
and No. 2 terminalswhen power is disconnected.

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

Checkfor continuitybetweenthe terminals.


. Thereshouldbe continuitybetweenthe No. 4 and
No.3 terminalswhen power and groundare connectedto the No. 1 and No. 2 terminals.
. Thereshouldbe no continuitybetweenthe No. 4
and No. 3 terminalswhen power is disconnected.

Connected

ABS pump motor relay

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,

SRS componentsare located in this area. Review the


SRScomponentlocations,precautions,and procedures
in the SRSsection{24)beforeperformingrepairsor service.

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.

Removethe driver'sdashboardlower coverand the


kneebolster(seesection20).

4.

Disconnectthe 5P connectorfrom the under,dash


tuse/relaybox and the 3P connectorf.om the main
wire harness{seeleft column).
R e m o v et h e s t e e r i n gc o l u m n c o v e r s( s e es e c t i o n
'17
t.
Insertthe ignitionkey,and turn it to "0".

7.

Removethe two screws and the electricalswitch


from the steeringlock,

5P CONNECTOR

Wiresideof
temaleterminals
Checktor continuitybetweenthe terminalsin each
switchpositionaccordingto the table.
rernrnal I

\
ros[ron

I3l

(ACC) {BAT} flG1) 0G2i

I1l

swrTcH

lsrl

LOCKCYLINDER

0 (LocK)

r(Accl

o- -o

fl (oN)

III(START)

o-

_o
-.o

{ I | 3Pconnector

7.

lf the continuitychecksdo not agreewith the table,


replacethe electricalswitch.
After reconnectingthe battery,enter the anti-theft
code for the radio,then enter the customer'sradio
stationpresets(with anti-theftfeature).

www.emanualpro.com

23-54

lnstallin the reverseorderof removal.


9.

After reconnectingthe battery,enter the anti-theft


code for the radio,then enter the customer'sradio
stationpresets(with antj-theftfeature).

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

www.emanualpro.com

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 ENGINEOIL PRESSURE


INDICATORLIGHT{1./rW}
MALFUNCTION
INOICATOR
LAMP {MIL)
BULBI1.4WI

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.

Removethe instrumentpanelcarefullyto avoiddamagingthe clips.

3.

Tilt the steeringwheeldown with the tilt adjustmentlever.

4,

Spreada protectivecloth over the steeringcolumn.

5.

Removethe four mountingscrewsfrom the gaugeassembly.

6.

Pullthegaugeassemblyout, and disconnectall connectorsfrom it.

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

Repairopen in the BLK wire


betwGonthe vSS .nd G101.

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?

Rep.ir op.n in th. BLK/YELwire


betwaen the VSS rnd the und6rdash fuse/.6lav box.

Test the BLU/WHTwi.s:


C o n n e c t h e G R Nt e s t h a r n e s s
c l i p t o t h e p o s i l i v ep r o b e o f a
voltmeter.and connectthe RED
test harnessclip to the negative
probe.

ls thereabout5 V or more?

(To next page)

23-62

www.emanualpro.com

TAPE

Repairopen in the BLU/WHTwiro


bstweon the VSS and PCM.

HARNESS

o-.

(Frompreviouspage)
WHT TESTHARNESS
CLIP

T6st the VSS:


1. Turn the ignition switch OFF.
2 , C o n n e c tt h e o t h e r t e s t h a r nessconnectorto the VSS,
3. Raisethe front and rearof the
vehiclea
, n d s u p p o r tj t w i t h
safety stands.
4. Put the transmissionin neut r a l w i t h t h e i g n i t i o ns w i t c h

TESTHARNESS
OTLAJ_ PT3O2OA
BEDTESTHARNESS

ct-tP

GRNTESTHARNESS

PROTECTIVE
TAPE

oN r).

5. Slowly rotateone wheel with


the otherwheelblocked.

Doesvoltage pulse from 0 to


approx,5 V or more?

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.

Doesthe meter indicatepulsing voltage?

www.emanualpro.com

'BGAUGEASSEMBLY16PCONNECTOR

Wire sideof
femaletermin6ls

R.p.ir opon in the BLU/WHTwire


betwen the VSS and the 3oeedomgter.

BLU/WHT

I
(v)
It

23-63

Integrated Gontrol Unit


CircuitDiagram-'97

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

www.emanualpro.com

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
www.emanualpro.com

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.

Removethe integratedcontrolunit from the under-dashfuse/relaybox.

4.

Inspectthe connectorand socketterminalsto be surethey are all makinggood contact.


. lf the terminalsare bent,looseor corroded,repairthem as necessary,
and recheckthe system.
.lftheterminalslookOK,makethefollowinginputtestsattheconnectorandthefuse/relayboxsocket.
- lf any test indicatesa problem,find and correctthe cause,then recheckthe system.
- lf all the inputtestsproveOK,the controlunit must be faulty;replaceit.

INTEGRATEO
CONTROLUNIT

rOPCONNECTOR

femaleterminals

23-6 8

www.emanualpro.com

All Systems:
Cavity

Test condition

Wire

414

Test: Desiredrsult

Underall conditions

Checkfor continuityto ground:


Thereshouldbe continuity.

Under all conditions

Checkfor voltageto ground:


Thereshouldbe batteryvoltage.

lgnitionswitchON (ll)

Checkfor voltageto ground:


Thereshouldbe batteryvoltage.

A9

A6

Possiblecauseif result is not obtained


. P o o rg r o u n d( G 4 0 1G
, 402)
. An open in the wire
. Blown No. 43 (7.5A) fuse in the
under-hoodfuse/relaybox
. An open in the wire
. Blown No. 25 (7.5A)fuse in the
underdashfuse/relaybox
. An open in the wire

Intermittent Wipol System:


Cavity

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.

Checkfor voltageto ground:


Thereshouldbe batteryvoltage.

Possiblecauss if result is not obtained


Elown No. 26 (20A)fuse in the
under-dashfuse/relaybox
Faultywindshieldwiper switch
Faultywindshieldwiper motor
An open in the wire
Blown No.26 (20A) fuse in the
under-dashfuse/relaybox
Faultywindshieldwiper motor

Anopeninthewire
B3

B4

YEVBLU

lgnitionswitchON (ll),
and windshieldwipe.
switch at INT

lgnitionswitchON (ll),
and windshieldwasher
WHT/BLK
switchON

Checkfor voltageto ground:


Thereshould be battery voltage.

Blown No. 26 (20A) tuse in the


under-dashfuselrefaybox
Faultywindshieldwiper switch
An open in the wire

Checkfor voltageto ground:


Thereshouldbe batteryvoltage.

Blown No. 26 (20A) fuse in the


under-dashfuse/relaybox
Faultywindshieldwasherswitch
An open in the wire

(cont'd)

www.emanualpro.com

23-69

lntegratedControlUnit
InputTest-'97 Model(cont'd)
At----------+A7

Key-in/SeatBelt Reminder,Lights-on RemindorSystem:


Wire

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

Checkfor voltageto ground:


Thereshouldbe batteryvoltage.

lgnitionswitchON {lll.
and driver'sseatbelt
switchunbuckled

Checkfor voltageto ground:


Thereshouldbe 1 V or less.

lgnitionswitchON (ll),
and driver'sseatbelt
switchbuckled

Checkfor voltageto groundl


Thereshouldbe 4 V or more.

Driver'sdoor open

Checkior voltageto ground:


Thereshouldbe 1 V or less.

Driver'sdoor closed

Checkfor voltageto ground:


Thereshouldbe 4 V or more.

lgnitionkey insened
into the ignitionkey
switch

Checkfor voltageto ground;


Thereshouldbe 1 V or less.

lgnitionkey removed
trom the ignitionkey
swrtch

Checkfor voltageto ground:


Thereshouldbe 4 V or more.

Possiblecause if re3ult is nol obtainod


B l o w nN o . 3 0( 7 . 5A ) f u s ei n t h e
under-dashfuse/relaybox
Faultycombinationlight switch
An open in the wire
Poorground (G552)
Faulty seat belt switch
Blownseatbelt reminderlight
bulb
An open in the wire
. Faultydriver'sdoor switch
. An open in the wire

Poorground(G401,G,[02)
Faultyignitionkey switch
An open in the wire

Bulb CheckSystem (BrakeSystem Light):


Cavity

Wire

A4

A13

23-70

www.emanualpro.com

Test condition

T6st: DGsirgd rosult

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

Checkfor voltageto ground:


Thereshouldbe batteryvoltage.

Possiblecause if resuh is not obtainod


Blown No. 25 (7.5A) iuse in the
under-dashfuse/relaybox
Blown brakesystemlight bulb
An open in the wire
Blown No.31 (7.5A) fuse in the
under-dashfuse/relaybox
Faultystartercut relay
FaultyA/f gear positionswitch
P o o rg r o u n d( G 1 0 1 )
An open in the wire

InputTest-'98 - 00 Models
and proceduresin the SRS
SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations,precautions,
section(24)beforeperformingrepairsor service.
L

Removethe driver'sdashboardlower coverand the kneebolster(seesection20).

2.

'l5P
Disconnect
the
connectorfrom the inteqratedcontrolunit.

3.

Removethe integratedcontrolunit from the under-dashfuse/relaybox.

4.

Inspectthe connectorand socketterminalsto be surethey are all makinggood contact.


. lf the terminalsare bent,looseor corroded.repairthem as necessary,
and recheckthe system.
.lftheterminalslookOK,makethefollowinginputtestsattheconnectorandthefuse/relayboxsocket.
lf any test indicatesa problem,find and correctthe cause,then recheckthe system.
- lf all the input testsproveOK,the controlunit must be faulty;replaceit.

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

Key-in/Se8t Beft Reminder,Lights-on Remindol System:


Cavity

Wire

A8

RED/BLU

814

B8

GRN

BLU/RED

Test condition

Test: Desiredresult

Possiblecaus it result is not obtained

Combinationlight
switch ON

Checkfor voltageto ground:


Thereshouldbe batteryvoltage.

Blown No. 30 (7.5A) fuse in the


under-dashfuse/relaybox
Faultycombinationlight switch
An open in the wire

lgnitionswitchON (ll),
and driver'sseatbelt
switchunbuckled

Checkfor voltageto ground:


Thereshouldbe 1 V or less.

lgnitionswitchON (ll),
and driver'sseat belt
switchbuckled

Checkfor voltageto ground:


Thereshouldbe 4 V or more.

Poorground{G552)
Faulty seat belt switch
Blownseatbelt reminderlight
b ul b
An open in the wire

Driver'sdoor open

Checkfor continuityto ground:


Thereshouldbe continuity,

Driver'sdoor closed

Checkfor continuityto ground:


Thereshouldbe no continuity.

lgnitionkey inserted
into the ignitionkey
swrtch

Checkfor voltageto ground:


Thereshouldbe 'l V or less.

lgnitionkey removed
from the ignitionkey
switch

Checkfor voltageto ground:


Thereshouldbe 4 V or more.

. Faultydriver'sdoor switch
. An open in the wire

Poorground(G401,G402)
Faultyignitionkey switch
An open in the wire

Bulb CheckSystem lBrake System Lightl:


Cavity

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 .

Blown No. 25 (7.5A) fuse in the


under-dashfuse/relaybox
Blown brakesystemlight bulb
An open in the wire

Checkfor voltageto ground:


Thereshouldbe batteryvoltage.

Blown No. 31 {7.5A) fuse in the


under-dashfuse/relaybox
Faultystarter cut relay
FaultyA,/Tgear positionswitch(A,/T)
Faultyclutchinterlockswitch(M/T)
Poorground{G101:AfI. G401and
G402:M/T)
An open in the wire

Possiblecaus if result is not obtained

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

@**'

rrf JLo -,.9,;,,

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

. DASHLIGHTS ' PARKING


LIGHTS
, DASHLIGHTS ' SIDEMAHKER
LIGHTS
E R I G H T N E S.ST A I L L I G H T S
LIGHT
C O N T H O L L E. RL I C E N SPEL A T

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

DaytimeRunningLightsControlUnit Input Test (Canadal


1.

DAYTIMERUNNINGLIGHTS
CONTBOLUNIT

Removethe driver's dashboard lower cover and the


knee bolstet (seesection 20).
Disconnectthe connectorsfrom the daytime running lightscontrolunit.
Inspectthe connectorand socket terminals to be
surethey are all makinggood contact.
lf the terminalsare bent,looseor corroded,repair
them as necessary,and recheckthe system.
l f t h e t e r m i n a l sl o o k O K , m a k e t h e t o l l o w i n g IP
CONNECTOR
inout testsat the connector'
- lf anv test indicatesa problem,find and correct
the cause,then recheckthe system.
- lf all the input tests prove OK, the control unrt
must be faulty; replaceit.

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

www.emanualpro.com

BLK,4iVHT

Checkfor voltageto ground:


Thereshouldbe batteryvoltage.

Combinationlight
"
"
switchin =D Posiuon

Checkfor voltageto ground:


There should be battery voltage.

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

Checkfor continuityto ground:


Thereshouldbe continuity.
Checktor voltageto ground:
There should be battery voltage.

lgnitionswitchoN (ll)

YEUBLK

RED

Tost: Desiredresult

Parkingbrakeleverup

Possiblecauseii r$uh is not obtained


. Poorground(G401,G402)
. An open in the wire
Blown No. 20 (7.5A) luse in the
under-dashfuse/relaybox
An open in the wire
Blown No. 18 (7.5A) fuse in the
under-dashtuse/relaybox
Faultyignitionswitch
An open in the wire
Blown No.,tg (30A) fuse in the
under-hoodfuse/relaybox
Faultycombinationlight switch
An open in the wire

Headlights(highbeam)should
come on, (andhigh beam
indicatorshouldcome on).

Poorground (G201.G202,G401,
G402)
Blown headlightbulbs
Faultydaytimerunninglights
resrslor
An open in the wire

Connectto ground:The brake


systemlight shouldcome on.

Blown No. 25 (7.5A) fuse in the


box
under-dashfuse/relaY
Blown brake system light
An open in the wire

Checkfor continuityto ground:


Thereshouldbe continuity

. Faulty parking brake switch


. An open in the wire

LightingSystem
Dafime RunningLightsResistor

Test (Canada)

CAUTION: The d.ytime running lights resistor becomes


very hot when the daytime running lights are on; do not
touch it or the attaching hardware immediatelyaller
the lighls have been turned off.
1.

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.

Removethe front bumper(seesection2O).

2.

Removethe mountingbolts.

3.

Disconnecteach connector,then removethe headlight assembly.

HEADLIGHTASSEMELY

Measurethe resistancebetweenthe resistorterminal No. 1 (or No. 2) and the powerterminalNo. 3.


Resistance:
1.0- 2.0 O
Replacethe resistorwith a new one if any of the
resistances
are beyondspecification.

23-80

www.emanualpro.com

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.

Removethe left innerfender{seesection20).

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

Checkthe verticaladjustmentindicator.The bubble


should be centeredunderneaththe longest scribe
markon the gauge.
VERTICALINDICATOR:

olwww.emanualpro.com

23-A1

RearSide MarkerLights/
LicensePlateLight

Taillights

Replacement

Replacement

RearSide Marke. Light:

1.

Openthe hatchglass.

1.

Removethe retainingspring, and removethe rear


side markerlight from the rearbumper.

2.

Disconnect
the 6P connectorfrom the taillight.

3.
2.

Disconnect
the 2P connectorfrom the light.

Removethe three screws,then pull out the outer


taillight.

RETAINING

HOUSING

LicensPlate Light:
1.

2.

Removethe two screwsfrom the licenseplate light,


and pull the light out part of the way.
Disconnect
the 2Pconnectorfrom the light,

Brak/Plrking light 2115W


Back-uplight: 21CP(18 W)
Turn signll light 21 W
Inspect the gasket; replace it if it is distorted or
$ays compressed.
Installthe taillight, and run water over it to make
sure it does not leak.

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

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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\

High Mount BrakeLight


Replacement

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.

Inspectthe relay and luselrelaybox socketterminals


to be surethey are all makinggood contact.
l f t h e t e r m i n a l sa r e b e n t , l o o s e o r c o r r o d e d ,
reparrthem as necessary,
and recheckthe system.
l f t h e t e r m i n a l sl o o k O K , m a k e t h e f o l l o w i n g
input testsat the fuse/relaybox socket.
- lf any test indicatesa problem,find and correctthe cause,then recheckthe system.
- lf all the input tests proveOK, the turn signal/
hazardrelaymust be faulty;replaceit.

'

IF\_-'l
- ]

$ o{+ll

/ll

FUSE/RCLAY
BOX
SOCKET
Cavity
2

Test condition

Tesl: Desiredresults

Possiblecause if result is not obtained


. P o o rg r o u n d( G 4 0 1G
, 402)
. An open in the wjre

Underall conditions

Checkfor continuityto ground:


Thereshouldbe continuity.

l g n i t i o ns w i t c h O N ( l l l

Connectfor voltageto ground:


Thereshouldbe batteryvoltage.

Blown No. 12 (7.5A) fuse in the


under-dashfuse/relaybox
Faultyhazardwarningswitch
An open in the wire

HazardwarningswitchON

Connectfor voltageto ground:


Thereshouldbe batteryvoltage.

Blown No. 53 (10A) fuse in the underhood fuse/relaybox


Faultyhazardwarningswitch
An open in the wire

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

Turn SignalSwitch Test

HazardWarningSwitch Test

1 . Removethe driver'sdashboardlower coverand the


kneebolster(seesection20).

1.

Removethe centerpanel{seesection20).

2.

Removethe two screws,then remove the switch


from the centerair vent.

Removethe steering column covers {see section


17]-.
D i s c o n n e c t h e 4 P a n d 7 P c o n n e c t o r sf r o m t h e
switch.
4.

Removethe screws,and slidethe switchtowardthe


driver'sdoor.

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

lgnition Key Light System-'97

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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ControlUnit Input Test


l. Bemovethe driver'sdashboardlowercoverand the kneebolster(seesection20).
the 5P connectorfrom the controlunit.
2, Disconnect
3. Inspectthe connectorand socketterminalsto be surethey are all makinggood contact.
.
.

and recheckthe system.


lf the terminalsare bent,looseorcorroded,repairthemas necessary,
lf the terminalslook OK, makethe followinginput testsat the connector.
- lf any test indicatesa problem,find and correctthe cause.then recheckthe system.
- lf all the inputtestsproveOK,the controlunit must be faulty;replaceit.

IGNITIONKEYLIGHT
CONTROLUNIT

5P CONNECTOR

))

Cavity

Wire
BLK

'I

WHT/BLK

Test: Desiredresult

Underall conditions

Checkfor continuityto ground:


Thereshouldbe continuity.

lgnitionswitchON (ll)

Checkfor voltageto ground:


Thereshouldbe batteryvoltage.

Driver'sdoor open

Checkfor voltageto ground:


Thereshouldbe 1 V or less.

Driver'sdoor closed

Checkfor voltageto ground:


Thereshouldbe 4 V or more.

Underall conditions

Connectto ground:lgnitionkey
light shouldcome on.

WHT/GRN

GRN

www.emanualpro.com

Test condition

Possiblecauseif rsult is not obtained


. Poorground{G401,G402}
. An open in the wire
. Blown No. 33 (7.5A) fuse in the
under-dashfuse/relaybox
. An open in the wire
. Faultydriver'sdoor switch
. An open in the wire

Blown No. 33 (7.5A) fuse in the


under-dashfuse/relaybox
Blown ignitionkey light bulb
An open in the wire

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.
.

lf the terminalsare bent,loose,or corroded,repair


them as necessary,
and recheckthe system.
. lf the terminalslook OK, makethe followinginput
tests at the connector.
- lf any test indicatesa problem,find and correct the cause.then recheckthe system.
- lf all the input tests prove OK, the controller
must be taulty;replaceit.

OASHLIGHTS
BRIGHTNESS
CONTROLLER

Wire sideof
lemaleterminals

Csvity

Wire

RED/BLK

BLK

RED

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Tst condhion

Tsst: Desiredresuli

Combinationlight
switch ON

Checkfor voltageto ground:


Thereshouldbe batteryvoltage.

Underall conditions

Checkfor continuityto ground:


Thereshouldbe continuitv.

Combinationlight
switchON

Connectto ground:
Dashlightsshouldcome on full
bright.

Possible cause if result is not obi8inod

Blown No. 30 (7.5A) fusein the


under-dashfuse/relaybox
Faultycombinationlight switch
An open in the wire
. Poorground(G401,G402)
. An open in the wire
. An open in the wire

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

Front and rgar:

1. Turn the spotlightswitchOFF.

1.

Turn the light switchOFF.

2.

Pry off the lens.

2.

Pry off the lens.

3.

Removethe two screwsand the housing.

3.

Removethe two mountingnuts and the housing.

4.

Disconnect
the 3P connectorfrom the housing.

4.

Disconnect
the 3P connectorfrom the housing.

1' 3' 2'

aULB(5Wx2l

Checkfor continuitvbetweenthe terminalsin each


switchpositionaccordingto the table,

Checkfor continuitybetweenthe terminalsin each


switchpositionaccordingto the table.

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.

Removethe centerdashboardlower cover (seesect i o n2 0 ) .

2.

Disconnect
the 2Pconnectorfrom the front accessory
socket.

If all the tests proveOK, replacethe front accessory


socket.

Inspectthe connectorterminalsto be sure they are


all makinggood contact.
lf the terminalsare bent,looseor corroded,repair
them as necessary,
and recheckthe system.
l f t h et e r m i n a l sl o o kO K ,g o t o s t e p4 .

PBOTECTOB
FACEPANEL

ACCESSORY
SOCKET

Turn the ignition switch to ACC (l), and checkfor


voltagebetweenthe No. 1 and No. 2 terminals.
.
.

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.

Removethe thermofusehousingand thermal pro


tector,then removethe socketand cover.

Disconnect
the connectors.

2.

lnspectthe connectorterminalsto be sure they are


all makinggood contact.

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}

Turnthe ignitionswitchto ACC(l),and checktor volt


agebetweenthe A and B terminals.
o Thereshouldbe batteryvoltage.
. lf there is no batteryvoltage,checkfor:
- b l o w nN o . 6 ( ' 1 0A ) a n d N o . 2 7 ( 1 0A ) f u s e si n
the under dashfuse/relaybox.
- faulty rear accessorysocketrelay (test,page
23-53).
- poor ground (G401,G402,G553).
- a n o p e ni n t h e w i r e .

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

www.emanualpro.com

23-9 8

Terminals

Removal
1.

Removethe centerair vent (seesection20).

2,

Disconnect
the 4Pconnector.

3.

Removethe two screws.

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

www.emanualpro.com

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

www.emanualpro.com

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

Installin the reverseorderof removal.


After installingthe audio unit, enter the anti-theft
code for the radio. then enter the customer's radio
station presets(with anti-theftfeature).

Wire

Connoct3 to

1{7)

RED/GRN

Right front door speaker@

2 {8}

BLU

3 {9)

RED/BLK

Lights-onsignal

4 (10)

WHT/BLU

Constantpower (tuning
memory)

5 (2)

YEURED

ACC (main sterso power


supplyl

7 (6)

BLU/YEL

Left rear soeaker@

8 (s)

RED/VEL

Rightrearspeaker@

9 (17)

BRN/BLK

Riqht f.ont door speakerO

1 0( 1 8 )

GRY/BLK

Left front door soeakerO

1 2( 1 9 )

RED

Dashlightsbrightnesscontroller

14 (20)

BLK

G r o u n d( G 5 0 1 )

1 5( 1 6 )

GRYMHT

Left rear speakerO

1 6( 1 5 )

BRN^ll/HT

Rightresr speakerO

Left front door speaker@

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

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23-102

SpeakerReplacement
1.

Removethe speakercover.

2.

Removethe threescrewsfrom the speaker.

3.

Disconnectthe 2P connector,and removethe door


speaker.

Mast AntennaReplacement
NOTE:To remove the antennalead, it is necessaryto
removethe dashboard(seesection20).
1.

Disconnect
the antennaleadfrom the audio unit.

2.

Removethe two mountingscrews,then removethe


mast antenna.

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

www.emanualpro.com

CAELEREEL
R e p l a c e m e n t ,s e c t i o n 2 4

HornTest

CircuitDiagram

1.

Removethe front bumper(seesection20).

2.

the 2P connectorfrom the horn


Disconnect

3,

Removethe horn.

HORN

2P CONNECTOR

} -

BLU/FED

fl"'

KEYLESSi
POWEF
DOOR
LOCK
CONTROL
UNIT

B L UFi E O

t
l

Test the horn by connectingbatterypower to one


terminaland groundingthe other.The horn should
sound.

5.

lf the horn failsto sound,replaceit

BLU/RED

g)iirrN I
BLK

4.

LOW
HORN

BLK

BLK

I
I
G201

www.emanualpro.com

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).

6. Removethe driver's airbag (see section 241,then


disconnectthe horn connectorfrom the steerinq
wneet.
7 . Checkfor continuity betweenthe No. 2 or No. 3 terminal of the cable reel sub-harness3P or 6P connectorand horn Dositiveterminal.

Disconnectthe cablereel sub-harness


3P or 6P connectorfrom the main wire harness.

CABI.I REEL
SUB.HARNESS
3P or 6P
CONNECTOR

MAIN WIRE
HARNESS
3P o. 6P
CONNECTOR

HORNCONNECTOR

37 modol

lf there is no continuity,replacethe cable reel


(seesection 24).
lf there is continuity.repair or replacethe horn
switch.

,98- 0Omodots
Terminal
sideof
maleterminals

Checkfor continuitybetweenthe No. 2 or No. 3 term i n a l o f t h e c a b l er e e l s u b - h a r n e s a


snd body
groundwith the horn switchpressed.
'97 model:

'98 - (X)modols:

8. lf sll tests prove OK, reinstall the driver's airbag


(seesection24), and reconnectthe cable reel subharnessconnector.
9 . Reconnect
the driver'sand front passenger's
airbag
connectors,and reinstallthe accesspanel on the
steeringwheel.
1 0 . Reconnectthe batterypositivecable,then the negative
cable.
1 1 . After installing the airbags, confirm proper system

operatron:
Terminalsideof

.
.

Terminalsideof

lf there is continuity.the horn switchis OK.


lf there is no continuity,go to step 6.

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,-

-:
[ ]:

www.emanualpro.com

'9&00rnodels

G551

23-107

PowerMirrors
FunctionTest
1.

Pry the switch out of the dashboard.Be carefulnot


to damagethe mirror switchor the dashboarddriver's lowercoverwhen pryingthe switchout.
Disconnect
the 10Pconnectorfrom the switch.
Choosethe appropriatetest dasedon the symptom:
. Both mirrorsdon't work, go to step 4.
. Left mirror doesn't work, go to step 6.
. Rightmirror doesn'twork,go to step 7.

Left mirror inoperative:


6.

Connectthe No. 2 {BLKI/EL)terminal of the ,l0p


connectorto the No. 3 (YEUREDIterminal and the
N o . 5 ( o r N o . 6 ) t e r m i n a lt o b o d y g r o u n d w i t h
jumper wires. The left mirror should tilt down (or
swing left) when the ignition switch is turned ON
t).
lf the mirror doei not tilt down (or does not swing
left),removethe left door panel,and checkfor an
open in the BLUMHT (or BLU/BLK)wire between
the left power mirror and the switch. lf the wire is
OK,checkthe left power mirror actuator,
lf the mirror neithertilts down nor swings left,
repairthe YEUREDwire.
lf the mirror operatesproperly,checkthe mirror
switch.

Right mirror inoperaiiva:


7.

Connectthe No. 2 {BLVYEL)terminat of the 1Opconnectorto the No. 3 (YEURED)


terminaland the No. 9
(or No. 8) terminal to body ground with jumper wires.
The right mirror should tilt down (or swing left) when
the ignitionswitchis turnedON l).
.

.
-.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

lf the mirror does not tilt down (or does not


swing left), remove the right door panel, and
checkfor an open in the GRN,4TVHT
(or yEUBLK)
w i r e b e t w e e nt h e r i g h t p o w e r m i r r o r a n d t h e
switch. lf the wire is OK, checkthe right power
mtrror actuator.
lf the mirror neithertilts down nor swings left.
repairthe YEUREDwire.
lf the mirror operatesproperly,checkthe mirror
switch.

Actuator Test

Switch Test
1.

Removethe switch as describedin FunctionTest


{seepage23-108).

2.

CheckJor continuitybetweenthe terminalsin each


switchpositionaccordingto the table.

Teminal

t*t*

Prv out the mirror mount cover (seesection20).

2.

the 8P connectorfrom the power mirror.


Disconnect
MIRRORMOUtrlT
COVER

\
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

www.emanualpro.com

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

www.emanualpro.com

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.

NOTE:To make an effectiverepair,the brokensection


m u s tb e n o l o n g e rt h a no n e i n c h .

Checkfor voltagebetweenthe positiveterminaland


body ground with the ignitionswitch and defogger
switchON.
Thereshouldbe batteryvoltage.
.

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.

Lightlyrub the areaaroundthe brokensectionwith


fine steelwool, then cleanit with alcohol.

2.

Carefullymaskaboveand belowthe brokenportion


of the defoggerwire with cellophanetape.
OPEN

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.

Checkfor continuitybetweenthe negativeterminal


and body ground.
l f t h e r e i s n o c o n t i n u i t yc, h e c kf o r a n o p e n i n t h e
defoggergroundwire.
Touch the voltmeter positiveprobe to the halfway
point of eachdefoggerwire, and the negativeprobe
to the negativeterminal.Be carefulnot to scratchor
damagethe defoggerwireswith the testerprobe.
Thereshouldbe approximately6 V with the ignition
switchand the defoggerswitchON.
.

lf the voltageis as specified,the defoggerwire is

oK.
.

lf the voltageis not as specified,repairthe defogger wire.


- lf it is more than 6 V, there is a breakin the
negativehalf of the wire.
- l f i t i s l e s st h a n 6 V , t h e r e i s a b r e a ki n t h e
positivehalf of the wire.
Checkfor continuityin the repairedwire.
5,

23-112

www.emanualpro.com

Apply a secondcoat of paint in the sameway. Let it


dry three hoursbeforeremovingthe tape.

Switch Input Test


NOTE:Beforetesting, check for blown No. 17 (7.5 A)
fuse in the under-dashfuse/relaybox.
1.

Removethe centerpanel{seesection20).

SWITCH
REARWINOOWDEFOGGER
lin the heatercontroloanel)

CENTERPANEL

Checkfor voltagebetweenthe 84 and 87 terminals


in each switch positionwhen batterypower is connectedto the B l terminal.
OFF

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

www.emanualpro.com

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

www.emanualpro.com

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

www.emanualpro.com

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

www.emanualpro.com

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

Inspectthe connectorand socketterminalsto be sure


they are all makinggood contact.
a lf the terminalsare bent,loose,or corroded,repair
them as necessary.and recheckthe system.
. lf the terminalslook OK, makethe following input
tests at the connector.
- lf any test indicatesa problem,find and correct
the cause,then recheckthe system.
- lf all the input tests are OK, replacethe control
UNII.

LT GRN/BLK
T GRN/RED\ LT
2

GRN/BLK

Cavity
4

Test condhion

BLK

LT GRN/
RED

Checkfor continuityto ground:


Thereshouldbe continuity.

lgnitionswitchON (lll

Checkfor voltageto ground;


There should be battery voltage.

Blown No. 3 (10A) fuse in the


under-dashfuse/relaybox
An open in the wire

lgnitionswitchON (ll),
and rearwindow
wiper/washerswitch
ON

Checkfor voltageto ground:


There should be battery voltage.

Blown No. 3 (10A) fuse in the


under-dashfuse/relaybox
Faultyrearwindow wiper/washer
switch
An open in the wire

lgnitionswitchON (lll

Checkfor voltageto ground;


Thereshouldbe batteryvoltage.

Blown No. 3 {10A) fuse in the


under-dashfuse/relaybox
Faultyrearwindow wiper motor
An open in the wire

lgnitionswitchON (ll)

Checkfor voltageto ground:


Thereshouldbe batteryvoltage.

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

Checkfor voltageto ground:


Thereshouldbe batteryvoltage.

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

www.emanualpro.com

23-118

Possiblecause il rasuh is not obtained

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.

Removethe driver'sdashboardlower coverand the


kneebolster(seesection20).

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.

Open the hood, removethe cap nuts, and caretully


remove the wiper arms so that they do not touch
the hood.
Removethe cowl cover(seesection201.
Disconnectthe 5P connectortrom the windshield
wiper motor.

\ lind3hi.ld:

tilt-rltl

IEZIA
RaarWindow:
1 12 3

I t-7 al

J-

Checkfor continuitybetlveenthe termlnalsin each


switchpositionaccordingto the tables.
Windshield Wiper/WasherSwitch:
Terminal
---__\
4

o
o
o

o
o

P*tOFF

oo

INT
LO

o
o

HI
"0N"
Mistswhch
switch"0N"
Washer

o
o
o
o

Test the motor by connectingbattery power and


groundaccordingto the table.
\

-l

Terminal

;fi;"

LOW SPEED

H I G HS P E E D

RearWindow Wipsr/Washer Switch


\

ti'"

ll www.emanualpro.com

---\Teminal

Washer
switch'0N'
(wiperswitchoFFl

OFF

ON

"ON'
Washer
switch
"0N"1
(Wiper
switch

-o
-o
o
-o

-o

lf the motor does not tun or fails to run smoothly,


replaceit.
Connectan analogvoltmeterbetweenthe No. 5 (+)
and No. 3 (-) terminals,and run the motor at low or
high speed.
The voltmeter should alternatelyindicate0 V 8nd
4 V or less.

-o
23-11 9

Wipers/Washers
RearWindow WiperMotor Test

WasherMotor Test

1 . Removethe tailgatetrim panel(seesection20),

1.

Disconnectthe 4P connectorfrom the wiper motor


assembly.

Removethe front bumper(seesection20).


D i s c o n n e c t h e 2 P c o n n e c t o r sf r o m t h e w a s h e r
molors,

REARWINDOW
WASHERMOTOR

4P CONNECTOR

Pushtab
to release,

4.

5.

WIPEB
LOWERCOVEn

Test the motor by connecting battery power to the


No. I terminal,and groundto the No. 3 terminal.

Test the washer motor by connecting battery power


and groundaccordingto the table.

lf the motor does not run or fails to run smoothly,


replaceit.

L_Iq'.r91

Reconnect
the 4P connectorto the wiper motor.

Disconnected
Connected

Connectan analogvoltmeterbetweenthe No. 4 (+)


and No. 2 (-) terminals.
Run the motor by turning the wiper/washerswitch

oN.

The voltmeter should alternatelyindicate0 V and


1 1V o r l e s s .

www.emanualpro.com

23-120

,l

Battery
@

a lf the motor fails to run smoothly, replaceit.


a lf the motor runs smoothly, but little or no washer

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.

Remove the dashboard lower cover (see section


20).

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

Checkfor continuitybetweenthe No. 1 and No. 2


terminals.
.
.

There should be continuity when the switch is


pushed.
Thereshouldbe no continuitywhen the switchis
released.

out,
G631

23-121

HatchGlassOpener
SolenoidReplacement

Solenoid Test
1.

Open the tailgateand removethe tailgatetrim (see


section20).

2.

Disconnect
the 2Pconnectorfrom the solenoid.

't. Removethe tailgatetrim (seesection20).


2.

Disconnect
the 2P connector.

SOLENOID

Terminalsade
of
maletermtnals

Removethe rod from the key cylinder.


Connectpowerto the No. 1 terminaland groundto
t h e N o . 2 t e r m i n a l sm o m e n t a r i l vT. h e s o l e n o i d
shouldooerate.

4.

Removethe three mountingbolts,then removethe


solenoid.
Installthe replacement
solenoidin the reverseoader
of removal.

www.emanualpro.com

23-122

Power Door Locks


ComponentLocationlndex
TRANSMITTER
Test, page23-130
Cod6 Input Procedure,
page23-131

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

www.emanualpro.com

23-123

Power Door Locks


CircuitDiagram(With KeylessEntrySystem)
FUSE/FELAY
UNDER.HOOD
BOX

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

www.emanualpro.com

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

www.emanualpro.com

'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.
.
.

lf the terminalsare bent,looseorcorroded,repairthemas necessary,


and recheckthe system.
lf the terminalslook OK, makethe followinginput testsat the connector.
- lf any test indicatesa problem,find and correctthe cause,then recheckthe system.
- lf all the input testsproveOK,the controlunit must be faulty;replaceit.

18PCONNECTON

BLU
GRN/BED

GRY

10

1t

YEL WHT/REO\ WHT/GRN

,/
1 21 1 3

GRN/WHT I

14
LT

femaleterminals

www.emanualpro.com

23-126

5
16

17

1E

Disconnocithe 18Pconnestor from the powr door lock control unit.


Cavity

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

Connectthe No. 'l8 terminalto the No. 8 terminal,


and the No.6 terminalto
the No. 17terminal
momentarily.

Connectthe No.6terminalto th6 No.I terminal,


WHT/RED and the No. 18terminalto
the No. 17terminal
momentarily.

BLU/RED

Connectan ohmmeter
betweenthe No. 9 terminal and the No. l7 terminal.Driver'sdoor lock
knobin UNLOCK

Po$ible csuse il result is not obtainod


. Poorground(G55'l)
. An openin the wire
Faultyactuator
Faultyjunctionconnector(C577)
An openin the wire
BlownNo. 51 (20Al{use in the underhoodfuse/relay
box
BlownNo.52 (15A)tuso in the underhood fuse/relaybox
Faultyhorn
Faultyhorn relay
An openin tho wire

Checkdoor lock operation:


Passenger'sdoors should 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.

' Faultydriver's door lock actualor


. An openin the wire

*: With keylessentry system


NOTE:To preventdamageto the motor,apply batteryvoltageonly momentarily.
Feconnoctthe 18Pconneqtorto the power door lock control unit,
Cavity

Wir6

Test condition

BlownNo. 51 (20Alfuse in the underhood tuse/relaybox


An openin the wire

Driver'sdoor lockknob in

Checktor voltageto ground:


Thereshouldbe 1 V or less.

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

BLU/RED tion switch

lgnitionkeyis in the igni-

Checkfor voltage to ground:


There should be battery voltage.

Connectthe No. 5
terminalto the No.I terminalmomentarily

Checkhatchglass lock operation:


Hatchglassshouldunlock.

. Faulty hatch glass opener solenoid


. An opon in the wire

Checkfor continuityto ground:


Thereshouldb continuity.
Checktor voltageto ground:
There should be battery voltage.
Checklor voltageto ground:
Thereshouldbe 1V or less.

. 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

'

www.emanualpro.com

Checktor voltageto ground:


Thereshouldb 1 V or less.

lgnitionswitchON (ll)
YEL

YEL

Possiblecauseif result is not obtaind

Checkfor voltageto ground:


There should be batteryvoltage.

WHT/GRN

Tost: Dsirodresult

Underall conditions

Front ceiling light


"MlDDLE" position

Driver'sdoor lock switch


GRNAr'VHT in LOCK
Driver'sdoor lock switch
GRN/ORN
in UNLOCK

Faultylront ceilinglight
An openin the wire
Faultydriver's door lock switch
Poorground{G551)
An openin the wire

23-127

Power Door Locks


Driver'sDoorLockKnobSwitchTest

Driver'sDoorLockActuatorTest

1.

Removethe driver'sdoor panel(seesection20).

1,

Removethe driver'sdoor panel(seesection20).

2.

Disconnectthe 6P connectorfrom the actuator.

2.

the 6P connectorfrom the actuator.


Disconnect

6P CONNECTOR

6P CONNECTOR

Terminalsideot
maleterfiinals

Terminalsideof
maleterminals

Checkfor continuitybetweenthe terminalsin each


switch position accordingto the table.
rsrmrnal

\
Position

\
LOCK

UNLOCK

Checkactuatoroperationby connectingpower and


ground accordingto the table.To preventdamsge
to the actuator. apply battery voltage only momentarilv,

o- -o
o- --o

Terminal

F*'',1."

__l

LOCK
UNLOCK

www.emanualpro.com

23-128

o
@

DoorLockActuatorTest
Passenger's

Driver'sDoor LockSwitch Test

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.

NOTE: The left rear door lock actuator is shown;


the front passenger's
and right reardoor lockactuators are similar.
2P CONNECTOR

Checkfor continuitvbetweenthe terminalsin each


switchpositionaccordingto the table.
lermlnal

\
Position

\
LOCK
OFF

UNLOCK

Terminal
sideof
maleterminals

o- --o
o- -_o

Checkactuatoroperationby connectingpower and


ground accordingto the table.To preventdamage
to the actuator, apply battery voltage only momenraflry.
\

Terminal

;;il;--r

,l

LOCK
UNLOCK
4.

www.emanualpro.com

@
@

lf the actuatordoes not work properly, replaceit.

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}.

www.emanualpro.com

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.

Within 1 to 4 sec.,turn the ignitionswitchOFF.

1 . Within 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.

9 . Within 1 to 4 sec.,turn the ignitionswitchOFF,


1 0 . Within 4 sec.,turn the ignitionswitchON (ll).
1 1 . 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 f
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.
1 2 . Confirm you can hear the sound of the door lock
aduators.

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.

1 5 . Confirmproperoperationwith the new code{sl.

www.emanualpro.com

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

www.emanualpro.com

23-132

RIGHT
wtNDowswTcH
T6sr,page23-137

GircuitDiagram
L]NDEFH@O FISETRELAY
BOX

@-*'

rblr (r0oA) rlo42t40A)

V
I

PASSENGEAS

FFONTPASSENGEFS

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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

BLK RED/WHTYEL/GRN YEL

Wire side of
femaleterminals

POWERWINDOWMASTEBSWITCH

RED/BLK

www.emanualpro.com

23-134

Cavity

Wi1

A11

Test condition

Tesi: Dssiredrosult

Underall conditions

Checkfor continuityto ground:


Thereshouldbe continuity.

lgnitionswitchON (ll)

Checkfor voltageto ground:


Thereshouldbe batteryvoltage.

BLK

Po$ible causeif 183uhis not obtained


. Poorground(G551)
. An open in the wire

B1
A 1 0 BLU/BLK
A9

GRN/BLK

A6

YEUBLK

Blown No. 7, 8, 10 or l1 (20A)


fuse in the under-dashfuse/relay
box
Faultypowerwindow relay
An open in the wire

412 RED/WHT

A4

A3

Connectthe A10 termiRED/BLU nalto the 43 terminal,


and the A4 terminalto
the A11 terminal,then
RED/YEL turn the ignitionswitch

Checkthe driver'swindow motor:


It shouldrun (thewindow moves
down).

. Faultydriver'swindow motor
. An open in the wire

oN flr).
A1

A2

A14

A8

Connectthe A9 termiBLUI/EL nalto the A2 terminal,


and the Al terminalto
t h e 4 1 1 t e r m i n a lt,h e n
BLU/ORN turn the ignitionswitch

Checkthe front Passenger's


window motor:
It shouldrun (thewindow moves
down).

window
Faultyfront passenger's
motor
Faultyfront passenger'swindow
switch
An open in the wire

Connectthe 46 terminalto the A13terminal,


and the 414 terminal
to the A11terminal,
YEUGRN then turn the ignition
switchON (ll).

Checkthe right rearmotor:


It shouldrun (thewindow moves
oown).

Faultyright rearwindow motor


Faultyrightwindow switch
An open in the wire

Connectthe A12 termi-

Check
the leftrearmotor:
,t shouldrun {thewindowmoves
down),

Faultyleft rearwindowmotor
Faulty,eftrearwindowsrrvitch
An openin thewire

Connectthe A10te.minalto the 43 terminal,


and the A11 terminal
to the 44 terminal.
then turn the ignition
switchON (ll).

Checkfor voltage betweenthe A5


and Al l terminals:
ADorox.6V shouldbe indicatedas
the driver'swindow motor runs.

Faultypulser
Faultydriver'swindow motor
An open in the wire

Combinationlight
switch ON

Checkfo. voltageto ground:


Thereshouldbe batteryvoltage.

Blown No.30 (7.5A) fuse in the


under-dashfuse/relaybox
Faultycombinationlight switch
An open in the wire

Combinationlight
switch ON

Connectto ground:
Dashlightsshouldcome on full
bright.

oN flr).

YEL

GBN/YEL nalto the A7 terminat,

GRN

and the A8 terminalto


the A11terminal.then
turn the ignitionswitch

oN flr).

A5

*cl

BLU

RED/BLK

RED

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' An open in the wire

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

Checkfor continuitybetweenthe terminalsin each


switchpositionaccordingto the tables.
DRIVER'S

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

Left R.ar Switch:


t - _ _ _ _ _ r - _ _

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

Swhch Light: '99 - 00 modls


\

Terminal

ti.*----_\
Underallconditions

o-

-o
ILED)

Window Switch Test


Passenger's

Driver'sWindow Motor Test

1 . Removethe inner handle(seesection20).

Motor Test:

Disconnectthe 5P connectorthen removethe two


mounting screwsfrom the passenger'sswitch.

1.

Removethe driver'sdoor panel,and disconnectall


connectors(seesection201.

2.

Disconnectthe 4Pconnectorfrom the window motor.

Terminalsideof
maleterminals

Testthe motor in eachdirectionby connectingbatt e r y p o w e r a n d g r o u n d a c c o r d i n gt o t h e t a b l e .


Whenthe motor stopsrunning.disconnectone lead
immediately.
Checkfor continuitybetweenthe terminalsin each
switchpositionaccordingto the table

Terminal
-\

\
;;b"

Terminal
__\
1

\
;"rL-

UP

o-

OFF

DOWN

www.emanualpro.com

o-

-o
-o o- -o
-o

4.

UP

(!r

DOWN

lf the motor doesnot run at all or doesnot run


smoothly.rePlaceit.

PulserTest:
5.

Connectthe test leadsof an analogohmmeterto the


No, 3 and No. 4 terminals.

6.

Run the motor by connectingpower and groundto


the No. 1 and No. 2 terminals.The ohmmeterneedle
shquldmove backand forth alternately.

23-137

PowerWindows
Passenger's
Window Motor Test
Front:
l.

Removethe passenger'sdoor panel,and disconnect


allthe connectors(seesection20).

2.

Disconnectthe 2Pconnectorfrom the window motor.

3.

Checkwindow motor operation by connectingpower


and ground accordingto the table.When the motor
stops running, disconnectohe lead immediatelv.
Front:
Terminal
\
.l\
;."b"

UP

DOWN

UP

DOWN

Rar:
I

;*r*

Terminal
-l\

lf the motor doesnot run at all or does not run


smoothly,replaceit.

Rear:
1.

Removethe passenger's
doo. panel,and disconnect
allthe connectors(seesection20).

2.

Disconnectthe2Pconnectorfromthe window motor.

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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FrontSeat Belt RePlacement


SRScomponentsare locatedin this area.Reviewthe SRS
and proceduresin this
componentlocations,precautions,
(24)
performing
or service('98 - 00
repairs
before
section
models).
CAUTION: Check the front seat bslts for damago. and
replacothom if necessary.Be careful not to damage
them during removal and in3tallation'
Front scat bolt:
1.

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)

10. lnstallationisthe reverseof the removalprocedure.


NOTE:
Checkthat the retractorlockingmechanismfunctions as describedon Page24-9.
Assemblethe washers,collarand bushingon the
uooerand lower anchorboltsas shown.
Eeforeinstallingthe anchor bolts, make sure there
are no twists or kinksin the front seat belt.
Make sure the seat belt tensionerconnectorls
connectedsecurelv.
Enterthe anti-theftcode for the radio,then enter
the customer's radio station presets

ANCHOR
CAP
('97 modell
LOWERANCHORBOLT
?,/1&20UNF
32 N.m {3.3 kgf.m,2,1lbf.ftl

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To avoid accidontal deployment and


@
possibteinlury, always disconnectthe soat bsh tonsionr connoctor bofore rsmoving th6 retractor l'98
- 00 modsls, se page 21-231.

SHOULDER
ANCHOR
ADJUSTER

ANCHOR
COVER
l'98- 00models)
RETRACTORBOLT
7/1&20UNF
32 N.m 13.3kgt m,
24 tbt.ft)

Disconnectthe seat belt tensiongr connector.

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

Lower anchor bolt construction:


'97 modol:
LOWERANCHOR

24-4

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Csntor anchor bolt construstion:

Ssat belt buckle:


1.

Slidethe front seatforwardfully

2.

Removethe centercover(seesection20).

3.

Driver's: Disconnectthe seat belt switch connector,


and detachthe harnessclips from the seatcushion
frame.

TOOTHED
LOCKWASHER

WAVE
WASHER

CENTER
ANCHOR
BOLT

>: Cliplocations
SPRING
WASHER

5.

WASHER

CENTER
ANCHOR

lnstallationis the reverseof the removalprocedure.


NOTE:Assemblethe washerson the centeranchor
bolt as shown.

To seat belt
buckle.

SEATBELT
swlTcH
CONNECTOR
4.

Removethe centeranchorbolt,then removethe seat


belt buckle. Pull out the seat belt switch harness
(with seat belt switchl.
SEATBELT
BUCKLE

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.

Carefullypull on the upper anchorcover and lower


anchorcoverto removethem.

6.

Installationis the reverseof the removalprocedure.


NOTE:
. Checkthat the retractorlockingmechanismfunctions as describedon page24-9.
. Assemblethe washers,collarand bushingon the
lower anchorbolt as shown.
. Beforeinstallingthe anchorbolt, makesurethere
are no twistsor kinksin the rearseatbelt.

Upper anchot bolt construction:

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

Lowel anchor bolt construqtion:


LOWERANCHOR
BOLT

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

Removethe lower anchorbolt.

WASHERS

COLLAR

LOWERANCHOR

4.

Remove(seesection20):
. Cargoareafloor and cargostoragebin
. Reartrim paneland rearsidetrim panel

Rgtractor boll construction:

/\

f/F\-.

Removethe upper anchor bolt, the retractorbolt.


the retractormounting bolt, and remove the rear
seatbelt and retractor.

P \v*\
/

T(X)THED
LOCKWASHER

24-6

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r>--->.

(t--nnnllH \
\

RETRACTOR

\
RETMCTOR
BOLT

) J
Seat belt buckles/Centerbelt tongue:

with tilt:

without tilt:

1.

forward.and tilt the rearseatup


Foldthe seat-back

2.

While holdingthe trunk floor extensionup, remove


the centeranchorbolts

1.

Removethe rearseaton eachslde.

2.

Raisethe trunk floor extensions,removethe cenler


anchorbolts,then removethe seat belt bucklesand
centerbelttongue.

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

and returnthe seatto its origiRaisethe seat-back,


position.
nal

Removethe center anchor bolts, then remove the


center belt tongue and seat belt 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)

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Seat Belts
RearSeat Belt Replacement(cont'dl
5.

Installationis the reverseof the removalDrocedure.


NOTE:Makesurethere are no twists or kinksin the
centerbelttongueand seatbelt buckle.

Cenler anchor bolt construction:

TOOTHED
LOCKWASHER
ANCHOR

24-8

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Inspection
Rear:

SRS componentsale located in this area. Reviewthe


SRScomponentlocations,precautions,and procedures
in this section(24)beforepreformingrepairsor service
('98- 00 models).

40.

/A

To avoid accidontaldeployment and possi!!!@


6i6-'rnpry. att"ays aisconnsct th seat beh tensioner connctor belore removing tho retrastor {.98 - 00 modols, seo

*1ix
\|
_t-. \ /

page2+231.

L =
ls

Rgtlastor Insgection

RETRACTOR

1.

Beforeinstallingthe retactor,checkthat the seatbelt


can be pulledout freely

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.

Beplacethe seatbeltwith a new assemblyif thereis


any abnormality.Do not disassembleany part of
the seatbeltfor any reason.

In-vehicleS68t Belt InsPestion


1.

Front:
'97 modol:

lnsida

Chckthat the seat belt is not twistedor caughton


anything.
After installingthe anchors,checkfor free movement on the anchorbolts lf necessary,removethe
anchorbolts,and checkthat the washersand other
partsare not damagedor improperlyinstalled.

.: Mounted Position

Checkthe seatbeltsfor damageor discoloration.


Cleanwith a shop towel if necessary.
CAUTION: Uso only soap and wator to clean.
NOTE:Dirt build-upin the metal loopsof the upper
anchorscan causethe seat belts to retractslowly
Wipe the insideof the loopswith a cleanclothdamP
enedin isopropylalcohol.

RETRACTOR
lnside

Forward -

Checkthat the seat belt does not lock when pulled


out slowlv. The seat belt is designedto lock only
duringa suddenstop or impact.

'98 - 00 modcls:

Makesurethat the seatbeltwill retractautomatically


when released.
For each passenger'sseat belt, make sure that the
locking mechanism in the seat belt retractorwill
engagewhen the seatbelt is pulledall the way out.
'1.
RETRACTOR
Forward -

Replacethe seatbeltwith a new assemblyif there is


any abnormality.Do not disassembleany part of
the seatbeltfor any reason.

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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.

NOTE:To installa child seat on the rearseat,selectthe


attachmentpoint you want to use,and removethe plug
coverfrom the attachmentpoint of the headliner.Install
the child seattetheranchorsecurely.

ATTACHMENT
POINTS

PLUGCOVERS

CHILOSEAT
TETHER
ANCHOR

TOOTHEDWASHER

24-10

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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)

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24-11

SupplementalRestraintSystem (SRS)

\
)

<D

.."....."" 24-14 Troubleshooting


SpecialTools
24-26
Self-diagnosticProcedures.............
Component/Wring Location
'97
'....."""24-15
model ..........'.."
.....".."'24'26
lndexReadingthe DTC ..................
Component/WiringLocation
Erasingthe DTCMemory ................24-28
24-16
lndex - '98 - 00 models ..............."
Troubleshooting lntermittent
.'.........."'.24'17
"'...........24'24
Description
Faifures
.........24'14
CircuitDiagram
DiagnosticTroubleGode {DTC}
"......24-29
Chart-'97 model ...."".......
Precautions/Procedures
(DTCI
DiagnosticTroubleGode
24-19
GeneralPrecautions......".."'...........
24-31
Chart-'98 - 00 models .............
Airbag/SeatBelt Tensioner
SRSIndicatorLight Wire
24-19
Handlingand Stolage ....''...........
','," 24'33
Connections
24-20
...............'......
SRSUnit Precautions
....-........24'34
Ffowcharts
lnspeciionAfter Deployment .......'.24'20
Driver's Airbag
WiringPrecautions.............'............24-21
..'......21'87
Repfacement
SpringJoadedLockConnector
with Built-inShort Contact '...'....24-21 Front Passenger'sAirbag
.....'.',24'AS
Repfacement
Spring-loadedLock Connectors.."' 24-22
GableReel
BackProbingSPring-loadedLock
,.......24-22
Conneetors
.......'.24-91
Replacement
and
Connectors
Airbag
Disconnectingthe
SRSUnit
the Seat Beh Tensioner
.........24-95
Replacement
....'....24-23
Connectors
Airbag/SeatBelt Tensioner
Steering-lelatedPrecautions..........24-25
.................24'97
Disposaf

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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

* 1: Includedin SRSTool Set 07MAZ- SM5000B


*2: Use with the stacking patch cords from T/N 07SAZ0010004,BackprobeSet.

/n

24-14

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PageReference
24-91
24-21
24-50
24-50
24-43

Component/WiringLocationsIndex-'97 model

LIGHT(ln the gaugeassembly)


SRSINDICATOR
page24-27
Troubleshooting,
Gaugeassembly,section23

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

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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

SRSINDICAIORLIcHT (ln the gauge assembty)


page24 27
Troubleshooting,
Gaugeassembly.section23

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

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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

NOTE:The SRSmain harnessusesall GRY('97model)or GRN('98- 00 models)wires.


UNDEF,HOOD
FUSE/RELAY
BOX

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

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24-18

GRY

Precautions/Procedures
GeneralPrecautions

Carefullyinspectany SRS part beforeyou install it.


Do not installany partthat showssignsof beingdropped or improperlyhandled,such as dents,cracksor
deformation:
-

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:
.

Store the removed airbag with the pad surface up.


The driver's/frontpassenger'sairbagconnectorsand
seat belt tensionerconnectorshave a built-in short
contact (see page 24-211.

r th airb.g is impropcrty stord face down,


@
accidental deployment could propel the unit with enough
forcto caus6serious iniury,

Use only a digital multimeterto checkthe system,lf


it's not a Honda multimeter,make sure its output is
10 mA (0,01A) or lesswhen switchedto the smallest
value in the ohmmeterrange.A testerwith a higher
outputcould damagethe airbagcircuitor causeaccidentaldeploymentand possibleinjury.
Do not install used SRS Dansfrom anothervehicle,
When makingSRSrepairs,useonly new pans.
E x c e p tw h e n p e r f o r m i n g e l e c t r i c a li n s p e c t i o n s ,
alwaysdisconnectboth the negativecable and positive cable from the batterv.and wait at least three
minutesbeforebeginningwork.
R e p l a c e m e not f t h e c o m b i n a t i o nl i g h t a n d w i p e r /
w a s h e rs w i t c h e sa n d c r u i s ec o n t r o ls w i t c h c a n b e
donewithout removingthe steeringwheel:
-

Combinationlight and wiper/washerswitch replacement{seesection231.


Cruisecontrolsevresumeswitchreplacement(see
section41.

Wheneverthe ignition switch is ON {ll}, or has been


turnedOFFfor lessthan three minutes,be carefulnot
to bump the SRSunit; the airbagscould accidentally
deployand causedamageor injuries.
Wheneverthe airbaghas been activated,replacethe
SRSunit.

The original radio has a coded theft protectioncircuit.


Be sure to get the customer'scode number before disconnectingthe batterycables.

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AIRBAGCONNECTORS

Store the removed on a secureflat surfaceawav from


a n y h i g h h e a t s o u r c e( e x c e e d i n g
2 1 2 " F / 1 0 0 ' Ca)n d
free of any oil, grease.detergentor water.
lmproperhandlingor storagecan internallydamage
the airbagand seatbelttensioner.makingthem inoperative.
lf you suspectthe airbagand seatbelt tensionerhave
b e e n d a m a g e d ,i n s t a l l n e w u n i t s a n d r e f e r t o t h e
Deploymenvoisposal
for disposingof the
Procedures
damaoedunits.

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.

Inspectall the SRS wire harnesses.Replace,don't


repair,any damagedharnesses

2.

Inspectthe cablereelfor heatdamage,lf thereis any


damage.replacethe cablereel.

3.

After the vehicle is completely repaired,turn the


ignitionswitch on. lf the SRS indicatorlight comes
on for about six secondsand then goesoff, the SRS
systemis OK. lf the indicatorlight does not function
properly,go to SRSTroubleshooting.

Be surethe SRSunit is installedsecurelv.


Do not disassemble
the SRSunit.
S t o r e t h e S R S u n i t i n a c o o l { l e s st h a n a b o u t
1 0 4 " F / 4 0 " Ca)n d d r y { l e s st h a n 8 0 o / o
h u m i d i t y .n o
moisture)place.Do not spill water or oil on the SRS
unit,and keepit awavfrom dust.
During installationor replacement,be carefulnot to
bump (impactwrench,hammer,etc.)the areaa[ound
the SRS unit, The airbagscould accidentallydeploy
and causedamageor injury.

rD

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24-20

Wiring Precautions
.

Spring-loadedLock Connestorwith
Built-in Short Gontact

Neverattemptto modify,spliceor repairSRSwiring.


NOTE:SRSwiring can be identifiedby specialyellow
outercoveflng.

The driver's airbag/frontpassenger'sairbag and seat


lockconnectorwith
belttensionershave a spring-loaded
a built-inshort contact.When this connectoris disconnected,the power terminal and the ground terminal in
shorted.
the airbagconnectorare automatically
Conngctorhalvcs diSconnested:
GROUNDTERMINAL

Be sureto installthe harnesswiresso that they are


pinchedor interferingwith otherparts.
ACT

SHORTCONTACT

CABIf REELCONNECTOR

Connector halves connected;


GROUNDTERMINAL

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

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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.

When checkingvoltageor resistanceon this type of


to removethe
connectorthe first time, it is necessary
retainerto insertthe testerprobefrom the wire side.
It is not necessaryto reinstallthe removed retainer;
the terminalswill stay lockedin the connectorhousinq.

SPRING-LOADED
SLEEVE

RETAINER
*Discardafter removal.

Connecting
1.

Hold the pawl-sideconnector hall and press on the


backof the sleeve-sideconnectorhalf in the direction
shown. As the two connector halves are Dressed
together,the sleeve is pushed back by the pawl. Do
not touch the sleeve.

To removethe retainer,insert a tlat-tip screwdriver


betweenthe connectorbody and the retainer.then
carefullypry out the retainer.Takecare not to break
the connector.

RETAINEN

When the connec-torhalvesare completelyconnected,


the pawl is released.and the spring-loadedsleeve
locksthe connector.
SPRING.LOAI'ED

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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)

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24-23

Precautions/Procedures
Disconneeting
the AirbagConnectorsand the Seat BeltTensioner

Connectors(cont'd)
1.

Disconnectthe batterynegativecable,then disconnectthe positivecablefrom the battery.and wait at


leastthree minutes.
D i s c o n n e ctth e a i r b a g a n d t e n s i o n e rc o n n e c t o r s
lsee page 24-22).
Driver's Airbag:
. R e m o v et 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'sairbagand cablereel.When
disconnected,
the airbag connectoris automaticallvshorted.

Seat Bslt Tensioner(38 - 00 modebl:


. Removethe left and (or) right centerpillar lower
trim panels(seesection20).
. Disconnectthe seat belt tensioner 2P connectors
from the left sidewire harness(driver'sside)and
(or)the right sidewire harness(frontpassenger's
side).When disconnected.
the seatbelttensioner
is automatically
shorted.

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

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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

To centerthe cable reel,rotatethe cable reel clockwise


(approxiuntil it stops,Then rotate it counterclockwise
matelytwo and a halfturns) until the arrow mark on the
cablereel labelpointsstraightup.

'98 - 00 models:

LABEL

Steering Column Bemoval


CAUTION: Before removing the stosring column, tirsi
disconneqt tha connsctor between tho cabls roel and
the SRSmain harness.
lf the steering column is going to be removed without
dismounting the steering wheel, lock the sieering by
turning the ignition key to o-LOCKposition, or remove
the key trom the ignition so that the steering wheel will
not turn.

www.emanualpro.com

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

0.3s 0.35 0.3s

, s--l f.-, s--.l

--1 M.h@de

r-

-r f-

DTC21
Mo6t r.@nl p.oblem

2.

--l fl-!

Main code (1)

Sub-code (2)

D T Cr . 2

-l

M.a^ code (rt


.............v_

--l F
Sub-cod6ltl

otc I r
Third.mGr .oconl

Intermittentfailure,SRSIndicatorLight is:

Light srayson in cas ol

DTC5,1

3.

Normal(no failure),SRSIndicatorLight is:

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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.

Makesurethe ignitionswitchis OFF.


Connectthe SCSserviceconnectorto the MES con,
nector(2P).Do not use a jumperwire.

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

Turn the ignitionswitchON (ll),


The SRS indicatorlight comeson for aboutsix seconds and then goes off. Removethe SCSservjcecon
nectorfrom the MES connector{2P)within four seconds afterthe SRSindicatorlight went otf.
The SRSindicatorlight comeson again.Reconnect
the SCS service connectorto the MES connector
(2P)within four secondsafterthe SRSindicatorlioht
comeson,
The SRS indicatorlight goes otf. Removethe SCS
s e r v i c ec o n n e c t o rf r o m t h e M E S c o n n e c t o r( 2 P )
within four seconds.
The SRSindicatorlight indicatesthat the memoryis
erasedby blinkingtwo times.
Turn the ignition switch OFF,and wait for ten sec
onos.

ON

t*F
l

--- _l

Shakethe wire harnessand the connector,


takea test
quick braking,cornering),
drive (quickacceleration,
and turn the steeringwheel fully left and right,and
hold it there for five to ten secondsto find the cause
of the intermittent
failure.
lf the problem recurs,the SRS indicatorlight will
stayon.

-+t

6!.c

l.-

,l sec or less
Problemrecurs,light stayson.
SRSindicator
liqtfi
OFF
MES
connac'lol
terminals

CONNECTED

6.

lf you can't duplicatethe intermiftent


tailure,the system is OK at thistime.

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

Openin the driver'sairbaginflator

24-50

in the driver'sairbag
Increasedresistance
inflator

24-50

Shortto anotherwire in the driver'sairbag


inflatoror decreasedresistance

doesn't go off

www.emanualpro.com

24-52

Shortto power in the driver'sairbaginflator

24-54

Shortto groundin the driver'sairbaginflator

24-56

airbaginflator
Open in the passenger's

24-58

airbag
Increasedresistancein the passenger's
inflator

24-54

Shon to anotherwire in the passenger's


airbag inflator or decreasedresistance

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

Internalfailureof the SRSunit

SRSunit replacement

24-96

Internalfailureof the SRSunit

SRSunit replacement

24-96

lnternalfailureof the SRSunit

SRSunit replacement

24-96

Internalfailureof the SBS unit

SRSunit replacemenr

24-96

Internalfailureof the SRSunit or two failures


at a time

Troubleshooting

24-82

Internalfailureof the SRSunit

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

*1: In caseof an intermittentfailureDTC9-1,it meanstherewas an internalfailure


of the SRSunit or a faultv SRSindicator light circuit.Do the troubleshooting
for intermittentfailures{seepage24-28),
*2: DTCcannotbe readwith a HondaPGMTester;checkby jumpingthe SCSserviceconnector.
NOTE: Before troubleshooting DTCS5-1 through 8-5, check battery/systemvoltage. lf voltage is low. repair the charging
systembeforetroubleshooting
the SRSsystem.

24-30

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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

Shortto anotherwire in the driver'sairbag


inflatoror decreasedreslstance

2,4

3-1
3-2

3-4
4-1

4-3
4-4

4-5

www.emanualpro.com

Troubleshooting

24-52

Shortto power in the driver'sairbaginflator


Shortto groundin the driver'sairbaginflator

24-54

airbaginflator
Open in the passenger's
airbag
in the passenger's
Increasedresistance
inflator

24-54

Shon to anotherwire in the passenger's


airbaginflatoror decreasedresistance
doesn't go off

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

Openin the driver'sseatbelttensioner

24-66

lncreasedresistancein the driver'sseatbelt


tensroner
Troubleshooting
Shon to anotherwire in the driver'sseatbelt
tensroner
Short to power in the driver'sseat belt tensioner

24-66

Shortto ground in the driver'sseatbelttensloner

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

Internalfailureof the SRSunit

SRSunit replacement

24-96

lnternalfailureof the SRSunit

SRSunit replacement

24-96

Internalfailureof the SRSunit

SRSunit replacement

24-96

Internalfailureof the SRSunit

SRSunit replacement

24-96

Internalfailureof the SRSunit

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

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..

SRSIndicatorLightWireConnections
SRS Indicator Light Power Circuit
WIREHARNESS
DASHBOARD
YEL
BLK
To UNDER-DASH
FUSE/RELAYBOX <_
20PCONNECTOR

csog

To GAUGE
assEMBLy

SRS Indicator Light Control Circuit

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

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MAIN WIREHARNESS3P CONNECTOR


MAIN wlRE HARNESS24PCONNECTOR

Terminalside of msle trminals

WIREHARNESS2OPCONNECTOR
DASHBOARD
WIREHARNESS24PCONNECTOR
OASHBOARD

Wire side of lemslo terminsls

DASHBOABDWIREHARNESS5P CONNECTOR
SRSMAIN HARNESS2P CONNECTOR

Wire sid ot lemale te.minals

SRSMAIN HARNESS3P CONNECTOR

Wire side ol female terminals

SRSMAIN HARNESST8PCONNECTOR

Wire side of lomrle terminals

Terminalaide of male terminals


Wire side of female trminal3
wire side ol f.male terminals

24-33

Troubleshooting
The SRSIndicatorLight Doesn'tComeOn

lr-

CAUTION:Wheneverthe ignition switch is ON D, or


has been turned OFF for less than three minutes, be
careful not to bump the SRS unit; the airbags could
accidentallydeploy and causedamage or iniuries.
Ch6ckthe power supply (fuse):
Turnthe ignitionswitchON {ll),and checkwhetherthe other
indicatorlightscomeon (brakesystem,e(c.r.
Do the other indicator liglrts com6 on?

Checkthe No. 25 (7.5A) fuse in the under-dash


tuse/relay
DOX.

ls the tus oK?


YES

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

Checkthe SRSindicator light circuit:


Replacethe bulb, and reconnectthe gauge assembly
conneclors.
Thenturn the ignitionswitchON {ll).
Doesthe SRSindicator light come on?

I YEs

No

:ND

(A)To page24-35

24-34

www.emanualpro.com

(B)To page24 35

lu

Jt
Frompage24 34
(A)

From page 24-34


(8)

DASHBOARDWIREHARNESS
5P CONNECTOR

Chockth6 SRSindic.lor light circuit:


1. Disconnectthe dashboardwire harness5P connector
from the gaugeassembly.
2. Connecta voltmeterbetweenthe No l terminal (+) o{
the 5P connectorand grouncl.
3. Turn the ignitionswitchON {ll),and measurevoltage
ls thero 8.5 V or lats for 3ix second! aflsr the ignition
switch ha3 bon turnod ON (ll)7

YES

NO

Fdulty SRS indicator light cilctlit in ths gauge sssomblY;


replaco tho SRS printod circuit board in the gauge
aasombly,

DASHBOARDWIREHARI{ESS
5P CONI{ECTOR

c509

Wire side ol female


terminals

MAIN WIREHARNESS

Chockth6 wire harn.$ of the SRSindicstor light circuh (11:


1. Turnthe ignitionswitchOFF.
2. Disconnectthe main wire harness24Pconnectorfrom
the dashboardwire harness3. Connecta voltmeterbetweenthe No 5 terminal (+) of
the ma;nwire harness24Pconneciorand ground
4. Turnthe ignitionON {ll),and measurevoltage.
ls there 8,5 V or lr3 tor six scond3efter the ignilion
switch has bssn turnod ON llll?

YES

NO
WIRE
DASHBOARO
HARNESS24P
CONNECfOR

Short to powor in the BLU wire of tho dashbosrd wire


harne3s;Epait the harne3.s.

MAIN WIREHARI{ESS2/tP COI{ ECTOR

Terminalsideof maleterminals
To page 24-36

(cont'd)

www.emanualpro.com

24-35

Troubleshooting
The SRSIndicatorLight Doesn'tComeOn (cont,dl
From page 24-35

Checklhe wire harnessotthe SRSindicator light circuit l2l:


L Turnthe ignitjonswitchOFF.
2. Disconnect
the SRSmain harness3p connectorfrom the
mainwire harness.
3. Connecta voltmeterbetweenthe No. I terminal (+) of
the SRSmain harness3P connectorand qround.
4. Turnthe ignitionswitchON (ll),and measurevoltaqe.
ls there 8.5 V o. less tor six seconds atter the ignition
switch has beenturned ON

MAIN WIREHARNESS
3P CONNECTOR

UNDER.DASH
FUSE/RELAY
BOX
'98 -

Short to power in th BLU wire of the main wiro halno3s;

'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

Short to power in the BLU wire oI the SRS main harngas;

24-36

www.emanualpro.com

FUSE/RELAY
BOX

The SRSIndicatorLight Doesn'tGo Off -'97 model


CAUTION:Wheneverth ignilion switch i3 ON (lll, ol
has been turnd OFF for less than three minutes, be
careful not to bump the SRS unit; the airbags could
accideniallydeploy and causedamag or iniuries.
Try to reproducethe sRs indicator light:
1. ErasetheDTCmemory(seepage24 28)
2. Turn the ignitionswitchON {ll),and checkthat the SRS
indicatorlight comeson for aboutsix secondsand then
goes off.
Doe3 the SRS indicator light slay on?

NO

YES

Intermiftent ftilure, system is OK at this time. So Troubl_


shootingIntermittentFailuteson p.ge 24_28.

Checkthe No. 13 (15 Al fuse:


'L Turn the ignition switch OFF.
2. Checkfor blown No. 13 (15 A) fuse in the under dash
fuse/relaybox.
ls lhe tuse OK?

No. 13 115Al FUSE


NO

YES

UNOER.DASH
FUSE/RELAYBOX

Replacethe luse, and err3e the memory


' 1 . R e p l a cteh e N o .1 3 ( 1 5 A ) f u s e
2. Erasethe DTc memory(seepage24-28).
3. Turnthe ignitionswitchON (ll).
ioes

the SRS indicatol light go off after 3ix s6conds?

YES

SRSUNIT

NO

ENO

Confirm tho OTC,and continuettouble3hooting.

Checkfor an open in the SRSmain hatnss{VA lins}:


1. Disconnectthe batterYnegativecable,then disconnect
the positivecable,and wait for threeminutes.
airbagcon
the driver'sand front passenger's
2. Disconnect
nectors(seepage24-23).
3. Disconnectthe SRS main harness18Pconnectorfrom
the sRs unit.
4. Reconnectthe battery positive cable, then reconnectthe
negativecable.
5. Connecta voltmeterbetweenthe No. 7 terminal (+) ot
the SRSmain harnessl8P connectorand 9rouncl
6. Turnthe ignilionswitchON {ll).
ls there battory voltage?
YES

SRSMAIN HARNESS
r8P CONNECTOR

SRSMAIN HARNESS18P CONNECTOR

NO

Ooen in the SRS main harness{VA line); replacethe


natnoss.

(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

Faulty SRSunit or poo. contact at the SRSmain ha.ness


18Pconnectoi; checkthe connector.
lfthe conneqtoris OK, replacethe SRSunit.

SRSMAIN HARNESS18PCONNECTOR

Oidtuse No. 13 (15Al blow?

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

Wire side ol female


terminals

T
243a

www.emanualpro.com

Frompage24-38
{B)

DASHBOARDWIREHARNESS
5P CONNECTOR

Checklhe SRSindicalor circuit:


1. Turnthe ignitionswitchOFF
2 . R e m o v et h e g a u g e a s s e m b l y D o n o t d i s c o n n e ctth e
dashboardwire harness5P connectorfrom the gauge
assemoly.
3. Turn the ignition switch ON (ll).
4. Connecttie dashboardwire harness5P connectorterminalsNo. I and No 5 with a iumperwire.
Doesthe SRSindicator light 90 otn

Faulty SRS indicator light circuit in the 9aug6 a$embly;


reolace the SRS printod circuit boa.d in th' gauge

DASHBOARDWIREHARNESS
5P CONI{ECTOR

Y;yfivvcsos
ffi
BLU
I

Checktor rn open in the SRSindicator light circuit:


1. Turnthe ignitionswitchOFF
2. Disconnectthe dashboardwire harness5P connector
from the gaugeassemblY.
between the No. 6 terminal ol the SRS
3. Checkres]sta-nce
main harness18Pconnectorand No l terminal ol the
dashboardwire harness5P connector;there should be

IYEL

JUMPERWIRE

Wir6.sideof female
lormrna|s

SRSMAI HAN ESS


t8P CO I{ECTOR

Wire side oI fsmale terminals

{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

Checkfor a short to ground in tho main wire ha.n.3s:


1. Disconnectthe dashboardwire harngss24p connector
from the main wire harness,
2. Checkresistancebetweenthe No. 5 terminal of the dash_
board wire harness24P connectorand ground. There
shouldbe 1 M0 or more.

OASHBOARD
WIRE
HARNESS
24PCONNECTOR

Short to ground in tho deshbosrd wire harne.r; raD.ir


the dashboardwiro harness.
DASHBOARDWIREHAff{ESS
24P COi{NECTOR

BLU

Wire side of female


t6rminals

MAIN wlRE HARNESS


3P CONNECTOB

Checktor a short to ground in tho SRSmain hfina3!:


1. Disconnectthe SBS main harness3p connectorfrom the
maanwire harness.
2. Checkresistancebetween the No. 1 terminal of the SRS
main harness3P connectorand ground.Thereshouldbe
1 MO or more.

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.

Short to ground in the SRS main hsrn6sa;.oplac. thc SRS


main harn6ss.

24-40

www.emanualpro.com

)
DASHBOARDwlRE hARNESS
5P CONNECTON

From page24-39
(D)

Checkthe SRSindicator circuit input voltage:


the SRS main harness18Pconnectorto the
1. Reconnect
SRSunit
2. Connecta voltmeterbetweenthe No 1 terminal (+) of
the dashboard5Pconnectorand ground.
3. Turn the ignition switch ON (ll), wait for six seconds,
then measurevoltage
fs there 8.5 V or more?

YES

NO

The oroblem hts disappoareddue to disconnoctingand


connecting the connectors. Be 3ure all terminals make
good contact, and rocheckthe system {see Trouble'
shooting Intermittent Failur6 on pagg2'l-281'

Pool contacl at the SRS main harness18Pconnector;check


the connector.
. lf the connoctor is OK. aubstituta a known-good SRS unit,
and recheck.
. ll the problem is still present, replaco the SRS main h'r-

DASHBOAROWIREHARI{ESS
5P CONI{EC'OR

c509

ness.
Frompage24-39
iE)

Checkfor an oPen in the dashboardwire hatn8s:


1. Disconnectthe main wire harness24P connectorIrom
the dashboardwire harness
2. Check resistancebetween the No. 6 terminal of the SRS
and No 5 terminalotthe main
mainhamess18Pconnector
wire harness24Pconnector;thereshouldbe 0- 1 0 O
15the resistance.s specified?

YES

NO

ODen in the BLU wire ot the dashboard wit6 harness;


rep.ir the dashboaldwite harness.

Terminalsideof malelerminals

Checkfor an open in the main wirc harness:


'1. Disconnect
the SRSmain harness3P connectorfrom the
mainwire harness,
2. Checkresistancebetweenthe No. 6 terminal of the SRS
and No 1 terminalofthe SRS
mainharness18Pconnector
shouldbe 0 - 1 0 u
main harness3Pconnector;there
|3 lhe re3istanceas sPecifiod?
YES

NO

Oon in the BLU wire ol the main wire harness; rcpair


tha main wire harness

SRSMAIN HABNSS
3P CONNECTOR

Opn in the SRS main harn4s; replacethe SRS msin har'


no3s.

www.emanualpro.com

24-41

Troubleshooting

tl-

The SRSIndicatorLight Doesnt Go Off - ,99- 00 models


CAUTION:Wheneverthe ignition switch is ON {lll, or
has been turnod OFF for less than three minutes, be
careful not to bump the SRS unit; the airbags could
accidentallydeploy and causedamage or iniuries.
T.y to reproducethe SRSindicator tight:
1. Erasethe DTCmemory(seepage24-28).
2. Turn the ignitionswitchON { }, and checkthat the SRS
indicatorlight comeson for aboutsix secondsand then
goes off.
Doesthe SRSindicator tight stey on?
YES

NO

Intermittent failure, system b OK at this time. 56 TroubleshootingInle.mittent Failureson page24-2g.

Checkthe No. 23 (10Alfuse:


1. Turnthe ignitionswitchOFF.
2. Checkfor blown No. 23 flO A) fuse in the under dash
luse/relaybox.
ls the fuse OK?
No. 23 110Al FUSE

YES

NO

FUSE/RELAY
BOX

Repl.ce the tuse, and erasethe memory


1. Beplacethe No. 23 (10Ai fuse.
2. Erasethe DTCmemory(seepage24-28).
3. Turnthe ignitionswitchON flt).
Doesthe SRSindicator light go ott after six secondt
YES

NO

END

Conti.m tha DTC,and continue troubl*hooting.

Chockfor an open in the SRS main harness(Vg line):


1. Disconnectthe batterynegativecable,then disconnect
the positivecable,and wait for threeminutes.
2. Disconnectthe driver,sand front passenger,sairbag con_
nectors,and discoonectthe seat belt tensionerconnectors
(seepage 24-23).
3. Disconnectthe SRS main harness18p connectorfrom
the sRs unit.
4. Reconnect
the bafterypositivecable,then reconnectthe
negativecable.
5. Connecta voltmeterbetweenthe No. 3 terminal (+) of
the SRSmain harness18pconnectorand oround.
6. Turnthe ignitionswitchON 0l).
ls there battery voltage?
YES

SRSMAIN HARNESS18PCONNECTOR

NO

Open in the SRS main harness(VB line); replacothe


natness,

|
(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?

Faulty SRSunit or poor contact at the SRSmain harness


18Pconnedor; checkthe connector.
lf the connoctoris OK, replacethe SRSunit

SRSMAIN HARNESS18PCONNECTOR
Did tuseNo. 23 {10A} blow?
JUMPERWIRE

1B)
fo page24-44

Check for a short to ground in the SRS indicator light circurl:


1. Turnthe ignitionswitchOFF.
2, Disconnectthe dashboardwire harness5P connector
from the gaugeassembly,
betweenthe No l terminalofthedash3. Checkresistance
r n d g r o u n d .T h e r e
b o a r dw i r e h a r n e s s5 P c o n n e c t o a
shouldbe 1 Mo or more.

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

Checkthe SRSindicator circuit:


1. Turnthe ignitionswitchOFF.
2 . R e m o v et h e g a u g e a s s e m b l y D
. o n o t d i s c o n n e ctth e
dashboardwire harness5p connectortrom the gauge
assemDty.
3. Turnthe ignitionswitchON 0l).
4. Connectthe dashboardwire hamess5p connectortermi
nalsNo. 1 and No. 5 with a iumoerwire.
Dooslhe SRSindic.tor light go offl
YES

NO

Fauhy SRS indic.tor light circuit in lho gruge a3samblv;


replaco the SRS print6d circuit bo.rd in the g.uge
assombly.

Checkfor an opeo in the SRSindicaior light circuit:


1. Turnthe ignitionswirchOFF.
2. Disconnectthe dashboardwire harness5p connector
from the gaugeassembly.
3. Checkresistance
betweenthe No. 6 terminalof the SRS
main haroess18Pconnectorand the No. 1 terminal ot
the dashboardwire harness5P connector;there should
be0-1.0O.
|3 the rosbtance a3 sDecified?

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

Chockfo. a short to glound in tho main wire harn63:


1. Disconnecttho dashboardwire harnoss24P connector
from the mainwire harness.
betweenthe No 5terminaloIthedash2. Checkresistance
board wire harness24P connectorand ground. There
shouldbs 1 Mo or more.

WIRE
OASHBOARD
HARNESS
2,rP CONNECTOR

Short to ground in tho dashboatd wilo harnots; repair


OASHBOARDWIREHARI{ESS
24P 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.

Short to ground in thc SRS mtin hemess; replacetho SRS

)
(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

Chckthe SRSindicator circuit input voltage:


1. Reconnectthe SRS main harness18p connectorto the
SRSunit.
2. Connecta voltmeterbetweenthe No. 1 terminal {+) of
the dashboard5P connectorand ground.
3. Turn the ignition switch ON {ll}, wait for six seconds,
then measurevoltage.
ls there 8.5 V or more?

YES

NO

The problem has disappareddue to disconnectingand


connecting tho connectors. Be sure all terminals make
good contact, and .echeck the system {seo Troublo_
shooting Intermiftent Failureson page2it-2E).
DASHEOARDWFE HARNESS
5P CONNECTOR
Poo. contact at the SRS main harn8s 18p connector;check
the connector.
. lf the connoctor is OK, aubstitute a known-good SRS unit,
end recheck.
. lf the problem is still present, .6place tho SRS m.in harne33.

c5ott

Wiresideof lemale
terminals

Ftom lage24-44

(E)

Checkfor an open in the dashboa.dwire harnessi


1. Disconnectthe main wire harness24p connectorfrom
the dashboardwire harness.
2. Checkresistancebetween the No. 6 terminal of the SRS
main harness18Pconnectorand No. S te.minalof the main
wire harness24Pconnector;thereshouldbe 0 - 1.00.
ls th resistancers speciliedT
YES

NO

Open in the 8LU wi.o ol the dashboard wire hrmess:


repair the dashboardwire ha.ness.

Torminalsideol maletermtnal

Checkfo. an open in the m.in wire hamess:


1. Disconnect
the SRSrnainharness3p connectorfrom the
main wire harness,
2. Check resistancebetweenthe No. 6 terminal of the SRS
rnain harness18Pconnectorand No. 1 terminalof the SRS
main harness3Pconnector;there
shouldbe 0 1.0O.

SRSMAIN HARNESS
18PCONNECTOR

c806

b the rGbtanco as sDecified?

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.

No. 13(r5 Al FUSE

ls the fuse OK?


YES

UNDER-DASH
FUSE/RELAYBOX

NO

The problm has disappeared.Ted{rive the vhicle and


see TroubfeshootingIntermittont Failureaon page21-28.

Check Ior short to ground between tho underdash tuse/


relay box and the SRSunil.
1. Turnthe ignitionswitchOFF.
2. Disconnectthe batterynegativecable,then disconnect
the positivecable, and wait for threeminutes.
3. Disconnectthe driver's and front passenger'sairbag connectors,and disconnectthe seat belt tensionerconnectors
(seepage24-23).
4. Disconnectthe SRS main harnessl8P connectorfrom
the sRs unit.
betweenthe No. 7 terminalof the SRS
5. Checkresistance
main harness18Pconnectorand ground.
Thereshouldbe 1 M0 or more.

SBSMAIN HARNESS
18PCONNECTOR

ls the .esistancoas soecified?


YES

NO

SRSMAIN HARNESS18PCONNECTOR

Faulty SRSunit; replacelhe SRSunit {seepage 24-951.

(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

Short to ground in tho under-da3hlus6/rolay box;


replacethe under-dashfuse/relav box,
Short to glound in the SRS m.in hernoss;roplacetho SRS
main hatnei3.

FUSE/RELAYBOX

J
(A)Frompage24-47

SRSMAIN HARNESS18PCONNECTOR

Checktor an opn in the SRSmain harness:


1. Turnthe ignitionswitchOFF.
2. Disconnectthe batterynegativecable,then disconnect
the positivecable.and wait for threeminutes.
3. Disconnectthe driver's and front passenge/sairbag con,
nectors,and disconnectthe seat belt tensionrconnectors
{seepage 24-23}.
4. Disconnectthe SRS main harness18Pconnectorfrom
the SRSunit.
5. Reconnectthe battery positive cable, then reconnectthe
negativecable.
6. Connecta voltmeterbetweenthe No. 7 terminaloI the
SRSmain harness18Pconnectorand ground.
7. Turnthe ignitionswitchON (lll , and measurevoltage.

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

Checktor an open in the SRSmain harne$:


1. Turnthe ignitionswitchOFF.
2. Disconnect
the SRSmain harness2P connectorlrom the
undeFdashfuse/relaybox.
3. Checkresistancebetween the No. 1 terminal of the SRS
main harness2P connectorand the No. 7 terminalof the
SRSmain harnessl8P connector.
Thereshouldbe 0 - 0.5O.
ls the re3istancas soecitiod?

YES

NO

Poor contact at iho SRS main harnoss2P connoctor;


checkthg connocior.
. lf the connector is OK. substitute a known-good underda3hfuse/rolav box, and .echeck.
'lf tho problm is still present. replace tho SRS main
harne3s.

UNDER-DASH
BOX
FUSE/RELAY

SRSMAIN HARNESSlEP CONNECTOR


Opon in the SRS main ha.ness;replacethe SRS main har
ness.

c801
SRSMAIN HARNESS
2P CONNECTOR

www.emanualpro.com

24-49

Troubleshooting
DTC1-1and DTC1-2
J

CAUTION:Wheneverthe ignition switch is ON {ll}, or


has been turned OFF for less than three minutes, be
careful not to bump the SRS unit; the airbags could
accidentallydeploy and causedamage o1 iniuries.

DRIVEF'SAIRBAG
2P CONNECTOR

Try to reproducethe SRSindicator light:


1. Erasethe DTCmemory(seepage24-28).
2. Turn the ignitionswitchON (ll),and checkthat the SRS
indicatorlight comeson tor about six secondsand then
ooes off.

CABLEREEL
2P CONNECTOR

Doesthe SRSindicator liqht stav on?

YES

NO

Intermiltent failure, svstem is OK at this time. See


Trouble3hootingIntermittent Failureson page 24-28.

Checktor an open in the driver's airbag inflatori


1. Turn the ignitionswitchOFF2. Disconnectthe batterynegativecable,then disconnect
the positivecable,and wait for threeminutes.
3. Disconnectthe driver's airbag 2P connectorfrom the
cable reel 2P connector-Do not disconnectthe passen
ger'sairbagconnector.
4. Connectthe specialtool(2 O)to the cablereel2P connec
tor.
5. Reconnect
the battervpositivecable,then reconnectthe
negativecable,
6. Erasethe DTCmemory(seepage24-28).
7. Readthe DTC{see page 24-261.
ls DTC 1-1or DTC 1-2 indicsted?

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

Open or increasedresistancein the driver'sairbaginflato.;


replacethed.ive.'s airbag (s6epage24-871.

Checkfoi an ooen in the cable reel:


1. Disconnectthe batterynegativecable,then disconnect
the positivecable,and waatfor threeminutes.
2. Disconnect
the specialtool (2 Oi from the cable reel 2P
3. Removethe dashboardlower cover,and disconnectthe
cablereel2P connectorfrom the SRSmain harness.
4. Connectthe specialtool (2 0) to the SBSmain harness2P
(cont'd)
connector,

To page24'51

24-50

www.emanualpro.com

SRSSIMULATOR
LEADC
07TAZ- SZ5011A
and SRSINFLATOR
SIMULATOR
120 JACKI
07sAz - TB4011A

)
Frompage24 50

Checkfor an opon in the cabl rel (cont'd):


5. Reconnect
the battervpositivecable,then reconnectthe
negativecable,
6. Erasethe DTCmemory(seepage24-28).
7. Readthe DTC(seepage24-2d.
ls DTC 1-1or DTC 1-2 indic.ted?
YES

NO

Open or increased resistance in the cable reel; replace


the cable reel (seepaqe 24-91J.

Checkfor an open in the SRSmain harne$:


1. Disconnectthe batterynegativecable,then disconnect
the positivecable,and wait lor threeminutes.
2- Disconnect
the front passenger's
airbagconnectorland
disconnect
both seatbelttensionerconnectors),
3, Disconnectthe SRS main harness18Pconnectorfrom
the SRS unit. Do not disconnectthe specialtool 12 O)
from the SRSmain harness.
4. Checkresistance
betweenterminalsNo. 1 and No. 13 of
the SRSmain harness18Pconnector.
Thereshouldbe aoorox.2.0 3.0 0.

SRSMAIN HARNESS
18PCONNECTOR

ls the rcsistancas soecified?

YES

NO

Poor contact at the SRS main harnoss 18P connctor;


check the connector.
. It the connecior is OK, substitute a lnown-good SRS
unit, and recheck.
.lf the problem is still present,.eplacethe SRS main
harness,

Opon or inc.oasedrc3istancein the SRS main harnoss;


roDlacetho ha]nss.3.

www.emanualpro.com

24-51

Troubleshooting
DTC1-3
J

CAUTION: Whonovor the ignition switch is ON (ll), or


has been turnod OFF for less thsn three minutss. be
caroful not to bump the SRS unit; tha ailbags could
accidentallydoploy and cau3odamage or iniuries.
Try to r.produce the SRSindicator light:
1. Erasethe DTCmemory(seepage24-28).
2. Turn the ignitionswitchON (ll),and checkthat the SRS
indicatorlight comeson for about six sacondsand then
goes off.
Do.s the SRSindic.tor light stay on?

YES

2P CONNECTOR

NO

Intermittenl failuro. sy3tom i3 OK at this time. Soo


Trouble3hootingIntormittenl Failure3on prqo 24-28.

Chockfor a short to enother wirG in the driver's sirbag inf,artor:


1. Tlrn tho ignitionswitchOFF.
2. Disconnectthe battery negativecable,then disconnect
the positivecable,and wait for three minutes.
3. Disconnctthe driver's airbag 2P connectorfrom the
cablo rel 2P connector,Do not disconnectthe oassenger'sairbagconnctor.
4. Connectthe specialtool(2 Olto the cablereel2P connector.
5. Reconnectthe baftery positive cable, then reconnectthe
negativecable.
6. Erasethe DTCmemory (seepage 24-28).
7. Readthe DTC(see page24-261.
b DTC1-3 indicatod?
YES

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

Sho.t in the driv6r's airb.g intletor; replacethe d vr's


.irb.g l3oo pag6 247).

Ch6cklor a short in the cablc reol:


'1. Disconnectthe
battery negativecable,then disconnect
the positivecable,and wait for threeminutes.
2. Disconnectthe specialtool {2 O) lrom the cable reel 2P
conneclor.
3. Removethe dashboardlower cover,and disconnectthe
cablereel2P connectorfrom the SRSmain harness.
4. Connectthe specialtool (2 O) to the SRS main harness
2P connector.
{cont'd}

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

Chockfor a shon in th6 cablo recl {cont'dl:


5. Reconnectthe battery oositive cable,then reconnecttha
negativecable.
6. Erssethe DTCmemory (seepage 24-28).
7. Readthe DTC(see page24-26l'.
ls DTC'l-3 indic{tod?

NO

YES

SRSUNIT

Short in the csble reel; replacetha cabls rcol lsao paga


24-911.

Chockfor a short in th SRSmain ha.nors:


1. Disconnectthe batterynegativecable,thn disconnect
the Dositivecable,and wait for three minutes.
2. Disconncttho lront passengor'sairbag connector (and
disconnectboth seat belt tensionerconnectors).
3. Disconnectthe SRS main harness18Pconnectorfrom
the SRS {rnit.Do not disconnectthe specialtool (2 0)
from the SRSmain harness2Pconnector.
4. Checkthe resistancebetweenterminals No. 1 and No. 13
of SRSmain harness18Pconnector.
Thereshouldbe aDorox.2.0- 3.00.

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

CAUTION: Whonover the ignition switch is ON (ll), or


has boen turned OFF for less than throe minutos, bs
carelul nol to bump tho SRS unit; the airbags could
accidentallydeploy and causedamago or iniuri63.
Try to rop.oducotho SRSindicator light:
1. Erasethe DTCmomory(soepage24-28).
2. Turn the ignitionswitchON {ll},and checkthat the SRS
indicatorlight comeson for aboutsix secondsand then
goes off.
Doe3th6 SRSindicltor light 3tay on?

YES

REEL
2P CONNECTOR

NO

Intormittent tailure, rystem is OK rt this timo. See


Troubl$hooting Intermittent Failurcson pago 2G28.

Chacklor a 3hort to powor in ths driyar's airbag inflrtor:


1. Turnthe ignitionswilchOFF.
2. Disconnectthe batterynegativecable,thn disconnect
the positivecable,and wait for threeminutes.
3. Disconnectthe driver's airbag 2P connector{rom the
cable reel 2P connector.Do not disconnectthe passenger'sairbagconnector.
4. Connectthe specialtool (2 0) to the cablereel2P conn6ctor,
5. Reconnctthe battery positive cable.then reconnectthe
negativecable.
6. Erasethe DTCmemory (seepage 24-28).
7. Readthe DTC{see page 24-261.
ls DTC 1-4 indicatod?
YES

SIMULATOR
LEAD C
07TAZ- SZ5011A
.rd SRSINFIATOR
/SIMULATOR
./ ea JA0KI

1(

ffi

otstz-terore

ltl

'97 model:

'98 - 00 models:
CABLE
REEL

NO

Short to powe. in the driv.r's rirbrg inflator; replacethe


ddver's airbeq (!o D.qa 2447).

Chckfor. short to powe. in tho cabl6.ool:


1. Disconnectthe batterynegativecable,then disconnect
the oositivecable,and wait lor three minutes.
the specialtool (2 O) from the cable reel 2P
2. Disconnect
connefior,
the
3- Removethe dashboardlower cover,and disconnect
cablereel2Pconnectorlrom the SRSmain harness.
4. Connectthe specialtool (2 0) to the SRS ma;n harnss
(cont'dl
2P connoctor.

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

Checkfor 6 short power in the cable r6el {cont'd):


5. Reconnectthe battery positive cable, then reconnectthe
negativecable.
6. Erasethe DTCmemory (seepage 24-28).
7. Readthe DTC(see page 24-261.
b DTC1-4 indicarodz

YES

NO

Short to power in lhe cablo roel; replace th cabl ieel


{seepago24-91).

Checktor a short to power in th. SRSmain harn$s:


1.Disconnectthe batterynegativecable,then disconnect
the positivecable, and wait for three minutes.
2. Disconnectthe front passenger's
airbagconnector{and
disconnect
both seatbelttensionerconnectors).
3. Rernovethe specialtool (2 O)from the SRSmain harness
2P connector.
4. Disconnectthe SRS main harness18Pconnectorfrom
the SRSunit.
5. Beconnectthe batterv positive cable, then reconnectthe
negativecable.
6. Connecta voltmeterbetweenthe No. 1 {+) terminalol
the SRSmain harness18Pconnectorand body ground.
7. Turn the ignition switch ON (ll), and measurevoltage.
Thereshouldbe 0.5V or less.
8. Turnthe ignitionswitchOFF.
9. Connecta voitmeterbetweenthe No. 13 {+i terminalof
the SRSmain harness18Pconnectorand body ground.
10.Turnthe ignitionswitch ON lll), and measurevoltage.
Thereshouldbe 0.5V or less.
Are voltagesas specified?
YES

SRSMAIN HARNESS
18PCONNECTOR

NO

Faulty SRSunit; replacoth SRSunit lsoo pas6 24-95).

Short to power in th SRS main hamoss; roplecethe SRS


main haanass.

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

Try to reproducethe SRSindicator light:


1. Erasethe DTCmemory(seepage24-28).
2. Turn the ignitionswitchON lll), and checkthat the SRS
indicatorlight comeson for aboutsix secondsand then
goes off.

CAALEREEL
2P CONNECTOR

Doostho SRSindicator liqht stav on?

YES

NO

Inte.mittent tailure,3y3tem is OK at this timo. 506


TroubleshoolingIntermittent Failureson Daq24-28.

Checktor a short to ground in the driver's ai.bag intlator:


1. Turnthe ignitionswitchOFF.
2. Disconnectthe battery negativecable,then disconnect
the positivecable,and wa:l for threeminutes.
3. Disconnectthe driver's airbag 2P connectorfrom the
cable reel 2P connector,Do not disconnectthe passen,
ger'sairbagconnector.
4. Connectthe specialtool {2 O}to the cablereel2Pconnector.
5. Reconnectthe battery positive cable. then reconnectthe
negativecable.
6. Erasethe DTCmemory(seepage24 28).
7. Readthe DTClsee page 24-261.
ls DTC1-5 indicated?
YES

NO

ar
h /
ffi

'97 model:

SRSSIMULATOR
LEADC
07TAZ- SZ50r1A
.nd SRSINFLATOR
SIMULATOR
{2 0 JACK)
07sAz - TBaolrA

'98 - 0Omodels:
CABLE
REEL
2PCONNECTOR

Short to ground in the driver's airbag inflator;replacethe


driver's airbag (s6epage 24-871.

Chockfor a short to ground in the cablo reel:


1. Disconnectthe battery negativecable,then disconnect
the positivecable,and wait for threeminutes.
2. Disconnect
the specialtool i2 O) from the cable reel 2P
3. Removethe dashboardlower cover,and disconnect
the
cablereel2P connectorfrom the SRSmain harness.
4. Connectthe specialtool {2 O) to the SRS main harness
(cont'd)
2P connector.

SRSSIMULATOR
LEAOC
07TAZ- SZ5011A
and SRSINFLATOR
SIMULATOR
t2 0 JACKI
07sAz - TB{01rA

To page24-57

J..
24-56

www.emanualpro.com

)
Frompage24 56

Check{or a short to ground in the cable reel (cont'd):


5. Reconnectthe batterv positive cable, then reconnectthe
negativecable.
6. Eraselhe DTCmemoty lsee page 24-28).
7. Readthe DTClsee page24 26).
ls OTC1-5 indicated?

YES

NO

Short lo ground in the cable reel; replacethe cable reel


{seeoaoe 2,1-91}.

Checkfor a short to ground in the SRSmain harness:


'1. Disconnect
the batterynegativecable,the disconnect
the
positivecable,and wait for threeminutes.
2. Disconnectthe tront passenger'sairbag 2P connector
(6nddisconnect
both seatbelttensionerconnectors).
3. Removethe specialtool 12{))fromthe SRSmain harness
2P connector.
4- Disconnectthe SRS main harness18Pconnectorfrom
the sRs unit.
5. Checkresistance
betweenthe No. l terminalo{theSRS
main harness18Pconnectorand ground,and between
the No. 13terminalof the SRSmain harness18Pconnector and ground.
Thereshouldbe I M0 or more.

SRSMAIN HARNESS
18PCONNECTOR

ls lhe resistanceas soecitiod?


YES

NO

Faulw SRSunit reDlacethe SRSunit lsee paqe 24-951.

Short to ground in the SRS main harness;replacethe SRS


main hamss,

www.emanualpro.com

24-57

Troubleshooting
DTC2-1 and DTC2-2

!a
SRSMAIN HARNESS

CAUTION:Wheneverthe ignition switch is ON lll), or


has been turned OFF tor less than throe minutes, be
careful not to bump the SRS unit; the airbags could
accidentallydeploy and causedamage or iniuries.
Try to reproducethe SRSindicator light:
1. Erasethe DTCmemory(seepage24-28).
2. Turn the ignitionswitchON (ll),and checkthat the SRS
indacator
light comeson for aboutsaxsecondsand then
Doesthe SRSindicator lioht stav on?

Intermittent tailure, svstem is OK ai lhis time. See


Troubl*hooting Intermittent Failureson paqe24-28.

Chockfor an open in the passongor'sairbag inflator:


1. Turnthe ignitionswitchOFF.
2. Disconnectthe batterynegativecable,then disconnect
the positivecable,and wait for threeminutes.
3- Disconnect
the front passenger's
airbagconnectorlrom
the SRSmain harness(seepage24-2:,,.
4. Connectthe specialtool (2 0) to the SRS main harness
2P connector.Do not disconnect
the driver'sairbagcon,
nector.
5. Reconnectthe battery positive cable, then reconnectthe
negativecable.
6. Erasethe DTCmemory(seepage24-28).
7. Readthe DTC(seepage 24 26!'.
ls DTC2-1 or DTC2-2 indicated?

Open or incrcased resistance in tho passenger'sairbag

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

Checkfo. an oD6nin the SRSmain harness:


1. Disconnectthe batterynegativecable,then disconnect
the positivecable,and wait for threeminutes.
2. Disconnectthedriver'sairbag2P connectorland disconnect
(seepage24 23).
both seatbelttensionerconnectors)
3. Disconnectthe SRS main harness18Pconnectorfrom
the SRS unit. Do not disconnectthe soecialtool (2 Oi
from the SRSmain harness.
4. Checkresistance
betweenthe No. 10terminaland No. 14
terminalof the SRS main harness18Pconnector.There
shouldbe aoorox.2.0- 3.0g.
ls the .osistancas soecified?
YES

NO

Poor contacl ai the SRS main harness 18P conneclori


checklhe connector,
.lf the conneclor is OK, substitute a known-good SRS
unit, and recheck.
.lf the problem is still present,replacethe SRS main

18PCONNECTOR

hatnesli,

Open or increasedresistancein the SRS main harness;


replacethe harness.

www.emanualpro.com

24-59

Troubleshooting
DTC2-3

{J

CAUTION: Whenevor the ignition switch is ON { }, or


has been turned OFF for less than three minutes, be
careful not to bump the SRS unit; lhe airbags could
accidentallydeploy and causodamage or iniuries.

SRSMAIN HARNESS

Try to reproducethe SRSindicator light:


1- Erasethe DTCmemory{seepage24 28).
2. Turn the ignitionswitchON (ll),and checkthat the SRS
indicatorlight comeson for aboutsix secondsand then
goes off.
Doesthe SRSindicator light stay on?

YES

NO

Intermittont failur, syslem is OK at this time. 560


T.oubloshootinglntormittent Failur6 on page 24-28.

Checkfor a short to another wiro or decreasedresbtanc in


the pa$nger's airbag inflator:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe batterynegativecable,then disconnect
the positivecable,and wait for threeminutes.
3. Disconnectthe front passenger'sairbag 2P connector
from the SRSmain harness(seepage24-23).
4. Connectthe specialtool (2 O) to the SRS main harness
2P connector.Do not disconnectthe driver,sairbagconnector.
5. Reconnectthe battery positive cable, then reconnectthe
negativecable.
6. Erasethe DTCmemory(seepage24 28i.
7. Readthe DTC(seepage 24-26).
ls DTC2-3 indicated?
YES

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

Faultv SRSunit; replacelhe SRSunit lsee page 24-95).

Short to anothor wire or decre.sed re3i3t.nce in the SRS


main harness;replacthe SRSmain harn*s.

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

Try to reproducethe SRSindicator light:


1. Erasethe DTCmemory(seepage24-28i.
2. Turn the ignitionswitchON (lli, and checkthat the SRS
indicatorlight comeson tor about six secondsand then
goes off.
Dosthe SRSindicator light stay on?
YES

NO

Inlermittent tailure, system is OK at this tim. Sce


Troubleshooting Intermitt.f Failureson page 2+28.

Checkfor a short to power in the passengar,sai.bag inflator:


1. Turnthe ignitionswitchOFF.
2. Disconnectthe bafterynegativecable,then disconnect
the positivecable,and wait for threeminutes.
3. Disconnectthe front passenger'sairbag 2P connector
Irom the SRSmain harnesslseepage24-23).
4. Connectthe specialtool (2 O) to the SRS main harness
2P connector.Do not disconnect
the driver,sairbagcon,
nector,
5. Reconnectthe battery positive cable, then reconnectthe
negativecable.
6. Erasethe DTCmemory(seepage24-28).
7. Readthe DTC(see page 24-26|'.
ls DTC2-4 indicsted?

YES

NO

Sho.t power in the passenger's airbag infator; rsplece tho


paisonge/i airbag {se pag 2il-89).

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

Are voltages .3 specifiedT


YES

NO

FaultySRSunit; replacethe SRSunit (sce page 24'95).

Short to powor in the SRS main ha.ne3s; replace the SRS


main hdrness.

www.emanualpro.com

24-63

Troubleshooting
DTC2-5
tl

CAUTION:Wheneverthe igniiion switch is ON {ll}, or


has ben turnd OFF for less than three minutes, be
careful nol to bump the SRS unit; the sirbags could
accidentallydoploy and causo damage or iniuries.
Try to rep.oducethe SRSindicstor tight:
1. Erasethe DTCmemory(seepage24-28).
2. Turn the ignitionswitchON 0l), and checkthat the SRS
indicatorlight comeson for aboutsix secondsand then
goes off.
ooes th6 SRSindicaror light st.y on?

YES

NO

Inte.mitt.nt failure, system is OK at thi3 time. Se


Troubl6hooting Intermittem Failur6 on page2+28.

Checkfor a short to gaound in th6 prsenger,i airbag inllator:


1. Turnthe ignitionswitchOFF.
2. Disconnectthe batterynogativecable,then disconnect
the positivecable,and wait for threeminutes.
3. Disconnectthe front passenger,sairbag 2p connector
from the SRSmain harness{seepage24-23).
4. Connectthe specialtool (2 0) to the SRS main harness
2P connector.Do not disconnectthe driver,sairbagcon,
nector.
5. Reconnectthe battery positive cable, then reconnectthe
negativecable.
6. Erasethe DTCmemory (seepage 24-28).
7. Readthe DTClsee page2[-261.
ls DTC2-5 indicated?
YES

NO

Short to ground in the pasngert airbeg inflator; ,cplace


the passenge/s airbag (se page 2+991.

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

Checkfor a short to ground in the SRSmain harnessl


1. Disconnectthe batterynegativecable,then disconnect
the posilivecable.and wait for threeminutes.
2. Disconnect
the driver'sairbag2P connector(anddisconnectboth seatbelttensionerconnectors),
3. Disconnectthe SBS main harness18Pconnectorfrom
the sRs unit.
4. Removethe specialtool (2 O)from the SRSmain harness
2Pconnector,
5. Checkresistance
betweenthe No. 10terminalof the SRS
main harness18Pconnectorand ground,and between
the No. 14terminalof the SRSmain harness18Pconnec
tor and ground.Thereshouldbe 1 M0 or more.
ls the resistanceas sDcitied?

YES

NO

sRs
Faultv SRSuniu replacethe SRSunit {seepaqe 24-951.

18PCONNECTOF

Short to ground in the SRS main harnss;replacihe SRS


main harness.

www.emanualpro.com

24-65

Troubleshooting
DTC3-1and DTC3-2

CAUTION:Wheneverthe ignition switch is ON flll, or


has been turned OFF for less than three minutes, b
careful not to bump th SRS unit; the airbags could
accidenlallydeploy and causedamage or iniuries.

DRIVER'S
SEATBELTTENSIONER
2P CONNECTOR

LEFTSIOEWIRE
HARNESS
2P CONNECTOR

Try to reproducethe SRSindicatoi light:


1. Erasethe DTCmemory(seepage24-29).
2. Turn the ignitionswitch ON 1 ), and checkthat the SRS
indicatorlight comeson for aboutsix secondsand then
goesoff.
Doesthe SRSindicaior lighr stay on?
YES

NO

Intermittent failure, system is OK at this time. See


Troubleshootinglfiermittent Failu.6son page24-28.

Checktor an open in the driver's seat b6lt tensioner:


1. Disconnect
the negativebatterycable,and wait lor three
minutes.
2. Disconnect
the drave/sseat belt tensioner2p connector
from the left side wire harness2P connector(see page
24-23).Do not disconnect
the lront passenger,s
seatbelt
tensioner2P connector.
3. Connectthe specialtool {2 O) to the left side wire harness
2P connector,
4. Reconnect
the negativebafterycable
5. Erasethe DTCmemory{seepage24,28).
6. Readthe DTC(see page 24-26).
ls OTC3-1or DTC3-2 indicatedT
YES

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

Checkfor an oFn in thc aide wir6 harne$:


1. Disconnect
the left sidewire harness2P connectorfrom
the SRSmain harness2P connector.
2. Connectthe specialtool (2 o) to the SRS main harness
2Pconnector.
3. Erasethe DTCmemory.
4. Readthe DTC.
ls DTC3-l or DTC3-2 indicated?

YES

NO

LEFTSIDEWIRE
HARNESS
2P CONNECTOR

SRSMAIN
HARNESS
2P CONNECTOR

Ooen or incrersd reeidance in the lelt side wire hame3s;


rDlacathe hamess.

art

00

SRSSIMULATOR
LEADC
07TAZ- SZ5011A
and SRSINFLATOR

Checkfor an open in the SRSmain harness:


1. Disconnect
the negativebatterycable,and wait for three
minutes.
2. Disconnectthe driver'sand front passenger'sairbags,
and front passenger's
seatbelttensionerconnectors(see
page24-231.
3. Disconnectthe SRS main harness18Pconnectorfrom
the SRS unit. Do not disconnectthe specialtool (2 O)
from the SRSmain harness2P connector.
4. Checkresistance
betweenthe No. 4 and No. 11terminals
Thereshouldbe
of the SRSmain harness18Pconnector.
2.0- 3.0 0.

{2 0 JACKI
07sAz - T84011A

13lhe resistance as soecified?

YES

NO

sRsUNIT

Faulty SFS unil or poor contad at the SRS main h.mss


18P connector and th SRS unit. check the connection
between the SRS main harn$s 18P connector and the
SRS unit. lf the connector i3 OK. rDlacoihe SRS unit
(s66pas6 24-951.

ODen or incaoasedresistancein the SRS msin harness;


reolacethe SRSmain harnss.

SRSMAIN HARNESS
.I8PCONNECTOR

)
terminals

www.emanualpro.com

24-67

Troubleshooting
DTC3-3

ra

CAUTION; Whenever the ignition switch is ON llll, or


has bon turned OFF for l6ss than three minutes, be
carelul not to bump the SRS unit; the airbags could
accidontallydeploy and causedamage or iniuries.

ORIVER'S
SEATEELTTENSIONER
2P CONNECTOR

Try to rproducethe SRSindicator light:


1. Erasethe DTCmemory(seepage24-28).
2. Turn the ignitionswitchON (lll, and checkthat the SRS
indicatorlight comeson for about six secondsand then
goes off.
Doesthe SRSindicator lighl stay on?

YES

NO

Intarmittent failure, system is OK at this time. 506


TroublshootingIntormittantFailureson paqe24-28.

Checktor a 3hort to anothr wire or decreasedresistancein


ihe driver's seat bolt tan3ioneri
1. Disconnect
the negativebatterycable,and wait for three
minutes,
2. Disconnectthe driver's seat belt tensioner 2P connector
from the left side wire harness2P connector(see page
24-23).Do not disconnect
the front passenger's
seat belt
tensioner2P connector,
3. Connectthe specialtool (2 O) to the left side wire harness
2P connector.
4. Reconnectthe negativebattery cable
5. Erasethe DTCmemory (seepage 24-28).
6. Readthe DTC(seepage 24.26l'.
ls DTC3-3 indicated?

YES

NO

Short to another wire or decreased.esistancein the


driver's s6at beh tcnsioner; replacthe diive.'s seat bolt
{seprge 24-911.
To page 24 69

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

Checklor a short to another wire or decreasedreaistancein


the side wire harnoss:
1. Disconnect
the left side wire harness2P connectortrom
the SRSmain harness2P connector.
2. Connectthe specialtool (2 0) to the SRS main harness
2P connector.
3. Erasethe DTCmemory.
4. Readthe DTC.
ls OTC3-3 indicated?
YES

NO

LEFTSIDEWIRE
HARNESS
2P CONNECTOR

SRSMAIN
HANNESS
2P CONNECTOR

0a

Short to another wire or decrcased resbtance in the le-h


side wire harness;reglacethe harneas.

I J

SRSSIMULATOR
LEADC
07TAZ- SZ5011A
and SRSINFLAToR
SIMULATOR
{2 0 JACK}
07sAz - TB4011A

Checklor a 3hort to another wire or dec.easedresistancein


the SRSmain ha.ne$:
1. Disconnect
the negativebatterycable,and wait for three
minutes,
2. Disconnectthe driver's and front passenger'sairbags,
(see
and front passenger's
seatbelttensionerconnectors
page24 23l'.
3. Disconnectthe SRS main harness18Pconnectorfrom
the SRSunit.
4. Disconnectthe specialtool (2 O)from the SRSmain harness
2P connector.
5. Checkresistancebetweenthe No. 4 and No. 11terminalsof
the SRS main harness18Pconnector.There should be
1 M0 or more.
ls the resistancas soocified?

YES

NO

SRSUNIT

Faulty SRSunit; replacethe SRSunit lso paqe 24-95).

Short to another wire or decrasodrosistanco in the SBS


main harness;replacethe SRSmain harness.

SRSMAIN HARNESS
18PCONNECTOR

I J
lerminals.

www.emanualpro.com

24-69

Troubleshooting
DTC3-4

CAUTION: Whenever the ignition switch is ON (lll, ol


has been turned OFF for l6ss than thr6e minutes, b
careful not to bump the SRS unit; lho airbags could
accidentallydeploy and causdamage or iniuries.

DRIVER'S
SEATBELTTENSIONER
2P CONNECTOR

Try lo reproducoth6 SRSindicator light:


1. ErasetheDTCmemory(seepage24-28).
2. Turn the ignitionswitchON (ll),and checkthat the SRS
indicatorlight comeson for aboutsix secondsand then
ooes off,
Doe3the SRSindicator liqht stav on?

YES

NO

Intcrmitt.nt f.ilur., iystem is OK at this time. Soe


Troubla3hooting Intermittent Failurca on Dage24-28.

Checklor a shortlo Dowar in the driver'33at beh tonsioncr:


1. Disconnoctthe negativebattery cable, and wait for three
minutes.
2. Disconnect
the driver'sseat belt tensioner2P connector
from the left side wire harness2P connector(see page
24 23).Do not disconnect
the front passenger's
seat belt
tensioner2P connector,
3. Connectthe specialtool {2 0) to the left side wire harness
2P connector.
4. Reconnectthe negativebattery cable.
5. Erasethe DTCmemory {see page24-28).
6. Readthe DTC(see page 24-26).
ls DTC3-4 indicsted?

YES

NO

Short to powar in the d.iver's seat belt tensioner;


replacethe d.iver's seat belt tensione. {3eepago 2il-31.

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

Short to power in the left side wire ha.n6ss;replecethe


narness.

00

SRSSIMULATOR
LEAOC
07TAZ- SZ5011A
and SRSINFLATOR

Checkfor a short to power in the SRSmein harness:


1. Disconnect
the negativebatterycable,and wait for three
mrnutes.
2. Disconnectthe driver'sand lront passenger'sairbags,
and front passenger's
seatbelttensionerconnectors(see
page 24-231.
3. Disconnectthe SRS main harness18Pconnectortrom
the SRSunit.
4. Disconnectthe
specialtool(2
0)fromthe SRSmainharness
2Pconnector,then reconnectthenegativebatterycable.
5. Turn the ignitionswitchON (lll.
6. Checklor voltage betweenthe No. 4 terminal ol the SFS
main harness'18Pconnectorand body ground. There
shouldbe 0.5 V or less.Checkfor voltagebetweenthe No.
11terminalsol the SRSmain harness18Pconnector.There
shouldbe 0.5V or less.
ls tho voltage as specffied?

YES

LEFTSIDEWIRE
HARNESS
2P CONNECTOR

(2 0 JACKI
07SAZ- TB/t011A

NO

Faulty SRSunit; replacetho SRSunit lsee paqe 24-95).

Short to power in the SRS m.in harness;.eplace the SRS


main hame3a.

SRSMAIN HARNESS
18PCONNECTOR

www.emanualpro.com

24-71

Troubleshooting
DTC3-5

*r

CAUTION: Whonover tho ignition switch is ON (ll), or


has been turned OFF for less than thres minutes, b
careful not to bump the SRS unit; the airbags could
accidontallydeploy and causedamsgo or iniurirs.

DRIVER'S
SEATBELTTENSIONER

Try to reproducothe SRSindioto. light:


1. Erasethe DTCmemory (s66 pag624-28).
2. Turn the ignitionswitchON (ll),and checkthat the SRS
indicatorlightcomoson Ior aboutsix seconds,and then
goes off.
Do. the SRSindicsto. light 3tav on?

YES

NO

lnto.mitlont hilure, ryltom is OK at thia timc. Ses


T.oubleshootinqIntermittont Failuroson page 2+28.

Chck for a short to ground in the djivoi's soat b6h tonsioner:


1. Disconnectthe negativebattery cable, and wait tor three
mtnutes.
2. Disconnoctthe driver's seat belt tensioner 2P connector
Irom the lft side wire harness 2P connector (see page
24-23).Do not disconnectthe front passenger'sseat belt
tensioner2P connector.
3. Connectthe specialtool (2 0) to the left side wire harness
2P connector,
4. Rgconnectthe negativebattery cable.
5. Erasethe DTCmemory (seepage 24-28).
6. Readthe DTC(see page21-26).
ls DTC3-5 indicated?

YES

NO

Short to ground in the driver's soai belt tensioner;


repllce the driver'3 seat belt lse Daq624-31.

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

Checklor . short to ground in lhe lido wire hrrnassi


1. Disconnect
the llt sidewiro hamess2P connectorfrom
the SRSmain harness2P connector.
2. Connectthe specialtool (2 0) to the SRS main harness
2P connoctor.
3. Erasethe DTCmemory.
4. Readthe DTC.

\r

LEFTSIDEwlRE
HARNESS
2P CONNECTOR

SRSMAIN
HARNESS
2P CONNECTOR

Short to ground in the lolt side wi.e harno3s;.eplscethe


hamer3.

00

Checkfor a short to ground in tho SRSmain harna+t:


1. Disconnecttho negativebattery cable, and wait for three
mtnutes.
2. Disconnectthe drive/s and front passenger'sairbags,
and front passenger'sseat bolt tensioner 2P connectors
(seepage24-231.
3. Disconnectthe SRS main harnessl8P connectorfrom
the SRSunit.
4. Removethe spacialtool {2 0) from the SRSmain hamess
2P connector,
5. Checkresistancebetween the No. 4 terminal of 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. ll terminalsofthe SRS main harness
18Pconnectorand body ground.Thereshouldbe 1 M0
or more.

/
I

SRSSIMULATOR
LEADC
07TAZ- SZ5011A
and SRSINFLATOR
SIMULATOR
/ (2 o JACK)
07sAz - TB4o11A

Short to ground in the SRS m.in hrrnar3; roplacotho SRS


mein hamoSs.

SRSMAIN HABNESS
18PCONNECTOR

www.emanualpro.com

24-73

Troubleshooting
DTC4-1and DTC4-2
!|

CAUTION: Whenever tho ignition 3witch is ON (ll), ot


has boen turnd OFF for less than thro6 minutos, bo
carful not to bump ihe SRS unit; the airbags could
accidentallydeploy and causodamage or iniurios,

FRONT
PASSENGER'S

RIGH1SIDEWIRE
HARNESS
2P CONNECTOR

Try to roproducathe SRSindicator light:


1. Erasethe DTCmomory(seepage24'28i.
2. Turn the ignitionswitchON (ll).and checkthat the SRS
indicatorlight comeson for aboutsix seconds.and then
ooes off,
Doesthe SRSindicator lisht stay on?
YES

NO

Intermittent failure, syatem i3 OK at this tim6. Soo


Trouble3hootingInta.mittent Failuroson page24-28.

Ched( for an open in the front p.ssongo/s 3eat bolt teruiona.:


1. Disconnect
the negativebatterycable,and wait for three
mrnutes.
2. Disconnectthe front passenger's
seat belt tensioner2P
connectorfrom the right side wire harnss2P conneclor
(see page 24-23).Do not disconnectthe driver's seat belt
tensioner2Pconnector.
3. Connectthe specialtool (2 O)to the right sido wire harness2P connector.
4. Reconnectthe negativebatterycable.
5. Erasethe DTCmemory lsee page 24 28).
6. Readthe DTC(seepage 24'26).
k DTC4-1 or DTC4-2 indicatodT

YES

NO

Open or increaaad resistance in lhe tront pa$enger's


seat belt tensioner; roplace the front p.s3engar's 3eat
belt lsee p.ge 24-31.

fo page24-75

24-74

www.emanualpro.com

SRSSIMULATOR
LEADC

07TAZ- SZ5n11A
andSRsINFLATOR
SIMULATOR

/izo.ncri
-

ozsAz T8.011A

)
Ftom page 2!-7a

Checklor .n oo.n in the side wire hsrness:


1. Disconnect
the rightsidewire harness2P connectorfrom
the SRSmain harness2Pconnector.
2. Connectthe specialtool (2 Oi to the SRS main harness
2Pconnector.
3. Erasethe DTCmemory.
4. Beadthe DTC.
ls DTC4-1 or DTC4-2 indicated?

YES

NO

Open or inc.oasedresistancein th right side wire harness;replacethe harness.

"r$

Checktor an open in the SRSmain harness:


1. Disconnect
the negativebatterycable,and wait for three
mtnutes.
2. Disconnectthe driver'sand front passenger'sairbags,
and driver'sseatbelt tensionerconnectors(seepage2423\.
3. Disconnectthe SRS main harness18Pconnectorfrom
the SRS unit. Do not disconnectthe specialtool (2 0)
from the SRSmain harness2P connector.
4- Checkresistance
betweenthe No. 5 and No. 12 terminals
of the SRSmain harness18Pconnector.
Theresho!ld be
2.0- 3.00.
ls the resistancaas soecified?

YES

RIGHTSIDEWIRE
HARNESS
2P CONNECTOR

SRSMAIN HARNESS
2P CONNECTOR

SRSSIMULATOR
LEADC
07TAZ- SZ5011A
.nd SRSINFLATOR
SIMULATOR
(2 0 JACK)
07sAz - TB4011A

NO

Faulty SRSunit or poor contact at the SRSmain harne3s


18P conneclor and the SRS unit, check the connestion
btween the SRS main harness 18P connctor and th6
SRS unit. lf the connector is OK, reDlacethe SRS unit
{seepage 24-951.

Open or increesedresistancoin the SRS main h.rnes3;


replacethe SRSmain harness.

SRSMAIN HABNESS
18PCONNECTOR

)
le.minals.

www.emanualpro.com

24-75

Troubleshooting
DTC4-3

CAUTION: Whonev.r ths ignition switch is ON (ll), or


has been turned OFF tor less than throe minutes, b
careful not to bump tho SRS unit; the airbags could
accidentallydeploy and csuse damage or iniuries.

FRONT
PASSENGER'S

RIGHTSIDEWIRE
HARNESS
2P CONNECTOR

Try lo reproducothc SRSindicator light:


'1. Erase
the DTCmemory (seepage 2{-28).
2. Turn the ignitionswitchON {ll},and checkthat the SRS
indicatorlight comeson for aboutsix seconds,and then
goes off.
Doosthe SRSindicstor light stay on?
YES

NO

Intermittent failure, rystgm ia OK rt this timo. S6c


TroubloshootingIntermittont Failu.oson pago 2+28.

Chock to. a short to .nothor wira or decre8od ro3btance in


the froni pa3sengor'3aoat belt ten3ioner:
1. Disconnect
the negativebatterycable,and wait for three
mrnutes.
2. Disconnectthe front passenger's
seat belt tensioner2P
connectorfrom the right side wire hamess 2P connector
(see page 24-23).Do not disconnectthe driver's seat belt
tensioner2P connector.
3. Connectthe specialtool (2 O)to the right side wire harness2P connoctor.
4. Reconnectthe negativebattgrycable.
5. Erasethe DTCmemory (see page 24-28).
6. Readthe DTClsee page 24-261.
|3 DTCG3 indicatod?

YES

NO

Short to .noth6r wire o. dc6e.rd raktanco in the front


passenger'3sat boh teniioner; roplaccthe lront pass6ng6r's aeat belt (sepsge 2a-31.

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

Chockto. a aho.l to lnothcr wire or dcreslod rosbtanco in


th. side wiro harn.$:
1. Disconnoct
the rightsidewire harness2Pconnectorlrom
the SRSmain harness2P connector.
2. Connoctthe specialtool (2 O) to the SRS main harness
2P connector.
3. Erasethe DTCmemory.
4. Readtho DTC.
13DIC +3 indicated?
YES

RIGHTSIOEWIRE
HARNESS
2P CONNECTOR

NO
SRSMAIN
2P CONNECTOR

Short to .noth6r wiro or doc.oasod r.sistanco in thG


dght sida wiro ha]ne3s;rapl.ce the hamcas.

SRSSIMULATOR
LEADC
07TAZ- SZ50114
and SRSINFLATOR
SIMULATOR
{2 0 JACK)
07saz - Ta1ol1A

Chackloi a short to anothor wire o. docreasdrGbtancc in


tho SRSmain h.]n$:
1. Disconnectthe negativebattery cable, and wait for three
mtnutes,
2. Disconnectth6 driver's and front passenger'sairbags,
and driver's seat belt tensionerconnectors(see page 24-

3. Disconnectthe SRS main harness18Pconnectorfrom


the SRSunit.
4. Disconnectthe specialtool (2 0) from the SRS main harness2P connctor.
5. Checkresistancebetweenthe No. 5 and No. '12terminals
of the SRSmain harness18Pconnector.
Thereshouldbe
1 MO or more.
b the raaistanco aa soscifiedT

YES

NO

F.ulty SRSunit; roplactho SRSunit lseo pase 24-951.

Short to enothor wi.o or decree3odr*istance in the SRS


main harnoit rophco the SRSmain ha.nsss.

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

Try to reproducethe SRSindicator light:


1. Erasethe DTCmemory{seepage24-28).
2. Turn the ignitionswitchON (ll),and checkthat the SRS
indicatorlight comeson for aboutsix seconds,and then
goes off.
Doosthe SRSindicator light 3t.y on?

vEs

NO

Intermittent f!ilure, system is OK at this time. See


T.oubleshootingIntermittent F.ilures on page 24-28.

Checktor a 3horl lo power in the frolt passnge.'ssat belt


tensaoneri
'1. Disconnect
the negativebatterycable,and wait for three
mrnutes.
2. Disconnect
the front passenger's
seat belt tensioner2P
connectorfrom the right sidewire harness2P connector
the driver'sseatbelt
{seepage24-23}.Do not disconnect
tensioner2P connector.
3. Connectthe specialtool (2 O) to the right sidewire harness2P connector.
4. Reconnectthe negaiivebafterycable.
5. Erasethe DTCmemory (seepage 24-28).
6. Readthe DTClseepage24-261.
ls DTC4-,1indicated?

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

Checkfor a short to power in the side wire harn6s:


1. Disconnect
the rightsidewire harness2P connectorfrom
the SRSmain harness2Pconnector,
2- Connectthe specialtool (2 0) to the SRS main harness
2Pconnector.
3. Erasethe DTCmemory.
4. Readthe DTC.
ls DTC4-{ indicated?
YES

NO

Short to power in the right side wire harness; replace


the harness.

) J

RIGHTSIDEWIRE
HARNESS
2P CONNECTOR

Checktor a short to oow6r in the SRSmain harness:


1. Disconnect
the negativebatterycable,and wait for three
mtnutes,
2. Disconnectthe driver'sand front passenger'sairbags,
and driver'sseatbelttensionerconnectors(seepage2423).
3. Disconnectthe SRS main harness18Pconnectorfrom
the sRS unit.
4. Disconnect
the specialtool i2 0) from the SRSmain har
ness2P connector,then reconnectthe negativebattery
caore.
5. Turnthe ignitionswitchON (ll).
6. Checkfor voltagebetweenthe No. 5 terminalof the SRS
m a i n h a r n e s s1 8 Pc o n n e c t o ar n d b o d y g r o u n d .T h e r e
should be 0.5 V or less.Checkfor voltagebetweenthe
No. 12 terminalsof the SRSmain harness18Pconnector.
Thereshouldbe 0.5V or less.

SRSMAIN
2P CONNECTOR

SBSSIMULATOR
LEADC
07TAZ- SZ5011A
and SRSINFLATOR
SIMULATOR
\
(2 0 JACK)
\
07sAz-T84011A

ls the voltage as specified?


YES

NO

Faulty SRSunit; replacethe SRSunit (seepase 24-95).

Short to power in the SRS main harness;replacethe SRS


main harness.
SRSMAIN HARNESS
18PCONNECTOR

www.emanualpro.com

24-79

Troubleshooting
DTC4-5

GAUTION: Whonever the ignition switch is ON fll). ol


has be6n turned OFF for less than thrso minuter. be
careful not to bump the SRS unit; the airbags could
accidontallydeploy and causodamage or iniurias.

RIGXTSIOEWIRE
HARNESS
2P

FRONT
PASSENGR'S

Try to roproducoth. SRSindicrtor tighi:


1. Erasethe DTCmemory(seepage24-28).
2. Turn the ignitionswitchON (ll),and checkthat the SRS
indicatorlight comeson for aboutsix seconds,and then
goes off.
Doe3the SRSindicator light stay on?

YES

NO

Intrmittent t.ilurG, syst.m is OK at thi! timo. So


TroubleshootingInte.miftnt Failure3on psqa 2+28.

Chcck Ior a shon to ground in the trodt parsnge/s lert beh


tensionea:
1. Disconnect
the negativebatterycable,and wait for three
mrnutes.
2. Disconnectthe front passenger's
seat belt tensioner2p
connectortrom the right sidewire harness2p connector
(see page 24-23).Do not disconnectthe driver's seat bek
tensioner2P connector.
3. Connectthe specialtool (2 0) to the right sidewire harness 2P connector,
4. Reconnectthe negativebatterycable.
5. Erasethe DTCmemory lsee page 24-28).
6. Readthe DTC(seopage 24-26!-.
k DIC G5 indicated?

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

Checklor a short to ground in the sido wir harness:


1. Disconnect
the rightsidewireharness2P connectorfrom
the SRSmain harness2P connector.
2. Connectthe specialtool {2 O) to the SRS main harness
2P connector.
3. Erasethe DTCmemorv.
4. Readthe DTC.
b DTC4-5 indicrtad?

YES

NO

Short to ground in the right side wire harness; replac.


the harne3!.

RIGHTSIDEWIRE
HARNESS
2P CONNECTOR

Checktor a short io ground in the SRSmain ha.nessi


1. Disconnect
the negativebatterycable,and wait for three
minotes,
2. Disconnectthe driver's and front passenger'sairbags,
and driver's seat belt tonsionerconnectors(see page 24231.
3. Disconnectthe SRS main harness18Pconnectorfrom

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

Faulty SRSunit replacethe SRSunit {seepace 2a-951.

Short to ground in the SRS main harness;replacethe SRS


main harnoss.
SRSMAIN HANNESS
18PCONNECTOR

www.emanualpro.com

24-81

Troubleshooting
DTC8-6 -'97

model
\

CAUTION: Whonever th ignition switch is ON fll). ol


has ben turned OFF for les3 than thro minutes, be
caretul not to bump the SRS unit; tho airbags could
accidentallydeploy and causedamage or iniurios.
Besidesindicatingan abnormalityin the SRS unit, DTC
8-6 may also indicatethat two problemsequivalentto
DTC1-1 and 2-4, 'l-4 and 2-1,or 1-4and 2-4 occurredat
the sametime. Proceedin the ordershown below.
Chockthe SBS main harnGs:
1. Disconnectthe batterynegativecable,then disconnect
the positivecable,and wait for threeminutes.
2. Disconnectthe driver's airbag and front passenger,s
afrDagconnectors{see page 24-23).
3. Disconnectthe SRS main harnesst8p connectorfrom
the sRs unit.
4. Reconnect
the batteryposative
cable,then reconnectthe
negativecable.
5. Turnthe ignitionswitchON 0t).
6. Connecta voltmeterand measurevoltagebetweenthe
No. 10 terminalot the SRSmain harnessl8p connector
and ground,and betweenthe No. 14terminaland qround.
Thereshouldbe aDorox.0-0.5V.
Are voltagesas specitied?

YES

NO

Shon to power in tho SRSmain harness;reglacethe SRS


main harn63.

Chockthe SRSmein harnels and the cable rel:


Connecta voltmeterand measurevoltagebetweenthe No. 1
t e r m i n a l o f t h e S R S m a i n h a r n e s sl 8 p c o o n e c t o ra n d
ground,and betweenthe No. 13terminaland ground.There
shouldbe approx.0 0.5V.
Are voltagesas specifiod?
YES

NO

Faulty SRSunit; replacethe SRSunit {saepago 24-951.

To page 24-83(A)

24-82

www.emanualpro.com

18PCONNECTOR

)
Frompage24-82iA)

Checkthe cable reeli


1. Turnthe ignitionswitchOFF.
2. Disconnectthe cable reel 2P connectorfrom the SRS
main harness,
3. Turnthe ignitionswitchON lli).
4. Connect a voltmeter and fieasute voltage beNveenthe
No. 'l terminaloI the SRS main harness18Pconnector
a n d g r o u n d , a n d b e t w e e nt h e N o . 1 3 t e r m i n a l a n d
ground.Thereshouldbe approx.0 - 0.5V.
Are voltagcs as specifiod?

YES

NO

Short to powor in the cable reel; replace the cable reel


{soooaqa 24-921.

Short to powe. in ths SRS main harn633;replaco tho SRS


main harness.

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.

No. 23 110Al FUSE


FUSE/RELAYBOX
Tho problem has dilappeared. T6t-drive the vohid and
see Troubl6hogting Intermittedt Failur6 on prgc 2il-2g.

Check for shon to ground botween the undor-darh fu36,/


relay box and tho SRSunit.
1. Turnthe ignitionswitchOFF.
2. Disconnectthe batterynegativecable,then disconnect
the positivecable,and wait for threeminutes.
3. Disconnect
the driver'sand front passenger,s
airbagconnectors{seepage 24,23).
4. Disconnectthe SRS main harness18p connectorfrom
5. Checkresistancebetween the No. 3 terminal of the SFS
main harness18Pconnectorand grouncl.
Thereshouldbe 1 M0 or more.

sRs
18PCONNECTOR

FauftySRSunit; replacoth6 SRSunit {3epage 2t-951.

To page 24-85

24-84

www.emanualpro.com

from page 24'84


(B)
Ch6ckfo. short io ground in the SRSmain harnes!:
1. Disconnect
the SRSmain harness2P connectorlrom the
under-dash
fuse/relay
box.
2. Checkresistance
betweenthe No. 3 terminalof the SRS
main harness18Pconnectorand ground.There should
be 1.0MO or more.
ls the resbtancoas soecitied?

YES

NO

Short to ground in the undor-dalh fuse/relay box;


rplacoth under-da3hfuse/relav box.
Short to ground in the SRS main harneas;replacothe SRS
main harneas.

(A) From page 24-84

FUSE/RELAY
BOX

SRSMAIN HARNESS
18P CONI{ECTOR

Chckfor an open in the SRSmain harnes:


1. Turnthe ignitionswitchOFF.
2. Disconnectthe batterynegativecable,then disconnect
the positivecable, and wait tor threeminutes.
3. Disconnect
the driver'sand front passenger's
airbagconnectors{see page2il 23).
4. Disconnectthe SRS main harness18Pconnectorfrom
the sRs unit.
5. Reconnectthe baftery positive cabie, then reconnectthe
negativecable.
6. Connecta voltmeterbetweenthe No. 3 terminalof the
SRSmain harness18Pconnectorand oround.
7. Turnthe ignitionswitchON (ll), and measure
SBS MAIN HARNESS
18P COI{l{ECTOR
Poor contrct at the SRS main harnss 18P connector;
checkthe connectoa.
. lf the connsctor is OK, substitute a known-good SRS
unit, and rccheck.
. lf the problom is still present. replaco the SRS main
harness,

To page 24'86

www.emanualpro.com

(cont'd)

24-85

Troubleshooting
DTC9-2-'97

model lcont'dl
Frompage24-85

Checkfor an open in the SRSmain harness:


1. Turnthe ignitionswitchOFF.
2. Disconnect
the SRSmain harness2p connectorfrom the
under-dashfuse/relaybox.
3. Checkresistance
betweenthe No. 2 terminalof the SRS
main harness2P connectorand the No. 3 terminalof the
SRSmain harness18Pconnector.
Thereshouldbe 0-0.5 0.
ls th6 resistanceas soecified?
YES

NO

Poor contact at the SRS main harness2p connector;


checktho connector,
. lf the connectori3 OK, substituto a known-good undrdash fuse/relaybox, and recheck.
. lf the problem is still present, roplace the SRS main
natness,

UNDER.OASH
FUSE/RELAY
BOX

Open in the SRS main harn$s;.eplace the SRS main harness.

SRSMAII{ HARI{ESS
2P CONNECTOR

24-86

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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.

Removethe two Torx bolts from the steering whsel,


and disconnectthe horn connector. Remove the
driver'sairbag,

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

Connectthe battery positive cable.then connectthe


negativecable.
7.

24-88,

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After installingthe airbagassembly,confirm proper


systemoperation:
. Turn the ignitionswitch ON llt); the SRS indicator light should come on for about six seconds
and then go off.
. Mske sure both horn buttons work.
o Takea test-drive,and make sure the cruisecontrol switcheswork.

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,

Removethe three mountingnuts from the bracket.


5.

Lift the front passsnger'sairbag out of the dashDOaro.


NOTE:The airbag lid has pawls on its side which
attach it to the dashboard.To remove the airbag,
cover the lid and dashboardwith a cloth, and pry
carefullvwith a flat tip screwdriver.

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.

Attachthe airbagconnectorto the connectorhold_


er, then reinstallthe glove box.

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.

Connectthe b8tterypositivecable,then connectthe


negativecable.
After installingthe airbag.confirm proper sysrem
ooerauon:
Turn the ignition switch ON ( ); the SRS indicator
l i g h t s h o u l d c o m e o n f o r a b o u t s i x s e c o n d sa n d
then go off.

24-90

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CableReel
Replacement

stors a removed airbag with the pad sur@


tace up. lf th airbag is improperly stored face down,
a c c i d e n t a ld 6 p l o y m e n t c o u l d p r o p e l t h e u n i t w i t h
gnough force to causeserious iniuty.

Makesurethe wheelsare alignedstraightahead.


Removethe two Torx bolts from the steering wheel,
a n d d i s c o n n e ctth e h o r n c o n n e c t o r R
, e m o v et h e
driver'sairbag,

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.

NOTE:Carefullyinspectthe airbag before installingit.


Do not installan airbagthat shows signs of being
droppedor improperlyhandled,suchas dents,cracksor
deformation,
'1.

Disconnectthe batterynegativecable,then disconnectthe positivecablefrom the battery, and wait at


leastthree minutes.
Removethe accesspanelfrom the steeringwheel,
then disconnectthe 2P connectorbetweenthe driver's airbagand cablereel.

DRIVER'S

DRIVER'SDASHBOARDLOWERCOVER

5.

*f
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Removethe driver's dashboard lower cover (and


the knee bolster).

(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.

Loosenthe steeringwheel bolt, then install a steering


wheel puller on the steeringwheel and remove it.
Note these items when removing the stee.ingwheel:
. Do not tap on the steering wheel or the steering
columnshaftwhen removingthe steeringwheel,
. lf you threadthe puller bolts into the wheel hub
more than five threads,the boltswill hit the cable
reel and damageit. To preventthis. installa pair
of jam nutsfive threadsup on eachpullerbolt.
STEERINGWHEEL

STEERING

Disconnectthe 3P [6P] connector betweenthe main


wire harnessand cable reel sub-harness,and the 2p
connectorbetweenthe cable reel and SRS main harness.

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

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)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.

11. Set the cancel sleeve so that the projectionsare


alignedas shown.

VERIC AL

PR(NECNONS

)...0
t5.

Installthe steeringwheel on to the steeringcolumn


shaft,makingsurethe steeringwheelshaftengages
the cable reel and cancelingsleve.Do not tap on
the steeringwheel or steeringcolumn shaft when
installingthe steeringwheel.
CABLEREEL

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

Reconnectthe driver's airbag 2P connectorto the


cable reel 2P connector,and reinstall the access
panelon the steeringwheel.
1 9 . Reconnect
the batterypositivecable,then the negative cable.

Replace.
DRIVER'S

20. After installingthe cable reel,confirm proper system operation:


.

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.

1 1 . Attach the cable reel 2P connectorto the connector


holder.Theninstall(thekneebolsterand)thedriver,s
dashboardlower cover.
CABLEREEL

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.

Disconnectthe batterynegativecable,then disconnectthe positivecablefrom the battery, andwaitat


leastthree minutes.

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

Removethe left slde cover from the SRSunit. then


d i s c o n n e ctth e S R S m a i n h a r n e s s1 8 Pc o n n e c t o r
from the SRSunit.

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.

Removethe right sidecoverfrom the SRSunit.

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

Removethe four Torx boltsfrom the SRSunit.then


oull out the SRSunit from the driver'sside.
(cont'd)

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.

9. Reconnectthe driver's aibag 2P connectorto the


cable reel 2P connector,then reinstallthe access
panelon the steeringwheel.

1 0 . Reconnectthe front passenger'sairbag connector


to the SRSmain harness.

1 ' t . Reconnectthe left side wire harness2P connector


to the driver'sseat belt tensionerand the right side
wire harness 2P connector to the front passenger's
seatbelttensioner('98- 00 models).
12. Reinstallthe centerpillar lowertrim panels{'98- 99
modelsl.

1 3 . Reconnectthe battery positive cable,then the negative cable.

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.

Connectthe SRSmain harnessl8P connectorto the


SRSuniu push it into positionuntil it clicks.

8.

Install the SRS unit covers (right and left). Make


surethe coverssnaptogetherin the middle.

24-96

www.emanualpro.com

1 4 . After installing the SRS unit, confirm proper system


operation:Turn the ignitionswitch ON (ll);the SRS
indicatorlight shouldcome on for aboutsix seconds
and then go off,

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.

Cut off the airbag(and seatbelt tensioner)connectors.


Strip the ends of the airbag (and seat belt tensioner)
wires. and connectthe deploymenttool alligatorclips
to the airbag (and seat belt tensioner).Placethe
deploymenttool at least thirty feet (10 meters)away
from the airbao(and seatbelttensioner),

DRIVER'S
AIBBAG

FRONTPASSENGER'S
AIRBAG

Doployingtho Airbags (and Soat B6li Ten3ione6):


ln-vehicle
lf an SRSvehicleis to be entirelyscrapped,its airbags
(and seat belt tensioners)should be deployedwhile still
in the vehicle.The airbags (and seat belt tensioners)
s h o u l d n o t b e c o n s i d e r e da s s a l v a g e a b l ep a r t s a n d
shouldneverbe installedin anothervehicle.
confirm that each airbag {and seat belt
@
tonsiongr) i3 ggcurely mountod; othgrwise, severe personal iniury could result from d6ploym6nt,

1.

Disconnectthe batterynegativecable,then disconnectthe oositivecable.

AI.IIGATOR

cuPs

lY6llowl

At lcast
thirty feot
110motersl

Confirmthat the specialtool is functioningproperly


by following the checkprocedureon the tool label
or on page24-98.
Removethe accesspanel,then disconnectthe 2P
connector betweenthe driver's airbag and the cable
reel(seepage24-23).
Removethe glove box, then disconnectthe 2P connector between the front passenger'sairbag and
SRSmain harness(seepage24-23).
Removethe centerpillar lower trim panel,then disconnect the 2P connector betweenthe seat belt tensionerand side wire harness('98- 00 models)(see
page 24-231.

(cont'd)

www.emanualpro.com

24-97

Airbag/SeatBelt Tensioner

Disposal(cont'dl
1.

Connecta 12 volt batteryto the tool'

Deploying tho Airbag: Out-ot.vohicle

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.

lf an intact airbag has been removedfrom a scrapped


vehicle,or has beenfound defectiveor damagsdduring
transit.storageor seryice,it should be deployedas follows:

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).
.
.

lf the airbagsdeploy and the green light on the


tool comeson, continuewith this procedure.
lf an airbag doesn't deploy,yet the green light
comes ON, its igniter is defective.Go to DamagedAirbagSpecialProcedure.
During deployment,the airbag can become hot
enough to burn you, Wait thirty minutes after
deploymentbeforetouchingthe airbag.

Disposeof the completeairbag.No part of it can be


reused.Placeit in a sturdy plasticbag, and seal it
securety.

'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.

Confirmthat the specialtool is functioningproperly


by followingthe checkprocedureon this pageor on
the tool label.
Positionthe airbagface up, outdoorson flat ground
at leastthirty feet (10 m) from any obstaclesor peoDte,
Followsteps6, 7, 8. and 9 of the in-vehicledeployment proceoure.

Dlmaged Airbsg {or Seat Beh Ten3ion6r}Sp6cial


Procgdure
r an airbag {or seat Beh rensioner} cannol
!@
be doployod,it should not be treated as normal scrap; it
should still be considereda potntially explosive device
lhat can causeserious iniury.
1.
2.
3.
4.

5.

lf installedin a vehicle.follow the removal procedure on page24-3and 24-87through90.


In all cases,makea shortcircuitby twistingtogether
the two airbag inflator wires.
Packagethe airbag in exactlythe same packaging
that the new reDlacement
Dartcame in.
Mark the outside of the box "DAMAGEDAIRBAG
{ o r T E N S I O N E RN) O T D E P L O Y E Ds"o i t d o e s n o t
get confusedwith your parts stock.
Contactyour Honda District Service Manager for
how and whereto returnit for disposal.

DeploymentTool: CheckProcedure
l.

www.emanualpro.com

24-98

Connectthe yellow clips to both switch protector


handleson the tool; connectthe tool to a battery.
Pushthe operationswitch:green meansthe tool is
OK: red meansthe tool is faultv.
Disconnect
the bafteryand the yellow clips.

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