Honda Civic EP3 PDF

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02’ 03’ EP3
service manual
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INTRODUCTION
How to Use This Manual -

This manualis dividedinto 23 sections.The first pageof each
seclionis markedwith a blacktab that linesup with its
corresponding thumb indextab on this pageand the backcover.
S p e c i fi c a ti o n s 1)ll:{l+'
You can quicklyfind the first pageof eachsectionwithout
lookingthrougha full tableof contents.The symbolsprintedat
the top cornerof each pagecan also be used as a quick
re{erencesystem.
M a i n te n a n c e
Eachsectionincludes:
1. A tableof contents,or an explodedview index showingl
. Partsdisassemblysequence.
. Bolttorquesand threadsizes.
. Pagereferencesto descriptionsin text.
2. Disassembly/assembly proceduresand tools.
3 . Inspefiron.
4. Testing/troubleshooting.
5. Repair.
6. Adjustments.
Safety
Your safety,and the satetyof others,is very important.To help
you makeinformeddecisions,we have providedsafety
messages,and othersafetyinformationthroughoutthis manual.
Of course,it is not practicalor possibleto warn you aboutall the
hazardsassociated with servicingthis vehicle.You must use
your own good judgment.
Emissions
You will find impoftantsafetyinformationin a varietyof forms
including:
. SatetyLabels- on the vehicle.
. Satetv Messages preceded by a salety alert symbol A and
one of threesignalwords, DANGEF,WARNING,or CAUTION.
Thesesignalwords mean:
tmEnEErily;,:H,ll i":5*i5"?;rsERIousLYHuBrir
E$EEEE ys,: HURT
ir
f#,ff ,:hl:3,:JjERrousLY
tlGtltT]llilll YoucAN b€ HUBTif vou don'tfollow
. lnstructions
- howto service
thisvehiclecorrectlv
andsafelv.
All informationcontainedin this manualis basedon the latest

productinformationavailableat the time of printing.We reserve
the right to makechangesat any time without notice.No part of
this OublicationmaVbe reDrodLrced, or storedin a retrieval
system,or transmitted,in any form by any means,electronic,
mechanical, photocopying,recording,or otherwise,without the
priorwritten permissiono{ the publisher.This includestext,
figures,and tables-
*Body z-tl!
As vou readthis manual,vou will tind informationthat is ^ t l
precededby a @ symbol.The purposeof this messageis
to help preventdamageto your vehicle,other property,or the
environment,
FirstEdition8/2002 1,168pages HONDAMOTORCO..LTD.

All RightsReserved ServicePublicationOffice
Specificationsapplyto U.S.A.and Canada
As seclion3 with *inclode SRS comoonentsi

special precautionsare required when servicing.
*Restraints

GeneralInformation
Ghassisand PaintCodes
- 2 0 0 2M o d e l . . . . . . . . . . . . . 1. .-.2.
Chassisand PaintCodes
- 2 0 0 3M o d e l . . . . . . . . . . . . .1. .-.3.
ldentification
NumberLocations ........1-4
Warning/Caution
LabelLocations......1-5
Under-hoodEmission
ControlLabel ........... .... 1-7
)
L i f ta n dS u p p o r P
t o i n t s. . . . . . . . . , . . . . , . . .1. .-.8. , .
Towing ......1-9
PaftsMarkingLocations......................
1-10

GeneralInformation
Chassisand PaintCodes- 2OO2
Model
VehicleldentfficationNumber EngineNumber
S H H E P 33 5 ' 2 U 300001 K2OA3 1700001
[[tttrtF c d e f g h a
a. Manufacturer, Make and Type of Vehicle a. EngineType

S H H ; H O N D A O F T H EU . K .M F G . ,L T D .U . K . K20A3: 2.0 0 DOHCVTECSequentialMultiport
H O N D AP a s s e n g evre h i c l e Fuel-injectedengine
b. Line, Body and EngineType b. Serial Number
EP3: CIVIC/K20A3
c. Body Type and Transmission Type Transmission
Number
3: 2-door HatchbacUs-speed Manual
d. VehicleGrade lSeries)
5:Si {U.S.} NBH3 1000001
5 ; S i R( C a n a d a )
6: Si with side airbagsystem (U,S.) I
6: SiR with side airbagsystem (Canada)
a
e. CheckDigit
l. ModelYear
2i 2002 TransmissionType
g. Factory Code N R H 3 ; s - s D e eM
danual
t
U : H o n d ao f U . K .M a n u f a c t u r i nign S w i n d o n ,
En gl a n d
0
h. Serial Number PaintCode
-
U . S , :3 0 0 0 0 1
1- Code Color u.s. Canada
B-92P Niqhthawk BlackPearl
NH-578 TaffetaWhite
NH-623M Satin Silver lvletallic
R-81 M i l a n oR e d
Y-62P E u r oY e l i o wP e a r l
V€hicle ldentif ication Numbo.

and Federal Motor Vehicle
Safety Standard Certification/
Color Label.
I
1-2
Chassisand PaintCodes- 2003Model
VehicleldentificationNumber EngineNumber
S H H E P 33 5 * 3 U 400001 K2OA3 2700001
[--t-rlF c d e fg h a
I
Manufacturer, Make and Type of Vehicle a. EngineType

S H H : H O N D A O F T H EU . K .M F G . ,L T D .U . K . K20A3: 2.0 0 DOHCVTECSequentialMultiport
HONDAPassengervehicle Fuel-injectedengine
Line. Body and EngineType b. SerialNumber
EP3: CIVIC/K20A3
G . Body Type and Transmission Type Transmission
Number
3: 2-door HatchbacldS-speed Manual
d . Vehicle Grade (Series)
5:Si (U.S.) NRH3 - 2000001
5 : S i R( C a n a d a )
6: Si with side airbagsystem (U.S.)
6: SiRwith side airbagsystem (Canada)
I
a
Check Digir
f. Model Year
3: 2003 TransmissionType
Factory Code N R H 3 : 5 - s p e eM
d anual
U: Hondaof U.K. Manufacturingin Swindon, SerialNumber
England
SerialNumber PaintCode
U.S.:400001
:700001 Code Color U , S . Canada
B-92P Niohthawk BlackPearl
B-520P V i v i d B l u eP e a r l
NH-578 Taffeta White
NH-623M Satin Silver N4etallic
R-81 M i l a n oR e d
Y-62P EuroYellow Pearl
VehicleldentificationNumber
and FederalMotor Vehicle
Saletv Standard Certif ication/
Color Label.
)_.
1-3
GeneralInformation
ldentificationNumber Locations (
Vehicle ldentif ication Vehicle ldentificalion

Number {vlN} Numbe.lvlN)
0 I
EngineNumber
t)
1-4
, I warning/cautionLabelLocations
O
NOTE:FRONTPASSENGER AIRBAG WARNING TAG Steering Wheel:
(CHILD
SEAT)is installedon the glovebox on the U.S.
mooet. DRIVERMODULE
DANGER
Passenger's
Compartment: CABLEREEL
CAUTION
SRSINFORMATION
U.Sm
. odel
SRS WARNING
INFORMATION
FRONTPASSENGER
MODULE DANGER
MONITOR
NOTICE
,/
FRONT
SEATBELT
TENSIONER
CAUTION
SIDEMODULE SIDEAIRBAG CAUTION
DANGER Located on driver's
ano passen9ers
doorjamb(not shown)
..r'
(cont'd)
1-5
GeneralInformation
Warning/CautionLabelLocations(cont'dl
SERVICEINFORMATIONLABEL
(Undor-hood Emission Control
SRSWARNING Informationlab€l)and ENGINE
LABEL COOLANTINFORMATION
TIREINFORMATION
RADIATOR
CAPCAUTION
BATTERY
CAUTION c
1-6
Under-hoodEmissionControlLabel
EmissionGroupldentification Families:
Engineand Evaporative
Example:2002model EngineFamily:
2 HNX V O2.O VBP

rr-tt--[
t t l
a b c d e
ModelYear
2:2002
. P AT I E R2 B I N5
T H I SV E H I C LCEO N F O R MTSO U . S E 3: 2003
AND NLEV LEV REGULATIONS APPLICABLE TO 2002 ManulacturerSubcode
MODELYEARNEWPASSENGER CARSAND H N X :H O N D A
CALIFORNIA REGULATIONS APPLICABLE TO 2OO2 c. FamilyType
MODELYEARNEWLEVIi LEVPASSENGER CARS. V: LDV
d. Displacement
Example:2003model e. SequenceCharacters
V B P2: 0 0 2
X K C 2: 0 0 3
Evaporative Family:
rH/ @ 2 HNX R OO99 AAH
THISVEHICLECONFORMSTO U.S. EPATIER2 BIN 5

t[-l=[
a b c d
AND NLEVLEVREGULATIONSAPPLICABLE TO 2O03
MODELYEARNEWPASSENGER CARSAND
CALIFORNIA APPLICABLE
REGULATIONS TO2OO3 Model Year
MODELYEARNEWLEVII LEVPASSENGER CARS, 2t 2002
3: 2003
Manufacturer Subcode
H N X :H O N D A
c. Family Type
R: EVAP/ORVR
d . Canister Work Capacity
e . Sequence Charactets
AAH: 2002
AAA: 2003
1-7
GeneralInformation
Lift and Support Points
NOTE:If you are going to remove heavycomponents FloorJack
such as suspensionor the fuel tank from the rear of the
vehicle,first supportthe front ofthe vehiclewith tall 1. Set the parkingbrake.
safetystands.When substantialweightis removed
from the rear of the vehicle,the centerof gravity can 2. Blockthe wheels that are not being lifted.
changeand causethe vehicleto tip forward on the hoist.
3. When liftingthe rear of the vehicle.put the
FrameHoist gearshiftIever in reverse.
1. Positionthe hoist lift blocks(A),or safetystands, 4. Positionthe floor jack underthe front jacking
under the vehicle'sfront support points (B)and rear bracket(A) or rearjackingbracket(B),centerthe
support points (C). jacking bracketin the jack lift ptatform(C),and jack
up the vehiclehigh enoughto fit the safetystands
u n d e ri t .
2. Raisethe hoist a few inches,and rock the vehicle

gentlyto be sure it is firmly supported.
c
3. Raisethe hoistto full height,and inspectthe lift Positionthe safetystandsunderthe support points
pointsfor solid contactwith the lift blocks. and adjustthem so the vehiclewill tevet.
Safety Stands Lower the vehicleonto the stands.
To supportthe vehicleon safetystands.use the same

suppon points (B and C) as for a frame hoist,Always
use satetystandswhen working on or under any
vehiclethat is supportedonly by a jack.
J t
1- 8
Towing
lf the vehicleneedsto be towed, call a professional Wheel Lift Equipment The tow truck usestwo
towing service.Nevertow the vehiclebehind another pivoting arms that go underthe tires (front or rear)and
vehiclewith just a rope or chain.lt is very dangerous. lifts them off the ground.The other two wheels remain
on the ground.This is an acceptableway of towing the
EmergencyTowing vehicle.
T h e r ea r et h r e ep o p u l a rm e t h o d so f t o w i n g a v e h i c l e .
Sling-typeEquipment The tow truck uses metal
Flat-bedEquipment The operatorloadsthe vehicle c a b l e sw i t h h o o k so n t h e e n d s .T h e s eh o o k sg o a r o u n d
on the backof a truck.This is the bestway of parts of the frame or suspensionand the cableslift that
transportingthe vehicle. e n d o f t h e v e h i c l eo f f t h e g r o u n d .T h e v e h i c l e ' s
suspensioa n n d b o d y c a n b e s e r i o u s l yd a m a g e di f t h i s
To accommodateflat-bedequipment.the vehicleis method of towing is attemPted.
equippedwith towing hooks(A)and tie down hooks{B).
lf the vehiclecannot be transportedby flat-bed,it
The towing hook can be usedwith a winch to pull the should be towed with the front wheels off the ground lf
vehicleonto the truck, and the tie down hooks slotscan due to damage,the vehiclemust be towed with the
be used to securethe vehicleto truck. front wheels on the ground, do the following:
. Releasethe parkingbrake.
. s h i f t t h e t r a n s m i s s i o inn N e u t r a l .
It is bestto tow the vehicleno farther than 50 miles (80

km), and keepthe speed below 35 mph (55 km/h).
. l m p r o p e rt o w i n g p r e p a r a t i ow
n i l l d a m a g et h e
transmission.Follow the above procedureexactly.lf
you cannot shift the transmission,the vehicle must
be transDortedon a flat-bed.
. Trying to lift or tow the vehicle by the bumperswill
c a u s es e r i o u sd a m a g e T , h e b u m p e r sa r e n o t
designedto supportthe vehicle'sweight.
1-9
GeneralInformation
PartsMarking
To deter vehicletheft, certainmajor componentsare markedwith the vehicleidentificationnumber (VlN).Original
partshave self-adhesivelabels.Replacementbody parts have genericself-adhesivelabels.The originalengrneor
transmissionVIN plate is transferredlo a replacementengine or transmissionand attachedwith break-offbolts.
NOTE:Be careful not to damagethe parts marking labelsduring body repair.Maskthe labelsbefore repairingthe part.
r a
1-10
ra
Specifications

Standardsand ServiceLimits
Enqine
ne Electrical
I
Item Measurement Oualification (
Standard or New Service Limit
lgnitioncoil Rated voltage 12V
F i r i n go r d e r 1 3-4 2
Sparkplug Type N G K t: Z F B 6 K 1 1
DENSO: SKJ20DR-M11
Gap 1 . 0 1 . 1 m m ( 0 . 0 3 90 . 0 4 3
in.) 1 . 3 m m ( O . OiSn 1. )
l g n i t i o nt i m i n g A t i d l e ( c h e c kr h e in neutral:8t2' ETDCat 650150rpm
Alternator Output At 13.5V and 80A

normalengine
temperature
Coillrotor)resistance At 68.F(20'C) 2.2 3.0 A
5|lp flng u.u. 14.4mm {0_57in.) 14.0mm (0.55in.)
Brushlength 10.5mm (0.41in.l 1.5mm {0.06in.)
Brushspringtension 2.9 3.5N (0.30 0.36kgf,0.7-0.8tbs)
Starter Output
Commutator micadepth 0.50 0.80mm (0.020-0.031
in.) 0.20mm 1O.OO8
in.)
Commutator tunout o:BlalqryL4i) max o.o5mm(0.002
in.)
Commutator O.D. 2 8 . 0m m ( 1 . 1 0
in.) 2 7 . 0m m ( 1 . 0 6
in.)
Brushlength 14.0 14.5mm {0.55 0.57in.) 9.0mm {0.35in.)
Enqtne
Item Measurement Oualification Standard or New Service Limit
Compression Pressurecheckat 250rpm with wide Minimum 930kPa(9.5kgflcmr,135psi)
openthroftle. (SeeDesignSpecsfor Maximum 200kPa{2.0kgf/cm',28psi)
rato,
e_
vanatton
.l
2-2
a Head
nder Head
Item
Warpage
Height
Measur6ment Oualification
'103.95104.05
Standard or New
mm
Service Limit
0.05mm {0.002in.)
(4.093 4.096in.)
Camshaft Endplay 0.05 0.20mm (0.002 0.008in.) 0.4mm (0.02in.)
C a m s h a f tt o h o l d e r o i l c l e a r a n c e No.l journal 0.030 0.069mm 0 . 1 5m m { 0 . 0 0i6n . )
{0.001 0.003in.)
N o . 2 , 3 ,4 , 5 0.060 0.099mm 0.15mm (0.006in.)
journals (0.002-0.004in.)
Totalrunout 0.03mrn (0.001in.)max. 0.04mm {0.002in.)
Cam lobe height Intake,primary 33.925mm (1.3356 in.)
Intake, 8 m (l.1668
2 9 . 6 3m in.)
Exhaust 34.092mm (1.3422 in.)

(cold)
clearance lntake 0.21 0.2smm 10.0080.010in.)
Exhaust 0.28 0.32mm (0.011 0.013in.)
StemO.D- lnlaKe 5.475 5.485mm 10.21560.2159in.) 5.445mm (0.214in.)
Exhaust 5.450 5.460mm (0.2146 0.2150in ) 5 . 4 2m m ( 0 . 2 1i3n . )
S t e m - t o - g L r i d cel e a r a n c e lntake 0.030 0.055mm (0.0012 0.0022in.| 0.08mm (0.003in.)
Exhaust 0.055 0.080mm (0.0022 0.0031in ) 0.11mm (0.004in.)
lntake 1.25 1.55mm (0.049 0.061in.) 2.00mm {0.079in.)
Exhaust 1.25 1.55mm (0.049 0.061in.) 2.00mm {0.079in.)
stem installed
height lntake 4 0 . 8 -4 1 . 0m m ( 1 . 6 0 6 1 . 6 1 4 i n . )
Exhaust 5 4 . 6 5 4 . 8m m ( 2 . 1 5 02 . 1 5 7 in.)
Valvesprings Freelength lntake 47.61mm (1.874 in.)
49.64mm (1.954in.)
o
Exhaust
5.515 5.530mm 5.55mm (0.219in.)
L Valveguides LD. Intake
Exhaust
|.0.21710.21174n.1
5.515 5.530 mm 5 . 5 5m m { 0 . 2 1i9n . )
\0.2111 0.2177in.l
I n s t a l l e dh e i g h t lntaKe 1 5 . 2" 1 6 . 2m m ( 0 . 5 9 80 . 6 3 8 i n . )
Exhaust 15.5 16.5mm (0.610 0.650in.)
Rockerarms Arm-to-shaftclearance lntaKe 0.025 0.052mm 0.08mm (0.003in.)
(0.00'100.0020in.)
Exhaust 0.018 0.056mm 0.08mm (0.003in.)
(0.0007 0.0022in.)
v
lo
2-3
Enqine
n q t n e Block
Block
Item
I Warpageof deck
Measurement Oualification Standardor New
0.07mm (0.003in.)max.
ServiceLimir
foro.. (ulur^^-"1
_ f
tsorediameter Aori 86.010 86.020mm 86.070mm (3.3886
in.)
(3.3862 3.3866in.)
Borll 86.000 86.010mm 86.070mm (3.3886
in.)
(3.3858 3.3862in.)
0 . 0 5m m ( 0 . 0 0 2I n . J
R e b o r i n gl r m i t
0 . 2 5m m ( 00 l i n . )
Piston SkirtO.D.at 11mm (0.4in.)from btt"' "' A 85.980 85.990mm (3.3850 3.3854in.) 85.930mm (3.383'l
F" in.)
bottom of skirt LetterB €s.980 r"i33846
l-il?0 85.920mm (3.3827 in.)
0.020 0.040mm (0 0008 0.0016in.) 0.05mm {0.002in.)
Top 1.220 1.230mm (0.0481 0.0484in.) 1.25mm 10.049 rn )
Second 1 . 2 2 0 1 . 2 3 0m m ( 0 . 0 4 8 1 0 0 a 8 4 I n . ) 1.25mm 10.049 in.)
i 2.005 2.025mm (0.0789 0.0797in.) ?.09rrl9.091lt )
Pistonring ",";"* fo.o:s o.oto.rnlo.oorao.ooza i.'.f 0.13mm (0.005in )
lFis,.€-"'" EO3t 0 056rn. {OJ01rOOO2 i") 0 . 1 3m m ( 0 . 0 0i5n . )
L-Ringend gap
Second(FEDEHAL 0.025 0.060mm (0.0010 0.0024in.) 0.13mm (0.005in )
I\4OGUL)
Top 0.20 0.35mm (0.008 0.014in.) 0.60mm (0.024in.)
Second 0.40 0.55mm {0.016 0.022in.) 0.70mm (0.028in.)
OiI(REKEN) 0.25 0.65mm (0.010 0.026in.) 0.75mm (0.030in.)
OiI(FEDERAL 0 20 0.70mm i0.008 0.028in.) 0.80mm 10.031in.)
I\4OGUL)
Pistonpin o.D. 21.961 21.965mm {0.8646 0.8648in.) 2 1 . 9 5 3m m l 0 8 6 4 3 i n
Pin'to-piston
clearance 0.005-*0.002 mm( 0.00020+ 0.005mm (0.0002 in.)
0.00008
c_
in.)
Connecting
rod Pin to-rod clearance 0.005 0.015mm (0.0002 0.0006in.) 0 . 0 2 m m l O 0 O O 8i n I
Small end bore diameler 21.970 21.976mm (0.8650 0.8652in.)
L a r g e - e n db o r e d i a m e t e r ( N o r m a l ) 4 8 . 0m m ( 1 . 8 9
in.)
Endplayinslalledon crankshaft 0.15 0.30mm (0.006 0.012in.) 0 . 4 0m m ( 0 . 0 1i6n . )
Crankshaft Main journal diameter No. l journal s4.e84 s5.008mm (2.1648=16illl
No.2 journal
N o .4 j o u r n a l
No.5 journal
No.3 journal 0 m ( 2 . 1 6 4 42 - 1 6 5 4 i n )
5 4 . 9 7 65 5 . 0 0 m
Rodjournal diameter 4 4 . 9 7 6 4 5 . 0 0 0m m ( 1 . 1 7 0 7 1 . 1 7 1 7i n . l
Rod/main 0.005mm 10.0002in.)max. 0.010mm (0.0004 in.)
Rod/mainiournalout of,round 0.005mm (0.0002
in.)max. 0.010mm (0.0004 in.)
E n dp l a y 0.10 0.35mm (0.004 0.0'14 in.) 0 . 4 5m m 1 0 . 0 1i 8
n.)
Runout 0.03mm (0.0012
in.)max. 0.04mm {0.0016
. . - ' . : - - ' + in.)
M a r n o e a r , n 9 - t o J o u r n ao
t t t c t e a r a n c e No. l journal m m ( 0 . 0 0 0 70 . 0 0 1i6n . )
0.017 0.041 0.050mm (0.0020 in.)
Deaflngs No.2 journal
No.4 journal
No.5
No.3 journa/ q0rr034, -rn {O'o010
0-o01r|"tl 0.055mm (0.0022in.)
Bodbearingclearance 0.021 0.049mm (0.0008 0.0019in.) 0.060mm (0.0024
in.)
2-4
o i nqlne
|tem
Engineoil
Lubrication
Capacity
Measurement Oualificalion Standerdor New
5.30 (5.6US qt)for engineoverhaul
ServiceLimil
4.20 (4.4US qt)for oil change,includingfilter

4.00 (4.2US qt)for oil change,withoutfilter
Oilpump lnner-toouterrotorclearance 0.02 0.16mm {0.001 0.006in.) 0.20mm (0.008in.)
Pumphousingto outerrotor 0-15 0.21mm {0.006-0.008 in.) 0.23mm (0.009in.)
clearance
Pumphousing-to-rotor axial 0.02 0.07mm (0.001 0.003in.) 0.12mm (0.005in.)
clearance
shafts,journaldiameter
Balancer No.1 journal,front 19.938 19.950mm 10.78500.7854in.) 19.92mm (0.784in.)
shaft
No 1 journal,rearshaft23.938 23.950mm (0.9424 0.9429in.) 23.92mm (0.942in.)
No.2 journal,frontand 32.949 32.961mm 11.29121.2911 in.l 32.93mm (1.296in.)
rearshaft
shafts,journaltaper
Ealancer 0.005rnm (0.0002
in.)max.
shafts,end play
Balancer Front 0.070 0.135mm (0.0028 0.0053in.) 0.15mm (0.006in.)
Rear 0.070 0.135mm (0.0028 0.0053in.) 0.15mm (0.006in.)
Balancershatts,shaft-to'bear;ng No. 1 iournal,front 0.050 0.082mm (0.0020 0.0032in.) 0 . 1 0m m ( 0 . 0 0i4n . )
clearance shaft
N o . 1 J o u r n a l ,r e a r s h a f t 0.050 0.082mm (0.0020 0.0032in.) 0.10mm (0.004in.i
N o . 2 j o u r n a l ,f r o n t a n d 0.060-0.120mm (0.0024 0.0047in.) 0.15mm (0.006in.)
rear shafl
LD.
shaftbearings,
Balancer No. 1 journal,front 20.000 20.020mm (0.1814 0.7442in.l 20.03mm (0.789in.)
shaft
No. 1 iournal,rearshaft Z+.OOO ZI.OZOm- tOSa+e-OSa57ir'.) 24.03mm (0.946in.)
a
No.2 journal,frontand 33.021 33.069mm (1.3000 1.3019 in.) 33.09mm {1.303in.)
L R e l i e f v a l v e ,o i l p r e s s u r ew i t h o i l
t e m p e r a t u r ea t 1 7 6 ' F ( 8 0 " C )
rearshaft
At idle
At 3,000rpm
7 0 k P a ( 0 . 7k q ? c m , 1 0 p s r )m i n .
300kPa{3.1ksf/cm',44psi)min.
Standardor New ServiceLimit

Coolantcapacity engine,
{includes 6 . 7L ( 7 . 1U S
heater,hoses,and reservoir)
0.53L (0.56US
93 123kPa(0.95 1.25kqtcm , 14 18psi)
't69 176'F(76 80'C)
Thermostat OPeningtemPerature
8.0mm {0.31in.)min.
TurnsOFF Subtract5 15'F(3 8"C)fromactualON
v a
2-5
Fueland Emissions
Item Measulement Oualification
f
Standardor New ServiceLimit . \
Fuelpressure Pressurewith fuel pressuregauge 320-370kPa13.3-'3.8
kgtcm',47 52psi)
regulator connected
Fueltank Capacity 5 04 ( 1 3 . 2U Sg a l i
Engineidle ldlespeedwith headlights and radiator Neutral 750 50 rpm
fan off
F a s ti d l e Neutral 1,600150rpm
Clutch
Item Mea3urem€nl Oualification Slandardor New ServiceLimit
Clutchpedal Heightfromthe floor 193mm (7.60in.)
Stroke 1 3 0 1 4 0m m 1 5 . 1 5 . 5 i n . )
10 16mm (0.39 0.63in.)
D i s e n g a g e m e n th e i g h t f r o m t h e f l o o r 1'15 mm (4.53 i n . )m i n .
Bunouton clutchmatingsurface 0.05mm 10.002 in.)max. 0.15mm (0.006in.)
Clutchdisc Bivetheaddepth 1.65 2.25mm (0.065 0.089in.) 0.7mm {0.03in.)
Ihickness 8.3 8.9mm (0.33 0.35in.) 6.0mm (0.24in.)
Pressureplate Warpage 0.03mm (0.001in.)max. 0 . 1 5m m ( 0 . 0 0i1n . )
Heightof diaphragm spring fingers Measured with 0.6mm (0.02in.)max. 0.8mm (0-03in.)
specialtooland
feelergauge
r a
\ < c
2-6
nualTransmissionand M/T Differential
O E Item
Transmission Capacity
M€asurement Oualification Standardor New
Forfluidchange:1.50 (1.6US qt)
Se.viceLimit
fluid U Sq t )
F o ro v e r h a u1l :. 70 1 1 . 8
' l - 0 . 1 7 ( 0 . 0 0 4 Adiust
Mainshaft Endplav 0.1 mm 0.007in.)
Diameterof bushingsurface 20.80 20.85mm {0.819 0.821in.) 20.75mm 10.817 in.)
D i a m e t e ro f d i s t a n c ec o l l a r 31.984-32.000 mm (1.2594 1.2598 in.) 3 m ( 1 . 2 5i7n . )
3 ' 1 . 9m
Diameter of ballbearingcontactarea 2 7 . 9 7 72 7 s 9 0m m \ 1 . 1 0 1 -51 . 1 0 2i0n . ) 27.92 m m ( 1 . 0 9i9n . )
(clutchhousingside)
'1.5354 38.93mm (1.5334n.)
Diameter of needlebearingcontact 38.984 39.000mm (1.5348 in.)
area
Diameterof ballbearingcontactarea 27.987 28.000mm (1.10'191.1024in.) 2 7 . 9 3m m { 1 . 1 0i0n . )
(transmission
housingside)
Runout 0.02mm (0.001in.)max. 0.05mm (0.002in.)
Mainshaft 3rd, t.D. 44.009 44.025mm 11.73261.7333 in.) 44.08mm (1.735in.)
4th and sth Endplay 0.06 0.16mm {0.002 0.006;n.) 0 . 2 5m m ( 0 . 0 1i0n . )
gears Thickness 23.92 23.97mm (0.94'10.944in.) 23.80mm (0.937in.)
Countershaft Diameterof needlebearingcontact 35.000-35.015mm (1.3780 '1.3785in.) 34.95mm (1.376in.)
area(clutchhousingside)
Diameterof distance
collarcontact 39.937 39 950mm (1.5723 1.512ain.| 39.88mm (1.570in.)
alea
D i a m e t e ro f b a l l b e a r i n gc o n t a c t a r e a 3 3m ( 1 . 1 8 1 91- . 1 8 2i4n . )
30.020-30.0m m m ( 1 . 1 8i0n . )
29.97
( t r a n s m i s s i o nh o u s i n g s i d e )
Runout 0.02mm {0.001in.)max. 0.05mm (0.002in.)
innerrace
35 mm shim-to'bearing 0.04 0.10mm (0.0016 0.0039in.) Adjust
clearance
52.010 52.029mm (2.0476-2.0484 52.08mm (2.050in.)
a
Countershaft LD. in.i
0.06 0.16mm (0.002 0.006in.) 0 . 2 5m m 1 0 . 0 1i 0
n.)
L Countershaft
End play
Thickness
t.D.
22.92 22.91$m 10.902-0.904in.)
52.010 52.029mm (2.0476 2.0484in.)
22.87mm (0.900in.)
52.08mm {2.050in.}
2ndgear Endplay 0.06 0.16mm (0.002 0.006in.) 0.25mm 10.010 4n.)
Thickness 21.92 27.91mtn \1.099 1.101in.) 27.87mm 11.097 in.)
Countershaft LD. 39.95 39.96mm (1.572a 1.5132in.) 39.97mm (1.574in.)
'lst gear o.D. 46.989-47.000mm (1.8499-1.8504 in.) 46.94mm (l.848in.)
collar Length
distance 23.03 23.08mm (0.907-0.909 in.i
Countersha{l l . D . 39.95 39.96mm {1.5728'-1.5732in.l 39.97mm (1.574in.)
2ndgear o.o. 46.989 47.000mm (1.8499 1.8504 in.) 46.94mm (1.848in.)
distance
coliar L e n g t h 28.03 28.08mm (l.104 1.106in.)
v o
2-7
Manual
anuatTransmission
I ransm ?
and Differentialcont'
Item Measutemenl Oualification Standardor New ServiccLimit
Nlainshaft4th LD. 32.00-32.01mm (1.2598 1.2602in.) 3 2 . 0 2m m ( 1 . 2 6i1n . )
and5thgears o.D. 38.989 39.000mm (1.5350 1.5354 in.) 38.94mm (1.533in.)
distance
collar L e n g t h 51.95 52.05mm (2.045 2.049in.)
B 24.03 24.08mm (0.946-0.947in.)
MBSdistance LD. 28.00 28.01mm(1.102 1.103in.) 2 8 . 0 2m m ( 1 . 1 0i3n . )

Len9th 23.95 24.05mm (0.943 0.947in.)
Reverseidler t.D. 20.016 20.043mm (0.7880 0.7891in.) 20.90mm (0.832in.)
gear G e a r l o r e v e r s eg e a r s h a f i c l e a r a n c e 0.036 0.08amm (0.0014 0.0033in.) 0 . 1 6m m { 0 . 0 0i6n . )
Synchroring Bingto'gearclearance Ringpushed 0.70 1.49mm (0.028 0 059in ) 0.4mm (0.0164n.)
againstgear
Triplecone Outersynchroring-tosynchrocone Ringpushed 0.70- '1.19
mm {0.028 0.047in.) 0.3mm (0.012in.)
clearance againstqear
Synchrocone-to-gearclearance Ringpushed 0.50 1.04mm (0.020 0.041in.) 0.3mm (0.012in.)
againstgear
Outersynchroring-to-gear
cone Ringpushed 0.95 1.68mm (0.037 0.066in.) 0.6mm (0.024in.)
clearance againstgear
Shift fork Fingerthickness 7.4 7.6mm 10.29 0.30in.)
Forkto-synchrosleeveclearance 0.35 0.65mm (0.014 0.026in.i 1.0mm (0.039in.)
Reverseshift Fingerthinkness 13.4 13.7mm (0.527 0.539in.)
fork Fork-to-reverse
idlergear clearance 0.20 0.59mm (0.007 0.024in.) 1.3mm (0.051in.)
Shiftarm t.D. 13.973 '14.000
mm (0.5501 0.5512in.)
16.9 '17.0
Selectlever
S h i f t f o r k d i a m e t e ra t c o n l a c ta r e a
S h i f t a r m ' t o - s h i f t l e v e rc l e a r a n c e
Fingerwidth
mm (0.665 0.669in.)
0.2 0.5mm (0.008 0.020in.)
14.85 '14.95
mm (0.585 0.589in.)
0 . 6 2m m ( 0 . 0 2i4n . ) L O
Shiftlever Shaft-to-selectleverclearance 0.05 0.25mm (0.002 0.010in.) 0.50mm (0.020in.)
Groove{to selectlever) 15.00 15.10mm {0.591 0.594in.)
Shaftto shiftarm clearance 0.013 0.07mm (0.0005 0.003in.) 0.1mm {0.004in.)
Mfi Pinionshaftcontactareal.D. 18.010 18.028mm (0.7091 0.7098in.)
differential C a r r i e r - t o - p i n i o ns h a f t c l e a r a n c e 0.027 0.057mm (0.0011 0.0022in.) 0.1mm (0.004in.l
carrier DriveshaftcontactareaLD. 28.025 28.045mm (1.1033 1.1041 in.)
Mfi Backlash 0.05 0.15mm {0.002 0.006in.)
differential t.D. 6 m ( 0 . 7 1 0 30 . 7 1 1 3 i n . )
1 8 . 0 4 21 8 . 0 6m
pinionqear P i n i o ng e a r t o p i n i o n s h a f t c l e a r a n c e 0.059 0.095mm (0.0023 0.0037in.) 0.15mm (0.006in.)
80 mm shim 80 mm shim to-bearing
outerrace 0 0.10mm (0 0.0039in.) Adjust
clearance
in transmission
housing
2-8
o Rotational
olavmeasured
at outside 0 10mm (0 0.39in.)
Startingloadmeasured
at outside 2 9 N ( 3 . 0k g f . 6 . 6 l b s )
A n g l e o f r a c kg u i d e s c r e w l o o s e n e d
n
Item Measurement Oualitication Standardor New ServiceLimit
W h e e l a l i g n m e nCamber
t Front 0'00' 45'
Rear 0'45'- 45
Caster Front 1"33' 11"
TotalToe lrytt 0-3 mm(0::0.12 in.)
Rear lN 2 ' , mm (0.08"' ,, in.)
Frontwheelturningangle l n s i d ew h e e l 37'40'-2'
Outsidewheel 29'50'(Reference)
Aluminumwheelrunout Axial 0 0.7mm (0 0.03in.) 2.0mm (0.08in.)
Radial 0 - 0 . 7m m ( 0 0 . 0 3 i n . ) l.5mm{0.06in.)
Wheelbearing Endplay Front 0 0.05mm (0 0.002in.)
Rear 0 0.05mm (0 0.002in.)
Y a
2-9
Brakes
Item
Parkingbrake
lever
Distance
M€asurement
traveledwhen leverpulled
with 196N (20kgf, 44 lbs) ol force
Oualification Standardor New
7 8 clicks
ServiceLimit
a
Brakepedal Pedalheight(carpetremoved) 1 8 4m m ( 7 4 / 1 6i n . )
Freeplay 0 . 4 3 . 0m m ( 00 1 6 0 ' 1 1 8
in.)
Mastercylinder Piston-to-pushrod
clearance 0 0.4mm (0 0.02in.)
Erakedisc Thickness Front 2 1 . 0m m ( 0 . 8 3
in.) 19.0m 0 m (0.75 in.)
Rear 9.0mm {0.35in.) 8-0mm (0.31in.i
Runout Front 0.10mm (0.004in.)
Rear 0.10mm (0.004in.)
Parallelism Frontand rear 0.015mm (0.0006 in.)
Brakepads Thickness Front 10.0mm (0.39in.) 1 . 6m m ( 0 . 0 6
in.)
llear 9.0mm {0.35in.) 1 . 6m m ( 0 . 0 6
in.)
Air Gonditionin
Item Moasurement Oualilication Standard or New Service Limit
Refrige.ant Tvpe H F C1 3 4a ( B - 1 3a4)
Capacityof system 500 550g 117.6 19.4oz)
Refrigerant
oil Type S P1 O
(P/N38897-P13-A01AH or 38899-P13-A01
)
Capacity
ofcomponents Condenser 25 m0,15/6fl ozl
Evaporator 45 mA111/2fl ozt
Eachline and 10m0 (1/3fl or)
hose
Compressor 1 3 0 1 5 0m 0 1 41 / 3 5 f l o z )
Compressor Startercoil resistance At 68"F(20"C) 3.05 3.350
Drivebelt
Pulley-to-pressure plateclearance 0.35 0.6mm (0.014 0.024in.)
Autotensioner lneedsno adjustment) e-
2-10
DesignSpecifications
O |tem
DIMENSIONS Overalllength
Overallwidth
Measurement Oualification
4 , 2 1 0m m { 1 6 5 .i8n . )
1,695mm 166.7 in.)
Specilication
Overallheight 1,44m 0 m (56.7 in.)

2,570 m m ( 1 0 1 .i2n . )
Track rront 1,470mm (57.9in.)
Rear '1,470 mm (57.9in.i
Groundclearance 152mm (5.98in.)
S e a t i n gc a p a c i t y four {4)
wEtGt-iT
{u.s.A.) G r o s s V e h i c l eW e i g h t R a t i n g 3,660rbs
(GVWR)
WEIGHT GrossVehicleWeightRating 1,660kg
(CANADA) {GVWR)
ENGINE Tvpe Watercooled.4 strokeDOHCV-ECengin(
Cylinderarrangement Inline4'cylinder, transverse
Boreand stroke 86 x 86 mm (3.39x 3.39in.)
Displacement cuin.)
1 , 9 9 c8 m ' ( 1 2 2
Compression ratio 9.8
Valvetrain Chaindrive.DOHCVTEC4 valvespercylinder
Lubricationsystem Forced, wet sump,withtrochoidpumP
Oil pumpdisplacement At 6,000engine 54.30 (57.4 US qo/minute
rpm
Waterpumpdisplacement At 3,400engine 82 0 (87US qt)/minute
F!el required UNLEADED gasolinewith 86 pumpoctanenumberor higher

STARTER Tvpe Gearreduction
o
Normaloutput
L Nominalvoltage
Hourrating
Directionof rotation
12V
30 seconds
C l o c k w i s ea s v i e w e c lf r o m g e a r e n d
CLUTCH C l u t c ht v p e S i n q l e p l a t ed r y , d i a p h r a g m s p r i n g
Clutchfrictionmaterialsurfacearea 1 7 4c m ' { 2 6 . 9s7q i n . )
I\,1AN
UAL Tvpe Svnchronized, s-speed forward,1 reverse
TRANSMISSIONPrimarvreduction D i r e c1t : 1
Gearratio lst 3.062
2nd 1.769
3rd 1.212
4th 0.921
5th 0.738
Reverse 3.583
Finalreduction Type Sinolehelicalgear
Gearratio 4.164
v o
2-11
DesignSpecifications
cont'
Item
STEERING Type
Measuremeni Oualification
Electric,
Powerassisted
Specilication
rackand pinion
C
Overallratio 15.1
Turns,lockto-lock
Steeringwheeldiameter 3 6 0m m ( 1 4 . 2
in)
SUSPENSION Type I n d e p e n d e n ts r r u l w i t h s t a b i l i T e rc. o i l s p r i n g
Rear D o u b l ew i s h b o n e
Shockabsorber Front Telescopic,
hydraulic.
nitrogengas-frlled
Rear Telescopic,
hydraulic,
nitrogengas,filled
WHEEL Camber Front 0"00'
ALIGNMENT Bear 0.45'
Caster Front 1'33'
Totaltoe Front 0 mm (0 in.)
Rear I n 2 m m ( 1 / 1 6i n . )
BRAKES Typeof servicebrake Front P o w e r a s s i s t e ds e l f - a d j u s l i n gv e n t i l a t e dd i s c
Bear Power-assisted self-adjusting soliddisc
Typeof parkingbrake Mechanical actuating, rearwheels
Padfriction surfacearea Front 4 5c m ' ( 7 . 0s q i n . ) x 2
Rear 2 8c m ' ( 4 . 3s q i n . )x 2
TIRES Sizeoffront and reartires Pl95/6081588V
Sizeo{ sparetire T125r0 D1595M
AIR Compressor Type Scroll
CONDITIONING Numberof
cylinders
Capacity 85.7m015.23 cu in.)/rev.
a
Maximumspeed 12,000rpm
Condenser
L u b r i c a n tc a p a c i t y
Lubricanttype
Type
130m0 {4 1/3floz)
SP-10(P/N38897'P13-A01AH
Corrugated fin
or38899-P13
A01) L
Evaporator Tvpe Corrugatedfin
Blower Type Siroccofan
Motor type 220 Wl12 V
Speed control 4 Speeo
M a x i m u m c a p a c i t y 480m" 116.900
cu ft)/h
T e m p e r a t u r ec o n t r o l Airmixtype
Compressor
clutch Tvpe Dry,singleplate,poly-Vbeltdrive
Electricalpower 42W maximumat 12V
cons!mptronat
68"F(20.C)
Refrigerant Type HFC134a(R-134a)
Capacity 500 550g (17.6 19.4oz)
../a
2-12
o Item
ELECTRICAL
RATINGS
Battery
Starter
Alternator
Measurement Oualilication
1 2 V 3 6A H / 5h o u r s
1 2V - . 1 . 1k W ,1 . 2k W
12V 95A,90A
Specitication
Fuses Under-hood
fuse 80A, 60A, 50A, 40A, 30A, 20A, 15A, 10A, 7.5A
Under'dash
Iuse 3 04 , 2 0 a , 1 5A , 1 0A , 7 . 5A
Light bulbs Headlighthigh '12v.' 60w

beam
Headlightlow 12V 55W
beam
Frontturnsignal 12V 21W
liqhts
Front parlinq lights 12V 5W
Bearturn signal 1 2 V" 2 1 W
lights
FronVrear side 12V 5W
markerlights
Brale/taillighls 12V 21/5W
H i g h m o L r n tb r a k e 12V 5W
light
Backup lights 12V 21W
License platelight 12V 5W
Ceilinglight '12v'.8 w
Cargoarea light 12V 5W
o
Spotlights 12V 5W
t Gauge lights
I n d i c a t o rl i g h t s
Sideturn signal
LED
12V 5W
light
v a
2-13
Body Specifications
Unit: mm {in.)
1.555{61.6)
1,i140(56.71
2-14
I
Maintenance
Lubricantsand Fluids
MaintenanceSchedulefor Normal
Conditions
Listed by Distance/Time
MaintenanceSchedulefor Severe
Gonditions
Listedby Distance/Time
t MaintenanceSchedule
Listedby Maintenance
ltemfor Normal
Conditions ...................
3-8
Listedby Maintenance
ltem for Severe
Conditions ...................3-9
\.4

Lubricantsand Fluids
For detailsof lubricationpoints and type of lubricantsto be applied,referto the illustratedindex and variouswork
ures{suchasAssem o v e r h a u l .l n s t a l l a t i o ne.t c . )c o n t a i n e di n e a c hs e c t i o n .
NO. LUBBICATION
POINTS LUBBICANT
1 Eng ine Honda Motor Oil (P/N08798-9023). The oil container
must disolavthe API Cenificationseal shown below.
M a k es u r ei t s a y s" F o r G a s o l i n eE n g i n e s . S
" AE
Viscositv:See chart below.
2 Transmission HondaMTF*'(P/N08798-9016)
3 Brakesvstem (includesABS line) HondaDOT 3 BrakeFluid*' (P/N08798-9008)
4 C l u t c hl i n e
5 Release f o r k ( m a n u a tl r a n s m i s s i o n l S u p e rH i g hT e m p U r e aG r e a s e{ P / N0 8 7 9 8 - 9 0 0 2 )
6 Throftlecableend (throttleIink)
7 Shift and selectcable ends (manual S i l i c o n eg r e a s e
transmission)
I Throttlecable end (dashboardlower panel hole)
9 Brakeboosterclevis grease
Multi-purpose
10 CIutchboosterclevis
11 Shift lever pivot
1' Pedalinkage
Batteryterminals
14 F u e lf i l l d o o r
H o o dh i n g e sa n d h o o d l a t c h
16 H a t c hh i n g e s
17 D o o rh i n o e s u , o D e ra n d l o w e r
18 Caliperpiston boot, caliperpins and boots HondaCaliDerGrease(P/N08C30-80234lvl)
19 A i r c o n d i t i o n i n cg o m p r e s s o r C o m p r e s s o r o iS
38899-P'13-A01)
l : P - 1 0( P / N3 8 8 9 7 - P 1 3 - A 0 1 A
o rH I
F o rr e f r i q e r a nH
t;FC'134 a ( R - 1 3 4a )
Recommond6dEngineOil
fanges
E n g i n eo i l v i s c o s i l yf o r a m b e n t t e m p e r a l u r e
-30 -20 -10 0 t0 20
* 1 : Always use HondaManualTransmissionFluid (MTF).Using motor oii can causestiffershifting becauseit does
not containthe Drooeradditives.
" 2 : Always use HondaDOT 3 BrakeFluid.Using a non-Hondabrakefluid can causecorrosionand decreasethe life of
the system.
3-2
t
o o o o o@@
o a9
3-3
MaintenanceSchedule
Listedby Distance/Timefor Normal Conditions
Thistwo pagel/lanitenance Scheduleoutlinesthe minimunrequiredmaintenance. Serviceat the indicated distance
or time,whichevercomes
first.use the lvlaintenance
Schedule
for Severeconditionsif the vehiclemeetsanyof the qualifiers
in the SevereConditions or if the
schedule
vehicleis normallydrivenin Canada.
(cold)(seepage6-321r
Inspectvalveclearance. 0.28 0.32mm (0.011 0.013in.)
0.21-0.25mm (0.008 0.010in.)Exhaust:
Intake:
Replace sparkplugs.UseIZFR6K'11(NGK)or SKJ20DR-M11 (DENSO).
1 . 0 1 . 1m m
120,000
mi/ 192,000km/6 years
I Replacetransmission fluid.UseHondaMTF(seepage13-3).
! Do items in A,B,alqq.,
/ / Y vcdrs
120,000
mil 192,000
Beplace coolant(seepage106).Capacity:
5.00 (5.3US qt).UseHondaAll SeasonAntifreeze/Coolant
Type2.
According to stateandlederalregulations,
tailureto do the maintenance
itemsmarkedwith an asterisk{*) will not voidthe customer's
emissions warranties,However,Hondarecommends thatall maintenance be doneat the recommended
services intervalto ensurelong-term I
reliability.
3-4
Dothe itemsin partsA, B, C, D, andE as requiredfor mileage/time
intervallisted.
A
Replace engineoillseepage8-5i. Capacity withoutlilterchange:4.0S (4.2US qt, 3.5lmp qt)
Rotatetires.Followthe patternshownin the Owner'sManual Checktireinformationandcondition.
B
Replace engineoil filterlseepage8-6). Capacity with filterchange:4.20(4.4US qt,3.7lmp qt)
Inspectfrontandrearbrakes(seepage19 3i.
. Checkpadsand djscsfor wear(thickness), damage,andcracks.
' Checkcalipers tor damage,leaks,andtjghtnessot mountbolts.
Checkparkingbrakeadjustment. ShouldbeIullyappliedwithin7 to I clicks.
Inspecttie rod ends,steeringgearbox,and boots{seepage17 5).
. Checkrackgreaseandsteeringlinkage.
. Checkbootsfor damageand leakinggrease
. Chackfluidline{or damageand leaks.
lnspectsuspensioncomponents.
. Chockboltsfor tightness.
. Checkconditionof balliointbootslor deterioration
and damage.
Inspectdriveshaftboots.Checkbootsfor cracksand boot bandsfor tightness(seepage16-3).
Insp€ctbrakehosesandlines{including ABS). Checkthemastercylinder, proponioning controlvalve,andABSmodulator{ordamage
andleakage.
add MTFlseepage13'3),engioecoolant,brakefluid,and
Checkall fluidlevelsandconditionot tluids;checkfor leaks.lf necessary,
windshield washerfluid.
L lnspectexhaust system*.Checkcatalytic converterheatshield, exhaustpipeand mufflerfordamage,leaks,andtightness{soepage9,8).
lnspect{uellinesandconnections*. Checkfor looseconnections, cracksand deterioration;
retightenlooseconnoctions
and replace
damagedparts(s€epage11 146).
l InsDect
andadiustdrivebelt.
. Lookfor cracksanddamage,andinspectautotensioner(needsno adjustment).
Replacethe dustandpollenlilter(seepage21 39).
. Replacethe dustandpollenfilterwheneverairflow lrom the heatingandcoolingsystemis lessthannormal.
D
air cleanerelementevery30,000miles(48,000
Replace km)(independent
of time).
E
brakefluidevery3 years(independent
i I Replace oI mileage).
Accordingto stateandfederalregulations,
failureto do the maintenance * ) will not voidcustomer's
itemsmarkedwith asterisk( emissions
warranties.
However,Hondarecommends thatall maintsnance servicebe doneat the recommendedintervalto ensurelongterm reliability.
3-5
MaintenanceSchedule
Listedby Distance/Timefor SevereConditions
Serviceat the indicated or time,whichevercomesfirst.Usethisscheduleif the vehicleis drivenMAINLYin Canadaor in anyof the
distance
tollowingconditions; il onlyOCCASIONALLY drivenin theseconditions,
usethe NormalConditions (seepage3-4).
schedule
SevereDrivingConditions
. Drivinglessthan5 miles{8 km) pertrip or, in freezingtemperatures,
drivinglessthan 10miles(16km)pertrip
. Drivingin extremelyhot (over90"F/32"C) conditions
. Extensive idl;ngor longperiodsof stopand go driving,suchasa taxior a commercial deliveryvehicle.
. Trailertowing,drivingwith a car-topcarrier,or drivingin mountainousconditions.
. Drivingon muddy,dusty,or de'icedroads
R e p l a c et r a n s m i s s i o nf l u i d . U s e H o n d a M T F { s e e p a g e 1 3 3 ) .
(cold)(seepage6 32):lntake:0.21 0.25mm (0.008 0.010in.)Exhaust:

Inspectvalveclearance. 0.28 0.32mm (0.011 0.013in.)
Replace sparkplugs.Use
IZFR6K 11 (NGK)or SKJ20DR'M 11 {DENSO)
km/ 6 years
R e p l a c et r a n s m i s s i o nf l u i d . U s e H o n d a M T F ( s e ep a g e 1 3 3 ) .
km/ 10years,thenevery60,000mi/ 96,000km/5 years

mil 192,000
Replace coolant(seepage10-6).Capacity:
5.0015.3US qt) UseHondaAll SeasonAntifreeze/coo
lantType2.
3-6
Dothe itemsin partsA, B, C,D, E,F,and G as requiredfor mileage/time
intervallisted.
A
Feplaceengineoil(seepageS5). Capacity q (4.2US qt,3.5lmpqt)
withoutlilterchange:4.0
I
Replace engjneoil filter(seepageI 6). Capacity with filterchange:4.20 14.4US qt,3.7lmp qt)
Insoectfrontand rearbrakes,
. Checkpadsanddiscsforwearlthickness), damage,andcracks.
. Checkcalipers for damage,leaks,andtightnessof mountbolts.
Lubricatedoorlocks,latchesand hingeswith Hondawhitelithiumgrease.
Rotatetires,if the vehiclehasbeendriventhe distancelisted.Followthe patternshownin the Owner'sManual-Checktire inflaronaoo
condition,
Inspecttierod ends,steeringgearbox,and boots(seepage17,5).
. Checkrackgreaseandsteeringlinkage.
. Checkbootsfor damageand leakinggrease.
. Checklluidlinefordamageandleaks.
L Inspectsuspensron components
. Checkboltsfor tightness.
. Checkconditionof balljointbootsfor deteriorationanddamage.
Inspectdriveshaft boots.Checkbootsfor cracksand bootbandsfor tightness(seepage16-3).
Checkparkingbrakeadjustment. Shouldbe fullyappliedwithin7 to 9 clicks.

Insp€ctbrakehosesandlioes.(including ABS). Checkthe mastercylinder,proportioning controlvalve,andABSmodulatorfor damage
and leakage (seepage19-24).
Checkall fluidlevelsandconditionot lluids;checkfor leaks.lf necessary,
add MTF (seepage13 3),enginecoolant,brakefluid,and
windshield washerf luid.
Inspectexhaustsystem*.Checkcatalytic converterheatshield,exhaustpipeand mufflerfor damage,leaks,andtightness(seepage9 8).
Inspectfuel linesandconnections*.Checkfor looseconnections, cracksand deterioration;
retightenlooseconnections
and replace
damagedpans(seopage11'146).
(seepage22-68).
L Checkalllights.Checkfunction
Inspectthe v€hicleunderbody.
otallinteriorandexteriorlights,andthepositionofthe headlights
Checkthe paintfor damage,scratches, stonechippin0,anddents.
D
InsDectand adiustdrive belt.
. Looktor cracksanddamage,and inspectautotensioner
{needsno adjustment).
Reolace dustand oollenfilter.
E
Replace
aircleanerelementevery15,000
miles124,000
km) in dustvcondition{independent
ol timei otherwiseuseNormalConditions
(seepage11-162).
scredule
F
lReplaceaircleanerelementevery30,000miles(48,000km)(independento{timei(seepagell-162).
brakefluidevery3 years(independent
Replace oJmileagei.
H
dustandpollenIilterevery15,000
Replacethe milesifvehicleis drivenmostlywhereair hashighconcentrationolsootfrom industryand
dieselpoweredvehiclesj
alsoreplacethe dustand pollenfilteranytimeaarflowis lessthanussal(seepags21-39).
A c c o r d i n gt o s t a t e a n d f e d e r a l r e g u l a t i o n s ,f a i l u r e t o d o t h e m a i n t e n a n c ei t e m s m a r k e d w i t h a s t e r i s k( * ) w i l l n o t v o i d c u s t o m e r ' s e m i s s i o n s
w a r r a n t i e s .H o w e v e r , H o n d a r e c o m m e n d s t h a t a l l m a i n t e n a n c es e r v i c e sb e d o n e a t t h e r e c o m m e n d e d i n t e r v a lt o e n s u r e l o n g - t e r m r e l i a b i l i t y ,
3-7
MaintenanceSchedule
Listedby Maintenanceltem for NormalConditions
Followthe NormalSchedule if the severedrivingconditions in the lMaintenance
specified Schedule on the nextpagedo
for SevereConditions
c
not apply,and if onlyOCCASIONALLY drivenin severedrivingconditions.
Followthe SevereConditionsscheduleif the vehicleis drivenMAINLYin Canada.
Serviceatthe indicated ortime,

distance milesx 1,000 t0 20 30 40 50 70 80 90 100 110 r20
whichevercomesfirst.
km x 1,000 16 32 48 64 80 96 112 128 144 160 192
months 12 24 3 48 60 12
engineoil
Replace o o o o a o o a a o O a
R o t a t et i r e s
{ C h e c kt i r e i n t l a t i o na n d c o n d i t i o n a t l e a s t o n c e p e r m o n t h )
engineoil filter
Replace o o a a a a
frontand rearbrakes
Inspect
C h e c kp a r k i n g b r a k e a d j u s t m e n t
Visuallyinspectthefollowingitems:
. Tie-rodends,steeringgearboxand boots
. Suspension components
. Driveshaftboots
. Brakehosesand lines(including ABSi
. Allfluidlevelsandconditionof{luids
. Exhaust system*
. Fuellinesandconnections*
Inspectandadjustdrivebelt a a a a
dustand pollenfilter
Replace
Reolace fluid
transmission a
Servicethefollowing items at the recommendedintervals
R e p l a c ea i r c l e a n e re l e m e n t Every miles(48,000
30,000 km)
sparkplugs
Replace Every miles(176,000
110,000 Lm)
Inspectvalveclearance Inspect
every110,000 km),otherwise
miles{176,000 onlyif noisy.
adiusl
I n s p e c ti d l e s p e e d * Every
160.000 km)or8 years
mres1256,000
R e p l a c ee n g i n e c o o l a n t miles(192,000
At 120,000 km)or 10years, miles(96,000
thenevery60,000 km)or5
brakefluid
Replace Every3 years
* : According failureto do the maintenance

to stateandlederalregulations, (*) will not voidcustomer's
itemsmarkedwith asterisk emissions
However,Hondarecommends
warranties. thatall maintenance servicebe doneat the recommendedintervalto ensurelong-termreliability-
3-8
Listedby Maintenanceltem for SevereConditions
Usethisschedule if the vehicleis drivenMAINLYin Canadaor in anvof thefollowinaconditions. NOTE:it onlyOCCASIONALLY
drivenin these
conditions,usethe NormalConditions schedute.
SovereDrivingConditions
. Drivinglessthan5 miles(8 km)pertrip or, in lreezingtemperatures, drivinglessthan 10miles(16km)pertrip.
. Drivingin extremely hot over90 "F 132'C)conditions.
. Extensive idling,or longperiodsot stop-and-go-driving, suchas a taxior a commercialdeliveryvehicle.
. Trailertowing,drivingwith a cartop carrier,or drivingin mountainous conditions.
. Drivingon muddy,dusty,or de icedroads.
Serviceat the indicated

distance
or time, milesx 1,000 10 20 30 40 50 60 70 80 90 100 110 120
whichevercomesfirst.
km x 1,000 16 48 64 80 96 112 128 144 160 176 192
months 12 24 36 48 60 72
Replace
engineoil Replace
every
5,000
miies18,000
km)or6 months
Rotatetires a o a a o a a o a a a o
{Checktire intlationandconditionat leastonceper monthi
R e p l a c ee n g i n e o i l f i h e r
Inspectfrontand rearbrakes
L u b r i c a t ea l l l o c k s ,h i n g e s ,a n d l a t c h e s
Visuallyinspectthe followingitems:
. Tie rod ends,steeringgearboxand boots
. Suspension components
' Driveshaftboots
Checlparkingbraleadjuslment a a O a o a
Visuallyinspectthefollowingitems:
. Brakehosesand lines{including ABSi
. Allfluidlevelsandconditionoflluids
. Exhaust system*
. Fuellinesandconnections*
. Lightsandcontrols,vehicleunderbody
Inspectand adjustdrivebeh o a o a
R e p l a c ed u s t a n d p o l l e n f i l t e r " o ' t '
Replace
transmission
lluid a a
Servicethe following items atthe recommendedinteruals
Replace
aircleanerelement miies(24,000
Every15,000 km)in dustyconditions,
otheMiseusenormalschedule.
sparkplugs
Replace Every miles(176,000
110,000 km)
Inspectvalveclearance Inspect miles(176,000

every110,000 km),otheMise
adiust
onlyif noisy.
I n s p e c ti d l e s p e e d ' Every miles(256,000
160,000 km)or8vears
Replace
enginecoolant miles(192,000
At 120,000 km)of 10years,lhen
every miles(96,000
60,000 km)or5
Replace
brakefluid Every3 years
* : A c c o r d i n gt o s t a t e a n d f e d e r a l r e g u l a t i o n s ,f a i l u r e t o d o t h e m a i n t e n a n c ei t e m s m a r k e d w i t h a s t e r i s k1 * ) w i l l n o t v o i d c u s t o m e r ' s e m i s s i o n s
w a r r a n t i e s .H o w e v e r , H o n d a r e c o m m e n d st h a t a l l m a i n t e n a n c es e r v i c eb e d o n e a t t h e r e c o m m e n d e d i n t e r v a lt o e n s u r e l o n g { e r m r e l i a b i l i t v .
N O T E 1 : R e p l a c et h e d u s t a n d p o l l e n f i l t e r a t 1 5 , 0 0 0m i l e s / 2 4 , 0 0 0k m i f t h e v e h i c l e i s d r i v e n m o s t l y i n u r b a n a r e a st h a t h a v e h i g h c o n c e n t r a t i o n s
o f s o o t i n t h e a i r f r o m i n d u s t r v a n d d i e s e l - D o w e r e dv e h i c l e s .
t,
3-9
EngineElectrical
EngineElectrical - +
SpecialTools 4-2
ENGINE
StartingSystem
Comoonent Location Index ............... 4-J
CircuitDiagram 4-4
StarterCircuit Troubleshooting 4-5
ClutchInterlockSwitchTest 4-6
StarterSolenoid Test .............. 4-7
StarterPerformance Test 4-8
StarterReolacement ............... 4-9
StarterOverhaul....................... 4-10
lgnition System
Component LocationIndex ............... 4-15
CircuitDiagram 4-16
lgnitionTimingInspection 4-17
lgnitionCoilRemoval/1nsta11ation .......................
4-18
SparkPlugInspection 4-19
ChargingSystem
Component LocationIndex ..................................
4-2O
CircuitDiagram ...........................
4-21
Charging CircuitTroubleshooting .......................
4-22
DriveBeltInspection ...................
4-26
DriveBeftReplacement ..............
4-26
DriveBeftAuto-tensioner Inspection.................. 4-27
DriveBeftAuto-tensioner Replacement ..............
4-28
AlternatorReolacement .............
4-29
AlternatorOverhaul ................ .... 4-30
CruiseControl
Component LocationIndex ..................................
4-36
CircuitDiagram ...........................
4-37
SymptomTroubleshooting Index .......................
4-38
CruiseControlUnitlnDutTest .............................
4-40
MainSwitchTesVReolacement ...........................
4-42
SeVResume/Cancel SwitchTesVReplacement .. 4-42
CruiseControlActuatorTest ......4-43
CruiseControlActuator/CableReplacement ......4-44
ActuatorCableAdjustment..................................
4-45
ClutchPedalPositionSwitchTest .......................
4-45
\.

EngineElectrical
SpecialTools \ C
Number Tool Number Description otv
o 07746-0010400 Attachment,52 x 55 mm 1
@ 07749-0010000 Driver 1
\(a
4-2
Starting System
ComponentLocationIndex
UNDER-DASH
FUSE/RELAYBOX
- l - -
-i
ar]]]ll I
-_-
-. rt_.1
_-- _. /
Itti:
: - l t . i t -i t! -t
!t:!|- CLUTCH INTERLOCKSWITCH
Test,page4-6
STARTERCUTRELAY
Test,page22-51
\ r \ ' l
\'\l I
\r\, l,
, . \ \ /
'....",r.v
\ \ /
\- \:,...)
\ /'\
t l \
STARTER
page4 5
StanerCircuitTroubleshoot,ng,
SolenoidTest,page 4-7
PerformanceTest,page4-8
Replacement,page 4-9
'10
Overhaul,page4
4-3
Starting System
CircuitDiagram
-
ilo.20lOA) :USAmotkl
No.2!l50A) : C.nid. model
UiIOENH@DfUSE/REI.IY
BOX
STHOTin STA8Tilll
UNDEiOASTI
FUST/ifLAY
80x
Y.
cLuTot
[{Tr8LocK
swtlcH
4-4
StarterCircuitTroubleshooting
NOTE: 4. Checkthe batterycondition.Checkelectrical
. Airtemperaturemust be between59'and 100'F(15' connectionsat the battery,the negativebaftery
and 38'C) during this procedure. cableto body, the engine ground cablesand the
. After this test, or any subsequentrepair,resetthe starterfor loosenessand corrosion.Then try
enginecontrolemodule (ECM)to clear any diagnostlc startingthe engine again.
trouble codes (DTCS){seepage 11-4).
. The batterymust be in good conditionand fully Did the statter crank the engine?
charged.
. lf you disconnectthe baftery,do the ECM idle learn YES Repairingthe looseconnectionfixed the
p r o c e d u r e( s e ep a g e1 1 - 1 3 9 ) . problem.The startingsystem is now OK.!
RecommendedProcedure: N O l f s t a r t e r w i l ln o t c r a n k t h e e n g i n ea t a l l ,g o t o
. Use a startersystemtester. step 5. lf it cranksthe engine erraticallyor too
. Connectand operatethe equipmentin accordance slowly, go to step 7. lf it won't disengagefrom the
with the manufacturer'sinstructions. flywheel ring gear when you releasethe key, check
for the following until you find the cause.
Alternate Procedure
. Solenoidplungerand switch malfunction
1. Hook up the following equipment: . Dirty drive gear or damagedoverrunningclutch
. Ammeter,0 400A
. Voltmeter,0 20 V (accuratewithin 0.1 volt) 5. Make sure the transmissionis in neutral,then
. Tachometer,0 1200rpm disconnectthe startersubharness1Pconnector(A)
'lP
from the enginewire harness connector(B).
Connecta jumper wire from the batterypositive
'l
terminalto the startersubharness P connector.
2 . Removethe No. 17 (15A)fuse from the under-dash

fuse/relaybox.
3 . With the clutch pedal pressed,turn the ignition

switchto start (lll).
Did the starter crank the enginenormally?

Did the starter crank the engine?
YES-The startingsystem is OK.I
YES-Go to step 6.
NO-Go to step 4.
NO Checkthe BLK,ANHT wire betweenthe starter
subharness1Pconnectorand the starter.lf wire is
OK, removethe starter,and repairor replaceas
necessary.
L
(cont'd)
4-5
StartingSystem
StarterCircuitTroubleshooting ClutchInterlockSwitch Test
(cont'dl
6. Checkthe following items in the order listeduntil
you find the open circuit.
1. Disconnect
the clutchinterlockswitch2Pconnector.
. Checkthe BLIVWHTwire and connectors
betweenthe under-dashfuse/relaybox and the
ignition switch,and betweenthe under-dash
fuse/relaybox and the starter.
. Checkthe ignition switch {seepage 22-53).
. Checkthe clutch interlockswitch and connector.
. Checkthe startercut relay (seepage 22-51).
. CheckLT GRNwire betweenthe startercut relayl
under-dashfuse/relaybox and the clutch
interlockswitch.
. Checkthe BLKwire betweenthe clutch interlock
switch and G501.
7, Checkthe crankingvoltageand currentdraw.
ls ctanking voltagegreatet than or equal to 8.7 V

and current draw less than or equal to 230 A?
YES-Go to step8.
NO Replacethe starter.or remove and

disassembleit, and checkthese items until you find 2. Removethe clutch interlockswitch (A).
thecause.
Checkfor continuitybetweenthe terminals
. Starterarmaturedragging accordingto the table.
. Shortedarmature winding
. E x c e s s i vder a g i n e n g i n e . lf the continuityis not as specified,replacethe
clutch interlockswitch.
8 . C h e c kt h e e n g i n es p e e dw h i l ec r a n k i n gt h e e n g i n e . . lf OK, installclutch interlockswitch and adjust
the pedal height (seepage 12-4l..
ls the engine speed above 100 tpm?
\ Terminal
YES Go to step 9. 2
Cl","f ri"t.tf ."tS""*Jrl
NO-Replace the starter,or remove and PRESSED o-- - --o
disassembleit, and checkfor the following until
RELEASED
y o u f i n dt h e c a u s e .
. Excessivelyworn starterbrushes
. Open circuit in commutator brushes
. Open circuit in starterarmaturecommutator
segments
. D i r t yo r d a m a g e dh e l i c asl p l i n e so r d r i v eg e a r
. Faultydrive gear clutch
9. Removethe starter,and inspectits drive gear and

the flywheel ring gear for damage.Replaceany
d a m a g e dp a n s . I
4-6
StarterSolenoidTest
from thestarter
the S andlvlconnectors
1. Disconnect
solenoid.
2. Checkthe hold-incoil for continuitybetweenthe S

terminal and the armaturehousing(ground).There
should be continuity.
. lf there is continuity,goto step 3.

. lf there is no continuity,replacethe solenoid,
3. Checkthe pull-incoil for continuitybetween the S

et terminaal n d M t e r m i n a lT
. h e r es h o u l db e
continuity,
. lf there is continuity,the solenoidis OK.

. lf there is no continuity,replacethe solenoid,
4-7
StartingSystem
Starter PerformanceTest
1 , Disconnectthe wires from the S terminal and the M 5. Disconnectthe batteryfrom the starterbody. lfthe
termrnal. pinion retractsimmediately,it is working properly.
Make a connectionas describedbelow using as

heavya wire as possible(preterablyequivalentto
the wire used for the vehicle).To avoid damaging
the starter,never leavethe batteryconnectedfor
more than 10 seconds,
Connectthe batteryas shown. Be sure to

disconnectthe startermotor wire from the solenoid.
lf the starterpinion moves out, it is working
propefly.
6 . Clampthe starterfirmly in a vise.
7 . Connectthe starterto the batteryas describedin

the diagram below,and confirm that the motor
starts and keepsrotating.
Disconnectthe batteryfrom the M terminal.lf the

pinion does not retract,the hold-incoil of the
solenoidis working properly.
lf the eiectriccurrent and motor speedmeet the

specificationswhen the batteryvoltage is at 11.5V,
the staner is working properly,
Specifications:
1.1 kw 90 A or less (Electriccurrent),

ot more
4-8
Starter Replacement
1. Make sure you havethe anti-theftcode for the radio. 5. Disconnectthe startercable (A)from the B terminal
then write down the frequenciesfor the radio's on the solenoid,then disconnectthe BLK,/WHT wire
presetbuttons. { B )f r o mt h eS t e r m i n a l .
10x 1.25mm
2. Disconnectthe negativecablefrom the batteryfirst, 44N.m{a.5kgf.m,33lblft)
then disconnectthe positivecable.
3. Disconnectthe knocksensorconnector.
4. Removethe bolt (A) securingthe harnessbracket,

then removethe intakemanifold bracket(B).
A
6x1,0mm
12 N.m {1.2kgf.m,
8.7 tbt.ft)
8 x 1 . 2 5m m
9Nm
10.9kgf.m,7 lbl ft) 2
S'-12x12smm
6ilNm
{ 6 . 5k g l m , 4 7 l b f f t )
Removethe two bolts holdingthe starter,then

removethe starter.
7 . lnstallthe starterin the reverseorder of removal.

8 x 1.25mm
22 N,m 12.2kgt.m, Make sure the crimped side of the ring terminal (A)
16rbf.ftl is facing out.
Connectthe positivecable and negativecableto

the batterY.
9 . Start the engineto make sure the starteroperates

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

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

' t 2 .Performthe enginecontrol module (EcM) idle learn
L procedure(seepage 1'1-139).
4-9
StartingSystem
Starter Overhaul f
Disassembly/Reassembly
STARTERSOLENOID
@
@
----_2<-
,--\
G
rw.h
; ,/ 1(-\
SOLENOIDLEVER
\:!@a - @-A
q -z\hsc6
b-.- ,"
OVERRUNNING
CLUTCHASSEMBLY
7:- o
o*"lu*. S#o
V*rN*
\#. A*@
\ c^)* -#""Jli[X:""
-v t^ fr/ /
a<-4 ffiA
9\:-/
,.. D lW
ffitr '!4/
END COVER t/
BRUSHHOLDER
\ r
4-10
\
Armature Inspection and Test 5. Checkthe commutatordiameter.lf the diameteris

below the servicelimit, replacethe armature.
1. Removethe starter(seepage 4-9).
Commutator Diameter
2 . D i s a s s e m b lteh e s t a r t e ra s s h o w na t t h e b e g i n n i n g Standard(Newl: 28.0mm (1.10in.l
of this procedure. ServiceLimit: 27.0 mm (1.06in.)
3. Inspectthe armaturefor wear or damagefrom

contactwith the permanentmagnet.lf there is wear
or damage,replacethe armature.
6 . Measurethe commutator (A) runout.
. lf the commutator runout is within the service

limit, checkthe commutatorfor carbondust or
?.- Checkthe commutator(A) surface.lf the surfaceis brasschips betweenthe segments.
dirty or burnt, resurfacewith emery cloth or a lathe . lf the commutator runout is not within the service
within the specificationsin step 5, or recondition limit, reolacethe armature.
with # 500 or # 600 sandpaper(B).
Commutator Runout
StandardlNew): 0.02mm 10.001in.) max.
ServiceLimit: 0.05mm (0.002in.)
(cont'd)
4-11
StartingSystem
StarterOverhaul(cont'dl
7. Checkthe mica depth (A).lf the mica is too high {B), 9. Placethe armature(A) on an armaturetester (B).
undercutthe mica with a hacksawbladeto the Hold a hacksawblade (C)on the armaturecore. lf
properdepth.Cut away allthe mica (C)between the blade is attractedto the core or vibrateswhile
the commutatorsegments.The undercutshould t h e c o r ei s t u r n e d ,t h e a r m a t u r ei s s h o n e d .R e p l a c e
not be too shallow,too narrow,or V-shaped(D). thearmature.
Commutator Mica Depth

Standard(New):0.50-0.80 mm {0.020-0.031in.)
ServiceLimit: 0.20 mm (0.008in.)
1 0 ,Checkwith an ohmmeterthat no continuityexists

betweenthe commutator(A) and armaturecoll
core (B),and betweenthe commutatorand
armatureshaft (C).lf continuityexists,replacethe
Checkfor continuitybetweenthe segmentsof the armature.
commutator.lf an open circuitexists betweenany
segments,replacethe armature.
4-12
Starter Brush Inspection Starter Brush Holder Test
11. lvleasurethe brush length.lf it is not within the 14, Checkthat there is no continuitybetweenthe (+ )
servicelimit, replacethe brush holder assembly. b r u s hh o l d e r{ A )a n d ( ) b r u s hh o l d e r( B } .l f t h e r e
is continuity,replacethe brush holder assembly.
Brush Length
Standard{New): 14.0-14.5 mm (0.55-0.57 in.)
Service Limit: 9.0 mm {0.35 in.)
Brush Spring Inspection

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

3.09 3.97lbf)
1 3 .Checkfor continuitybetweeneach brush (A) and

the armaturehousing(B).li there is continuity,
replacethe armaturehousing.
(cont'd)
4-13
StartingSystem
StarterOverhaul(cont'dl
Planetary Gear Inspection Starter Reassembly
1 6 . C h e c kt h e p l a n e t a r yg e a r s( A )a n d r i n g g e a r{ B ) . 20, Pry backeach brush spring with a screwdriver,then

Replacethem if they are worn or damaged. positionthe brush about halfwayout of its holder,
a n d r e l e a s et h e s p r i n gt o h o l d i t t h e r e .
NOTE:To seatthe new brushes.slip a strip of #5OO

or # 600 sandpaper.with the grit side out, be&veen
the commutatorand each brush,and smoothly
rotatethe armature.The contactsurfaceof the
brusheswill be sandedto the same contouras the
commutator.
OverrunningCluich Inspection
17. Slidethe overrunningclutchalong the shaft.

Replaceit if it does not slide smoothly.
18. Rotatethe overrunningclutch(A) both ways. 21 l n s t a l l t h ea r m a t u r ei n t h e h o u s i n ga, n d i n s t a l l t h e

Doesit lock in one directionand rotatesmoothly in brush holder.Next, pry backeach brush spring
reverse?lf it does not lock in eitherdirectionor it a g a i n ,a n d p u s ht h e b r u s hd o w n u n t i li t s e a t s
locksin both directions,replaceit. againstthe commutator,then releasethe spring
againstthe end of the brush.
1 9 .lf the starterdrive gear (B) is worn or damaged,

s
replacethe overrunningclutch assembly;the gear Installthe starterend cover to retainthe brush
is not availableseparately. holder.
Checkthe conditionof the flywheel ring gear.
Replaceit if the starterdrive gear teeth are
oamageo.
i.-
4-14
lgnition System
SPARKPLUG
page4-'19
Inspection, IGNITION COIL
page4-17
lgnitionTimingInspection,
page4-18
Removal/lnstallation,
4-15
lgnition System
GircuitDiagram (
'No.20lOA)
:USAmo&l
UNDEBHOOD
FUST/8TIAY
M)( No.Al50A):Cmrda
model
lG1tioT in 0N {ll)
rd SIARIilll)
4-16
lgnition Timing Inspection
1 . Connectthe Honda PGM Testerto the data link 6. Pointthe light toward the pointer (A) on the cam
connector(DTC),and checkfor DTC'S.lf a DTCis c h a i nc a s e .C h e c kt h e i g n i t i o nt i m i n g u n d e rn o l o a d
present,diagnoseand repairthe causebefore conditions:headlights,blower fan. rearwindow
i n s p e c t i n tgh e i g n i t i o nt i m i n g . defogger,and air conditionerare not operaling.lf
the ignitiontiming differsfrom the specification,
Startthe engine.Holdthe engine at 3,000rpm with and there are no enginecontrol module {ECM)DTcs,
no load (in Neutral)until the radiatorfan comes on, r e p l a c et h e E C M( s e ep a g e1 1 - 4 )
then let it idle.
lgnition Timing:
C h e c kt h e i d l es p e e d( s e ep a g e1 1 - 1 3 8 ) . 8"+2" BTDC{REDmark {B))during idling in neutral
"SCS" menu A
4. Follow the tester'sprompts in the
{seethe testeroperator'smanual),
5 . Connectthe timing light to the serviceloop.
o 7. Turn the ignition switch OFF.
e o n d aP G MT e s t e ra n dt h e t i m i n g
D i s c o n n e c t t hH
light.
4-17
lgnition System
lgnitionCoilRemoval/lnstallation
1. Removethe ignition coil cover (A),then removethe
i g n i t i o nc o i l s( B ) .
6x1.0mm
9.8 N.m (1.0kgf.m,7.2lbf ftl
2. Installthe ignition coils in the reverseorder of
---a
removal.
4-18
SparkPlug Inspection
1 . Inspectthe electrodesand ceramicinsulator. 3. Replacethe plug at the specifiedinterval,or if the
centerelectrodeis rounded{A). Use onlVthe spark
Burned or worn electrodes may be caused by: plugs listedbelow.
. Advancedignitiontiming
. Loosespark plug Spark Plugs: lZFR6Kl1(NGK)
. Plug heat rangetoo hot SKJ2ODR-M11(DENSO)
.Insufficientcooling
Fouledplug may be causedby:

. Retardedignitiontiming
. O i l i n c o m b u s t i o nc h a m b e r
. Incorrectspark plug gap
. Plug heat rangetoo cold
. Excessiveidling/lowspeed running
. C l o g g e da i r c l e a n e re l e m e n t
. Deterioratedignitioncoils
Worn or deformed
electrodes
f .lmpropergap
I J.Oil-touling
. Cs6on deposits
'r- 1I . Crackedcenter
\ electrodeinsulator 4 . Apply a small quantityof anti-seizecompoundto
the plug threads,and screwthe plugs into the
cylinder headfinger-tight.Then torque them to
1 8 N m ( 1 . 8k g f . m ,1 3 l b f f t ) .
L
Do not adjustthe gap of iridium tip plugs (A);

replacethe spark plug if the gap is out of
specification.
Electrode Gap:
Standard(New): 1.0 1.1 mm
{0.039-0.0€ in.)
ServiceLimit: 1.3 mm {0.051in.l
4-19
GhargingSystem
CHARGING SYSTEMINDICATOR
(ln the gaugeassembly)
q*o
BATTERY
Test,page22-50
ALTEBNATOR
page4-22
Troubleshooting,
DRIVEBELT page4-29
Replacement,
page4 26
Inspection, page4-30
Overhaul,
Replacement,page4 26
4-20
\ CircuitDiagram
'flo.
{l0Al :uSAhod.l
UNDTRXOOD
FUSI/RILAY
MX ilo.20l50Al:C.n.d.mod.l
+--,
I fmlil*t"t'
T-
+ilt
L = l
4-21
GhargingSystem
ChargingCircuitTroubleshooting
lf the chargingsystem indicatordoes not come on or 6. Measurethe voltageat the No. 3 terminal of the
does not go off, or the batteryis dead or low, test these e n g i n ew i r e h a r n e s s6 P c o n n e c t ow
r iththe ignition
items in the order listedbelow: s w i t c hO N {l l ) .
Battery(seepage 22-50) ENGINEWIREHARNESS6P CONNECTOR

Chargingsystem indicator
Alternatorand regulatorcircuit
Alternatorcontrol system
IBLK/YEL}
ChargingSystemIndicatorTest
1 . T u r nt h e i g n i t i o ns w i t c hO N { l l ) .
Does the chatging system indicator come on?
YES Go to step 2. Wiresideof femaleterminals
NO Go to step 3.
ls there battery voltage?
2. Startthe engine.
YES-Go to step 7.
Does the charging system indicator go off?
N O - C h e c k f o r a b l o w nN o . 4{ 1 0 A )f u s e i n t h e
YES-Charging system indicatorcircuitis OK. Go under-dashfuse/relaybox. lf the fuse is OK, repair
to the Alternatorand RegulatorcircuitTest.t open in the wire betweenthe alternatorand the
under-dashfuse/relaybox.I ?
NO-Go to step 3.
7 . Turn the ignition switch OFF.
3. Turn the ignitionswitch OFF.
8 . Disconnectenginecontrol module (ECM)connector
4. Troubleshootthe multiplexcontrol system (see B (24P).
page 22 172).
9 . Checkcontinuitybetweenthe ECMconnector
ls the multiplex control system OK? t e r m i n a lB ' 1 0a n d e n g i n ew i r e h a r n e s s6 Pc o n n e c t o r
t e r m i n a lN o . 6 .
YES Go to step 5.
ECM CONNECTOB A (24P)
NO Checkthe multiplexcontrol system as

indicatedby the diagnostictrouble code (DTC) (see
s t e p8 o n p a g e2 2 - 1 7 2 ) . 1
A C G L{ W H T / B L U )
5. Disconnectthe enginewire harness6P connector
from the startersub harness6P connector.
E N G I N EW I B E
HARNESS
6P
L (WHT/BLUI
W i r e s i d eo f f e m a l e t e r m i n as
ls there continuity?
YES Go to step 10.
NO-Repair open in the wire betweenthe

a l t e r n a t oar n dt h e E C N 4 . I
\"4
4-22
'10.
Checkcontinuitybetweenthe ECMconnector Alternator and RegulatorCircuitTest
t e r m i n a l8 1 0 a n d b o d y g r o u n d .
1. Be sure the batteryis sufficientlychargedand in
ECMCONNECTOR
S I24PI good condition{seepage 22-50),and the
connectionsat the fuse box and alternatorare
clean and tight.
2 3 t 4t 5 6 7
8 I 10 ,/1,/ 3 15 2. Raisethe hoist to full height.
1 1 8 ,N nt,/ 21 23
ACGL(WHT/BLUI 3. Hook up the ammeter,0 400 A, to the starter
t1' subharness.
Wire side ol femaleterminals
YES- Repairshort to ground in the wire between

the ECMand the enginewire harness6P connector.
t
NO-Go to alternatorand regulatortest.
Lower the hoist.
Hook up the voltmeter,0 20 V (accuratewithin

0.1V),toT101.
(cont'd)
4-23
GhargingSystem
(cont'd)
ChargingCircuitTroubleshooting
6. Startthe engine.Hold the engineat 3,000rpm with Alternator Control SystemTest
no load (in Neutral)until the radiatorfan comes on,
then let it idle. NOTE:After troubleshooting,performthe engine
control module (ECM)idle learn procedure(seepage
7. Raisethe engine speedto 2,000rpm, and hold it 11-139).
there.
1. Checkfor proper operationof the electricalload
8. Turn the headlights(high beam)on, and measure detector(ELD)by checkingthe malfunction
voltageat the under-hoodfuse/relaybox terminal. i n d i c a t o lra m p ( M l L ) ( s e ep a g e1l - 3 ) .l f a D T Ci s
present,diagnoseand repairthe causebefore
ls the voltagebetween 13.9and 15.1v? continuingwith this test.
YES-Go to step 9. 2. Disconnectthe enginewire harness6P connector

from the startersub harness6P connector.
NO Repairor replacethe alternatorcomponents
(seepage 4-30).1 3. Start the engine,and turn the headlights(high
b e a m )O N ,
'13.5V.
9. Readthe amperageat
4. Measurevoltage betweenthe enginewire harness
NOTE:Adjust the voltage by turning the blower 6P connectorterminal No. 2 and the positive
motor, rearwindow defogger,brakelights.etc.ON. terminal of lhe battery.
ls the amperage604 ot morc? BATTERY
YES-Alternator/regulatoroperationis OK.I
NO Repairor replacethe alternatorcomponents

(seepage 4-30).1 C {WHT/GRN)
ENGINE
WIREHARNESS
6PCONNECTOR
Wiresideof femaleterminals
ls there 1 V or less?
YES Go to step 8.
N O - G o t o s t e p5 .
5 . T u r nt h e h e a d l i g h t a
s n d i g n i t i o ns w i t c hO F F .
6 . DisconnectECMconnectorB (24P).
\,
4-24
\
7, Checkfor continuitybetweenECMconnector 10. Checkfor continuitybetweenECMconnector

t e r m i n a l8 1 8 a n d b o d y g r o u n d . t e r m i n a l8 1 8 a n d e n g i n ew i r e h a r n e s s6 Pc o n n e c t o r
ECM CONNECTORB {24PI
ECM CONNECTORB l2,lPI
1 2 3 t 4t 5 6 1 1 2 3 1 4 l 5 l l6l 7
8 9 10 ,/1,/ 3 5 8 9 10 t.) 15
11o nt,/21 23 11o n
21 23
ACGC{WHT/GRN} ACGC(WHT/GRN)
o C (WHT/GRN)
o
2 3
5 6
Wire side ot femaleterminals
ENGINEWIREHARNESS6P CONNECTOR
Wire side oI lemale terminals
ls therc continuity?
YES-Repair short to ground in the wire between
the alternatorand the ECM.I YES Repairor replacethe startersubharnessor
the alternator(seepage 4-30).I
NO-Check that the terminalsare firmly seatedat
the ECMconnectorB. lf OK, substitutea known- NO Repairopen in the wire betweenthe
good ECM,and recheck(seepage 11-6). a l t e r n a t oar n d t h e E C M . I
lf prescribedvoltage is now available.replacethe
L o r i g i n aE
l CM,I
Turn the headlightsand ignition switch OFF.
4-25
ChargingSystem
DriveBelt Inspection DriveBelt Replacement
indicator(A)is withinthe
Checkthatthe auto-tensioner 1, Move the auto-tensioner(A) to relievetensionfrom
standardrange (B)as shown.lf it is out of thestandard the drive belt (B).and removethe drive belt.
range,replacethedrivebelt(seepage4-26).
2. Installthe new belt in the reverseorder of removal.
4-26
\
DriveBelt Auto-tensionerInspection
1 . Checkwhether there is a changein the positionof Removethe auto-tensioner(seepage 4-28).
the auto-tensionerindicatorbeforestartingthe
engineand after startingthe engine.lf there is a I n s t a ltlh e t e n s i o n e p
r ulley.
c h a n g ei n t h e p o s i t i o nr, e p l a c et h e a u t o - t e n s i o n e r .
7 . Clampthe auto-tensioner(A) by using two 8 mm
bolts (B)and a vise (C)as shown. Do not clamp the
auto-tensioneritself.
C h e c kf o r a b n o r m a n l o i s ef r o m t h e t e n s i o n e p r ulley.
lf abnorman l o i s ei s h e a r d ,r e p l a c et h e t e n s i o n e r
pulley.
3 . Removethe drive belt (seepage 4-26).

8 . Set the torque wrench (D)on the pulley bolt.
lMovethe auto-tensionerwithin its limit with the
belt tension releasetool in the directionshown. 9 . Align the indicator{E)on the tensionerbasewith
Checkthat the tensionermoves smoothly and c e n t e rm a r k( F )o n t h e t e n s i o n e ar r m b y u s i n gt h e
without any abnormal noise.lf the tensionerdoes torque wrench, and measurethe torque. lf the
not move smoothly or there is abnormal noise, torque value is out of specification,replacethe
replacethe auto-tensioner. auto-tensioner,
NOTE;lf the indicatorexceedsthe centermark,
recheckthe torque.
Auto-tensioner spring torque:

26.5-36.3 N.m 12.7-3.7 kg.m, 19.5-26.8lbt.ft)
4-27
ChargingSystem
DriveBelt Auto-tensionerReplacement
1. Removethe drive belt (seepage 4'26). 4. Removethe auto-tensioner,
2 . R e m o v et h e i d l e rp u l l e y .
6xl.0mm
9.8 N.m
(1,0kgl.m,
7.2 tbf.ft)
I
6x1,0mm
12 N.m
('1.2kgt.m.8.7lbt.ft)
x 1.25mm
22 N.m
{2.2 kgt m, 16 lbf ft}
3. Removethe tensionerpulley. 8 x 1.25mm

22 N.m (2.2kgf.m, 16lbt.ft)
5. lnstall in the reverse order of removal.
\-a
4-28
l\- AlternatorReplacement
1. Make sure you havethe anti-theftcode for the radio, 9 . Removethe alternator.
then write down the frequenciesfor the radio's
preset buttons, 1 0 . Installthe alternatorand drive belt in the reverse
order of removal.
2. Disconnectthe negativecablefrom the batteryfirst,
then disconnectthe positivecable. 'I
1 . Connectthe positivecable and negativecableto
the battery.
3. Removethe front bumper (seepage 20-85).
tt. Enterthe anti-theftcode for the radio,then enter
4. Removethe right side headlight(seepage 22-79). the customer'sradio station presets.
5. Removethe reservetank from the bracket. 1 3 .Set the clock.
6. Removethe drive belt (seepage 4-26). 1 4 . Performthe enginecontrol module {ECM)idle learn
p r o c e d u r e( s e ep a g e1 1 - 1 3 9 ) .
7. Removethe three bolts securingthe alternator.
8 x 1 . 2 5m m
22 N.n 12.2kgl.m,
Disconnectthe alternatorconnector(A) and BLK

wire (B)from the alternator.
8 N.m
10.8kgf.m,6lbf.ft)
\
6
4-29
ChargingSystem
AlternatorOverhaul
ExplodedView
-
W|UF.,.oy." REARBEARING /
ROTOR
\ \ /
\ ,/ ./ FRoNrB
BEARING
@b.J.y{=RE+LN'"'
vVFko"-% \ I/
qtr*njlv
V ("rV) , PULLEY
BRUSH \11
-\\
/ PULLEY
BRUSH
HOLOER HOLDER LOCKNUT
TNSULATOR \ \l \ /
\ \ VOLTAGE
REGULATOR
}
(- /@
\-
@*F,-\:
\
v_re*î \-a
\gP^@'I
TERMINAL
*ffilw9
INSULATOR
REARHOUSING
ASSEMBLY
INSULATOR
BUSHING
4-30
L
Special Tools Required 5 . R e m o v et h e e n d c o v e r( A )a n d d u s t s e a l{ B ) .
. Driver07749-0010000
. Attachment,52x 55 mm 07746-0010400
NOTE:Referto the ExplodedView as neededduring

this procedure.
1, Testthe alternatorand regulatorbeforeyou

remove them (see page 4-22l,.
2. Removethe alternator(seepage 4-29).
3. lf the front bearingneedsreplacing,removethe

pulley locknutwith a 10 mm wrench (A) and a
22 mm wrench (B).lf necessary,use an impact
wrencn.
6 . Removethe brush holder (A),voltage regulator(B),

a n dt h e r u b b e rs e a l{ C } .
, (( , t tI
; r _l L t
L1i.21---^
tqLJ
Removethe harnessbracket(A),insulator(B).three B-"--|.

flange nuts (C),and the screw (D),then removethe
p l a t et e r m i n a l( E ) .
1!q[-dr,:l
(cont'd)
4-31
ChargingSystem
AlternatorOverhaul(cont'dl
7. Removethe four screws,then removethe rectifier 9. lf you arenot replacing
the frontbearingand/or
( A )a n d f o u r i n s u l a t o r (sB ) . '16.
rearbearing,go to step Removethe rotorfrom
the statordriveendhousing.
1 0 .Inspectthe rotor shaftfor scoring,and inspectthe

bearingjournal surfacein the statorhousingfor
s e t z u r em a r k s .
Removethe four flange nuts,then removethe rear
h o u s i n g( A )a n dw a s h e r( B ) . . l f e i t h e r t h er o t o r o r s t a t o r h o u s i n g
isdamaged,
replacethe alternator,
. lf both the rotor and the stator housingare OK,
g o t o s t e p1 1 .
\"
o\ 'l
1 . R e m o v et h e r e a rb e a r i n gu s i n ga p u l l e ra s s h o w n .
f.r,e
4-32
\-
1 2 . W i t h a h a m m e ra n d c o m m e r c i a l l a
yvailable
tools 14. Supportthe stator housingin a vise, and drive out
shown, installa new rear bearingon the rotor shaft. the front bearingwith a brassdrift and hammer.
NOTE:Installthe bearingusing the inner race.
1 5 . W i t h a h a m m e ra n d t h e s p e c i a l t o o l si ,n s t a l a
l new
front bearingin the stator housing.
13. Removethe front bearingretainerplate.
sH qE
6 e
u s 07749-0010000
f-\
\r-:1
\s---'^/
07746-0010400
( c o n t ' d)
4-33
ChargingSystem
AlternatorOverhaul(cont'd)
Rectitier Test Alternator Brush Inspection
16. Checkfor continuityin each direction,betweenthe 1 7 . M e a s u r et h e l e n g t ho f b o t h b r u s h e s( A ) w i t ha

B terminal and P terminals,and betweenthe E v e r n i e rc a l i p e r{ B ) .
terminaa l n d P t e r m i n a l so f e a c hd i o d ep a i r .
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 yi n o n l y o n e . l f e i t h e rb r u s hi s s h o r t e r t h a n t h es e r v i c el i m i t ,
direction.Becausethe rectifierdiodes are designed r e p l a c et h e b r u s ha s s e m b l y .
to allow currentto pass in one direction,and the . lf brush length is OK, go to step '18.
rectifieris made up of eight diodes (four pairs).you
musttest each diode in both directionsfor Alternator Brush Length:
continuitywith an ohmmeterthat has diode Standard(New): 10.5mm (0.41in.)
checkingcapability:a total of 16 checks. ServiceLimit: 1.5 mm (0.06in.)
. lf any diode is faulty. replacethe rectifier

assembly.{Diodesare not availableseparately.)
' lf all the diodes are OK, go to step 17.
/--:',t- -L . --
- -o \-- l'-=
\"
Rotor Slip Bing Test
18. Checkthat there is continuitybetweenthe slip rings

{A).
B P " . lf there is continuity,go to step 19.

. lf there is no continuity,replacethealternator.
P,
P.
P,
P.
1 9 . Checkthat there is no continuitybetweeneach slip

ring and the rotor (B) and the rotor shaft (C).
. lf there is no continuity,goto step 20.

. lf there is continuity,replacethe alternator.
\r'a
4-34
Stator Test
20. Checkthatthereis continuitybetweeneach pair of

leads(A).
lf there is continuity,go to step 21.

lf there is no continuity,replacethe alternator.
'--l-- --i
2 1 .Checkfor no continuitybetweeneach lead and the

coil core (B).
. lf there is no continuity,goto step 22.

. lfthere is continuity,replacethe alternator.
22. Assemblethe alternatorin reverseorder of

disassembly,and note these items:
. Be carefulnot to get any greaseor oil on lhe slip

nn g s .
. lf you removedlhe pulley,tighten its locknutto
1 1 1N . m ( 1 1 . 3k g f m , 8 1 . 7l b f . f t ) w h e n y o ui n s t a l l
it.
4-35
GruiseControl
CRUISECONTROLINDICATOR
(Builtinto gaug6assembly)
CLUTCH PEDALPOSITION CRUISECONTROLUNIT

swtTcH lnputTest,page4-40
Test,page4-45
ClutchPedalAdjustment,
page12-4 BRAKEPEDALPOSITION SWITCH
Test,page22-84
page'19-6
PedalHeightAdjustment,
- l l
t.- _,- _
CRUISE CONTROL
ACTUATOR
Test,page4'43 ACTUATORCABLE
Replacement,page4-44 Adjustment,page4-45
\-a
4-36
CircuitDiagram
'
No.aloAl USAnod.l
No.20itoAl C.md! modrl
fUS'/iILAY IOX
UISEF NOOD
-to ots BU/YIL
lcl H0Tii0llilll
mdSTARTlllll
1 Honilsffroi
2 6 1 1 1 3
uNtT
cnu6EcoNTnoL l0
CTuICIIPEDAL
P0sm0swtrct
4-37
CruiseControl
Symptom TroubleshootingIndex
NOTE:
' The numbersin the table showthetroubleshootingsequence.
. Beforetroubleshooting.
- checkthe No, 10 (7.5A)and No. 4 (10A)fuses in the under-dashfuse/relaybox. and the No. 7 (15A)
fuse in the
under-hoodfuse/relaybox,
- checkthat the horn sounds.
- checkthe tachometerto see if it works properly.
- checkthe speedometerlo see if it works properly.
Symptom Diagnostic procedure Also check for

Cruisecontrol cannot be 1. Checkmain switch (seepage 4-42) . Poorground:
set 2. CheckSET/RESUME/CANCEL switch (seepage 4-42) G501
3. Test brakepedal positionswitch (seepage 22-84)and check . Opencircuit,
its adjustment{seepage 19,6) looseor
4. Test clutch pedal positionswitch (seepage 4-45)and check disconnected
its adjustment(seepage 12-41 t e r mi n a l s :
5. Checkcruisecontrol unit {seepage 4-40} L TG R N ,
6. Checkvehiclespeed sensor(VSS)(seepage 22-65) BLI(ORN.
GRY/RED, BLU.
LTBLU,
BLUAA/HT
Cruisecontrol can be set 1. Checkcruisecontrolindicatorbulbin gaugeassembly{see . Poor ground:
but indicatorlight does page 22-631 G501
not go on 2. Checkcruisecontrolunit(seepage4-40) . Open circuit,
looseor
disconnected
termrnats:
YEL,BLUA/EL
ar, 'i.a câa.l ic 1. Checkvehiclespeed sensor(VSS){seepage 22-65)
noticeablh y i g h e ro r Checkcruisecontrol actuator{seepage 4-43)
lower than what was set 2. Checkcruisecontrol unit (seepage 4-40)
Excessiveovershooting 1. Checkcruisecontrol actuator(seepage 4-43)

or undershootingwhen 2. Checkvehiclespeed sensor(VSS)(seepage 22-65)
trying to set speed Checkcruisecontrol unit (seepage 4-40)
3.
Speedfluctuationon a 1. Checkvehiclespeedsensor(VSS)(seepage22-65)
flat road with cruise Checkcruisecontrol actuator(seepage 4-43)
control set 2. Checkcruisecontrol unit (seepage 4-40)
Vehicledoes not 1. CheckSET/RESU ME/CANCELswitch (seepage 4-42) Open circuit,loose

decelerateor accelerate 2. Checkcruisecontrol unit {seepage 4-40) or disconnected
accordinglywhen SET/ terminals:
RESUME/CANCEL button GRY/RED,
is pushed LT GRN/BLK
Set speed does not 1. Testclutch pedal positionswitch (seepage 4-45)and check Shortto groundin
cancel(enginerpm stays its adjustment(see page 12-4) the LTBLUwire
h i g h )w h e n c l u t c hp e d a l 2. Checkcruisecontrol unit (seepage 4-40)
is pushed
'1.
Set speeddoes not Test brakepedal positionswitch (seepage 22-84)and check Open circuit,loose
cancelwhen brakepedal its adjustment(seepage 19-6) or disconnected
is pushed 2. Checkcruisecontrol unit (seepage 4-40) terminals:
WHT/BLK
g ,
4-38
svmptom Diagnosticprocedure Also check for
Set speeddoes not 1. Checkmain switch (seepage 4-42) Short to power in
cancelwhen main switch 2. Checkcruisecontrol unit (seepage 4-40) the LT GRNwire.
i s o u s h e dO F F
Set speeddoes not 1. CheckSET/RESU ME/CANCELswitch (seepage 4-42) Opencircuit,loose
c a n c ewl henCANCEL 2. Checkcruisecontrol unit (seepage 4-40) or disconnected
button is pushed terminals:
GRYiRED,
LTGRN/BLK
Set speedwill not 1. CheckSET/RESU ME/CANCELswitch (seepage 4-42) Open circuit,loose
r e s u m ew h e n R E S U M E 2. Checkcruisecontrol unit {seepage 4-40) or disconnected
button is pushed(with terminals:
main switch on, and set L TG R N / B L K
speedtemporarily
cancelledby pressingthe
brakeDedal)
4-39
CruiseGontrol
CruiseControl Unit Input Test
SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations(seepage 23-'13)and precautionsand
procedures(seepage 23-14)in the SRSsectionbefore performingrepairsor service.
1. Disconnectthe 14Pconnectorfrom the control unit.
2. Inspectthe connectorand socketterminalsto be sure they are all makinggood contact.
. lf the terminalsare bent, loose,orcorroded, repairthem as necessary,and recheckthesystem.

. lf the terminalslook OK, go to step 3.
Wire sideof
femaleterminals
3. With the 14Pconnectordisconnected,make these inDuttests.
Cavity Wire Test condition Test:Desiredresult Possiblecause ifresuhis notobtained

BRN/WHT Connectbattery Checkthe operationof the ' Faultyactuator
power magneticclutch:Clutch . P o o rg r o u n d( G 3 0 1 )
s h o u l dc l i c ka n d o u t p u tl i n k . An open in the wire
should be locked. . Shon to ground (arcswhen
Doweris connected)
2 BLU lgnitionswitch ON Checkfor voltageto ground; . Faultybrakepedal position
(ll),main swltch ON There should be 0 V with lhe switch
and brakepedal pedal pressedand battery . A n o p e ni n t h e w i r e
pressed,then voltagewith the pedal . Open in cruisecontrol main
reteaseo released. swrtcn
. B l o w nN o . 4 ( 1 0A ) f u s e i n t h e
under/dashfuse/relavbox
3 BLK U n d e ra l l c o n d i t i o n s Checkfor continuityto . P o o rg r o u n d( G 5 0 1 )
grouno: . An open in the wire
There should be continuitv
BLIVORN l g n i t i o ns w i t c hO N Checkfor voltageto ground: B l o w nN o . 4 ( 1 0A ) f u s e i n t h e
flr) Thereshould be battery under-dashf use/relaybox
vottaqe. An oDenin the wire
5 WHT/BLK Brakepedal pressed, Checkfor voltageto ground: B l o w nN o . 7 { 1 5A ) f u s ei n t h e
then released There should be battery under-hoodfuse/relaybox
voltagewith the pedal Faultybrakepedal position
pressed,and 0 V with the SWIICN
pedal released. A n o D e ni n t h e w i r e
4-40
Cavity Wire Test condition Test:Desiredresult Possible cause il resultis notobtained
6 GRYiRED Setbuttonpushed Checkfor voltageto ground: B l o w nN o . 7 ( 1 5A ) f u s e i n t h e
Thereshould be battery under-hoodfuse/relaybox
voltage, Faultyhorn relay
W h e nt e s t i n gt e r m i n a lN o . 6 , Faultysevresume/cancel
there should be no voltageon swrtch
t e r m i n a lN o . 7 . Faultycable reel
7 LT GRN/ Resumebutton Checkfor voltageto ground: An open in the wire
BLK pusneo Thereshould be battery Shon to ground (horn sounds
voltage. when button is pressed)
W h e nt e s t i n gt e r m i n a lN o . 7 ,
there should be no voltageon
BRN Connectbattery Checkthe operationof the . Faultyactuator
11 BRNI/EL power to the BRN actuatormotor: You should . An open in the wire
t e r m i n a la n d g r o u n d be ableto hear the motor.
to the BRNIVEL
termrnal
10 BLUIVEL lgnitionswitch ON Attachto groundi Blown No. 10 (7.5A) fuse in
0r) C r u i s ei n d i c a t o lri g h ti n t h e the under-dashfuse/relaybox
g a u g ea s s e m b l ys h o u l dc o m e Blown cruise indicatorbulfl
on. F a u l t yg a u g ea s s e m b l y
An open in the wire
12 BLU/VVHT lgnitionswitch ON Checkfor voltage between FaultyVSS
(ll) and main switch thE BLU/VVHT (+) ANdBLK An openin thewire
ON; raisethe front of ( )terminals: Shortto ground
the vehicle,and T h e r e s h o u l d b e 05 V o r
rotateone wheel more repeatedly.
s l o w l yw h i l e h o l d i n g
the other wheel
13 LTGRN lgnitionswitchoN Checkfor voltageto ground: B l o w nN o . 4 ( 1 0A ) f u s e i n t h e
{ l l )a n dm a i ns w i t c h Thereshouldbe battery under-dashfuse/relaybox
ON voltage. Faultymain switch
An oDenin the wire
14 LT BLU C l u t c hp e d a l Checkfor continuityto Faultyclutch pedal position
reteaseo grouno: swtlcn
T h e r es h o u l db e c o n t i n u i t y . P o o rg r o u n d( G 5 0 1 )
N O T E : T h e r se h o u l db e n o Incorrectclutchswitch
continuitywhen the clutch adjustment
oedal is Dressed. An open in the wire
lf any test indicatesa problem,find and correctthe cause,then recheckthe system.lf all the input tests prove OK,
the cruisecontrol unit may be faulty. Substitutea known-goodcruisecontrol unit and retest.lf the system works
properly,replacethe cruisecontrol unit.
4-41
CruiseControl
Main Switch Test/Replacement Set/Resume/Cancel
Switch Test/
Replacement
1 . Removethe driver's dashboardlower cover (see
page 20-59).
1. Removethe two screws.then removethe switch.
Releasethe clips of the main switch and push the
main switch 1A)out of the panel,then disconnect
the 5P connector(B)from the main switch.
Checkfor continuitybetweenthe terminalsin each

switch positionaccordingto the table.
. lfthere is continuity,and it matchesthe table, but

Checkfor continuitybetweenthe terminalsin each switchfailure occurredon the cruisecontrol unit
switch positionaccordingto the table. lf the input test, checkand repairthe switch circult.
continuityis not as specified,replaceillumination . lf there is no continuityin one or both positions,
bulbs (C)or the switch. replacethe switch.
\-------11v1 1 4
\
;"itl*
Terminal
'\ 2
Position
sET(ONt CF --o
OFF (9 @ --o
RESUME
ION) o
ON o @ o \J o CANCEL{ON}
o
r\--
4-42
CruiseControlActuatorTest
1. Disconnectthe 4P connector(A) from the cruise 6. Checkthe operationof the actuatormotor in each
control actuator(B). output linkagepositionaccordingto the table.You
should be able to hear the motor.
Batterypower Output linkageposition

Dolarities
FULt MIDDLEFUtL
CLOSE PO$TIONOPEN
No,4 No.3 The The The
Terminal Terminal motor motor motor
runs. runs. stoDs,
No.3 N o .4 The The The
Terminal Terminal motor motor motor
sIoos. runs. runs.
OUTPUTLINKAGE
2. Removethe cover (A),and checkthe output linkage
(B)for smooth movement.
,to
FULLCLOSE
1 . lf the actuatormotor does not operateas specified,

replacethe cruisecontrol actuatorassembly,
Connectbatterypower to the No, 2 terminal and

g r o u n dt o t h e N o . 1 t e r m i n a l .
C h e c kf o r a c l i c k i n gs o u n df r o m t h e m a g n e t i cc l u t c h .
The output linkageshould be locked.
5 . lf the output linkageis not locked,replacethe

cruisecontrol actuatorassembly,
4-43
CruiseControl
CruiseControlActuator/CableReplacement
1 . Fully open the cruisecontrol link by hand,then 3 . Removethe actuatorcover (A),then removethe
removethe cruisecontrol cable{A) from link. actuatorcable (B)from the cruisecontrol actuator.
Loosenthe locknut(B),and removethe cablefrom
the bracket.
4 . Installin the reverseorder of removal,and adjust

the free play at the throttle linkageafter connecting
2 . Disconnectthe 4P connector,and removethe three the actuatorcable.
bolts securingthe cruisecontrol actuator.
6x1,0mm
12 N.m (1.2kgf.m,8.7lbf.ft)
\rla
4-44
ActuatorCableAdiustment ClutchPedalPositionSwitch Test
1. Checkthat the actuatorcable{A) moves smoothly 1. Disconnectthe 2P connectorfrom the clutch pedal
with no binding or sticking. positionswitch (A),
SWITCH2PCONNECTOR
CLUTCHPEOALPOSITION
T e r m i n a l s i do
ef
m a l et e r m i n a l s
2. Startthe engine.
3. Measurethe amount of movementof the output

linkage(B) until the engine speedstartsto increase.
At first, the output linkageshould be locatedat the Removethe clutch pedal positionswitch.
fully closedposition(C).The free play (D)should be
3 . 7 5 1 0 . 5m m ( 0 . 1 5 1 0 . 0 2i n , ) . Checkfor continuitybetweenthe terminals
accordingto the table.
4. lf the free play is not within specs,loosenthe . lf the continuityis not as specified,replacethe
locknut(E).and turn the adjustingnut (F)untilthe clutch pedal positionswitch.
free play is as specified,then retightenthe locknut . lf OK, installtheclutch pedal positionswitch and
adjustthe pedal height (seepage 12-4).
Terminal
Cl"t"h P"d"l I 1 2
PositionSwitch
PRESSED
RELEASED o o
4-45
EngineAssembly
EngineRemoval \,
Special Tools Required 6. Disconnecttheintakeairtemperature(lAT)sensor

FrontsubframeadapterEOS02C00001
1 connector(A),removethe breatherhose (B)and
v a c u u mh o s e( C ) ,t h e n r e m o v et h e a i r c l e a n e r
NOTE: housingcover/intakeair duct assemblv(D).
. Usefender coversto avoid damagingpainted
surfaces.
. To avoid damage,unplug the wiring connectors
carefullywhile holdingthe connectorportion.
. Mark all wiring and hosesto avoid misconnection.
Also, be sure that they do not contactother wiring or
hoses,or interferewith other parts.
I 1. Securethe hood in the wide open position(support

rod in the lower hole).
2. Make sure you have the anti-theftcode for the radio,

presetbuttons.
3. Disconnectthe negativecablefrom the batteryfirst,

then disconnectthe positivecable.
A C
4. Removethe battery. 7 . R e m o v e t h e a i r c l e a n e rh o u s i n g .
5. Removethe intakemanifoldcover.
II
5-2
8. Removethe intakeair duct. 10. Fullv ooen the throttle link and cruisecontrol link
by hand,then removethe throttlecable (A) and
c r u i s ec o n t r o lc a b l e( B ) f r o mt h e l i n k s .L o o s e nt h e
locknuts{C),and removethe cablesfrom the
bracket.
9. Removethe batterycables{A) fromthe under-hood

fuse/relaybox. then removethe harnessclamp (B)
a n d g r o u n dc a b l e( C ) .
1 1 . R e l i e v e f u epl r e s s u r e( s e ep a g e1 1 - 1 4 4 ) .
1 2 . R e m o v et h ef u e ll i n e ( s e e p a g e l l - 1 4 9 ) .
13. Removethe evaporativeemission(EVAP)canister

hose {A) and brakeboostervacuum hose (B).
(cont'd)
5-3
EngineAssembly
EngineRemoval(cont'dl ..4,
1 4 . R e m o v et h e c l u t c hs l a v ec y l i n d e r{ A )a n d c l u t c h l i n e 16. Disconnectthe engine control module (ECM)
bracketmounting bolt (B). connectors(A) and main wire harnessconnector
(B).
15. Removethe shift cable (A) and selectcable (B).
't7. Remove
the harnessclamps (A) and grommet (B),
t h e n p u l l t h ee n g i n ew i r e h a r n e s st h r o u g ht h e
bulkhead.
\l,
5-4
1 8 .Removethe drive belt (seepage 4-26). 30. Disconnectthe air fuel ratio {4,/F)sensorconnector
(A) and secondaryheatedoxygen sensor
1 9 .R e m o v et h e l v C l i n e m o u n t i n gb o l t . (secondaryHO2S)connector(B),then removethe
three way catalyticconverter{TWC)assembly{C).
20. Removethe radiatorcap.
2 1 . R a i s et h e h o i s tt o f u l l h e i g h t .
22. Removethe front tires/wheels.
23. Removethe splashshield. 3 1 . R e m o v et h e l o w e rh o s e .
o@
2 4 . L o o s e nt h e d r a i np l u g i n t h e r a d i a t o r t od r a i nt h e
enginecoolant(seepage 10-6).
2 5 . D r a i nt h e t r a n s m i s s i ofnl u i d ( s e ep a g e1 3 ' 3 ) .
26. Drainthe engineoil {seepage8-5).
t e s t a b i l i z el ri n k s( s e ep a g e1 8 - 1 8 ) .
2 7 . D i s c o n n e ct h
28. Disconnectthe suspensionlower arm ball joints

( s e es t e p3 o n p a g e1 8 - 1 9 ) .
29. Removethe driveshafts{seepage 16-3).Coat all

precision f i n i s h e ds u r f a c e sw i t h c l e a ne n g i n eo i l .
Tie plasticbags over the driveshaftends.
(cont'd)
5-5
EngineAssembly
EngineRemoval(cont'd)
32. Lowerthe hoist. 36. Removethetransmission
mountbracketsupport
boltandnuts.
33. Removethe upperhose(A)andheaterhoses(B).
37. Removethe upperbracketmountingboltandnut.

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

(.g
\a
5-6
Make sure the hoist bracketsare positioned 41. Attachthe subframeadaptertofrontofthe
properly.Raisethe hoist to full height. subframe,thentightenthe knurledknob.
39. Removethe rear mount mounting bolts.
Raisethe jack. Line up the slots in the arms with the

bolt holeson the corner of the jack base,then
attachthe adaDterto the iack basewith the bolts.
40. Removethefrontmountbracketmountinqbolt.
(cont'd)
5-7
EngineAssembly
EngineRemoval(cont'd)
43. Use a markerto make alignmentmarks on the 45. Disconnectthe compressorclutchconnector(A),
referencelines(A) that align with the centersof the then removethe Ay'Ccompressor(B)without
r e a rs u b f r a m em o u n t i n gb o l t s( B ) . disconnectingthe A'./Choses.
:r -
, !:_- _l.= -- ---.-','-
ffi4
ffit'"
46. Checkthat the engine/transmission is completely

free of vacuum hoses,fuel and coolanthoses,and
e l e c t r i c awl i r i n g .
4 7 . S l o w l yl o w e rt h e e n g i n ea b o u t1 5 0m m ( 6 i n . ) .
C h e c ko n c ea g a i nt h a t a l l h o s e sa n d w i r e sa r e
disconnectedtrom the engine/transmission.
48. Lowerthe engineall the way. Removethe chain

hoistfrom the engine.
4 9 . Removethe enginefrom under the vehicle.

44. Removethe front subframe(C).
5-8
Enginelnstallation
Special Tools Required
FrontsubframeadapterEOS02C00001
1
1. lnstallthe accessorybrackets,and tighten their bolts and nuts to the specifiedtorques.
ENGINEMOUNTBRACKET
1 0x 1 . 2 5m m
il4 N.m {4.5kgf.m,33lbl.ft)
A/C COMPRESSOR
BRACKET
10 x 1,25mm
44 N.m {4.5kgf.m,33lbt.ft)
(cont'dl
5-9
EngineAssembly
EngineInstallation(cont'd)
Positionlhe engine under the vehicle.Attachthe 5. Installthe subframe(A).Alignthe reference marks
chain hoistto the engine,then lift the engine into (B)on the subframewiththe centerof the bolt
p o s i t i o ni n t h e v e h i c l e . h e a d st ,h e nt i g h t e nt h eb o l t s .
Reinstallthem o u n t i n gb o l t s / s u p p o rntu t si n - - -.'.: - --=---=-- .-€..'tt-

the sequencegiven. Failureto follow this
---:- -
sequencemay causeexcessivenoiseand
vibration,and reducebushinglife.
3. Installthe A,/Ccompressor(A),and connectthe

compressorclutchconnector{B).
1 4 x 1 . 5m m
103Nm
{ 1 0 , 5k g f m .
6r" F 76 rbt.ftl
Replace.
I
6-_-'-
6. Tightenthe rear mount mounting bolts.

8 x 1.25mm
22 N.m 12.2kgf m. 16 lbf.ft)
4. Supportthe subframewith the subframeadapter

a n da j a c k .
l 0 x 1 . 2 5m m
59 N.m (6.0 kgf.m, 4:] lbI.ft)
5- 10
7. Looselytightenthe front mount bracketmounting 10. Tightenthe transmissionmount bracketsupport
bolt. bolt and nuts.
1 2x 1 . 2 5m m
54 N m {5.5kgt m, 40 lbf.ft}
8 . Lower the hoist.
9 . Tightenthe upper bracketmounting bolt and nut.

'l '1.
Raisethe hoistto full height.
' t 2 . Tighten
the front engine mount bracketmounting
bolt.
12x 1.25rnrn
64 N.m{6.5kgf.m,
47 tbt.ftl
:l
13. Lower the hoist.
1 4 . R e m o v et h e c h a i nh o i s tf r o m t h e e n g i n e .
'15.
I n s t a l l t h er a d i a t o r( s e ep a g e1 0 - 1 0 ) .
'16.
R a i s et h e h o i s tt o f u l l h e i g h t .
17. Installa new set ring on the end of each driveshaft,

then installthe driveshafts.Make sure each ring
"clicks" into place in the differentialand
intermediateshaft.
(cont'd)
5-11
EngineAssembly
EngineInstallation{cont'dl
1 8 . Connectthe suspensionlower arm ball joints (see 2 3 . I n s t a l l t h es p l a s hs h i e l d .
s t e p6 o n p a g e1 8 - 1 9 ) .
1 9 . Connectthe stabilizerlinks (seepage 18-18). -t- -- - -- --r

.
20. Installthe three way catalyticconverter(TWC)
assembly(A);use new gaskets(B) and new self-
lockingnuts {C).
10x 1.25mm
33 N.m{3.i1kgf.m,
25 tbt.ftl
24. Lowerthe hoist.
25. I n s t a l l t hder i v eb e l t .
26. InstalltheA,/Clinemountingbolt.
6 x '!.0mm
9.8 N.m (1.0kgf.m,
7.2 tbt.ftl
-d
,ry
6\
8 x 1.25mm
22N.m |.2.2kglm,
\ 16tbt.ft)
D
2 1 . Connectthe air fuel ratio (4,/F)sensorconnector(D)

and secondaryheatedoxygen sensor(secondary
HO2S)connector(E).
Installthe lower radiatorhose.
v a
5-12
27. lnstallthe upper radiatorhose {A) and heaterhoses 30. Connectthe ECI\4connectors(A) and main wire
(B). harnessconnector(B).
Pushthe enginecontrolmodule(ECM)connectors
throught h eb u l k h e a tdh, e ni n s t a l l t hger o m m e(tA ) .
3 1 .Installthe throttlecable (seepage 11-164),then

a d j u s t t h ec a b l e{ s e ep a g e1 1 - ' 1 6 3 ) .
3 2 . Installthecruisecontrol cable (seepage 4-44),then

adjustthe cable (seepage 4-45),
33. Installthe brakeboostervacuum hose (A) and the

evaporativeemission(EVAP)canisterhose (B).
2 9 . I n s t a l l t h eh a r n e s sc l a m p s( B ) .
3 4 . I n s t a l l t h ef u e l l i n e ( s e ep a g e1 1 - 1 5 0 ) .
(cont'd)
5-13
EngineAssembly
EngineInstallation{cont'dl \"
Installthe selectcable (A) and shift cable(B) using 37. Installthe batterycables(A) on the under-hood
the plasticwashers(C),washers(D),and new cotter fuse/relaybox, then installthe harnessclamp (B).
p i n s( E ) .
6x1.0mm
9.8N.m(1.0kgf.m, 6x1.0mm
7.2tbl.ftl 12Nm{1.2kgt.m,
8.7rbf.ft)
"-.----->)
"------'6
I n s t a l l t h eg r o u n dc a b l e( C ) .
3 9 . I n s t a l l t h ei n t a k ea i r d u c t .
6x1.0mm
12Nm{1.2kgf.m,
I n s t a ltlh e c l u t c hs l a v ec y l i n d e r( A )a n d c l u t c hl i n e 8.7 tbf.ft) \-
bracketmounting bolt (B).
6x1.0mm
8 x '1.25mm 9.8 N.m
24 N.m (2.4kgl.m, {1.0kgf.m,
7.2 tbt.ft)
a
5-14
4 0 . I n s t a ltlh e a i r c l e a n e rh o u s i n q . 4 3 . I n s t a l l t h ei n t a k em a n i f o l dc o v e r .
6x1.0mm 6x1.0mm
12 N m (1.2kgf.m,8.7lbt.ft) 12Nm11.2kgf.m.
8.7 tbf.ft)
E Y
44. Installthe battery.Cleanthe batterypostsand

4 1 . I n s t a ltl h e a i r c l e a n e rh o u s i n gc o v e r( A )a n d c a b l et e r m i n a l sw i t h s a n d p a p e rt ,h e n a s s e m b l e
connectthe intakeair temperature(lAT)sensor them and apply greaseto preventcorrosion.
connector(B),
]tE Checkthat the transmissionshifts into gear
smoothly.
46. Inspectfor fuel leaks.Turn the ignition switch ON

(ll) {do not operatethe starter)so that the fuel pump
runs for about 2 secondsand pressurizesthe fuel
line. Repeatthis operationtwo or three times, then
checkfor fuel leakageat any point in the fuel line.
41. R e f i l l t h ee n g i n ew i t h e n g i n eo i l ( s e ep a g e8 - 5 ) .
n i t h f l u i d ( s e ep a g e1 3 - 3 ) .
48. R e f i l tl h e t r a n s m i s s i ow
4 9 . Refillthe radiatorwith enginecoolant,and bleed

air from the cooling system with the heatervalve
o p e n ( s e ep a g e1 0 - 6 ) .
5 0 . P e r f o r mt h e e n g i n ec o n t r o lm o d u l e( E C M )i d l el e a r n
4 2 . I n s t a l l t h eb r e a t h e hr o s e( C )a n d v a c u u mh o s e1 D ) . p r o c e d u r e( s e ep a g e1 1 - 1 3 9 ) .
5 1 . Inspectthe idle speed (seepage 11-138).
52. I n s p e ctth e i g n i t i o nt i m i n g ( s e ep a g e4 - 1 7 ) .
5 3 . C h e c kt h e w h e e la l i g n m e n {t s e ep a g e1 8 - 4 ) .
54. Enterthe anti-theftcode for the radio,then enter

the customer'sradio station presets.
55. Set the clock.
5-15
\
EngineMechanical
CylinderHead
SpecialTools 6-2
Comoonent LocationIndex 6-3
EngineCompression Inspection b-t'
VTECRocker Arm Test ........... ............ 6-7
VTCActuatorInspection .................... 6-8
ValveClearance Adjustment ............. 6-9
Crankshaft PulleyRemovaland Installation.............. 6-11
C a mC h a i nR e m o v a l . . . . . . . . . . . . . . . . . . .6. -. 1
. .2. . . .
C a mC h a i nI n s t a l l a t i o n . . . . . . . . . . . . . . . .6. .-.1. .5. .
Auto-Tensioner Removal/1nsta11ation ......................... 6-19
ChainCaseOil SealInstallation ........6-21
CyfinderHeadCoverRemoval .......... 6-22
CylinderHeadRemoval ..................... 6-23
WC Actuator.ExhaustCamshaftSorocket
R e paf c e m e n t .........6-24
Cylinder Head Inspection for Warpage...................... 6-25
Rocker Arm AssemblyRemoval................................. 6-26
Rocker ArmsandShafts
Disassembly/Reassembly .............. 6-27
Rocker ArmsandShaftsInspection............................ 6-28
Camshaft Inspection .......................... 6-29
Valves,Springs,andValveSealsRemoval................ 6-31
ValveInsoection...................... ........... 6-32
ValveStem-to-Guide Clearance Insoection............... 6-32
ValveGuideReolacement ................. 6-33
ValveSeatReconditioning ................ 6-35
Valves,Springs, andValveSealsInstallation............ 6-37
Rocker Arm AssemblvInstallation .... 6-38
C v l i n d eHr e a dI n s t a l l a t i o.n. . . . . . . . . . . . . . . . . . . . . . . . . . . .6. -. 3
. .9. . . . . . . . . .
CylinderHeadCoverInstallation ......6-41

CylinderHead
SpecialTools a
Ref. No. Tool Number Description Oty
O OTAAJ.PNAA'IOO Air Pressure Regulator 1
.D OTHAH-PJ7O1OB V a l v eG u i d eR e a m e r5, . 5m m 1
o ozoa
I oz..rae-oot Socket,19 mm 1
@ 07JAB-0010204 H o l d e rH a n d l e 1
o 07NAB-0010404 HolderAttachment,50 mm 1
G) 07VAE-001010A Valve Spring CompressorAttachment 1
OTZAJ.PNAAlOO VTECAir Adapter 2
E] OTZAJ-PNAA2OO VTECAlr Stopper 1
Air Joint Adapter 1
O I 07ZAJ-PNAA300
tro 07742-0010100 V a l v eGu i d eD r i v e r , 5 . 5m m
I
@ 07746-001o4oo Attachment,52 x 55 mm
(D 07749-0010000 Driver
- -- -i
-- - l-:
'a- ti-- -
- 1jr-
r-
,.
',..)-)--'
@ o o
''
,- ,)
..'.,i2
a:-t'"
,.-/
Lq-,
r--\
.<:'':'v''
5'r'
o a l?
..#
..a:-"
/":
't'tY-,l
-- -'''
a,/'/'
@ OD @
6-2
ComponentLocationlndex
IGNITIONCOIL
COVER
CYLINDER HEAD
COVER
Removal, page6-22
page6-41
lnstallation,
CAM CHAIN
Bemoval,page6-'12
Installation,page6-15
frn CAM CHAINGUIDEB
CAM CHAINGUIDEA
"p
| ] t J,
VARIABLE VALVE
TIMINGCONTROL
twc) olL soLENotD
VALVE
CRANKSHAFT PULLEY
R e p l a c e m e npt a
, g e6 1 1
TENSIONER
ARM
AUTO.TENSIONER
page6-'lI
Replacement, O-RING
(cont'd)
6-3
CylinderHead
ComponentLocationIndex(cont'd)
CAMSHAFT
HOLDER
Fg
Y f\
R fr CAMCHAIN
GUIDEB
LI T
F]
EEI /
CAMSHAFTPOSITION -"-oowetew
ICMP}SENSOR g-----
TOPDEADCENTER
(TDC)SENSOR
EXHAUSTCAMSHAFT
SPROCKET
Removal,page6 24
page6-25
Installation,
EXHAUSTCAMSHAFT
ROCKER ARM
ASSEMBLY
Overhaul,page6 27
Inspection,page 6-28
6-4
.\
SPRING
RETAINER
vALvE / .""or", uo.u, ,H v .-- spntruc
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>il( G\-r_
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aFl
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| | -/ TNTAKE
vALVE
EXHAUSTVALVE
T1 II ^-'-- 9E4L
--€.i
SEAL l l I I U- Replacement, Page6-31
l* I / uo.ur.r","o l l H e ,
H tl
Y
E-
I 1.-
U
_-/ |NTAKEVALVE
GUIDE
page6-33
Replacement,
,p
2bw
9)
\*""'RArNERcovER
wcsrRArNER
\
CYLINDER HEAD
Removal,page6'23
Inspection,page6-25
HEATSHIELD Installation,page6-39
EXHAUSTVALVE
Removal,page6-31
Installation,page6-37
INTAKEVALVE
Removal,page6 31
Installation,page6 37
CYLINDER
HEAD
GASKET
6-5
CylinderHead
EngineCompressionInspection \
1 . W a r m u p t h e e n g i n et o n o r m a lo p e r a t i n g 9 . Open the throttlefully, then crankthe enginewith

temperature(coolingfan comes on). the startermotor and measurethe compression.
2. Turn the ignition switch OFF. Compression Pressure

Above 930 kpa (9.5 kgf/cm', 135 psi)
3. Removethe intakemanifoldcover (seestep 1 on
page6-22). 1 0 .Measurethe compressionon the remaining
cylinders,
4, Disconnectall four injectorconnectors.
Maximum vadation
5. Startthe engine,and let it run until it stalls. Within 200 kPa (2.0 kgf/cm', 28 psi)
6 . R e m o v et h e i o u r i g n i t i o nc o i l s( s e ep a g e4 - 1 8 ) . 1 1 .lf the compressionis not within specifications,

checkthese items,then remeasurethe
7. Removethe four spark plugs. compressron.
8. Attachthe compressiongaugeto the spark plug . Damagedorworn valvesand seats

note. . Damagedcylinder head gasket
. Damagedor worn piston rings
. Damagedorworn piston and cylinderbore
\-
V,
6-6
WEC RockerArmsTest
Special Tools Required Repeatstep 3 on the remainingintakeprimary
. Air pressureregulator07AAJ-PNAA100 rockerarms with each piston at TDC.When all the
. VTECair adaoter07ZAJ-PNAA100 primary rockerarms passthe test, go to step 5.
. WEC air stoDoer07ZAJ-PNAA200
. Air joint adapter07ZAJ-PNAA300 Checkthat the air pressureon the shop air
compressorgauge indicatesover 400 kPa
1. Removethe cylinder headcover (seepage 6-22). (4 kgflcm',57 psi).
2. Set the No. 1 pistonat top dead center(TDC)(see 6 . Inspectthe valve clearance(seepage 6-9).
step 1 on page6-12).
7 . Removethe sealingbolt (A)from the relief hole,
3. Verify that the intakeprimary rockerarm (A) moves and installthe VTECair stopper(B).
independentlyof the intakesecondaryrockerarm
(B). D
OTAAJ.PNAAlOO OTZAJ-PNAA3OO
. lf the intakeprimary rockerarm does not move,

removethe primary and secondaryrockerarms
as an assemblyand checkthat the pistonsin the
secondaryand primary rockerarms move
smoothly.lf any rockerarm needs replacing,
replacethe primary and secondaryrockerarms
as an assemblv,and test.
. lfthe intakeprimary rockerarm moves freely,go
to step 4.
OTZAJ.PNAAlOO
Removethe No. 2 and No. 3 camshaftholder bolts,

and installthe VTECair adapters(C)finger-tight.
Connectthe air joint adapter(D),and air pressure

regulatorwith a 0-100psi gauge (E).
(cont'd)
6-7
CylinderHead
WEC RockerArms Test (cont'dl VTGActuator Inspection
'10. '11.
Loosenthe valve on the regulator,and apply the Removethe cylinder headcover (seepage 6-22lr.
specifiedair pressure.
2. Removethe auto-tensioner(seepage6-19).
Specified air pressure:
290 kPa 13.0kgt/cm', 42 psi) 3. Loosenthe rockerarm adjustingscrewslsee step 2
on page6-26).
NOTE:lf the synchronizingpiston does not move
after applyingair pressure;move the primary or 4. Removethe camshaftholder (seestep 3 on page 6-
secondaryrockerarm up and down manuallyby 26t.
rotatingthe crankshaftclockwise.
5. Removethe intakecamshaft.
1 1 . W i t h t h e s p e c i f i e da i r p r e s s u r ea p p l i e d m
, o v et h e
i n t a k ep r i m a r yr o c k e ra r m ( A ) f o r t h e N o , 1 c y l i n d e r . 6, Checkthat the variablevalve timing control (VTC)
The primary rockerarm and secondaryrockerarm actuatoris lockedby turning the VTCactuator
( B )s h o u l dm o v e t o g e t h e r . clockwiseand counterclockwise. lf the VTC actuator
is not locked,replacethe VTCactuator.
lf the intakesecondaryrockerarm does not move,
removethe primary and secondaryrockerarms as 7 . S e a lt h e a d v a n c eh o l e s( A ) a n dr e t a r dh o l e s( B )i n
an assembly,and checkthat the pistonsin the the No. 1 camshaftjournal with tape.
primary and secondaryrockerarms move
smoothly.lf any rockerarm needsreplacing,
replacethe primary and secondaryrockerarms as
an assembly,and test.
Puncha hole through the tape over one of the

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

22N m 12.2kgf.m, 16 lbf.ft).
1 4 . T i g h t e nt h e s e a l i n gb o l t t o 2 0 N . m ( 2 . 0k g f . m ,
14 tbf.ft).
t5. I n s t a l l t h ec y l i n d e rh e a dc o v e r( s e ep a g e6 - 4 1 ) .
6-8
ValveGlearanceAdiustment
9. Apply air to the advancehole to releasethe lock. NOTE:Adjust the valvesonly when the cylinder head
temperatureis lessthan 100'F (38'C).
1. Removethe cylinderhead cover (seepage6-22).
2. Set the No. 1 piston at top dead center(TDC).The

punch mark (A) on the variablevalve timing control
(VTC)actuatorand the punch mark (B)on the
exhaustcamshaftsprocketshould be at the top.
Align the TDC marks (C)on the VTC actuatorand
exhaustcamshaftsprocket.
1 0 .Checkthat the VTCactuatormoves smoothly.lf the

VTC actuatordoes not move smoothly, replacethe
VTC acluator.
{cont'd)
6-9
GylinderHead
ValveClearanceAdjustment (cont'd) \. I
feelergaugefor the
3. Selectthe correctthickness 5 . l f y o u f e e lt o o m u c h o r t o o l i t t l e d r a g ,l o o s e n t h e
valvesyou'regoingto check. locknut(A),and turn the adjustingscrew {B) until
the drag on the feelergauge is correct..
Intake: 0.21 0.25mm (0.008-0.010 in.)
Exhaust; 0.28 0.32mm (0.011 0.013in.)
Adiustingscrew locations:
EXHAUST
No. 1 N o .2 No.3 N o .4
Tightenthe locknut,and recheckthe clearance.

Repeatthe adjustmentif necessary
No. 1 No.4
7 . Rotatethe crankshaft180"clockwise(camshaft
p u l l e yt u r n s9 0 ' ) .
4. Insertthe feeler gauge {A) betweenthe adjusting
s c r e w( B )a n d t h e e n d o f t h e v a l v es t e m ,a n d s l i d ei t t.
backand forth; you should feel a slight amount of \-
d rag.
8. Checkand, if necessary,adjustthe valve clearance

o n N o .3 c y l i n d e r .
6-10
CrankshaftPulleyRemovaland
Installation
9. Rotatethe crankshaft180"clockwise(camshaft
pullevturns 90').
. Holder handle07JAB-001020A
. Holderattachment,50 mm 07NAB-001040A
. Socket,19 mm 07JAA-001020,4 or a commercially
a v a i l a b l e1 9 m m s o c k e t
Removal
1. Removefront tires/wheels.
2. Removethe splashshield (seestep 23 on page 5-5).
3 . H o l dt h e p u l l e yw i t h h o l d e rh a n d l e( A )a n d h o l d e r
attachment(B).
B
1 0 .Checkand, if necessary,adjustthe valve clearance 07NAB-001040A
on No.4 cylinder.
1 1 .Rotatethe crankshaft180"clockwise(camshaft
el / Srroo.oo,oroo
p u l l e yt u r n s9 0 " ) . (or
/ commercially
f available)
Removethe bolt with a 19 mm socket(C)and

breakerbar.
1 2 .Checkand, if necessary,adjustthe valve clearance

o n N o .2 c y l i n d e r .
Installthe cylinder headcover (seepage 6-41).
(cont'd)
6-11
CylinderHead
CrankshaftPulleyRemovaland CamChainRemoval a
Installation(cont'dl
NOTE:Keepthe cam chain away from magneticfields.
Installation 1. Turn the crankshaftpulley so ils top dead center

( T D C )m a r k( A )l i n e su p w i t h t h e p o i n r e r( B ) .
1. Cleanthe crankshaftpulley (A),crankshaft(B),bolt
(C).and washer (D).Lubricateas shown below.
. .: Clean
O; Lubricate
ll
ll
t[] rL
-'....-----=a
(-, ,
5U-1J
It
t -
2 . Removethe front tires/wheels.
I n s t a l l t h ec r a n k s h a fpt u l l e y ,a n d h o l dt h e p u l l e y 3 . R e m o v et h e s p l a s hs h i e l d .
with holder handle(A) and holder attachment{B).
- , , - - . = . - - - - - _ _ - - _
B
07NAB-0010iroA
\
A
07JAB-001020A
4. Removethe drive belt (seepage 4-26).
Tightenthe bolt to 245 N.m (25.0kgf.m, 181 tbf.ft) 5. Removethe cylinder headcover (see page6-22).
with a torque wrench and 19 mm socket(C).Do not
use an impactwrench. 6 . R e m o v et h e c r a n k s h a fpt u l l e y( s e ep a g e6 - 1 1 ) .
I n s t a ltl h e s p l a s hs h i e l d( s e es t e p2 0 o n p a g e5 - 1 2 ) .
5 . Install front tires/wheels.
\-
6-12
7. Disconnectthecrankshaftposition(CKP)sensor 1 1 . R e m o v et h e s i d ee n g i n em o u n tb r a c k e t .
connector{A) and variablevalvetiming control
{VTC)oil control solenoidvalve connector(B).
1 2 . R e m o v et h e c h a i nc a s e .
Removethe VTC oil control solenoidvalve (see

s t e p1 o n p a g e1 1 - 1 2 7 ) .
9 . Supportthe enginewith a iack and wood block

u n d e rt h e o i l p a n .
1 0 .Removethe ground cable (A).and removethe

upper bracket(B).
(cont'd)
6-13
CylinderHead
CamChainRemoval(cont'd) \ (
Looselyinstallthe crankshaftpulley. 16. Removethe auto-tensioner.
1 4 . Turn the crankshaftcounterclockwiseto compress

the auto-lensioner,
1 7 . R e m o v et h e c a m c h a i ng u i d eB .
gffi
llll
t5. Align the holes on the lock (A) and the auto-
t e n s i o n e (r B ) ,t h e n i n s e na 1 . 5m m ( 0 . 0 6i n . )
diameterpin (C)into the holes.Turn the crankshaft
clockwiseto securethe Din.
U U a
\-
6 -14
CamChainInstallation
1 8 . R e m o v et h e c a m c h a i ng u i d eA ( A )a n d t e n s i o n e r NOTE:Keepthe cam chain away from magneticfields.
a r m( B ) .
1. Set the crankshaftto top dead center(TDC).Align
t./6. | \
,o the TDC mark {A) on the crankshaftsprocketwith
t h e p o i n t e r( B )o n t h e c y l i n d e rb l o c k .
{n$1J;
g"'-
1 9 . R e m o v et h e c a m c h a i n . Setthe camshaftsto TDC.The punch mark (A) on

the variablevalve timing control {VTC)actuatorand
t h e p u n c hm a r k( B )o n t h e e x h a u s ct a m s h a f t
t sprocketshould be at the top. Align the TDC marks

(C)on the VTC actuatorand exhaustcamshaft
sprocKet.
(cont'd)
6-15
GylinderHead
CamChainInstallation(cont'dl \ {
3. Installthecamchainon the crankshaft

sprocket 5 . I n s t a l l t h ec a m c h a i ng u i d eA ( A )a n d t e n s i o n ear r m
with thecoloredpiece(A)alignedwiththe punch (B).
mark(B)on the crankshaft
sprocket.
6x1.0mm
1 2N . m
{1,2kgf.m,
8.7 tbf.ftt
'6I
8 x 1 . 2 5m m
22 N.m
Installthecam chain on the VTCactuatorand 12.2kgt.m,
exhaustcamshaftsprocketwith the punch marks 16tbf.ft)
(A) alignedwith the two colored pieces(B).
6. Installthe auto-tensi
B
6x1,0mm
12Nm
(1.2kgt.m,8.7 lbf ti)
a
6-16
7 , I n s t a ltlh e c a m c h a i ng u i d eB . 1 0 .Removeold liquid gasketfrom the chain case
mating surfaces,bolts,and bolt holes.
8 x 1.25mm
H4
\ilt
22 N.m
(2.2kgf.m,16lbt.ft) 1 1 .Cleanand dry the chain case mating surfaces.
Apply liquid gasket.P/N 08718-0009,

cylinder block mating surfaceofthe chain caseand
evenlyto the
H g
q
t o t h e i n n e rt h r e a d so f t h e h o l e s .
8. Removethe Dinfrom the auto-tensioner,
Apply liquid gasket

alongthe brokenline.
Apply liquid gasketto the cylinder blockupper

surfacecontactareas(A) on the chaincase.
1 4 . Apply liquid gasket,PiN 08718-0009, evenlyto the

oil pan mating surfaceof the chain caseand to the
innerthreadsof the holes.
NOTE:Do not installthe parts it 5 minutesor more

9 . Checkthe chain caseoil sealfor damage.lf the oil have elapsedsinceapplying liquid gasket.lnstead,
seal is damaged,replacethe chain case oil seal reapplyliquid gasketafter removing old residue.
( s e ep a g e6 - 2 1 ) .
Apply liquid gasket

(cont'd)
6-17
GylinderHead
CamChainInstallation(cont'd) t {
'15.
Installthe new O-ring(A) on the chain case.Set the 1 6 . l n s t a l l t h es i d ee n g i n em o u n t . b r a c k e t .
edge of the chain case (B)to the edge of the oil pan
( C ) ,t h e n i n s t a ltl h e c h a i nc a s eo n t h e c v l i n d e rb l o c k
(D).
NOTE:When installingthe chain case,do not slide

the bottom surfaceon the oil pan mounting surface.
rbf.ft)
',.9
17. Installthe upper bracket(A),then tightenthe bolv

nuts in the numberedseouenceshown.
6 x 1 . 0m m 1 2 x 1 . 2m
5m
12 N.m 54 N.m
{1.2kgl m, 8.7 lbf ft} (5.5 kgt m, 40 lbf.ft)
a
6x1.0mm
1 2N . m 6x1.0mm
(1.2kgt.m.8.7lbf.ft) 12Nm I
(1.2kgf.m,8.7lbf.ft) \
1 8 . I n s t a ltl h e g r o u n dc a b l e( B ) .
\-
6-18
Auto-TensionerRemovaU
lnstallation
1 9 . lnstallthe variablevalve timing control (VTC)oil
c o n t r o ls o l e n o i dv a l v e( s e es t e p 1 o n p a g e1 1 ' 1 2 7 ) .
Removal:
20. Connectthe crankshaftposition(CKP)sensor
connector{A) and VTC oil control solenoidvalve 1 . R e m o v et h e c h a i nc a s ec o v e r .
connector(B).
Turn the crankshaftcounterclockwiseto compress

21. Installthe crankshaftpulley (seepage 6-12). the auto-tensroner.
2 2 . I n s t a l l t h ec y l i n d e rh e a dc o v e r( s e ep a g e6 - 4 1 ) .
2 3 . I n s t a l l t h ed r i v eb e l t .
2 4 . I n s t a l l t h es p l a s hs h i e l d .
€D@
{cont'd)
6-19
GylinderHead
Auto-TensionerRemoval/lnstallation(cont'dl \
3. Align the holes on the lock (A) and the auto- Installation:
t e n s i o n e (r B ) ,t h e n i n s e r ta 1 . 5m m ( 0 . 0 6i n . )
diameterpin (C)into the holes.Turn the crankshaft 1. Installthe auto-tensioner.
clockwiseto securethe oin.
6x1.0mm
4. Removethe auto-tensioner. 12 N.m {1.2kgt.m,8.7 lbt.tt)
Remove the pin from the auto-tensioner.
\ a
\-
6-20
ChainCaseOil SealInstallation
Removeold liquid gasketfrom the chain casecover SpecialToolsRequired
mating surfaces,bolts,and bolt holes. . Driver07749-0010000
. Attachment,52 x 55 mm 07746-0010400
4 . Cleanand dry the chain casecover mating surfaces.
1 . U s et h e s p e c i atl o o l st o d r i v ea n e w o l l s e a l
Apply liquid gasket,P/N 08718-0009, evenlyto the squarelyinto the chain caseto the specified
chain case mating surfaceof the chain casecover i n s t a l l e dh e i g h t .
and to the innerthreadsof the holes.
NOTE:Do not installthe parts if 5 minutesor more

have elapsedsinceapplyingliquid gasket.Instead,
reapplyliquid gasketafter removing old residue.
07749-0010000
Apply liquid gasket

a l o n gt h e b r o k e nl i n e . 2. Measurethe distancebetweenthe chain case
s u r f a c e( A )a n d o i l s e a l1 B ) .
6 . I n s t a l l t h ec h a i nc a s ec o v e r .
Oil Seal InstalledHeight:
3 3 . 0 - 3 3 . 7m m ( 1 . 3 0 -1 . 3 3i n . )
6x1.0mm
1 2N . m
{1.2kgt.m,
8.7 tbf.ft)
33.0 33.7mm
{ 1 . 3 0 1 . 3 3i n . l
6-21
GylinderHead
CylinderHeadCoverRemoval \ (
1. Removethe intakemanifoldcover. 4, Removethe cylinder headcover
V:t :;t 1
|,'.i/
2. Removethe four ignition coils (seepage 4-'18).
3. Removethe dipstick(A) and breatherhose (B).
\-
6-22
GylinderHeadRemoval
NOTE: 8. Removethe enginewire harnessconnectorsand
. Usefendercoversto avoiddamagingpainted wire harnessclampsfrom the cylinder head.
surfaces.
To avoid damage,unplug the wiring connectors . Enginecoolanttemperature(ECT)sensor
carefullywhlle holdingthe connectorportion. conneclor
To avoid damagingthe cylinderhead,wait until the . Camshaftposition(Cl\4P)(top dead center(TDC))
enginecoolanttemperaturedrops below 100'F(38"C) sensor B connector
betore looseningthe cylinder head bolts. . Camshaftposilion (CMP)sensorA connector
Mark all wiring and hosesto avoid misconnection.
Also, be sure that they do not contactother wiring or 9. Removethe upper radiatorhose (A) and heater
hoses,or interferewith other parts. h o s e( B ) .
' 1 .Drainthe
enginecoolant(seepage 10-6).
2 . Removethe drive belt (seepage 4-26).
3 . Removethe intakemanifold {seepage 9-3).
Removethe air cleanerhousing(seestep 7 on page

5-2t.
5. Removethe water bypasshose (A).
'10.
Removethe harnessholder (A)from the bracket,
then removethe connectingpipe mounting boh {B)
and brakeboostervacuum line mounting bolts {C).
6 . Removethe exhaustmanifold (seepage9-7) .
7 . Removethe cam chain (seepage 6-12).
11. Removethe water bvpasshose (D).
(cont'd)
6-23
CylinderHead
CylinderHeadRemoval(cont'd) VTCActuator,ExhaustCamshaft \
SprocketReplacement
Removethe rockerarm assembly(seepage 6-26).
tJ. Removethe cylinderhead bolts.To prevent Removal:

warpage,unscrewthe bolts in sequence1/3turn at
a t i m e ; r e p e a t h e s e q u e n c eu n t i la l l b o l t sa r e 1 . R e m o v et h e c a m c h a i n( s e ep a g e6 - 1 2 ) .
loosened.
2. Hold the camshaftwith an open-endwrench,then
CYLINDERHEADBOLTSLOOSENINGSEQUENGE: loosenthe variablevalve timing control (VTC)
actuatormounting bolt and exhaustcamshaft
sprocketmounting bolt.
1 4 . R e m o v et h e c y l i n d e rh e a d .
I
\ (
Removethe VTC actuatorand exhaustcamshaft

sprocket.
I
6-24
CylinderHeadInspectionfor
Warpage
Installation:
1. Installthe VTC actuatorand exhaustcamshaft 1 , Removethe cylinder head{see page 6-23).
sprocket.
Inspectthe camshaft(seepage 6-29).
2. Apply engineoil to the th readsof the VTC actuator
mounting bolt and exhaustcamshaftmounting bolt, Checkthe cylinder headfor warpage.Measure
then installthem. along the edges,and three ways acrossthe center.
3. Hold the camshaftwith an open-endwrench,then . lf warpage is lessthan 0.05mm (0.002in.)

tighten the bolts. cylinder head resurfacingis not required.
. lf warpage is between0.05 mm (0.002in.) and
Specified torque: 0.2 mm (0.008in.),resurfacethe cylinder head.
VTC actuator mounting bolt: . Maximum resurfacelimit is 0.2 mm (0.008in,)
1 1 3N . m ( 1 1 . 5k g l . m , 8 3l b l . f t ) basedon a height of 104mm (4.09in.).
Exhaust camshaft sprocket mounting bolt:
72 N m (7.3 kgf.m, 53 lbf.ft) Cylinder Head Height;
Standard{New}: 103.95 104.05mm
{4.093 4.096in.}
4 . I n s t a ltl h e c a m c h a i n{ s e ep a g e6 - 1 5 ) .
6-25
CylinderHead
RockerArm AssemblyRemoval
'1. 4 . Removethe cam chain guide B, camshaftholders,
Removethe cam chain (seepage 6-12).
and camshafts.
2 . Loosenthe rockerarm adjustingscrews (A),
5 . Insertthe bolts (A) Into the rockershaft holder,then
A removethe rockerarm assembly(B).
3. Removethe camshaftholder bolts.To Drevent

damagingthe camshafts,unscrewthe bolts two
turns at a time, in a crisscrosspattern.
CAMSHAFTHOLDERBOLTS LOOSENING
SEOUENCE:
\- {
6-26
RockerArms and ShaftsDisassembly/Reassembly
NOTE:
ldentifypartsas they are removedto ensurereinstallationin original location.
Inspectthe rockershaftsand rockerarms (seepage 6-28).
The rockerarms must be installedin the same positionsif reused.
When removing or installingthe rockerarm assembly,do not removethe camshaftholder bolts.The bolts will keep
the holders,springsand rockerarms on the shaft.
Priorto reassembling,cleanall the parts in solvent,dry them, and apply lubricantto any contactpoints.
Bundlethe rockerarms with rubber bandsto keeDthem tooetheras a set.
EXHAUSTROCKER
SHAFT
EXHAUSTROCKER
ARM
rffin
,ffif-
wASHEB Yr rY Y V
\nl I ltnrllln
IJI_J;-L,JLI
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- l
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o
INTAKE ROCKER
ARM ASSEMBLY
INTAKEROCKERSHAFT
6-27
CylinderHead
RockerArms and ShaftsInspection \
1 . Removethe rockerarm assembly(seepage 6-26). 4. Measurethe insidediameterofthe rockerarm, and

checkit for an out-of-roundcondition.
2 . Measurethe diameterof the shaft at the first rocker
location. Rocker Arm-to-Shaflt Clearance:
Standard lNew):
lntake: 0.025 0.052 mm
(0.0010 0.0020in.)
Exhaust: 0.018 0.056mm
(0.0007 0.0022in.)
Service Limit: 0.08 mm (0.003in.)
3. Zero the gauge (A)to the shaft diameter.
5. Repeatfor all rockerarms and both shafts.lfthe

\. (
clearanceis over the Ilmit. replacethe rockershaft
and all overtolerancerockerarms. lf any VTEC
rockerarm needs replacement,replacethe rocker
arms (primaryand secondary)as a set.
6. Inspectthe rockerarm pistons{A}.Pusheach

p i s t o nm a n u a l l y .
lf it does not move smoothly,replacethe rocker
arm set.
NOTE:Apply oil to the pistonswhen reassembling.
,,,@@
6-28
GamshaftInspection
NOTE:Do not rotatethe camshaftduring inspection. 3. Seatthe camshaftby pushing it away from the
camshafp t u l l e ye n d o f t h e c y l i n d e rh e a d .
1. Removethe rockerarm assembly(seepage 6-26).
and disassembleit (seepage6-27). 4. Zero the dial indicatoragainstthe end of the
camshaft,then push the camshaftbackand forth
2. Putthe rockershaft holders,camshaft,and and read the end play. lf the end play is beyondthe
camshaftholderson the cylinderhead,then tighten servicelimit, replacethe camshafthead and
the bolts to the specifiedtorque. recheck.lf it is still beyondthe servicelimit, replace
thecylinder.
Specified torque:
I mm bolis: CamshaftEnd Play:
22 N.m {2.2kgt m, 16lbf.ft} Standard{New}:0.05 0.20 mm
6 mm bolts: (0.002 0.008in.l
12 N.m {1.2kgf.m,8.7 tbf.ftl ServiceLimit: 0.4 mm (0.02in.)
6 mm bolts: @, €0, @
(cont'd)
6-29
CylinderHead
CamshaftInspection(cont'dl \ {
Unscrewthe camshaftholder boltstwo turns at a 10. Checkthe total runoutwith the camshaftsupported
time, in a crisscrosspattern.Then removethe on V-blocks,
camshaftholdersfrom the cylinder head.
. l f t h e t o t a l r u n o u to f t h e c a m s h a f its w i t h i nt h e
Lift the camshaftsout of the cylinder head,wipe servicelimit, replacethe cylinder head.
them clean.then inspectthe lift ramps.Replacethe . lf the total runout is beyondthe servicelimit,
camshaftif any lobes are pitted,scored,or replacethe camshaftand recheckthe camshaft-
excessivelyworn, to-holderoil clearance.lf the oil clearanceis still
beyondthe servicelimit, replacethe cylinder
1 . C l e a nt h e c a m s h a fjto u r n a ls u r f a c e si n t h e c y l i n d e r neao.
head,then set the camshaftsbackin place.Placea
plastigagestrip acrosseachjournal. Camshaft Total Runout:
Standard(New):0.03mm (0.001in.) max.
Installthe camshaftholders,then tighten the bolts ServiceLimit: 0.04mm {0.002in.)
to the specifiedtorque as shown in step 2.
9 . Removethe camshaftholders.Measurethe widest

portionof plastigageon eachjournal.
. lf the camshaft-to-holder clearanceis within

l i m i t s ,g o t o s t e p 11 .
. lf the camshaft-to-holder clearanceis beyondthe
servicelimit and the camshafthas been replaced,
replacethe cylinder head.
. lf the camshaft-to-holder clearanceis beyondthe
servicelimit and the camshafthas not been
replaced,go to step 10. \, I
Camshaft-to-Holder Oil Clearance:
Standard (New): 1 1 . M e a s u r ec a m l o b eh e i g h t .
No. 1 Journal: 0.030 0.069mm
{0.001 0.003in-) Cam Lobe HeiohtStandard(New
No.2,3,4,5 Journals: 0.060*0.099mm INTAKE EXHAUST
{0.002 0.004in.) PRI 3 3 . 9 2 5m m 34.092mm
ServiceLimit: 0 . 1 5m m { 0 . 0 0i6n . ) (1.3356 in.) \1.3422in.l
SEC 2 9 . 6 3m8m
( 1 . 1 6 6i n8 . )
P R IP
: rimary SEC:Secondary
C/C:CamChain
\-
6-30
Valves,Springs,and ValveSealsRemoval
Special Tools Bequired 4 . I n s t a l l t h ev a l v eg u i d es e a lr e m o v e r .
Valvespring compressorattachment07VAE-001010A
ldentifythe valvesand valve springsas they are

removedso that each item can be reinstalledin its
original position.
1. Removethe cylinder head (seepage 6-23).
2. Using an appropriate-sized socket(A) and plastic

mallet {B),lightly tap the valve retainerto loosen
the valve keepers.
5 . Removet h e v a l v es e a l .
Installthe spring compressor.Compressthe spring,

and removelhe valve keepers.
6-31
GylinderHead
ValveInspection ValveStem-to-GuideClearance \
Inspection
1 . R e m o v et h e v a l v e s( s e ep a g e6 - 3 1 ) ,
2 . Measurethe valve in these areas. 1 . Removethe valves (seepage6-3'1).
lntake Valve Dimensions S l i d et h e v a l v eo u t o f i t s g u i d ea b o u t1 0 m m . t h e n

A StandardlNewl: 34.85 35.15mm measurethe guide-to-stemclearancewith a dial
{ 1 . 3 7 2 1 . 3 8 4i n . l indicatorwhile rockingthe stem in the directionof
B Standard{Newl: 108.7- 109.5mm normal thrust (wobble method).
14.280-4.311in.) . l f t h e m e a s u r e m e net x c e e d s t h es e r v i c el i m i t ,
C StandardlNew): 5.475 5.485 mm recheckit using a new valve.
1 0 . 2 1 5 6 - 0 . 2 1 5i n9 . ) . lf the measurementis nowwithin the service
C ServiceLimit: 5.445mm {0.214in.l limit, reassembleusing a new valve.
. l f t h e m e a s u r e m e n t w i ta h n e w v a l v es t i l l
ExhaustValve Dimensions exceedsthe servicelimit, go to step 3.
A Standard(New):29.85-30.15 mm
( 1 . 1 7 5 -1 . 1 8 7i n . ) lntake Valve Stem-to-Guide Clearance:
B Standard(New):108.3 109.1mm StandardlNew): 0.06 0.11 mm
(4.264- 4.295 in.l {0.002 0.004in.}
C Standard(New):5.450 5.460mm ServiceLimil: 0.16mm {0.006in.)
(0.2146 0.2150in.)
C ServiceLimit: 5.42mm (0.213in.) Exhaust Valve Stem-to-Guide Clearance:
S t a n d a r dl N e w l : 0 . 1 1- 0 . 1 6 m m
10.004 0.006in.)
ServiceLimit: 0.22 mm 10.009in.)
.<
4,. (
3 . Subtractthe O.D.of the valve stem. measuredwith

a micrometer,from the LD. of the valve guide,
m e a s u r e dw i t h a n i n s i d em i c r o m e t eor r b a l lg a u g e .
Takethe measurementsin three placesalong the
v a l v es t e m a n dt h r e ep l a c e si n s i d et h e v a l v eg u i d e .
The differencebetweenthe largestguide
m e a s u r e m e nat n dt h e s m a l l e s st t e m m e a s u r e m e n t
should not exceedthe servicelimit
lntake Valve Stem-to-GuideClearance:

Standard(New):0.030 0.055mm
{0.0012 0.0022in.)
ServiceLimit; 0.08mm (0.003in.l
ExhaustValve Stem-to-GuideClearance:
Standard{Newl: 0.055 0.080mm
(0.0022-0.003rin.l
t- I
6-32
ValveGuideReplacement
SpecialToolsRequired Working from the camshaftside. usethe driver and
. Valveguidedriver,5.5mm 07742-0010100 an aarhammerto drive the guide about 2 mm (0.1
. Valveguidereamer,5.5mm 07HAH-PJ7o108 in.)towardsthe combustionchamber.This will
knockoff some of the carbon and make removal
1 . Inspectvalve stem-to-guideclearance(seepage 6- easier.Hold the air hammer directlyin line with the
32t. valve guide to preventdamagingthe driver.
As illustratedbelow, use a commerciallyavailable Turn lhe head over, and drive the guide out toward
air-impactvalve guide driver (A) modifiedto fit the the camshaftside of the head.
diameterof the valve guides.In most cases,the
same procedurecan be done usingthe specialtool
and a conventionalhammer.
-_|Jfillr-.-4fi'11., tT
-
10.8mm
{0.,|2in.)
3. Selectthe proper replacementguides,and chill

lhem in the freezersectionof a refriqeratorfor
about an hour.
4. Use a hot plate or oven to evenly heatthe cylinder

headto 300'F (150"C).Monitor the temperature
with a cookingthermometer.Do not getthe head
hotterthan 300'F (150"C);excessiveheat may
loosenthe valve seats.
7 . lf a valve guide won't move, drill it out with a I mm

( 5 / 1 6i n c h )b i t .t h e nt r y a g a i n .D r i l lg u i d e so n l y i n
extremecases;youcould damagethe cylinder
head if the guide breaks.
Removethe new guide(s)from the freezer,one at a

time, as vou needthem.
(cont'd)
6-33
CylinderHead
ValveGuideReplacement(cont'dl \
Apply a thin coat of clean engineoil to the outside 1 0 .Coat both reamerand valve guide with cutting oil.
of the new valve guide. Installthe guide from the
camshaftside of the head;usethe specialtool to 1 1 .Rotatethe reamerclockwisethe full length of the
drive the guide in to the specifiedinstalledheight v a l v eg u i d eb o r e .
( A )o { t h e g u i d e( B ) .l f y o u h a v ea l l 1 6 g u i d e s t od o ,
you may have to reheatthe head.
O7HAH.PJ7O1OB
Valve Guide Installed Height:
Intake: 15.2 16.2mm (0.598-0.638in.)
Exhaust: 15.5 16.5mm (0.610-0.650in.) ' - \
Continueto rotatethe reamerclockwisewhile

removing it from the bore.
Thoroughlywash the guide in detergentand water

to remove any cutting residue.
s i t h a v a l v e( s e ep a g e6 3 2 ) .
1 4 . C h e c kt h e c l e a r a n c ew
Verifythat a valve slidesin the intakeand exhaust
valve guideswithout exening pressure.
6-34
ValveSeat Reconditioning
1. Inspectvalve stem-to-guideclearance(seepage 6- 5. Make one more very light passwith the 45" cutter
32).lf the valve guidesare worn, replacethem (see to removeany possibleburrs causedby the other
page6-33)beforecuttingthe valve seats. cutters.
2 . R e n e wt h e v a l v es e a t si n t h e c y l i n d e rh e a du s i n ga Valve Seat Width:

valve seat cutter. Standard(New): 1.25 1.55mm {0.049 0.061in.)
6. After resurfacingthe seat,inspectfor even valve

s e a t i n gA: p p l y P r u s s i a nB l u ec o m p o u n d( A )t o t h e
v a l v ef a c e .I n s e r t h e v a l v ei n i t s o r i g i n a l o c a t i o ni n
the head,then lift it and snap it closedagainstthe
seat severaltrmes.
3 , C a r e f u l l yc u t a 4 5 ' s e a t ,r e m o v i n go n l y e n o u g h
materialto ensurea smooth and concentricseat.
4 . Bevelthe upper and lower edgesat the angles

shown in the illustration.
Checkthe width of the seat and adjustaccordingly.
INTAKE:35" 1 . The actualvalve seatingsurface(B),as shown by

EXHAUST:30'
the blue compound,should be centeredon the seat.
- 45'
, { 67.5' . lf it is too high (closerto the valve stem),you
must make a secondcut with the 67.5' cutterto
move it down, then one more cut with the 45"
cutterto restoreseatwidth.
. lf it is too low (closeto the valve edge),you must
make a secondcut with the 35'cutter (intake
sidel or the 30" cutter (exhaustside)to move it up,
then make one more cut with the 45" cutterto
restoreseatwidth.
N O T ET
: h e f i n a lc u t s h o u l da l w a y sb e m a d ew i t h
the 45'cutter.
(cont'd)
6-35
CylinderHead
ValveSeat Reconditioning(cont'dl \ (
8 . Insen the intakeand exhaustvalves in the head,

and measurevalve stem installedheight (A).
Intake Valve Stem Installed Height:

Standard{New):40.8 41.0mm
( 1 . 6 0 6 1 . 6 1 4i n . )
Exhaust Valve Stem Installed Height:

Standard(New):54.6-54.8 mm
|'2.150-2.157 in.l
L lf valve stem installedheight is over the standard, \-

replacethe valve and recheck.lf it is still over the
standard,replacethe cylinder head;the valve seat
in the head is too deeD.
\-
6-36
Valves,Springs,and Valve SealsInstallation
Special Tools Required l n s t a l l t h ev a l v es p r i n g .P l a c et h e e n d o f t h e v a l v e
Valve spring compressorattachment07VAE-00101
0A spring with closelywound coils toward the cylinder
ne a o .
1. Coatthe valve stemswith engine oil. lnstallthe
valves in the valve guides. 6 . Installthe valve retainer.
2. Checkthat the valves move up and down smoothly. 7 . Installthevalve spring compressor,Compressthe
spring, and installthe valve keepers.Removethe
Installthespring seatson the cylinder head. valve spring compressor.
Installthe new valve seals(A) usingthe valve guide

s e a li n s t a l l e(rB ) .
NOTE:The exhaustvalve seal (C)has a blackspring

(D),and the intakevalve seal (E)has a white spring
(F).They are not interchangeable.
Lightlytap the end of each valve stem two or three

times with a plasticmallet (A)to ensureproper
seatingof the valve and valve keepers.Tap the
valve stem only along its axis so you do not bend
the stem.
6-37
CylinderHead
RockerArm AssemblyInstallation \
:,ean and dry the No. 5 rockershaft holder mating 5 . Removethe bolts from the rockershaft holder.
surfaces.
6 . M a k es u r et h e D U n c hm a r k so n t h e v a r i a b l ev a l v e
eeassemblethe rockerarm assembly(seepage 6- timing control (VTC)actuatorand exhaustcamshaft
2 1t . sprocketare facing up. then set the camshafts(A) in
the holder.
Apply liquid gasket,P/N 08718-0009,evenlyto the
:ylinder head mating surfaceofthe No. 5 rocker
shaft holder.
\OTE: Do not lnstallthe partsif 5 minutesor more

fl
c
r a v e e l a p s e ds i n c ea p p l y i n gl i q u i dg a s k e tI.n s t e a d , I
'eapply liquid gasketafter removingold residue.
Apply liquid gasket

7 . Set the camshaftholders(B) and cam chain guide B

\- a
Insertthe bolts (A) into the rockershaft holder,then ( C )i n p l a c e .
installthe rockerarm assembly(B)on the cylinder
head. Tightenthe bolts to the specifiedtorque.
Specified torque:
8 mm bolts: 22 N.m (2.2 kgf.m, 16 lbl.ft)
6 mm bolts: 12 N.m {1.2kgf.m,8.7 lbf.fil
6 mm bolts: @),@.@
lnstallthe cam chain (seepage 6-15).and adjustthe

valve clearance(seepage 6-9). l- {
6-38
CylinderHeadInstallation
Installthe cylinder head in the reverseorder of 5. Measurethe diameterof each cylinder head bolt at
removat: ooint A and DointB.
1. Cleanthe cylinderhead and blocksurface. a 50mm (2.0in.l

f.f )>-
A '15mm {'1.8in.)
2. Installthe new cylinder headgasket(A) anddowel " < > .
pins (B)on the cylinderblock.Always use a new
cylinder headgasket.
l f e i t h e rd i a m e t e ri s l e s st h a n 1 0 . 6m m { 0 . 4 2i n . ) ,
replacethe cvlinder head bolt.
Set the crankshaftto top dead center{TDC).Align

the TDC mark (A) on the crankshaftsprocketwith
the pointer(B)on the cylinderblock.
4. Installthe cylinderhead on the block.
( c o n td )
6-39
CylinderHead
CylinderHeadlnstallation(cont'd) \ {
7 . Apply engine oil to the bolt threadsand under the 10. Installthe rockerarm assembly{seepage6-38).
b o l t h e a d so f a l l t h e c y l i n d e rh e a db o l t s .
1 ' .t Installthe water bypasshose (A).
8 . Tightenthe cylinder head bolts in sequenceto 39
N.m {4.0 kgf.m,29 lbf.ft).Use a beam-typetorque
---l.-.
wrench.When using a 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 first step.
B
6 x1.0mm
'r2N.m
c (1.2kgl.m,8.7lbf.ftl
6 x l . 0 m m
'12N,m(1.2kgt.m,8.7
lbf.ft)
9 . After torquing,tighten all cylinderhead bolts in two 1 2 .Tightenthe connectingpipe mounting bolt (B)and
steps(90" per step).lf you are using a new cylinder brakeboostervacuum line mounting bolts (C),then
head bolt,tighten the bolt an extra 90.. i n s t a l l t h eh a r n e s sh o l d e r( D )o n t h e b r a c k e t .
't3. Installthe
upper radiatorhose {A) and heaterhose
(B).
FIRSTSTEP
SECOND
STEP
6-40
GylinderHeadCoverlnstallation
1 4 . I n s t a l l t h ew a t e rb v p a s sh o s e . 1. Thoroughlycleanthe headcover gasketand the
groove.
2. Installthe head cover gasket(A) in the groove of

t h e c y l i n d e rh e a dc o v e r( B ) .
1 5 . I n s t a l l t h ea i r c l e a n e rh o u s i n g( s e es t e p3 7 o n p a g e
5-15).
1 6 . I n s t a l l t h ei n t a k em a n i f o l d( s e ep a g e9 - 5 ) .
1 7 . I n s t a l l t h ee x h a u s tm a n i f o l d( s e ep a g e9 - 7 ) . Checkthat the mating surfacesare clean and dry.
'18. Apply liquid gasket.P/N 08718-0009,

on the chain
I n s t a l l t h ec a m c h a i n ( s e ep a g e6 - 1 5 ) .
caseand the No.5 rockershaft holder mating areas.
1 9 . A d j u s tt h e v a l v ec l e a r a n c e( s e e p a g e 6 - 9 ) .
2 0 . I n s t a l l t h ed r i v eb e l t( s e ep a g e4 - 2 6 ) . have elapsedsinceapplying liquid gasket.Instead,
21. Cleanthe batterypostsand cableterminalswith
, e n a s s e m b l et h e m a n d a p p l yg r e a s e
s a n d p a p e rt h
to preventcorrosion.
2 2 . A f t e ri n s t a l l a t i o nc ,h e c k t h a t a ltl u b e s ,h o s e s a n d
connectorsare installedcorrectly.
2 3 . I n s p e c t f o r f u elle a k sT. u r nt h e i g n i t i o ns w i t c hO N
{ll) {do not operatethe starter)so that the fuel pump
runs for about 2 secondsand pressurizesthe fuel
line. Repeatthls operationtwo or three times, then
c h e c kf o r f u e l l e a k a g ea t a n y p o i n ti n t h e f u e l l i n e .
24. Refillthe radiatorwith enginecoolant,and bleed

air from the cooling systemwith the heatervalve
open (seepage 10-6).
2 5 . I n s p e ctth e i d l es p e e d( s e ep a g e1 1 - ' 1 3 8 ) .
2 6 . I n s p e ctth e i g n i t i o nt i m i n g ( s e ep a g e4 - 1 7 ) .
(cont'd)
6-41
GylinderHead
CylinderHeadGoverInstallation(cont'd)
Set the spark plug seals(A) on the spark plug tubes. 7. Tightenthe bolts in two or three steps.In the final
O n c et h e c y l i n d e rh e a dc o v e r( B )i s o n t h e c y l i n d e r s t e p ,t i g h t e na l l b o l t s ,i n s e q u e n c et ,o 9 . 8 N . m ( 1 . 0
head,slide the cover slightly backand forth to seat kgf.m,7.2 lbf.ft).
the head cover gasket.
8 . I n s t a ltlh e d i p s t i c k( A )a n d b r e a t h e hr o s ei B ) .
Inspectthe cover washers(C).Replaceany washer

that is damagedor deteriorated. \
\l
6-42
9 . Installthe four ignition coils (seepage 4-'18).
1 0 . Checkthat all tubes, hoses,and connectorsare

installedcorrectly.
1 1 .lnstallthe intakemanifoldcover.
6 x 1 , 0m m
'12N.m{1.2kgf m.
8.7tbf.ftl
12. After assemblv,wait at least30 minutesbefore

f i l l i n gt h e e n g i n ew i t h o i l .
6-43
EngineMechanical
EngineBlock
S o e c i aTl o o l s . . . . . . . . . .7.-.2.
C o m o o n e nLto c a t i oInn d e x . . . . . . . . . . . . . . . . . . . . . . . . . . .7. .-.3. . . . . . . . . . .
Connecting RodandCrankshaft EndPlay
InsDection .............. 7-5
Crankshaft Main Bearing Replacement ...................... 7-6
Connecting RodBearingReplacement...................... 7-8
O i lP a nR e m o v a .l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7. .- 1 1
Crankshaft and Piston Removal ........7-12
Crankshaft Inspection ........................ 7-14
B l o c ka n dP i s t o nI n s o e c t i o n . . . . . . . . . . . . . . . . . . . . . . . . . . .7.-. 1. .5. . . . . . . . .
C y f i n d eHr o n i n g. . . . . . . . . . . . . " . . . . . . . . . . . . .7. -. .' 1. .7. .
Piston,PinandConnecting RodReplacement .......... 7-18
PistonRingReplacement ................... 7 -21
Pistonlnstallation.................... ........... 7-23
Connecting Rod Bolt Inspection .......' 7 -24
Crankshaft lnstallation .....................'. 7-24
O i lP a nl n s t a l l a t i o .n. . . . . . . . . . . . . . . . . . . . . . . . . .7.-.2 7
Transmission EndCrankshaft Seal
lnstallation-ln Car ................... ........'7-28

EngineBlock
SpecialTools \ {
Ref.No. Tool Number Description Oty

OTZAD-PNAAlOO Oil Seal DriverAttachment96 1
6 07746-0010700 Attachment,24 x 26 mm 1
@ 07749,0010000 Driver 1
I o
\ {
7-2
BAFFLEPLATE
LOWERBLOCK
fi E
fr
" 8
I
-4
FLYWHEEL
MAINBEARINGS
O i l c l e a r a n cpea,g e7 - 6
Selection, page7-6
CRANKSHAFT OILSEAL.
TRANSMISSION END
step21on page7-26
Installation,
THRUSTWASHERS
CRANKSHAFT
End play,page7-5
R u n o u t p, a g e7 - 1 4
Out-of-Round, page7-14
Removal,page7-12
lnstallation,page7-24
(cont'd)
7-3
EngineBlock
/^., \
D->< | nrrucs
_,-ersroru
Benlacement. 7-21Page
Y1 l-"t
rkrej, I
ffil
rG\ AalQ
[=l
ôJ
\ PISTONPIN
Removal,page7-18
f,
PISTON I n s p e c t i o np ,a g e7 - 1 9
Removal,page7-'12 Installation,page7,20
Measurement,page7-15
CONNECTINGROD
End play, page7-5
Small end measurement,page7-19
6
\ (
ENGINEBLOCK
Cylinderbore inspection,page7-'15
Warpageinspection,page7-15
C y l i n d e br o r eh o n i n g ,p a g e1 - 1 1
Ridgeremovai,step 13 on page7-13
CONNECTINGROD
CONNECTINGROD BOLT
page7 24
lnspectaon,
7-4
ConnectingRod and CrankshaftEnd PlayInspection
the oil pump(seepage8-9).
1 . Remove 5. lnstalla dial indicatoras shown. Pushthe
crankshaftfirmly away from the dial indicator,and
Removethe baffleplates(seestep6 on page1 -12). zerothe dial againstthe end of the crankshaft.Then
pull the crankshaftfirmly backtoward the indicator;
3. Measurethe connectingrod end play with a feeler the dial readingshould not exceedthe servicelimit.
gauge betweenthe connectingrod and crankshaft.
Crankshaft End Plav
ConnectingRod End Play StandardlNew): 0.10-0.35 mm
Standard{New):0.15 0.30mm { 0 . 0 0 4 - 0 . 0 1 4i n . l
(0.006-0.012in.l ServiceLimit: 0.45mm {0.018in.)
ServiceLimit 0.40mm (0.016in.l
lf the end play is out-of-tolerance,

replacethe thrust
4 . lf the connectingrod end play is out-of-tolerance, washersand recheck.lf it is still out-of-tolerance,
installa new connectingrod, and recheck.lf it is replacethe crankshaft.
replacethe crankshaft(see
still out-of-tolerance,
page 7 -12],.
7-5
EngineBlock
CrankshaftMain BearingReplacement
MainBearingClearance
Inspection 6. lf the plastigagemeasurestoo wide or too narrow,
removethe crankshaft.and removethe upper half
1. To checkmain bearing-to-journaI oil clearance. ofthe bearing.Installa new, completebearingwith
removethe lower block and bearinghalves(see the same color code{s),and recheckthe clearance.
page 1 -12).. Do not file, shim, or scrapethe bearingsor the caps
to adjustclearance.
2 , C l e a ne a c hm a i nj o u r n a la n d b e a r i n gh a l fw i t h a
cleanshop towel. 7. lf the plastigageshows the clearanceis still
incorrect,try the next largeror smaller bearing(the
3. Placeone strip of plastigageacrosseach main color listedabove or below that one),and check
l o ur n a l . again.lf the proper clearancecannot be obtained
b y u s i n gt h e a p p r o p r i a t e
l a r g e ro r s m a l l e rb e a r i n g s ,
4. Reinstallthe b e a r i n g sa n d l o w e rb l o c k t, h e nt o r q u e replacethe crankshaftand start over.
the bolts to 29 N.m {3.0kgf.m,22 lbf.ft) + 56'.
NOTE:Do not rotatethe crankshaftduring

Inspeclton.
5 . R e m o v et h e l o w e rb l o c ka n d b e a r i n g sa g a i n ,a n d
measurethe widest part of the plastigage.
Main Bearing-to-Journal Oil Clearance

N o . 1 , 2 ,4 , 5 J o u r n a l s :
10.0007 0.0016in.l
Service Limit: 0.050mm {0.0020in.)
No.3 Journal:
Standard{Newl:0.025- 0.049mm
(0.0010 0.0019in.)
ServiceLimit: 0.055mm (0.0022in.l
\.
7-6
Main BearingSelection Main Journal Code Location
Crankshaft Bore Code Location 2. The main journal codesa{e stampedon the
cran kshaft.
1. Numbersor lettersor bars have been stampedon
the end of the block as a code for the sizeof each of
the five main journal bores.Write down the crank
bore codes.lf you can't readthe codes becauseof
accumulateddirt and dust, do not scrub them with
a wire brush or scraper.Cleanthem only with
solventor detergent.
No. 5 JOURNAL No. 1 JOURNAL

{FLYWHEEL END) IPULLEYEND}
No. 1 JOURNAL No. 5 JOURNAL
(cont'd)
7-7
EngineBlock
CrankshaftMain Bearing ConnectingRodBearing \
Replacement(cont'd) Replacement
3. Usethe crank bore codes and crankjournal codes RodBearingClearance

lnspection
to selectthe appropriatereplacementbearings
from the following table. 1 . R e m o v et h e o i l p u m p ( s e ep a g e8 - 9 ) .
NOTE: 2. Bemovethe baffle plates(seestep 6 on page7-12).

. Color code is on the edge of the bearing.
. When using bearinghalvesof differentcolors.it 3. Removethe connectingrod cap and bearinghalf.
does not matterwhich color is used in the top or
bottom. 4 . C l e a nt h e c r a n k s h a frto d j o u r n a la n d b e a r i n g h a l f
with a clean shop towel.
Crank ---=-> Lalgercrankbore

5. Placeplastigageacrossthe rod journal.
bore | 1or 2ot 3or c oi__-l
Main code IAorl Borll C o r l l l D o r t t t It
iournsl -- --> Smaller bearing 6 . R e i n s t a l l t hb
e e a r i n gh a l fa n d c a p ,a n dt o r q u et h e
cooe {Thickerl b o l t st o 2 0 N . m ( 2 . 0k g f . m ,1 4 l b f . f t )- l 9 0 " .
1 Pink f!1f;* v"rro* c,""n NOTE:Do not rotatethe crankshaftduring

l l inspection.
2 v"no*c,""" $;;fl
f111f;,," 7 . R e m o v et h e r o d c a pa n d b e a r i n gh a l f ,a n d m e a s u r e
cr""n $ffi ero-n the widest part of the plastigage.
ConnectingRod Bearing-to-JournalOil
4 ffi#Tr,.*" i.,""*
Creen ; g=jiff;i Brown Black
'---l-'o"*, Clearance:
\-
5
;;lT]*Brown Black 6il; (0.0008--0.0020in.l
Brack !l;kr ar*
(Thicker)
7-8
8 . lf the plastigagemeasurestoo wide or too narrow, RodBearingSelection
removethe upper half of the bearing,installa new,
completebearingwith the same color code(s),and 1. Inspecteach connectingrod for cracksand heat
recheckthe clearance.Do not file. shim, or scrape damage.
the bearingsor the capsto adjustclearance.
Connecting Rod Big End Eore Code Locations
9 . lf the plastigageshows the clearanceis still
incorrect,try the next largeror smaller bearing(the 2 . E a c hr o d h a sa t o l e r a n c er a n g ef r o m 0 0 . 0 2 4m m
color listedabove or below that one),and check (0.0009in.),in 0.006mm (0.0002in.) increments,
clearanceagaln.lf the properclearancecannot be dependingon the sizeof its big end bore. lt's then
obtainedby usingthe appropriatelarger or smaller s t a m p e dw i t h a n u m b e ro r b a r ( 1 ,2 , 3 o r 4 / 1 l,l , l l l ,o l
bearing,replacethe crankshaftand stan over. t h e r a n g e .Y o u m a y f i n d a n y
l l l l )i n d i c a t i n g
c o m b i n a t i o no f n u m b e r sa n d b a r si n a n y e n g i n e .
( H a l ft h e n u m b e ro r b a r i s s t a m p e do n t h e b e a r i n g
cap,the other half on the rod.)
lf you can't readthe code becauseof an

accumulationof oil and varnish.do not scrub it
with a wire brush or scraper.Cleanit only with
solventor detergent.
Normal Bore Size: 48.0 mm 11.89in.l
(cont'd)
7-9
EngineBlock
ConnectingRod BearingReplacement(cont'dl \ {
Connecting Rod Journal Code Location 4. Use the big end bore codes and rod journalcodes
to selectappropriatereplacementbearingsfrom
3. The connectingrod journalcodesare stampedon the followingtable.
the crankshaft.
NOTE:
Connecting Rod Journal Code Location (Letters or . Color code is on the edge of the bearing.
Bars) . When using bearinghalvesof differentcolors,it
does not matter which color is used in the top or
bottom.
Big end ----------> Largerbig end bore

bore
codo
lorl 2oJll 3 ol lll 4 orllll
Rod
---------> Smallsrb.aring {Thickerl
Pink Pink/ Yollow/ Green

Yellow Grecn
B Yellow Yellow/ Green/ Brown

Green Brown
c Green Green/ Erown/ Black

Brown Black
D Brown Brown/ Black/ Blue

Black Blue
\ {
(Thicker)
No.l JOURNAL No.4 JOURNAL
7-10
OilPanRemoval
1 . Drainthe engineoil (seepage8-5). 5 . C u tt h eo i l p a n s e abl y s t r i k i n g t h e s i d e o f t h e c u t t e r
to slidethecutteralongthe oil pan.
lf the engine is still in the vehicle,removethe
subframe.
-1 Attachthe chain hoistto the engine (seestep

35 on page 5-6).
-2 Disconnectthesuspensionlower arm ball
joints (seestep 3 on page 18-19).
-3 Removethe rear mounl mounting bolts (see
step 39 on page 5-7).
-4 Removethe front mount mounting bolt (see
-5 Use a markerto make alignmentmarks on the
referencelinesthat align with the centersof
the rear subframemounting bolts.Removethe
front subframe(seestep 43 on page 5-8).
6 . R e m o v et h e o i l p a n .
Removethe bolts/nutssecuringthe oil pan.
Drivean oil pan seal cutter betweenthe oil pan and

cylinderblock.
7-11
EngineBlock
Crankshaftand PistonRemoval
1 . R e m o v et h e e n g i n ea s s e m b l y( s e ep a g e5 - 2 ) . 8. Removethe bearingcap bolts.To preventwarpage,
unscrewthe bolts in sequence1/3turn at a time:
2 . R e m o v et h e t r a n s m i s s i o (ns e ep a g e1 3 - 4 ) . repeatthe sequenceuntil all bolts are loosened.
3 . R e m o v et h e o i l p a n ( s e ep a g e7 - 11 ) .
4. Removethe oil pump {seepage8-9).
5. Removethe cylinderhead (seepage 6-23).
6. Removethe baffle plates.
L Removethe lower blockand bearings,Keepall \

7. Removethe 8 mm bolts. bearingsin order.
7-12
1 0 .Removethe rod caps/bearings.Keepall caps/ 14. Use the wooden handleof a hammer (A)to drive
b e a r i n g si n o r d e r . out the pistons(B).
1 1 .Liftthe crankshaftout ofthe engine,being careful

n o t t o d a m a g et h e j o u r n a l s .
1 5 . Reinstallthe lower block and bearingson the

engine in the proper order,
to. R e i n s t a l l t h ce o n n e c t i n gr o d b e a r i n g sa n d c a p s
after removingeach piston/connectingrod
assembly.
1 7 .To avoid mixup on reassembly.mark each piston/

connectingrod assemblywith its cylinder number.
Removethe upper bearinghalvesfrom the NOTE:The existingnumber on the connectingrod

connectingrods.and set them asidewith their does not indicateits positionin the engine,it
respectivecaps. indicatesthe rod bore size.
t.J. lf you can feel a ridge of metal or hard carbon

aroundthe top of eachcylinder,remove it with a
r i d g er e a m e r{ A ) .F o l l o w t h er e a m e rm a n u f a c t u r e r ' s
instructions.lf the ridge is not removed,it may
damagethe pistonsas they are pushedout.
7-13
EngineBlock
Crankshaftlnspection \
Out-ol-Round and Taper Straightness
1. Removethe crankshaftfrom the cylinder block(see 6. Placethe cylinder blockon the surfaceplate.
page7-121.
7 . C l e a na n d i n s t a l l t h eb e a r i g n so n t h e N o . 1a n d N o . 5
2. Cleanthe crankshaftoil passageswith pipe j o u r n a lo f t h e c y l i n d e rb l o c k .
c l e a n e r so r a s u i t a b l eb r u s h .
8. Lowerthe crankshaftinto the block.
3. Cleanthe keywayand threads.
9 . M e a s u r er u n o u to n a l l m a i nj o u r n a l sR
. o t a t et h e
4. Measureout-of round at the middle of each rod and crankshafttwo completerevolutlons.The
main journal in two places.The differencebetween differencebetweenmeasurementson eachjournal
measurementson each journal must not be more must not be more than the servicelimit.
than the serviceIimit.
Crankshaft Total Runout
Journal Out-ot-Round Standard(New):0.03mm 10.0012in.l max.
Standard(New):0.005mm (0.0002in.) max. ServiceLimit: 0.04mm (0.0016in.l
ServiceLimit; 0.010mm (0.0004in.)
(
L
I_JJ
fl
5. Measuretaper at the edgesof each rod and main
journal.The differencebetweenmeasurementson
eachjournal must not be more than the service
limit.
JournalTaper
StandardlNewl: 0.005mm (0.0002in.) max.
ServiceLimit: 0.010mm {0.0004in.)
7- 14
Blockand PistonInspection
1 . Removethe crankshaftand pistons(see pageT -121. 4. Measurewear and taper in directionX and Y at
t h r e el e v e l si n e a c hc y l i n d e ra s s h o w n .l f
Checkthe pistonfor distortionor cracks, measurementsin any cylinder are beyondthe
oversizebore servicelimit. replacethe block.lf the
M e a s u r et h e p i s t o nd i a m e t e ra t a p o i n t I 1 m m { 0 . 4 block is to be rebored,referto step 7 after reboring.
in.)from the bottom of the skirt.There are two
standard-size pistons(No Letteror A, and B).The CylinderBore Size
letteris stampedon the top of the piston.Letters Standard(New):
are also stampedon the blockas cylinder bore A or l: 86.010 86.020mm
stzes. 13.3862 3.3866in.)
B or ll: 86.000 86.010mm
Piston Diameter: (3.3858 3.3862in.)
Standard(Newl: Service Limit: 86.070 mm (3.3886in.)
No Letter {or A): 85.980 85.990 mm
(3.3850 3.3854in.) Oversize:
B: 85.970-85.980mm O.25t 96.250 86.260 mm (3.3957 3.3961 in.)
(3.3846-3.3850in.)
Reboringlimit: 0.25mm (0.01in.l max.
Service Limit:
No Lefter lor A): 85.930mm (3.3831in.) Bore Taper:
B: 85.920mm 13.3827in.) Limit: (Differencebetween first and third
measurement)0.05mm (0.002in.)
6 mm {0.2in.}
First
Measurement
Second
Measutement
Third
Measurement
6 mm {0.2in.}
Oversize Piston Diameter:

0.25: 86.230-85.240mm (3.3949-3.3953 in.l
(cont'd)
7-15
EngineBlock
Blockand PistonInspection(cont'd) \
Scoredor scratchedcylinderbores must be honed. 7. Calculatethe differencebetweenthe cylinder bore

diameterand the plstondiameter.lf the clearance
Checkthe top of the blockfor warpage.Measure is near or exceedsthe servicelimit, inspectthe
along the edgesand acrossthe centeras shown. pistonand cvlinder blockfor excessivewear.
Engine Block Warpage Piston-to-Cylinder Clearance

StandardlNew): 0.07mm (0.003in.) max. StandardlNew): 0.020 0.040mm
ServiceLimit: 0.10mm (0.004in.l {0.0008 0.0016in.)
++ PISTON-TO-CYLINDER
CLEARANCE
PRECISION
STRAIGHT
EDGE
\
7-16
CylinderHoning
Only a scoredor scratchedcylinderbore should be
noneo.
'L
M e a s u r et h e c y l i n d e rb o r e s{ s e ep a g e7 - 1 5 ) .
lf the block is to be reused,hone the cylindersand
remeasurethe bores.
H o n et h e c y l i n d e rb o r e sw i t h h o n i n go i l a n d a f i n e
(400grit) stone in a 60 degreecross-hatchpattern
(A).Use only a rigid hone with 400 grit or finer
stone such as Sunnen,Ammco, or equivalent.Do
not use stonesthat are worn or broken.
3 . W h e n h o n i n gi s c o m p l e t et,h o r o u g h l yc l e a nt h e
engine blockof all metal particles.Wash the
cylinder boreswith hot soapywater,then dry and
oil them immediatelyto preventrusting.Never use
solvent,it will only redistributethe grit on the
c y l i n d e rw a l l s .
lf scoringor scratchesare still presentin the

cylinderboresafter honing to the servicelimit,
reborethe cylinder block.Some light vertical
scoringand scratchingis acceptableif it is not deep
enoughto catchyour fingernailand does not run
the full length of the bore.
7-17
EngineBlock
Piston,Pin,and ConnectingRod Replacement
Disassembly 4 . Heatthe piston and connectingrod assemblyto
about 158'F(70"C),then removethe piston pin.
1. Removethe pistonfrom the cylinderblock (see
page7 -12).
2 . A p p l ye n g i n eo i l t o t h e p i s t o np i n s n a p r i n g s( A ) ,
and turn them in the ring grooves until the end
gaps are lined up with the cutoutsin the piston pin
b o r e s( B ) .
NOTE;Takecare not to damagethe ring grooves.
\ (
Removeboth snap rings (A).Start at the cutout in
t h e p i s t o np i n b o r e .R e m o v et h e s n a pr i n g s
carefullyso they do not go flying or get lost.Wear
eve protection.
\"
7-18
Inspection 3. Checkthe differencebetweenthe DistonDin
d i a m e t e ra n d p i s t o np i n h o l ed i a m e t e ri n t h e p i s t o n .
NOTE:Inspectthe piston,piston pin, and connecting
rod when they are at room temperature. Piston Pin-to-Piston Clearance
Standard(Newl: -0.005 to +0.002 mm
1. Measurethe diameterof the piston pin. (-0.00020 to +0.00008 in.)
Piston Pin Diameter
(0.8646-0.8648in.)
ServiceLimit: 21.953mm 10.8643 in.l
4 . Measurethe piston pin-to-connecting

rod clearance.
Piston Pin.to-Connecting Rod Clearance

2. Zerc the dial indicatorto the piston pin diameter. Standard(New):0.005 0.015mm
{0.0002 0.0006in.}
ServiceLimil: 0.02mm (0.0008in.l
v
(cont'd)
7-19
EngineBlock
(cont'd)
Piston,Pin,and ConnectingRodReplacement \
Reassembly 4. Installthe piston pin (A).Assemblethe piston (B)

and connectingrod (C)with the arrow (D)and the
1 . I n s t a l al p i s t o np i n s n a pr i n g ( A ) . e m b o s s e dm a r k ( E )o n t h e s a m es i d e . -
Coatthe piston pin bore in the piston,the bore in

the connectingrod, and the piston pin with engine
oil.
3 . Heatthe pistonto about 158"F(70'C).
5 . I n s t a ltlh e r e m a i n i n gs n a pr i n g ( F ) .
6 . T u r nt h e s n a pr i n g si n t h e r i n gg r o o v e su n t i l t h e
end gaps are positionedat the bottom of the piston.
7 -20
PistonRing Replacement
1. Removethe piston{rom the cylinder block(see 4. Using a piston,push a new ring (A) into the
page 7 -121. c y l i n d e rb o r e 1 5 - 2 0 m m { 0 . 6 - 0 . 8 i n . )f r o m t h e
bottom.
2. Using a ring expander(A),removethe old piston
r i n g s( B ) .
15 20 mm (0.6 0.8 in.)

I
Measurethe piston ring end-gap(B)with a feeler

3. Cleanall ring groovesthoroughlywith a squared- g au g e :
off brokenring or ring groovecleanerwith a blade
to fit the pislon grooves.The top and 2nd ring . l f t h e g a p i s t o o s m a l l ,c h e c k t os e ei f y o u h a v e
g r o o v e sa r e 1 . 2m m ( 0 . 0 5i n , ) w i d e T
. h eo i l r i n g t h e p r o p e rr i n g sf o r y o u r e n g i n e .
groove is 2.0 mm (0.08in.) wide. Filedown a blade . l f t h e g a p i s t o o l a r g e ,r e c h e c k t h e c y l i n d ebro r e
lf necessary.Do not use a wire brush to cleanthe diameteragainstthe wear limits (seeslep 4 on
ring grooves,or cut the ring groovesdeeperwith p a g e7 - 1 5 ) .
t h e c l e a n i n gt o o l s . . l f t h e b o r e i s o v e r t h es e r v i c el i m i t ,t h e c y l i n d e r
block must be rebored.
NOTE:lf the piston is to be separatedfrom the
connectingrod, do not installnew rings yet. PistonRing End-Gap
Top Fing
Standard(Newl: 0.20 0.35 mm
(0.008 0.014in.l
ServiceLimit: 0.60mm (0.024in..
SecondRing
Standard(New):0.40-0.55 mm
{0.016 0.022in.)
Oil Ring
REKENmanufacturedring
Standard(Newl: 0.25 0.65 mm
(0.010 0.026in.l
FEDERALMOGUL manufacturedrino
StandardlNew): 0.20 0.70mm
{0.008 0.028in.}
(cont'd)
7-21
EngineBlock
PistonRing Replacement(cont'd) \ {
6. Installthe top ring and secondring as shown.The 8. Positionthe ring end gaps as shown:
t o p r i n g ( A )h a sa 1 R m a r ko r n o m a r ka n dt h e
s e c o n dr i n g ( B )h a sa 2 R m a r ko r 2 N D m a r k .T h e
marks must be facing upward. About 90'
OIL RINGGAP SECONDRINGGAP
About 45"
TOP RINGGAP OIL RINGGAP

and SPACER
RINGGAP PISTONPIN
9. After installinga new set of rings,measurethe

o\,"16. ring-to-grooveclearances:
s \ =:-=2 Top RingClearance

\5 Standard {New}:
V" 0.035-0.060 mm {0.0014-0.0024
in.)
12-)
V SecondRing Clearance
P'ffi+a StandardlNew): {
\aq*-pogd REKENmanutactured ring
.ZR, 0.030-0.055 mm (0.0012-0.0022
in.)
V FEDERALMOGUL manulactured ring
PistonRingoimensions: 0.025-0.060mm (0.0010-0.0024in.)
t ToPRing{Standardl:
| | o
- A :3 . 1m m { 0 . 1 2in.l
| | J B : 1 . 2m m { 0 . 0 5
in.)
SocondRing{Standard):
- A : 3 . 4m m { 0 . 1 3
in.}
A- B:'1.2mm (0.05in.i
7, Rotatethe rings in their groovesto make sure they

do notbind.
7-22
PistonInstallation
lf the crankshaftis alreadyinstalled lf the crankshaftis not installed
1. Setthe crankshafttobottom dead center(BDC)for 1 . Removethe connectingrod caps.then installthe
e a c hc y l i n d e r . r i n g c o m p r e s s o ra, n d c h e c kt h a tt h e b e a r i n gi s
s e c u r e l yi n p l a c e .
2. Removethe connectingrod caps,then installthe
ring compressor,and checkthat the bearingis 2. P o s i t i o nt h e a r r o w( A ) f a c i n gt h e c a m c h a i ns i d eo f
securelyin place, Ineengrne.
3. Positionthe arrow {A) facingthe cam chain side of

r n ee n g t n e .
\--lno
\ ^ un\-.--l. t
Positionthe piston in the cylinder,and tap it in

Positionthe piston in the cylinder,and tap it in u s i n gt h e w o o d e nh a n d l eo f a h a m m e r( A ) ,
u s i n gt h e w o o d e nh a n d l eo f a h a m m e r( A ) . Maintaindownward force on the ring compressor
N4aintain downward force on the ring compressor (B)to preventthe rings from expandingbefore
(B)to preventthe rings from expandingbefore enteringthe cylinder bore.
enteringthe cylinder bore.
>-*/zi
wr
.,.'_\pf{
(( 'V,/:
Stop afterthe ring compressorpops free, and
checkthe connectingrod-to-crankjournal 4. Positionall pistonsattop dead center.
alignmentbeforepushingthe piston into place.
6 . Checkthe connectingrod bearingclearancewith

plastigage(seepage7-8).
7 . lnspectthe connectingrod bolts (seepage 7 241.
Apply engine oil to the bolt threads,then installthe

rod capswith bearings.Torquethe bolts to 20 N.m
{2.0kgf m, 14 lbf ft) + 90'.
7-23
EngineBlock
ConnectingRod Bolt Inspection CrankshaftInstallation (
1 . Measurethe diameterof each connectinqrod bolt Special Tools Bequired

at DointA and ooint B. . Driver07749-0010000
. Attachment,24 x 26 mm 07746-0010700
35 mm . Oil seal driver attachment96 o7ZAD-PNAAl00
1 . I n s t a ltl h e c r a n k s h a fet n d b u s h i n gw i t h t h e s p e c i a l
tools when replacingthe crankshaft.Drive in the
c r a n k s h a fet n d b u s h i n gu n t i lt h e s p e c i atl o o l s
bottom aqainstthe crankshaft.
mm
07749-0010000
07746-00'l
Calculatethe differencein diameterbetweenpoint
A a n d p o i n tB .
Point A-Point B = Difference in Diameter
Diflerence in Diameter: I (
\-
Specification:0 0.1 mm (0 0.004in.)
3 , lf the differencein diameteris out of tolerance,

replacethe connectingrod bolt.
C h e c kt h e c o n n e c t i n gr o d b e a r i n gc l e a r a n c w
e ith
plastigage{seepage7-8).
e ith plastigage
C h e c kt h e m a i n b e a r i n gc l e a r a n c w
( s e ep a g e7 - 6 ) .
4 . lnspecttheconnectingrod bolts (seepageT-241.
\- a
7-24
5 . I n s t a l l t h eb 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 12. Tightenthe connectingrod bolts to 20 N.m
conneclrngrods. (2.0kgf.m, 14 lbf.ft).
6 . A p p l ya c o a to f e n g i n eo i l t o t h e m a i n b e a r i n g sa n d 13. Tightenthe connectingrod bolts an additional90".

rod bearings.
14. Removeold liquid gasketfrom the lower block
7 . H o l dt h e c r a n k s h a fsto r o d j o u r n a lN o . 2 a n d r o d mating surfaces,bolts and bolt holes.
journal No. 3 are straightup, and lower the
crankshaftinto the block. 15. Cleanand dry the lower block mating surfaces.
8 . l n s t a l l t h et h r u s tw a s h e r s( A )i n t h e N o . 4 j o u r n a lo f 16. Apply liquid gasket,P/N 08718-0009, evenlyto the

the cylinder block. cylinderblock mating surfaceof the lower block
a n dt o t h e i n n e r t h r e a d o
s f t h e b o l th o l e s .

have elapsedsinceapplying liquid gasket.Instead,
.\
,i,
\-1
Apply liquid gasket

alongthe broken line.
9 . Apply engine oil to the threadsot the connecting

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

connectingrod No. 4. Line up the mark (B)on the
connectingrod and cap,then installthe caps and
bolts finger-tight.
'11. Rotate
the crankshaftclockwise,and seatthe
j o u r n a l si n t oc o n n e c t i n g
r o d N o . 2 a n dc o n n e c t i n g
rod No. 3. Line up the mark on the connectingrod
and cap, then installthe caps and bolts finger-tight.
(cont'd)
7-25
EngineBlock
CrankshaftInstallation(cont'd) {
'17
. Putthe lower blockon lhe cylinderblock. 2'1. Use the specialtoolsto drive a new oil seal
squarelyinto the blockto the specifiedinstalled
1 8 . Tightenthe bearingcap bolts in sequenceto height.
29 N.m (3.0kgf m, 22 lbf.ft).
07749-0010000
07zAo-PNAA100
Measurethe distancebetweenthe crankshaft(A)

a n d o i l s e a l( B ) .
Oil Seal InsialledHeight: 5.5 6.5 mm

|10.22 0.26 in.l
\ {
1 9 . Tightenthe bearingcap bolts an additional56". 5.5-6.5 mm
{0.22 0.26in.l
20. Tightenthe I mm bolts in sequenceto 22 N.m 12.2

kgf m, 16 lbf.ft).
7-26
OilPanlnstallation
23. Installthe baffle plates. 1 . Removeold liquid gasketfrom the oil pan mating
surfaces,bolts,and bolt holes.
6x1.0mm
1 2N . m
(1.2ksf m, 8.7lbf ft) 2 . Cleanand dry the oil pan mating surfaces.
3 . Apply liquid gasket,P/N 08718-0009, evenlyto the

cylinderblock mating surfaceof the oil pan and to
the innerthreadsof the bolt holes.

have elapsedsinceapplying liquid gasket.Instead,
2 4 . I n s t a l l t h eo i l p u m p ( s e ep a g e8 - 1 4 ) .
25. Installtheoil pan (seepage7-27).

Apply liquid gasket
26. Installthecylinderhead (seepage 6-39).
27. Installthetransmission(seepage 13-8). 4. I n s t a l l t h eo i l p a n .
28. Installtheengine assembly(seepage 5-9). 5. Tightenthe bolts in two or three steps.In the final
s t e p ,t i g h t e na l l b o l t s ,i n s e q u e n c et ,o 1 2 N . m ( 1 . 2
kgf m, 8.7 lbf.ft).
( } @
(cont'd)
7-27
EngineBlock
Oil PanInstallation(cont'dl TransmissionEndGrankshaftSeal
Installation- In Car
I
6 . l f t h e e n g i n ei s s t i l l i n t h e v e h i c l e i,n s t a l tl h e
subframe,
- 1 I n s t a l l t h es u b f r a m eA. l i g nt h e r e f e r e n c e
lines . Driver07749-0010000
on the subframewith the bolt head center,then . Oil seal driver attachment 96 07ZAD-PNAA100
tighten the bolts (seestep 5 on page 5-10).
-2 Tightenthe front mounting bolt (seestep 6 on '1.
D r y t h e c r a n k s h a fot i l s e a lh o u s i n g .
p a g e5 - 1 0 ) .
-3 Tightenthe rear mount mounting bolts (see 2. Use the specialtools to drive a new oil seal
s t e p7 o n p a g e5 - 1 1 ) . squarelyinto the blockto the specifiedinstalled
-4 Connectthe suspensionlower arm ball joints height.
(seestep 6 on page 18-19).
07749-0010000
7. After assembly,wait at least30 minutes before
/$rRfr4T
tr*W(r
-]t fl\ OTZAD.PNAAlOO a
Measurethe distancebetweenthe crankshaft(A)
a n d o i l s e a l( B ) .
Oil Seal InstalledHeight:

5.5 6.5 mm 10.22-0.26in.l
5.5 6.5 mm
l0.22- O.26in .l
7-28
EngineMechanical
t--l
r_::::-l

EngineLubrication
SpecialTools \
Ref. No. Tool Number Descriotion Otv

o 07HAA-PJ70100 Oil FilterWrench
\-
8-2
WASHER
DRAINBOLT
OILPAN
R e m o v apl ,a g e7 1 1
Installataon, page7-27
OILPUMP
page8-8
OverhaLrl,
HL]
BAFFLEPLATE
OILPUMP OILCONTROL
CHAINTENSIONER ORIFICE
-&\JrI OIL FILTERFEEDPIPE

Replacement,page8-7
--t
ksrarr
N\
lN-?
cKEr dczt$) OILFILTER
page8-6
Replacement,
# 1 OIL PRESSURESWITCH
SwitchTest,page8 4
\ Oil Pressuretest, page8'4
OIL PUMP R e p l a c e m e npt a, g e8 1 6
CHAINGUIDE
8-3
EngineLubrication
Oil PressureSwitch Test Oil PressureTest {
1 . R e m o v et h e Y E U R E Dw i r e ( A ) f r o mt h e e n g i n eo i l lf the oil pressureindicatorstayson with the engine

pressureswitch (B). r u n n i n g c. h e c kt h e e n g i n eo i l l e v e l .l f t h e o i l l e v e li s
correct:
'1.
Connecta tachometer.
Removethe engine oil pressureswitch,and install

a n o i l p r e s s u r eg a u g e{ A ) .
2. Checkfor continuitybetweenthe positiveterminal

( C )a n d t h e e n g i n e( g r o u n d )T. h e r es h o u l db e
continuitywith the engine stopped.There should
be no continuitywith the engine running.
lf the switch fails to operate,checkthe engineoil

l e v e l .l f t h e e n g i n eo i l l e v e li s O K .c h e c kt h e e n g i n e
oil pressure.lf the oil pressureis OK, replacelhe oil (
Dressureswitch. \.
Start the engine.Shut it off immediatelyif the
gauge registersno oil pressure.Repairlhe problem
beforecontinuing.
4. Allow the engineto reachoperatingtemperature

(fan comes on at leasttwice),The pressureshould
be:
EngineOil Temperature: 176'F (80'Cl

EngineOil Pressure:
At ldle: 70 kPa (0.7kgf/cm', 10 psi)
mtntmum
At 3,000rpm: 300 kPa (3.1kgf/cm',44 psi)
minimum
lf the oil pressureis NOT within specifications,

inspectthese items:
. C h e c kt h e o i l s c r e e n f o r c l o g g i n g .
. Checkthe oil pump (seepage8-8).
. Checkcrankshaftand connectingrod bearing
clearances.
8-4
EngineOil Replacement
1 . Warm up the engine.
2 . R e m o v et h e d r a i nb o l t ( A ) ,a n d d r a i nt h e e n g i n eo i l .
n A
44 N.m {i1.5kgf.m,33lbf.ft)
Donotovertighten.
3 . Reinstallthe drain bolt with a new washer (B).
d i l ( s e ep a g e3 - 2 ) .
R e f i l l w i t ht h e r e c o m m e n d e o
Capacity
4.0 0 (4.2US qt) at oilchange.
4.2 014.4US qt) at oilchange includingfilter.
5.3 015.6US $) after engineoverhaul.
5 . Run the enginefor more than 3 minutes.then check

for oil leakage.
8-5
EngineLubrication
EngineOil FilterReplacement
Special Tool Fequired 5. lf 4 numbersor marks (1 to 4 or V to VVVV) are
Oil filter wrench 07HAA-PJ70100 printedaroundthe outsideof the filter, usethe
following procedureto tighten the filter.
EngineOil Filter(3/4-turntype)
. Spin the filter on until its seal lightly seatsagainst
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 D e c i at ol o l . t h e b l o c k ,a n d n o t ew h i c h n u m b e ro r m a r ki s a t
the bottom.
2. Inspectthe threads{A) and rubber seal (B)on the . Tightenthe filter by turning it clockwise3
new filter. Wipe off the seat on the engine block, numbersor marksfrom the one you noted.For
then apply a light coat of oil to the filter rubber seal. example,if number 2 is at the bottom when the
Use only filterswith a built-inbypasssystem. seal is seated,tightenthe filter until the number 1
comes around the bottom.
Number when rubber Number aftertightening.

seal is seated. (
\..
I n s t a l l t h eo i l f i l t e rb y h a n d .
N u m b eor r 1 2 3 4
After the rubberseal seats,tightenthe oil filter M a r kw h e n or or or or
clockwisewith the specialtool. r u b b esr e a li s V VV VVV VVVV
Tighten: 3/4 turn clockwise.

Tighteningtorque: 12 N.m (r.2 kgf.m,8.7 lbf.ft) N u m b e ro r 4 1 2 3
Mark after or or or or
tightening vvvv. v VV VVV
6 . A f t e ri n s t a l l a t i o nf i,l l t h e e n g i n e w i t ho i l u p t o t h e
specifiedlevel,run the enginefor more than 3
m i n u t e st,h e n c h e c kf o r o i l l e a k a g e .
07HAA-PJ70100
\,
8-6
Oil FilterFeedPipeReplacement
1 . Removethe oilfilter (seepage8-6).
Removethe oil filter feed pipe.
3 . l n s t a l l t h e t w o 2 x0 1 . 5 m m n u t s ( Ao) n t o t h e n e w
oil filter feed pipe. Holdthe nut with a wrench,then
tighten the other nut.
4 . T i g h t e n t hoei lf i l t e r f e e p
d i p e t o t h eb l o c k t o4 9N .
m {5.0kgf.m,36 lbf ft),thenremovethe nutsfrom
the oil filterfeedoiDe.
8-7
EngineLubrication
OilPumpOverhaul
ExplodedView
6x1.0mm
BAFFLEPLATE 1 2N . m
{1.2kgfm,8.7lbf.ft)
x 1 . 2 5m m
27 N.m
6x1.0mm (2.8kst m, 20 lbt ft)
12 N.m A p p l ye n g i n o
eilto
11.2kgf.m,8.7 lbt ft) the boltthreads.
Ptr
P UI" I
EU
UPPERBALANCER
SHAFTHOLDER
$--."Dowetem
BALANCERSHAFT
BEARINGS
DOWELPIN
\
REAR
BALANCER
SHAFT
-
/=.---'n
FRONT
BALANCER
fs/ SHAFT
t w
LOWERBALANCER
SEALINGBOLT SHAFTHOLDER
39 N.m
{4.0kgf.m,29lbf.ftl
\-
8-8
Oil PumpRemoval 6. Removethe oil pump sprocket(A),then removethe
oil pump(B).
1. Setthe No. 1 piston attop deadcenter{TDC){see
s t e p1 o n p a g e6 - 1 2 ) .
2 . R e m o v et h e o i l p a n ( s e e p a g e T - 1 1 ) .
3 . R e m o v ea n d d i s c a r dt h e o i l p u m p c h a i n t e n s i o n e r .
4. To hold the rear balancershaft,inserta 6 mm pin

driver (A) into the maintenancehole in the lower
balancershaft holderand through the rear balancer
shaft.
5. Loosenthe oil pump sprocketmounting bolt.
(cont'd)
8-9
EngineLubrication
Oil PumpOverhaul{cont'dl {
Oil PumpInspection 3. Checkth e h ousing-to-roto r axiaI clearancebetween

t h e r o t o r( A )a n d p u m p h o u s i n g( B ) .l f t h e h o u s i n g -
1 . R e m o v et h e p u m p h o u s i n g . to-rotoraxial clearanceexceedsthe servicelimit.
r e p l a c et h e o i l p u m p .
Housing"to-Rotor Axial Clearance

Standard(New):0.02 0.07 mm (0.001-0.003 in.l
Checkthe inner-to-outerrotor radialclearance

betweenthe inner rotor (A) and outer rotor {B).lf
the inner-to-outerrotor radialclearanceexceeds
the servicelimit, replacethe oil pump.
Inner Rotor-to-Outer Botor Radial Clearance 4 . Checkthe housing-to-outer

rotor radialclearance
Standard{New):0.02 0.16mm (0.001-0.006 in.) betweenthe outer rotor (A) and pump housing(B).
ServiceLimit: 0.20mm (0.008in., lf the housing-to-outerrotor radialclearance
exceedsthe servicelimit, replacethe oil pump. \,
Housing-to-Outer Rotor Radial Clearance

StandardlNewl: 0.15 0.21mm (0.006-0.008in.l
ServiceLimit; 0.23mm (0.009in.)
1'[1e-\1.-,-2
'a -
1 :.: ,-'r'
Inspectboth rotors and the pump housingfor

scoringor other damage.Replaceparts if
necessary.
\-
8- 10
BalancerShaft Inspection 3. Removethe baffle plate (A) and upper balancer
shaft holder {with bearings)(B),then removethe
1 . Seatthe balancershaft by pushingit away from the front balancershaft (C)and rear balancershaft (D).
o i l p u m p s p r o c k eet n d o f t h e o i l p u m p .
9 H . A
2 . Zero the dial indicatoragainstthe end of the ''/
.r L=] j/
balancershaft,then push the balancershaft back
and forth and readthe end olav. R
Rfl|]
Balancer Shaft End Play: 3B eI ]U U
Fronl Balancer Shaft: r
+-
{0.0028 0.0053in.}
Rear Balancer Shaft:
Standard{New):0.070-0.135 mm
(0.0028 0.0053in.l
(cont'd)
8-11
EngineLubrication
Oil PumpOverhaul(cont'dl (
4. Measure the innerdiameterof the No. 1 bearingfor 5 . Measurethe diametersof the No. 1 journalson the
thefrontbalancershaftholeandthe rearbalancer front balancershaft and rear balancershaft.
shafthole.
NO.1Journal Diameter:
BearingInnerDiameier: Front:
Front: StandardlNew): 19.938 19.950mm
Standard(New):20.000-20.020mm (0.7850 0.7854in.)
(0.7874 0.7882in.) ServiceLimit: 19.92mm {0.784in.)
ServiceLimit; 20.03mm (0.789in.) Rear:
Rear: StandardlNewl: 23.938 23.950mm
Standard(New):24.000-24.020mm in.)
{0.9424-0.9/129
in.)
10.9/t49-0.9457 ServiceLimit: 23.92mm (0.942in.)
Front:
Front:
a
Rear:
8-12
6. Cleanboth balancershaft No. 2 journalsand 1 0 . A l i g nt h e p u n c hm a r ko n t h e r e a rb a l a n c esr h a f t
bearinghalveswith a cleanshop towel. with the centerof the two punch marks on the front
balancershaft,then install'thebalancershaftsin
7. Placeone strip of plastigageacrosseach No.2 the lower balancershaft holder
journal.
8 . Reinstallthe bearingsand upper balancershaft

holder,then torque the bolts.
NOTE;Do not rotatethe balancershaft durinq

insDection.
9 . Removethe uooer balancershaft holder and

bearingsagain,and measurethe widest part of the
plastigage.lf the balancershaft No. 2 journal oil
clearanceis out-of-tolerance. installthe new
bearings,and recheck.lf it is still out-of-tolerance,
replacethe balancershafts.
No. 2 Journal Oil Clearance:

StandardlNewl; 0.060 0.120mm
(0.0024 0.0047in.l
1 1 .Apply engine oil to the threads of the 8 mm bolts
(A).
6 x1.0mm
'12N.m
(1.2kgt.m,8.7 lbt ft)
1 2 . I n s t a l l t h eu p p e rb a l a n c esr h a f th o l d e r( B )a n d
bafile plate (C).
(cont'd)
8-13
EngineLubrication
Oil PumpOverhaul(cont'd)
1 3 . l n s t a l l t h ep u m p h o u s i n g . Oil PumpInstallation
1. Make sure the No. 1 piston is at TDC (seestep 1 on
p a g e6 - 1 2 ) .
2. Align the dowel pin{A} on the rear balancershaft

with the mark (B)on the oil pump.
6x1,0mm
9%ttrc
1 2N . m
(1.2kgt.m,8.7lbf.ft) +:.:4.4 / t\ \
o/.-lY\
To hold the rear balancershaft, inserta 6 mm pin

driver {A) into the maintenancehole in the lower
balancershaft holder and through the rear balancer
shaft.
\,-
-rrdv :aa:'
f,o-;
8- 14
4. Apply engine oil to the threadsof the oil pump 8. Squeezethe new oil pump chain tensioner(A),then
sprocketmounting bolt (A). installthe set clip (B)on it as shown.
N O T ET
: h e s e tc l i p i s s u p p l i e dw i t h t h e o i l p u m p
chain tensioner.
A
10x 1.25mm
{4 N.m
(a.5kg{ m, B
I
33 rbf.ftl
9. Installthe oil DumD chain tensioner.
6x1.0mm
12N.m(1.2kgf.m,
8.7rbf.ft)
1 0 x1 . 2 5m m 8 x 1 , 2 5m m
,l,t N.m {4.5kgf.m, 22N m l2.2kot m.
33 tbt.ftl r6 tbt.fti
5 . L o o s e l yi n s t a l l t h eo i l p u m p( B ) t, h e ni n s t a l l t hoei l
pump sprocket(C).
Removethe pin driver (D).
7 . Tightenlhe oil pump mounting bolts.
(cont'd)
8-15
Downloaded
I from www.Manualslib.com manuals search engine
EngineLubrication
I
Oil PumpOverhaul(cont'dl Oif PressureSwitch Replacement (
1 0 . R e m o v et h e s e tc l i pf r o m t h e o i l p u m p c h a i n 1. Disconnectthe oil pressureswitchconnector,then

tensioner. removethe oil pressureswitch.
2. Apply liquid gasketto the oil pressureswitch

1 1 . I n s t a ltl h e o i l p a n ( s e ep a g e T - 2 7 ) . threads,then installthe oil pressureswitch.
8-16
r
EngineMechanical r-!i!1
IntakeManifoldand ExhaustSystem
lntakeManifoldRemovaland Installation.................
9-2
ExhaustManifoldRemovalandInstallation..............
9-7
ExhaustPipeand MufflerReplacement .....................
9-8

lntakeManifoldRemovaland Installation \
Exploded View:
8 x 1 , 2 5m m
22 N.m {2.2kgf.m, 16 lbf ft}
I
INTAKEMANIFOLD
Replaceif crackedor
if mating surfaceis GASKET
Replace.
k
'e)
w)
\ '! (
t9
INTAKE MANIFOLDPLATE
Replaceif crackedor
k
if matingsurfaceis \
damaged. 8 xx1.25
. 2 5mm
222 N' mm
2
12.2ksf
kgf.m, 1 6
6x1.0mm
1 2N . m
{1.2kgf.m,8.7lbf.ft)
8 x 1 . 2 5m m
22 N.m
(2.2kgf m. 16 lbt.ft)
\- (
9-2
Removal: 3. Disconnecttheintakeairtemperature(lAT)sensor
connector(A),and removethe breatherhose (B),
'1.
Removethe intakemanifoldcover. then removethe air cleanerhousingcover/intake
a i r d u c ta s s e m b l y( C ) .
2 . Removethe evaporativeemission(EVAP)canister
hose (A),brakeboostervacuum hose (B),and 4. Fully open the throttle link and cruisecontrol link
vacuum hoses{C). by hand,then removethe throttlecable (A) and
cruisecontrol cable(B)from the links.Loosenthe
locknuts{C).and removethe cablesfrom the
bracket.
(cont'd)
9-3
IntakeManifoldRemovaland Installation(cont'dl (
5. Be preparedto catch and clean up spilledcoolant. 9 . Removethe enginewire harnessconnectorsand

Removethe water bypasshoses,then plug the w i r e h a r n e s sc l a m p sf r o m t h e i n t a k em a n i f o l d .
water bypasshoses.
. Four injectorconnectors
. ldle air control (lAC)valve connector
. Throttleposition(TP)sensorconnector
. fvlanifoldabsolutepressure{lvlAP)sensor
connector
. Evaporativeemission(EVAP)canister purge
valve connector
'10. Removethe bolt securingthe intakemanifoldand
bracket.
6 . R e l i e v e f u epl r e s s u r e( s e ep a g e1 1 - ' 1 4 4 ) .
7 . R e m o v et h e f u e l l i n e ( s e e p a g e l l - 1 4 9 ) .
8. Removethe positivecrankcaseventilation(PCV)
hose (A),harnessholder mounting bolt (B)and
h a r n e s sc l a m pm o u n t i n gb o l t ( C ) .
1 1 .Removeallthe intakemanifold mounting bolts/

nuts.
1'> Removethe two stud bolts (A),then removethe

i n t a k em a n i f o l d( B ) .
\-
9-4
4 . Installthe PCVhose {A), harnessholder mounting
b o l t ( B ) ,a n d h a r n e s sc l a m pm o u n t i n gb o l t( C ) .
1. Installthe intakemanifold (A)with a new gasket(B),
then installand tighten the two stud bolts (C).
w
e-li*h,r
*&
\
8 x 1.25mm
22 N.m
|.2.2k91.m.
16 tbt.ft)
8 x 1.25mm
22 N.rn
(2.2kgf m. 16 lbf.ttl
6x1.0mm
2. Tightenall intakemanifold mountlng bolts/nutsin a 12N.m(1.2kgf.m,8.7lbf.ft)
crisscrosspatternin two or three steps,beginning
with the inner bolt. 5 . I n s t a l l t h ef u e l l i n e ( s e ep a g e1 1 - 1 5 0 ) .
? Tightenthe bolt securingthe intakemanifold and 6 . Installthewater bypasshoses.

bracket.
7 . I n s t a ltl h e t h r o t t l ec a b l e( s e ep a g e11 - 1 6 4 )t ,h e n
a d j u s t h e c a b l e( s e ep a g e1 1 - 1 6 3 ) .
8 x 1.25mm
22 N.m (2.2ksf m, 16lbf.ft)
8 . Installthe cruisecontrol cable (seepage 4-44).then
adjustthe cable (seepage 4-45).
(cont'd)
9-5
lntake Manifoldand ExhaustSystem
IntakeManifoldRemovaland Installation(cont'd)
9 . l n s t a l l t h ea i r c l e a n e rh o u s i n gc o v e r( A ) ,a n d 1 2 . I n s t a l l t h ei n t a k em a n i f o l dc o v e r .
connectthe IAT sensorconnector(B).
6x1.0mm
1 2N . m
l.1.2k91.m,
8.7 tbf.ftl
B C
C l e a nu p a n y s p i l l e de n g i n ec o o l a n t .
1 0 .Installthebreatherhose(C).
After installation,checkthat all tubes,hoses,and
1 1 .lnstalltheEVAPcanisterhose(A),brakebooster connectorsare installedcorrectly.
v a c u u mh o s e( B ) a
, n dv a c u u mh o s e s{ C ) .
Inspectfor fuel leaks.Turn the ignition switch ON
(ll) (do not operatethe starter)so that the fuel pump
runs for about 2 secondsand pressurizesthe fuel \-
line. Repeatthis operationtwo or three times,then
checkfor fuel leakageat any point in the fuel line.
to. Refillthe radiatorwith enginecoolant,and bleed

air from the cooling systemwith the heatervalve
open (seepage 10-6).
9-6
ExhaustManifoldRemovaland Installation
1 . Removethe VTECsolenoidvalve (seepage 1'1-128).
2 . Removethe driveshaftheat shield(seepage 16-19).
3 . Removethe cover and exhaustmanifold bracket,then removethe exhaustmanifold.

8 x 1 . 2 5m m
22 N.m
(2.2kgf.m, 16lbt.ftl
SELF-LOCKING NUT
10x 1.25mm
44 N.m {4.5ksf.m, 33lbt.ftl
#'-.-
Beplace.
1 0x 1 . 2 5m m
44 N.m
(4.5kgt.m, 33 lbl ftl
Replace.
GASKET
Replace.
8 x 1-25mm
WASHEB 22 N.m (2.2kgI m, 16lbf.ft)
Replace.
Tightenthe boltsin steps,
10x 1.25mm alternating
sideto side.
14 N.m
{4.5kgl.rn, 33lbf.ft)
Installthe exhaustmanifoldand tighten the bolts/nutsin a crisscrosspatternin two or three steps,beginningwith

the inner bolt.
5 . Installtheother parts in the reverseorder of removal.
9-7
lntake Manifoldand ExhaustSystem
ExhaustPipeand Muffler Replacement \
NOTE:Use new gasketsand self-lockingnuts when reassembling.
8 x 1 . 2 5m m
22 N.m (2.2kst.m. 16lbf.ftl
Replace.
Tightenthe bolts in steps,
alternatingside'to side.
EXHAUSTPIPEB
HEATSHIELD
\,
6x1.0mm
9.8 N.m
{1.0kgt.m,7.2 lbf ft}
GASKET
Replace.
SELF-LOCKING NUT SECONDARY

HEATED
1 0x 1 . 2 5m m OXYGENSENSOR
33N.m{3.4kgf.m, HO2SI
{SECONDARY
25 rbf.ft) il4Nm
Beplace. (4.5 ksf.m,33 lbf.ftl
8 x 1.25mm
22 N.m {2.2kgf m, 16lbf.ft)
Replace. AIR FUELRATIO {A/F)
Tightenthe bolts in steps, SENSOR
alternatingside to-side. 44 N.m (it.s kgf.m, 33 lbf ftl
\-.
9-8
EngineCooling
CoolingSystem
Component Location Index ......................................... 10-2
Radiator CapTest ..................... .......... 10-3
RadiatorTest ............. 10-3
FanMotorTest ..........l0-4
Thermostat Test ...................... ........... 10-4
WaterPumpInspection ..................... 10-5
WaterPumpReplacement ................. 10-5
C o o l a nCt h e c k. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. .0. .- .6. .
CoolantReplacement ......................... 10-6
Thermostat Replacement .................. 10-8
WaterPassage Installation ................ 10-9
WaterOutletInstallation .................... 10-9
Radiator andFanReplacement ................................... 10-10
FanControls
C o m p o n e nLto c a t i oInn d e x . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. .0. .-.1. .1. . . . . . .
SymptomTroubleshooting Index ............................... 10-12
CircuitDiagram .........10-13
Radiator FanCircuitTroubleshooting ........................ 10-14
Radiator FanSwitchCircuitTroubleshooting
( O p e n ). . . . . . . . . . . . . . . . . . .1. 0 - 1 6
Radiator FanSwitchCircuitTroubleshooting
( S h o r t ). . . . . . . . . . . . . . . . . . .1. 0 - 1 6
Radiator FanSwitchTest ................... 10-17
Radiator FanSwitchReolacement .............................. 10-17

CoolingSystem
ComponentLocationIndex \
WATER OUTLET,
I n s t a l l a t i opna,g e ' 1 0 - g
WATERPUMP
page10-5
Inspection,
Replacement.page10-5
\\f
PIPE
CONNECTING
RESERVE
TANK
WATERPASSAGE
page10-9
Installation,
THERMOSTAT
Test,page10 4
RADIATOR Replacement,page108
CAP
RAOIATORFAN SWITCH RADIATOR

Test,page 10-17 page 10-'l0
Replacement,
Replacement, page 10'17
RADIATORFAN
ASSEMgLY
A/C CONDENSER R e p l a c e m e npta, g e1 0 - 1 0
FAN ASSEMBLY Fan MotorTest,page 10 4
Replacement,page 10'10-4
10
Fan Motor Test,page
\J
10-2
RadiatorCapTest RadiatorTest
1. Removethe radiatorcap {A),wet its sealwith 1 . Wait untilthe engine is cool, then carefullyremove
engine coolant,then installit on the pressuretester the radiatorcap and fill the radiatorwith engine
( B )( c o m m e r c i a l layv a i l a b l e ) . coolantto the top of the filler neck.
Attachthe pressuretester (A) (commercially

a v a i l a b l et)o t h e r a d i a t o r .
'123
Apply a pressureof 93 kPa{0.95 1.25
kgf/cm', l4 18 psi).
3 . Checkfor a drop in pressure.
4 . lf the pressuredrops, replacethe cap.
3 . Apply a pressureot 93 '123kPa(0.95 1.25

'14
kgf/cm', 18 psi).
4 . I n s p e cfto r e n g i n ec o o l a n tl e a k sa n d a d r o p i n
pressure.
Removethe tester,and reinstallthe radiatorcap.
10-3
CoolingSystem
FanMotor Test ThermostatTest \ (
1. Disconnectthe 2P connectorsfrom the radiatorfan Replacethe thermostatif it is open at room

motor and condenserfan motor. remperalure.
To test a closedthermostatl
1. Suspendthe thermostat(A) in a containerof water.

Do not let the thermometer{B)touch the bottom of
t h e h o tc o n t a i n e r .
Testthe motor by connectingbatterypower to the

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

r e p t a c er L
2. Heatthe water, and checkthe temDeraturewith a
thermometer.Checkthe temperatureat which the \.
thermostatfirst opens,and at which it is fully open.
3 . Measurethe lift height of the thermostatwhen it is

f u l l vo o e n .
STANDARDTHERMOSTAT
Lift height; above 8.0 mm (0.31in.)
Starts opening: 169 176"F(76 80"C)
Fullyopen: 194"F{90'Cl
10- 4
Water Pump Inspection Water Pump Replacement
1 . Removethe drive belt (seepage 4-26), 1. Removethe drive belt (seepage 4-26).
2 . Turn the water pump pulleycounterclockwise. 2 . D r a i nt h e e n g i n ec o o l a n t{ s e ep a g e1 0 - 6 ) .

Checkthat it turns freely.
3 . R e m o v et h e c r a n k s h a fpt u l l e y( s e ep a g e6 - 1 1 ) .
Checkfor signs of seal leakage.A small amount of
"weeping" from
the bleed holes(A) is normal. 4. Removethe six bolts securingthe water pump,
then removethe water pump (A).
6x1.0mm
1 2 N m { 1 . 2k g t m ,
8.7 rbf.ft)
Inspectand cleanthe O-ring groove and mating

surfacewith the water passage.
I n s t a l l t h ew a t e r p u m pw i t h n e w O r i n g si n t h e
reverseorder of removal.
7 . C l e a nu p a n y s p i l l e de n g i n ec o o l a n t .
8 . I n s t a l l t h ec r a n k s h a fpt u l l e y( s e ep a g e6 - 1 2 ) .
L R e f i l tl h e r a d i a t o w
r i t h e n g i n ec o o l a n t a, n d b l e e d
air from the cooling system with the heatervalve
o p e n{ s e ep a g e1 0 - 6 } .
10-5
CoolingSystem
GoolantCheck CoolantReplacement \
1. Look at the coolantlevel in the reservetank. Make 1 . Startthe engine.Set the heatertemperaturecontrol
sure it is betweenthe MAX mark (A) and MIN mark dial to maximum heat.then turn off the ignition
(B), switch.Make surethe engine and radiatorare cool
to the touch.
Removethe radiatorcap.
Removethe splashshield(seestep 23 on page5-5).
Loosenthe drain plug (A),and drain the coolant.
lf the coolantlevel in the reservetank is at or below

the MIN mark, add coolantto bring it up to the l\4AX
mark, and inspectthe cooling system for leaks.
\
Removethe reservetank drain cap (A),and drain
the coolant.
\-
10-6
After the coolanthas drained,tighten the radiator 8. Pour HondaAll SeasonAntifreeze/Coolant Type 2
drain plug securely.and installthe reservetank into the radiatorup to the baseof the filler neck.
drain cap securely.
NOTE:
1 . Fillthe reservetank to the MAX mark (A) with . Always use HondaAll SeasonAntifreeze/Coolant
HondaAll SeasonAntifreeze/Coolant Tvpe 2 Type 2 {P/N01999-9001).Using a non-Honda
(P/NO1999-9001). c o o l a n tc a n r e s u l ti n c o r r o s i o nc, a u s i n gt h e
cooling systemto malfunctionor fail.
. HondaAll SeasonAntifreeze/Coolant Type 2 is a
mixture of 50% antifreezeand 507owater. Pre-
m i x i n gi s n o t r e q u i r e d .
EngineCoolant RefillCapacity includingthe

reserve tank capacity of 0.53 4 (0.56 US gtl :
5.0 0 (s.3US qt)
L I n s t a l l t h er a d i a t o cr a p l o o s e l y .
1 0 .Startthe engine,and let it run until it warms up (the

radiatorfan comes on at leasttwice).
1 1 .Turn off the engine.Checkthe level in the radiator,

and add HondaAll SeasonAntifreeze/Coolant Type
2 if needed.
P u tt h e r a d i a t o cr a p o n t i g h t l y ,t h e n r u n t h e e n g i n e
a g a i na n d c h e c kf o r l e a k s .
tJ. lnstallthe splashshield(seestep 22 on page 5-12).
10-7
GoolingSystem
ThermostatReplacement a
1 . D r a i nt h e e n g i n ec o o l a n t( s e ep a g e1 0 - 6 ) .
2. Removethe splashshield (seestep 23 on page 5-5).
3. Removethe lower hose,then removethe thermostat.
6 x 1 . 0m m
9.8N.m
( 1 . 0k g f . m , 7 . 2 l bf ft )
THERMOSTAT
i* -
LOWERHOSE
4. Installthethermostatwith a new O-ring,then installthe lower hose.
5 . I n s t a l l t h es p l a s hs h i e l d( s e es t e p2 2 o n p a g e5 - 1 2 ) .
6. Refillthe radiatorwith engine coolant,and bleed air from the cooling systemwith the heatervalve open (seepage
10_6).
\_
10-8
Water PassageInstallation Water Outlet lnstallation
1 . Cleanand dry the water passagemating surfaces. e a t e ro u t l e (t A ) w i t ha n e wO - r i n g{ B ) ,
I n s t a l l t hw
Apply liquid gasketP/N 08718-0009, evenlyto the

c y l i n d e rb l o c km a t i n gs u r f a c eo f t h e w a t e r p a s s a g e
and to the inner threadsof the bolt holes.

h a v ee l a p s e ds i n c ea p p l y i n gl i q u i dg a s k e t I. n s t e a d ,
1 2 N m ( 1 . 2k g t m , 8 , 7 l b ff t )
3 . I n s t a l l t h ew a t e rp a s s a g e( A ) w i t ha n e w O - r i n g( B ) .
.t':.:
1 0x 1 . 2 5m m
44N m {4.5kgtm.33 lbf.ft}
4. After assembly,wait at least30 minutes before

10-9
CoolingSystem
Radiatorand FansReplacement {
1. Drainthe enginecoolant(seepage 10-6).
2. Removethe front bumper {seepage 20,85).
3. Removethe bulkhead.
4. Removethe upper radiatorhose and lower radiatorhose.
DRAINPLUG
O.RING RADIATOR
CAP
UPPERBADIATORHOSE
BADIATOB
BAOIATOAFAN
ASSEMBLY
\-
LOWERCUSHION
RADIATOR FAN
swtTcH
24Nm
{ 2 . 1kt g l m . 1 7 l b l h l
LOWERFADIATOR
HOSE
RESERVETANK
A/C CONDENSER
FANASSEMBLY
9 . 8N m { 1 . 0k g f m , 7 . 2l b ff t )
CONNECTORS
RADIATOBFANSWITCH
CONNECTOB
5. Disconnectthe fan motor connectorsand radiatorfan switch connector,then pull the radiatorup and out.
6. Removethe fan shroud assembliesand other partsfrom the radiator.
7 . I n s t a l l t h er a d i a t o ri n t h e r e v e r s eo r d e ro f r e m o v a l M
. a k es u r et h e u p p e ra n d l o w e rc u s h i o n sa r e s e t s e c u r e l V .
8 . I n s t a ltlh e b u l k h e a di n t h e r e v e r s eo r d e ro f r e m o v a l A
. p p l y b o d y p a i n tt o t h e b u l k h e a dm o u n t i n gb o l t s .
r i t h e n g i n ec o o l a n ta n d b l e e dt h e a i r ( s e ep a g e1 0 - 6 ) .
9 . F i l lt h e r a d i a t o w
\.
10-10
FanControls
UNDER.HOOD
FUSE/RELAY
BOX
RADIATORFAN RELAY
RADIATOBFAN SWITCH RADIATORFAN ASSEMBLY

Test,page 10'17 Motor Test,page 10 4
R e p l a c e m e npt a, g e ' 1 0 - 1 7
CONDENSER FAN ASSEMBLY
Motor Test,page 10-4
10-11
FanControls
Symptom TroubleshootingIndex \ {
Beforeperformingany troubleshootingprocedurescheck:
. Fuses
. Grounds
. Cleanlinessand tightnessof all connectors
SYMPTOM PROCEDURE
Radiatorfan does not run at all RadiatorFanCircuilTroubleshooting(seepage 1O-14).
Radiatorfan does not run for enginecooling, but it runs RadiatorFan Switch CircuitTroubleshooting(Open)
with A,/CON ( s e ep a g e1 0 - 1 6 ) .
Radiatorfan runs with ignition switch ON (ll),Ay'COFF, RadiatorFan Switch CircuitTroubleshooting(Short)

and enginetemperaturebelow 199"F(93"C) (seepage 10-'16).
\ , 4
\-
10-12
o CircuitDiagram
'
No.20loA): USA
modd
: Cm.de
No.20l50A) mod.l
UNDEN
DASX
UIIDEFHOOD BOX
FJSE/NILAY FUSE/RELAY
BOX
lG2H0TiiAClill,
0N{lllrndSTABI
llll)
10-13
FanGontrols
RadiatorFanCircuitTroubleshooting (
1. Checkthe No. 4 (20A)fuse in the under-hood 4 . C o n n e ct th e N o . l a n d N o . 2 t e r m i n a l s o f t h e

fuse/relaybox, and the No. 14 (10A)fuse in the radiatorfan relay 4P socketwith a jumper wire.
under-dashfuse/relaybox.
ls the tuse (s) OK?

RADIATORFAN RELAY4P SOCKET
YES-Go to step 2.
NO- Replacethe fuse (s) and recheck.l JUMPER

WIRE
2. Removethe radiatorfan relayfrom the under-hood
fuse/relaybox, and test it (seepage 22-51).
ls the relay OK?
YES Go to step 3. T e r m i n asli d eo f I e m a l tee r m i n a l s
NO Replacethe radiatorfan relay.t

Does the radiatot fan run?
3. Measurethe voltage betweenthe No. 2 terminal of
the radiatorfan relay 4P socketand body ground. YES Go to step 5.
NO Go to step 6.
RADIATORFAN RELAY4PSOCKET
Disconnectthe jumper, and turn the ignition switch
ON {ll}. Checkfor voltage betweenthe No. 3
terminal of the radiatorfan relay 4P socketand \-
b o d yg r o u n d .
BADIATOB
FANRELAY4PSOCKET
Terminalside of femaleterminals
ls therebatteryvoltage?
YES Goto step4.

Termlnalsideof femaleterminals
NO Replace
the under-hood
fuse/relay
box.I
ls there battety voltage?
YES-Go to step 9.
NO Checkfor an open in the wire betweenthe

under-hoodfuse/relaybox and under-dashfuse/
relay box.l
\-
10-14
Disconnectthe radiatorfan motor 2P connector. 9 . Reinstallthe radiatorfan relay.
7 . Checkfor continuitybetweenthe No. 1 terminal of 1 0 .Disconnectthe radiatorfan switch 2P connector.

the radiatorfan relay 4P socketand the No. 2
terminal of the radiatorfan motor 2P connector. 1 1 .Connectthe No. 1 and No. 2 terminals,of the
radiatorfan switch 2P connectorwith a jumper wire.
RAOIATOR
FANREI-AY
4PSOCKET RAOIATORFANSWITCH
2P CONNECTOR
Terminalsideof
femaleterminals 5\-'fl \ IJUMPER
f-; I wrRE
\r--
RADIATORFAN MOTOR2P CONNECTOR
Does the radiator fan run?

ls thete continuity?
YES- Replacethe radiatorfan switch.l
YES-Go to step8.
N O - G o t o s t e p1 2 .
NO Repairopenin the wire betweenthe under-
hoodfuse/relay
boxandthe radiatorfan motor2P Removethe jumper wire, and measurethe voltage
terminalNo.2,I
connector betweenthe No, 2 terminal of the radiatorfan
switch connectorand body ground,
8. Checkfor continuitybetweenthe No, 1terminal of
the radiatorfan motor 2P connectorand bodv
RADIATORFANSWITCH
g round. 2P CONNECTOR
RADIATORFAN MOTOR2P CONNECTOR
rftr
T-
Y
Wire side of femaleterminals
YES Checkfor an open in the wire between

ls there continuity? radiatorfan switch 2P connectorterminal No. 1 and
body ground. lf the wire is OK, checkfor a poor
YES Replacethe radiatorfan motor.l g r o u n da t G 3 0 1 . 1
NO Checkfor an open in the wire between NO Repairopen in the wire betweenthe radiator
radiatorfan motor 2P connectorterminal No. 1 and fan switchterminal No. 2 and the under-hood
body ground. lf the wire is OK, checkfor a poor fuse/relaybox.l
g r o u n da t G 3 0 1 . 1
10-15
FanControls
RadiatorFanSwitch Circuit
Troubleshooting(Openl
RadiatorFanSwitch Circuit
Troubleshooting(Short)
\ I
1. Disconnectthe radiatorfan switch 2P connector. NOTE:After troubleshooting,perform the engine
c o n t r o lm o d u l e( E C M ) i d l el e a r np r o c e d u r e( s e ep a g e
2 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) . 11 , 1 3 9 ) .
3 . M e a s u r ev o l t a g eb e t w e e nt h e N o . 2 t e r m i n a lo f t h e 1 . R e m o v et h e r a d i a t o fra n r e l a yf r o m t h e u n d e r - h o o d
radiatorfan switch 2P connectorand body ground. fuse/relaybox, and test it (seepage 22-51).
RADIATORFAN SWITCH2P
ls the relay OK?
CONNECTOR
YES Go to step 2.
NO Replacethe radiatorfan relay.I
2. Removethe radiatorfan switch,and test it (see

p a g e1 0 - 1 7
).
Is the radiatot tan switch OK?
YES Go to step 3.
ls there battety voltage? NO Replacethe radiatorfan switch.I
YES-Go to step 4. Disconnectthe batterynegativecablefrom the

battery.
NO- Repairopen in the wire betweenthe radiator \
fan switch 2P connectorterminal No. 2 and under- 4 . Disconnectenginecontrol module {ECM)connector
hood fuse/relaybox.l B ( 2 4 Pa
) n d t h e u n d e r h o o df u s er e l a yb o x 1 4 P
connector.
Turn the ignition switch OFF,and checkfor
continuitybetweenthe No. '1terminal of the Checkfor continuitybetweenthe No. 2 terminal of
radiatorfan switch 2P connectorand body ground. the radiatorfan switch 2P connectorand body
grouno.
RADIATOBFAN SWITCX2P
CONNECTOR
RADIATORFAN SWITCH
2P CONNECTOR
ls there continuity? lstnere continuity?
YES Replacethe radiatorfan switch.t YES Repairshort in the wire betweenthe radiator
f a n s w i t c h2 P c o n n e c t otre r m i n a lN o . 2 a n d u n d e r -
NO Checkfor an open in the wire betweenthe hood fuse/relaybox.l
radiatorfan switch 2P connectorterminal No. 1 and
body ground. lf the wire is OK, checkfor a poor NO Replacethe under-hoodfuse/relaybox.t
g r o u n da t G 3 0 1 . 1 \-
10-16
RadiatorFanSwitch Test RadiatorFanSwitch Replacement
NOTE:Bleedair from the cooling system after installing 1 . Disconnectthe radiatorfan switch connector,then
the radiatorfan switch (seepage 10-6). removethe radiatorfan switch (A).
1, Removethe radiatorfan switchfrom the radiator A

24 N m (2.4kgt.m,17lbt.ftl
( s e ep a g e1 0 - 1 7 ) .
2 . S u s p e n dt h e r a d i a t ofra n s w i t c h( A )i n a c o n t a i n e r
of water as shown.
2. Installthe radiatorfan switchwith a new O-ring(B).
3. Heatthe water, and checkthe temperaturewith a

thermometer.Do not let the thermometer(B)touch
the bottom of the hot conlainer.
4. Measurethe continuitybetweenterminal No. 1 and

terminal No. 2 accordingto the table.
\ Termina
1
Operation lTemperature
ON 196" 203'F
(91" gs"C)
swtTcH 5' 15'F {3' 8'C) lowel
OFF than the temoerature
when it goes on
10-17
Fueland Emissions
Fueland EmissionsSystems F u eP l r e s s u r e T e s. .t. . . . . . . . . . . .1. 1. .-.1. 4 5

SpecialTools 1't-2 FueL l i n e sI n s p e c t i o.n. . . . . . . . . .1. .1. .- 1 4 6
General
Troubleshooting FuelLine/Ouick-Connect
Information I I-J FittingsPrecautions............. 11-148
DTCTroubleshootinglndex .... 11-7 FuelLine/Ou ick-Con nect
SymptomTroubleshooting F i t t i n gRs e m o v a l. . . . . . . . . . . . .1. 1. .-.1. 4 9
1ndex............... 11 - 1 0 FuelLine/Ou ick-Con nect
SystemDescriptions
................
11-12 F i t t i n glsn s t a l l a t i o.n. . . . . . . . . .1. .1. .- 1 5 0
Howto SetReadinessCodes.. 11-46 FuelPressure Regulator
R e p l a c e m e .n.t. . . . . . . . . . . . . . . 1 . .1. .-.1. .5. 2
PGM-FlSystem FuelFifterReplacement ........... 11-152
Component Location Index .... 11-49 FuelPump/Fuel GaugeSending
D T CT r o u b l e s h o o t i n. .g. . . . . . . . .11-52
... U n i t R e D l a c e m e. .n. t. . . . . . . . . 1 . .1. .-.1 5 3
MILCircuitTroubleshooting ... 11-97 F u ePl u l s a t i oDna m o e r
DLCCircuitTroubleshooting .. 1 1 - 1 0 9 R e p 1 a c e m e. n . .t. . . . . . . . . . . . . . 1
. .1. .-.1. .5. 4
InjectorReplacement ............... 11-111 F u eTl a n kR e o l a c e m e n . .t. . . . . . .1. 1. - 1 5 5
A,/FSensorReplacement .........1 1 - 1 1 3 F u eGl a u g e S e n dUi n igt T e s. .t . . . .1. 1 - 1 5 6
Secondary HO2S LowFuellndicatorTest ................. 11-158
Replacement 11-113
ECTSensorReolacement.......1 1 - 1 1 4 IntakeAir System
CMPSensorB {TDCSensor) C o m o o n e nLt o c a t i o nI n d e x . . . . 1 1 - 1 5 9
Replacement 11-114 T h r o t t l eB o d y T e s t . . . . . . . . . . . . . . 1
. .1. .-.1 6 0
I A TS e n s oR
r e p l a c e m e.n. t. . . . . 1. .1 - 1 1 5 IntakeAir BypassControl
KnockSensorReplacement .... 1 1 - 1 1 5 T h e r m aV l a l v eT e s t . . . . . . . . . . .1. .1. - 1 6 1
CKPSensorReolacement .......1 1 - 1 1 6 A i r C l e a n eR r e o l a c e m e n .t . . . . . .1. 1 - 1 6 2
A i r C l e a n eE r lement
VTEC/VTC R e o l a c e m e n.t. . . . . . . . . . . . . . . . . 1. .1. .-.1. .6 2
Comoonent LocationIndex .... 11-117 ThrottleCableAdjustment ...... 11-163
D T CT r o u b l e s h o o t i n. .g. . . . . . . . .1.1. .- 11 8 ThrottleCable
VTCOil ControlSolenoid Removal/lnstallation ............ 11-164
ValveRemoval/Test ............. 11-127 Th rottleBody Removal/
CMPSensorA Replacement ... 11-128 Installation .. 11-165
VTECSolenoid Valve Th rottleBody Disassembly/
R e m o v a l / l n s o e c t.i .o. n. . . . . . .11-128
... R e a s s e m b l v. . . . . . . . . . . . . . . . . . .1. .1. .- .1. 6. 6
ldle ControlSystem CatalyticConverterSystem

Location
Component Index 11-129 D T CT r o u b l e s h o o t i n. .g. . . . . . . . .1.1. .- 1 6 7
D T CT r o u b l e s h o o t i n g . . . . . . . . . . .1. .I.- 1 3 0
A,/CSignalCircuit PCVSystem
T r o u b l e s h o o t i n.S. . . . . . . . . . . . . .I .t.-. t.5 5 D T CT r o u b l e s h o o t i n g. . . . . . . . . . .1. .1.- 1 6 8
AlternatorFRSignalCircuit PCVValveInsDection
T r o u b l e s h o o t i n.S. . . . . . . . . . . . . .1. 1. .-. 1 3 4 a n dT e s t . . . . . .11 -1 6 9
EPSSignalCircuit P C VV a l v eR e o l a c e m e n.t. . . . . . . .1.1 - 1 6 9
T r o u b l e s h o o t i n.S. . . . . . . . . . . . . .1.1. .-1. 3 5
Brake PedalPosition SwitchSignal EVAPSystem
Circuit Troubleshooting ............. 11 - 1 3 7 C o m p o n e nLt o c a t i o nI n d e x . . . . 1 1 - 1 7 0
ldle SpeedInspection 11 - 1 3 8 D T C T r o u b l e s h o o t i n.g. . . . . . . . . .1. .1. - 1 7 1
E C Ml d l el e a r nP r o c e d u r e. . . . . . .11 - 1 3 9 EVAPTwo Way ValveTest ......11-186
FuelTank VaoorControl
FuelSupplySystem ValveTest ... 11-187
ComponentLocationIndex 11 - 1 4 0 E V A PC a n i s t eRr e p l a c e m e n.t. . 1 1 - 1 8 9
FuelPump Circuit Troubleshooting 1 1 - 1 4 1 FuelTank VaoorControl
F u e lP r e s s rue R e l i e v i n g. . . . . . . . .1. .1 - 1 4 4 V a l v eR e o l a c e m e n.t. . . . . . . . . .1. .1.- 1 8 9

Fueland EmissionsSystems
(
SpecialTools \,
Rel. No. Tool Number Description otv

(L) A973X-041-XXXXX V a c u u mP u m p / G a u g e0, 3 0 i n . H g 1
@ 07JAZ-0010008 Vacuum/Pressure Gauge.0 4 in.Hg 1
o 07sAz-001000A BackprobeSet 2
@ 07vAJ-0040100 Fuel PressureGaugeAdapter 1
@ 07NAJ-P07010A PressureGaugeAdapter 1
@ 07xAA-001010A FuelSenderWrench 1
o 07zAJ-S5AA200 Hose,Oil Pressure
@-t 07406-0020201 A,/TPressureHose
@-2 07406-0070300 A,/TLow PressureGaugeW/Panel
O-3 OTMAJ-PY4O11A A,/TPressureHose,2,210 mm
@-4 07MAJ-PY40120 A,/TPressureHoseAdapter
@ 07406-004000A F u e lP r e s s u r eG a u g e
(iD 07zAJ-S5A0100 FuelPressureGauoeSet
ffi a=:t=' (F
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11-2
GeneralTroubleshooting
Information
IntermittentFailures 2. lf the MIL stayson, connectthe HondaPGM Tester
(A) or an OBD ll scantool to the Data Link
The term "intermittentfailure" means a svstem mav Connector{DLC)(B) locatedunderthe driver'sside
have had a failure.but it checksOK now. lf the o f t h ed a s h b o a r d .
MalfunctionIndicatorLamp (MlL)on the dash does not
come on, checkfor Doorconnectionsor looseterminals
at all connectorsrelatedto the circuitthat Vou are
troubleshooting.
Opensand Shorts
"Ooen" and "Short" are common
electricalterms.An
open is a breakin a wire or at a connection.A short is
an accidentalconnectionof a wire to ground or to
anotherwire. In simple electronics,this usuallymeans
somethingwon't work at all. With complex electronics
( s u c ha s E C M s ) t h i sc a n s o m e t i m e sm e a ns o m e t h i n g
works, but not the way it's supposedto.
How to Usethe PGMTesteror a ScanTool

3 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
lf the MIL {Malfunction Indicator Lamp} has come on
Checkthe DiagnosticTroubleCode (DTC)and note
'1.
S t a r tt h e e n g i n ea n d c h e c kt h e M I L { A ) . it. Also checkthe freezedata.Referto the DTC
T r o u b l e s h o o t i nIgn d e x ,a n d b e g i nt h e a p p r o p r i a t e
N O T E l: f t h e i g n i t i o ns w i t c hi s t u r n e dO N ( l l ) ,a n d troubleshootingprocedure.
the engine is not started,the MIL will stay on for
1 5 2 0 s e c o n d s( s e ep a g e1 1 - 4 6 ) . 5 . lf you do not find any DTCS,go to MIL circuit
t r o u b l e s h o o t i n(gs e ep a g e1 1 - 9 7 ) .
K->;"PN/.- -:::--d V-: ! NOTE:
w:ix&K#
. Freezedata indicatesthe engineconditionswhen the
first malfunction,misfire,or fuel trim malfunction
was detected.
. The scantool and the Honda PGM Testercan readthe
DTC,freezedata,currentdata,and other Engine
Controll\4odule{EClvl)data.
. For specificoperations,referto the user's manual
that came with the scantool or HondaPGl\4Tester.
lf the MIL did not stay

lf the MIL did not come on but there is a driveability
problem,referto the Symptom TroubleshootingIndex
i n t h i ss e c t i o n .
lf you can't duplicate the DTC

Some of the troubleshootingin this sectionrequires
you to resetthe ECM and try to duplicatethe DTC.lf rhe
problem is intermittentand you can't duplicatethe code,
d o n o t c o n t i n u et h r o u g ht h e p r o c e d u r eT. o d o s o w i l l
o n l y r e s u l ti n c o n f u s i o na n d ,p o s s i b l ya, n e e d l e s s l y
r e p l a c e dE C M .
(cont'd)
11-3
GeneralTroubleshootingInformation(cont'dl J
How to Resetthe ECM How to Removethe ECMfor Testing
You can resetthe ECM in eitherof two ways: 1. Removethe passenger'sdashboardlower cover
{seepage 20-63),the passenger'skick panel (see
. U s et h e O B Dl l s c a n t o o lo r H o n d aP G M T e s t e r t o page 20-63),and the glove box (seepage 20-63).
resetthe ECM memory.
Seethe OBD ll scantool or HondaPGI\4Testeruser's 2. Removethe ECM mounting bolts (B)and the ECM
manualsfor specificinstructions. (c),
' Turn the ignition switch OFF,and removethe No. 6
ECU{ECM}(15A)fuse (A)from the under-hoodfuse/
r e l a vb o x ( B l f o r 1 0 s e c o n d s .
9.8 N.m
{1.0kgf.m,7.2lbt.ft}
3 . R e m o v et h e E C M ( B ) .
How to Enda TroubleshootingSession
L
(requiredafterany troubleshootingl 4. Installthe ECM in the reverseorder of removal.
1. Resetthe ECM as describedabove.
2 . D o t h e E C Mi d l e l e a r np r o c e d u r e( s e ep a g e1 1 - 1 3 9 )
3. Turn the ignition switch OFF.
4. DisconnecttheOBD ll scantool or Honda PGM

Testerfrom the DLC.
NOTE:The ECM is part of the immobilizersystem.

lf vou replacethe ECM,it will have a different
immobilizercode. In order for the engineto start,
you must rewritethe immobilizercode with the
Honda PGM Tester.
\- ta
11-4
How to TroubleshootCircuitsat the ECM a s a g u i d ef o r t h e
2 . U s i n gt h e w i r e i n s u l a t i o n
contouredtip ofthe backprobeadapter,gently slide
Special Tools Required the tip into the connectorfrom the wire side until it
. DigitalMultimeterKS-AHM-32-003 (1) or a touchesthe end of the wire terminal.
commerciallyavailabledigital multimeter
. BackprobeSet 07SAZ-0010004 (2) 3. lf you cannot get to the wire side of the connector
or the wire side is sealed(A),disconnectthe
1. Connectthe backprobeadapters(A) to the stacking connectorand probe the terminals(B)from the
patchcords (B),and connectthe cords to a digital terminal side. Do not force the Drobeinto the
m u l t i m e t e (r C ) . connector.
Do not puncturethe insulationon a wire.

Puncturescan causeDooror intermittent
electricalconnections.
07sAz-001000A
(cont'd)
11-5
Information(cont'd)
GeneralTroubleshooting (
ECMUpdatingand Substitutionfor Testing How to Substitute the ECM

'1.
Special Tools Bequired Removethe ECMf rom the vehicle.
HondaInterfaceModule (HlM) EOS05435570
2. Installa known-goodECM in the vehicle.
Usethis procedurewhen you haveto substitute a
known-goodECM in a troubleshootingprocedure. 3 . R e w r i t et h e i m m o b i l i z ecr o d ew i t h t h e E C M
U pdatethe ECMonly if the ECN4
does not alreadyhave replacementprocedurefrom the Honda PGM
the latestsoftwareloaded, Tester.lt allows you to startthe engine.
NOTE; 4. After completingyour tests,reinstallthe original

. lMakesure the batteryis fully chargedbeforeyou E C Ma n d r e w r i t et h e i m m o b i l i z ecr o d ew i t h t h e
updatethe ECN4. E C Mr e p l a c e m e nptr o c e d u r eo n t h e H o n d aP G M
. To preventECMdamageduring the update,do not T e s t e ra g a i n .
turn the ignition switch OFF,and do not use any of
the vehicle'selectricaldevices(light,horn, radio,etc. ).
How to Update the ECM
1. Turn the ignition switch ON (ll).Do not startthe

e n gI n e .
2. Connectthe HondalnterfaceModule (HlM)to the

Data Link Connector{DLC)(A) locatedunderthe
d r i v e r ' ss i d eo f d a s h b o a r d .
L I
EOS05A35570
Do the ECM updateprocedureas describedon the

HlN4label and in the ECM updatesystem.
\-
11-6
DTCTroubleshootingIndex
DTC Temporary
DTC Detection ltem Note
{MlLindication*)
P 0 0 1 (05 6 ) VariableValveTiming Control{VTC)Oil Control { s e ep a g e11 ' 11 8 )
S o l e n o i dV a l v eM a l f u n c t i o n
P 0 0 1 (15 6 ) P0011 VariableValveTiming Control(WC) System ( s e ep a g e1 1 -11 9 )
Malfunction
P 0 1 0 (73 ) (MAP)SensorCircuit
ManifoldAbsolutePressure ( s e ep a g e1 ' l - 5 2 1
LowVoltaqe
P 0 1 0 (83 ) (MAP)SensorCircuit
ManifoldAbsolutePressure ( s e ep a g e1 1 - 5 3 )
HiqhVoltaqe
P 0 1 1 2( 1 0 ) IntakeAir Temperature(lAT)SensorCircuitLow (seepage 11-55)
Voltaoe
(10)
P01r3 IntakeAir Temperature(lAT)SensorCircuitHigh (seepage '11-56)
Voltaoe
P 0 1 1 6{ 8 6 ) P0116 EnglneCoolantTemperature(ECT)Sensor Range/ { s e ep a g e1 1 - 5 7 )
PerformanceProblem
P0117
{6) (ECT)SensorCircuit
EngineCoolantTemperature ( s e ep a g e1 1 - 5 8 )
LowVoltaqe
P 0 1 1{86 ) EngineCoolantTemperature(ECT)SensorCircuit { s e ep a g e1 1 - 5 9 )
Hiqh Voltaqe
P 0 1 2 t27 \ Throttle Position(TP)SensorCircuitLow Voltaqe ( s e eD a q e1 1 - 6 0 )
P 0 1 2 {37 ) Throttle Posltion(TP)SensorCircuitHiqh Voltaoe ( s e ep a q e1 1 - 6 2 )
P 0 1 2 8( 8 7 ) P0128 CoolinqSVStemMalfunction ( s e eD a q e1 1 - 6 4 )
P 0 1 3 4( 4 1 ) Air Fuel Ratio(Ay'F) Sensor(Sensor1) No Activity ( s e ep a g e1 1 - 6 5 )
Detected
P 0 1 3 (76 3 ) P0137 SecondaryHeatedOxygen Sensor (SecondaryHO2S) ( s e ep a g e1 1 - 6 5 )
(Sensor2) CircuitLow Voltaqe
P 0 1 3 8( 6 3 ) P0138 SecondaryHeatedOxygen Sensor (SecondaryHO2S) ( s e ep a g e1 1 - 6 6 )
( S e n s o2
r ) C i r c u i tH i q hV o l t a q e
P 0 1 3 (96 3 ) P0139 SecondaryHeatedOxygen Sensor (SecondaryH02S) ( s e ep a g e1 1 - 6 7 )
( S e n s o2
r )SlowResDonse
P 0 1 4 1( 6 5 ) SecondaryHeatedOxygen Sensor(SecondaryH02S) ( s e ep a g e1 1 - 6 8 )
(Sensor2) HeaterCircuitMalfunction
P 0 1 7 1( 4 5 ) PO\11 FuelSvstemToo Lean ( s e ep a q e1 1 - 7 0 )
PO112l'45) PO\l2 FuelSystemToo Rich ( s e eo a o e1 1 - 7 0 )
P0300andany P0300andany R a n d o mM i s f i r e ( s e ep a g e1 1 - 7 1 )
of of
P 0 3 0 (17 1 ) P0301
PO302 (721 P0302
P0303(73) P0303
P0304(74) P0304
P0301(7'1) P0301 No. 1 Cyl n d e rM i s f i r e { s e ep a g e1 1 - 7 2 )
P0302(721 P0302 No.2 Cvl n d e rM i s f i r e { s e ep a q e11 - 7 2 )
P0303(73) P0303 N o . 3 C v l nder Misfire ( s e eo a q e1 1 - 7 2 )
P0304{74) P0304 N o . 4 C v l nder Misfire {seeDaqe11-72)
" ; T h e s e D T C sa r e i n d i c a t e db y a b l i n k i n gm a l f u n c t i o ni n d i c a t o lra m p ( M l L ) w h e nt h e S C Ss e r v i c es i g n a l i n e i s
jumped with the Honda PGM Tester.
{cont'd)
11-7
DTCTroubleshootingIndex(cont'd) \ (
KnockSensorCircuitN4alfunction
CrankshaftPosition(CKP)SensorIntermittent ( s e ep a g e1 1 - 7 8 )
CamshaftPosition(CMP)SensorA No ( s e eo a q e1 1 - 1 2 1
CamshaftPosition(CMP)SensorA Intermiftent i s e ep a g e1 1 - 1 2 1 )
VelyeTiTing_controlll/T!)
Yetrgb-le Phqse
G s e eo a o e1 1 - 1 2 2
PO4i{ CqJalystSystemElficie-ncy Below Threshold s e eo a q e11 -1 6 7
P 0 4 5 1( 9 1 ) TU45I ( F T PS
F u e lT a n kP r e s s u r e ) e n s o rR a n g e / P e r f o r m a n c e( s e e p a g e l l 1 7 1 )
P0452 SensorCircuitLow V 11-172

FuelTank Pressure(FTP)SensorCircuitHigh V
V e h i c l eS D e e dS e n s o r C i r c u i tM a l fu n c t i o n
s e eD a q e1 1 - 1 3 0 )
l o d u l e( E C N 4P)o w e rS o u r c eC i r c u i l
E n g i n eC o n t r o M ( s e ep a g e11 - 8 1 )
SeriaC
l o m m u n i c a t i o Ln i n kM a l f u n c t i o n Referto the l\4ultiplex
ControlSystem
T r o u b l e s h o o t i n{gs e e
P 1 1 0(61 3 ) Barometric
Pressure (BARO)
SensorRange/ ( s e ep a g e11 - 8 3 )
P 1 1 0(?1 3
P 11 0 8( t s '
PerformanP
BarometriP
c er o b l e m
( B A R OS
c ressure
BarometriP
) e n s o rC i r c u i tL o w
( B A R OS
c ressure ) e n s o rC i r c u i tH i g h
( s e ep a S e11 ' 8 3 )
{ s e ep a g e1 1 - 8 3 )
l\."
a
P112111) P't121 T h r o t t l eP o s i t i o n{ T P iS e n s o rS i g n a lL o w e rT h a n ( s e ep a g e1 1 - 6 3 )
-
P1122ll J Pl122 T h r o t t l eP o s i t i o n( T P )S e n s o rS i g n a lH i g h e rT h a n tsee page I r-oJ,
i j 1 1 2 8( 5 ) P11f,.8 (l\,4AP
M a n i { o l dA b s o l u t eP r e s s u r e S }e n s o rS i g n a l G;tp"s" 1154)
Loqer Than Expected
P 11 2 9( 5 ) ManifoldAbsolutePreisure (MAP)SeiiioiSgnul ( * " p a S e11 5 4 )
H i q h e rT h a nE x
P 1 1 5 7( 4 8 ) A i r F u e lR a t i o( A V FS) e n s o r( S e n s o r1 ) R a n g e / ( s e ep a g e1 1 - 8 4 )
R e r f o r m a n cP eroblem
Pr 158 (48) r ) A F S T e r m i n a l ( s e ep a g e11 - 8 5 )
A i r F u e lR a t i o { A " FS) e n s o r{ S e n s o 1
'l)
P 11 5 9( 4 8 ) A i r F u e lR a t i o1 A V FS)e n s o ri s e n s o r A F S+ T e r m i n a l ( s e ep a g e11 - 8 6 )
P 1 1 6 3( 6 1 Air FuelRatio{A,/F)Sensor{SensorI ) Slow Response

P 1 1 6 4( 6 1 ) A i r F u e lR a t i o( A / F )S e n s o r( S e n s o r1 ) R a n g e / ( s e ep a g e 11 - 8 8 )
P 11 6 6( 4 1 ) Air Fuel Ratio(4,/F)Sensor(Sensor1) HeaterCircuit ( s e ep a g e1 1 - 8 9 )

Malfunction
P 11 6 7( 4 1 )' Air Fuel Ratio(A,/F)Sensor(Sensor1) HeaterSystem ( s e ep a g e1 1 - 9 1 )
Malfunction
" : T h e s eD T C Sa r e i n d i c a t e db y a b l i n k i n gM I L w h e n t h e S C Ss e r v l c es i g n a l i n e i s j u m p e dw i t h t h e H o n d aP G M
Tester.
* 1 r' 0 2 m o d e l
\.
11-8
DTC Temporary
DTC Detectionltem Page
{MlLindication*l
P1259t22J VTECSystem l\4alfunction ( s e eD a q e1 1 - 1 2 3 )
P1291t20\ ElectricalLoad Detector(ELD)CircuitLow Voltaqe ( s e eD a q el 1 - 9 2 )
P1298(20) ElectricalLoad Detector(ELD)CircuitHiqh Voltaqe ( s e eo a o e1 1 - 9 3 )
P 1 3 6 1( 8 ) CamshaftPosition(CMP)SensorB (Top DeadCenter ( s e ep a g e1 1 - 9 5 )
(TDC)Sensor)IntermittentSional InterruDtion
P 1 3 6 (28 ) CamshaftPosition(CMP)Sensor B (Top DeadCenter ( s e ep a g e1 1 - 9 5 )
( T D C )S e n s o r N
) o Siqnal
P'r456(90) P1456 EvaporativeEmissions(EVAP)ControlSystem ( s e ep a g e1 1 - 1 7 5 )
Leakaqe(FuelTank Svstem)
(90)
P14s7 P1457 EvaporativeEmissions(EVAP)ControlSystem ( s e ep a g e1 ' l - 1 8 0 )
Leakaqe(EVAPCanisterSvstem)
P 1 5 0 (51 0 9 ) P1505 PositiveCrankcaseVentilation(PCV)Air Leakaqe ( s e eo a q e1 1 - 1 6 8 1
P1519 (14) ldle Air Control(lAC)ValveCircuitMalfunction { s e ep a q e1 1 - 1 3 1 )
P 1 6 0 7( ) EnginC l o d u l e( E C MI)n t e r n aCl i r c u i t
e o n t r oM ( s e ep a g e11 - 9 6 )
Malfunction
" : TheseDTCSare indicatedby a blinking MIL when the SCSservicesignal line is jumped with the Honda PGM
Tester.
11-9
Symptom TroubleshootingIndex \
When the vehiclehas one of these symptoms,checkthe diagnostictrouble code (DTC)with the scantool. lf there is no
DTC,do the diagnosticprocedurefor the symptom, in the sequencelisted,until you find the cause.
Svmotom Diaqnostic procedure Also check lor

E n g i n ew i l l n o t s t ar t 1. Testthe battery{seepage 22-50). Low compressron
(MlL works OK, no DTCSset) 2. Testthe starter(seepage 4-8). N o i g n i t i o ns p a r k
3. Troubleshootthe fuel pump circult(seepage 11 l n t a k ea i r l e a k s
141). L o c k e du p e n g i n e
B r o k e nt i m i n gc h a i n
Contaminatedfuel
'1-97).
E n g i n ew i l l n o t s t a r t( M l L Troubleshootthe l\4lLcircuit(seepage 1
comes on and stayson, or
n e v e rc o m e so n a t a l l ,n o
DTCSset)
Enginewill not start Troubleshootthe immobilizersystem (seepage 22-165).
(immobilizerindicatorstays
on or flashs)
Hardstarting 1. Testthe battery(seepage22-50). Low compression
(MlLworksOK,no DTCS
set) 2 . C h e c k t h ef u e l p r e s s u r e( s e ep a g e1 1 - 1 4 5 ) . I n t a k ea i r l e a k s
Contaminatedfuel
Coldfast idle too low 1 . D o t h e E C Mi d l e l e a r np r o c e d u r e( s e ep a g e1 1 - 1 3 9 ) .
(MlL works OK. no DTCSset) 2 . C h e c k t h ei d l e s D e e d( s e ep a q e1 1 - 1 3 8 ) .
' ] D o t h e E C I \ 4i d l e l e a r np r o c e d u r e( s e ep a g e11 -1 3 9 ) .
Coldfast idle too high
(MlL works OK, no DTCSset) 2. C h e c k t h ei d l es p e e d{ s e ep a g e1 1 - 1 3 8 ) .
'1-'163).
3 . Inspect/adjust the throttlecable (seepage 1
Inspectand test the throttle body {seepage 11-160}.
ldle speedfluctuates 1 . D o t h e E C Mi d l e l e a r np r o c e d u r e ( s e ep a g e1 1 - ' 1 3 9 ) .I n t a k ea i r l e a k s \-
(MlL works OK, no DTCSset) 2 . C h e c kt h e i d l es p e e d( s e ep a g e1 1 - 1 3 8 ) .
3, Inspecvadjustth e throttlecable (seepage 11''163).
4. Insoectand test the throttle bodv (seepaqe 11-160)
After warming up, idle speed 1 . D o t h e E C I Vi dI l e l e a r np r o c e d u r e( s e ep a g e11 -1 3 9 ) . Vacuum hose clogged/
is below specificationswith 2. TroubleshootthealternatorFRsignalcircuit (see cracked/poor
no load p a g e1 1 - ' 1 3 4 ) . connectron
{MlL works OK, no DTCSset) 3. InsDectand test the throttle bodv {seepaqe 11-160).
After warming up, idle speed 1 . D o t h e E C Mi d l e l e a r np r o c e d u r e { s e ep a g e1 ' j - 1 3 9 ) .
is above specificationswith 2 . T r o u b l e s h o ot ht e a l t e r n a t oFr Rs i g n a lc i r c u i t ( s e e
no toao p a g e1 1 - 1 3 4 ) .
(MlL works OK. no DTCSset)
Low power 1 . C h e c kt h e f u e l p r e s s u r e ( s e e p a g e l l - 1 4 5 ) . Low compressron
(MlL works OK, no DTCSset) 2. Inspectand test the th roftle body (seepage 11-160). C a m s h a ftti m i n g
3 . I n s p e c v a d j u tsht e t h r o t t l ec a b l e( s e ep a g e1 1 - ' 1 6 3 ) . problem
E n g i n eo i l l e v e l
prootem
E n g i n es t a l l s 1. D o t h e E C Mi d l el e a r np r o c e d u r e( s e ep a g e1 ' l ' 1 3 9 ) . l n t a k ea i r l e a k s
(MlL works OK. no DTCSset) 2. C h e c kt h e f u e l p r e s s u r e { s e e p a g e l l - 1 4 5 ) . F a u l t yh a r n e s sa n d
3. C h e c kt h e i d l es p e e d( s e ep a g eI 1 - 1 3 8 ) . sensorconnections
4. Troubleshootthebrakepedal positionswitch signal
c i r c u i t( s e ep a q e1 1 - 1 3 7 ) .
\-
11-10
Symptom Diagnosticprocedure Also checktor
Difficultto refuel 1 . T e s t t h e f u e lt a n kv a p o rc o n t r o lv a l v e { s e e p a g e1 ' l - M a l f u n c t i o n i ngga s
(MlL works OK. no DTCSset) 2. 1471. s t a t i o nf i l l i n gn o z z l e .
I n s p e ctth e f u e lt a n kv a p o rc o n t r o ls i g n a lt u b e
3. betweenthe fuel pipe and the fuel tank vapor
control valve.
4. Inspectthe fuel tank vapor vent tube betweenthe
EVAPcanisterand the fuel tank vapor control valve.
Checkthe EVAPcanister.
Fueloverflowsduring Replacethe fuel tank vapor control valve (seepage '11 Malfunctioninggas
refueling 189). stationfilling nozzle.
(No DTCSset)
11-11
SystemDescriptions \ {
ElectronicControl System
The functionsof the fuel and emlssioncontrol systemsare managedby the enginecontrol module (ECM).
Fail-safeFunction
When an abnormalityoccursin the signalfrom a sensor,the ECI\4ignoresthat signaland assumesa pre-programmed
value for that sensorthat allowsthe enqineto continueto run.
Back-up Function
When an abnormalityoccursin the ECM,the injectorsare controlledby a back-upcircuitindependentof the systemto
p e r m i tm i n i m a ld r i v i n g .
Self-diagnosis
When an abnormalityoccursin the signalfrom a sensor,the ECM suppliesground for the malfunctionindicatorlamp
{MlL) and storesthe diagnostictrouble code {DTC)in erasablememory.When the ignition is first turned on, the EClvl
suppliesground to the l\4lLfor 15 to 20 secondsto checkthe M lL bulb condition.
Two Driving Cycle Detection Method

"two driving cycle detectionmethod" is usedfor some self-diagnostic
To preventfalse indications,the functions.
When an abnormalityoccurs,the ECM storesit in its memory. When the same abnormalityrecursafterthe ignition
s w i t c hi s t u r n e dO F Fa n d O N ( l l )a g a i n ,t h e E C Mt u r n so n t h e M l L .
\.
11-12
ECMData
You can retrievedata from the ECI\4by connectingthe OBD ll scantool or the Honda PGM Testerto the data link
connector(DLC).The items listedin the table below conform to SAE recommendedpractice.The HondaPGM Tester
also readsdata beyondthat recommendedby SAEto help you find the causesof intermittentproblems.
The "operatingvalues" listedare approximateand may vary dependingon the environmentand the individual
vehicle.
Unlessnoted otherwise,"at idle speed" means idling with the enginecompletelywarmed up in the neutralposition,
and the A,/Cand all
Diagnostic lf the ECM delectsa problem, it will store it as a code l f n o p r o b l e mi s YES

Trouble Code consistingof one letterand four numbers.Dependingon detected,there is no
(DTC} the problem,an SAE-definedcode (Poxxx)or a Honda, ourpul.
definedcode {P1xxx)will be output to the tester.
TheECI\4 computesenginespeedfromthe signalssent N e a r l yt h e s a m ea s
position(CKP)sensor.Thisdatais
fromthe crankshaft tachometerindication
usedfor determining
thetimeandamountof injectedfuel. At idle speed;
The ECMconvertspulsesignalsfrom the vehiclespeed N e a r l yt h e s a m ea s

sensor(VSS). speedometer
indication
Manifold The absolutepressurecausedin the intakemanifold by Withenginestopped: YES
Absolute e n g i n el o a da n d s p e e d . Nearlythe same as
Pressure almospnencpressure.
(MAP) At idle speed:about
20 4'1kPa
( 1 5 0 3 1 0m m H g ,
6 - 1 2 i n . H q ) . 0 . 71 . 3V
The ECTsensorconvertscoolanttemperatureinto voltage W i t h c o l d e n g i n e :
and signalsthe ECM.The sensor is a thermistorwhose S a m ea s a m b i e n t
internalresistancechangeswith coolanttempetature.The temperatureand IAT
ECM usesthe voltagesignalsfrom the ECTsensorto With enginewarmed
determinethe amount of injectedfuel. u p ; a b o u t1 1 6 2 ' 1 2 " F
1 0 0 ' c ) . 0 . 5 - 0 .v8
Air Fuel Ratio The A,/Fsensordetectsthe oxygen content in the exhaust 0.0- 1.25 V
( A y ' FS)e n s o r . g a s a n d s e n d sv o l t a g es i g n a l st o t h e E c l v l ,B a s e d o n t h e s e 8 . 0 1 1 . 0 m A ( P G M
(Sensor1) signals,the ECMcontrolsthe airlfuel ratio.When the I Tester)
oxygen contentis high (that is, when the ratio is leaner At idle speed:
than the stoichiometricratio),the voltagesignal is Iower. about 0.1 0.9 V
When the oxygencontent is low (that is, when the ralio is
richerthan the stoichiometricratio).the voltagesignal is
higher.The A'lFsensorsignalsare electricalcurrentthat
are indicatedas voltaqe on the
Secondary The HO2Sdetectsthe oxygen contentin the exhaustgas 0 . 0 1 . 2 5V NO
Heated a n d s e n d sv o l t a g es i g n a l st o t h e E C M .B a s e do n t h e s e At idle speed:
Oxygen signals,the ECMcontrolsthe airlfuel ratio.When the a b o u t0 . 1 0 . 9V
Sensor oxygen contentis high (that is, when the ratio is leaner
(Secondary than the stoichiometricratio),the voltagesignal is lower.
H02S, When the oxygen content is low (that is, when the ratio is
Sensor2) r i c h e rt h a nt h e s t o i c h i o m e t r irca t i o ) t, h e v o l t a g es i g n a li s
(cont'd)
11-13
SystemDescriptions(cont'd) r a
ECMData(cont'd)
Data Description Opera'tingValue FreezeData
"open" or "closed". At idle speed:closed YES
FuelSystem Fuelsystem statusis indicatedas
Status Closed:Basedon the A,/FSensoroutput,the ECM
determinesthe airlfuel ratio and controlsthe amount of
injectedfuel.
Open: lgnoringAy'FSensoroutput,the ECM refersto
signalsfrom the throttle position{TP),manifoldabsolute
pressure(MAP),intakeair temperature(lAT),barometric
pressure(BARO),and enginecoolanttemperature(ECT))
sensorsto controlthe amount of iniectedfuel.
Short Term The airlfuel ratio correctioncoefficientfor correctingthe o.7 1.5 YES
FuelTrim amount of injectedfuel when the fuel system status
is "closed." When the ratio is leanerthan the
sloichiometricratio,the ECM increasesshort term fuel
trim gradually,and the amount of iniectedfuel increases.
The airlfuel ratio graduallygets richer,causinga lower
oxygen content in the exhaustgas. Consequently,the
short term fuel trim is lowered,and the ECM reducesthe
amount of injectedfuel.
This cvcle keepsthe airlfuelratio closeto the
stoichiometricratio when in closedloop status.
LongTerm Long term fuel trim is computedfrom short term fuel trim 0.8 1.2 YES
F u eT
l rim and indicateschangesoccurringin the fuel supply system
over a long period.
l f l o n gt e r m f u e lt r l m i s h i g h e rt h a n 1 . 0 0t,h e a m o u n lo f
w
injectedfuel must be increased.lf it is lower than 1.00,the
amount of injectedfuel must be reduced.
IntakeAir The IAT sensorconvertsintakeair temperatureinto W i t h c o l de n g i n e : YES
Temperature v o l t a g ea n d s i g n a l st h e E C M .W h e n i n t a k ea i r S a m ea s a m b i e n t
{IAT) temperatureis low, the internalresistanceofthe sensor temperature a n dE C T
increases,and the voltagesignal is higher.
Throttle Basedon the acceleratorpedal position,the opening At idle speed: YES
Position anole of the throttlevalve is indicated. a b o u t1 0%
lgnition lgnitiontiming is the ignition advanceangle set by the At idle speed:8" t 5" NO
Timing ECM.The ECM matchesignitiontiming to driving | ' t u L w n e nr n e > L )
conditions. s e r v i c es i g n a l i n e i s
jumped with the Honda
PGM Tester
Calculated cLV is the enoine load calculatedfrom IMAPdata. At idle speed: YES
L o a dV a l u e 12 34%
(cLV) At 2.500rpm with no
toao:
't4- 34%
\.,
11-14
J/-\
-1\_/
BEIAY2
A/C CLUTCHRELAY
I
) RAOIATOR
UNDER.HOOD
FUSE/RELAY BOX:
ONo. 19BATTERY (8oA)
ONo.6 ECU(ECM)(15A1
(3)No.20lG{40A1
{Canada:50A}
ONo.l4 OPTION {40A1
€)No.9 BACKuP (7.5A1
lo)No.7 HORN,STOP{15A}
UNDER.DASH
FUSE/RELAY BOX:
ONo. 17FUELPUMP
{15A}
@No.,t ACG{10A)
ONo.1 IGNCOIL(1sA)
q)No.10METER (7.5A)
0)No.14A/C CLUTCH
RELAY IlOA)
@No.2+B LAF(A/F)
HEATER (2OA)
(cont'd)
11-15
SystemDescriptions(cont'dl \ a
ECMElectricalConnections
MAPSENSON
No. INJECTOR
No,2INJECTOR
TPSENSOR
No.3 INJEC]OB
No./tINJECTOF
IATSENSOR
ECTSENSOB
\'
CMP SENSORB
(TDCSENSOSJ
CKPSENSOR
F€VERSELOCK
SOLENOIDVAIVE
\-
11-16
A/FSENSOR
EVAPCANISTE6
PURGEVAIVE
EVAPCANISTER
VENTSHUTVATVE A/FSENSOR
(sENSOn 1)
sotENotovAtvE
CMP SENSOFA
VIC OIL CONTROL

SO!ENOIDVALVE
No. 1 IGNITIONCOIL
wEcorl
PRESSUSESWTICH
N o . 2 l G N l l l O NC O I L
No. 3 IGNITIONCOIL
VTEC SOLENOID
No. a IGNITIONCOIL
{cont'd)
11-17
SystemDescriptions(cont'd) \
ECMElectricalConnections
ARAKEPEDAL
POStTtONSWTTCH
GAUGEASSEMBLY
IMMOBILPENUN|T
EPSCONTROTUNIT
TERMINALLOCATIONS
\-
11-18
ECMInputsand Outputsat ConnectorA (31P)
1 2 3 6 1 I
AFS]TC ]GP2 IGPl ^:^ I -:, AFS+ CKP KS
'10
t1 12 15 T6 18 1 9 2A 21
SG2 ACV TPS AFS_ V S S IVAP vcc2 vccl
22 23 26
25 CMPB 27 28 29 30
HTC+ LG2 CMPA(rDc) tGPts,lrcPts3tGPts2GPLS1
NOTE:Standardbatteryvoltageis 12V.
Terminal Who color forminal name Description Signal

numb€r
ELKAVHT AFSHTC(AIRFUELRATIO DrivesAy'Fsensorheater Withignit'onswitchON {ll):batteryvoltage
(4./F)SENSOR
HEATER Withfullywarmedup enginerunnang: 0V
CONTROL}
2 YEUBLK IGP2(POWEBSOURCE) Powersourcefor the ECM Withthe ignitionswitchON 1ll):batteryvoltage
circuit Withthe ionitionswitchOFF:about0 V
3 YEUBLK IGPl {POWER
SOURCE) Powersourcefor the ECM Withthe ignitionswatch ON {ll):batteryvoltage
Withthe ionitionswitchOFF:about0 V
4 BLK PG2(POWER GROUND Groundforthe ECMcircuit Lessthan 1.0V at all times
5 BLK PG1(POWER GROUND Groundforthe ECMcircuit Lessthan 1.0V at all times
6 RED AFS+ (AIRFUELRATIO DetectsAy'Fsensor
(A,/F}SENSOR, SENSOR1 {sensor1)signal
+ stDE)
1 8LU CKP(CRANKSHAFT Detects
CKPsensorsignal Withenginerunning:pulses
POSITION SENSOR)
9 BED/BLU ) KS E N S O B ) Detectsknocksensorsiqnal Withenqineknocking: pulses
10 YEL 2 {SENSOR; R O U N D ) Sensorqrounr Lessthan1.0Vat elltimes
G 1{ S E N S O R ;ROUND) Sensorqroun( L e s s t h a 1n . 0 Va t a l l t i m e s
12 BLIVRED IACV(IDLEAIRCONTROL DrivesIACvalve Withenginerunningrdutycontrolled
(IAC)VALVE)
RED/BLK TPS(THROTTLE POSITION Detects
TPsensorsignal Withthrottlefullyopen:about4.8V
SENSOR) Withthronlefullvclosed:ahout0-5V
REDI/EL AFS (AIRFUELRATIO Detects!y'Fsensor
(4,/F)SENSOR, SENSOB1 ( s e n s o1r) s i g n a l
SIDE)
18 WHT/GRN V S S ( V E H I C L ES P E E D Detects
VSSsignal WathignitionswitchON (lli andfrontwheels
SENSOR) rotating:
cyclesfrom about0 V to about5 V or
(cont'd)
11-19
SystemDescriptions{cont'd) \. il
ECMInputsand Outputsat ConnectorA (31P)
1 2 3 4 5 6 1 I
AFS]TC GP2 IGPl PG2 PG.1 AFS+ CKP KS
12 '15 1 6 18 1 9 20 21
10 11
SG2 sG1 IACV TPS AFS_ V S S IVAP vcc2 vccl
22 23 25 CMPB26 27 28 29 30
AFS LG2 IGPLS4
IGPLS3 IGPLS,I
IGPLS2
HTC+ Ct\.4PA
(rDc)
batteryvoltageis 12V.
NOTE:Standard
Jorminal Wirecolor [€rminal namo Description Signal

number
19 GRN/RED MAP(MANIFOLD DetectsMAPsensorsignal With ignitionswitchON (ll):about3 V
ABSOLUTE PRESSURE A t i d l e : a b o u t 1 . 0V ( d e p e n d i n go n e n g i n e s p e e d )
SENSOR)
20 YEUBLU VCC2(SENSOR VOLTAGE) P r o v i d e ss e n s o r v o l t a g e With ignitionswitchON {ll):about5 V
WithionitionswitchOFF:about0V
21 YEURED VCC](SENSOB
VOLTAGE) Provides
sensorvoltage WithignitionswitchON {ll):about5 V
22
23
24
BRN?ryE
BRN?ryE
L
L
AFSHTC- (AIRFUEL
RATIO(A"iFiSENSOR
HEATER
LG2(LOGIC
1(L
CONTROL
GROUND
+ SIDE)
Detectsa,/Fsensorheater
voltage
roundfor the ECMcircu

roundfor the ECMcircu
With ionitionswitchOFF:about0V
W i t h i g n ; t i o ns w i t c h O N l l l ) : b a n e r y v o l t a g e
Lessthan1.0V at alltimes
L e s st h a n
'1.0
V at alltimes
\. a
25 BLU,^/VHT CMPA (CAMSHAFT D e t e c t sC M P s e n s o r A Withenginerunning:pulses
POSITION SENSOR A) stonal
26 GRN CMPB CAMSHAFT Detects CMPsensor8 (TDc Withenginerunning:pulses
POSITION (CMP)SENSOB sensor)
B (TDC(TOPDEADCENTER
SENSORi)
27 BRN I G P L S 4{ N o .4 I G N I T I O N DrivesNo, 4 ignitioncoi WithignitionswitchON (ll)rabout0 v
COILPULSE) Withenginerunning:pulses
28 WHT/BLU I G P L S 3{ N o . 3 I G N I T I O N O r i v e s N o . 3 r g n i t i o nc o i
COILPULSE)
29 BLU/RED l G P L S 2 l N o .I 2
GNITION DrivesNo.2 ignitioncoil
COILPTJLSE)
30 YEUGRN IGPLSI(No.1 IGNITION DrivesNo. I ignitioncoil
co PlltsF)
\. a
11-20
Wire side o{ femaleterminals
NOTE:Standardbafteryvoltageis 12V.
Terminal Wirecolor [erminal name Description Signal

numo€t
BLUAvHT VTC+ lVTCOILCONTBOL DrivesVTCoilcontrol WithignitionswitchON (ll):0 V
SOLENOID VALVE+SIDE)
2 lNJa{No.4INJECTOR) Drives o. 4 iniector At idle:dutycontrolled
3 BL Jo.3INJECTORI Drives o.3 iniector
4 R1 )TOR) Drives o . 2 i n i e c t o r
5 BRN lNJl 1No.I INJECTOR) DrivesNo. 1 iniector
6 GRN FANC(RAOIATOR FAN With radiatorfan running:about0 V
Drivesradiatorfan relay
CONTROL) With radiatorfan stopped:battervvoltaoe
7 GRN/vVHT RVS(REVERSE LOCK Drivesreverselocksolenoid Withvehiclespeedbelow9.4mph (15km/h):
SOLENOID VALVE) batteryvoltage
Withvehiclespeedabove12.5mph (20km/h):0 V
8 REDAVHT ECT(ENGINE COOLANT DetectsECTsensorsignal Withthe ignitionswitchON (ll):about0.1 4.8V
TFMPFRATURE SENSOR) ideoendino on enoinecoolanttemDerature)
9 BLU/BLK VTPSW(VTECOIL Detects VTEcoil pressure Withengineat low enginespeed:about0 .
PRFSSTIRF SWITCH) switch sional Wirhenoineat hiohenoinesoeed:battervvoltaqe
10 WHT/BLU ALTL(ALTEBNATOR L Detects L signal With ignitionswit'chON (ll):about0 V
alternator
SIGNAII Whh enoinerunnino:battervvoltaqe
WHT/RED ALTF(ALTERNATOR FR DeteclsalternatorFBsignal Withenginerunning:about0 V- 5 V
S I GN A L I {deoendinq load)
on electrical
GRN/YEL VTS {VTECSOLENOID DrivesVIECsolenoidvalve A t i d l e : a b o u t 0 V
'17 IAT(INTAKE With ignitionswitchON {ll):about0.1V 4.8v
DetectsIATsensorsignal
REDI/EL AIR
TEMPERATURE SENSOR) l.lcnen.iino on intakeairtemoerature)
18 WHT/GRN ALTC(ALTERNATOR control
Sendsalternator Withenginerunning:about0 V 5 V
CONTROL) (.lcocn.lino on electrical ioad)
21 YEUBLU PCS{EVAPORATIVE purge Withenginerunning,enginecoolantbelow149'F
DrivesEVAPcanister
EMISSIONCANISTER valve 165'C): batteryvoltage
PURGE VALVE) Withenginerunning,enginecoolantabove149'F
165"C): dutvcontrolled
23 BLK/Vr'HT VTC (VTCOILCONTROL DrivesVTCoilcontrol W i t h t h e i g n i t i o n s w i t c h O N ( l l ) :0 V
SOIFNOIDVALVE SIDE)
(confd)
11-21
SystemDescriptions(cont'dl L
ECMlnputsand Outputsat ConnectorE (31P}
1 2 3 4 6 8
iMo 1 I
sr-{]zsLG3 SG3 $1025 MRLY AFS
FPR HTC HTCR
14 15 16 18 20 21
FTP ELD EPS
LD ACC Z/VBS VSV
22 23 24 26 21 29 30 31
BKSWK-LINESEFMJ NEP rMo scs WEN MIL
CD
NOTE:Standardbatteryvoltageis '12V.
Terminal Wire color ferminal name Description Signal

number
GRNI/EL IMOFPR(IMMOBILIZER D r i v e s P G M F l m a i n r e l a y 2 0Vfor2 secondsafterturningignitionswitchON
FLJEL
PUMPRELAYI {ll).then battervvoltaoe
2 WHT/RED SHO2S(SECONDARY DetectssecondaryHO2S WiththrottleJullyopenedfrom idlewith fully
HEATEDOXYGENSENSOR {sensor2) signal warmedup engine:above0.6V
(SECONDARYHO2S), Withthrottlequicklyclosed:below0.4V
SENSOR2r
3 BRN/YEL LG3(LOGICGROUND) cround forthe ECM/PCM Lessthan1.0V at all times
4
5
PNK SG3{SENSOR
YEUELU VCC3{SENSOR
controlcircuit
GBOUND) Sensororound
VOLTAGE) Providessensorvoltage
Lessthan 1.0V at all times
With ignitionswitchON (ll):about5 V
u
With ionitionswitchOFF:about0 V
6 BLKATr'HT SO25HTC(SECONDARY Drivessecondary HO2S With ignitionswitch ON (ll):bafteryvoltage
HEATEDOXYGENSENSOR heater Wilh fullvwarmedup enginerunning:dul,
(SECONDARYH02S) controlled
HEATER
CONTROL)
1 REDA/EL MRLY(PGM.FI MAIN DrivesPGM-Flmain relay1 WithignitionswitchON (ll):about0 V
RELAY} Powersourceforthe DTC With ignitionswitchOFF:batteryvoltage
I ORN AFSHTCR {AIRFUELBATIO Drivesairfuel ratiosensor WithignitionswirchON {ll):0 V
(Iy'F)SENSORHEATER heaterrelay
CONTROLRELAY)
I YEUBLK IGl (IGNITION
SIGNAL) D e t e c r si g n i t i o n s i g n a l With ignition switch ON (ll): battery voltage
't4 With iqnition switch OFF: about 0 V
LT GRN FIP lFUELTANK DetectsFTPsensorsignal WithignitionswitchON (ll)andfuelfill capopen:
PRESSURE (FTP)SENSOR) about2.5V
GRN/RED ELD(ELECTRICAL LOAD DetectsELDsignal WithignitionswjtchON itt):aOoutO.t V l-gV
DETECTOF) (deDendino on electrical
load)
LTGRN/8LK EPSLD(ELECIRICAL DetectsPowersteeringload At idlewith steeringwheelin straightahead
POWEBSTEEBING LOAD srgnal position:about0 V
DETECT) At idlewith steeringwheelatfulllock:momentary
'18 RED ACC(Ay'C
CLUTCH
RELAY) DrivesP,/Cclutch relay Withcompressor ON:about0 V
With comoressorOFF:battervvoltaoe
\-
11-22
ECMInputsand Outputsat ConnectorE (31P)
l
2 i 6 1 I 9
t M o $.c2s SFIO2S
IVRLY
AFS
tGl
FPR HTC HTCR
14 15 16 t8 20 21
FTP ELD EPS 2,4/BS VSV
LD
22 23 24 26 21 29 30 31
BKSWK LINESEFMJ NEP lvo scs WEN MIL
CD
NOTE:Standardbatteryvoltageis 12V.
Terminal Wire color Terminalname Description Signal
20 BLU/RED 2WBS(EVAPORATIVE DrivesEVAPbypass WithignitionswitchON (ll):bafteryvoltage

EMISSION(EVAP)BYPASSsolenoidvalve
SOLENOID VALVE)
21 LT GRN/RED VSV (EVAPORATIVE DrivesEVAPcanistervent W i t h i g n i l i o n s w i t c h O N ( l l ) :b a t t e r y v o l t a g e
EI\4ISSION
iEVAP) shutvalve
CANISTEBVENTSHUT
VALVE)
22 WHT/BLK BKSWlBRAKEPEDAL Detects brake pedal With brakepedalreleased:
about0 V
POSITIONSWITCH) o o s i t i o ns w i t c h s i o n a l With hrake nedal nresse.l: batterv voltaoe
23 LT BLU K-LIN E Sendsand receives scan With ignitionswitchON (li)rpulsesor battery
YEL SEFMJ With ignitionswitchON (ll):about5 V

C o m m u n i c a t e sw i t h
mrltinleYeontrolunit Withenoinerunninounderload:DUlses
26 BLU N E P( E N G I NSEP E E D Outputsenginespeedpulse Withenginerunning:pulses
PULSE)
21 RED/BLU \40CDfl\4MOBTLTZER D e t e c t si m r n o b i l i z e rs i g n a l
CODE)
29 BRN S C S ( S E R V I C EC H E C K checksignalshortedwith the PGM
O e t e c t ss e r v i c ec h e c k s i g n a l Withthe service
SIGNAL) Tester:about0 V
Wiih rheservicechecksionalooened:about5 V
30 RED,A/VHT WEN(WRITEENABLE D e t e c t sw r i t e e n a b l e s i g n a l W i t h i g n i t i o n s w i t c h O N ( l l ) :a b o u t 0 V
SIGNALi
GRN/ORN MIL(MALFUNCTION DrivesN4lL WithMILturnedON:about0 V
LAMP)
INDICATOR WithMILturnedOFF:battervvoltaqe
(cont'd)
11-23
SystemDescriptions(cont'dl !
VacuumHoseRouting
INTAKEAIR
BYPASSCONTROL
THERMALVALVE
\*
FRONTOF
VEHICLE
EVAPORATIVEEMISSION
{EVAP}CANISTERPURGEVALVE
\,
11-24
VacuumHoseRouting
O AIRFUELRATIOIA/F)SENSOR {SENSOR 1} @ RESONATOR

O SECONDARY HEATED OXYGENSENSOR (9 AIRCLEANER
ISECONDARYHO2S}{SENSOR 2} VENTILATION{PCVIVALVE
@ POSITIVECRANKCASE
O MANIFOLD ABSOLUTE PRESSURE (MAPISENSOR @ THREE WAYCATALYTICCONVERTER
O ENGINECOOLANTTEMPERATURE {ECT)SENSOR @ EVAPORATIVEEMISSION{EVAPICANISTER
O INTAKEAIRTEMPERATURE (IAT)SENSOR @ EVAPORATIVEEMISSION{EVAP)CANISTER
O CRANKSHAFT POSITION (CKP)SENSOR PURGEVALVE
O KNOCKSENSOR EMISSION
{} EVAPORATIVE (EVAPICANISTER
O CAMSHAFT POSITION (CMPISENSOR B VENTSHUTVALVE
ITOPDEADCENTER ITDC)SENSOR) EMISSION
{' EVAPORATIVE {EVAP)TWOWAYVALVE
O CAMSHAFT POSITION ICMPISENSOR A @ EVAPORATIVEEMISSIONIEVAPIBYPASS
@ IDLEAIRCONTROL (IACIVALVE SOLENOIDVALVE
O THRONLEBODY @ FUELTANKPRESSURE (FTP)SENSOR
.OINJECTOR @ EVAPORATIVEEMISSIONIEVAP}VALVE
@ FUELPULSATION OAMPER @ FUELTANKVAPORCONTROL VALVE
[I FUELFILTER 60)FUELTANKVAPORRECIRCULATIONVALVE
@ FUELPRESSURE REGULATOR O INTAKEAIRBYPASSCONTROL THERMALVALVE
@ FUELPUMP
@ FUELTANK
(cont'd)
11-25
SystemDescriptions(cont'd)
PGM-FISystem CamshaftPosition(CMPISensorB (TopDeadCenter
(TDCISensor)
The ProgrammedFuel Injection(PGM-Fl)system is a TheCMPsensorB (TDCsensor)detectsthe positionof
sequentialmultiport fuel injectionsystem. the No.1 cylinderasa reference
for sequential
fuel
injectionto eachcylinder.
Air Conditioning {A/C) Compressor Glutch Relay
When the ECfMreceivesa demandfor coolingfrom the
Ay'Csystem,it delaysthe compressorfrom being
energized,and enrichesthe mixture to assuresmooth
transitionto the AVCmode.
Air Fuel Ratio lA/Fl Sensor

The Ay'FSensoroperatesover a wide airlfuel range.The
Ay'FSensoris installedupstreamof the TWC, and sends
signalsto the ECMwhich variesthe durationof fuel
MAGNET
injectionaccordingly.
SENSOR
TERMINALS
ztRcoNta Crankshaft Position (CKPISensor
ELEMENT
The CKPsensordetectscrankshaftsoeedand
determinesignitiontiming and timing for fuel injection
of each cylinderas well as detectingengine misfire.
HEATER
HEATER
TERMINALS
Barometric Pressure {BAROI Sensor

The BAROsensoris insidethe ECM.lt convens
atmosphericpressureinto a voltagesignalthat the ECM
usesto modify the basicdurationof the fuel injection
discharge. Engine Coolant Temperature (ECT)Sensor
The ECTsensoris a temperaturedependentresistor
(thermistor).The resistanceof the thermistordecreases
as the enginecoolanttemperatureincreases.
TERMINAL
\,
11-26
lgnition Timing Control MalfunctionIndicatorLamp lMlLl Indication{ln relation
The ECMcontainsthe memory for basicignitiontiming to ReadinessCodes)
"readinesscodes" that are part
at variousengine speedsand manifold absolute The vehiclehas certain
pressure.lt also adjuststhe timing accordingto engine of the on-boarddiagnosticsfor the emissionssystems.
coolanttemperature. lf the vehicle'sbafteryhas been disconnectedor gone
dead.if the DTCShave been cleared,or if the ECM has
Iniector Timing and Duration been reset.these codesare set to incomplete.In some
The ECM containsthe memory for basicdischarge states,part of the emissionstesting is to make sure
d u r a t i o na t v a r i o u se n g i n es p e e d sa n d m a n i f o l d these codes are set to comDlete.lf all of them are not
pressures.The basicdischargeduration,after being set to complete,the vehiclemay fail the test and the
read out from the memory, is further modified by test cannot be finished.
signalssent from varioussensorsto obtain the final
d i s c h a r g ed u r a t i o n . To checkif the readinesscodes are set to complete,
By monitoring long term fuel trim, the ECMdetectslong turn the ignition switch ON (ll). but do not startthe
term malfunctionsin the fuel systemand sets a e n g i n e . T h e M I L w ci lol m e o n f o r l S 2 0 s e c o n d sl f. i t
DiagnosticTrouble Code{DTC). then goes off, the readinesscodesare set to complete,
lf it blinksseveraltimes,one or more readinesscodes
Intake Air Temperature (lAT) Sensor are not set to comolete.To set each code, drive the
The IAT sensoris a temperaturedependentresistor v e h i c l eo r r u n t h e e n g i n ea s d e s c r i b e di n t h e
{thermistor).The resistanceof the thermistor decreases proceduresto set them in this section(seepage 11-46).
as the intakeair temDeratureincreases.
Manifold Absolute Pressure {MAP) Senso]
The MAP sensorconvertsmanifoldabsolutepressure
i n t oe l e c t r i c asl i g n a l st o t h e E C M .
SENSOR
UNIT
Knock Sensor
The knockcontrol system adjuststhe ignitiontiming to
minimizeknock.
PIEZO
CERAMIC
(cont'd)
11-27
SystemDescriptions(cont'dl (
Secondary Heated Oxygen Sensor (Secondary HO2S) Vehicle Speed Sensor (VSS)
The secondaryHO2Sdetectsthe oxygen content in the The VSS is driven by the differential.lt generatesa
exhaustgas downstreamof the three way catalytic pulsedsignalfrom an input of 5 volts.The number of
converter(TWC)and sendssignalsto the ECMwhich pulsesper minute increases/decreases with the speed
checksthe efficiencyof the TWC.To stabilizeits output, of the vehicle.
the sensorhas an internalheater.The secondarvHO2S
i s i n s t a l l e di n t h e T W C .
BEARING
ztRcoNta SENSOR
ELEMENT TERMINALS
HEATER
TERMINALS
Starting Control
When the engine is started,the ECM providesa rich
mixture by increasinginjectorduration.
(
Throttle Position ITP)Sensor
The TP sensoris a potentiometerconnectedto the
throttlevalve shaft.As the throttle positionchanges,the
sensorvariesthe signalvoltageto the ECM.The TP
sensoris not replaceableapart from the throftle body.
ELEMENT BRUSHHOLDER
gRUSH
11-28
wEc/wc
The i-WEC has a VTC (VariableValveTiming Control)mechanismon the intakecamshaftin additionto the usual
VTEC.
This mechanismimprovesfuel efficiencyand reducesexhaustemissionsat all Ievelsof engine speed,vehiclespeed.
a n d e n g i n el o a d .
The VTECmechanismchangesthe valve lift and timing by using more than one cam profile.
The VTCchangesthe phaseof the intakecamshaftvia oil pressure.lt changesthe intakevalve timing continuously.
HIGH
LOW<- ENGINESPEED
DrivinoCondition VTC Control DescriDtion

Qr Light-load B a s eP o s i t i o n Cam angle is retardedto reducethe entry of exhaust
gas into the intakeport and to achievestablefuel
c o n s u m D t i o dn u r i n ql e a nb ur n .
?l M edium/high-load AdvanceControl Cam angle is advancedfor EGReffectand to reduce
this pumping loss.The intakevalve is closedquickly
to help reducethe entry of airlfuel mixture into the
intakeport and improve the chargingeffect.
€) High speed Advance-BasePosition C a m p h a s ea n g l ei s c o n t r o l l e df o r o p t i m u mv a l v e
t i m i n qa n d m a x i m u me n o i n eo o w e r .
{cont'd)
11-29
SystemDescriptions(cont'dl (
VTC system
. The VTC system makescontinuousintakevalvetiming changesbasedon operatingconditions.
. Intakevalve timing is optimizedto allow the engineto producemaximum power.
'CamangleisadvancedtoobtaintheEGReffectandreducethepumpingloss.Theintakevalveisclosedquicklyto
reducethe entry of the airlfuel mixture into the intakeport and improvethe chargingeffect.
. Cam angle is reducedat idle to stabilizecombustionand reducesenginespeed.
' l f a m a l f u n c t i o n o c c u r s , t h e V T C s y s t e m c o n t r iosl d i s a b l e da n dt h e v a l v et i m i n g i s f i x e da t t h e f u l l y r e t a r d e dp o s i t i o n .
TDC
MAXIMUM VTCADVANCE50' MAXIMUM VTC ADVANCE50'
i l(-4 sHoRToVERLAP
'+-|l LoNGoVERLAP
VTEC system
' The VTECsystemchangesthe cam profileto correspondto enginespeed.lt maximizestorque at low enginespeed
and output at high engine speed.
. The low lift cam is used at low engine speeds,and the high lift cam is used at high enginespeeds.
LOWSPEEDVALVETIMING HIGHSPEEDVALVETIMING
11-30
System Diagram
CMPSENSORA
From No. il
ACC{10A)fuse
INTAKE BRN/YEL BLU/WHT

CAMSHAFT -:-
BLU/WHT VARIOUS
SENSORS
BLK/WHT
GRN/YEL
BLU/BLK
BLK
It
:5i.T,""
Camshaft Position {CMP}Sensor

The CMP sensordetectscamshaftangle positionfor the VTC system.
{cont'd}
11-31
(
SystemDescriptions(cont'd)
ldle Control System FuelSupply System
When the engine is cold, the Ay'Ccompressoris on, the Fuel Cut-off Control
transmissionis in gear,the brakepedal is pressed.the Duringdecelerationwith the throttle valve closed,
power steeringload is high, or the alternatoris currentto the injectorsis cut off to improve fuel
charging,the ECIMcontrolscurrentto the ldle Air economy at enginespeedsover 1,030rpm. Fuelcut-off
Control(lAC)valveto maintainthe correctidle speed. actionalso occurswhen enginespeedexceeds
Referto the System Diagramto seethe functional 6,900rpm, regardlessof the positionof the throttle
layout of the system. valve,to protectthe enginefrom over-rewing. When
the vehicleis stopped.the ECMcuts the fuel at engine
Brake Pedal Position Switch speedsover 6,500rpm.
The brakepedal positionswitch signalsthe ECMwhen
the brakepedal is oressed. Fuel Pump Control
When the ignition is turned on, the ECMgroundsthe
Electrical Power Steering (EPS)Senser PGM-Flmain relay which feeds currentto the fuel pump
The EPSsensorsignalsthe ECMwhen the power for 2 secondsto pressurizethe fuel system,With the
s t e e r i n gl o a di s h i g h . e n g i n er u n n i n gt.h e E C Mg r o u n d st h e P G M - Fm
l ain
relay and feeds currentto the fuel pump. When the
ldle Air Control llACl Valve engine is not running and the ignition is on, the ECI\4
To maintainthe proper idle speed,the IACvalve cuts ground to the PGM-Flmain relaywhich cuts
changesthe amount of air bypassingthe throttle body currentto the fuel pump.
in responseto an electricalsignalfrom the ECM.
PGM-FIMain Relay1 and 2
From AIR To INTAKE
CLEANER MANIFOLD The PGM-Flmain relay consistsof two separaterelays.
Relay1 is energizedwheneverthe ignition switch is ON
(ll)to supply batteryvoltageto the ECM power to the
{
injectors,and power for relay,Relay2 is energizedto
supply power to the fuel pump for 2 secondswhen the
i g n i t i o ns w i t c hi s t u r n e dO N ( l l ) ,a n d w h e n t h e e n g i n ei s
runnrng.
IAC VALVE
11-32
IntakeAir System Throttle Body
The throttle body is a single-barrelside draft type. lt
Referto the SystemDiagramto seethe functional housesthe TP senserand the IACvalve.The lower
layout of the system. portion of the IAC valve is heatedby enginecoolant
f r o m t h e c y l i n d e rh e a d .
Intake Air Bypass Control Thermal Valve
W h e nt h e e n g i n ei s r u n n i n g t, h e i n t a k ea i r b y p a s s
controlthermal valve sendsair to the iniectors,
IACVALVE
INJECTOR
{cont'd)
11-33
SystemDescriptions(cont'dl {
GatalyticConverterSystem PositiveCrankcaseVentilation (PCVISystem

ThreeWay CatalyticConverter(TWC) The PCVvalve preventsblow-by gassesfrom escaping
TheTWCconvertshydrocarbons (HC),carbon into the atmosphereby ventingthem into the intake
monoxide{CO),andoxidesof nitrogen(NOx)in the manifold.
exhaustgasto carbondioxide(C02),dinitrogen(N2),
andwatervaDor.
BREATHERPIPE
THREEWAY
CATALYST
FRONTOF
VEHICLE BLOW-BY
:: VAPOR
€: FRESH
AIR
11-34
Emission(EVAPIControl
Evaporative EVAP Two Way Valve and EVAP Eyp8s Solenoid
System Valve
The EVAPtwo way valve is installedbetweenthe fuel
Referto the SystemDiagramto see the functional tank and the EVAPcanisterline.
layout of the system. The EVAPtwo way valve sendsfuel vapor to the EVAP
canistercorrespondingto the pressureinsidethe tuel
EVAPCanister tank. lt also relievesexcessvacuum in the tank by
The EVAPcanistertemporarilystoresfuel vapor from allowingfresh air to be drawn into the tank through the
the fuel tank until it can be purged back into the engine EVAPcanister.
a n db u r n e d . The EVAPbypasssolenoidvalve opensto bypassthe
two way valve during the EVAPleakcheck.
EVAP Canister Purge Valve
When the enginecoolanttemperature is below 149'F EVAP BYPASS
SOLENOID VALVE
(65'C),the ECMturns off the EVAPcanisterpurge valve
which cuts vacuum to the EVAPcanister.
FuelTank Pressure (FTP)Sensor

The FTPsensorconvertsfueltank absolutepressure
into an electricalinputto the ECMduring the EVAPleak VALVE
cnecK.
SENSOR
UNIT
To FUELTANK
(cont'd)
11-35
SystemDescriptions(cont'dl \ {
ldle Control System Diagram

The idle speedof the engine is controlledby the ldle Air Control(lAC)varve:
'Aftertheenginestarts,theIACvalveopensforacertainamountoftime.Theamountofairisincreasedtoraisethe
i d l es D e e d .
. When the engine coolanttemperatureis low, the IACvalve is openedto obtain the properfast idle speed.The
amount of bypassedair is controlledin relationto enginecoolanttemperature.
INTAKE MANIFOLD IACVALVE AKEAIR DUCT

CLEANER
YEL/BLK ---< From

PGM.FI
BLK/ MAIN
REO RELAY
THROTTLEAODY
VARIOUS
SENSOnS
BLK
IntakeAir SystemDiagram
This systemsuppliesair for engine needs.A resonatorin the intakeair pipe providesadditionalsilencingas air is
drawn into the svstem.
THROTTLEAODY
VARIOUS
SENSORS
BLK
11-36
Emission(EVAPIControlDiagram
Evaporative
The EVAPcontrolsminimizethe amount of fuel vapor escapingto the atmosphere.Vapor from the fuel tanKrs
temporarilystoredin the EVAPcanisteruntil it can be purgedfrom the canisterinto the engine and burneo.
. The EVAPcanisteris purged by drawing fresh air through it and into a port on the intakemanifold.
The purgingvacuum is controlledby the EVAPcanisterpurge valve,which operateswheneverengine cootant
temperatureis above 149'F(65"C).
'WhenvaporpressureinthefueltankishigherthanthesetvalueoftheEVAPtwowayvalve,thevalveopensan
regulatesthe flow of fuel vapor to the EVAPcanister.
' D u r i n g r e f u e l i n g , t h e f u e l t a n k v a p o r c o n t rvoal l v eo p e n sw i t h t h e p r e s s u r ei n t h e f u e lt a n k ,a n d f e e d st h e f u e lv a D o r
to the EVAPcanister.
FUELTANK
VAPOR
FUELTANK SIGNALTUBE
VAPOR
RECIRCULATION
VALVE BLU/RED
BLK
FUELFILLCAP EVAP +
CANISTER
VENTSHUT
FUELTANK FUELTANK VALVE
From
VAPOR BLK/YEL --<No. 4 Acc
RECIRCULATION { 1 0A } f u s e
TUBE
EVAP
CANISTER
EVAPTWOWAY
VALVE
(cont'd)
11-37
SystemDescriptions(cont'd) I
ECM Circuit Diagram
CONNECTOi
mrrrrn
CMP SENSORB
(TDCSENSOn)
I-BRN/YEr-
\, a
11-38
wEc solENorD
_YEL/aLU __f
F=-1
-RED/aLK -----l
Hi I
|-GFN/YEL _l t_r I
I?SCNSOn
I
+
L!l
I ff:l_l
*'*"_-ll-t
I croz
-KnocK
l-
l
I SENSOn I
Y -l-
Ll]
wcoLcoNTnoL
SoLENO|OVAIVE
(cont'd)
11-39
SystemDescriptions(cont'dl \
ECMCircuitDiagram{cont'd)
-{ffi]
---1t-|
IATSENSOR
-{El
------l
ECTSENSOS
T_""",,..
I-BFN/YEL
CMPSENSOAA
L- IJUNCTION
I CONNECTOR
-
ft^--l
, " , " . , J | t -' :
I REVERSE
I LocK
I soleloto
+ vaLvE
t!j]]
11-40
_1ffi1
----1 | |Fahdl
-'- |
G8N
t ,
I l -r l
'--r- '8r-K-L-| | T
l
BLU/
J.-
HcoNNEcroR
-l .lurcrroru
L9l
F
EVAPCANISTEB
ALK/YEL
WHT/ALU
WHT/NED
WHI/GRN
JUNCTION
CONNECTOR
rrrn
tcM PLUG
N o . 2 I G N I T I O NC O l t
PLUG
No.3IGNITION COIL
(cont'd)
11-41
SystemDescriptions(cont'd) a
ECMCircuitDiagramlcont'dl
YEI/BLK
IGP2
VET/BLK
---rF-rl
-lF-forl
--JliD\l
--t-l
MAIN BETAV2
a
t_,", :t
l-,r'l r,
-,u-
I SENSOS
f-"'*'o""
tr
IMMOAIL|zERUNIT
a
11-42
SECONDAFY
H02S
(s€NsoR2l
m
tlil
TPS€NSOR
'--{=l
-{r I
CANISTERVEAIT
SHUTVALVE
t-_]
--lti l
EVAP EYPASS
solENorD
To€PS
CONTROLUNIT
CPU
GAUGE ASSEMBTY
(cont'd)
11-43
SystemDescriptions(cont'dl L
ECMCircuitDiagram(cont'd)
UNDER.HOOD
!
FUSE/RELAY9OX
CONN€CTOF
CONNECTOi
WHI/NED
BLK/YET
lalLREllY_ _l
a
11-44
CONNECTOR
E
""rr"a*J
r''lHr/cnN
I
1
CONNECTOiK
IGNITIONSWITCH
lG2
' I
CONNECTOFJ
/GRN
TEST
TACHOMETER
CONNECTO8
UNDER.HOOD
UNDER.DASH
FUSE/FELAYBOX
UNDER.DASH
FUSE/RELAY BOX: POStTtONSWTTCH
4 ACG (1oAt ,or"-9J3{51
1 tGN CO|Lt15A)
2 A/F HEATER{2OA) re* _{F "_.rl
17 FUELPUMPI15A}
1OMETER{7.5AI Brake pedal pressed: closed
14 A/C CLUTCHRELAY{1OA} Brake pedal releasedropen
11-45
How to Set ReadinessCodes L
MalfunctionlndicatorLamp(MlL)Indication CatalyticConverterMonitorand Readiness
(ln relationto Readiness
Codesl Code
The vehiclehas certain"readinesscodes" that are part NOTE:
of the on-boarddiagnosticsfor the emissionssystems. . Do not turn the ignition switch off during the
lf the vehicle'sbatteryhas beendisconnectedor gone procedure.
dead,if the DTCShave beencleared,or if the ECM has . All readinesscodes are clearedwhen the batteryis
been reset,these codesare set to incomplete.In some disconnectedor when the ECM is clearedwith the
states,part of the emissiontesting is to make sure these OBD ll scantool or HondaPGlvlTester.
codesare set to complete.lf all of them are not set to . Low ambienttemperaturesor excessiveslop-and-go
complete,the vehiclemay fail the emissiontest, or the traffic may increasethe drive time neededto switch
test cannot be finished. the readinesscode from incompleteto complete.
' The readinesscode will not switchto com Dleteuntil
To checkifthe readinesscodesare complete,turn the a l l t h e e n a b l ec r i t e r i aa r e m e t .
ignitionswitch ON (ll), but do not startthe engine.The . lf a fault in the secondaryHO2Ssystemcausedthe
MIL will come on for 15 20 seconds.lf it then goes off, MIL to come on. the readinesscode cannot be set to
the readinesscodesare complete.lf it blinksseveral comDleteuntil vou correctthe fault.
times, one or more readinesscodes are not complete.
To set readlnesscodesfrom incompleteto complete. EnableCriteria
do the procedurefor the appropriatecode. . E C Ta t 1 5 8 " F( 7 0 ' C )o r h i g h e r .
. I n t a k ea i r t e m p e r a t u r e
( l A T )a t 2 0 " F( - 7 ' C ) o r h i g h e r .
. Vehiclespeed is steady,and vehiclespeedsensor
( V S S )r e a d sm o r et h e n 2 5 m p h ( 1 3 k m / h ) .
Procedure
1 . C o n n e ctth e s c a nt o o l t o t h e v e h i c l e ' sd a t al i n k \
c o n n e c t o(rD L C i a, n d b r i n gu p t h e t o o l ' sg e n e r i c \"
O B Dl l m o d e .
2 . Startthe engine.
3 . Test-drivethe vehicleunder stop-and-goconditions

with short periodsof steadycruise.After about
5 miles (3 km),the readinesscode should switch
from incompleteto complete.
lf the readinesscode is still set to incomplete,check

for a temporary DTC.lf there is no DTC,one or
more of the enablecrlteriawere probablynot met;
11-46
EvaporativeEmissions(EVAP)Control Air FuelRatio(A/FlSensorMonitorand
SystemMonitor and Readinesscode ReadinessCode
NOTE: NOTE:
All readinesscode are clearedwhen the batterVis . Do not turn the ignitionswitch off during the
disconnectedor when the ECM is clearedwith the orocedure.
OBD ll scantool or HondaPGM Tester. . All readinesscodesare clearedwhen the bafteryis
The enablecriteriamust be repeatedif the intakeair disconnectedor when the ECM is clearedwith the
temperature(lAT)drops lower than 36'F (20"C)from OBD ll scantool or Honda PGM Tester.
i t s v a l u ea t e n g i n e$ a n u p .
EnableCriteria
EnableCriteria ECTat 140'F(60"C)or higher.
At enginestart up, ECTand IAT are higherthan 32'F
(0"C), but lower than 95'F (35"C). Procedure
At enginestart up, the ECTand IAT are within 12'F 1. Connectthe scantoolto the vehicle'sdata link
(7'C)of each other. connector(DLC),and bring up the tool's generic
O B Dl l m o d e .
Procedure
1. Connectthe scantool to the vehicle'sdata link 2. Start the engine.
connector(DLC),and bring up the tool's generic
O B Dl l m o d e . 3. Test-drivethe vehicle under stop-and-goconditions
with short periodsof steadycruise.Duringthe
2. Startthe engine. drive, decelerate(wirh the throttlefully closed)for
5 seconds.After about 3.5 miles (2.2km).the
3. Test-drivethe vehicleunder stop-and-goconditions readinesscode should switch from incomDleteto
with short periodsof steadycruise.After about complete.
2 . 5m i l e s( 1 . 6k m ) ,t h e r e a d i n e scso d es h o u l d
switchf rom incompleteto complete. 4 . l f t h e r e a d i n e s s c o d e i s s t isl le tt o i n c o m p l e t ec,h e c k
for a temporary DTC.lfthere is no DTC,the enable
4. lf the readinesscodeisstill setto incomplete,check criteriawas probablynot meU repeatthe procedure.
for a temporaryDTC.lf there is no DTC,one or
more of the enablecriteriawere probably not met; Air/FuelRatio(A/FlSensorHeaterMonitor
repeatthe procedure. ReadinessCode
NOTE;All readinesscodes are clearedwhen the battery
is disconnectedor when the ECM is clearedwith the
OBD ll scantool or HondaPGM Tester,
Procedure
'1.
Connectthe scantool to the vehicle'sdata link
connector{DLC),and bring up the tool's generic
O B Dl l m o d e .
2. Startthe engine,and let it idle for 1 minute.The

readinesscode should switch from incompleteto
comDlete.
3. lf the readinesscode is still set to incomplete,check

for a temporary DTC.lf there is no DTC,repeatthe
proceoure.
(cont'd)
11-47
How to Set ReadinessCodes(cont'd) \-
MisfireMonitorand Readiness
Code
. This readinesscode is alwaysset to available
becausemisfiring is continuouslymonitored.
. l\4onitoringpauses,and the misfirecounterresets,if
the vehicleis driven over a rough road.
. Monitoringalso pauses,and the misfire counter
holds at its currentvalue.if the throttle position
changesmore than a predeterminedvalue,or if
driving conditionsfall outsidethe rangeof any
relatedenablecriteria,
FuelSystemMonitorand Readiness
Code
. This readinesscode is always setto available
becausethe fuel system is continuouslymonitored
during closedloop operation.
. Monitoringpauseswhen the catalyticconverter,
EVAPcontrol system,and Ay'Fsensor monitorsare
active.
. Monitoringalso pauseswhen any relatedenable
criteriaare not being met. Monitoring resumeswhen
lhe enablecriteriais again being met.
Readiness
Code
ComponentMonitorand
Comprehensive
This readinesscode is always set to availablebecause

L a
the comprehensivecomponentmonitor is continuously
r u n n i n gw h e n e v e tr h e e n g i n ei s c r a n k i n go r r u n n i n g .
a
11-48
PGM-FISystem
CAMSHAFTPOS]TION{CMP)SENSORB
(TOPDEAD CENTER(TDC}
SENSORI
Troubleshootina.
oaoe 11-95
p;ge 1-1.1
Replacement, 14
ii'- r'1
ELECTRICAL LOAD
.I11---:,I DETECTOR {ELDI
''.!,i(..,.?:fir-J- Troubleshooting,
page1'l-92
.....,..:--.
INTAKEAIRTEMPERATURE
{IATISENSOR
Troubleshooting,
page'l'l-55
Replacement, page11-'l15
f - \
ENGINECOOLANTTEMPERATURE
r l (ECTISENSOR
Troubleshooting, page11-57
R e p l a c e m epnat ,g e1 11 1 4
MANIFOLD ABSOLUTEPRESSURE
(MAP)SENSOR
page11-52
Troubleshooting,
THROTTLEPOSITION
ITP}SENSOR
CRANKSHAFTPOSITION page11-60
Troubleshooting,
ICKPISENSOR KNOCKSENSOR
page'l1-78
Troubleshooting, Troubleshooting, page11-77
page 11-'l16
Beplacement, B e p l a c e m epnat ,g e1 11 1 5
AIR FUELRATIO{A/F)
SENSORISENSOR1}
page 11-84
Trorrbleshooting,
{cont'd)
11-49
PGM-FlSystem
ComponentLocationIndex(cont'd) \
\.,
11-50
'}
DATALINKCONNECTOR IDLCI
Information,page 1l 3
PGM.FIMAINRELAY1
page11-97
Troubleshooting,
ENGINECONTROLMODULE
GeneralTroubleshooting Information,
p a g e1 1 3
page I 1-96
Troubleshooting,
11-51
PGM-FISystem
DTCTroubleshooting \ (
DTCP0107:
MAPSensorCircuitLowVoltage ls there about 5 V?
1 . T u r nt h e i g n i t i o ns w i t c hO N ( l l i . YES-Repair open in the wire betweenthe Eclvl

( A 2 1 ) a n dt h e M A P s e n s o r . l
2. Checkthe MAP with the scantool.
NO Updatethe ECMif it does not havethe latest
ls about 101kPa (760 mmHg,30 in.Hg)or 2.9 V software,or substitulea known-goodECM,then
indicated? recheck(seepage 'l1-6).lf the symptom/indication
goes away with a known-goodECfvl,replacethe
YES Intermittentfailure, system is OK at this time. originaE
l CM.I
Checkfor poor connectionsor looseterminalsat
t h e M A P s e n s o ra n d a t t h e E C M . I 8 . Checkthe MAP with the scantool.
N O - G o t o s t e p3 . ls 2 kPa (15 mmHg,0.6 in.Hg) ot lessor 0 V

indicated?
YES-Go to step 9.
4. Disconnectthe MAP sensor3P connector.
NO Replacethe lvlAPsensor.l
5 . T u r nt h e i g n i t i o ns w i t c hO N ( l l l .
9 . Turn the ignitionswitch OFF.
6. lvleasurevoltage betweenMAP sensor3P
'10.Disconnect
c o n n e c l o tre r m i n a l sN o . 1 a n d N o . 3 . ECMconnectorA (31P).
MAP SENSOR3P CONNECTOF 1 1 .Checkfor continuitybetweenMAP sensor

connectorterminal No. 2 and body ground. (
\
MAP SENSON3P CONNECTOA
sGl
{GRN/WHTI
Wires de of femaleterminais
ls there about 5 V?
YES Go to step8.
YES-Repair short in the wire betweenthe ECM
1 . Measurevoltage betweenEClvlconnector ( A 1 9 )a n d t h e M A P s e n s o r . l
t e r m i n a l s4 1 1 a n d 4 2 ' 1 .
NO Updatethe ECM if it does not have the latest
ECM CONNECTOR
A 13'IP} software,or substitutea known-goodECM,then
recheck(seepage 11-6).lf the symptom/indication
goes away with a known-goodECM,replacethe
vccr o r i g i n aE
l CM.I
{YEL/BED)
sGr
{GRN/WHT}
Wire side of female terminals (
11-52
DTCP0108:MAPSensorCircuitHighVoltage 9. MeasurevoltagebetweenMAPsensor3P
terminalsNo.1 andNo.3.
connector
'1.
Startthe engine.Holdthe engine at 3,000rpm with
no load (in neutral)until the radiatorfan comes on, MAP SENSOR3PCONNECTOF
then let it idle.
vccl
{ Y E L / Rl E
, lD
o) cl
2. Checkthe MAP with the scantool. l . l . r l
I lsct
le about 101kPa (780 nmHg, 30 in.Hg)ot highet, d) l{GRN/wHrr
or about2.9 V or higher indicated? Y i
Il
l l
YES Go to step 3.
W i r es i d eo f f e m a l el e r m i n a l s
NO-lntermittent failure,system is OK at this time.
the MAP sensorand at the ECM.I ls there about 5 V?
3. Turn the ignitionswitch OFF. YES Go to step 10.
4. DisconnecttheMAP sensor3P connector. NO Repairopen in the wire betweenthe ECM

(A11) and the MAP sensor.I
5, ConnectMAP sensor3P connectorterminalsNo. 2
and No. 3 with a jumper wire. 1 0 .Turn the ignitionswitch OFF.
MAP S€NSOR3P CONNECTOR t C Mc o n n e c t otre r m i n a l sA 1 1 a n d A 1 9

1 1 .C o n n e c E
with a jumper wire.
A {31PI
ECMCONNECTOR
1 2 3
MAP
{GRN/REO} SG1(GRN/WHTI
JUMPER
WIRE
J U M P E RW I A E
Wire side of fema e te.minals
6. Turn the ignition switch ON (ll).

T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
7. Checkthe MAP with the scantool.
Checkthe MAP with the scantool.
ls about 101kPa (760 mmHg,30 in.Hg) ot higher,
or about2.9 V or higher indicated? ls about 101kPa (760 mmHg,30 in.Hg)or higher,
or about2.9 V ot higher indicated?
YES-Go to step 8.
YES Updatethe ECM if it does not have the lalest
NO Replacethe MAP sensor.I software,or substitutea known-goodECM,lhen
8 . R e m o v et h e j u m p e rw i r e . goes away with a known good ECM,replacethe
originaE
l CM.I
NO-Repair open in the wire betlveenthe ECI\il

( A 1 9 )a n dt h e M A P s e n s o r . I
11-53
PGM-FISystem
DTCTroubleshooting(cont'dl \
DTCPl128:MAPSensorSignalLowerThan DTCPl129:MAPSensorSignalHigherThan
Expected Expected
1. Turn the ignition switch ON (ll). 1. Startthe engine.Hold the engineat 3,000rpm with
no load (in neutral)until the radiatorfan comes on,
2. Checkthe MAP with the scantool. then Iet it idle.
ls 54.1 kPa(406mmHg, 16.0in.Hg),1.6 V, or 2. Checkthe MAP with the scantoot.

higher indicated?
ls 36.9 kPa (277 mmHg, 10.9 in.Hg),1.1 V , or less
YES- Intermittentfailure.system is OK at this indicated?
time.I
YES- lntermittentfailure,system is OK at this
NO Replacethe MAP sensor.l time.l
NO Replacethe MAP sensor.l
\ a
11-54
IATSensorCircuitLowVoltage
DTCP0112: 8. Checkthe temperaturereadingon the scantool.
Be aware that if the engine is warm, the reading
1 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) . w i l l b e h i g h e rt h a n a m b i e n t e m p e r a t u r el I. t h e
engine is cold, the IAT and ECTwill have the same
2. Checkthe IAT with the scantool. v al u e .
ls 302'F (150'C) or highet (or H-Limit in Honda ls the correct ambient temperatureindicated?
node of PGM Tester),ot 0 V indicated?
YES lntermittentfailure,system is OK at this time
VES-Go to step 3. Checkfor poor connectionsor looseterminalsat
t h e I A Ts e n s o ra n d a t t h e E C M . I
NO Go to step 8.
NO Replacethe IAT sensor.l
Disconnectthe IAT sensor2P connector.
4 . Checkthe IAT with the scantool.
ls 302'F(150'C)or higher (or H-Limit in Honda

mode of PGM Testet),ot 0 V indicated?
YES-Go to step 5.
NO- Replacethe IAT sensor.I
7 . Checkfor continuitybetweenIAT sensor2P

c o n n e c t otre r m i n a lN o . 2 a n d b o d y g r o u n d ,
IAT SENSOR2PCONNECTOR
,^\
,
l r 2 l
t
-----Tr--- - l
IAT
_t{RED/YELI
II
W i r es i d eo f f e m a l et e r m i n a i s
YES Repairshon in the wire betweenthe ECM

( B ' 1 7a) n d t h e I A Ts e n s o r . l

software,or substitutea known-goodECM,then
originaE
l CM.I
11-55
PGM-FISystem
DTCTroubleshooting(cont'dl \ I
DTCP0113:
IATSensorCircuitHighVoltage 7. Checkthe IAT with the scantool.
1. Turnthe ignitionswitchON (ll). ls - 4"F ( 20'C) or less(or L-Limitin Honda

mode ot PGM Tester) or 5 V indicated?
2. Checkthe IATwith the scantool.
YES Go to step 8.
ls 4'F (-20'C) or less(or L-Limitin Honda
modeot PGM Tester)or 5 V indicated? NO - Replacethe IAT sensor.l
YES-Go to step 3. 8. Turn the ignition switch OFF.
NO Intermitentfailure,system is OK at this time. 9 . R e m o v et h e j u m p e rw i r e .

the IAT sensorand at the ECM.I 1 0 . C o n n e cE t C Mc o n n e c t otre r m i n a l sA 1 0 a n d 8 1 7
w i t h a j u m p e rw i r e .
ECM CONNECTORS
4. Disconnectthe IAT sensor2P connector.
A (31 P) B {24 P)
ConnectIAT sensor2P connectorterminalsNo. 1
a n d N o . 2 w i t h a j u m p e rw i r e .
IATSENSOR
2PCONNECTOR
:--- JUMPERWIRE
rJ-- \" {
l ' l L l
-'_-l--_----r--_
sG2 I rAT Wiresideof femaleterminals
{GRN/YEL) IRED/YEL)
I
L ] 1 1 .T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
JUMPER WIRE
12. Checkthe IAT with the scantool.
ls - 4"F ( 20"C) or less (or L-Limitin Honda
mode of PGM Tester) or 5 V indicated?
YES Updatethe ECMif it does not have the latest
software,or substitutea known-goodECI\4then
goes away with a known-goodECM.replacethe
originaE
l C M !.
NO Repairopen in the wire betweenthe ECM

( A 1 0 ,8 1 7 )a n dt h e I A Ts e n s o r . I
(
\
11-56
DTCP0116:ECTSensorRange/Performance
Problem
NOTE:lf DTCP0117and/or P0118are storedat the
same time as DTCP0116,troubleshootthose DTCSfirst,
then recheckfor DTCP0116,
1. Stanthe engine.Hold the engineat 3,000rpm with

no load {in neutral)until the radiatorfan comes on,
then let it idle.
2. Checkthe ECTwith the scantool.
ls 176- 212'F (80 100"C)or0.5 0.8V

indicated?
YES Intermittentfailure.system is OK at this time.

Checkthe thermostatand the cooling system.l
NO-Checkthe thermostatand the cooling system.

lf they are OK, replacethe ECTsensor.l
11-57
PGM-FISystem
DTCTroubleshooting(cont'dl \ (
DTCP0117:ECTSensorCircuitLow Voltage 7. Checkfor continuitybetweenthe ECTsensor2P

connectorterminal No. 1 and bodv oround.
ECTSENSOR2PCONNECTOR
ls 150'C (302'F)or higher (ot H-Limit in Honda

mode of PGM Tester) or 0 V indicated?
YES Go to step 3.
NO Intermittentfailure,system is OK at this time.

the ECTsensorand at the ECM.t
3. Disconnectthe ECTsensor2P connector.
4. Checkthe ECTwith the scantool. ls there continuity?
ls 150'C (302"F)or higher (ot H-Limit in Honda YES-Repair short in the wire betweenthe ECM
mode ot PGM Tester) or 0 V indicated? ( B 8 )a n d t h e E C Ts e n s o r . l
YES-Go to step 5. NO-Update the ECMif it does not havethe latest

software,orsubstitutea known-goodECM,then
NO Replacethe ECTsensor.! recheck{seepage 11-6).lf the symptom/indication
goes away with a known-goodEClvl,replacethe (
5. Turn the ignition switch OFF. originaE
l CM.I
6. DisconnectECMconnectorB (24P).
11-58
ECTSensorCircuitHighVoltage
DTCP0118: 1 . Checkthe ECTwith the scantool.
1 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) . ls 20"C ( 4"F)or less (or L-Limitin Honda

mode ot PGM Tester) or 5 V indicated?
YES-Go to step 8.
ls 20'C ( 4'F)or less(or L-Limitin Honda
mode of PGM Tester) or 5 V indicated? t h e E C Ts e n s o r . I
NO Replace
YES Go to step 3. 8 . Turn the ignition switch OFF.
NO lntermittentfailure,system is OK at this time. 9 . R e m o v et h e j u m p e rw i r e .

the ECTsensorand at the ECM.I 1 0 . ConnectECMconnectorterminalsA10 and Bg with
a j u m p e rw i r e .
? Turn the ignitionswitch OFF.
ECM CONNECTORS
Disconnectthe ECTsensor2P connector.
a {31P} B {24P)
5 . Connectthe ECTsensor2P connectorterminals
N o . 1 a n d N o . 2 w i t h a j u m p e rw i r e .
ECTSENSOR2P CONNECTOR
\ JUMPERWIRE
lt tt .l t l l
-I-l*,
Ecr Wiresideof femaleterminals
(RED/WHT) {GRN/YEL)
t l 1 1 .T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
WIRE
JUMPER
1 2 . Checkthe ECTwith the scantool.
wire sideoI Iemaleterminals
ls 20"C ( 4"F) or less (or L-Limitin Honda
mode of PGM Tester) ot 5 V indicated?
6 . T u r nt h e l g n i t i o ns w i t c hO N ( l l ) .
YES- Updatethe ECM if it does not havethe latest
software,or substitutea known-goodECI\4,then
recheck(seepage 11-6).If the symptom/indication
o r i g i n aE
l CM.I

( A 1 0 ,8 8 ) a n d t h e E C Ts e n s o r . l
11-59
PGM-FISystem
DTCTroubleshooting(cont'dl
DTCP0122:TP SensorCircuitLowVoltage 8. At the sensorside, measureresistancebetweenthe
TP sensor3P connectorterminalsNo. 1 and No. 2
1 . T u r nt h e i g n i t i o ns w i t c ho N ( 1 1 1 . with the throttlefully closed.
2. Checkthe throttle positionwith the scantool.

TP SENSOR3P CONNECTOR
ls there about 10./.or 0.5 V when the thrcttle is
fully closed and about 90% or 4.5 V when the
throttle is fully opened?
YES Intermittentfailure,system is OK at this time.

the TP sensorand at the ECM.t
NO Go to step 3.
T e r m i n as li d eo f m a l et e r m i n a l s
3. Turn the ignition switch OFF,
4. Disconnectthe TP sensor3P connector. Is there about 0.5 0.9 kQ ?
5 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) . YES Go to step 9.
6. Measurevoltagebetweenthe TP sensor3P NO Replacethe throttle body (theTP sensoris not

connectorterminals No. 1 and No. 3. a v a i l a b l es e p a r a t e l yI) .
TP SENSOR3P CONNECTOR 9 . Measureresistancebetweenthe TP sensor3P

connectorterminalsNo. 2 and No. 3 with the \
throttlefully closed.
TPSENSOR
3PCONNECTOB
ls thereabout5 V?
Terminalsideof maleterminals
YES-Go to step7.
N O G ot o s t e p1 4 . ls there about 4.5k{l ?
1 . Turnthe ignitionswitchOFF. YES Go to step 10.
NO Replacethe throttle body (theTP sensoris not

a v a i l a b l es e p a r a t e l yI) .
r (31P).
1 0 . D i s c o n n e cEt C Mc o n n e c t oA
11-60
11. At thewire harnessside,checkfor continuity 13. At thewire harnessside,checkfor continuity
betweenTPsensor3Pconnector terminalNo,2 betweenTPsensor3Pconnector terminalNo.2
a n db o d yg r o u n d . a n db o d yg r o u n d .
TP SENSOR3P CONNECTOR TP SENSOR3PCONNECTOR
11 2 1 3 1 2 3
'PS TPS
(RED/BLX}
REO/BLKI
Wire sideof female terminals

Wire side ot Iemaleterminals
ls thetecontinuity?
YES-Update the ECM if it does not have the latest
YES-Repairshortin the wire betweenthe ECM software,or substitutea known-goodECM,then
{ A 1 5a) n dt h eT Ps e n s o r . l l recheck(seepage 11-6).lf the symptom/indication
N O - G o t o s t e p1 2 . originaE
l CM.I
12. ConnectECMconnector terminalA15to body NO- Repairopen in the wire betweenthe ECM
groundwith a jumperwire. ( A 1 5 )a n d t h e T P s e n s o r . l
A 131P)
ECMCONNECTOR 14. lvleasurevoltage betweenECMconnector
t e r m i n a l s4 1 0 a n d A 2 0 .
1 1 2 1 34 5 6 7 9 A 131P}
ECMCONNECTOB
10 1 1 1 1 2 t c 6 19
8 t2021
23124 28129130
wrne
,tf$,rr*, ];uueen
vcc2
(YEL/8LU)
Wire side oJ.femaleterminals
Wire side of female terminals
ls there about 5 V?
YES Repairopen in the wire betlveenthe ECM

( A 2 0 )a n d t h e T P s e n s o r . I
NO Updatethe ECM if it does nor have the latest

software,or substilutea known-goodECM,then
r e c h e c k( s e ep a g e11 - 6 ) l.f t h e s y m p l o m i n d i c a t i o n
goes away with a known-goodECM.replacelhe
originaE l CM.I
11-61
PGM-FISystem
DTCTroubleshooting(cont'd) (
DTCP0123:
TPSensorCircuitHighVoltage 7. Measurevoltage betweenECMconnector
terminalsA10 and A20.
1 . T u r nt h e i g n i t i o ns w i t c ho N ( l l )
ECMCONNECTOR
A 131PI
2. Checkthe throttle positionwith the scantool.
ls there about 10%or 0.5 V when the throttle is

fully closed and about 90% or 4.5 V when the
throttle is f ully opened?
YES lntermittentfailure.system is OK at this time.

t h e T P s e n s o ra n d a t t h e E C M I,
NO Go to step 3. Wiresideof femaleterminals

Is there about 5 V?
4. Disconnectthe TP sensor3P connector.
YES- Repairopen in the wire betweenthe ECM
5 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) . (A10)and the TP sensor.t
6. At the wire harnessside, measurevoltage between NO Updatethe ECMif it does not havethe latest
the TP sensor3P connectorterminalsNo. 1 and soflware,or substitutea known-goodECM,then
No.3. recheck(seepage 11-6).lf the symptom/indication
goes away with a known-goodECM,replacethe (
TP SENSOR3P CONNECTOR o r i g i n aE
l CM.I
W;resideof femaleterminals
ls thete about 5 V?
YES-Replace the throttle body (theTP sensor is

not availableseparately).
I
NO Go to step 7.
11-62
DTCPl121:TPSensorSignalLowerThan SensorSignalHigherThan
DTCP1122:.fP
Expected Expected
1 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) . 1 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
2. Checkthe throttle positionwith the scantool. 2. Checkthe throttle positionwith the scantool.
ls 12.9'/.,0.6 V, or higher indicated when the ls 12.9%,0.6 V, or lessindicated when the throttle
throttle is tully opened? is f ully closed?
YES- Intermittentfailure,system is OK at this YES Intermittentfailure,system is OK at this

time.I time.l
NO-Replace the TP sensor(the TP sensor is not NO Replacethe TP sensor(theTP sensoris not

availableseparately).
I availableseparately).
I
11-63
PGM-FISystem
(cont'dl
DTGTroubleshootang \ a
DTCP0128:CoolingSystemMalfunction 3. Checkthe radiatorfan.
Does the tadiator fan keep running?

NOTE;lf the DTCSlistedbelow are stored at the same
time as DTCP0128.troubleshootthose DTCSfirst, then YES Checkthe radiator fan circuit(seepage 10-
recheckfor P0128. 14),the radiatorfan switch circuit(Short)(seepage
10-'16), and the radiatorfan switch (seepage 10-17).
P 0 1 0 7P, 0 1 0 8P, 1 1 2 8P , 1 1 2 9N : 4 a n i f o ladb s o l u t e Also, inspectthe ECTand IAT circuitsand terminal
pressure(MAP)sensor connections.lf the circuits,the switch,and the
P] I06, P1107,P1108:Barometricpressure(BARO) connectionsare OK, updatethe ECI\4if it does not
sensor have the latestsoftware.or substitutea known-
P1259:VTECsystem good ECM,then recheck(seepage 11-6).lf the
P0116,P0117, P0118:Enginecoolanttemperature(ECT) symptom/indicationgoes away with a known-good
sensor E C M ,r e p l a c et h e o r i g i n a E
l CM.I
P0112,P0113: Intakeair temperature(lAT)sensor
P0500:Vehiclespeedsensor{VSS) NO Replacethe thermostat(seepage 10-8).1
P0335,P0336:Crankshaftposition(CKP)sensor
P0300:Randommisfire
P 0 3 0 1P, 0 3 0 2P, 0 3 0 3P , 0 3 0 4N : o . 1 ,N o .2 , N o . 3 o r N o . 4
cylinder misfire
P0505:ldle control system malfunction
P 1 5 1 9l:d l ea i r c o n t r o l( l A C ) v a l v e
DTCP0128can occasionallyset when the hood is

o p e n e dw h i l e t h e e n g i n ei s r u n n i n g .
1. Checkthe enginecoolant level
Is the engine coolantlevel low?
VES Refillthe enginecoolant.lf necessary,repair

t h e c o o l a n tl e a k a g e . l
NO Go to step 2.
2 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d m a k es u r et h e
A,/Cis off.
11-64
DTCP0134:Ay'FSensor(Sensor1) No Activity DTCP0137: HO2S(Sensor
Secondary 2)
Detected CircuitLowVoltage
1. Checkthe attachmentstateof the A,/Fsensor 1 . R e s e t h e E C M( s e ep a g eI 1 - 4 )
( S e n s o r1 ) .
2. Start the engine.Holdthe engine at 3,000rpm wilh
ls it slacked f rom the exhaust pipe? no load (in neutral)until the radiatorfan comes on.
YES- Reinstallthe Ay'Fsensor(Seneor1) (seepage 3. Checkthe secondaryHO2S(Sensor2) output

11-113).t voltageat 3,000rpm with the scantool.
NO-Go to step 2. ls there 0.3 V or less?
2 . R e s e t h e E C M( s e ep a g e11 - 4 ) . YES Go to step 4.
3 . S t a nt h e e n g i n e H
. o l dt h e e n g i n es p e e da t NO-lntermittent failure,system is OK at this time.
3,000rpmwith no load (in neutral)until the radiator Checkfor poor connectionsor looseterminalsat
fan comes on, then let it idle for 2 minute. the secondaryHO2S(Sensor2) and at the ECM.I
ls DTC PO134 indicated? 4. T u r nt h e i g n i t i o ns w i t c hO F F .
YES-Replacethe Ay'Fsensor{Seneor1) (seepage 5 . Disconnectthe secondaryHO2S(Sensor2) 4P

11-113).t connector.
NO - Intermittentfailure, sistem is OK at this time. 6 . Turn the ignition switch ON (ll).

the Ay'Fsensor(Seneor1) and the ECM.I 7 . Checkthe secondaryHO2S(Sensor2) output
voltagewith the scantool.
ls there 0.3 V or less?
YES Go to step 8.
t h e s e c o n d a r yH O 2 S( S e n s o 2
NO Replace r ).1
r (31P).
9 . D i s c o n n e cEt C Mc o n n e c t oE
icont'd)
11-65
PGM-FISystem
DTCTroubleshooting(cont'dl a
10. Checkfor continuitybetweenthe secondaryHO2S DTCP0138: HO2S(Sensor
Secondary 2)
(Sensor2) 4P connectorterminal No. 2 and body CircuitHighVoltage
ground.
1 . R e s e t t h eE C M{ s e ep a g e ' 1 1 - 4 ) .
SECONDARY H02S
2) 4PCONNECTOR
ISENSOR
2. Startthe engine.Hold the engineat 3,000rpm with
no load (in neutral)until the radiatorfan comes on.
3. Checkthe secondaryHO2S(Sensor2) output

voltageat 3,000rpm with the scantool.
ls thete 1.0 V or morc?
YES Go to step 4.

Terminalside of male terminals Checkfor poor connectionsor looseterminalsat
the secondaryHO2S(Sensor2) and at the ECM.I
YES-Repair shon in the wire betweenthe ECM
(E2)and the secondaryHO2S(Sensor2).t 5. Disconnectthe secondaryHO2S(Sensor2) 4P
connector.
software,or substitutea known-goodECM,then ConnectsecondaryH02S (Sensor2) 4P connector
recheck(seepage 11-6).lf the symptom/indication t e r m i n a l sN o . 1 a n d N o . 2 w i t h a j u m p e rw i r e .
originaE
l CM.I| SECONDARY HO2S
{SENSOR2) 4P CONNECTOR
JUMPERWIRE
SG3 (PNKI SHO25(WHT/RED)
T e r m i n asl i d eo Jm a l et e r m i n a l s
7. Turn the ignitionswitch ON (ll).
11-66
8 . Checkthe secondaryH02S (Sensor2) output DTCP0139:SecondaryHO2S(Sensor2l Slow
voltagewith the scantool, Response
ls there 1.0 V ot mote? 1 . R e s e t t h eE C M( s e ep a g e1 1 - 4 ) .
YES-Go to step 9. Start the engine.Holdthe engine at 3,000rpm with

NO Replacethe secondaryHO2S(Sensor2).1
3 . Checkthe secondaryHO2S(Sensor2) output
9 . Turn the ignitionswitch OFF. voltageat 3,000rpm with the scantool.
1 0 . ConnectECMconnectorterminalsE2 and E4 with a ls thete 0.3- 0.8 V, fot 2 minutes?

J U m p ew
r rre.
YES Replacethe secondaryHO2S(Sensor2).!
E 131PI
ECMCONNECTOR
NO- lntermittentfailure,system is OK at this time.
Checkfor poor connectionsor looseterminaisat
JUMPERWIRE the secondaryHO2S(Sensor2) and at the ECM.I
1 1 .Turn the ignition switch ON (ll).
1 2 . Checkthe secondaryHO2S(Sensor2) output

voltagewith the scantool.
ls there 1.0 V or more?
YES Updatethe ECM if it does not have the latest

soflware,or substitutea known-goodECM,then
goes away with a known-goodECM.replacethe
originaE
l CM.I
NO Repairopen in the wire betweenthe ECM (E2,

E4)and the secondaryHO2S{Sensor2).I
11-67
PGM-FISystem
DTCP0141: Secondary HO2S(Sensor
2l 6. Checkfor continuitybetweenbody ground and
HeaterCircuitMalfunction secondaryH02S (Sensor2) 4P connectorterminals
N o . 3 a n d N o .4 i n d i v i d u a l l y .
1. Resetthe ECM(seepage 1 l-4)

SECONDARY
HO2S{SENSOR
214PCONNECTOR
2. Startthe engine.
ls DTC P0141indicated?
YES-Go to step 3.

the secondaryHO2S(Sensor2) and at the ECM.I
Disconnectthe secondaryH02S (Sensor2) 4P ls therecontinuity?

connecror.
YES- Replace HO2S(Sensor2).1
the secondary
5 . At the secondaryHO2S(Sensor2) side, measure
resistancebetweenH02S 4P connectorterminals NO-Go to step7.
N o . 3 a n d N o .4 .
7 . Turnthe ignitionswitchON (ll).
HO2S(SENSOR
SECONDARY 214PCONNECTOR
8 . Measure
voltagebetweensecondary
H02S4P
t
connector
terminalsNo.3 andNo.4,
SECONDARYHO2S (SENSOR2l ilP CONNECTOR
s02sHTc
{BLK/WHTI IG1(BLK/ORN}
Wire side ol lemale terminals
ls thereabout3.3 Q ?
T e r m i n asli d eo f m a l et e r m i n a l s
YES Goto step6.
NO- Replace HO2S(Sensor

the secondary 2).t ls there battery voltage?
YES Go to step 9.
NO Go to step 12.
1 0 . DisconnectECMconnectorE {31P)
11-68
11. Checkfor continuitybetweenECMconnector 1 3 .Turn the ignitionswitch OFF.
terminalE6andbodyground.
1 4 . Reconnectthe secondaryHO2S(Sensor2) 4P
ECM CONNECTORE {31PI connector.
t5. DisconnectECMconnectorE (31P).
to. Turn the ignition switch ON (ll).
1 7 . Measurevoltage betweenECMconnectorterminal
E 6a n d A 5 .
ECMCONNECTORS
Wire side o{fIemaleterminals

A (31 P)

( E 6 )a n d t h e s e c o n d a r yH O 2 S( S e n s o 2
r ).1
E {31P}
NO-Update the ECM if it does not have the latest

recheck(seepage 11-6).lf the symptom/indication Wire side ot femaleterminals
o r i g i n aE
l CM.I Is there 0-1 V or less?
MeasurevoltagebetweensecondaryHO2S YES-Repair open in the wire betweenthe ECM

(Sensor2) 4P connectorterminal No. 4 and body (E6)and the secondaryHO2S(Sensor2).!
g round.
NO Updatethe ECM if it does not havethe latest
HO2S{SENSOR
SECONDARY 2I 4PCONNECTOR software,or substitutea known-goodECM,then
o r i g i n aE
l CMa
.
tFff I
l[faJl--ro'
14 |
IBLK/OFN)
Y
I
Terminal
sideof maleterminals
YES Go to step 13.
N O - C h e c k t h e N o . 4 A C G ( 1 0 A )f u s ei n t h e u n d e r -
dash fuse/relaybox. lf the fuse is OK, repair open in
the wire betweenthe secondaryHO2S(Sensor2)
a n d N o . 4 A C G ( 1 0 A )f u s e . l
11-69
PGM-FISystem
FuelSystemToo Lean
DTCP0171: 3. Turn the ignition switch OFF.
DTCP0172:FuelSystemToo Rich 4. With a vacuum pump, apply vacuum to the

evaporativeemission(EVAP)canisterpurge valve
NOTE:lf some of the DTCSlistedbelow are storedat (A) from the evaporativeemission(EVAP)canister
the same time as DfC PO17'land/ot PO172, side.
troubleshootthose DTCSfirst, then recheckfor P0171
andlot P0112.
P 0 1 0 7P, 0 1 0 8P. 11 2 8 .P 11 2 9 :M a n i f o l da b s o l u t e
p r e s s u r e( M A P )s e n s o r
P1162.P1166,P 1167:4,,/Fsensor(Sensor1) heater
P 0 1 3 7P, 0 1 3 8S: e c o n d a r yH O 2 S( S e n s o 2 r)
P014'l:SecondaryHO2S(Sensor2) heater
P1259:VTECsystem
1 . C h e c kt h e f u e l p r e s s u r e( s e ep a g e1 1 - ' 1 4 5 ) .
'
A973AX-041-XXXXX
ls luel pressure OK?
YES Go to step 2.
Does it hold vacuum?
NO Checkthese items:
YES-Check the enginevalve clearancesand adjust
. lf the pressureis too high, replacethe fuel if necessary,lf the valve clearancesare OK, replace
p r e s s u r er e g u l a t o(rs e ep a g e1 1 - 1 5 2 ) . 1 t h e i n j e c t o r s( s e ep a g e11 - 111 ) . 1
. l f t h e p r e s s u r ei s t o o l o w . c h e c k t h e f u epl u m p ,
the fuel feed pipe,the fuel filter, and replacethe NO-Replace the EVAPcanisterpurge valve.l
f u e l p r e s s u r er e g u l a t o (r s e ep a g e1 1 - 1 5 2 ) . I

11-70
DTCP0300:
RandomMisfireandAny Combination
of the Following:
DTCP0301:
No.1 CylinderMisfire
DTCP0302:No.2 CvlinderMisfire
DTCP0303:
No,3 CvlinderMisfire
DTCP0304:No. 4 CvlinderMisfire
NOTE:
. lfthe misfiring is frequentenoughto trigger detectionof increasedemissionsduring two consecutivedriving cycles.
the MIL will come on, and DTCP0300(and some comlrinationof P0301through P0304)will be stored.
. lf the misfiring is frequentenoughto damagethe catalyst,the MIL will blink wheneverthe misfiring occurs,and OTC
P0300(and some combinationof P0301through P0304)will be stored.When the misfirlng stops,the MIL will remain
on.
1. Troubleshootthe following DTCsfirst if any of them were stored along with the random misfire DTC(s):
P 0 ' 1 0 7P,0 1 0 8P, 1 1 2 8P , 1 1 2 9N r 4 a n i f o ladb s o l u t ep r e s s u r e( M A P )s e n s o r
P0111.P0'172t Fuelsvstem
P0335.P0336:Crankshaftposition(CKP)sensor
P0505:ldle control system
P1149,Pl 162,P1163,P1164,P 1165:Air fuel ratio (Ay'F) sensor
P1259:VTECsystem
P1361,P1362:Camshaftposition(CMP)sensorB {Top dead center(TDC)sensor)
P 1 5 1 9l:d l ea i r c o n t r o l( l A C )v a l v e
2. Test-drivethe vehicleto verify the symptom.
3. Findthesymptom inthechart below, and dothe relatedproceduresin the order listeduntil you find the cause.
Symptom Procedure(sl Also check foi:

R a n d o mm i s f i r eo n l y Checkfuel pressure(seepage 11-145). . Lowcompressron.
at low RPMand . Lowqualityfuel.
under load
R a n d o mm i s f i r eo n l y Checkfuel pressure(seepage 11-145). Malfunctionin the
du ring acceleration VTECsystem(seepage
1' t-123).
Randommisfire at C h e c kf u e l p r e s s u r e( s e ep a g e1 1 - 1 4 5 ) . Correctenginevalve
h i g h R P M ,u n d e r clearances(seepage 6-
l o a d ,o r u n d e r 91.
random conditions
11-71
PGM-FISystem
DTCTroubleshooting(cont'dl I
DTCP0301:
No.1 CylinderMisfire 1 . Determinewhich cylinder(s)had the misfire.
DTCP0302:No.2 CylinderMisfire Does the misf ire occur in the cylinder where the
ignition coil was exchanged?
DTCP0303:No.3 CylinderMisfire
YES Replacethe faulty ignitioncoil.!
DTCP0304:No. 4 CylinderMisfire
NO-Go to step 8.
1. After checkingand recordingthe freezedata,reset 8 . Turn the ignition switch OFF.

the ECM (seepage 11-4).lf there is no freezedata of
the misfire,just clearthe DTC. 9 . Exchangethe spark plug from the problemcylinder
with one from anothercylinder.
2. Startthe engine,and listenfor a clickingsound
from the injectorat the problemcylinder. 1 0 .Test-drivethe vehiclefor severalminutes in the
rangeof the freezedata or under various
conditionsif there was no freezedata.
Does the injector click?
1 1 .Checkfor a DTCor TemporaryDTCwith the scan
YES-Go to step 3. Tool.
NO-Go to step 30. ls DTC ot Tempotary DTC P0301, P0302, P0303

or P0304indicated?
YES Go to step 12.
4. Exchangethe ignition coil from the problem
cylinderwith one from anothercylinder, NO Intermittentmisfiredue to spark plug fouling,
e t c .( n o m i s f i r ea t t h i st i m e ) . 1
5. Test-drivethe vehiclefor severalminutesin the
range of the freezedata or under va rious Determine
w h i c h c y l i n d e r ( sh)a dt h e m i s f i r e .
Does the misl ire occur in the cylinder where the
6. Checkfor a DTCor a TemporaryDTCwith the scan spark plug was exchanged?
root.
t h e f a u l t ys p a r kp l u g . l
YES Replace
ls DTC or Tempotaty DTC P0301, P0302, P0303
or P0304 ind icated? NO Go to step 13.
YES Go to step7. Turn the ignition switch OFF.
NO Intermittentmisfire due to poor contactat the 1 4 . Exchangethe lnjectorfrom the problemcylinder

i g n i t i o nc o i l c o n n e c t o r {sn o m i s f i r ea t t h i st i m e ) . w i t h o n ef r o m a n o t h e rc y l i n d e r .
Make sure the coil connectionsare secure.l
t5. L e tt h e e n g i n ei d l ef o r 2 m i n u t e s .
11-72
1 6 .Test-drivethe vehiclefor severalminutesin the 22. Measurevoltage betweenignition coil 3P
rangeof the freezedata or under various connectorterminal No. 3 and body ground.
't7. IGNITIONCOIL3P CONNECTOR
Checkfor a DTCor a TemporaryDTCwith the scan
Tool.
ls DTC or TemporaryDTC P0301,P0302, P0303

or P0304 indicated?
YES Go to step 18.
NO lntermittentmisfire due to bad contactat the

injectorconnector(no misfireat this time). Make
surethe injectorconnectionis secure.Checkfor Wire side ol femaleterminals
poor connectionsor looseterminalsat the
injector.l
1 8 .Determinewhich cylinder(s)had the misfire.
YES-Go to step 23.
Does the misf ire occur in the cylinder where the
i njector w as exchanged ? NO Repairopen in the wire betweenthe No. 1
I G NC O I L( 1 5 A ) f u s ea n dt h e i g n i t i o nc o i l . I
YES- Replacethe faulty injector.I
2 3 . Turn the ignitionswitch OFF.
NO-Go to step19.
24. Checkfor continuitybetweenignitioncoil 3P
1 9 .Turn the ignitionswitch OFF. connectorterminal No. 2 and body ground.
20. Disconnectthe ignitioncoil 3P connectorfrom the IGNITIONCOIL3PCONNECTOR

problemcylinder.
Turn the ignition switch ON (ll).
YES Go to step 25.
NO Repairopen in the wire betweenthe ignition

c o i l a n dG 1 0 1 . 1
DisconnectECMconnectorA {31P)
(cont'd)
11-73
PGM-FISystem
DTCTroubleshooting(cont'dl a
26. Checkfor continuitybetweenbody ground and 28. Checkfor continuitybetweenbody ground and
ECMconnectorterminal (seetable). ECMconnectorterminal (seetable).
ECMCONNECTOR
A {31PI ECMCONNECTOR
A {31P}
PROBLEIVI DTC ECM WIRE PROBLEM DTC ECM WIRE

CYLINDER TERMINAL COLOR CYLINDER TERI\4INAL COLOR
N o .1 P0301 430 YEUGRN No.1 P0301 A30 YEL/GRN
No.2 P0302 A.29 BLU/RED N o .2 P0302 429 BLU/RED
No.3 P0303 428 WHT/BLU N o .3 P0303 A.28 WHT/BLU
No,4 P0304 421 BRN N o .4 P0304 A.21 BRN
ls there continuity? ls there continuity?
YES Repairshon in the wire betweenthe EClvl YES-Go to step 29.

a n dt h e i g n i t i o nc o i l . l
NO Repairopen in the wire betweenthe ECMand
NO-Go to step 27. t h e i g n i t i o nc o i l . l
2 7 . C o n n e c itg n i t i o nc o i l 3 P c o nn e c t o rt e r mi n a l N o . 1 t o 29. Checkthe engine compression

body ground with a jumper wire (seetable).
IGNITIONCOII 3PCONNECTOR ls the compression OK?

originaE
l CI\4.I
Wire s de of femaleterminals N O - R e p a i tr h e e n g i n e . l
3 0 . DisconnectECMconnectorB (24P).
PROBLEM DTC WIRECOLOR
CYLINDER T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
No.1 P0301 YEUGRN
N o .2 P0302 BLU/RED
N o .3 P0303 WHT/BLU
N o .4 P0304 BRN
11-74
voltagebetweenbodygroundandECM
32. fvleasure 36. Exchangethe injectorfrom the problemcylinder
terminal(seetable).
connector w i t h o n e f r o m a n o t h e rc y l i n d e r .
B (24P)
ECMCONNECTOR
3 7 . L e t t h ee n g i n ei d l ef o r 2 m i n u t e s .
3 8 . Test-drivethe vehiclefor severalminutes in the

r a n g eo I t h e l r e e z ed a t ao r u n d e rv a r i o u s
condilionsif there was no freezedata.
39. Checkfor a DTCor TemporaryDTCwith the scan

tool.
ls DTC or TemporaryDTC P0301,P0302, P0303,

or P0304 indicated?
W i r e s i d e o f f e m a l et e r m r n a l s
YES Go to step 40.

PROBLEM DTC ECt\4 WIRE
CYLINDER TERMINAL COLOR NO Intermittentmisfiredue to injector
No. 1 P0301 B5 BRN malfunction,etc. Make sure the injector
No.2 P0302 B4 RED connectionsare secure.Checkfor poor connections
No.3 P0303 B3 BLU or looseterminalsat the injectorconnector.l
No.4 P0304 YEL
D e t e r m i n ew h i c hc y l i n d e r { sh}a d t h e m i s f i r e .
Does the mislirc occur in the cylinder whete the
YES-Go to step 33, i nj ector w as exchanged ?
N O G o t o s t e p4 1 . YES Replacethe faulty injector.l
33. Turn the ignitionswitch OFF,and removethe NO Updatethe ECM if it does not have the latest
engine cover. software,or substitutea known-goodECM.then
recheck(seepage 1'l-6).lf the symptom/indication
34. Disconnectthe injector2P connectorfrom the goes away with a known-goodEClvl,replacethe
p r o b l e mc y l i n d e r . originaE
l CM.I
3 5 , Measurethe resistancebetweeninjector2P 4 1 .Turn the ignition switch OFF.

c o n n e c t otre r m i n a l sN o . 1 a n d N o . 2 .
42. Removethe enginecover.
INJECTOB2P CONNECTOR
43. Disconnectthe injector2P connectorfrom the
p r o b l e mc y l i n d e r .
4 4 . T u r nt h e i g n i t i o ns w i t c hO N ( l l )
Terminal side of male terminals
l s t h e r e 1 0Q 13A?
YES-Go to step 36.
t h e i n j e c t o r( s e ep a g e11 -1 1I ) .t
NO Replace
(cont'd)
11-75
PGM-FISystem
45. Measure voltagebetweeninjector2Pconnector 48. Connectinjector2PconnectorterminalNo.2to
t e r m i n aNl o .1 a n db o d yg r o u n d . bodygroundwith a jumperwire {seetable).
INJECTOR
2P CONNECTOR INJECTOR2P CONNECTOR
tll-z]
-lt- tll-Z-l
-]_r-l_rNJ
,o,,"=rrrr*,
oI IJUMPER
IwrBE
Wire side of {emaleterminals

PROBLEM DTC WIRECOLOR
YES-Go to step 46. CYLINDER
No.1 P0301 BRN
NO-Repair open in the wire betweenthe injector No.2 P0302 RED
a n d t h e P G M - Fm
l a i n r e l a yl . l N o .3 P0303 BLU
N o .4 P0304 YEL
4 7 .Checkfor continuitybetweenbody ground and

ECMconnectorterminal (seetable).
B {24P)
ECMCONNECTOR
49. Checkfor continuitybetweenbody ground and
ECMconnectorterminal (seetable).
ECM CONNECTORB I24P)

a
Wire side oJtemaleterminals

W i r es i d eo f f e m a l et e r m i n a l s
PROBLEM DTC ECM WIRE
PROBLEM DTC ECM WIRE CYLINDER TERMINAL COLOR
CYLINDER TERMINAL COLOR No.1 P0301 B5 BRN
N o .1 P030'1 B5 BRN N o .2 P0302 B4 RED
No.2 P0302 B4 RED N o .3 P0303 B3 BLU
No.3 P0303 B3 BLU N o .4 P0304 82 YEL
N o .4 P0304 82 YEL
YES Replacethe injector,then recheck.l
NO Repairopen in the wire betweenthe ECM and
I
a n dt h e ; n j e c t o r . I
the injector.I
N O - G o t o s t e p4 8 .
11-76
DTGP0325:Malfunctionin KnockSensor 7. Connectstanersubharness 6Pconnector terminal
Circuit N o .5 t o b o d yg r o u n dw i t ha j u m p e w
r ire.
1 . R e s e t h e E C M( s e ep a g e1 1 - 4 ) . STARTERSUAHARNESS
6P CONNECTOR
then let it idle. l1l213l
l._, / l 5 l 6 l
3. Holdthe engineat 3,000-4,000 rpm for at least KS IJUMPER
60 seconds. |RED/BLU)
IW|RE
I
ls DTC P0325 indicated?
YES-Go to step 4.
NO Intermittentfailure,system is OK at this time. 8 . Checkfor continuitybetweenbodygroundand

Checkfor poor connectionsor looseterminalsat ECMconnector terminalA9.
the knocksensorand at the ECM.I
ECMCONNECTOR
A {31PI
5. Disconnectthe startersubharness6P connector.
6. Checkfor continuitybetweenECMconnector
terminalAg and body ground.
ECMCONNECTOR
A 131P)
YES-Go to step 9.
NO Repairopen in the wire betweenthe ECM (A9)

and the startersubharness6P connector.l
Wire side of lemaleterminals
9 . Checkthe startersubharnessbetweenthe 6P
connectorand the knocksensorfor an open or
ls therecontinuity? short. lf it's OK, substitutea known-goodknock
sensorand recheck.
YES-Repairshortin thewire betweenthe ECM
(A9)andthe startersubharness
6Pconnector.l ls DTC P0325 indicated?
NO Goto step7. YES Updatethe ECM if it does not have the latest
software.or substitutea known-goodECM,then
recheck{seepage '11-6). lf the sym ptomlindication
goes away with a known good ECM,replacethe
originaE
l CM.I
NO Replace t h e o r i g i n a kl n o c ks e n s o ra n d / o r
starter subharness.l
11-77
PGM-FISystem
DTCTroubleshooting(cont'd)
DTCP0335:CKPSensorNo Signal 7. Measurevoltage betweenCKPsensor3P connector
t e r m i n a lN o , 1 a n d b o d y g r o u n d
DTCP0336:CKPSensorIntermittent
Interruption CKPSENSOR3P CONNECTOR
'1. Reset '1-4).

the ECM (seepage 1
2. Start the engine.
ls DTC P0335 and/or P0336 indicated?
YES Go to step 3.
Wire side of female tefminals
t h e C K Ps e n s o ra n d a t t h e E C M . I ls thereabout5 V?
3. Turn the ignition switch OFF. YES Goto stepL
4. Disconnectthe CKPsensor3P connector. N O G ot o s t e p1 0 .
5. Turn the ignitionswitch ON {ll). 8. Measure voltagebetweenCKPsensor3Pconnector

s o . 2a n dN o .3 .
t e r m i n a lN
6. Measurevoltage betweenCKPsensor3P connector
t e r m i n a lN o . 3 a n d b o d y g r o u n d .
CKPSENSOR3PCONNECTOF
CKPSENSOR3PCONNECTOR
,llYtL
L " l
a
IGP
(YEL/BLK} LGl
(
1 2 3 {BRN/YELI
W i r e s i d eo f f e m a l et e r m i n a l s
Wiresadeof femaleterminals ls there battery voltage?
YES Go to step 9.
Is therebattery voltage?
NO Repairopen in the wire betweenthe CKP
YES- Goto step7. s e n s o ra n d G 1 0 1. I
NO Repairopenln thewire betweenPGM-Flmain 9. Substitutea known-goodCKPsensorand recheck.

r e l a y1 a n dt h eC K Ps e n s o r . !
ls DTC P0335 and/or P0336 indicated?

software.or substitutea known good ECM,then
recheck{seepage 11-6).lf the symptom/indication
originaE
l CM.I
NO Replace
t h e o r i g i n aC
l K Ps e n s o r . l
a
11-78
'10.l\4easure
voltagebetweenECMconnector
terminal
A7 andbodyground,
ECMCONNECTOR
A 13lPI
Wiresideot femaleterminals
ls there about 5 V?
YES-Repair open in the wire betweenthe ECM

(A7)and the CKPsensor.t
N O - G o t o s t e p1 1 .
1 1 .Turn the ignitionswitch OFF.
DisconnectECMconnectorA (31P)
1 3 . Checkfor continuitybetweenECMconnector
terminal 47 and body ground.
ECMCONNEfiORA (31P)

(A7)and the CKPsensor.t

software.or substitutea known-goodECI\4,then
originaE
l CM.t
11-79
PGM-FlSystem
DTCP0500:VSSCircuitMalfunction 9. Turn the ignitionswitch OFF.
1. Test-drivethe vehicle. 10. DisconnectECMconnectorA (3'1P).
2. Checkthe vehiclespeedwith the scantool. 11 . T u r nt h e i g n i t i o ns w i t c hO N { l l } .
ls the correct speed indicated? 12. Blockthe right front wheel. and slowly rotatethe
left front wheel.
YES-lntermiftent failure,system is OK at this time.
'!3.
Checkfor poor connectionsor looseterminalsat lMeasurevoltage betweenECMconnector
t h e V S Sa n d a t t h e E C M . I t e r m i n a l sA 1 8 a n d A 2 4 .
NO Go to step 3. A I31PI
ECMCONNECTOR
4. Blockthe rearwheels,and set the parkingbrake.
5. Raisethe front ofthe vehicle,and make sure it is

securelysupported,
6 . Turn the ignition switch ON (ll).
1 . Blockthe right front wheel, and slowly rotatethe Wiresideof femaleterminals

left front wheel.
8. Measurevoltage betweenECMconnector Does the voltage pulse between 0 V and 5 V ol

t e r m i n a l sA 1 8 a n d A 2 4 . between0V and battety voltage?
A {31P)
ECMCONNECTOR
origlnaE
l CM.I
NO Checkthese items:
. A short or an open in the wire betweenthe ECM

( A 1 8 )a n d t h e V S S . I
. l f t h e w i r e i s O K , t e s t t h e V S S( s e ep a g e2 2 7 1 ) . 1
Does the voltage pulse between 0 V and 5 V or

between 0V and battery voltage?
YES-Update the ECM if it does not havethe latest

software,or substitutea known-goodECM.then
originaE
l CN4.l
NO Go to step 9.
11-80
DTCP0563:ECMPowerSourceCircuit 9 . Removethe glove box (seepage20-63).
Unexpected
Voltage
1 0 .Removethe PGM-FImain relay 1 (A7.
1 . R e s e t h e E C I \ {4s e ep a g el 1 - 4 } .
3. Wait 5 seconds.
4 . T u r nt h e i g n i t i o ns w i t c hO N { l l l .
YES Go to step 5.
NO-lntermiltent failure,system is OK at this time.

t h e N o . 6 E C U( E C M ){ 1 5A ) f u s ei n t h e u n d e r - h o o d
fuse/relaybox and at the ECM.I 1 1 .Checkfor continuitybetweenECMconnector
terminal E7 and body ground.
Turn the ignitionswitch OFF.
ECMCONNECTOR
E 131P)
6 . DisconnectECI\4connectorE {31P).
MRLY
{RED/YEL)
8 . lvleasurevoltagebetweenECMconnectorterminal
E7 and body ground.
ECMCONNECTOR
E {31P}
MRLY
Wiresideof {emaleterminals

{ E 7 )a n d t h e P G M - Fm
l a i n r e l a y1, I
Wiresideol remaleterminals NO Replace

t h e P G M - Fm
l a i n r e l a y1 . 1
tt. Turn the ignition suitchOFF.

'13.R e c o n n e cEt C M
r (31P).
c o n n e c t oE
YES Go to step 12.
NO Go to step 9.
(conl'd)
11-81
PGM-FISystem
14. Measurevoltage betweenECMconnectorterminal 1 8 .Removethe glove box (seepage 20-63).
E7 and body ground.
1 9 .Removethe PGM-FImain relay '1{A).
ECMCONNECTORE 13lPI
MRLY
IBEO/YEL)
YES Go to step 15.
NO-Update the ECM if it does not have the latest 20. Measure voltagebetween body ground and ECM
software,or substitutea known-goodEClvl,then connector terminals A3 and A2 individually.
ECMCONNECTOR
A {31PI
o r i g i n aE
l CM.I
IGP2 IGP1
(YEL/BLK) (YEL/BLK)
1 5 . DisconnectECI\4connectorA (31P).
to. T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
1 7 . Measurevoltage betweenbody ground and ECIM

c o n n e c t otre r m i n a l s4 3 a n d4 2 i n d i v i d u a l l y .
ECMCONNECTOR
A {3.IP)
IGP2 IGP1 Wiresideof femaleterminals

(YEI./BLX) (YEL/BLKI
I s there battery v oltage?
YES Repairshortto power in the wire between

( A 2 . A 3a) n d t h e P G M - Fm
the ECI\4 l a i n r e l a y1 . 1
W i r es i d eo f f e m a l el e r m i n a l s N O R e p l a c e t h eP G M F l m a i n r e l a y1 . !
YES-Go to step 18.

originalECM/PCl\4.1
11-82
DTGPl106:BAROSensorRange/Perfomance DTCPl107:BAROSensorCircuitLowVoltage
Problem
DTCPl108:BAROSensorCircuitHigh
1 . R e s e t h e E C M( s e ep a g e1 1 - 4 ) . Voltage
2. Startthe engine.Holdthe engineat 3,000rpm with 1 . R e s e t h e E C M{ s e ep a g e11 - 4 ) .
then let it idle. 2. Turn the ignition switch ON (ll).
Test-drivewith the transmissionin 4th gear. l s D T C P 1 1 0 7o r P 1 1 0 8i n d i c a t e d ?
Acceleratefor 5 secondsusingwide open throttle. YES-Update the ECM if it does not havethe iatest
Checkfor a TemporaryDTCwith the scantool. recheck(seepage 11-6).lf the symptom/indication
Is TemporaryDTC Pl106 indicated? originaE
l CI\4.I
YES-Update the ECM if it does not have the latest NO- Intermittentfailure,system is OK at this
software,or substitutea known-goodECM.then trme.l
o r i g i n aE
l C M !.
NO Intermittentfailure,system is OK at this
time.I
11-83
PGM-FISystem
DTGTroubleshooting(cont'dl L
Sensor(Sensor1)Range/
DTCPl157:Ay'F 6. Checkfor continuitybetweenECMconnector
Performance
Problem t e r m i n a l4s6 a n dA 1 6 .
1 . R e s e t t h eE C I M( s e ep a g e1 1 - 4 ) .
ECMCONNECTOR
A {3IP)
2. Startthe engine.
ls DTC Pl157 indicated?
YES-Go to step 3.

the Ay'Fsensor(Sensor1) and at the ECN4.I
Disconnectthe Ay'Fsensor(Sensor1) 4P connector

r (31P).
a n d E C Mc o n n e c t oA ls therecontinuity?
ConnectA,/Fsensor(Sensor1) 4P connector YES Goto step9.

t e r m i n a l sN o . 1 a n d N o . 2 w i t h a j u m p e rw i r e .
NO Goto step7.
(SENSOR
A/F SENSOR 1) 4PCONNECTOR
A/Fsensor(Sensor1)4Pconnecror
7 . Connect
t e r m i n aNl o .1 t o b o d yg r o u n dw i t ha j u m p e w
r ire.
(
AFS+ {BLU)
A/F SENSOR{SENSOR1I 4P CONNECTOR
JUMPERWIRE
11-84
8. Checkfor continuitybetweenECMconnector Sensor(Sensor1)AFS-
DTCPl158:Ay'F
terminals46 andbodyground. TerminalLowVoltage
A 131P}
ECMCONNECTOR 1 . R e s e t t h eE C M( s e ep a g e1 1 - 4 ) .
2. Startthe engine.
YES Go to step 3.
NO-lntermittent failure,system is OK at this time

Checkfor poor connectionsor loosetermanalsat
the Ay'Fsensor(Sensor1) and at the ECIMI
Wire side ol lemaleterminals
ls there continuity? 4, DisconnecttheAy'Fsensor(Sensor1) 4P connector,

r (31P).
a n d E C Mc o n n e c t oA
YES-Repair open in the wire betweenthe Ay'F
sensor(Sensor1) and the ECM(416).1 5. Checkfor continuitybetweenECMconnector
l 1 6 a n d b o d yg r o u n d .
termina4
NO-Repair open in the wire betweenthe Ay'F
sensor(Sensor1) and the ECM (46).1 A (31P)
ECMCONNECTOR
9 . Substitutea known-goodAy'Fsensor(Sensor1) and

recheck.
YES- Updatethe ECM if it does not have the latest

recheck(seepage 11-6).if the symptom/indication
original ECM.! Wire side oJfemaleterminals
NO- Replacethe Ay'Fsensor{Sensor1).!

YES-Repair shon in the wire betweenthe A,/F

s e n s o r( S e n s o r1 ) a n dt h e E C M( A 1 6 ) . 1
NO Go to step 6.
' c o n td )
11-85
PGM-FISystem
DTCTroubleshooting(cont'd) (
6. Substitutea known-goodAy'Fsensor(Sensor1)and DTCPl159:A,/FSensor(Sensor1)AFS +

recheck. TerminalLowVoltage
Is DTC P1158 indicated? 1 . R e s e t t h eE C M( s e ep a g e1 1 - 4 ) .
YES Updatethe ECM if it does not have the latest 2. Start the engine.
recheck(seepage 11-6).if the symptom/indication ls DTC P1159 indicated?
originaE
l CM.I YES-Go to step 3.
NO- Replacethe Ay'Fsensor(Sensor1).t NO-lntermiftent failure.system is OK at this time.

Checkfor poor connectionsor looseterminaisat
the A,/Fsensor(Sensor1) and at the ECM.I
4. Disconnectthe Ay'Fsensor(Sensor1) 4P connector

r (31P).
a n d E c M c o n n e c t oA
terminal 46 and body ground.
a
ECMCONNECTOR
A {31PI
ls therecontinuity?
YES-Repairshortin thewire between the Ay'F

s e n s o(rS e n s o1r )a n dt h eE C M( A O ) . I
NO Goto step6.
11-86
6. Substitutea known-goodAy'Fsensor(Sensor1i and
recnecK.
l s D T C P 1 1 5 9i n d i c a t e d ?

recheck(seepage 11-6).if the symptom/indication
goes away with a known-goodECN4, replacethe
o r i g i n aE
l CM.I
t h e A y ' Fs e n s o r( S e n s o r1 ) . 1
NO Replace
11-87
PGM-FISystem
DTCPl163:Ay'FSensor(Sensor1) Slow DTCPl164:A,/FSensor(Sensor1)Circuit
Response Range/Performance
Problem
NOTE:lf DTCP1162is storedat the same time as DTC ( s e ep a g e1 t - 4 ) .
1 . R e s e t t h eE C I \ 4
P1163.troubleshootDTCP1162first, then recheckfor
D T CP 1 1 6 3 . 2 . S t a r tt h e e n g i n e .H o l d t h e e n g i n e a t 3 , 0 0r0p m w i t h
1 . R e s e t h e E C M( s e ep a g e11 - 4 ) .
3. Test-drivein 3rd gear.Startingat 1,600rpm,
2. Startthe engine.Hold the engine at 3,000rpm with accelerateusing wide open throttlefor at least
no load (in neutral)until the radiatorfan comes on. 5 seconds.Then deceleratefor at least5 seconds
with the throttle completelycloseduntil the A,/F
3. Test-driveunderthe following conditions: sensorreadinesscode is set to completeor
TemporaryDTCP1164comes on.
. 55 mph (89 km/h) steadyspeed
' Transmissionin sth gear 4. Checkfor a TemporaryDTCwith the scantool.
' Until the Ay'Fsensorreadinesscode or
TemporaryDTCPl163 comes on ls TemporaryDTC P1164indicated?
4. Checkfor a TemporaryDTCwith the scantool. sensor(Sensor1).I

YES- Replacethe A,,/F
ls Temporary DTC P 1163indicated? NO Intermittentfailure,system is OK at this time.

YES Replacethe Ay'Fsensor(Sensor1).I the Ay'Fsensor relay,at the Ay'Fsensor(Sensor1),
a n da t t h e E c M . l
NO Intermittentfailure, system is OK at this time.
the A'lFsensor (Sensor1) and at the ECM.t
11-88
DTCPl166:Ay'FSensor(Sensor1)Heater Is therc battery voltage?
CircuitMalfunction
1 . R e s e t t h eE C M( s e ep a g e1 1 - 4 ) . soflware,or substitutea known-goodECM.then
2. Startthe engine. goes away with a known-goodECM,replacethe
o r i g i n aE
l CM.I
NO-Go to step 5.
YES-Go to step 3.
5. MeasurevoltagebetweenECMconnector
NO-lntermittent failure,system is OK at this lime. terminalsA22 and A24.
the Ay'Fsensorrelay,the A,/Fsensor(Sensor1),and A {31P}
ECMCONNECTOR
t h e E c M .!
3. Checkthe following fuse:
. No. 14 OPTION(30A)fusein under-hoodfuse/

rerayDox.
. No. 2*B LAF (Ay'F)HEATER(20A)fuse in under-
dash fuse/relaybox.
. No. 4 ACG (10A)in underdash fuse/relaybox.
Are any of the fuses blown? Wire side of femaleterminals
YES Repairshort in the wire betweenthe Ay'F

sensorrelay and the fuses.I ls therebattery voltage?
NO Go to step 4. YES Goto step6.
4. MeasurevoltagebetweenECMconnector N O - G o t o s t e p1 0 .
terminalsA1 and A24. 30 secondsafter the ignition
s w i t c hi s t u r n e dO N ( l l ) . 6. Turnthe ignitionswitchOFF.
E (31P).
ECMconnector
7. Disconnect
A I31P)
ECMCONNECTOR
8 . T u r nt h ei g n i t i o n
s w i t c hO N{ l l ) .
W i r es r d eo f l e m a l et e r m i n a l s
(cont'd)
11-89
PGM-FISystem
9. ConnectECMconnectorterminal EStobody ls there continuity?
ground with a jumper wire, then measurevoltage
betweenECMconnectorterminalsA1 and 424. YES Repairshort in the wire betweenthe A|/F
sensorrelay,A,/Fsensor{Sensor1) and ECM
ECMCONNECTORS
lA22J.a
NO Go to step 13.
t5. Turn the ignition switch ON (ll).
1 4 . Measurevoltage betweenECMconnector
terminalsE8 and A24.
ECM CONNECTORS
E {31P)
YES- Updatethe ECM if it does not have the latest a {31P)

originaE
l C M t.
NO Repairopen in the wire betweenthe Ay'F
s e n s o r( S e n s o 1
r ) a n d E C M( A 1 ) t. ls there battety voltage?
1 0 .Turn the ignitionswitch OFF. YES-Repair open in the wire betweenthe ECM
(A22)and the IVF sensor(Sensor1).I
1 1 .Disconneclthe ECfMconnectorA (31P)and the Ay'F
sensor(Sensor1) 4P connector. N O - G o t o s t e p1 5 .
1 2 . Checkfor continuitybetweenthe Ay'Fsensor Checkfor continuityin the wires betweenthe Ay'F

( S e n s o r1 ) 4 Pc o n n e c t otre r m i n a lN o . 3 a n d b o d y sensorand the fuses.
ground.
(SENSOR
A/F SENSOR 1)4PCONNECTOR
YES-The wires are OK. Replacethe A,/Fsensor
relay.l
NO Repairopen in the wire betweenthe Ay'F

sensorrelay and the fuses.l
Wire side ot Iemaleterminals
11-90
DTCPl167:Ay'FSensor(Sensor1)Heater 6. Checkfor continuitybetweenECMconnector
CircuitMalfunction t e r m i n a l s, 4 6a n d 4 1 6 .
NOTE:lf DTCP1162is storedat the same time as DTC A {31P)

ECMCONNECTOR
P1167,troubleshootDTCP1162first, then troubleshoot
D T CP 1 1 6 7 . AFS- {RED)
1 . R e s e t t h eE C I \ (4s e ep a g e1 1 - 4 ) trTzTil,ilsl l t 9
t8 2C21
2. Startthe engine.Wait for at least80 seconds. l?rlzsIels
AFS IRED/YEL)
YES Go to step 3.
Wire side of lemale terminals
the Ay'Fsensorrelay,at the Ay'Fsensor(Sensor1), ls thetecontinuity?
a n da t t h e E C M . I
h eA / Fs e n s o(rS e n s o1r ) . 1
Y E S - R e p l a ct e
? Turn the ignitionswitch OFF.
NO-Repairopenin thewire betweenthe Ay'F
Disconnectthe A,/Fsensor4P connectorand ECM s e n s o(rS e n s o1r) a n dt h eE C M( 4 6o r A 1 6 ) . I
connectorA (31P).
5 . Connectthe Ay'Fsensor(Sensor1) 4P connector

t e r m i n a l sN o . 2 a n d N o . 1 w i t h a j u m p e rw i r e .
A/F SENSOR(SENSOR1)
4P CONNECTOR
JUMPERWIRE
Wire side of
f e m a l et e r m i n a l s
11-91
PGM-FISystem
DTCPl297:ELDCircuitLowVoltage 8. Turn the ignition switch OFF.
1 . R e s e t h e E C M{ s e ep a g e1 1 - 4 ) . 9. DisconnectECMconnectorE {31P).
2. Startthe engine. 10. Checkfor continuitybetweenbody ground and

E C Mc o n n e c t otre r m i n a lE 1 5 .
3 . T u r no n t h e h e a d l i g h t s .
ECMCONNECTOR
E 131PI
YES Go to step 4. I l 2 l 34 5 6 1 7 8 I
to td / 12021
NO Intermittentfailure,system is OK at this time. ,2 2al2/ tA 31
Checkfor poor connectionsor looseterminalsat ELD
t h e E L Da n d a t t h e E C M . I (GRN/RED}
7\'
4. Turn the ignition switch and the headlightsOFF.
5. DisconnecttheELD3P connector. Wire side of femaleterminals
6. Turn the ignition switch ON {ll).

7. Measurevoltage betweenbody ground and ELD3P
connectorterminal No. 3. YES-Repair short in the wire betweenthe ECM
ELO3P CONNECTOB
ELD{GRN/REDI
( E1 5 )a n d t h e E L D r.
NO- U pdatethe ECM if it does not havethe latest

a
Z 3 recheck(seepage 11-6).lf the symptom/indication
o r i g i n aE
l CM.I
ls thereabout5 V?
YES Replace
the ELD.t
11-92
DTCPl298:ELDCircuitHighVoltage 8. T u r nt h e i g n i t i o ns w i t c hO F F .
1 . R e s e t t h eE C M( s e ep a g e1 1 - 4 ) 9 . ConnectELD3P connectorterminal No. 3 to body

g r o u n dw i t h a j u m p e rw i r e .
2. Stan the engine.
ELD3P CONNECTOR
3. Turn on the headlights.
---F-------
l 1 l 2: r l
ELD
YES-Go to step 4. (GRN/RED)
wrRE
NO- Intermittentfailure.system is OK at this time. IJUMPER
I
I
t h e E L Da n d a t t h e E C M . I
4. Turn the ignition switch and headlightsOFF.

Wire side of temaleterminals
5. DisconnecttheELD3P connector.
1 0 .DisconnectECMconnectorE (31P).
1 1 .Checkfor continuitybetweenbody ground and
7. Measurevoltagebetweenbody ground and ELD3P ECMconnectorterminal E15.
connectorterminal No. 1.
E 131PI
ECMCONNECTOR
ELD3PCONNECTOR
1 2 1 34 5 o t / I I
14 L C 6 l / 1 8 2C 21
IG1IBLK/ORNI
22123
24 21./ 2Q 30 J
ELD
i1' IGRN/RED)
Wire side ot {emaleterminals

Is thetecontinuity?
Y E S - G ot o s t e p1 2 .
YES-Go to step 8.
NO Repairopenin thewire betweenthe ECM
N O - C h e c k t h e N o . 4 A C G ( 1 0 A ) f u s ei n t h e u n d e r - ( E 1 5a) n dt h eE L D .
dash fuse/relaybox. lf the fuse is OK, repairopen in
the wire betweenthe No. 4 ACG (10A)fuse and the
ELD.I
(cont'd)
11-93
PGM-FISystem
12, Checkfor continuitybetweenELD3P connector
t e r m i n a lN o . 2 a n d b o d y g r o u n d .
E L D 3 PC O N N E C T O R
YES Go to step 13.
NO- Repairopen in the wire betweenthe ELDand

G 2 0 1I.
Reconnectthe ELD3P connectorand ECM

connectorE (31P).
1 4 . Startthe engineand let it idle.
t5_ While measuringvoltage betweenECMconnector

t e r m i n a l s4 2 4 a n d E 1 5 ,t u r n t h e h e a d l i g h t os n
t hi g h ) .
ECM CONNECTORS
W i . e s i d eo f f e m a l et e r m i n a l s
Does the voltage drop?

originaE
l CM.I
NO Replace
the ELD.I
11-94
DTCPl361:CamshaftPosition(CMP)Sensor 7. l\4easure
voltage betweenCMP sensorB {TDC
B (TDCSensor)Intermittent
Interruption sensor)3P connectorterminal No. 1 and body
ground.
DTCPl362:CamshaftPosition(CMP)Sensor
B (TDCSensor)No Signal CMP S€NSOR 8 ITDCSENSOR)3P CONNECTOR
1 . R e s e t h e E C M( s e ep a g e1 1 - 4 ) .
2. Startthe engine.
ls DTC P1361and/or P1362 indicated?
YES Go to step 3. Wlres de ollemaleterminals
NO- Intermittentfailure.system is OK at this time.

Checkfor poor connectionsor looseterminalsat ls thereabout5 V?
t h e C M Ps e n s o rB ( T D Cs e n s o r a
) n da tt h e E C M . I
YES-Go to step8.
N O - G o t o s t e p1 0 .
4 . DisconnecttheCMP sensorB (TDCsensor)3P
connector. 8. Measure voltagebetweenCl\ilPsensorB (TDC
s e n s o r3)Pc o n n e c t ot er r m i n a lN
s o .2 a n dN o ,3 .
5 . Turn the ignitionswitch ON (ll).
CMPSENSON
B llOC SENSOfi)3P CONNECTOF
6 . Measurevoltage betweenCMP sensorB (TDC

sensor)3P connectorterminal No. 3 and body
grouno.
B {TDCSENSOR)
CMPSENSOR 3PCONNECTOR
Wire s de olfema etefminals
IGP
{YEL/BLK}
1 2 3 ls there battery voltage?
Y E S - G o t o s t e p9 .
NO Repairopen in the wire betweenthe CMP

s e n s o rB ( T D Cs e n s o r a
) n dG 1 0 1 . 1
Wiresideol temaleterminals 9. Substitutea known-goodCMP sensorB (TDC

sensor)and recheck.
ls there battety voltage? ls DTC P1361and/or P1362 indicated?
YES Go to step 7. YES Updatethe ECMif it does not have the latest
NO-Repair open in the wire betweenthe PGM-Fl recheck(seepage 11-6).lf the symptom/indication
m a i n r e l a y1 a n dt h e C M Ps e n s o rI ( T D Cs e n s o r ) . I goes away with a known-goodECM,replacethe
originaE
l CM.I
NO ReplacetheoriginaC
l MPsensorB(TDC
sensor).1
(cont'd)
11-95
PGM-FISystem
(cont'd)
DTCTroubleshooting
10. MeasurevoltagebetweenECI\4
connectorterminal DTCPl607:Malfunction
in ECMInternal
A26andbodyground. Circuit
A (31P)
ECMCONNECTOR 1. ResettheEC|\illsee page 11-4).
2 , T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d w a i t f o r
1 2 3 4 5 6 1 7 I 40 seconds.
0 1 11 2 1 . / 61,/18 I 2C2l
2324 21m 30 ls DTC P 1607 indicated?
TDC {GRN}
recheck(seepage 11 6). lf the symptom/indication
Wire side oI temaleterminals o r i g i n aE
l CM.I

ls thereabout5 V ? A low batterycan causethis problem . Ask the
customerif there has been any recenttrouble
YES- Repairopenin thewire betweenthe ECM s t a r t i n gt h e e n g i n e . l
(426)and CMPsensorB (TDCsensor).1
N O - G o t o s t e p1 1 .
1 1 .Turnthe ignitionswitchOFF.
\
1 2 . Disconnect
ECIM A (31P)
connector
Checkfor continuitybetweenECMconnector
terminal426 andbodyground.
ECMCONNECTOR
A {31PI
YES Repairshort in the wire betweenthe ECM

(426)and the CMP sensor B (TDCsensor).1

originaE
l CM.I
11-96
MIL CircuitTroubleshooting
1. Connectan OBD ll scantool/HondaPGM Tester . A l o o s eN o . 1 7 F U E LP U M P( 1 5 A ) f u s ei n t h e
( s e ep a g e1 1 - 3 ) . under-dashfuse/relaybox.
. A p o o rc o n n e c t i o n
a t E C Mt e r m i n a E
l 31.
2. Turn the ignition switch ON (ll) and readthe OBD ll . An intermittentopen in the GRN/ORNwire
scantool/HondaPGM Tester. b e t w e e nt h e E C M( E 3 1 a) n d t h e g a u g ea s s e m b l y .
. An intermittentshort in the wire betweenthe
Does the OBD ll scan tool/Honda PGM Tester ECM(A21)and the manifold absolutepressure
communicatewith the ECM? ( M A P )s e n s o r .
YES Go to step 3. ECI\4(A20)and the throttle posilion (TPisensor.
"
NO Go to troubleshooting DLCCircuit ECM (E5)and the fuel tank pressure(FTP)sensor.
T r o u b l e s h o o t i n g (" s e ep a g e1 1 - 1 0 9 ) .
3. Checkthe OBD ll scantool/HondaPGM Testerfor
DTCs. 7 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
Are any DTCs indicated? ls the low oil pressure light on?
YES Go to the DTCTroubleshootingIndex. YES Go to step 10.
NO-Go to step 4. N O - G o t o s t e p8 .
4. Turn the ignitionswitch OFF. 8 . I n s p e c t t h eN o . 1 0 l \ 4 E T E(R7 . 5 A ) f u s ei n t h e u n d e r -

dash fuse/relaybox.
5 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) a n dw a t c ht h e
l M a l f u n c t i oIn d i c a t oLr a m p( M l L ) . ls the luse OK?
Does the MIL come on and stay on for more than YES Go to step L
20 secondsaftet turning the ignition switch
oN (tr)? N O R e p a i rs h o n i n t h e w i r e b e t w e e nN o . 1 0
M E T E R( 7 . 5 A ) f u s e a n d t h e g a u g ea s s e m b l yA. l s o
YES lf the MIL alwayscomes on and stayson, go r e p l a c e t h eN o . 1 0 M E T E R{ 7 . 5 A f) u s e . l
to step 76. But if the lMlLsometimesworks
normally,first checkfor these problems. 9. Inspectthe No. 20 lG1 (40A)(Canada:50A)fuse in
the under-hoodfuse/relaybox.
E C I M( E 2 9 a
) n dt h e d a t al i n kc o n n e c t o(rD L C ) . ls the f use OK?
E C M( E 3 1 a ) n dt h e g a u g ea s s e m b l y . YES Repairopen in the wire betweenthe No. 20
l G ( 4 0 A ){ C a n a d a5r0 A ) f u s ea n d t h e g a u g e
NO lf the MIL is alwaysoff, go to step 6. But if the assembly.lf the wire is OK, test the ignition switch
lvllLsometimesworks normally,first checkfor {seepage 22 53).
these problems.
N O R e p a i rs h o r ti n t h e w i r e b e t w e e nN o . 2 0 l G
. A l o o s eN o . 1 0 M E T E R( 7 . 5 A f)u s ei n t h e u n d e r ( 4 0 A )l C a n a d a5: 0 A ) f u s ea n d t h e u n d e r ' d a s h
fusel
dash fuse/relaybox. r e l a yb o x .A l s o r e p l a c et h e N o . 2 0 l G ( 4 0 A i
. A l o o s eN o . 2 0 l G ( 4 0 A )( C a n a d a5: 0 A ) I u s ei n t h e ( C a n a d a5: 0 A )f u s e . I
under-hoodfuse/relaybox.
. A i o o s eN o . 6 E C U( E C M )( 1 5 A )f u s ei n t h e u n d e r -
hood fuse/relaybox.
(conr'd)
11-97
PGM-FISystem
MIL CircuitTroubleshooting(cont'dl
1 0 .Tryto startthe engine. to. Removethe blown No. 6 ECU{ECfU)(154)fuse
from the under-hoodfuse/relaybox.
Doesthe enginestart?
1 7 . Removethe glove box (seepage 20-63)and the
Y E S - G ot o s t e p1 1 . P G M ' F Im a i n r e l a y1 .
N O - G o t o s t e p1 4 .
1 1 .Turnthe ignitionswitchOFF.
12. ConnectECMconnector terminalE31to body

groundwith a jumperwire.
ECMCONNECTOR
E 13lPI
l l 2 l 34 5 6 1 7 l1 8I
4 1 5161,/118 2( 2t
2' 23 24 z7l/ 129 31
1 8 . Checkfor continuitybetweenbody ground and
JUMPER MIL
(GRN/ORN}
WIRE P G M - Fm l a i n r e l a y1 4 P c o n n e c t otre r m i n a l sN o . 2
a n d N o .4 i n d i v i d u a l l v .
PGM-FIMAIN RELAY1
Wire side of femaleterminals 4P CONNECTOR
ls the M lL on?
f V (wHr/
B
v)
YES Updatethe ECM if it does not have the latest BLK)(
software,or substitutea known-goodECM,then IA
goes away with a known-goodECIM,replacethe
o r i g i n aE
l CM.I W r r es r d eo l l e m a l et e r m r n a l s
NO-Check for an open in the wire betweenthe ls there continuity?

E C M( E 3 1 a) n d t h e g a u g ea s s e m b l yA. l s o c h e c kf o r
a b l o w nM I L b u l b .l f t h e w i r e sa n d t h e b u l ba r e O K , Y E S - R e p a i rs h o r ti n t h e w i r e b e t w e e nt h e N o . 6
replacethe gauge assembly.l E C U( E C l \ 4( 1 ) 5 A )f u s ea n d t h e P G M - Fm l a i n r e l a y1 .
A l s o r e p l a c et h e N o . 6 E C U( E C M )( 1 5 A )f u s e . l
't4. Turn
the ignltion switch OFF,
N O - G o t o s t e p1 9 .
1 5 . Inspectthe No. 6 ECU (ECIM)
(15A)fuse in the
ls the f use OK?
YES-Go to step 22.
N O - G o t o s t e p1 6 .
11-98
19. Disconnecteach of the componentsor the 21. Checkfor continuitybetweenPGM-FImain relay 1
connectorsbelow, one at a time, and checkfor 4P connectortermlnal No. 1 and body ground.
continuitybetweenPGM-FImain relay 1 4P
PGM-FIMAIN RELAY1
connectorterminal No. 1 and body ground. 4P CONNECTOR
. PGfvl-Flmain relay 2
. ECMconnectorA (31P)
. Eachinjector2P connector
. ldle air control (lAC)valve3P connector
. CamshaftPosition(CMP)sensorB (Topdead
center(TDC)sensor)3P connector
. Crankshaftposition(CKP)sensor3P connector
PGM-FIMAIN RELAY1
4PCONNECTOR
YES Repairshort in the wire betweenthe PGM-Fl

main relay 1 and each item. Also replacethe No. 6
E C U{ E C M )( 1 5 A )f u s e . l
l a i n r e l a y1 .A l s o r e p l a c e
N O - R e p l a c et h e P G M - Fm
t h e N o 6 E C U{ E C I M()1 5 A )f u s e .I
( 1 5 A ) f u s ei n t h e
22. I n s p e c t t h eN o . 1 7 F U E LP U I \ 4 P
ls thete continuity? under-dashf use/relaybox.
YES Go to step 20. ls the tuse OK?
NO- Replacethe componentthat made continuity YES Go to step 34.

to body ground go away when disconnected.lf the
item is the ECM,updatethe ECM if it does not have NO Go to step 23.
the latestsoftware.or substitutea known-good
ECM,then recheck(seepage 11-6).lf the symptom/ 23. R e m o v et h e b l o w nN o , 1 7 F UE LP U M P( 1 5 A )f u s e
indicationgoes away with a known'good ECM, from the under-dashfuse/relaybox.
r e p l a c et h e o r i g i n a E
l CM.
Also replacethe No. 6 ECU(ECM)(15 A) fuse, 2 4 . DisconnectECfvlconnectorE (31P).
20. Disconnectthe connectorsof all these components.
. P G M - Fm l a i n r e l a y2
. E C Mc o n n e c t oA r (31P)
. lnjectors
. l d l ea i r c o n t r o l( l A C ) v a l v e
. CamshaftPosition{CMP)sensorB (Top dead
center(TDC)sensor)
. Crankshaftposition(CKP)sensor
(conr'd)
11-99
PGM-FISystem
25. Checkfor continuitybetweenECMconnector 27. Checkfor continuitybetweenECIVI
connector
terminal E9 and body ground. terminalEgandbodyground.
E (31P)
ECMCONNECTOR ECMCONNECTOR
E 131P)
Wire side o{ {emaleterminals Wire side oI Jemaleterminals
ls therc continuity? ls there continuity?
YES-Go to step 26. YES Repairshort in the wire betweenthe No. 17

F UE LP U M P( 1 5 A ) f u s ea n d t h e E C M( E 9 ) o ,r
N O R e p l a cteh e N o . l T F U E L P U M P ( 1 5 A ) f u s e , betweenthe No. 17 FUELPUMP (15A) fuse and the
and updatethe ECM if it does not have the latest P G M - Fm
I a i n r e l a y2 . A l s o r e p l a c et h e N o . 1 7 F U E L
software.or substitutea known-goodECM,then P U M P( 1 5 A ) f u s e . l
goes away with a known-goodECM.replacethe NO Go to step 28. \
originaE
l CM.I
28. Removethe rear seatcushion (seepage 20-80).
26. Removethe PGM-Flmain relay 2 (A).
29. Removethe accesspanelfrom the floor.
30. Disconnectthe fuel pump 5P connector.
11-100
31. Checkfor continuitybetweenfuel pump5P 33. Checkfor continuitybetweenfuel pump5P
connectorterminalNo.5 andbodyground. connectorterminalNo.5 andbodyground.
FUELPUMP5PCONNECTOR FUELPUMP5P CONNECTOR
=
Wire side ol lemal€ rerminals

ls therc continuity? YES Replacethe PGM-Flmain relay 2. Also

r e p l a c et h e N o . 1 7 F U E LP U M P( 1 5 A )f u s e . l
YES Repairshortin thewire betweenthefuel
p u m pa n dt h eP G M - Fml a i nr e l a y2 .A l s or e p l a c e NO Checkthe iuel pump, and replaceil if
t h EN O .1 7F U E LP U M P( 1 5 Af)U S E . T necessary.Also replacethe No. 17 FUELPUMP
( 1 5 A )f u s e . !
NO-Go to step32.
34. DisconnectECMconnectorE (31P).
PGM-Flmainrelay2 (A).
32. Reinstallthe
3 5 . T u r nt h e i g n i t i o ns w i r c hO N { 1 1 1 .
36. Measurevoltage betweenECMconnectorterminal

E9 and body ground.
ECfl CON|{CCIORE (3rPt
Wire side ol female lerminals
YES Go to step 37.
NO Repairopen in the wire betweenthe No. 17

F U E LP U M P( 1 5 A ) f u s ea n d t h e E C M( E 9 ) . 1
(cont'd)
11-101
PGM-FISystem
(cont'dl
MIL CircuitTroubleshooting
37. lvleasure voltagebetweenECM/PCM connector 40. lvleasurevoltage betweenPGN4-Fl main relay 1 4P
t e r m i n aEl 7a n db o d yg r o u n d . c o n n e c t otre r m i n a lN o . 4 a n d b o d vq r o u n d .
PGM-FIMAIN RELAY1
ECM CONNECTORE {31PI ilP CONNECTOR
MRLY

Wire side ot lemale terminals
ls there battery voltage? ls there battery voltage?
YES Go to step 42. Y E S - G o t o s t e p4 1 .
NO Go to step38. NO Repairopen in the wire betweenthe No. 6

E C U( E C M )( 1 5 A )f u s ea n d t h e P G f M - Fml a i n r e l a y1 .
38. Turn the ignitionswitch OFF. I
3 9 . Removethe PGM-FImain relay 1 {A} 4 1 . Checkfor continuitybetweenPGM-FImain relay 1

4P connectorterminal No. 3 and ECMconnector \
-A
t e r m i n a lE 7 .
PGM.FIMAIN RELAY1
4P CONNECTOR
MRLY(RED/YEL)
ECMCONNECTOR
E 131PI
MRLY(RED/YEL)
YES-Testthe PGM-Flmain relay 1 (seepage22-

51). lf the relay is OK, updatethe ECM if it does not
have the latestsoftware,or substitutea known-
good ECM,then recheck{seepage 11'6).lf the
symptom/indicationgoes away with a known-good
E C M ,r e p l a c et h e o r i g i n a E
l CM.I
NO*Repair open in the wire betweenthe PGM-FI

m a i n r e l a y1 a n d t h e E C M( E 7 ) . 1
11-102
42. ReconnectECI\4connectorE {31P). 48. MeasurevoltagebetweenPGM-FImainrelay1 4P
terminalNo.2 andbodyground.
connector
4 3 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
PGM.FIMAIN RELAY1
4PCONNECTOR
44. Measurevoltage betweenbody ground and ECM
connectorterminals42 and 43 individually.
ECMCONNECTOR
A {31PI

YES Go to step 49.
ls there battery voltage? N O R e p a i ro p e ni n t h e w i r e b e t w e e nt h e N o . 6

E C U{ E C M )( 1 5 A } f u s ea n d t h e P G M - Fml ain
YES Go to step 51. r e l a y1. !
NO Go to step 45. 4 9 . T u r nt h e i g n i t i o ns w i t c hO F F .
4 5 . T u r nt h e i g n i t i o ns w i t c hO F F . 5 0 . Checkfor continuitybetweenPGM-Flmain relay 1

4P connectorterminal No. 1 and ECMconnector
46. R e m o v et h e P G M ' F m
l a i n r e l a y1 {A) t e r m i n a l s4 2 a n d 4 3 i n d i v i d u a l l y .
,A PGM.FI MAIN RELAYI
ilP CONNECTOR
IGPl (YEL/BLK)
4 7 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) . ls there continuity?
YES Replace
t h e P G M - Fm
NO Repairopen in the wire betweenthe PGM-FI

'1
m a i n r e l a y a n d t h e E C M( A 2 ,A 3 ) . 1
{cont'd}
11-103
PGM-FISystem
51. MeasurevoltagebetweenbodygroundandECM 53. Turn the ignitionswitch OFF.
terminals44, A5,423,and424
connector
individuallv. 54. Disconnectthe manifoldabsolutepressure(MAP)
sensor3P connector.
ECMCONNECTOR
A 131P)
PG2(BLK) PG1IBLKI 55. T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .

c o n n e c t otre r m i n a A
l 21.
ECMCONNECTOR
A {31P)
ls there morc than 1.0 V ?
YES Go to step 52.
N O - R e p a i r o p e ni n t h e w i r e ( s )t h a t h a d m o r et h a n Wiresideof femaleterminals
1.0V betweenG 10'l and the ECM (A4,A5, A23,
A24l.a ls there about 5 V?
Measurevoltagebetweenbody ground and ECM YES Replacethe MAP sensor.l \

c o n n e c t otre r m i n a 4
l 21.
NO Go to step 57.
ECMCONNECTOR
A 131P)
5 7 . Turn the ignition switch OFF.
r (31P).
5 8 . D i s c o n n e cEt C Mc o n n e c t oA
ls there about 5 V?
YES-Go to step 60.
N O - G o t o s t e p5 3 .
11-104
59. Checkfor continuitvbetweenECIM connector t t, Turn the ignition switch OFF.
t e r m i n a4l 2 1a n db o d yg r o u n d .
o z , Disconnectthe throttle position(TP)sensor3P
ECM CONNECTORA {3,IPI connector.

connectorterminal 420,
ECMCONNECTOR
A 131P)
YES*Repair short in the wire betweenthe ECM

( 4 2 1 )a n d t h e M A P s e n s o r . l
NO Updatethe ECM it it does not have the latest Wiresideof femaleterminals

recheck(seepage 1'l-6).lf the symptom/indication ls there about 5 V?
originaE
l CM.I YES Replacethe thronle body (theTP sensoris
not availableseparately).
I
6 0 . Measurevoltagebetweenbody ground and ECM
connectorterminal 420. NO Go to step 65.
ECMCONNECTOR
A {3TP} 65. Turn the ignition switch oFF.
66. DisconnectECMconnectorA (31P).

1 1 2 1 43 5 o t / I
1 0 11112 5 6 / 1189 2t 21
2' 231?4 ? q Tln 29
vcc2
IYEL/
BLU)
W i r es i d eo t f e m a l tee r m i n a l s
ls there about 5 V?
YES-Go to step 68.
N O - G o t o s t e p6 1 .
conlo
11-105
PGM-FISystem
MIL CircuitTroubleshooting(cont'd)
6 7 . Checkfor continuitybetweenECIM connector 68. Measurevoltage betweenbody ground and ECM
t e r m i n aAl 2 0a n db o d yg r o u n d . c o n n e c t otre r m i n a lE 5 .
A (31P)
ECMCONNECTOR
E (31PI
ECMCONNECTOR
r l 2 l 3 1 54 o t / 9
10 t1 121,/1,/ 1516 ta, 9 2A21
22 '3 241 12526 n
vcc2
{YEL/
o BLU}

ls there continuity? Is there about 5 V?
YES Repairshon in the wire betweenthe ECN4 YES U pdatethe ECM if it does not have the latest
{A20)and the TP sensor,or repairshort in the wire software,or substitutea known-goodECM,then
betweenthe ECM (A8) and the knocksensor.t recheck(seepage 11-6).lf the symptom/indication
goes away with a known-goodEClvl,replacethe
NO Updatethe ECM if it does not have the latest o r i g i n aE
l CM.t
recheck(seepage l1-6).lf the symptom/indication NO-Go to step 69.
originaE
l CM.t 6 9 . Turn the ignition switchOFF.
7 0 . Disconnectthe fuel tank pressure(FTP)sensor3P

connector.
11-106
72. MeasurevoltagebetweenbodygroundandECM 7 6 . T u r nt h e i g n i t i o ns w i t c hO F F .
connector
terminalE5.
7 7 .T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
ECMCONNECTOR
E 131P}
7 8 . Measurevoltage betweenECMconnectorterminal
E 2 9a n d b o d y g r o u n d .
E (31P)
ECMCONNECTOR
r l 2 l 3 1 4
5 6 1 8 9
,/1,/114
15 6 2A21
22 23 241 l,/ 2930
scstBRN)
ls there about 5 V?
YES Replacethe FTPsensor.t
NO Go to step 73. ls there about 5 V (or battery voltage)?
1 3 . Turn the ignitionswitch OFF. YES-Go to step 82.
7 4 . DisconnectECMconnectorE (3'lP). NO Go to step 79.
7 5 .Checkfor continuitybetweenECMconnector 7 9 . Turn the ignitionswitch OFF.

t e r m i n a lE 5 a n d b o d y g r o u n d .
8 0 . DisconnectECMconnectorE (31P).
ECMCONNECTOR
E {31PI
Is there continuity?

( E 5 )a n dt h e F T Ps e n s o r . l

originaE
l CM.I
(cont'd)
11-107
PGM-FISystem
MIL GircuitTroubleshooting(cont'd)
t e r m i n a lE 2 9a n d b o d y g r o u n d .
ECMCONNECTOR
E 131P}
r l 2 l 34 5 8 I
14 t c 61,/118 2A21
22123124 271./ 3031
scs(BRN)
o
YES-Repair short in the wire betweenthe data link

connector(DLC)and the ECM(E29).1

o r i g i n aE
l CI\4,I
Turn the ignition switch OFF.
DisconnectECMconnectorE (31P).
Does the MIL stay on?
YES-Repair short in the wire betweenthe gauge

a s s e m b l ya n dt h e E C M( E 3 1) . l f t h e w i r e i s O K ,
r e p l a c et h e g a u g ea s s e m b l y . l

originaE
l CM.I
11-108
DLCCircuitTroubleshooting
lf the ECMdoes not communicatewith the OBD ll scan 3. Measurevoltage betweenDLCterminalsNo. 5 and
tool, HondaPGfMTester,or l/M test equipment,do this No. 16.
troubleshootingprocedure.
DATALINKCONNECTOR
{DLC)
1. Measurevoltage betweenDLCterminal No. 16 and
body ground.
DATALINKCONNECTOR
{DLCI
(WHT/RED)

Terminal
sideof lemaleterminals
YES Go to step 4.
ls therc battery voltage? NO- Repairopen in the wire betweenDLCterminal

N o . 5 a n dt h e E C M( E 3 )t.
YES-Go to step 2.
NO-Repair open in the wire betweenDLCterminal
N o . 1 6 a n d t h e N o . 9 B A C KU P ( 7 . 5A ) f u s ei n t h e 5 . M e a s u r ev o l t a g eb e t w e e nD L Ct e r m i n a l sN o . 5 a n d
under-hoodf use/relaybox.I No.7.
Measurevoltage betweenDLCterminalsNo. 4 and DATA LINKCONNECTOR

{DLCI
No.16.
DATA LINK CONNECTOR(DLCI
T e r m i n asli d eo f l e m a l et e r m i n a l s
Terminalsideof Jemale
terminals ls there 8.5 V or more?
YES Go to step 10.

Is there battery voltage?
NO Go to step 6.
YES Go to step 3.
NO Repairopen in the wire betweenDLCterminal
N o . 4 a n d b o d yg r o u n d . l
(cont'd)
11-109
PGM-FISystem
DLCCircuitTroubleshooting
{cont'dl
7. DisconnectEClvlconnectorE (31P).Make sure the ls there continuity?
O B Dl l s c a nt o o l o r H o n d aP G MT e s t e ri s
disconnectedfrom the DLC. YES U pdatethe ECMif it does not have the latest
8. Checkfor continuitybetweenDLCterminal No. 7 recheck(seepage 11-6).lf the symptom/indication
a n d b o d yg r o u n d . goes away with a known-goodECM,replacethe
originaE
l CI\4.I
DATALINKCONNECTOR
IDLC)
NO Repairopen in the wire betweenDLCterminal
N o . 7 a n dt h e E C M{ E 2 3 )A. f t e rr e p a i r i n gt h e w i r e ,
checkthe DTCwith the OBD ll scantool/Honda
PGl\4Tester,and go to the DTCTroubleshooting
Index.l
1 0 .T u r nt h e i g n i t i o ns w i t c hO F F .
' I.
1 DisconnectECI\4connectorE (31P).l\4akesure the
O B Dl l s c a nt o o l o r H o n d aP G MT e s t e ri s
Ierminal side of femaleterminals disconnectedfrom the DLC.
tJ. Measurevoltage betweenDLCterminalsNo. 5 and
YES-Repair short to ground in the wire between No.7.
DLCterminal No. 7 and the ECM {E23).After
r e p a i r i n gt h e w i r e ,c h e c kt h e D T Cw i t h t h e O B Dl l
scantool/HondaPGM Tester,and go to the DTC
DATALINKCONNECTOR
{DLC} t
Troubleshootingindex.I
NO Go to step 9.
9 . Checkfor continuitybetweenDLCterminal No. 7

a n d E C Mt e r m i n a lE 2 3 ,
ECMCONNECTOR
E {31PI
K-LINE{LTBLU) Is there 0 V?
YES Updatethe ECMif it does not havethe latest

DATA LINK CONNECTOR
originaE
l CM.I
NO Repairshort to power in the wire betweenthe
D L Ct e r m i n a lN o . 7 a n d t h e E C M( E 2 3 )A. f t e r
repairingthe wire, checkthe DTCwith the OBD ll
scantool/HondaPGMTester,and go to the DTC
T r o u b l e s h o o t i ni g
n d e x I.
11-110
InjectorReplacement
(seepage1l-144).
fuel pressure
1 . Relieve
2 . Disconnect fromthe injectors(A),disconnect

the connectors the groundcable(B),andremovethe bracket(C).
(2.2 kgf.m, l6 lbf.ftl
ffi\t\
*\
3. Disconnectthe quick-connectfittings (D).
4 . R e m o v e t h e f u erl a i lm o u n t i n g n u t s ( Ef)r o m t h e f u e l r a i l( F ) t h e nr e m o v e t h e f u e rl a i la n d i n j e c t o r sa s a n a s s e m b l y .
5. Removethe injectorclip (G)from the injector.
6. Removethe injectorfrom the fuel rail.
(cont'd)
11-111
PGM-FISystem
InjectorReplacement(cont'd)
7 . C o a t t h e n e w o - r i n g s ( A ) w i t h c l e a n e n g i n e o l l , a n d i n s e r t t h e i n j e c t o risn(tBo)t h e f u e lr a i l( C ) .
8 , l n s t a ltl h e i n j e c t o cr l i p { D ) .
9. Coatthe injectoro-rings(E)with cleanengine oil.
1 0 . I n s t a l l t h ei n j e c t o r si n t o t h e f u e lr a i l ,t h e n i n s t a l tl h e f u e l r a i li n t o t h e i n t a k e m a n i f o l d ( G ) .
1'1. Installthe fuel rail mounting nuts,ground cable.and bracket.
12. Connectthe connectorsto the injectors.
13. Connectthe quick-connectfittings.
1 4 . T u r n t h ei g n i t i o ns w i t c hO N ( l l ) ,b u t d o n o t o p e r a t e t h es t a r t e rA. f t e r t h e f u e lp u m p r u n sf o r a b o u t2 s e c o n d st,h e
fuel pressurein the fuel line rises.Repeatthis two or three times. then checkfor fuel leakage.
11-112
A/F SensorReplacement SecondaryHO2SReplacement
Special Tools Required Special Tools Fequired
O2 sensorwrench,Snap-onYA8875.SPTools 93750, 02 sensorwrench,Snap-onYA8875,SP Tools 93750,
o r e q u i v a l e n ct ,o m m e r c i a l l a
yvailabre o r e q u i v a l e n tc,o m m e r c i a l l a
Vv a i l a b l e
1. Disconnectthe A,/Fsensor4P connector(A),then 1. Disconnectthe secondaryHO2S4P connector(A),

removethe A,/Fsensor{B). then removethe secondaryH02S (B).
\I B
ffi 44N.m
InstalltheIVF sensorin the reverseorder of

removal.
2 . InstallthesecondaryHO2Sin the reverseorder of
removal.
11-113
PGM-FlSystem
ECTSensorReplacement CMPSensorB (TDCSensorl
Replacement
'1.
R e m o v et h e a i r c l e a n e r{ s e ep a g e1 1 - 1 6 2 ) .
2. Disconnectthe ECTsensor2P connector.

' t . R e m o v et h e a i r c l e a n e r( s e ep a g e1 1 - 1 6 2 ) .
3. Removethe ECTsensor(A). 2. Disconnectthe CN4PsensorB (TDCsensor)3P

conneclor.
Removethe CMP sensorB (TDCsensor)(A).
{1.2kgt m.8.7 lbt.ft} ----

r, ".- ,',',.,*nr...
8.7tbf.ftl
l n s t a l l t h es e n s o ri n t h e reverse order of removal
with a new o-ring {B). 4 . lnstallthe sensorin the reverseorder of removal
with a new o-ring {B).
11-114
IAT SensorReplacement KnockSensorReplacement
1, Dlsconnectthe IAT sensor2P connector. 1. Removethe intakemanifold bracket(A).
2. Removethe clip (A) and the IAT sensor(B).
3. lnstallthe sensorin the reverseorder of removal.
24Nm
(2.4kgt.m,17lbt.ftl
2. Disconnectthe knocksensor 1Pconnector.
3 . R e m o v et h e k n o c ks e n s o r( B ) .
4 . Installthesensorin the reverseorder of removal.
11-115
PGM-FISystem
GKPSensorReplacement
the CKPsensor3Pconnector.
1. Disconnect
2. RemovetheCKPsensor{A).
12 N.m (1.2kgt m.
8.7 tbf.ftl
3. lnstallthe sensorin the reverseorder of removal

with a new o-ring (B).
11-116
VTEC/VTC
-gl
:1
ia i- r-:
@'-;'
-
--tl ;'l--i
lt i..,,
€)
'-
tt
,.. '--'- /
. -'
VTCOILCONTROL
SOLENOID VALVE CAMSHAFTPOSITION
page11-118
Troubleshooting, ICMPISENSORA
11-'l27
Test,page Troubleshooting,page 11-121
Pagel'!-128
Replacement,
VTCSOLENOID VALVE
page11-123
Troubleshooting,
page11-128
Removal/lnspection,
11-117
VTEC/VTC
DTGTroubleshooting
DTCP0010:WC Oil ControlSolenoidValve 8. MeasureresistancebetweenVTCoil control
Malfunction s o l e n o i dv a l v e2 Pt e r m i n a l sN o . 1 a n d N o . 2 .
1 . R e s e t t h eE C M( s e ep a g e1 1 - 4 ) . VTC OIL CONTAOLSOLENOID

VAI"VE2P CONNECTOB
2. Start the engine.Hold the engineat 3,000rpm with

t h e nl e t i t i d l e .
3. Test-driveat a steadyspeed between20-40mph

(30-60km/h)for 10 minutes.
T e r m i n a s i d 6 o t m a t e t e r m i n as
YES Go to step 4. ls there 6.75 8.25 Q ?
NO- Intermittentfailure,system is OK at this time. YES-Go to step L

the VTC oil control solenoidvalve and at the NO-Replace the VTC oil control solenoidvalve
ECM.I (seepage 11-1271.a
4. Turn the ignition switch OFF. 9 . C o n n e cVt T Co i l c o n t r o ls o l e n o i d v a l v e 2 P

connectorterminalsNo. 1 and No. 2 to body
5. Disconnectthe ECMconnectorB {24P). g r o u n dw i t h a j u m p e r w i r ei n d i v i d u a l l y .
6. MeasureresistancebetweenECrUconnector wc otl coNTBoL

sotENoto
VALVE 2P CONNECTOR \
t e r m i n a l sB 1 a n d 8 2 3 .
-4-
t 1 t 2 l
ECMCONNECTOR
B I24P)
wc I lwc*
tBr-K/wHT) | liELU/WHT)
JUMPER WTREI IJUMPEnW|RE
W i r e s i d eo f 1 6 m a l et e . m i n a t s

t e r m i n a l sB 1 a n d 8 2 3 a n d b o d y g r o u n di n d i v i d u a l l y .
ls there 6.75 8.25 Q ?
YES Go to step 11.
NO Go to step7.
7. Disconnectthe VTC oil control solenoidvalve2P ls there continuity?

connector.
Y E S G o t o s t e p1 1 .
NO- Repairopen in the wire betweenthe ECM (B1,

B23)and the VTCoil control solenoidvalve.I
11-118
11. Checkfor continuitybetweenECMconnector DTCP0011:VTCSystemMalfunction
t e r m i n a l sB 1 a n d B 2 3a n d b o d y g r o u n di n d i v i d u a l l y .
1. Resetthe EClvl(seepage 11-4).
2 . S t a r tt h e e n g i n e .H o l dt h e e n g i n ea t 3 , 0 0 0r p m w i t h
n o l o a d ( i n n e u t r a l u) n t i lt h e r a d i a t o fra n c o m e so n .
3. Test-driveat a steadyspeed between20 40 mph

VTC (30 60 km/h)for 10 minutes.
(BtK/WHT)
4 . Checkfor TemporaryDTCP0011with the scantool
ls Tempotaty DTC P0011indicated?
ls there continuity? YES-Go to step 5.
YES Go to step 12. NO- Intermittentfailure, system is OK at this time.

Checkfor poor connectionsor loosewires at the
NO Updatethe ECM if it does not have the latest V T Co i l c o n t r o ls o l e n o i dv a l v ea n d a t t h e E C M . I
recheck(seepage 11-6).lf the symptom/indication Watch the low oil pressurelight with the engine
goes away with a known-goodECM,replacethe r un n i n g .
original EClvl.!
ls the low oil pressute light on?
12. Disconnectthe VTC oil control solenoidvalve 2P
connector. YES- Checkthe oil pressure(seepage 8-4).I
1 3 .Checkfor continuitybetweenECMconnector N O - G o t o s t e p6 .
t e r m i n a l sB 1 a n d 8 2 3 a n d b o d y g r o u n di n d i v i d u a l l y .
7 . Removethe auto-tensioner(seepage 4-28).
vfc
(8LK/WHT)
W i r e s i d eo f f e m a l er e r m i n as
Y E S - R e p a i rs h o r ti n t h e w i r e b e t w e e nt h e E C M( B 1 ,
B23)and the VTCoil control solenoidvalve.l
NO Replacethe VTC oil control solenoidvalve

(seepage 11-1211.a
(cont'd)
11-119
VTEC/VTC
Removethe VTC strainer(A).Checkthe WC 13. ConnectECM connectorterminalsA3 and 81 witha
s t r a i n e fro r c l o g g i n g . j u m p e rw i r e m o m e n t a r i l y .
NOTE:Do not jump for more than 1 minute,
ECM CONNECTORS
ls the strainet OK?

YES Go to step g.
NO-Clean the VTC strainer,then replacethe Did the engine stall or run rough?
e n g i n eo i l f i l t e ra n d t h e e n g i n eo i l . l
YES Test-driveat a steadyspeedbetween
9. Checkthe VTCoil control solenoidvalve{seepage 20 40 mph (30 60 km/h)for 10 minutes.
11-127
). lf temporaryDTCP00'l1 is indicated,updatethe
ECIVIif it does not have the latestsoftware,or \
ls the VTC oilcontrol solenoid valve OK? substitutea known-goodECM,then recheck(see
page 11-6).lf the symptom/indicationgoes away
YES Go to step 10. with a known-goodECM,replacethe original
E C M !.
NO Cleanthe ports of the WC oil control solenoid
valve,or replacethe VTCoil control solenoidvalve NO Go to step 14.
{seepage 11-127).a
1 4 . Checkthe VTC actuator(seepage6,8).
1 0 .InstalltheVTCoil control solenoidvalve.
ls the VTC actuatot OK?
1 1 .Startthe engine.Hold the engine at 700 1,000rpm.
YES Removethe auto-tensioner(see page 4-281,
1 2 . C o n n e cEt C Mc o n n e c t otre r m i n a lB 2 3 t o b o d v and clean or replacethe VTC oil strainer.Update
g r o u n dw i t h a j u m p e rw i r e . the ECI\4if it does not have the latestsoftware,or
substitutea known-goodECM,then recheck(see
ECMCONNECTOR
B {24PI
page 11-6).lf the symptom/indicationgoes away
with a known-goodECM,replacethe original ECM.
T
213415 6 7
8 e l1a,/1,/ 15 NO Replacethe VTC actuator.t
1 181./l l./ 21 23
vTc JUMPER
(BLK/WHT} WIRE
11-120
CMPSensorA No Signal
DTCP0340: 7. MeasurevoltagebetweenCMPsensorA 3P
terminalNo. 1 andbodyground.
connector
DTGP0344:CMPSensorA Intermittent
Interruption CMP SENSORA 3P CONNECTOR
'11-4).
1 . R e s e t h e E C M( s e ep a g e
2. Startthe engine.
ls DTC P0340and/or P0344indicated?
YES-Go to step 3. W i r e s i d eo l f e m a l e t e r m i n as

Checkfor poor connectionsor looseterminalsat ls thercabout5 V?
t h e C M Ps e n s o rA a n d a t t h e E C M . I
YES-Go to step8.
NO-Go to step10.
4. Disconnectthe CMPsensorA 3P connector.
8. Measure voltagebetweenCMPsensorA 3P
5 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) . s o .2 a n dN o .3 .
c o n n e c t ot er r m i n a lN
6. Measurevoltage betweenCMPsensorA 3P CMP SENSORA 3P CONNECTOF
connectorterminal No. 3 and body ground.
;f-;-1 J ,o,,r.*,"r.,
CMPSENSORA 3P CONNECTOR I l1 l-t
,-or---T--I
{8RN/YEL)
ni-
tG1
(BLK/YEL}
1 2 3
YES Go to step 9.
NO-Repair open in the wire betweenthe Cl\4P
s e n s oA
r a n dG 1 0 1 . 1
9. Substitutea known-goodCMPsensorA and
YES Go to step 7. recheck.
N O C h e c kt h e N o . 4 A C G { 1 0 A )f u s ei n t h e u n d e r - ls DTC P0340and/ot P0344indicated?

dash fuse/relaybox. lf the fuse is OK, repairopen in
the wire betweenthe CN4PsensorA and No. 4 ACG YES Updatethe ECM if it does not have the latest
( 1 0 A )f u s e . I software,or substitutea known-goodECM,then
o r i g i n aE
l CM.I
NO Replace l M Ps e n s o rA { s e ep a g e
t h e o r i g i n aC
11-128).t
(cont'd)
11-121
VTEC/VTC
1 0 .Measurevoltage betweenECMconnectorterminal DTCP0341:WC PhaseGap
A25 and body ground.
1 . R e s e t t h eE C M{ s e ep a g e1 1 - 4 ) .
ECMCONNECTORA 131P)
2. Startthe engine.
YES Go to step 3.

t h e C M Ps e n s o rA a n d a t t h e E C M . I
Wiresideof femalete.minals
3. Checkthe VTC oil control solenoidvalve (seepage
11_127]-.
ls there about 5 V?
Isthe VTC oil control solenoid valve OK?
YES-Repair open in the wire betweenthe ECM
( A 2 5 )a n d C M Ps e n s o rA . I YES-Go to step 4.
N O - G o t o s t e p1 1 . NO-CIean the VTCoil control solenoidvalve,or

r e p l a c ei t ( s e ep a g e1 1 - ' l 2 7 l . a
1 1 .Turn the ignition switch OFF.
4. Removethe head cover,and checkthe cam chain
't2.
DisconnectECMconnectorA (31P) {seepage 6-12).
Checkfor continuitybetweenECMconnecror ls the cam chain OK?

terminal A25 and body ground.
ECMCONNECTONA 131P}
YES Go to slep 5.
t h e c a m c h a i n( s e ep a g e6 - 1 2 ) . 1
NO Replace
5. Checkthe VTC actuator(seepage 6-8).
ls the VTC actuator OK?
YES- U pdatethe ECM if it does not have the tatest

soflware,or substitutea known-goodECI\4, then
Wiresideof femaleterminals originaE
l CM.I
ls tnere continuity? NO- Replacethe VTC actuator.l

(A25)and the CMP sensorA. t
NO Updatethe ECt\4if it does not have the latest

originaE
l CM.I
11-122
DTCPl259:WEC SystemMalfunction 6. Disconnectthe VTECoil pressureswitch2P
connector.
SpecialToolsRequired
. Pressuregaugeadapter07NAJ P07010A 7. Checkfor continuitybetweenVTECoil pressure
. A/T low pressuregaugew/panel 07406-0070300 switch 2P connectorterminals No. 1 and No. 2
. A/T pressurehose 07406-0020201
. Av/Tpressurehose,2,210mm 07IMAJ-PY4o11A SWITCH
VTECOILPRESSURE
. l"/T pressureadapter07MAJ-PY40120 2PCONNECTOR
. Oil pressurehose 07ZAJ-S54,4200
2 . C h e c kt h e e n g i n eo i l l e v e l ,a n d r e f i l li f n e c e s s a r y .

no load {in neutral)until the radiatorfan comes on.
4. Roadtestthe vehicle: T e r m i n asl i d eo f m a l et e r m i n a l s

Acceleratein the 1stgear to an engine speedover
4.000rpm. Holdthe speedfor at least2 seconds.lf
DTCP1259is not repeatedduring the first road test, Is therecontinuity?
repeatthe test two more times.
YES-Go to step8.
theVTECoil pressure
NO Replace switch.l
YES Go to step 5.
s w i t c hO N( l l ) .
NO-lntermittent failure,system is OK at this time
Checkthe oil consumptionif oil was added in step voltagebetweenVTECoil pressure
9. Measure switch
2. Checkfor poor connectionsor looseterminalsat terminalNo.1 andbodyground
2Pconnector
the VTECsolenoidvalve,the VTECoil pressure
switch,and at the ECI\4.
I VTECOILPRESSURESWITCH
2PCONNECTOR
5, Turn the ignitjon switch OFF. VTPSW
/T\ {BLU/BLK}
{.--rr-l'--.l
\rJ II
oI
Y E S G o t o s t e P1 4 .
NO-Go to step 10.
(cont'd)
11-123
VTEC/VTC
10. Measurevoltage betweenECMconnectorterminal 14. fMeasure voltagebetweenVTECoil pressure switch
89 and body ground. 2 Pc o n n e c t ot er r m i n a lN
s o .1 a n dN o .2 ,
B (24P)
ECMCONNECTOR
VTECOILPRESSURE
SWITCH
2P CONNECTOR
213415 o 1 VTPSW
8 I a t / t / n 3 15 (BLU/BLK)
(BRN/YELI
WPSW {BLU/BLK}
WiresideofIemale
terminals Wire side of Iemaleterminals

YES Repairopen in the wire betweenthe VTECoil
pressureswitch and the ECM(89).t Y E S - G o t o s t e p1 5 .
N O - G o t o s t e p1 1 . NO Repairopen in the wire betweenthe VTECoil

p r e s s u r es w i t c ha n d G 1 0 1 . 1
1 1 .Turn the ignition switch OFF.
DisconnectECMconnectorB {24P).
to. Disconnectthe VTECsolenoidvalve 2P connector.
t e r m i n a lB g a n d b o d y g r o u n d . 1 7 . Checkfor resistancebetweenVTECsolenoidvalve
2 Pc o n n e c t otre r m i n a l sN o , 1 a n d N o . 2 .
ECMCONNECTOR
B {24P)
VTECSOLENOIDVALVE
2PCONNECTOR
2 3 415 6 7
I 9 ol./ ./ 13 15
VTPSW{BLU/BLK}
Wrre side of femaleterminals
YES Repairshort in the wire betweenthe VTECoil ls there 14- 30 Sl ?

pressureswitch and the ECM (89).I
YES Go to step 18.
software.or substitutea known-goodECM,then NO Replacethe VTECsolenoidvalve (seepage
recheck(seepage 11-6).lf the symptom/indication 11-128).t
originaE
l C N 4! .
11-124
1 8 . Removethe VTECoil pressureswitch (A) and 23. Turn the ignitionswitch OFF.
s s s h o w n ,t h e n r e i n s t a ltlh e
i n s t a l l t h es p e c i a l t o o l a
VTECoil pressureswitch. 24. Disconnectthe VTECsolenoidvalve 2P connector.
07406-0020201
ot 25. Aftachthe batterypositiveterminalto VTEC
07MAJ-PY,lo11A
and
07406-0070300 07MAJ-PY40120 s o l e n o i dv a l v e2 P c o n n e c t otre r m i n a lN o . 2 .
\lsl 26. Startthe engine,then connectthe batterynegative
t:={
t e r m i n a l t oV T E Cs o l e n o i dv a l v e2 P c o n n e c t o r
R A
22 N.m t e r m i n a lN o . 1 , a n d c h e c kt h e o i l p r e s s u r ea t a n
l2.2kgt.m, engine speedof 3,000rpm.
16rbf.ft)
07NAJ-P07010A ls the oil pressure above 390 kPa (4.0 kgt/crtf ,
57 psi)?
YES Go to step 27.
NO InspecttheVTECsolenoidvalve (seepage I1-

12Al.a
1 9 .Reconnectthe VTECsolenoidvalve 2P connector
and VTECoil pressureswitch 2P connector. 27. With the batteryterminalsstill connectedtothe
VTECsolenoidvalve connector,measurevoltage
20. Connecta tachometeror OBD ll scantool/Honda betweenECMconnectorterminal 89 and bodv
PGM Testerto the DLC. oround.
B {24P)
ECMCONNECTOR
2 1 . Startthe engine.Holdthe engine at 3,000rpm with
22. Checktheoil pressureat enginespeedsof 1,000

and 2.000rpm. Keepthe measuringtime as shon
a s p o s s i b l e{ l e s st h a n 1 m i n u t e )b e c a u s et h e e n g i n e
i s r u n n i n gw i t h n o l o a d .
ls the oil ptessure below 49 kPa (0.5 kgf/cnf,

7 psi)?
YES Go to step 23.

NO Inspectthe VTECsolenoidvalve (seepage 11-
't28l.a ls there battery voltageabove 4,000 tpm?
YES Go to step 28.
NO-Replace the VTECoil pressureswitch (see

p a g e1 1 ' 1 2 8 ) . 1
29. Disconnectthe batteryterminalsfrom the VTEC

solenoidvalve terminal connector.
(cont'd)
11-125
WEC/VTC
30. DisconnectECMconnector B (24P) 32. ConnectVTECsolenoidvalve 2P connector
terminal No. 2 to body ground with a jumper wire.
VTEC SOLENOIDVALVL
2P CONNECTOR
ECM CONNECTORB {24P)
r-.'-r.---.1
t 1 t 2 l
+
JUMPERI VtS
WIRE I IGRN/YEL)
I
Wire side of femaleterminals Checkfor continuitybetweenECMconnector

ls therecontinuity?
ECM CONNECTORB {24PI
YES-Repairshortin thewire betweentheVTEC
s o l e n o ivda l v ea n dt h eE C M( 8 1 5 ) . 1
NO Goto step32.

originaE
l CM.I
NO Repairopen in the wire betweenthe VTEC

s o l e n o i dv a l v ea n dt h e E C M( 8 1 5 ) . I
11-126
WC OilControlSolenoidValveRemoval/Test
1 . R e m o v et h e W C o i l c o n t r o ls o l e n o i dv a l v e( A ) . Connectthe batterypositiveterminal to VTC oil
control solenoidvalve 2P connectorterminal No. 2.
NOTE:lnstallthe valve in the reverseorder of
removalwith a new o-ring (B),then checkthese VTCOILCONTROLSOLENOID
VALVE2PCONNECTOR
tlems:
Cleanand dry the VTCoil control solenoidvalve

mating surface.
Coatthe O-ringwith engineoil.
Do not installthe VTC oilcontrol solenoidvalve Terminalside oJ
while wearingfibrous gloves, m a l et e r m i n a l s
Be carefulnot to contaminatethe cylinder head
openrng.
BATTERY
Connectthe batterynegativeterminalto VTC oil

c o n t r o ls o l e n o i dv a l v e2 Pc o n n e c t otre r m i n a lN o . 1 ,
t h e n m a k es u r et h e v a l v e( A )o p e n sf u l l y .
Checkthe VTC oil control solenoidvalve filter for

clogging.lf it is clogged,replacethe VTC oil control
solenoidvalve.
Checkthe clearancebetweenthe port (advance

side)and the valve.The clearance(A) should be at
l e a s t2 . 8m m ( 1 / 8i n . ) .
11-127
VTEC/WC
CMPSensorA Replacement WEC SolenoidValveRemoval/
Inspection
1 . R e m o v et h e a i r c l e a n e r( s e ep a g e11 - 1 6 2 ) .
Disconnectthe CMP sensorA 3P connector. 1 . Disconnectthe VTECsolenoidvalve 2P connector.
Removethe CMPsensorA (A). MeasureresistancebetweenVTECsolenoidvalve

c o n n e c t otre r m i n a l sN o . 1 a n d N o . 2 .
Resistance:14-30 Q
B-'-----'-l:,",14*
Installthe sensorin the reverseorder of removal
with a new o-ring (B).
3. lf the resistanceis within specifications,removethe

VTECsolenoidvalve assemblv(A)from the
cylinder head,and checkthe VTECsolenoidvalve
f i l t e r( B ) f o rc l o g g i n g l.f i t i s c l o g g e d r, e p l a c et h e
L
solenoidvalve filter,the engine oilfilter, and the
e n g i n eo i l .
6x1.0mm
9.8 N.m (1.0kgf.m, 7,2 lbf.ftl
11-128
ldleGontrolSystem
TE'
IDLEAIRCONTROL{IAC)VALVE
page11-'131
Troubleshooting,
11-129
ldle ControlSystem
(
DTCTroubleshooting
DTCP0505:ldle ControlSystemMalfunction 7 . P u ty o u r f i n g e r so n t h e l o w e rp o n ( A )i n t h e t h r o t t l e
oooy.
NOTE:lf DTCP1519is storedatthe same time as DTC
P0505,troubleshootDTCP1519first, then recheckfor
DTCP0505.

then let it idle,
2. Checktheengine speedat idle with no,load

conditions:headlights,blower fan, rear defogger,
radiatorfan, and air conditioneroff.
Is the engine running at 750t50 rpm?
YES- Intermittentfailure,system is OK at this

trme.I Does the enginestall?
NO lf the idle speed is lessthan 700 rpm, go to Y E S C h e c k t h ei d l es p e e d( s e ep a g e1 1 - 1 3 8 )l f. i t ' s

step 3; if it's 800 rpm or higher,go to step 4. out of specification,replacethe IACvalve.l
3 . D i s c o n n e ct h
t e i d l e a i r c o n t r o l{ l A C )v a l v e 3 P NO With the throttlevalve completelyclosed,
connector. c h e c kf o r v a c u u ml e a k sa, n d r e p a i ra s n e c e s s a r y . l
Does the engine speed increase or fluctuate?
YES- Checkthe idle speed{seepage 1 1-138).lf the

idle will not adjust properly,cleanthe passagein
the throttle body, and then adjustthe idle.I
NO- Replace
t h e I A Cv a l v e . I
5. Removethe intakeair duct from the throttle body.
6. Startthe engine,and let it idle.
11-130
DTCPl519:IACValveCircuitMalfunction 8, Checkfor continuitybetweenbody ground and IAC
v a l v e3 Pc o n n e c t otre r m i n a lN o . 1 .
1 . R e s e t t h eE C M( s e ep a g e1 1 - 4 ) .
IACVALVE3PCONNECTOR
2. Turn the ignition switch ON (ll)
ls DTC P 1519indicated? 1 2 3
YES Go to step 3. PG1{BLK}

a.
the IACvalve and at the ECM.I

4. Disconnectthe IACvalve 3P connector.
6. Measurevoltage betlveenIACvalve 3P connector
terminal No. 2 and body ground. NO Repairopen in the wire betweenthe IACvalve
a n dG ' 1 0 1 . 1
IACVALVE3PCONNECTOR
9 . DisconnectECMconnectorA (31P)
1 0 . Checkfor continuitybetweenbody ground and

1 2 3 E C Mc o n n e c t otre r m i n a A
l 12.
IGP{YEL/BLK) ECM CONNECTORA 131P)
r l 2 l 3 l 45 6 1 7 s
r0 1l 12./ / 115 6 ./118192C21
da 25126 l27ln2930
Wire side of femaleterminals IACV{BLK/RED}
1,)
ls therebattery voltage?
YES Goto step7.
NO-Repairopenin thewire betweenthe IACvalve WiresideoJJemale

terminals
a n dt h eP G M - Fml a i nr e l a y1 . 1
7 . Turnthe ignitionswitchOFF.
YES-Repair short in the wire betweenthe IAC
v a l v ea n dt h e E C M( A 1 2 ) . 1
N O G o t o s t e p 11 .
LCOnIOl
11-131
ldle ControlSystem
(
11. ConnectIACvalve3Pconnector terminalNo.3to 15. Measurevoltagebetweenbody ground and ECM
bodygroundwith a jumperwire. c o n n e c t otre r m i n a A
l 12.
IACVALVE3PCONN€CTOR
ECMCONNECTOR
A 131P}
r l 2 l 3 1 54 6 1 7 9
IACVIBLK/REO} t 0 1tl12l,/l/ tc 6 ,/ 118 2C21
22 231?4l|
12. zil28 30
JUMPERWIRE
IACVIBLK/RED)
Checkfor continuitybetweenECMconnector I s there battery voltage?

t e r m i n a l A l 2 a n d b o d yg r o u n d .
YES-Update the ECI\4if it does not have the latest
ECMCONNECTOR
A 131P) recheck(seepage 11-6).lf the symptom/indication
o r i g i n aE
l CI\4.1
N O - R e p l a c et h e I A Cv a l v e . I
!
ls therecontinuity?
YES Goto step13.
NO-Repairopenin thewire betweenthe IACvalve

a n dr h eE c M( A 1 2 ) . r
1 3 .Reconnect
the IACvalve3Pconnector.
1 4 .Turnthe ignitionswitchON (ll).
11-132
A/G SignalCircuitTroubleshooting
1 . Turn the ignitionswitch ON (ll). 6. Momentarilyconnectunder-hoodtuse/relaybox
14Pconnectorterminal No. 10 to body ground with
2 . MomentarilyconnectECMconnectorterminals424 a jumper wire severaltimes.
and E18with a jumper wire severaltimes.
UNDER.HOODFUSE/RELAY
BOX
I4P CONNECTOR
1 2 3 5 6
1 8 9 10 11 I J 14
ACC (RED)
JUMPERWIRE
ls there a clicking noise f rom the NC compressor
ls there a clicking noise I rom the NC compressor clutch?
clutch?
YES- Repairopen in the wire betweenthe ECM
YES Go to step 3. (E'18)and the Ay'Cclutch relay.l
NO-Go to step 6. NO- Checkthe A/C systemfor other symptoms.l
Start the engine.
Turn the blower switch ON.
5. Turn the Ay'Cswitch ON.
Does the NC operate?
Y E S - T h e a i r c o n d i t i o n i n sg i g n a li s O K . I

software,or substitutea known-goodECM.then
o r i g i n a€
l CM.l
11-133
ldle GontrolSystem
AlternatorFRSignalCircuitTroubleshooting
' t . Disconnectthe alternator4P '11.
connectorfrom the Connectalternator4P connector term inal No.4 to
alternalor. body ground with a jumper wire.
2. T u r nt h e i g n i t i o ns w i t c hO N { l l ) .
ALTERNATOR4P CONNECTOR
3 . Measurevoltage betweenECMconnector
t e r m i n a l s4 2 4 a n d 8 1 3 . 1 2
ECM CONNECTORS ALTFIWHT/RED)
A l31Pl 3 4
1 2 1 3 4 5 6 1 1| 1 . , 'I JUMPERWIRE
10 1 1 1 1 2 , / 5 6 , / r8119l2C21
23124 28129130
L (BRN/Y EL)
ALTF
(WHT/REDI
213 4t5 6 1
8 9ltal,/l/ 15 1 2 .Checkfor continuitybetweenbody ground and
EClvlconnectorterminal 813.
B (24PI
ECMCONNECTOB
ls there about 5 V?
YES Go to step 4.
\
N O - G o t o s t e p1 3 .
5. Reconnectthe alternator4P connector.
6. Slan the engine.Hold the engineat 3,000rpm with Wire side of femaleterminals
then let it idle. ls there continuity?
7. lvleasurevoltagebetweenECMconnector YES-Testthe alternator(seepage 4-22).1

t e r m i n a l sA 2 4 a n d B 1 3 .
Does the voltage decrease when the headlights ( B1 3 )a n dt h e a l t e r n a t o r . l
and rear window defogger arc tutned on?
Y E S T h e a l t e r n a t oFr Rs i g n a li s O K . l
't4. DisconnectECMconnectorB (24P).
9. DisconnectECMconnectorB (24P).
10. Disconnectthe alternator4P connector.
11-134
ElectricalPowerSteering(EPSI
SignalCircuitTroubleshooting
15. Checkfor continuitybetweenbody ground and 1 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .

ECIMconnectorterminal 813.
2 . l\4easure voltage betweenECMconnector
ECM CONNECTORB I24P}
t e r m i n a l s4 2 4 a n d E 1 6 .
( 8 1 3 )a n dt h e a l t e r n a t o r . l ls there battery voltage?
NO Updatethe ECM if it does not have the latest YES Go to step 6.

rechecklsee page 11-6).lf the symptom/indication NO Go to step 3.
o r i g i n aE
l CM.I 3 . Startthe engine.
4 . Turn the steeringwheel lo the full lock position.
5 . l\4easurevoltage betweenECMconnector
t e r m i n a l sA 2 4 a n d E 1 6 .
ls there momentatybattery voltage?
Y E S T h e E P Ss i g n a li s O K . t
N O G o t o s t e p1 0 .
6 . T u r nt h e i g n i t i o ns w i t c hO F F .
7. Disconnectthe EPScontrol unit 20Pconnector.
(cont'd)
11-135
ldle ControlSystem
ElectricalPowerSteering(EPSISignalCircuitTroubleshooting(cont'd)
'13.
9. Measure voltagebetweenEPScontrolunitterminal l\4easure voltagebetweenEPScontrol unitterminal
N o . l 7a n db o d yg r o u n d . N o . 1 7a n d t h e b o d y g r o u n d .
EPSCONTROLUNIT2OPCONNECTOR
EPSCONTROLUNIT2OPCONNECTOR

ls there battety voltage? YES Substitutea known-goodEPScontrol unit

andrecheck.l
YES-Substitute a known-goodEPScontrol unit
a n dr e c h e c k . I N O - G o t o s t e p1 4 ,
NO- Repairopen in the wire betweenthe ECM 1 4 . Turn the ignition switch OFF.
( E1 6 )a n d t h e E P Sc o n t r o lu n i t . l
t5_ D i s c o n n e c t t hE
e C Mc o n n e c t oE
r {31P).
1 0 .Turn the ignitionswitch OFF. 1 6 .Checkfor continuitybetweenbody ground and

E C I \ c4o n n e c t otre r m i n a E
l 16.
I ' I. Disconnectthe EPScontrol unit 20Pconnector.
ECMCONNECTOR
E {31PI
1 2 3 4 5 6 1 7 l1 89
5 6 . / 1 8 2A21
22 23 zi ./ 2930 o l
EPSLD
{LTGRN/BLK)
a,
Wiresideot Iemaleterminals
lsthere continuity?
YES Repairshort in the wire betweenthe ECN4

( E1 6 )a n d t h e E P Sc o n t r o lu n i t . l

originaE
l CM.I
11-136
BrakePedalPositionSwitch SignalCircuitTroubleshooting
1. Checkthe brakelights. , T O P( 1 5 A )f u s el n t h e
4 . I n s p e ctth e N o . 7 H O R N S
Are the brake lights on without pressing the brake
pedal? ls the tuse OK?
YES Inspectthebrakepedal positionswitch YES- Repairopen in the wire betweenthe brake

( s e ep a g e1 9 - 6 ) . I pedal positionswitch and the No.7 HORN,STOP
( l5A) fuse, Inspectthe brakepedal positionswitch
NO Go to step 2. ( s e ep a g e1 9 - 1 0 ) . 1
2. Pressthe brakepedal. NO Repairshort in the wire betweenthe ECM

( E 2 2 )a n dt h e N o . 7 H O R N ,S T O P( 1 5 A ) f u s e .
Do the brake lights come on? Replace the No.7 HORNS , T O P( 1 5 A ) f u s e . t
YES-Go to step 3.
NO Go to step 4.
3. MeasurevoltagebetweenECMconnector
terminalsA24 and E22with the brakepedal
presseo.
YES-The brakepedal positionswitch signal is

oK,I
NO Repairopen in the wire betweenthe Eclvl

(E22)and the brakepedal positionswitch.l
11-137
ldle ControlSystem
ldle Speedlnspection
NOTE: 3 . Startthe engine.Holdthe engineat 3,000rpm with
' Leavethe idle air control (lAC)valve connecled. n o l o a d ( i n n e u t r a l u) n t i lt h e r a d i a t ofra n c o m e so n ,
. Beforecheckingthe idle speed,checkthese items: t h e nl e t i t i d l e .
- T h em a l f u n c t i o n i n d i c a t o lra m p ( M l L )h a s n o t b e e n
reportedon. 4 . Checkthe idle speedwith no-loadconditions;
- l g n i t i o nt i m i n g headlights,blower fan, radiatorfan, and air
- S p a r kp l u g s conditioneroff.
- Aircleaner
- PCVsystem ldle speedshould be: 750 t 50 rpm
. P u l l t h ep a r k i n gb r a k el e v e ru p . S t a r tt h e e n g i n e a
, nd
make sure the headlightsare off. 5 . Let the engine idle for 1 minute with the heaterfan
switch on Hl and air conditioneron, then checkthe
1. Disconnectthe evaporativeemission(EVAP) i d l es p e e d .
canisterpurge valve 2P connector.
ldle speedshould be: 750 t 50 rpm
2. Connecta tachometer(A)to the test tachometer
connector(B),or connectthe HondaPGM Tester(C) NOTE:lf the idle speed is not wilhin specification,
or an OBD ll scantool to the data link connector go to the Symptom TroubleshootingIndex,
(DLC)(D) locatedunder the driver'sside of the
dashboard. 6 . Reconnectthe EVAPcanisterpurgevalve 2P
connector.
11-138
ECMldle LearnProcedure
The idle learn proceduremust be done so the ECMcan
learnthe engine idle characteristics.
Do the idle learn procedurewheneveryou do any of

these actions:
. Disconnectthe battery.
Replacethe ECMor disconnectits connector.
Resetthe ECM.
NOTE:ErasingDTCSwith the HondaPGM Tester
does not requireyou to do the idle learn procedure.
Removethe No.6 ECU{ECM)( 15A)fuse from the
Removethe No.19baftery(80A)fuse from the under-
hood fuse/relaybox.
R e m o v eP G M - Fm I a i n r e l a y1 .
Removeany of the wires from the under-hoodfuse/
retayDox.
Disconnectany of the connectorsfrom the under
hood fuse/relaybox.
Disconnectthe connectorbetweenthe engine
compartmentwire harnessand ECMwire harness.
Disconnectthe G2 terminal from the transmission
h ous r n g .
DisconnecttheG'l terminal from the body.
D i s c o n n e c t t hG
e 1 0 1t e r m i n a fl r o m t h e c y l i n d e rh e a d
cover.
Procedure:
To completethe idle learn procedure,do this:
1. Make sure all electricalitems (Ay'C,

audio, rear
defogger,l:ghts,etc.,)are off.
2. Startthe engine,and hold it at 3,000rpm with no

l o a d{ i n n e u t r a l u) n t i lt h e r a d i a t o fra n c o m e so n , o r
u n t i lt h e e n g i n ec o o l a n t t e m p e r a t u r e a c h e s1 9 4 " F
(90'c).
3. Let the engine idle for about 5 minuteswith the

NOTE:lf the radiatorfan comes on, do not includeits

r u n n i n gt i m e i n t h e 5 m i n u t e s .
11-139
FuelSupplySystem
ComponentLocationIndex {
PUMP
T e s t ,p a g e1 1 - 1 4 1
Fleplacement, page 11'153
FUELFILTER
Replacement, page 11-152
FUELGAUGESENDINGUNIT
T e s t ,p a g e1 1 - 1 5 6
FUELPRESSUN REGULATOR
Replacement, page'11-'152
FUELFILLCAP
FUELTANK
R e p l a c e m epnat ,g e '1l - 1 5 5
FUELTUBE/OUICK.CONNECT FITTINGS
Precautions, page 11-148
Removal, p a g e11-'149
Installation,page 11-'l50
FUELFEEDLINE FUELVAPORLINE
a
FUELPULSATIONDAMPER
page11'154
Replacement,
i . . /
PGM.FIMAIN RELAY1
PGM.FIMAINRELAY2
T r o u b l e s h o o t ipnagg, e ' l ' l - 1 4 1
11-140
FuelPumpCircuitTroubleshooting
lf you suspecta problemwith the fuel pump, checkthat 5. N4easure
voltage betweenPGM-Flmain relay 2 5P
the fuel pump actuallyruns;when it is on, you will hear connectorterminal No. 1 and body ground.
some noise if you listento the fuel fill port with the fuel
fill cap removed.The fuel pump should run for 2 PGM.FI MAIN RELAY2
5P CONNECTOR
secondswhen the ignition switch is first turned on. lf
the fuel pump does not make noise,checkas follows:
2. Removethe glove box {seepage 20-63),then

removethe PGM-FImain relay 2 (A).
Wire side oJfemaleterminals
YES Go to step 6.
NO Repairopen in the wire betweenthe under-

d a s hf u s e / r e l a yb o x a n d P G M - Fm
3 . Turn the ignitionswitch ON {ll). 7. DisconnectECMconnectorE (31P).
Measurevoltage betweenPGM-Flmain relay 2 5P 8. Checkfor continuitybetweenPGM-FImainrelay2

connectorlerminal No. 5 and body ground. 5P connectorterminal No. 3 and ECMconnector
t e r m i n a lE 1 .
PGM.FIMAIN RELAY2
5P CONNECTOR PGM-FIMAIN RELAY2 5PCONNECTOB
E
t 2 l
IGPl
(YEL/BLK}
Ftxm
7 -
z
IMOFPR ECMCONNECTOR
E 131P}
(GBN/
YEL)
ls therecontinuity?
YES-Go to step 5.
YES-Go to step9.
NO Repairopen in the wire betweenthe PGM'Fl
m a i n r e l a y1 a n dt h e P G M - Fm
l a i n r e l a y2 . t NO-Repairopenin thewire betweenthe PGMFl
m a i nr e l a y2 a n dt h eE C M( E 1 ) . 1
(cont'd)
11-141
FuelSupplySystem
FuelPumpCircuitTroubleshooting(cont'dl (
L R e i n s t a l l t hP
e G M - Fm
l a i n r e l a y2 . ls there battery voltage?
1 0 .T u r nt h e i g n i t i o ns w i t c hO N ( l l ) . YES U pdatethe ECM if it does not havethe latest

so{1ware,or substitutea known-goodECM.then
1 ' ] .Measurevoltage betweenECI\4/PCM
connector recheck(seepage 11-6).lf the symptom/indication
t e r m i n a lE 1a n d b o d y g r o u n d . goes away with a known-goodECM,replacethe
o r i g i n aE
l CM.I
ECMCONNECTOB
E {31P)
NO Go to step 15.
t5. Turn the ignition switch OFF.
to. Removethe rear seat cushion (seepage 20-80).
1 1 . Removethe accesspanelfrom the floor.
1 8 . Measurevoltage betweenfuel pump 5P connector

Wiresideof femaleterminals terminal No. 5 and body ground within the first 2
secondsafter the ignition switchwas turned ON (ll).
ls there battety voltage? FUELPUMP5P CONNECTOR
YES Go to step 12.
N O - R e p l a c et h e P G M - Fm
(
1 3 .ReconneclECMconnectorE (31P).
1 4 .Turn the ignitionswitch ON (ll),and measure

voltagebetweenECMconnectorterminal E1 and wire sideoI femaleterminals
body ground within the first 2 secondsafterthe
i g n i t i o ns w i t c hw a s t u r n e dO N ( l l ) .
E (31PI
ECMCONNECTOR
YES Go to step 24.
N O - G o t o s t e p1 9 .
20. R e m o v et h e P G M - Fm
l a i n r e l a y2 .
11-142
21. ConnectPGM-Flmain relay 2 5P connector 25. Checkfor continuitybetweenfuel pump 5P
terminalsNo. 1 and No. 2 with a iumDerwire. connectorterminal No. 4 and body ground.
PGM.FIMAIN RELAY2
5P CONNECTOR FUELPUMP5P CONNECTOR
FUEL
PUMP
(YEL/
GRN) FNI E
JUMPER
WIRE tri
rcr fv
{YEL/BLK)
dffi
A

Wiresideof {emaleterminals
22. Turn the ignitionswitch ON (ll). ls therecontinuity?
23. Measurevoltagebetweenfuel pump 5P connector Y E S R e p l a cteh ef u e lp u m p . l

terminal No. 5 and body ground.
NO-Repairopenin thewire betweenthefuel
FUELPUMP5PCONNECTOR p u m p5 Pc o n n e c t oarn dG 5 5 1 . 1
Wiresideol femaleterminals
Y E S R e p l a c e t h eP G M - Fm
l a i nr e l a y 2 . t
NO-Repair open in the wire betweenthe PGM-Fl

main relay 2 and the fuel pump 5P connector.l
11-143
FuelSupplySystem
FuelPressureRelieving
Beforedisconnectingfuel lines or hoses,relieve 9. Placea rag or shop towel over the quick-connect
pressurefrom the system by disconnectingthe fuel fitting (A).
tube/quickconnectfitting in the enginecompartment.
1 . T u r nt h e i g n i t i o ns w i t c hO F F ,
l a i n r e l a y2 ( A ) .
2 . R e m o v et h e P G M - Fm
1 0 .Disconnectthe quick-connectfifting (A):Hold the

connector(B)with one hand and squeezethe
retainertabs (C)with the other handto release
them from the lockingpawls {D).Pullthe connector
off.
3 . S t a r t t h ee n g i n e a, n d l e t i t i d l e u n t i li t i s s t a l l s . NOTE:
. P r e v e ntth e r e m a i n i n gf u e l i n t h e f u e lf e e d l i n e o r
NOTE:The DTCSor TemporaryDTCSP0301.P0302, hosefrom flowing out with a rag or shop towel.
P0303,P0304may come on during this procedure. . Be carefulnotto damagethe line (E)or other
lf any DTCSare stored,ignorethem. parts.
. Do not use tools.
4 . Turn the ignitionswitch OFF. . l f t h e c o n n e c t o r d o e ns o t m o v e ,k e e p t h er e t a i n e r
tabs presseddown, and alternatelypull and push
Removethe fuel fill cap, and relievefuel pressure the connectoruntil it comes off easily.
inthefueltank. . Do not removethe retainerfrom the line; once
removed,the retainermust be replacedwith a
6 . Removethe enginecover. new one.
7 . Disconnectthe negativecablefrom the battery.
8 . Checkthe fuel quick-connectfitting for dirt, and

cleanit if necessary.
1 1 After disconnectingthe quick-connectfifting, check

i t f o r d i r t o r d a m a g e( s e ep a g e11 - 1 4 9 ) .
11-144
FuelPressureTest
. Fuel pressuregauge 07406-0040004
. Fuel pressuregaugesel 07ZAJ-S5A0100
1 . R e l i e v et h e f u e l p r e s s u r e( s e ep a g e1 ' 1 - 1 4 4 ) .
2. Disconnectthe quick-connectfitting (A).Aftachthe

fuel pressuregaugeset and fuel pressuregauge.
Startthe engineand let it idle.
. lf the enginestarts,goto step 5.

. lf the enginedoes not start,goto step 4.
Checkto see if the fuel pump is running:listento

the fuel fill port with the fuel fill cap removed.The
fuel pump should run for 2 secondswhen the
ignitionswitch is first turned on.
. lf the pump runs,go to step 5.

. l f t h e p u m p d o e sn o t r u n ,d o t h e f u e l p u m pc i r c u i t
t r o u b l e s h o o t i n(gs e ep a g e11 - 14 1) .
5 . Readthe pressuregauge.The pressureshould be

320-370 kpa (3.3-3.8 kgf/cm',a7-52 psi)
. lf the pressureis OK, the test is complete.

. lf the pressureis out of specification,replacethe
fuel pressureregulatorand the fuel filter (see
p a g e1 1 - 1 5 2 t) h, e n r e c h e c kt h e f u e l p r e s s u r e .
11-145
FuelSupply System
FuelLineInspection
Checkthe fuel system lines,hoses,and fuel filter for damage,leaks,and deterioration.Replaceany damagedparts.
Makesurethe connectionis
secureand the quick-connect
fitting cover is firmly lockedinto place.
11-146
Checkall clampsandretightenif necessary.
A: Do notdisconnect
the hosefromthe lineat theseioints.
Settheboltflange
T h e r es h o u l d b e n o
W.W Setthispart
C l a m pi n t h e m i d d l e .
C l a m pi n t h e m i d d l e .
t h e f u e l { i l lt u b e ,
a l i g nt h e m a r k s
on the tubeand
t h el i n e .
11-147
FuelSupply System
FuelLine/Ouick-Connect
FittingsPrecaution
The fuel tube/quick-connect fittings connectthe fuel rail
(A)to fuel feed hose (B),the fuel feed hose (B)to the
f u e l l i n e( C ) ,a n dt h e f u e l t u b e( D )t o t h e f u e l p u m p
a s s e m b l y( E ) .W h e n r e m o v i n go r i n s t a l l i n gt h ef u e l f e e d
hose,fuel pump assembly,or fuel tank, it is necessary
to disconnector connectthe quick-connectfittings.
Pay attentionto the following:
. T h e f u e lf e e dh o s e( B ) ,f u e lt u b e ( D ) ,a n d q u i c k -
connectfittings (F)are not heat-resistanU be careful
not to damagethem during welding or other heat-
generalrngproceoures.
. T h ef u e l f e e dh o s e( B ) ,f u e l t u b e( D )a n d q u i c k -
connectfittings (F)are not acid-proof;do not touch
them with a shop towel which was used for wiping
batteryelectrolyte.Replacethem if they came into
contactwith electrolyteor somethingsimilar.
. When connectingor disconnectingthe fuel feed hose

(B),fuel tube (D),and quick'connectfittings (F).be
carefulnot to bend or twist them excessivelv.ReDlace
them it they are damaged.
A disconnectedquick-connectfitting can be
reconnected,but the retaineron the mating line cannot
be reusedonce it has been removedfrom the line.
Replacethe retainerwhen I
. replacingthe fuel rail.
. replacing t h ef u e ll i n e .
. replacingthe fuel pump.
. replacingthe fuel filter,
. replacingthe fuel gaugesendingunit.
. it has been removedfrom the line.
. it isdamaged.
PART I\4ANUFACTUREB RETAINER

COLOR
EN GI N E TOKAI GREEN
COI\4PARTMENT
( F U EFLEED
H O S EF; UE L
L I N ES I D E )
E NGI N E TOKAI BLU
COIVIPARTMENT
( F U EFLEED
H O S EF: U E L
R A I LS I D E )
FUELTANK SANOH WHITE
UNIT
11-148
FittingsRemoval
FuelLine/Ouick-Gonnect
1 . R e l i e v ef u e l p r e s s u r e( s e ep a g e1 ' l - 1 4 4 ) . 4. Checkthe contactarea (A) of the line (B)for dirt and
d am a g e .
2 . Checkthe fuel quick-connectfiftingsfor din, and
clean if necessary. . lf the surfaceis dirty, clean it.
. if the surfaceis rusty or damaged,replacethe
Hold the connector(A) with one hand and squeeze f u e l p u m p ,f u e l f i l t e r f, u e l f e e dl i n e .
the retainertabs(B)with the other hand to release
them from the lockingpaws (C).Pullthe connector
off.
=k
NOTE:
. B e c a r e f u ln o t t o d a m a g et h e l i n ei D ) o r o t h e r
parts.Do not usetools.
. lf the connectordoesnot move, keepthe retainer
tabs presseddown, and alternatelypull and push
the connectoruntil it comes off easily.
. Do not removethe retainerfrom the line; once
removed,the retainermust be replacedwith a
new one.
To preventdamagedand keepforeign matter out,

cover the disconnectedconnectorand line end with
plasticbags (A).
NOTE:
. The retainercannot be reusedonce it has been
r e m o v e df r o m t h e l i n e .
Replacedthe retainerwhen
- replacing t h e f u e lr a i l .
- r e p l a c i n gt h e f u e lf e e dI i n e .
- r e p l a c i n gt h e f u e l p u m P .
- replacingthe fuel filter.
- replacing t h e f u e l g a u g es e n d i n gu n i t
- it has been removedfrom the line.
- it is damaged.
11-149
FuelSupply System
FuelLine/Ouick-Connect
Fittingslnstallation
1. Checkthe contacta rea (A) of the line (B)for dirt and 3. Beforeconnectinga new fueltube/quick-connect
damage,and clean if necessary. fitting assembly(A),removethe old retainerfrom
t h e m a t i n ol i n e ,
Inserta new retainer(A) into the connector(B) if the

retaineris damaged,or after
. r e p l a c i n gt h e f u e l r a i l .
. replacingthe fuelfeed line.
. replacingthe fuel pump.
. replacingthe fuel filter.
. r e p l a c i n gt h e f u e l g a u g es e n d i n gu n i t
. removingthe retainerfrom the line.
11-150
4. Align the quick-connectfittingswith the line (A). 5. lvlakesure the connectionis secureand that the
a n d a l i g nt h e r e t a i n e (r B )l o c k i n gp a w l sw i t h t h e p a w l sa r ef i r m l y l o c k e di n t o p l a c e c; h e c kv i s u a l l y
connector{C)grooves.Then pressthe quick- and by pullingthe connector.
connectfittings onto the line until both retainer
p a w l sl o c kw i t h a c l i c k i n gs o u n d .
N O T E ;l f i t i s h a r dt o c o n n e c tp, u t a s m a l la m o u n to f
n e w e n g i n eo i l o n t h e l i n ee n d .
Connectionwith new retainer:
6. Reconnectthenegativecableto the battery,and

t u r n t h e 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
run for about 2 seconds,and fuel pressurewill rise
Repeat2 or 3 times, and checkthat there are no
fuel leaks.
Reconnectionto existing retainer:
11-151
FuelSupply System
FuelPressureRegulator FuelFilterReplacement \ {
Replacement
The fuel filter should be replacedwheneverthe fuel
pressuredrops belowthe specifiedvalue {270 320 kpa,
1 . R e m o v et h e f u e l p u m p ( s e ep a g e11 - 1 5 3 ) . 2.8 3.3 kgflcm', 40 47 psi),after makingsure that the
fuel pump and the fuel pressureregulatorare OK.
2 . Removethe fuel pressureregulator(A).
1 . R e m o v et h e f u e l p u m p ( s e e p a g e l l - ' 1 5 3 ) .
2. Removethe fuel filter (A).
@-to
Re
IJ
e"^
ê
AR
...\
g s @n-)
s g
Installthe part in the reverseorder of removalwith
a n e w o - r i n g( B ) .
Installin the reverseorder of removalwith a new

basegasket(B)and a new o-ring (C),then check
these items:
' When connectingthe wire harness,make sure

the connectionis secureand the terminal (D) is
firmly lockedinto place.
. W h e ni n s t a l l i n g
t h e f u e l g a u g es e n d i n gu n i ti E ) ,
make sure the connectionis secureand the
connectoris firmly lockedinto place.Be careful
not to bend or twist it excessively.
11-152
FuelPump/FuelGaugeSendingUnit Replacement
SpecialToolsRequired 8 . R e m o v et h e l o c k n u (t A )a n d t h e f u e lt a n k u n i t .
F u e ls e n d e rw r e n c h0 7 X A A - 0 0 1 0 1 0 A
1 . R e l i e v et h e f u e l p r e s s u r e( s e ep a g e1 1 - 1 4 4 ) .
Removethe fuel fill cap.
Removethe seat cushion(seepage 20-80).
Removethe accesspanel (A)from the floor.
9 . R e m o v et h e s t o p p e r{ O ) .R e l e a s e t h e h o o k ( P )a n d
r e m o v et h e f u e lf i l t e r( B ) ,t h e f u e l g a u g es e n d i n g
t e f u e l p u m p 5 Pc o n n e c t o(rB ) .
5 . D i s c o n n e ct h u n i t ( C ) .t h e c a s e( D ) ,t h e w i r e h a r n e s s( E ) ,a n d t h e
fuel pressureregulator(F).
Disconnectthe quick-connectfitting {C)from the
f u e lt a n ku n i t . 1 0 . W h e nc o n n e c t i n g t h e f u e lt a n k u n i t ,m a k es u r et h e
connection i s s e c u r ea n d t h e s u c t i o nf i l t e r( G )i s
7 . U s i n gt h e s p e c i atlo o l ,l o o s e nt h e f u e lt a n ku n i t t o t h e f u e lp u m p ( H ) .
f i r m l yc o n n e c t e d
locknut(A).
1 1 . I n s t a ltl h e f u e lt a n ku n i t i n t h e r e v e r s eo r d e ro f
r e m o v aw l i t h a n e w b a s eg a s k e t( l ) a n dn e w o - r i n g s
( J ) ,t h e nc h e c kt h e s ei t e m s :
. W h e nc o n n e c t i n tgh e w i r e h a r n e s sm , a k es u r e
t h e c o n n e c t i o ni s s e c u r ea n d t h e c o n n e c t o(rK )i s
f i r m l y l o c k e di n t ot h e p l a c e .
. W h e n i n s t a l l i n gt h e f u e l g a u g es e n d i n gu n i t ,
make sure the connectionis secureand the
c o n n e c t oirs f i r m l y l o c k e di n t o p l a c e .B e c a r e f u l
not to bend or twist the connectorexcessively.
. W h e ni n s t a l l i n g t h e f u e l t a n ku n i t ,a l i g nt h e m a r k s
93 N.m ( L )o n t h e f u e lt a n k( M ) a n d t h e f u e lt a n k u n i t( N i
19.5kgf.m,69 lbf.ftl
11-153
FuelSupply System
FuelPulsationDamperReplacement
1 . R e l i e v et h e f u e l p r e s s u r e ( s e e p a g e l l - 1 4 4 ) .
2. Removethe enginecover.
3. Removethe fuel rail mounting nuts from the fuel

rail.
4 . R e m o v et h e g r o u n dc a b l e( G1 0 1 .
5 . R a i s et h e f u e l r a i l .
6 . P l a c ea w r e n c h( A )o n t h e f u e l r a i l( B ) .
7 . P l a c ea w r e n c h( C )o n t h e f u e l p u l s a t i o nd a m p e r( D ) .
8. Removethe pulsationdamper.
9. Installthefuel pulsationdamper in lhe reverse

order of removalwith new washers.
NOTE:
. Replaceall washerswhenever the fuel pulsation
damper is loosenedor removed,
. l f t h e d r a i nh o l e( A )o f t h e f u e l p u l s a t i o n d a m p e r
cover does not face bottom, reinstallit as shown.
11-154
FuelTank Replacement
1 . R e l i e v e t h e f u epl r e s s u r e( s e ep a g e1 1 - 1 4 4 ) .
2 . D r a i nt h e f u e lt a n k :R e m o v et h e f u e l p u m p ( s e ep a g e11 - 1 5 3 )U. s i n ga h a n dp u m p ,h o s e ,a n d c o n t a i n esr u i t a b l ef o r

gasoline.draw the fuel from the fuel tank.
3 . Jack up the vehicle,and suppon it with safetystands.
Removethe fuel pipe cover (A).Disconnectthe fuel vapor hose and quick-connectfittings.
Disconnectthe hoses.Slide backthe clamps (B),then twist the hosesas you pull to avoid damagingthem.
(}
\
A 38N.m
(3.9ksf.m,28lbfft)
5. Placea jack or other supportunder the tank.
6 . R e m o v e t h es t r a pb o l t s ,a n d l e t t h e s t r a p( C )h a n g f r e e .
7 . R e m o v et h e f u e lt a n k ( D ) .l f i t s t i c k s t o t h eu n d e r c o a t o ni t s m o u n t ,c a r e f u l l yp r y i t o f f t h e m o u n t
8. Installthe parts in the reverseorder of removal.
11-155
FuelSupply System
FuelGaugeSendingUnit Test
Special Tools Required 7. Measurevoltage betweenfuel pump 5P connector
Fuelsenderwrench 07XAA-001010A terminalsNo. 1 and No. 2 with the ignition switch
ON (ll).There should be batteryvoltage.
NOTE;For the fuel gauge system circuitdiagram,refer
to the GaugesCircuitDiagram(see page 22-58||. . lf the voltage is as specified,go to step 8.
. l f t h e v o l t a g ei s n o t a s s p e c i f i e d , c h e c k f o r :
1 . C h e c k t h eN o . 1 0 f U E T E R
{ 7 . 5 A ) f u s ei n t h e u n d e r -
dash fuse/relaybox beforetesting. - a n o p e n i n t h e Y E U B L Ko r B L Kw i r e .
- p o o r g r o u n d( G 5 5 1 ) .
2. Do the gauge drive circuitcheck(see page 22-56|l.
' lf the fuel gauge needlesweepsfrom minimuni FUELPUMP5PCONNECTOR

to maximum positionand then returnsto the
m i n i m u mp o s i t i o nt.h e g a u g ei s O K .G o t o s t e p3 .
. lf the fuel gauge needle does not sweep from
m i n i m u mt o m a x i m u mp o s i t i o np o s i t i o na n d
then returnto the minimum position,replacethe
gauge assemblyand retest.
3 . T u r nt h e i g n i t i o ns w i t c hO F F .
4. Removethe rear seat cushion{seepage 20-80). Wiresideof femaleterminals
5. Removethe accesspanel (A)from the floor.

Turn the ignition switch OFF.Removethe No. 9
BACKUP (7.5A)fusefrom the under-hoodfuse/
-ztr relay box for at least 10 seconds,lhen reinstallit.
Installa 2 Q resistorbetweenfuel pump 5P

connectorlerminals No. 1 and No. 2, then turn the
i g n i t i o ns w i t c hO N ( l l ) .
FUELPUMP5P CONNECTOR
-VVV-
{Y
{YEL/BLK)
2 9 RESISTOR,
(elrt \
=-a \
//,
\ 4 5 /
6. Disconnectthe fuel pump 5P connector{B).
11-156
1 0 . C h e c k t h a t t h ep o i n t e r o ft h e f u e lg a u g ei n d i c a t e s 1 5 . M e a s u r er e s i s t a n cbee t w e e nt h e N o . 1 a n d N o . 2
"F". 'l12
terminalswith the float at E (EN4PTY), \HALF
F U L L )a, n d F { F U L L p ) ositions.
. lf the pointerdoes not indicate"F", replacethe lf you do not get the following readings,replacethe
g au g e . f u e l g a u g es e n d i n gu n i t{ s e ep a g e1 ' 1 - 1 6 3 ) .
. lf the pointerindicates"F", inspectthe fuel
gauge sendingunit. Float F
'U2 LOW E
Position
NOTE:The pointerof the fuel gauge returns to the Resistance 1 1 68,5 114.4 130
bottom of the gaugedial when the ignition switch {0) to 13 to 74.5 to 126.6 to 132
is OFF,regardlessof the fuel level.-
NOTE:Removethe No. 9 BACKUP (7.5A)fuse from
11. Relievethe fuel pressure(seepage 11-144\. the under-hoodfuse/relaybox for at least 10
secondsafter completingtroubleshooting,
1 2 . R e m o v et h e f u e l f i l l c a p . otherwiseit may take up to 20 minutesfor the fuel
gaugeto indicatethe correctfuel level.
13. Disconnectthe quick-connectfittingsfrom the fuel
pump.
1 4 . U s i n gt h e s p e c i atlo o l ,l o o s e nt h e f u e lt a n ku n i t
locknut(A).
A
93Nm
{9.5ksf.m,69 lbf.ft}
11-157
FuelSupply System
Low FuelIndicatorTest
1 . Do the fuel gauge sendingunit test (seepage 11,
rcol.
. lf the system is OK, go to step 2.

. lf the system has any malfunction,repair it.
Turn the ignition switch OFF.Removethe No. 9

BACKUP (10A)fuse from the under-hoodfuse/
relay box for at least30 seconds,then reinstallit.
Turn the ignition switch ON (ll)with the float at the

E (EMPry) position.
. lf the low fuel indicatoris on, go to step 4.

. lf the low fuel indicatoris not on, referto the low
fuel indicatorCircuitDiagram(seepage 22-58)
and checkthe circuit.
4, Turn the ignition switch OFF.Removethe No. 9

BACKUP (10A)fuse from the under-hoodfuse/
relay box for at least30 seconds,then reinstallit.
Lift the float above the LOW position.
. l f t h e l o w f u e li n d i c a t o r g o eo
s f f , t h es y s t e mi s O K .
. lf the low fuel indicatoris still on, referto the low
\,
fuel indicatorCircuitDiagram{seepage 22-58),
and checkthe circuit.
11-158
IntakeAir System
i l .
INTAKE AIR BYPASSCONTROL AIR CLEANER

THERMALVALVE R e p l a c e m e npt a, g e11 ' 1 6 2
Test,page 1'1-161 AIR CLEANERELEMENT
R e p l a c e m e npta, g e11 - 1 6 2
THROTTLE CABLE
Adjustment, page11-163
THROTTLEBODY R e m o v a l / l n s t a l l apt a
i ogne1, 1 - 1 6 4
Test,page l'l-160
page 11-165
Disassembly/Reassembly,page 11 166
11-159
IntakeAir System
Throttle BodyTest
NOTE:
. Do not adjustthe throttlestop screw. lt is presetat the
factory.
. lfthe malfunction i n d i c a t o lra m p ( M l L )h a sb e e n
reportedon, checkfor diagnostictrouble codes
( D L C S()s e ep a g e1 1 3 ) .
1. With the engine off, checkthe throttle cable

movement.The cableshould move without binding
or sticking.
. lf lhe cable moves OK, goto step 2.

. lf the cable binds or sticks,checkit and its routing.
. l f t h e c a b l ei s f a u l t y ,r e r o u t ei t o r r e p l a c ei t a n d
a d j u s ti t ( s e ep a g e1 1 - 1 6 3 )t h , e ng o t o s t e p2 .
2. l\4ovethe throttle lever by hand to see if the throftle

valve and/or shaft are too looseor too tight.
. lf there is excessiveplay in the throttlevalve

shaft,or any binding in the throttlevalve at the
fully closedposition,replacethe throttle body.
. l f t h e t h r o t t l e v a l v ea n d s h a f ta r e O K ,g o t o s t e p 3 .
3. Connectthe scantoolto the DLC.
!
5 . Checkthe throttle positionwith the scantool. The
readingshould be about 10%when the throttle is
fully closedand about 90% when the throttle is fully
openeo.
. lf the throttle positionis correct,the throttle body

is OK.
. lf thethrottle positionis notcorrect,replacethe
throttle body.
11-160
Test
IntakeAir BypassGontrolThermalValve
Special Tools Required 5 . R a i s ea n d l o w e rt h e e n g i n es p e e d a
, n d m a k es u r e
Vacuum Pump/Gauge,0 30 in. Hg A973X-041-XXXXX the vacuum gauge readingdoes not changeas the
rpm cnanges.
1 . S t a nt h e e n g i n e T
. h e nl e t i t i d l € .
lf the vacuum readingchanges,checkfor these
NOTE:The enginecoolanttemperaturemust be proorems:
b e l o w1 4 9 ' F ( 6 5 ' C ) .
. l\4isrouted, leaking,broken,or cloggedintakeair
2 . R e m o v et h e v a c u u mh o s e( A ) f r o mt h e i n t a k ea i r bypasscontrol systemvacuum lines.
duct, and connecta vacuum pump/gaugeto the . A crackedor damagedintakeair bypasscontrol
nose. t h e r m a lv a l v e .
3 . R a i s ea n d l o w e r t h ee n g i n es p e e d a
. n d m a k es u r e
t h e v a c u u mg a u g er e a d i n gc h a n g e sa s t h e e n g i n e
speeocnanges.
lf the vacuum readingdoes not change,checkfor

these problems:
. M i s r o u t e dl,e a k i n gb, r o k e n o, r c l o g g e di n t a k ea i r
bypasscontrol system vacuum lines.
. A crackedor damagedintakeair bypasscontrol
t h e r m a lv a l v e .
4 . H o l dt h e e n g i n ea t 3 , 0 0 0r p m w i t h n o l o a d( i n
neutral)until the radiatorfan comes on, then let it
i dl e .
11-161
IntakeAir System
Air CleanerReplacement Air CleanerElementReplacement
1. Removethe nuts (A) and the stud (B). 1 . D i s c o n n e ct h
t e P C Vh o s e1 A ) .
{0.3kgf m,2lbf.ft)
2. Removethe air cleaner(C). 2 . O p e nt h e a i r c l e a n e rh o u s i n gc o v e r( B ) .
3 . Installin the reverseorder of removal. 3 . R e m o v et h e a i r c l e a n e r( C )f r o m t h e a i r c l e a n e r

h o u s i n g( D ) .
\,
4 . Installin the reverseorder of removal.
11-162
Throttle CableAdjustment
1 . Checkcablefree play at the throttle linkage.Cable
f r e e p fa v ( A )s h o u l db e 1 0 1 2 m m ( 3 / 8 1 / 2i n . ) .
lf the free play is not within spec (10- 12 mm,

3 1 8 - 1 1 2 l n . l , l o o s etnh e l o c k n u (t B ) ,t u r n t h e
adjustingnut (C)untilthe free play is as specified,
then retightenthe locknut.
With the cable properlyadjusted,checkthe throttle

valve to be sure it opens fully when you push the
acceleratorpedalto the floor. Also checkthe
throttlevalve to be sure it returnsto the idle
positionwheneveryou releasethe accelerator
peoar.
11-163
IntakeAir System
Throttle CableRemoval/lnstallation
1. Fully open the throttlevalve,then removethe Installin the reverseorder of removal.
throttle cable (A)from the throttle link (B).
5 . After installing,startthe engine.Holdthe engine at
3,000rpm with no load (in neutral)untilthe radiator
fan comes on, then let it idle.
H o l dt h e c a b l e ,r e m o v i n ga l l s l a c kf r o m i t .
7 . Set the locknuton the cable bracket{A).

Turn the adjustingnut (B)so that its free play is
0 mm.
T h e s h o u l db e
no crearance.
(P/N08?98-9002)
2 . R e m o v et h e c a b l eh o u s i n g( C ) f r o mt h e c a b l e ('1.0kgf.m,
bracket(D). 7.2 tbf.ftl
3 . Removethe throttlecable (A)from the accelerator

p e d a l( B ) .
!
8 . Removethe cablefrom the cable bracket(A).Set
the adjustingnut on the other side of the throttle
bracket,then tightenthe locknut{C}.
9 . With the cable properlyadjusted,checkthe throttle

valve to be sure it opensfully when you push the
acceleratorpedalto the floor. Also checkthe
throttlevalveto be sure it returnsto the idle
positionwheneveryou releasethe accelerator
Deoat.
SILICONEGREASE B
(P/N08798-9002)
11-164
Throttle Body Removal/lnstallation
NOTE:
' Do not adjustthe throttle stop screw.
. A f t e r r e a s s e m b l y , a d j u s t t h e t h r o t t l e c a b l e { s e e p a g e l l - 1a6n3d)t h e c r u i s ec o n t r o lc a b l e( s e ep a g e4 - 4 5 ) .
. The throttle position(TP)sensoris not removable.
THROTTLE
LEVER
Thereshould be
noclearance
THROTTLECABLE
MANIFOLD
ABSOLUTEPRESSURE
{MAP}SENSOR
22Nm
(2.2 kgt.m, 16 lbf.ft)
EVAPORATIVEEMISSION{EVAPI
CANISTERPURGEVALVE
IDLEAIR CONTROL
{IACI VALVE
11-165
IntakeAir System
Throttle Body Disassembly/Reassembly
2 N.m
{0.2 kgt m, 1 lbf.ft)
V MAPSENSOR
EMISSION
EVAPORATIVE {EVAP)
PURGE
CANISTER VALVE
TPSENSOR THROTTLEBODY
3.5 N.m
(0.35kgf m.2.5lbf ft)
11-166
CatalyticConverterSystem
DTCTroubleshooting
DTCP0420:CatalyticSystemEfficiency
BelowThreshold
NOTE:lf some of the DTCSlistedbelow are storedat
the same time as DTCP0420,troubleshootthose DTCS
first, then recheckfor DTCP0420.
P 0 1 3 7P, 0 1 3 8S: e c o n d a r yH e a t e dO x y g e nS e n s o r
(secondaryHO2S)(Sensor2)
P 0 1 4 1S: e c o n d a r yH O 2 S( S e n s o 2 r )heater
1 . R e s e t h e E C M{ s e ep a g e1 ' l - 4 }t,h e nc o n t i n u et o
step 2 through 5 to resetthe readinesscode.

n o l o a d( i n n e u t r a lu) n t i l t h er a d i a t o fr a n c o m e so n .
D r i v ef o r a b o u t l 0 m i n u t e sw i t h o u ts t o p p i n gY. o u r
speeocan vary.
4 . With the transmissionin 4th gear,drive at a steady

speed between50 62 mph (80-'100 km/h)for
30 seconds.
Repeatstep 4 three times. Betweeneach repetition,

closethe throttlecompletelyfor 1 2 seconds.lf
the engine is stoppedduring this part of the
procedure,repeatsteps3, 4 and 5.
Checkfor a TemporaryDTCwith the scantool.
Does the scan tool indicate Temporaty DTC

P0420?
YES Checkthe TWC. lf necessary,replacethe

TWC.I
N O C h e c kf o r r e a d i n e s cs o d ec o m p l e t i o nl.f t h e
readinessis complete,it was a interminentfailure,
and the system is OK at this time. lf the readiness
code is incomplete,repeatsteps2 through 5.1
11-167
PCVSystem
DTCTroubleshooting
DTCP1505:PCVAir Leakage

n o l o a d( i n n e u t r a l u) n t i lt h e r a d i a t o fra n c o m e so n
3. Letthe engineidle tor al least40 secondswith the

4. Checkfor a DTCP1505with the scantool
YES-Check these partsfor vacuum leaks l
. PCVvalve
. PCVhose
. EVAPcanisterpurge valve
. Throttlebody
. Brakeboosterhose
NO - Intermittentfailure,system is OK at this
time.l
11-168
PCVValve Inspectionand Test PCVValve Replacement
1. Checkthe PCVvalve (A),hoses{B),and 'L
Disconnectthe PCVhose.
connectionsfor leaksor restrictions.
Removethe PCVvalve (A).
2 . At idle, make sure there is a clickingsound from the (4.5kgf.m,33lbf.ft)

PCVvalve when the hose betweenthe PCVvalve
a n d i n t a k em a n i f o l di s l i g h t l yp i n c h e d{ A ) w i t hy o u r l parts in the reverseorder of removal
3 . I n s t a lthe
f i n g e r so r p l i e r s . with a n e w g a s k e t( B ) .
lf there is no clickingsound,checkthe PCVvalve
grommet for cracksor damage.lf the grommet is
OK. reDlacethe PCVvalve and recheck.
11-169
EVAPSystem
EVAPORATIVEEMISSIONIEVAPI
CANISTERPURGEVALVE
Troubleshooting, 'l1-175,
step 3 on page
s t e p1 o n p a g e1 1 - 1 8 0
FUELTANK VAPORCONTROLVALVE
Test,page 11'187
R e p l a c e m e npt a, g e1 1 1 8 9
EVAPORATIVEEMISSION{EVAPI
CANISTER
step 28 on page 11'183
Troubleshooting,
page 11-189
Replacement,
FUELTANKPRESSURE SENSOR
T r o u b l e s h o o t ipnagg, e11 - 1 7 1
EVAPORATIVEEMISSION{EVAP}
BYPASSSOLENOIDVALVE
Troubleshooting,
s t e p1 p a g e' 1 1 ' 1 7 6 ,
' 120o n
s t e p o n p a g e1 1 1 8 1
EVAPORATIVEEMISSION{EVAP)
CANISTERVENT SHUT VALVE EVAPOBATIVEEMISSON{EVAP)
Troubleshooting, VALVE
TWO WAY 'l1-'186
step 23 on page 1'l 178, Test,page
s t e p1 go n p a g el 1 - 1 8 2
11-170
DTCTroubleshooting
DTCP0451:FTPSensorRange/Performa
nce 6. Connecta vacuum pump to the open end of the
Problem hose.
SpecialTools Required
Vacuum Pump/Gauge,0-30 in. Hg A973X-041-XXXXX
1 . R e m o v et h e f u e lf i l l c a p .
3. l\4onitorfuel tank pressure(FTP)sensorvoltage

with the HondaPGM Tester,or medsurevoltage
betweenECMconnectorterminalsE4 and E14.
ECMCONNECTOR
E 131P)
7 . Turn the ignition switch ON {ll).
8 . l\4onitorFTPsensorvoltagewith the Honds PGM

Tester,or measurevoltage betweenECM
c o n n e c t otre r m i n a l sE 4 a n d E 1 4 ,a n d c a r e f u l l y
s q u e e z et h e v a c u u mp u m p a l i t t l e .
ECMCONNECTOR
E 13lPI
W i r es i d eo f f e m a l tee r m i n a l s
ls there about 2.5V?
YES-Go to step 4.
NO Replacethe FTPsensor.I

Wiresideof lemaleterminals
5 . Disconnectthe hose betweenthe EVAPtwo way
valve and the FTPsensorat the EVAPtwo way
valve end. 9 . The voltageshould smoothly drop from about 2.5 V
t o a b o u t1 . 5V . S t o pa p p l y i n gv a c u u mw h e n t h e
voltagedrops to about 1.5V or damageto the FTP
sensormay occur.
Does the voltage drop to about 1.5 V and hold?
YES Checkfor misrouted,leaking,or brokenFTP

s e n s o rv a c u u ml i n e s .l f t h e v a c u u ml i n e sa r e O K ,
updatethe ECM if it does not havethe latest
originaE l CM.I
NO Replacethe FTPsensor.!
11-171
EVAPSystem
DTCP0452:FTPSensorCircuitLow Voltage 6. Turn the ignition switch OFF.
1. Checkthe vacuum lines at the FTPsensorfor 7 . R e i n s t a l l t h feu e lf i l l c a p .

misrouting,leakage.breakage,or clogging.
8. Disconnectthe FTPsensor3P connector.
Are the vacuumlines OK?
YES Go to step 2.
10. Measurevoltage betweenFTPsensor3P connector
NO Repairor replacevacuum lines as t e r m i n a l sN o . 1 a n d N o . 2 .
necessary.I
FUELTANKPRESSURE 3PCONNECTOR
SENSOR
3 . R e m o v et h e f u e l f i l lc a p .
VCgl {YEL/BLU}
5. Monitor FTPsensorvoltagewith the HondaPGM

Tester,or measurevoltage betweenbody ground
and ECMconnectorterminal E14.
E 131PI
ECMCONNECTOR
1 2 t 3 t 45 o / 8 9
././114 tc 61./18 2C 21 ls there about 5 V?
22123241 t 26 271/ 29 31 '1.
TP (LTGRN) YES Go to step 1
NO-Repair open in the wire betweenthe FTP

s e n s o ra n dt h e E C M{ E 5 ) . 1
ls thete about2.5 V?
YES- Intermittentfailure,system is OK at this time.

the FTPsensorand at the ECrM.l
NO Go to step 6.
11-172
11. MeasurevoltagebetweenFTPsensor3P connector DTCP0453:FTPSensorCircuitHighVoltage
t e r m i n a l sN o . 2 a n d N o . 3 .
FUELTANKPRESSUBE
1. Checkthe vacuum lines at the FTPsensorfor
SENSOR3P CONNECTOR
misrouting,leakage,breakage,or clogging.
Are the vacuumlines OK?

FTP(LT GBN)
N O R e p a i ro r r e p l a c ev a c u u ml i n e sa s
necessary.I
2 . R e s e t h e E C M{ s e ep a g e1 1 ' 4 ) .
W i r e s i d eo f f e m a l e t e r m i n a l s
3. Removethe fuel fill cap.

ls there about 5 V?
YES- Replacethe FTPsensor.t
5. lvlonitorFTPsensorvoltagewith the Honda PGM
N O - G o t o s t e p1 2 . Tester,or measurevoltage betweenbody ground
a n d E C Mc o n n e c t otre r m i n a lE ' 1 4 .
' t 2 .Turn
the ignitionswitch OFF.
ECMCONNECTOR
E 131PI
1 3 .DisconnectECMconnectorE (31P),
1 4 .Checkfor continuitybetweenFTPsensor3P 1 1 2 1 34 5 6 7 I 9
connectorterminal No. 3 and body ground. 5 6 / t18 2C 21
24 2il./ 29 30 31
FTPSENSOR3P CONNECTOB TP {LTGRN}
FTP (LT GRNI

Is there about 2.5 V?
YES Intermittentfailure,system is OK at this time.

W i r es i d eo f f e m a l e l e r m i n a t s
t h e F T Ps e n s o ra n d a t t h e E C M . I
ls there continuity? NO Go to step 6.
YES Repairshort in the wire betweenthe FTP

s e n s o ra n d t h e E C I \ {4E 1 4 ) . I
NO-Update the ECM if it does not have the latest

goes away with a known-goodEClvl,replacethe
originaE
l CM.I
{cont'd)
11-173
EVAPSystem
6. Turn the ignitionswitch OFF. 11, Measurevoltage betweenFTPsensor3P connector
t e r m i n a lN
s o . 2 a n dN o . 3 .
7 . R e i n s t al h
l e f u e lf i l l c a p .
FTPSENSOR3P CONNECTOR
8. Disconnectthe FTPsensor3P connector.
FTPILT GRN}
'10.
l\4easure voltage betweenFTPsensor3P connector
t e r m i n a l sN o . 1 a n d N o . 2 .
FTPSENSOR3P CONNECTOR
VCC3(YEL/BLU) Wiresideof femaleterminals
ls there about 5 V?
YES Replacethe FTPsensor.l
NO Go to step 12.
Wire side of femaleterminals l\4easure voltage betweenECMconnector

t e r m i n a l sE 4 a n d E1 4 ,
ls there about 5 V?
\
E (31P)
ECMCONNECTOR
NO-Repair open in the wire betweenthe FTP

sensorand the ECM (E4).!
ls there about 5 V?
YES Repairopen in the wire betweenthe FTP

s e n s o ra n d t h e E C M( E 1 4 ) . I

software,or substitutea known-goodECN4. then
originaE
l CM.I
11-174
DTCPl456:EVAPControlSystemLeakage EVAP Canister Purge Valve Test
(FuelTankSvstem)
3. Disconnectthe vacuum hose from the EVAP
canisterpurge valve (A),and connecta vacuum
The fuel system is designedto allow specified oumo to the hose.
maximum vacuum and pressureconditions.Do not
deviatefrom the vacuum and pressuretests as
indicatedin these procedures.Excessivepressure/
vacuum would damagethe EVAPcomponentsor cause
eventualfuel tank failure.

Vacuum Pump/Gauge,0-30 in. Hg A973X-041-XXXXX
This is a two-trip code. Oncecleared,it cannot be

reproducedin one trip. Also, cenain specificdriving
and ambientconditionsmust occur beforethe ECMwill
completethe systemchecks.Additionaltest drives may
still not meet the specificconditionsneededto A973X-041-XXXXX
reproducethe code.
Follow thesetroubleshootingprocedurescarefullyto
ensurethe integrityof the system and to confirm the 5 . Apply vacuum to the hose.
causeof the problemor code.
Does the valve hold vacuum?
NOTE:Freshfuel has a highervolatilitythat creates
greaterpressure/vacuum. The optimum condltlonfor YES-The EVAPcanisterpurge valve is OK. Go to
testing is fresh fuel, and must be lessthan a full tank. lf s t e p1 1 .
possible,to assistin leakdetection,add 1 gallon of
fresh fuel to the tank (as long as it will not fill the tank). NO-Go to step 6.
just beforestartingthese procedures.
Fuel Fill Cap Check
7 . Disconnectthe EVAPcanisterpurge valve 2P
1. Checkthe fuel fill cap (the cap must say "lf not connecror.
tightened3 clickscheckengine light may come
o n ") .
ls the proper luel till cap installed and properly

tightened?
YES Go to step 2.
NO- Replaceor tightenthe cap.I
2. Checkthe fuel fill cap seal.
ls the tuel fill cap seal missing or damaged?
YES- Replace
t h e f u e lf i l l c a p . I
N O T h e f u e l f i l lc a p i s O K .G o t o s t e p3 .
{cont'd)
11-175
EVAPSystem
8. Checkfor continuitybetweenEVAPcanisterpurge EVAP Bypass Solenoid Valve Test
valve2Pconnenctor terminalNo.2 andbody
grouno. 11, Disconnectboth vacuum hosesfrom the EVAPtwo
way valve (A),and connecta vacuum pump to the
EVAP CANISTERPURGE canisterport on the EVAPtwo way valve.
VALVE 2P CONNECTOR

F-
A973X-041-XXXXX
ls therecontinuity?
YES Goto step9. Turn the EVAPbypasssolenoidvalve on with the

Honda PGM Tester,or connectECMconnecter
the EVAPcanisterpurgevalve.l
NO Replace terminal E20to body ground with a jumper wire.
9 . Disconnect B (24P).
ECMconnector E 131P)
ECMCONNECTOR
1 0 . Checkfor continuitybetweenEVAPcanisterpurge
terminalNo.2 andbodyground.
valve2Pconnector 1 2 3 4 5 6 1 7 l1 8 9
4 5 6 / 118 2C21
EVAPCANISTERPURGE
2 2 t 2 ? 24 z7l./29
VALVE2PCONNECTOR 2WBS
(BLU/RED}
JUMPER
WIRE
1 2
PCS Wiresideof femaleterminals
{YEL/BLU)
'.\'
1 3 .Turn the ignitionswitch ON (ll).
Wire side of femaleterminals 1 4 .Apply vacuum to the hose.

Y E S - G o t o s t e p1 5 ,
YES Repairshort in the wire betweenthe EVAP
canistep
r u r g ev a l v ea n dt h e E C I \ {48 2 1 ) . 1 NO Go to step 20.

originaE
l CM.I
v
11-176
1 5 . Turn the ignition switch OFF. '19.
Measurevoltage betweenEVAPbypasssolenoid
valve 2P connectorterminal No. 1 and body ground.
to. Disconnectthe EVAPbypasssolenoidvalve 2P
connecror. EVAPBYPASSSOLENOID
VALVE2PCONNECTOR
1 7 . Checkfor continuitybetweenEVAPbypass
solenoidvalve 2P connectorterminal No. 2 and
body ground.
2
tG'l
EVAP BYPASSSOLENOID {BLK/ORN)
VALVE 2P CONNECTOR
Wire side ol lemale terminals
Wire side oI Iemaleterminals
YES Go to step 18.
NO-Repair open in the wire bet\iveen

the EVAP
bypasssolenoidvalve and the ECM (E20).1
'18.T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
YES Replacethe EVAPtwo way/bypasssolenoid

v a l v e( A ) . 1
NO-Repair open in the wire betweenthe EVAP

bypasssolenoidvalve and the No. 4 ACG (10A)
fuse.l
{cont'd)
11-177
EVAPSystem
(cont'dl
DTCTroubleshooting
2 0 . P l u gt h e f u e l t a n kp o r t ( A )o f t h e E V A P t w o w a y EVAP Canister Vent Shut Valve Test
valve,
22. Disconnectthe vacuum hosefrom the EVAP
canistervent filter (A),and connecta vacuum pump
to the hose.
While monitoring FTPsensorvoltagewith the

HondaPGM Tester,or measuringthe voltage
b e t w e e nE C Mc o n n e c t otre r m i n a l sE 4a n d E1 4 , T u r nt h e i g n i t l o ns w i t c hO N ( l l ) .
slowly pump the vacuum pump until the voitage
droDSto about 1.5volts. Apply vacuum to the hosewith five strokesof the
pump.
ECMCONNECTOR
E {31PI
YES Go to step 25. \
NO The EVAPcanistervent shut valve is OK. Go

to step 30.
25. T u r nt h e i g n i t i o ns w i t c hO F F .
26. Disconnectthe EVAPcanistervent shut valve 2P

Wiresideof femaleterminals conneclor.
2 1 . Checkfor continuitybetweenEVAPcanistervent
Does the voltagedtop to 1.5 V and hold fot at s h u tv a l v e2 Pc o n n e c t otre r m i n a lN o . 2 a n d b o d y
Ieast 20 seconds? ground.
YES-The EVAPbypasssolenoidvalve/EVAPtwo EVAPCANISTEBVENTSHUT

way valve is OK. Go to step 22. VALVE2PCONNECTOR
N O R e p a i rt h e l e a kf r o m t h e E V A Pb y p a s s
solenoidvalve, EVAPtwo way valve.or
F T Ps e n s o r . l
{LTGRN/REOI
11-178
VacuumHosesand ConnectionsTest
3 0 . Do the fuel tank vapor control valve test (seepage

11 - 1 8 7 ) .
ls the fuel tank vapot control valve OK?
Y E S - G o t o s t e p3 1 .
t h e f u e l t a n kv a p o rc o n t r o lv a l v e . l
NO Replace
5 t . Tightenthe fuel cap 3 "clicks", then monitorthe

FTPsensor readingswith the Honda PGM Tester.
Startthe engine.and let it idle for 5 minutes.

Checkthe FTPsensor readings.
YES-Go to step 28.
NO-Replace the EVAPcanistervent shut valve (A)

a n d o - r i n g( B ) . 1
28. DisconnectECMconnectorE (31P).
29. Checkfor continuitybetweenEVAPcanistervent

s o l e n o i dv a l v e2 P c o n n e c t otre r m i n a lN o . 2 a n d
body ground.
EVAPCANISTERVENTSHUT
VALVE2PCONNECTOR
ls the reading above 0.5 kpa (4 mm Hg, 0.16 in.

Hg) pressure, or about 3 V?

goes away with a known-goodECfvl,replacethe
Wire side o{ femaleterminals originaE
l CM.t
NO Checkthe following partsfor leaks:l

. F u e l t a n k( A )
YES-Repair short in the wire betweenthe EVAP . F u e lf i l l c a p ( B )
c a n i s t e vr e n ts h u tv a l v ea n dt h e E C M( E 2 1 ) . 1 . F u e lf i l l p i p e ( C )
. F u e l t a n kv a p o rc o n t r o lv a l v e ( D )
NO Updatethe ECM if it does not have the latest . F u e l t a n kv a p o rr e c i r c u l a t i ovna l v e( E )
soflware,or substitutea known-goodECM,then . F u e l t a n kv a p o rr e c i r c u l a t i otnu b e ( F )
recheck(seepage 11-6).lf the symptom/indication . F u e l t a n kv a p o rs i g n a l t u b e( G )
goes away with a known-goodECM,replacethe . F u e l t a n kv a p o rc o n t r o lv e n t t u b e ( H )
o r i g i n aE
l CM.I . FTPsensor(J)
- R e p a i ro r r e p l a c ea n y l e a k i n gp a r t s .
11-179
EVAPSystem
DTCPl457:EVAPControlSystemLeakage 2. Turn the EVAPcanisterpurge valve on with the
(EVAPCanisterSystem) HondaPGM Tester,or connectECMconnector
terminal 821 to body ground with a jumper wire.
The fuel system is designedto allow specified ECMCONNECTOR

A I24P'
maximum vacuum and pressureconditions.Do not
deviatefrom the vacuum and pressuretests as
indicatedin these procedures.Excessivepressure/
vacuum would damagethe EVAPcomponentsor
causeeventualfuel tank systemfailure.
Vacuum pump/gauge,0-30 in.HgA973X-041-XXXXX
W i r e s i d eo f l e m a l et e r m i n a l s
This is a two-trip code.Once cleared,it cannot be
reproducedin one trip. Also, certainspecificdriving
and ambientconditionsmust occur beforethe ECfMwill Turn the ignition switch ON (ll).
completethe system checks,Additionaltest drives may
still not meet the specificconditionsneededto 4 . Apply vacuum to the hose.
16^r^.1' '^6 rh6 ^^.16

Followthesetroubleshootingprocedurescarefullyto
ensurethe integrityof the system and to confirm the YES-Go to step 5.
causeof the problem or code.
NO-The EVAPcanisterpurge valve is OK. Go to
NOTE:Freshfuel has a highervolatilitylhat creates
greaterpressure/vacuum. The optimum conditionfor
step 10.
t
testing is fresh fuel, and there must be lessthan a full Turn the ignition switch OFF.
tank. lf possible,to assistin leakdetection,add I gallon
of fresh fuel to the tank (as long as it will not fill the b. Disconnectthe EVAPcanisterpurge valve 2P
tank),just beforestartingthese procedures. conneclor,
EVAPCanister Purge Valve Test 7 . Checkfor continuitybetweenEVAPcanisterpurge

valve 2P connectorterminal No. 2 and body ground.
1. Disconnectthe vacuum hose from the EVAP
canisterpurge valve (A),and connecta vacuum EVAPCANISTEN
PURG€
VALVE2PCONNECTOR
pump to the hose.
-4-
l-fircs
ll2l
IYEL/8Lu)
(f])
I
W i r e s i d eo f f e m a l e l e r m i n a l s
ls therecontinuity?
YES-Goto step8.
4973X-041-XXXXX
NO Repairopenin thewire betweenthe EVAP
c a n i s t epru r g ev a l v ea n dt h eE C M / P C(M
821).I
s w i t c hO N( l l ) .
11-180
9. MeasurevoltagebetweenEVAPcanisterpurge EVAP Bypass Solenoid Valve Test
terminalNo. 1 andbodyground.
valve2Pconnector
10. Disconnectboth vacuum hosesfrom the EVAPtwo
EVAPCANISTERPURGE way valve {A),and connecta vacuum pump to the
VALVE2PCONNECTOR canisterport on the two way valve.
Wire side oI lemaleterminals
ls thetebatteryvoltage?
the EVAPcanisterpurgevalve.l
YES- Replace
1 1 .T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
NO Repairopenin thewire betweenthe EVAP
'It
canisterpurgevalveandthe No.4 ACG(10A) Apply vacuum to the hose.
fuse.I
YES The EVAPtwo way/bypasssolenoid valveis

O K . G o t o s t e p1 8 .
N O - G o t o s t e p1 3 .
1 4 . Disconnectthe EVAPbypasssolenoidvalve 2P
connector.
Checkfor continuitybetweenEVAPbypass
s o l e n o i dv a l v e2 P c o n n e c t otre r m i n a lN o . 2 a n d
b o d yg r o u n d .
EVAPBYPASSSOLENOID
VALVE2P CONNECTOR
Wire sideof female terminals
(cont'd)
11-181
EVAPSystem
EVAP Canisler Vent Shut Valve Test
18. Disconnectthe vacuum hosefrom the EVAP

canistervent filter (A),and connecta vacuum pump
to the hose.
YES Go to step 16.
NO- Replacethe EVAPtwo waylbypasssolenoid

valve (A).1
to. DisconnectECMconnectorE {31P). 19. Turn the EVAPcanistervent shut valve on with the
HondaPGM Tester,or connectECMconnector
't7.
Checkfor continuitybetweenEVAPbypass terminal E21to body ground with a jumper wire.
solenoidvalve 2P connectorterminal No. 2 and
body ground.
E (3TP)
ECMCONNECTOR
EVAPBYPASSSOLENOID
VALVE2P CONNECTOR
1 1 2 1 34 5 8 9 vsv(
{LTGBN/RED)
\ ,
1/ 1 5tal/la 2A21
lI l tl - 2l l z3lz4 zil./ m 31
2WBS JUMPER
WIRE
-[BLU/REo)
())
I
Wiresideol lemaleterminals
20. Turn the ignitionswitch ON (ll)

2 1 .Apply vacuum to the hose.
YES Repairthe short in the wire betweenthe
EVAPbypasssolenoidvalve and the ECM{E20).f Does the valve hold vacuum?
NO Updatethe ECI\4if it does not havethe latest YES-The EVAPcanistervent shut valve is OK. Go
software.or substitutea known-goodEClvl,then to step 27.
recheck(seepage 11-6).lf the symptom/indlcation
goes away with a known-goodECM,replacethe NO Go to step 22.
o r i g i n aE
l CM.I
2 3 . Disconnectthe EVAPcanistervent shut valve 2P

connector.
11-182
24. Checkfor continuitybetweenEVAPcanistervent Canister System Leak Test
Nlo . 2 a n d b o d y
s h u t v a l v e2 P c o n n e c t o r t e r m i n a
ground. 27. Turn the ignition switch oFF.
VATVE2P CONNECTOR
2 8 , C o n n e c t t w ot,h r e e - w a yT - f i t t i n g s( A )i n t o t h e h o s e
from the EVAPcanisterto the EVAPtwo way valve.
-4- Connectthe FTPsensorto one of the T-fittingsand
r 2l
l-T_*u t h e v a c u u mp u m p t o t h e o t h e l
ILTGFN/REDI
@
wn€ s de ol l€ma1e terminals
YES Go to step 25.
NO Repairopen in the wire betweenthe EVAP

c a n i s t e vr e n ts h u tv a l v ea n dt h e E C I V(IE 2 1 ) . 1
25. T u r nt h e i g n i t i o ns w i t c ho N ( l l ) .
26. Measurevoltage betweenEVAPcanistervent shut

v a l v e2 P c o n n e c t otre r m i n a lN o . 1 a n d b o d yg r o u n d . 29. Removethe vent hosefrom the EVAPcanistervent
shut valve (A),and cap the port (B)to sealthe fresh
VENTSHUT
EVAPCANISTER air vent of the EVAPcanister.
VALVE2PCONNECTOR
Wlreside oflem. € rerm na s
YES Replacethe EVAPcanistervent shut valve

( A )a n d t h e o - r i n g( B ) . I
NO Repairopen in the wire betweenthe EVAP

c a n i s t e vr e n ts h u tv a l v ea n dt h e N o . 4 A C G ( 1 0 A )
fuse.I
(cont'd)
11-183
EVAPSystem
31. While monitoring FTPsensorvoltagewith the 37. While monitoringFTPsensorvoltagewith the
Honda PGM Tester,or measuringvoltage between Honda PGM Tester,or measuringvoltage between
ECMconnectorterminalsE4 and E14,slowly pump E C Mc o n n e c t otre r m i n a l sE 4a n d E1 4 ,s l o w l yp u m p
the vacuum oumD. t h e v a c u u mp u m p .
ECMCONNECTOR
E 13lPI ECMCONNECTOR
E {31PI
Wire side ot femaleterminals Wiresideof lemaleterminals
32. Continueto pump vacuum until the voltagedrops 38. Continueto pump vacuum until the voltagedrops
to about 1.5V. Make sure the enginecoolant to about 1.5V.Make sure the enginecoolant
temperatureis still above 95'F 135.C)and your temperatureis still above95"F (35"C)and your
v a c u u mp u m p h a s n o l e a k . vacuum pump has no leak.
33. Monitor the voltagefor 20 seconds. 39. Monitor the voltagefor 20 seconds
Does the voltage drop 1.5V and hold for at least Does the voltage hold for at least 20 seconds?
20 seconds?
YES Inspeclthe fuel tank vapor control lineand
YES Inspectthe EVAPcanistervent shut valve connections.I
l i n ea n d c o n n e c t i o n s . l
NO Go to step 40.
NO-Go to step 34.
40. T u r nt h e i g n i t i o ns w i t c hO F F .
4 1 .Disconnectthe purge line hose {A) from the
35. Disconnectthe quick-connectfitting (A) fromthe c a n i s t e ar t t h e m e t a ll i n e a n d p l u gt h e h o s e( B ) .
EVAPcanister,and plug the canisterport {B).
11-184
43. While monitoringFTPsensorvoltagewith the
Honda PGM Tester,or measuringvoltage between
ECMconnectorterminalsE4 and E14,slowly pump
t h e v a c u u mp u m p .
ECMCONNECTOR
E {31P)
4 4 . Continueto pump vacuum until the voltagedrops

to about 1.5V.Make sure the enginecoolant
temperatureis still above 95'F (35'C)and your
v a c u u mp u m p h a sn o l e a k .
45. Monitor the voltagecontinuouslyfor 20 seconds.
Does the voltage drop to 1.5 V and hold f or at

least 20 seconds?
YES Inspectthe EVAPcanisterpurge valve line

and connections.lf they are OK, perform the EVAP
two way valvetest (seepage 11-186)and the fuel
tank vapor controlvalve test (seepage 1'l-187)l
NO-Replace the EVAP canister

( s e ep a g e1 1 - 1 8 9 ) . 1
11-185
EVAPSystem
EVAPTwo Way ValveTest
Special Tools Required 4. Move the vacuum pump hosefrom the vacuum
. V a c u u mp u m p / G a u g e , 0 - 3 0i n . H g fitting to the pressurefitting,and move the vacuum
A973X-041-XXXXX gauge hosefrom the vacuum side to the pressure
. Vacuum/Pressure cauge.0-4 in. Hg 07JAZ-0010008 side (A) as shown.
1 . R e m o v et h e f u e l f i l l c a p .
2. Disconnectthe vapor line from the EVAPtwo way

valve (A).Connectit to a T-fitting(B)from the
v a c u u mg a u g ea n d t h e v a c u u mp u m p a s s h o w n ,
07JAZ-0010008
Slowly pressurizethe vapor line while watchingthe

gauge.The pressureshould stabilizemomentarilV
a b o v e1 . 0k P a( 8 m m H g ,0 . 3i n . H g ) .
. lfthe pressuremomentarilystabilizes(valve
o p e n s )a b o v e1 . 0k P a( 8 m m H g , 0 . 3i n . H g )t,h e
Apply vacuum slowly and continuouslywhile v a l v ei s O K .
watchingthe gauge.The vacuum should stabilize . lf the pressurestabilizesbelow 1.0 kPa(8 mmHg,
m o m e n t a r i l ya t 0 . 8 2 . 1 k P a( 6 1 6 m m H g , 0.3 in.Hg),installa new valve and retest.
0 , 2 0 . 6i n . H g ) .
lf the vacuum stabilizes{valveopens)below 0.8 kpa
( 6 m m H g , 0 . 2i n . H g )o r a b o v e2 . 1k P a( 1 6m m H g ,
0.6 in.Hg),installa new valve and retest.
11-186
FuelTankVaporControlValveTest
SpecialToolsRequired ValveTest
VacuumPump/Gauge, 0-30 in. HgA973X-041-XXXXX
1 . N 4 a kseu r et h e f u e lt a n ki s l e s st h a n h a l ff u l l
FloatTest
2 . R e m o v et h e f u e l f i l l c a p .
1 . M a k es u r et h e f u e lt a n ki s l e s st h a n h a l ff u l l .
3. Disconnectthe fuel tank vapor signaltube (A).
2. Removethe fuel fill cap to relievefuel tank
pressure,then reinstallthe cap.
3. Disconnectthe fuel tank vapor recirculationtube

t v a c u u mP u m Pt o i t .
{ A ) ,a n d c o n n e c a
4 . Disconnectthe vacuum hoses(A) from the EVAP

canister(B),then plug the ports with plugs (C)
A973X-041-XXXXX
P l u gt h e l i n e( B ) .
5 . Apply vacuum to the fuel tank vapor recirculation

tuDe.
lf the vacuum holds, replacethe fuel tank vapor

c o n t r o lv a l v e( s e ep a g e1 1 - 1 8 9 ) .
lf the vacuum does not hold, the float is OK. Do
the valve test.
A973X-O41-XXXXX
5. Disconnectthe vacuum hose (D)from the EVAP

canistervent shut valve (E),and connecta vacuum
pump to the vacuum hose.
6 . P u m pt h e v a c u u mp u m p 8 0 t i m e s .
. l f t h e v a c u u mh o l d s ,g o t o s t e P7 .
. l f t h e v a c u u md o e sn o 1h o l d ,g o t o s t e p 1 0 .
(cont'd)
11-187
EVAPSystem
FuelTankVaporControlValveTest (cont'd)
7. Connecta secondvacuum pump to the fuel tank Fill the fuel tank with fuel, then checkfor fuel in the
v a p o rs i g n a l t u b e( A ) . EVAPtwo way valve (A),and fuel tank vapor
recirculationhose (B).
NOTE:At either location,tiny dropletsof fuel are

normal.
. lf fuel runs out of th e hosesat either location,

replacethe fuel tank vapor control valve.
. l f t h e f u e l d o e sn o t r u n o u t o f t h e h o s e s t, h e f u e l
tank vapor systemfunction is normal.
8. Apply vacuum (1 pump) to the fuel tank vapor

signaltube (A).then checkthe vacuum on the
pump in step 6.
. lf the vacuum holds,replacethe fueltank vapor

c o n t r o lv a l v e{ s e ep a g e1 1 - 1 8 9 ) . Checkfor fuel rirnningout.
. If the vacuum is released,goto step 9.
Checkfor fuel runningout.
1 0 .Disconnectthe fuel tank vapor quickdisconnect

from the EVAPcanister,then plug lhe port on the
canister.Reapplyvacuum (80 pumps).
. lf the vacuum holds,replacethe fuel tank control

v a l v e( s e ep a g e11 - 1 8 9 ) .
. lf the vacuum does not hold, insDectthe EVAP
canistervent shut valve o-ring.lf the o-ring is OK,
replacethe EVAPcanister,and repeatstep 4.
11-188
EVAPCanisterReplacement FuelTankVapor ControlValve
Replacement
l. Removethe vacuum hoses(A).
1 . R e m o v et h e f u e lt a n k ( s e e p a g e l l - 1 5 5 ) .
2 . R e m o v et h e f u e l t a n kv a p o rc o n t r o lv a l v e ( A )f r o m
t h e f u e lt a n k( B ) .
2. Removethe boit (B).
3. Removethe EVAPcanister(C). 3 . Installthe fuel tank vapor control valve.

'l
4. Installin the reverseorder of removal. 4 , Installthe fuel tank (seepage 1 -155).
11-189
Clutch
Tools
Special .........12-2
Comoonent L o c a t i oInn d e x . . . . . . . . . . . . . . . . . . . . . . . , .1. .2.-. 3
........
ClutchPedal,ClutchPedalPosition Switch,and
ClutchInterlock SwitchAdiustment.................... 12-4
CfutchMasterCylinderRep|acement ..................... 12-5
SlaveCylinderReplacement .'........ 12-7
ClutchReplacement ................... .....12-9

Clutch
SpecialTools a
Ref. No. Tool Number Description Oty
(1, OTJAF-PM7O11A C l u t c hA l i g n m e n tD i s c ,l
@ 07LAB-PV001
00 or 07924-PD20003 R i n gG e a rH o l d e r 1
o 07zAF-PR8A100 C l u t c hA l i g n m e n tS h a f t 1
@ 07936-3710100 R e m o v e rH a n d l e 1
l .
l _ l
'l-r
o o
.{\
.tt./
'\-'/
I
o
a
12-2
CLUTCHINTERLOCKSWITCH
""*--/ page12-4
Adjustment,
\,L_.Ei
/i
(,'.' CLUTCH PEDAL
POSTTTON SWITCH
_,___-,-s\
RETAININGCLIP
A d j u s t m e npta, g e ' 1 2 - 4
Replace.
O-RING UTCHPEDAL
Replace. A d j u s t m e n tP, a g e1 2 4
CLUTCHMASTERCYLINDER
pagel2-5
Replacement,
CLUTCHDISC
Bemoval,page 12-9
I n s t a l l a t i op
na, ge'12-12
PRESSURE PLATE
Removal, page'12-9
l n s t a l l a t i opna,g e1 2 - 1 2
RELEASE BEARING
B e p l a c e m epnat ,g e1 2 - 1 3
FLYWHEEL
page'12-1
Inspection, 1
Replacement,page12-11
CLUTCHHOSE
CLIP
SLAVECYLINDER \".rr"*"o*
page 12-7
Replacement,
12-3
Clutch
ClutchPedal,ClutchPedalPositionSwitch, and ClutchInterlockSwitch
Adjustment
NOTE: 3. Tightenthe clutch push-rodlocknut(D).
. To checkthe clutch pedal positionswitch
(seepage 4-45). 4. With the clutch pedal released.turn the clutch
. To checkthe clutch interlockswitch (seepage 4-6). pedal positionswitch (B) in until it contactsthe
. Removethe driver's side floor mat beforeadjusting clutch pedal (C).
the clutch pedal.
. The clutch is self-adjustingto compensatefor wear. 5. Turn the clutch pedal positionswitch {B) in an
. lf there is no clearancebetweenthe mastercylinder additional3/4 to 1 turn.
pistonand push rod, the releasebearingwill be held
againstthe diaphragmspring.which can resultin 6. Tightenthe clutch pedal positionswitch locknut(A).
clutchslippageor other clutch problems.
7. Loosenlocknut(J)and the clutch interlockswitch
1. Loosenthe clutch pedal positionswitch locknut(A), (K).
and backoff the clutch pedal positionswitch (B)
until it no longertouchesthe clutch pedal (C). 8. Pressthe clutch pedalto the floor.
J
9.8 N.m 9 . R e l e a s teh e c l u t c hp e d a l1 0 ' l 6 m m ( 0 , 3 9 0 . 6 3 i n . )
(1.0kgf.m,7.2lbf.ft) from the fully pressedposition,and hold it there.
Adjust the positionof the clutchinterlockswitch (K)
so that the enginewill startwith the clutch pedal in
thls position.
A
9.8 N.m 10. Tightenthe clutch interlockswitch locknut(J).
11.0kgf.m,7.2 lbf.ft)
o
18 N.m
{1.8kgf.m,
13 tbf.ftl
Loosenthe clutch push-rodlocknut(D).and turn

the push rod (E)in or out to get the specifiedheight
(F),stroke(G).free play (H)and disengagement
h e i g h t( l ) a t t h e c l u t c hp e d a l .
Clutch PedalStroke: 130 140 mm

( 5 . 1 2 5 . 5 1i n . l
Clutch PedalFreePlay: l0 16 mm (0.39-0.63 in.)
Clutch PedalHeight: 193 mm (7.60in.)
Disengagement
Height: 115 mm (4.53in.)
Between Floor And
Carpet Height
(ApproximateValuel: 38 mm {1.50in.l
12-4
ClutchMasterCylinderReplacement
NOTE:Do not spill brakefluid on the vehicle;it may 6. Disconnectthe reservoirhose (D)fromtheclutch
damagethe paint; if brakefluid does contactthe paint, mastercylinder reservoir.Plugthe end of the
wash it off immediatelVwith water. reservoirhose with a shop towel to preventbrake
fluid from coming out.
1 . P r yo u t t h e l o c kp i n ( A ) ,a n d p u l l t h e p e d a lp i n ( B )
out of the yoke. Removethe mastercylinder 7. Removethe O-ring(E)and the clutch master
mounting nuts (C). cylinderseal (F)from the mastercylinder.
8. Installtheclutch mastercylinder in the reverse

order of removal.Installa new O-ring.
9. Make sure the hose clamps (A) are positionedon

the mastercylinder (B)and reservoir(C)as shown.
UP
i
R e m o v et h e a i r c l e a n e rh o u s i n gc o v e ra n dt h e a i r
cleanerhousing (seestep 6 on page 5-2).
3 . Removethe brakefluid from the clutch master

cylinder reservoirwith a syringe.
Removethe clutchline bracketfrom the frame rail,

and removethe clutch line clip.
Removethe clutch mastercylinder(A),and pull it

toward the middle of the enginecompartment.
Removethe retainingclip (B).Disconnectthe clutch
line (C).Plugthe end of the clutch line with a shop
towelto preventbrakefluid from coming out.
g-E
(cont'd)
12-5
Clutch
ClutchMasterCylinderReplacement(cont'd)
10. To preventthe retainingclip (A)from coming off,
pry open the tip of the retainingclip (B)with a
screwdriver,
1 1 .Tightenthe mastercylindermounting nuts to 13 N

m ( 1 . 3k g f m , 9 . 4 l b f . f t ) .
Bleedthe clutch masterhydraulicsystem (seestep

11 o n p a g e 1 2 - 8 ) .
: h e r e s e r v o ifri l l i n gi s c o v e r e di n t h e
N O T ET
bleedingprocedure.
I
l n s t a l l t h ea i r c l e a n e rh o u s i n g( s e es t e p3 7 o n p a g e
5-15).
12-6
SlaveCylinderReplacement
NOTE: 6. Removethe mounting bolts (A) andtheslave
. U s ef e n d e rc o v e r st o a v o i dd a m a g i n gp a i n t e d c y l i n d e r( B ) .
surfaces.
. D o n o t s p i l lb r a k ef l u i d o n t h e v e h i c l e i; t m a y d a m a g e
the paint; if brakefluid does contactthe paint,wash it
off immediatelywith water.
1. Write down the frequenciesfor the radio's preset

buttons.Disconnectthe negative( ) cablefirst,
then the positive(+)cable from the battery.
Removethe battery.
2. Removethe batterytray.
7 . Removethe roll pins (C).Disconnectthe clutch line

( D ) ,a n d r e m o v et h e O - r i n g( E ) .P l u gt h e e n d o f t h e
clutch line with a shop towel to preventbrakefluid
f rom coming out.
Installtheslavecylinder in the reverseorder of

removal.Installa new O-ring (A).
R e m o v et h e a i r c l e a n e rh o u s i n gc o v e ra n dt h e a i r
c l e a n e rh o u s i n g( s e es t e p6 o n p a g e5 - 2 ) .
4 . Removethe intakeair duct (seestep 8 on page 5-3). ,,6NJ' =--

5 . Removethe clutch line bracket(A). #.q!4sEn
(P/N08798-90021
(Brak6Assembly
Lube)
9 . P u l l t h eb o o t ( B )b a c k ,a n d a p p l yb r a k ea s s e m b l y
l u b et o t h e b o o ta n d s l a v ec y l i n d e r o d ( C ) .R e i n s t a l l
the boot.
1 0 .Apply super high temp urea grease(P/N08798-

9 0 0 2 )t o t h e p u s h r o d o f t h e s l a v ec y l i n d e rT. i g h t e n
t h e s l a v ec y l i n d e rm o u n t i n gb o l t st o 2 2 N m ( 2 . 2
kgfm, 16lbf.ft).
(cont'd)
12-7
Clutch
SlaveCylinderReplacement(cont'd)
11. Bleedthe clutch hydraulicsystem.
. Aftach a hoseto the bleederscrew (A),and

suspendthe hose in a containerof brakefluid.
. M a k es u r et h e r ei s a n a d e q u a t es u p p l yo f f l u i d i n
the clutch mastercylinder,then slowly pump the
clutch pedal until no more bubblesappearatthe
bleederhose.
. lt may be necessaryto llmit the movement of the
releasefork (B)with a blockof wood to remove
all the air from the system.
. Tightenthe bleedscrewto I N.m (0.8kgf.m,6 lbf
ft); do not ovenightenit,
. Refillthe clutch mastercylinderwith fluid when
done.
. Always use only Honda DOT3 brakefluid.
L
12. Installthe intakeair duct (seestep 36 on page 5-14).
1 3 .I n s t a l l t h ea i r c l e a n e rh o u s i n g( s e es t e p3 7 o n p a g e
5-15).
1 4 . Installthe batterytray.
t5. Installthe battery,connectthe positive(+) cable

first, then the negative(- ) cable.
1 6 . Resetthe frequenciesfor the radio stationpreset

buttons,
12-8
ClutchReplacement
Spscial Tools Required 2 . I n s t a l l t h es p e c i atl o o l s .
. Clutchalignmentdisc 07JAF-PM7011A
. Ringgear holder07LAB-PV00100or A
07924-PD20003
. Clutchalignmentshaft 07ZAF-PR8A100
. Removerhandle07936-3710100 \-
PressurePlateand GlutchDiscRemoval
1 . C h e c kt h e d i a p h r a g ms p r i n gf i n g e r sf o r h e i g h t
using lhe speciallool and feelergauge.lf the height
is more than the servicelimit, replacethe pressure A-.- nl I
ptate. \ffim 9fra-I tP 07LAB-PV00100
or
StandardlNewl: 0.6 mm (0.02in.) max. |- 07924-PD20003
ServiceLimit: 0.8 mm {0.03in.)
To preventwarping,unscrewthe pressure plate
07zAF-PR8A100 mountingbolts(A)in a crisscross
patternin several
07936-3710100 plate(B).
OTJAF-PM7O11A steps,then removethe pressure
Inspectthefingersof the diaphragmspring(A)for

wearat the releasebearingcontactarea.
5. Inspectthe pressureplate 1A)surfaceforwear,

cracks.and burning.
(cont'd)
12-9
Clutch
ClutchReplacement(cont'd)
6. Inspeclfor warpage using a straightedge (A) and 9. lvleasure th e clutchd isc th ickness.lfthethickness
feeler gauge (B).l\4easureacrossthe pressureplate is lessthan the servicelimit, replacethe clutchdisc.
(C).lf the warpage is more than the servicelimit,
replacethe pressureplate. StandardlNew): 8.3 8.9 mm
(0.33 0.35in.)
Standard{New): 0.03mm (0.001in.) max. ServiceLimit: 6.0 mm {0.24in.)
1 0 .Measurethe rivet depthfrom the clutchdisc lining

7 . R e m o v et h e c l u t c hd i s ca n d s D e c i a l t o o l s . surface(A) to the rivets(B)on both sides.lf the
rivet depth is lessthan the servicelimit, replacethe
c l u t c hd i s c .
1 d Standard(New): 1.65 2.25 mm

(0.065 0.089in.)
L
I n s p e c t t h el i n i n go f t h e c l u t c hd i s cf o r s i g n so f
s l i p p i n go r o i l . l f t h e c l u t c hd i s ci s b u r n e db l a c ko r
oil soaked.reolaceit.
12-10
FlywheelInspection FlywheelReplacement
1. Inspectthe ring gear teeth for wear and damage. 1 . I n s t a l l t h es p e c i atlo o l .
2. Inspectthe clutchdisc mating surfaceon the

flywheel for wear, cracks,and burning.
3. Measurethe flywheel (A) runout using a dial

indicator(B)through at leasttwo full turns. Push
againstthe flywheel eachtime you turn it to take up
the crankshaft th rust washerclearance.lf the
runout is more than the servicelimit, replacethe
flywheel and recheckthe runout.Resurfacingthe
flywheel is not recommended.
Standard(New): 0.05mm (0.002in.) max.

2 . Removethe flywheel mounting bolts in a crisscross

patternin severalsteps,then removethe tlywheel.
3 . Installtheflywheel on the crankshaft,and install

the mounting bolts fingertight.
4 . I n s t a l l t h es p e c i a l t o o lt,h e nt o r q u et h e f l y w h e e l
mounting bolts in a crisscrosspatternin several
sreps.
1 2 x 1 . 0m m
103 N.m
(10,skst.m. 76 lbf ftl
(cont'd)
12-11
Glutch
ClutchReplacement(cont'dl
ClutchDiscand PressurePlateInstallation 5. Torquethe mountingboltsin a crisscrosspattern,
Tightenthe boltsin severalstepsto prevent
'L
T e m p o r a r i l yi n s t a ltl h e c l u t c hd i s co n t o t h e s p l i n e s warping t h ed i a p h r a g m
spring.
of the transmissionmainshaft,Make sure the clutch
disc slidesfreely on the mainshaft. PRESSURE PLATE MOUNTING BOLTTOROUE:
25 N.m{2.6kgt.m,19lbt.ft)
2 . l n s t a l l t h er i n g g e a rh o l d e r .
o
O?ZAF.PRSAIOO
\---,
/v
07936-3710100
{P/N08798-9002)
07LAB-PVo0'100
or
0792,1-PD20003
3 . Apply super high temp urea grease(P/N08798-

9002)to lhe splines(A) of the clutch disc (B),then
installthe clutchdisc usingthe specialtools.
Removethe specialtools.
Installthe pressureplate (A) and the mounting
bolts (B)finger-tight. 1 . Make sure the diaphragmspringfingers are all the
s a m eh e i g h t .
12-12
ReleaseBearingReplacement 4 . Apply super high temp urea grease{P/N08798-
9002)to the releasefork (A),the releasefork bolt
'L
Removethe releasefork boot (A)from the clutch ( B ) ,t h e r e l e a s eb e a r i n g( C ) ,a n d t h e r e l e a s eb e a r i n g
h o u s i n g( B ) . g ui d e ( D )i n t h e s h a d e da r e a s .
1 . 0 1 . 6g
10.04 0.06oz)
l-'..\
\\ \\
!ac
\ ) ) /
/-/
Xrl-Rl
It\'1
{re\
f-l\-._
0 . 4 1 . 0g
10.01 0.04o
I L!),l-*E
-A
" 0.t 1.09 (0.01 0.04oz)
2 . Removethe releasefork (C)from the clutch
h o u s i n g( B )b y s q u e e z i n tgh e r e l e a s ef o r k s e ts p r i n g With the releasefork slid betweenthe release
( D ) w i t hp l i e r s R
. e m o v et h e r e l e a s eb e a r i n g( E ) . b e a r i n gp a w l s .i n s t a l l t h er e l e a s eb e a r i n go n t h e
m a i n s h a fw t h i l e i n s e r t i n gt h e r e l e a s ef o r kt h r o u g h
3 . Checkthe releasebearingfor play and noise by t h e h o l ei n t h e c l u t c hh o u s i n g .
p l a yo r
s p i n n i n gi t b y h a n d .l f t h e r ei s e x c e s s i v e
n o i s e ,r e p l a c et h e r e l e a s eb e a r i n gw i t h a n e w o n e . 6 . Align the detentof the releasefork with the release
fork bolt,lhen pressthe releasefork over the
NOTE:The releasebearingis packedwith grease. r e l e a s ef o r k b o l ts q u a r e l yM. a k es u r et h e r e l e a s e
Do not wash it in solvent. f o r k s e t s p r i n g( F )i s p r o p e r l ys e t .
7 . I n s t a l l t h er e l e a s ef o r k b o o t{ E ) .M a k es u r et h e b o o t
s e a l sa r o u n dt h e r e l e a s ef o r k a n d c l u t c hh o u s i n g .
8 . Move the releasefork (A) right and left to make

s u r et h a t i t f i t s p r o p e r l ya g a i n s t h e r e l e a s eb e a r i n g
( B )a n d t h a tt h e r e l e a s eb e a r i n gs l i d e ss m o o t h l y .
12-13
ManualTransmission
SpecialTools 13-2 SynchroRingandGear
Transmission FluidInspection Insoection .......13-39
a n dR e o 1 a c e m e. n. .t. . . . . . . . . . . .|.5-J
...-. Mainshaft BearingandOilSeal
Back-Up LightSwitchTest ..........t J - 5 R e p l a c e m e n. .t. . . . . . . . . . . . . . . . .1. .3. .-.4, .1. .
Transmission Removal 13-4 Countershaft Bearing
Transmission Installation........... I J-at ReDlacement .. 13-42
Transmission Disassemblv........1 3 - 1 4 Mainshaft ThrustClearance
Reverse ShiftForkClearance Adiustment .....13-43
lnsoection 13-19 Transmission Reassemblv.........13-46
ChangeLeverClearance Gearshift Mechanism
lnsoection 13-19 R e p l a c e m e n. .t. . . . . . . . . . . . . . . . .1. .3. .-.5. .1. .
ChangeLeverAssembly
Disassembly/Reassembly .......13-20 M/T Differential
ShiftForksClearance Comoonent LocationIndex ........13-52
Inspection 13-21 Backlash Inspection.....................
13-53
ShiftForks FinalDrivenGear/Carrier
Disassembly/Reassembly .......13-22 Replacement .. 13-53
Mainshaft Assemblv CarrierBearingsReplacement ... 13-54
Clearance Inspection 13-23 Oil SealReplacement 13-55
..................
Mainshaft Disassembly 't3-25 Differential
ThrustClearance
Mainshaft lnsoection 13-26 Adiustment .....13-56
Mainshaft Reassembly | 5-2.5
Countershaft Assemblv
Clearance Inspection 13-31
Countershaft Disassembly .........13-32
Countershaft Inspection............. 13-33
Countershaft Reassembly.......... 13-34
SynchroSleeveand Hub
Inspection andReassembly .... 13-39

ManualTransmission
SpecialTools
Ref.No. ToolNumber Description Oty
(!l vs802c000015 E n g i n eH a n g e rA d a p t e r ,2 . 0t o 2 . 4 L i t e r
ar\ vs802c000018 E n g i n eH a n g e r
ral
l
07GAJ-PG20' ]10 M a i n s h a fHt older
@ 07GAJ-PG20130 M a i n s h a fBt ase
07JAD-P190100 O i l S e a lD r i v e r
o 07NAD-P20A100 Oil Seal DriverAftachment
o 07736-A01000B AdjustableBearingPuller,20-40mm
,l
ri)
l
07746-0010300 Attachment,42 x 47 mm
@ 07746-0030100 Driver,40 mm LD.
@ 07746-0030300 Driver,30 mm LD.
@ 07749-0010000 Driver
of Mainshaft Inspection on T o o lS
Tool e t .0 7 G A J - P G 2 0 1 0 2 .
Set,
'16
M u s t b e u s e dw i t h c o m m e r c i a l lay v a i l a b l e3 / 8 " S l i d eH a m m e r .
Z-'
-4
U
@ o
I I
rS'D
A nDr f ;
\'---''
\".,i'i
IN
@ @
-4
-a ,/
Q)-''
o @
13-2
Transmission
FluidInspectionand Back-UpLight Switch Test
Replacement
1. Disconnecttheback-uplight switch (A) connector.
'1.
Parkthe vehicleon level ground,and turn the
e n g i n eO F F .
2 . R e m o v et h e o i l f i l l e rp l u g ( A )a n d w a s h e r( B ) ,c h e c k
the conditionof the fluid, and make sure the fluid is
at the proper level (C).
2 . Checkfor continuitybetweenthe back up light

s w i l c h2 P c o n n e c t o N
r o.1 andNo.2 terminals.
There should be continuitywhen the shift lever is in
reverse.
l f t h e t r a n s m i s s i ofnl u i d i s d i n y , r e m o v et h e d r a i n 3 . lf necessary,replacethe back-uplight switch.

p l u g( D )a n d d r a i nt h e f l u i d . A p p l y l i q u i dg a s k e t( P / N0 8 7 1 8 - 0 0 0 1a)n, d i n s t a l il t
o n t h et r a n s m i s s i oh nousing.
A
44 N.m{4.5kgt.m,
33rbr.ftl
R e i n s t a tl lh e d r a i np l u gw i t h a n e w w a s h e r ,a n d
refillthe transmissionfluid to the proper level.
Oil Capacity
1.50 (1.6US (F) at tluid change
1.70 {1.8US qt) at overhaul
Always use Honda ManualTransmissionFluid

(MTF).Using motor oil can causestiffer shifting
and noise becauseit does not containthe proper
additives.
5 . R e i n s t a tl lh e o i l f i l l e rp l u gw i t h a n e w w a s h e r .
13-3
ManualTransmission
Transmission
Removal
SpecialToolsRequired 8. Removethe cable bracket(A).then disconnectthe
. E n g i n eh a n g e ra d a p t e r . 2 . t0o 2 . 4l i t e rV S B 0 2 C 0 0 0 0 1 5 c a b l e s( B )f r o m t h e t o p o f t h e t r a n s m i s s i o h
nousing.
. E n g i n eh a n g e rV S B 0 2 C 0 0 0 0 1 8 Carefullyremove both cablesand the bracket
. Enginesupport hanger,A & RedsAAR'T 12566' togetherso as not to bend the cables.
. SubframeadaDterEOS02C000011 '
* A v a i l a b l et h r o u g ht h e H o n d aT o o l a n d E q u i p m e n t
Program888-424-6857 H A @
i l B
NOTE:Use fender coversto avoid damaging painted
surfaces.
1 . Write down the frequenciesfor the radio'spreset

buttons.Disconnectthe negative( ) cablefirst,
then the positive( )cable from the battery.
Removethe battery.
Removethe intakemanifoldcover {seepageg-3).
R e m o v et h e a i r c l e a n e rh o u s i n g( s e ep a g e11 - 1 6 2 ) .
4 . Removethe intakeair duct {seestep 8 on page 5-3).
Removethe batterytray (A).

9 . R e m o v et h e h a r n e s sc l i p .
t e t r a n s m i s s i o gn r o u n dc a b l e( B ) .
D i s c o n n e ct h
7 . Disconnectthe back-uplight switch connector(A)

a n dv e h i c l es p e e ds e n s o r( V S S )c o n n e c t o(rB ) .
13-4
10. Carefullyremovethe slavecylinderand clutchline 12. Attach the specialtool to the threaded hole in the
bracketso as not to bend the clutch line. Do not c y l i n d e rh e a d .
operatethe clutch pedalonce the slavecylinder has
been removed,
vsB02c00001s
tJ. I n s t a l l t h ee n g i n eh a n g e r( A ) a n d t h e e n g i n es u p p o r t
hanger {B) to the vehicle,then attachthe hook to the
1 1 .Removethe enginewire harnesscover (A) by
sDeciaitool.
lifting up on the locktab (B),then slidethe harness
f o r w a r do f f t h e a i r c l e a n e rh o u s i n gm o u n t i n g
bracket{C). vs802c000015
1 4 . Removethe two upper transmissionmounting

bolts.
(cont'd)
13-5
ManualTransmission
Removal(cont'd)
Transmission
15. Removethe transmissionmount bracket(A) and 20. Removethe three way catalyticconverter(TWC)
n o u n t i n gb o l t ( B ) .
t r a n s m i s s i om assembly(seestep 30 on page 5-5)
2 1 . Removethe driveshafts(seepage 16-3).
22. Removethe intermediateshaft {seepage 16-19).
23. Removethe front enginemount bracketmounting

bolt.
to. R e m o v et h e a i r c l e a n e rb r a c k e {t C ) .
1 7 . R a i s et h e v e h i c l e a, n d m a k es u r ei t i s s e c u r e l y
supponed.
1 8 . D r a i nt h e t r a n s m i s s i o fnl u i d .R e i n s t a tl lh e d r a i nb o l t
w i t h a n e w w a s h e r( s e ep a g e1 3 - 3 ) .
1 9 . R e m o v et h e s p l a s hs h i e l d . 24. Removethe three bolts securingthe transmission

r e a rm o u n I .
db-
-qF
€Ds
1 3- 6
25. Supportthe subframewith the subframeadapter 27. Removethe clutchcover.
and a jack.
---
EOS02C000011
2 8 . R e m o v et h e f r o n t e n g i n em o u n t .
26. Make referencemarks (A) on the front suspension

subframe(B)and mounting bolts (C).then remove
the front suspensionsubframe.
29. P l a c et h e t r a n s m i s s i oina c ku n d e rt h e t r a n s m i s s i o n ,
and removethe transmissionmounting bolts.
(cont'd)
13-7
ManualTransmission
TransmissionRemoval(cont'd) TransmissionInstallation \
30. Pullthe transmissionaway from the engine until Special Tools Required
the transmissionmainshaftclearsthe clutch . Enginehangeradapter,2.0to 2.4 liter VS802C000015
pressureplate,then lower the transmissionon the . En g i n eh a n g e rV S 8 0 2 C 0 0 0 0 1 8
transmissionjack. . Enginesupport hanger,A & RedsAAR-T-12566"
. subframe adaDterEoS02c000011
Removethe transmissionrear mount (A) and the * Availablethrough the HondaTool and Equipment
transmissionrear mount bracket{B). Program888-424-6857
1. Checkthe two dowel pins are installedin the clutch

h o u s nr g .
Apply super high temp urea grease(P/N08798-

9002)to the releasefork (A) and the releasebearing
(B).Installthe releasefork and the releasebearing.
1 . 0 ' 1 . 6g
{0.04 0.06oz)
3 2 . Removethe boot (A),the releasefork {B).and the

r e l e a s eb e a r i n g( C )f r o m t h e t r a n s m i s s i o (nD ) .
0.4 1.0g {0.01 0.04ozl
3 . I n s t a l l t h et r a n s m i s s i o rne a rm o u n tb r a c k e (t A ) a n d
t h e t r a n s m i s s i o rne a rm o u n t( B ) .
't2x 1 . 2 5m m
64 N m {6.5kgf.m, 1 2 x 1 . 2 5m m
47
64 N.m
{6.5 ksf.m,
47 tbf.ft)
P l a c et h e t r a n s m i s s i o o
n n t h e t r a n s m i s s i o ina c k .
and raiseit to the engine level.
13-8
5 . I n s t a l lt h e t r a n s m i s s i o nm o u n t i n g bolts. 8. Supportthe subframewith the subframeadapter
a n da j a c k .
1 2 x 1 . 2 5m m
64 N.m 16.5kgf m.47 lbt ft)
1 2 x 1 . 2 5m m
64 N.m (6.5kgf.m,47 lbf.ft)
6 . I n s t a l l t h ef r o n t e n g i n e m o u n t .
9 . I n s t a l l t h ef r o n t s u s p e n s i o sn u b f r a m e( A )i n i t s
originap l o s i t i o nb y a l i g n i n gt h e m a r k s( B )y o u
made in the removal procedure,
12 x 1.25ftrn
64 N.m
(6.5 kgf m. 47 lbf.ft)
12x 1.25mm
64 N.m
(6.5kst.m,47 lbf ft)
7 . l n s t a l l t h e c l u t c hc o v e r .
1 4x 1 . 5m m
6x1.0mm
12 N.m {1.2kgI.m,9 lbf ftl
(cont'd)
13-9
ManualTransmission
Transmission
'10.
Installthethree rear mounting bolls for the 1 5 .Installthe transmissionmount bracket(A) and the
transmissionrear mount. transmissiom
n o u n t i n gb o l t{ B ) .
1 2 x 1 . 2 5m m
6x1.0mm 54 N.m {5.5ksf.m, 40lbf.ft)
12Nm
12x 1.25nn
54 N.m
(5.5kgf.m,
40 tbt.ft)
/t':::= 12 x 1.25 mm
-) 54 N.m
(5.5kgf.m,
40 tbf.ftl
1 6 . Installthe air cleanerbracket(C).

10 x 1.25mm
59 N.m(6.0kgf.m,43tbf.ft) 1 7 . Installthe two uppertransmissionmounting bolts.
1 1 .Looselytighten the front engine mount bracket

mounting bolt.
12x 1.25mrn
64 N.m(6.5kgt.m,47lbf.ftl
12. Installthe intermediateshaft (seepage 16-24). 1 8 . R e m o v et h e e n g i n eh a n g e ra n d s p e c i atlo o l f r o m
engrne.
t5. Installthedrivershafts(seepage 16-17).
1 4 . lnstallthe three way catalyticconverter(TWC)

assembly(seestep 17 on page 5-12).
13-10
19. Tightenthe front engine mount bracketmounting 21. lnstallthe brakeboosterand EVAPline bracket
bolt. mounting bolts (A).and air cleanerhousing bracket
'12x 1.25mm m o u n t i n gb o l t ( B ) .T i g h t e nt h e a i r c l e a n e rh o u s i n g
64 N.m 16.5kgf.m, bracketmounting bolt (C),and installthe water
il7 lbf.ft) pipe mounting bolt (D).
A
9.8N.m
( 1 , 0k q f
22N.m
l2.2kglm,
2 0 . I n s t a ltl h e s p l a s hs h i e l d . 16rbt.ft)
%,
9.8Nm
(1.0kgf m.
'B 7.2tbl{rl
22Nm
{2.2kgf m, 16 lbf ft)
22. I n s t a l l t h ee n g i n eh a r n e s sc o v e r .
(cont'd)
13-11
ManualTransmission
Transmission
Applysuperhightemp ureagrease(P/N08798- 2 5 . I n s t a l l t h ec a b l eb r a c k e (t A )a n d c a b l e s( B ) .
9002)to the endof the slavecylinderrod.Installthe
slavecylinderandthe clutchlinebracket. Takecare
not to bend the clutch line.
8 x 1.25mm
BWZ[i:i'u'T!'*n'-'
6x1.0mm
22 N.m (2.2 kgf.m, 16 lbf ft) 9.8 N.m
(1.0kgf.m,
a^_
#._gEEa9En 7.2 tbt.ftl
(P/N08798-9002)
lPlN 08798-9002)
2 4 . I n s t a l l t h eh a r n e s sc l i p . 26. Apply a light coat of super high temp urea grease

(P/N08798- 9002)to the cable ends.
t1 Connectthe back-uplight switch connector(A) and

t h e v e h i c l es p e e ds e n s o r{ V S S ) c o n n e c t o( B
r ).
13-12
28. Connectthe transmissionground cable (A).
8 x 1.25mm
22 N.m (2.2kgf.m, 16lbf.ft)
B [---.-.---e
e
6x1,0mm
9.8 N.m
{1.0kgl m. 7 lbf ftl
8x125mm
22Nm
12.2kgt m, 16lbf ft)
29. lnstallthe batterytray (B).
30. Installthe intakeair duct (seestep 36 on page 5-14).
I n s t a l l t h ea i r c l e a n e rh o u s i n g( s e es t e p3 9 o n p a g e
5-15).
3 2 . Installthe intakemanifoldcover (seestep 41 on

p a g e5 - 1 5 ) .
33. Installthe battery.Connectthepositive(+) cable

first, then the negative(-)cable to the battery.
34. R e f l l l t h et r a n s m i s s i ofnl u i d ( s e ep a g e1 3 - 3 ) .
35. Test-drivethe vehicle.
36. Checkthe clutchoperation.
3 1 .Checkthe front wheel alignment(seepage 18-4).

39. D o t h e e n g i n ec o n t r o lm o d u l e( E C M )i d l e l e a r n
13-13
ManualTransmission
Transmission
Disassembly
ExplodedView-ClutchHousing
,.Y
:
' r'<__J'.@t / ,, tl
j=-X ri ,1.-6
'-==-Yh,_-9
n""
-'- R
,ot/u
v
,t- -1
A' i6 t3l
\?
q'/V^
t€4
.!) DIFFERENTTAL ASSEMBLY i[, 28 mm SPRINGWASHER ?]] BACK-UPLIGHTSWITCH

r2lSHIFTFORKASSEMBLY iO BALLBEARING 29 N m (3.0kgf.m,22 lbf ftl
a9l6 mm FLANGEBOLT (l 28 x 43 x 7 mm OIL SEAL .?1O.RING
1 2 N . m ( 1 . 2k g f m , 9 l b f f t l Replace. Replace.
..4]BEARINGsET PLATE .D REVERSE GEARSHAFT 1!)VEHICLE
SPEEo (Vss)
sENsoR
G, COUNTERSHAFTASSEMBLY 1' REVERSE IDLERGEAR .O 8 mm FLANGEBOLT
O NEEDLEBEARING f lr 6 mm SPECIALBOLT 22 N.m (2.2kgf m, 16lbf.ftl
3 OIL GUIDEPLATEC 15 N.m (1.5kgt.m, 11 lbf.ft) .' CLUTCHHOUSING
e 14 x 20 mm DOWELPIN (!I REVERSESHIFTFORK iI6)TRANSMISSIONHANGER
.9-iMAGNET .4' REVERSELOCKCAM tl 10 mm FLANGEBOLT
i.!! MAINSHAFTASSEMBLY Q-t35 x 58 x 8 mm OIL SEAL 44 N.m {4.5kgt.m,33 lbf.ft}
U 28 mm WASHER Replace.
13-14
Housing
ExplodedView-Transmission
tt-P
"=-@ @
'\b e
o,. @\ rai
\€:/
P \ B- o
z-W €: iq { " f / o
@------
dd
O=-rl
\ F,z
@
,-1 _\
(g/----------__-
"^\
\-/r*---------..-,
O TRANSMISSIONHOUSING {i) 80 mm SHIM @)20 mm WASHER

O 10 mm WASHER 0 8 x 14mm DOWEL PIN Replace.
Replace. [A CHANGELEVERASSEMBLY q,]FILLERPLUG
@ 10 mm FLANGEBOLT a06 mm FLANGEBOLT 44 N m {4.5kgf.m,33 lbf.ft)
44 N.m {4.5kgf.m,33lbf.ft) 12N m {1.2kgf.m,9lbfft} @ 40 x 56 x 8 mm OILSEAL
O 8 mm FLANGEBOLT O DETENT BOLT Replace.
27 N.m 12.8kgf m,20lbl.ft) 22 N.m{2.2kgf.m,16lbf.ft) qO14 mm WASHER
.' TRANSMISSIONHANGERA O 12mm waSHER Replace.
ReDlace. q' DRAIN PLUG
O INTERLOCKBOLT
39N m (4.0ksf.m,29lbf.ft) (D SPRING 39 N.m (4.0kgf.m,29 lbf.ftl
O OILGUIOEPLATEM [I STEELBALL @ 32 mm SEALINGCAP
(D TRANSMISSION HANGERB 34 N m (3.5 kgf.m, 25 lbf.ft)
€.172 mm SHIM
(9 CLUTCHLINE CLIPBRACKET
.' OIL GUTTEBPLATE
(cont'd)
13-15
ManualTransmission
TransmissionDisassembly(cont'd)
NOTE:Placethe clutch housingon two piecesof wood 3, Removethe interlockbolt (A),the changelever
thick enoughto keepthe mainshaftfrom hittingthe a s s e m b l y( B ) ,8 x 1 4 m m d o w e lp i n s( C ) ,a n d t h e
workbench. c l u t c hl i n ec l i p b r a c k e{t D ) .
1. Removethe detent bolts (A),springs,steel balls,

and back-uplight switch (B).
R e m o v et h e d r a i np l u g( A ) ,f i l l e rp l u g( B ) ,a n d
1 0 m m f l a n g eb o l t ( C ) .
Removethe vehiclespeedsensor(VSS)(A) and

O - r i n g( B ) .
13-16
5. Removethe 8 mm flange bolts in a crisscross 10. Removethe reverselock cam.
Datternin severalsteos.
g
t.l Y
g
(,
Â
1 1 .Removethe reverseidler gear {A) and reversegear
6 . Removethe transmissionhangerA, and s h a f t{ B ) .
transmissiohn a n g e rB .
7 . R e m o v et h e 3 2 m m s e a l i n gc a p ( A ) .
E x p a n dt h e 7 2 m m s n a pr i n g ( B )o n t h e
countershaftball bearing,and remove it from the
groove using a pair of snap ring pliers.
n o u s i n g( C )a n d
L R e m o v et h e t r a n s m i s s i o h
1 4 x 2 0 m m d o w e l p i n s( D ) .
(cont'd)
13-17
ManualTransmission
TransmissionDisassembly(cont'd)
12. Removethe reverseshift fork. 15. Removethe differentialassembly(A) and magnet
( B) .
t7
t1
I
Apply vinyl tape to the mainshaftsplinesto protect

the seal,then removethe mainshaftassembly(A) 1 6 . Removethe oil gutter plate (A),72mm shim (B),
and countershaftassembly(B)with the shift forks a n d o i l g u i d ep l a t eM .
{ C ) f r o mt h e c l u t c hh o u s i n g( D ) .
1 4 . R e m o v et h e 2 8 m m s p r i n gw a s h e r( E )a n d 2 8 m m
w a s h e r( F ) .
13-18
ReverseShift ForkClearance ChangeLeverClearanceInspection
Inspection
1 . Measurethe clearancebetweenchangelever (Al
and the selectlever (B)with a feelergauge (Cf.lf
1. Measurethe clearancebetweenthe reverseidler theclearance i s m o r et h a nt h e s e r v i c el i m i t ,g o r o
gear {A) and the reverseshift fork (B)with a feeler step 2.
gauge (C).lf the clearanceis more than the service
limit, go to step 2. Standard: 0.05 0.25 mm (0.002-0.010in.)
Standard: 0.20-0.59 mm (o.oo7 0.024 in.l
ServiceLimit: r.3 mm {0.051in.)
2. Measurethe groove of the changelever'
Measure the width of the reverseshift fork. . lf distanceis not within the standard,replacethe
c h a n g el e v e rw i t h a n e w o n e .
. l f d i s t a n c ei s n o t w i t h i n t h e s t a n d a r dr ,e p l a c e t h e . l f d i s t a n c ei s w i t h i n t h es t a n d a r dr,e p l a c e t h e
reverseshift fork with a new one. selectlever with a new one.
. lf distanceis within the standard,replacethe
reversegear wrln a new one. Standard: 1 5 . 0 0 1 5 . 1 0m m ( 0 . 5 9 1 - 0 . 5 9 4i n . )
Standard: 13.4 13.7mm (0.527 0.539in.l

,tl I
qI
I
13-19
ManualTransmission
ChangeLeverAssemblyDisassembly/Reassembly
Priorto reassembling,clean all the parts in solvent,dry them, and apply lubricantto any contactsurface.
SELECT LEVER
@).1 I Becarefulnotto damagethedustseal
BREATHER CAP
Turnthe arrowtowardthe{ront
r rrl
l L l w h e ni n s t a l l i ni tg.
DUSTCOVEB
o{thevehicle,
andinstallit.
I a^^
7 Fr"irr6-rooa
SHIFTARM COVER
ROLLER
(P/N 08798-9002)
6x1.0mm
12 N.m
(1.2kgl.m,8.7 lbf.ft)
\op
WASHER
(g)'
\r' -, OILSEAL
'^ E-='- /-r,s
,/ ReDlace.
Fl !-d 1sr/2No \__/

q )-=^l sELEcr
€2 sPntruc
i INTERLOCK
,.* (A)
tace.ix#,,l
SHIFTARM
H\
lV srx
SELECT
-z:-=:l-': SPRING
r \
tr7
,/u
/
SELECTSTOP
PLATE
9.8Nm
{1.0kgf.m,7.2 lbf.ft)
REVERSELOCKCAM
STRIKER
13-20
Shift ForksGlearanceInspection
NOTE:The synchrosleeveand synchrohub should be 3. Measurethe clearancebetweenthe shift fork (A)
replacedas a set. and the shift arm (B).lf the clearanceexceedsthe
servicelimit, go to slep 4.
1. Measure the clearancebetweeneach shift fork (A)
and its matchingsynchrosleeve(B).lf the Standard: 0.2-0.5 mm (0.007 0.020in.)
clearanceexceedsthe servicelimit, go to step 2. ServiceLimit: 0.62mm (0.024in.)
Standard: 0.35 0.65 mm {0.014 0.026in.1

ServiceLimit: 1.0 mm 10.039in.l
4 . Measurethe width of the shift arm.
. l f t h e w i d t h o f t h e s h i f t a r mi s n o t w i t h i n t h e
A standard,replacethe shift arm with a new one.
2 . l\4easurethe thicknessof the shift fork fingers. . l f t h e w i d t h o f t h e s h i f ta r m i s w i t h i n t h es t a n d a r d ,
replacethe shift fork and shift piecewith a new
. l f t h e t h i c k n e s s otfh e s h i f tf o r k f i n g e ri s n o t one.
within the standard,replacethe shift fork with a
new one. Standard: 16.9-17.0 mm (0.665-0.669in.)
. l f t h e t h i c k n e s s otfh e s h i f tf o r k f i n g e ri s w i t h i n
the standard,replacethe synchrosleevewith a
new one.
Standard:7.4 7.6 mm (0.29-0.30 in.)
13-21
ManualTransmission
Shift ForksDisassembly/Reassembly
Priorto reassembling,clean all the parts in solvent,dry them, and apply lubricantto any contactparts.
sTH SHIFTFORK
PINDRIVER,
5 mm
13-22
MainshaftAssemblyClearanceInspection
NOTE:lf replacementis required,always replacethe 4. Measurethe clearancebetween4th gear (A) and
synchrosleeveand hub as a set. t h e d i s t a n c ec o l l a r( B )w i t h a d i a l i n d i c a t o (r C ) .
1. Supportthe bearinginner racewith an appropriate . lf the clearanceis more than the servicelimit, go
sizedsocket(A).and push down on the mainshaft to step 5.
(B). . lf the clearanceis within the servicelimit, go to
step 7.
Standard: 0.06 0.16 mnl

(0.002 0.006in.)
Measurethe clearancebet\iveen2nd (C)and 3rd (D)

gearswith a feelergauge {E).
. l f t h e c l e a r a n c ies m o r et h a nt h e s e r v i c el i m i t .g o
to step 3.
. lf the clearanceis within the servicelimit, go to
step 4.
MeasuredistanceO on the distanceco[ar.
Standard: 0.06 0.16mm
{0.002 0.006in.l . lf distance't is notwithin the standard,replace
ServiceLimit: 0.25 mm (0.010in.l the distancecollarwith a new one.
. lf distancee is within the standard,go to step 6.
Measurethe thicknessof 3rd gear.
. lf thethickneso s f 3 r d g e a r i s l e s s t h a n t h es e r v i c e {0.946-0.9/uin.}
l i m i t ,r e p l a c e3 r d g e a r w i t ha n e w o n e .
. lf thethickneso s f 3 r dg e a r i s w i t h i n t h e s e r v i c e
limit, replacethe 3rd/4thsynchrohub with a new
one.
Standard: 23.92-23.97 mm
(0.941 0.944in.)
(cont'd)
13-23
ManualTransmission
MainshaftAssemblyClearanceInspection(cont'd)
6. Measurethe thlcknessof 4th gear. 8. MeasuredistanceO on the distancecollar.
. lf thethickneso s f 4 t h g e a ri s l e s s t h a n t h e s e r v i c e . l f d i s t a n c eO i s n o t w i t h i n t h e s t a n d a r dr ,e p l a c e
limit, replace4th gear with a new one. the distancecollar with a new one.
. l f t h e t h i c k n e s s o4f t h g e a r i s w i t h i nt h e s e r v i c e ' l f d i s t a n c e Oi s w i t h i n t h es t a n d a r dg, o t o s t e p 9 .
limit. replacethe 3rd/4thsynchrohub with a new
one. Standard: 24.03 24.08mm
(0.946 0.947in.)
(0.941 0.944in.)
9. Measurethe thicknessof 5th gear.
. l f t h e t h i c k n e s s o5f t h g e a r i s l e s s t h a n t h e s e r v i c e
7. l\4easure the clearancebetweenthe distancecollar limit, replace5th gear with a new one.
( A )a n d s t h g e a r( B )w i t h a d i a l i n d i c a t o (r C ) .l f t h e . lf the thicknessof sth gear iswithin the service
clearanceis more than the servicelimit. go to step limit. replacethe 5th synchrohub with a new one.
8.lf theclearance i s w i t hi n t h e s e r v i c el i m i t ,g o t o
steD10. Standard: 23-92 23.97mm
10.9410.944in.l
Standard: 0.06 0.16mm Service Limit: 23.80mm (0.937in.l
(0.002-0.006in.)
13-24
MainshaftDisassembly
1 . R e m o v et h e a n g u l a rb a l l b e a r i n g( A )a n d t h e
taperedcone ring using a commerciallyavailable
'10.
M e a s u r et h e t h i c k n e s so f t h e M B S d i s t a n c ec o l l a r . b e a r i n gs e p a r a t o{rB )a n d a c o m m e r c i a l l a yvailable
b e a r i n gp u l l e r{ C ) .B e s u r et h e b e a r i n gs e p a r a t oirs
. l f t h et h i c k n e so
s f M B S d i s t a n c ec o l l a ri s l e s s u n d e rt h e t a p e r e dc o n er i n g .
than the standard,replacethe MBS distance
c o l l a rw i t h a n e w o n e .

{0.9(3 0.947in.)
E-f
Support5th gear (A) on steel blocks,and pressthe
mainshaftout of the sth synchrohub (B).Use of a
jaw-typepuller can damagethe gear teeth.
(cont'd)
13-25
ManualTransmission
MainshaftDisassembly(cont'dl MainshaftInspection
3. Supportthe 3rd gear (A) on steel blocks,and press 1. Inspectthe gear surfaceand bearingsurfacefor
the mainshaftout of the 3rd/4thsynchrohub (B). w e a r a n d d a m a g et,h e n m e a s u r et h e m a i n s h a fat t
Use of a jaw-type puller can damagethe gear teeth. pointsA, B, C, D, and E. lf any part of the mainshaft
is lessthan the servicelimit, reDlaceit with a new
on e .
Standard:
A Ball bearingsurface(transmissionhousingside):
2 7 . 9 8 7 2 8 . 0 0 0m m ( 1 . 1 0 1 9 1 . 1 0 2 4 i n . )
B Distance collar surtace:
31.984 32.000mm {1.2594 1.2598in.)
C Needle bearing surlace:
38.984-39.000mm (1.53/t8 1.5354in.)
D Ball bearingsurface(clutchhousingside):
2 7. 9 7 7- 2 7 . 9 9 0m m ( 1 . 1 0 1 5 1 . 1 0 2 0 i n . )
E Bushing surface:
20.80 20.85mm (0.819 0.821in.)
ServiceLimit;
A : 2 7 . 9 3m m 1 1 . 1 0 i0n . l
B: 31.93 mm |.1.257in.l
C: 38.93mm 11.533in.l
Di 27.92mm {1.099in.l
E: 20.75mm 10.817in.l
13-26
2. Inspectthe runout by supponing both ends of the
mainshaft.Rotatethe mainshafttwo complete
revolutionswhen measuringthe runout. lf the
runout is more than the servicelimit. reolacethe
mainshaftwith a new one.
Standard: 0.02mm (0.001in.) max.

13-27
ManualTransmission
MainshaftReassembly
ExplodedView
ANGULAB BALL BEARING

Checkfor wear and operation.
A 3RD/4TH
SYNCHRO
SLEEVE
Note the directionof
installation.
QJ'
TAPEBEDCONERING
3RD/4TH
SYNCHROHUB MBS DISTANCECOLLAR
frfl
Y7
SYNCHRO
SPRING
SYNCHROSLEEVE
SYNCHRORING
NEEDLE BEARING
Checkfor wearandoperation.
MAINSHAFT NEEDLEBEARING (
Checkfor wear and operation. \
GEAR
4TH/5TH GEAB DISTANCECOLLAR
SYNCHRORING
SYNCHROSPRING
a
13-28
SpecialTools Required 6. Installthe3rd/4thsynchrosleeve(A) by aligning
. D r i v e r , 4 0m m 1 . D . 0 7 7 4 6 - 0 0 3 0 1 0 0 the stops (B)with the 3rd/4thsynchrosleeveand
. Attachment,30mm l.D.07746-0030300 hub. After installing,checkthe operationof the 3rd/
4th synchrohub set.
this procedure.
'1.
Cleanall the parts in solvent,dry them, and apply @--
lubricantto all contactsurfacesexceptthe 3rd/4th
and 5th synchrohubs.
2. I n s t a l l t h en e e d l eb e a r i n ga n d 3 r d g e a ro n t h e
mainshaft.
I n s t a l l t h es y n c h r or i n g a n dt h e s y n c h r os p r i n g .
4 . I n s t a l l t h e3 r d / 4 t hs y n c h r oh u b ( A ) b y a l i g n i n gt h e
synchroring fingers (B)with 3rd/4thsynchrohub
grooves(C).
7 . I n s t a l l t h es y n c h r os p r i n g( A ) .
-A
lnstallthe 3rd/4thsynchrohub {A) usingthe special

tool. I n s t a l l t h es y n c h r or i n g ( B )b y a l i g i n gt h e s y n c h r o
cone fingers (C)with 3rd/4thsynchrohub grooves
(D).
9 . I n s t a l l t h e4 t h g e a r ,n e e d l eb e a r i n gd, i s t a n c ec o l l a r ,
n e e d l eb e a r i n ga, n d s t h g e a r .
07746-0030100
(cont'd)
13-29
ManualTransmission
MainshaftReassembly(cont'dl \
1 0 . I n s t a l l t h es y n c h r or i n g a n d t h e s y n c h r os p r i n g . 1 4 . I n s t a l l t h es y n c h r os p r i n g( A ) .
'1.
1 I n s t a l l t h es t h s y n c h r oh u b ( A )b y a l i g n i n gt h e
synchrocone fingers (B)with sth synchrohub
grooves(C).
t5. I n s t a l l t h es y n c h r or i n g ( B )b y a l i g n i n gt h e s y n c h r o
cone fingers (C)with sth synchrohub grooves(D).
12. I n s t a l l t h e5 t h s y n c h r oh u b ( A )u s i n gt h e s p e c i a l 1 6 . I n s t a l l t h eM B S d i s t a n c ec o l l a ra n dt h e t a p e r e d
tools. c o n er i n g .
1 1 . I n s t a l l t h en e w b a l l b e a r i n g{ A ) u s i n gt h e s p e c i a l
t o o l sa n d a p r e s s( B ) .
U 1
07746-0030100
07746-0030100
07746-0030300
1 3 . I n s t a l l t h e5 t h s y n c h r os l e e v e .
\.
13-30
CountershaftAssemblyClearancelnspection
1 . Measurethe clearancebetweenthe 1st gear (A) 3. Measure the thicknessof the 1st oear.
a n dt h e d i s t a n c ec o l l a r( B ) w i t ha f e e l e rg a u g e( C ) .
. l f t h e t h i c k n e s s o lfs t g e a r i s l e s s t h a n t h es e r v i c e
. lftheclearance
i s m o r et h a nt h e s e r v i c el i m i t ,g o l i m i t ,r e p l a c el s t g e a r w i t h a n e w o n e .
to step 2. . lf the thicknessof '1stgear is within the service
. lftheclearance
i s w i t h i nt h e s e r v i c el i m i t .g o t o limit, replacethe lst/2nd synchro hub with a new
step 4. one.
Standard: 0.06 0.16mm 10.002 0.006in.l Standard: 22-92 22.97 mm 10.902 0.904 in.l
ServiceLimit: 0.25 mm (0.010in.l ServiceLimit; 22.87mm {0.900in.)
2. fvleasurethe thicknessof the distancecollar. 4. Measurethe clearancebetweenthe 2nd gear (A)

a n d 3 r d g e a r( B )w i t h a f e e l e rg a u g e( C ) .l f t h e
. l f t h e t h i c k n e s iss n o t w i t h i nt h e s t a n d a r dr,e p l a c e clearanceis more than the servicelimit, go to
t h e d i s t a n c ec o l l a rw i t h a n e w o n e . steD5.
' lf the thicknessis within the standard,go to
Standard: 0.06 0.16 mm (0.002 0.006in.)
ServiceLimit: 0.25mm {0.010in.l
Standard: 23.03 23.08mm (0.907 0.909in.l
(cont'd)
13-31
ManualTransmission
CountershaftAssemblyClearance CountershaftDisassembly
Inspection(cont'd)
1 . Securelyclamp the countershaftassemblyin a
benchvlse with wood blocks.
5. Measurethe th icknessof the distancecollar.
. l f t h e t h i c k n e s si s n o t w i t h i nt h e s t a n d a r dr,e p l a c e
the distancecollar with a new one.
. l f t h e t h i c k n e s si s w i t h i n t h es t a n d a r dg, o t o
step 6.
Standard: 28.03 28.08mm {1.104-1.106in.)
Removethe specialbolt (left-handthreads).
Supportthe ball bearing(A) on steel blocks,then

use a press (B)and an attachment(C)to pressthe
countershaftout of the ball bearing.
6. Measurethe thicknessof the 2nd qear.
. lf thethickneso s f 2 n d g e a r i s l e s s t h a nt h e
servicelimit, replace2nd gear with a new one.
. l f t h e t h i c k n e s s o2f n d g e a r i s w i t h i n t h e s e r v i c e
limit, replacelhe 1sV2ndsynchro hub with a new
one.
Standard: 27-92-21.97 mm|.1.099 1.r01 in.l

ServiceLimit: 27.87mm 11.097in.)
4 . R e m o v et h e 3 5 m m s h i m a n d d i s t a n c ec o l l a r .
13-32
Countershaftlnspection
5. Support4thgear(A)on steelblocks,thenusea 1. Inspectthe gear surfaceand bearingsurfacefor
pressandan attachment(B)to pressthe w e a r a n d d a m a g e t, h e n m e a s u r et h e c o u n t e r s h a f t
(C)
countershaft out ofthe 5thgear. at pointsA, B, and C. lf any part of the countershaft
is lessthan the servicelimit, replaceit with a new
one.
Standard:
A Ballbearingsurfaceltransmissionhousingsidel:
3 0 . 0 2 0- 3 0 . 0 3 3m m { 1 . 1 8 1 9 1 . 1 8 2 4 i n . )
B Distancecollar surface;
39.937- 39.950mm 11.5723 1.572Ain.l
C Needlebearingsurface(clutchhousingside):
3 5 . 0 0 0 3 5 . 0 1 5m m { r . 3 7 8 0 - 1 . 3 7 8 5i n . )
Service Limit:
A : 2 9 . 9 7m m { 1 . 1 8 0i n . )
B: 39.88mm {1.570in.l
C: 34.95mm {1.376in.)
6 . Support2nd gear (A) on steel blocks,then use a

Dressand an attachment{B}to pressthe
countershaft(C)out of the 3rd gear.
2 . lnspectthe runout by supportingboth ends of lhe

countershaft.Rotatethe countershafttwo complete
revolutionswhen measuringthe runout. lf the
runout exceedsthe serviceIimit, replacethe
countershaftwith a new one.
Standard: 0.02mm (0.001in.) max.

13-33
ManualTransmission
CountershaftReassembly
ExplodedView
SPECIAL BOLT
Eeplace.
1 1 8N . m 1 2k g fm ,8 7l b ff t )
(
BALL BEARING
Checkfor wear and
operation.
REVERSE
GEAR Note the directionof installation.
1ST/2ND
SYNCHRO
HUB 35 mm SHIM
SPRING ANCE COLLAR

TRIPLECONESYNCHRO GEAR
4THGEAR
1STGEAR
NEEDLE BEARING
Checkfor wear
anoopera!on. Checkfor wear and
DISTANCECOLLAR operation.
DISTANCECOLLAR
FRICTIONDAMPER
Checkfor wear and damage.
(
COUNTERSHAFT TRIPLECONESYNCHRO
SYNCHROSPRING
13-34
SpecialToolsRequired 6 . I n s t a l l t h es y n c h r os p r i n g( A ) .
. Driver,40 mm l.D.07746-0030100
. Aftachment.30 mm 07746-0030300
NOTE:Referto the Exploded

Viewas neededduring
lhis procedure.
1. Cleanall partsin solvent,dry them,andapply

lubricanttoall contactsurfaces.
I n s t a l l t h ed i s l a n c ec o l l a r ,n e e d l eb e a r i n ga, n d 1 s t
gear onto the countershaft.
3 . Installthe triple cone synchroassembly(A) by

'lst gear
aligningthe synchrocone fingers (B)with
grooves(C),then installthe synchrospring {D).
1 . lnstallthe triple cone synchroassembly(B) by
aligningthe synchrocone fingers (C)with the
1sv2ndsynchro hub grooves(D).
8 . Installthedistancecollar (A) and friction damper

(B) by aligningthe friction damper fingers (C)with
the 1sv2ndsynchro hub grooves(D).
'1st/2nd
Installthe s y n c h r oh u b ( A ) b y a l i g n i n gt h e
synchrocone fingers (B)with 1sV2ndsynchrohub
grooves(C).
5 . I n s t a l l t h er e v e r s eg e a r .
(cont'd)
13-35
ManualTransmission
CountershaftReassembly(cont'dl L,
9 . I n s t a ltl h e n e e d l eb e a r i n g . 1 2 . I n s t a ltlh e 4 t h g e a r( A )u s i n gt h e s p e c i a l t o oal n d a
press(B).Do not exceedthe maximum pressure.
1 0 .I n s t a l l t h e2 n d g e a r( A )b y a l i g n i n gt h e s y n c h r o
cone fingers (B)with znd gear grooves(C). B
14,700N {1,500 kgt,
3,307lbf) max.
07746-0030100
I n s t a l l t h e5 t h g e a r( A )u s i n gt h e s p e c i atl o o l a n d a
'l
1 . Supoortthe countershaft(A) on the steel blocks, press(B).Do not exceedthe maximum pressure.
t h e n i n s t a ltl h e 3 r d g e a r( B )u s i n gt h e s p e c i atlo o l
and a press(C).Do not exceedthe maximum 14,700N (1.500kgl,
Dressure. 3.307lbf) max.
07746-0030100
14,700N (1,500kgf,
3,307lbflmax. I
07746-0030100
13-36
1 4 . I n s t a ltlh e d i s t a n c ec o l l a r( A ) ,3 5 m m s h i m ,a n d o l d 16. lf the clearanceis more than the standard,selecta
ball bearing(B)using the specialtools and a press new shim from the following table. lf the clearance
(c). measuredin step 15 is within the standard,replace
o n l yt h e b a l lb e a r i n g .
35 mm Shim
PartNumber Thickness
23981-PPP-0000.87mm (0.0343n .
B 23981-PPP-9000 . 9 1m m { 0 . 0 3 5 8 n,
c 23982-PPP-0000 . 9 5m m ( 0 . 0 3 7 4 n.
D 23982-PPP-9000.99mm (0.0390n ,
E 23983-PPP-0001 . 0 3m m 1 0 . 0 4 0n6,
F 23983-PPP-9001 . 0 7m m ( 0 . 0 4 2 1n .
23984-PPP-0001 . 11 m m ( 0 . 0 4 3 7 n.
11 23984-PPP-9001 . 1 5m m ( 0 . 0 4 5 3 n.
J 23985-PPP-0001 . ' 1 9m m ( 0 . 0 4 6 9n .
K 23985-PPP-9001 . 2 3m m ( 0 . 0 4 8 4 n
L 23986-PPP-0001 . 2 7m m ( 0 . 0 5 0 0 n.
M 23986-PPP-9001 . 3 1m m ( 0 . 0 5 1 6i n .
N 23987-PPP-0001 . 3 5m m ( 0 . 0 5 3 1i n .
P 23987-PPP-9001 . 3 9m m ( 0 . 0 5 4 7n .
o 23988-PPP-0001 . 4 3m m ( 0 . 0 5 6 3i n .
R 23988-PPP-9001 . 4 7m m ( 0 . 0 5 7 9i n
t5. Measurethe clearancebetweenthe old bearing(A) 23989-PPP-000 1 . 5 1m m ( 0 . 0 5 9 4
in
a n dt h e 3 5 m m s h i m ( B )w i t h a f e e l e rg a u g e( C ) . T 23989-PPP-900 1 . 5 5m m ( 0 . 0 6 1 0
in
U 23990-PPP-0001 . 5 9m m { 0 . 0 6 2i6n .
Standard: 0.04 0.10mm 10.002 0.004in.) 23990-PPP-9001 . 6 3m m { 0 , 0 6 4i2n .
X 23991-PPP-0001 . 6 7m m ( 0 , 0 6 5 7i n
Y 23991-PPP-900 1 . 7 1m m { 0 . 0 6 7 3i n
z 23992-PPP-0001 . 7 5m m ( 0 . 0 6 8 9i n
23992-PPP-9001 . 7 9m m ( 0 . 0 7 0 5i n
AB 23993-PPP-0001 . 8 3m m ( 0 . 0 7 2i0n
AC 23993-PPP-9001 . 8 7m m ( 0 . 0 7 3 6i n
AD 23994-PPP-000' 1 . 9 1m m ( 0 . 0 7 5 2i n
AE 23994'PPP-900 1 . 9 5m m ( 0 . 0 7 6 8
in.
AF 23995PPP-000 1 . 9 9m m ( 0 . 0 7 8 3in.
{cont'd)
13-37
ManualTransmission
CountershaftReassembly(cont'd)
1 1 . Supportballbearing(A)on steelblocks(B),then 20. Tightenthe new specialbolt (A) (left-handthreads).
usea press(C)andan attachment (D)to pressthe
(E)out of the ballbearing.
countershaft
'l18 N.m (12kgf.m,

87 tbf.ftl
1 8 . l f n e c e s s a r yi n, s t a l l t h e3 5 m m s h i m s e l e c t e di n
step 16,then recheckthe clearance,
1 9 . Installthe distancecollar (A).35 mm shim, and new

b a l l b e a r i n g( B )u s i n gt h e s p e c i a l t o o l a
s n da p r e s s
(c).
46-0030r00
13-38
SynchroSleeveand Hub Inspection SynchroRingand GearInspection
and Reassembly
1 . Inspectthe insideof each synchroring (A) for wear.
Inspectthe teeth (Bi on each synchro ring for wear
1. lnspectthegearteeth on ali synchro hubs and (roundedoff).
synchrosleevesfor roundedoff corners,which
indicatewear.
2. Installeach synchrohub (A) in its mating synchro

sleeve(B),and checkfor freedom of movement.Be
sure to match the three sets of longerteeth (C)(120
degreesapart)on the synchrosleevewith the three
sets of deepergrooves(D) in the synchrohub. Do
not installthe synchrosleevewith its longerteeth
in the 1sv2ndsynchrohub slots (E)becauseit will
d a m a g et h e s p r i n gr i n g .
NOTE;lf replacementis required,always replace

the svnchrosleeveand svnchrohub as a set.
Exampleof synchroring teeth
I / \
I l I
GOOD WORN
Inspectthe teeth (C)on each synchrosleeveand

matchingteeth on each gear for wear (roundedoff).
Exampleof synchro sleeve teeth and gearteeth
t l
GOOD WORN
\
(cont'd)
13-39
ManualTransmission
SynchroRing and GearInspection(cont'dl \ {
3. Inspectthe thrust surface{D)on each gear hub for 7. Measurethe clearancebetweeneach gear (A) and
wear. i t s s y n c h r or i n g ( B )a l l t h ew a y a r o u n d .H o l dt h e
synchroring againstthe gear evenlywhile
measuringthe clearance.lf the clearanceis less
than the servicelimit, replacethe synchro ring and
gear.
Synchro Ring.to.Gear Clearance

Standard: 0.70 1.49mm 10.028 0.059in.)
ServiceLimit: 0.4 mm {0.016in.)
Triple Cone Synchro-to-Gear Clearance

Slandard:
O: Outer Synchro Ring {B}to SynchroCone (Cl
0-70 1.19mm (0.028-0.047in.)
@: Synchro Cone lC) to cear (A)
0.50- 1.04mm (0.020-0.041in.)
Inspectthe cone surface(E)on each gear hub for O: Outer Synchro Ring (B) to Gear (Al
wear ano rougnness. 0.95 1.68mm 10.037 0.066in.)
ServiceLimit:
Inspectthe teeth on all gears(F)for unevenwear, O: 0.3 mm (0.012in.)
s c o r i n gg, a l l i n g a
, n dc r a c k s . : 0.3 mm (0.012in.)
O; 0.6 mm 10.024in.l
Coatthe cone surfaceof each gear (E)with oil, and
placeits synchro ring on it. Rotatethe synchroring,
m a k i n gs u r et h a t i t d o e sn o t s l i p .
\
13-40
MainshaftBearingand Oil SealReplacement
Special Tools Required 4 . Drive the new oil seal in from the transmissionside
. O i l s e a ld r i v e r0 7 J A D - P 1 9 0 1 0 0 using the specialtools.
. A d j u s t a b l eb e a r i n gp u l l e r , 2 0 4 0 m m
07736-4010008
. Driver07749-0010000
. Attachment,42x 47 mm 07746-0010300 07749-0010000
. S l i d eh a m m e r ,c o m m e r c i a l l a yvailable
07746-0010300
1. Removethe differentialassembly,
2 . R e m o v et h e b a l l b e a r i n g( A ) f r o mt h e c l u t c h
h o u s i n g( B )u s i n gt h e s p e c i a l t o oal n d a
c o m m e r c i a l lay v a i l a b l e3 / 8 " - l 6 s l i d eh a m m e r( C ) .
Drivethe new ball bearing(A) in from the

t r a n s m i s s i o sni d eu s i n gt h e s p e c i a l t o o l .
Removethe oil seal (A) from the clutch side. Be

carefulwhen removingthe seal so the clutch
h o u s i n gi s n o t d a m a g e d .
13-41
ManualTransmission
CountershaftBearingReplacement
Special Tools Required 3. Positionthe oil guide plate C and new needle
. Adiustablebearingpuller,20-40 mm 07736-A0tOOOB bearing(A) in the bore of the clutchhousing(B).
. Oil seal driver 07JAD-AP190100
. S l i d eh a m m e r ,c o m m e r c i a l l a
yvailable
1. Removethe bearingset plate (A)from the clutch

h o u s i n g( B ) .
I n s t a l l t h en e e d l eb e a r i n gu s i n gt h e s p e c i a l t o o l .
Installthe bearingset plate (A)wirh bolts (B).
B
Removethe needlebearing(A) usingthe special 6 x 1 . 0n n
12N.m{1.2kgt m,
tool and a commerciallyavailable3/8" - 16 slide 8.7 tbf.ft)
hammer (B),then removethe oil guide plate C.
(
07736-A010008
13-42
MainshaftThrust ClearanceAdiustment
Special Tools Required 5 . Measuredistance@ betweenthe end of the clutch
. Mainshaftbase07GAJ-PG20130 h o u s i n g( A )a n d t h e b e a r i n gi n n e rr a c e( B ) w i t ha
. M a i n s h a fht o l d e r0 7 G A J - P G 2 0 1 1 0 straightedge and depth gauge.Measureat three
locationsand averagethe readings.
1 . R e m o v et h e 7 2 m m s h i m ( A )a n d o i l g u i d ep l a t eM A
from the transmissionhousing(B).
,5---o
v/
Shim Selection Formula:
Installthe3rd/4thsynchrohub (A),the distance 6, Selectthe proper 72 mm shim from the chan.

c o l l a r( B ) ,t h e 5 t h s y n c h r oh u b { C ) .d i s t a n c ec o l l a r Follow the examplebelow, and use the
( D ) ,a n d b a l l b e a r i n g( E )o n t h e m a i n s h a f(t F ) ,t h e n measurementsyou made in steps4 and 5:
i n s t a l l t h ea s s e m b l e dm a i n s h a fitn t h e t r a n s m i s s i o n
h o u s i n g( G ) . ( B a s i cF o r m u l a )
O+@ ( 0 . 8* 0 . 1 1 )= s h i m t h i c k n e s s( m a x i m u m )
O + O ( 0 . 8+ 0 . 1 7 )= s h i m t h i c k n e s s( m i n i m u m )
. Add distanceO (step5) to distanceO (step4)

. 0 . 8m m ( 0 . 0 3 1i n ) :S p r i n gw a s h e r ,a d i m e n s i o ni n
the installation.
. 0 . 1 1m m ( 0 . 0 0 4i n ) :l v l i n i m u mt h r u s tc l e a r a n c e
. 0 . 1 7m m ( 0 . 0 0 7i n ) :M a x i m u mt h r u s tc l e a r a n c e .
( F o re x a m p l e )
2 . 3 2+ 0 . 1 5- ( 0 . 8+ 0 . 1 1 ) =1 . 5 6m m ( 0 . 0 6 1i n . )
2 . 3 2+ 0 . 1 5- ( 0 . 8+ 0 . 1 7 ) =1 . 5 0m m ( 0 . 0 5 9i n . )
T a k et h e m i d d l ev a l u eo f t h e m i n i m u mv a l u ea n d
t h e m a x i m u mv a l u e ,a n d s e l e c t h e 1 . 5 3m m
lnstallthe washer (H) on the mainshaft. ( 0 . 0 6 0i n . )s h i m .
MeasuredistanceO betweenthe end of the

transmissionhousingand washerwith a straight
edge and verniercaliper.Measureat three
locationsand averagethe reading.
{cont'd)
13-/li|
ManualTransmission
MainshaftThrust ClearanceAdjustment (cont'dl
72 mm Shim 7 . I n s t a l l t h e7 2 m m s h i m ( A )s e l e c t e da n d o i l g u i d e
PartNumber Thickness p l a t eM i n t h e t r a n s m i s s i o h
n o u s i n g( B ) .
2 3 9 3 1 - P 2 1 - 0 0 00 . 6 0m m { 0 . 0 2 3i6n . )
B 23932-P21-000 0.63mm (0.0248 in.
c 2 3 9 3 3 - P 2 1 - 0 0 00 . 6 6m m ( 0 . 0 2 6i0n .
,6,,-o
V
D 2 3 9 3 4 - P 2 1 - 0 0 00 . 6 9m m ( 0 . 0 2 7 1i n .
E 23935-P21-000 0 . 7 2m m ( 0 . 0 2 8i3n .
F 23936-P21-000 0 . 7 5m m ( 0 . 0 2 9i5n .
23931-P21-000 0 . 7 8m m ( 0 . 0 3 0i7n .
- 23938-P2'l-000 0 . 8 1m m ( 0 . 0 3 1i9n
23939-P21-000 0 . 8 4m m ( 0 . 0 3 3i1n
J 23940-P21-000 0 . 8 7m m { 0 . 0 3 4 3i n ,
23941-P21-000 0.90 mm (0.0354in.
L 23942.P21-000 0.93mm (0.0366in.
M 23943-P21-000 0 . 9 6m m ( 0 . 0 3 7i8n .
N 23944-P21.000 0 . 9 9m m ( 0 . 0 3 9i0n .
o 23945-P21-000 1 . 0 2m m ( 0 . 0 4 0i2n .
P 23946-P21-000 1 . 0 5m m ( 0 . 0 4 1 3i n . 8 . Thoroughlycleanthe spring washer (A) and
o 23941-P2't-000 'l.08mm (0.0425 in washer (B) before installingthem on the clutch
R 23948-P2'l-000 ' 1. 11 m m { 0 . 0 4 3i7n h o u s i n gs i d eb a l l b e a r i n g{ C ) .N o t et h e i n s t a l l a t i o n
23949-P21-000 ' 1 . 1 4m m ( 0 . 0 4 4 9i n directionof the spring washer.
T 23950-P21-000 1 . 1 7m m { 0 . 0 4 6 1n .
U 23951-P21-000 1.20mm 10.0472 n.
23952-P21-000 1.23mm (0.0484n .
23953-P21-000 1 . 2 6m m { 0 . 0 4 9 6 n.
X 23954-P21-000 1 . 2 9m m ( 0 . 0 5 0 8n .
23955-P21-000 1 . 3 2m m ( 0 . 0 5 2 0 n.
{
z 23956-P21,000 1 . 3 5m m ( 0 . 0 5 3i1n
23957-P21-000 1 . 3 8m m ( 0 . 0 5 4i3n
AB 23958-P21-000 1 . 4 1m m ( 0 . 0 5 5 5n
AC 23959-P21-000 1 . 4 4m m ( 0 . 0 5 6 7 n.
AD 23960-P21-000 1.47mm (0.0579n .
AE 2 3 9 6 1 - P 2 1 - 0 0 01 . 5 0m m ( 0 . 0 5 9 1n .
AF 23962-P21-OOO 1 . 5 3m m ( 0 . 0 6 0 2 n.
AG 23963-P21-000 1 5 6 m m ( 0 . 0 6 1 4n .
AH 23964-P21-000 1 . 5 9m m ( 0 . 0 6 2 6n .
AI 23965-P21-000 1 . 6 2m m ( 0 . 0 6 3 8i n 9 . l n s t a l l t h em a i n s h a fitn t h e c l u t c hh o u s i n g .
AJ 23966-P21-000 1 . 6 5m m ( 0 . 0 6 5i0n
AK 23967-P21-000 1 . 6 8m m ( 0 . 0 6 6i1n 1 0 .Placethe transmissionhousingover the mainshaft
AL 23968-P2r -000 1 . 7 1m m ( 0 . 0 6 7i3n . and onto the clutchhousing.
AM 23969-P21-000 1 . 7 4m m ( 0 . 0 6 8i5n .
AN 23970-P21-000 1 . 7 7m m ( 0 . 0 6 9i7n . 1 1 .Tightenthe clutchand transmissionhousingswith
AO 2 3 9 7 1 - P 2 ' t - O O O1 . 8 0m m ( 0 . 0 7 0 9
in. several8 mm bolts.
NOTE:lt is not necessaryto use sealingagent

betweenthe housings.
12. Tap the mainshaftwith a plastichammer.
13-44
13. Attachthe specialtool to the mainshaftas follows: 1 6 . Z e r oa d i a l g a u g e{ A )o n t h e e n d o f t h e m a i n s h a f t .
. B a c k - o ut th e m a i n s h a fht o l d e rb o l t{ A )a n d l o o s e n
the two hex bolts (B).
. Fit the holderover the mainshaftso its lip is
towards the transmission.
. Align the mainshaftholder'slip aroundthe
groove at the insideof the mainshaftsplines,
then tightenthe hex bolts.
07GAJ-PG20130
1 7 . Turn the mainshaftholder bolt (B)clockwise;stop

turning when the dial gauge (A) has reachedits
07GAJ-PG20130 maximum movement.The readingon the dial
gauge is the amount of mainshaftend play
NOTE:Do not turn the mainshaftholder bolt more

than 60 degreesafter the needleof the dial gauge
1 4 . Seatthe mainshaftfully by tapping its end with a stops moving,this may damagethe transmission.
p l a s t i ch a m m e r .
1 8 .lf the readingis within the standard,the clearance
Threadthe mainshaftholder bolt in until it just is correct.lf the readingis not within the standard,
contactsthe wide surfaceof the mainshaftbase. recheckthe shim thickness.
Standard:0.11-0.17 mm (0.004 0.007in.)
13-45
ManualTransmission
Transmission
Reassembly \ (
N O T E :P r i o r t or e a s s e m b l i n gc ,l e a na l l t h e p a r t si n 4. Installthe reverseshift fork.

solvent,dry them, and apply lubricantto any contact
surfaces. 6x1.0mm
15 N.m (1.5kgf.m,11 lbf.ft)
1. Installthe magnet (A) and differentialassembly(B).
n-",-o
l;-D
f.)
Installthe reverseidler gear (A) and reversegear
s h a f t( B )b y a l i g n i n gt h e m a r k{ C ) w i t ht h e r e v e r s e
g e a rs h a f th o l e( D ) .
Installthe 28 mm spring washer (A) and 28 mm

washer (B) over the ball bearing(C).Note the
installationdirectionof the spring washer {A).
Apply vinyl tape to the mainshaftsplines(D)to

p r o t e c t t h es e a l .I n s t a l l t h em a i n s h a fat n d
countershaft(E)into the shift forks {F}.and install
themas an assembly.
13-46
6 , l n s t a l l t h er e v e r s el o c kc a m . 8. Removethe dirt and oil f rom the tramsmission
h o u s i n gs e a l i n gs u r f a c eA. p p l y l i q u i dg a s k e t( P / N
- 2 6 x 1 , 0m m 08718-0001) to the sealingsurface.Be sure to seai
z/ / 15 N.m
--' / {1 5 kgf m, the entirecircumferenceof the bolt holesto
€t I 11 tbf.ft) preventoil leakage.
Fl g NOTE:lf 5 minuteshave passedafter applying
E liquid gasket,reapplyit and assemblethe housings.
Allow it to cure at least20 minutesafter assembly
beforefilling the transmissionwith oil.
7 . Selectthe proper size72 mm shim (A) accordingto

the measurementsmade during the Mainshaft
'13-43),
Thrust ClearanceAdjustment(seepage
I n s t a l l t h eo i l g u t t e rp l a t e( B ) ,o i l g u i d e p l a t el \ 4 a
, nd
7 2 m m s h i m i n t ot h e t r a n s m i s s i o h n o u s i n g( C ) .
- - -Liquid gasket
{cont'd)
13-47
ManualTransmission
TransmissionReassembly(cont'dl (
9 . I n s t a ltlh e 1 4x 2 0 m m d o w e lp i n s( A ) . 11. Lowerthe transmissionhousingthe rest of the way

as you expandthe 72 mm snap ring {C).Release
34 N.m the snap ring so it seatsin the groove of the
(3.5 kgf.m, countershaftbearing.
25 rbf.ft)
12. Checkthat the 52 mm snap ring is securelyseated
in the groove of the countershaftbearing.
DimensionO as instalted: 3.3 6.0 mm

{ 0 . 1 3 0 . 2 4i n . l
1 3 .Apply liquid gasket(P/N08718-0001)

to the threads
o f t h e 3 2 m m s e a l i n gc a p { D ) ,a n d i n s t a l il t o n t h e
transmissioh nousing,
't4.
I n s t a ltl h e t r a n s m i s s i o h
n a n g e r sA . a n d B , a n d t h e
8 mm flange bolts finger-tight.
\A
e./
./
1 5 . Tightenthe 8 mm flange bolts in a crisscross

PatternIn severalsteDs.
8 x 1.25mm
27 N.m
(2.8kgf.m.
20 rbf.ft)
1 0 .Set the taperedcone ring (B)as shown. Placethe

transmissionhousingover the clutch housing,
being carefulto line up the shafts.
(t
13-48
16. Removethe dirt and oil from the shift iever cover 1 9 . I n s t a l l t h ed r a i np l u g( A ) ,f i l l e rp l u g ( B ) ,a n d 1 0 m m
s e a l i n gs u r f a c eA. p p l y l i q u i dg a s k e t( P / N0 8 7 1 8 - f l a n g eb o l t ( C )w i t h n e w w a s h e r s .
0001)to the sealingsurface.
/..l-.=,'-B
g ^ 44N.m
NOTE:lf 5 minuteshave passedafter applylng
liquid gasket.reapplyit and assemblethe housings.
@ Ut !?iJl'.'l,''
Allow it to cure at least20 minutesafter assembly
b e f o r ef i l l i n gt h e t r a n s m i s s i ow
n ithoil.
R\-: \
A
39Nm
(4.0 kgf m,
33 tbl.ft)
-.-t ?0,,.ru^
44 N m {4.5kgt m,33lbf.ft}
20. Installthedetent bolts (A),spring,and steel balls

with new washers.
- - -Liquidgasket
1 7 . I n s t a l l t h e8 x 1 4 m m d o w e lp i n s( A ) .c l u t c hl i n ec l i p
b r a c k e (t B ) ,a n d c h a n g el e v e ra s s e m b l y( C ) .
{3.0kgf.m.22lbf.ft)
2 1 . A p p l y l i q u i dg a s k e t{ P / N0 8 7 1 8 - 0 0 0 1 } t oh e t h r e a d s
o i t h e b a c k - u pl i g h ts w i t c h( B ) ,a n d i n s t a l il t i n t h e
transmissioh nousing.
6x1.0mm
12N.m(1.2kgf.m,9lbtft)
1 8 . A p p l y l i q u i dg a s k e t( P iN 0 8 7 1 8 - 0 0 0 t1o) t h e t h r e a d s
of the interlockbolt (D),and installit on the
transmissioh nousing.
(cont'd)
13-49
ManualTransmission
TransmissionReassembly(cont'dl (
22. Installthevehiclespeedsensor(VSS){A)and
O - r i n g( B ) .
22 N.m (2.2kgf.m,r6 lbf.ft)
13-50
GearshiftMechanismReplacement
--SHIFT LEVER KNOB

\ / ,.-,'-' 8 N m {0.8ksr.m.5.8lbf.ft}
8 x 1.25mm
22 N.m (2.2 kgf.m, 16 lbt ftl
l'/
SHIFTLEVERHOUSING
{P/N 08798-9002}
SHIFTCABLECLIP
Replace.
r-LlRotatethe shift cable
t o w a r dt h e o p e n i n g .
6x1.0mm
9.8Nm
(1.0kgf.m,
7.2 tbf.fr)
COTTERPINS
qrBemovethe shift cable
{P/N 08798-9002) from the shift leverbracket.
13-51
M/T Differential
ComponentLocationIndex \ (
DRIVENGEAR
Beplacement,page 13-53
\ I
BacklashInsoection.oaoe 13-53
Feplacemeni,paoe I 3-5-3
,<-=- ,/BALL BEARING

Beplacemenl,page 13-54
/ \ ,/
I \c1 l/
\ = /
13-52
Backlashlnspection FinalDrivenGear/Carrier
Replacement
1 . Placethe differentialassemblyon V-blocks(A),and
installboth axles.
1. Removethe bolts (left-handthreads)in a crisscross
patternin severalsteps,then removethe final
driven gear (A)from the differentialcarrier{B).
\tt x t . om m { t o )
1 2 1N m
(12.3kgf m,
89 rbt.ft)
o f b o t h p i n i o ng e a r s( B )w i t h
M e a s u r et h e b a c k l a s h
a dial indicator(C).lf the backlashis not within the
standard,replacethe differentialcarrier.
Installthe final driven gear with the chamferon the
Standard(New):0.05 0.15mm (0.002 0.006in.) i n s i d ed i a m e t e fra c i n gt h e c a r r i e rA
. l i g nt h e m a r k s
o n t h e f i n a ld r i v e ng e a ra n d t h e c a r r i e rT. i g h t e nt h e
bolts in a crisscrosspatternin severalsteps.
13-53
M/T Differential
CarrierBearingsReplacement \ {
Special Tool Bequired 3. Installthe new bearings(A)with the specialtool

Driver,40 mm l.D.07746-0030100 and a press.Presseach bearingon until it bottoms.
There should be no clearancebetweenthe bearinos
1. Checkthe carrierbearingsfor wear and rough and the carrier.
rotation.lf they rotatesmoothly and their rollers
show no signs of wear, the bearingsare OK, NOTE:Turn the sealed(B)side of the bearingaway
from the differentialtoinstallit.
2. Removethe carrierbearing(A) with a
c o m m e r c i a l l y - a v a i l a bbleea r i n gp u l l e r( B ) .
077i16-0030100
6 07746-0030100
13-54
Oil SealReplacement
Special Tools Required 4 . I n s t a l l t h en e w o i l s e a li n t h e t r a n s m i s s i o hn o u s i n q
. Driver07749-0010000 with the specialtools.
. Oil seal driver attachment07NAD-P20A100
1. Removethe differentialassembly.
2. Removethe oil seal (A) from the transmission

h o u s i n g( B ) .
5 . I n s t a l l t h en e w o i l s e a li n t h e c l u t c hh o u s i n gw i t h
the specialtools.
3 . R e m o v e t h e o i sl e a l( A )f r o m t h e c l u t c hh o u s i n g( B ) .
13-55
M/T Differential
DifferentialThrust ClearanceAdjustment
SpecialToolRequired Installthe transmissionhousingonto the clutch
Driver.40 mm LD.07746-0030100 housing,then tightenthe 8 mm flange bolts in a
crisscrosspatternin severalsteps(seestep 15 on
1 . I n s t a lal n 8 0 m m s h i m t h a t ' st h e s a m es i z ea s t h e page 13-48).
one you removeo.
8 x 1 . 2 5m m
27 N m (2.8 kgf'm, 20 lbf.ft)
Use the specialtoolto bottom the differential

a s s e m b l yi n t h e c l u t c hh o u s i n g .
00746-0030100
2 . Installthe differentialassemblyinto the clutch

housing.
5 . Measurethe clearancebetweenthe 80 mm shim

a n d b e a r i n go u t e rr a c ei n t h e t r a n s m i s s i o h
nousing.
Standard:0 0.10mm l0 0.004in.)
-i.
w
.t ..1
-- -- :,- -=.
13-56
6. lf the clearanceis more than the standard,selecta
n e w s h i m f r o m t h e f o l l o w i n gt a b l e .l f t h e c l e a r a n c e
m e a s u r e di n s t e p5 i s w i t h i nt h e s t a n d a r dg, o t o
step 9.
80 mm Shim
Part Number Thickness
4 1 4 4 1P L 3 - 8 0 0 1 1 . 0m m ( 0 . 0 3 9 4 n.
B 41442-PL3-B001 1 mm (0.0433 n.
c 4 1 4 4 3 - P L 3 - 8 0 0 1 1 . 2m m ( 0 . 0 4 7 2
n.
D 4 1 4 4 4 - P L 3 - B 0 0 1 1 . 3m m { 0 . 0 5 1 2n .
E 4 1 4 4 5 - P L 3 - 8 10 0 1 . 4m m 1 0 . 0 5 5 1n .
F 4 1 4 4 6 - P L 3 - 8 0 0 1 1 . 5m m { 0 . 0 5 9 1n .
41447-PL3-8 1 0 0 1 . 6m m ( 0 . 0 6 3 0n .
rt 4 1 4 4 8 - P L 3 - B 0 0 1 1 . 7m m { 0 . 0 6 6 9n .
J 4 1 4 4 9 - P L 3 - 8 0 0 1 . 8m m ( 0 . 0 7 0 9n .
41450-PL3-80001. 0 5m m ( 0 . 0 4 1 3n . )
4 1 4 5 1 - P L 3 - 8 0 0 01. 1 5m m ( 0 . 0 4 5 3n . l
tvl 41452-PL3-80001 . 2 5m m ( 0 . 0 4 9 2n . l
N 41453-PL3-8000 1 . 3 5m m ( 0 . 0 5 3 ' ln . )
P 41454-PL3-80001. 4 5m m ( 0 . 0 5 7 1n . l
o 41455-PL3-80001 . 5 5m m ( 0 . 0 6 1 0n . )
R 41456-PL3-8000' 1 . 6m
5 m ( 0 . 0 6 5i0n . )
41457-PL3-8000 1 . 7 5m m ( 0 . 0 6 8 9i n . )
7 . R e m o v et h e b o l t sa n dt r a n s m i s s i o h
nousing.
8 . Replacethe thrust shim selectedin step 6, then

recheckthe clearance.
9 . R e i n s t a tl h
l et r a n s m i s s i o n .
13-57
Driveline/Axle
SpecialTools .............
16-2
Driveshaft
Inspection .........................
16-3
Driveshafts
Removal ..........................
16-3
Driveshafts
Disassembly ...................
16-5
DynamicDamperReplacement ........16-8
Driveshafts
Reassembly ....................
16-9
Driveshafts
lnstallation ......................
16-17
lntermediate
ShaftRemoval ..............
16-19
Intermediate
ShaftDisassembly .................................
16-20
lntermediate
ShaftReassembly ..................................
16-22
lntermediate 16-24
Shaftlnstallation....................................

Driveline/Axle
SpecialTools L
Ref. No. ToolNumber DescriDtion Orv
n] 07GAD-PH70201 O i l S e a lD r i v e r 1
@ 07MAC-S100200 B a l l J o i n tR e m o v e r2, 8 m m 1
o 0 7N A F - S R 3 0 1 0 1 Half Shaft Base 1
@ 07xAc-001010A ThreadedAdapter,22 x 1.5mm 1
t9 07746-0010400 Attachment,52 x 55 mm 1
6) 07746-0030400 u f l v e r ,J 5 m m L U . 1
o 07749-0010000 Driver 1
(D 07947-S800100 O i l S e a lD r i v e r 1
o @
t g[] r\J ? ) \* a
,0)
16-2
DriveshaftInspection DriveshaftsRemoval
1. Checkthe inboardboot (A) andthe outboardboot Special Tool Required
(B)on the driveshaft(C)for cracks,damage,leaking B a l l j o i n tr e m o v e r 2, 8 m m 0 7 M A C - S 1 0 0 2 0 0
grease,and loose boot bands (D).lf any damageis
found, reDlacethe boot and boot bands. 1. Loosenthe wheel nuts slightly
2. Raisethe front of the vehicle,and support it with

safetystandsin the proper locations(seepage 1-8).
3. Removethe wheel nuts and front wheels.
Turn the driveshaftby hand,and make sure the

splines(E)and joint are not excessivelyloose.
Make sure the driveshaftis not twisted or cracked;

if it is, replaceit.
4 . Lift up the lockingtab (A) on the spindle nut (B),

then removethe nut.
lf the !eft driveshaftor the intermediateshaft is to

be removed,drain the transmissionfluid. Reinstall
t h e d r a i np l u g u s i n ga n e w w a s h e r( s e ep a g e1 3 - 3 ) .
H o l dt h e s t a b i l i z ebr a l l j o i n tp i n ( A )w i t h a h e x
wrench {B),and removethe flange nut (C).
Separatethe front stabilizerlink (D)from the lower
ar m .
(cont'd)
16-3
Driveline/Axle
DriveshaftsRemoval(cont'd) \
7 . R e m o v et h e l o c kp i n { A ) f r o mt h e l o w e ra r m b a l l 10. Left driveshaft:Pry the inboardjoint (A)from the

joint castlenut (B),and removethe nut. differentialcasewith a prybar.Rightdriveshaft:
Drivethe inboardjoint (A) off of the intermediate
NOTE: shaft with a drift and hammer. Removethe
. T o a v o i dd a m a g i n gt h e b a l l j o i n t ,i n s t a l a
l hexnut driveshaftas an assembly.Do not pull on the
on to the threadsof the ball joint, driveshaft(B),becausethe inboardjoint may come
. Be carefulnot to damagethe balljoint boot when apart.Draw the driveshaftstraightout to avoid
installingthe remover. d a m a g i n gt h e o i l s e a l .
Left driveshaft:
t
07MAC-S100200 .."8
w^
'e
Separatethe ball joint from the lower arm (C)with
the specialtool (seestep 3 on page 18-19).
Be carefulnot to dislodgethe lower ball joint from
the knuckle. Right driveshaft:
9 . Pullthe knuckleoutward,and removethe

driveshaftoutboardjoint from the front wheel hub
u s i n ga p l a s t i ch a m m e r .
16-4
Driveshafts
Disassembly
. T h r e a d e da d a D t e r . 2 x2 1 . 5m m 0 7 X A C - 0 0 1 0 1 0 A
. S l i d eh a m m e r ,c o m m e r c i a l l a
yvailable
. Boot band pincers,commerciallyavailable
Inboard Joint Side:
1. Removethe set rlng from the inboardjoint.
Low Profile Type
Removethe boot bands.Be carefulnot to damage

the boot and dynamic damper.
. lf the boot band is a welded type (A),cut the boot
b a n d( B ) .
. lf the boot band is a double loop type (C),lift up
t h e b a n db e n d( D ) ,a n d p u s hi t i n t ot h e c l i p ( E ) .
. lf the boot band is a low profiletype (F),pinch the
b o o t b a n du s i n ga c o m m e r c i a l l a
y v a i l a b l eb o o t
b a n dp i n c e r s( G ) .
Welded Type
(cont'd)
16-5
Driveline/Axle
DriveshaftsDisassembly{cont'd)
M a k ea m a r k( A )o n e a c hr o l l e r( B )a n d i n b o a r dj o i n t 8. Wrap the splineson the driveshaftwith vinyl tape
(C)to identifythe locationsof rollersand grooves (A)to preventdamageto the boot.
i n t h e i n b o a r dj o i n t .T h e n r e m o v et h e l n b o a r dj o i n t
on the shop towel (D).Be carefulnot to drop the
rollerswhen separatingthem from the inboard
Jornt.
9 . R e m o v et h e i n b o a r db o o t .B e c a r e f u n
l ottodamaoe
the boot.
10. Removethe vinyl tape.

N4akea mark (A) on the rollers(B) and spider (C)to
identifythe locationsof rollerson the spider,then
removethe rollers.
R e m o v et h e c i r c l i p{ D ) .
6 . Mark the spider (C)and driveshaft(E)to identifythe

positionof the spider on the shaft,
7 . R e m o v et h e s p i d e r( C ) .
16-6
OutboardJoint Side: Wipe off the greaseto exposethe driveshaftand
t h e o u t b o a r dj o i n t i n n e rr a c e .
1 . R e m o v et h e b o o t b a n d s .B e c a r e f u n
l ottodamage
t h e b o o ta n d d y n a m i cd a m p e r . 4 . Make a mark (A) on the driveshaft(B) at the same
positionof the outboardjoint end {C).
. l f t h e b o o t b a n di s a n e a r c l a m p t y p e( A ) ,l i f t u p
the three tabs (B)with a screwdriver.
Ear Clamp Type
5. Carefullvclamp the driveshaftin a vise.
2 . Slidethe outboardboot (A)to the inboard ioint side.

Be carefulnot to damaoethe boot.
Removethe outboardjoint (A) usingthe special

t o o l a n da c o m m e r c i a l la
y v a i l a b l e5 / 8 " x 1 8s l i d e
h a m m e r( B ) .
7 . Removethe driveshaftfrom the vise.
(cont'd)
16-7
Driveline/Axle
DriveshaftsDisassembly(cont'dl DynamicDamperReplacement
8. Removethe stopringtromthe driveshaft. 1 . R e m o v et h e i n b o a r dj o i n t ( s e ep a g e1 6 - 5 ) .
2, Removethe dynamic damper bands.Be carefulnot

to damagethe dynamic damper (seepage 16-5).
. l f t h e b o o l b a n di s a w e l d e d t y p e . c u t t h eb o o t
band.
. l f t h e b o o t b a n di s a d o u b l el o o p t y p e ,l i f t u p t h e
band bend, and push it into the clip.
. lfthe boot band is a low profiletype, pinch the
b o o t b a n du s i n ga c o m m e r c i a l l a y v a i l a b l eb o o t
band pincers.
3. Wrap the splineson the driveshaftwith vinyl tape

(A)to preventdamageto the dynamic damper.
9 . Wrap the splineson the driveshaftwith vinyl tape

(A) to preventdamageto the boot.
Removethe dynamic damper. Be carefulnot to

d a m a g et h e d y n a m i cd a m p e r .
5 . Adjust the positionof the new dynamic damper to

the figure below.
1 0 . Removethe outboardboot. Be careful not to Left driveshaft{Directionall: 296 300mm

damagethe boot. ( 1 1 . 6 -1 1 . 8i n . )
Right driveshaft(Directionall: 301 305 mm
1 1 .Removethe vinyl tape. ( 1 1 . 9- 1 2 . 0i n . l
6 . I n s t a l l t h ed y n a m i cd a m p e rb a n d( s e es t e pI o n
p a g e1 6 ' 1 2 ) .
7 . I n s t a ltlh e i n b o a r dj o i n t ( s e ep a g e1 6 - 11 ) .
16-8
DriveshaftsReassembly
ExplodedView
'02 model
SETRING
Replace.
/
0e //ROLLER
\)
6) /''"oH?"'
#'g!!a$il
/
YJ .?-- / Use the greaseIncluded
rr in the
// "\ ,I inboardboot
inboard boot set.
set
// /,/7\
II t,//>\ {\
\\1lg n --.-
r. .'(9
Usethe greaseincludedin the -<
inboardboot set.
- l>-
OOUBLELOOPBAND
/'..-:'\ Replace.
/ .-\
I .^-.1
I | //^\l r\
, \ V L/ A
DYNAMTC
.''
DAMPER
y
,/
//
DOUBLELOOPBAND STOPRING
Replace. Replace.
EAR CLAMP BANDS
JOINT
OUTBOARD
Usethe greaseincludedin the

outboardboot set,
(cont'd)
16-9
Driveline/Axle
DriveshaftsReassembly(cont'dl I
ExplodedView
'03 model
SET RING DOUBLE LOOPBAND

INBOAROJOINT Replace.
/ Replace. ROLLEB (Bootbandreplacement
only.)
,
CIRCLIP
s l
E.
-"-,,, @(
Usethe greaseincluded
(^Y \ in the nboard boot set.
\_,/
>
LOWPROFILE
BAND
Beplace.
Usethe greaseincluded
in the inboardboot set. DOUBLELOOPBAND
Replace.
(Boot band replacementonly.)
DYNAMICDAMPER
OUTBOARDJOINT
at-
BOOTITPI
OUTBOARD

outboardboot set.
16-10
Special Tools Required 3. Installthe spider (A) onto the driveshaftby aligning
. Boot band tool, KD-3191or equivalent,commercially the marks (B)on the spider and the end of the
available driveshaft.
. Boot band pincers,Kent-MooreJ-359'10or equivalent,
commerclallyavailable
. Boot band pincers,commercially available

this procedure.
lnboardJoint Side:
1. Wrap the splineswith vinyl tape (A)to prevent
damageto the inboardboot.
4 . Fit the circlip (C)into the driveshaftgroove.Always

rotatethe circlip in its groove to make sure it is fully
seated.
5 Fit the rollers (A) onto the spider {B)with their high
shouldersfacing outward,and note these items:
' Reinstalltherollers in their original positionson

the spider by aligningthe marks (C).
. Holdthe driveshaftpointed up to preventthe
Installthe inboardboot onto the driveshaft,then rollersfrom falling off.
removethe vinyl tape, Be carefulnot to damageI n e
inboardboot.
(u
@\
(cont'd)
16-11
Driveline/Axle
DriveshaftsReassembly(cont'd) I
6 . Packthe inboardjointwith thejointgrease 8 . Make sure the ends of the boot are sealedin the
includedin the newdriveshaft
set. groovesin the driveshaftand joint, then installthe
boot bands.
Greasequantity
Inboardioint: 130 140g (4.6-4.9oz) . For the double loop type, go to step 12.
(Replacementboot bands only)
. For the low profiletype, go to step 9.
inboardboot set. 9 . Installthe new low profile band {A) onto the boot
{B).then hook the tab (C)of the band,
7 . Fit the inboardjoint onto the driveshaft,and note

these items:
. Reinstallthe inboardjoint onto the driveshaftby

a l i g n i n gt h e m a r k s( A )o n t h e i n b o a r dj o i n ta n d
the rollers.
. Hold the driveshaftso the inboardjoint is 1 0 .Closethe hook portionof the band (A) with a \
pointing up to preventit trom falling off. commerciallyavailableboot band pincers(B),then
hook the tabs of the band.
1 1 .Installthe boot band on the other end of the boot,

and reoeatsteos9 and 10.
16-12
Fit the boot ends onto the driveshaftand the 15. Threadthe free end ofthe band through the nose
inboardjoint, then installthe new double loop band sectionof the commerciallyavailableboot band
{A) onto the boot. tool KD-3191or equivalent(A),and into the slot on
t h e w i n d i n gm a n d r e l( B ) .
P u l lu p t h e s l a c ki n t h e b a n db y h a n d
M a r ka p o s i t i o n( A )o n t h e b a n d 1 0 - 1 4 m m ( 0 . 4 -
0 . 6i n . )f r o m t h e c l i p { B ) .
1 6 . Placea wrench on the winding mandrelof the boot

band tool, and tightenthe band until the marked
spot (C)on the band meetsthe edge of the clip
1 7 . L i f tu Dt h e b o o t b a n dt o o l t o b e n d t h e f r e e e n d o f
the band 90 degreesto the clip. Center-punchthe
c l i o ,t h e nf o l d o v e rt h e r e m a i n i n gt a i l o n t ot h e c l i p .
(cont'd)
16-13
Driveline/Axle
DriveshaftsReassembly(cont'dl {
18. Unwind the boot band tool, and cut off the excess 2 ' 1 .I n s t a l l t h en e w s e t r i n g .
free end of the bandto leavea 5- 10 mm (0.2-0.4
in.) tail protrudingfrom the clip
19. Bendthe band end (A) by tapping it down with a

nammer.
NOTE;
. Make sure the band and clip do not interferewith
anythingand the band does not move.
. Removeany greaseremainingon the
surroundingsurfaces
20. Repeatsteps 12through 19 for the band on the

other end of the boot.
16-14
OutboardJoint Side: 4. Insertthe driveshaft(A) into the outboardjoint (B)
until the stop ring (C)is closeto the joint.
1. Wrap the splineswith vinyl tape (A) to prevent
damageto the outboardboot.
I n s t a l l t h en e w e a r c l a m pb a n d s( B )a n d o u t b o a r d
boot,then removethe vinyl tape. Be carefulnot to 5 . To completelyseatthe outboardjoint, pick up the
damagethe outboardboot. driveshaftand joint, and drop them from about 10
cm (4 in.) onto a hard surface.Do not use a
3 . Installthe new stop ring into the driveshaftgroove hammer as excessiveforce may damagethe
t (A). driveshaft.Be carefulnot to damagethe threaded

section(A) of the outboardjoint.
1 0c m
( 4i n . )
- ..,..,1;,t,:-,;
{cont'd)
16-15
Driveline/Axle
DriveshaftsReassembly(cont'd) {
Checkthe alignmentof the paint mark (A)with the 8. Adjust the length of the driveshaftsto the figure
o u t b o a r dj o i n t e n d ( B ) . below,then adjustthe boots to halfwaybetween
full compressionand full extension.Make sure the
ends of the boots seat in the groovesof the
driveshaftand joint.
Leftdriveshaft:497502mm (19.6 19.8in.)
t
-tTfi'.D.ilTD
Rightdriveshaft:475 480 mm {18.7 1 8 . 9i n . l
7. Packthe outboardjoint (A)with the joint grease

includedin the new ioint boot set.
Grease quantity
Outboardioint: 105 115g (3.7 4.1 ozl 9 . Fit the boot (A) ends onto the driveshaft(B)and
/llt,)r
o u t b o a r dj o i n l ( C ) .
-*>
\{(
'.,o"o
:;,"0'A?g.fff
:l:f
16-16
DriveshaftsInstallataon
10. Closethe ear portion (A) of the band with a 1. Installa new set ring onto the set ring groove of the
commerciallyavailableboot band pincersKent- driveshaft{left driveshaft).
Moore J-35910or equivalent(B).
Apply 0.5 1.0g {0.02 0.04oz) of specifiedgrease

t o t h e w h o l e s p l i n e ds u r f a c e( A )o f t h e r i g h t
driveshaft.After applyinggrease,removethe
1 1 .Checkthe clearancebetweenthe closedear portlon greasefrom the splinedgroovesat intervalsof 2-
of the bands.lf the clearanceis not within the 3 s p l i n e sa n d f r o m t h e s e t r i n gg r o o v e( B )s o t h a t
standard,closethe ear podion of the bandsfarther. air can bleedfrom the intermediateshaft.
in.)MAX
6.0mm 10.24
3.0 mm {0.12in.} MAX
12. R e p e ast t e p s1 0 a n d 1 1 f o r t h e b a n do n t h e o t h e r
end of the boot.
(cont'd)
16-17
Driveline/Axle
DriveshaftsInstallation(cont'd) {
Cleanthe areaswhere the driveshaftcontactsthe 5 . W i p e o f f t h e g r e a s ef r o m t h e b a l l i o i n ta n d l o w e r

differentialthoroughlywith solvent,and dry with arm taperedsurfaces.Installtheknuckle(A) onto
compressea d i r .I n s e n t h ei n b o a r de n d { A )o f t h e the lower arm {B).Be careful not to damagethe ball
driveshaftinto the differential(B)or intermediate joint boot.Wipe off the greasebeforetightening
shaft {C) until the set ring (D)locks in the groove (E). the nut at the ball joint. Torquethe new castlenut
(C)to the lower torque specification,then tighten it
o n l y f a r e n o u g ht o a l i g nt h e s l o tw i t h t h e b a l lj o i n t
p i n h o l e .D o n o t a l i g nt h e n u t b y l o o s e n i n gi t .
NOTE:Make sure the ball joint boot is not damage

or cracks.
"-'t-
4. Installthe outboardjoint (A) into the front hub (B).

1 2 x 1 . 2 5m m
59 69 N.m
(6.0-7.0 kgf m,
43 51 tbt.ftl
I n s t a l l t h en e w l o c kp i n { D )i n t ot h e b a l l j o i n tp i n
hole from the insideto the outsideof the vehicle.
7 . Connectthe front stabilizerlink {A)to the lower arm.

H o l dt h e s t a b i l i z elri n kb a l l j o i n tp i n ( B )w i t h a h e x
w r e n c h{ C ) ,a n d t i g h t e nt h e n e w f l a n g en u t { D ) .
'10x 1.25mm
39 N.m
{4.0kgf.m,29 lbf.ft)
16-18
lntermediateShaft Removal
8. Installa newspindlenut{A),thentightenthe nut. 1 . Removethe right driveshaft(seepage 16-3).

usea driftto stakethe spindlenut
Aftertightening,
shoulder{B)againstthe driveshaft. 2 . R e m o v et h e h e a ts h i e l d .
108N.m
(11.0kgf.m,
80 tbt.ft)
/
o
oo
e
3 . R e m o v et h e f l a n g eb o l t{ A )a n d t w o d o w e l b o l t s ( B ) .
22x 1.5 mm
1 8 1N . m
{18.5kgf.m,134lbt.ft) €.---2"
E J /
9. Cleanthe mating surfacesofthe brakedisc and the €
front wheel, then installthe front wheel with the
w
wheel nuts.
10. Turn the front wheel by hand,and make sure the

clearancebetweenthe driveshaftand
circumferenceparts.
1l. Refillthe transmissionwith recommended

transmissionfluid (seepage 13-3).
12. Checkthe front wheel alignment,and adjust it if

necessary(seepage 18-4).
(cont'd)
16-19
Driveline/Axle
IntermediateShaft Removal IntermediateShaft Disassembly {
(cont'dl
4. Removethe intermediateshaft (A) from the Special Tools Required
differential.Hold the intermediateshaft horizontal . Oil seal driver 07947-5800100
until it is clear of the differentialto preventdamage . Half shaft base07NAF-SR30101
to the differentialoil seal (B).
1 . R e m o v e t h e s e rt i n g ( A ) ,o u t e r s e a (l B ) ,a n d e x t e r n a l
s n a pr i n g ( C ) .
Pressthe intermediateshaft (A) out of the

intermediateshaft bearing(B) using a press.Be
carefulnot to damagethe metal rings (C)on the
intermediateshaft during disassembly.
PRESS L
16-20
3. Removethe internalsnap ring.
4. Pressthe intermediateshaft bearing(A) out of the

b e a r i n gs u p p o r t( B )u s i n gt h e s p e c i atl o o l sa n d a
oress.
07947-s800100
07NAF-SR30101
16-21
Driveline/Axle
IntermediateShaft Reassembly
ExplodedView
FLANGEBOLT
INTERMEDIATE
SHAFTRING 10 x '1.25mm
39IVm
{4.0kgf.m,29lbt.ftl
\^
,tto", *,"o p
\--'+7\ E
BEARING
SUPPOBT
Packthe interiorof the outer seal.
16-22
Special Tools Required 4. Pressthe intermediateshaft (A) intotheshaft
. Driver07749-0010000 b e a r i n g( B )u s i n gt h e s p e c i atl o o l a n d a p r e s s .
. Attachment,52x 55 mm 07746-0010400
. Attachment,35 mm 1.D.07746-0030400 PRESS
. Oil seal driver 07GAD-PH70201
I

this procedure.
1 . C l e a nt h e d i s a s s e m b l epda r t sw i t h s o l v e n t a, n d d r y
them with compressedair. Do not wash the rubber
partswith solvent.
2. Pressthe intermediateshaft bearing(A) intothe

b e a r i n gs u p p o r t( B )u s i n gt h e s p e c i atl o o l sa n d a
press.
PRES
I 07746-0030400
I n s t a l lt,h e n s e a tt h e e x t e r n asl n a pr i n g { A ) i n t ot h e
groove of the intermediateshaft (B).
07746-0010400
3 . I n s t a l lt,h e n s e a tt h e i n t e r n asl n a pr i n g i n t ot h e
groove ofthe bearingsupPort.
(cont'd)
16-23
Driveline/Axle
IntermediateShaft Reassembly IntermediateShaft Installation
(cont'd)
1 . U s es o l v e n to r b r a k ec l e a n e tr o t h o r o u g h l yc l e a n
the areaswhere the intermediateshaft {A) contacts
6 . l n s t a l l t h eo u t e rs e a l( A )i n t o t h e b e a r i n g s u p p o r t ( B ) the transmission(differential),and dry with
usingthe specialtool and a press. compressedair. Insertthe intermediateshaft
PRESS assemblyinto the differential.Hold the
intermediateshaft horizontalto preventdamageto
I the differentialoil seal (B).
Packthe interior
ofthe outer seal.
7 . I n s t a l l t h es e t r i n g .
2 . I n s t a l l t h el l a n g eb o l t( A )a n d t w o d o w e lb o l t s( B l .
A B
10 x 1.25mm l 0 x 1 . 2 5m m
39Nm 39 N.m (
(4.0kgf.m,29lbf.ft) (4.0kgf.m,
29 tbf.ftl
16-24
3. Installthe heat shield,and tightenthe three bolts.
8 x 1.25mm
22Nm
12.2
4 . I n s t a l l t h er i g h td r i v e s h a f(ts e ep a g e1 6 - 1 7 ) ,
16-25
Steering
Steering
S p e c i aTl o o l s . . . . . . . . . .1. .7.- 2
C o m o o n e nLto c a t i oInn d e x . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. .7. .-.3. . . . . . . . .
Steering WheelRotational PlayCheck.....................". 17-4
PowerAssistCheck.................. .......... 17-4
SteeringLinkage andGearboxInspection ................. 17-5
S t e e r i nW
g h e eR l e m o v a.l . . . . . . . . . . . . . . . . . . . . . . . . , . . . .1. .7. -. 6...........
Steering WheelDisassembly/Reassembly ................ 17-7
Steering WheelInstallation ............... 17-8
Steering ColumnRemovalandInstallation...........'... 17-9
Steering ColumnInspection .............. 17-11
SteeringLock Replacement .......................................'. 17-'12
R a c kG u i d eA d i u s t m e n t . . . . . " . . . . . . . . '1. .7' .- .1 3
ElectricalPowerSteering(EPS) 17-15

Steering
(
SpecialTools
Ref.No. Tool Number Description Oty
o 07MAA-S100200 LocknulWrench.43 mm
E
-.tt)-
---<,/
L\2 r
.V-
6Y
o
1 7-2
DRIVER'S AIRBAG
ASSEMBLY
p a g e2 3 - 1 1 3
STEERINGWHEEL
Removal,page 17-6
Disassembly/Reassembly,
page 17-7
Installation,page 17-8
STEERING COLUMN
SteeringColumnRemovaland Installation,
p a g e1 7 ' 9
SteeringColumn Inspection,
p a g e1 7 - 1 ' l
SteeringLockReplacement,
page 11-12
STEERINGGEARBOX
page'17-13
RackGuideAdjustment,
17-3
Steering
SteeringWheelRotationalPlay PowerAssistCheck \
Check
1 . Startthe engine,and let it idle.
1. Turn the front wheelsto the straightaheadposition. Attach a commerciallyavailablespring scaleto the
s t e e r i n gw h e e l .W i t h t h e e n g i n ei d l i n ga n d t h e
2. Measurehow far you can turn the steeringwheel v e h i c l eo n a c l e a n ,d r y f l o o r ,p u l lt h e s c a l ea s
left and right without moving the front wheels. shown, and read it as soon as the tires begin to turn.
. lf the play is within the limit, the gearboxand

l i n k a g ea r e O K .
. lfthe playexceedsthe l i m i t ,a d j u s t t h er a c kg u i d e
'17-13).
{seepage lf the play is still excessiveafter
rackguide adjustment,inspectthe steering
l i n k a g ea n d g e a r b o x{ s e ep a g e1 7 - 5 ) .
PLAY:0 10mm (0-0.39in.l

BOTATIONAL
+ :
3 . l f t h e s c a l er e a d sn o m o r e t h a n2 9 N ( 3 . 0k g f , 6 . 6l b f ) ,
the power assistis OK. lf it readsmore, checkthese
items:
. Fronttire pressure
. Steeringlinkage(seepage 17-5)
. Rackgulde adjustment(seepage 17-13)
. EPSsystem (seepage 17-18)
17-4
SteeringLinkageand GearboxInspection
BOOT
Inspect
Ior damageanddeterioration.
Checkfor looseness,
a n db i n d i n g . 12 mm BOLTS
Inspectfor looseness.
I STEERING COLUMN
Inspect
for loosecolumn
mountinghardware
STEERING JOINTS
TIE.RODLOCKNUTS Checkfor looseioint bolts,
Checkfor looseness. andlooseor bindingioints.
STEERING GEARBOX
Inspectfor loosemounting hardware.
GEARBOXMOUNTING CUSHIONS
Inspectfor deterioration.
TIE.RODENOBALLJOINT
lnsoect tor looseness,
b i n d i n ga,n dd a m a g e .
BALLJOINT BOOT
Inspect
for damageanddeterioration.
17-5
Steering
SteeringWheelRemoval {
SRScomponentsare locatedin this area.Reviewthe 3. Installa commerciallyavailablesteeringwheel

SRScomponentlocations(seepage 23-13),and puller {A) on the steeringwheel (B).Freethe
precautionsand procedures(seepage 23-14)in the SRS steeringwheel from the steeringcolumn shaft by
sectionbeforeperformingrepairsor service. t u r n i n gt h e p r e s s u r eb o l t( C )o f t h e p u l l e r .
1. Align the front wheels straightahead,then remove Note these items when removing the steering
the driver'sairbagfrom the steeringwheel (see wheel:
p a g e2 3 - 1 1 3 ) . . Do not tap on the steeringwheel orthesteering
column shaft when removingthe steeringwheel.
2. Disconnectthe cruisecontrol sevresumeswitch . l f y o u t h r e a dt h e p u l l e rb o l t s( D )i n t o t h e w h e e l
connector(A),and loosenthe steeringwheel nut hub more than 5 threads,the bolts will hit the
{B). cable reel and damageit. To preventthis, install
a p a i ro f j a m n u t s5 t h r e a d su p o n e a c hp u l l e rb o l t .
Bemovethe steeringwheel puller,then removethe

steeringwheel nut and steeringwheel from the
sleerinocolumn.
17-6
SteeringWheelDisassembly/Reassembly
WHEEL
STEERING
CONTACTPLATE ACCESSPANELA
CONNECTORHOLDERS 75*-=offi
,/*
MOOULESETBRACKET
ffi)Y
-f
b
/
WHEELREABCOVER
STEERING
accEss
PANEL
B
CRUISECONTROLSWITCH
17-7
Steering
SteeringWheelInstallation
1 . B e f o r ei n s t a l l i n g
t h e s t e e r i n gw h e e l ,m a k es u r et h e 3. Installthe steeringwheel nut (A),and tighten it to
front wheels are alignedstraightahead,then center the specifiedtorgue.
the cable reel (A).Do this by first rotatingthe cable
reel clockwiseuntil it stops.Then rotate it A _
39 N.m(4.0kgf m.29lbt ftl B
counterclockwiseabout two and a half turns.The
a r r o w m a r k( B )o n t h e c a b l er e e ll a b e ls h o u l dp o i n t
straightup.
lr,',,t
;. _,:!
'' '1i::..'.'l
Connectthe cruisecontrol set/resumeswitch

connector(B).fvlakesure the wire harnessis routed
and fastenedproperly.
Positionthe two tabs (A) of the turn signal
canceling s l e e v e( B )a s s h o w n .I n s t a l l t h es t e e r i n g I n s t a ltlh e d r i v e r ' sa i r b a g a
, n d c o n f i r mt h a tt h e
wheel onto the steeringcolumn shaft, makingsure system is operatingproperly{seepage 23-113).
the steerlngwheel hub (C)engagesthe pins (D) of
the cable reel and tabs of the cancelingsleeve.Do C h e c kt h e h o r n ,t u r n s i g n a lc a n c e l i n g
a n dc r u i s e {
not tap on the steeringwheel or steeringcolumn control switchesfor proper operation.
shaft when installingthe steeringwheel.
7 . Reconnectthe batteryand do the following:
. D o t h e e n g i n ec o n t r o lm o d u l e( E C M )i d l e l e a r n
p r o c e d u r e( s e ep a g e1 l - 1 3 9 ) ,
. Powerwindow control unit resettingprocedure
\see page 22-1281.
. Enterthe anti-theftcord for the radio,then enter
the custmer'sradio stationpresets.
. Set the clock.
17-8
SteeringColumnRemovaland Installation
SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations(seepage 23-13)and precautionsand
procedures(seepage 23-14)in the SRSsectionbefore performingrepairsor service.
Removal
1, Recordthe radio stationpresets,and disconnectthe battery.
2 . R e m o v e t h e d r i v e r ' s a i r b a g a s s e m b l y ( s e e p a g e 2 3 -a1n1d3t)h e s t e e r i n gw h e e l( s e ep a g e1 7 - 6 ) .
3 . R e m o v e t h ed r i v e r ' sd a s h b o a r dl o w e r c o v e r ( s e ep a g e2 0 - 5 9 a) n d u n d e r c o v e r ( s e e
p a g e2 0 - 6 0 ) .
4. Removethe column covers(A:
I x 1.25mm
16 N.m (1.6kgf.m,
12 lbl.fr) b
5 . Disconnectthe wire harnessconnectorsfrom the combinationswitch assembly{B).
6 . Removethe combinationswitch assemblyfrom the steeringcolumn shaft by removingthe screw (C)on the top of
the combinationswitch.
7. Disconnectthe connectorsfrom the ignition switch,and releasethe wire harnessclips from the steeringcolumn.
8. Disconnectthe steeringjoint (D),and remove it from the column shaft.
9. Removethe steeringcolumn {E)by removingthe attachingnuts and bolts.
\
(cont'd)
17-9
Steering
SteeringColumnRemovaland Installation(cont'd) {
lnstallation
1 . I n s t a ltl h e s t e e r i n gc o l u m n ,a n d m a k es u r et h e
wires are not caught or pinchedby any parts.
Insertthe upper end ofthe steeringjoint onto the

steeringshaft {A) (line up the bolt hole (B)with the
flat portion (C)on the shaft).
8 x 1 , 2 5m m
28 N.m
{2.9 kgf m,
21rbr.ft)
A
Slip the lower end of the steeringjoint onto the

pinion shaft {D) (line up the bolt hole with the
g r o o v e( E )a r o u n dt h e s h a f t )a, n d l o o s e l yl n s t a l l t h e
lower joint bolt. Be sure that the lower joint bolt is
securelyin the groove in the pinion shaft.
4 . Pull on the steeringjoint to make sure that the

s t e e r i n gj o i n t i s f u l l y s e a t e dT. h e n i n s t a l l t h eu p p e r
joint bolt, and tighten it to the specifiedtorque.
Tightenthe lower joint bolt to the specifiedtorque.
Finishthe installation,and note these items:

. Make surethe wire harnessis routed and
fastenedproperly.
. Make sure the connectorsare properlyconnected.
. R e i n s t a l l t h se t e e r i n gw h e e l( s e ep a g e1 7 - 8 ) .
. Reconnectthe battery.
- Do the power window control unitreset
procedure{seepage 22-128).
- Enterthe anti-theftcode for the radio,then
enterthe custmer'sradio stationpresets.
- Set the clock.
. Verify horn, turn signalswitch,and cruisecontrol
switch operation.
. Checkwheel alignment,if necessary(seepage
18-4).
. D o t h e e n g i n ec o n t r o lm o d u l e( E C M )i d l el e a r n
p r o c e d ur e { s e ep a g e' 1 1 - 1 3 9 ) .
17-10
SteeringColumnInspection
. C h e c kt h e s t e e r i n gc o l u m nb a l l b e a r i n g ( A a) n d t h e s t e e r i n g j o i n t b e a r i n g s ( B ) f o r p l a y a n d p r o p e r m o v e m el fnatn. y
bearingis noisy or has excessiveplay, replacethe steeringcolumn as an assembly,
' C h e c k t h e a b s o r b i n g p l a t e s ( C ) , a b s o r b i n g p l a t e g u i d e s ( D ) , s t o p ( E ) , a n d c o a t i n g p l af o
t er sd(i F
s t)o r t i o na n d
breakage.lf there is distortionor breakage,replacethe steeringcolumn as an assembly.
17-11
Steering
SteeringLockReplacement
NOTE:Do not try to re-keya replacementsteeringlock. 7. Tightenthe shearbolts (A) untilthe hex heads(B)
lf necessary,re-keythe other locks. twist off.
1 . R e m o v et h e s t e e r i n gc o l u m n( s e ep a g e1 7 - 9 ) .
A
2. Centerpunch each ofthe two shear bolts (A),and
drill their headsoff with a 5 mm (3i16 in.) drill bit.
Be carefulnot to damagethe switch body when
I
removingthe shear bolts,
:..'-":'
3. Removethe shear bolts from the switch body.
4. Installtheswitch body without the key inserted. I

5. Looselytighten the new shear bolts.
6. Insertthe ignition key,and checkfor proper

operationof the steeringwheel lock and that the
ignition key turns freely.
17-12
RackGuideAdjustment
Special Tool Required 6. Tightenthe rackguidescrew(A)ro25 N.m (2.5
Locknutwrench, 43 mm 07MAA-S100200 kgf.m,18lbf.ft).thenloosenit.
1. Set the wheels in the straightaheadposition. 5" Max.

j
i-rrrr-,
2. Removethe heat shield(A).
'-.i. '' '
9 . 8N . m ( r . 0 k g f . m , 7 . 2 l b t f t )
I 4il N.m
{a.5kgf.m,33lbt.ft)
3 . Removethe transmissionmount bracket(seestep
32 on page 13-8). 7 . Retightenthe rack guide screw to 6 N.m (0.6kgf m,
4 lbf.ft),then back it off to the specifiedangle.
Loosenthe rackguide screw locknut(A)with the
specialtool, then removethe rack guide screw (B). Specified Return Angle: 5' Max.
07MAA-S100200
Hold the rack guide screw stationarywith a wrench,
and tighten the locknutby hand until it's fully
seated.
9 . I n s t a l l t h es p e c i atl o o l o n t h e l o c k n u (t B ) ,a n d h o l d
the rackguide screw (A) stationarywith a wrench,
Tightenthe locknutan additional30" with the
specialtool.
1 0 .Reinstallthe transmissionmount bracketand heat

s hi el d ,
Removethe old sealantfrom rackguide screw,and 1 1 .Checkfor unusualsteeringeffort through the

apply new sealantto the middle of the threads(A). c o m p l e t et u r n i n gt r a v e l .
Looselyinstallthe rackguide screw on the steering
gearDox. 12. Checkthe steeringwheel rotationplay (seepage
17-4)and the power assist(seepage 17-4).
17-13
ElectricalPowerSteering(EPSI
SpecialTools . . . . . . . . . .1. .7-. 1 6
C o m p o n e nLto c a t i oInn d e x . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.7. .-.1. .7. . . . . . .
General Troubleshooting Information....................... 17-18
DTCTroubleshooting Index .............. 17-22
SymptomTroubleshooting Index ............................... 17-23
SystemDescription................. ........... 17-24
DTCTroubleshooting ............... .......... 17-28
EPSlndicator CircuitTroubleshooting ....................... 17-47
MotorRemoval/lnstallation ............... 17-49
Steering GearboxRemoval ............... 17-51
Steering GearboxOverhaul ............... 17-55
Steering GearboxInstallation ........... 17-63
EPSControlUnitRemova l/lnsta llation....................... 17-67
Tie-rodBallJointBootReplacement .......................... 17-67

EPSComponents
SpecialTools \
Rel.No. Tool Number Description otv

(!) '1
07MAC-S100200 B a l lJ o i n t R e m o v e r2, 8 m m
at' 070AD-P0A0100 Attachment,42 mm 1
'l
o 07zAA-S5A0100 LocknutWrench
-)
,.^G) C\
_---1t )
h5--d-'
u_r-.c_-
t t )
\L-,
a
17-16
GAUGE
ASSEMBLY
UNDER.DASH
FUSE/RELAY
BOX
UNDER.HOOD
FUSE/RELAY
BOX
-,'/.,....
'.,i,
X \ ]
DATA LINK CONNECTORI16P)
TOROUE
SENSOR
STEERINGGEARBOX
EPSCONTROL UNIT SteeringGearboxRemoval,page 17-51
EPSControlUnitRemoval/lnstallation, SteeringGearboxOverhaul,page 17-55
page17-67 SteeringGearboxInstallation,page 17-63
MOTOR
page l7-49
17-17
EPSComponents
Information a
EPSIndicator . TheDTCS arememorized in theEEPRO|(non-volatile
memory)therefore the memorizedDTCScannotbe erased
Undernormalconditions, the EPSindicator
comeson when by disconnecting
the battery.
Perform
thespecified
the ignitlonswitchis turnedto theON(ll)position,
thengoes procedures
to clearDTCS.
off afterthe engineis started.
Thisindicates
thatthebulband
itscircuitareoperating correctly. Self-diagnosis
lf thereis anytroublein thesystemaftertheengineis started,
theEPSindicator will stayon,andthe powerassistis turned Self-diagnosiscan be classifiedinto two categories:
off. . I n i t i a l d i a g n o s i sp: e r f o r m e dr i g h ta f t e rt h e e n g i n e
startsand until the EPSindicatorgoes off.
WhenEPSindicator lightcomeson,thecontrolunit . Regulardiagnosis:performedright after the initial
memorizes the DTC.In thiscase,thecontrolunitwill not d i a g n o s i su n t i lt h e i g n i t i o ns w i t c hi s t u r n e dO F F .
the EPSsystemaftertheenginestartsagain,but it
activate
keepsthe EPSindicator on. The EPScontrol unit performsthe following functions
when a problem is detectedby self-diagnosis;
WhenDTC12,16,17,18or 67 is storedin thecontrolunit,the
'1.
EPSindicatorwill stayon untiltheDTCis erased.Whena T u r n so n t h e E P Si n d i c a t o r .
problemis detected andthe EPSindicator comeson,thereare 2. Memorizesthe DTC.
caseswhenthe indicator stayson untiltheignitionswitchis 3. Stops power assistand manual steeringoperation
turned0FF,andcaseswhenthe indicator goesoff begrns.
whenthesystemreturnsto normal.Eventhough
automatically
thesystemis operating normally, the EPSindicator
will come NOTE:
on underthefollowingconditions: . When DTC23 (a problemwith the circuitfor
enginespeedsignal)is detected,the power
'1:
Condition a s s i sw
t i l l r e t u r nt o n o r m a lw h e n t h e v e h i c l e
. Thevehiclewastraveling at least12.4mph(20km/h),then s p e e di s 0 . 6 2m p h ( 1 k m / h )o r a b o v e .
. A rapid changein vehiclespeedwas detected,then . Fot DfCs 22,23, 64, or 66 the EPSindicatorgoes
. Thevehicle(orthevehiclespeedsensorsignal)stoppedfor off automaticallywhen the system relurnsto
at least5 seconds n o r m a l .F o ra l l o t h e rc o d e s t, h e E P Si n d i c a t o r
. T h ee n g i n se p e e d 'l,640rpmorhigherforatleastS goes off when the system is OK afterthe ignition
w a ss t i l l
seconds switch is turned from OFFto ON (ll).
C o n d i t i o n2 : Restrictionon PowerAssistOperation
Afterthevehicle(orthevehiclespeedsensorsignal)has
stopped yettheenginespeedwasstill
for at least10seconds, Repeatedextremesteeringforce.such as turning the
1,640rpmor higherforat least20seconds. steeringwheel continuouslyback-and-forth with the
vehiclestopped,causesan increaseof power
C o n d i t i o n3 : consumptionin the EPSmotor. The increaseof electric
When theengine is280rpmor less,
speed andthevehicle
istraveling
at c u r r e n tc a u s e st h e m o t o rt o h e a tu p . B e c a u s e
t h i sh e a t
a speed of6,2mph(10km/h) or morefor3 seconds. adverselyaffectsthe system,the control unit monitors
the electriccurrent of the motor.
theactualcauseofthe problem,question
To determine the
customer duringwhichthe problem
abouttheconditions When the control unit detectsheat build-upin the motor,
takingtheaboveconditions
occured, intoconsideration. it reducesthe electriccurrentto the motor graduallyto
protectthe system,and it restrictsthe power assist
DiagnosticTroubleCode(DTCI o p e r a t i o nT. h e E P Si n d i c a t o dr o e sn o t c o m e o n d u r i n g
t h i sf u n c t i o n .
. lf theCPUcannotbeactivated,or itfails,theEPSindicator
comeson,butthe DTCis notmemorized. When steeringtorque is not appliedto the steering
. Thememorycanholdanynumberof DTCS. However, when wheel, or when the ignition is turned off, and the motor
thesameDTCis detected morethanonce,the mostrecent cools,the control unit will restorethe power assist
DTCis writtenoverthe priorDTC,therefore onlyone graduallyuntil it's fully restored(afterapproximately15
occurrence is memorized. m i n u t e sm a x i m u m ) .
. TheDTCS areindicatedrepeatedlyuntiltheignitionswitchis
turnedOFF.
. lf theDTCis not memorized,the
EPSindicator blinks.
17-18
How to TroubleshootEPSDTCs 2 . T u r nt h e i g n i t i o nO N ( l l ) ,a n d f o l l o wt h e p r o m p t so n
the PGM Testerto displaythe DTC(s)on the screen.
The troubleshootingflowchart proceduresassumethat After determiningthe DTC,referto the DTC
the causeof the problem is still presentand the EPS TroubleshootingIndex.
indicatoris still on, Followingthe flowchartwhen the
EPSindicatordoes not come on can result in incorrect NOTE:See the HondaPGM Testeruser's manual
diagnosis. for specificinstructions.
The connectoriliustrationsshow the female terminal
s i t h a s i n g l eo u t l i n ea n d t h e m a l et e r m i n a l
c o n n e c t o rw ServiceCheckSignalCircuit Method:
connectorswith a double outline.
1 . W i t h t h e i g n i t i o ns w i t c hO F F ,c o n n e c t h e H o n d a
1. Ouestionthe customeraboutthe conditionswhen P G MT e s t e r( A ) t o t h e 1 6 Pd a t al i n kc o n n e c t o(rD L C )
the problem occured,and try to reproducethe (B) locatedunderthe dash on the driver'sside of
same conditionsfor troubleshooting.Find out the vehicle.
when the EPSindicatorcame on, such as while
t u r n i n g .a f t e r t u r n i n gw, h e n t h e v e h i c l ew a s a t a
certain speed,etc.
2. When the EPSindicatordoes not come on during

the test drive, but troubleshootingis done basedon
the DTC,checkfor looseconnectors,poor terminal
contact.etc in the affectedcircuit,beforeyou start
troubleshooting.
3. After troubleshooting,clearthe DTCand test-drive

the vehicle.Be sure the EPSindicatordoes not
c o m eo n .
How to RetrieveEPSDTCs
Honda PGM Tester Method: Short the SCScircuitto body ground using the
HondaPGN4Tester.
1, With the ignition switch OFF,connectthe Honda
PGM Tester(A)to the 16Pdata link connector(DLC) T u r nt h e i g n i t i o ns w i t c hO N { l l ) .
(B) locatedunderthe dash on the driver'sside of
thevehicle. Recordthe DTC.
(cont'd)
17-19
EPSComponents
GeneralTroubleshootingInformation(cont'dl
5. The blinkingfrequencyindicatesthe DTC.DTCSare How to ClearEPSDTCs
indicatedby a seriesof long and short blinks.One
l o n g b l i n ke q u a l s1 0 s h o r tb l i n k s A
. d d t h e l o n ga n d Honda PGM Tesler Method:
short blinkstogetherto determinethe DTC.After
determiningthe DTC,referto the DTC 1. With the ignition switch OFF,connectthe Honda
TroubleshootingIndex. PGM Tester(A)to the 16Pdata link connector(DLC)
( B )l o c a t e du n d e rt h e d a s ho n t h e d r i v e r ' ss i d eo f
The system will not indicatethe DTCunlessthese the vehicle.
conditionsare met:
. Set the front wheels in the straightaheaddriving
position.
. The ignition switch is turned ON (ll).
. The engine is stopped.
. The SCScircuit is shortedto body ground before
the ignition switch is turned ON (ll).
Exampleof DTC23
Long blinks Short blinks

(two times) (three timesl
Turn the ignition switch ON (ll),and clearthe

DTC{s)by following the screenpromptson the
PGM Tester.
NOTE:Seethe Honda PGMTesteruser'smanual

for specificinstructions.
7 . Disconnectthe Honda PGM Testerfrom the DLC.
17-20
Service Check Signal Circuit Method: 1 . Within 4 secondsafter the EPSindicatorgoes off,
returnthe steeringwheel to the straightahead
NOTE:Use this procedurewhen the PGM Tester driving positionagain and releasethe steering
softwaredoes not matchthe yearlmodelvehicleyou wheel.The EPSindicatorblinkstwice 4 seconds
are working on. after releasingthe steeringwheel, indicatingthat
the DTCwas erased.
1. With the ignitionswitch OFF,connectthe Honda
PGM Tester(A)to the 16Pdata link connector{DLC) NOTE:If the EPSindicatordoes not blinktwice, an
(B) locatedunderthe dash on the driver'sside of error was made in the procedureand the DTCwas
the vehicle. not erased.Turn the ignition switch OFF,and
repeatthe operationfrom step 3.
Turn the ignition switch OFFafterthe EPSindicator

blinkstwice.
9. Disconnectthe Honda PGM Testerfrom the DLC.
10. Performthe DTCcode output operation,and be

sure that the code has been erased.
With the vehicleon the ground,set the front wheels

in the straightaheaddriving position.
Short the SCScircuitto body ground using the

HondaPGM Tester.
4. Turn the ignition switch ON (ll).The EPSindicator

comes on for about 6 seconds.Within 4 secondsof
turning the switch ON, while the EPSindicatoris on,
turn the steeringwheel 45 degreesto the left from
the straightaheaddriving position,and hold the
steeringwheel in that positionuntil the EPS
indicatorgoes off.
Within 4 secondsafterthe EPSindicatorgoes off,

returnthe steeringwheel to the straightahead
driving positionand releasethe steeringwheel.
The EPSindicatorcomes on again 4 secondsafter
releasingthe steeringwheel,
Within 4 secondsafter the EPSindicatorcomes on,

turn the steeringwheel 45 degreesto the left again
and hold it in that position.
The EPSindicatorgoes off after 4 seconds.
17-21
EPSComponents
DTC;12 A problem with voltagefor torque sensorT/SlG (seepage 17-28)
D T C1: 6 A problemwith averageof voltagefor torque sensorVT3 and VT6 (seepage 17-29)
DTC:17 A problemwith thevoltagefor torquesensor12V powersourceVcc1 ( s e ep a g e1 7 - 3 1 )
DTC:18 A problemwith the voltagefor torque sensor5 V power sourceVcc 2 ( s e ep a g e1 7 - 3 1 )
DfC:22 A problemwith the averagefor vehiclespeedand enginespeed ( s e ep a g e1 7 - 3 3 )
Excessivechangeof the vehiclespeed sensorsignal {seepage 17-33)
DTC:23 A problemwith the engine speedsignal circuit ( s e ep a g e1 7 - 3 3 )
DTC:37 A problemwith the circuitfor input motor voltage in the EPScontrol unit (seepage 17-35)
DTC:41 A problemwith the motor voltage ( s e ep a g e1 7 3 6 )
DfC: 42 A problemwith the motor driven current (opencircuitor short to grounol (seepage '17-38)
DTC:43 A problem with the motor driven current (shortto power) ( s e ep a g e1 7 - 4 1 )
DTC:45 A problemwith the motor driven current (opencircuitor short to grounol (seepage 17-38)
DfC: 47 A problemwith the motor relav in the EPScontrol unit { s e ep a g e1 7 - 4 2 )
DTC:50 A problem with the CPU in the EPScontrol unit ( s e ep a g e1 7 - 4 3 )
D T C :5 1 A problemwith EEPROM
in the EPScontrolunlt (seepage 17-43)
DTC:62 Fail-saferelay stuckON ( s e ep a g e1 7 - 4 4 )
DTC:64 A problem with low batteryvoltage (seepage 17-44)
Fail-saferelay contactfailure (seepage 17-44)
DTC:66 A problem with the motor driven voltage {seepage 17 45)
DTC:67 A problemwith the torque sensorl/F circuit ( s e ep a g e1 7 ' 4 5 )
DTC:68 A problemwith the interlockcircuit (torque) {seepage 17-45)
DTC:69 A p r o b l e mw i t h t h e i n t e r l o c kc i r c u i t( c u r r e n t ) ( s e ep a g e1 7 - 4 6 )
17-22
Symptom Diagnostic procedure Also check fo]
EPSindicatordoes not EPSlndicatorCircuitTroubleshooting(seepage 17-47)

come on
EPSindicatordoes not go EPSIndicatorCircuitTroubleshooting(seepage 17-47)

off and no DTC is stored
EPSindicatordoes not stay 1. Checkthe motor wires betweenthe EPScontrol unit and the
on, no DTCis stored,and motor for a short to ground. Repairas needed.
there is no power assist 2. lf the motor wires are OK, replacethe steeringgearbox
{short in the motor).
17-23
EPSGomponents
SystemDescription
EPSGontrolUnit Inputsand Outputsat ConnectorA (2pl
EPSCONTROLUNIT CONNECTORA {2P)
Termanal Wire color Terminalsign Description Measurement

numbol (Terminalnamel Terminals Conditions Voltage
lqnitiqr switch ON (lll
WHT/BLU -' BAT Powersourcefor the l Ground Constant Battery voltage
(Plus
bafterv) actuatormotor
2 8LK PG Groundforthe actuator 2-Ground
EPSControlUnit Inputsand Outputsat ConnectorB (2P)
EPSCONTROLUNITCONNECTOB
B {2P}
Terminal Wire colol Terminalsign Description Measuremenl

numDer {Te.mioalname) Terminals Conditions Voltage
lqnition switch ON llll
1 RED M1 Driveslhe actuatormotor 1-Ground
(Motor 1
2 GRN M2 Drives the actuator motor 2'Ground
17-24
EPSGontrolUnit Inputsand Outputsat ConnestorC (20P1
C (2OP)
EPSCONTROLUNITCONNECTOR
Terminal Wire color Terminalsign Descriplion Measuremeni

numbel {Terminelname} Terminals Conditions Voltage
{lqnitionswitch ON {lll)
2 PNK T/SGND Groundfor the torque
(Torquesensorqround)
ORN vccl Powersourcefortorque 3-Ground tarttheenqrne Ba$ervvoltaqe
(Voltaqe common1 OV
5 YEUBED VT6 Detectstorque sensor 5 Ground Starttheengineand About
(Voltaqe torque6) stonal turnthe steerinowheel
YEUBLU Drivesthe EPSindicator 6 Ground E P S ON OV
(Warninqlamp) lidhr tnotcatol uTl- Banervvoltaqe
7 BLUAVHT VSP Detectsthe vehiclespeed Raisethe vehicleoff the Alternating
( V e h i c l es p e e d p u l s e i inputsignalfor the speed groundandspinthe voltageabout
sensoror the ECM(4 pulse/ OV 5V OV-5V
BRN SCS Detectsservicecheck 8-Ground SCSnot grounded Batteryvoltage

{Servjco checksiqnal)
10 YEL IG1 Powersourcefor activating 10-Ground on switchON (ll) Battervvoltaqe
llqnition1 on switchOFF
11 GRN//EL vcc2 Drivesthetorquesensor 1'l-Ground tan the enoine About5V
(Voltaqe
common2) on switch OFF
8LU/ORN VT3 Detectstorque sensor 13-GroundStarttheengineand About
(Voltaoe
toroue3) trrrnthe steerinowheel 5 - 0 v
YEUBLK T/SIG Detectstorque sensor 15-GroundStarttheengine Momentarily
5V
(TorquesensorF/S srgnal
1'l LT GRN/ PSW Providespower steering l7-Ground Starttheengineand 0-12V

B IK iPowersteerinoswitch) switchsional nrrnthe steerinowheel
19 BLU NEP Detectsthe enginepulse 19-GroundStarttheengine,and let
;t idte
20 GRY DIAG-H with
Communications 20-Ground PGMTesternot 5V
HondaPGNITester
17-25
EPSComponents
CircuitDiagram \ a
SPE€DSENSOR GAUGEASSEMBLY22PCONNECTON
3P CONNECTOR
GAUGEASSEMATY22PCONNECTOR TOFOUESENSOR
6P CONNECTOR
lli2l3F
r;T;T-I
(=J_:_LvJ
Wn. !ide ot f.m.l€ r.fmin.ls
17-26
EPSCOI{IFOIUNIT OATA !IN( CONN€CTOA(T6P)
cou{EcToR A (2P)
F-l
A vTTrvaEvnrv
EPSCONTNOLUNIT
wwzna
co|lNEcTofi 8 {2P} MOTOF
CONNECTOR
| l l riTt T.rmin.l.id. oll.m.l.r.rmin.l.

t2)
Wir. !.le ol l.m.l. t.tman.r.
17-27
EPSComponents
DTCTroubleshooting
DTC12: TorqueSensorT/SIG 1 . Turn the ignition switch ON (ll).
1 . C l e a rt h e D T C . 8 . Measurethe voltage betweenEPScontrol unit

r ( 2 0 P ) t e r m i n aNl o . 1 5 a n d b o d y g r o u n d .
c o n n e c t oC
2 . S t a nt h e e n g i n e .
EPSCONTROL C (2OP)
UNITCONNECTOR
3. Wait at least 10 seconds.
Does the EPS indicatot come on? 2 3 5 6 1 8 0

YES Go to step 4.
T/SIG
{YEL/BLK)
NO Checkfor loosewires or poor connections.lf
the connectionsare good, the system is OK at this
time.l
4 . Stop the engine,and verify the DTC. Wire side ot lemaleterminals
ls DTC12 indicated?
I s there battery v oltage?
YES Go to slep 5.
YES-Repair short to power in the + circuitwire
NO-Perform the appropriatetroubleshootingfor betweenthe torque sensorand EPScontrol unit.l
the code indicated.t
NO Go to step 9.
5 . Make sure the ignitionswitch is OFF,then
disconnectEPScontrol unit connectorC (20P)and
\
the torque sensor6P connector.
1 0 . Checkfor continuitybetweenEPScontrol unit
Checkfor continuitybetweenEPScontrol unit connectorC (20P)terminal No. 15 and the torque
c o n n e c t oC sensor6P connectorterminal No. 4.
EPSCONTROL C (2OPI
UNITCONNECTOR
EPSCONTROL
UNITCONNECTOR
C {2OP)
T/SIG W i r es i d eo f f e m a l et e r m i n a l s
(YEL/BLK)
TOROUE
SENSOR
6PCONNECTOR
T/SIG
(YEL/BLK)
ls therecontinuity? ls there continuity?
YES- Repairshortto bodygroundin thewire YES Go to step 1'1,

betweenthetorquesensorandEPScontrolunit.l
NO Repairopen in the wire betweenthe torque
NO Go to step7. sensorand the EPScontrol unit.I
17-28
'I
1 . Substitutea known-goodEPScontrol unit, and DTC16:TorqueSensorVT3andW6
connectthe all disconnectedconnectors.
1 . C l e a rt h e D T C .
1 2 .Start the engine. 2. Startthe engine.
3 . W a i t a t l e a s t1 0 s e c o n d s .
Does the EPS indicator come on?
YES Go to step 13.
YES Go to step 4.
NO Checkfor loose EPScontrol unitconnectors.lf
necessary,replacethe EPScontrol unit and NO Checkfor loosewires or poor connnections.lf
retest.l the connectionsare good,the system is OK at this
time.l
1 3 .Stop the engine,and verify the DTC.
4. Stop the engine,and verify the DTC.
ls DTCl2 indicated?
ls DTC16 indicated?
YES Checkfor loosetorque sensorconnectors.
lf necessary,substitutea known-goodsteering YES-Go to step 5.
gearboxand recheck.l
NO Performthe appropriatetroubleshootingfor
NO-Perform the appropriatetroubleshootingfor the code indicated.t
the code indicated.!
5. Make sure the ignition switch is OFF,then
6, Checkfor continuitybetweenthe appropriateEPS

control unit connectorC (20P)terminal and body
ground (seetable).
Terminalname C
EPScontrolunitconnector
terminalNo.
Vccl 3
Vcc2 11
VT3 13
VT6 5
T/S GND 2
C (2OP)
EPSCONINOTUNITCONNECIOR
W re s d€ oltemalelermi.als
YES- Repairshort to body ground in the

appropriatesensorcircuit betweenthe torque
sensorand EPScontrol unit,!
NO Go to step7.
{cont'd)
17-29
EPSComponents
DTCTroubleshooting(cont'd) I
7 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) . 9 . Turn the ignition switch OFF.
8 . Measurethe voltage betweenthe appropriateEPS 1 0 . Checkfor continuitybetweenthe appropriateEPS

control unit connectorC (20P)terminal and body control unit connectorC {20P)terminal and the
ground (seetable). torque sensorterminal (seetable).
Terminalname EPScontrol unitconnector

C T e r m i n a l TorqueSensor EPScontrol
t e r m i nN
a lo . name t e r m i n aNl o , unitconnector
Vccl 3 C t e r m i n aNl o .
Vcc2 11 Vccl 2 3
VT3 13 Vcc2 3 11
VT6 5 VT3 'l 't3
T/S GND 2 VT6 6 5
T/S GND 6 2
C {2OP}
TOROUESENSOR6PCONNECTOR
Vccz
(GRN/YELI
Wire side of
f e m a l et e r m i n a l s
VT6 {YEL/RED)
T/S GND {PNK) EPSCONTROLUNIT

CONNECTORC I2OP) \
VT6{YEL/RED}
ls thete battery voltage?
YES Repairshon to power in the + circuitwire

betweenthe EPScontrol unit and torque sensor.l
NO Go to step 9.
ls therecontinuty?
Y E S G ot o s t e p1 1 .
NO Repairopenin the appropriatetorquesensor

wirecircuitbetweenthe EPScontrolunitandthe
t o r q u es e n s o r . l
17-30
1 1 .Substitutea known-goodEPScontrol unit, and DTC17: TorqueSensorVccl
reconnectthe disconnectedconnectors.
DTC18:TorqueSensorVcc2
't2.
Start the engine.
2 . S t a r tt h e e n g i n e .
YES Go to step 13.
3. Wait at least 10 seconds.
NO Checkfor looseor poor connectionsat the
EPScontrol unit and the torque sensorconneclors. Does the EPS indicator come on?
lf the connectionsare good, replacethe EPScontrol
u n i ta n d r e c h e c k . I YES Go to step 4.
1 3 .Stop the engine,and verify the DTC. NO Checkfor loosewires or poor connections.lf
ls DTC16 indicated? time.I
YES Replacethe steeringgearboxand recheck.l 4 . Stop the engine,and verify the DTC.
NO Performthe appropriatetroubleshootingfor Is DTCl7 or DTCl8 indicated?

the code indicated.l
YES Go to step 5.
NO Do the troubleshootingfor the DTc

indicated.I
Make sure the ignition switch is OFF,then

Checkfor continuitybetweenEPScontrol unit

r ( 2 0 P ) t e r m i n aNl o . 3 a n d b o d y g r o u n d .
c o n n e c t oC
C (2OP)
UNITCONNECTOR
EPSCONTROL
Wiresideo{ femaleterminals
Y E S R e p a i rs h o n t o b o d y g r o u n di n t h e w i r e
betweenthe torque sensorand EPScontrol unit.I
NO Go to step 7.
(cont'd)
17-31
EPSComponents
DTCTroubleshooting(cont'dl \
7. Checkfor continultybetweenEPScontrol unit 9. Checkfor continuitybetweenEPScontrol unit

r ( 2 0 P t)e r m i n a lN o . 3 a n d t h e t o r q u e
c o n n e c t oC connectorC {20P)terminal No. 11 and the torque
sensor6P connectorterminal No. 2. sensor6P connectorterminal No. 3.
EPSCONTROL
UNITCONNECTOR
C I2OP) EPSCONTROL C (2OP}
UNITCONNECTOR
Vcc2(GRN/YEL)
Wire side ol lemale terminals Wire side of femaleterminals
ls thete continuity? ls therc continuity?
YES Go to step 8. YES-Go to step 10.
NO Repairopen in the wire betweenthe torque NO Repairopen in the wire betweenthe torque
s e n s o ra n d E P Sc o n t r o lu n i t . I sensorand EPScontrol unit.l
8 . Checkfor continuitybetweenEPScontrol unit 1 0 .Substitutea known-goodEPScontrol unit, and

r ( 2 0 P t)e r m i n a lN o . 1 1 a n d b o d y g r o u n d .
c o n n e c t oC connectall the disconnectedconnectors.
EPSCONTROL C (2OP)
UNITCONNECTOR 1 1 .Start the engine.
2 3 5 6 1 8 0 YES Go to step 12.
{GRN/YEL) NO Checkfor looseor poor connectionsat the

lvcc2
EPScontrol unit and the torque sensorconnectors.
lf the connectionsare good, replacethe EPScontrol
u n i ta n d r e c h e c k . l
Wire side of femaleterminals 12. Stop the engine,and verity the DTC.
ls DTC17 or DTC18 indicated?

ls therecontinuity?
YES-Replace the steeringgearboxand recheck.l
YES Repairshortto bodygroundin thewire
betweenthetorquesensorandEPScontrolunit.t NO Performthe appropriatetroubleshootingfor
NO Goto step9.
17-32
DTC22: VehicleSpeedSensorSignal 3 . Blockthe rearwheels and raisethe vehicle,and
make sure it is securelysupported.
DTC23: EngineSpeedSignal
NOTE:
. lf the MIL indicatoris ON, troubleshootthe PGIVI-Fl 5 . Blockthe right front wheel, and slowly rotatethe
systemfirst. left front wheel, and measurethe voltage between
. Eventhough the system is operatingnormally,the r ( 2 0 P ) t e r m i n aNl o . 7
E P Sc o n t r o lu n i tc o n n e c t oC
EPSindicatorwill come on underthe following a n d b o d yg r o u n d .
conditions.
EPSCONTROL
UNITCONNECTOR
C {2OP)
- C o n d i t i o n1 :
. The vehiclewas travelingat least '12.4mph
(20 km/h),then
. A rapld changein vehiclespeedwas detected,
then
. T h e v e h i c l e( o rt h e v e h i c l es p e e ds e n s o rs i g n a l )
stoppedfor at least5 seconds,and
. The engine speedwas still 1,640rpm or higherfor
at least5 seconds
- Condition2:
After the vehicle(or the vehiclespeedsensor Wire side of femaleterminals
signal)has stoppedfor at least10 seconds,yetthe
e n g i n es p e e dw a s s t i l l 1 , 6 4 0r p m o r h i g h e rf o r a t
least20 seconds. Does the voltagepulse 0 V and 5 V?
- Condition3:
W h e nt h e v e h i c l es p e e di s 1 0 k m / h ( 6 . 2m p h )o r YES Go to step 6.
a b o v ea n d t h e e n g i n ei s r u n n i n ga t 2 8 0 r p m o r
below for 3 seconds. NO Repairopen in the wire betweenthe EPS
control unit and the VSS. lf the wire is OK,checkfor
1. Startthe engineand checkthe tachometer. a loose or poor connectionsat the EPScontrol unit.
lf necessary,substitutea known-goodEPScontrol
ls the tachometer working correctly? u n i t ,a n d r e c h e c k . l
YES- Go to step 2.
2. Test-drivethe vehicleabove 15 km/h {9.3mph).
ls the speedometerworking correctly?
YES Go to step 3.
NO-Perform the speedometersystem

troubleshooting{see page22-651.a
(conr'd)
17-33
EPSGomponents
Turn the ignition switch OFF,and disconnectEPS 11. Measurethe voltage betweenEPScontrol unit
control unit connectorC (20P). r ( 2 0 P ) t e r m i n aNl o . 1 9 a n d b o d y g r o u n d .
c o n n e c t oC
7 . Startthe engine,and let it idle. EPSCONTROLUNITCONNECTOR

C {2OPI
8 . Measurethe voltage betweenEPScontrol unit

r { 2 0 P t) e r m i n a lN o . 1 9a n d b o d y g r o u n d .
c o n n e c t oC
EPSCONTROL
UNITCONNECTOR
C {2OP)
ls there about 6 V at idle? (With the metet set tor

trequency, is therc 33 Hz per 1,000 engine rpn?)
Wire side of {emaleterminals
YES Checkfor loose EPScontrol unitconnectors.
lf necessary,substitutea known-goodEPScontrol
ls there about 6 V at idle? (With the meter set lol u n i ta n d r e c h e c k . I
t requency,is there 33 Hz per 1,000engine rpm?)
'12.
NO Go to step
YES Checkfor loose EPScontrol unit connectors.
lf necessary,substitutea known-goodEPScontrol 1 2 .Turn the ignition switch OFF.
1 3 .Disconnectthe ECMconnectorE (31P)connector.
NO Repairopen in the wire betweenthe EPS
c o n t r o lu n i ta n d t h e E C M . I
9 . Turn the ignition switch OFF,and disconnectEPS

control unit connectorC (20P).
1 0 .Startthe engine,and let it idle.
17-34
'14.
Checkfor continultvbetweenEPScontrol unit DTC37: EPSControlUnitInternal Circuit
r ( 2 0 P ) t e r m i n aNl o . 1 9 a n d E C M
c o n n e c t oC (lnputCircuitForMotorVoltage)
connectorE (31P)terminal No. 26.
ECMCONNECTOR
E {31PI
2. Startthe engine.
3. Turn the steeringwheel from lock-to-lockseveral

times, and wait 10 secondsor more.
YES Go to step 4.

the connectionsare good,the system is OK at this
trme.l
ls thete continuity? 4. Stop the engine,and verify the DTC.
YES-Go to step 15. ls DTC 37 indicated?
N O - R e p a i r o p e n i n t h e w i r e b e t w e e nt h e E P S Y€S Checkfor loose EPScontrol unit conneclors.

c o n t r o lu n i ta n d E C M . I lf necessary,substitutea known-goodEPScontrol
1 5 . Disconnectthe gauge assembly22Pconnector.
Checkfor continuitybetweenEPScontrol unit the code indicated.l
r ( 2 0 P ) t e r m i n aNl o . 1 9 a n d b o d y g r o u n d ,
c o n n e c t oC
EPSCONTROL C (2OP}
UNITCONNECTOR
Y E S R e p a i rs h o r t t ob o d y g r o u n di n t h e w i r e
betweenthe EPScontrol unit, the test tachometer
connector,the gaugeassembly,and the ECM.I
NO Checkfor loose ECMcontrol unit connectors.

lf necessary,substitutea known-goodECMcontrol
u n i ta n d r e c h e c k . I
17-35
EPSComponents
DTCTroubleshooting(cont'dl .l
DTC41: VoltageForMotor 7. Checkfor continuitybetweenEPScontrol unit
r ( 2 P ) t e r m i n aNl o . 2 a n d b o d y g r o u n d .
c o n n e c t oB
B I2P)
2 . S t a r tt h e e n g i n e .
3. Turn the steeringwheel from lock-to-lockseveral Tit

times, and wait 10 secondsor more, M2 {GRN)FJ
-r
o)
YES-Go to step 4. I
T
the connectionsare good,the system is OK at this Wiresideof femaleterminals
time.l
4. Stop the engine,and verify the DTC. ls there continuity?
ls DTC 41 indicated? Y E S - R e p a i rs h o r tt o b o d y g r o u n di n t h e G R Nw i r e
betweenthe EPScontrol unit and the motor,l
YES Go to step 5.
NO Go to step 8.
t h e c o d ei n d i c a t e d . l Checkfor continuitybetweenEPScontrol unit
r ( 2 P ) t e r m i n aNl o . 1 a n d N o . 2 .
c o n n e c t oB
5. Make sure the ignition switch is OFF,then \
disconnectEPScontrol unit connectorB (2P)and EPSCONTROL B {2P)
UNITCONNECTOR
the motor 2P conneclor.
6. Checkfor continuitybetweenEPScontrol unit

r ( 2 P )t e r m i n a lN o . 1 a n d b o d y g r o u n d .
c o n n e c t oB
EPSCONTROLUNIT CONNECTOR
B {2P}
M2 (GRNI
M1 (RED}H
F---t||
Itr
(f))
T
,L ls there continuity?
YES Repairshort betweenthe REDand GRN

Wiresideof femaleterminals wires in the motor circuit betweenthe EPScontrol
u n i t a n dt h e m o t o r . l
YES Repairshort to body ground in the REDwire

betweenthe EPScontrol unit and the motor.!
17-36
9. Turn the ignition switch ON (ll),and measurethe 1 1 .T urn the ignition switch is OFF.
voltagebetweenEPScontrol unit connectorB (2P)
terminal No. 1 and body ground Substitutea known-goodEPScontrol unit, and
connectall the disconnectedconnectors.
B (2P)
1 3 .Start the engine,and turn the steeringwheel from
lockto lock severaltimes.
M1 IREDI H Does the EPS indicator come on?

r-_-1 ||
,<.)\
tr Y E S - G o t o s t e p1 4 .
uL,/
Y
I NO-Check for loose or poor connectionsatthe
EPScontrol unit and the motor connections.lfthe
connectionsare good, replacethe EPScontrol unit
WiresideoI femaleterminals andrecheck.l
1 4 . S t o pt h e e n g i n e a
, n d v e r i t yt h e D T C .
Is there battety voltage?
ls DTC 41 indicated?
YES Repairshort to power in the + circuitwire
betweenthe EPScontrol unit and the motor.I YES Replacethe steeringgearboxmotor and
recheck.l
N O - G o t o s t e p1 0 .
1 0 .Measurethe voltagebetweenEPScontrol unit t h e c o d ei n d i c a t e d . l
c o n n e c t oB
EPSCONTROL B (2P)
UNITCONNECTOR
razrcnrrrr
l{. I
l-t
I
(v)
Y
I
YES-Repair shortto power in the - circuitwire

betweenthe EPScontrol unit and the motor.!
17-37
EPSComponents
DTCTroubleshooting(cont'd) {
DTC42,45: MotorDrivenCurrent 7. Checkfor continuitybetweenEPScontrol unit

r ( 2 P l t e r m i n aNl o . 2 a n d b o d y g r o u n d .
c o n n e c t oB
1. Clearthe DTC.
B I2PI
2. Start the engine.

t i m e s ,a n d w a i t 1 0 s e c o n d so r m o r e . r',rz
tcnnrt
ll
-]-
(o)
YES- Go to step 4. T
I
NO-Check for loosewires or poor connections.lf
the connectionsare good, the system is OK at this Wiresideof femaleterminals
time.I
Stop the engine,and verify the DTC. lsthere continuity?
ls DTC 42 or 45 indicated? YES Repairshort to body ground in the GRNwire

betweenthe EPScontrol unit and the motor.l
YES-Go to step 5.
NO Go to step 8.
NO- Performthe appropriatetroubleshootingfor
t h e c o d ei n d i c a t e d . I Checkfor continuitybetweenEPScontrol unit
r ( 2 P )t e r m i n a lN o . 1 a n d N o . 2 .
c o n n e c t oB
M a k es u r et h e i g n i t i o ns w i t c hi s O F F ,t h e n
disconnectEPScontrol unit B connector(2P)and EPSCONTROL
UNITCONNECTOR
B {2P)
the motor 2P connector.
6 . Checkfor continuitybetweenEPScontrol unit

c o n n e c t oB
EPSCONTROL
UNITCONNECTOR
B I2P)
M2 {GRN)
M1 IRED}H
I f2-l W i r es i d eo f f e m a l et e r m i n a l s
(C))
T
I ls there continuity?
YES Repairshort betweenthe REDand GRN

Wire side of femaleterminals wires in the motor circuit betweenthe EPScontrol
u n i ta n d t h e m o t o r . l
YES Repairshort to body ground in the REDwire

betweenthe EPScontrol unit and the motor,I
17-38
9. Turn the ignition switch ON (ll),and measurethe 11. Checkfor continuitybetweenEPScontrol unit
voltage betweenEPScontrol unit connectorB (2P) connectorB (2P)terminal No. 1 and the motor 2P
t e r m i n a lN o . I a n d b o d y g r o u n d . connectorterminal No. 2.
B (2PI
EPSCONTROLUNITCONNECTOR EPSCONTROLUNIT MOTORCONNECTOR
{2PI
B 12P)
CONNECTOR
M1{RED}H M1 IRED)
T-----l | |
lil
(v) M1 (RED}
I
I
Wiresideo{ Iemaleterminals Wire side of femaleterminals
ls there battety voltage? ls therecontinuity?
YES-Repair short to power in the + circuitwire YES-Go to step'12.

betweenthe EPScontrol unit and motor.l
NO-Repairopenin the REDwire betweenthe EPS
NO Go to step 10. controlunitandthe motor.l
1 0 .Measurethe voltage betweenEPScontrol unit

r { 2 P } t e r m i n aNl o . 2 a n d b o d y g r o u n d .
c o n n e c t oB
EPSCONTROL B (2P}
UNITCONNECTOR
mzrcnrur
ll-l
A
(v)
Y
I
Y E S R e p a i rs h o r tt o p o w e ri n t h e + c i r c u i t w i r e
betweenthe EPScontrol unit and the motor.a
N O - G o t o s t e p1 1 .
(cont'd)
17-39
EPSGomponents
DTGTroubleshooting(cont'd) L (
12. Checkfor continuitybetweenEPScontrol unit 15. Stop the engine,and verify the DTC.
c o n n e c t oBr ( 2 P ) t e r m i n aNl o . 2 a n dt h e m o t o r2 P
c o n n e c t otre r m i n a lN o . 1 . ls DTC 42 or 45 indicated?
EPSCONTROLUNIT MOTORCONNECTOR
{2P) YES Replacethe steeringgearboxmotor and
CONNECTORB I2PI recheck.l
M2 IGRN)
Y E S - G o t o s t e p1 3 .
NO-Repair open in the GRNwire betweenthe EPS

control unit and the motor.l
Checkfor loosewires or poor connections,if the

connectionsare good. substitutea known-good
EPScontrol unit, and connectallthe disconnected
connectors.
1 4 . Startthe engine,and turn the steeringwheel from

Does the EPS indicatot come on?
YES Go to step 15.
NO Checkfor loose EPScontrol unitconnectors.lf

necessary,replacethe EPScontrol unit and
recheck.a
17-40
DTCtli|: MotorDrivenCurrentis Excessively 8. Measurethe voltagebetweenEPScontrol unit
Hish r ( 2 P ) t e r m i n aNl o . 2 a n d b o d y g r o u n d .
c o n n e c t oB
1 . C l e a rt h e D T C . EPSCONTROL
UNITCONNECTOR
B I2PI
2. Startthe engine.
Til
3. Turn the steeringwheel from lock-to-lockseveral M2tcRNl F-l
'10 f---1 z I
times, and wait secondsor more.

(v)
Y
YES Go to step 4.
I
NO-Check for loosewires or poor connections.lf W i r es i d eo f f e m a l et e r m i n a l s

the connectionsare good,the system is OK at this
ttme.I
YES- Repairshort to power in the - circuitwire
ls DTC 43 indicated? betweenthe EPScontorl unit and the motor.!
YES Go to step 5. NO-Go to step 9.
NO-Perform the appropriatetroubleshootingfor 9 . Turn the ignition switch OFF.

the code indicated.I
1 0 . Checkfor continuitybetweenEPScontrol unit
5. Make sure the ignition switch is OFF,then r ( 2 P )t e r m i n a l sN o . 1 a n d N o . 2 .
c o n n e c t oB
disconnectEPScontrol unit connectorB (2P)and
the motor 2P connector. EPSCONTROL
UNITCONNECTOR
B {2P)
7. Measurethe voltage betweenEPScontrol unit

'1
r ( 2 P ) t e r m i n aNl o . a n d b o d y g r o u n d .
c o n n e c t oB
B {2P}
M2 {GBN)
M 1 { R E o )H Wire side of femaleterminals

T------t I I
Itr
(v) ls there continuity?
T
-L
YES Repairshort betweenthe GRN and RED
wires in the motor circuitbetweenthe EPScontrol
Wiresideot Iemaleterminals u n i ta n d t h e m o t o r . l
ls therc battery voltage?
YES Repairshort to power in the + circuitwire

betweenEPScontrol unit and motor.l
N O - G o t o s t e p8 . ( c o n td )
17-41
EPSComponents
DTCTroubleshooting(cont'dl (
1 1 .Substitutea known-goodEPScontrol unit, and DTC47: EPSControlUnitlnternalCircuit

connectall the disconnectedconnectors. (PowerRelay)
1 2 .Start the engine,and turn the steeringwheel from 1. Clearthe DTC.
2. Startthe engine.
YES Go to step 13.
YES-Go to step 3,
NO -Check for loose or poor connectionsat the
EPScontrol unit and the motor connections.lf the NO-Check for loosewires or poor connections,lf
connectionsare good, replacethe EPScontrol unit the connectionsare good, the system is OK at this
and recheck.l time.I
1 3 .Stop the engine,and verity the DTC. 3. Stop the engine,and verify the DTC.
ls DTC 43 indicated? ls DTC 47 indicated?
YES-Replacethe steeringgearboxmotor and YES Checkfor loose EPScontrol unit connectors.

recheck.tl lf necessary,substitutea known-goodEPScontrol
NO-Perform the appropriatetroubleshootingfor
the code indicated.l NO Performthe appropriatetroubleshootingfor
the code indicated.I
17-42
DTC50: EPSControlUnit InternalCircuit DTC51: EPSControlUnitInternalCircuit
(CPUor Microcomputer) (EEPROM)
1. Clearthe DTC. 1 . C l e a rt h e D T C .
2. Start the engine. 2. Start the engine.
Does the EPS indicator come on? Does the EPS indicatot come on?
YES Go to step 3. YES-Go to step 3.
NO Checkfor loosewires or poor connections.lf NO-Check for loosewires or poor connections.lf

the connectionsare good. the system is OK at this the connectionsare good, the system is OK at this
t i m e .t time.I
3. Stop the engine,and verify the DTC. 3. Stop the engine,and verify the DTC.
YES-Check for looseor poor connectionsat the YES-Check for looseor poor connectionsat the
EPScontrol unit connections.lf the connectionsare EPScontrol unit connections.lf the connectionsare
good, substitutea known-goodEPScontrol unit. lf good. substitutea known-goodEPScontrol unit. lf
the symptom/indicationgoes away, replacethe the symptom/indicationgoes away, replacethe
original EPScontrol unit.l original EPScontrol unit.!
NO Performthe appropriatetroubleshootingfor NO Performthe appropriatetroubleshootingfor

the code indicated.t the code indicated.t
17-43
EPSComponents
(cont'dl
DTCTroubleshootang (
DTC62: EPSControlUnit InternalCircuit DTC64: BatteryVoltageis Excessively

Low
(Fail-safe
RelayStuckON) (Fail-safe
RelayContactFailureandMotor
VoltageFallOff)
'1.
Clearthe DTC.
2. Startthe engine. 2. Startthe engine.
Does the EPS indicator come on? Does the EPS indicatot come on?
YES-Go to step 3. YES Go to step 3.
NO-Check for loosewires or poor connections.lf NO Checkfor loosewires or poor connections.lf

the connectionsare good, the system is OK at this the connectionsare good,the system is OK at this
time.I trme.l
3. Stop the engine,and verify the DTC. 3. Stop the engine,and verify the DTC.
YES-Check for loose or poor connectionsat the YES Go to step 4.

EPScontrol unit. lf the connectionsare good,
substitutea known-goodEPScontrol unit. lf the NO Performthe appropriatetroubleshootingfor
symptom/indicationgoes away, replacethe the code indicated.
originalEPScontrol unit and recheck.l
'18(604)
4. Checkthe No. fuse in the under-hoodfuse/
NO-Perform the appropriatetroubleshootingfor relay box, and reinstallthefuse if it is OK.
Is the f use OK?
YES Go to step 5.
NO Replacethe fuse and recheck.l
5. DisconnectEPScontrol unit connectorA (2P).

r ( 2 P )t e r m i n a lN o . 1 a n d b o d y g r o u n d .
c o n n e c t oA
-Blwt{r/Bl.urH
l
\9
I
YES- Checkfor loose or poor connectionsat the

EPScontrol unit connectors,and checkfor a poor
ground at G 151. lf necessary,substitutea known-
good EPScontrol unit and recheck.l
NO Repairopen in the WHT/BLUwire between

t h e N o . 1 8 ( 6 0 , 4 ) f u saen d E P Sc o n t r o lu n i t . l
17-44
DTC66,68: EPSControlUnitlnternalCircuit DTC67: TorqueSensorl/FCircuit
1 . C l e a rt h e D T C . 1. Clearthe DTC.
2. Start the engine. 2 . S t a r tt h e e n g i n e .
3. Turn the steeringwheel from lock-to-lockseveral 3. Turn the steeringwheelfrom lock-to-lockseveral

times, and wait 10 secondsor more. times, and wait 10 secondsor more.
Does the EPS indicator come on? Does the EPS indicator come on?
YES-Go to step 4. YES-Go to step 4.
NO-Check for loosewires or poor connections.lf NO Checkfor loose wires or poor connections.lf the
the connectionsare good.the system is OK at this connectionsare good, the system is OK at this time. !
time.l
4. Stop the engine.and verify the DTC.
ls DTC 66 or 68 indicated?
YES Checkfor looseor poor connectionsat the
YES-Check for looseor poor connectionsat the EPScontrol unit. lf the connectionsare good,
EPScontrol unit. lf the conneclionsare good, substitutea known-goodEPScontrol unit. lf the
substitutea known-goodEPScontrol unit. lf the symptom/indicationgoes away, replacethe
symptom/indicationgoes away, replacethe original EPScontrol unit and recheck.!
original EPScontrol unit and recheck.I
NO-Perform the appropriatetroubleshootingfor
NO Performthe appropriatetroubleshootingfor the code indicated.I
17-45
EPSComponents
DTC69: EPSControlUnit InternalCircuit
2. Startthe engine.

times, and wait 10 secondsor more,
YES Go to step 4.
NO-Check for loosewires or poor connections.lf

time.l
YES-Check for loose or poor connectionsat the

substitutea known-goodEPScontrol unit. lf the
symptom/indicationgoes away, replacethe
original EPScontrol unit and recheck.l
NO- Performthe appropriatetroubleshootingfor

17-46
EPSIndicatorCircuitTroubleshooting
1 . Turn the ignitionswitch ON (ll),startthe engine, 5. Turn the ignition switch OFF.
and watch the EPSindicator.
6. DisconnectEPScontrol u n it connectorC (20P).
YES lf the EPSindicatorcomes on and goes off, it's
OK. lf the EPSindicatorstayson or blinks.go to 8. ConnectEPScontrol unit connectorC (20P)
s t e p1 2 . terminal No. 6 to body ground with a jumper wire.
NO Go to step 2. EPSCONTBOLUNIT CONNECTOBC {2OP)
Turn the ignition switch OFF,then ON (ll) again,

and watch the brakesystem indicator,
Does the brake system indicator come on?
YES-Go to step 3.
W i r e s d € o f l e m a l e 1 6 r m i n as
NO Repairopen in the indicatorpower source
circuit.l
. B l o w nN o . 1 0 ( 7 . 5 A ) f u s e . Does the EPS indicatot come on?
. Open in the wire betweenthe No. 10 (7.5A)fuse
and gaugeassembly. YES Go to step 9.
. Open circuitinsidethe under-dashfuse/relaybox,
. Faultygauge assembly. NO Repairopen in the wire betweenthe gauge
assemblyand the EPScontrol unit.l
3 . Turn the ignitionswitch OFF,
4 . Connecta jumper wire betweenthe gauge
assembly22Pconnectorterminal No. 13 and body 1 0 .DisconnectEPScontrol unit connectorA (2P),
g r o u n d ,t h e nt u r n t h e i g n i t i o ns w i t c hO N ( l l ) .
' l1 .
Checkfor continuitybetweenEPScontrol unit
(Blueconnector) connectorA terminal No. 2 and body ground.
GAUGEASSEMBLY
22PCONNECTOR
EPSCONTROL A I2PI
UNITCONNECTOA
w i r e s d e o f t e m a l et e r m i n a l s
YES Checkfor loose or poor connectionsat the
YES-Go to step 5. E P Sc o n t r o lu n i t .l f t h e c o n n e c t i o nasr e g o o d ,
N O I n s p e ctth e E P Si n d i c a t o b r u l b ,i f t h e b u l b i s symptom/indicationgoes away, replacethe
O K , r e p l a c et h e b u l bc i r c u i tb o a r di n t h e g a u g e originaE l P Sc o n t r o lu n i ta n d r e c h e c k . I
assembly.l
N O R e p a i ro p e ni n t h e w i r e o r a b a d g r o u n da t
G151,t
(cont'd)
17-47
EPSComponents
EPSIndicatorCircuitTroubleshooting(cont'dl I
1 2 .Turn the ignitionswitch OFF. 16. Measurethe voltagebetweenEPScontrol unit
'1
connectorA (2P)terminalNo. and body ground.
1 3 .DisconnectEPScontrol unit connectorC (20P).
EPSCONTROL A (2P}
UNITCONNECTON
1 4 .Turn the ignitionswitch ON (ll).

+B (WHT/BLUIH
YES-Repair short to ground in the YEUBLUwire Itr
betweenthe gaugeassemblyand the EPScontrol
unit,or replacethe bulb circuit board in the gauge
assembly.l
v-L
NO-Go to step 15. Wire side of female terminals
Measurethe voltagebetweenEPScontrol unit

c o n n e c t oC ls there battery voltage?
EPSCONTROL
UNITCONNECTOR
C I2OP) YES-Go to step 17.
NO-Check for a blown No. 18 (604)fuse in the

under-hoodfuse/relaybox or open/shortin the
WHT/BLUwire betweenthe under-hoodfuse/relay
box and the EPScontrol unit.l

1 8 , ReconnectEPScontrol unit connectorA (2P).
connectorC (20P)terminalNo. 8 and body ground.
EPSCONTROL C (2OP)
UNITCONNECTOR
ls therebatteryvoltage?
Y E S - G ot o s t e p1 6 .
NO-Repairopenin thewire betweenEPScontrol

C (20P)andthe No, 10(7.5A)fuse.t
unitconnector
ls therc about 10 V?
YES Checkfor looseor poor connectionsat the

symptom/indicationgoes away, replacethe
originalEPScontrol unit and recheck.l
NO Repairshort to ground in the BRNwire

betweenthe data link connectorand the EPS
c o n t r o lu n i t . I
17-48
Motor Removal/lnstallation
Bemoval 4. Removethe connectorbracket(A) onthegearbox
housing,and disconnectthe motor 2P connector
1. Make sure you havethe anti-theftcode for the radio, (B).
then write down the frequenciesfor the preset
buttons. 9.8 N.m {1.0kgf.m,
2. Disconnectthe negativecablefrom the battery,and

wait 3 minutesbefore beginningwork.
3. Removethe air cleanerassembly(A).
5. Removethe motor {A) from the gearboxhousing.
6. Removethe O-ring (B)and discardit.
(cont'd)
17-49
EPSComponents
(cont'dl
Motor RemovaUlnstallation (
lnsiallation r 0 .Installthe motor on the gearboxby engagingthe

motor shaft and worm shaft (D).Note the motor
7. Cleanthe mating surfaceof the motor (A) and installationposition{directionof motor wires).
gearbox.
1 1 .Beforetighteningthe bolts,turn the motor two or
8 x '1.25
mm three times right and left about 45 degrees.lvlake
20 N.m
12.0kgt.m,7.2lbl ftl sure the motor is evenlyseatedon the steering
q gearboxand that the O-ring is not pinchedbetlveen
E the mating surfaces.
1 2 .Installthe removedDartsin the reverseorder of

removal.and note these items:
lvlakesure the motor 2P connectoris properly

connected.
lvlakesurethe motor and EPSwires are not
caughtor pinchedby any parts.
Reconnectthe negativecableto the battery.
c].E@
L==- D o t h e e n g i n ec o n t r o lm o d u l e( E C M )i d l e l e a r n
Enterthe anti-theftcode for the radio station
Dresets.Resetthe clock,
Do the oower window control unit reset
procedure(seepage 22-1241.
Apply a thin coat of siliconegrease(P/N08733- 1 3 .After installation,startthe engine,and let it idle.

8070E)tothe new O-ring(B),and carefullyfit it on Turn the steeringwheel from lock-to-lockseveral
the motor. times. Checkthat the EPSindicatordoes not come
on.
9 . Apply grease{Nippon GreaseWR-S or equivalent
steeringgear grease)into the motor shaft (C).
17- 5 0
SteeringGearboxRemoval
Special Tool Required 8. Removethe cotter pin (A)from the tie-rod balljoint
Ball ioint remover,2Smm 0TlvlAC-S100200 nut {B),and loosenthe nut.
1. Raisethe front of vehicle,and make sure it is

securelysupponed. _t\
2. Removethe front wheels.
R e m o v et h e d r i v e r ' sa i r b a g ( s e e p a g e 2 3 - 1 1 3 ) .
4 . Removethe steeringwheel (seepage 17-6).

l- '/
--L-
5 . Removethe motor on the steeringgearbox (see ,a.:
p a g el T - 4 9 ) .
6 . Removethe driver'sdashboardlower cover (see

page20-59)and under cover {seepage20-60). r0 mm HEXNUT
07MAC-S100200
7 . Removethe steeringjoint bolts (A),and disconnect 9 . Separatethe tie-rod balljoint and damper steering
the steeringjoint by moving the steeringjoint (B) arm usingthe specialtool (seepage 18-10).Repeat
toward the column. on the other side of the vehicle.
1 0 .G r a s pt h e r i g h ts i d et i e - r o d a, n d p u l lt h e r a c ka l l t h e
way to the passenger'sside,
1 1 . Removethe heat shield (A) mounting bolts from

the body stiffener,and let the heat shield lay
againstthe exhaust.
' i l
(cont'd)
17-51
EPSComponents
SteeringGearboxRemoval(cont'd)
12. Disconnectthe EPSwire harness6Pconnector
(A), 1 4 . R e m o v et h e e n g i n ew i r e h a r n e s sc l a m p s{ A ) f r o m
andremovethe EPSwire harness(B)andmountino the three mounting brackets.
bracket(C).
-a--zi i F--_1
t5. Removethe heaterhose {B)from the bracket.
1 3 . Removethe groundcableterminal(A)fromthe 1 6 . Open the heatervalve cableclamp (A),and

steeringgearboxhousing. disconnectthe heatervalve cable(B).Removethe
heatervalve (C)from the bulkhead,and move jt
..(
.,/ a aside.
b-
H \ I
ry T,-.lt'^ \
'" \--
_ - 1 . . 1 . - '
17-52
17. Removethe bodv stiffener(A). 19. Removethe steeringstiffenerB from the right side
of the steeringgearbox.
i t1-:: .,
1 8 .Removelhe steeringstiffenerA from the left side

of the steeringgearbox. 20. Lower the steeringgearbox,and rotateit so the
pinion shaft points upward.
21. Removethe pinion shaft grommet (A)from the top

of the torque sensor.
(cont'd)
17-53
EPSComponents
SteeringGearboxRemoval{cont'd)
22. Move the steeringgearboxand tie-rod ends as an
assemblyto the wheelwellopening on the
passenger'sside.
23. Carefullyraisethe driver'sside (pinionside)ofthe

steeringgearbox(A) and tie-rod (B) until clearsthe
mastercylinderand under-hoodfuse relay box,
then removethe steeringgearbox.Be careful not to
damagethe hoses,linesand wtre narnesses.
17-51
SteeringGearboxOverhaul
ExplodedView
I x '1.25
mm
20 N.m(2.0kgf.m,7.2lbt
ftl
O.RING
Replace.
CONNECTOR
PINION
SHAFT
GROMMET
RACKGUIDE
. -@ -sPRrNG
. DISCWASHEB @'---
g
L)-RACKGUIDE SCREW
6
' v---\
\.oc**u.
''
-'t
6^:,; v
BOOT BAND
Beplace.
'"''/
\ >-*\{i#rî
--. i
. s(./t' J
-l
GUIDE \
SLTDER
\ \
{îl \ stot *,tttc
Renrace
\J" \
@ \ LocK
'162 scREw
N.m
II \
\
l t o . sr g f m , 1 1 9 l bfft )
SRACKET Beqtace.
BOOTBAND
LOCKWASHER - Replace.
Replace.
TIE.RODEND
rtE-ROD
54 N m {5.5kgf.m,40lbf ft)
44 N m {4.5 kgf.m, 33 tbt.ft)
(cont'd)
17-55
EPSComponents
SteeringGearboxOverhaul(cont'dl
Special Tools Required 4. Removethe stop plate (A).the 12 mm flange bolts
. Locknutwrench 07ZAA-S5A0100 (B),the O-rings(C),and the bracket(D)from the
. Pincers,Oetiker1098or equivalent,commercially
sleeringgearbox.
available.
NOTE:
. Referto the ExplodedView as neededduring this
procedure.
. Do not allow dust, dirt, or other foreign materialsto
enter into the steeringgearbox.
Eemoval
1, Removethe steeringgearbox(seepage 17-b1).
Disassembly
2. Unbendthe lock washer (A).
-,'i.
. -
Loosenthe locknut(A),then removethe rack guide

screw (B),sprlng (C),disc washer (D),and rack
g u i d e( E )f r o m t h e s t e e r i n gg e a r b o x .
- -.i::..:4,.-, -
:.--. '
Holdthe bracket(A) with one wrencn, anq unscrew

both tie-rod ends (B)with anotherwrench. Remove
the lockwashers.
1 7-56
6. Removethe two boot bands (A)from boot (B). 8. Installthespecialtool (A) on the lock screw (B)
Compressthe boot by hand,and apply vinyl tape securely.then loosenand removethe lock screw
(C)so the boot ends stay collapsedand pulled back from the steeringgearboxhousing.
07zAA-S5A0r00
1 . Attachthe yoke (A) of a universalpullerto the Removethe specialtool.

steeringgearboxmounts with bolts.Securely
clamp the yoke in a vise as shown. Do not clamp 1 0 .Pull on the rackhousing(A)to remove it from the
the steeringgearboxhousingin the vise. steeringgearboxhousing,Removethe boot {B) and
s l i d e rg u i d e( C )f r o m t h e c y l i n d e r .
(cont'd)
17-57
EPSComponents
SteeringGearboxOverhaul(cont'd)
'll.
Checkthe slider guide for damageand cracks. 15. Applymultipurpose greaseto the indicatedpart
Using verniercalipersto measurethe thicknessof part)
{shaded of the outersurfaceof the rack
the slider guide. lf the thicknessis lessthan service housing.Do not applyto the dentsandgrooves.
l i m i t ,r e p l a c et h e s l i d e rg u i d e ,
f
(fr--', -.----
Z,-----:-r-.--------.t.t'E-r
Il i l ( t t ,
/i\
,)))
I
i @ r |
25.3mm 25.3 mm
{0.925in.} {0.925in.l
12 Removeanddiscardthestopring{A)onthe
cylinderby expanding
it with snapringpliers.
Removeanddiscardthe lockscrew{B}.
13. Installthe new lock screw on the rack housing.
1 4 . I n s t a l l t h en e w s t o p r i n g i n t h e g r o o v e( C ) o nt h e
cylinderby expandingit with a snap ring pliers.Be
carefulnot to scratchor damagethe housing
surfacewith the stop ring edges.
17-58
'19. Pushthe rack housing(A) into the steeringgearbox
16. Set the new boot bands (A) on the band installation
groovesof the boot (B) by aligningthe tabs (C)with housing(B) so the notch (C)is alignedwith the pin
the holes (D)of the band.Do not closethe ear of the (D)on the bottom of the gearboxhousinginside
boot band in this step.
20. Tightenthe lock screw {A) by hand first, then install

the specialtool (B)on the lock screw. Lightly
1 1 . Compressthe boot by hand,and apply vinyl tape tighten the lock screw.Do not tighten the lock
(E)to the bellowsso the boot ends stay collapsed screwto the specifiedtorque Yet.
and pulled back.
Passthe boot over the rack housingso the smaller
diameterend of the boot facesthe steering
gearboxhousing.
1 8 .Attachthe yoke (A) of a universalpuller to the

gearboxhousingmounts with bolts.then securely
clamp the yoke in a vise as shown. Do not clamp
the steeringgearboxhousingin a vise.
21. Removethe specialtool.
(cont'd)
17-59
EPSComponents
SteeringGearboxOverhaul(cont'dl {
22. Apply multipurposegreaseto the sliding surface 25. Centerthesteeringrackwithin its stroke,and align
and circumferenceofthe rackguide (A),and install t h e s l i d e rg u i d e( A ) w i t ht h e h o t e s( B )i n t h e b o o t ( C ) .
it onto the gearboxhousing.Wipe the greaseoff Fit the slider guide to the boot by pressingaround
the threadedsectionofthe housrno. the edgesof the holessecurely
'1 - .- =-1,-
...'.
,. ,l
.j
E
25 N.m 12.5kgt.m,18tbt.ft)
2 3 . I n s t a l l t h ed i s cw a s h e r( B ) w i t hi t s c o n v e xs i d e
f a c i n gt h e r a c kg u i d e .I n s t a l l t h es p r i n g( C ) .A p p t y 26. Beforeinstallingthe bracket(D),cleanthe mating
sealantto the middle of the threadson the rack surfaceofthe 12 mm flange bolts (E)and the
guide screw (D),then installand tighten it to 25 bracket.Coatthe new O-rings{F)with multipurpose
N m (2.5kgf.m, 18 lbf.ft).Looselyinstatlrhetocknut g r e a s ea, n d i n s t a l l t h e mo n t h e ' 1 2m m f l a n g eb o l t s .
(E).
27. Looselyinstallthe bracketon the steeringrack by
24. Apply multipurposegreaseto the sliding surfaceof tighteningthe 12 mm flange boltsto 25 N.m (2.5
the slider guide (A).Keepgreaseoff of the rack-to- kgf.m, 18lbf.ft).
slider guide mating surfacesand the boot-to-slider
guide mating surfaces. 28. Hold the gearboxhousingusing a yoke,then install
Slidethe steeringrack all the way to left, and place the specialtoolon the lock screw (A).Retightenthe
t h e s l i d e rg u i d eo n t h e s t e e r i n gr a c kb y a l i g n i n gt h e lock screwto the specifiedtorque values.
bolt holes (B).
A
{ 1 6 . 5k g t . m , 1 1 9 l b f . f t }
29. Removethe specialtool.
17-60
30, Retightenthe 12 mm flange bolts (A) to the 3 4 . C l o s et h e e a r p o r t i o n( A )o f t h e b a n d s( B ) w i t h
soecifiedtoroue value. c o m m e r c i a l lav v a i l a b l ep i n c e r sO
, e t i k e r1 0 9 8o r
e q u i v a l e n(tC ) .
74 N.m (7.5kgf.m,5irlbf.ft)
5 t . After tighteningthe 12 mm flange bolts, installa

new stop plate (B)over one of the bolt heads.Be
surethe tabs (C)of the stop plate are alignedwith
the flat surfacesof the bolt head.
32, Cleanoff any greaseor contaminationfrom the

b o o t i n s t a l l a t i ognr o o v e so n t h e h o u s i n g . 3 5 . I n s t a l l t h en e w l o c kw a s h e r( A )w i t h i t s r a d i u s e d
side facing (B)the tie-rod (C),and screwthe tie-rod
Expandthe boot (A) by removingthe vinyltape, on the bracket(D).Repeatthis stepfor the other
and fit the boot ends (B) in the installationgrooves side of the tie-rod.Hold the bracketwith one
o n t h e c y l i n d e rh o u s i n g . wrench,and tightenthe tie-rodsto the specified
torque with anotherwrench.
. .,,";=-.
, . ,
*=,,',
(cont'd)
17-61
EPSComponents
SteeringGearboxOverhaul(cont'dl
36. Bendthe lock washer againstthe flat spots on the
bracketwitha Iarge pair of pliers.
37. Adjust the rackguide screw {seepage 17-13).
17-62
SteeringGearboxInstallation
'1. 4. Insertthe pinion shaft up through the bulkhead,
Beforeinstallingthe steeringgearbox,slidethe
rack all the way to the passenger'sside (right then slip the right side of the steeringgearbox
direction). housing(A) over the mounting stud (C)on the
gearboxmounting bracket.
2 . Passthe right side of the steeringgearboxtogether
with the tie-rodsthrough the wheelwell openingon \- --' '.'', i
the passenger'sside.Continuemoving the steering
gearboxtoward the passenger'sside untilthe :-1
. . . .
driver'sside tie-rodend and gearboxclearsthe
mastercylinderand under-hoodfuse Ielay box.
Lower the steeringgearbox.and move it toward
t h e d r i v e r ' ss i d eu n t i l t h es t e e r i n gg e a r b o xi s l n
Dosition.
Be carefulnot to damagethe hoses,lines

and wire harnesses.
10 x '1.25mm
61 N.m
{62 kgl m, 45 lb{ ftl
Installthe steeringstiffenerB, and lightlytighten

the steeringgearboxmounting nuts.
Installthe steeringstiffenerA with the gearbox

m o u n t i n gb o l t s .T h e nt i g h t e na l l t h e s t e e r i n g
gearboxmounting hardwareto the specifiedtorque.
1 0x 1 . 2 5m m
6l N.m
(6.2 kgt.m, 45 lbt.ft)
3 . I n s t a l l t h ep i n i o ns h a f tg r o m m e t( A ) .
.: --.-{
.
( c o n t ' d)
17-63
EPSComponents
SteeringGearboxInstallation(cont'd)
7. Installthebodystiffener(A),andtorquethe 9. Reinstallthe heaterhose (A) on the hose bracket.
mountingboltsto the specifiedtorque.
8 x 1.25mm
29 N.m {3.0kgf.m,22lbf.ftl
1 0 .Installthe enginewire harnessclamps (B)to the

three harnessbrackets.
L Installthe heatervalve (A) on the bulkhead,and ' It . Under

the steeringgearbox,installthe ground
connectthe heatervalve cableend (B)to the heater cableterminal (A) on the steeringgearboxhousing.
valve arm (C).Readjustthe heatervalve cable{see
page21-46). 9 . 8N . m
L-t ,
:.i.t'
9.8N.m
(1.0kgf m,
7.2tbf.ftl
17-64
12. lnstalltheEPSwire harnessbracket(A)on the 1 4 . Centerthe steeringrackwithin its stroke.
gearboxhousing,andconnectthe 6Pconnector (B)
propefly. 1 5 . Wipe off any greasecontaminationfrom lhe ball
joint taperedsectionand threads.Then reconnect
9.8 N.m the tie-rod ends 1A)tothe damper steeringarms.
{1.0kgt m,7.2 lbt.ftl
lnstallthe ball joint nut (B) and tighten them.
,-', ''l
: 1 )
B
10x 1.25mm
i€ N.m
{4.4 kgf.m.
1 3 . I n s t a l l t h eh e a ts h i e l d( A ) . 32 tbt.ftl
to. Installthe new cotter pins (C),and bend them as

shown.
,.!,..
''6 f
(cont'd)
17-65
EPSComponents
SteeringGearboxInstallation(cont'dl 4
1 7 . Installthe motor on the steeringgearbox(seepage 22. After installation,performthe following checks.
17-49).
. Performthe front toe inspection.
1 8 . lnstallthe steeringjoint (A).and reconnectthe . C h e c kt h e s t e e r i n gw h e e ls p o k e a n g l el.f s t e e r i n g
steeringshaft (B) and pinion shaft (C).Make sure spokeanglesto the right and left are not equal
the steeringjoint is connectedas follows: (steeringwheel and rackare not centered),
correctthe engagementof the joinvpinion shaft
. I n s e r t t h eu p p e r e n do f t h e s t e e r i n gj o i n t o n t o t h e serrations,then adjustthe front toe by turning
steeringshaft (line up the bolt hole (D)with the the tie-rods,if necessarv.
flat portion (E)on the shaft).
. Slip the lower end of the steeringjoint onto the
pinion shaft (line up the bolt hole with the groove
(F)around the shaft),and looselyinstallthe lower
joint bolt. Be sure that the lower joint bolt is
securelyin the groove in the pinion shaft.
. Pull on the steeringjoint to make surethat the
steeringjoint is fully seated.Then installthe
upper joint bolt, and tighten it to the specified
torque.Tightenthe lower joint bolt to the
specifiedtorque.
\
8 x '1.25mm
28 N.m
{2.9kgf.m,
21 tbt.ft)
1 9 .Installthedriver's dashboardlower cover (see

page 20-59)and under cover (seepage 20-60).
20. lf the steeringwheel was turned,centerthe cable

reel by first rotatingit clockwiseuntil it stops.Then
rotateit counterclockwise(abouttwo and half
turns) untilthe arrow mark on the label points
straightup. Reinstallthe steeringwheel (seepage
17-8).
)1 Installthe front wheels.
17-66
EPSControlUnit Removal/ Tie-rodBallJoint Boot Replacement
Installation
Special Tool Required
Attachment,42 mm 07OAD-P0A0100
1. Removethe passenger'sunder panel.
l. Removethe boot from the tie-rod end, and wipe the
2. Turn up the floor carpel,removelhe EPScontrol old greaseoff the ball pin.
untr.
2 . P a c kt h e l o w e ra r e ao f t h e b a l l p i n ( A ) w i l h f r e s h
mulr purposegrease.
*-4
r/\-,
d______i.l+_D
-6rA
3 . Disconnectthe EPScontrol unit connectors.
lnstallthe EPScontrol unit in the reverseorder of 3. Packthe interiorof the new boot (B) and lip (C)with
removal. fresh multipurposegrease.
E After installation,startthe engine,and let it idle. Note these items when installingnew grease;
Turn the steeringwheelfrom lock-to-lockseveral
times. Checkthat the EPSindicatordoes not come . Keepgreaseoffthe boot installationsection(D)
on. and the taperedsection(E)of the ball pin.
. Do not allow dust, dirt, or other foreign materials
to enterthe boot.
4. Installthe new boot (A) usingthe specialtool.The

boot must not have a gap at the boot installation
sections(B).After installingthe boot.checkthe ball
pin taperedsectionfor greasecontamination,and
wipe it if necessary.
07(lAD-P0A0100
17-67
Suspension
Frontand RearSuspension
SpecialTools ............. 18-2
Component LocationIndex ......................................... 18-3
W h e eA l l i g n m e n .t . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. 8. - 4
WheelBearingEndPlayInspection............................ 18-8
WheelRunoutInspection .................. 18-9
B a l Jl o i n tR e m o v a l ... 18-10
FrontSuspension
Knuckle/Hu bAVheelBearingReplacement 18-1
BallJoint Boot Reolacement.................. 18-16
StabilizerBar Rep|acement.................... 18-17
StabilizerLink Removal/lnstallation 18-18
LowerArm Removal/lnstallation ............... 18-19
Damper/Spring Replacement 18-20
RearSuspension
H u bB e a r i n U
g n i tR e p l a c e m e .n. t. . . . . . . . . . . . . . . . . . . 18-26
KnuckleReolacement 18-28
Stabilizer BarReplacement .................... 18-30
Stabilizer Link Removal/lnstallation .......................... 18-31
UpperArm Removal/lnstallation ............... 18-32
TrailingArm Removal/lnstallation 18-33
Damper/Spring Replacement 18-34

SpecialTools
Ref.No. Tool Number Description otv
o 07GAF-SE00100 Hub Dis/AssemblyTool
@ 07MAC-S100200 B a l lJ o i n t R e m o v e r2, 8 m m
07746-0010500 Attachment,62 x 68 mm
o 07749-0010000 Driver
07965-SA50500 Front Hub Dis/AssemblyTool
G) 07965-SD90100 Support Base
o o
[]
I
@ o a6,l
18-2
FrontSuspension:
DAMPER/SPRING
page18-20
Replacement,
STABILIZER
BAR
page18-17
Replacement,
STABILIZER
LINK
page18 18
KNUCKLE/HU8/WHEELBEARING
Ball Joint Boot
Replacement, page'18-16
LOWEBARM
page 18 19
RearSuspension:
STABILIZER
BAR
page18-30
Replacement.
UPPERARM
page'18-32
DAMPER/SPRING
page'18-34
Replacement,
HUBBEARINGUNIT
page18'26
Replacement,
KNUCKLE
page18-28
Replacement,
TRAILINGARM
page 18 33
18-3
WheelAlignment
The suspensioncan be adjustedfor front camber,front Front Casterlnspection
toe, and reartoe. However,each of these adjustments
are interrelatedto each other. For example,when you U s ec o m m e r c i a l l a
vvailable c o m D u t e r i z ef do u rw h e e l
adjustthe toe, the camberchanges.Therefore,you a l i g n m e net q u i p m e ntto m e a s u r ew h e e la l i g n m e n t
must adjustthe front wheel alignmentwheneveryou (caster,camber,toe, and turning angle).Follow the
adjustthe camberor toe. eouiomentmanufacturer'sinstructions.
Pre-Alignment
Checks Checkthe casterangle.lf the casterangle is not within
the specification,checkfor bent or damaged
For proper inspectionand adjustmentof the wheel susoensroncomoonents.
alignment,do these checks:
Front casterangle: 1'40't 1"
1. Releasethe parkingbraketo avoid an incorrect
measurement.
2 . Make sure the suspensionis not modified.
3 . C h e c kt h e t i r e s i z ea n d t i r e p r e s s u r e
Tire size:
Front/rear: 195/60R15
Tire pressure:
Front: 230 kPa {2.3kgf/cm',33 psil
Rear: 210 kPa |'2.1kgf/cm', 30 psi)
Checkthe runout of the wheels and tires. \
Checkthe suspensionball joints. (Holda wheel

with your hands,and move it up and down and
right and left to checkfor wobbling),
Bouncethe vehicleup and down severaltimes to

stabilizethe suspension.
18-4
Front CamberInspection Front CamberAdjustment
Use commerciallyavailablecomputerizedfour wheel The front cambercan be adjustedby exchangingone or
alignmentequipmentto measurewheel alignment both of the damDerDinchbolts with the smaller
(caster,camber,toe, and turning angle).Follow the diameteradjustingbolt(s).The differencebetweenthe
equipmentmanufacturer'sinstructions. adjustingbolt diameterand the pinch bolt hole
d i a m e t e ra l l o w sa s m a l lr a n g eo f a d j u s t m e n t .
Checkthe camberangle.lf the camberangle is not
within the specification,adjustthe camber.
Front camber angle: 0"30' t 45'

DamDerPinchBolt: AdiustingBoh:
P/N 90188-55A-000
1 . Raisethe front of the vehicle,and support it with

safetystandsin the proper location(seepage 1-8).
Removethe front wheels.
L o o s e nt h e d a m p e rp i n c h n u t sa n d b o l t s( A ) ,a n d
adjustthe camber by moving the bottom of the
d a m p e rw i t h i nt h e r a n g eo f t h e d a m p e rp i n c hb o l t
free play.
-+ +t A
1 6 x 1 . 5m m
157 N.m
(16.0kgf.m,
116 tbf.ftl
3 . Tightenthe boltsto the specifiedtorque.
4 . Reinstallthe front wheels.Lower the front of the

v e hi c l et o t h e g r o u n d ,a n d b o u n c et h e v e h i c l e
s e v e r atl i m e st o s t a b i l i z teh e s u s p e n s i o n .
5 . C h e c kt h e c a m b e ra n g l e .l f i t i s w i t h i nt h e
specification,checkthe front toe. lf it is not within
the specification,go to step 6.
(cont'dl
18-5
WheelAlignment (cont'd)
Raisethe front of the vehicle,and support it with RearCamberInspection
Removethe front wheels. Use commercially-available computerizedfour wheel
alignmentequipmentto measurewheel alignment
7 . Replacethe damper pinch boltswith the adjusting (caster,camber,toe, and turning angle).Followthe
bolts (A),and adjustthe camber angle. eouiDmentmanufacturer'sinstructions.
NOTE:The camberangle can be adjustedup to t C h e c kt h e c a m b e ra n g l e .l f l h e c a m b e ra n g l ei s n o t

15' (centerof tolerance)by replacingone damper within the specification,checkfor bent or damaged
pinch bolt with the adjustingbolt. The camber susDenstoncomoonenrs.
angle can be adjustedup to a 30' by replacingboth
upper and lower damper pinch bolts with the Rearcamberangle: 0"55' t 45'
0
adjustingbolts.
NOn-dEl
Do not loosenthe specialb o l t so n t h e t r a i l i n ga r m .
1 5 x 1 . 5m m
157N.m
{16.0kgt.m,
116tbf.ft)
'rntr
i,iY.a
.:r,//
8 . Tightenthe boltsto the specifiedtorque.
Reinstallthe front wheels.Lower the front of the

vehicleto the ground, and bouncethe vehicle
severaltimes to stabilizethe suspension.
1 0 .Checkthe camber angle.lf it is within the

specification,checkthe front toe. and adjust it if
necessary.lf it is not within the specification,
readjust,and recheck.lJthe camber anglecannot
be adjustedto the specification,checkfor bent or
damagedsuspensioncomponents.
18-6
Front Toe Inspection/Adjustment RearToe Inspection/Adiustment
Use commercially-available computerizedfour wheel Use commercially-available computerizedfour wheel
a l i g n m e net q u i p m e ntto m e a s u r ew h e e la l i g n m e n t a l i g n m e net q u i p m e ntto m e a s u r ew h e e la l i g n m e n t
(caster,camber,toe, and turning angle).Followthe (caster,camber,toe, and turning angle).Followthe
equipmentmanufacturer'sinstructions, equipmentmanufacturer'sinstructions.
1. Centerthe steeringwheel spokes. t h e p a r k i n gb r a k e .

1, Release
2. Checkthetoe.lf it is not with in the specification,go 2. Checkthetoe. lf it is not within the specification.go
to step 3. to step 3.
Front toe-in: 0 t 3 mm {0 t 0.12in.) Reartoe-in {inspection):

1 1 3 mm (0.04a 0.12 in.)
3. Loosenthe locknut(A) while holdingthe tie-rod end
( B) . 3. Loosenthe self-lockingnut (A)while holdingthe
adjustingbolt (B).
1,; A
1 4 x 1 . 5m m
,14N.m
(a.5 kgt m,33 lbt.ftl Do not loosenlhe specialbolts (C)on the
lower arm to adjustthe alignment.
Turn the tie-rod(C)untilthe toe is correct.
5 . After adjusting,tighten the locknutwhile holding

the tie-rodend. Make sure the toe settingdoes not
change.
4. Replacethe self-lockingnut with a new one, and

l i g h t l yt i g h t e n .
NOTE:Always use a new self-lockingnut whenever

it has been loosened.
Turn the adjustingbolt until the toe is correct.
Rear toe.in (adiustment):

2 ' , mm {0.08 "' ,. in.}
Tightenthe self-lockingnut to the specifiedtorque

w h i l e h o l d i n gt h e a d j u s t i n gb o l t .
( c o n t ' d)
18-7
WheelAlignment (cont'dl WheelBearingEnd PlayInspec'tion
TurningAngleInspection 1. Raiselhe vehicle,and support it with safetystands
in the proper location(seepage 1-8).Removethe
Use commercially-available computerizedfour wheel wheels.
a l i g n m e net q u i p m e ntto m e a s u r ew h e e la l i g n m e n t
(caster.camber,toe, and turning angle).Followthe 2. Installsuitable f lat washers (A) and wheel nuts,and
equiDmentmanufacturer'sinstructions. tighten the nuts to the specifiedtorque to hold the
b r a k ed i s cs e c u r e l ya g a i n s t h e h u b .
1 . T u r nt h e s t e e r i n gw h e e lf u l l y t o t h e r i g h t a n d l e f t
while applyingthe brake,and checkthe turning Front:
anglesof both front wheels, lf the turning angle is
not within the specificationor the inward turning
anglesdiffer betweenthe right and left side,go to
steD2.
Turning angle:
lnward: 34'00'+ 2'
Outward: 28'00' {reference)
108N.m
(11.0kgf.m,
80 rbf.ft)
Rear:
\
Checkthe toe. lf it is correct,but the turning angle 108N.m

is not within the specification,checkior bent or (11.0kgf.m,80 lbf.ft)
damagedsuspensioncomponents,
3 . S e t u p t h e d i a lg a u g ea g a i n s t h e h u b f l a n g ea s
shown, and measurethe bearingend play moving
the brakedisc inward and outward.
Bearing end play:

Standard:
Front/rear: 0 0.05 mm {0 0.002in.}
4. lf the bearingend play is more than the standard,

replacethe wheel bearing.
18-8
WheelRunoutInspection
1 . Raisethe vehicle,and supportit with safetystands 4 . R e s e t h e d i a l g a u g e t o t h ep o s i t i o ns h o w n ,a n d
in the proper location(seepage 1-5,. measurethe radial runout.
Checkfor a bent or deformedwheel. Front and rear wheel radial runout:

Standard:
Set up the dial gauge as shown, and measurethe Aluminum wheel: 0 0.7 mm (0 0.03io.)
axial runout by turning the wheel. Servicelimit: 1.5 mm {0.06in.}
Front and rear wheel axial runout:

Standard:
Aluminum wheel: 0-0.7 mm (0-0.03 in.)
Servicelimit: 2.0 mm {0.08in.l
lf the wheel runout is not within the specification,

checkthe wheel bearingend play (seepage 18-8),
and make sure the mating surfaceson the brake
disc and the insideof the wheel are clean.
lf the bearingend play is within the specification

but the wheel runout is more than the servicelimit.
replacethe wheel.
18-9
BallJointRemoval
Special Tools Required 3. Loosenthe pressurebolt (A),and installthe special
Ball ioint remover.2Smm 07MAC-SL00200 tool as shown. Insen the jaws carefully,making
sure not to damagethe ball joint boot. Adjustthe
jaw spacingby turning the adjustingbolt (B).
Always use a ball joint removerto disconnecta ball
joint. Do not strikethe housingor any other part of 10 mm HEXNUT
the ball joint connectionto disconnectit.
'1,
I n s t a lal h e x n u t ( A )o n t o t h e t h r e a d s o f t h e b a l l j o i n t
{ B ) .M a k es u r et h e n u t i s f l u s hw i t h t h e b a l l j o i n tp i n
end to preventdamageto the threadedend of the
b a l l i o i n to i n .
07MAC-S100200
After adjustingthe adjustingbolt, make sure the

head (C)of the adjustingbolt is in the position
shown to allow the jaw to pivot.
5 . With a wrench,tighten the pressurebolt until the

b a l li o i n t p i n p o p sl o o s ef r o m t h e s t e e r i n ga r m o r
knuckle.lf necessary.apply penetratingtype
lubricantto loosenthe ball joint pin
2 . Apply greaseto the specialtool on the areasshown
(A).This will easeinstallationof the tool and NOTE:Do not use pneumaticor electrictools on
preventdamageto the pressurebolt {B)threads. the pressurebolt.
6 . Removethe tool, then removethe nut from the end

o f t h e b a l l j o i n tp i n ,a n d p u l l t h eb a l l j o i n to u t o f t h e
s t e e r i n ga r m o r k n u c k l eI.n s p e c t t h eb a l l j o i n tb o o t ,
and replaceit if damaged.
18-10
FrontSuspension
Knuckle/Hub/WheelBearingReplacement
ExplodedView
WHEELBEARING
Replace.
SNAPRING
5 mm SCREWS
Replace.
FLATSCREWS
6x1.0mm
9.8Nm
(1.0kgf.m,7.2lbf.ft)
KNUCKLE
Checkfor delormation
a n oo a m a g e .
SPLASHGUARD
Checkfor corrosion.delormation.
and damage.
Replaceif rusted.
BRAKEDISC
SPINDLENUT
22 x 1.5mm
1 8 1N m
(18.5kgf.m, 134 lbt.ft)
Replace.
'--7.l
'tq
I
A p p ya s m a lal m o u not f e n g i n o
eil
to theseatingsurface.
lcont'd)
18-11
FrontSuspension
Knuckle/Hub/WheelBearingReplacement{cont'dl
Special Tools Required 5. Raisethe stake(A),and removethe spindle nut (B).
. Hub dis/assemblytool 07GAF-SE00100
. Balljoint remover,2Smm 0TlvlAC-S100200
. Attachment62 x 68 mm 07746-0010500
. Driver07749-0010000 - B
. SuDDortbase07965-5D90'100 ' 22x1.5mm
, 1 8 1N . m
1. Raisethe front of the vehicle,and support it with ('18.skgf.m,
134tbt.ft)
2. Removethe wheel cap,wheel nuts, and front wheel.
1 0 8N . m
(11.0kgf m,
80 rbf.ftl
6. Removethe brakedisc retainingflat screws(A).
3. Removethe brakehose bracketmounting bolt (A).

A \
6x1.0mm
9.8 N.m
A {1.0kgt.m,
8 x 1.25mm 7.2 tbl.ttl
22N.m
12.2ksl.m,
26 tbf.ftl
B
12 x 1.25mm
108N.m
{11.0kgf.m,
80 rbf.ftl
7. Screwtwo 8 x 1.25mm bolts (B)into the discto
oush it awav from the hub. Turn each bolt two turns
at a time to preventcockingthe disc excessively,
4 . Removethe caliperbracketmounting bolts (B),and
removethe caliperassembly(C)from the knuckle.
To preventdamageto the caliperassemblyor
brakehose,use a short pieceof wire to hang the
caliperassemblyfrom the undercarriage.Do not
twist the brakehose with force.
18-12
8. Removethe flange bolt {A) andwheel sensor(B) 10. Removethe lock pin (A)from the lower arm ball
from the knuckle.Do not disconnectthe wheel joint, and removethe castlenut (B).
sensorconneclor.
NOTE:During installation,insertthe lock pin into
A
5x1.0mm t h e b a l l j o i n tp i n f r o m t h e l n s i d et o t h e o u t s i d eo f
9.8 N.m the vehicle.The closedend of the lock Din must be
(1.0kgl.m,
7.2 tbt.ftl
i n t h e r a n g es h o w n .
07MAC-SL00200
€--....-"
'R. 12x 1.25mm
59 69N m
(6.0 7.0 kgl m,
9 . Removethe flange nut (A) while holdingthe joint 43 -51 lbf tt)
pin (B)with a hex wrench (C),and disconnectthe
s t a b i l i z el ri n k{ D )f r o m t h e l o w e ra r m ( E ) . 1 1 .Disconnectthe lower arm from the knuckleusing
the specialtool (seepage l8-10).
12. Loosenthe damper pinch bolts (A) while holding

the nuts (B),and removethe bolts and nuts.
10 x 1.25mm
39 N.m (,1.0kgf.m,29lbf.ft)
'13.Removethe driveshaftoutboardjoint
{C)fromthe
knuckle(D) by tappingthe driveshaftend (E)with a
plastichammer while drawing the knuckleoutward,
then removethe knuckle.
NOTE:Do not Dullthe driveshaftend outward.The

driveshaftjoint may come off.
(cont'd)
18-13
FrontSuspension
Knuckle/Hub/Wheel (cont'd)
BearingReplacement
14. Separatethe hub (A)from the knuckle(B) usingthe 1 6 . R e m o v et h e s n a pr i n g ( A )a n dt h e s p l a s hg u a r d( B )
specialtool and a hydraulicpress.Be carefulnotto f r o m t h e k n u c k l e( C ) .
deform the splashguard. Hold onto the hub to keep
it from falling when pressedclear.
07GAF-SE00100
./ .-''- .|
a'\s
1 1 . Pressthe wheel bearing(A) out of the knuckle(B

usingthe specialtool and a press.
1 5 . Pressthe wheel bearinginner race(A) off of the
+
h u b ( B )u s i n gt h e s p e i i a l t o o l ,a c o m m e r c i a l l y Pross
a v a i l a b l eb e a r i n gs e p a r a t o(rC ) ,a n d a p r e s s .
07GAF-SE00100
\r
\ Press
\
18-14
1 8 . W a s ht h e k n u c k l ea n d h u b t h o r o u g h l yi n h l g hf l a s h 2 2 . P r e s sa n e w h u b b e a r i n gu n i t{ A )o n t o t h e h u b ( B )
point solventbefore reassembly. usingthe specialtools and a press.
1 9 . Pressa new wheel bearing(A) into the knuckle(B)

usingthe old bearing(C),a steel plate {D).the
specialtool, and a press.Placethe wheel bearing
on the knucklewith the packseal side facing (metal
color)toward the inside.Be careful not to damage
the sleeveof the packseal.
"-t-_"*,,''
_,.' . . a-.)
../
..-. 23. I n s t a l l t h ek n u c k l e / h u b / h ubbe a r i n gu n i t i n t h e
reverseorder of removal,and notethese items:
. B ec a r e f u n l o t t o d a m a g e t h eb a l l j o i n tb o o t w h e n
2 0 . I n s t a ltlh e s n a pr i n g ( A )s e c u r e l yi n t h e k n u c k l e( B ) . installing the knuckle.
. Tightenall mounting hardwareto the specified
l O r q u ev a l u e s .
. Torquethe castlenut to the lower torque
specification,then tighten it only far enoughto
a l i g nt h e s l o tw i t h t h e b a l lj o i n t p i n h o l e .D o n o t
align the castlenut by looseningit.
. Installa new look pin on the castlenut after
torquing.
. U s ea n e w s p i n d l en u t o n r e a s s e m b l y .
. B e f o r ei n s t a l l i n g
t h e s p i n d l en u t ,a p p l ya s m a l l
amount of engine oil to the seatingsurfaceof the
nut. After tightening,use a drift to stakethe
s p i n d l en u t s h o u l d e ra g a i n s t h e d r i v e s h a f t .
. B e f o r ei n s t a l l l n gt h e b r a k ed i s c ,c l e a nt h e m a t i n g
D surfaceof the front hub and the insideof the
6 N.m10.6kgf.m,4lbfft)
b r a k ed i s c .
lnstallthe splashguard (C),and tighten the screws . B e f o r ei n s t a l l i n gt h e w h e e l ,c l e a nt h e m a t i n g
(D)to the specifiedtorque. surfaceof the brakedisc and the insideof the
wneet.
. Checkthe front wheel alignment,and adjustit if
18-15
FrontSuspension
BallJoint Boot Replacement
Special Tools Required Inst€llthe boot onto the ball joint pin, then squeeze
Front hub dis/assemblytool 07965-5450500 it gentlyto force out any air. Do not let dlrt or other
foreign materialsget into the boot.
1. Removethe boot.
Pressthe boot with the specialtool until the bottom
2. Packthe interiorand lip (A) of a new boot with fresh seatson the knuckle(A) evenly around.
grease.Keepthe greaseoff of the boot-to-knuckle
pross
mating surfaces(B).
07965-SA50500
-6r
rffi
€l
- - B
t
I
6 . After installinga boot,wipe any greaseoff the

exposedportion of the ball joint pin.
i
Wipe the greaseoff the taperedsectionof the pin
(C),and packfresh greaseonto the base (D).
18-16
StabilizerBar Replacement
1 . Raisethe front of the vehicle,and support it with 4. lnstallthe stabilizerbar in the reverseorder of
safetystandsin the proper location(seepage 1-8). removal.and note these itemsl
. Use new self-lockingnuts on reassembly.
Removethe self-lockingnuts (A)while holdingthe . Note the right and left directionof the stabilizer
joint pin (B)with a hex wrench (C),and disconnect oar.
t h e s t a b i l i z el ri n k s( D ) f r o mt h e s t a b i l i z ebr a r ( E )o n . A l i g nt h e e n d so f t h e p a i n tm a r k s( A )o n t h e
the right and left. stabilizerbar with each end of the bushings(8).
. Note the forelaft directionofthe bushing holders.
D . Referto stabilizerLink Replacementto connect
''i] t h e s t a b i l i z ebr a r t o t h e l i n k s( s e ep a g e1 8 - 1 8 ) .
,.'i i
. i.',.:-l I
\'r'j--,r'r-'1
,' _: i :..
i'
i-ii::;i
;4-llt,-'j--;
1 0x 1 . 2 5m m
39Nm
(4.0 kgf m,
29 tbl,ft)
Removethe flange bolts {A) and bushingholders

{B),then removethe bushings(C)and the stabilizer
b a r( D ) .
FORWARD
A
1 0x 1 . 2 5m m
39Nm
(4.0ksf.m, 29lbl.ftl
18-17
Front Suspension
StabilizerLink Removal/lnstallation
1 . Raisethe front of the vehicle,and support it with 4. Installthe self-lockingnut and flange nut, and
safetystandsin the proper location(seepage 1-8). lightlytighten them.
NOTE:Use a new self-lockingnut on reassembly.
Removethe self-lockingnut (A) and flange nut {B)
while holdingthe respectivejoint pin (C)with a hex 5. Placethe floor jack under the lower arm balljoint,
wrench (D),and removethe stabilizerlink (E). and raisethe suspensionto load it with the vehicle's
weaght.
mri-dEl
Do not placethe jack againstthe lower arm
balljoint.
6. Tightenthe self-lockingnut (A) and flange nut (B)to

the specifiedtorque valueswhile holdingthe
respectivejoint pins (C)with a hex wrench (D).
A
10 x 1.25mm
38 N.m
(3.9kgf m,28 lbf.ft)
3 . l n s t a l l t h es t a b i l i z el ri n k( A )o n t h e s t a b i l i z ebr a r { B )
and lower arm (C)with the joint pins (D)set at the
centerof their rangeof movement.
..,
B
10 x 1.25mm
39 N.m
{4.0kgf.m,29lbf.ft}
1 . After 5 minutesof driving, re-tightenthe self,

lockingnut again to the specifiedtorque.
18-18
Lower Arm Removal/lnstallation
SpecialToolsRequired 5. Removethe flange bolts (A),and removethe lower
Balljoint remover,2Smm 07|MAC-S100200 arm {B}.
1. Raisethe front of the vehicle,and supportit with

Removethe flange nut (A) while holdingthe joint

pin {B)with a hex wrench (C),and disconnectthe
s t a b i l i z el ri n k( D ) f r o mt h e l o w e ra r m ( E ) .
1 4x 1 . 5m m
83 N.m(8.5kgf.m,61lbf.ft)
6. Installthe lower arm in the reverseorder of

removal,and note these items:
. Be carefulnot to damagethe ball joint boot when

connectingthe lower arm to the knuckle.
' Tightenall mounting hardwareto the specified
torque values,
10x 1.25mm . F i r s t i n s t a lal l l t h e c o m p o n e n t sa n d l i g h t l y t i g h t e n
39 N.m
{4.0kgf m, 29 lbt.ft) the bolts and nuts.then raisethe suspensionto
load it with the vehicle'sweight beforefully
tighteningit to the specifiedtorques.
3 . Removethe lock pin (A) from the lower arm ball . Torque the castlenut to the lower torque
joint, and removethe castlenut (B). specification, then tighten it only far enoughto
align the slot with the ball joint pin hole. Do not
NOTE:During installation,insertthe lock pin into allgn the castlenut by looseningit.
the ball joint pin from the insideto the outsideof . Installa new lock pin on the castlenut after
the vehicle.The closed end of the lock pin must be torquing.
i n t h e r a n g es h o w n . . Beforeinstallingthe wheel, cleanthe mating
surfaceof the brakedisc and the insideof the
wneet.
. C h e c kt h e w h e e la l i g n m e n ta, n d a d j u s t i t i f
'18-4).
necessary(seepage
oTMAc-sloo2oo
6--__
@a
1 2x 1 . 2 5m m
59 69Nm
16.0-7.0kgt-m,
43 51 lbf.ft)
4 . Disconnectthe lower arm from the knuckleusing

t h e s p e c i atl o o l ( s e ep a g e1 8 - 1 0 ) .
18-19
Front Suspension
Damper/SpringReplacement
ExplodedView
./ SELF-LOCK|NGNUT
/.' 12 x 1.25inm
,,/ 44 N.m {4.5kgt.m,33lbf.ftl
,/ neDtace.
â
ta
e9
-€.- - DAMPER MOUNTINGBASE
checkfor delormation
1, @-:'\--""'
lF \-:-./ - ,
E9-
DAMPERMOUNTING
BEARING
UPPER SPRINGMOUNTING
CUSHION
Checkfor deterioration
anooamage,
DAMPER SPRING
Checkfor lreelength.
DAMPERUNIT
Checkfor oil leaks,
gas leaks,and smooth
operatron.
18-20
SpecialToolsRequired 5. Removethe damper pinch bolts (A)while holding
Balljoint remover,28mm 07MAC-S100200 t h e n u t s( B ) .
Removal
1. Raisethe front of the vehicle,and supportit with
Removethe cotterpin (A) from the tie-rod end ball

ioint, and removethe nut (B).
6. Removethe flange nuts (A)from the top ofthe

damper,
A 'l.25
10x mm
10 mm HEXNUT
07MAC-S1002000
Disconnectthetie-rodend from the steeringarm

o n t h e d a m p e ru s i n gt h e s p e c i a l t o o(l s e ep a g e1 8 -
1 0) .
4. Removethe bolts,and removethe wheel sensor

harnessbracket{A) and brakehose bracket(B)
from the damper.Do not disconnectthe wheel
sensorconnector.
7. Lower the lower arm, and removethe damper
A 6x1.0mm a s s e m b l y( B ) .
x 1.25nm
q /.8
(cont'd)
18-21
FrontSuspension
Damper/Spring (cont'd)
Replacement
Disassembly/lnspection Reassembleall the pans, exceptfor the upper
s p r i n gs e a ta n d s p r i n g .
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 c o m m e r c i a l l y
availablestrut spring compressor(A) accordingto 4. Compressthe damper assemblyby hand,and
the manufacturer'sinstructions.then removethe checkfor smooth operationthrough a full stroke.
s e l f - l o c k i nngu t ( B ) w h i l eh o l d i n gt h e d a m p e rs h a f t both compressionand extension.The damper
(C)with a hex wrench (D).Do not compressthe should extend smoothly and constantlywhen
spring more than necessaryto removethe nut, compressionis released.lf it does not, the gas is
leakingand the damper should be replaced.
Releasethe pressurefrom the strut spring

compressor,then disassemblethe damper as
\
shown in the ExplodedView.
C h e c kf o r o i l l e a k s a
, bnorman
l o i s e sa, n d b i n d i n g
during thesetests.
18-22
FrontSuspension
Damper/Spring (cont'dl
Replacement
Right side: Installation
1. Lower the lower arm, and positionthe damper
assemblyin the body, Turn the damper mounting
baseso the "AL" or "AR" mark (A)facestoward
the outsideof the vehicle.
B
10x 1.25mm
,14N.m
{4.5kgt.m,33lbf.ft)
Hold the bottom of the damper with your hand,and

compressthe spring. Do not compressthe spring
excessively.
9 . I n s t a l l t h e1 2 m m n u t ( A )o n t h e d a m p e rs h a f t( B ) .
Hold the damper shaft with a hex wrench (C),and
tighten the 12 mm nut to the specifiedtorque.
,1,6
Looselyinstallthe flange nuts (A) onto the top of
the damper. L
(4.5 kgt.m, 33 lbf ft)
1 0 .Removethe damperassembly
fromthe strutspring
compressor.
18-24
3 . P o s i t i o nt h e d a m p e ro n t h e k n u c k l ea, n d i n s t a l l t h e 8. Connectthe tie-rod end to the steeringarm, and
new damper pinch bolts (A) and nuts (B),and tightenthe nut (A)to the specifiedtorque. Install
lightlytighten the nuts. the cotterpin (B)after tightening,and bend lts end
asshown.
B
1 6 x 1 , 5m m
157N.m
(16.0kgt m,
116tbt.ftl
4 . P l a c et h e f l o o rj a c ku n d e rt h e l o w e ra r m b a l l j o i n t ,
and raisethe suspensionto load it with the vehicle's
weight.
Do not placethe jack againstthe lower arm 9. Cleanthe mating surfaceofthe brakedisc and the
balljoint. insideof the wheel,then installthe front wheels.
5 . Tightenthe flange nuts on the top of the damperto 1 0 . C h e c kt h e w h e e la l i g n m e n ta, n d a d j u s t i t i f

the specifiedtorque. necessary{seepage 18-4).
Tightenthe damper pinch nuts to the specified

torque.
1 . Installthe brakehose bracket(A) and the wheel

sensorharnessbracket(B)onto the damper,and
tighten the bolt to the specifiedtorque.
9.8N.m 22N|rl.
11.0kgf.m,7.2lbf.ftl 12.2kgI m,
16rbr,ftl
18-25
RearSuspension
Hub BearingUnit Replacement
ExplodedView
SPLASHGUARD
Checkfor deformation.
x 1.0 mm
9.8 N.m (1.0kgf.m,?1 lbf ftl
Checkfor wear and damage.
',[ ',, / -o\ ' 0
KNUCKLE
un
Checkfor delormation.
HUBBEARING UNIT
Y
Checkfor faultymovement 6x1.0mm
andwear. 9,8 N.m HUB CAP
{1.0kgf.m,7 lbf.ft} Replace.
SPINDLENUT
22 x 1.5mm
181 N.m {18.5kgt.m, 134lbf.ft}
Beplace.
-A
T
Appy a small amount oI engineoil
to the seatingsurface.
18-26
1 . Raisethe rear of the vehicle,and support it with Releasethe parkingbrakelever.
'l-8).
safetystandsin the proper location(seepage
5 . Removethe brakehose mounting bolt (A).
Removethe wheel cap. wheel nuts, and rearwheel.
B
1 0x 1 . 2 5m m
55Nm
C {5.6kgf m.41lbf.ft}
108N.m(11.0kgf.m,80lbfftl
(2.2kgtm, 16lbt.ftl
Removethe hub cap (A), raisethe stake(B),and
r e m o v et h e s p i n d l en u t ( C ) .
Removethe caliperbracketmounting bolts (B),and
hang the caliper(C)to one side.To preventdamage
to the caliperor brakehose,use a short pieceof
w i r e t o h a n gt h e c a l i p e rf r o m t h e u n d e r c a r r i a g e .
7 . Removethe brakedisc retainingscrews(A).
O
\
A
ap
2 2 x 1 , 5m m
1 8 1N . m
(18.5kgf.m, 134lbf.ftl
t
\
I
A
6x1.0mm
9 . 8N . m
(1.0kgf.m,?.2lbf.ftl
Screwtwo 8 x 1.25mm bolts (B) into the disc {C)to

oush it awav from the hub. Turn each bolt two turns
at a time to preventcockingthe disc excessively.
Removethe brakedisc.
(cont'd)
18-27
RearSuspension
Hub BearingUnit Replacement KnuckleReplacement
(cont'd)
1 . Raisethe rear of the vehicle,and suppon it with
9. Removethe hub bearingunit (A) from the spindle. Removethe rear wheels.
R e m o v et h e b r a k ed i s ca n d h u b b e a r i n gu n i t( s e e
s t e p 1 o n p a g e1 8 - 2 7 ) .
Removethe flange bolts (A) and splashguard (B)

from the knuckle.
,=,,,
1 0 .Installthe hub bearingunit in the reverseorder of

. Tightenall mounting hardwareto the specified

torque values,
. Beforeinstallingthe brakedisc,cleanthe mating
kgf.m,7.2lbf ft)
11.0
surfaceot the hub and the insideof the brake
disc.
. Use a new spindle nut on reassembly.
4. Removethe wheel sensor(A),braKenose
m o u n t i n gb r a c k e (t B ) ,a n d p a r k i n gc a b l em o u n t i n g
tt
. After tightening,use a drift to stakethe spindle bracket(C)from the knuckle.Do not disconnectthe
n u t s h o u l d e ra g a i n s t h e s p i n d l e . wheel sensorconnector.
. Use a new hub cap on reassembly.
. Beforeinstallingthe wheel, cleanthe mating
wneel.
8 x 1.25mm
22 N.m
{2.2kgfm, 16lbf ftl
6x1.0mm
9.8 N,m
{I.0 kgt.m,7.2lbf ft)
18-28
5. Placethe floor jack underthe trailing arm {A),to 9 . I n s t a l l t h ek n u c k l ei n t h e r e v e r s eo r d e ro f r e m o v a l ,
support it. and note these items:
. F i r s ti n s t a l a
l l l t h e s u s p e n s i o cno m p o n e n t sa, n d
Do not placethe jack againstthe plate lightlytighten the bolts and nuls,then placea
sectionof the lower arm, Be carefulnot to floor jack under the lower a rm, and raisethe
damageany suspensioncomponents. suspensionto load it with the vehicle'sweight
beforefully tighteningthe bolts and nutsto the
specifiedtorque values.
. Align the cam positionsof the adjustingbolt (A)
and adjustingcam (B)with the markedpositions
w h e nt i g h t e n i n g .
. Use a new self-lockingnut on reassembly.
. T i g h t e na l l t h e m o u n t i n gh a r d w a r et o t h e
. U s ea n e w s p i n d l en u t o n r e a s s e m b l y .
12x 1.25mm . B e f o r ei n s t a l l i n g
59 N.m t h e s p i n d l en u t ,a p p l ya s m a l l
{6.0ksf.m.43lbf.ft) amount of engine oil to the seatingsurfaceof the
nut. After tightening,use a drift to stakethe
s p i n d l en u t s h o u l d e ra g a i n s t h e d r i v e s h a f t .
. Beforeinstallingthe brakedisc,cleanthe mating
surfaceof the hub and the insideof the brake
drsc.
. U s ea n e w h u b c a po n r e a s s e m b l y .
Removethe flange bolt (B),and disconnectthe surfaceof the brakedisc and the insideof the
upper arm {C)from the knuckle. wheel.
. Checkthe wheel alignment,and adjust it if
1 . Mark the cam positionsof the adjustingbolt (A) and necessary{seepage 18-4).
adjustingcam (B),the removethe self-lockingnut
{C},adjustingcam, and adjustingbolt. Discardthe
self-lockingnut.
12x 1.25mm
59Nm(6.0kgf.m,
43 tbI.ftl
12x 1.25mm
59 N.m {6.0kgf m,43lbl.ft)
8. Remove the flange bolt (D), and remove the
k n u c k l e{ E ) .
18-29
RearSuspension
StabilizerBar Replacement
1 . Raisethe rear of the vehicle,and supportit with 4. Inslallthestabilizerbar in the reverseorder of
safetystandsin the proper location(seepage 1-8). removal,and notethese items:
Removethe rearwheels.
. Use new self-lockingnuts on reassembly.
Removethe self-lockingnuts (A)while holdingthe . lMakesure the right and left ends of the stabilizer
joint pins (B)with a hex wrench (C),and disconnect bar are installedon their respectivesidesof the
t h e s t a b i l i z el ri n k s( D )f r o m t h e s t a b i l i z ebr a r { E )o n vehicle.
the right and left. . Align the ends of the paint marks (A) on the
s t a b i l i z ebr a r w i t h t h e b u s h i n g s( B ) .
A . Referto StabilizerLink ReDlacement
1 0 x 1 . 2 5m m to connect
38 N.m t h e s t a b i l i z ebr a rt o t h e l i n k s{ s e ep a g e1 8 - 3 1 ) .
(3.9 kgf.m,28 lbf.ft)
\....'..: .
Al
.----'';-r'--\---r-
-tt'.,'t),
Removethe flange bolts (A) and bushing holders

(B),then removethe bushings{C)and the stabilizer
bar(D).
18-30
StabilizerLink Removal/lnstallation
1. Raisethe rear of the vehicle,and support it with 4. lnstallthe self-lockingnut and flange nut, and
safetystandsin the proper location(seepage 1-8). lightlytighten them.
NOTE:Use a new self-lockingnut on reassembly.
2. Removethe self-lockingnut (A) and flange nut (B)
while holdingthe respectivejoint pin {C)wilh a hex Placea jack under the trailing arm at the knuckle
wrench (D),and removethe stabilizerlink (E). side end. and raisethe suspensionlo load it with
the vehicle'sweight.
Tightenthe selflocking nut (A) and flange nut {B)to

the specifiedtorque valueswhile holdingthe
respectivejoint pins (C)with a hex wrench (D).
A
1 0 x 1 . 2 5m m
38 N.m 13.9kgf.m,28lbf.ftl
\,1 i
i'-r d
*l'',:
3 . I n s t a l l t h es t a b i l i z el ri n k( A )o n t h e s t a b i l i z ebr a r { B )
a n dt r a i l i n ga r m ( C )w i t h t h e j o i n t p i n s( D )s e ta t t h e
centerof each moving range,
7. After 5 minutesof driving, re-tightenthe self-

lockingnut again to the specifiedtorque.
18-31
RearSuspension
UpperArm Removal/lnstallation
1 . Raisethe rear of the vehicle,and supportlt with 5. Installthe upper arm in the reverseorder of
safetystandsin the proper location(seepage 1-8). renloval,and note these items:
l l l t h e s u s p e n s i o cno m p o n e n t sa n d
P l a c ea f l o o rj a c ku n d e rt h e t r a i l i n ga r m , a n d lightlytighten the bolts and nuts,then placea
supportthe suspensron. j a c ku n d e rt h e t r a i l i n ga r m , a n d r a i s et h e
suspensionto load it with the vehicle'sweight
Removethe flange bolt (A) and wheel sensor beforefully tighteningthe bolts and nuts to the
h a r n e s sb r a c k e (t B ) . specifiedtorque values.
. T i g h t e na l l t h e m o u n t i n gh a r d w a r et o t h e
' B e f o r ei n s t a l l i n g t h e w h e e l ,c l e a nt h e m a t i n g
wheel.
. Checkthe wheel alignment,and adjustit if
8 x 1 . 2 5m m
22 N.m(2.2kgf.m,
16rbf.ft)
Removethe flange bolts (A),and removethe upper

arm{B).
1 2 x 1 . 2 5m m
59 N.m {6.0kgf.m,
ir3 lbf.ft)
1 2 x 1 . 2 5m m
59 N.m 16.0kgf m,
43 tbf.ft)
18-32
TrailingArm Removal/lnstallation
1 . Raisethe rear of the vehicle,and suppon it with 7. Removethe trailing arm rear mounting bolt (A).
safetystandsin the proper location(seepage 1,8).
Do not loosenthe specialbolts (B)on the
Removethe knuckle(seepage 18-28). t r a i l i n ga r m .
3 . P l a c et h e f l o o rj a c ku n d e rt h e t r a i l i n ga r m ( A )t o A
12 x 1.25mm
support it. 59 N.m
-----\':,'.ttg
'.,--1..-r.':1
B
1 0x 1 . 2 5m m
38Nm
(3.9kgl.m,
28 tbf.ftl
1 2x 1 . 2 5m m 8 . Lower the jack,and removethe trailing arm.

61N m (6.2kgt m.
4s tbf,ft)
A
9 . Installthe trailing arm in the reverseorder of
Removethe flange nut (B),and disconnectthe removal,and note these items:
s t a b i l i z el ri n k( C )f r o m t h e t r a i l i n ga r m .
l l l t h e s u s p e n s i o cn o m p o n e n t sa n d
Removethe flange bolt {D),and disconnectthe lightly tlghtenthe bolts and nuts,then placea
d a m p e r( E )f r o m t h e t r a i l i n ga r m . j a c ku n d e rt h e t r a i l i n ga r m , a n d r a i s et h e
suspensionto load it with the vehicle'sweight
Removethe trailing arm front mounting bolts (A). beforefully tighteningthe bolts and nuts to the
. Tightenallthe mounting hardwareto the
specified torque values.
wneei.
. Checkthe wheel alignment,and adjust it if
necessary(seepage'18-4).
, ' a ' : -r
A
12 x 1.25Jnm
108N.m {11.0kgt.m,
80 tbf.ft)
18-33
RearSuspension
Replacement
Damper/Spring I
ExplodedView
9-----.---.-.
-=\
SELF-LoCK|NGNUT
I€tI
t=J 10 x 1.25mm
29 N m {3.0kgf.m,22 lbf.ft}
Replace.
DAMPERMOUNlING
COLLAR
DUSTCOVER
-t-
9...
r€)
qnJ/ \ \
E Z \
\
sroP PLArE
BUMP
n \
lt \
/t \ BUMPSTOP
tor weakness
Check
and damage.
DAMPERSPRING
Checkfor weakened
compressionand damage.
OAMPERUNIT
Checkfor oil leaks,
gas leaks,and smooth
operation,
18-34
Removal 5. Removethe damper assemblyfrom the body.
1. Raisethe rear of the vehicle.and support it with

i
2. Removethe flange bolt {A) from the bottom of the
damper.
3 . Removethe rear bulkheadcover (seepage 20-51).
Removethe flange nuts (A) from the top of the

damper in the trunk.
( c o n td )
18-35
RearSuspension
Damper/Spring (cont'dl
Replacement
Disassembly/lnspection Reassembly
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 c o m m e r c i a l l y 1 . I n s t a lal l l t h e p a r t s e x c e p t t h e
s e l f - l o c k i nngu t o n t o
availablestrut compressor(A) accordingto the the damper unit by referringto the ExplodedView.
manufacturer'sinstructions.then removethe self- Align the bottom of the spring {A} and the stepped
l o c k i n gn u t ( B ) w h i l eh o l d i n gt h e d a m p e rs h a f t( C ) part of the lower spring seat (B),and align the
with a hex wrench (D).Do not compressthe spring d a m p e rm o u n t i n gb a s ea s s h o w n ,
more than necessarvto removethe nut.
,, '161\ 7fi)1,, "

\3P qY/
Releasethe pressurefrom the strut spring I n s t a l l t h ed a m p e ra s s e m b l yo n a c o m m e r c i a l l y
compressor,then disassemblethe damper as availablestrut spring compressor(C).
shown ln the ExplodedView.
C o m p r e s tsh e d a m p e rs p r i n gw i t h t h e s p r i n g
? Reassembleall the pans, exceptfor the spring. compressor.
4 . Compressthe damper assemblyby hand,and Installthenew self'lockingnut (A) on the damper

checkfor smooth operationthrough a full stroke, shaft.
both compressionand extension.The damper
should extend smoothly and constantlywhen
compressionis released.lf it does not, the gas is
leakingand the damper should be replaced.
10 x 1.25mm
29Nm
(3.0kgt m,22 lbt.ft)
5. Hold the damper shaft {B)with a hex wrench (C),

and tighten the self-lockingnut to the specified
torque.
Checkfor oil leaks,abnormal noises,or binding

during thesetests.
18-36
Installation 3. Looselyinstallthe flange bolt (A) on the bottom of
thedamper.
1. Positionthe damper assemblyin the body. Note
the directionof the damper mounting base so that
the small hole dot on it is toward the front and
insideof the vehicle.
1 2 x1 . 2 5m m
61N m {6.2kgf.m.45lbf.ft)
Raisethe suspensionwith a floor jack to load the

vehicleweight, and tighten the nuts and bolt to the
Looselyinstallthe flange nuts (A) onto the top of specifiedtorque values.
the damper,
C l e a nt h e m a t i n gs u r f a c eo f t h e b r a k ed i s ca n d t h e
D A
1 0 x 1 . 2 5m m
59 N.m
16.0kgt.m, ia lbt ft)
i n s i d eo f t h e w h e e l ,t h e n i n s t a ltl h e r e a rw h e e l .
Checkthe wheel alignment,and adjust it if

18-37
Brakes
ConventionalBrakeComponents
Special Tools ........... l9-2
C o m p o n e nLto c a t i oInn d e x . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. .9. .-.3. . . . . . . . .
BrakeSystemInspectionand
Tests............... .......... 19-4
BrakePedaland BrakePedalPositionSwitch
Adjustment .............. 19-6
ParkingBrakeCheckand
Adjustment .............. 19-7
BrakeSystemBleeding ...................... 19-8
BrakeSystemIndicatorCircuit
Diagram . . . . . . . . . . . . . .1. 9. .-.9.
ParkingBrakeSwitchTest ................. 19-10
BrakeFluidLevelSwitchTest ...................................... 19-10
FrontBrakePadslnsoection and
Replacement ........... 19-11
FrontBrakeDiscInspection ............... 19-13
FrontBrakeCalioerOverhaul...................................... 19-14
MasterCylinderReplacement ........... 19-15
MasterCylinderInspection ................ 19-16
BrakeBooster
PushrodClearance Adjustment................................ 19-16
BrakeBoosterTest................... .......... 19-18
BrakeBoosterReolacement .............. 19-19
RearBrakePadsInspection and
Reolacement ........... 19-20
RearBrakeDiscInspection ................ 19-22
RearBrakeCaliperOverhaul....................................... 19-23
BrakeHosesand LinesInsoection .... 19-24
BrakeHoseReolacement ................... 19-25
ParkingBrakeCableReplacement .............................. 19-26
ABS (Anti-lockBrakeSystem)
Gomponents ... 19-29

SpecialTools
Ref.No. Tool Number DescriDtion Qty
o 07JAG-SD40100 PushrodAdiustmentGauoe 1
19-2
INDICATOR
BrakeSystemIndicatorCircuit
D i a g r a mp, a g e1 9 - 9
ParkingBrakeSwitch
Test,page 19 10
BrakeFluidLevelSwitch
Test,page 19-10
BRAKECABLE
P a r k i n gB r a k eC a b l e
Replacement,page 19 26
REARDISCBRAKE
RearBrakePads Inspectionand
Replacement,page l9-20
FRONTBRAKES RearBrakeDisc
FrontBrakePads,Inspectionand Inspection,page 19'22
Replacement, page 19-11 R e a rB r a k eC a l i p e O
r verhaul,
FrontBrakeDisc page 19'23
Inspection,page 19'13
FrontBrakeCaliper
O v e r h a u lp, a g e1 9 - 1 4 PARKING BRAKELEVER
BRAKEBOOSTER
Parkino
Brake
page19-7
CheckandAdjustment,
BrakeBooster
Test,page 19-18
BrakeEooster BRAKEPEDAL
Replacement, page 19 19 BrakePedalandErakePedalPosition
Switch
Adjustment,pagel9-6
BRAKEHOSESand LINES
BrakeHosesand Lines
Inspection,page 19 24
BrakeHoses
Replacement, page 19 25
MASTERCYLINDER
MasterCylinder
Fl6^1.^6m6nr ^2ô 1O-18
M a s t e rC y l i n d eIrn s p e c t i o np ,a g e1 9 - 1 6
BrakeBoosterPushrodClearance
A d j u s t m e n tp, a g e ' 1 9 - 1 6
BrakeSystemBleeding,page 19-8
19-3
BrakeComponents
Gonventional
BrakeSystemInspectionand Tests
Component Procedure Also check for:

l\4asterCylinder Look for damageor signs of fluid leakageat;
. Reservoiror reservoirgrommets
. L i n ej o i n t s
. Betweenmastercvlinderand booster
BrakeHoses Look for damageor signs of fluid leakageat: Bulging,twisted or bent lines.
. Line joints and banjo bolt connections
. Hosesand lines.also inspectfor twisting or
damaqe
Caliper Lookfor damageor signs of fluid leakageat: S e i z e do r s t i c k i n gc a l i p e rp i n s .
. Pistonseal
. Banjo bolt connections
. Bleederscrew
ABS l\ilodulator Lookfor damageor signs of fluid leakageat:
. Linejoints
. Modulator
BrakeSystemTest
Brake pedal sinks/fades when braking
1. Startthe engine,and let it warm up to operatingtemperature.
2. Attacha 2-inchpieceof maskingtape along the bottom of the steeringwheel, and draw a horizontalreference
mark acrossit.
t-
3 . With the transmissionin Neutral,pressand hold the brakepedal lightly,then releasethe parkingbrake.
While still holdingthe brakepedal,hook the end of the tape measurebehind it. Then pull the tape up to the
steeringwheel, noting where the tape measurelines up with the referencemark you made on the maskingtape.
5 . Apply steadypressureto the brakepedalfor 3 minutes.
6 . Watch the tape measure.
. if it moves lessthan 10 mm, the mastercylinderis OK.

. if it moves more than 10 mm replacethe mastercylinder.
19-4
Rapid brake pad wear. Vehicle vibration {after a long 5. Loosenthe hydrauliclines at the mastercylinder,
drivel, or High, hard brake pedal then spin the wheelsto checkfor brakedrag.
1 . D r i v et h e v e h i c l eu n t i lt h e b r a k e sd r a go r u n t i l t h e ls there brake drag at any of the wheels?

pedal is high and hard.This can take 20 or more
brakepedal applicationsduring an extendedtest YES Go to step 6.
drive.
NO- Replacethe mastercylinder.l
2 . W i t h t h e e n g i n er u n n i n g r, a i s et h e v e h i c l eo n a l i f t ,
a n d s p i n a l l f o u r w h e e l sb y h a n d . 6. Loosenthe bleederscrewsat each caliper,then
spin the wheels to checkfor brakedrag.
ls there btake drag at any of the wheels?
Is there brake drag at any of the wheels?
YES Go to step 3.
YES Disassembleand repairthe caliperon the
NO Lookfor other causesof the pad wear, high w h e e l ( sw
) i t h b r a k ed r a g . l
p e d a l ,o r v e h i c l ev i b r a t i o n . I
NO Inspectbrakehose (s)/line(s).
3. Turn the engineoff, pump the brakepedalto
depletethe vacuum in the brakebooster,and then
spin the wheels againto checkfor brakedrag.
ls therc brake dtag at any ot the wheels?
YES-Go to step 4.
NO Replacethe brakebooster.I
4. Without removingthe brakelines,unbolt and

separatethe mastercylinderfrom the booster,then
spin the wheelslo checkfor brakedrag.
ls there btake drag at any of the wheels?
YES Go to step 5,
NO-Check the brakepedal positionswitch

adjustmentand pedalfree play.I
19-5
BrakePedalandBrakePedalPosition
SwitchAdjustment
PedalHeight PedalFreePlay
1 . Disconnectthe brakepedal positionswitch 4. With the engineoff, inspectthe play (A) on the
connector,turn the brakepedal positionswitch (A) p e d a lp a d ( B )b y p u s h i n gt h e p e d a lb y h a n d .
c o u n t e r c l o c k w i saen, d p u l l i t b a c ku n t i li t i s n o
l o n g e rt o u c h i n gt h e b r a k ep e d a l . F r e eP l a y :0 . 4 - 3 . 0 m m { 0 . 0 1 6 0 . ' l 1 8 i n . )
Lift up the carpetand the insulatorcutout (B).

l\4easure the pedal height (C)from the middle of
the left side of the pedal pad (D).
StandardPedalHeight (with carpet removed):

184 mm (7 4/16in.)
lf the pedalfree play is out of specification,adjust

the brakepedal positionswitch (C).lf the pedalfree
p l a yi s i n s u f f i c i e n itt, m a y r e s u l ti n b r a k ed r a g .
6 . Pushin the brakeoedal oositionswitch until its

t
dnd(A)touching
p l u n g e ri s f u l l y p r e s s e d( t h r e a d e e
the pad (B)on the pedal arm).Then,turn the switch
45" clockwiseto lock it. The gap betweenthe brake
pedal positionswitch and the pad is automatically
a d j u s t e dt o 0 . 4t o 3 . 0m m ( 0 . 0 1 6 0 . 1 1 8i n . )b y
Loosenthe pushrodlocknut(A),and screwthe l o c k i n gt h e s w i t c h .M a k es u r et h e b r a k el i g h t sg o
pushrodin or out with pliers until the standard otf when the pedal is released.
pedal heightfrom the floor is reached.After
adjustment,tighten the locknutfirmly. Do not
adjustthe pedal heightwith the pushrodpressed.
1 5N . m
(1.5kgl m. 11lbl ft) 7 . C h e c kt h e b r a k ep e d a lf r e e p l a ya s d e s c r i b e db e l o w .
19-6
ParkingBrakeCheckand Adiustment
Check Removethe rear console{seepage 20-57).
1. Pullthe parkingbrakelever {A) with 196 N (20 kgf, Pull the parkingbrakelever up one click,
44 lbf) of forceto fully apply the parkingbrake.The
parkingbrakelever should be lockedwithin the
specifiednumber of clicks(B).
Leverlockedclicks: 7-8
- l2okqf,a4lbl) 7, Tightenthe adjustingnut {A} until the parking

brakesdrag slightlywhen the rear wheels are
2. Adjustthe parkingbrakeif the leverclicksarenot t ur n e d .
withinthe specification.
A /
Adjustment
1. Releasethe parkingbrakeleverfully.
Loosenthe parkingbrakeadjustingnut, startthe

engine,and pressthe brakepedal severaltimes to
set the self-adjustingbrakebeforeadjustingthe
parkingbrake.
Blockthe front wheels,then raisethe rear of the

vehicle,and supportit with safetystandsin the
proper location(seepage 1-8).
Make sure the parkingbrakearm (A) on the rear 8 . Releasethe parkingbrakelever fully, and check
brakecalipercontactsthe brakecaliperpin (B), that the parkingbrakesdo not drag when the rear
wheels are turned. Readjustif necessary.
NOTE:The parkingbrakearm will only contactthe
brakecaliperpin when the parkingbrakeadjusting 9 . Make surethe parkingbrakesare fully applied
nut is loosened. when the parkingbrakelever is pulled up fully.
1 0 . Reinstallthe rear console.
19-7
BrakeSystemBleeding
NOTE: 5. ReDeattheprocedurefor eachwheel in the
. Do not spill brakefluid on the vehicle;it may damage sequenceshown below until air bubblesno longer
the painUif brakefluid does contactthe paint.wash it a p p e a ri n t h e f l u i d .
off immediatelywith water.
. The reservoiron the mastercylindermust be at the BLEEDING
SEOUENCE:
MAX (upper)level mark at the start of the bleeding
procedureand checkedafter bleedingeach brake OFront Right ORe.r Right
c a l i p e rA
. d d f l u i da s r e q u i r e d .
. Do not reusethe drainedfluid.
. Always use Honda DOT3 brakefluid. Non-Honda
brakefluid can causecorrosionand shortenthe life of
the system.
. Make sure no din or other foreign matter is allowed
to contaminatethe brakefluid.
O Front Left ORoar Loft
1 . M a k es u r et h e b r a k ef l u i d l e v e li n t h e r e s e r v o i irs a t
t h e M A X ( u p p e r )l e v e ll i n e( A ) .
Refillthe mastercylinder reservoirto the MAX
{upper)level line.
FRONTBRAKE:
9 N.m 10.9kgf.m,7 lbl.ft)
t-
2 . Slide a pieceof clear plastichoseover the flrst

bleed screw,and submergethe other end in a
containerof new brakefluid.
Havesomeoneslowly pump the brakepedal

severaltimes,then apply steadypressure. REARBRAKE:
Startingat the left-front,loosenthe brakebleed

screwto allow air to escapefrom the system.Then 9 N m 10.9kgf.m, 7 lbf ft)
tighten the bleedscrew securely.
19-8
BrakeSystemIndicatorCircuitDiagram
UNDER.OASH
FUSE/FELAYBOX
I GRN/ORN
A
Y
EBAK€FLUID
IEVELSwlICH ,tk ,o"","o ""o*.
(b, 3s1E8,.""",,"
oPEN,Leve,down
BtK I
I
+ -=:
csor
19-9
Conventional
BrakeComponents
ParkingBrakeSwitch Test BrakeFluidLevelSwitch Test
1. Removethe rear console,and disconnectthe Checkfor continuitybetweenthe terminals(A) with the
connector(A)from the switch (B). float in the down positionand the up position.
. Removethe brakefluid completelyfrom the reservoir.

With the float down, there should be continuity.
R . F j l l t h er e s e r v o iw
r i t h b r a k e f l u i d t oM A X ( u p p e r )l e v e l
'dFu
\!E
!UF-
(B).With the float up, there should be no continuity.
Checkfor continuitybetweenthe switchterminal

a n d b o d yg r o u n d :
. With the brakelever up, there should be

continuity.
. With the brakelever down, there should be no
continuity.
\
19-10
Front BrakePadsInspectionand Replacement
Replacement
F r e q u e nitn h a l a t i o no f b r a k ep a d d u s t ,r e g a r d l e sos f 1 . R e m o v et h e b o l t( A ) ,a n d p i v o tt h e c a l i p e r( B )u p o u t
m a t e r i acl o m p o s i t i o nc,o u l db e h a z a r d o utso y o u r of the way. Checkthe hose and pin boots for
d a m a g ea n d d e t e r i o r a t i o n .
. Avoid breathingdust particles.
. N e v e ru s ea n a i r h o s eo r b r u s ht o c l e a nb r a k e
a s s e m b l i e sU. s ea n O S H A - a p p r o v evda c u u m
cleaner.
lnspection
1. Raisethe front of the vehicle,and support it with
safetystandsin the proper location{seepage 1'8).
2. Checkthe thicknessof the inner pad iA) and outer

p a d { B ) .D o n o t i n c l u d et h e t h i c k n e s so f t h e b r a k e &
pad backingplate.
\
Brakepad thickness:
Standard: 9.5 10.5mm (0.37 0.41 in.l A
Servicelimit: 1.6 mm (0.06in.)
2 . R e m o v et h e p a d s h i m i A ) a n d p a d s { B ) .
Innerpad:
' . . '
, .a
Outer pad:
.^hv/
\v \ \."r------B
tJ I
lf the brakeDadthicknessis lessthan the service
l i m i t ,r e p l a c ea l l t h e p a d sa s a s e t .
(cont'd)
19-11
ConventionalBrakeGomponents
Front BrakePadsInspectionand Replacement(cont'dl
3. Removethe pad retainers(A),and checkthe caliper 10. Push in the piston (A) so the caliperwill fitoverthe
pins for free movement. pads.Checkthe brakefluid level.The brakefluid
may overflow if the reservoiris too full. lvlakesure
the piston boot is in positionto preventdamagingit
when pivotingthe caliperdown
/:-."
t-.. 8x1.0mm
. .,.';- 34 N.m
i '1='
r 3.5 kgt m.
i.: r 25 tbf.ft)
..a.-
4. Cleanthe caliperthoroughly;remove any rust,and

checkfor groovesand cracks.
5. Checkthebrakedisc for damageand cracks.
6. Apply Dow CorningMolykoteM77 greaseto the

retainerson their mating surfacesagainstthe 11. Pivotthe caliperdown into position.Beingcareful
caliperbracket. not to damagethe pin boots,installthe bolt (B),and
tighten it to the specifiedtorque.
7. Installthe pad retainers.Wipe excessgreaseoffthe
retainers.Contaminatedbrakediscsand pads 1 2 . P r e s st h e b r a k ep e d a ls e v e r atli m e s t o m a k e s u r e
reducestoppingability.Keepgreaseoff the discs
\
the brakeworks,then test drive.
andpads.
NOTEE : n g a g e m e not f t h e b r a k em a y r e q u i r ea
8. Apply Molykote l\477greaseto both sidesof the greaterpedal strokeimmediatelyafter the brake
p a d s h i m { A ) ,t h e b a c ko f t h e p a d s( B ) ,a n d t h e o t h e r pads have been replacedas a set.Several
areasindicatedby the arrows. applicationsof lhe brakepedalwill restorethe
Wipe excessgreaseoff the shim. Contaminated normal pedalstroke.
brakediscsand pads reducestoppingability.Keep
greaseoff the discs and pads. 13. After installation,checkfor leaksat hose and line
joantsor connections,and retightenif necessary.
, a .).
Installthe brakepads and pad shim correctly.

Installthe padswith the wear indicators(C)on the
inside.
lf you are reusingthe pads,always reinstallthe
brakepads in their original positionsto preventa
momentary loss of brakingefficiency.
19-12
Front BrakeDisclnspection
Runout Thicknessand Parallelism
1. Raisethe front of the vehicle,and support it with 1. Raisethe front of the vehicle,and supportit with
safetystandsin the proper location(seepage 1-8). safetystandsin the proper location(seepage 1-8).
Removethe front wheels. Removethe front wheels.
2 . R e m o v et h e b r a k ep a d s( s e ep a g e1 9 - 1 1 ) . 2. Removethe brakepads (seepage 19-11).
3. Inspectthe disc surfacefor damageand cracks. 3. Using a micrometer,measurediscthicknessat

Cleanthe discthoroughly,and removeall rust eight points,approximately45" apart and 10 mm
{0.4 in.) in from the outer edge of the disc.
4. lnstallsuitable flat washers(A) andwheel nuts,and
tightenthe nuts to the specifiedtorque to hold the Brake Oisc Thickness:
brakedisc securelyagainstthe hub. Standard:20.9 21.8mm {0.82-0.86 in.}
Max. RefinishingLimit: 19.0mm 10.75in.)
Brake Disc Parallelism: 0.015 mm 10.0(X)6
in.)
max.
NOTE:This is the maximum allowabledifference

betweenthe thicknessmeasurements
10 mm lo.itin.l
': . --'t-'"'-
t , .
Set up the dial gaugeagainstthe brakedisc as

shown, and measurethe runout at 10 mm (0 4 in.)
from the outer edge of the disc.
BrakeDiscRunout:
ServiceLimit: 0.10mm (0.00ttin.l
lf the disc is beyondthe servicelimit, refinishthe

brakedisc.
t e a s u r e m e ni ts l e s st h a nt h e m a x .
4 . l f t h e s m a l l e sm
Max. RetinishLimit: 19.0mm (0.75in.) refinishinglimit, replacethe brakedisc (seepage
18-11).
NOTE:
. l f t h e b r a k e d i s ci s b e y o n d t h e s e r v i c lei m i t f o r lf the disc is beyondthe servicelimit for parallelism,
r e f i n i s h i n gr ,e p l a c ei t ( s e ep a g e1 8 - 11 ) . refinishthe brakedisc with an on-carbrakelathe.
. A new disc should be refinishedif its runout is The Kwik-Latheproducedby Kwik-way
"Front BrakeDisc
g r e a t e rt h a n0 . 1 0m m ( 0 . 0 0 4i n . ) . ManufacturingCo. and the
Lathe" offered by Snap-onTools Co. are approved
for this operation.
19-13
Front BrakeCaliperOverhaul {
Frequentinhalationof brakepad dust, regardlessof materialcomposition,could be hazardousto your health.

' N e v e ru s ea n a i r h o s eo r b r u s ht o c l e a nb r a k ea s s e m b l i e su.s e a n o s H A - a p p r o v e d
v a c u u mc l e a n e r .
Remove,disassemble,inspect,reassemble,and installthe caliper,and note these items:

' D o n o t s p i l lb r a k ef l u i d o n t h e v e h i c l e i;t m a y d a m a g et h e p a i n t ;i f b r a k e f l u i d g e t s o n t h e p a i n t , w a s h i t o f f
immediatelywith water.
. To preventdripping,cover disconnectedhose joints with rags or shop towels.
. C l e a n a l lp a r t s i n b r a k e f l u i d a n d a i r d r y ; b l o w o u t a lpl a s s a g e s w i t ch o m p r e s s e d
air.
. Beforereassembling,checkthat all parts are free of dust and other foreign particles.
. Replacepartswith new ones as specifiedin the illustration.
. Make sure no dirt or other foreign matter is allowedto contaminatethe brakefluid,
' When reusingpads,always reinstallthemin their original positions to preventloss of
brakingefficiency.
. Do not reusedrainedbrakefluid.
'AlwaysuseHondaDOT3brakefluid.Non'Hondabrakefluidcancausecorrosionandshortenthelifeofthesvstem.
. Do not mix differentbrandsof brakefluid as they may not be compatible.
. C o a t t h ep i s t o n ,p i s t o ns e a lg r o o v e ,a n d c a l i p e rb o r e w i t h c l e a nb r a k e f l u i d .
. Make sure no greaseor oil gets on the brakediscs or pads.
. Replaceall rubber partswith new ones wheneverdisassembled.
. After installingthe caliper,checkthe brakehose and line for leaks,interference,and twistinq.
>:@:Honda caliper sreaso tplN 08C30-80234M)
Boors 3i,l'1.'"
-ffiFA / isli\ii ^ zswttt
BRAKEHOSE/ /8LEEO SCREW
/ / /eNm
/paq\
t l l l /
/
/
/
/ / (o.s
kgr'm.
| itbt.ftl
, 1
,\L,.'iE/ [ *fL-f
(}',
^ l^ /caLl
-ffi
-ffi
CALIPER
PINA
\:7
\--l "=;lGoX-
u";;;lqEty'
/ 3.4N.m >vr
\ / {3.5kef m, / ,,'
\ / 25 lbf ft) //'
t / SEAL|NG
)-
/) II ---=-?
.===? WASHEaS
WAStrtXS \
t9..-\ | #.'@ RepracF
- /7\
!s-
*d':ffi
(hA PADRETATNERS
\t/ \
^/rkr) ,-o/ ffi

vlJ
Es,lry:' E*,e,a
["fif:i#l1t*"_,,.
\
.==f@ tz x t.zsmm ourEBpaDsHrM
1 0 8N . m 1 1 1 . 0k g f . m ,
80 tbt.ft)
19-14
MasterCylinderReplacement
NOTE:Do not spill brakefluid on the vehicle;it may 3 . R e m o v et h e c l u t c hr e s e r v o i (r B )a n d e n g i n e w i r e
damagethe paint;if brakefluid does contactthe paint, harnessclip (C)from the mastercylindermounting
wash it off immediatelywith water, b a s e( D ) .
r s s e m b l y( A ) .
1 , R e m o v et h e a i r c l e a n e a 4. Removethe reservoircap and brakefuid from the
reservoir.
5. Removethe reservoir(E)on the mastercylinder

m o u n t r n gD a s e .
6, Disconnectthe brakelines (F)from the master

cylinder (G).To preventspills,cover the hosejoints
with rags or shop towels.
7. Removethe mastercylinder mounting nuts {H)and

washers.
8. Removethe mastercylinderfrom the brakebooster.

Be carefulnot to bend or damagethe brakelines
when removingthe mastercylinder.
2, Disconnectthe brakefluid level sensorconnector
(A). 9. Removethe rod seal (l) from the mastercylinder.
10. Installthe mastercylinder in the reverseorder of

. Replaceall the rubber partswith new ones

wheneverthe mastercylinder is removed.
. Checkthe pushrodclearancebeforeinstallingthe
mastercylinder.and adjust it if necessary(see
p a g e1 9 - 1 6 ) .
. Use a new rod seal on reassemblY
. Coatthe inner bore lip and outer circumference
of the new rod seal {A) with the recommended
seal greasein the mastercylinderset.
. I n s t a l l t h er o d s e a lo n t o t h e m a s t e rc y l i n d e rw i t h
its groovedside (B)towardthe mastercylinder.
. Checkthe brakepedal height and free play after
installing t h e m a s t e rc y l i n d e ra, n d a d j u s ti t i f
1 5N . m necessary(seepage 19-6).
{1.5kgt.m,11 lbt.ft)
19-15
MasterCylinderInspection BrakeBoosterPushrodClearance
Adjustment
NOTE:
. Beforereassembling,checkthat alI partsare f ree of
dust and other foreign particles. SpecialToolsRequired
. D o n o t t r y t o d i s a s s e m b l e t hm
e astercylinder Pushrodadjustmentgauge07JAG-SD40100
assembly.Replacethe mastercylinder assemblywith
a new part if necessary. NOTE:Brakeboosterpushrod-to-piston clearancemust
. Do not allow dirt or foreign matterto contaminatethe be checkedand adjustmentsmade, if necessarV,before
b r a k ef l u i d . installingthe mastercylinder.
RESERVOIB CAP
I unecKIor otocKage 1 . S e t t h e s p e c i atlo o l ( A )o n t h e m a s t e r c y l i n d ebr o d v
of vent holes. (B),push in the centershaft (C)until the top of it
,--l RESERvOIRSEAL contactsthe end of the secondarypiston {D) by
Checklor damaoe t u r n i n gt h e a d j u s t i n gn u t ( E ) .
RESERVOIR and deterioration.
r ' , , . J \ + STRAINER
v Removeaccumulated
seotment.
RESERVOIR HOSES
Inspecthosesfor
damage,leaks,and
deterioration.
MASTER CYLINDER
Checkfor leaks,rust,anddamage
Without disturbingthe centershaft'sposition,

installthe specialtool(A) backwardson the booster.
1 5N m { r . 5
11tbf.ftl
Installthe mastercylinder nuts (B),and tighten

them to the specifiedtorque.
Conneclthe boosterin line with a vacuum gauge

{ C )0 - 1 0 1 k P a{ 0 ' - 7 6 0m m H g ,3 0 i n . H g )t o t h e
booster'senginevacuum supply,and maintainan
e n g i n es p e e dt h a tw i l l d e l i v e r6 6 k P a( 5 0 0m m H g ,
2 0 i n . H g )v a c u u m .
19-16
5. With a feelergauge (A),measurethe clearance 9 . C h e c kt h e p u s h r o dl e n g t h( A )a s s h o w n i f t h e
betweenthe gauge body and the adjustingnut (B) boosteris removed,lf the length is incorrect,
as snown, loosenthe pushrodlocknut(B),and turn the clevis
lf the clearancebetweenthe gauge body and the (C)in or out to adjust.
adjustingnut is 0.4 mm (0.02in.),the pushrod-to- A
pistonclearanceis 0 mm. However.if the clearance 1 1 6m m { 4 . 6i n . )
betweenthe gauge body and the adjustingnut is
0 mm, the pushrod-to-piston clearanceis 0 4 mm
{0.02in.) or more. Thereforeit must be adjusted
and rechecked.
Clearance: 0-0./t mm (0-0.02 in.)
1 0 x 1 . 0m m
1.5 N'm
11.5kgf.m,11 lbf.ftl
1 0 . I n s t a l l t h em a s t e rc y l i n d e r( s e ep a g el 9 - 1 5 )
lf the clearanceis incorrect,loosenthe star locknut

(A).and turn the adjuster(B)in or out to adjust.
. Adjustthe clearancewhile the specifiedvacuum

is appiiedto the booster.
. Holdthe clevis(C)while adjusting.
A
0 0.4mm l0 -0.02in.) 22N.n
07JAG-SO40100
7. Tightenthe star locknutsecurely.
8. Removethe specialtool (D).
19-17
Gonventional
BrakeComponents
BrakeBoosterTest I
FunctionalTest 3. Disconnectthe brakeboostervacuum hose (check
valve built-in)(A) at the boosterside.
1. With the enginestopped,pressthe brakepedal
severaltimes to depletethe vacuum reservoir,then
pressthe pedal hard, and hold itfor 15 seconds.lf
the pedalsinks,eitherthe mastercylinderis
bypassinginternally,or the brakesystem (master
c y l i n d e rl,i n e s .m o d u l a t o ro, r c a l i p e r si)s l e a k i n g .
2. Startthe enginewith the brakepedal pressed.lf the

pedal sinksslightly,the vacuum boosteris working
properly.lf the pedal heightdoes not vary, the
boosteror checkvalve is faulty.
3. With the engine running,pressthe brakepedal

l i g h t l y .l f t h e b r a k ep e d a ls i n k sm o r e t h a n 1 Om m
{3/8 in,) in 3 minutes,the mastercylinder is faulty.
A slight changein pedal heightwhen the Ay'C 4 . Startthe engine,and let it idle.Thereshould be
compressorcycleson and off is normal.(TheA,/C v a c u u ma v a i l a b l el .f n o v a c u u mi s a v a i l a b l et ,h e
compressorload changesthe vacuum availableto checkvalve is not working properly.Repiacethe
the booster.) brakeboostervacuum hose and checkvalve,and
relesI.
LeakTest
5 . Reconnectthe brakeboostervacuum nose.
1. Pressthe brakepedalwith the engine running,then Startthe engine,and then pinch the brakebooster
stop the engine.lf the pedal height does not vary vacuum hose betweenthe checkvalve and the
while pressedfor 30 seconds,the vacuum booster booster,
is OK. lf the pedal rises,the boosteris faulty.
Turn the ignition switch OFF,and wait 30 seconds,
2. With the engine stopped,pressthe brakepedal Pressthe brakepedal severaltimes using normal
severaltimes using normal pressure.When the pressure,
pedal is first pressed,it should oe row. When the pedal is first pressed,it should be low.
On consecutiveapplications,the pedal height On consecutiveapplications,the pedal height
s h o u l dg r a d u a l l yr i s e .l f t h e p e d a lp o s i t i o nd o e s n o t s h o u l dg r a d u a l l yr i s e .
varv, checkthe boostercheckvalve.
. lf the pedal positiondoes notvary, replacethe
brakebooster.
. lf the pedal positionvaries,replacethe brake
boostervacuum hose/checkvalve assembly.
19-18
BrakeBoosterReplacement
1 . R e m o v et h e m a s t e rc y l i n d e r( s e ep a g e1 9 - 1 5 ) . 5 . R e m o v et h e c l i p ( A )a n dt h e j o i n t p i n ( B ) .a n d
disconnecttheyoke from the brakepedal.
Removethe mastercylinder brakelines {A) from
t h e b r a k el i n ec l i p . .,.,....
alu
'..
i
' - / c
6x1.0mm {'l.3kgf.m,9lbf.ftl
9.8 N.m
(1.0kgf.m,
7.2 tbf.ft) Removethe brakeboostermounting nuts (C).
Removethe vacuum hose mounting bracket(B). 7 . Removethe brakebooster(A)from the engine

comparlmenr.
Disconnectthe vacuum hose {C)from the brake
booster. INdAdEI
. Be carefulnot to damagethe booster
surfacesand threadsof the boosterstud
bolts.
. Be carefulnot to bend or damagethe
b r a k el i n e s .
lnstallthe brakeboosterin the reverseorder of

. Adjustthe pushrodclearancebeforeinstalling
the brakebooster(seepage 19-16).
. U s ea n e w c l i pw h e n e v e ri n s t a l l i n g .
. After installingthe brakeboosterand master
cylinder,fill the reservoirwith new brakefluid,
bleedthe brakesystem (seepage 19-8),and
adjustthe brakepedal height and free play (see
p a g e1 9 - 6 ) ,
19-19
Conventional
BrakeComponents
RearBrakePadsInspectionand Replacement
Replacement
Frequentinhalationof brakepad dust, regardlessof 1. Removethe bolt (A) and brakehose {B}from the
materialcomposition,could be hazardousto your mounting bracket.
h e ah h .
. Never use an air hose or brushto clean brake
assemblies,Use an OSHA-approvedvacuum
cleaner.
Inspection
'1.
Raisethe rear of the vehicle,and supportjt with
Removethe rearwheels,
2. Checkthe thicknessof the inner pad (A) andouter

pad (B).Do not includethe thicknessof the brake
pad backingplate.
Brakepad thickness:
Standard: 8.5 9.5 mm {0.33-0.37 in.} Removethe caliperbolts (C),and removethe
Servicelimit: 1.6 mm (0.06in.) caliper(D)from the caliperbracket.
3 . R e m o v et h e p a d s h i m s( A )a n d p a d s( B ) .
A
t {
\
-::--
B
3 . lf the brakepad thicknessis lessthan the service A

tI
l i m i t ,r e p l a c ea l l t h e p a d sa s a s e t . \ A
r\
) )
\
19-20
4. Removethe pad retainers(A).and checkthe caliper 11. Rotatethe caliperpiston clockwiseinto the cylinder,
pins for free movement. then align the cutout (A) in the pistonwith the tab
:.i _ _l
{B) on the inner pad by turning the piston backso
t h e c a l i p e rc a n b e i n s t a l l e do n t h e p a d .L u b r i c a t e
the boot with rubbergreaseto avoid twisting the
Distonboot. lf the piston boot is twisted,back it out
so it is positionedproperly.
8 x 1 . 2 5m m
5. Cleanthe caliperthoroughly;remove any rust.and 22 N.m
checkfor groovesand cracks. l2.2kgt m,
16rbl.ttl
6, Checkthe brakedisc for damageand cracks.
7 . Apply Dow CorningMolykoteM77 greaseto the

retainerson their mating surfacesagainstthe
caliperbracket,
.ar
8 . Installthe pad retainers.Wipe excessgreaseoffthe

retainers.Contaminatedbrakediscs and pads
reducestoppingability.Keepgreaseoff the discs D
a n dp a d s . 8 x 1.25mm
23Nm
{2.3kgf.m,
9 . Apply Dow CorningMolykotelvl77greaseto both 17rbf.ft)
sidesof the pad shims {A),the backof the pads (B),
and the other areasindicatedby the arrows.Wipe
excessgreaseoff the shim. Contaminatedbrake
discs and pads reducestoppingability.Keep
greaseoff the discsand pads.
. I n s t a l l t h eb r a k ec a l i p e r( C )a n d c a l i p e rb o l t s( D ) .
.-. and tighten the boltsto the specifiedtorque.
1 3 .I n s t a l l t h eb r a k eh o s e( E ) .
1 4 . Pressthe brakepedal severaltimes to make sure

the brakeworks, then test-drive.
NOTE:Engagementof the brakemay requirea

greeterpedal strokeimmediatelyafterthe brake
pads have been replacedas a set. Several
applicationsof the brakepedalwill restorethe
n o r m a lp e d a ls t r o k e ,
1 5 . C h e c kt h e p a r k i n gb r a k ea d j u s t m e n{ts e ep a g e1 9 - 7 ) .
1 0 . I n s t a l l t h eb r a k ep a d sa n d p a d s h i m sc o r r e c t l y .
I n s t a l l t h ep a d sw i r h t h e w e a r i n d i c a t o r {sC )o n t h e 1 6 . A f t e ri n s t a l l a t i o nc ,h e c kf o r l e a k sa t h o s ea n d l i n e
inside. joints or connections,and retightenif necessarY.
lf you are reusingthe pads,always reinstallthe
brakepads in their originalpositionsto preventa
momentaryloss of brakingefficiency.
19-21
Conventional
BrakeComponents
RearBrakeDiscInspection
Runout Thicknessand Parallelism
1. Raisethe rear of the vehicle,and support it with 1. Raisethe rear of the vehicle,and supportwith
safetystandsin the proper location(seepage 1-8). safetystandsin the proper location(seepage l-g).
Removethe rear wheels, Removethe rearwheels.
2. Removethe brakepads (seepage 19-20). 2. Removethe brakepads {seepage 19 20).
3. Inspectthe disc surfacefor damageand cracks. 3, Using a micrometer,measurediscthicknessat

Cleanthe discthoroughly,and remove all rust, e i g h tp o i n t s a
, p p r o x i m a t e l4y5 ' a p a r ta n d 1 0 m m
{0.4 in.)from the outer edge of the disc.
4. lnstallsuitable f lat washers(A) and wheel nuts, and
tighten the nuts to the specifiedtorque to hold the BrakeDiscThickness:
brakedisc securelyagainstthe hub. Standard:9.9-10.1 mm (0.389 0.397in.l
Max. RetinishingLimit: 9.0 mm (0.35in.)
BrakeDiscParallelism: 0.016mm 10.0006in.)
max.
108N.m (11.0kgf.m,80lbf.ft)
Set up the dial gauge againstthe brakedisc as

shown. and measurethe runout at 10 mm (0.4in.)
from the outer edge of the disc.
Brake Disc Runout;

lf the disc is beyondthe servicelimit, refinishthe

brakedisc.
4 . lf the smallestmeasurementis lessthan the max.
Max. RefinishLimit: 9.0 mm (0.35in.) refinishinglimit, replacethe brakedisc (seepage
18-26).
NOTE:
. l f t h e b r a k ed i s ci s b e y o n d t h e s e r v i c lei m i t f o r lf the disc is beyondthe servicelimit for parallelism,
refinishing,replaceit (seepage 18-26). refinishthe brakedisc with an on-carbrakelathe.
. A new disc should be refinishedif its runout is
g r e a t e rt h a n0 . 1 0m m ( 0 . 0 0 4i n . ) .
19-22
RearBrakeCaliperOverhaul
Frequentinhalationof brakepad dust, regardlessof materialcomposition,could be hazardousto your health.

' Avoid breathingdust particles.
. Never use an air hose or brushto clean brakeassemblies.Use an OSHA-approvedvacuum cleaner'
Remove,disassemble,inspect,reassemble,and installthe caliper,and note these items:

. D o n o t s p i l lb r a k ef l u i d o n t h e v e h i c l e i;t m a y d a m a g et h e p a i n t ;i f b r a k ef l u i d g e t so n t h e p a i n t ,w a s h i t o f f
. To preventdripping.cover disconnectedhosejoints with rags or shop towels.
. C l e a n a l lp a r t s i n b r a k e f l u i d a n d a i r d r y ; b l o w o u t a lpl a s s a g e s w i t ch o m p r e s s e adir'
. Beforereassembling,checkthat all parts are free of dust and other foreign particles
. Replacepans with new ones as specifiedin the illustration.
. Make sure no dirt or other foreign matter contaminatesthe brakefluid.
. When reusingpads,always reinstallthemin their originalpositionsto preventloss of b raking efficiency.
. Do not reusedrainedbrakefluid.
. U s eo n l y c l e a nH o n d aD O T3 b r a k ef l u i d .N o n - H o n d a b r a k ef l u i d c a nc a u s ec o r r o s i o na n d s h o r t e nt h e l i f eo f t h e
system.
. Do not mix differentbrandsot brakefluid as they may not be compatible.
. C o a t t h ep i s t o n ,p i s t o ns e a lg r o o v e ,a n d c a l i p e rb o r ew i t h c l e a nb r a k ef l u i d .
. Make sure no greaseor oil gets on the brakediscsor pads.
. R e p l a c e a lrlu b b e rp a r t sw i t h n e w o n e sw h e n e v e rd i s a s s e m b l e d .
. After installingthe caliper,checkthe brakehose and line for leaks,interference.and twisting.
BOLT
oG , nonau."rip6r qreas€lP/N 08c30-aoa4Ml 3 4 N . m( 3 . 5k g f m , 2 5 l b t f t )
WASHERS
BRAKEHOSE
\-"o, V((rA ",1 ;[.,.JF

/;;;;---
ADJUSTINGBOLT
t H\a \l / t,i*t'*" a ,/
i,,'IltE"
/ !!;,ff
?,,.t/*"^.,,.:,"",
l, /"V4# olT-J,.o"c. O.RING
Beplace.
CUP
Beplace.
.ARKING
NUr lii.'i rz.rrgr.. Gd ffi
2 7 N m { 2 . 8 k g ft .mm, ,
20 tbf.ftr PADSPRING
A,n Na 7lfl,lif,loffi',,0,n, \ ,,:,o"\

--t\)(*ff l^7k ''"'t!1'ry#'
INNEBPA'SHIM
'(
/ .r.:._U
":;*" *dF i*E
,.2>a>-
fr.x{_>@ fftt **-->**^'"
,,.-"iV ,/q &'"o.,"."""o"^.,
: 10 MM FLANGE BOLTS
.:r=,9!q!q}l 55 N m (5.6 lgf-m, 4r lbt ft)
19-23
BrakeHosesand LinesInspection {
1. Inspectthe brakehosesfordamage,deterioration,leaks,interference,andtwisting.
2. Checkthe brakelinesfor damage,rusting.and leakage.Also checkfor bent brakelines.
3. Checkfor leaksat hose and line joints or connections,and retightenif necessary.
4. Checkthe mastercylinderand ABS modulator unit for damageand leakage.
NOTE:Replacethe brakehose clip wheneverthe brakehose is serviced.
BRAKELINE-to-BRAKE
HOSE
15 N.m (1.5kgf.m, 11 lbf.ftl
BRAKEHOSE-to-CALIPER
lBANJOBOLTI
3il N.m {3.5kgf.m.25lbt'ft)
BLEEO SCREW
9 N.m{0.9kgf.m,7lbf.ftl
ABS MODULATORUNIT-Io-BRAKELINE
15N.m{1.5kgf m.11lbf.ftl
/,i'i'
t'' ,/ ,l
t t,.. -)
MASTERCYLINDEB-to-BRAKE LINE
15 N m {1.5kgt.m,ll lbf.ft)
BRAKEHOSE.tO-CALIPER
{BANJO BOLTI CONTROLVALVE-to-
34 N.m {3.5kgf.m,25 lbl.ft) BRAKELINE
15N.m11.5kgf m, 11lbf.ft)
BLEEDSCBEW
9 N.m BRAKELINE-Io-BRAKEHOSE
10.9kgf.m, 7 lbf ft) 15 N.m (1.5kgf.m,11lbf.ftl
19-24
BrakeHoseReplacement
NOTE: 6. Installthe brakehose bracket(A)on the damper
. Do not spill brakefluid on the vehicle;it may damage with the flange bolt (B)first, then connectthe brake
the paint;if brakefluid gets on the paint,wash it off hose (C)to the caliperwith the banjo bolt {D) and
immediatelywith water. n e w s e a l i n gw a s h e r s( E ) .
. To preventdripping,cover disconnectedline joints
with rags or shop towels.
. Beforereassembling,checkthat all parts are free of
dust and other foreign particles.
. Replacepartswith new ones wheneverspecifiedto
do so.
1. Replacethe brakehose (A) if the hose is twisted,

cracked,or if it leaks.
7. lnstallthe hose onto the hose bracketon the bodv

with a new hose clip (A).
1 0 x 1 . 0m m
15 N.m
i (1.5kgf.m,
! 1t tbt.ftl
Disconnectthe brakehosefrom the brakeline (B)

using a 10 mm flare nut wrench {C)
Removethe flange bolt (A),and removethe brake

hose bracketsfrom the damper.
Connectthe brakeline to the brakehose.
9 . After installingthe brakehose,bleedthe brake

system (seepage l9-8).
1 0 .Do the following checks:

I x 1 . 2 5m m
. Checkthe brakehose and line joint for leaks,and
tighten if necessary.
. Checkthe brakehosesfor interferenceand
twisting.
4. R e m o v ea n d d i s c a r dt h e h o s ec l i p ( B ) .
Removethe banjo bolt (C),and removethe brake

h o s e( D ){ r o m t h e c a l i p e r .
19-25
ParkingBrakeCableReplacement 1
ExplodedView
ADJUSTING
NUT
PARKINGBRAKE
swtTcH
e
8 x 1.25
PARKING BRAKECABLE 22 N.m
for stiffness,
Check binding,anddamage. 12.2kgl
19-26
NOTE: 7 . l n s t a l l t h en e w c a b l ei n t h e r e v e r s eo r d e ro f
. The parkingbrakecablesmust not be bent or removal.and note these items:
distorted.This will leadto stiff operationand
prematurefailure. . Be careful not to bend or distortthe cable.
. Referto the ExplodedView as neededduring this . M a k es u r et h e p a r k i n gb r a k ec a b l ec l i p i s f u l l y
proceoure. seatedon the cable housing.
. Do the parkingbrakecable adjuslment(seepage
1 . R e l e a s teh e p a r k i n gb r a k el e v e rf u l l y . 1 9 - 7) .
2. Removethe rearconsole(seepage 20-57).
4 . Removethe parkingbrakecableclip (A) from the

b r a k ec a b l e( B ) .
Disconnecttheparkingbrakecablefrom the lever

{c).
6 . Removethe parkingbrakecable mounting
hardware,then removethe cable.
19-27
Brakes
BrakeComponents................
Conventional 19-1
ABS (Anti-lockBrakeSystem)Components
C o m o o n e nLto c a t i olnn d e x . . . . . . . . . . . . . , . . . . . . . . . . . . . 1
. .9. .-.3. .0. . . . . . .
DTCTroubleshooting Index .............. 19-34
SymptomTroubleshooting Index ...,........................... 19-35
SystemDescription ................. ........... 19-36
ABSIndicator CircuitTroubleshooting ......................19-52
BrakeSystemIndicator Circuit
T r o u b l e s h o o t i n. .g. . . . . . . . . . . . . . . . . . . . . . . . . .1. 9 - 5 5
ABSModulator-Control UnitRemovaland
lnstallation ............. 19-57
WheelSensorInsoection ...................19-59
WheelSensorReolacement .............. 19-59

ABSGomponents
ComponentLocationIndex (
RIGHT-REARWHEELSENSOR
page19-59
Inspection,
UNDER.OASH
FUSE/RELAY
BOX
UNDER.HOOD
FUSE/RELAY
BOX
\L
LEFT.REAR
WHEELSENSOR
DATA LINKCONNECTOR
I16PI
RIGHT.FRONT WHEELSENSOR
ABSMODULATOR.CONTROL UNIT
page19'57
andInstallation,
Removal LEFT-FRONTWHEELSENSOR
page19-59
Inspection,
Replacement,page1959
19-30
GeneralTroubleshootingInformation
ABS Indicator DiagnosticTroubleCode{DTCI
. lf the system is OK,theABS indicatorgoes off 2 . The memory can hold three DTCS.However,when
secondsafter turning the ignition switch ON (ll) the same DTCis detectedmore than once,the more
without startingthe engine,and then comes on again recentDTCis written over the earlierone.
and goes off 2 secondslater after startingthe engine. Therefore,when the same problem is detected
This occursbecausethe ABS control unitisturned repeatedly,it is memorizedas a single DTC.
on by the lG2 power source. . The DTCsare in the order they occurred,beginning
. The ABS indicatorcomes on when the ABS control with the most recent.
unit detectsa problem in the system.However,even . The DTCSare memorizedin the EEPROM(non-
though the system is operatingproperly,the indicator volatile memory).Therefore.the memorizedDTCs
will come on underthese conditions: are not clearedwhen the batteryis disconnected,the
- Only the drive wheels rotate ignition switch is turned off, or the system returnsto
- One drive wheel is stuck normal. Do the specifiedproceduresto clearthe
- The vehiclegoes into a spin DTCs.
- The ABS continuesto operatefor a long time.
- The vehicleis subjectedto an electricalsignal Self-diagnosis
disturbance
. Self-diagnosiscan be classifiedinto two categories:
To determinethe actualcauseof the problem,question - I n i t i ad
l iagnosis:
the customeraboutthe problem.taking the above Done right after the enginestarts and until the ABS
condilionsinto consideration. indicatorgoes off
- R e g u l ad r iagnosis:
. When a Droblemis detectedand lhe ABS indicator D o n er i g h t a f t e r t h ei n i t i a d
l i a g n o s i su n t i lt h e
comes on, there are caseswhen the indicatorstays ignition switch is turned OFF
on until the ignition switch is turned OFF,and cases . When a problem is detectedby self-diagnosis, the
when the indicatorgoes off automaticallywhen the system does the following:
sYstemreturnsto normal. - Turnsthe ABS indicatoron
- DTC61: The ABS indicatorgoes off automatically - Memorizesthe DTC
when the system returnsto normal. - StopsABS control
- D T C1 1 ,1 3 , 1 5 , 1 7, 3 1 , 3 2 , 3 3 ,3 4 ,3 5 ,3 6 ,3 7 ,3 8 ,5 4 ,
or 81: The ABS indicatorstayson until the ignition Kickback
switch is turned OFFwhether or not the system
returnsto normal. The pump motor operateswhen the ABS is functioning,
- D f C 1 2 ,1 4 ,1 6 ,1 a , 2 1 , 5 1 , 5 2o, r 5 3 ;T h e A B S and the fluid in the reservoiris forced out to the master
indicatorgoes off when the vehicleis driven again k t t h e b r a k ep e d a l .
c y l i n d e rc, a u s i n gk i c k b a c a
and the system is OK afterthe ignition switch is
t u r n e df r o m O F Ft o O N { l l } . PumpMotor
. The pump motor operateswhen the ABS is
functioning.
. The ABS control unit checksthe pump motor
operationwhen the vehicleis startedthe first time
after the ignition switch is turned ON (ll).You may
hearthe motor operateat this time, but it is normal.
(cont'd)
19-31
ABSComponents
GeneralTroubleshootingInformation(cont'd)
How to TroubleshootABS DTCs 2 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n df o l l o wt h e
prompts on the PGM Testerto displaythe DTC{S)
The troubleshootingflowchartproceduresassumethat on the screen.After determiningthe DTC,referto
the causeof the oroblem is still Dresentand the ABS the DTCTroubleshootingIndex.
indicatoris still on. Followingthe flowchartwhen the
ABS indicatordoes not come on can resultin incorrect NOTE:Seethe HondaPGM Testeruser'smanual
diagnosis. for specificinstructions.
The connectorillustrationsshow the female terminal
connectorswith a singleoutline and the male terminal Service Check Signal (SCS)Circuit Method:
connectorswith a double outline. 1. With the ignition switch OFF,connectthe Honda
PGM Tester(A)to the 16Pdata link connector(DLC)
1. Ouestionthe customeraboutthe conditionswhen (BI underthe driver'sside of the dashboard.
the problem occured,and try to reproducethe
same conditionsfor troubleshooting.Find out
when the ABS indicatorcame on, such as during
ABS control,after ABS control,when the vehicle
was at a certainspeed,etc.
2. When the ABS indicatordoes not come on during

the test-drive,but troubleshootingis done basedon
the DTC,checkfor looseconnectors.poor terminal
contact,etc.,beforeyou starttroubleshooting.
3. After troubleshooting,clearthe DTC,disconnectthe

HondaPGM Tester.and test-drivethe vehicle.
Make sure the ABS indicatordoes not come on.
How to RetrieveABS DTCs

2. Short the SCScircuitto body ground usingthe
Honda PGM Tester Method: HondaPGM Tester.
1, Wjth the ignition switch OFF,connectthe Honda
PGMTester(A)to the 16Pdata link connector(DLC) 3. Turn the ignition switch ON (ll).
(B) under the driver'sside of the dashboard.
19-32
4. The blinkingfrequencyindicatesthe DTC.DTCSare How to ClearABS DTCs
indicatedby a seriesof long and short blinks.One
l o n gb l i n ke q u a l s1 0 s h o n b l i n k s A
. d d t h e l o n ga n d Honda PGM Tester Method:
short blinkstogetherto determinethe DTC.After 1. With the ignition switch OFF,connectthe Honda
determiningthe DTC,referto the DTC P G MT e s t e r( A ) t o t h e l 6 P d a t a l i n kc o n n e c t o (r D L C )
T r o u b l e s h o o t i nI gn d e x . { B }u n d e rt h e d r i v e r ' ss i d eo f t h e d a s h b o a r d .
NOTE:
. lf the DTCis not memorized,the ABS indicator
will go off for 3.6 seconds,and then come back
on.
. lf the ABS indicatorstayson, troubleshootfor
"ABS indicator
does not go off" (seestep 1 on
page 19-53).
Th€ system will not indicate the DTC unless these

conditions are met:
. The brakepedal is not pressed.
. The ignitionswitch is turned ON {ll).
. The SCScircuitis shortedto body ground before
t h e i g n i t i o ns w i t c hi s t u r n e dO N ( l l ) .
Example
ot DTC15
Short blinks T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d c l e a r t h e
Long blink {five timesl DTC(s)by following the screenprompts on the
PGM Tester.
NOTE:Seethe HondaPGl\4Testeruser's manual

for sDeclfic instructions.
Cycling the lgnition Switch Method:

Examole of DTC 22 C l e a rt h e D T Cb y t u r n i n gt h e i g n i t i o ns w i t c hO N ( l l )t h e n
Long blinks (two times) O F Fa t l e a s t2 0 t i m e s .
5 . Turn the ignition swltch OFF,
Disconnectthe HondaPGM Testerfrom the DLC.
19-33
ABSGomponents
DTC:11 Rioht-frontwheel sensor{ooen/shortto bodv qround/shortto power) (seeoaoe 19-45)
DTC:12 Faultv riqht-frontwheel sensoroulse siqnal {seeoaoe 19-46)
DTC:13 Left-frontwheel sensor{oDen/shortto bodv qround/shortto power) (seeoaqe 19-45)
DTC:14 Faultvleft-frontwheel sensorDulsesrqnal (seepaqe 19-46)
DTC;15 Riqht-rearwheel sensor(oDen/shortto bodv qround/shortto power) (seeDaqe19-45)
DTC:16 F a u l t vr i q h t - r e awr h e e ls e n s o ro u l s es i q n a l (seepaqe 19-46)
DTC:17 Left-rearwheel sensor (open/shortto bodv qround/shortto power) (seeDaoe'19-45)
DTC:18 Faultvleft-rearwheel sensorDulsesiqnal (seeDaqe'19-46)
Drc:2l C o n t i n u o uo s D e r a t i o (nc h i o D e D
d ulser) (seepaqe 19-47)
DTC:3'l Solenoid (seeDaoe19-48)
DTC:32 Solenoid { s e eD a q e1 9 - 4 8 )
DTC:33 Solenoid {seeDaoe19'48)
DTC:34 Solenoid lsee oaqe 19-48)
DTC:35 Solenoid (seepaqe 19-48)
DTC;36 S ol en oi d (seeDaqe19-48)
DTC:37 S ol en o i d (seeDaqe19-48)
DTC:38 S o l en oi d (seeDaoe19-48)
DTC:51 lvlotor Iocked ( s e eD a q e1 9 - 4 8 )
DTC:52 lvlotor stuck off (seeDaoe19-49)
DTC:53 lMotorstuckon (seeDaoe19-50)
DTC:54 Main relav stuckoff ( s e ep a q e1 9 - 5 1
DTC:61 lG2 voltaqe { s e eo a q e1 9 - 5 ' l
DTC:81 cPU (CentralProcessinqUnit) {seepaqe 19-52)
19-34
Symptom Troubleshooting Index
Symptom Diagnostic procedure Also check for
ABS indicatordoes nol come on ABS IndicatorCircuitTroubleshooting(seepage
19-52)
ABS indicatordoes not go off and no ABS IndicatorCircuitTroubleshooting{seestep 1
ABS DTCis stored on Daqe19-53)
Brakesystem indicatordoes nol come BrakeSystem lndicatorCircuitTroubleshooting
on (seepaqe 19-55)
Brakesystem indicatordoes not go off BrakeSystemIndicatorCircuitTroubleshooting
and no ABS DTCis stored (seesteo1 on Daqe19-55)
19-35
ABS Gomponents
SystemDescription
ABSControlUnit Inputsand Outputsfor 31PConnector
1 2 4 5 6 7 B I 1112 1 41 5
20 ?1/t/t/l/t/
1 6 1 1 1B 1 9
Terminal Wire Terminal

sign Description Measurement
number color Terminals Conditionsllgnition Voltage
switch ON (ll))
BLU/ RRS Detects
righfrear
YEL wneetsensor
GRN/ (+)
RRS srgnal
YEL
BLU F R S( - ) Detectsright-front ;a-_-l S p i nw h e e l a t AC:0.053V or
wneetsensor I turn/second above
srgnal
5 GRN/ F R S( + ) Wheel Oscilloscope
BLK 0 . 1 5V p - po r
above
6 BRN/ F L S( _ ) Detectsleft-front 6-7
WHT wneetsensor
7 BLU/ F L S{ + ) srgnal
ORN
8 GRY/ R L SH Detectsleft-rear 8 9
RED wneetsensor
9 YEU R L S( + ) srgnal
RED
11 LT BLU DIAG K Communications
with HondaPGM
rester
12 BRN DIAG L DTCindication
19-36
Terminal Wire Terminalsign Description Measurement
number color Terminals Conditions {lgnition Voltage
switch oN lll))
14 WHT/ STOP Detectsbrake I 4 - GN D Brakepedal Pressed Eattery
BLK switchsiqnal Released voltaoe
t5 BLV rG2 Powersourcefor 15-GND Baftery
ORN activating
the voltage
svstem
16 BLK M-GND Groundforthe 16-GND Below
0.3V
0umD motor
WHT/ + B-MR Powersourcefor 17-GND Atalltimes Battery
RED the oumDmotor voltaoe
18 WHT/ + B-FSR ,18-GND
Powersourcefor Atalltimes Battery
GRN thevalverelav voltaoe
'19 BLK GND Groundfor the 19.GND Below
0.3V
modulator
assemDtv
20 BLU/ ABS DrivesABS 20-GND ABS ON A b o u t1 1V
RED indicator indicator OFF Below 1 V
BRN/ EBD Drivesbrake 2 1 - G N D Brakesystem OFF Below0.3V
YEL (Electronic
brake systemindicator indicator ONfor 8attery
distribution) bulb voltage
cnecK
( c o n t ' d)
19-37
ABS Gomponents
SystemDescription(cont'd)
Features
When the brakepedal is pressedduring driving,the wheels can lock beforethe vehiclecomesto a stop. In such an
event.the maneuverabilityof the vehicleis reducedif the front wheels are locked,and the stabilityof the vehicleis
reducedif the rearwheels are locked,creatingan extremelyunstablecondition.The ABS preciselycontrolsthe slip
rate of the wheelsto ensuremaximum grip force from the tires,therebyensuringthe maneuverabilityand stabilityof
thevehicle.
The ABS calculatesthe slip rate of the wheels basedon the vehiclespeedand the wheel speed,then it controlsthe
brakefluid pressureto reachthe target slip rate.
Grip Force of Tire and Road Surface
TARGETSLIPRATE
OF
COEFFICIENT
FRICTION
SLIPRATE
19-38
ABSControlUnit
Main Control
The ABS control unit detectsthe wheel speed basedon the wheel sensorsignal it received,then it calculatesthe
vehiclespeed basedon the detectedwheel speed.The control unit detectsthe vehiclespeedduring deceleration
basedon the rate of deceleration.
The ABS control unit calculatesthe slip rate of eachwheel and transmitsthe control signalto the modulatorunit
solenoidvalve when the slip rate is high.
The pressurereductioncontrol hasthree modes: pressurereducing,pressureretaining,and pressureintensifying.
T---
Self-diagnosisFunction
1 . T h e A B S c o n t r ou ln i t i s e q u i p p e d w i t h a m a i n C P U a n d a s u b - C P U . E a c h C P U c h e c k s t h e o t h e r f o r p r o b l e m s .
2. The CPUScheckthe circuitof the system.
3 . T h e A B S c o n t r oul n i t t u r n so n t h e A B S i n di c a t o rw h e n t h e u n i t d e t e c t s ap r o b l e ma n d t h e u n i ts t o p st h e s y s t e m .
4. The self-diagnosiscan be classifiedinto thesetwo categories:
. l n i t i a ld i a g n o s i s
. R e g u l ad r iagnosis
On-boardDiagnosisFunction
The ABS can be diagnosedwith the Honda PGM Tester.
The ALB Checkercannot be usedwith this system.For air bleedingand checkingwheel sensorsignals.usethe Honda
PGM Tester.Seethe Honda PGMTesteruser's manualfor specificoperatinginstructions.
(cont'd)
19-39
ABSComponents
SystemDescription(cont'd)
ABSModulator
The ABS modulatorconsistsof the inlet solenoidvalves,outlet solenoidvalves,reservoir,pump, pump motor, and the
damping chamber.The modulator reducesthe caliperfluid pressuredirectly.lt is a circulating-typemodulator
b e c a u s e t h eb r a k e f l u i d c i r c u l a t e s t h r o u g h t h e c a l i p e r , r e s e r v o i r , a n d t h e m a s t e r c y l i n d e r . T h e h y d r a u l i ch caos n t r o l
three modes:pressureintensifying,pressureretaining,and pressurereducing.The hydrauliccircuitis an independent
four-channeltype o ,n e c h a n n efl o r e a c hw h e e l .
Pressureintensifyingmode: Inletvalveopen,outlel valve closed

M a s t e rc y l i n d e fr l u i d i s p u m p e do u t t o t h e c a l i p e r .
Pressureretainingmode: lnlet valve closed,outlet valve closed

Caliperfluid is retainedby the inlet valve and outlet valve.
Pressurereducingmode: Inletvalve closed,outlet valve open

Caliperfluid flows through the outlet valveto the reservoir.
lvlotoroperationmode: When startingthe pressurereducingmode,the pump motor is ON.

When stoppingABS operation,the pump motor is OFF.
T h e c a l i p e rf l u i d i s p u m p e do u t b y t h e p u m p ,t h r o u g ht h e d a m p i n gc h a m b e rt,o t h e
m a s t e rc v l i n d e r .
19-40
t
WheelSensors
The wheel sensorsare the magneticcontactlesstype. As the gear pulserteeth rotate pastthe wheel sensor'smagnetic
coil, AC current is generated.The AC frequencychangesin accordancewith the wheel speed.The ABS control unit
detectsthe wheel sensorsignalfrequencyand therebydetectsthe wheel speed.
GEARPULSER
WHEELS€NSOR .r HIGXSPEED
!t LOW SPEED
Wheel Speed and Modulator Control
VEJ!q!ESPEEq
8E!EEETqE
PRESSURE
OUTLET
VALVE 9p
OFF
INLET
VALVE oN
OFF
MoroR I
-,. l
t l
OFF
When the wheel speeddrops sharplybelow the vehiclespeed,the inlet valve closesand il necessary,the outlet valve
opens momentarilyto reducethe caliperfluid pressure.The pump motor startsat this time. As the wheel speed is
restored,and the outlet valve closes,the inlet valve opens momentarilyto increasethe caliperfluid pressure.
19-41
ABSGomponents
CircuitDiagram
"'-----
G50l
L "*'*" lJ5 Il
rI * *r +' tl ? l
I ^ lo+-sN
Gu csl LqF**,
19-42
*- :ffrre, *-
riq.r.srbm r.l q_ md/Y4

I L
7--:::
19-43
ABSComponents
CircuitDiagram(cont'd)
UNDER-HOOD
FUSE/RELAY
BOXCONNECTORS BRAKEPEDALPOSITION
CONNECTOR
CONNECTOR
A {12P)
{12P) CONNECTOR
B {2P} SWITCH4PCONNECTOR
UNDER.DASH
FUSE/RELAY
BOXCONNECTORS MULTIPLEXCONTROL
CONNECTOR
I {5P) CONNECTOR
K I17P) UNIT13PCONNECTOR
1l2l3l,/15 1 2 3 4 5 67 1 2 3 ,/ ,/
8 1011121 31 415 1 1 6 7 8 9 10 11n213
GAUGEASSEMBLYCONNECTORS
CONNECTOR
A I22P) CONNECTOR
B I22PI
ABSCONTROL
UNIT3IP CONNECTOR q,
1 2 4 5 6 7 8 I 1112 1 415
20 21/1,/1,/vl,/l
16 1 1 1 8 1 9
/t,/t/t,/t/
OATA LINK CONNECTOR{16P) WHEELSENSOR2PCONNECTORS

FRONT
J --T:-l L
'lt L_.:-:J
q t t / ) l
\-r-----Tr' r
e:l
Terminalside of femaleterminals RIGHT.REAR LEFT-REAR
tslTt?t /J 1T-1\
I tL | \t rlziJ
T e r m i n asl i d eo f m a l el e r m i n a l s
19-44
DTCTroubleshooting
DTC11,13,15,17:WheelSensor 5. Checkfor continuitybetweenthe appropriate
(Open/Short to Power)
to BodyGround/Short wheelsensor(+ ) circuitterminalandbodyground
{ s e et a b l e ) .
1. Disconnectthe ABS control unit 31Pconnector.
DTC Appropriate Terminal
2. Start the engine. 11 (Riqht-front) N o .5 : F R S( + )
13(Left-front) N o . 7 : F L S( * )
3. Measurethe voltagebetweenthe appropriate 1 5( R i o h t - r e a r ) No.2R : R S( * )
w h e e ls e n s o r( * ) c i r c u i t t e r m i n a lo f t h e A B S 17(Left-rear) N o . 9R L S( + l
control unit 31Pconnectorand body ground (see
table).
ABS CONTROLUNIT31PCONNECTOR
DTC ADpropriate Terminal
11(Rioht-front) N o . 5 :F R S( t )
13(Left-front) N o , 7 : F L S( * )
15 {Riqht-rear} N o .2 : R R S( * )
17 (Left-rear) N o . 9R t S( f )
ABS CONTROLUNIT 31P CONNECTOR
F R S{ + I I G N R / B L K } F L SI + I ( B L U
R R S{ + )
(GNR/YEL)
s i d eof femaleterminals
W i r eside
Wire
\ ls therecontinuity?
YES Goto step6.
NO-Go to step7.
Disconnectthe harness2P connectorfrom the
ls thete battery voltage? appropriatewheel sensor,then checkfor continuity
b e t w e e nt h e 1 + ) a n d ( ) t e r m i n a l so f t h e h a r n e s s
YES Repairshort to power in the (+) circuitwire and body ground.
betweenthe ABS modulator-controlunit and the
appropriatewheel sensor.I ls there continuity?
NO Go to step 4. Y E S - R e p a i rs h o r t t o b o d y g r o u n di n t h e ( + ) o r { )
circuitwire betweenthe ABS modulator-control
4. Turn the ignition switch OFF. unit and the wheel sensor.l
NO Repiacethe wheel sensor.l
(cont'd)

19-45
ABS Components
7. Checkthe resistancebetweenthe appropriate DTC12,14,
16,18:WheelSensorPutse
w h e e ls e n s o r( + ) a n d ( ) c i r c u i t e r m i n a l s{ s e e Signal
ta ble).
NOTE:lf the ABS indicatorcomes on for the reasons
DTC Appropriate Terminal describedbelow,the indicatorgoes off when you test-
l+) Side *lSide d r i v et h e v e h i c l ea t 3 1 m p h ( 5 0k m / n l .
11 {Riqht-front) N o . 5 :F R S( * ) N o . 4 : F R1S- )
'13
{Left-front) N o .7 : F L S{ + i N o . 6F: L S( - . Only the drive wheel rotated
1 5( R i o h t - r e a r ) No.2:RBS {+) N o .1 : R B S (-) . T h e v e h i c l es p u n
17 (Left-rear) N o . 9 :R L S1 - N o . 8B : L S( - . Electricalnoise
1 . V i s u a l l yc h e c kf o r a p p r o p r i a t w
e h e e ls e n s o r a n d
ABS CONTROLUNIT31PCONNECTOR pulserinstallationand condition(seetable).
DTC Appropriate Wheel Sensor

12 Riqht-front
14 Left-front
Riqht-rear
18 Left-rear
Ate they installed correctly and not damaged?
YES-Go to step 2,
NO Reinstallor replacethe appropriatewheel
s e n s o ro r p u l s e r , I \\|D
Is the rcsistance between 450 2,000 A ?
YES Checkfor a looseABS control unit3lP
connector.lf necessary.substitutea known-good 3 . Measurethe resistancebetweenthe appropriate
ABS modulator-controlunit, and recheck.l w h e e ls e n s o r( f ) a n d ( ) c i r c u i t e r m i n a l s( s e e
table).
NO Go to step 8.
DTC Appropriate Terminal
Disconnectthe harness2P connectorfrom the l*) Side ) Side
appropriatewheel sensor,and checkthe resistance 12 {Rioht-front) N o . 5 : F (B*S No.4:FBS
b e t w e e nt h e ( + ) a n d { ) t e r m i n a l s o ft h e w h e e l 14 (Left-front) N o . 7 ; F Ll *S No,6:FLS
sensor. 1 6( R i q h t . r e a r ) N o . 2R: R(S* N o1
. :BRS
18 (Left-read N o . 9B: L S1- No.8:RLS
ls the resistance between 450- 2,000 Q ?
Y E S - R e p a i ro p e ni n t h e ( + ) o r ( - ) c i r c u i tw i r e ,o r
short betweenthe (+) circuitwire and the { )
circuitwire betweenthe ABS modulator-control
u n i ta n d t h e w h e e ls e n s o r . l
NO Replace
t h e w h e e ls e n s o r . l
ls therc less than 450 Q ?
YES Go to step 1.
19-46
4. Checkfor continuitybetweenthe appropriate DTC21:Continuous (Chipped
Operation
w h e e ls e n s o r( + ) c i r c u i t t e r m l n aal n d o t h e r w h e e l pulser)
s e n s o r( + ) c i r c u i t e r m i n a l s( s e et a b l e ) .
1. Clearthe DTC,then disconnectthe HondaPGM
DTC Appropiate Other Terminal tesler.
Terminal
12 No.5: No.7 No.2 No.9 2. Test-drivethe vehicleat 19 mph (30 km/h)or more.
F R W( * i
'14 No.5 No.2 No.9 Doesthe ABS indicator come on and is DTC 21
No.7:
FLWIT.) indicated?
to No.2; No.5 No.7 No.9
RRW(T-) YES Go to step 3.
18 No.9: No.5 N o .7 No.2
R L W( * ) NO The system is OK at this time.l
ls there continuity? 3. Checkthe pulsergear for a chippedtooth.
YES Repairshort in the wires betweenthe ls the pulser OK?

appropriatewheel sensorand the other wheel
s e n s o rh a r n e s s e s . l YES Checkfor a looseABS control unit 31P
connector.lf necessary,substitutea known-good
NO Clearthe DTC,disconnectthe Honda PGM ABS modulator-controlunit, and recheck.l
Tester,and test-drivethe vehicle.lf the ABS
indicatorcomes on and the same DTCis indicated, NO Replacethe driveshaftor hub unit (chipped
replacethe ABS modulator-controlunit.l p u l s e rg e a r ) . 1
Disconnectthe harness2P connectorfrom the

appropriatewheel sensorand checkthe resistance
b e t w e e nt h e ( + ) s i d ea n dt h e ( - ) s i d eo f t h e w h e e l
sensor.
ls there lessthan 450 Q ?
YES Replacethe wheel sensor.
NO- Repairshort to wire betweenthe appropriate

w h e e ls e n s o r( + ) a n d ( - ) c i r c u i t s . l
1g-47
ABSComponents
DTC31,32.33,34,35,36,37,38:Solenoid DTC51:Motor Locked
1. Clearthe DTC,thendisconnect
the HondaPGN4 '1.
C h e c kt h e N o . 1 0 ( 4 0 A ) f u s ei n t h e u n d e r - h o o d f u s e /
Tester. retayDox.
2. Test-drive
thevehicle. ls the tuse OK?
Doesthe ABSindicator comeon and are DTCs 31, YES-Reinstall the fuse, and go to step 2.
32, 33, 34, 35, 36, 37, 38 indicated?
NO- Replacethe fuse, and recheck.l
YES Replace
theABSmodulator-control
unit.t
NO Thesystemis OKat thistime.t
3. Measurethe voltagebetweenthe ABS control unit
3 1 Pc o n n e c t otre r m i n a lN o . 1 7a n d b o d y g r o u n d .
I
ls thete battery voltage?
YES Go to step 4.
NO Repairopen in the wire betweenthe N o . 1 0

(40A)fuse and the ABS control unit.l
19-48
4. Checkfor continuitybetweenthe ABS control unit DTG52:MotorStuckOFF
31P connectorterminal No. 16 and body ground.
1 . C h e c tkh eN o .1 0 ( 4 0 Af )u s ei n t h eu n d e r - h o o d
fuse/relay box.
ls thef useOK?
YES-Reinstall the fuse, and go to step 2.
NO-Replace the fuse, and recheck.l|
3 . Measurethe voltage betweenthe ABS control unit

Wire side of femaleterminals 3 1 Pc o n n e c t otre r m i n a lN o . 1 7 a n d b o d y g r o u n d
UNIT31PCONNECTOR
ABSCONTROL
YES-Go to step 5.
NO Repairopen in the wire betweenthe ABS

control unit and body ground (G202).1
Reconnectthe ABS control unit 31Pconnector.
6. Clearthe DTC,then disconnectthe HondaPGM

tester. Wire side of femaleterminals
7 . Test-drivethe vehicleat 6 mph (10 km/h) or more.

Doesthe ABSindicator come on, and is DTC 51
indicated? YES-Go to step 4.
YES Replacethe ABS modulator-controlunit.l NO Repairopen in the wire betweenthe N o . 1 0

(40A)fuse and the ABS control unit.l
NO The system is OK at this time.l
(cont'di
19-49
ABS Components
4. Checkfor continuitvbetweenthe ABS control unit DTC53:MotorStuckON
3 1 Pc o n n e c t otre r m i n a lN o . 1 6 a n db o d y g r o u n d .
1 . C l e a rt h e D T C t, h e n d i s c o n n e ct th e H o n d ap GM
ABSCONTROL
UNIT31PCONNECTOR Tester.
2. Test-drivethe vehicle.
Does the ABS indicatot come on and is DTC 53

indicated?
YES -Go to step 3.
NO- lntermittentfailure,the system is OK at this

trme.l
3 . Disconnectthe ABS control unit 31Pconnector.
ls there continuity? Checkfor continuitybetweenthe ABS control unit

3 1 Pc o n n e c t otre r m i n a lN o , 1 6 a n d b o d y g r o u n d .
YES-Check for looseterminalsin the ABS control
unit 31Pconnector.lf necessary,substitutea
ABSCONTROL
UNIT3,IPCONNECTOR
known-goodABS modulator-controlunit, and
recheck.l
NO Repairopen in the wire betweenthe ABS

c o n t r o lu n i ta n d b o d y g r o u n d( G 2 0 2 ) . 1
YES-Replacethe ABS modulator-controlunit.t
NO-Repair open in the wire betweenthe ABS

c o n t r o lu n i ta n d b o d y g r o u n d( G 2 0 2 ) . I
19-50
DTC54:MainRelayStuckOFF DTC61:lG2Voltage
1 . C h e c k t h eN o . 8 ( 2 0 A )f u s e i n t h e u n d e r - h o o fdu s e / : h e c kt h e N o . 1 1 ( 7 . 5 A f)u s e i n t h e u n d e r - d a s h
N O T EC
f u s ei f i t i s O K .
r e l a yb o x ,a n d r e i n s t a l l t h e fuse/relaybox beforetroubleshooting.
ls the f use OK? 1 . C l e a rt h e D T C ,t h e n d i s c o n n e ct th e H o n d aP G M

tesler.
YES-Go to step 2.
2. Test drive the vehicle.
NO Replacethe fuse, and recheck.l
Doesthe ABS indicator come on and is DTC 61
2. Disconnectthe ABS control unit 31Pconnector. indicated?
3. l\4easure the voltagebetweenthe ABS control unit YES Go to step 3.

c o n n e c t otre r m i n a lN o . 1 8 a n d b o d y g r o u n d .
NO The system is OK at this time.l
ABSCONTROL
UNIT31PCONNECIOR
t e A B S c o n t r o lu n i t 3 l P c o n n e c t o r .
5. Measurethe voltage betweenthe ABS control unit

3 1 Pc o n n e c t o r t e r m i n aNl o . 1 5 a n d b o d y g r o u n d .
UNIT31PCONNECTOR
ABSCONTROL
Is there battety voltage?
YES Replacethe ABS modulator-controlunit.l

control unit and the under-hoodfuse/relaybox.I
NO - Repairopen in the wire betweenthe ABS

control unit and the under-hood{use/relaybox.l
19-51
ABSComponents
DTCTroubleshooting(cont'd) ABS IndicatorGircuit
Troubleshooting
DTC81:CPU(Central
Processing
Unit)
1. Clearthe DTC,then disconnectthe HondaPGM ABS indicator does not come on
Tester.
1 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d w a t c ht h e A B S
2. Test-drivethe vehicle. indicator.
Does the ABS indicator come on and is DTC 81 Does the ABS indicator come on?
indicated?
YES The system is OK at this time.I
NO Go to step 2,
NO-The system is OK at this time. t
Pull up the parkingbrakelever.
Does the btake system indicator come on?
YES Go to step 3.
NO Repairopen in the indicatorpower source

circuit.lf necassary,substitutea known-goodABS
modulator-controlunit, and recheck.I
. Blown No, 10 (7.5A)fuse.
. O p e ni n t h e w i r e b e t w e e nt h e N o . 1 0 ( 7 . 5 A ) f u s e
a n dl h e g a u g ea s s e m b l y ,
. Open circuitinsidethe fuse box.
Disconnectthe ABS control unit 31Pconnector.
5. T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
Does the ABS indicator come on?
YES-Check for looseterminalsin the ABS control

unit 31Pconnector.lf necessary,substitutea
known-goodABS modulator-controlunit, and
recheck.l
NO Go to step 6.
7 . Removethe gauge assembly(seepage 22-64).
19-52
8 . Disconnectthe gaugeassemblyconnectorA (22P). ABS indicator does not go off
9 . Checkfor continuitybetweengauge assembly 1. ChecktheNo.8 (20Alfusein the under-hood fuse/
connectorA {22P)terminal No, 12 and body ground. relaybox,andreinstallthefuseif it is OK.
A (22P) ls the fuse OK?

GAUGEASSEMBLY
CONNECTOR
YES Goto step2.
NO-Replacethefuse,andrecheck. lf thefuseis
blown,checkfor a shonto bodygroundin thisfuse
circuit.ll thecircuitis OK,replacetheABS
modulator-control unit.I
Checkthe No. 11 (7.5A)fuse in the under-dash

fuse/relaybox, and reinstallthe fuse if it is OK.
ls the f use OK?
ls there continuity? YES Go to step 3.
YES- Repairshon to body ground in the wire NO Replacethe fuse, and recheck.If the fuse is
betweenthe gaugeassemblyand the ABS control blown, checkfor a shortto body ground in this fuse
unit.l circuit.lf the circuit is OK, replacethe ABS
modulator-controlunit.I
NO Go to step 10.
3 . Disconnectthe ABS control unit 31Pconnector.
'10.Disconnectthe gaugeassemblyconnectorB (22P).
Measurethe voltage betweenterminal No. l8 and
1 1 .Checkfor continuitybetweengauge assembly body ground.
connectorB (22P)terminal No. 12 and body ground.
UNIT3lP CONNECTOR
A8S CONTROL
GAUGEASSEMBLY B (22PI
CONNECTOR

Wiresideol Iemaleterminals

YES-Go to step 5.
YES Checkfor looseterminalsin the gauge
assemblyconnectors.lf the connectorsare OK, NO Repairopen in the wire betweenthe No. 8
replacethe gaugeassembly.l (20A)fuse and the ABS control unit.l
NO Repairopen in the wire betweenthe gauge

a s s e m b l ya n d b o d y g r o u n d( G 5 0 1 ) . 1
(cont'd)

19-53
ABSComponents
ABS IndicatorCircuitTroubleshooting(cont'dl
5. Turn the ignitionswitch ON (ll). 10. Connectthe ABS control unit3lPconnector
t e r m i n a lN o . 2 0 a n d b o d y g r o u n dw i t h a j u m p e r
6 . Measurethe voltage betweenthe ABS control unit wire.
31PconnectorterminaI No. 15 and body ground.
ABSCONTROL
UNIT3IP CONNECTOR ABSCONTROLUNIT31PCONNECTOR
Wire side of femaleterminats
Wiresideof femaleterminals Does the ABS indicator go off?
Is there battety voltage? YES-Check for looseterminalsin the ABS control

unil 31Pconnector.lf necessary,substitutea
YES-Go to step 7. known-goodABS modulator-controlunit, and
recheck.I
NO-Repair open in the wire betweenthe No. 11
(7.5A)fuse and the ABS control unit.I NO Go to step 11.
'l '1. \
1 . Turn the ignition switch OFF. Removethe gaugeassembly,and leavethe
connectorsconnected.Connectthe gauge
8 . Checkfor continuitybetweenthe ABS control unit r ( 2 2 P t)e r m i n a lN o . ' 1 2a n d
a s s e m b l yc o n n e c t oA
31Pconnectorterminal No. 19 and body ground. body ground with a jumper wire.
ABSCONTROL
UNIT31PCONNECTOB GAUGEASSEMBLY A (22P)
CONNECTOR
Wire side ot Iemaleterminals Wiresideof femaleterminals
ls there continuity? Does the ABS indicator go off?
YES Go to step 9. YES-Repair open in the wire betweenthe gauge

a s s e m b l ya n d t h e A B S c o n t r o lu n i t . I
control unit and body ground (G202).t NO-Check for loosegauge assemblyconnectors.
lf the connectorsare OK, replacethe printedcircuit
9 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) . b o a r di n t h e g a u g ea s s e m b l y . l
19-54
BrakeSystemIndicatorGircuitTroubleshooting
Brakesystem indicator does not come on Brakesystem indicatordoes not go off
'1. 1 . T u r nt h e i g n i t i o ns w i t c hO N { l l ) .
Disconnectthe m ultiplexcontroI unit l3Pconnector
and the ABS control unit 31Pconnector.
t h e p a r k i n gb r a k e .
2. Release
2. Checkfor continuitybetweenthe ABS control unit
3 l P c o n n e c t otre r m i n a lN o , 2 1 a n d b o d y g r o u n d . Does the brake system indicatot go ofl after
several seconds?
YES The system is OK at this time.l
NO Go to step 3.
3. Checkthe brakefluid level.
ls the level OK?
YES Go to step 4.
Wire side of femaleterminals NO Refillthe brakefluid, and recheck.l
4. Checkthe ABS indicator.

Does the ABS indicator stay on?
YES Repairshort to body ground in the wire
betweenthe multiplexcontrol unit and the ABS YES Readthe ABS DTC(seestep 1 on page 19-32).
c o n t r o lu n i t . l and do the applicabletroubleshootingfor the DTC
NO Go to multiplexcontrol system NO Go to step 5.

trou bleshootinglsee page 22''172).a
t e A B S c o n t r o lu n i t 3 l P c o n n e c t o r .
7 . C o n n e ctth e A B S c o n t r o lu n i t3 1 Pc o n n e c t o r
t e r m i n a lN o . 2 1 a n d b o d y g r o u n dw i t h a j u m p e r
W i r es r d eo f l e m a l el e r m i n a l s
(cont'd)

19-55
ABSComponents
BrakeSystemIndicatorGircuitTroubleshooting(cont'd)
8 . Turn the ignititonswitch ON (ll).
9 . Checkthe brakesystem indicator.
Does the brake system indicatot go off?
YES-Replace the ABS modulator-controlunit.l
NO-Go to step 10.
1 1 .Connectthe multiplexcontrol unit 13Pconnector

'l
t e r m i n a lN o . a n d b o d y g r o u n dw i t h a j u m p e rw i r e .
MULTIPLEX
CONTROL
UNIT13PCONNECTOR
JUMPER
WIRE
\
1 3 .Checkthe brakesystem indicator.
Does the btake system indicatot go off?
YES Repairopen in the wire betweenthe

multiplexcontrol unit and the ABS control unit.l
NO Go to multiplexcontrol system
troubleshooting (seepage22-172).a
19-56
ABS Modulator-ControlUnit Removaland lnstallation
NOTE:
. D o n o t s p i l lb r a k ef l u i d o n t h e v e h i c l e i;t m a y d a m a g et h e p a i n Ui f b r a k e f l u i d g e t s o n t h e p a i n t , w a s h i t o f f
. Becarefulnot to damageor deform the brakelines during removal and installation.
. To preventthe brakefluid from flowing, plug and cover the hose ends and joints with a shop towel orequivalent
malenal.
Removal
'1.
2 . P u l lu p t h e l o c k ( A )o f t h e A B S c o n t r o u
l nit3lPconnector(B),thendisconnecttheconnector.
FLARENUT
l5 N.m (1.5kgt.m,11lbt.ftl
6)o
CI I mm NUT
8.8N.m {0.9kgl m.6.5lbfft)
\.
--/Q \,
\---'
6 mm BOLT
9.8N.m
11.0ksf.m,7.2lbf.ft)
(cont'd)
19-57
ABS Gomponents
ABS Modulator-ControlUnit Removaland Installation{cont'dl
3. Disconnectthesix brakelines.
4. Removethe two I mm nuts.
5. Removethe ABS modulator-controlunit (C).
Installation
'1.
I n s t a l l t h e A B Sm o d u l a t o r c o n t r oul n i t ,t h e nt i g h t e nt h e t w o 8 m m n u t s .
2. Align the connectingsurfaceofthe ABS control unit 3'lP connector.
3 . P u s h i n t h e l o c k o f t h e A B S c o n t r oul n i t3 1 Pc o n n e c t o ur n t i ly o u h e a ri t c l i c ki n t o p l a c e t. h e nc o n n e c t h e c o n n e c t o r .
4. Connectthe six brakeIines.
5. Bleedthe brakesystem,startingwith the front wheels.
6. Connectthe PGMTester,and do the solenoidfunctiontest for each wheel.
7. Bleedthe brakesystem again,staning with the front wheels.
8. Startthe engine,and checkthat the ABS indicatorand brakesystem indicatorgo off.
9. Disconnectthe Honda PGMTester.Test-drivethe vehicle,and checkthat the ABS indicatorand brakeqvqtem

i n d i c a t odr o n o t c o m e o n .
19-58
WheelSensorInspection WheelSensorReplacement
1 . Inspectthe front and rear pulsersfor chippedor NOTE:Inslallthe sensorscarefullyto avoid twisting the
damagedteeth. wtres.
2. Measurethe air gap betweenthe wheel sensorand Front:

the pulserall the way around while rotatingthe
pulser.Removethe rear brakedisc to measurethe 6 mm BOLT
9.8 N.m
gap on the rearwheel sensor.lf the gap exceeds {1.0kgf.m,7.2lbf.ftl
1 . 0m m ( 0 . 0 4i n . ) ,c h e c kf o r a b e n ts u s p e n s i o a
nrm.
Standard:
Front; 0.4- 1.0mm (0.02-0.04 in.)
Rear: 0.2 1.0mm (0.01 0.04 in.l
Front:
0.4 '1.0mm
10.02 0.0'l in.l
I
t 6 mm BOLT
9.8 N.m
{1.0kgf.m,7.2lbf.ftl WHEELSENSOR
Rear:
6 mmBOLT
9.8 N.m
11.0kgf.m,7.2lbf.ft)
6 mm BOLT
9.8 N.m
(1.0kgf'm,
7.2rbr.ft)
Bear:
0.2 1.0mm
{0.01 0.04in.}
19-59
Body
Doors Dashboard
C o m p o n e nLto c a t i oInn d e x . . . . . . . . . . . 20-2 InstrumentPanelRemoval/lnstallation ........20-59
D o o rP a n eR l e m o v a l / l n s t a l l a t i o. .n. . . , . . . . . .20,4
.... Driver'sDashboardLowerCover
DoorOuterHandleReplacement 20-6 RemovatInstallation 20-59
DoorLatchReplacement 20-7 Driver'sDashboardUnderCover
DoorGlassand Regulator Removat Installation 20-60
Replacement 20-9 Oriver'sPocketRemoval/lnstallation ............ 20,60
D o o rS a s hT r i mR e p l a c e m e n. .t. . . . . . . . . . . . . . 2. .0. .t.0. . ShiftLeverTrim Removal/lnstallation ..........2 0 6 1
DoorGlassOuterWeatherstrip C e n t eP r a n eR
l e m o v a l / l n s t a l l a t i. o. .n. . . . . . . .20-62 ....
Replacement 20- 10 Passenger's DashboardLowerCover
DoorWeatherstrip Beplacement 20-11 Removal/lnstallation 20-63
D o o rG l a s sA d j u s t m e n t. . . . . . . . . . . . . . . . . . . . . . .20-11
.......... x GloveBox Removal/lnstallation 20-63
D o o rP o s i t i oAn d j u s t m e n .t . . . . . . . . . . . . . . . . . . .20-12
......... Dashboard SideVent
D o o rS t r i k eAr d i u s t m e n.t. . . . . . . . . . . . . . . . . . . . .2. .0. .1. 3. . . . . R e m o v a l / l n s t a l l a t i. o. .n. . . . . . . . . . . . . . . . . . . . 2
. .0. .-.6. .4. . . .
Mirrors BeverageHolderRemoval/lnstallation ........20-64
C o m p o n e nLto c a t i o Inn d e x . . . . . . . . . . . . . . . . . . .20-14
........ Driver'sTrayRemoval/lnstallation ............... 20-65
P o w e rM i r r o rR e p l a c e m e n. .t . . . . . . . . . . . . . . . . .2. 0
. .-. 1. .5. . Passenger's Tray Removal/lnstallation ........20 65
M i r r o rH o l d e R
r e p l a c e m e n. .t. . . . . . . . . . . . . . . . .20-15
........ * DashboardRemoval/lnstallation .................. 20-66
Rearview M i r r o rR e p 1 a c e m e.n. t. . . . . . . . . . . . . .2. 0. .-.1. .6 S t e e r i"n H
q a n q eBr e a mR e o l a c e m e n. .t. . . . . . .2. 0. - 6 8
Glass Seats
C o m p o n e nLto c a t i o Inn d e x . . . . . . . . . . . . . . . . . . .2. 0
. .1
. .1. . . ComponentLocationIndex ........................... 20-10
W i n d s h i e lR
deplacement 20-19 * FrontSeatRemoval/lnstallation ................... 20-11
B e a rW i n d o wR e p 1 a c e m e.n. .t . . . . . . . . . . . . . . . .20-25
........ * FrontSeatDisassembly/
r l a s sR e p l a c e m e n. .t . . . . . . . . . . . . . . . . 20-29
O u a r t eG ........ R e a s s e m b l y - D r i v e. .r .' s. . . . . . . . . . . . . . . . . . . . 2. .0. .-.7. .3. . . .
Moonroof * FrontSeatDisassembly/
C o m p o n e nLto c a t i o Inn d e x . . . . . . . . . . . . . . . . . . .20,35 ........ R e a s s e m b l y - P a s s e n g. .e.r. '.s. . . . . . . . . . . . . .2. 0 . .-. 7. .4. .
SymptomTroubleshooting Index 20-36 * F r o n tS e a tC o v e rR e p l a c e m e n. .t . . . . . . . . . . . . .2. .O. .-.7. 5
G l a s sH e i g hA t d j u s t m e n.t. . . . . . . . . . . . . . . . . . . . 20-37
.......... R e a rS e a tR e m o v a l / 1 n s t a 1 1.a. t. i. o. .n. . . . . . . . .2. .0. -. .8.0
G l a s sR e p l a c e m e n t 20-31 RearSeat-back LatchReplacement.............. 20-81
W i n dD e fl e c t o r8 e p 1 a c e m e n. .t. . . . . . . . . . . . . . .20-38 ....... RearSeat-backStriker Replacement............ 20-81
D r a i nC h a n n eRl e p 1 a c e m e.n. .t. . . . . . . . . . . . . . .20 . . . .39
.... RearSeat-back CoverReplacement............. 20-82
S u n s h a dR e e p l a c e m e n. .t. . . . . . . . . . . . . . . . . . . . .20-40
.......... R e a rS e a tC u s h i o n
C o v e rR e p l a c e m e n. .t . . . .2. 0 . 8 4
Motor Replacement 20-41 Bumpers
Frameand DrainTubeReplacement............ 20,42 F r o n tB u m p e R r e m o v a l / l n s t a l l a t .i o
. .n. . . . . . .20,85
...
D r a i nC h a n n eSl l i d e ar n dC a b l eA s s e m b l y R e a rB u m o e R r e m o v a l / l n s t a l l a t.i.o. .n. . . . . . .20-86
....
Replacement 20 44 Hood
L i m i tS w i t c hA d j u s t m e n .t . . . . . . . . . . . . . . . . . . . . 20-46
.......... Adjustment 20-47
ClosinoForceand ODeninaDraqCheck ......20,44 H o o dS e a lR e p l a c e m e n t 20,88
lnterioiTrim H o o dI n s u l a t oRr e p 1 a c e m e.n. .t. . . . . . . . . . . . . . .20,89
.......
C o m p o n e nLto c a t i oInn d e x . . . . . . . . . . . . . . . . . . .20-49
........ Hatch
Trim Removal/lnstallation DoorArea .......... 20 50 Adjustment . . . . . . . . . . . . . .2. 0
. .-. 9. 0
Trim Removal/lnstallation H a t c hS u p p o nS t r u tR e p l a c e m e n. .t. . . . . . . . . .2. .0.-. 9 1
-RearSideArea 20-51 HatchWeatherstriD Reo1acement ................. 20-92
Trim Removal/lnstallation FuelFill Door
-CargoFloorArea 20-52 Adiustment . . . . . . . . . . . . . .2. 0
. .-. 9. 3
Trim Removal/lnstallation-Hatch Area .........20-53 ExteriorTrim
HeadlinerRemoval/lnstallation 20-54 F r o n tG r i l l eR e p l a c e m e n. .t. . . . . . . . . . . . 20-94
* C a r p eR
t e p 1 a c e m e.n. .t. . . . . . . . . . . . . . . . . . . . . . . .20-55
............ CowlCoversReplac"rn""t .. . ..................... 20-95
Consoles A p i l l a rC o r n eTr r i mR e p l a c e m e n. .t. . . . . . . . . .20-96 ....
Frontand Rear
Consoles, R o o fl M o l d i nR g e p l a c e m e n. .t. . . . . . . . . . . . . . . . .20-97
........
Removal/lnstallation 20-57 RearLicenseTrim Replacement 20,98
FrontConsoleDisassembly/Reassembly
.....20-58 H a t c hS p o i l e8r e p 1 a c e m e .n.t. . . . . . . . . . . . . . . . .20-99
........
E m b l e mR e p 1 a c e m e.n. .t. . . . . . . . . . . . . . . . . . . . . .2 0 - 1 0 0

Fenderwell
FrontInnerFenderReplacement 20-102
F r o n tF e n d eFr a i r i n gR e p l a c e m e n. .t . . . . . . . . .2. .0. .- 1 0 3
FuelPipeProtectorReplacement 20-104
R e a rA i r O u t l e R
t e p 1 a c e m e.n. .t. . . . . . . . . . . . . . .20-'to4
.......
Openers
C o m p o n e nLto c a t i oInn d e x . . . . . . . . . . . . . . . . . . .2. .0. -. 1 . .0. .5
H o o dO p e n eC r a b l eR e p l a c e m e n. .t . . . . . . . . . .2. .0.-. 1 0 6
* FueF l i l lD o o rO p e n eC r able
Replacement 20 107
H o o dL a t c hR e p 1 a c e m e .n. t. . . . . . . . . . . . . . . . . . .2. 0 . .-.1. .0. .8.
FueF l i l lD o o rO p e n eR r e p l a c e m e n. .t. . . . . . . . .2.0. .- 1 0 9
H a t c hH a n d l eR e p l a c e m e n. .t. . . . . . . . . . . . . . . . .2. .0. -. 1.1. .0.
H a t c hL a t c hR e p l a c e m e n. .t. . . . . . . . . . . . . . . . . . .2. .0.-. 1. .1. .0.
H a t c hL o c kC y l i n d eRr e p l a c e m e n. .t. . . . . . . . . .20-111 ....
Frame
SubframeReplacement.................................
20-112
FrameStiffener,Brace,and Gusset
Replacement .............
20-113
r Fremp RFnrir Chrrr . . . . . . . . . . . . . .2. 0
. -114

Doors
ComponentLocationIndex a
DOOROUTERTRIM
DOORSASHTRIM
page20-10
Replacement,
DOORGLASSOUTER
WEATHERSTRIP
page20-10
Replacement,
DOOR
Adiustment,
Position
page20-12
K-p
IJ A'A
dq
W2"'
Ya
\J aita.
DOORWEATHERSTRIP
page20-'l'l
Replacement,
POWERWINDOW
swtTcH
\
POWERDOORLOCKSWITCH
(Driver's)
20-2
GLASS
Adjustment,page20-11
IMMOBILIZER
LABEL
REGULATOR
page20-9
Replacement,
RETAINERCLIP
LOCK
CYLINDER
\
\
LOCKKNOB O
OUTERHANDLE
CYLINDERROO PROTECTOR
PROTECTOR ,-\
tt \
v4,,(,
E ) i l
- /6X@
W (
STRIKER
Adjustment,page20-13
LATCH
page20-7
Replacement,
POWERDOOR
LOCKACTUATOR
20-3
Doors
Door PanelRemoval/lnstallation
SpecialToolsRequired 3. Removethe armrestcover (A).Takecare not to
Trim pad remover,Snap-onA 177Aor equivalent, scratchthe door panel.
c o m m e r c i a l la
yvailable.
-1 Pry out the front edge of the cover to release
NOTE:When prying with a flat-tipscrewdriver,wrap it the hooks(B).
with protectivetape, and apply protectivetape around -2 Pry out the bottom and rear edge of the cover
the relatedparts.to preventdamage. to releasethe hooks(C).
-3 Pry out along the top to releasethe tabs (D).
1. Removethe mirror mount cover (seepage 20-15).
2. Inserta hex wrench through the hole (A) in the door

grip base(B),Pushthe door grip cover (C)out to
r e l e a s et h e h o o k( D )a n d t a b ( E ) ,a n d p u l l o u t t h e
cover to releasethe tabs (F)and hook (G) by hand,
then removethe cover.
4 . Removethe screws(A, B), and releasethe tabs (C),

then removethe door grip base(D).Removethe
screw (A) securingthe door panelfrom the armrest
portion.
FastgngrLocations
A> : Screw,3 B > : Screw,5
20-4
5. Pull out the switch panel (A)to releasethe hook (B), 7. Disconnectthe inner handlecable {A) from the
then removethe panelfrom the door panel. i n n e rh a n d l e( B ) ,a n d d i s c o n n e c t t h p
e o w e rd o o r
Disconnectthe power window switch connector(C). lock switch connector(C){driver's).Takecare not to
bend the cable.
8. Detachthe harnessclip (A)from the door panel (B).

B
Releasethe clipsthat hold the door panel (A) with a
commerciallyavailabletrim pad remover (B),then
removethe door panel by pulling it upward.
Removethe door panelwith as little bendingas
possibleto avoid creasingor breakingit,
FastenerLocations
95 mm (3.74in.l
> : Clip,9
12 mm r q----------
i.0.17in.l r <_--'r-
ffi
EtA lmm
{0.04in.l
45 mm {1.77in.l 9 . Installthe door panel in the reverseorder of
. Replaceany damagedclips.
. Make sure the cable is connectedsecurely,and
the connectoris plugged in properly.
. Checkthe window and power door lock
operatrons,
20-5
Doors
Door Outer HandleReplacement
NOTE:Puton glovesto protectyour hands. 4. Disconnectthe cylinder rod (A),and releasethe
retainerclip (B).then removethe lock cylinder(C).
1, Removetheseitems:
. Door panel (seepage 20-4)

. Plasticcover,as necessary(seepage 20-2)
2 . R a i s et h e g l a s sf u l l y .
5. Removethe lock rod protector(A).
-l Removethe screw.
-2 Releasethe protectorfrom the latch protector
(B).
-3 Pullthe protectordown to releasethe hook (C)
from the door.
FastenerLocation Disconnectthe outer handle rod (A).

) : Screw,1
FastenorLocations
> : Bolt,2
6x1.0mm
9.8 N.m
{1.0kgf.m,
7.2 tbt.ft')
6 . Removethe maintenancecap (B),and removethe

b o l t ss e c u r i n gt h e o u t e rh a n d l e( C )w h i l e h o l d i n g
the handlefrom outside.Releasethe hook (D).then
removethe outer handleprotector(E).
20-6
Door LatchReplacement
7. Pull out the outer handle(A),then remove it. NOTE:Put on glovesto protectyour hands.
1. Removethese items:

. Plasticcover,as necessary(seepage 20-2)
Raisethe glassfully.
3 . Removethe lock rod protector(seestep 3 on page

20-6).
4 . Pullthe glass run channel(A) away as necessary,

and removethe bolt, then removethe centerlower
channel(B) by pulling il downward
q
Installthe handlein the reverseorder of removal, FastenorLocation
and note these items: > : Bolt,1
. Make sure each rod is connectedsecurelv. IIilE
. Make sure the door locksand opens properly.
. W h e n i n s t a l l i n tgh e l o c kc y l i n d e rl.e a v e t h e o u t e r
door handlebolts looseso the inner protector
does not interferewith the lock cylinder
installation,then tighten the handle bolts.
. Installthe lockcylinder retainingclip on the
handle,then installthe lockcylinder.Be sure the
c l i p i s f u l l y s e a t e di n t h e s l o to n t h e l o c kc y l i n d e r .
. W h e n r e i n s t a l l i ntgh e d o o r p a n e l ,m a k es u r et h e
plasticcover is installedproperly,and is sealed
aroundthe coversDerimeter.
6x1.0mm
8 N.m
{0.8 kgf.m, 6 lbf.ftl
(cont'd)
20-7
Doors
Door LatchReplacement(cont'dl
5 . Disconnectthe cylinder rod (seestep 4 on page 20- 9. Installthe latch in the reverseorder of removal,and
6). notethese rtems:
6 . Disconnectthe outer handle rod (seestep 5 on . [Vlakesure the actuatorconneclorsare pluggedin

page 20-6). properly,and that each rod and cable are
connectedsecurely.
7 . Disconnectthe actuatorconnectors(A),and release . W h e n r e i n s t a l l i ntgh e d o o r p a n e l ,m a k es u r et h e
t h e i n n e rh a n d l ec a b l e( B ) f r o mt h e d o o r b y plasticcover is installedproperly,and is sealed
d e t a c h i n gt h e c a b l ec l i p ( C i . aroundthe coversperimeter.
. M a k es u r et h e d o o r l o c k sa n d o p e n sp r o p e r l y .
8 . Removethe screws,then removethe latch{A)

through the hole in the door. Takecare not to bend
the outer handle rod (B),cylinderrod (C),lock rod
( D ) ,a n d i n n e rh a n d l ec a b l e( E ) .
FastenerLocations
) : Screw
U.#
6x1.0mm
5Nm
{0.5kgf.m,
4 tbf.ft)
20-8
Door Glassand RegulatorReplacement
NOTE:Put on glovesto protectyour hands. 3. Disconnectand detachthe connector(A) and
h a r n e s sc l i p ( B )f r o m t h e d o o r .
FastonorLocations
. Door panel (seepage 20-4) C>: Bolt.1 D>: Bolt,5
. Plasticcover.as necessary(seepage 20-2)
2 . C a r e f u l l yr a i s et h e g l a s s( A )u n t i ly o u c a n s e e t h e
bolts,then removethem. Carefullypull the glass
out through the window slot.Takecare not to drop
the glass insidethe door.
6x1.0mm
8 N.m
FastenerLocations (0.8kgf.m,
6 rbf.ftl
):Boh,2
@
Removethe bolts(C),andloosenthe bolts(D),then
removethe regulator(E)throughthe holein the
door,
Applymultipurpose greaseto allthe sliding

of the regulator(A)whereshown.
surfaces
6x1.0mm
9.8 N m {1.0kgl.m, 7.2 lbf.ftl
Installtheglassand regulatorin the reverseorder

of removal,and note these items:
. R o l l t h eg l a s su p a n d d o w n t o s e ei f i t m o v e s
freely without binding.
. Make sure that there is no clearancebetweenthe
g l a s sa n d g l a s sr u n c h a n n e w l h e n t h e g l a s si s
ctoseo.
. Adjust the positionof the glassas necessary(see
p a g e2 0 - 11 ) .
. Checkfor water leaks(seestep 7 on page20-121.
. Test-driveand checkfor wind noiseand rattles.
. W h e n r e i n s t a l l i ntgh e d o o r p a n e l ,m a k es u r et h e
plasticcover is installedproperlyand sealed
around its perimeter.
20-9
Doors
Door SashTrim Replacement Door GlassOuterWeatherstrip I
Replacement
NOTE:Takecare not to scratchthe door.
1. Removethe door glassouter weatherstrip. NOTE:

. Put on glovesto protectyour hands.
2. Pull backthe door weatherstrip(A) at the rear . Takecare not to scratchthe door
upper corner,and removethe screw.
1 . R e m o v et h e p o w e rm i r r o r( s e ep a g e2 0 - 1 5 ) .
Fasten6r Location
) : Screw, I 2. Startingat the front, pry the door glassouter

weatherstrip(A) up to detachthe clips (B),and
releasethe weatherstripfrom the door sashtrim
(C),then removethe weatherstrip.
Fastener Locations
B>:Clip,s
3 . Lift up the door sashtrim {B)to releasethe hooks

(C),then removethe trim.
lnstallthe trim in the reverseorder of removal.

3 . Installthe weatherstripin the reverseorder ot
removal,and replaceany damagedclips.
20-10
Door WeatherstripReplacement Door GlassAdjustment
NOTE: NOTE:
. Takecare not to scratchthe door. . Checkthe weatherstripsand glassrun channelfor
. Use a clip removerto removethe clips. damageor deterioration,and replacethem if
necessary.
1. At the A-pillar,removethe door stop mounting bolt . Wipe the run channelcleanwith a shop towel.
(A). . Lubricatethe run channelwith Shin-Etsugrease
P/N 08798-9013.
FastenerLocations
A > : B o t t ,1 B>:Clip,1 C > : C l i p ,1 8 1. Placethe vehicleon a firm, level surface.

. Plasticcover {see page20'2)
3. Carefullymove the glass (A) until you can seethe

glass mounting bolts (B),then loosenthem.
'
14.----'
'r,
.,'o-,,tL' .
.rrt
B
6x1.0mm
9.8N.m(1.0kgf.m,7.2lbf.ft)
Pushthe glassagainstthe channel(C),then tighten

the glass mounting bolts.
Detachthe clips (8, C),then removethe door Checkthat the glassmoves smoothly.
weatherstrip(D).
Installthe weatherstripin the reverseorder of

removaland note these items:
. Make sure the weatherstripis installedln the
h o l d e r( E )s e c u r e l y .
. A p p l y l i q u i dt h r e a dl o c kt o d o o r s t o p m o u n t i n g
bolt beforeinstallation.
. Checkfor water leaks(seestep 7 on page20-'121.
. Test-driveand checkfor wind noase.
(cont'd)
20-11
Doors
DoorGlassAdiustment{cont'd) Door PositionAdiustment \
6. Raisethe glassfully, and checkfor gaps.Checkthat NOTE;Checkfor equal gaps betweenthe front, rear,
the glass(A) contactsthe glass run channel(B) and bottom door edgesand the body. Checkthat the
evenrv. door and body edges are parallel.
1. Placethe vehicleon a firm, levelsurfacewhen

adjustingthe door.
2. Adjust at the hinges{A):
. Removethe front innerfender (seepage 20-102)

and front fenderfairing (seepage 20-103).
Loosenthe hinge mounting bolts (B) slightly,and
move the door backwardor forward, uD or down
as necessaryto equalizethe gaps.
. Placea shop towel (C)on the jack (D)to prevent
damageto the door when adjustingthe door.
7 . Checkfor water leaks.Run water over the roof and

on the sealingarea as shown, and note these items:
. U s ea 1 2 m m ( 1 / 2i n . )d i a m e t e rh o s e( A ) .
. Adjust the rate of water flow as shown {B).
. Do not use a nozzle.
. H o l dt h e h o s ea b o u t3 0 0 m m ( 1 2i n . )a w a y f r o m
the door (C).
\
t, 8x1.25mm
29 N.m (3.0kgf.m,
12mm1112in,l ! 22 tbt.trl
\e
300mm {12in.l
Attachthe plasticcover,and installthe door panel

(seepage 20-4).
9. Test-driveand checkfor wind noise.
20-12
Door StrikerAdjustment
3. Checkthat the door and body edges are parallel.lf M a k es u r et h e d o o r l a t c h e s e c u r e l yw i t h o u ts l a m m i n g
necessary,adjustthe door cushions(A)to make the it. lf necessary,adjustthe striker(A):The strikernuts
rear of the door flush with the bodv. a r ef i x e d ,b u t t h e s t r i k e rc a n b e a d j u s t e ds l i g h t l yu p o r
d o w n ,a n d i n o r o u t .
1. Loosenthe screws(B),rhen inserta shop towel (C)

betweenthe body and striker.
Apply body paintto the hinge mounting bolts and

a r o u n dt h e h i n g e s .
8 x 1 . 2 5m m
5 . Checkfor water leaks(seestep 7 on page 20-12). 18 N.m 11.8kgf m, 13 lbf.ft)
Test-driveand checkfor wind noise. Lightlytlghten the screws.
Wrap the strikerwith a shop towel, then adjustthe

s t r i k e rb y t a p p i n gi t w i t h a p l a s t i ch a m m e r( D ) .D o
not tap the strikertoo hard.
Loosenthe screws,and removethe shop towel.
5 . Lightlytighten the screws.
6 . Hold the outer handleout, and push the door

againstthe body to be sure the strikerallows a
flush fit, lf the door latchesproperly,tighten the
screwsand recheck.
20-13
Mirrors
POWERMIRRORACTUATOR
page22-1'18
Replacement,
.a\
|
b\.\
\ \-r<,,/
\.J
\.4
\\
1 \
TWEETER
\
TWEETER
MIRRORMOUNTCOVER
POWERMIRROR
page20-15
Replacement,
MIRRORHOLDER
Replacement,page20 '15
__.Q
-'-'
MOUNT
REARVIEWMIRROR
page20 16
Replacement,
20-14
PowerMirror Replacement Mirror HolderReplacement
1 . Lower the door glassfully. 1 . C a r e f u l l yp u l l o u t t h eb o t t o me d g eo f t h e m i r r o r
holder (A) by hand.Takecare not to scratchthe
2. Carefullypry out the mirror mount cover (A) by mrrror.
hand in the sequenceshown. Disconnectthe
tweeterconnector(B),and releasethe wire harness
(C)from the hook (D).
FastenerLocation
) : Clip,1
Separatethe mirror holderfrom the actuator(B) by

slowly pullingthem apart while detachingthe clips
(C).lf equipped,disconnectthe mirror defogger
3 . R e m o v et h e d o o r p a n e l( s e e p a g e 2 0 - 4 ) . connectors{D) from the heaterpad terminals.
4. Disconnecttheconnector(A),and detachthe lf equipped,reconnectthe mirror defogger

h a r n e s sc l i p ( B ) .W h i l eh o l d i n gt h e m i r r o r{ C ) , connectors.
removethe nuts,then removethe mirror. Takecare
not to scratchthe door. Reattachthe clips of the mirror holderto the
actuator,then positionthe mirror holderon the
FastenerLocrtions actuator.Carefullypush on the clip portionsof the
O: Nut.3 m i r r o rh o l d e ru n t i l t h em i r r o rh o l d e rl o c k si n t o
prace.
5 . Checkthe operationof the actuator
5 . lnstallthe mirror in the reverseorder of removal,

and note these items:
. Make sure the connectoris plugged in properly.

. Attachthe harnessclip.
20-15
Mirrors
RearviewMirror Replacement
1. Turnthe mirrorbase(A)90.in eitherdirection. 4, Fit the mirror base over the mount, and securethe
mirror by turning the base90".
2. Slide the rearviewmirror (A) down toward the

bottom of the windshield,then detachit from the
spring (B) in the mount (C),and removethe
rearviewmirror. Takecare notto scratchthe mirror
Dase.
3. lf necessary,removethe spring from the mount.
20-16
Glass
FASTENER,2
PASSENGER'SAIRSAG glassside)
{Self-adhesive-type,
CAUTION LABEL
SIDERUBBERDAM
WINDSHIELDSIDETRIM
4 ',
m-_-==}lny'
S{|---..------'RErA'NER,6
f..N\
;\tJ
e
N8*?' CLIP,4
Blue
WINDSHIELD CLIP
page20-19
Beplacement,
LOWERRUBBER
DAM
UPPER DAM,4
RUBBER
SPOILER
FASTENER,2
(Selt-adhesive-type)
'9>
LOWERRUBBERDAM
(cont'd)
20-17
Glass
OUARTERGLASS - UPPER CLIP

FRONTSEAL tsetl adhesive-typel
..,////
\n iT- \
/nJ l"
l/ / Pll
vI - \
/ .--"..---.-_
LowERcLrp
(Self-adhesive-type)
b
I
-.,-
-''
LEVEMBLEM
('03model) OUARTERGLASS R €AR CLIP
page20-100
Replacement. page20-29
Beplacement, (Self-adhesive-type)
20-18
WindshieldReplacement
NOTE: Removethe cowl covers(seepage 20-95).
. Puton glovesto protectyour hands,
. Weareyeprotection whilecuttingthe glassadhesive 4. Removethe molding (A) from the upper edge of the
with pianowire. windshield(B).lf necessary,cut the molding with a
. Useseatcoversto avoiddamaging the seats. utility knife.
1. Removetheseitems:
. Rearview
mirror(seepage20-16)
. Windshield
wiperarms(seepage22-145)
the clips(B)from
2. Pullup the sidetrim (A)to release
the retainers(C),andpullthetrim rearwardto
releaseit fromthecliD(D)thenremovethetrim
from eachsideof thewindshield.
lf the old windshieldis to be reinstalled,make

alignmentmarks acrossthe glassand body with a
greasepencil.
Pull down the front portionof the headliner(see

page 20-54).Takecare not to bend the headliner
excessively,or you may creaseor breakit.
7 . Apply protectivetape along the edge of the

dashboardand body. Using an awl, make a hole
through the rubber dam, adhesive.and dashboard
sealfrom insidethe vehicleat the corner ponion ot
the windshield.Pusha pieceof piano wire through
the hole, and wrap each end around a pieceof
wood.
(cont'd)
20-19
Glass
WindshieldReplacement(cont'd)
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 ow i r e { A ) 10. With a knife,scrapethe old adhesivesmooth to a
backand forth in a sawing motion. Hold the piano thicknessof about 2 mm (0.08in.) on the bonding
wire as closeto the windshield(B)as possibleto surfacearoundthe entirewindshieldopening
preventdamageto the body and dashboard. flange:
Carefullycut through the rubber dam and adhesive
( C )a r o u n dt h e e n t i r ew i n d s h i e l d . . Do not scrapedown to the paintedsurfaceofthe
body; damagedpaint will interferewith proper
-A bonding.
\, ,.- . Removethe rubber dam and fastenersfrom the
oooy.
11. Cleanthe body bonding surfacewith a sponge

dampenedin alcohol.After cleaning,keepoil,
greaseand water from getting on the cleansurface.
,,t""""""""',-\
i-.. 12. lf the old windshieldis to be reinstalled,use a puttv
-1:-, -
knifeto scrapeoff all of the old adhesive,the
-= -.-- fastenersand the rubber dam from the windshield.
Cleanthe insideface and the edge of the
windshieldwith alcoholwhere new adhesiveis to
be applied.Make sure the bondingsurfaceis kept
free of water, oil, and grease.
20-20
t5. Glue the side rubber dams (A) and lower rubber 1 4 . G l u et h e m o l d i n g( A ) w i t ha d h e s i v et a p e{ B )
dam (B)with adhesivetape (NITTO501M,or ( 3 M 4 2 1 2 ,o r e q u i v a l e n t ) t toh e u p p e re d g eo f t h e
equivalent).Glue the fasteners(C)with adhesive w i n d s h i e l d( C ) ;
tape (3M 4215,or equivalent)to the insideface of
t h e w i n d s h i e l d{ D )a s s h o w n : . B e s u r et h e a l i g n m e n m t a r k( D )o f t h e m o l d i n g
l i n e su p w i t h t h e a l i g n m e n mt a r k( E )o f t h e
. Be sure the rubber dams and fastenersline uD windshield.
withthealignmenm t a r k s( E ) . . Be carefulnot to touch the windshieldwhere
. Be carefulnot to touch the windshieldwhere a d h e s i v ew i l l b e a p p l i e d .
a d h e s i v ew i l l b e a o o l i e d .
t3. Installthe fasteners(A),retalners(B, C),and clips

(D)to lhe body.
FastenerLocations
A>:Fastener.2 B>:Retainer,2
q\
C > : R e t a i n e r , 6O> : C l i p , 2
(cont'd)
20-21
Glass
WindshieldReplacement(cont'dl
t o . Set the windshieldin the opening,and centerit. 18. With a sponge,apply a light coat of glassprimer
Make alignmentmarks (A) acrossthe windshield aroundthe edge of the windshield(A) betweenthe
and body with a greasepencilat the four points d a m s ( B )a n d m o l d i n g{ C )a s s h o w n ,t h e n l i g h t l y
shown. Be careful not to touch the windshield wipe it off with gauzeor cheesecloth:
w h e r ea d h e s i v ew i l l b e a p p l i e d .
. A p p l yg l a s sp r i m e rt o t h e m o l d i n g .
. Do not apply body primer to the windshield,and
do not get body and glassprimer spongesmixed
up.
. Nevertouch the primed surfaceswith your hands.
lf you do, the adhesivemay not bond to the
w i n d s h i e l dp r o p e r l yc. a u s i n ga l e a ka f t e r t h e
w i n d s h i e l di s i n s t a l l e d .
. Keepwater. dust, and abrasivematerialsaway
from the primed surface.
'l',,1r-
r Applyglassprimerhere.
) - '
1 7 . R e m o v et h e w i n d s h i e l d . G1)'r'
l l
ol
B
,,/ ll\
tl
-A
lnside
20-22
19. With a sponge,apply a light coat of body primer to 21. Packadhesiveinto the cartridgewithout air pockets
the originaladhesiveremainingaroundthe to ensurecontinuousdelivery.Putthe cartridgein a
windshieldopeningflange, Letthe body primer dry caulkinggun, and run a bead of adhesive(A)
for at least 10 minutes: aroundthe edge of the windshield(B) betweenthe
d a m s ( C )a n d m o l d i n g( D )a s s h o w n .A p p l yt h e
. Do not apply glassprimer to the body, and be adhesivewithin 30 minutesafter applyingthe glass
carefulnot to mix up glassand body primer primer. Make a slightlythickerbead at each corner.
sponges.
. l\4askoff the dashboardbefore paintingthe
l'1fifr.,1:
?mm n
flange. in.l
10.28 ,..-
A..
20 mm )t
(0.79in.l
$?I.",x1"u.80.".,
trl
.,r []\"
Inside
- '
"V" c.. N
20. Beforefilling a cartridge,cut a in the end of the \F1
n o z z l e( A )a s s h o w n . 2 m m I 'Zn l
in.}I
{0.08 l
./"
A
12 mm (0.47in.)
U s es u c t i o nc u p st o h o l dt h e w i n d s h i e l do v e rt h e
o p e n i n ga, l i g ni t w i t h t h e a l i g n m e n m
t a r k sm a d ei n
step 16,and set it down on the adhesive.Lightly
p u s ho n t h e w i n d s h i e l du n t i li t s e d g e sa r ef u l l y
s e a t e do n t h e a d h e s i v ea l l t h e w a y a r o u n d .D o n o t
open or closethe doors until the adhesiveis dry.
7 mm {0.27in.)
(cont'd)
20-23
Glass
WindshieldReplacement(cont'd)
23. Scrapeor wipe the excessadhesiveoff with a putty 27. On both sidesofthe windshield,installthe side
knife or towel. To remove adhesivefrom a painted trim (Alto the clip (B),then set the bottom edge of
surfaceor the windshield,wipe with a soft shop the side trim over the cowl cover (C),and align the
towel dampensdwith alcohol. c l i p s( D ) w i t ht h e r e t a i n e r (sE ) ,a n d p u s ho n t h e c l i p
portionsof the trim until the trim is fully seatedon
24. Let the adhesivedry for at least t hour, then spray thewindshield.
water over the windshieldand checkfor leaks.
Mark Ieakingareas,and let the windshielddry, then
seal with sealant:
. Let the vehiclestand for at least4 hours after

windshieldinstallation.lf the vehiclehas to be
usedwithin the first 4 hours,it must be driven
slowly.
. Keepthe windshielddry for the first hour after
installation.
Reinstallthecowl covers(seepage 20-95).
NOTE:Thecowl cover clips may not set properlyif

the windshieldadhesiveis too wet.
Installthe clips (A, B) on both side trim {C).lf the

clip (D) is damaged,replacethe side trim and clips
as an assembly.
A: Grey 28. R e i n s t a al l l l r e m a i n i n gr e m o v e dp a r t s .I n s t a l l t h e
B :B l u e
rearviewmirror afterthe adhesivehas dried
thoroughly.
NOTE:Advise the customernot to do the following

things for 2 to 3 days:
. S l a mt h e d o o r sw i t h a l l t h e w i n d o w sr o l l e du p .
. Twist the body excessively(suchas when going
i n a n d o u t o f d r i v e w a y sa t a n a n g l eo r d r i v i n g
over rough, unevenroads).
20-24
RearWindow Replacement
NOTE: 6. With a helperon the outside,pull the piano wire (A)
. Put on glovesto protectyour hands. backand Jorthin a sawing motion. Holdthe piano
. Wear eye protectionwhile cuttingthe glassadhesive wire as closeto the rearwindow (B)as possibleto
w i t h p i a n ow i r e . preventdamageto the hatch,and carefullycut
. Use seatcoversto avoid damagingany surfaces. t h r o u g ht h e a d h e s i v e{ C }a r o u n dt h e e n t i r er e a r
. Do not damagethe rearwindow defoggergrid lines
a n dt e r m i n a l s .
1 . Removethese items:
. Hatchlower trim panel (seepage 20-53)

. Hatchspoiler(seepage 20-99)
Removethese items:
. High mount brakelight {seepage 22-821

. Rearwindow wiper motor {see page22-1461
Disconnectthe rearwindow defoggerconnectors

(A).
Cutting positions:
4 . lf the old rear window is to be reinstalled,make

alignmentmarksacrossthe glassand body with a
g r e a s ep e n c r l ,
7 . C a r e f u l l yr e m o v et h e r e a rw i n d o w .
Apply protectivetape along the insideand outside
e d g e so f t h e h a t c h .U s i n ga n a w l , m a k ea h o l e
t h r o u g ht h e a d h e s i v ef r o m i n s i d et h e v e h i c l ea t t h e
corner portionof the rearwindow. Pushthe piano
w i r e t h r o u g ht h e h o l e ,a n d w r a p e a c he n d a r o u n da
pieceof wood,
(cont'd)
20-25
Glass
RearWindow Replacement(cont'd)
With a putty kniie. scrapethe old adhesivesmooth 1 1 . G l u et h e s i d eu p p e rf a s t e n e r s( A )a n d s i d e l o w e r
to a thicknessof about 2 mm (0.08in.) on the fasteners{B)with adhesivetape {3M 5312,or
bonding surfacearoundthe entire rear window ) . l u et h e u p p e rr u b b e rd a m s ( C ) w i t h
e q u i v a l e n tG
openingflange: adhesivetape (NITTO501fM,or equivalent)and
glue the lower rubberdam (D)with adhesivetape
. Do not scraDedown to the Daintedsurfaceof the (3M 4216,or equivalent)to the insideface of the
body; damagedpaint will interferewith proper rearwindow (E)as shown. Beforeinstallingthe
bonding lower rubber dam, apply primer (3M N-200,or
. Removethe fastenersfrom the tailqate. equivalent)to the areasbetweenthe alignment
marks {F),then glue the rubber dam on. lf
Cleanthe hatch bonding surfacewith a sponge necessary,glue the spoilerfasteners(G)with
dampenedin alcohol.After cleaning,keepoil, adhesivetape (3M 5671,or equivalent)to the
greaseand water from getting on the surface, outsideface of the rearwindow:
1 0 .lf the old rearwindow is to be reinstalled,use a . Be sure the side upper fasteners,and upper
putty knifeto scrapeoff all of the old adhesive,the r u b b e rd a m s l i n e u p w i t h a l i g n m e n m
t a r k s{ H ,l ) .
fastenersand the rubberdams from the rear . Be sure both ends of the lower rubber dam line
window. Cleanthe insideface and the edge oi the up with the edge of the glass,
rear window with alcoholwhere new adhesiveis to . Be sure the spoilerfastenersline up with
be applied.Make sure the bonding surfaceis kept a l i g n m e nmt a r k s{ J ) .
free of water, oil and grease. . Be carefulnot to touch the rearwindow where
a d h e s i v ew i l l b e a D o l i e d .
: Applyprimerhere.
1,1,.,1,'
E G
"6'J1r-,
20-26
12. Glue the side upperfasteners(A) andsidelower , p p l ya l i g h tc o a to f g l a s sp r i m e r
1 5 . W i t h a s p o n g ea
fasteners(B)with adhesivetape (3M 5312,or along the edge of the rear window (A),upper
equivalent)tothe hatch as shown. rubber dams (B),and lower rubberdam (C)as
shown, then lightly wipe it off with gauzeor
FastonerLocations
cheesecloth:
A>: Fastener,
2 B >: Fastener,
2
. With the printeddots (D) on the rearwindow as a
cl
T-8. ar\\
itf,
guide, apply the glassprimer to both side
portionsof the rearwindow.
. Do not apply body primer to the rearwindow,
and do not get hatchand glass primer sponges
m i x e du p .
lf you do, the adhesivemay not bond to the rear
window properly.causinga leak afterthe rear
w i n d o wi s i n s t a l l e d .
. Keepwater, dust, and abrasivematerialsaway
from the primed surface.
.. : Applyglasspiimer here.
t5. Set the rearwindow in the opening,and centerit.

Align the clips (A) of the rearwindow with the holes
t a r k s( B )
i n t h e o p e n i n gf l a n g e .M a k ea l i g n m e n m
acrossthe rearwindow, hatch,and body with a
greasepencilat the four pointsshown. Be careful
not to touch the rearwindow where adhesivewill
beapplied.
1 4 . R e m o v et h e r e a rw i n d o w .
(cont'd)
20-27
Glass
RearWindow Replacement(cont'd) I
1 6 .With a sponge,apply a light coat of body primer to 18. Packadhesiveinto the cartridgewithout air pockets
t h e o r i g i n aa
l d h e s i v er e m a i n i n ga r o u n dt h e r e a r to ensurecontinuousdelivery.Putthe cartridgein a
window openingflange. Letthe body primer dry for caulkinggun, and run a bead of adhesive(A)
at least 10 minutes; aroundthe edge of the rearwindow (B)as shown.
With the glassprimer (C)you appliedin step 15 as
. Do not apply glassprimer to the body, and be a guide,apply the adhesiveto both side portionsof
carefulnot to mix up glassand body primer the rearwindow.
sponges. Apply the adhesivewithin 30 minutesafter
. Nevertouch the primed surfaceswith your hands. applyingthe glassprimer. fMakea slightlythicker
',,,,,': Applybodyprimerhe.e. bead at each corner.
12 mm r,
10.47in.) ,\
A
ii'-
(0.28in.l
20 mm
in.l
10.79
\
2mm
{0.08in.)
aru'.1{-----"
"V" in the end ofthe

1 7 . Beforefilling a cartridge,cut a
nozzle{A} as shown.
7 mm (0.27in.)
20-28
OuarterGlassReplacement
19. Use suctioncups to hold the rearwindow over the NOTE:
opening.align it with the alignmentmarks you . Put on glovesto protectyour hands.
'13, . Wear eye protectionwhile cuftingthe glassadhesive
made in step and set it down on the adhesive.
Lightlypush on the rearwindow until its edgesare with piano wire,
fully seatedon the adhesiveall the way around.Do . Use seatcoversto avoid damagingany surfaces.
not open or closethe doors until the adhesiveis dry.
1 . R e m o v et h e C - p i l l atrr i m ( s e ep a g e2 0 - 5 1 ) .
20. Scrapeor wipe the excessadhesiveoff with a putty lf necessary,removethe rear side trim panel (see
knife or towel. To removeadhesivefrom a painted page 20-51) and B-pillarupper trim (seepage 20-
surfaceor the rearwindow, use a soft shop towel 50).
dampenedwith alcohol.
2. Removethe front seal {A) from the front edge of the
21. Letthe adhesivedry for at least 'l hour,thenspray glass (B).lf necessary,cut the seal with a utility
water over the rear window and checkfor leaks. knife.
Mark the leakingareas,let the rear window dry,
then sealwith sealant.Let the vehiclestandfor at
least4 hours after rearwindow installation,lf the
vehiclehas to be used within the first 4 hours,it
must be driven slowly.
2 2 . R e i n s t a l l a lrle m a i n i n gr e m o v e dp a r t s .
NOTE:Advise the customernot to do the following

. S l a mt h e d o o r sw i t h a l l t h e w i n d o w sr o l l e du p .
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
(cont'd)
20-29
Glass
OuarterGlassReplacement(cont'dl
3 . Apply protectivetape to along the insideand 6 . With a putty knife,scrapethe old adhesivesmooth
outsideedgesof the body. Using an awl, make a to a thicknessof about 2 mm (0.08in.) on the
hole through the adhesivefrom insidethe vehicle. bonding surfacearoundthe entirequaner glass
Pusha pieceof piano wire through the hole, and o p e n i n gf l a n g e :
wrap each end around a pieceof wood.
. Do not scrapedown to the paintedsurfaceof the
With a helperon the outside,pull the piano wire (A) body; damagedpaint will interferewith proper
backand forth in a sawing motion. Holdthe piano bonding
wire as closeto the quarterglass(B) as possibleto . Removethe clips from the body.
preventdamageto the body, and carefullycut
through the adhesive(C)aroundthe entirequarter 7 . Cleanthe body bondingsurfacewith a sponge
grass. d a m p e n e di n a l c o h o lA
. f t e rc l e a n i n gk. e e po i l ,
greaseand water from getting on the surface.
lf the old quarter glassis to be reinstalled,use a

putty knifeto scrapeoff all of the old adhesiveand
the rubberdam from the glass.Cleanthe inside
face and the edge of the glasswith alcoholwhere
new adhesiveis to be applied.Make sure the
bonding surfaceis keptfree of water, oil, and
grease.
Cuttingpositions:
5. Carefullyremovethe quarterglass.
20-30
9. Set the quarterglass(A) in the opening,and center 11 . A l i g nt h e u p p e rc l i p { A )a n d l o w e rc l i p ( B )w i t h t h e
i t . F r o mi n s i d et h e v e h i c l e m
, a k ea n a l i g n m e n mt ark edge of the quarter glass(C),then anachthem with
(B)to the quarterglasswhere the rear clip will be adhesivetape (NITTO571,or equivalent)to the
installedwith a greasepencil.Be careful not to insideface of the quarter glass,and align the center
l o u c ht h e g l a s sw h e r ea d h e s i v ew i l l b e a p p l i e d . of the rearclip (D)with the alignmentmark (E)you
made in step 9, and attach it with adhesivetape (3
M 4215,or equivalent)to the insideface of the
quarterglassas shown. Be carefulnot to touch the
glasswhere the adhesivetape will be applied.
25.5mm
{ 1 . 0i n . )
10. Removethe quarterglass.
(cont'd)
20-31
Glass
OuarterGlassReplacement(cont'dl
Firstglue the front seal (A)with adhesivetape {31\4 '13.
With a sponge,apply a light coat of glassprimer
) .n d g l u et h e r u b b e rd a m ( B )
4 2 1 3 ,o r e q u i v a l e n t a along the edge of the rubber dam (A) and front seal
with adhesivetape (NITTO501M,or equivalent)to (B)as shown, then lightly wipe it off with gauzeor
the insldeface of the quarterglass(C)as shown. cheesecloth:
Beforeinstallingthe front seal and rubber dam,
a p p l yp r i m e r( 3 M N - 2 0 0 o, r e q u i v a l e n t ) t toh e i n s i d e With the printeddots (C)on the quarterglass(D)
tace of the glass.then glue the seal on: as a guide, apply the glass primer to the upper
and lower corner ponions of the quarterglass.
. Be sure the front seal lines upwiththe bottom Do not apply body primer to the quaner glass,
and front edgesof the glass. and do not get body and glassprimer sponges
. Be careful not to touch the glasswhere adhesive m r x e du p .
will beaoolied. Nevertouch the primed surfaceswith your hands.
lf you do, the adhesivemay not bond to the
.,1.,,/:/| Apply prlJnerhete.
quarterglassproperly,causinga leak afterthe
quarterglassis inslalled.
Keepwater, dust, and abrasivematerialsaway
30 mm from the primed surface.
-"-c 1 1 . 1i8n . l
50 mm I
{1.97in.1
/
\ t
nL
v - -
i--l
'100mm
{3.9i1in.)
45 mm
{ 1 . 7 7i n . }
6 mm (0.24in.) 3.5 mm
{0.r4 in.l
1 1m m
lo.i(} in.)
20-32
14, With a sponge.apply a light coat of body primer to 16. Packadhesiveinto the cartridgewithout air pockets
l d h e s i v er e m a i n i n ga r o u n dt h e q u a r t e r
t h e o r i g i n aa to ensurecontinuousdelivery.Putthe cartridgein a
glassopeningflange.Let the body primer dry for at caulkinggun, and run a bead of adhesive(A)
least 10 minutes: around the edge of the rubber dam (B) as shown.
W i t h t h e g l a s sp r i m e r( C ) y o ua p p l i e di n s t e p 1 3 o n
. Do not apply glass primer to the body, and be the quarterglass (D)as a guide. apply the adhesive
carefulnot to mix up glassand body primer to the upper and lower corner portionsof the
sponges. quarterglass.Apply the adhesivewithin 30
. Nevertouch the primed surfaceswith your hands. minutesafter applyingthe glass primer. lvlakea
slightlythickerbead at each corner.
)'/ii,/ii. I Apply bodv prime. here,
20 mm
mm
(0.08in.l
(0.79in.) l.:J611,
;\
2mm 7mm
{0.08in.) {0.28in.)
3mm
{ 0 . ' 1 2i n . }
I
A
20 mm
{0.79in.)
t5. Beforefilling a cartridge,cut a "V" in the end ofthe

nozzle(A) as shown.
'10mm (0.39in.)
7 mm 10.27in.)
( c o n l ' d)
20-33
Glass
OuarterGlassReplacement(cont'd)
17. Use suctioncups (A)to hold the quarterglassover
the opening.align it with the clips (B)and set it
down on the adhesive.Lightly push on the quarter
glass until its edges are fully seatedon the
adhesiveall the way around.Do not open or close
the doors untilthe adhesiveis drv.
18. Scrapeor wipe the excessadhesiveoff with a putty

knife or towel. To remove adhesivefrom a painted
surfaceor the quarterglass,use a soft shop towel
dampenedwith alcohol.
19. Let the adhesivedry for at least t hour,thenspray

water over the quarterglassand checkfor leaks,
Mark the leakingareas,let the quarterglassdry,
then sealwith sealant.Let the vehiclestand for at
least4 hours after quarterglassinstallation.lf the
vehiclehasto be usedwithin the first 4 hours.it
must be driven slowlv.
20. Reinstallall remainingremoved parts.
NOTE:Advisethe customernot to do the following

. Slam the doors with all the windows rolled up.

in and out of drivewaysat an angle or driving
20-34
Moonroof
GLASS
HeightAdjustment,page 20 37
Replacement, paqe 20-37
C l o s i n oF o r c ea n d O o e n i n" oD r a o
Check;page20-48
DRAINCHANNEL
page20-39
Replacement,
COVER
/,BR^CKEI
,5
_-""-\\q @?a<&,
..t'- ? LIMITSWITCH
@ (AUTO.STOPSWITCH)
-@c
.@
page20-46
Adjustment,
E R
I _a
WIND DEFLECTOR
page20-38
Replacement,
CABLETUBE
REARBRACKET
E
@
E STOP
.a'
CABLEASSEMBLY
Beplacement,page20-44
page20'41
Replacement,
gJ
-.- REARDRA'N TUBE
*\
MOONROOF
CONTROLUNIT
)
REARDRAIN VAI-VE
FRAME
page 20-42
Replacement,
20-35
Moonroof
Symptom Diagnosticprocedure Also check for
'1. Gl a s sh e i g h t
Water leaks Checkfor a cloggeddrain tube.
2. Checkfor a gap betweenthe glassweatherstripand the roof adJustment
panel.
3. Checkfor a defectiveor an improperlyinstalledglass
p r d r a i nc h a n n e l .
w e a t h e r s t r io
4. Checkfor a gap betweenthe drain seal and the roof panel.
W i n dn o l s e 1. Checkfor excessiveclearancebetweenthe glassweatherstrip G l a s sh e i g h t

and the root panel. adjustment
Deflectornoise 1. Checkfor a imDrooerclearancebetweendeflectorseal and

roof panel.
2, Checkfor a insufficientdeflectorextension.
3. Checkfor a deformeddeflector.
Motor noise 1. Checkfor a loose motor. Checkclosingforce

2 . C h e c kf o r a w o r n g e a ro r b e a r i n g .
3. Checkfor a deformedcable assembly.
Glassdoes not move, 1 . C h e c kf o r a d e f e c t i v eg e a ro r i n n e rc a b l e .

but motor turns 2. Checkfor foreign matter stuck betweenthe guide rail and the
s l i d er .
3 . C h e c kf o r a l o o s ei n n e rc a b l e .
4. l\,4ake sure the cableassemblyis attachedproperly.
Glassdoes not move 1. Checkfor a blown fuse.

and motor does nol 2. Checkfor a faulty moonroof switch.
t u r n ( g l a s sc a n b e 3. Checkthe limit switch.
moved with 4. Checkfor a run down battery.
moonroofwrench) 5. Checkfor a defectivemotor.
6. Checkfor a faulty relay.
20-36
GlassHeightAdjustment GlassReplacement
The roof panel (A) should be even with the glass 'L
C l o s et h e g l a s sf u l l y .
weatherstrip(B).to within 2*0.5/ 1 mm (0.08+0.02l
0.04 in.) all the way around.lf not, make the following S l i d et h e s u n s h a d ea l l t h e w a y b a c k .
adjustment:
Removethe screws (A),then remove both bracket
B covers (B).Removethe nuts (C)and shims {D)from
both glassbrackets(E).
2 + 0.5/ 1mm FastengrLocations
{0.08+ 0.02/-0.0i1in.}
A } : Screw, 2 c O ,Nut. il
@
E
\o
1 , Removethe bracketcover from each side.
2. L o o s e nt h e n u t s{ A ) ,a n d i n s t a l l t h es h i m s( B )
betweenthe glassframe (C)and glass bracket(D)
on each side.
6x1.0mm
9 N.m {0.9kgf.m,7 lbf.ft}
Shim ihickness: Front and rear max. 2 mm 10.08in.l
4. Removethe glass{A) by lifting it up. Do not
B damagethe roof panel.
Forward
A
6x1.0mm
I N.m(0.9kgf.m,7lbt.ft)
3. lf necessary,repeaton the oppositeside.
5. Installthe glassin the reverseorder of the removal,

a n d a d j u s t h e g l a s sh e i g h ta l i g n m e n t .
6. Checkfor water leaks.Use free-flowingwater from

a hose without a nozzle.Do not use high-pressure
water.
20-37
Moonroof
Wind DeflectorReplacement
1 . O p e nt h e g l a s sf u l l y . 3. Installthedeflector(A) in the reverseorder of
removal,and checkthat lhe deflectorarm base (B)
2 . Removethe screws(A, B), and releasethe hooks and deflectorlink pivot base (C)line up with the
(C),then removethe wind deflector(D). s a m ea l i g n m e n lti n e s( D ) .l f n e c e s s a r ya,d j u s t h e m
forward or backwardso the edge of the deflector
Fastener Locations seal (E)touchesthe roof panel (F)evenly.Each
A>:Screw,2B>: Screw, 2 base must be moved the same amount for
adjustment.lf the deflectorseal and roof panel
make a rubbing sound, move the deflector
backwardas necessaryto positionit properly.
4il mm
( 1 . 7i n . )
_ - l
' a -- ' -
20-38
DrainChannelReplacement
1 . Removethe moonroof glass(seepage 20-37). 4 . R e m o v et h e d r a i nc h a n n e (l A ) .
2 . With the moonroofwrench,move both glass

brackets(A) to the positionwhere the moonroof
normally pivots down, and removethe screws
s e c u r i n gt h e d r a i nc h a n n e (l B ) .
FastenerLocations
) : Screw,2
I n s t a l l t h ec h a n n e il n t h e r e v e r s eo r d e ro f r e m o v a l ,
and notethese items:
P u s ht h e d r a i nc h a n n e o
l n t ot h e h o o k su n t i la
faint click is heard.
Checkthe glass height adjustment(seepage 20-
Releasethe drain channel(A)from both hooks{B) 31).
o f t h e d r a i nc h a n n e sl l i d e rb y p u l l i n gt h e d r a i n
channelforward, Checkfor water leaks.Letthe water run freely from
a hose without a nozzle.Do not use a high-pressure
spray.
20-39
Moonroof
SunshadeReplacement
1 . R e m o v et h e d r a i nc h a n n e l . 4. While liftingthe front portionofthe sunshade(A),
move the sunshadeforward until you can see both
Slidethe sunshade(A) until you can see both s u n s h a d er e a rh o o k s( B ) .D o n o t d a m a g et h e
s u n s h a d es l i d e rs p a c e r s( B ) . s u n s h a d ea n d h o o k s .
FastenerLocations FastenerLocations
> : Screw,4 ) : Screw,4
tF (F
3. Removethe screws,then remove both spacers. 5. Removethe screws,then remove both hooks.
20-40
Motor Replacement
6. Removethe sunshade(A), 1 . Removethe headliner(seepage 20-54).
Put on glovesto protectyour hands.Disconneclthe

connector(A),and removethe bolts,then remove
::lll' the motor (B).
=r'"'---
----.-..
--., FastenerLocations
>:Bolt,2 A
\ 'l'i
@@
? ,
..
7 . Removeboth front sunshadebasesliders (A) and

b o t h r e a rs u n s h a d eb a s es l i d e r s( B )
{0.9kgf.m.
7 rbf.ftl
t'-^' Installthe motor in the reverseorder of removal,

' a { . lvlakesurethe connectoris plugged in properly.
. Checkthe motor operation.
8 . I n s t a l l t h es u n s h a d ei n t h e r e v e r s eo r d e ro f r e m o v a l ,
and checkthe glassheight adjustment(seepage
20-37).
9 . Checkfor water leaks.Let the water run freely from

a hose without a nozzle.Do not use a high-pressure
spray.
20-41
Moonroof
Frameand DrainTubeReplacement
. Headliner(seepage 20-54)
. Moonroof glass(seepage20-37)
2. Put on glovesto protectyou r hands.Disconnectthe motor connector(A),open/close-tilt/close

switch connector
{B),moonroof control unit connector{C),auto-stopswitch connector(D),and the drain tubes (Ei,and removethe
moonroofrelays(F).
FastenorLocations
> : Bolt,10
{um
irl
/^
6x1.0mm
9.8N.m
(1.0kgf.m,7.2lbfft)
Removethe interiorharness(G) by detachingthe harnessclips (H).
4 . With an assistantholdingthe frame (l). removethe bolts,startingat the rear,and releasethe rear hooks (J) by
moving the f rame forward,then removethe frame.
5 . With the help of an assistant,carefullyremovethe frame through the passenger'sdoor opening.Takecare not to
scratchthe interiortrim and body, or tear the seat covers.
20-42
6. To removea front drain valve (A)from the body, 8 . I n s t a l l t h ef r a m ea n d d r a i nt u b e i n t h e r e v e r s eo r d e r
removethe kick panel,left or right (seepage 20-50). of removal,and note these items:
Tie a string to the end of the drain tube, then pull
the front drain tube (B)down out of the front pillar. . B e f o r ei n s t a l l i n g
t h e f r a m e ,c l e a rt h e d r a i nt u b e s
and drain valves using compressedair.
. Checkthe frame seal.
. C l e a nt h e s u r f a c eo f t h e f r a m e .
. When installingthe frame, first attachthe rear
hooks into the body holes.
. Make sure the connectorsare plugged in
properly.
. When connectingthe drain tube, slide it overthe
f r a m en o z z l ea t l e a s t1 0 m m ( 0 . 3 9i n . ) .
.Installthetubeclip(A o )n t h e d r a i nt u b e( B )a s
shown.
1 . To remove a rear drain valve (A)from the cargo

compartment,removethe rear side trim panel (see Upward
p a g e2 0 - 5 1 ) . D e t a tchhe c l i p s( B ) ,t h e n r e m o v et h e
d r a i nt u b e ( C ) ,
B
tI -
I
B
9 . Checkfor water leaks.Let the water run freely from

a hosewithout a nozzle.Do not use a high-pressure
spray.

20-43
Moonroof
DrainChannelSliderand CableAssemblyReplacement
1. Removethe frame (seepage 20-42). 5 . P i v o t t h eg l a s sb r a c k e (t A )d o w n b y s l i d i n gt h e l i n k
lifter (B) back,then slide both glassbracketsback
2. Removethese partsfrom the frame: with the link lifter.
. Sunshade(seepage 20-40)
. Moonroof motor (seepage 20-41)
3. Put on glovesto protectyour hands,Removethe

screws(A, B),then removethe slide stops (C)and
cabletube rear brackets(D).Removethe bolts (E)
from the cabletube side bracket(F)and the cable
tube mounting screws(G)from both sidesof the
f r a m e( H ) .
FastenerLocations
A> rScrew.2 B): Screw,2 E > : B o l t , 2
@ @
r): Screw S l i d et h e c a b l ea s s e m b l y( A )a n d b o t hg l a s s
6\-'1 brackets(B) back,then removethem from the
f r a m e( C ) .
Position switch side:
6x1.0mm
A c g , aN . m
No switch sidel
o 6x1.0mm C
9.8 N.m
B 11.0kgf.m,7.2 lbf.ft)
V
Detachthe onen switch connectorclip {l)from the

frame.
20-44
7 . R e m o v et h e d r a i nc h a n n e sl l i d e r ( A )f r o m t h e g l a s s 8 . I n s t a l l t h es l i d e ra n d c a b l ea s s e m b l yi n t h e r e v e r s e
bracket(B). o r d e ro f r e m o v a l a, n d n o t et h e s ei t e m s ;
. D a m a g e dp a r t ss h o u l db e r e p l a c e d .
' Apply multipurposegreaseto the glassbracket
( A )a n d g u i d er a i lp o r t i o no f t h e f r a m e ( B )
indicatedby the arrows.
. Beforereinstallingthe motor, make sure both
l i n kl i f t e r sa r e p a r a l l e la, n d i n t h e f u l l y c l o s e d
position.
. Beforereinstallingthe motor, installtheframe
a n d g l a s s t, h e nc h e c kt h e o p e n i n gd r a g ( s e ep a g e
20-481.
B ---
\ -':rdrt'Irrt
\ fl u,t L-
----lll
a/J' I ll
l$=-r:-
20-45
Moonroof
Limit Switch Adjustment
1. Removethe headliner(seepage 20-54).
Fullyclosedpositionadiustment
2. With the moonroof wrench,closethe glass(A) fully:
. Make sure both link lifters(B)are parallel,and in the positionshown.

. Checkthe g lassfit to the roof panel and the glass height (seepage 20-37).
5x0.8mm
5 N.m {0.5kgf.m,4lbf.ft)
3 . W i t h a n o p e n - e n dw r e n c h ,l o o s e nt h e l i m i ts w i t c hm o u n t i n gb o l t s( C ) .
4. Adjust the limit switch (D):
' Move the switch plate (E)a little at a time, then secureit atthe positionwhere you hear a faint clickwhen
the
switch cam (F) pushesthe positionswitch (open/close).
. Checkthat the switch plate contactsthe switch bracket(G).
20-46
Auto-stop position adiustment
5. With the moonroofwrench.operatethe glass(A)to the auto-stopposition.
/--:.!Jtr+rtl
\_-_:_t+#1 <F
. / \
, / \
G i! .. I
5 N.m {0.5kgt.m,4 lbt ft)
With an open-endwrench, loosenthe auto-stopswitch m o u n t i n g b o l t s ( C ) .
7 . Adjustthe auto-stopswitch (D):
. N 4 o v e t h se w i t c hp l a t e( E )a l i t t l e a t a t i m e , t h e n s e c u r e i t a t t h e p o s i t i o n w h e r e y o u h e a r a f a i n t c l i c k w h e n t h e
switch cam (F)pushesthe switch (auto-stop).
. Checkthat the switch platecontactsthe switch bracket(G).
8 . Checkthe operationof the glassby operatingthe moonroof switch:From the tilt-up positionto the fully closed
position,from the fully open positionto the auto-stopposition,from the auto-stoppositionto the fully closed
posltron.
L Checkfor water leaks.Letthe water run fleely from a hosewithout a nozzle.Do not use a high-pressurespray
20-41
Moonroof
ClosingForceand OpeningDragCheck
1 . R e m o v et h e h e a d l i n e(rs e ep a g e2 0 - 5 4 ) . 4. Openingdrag check:Protectthe leadingedge of the
glasswith a shop towel (A).Measurethe effort
2. Closingforce check: requiredto open the glass using a spring scale(B)
as shown.
. With a shop towel {A) on the leadingedge of the
g l a s s( B ) ,a f t a c ha s p r i n gs c a l e( C )a s s h o w n .
. Havean assistanthold the switchto closethe
glasswhile you measurethe force requiredto
stop it.
. Readthe force as soon as the glassstops moving,
then immediatelyreleasethe switch and spring
scale.
Closing Force; 200 290 N (20 30 kgf,44 66 tbl)
5 . lf the load is over 40 N (4 kgf,9 lbf),check;
. The side clearanceand glass heightadjustment

(seepage 20'37),
. F o r b r o k e no r d a m a g e ds l i d i n gp a r t s .l f a n y
s l i d i n gp a r t sa r e d a m a g e d r, e p l a c et h e m .
\
lf the force in not within specification,removethe

moonroof motor (seepage 20-41),then check:
. The gear portion and the inner cablefor breakage

and damage.lf the gear portion is broken,
r e p l a c et h e m o t o r .l f t h e i n n e rc a b l ei s d a m a g e d ,
removethe frame (seepage 20-42),and replace
the cable assembly(seepage20-44).
' T h e m o o n r o o fm o t o r ( s e ep a g e2 2 - 1 1 2 )I .f t h e
motor fails to run or doesn'ttu rn smoothlv.
replaceit (seepage 20-41),
. The opening drag. Go to step 4.
20-48
InteriorTrim
HATCHLOWERTRIM PANEL
oaoe20-53
HATCHSIDETRIM
page20 53
B.PILLARUPPEBTRIM
page20-50
TRIM
C-PILLAR
page20'51
DOOROPENINGTRIM
page20-50
A.PILLARTRIM
page20-50
R e m o v a l / l n s t a l l a t ipoang, e2 0 5 4
KICKPANEL
page20 50
Replacement,
page20-55
DOORSILLTRIM
page20-50
CARGOAREA FLOOR
page20-52
REARSIDESHELF
page20 5l
REARCENTERSHELF
page20-51
REARSIDETRIM PANEL CARGOFLOORMAT
page20-51 page20-52
REARTRIM PANEL
page 20-52
20-49
InteriorTrim
Trim Removal/lnstallation- Door Area
NOTE:
. When prying with a flat-tipscrewdriver,wrap it with protectivetape to preventdamage.
. Takecare not to bend or scratchthe trim and panels.
1 . R e m o v et h e t r i m a s s h o w n .T o r e m o v et h e d o o r s i l l t r i m a n d B - p i l l a ur p p e rt r i m , r e m o v et h e r e a rs i d et r i m p a n e l
as necessary(seepage 20-51).
2. Installthetrim in the reverseorder of removal,and note these items:
. Replace a n y d a m a g e dc l i p s .
. Apply liquid thread lockto the anchor bolts before reinstallatior,.
. Beforeinstallingthe anchorbolts, make sure there are no twists or kinks in the belts.
FastenerLocations
A>: Clip,2 B > r C l i p , 3 C > : C l i p , ?
(Black) {White)
FRONTSEATBELT
2ffi ,"lF
\r{ UPPER ANCHORBOLT
Tl|t 7/16-20UNF
32 N m (3.3kgf m,24 lbf.ft)
A-PILLARTRIM
il-::7
KICKPANEL
ao----- LowERANcHoRcAP
/
FRONTSEAT BELTLOWER
ANCHORBOLT
7/16-20UNF
32 N.m (3.3kgt.m,24lbl.ftl
REARSIDETRIM PANEL
20-50
Trim Removal/lnstallation- RearSideArea
NOTE:
'1.
To removethe rear side trim panel,removethese items:
. Rearseat cushionand rear seat-back(seepage20-80)

. Cargofloor mat and cargo areafloor (seepage 20-52)
. R e a rt r i m p a n e l{ s e ep a g e 2 0 - 5 2 )
2 . Removethe trim as shown. On the right side,disconnectthe cargo compartmentlight connector.
3 . Installthetrim in the reverseorder of removal,and note these items:
. Replace a n y d a m a g e dc l i p s .
. Make sure the cargo compartmentlight connectoris pluggedin properly.
. l f t h e t h r e a d s o n t h e r e a r s i d e t r i m p a n e lm o u n t i n gs e l f - t a p p i nEg Ts c r e w sa r ew o r n o u t , u s ea n o v e r s i z e sd e l f -
t a p p i n gE T s c r e w( P / N9 0 1 3 7 - S 1 A - E1o)1m a d es p e c i f i c a l lfyo r t h i s a p p l i c a t i o n .
. W h e ni n s t a l l i n g t h e r e a rs i d es h e l f ,s l i pt h e r e a rs e a tb e l tt h r o u g ht h e s l i t i n t h e t r i m .
' A p p l y i i q u i dt h r e a dl o c k t ot h e a n c h o rb o l t sb e f o r er e i n s t a l l a t i o n .
. Beforeinstallingthe anchorbolts,make sure there are no twists or kinks in the belt.
Fasten€r Locations
A>:Clip,11 B> rClip,2 c>rClap,l
-..:.:'
TRIM
S I D ES H E L F
REARSEATSELT
SIDETRIM PANEL
SEAT
STRIKERCAP
S I L LT R I M
SELF-TAI
scREws
5x0.8mm
{ 0 . 4k g f m , 3 l b f . f t )
.. F . -\ *: : :- . n: \
,/\ I FRONTSEAT AELT
\*J REARSEAT BELTLOWER \
LOWERANCHORBOLT
,/ ANCHOF BOLT
7/16-20UNF
\
\
7/16-20UNF
32 N.m
R E A RB U L K H E A O { 3 . 3k g f m , 2 4 l b t . t t )
COVER REARSPEAKERCOVER 32 N m (3.3 kgf m, 24 lbf ft, \
L O W E RANCHORCAP

20-51
lnteriorTrim
- CargoFloorArea
Trim Removal/lnstallation
NOTE:
. When jrying with a flat-tipscrewdriver,wrap it with protectivetape to preventdamage'
. Takecare notto bend or scratchthe trim and panels.
( s e ep a g e2 3 - 1 1 ) '
1 . T o r e m o v et h e r e a rt r i m p a n e l ,r e m o v et h e c h i l ds e a tt e t h e ra n c h o r
2. Removethe trim as shown.
, n d r e p l a c ea n y d a m a g e dc l i p s '
3 . I n s t a l l t h et r i m i n t h e r e v e r s eo r d e ro f r e m o v a l a
Fastener Locations
A > :C l i p , 3 B > : C l i p . 4
j-=
E T r
\t
FLOORMAT
COVER
REARSEAT-BACK
-t
CARGOAREA FLO
7
To rearsade
trim panel.
To rearsidetrim
panel.
REARTBIM PANEL
20-52
Trim Removal/lnstallation- HatchArea
NOTE:
1. Removethe trim in the sequenceshown.
. Hatchuppertrim panel
. Left hatchside trim
. Righthatchside trim
. Hatchlower trim panel
, n d r e p l a c ea n y d a m a g e dc l i p s .
Fastener Locations
o>
A>;crip,a B>:crip,2 .>,l,l,Jil,l3 E>:crip.2
3il;1,
"-{q .1
\. n l f nl t
gg itr^
Y,]
O HATCHLowER TRrM
PANEL
HATCHLOWERTRIMPANEL
a- ,,) I
t7,
f.
) a =- -1 a ->
.D HATCHUPPERTRIM PANEL
HATCH UPPERTRIM PANEL
HATCHSIDETRIM
20-53
InteriorTrim
HeadlinerRemovaUlnstallation
NOTE: 3. From both rear passenger's,removethe caps (A),
. When prying with a flat-tip screwdriver,wrap itwith and removethe screws,then removethe grab
protectivetape to preventdamage. h a n d l e s( B ) .
. Takecare not to bend and scratchthe headliner.
. Be carefulnot to damagethe dashboardand other FastenerLocations
interiortrim. > : Screw,4
1. Removethese items: t , t;---iJ
. A-pillartrim, both sides(seepage 20-50)

. B-pillau r p p e r t r i m ,b o t h s i d e s( s e ep a g e2 0 - 5 0 )
. Hatchweatherstrip,as necessary{seepage 20-
92\
. C - p i l l atrr i m , b o t hs i d e s( s e ep a g e2 0 - 5 1 )
. Moonroof switch (seepage22-'112)
. Spotlights(seepage 22-961
)e
. Ceilinglight (seepage 22-96)
5x0.8mm
Removethe sunvisor{A) and holder {B)from both 4 N.m
srdes. {0.4 kgf.m, 3 lbf.ft}
-1 Removethe caps {C).

-2 Removethe screws.
-3 Removethe sunvisorfrom the body and holder.
-4 Using a flat-tipscrewdriver,push the hook (D),
a n d t u r n t h e h o l d e r9 0 ' . t h e n p u l l i t o u t .
FastenerLocations
> : Screw,4
r(\'-r
\)*
5x0.8mm
5 N.m
{0.5kst m.4lbf ft}
20-54
CarpetReplacement
4. Removethe headliner. SRScomponentsare locatedin this area.Reviewthe
SRScomponentlocations(seepage 23-13)and the
-1 Removethe socketplug (A). precautionsand procedures(seepage23-14)in the SRS
- 2 R e m o v et h e r e m a i n i n gd o o r o p e n i n gt r i m { B } sectionbefore performingrepairsor service.
from each roof portion.
-3 Detachthe clips (C),and releasethe fasteners NOTE:
( D )b y p u l l i n gt h e f r o n t p o r t i o no f t h e h e a d l i n e r . Put on glovesto protectyour hands.
(E)down. . Takecare not to damage,wrinkle. or twist the carpet.
-4 With the help of an assislant,releasethe clips . Be carefulnot to damagethe dashboardor other
(F)of the headlinerfrom the moonroof frame interiortrim pieces.
( G ) ,a n d r e l e a s et h e h e a d l i n efrr o m t h e c l i p s( H )
by slidingthe headlinerforward, and lowering 1. Removethese items:
the headliner.
-5 Removethe headlinerthrough the passenger's . Frontseats,both sides(seepage 20-111
opening. . Driver'sdashboardunder cover (seepage 20-60)
. Passenger'sdashboardIower cover (seepage
FastenerLocations 20-631
C>:Clip,3 F>:Clip,2 H>:Clip,2 . Rearseatcushion(seepage 20-80)
. Kick panels,both sides(seepage 20-50)
a
o . Door silltrim, both sides(seepage 20-50)
. Consoles,front and rear (seepage20-57)
2 . R e m o v et h e n u t ( A ) ,a n d u s i n ga h e xw r e n c h ,
releasethe clip (B),then removethe footrest(C).
FastenerLocations
Aa:Nut,1 B):Clip,'l
--'1
I
--\ -JrL
tj=\-/I ;tt4f
l[il
A
6x1.0mm
9.8Nm
5 . Installthe headlinerin the reverseorder of removal, 11.0kgf m,7.2 lbf.ft)
-o
. 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
passenger'sdoor opening,be carefulnot to fold
or bend it, Also, be carefulnot to scratchthe
DOOy.
. C h e c kt h a t b o t hs i d e so f t h e h e a d l i n ear r e
securelyattachedto the trim.
. R e p l a c ea n y c l i p st h a t r e m a i ni n t h e r o o f d u r i n g
r e m o v a lR. e i n s t a l l t h cel i p sb a c ki n t h e h e a d l i n e r
before installation.
(cont'd)
20-55
InteriorTrim
CarpetReplacement(cont'dl
Using a utility knife,cut the carpet(A) underthe 5. Installthecarpetin the reverseorder of removal,
heaterareas(B),and cut out the parkingbrakelever and note these items:
area (C)as shown, then pull backthe carpet.
. T a k ec a r en o t t o d a m a g e w , r i n k l e ,o r t w i s t t h e
A B
carpeL
. Make sure the seat harnessesare routed
correctly.
. S l i pt h e c a r p e tu n d e rt h e r e a rs i d et r i m p a n e lo n
each side properly.
. Replace t h e c l i p i f i t ' sd a m a g e d .
. Reattachthe cut areasunder the heateraround
the parkingbrakelever with a wire tie.
. When installingnew carpet,cut the carpet(A)
underthe heaterareas(B),and around the
parkingbrakelever (C).After installingthe new
carpet,slip the carpetfrom the driver's and
passenger'sside through the spacebetweenthe
heaterunit and body, and reattachthe cut area
{C)around the parkingbrakeleverwith wire ties.
4 . Removethe clip (A),and releasethe fasteners(B).

t
Pullthe carpetout from both rear side trim panels
(D),then removethe carpet(C).
FastenerLocation
A >: Clip.1
tr
&z
20-56
Consoles
Console,Frontand RearRemoval/lnstallation
NOTE:Takecare not to scratchthe front seal, 2. Removethe front console(A).
dashboard,and relatedparts.
- 1 P u l lo u t t h e d a s h b o a r dc e n t e rl o w e rc o v e r{ B )
1 . R e m o v et h e r e a rc o n s o l e( A ) . to detachthe clips (C).
-2 Dlsconnectthe accessorypower socket
-1 Slidethe front seatforward fully on each side. c o n n e c t o(rD ) .
-2 Removethe screws{B)from the rear portionof 3 R e m o v et h e c o n s o l eb o x m a t ( E ) .
the rearconsole, - 4 R e m o v et h e b o l t s( F ) ,s c r e w s( G ) ,a n d c l i p s( H ) .
-3 Slidethe front seat rearwardfully on each side. -5 Gently pull out the front consoleto releasethe
- 4 P u l l t h ef r o n t p o r t i o no f t h e r e a rc o n s o l eu p t o h o o k s( l ) a n dp i n s ( J ) .
detachthe clips (C)and hooks (D),then release
the rearconsolefrom the front console(E). FastenerLocations
- 5 S t a r t i n ga t t h e r e a r ,p u l l t h e r e a rc o n s o l eu p , C > : C l i p , 3 F > i B o l t , 2 G > : S c r e w . 2H ) : C l i p , 2
then remove it.
*..4-
' * q ' 4!--
J - L } * fF-
J \ . / -,-('E9'/
d
FastenerLocations
B >:Screw,2 C >: Clip,2
6x1.0mm
98Nm
(1.0kgt.m,7.2lbf.ft)
Installthe consolein the reverseorder of removal,

and note these ltems:
. R e p l a c ea n y d a m a g e dc l i p s .
. Make sure the accessorypower socketconnector
i s p l u g g e di n p r o p e r l y .
. P u s ht h e c l i p si n t o p l a c es e c u r e l y .

20-57
Consoles
Front ConsoleDisassembly/Reassembly
NOTE;Takecare not to scratchthe consoleand relatedparts.
Fastener Locations
):Screw,8
C*
FRONTCONSOLE
\ a
BEVERAGE
HOLDER
ASSEMBLY
,/
',/
BOX
CONSOLE
20-58
Dashboard
InstrumentPanelRemoval/ Driver'sDashboardLower Cover
Installation Removal/lnstallation
NOTE: NOTE:Takecare not to scratchthe dashboardand

. When prying with a flat-tipscrewdriver,wrap it with relatedParts.
protectivetape, and apply protectivetape aroundthe
relatedparts,to preventdamage. 1. Removethe driver'sdashboardlower cover (A).
. Takecare not to scratchthe dashboardand related
parts. -1 Turn the lock knob (B)90".
-2 Gently pull out the left side to releasethe
1. Tilt the steeringcolumn down. h o o k s( C ) ,
-3 Pull out the panelto releasethe hooks (D).
2. Removethe steeringcolumn upper cover {seepage
17,9).
Removethe instrumentpanel (A).
-1 Gently pull out along the bottom to releasethe

c l i p s( B )a n d h o o k s( C ) .
-2 Gently pull out the upper portionto releasethe
c l i p s( D )a n d h o o k s( E ) .
FastenerLocations
B> : c l i p . 2 D D:,C l i p , 2
^*,
Installthecover in the reverseorder of removal,

and push the hook portions into placesecurely.
4 . Installthe panel in the reverseorder of removal,

and push the clip and hook portionsinto place
securery.
20-59
Dashboard
Driver'sDashboardUnderCover Driver'sPocketRemoval/
Removal/lnstallation lnstallation
NOTE:Takecare not to scratchthe dashboardand NOTE:

relatedparts. . Put on glovesto protectyour hands.
1. Removethe driver'sdashboardunder cover (A). p an s .
- 1 T u r nt h e l o c kk n o b( B )9 0 ' . 1. Removethe driver's pocket(A)

-2 Gentlypull down the rear edgeto releasethe
clip(C). -1 Removethe driver'sdashboardunder cover.
-3 Pullthe cover away to releaseit from the clip -2 Removethe screws(B).
{D). -3 From behindthe dashboard,push the pocket
b a c kb y h a n dt o r e l e a s et h e c l i p s( C ) .
FastenerLocations 4 Release t h e h o o k( D ) .
C >: Clip.1
n FastenerLocations
B):Screw,2 C>: Clip,2
','"\5
;;t='
Installthecover in the reverseorder of removal, 2 . Installthe pocketin the reverseorder of removal,

and push the clip portion into placesecurely. and push the clip portionsinto placesecurely.
20-60
Shift LeverTrim Removal/lnstallation
NOTE: 4. Pull outthe shift levertrim (A) by hand to release
. Takecare not to scratchthe dashboardand related t h e r e m a i n i n gc l l p s( 8 , C ) a n d h o o k s( D ) ,a n d
parts. disconnectthe hazardwarning switch connector(El,
. Put on glovesto protectyour hands. then removethe trim.
,,.;w,
1. Removethe glove box (seepage20-63). FastenerLocations
B >:Clip,1 C > : C l ; p1, D>: Hook,3
2. Removethe shift knob.
, ,
U s i n ga r a t c h ew
t r e n c ha n d a n 1 1 i n c he x t e n s i o n
(A)wrapped with a shop towel (B),carefullyinsert
the extensionthrough the glove box opening,and Installthe trim in the reverseorder of removal,and
push the shift levertrim (C)from underthe trim to note these rtems.
releasethe clips (D)and hooks (E)of the left side.
. Make sure the hazardwarning switch connectot
Fastener Locations is plugged in properly.
D>clip,2 E> H o o k , 2 . Pushthe clip and hook portionsinto place
.-a7 securely,
i:F \r-
t1
\V u
20-61
Dashboard
DashboardCenterPanelRemoval/lnstallation
NOTE: 4. Pull out the centerpanel (A)to releasethe clips (B)
. Put on glovesto protectyour hands. and hooks (C),and removethe harnessholder (D)
. When prying with a flat-tipscrewdriver,wrap it with from the bracket(E).Disconnectthe audio unit
protectivetape, and apply protectivetape around the connector(F),antennalead (G),heaterswitch
relatedparts,to preventdamage. connector(H)and heatercontrol unit connectors(l).
parts. FastenerLocations
B ): Clip,8
1. Make sure you have the anti-theftcode for the radio, *4
the write down the frequenciesfor the preset
, F
buttons.
. Driver'sdashboardlower cover (seepage20-59)

. Passenger'sdashboardlower cover (seepage
20-63).
. Glove box (seepage20-63).
. Shift levertrim {seepage20-61).
From the glove box and driver'sdashboardIower

cover openings,loosenthe bolts (A) securingthe
centerpanel (B).
Fastener Locations Installthe panel in the reverseorder of removal,

A): Bolt,2 x 0.8 mm
5Nm and note these items:
\
Make sure eachconnectoris pluggedin properly,
and antennalead is connectedproperly.
Pushthe clip portionsinto placesecurely.
Reconnectthe negativecableto the battery.
Do the ECN4/PCt\4idle learn procedure{seepage
1l-139).
;.'
Enterthe anti-theftcode for the radio.then enter
Resetthe clock.
20-62
Passenger's
DashboardLower GloveBox Removal/lnstallation
CoverRemoval/lnstallation
SRScomponentsare locatedin this area.Reviewthe
S R Sc o m p o n e n lto c a t i o n s( s e ep a g e2 3 - 1 3 a) n dt h e
NOTE:Takecare not to scratchthe dashboardand p r e c a u t i o nasn d p r o c e d u r e (ss e ep a g e2 3 1 4 )i n t h e S R S
relatedparts. sectionbeforeperformingrepairsor service.
1. Removethe passenger'sdashboardlower cover NOTE:Takecare not to scratchthe dashboardand

(A). relatedparts.
-1 Gently pull down the rear edge to releasethe 1. Removethe passenger'sdashboardlower cover.
c t i p s( B ) .
-2 Pullthe cover away to releasethe pins (C)from 2. While holding the glove box (A),removethe glove
t h e h o l d e r s( D ) . box stop (B)on each side.
FastenerLocations FastenerLocalions
B>: Clip,3 >Boh.2
.-6\
A
I jl
.-<,/fir-"b
{Ill
tJ
r-3t.oi,t-'
10.5kgf m,
4 tbf.ft)
Installthe under cover in the reverseorder of Removethe bolts,then removethe glove box.
removal,and push the clip ponions into place
securety. 4 . l n s t a l l t h eg l o v eb o x i n t h e r e v e r s eo r d e ro f
removal.
20-63
Dashboard
DashboardSide Vent RemovaU BeverageHolderRemoval/
Installation lnstallation
NOTE: NOTE:
. Takecare not to scratchthe dashboard. . Takecare not to scratchthe dashboard,
. Put on glovesto protectyour hands. . Put on glovesto protectyour hands.
1. Removethe dashboard(seepage 20-66). 1. Removethe dashboard(seepage20-66).
2. Removethe steeringhangerbeam from the 2. Removethe screws,then removethe beverage

dashboard(seepage 20-68). h o l d e r( A ) .
FastenerLocations
3. Removethe screws,then removethe air duct (A)
f r o m t h e d a s h b o a r d( B ) . ):Screw.2
FastenerLocations
):Screw, 7
6hD
t
4 . Remove the screws, lhen remove the slde vent (A). 3 . Installthe beverageholder in the reverseorder of
removat.
Fastener Locations
):Screw,4
5 . l n s t a l l t h es i d ev e n t i n t h e r e v e r s eo r d e ro f r e m o v a l .
20-64
Driver'sTray Removal/lnstallation Passenger's Tray Removal/
Installation
NOTE:
. Takecare not to scratchthe dashboard.
. Put on glovesto protectyour hands. NOTE:
. Takecarenotto scratchthe dashboard.
1. Removethe dashboard(seepage 20-66). . Puton glovesto protectyourhands.
2. Removethe beverageholder(seepage 20-64). 1 . Removethe dashboard(seepage 20-66),
3. Removethe screws,then removethe driver'stray 2 . Removethe steeringhanger beam from the

(A). dashboard(seepage 20-68).
FastenerLocations
3 . Removethe air duct (seestep 3 on page20-64).
):Screw.3
4 . Removethe screws,then removethe passenger's
tray(A).
FastenerLocations
):Screw, 8
4, lnstallthe tray in the reverseorder of removal.
5. lnstallthe trav in the reverseorder of removal.
20-65
Dashboard
DashboardRemoval/lnstallation
SRScomponentsare locatedin this area.Reviewthe 4. From the centerpanelopening,removethe screws,
SRScomponentlocations(seepage23-13)and the then removethe centerbracket(A).
precautionsand procedures(seepage23-14)in the SRS
FastenerLocations
sectionbeforeperformingrepairsor service.
):Screw,2
NOTE:
. When prying with a flat-tipscrewdriver,wrap it with
protectivetape, and apply protectivetape aroundthe
relatedpartsto preventdamage.
. Havean assistanthelp you when removing and
installingthedashboa rd.
. Takecare not to scratchthe dashboard,body, and
other relatedparts.

buttons.
Disconnectthe negativecablefrom the battery,and

wait at leastthree minutesbefore beginningwork. Removethe shift lever (seepage 13-51).
Removethese items: From outsideof the passenger'sdoor, gently pull

out along the edge of the dashboardside cover (A)
. Driver'sdashboardlower cover (seepage 20-59) to releasethe hooks (B),then releasethe upper
. Driver'sdashboardunder cover (seepage 20-60) hook (C),to removethe cover.
. Passenger'sdashboardlower cover (seepage
20-63)
. Glove box (seepage 20-63)
. Consoles,front and rear (seepage 20-57)
. Shift levertrim {seepage 20-61)
. Centerpanel (seepage 20-62)
. Kick panels,both sides(seepage 20-50)
. A-pillartrim. both sides(seepage 20-50)
. Steeringcolumn (seepage 17-9)
20-66
Driver's side: Middle portion:
7. From underthe dash,disconnectthe interiorwire 8. Disconnectthe floor wire harnessconnectors(A)

harnessconnector(A),driver'sdoor wire harness s u b h a r n e scso n n e c t o(rB ) .
a n dc o m b i n a t i o n
connectors(B),side turn signallight connector(C).
roof antennaconnector(D),antennalead (E).clutch
switch connectors(F),and brakeswitch connector
(G),and disconnectthe floor wire harness
connectors(H)and engine compartmentwire
harnessconnectors(l)from the under-dashfuse/
r e l a vb o x ( J ) .
Passenger'sside:
9. From under the dash,disconnectthe dashboard

wire harnessconnectors(A),EPSsubharness
connectors(B),enginecompartmentwire harness
connectors(C),A,/Csubharnessconnectors(D),
passenger'sdoor wire harnessconnectors{E),and
s i d et u r n s i g n a l i g h tc o n n e c t o(rF ) .
1 0 . D e t a c ha l l o f t h e h a r n e s sa n d c o n n e c t ocr l i p s .
(cont'd)
20-67
Dashboard
DashboardRemoval/lnstallation SteeringHangerBeam
(cont'd) Replacement
11. From outsidethe driver'sdoor, removethe caps (A), NOTE:Put on glovesto protectyour hands.
then removethe bolts (8, C, D),and lift up on the
dashboard(E)to releaseit from the guide pins 1, Removethe dashboard(seepage 20-66).
(F.G) on the body.
2. Removethese items from the dashboard:
FastenerLocations
B>rBolt.3 C>: Bolt,2 D>: Bolt,2 . lnstrumentpanel (seepage 20-59)
. Driver'spocket(seepage20-60)
m6[-,,,,",",,-,F6't---''
v{/- ffi'!-- . G a u g ea s s e m b l y( s e ep a g e2 2 - 6 4 )
Kr* w- . Passenger'sairbag(seepage 23-'l14)
Removethe screws,thenremovethe glovebox

striker(A).
FasteneaLocations
):Screw,4
B
$7:
^/761:
/ , -
,. r:; 8 x 1.25mm
22Nm
{2.2kgf m, 16lbf.ftl (2.2kgf.m,16lbf.ft)
\
Carefullyremovethe dashboardthrough the front
d o o ro p e n i n g .
1 3 .lnstallthe dashboardin the reverseorder of

. Make sure the dashboardfits onto the guide pins

correctly.
. A p p l y l i q u i dt h r e a dl o c kt o t h e d a s h b o a r d
mounting bolts of the middle portion before
reinstallation.
. Beforetighteningthe bolts,make sure eachwire
harnessand control cablesare not pinched.
properly,and the antennalead is connected
propeny.
. Reconnectthe negativecableto the battery.
. Enterthe anti-theftcode for the radio,then enter
. Resetthe clock.
. D ot h e E C M / P C M i d l el e a r np r o c e d u r ei s e ep a g e
'1-139).
1
20-68
4. Removethe bolts (A) and screws(B)securingthe 5 . I n s t a l l t h eb e a mi n t h e r e v e r s eo r d e ro f r e m o v a l ,
d a s h b o a r d( C )a n d s t e e r i n gh a n g e rb e a m( D ) ,a n d and note these items:
disconnectthe power mirror switch connector(E)
and cruisecontrol main switchconnector(F). . N 4 a kseu r et h e d a s h b o a r dw i r e h a r n e s s( G ) i s n o t
S e p a r a t et h e d a s h b o a r da n d s t e e r i n gh a n g e rb e a m . pinched.
FaslenerLocations properly.
A>rBolt,4 B>:Screw,9
5 N.m {0.5kgf m,4lbf,ftl
20-69
Seats
REARSEAT
page20-80
Seat-backLatchReplacement,
page20-81
Seat-backStrikerReplacement,
page20-81
Seat'backCoverReplacement,
page 20-82
SeatCushionCoverReplacement,
page20-84
FRONTSEAT
page20-i 1
page20 73
Disassembly/Reassembly-Driver's,
page20-74
Disassembly/Reassembly-Passenger's,
SeatCoverReplacement,page20-75
20-70
Front Seat Removal/lnstallation
For some models:SRScomponentsare locatedin this 4. Removethe bolts securingthe front seat.
area.Reviewthe SRScomponentlocations(seepage
23-'13)and the precautionsand procedures(seepage FastenerLocations
23-14)in the SRSsectionbefore performingrepairsor > : Bolt,
service.
NOTE
. When prying with a flat-tipscrewdriver,wrap it with
@
protectivetape to preventdamage.
. Takecare not to scratchthe body or tear the seat
covers.
1, Make sure you have the anti-theftcode for the radio,

butlons.

wait at least3 minutesbefore beginningwork.
3 . Removethe seattrackend covers(A)from the back

of both seattracks.
Outef:
1 0 x 1 . 2 5m m
lnner:
(cont'd)
20-71
Seats
(cont'dl
FrontSeatRemoval/lnstallation
Lift up the front seat,then detachthe harnessclip
(A).and disconnectthe seat belt switch connector
( B )a n d s e a tb e l tb u c k l et e n s i o n ecr o n n e c t o(rC ) .l f
e q u i p p e dw i t h a s i d ea i r b a g d, i s c o n n e ct th e s i d e
a i r b a gc o n n e c t o (r D ) ,a n d o n t h e p a s s e n g e r 'sse a t ,
d i s c o n n e ct th e O P D Su n i tc o n n e c t o(rE ) .T h e
p a s s e n g e r 'sse a ti s s h o w n ,t h e d r i v e r ' ss e a ti s
s i m i l a re x c e p ti t h a sn o O P D Su n i tc o n n e c t o r .
6 . With the help of an assistant,carefullyremovethe

front seatth rough the front door opening.
7 . I n s t a l l t h es e a ti n t h e r e v e r s eo r d e ro f r e m o v a l a
, nd
notethese rtems:
. l\4akesure each connectoris plugged in properly.

. A p p l y l i q u i dt h r e a dl o c kt o t h e s e a tm o u n t i n g
bolts before reinstallatlon.
. Resetthe clock.
. Do the ECM/PCMidle learn procedure(seepage
11 - 1 3 9 ) .
20-72
- Driver's
FrontSeat Disassembly/Reassembly
For some models:SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations(seepage 23-13)
and the precautionsand procedures(seepage 23-14)in the SRSsectionbefore performingrepairsor service.
NOTE:
. Takecare not to tear the seamsor damagethe seatcovers,
. When prying with a flat-tipscrewdriver.wrap it with protectivetape to preventdamage.
' Apply multipurposegreasetothe moving portion of the seattrack.
. To preventwrinklesin the seat cushioncover,stretchthe materialevenlyoverthe pad.
Releasethe seatcushion
coverfrom the cushion
f r a m es p r i n g .
SEAT-BACK
10 x 'l.25mm
47 N.m {4.8kgf.m,
35 rbt.ft)
WIRETIE
RECLINECOVER
RECLINEKNOB
20-73
Seats
- Passenger's
FrontSeat Disassembly/Reassembly
For some models:SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations(seepage23-'13)
and the precautionsand procedures(seepage 23-14)beforedoing repairsor service.
NOTE;
. Takecare not to tear the seamsor damagethe seatcovers
. When prying with a flat-tipscrewdriver,wrap it with protectivetape to preventdamage
. Apply multipurposegreaseto the moving portion of the seattrack
. To Dreventwrinklesin the seat cushioncover,stretchthe materialevenlyover the pad.
. lvlakesure the rear seat accesscable is connectedproperlyon each side
. Replaceany damagedclips,and replacethe wire ties with new ones
SIDEAIRBAG
SEAT"BACK HARNESS
Releasethe seatcushion
coverfrom the cushion
f r a m es p r i n g .
10 x 1.25mm
47 N.m (4.8kgf.m,
3s rbf.ft)
HANGERSPRING
OPDSHARNESS
u
CENTEBCOVER
WIRETIE
SEATCUSHION
FRAME/SEAT
TRACKS
/
REARSEAT ,/CLIP
ACC€SSCABLE
v/
N
*r(".o,
ACCESSKNOB ,/
/- /
I
SLIDELEVER
/ H o o K
RECLINEKNOB
RECLINE
COVER
20-74
Front SeatCoverReplacement
For some models:SRScomponentsare locatedin this 3 . Foldthe seat-backforward.
area.Reviewthe SRScomponentlocations(seepage
23 13)and the precautionsand procedures(seepage t h e h o o k s( A ) ,a n d u n z i pt h e s e a t - b a c k
4. Release
23-'14)in the SRSsectionbeforeperforming repairsor c o v e r( B ) .
service,
NOTE:
. Takecare not to tear the seamsor damagethe seat
covers,
. On the passenger'sseatwith side airbag,do not
touch the OPDSsensorin the seat-backpad, and keep
it away from oil. Oil can corrodethe sensorcausingit
to fail.
. Puton glovesto protectyour hands.
Seat-backCover
'L
Removethe front seat isee page 20-71).
2. W i t h s i d ea i r b a g :F r o mu n d e rt h e s e a tc u s h i o n ,
detachthe side airbagconnectorclip (A),and on
the passenger'sseat,detachthe OPDSunit
c o n n e c t ocr l i p ( B ) .R e l e a s teh e h o o ks p r i n g s( C )
f r o m t h e s e a tc u s h i o nf r a m es p r i n g{ D ) ,t h e n p u l l
the guide cover (E)back,and removethe wire ties
(F).The passenger'sseat is shown, the driver'sseat
is svmmetricalexceptit has no OPDSunit
connector.
(cont'd)
20-75
8 . Using a flat-tipscrewdriverwrappedwith 9. Unzipthe headrestportionof the seat-backcover
protectivetape, insert it into the hook portions ( A ) ,t h e n r e m o v et h e z i p p e ri B ) ,a n d r e m o v et h e
( s e v e np l a c e so) f t h e h e a d r e srte a rt r i m i A ) f r o m t h e cover.
headrestfront trim side. Prv up the hooks (B)to
releasethe labs (C)of the headrestfront trim (Di
w h i l e p u l l i n gt h e h e a d r e sftr o n tt r i m f o r w a r d ,a n d
removethe tflm.
D
1 0 .installthe cover in the reverseorder of removal,

. Fit all the hooksof the headrestfront trim into the

h o l e si n t h e h e a d r e srt e a rt r i m ,t h e n p u s ho n t h e
h e a d r e sttr i m u n t i lt h e h o o k ss n a pi n t o p l a c e .
. To preventwrinkleswhen installinga seat back
cover, make sure the materialis stretchedevenly
over the pad beforesecuringthe clips, hooks,
a n d h o o ks p r i n g s .
. M a k es u r et h e s i d ea i r b a gh a r n e s sO , PDS
harness{passenger'sseat).and rear seataccess
cable(passenger'sseati are routed properly.
. lf necessary,reinitializethe OPDScontrol unit
( s e ep a g e2 3 - 1 2 4 ) .
(cont'd)
20-77
Seats
Front Seat CoverReplacement{cont'd)
SeatCushionCover Outside:
1. Removethe front seat (seepage 20,71).
2. Removethese items from the front seat:
. Reclinecover,driver's seat (seepage 20-73)

passenger'sseat {seepage 20-74l
. Frontseat belt buckle{seestep 4 on page 23-6)
3. From underthe seat cushion,detachthe side

airbagconnectorclip, and on the passenger'sseat,
detachthe OPDSunit connectorclip. Releasethe
hook springsfrom the seatcushionframe spring,
then pull the guide cover back,and removethe
wire ties.
Releasethe seat-backcover (A)from the cushion
4. Releasethe hooks(A). frame spring (B),and releasethe hooks(C)from
u n d e rt h e s e a tc u s h i o n .
Inside:
20-78
6 . R e m o v et h e s e a tc u s h i o nc o v e r( A )w i t h t h e s e a t 8. Installthecover in the reverseorder of removal,
cushion pad from the seat cushionframe. and note these items;
. To preventwrinkleswhen installlnga seat

cushioncover, make sure the materialis
stretchedevenlyover the pad beforesecuring
t h e c l i p sa n d h o o k s .
. Make sure the side airbag harnessand OPDS
harness(passenger'sseat)are routed properly.
. Replaceany clips you removedwith new ones
( A ) .I n s t a l l t h e mw i t h c o m m e r c i a l l a
yvailable
upholsteryring pliers (B).
1 . Pull backthe edge of the seatcushioncover all the

way around.and releasethe clips {A),then remove
the seat cushioncover (B).
r {, ]
: F + r
r * ?
20-79
Seats
RearSeat Removal/lnstallation
NOTE:Takecare not to scratchthe body or tear the seatcovers.
'1.
Removethe rear seat as shown.To removethe seat-back,removethe front portion of the cargofloor mar lsee
page 20-52).
2. Installthe seat in the reverseorder of removal,and note these items:
'Beforeinstallingthecenteranchorboltsontheseat-backwiththecentershoulderbelt,makesurethereareno
twists or kinksin the belt.
. Make sure the seat-backslock securelv.
Fastener Locations
A > : B o l t , 2 B > r B o l t 1, C > : B o t t1, D > : C l i p ,2

lltl
/-<.{\.-- agr
| J ] . P F.i\--
t-HAP K\- f ( 1
Vt-
r_r+*.
8 x 1.25mm
22 N.m 12.2kgt m, 16lbf.ft)
CENTERPIVOTBOLT
8 x 1.25mm SEAT.BACK
\'7
22 N.m CENTERHINGE
{2.2kgf.m, 16lbf.ftl
BUSHING
RIGHTSEAT-BACK LEFTSEAT.BACK
CENTERBELT
PIVOTBUSHING
PIVOT
BUSHING
CENTERANCHORBOLT
7/16-20UNF
32Nm
(3.3kgf m.24 lbt ftl
SEATBELTBUCKLE
6x1.0mm
9.8Nm
HOOK
SEATCUSHION
20-80
I RearSeat-backLatchReplacement RearSeat-backStriker Replacement
1 . Removethe seat-back(seepage 20-80). NOTE:Takecare not to scratchthe interiortrim.
Removethe seat-backcover (seepage 20-82). 1 . R e m o v et h e r e a rs i d et r i m p a n e l( s e ep a g e2 0 - 5 ' l ) .
Removethe seat-backpad {A) from the seat-back 2. Removethe bolts,then removethe seat-back
frame (B).On right seat-backwith centershoulder striker(A).
belt,passthe centerbelt (C)through the hole in the
FastenerLocations
seat-backpad.
) : Bolt,2
F
,-;1
8 x 1.25mm
22 N m 12.2kgl rn,
16 tbf.ft)
3 . l n s t a l l t h es t r i k e ri n t h e r e v e r s eo r d e ro f r e m o v a l ,
Removethe bolts,then removethe seat-backlatch and move the striker(A) up or down until it is
(A)from the seat-backframe (B),and releasethe centeredin the seat-backlatch {B).
\ pivot pin {C)of the latch lever (D)from the seat'
backf rame.
FastenerLocations
lnstallthe latch in the reverseorder of removal,and

make sure the seat-backlocksand unlocksproperly.
20-81
Seats
RearSeat-backCoverReplacement
NOTE: 5. On right seat-backiUsing a Torx T30 bit, remove
. Takecare not to tear the seamsor damagethe seat the bolts,then removethe belt holdertrim (A),and
covers. removethe trim from the centerbelt (B).
FastenerLocations 6x1.0mm
'1. 9.8Nm
Removethe seat-back(seepage 20-80). ) : Bolt, (1.0kgf.m,7.2lbf.ft)
A*-
Removethe headrest. \./-
Pull up the latchcover (A)to teleasethe clips.then

remove it.
Fastener Locations
) : Clip,4
1W
Releasethe hook (A),and unzipthe seat-backcover
(B).The right seat-backis shown. the left seat-back
i ss i m i l a r .
\
4 . Pull up the outsideedge of the latch lever cover (A)
to releasethe clips, and releasethe cover from the
p i v o tp i n s( B )o f t h e l a t c hl e v e r{ C )w h i l e p u l l j n gt h e
latch lever.
Fastener Locations
D : Clip,2
i\r*
rJ
20-82
7. Pull backthe edge of the seat-backcover (A),and 9. Removethe seat-backcover (A)from the seat-back
r e l e a s et h e c l i p s{ B ) . pad (B).On right seat-backwith centershoulder
belt, passthe centerbelt (C)through the hole in the
seat-bacl(cover.
Pull backthe edge of the seat-backcover,and pull

out the seat-backframe {A) from the seat-backpad
{ B ) ,t h e n p u l l o u t t h e h e a d r e sgt u i d e( C )w h i l e
p i n c h i n gt h e e n d o f t h e g u i d e s a, n d r e m o v et h e m . 1 0 ,lnstallthe cover in the reverseorder of removal,
. To preventwrinkleswhen installinga seat-back

cover, make sure the materialis stretchedevenly
over the pad beforesecuringthe hooksand clips
. On right seat-back:When installingthe seat-back
frame to the pad, slip the centerbeltthrough the
hole in the seat-backcover and pad.
. Replaceany clips you removedwith new ones.
I n s t a ltlh e m w i t h c o m m e r c i a l l a
yvailable
upholsteryring pliers.
20-83
Seats
RearSeat CushionCoverReplacement
'1.
Removethe rear seat cushion (seepage 2O-80). 4. Installthecover in the reverseorder of removal,
and note these items;
Releaseall the clips (A)from under the seat
c u s h i o n a, n d f o l d b a c kt h e s e a tc u s h i o nc o v e r( B ) . . To preventwrinkles,make surethe materialis
stretchedevenlyover the pad beforesecuring
t h ec l i p s .
. Replaceany clips {A) you removedwith new
o n e s .I n s t a ltlh e m w i t h c o m m e r c i a l l a
yvailable
u p h o l s t e r yr i n g p l i e r s( B ) .
Pull backthe edge of the seatcushioncover all the

way around,and releasethe clips (A),then remove
the seatcushioncover.
\
iw F 1., +. ts+'
1L
i l
1 r
l-,+ J ,+ l
l
20-84
Bumpers
Front BumperRemovaUlnstallation
NOTE:
. H a v ea n a s s i s t a nht e l py o u w h e n r e m o v i n ga n d i n s t a l l i n g
t h ef r o n tb u m p e r .
. Takecare not to scratchthe front bumper and body.
. Puton glovesto protectyour hands.
'L
Removethe front bumper as shown.
, n d n o t et h e s ei t e m s :
2 . I n s t a l l t h eb u m p e ri n t h e r e v e r s eo r d e ro f r e m o v a l a
. Make sure both front side markerlight connectorsare plugged in properly.

. Make sure the front bumper engagesthe hooksof the side spacersand upper beamson both sidessecurely.
. Replacea n y d a m a g e dc l i p s .
FastenerLocations
A ) , Screw, 2 B >: Screw,2 C>:Bolt.4 D>:Clip,7 E>:Clip,2
f
{D[] k/- ' h
*S- 6
=$
4
t
ABSORBER
SIDESPACER
UPPERBEAM
LEFTFRONTSIDEMARKER
LIGHTCONNECTOR
' * D ;
e 3 INNER
FRONT
FENDER
BUMPER e
ti-\ FEONTBUMPER
A
C l E
I
FRONTAIR SPOILER
SPOILER
AIR SPOILER 6 x 1 . 0m m
PLATE PLATE 9.8 N.m (1.0kgt.m,7.2lbf.ft)
20-85
Bumpers
RearBumperRemovaUlnstallation
NOTE:
' Havean assistanthelp you when removingand installingthe rear bumper.
. Takecare not to scratchthe rear bumper and body.
L R e m o v et h e r e a rb u m D e ra s s h o w n .
2. Installthe bumper in the reverseorder of removal,and note these items:
. Make sure both rear side marker light connectorsare pluggedin properly.
'Makesuretherearbumperengagesthehooksofthesidespacers,sidebrackets,andupperbracketsonboth
sidessecurely.
. Make sure the upper spacersof the rear bumper engagethe clips on the body securely.
Fastener Locations
A>:Bolt,2 B) : Screw, 2 c >: Screw, 2 ) : Clip,

?
/h-
\-P-
ffiI"-
ut ^* XJ \s ri)
SIDEBRACKET
UPPERBRACKET
\
, 6 x 1 . 0m m
/ 9.eN.n
,/ 11.0kgl m,
./ 1.2tbt.ttl
SIDESPACER
a
\
'-
:r A
CAP
LEFTREARSIDEMARKER
LIGHTCONNECTOR
A
D
UPPERSPACER
REARBUMPER
20-86
Hood
Adjustment
'1.
Slightly looseneach hood hinge bolt,
2 . Adjustthe hood (A) alignmentin this sequence.
. A d j u s t t h e h o o d r i g h t a n d l e f t , a s w e al l s f o r w a r da n d r e a r w a r db, y u s i n gt h e e l o n g a t e dh o l e so n t h e h o o dh i n g e
(B).
. Turn the hood edge cushions(C),as necessary,to makethe hood iit flush with the body at the front and side
edges.
6x1.0mm
6x1.0mm 9.8 N.m
9.8 N.m {1.0kgf.m,7.2lbf.ft}
{1.0kgl.m,7.2 lbf.ftl
3 . Adjustthe hood latch (D)to obtainthe proper height at the forward edge,and move the hood latch right or left
until the striker(E)is centeredin the hood latch.
Tighteneach bolt securely.
(contd)
20-87
Hood
Adjustment(cont'd) HoodSealReplacement
5. Checkthat the hood opens properlyand locks 1 . Using a clip remover,detachthe clips,then remove
securely. the hood seal (A).Takecare not to scratchthe hood.
6. Apply body paint to the hinge mounting bolts and Fastener

Locations
a r o u n dt h e h i n g e s .
7. Apply multipurposegreaseto each locationof the

hood latch and hood hinge as indicatedby the
arrows.
I n s t a l l t h es e a li n t h e r e v e r s eo r d e ro f r e m o v a l a, n d
note these items:
. :I
20-88
HoodInsulatorReplacement
t e w i n d s h i e l dw a s h e rt u b e s( A ) .
FastenerLocations
'10
) : Clip,
t*'-&
,2V..=-'
( \
Using a clip remover,detachthe clips. Releasethe

h o o k s( B ) ,t h e n r e m o v et h e h o o di n s u l a t o (r C ) .T a k e
care not to scratchthe hood.
I n s t a l l t h ei n s u l a t o irn t h e r e v e r s eo r d e ro f r e m o v a l ,
. Pushthe clips into placesecurely.

20-89
Hatch
Adjustment
1. Removethe support strut from each side (seepage 20-91).
2 . R e m o v e t h e C - p i l l a r t r i m f r o m e a c h s i d e ( s e e p a g e 2 0 - 5 ' l ) ,daonw
dnp tuhl le r e a r p o n i o n o f t h e h e a d l i n e r ( s e e
page20-54).Takecare not to bend the headlinerexcessively.
3. Removethe reartrim panel (seepage 20-52).
4, Slightly looseneach bolt and nut.
5 . A d j u s t t h eh a t c h( A )a l i g n m e n it n t h e f o l l o w i n gs e q u e n c e .
. Adjustthe hatch hinges(B) right and left, as well as forward and rearward,using th e elongatedholes.
'Turnthehatchedgecushions(C),inoroutasnecessary,tomakethehatch(D).fitflushwiththebodyattheside
edges.
. Adjustthe fit betweenthe hatch and hatchopening by moving the striker(D).
8 x 1.25mm
22 N.m
{2.2kgf.m,16lbf.ft} \
8 x 1.25mm
18 N.m 11.8kgf.m, 13 lbf.ft)
20-90
HatchSupportStrut Replacement
Tighteneach bolt and nut securely. 1 . With the help of an assistant,use a flat-tip
screwdriver(A)to pry the supportstrut clips (B)
7 . Checkthat the hatchopens properlyand locks from each end of the supportstrut (C)at the hatch
securery. and body, then releasethe supportstrut from the
pivot bolts (D).Do not removethe clips from the
Reinstallthe supportstruts securely. supportstrut.
9 . R e i n s t a lal l l r e m a i n i n gr e m o v e dp a r t s .
1 0 .Apply multipurposegreaseto the pivot portion of

the hatch hinges{A) as indicatedby the arrows.
D
8 x 1.25mm
22 N.m(2.2kgf.m,16lbf ft)
2 . Set the clips (A) to the original position,then

reattachthe supportstrut (B)on the pivot bolts (C)
by pushingon the supportstrut.
20-91
Hatch
HatchWeatherstripReplacement
1 . R e m o v et h e h a t c hw e a t h e r s t r i{pA ) b y p u l l i n g o u t
on it.
2 . L o c a t et h e p a i n t e da l i g n m e n mt a r k{ B )o n t h e h a t c h
weatherstrip.Allgn the paintedmark with the
alignmenttab in the the centerof the hatchopening,
a n d i n s t a l tl h e h a t c hw e a t h e r s t r i a
p l l t h ew a y
around in the directionshown. Make surethere are
no wrinklesin the weatherstrip.
3. Checkfor water leaks.
20-92
FuelFill Door
Adjustment
1. Removethe nut (A),and removethe fuel fill door 7. Apply multipurposegreaseto each location
o p e ns p r i n g{ B ) . indicatedby the arrows.
8 . Apply body paint to the hinge mounting bolts and

5x0.8mm around the hinges,
1.8Nm
(0.18kgf.m,
1.3rbf.ft)
>t=-
r'
2 . S l i g h t l yl o o s e nt h e h i n g em o u n t i n gb o l t s( A ) .
3 . A d j u s tt h e f u e lf i l l d o o r ( B )i n o r o u t u n t i li t ' sf l u s h
with the body, and up or down as necessaryto
a^rr.li7a tha n.nc
T i g h t e nt h e h i n g em o u n t i n gb o l t s .
5 . R e i n s t a l l t h feu e lf i l l d o o r s p r i n g .
6 . Checkthat the fuel f ill door opens properlyand

lockssecurely,and checkthat the rear of the door is
flush with the body.
20-93
ExteriorTrim
FrontGrille Replacement
1 . Removethe front bumper (seepage 20-85).
2 . Removethe front grille (A),Takecare not to scratch

the front bumper (B).
-1 Removethe screws (C).

-2 Removethe clips (D).
-3 Releasethe bottom hooks(E)ofthe grille,
-4 Pull out the boftom of the grille to releasethe
u p p e rh o o k s( F ) .
- 5 P u l lo u t t h e g r i l l et o r e l e a s et h e s l i t s( G ) f r o m
the ribs {H),then removethe grille.
FastqnErLocations
C >:Screw.4 D ) : Clip, 4
ll
-S---: \
i")
F
3 . I n s t a l l t h eg r i l l ei n t h e r e v e r s eo r d e ro f r e m o v a l ,
a n d r e p l a c ea n y d a m a g e dc l i p s .
Reinstallthe front bumper.
20-94
Cowl CoversReplacement
1 . R e m o v et h e w i n d s h i e l dw i p e r a r m s ( s e ep a g e2 2 - 1 4 5 ) .
2. Removethe windshieldsidetrim from both sides(seestep 2 on page 20-19).
3. Pullthe hood rear seal (A) away from the cowl covers,then remove it, and using a clip remover,detachthe clips
(B)from the cowl covers.Takecare not to scratchthe cowl covers.
FastenerLocations
B> rClip,3 C>:Clip,8
:- ::::
= - --::;-:
4 . Detachthe clips (C)by carefullypulling the passenger'scowl cover {D) upward,to releasethe hooks{E),and pull
out the cover forward to releasethe hooks(F),then removethe cover.Takecare not to scratchthe body,
Detachthe clips (C)by carefullypulling the driver'scowl cover (G) upward.and pull out the cover forward to
releasethe hooks(H),then removethe cover.Takecare not to scratchthe body.
Installthecovers in the reverseorder of removal,and note these items:
. Pushthe clip portionsinto placesecurely.
. Reinstallboth windshieldside trim properly(seestep 26 on page 20-24).
20-95
ExteriorTrim
A-PillarCornerTrim Replacement
1 . Open the door. 5 . R e p l a c ea n y d a m a g e dc l i p s .
Wrap a flat-tipscrewdriverwith protectivetape, H o l dt h e t r i m u p , a n df i t t h e u p p e rc l i p a n d l o w e r

and apply protectivetape aroundlhe body to c l i p si n t ot h e h o l e si n t h e b o d y ,t h e n p u s ho n t h e
preventdamage.Carefullyinserta flat-tip t r i m u n t i lt h e c l i p ss n a pi n t op i a c e .
screwdrivernext to the upper clip, and detachthe
c l i p b y p r y i n go n t h e A - p i l l a rc o r n e rt r i m ( A ) .T a k e
care not to scratchthe body and relatedparts.
FastenerLocation
3 . Closethe door half-way.
Pullthe A-pillercornertrim (A) out to detachthe

\
lower clips,then removethe trim.
FastenerLocations
20-96
RoofMolding Replacement
1 . Apply protectivetape to the body (A).Using a 4, Pull up and releasethe rear bracket(A)from the pin
flat-tipscrewdriverwrapped with protectivetape (B),then removethe roof molding (C).
(B),pry up on the roof molding (C).Takecare not to
scratchthe bodv.
..:.::.l.
g
5 . Installthe molding in the reverseorder of removal,

. T a k ec a r en o t t o d a m a g et h e w i n d s h i e l dm o l d i n g .
. Make sure the roof molding is installedsecurely.
Pull up and slidethe roof molding to releasethe
front bracket(D)from the pin (E).
Pull up the front portion of roof molding.
20-97
ExteriorTrim
RearLicenseTrim Replacement
NOTE:Put on glovesto protectyour hands. 3 . F r o mi n s i d et h e h a t c h ,r e l e a s et h e c l i p s( A , B ) w h i l e
h o l d i n gt h e r e a rl i c e n s et r i m ( C ) ,t h e n r e m o v el h e
1. Removethe hatch lower trim panel (seepage 20- trim, Takecare not to scratchthe hatch.
FastenerLocations
2. On insidethe hatch.removethe bolts securingthe A>:Clip,2 B>:Clip.2
r e a rl i c e n s et r i m ( A )a n d h a t c hl o c kc y l i n d e r( B ) . \ ! -
FastenerLocations
cHl €:t+
> : Bolt,2
-)
, nd
note these rtems:
. Pushthe clip portionsinto placesecurely. \
6x1.0mm
9.8 N.m (1.0kgf.m,7.2lbf.ftl
20-98
HatchSpoilerReplacement
NOTE:Put on glovesto protectyour hands. 4 . F r o mi n s i d et h e h a t c h ,r e l e a s et h e c l i p s ,w h i l e
p u l l i n gt h e h a t c hs p o i l e r( A )a w a y ,a n d r e l e a s et h e
'l.
Removethe hatch upper trim (seepage 20-53). fasteners(B),then removethe spoiler.Takecare
not to scratchthe body.
2. Removethe high mount brakelight (seepage22-
82). FastenerLocations
> : C l i p2.
3. From insidethe hatch,removethe bolts {A} and t
n u t s( B ) .
Fastener Locaiions
A>: Bolt,2 Bar Nut,
fi'f$t-- /,fl
uLt* v_/
$. A
5 . I n s t a l l t h es p o i l e ri n t h e r e v e r s eo r d e ro f r e m o v a l ,
5x1.0mm
9.8Nm
(1.0kgf.m.7.2lbf.ft) R e p l a c ea n y d a m a g e dc l i p s .
Replaceany damagedfasteners.Before
installingthe fastenerto the spoiler,cleanthe
spoilerbonding surfacewith a sponge
d a m p e n e di n a l c o h o l G
. l u et h e f a s t e n e wr ith
a d h e s i v et a p e( 3 M 5 6 7 1 ,o r e q u i v a l e n t ) t toh e
spoiler.
Pushthe clip and fastenerportions into place
securely.
20-99
ExteriorTrim
EmblemReplacement
NOTE:When removingthe emblem,take care not to scratchthe body.
"H" emblem and front type emblem, removethe front bumper (seepage 20-85)
1. To removethe front
2. Cleanthe bonding surfacewith a spongedampenedin alcohol.After cleaning,keepoil, grease,and water from

getting on the surface.
3 . A p p l yt h e e m b l e m ,w h e r es h o w n .
. Wheninstalling t h e s i d ei - V T E Ce m b l e mo n t h e b o d y ,a l i g nt h e a p p l i c a t i otna p ew i t h t h e e d g eo f t h e w h e e la r c h ,
then pressthe emblem into place,and removethe applicationtape.
. ' 0 3 m o d e l :W h e n i n s t a l l i n g t h e L E Ve m b l e mo n t h e q u a r t e rg l a s s ,a l i g nt h e a p p l i c a t i o tna p ew i t h t h e e d g eo f t h e
b l a c kc e r a m i ca n d a l i g n m e n m t a r ko n t h e q u a r t e rg l a s s t, h e n p r e s st h e e m b l e mi n t o p l a c e a, n d r e m o v et h e
a p p l i c a t i o tna p e .
FRONTTYPEEMBLEM
FBONT"H" EMBLEM
FRONT"H" EMBLEMBASE FBONTGRILLE i

SCREWS
FRONTSi EMBLEMPLATE
PUSHNUTS
PINS
FRONTGRILLE FRONTGRILLE
20-100
REARCIVICEMBLEM
LEVEMBLEM
(Leftsideonly)
('03model)
REARVERSIONEMBLEM
SIDE|-VTECEMBLEM
REAR"H" EMBLEM
Unit: mm {in.l
Adhesivetape: 3M 4213E,o. equivalent
Thickness:0.8mm (0.03in.)
REAR"H'' EMBLEM APPLICATION

TAPE Edoeol the blackceramic.
LEVEMBLEM
Align. Ontoinsideface
of the guarterglass.
REARLICENSE
HATCHLINE TRIM REARSiR EMBLEM
REARsi EMBLEM (Canada)
34
11.3)
, ilg .,!!ll,'nt
(1.93) I (1.s31
=-t
50
{'!,9?)
CIVICEMBLEM E d g eo f t h e
hatch.
ADHESIVETAPE Edge of the
hatch.
SIDEi-VTECEMBLEM
Left Side: SIDEi.WEC Right Side: 63 (2.5)
EMBLEM
. 114(4.49)
F.l^6 ^l rh-
wheelarch.
.=4,
y'
Li.Est
112
(5'5s)
Edgeof the BODY BODY o"f,r,ao.o"
APPLICATION LINE
wheel arch. TAPE LINE TAPE
4. After installingthe front "H" enblem and front type emblem, reinstallthe front bumper.

20-101
Fenderwell
FrontInnerFenderReplacement
NOTE:Takecare not to scratchthe body.
1, Removethe front inner fender (A).
-1 On the backofthe wheel arch,removethe screws(B).

- 2 F r o mu n d e r t h e f r o n tb u m p e r ( C )r, e m o v e t h e s c r e w( B )s e c ur i n gt h e f r o n t b u m p e r .s p l a s hs h i e l d( D ) ,a n d f r o n t
inner fender,and removethe clip (E)securingthe front air spoiler,front bumper,and front inner fender.
- 3 F r o m t h e w h e e la r c h ,r e m o v et h e c l i p s{ F ,G ) s e c u r i n gt h e f r o n t i n n e rf e n d e r( a n ds p l a s hs h i e l d )o n t h e b o d y .
- 4 R e l e a s teh e h o o k( H )o f t h e s p l a s hs h i e l d , t h e nr e m o v e t h e f r o n it n n e r f e n d e r .
FastenerLocations
B):Screw,4
0*€
E>:Clip,1
,ws
F > : C l i p ,1 G):Clip,8
2. Installthe inner fender in the reverseorder of removal,and note these items:
20-102
Front FenderFairingReplacement
1 . Removethe front inner fender as necessary(see 3. From the wheel arch, removethe clip (A),and
p a g e2 0 - 1 O 2 1 . releasethe clip (B),then removethe front fender
f a i r i n g( C ) .
Open the front door. From outsidethe door,
r e m o v et h e u p p e rc l i p ( A ) ,a n d f r o m i n s i d et h e d o o r , FastenerLocations
removethe lower clip (A) securingthe front fender A > : C l i p1, B > : C l i p1,
f a i r i n g( B )a n d f r o n tf e n d e r( C ) .
FastenerLocations J*.' -@
A>:Clip,2
J<a-'
4 . Installthe fender fairing in the reverseorder of

\
. R o u t et h e s i d et u r n s i g n a l i g h t h a r n e s s ( A )
through the slit (B)of the front fender fairing (C).
. B e f o r ei n s t a l l i n g
t h e c l i p so f t h e d o o r u p p e ra n d
lower ponions, installthe front fender fairing (A)
to the front fender (B) properlyas shown.
. Pushthe clips into placesecurely.
o --____--
20-103
Fenderwell
(
FuelPipeProtectorReplacement RearAir Outlet Replacement
1 . R e m o v et h e c l i p s ,t h e n r e m o v et h e f u e l p i p e 1 . R e m o v et h e r e a rb u m p e r( s e ep a g e2 0 - 8 6 ) .
protector(A).Takecare not to scratchthe body.
r n e r e a ra t r
Fastener Locations the body.
> : Clip,4
I n s t a l l t h ea i r o u t l e t sb y p u s h i n go n t h e h o o k
I n s t a l l t h ep r o t e c t o irn t h e r e v e r s eo r d e ro f r e m o v a l , p o r t i o n su n t i l t h eh o o k ss n a pi n t o p l a c e .
. P u s ht h e c l i p si n t o p l a c es e c u r e l v .
20-104
Openers
HATCHLOCK
CYLINDER
page20-1'l1
Replacement,
HATCHHANDLE
Replacement,
p a g e2 0 - 1 1 0
HATCHLATCH
Replacement,page20'110
FUELFILLDOORLATCH
page20-107
FUELFILLDOOROPENEBCABLE
page 20-107
Replacement,
FUELFILLDOOROPENER
I{OOD RELEASEHANDLE
page20-'106
HOODOPENERCABLE
z)-105
Openers
Hood OpenerCableReplacement
NOTE:
. Takecare not to scratchthe body and relatedparts.
l. Removethese items:
. Front bumper (seepage 20-85)

. F r o n ti n n e rf e n d e r ,l e f t s i d e ( s e e p a g e 2 0 - 1 0 2 )
. Kick panel,left side (seepage 20-50)
2. Disconnectthe hood openercable(A) from the hood latch {B) (seepage20-108),and removethe bolts (C),then
removethe hood releasehandle(D)from the body.
FastenerLocations
6x1.0mm
C>:Bolt,2 E >:Clip,3 9,8 N.m
11.0kgl.m, 7.2 lbl.ft)
@m l,.t'.
W:"
Using a clip remover,detachthe clips (E),and removethe grommet (F)from the body, then removethe hood
openercablefrom the vehicle.Takecare not to bend the cable.
4 . I n s t a l l t h ec a b l ei n t h e r e v e r s eo r d e ro f r e m o v a l a
, n d r e p l a c ea n y d a m a g e dc l i p s .
20-106
FuelFill Door OpenerCableReplacement
SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations(seepage 23-13)and the precautions
and procedures(seepage 23-14)in the SRSsectionbeforeperformingrepairsor service.
NOTE;
. Takecare notto scratchthe body and relatedparts.
1. Removethese items from the left side of the vehicle:
. D o o rs i l l t r i m { s e ep a g e2 0 - 5 0 )
. R e a rs i d et r i m p a n e l( s e ep a g e2 0 - 5 1 )
2 . Pullthe carpetbackas necessary(seepage 20-55).
5. Disconnectthe fuel fill door openercable (A)from the opener(B) (seestep 3 on page 20-109).
FastenerLocations
C > : C u s h i o n t a p e1, D > : C l i p 1, E > : Clip,2
4 . K C m o d e l :R e m o v e t h el e f tm i d d l ef l o o rc r o s s - m e m b egru s s e t( s e ep a g e2 0 - 1 1 3 ) .
5 . R e m o v et h e c u s h i o nt a p e{ C ) ,a n d r e l e a s et h e c a b l ef r o m t h e c l i p s( D ,E ) .
6 . R e m o v e t h e f u efli l l d o o r l a t c h( F ) f r o m t h eb o d y b y t u r n i n gi t 9 0 ' .
7. Removethe fuel fill door openercablefrom the vehicle.Takecare not to bend the cable
8 . I n s t a lt lh e o p e n e r c a b l e i n t h e r e v e r s e o r d e r o f r e m o v a l , r e p l a c e t h e c u s h i o n t a p e , a n d r e p l a c e t h e c l i p i f i t i s
oamageo.
20-107
Openers
Hood LatchReplacement
NOTE: Installthe hood latch in the reverseorder of
. Put on glovesto protectyour hands. removal,and note these items:
. Takecare not to scratchthe body.
. Apply multipurposegreaseto each locationof
1. Removethe bolts,then removethe hood latch (A) the hood latch indicatedby the arrows.
from the body. . Make sure the hood openercable is connected
properly.
FastenerLocations . Make sure the cableactuatesthe latch beforeyou
> i Bolt,3 closethe hood,
. Adjustthe hood latchalignment(seestep 3 on
page 20-87).
. M a k es u r et h e h o o do p e n sp r o p e r l ya n d l o c k s
securely.
--------------'
6x1.0mm
9.8 N.m (1.0kgf.m,7.2lbf.ft)
Disconnectthe hood openercable (B)from the

hood latch.Takecare not to bend the cable.
20-108
FuelFillDoorOpenerReplacement
1 . Using a flat-tipscrewdriverwrapped with 4. Disconnectthe fuel fill door openercable (A),then
protectivetape, detachthe hooks(A) by prying the removethe openeriB). Takecare not to bend the
front side cap (B),then remove it from the left door c ao t e .
s i l l t r i m ( C ) ,a n d l o o s e nt h e b o l t ( D )s e c u r i n gt h e
f u e lf i l l d o o r o p e n e r .
6x1.0mm
9.8 N.m 5 . Installthe opener in the reverseorder of removal,
11.0kgf m,7.2 lbf.ft) and note these items:
2. Removethe left door sill trim (seepage 20-50i. lMakesure the openercable is connected
properly.
3 . R e m o v et h e o p e n e r( A l f r o m t h e b o l t{ B ) . lvlakesure the fuel fill door opens properlyand
lockssecurely.
20-109
Openers
HatchHandleReplacement HatchLatchReplacement
NOTE:Put on glovesto protectyour hands. NOTE:Put on glovesto protectyour hands.
1. Removethese items: '1.

Removethe hatch lowertrim panel (seepage 20-
53).
. Hatchlower trim panel (seepage 20-53)
. Rear licensetrim panel (seepage 20-98) 2. Disconnectthe hatch openercable (A),cylinder rod
(B).hatchactuatorconnector(C).and hatch latch
2. Removethe rearwindow wiper motor (seepage switch connector{D).and detachthe hatch actuator
22-1461. connectorand hatch latch switch connectorfrom
the hatch.
3. Disconnectthe hatch o p e n e rc a b l e1 A ) f r o mt h e
h a t c hh a n d l e( B ) ,a n d removethe nuts. FaslenerLocations
) : Bolt,3
Fastener Locations 6x1.0mm
9.8N.m ttb
a : Nut, (1.0 kg{.m,7 2 tbt.{t\
()rI
a
,t.
4. Pull outthe hatch handle(A),then remove it.

L-
i-'-3;li9#-
k g tm , 7 . 2 l bfft l
11,0
R e m o v et h e b o l t s ,t h e n p u l l t h eh a t c hl a t c h( E )o u t ,
then remove it.
I n s t a l l t h el a t c hi n t h e r e v e r s eo r d e ro f r e m o v a l a, n d
notethese items:
. Make sure each connectoris plugged in properly,

and the rod and cableare connectedproperly.
. l\4akesure the cable actuatesthe latch beforeyou
c l o s et h e h a t c h .
. Make sure the hatch opens properlyand locks
securely.
I n s t a l l t h eh a n d l ei n t h e r e v e r s eo r d e ro f r e m o v a l .
lMake surethe hatchopenercableis connected

securely.
M a k es u r et h eh a t c ho p e n sp r o p e r l y .
20-110
HatchLockCylinderReplacement
NOTE;Put on glovesto protectyour hands. 4. Installthe lock cylinder in the reverseorder of
'1.
Removethese items:
. Make sure the rod is connectedproperly.
. Hatchlower trim panel (seepage 20-53). . Make sure the hatchopens properlyand locks
. Rearlicensetrim (seepage 20-98). securely.
2. Disconnectthe cylinder rod (A)
- . .
From outsidethe hatch,removethe bolt securing

the lock cylinder{A}.From insidethe hatch,pull the
l o c kc y l i n d e ro u t b y r e l e a s i n tgh e h o o k( B ) .
Fastener Location
6 x 1 . 0m m
> : Bolt,1 9.8Nm
(1.0kgf m,7.2lbt.ftl
rS'l-.
u-ar
*/t
20-111
Frame
SubframeReplacement
SubframeTorque
NOTE:After looseningthe subframemounting bolts,be sureto replacethem with new ones.
Referenceholesalignment:
SUBFRAME
REFERENCE HOLE
( B o d yS i d e )
INSTALLATION
REFERENCEHOLE
(Subframe
side)
INSTALLATION
REFERENCE HOLE
FRONTSUSPENSION
SCREWDRIVER
or TAPEREDPUNCH INSTALLATION
To body. REFERENCE HOLE
To body.
I
n
E
SPECIAL
' 1 4x 1 . 5mBOLTS
m
103 N.m
(10.5kgf.m,75lbf.ft)
Replace.
20-112
FrameStiffener,Brace,and GussetReplacement
FrameStiffener,Brace,and GussetTorque
NOTE:When installingthe middle floor cross member braceor gussets,torque the mounting hardwarein the
following sequenceto avoid damageto the quarterpanel.
MIDDLE
FLOOR
CROSS-MEMgER
BRACE/GUSSET
SIDEFRAMESTIFFENER
8 x 1 . 2 5m m
29 N.m
(3.0kgf m,22 lbf ft)
To body.
U.S.model: model:
Canada
1 0x 1 . 2 5m m
38 N.m
(3.9kgf.m.28lbf.ftl
MIODLE
FLOOR MIDDLE
FLOOR
CROSS-MEMBER CROSS.MEMBER
BRACE GUSSET
__!:::-- 1 0 x 1 . 2 5m m
.. | - 38Nm
(3.9kgf.m,28 lbl.ftl
1 0 x 1 . 2 5m m
38 N m (3.9 kgt.m, 28 lbf.ftl
20-113
Frame
FrameRepairChart
Top view
Unit:mm {in.} a Forsublrameo1510.59) o Fordampermounts11.5{0.45}

o: Inner diametel b1 Forenginemount e13 (0.511 For damper centero78 (3.07)
b2 Forenginemount o13 (0.51) I Fordampermounts11.5(0.451
b3 Forenginemount rl3 (0.51) g Fordampeimountd11.510.45)
cl Formanualtransmission mouoto13{0.5' h Forsubframeo15 {0.591
c2 Formanualtransmission mounto13 10.5' Localinghole s25 {0.98}
c3 Formanualt.ansmissionmo!nt d13{0.51) Locatingholee50 (1.97)
VEFTICAL
UNE
20-114
K Locatinghole d25 (0.981 Fortrailingarm d13 (0.511
Fortrailing.rm rl3 10.51) For upper arm bracketcenterrl5 {0.59)
m Locatinghole o25 (0.981 t1, t2 Locatingholes13 (0.51)
n Locatinghole s20 (0.79) Foruppe.arm o13{0.511
Trailingarm center For rear lower arm cent€r
p Reardampercenter Locatingholes50 (1.97)
q Forupperarm o13 (0.51) x1 Locatinghole s20 (0.79)
x2 Locatinghole o25 (0.981
(cont'd)
20-115
Frame
FrameRepairChart(cont'dl I
Sideview
Unitrmm {in.) a For subframe015 {0.59} o Fordampermounto11.5{0.45)

o: InnerdiameteJ b1 Forenginemount o13 (0.511 e For damper centerr78 {3.07}
b2 Forenginemount 01310.51) I Fordampermounto11.5(0.45)
b3 Forenginemount 113(0.511 s Fordampermountr11.5{0./t5l
cl Formanualtransmission mount 013{0.51) h Forsubtrameel5 10.591
c2 Formanualtrensmission mount 613{0.51} Locatinghole o25 (0.98)
c3 Formanualtrrnsmissionmounro13{0.51} i Locatinghole s 11.97)
SECTIOiIAA
BASE
UNE
trr2xt.6 l
VERTICAI
LINE
20-116
Locatinghole o25 {0.98) Fortrailingarm s13 {0.51}
Fortrailingarm 613 {0.511 For upper arm bracketcenter o15 {0.591
m Locatinghole d25 {0.98} 11,t2 Locatingholeo13{0.51}
Locatinghole r20 {0.79) Forupperarm d13{0.51)
Trailingarm center For rear lower arm centei
p Reardamper centel Locatingholeo50{1.97}
q Forupperarm o13 (0.51) xl Locatinghole a20 {0.79}
x2 Locetinghole s25 (0.98)
20-117
HVAC(Heating,
Ventilation,
andAir Gonditioningl
HeatingandAir Conditioning DustandPollenFilter
SpecialTools 21-2 Reolacement ..21-39
Comoonent Location lndex ........z t-'5 BlowerUnitRemovaland
A/CService Tiosand lnstallation ......21-39
Precautions z t-o BlowerUnitComoonents
A,/CRefrigerant Oil R e D l a c e m e .n. t. . . . . . . . . . . . . . . . .2. .1. .- .4. 1. . .
ReDlacement z t-o Evaporator Core
General Troubleshooting Reolacement ..21-42
lnformation 21-8 *HeaterUnit/Core
DTCTroubleshooting Index .......21-9 ReDlacement ..21-43
SymptomTroubleshooting HeaterValveCable
1ndex.............. 21-10 Adjustment .....21-46
SystemDescription..................... 21-11 CompressorReplacement .......... 21-47
CircuitDiagram 21-14 Comoressor ClutchCheck .......... 21-48
D T CT r o u b l e s h o o t i n. .g. . . . . . . . . . .z. .t .- .t .o Comoressor ClutchOverhaul.....21-49
Recirculation ControlMotor Compressor ThermalProtector
CircuitTroubleshooting .......... 21-25 R e o 1 a c e m e.n. .t . . . . . . . . . . . . . . . .2. .1. .- .5. 1. . .
HeaterControlPowerandGround Comoressor ReliefValve
Circuits Troubleshooting ........21-27 R e o l a c e m e n. .t. . . . . . . . . . . . . . . . .2. .1. .- .5. 1. . .
Condenser FanCircuit Condenser Reolacement............ 21-52
Troubleshooting ...................... 21-28 Refrigerant Recovery .................. 21-53
Radiator andCondenser Fans SystemEvacuation ...................... 21-54
CommonCircuit SystemCharginS......................... 21-55
Troubfeshooting ...................... 21-29 Refrigerant LeakTest.................. 21-56
Compressor ClutchCircuit A,/CSvstemTests ........................ 21-57
T r o u b l e s h o o t i n. .g. . . . . . . . . . . . . 2
. .1. .-.3. .0
A,/CPressureSwitchCircuit
Troubleshooting ...................... 21-32
Air Mix ControlMotor
TestandReolacement ............. 21-34
ModeControlMotor
TestandReplacement ............. 21-35
Recirculation ControlMotor
TestandReolacement ............. 21-36
Evaporator Temperature Sensor
Reolacement andTest ............. 21-31
PowerTransistor Test ................. 21-38
HeaterControlPaneland
PushSwitchAssemblv
RemovalandInstallation........21-38

HVAC{Heating,Ventilation,and Air Conditioning)
SpecialTools
Ret.No. Tool Number DescriDtion Otv
o 07sAz-001000A BackprobeSet 2
---2
att-,,- KCe
"-t--'
/'Tt
e^t"'
T
21-2
Heatingand Air Gonditioning
EVAPORATOR CORE
VALVE
SERVICE (Built-in theheaterunit)
{LOW.PRESSUBE
SIDEI B e p l a c e m epnat ,g e2 1 4 2
SERVICE
VALVE
{HIGH-PRESSURE
SIDEI
RECEIVER/DRYER
COMPRESSOR
Beplacement,page21 47
ClutchCheck,page21-48 CONOENSEB
page 21-52
Replacement,
C l u t c hO v e r h a u lp, a g e2 1 - 4 9
ThermalProtectorCheck,page21-48
ThermalProtectorReplacement, page21 51
R e l i eVf a l v eR e p l a c e m e npta, g e2 1 5 1

Heatingand Air Conditioning
ComponentLocationIndex(cont'dl
RADIATORFAN RELAY
Test,page22-51
CLUTCHRELAY
Tesl, page 22-51
MOTORRELAY
Test, page 22-5I
'-t
t_]]l UNDER.HOOD BOX
FUSE/RELAY
/l I T I -
-::--
l- -l -
CONDENSERFAN
Test, page 22-51
.\\
... A/C PRESSURE
SWITCH
-
RADIATORFAN
CONOENSERFAN
21-4
BLOWENUNIT
HEATERUNIT/CORE Removal page21-39
andInstallation,
page21-43
Beplacement,
BLOWERUNITCOMPONENTS
page21-41
Replacement,
HEATERVALVECABLE
page21-46
Adjustment,
DUSTAND POLLEN
FILTER
page21'39
Replacement,
RECIRCULATION CONTROLMOTOR
Test,page21-36
page21-36
Replacement,
MODE CONTROLMOTOR
Test,page21-35
POWERTRANSISTOR
Test,page 21-38
AIR MIX CONTROLMOTOR

Test,page21'34
page21'34
Replacement,
PUSH SWITCHASSEMBLY
EVAPORATORTEMPERATURE Removaland Installation,page21'38
SENSOR
Test,page21-37
HEATERCONTROLPANEL
RemovalandInstallation,page21 38
21-5
HeatingandAir Conditioning
A/C ServiceTips and Precautions A/C Refrigerant
Oll Replacement
R e c o m m e n d eP
d A Go i l : K E I H I NS P 1 0 :
Compressedair mixed with R-134aforms a . P/N38897-Pl3-A01AH:'120m0 i4 fl oz)

combustible vapor. . P/N38899-P13'A01:
40 m0 i1 1/3fl oz)
T h e v a p o rc a n b u r n o r e x p l o d ec a u s i n gs e r i o u s
injury. Add the recommendedrefrigerantoil in the amount
Never use compressedair to pressuretest listedif you replaceany of the following parts.
R - 1 3 4 as e r v i c ee q u i p m e not r v e h i c l ea i r
c o n d i t i o n i n sg y s t e m s . . T o a v o i dc o n t a m i n a t i o nd.o n o t r e t u r nt h e o i l t o t h e
c o n t a i n eor n c ed i s p e n s e da, n d n e v e rm i x i t w i t h o t h e r
refrigerantoils.
. l m m e d i a t e la y f'teu r s i n gt h e o i l , r e i n s t a l l t h e
c a po n
the container,and seal it to avoid moisture
A i r c o n d i t i o n i n gr e f r i g e r a not r l u b r i c a nvt a p o r aosorpron.
can irritateyour eyes,nose,or throat. . D o n o t s p i l lt h e r e f r i g e r a not i l o n t h e v e h i c l e i;t m a y
Be carefulwhen connectingserviceequipment. damagethe paint. lf it gets on the paint,wash it off
Do not breatherefrigerantor vapor. immediately.
T h e a i r c o n d i t i o n i n sg y s t e mu s e sH F C - 1 3 4(aR - 1 3 4 a ) C o n d e n s e r. . . . . . . . . . . 2m5A\ 5 1 6t l . o z 0 , . 9l m p . o z )
'1.4
r e fr i g e r a n at n d p o l y a l k y l e n e g l y c(oPl A G )r e fr i g e r a n ot i l , . m0 (1113Il.oz, lmp.oz)
E v a p o r a t o r. . . . . . . . .4. 5
'10
w h i c ha r e n o t c o m p a t i b l e w i t h C F C ' 1 2( R - 1 2r)e f r i g e r a n t L i n eo r h o s e . . . . . . . . . m 0 { 1 / 3f l . o z , 0 . 4l m p . o z )
'10
andminerao l i l .D o n o t u s eR - ' 1 2r e f r i g e r a not r m i n e r a l R e c e i v e r / D r y e.r. . . m 0 ( ' 1 1f3l . o z , 0 . 4l m p . o z )
oil in this system,and do not aftemptto use R 12 Leakagerepair ....25 m0,1516 Il oz,0.9 lmp.oz)
s e r v i c i n ge q u i p m e n td; a m a g et o t h e a i r c o n d i t i o n i n g C o m p r e s s o r. . . . . . . F . .o rc o m p r e s s orre p l a c e m e n l ,
s y s t e mo r y o u r s e r v i c i n ge q u i p m e nw t ill result. s u b t r a ctth e v o l u m eo f o i l d r a i n e d
U s eo n l y s e r v i c ee q u i p m e ntth a t i s U . L . - l i s t eadn d i s from the removedcompressorfrom \
certifiedto meet the requirementsof SAE J2210to 1 3 0m 0 ( 4 1 / 3 f l . o z4, . 6 l m p . o z )a, n d
r e m o v eR - 1 3 4 af r o m t h e a i r c o n d i t i o n i n sg y s t e m . d r a i nt h e c a l c u l a t e vdo l u m eo f o i l
'130
f rom the new compressor: m0
lf accidentalsystem dischargeoccurs,ventilatethe i . 4 1 1 f3l . o z , 4 . 6l m p . o z ) V o l u m eo f
w o r k a r e ab e f o r er e s u m i n gs e r v i c e . removedcompressor= Volume to
d r a i nf r o m n e w c o m p r e s s o r .
R - 1 3 4 as e r v i c ee q u i p m e not r v e h i c l ea i r c o n d i t i o n i n g
systemsshould not be pressuretested or leaktested NOTE:Evenif no oil is drainedfrom
withcompressed air. the removedcompressor,don't
d rain more than 50 m0 \1 2/3 fl.oz,
' 1 . 8l m p
A d d i t i o n ahl e a l t ha n d s a f e t yi n f o r m a t i o nm a y b e o z ) f r o mt h e n e w
obtainedfrom the refrigerantand lubricant compressor.
manufacturers.
. Always disconnectthe negativecablefrom the REMOVED NEW

COMPBESSOR COMPRESSOR
parts.
b a t t e r yw h e n e v e r e p l a c i n ga i r c o n d i t i o n i n g
. Keepmoistureand dirt out of the system.When
r\ A /- a\
i t l
d i s c o n n e c t i nagn y l i n e s ,p l u go r c a pt h e f i t t i n g s
immediately;don't removethe caps or plugs until
l i \ r /
\.. rJ \:)-) -/
iust be{oreyou reconnecteach line.
' B e f o r ec o n n e c t i n ga n y h o s eo r l i n e ,a p p l ya f e w d r o p s
of relrigerantoil to the O-ring.
\tb 'r:l_
_ 0L
. W h e nt i g h t e n i n go r l o o s e n i n ga f i t t i n g ,u s ea s e c o n d I "o*tttu" _*lH I I I DRAINING

I voLUME
wrench to supportthe matchingfitting.
. W h e n d i s c h a r g i ntgh e s y s t e m u , s ea R - ' 1 3 4 a
,lEL.- ],^
refrigerantrecovery/recycling/charging station;don't
A: 130 m0 {4 l/3 tl.oz,4.6lmp.oz)
releaserefrigerantinto the atmosphere.
21-6
RECEIVER
LINEA
RECEIVER/DRYER
CONDENSER
LINE
Dischargehoseto the compressor{6 x 1.0 mm) : 9.8 N.m {1.0kgf.m,7.2 lbl.ft}

Dischargehoseto the condenser(5 x 1.0mml : 9.8 N.m {1.0kgt.m,7.2 lbf ft)
Condenserline to the condenser(6 x 1.0mm) : 9.8 N.m {1.0kgf,m,7.2 lbt.ft}
Condenserfine to the receiver/dryer{6 x 1.0mm} : 9.8 N.m (1.0kgt.fi,7.2lbt.ltl
ReceiverlineAtothe receiver/dryer{6 x 1.0mm} : 9.8 N.m {1.0kgf.m. 7.2 lbf.ft}
Receiverline A to the receiveiline B : 13 N.m (1.3kgr.m,9.4 lbf.ft)
Receiverline B and the suctionline to the evaporator(6 x 1.0mm) :9.8 N.m 11.0kgf.m,7,2 lbf.ft)
Suction line to the suction hose : 3l N m {3.2 kgf.m, 23 lbf ftl
Suctionhose1o the compressor(6 x 1.0mm) : 9.8 N.m 11.0kgf.m.?.2 lbf.lt)
Compressorto the compressor b.acket {8 x 1.25 mm) : 22 N m {2.2 kgt.m, 16 lbf.ft)
Compr€ssorbracketto the engineblock {10 x 1.25mm} : ,14N.m 14.5kgf.m,33 lbf.ft)

21-7
How to Retrievea DTC
The heatercontrol panel has a self-diagnosisfunction.To run the self-diagnosisfunction,do the following:
1 . T u r nt h e f a n s w i t c hO F F .
2. Pressandholdthe recirculationcontrol switch andthe rearwindow defoooerswitch down.
3 . T u r nt h e i g n i t i o ns w i t c ho N { l l i .
4. Releaseboth switches.The recirculationindicatorand the rearwindow defoggerindicatorcome on. The

recirculationindicatorgoes off 3 secondslater and the Ay'Cindicatorcomes on. then the self-diagnosiswill begin.
About 10 secondslater,the self-diagnosiswill finish and the A,/Cindicatorgoes off.
.lfanytroubleisfound.therecirculationindicatorblinksthediagnostictroublecode(DTC)toindicateafaulty
circuil or comDonent.
. lf the system is OK, the recirculationindicatorstaysoff.
atc INOICATOR
BECIRCULATION REARWINDOW
INDICATOB OEFOGGERINDICATOR
/A\
-:@
RECIRCULATION
@r REARWINDOW
CONTROLSWITCH DEFOGGERSWITCH
Examole of DTC indication Pattern IDTC7)
DTC 7
Recirculation +
indicatot
Recirculation+
indicalor
go6s oft ----->
Reseiting the Selt-diagnosis Function
Turn the ignition switch OFFto cancelthe self-diagnosisfunction.After completingrepairwork, run the self-diagnosis
f u n c t i o na o a i nt o m a k es u r et h a t t h e r ea r e n o o t h e rm a l f u n c t i o n s .
21-8
DTC{Recirculation Detection ltem Page
IndicationBlinks)
7 A n o p e n i n t h e a i r m i x c o n t r o lm o t o rc i r c u i t ( s e ep a q e2 1 - 1 6 )
8 A short ln the air mix control motor circuit ( s e eD a o e2 1 - ' 1 6 )
9 A p r o b l e mi n t h e a i r m i x c o n t r o l i n k a q ed, o o r ,o r m o t o r ( s e ep a q e2 1 -1 7 )
10 An open or shon in the mode control motor circuit ( s e eo a q e2 1 - 1 8 )
11 A p r o b l e mi n t h e m o d ec o n t r o l i n k a g ed, o o r s ,o r m o t o r ( s e ep a q e2 1 1 9 1
12 A p r o b l e mi n t h e b l o w e rm o t o rc i r c u i t ( s e ep a q e2 1 - 2 0 )
13 A problem in the EEPROMin the heatercontrol panel; ( s e ep a g e2 1 - 3 8 )
the control oanel must be reolaced
14 An ooen in the evaDoratortemDeraturesensorcircuit (seepaqe 21-23)
A short in the evaDoralortemoeraturesensorcircuit ( s e eo a q e2 1 - 2 4 1
In case of multiple problems,the recirculationindicatorwill indicateonly the DTCwith the least number of blinks.
ln caseof an intermittentfailure,the heatercontrol panelwill storethe DTCuntil the ignition is turned off.
21-9
SymptomTroubleshooting
Index \ {
Svmptom Diagnosticprocedure Also check for

Recirculationcontrol doors do not RecirculationControl Motor C l e a n l i n e sasn d t i g h t n e s so f a l l
changebetweenFreshand Recirculate CircuitTroubleshooting(seepage connectors
21 251
Both heaterand Ay'Cdo not work HeaterControlPowerandGround B l o w nf u s eN o .' 1 4( 1 0 Ai)n t h e
(see
CircuitsTroubleshooting under-dash fuse/relay box
page21-27) Poorgroundat G501
C l e a n l i n easns dt i g h t n e sosf a l l
conneclors
Condenserfan does not run at all (but C o n d e n s eFr a nC i r c u i t . P o o rg r o u n da t G 3 0 1
radiatorfan runs with the Ay'Con) Troubleshooting{seepage 21-28) . C l e a n l i n e sasn d t i g h t n e s so f a l l
connectors
Both fans do not run with the A,/Con R a d i a t oarn dC o n d e n s e Fra n s B l o w nf u s eN o . 1 ( 2 0 A )a n d N o . 4
CommonCircuitTroubleshooting (20A)in the under-hoodfuse/relay
( s e ep a g e2 1 - 2 9 ) box
P o o rg r o u n da t G 3 0 l
C l e a n l i n e sasn dt i g h t n e s so f a l l
connectors
Compressorclutchdoes not engage CompressorClutchCircuit C l e a n l i n e sasn dt i g h t n e s so f a l l
(both fans run with A,/Con) T r o u b l e s h o o t i n(qs e eD a q e2 1 - 3 0 ) connectors
A/C system does not come on (both Ay'CPressureSwitch Circuit B l o w nf u s eN o . 1 ( 2 0 A )a n d N o . 4
fans and compressor) T r o u b l e s h o o t i n(gs e ep a g e2 1 - 3 2 ) (20A)in the under-hoodfuse/relay
box
Poor ground at G301
C l e a n l i n e sasn dt i g h t n e s so f a l l
connectors
\ a
! a
21-10
SystemDescription
HeaterControlPanelInputsandOutputs
HEATERCONTFOLPANELCONNECIORS
CONNECTOR
A {r/rP) CONNECTORB (22P)
W res deoitema eterm nals
CONNECTOR
Cavity Wire color Sional
_| \ln Y AIRMIXPOTENTIAL +5V OUTPUT
2 LT GRN S E N S OC
RO M M O N
GROUND INPUT
3 PNK/BLU AIR MIX HOT OUTPUT
BLU A,/CPRESSURE
SWITCH INPUT
5 GRNA/EL RECIRCULATE INPUT
6 GRNA/VHT FRESH INPUT
7 BLUI/EL POWER TRANSISTOR OUTPUT
8 BLU/RED BLOWERFEEDBACK INPUT
I GRN AIR MIX COOL OUTPUT
10 YEL/RED MODEDEF OUTPUT
11 . YEVBTU MODEVENT OUTPUT
YEL/BLK REARWINDOWDEFOGGERRELAY INPUT
BLK GROUND OUTPUT
14 BLK/YEL l G 2( P o w e r ) INPUT
CONNECTOR
B on
Cavity Wire color Siqnal --T
1
2
3 BLIVRED R E A RW I N D O WD E F O G G ES
RW I T C HL E D INPUT
4 LT GRN A./CSWITCHLED INPUT
5 L TG R N / B L K RECIRCULATIO CNONTROL S W I T C HL E D INPUT
6 PNVBLK AIR MIX POTENTIAL OUTPUT
7 BRN EVAPORATOR
TEIMPERATURE
SENSOR OUTPUT
8
9
10
11 RED GAUGE
ASSEMBLY al' 'TDr ri
RED/BLK TAILLIGHTSRELAY INPUT
14 BLU REARWINDOWDEFOGGER
SWITCH INPUT
ic LT GRN/RED A/C SWITCH INPUT
16 YEVRED RECIRCULATIO
CNONTROL
SWITCH INPUT
17 YEUGRN MODE4 OUTPUT
18 WHT/BLU MODE3 OUTPUT
19 RED/BLU M O D E2 OUTPUT
20 RED/YEL M O D E1 OUTPUT
BRN^,^/HT I G N( P o w e d OUTPUT
22 REDA/r'HT (Not used)
(cont'd)
21-11
SystemDescription(cont'dl
The air conditioningsystem removesheatfrom the passengercompartmentby circulatingrefrigerantthrough the
system as shown below.
BLOWER
FAN
\ \
\ r\,u /
EXPANSIONVALVE
(Metersthe required
amount of refrigerant
into the evaporator)
APOBATORTEMPERATURE
SENSOR
A/C PRESSURESWITCH THERMALPROTECTOR

When the refriqerantis below (Opensthe compressorclutchcircuit
196kPa(2.0kgi/cm',28psi) when the compressottemperature
or above3,140kPa(32 kgf/cm' becomestoo high)
455 psi),the Py'cpressure
switchopensthe circuitto RELIEF VALVE
the Py'Cswitch and stopsthe (Relieves pressure at thecompressor
air conditioningto protectthe w h e nt h ep r e s s u ri e
st o oh i g h )
compressor-
A/C COMPRESSOR
RECEIVER/DRYER (Suctionand comoression)
(Trapsdebris,and \-^
removesmorsturel
/- I vAPoR
HrcHPRESSURE
CONDENSER
(Radiationof heat) -:--l
[ '.... Low PREsSUBE
LrourD
tffi Low PREssURE

vAPoR
This vehicleuses HFC-134a(R-'134a)

refrigerantwhich does not containchlorofluorocarbons.Pay attentionto the
following serviceitems:
. D o n o t m i x r e f r i g e r a n tCs F C - 1 2 ( R - 1 2a) n d H F C - 1 3 4(aR - 1 3 4 aT) .h e ya r e n o t c o m p a t i b l e .

. U s eo n l y t h e r e c o m m e n d e p '!0)
d o l y a l k y l e n e g l y c(oPl A G) r e f r i g e r na t o i l ( K E l H l NS P designedfortheR-134a
compressor.Intermixingthe recommended (PAG) refrigerant oil with any other retrigerant oil will resultin
compressorfailure.
. AllAy'Csystem parts (compressor,dischargeline, suction line,evaporator,condenser,receiver/dryer. expansion
valve,O-ringsfor joints) have to be designedfor refrigerantR 134a.Do not exchangewith R-'12parts.
. Use a halogengas leakdetectordesignedfor refrigerantR-134a.
. R-12and R-134arefrigerantservicingequipmentare not interchangeable. Use only a recovery/recycling/charging
s t a t i o nt h a t i s U . L . - l i s t eadn d i s c e r t i f i e dt o m e e tt h e r e q u i r e m e n tosf S A EJ 2 2 1 0t o s e r v i c eR - 1 3 4 a i r c o n d i t i o n i n g
system.
. Always recoverthe refrigerantR-134awith an approvedrecovery/recycling/charging stationbeforedisconnecting
any Ay'Cfifting.
21-12
GircuitDiagram
|GNUION SWTCfi UNOERDASN

UNDEN
rcODFUSVRELIYSOX lG2HoI ii 0l\lllll fUSE/8EIlYBOX
+. C}F BLK/RED
\ rG2/
/
.I
\ IHEFMAI
I
PBorEcro8 I
Y I
lTl *n*,*,
| <l I CLUTCH
I
tf
_l n
I
.
G301
MUITIPLD(
CONTFOI
UNITI
A/CPnESSUEt
swTOt
-!10. irgF 8Ll t...iCF BLU
T T
RADIATOS\ NADIATOS CONDEN$N

) tAl'/
oT0n / swtlcll MOTOB
I I
j
193"C) l
19S"F
B LX 8u(
I
G301
I I ilnthoundor dasiluse/lelay
box
21-14
- BU/YEL
-8lU/wH'I
EVAPORATOB
TEMPERATUNESENSOR
sn 4-Lrenil
m
::-:::: ., . a/c
YEUBLU
YEL/NED M DEF
MODEl
M00l
BED/YEI Mq)EI co TnoL
MOTOS
RED/8LU M00€2
M00t3 s
WHT/8LU MOOE3
YEL/GRN MOOEI
LTGRI'l
ffftH,,
F*u,*
GNNMHT 8U
GRN/YEL
8LK--..-...-l
(
f
coNNEcroFrir.Pt
mxr{EcroB
! {2P)
G5'1
I
G602
21-15
DTCTroubleshooting
DTC7:An Openin theAir Mix ControlMotor DTC8:A Shortin theAir Mix ControlMotor
Circuit Circuit
1. Test the air mix control motor {seepage 2'l-341. 1. Testthe air mix control motor(see page 21-341.
ls the air mix control motor OK? ls the ait mix control motor OK?
YES-Go to step 2.
N O - R e p l a c et h e a i r m i x c o n t r o lm o t o r . l YES-Go to step 2.
2. Disconnectthe air mix control motor 5P connector. NO-Replace the air mix contorol motor.I
3. Disconnectheatercontrol panel connectorsA {14P) 2. Disconnectthe air mix control motor 5P connector.
a n dB ( 2 2 P ) .
3. Disconnectheatercontrol panelconnectorsA (14P)
4. Checkfor continuitybetweenthe following andB (22P).
terminalsof heatercontrol panel connectorsA
(14P)and B (22P)and the air mix control motor 5P 4. Checkfor continuitybetweenbody ground and
connector, heatercontrol panelconnectorA (14P)terminals
14P: 5P: No. 1, 2, 3, and 9 individually,and betweenbody
N o .1 No.5 ground and heatercontrol panelconnectorB (22P)
No.2 No.4 t e r m i n a lN o . 6 .
No.3 No.2
No.9 N o .1
HEATERCONTROL A {I4PI
PANELCONNECTOR
22P: 5P:
No.6 No.3
HEATERCONTFOL PANELCONNECTORB I22P1
Wire side ol lem.letehi.6ls
YES-Check for loosewires or poor connectionsat
heatercontrol oanel connectorsA (14P)and B (22P)
and at the air mix control motor 5P connector.lf the W i r e s i d eo i l e m a e l e r m i n a l s
connectionsare good. substitutea known-goodair
mix control motor, and recheck,lf the symptom/
indicationgoes away, replacethe originalair mix ls therc continuity?
control motor. lf the symptom/indicationcontinues,
substitutea known-goodheatercontrol panel,and Y E S - R e p a i ra n y s h o r t t o b o d y g r o u n dl n t h e
recheck.lf the symptom/indicationgoes away, wire(s)betweenthe heatercontrol panel and the air
replacethe original heatercontrol panel.l mix control motor.l
N O R e p a i ra n y o p e n i n t h e w i r e ( s )k e t w e e n t h e
heatercontrol panel and the air mix control N O - G o t o s t e p5 .
motor.l
21-16
5. Turn the ignition switch ON (ll),and checkthe same DTC9: A Problemin the Air Mix Control
terminalsfor voltage. Linkage,Door,or Motor
HEATERCONTROLPANELCONNECTOR
A {14PI 1, Test the air mix control motor (seepage 21-34).
ls the air mix control motor OK?
YES-Substitute a known-goodheatercontrol
panel,and recheck.lf the symptom/indicationgoes
away, replacethe original heatercontrol panel.l
NO-Replace the air mix control motor, or repair

t h e l i n k a g ea n d d o o r . l
B I22PI
ls there any voltage?
YES-Repair any short to power in the wire(s)

betweenthe heatercontrol panel and the air mix
control motor. This short may also damagethe
heatercontrol panel.Repairthe short to power
before replacingthe heatercontrol panel.l
NO Substitutea known-goodair mix control

motor, and recheck.lf the symptom/indicationgoes
away, replacethe originalair mix control motor. lf
the symptom/indicationcontinues,substitutea
known-goodheatercontrol panel,and recheck.lf
the symptom/indicationgoes away, replacethe
originahl e a t e rc o n t r o lp a n e l . I
21-17
DTCTroubleshooting.(cont'd)
DTC10:An Openor Shortin the Mode 5 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d c h e c kt h e s a m e
ControlMotorCircuit t e r m i n a l sf o r v o l t a g e .
1. Test the mode control motor (seepage 21-35). HEATEB

CONTROL
PANEL
CONNECTOR
A {14P)
ls the mode cottol motor OK?
YES Go to step 2.
NO Replacethe mode control motor.I
2. Disconnectthe mode control motor 10Pconnector.
s (14P)
3 . D i s c o n n e cht e a t e rc o n t r o lp a n e lc o n n e c t o r A
and B \22P1. Wire side of femaleterminal
Checkfor continuitybetweenbody ground and

h e a t e rc o n t r o lp a n e lc o n n e c t oA r ( 1 4 P t)e r m i n a l s
N o . 2 , 1 0 ,a n d 1 1 i n d i v i d u a l l ya,n d b e t w e e nb o d y HEATERCONTROLPANELCONNECTOR
B {22PI
g r o u n da n d h e a t e rc o n t r o lp a n e lc o n n e c t o B r (22P)
'17,
t e r m i n a l sN o . 1 8 ,1 9 ,a n d 2 0 i n d i v i d u a l l y .
3 5 X 6
tl 12 15 T6 1 1 1 8 t 9 2A 21 22
HEATER
CONTROL
PANEL
CONNECTOR
A {14PI
RED/YEL
WHT
Wire side ol lemale terminals ls there any voltage?
YES-. Repairany short to power in the wire(s)

betweenthe heatercontrol panel and the mode
B {22P) control motor. This short may also damagethe
heatercontrol panel.Repairthe short to power
before replacingthe heatercontrol panel.l
NO- Go to step 6.
W i r e s i d e o f f e m a L el e r m i n a l s
Y E S R e p a i ra n y s h o r t t o b o d y g r o u n di n t h e
wire(s)betweenthe heatercontrol panel and the
mode control motor.l
NO Go to step 5.
21-18
Turn the ignition switch OFF,and checkfor DTC11:A Problemin the ModeControl
continuitybetweenthe following terminalsof Linkage,
Doors,or Motor
heatercontrol panel connectorsA (14P)and B (22P)
and the mode control motor 10Pconnector. 1. Testthe mode control motor (seepage 21-35).
14P: 10P:
'10
N o .2 No. ls the mode control motor OK?
No.10 No,1
N o .1 1 No.2 YES Substitutea known-goodheatercontrol
22P: 10P: away, replacethe original heatercontrol panel.l
N o .1 7 No.8
N o .1 8 No.6,9 NO Replacethe mode control motor, or repairthe
No.19 No.5 l i n k a g ea n d d o o r s . l
N o .2 0 N o .4 , 7
HEATER
CONTROL PANELCONNECTOR A (14PI
MODECONTROLMOTORlOPCONNECTOR
HEATERCONTROLPANELCONNECTORB {22PI
YES-Check for loosewires or poor connectionsat

heatercontrol panelconnectorsA (14P)and B (22P),
and at the mode control motor 10Pconnector.lf the
connectionsare good, substitutea known-good
mode control motor, and recheck.lf the symptom/
indicationgoes away. replacethe original mode
control motor.lfthe symptom/indicationcontinues,
substitutea known-goodheatercontrol panel,and
recheck.lf the symptom/indicationgoes away,
replacethe originalheatercontrol panel.l
NO Repairany open in the wire(s)betweenthe

heatercontrol Daneland the mode control motor.l
21-19
HeatingandAir Gonditioning
DTCTroubleshooting{cont'd)
DTC12:A Problemin the BlowerMotor 7. Checkfor continuitybetweenthe No. 3 terminal of
Circuit the power transistor4P connectorand body ground.
'1.
C h e c kt h e N o . 1 2 ( 4 0 A ) f u s ei n t h e u n d e r - h o o d POWERTRANSISTOR4P CONNECTOR
fuse/relaybox, and the No. 14 (10A)fuse in the
under-dashf use/relaybox.
2
Are the tuses OK?
3 4
YES-Go to step 2. BLK
o
NO Replacethe fuse(s),and recheck.l
2. Connectthe No. 2 terminal of the blower motor 2P

connectorto body ground with a jumper wire. Wire side ol temaleterminals
BLOWERMOTOB2PCONNECTOR
YES-Go to step 8.
NO-Check for an open in the wire betweenthe

power transistorand body ground. lf the wire is OK,
JUMPER] BLU/BLK checkfor poor ground at G502.I
8 . Connectthe No. 1 and No. 3 terminalsof the power

transistor4P connectorwith a jumper wire.
TRANSISTOR
POWER 4PCONNECTOR
Does the blowet motor run?
YES Go to step 4,
NO Go to step 17.

5. Disconnectthe jumper wire.
6. Disconnectthe power transistor4P connector. 9 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
Does the blower motor tun at high speed?
Y E S - G o t o s t e p1 0 .
NO-Repair open in the wire betweenthe power

transistorand the blower motor.l
1 1 . Disconnectlhe jumper wire.
21-20
1a Disconnectheatercontrol panelconnectorA (14P). 1 5 . Reconnectheatercontrol panel connectorA (14P).
1 3 .Checkfor continuitybetweenthe No. 7 and No. 8 lo. Test the power transistor(seepage 21-38).
terminalsof heatercontrol panel connectorA (14P)
a n d b o d y g r o u n di n d i v i d u a l l y . ls the power transistorOK?
HEATER
CONTNOL
PANEL
CONNECTOR
A {14PI YES Checkfor loosewires or poor connectionsat
heatercontrol panel connectorA (14P)and at the
power transistor4P connector.lf the connections
are good, substitutea known-goodheatercontrol
away, replacethe original heatercontrol panel.l
NO Replacethe power transistor.I
1 7 . Disconnectthe jumper wire.
1 8 . Disconnectthe blower motor 2P connector.
ls there continuity? 1 9 . Measurethe voltagebetweenthe No, 1 terminal of

the blower motor 2P connectorand body ground.
YES Repairany shortto body ground in the
wire(s)betweenthe heatercontrol panel and the BLOWERMOTOR2PCONNECTOR
power transistor.I
NO Go to step 14, BLU/WHT
1 4 . Checkfor continuitybetweenthe following

terminalsof heatercontrol panelconnectorA ( 14P)
and power transistor4P connector.
'l4Pt 4P:
No.7 No.4
No.8 No.2
HEATER
CONTROL
PANEL A (14P)
CONNECTOR
I z 3 4 1 5 1 6 ls thete battery voltage?
T 8 9 r ol x l I 1 2 l1 3l 1 4
BLU/YEL YES- Replacethe blower motor.l
) NO Go to step 20.
8LU/RED
2 1 .Removethe blower motor relayfrom the under-

ILU/YEL hood fuse/relaybox, and test it (seepage 22-511.
POWERTRANSISTOR 4PCONNECTOR
ls the relay OK?
ls thete continuity? YES Go to step 22.
YES Go to step 15. NO- Replacethe blower motor relay.l
NO Repairany open in the wire(s)betweenthe

heatercontrol paneland the power transistor.l
(cont'd)
21-21
DTCTroubleshootinglcont'd)
22. Measurethe voltage betweenthe No. 3 terminal of 25. Turn the ignition switch OFF,
the blower motor relay 4P socketand body ground.
26. Checkfor continuitybetweenthe No. 1 terminal of
the blower motor relay 4P socketand body ground.
BLOWERMOTORRELAY4PSOCKET
2 1
4 3
YES-Go to step 23. ls there continuity?
NO Replacethe under-hoodfuse/relaybox.t YES-Repair open in the BLUIr'/HTwire between

the blower motor relay and the blower motor.l
23. Turn the ignitionswitch ON {ll).
Measurethe voltage betweenthe No. 2 terminal of blower motor relay and body ground. lf the wire is
\
the blower motor relay 4P socketand body ground, O K ,c h e c kf o r p o o r g r o u n da t G 3 0 1 . 1
ls therebattery voltage?
YES-Go to step25.
NO Repairopenin thewire betweenthe No.14

fusein the under-dash
fuse/relay
boxandthe
blowermotorrelay.I
21-22
DTC14:An Openin the Evaporator 4. Checkfor continuitybetweenthe No. 7 terminal of
Temperature
SensorCircuit heatercontrol panelconnectorB (22P)and the
No. 1 terminal of the evaporalortemperature
1. Removethe evaporatortemperaturesensor(see s e n s o r2 P c o n n e c t o r .
p a g e2 1 - 3 7 ) .
HEATERCONTROLPANELCONNECTOR B {22P)
2. Measurethe resistancebetweenthe No. l and Wiresideof femaleterminals
No. 2 terminalsof the evaporatortemperature
sensor.
x D i pt h e s e n s o ri n i c ew a t e r ,a n d m e a s u r e
resistance.Then pour hot water on the sensor,and
c h e c kf o r c h a n g ei n r e s i s t a n c e .
TORTEMPERATURE
EVAPORA SENSOR
t-l
ll#l EVAPORATOR
TEMPERATURE SENSOR 2PCONNECTOR
lI UT-TU
l , l , l l
---r---T--I
t ^
11c))-l ls there continuity?
\9/
T e r m i n asl i d eo f m a l et e r m i n a l s YES Go to step 5.
NO Repairopen in the wire betweenthe heater

control panel and the evaporatortemperature
sensor.I
RESISTANCE 5. Disconnectheatercontrol panelconnectorA (14P).

k0
50 68 86'F
10 20 30'c
TEMPERATURE
ls the tesistancewithin the specificationsshown

on the graph?
NO Replacethe evaporatortemperature
sensor.I
3. Disconnectheatercontrol panelconnectorB {22P).
(cont'd)
21-23
6. Checkfor continuitybetweenthe No. 2 terminal of DTC15:A Shortin the Evaporator
heatercontrol panel connectorA (14P)and the Temperature
SensorCircuit
No, 2 terminal of the evaporalortemperature
sensor2P connector. 1. Removethe evaporatortemperaturesensor(see
p a g e2 1 - 3 7 ) .
HEATER
CONTROL PANELCONNECTOR A {14PI
Wiresideof femaleterminals 2. Testthe evaporatortemperaturesensor(seepage
LT GRN 21-37J.
ls the resistance within the specifications shown

on the graph?
YES Go to step 3.
NO Replacethe evaporatortemperature
sensor.!
EVAFORATOR
TEMPERATURE SENSOR 2PCONNECTOR
Wiresideof femaleterminals Disconnectheatercontrol panel connectorB l22Pl.
4. Checkfor continuitybetweenthe No. 7 terminal of

ls there continuity? heatercontrol panel connectorB {22P)and body
ground.
YES-Check for loosewires or Doorconnectionsat
heatercontrol panel connectorA ('l4P)and B l22Pl
HEATER
CONTROL B (22P)
PANELCONNECTOR
and at the evaporatortemperaturesensor2P
connector.lf the connectionsare good, substitutea
\
known-goodheatercontrol panel,and recheck.lf
original heatercontrol panel.l
NO Reoairooen in the wire betweenthe heater

control panel and the evaporatortemperature
sensor.I
YES Repairshort to body ground in the wire

betvveenthe heatercontrol paneland the
evaporatortemperaturesensor.I
NO-Substitute a known-goodheatercontrol panel,

and recheck.lf the symptom/indicationgoes away,
replacethe original heatercontrol panel.I
21-24
RecirculationControlMotor CircuitTroubleshooting
1 . C h e c kt h e N o . 1 4 ( ' 1 0 A ) f u sien t h e u n d e r - d a s h f u s e / 8. Checkfor continuitybetweenthe No. 5 and No. 6
relay box. terminalsof heatercontrol panelconnectorA (14P)
and body ground individually.
ls the f use OK?
HEATER
CONTROL A I14P)
PANELCONNECTOR
YES Go to step 2.
NO- Replacethe fuse, and recheck.l
2. Disconnectthe recirculationcontrol motor 5P

conneclor.
lvleasurethe voltage betweenthe No. 5 terminal of

the recirculationcontrol motor 5P connectorand Wire side of femaleterminals
body ground.
RECIRCULATIONCONTROLMOTOR
5P CONNECTOR
YES Repairany shortto body ground in the
wire(s)betweenthe heatercontrol panel and the
recirculationcontrol motor.l
NO-Go to step 9.
9. Turn the ignition switch ON (ll),and checkthe same

wires for voltage.
Wiresideof femaleterminals HEATER A Il4PI

PANELCONNECTOR
CONTROL
YES Go to step 5.
NO- Repairopen in the wire betweenthe No. 14

fuse in the under-dashfuse/relaybox and the
recirculationcontrol motor .l
5 . Turn the ignitionswitch OFF. Wiresideof lemaleterminals
6 . Testthe recirculationcontrol motor {seepage 21-

36), ls therc any voltage?
ls the recirculationcontrol motor OK? Y E S R e p a i ra n y s h o n t o p o w e ri n t h e w i r e ( s )

betweenthe heatercontrol panel and the
YES Go to step 7. recirculationcontrol motor. This shon may also
d a m a g et h e h e a t e rc o n t r o lp a n e l .R e p a i rt h e s h o n
NO- Replacethe recirculationcontrol motor, or to power before replacingthe heatercontrol
r e p a i rt h e l i n k a g ea n d d o o r s . I p an e l .I
7 . Disconnectheatercontrol panel connectorA (14P). N O - G o t o s t e p1 0 .
{cont d r
21-25
RecirculationControl Motor CircuitTroubleshooting(cont'd!
10. Turn the ignition swirchOFF.
11. Checkfor continuitybetweenthe following

terminalsof heatercontrol panel connectorA ( 14P)
and the recirculationcontrol motor 5P connector.
'l4Pt
5P:
No.5 N o .1
No.6 No.2
HEATER
CONTROL PANEL CONNECTOR A {14P}
Wiresideol temaleterminats
RECIRCULATION
CONTROL MOTOR5PCONNECTOR
Wiresideol lemaleterminals
YES Checkfor loosewires or poor connectionsat

heatercontrol panel connectorA ( 14P)and at the
recirculationcontrol motor 5P conneclor.lf the
connectionsare good, substitutea known-good
heatercontrol panel,and recheck.lf the symptom/
indicationgoes away, replacethe original heater
control panel,I
NO Repairany open in the wire{s)betweenthe

heatercontrol panel and the recirculationcontrol
motor.l
21-26
HeaterControlPowerand GroundCircuitsTroubleshooting
1 . C h e c kt h e N o . 1 4( 1 0 A ) f u s ei n t h e u n d e r - d a s h 6. Checkfor continuitybetweenthe No. l3terminal of
fuse/relaybox. heatercontrol panelconnectorA (14P)and body
g round.
ls the f use OK?
A (1ilP)
CONTRoLPANELCONNEcToR
HEATER
YES-Go to step 2.
N O - R e p l a c et h e f u s e ,a n d r e c h e c k . l
1 2 3 4 5 6
2. Disconnectheatercontrol panelconnectorA{'14P). I 8 9 r0t, 1 l 12 14

BLK
3. Turn the ignition switch oN (ll).
.o
4. Measurethe voltage betweenthe No. l4terminal
of heatercontrol panelconnectorA (14P)and body
grouno. Wire side of temaleterminals
HEATER
CONTROL A {14P}
PANELCONNECTOR
YES Checkfor loosewires or poor connectionsat

2 3 4 5 6
healercontrol panel connectorA (14P).lfthe
7 8 I 1 0l , 11 12 14 connectionsare good, substitutea known-good
BLK/YEL heatercontrol panel,and recheck.lf the symptom/
indicationgoes away, replacethe original heater
control panel.l

Wire side of temaleterminals heatercontrol paneland body ground. lf the wire is
O K ,c h e c kf o r p o o r g r o u n da t G 5 0 1I.
YES-Go to step 5.
NO Repairopen in the wire betvveenthe No. 14

heatercontrol panel.l
21-27
CondenserFanCircuitTroubleshooting
NOTE:lf neitherthe condenserfan nor the radiatorfan 4 . C o n n e ctth e N o . l a n d N o . 2 t e r m i n a l s o f t h e
work, go to Radiatorand CondenserFansCommon condenserfan relay 4P socketwith a jumper wire.
CircuitTroubleshooting(seepage21-29).
CONDENSERFAN RELAYitP SOCKET
1. Checkthe No. 1 (20A)fuse in the under-hood
f u s e / r e l a yb o x ,a n d t h e N o . 1 4 ( 1 0 A ) f u s ei n t h e
under-dashf use/relaybox.
Are the tuses OK? JUMPERWIRE
YES-Go to step 2.
NO Replacethe fuse(s),and recheck.t
2. Removethe condenserfan relayfrom the

under-hoodfuse/relaybox, and test it
( s e ep a g e2 2 - 5 1 ) .
Does the condenser lan tun?
ls the relay OK?
YES-Go to step 5.
YES Go to step 3.
NO Go to step8.
NO- Replacethe condenserfan relay.l
5. Disconnectthe jumper wire.
3. Measurethe voltage betweenthe No, 2 terminal of
the condenserfan relay 4P socketand body ground. 6. Turn the ignition switch ON (ll).
CONDENSERFAN RELAYilP SOCKET 7. Measurethe voltage betweenthe No, 3 terminal of

the condenserfan relay 4P socketand body ground.
CONDENSER
FAN FELAY4PSOCKET
r-,_-l
1 2 |
Flr
\----1--rl
IELK/YEL
d,
ls thete battery voltage? I
YES-Go to step 4.
NO-Replace the under-hoodfuse/relaybox.l
YES Replacethe under-hoodfuse/relaybox.t
N O - R e p a i r o p e ni n t h e w i r e b e t w e e nt h e N o . 1 4
c o n d e n s efra n r e l a y . l
Disconnectthe jumper wire.
21-28
Radiatorand CondenserFans
CommonCircuitTroubleshooting
9 . Disconnectthe condenserfan 2P connector,
1 0 .Checkfor continuitybetweenthe No. 1 terminal of NOTE;lf both fans and the Ay'Ccompressorclutchdo
the condenserfan relay 4P socketand the No. 2 not work when the Ay'Cswitch is on, go to Ay'CPressure
terminal of the condenserfan 2P connector. Switch CircuitTroubleshooting(seepage 21-32l,.
CONDENSER
FANRELAY4PSOCKET 1. Checkthe No. 1 {20A}and No. 4 (20A)fuses in the
under-hoodfuse/relaybox, and the No. 14 (10A)
fuse in the under-dashfuse/relaybox.
Are the tuses OK?
YES Go to steD2.
NO Replacethe fuse(s),and recheck.l
2. Removethe condenserfan relavfrom the

CONDENSERFAN 2P CONNECTOR under-hoodf use/relaybox.
3 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ; .
YES Go to step 11. the condenserfan relay 4P socketand body ground.
NO- Repairopen in the wire betweenthe

CONDENSER
-l
FANRELAY4PSOCKET
'11.
c o n d e n s efra n r e l a ya n d t h e c o n d e n s efra n , I
Checkfor continuitybetweenthe No. 1 terminal of

r-,
the condenserfan 2P connectorand body ground. 1 2 l
f---r---
FAN2PCONNECTOR
CONDENSER
l,l,l
lar-vver-
l
1 2
oI
BLK
o ls there battery voltage?
YES Go to step 5.
Wire side of {emaleterminals NO Repairopen in the wire betweenthe No. 14

ls there continuity? radiatorfan relay,and the condenserfan relay.l
YES- Replacethe condenserfan motor.I 5. Turn the ignition switch OFF.
NO Checkfor an open in the wire betweenthe l e c o n d e n s efra n r e l a y .

6 . R e i n s t a tl h
condenserfan and body ground. lf the wire is oK,
c h e c kf o r p o o rg r o u n da t G 3 0 1 . 1 7 . M a k es u r et h e I V Cs w i t c hi s O F F .
(cont'd)
21-29
Radiatorand CondenserFans CompressorClutchCircuit
CommonCircuitTroubleshooting Troubleshooting
(cont'dl
1. Checkthe No. 1 (20A)fuse in the under-hood
9. Using a BackprobeSet, measurethe voltage f u s e / r e l a yb o x ,a n dt h e N o . 1 4 { 1 0 A ) f u s ei n t h e
betweenthe No. 6 terminal of ECN4
connectorB under-dashfuse/relaybox.
{24P)and body ground with the ECMconnectors
connecteo. Are the tuses OK?
ECMCONNECTOR
B {24P} YES Go to step 2.
NO Replacethe fuse(s),and recheck.I
2. Checkthe enginecoolanttemperature,the throttle

positionsensor,and the idle speed (usethe Honda
PGMTesterPGM-Fldata list if possible).
ls the coolant temperaturc above nomal, the

throttle position sensor rcading too high, or the
idle speed too low?
YES Troubleshootand repairthe causeof the
high enginecoolanttemperature,high throttle
ls there battery voltage? positionsensor reading,or low idle speed.l
YES UDdatethe ECM if it does not have the latest NO-Go to step 3.
so{tware,or substitutea known-goodECM,then
recheck(seepage 11-6).lf the symptom/indication \
3. Removethe compressorclutchrelay from the
goes away with a known-goodECM,replacethe under-hoodfuse/relaybox, and test it (seepage 22-
originaE
l CM.I 5 1) .
NO Repairopen in the wire betweenthe radiator ls the relay OK?

fan relay,the condenserfan relay and the ECM.t
YES Go to step 4.
NO Replacethe compressorclutch relay.I

the compressorclutch relay 4P socketand body
ground.
COMPfiESSON
CLUTCHBELAY'P SOCKET
YES Go to step 5.
NO Replacethe under-hoodfuse/relaybox.I
21-30
5. Connectthe No. 1 and No. 2 terminalsof the L Turn the ignition switch OFF.
compressorclutch relay 4P socketwith a jumper
wire. 10. Reinstallthecompressorclutch relay.
COMPRESSORCLUTCHRELAY4P SOCKET
11. l\4akesure the Ay'Cswitch is OFF.
1 2 . T u r nt h e i g n i t i o ns w i t c hO N { l l ) .
13. Uslng the BackprobeSet, measurethe voltage

JUMPERWIRE betweenthe No. 18 termina!of ECI\4connector
E {31P)and body ground with the ECMconnectors
connected.
ECMCONNECTOR
E 131P}
2 3 t 4 5 6 1 E 9
1 4 1 5 16 m 21
Does the compressor clutch click ? 22 23 24 26 27 29 31
RED
YES Go to step 6.
N O - G o t o s t e p1 4 .
6. Disconnectthe jumper wire. Wire side of femaleterminals
8. Measurethe voltagebetweenthe No. 3 terminal of
the compressorclutch relay 4P socketand body YES Updatethe ECM if it does not have the latest
ground. software,or substitutea known-goodECM,then
CLUTCHRELAY4PSOCKET
COMPRESSOR goes away with a known-goodECIM,replacethe
o r i g i n aE
l CM.I
NO Repairopen in the wire betweenthe

c o m p r e s s ocr l u t c hr e l a ya n d t h e E C M . I
t e j u m p e rw i r e .
1 4 . D i s c o n n e ct h
15. Disconnectthe compressorclutch lPconnector.
YES-Go to step 9.
NO Repairopen in the wire betweenthe No. 1 4

compressorclutch relay,I
{cont'd)
21-31
Compressor
ClutchCircuit A/C PressureSwitch Circuit
Troubleshooting(cont'dl Troubleshooting
16. Checkfor continuitybetweenthe No. lterminal of '1.

Turn the ignition switch ON {ll).
the compressorclutch relav 4P socketand the No. l
terminal of the compressorclutch 1Pconneclor. 2. Turn the blower switch on, and checkfor blower
motor operatron.
COMPRESSON
CLUTCHRELAY4PSOCKET
Does the blower motor run on all speeds?
YES Go to step 3.
NO Troubleshootthe blower motor circuit(see

page21-20).
4. Disconnectheatercontrol panelconnectorA ('14P).

COMPRESSORCLUTCH1P CONNECTOR
Terminalside of male terminals 5 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
ls therc continuity? 6. Measurethe voltage betweenthe No, 4 terminal of

heatercontrol panelconnectorA {14P)and body
YES-Check the compressorclutchclearance,the ground.
thermal protector,and the compressorclutchfield
c o i l ( s e ep a g e2 1 - 4 8 ) . I
HEATER
CONTROL A (I4P}
PANELCONNECTOR
NO-Repair open in the wire betweenthe
compressorclutch relay and the compressor
clutch.l
Wire side of femaletermina's
YES Go to step 7.
1 . S t a nt h e e n g i n e .
21-32
8. Connectthe No.4terminal ofheatercontrol 11. Checkfor continuitybetweenthe No. 2 terminal of
connectorA (14P)to body ground with a jumper the A,/Cpressureswitch 2P connectorand the No. 9
wire, terminal of under-dashfuse relav box connector
F t12Pt.
HEATER
CONTROLPANELCONNECTOR
A I14P} A/C PRESSURE SWITCH2PCONNECTOR
BLU
2 3 4 5 6
7 8 I r 0 l x 11 12 l 3 t 4
JUMPER
WIBE
Wiresideoffemale
terminals UNDER.OASHFUSE/RELAYBOX CONNECTORF (12P)
W i r es i d eo f f e n a l e l e r r r i n a l '
Does the A/C system come on? ls there continuity?
YES Replacethe heatercontrol panel.! YES Go to step 12.
NO Referto the multiplexcontrol system (see NO Repairopen in the wire betweenthe

p a g e2 2 - 1 6 8 ) . 1 pressure
under-dashfuse/relaybox and the A,,/C
switch.I
9 . Usingthe BackprobeSet,connectthe No. 9
terminal of under-dashfuse/relaybox connector 1 2 . Checkfor continuitybetweenthe No. 1 and No. 2
F ( 1 2 P t)o b o d y g r o u n dw i t h a j u m p e rw i r e . terminalsof the A,/Cpressureswitch.
A/C PRESSURE
SWITCH
UNOER.DASH BOXCONNECTOR
FUSE/RELAY F{12P}
2 5
6 1 B g l r ot l l2
BLU/WHT
JUMPER
WIRE
Does the NC system come on?
YES Repairopen in the wire betweenthe heater
YES Go to step 10. control panel and the A,/Cpressureswitch.l
NO- Referto the multiplexcontrol system (see N O G o t o s t e p1 3 .

p a g e2 2 - 1 6 8 ) . 1
'13.check for properAy'Csystem pressure.
'1.
N O T EC : h e c kf o r m u l t i p l e xc o d e si n m o d e F o l l o w
the troubleshooting{or any codesfound. lf no ls the pressure within specitications?
codesare found, subsititutea known-9ood
m u l t i p l e xc o n t r o lu n i ta n d a E C Mo n e a t a t i m e . YES Replacethe AilCpressureswitch.l
1 0 . Disconnectthe Ay'Cpressureswitch 2P connector NO Repairthe AilCpressureproblem.I

and under-dashfuse/relaybox connectorF { 12P).
21-33
Air Mix ControlMotorTest Air Mix ControlMotor Replacement
1. Disconnectthe 5P connectorfrom the air mix 1 . Removethe under-dashfuse/relaybox (seepage
control motor. 22-491.
2. Connectbatterypowertothe No. l terminal ofthe Disconnectthe 5P connector{A) from the air mix
air mix control motor, and ground the No. 2 control motor (B).Removethe self-tappingscrews
t e r m i n a l t; h e a i r m i x c o n t r o lm o t o rs h o u l dr u n ,a n d and the air mix control motor from the heaterunit.
stop at Max Cool.lf it doesn't,reversethe R e m o v et h e r o d ( C )f r o m t h e a r m ( D )o f t h e a i r m i x
connections;theair mix control motor should run, controi motor.
and stop at Max Hot. lf the air mix control motor
does not run, remove it. then checkthe air mix ,.,:l'
control linkageand door for smooth movement.
. lf the linkageand door move smoothly,replace

the air mix control motor.
. l f t h e l i n k a g eo r d o o r s t i c k o rb i n d ,r e p a i r t h e ma s
needed.
. lf the air mix control motor runs smoothly,go to
step 3.
AIRMIX CONTROLMOTOR
3 . Installthe motor in the reverseorder of removal.

After installation,make surethe motor runs
smoothly.
\'
3 . Measurethe resistancebetweenthe No. 4 and

No. 5 terminals.lt should be between2.1 k to
3 . 9k Q .
4 . Reconnectthe air mix control motor 5P connector,

t h e nt u r n t h e i g n i t i o ns w i t c hO N { l l ) .
Using the BackprobeSet, measurethe voltage

betweenthe No. 3 and No. 4 terminals.
Max Cool about 1V

Max Hot about 4 V
lf eitherthe resistanceor voltage readingsare not

as specified,replacethe air mix cotrol motor.
21-34
Mode ControlMotor Test Mode ControlMotor Replacement
'1.
Disconnectthe 10Pconnectorfrom the mode 1 . R e m o v et h e E C M( s e ep a g e 1 1 - 4 ) .
control motor.
2. Removethe relay mount bracketbolt, and move
Connectbatterypower to the No. 1 terminal of the the relaysout of the way.
mode control motor, and groundthe No. 2
terminal;the mode control motor should run 3 . Disconnectthe 10Pconnector{A) from the mode
smoothly and stop at Defrost.lf it doesn't,reverse control motor (B).Removethe self-tappingscrews
the connections;the mode control motor should and the mode control motor from the heaterunit.
run smoothly and stop at Vent.When the mode
control motor stops running,disconnectbattery
power immediately.
MODECONTROLMOTOR
4 . lnstallthe motor in the reverseorder of removal.

lvlakesure the pin on the linkageis properly
engagedwith the motor. After installation.make
3. lfthe mode control motor does not run in step 2, sure the motor runs smoothly.
remove it, then checkthe mode control linkageand
doors for smooth movement.
. lf the linkageand doors move smoothly. replace

the mode control motor.
. l f t h e l i n k a g eo r d o o r s s t i c ko r b i n d ,r e p a i r t h e m
as neeoeo.
. lfthe mode control motor runs smoothly,go to
step 4.
4 . Use a digital multimeterwith an output of 1 mA or

lessat the 20 k Q range.With the mode control
motor running as in step 2, checkfor continuity
b e t w e e nt h e N o . 4 , 5 , 6 , 7 , 8 , a n d 9 t e r m i n a l sa n d
t h e N o . 1 0t e r m i n a li n d i v i d u a l l yT.h e r es h o u l db e
c o n t i n u i t yf o r a m o m e n ta t e a c ht e r m i n a la s t h e
motor moves past each mode position.
lf there is no continuityfor a moment at each

terminal. replacethe mode control motor.
21-35
RecirculationControlMotor Test RecirculationControlMotor I
Replacement
1. Disconnectthe 5P connectorfrom the recirculation
control motor.
1 . R e m o v et h e E C M( s e ep a g e1 1 - 4 ) .
Incorrectlyapplying power and ground to Removethe relay mount bracketbolt.and move

the recirculationcontrol motor will damge it. the relaysout of the way,
Follow the instructionscarefullv.
Disconnectthe 5P connector(A)from the
2. Connectbattervoower to the No. 5 terminal ofthe recirculationcontrol motor (B),Removethe self-
recirculationcontrol motor, and ground the No. 1 tapping screwsand the recirculationcontrol motor
and No. 2 terminals;the recirculationcontrol motor from the blower unit.
should run smoothly.To avoid damagingthe
recirculationcontrol motor, do not reversepower
and ground. Disconnectthe No. 1 or No. 2
terminalsfrom ground;the recirculationcontrol
motor should stop at Freshor Recirculate.Don't
cyclethe recirculationcontrol motor {or a long time.
RECIRCULATION
CONTROL
MOTOR
Installthe motor in the reverseorder of removal. \

Make sure the pin on the motor is properly
engagedwith the linkage.After installation.make
sure the motor runs smoothly.
lf the recirculationcontrol motor does not run in

step 2, remove it, then checkthe recirculation
control linkageand doors for smooth movement.
. lfthe linkageand doors move smoothly,replace

the recirculationcontrol motor.
. l f t h e l i n k a g e o r d o o r s s t i c k obr i n d ,r e p a i r t h e m
as neeoeo.
21-36
EvaporatorTemperatureSensor EvaporatorTemperatureSensor
Replacement Test
1 . Removethe driver'sdashboardlower cover (see l. Dip the sensorin ice water, and measurethe
page 20-59)and the under cover (seepage 20-60). resistancebetweenits terminals
Removethe under-dashfuse/relaybox (seepage EVAPORATOR

TEMPERATURE
SENSOR
22-491.
Disconnectthe 2P connector(A)from the

evaporatortemperaturesensor(B),then remove
the connectorclip (C).Removethe self-tapping
screw,and carefullypull out the evaporator
temperature.
Terminalside ol male terminals
2 . Then pour hot water on the sensor,and check{or a

changein resistance.
3 . Comparethe resistancereadingswith the

specificationsshown in the graph;the resistance
should be within the specifications
4. Installthe sensorin the reverseorder of removal,

RESISTANCE
k9
t0
32 50 68 86 'F
0 10 20 30'c
TEMPERATURE

21-37
PowerTransistorTest HeaterControlPaneland Push a
Switch AssemblyRemovaland
1. Disconnectthe 4P connectorfrom the power Installation
Iranslslor.
2, Measurethe resistancebetweenthe No. 1 and 1 . Removethe centerpanel (seepage 20-62).

No. 2 terminalsof the power transistor.lt should be
'1.4
about 1 . 5k Q . Removethe dials (A),then removethe self-tapping
screwsand the heatercontrol panel (B)from the
. lf the resistanceiswithln the specifications,go to centerpanel (Cl. Removethe self-tappingscrews
step 3. and the push switch assembly(D)from the center
. lf the resistanceis notwithin the specifications, panel.
replacethe power transistor.
POWERTRANSISTOB
C a r e f u l l yr e l e a s et h e l o c kt a b o n t h e N o . 4 t e r m i n a l \
(BLUI/EL)(A) in the 4P connector,then removethe
terminaa l n d i n s u l a t ei t f r o m b o d y g r o u n d .
3 . lnstallthe control panel and push switch assembly
in the reverseorder of removal.After installation,
operatethe control panel controlsto see whether it
worKspropeny.
4 . Runthe self-diagnosis
functionto confirm that
there are no problemsin the system (seepage21-
8).
(To112 power
2V p o w e rssource on
o u r c eo n vvehicle)
ehicle)
Reconnectthe 4P connectorto the power transistor.
S u p p l y1 2v o l t st o t h e N o . 4 c a v i t yw i t h a j u m p e r
wire.
T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d c h e c kt h a tt h e
b l o w e rm o t o r r u n s .
. lf the blower motor does not run, replacethe

power rranstsror.
. l f t h e b l o w e rm o t o r r u n s , t h ep o w e r t r a n s i s t o r i s
oK.
21-38
Dustand PollenFilterReplacement BlowerUnit Removaland
lnstallation
The dust and pollenfilters should be replacedevery
3 0 , 0 0 0m i l e s( 4 8 . 0 0 0
k m ) o r 2 4 m o n t h sw h i c h e v e r
comes first. Replacethe filters more often if the air flow For some models:SRScomponentsare locatedin this
i s l e s st h a n u s u a l . area.Reviewthe SRScomponentlocations(seepage
23-13)and precautionsand procedures(seepage 23-14)
1. Openthe glove box. Removeboth glove box stops, in the SRSsectionbeforeperforming repairsor service.
then let the glove box hang down (seepage 20 63).
1. Make sure you havethe anti-theftcode for the radio,
2 . R e m o v et h e f i l t e rl i d ( A ) f r o mt h e b l o w e ru n i t ,t h e n then write down the frequenciesfor the preset
p u l l o u t t h e f i r s td u s ta n d p o l l e nf i l t e r( B ) .S l i d et h e buttons.
secondfilter to the left,and pull it out.
2. Disconnectthe batterynegativecable,and wait 3
minutesbefore beginningworK.
3. Removethe right kick panel (see page 20-50),

passenger'sdashboardlower cover,and the glove
box {seepage 20-63).
4. Cut the plasticcross bracein the glove box opening

with diagonalcuttersin the area shown. Remove
and discardthe plasticcross brace,
Removethe filter {A) from the housing (B),and

replacethe filter.
Cut heare.
4. Installthe filters in the reverseorder of removal.
{cont'd)
21-39
Blower Unit Removaland Installation{cont'd}
Removethe steeringhangerbeam bracketcover 10. Disconnecttheconnector{A) from the recirculation
from the right side of the glove box opening,then control motor, then removethe wire harnessclip
removethe bolts and the olove box frame. {B).Removethe mounting bolts,the mounting nuts
a n d t h e b l o w e ru n i t ( C ) .
Removethe ECM(seepage 11-4).
1 . Removethe EPScontrol unit (seepage 17-67).

6 x 1 . 0m m I 6x1.0mm
9.8N.m(1.0kgt.m, 9.8 N.m (1.0kgf.m,
8 . Disconnectand removethe PGM-Flmain relays 7.2tbt.ftl ?.2 tbf.ft)
and bracketassembly,then removethe ECM
bracket. 1 1 .I n s t a l l l h eu n i t i n t h e r e v e r s eo r d e ro f r e m o v a l .
M a k es u r et h a tt h e r ei s n o a i r l e a k a g e .
\
9 . Disconnectthe connectors{A) from the blower
motor and the power transistor,then removethe Reconnectthe negativebatteryterminal.
wire harnessclips (B)and the connectors(C).
'13.
Removethe self-tappingscrewsand the bracket(D). D o t h e e n g i n ec o n t r o lm o d u l e( E C M )i d l e l e a r n
procedure { s e ep a g e1 1 - 1 3 9 ) .
A
1 4 . Enterthe anti-theftcode for the radio,then enter
21-40
Blower Unit ComponentsReplacement
Nole these items when overhaulingthe blower unit;
' The recirculationcontrol motor (A),the power transistor(B),the blower motor (C),and the dust and pollenfiltefs (D)
can be replacedwithout removingthe blower unit.
. Beforereassembly,make surethatthe recirculationcontrol linkageand doors move smoothly.
. After reassembly,make surethe recirculationcontrol motorruns smoothly (seepage 2j-36).
21-41
EvaporatorCoreReplacement a
1 . Recoverthe refrigerantwith a recovery/recycling/ 5. Carefullypull out the evaporatorcore without
chargingstation(seepage 21-53). bendingthe pipes.
Removethe bolt, then disconnectthe suctionline

(A) and the receiverline (B)from the evaporator
core.
6 . Installthecore in the reverseorder of removal,and

6x10mm note these items.
9.8N.m(1.0kgt.m,7.2lbf.ft)
. lfyou're installinga new evaporatorcore, add
Removethe blower unit (seepage 21-39). r e f r i g e r a not i l ( K E l H l NS P - ] 0 )( s e ep a g e2 1 - 6 ) .
. Replacethe O-ringswith new ones at eachfitting,
Removethe self-tappingscrewsand the expansion and apply a thin coat of refrigerantoil before
valve cover. installingthem. Be sure to use the correctO-rings
f o r H F C - 1 3 4(aR - ' 1 3 4 tao) a v o i dl e a k a g e .
. l m m e d i a t e l y a f t eurs i n g t h eo i l , r e i n s t a l l t h e c a p
on the container,and seal it to avoid moisture
absorotion.
. Do not spill the refrigerantoil on the vehicle;it
may damagethe paint. lf the refrigerantoil
contactsthe paint,wash it off immediately.
. Chargethe system (seepage 21-55).
21-42
HeaterUnit/CoreReplacement
SRScomponentsare locatedin this area.Reviewthe 6. Slidethe hose clamps (A) back,then d isconnectthe
SRScomponentlocations(seepage23'13),and inlet heaterhose (B)and the outlet heaterhose (C)
precautionsand procedures(seepage 23-14)in the SRS from the heatercore. Enginecoolantwill run out
sectionbefore performingrepairsor service. when the hosesare disconnected;drain it into a
clean drip pan. Be sure not to let coolantspill on
1. Make sure you have the anti-theftcode forthe radio, the electricalpartsor the paintedsurfaces.lf any
then write down the freouenciesfor the radio's coolantspills,rinse it off immediately.
Dresetbuttons.
Disconnectthe negativecablefrom the battery,
Disconnectthe suctionand receiverlinesfrom the

evaporator core (see page 21-42).
4 . From underthe hood, open the cableclamp (A),

then disconnectthe heatervalve cable (B)from the
heatervalve arm (C).Turn the heatervalve arm to
the fully openedpositionas shown
7 . Removethe bolt and the heatervalve,then remove

the mounting nut from the heaterunit. Takecare
not to damageor bend the fuel lines and the brake
lines,etc.
W h e nt h e e n g i n ei s c o o l ,d r a i nt h e e n g i n ec o o l a n t
from the radiator(seepage 10-6).
8 x 1.25mm
12 N.m (1.2kgf.m,8.7lbf.ft)
(cont'd)
21-43
HeaterUnit/CoreReplacement(cont'd)
8. Removethe dashboard{seepage 20-66). 1 1 . R e m o v et h e m o u n t i n gb o l t s ,t h e m o u n t i n gn u t s ,
and the heaterunit.
9. Disconnecttheconnectors(A) from the blower
motor, the recirculationcontrol motor, the mode
control motor, and the power transistor,then
removethe wire harnessclips (B)and the
connector(C).Removethe self-tappingscrewsand
the bracket(D).
7 t ,
5 x 1 . 0m m
9.8 N.m
11.0kgl m,
7.2 tbf.ftl
12. Removethe self-tappingscrewsand the expansion

valve cover (A).Carefullypull out the evaporator
core (B)so you don't bendthe inlet and outlet pipes.
Removethe grommet (C),then removethe self-
tapping screwsand the flange cover (D).Bemove
1 0 ,Disconnectthe connectors(A) from the evaporator the self-tappingscrewsand the pipe cover (E),then
temperaturesensorand the air mix control motor, carefullypull out the heatercore (F)so you don't
then removethe wire harnessclips (B) and the bend the inlet and outlet oioes.
connector(C).Removethe self-tappingscrew and
the cover (D).Disconnectthe heatervalve cable (E).
21-44
13. Installthe heatercore and the evaporatorcore in
the reverseorder of removal.
14. Installthe heaterunit in the reverseorder of

. Do not interchangethe inlet and outlet heater

hoses,and installthe hoseclamps securely.
. Refillthecooling systemwith engine coolant(see
page 10-6).
. Adjust the heatervalve cable (see page2'l-461.
. Make sure that there is no coolantleakage.
. Make sure that there is no air leakage.
. Referto evaporatorcore replacement{seestep 6
o n p a g e2 1 - 4 2 ) .
. Do the enginecontrol module (ECl\4)idle learn
the customer'sradio stationDresets.
21-45
HeaterValveCableAdjustment
1 . F r o mu n d e r t h eh o o d ,o p e nt h e c a b l ec l a m p{ A ) , 5, From under the hood,turn the heatervalve arm {C)
then disconnectthe heatervalve cable (B)from the to the fully closedpositionas shown, and hold it.
heatervalve arm {C). Attachthe heatervalve cable (B)to the heatervalve
a r m ,a n d g e n t l yp u l l o n t h e h e a t e rv a l v ec a b l e
housingto take up any slack,then installthe heater
v a l v ec a b l eh o u s i n gi n t ot h e c a b l ec l a m p( A ) .
.'.-:',,
- " l l
.....-
t From under the dash,disconnectthe heatervalve

c a b l eh o u s i n gf r o m t h e c a b l ec l a m p( A ) ,a n d
disconnectthe heatervalve cable (B)from the air
m i x c o n t r o l i n k a g e{ C ) .
t.- l
,
\'r2t' ''' '

' ::"'
Set the temperaturecontrol dial on Max Cool with

the ignition switch ON (ll).
Attachthe heatervalve cable (B)to the air mix

control linkage(C)as shown above,then snap the
h e a t e rv a l v ec a b l eh o u s i n gi n t ot h e c a b l ec l a m p( A ) .
21-46
CompressorReplacement
1 . l f t h e c o m p r e s s oirs m a r g i n a l l yo p e r a b l er,u n t h e 8. Removethe mounting bolts and the compressor.
engineat idle speed,and let the air conditioning
work for a few minutes,then shut the engine off.

presetbuttons.
3. Disconnectthe negativecablefrom the battery.
4. Recoverthe refrigerantwith a recovery/recycling/

chargingstation(seepage 21-53).
5. Removethe alternator(seepage 4-29).

8 x 1 . 2 5m m
6. Removethe Ay'Ccondenserfan assembly(seepage 22 N.m12.2kgf.m.
10-10).
9 . I n s t a l l t h ec o m p r e s s oirn t h e r e v e r s eo r d e ro f
7. Disconnectthecompressorclutchconnector(A), removal,and note these items:
removethe bolts,then disconnectthe suction line
( B )a n d t h e d i s c h a r g el i n e( C ) f r o mt h e c o m p r e s s o r . . Beforeinstallingthe new compressor,checkfor
Plug or cap the lines immediatelyafter m e t a lo r o t h e rc o n t a m i n a t i o inn t h e l i n e .R e p l a c e
disconnectingthem to avoid moistureand dust any contaminatedparts.
contamination. . lf you're installinga newcompressor,you must
calculatethe amount of refrigerantoil to be
6 x '1.0mm
9.8 N.m removedfrom it (seepage 21-6).
11.0kgt.m, . Replacethe O-ringswith new ones at each fitting,
7.2 tbl.ttl
u1/
and apply a thin coat of refrigerantoil before
installingthem. Be sure to use the correctO-rings
f o r H F C - 1 3 4{aR - 1 3 4 at o ) a v o i dl e a k a g e ,
. U s er e f r i g e r a not i l ( K E l H l NS P - ' 1 0f o ) r HFC-134a
K E I H I Ns p i r a lt y p e c o m p r e s s oor n l y .
. To avoid contaminatlon,do not returnthe oilto
( the containeronce dispensed,and never mix it
with other refrigerantoils.
o . l m m e d i a t e l ya f t e ru s i n gt h e o i l , r e i n s t a l l t h ec a p
absorption.
. Do not spill the refrigerantoil on the vehicle;it
may damagethe paint. lf the refrlgerantoil
. D o t h e e n g i n ec o n t r o lm o d u l e( E C M )i d l e l e a r n
p r o c e d u r e( s e ep a g e1 1 - ' 1 3 9 ) .
. Enterthe antitheft code for the radio,then enter
21-47
CompressorClutchCheck a
1 . Checkthe armatureplatefor discoloration,peeling, 4. Releasethe field coil connectorf rom the holder,
or other damage.lf there is damage,replacethe then disconnectit. Checkthe thermal protectorfor
clutch set (seepage 21-49), continuity.lf there is no continuity,replacethe
t h e r m a lp r o t e c t o (r s e ep a g e2 1 - 5 1 ) .
Checkthe rotor pulley bearingplay and drag by
rotatingthe rotor pulley by hand.Beplacethe NOTE:The thermal Drotectorwill have no
clutchset with a new one if it is noisy or has c o n t i n u i t ya b o v e2 5 2 t o 2 7 0 " F\ 1 2 2 l o 1 3 2 ' C )W
. hen
excessiveplay/drag(seepage 21-49). t h et e m p e r a t u r e d r o p sb e l o w2 4 1t o 2 1 9 ' F( 1 1 6t o
104'C),the thermal protectorwill have continuity.
,\.
Measurethe clearancebetweenthe rotor pulley (A)
and the armatureplate (B)all the way around.lf the Checkresistanceof the field coil. lf resistanceis not
clearanceis not within specifiedlimits, removethe within specifications,replacethe field coil
armatureplate (seepage 21-49)and add or remove ( s e ep a g e2 1 - 4 9 ) .
shims as neededto increaseor decreaseclearance.
FieldCoil Resistance: 3.05 3.35ohmsat68"F
Clearance: 0.510.15 mm {0.02010.006in.) t20"c)
N O T ET: h e s h i m sa r e a v a i l a b l ei n f o u r t h i c k n e s s e s :
0 . 1m m . 0 . 2m m , 0 . 4m m , a n d0 . 5m m .
21-48
Compressor
ClutchOverhaul
Special Tool Required 3. lf you are replacingthe field coil, removethe snap
A,/Cclutch holder,Robinair10204.Kent-MooreJ37872, ring (A) with snap ring pliers,then removethe rotor
or HondaTool and EquipmentKMT-J33939, pulley (B).Be careful not to damagethe rotor pulley
yvailable or tne compressor.
1 . R e m o v et h e c e n t e rn u t ( A )w h i l e h o l d i n gt h e
armatureplatewith a commerciallyavailableA,/C
c l u t c hh o l d e r( B ) .
\ot
1 7 . 6N . m
{1.8kgf.m,
13 tbt.ft)
-@
/@h"
.ffi
4. Removethe bolt and holder (A).then disconnect
the field coil connector(B).Loosenthe clamp screw
(C)to iree the field coil wire. Removethe snap ring
{ D ) w i t hs n a pr i n g p l i e r s t, h e n r e m o v et h e f i e l dc o i l
Removethe armatureplate (A) and shim(s)(B), (E).Be careful not to damagethe field coil or the
taking care not to losethe shim(s).lf the clutch comoressor.
needsadjustment,increaseor decreasethe
number and thicknessof shims as necessary,then
reinstallthearmatureDlate,and recheckits
clearance(see page21-481.
N O T ET : h e s h i m sa r e a v a i l a b l ei n f o u r t h i c k n e s s e s :
0 . 1 m m , 0 . 2 m m , 0 . 4 m m , a n d 0 . 5m m .
7.4 N.m
(0.75kgf m,
9-=-g 5 tbf.ft)
----------------
"\)
(cont'd)
21-49
CompressorClutchOverhaul(cont'd)
5. Reassemblethe clutch in the reverseorder of
disassembly,and note these items:
. I n s t a l l t h ef i e l dc o i lw i t h t h e w i r e s i d ef a c i n g
down, and align the boss on the field coil with the
h o l ei n t h e c o m p r e s s o r .
. Cleanthe rotor pulley and compressorsliding
surfaceswith contactcleaneror other
non-petroleumsolvent.
. I n s t a l l n e w s n a pr i n g s ,n o t et h e i n s t a l l a t i o n
direction,and make surethey are fully seatedin
the groove.
. Make sure that the rotor pulleyturns smoothly
after it's reassembled,
. R o u t ea n d c l a m pt h e w i r e sp r o p e r l yo r t h e y c a n
be damagedby the rotor pulley.
21-50
CompressorThermalProtector CompressorReliefValve
Replacement Replacement
1. Removethe bolt,the ground terminal (A),and the 1 . Recoverthe refrigerantwith a recovery/recycling/

holder (B).Disconnectthe field coil connector(C). chargingstation(seepage 21-53).
then removethe thermal protector(D).
2 . Removethe reliefvalve (A) and the O-ring (B).Plug
the openingto keepforeign mafterfrom entering
the system and the compressoroil from running
out.
7.4 N.m
(0.75kgf.m,
5 rbf.ftl
A
9,8 N.m
(1.0kgf m,7.2lbf.ft)
Replacethe thermal protector(A)with a new one,
and apply siliconesealant(B)to the bottom of the Clean the mating surfaces.
thermal Drotector.
4 . Installa new O-ringon the reliefvalve, and apply a
thin coat of refrigerantoil to the O-ring.
Removethe plug, and installand tightenthe relief

valve.
Chargethe system (seepage21-55).
3. lnstall in the reverse order of removal.
21-51
GondenserReplacement
1 . Recoverthe refrigerantwith a recovery/recycling/ 4, Removethe mounting bolts,then removethe
chargingstation(seepage 21-53). condenserby lifting it up. Be carefulnot to damage
the radiatoo
r r t h e c o n d e n s efri n s w h e n r e m o v i n o
Removethe front bumper {seepage 20-85). the condenser.
Removethe bolts,then disconnectthe discharge

line (A) and the condenserline (B)from the
condenser.Plug or cap the lines immediatelyafter
disconnectingthem to avoid moistureand dust
conlamtnaflon. 6 x '1.0mm
9.8 N.m ('1.0kgf.m,
7.2 tbl.ftl
t -"'. t-
f,
-li .:)-
:.--\ ---- - -'
5 . l n s t a l l t h ec o n d e n s eirn t h e r e v e r s eo r d e ro f
removal,and note these items.
6x1.0mm
9.8 N.m ('1.0kgf.m,7.2lbf.ft) . l f y o u ' r ei n s t a l l i n ga n e w c o n d e n s e ra,d d
r e f r i g e r a not i l ( K E l H l NS P -1 0 )l s e ep a g e2 1 ' 6 ) .
. Replacethe O-ringswith new ones at eachfitting,
and apply a thin coat of refrigerantoil before
installingthem. Be sure to usethe correctO-rings
f o r H F C - 1 3 4(aR - ' 1 3 4 a ) a t ov o i dl e a k a g e .
. lmmediatelyafter using the oil, reinstallthecap
absorption.
. D o n o t s p i l l t h er e f r i g e r a not i l o n t h e v e h i c l e ; i t
,t\
may damagethe paint.lf the refrigerantoil
. Be carefulnot to damagethe radiatoror the
condenserfins when installingthe condenser.
6x1.0mm
9.8 N.m (1.0kgt.m.7.2lbf.ft)
21-52
RefrigerantRecovery
1. Connecta R-134arefrigerantrecovery/recycling/
chargingstation{A) to the high-pressureservice
Air conditioningrefrigerantor lubricantvapor port (B)and the low-pressureserviceport (C),as
can irritateyour eyes,nose.or throat. shown, following the equipmentmanufacturer's
Be carefulwhen connectingserviceequipment. instructions.
Do not breatherefrigerantor vapor
r: -:
1!l i t:
-'', - (
Use only serviceequipmentthat is U.L.-listedand is
certifiedto meet the requirementsof SAE J2210to
r e m o v eH F C - 1 3 4(aR - 1 3 4 af r) o m t h e a i r c o n d i t i o n i n g '=i -
system.
lf accidentalsystemdischargeoccurs,ventilatethe
work area before resumingservice
r
Additionalhealthand safetyinformationmay be
obtainedfrom the refrigerantand lubricant
manufacturers.
lvleasurethe amount of refrigerantoil removed

from the Ay'Csystem after the recoveryprocessis
completed.Be sure to put the same amount of new
refrigerantoil backinto the Ay'Csystem before
chargrng.
21-53
SystemEvacuation
chargingstation(A)to the high-pressureservice
. Air conditioningrefrigerantor lubricantvapor pon (B)and the low-pressureserviceport (C),as
can irritateyour eyes,nose,or throat. shown,following the equipmentmanufacturer's
. Be carefulwhen connectingserviceequipment. instructions.Evacuatethe system.
. Do not breatherefrigerantor vapor.
Use only serviceequipmentthat is U.L.-listedand is -i - r4.t

certifiedto meet the requirementsof SAE J2210to
r e m o v eH F C - 1 3 4(aR - 1 3 4 a ) f r o m
t h e a i rc o n d i t i o n i n q
system.
lf accidentalsystem dischargeoccurs,ventilatethe
work area before resumingservice.
Additionalhealthand safety informationmay be

manufacturers.
1. When an Ay'Csystem has been openedto the

atmosphere,such as during installationor repair,it
must be evacuatedusing a R-134arefrigerant
recovery/recycling/chargingstation(lf the system
has been open for severaldays,the receiver/dryer
should be replaced,and the system should be
evacuatedfor severalhours.)
lf the low-pressuredoes not reachmore than 93.3

k P a{ 7 0 0m m H g ,2 7 . 6i n . H g )i n 1 5 m i n u t e st,h e r ei s
probablya leak in the system.Partiallychargethe
system,and checkfor leaks(seestep 3 on page 21-
56).
21-54
SystemCharging
2 . Evacuatethe system(seepage 21'54).
Air conditioningrefrigerantor lubricantvapor 3 . Add the same amount of new refrigerantoil to the
can irritateyour eyes,nose,or throat. systemthat was removedduring recovery.Use
Be carefulwhen connectingserviceequipment. only KEIHINSP-10refrigerantoil.
Do not breatherefrigerantor vapor,
4 . Chargethe system with the specifiedamount of
R-134arefrigerant.Do not overchargethe system;
U s eo n l y s e r v i c ee q u i p m e ntth a t i s U . L . ' l i s t e a
dn di s the compressorwill be damaged.
certifiedto meet the requirementsof SAEJ2210to
r e m o v eH F C - 1 3 4{aR - 1 3 4 af r) o m t h e a i r c o n d i t i o n i n g Selectthe appropriateunits of measurefor your
system. refrigerantchargingstation.
lf accidentalsystem dischargeoccurs,ventilatethe Refrigerant capacity:

work area before resumingservice 500 to 550 g
0.50to 0.55 kg
Additionalhealthand safetyinformationmay be 1 . 1 0t o 1 . 2 1l b s
obtainedfrom the refrigerantand lubricant 17.6to 19.4oz
manufacturers.
Checkfor refrigerantleaks(seepage 21'56).
c h a r g i n gs t a t i o n( A )t o t h e h i g h - p r e s s u rsee r v i c e Checkfor system performance(seepage 21-58).
pon (B)and the low-pressureserviceport {C),as
shown, following the equipmentmanufacturer's
instructions.
21-55
RefrigerantLeakTest
Special Tool Required 1. Connecta R-134arefrigerantrecovery/recycling/
Leakdetector,HondaTool and EquipmentYGK-H-10PM chargingstation(A)to the high-pressureservice
vvailable port (B)and the low-pressureserviceport (C),as
shown, following the equipmentmanufacturer's
anstructions.
Compressedair mixed with R-134aforms a

combustiblevapor.
The vapor can burn or explodecausingserious
injury.
Neverusecompressed
airto pressure
test
R - 1 3 4 as e r v i c ee q u i p m e n ot r v e h i c l ea i r
conditioningsystem.
A i r c o n d i t i o n i n gr e f r i g e r a not r l u b r i c a nvt a p o r
can irritateyour eyes,nose,or throat.
Be carefulwhen connectingserviceequipment.
Do not breatherefrigerantor vapor
Use only serviceequipmentthat is U.L.-listedand is

certiifiedto meet the requirementsof SAE J2210to
r e m o v eH F C - 1 3 4(aR - 1 3 4 af r) o m t h e a i r c o n d i t i o n i n g
system.
lf accidentalsystem dischargeoccurs,ventilatethe
work area before resumingservice.
Open the high pressurevalve to chargethe system
R - 1 3 4 as e r v i c ee q u i p m e n o
t r v e h i c l ea i r c o n d i t i o n i n g to the specifiedcapacity,then closethe supply
systemsshould not be pressuretestedor leaktested valve,and removethe chargingsystem couplers.
with compressedair.
Selectthe appropriateunits of measurefor your
Additionalhealthand safety informationmay be refrigerantchargingstation.
manufacturers. Refrigerant capacity:
500 to 550 g
0.50to 0.55kg
1 . 1 0t o 1 . 2 1l b s
17.6to 19.4oz
3 . Checkthe systemfor leaksusing a R-134a

refrigerantleak detectorwith an accuracyof 14 g
(0.5oz) per year or better.
lf you find leaksthat requirethe systemto be

opened(to repair or replacehoses,fittings,etc.),
recoverthe system.
After checkingand repairingleaks,evacuatethe

system.
21-56
A/C SystemTests
Pressure
Test
Test results svmotom3 DGaUSe
Discharge (high) pressure
Afterstoppingcompressor, Air in system Recover,evacuate(seepage21-54),
pressure dropsquickly,andthencontinues
to and rechargewith specifiedamount
abnormallyhigh {seeoaoe21 55).
or no airflow through
Beduced Cloggedcondenser or radiator Clean
condenser fins Checkfan voltageand rpm.
Condenseror radiatorfan not Checkfan direction.
Lineto condenser hot.

is excessively Restrictedflow of refrigerantin restricted
Replace lines.
pressure Highand low pressures

Discharge arebalanced . Faultycompressor discharge the compressor.
Beplace
soonafterstoppingcompressor, Low valve
sideis hioherthannormal. . Faultvcomoressorseal
Outletof expansionvalve is not Faultyexpansionvalve . Replacethe expansion valve.
frosted,low pressure
gaugeindicates Moisturein system . Recover,evacuatefor at least
30 minutes,and rechargewith
sDecified
amount.
(low)
Suction Expansionvalveis not frosted,and ' Frozenexpansion valve Recover,evacuatefor at least
pressure lineis not cold.Low
low-pressure (Moisturein system) 30 minutes,and recharge with
low
abnormally pressure
gaugeindicates vacuum, . Faultyexpansion valve amount.
specified
Beplacethe expansion valve.
Discharge temperature is low,andthe Frozenevaporator Runthe fan with compressoroff, then
air flow from vents is restricted. checkevaooratottemoeraturesensor.
Exoansion valveis frosted. eanor reolace,
Receivetdryer outletis cool,and inlet Cloggedreceiver/dryer Replacereceaver/dryer.
is warm (shouldbe warm during
ooeralton),
Suctionpressure Low pressure hoseandcheckjointare E x p a n s i o nv a l v e o p e n t o o l o n g Bepairor replace.
abnormallyhigh coolerthanthetemperature around
evaoorator,
Suctionpressure is loweredwhen Excessive refrigerant in system Recover,evacuate,and rechargewith
..nrlenser is cooled bv water. qnp.ifie.lamo'rnr
Highand low pressure

areequalized Faultygasket Replace
the compressor.
assoonasthecompressor is stopped, Faultyhigh pressure
valve
andbothgaugesfluctuatewhile Foreignpaniclestuckin high
Suctionand Reduced airflow throughcondenser. . Cloggedcondenser or radiator Clean

dascharge fins Checkvoltageand fan rpm.
pressures ' Condenser or radiatorfan not Checkfan direction.
abnormallvhioh workinoorooerlv
Suctionand Low-pressure hoseand metalend Cloggedor kinkedlow-pressure Repairor replace.
pressure
discharge areasarecoolerthanevaoorator, hoseoarts
abnormallylow Temperature valve C l o g g e d h i g h - p r e s s u r el i n e
aroundexpansion Repairor replace,
is too low comparedwith thataround
leaks
Fefrigerant clulchis dirtv.
:omoressor :omoressor shaftsealleakinq Reolacethe comDressor,
lomoressorbolt(s)aredirtv. no aroundbolt(s) Tiohtenbolt{s)ot reolacecomDressor,
; o m D r e s s o ro a s k e t i s w e t w i t h o i l . iet no acethe comoressor.
(cont'd)
21-57
A/C SystemTests(cont'd)
PerformanceTest Open the glove box. Removeboth glove box stops,
then let the glove box hang down (seepage 20-63).
4 . Inserta thermometer(A) in the centervent, and

' Compressedair mixed with R-134aforms a placeanotherthermometer{B) nearthe blower unit.
combustiblevapor.
. T h e v a p o rc a n b u r n o r e x p l o d ec a u s i n gs e r i o u s
Injury.
. Never use compressedair to pressuretest
R - 1 3 4 as e r v i c ee q u i p m e n ot r v e h i c l ea i r
conditioning systems.
Air conditioningrefrigerantor lubricantvapor

can irritateyour eyes,nose,or throar.
Be carefulwhen connectingserviceequipment.
Do not breatherefrigerantor vapor.
Test conditions:
The performancetest will help determineif the air
conditionersystem is operatingwithin specifications. . Avoid direct sunlight.
. Open the hood.
Use only serviceequipmentthat is U.L.-listedand is . Open the front doors.
cenified to meet the requirementsof SAE J2210to . Sel the temperaturecontrol dial on Max Cool,the
r e m o v eH F C - 1 3 4(aR - 1 3 4 a l f r o m
t h e a i rc o n d i t i o n i n g mode control dial on Vent,and the recirculation
system. control switch on Recirculate.
. Turn the A,/Cswitch on and the fan switch on Max.
lf accidentalsystem dischargeoccurs,ventilatethe . R u nt h e e n g i n ea t 7 5 0 r p m .
work area before resumingservice . N o d r i v e ro r p a s s e n g e risn v e h i c l e .
R - 1 3 4 as e r v i c ee q u i p m e n ot r v e h i c l ea i r c o n d i t i o n i n g A f t e r r u n n i n gt h e a i r c o n d i t i o n i n fgo r I 0 m i n u t e s
systemsshould not be pressuretestedor leaktested underthe above test conditjons,read the delivery
with compressedair. temperaturefrom the thermometerin the center
vent, the intaketemperaturenear the blower unit,
Additionalhealthand safety informationmay be and the high and low system pressurefrom the Ay'C
obtainedfrom the refrigerantand lubricant g au g e s .
manufacturers.
1 . Connecta R-134arefrigerantrecover/recycling/
chargingstationto the high-pressureserviceport
and the low-pressureserviceport, following the
equipmentmanufacturer'sinstructions.
D e t e r m i n et h e r e l a t i v eh u m i d i t ya n d a i r
Iemperarure.
21-58
7. To completethe charts:
. r el o n gt h e v e r t i c a l i n e .
M a r k t h ed e l i v e r y t e m p e r a t u a
. Mark the intaketemperature(ambientair temperature)along the bottom line.
. Draw a line straightup from the air temperatureto the humidity.
. M a r ka p o i n t 1 0% a b o v ea n d 1 0% b e l o w t h eh u m i d i t yl e v e l .
. From each point. drawa horizontalline acrossthe deliverytemperature.
. The delivervtemperatureshould fall betweenthetwo lines
. Completethe low-sidepressuretest and high-sidepressuretest in the same way.
. Anv measurementsoutsidethe line may indicatethe needfor further inspection.
kPa
(ksl{cm') {kgflcm')
Lpsrl Lpsil
2500- 600
[25) _ {6t
360l tssl 80 yo
a0 0/"
2000 HUMIDITY
(201 LEVEL
1280
fcl 30 9o
1500-
{1s} 30%
,21o)
80%
1000-
(101
:1401
500 -
{5)
171l
DELIVERY
PRESSURE
100
{11
h4l
INTAKE
PRESSURE
OELIVERY
TEMPERATURE
I I I
.F
68 77 86 95 104
t20l t25l t30) (35) {40) {'cl
INTAKETEMPEBATURE
21-59
BodyElectrical \
Body Electrical Entry Lightscontrol system

SpecialTools ComponentLocationIndex ....................... 22-89
tntorrnaiion.'......
22,3 C i r c u iD t iagram . . . . . . . 2. .2 9 0
lgnitionKeySwitchTest .....................,...... 22-9'l
RelayandControlUnit Locations.....22-7 l g n i t i o nK e yL i g h tT e s t . . . . . . . . . . . . . . . . . . . . . 2. .2. .-.9. .1. . .
C o n t r oUl n i tI n p u tT e s t . . . . . . . . . . , . . . . . . . . . . 2 . .2. .9. 2
.....
Connectors
and Harnesses 22-13
InteriorLights
Fuse/Relay
Boxes...............................
22-44 ComponentLocationIndex ....................... 22-94
PowerDistribution.............................
22-46 CeilingLighVSpotlights
T e s V R e p l a c e m e. n
. .t. . . . . . . . . . . . . . . . . . . . .2. .2. -. .9.6. . . . .
GroundDistribution...........................
22-4A RearCeilingLightTesVReplacem ent ........22-96
CargoAreaLightTest/Replacem ent .........22-97
Under-dash
Fuse/Relay
Box ..............
22-49 HatchLatchSwitchTest ..,..,....................... 22-97
Battery .............. 22-50 *Audio System

ComponentLocationIndex .......................
22-98
Relays................ 22-51 CircuitDiagram .........22,99
AudioUnit Removal/lnstallation ...............
22-1OO
*lgnitionSwitch .............. 22-53 Audio Unit ConnectorReplacement.........22-101
SpeakerReplacement................................
22-102
*Gauges RoofAntennaRep1acement ....................-..
22-103
C o m p o n e nLto c a t i o Inn d e x . . . . . . . . . . . . . . . . 22-54 .......
S e l f - d i a g n o sPt irco c e d u r .e. . . . . . . . . . . . . . . . . 22-56
........ Rear Window Defogger
CircuitDiagram 22-54 ComponentLocationIndex ........... 22-104
G a u g eB u l bR e p l a c e m e n. .t . . . . . . . . . . . . . . . .22 . . . .63
.... C i r c u iD
t i a s r a m. . . . . . . . . . . . . . . . . . . . . : : : : : . : :22-105
.::.
GaugeAssemblyReplacement 22-64 FunctionTest
CoolantTemperature D e f o g g eW r i r eR e p a i r. . . . . . . . . . . . . . . . . . . . . . .22-106
..........
G a u g eT r o u b l e s h o o t i n.g. . . . . . . . . . . . . . . . 22-64...... N o i s eC o n d e n s eCra p a c i t y T e s. t. . . . . . . . . . .22-107 .... \
VehicleSpeedSignalCircuit
Troubleshooting 22-65 Moonroof
VSSReplacement 22 61 C o m p o n e nLto c a t i o Inn d e x . . . . . . . . . . . . . . . . 2. .2. .-.1. .O B
ExteriorLights MoonroofControlUnitInputTest ............. 22-'l10
C o m p o n e nLto c a t i oInn d e x . . . . . . . . . . . . . . . . 22-68 ....... S w i t c hT e s V R e p l a c e m e. n
. .t. . . . . , . . . . . , . . .2. .2. .- .11. .2.
C i r c u iD t iagram 22--71 MotorTest ................. 22-112
DaytimeRunningLightsControi LimitSwilchTest ......22-'l'13
U n i tI n p u tT e s t( C a n a d a .) . . . . . . . . . . . . . . . .22-7 . . . . .6. . Auto-stopSwitchTest ................................ 22-113
H e a d l i g hAtd , u s t m e n .t . . . . . . . . . . . . . . . . . . 22-74
H e a d l i g hRr e p l a c e m e n. .t. . . . . . . . . . . . . . . . . . .22-79
......... PowerMirrors
CombinationLightSwitch ComponentLocationIndex ....................... 22-114
Test/Replacement 22-AO CircuitDiagram .........22-115
B u l bR e p l a c e m e n t 22-41 FunctionTest ............. 22-116
T a i l l i g hRt e p l a c e m e n. .t . . . . . . . . . . . . . . . . . . . .22-82
.... P o w e rM i r r o rS w i t c hT e s t . . . . . . . . . . . . . . . . . . 2. .2. .-.l .l .7.
HighMountBrakeLightReplacement......22-42 PowerMirrorActuatorTest ....................... 22-117
LicensePlateLightReplacement.............. 22-43 PowerMirrorActuatorReplacement........22-11A
S i d eM a r k e L r i g h tR e p l a c e m e n. .t. . . . . . . . . .22-43 ....
BrakePedalPositionSwitchTest .............. 22-44 * Horns
SideTurn SignalLightReplacement........22-84 ComponentLocationIndex ....................... 22-120
Turn Signal/Hazard H o r nT e s V R e p l a c e m e. n
. .t. . . . . . . . . . . . . . . . .2. .2. -. .1. 2. -2.
Flasher System HornSwitchTest .,....22-122
C o m p o n e nLto c a t i o Inn d e x . . . . . . . . . . . . . . . . 22-85
.......
C i r c u iD
t iagram 22 A6
Turn Signal/Hazard RelaylnputTest ........22-87
HazardWarningSwitchTest 22-88

PowerWindows Multiplex ControlSystem
ComponentLocationIndex .......... 22 124 ComponentLocationIndex ........... 22,164
c i r c u i tD i a g r a m. . . . . . . . . . . . . .......... . . . . : . : : : : .22-125
::::.: c i r c u i tD i a g r a m. . . . .... . . . . . . . . . . . . . . . . . . . . . . :22-169
:.:..:.::.:
M a s t eS r w i t c hI n p u tT e s t . . . . . . . . . . . . . . . . . . .22-126........ SvstemDescriDtion 22-17'l
MasterSwitchTest 22-128 Troubleshooting 22,112
D r i v e r 'Ws i n d o wM o t o rT e s t . . . . . . . . . . . . . . .22-129 ...... M u l t i o l eC x o n t r oUl n i tI n D uTt e s t . . . . . . . . . . .2.2. - 1 7 5
Passenger's WindowSwitchlnputTest ... 22- t30
Passenger's WindowSwitchTest ............. 22-132
Passenger's WindowMotorTest .............. 22 132
lMaster SwitchReplacement...................... 22-133
Passenger's WindowSwitch
Replacement 22-133
Wipers/Washers
ComponentLocationIndex ....................... 22-134
C i r c u iD
t iagram
RearWindowWiperIntermiftent
C o n t r oU l n i tI n p u tT e s t . . . . . . . . . . . . . . . . . . .22-138
........
Wiper/Washer Switch
TesVReplacement 22-140
C o n t r oUl n i tI n p u tT e s t . . . . . . . . . . . . . . . . . . . . . .2.2. .-.1. .4. 1
..
WiperMotorTest 22-143
WasherMotorTest 22-144
WasherFluidLevelSwitchTesV
R e p l a c e m e(nCt a n a d a.l . . . . . . . . . . . . . . . . . .22-144 .......
WindshieldWiperMotor Replacement.... 22-145
RearWindowWiperMotor
Replacement 22-146
W a s h eR r e s e r v oR i r e p l a c e m e n. .t. . . . . . . . . .22-146 ....
W a s h eTr u b e sB e p l a c e m e n. .t. . . . . . . . . . . . . .22 . . . 147
...
Accessory Power Socket

AccessoryPowerSocket
T e s V R e p l a c e m e. n
. .t. . . . . . . . . . . . . . . . . . . . .2. .2. .- .14. .9. . . .
Keyless/Power Door Lock System

ComponentLocationIndex ....................... 22-150
KeylessReceiver Unit InputTest ............... 22-153
ControlUnit InputTest ............................... 22-155
D o o rL o c k A c t u a t o r T e s. .t. . . . . . . , . . . . . . . , . .2, 2. ,-.1. .5. .8
H a t c hL o c k A c t u a t o r T e s. .t. . . . . . . . . . . . . . . . .2. .2. -. 1
. .5. .9
DoorLockKnobSwitchTest ...................... 22-160
DoorLockSwitchTest ................................ 22-160
TransmitterTest .......22-161
T r a n s m i t t ePrr o g r a m m i n .g. . . . . . . . . . . . . . . . .2. 2. .-.1. .6. 1
lmmobilizerSystem
componentLocationIndex ........... 22-162
S y s t e mD e s c r i p t i o .n. . . . . . . . . . . . . . . :. . . : . . : . :22-163
...
CircuitDiagram 22-164
Troubleshooting
lmmobilizerControlUnit
- R e c e i v eRre p l a c e m e n. .t. . . . . . . . . . . . . . . . .22-167 ........

BodyElectrical
SpecialTools
Ref. No. Tool Number Description Otv
Q) 07wAz-001010A MPCSServiceConnector 1
o) O7LAJ-PT3O2OA Test Harness 1
o 07TAz-001020A BackProbeAdaotet 1
22-2
Tipsand Precautions Some connectorshave a clip on their side used to
attachthem to a mount bracketon the body or on
Before Troubleshooting a n o t h e rc o m p o n e n tT. h i sc l i p h a sa p u l lt y p e l o c k .
1. Checkapplicablefuses in the appropriatefuse/relay Some mountedconnectorscannot be disconnected
oox. unlessyou first releasethe lock and removethe
connectorfrom its mount bracket(A).
2. Checkthe batteryfor damage.stateof charge,and
cleanand tight connections.
. Do not quick-chargea batteryunlessthe battery

ground cable has been disconnected,otherwise
you will damagethe alternatordiodes.
. Do not attemptto crankthe enginewith the
batteryground cable looselyconnectedor you
w i l l s e v e r e l yd a m a g et h e w i r i n g .
Handling Connectors
. Make surethe connectorsare clean and have no
l o o s ew i r e t e r m i n a l s .
. Make sure multiplecavity connectorsare packedwith
dielectricgrease(exceptwatertight connectors). Nevertry to disconnectconnectorsby pulling on their
. All connectorshave push-downreleasetype locks(A). wires; pull on the connectorhalvesinstead.
Alwavs reinstallDlasticcovers,
Beforeconnectingconnectors,make sure the

terminals(A) are in placeand not bent.
(cont'd)

22-3
BodyElectrical
GeneralTroubleshootingInformation(cont'd)
Checkfor looseretainer(A)andrubberseals(B). HandlingWires and Harnesses
. Securewires and wire harnessesto lhe frame with
their respectivewire ties at the designatedlocations.
. Removeclips carefully;don't damagetheir locks(A).
The backsof some connectorsare packedwith

dielectricgrease.Add greaseif necessary.lf the S l i p p l i e r s( A ) u n d e rt h e c l i p b a s ea n dt h r o u g ht h e
greaseis contaminated,replaceit. hole at an angle,then squeezethe expansiontabs to
r e l e a s et h e c l i p .
After installingharnessclips, make sure the harness

lnsertthe connectorall the way and make sure it is doesn't interferewith any moving pans.
securelvlocked. Keepwire harnessesaway from exhaustpipes and
Positionwires so that the open end of the cover faces other hot parts,from sharp edgesof bracketsand
oown. holes,and from exposedscrewsand bolts.
Seatgrommets in their grooves properly{A). Do not
leavegrommets distorted(B).
| . , ./ f
.ll t/
lwtl"//
----E;
'l/ F. \--------\
tflr'---'..-
I It
22-4
Testingand Repairs UsebackDrobeadaotor07TM-0010204.
. Do not usewires or harnesseswith brokeninsulation.
Replacethem or repairthem by wrappingthe break
withelectricaltape.
. After installingparts,make surethat no wires are
o i n c h e du n d e rt h e m .
. When using electricaltestequipment,followthe
manufacturer'sinstructionsand those describedin
t h i sm a n u a l .
. l f p o s s i b l ei ,n s e r t t h ep r o b eo f t h e t e s t e r f r o m t h ew i r e
side (exceptwaterproofconnector).
Referto the instructionsin the HondaTerminal Kit for

identificationand reolacementof connectorterminals.
( c o n td )
22-5
BodyElectrical
Five-stepTroubleshooting Wire Color Codes
'1.
Verify The Complaint The following abbreviationsare usedto identifywire
T u r n o n a l l t h e c o m p o n e n t si n t h e p r o b l e mc i r c u i t colors in the circuitschematics:
to verify the customercomplaint.Note the w H T . . . . . . . . . . . . . . . . . . . . , . , . White ............
symptoms.Do not begin disassemblyor testing Y E L . . . . . . . . . . . . . . . . . . . . . . , , .Y. .e.l.l .o. w ,......
until you have narroweddown the problem area. B 1 K . . . . . . . . . . . . . . . . . . . . . . . . . . .B. .l.a. .c. k. . . . .
B L U. . . . , . . . . . . . . . . . . . . . . . . . . . . .B. .l.u. .e. . . .
2. AnalyzeThe Schematic G R N . . . . . . . . . . . . . . . . . . . . . . . .G . .r.e. .e.n. . . . . . .
Look up the schematicfor the problem circuit. R E D. . . . . . . . . . . . . . . . . . . . . . . . . . . .Red
........,
Determinehow the circuit is supposedto work by o R N . . . . . . . . . . . . . . . . . . . . . . . . Orange.............
tracingthe currentpathsfrom the power feed P N K . . . . . . . . . . . . . . . . . . . . . . . .P . .i,n. k. . . . . . . . .
through the circuitcomponentsto ground. lf B R N . . . . . . . . . . . . . . . . . . . . . . . .Brown .............
severalcircuitsfail at the same time, the fuse or G R Y . . . . . . . . . . . . . . . . . . . . . . . .Gray ............,
g r o u n di s a I i k e l yc a u s e . P U R . . . . . . . . . . . . . . . . . . . . . . . .P . .u. .r .p.l.e. . . . . .
1 T 8 1 U . . . . . . . . . . . . . . . . . . . . . Light . . . . . ,Blue
.....
Basedon the symptoms and your understandingof 1TGRN....................L . .i.g. h
. .G
t. ,r.e. .e n
the circuitoperation,identifyone or more possible
causesof the problem. The wire insulationhas one color or one color with
anothercolor stripe.The secondcolor is the stripe.
3. lsolateThe ProblemBy TestingThe Circuit
Make circuitteststo checkthe diagnosisyou made
i n s t e p2 . K e e pi n m i n d t h a t a l o g i c a ls, i m p l e
procedureis the key to efficienttroubleshooting.
Testfor the most likelycauseof failure first, Try to
make tests at pointsthat are easilyaccessible.
4. Fix The Problem

Oncethe specificproblem is identified.make the
repair.Be sure to use propertools and safe
proceoures.
5. Make Sure The CircuitWorks

Turn on all componentsin the repairedcircuit in all
modes to make sure you've fixed the entire
problem.lf the problemwas a blown fuse, be sure
to test all of the circuitson the fuse. Make sure no
n e w p r o b l e m st u r n u p a n d t h e o r i g i n a p
l roblem
does not recur.
22-6
Relayand Control Unit Locations
EngineCompartment
BLOWERMOTORRELAY
RADIATORFAN
RELAY
HORNRELAY
CONDENSERFAN
RELAY
ELDUNIT
UNDER-HOOD
FUSE/RELAY
BOX
\...
,-:1-'...
22-7
Relayand GontrolUnit Locations
Dashboard
_DAYTIME RUNNINGLIGHTSEELAYlCanada)
lWirecolorsrRED,RED/YEL,I
LRED/BLKandRED/8LU I
_LOW BEAMCUTRELAYlcanada) _
lWire REDMHT,
colors: RED/BLK,I
LBEDA/ELandRED/BLU I
KEYLESSRECEIVER
UNIT
CRUISECONTROLUNIT
'
'-.:- ':
..? ;,
POWERWINOOW RELAY
TURN SIGNAL/HAZARDRELAY
TAILLIGHTRELAY UNDER.DASH
; .[:_- - FUSE/RELAY
BOX
-l:r --
MULTIPLEXCONTROLUNIT
22-8
(cont'd)
22-9
Relayand Control Unit Locations
Dashboard(cont'd) a
SRSUNIT
PGM.FIMAINRELAY1
EPSCONTROLUNIT lWirecolors:YEUBLK,
LWHT/BLK,WHT/BLKand RED/YEL
AIR/FUEL RATIOSENSORRELAY PGM.FIMAN RELAY2
[WirecolorsrWHT,WHT/RED, I fwirecolors:YEUBLK, I
OBNandBLK/ORN I YEUBLKand GRN/YELI
LYEUGRN,
22-10
Rearand Roof
MOONROOF OPENRELAY -
Wirecolors:GRNI/EL,GRN, I
LRED/YEL, BLKandYEL/GRNI
MOONROOF CLOSERELAY
fwire colors:GRN/BLK,
GRN, l
IGRN,AtVHT,BLKand YEL/GRNI
REARWINDOWWIPERINTERMITTENT
CONTBOLUNIT
22-11
Relayand ControlUnit Locations
Door and Seat
Driver'sDoor:
l\:
].\
POWERWINDOWMASTERSWITCH
lHasbuilt-incontrolunit)
Passenger's
Seat:
22-12
Gonnectors
and Harnesses
a GonnectorIndex
ldentification
numbershavebeenassigned to in-lineconnectors. by the letter"C" for connectors,
The numberis preceded "G" for ground
terminalsor "T" for non groundterminals.
Hamess Location
EngineCompartment Dashboard Others{Floor,Door, Not€s
Trunk.and Roo{l
Startersubharness C 1 0 2a n dC 1 0 3 (seepage22-15)
T1 andT2
T 1 0 1a n dT 1 0 2
Batterygroundcable T3 {seepage22-l!)
G'l and ( -
Enginegroundcable T4 {seepage22-14)
Enginewire harness C l 0 l t h r o u g hC 1 0 4 (seepage22 16)
G1 0 1
Enginecompartment
wire harness G201andG202 (seepage22 18)
{riohtbranchi
Enginecompartment
wire harness G301 (seepage22 18)
(leftbrench)
Enginecompartment
wire harness (seepage22-18)
(dashboard) c401
C451and C452
C501throughC503
c551
c851
G402
EPSsubharness C 1 5 1a n d C 1 5 2 \seepage22 241
G'151
Dashboard wire harness
A C504throughC510 (seepage22-26)
lleftbranch) G501andG503
L e f ts i d et u r n s i g n a l l i g h t c506 (seepage22-26)
Dashboard wire harness

A C50lthroughC503 (seepage22-26)
(rightbranch) C 5 l l t h r o u g hC 5 1 5
C852andC853
G502
Rightside turn si9nal light lseepage22-26)
sub harness
Dashboard
wire harnessB C40lthroughC403 (seepage22-30)
c510
G40l
ECMwire harness c101 {seepage22-32}
cl52
C451 through
C453
c511
G451
Floorwireharness(frontside) C402andC403 G551 (see page 22'34)
c453
C508andC509
c512
C 5 5 1a n . l C 5 5 ?
Floorwire harness(rearside) C553and C554 (seepage22-34)
Roo{wire harness c507 (seepaqe22-38)

Hatchwire harness C553andC554 ( s 6 ep a q e 2 2 ' 3 9 )
Driver'sdoorwire harness C504andC505 (see paqe 22-40)
P a s s e n q e r ' sd o o r w i . e h a r n e s s 5 1 4a n dC 5 1 5 ( s e eo a o e 2 2 - 4 1
T eh a r n e s s )552 (seeoaqe22-42i
/C wire harness c851 rhrouoh c853 ( s e ep a q e 2 2 . 4 3 i
22-13
and Harnesses
Connectors
Gonnectorto Harnesslndex
BatteryGroundCable
Connectoror Terminal Cavities Location Connectsto Notes
T3 Left side of enqinecompartment
Left side of enginecompartment Bodygroundviabattery
qroundcar)le
2 Batterv B a t t e r vn e o a t i v et e r m i n a l
EngineGround Cable
Connectoror Terminal Cavities focation Connec{sto Notes
r4 5 Riohtsideof enoine
4 Rightsideof enginecompartment Bodygroundviaengine
ENGINEGROUNDCABLE
BATTERYGROUNDCABLE
\.....
22-14
StarterSubharness
Connectoror Terminal Ret Cavities Location Connoc,ts
to Notes
Alternator 10 4 Right side of eng;necompartment
Knocksensor 8 1 Front of engine
Startersolenoid 5 1 Middle of enginecompartment
c102 7 6 Front of enginecompartment Enginewire harness(see
page22 16)
c103 6 1 F r o n t o f e n g a n ec o m p a r t m e n t Enginewire harness(see
o a a e2 2 - 1 6 )
T1 2 L€tt sideof enginecompartment Underhoodfuse/relay box
r2 4 Middleor enoinecomDanment Stanermotor
T101 1 Under-hood fuse/relay
box
r102 I Alternator
Batterv Battervpositiveterminal
STARTERSUB HARNESS
22-15
Connectorsand Harnesses
Connectorto HarnessIndex(cont'dl
EngineWireHarness
2 Transmission housing
Camshaft position(CMP)sensor 3 Leftsideof engine
Lllr sensor 3 Rightsideofengine
EC[,4connectorA Underglovebox
ECI/lconnectorB 24 Underglovebox
Enginecoolanttemperature (ECT) 2 Leftside of engine
sensor
Engineoil pressure switch 28 1 BightsideoI engine
EVAPcanisterpurgevalve 2 Leftside of intakemanifold
ldleair control(lAC)valve 18 3 Left sideof intakemanifold
lgnitioncoilNo. l 4 3 Middleof enginecompartment
lgnitioncoilNo.2 5 3 Middleof enginecompartment
IniectorNo. 1 25 2 Middleof enginecompartment
InlectorNo.2 24 2 Middleof enginecompartment
IniectorNo.3 20 2 Middleof enginecompartment
IniectorNo.4 19 2 Middleof enginecompanment
Intakeairtemperature {lAT)sensor 12 2
3 Leftsideof intakemanifold
TDCsensor 8 3 Leftsideof engine
Throttleposition(TP)sensor 11 Left side of intakemanifold
Vehiclespeedsensor(VSSI 10 3 Transmission housing
VTCoil controlsolenoidvalve 27 2 Rightsideo{ engine
VTECoil pressureswitch 29 2 Rightsideof engine
VTECsolenoidvalve 30 2 Rightsideof engine
c 101 3 20 Underrightsideof dash ECMwire harness{seepage
22-321
c102 22 Frontof enginecompanment (seepage
Startersubharness
22-15)
Frontof enginecompartment (seepage
Startersubharness
22 151
22-16
....-
10
11
13
14
22-17
Connectorto HarnessIndex{cont'dl
EngineCompartmentWire Harness(Rightbranch)
Connsctoror Terminal Cavitiss Location Connectsto Notes
ABSmodulator-control unit Bightsideo{ enginecompartment
Bearwasher motor 8 2 Behindrightsideof {rontbumper
RightfrontABSwheelsensor 12 2 Rightsideot enginecompartment
Rightfrontairbags€nsor 2 Behindrightsideof frontbumper
Bightfrontparkinglight 1 2 Behindrightheadlight
Rightfrontsidemarkerlight 10 2 Behindrightsideof Jrontbumper
Rightfrontturn signallight 11 2 Behindrightheadlight
Rightheadlight 2 Behindrightheadlight
Righthorn I Behindfrontbumper
wash€rfluidlevelswitch 7 2 Behindrightsideof trontbumper Canada
Windshield washermotor 2 Behindriohtsideof frontbumoer
G201 6 Behindrightsideof trontbumper Bodygroundvia€ngine
compartment
wtreharness
G202 Behindrightsideof Jrontbumper Bodygroundviaengine
.omnerhent wire harness
22-18
ENGINECOMPARTMENT
WIRE
HARNESS
(cont'd)
22-19
and Harnesses
Connectors
Connectorto HarnessIndex (cont'dl
EngineCompartmentWire Harness(Left branch)
24 l Frontof enginecompanment
22 2 Leftsideof enginecompartment
AirJuel(A,,/F)
ratiosensor 2 Leftsideof enginecompartment
Brakefluidlevelswitch 2 Leftsideo{ enginecompartment
Condenser fan motor 25 2 Frontof enginecompartment
Cruisecontrolactuator 1 4 Underrightsideof cowlcover
ELDunit 9 3 Under'hood f use/relay
box
Foglightconnector ,l Leftsideof enginecompartment
LeftfrontABSwheelsensor 12 2 Leftsideof enginecompanment
Leftfrontairbagsensor 2 Behindleftsideof frontbumper
Leftfrontparkinglight 17 2 Behindleftheadlight
Leftfrontsidemarkerlight 2 Behindleftsideof frontbumper
Leftlrontturnsignallight 13 2 Eehindleftheadlight
Leftheadlight 20 3 Behindleftheadlight
Lefthorn 21 l Behindfrontbumper
Radiatorfan motor 23 2 Leftsideof enginecompartment
Radiatorfan switch 2 Frontof enginecompartment
Secondary heatedoxygen(SHO2S) 3 4 Leftsideof enginecompartment
Testtachometer connector 2 Leftsideof enginecompanment

Windshieldwipermotor 11 5 L.Jnder
leftsideof cowlcover
Under'hood fuse/relaybox 7 2 L.Jnder
hoodfuse/relay box
A {seepage22-44)
connector
Under-hood f use/relay
box I 5 L.Jnder
hoodfuse/relay
box
connectorB (seepage22-44)
Underhoodfuse/relay box 10 12 L.Jnder'hood
f use/relay
box
C (seepage22-44)
connector
Underhoodfuse/relay box 5 underhoodfuse/relay
box
D (seepage22 44)
connector
Under-hood fuse/relaybox 6 fuse/relay
Under-hood box
\
22-20
l' \-
ENGINECOMPARTMENTWIRE
HARNESS
(conr'd)
22-21
and Harnesses
Connectors
Connectorto HarnessIndex (cont'd)
EngineCompartmentWire Harness(Dashboard)lcont'dl
Foglightconnector 5 1 Undermaddle of dash Oplion
Under'dash fuse/relaybox 12 Underleftsideof dash
connectorF (seepage22-45)
Underdash fuse/relaybox 5 10 Underleftsideof dash
connectorG (seepage22-45)
Underdash fuse/relay
box 3 Underleftsideof dash
connectorH (seepage22'45)
Under-dash fuse/relay
box 2 5 Underleftsideof dash
connector| (seepage22'45)
box 3 8 Underleftsideol dash
connectorJ (seepage22-45)
c151 12 2 Underrightsideof dash EPSsubharness {seepage22-
24)
c401 1 Underrightsideot dash Dashboard wire harnessB
(seepage22-30)
c451 I Underrightsideot dash ECMwire harness(seepage
22-321
c452 9 UnderrightsideoJdash ECMwire harness(seopage
22 32)
c501 10 '10 UnderrightsideoI dash Dashboard wire harnessA
(seepage22-26)
c502 6 4 Underrightsideol dash Dashboard wire harnessA USA
lsee page 22-261
c502 6 8 UnderrightsideoJdash Dashboard wire harnessA Canada
(seepage22-26)
c503 5 UnderrightsideoJdash Dashboard wire harnessA
(seepage22-26)
10 Undermiddleof dash Floorwireharness(seepage
22-34l'
'14
c851 1 Underrightsideof dash ,VCwire harnesslsee page
22-43\
G402 1' I Eodygroundviaengine
..mdarlma.t w,rc harncss
22-22
BOX
FUSE/RELAY
UNDER-DASH
WIRE
ENGINECOMPARTMENT
D
' -
-.,.i ' 1_-1.:,
ifa.: ,, ..j
. - ,
-,,
-g'-.t ';.-a

22-23
Connectorto Harnesslndex (cont'dl
EPSSubharness
EPScontrolunitconnectorA 2 2 Underrightsideofdash
EPScontrolunitconnectorB ,l 2 Underrightsideof dash
EPScontrolunitconnector
C 3 20 Underrighrsideof dash
EPSmotor 1 2 Middleof enginecompanment
EPStorquesensor 6 Middleof enginecompartment
c151 6 2 Underrightsideof dash Enginecompartment wire
harness(seepage22-18)
c152 4 I Underrightsideof dash wire harness(seepage
ECI\,4
22-321
G151 5 aodygroundvia EPS
22-24
EPSSUB HARNESS

22-25
DashboardWire HarnessA {Leftbranchl
Connectoror Terminal ffi
Accessorypower socket 22 2 Undermiddleof dash
Audioantenna 2 2 Underleftsideof dash
Brakepedalpositionswitch 26 4 ] Underleftsideof dash
Clutchinterlockswitch 2 ] Underleftsrdeof dash
Clutchpedalpoistionswitch 30 2 | Underleftsideof dash
Cruisecontrolunit 29 14 I Underleftsideof dash
Cruisemainswitch 6 5 Underleftsideof dash
Daytimer!nning lightscontrolunit 28 14 Underlettsideof dash Canada
Daytimerunninglightsrelay 4 Underlettsideof dash Canada
Gaugeassembly connectorA I 22 I Behindgaugeassembly
GaugeassemblyconnectorB 8 22 i Behindgaugeassembly
Hazardwarningswitch 20 10 Behindhazardwarnningswitch
Heatercontrol panelconnectorA 11 22 Behindheatercontrolpanel
Heatercontrol panelconnectorB 18 '14 Behindheatercontrolpanel
HVACpush switch assembly 19 10 ] BehindHVACswitchassembly
Keylessreceiverunit 10 5 I Undermiddleof dash
Low beamcut relay 5 5 lUnderleftsideofdash
Optionalsecurityconnector 3 16 Underlefrsideof dash
Powermirrorswitch 27 13 UnderleftsideoI dash
Under-dash fuse/relaybox 17 ln the under-dashfuse/relay
box
connectorK (seepage22-45)
Under'dashfuse/relaybox ,I4 l0 In the under-dash
fuse/relay
box
L {seepage22-45}
Underdashfuse/relay box 12 In the undeFdash
fuse/relay
box
connectorM lsee page22'45)
Under-dashfuse/relaybox In the underdashfuse/relay
box
connectorN (seepage22-45)
UndeFdash fuse/relaybox 12 Inthe under-dash
fuse/relay
box
connector
UndeFdash
O (seepage22-45)
fuse/relaybox
connectorY(seepage22 45)
11 In the under-dash
fuse/relay
box L
c504 Underleftsideof dash Driver'sdoorwire harness
(seepage22'40)
c505 Underleftsideot dash Driver'sdoorwire harness
(seepage22-40)
c506 34 Underleftsideof dash Leftsideturo signallight
suonarness
c507 1 Underleftsideof dash Roofwire harness(seepage
22 3Al
c508 Undermiddleof dash Floorwire harness{seepage
22-341
c509 24 Undermiddleof dash Floorwire harness(seepage
22 34J
c510 25 12 Undermiddleol dash Dashboard wire harnessB
(seeoaoe22-30)
G501 1 Undergaugeassembly Body ground via dashboard
G503 21 Underleftsideof dash Body ground via dashboard
Left Side Turn Signal Light Sub harness

Connectoror Terminal Cavities Location Connectsto Noles
Leftsideturn signallight 35 2 B e h i n d l e f t s i d e t u r n s i g n a ll i g h t
c506 34 2 Under left side of dash Dashboard
wire harnessA
22-26
WIRE
DASHBOARD
A
HARNESS
,./
-19
20
34 I
LEFTSIDETURN SIGNAL LIGHT ). \'u

SUB HARNESS 2s )t
30
(cont'd)

22-27
DashboardWire HarnessA (Rightbranch)
Connecloror Terminal Cavities Location Connectsto Notes
Audiounitconnector 20 Eehindaudiounit
c501 6 10 Underrightsideof dash Enginecompartment wire
harness(seepage22,18)
c502 5 4 Underrightsideof dash Enginecompanmentwire USA
c502 5 8 Underrightsideof dash Enginecompartment wire Canada
c503 4 5 tJnderrightsideof dash Enginecompartment wire
c5' 11 Undermiddleof dash ECN4 wire harness(seepage
22-321
c512 12 8 Undermiddleof dash Floorwire harness{seepage
22-341
8 2 Underrightsideof dash Rightsideturn signallight
suonarness
c514 9 Underrightsideof dash Passenger's doorwire
harness(seepage22 4l)
10 6 Underrightsideof dash Passenger's doorwire
harness(seepage22 4'l)
ca52 2 21 Undermiddleofdash A,/Cwire harness(seepage
'l 22-43)
c853 3 Undermiddleof dash ly'Cwire harness(seepage
22-431
G502 Underrightsideof dash Eodygroundvia dashboard
Right Side Turn Signal Light Sub harness
ConnectororTorminal Cavities Location Connectsto Not€s

Rightsideturn signallight 1 2 Eehindrightsideturn signallight
c5't3 8 2 Underriohtsideof dash Dashboard
wire harnessA
22-28
WIBE
DASHBOARO
HARNESS
A
'---/...'
T
I

22-29
Connectors
and Harnesses
Connectorto HarnessIndex(cont'd)
DashboardWire HarnessB
Collqctor or Terminal Cavities Locatiol| Connectsto Notes
C a b l e reel 2 5 In steeringcolumncover
Combination lightswitch 1 In steeringcolumncover
Driver'sairbaginflator 17 4 In steeringcolumncover
lgnitionkey switch 16 In steeringcolumncover
lgnitionswitch 't9
1 In steeringcolumncover
lmmobilizer controlunit receiver 18 1 In steeringcolumncover
Passenger's airbaginflator I 4 Undermiddleof dash
SRSunitconnector A 18 Undermiddleofdash
Wiper/washerswitch 3 14 In steeringcolumncover
Underdashfuse/relay box 5 5 Underleft sideof dash
connectorAlseepage22,45)
Under dashluse/relaybox 6 6 Underleftsideofdash
connectorB (seepage22-45)
Under'dash fuse/relaybox 14 Underleftsideof dash
connectorC (seepage22-45)
Under-dash fuse/relaybox 1 2 Underlettsideof dash
connector S lseepage22-45)
Under'dash fuse/relaybox 8 8 Under left sideof dash
connectorX(seepage22 45)
c401 10 Underrightsideof dash Enginecompartment wire
harness(seepage22-'18)
c402 12 10 Undermiddleof dash Floorwire harness(seepage
22-34J
c403 11 4 Undermiddleof dash Floorwire harness(seepage
22-341
G510 14 12 Undermiddlesideof dash Dashboard wire harnessA
(seeoaoe22-26)
G40l Undergaugeassembly Bodygroundviadashboard
22-30
WIRE
OASHBOARD
HARNESS
B
22-31
Connectors
and Harnesses
ECMWire Harness
Connectoror TerminiF I Re- lcavities L Location Connectsto Notes
Arrruert/vrl ralo sensorretay Eehindglovebox
Datalinkconnector Undermiddleof dash
EC[/lconnectorE 8 Behindglovebox
PGM-Flmainrelay1 7 4 Behindglovebox
PGM-Flmainrelay2 6 4 Behindglovebox
box 1 In the under-dash
fuse/relay
box
connector D (seepage22 45)
Underdashfuse/relay box 2 Inthe under-dash
fuse/relay
box
connectorE lsee page22-45)
under-dashfuse/relaybox 3 6 In the under-dash
fuse/relay
box
connectorR lsee page22-45)
c10'1 4 20 Underrlghtsideof dash Enginewire harness(see
page22'16)
c152 1' I 8 Underrightsideof dash EPSsubharness(seepage
22-24)
c451 I Underrightsideof dash Enginecompanment wire
harness{seepage22-18)
c452 10 4 Underrightsideot dash Enginecompartment wire
harness{seepage22-18)
c453 14 6 UndermiddleoI dash Floorwire harness(seepage
22-34)
c511 12 Undermiddleof dash Dashboard wire harnessA
{seeoaoe22-26)
G451 Undergaugeassembly Bodygroundvia ECMwire
harness
22-32
ECMWIREHARNESS

22-33
Connectorto Harnesslndex (cont'd)
FloorWire Harness(Frontsidel
Connec-tor or Terminal I Ref uavftres Location connects to Nol6s
Driver'sseatbeltswitch 11 3 I Underdriver'sseat
Driver'ssideairbaginflator l0 2 i Underdriver'sseat
Driver'ssideimpactsensor 13 2 I Leftside offloor
Leftside seatbelt buckletensioner 12 4 Underdriver'sseat
Memoryerasesignal(MES)connector 19 2 Underdashfuse/relaybox
Parkingbrakeswitch 9 1 1Middleoffloor
Passenger's seatbelt switch 5 3 Underpassenger's seat
Passenger's sideairbaginflator 3 2 Underpassenger's seat
Passenger's sideimpactsensor 7 2 Rightsideoffloor
Rightsideseatbeltbuckletensioner 4 4 Underpassenger's seat
SRSunitconnector B 20 18 I Undermiddleof dash
SRSunitconnector C 21 8 Undermiddleof dash
Under-dashfuse/relaybox 11 18 Underdashfuse/relaybox
connector P {seepage22-45)
Under-dash fuse/relaybox 'r8 8 Underdashfuse/relay
box
connectorO (seepage22,45) ]
c402 22 10 Undermiddleof dash Dashboard wire harnessB
I {seepage22 30)
c403 23 4 Undermiddleof dash Dashboard wire harnessB
(seepage22-30)
c453 6 Undermiddleof dash ECMwire harness(seepage
22-321
c508 2 4 Undermiddleof dash Dashboard wire harnessA
(seepage22-26)
c509 14 6 Undermiddleofdash Dashboard wire harnessA
\see page 22-26)
c512 1 8 Undermiddleof dash Dashboard wire harnessA
I {seepage22-26)
10 Undermiddleof dash Enginecompartment wire
harness(seepage22 18)
6 4 ] Unaermiddleof aasn OPDSunitharness(seepage
22-421
G551 I L,nderpassenger's
seat Bodygroundviafloorwire
22-34
- 10
11
FLOORWIREHARNESS
( c o n t ' d)

22-35
Gonnectors
and Harnesses
Connectorto HarnessIndex (cont'dl a
Floor Wire Harness {Rear side}(cont'dl
Cargoarea 2 side of cargo area

Driver'sdoorswitch 6 1 LeftB pillar
EVAPemissionbypasssolenoidvalve 2 2 Fueltank
EVAPemissioncontrolcanistervent 24 2 Fueltank
shutvalve
Fuelpump/sending unit I 5 Fueltank
Fueltankpressure sensor 3 3 Fueltank
Left back-uplight 25 2 Lefttaillight
Left rearABS wheel sensor 1 2 Left rear offloor
Leftrearsidemarkerlight 26 2 Behindleftsideof rearbumper
Left rear speaker 4 2 Leftquarterpanel
Leftrearturn signallight 2A 2 Lefttaillight
Leftsideseatbelttensioner 5 2 LeftB-pillar
LefttaillighVbrake light 27 3 Lefttaillight
Noisecondenser (rearwindow '13 2 Rightquarterpanel
defogger)
Noisecondenser (rearwindowwiper) 18 2 Rightquarterpanel
Passenger's door switch 10 1 t pillar
R i g hB
Rearwindowwiperintermiftent 11 20 Rightq uarterpanel
controlunit
Rightback-uplight 22 2 Righttai ight
Righttaillighvbrake tight 20 3 Righttaillight
Rightrearturn signallight 21 2 Righttaillight
BightrearABSwheelsensor 15 2 Rightsideof cargoarea
Rightrearsidemarkerlight 19 2 Behindrightsideof rearbumper
Rightrearspeaker 12 2 Rightquanerpanel
Rightsideseatbelttensioner 11 2 RightB-pillar
7 12 Rightquanerpanel H a t c hw i r e h a r n e s s( s e ep a g e
22 39)
c554 I 12 Rightquanerpanel H a t c hw i r e h a r n e s s( s e e p a g e
rearseal bdcl Bodv ground vta
Rightsideof cargoarea Bodygroundviafloorwire
22-36
FLOORWIREHARNESS

22-37
Connectors
and Harnesses
RoofWire Harnsss
Connectoror Terminal Cavities tocation Connectsto Notes
Moonroofclose relay 6 5 Middleof roof
Moonrool control unit I 5 Middleof roof
Moonroofmotor 2 Middleof roof
Moonrootopenrelay 7 5 Middleof roof
Moonroofpositionsensor1 8 2 MiddleoI roof
N4oonroofpositionsensor2 5 4 Middleof roof
Moonroofswitch 1 5 Frontof roof
Rearceilinglight 3 N4iddleof roof
SpotlighVceiling
light 2 4 Frontof roof
c507 10 8 Underleftsideof dash Dashboardwire harnessA
(seeoaoe22-261
22-38
HatchWire Harness
Connectoror Torminal Cavities Location Connects to Notes
Hatchlatchswitch 7 2 Middleo{ hatch
Hatchlockactuator 2 Middleof hatch
Highmountbrakelight 8 2 Behindhighmountbrakelight
Licenseplatelight connectorA 2 Middleof hatch
Licenseplatelight connectorB I 2 Middleof hatch
Rearwindowde{ogger connector
A 3 1 RightC-pillar
Bearwindowdetoggerconnector
B 10 1 LeftC-pillar
( )
Bearwindowwipermoto. 6 4 Middleof hatch
c553 2 12 Rightquanerpanel Floorwire harness(seepage
22-341
c554 l 2 Rightquanerpanel Floorwire harness(seepage
)2-34\
22-39
and Harnesses
Connectors
Connectorto Harnesslndex (cont'd) \,
Driver'sDoorWire Harness
Connectoror Terminal ReI Cavities Location Connectsto Notes
Driver'sdoor lockactuator 9 2 Driver'sdoor
Driver'sdoorlockknobswitch 10 3 Driver'sdoor
Driver'sdoor lockswitch 1 3 Driver'sdoor
Driver'sdoorspeaker 7 2 Driver'sdooa
Driver'spowerwindow motor 2 Driver'sdoor
Left power mirror actuator 3 6 Driver'sdoor
Left tlveeter 2 Driver'sdoor
Powerwindow masterswitch 8 Driver'sdoor
c504 5 20 Underleftsideof dash Dashboard A
wire harness
't3 \seepage22-261
c505 6 Underleftsideof dash Dashboard A
wire harness
DRIVER'SOOORWIREHABNESS
22-40
Passenger'sDoor Wire Harness
Connectoror Terminal Rel Cavities Location Connectsto Notes
Passenger's
doorlockactuator 6 2 Passenger's
door
Passenger's
doorspeaker I 2 Passenger's
door
powerwindowmotor
Passenger's 5 2 Passenger's
door
powerwindowswitch
Passenger's 1 5 Passenger's
door
Rightpowermirroractuator 4 6 Passenger's
door
Righttweeter 3 2 Passenger's
door
c514 2 13 Underrightsideof dash Dashboard wire harnessA
(seepage22'26)
1 6 Underrightsideof dash Dashboard wire harnessA
lsee oeoe 22-26\
PASSENGER'S
DOORWIREHABNESS
22-41
and Harnesses
Gonnectors
Connectorto Harnesslndex {cont'dl
OPDSUnit Harness
ConnoctororTorminal Cavitios Location Connectsto Notes
OPDSunit 2 I In frontpassenger's
seat
1 Underfrontpassenger'sseat Floorwareharness(seepage
22-34)
FLOORWIBEHARNESS
22-42
A/C Wire Harness
Connoctoror Terminal Rel Cavities Location Connec'tsto Notes
Air mix controlmotor I 5 Undermaddle of dash
Blowermotor 2 2 Underrightsideof dash
Evaporator temperaturesensor 8 2 Undermiddleof dash
Modecontrol motor 3 10 Underrightsideof dash
Powertransistor 4 Underrightsideof dash
Recirculationcontrolmotor 1 5 Underrightsideof dash
c851 1 1 Undermiddleol dash Enginecompartment wire
c852 6 21 Undermiddleofdash Dashboard wire harnessA
{seepage22 26i
c853 5 ,] Undermiddleo{ dash Dashboard wire harnessA
lsee oaoe 22-261
22-43
Fuse/Relay
Boxes
Connectorto Fuse/RelayBox Index
Under-hoodFuse/RelayBox
Socket Ref Terminal Connects to

14 2 Enginecompartmentwire harness(seepage 22-18)
Ay'Ccompressorclutch relay 2 4
B 5 Enginecompartmentwire harness(seepage22-18)
Blower motor relay 4
c 15 Enginecompartmentwire harness(seepage 22-18)
C o n d e n s efra n r e l a y 9 4
D 1' 14 Enginecompartmentwire harness(seepage 22-18)
E 11 7 E n g i n ec o m p a r t m e nwt i r e h a r n e s s( s e ep a g e2 2 - 1 8 )
E L Du n i t to 3 Enginecompartmentwire harness{seepage 22-18)
H e a d l i g hrte l a y1 5 4
Headlightrelay 2 6
Horn relay 10 4
Radiatorfan relay 'l 4
Rearwindow defoqqerrelay J 4
T1 (Batterv) 8 Startersubharness(seeoaqe22-15)
T101 (Alternator) 7 Startersubharness{seeoaoe22-'15}
- a-------) | | T---r .-:-

tt || t L _ _| . 1 I
- - - - - - t t t L " "
t t-l t t_l t tIl L l L l t l ' " . -
""""-l- tr T T
I tTt Tr
,/^-------lFr
-/1-l
r^l sz- l:!)
L' lrt
lview of tront sidel {View of back side)
22-44
Under-dashFuse/RelayBox
Socket Ref Terminal Connects to

2 5 Dashboardwire harnessB {seepage 22-30)
B 3 6 Dashboardwire harnessB {seepage 22-30)
c 1 14 Dashboardwire harnessB (seepage 22-30)
D ECMwire harness(seepage 22-32)
E 5 13 ECI\4wire harness(seepage 22-32)
F 19 12 Enginecompartmentwire harness(seepage 22-'l8l
G 9 10 Enginecompartmentwire harness(see page 22-181
H I 3 E n g i n ec o m p a r t m e nwt i r e h a r n e s s( s e ep a g e2 2 - 1 8 )
20 Enginecompartmentwire harness(see page 22-18)
J : Enginecompartmentwire harness(seepage 22-18)
K 11 Dashboardwire harnessA (seepage 22-26)
'10
24 Dashboardwire harnessA (seepage 22-26)
M 22 1: Dashboardwire harnessA (seepage 22-26)
N 27 Dashboardwire harnessA (seepage 22-26)
.o^
o 26 Dashboardwire harnessA (seepage 22-26)
P 7 ;; Floorwire harness(seepage 22-34)
Powerwindow relay 4
o 6 8 Floorwire harness(seepage 22-34)
ECMwire harness(seepage 22-32)
R
S
10
25
14
2 Dashboardwire harnessB (seepage 22-30)
Startercut relay
T
Taillightrelay
18 in Multiplexcontrol unit servicecheckconnector
l
Turn signal/hazardrelay 11 a l
U Optionalconnector
W ( M e m o r ye r a s es i g n a l( M E S )
l5
to
17
l t
2
Optionalconnector
Floorwire harness(seepage22-34)
connector)
X 28 I {Plugsdirectly into the multiplexcontrol unat)
Y 13 ( P l u q sd i r e c t l vi n t ot h e m u l t i D l e cx o n t r o lunrl)
tn--rl
I U LI L.]L.J
h - - n -
UL]L]UL]
I] L] L] LI L]
!3 12
22-45
PowerDistribution
Fuseto Componentslndex
Under-hoodFuse/RelayBox
Fuse Amps WireColor Component(sl or Circuit(s) Protected

Number
'I
204 BLUI/EL Condenserfan motor
BLU/RED Ay'Ccompressorclutch
15A WHT/GRN Dashlights,Front parkinglights,Frontside marker lights,Licenseplate
l i q h t ,R e a rs i d em a r k e rl i q h t s T
, ailliqhts
7.5A WHT/BLU C a r q oa r e al i q h t ,C e i l i n ql i q h t s l. q n i t i o nK e v l i q h t .S o o t l i o h t s
204 BLU/BLK Radiatorfan motor
5 10A WHT/BLK Turn siqnal/hazardrelav,Turn siqnal liqhts
15A WHT/BLK CKPsensor,ECM,IACvalve, lmmobilizercontrol unit-receiver,Injectors,
P G M - Fm
I a i n r e l a v1 a n d 2 . T D Cs e n s o r
7 15A WHT/GRN Brakelights,Brakesignals(to ABS modulator-controlunit, Cruisecontrol
unit, ECM)
B L U / R E D i1Orns
8 20A WHT/GRN ABS modulatorcontrol unit
9 10A WHT/RED A u d i o u n i t ,D a t al i n kc o n n e c t o(rD L C )G
, a u g ea s s e m b l yl,m m o b i l i z e r
control unit-receiver,lmmobilizerindicatorlight. Keylessreceiverunil,
lvlultiDlexcontrol unit
10 40A WHT/RED ABSmodulator-control unit
11 30A BLK/YEL Noisecondenser,Rearwindow defoqqer
40A BLU^^/HT Blower motor
IJ 40A WHT/BLK No. 7 fuse (in the under-dashfuse/relavbox), Powerwindow relav
14 40A WHT/RED No.2 and No.3 fuses (in the under-dashfuse/relavbox)
t5 15A REDI/EL Daytimerunning lightscontrol unit (Canada),Daytimerunning lights relay
{ C a n a d a )H, i o hb e a mi n d i c a t o lri q h t .L e f th e a d l i q h t
16 204 WHT Multiplexcontrol unit
17 15A RED D a v t i m er u n n i n ql i q h t sc o n t r o lu n i t ( C a n a d a )R. i o h th e a d l i o h t
18 60A WHTiBLU EPScontrol unit
19 80A Batterv.Power distribution
20 40A' WHT lgnition switch (BAT)
50A'?
* 1 :U S A
" 2. Canada
l l I
t
t t
t4 " t | lI
l l - - -
- E'l E,l E,l r--r r---rt__J i; i6'!/'
E,l E,l E,l Eol E l f__--l

II l'lr]n
r L__J,a | |
,..r^{-------l^-,
" N2,
n[:]$"Lrt nf - r^l
O: Sparefuse
22-46
Fuse Amps Wire Color Component(s) or Circuit(s) Protected

Number
1 15A BLKA/VHT l g n i t i o nc o i l s
2 204 WHT/RED Airlfuelratiosensor,ECM
3 10A RED/BLU D a y t i m er u n n i n gI i g h t sc o n t r o lu n i t{ C a n a d a )
10A BLI(ORN Air/fuel ratio sensorrelay,Alternator,CMP sensor,Cruisecontrol main
switch,Cruisecontrol unit. ELDunit, Evaporativeemission(EVAP)bypass
solenoidvalve, Evaporativeemission(EVAP)canisterpurge valve,
Evaporativeemission(EVAP)canistervent shut valve,SecondaryH02S,
Vehiclespeed sensor
5 Not used
6 7.5A Y E U G R N Moonroof control unit, Moonroof open and close relay,Powerwindow
relaV
7 204 GRN Moonroof motor
I 7.5A YEURED A u d i o u n i t
9 10A GRN OPDSunit, Rearwindow wiper motor, Rearwindow washer motor, Rear
window wiper intermittentcontrol unit
10 7.54 YEL Back-uplights,Cruiseindicatorlight, EPScontrol unit, Gaugeassembly,
Keylessreceiverunit, Multiplexcontrol unit, Securitycontrol unit
connector(optional)
11 7.5A BLIVORN ABS modulator-controlunit
12 7.5A YEURED D a y t i m er u n n i n ol i o h t sc o n t r o lu n i t ( C a n a d a )
13 10A PNK S R Su n i t
't4
10A BLK/YEL A,,/C compressorclutch relay,Blower motor relay,Condenserfan relay,
Heatercontrol panel,Power mirror actuator,Power mirror defogger
(Canada),Radiatorfan relay,Rearwindow defoggerrelay,Recirculation
control motor
1E Not used
lo Notused
17 15A YEL/BLK E C M ,F u e lp u m p
BLK/YEL >H> Unrr
18 15A Y E U G R N Accessorypower socket
19 7.5A Y E U B L K T u r ns i q n a l / h a z a rrde l a v T , u r ns i q n a l i o h t s
20 30A G R N / B L K M u l t i p l e xc o n t r o lu n i t ,W i n d s h i e l dw a s h e rm o t o r .W i n d s h i e l dw i o e r m o t o r
21 Not used
22 204 G R N / B L K Passenqer'swindow motor
23 20A. GRN,A/VHT Driver'swindow motor
24 Not used
25 Notused
_ _ ^ :
Hr tl_l
f at-t
at\t I
r^,rl fl
!!;r -
!f 3 3 9: , i ; s ! ! s
Fnf |rnITf

22-47
GroundDistribution
Groundto ComponentsIndex
Ground Componentor circuit qrounded
Batterv,Transmissionhousinq
En g i n e
G1 0 1 ECM(PGis BLK;LGis BRN/YEL)
BLK:IACvalve,lgnitioncoils,Vehiclespeedsensor,VTECsolenoidvalve
BRNA/EL:Camshaft oosition(CMP)sensor.CKPsensor,TDCsensor.VTECoil pressure
switch
G 15' ] EPScontrolunit
G201 ELDunit. Multiplexcontrol inspectionconnector,Multiplexcontrol unit, Powerwindow relay,Rear
window washer motor, Rightfront parkinglight, Rightfront side marker light, Rightfront turn signal
light,Turn signal/hazardrelay,Washerfluid level sensor(Canada), Windshieldwasher motor,
WindshieldwiDer motor
G202 ABSmodulator-control
unit
G301 Blower motor relay,Brakefluid level switch,Condensorfan motor, Cruisecontrol actuator,Leftfront
parkinglight, Leftfront side marker light, Leftfront turn signallight, Radiatorfan motor, Radiatorfan
swrtcn
G401 Combinationliqht switch,lqnitlon kev srvitch,Wiper/wasfrersr,virch
G402 Left and riqht airbaqsensors,SRS unit
G4 5 1 Datalink connector(DLC)
G501 Clutchinterlockswitchm Clutchpedal positionswitch (for cruisecontrol),Cruisecontrol main switch,
Cruisecontrol unit, Daytimerunning lightscontrol unit (Canada),Driver'sdoor lock knob switch,
Driver'sdoor lockswitch,Driver'spower window motor, Heatercontrol panel,Left power mirror
defogger(Canada),left side turn signal light, Moonroof control unit, Monroof open and close relays,
'1,
Moonroof positionsensor Moonroof seitch,Power mirror switch,Powertransistor,Powerwindow
masterswitch.SDotliqhts
G502 Accessorypower socket,Gaugeassembly,Keylessreceiverunit, lvlultiplexcontrol unit, Right power
m i r r o rd e f o g g e {r C a n a d a )
G503 A u d i ou n i t
G551 Driver'sseat belt switch,Fuelgauge sendingunit, Fuelpump, Memory erasesignal(IMES)connector,
OPDSunit. Riohtseat belt switch
G552 High mount brakelight, Licenseplate lights,Rearwindow defogger,Rearwindow defoggernoise
condenser.Rearwindow wioer motor, Hatchlatch switch
Back-uplights,Brakelights,Rearside marker lights,Rearturn signal lights,Rearwindow wiper noise
condenser,Rearwindow wiper intermittentcontrol unit, Taillights
22-48
Removaland Installation
SRScomponentsare locatedin this area.Reviewthe 5. Removethe mounting bolt, and slidethe under-
SRScomponentlocations{seepage 23-13)and dash fuse/relaybox (A) down from the bracket{B).
sectionbeforeperformingrepairsor service. 6. Disconnectthe backside from connectorsfrom the
back of the under-dashfuse/relaybox, and remove
Removal the fuse/relaybox.
1. Make sure you have the anti-theftcode for the radio, N O T E : T h eS R Sc o n n e c t o irs a s p r i n g - l o a d eldo c k
then write down the frequenciesfor the radio's type (seepage 23-11).
presetbuttons.
lnstallation
2. Disconnectthebatterynegativecable,then
disconnectthe positivecable,and wait at least 1. Installthe under-dashfuse/relaybox in the reverse
three minutes. order of removal and connectall connectorsto the
under-dashfuse/relaybox.
3. Removethe driver'sdashboardlower cover (see
page 20-59). 2 . I n s t a l l t h ed r i v e r ' sd a s h b o a r dl o w e rc o v e r .
4. Disconnectthe connectorsfrom the fuse side of the 3. Connectboth the negativecable and positivecable
under-dashfuse/relaybox. to the battery.

5. Confirmthat all systemswork properly,
6 . D o t h e e n g i n ec o n t r o lm o d u l e( E C M )i d l e l e a r n
22-49
Battery
Battery Test {
A batterycan explodeif you do not follow the

proper procedure,causingseriousinjury to anyone
nearby.Follow all procedurescarefullyand keep
sparksand open flames away from the battery.
Use eithera JCI or BearARBSTtester,and follow the

manufacturer'sprocedures.lf Vou don't have one of
these computerizedtesters,follow this conventional
test procedure:
1. Be sure the temperatureof the electrolyteis

between70'F (21"C)and 100'F(38'C).
2. Inspectthe batterycasefor cracksor leaks.
. l f t h e c a s ei s d a m a g e d r, e p l a c e t h eb a t t e r y . l
. lf the case looksOK, go to step 3.
3. Checkthe indicatorEYE.
. lf the EYEindicatesthebafteryischarged,goto
step 4.
. l f t h e E Y Ei n d i c a t e s al o w c h a r g e ,g o t o s t e p 7 .
4. Apply a 300 amp load for 15 secondsto removethe

surfacecharge.
5, Wait 15 seconds,then apply a test load of 280 amps

for 15 seconds.
6. Recordbatteryvoltage.
. l f v o l t a g ei s a b o v e 9 . 6 v o l t s , t h e
b a t t e r yi s O K . l
. l f v o l t a g ei s b e l o w 9 . 6 v o l t sg, o t o s t e p T .
7 . C h a r g et h e b a t t e r yo n H i g h( 4 0a m p s )u n t i lt h e E Y E
shows the batteryis charged,plus an additional30
minutes.lf the batterychargeis very low, it may be
necessaryto bypassthe charger'spolarity
protectioncircuitry.
. l f t h e E Y Ei n d i c a t e s t h eb a t t e r yi s c h a r g e d w i t h i n
3 hours,the batteryis OK.l
. lf the EYEindicatesthebatteryis notcharged
within 3 hours,replacethe battery.l
22-50
Relays
PowerRelayTest
Usethischanto identifythetypeof relay,thendo the type 1:
testlistedfor it.
relayinputtest(seepage22-
NOTE:Turnsignal/hazard
87).
Relay Test
A'lCcomoressor
clutchrelav Normally-open
Airlfuel ratio sensorrelav type A
Condenserfan relay
H e a d l i o hrte l a v1
H e a d l i q hrte l a v2
H o r nr e l a v
Powerwindow relay type 2:
R a d i a t oIra n r e l a y
Reverserelav
Startercut relav
T a i l l i q h rt e l a V
D a y t i m er u n n i n gl i g h t sr e l a y
{ C a n a d)a
P G M - FmI a i nr e l a v1
P G M - Fm
l a i n r e l a v2
Blower motor relav Normally-open
Rearwindow defoqoerrelav tvpe B
Moonroofclose relay F i v et e r m i n a l
Moonroof oDenrelav type
Low beam cut relav {Canada) PGM-FImain relay 1
PGM-FImain relay 2
Normally-open
type A: type 1:
Checkfor continuitvbetweenthe terminals.
. Thereshould be continuitybetweenthe No. 1 and

N o , 2 t e r m i n a l sw h e n p o w e ra n d g r o u n da r e
connectedto the No. 3 and No. 4 terminals.
. Thereshould be no continuitybetweenthe No. 1 and
N o . 2 t e r m i n a l sw h e n p o w e ri s d i s c o n n e c t e d .
type 2:
(cont'd)
22-51
Relays
PowerRelayTest (confdl
Normally-open
type B: Five-terminal
type
Checkfor continuitybetweenthe terminals. C h e c kf o r c o n t i n u i t yb e t w e e nt h e t e r m i n a l s .
. Thereshould be continuitybetweenthe No. 1 and . T h e r es h o u l db e c o n t i n u i t yb e t w e e nt h e N o . 1 a n d

N o . 3 t e r m i n a l sw h e n p o w e ra n d g r o u n da r e N o . 2 t e r m i n a l sw h e n p o w e ra n d g r o u n da r e
connected t o t h e N o .2 a n d N o . 4 t e r m i n a l s . c o n n e c t e tdo t h e N o . 3 a n d N o . 5 t e r m i n a l s .
' Thereshould be no continuitybetweenthe No, 'l and . T h e r es h o u l db e c o n t i n u i t yb e t w e e nt h e N o . 1 a n d
No. 3 terminalswhen power is disconnected. N o . 4 t e r m i n a l sw h e n p o w e ri s d i s c o n n e c t e d .
tF-gr
tJ 1l
Rearwindow defonn* *O, type 1:
6:)
rc*V
.r{{
(n F, t )\ \
Blower motor relay

s3.
type 1:
type2:
type 2;
22-52
lgnitionSwitch
Test
SRScomponentsare locatedin this area.Reviewthe
S R Sc o m p o n e n lto c a t i o n s( s e ep a g e2 3 - 1 3 a
) nd
precautionsand procedures{seepage 23-'l4)in the SRS
sectionbefore performingrepairsor service.
1, Removethe driver's dashboardlower cover {see

page 20-59).
2. Disconnectthe 5P connectorfrom the under-dash

fuse/relaybox.
WHT/RED
Wiresideof
f e m a l tee r m i n a l s
BLK/WHT BLK/YEL
BLK/RED

Terminal WHT/ BLK/ BLK/ BLK/

\
RED WHT YEL RED WHT
p.J,i""-\ (ACC) (BAT) flGl) trc2t (sr)
o (LocK)
| (ACC) o- --o
[ (oN) c)- _H
III (START) o _H
lf the continuitychecksdo not agreewith the table,

replacethe steeringlock assembly(seepage'17-121.

22-53
Gauges
\-
PARKINGBRAKESWITCH
p a g e1 9 - 1 0
FUELGAUGESENDING
p a g e1 1 - 1 5 6
SWITCH
ENGINEOILPRESSURE
page8-4
GAUGEASSEMBLY
Procedure,page22-56
SelJ-diaqnostic
Gauqedulb Replacement,page22 63
Rep6cement,page22-64
CoolantTemperatureGauge
page22'64
TroLrbleshooting,
BRAKEFLUIDLEVELSWITCH
p a g e1 9 - 1 0
VEHICLESPEEDSENSOR{VSS)
page22-65
Troubleshooting,
22-54
CONNECTORA CONNECTOR B
(bluel lgreenJ
SPEEDOMETER
VehicleSpeedSignalCircuit
page22-65
Troubleshooting,
TACHOMETEB
\7
t----/ \
_ / \
i . . _ -
FUELGAUGE
ODO/TRIPMETER Test,page11-156
22-55
Gauges
Self-diagnosticProcedure v
The gaugeassemblyhas a self-diagnosisfunction.
. T h e B e e p e rD r i v eC i r c u i C
t heck
. The IndicatorDrive CircuitChecL
. The LCDSegmentsCheck
. The GaugesDrive CircuitCheck(Speedometer,Tachometer,Fuelgauge,Coolanttemperaturegauge)
. T h e C o m m u n i c a t i oLni n eC h e c k( t h ec o o l a n t t e m p e r a t u rsei g n a l i n e b e t w e e nt h e g a u g ea n d E C M )
NOTE:Indicatorsare also controlledvia the communicationline.
Enteringthe self-diagnosis
f unction:
Beforedoing the self-diagnosisfunction,checkthe No. 9 (10A)fuse in the under-hoodfuse/relaybox and No. 10 {7.5A)
fuse in the under'dashfuse/relaybox.
1. Pushand hold the trip/resetbutton.

2 . T u r nt h e l i g h t i n gs w i t c hO N .
4 . W i t h i n5 s e c . ,t u r n t h e l i g h t i n gs w i t c hO F F ,t h e n O N a n d O F Fa g a i n .
5. Within 5 sec.,releasethe trip/resetbutton,then push and releasethe buttonfour times reDeatedlv.
NOTE:
. While in the self-diagnosismode, the dash lights brightnesscontrolleroperatesnormally.
'Whileintheself-diagnosismode,thetrip/resetbuttonisusedtostartthebeeperdrivecircuitcheckandthegauge
drive cicuit check.
. lf the vehiclespeedexceeds1.2 mph 12km/h)orthe ignition switch is tu rned OFF,the self,diagnosis mode ends.
oN flrl
lgnition
OFF
Switch
Lighting
Switch
Trip/Reset
Switch -> Move to selt-diagnosis mode.
5 sec. 5 sec.
The BeeperDriveCircuitCheck:
When enteringthe self-diagnosismode, the beepersoundsfive times
TheIndicatorDriveCircuitCheck:
When enteringthe self-diagnosismode,the following indicatorsblink.
Seatbelt indicator,Door/hatchindicator,Brakesystem,Lowfuel indicator,Maintenancerequiredindicator(USA),
W a s h e rf l u i d l e v e li n d i c a t o (r C a n a d a O
) , i l p r e s s u r el i g h t .
22-56
\
The LCDSegmentCheck:
W h e ne n t e r i n gt h e s e l f - d i a g n o s m
i s o d e ,t h e o d o / t r i ps e g m e n tb l i n k sf i v et i m e s .
TheGaugeDriveCircuitCheck:
i s o d e ,t h e s p e e d o m e t e trh, e t a c h o m e t e rt ,h e f u e l g a u g e ,a n d t h e c o o l a n t
W h e ne n t e r i n gt h e s e l f - d i a g n o s m
temperature g a u g en e e d l e ss w e e pf r o m t h e m i n i m u mp o s i t i o nt o m a x i m u mp o s i t i o nt,h e n r e t u r nt o t h e m i n i m u m
posrtron.
NOTE:After the beeperstops soundingand the needlesreturnto the minimum position,pushingthe trip/resetbutton
s t a r t st h e b e e p e rd r i v ec i r c u i tc h e c k( o n eb e e p )a n d t h e g a u g ed r i v ec i r c u i tc h e c ka g a i n .
T h e c h e c kc a n n o tb e s t a r t e du n t i l t h en e e d l e sr e t u r nt o t h e m i n i m u mp o s i t i o n .
Self-diagnosis ON
mode OFF
Trip/Reset
9l- r n =--llJL--
@,
switch oFF _---
causeneedlesXl" f---U---------l [-----l

ON r-r r-r r-r .-1 r-r r-r
Beeper
;; lll u u l_lL__l
I l-l
The needlessweepfrom the
5 sec minimum positionto the
maximum position,then return
t o t h e m i n i m u mp o s i t i o n -
The Communication Line Check:

In the self-diagnosismode, after the odo/trip LCDsegmentscheck,the self-diagnosisstartsthe communicationline
cnecK.
l f a l l s e g m e n t sc o m e so n , t h e c o m m u n i c a t i o lni n e i s O K .
" E r r o r "i s i n d i c a t e d ,
l f t h ew o r d t h e r ei s a m a l f u n c t i o ni n t h e c o m m u n i c a t i o lni n e b e t w e e nt h e g a u g ea s s e m b l yt.h e
m u l t i D l e cx o n t r o lu n i t .a n d t h e E C M .
Normal: Faulty:
iD ,-
:-l!:!!JlJ!J t l
i-
f l
O i -
t
--
i-
-
| | | t t f
,- r-
r-
i-
,
Endingthe self-diagnosisfunction:
T u r nt h e i g n i t i o ns w i t c hO F F .
N O T E lrf t h e v e h i c l es p e e de x c e e d s1 . 2m p h { 2 k m / h ) t, h e s e l f d i a g n o s i sf u n c t i o ne n d s .
22-57
Gauges
CircuitDiagram
'
UflOEN fiOOOFUSE/8ILAY
8OX N o 2 0 i o A: lU S A
ECM/PCM
V
I
-r'
r--l
l J , ii-ciorurnn
I coNNECron
I 8|
COOLANI
TEMPfNAIUFT
SPIEDOMEIENTACHOMEIIR FUTLGAUGI GAUGE
Norll0AlFUSE
8L(
-o-
22-58
ti) l To mxr I
MAi{IIiIANCE
ft0unlD
[{0tcaTo8
LIGH]
(LEDI
(cont'd)

22-59
Gauges
CircuitDiagram(cont'dl I
No2il5AlFUSE
ilnlh.undi hooq DASH
llu!./rcl.ybox r LGHTS
Yt Yl
t l
'- -t
WASHEF
Itut0
I!VEL
6t0tc ToR
UGHT
(tDl
J
ls?2
I
BLUIYEL
I
J
cSutsE
m n0L
a
22-60
'- --t
I DAYTIME I
./ ib-n'rnoL ! BUNN|NG ;
tNGniEorL UNIT i LIGHTS I
PRESSUBE I @NTROL
swtTcH I UNII
i
lCld.d Eisin.3topp.d
l I
iopd Ersin.runni.si L -.-..
icmadd
(cont'd)
22-61
Gauges
CircuitDiagram(cont'dl \"
GRNIfiED
I
\""'7
V
LEFTTUN
SIGI'IAL
II'{DICATOR
GAUGIASSEi|BLY LTCHTS
HIGHSEAM -|. IMMOBITIZER

ltDtcATon r/: \ tilucaToB \,
f,il vll9i,]
CoME|NAT|ON tMf,tOBtUZEn
LtctlTswtTclt @l\tTRoL
UN|I ftCtIVER
22-62
GaugeBulb Replacement
RIGHTTURNSIGNALINDICATOR
LIGHT{1.4WI
CRUISE ITORLIGHT{I.4W)
HIGHBEAMINOICATOR
LIGHT{1.4W) LEFTTURNSIGNALINDICATORLIGHTl1.il wl
GAUG€LIGHT{1.4WI
GAUGELIGHT{1.4W}
IMMOBILIZENINDICATOR
{1.4Wl
LTGHT
22-63
Gauges
GaugeAssemblyReplacement CoolantTemperature
Gauge
Troubleshooting
1 . Removethe instrumentpanel (seepage 20-59),
t h e n r e m o v et h e u p p e rc o l u m nc o v e r{ s e ep a g e1 7 -
Beforetesting,checkthe No. I { 10A)fuse in the under-
hood fuse/relaybox and the No. '10(7.5A)fuse in the
2. P l a c ea c l e a ns h o pt o w e l ( A )u n d e rt h e g a u g e under dash fuse/relaybox.
assemblyto preventscratchingthe steering
c o l u mn o r d a s hp a n e l . 1. Startthe engine,and checkthe malfunction
i n d i c a t o lra m p ( M l L ) .
3 . Removethe screwsfrom the gauge assembly(B).
Does the MIL come on?
YES- Troubleshootthe causeof the ECM DTC(see

p a g e11 - 5 7 )a, n d r e c h e c k .
NO-Go to step 2.
2. Checkfor a multiplexcontrol unit DTC(seepage

22,168).
ls a DTC indicated?
YES Troubleshootingthe causeof the multiplex

control unit DTC{seepage 22-168),and recheck.
NO Go to step 3.
3 . D o t h e c o m m u n i c a t i o lni n ec h e c kw i t h t h e s e l f -
4. Disconnectthe connectors(C),and removethe diagnosisprocedure(seepage 22-56).
g a u g ea s s e m D r y .
ls the word "Error" indicated on the odo/ttip
I n s t a l l t h eg a u g ea s s e m b l yi n t h e r e v e r s eo r d e ro f d isplay ?
removal.
YES The gaugecannot receivethe signalfrom the
multiplexcontrol unit and the ECI\,4. Checkfor an
open in the WHT/GRNwire (gaugeconnector
t e r m i n a lB1 3 ) .l f n o o p e ni s f o u n d ,g o t o s t e p5 .
NO Go to step 4.
4. Do the gaugedrive circuitcheckwith the self-

d i a g n o s i sp r o c e d u r e( s e ep a g e2 2 - 5 6 ) .
Does the temperaturegauge needle sweep lrom

the minimum position to the maximum, then tetutn
to the minimumposition?
YES Go to step 5.
NO Replace t h e g a u g ea s s e m b l y . l
5. Substitutea known-goodECM and recheck.
Did the symptom/ ind ication go away?
YES Replace theECM.

NO Substitutea known good gaugeassembly.lf
g a u g ea s s e m b l y . l
22-64
I VehicleSpeedSignalCircuitTroubleshooting
Special Tools Required: 5. Connectthe WHT test harnesscliD(B)to the
Test Harness07LAJ-PT3020A positiveprobe of a voltmeter,and connectthe RED
test harnessclip (C)to the negativeprobe.
Beforetesting,inspectthe No. 4 (10A)and No. 10 (7.5A)
fuses in the under-dashfuse/relaybox.
1. Disconnectthe 3P connectorfrom the vehicle

speedsensor(VSS){A).
le thara h2ltarv v^ltada?
Connectthe test harnessonly to the enginewire
harness. NO Repairopen in the BLK,/YEL wire betweenthe
VSS and the under-dashfuse/relaybox.l
3 . Connectthe REDtest harnessclip (B)to the positive
probe of an ohmmeter.Coverthe white (C)and 7 . Disconnectthe WHT test harnessclip (B).
green {D)test harnessleadswith protectivetape (E).
8 . C o n n e ctth e G R Nt e s th a r n e s sc l i p{ D )t o t h e
4 . Checkfor continuitybetweenthe REDtest harness positiveprobe of a voltmeter.
c l i p a n d b o d yg r o u n d ,
YES Go to step 5.
N O R e p a i ro p e ni n t h e B L Kw i r e b e t w e e nt h e V S S
a n dG1 0 1 . I
Is there 5 V or more?
YES- Go to step 9.
NO Repairshort or open in the BLUMHT or WHT/

GRNwire betweenthe VSS and the cruisecontrol
u n i t ,o r t h e E C M . I
(cont'd)

22-65
Gauges
VehicleSpeedSignalCircuitTroubleshooting(cont'dl
9 . Turn the ignitionswitch OFF. 14. Disconnectthe 22Pconnector"8" from the gauge
assemDry.
1 0 .Connectthe other test harnessconnector(A)to the
V S S( B ) ,
GAUGE
ASSEMBLY B (22P)
CONNECTOR
'15.
Connectthe positiveprobe of a voltmeterto the
BLU/WHTwire and the negativeprobeto ground.
1 1 .R aisethe front of the vehicle,and make sure it is
securelysupported. '16.
Slowly rotateone wheel with the other wheel
blocked.
' t 2 .Put
the vehiclein neutralwith the ignitionswitch
o N { |)| , Does voltage pulse f rom 0 to about 5 V or more?
t5. Slowly rotateone wheel with the other wheel YES- Replacethe speedometerassembly.I
blocked.
NO Repairopen in the BLUMHTwiTe between
Does voltage pulse ttom 0 to about 5 V ot morc? the VSS and the speedometer.l
YES Go to step 14.
NO Replacethe VSS.I
22-66
I J VSS Replacement
1. Removethe intakeresonator.
2. Disconnectthe 3P connectorfrom the vehicle

speed sensor{VSS)(A).
Removethe mounting bolt, then removethe VSS.
4 . lnstallthe VSS in the reverseorder of removal.
22-67
ExteriorLights
GomponentLocationIndex
UNDER.HOOD
FUSE/RELAY
BOX
HEADLIGHT RELAY1
Test,page22-51
HEADLIGHT RELAY2
Test,page22-5'l
BRAKEPEDALPOSITION
swtTcH
Test,page22-84
Adjustment,page l9'6
0/
SIDETURN SIGNAL LIGHT

page22-84
Replacement,
\ /
FRONTTURNSIGNAL
LIGHT
B u l bB e p l a c e m e npt a
, g e2 2 8 1
HEADLIGHTS PARKINGLIGHT
Replacement,page22 79 B u l bR e p l a c e m e npt a, g e2 2 - 8 1
Adjustment.page22-78
page22-81
Eulb Replacement, FRONTSIDEMARKERLIGHT
Bulb Replacement,page22 83
22-68
-a-.,_
z
HIGHMOUNTBRAKELIGHT
page22-82
Replacement,
LICENSE
PLATELIGHTS
page22-83
Replacement,
BACK.UPLIGHT
page22-82
Replacement,
TAILLIGHTSsnd BRAKELIGHTS
page22-82
Replacement,
REARSIDEMARKERLIGHT REARTURNSIGNALLIGHT
page22-83
Replacement, Beplacement,page22-82
(cont'd)
22-69
ExteriorLights
ComponentLocationIndex(cont'dl !
DAYTIMERUNNINGLIGHTSRELAY{Canadal
[Wirecolors:RED,REDryEL,
I
LRED/BLKandRED/BLU I
Test,page22-51
_LOW BEAMCUTRELAY {Canadal_
WirecolorsrREDMHT,RED/BLK,I
LREDryELandRED/BLU I
Test,page22-51
DASH LIGHTSBRIGHTNESS
CONTROLLER
. . i \
'
:' --,': -
' i,-'-'l
/ DRLINDICATOR
LIGHT{Canadal
HIGH BEAM INDICATORLIGHT

COMBINATIONLIGHTSWITCH page22-63
Bulb Replacement,
page22-80
TesVReplacement,
oAYTIME RUNNING LIGHTSCONTROLUNIT lcanada)

InputTest,page22-76
I t- -
FUSE/
UNDER.DASH
RELAYBOX
22-70
LET] f,IGHT IETT I ucEr\6E
FBOIII TSONT NEANSIDE I PI.ATE
SIDE s]0E MAircN
MAiKEE
L.IGHT
MANXtF
IJGIIT
IIGHT |fiIli
I
8L.l(
_o

22-71
ExteriorLights
CircuitDiagram- Canada t J
UNOEN
HOOO
FUSE/8ELAY
BOX
N ol 9 l 8 0 A l
) to.o No.1'l
- i50Al loa)
IT WHT ED RED,I
N o . ! 0S( 7A lusE
r
d.3hl
/', t-\
I EAr \ rc|'/moN
. rcz/ swfrcH
'2
I- _ l
-- ,'orrro"
V \ vG2Horin0N{ll) .) INDICAIOF
-/ l'lcli;
'l'I
I
I
BU1
BED *01
I
I
=
.|
I RE
A DNL
) No12
i l7.5Al fifili{*1l,.H'
I DAYTIME
--t
BUNNINC
\y
II
TIGHT
luDl
II LIGHTS
EfLAY
t J
HT/BI tU RED/
BLU RE
In 12 , ll t0 t1
8
,{ oorr,",rr.,ro { r- SLU/BID
uctrrscournoLu,'r"
l
T
I I J l
!3 3
||MoS|UZEn
CONTNOL
SYSIIMUGHI UNIT RECEIVEB BI( BI BI G8N
VY 17
Y
I I
GNfl/FEO GRI\/NED
II
I
f'
r\ 88A(E F\ PANKNG
I FiUrD ; } BNAXE
( 2 , LTVEL +./ swrTcH
[./ SWITCH
'nddoM
I
I
i i
G301 cl.1
G501
\, J
22-72
J
DASH
LIGHTS
COMEINATION
LIGHT
SWIqI
LEFT TTFT BIGHT FIGIIT LEFT LEFT RIGHT NEHI I LICENSE

PAfiX*'IG TRONT PANKNG FBONT TAIILGl T BEAFSIDE RIAFSIDI IAILUOHI I PLAII
LIG}IT 3r0E LIGIIT SIDE I/IAFrc8 I LIGNTS
MABKER MAfircF LJGHT UCHT (twr2l
LIG}IT LJGHT |
l5w) 8LI
BLI( BL]( I
!
t
l ! I
l
I
G301 G301 G552
22-73
ExteriorLights
CircuitDiagram- BrakeLights \
UiDENHOOD
FUSE/NEUYBOX
SATIISY
r!o7l15A)
I |
\ ,r-T-v--rrni'citr
22-74
CircuitDiagram- Back-upLights
UiDEN H@DFUSI/8EIAY
80)(
22-75
ExteriorLights
DaytimeRunningLightsControlUnit InputTest- Canada \
T h e D R Li n d i c a t o lri g h ti n t h e g a u g ea s s e m b l yw i l l c o m e o n w h e n y o u t u r n t h e i g n i t i o ns w i t c ht o O N ( l l )w i t h t h e
headlightswitch off and the parkingbrakese1.lt should go off when you turn on the headlightswitch and releasethe
parkingbrake.lf it comes on at any other time, do the control unit input test.
r i l l g l o w a t h a l fi t s n o r m a li n t e n s i t y .
: h e nt h e d a y t i m er u n n i n gl i g h t sa r e o n ,t h e h i g h b e a mi n d i c a t ow
N O T EW
1. Removethe driver'sdashboardlower cover (seepage 20-60).
2 , D i s c o n n e c t t hle4 P c o n n e c t o r ( Af)r o m t h e d a y t i m er u n n i n gl i g h t s c o n t r oul n i t ( B ) .
RED/BLU
GNN/BLK
RED/BLU GRN/BLK
GRN/ORN
BLU/RED RED/YEL YEL/RED
Inspectthe connectorand socketterminalsto be sure they are all makinggood contact.
. lf the terminalsare bent,loose orcorroded, repairthem as necessary,and recheckthesystem.

' lf the terminalslook OK, go to step 4.
22-76
4. Makethese input tests at the connector,
.lfanytestindicatesaproblem,findandcorrectthecause,thenrecheckthesystem.
. lf all the input tests prove OK,the control unit must be faulty. Replaceit.
Cavity Wire Test condition Test:Desiredresult Possiblecauseif resultis not obtained

2 RED/BLU U n d e a
r ll Checkfor voltageto ground: Blown No. 14 (40A)fuse in the
conditions Thereshould be batteryvoltage. under-hoodfuse/relaybox
B l o w nN o . 3 { 1 0 A ) f u s ei n t h e
under-dashfuse/relaybox
A n o p e ni n t h e w i r e
12 YEL/RED lgnitionswitch Checkfor voltageto ground: B l o w nN o . l 2 ( 7 . 5 A ) f u s ei n t h e
o N( r ) Thereshould be batteryvoltage. under-dashfuse/relaybox
An open in the wire
BLK U n d e ra l l C h e c kf o r c o n t i n u i t yt o g r o u n d : . P o o rg r o u n d{ G 5 0 ' 1 )
conditions T h e r es h o u l db e c o n t i n u i t v . . An oDenin the wire
7 BLK U n d e ra l l Checkfor continuityto ground: . P o o rg r o u n d( G 5 0 1 )
conditions Thereshould be continuitv. ' A n o p e ni n t h e w i r e
10 REDI/EL C o m b i n a t i o n Checkfor voltageto ground: B l o w nN o . 1 5 ( 1 5 A )f u s ei n t h e
light switch ON Thereshould be batteryvoltage. under-hoodfuse/relaybox
/ =f\\
Faultyheadlightrelay 2
Faultycombinationlight switch
An open in the wire
1 RED/BLU Combination Connecta jumper wire between B l o w nb u l b
light switch ON No.3 andNo.1terminals. Faultylow beam cut relay
{iD), and B o t hh e a d l i g h t (sH I G H a) n d Faultycombinationlight switch
dimmer switch h i g h b e a mi n d i c a t o lri g h t Poor ground (G50'l)
inHIGH s h o u l dc o m eo n . An open in the wire
'11
RED/BLK C o m b i n a t i o n Connecta jumper wire between . B l o w nb u l b
light switch ON N o . 5 a n d N o . 1 1t e r m i n a l s . . Faultycombinationlight switch
(iD), and (
R i g h th e a d l i g h t H I G H )
should . Poor ground (G50'1)
dimmer switch c o m eo n . . A n o p e ni n t h e w i r e
inHIGH
3 G R N / B L K C o mb i n a t i o n C h e c kf o r c o n t i n u l t yt o g r o u n d . Faultycombinationlight switch
5 light switch ON T h e r es h o u l db e c o n t i n u i t y . . P o o rg r o un d { G 5 0 1 )
(iD), and . A n o p e ni n t h e w i r e
dimmer switch
inHIGH
6 G R N / O R NParkingbrake C h e c kf o r c o n t i n u i t yt o g r o u n d : Faultyparkingbrakeswitch
l e v e ro u l l e d There should be continuitv. A n o p e ni n t h e w i r e
8 B L U / R E DC o m b i n a t i o n Checkfor voltageto ground: F a u l t yh e a d l i g hrt e l a y s
l i g h ts w i t c hO F F Thereshould be batteryvoltage. Short to ground
A n o o e ni n t h e w i r e
WHT/BLU lgnitionswitch Attachto ground: . B l o w nN o . 1 0 ( 7 . 5 A f)u s e i n t h e
o N0 r ) T h e D R Li n d i c a t o lri g h ts h o u l d under-dashfuse/relaybox
c o m eo n . . FaultyDRLindicator
. A n o o e ni n t h e w i r e
t5 GR N / R E D lgnition switch Attachto ground: Faultybrakesystem indicator
o N( | | ) T h e b r a k es y s t e ml i g h ts h o u l d A n o p e ni n t h e w i r e
c o m eo n .

22-77
ExteriorLights
HeadlightAdjustment \
2. Parkthe vehicle7.5 m (25 ft) away from a wall or a

screen(A).
Headlightsbecomevery hot during use;do not
touch them or any attachinghardwareimmediately 7.5m {25ftl
afterthey have beenturned off.
Beforeadiustingthe headlights:
. Parkthevehicleon a levelsurface.
. Makesurethetire pressures arecorrect.
. Thedriveror someonewho weighsthe sameshould
sit in the driver'sseat.
'1.
Cleanthe outer lens so that you can seethe center
of the headlights(A).
3 . O p e nt h e h o o d .
22-78
HeadlightReplacement
'1.
T u r nt h e l o w b e a m so n . Removethe front bumper (seepage 20-85).
5 Determineifthe headlightsare aimed properly. 2 . Disconnectthe connectors(A)from the headlight

(B).
Verticaladjustment:
Measurethe height ofthe headlights(A).The lights
should reflect52 mm (2.'1in.) below headljght
h e i g h t( B ) .
6. lf necessary,adjustthe headlightsto local

requirementsby turning the verticaladjuster.
Removethe five mounting bolts,then removethe

corner upper beam (C)and headlightassembly.
Installin the reverseorder of removal.
5 . After replacement,adjustthe headlightsto local

requirements.
22-79
ExteriorLights
CombinationLight Switch Test/Replacement
1. Removethe driver's dashboardlower cover (seepage 20-60).
2. Removethe steeringcolumn covers(seepage 17-9).
3 , D i s c o n n e c t t hle6 P c o n n e c t o r ( Af)r o m t h e c o m b i n a t i o nl i g h ts w i t c h( B ) .
4 . Removethe tlvo screws,then slide out the combinationlight switch.
5 . Inspectthe connectorterminalsto be surethey are all makinggood contact.
. lf the terminalsare bent, looseor corroded,repair them as necessary, a nd recheckthe system.

.lftheterminalslookOK,checkforcontinuitybetweentheterminalsineachswitchpositionaccordingtothe
tables.
- lf the continuityis not as specified,replacethe switch.
Light switch:
\ Telmint
4 5 12 13
Position
OFF
Headlight switch
LOW o--
HIGH o--
OFF
Passingswitch
ON
o-
Turn signalswitch:
\ Terminal
2 10 11
Position
LEFT ----o
NEUTRAL
RIGHT o--
22-80
Bulb Replacement
Headlight: FrontTurn SignalLight:
ParkingLight:
1. Disconnectthe 3P connector(A)from the headlight.
1 . R e m o v et h e i n n e rf e n d e r( s e ep a g e2 0 - 1 0 2 ) .
Headlight{high/low): 60/55 W
2. Disconnecttheconnectors(A) from the lights.
Frontturn signallight: 21W

Parkinglight: 5W
f-rI
-'-+l
A- )/
2. Removethe rubbercover (B).
Pullthe retainingspring (C)away from the bulb (D),

then removethe bulb. Turn the bulb sockets(B) 45'counterclockwiseto
removethem from the headlighthousing.
Installa new bulb in the reverseorder of removal.
Make sure the notchesin the bulb align with the 4 . Installthe new bulb(s)in the reverseorder of
t a b sl n t h e h e a d l i g h t . removat.
22-81
ExteriorLights
TaillightReplacement HighMount BrakeLight
Replacement
1 . Removethe rearbumper(seepage20-86).
2 . Openthetailgate,anddisconnect
the connectors 1. Open the hatch.
(A)fromthetaillight(B).
2. Removethe plastictrim.
Brako/Taillight; 2115W
TurnSignalLight: 21 W 3. Disconnectthe2P connectors(A)from the high
Back-upLight: 21W m o u n tb r a k el i g h t( B ) .
High Mounl BrakeLight: 5W x 5
=\\
ili--- _\ \
, \ .
r B ---'a
\r t
\ Carefullyremovethe high mount brakelight.
Removethe mounting nuts and bolts,then remove 5 . lnstallthe light in the reverseorder of removal.
t h et a i l l i g h t .
Turn the bulb socket45' counterclockwise

to
removethe bulb socket.
When installingthe taillight.checkthe gasket;if it is

distortedor stayscompressed,replaceit.
After installingthe taillight.run water over the

taillightto make sure it does not leak.
'
22-82
LicensePlateLight Replacement Side Marker Light Replacement
1 . Removethe hatch lower trim panel (seepage20- 1. Carefullyprythe light(A)outofthe rearbumper,
anddisconnect the 2Pconnector (B)fromthe light.
Becarefulnotto damagethe rearbumper.
P u l l t h el i c e n s ep l a l el i g h ta s s e m b l yo u t . a n d
disconnectthe 2P connector(A) from the light. Side Marker Light: 5W
LicensePlateLight: 5Wx2
'[-J^
,^f , t lo \
+tiP'-
' f l ^
t \-J
"/
\==-^ 2 . Removethe bulbsocket(A)by turningit 45'
3 . S e p a r a t et h e l e n s( B )a n d h o u s i n g( C ) ,t h e n r e m o v e counterclockwise.
thenreolace the bulb.
the bulb.
4 . l n s t a l l t h el i g h ti n t h e r e v e r s eo r d e ro f r e m o v a l .
22-83
ExteriorLights
BrakePedalPositionSwitch Test SideTurn SignalLight Replacement
1. Disconnectthe4P connector(A) from the brake NOTE:Be careful nol to damagethe fender.
pedal positionswitch {B).
1 . P u s ht h e r e t a i n i n gs p r i n g( A ) .a n d r e m o v et h e s i d e
t u r n s i g n a l i g h t( B ) ,
Side Turn Signal Light: 5W
Checkfor continuitybetweenthe No. 1 and No. 2

termtnals.
2. Disconnectthe 2P connector{C)from the light.
. T h e r es h o u l db e c o n t i n u i t yw h e n t h e b r a k ep e d a l
rs presseo.
. Thereshould be no continuitywhen the brake
pedal is released.

terminals{with cruisecontrol).
T h e r es h o u l db e n o c o n t i n u i t yw h e n t h e b r a k e
pedal is pressed.
T h e r es h o u l db e c o n t i n u i t yw h e n t h e b r a k ep e d a l
is released.
lf necessary,adjustor replacethe switch,or adjust

t h e p e d a lh e i g h t( s e ep a g e1 9 - 6 ) .
22-84
TurnSignal/Hazard
Flasher
COMBINATION LIGHT/TURN
SIGNALSWITCH
Test,page22-80
page22-80
Beplacement,
TURNSIGNALINDICATOR LIGHTS
(lnthegaugeassembly)
page22'63
BulbReplacement,
HAZARDWARNINGSWITCH
Test,page22-88
page22-88
Replacement,
TURNSIGNAL/HAZARDRELAY
InputTest,page22-87
FUSE/RELAY
UNDER.DASH BOX
22-85
TurnSignal/Hazard
Flasher
CircuitDiagram \
'No20lr0A
USA
DASH
Ut\toEB No.2{
l50A):Cmada
UNDff HOOD
FUSUftIIY8OX TUSVRILAY
8OX
fiIGHTT
INDICATON FBONT
IIGHT
11.1W)
22-86
RelayInputTest
TurnSignal/Hazard
1 . R e m o v e t h e t u r ns i g n a l / h a z a rrde l a y( A )f r o m t h e u n d e r - d a sfhu s e / r e l a yb o x ( B ) .
000i0!1000
00u!u0
Inspectthe relay and fuse/relaybox socketterminalsto be sure they are all makinggood contact
. lf the terminalsare bent.loose,or corroded,repairthem as necessary,and recheckthesystem.

Make these input tests at the fuse/relaybox.
.lfanvtestindicatesaproblem,findandcorrectthecause,thenrecheckthesystem.
. l f a l l t h e i n p u t t e s t sp r o v eO K , t h e t u r ns i g n a l / h a z a rrde l a ym u s t b e f a u l t y .R e p l a c ei t
Cavitv Tesl condition Test: Desired result Possiblecauseil resultis not obtained
1 U n d e ra l l c o n d i t i o n s Checkfor continuityto ground: . P o o rg r o u n d( G 2 0 1 )
Thereshould be continuiw. . An ooenin thewire
3 lgnitionswitch ON ll) ( Check for voltage to ground: ' Blown No. 19 (7.5A)fuse in the
Hazardwarning switch Thereshould be batteryvoltage. under-dashfuse/relaybox
OFF . Faultyhazardwarning switch
. A n o o e ni n t h e w i r e
Hazard warningswitch Checkfor voltageto ground: . Blown No. 5 {10A)fuse in the
ON There should be battery voltage. under-hoodfuse/relaybox
lgnitionswitchOFF . Faultyhazardwarning switch
. An ooen in the wire
2 (
l g n i t i o ns w i t c hO N l l ) C o n n e cN t o . 2 t e r m i n a l t oN o . 3 . P o o rg r o u n d( G 2 0 1G , 3 0 1 ,G 5 0 1 ,
and turn signal switch terminal: G502, G553)
in Rightor Left position R i g h to r l e f tt u r n s i g n a l i g h t s . Faultyturn signalswitch
s h o u l dc o m e o n . . A n o D e ni n t h e w i r e
lgnitionswitch OFF C o n n e cN t o . 2 t e r m i n a tl o N o . 3 . P o o rg r o u n d( G 2 0 1G , 3 0 1 ,G 5 0 1 ,
Hazardwarning switch t e r m r n a l : G502, G553)
ON H a z a r dw a r n i n gl i g h t ss h o u l d . Faultyhazardwarning switch
c o m eo n . . An open in lhe wire

22-87
TurnSignal/Hazard
Flasher
HazardWarningSwitch Test
1 . Removethe centerpanel (seepage 20-62).
2 . Disconnectthe 10Pconnector(A)from the hazard

w a r n i n gs w i t c h( B ) .
3 . Pushout the hazardwarning switch from behind

t h e c e n t e rp a n e l( C ) .
4 . Checkfor continuitybetweenthe terminalsin each

lf the continuityis not as specified,replacethe bulb

( D )o r t h e h a z a r dw a r n i n gs w i t c h .
\ Termin6l
1 2 4 7 10
;;;-_-\
OFF
ON @
22-88
Entry Light ControlSystem
CEILINGLIGHT/SPOTLIGHTS
Test,page22-96
REARCEILING LIGHT
Test,page22-96
page22-96
Replacement,
FRONTPASSENGER'S
DOORSWITCH
IGNITIONKEYLIGHT
Test,page22-91
IGNITIONKEY SWITCH HATCHLATCHSWITCH

lest, page22-91 Test,page22-97
DRIVER'SDOORSWITCH CARGO AREALIGHT

Test,page22-97
page22 97
Replacement,
22-89
EntryLightControlSystem
CircuitDiagram t J
'No.20({0A)
USA
UiIOTf,HOOD
fUSE/8ELAY
BOX
EiIIpN
SMTqI
lGlHoTin0Nilll
nd STAnT0D CEILING
UGHT
Y
I
I
\ J
DtrVTN'S
DOOR
Locx
(NOB
ORIVEBS
DOOR
SWITCH
PASSTNGERS
DOOB
SWITCH
IGNIlx)N
KEY
SWtTCH
j
l'
s!t/tTc8 i9r"..d l
BU
I
G()t
22-90
\
lgnition KeySwitch Test lgnition Key Light Test
NOTE:For more key-inbeeperinformation,referto the 1 . Removethe steeringcolumn upper and lower

circuitdiagram (seepage 22-90)and input test (see covers(seepage 17-9).
page 22-921.
Disconnectthe 6P connector,
When the ignition key is in the ignition switchthe
multiplexcontrol unit sensesground through the
closedignition key switch.When you open the driver's
door, the multiplexcontrol unit sensesground through
the closeddoor switch and soundsthe beeper.
i'
1. Removethe steeringcolumn upper and lower /.'
c o v e r s( s e ep a g e ' 1 7 - 9 ) .
2. Disconnectthe 6P connector.
The LEDshouldcome on when power is connected

to the No. 6 terminal and ground is connectedto
N o .5 t e r m i n a l .
lf the LEDdoes not come on, replacethe ignition

swrtch.
3 . Checkfor continuitybetweenthe No. 1 and No. 2

termrnars.
. There should be continuitywith the key in the

ignition switch.
. Thereshould be no continuitywith the key
removedfrom the ignitionswitch.
lf the continuityis not as specfied,replacethe

ignition switch.
22-91
EntryLightControlSystem
Control Unit Input Test
1. Beforetesting,trou bleshootthe m u ltiplex control system (seepage22-172).
2. Removethe dashboardlower cover.
3. Disconnectthe under-dashfuse/relaybox connectors.
NOTE:All connectorsare wire side of femaleterminals.
UNDER.DASH
FUSE/RELAY
BOXCONNECTOR
K Il7PI
UNDEB-DASIJ
FUSE/RELAYBOX CONNECTOR
O {,I2PI
GRN/RED
UNDEB.DASH
FUSE/RELAY
BOXCONNECTOR
P {18PI
3 4 5 6),/18.
GRN LT GRN/REO
UNOER.DASHFUSE/REI"AY
BOX CONNECTOBX I8PI
1 ,/13 4 5 7 8
8ED/WHT WHT/BLK
UNDER.DASH
FUSE/RELAY
BOXCONNECTOR
Y {13PI
YEL/RED
4 . Inspectthe connectorand socketterminalsto be sure they are all making good contact.
. lf the terminalsare bent, looseorcorroded, repairthem as necessary,and recheckthe system.

22-92
I
maketheseinputtestsat theconnector'
stilldisconnected,
5. Withtheconnectors
. lf anvtestindicates a problem,find andcorrectthe cause,then recheck
the system
. lf allthe inpultestsproveOK,go to step6.
Cavitv Wire Test condition Test:Desiredresult Possiblecquseil resultis not obtained

K2 8LU/ORN lJnderallconditions Checkfor continuitybetweenthe K2 An open in the wire
terminalandthe keylessreceiver
unit5Pconnector No.2 terminal:
Thereshouldbecontinuitv.
o7 GRN/RED C e j l i n gl i g h t s w i t c h i n Attachto ground: BlownNo.3 (7.5A)fusein the underhood
middle position. comeon.
Ceilinglight(s)should
Blownbulb
Faultyceilinglight
An ooenin the wire
X8 r l l c o n d i t i o n s Attachto ground:
WHT/BLK U n d e a ElownNo.3 (7.5A)fuse in the underhood
lgnitionkeylightshouldcomeon. fuse/relay
box
Faultyignitionkeylight(LED)
An ooenin the wire
6. Reconnect to the underdashfuse/relaV

the connectors on the under-dash
connectors
box,and maketheseinputtestsat the appropriate
fuse/relay
box.
.lfalltheinputtestsproveOK,themultiplexcontrolunitmustbefaulty.Replacetheunder'dashfuse/relaYboxassemblY
Cavitv Wire Test condition Test:Desiredresult Posq!!!c sq!!ej1!.9!!!!j €d

P18 RED H a t c ho p e n C h e c kf o r v o l t a g et o g r o u n d : Poorground(G552)
Thereshould be 1 V or less. Fauhyhatchlatchswitch
An openinthewire
H a t c hc l o s e d Checkfor voltageto ground: Faultyhatchlatchswitch
Thereshouldbe 5 v or more. Shorttooround
Q3 GRN Driver'sdooropen C h e c kf o r v o l t a g e t o g r o u n d : Faultydrlver'sdoorswitch
Thereshould be 1 V or less. An oDenin thewire
Driver'sdoorclosed Checkfor voltageto ground: Faultydriver'sdoorswitch
Thar. shoul.lhe 5 V or more.
o4 LTGRN/ Passenger's
door Checkfor voltageto ground: ' Faultypassenger'sdoorswitch
BED Thereshouldbe 1 V or less. ' An oneninthewire
Passenger's door Checkforvoltageto ground: . Faultypassenger'sdoorswitch
croseo Thereshouldbe 5 Vor more. . Shor o oround
X5 RED^vHT lgnitionkey inserted Checkfor voltageto ground: Poorground(G401)
intothe ignition Thereshouldbe 1 V or less. Faultyignitionkeyswitch
An ooenin the wire
lgnitionkey removed C h e c kf o r v o l t a g et o g r o u n d : F a u l t yi g n i t i o n k e y s w i t c h
from the ignition Thereshould be 5 V or more. Short to ground
Y8 YEURED Driver'sdoorlock Checkfor voltageto ground: Poorground{G501)

knob switchlocked Thereshouldbe 1 V or less. Faultydriver'sdoorlockknobswitch
An ooenin thewire
Driver'sdoorlock Checkfor voltageto ground: Faultydriver'sdoorlockknobswitch
kn6h cwirch Inl6cke.l Thereshouldbe 5 V or more. Shortto oround

22-93
InteriorLights
ComponentLocationIndex u J
CEILINGLIGHT/SPOTLIGHTS
Test,page22-96
page22-96
Replacement,
REARCEILING LIGHT
Test,page22-96
page22-96
Replacement,
v J
HATCHLATCHSWITCH
Test,page22-97
CARGOAREALIGHT
fesl, page 22-97
Replacement, page22-97
$ J
22-94
CircuitDiagram
STAB
ctu[G
LIGHT
MUITIPLEX
c0NTlot
UIIIT
\ J
HATCH
LATClI
swtTcH
22-95
Interior Lights
CeilingLight/SpotlightsTest/ RearCeilingLight Test/
Replacement Replacement
1 . Turn the ceiling lighvspotlightsswitchesOFF. 1 . Turn the light switch OFF.
2 . Carefullypry off the lens {A) wilh a small 2 . Carefullypry offthe lens (A) with a small
screwdnver, screwdriver.
CeilingLight: 5W CeilingLight: 8 W
Spotlight: 5Wx2
x 1-0 mm
5x1.0mm
\A
3. Removethe two screwsand the housing(B). A.
t e 4 Pc o n n e c t o(rC )f r o m t h e h o u s i n g .
4 . D i s c o n n e ct h 3. Removethe two mounting screws.
5. Checkfor continuitybetweenthe terminalsin each 4. Disconnectthe 3P connector(B)from the housing

switch positionaccordingto the table. {c).
Terminal Checkfor continuitybetweenthe terminalsin each
\ -----_l il
P."lil;- switch positionaccordingto the table.
oFF
celL,"ca,c", Terminal
isoottiohts\ MIDDLE re -o 1 2 3
'uir Position
oN a}-+4 -o
OFF
R
ON o (.F.O
SPOTLIGHTS OFF MIDDLE o
I C e i l i n ql i o h t
r o F F - - i
L
ON G- ON G -@- O
OFF
lf the continuityis not as specified,checkthe bulb.
lf the continuityis not as specified,checkthe bulb. l f t h e b u l b i s O K , r e p l a c et h e r e a rc e i l i n gl i g h t .
l f t h e b u l bi s O K , r e p l a c et h e c e i l i n gl i g h v s p o t l ihgt s .
22-96
CargoArea Light Test/Replacement Hatch Latch Switch Test
'1.
1 . Open the hatch. Open the hatch.
Carefullypry out the cargo area light (A). Removethe hatch lower trim panel (seepage 20-
s3).
CargoArea Light: 5W
Disconnectthe 2P connector{A) from the hatch
l a t c h( B ) ,
Disconnectthe 2P connector(B)from the light.
Checkfor continuitybetweenthe No. 1 (+) and 4 . Checkfor continuitybetweenthe No. 1 and No. 2
N o . 2 ( ) t e r m i n a l sT. h e r es h o u l db e c o n t i n u i t y . terminals.
lf there is no continuitv,checkthe bulb. lf the bulb
is OK, replacethe cargo area light. . Thereshould be continuitywith the hatch open
. Thereshould be no continuitywith the hatch
ctoseo.
lf the continuityis not as specified,replacethe

hatch latch.

22-97
AudioSystem
AUOIOUNIT
Removal/f
nstallation,
Daoe22-100
Connector
Terminals,pa-ge
22-101
RIGHTDOOBTWEETER
page22-102
Replacement,
ROOFANTENNA
page22-'1
Replacement, 03
ANTENNA SUB LEAD
DRIVER'SDOORSPEAKER
page22 102
Replacement,
LEFTREARSPEAKER
page22-102
Replacement,
RIGHTREARSPEAKER
page22-102
Replacement,
ANTENNA LEAD
22-98
t CircuitDiagram
'
No.20ioA)
:USA
/ 8AT \
--------F f!t- WHT/FED
\ ACC/
ACC
HoTinACC
lllmd0Nllll
AUDIO
UflIT
t - r a - r : - r a O e ? a
DRIVER'S IEFITWEETER PASSE!{GIF'S SIGIITTWEETEB LEFTFEAB NrcBTREAF

DOORSPEArcF DOOB
SPEAKES SPEA(I8 SPEAKEF

22-99
AudioSystem
Audio Unit Removal/lnstallation !\,
NOTE: Removethe heatercontrol panel (seepage 21 38).
. Takecare not to scratchthe dashboardand related R e m o v et h e f o u r m o u n t i n gb o l t sa n d t h e a u d i ou n i t
parts. from the radio brackets.

presetbuttons.
2. Removethe driver's dashboardlower cover (see

page20-59).
3. Removethe two mounting bolts,then pull out the

centerpanel (A).
7 . I n s t a l l t h ea u d i ou n i ti n t h e r e v e r s eo r d e ro f
\v
. Make sure the audio unit and A/C connectorsare
pluggedin properly,and the antennalead is
connectedproperly.
4 . Disconnectthe audio connector(B)and antenna the customer'sradio stationpresets.
lead (C),heatercontrol panelconnectors(D) and
HAVCpush switch assembly(E),then removethe
center panel.
22-100
Audio Unit ConnectorReplacement
Cavity Wire Connectsto
1 YEUGRN Roof antenna
2 YEURED ACC (Power)
3 Not used
4 Not used
5 PNK R i o h tr e a rs D e a k e(r+ I
6 BLU^/vHT (+)
LeftrearsDeaker
7 GRN/YEL Front oassenqer'sdoor sDeaker{+)/Riqht tweeter (+)
8 GRN/BLK Driver'sdoor speaker{ + )/Lefttweeter (+ )
9 RED/BLK Liqhts on siqnal
10 WHT/RED Constantpower
11 Not used
12 Not used
Not used
14 Notused
ta BLU/YEL R i o h tr e a rs o e a k e (r -
to BLU/BLK Left rear sDeaker(
11 GRY/RED Front passenqer'sdoor speaker( )/Riqhttweeter{
18 LT GRN Driver'sdoor sDeaker( )/Lefttweetr ( -
19 RED Dashliqhts briqhtnesscontroller
20 BLK Gr o u n d( G 5 0 3 )
AUDIOUNIT2OPCONNECTOR

22-101
AudioSystem
SpeakerReplacement
DoorSpeaker: Rear:
1 . R e m o v et h e d o o r p a n e l( s e e p a g e 2 0 - 4 ) . 1 . Removethe speakercover (A).
2. Pullthe top of the speaker{A) straightout, just 2. Removethe three screws,then disconnectthe 2P
enoughto releasethe upper clip. lf you pull the connector(B)from the speaker(C).
speakerout too far, you will damagethe lower clips
(C).Then lifi the speakerstraightup to releasethe
lower clips.
3. Disconnectthe 2P connector(B),and removethe

speaKer.
Tweeter:
Carefullypry the tweeter (A) out of the mirror mount
cover,then disconnectthe 2P connector(B)from the
'-----d
tweeter.
22-102
RoofAntennaReplacement
1. Removethe rear part of headliner(seepage20-54).
2, Disconnectthe antennalead connector(A) and 1P

connector(B)from the roof antenna(C).
3. Removethe mounting nut and the antenna.
22-103
RearWindow Defogger
ComponentLocationIndex t J
*:Rearwindow defoggerswitch is built into the heatercontrol panel.
REARWINDOWDEFOGGER
RELAY
UNDER.HOOD
FUSE/RELAY
BOX Test,page22-51
REARWINDOW
DEFOGGERSWITCH+
u I
NOISE
CONDENSER
page22 107
CapacityTest,
REARWINDOWDEFOGGEB
Test,page22 106
Function
DefoggerWire Repair,page22 106
22-104
J CircuitDiagram
T f,rAiwrxDow
,74 DEfOGGES
;Hl}lj.'fl,1fl1fi" BEATERcoNrf,oLpANrL(\iP\/ I SWrcfl
INDIATOR
t
L ILEDI
22-105
RearWindowDefogger
FunctionTest DefoggerWire Repair
NOTE: NOTE:To make an effectiverepair,the brokensection
. Be carefulnot to scratchor damagethe defogger m u s t b e n o l o n g e rt h a n o n e i n c h .
wires with the testerprobe.
. Beforetesting,checkthe No. 11 (30A)fuse in the 1. Lightly rub the area aroundthe brokensection(A)
'14('10A)
under-hoodfuse/relaybox and No. fuse in with fine steelwool, then clean it with alcohol.
the under-dashfuse/relaybox.
1. Checkfor voltage betweenthe verticaI dividersand

body ground with the ignitionswitch and defogger
switch ON.
There should be voltageas shown.
. lf there is no voltage.checkfor:
- faulty defoggerrelay.
- an open in the BLK,BLK,/YEL, or YEL/BLKwire.
- taulty heatercontrol panel.
. lf there is batteryvoltage,goto step 2.
2. Carefullymask above and below the brokenportion

of the defoggerwire (B)with transparenttape {C).
Mix the silverconductivepaint thoroughly.Using a

small brush,apply a heavy coat of paint extending
about 1/8 inch on both sidesof the break.Allow 30
minutesto dry.
6V
2 . Checkfor continuitybetweenthe negativeterminal

( B )a n d b o d y g r o u n d .
lf there is no continuity,checkfor:
. a n o p e n i n t h e B L Kw i r e .
. Poor body ground at the window antennacoil
mounting bolt.
Touchthe voltmeterpositiveprobe to the halfway

point of each defoggerwire. and the negative
probeto the negativeterminal,
Thereshould be about 6 V with the ignitionswitch Checkfor continuityin the repairedwire.
and the defoggerswitch ON.
5 . Apply a secondcoat of paint in the same way. Let it
. l f t h e v o l t a g ei s a s s p e c i f i e dt ,h e d e f o g g e r w l r ei s dry 3 hours before removingthe tape.
oK.
. lf the voltage is not as specified,repairthe
defoggerwire.
- l f i t i s m o r et h a n 6 V , t h e r ei s a b r e a ki n t h e
n e g a t i v eh a l fo f t h e w i r e .
- lf it is lessthan 6 V, there is a breakin the
positivehalf of the wire.
22-106
NoiseGondenserCapacityTest
1 . Removethe right rear side trim panel (seepage 20-
66).
Disconnectthe 2P connector(A)from the noise

condenser.
Noise condenser capacity:

0.47 a 0.09 microfarads
Use a commerciallyavailablecondensertester.
Connectthe condensertester probes,and the
measurecondensercapacity.
4. lf it is not within the specification,replacethe noise

condenser.
22-107
Moonroof
MOONROOF SWITCH
f e $ , p a g e2 2 - 1 1 2
R e p l a c e m epnat ,g e2 2 - 1 2
T e s tp. a g e 2 2 - 1 1 2
MOONROOFLIMIT SWITCH
Test,page22-113
\|.
MOONROOF CONTROLUNIT
InputTest,page22-'l10
MOONROOFAUTO-STOPSWITCH MOONROOF OPENRELAY

Test,page22'113
lwire colors:GRN/YEL,
GRN, I
LRED/YEL, BLKandYEUGRNI
Test,page22-51
MOONROOF CLOSERELAY
lwire colorsrGRN/BLK,
GRN, I
LGRN/WHT, BLKand YEL/GRNI
Test,page22-51
22-108
CircuitDiagram
-
No.20lOAl:US
UNDIR OAS8FUSE/NILAY
MX No.20150
) :Canda
A Clos.dfom lh€ ruto nop poshio. to lh€ doed porhion

B Clo!.d in th€ lilt or do3.d poilion
C : Clo!.d in anyop.n (io! riltl posirion
D Clos.d in th€ tilt po6iiion
BL|( 8LI
+
G50t
I
G5{1
22-109
Moonroof
MoonroofControlUnit Input Test I J
1 . R e m o vteh eh e a d l i n e( sr e ep a g e2 0 - 5 4 ) .
2 . Disconnect (A)fromthecontrolunit(B).
the 5Pconnector
GRN/WHT LT GRN
2 Wire sideof
1 3 4 5 f e m a l et e r m i n a l s
RED/YEL BLK
Inspectthe connectorand socketterminalsto be sure they are all making good contact. b J
. lf the terminalsare bent, looseor corroded,repairthem asnecessary.and recheckthesystem.
$ J
22-110
4- Reconnect
the moonroolcontrolunit5Pconnector,
andmaketheseinputtestsattheconnector.
. lf all the inputtestsproveOK,go to step5.
Caviiy Wire Test condition Test:Desiredresuh Possiblecaus6if result is not obtained
5 BLK Underallconditions Checkfor continuityto ground: Poorground(G501)

Thereshouldbe continuity. An openin the wire
,l
YEUGRN lgnitionswitchON (ll) C h e c kf o r v o l t a g e t o g r o u n d : BlownNo.6 (7.54)tusein the under
There should be baftery voltage. dashfuse/relaybox
An openin the wire
LT GRN lgnitionswitchON (ll) C h e c kf o r v o l t a g et o g r o u n d : Poorground(G501)

Moonroofclosed Thereshould be 1V or less. Faultymoonroof auto-stopswitch
An openinthewire
Moonroof open Checkfor voltageto ground: Shorttoground

Thereshouldbe batteryvoltage. Faultymoonroofauto-stop
switch
Disconnectthe
moonroofcontrolunit5Pconnector,
andmakethese;nputtests
at the connector
'lfanytestindicatesaproblem,findandcorrectthecause,thenrecheckthesystem.
. lf all the inputtestsproveOK,the controlunit mustbefaultv.Replace
it.
Cavity Wire Test condition Test:Desiredrosult Possiblecauseif resultis not obtained
3 RED//EL lgnitionswitchON lll) Connecta jumperwire betweenNo, Poorground(G501)

3 and No.5 terminals. BlownNo.6 (7.5Aifusein the under'
Moonroofmotorshouldrun dashfuse/relaybox
(opened). BlownNo.7120Alfuse inthe under
dashfuse/relay box
Faultymoonroofopenrelay
Faultymoonroofcloserelay
FaultymoonrooJmotor
A n o p e n ; nt h e w i r e
2 cRN,4/VHTl g n i t i o n s w i t c h O N ( l l ) Connecta jumperwire betweenNo. Poorground(G501)

2 and No.5 terminals. BlownNo.6 (7.5Aifusein the under
I\,4oonroof
motorshouldrun {closed). dashfuse/relaybox
ElownNo.7 (20A)fusein the under
dashfuse/relaybox
Faultymoonroofopenrelay
Faultymoonroolcloserelay
Faultymoonroof motor
An openin thewire
22-111
Moonroof
Switch Test/Replacement Motor Test \ J
'1 1 . R e m o v et h e h e a d l i n e(rs e ep a g e2 0 - 5 4 ) .
. Carefullypry the moonroof switch (A) out of the
headlin
er.
2. Disconnectthe 2P connectorfrom the moonroof
motor.
2. Disconnectthe5P connector(Blfrom the moonroof 3. Checkthe motor by connectingpower and ground

swtrcn. accordinoto the table.
3. Checkfor continuitybetweenthe terminalsin each \ Terminal J

switch positionaccordingto the table. pl.iri""---\
\ Terminal
--\
OPEN \7 o
1 4 5
Pi.iti.. CLOSE (,
CLOSE FO
TILT lf the motor does not run. replaceit,
OPEN -o NOTE:See closingforce check(seepage20-48)for

motor clutchtest.
4 . lf the continuityis not as specified.replacethe
moonroof switch.
22-112
Limit Switch Test Auto-stopSwitch Test
l . Removethe headliner(seepage 20-54). 1 . Removethe headliner(seepage 20-54).
2. Disconnectthe 4P connectorfrom the moonroof 2 . Disconnectthe 2P connectorfrom the moonroof

limit switch. auto-stopswitch.
Checkfor continuily betweenthe terminalsin each Checkfor continuitybetweenthe terminalsin each

switch positionaccordingto the table. switch positionaccordingto the table.
NOTE:Turn the motor by hand with the wrench. NOTE:

. Turn the motor by hand with the wrench,
\ Terminal . The auto-stoppositionis about 145 mm (5.75in.)
1 3 4
Position from fully closed.
TILT o- o- Terminal
1 2
OPEN Position
CLOSE BotwoenAUTO-STOP
andCLOSE
lf the continuityis not as specified,replacethe Between OPEN and

AUTO.STOP
moonroof limit switch.
lf the continuityis not as specified,repairor replace

the auto-stopswitch.
22-113
PowerMirrors
POWERMIRRORS
FunctionTest,page22-116
ActuatorTest,page22-117
ActuatorReplacemenl,page22-118
q3:.[ ---\,--,-'/
j-' ',i. it .i/
-:,)
'\ \,
-,''
-lo'
t:
-o '
,.'7
POWERMIRRORand
MIRRORDEFOGGERSWITCH
lesl, page22-111
$r-
22-114
CircuitDiagram
'1
ih.a i|0At :Usa
UiD$ DASH
UiIDTSrcODR]SE/R€LAY
8OX rcilmoN
s1/vtTcH N'SUnIIAY8OX
t J
22-115
PowerMirrors
FunctionTest
1. Removethe driver's pocket(seepage 20-60). Left mirror
2. Reachthrough the pocketopening,and push out 7 . C o n n e ctth e N o . 2 t e r m i n a tl o t h e N o . l 0 t e r m i n a l ,

the power mirror switch (A). a n dt h e N o . 5 ( o r N o . 1 2 )t e r m i n a tl o t h e N o . 6
t e r m i n aw l i t h j u m p e rw i r e s .T h e l e f tm i r r o rs h o u l d
t i l t d o w n ( o r s w i n gl e f t ) w i t ht h e i g n i t i o ns w i t c hO N
, \
flr).
. l f t h e m i r r o r d o e sn o t t i l t d o w n ( o r d o e sn o t s w i n g
left),checkfor an open in the GRN/WHT(or BLU/
Wl-lT)wirebetweenthe left mirror and the 13P
conneclor,lf the wire is OK, checkthe left m irror
actualor.
. lf the mirror neithertiltsdown nor swings left.
r e p a i rt h e B L U / B L K wire.
. l f t h e m i r r o r w o r k sp r o p e r l yc, h e c k t h em i r r o r
RED B SWIICN,
Right mirror
W i r es i d eo f
t e m a l et e r m i n a l s
8 . C o n n e ctth e N o . 2 t e r m i n a l t ot h e N o . 1 1t e r m i n a l ,
WHT/RED a n d t h e N o . 5 { o r N o . 1 3 )t e r m i n a tl o t h e N o . 6
terminaw l i t h j u m p e rw i r e s .T h e r i g h tm i r r o rs h o u l d
RED/BLK RED/YEL tilt down (or swing left)with the ignition switch ON
( ).
o n n e c t o(rB )f r o m t h e s w i t c h .
3 . D i s c o n n e c t t h e ' 1 3cP . lf the mirror does not tilt down (or does not swing
left),checkfor an open in the GRN/WHT(or WHT/
4. Choosethe appropriatetest basedon the R E D ) w i r eb e t w e e nt h e r i g h tm i r r o ra n d t h e 1 3 P
symptom: connector.
. Both mirrors don't work, go to step 5. lf the wire is OK, checkthe right mirror actuator.
. Left mirror doesn'twork, go to step 7. . l f t h e m i r r o r n e i t h e r t i l t s d o w n o r s w i n g sl e f t ,
. Rightmirror doesn'twork, go to step 8. repalrthe RED|YELwire.
. Defoggerdoesn'twork (Canada),go to step 9. ' l f t h e m i r r o r w o r k sp r o p e r l yc. h e c k t h em i r r o r
swrrcn.
Both mirrors
Defogger(Canada)
5. Checkfor voltage betweenthe No. 2 terminal and
b o d y g r o u n dw i t h t h e i g n i t l o ns w i t c hO N ( l l ) . 9 . C o n n e ctth e N o . 1 a n d N o . I t e r m i n a l sw i t h a
There should be batteryvoltage. jumper wire, and checkfor voltage betweenthe
. lf there is no batteryvoltage,checkfor: N o . 2 t e r m i n a lo f t h e m i r r o rc o n n e c t oar n d b o d y
- b l o w n N o . 1 4 ( 1 0 A )f u s e i n t h e u n d e r ' d a s h ground.Thereshould be batteryvoltageand both
fuse/relaybox. m i r r o r ss h o u l dw a r m u p w i t h t h e i g n i t i o ns w i t c h
- a n o p e ni n t h e B L K r y E L wire. oN t).
. lf there is batteryvoltage,goto step 6. . l f t h e r ei s n o v o l t a g eo r n e i t h e r w a r m su p , c h e c k
for:
6. Checkfor continuitybetweenthe No. 6 terminal - a n o p e n i n t h e B L K I / E Lo r o R N w i r e .
a n d b o d yg r o u n d . - b l o w n N o . 1 4 ( ' l 0 A ) f u s ei n t h e u n d e r - d a s h
T h e r es h o u l db e c o n t i n u i t y . fuse/relaybox.
. lf there is no continuity,checkfor: . l f o n l y o n e f a i l st o w a r m u p , c h e c k :
- a n o p e ni n t h e B L Kw i r e . - its defogger.
- p o o r g r o u n d( G 5 0 1 ) . - p o o r g r o u n d( G 5 0 1G , 502)
. lf there is continuity,checkboth mirrors . l f b o t hw a r m u p , c h e c k t h e d e f o g g e r s w i t c h .
i n d i v i d u a l la
y s d e s c r i b e di n t h e n e x tc o l u m n .
22-116
PowerMirror Switch Test Power Mirror ActuatorTest
1 . Removethe driver'spocket(seepage 20-60). 1 , Removethe door panel (seepage 20-4).
2 . Reachthrough the pocketopening,and push out 2 . Disconnectthe 6P connector(A) from the power
the power mirror switch (A). m i r r o ra c t u a t o r( B ) .
3 . Disconnectthe 13Pconnector(B)f rom the switch.

Checkactuatoroperationby connectingpower and
Mirror Switch: ground accordingto the table.
\.f9.-'"1L 2 5 6 10 11 12 13 \ Terminal
6 4
Position Position
--o
UP
CF
o- o
TILTUP o o
o- o
TILTDOWN o
G -c) SWINGLEFT o @
o- -o SWING RIGHT @
o- !
-o 4. lf the mirror fails to work properly,replacethe
RIGHT -o
o mtrror actuator.
UP
DefoggerTest {Canada);
"[T 5 . C h e c kf o r c o n t i n u i t yb e t w e e nt h e N o . 1 a n d N o . 2
terminalsof the 6P connector.Thereshould be
continuity.lf there is no continuity,checkfor an
open circuit.
RIGHT
Defogger Switch (Canadal:
Te.minal
\ tlf I 8
il;;;
ON o o
OFF
5 . lf the continuityis not as specified,replacethe

power mirror switch.
22-117
PowerMirrors
PowerMirror Actuator Replacement \ 4
'1.
Removethe power mirror (seepage 20-15). 8. Removethe three Torx screws,and separatelhe
actuator(A)from the mirror housing{B).
2 . Carefullyremovethe mirror holderfrom the mirror
. e n t l yp u l l i t o u t b y h a n d( s e ep a g e2 0 - 1 5 ) .
h o u s i n gG
3 . Disconnectthe connector.
4 . Removethe cover,then removethe two Torx

screwsfrom the mirror connector.
5 . Recordthe terminal locationsand wire colors.
6 . Cut the wire harnesswith the wire cutter.
9 . Routethe wire harness{A) ofthe new actuator

t h r o u g ht h e h o l ei n t h e b r a c k e (t B ) .
\ J
7. Removethe three screws,and separatethe mirror

housinqfrom the mirror base.
22-118
10. lnsertthe terminalsinto the connectorin the
o r i g i n aa
l r r a n g e m e nat s s h o w nb e l o w .
LEFTMIRROR
CONNECTOR RIGHTMIRROR
CONNECTOR
*:Canada
'l'1.
Reassemblein the reverseorder of disassembly.
Be carefulnot to breakthe mirror holderwhen
reinstallingit to the actuator.
1 2 .R e i n s t a l l t h m
e i r r o ra s s e m b l yo n t h e d o o r .
tJ. Operatethe power mirror to ensuresmooth

operation.
22-119
Horns
ComponentLocationIndex \
UNDER-HOOD
FUSE/RELAY
BOX
HORNRELAY
Test,page22-51
.-
:.."'
HORNSWITCH
fesl, page22-122
CABLEREEL
HORNS page23,119
Replacement,
Test,page22 122
B e p l a c e m e npt a
, g e2 2 1 2 2
*r
22-120
J GircuitDiagram

22-121
Horns
Horn Test/Replacement Horn Switch Test
1 . Removethe front bumper {seepage 20-85). 1 . Removethe steeringcolumn covers(seepage '17-
9).
Disconnectthe 1Pconnector(B),and removethe
horn (A). Disconneclthe dashboardwire harnessB 5P
connector(A) from the cable reel (B).
|. . . . : .../..
...,
3 . Testthe horn by connectingbatterypower to the

terminal (A) and ground to the bracket(B).The horn
s h o u l ds o u n d .
Using a jumper wire . connectthe dashboardwire

harnessB 5P connector(A) No. 2 terminal to body
g r o u n d.
. lf the horns sound,goto step 4.

. l f t h e h o r n sd o n o t s o u n d ,c h e c k t h e s ei t e m s :
- Horn relay
- N o . 7 ( 1 5 A ) f u s ei n t h e u n d e r - h o o fdu s e / r e l a y
box
- Horns (see page 22-122).
- An open in the wire
4. lf it fails to sound, replaceit.
22-122
I
4. Reconnect wire harnessB 5P
the dashboard 1 . Usinga jumperwire,connentthe steering
wheelto
connector{A),anddisconnectthe hornswitch b o d yg r o u n d .
positive1Pconnector(B).
8 . Closethecontactsbetweenthe hornplateandthe
contactplate.
. lf the hornssound,replacethesteeringcolumn.
. l f t h eh o r n s d on o t s o u n dr,e p l a c e t hheo r na n d
contactplate.
Using a jumperwire, connectthehorn switch

positive1Pconnector(B)to ground
. lf the horns sound,go to step 6.

. l f t h e h o r n sd o n o t s o u n d ,r e p l a c e t h e c a b lree e l .
6 , Reconnectthe horn switch positive1Pconector(B).
22-123
PowerWindows
ComponentLocationIndex I J
UNDER.DASH
FUSE/RELAY
BOX
al.l ' -f..--.-- POWERWINDOWRELAY

Iest, page22-51
L - . : :
FRONTPASSENGER'S
WINDOWMOTOR
Test,page22-132
t J
DRIVER'SWINDOWMOTOR
Test,page22-129
POWERWINDOW MASIER SWITCH

InputTest.Daqe22.126
Test,page22--128
FRONTPASSENGER'SWINDOW SWITCH
t e s l ,p a q e2 2 - 1 3 0
I n D uT
f est, page 22-132
\ J
22-124
CircuitDiagram
'No.20il0A)
: USA
UNOERHMO FUSI/8tLAY8OI tGt'TtoitswtTcfi
--+r o'F BTTYEL

U/
lGl HOTin 0N {ll)
tnd STABT{llll
WHT/BU

22-125
PowerWindows
MasterSwitch Input Test
NOTE:Thepowerwindowcontrolunitis builtintothe powerwindowmasterswitch,andit onlycontrolsthe driver's
windowoperations.
1. Removethe windowmasterswitch{A)(seepage22-133).
2. Disconnect (B)from the masterswitch.

the 14Pconnector
GRN/WHT
. lf theterminals are bent, looseorcorroded, repairthem as necessary,and recheckthesystem.

22-126
4. Withthe connectorstill disconnected,maketheseinputtests attheconnector.
.lfanytestindicatesaproblem,findandcorrectthecause.thenrecheckthesystem.
. l f a l l t h e i n p u t t e s t sp r o v eO K ,g o t o s t e p5 .
Cavity Wire Test condition Test:Desiredresult Possiblecauseif result is not

obtained
10 BLK U n d e ra l l c o n d i t i o n s Checkfor continuityto . P o o rg r o u n d{ G 5 0 ' 1 )

grouno: . An openin thewire
14 Thereshould be continuity.
11 GRN^,^/HT l g n i t i o ns w i t c hO N ( l l ) Checkfor voltageto B l o w nN o . 6 ( 7 . 5 A f)u s e i n

ground: the under-dashfuse/relay
2 GRN/BLK Thereshould be battery box
voltage. Blown No. 22,23 l2OA)tuse
in the under-dashfuse/
relay Dox
Faultypower window relay
P o o rg r o u n d( G 2 0 1 )
An open in the wire
'l'1 . Faultydriver'swindow
1 RED/YEL C o n n e ctth e N o . and Checkfor driver'swindow
N o . 7 t e r m i n a l sa, n d t h e molor operaflon: motor
RED/BLK N o , 4 a n d N o . 1 4t e r m i n a l s , I t s h o u l dr u n ( t h ed r i v e r ' s . An open in the wire
and turn the ignition switch w i n d o w m o v e sd o w n ) .
oN flr).
3 B L U / R E DConnectthe No. 2 and No. 1 Checkfor passenger's Faultypassenger'swindow

t e r m i n a l sa, n dt h e N o . 3 window motor operation: motor
BLU/WHT a n d N o . 1 0t e r m i n a l sa, n d I t s h o u l dr u n ( t h e Faultypassenger'swindow
t u r n t h e i g n i t i o ns w i t c hO N passenger'swindow moves swatch
fir), oown). An open in the wire
5. Reconnectthe 14Pconnectorto the switch,and performthe following input tests.
. lf all the input tests prove OK, the control unit must be faulty. Replacethe power window masterswitch.
Cavity Wire Test condition Test: Desired result Possible cause if result is not
obtained
13 ORN C o n n e ctth e N o . 1 1 a n d Checkfor voltagebetween . Faultydriver'swindow

N o . 7 t e r m i n a l sa, n d t h e t h e N o . 1 3a n d N o . 1 4 molor
N o . 4 a n d N o . 1 4t e r m i n a l s , termtnals: . A n o p e ni n t h e w i r e
and turn the ignition switch About6Vshouldbe
o N0 r ) . indicatedwith the driver's
window motor running.

22-127
Driver'sWindow Motor Test
Motor Test: PulserTest:
1 . Removethe door panel (seepage 20-4). 1 . Reconnectthe 4P connectorto the driver'swindow
motor, and reconnectthe 20Pconnectorto the
Disconnectthe 4P connector(A)from the driver's power window masterswitch.
window motor.
Connectthe test leadsof a voltmeterto the No, 3
and No. 4 terminalsof the driver'swindow motor
4P connector.
Run the motor usingthe masterswitch.The

voltmetershould read about 6 V.
lf the voltageis not as specified,checkfor an open

in the wires. lf the wires are OK, replacethe driver's
window motor.
Testthe motor in each directionby connecting

batterypower and ground accordingto the table.
When the motor stops running,disconnectone
lead immediatelv.
Terminal
\
2
il;;'-\
UP e o
DOWN @ e
4 . lf the motor does not run or fails to run smoothly,
replacerL

22-129
PowerWindows
Passenger's
Window Switch Input Test
1 . Removethe switch panel (seepage 20-4).
2 . Disconnectthe 5P connector(A)from the switch (B).
'' "'"1.
o Wire side of femaleterminals
BLU/WHT GRN/BLK
Inputthe connectorand socketterminalsto be sure they are all making good contact.
. lf theterminals are bent, looseor corroded,repairthem as necessary,and recheckthesystem.

4 . Reconnectthe connector,and using a back probe, makethese input tests at the connector.lf any test indicatesa
problem,find and correctthe cause,then recheckthe svstem,
Cavitv Wire Test condition Test:Desiredresult Possiblecauseif resultis not obtained

3 G R N / B L K lgnitionswitch ON Checkfor voltageto B l o w nN o . 6 ( 7 , 5 A ) f u s ei n t h e
{l l ) grouno: under-dashfuse/relaybox
There should be battery B l o w nN o . 2 2 { 2 0 A ) f u s ei n t h e
voltage. under-dashfuse/relaybox
Faultypower window relay
An open in the wire
P o o rq r o u n d( G 2 0 1 )
2 BLD,A/VHT lgnitionswitch ON Checkfor voltageto Faultymasterwindow switch
( ) ground: An open in the wire
At the master Thereshould be battery
window switch, voltage.
pressand hold
down the
passenger'sswitch
BLU/RED lgnitionswitch ON Checkfor voltageto Faultymasterwindow switch
(||) grouno: An open in the wire
At the master Thereshould be battery
window switch, voltage.
p u l lu p a n d h o l d
the passenger's
switch
22-130
5. Disconnect
the 5Pconnector,
andmaketheseinputtests.
Cavitv Wire Test condition Test: Desired result Possiblecauseil resultis not obtained
1 RED Connectthe No. 2 Checkfor passenger's Faultymaster'swindow switch
RED/BLU t e r m i n a tl o t h e N o . window motor operation:lf An open in the wire
, n dt h e should run (the passenger's
1 t e r m i n a la Faultypassenger'swindow
N o . 4 t e r m i n a tl o window moves down), moror.
t h e N o . 5 t e r m i n a l , There should be battery
a n dt u r n t h e voltage.
ignition switch ON
{ll),and pressthe
down button on
the power window
masterswitch for
the passenger's
window.
6. lf allthe tests prove OK, the switch must be faulty. Replaceit.

22-131
PowerWindows
Passenger's
Window Switch Test Passenger's
Window Motor Test
1 . Removethe switch panel (seepage 20-4). 1 . Removethe passenger'sdoor panel (seepage20-
4).
Removethe power window switch (A) from the
doorpanel. Disconnectthe 2P connector(A)from the
passenger'spower window motor.
Disconnectthe 5P connector(B)from the
passenger'spower window switch.
Terminalside of
tfiTtTtT;Etl
l' '-r--r-,Jl
Testthe motor in each directionby connecting

batterypower and ground accordingto the table.
When the motor stops running,disconnectone
Checkfor continuitybetweenthe terminalsin each l e a di m m e d i a t e l y .
\ Terminal
1
Dl*;;;__\
\Torminal 1 2 4
Poiition\ UP
I o
UP DOWN o o
OFF
lf the motor does not run or fails to run smoothly,
DOWN reptacert.
lf the continuityis not as specified,replacethe

swtlcn.
22-132
MasterSwitch Replacement Passenger's
Window Switch
'1.
Replacement
Removethe door grip (seepage 20-4).
2 . Removethe power window masterswitch (A)f rom 1 . Removethe door grip {seepage 20-4).
t h e d o o rp a n e l .
2 . Removethe power window switch (A) from the
o o o rp a n e r .
3 . Disconnectthe 14Pconnector(B)from the switch.
Removethe three screwsand the switch from the

switch panel. 3 . Disconnectlhe 5P connector(B)from the switch.
4 . Removethe two screwsand the switch from the

switch panel.

22-133
Wipers/Washers
WINDSHIELDWIPERARMS and LINKAGE

page22-'145
Replacement,
WIPER/WASHERSWITCH
Test,page22-140
Replacement,page22 140
WINDSHIELD WIPERMOTOR
Test,page22-'143
Replacement,page22-145 UNDER.DASH
FUSE/RELAY
BOX
INTERMITTENT WIPERCIRCUIT
l l nt h em u l t i p l ecxo n t r oul n i t )
InputTest,page22-138
22-134
WASHER TUBES
page22-147
Replacement,
WASHER RESERVOIB
page22'146
Replacement,
WASHERFLUIDLEVELSWITCH{Canada)
TesI,page22-144
REARWINOOWWASHERMOTOR WINDSHIELD WASHERMOTOR

Test,page22-144 fesl, page22 144
page22 146
Replacement, Beplacement, page22-146
CONDENSER
CapacityTest,page22 107
REARWINDOWWIPERINTERMITTENT
CONTROL UNIT
InputTest,page22'138
REARWINDOWWIPERMOTOR
f e$, page22-143
Replacement, page22 146
BEARWINDOWWIPERARM
page22 146
Replacement,
22-135
Wipers/Washers
CircuitDiagram- Windshield \ 1
UNOENHOOD
FL]SE/8ELAY
BOX IGNITIONSWITCN
'7{
F;^--il I
-':-;--u,Hr- 6\
U-I^-- o,f-''*""
MULTIPIIX
coiln0L
UNIT
L\'
\,!
22-136
CircuitDiagram- RearWindow
-
No2olaoAl
:USA
UI\IOIF H@OFUSE/RELAY
MX GNMOIIISW|ICH
-;i
BATTERYr---------------
l No'g,soA, ro2o. | /,^1\
(-;1_=l----_--_fww{"-' l
\+y
lErHorb0Ni||l
andsra8r
0
I
ffAn w$tDowwtPEE
INTE$'ITTEI'IT
C{)NNOL
UI'/IT
f--------------- li

22-137
Wipers/Washers
RearWindowWiperIntermittentGontrolUnit InputTest
the rightrearsidetrim panel{seepage20-51).
1 . Remove
2 . Disconnect (A)fromthe rearwindow.wiDer

the 20Pconnector controlunit(B).
intermittent
LTGRN/REO WHT/RED
WHT/RED LT GRN
LT GRN/BLK
andsocketterminalsto be suretheyareall makinggoodcontact.

Inspecttheconnector
. lf theterminalsare bent,looseorcorroded,repairthemas necessary,

andrecheckthe
system.
. lf theterminalslookOK,go to step4.
22-138
\
4. With the connectorstill disconnected,maketheseinput tests at the connecrors.
' lf all the input tests prove OK, the control unit must be faultv. Replaceit.
Cavitv Wire Tesl condition Test: Desired result Possiblecauseif resultis not obtained
GRN lgnitionswitch ON Checkfor voltageto ground: . B l o w nN o . 9( 1 0 A ) f u sien t h e
flr) Thereshould be battery under-dash fuse/relay box
voltaqe. . An openin thewire
10 BLK U n d e ra l l Checkfor continuity
to Poor ground (G553)
conditions grouno: A n o p e ni n t h e w i r e
Thereshouldbe continuitv.
6 WHT/RED lgnitionswitch ON Checkfor voltageto ground: B l o w nN o . 9 ( 1 0 A )f u s ei n t h e
( l l )a n d r e a r Thereshould be battery under-dashfuse/relaybox
window washer vortage. Faultyrearwlndow wiper/
switch ON washer switch
4 LT GRN/ lgnition switch ON Attachto groundl A n o p e ni n t h e w i r e
RED ( l l )a n d r e a r The rearwindow wiper motor
window wiper s h o u l dr u n .
switch ON
LT GRN lgnition switch ON Attachto ground: B l o w nN o . 9 ( 1 0 A ) f u s ei n t h e
flr) The rear window wiper motor under-dashfuse/relaybox
s h o u l dr u n . Faultyrearwindow wiper motor
An open in the wire
20 LT GRN/ lgnitionswitch ON Checkfor voltageto ground: B l o w nN o . 9 ( 1 0 A )f u s ei n t h e
BLK (ll) Thereshould be battery under-dashfuse/relaybox
voltage. Faultyrearwindow wiper motor
A n o D e ni n t h e w i r e
22-139
Wipers/Washers
Wiper/WasherSwitch Test/Replacement
lowercover{seepage20-60).
the driver'sdashboard
1 . Remove
Removethesteeringcolumncovers(seepage17-9).
Disconnecl (A)fromthewiper/washer
the 14Pconnector switch{B)
Removethe two screws,then pull out the wiper/washerswitch.
Inspectthe connectorterminalsto be sure they are all making good contact.
. lf the terminalsare bent, looseor corroded,repairthem as necessary,and recheckthe system.

.lftheterminalslookOK,checkforcontinuitybetweentheterminalsineachswitchpositlonaccordingtothe
tables,
- lf the continuityis not as speciiied,replacethe switch.
Terminal
6 4 14 l2 12 11
Position
OFF o- -{
tNl o-
LO o-
HI
Mist switchON r
Washor 3witch ON
22-140
ControlUnit InputTest
l . Beforetesting,troubleshootthe multiplexcontrol system lsee page22-jj2).
2 . Removethe dashboardlower cover,
3 . Disconnectthe under-dashfuse/relaybox connectorsB, G, J, X and y
NOTE:All connectorsare wire side of female terminals.
UNDER-DASH
FUSE/RELAY
BOX UNDER.DASH
FUSE/RELAY
BOX UNDER-DASHFUSE/RELAY
BOX
CONNECTORB I6PI CONNECTOR
G {1OP) CONNECTORJ {8PI
WHT/BLU
\
l-,1
€ l l
- l-rl l-,1 - llTtl
F_j-JF-#
lslrlzlol 1 4 1 5 1 76 l 8 l
\
BLU/RED BLU/WHT
UNDER.DASH
FUSE/RELAY
BOX
CONNECTOR
X I8PI
BLU/BLK
. lf the terminalsare bent, looseor corroded,repairthem as necessary,and recheckthesystem.

. l f t h e t e r m i n a l sa r e O K ,g o t o s t e p5 .
(cont'd)
22-141
Wipers/Washers
ControlUnit Input Test (cont'dl \ J
5. Reconnectthe connectors,and make these input tests at the connector.
. l f a l l t h e i n p u t t e s t s p r o v e O K , t h e m u l t i p l e x c o n t r ou ln i tm u s t b e f a u l t y .R e p l a c e
t h e u n d e r - d a sfhu s e / r e l a yb o x
assembly.
Cavity Wire Test condition Test:Desiredresult Possiblecauseif resultis not obtained

J4 BLK U n d e ra l l C h e c kf o r v o l t a g et o g r o u n d : . P o o rg r o u n d( G 5 0 1 )
conditlons T h e r es h o u l db e 1 V o r l e s s . . AnoDeninthewire
Y6 BLK U n d e ra l l Checkfor voltageto ground: . Poor ground (G502)
conditions T h e r es h o u l db e 1 V o r l e s s . . A n o D e ni n t h e w i r e
BI WHTiBLU lgnitionswitch ON Checkfor voltageto ground: Blown No. 20 (20A)fuse in the
{ l l )a n d w a s h e r Thereshould be battery under-dashfuse/relaybox
switch ON vortage. Faultywiper/washerswitch
An open in the wire
E'0 BLU/RED lgnitionswitch ON Checkfor voltageto ground: Blown No. 20 (20A)fuse in the
( l l )a n d w i p e r There should be battery under-dashfuse/relaybox
switch OFF(wiper voltage. Faultywiper/washerswitch
motor stopped) F a u l t yw i n d s h i e l dw i p e r m o t o r
An open in the wire
G7 BLUA/VHT lgnitionswitch ON Checkfor voltageto ground: B l o w nN o . 2 0 ( 2 0 A ) f u s ei n t h e
( l l )a n d w i p e r si n There should be battery under-dashfuse/relaybox
p a r kp o s i t i o n voltage. F a u l t yw i n d s h i e l dw i p e r m o t o r
An ooen in the wire
x1 B L U / B L K l g n i t i o ns w i t c hO N Checkfor voltageto ground: B l o w nN o . 2 0 ( 2 0 A ) f u s ei n t h e
( l l )a n d w i p e r There should be battery under-dashfuse/relaybox
switch in INT voltage. Faultywiper/washerswitch \ J
An oDenin the wire
L J
22-142
Wiper Motor Test
Windshield: RearWindow:
1. Open the hood,and carefullyremovethe cap nuts 1. Open the hatch,and removethe hatchtrim panel
and the wiper arms. Make surethey do not touch (seepage 20-53).
the hood.
2. Disconnectthe4P connector{A) from the motor {B).
2, Removethe hood seal andcowl cover.
3 . D i s c o n n e c t t h5eP c o n n e c t o(rA ) f r o mt h e m o t o r ( B ) .
Testthe motor by connectingbatterypower and

ground accordingto the table. lf the motor does not
run or fails to run smoothly,replaceit.
Testthe motor by connectingbatterypower and
ground accordingto the table. lf the motor does not Telminal
run or fails to run smoothly,replaceit. Battery
Terminal
Connected @ o
1 2 4
P-"-,tion
LOWSPEED O O
HIGHSPEED o o 4 . Testthe wiper motor park switch by connectingan
a n a l o gv o l t m e t e rb e t w e e nt h e N o . 4 ( + ) t e r m i n a l
and ground, and run the motor. The voltmeter
5 . Testthe wiper motor park switch by connectingan should indicate12 V and 4 V or lessalternatelv.lf it
a n a l o gv o l t m e t e rb e t w e e nt h e N o , 5 ( + ) t e r m i n a l does not, reolacethe motor.
a n d g r o u n d ,a n d r u n t h e m o t o ra t l o w o r h i g hs p e e d .
T h ev o l t m e t e rs h o u l di n d i c a t e1 2V a n d 4 V o r l e s s
alternately.lf it does not, replacethe motor.
.l J
j
22-143
Wipers/Washers
WasherMotorTest WasherFluidLevelSwitch Test/
Replacement- Canada
1. Partiallyremovethe right inner fender (seepage
20-'t021.
1 . Partiallyremovethe right innerfender (seepage
2. Disconnectthe 2P connectors(A) from the washer 20-102).
motors (B).
Disconnectthe 2P connector{A) from the washer
level switch.
Testthe washer motor by connectingbattery

power and ground accordingto the lable.
3 . Removethe washer fluid level switchfrom the
Terminal reservoir.
1 2
Battery
Connected @ o : l u i dm a y f l o w o u t t h e o p e n i n g .
NOTEF
4 . Checkfor continuitybetweenthe terminalsin each

float (B) positionaccordingto the table.
4. lf the motor does not run, replaceit, Terminal

2
Position
FLOATUP
FLOATDOWN o- ---o
lf the continuityis not as specified.replacethe
swtTcn.
22-144
WindshieldWiper Motor Replacement
1 . Open the hood. Removethe nuts (A) and the 5 . S c r i b ea l i n e ( A )a c r o s st h e l i n ka n d w l n d s h i e l d
w i n d s h i e l dw i p e ra r m s ( B ) . wiper linkageto show the original adjustment.
Separate t h e w i n d s h i e l dw i p e r l i n k a g e( B )f r o m t h e
w i p e r m o t o r( C ) .
N.m
(3.2ksf.m,23 lbt.ft)
Removethe hood seal and cowl cover.
Djsconnectthe 5P connector(A)from the wiper Installin the reverseorder of removal,and note

motor (B). lhese items.
9.8 N.m (1.0 Apply multipurposegreaseto the moving parts.

Beforereinstallingthe wiper arms,turn the wiper
switch ON, then OFFto returnthe wiper shaftsto
the oark oosition.
lf necessary,replaceany damagedclips,
Checkthe wioer motor oDeration.
R e m o v et h e b o l t s( C ) ,m o v ew i n d s h i e l dw i p e r
l i n k a g ea s s e m b l y{ D ) t o w a r dt h e p a s s e n g e r 'ssi d e
of the vehicle until it slidesoff of the pin (E),then
removethe assembly.
22-145
Wipers/Washers
RearWindow Wiper Motor WasherReservoirReplacement
Replacement
1 . Partiallyremovethe right inner fender.
1 . Open the hatch,and removethe hatchtrim panel Disconnectthe 2P connectors(A)irom the washer
(seepage 20-53). motors (B) and level switch (Canada).
Removethe mounting nut (A),the wiper arm (B)

and the specialnut (C).
A
9.8N.m {1.0kgf.m,
7.2rbf.ftl
B
8 N.m 10.8kgt.m,
6.0rbf.ft) 3 . Disconneclthe tubes (C)from the washer motors.
Removethe three bolts (A) and the washer

reservoir(B).
the 4Pconnector
Disconnect {A),removethethree
mountingbolts(B),thenremovethe rearwindow
wiDermotor(C).
A
9.8 N.m
(1.0kgt.m,
B 7.2 tbf.tt)
9.8 N.m
{1.0kgt.m,7.2lbfftl
4 , Installin the reverseorder oI removal,and note

these items.
Apply multipurposegreaseto the moving parts.

Beforereinstallingthe wiper arm, turn the wiper
switch ON, then turn OFFto returnthe wiper
shaft to the Darkoositon.
lf necessary,replaceany damagedclips.
Checkthe wiDer motor operation.
22-146
WasherTubesReplacement
1 . Removethe rightinnerfender{seepage20-102).
2 . Remove
the washernozzles
andclips,thenremovethetubes.
<=>
r"-----------='
--==':?-
L-!
(cont'd)
22-147
Wipers/Washers
WasherTubesReplacement(cont'dl
3 . I n s t a l il n t h e r e v e r s e o r d e r orf e m o v a lT. a k ec a r en o t t o p l n c h t h e w a s h e r t u b e sC. h e c kt h e w a s h e ro p er a t i o n .
22-148
AccessoryPowerSocket
CircuitDiagram AccessoryPower Socket Test/
Replacement
1 . Carefullypry the accessorypower socket(A) out

from the centerlower cover.
Disconnectthe 2P connector(B)from the socket.
Inspectthe connectorterminalsto be sure they are

all making good contact.
. lf the terminalsare bent, loose orcorroded,

repairthem as necessary,and recheckthe
system.
4 . Turn the ignition switchACC (l), and checkfor

voltage betweenthe No. 'l and No. 2 terminals.
. Thereshould be batteryvoltage.
. lf there is no baneryvoltage,checkfor:
- p o o r g r o u n d{ G 5 0 2 ) .
- an open in the wire.
- b l o w n N o . 1 8 ( 1 5 A ) f u s ei n t h e u n d e r - d a s h
fuse/relaybox.
22-149
DoorLockSystem
Keyless/Power
Test,page22-161
P r o g r a m m i n gp,a g e2 2 - 1 6 1
DRIVER'SDOORLOCKSWITCH
Test,page22-160
RECEIVER
UNIT
lnput Test,page22-153
IGNITIONKEYSWITCH
Test,page22-91
PASSENGER'S DOORLOCKACTUATOR
Test,page22 158
MUTIPLEXCONTROLUNIT
DRIVER'SDOORSWITCH HATCHLATCHSWITCH
Test,page22-97
HATCHLOOKACTUATOR
Test,page22 159
DRIVER'SDOORLOCK
ACTUATOR/KNOB SWTICH
Test,page22-158
Actuator PASSENGER'SDOORSWITCH
KnobSwitchTest,page22 160
22-150
\ J CircuitDiagram
UNOEE DASH
UiDENHooDFUSE/RETIY
8OX fUSE/SELAYBOX
/ 8Ar \
-) cl-
\ lG1,/
lG1HoTin0N(lllaidSTAfft(llll
l3
IT
I
BLK
I
UI'IDE8DASH
f USE/RETAY
80X G502
MULTIPUX
CONTNo!
Uflfi
I J
000R
Loc(KNOE
tl
\"2 PASSTNGtrS
xtY
0008100(
t'-F>
Li___J-
ACTUATOi
DBt!'t8'S
000R100(
ACTUATOB
t
(cont'd)

22-151
Keyless/PowerDoor LockSystem
CircuitDiagram(cont'dl \ J
HOOD
UNDEN FU8E/BELAY
MX
l\br t15a)FUSE
t"-
HORN
SWTCH
UNDEN
DAS}I
FUSE/8ELAY
8OX
t J
Y,,, mMErNAllofl
LIGHISWITCH
DFIVES'S Df,IVEB'S tG tltot\t HATCH

DOOB 0008 IGY LATCH
TOCK swtrcH stvrTcH swlrol
6WTCH plo'.d l
22-152
KeylessReceiverUnit Input Test
1. Removethe driver'sdashboardlower cover (seepage 20-59).
2 . R e m o v et h e a u d i ou n i t ( s e ep a g e2 2 - 1 0 0 ) .
3. Disconnectthe 5P connector(A)from the keylessreceiverunit (B).
WHT/RED
e a kl li n gg o o dc o n t a c t .
4 . I n s p e c t t h e c o n n e c t o r a n d s o c k e t t e r m i n a l s t o b e s u r e t h e y a rm
. lf the terminalsare bent.Iooseorcorroded, repairthem as necessary,and recheckthesystem.

. lf the terminalsare OK, go to step 5.
t
(cont'd)
22-153
KeylessReceiverUnit Input Test (cont'dl
With the connectorstill disconnecled,makethe input test at the connector.
.lftestindicatesaproblem,findandcorrectthecause,thenrecheckthesystem.
. lf the inputtest provesOK, goto step 6.
Cavity Wire Test condition Test:Desiredresult Possiblecauseil resultis not obtained

2 BLU/ORN U n d e ra l l Checkfor continuitybetween An open in the wire
conditions t h e N o . 2 t e r m i n a la n dt h e
N o . 2 t e r m i n a lo f t h e
under-dashfuse/relaybox
connectorK { 17P).
There should be continuitv.
Reconnectthe 5P connector,and make these input tests at the connector.
.lfanytestindicalesaproblem,findandcorrectthecause,thenrecheckthesystem.
. lf all the inputtests prove OK, replacethekeylessreceiverunit.
Cavitv Wire Test condition Test:Desiredresult Possiblecauseif resultis not obtained

1 BLK U n d e ra l l Checkfor voltageto ground: . Poor ground (G502)
conditions There should be 1 V or less. . An oDenin the wire
YEL lgnition switch Checkfor voltageto ground: Blown No. 10 {7.5A)fuse in lhe
o N( | | ) There should be battery under-dashfuse/relaybox
voltaqe. An ooen in the wire
WHT/RED U n d e a
r ll Checkfor voltageto ground: ' B l o w nN o . 9 ( 1 0 A )f u s ei n t h e
conditions There should be battery under-hoodfuse/relaybox
voltaqe. . A n o o e ni n t h e w i r e
22-154
Control Unit Input Test
1. Beforetesting,trou bleshootthe m u ltiplexcontroI system (seepage 22-172).
2, Removethe dashboardlower cover.
3. Disconnectthe under-dashfuse/relaybox connectors.
FUSE/RELAY
UNDER.DASH BOX UNDER.DASH
FUSE/RELAY
BOX UNDER-OASH BOX
FUSE/RELAY
CONNECTOR
C {1itPl CONNECTOR
F I12P) CONNECTORJ {8PI
BLU BLU/RED
FUSE/RELAY
UNDER.DASH BOX UNDER.DASH
FUSE/RELAY
BOX FUSE/RELAY
UNDER.OASH BOX
CONNECTORK {17PI CONNECTOR
M Il2PI P I18PI
CONNECTOR
BLU/ORN
YEL/BLKYEL/BLK YEL YEL YEL YEL/BLK
UNDER.DASH
FUSE/RELAY
BOX UNDER-DAsH
FUsE/neLeY
sbx FUSE/RELAY
UNDER.DASH BOX
O (8P)
CONNECTOR X (8P)
CONNECTOR Y {13P)
CONNECTOR
,/1,/ 3 4 5 6 8
GRN LT GRN/RED RED/WHT WHT/BLK YEL/RED WHT/GRN WHT/BLU
4. Inspectthe connectorand socketterminalsto be sure they are all making good contact.
. lf the terminalsare bent, loose orcorroded, repairthem as necessary,and recheckthesystem.

(cont'd)

22-155
Control Unit Input Test (cont'dl
5. Reconnectall connections
to the underdashfuse/relay
box,and maketheseinputtestsat the appropriate
connectors
on the under-dash
fuse/relay
box.
'lfanytestindicatesaproblem,findandcorrectthecause,thenrecheckthesystem.
. lf all the inputtestsproveOK,goto step6.
Cavitv Wire Test condition Test:Desiredresult Possible causeif resultis notobtained

c1'l 8LU Underall conditions Aftachto ground: B l o w nN o . 2( 1 5 A ) f u si en t h eu n d e r
Parking,sidemarker,license hoodfuse/relaybox
platelights,andtajllightsshould Faultytaillightrelay
comeon. Faultyunder-dash fuse/relay box
An onen in rhc wire
BLU/BEO Underall conditions Attachto ground: B l o w nN o .1 5o r 1 7( 1 5 A ) f u si en t h e
Headlightsshouldcomeon. underhoodfuse/relay box
Faultyheadlight relay'1or 2
An ooen in the wire
J2 WHT/RED Underall conditions Checkfor voltageto ground: B l o w nN o . 9( 1 5 A ) f u si e
n t h eu n d e r -
Thereshouldbe batteryvoltage. hoodfuse/relay box
An oncn in thc wirc
BLK Underall conditaons Checkfor voltageto ground: Poorground(G501)
Thcreshoulnhc 1 V or lpqs An ooenin the wire
J6 OBN Under allconditions Attachto ground: BlownNo.7 (15A)fusein the under
The horns should sound. hoodfuse/relay box
Faultyhornrelay
Faultyhorns
An 6nen in rhe wire
J7 Under all conditions Checkfor voltageto ground: ElownNo.16(20A)fusein the under
Thereshouldbe batteryvoltage. hood fuse/relaybox
An oocn in ihc wi.c
P18 BED H a t c ho p e n Checkfor voltageto ground: Poorground(G552)
Thereshouldbe 1 V or less. Faultyhatchlatchswitch
An oncn in rhc wirF
H a t c hc l o s e d Checkfor voltageto groundl Faulty hatch latch switch
Thereshoul.lhe 5 V or more
GBN Driver'sdooropen C h e c kf o r v o l t a g et o g.ound: . Faultydriver'sdoorswitch
There should be 1 V or less . An ooenin thewire
Driver'sdoorclosed C h e c kf o r v o l t a g e t o ground: Faultydriver'sdoorswitch
Thereshould be 5 V or more. Shortto oround
o4 LT GRN Passenger's
dooropen Checkfor voltageto ground: Faultypassenger'sdoorswitch
/RED Thereshouldbe 1 V or less. An ooeninthewire
Passenger's
doorclosed C h e c kf o r v o l t a g e t o g r o u n d l . Faultypassenger'sdoorswitch
There should be sVor more . Shortto oround
X5 REDAVHT lgnition key inserted into C h e c kf o r v o l t a g e t o g r o u n d : Poorground{G401)
the ignitionswhch There should be 1 V or less. Faultyignitionkeyswitch
An ooeninthewire
lgnitionkeyremovedfrom C h e c kf o r v o l t a g e t o ground: Faultyignitionkeyswitch
rhe ionitionswitch There should be 5 V or more. Shortto oround
Y1 WHT/BLK Driver'sdoorlockknob C h e c kf o r v o l t a g e t o groundl Poorground(G50'l)
switchunlocked There should be 1 V or less. Faultydriver'sdoorlockknobswitch
An openin thewire
Driver'sdoorlockknob C h e c kf o r v o l t a g e t o groundl Faultydriver'sdoorlockknobswitch
Ihere should be 5 V or more. Shortto oround
Y8 YEURED Driver'sdoorlockknob C h e c kf o r v o l t a g e t o groundl Poorground(G50'l)
switch locked There should be 1 V or less. Faultydriver'sdoorlockknobswitch
An oncn inihewire
Driver'sdoorlockknob C h e c kf o r v o l t a g e t o g r o u n d : ' Faultydriver'sdoorlockknobsw;tch
switch unlocked There should be 5Vor more . Shorrto oround
Y10 WHT/GRN Drtver's door lock switch C h e c kf o r v o l t a g e t o g r o u n d l Poorground(G501i
unlocked There should be 1 V or less. Faultydriver'sdoorlockswitch
An ooenin the wire
Driver'sdoorlockswitchin C h e c kf o r v o l t a g e t o g r o u n d : Faultydriver'sdoorlockswitch
Therc shorl.l be 5V or m6rp Short to o rolrnd
Y12 WHT/BLU Driver'sdoorlockswitch C h e c kf o r v o l t a g e t o g r o u n d : Poorground(G501)
'l
locked There should be V or less. Faultydriver'sdoorlockswitch
An oDenin the wire
Driver'sdoorlockswitchin C h e c kt o r v o l t a g e t o g r o u n d : F a u l t yd r i v e r ' s d o o r l o c k s w i t c h
There should be 5Vor more
22-156
6. Disconnect
the M, P,K andJ connectors
fromthe underdashfuse/relay
box,and maketheseinputtestsat the connectors.
.lfalltheinputtestsproveOK,themultiplexcontrolunitmustbefaulty.Replacetheunder-dashfuse/relayboxassembly.
Cavitv Wire Test condition Test:Desiredresult Pdsiblo c6useif resultis not obtain€d
K2 BLU/ORN Underall conditions Checkfor continuitybetween An openin the wire
the K2terminalandthe keyless
receiverunit5Pconnector
disconnected:
Thereshouldbe continuitv.
M7 YEUBLK ConnectJ7 terminalto [,47 Checkactuatoroperation: Faultydriver'sdoorlockactuator
M9 YEL lMgl terminal,and Mg Thedriver'sdoorlockactuator An openin the wire
lMTl terminaltoJ4 shouldlock lunlockl
M6 YEUBLK ConnectJ7 terminalto M6 Checkactuatoroperation: Faultypassenger'sdoorlockactuator

M8 YEL lMSl terminal,and M8 The passenger'sdoorlock An openin the wire
lM6l terminaltoJ4 actuatorshouldlock iunlockl
P16 YEL Connect J7 terminalto P17 Checkactuatoroperation: . Faultyhatchlockactuator

P17 YEUBLK lP16l terminal,and P16 The hatchlockactuatorshould . An openin the wire
l P 1 7 l t e r m i n a l t Jo4 lock lunlockl
22-157
I
Keyless/Power
DoorLockSystem
Door LockActuatorTest
Driver'sdoor: Passenger'sdoor:
1 . R e m o v et h e d r i v e r ' sd o o r p a n e l( s e e p a g e 2 0 - 4 ) . 1 . R e m o v et h e p a s s e n g e r 'dso o r p a n e l( s e e p a g e 2 0 -
4).
2. Disconnectthe 2P connectorfrom the actuator.
2. Disconnectthe 2P connectorfrom the actuator,
Checkactuatoroperationby connectingpower and

ground accordingto the table.To preventdamage Checkactuatoroperationby connectingpower and
to the actuator,apply batteryvoltageonly ground accordingto the table.To preventdamage
momenlanry. to the actuator,apply batteryvoltageonly
momenlanty.
Terminal
\ 'l 2
ilil;lll \
Terminal
2
LOCK e e P."I,l.;--\
UNLOCK e e LOCK e e
UNLOCK e o
4 . lf the actuatordoes not operateas specified,
repracerr. lf the actuatordoes not operateas specified,
reprace[,
22-158
Hatch Lock Actuator Test
1. Open the hatch.
2. Removethe hatch lower trim panel lsee page 20-

53).
3. Disconnectthe 2P connectorfrom the hatch lock

actualor.
Terminalside of
J
4. Checkactuatoroperationby connectingpower and
ground accordingto the table.To preventdamage
to the actuator,apply batteryvoltage only
momentaflty.
\Terminal 1
Po.irion\
LOCK @
UNLOCK o

22-159
Keyless/Power
DoorLockSystem
Door LockKnob Switch Test Door LockSwitch Test Tr
the driver'sdoorpanel(seepage20-4).
1 . Remove '1.
Removethe driver'sdoor panel (seepage 20-4). NO
Disconnect fromthe actuator.

the3Pconnector Removethe two mounting screwsand the door I
lock switch.
. t i
I
. l
I
(
. 1
I

term anals. Checkfor continuitybetweenthe terminals.
. Thereshould be continuitywhen the door lock . Thereshould be continuitybetweenthe No. 1

knob switch is in the LOCKEDposition. and No. 2 terminalswhen the door lock switch is
. Thereshould be no continuitywhen the door lock in the LOCKEDposition.
knob switch is in the UNLOCKEDposition. . Thereshould be continuitybetweenthe No. 2
and No. 3 terminalswhen the door lock switch is
Checkfor continuitybetweenthe No. 2 and No. 3 in the UNLOCKEDposition.
termtnals.
lf the continuityis not as specified.replacethe door
. Thereshould be continuitywhen the door lock lock switch.
knob switch is in the UNLOCKEDposition.
. Thereshould be no continuitywhen the door lock
knob switch is in the LOCKEDposition.
5. lf the continuityis not as specified,replacethe door

locl(actuator.
22-160
TransmitterTest TransmitterProgramming
NOTE: Storingtransmittercodes:
. l f t h e d o o r su n l o c k o r l o c k w i t h t h e t r a n s m i t t ebru, t The codes of up to three transmitterscan be storedin
the LEDon the transmitterdoes not come on, the LED the keylessreceiverunit memory. (lf a fourth code is
is faulty. Replacethe transmitter, stored.the code which was input first will be erased.)
. l f a n y d o o r i s o p e n ,y o u c a n n o t l o c k t h e d o o r w i t h t h e NOTE:lt is importantto maintainthe time limits
transmrtter. betweenthe steps.Make sure the doors and the hatch
. lf you unlockedthe doors with the transmitter,but do are closed.
not open any of the doors within 30 seconds,the 1 . T u r nt h e i g n i t i o ns w i t c hO N ( l l i .
doors relockautomatically.
. The doors do not lock or unlockwith the transmitterif 2. Within 1 to 4 sec.,push the transmitterlock or
the ignition key is insertedin the ignition switch. unlockbutton with the transmitteraimed at the
receiverin the multiplexcontrol unit behindthe
1. Pressthe lock or unlock buttonfive or six times to d r i v e r ' ss i d eo f t h e d a s h .
resetthe transmitter.
3. Within 1 to 4 sec.,turn the ignition switch OFF.
. lf the lockswork, the transmitteris OK.
. lf the locksdon't work, go to step 2. 4. Within 1 to 4 sec.,turn the ignition switch ON (ll).
2. Open the transmitterand checkfor water damage. 'l

5. Within to 4 sec.,push the transmitterlock or
unlock buttonwith the transmitteraimed at the
. lf you find any water damage,replacethe receiverin the multiplexcontrol unit behindthe
transmrtter. d r i v e r ' ss i d eo f t h e d a s h .
. lf there is no waterdamage,go to step 3.
6. Within 1 to 4 sec.,turn the ignitionswitch OFF.
3. Replacethe transmitterbattery(A)with a new one,
and try to lock and unlockthe doors with the 7 . W i t h i n4 s e c . t, u r n t h e i g n i t i o ns w i t c hO N ( l l ) .
transmitterby pressingthe lock or unlock button
five or six times. 8. Within 1 to 4 sec.,push the transmitterlock or
unlockbuttonwith the transmifteraimed at the
. lf the doors lock and unlock,the transmifteris OK. receiverin the mupltiplexcontrol unit behindthe
. lf the doors don't lock and unlock,go to step 4. driver's side of the dash.
9. Within 1 to 4 sec.,turn the ignition switch OFF,

'10.
W i t h i n4 s e c . t, u r n t h e i g n i t i o ns w i t c hO N ( l l ) .
1 1 . W i t h i n1 t o 4 s e c . ,p u s ht h e t r a n s m i t t elro c ko r
unlockbutton with the transmitteraimed at the
r e c e i v e irn t h e m u l t i p l e xc o n t r o lu n i t b e h i n dt h e
driver'sside of the dash.
1 2 . C o n f i r my o u c a n h e a r t h es o u n do f t h e d o o r l o c k
actuators.Within 1 to 4 sec.,push the transmitter
lock or unlockbutton again,
13, Within 10 sec.,aim the transmitters(up to two

4 . Reprogramthe transmitter,then try to lock and additionalones)whose codesyou want to store at
u n l o c kt h e d o o r s . the receiver,and pressthe transmitterlock or
unlockbuttons.
. l f t h e d o o r sl o c k a n du n l o c k . t h e t r a n s m i t t ei srO K . Confirmthat you can hear the sound of the door
. l f t h e d o o r sd o n ' t l o c k a n du n l o c k r, e p l a c e t h e lock actuatorsafter eachtransmittercode is stored.
transmitter.
1 4 . T u r nt h e i g n i t i o ns w i t c hO F F ,a n d p u l l o u t t h e k e y .
'15.
Confirm proper operationofthe transmitter.

22-161
lmmobilizerSystem
INOICATOR LIGHT ECM

page 22 63
Bulb Replacement, Replacement, page 11-4
Substituteknown-goodfor testing,
p a g e1 1 - 5
CONTROLUNIT.RECEIVER
IMMOBILIZER
page22-165
Troubleshooting,
page22-167
Replacement,
TRANSPONDER
(8uiltintothe ignitionkey)
22-162
SystemDescription
The vehicleis equippedwith an immobilizersystemthat will disablethe vehicleunlessthe proper ignition key is used.
This system consistsof a transponderlocatedin the ignition key, an immobilizercontrol unit-receiver,an indicator
l i g h t ,a n d t h e E C M .
When the key is insertedin the ignition switch and turned to the ON {ll) position,the immobilizercontrol unit-receiver
sendspower to the transponderin the ignition key.The transponderthen sendsa coded signal backto the immobilizer
control unit-receiverwhich then sendsa coded signalto the ECI\4.
IMMOBILIZER
CONTROLUNIT.RECEIVER
KEYCYLTNDER
iEl'JUiliii'tlun"oona"|.r
lf the proper key has been used,the immobilizerindicatorlight will come on for about 2 seconds,then go off.
lf the wrong key has been used or the code was not receivedor recognizedby the unit,the indicatorlight will come
on for about 2 seconds,then it will blink until the ignition switch is turned OFF.
lf the ignition switch is turned OFF,the indicatorwill blinkfor about 5 secondsto signalthat the unit has reset
correctly,then the indicatorwill go off.
lf the customerhas lost his key,and cannot startthe engine,contactHondaCustomerRelations.
IMMOBILIZER
INDICATOR
LIGHTBLINKING
PATTERN:
IGNITIONSWITCH ON
OFF
PROPER
KEY INDICATOR ON
INSERTED LIGHT
WRONGKEY INDICATOR ON
INSERTED LIGHT
OFF
(| i.,

22-163
)
lmmobilizerSystem
CircuitDiagram t J
'
No20(LAl r USA
UNDTRrcODFUSE/RELAY
8OX
rGNtTt0i/
swlrcH
lct HoTin0N{ll)
.ndSIAnTl|l)
F G N
8ELAY1
YEUBIJ(
t I
0R8 itAWStY tct tGPl tGPz LG3 |M0CD

EC DATA . PA8(II'IG
LIN( SMIG
LGI LG2 CONNECIOR SWITCH
{0Lcl .8nA{E
FTUID
I!VEL
SWTfi
\ J
22-164
)
Troubleshooting
Beforetroubleshootingthe immobilizersystem, 5. Disconnectthe 7P connector(A)from the
troubleshootany EClvlDiagnosticTroubleCodes(DTCS) i m m o b i l i z ecr o n t r o lu n i t - r e c e i v e( B
r ),
( s e ep a g e1 1 - 3 )a, n d m a k es u r et h e E C Mh a s n o
malfunction.
Note these items beforetroubleshooting:
. Due to the actionof the immobilizersystem,the

enginetakesslightly more time to startthan on a
vehiclewithout an immobilizersystem.
. When the system is normal,and the proper key is
inserted,the indicatorlight comes on for 2 seconds,
then it will go off.
. If the indicatorstartstoblink after 2 seconds,or if the
enginedoes not start.removeany other immobilizer
keysor large key fobs on the key ring,then repeatthe
startingprocedure.
lf the engine still does not start,continuewith this Checkfor voltage betweenthe immobilizercontrol
procedure. unit-receiver7P connectorNo. 7 terminal and body
ground.
1. Turn the ignitionswitch ON {ll) with proper key.
2. Checkto see if the immobilizerindicatorlight
c o m e so n . YES-Go to step 7.
I Does the indicator light blink? NO Checkfor these problems;
YES Disconnectthe 7P connectorfrom the . B l o w nN o . 9 { 1 0 A ) f u s ei n t h e u n d e r - h o o fdu s e /

immobilizercontrol unit-receiver,then go to step 9. relay box.l
. An open in the WHT/REDwire.l
NO Checkfor these problems,then go to step 3.
1 . Checkfor voltage betweenthe immobilizercontrol
. Blown No. 9 (10A)fusein the under-hood unit-receiver7P connectorNo. 6 terminal and body
fuse/relaybox.I ground with the ignition switch ON {ll).
. An open in the wire betweenthe gaugeassembly
a n d t h e i m m o b i l i z ecr o n t r o lu n i t - r e c e i v e r . l ls there battery voltage?
. A f a u l t yi m m o b i l i z eirn d i c a t o lri g h t , I
. An open in the wire betweenthe gauge assembly YES- Go to step 8.
and the under-hoodfuse/relaybox.l
NO Checkfor these problems:
Removethe driver'sdashboardlower cover (see
page 20-59). . B l o w nN o . 6 ( 1 5 A ) f u s ei n t h e u n d e r - h o o d
fuse/relaybox,I
Removethe steeringcolumn lower cover (seepage . F a u l t yP G M - Fml a i n r e l a y1 , t
11-9). . A n o p e ni n t h e Y E U B L Kw i r e . l
l
(cont'd)

22-165
lmmobilizerSystem
Troubleshooting(cont'dl
8. Checkfor voltage betvveenthe immobilizercontrol Checkfor continuitybetweenthe immobilizer
unit-receiver7P connectorNo. 6 terminal and No. 1 control unit-receiver7P connectorNo. 2 terminal
rermlnat. a n d E C Mt e r m i n a lE 2 7 .
ls thete battery voltage? ls there continuity?
YES Go to step 12. Y E S - G o t o s t e p1 3 .
NO Checkfor these problems, N O - R e p a i tr h e o p e ni n t h e R E D / B L U

wire.I
. Open on the BRNI/ELwire.l 1 3 .Reconnectthe 7P connectorto the immobilizer

. F a u l t yE C M . I control unit-receiver.
9. Removethe driver's dashboardlower cover (see 1 4 . Checkfor voltage betweenthe immobilizercontrol

page20-59). unit-receiver7P connectorNo. 4 terminal and body
ground with the parkingbrakelever pulled,then
10. Removethe steeringcolumn lower cover (seepage released.
17-9).
ls there 1 V or less,then 5 V or more?
11. Disconnectthe 7P connector(A) from the
immobilizercontrol unit-receiver(B). YES Replacethe immobilizercontrol unit-receiver.
After replacingthe immobillzercontrol unit-
receiver,rewritethe unit with a HondaPGM
Tester.l
NO Checkfor these problems: {

. Faultyparkingbrakeswitch or a poor body
ground of the parkingbrakeswitch.l
. R e p a i rs h o r to r o p e ni n t h e G R N / O R N
w i r e .I
22-166
t lmmobilizerControl Unit-ReceiverReplacement
'L
Removethe driver'sdashboardlower cover (see
page20-59).
2 . Removethe steeringcolumn covers(seepage 17-
3 . Disconnectthe 7P connector(A)from the

immobilizercontrol unit-receiver(B).
Removethe two screwsand the immobilizer

control unit-receiverfrom the ignition key cylinder
I J (c).
5 . Installthe immobilizercontrol unit-receiverin the
reverseorder of removal.
6 . After replacement,rewritethe unit with a Honda

PGM Tester,then checkthe immobilizersystem.
22-167
MultiplexControlSystem
ComponentLocationIndex lr, J
REARCEILINGLIGHT
Test,page22'96
LIGHT/SPOTLIGHTS
Test,page22-96
ASSEMBLY
GAUGE
IGNITIONKEYLIGHT
Test,page22'91
ECM
MULTIPLEXCONTROLUNIT
{Builtinto the under-dash
fus6/relav boxl
Troubleshooting,page22'172
22-168
I CircuitDiagram
'
I'10.20 :usA
{a0AJ
UNDEf,
DASH ib.a)l50A):C.nd.
UiIDM HOOD
IUSE/NEUY
BOX IGNITiON
SWITCH FUSE/NEUYBOX
/ BAI \
--_to oJ- BLI,'YEL
\ tcl ./
MULTIPLEX
c0NT80r
tNsPECTror!
CONNECIOF
HAICII
LATCH
SWITCH
G201
{cont'd)

22-169
CircuitDiagram(cont'd) J
l'1o.3 tUSt
l7.5AJ
lln$.uidt hoodr
itutefd4bor I
V
I
wHTPLU
l0
t--t---
lrfl | I.l|MOBItEER
@NTIOL UIIIT
lE lnv*-
| > | ucHT
CIILINGLIGHT RECEIVEE
VI
lt A
Y l
l'*'
I' I
22-170
I SystemDescriptions
The MultiplexControlSystem hasfour internal MultiplexCommunication
functions:
. Multiplexing ( s e n dm u l t i p l es i g n a l so v e rs h a r e d To reducethe number of wire harnesses,digital signals
wtres) a r e s e n tv i a s h a r e dm u l t i p l e xc o m m u n i c a t i o lni n e s
. Wake up/sleep(runsat full power only on demandto r a t h e rt h a n s e n d i n gn o r m a le l e c t r i c asl i g n a l st h r o u g h
reducebatterydraw) i n d i v i d u awl i r e s .
. Fail-safe(fixesor ignoresfaulty signals) . The input signalsfrom each switch are convertedto
. Self-diagnosis(Mode 1 for the system,Mode 2 for digital signalsat the centralprocessingunit (CpU).
i n p u tl i n e s ) . T h e d i g i t a ls i g n a l s a r e s e n t f r o m t h e t r a n s m i t t i nu gn i t
t o t h e r e c e i v i n gu n i t a s s e r i a ls i g n a l s .
The systemcontrolsthe functionof these circuits: . The transmittedsignalis convertedto a switch signal
. E n t r yl i g h t c o n t r o(l i g n i t i o nk e y l i g h t a n d c e i t i n gl i g h t ) at the receivingunit, and it operatesthe related
. Wiper/washerintermittentwipe and park functions componentor monitors a swltch.
. Keyless/powerdoor lock . There are exclusivecommunicalionlines between
. Meter assembly,temperaturegauge,and indicator the ECM,the gauge assembly,and the under,dash
lights fuse/relaybox.
. HVAC(compressorand fan control)
. K e y - i nr e m i n d e r Wake-upand Sleep
. H e a d l i g hrte m i n d e r
. Seatbeltreminder The multiplexcontrol system has "wake-up" and
"sleep" functions
to decreaseparasiticdraw on the
batterywhen the ignitionswitch is OFF.
. ln the sleep mode,the multiplexcontrol unit stops
functioning(communicationand CPUcontrol)when it
is not necessaryfor the systemto operate.
I J . As soon as any operationis requested(for example,a
door is unlocked),the relatedcontrol unit in the sleep
mode immediatelywakes up and beginsto function.
. When the ignition switch is turned OFF,and the
driver'sor front passenger'sdoor is opened,then
closed,there is about a 10 seconddelay beforethe
control unit goes from the wake-upmode to the sleep
mode.
. lf any door is open,the sleep mode will not function.
. l f a k e y i s i n t h e i g n i t i o ns w i t c h ,t h e s l e e pm o d ew i l l
not function.
. When in sleep mode,the draw is reducedfrom
70 80 mA to lessthan 10 mA.
Fail-safe
To preventimproper operation,the multiplexcontrol
system has a fail-safefunction.In the fail-safemode,
the output signal js fixed when any part of the system
malfunctions(for examplea faulty control unit or
c o m m u n i c a t i o lni n e ) .
Eachcontrol unit has a hardwarefail-safefunctionthat
fixes the output signalwhen there is any CPU
malfunction,and a softwarefail-safefunctionthat
i g n o r e st h e s i g n a lf r o m t h e m a l f u n c t i o n i ncgo n t r o lu n i t
and allowsthe systemto operatenormally.
22-171
Downloaded
/ar
from www.Manualslib.com manuals search engine
Multiplex ControlSystem
Troubleshooting
Mode 1 Tset 7. Checkfor continuitybetweenterminal 4ofthe
under-dashfuse/relaybox connectorJ and body
1. Removethe driver's dashboardlower cover {see ground.
page 20-59).
2. Checkthe No. 9 ( 10A)fuse in the under-hoodfuse/
relay box and the No. 10 (7.5A)fuse in the under- YES Replacethe under-dashfuse/relaybox.l
dash fuse/relaybox.
N O- R e p a i tr h e o p e n i n t h e w i r e . l ft h e w i r e i s o k ,
Are the fuses OK? r e p a i rG 3 0 1 . 1
YES-Go to step 2. 8. lf ther are any DTCSpresent,the spotlightand

ceiling light will blink to indicatethe DTC(S). lf more
N O - F i n d a n d r e p a i r t h ec a u s eo f t h e b l o w nf u s e . ! than one DTCis present,the DTCSwill be displayed
in ascendingorder,lf there are no DTCSthe
3 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) . l tf h e d r i v e r ' s s p o t l i g h at n d c e i l i n gl i g h tw i l l n o t b l i n ka g a i na f t e r
seatbeltis unbuckledthe seat belt reminderwill the mode1 indication.
c h i m e6 t i m e s .
Are there any DTCg?
4. Set the ceiling light to the centerpositionand close
a l l t h ed o o r s . YES Go to step 9.
5. Connectthe specialtoolto the multiplex inspection NO Go to the Mode 2 test.

conneclor.
9. Troubleshootthe DTC(S)in the order indicated
6. After about 5 secondsthe spotlightand ceiling light u s i n gt h e f o l l o w i n gc h a r t s .
should come on for 2 seconds,go out, then blink on
for 0.2 secondto show the system is now in mode lf a faulty control unit is suspected,substituteit
1. with a known food part and recheckfor DTCS,
Did the spotlight and ceiling light indicate mode . lf the DTC(s)isstill present.go to the next step
1? listedfor the DTC.
. lf the DTC(S)is no longer presentreplacethe
YES-Go to step 8. originap l art.
NO Go to step 7.
22-172
I
Individual DTCs
Multiplex Probable Cause Multiplex Probable Cause
DTC DTC
The multiplexcontrol unit cannot 1 , 2a n d3 Short to ground on one of the
receivesignalsfrom the gauge & communicationwires.
assemDty. ECMDTC Short to ground on the YELwire
'l
Faultypoweror groundto the P0600 betweenthe PCMterminal E24
gaugeassembly Simultane and the under-dashfuse/relay
2 . Faultygauge assemblv ously b o x t e r m i n a lE 1 0
3 . Faultyunder-dashf use/relay 2 . Short to ground on the WHT/
box GRNwire betweenthe Gauge
The multiplexcontrol unit cannot assemblyterminal A2 and
receivesignalsfrom the ECM under-dashfuse/relaybox
1 Faultypower or ground to the t e r m i n a lK 1 0
ECM 1 a n d 6 Open in the communicationwire
2 . F a u l t yE C M Simultane I Open in WHT/GRNwire
? Faultyunder-dash
fuse/relay o u sl y betweenthe under-dashfuse/
box relay box terminal K10 and the
J Internalfailure of the multiplex GauqeassemblVterminal 42
control unit 2 a n d 5 O p e ni n t h e c o m m u n i c a t i o w n ire
1 Faultyunder-dash fuse/relay S i m u l t a n e 1 Open in the YELwire between
box ously the under-dashfuse/relaybox
5 The gaugeassemblycannot receive t e r m i n a lE 1 0a n d E C Mt e r m i n a l
signalsfrom the multiplexcontrol
u n i ta n d t h e E C M
I Faultypower or ground to the

g a u g ea s s e m b t v
F a u l t yq a u g ea s s e m b l v
6 The ECMcannot receivesignals
from multiplexcontrol unit and the
gaugeassembty
1 Faultypower or ground to the
ECM
F a u l t yE C M '
'Before
replacinga FaultyECM/PCMmake sure it
has the latestsoftwarerevision.UDdateif
necessarybeforeswappingor replacing.
(cont'd)
22-173
I MultiplexControlUnit Input Test
1 . Removethe driver'sdashboardlower cover (seepage20-59).
2 . Disconnectthe under-dashfuse/relaybox connectorsC, E, F, J, K, O, p, O, X and y.
CONNECTOR
C {14P} CONNECTOR
E I13P) CONNECTOR
F {12P} CONNECTOR
J {8PI
GRN/RED
{USAI WHT/RED
(Canada)
GRN/ORN
3 4 5 1 2 3
6 7 E 1 0) . / 12 4 5 6 1
GRN/ORN BLU YEL GRN/RED BLK
CONNECTOR
K {17P) CONNECTOR
O I12P) P (18P)
coNNECTOR
1 2 4 5 7 3 5 6 7 I
8 10 /V ,/ l,/ ,/1,/l,/ 12 15 17
I WHT/GBN GRN/RED RED
O (8P}
CONNECTOR CONNECTOR
X {8P) CONNECTORY {13P)
LTGRN/RED GRN/ORN WHT/BLK BRN/YEL
2 3 ,/1,/
6 1 8 r0 12
BLU/RED BLU/RED RED/WHT BLK
{cont'd)
22-175
MultiplexControl Unit lnput Test (cont'd)
3. Inspect
the connector to be suretheyareall makinggoodcontact
andsocketterminals
.lftheterminalsarebent,looseorcorroded,repairthemasnecessary,andrecheckthesystem
. llthe terminalslookOK,go to step4.
Cavitv Wire Test condition Test:Desired.esult r causeif resullEqS!q!!e!!ed

Possible
J4 BLK [ Jn d e r a l l c o n d i t i o n s Check{or voltage1oground: Poorground(G20'l)
Therc sholl.l he 1V or less An ooenin the wire
Y6 BLK lJnderall conditions C h e c kf o r v o l t a g et o g r o u n d : Poorground1G501)
There should bc 1 V or less. An ooenin thewire
Y1 BFNryEL Parkingbrakelever Checkfor voltageto ground: An openin thewire
down,turn the Thereshouldbe batteryvoltage Shorttoground
igntionswitchON (ll) whilethe Brakesystemindicatoris FaultyABSmodulatorcontrol unit
on forthe buldcheck.
Checkfor voltageto ground:
Thereshouldbe 1V or lesswhenthe
J2 r l l c o n d i t i o n s Checkfor voltageto groundi

WHT/RED U n d e a BlownNo.9 (10A)fusein the under'hood
Thereshouldbe bafteryvoltage. box
fuse/relay
An oncnin rhc wire
4. Reconnectthe underdashfuserelaybox,andmakesuretheseinputtestsatthe appropriate

connectorstothe on lhe under-
connectors
dashfuse/relav
box.
. lf anytestindicatesa problem,{ind andcorrectthe cause,then recheckthe system
. lf alltheinputtestsproveOK,the multiplexcontrolunit mustbe faulty.Replace fuse/relay
the under_dash box assembly
Cavitv Test condition Tesi: Oesiredresult causeifresultis notobtained

Possible
o3 GRN Driver'sdooropen C h e c kf o r v o l t a g e t o g r o u n d : Faultydriver'sdoorswitch
There should be 1 V or less- An ooenin the wire
Driver'sdoorclosed C h e c kf o r v o l t a g e t o g r o u n d : Faultydriver'sdoorswitch
There should be 5 V or more. Shortto qround
O4 LT GRN/RED Passenger's
door C h e c k. f o rv o l t a g e 1 0 g r o u n d : Faultypassenger's doorswitch
There should be 1 V or less. An ooeninthewire
door
Passenger's Checkfor voltageto ground: Faultypassenger's doorswitch \
Thereshouldbe 5 V or more. Shortto oround
osI]l GRN/ORN Parkingbrakelever C h e c kf o r v o l t a g et o g r o L r n d : F a u l t yp a r k i n gb r a k e s w i t c h
. l Thereshorl.l be 1 V or less. . An ooen in thewire
4., GRN/ORN C h e c kf o r v o l t a g e t o g r o u n d : . Faultyparkingbrakeswitch
There should be 5 V or more. Shorttoground
F1 GRN/RED
(USA)
F8 GRN/ORN
(Canada)
o5 BLU/RED lgnitionswitchON (ll), C h e c kf o r v o l t a g et o g r o u n d : Faultydriver'sseatbeltswitch

driver'sseatbeltis Thereshould be 1V or less. P o o r g r o u n(dG 5 5 1 )
An oDenin the wire
Q6 BLU/RED lgnitionswitchON (ll) Check{or voltageto ground: Faultydriver'sseatbeltswitch
driver'sseatbeltis Thereshouldbe 6 V or more. Shorttoground
buckled.
H",=
P18 RED Checkfor voltageto ground: Faultyhatchlatchswrtch
Theresho0ldbe 1V or less- Poorground(G552)
An openin the wire
f-9*:li:'^:**:':s*:* F a u l t yh a t c h l a t c hs w i t c h
X5 l g n i r i o nk e y i n t h e C h e c kf o r v o l i a g e t o g t o u n d : . F a u l t yi g n i t i o n k e y s w i t c h
ignit on switch Thpre should be I V or lcss . Poorground (G401)
. An open in the wire
l g n r t r o nk e v o u r o { t h e C h e c kf o r v o l l a g e t o g r o u n d : **6
I : [11y.'::i':::1"'
22-176
I J
Cavitv Wire Test condition Test:Desiredresult Possible
causeif resukis notobtained
X8 WHT/BLK Underallconditions Attachto ground:Theignitionkey BlownNo.3 (7.5A)fuse in the under,hood
lightshouldcomeon.
BlownLED
An ooenin the wire
o7 GRN/RED Ceilinglightswitchin A t t a c h t o g r o u n d : T h e c e i l i n g l i g h t , ElownNo.3 (7.54)fusein the undeFhood
the middleposition, s p o t l i g h t ss h o u l d c o m e o n .
all doorsclosed Faultyceilinglight
An oDenin the wire
c]1 BLU Underall conditions Attachto ground:Dashlightsshould BlownNo.2 (15Aifusein the under-hood
fuse/relaybox
Faultytaillightrelay
An ooenin the wire
F8 GRN/RED Brakefluidreservoir C h e c kf o r v o l t a g et o g r o u n d : Faultybrakefluidlevelswitch
float in down T h e r e s h o u l d b e l e s st h a n I V . An openin thewire
position(brakefluid
Brakelluid reservoir Checkfor voltageto ground: Faultybrakefluid levelswitch

floatin up position Thereshouldbe 5 V or more. Shorttoground
(brakefluidat full
level)
E10 YEL Underall conditions C h e c kf o r v o l t a g et o g r o u n d : . An openor shortin thewire
T h e r e s h o u l d b e b a t t e r yv o l t a g e i n
t h e s l e e pm o d e a n d 3 T v o l t s w h e n
K10 WHT/GRN Underall conditions Checkfor voltageto ground: An openor shortin the wire
Thereshouldbe batteryvoltagein
the sleepmodeand3 Tvoltswhen
I J
I J
22-177
I
Restraints
Restraints
SpecialTools .............
23-2
SeatBelts
Component LocationIndex .........................................
23-3
FrontSeatBeltReplacement .......................................
23-4
RearSeatBeltReplacement ........................................
23-6
Inspection ..................
23-8
ChildSeatTetherAnchorRemoval/lnstallation ........23-9
SRS(SupplementalRestraintSysteml
Component LocationIndex ......................................... 23-13
Precautions and Procedures ,,.,......... 23-14
I DTCTroubleshooting
SymptomTroubleshooting
Index ..............
Index...............................
23-28
23-30
SystemDescription................. ........... 23-31
SRS Indicator CircuitTroubleshooting ....................... 23-105
ComponentReplacemen(/lnspection After
Deployment ..............23-112
Driver'sAirbagReplacement ............ 23-113
FrontPassenger's AirbagReplacement ..................... 23-114
SideAirbagReplacement .................. 23-115
A i r b a gD i s p o s a.l . . . . . . . . . . . . . . . . . . . . . . ........2 . .3. - 1 1 6
C a b l eR e eR l eplacement . . . . . . . . . . . . . .2. .3. .- .1. 1 9
SRSUnitRepfacement ....................... 23-122
SidefmpactSensorReplacement ..........,.................... 23-123
OPDSUnitReplacement .................... 23-124
FrontfmpactSensorReplacement .............................. 23-125

Restraints
SpecialTools \
' 07HAZ-SG00500 DeploymentTool

8t oTPM-oo101oo SCSServiceConnector
€ oTsM-TB4o114 S R SI n f l a t o S
r i mu l a t o r
O oTTM-sz5o114 S R SS i m u l a t o rL e a dC
o-' 07TM-0010204 B a c k p r o bA e dapter1 , 7m m
@
-1 o7xAz-s140200 S R SS i m u l a t o rL e a dE
07xAz-s230100 S R SS i m u l a t o rL e a dF
S R SS i m u l a t o rL e a dH
* 1 : I n c l u d e di n S R ST o o l S e t0 7 M M ' S M 5 0 0 0 8
*2: Use with the stackingpatchcords from T/N 07SAZ-0010004, BackprobeSet.
o o
\ J
@ Gl
ro
L .
23-2
SeatBelts
I ComponentLocationIndex
REARCENTER BELTand
REARSEATBELTBUCKLES
step1 on page23-8
page23 9
Inspection,
SHOULDER
ANCHOR ADJUSTER
step8 on page23-4
FRONTSEATBELT
page23 9
Inspection,
I
CHILDSEATTETHER
ANCHORS
page23-11
REARSEATBELT
Beplacement,page23.7
page23-9
Inspection,
FRONTSEAT
BELTBUCKLES
step1 on page23'6
23-3
SeatBelts
FrontSeat Belt Replacement
SRScomDonentsare locatedin this area.Reviewthe 6. Removethe upper anchorcover {A),and remove
SRScomponentlocations(seepage23-13)and the t h e u p p e ra n c h o rb o l t( B ) .
sectionbefore performingrepairsor service, B
7/16-20
UNF
32N m (3.3kgf.m,24lbt.ft)
NOTE:Checkthe front seat beltsfor damage,and
replacethem if necessary.Be careful not to damage
them during removaland installation.
Front Seat Belt

1 . Make sure you have the anti-theftcode for the radio,
buttons.

wait at least3 minutes beforebeginningwork.
3 . Slidethe front seatforward fully. 7. Disconnectthe seat belt tensionerconnector(A).

Removethe retractormounting self-tappingET
Removethe lower anchorcap (A),and removethe screw {B),and the retractorbolt (C),then remove
lower anchor bolt (B). the front seat belt (D) and retractor(E).
6x1.0mm
3.4N m {0.35kgf.m,2.5lbf.ft)
7/16-20
UNF
5 . R e m o v et h e r e a rs i d et r i m p a n e l( s e e p a g e 2 0 - 5 1 ) . 32 N.m(3.3kgf m,2irlbf.ft)
8. lf necessary,removethe front seat belt protecto

(F).
qt
23-4
9 . Removethe B-pillaruppertrim {seepage20-50) Upperanchorbolt construction:
1 0 .Removethe shoulderanchoradjuster{A).
UPPERANCHOR UPPERANCHOR COLLAR
BOLT
BUSHING TOOTHED
LOCKWASHER
Lower anchor bolt construction:
8 x 1.25mm
22 N.m(2.2kgf.m,16lbf.ftl WASHER
1 1 .Installtheseat belt in the reverseorder of removal,

. lf thethreads on the retractormounting self-

tapping ET screw are worn out, use an oversized
self-tappingET screw (P/N90133-SZ4-0030)
made specificallyfor this application.
. Checkthat the retractorlockingmechanism
functions(seepage 23-9).
. A s s e m b l et h e w a s h e r sc, o l l a r s a, n d b u s h i n go n TOOTHEDLOCKWASHER
LOWERANCHORBOLT
the upper and lower anchorbolts as shown.
. lf the seat belt tensionerhas been deployed
replacethe front seat belt protectorwith a new
one.
. A p p l y l i q u i dt h r e a dl o c kt o t h e a n c h o rb o l t s
beforereinstallation.
. Beforeinstallingthe anchorbolts,make sure
there are no twists or kinksin the front seat belt.
. Make sure the seat belt tensionerconnectoris
pluggedin properly.
. Resetthe clock.
. Do the ECM/PCMidle learn procedure{seepage
11,139).
{cont'd)

23-5
Seat Belts
Front Seat Belt Replacement(cont'd)
SeatBelt Buckle 7. Installthe bucklein the reverseorder of removal,
then write down the frequenciesfor the preset . Assemblethe washerson the centeranchor bolt
buttons. as shown.
. Apply liquid thread lockto the centeranchor bolt
2. Disconnectthe negativecablefrom the battery, before reinstallation.
and wait at least3 minutesbefore beginningwork. . lf the seat belt tensionerhas been deployed,
replacethe front seatbelt protectorwith a new
3. Removethe front seat (seepage 20-7'1). one.
. Apply liquid thread lockto the seat mounting
4. Detachthe seat belt switch connectorclip (A),seat bolts before reinstallation
belt buckletensionerconnectorclip (B),and . Reconnectthe negativecableto the battery.
h a r n e s sc l i p ( C ) . . Enterthe anti-theftcode for the radio,then enter
. Resetthe clock.
. Do the ECMiPCMidle learn procedure(seepage
11 _ 1 3 9 ) .
.-..:.a--
5. Removethe centeranchor bolt (A),and removethe COLLAR

seat belt buckle{B).
7/16-20
UNF
32N m {3.3kgf m,24lbf.ft)
6. Pullthe seat belt switch/tensionerharness(C)out

through the hole on the seattrack.
23-6
I RearSeat Belt Replacement
NOTE:Checkthe rear seat beltsfor damage,and 5. Installtheseat belt in the reverseorder of removal,
replacethem if necessary.Be carefulnot to damage and note these items:
t h e m d u r i n gr e m o v a a
l n di n s t a l l a t i o n .
. lf the threadson the retractormounting self-
RearSeatBelt tapping ET screw are worn out, use an oversized
self-tappingET screw (P/N90133-524-0030)
1 . R e m o v et h e r e a rs e a tc u s h i o n( s e ep a g e2 0 8 0 ) . m a d es p e c i f i c a l lfyo r t h i s a p p l i c a t i o n .
. Apply liquid thread lockto the anchorbolt before
2. Removethe lower anchor bolt {A}. reinstallation.
' Checkthat the retractorlockingmechanism
A functions{seepage 23-9).
7/16-20UNF
32 N.m (3.3kgf.m, . Beforeinstallingthe anchor bolt, make sure there
24 tbf.ftl are no twists or kinksin the rear seat belt.
l . \ J ,
I 3 , R e m o v et h e r e a rs i d et r i m p a n e l( s e ep a g e2 0 - 5 1 ) .
4 . Removethe retractormounting self-tappingET

screw (A),and the retractorbolt (B),then remove
the rear seat belt (C)and retractor{D).
B
7/16-20
UNF
N m {3.3kgf.m,2irlbf.ft)
A
6x1.0mm
3.4 N.m {0.35kgl m,2.5 lbf.ftl
(cont'd)
23-7
SeatBelts
RearSeat Belt Replacement{cont'd)
CenterBelt and Seat Belt Buckles 7. Removethe seat belt guide (A)from the pin (B),
and releasethe centerbelt (C)from the seat belt
1. Removethe seatcushion{seepage 20-80). g ui d e .
2. Removethe centeranchor bolts (A),and remove

the seat belt buckles(B)and centerbeh (C).
A
7/16-20 UNF
32N.m13.3kgf.m,
24 tbt.ft)
'.;r-
1-..i, ,
<i..
-"':''
'" "':
Removethe retractormounting bolt (A),and the

retractorbolt (B),then removethe centerbelt (C)
and retractor(D)from the seat-backframe (E).
A
6x1.0mm 7/16-20UNF
3. Removethe right seat-back(seepage 20-80). 9.8 N.m (1.0kgf m, 32 N.m(3.3kgf m,
7.2 tbl.ttl 24 tbf.ftl
4. Removethe seat-backcover (seepage20-82).
5, Removethe seat-backpad from the seat-back

frame (seestep 3 on page 20-81).
6. Removethe screw,and releasethe hooks (A),then

removethe retractorcover (B).
FastenerLocation B
.:.',
t.)
23-8
I Inspec'tion
9. lnstallthe seat belt and bucklesin the reverseorder with seatbelttensioners.
Forfrontseatbeltretractors
of removal,and note these items: reviewtheSRScomponent locations(seepage23-13)
andthe precautionsandprocedures (seepsge23-14)in
. Checkthat the retractorlockingmechanism the SRSsectionbeforeperformingrepairsor service.
functions(seestep 1 on page 23-10).
. Assemblethe washerson the centeranchor bolt Retractor,Front and Rear
as shown (exceptcentershoulderbelt).
. Apply liquidthread lock to the anchor bolts 1. Beforeinstallingthe retractor,checkthat the seat
beforereinstallation. belt can be pulled out freely.
. Beforeinstallingthe centeranchor bolt, make
sure there are no twlsts or kinksin the centerbelt, 2. l\4akesure that the seat belt does not lockwhen the
retractor(A) is leanedslowly up to 15'from the
Canler anchor bolt construction: mounted position.The seat belt should lock when
the retractoris leanedover 40'. Do not attemDtto
disassemblethe retractor.
WASHER Front:
Forward lnside
Rear:
Forward Inside
Replacethe seat belt with a new assemblyif there

is any abnormality.Do not disassembleany pan of
the seat belt for any reason,
(cont'd)

23-9
Seat Belts
Inspection(cont'd)
RetraEtor,RearCenter In-vehicle
1. Beforeinstallingthe retractor,checkthat the seat 1. Checkthat the seat belt is not twisted or caught on
belt can be pulled out freely. anything.
2, Make sure that the seat belt does not lockwhen the 2. After installingthe anchors.checkfor free
retractor(A) is leanedslowly up to 15' from the movementon the anchorbolts. lf necessary,
mounted position. removethe anchor bolts and checkthat the
washersand other partsare not damagedor
i m p r o p e r l yi n s t a l l e d .
3. Checkthe seat beltsfor damageor discoloration.

Cleanwith a shop towel if necessary.Use only
soap and water to clean.
NOTE:Dirt build-upin the loops of the upper

anchorscan causethe seat beltsto retractslowly.
Wipe the insideof the loops with a cleancloth
d a m p e n e di n l s o p r o p yal l c o h o l .
Checkthat the seat belt does not lockwhen pulled

lnside Forward out slowly. The seatbelt is designedto lock only
during a sudden stop or impact.
3 , Leanthe retractorover 40', and make sure that the For rearcentershoulderbelt,checkthat the seat
seat belt does not lockwhen pulled out over 900 b e l tl o c k sw h e n p u l l e do u t o v e r 4 0 0m m ( 1 5 . 7i n . )
mm (35.4in.).Do not aftemptto disassemblethe with the seat-backfolded down.
retractor.
Make sure that the seat belt will retract
4 . Replacethe seat belt with a new assemblyif there automaticallywhen released.
is any abnormality.Do not disassembleany part of
the seat belt for any reason. 7 . For each passenger'sseat belt, checkthe seat belt
retractorlockingmechanismALR (automatic
lockingretractor).This function is for securingchild
seats.
- 1 P u l l t h es e a tb e l ta l l t h e w a y o u t t o e n g a g et h e
ALR.The seat belt should retractwith a
ratchetingsound, but not extend.This is
normal.
-2 To disengagethe ALR, releasethe seat belt and

a l l o w i t t o f u l l y r e t r a c tt,h e n p u l l t h es e a tb e l t
out part-way.The seat belt should retractand
extend normally.
8 . Replacethe seat belt with a new assemblyif there

is any abnormality.Do not disassembleany part of
the seat belt for any reason.
\,J
23-10
I ChildSeatTetherAnchorRemovaUlnstallation
Middle Side
1. Removethe child seattether anchorcover (A) in 1. Removethe rear bulkheadcoversfrom both sides
t h e r e a rt r i m p a n e l( B ) . ( s e ep a g e2 0 - 5 1 ) .
2. Removethe anchorbolt (A),then removethe child

seattether anchor (B)from behindthe seat-backon
each side ofthe cargo compartment.Do not
removethe toothedwasher (C)from the tether
anchor.
f-..- t"
.i..].-
,tltl
8 x 1.25mm
22 N m {2.2ksf.m, 16lbf.ft)
v\
2 . R e m o v et h e a n c h o rb o l t( C ) ,t h e n r e m o v et h e c h i l d A I 1
8 x 1 . 2 5m m
seattether anchor(D).Do not removethe toothed 22 N.m {2.2kgt m. 16lbfft)
washer (E)from the tether anchor.
l n s t a l l t h ea n c h o r si n t h e r e v e r s eo r d e ro f r e m o v a l .
3 . I n s t a l l t h ea n c h o ri n t h e r e v e r s eo r d e ro f r e m o v a l .
I J

23-11
sRs
LEFTFRONTIMPACTSENSOB SRSINOICATOR
page23-105
Troubleshooting,
RIGHTFRONTIMPACTSENSOR
SIDEAIRBAG CUTOFFINDICATOR
AIRBAG
DRIVER'S
page23-113
Replacement,
page
Disposal, 23 1'16
FRONTPASSENGER'SAIRBAG
Disposap
l , a g e2 3 ' 1 1 6
SENSOR/
SEATBACK
Replacement,
page20-75
FRONTPASSENGER'S
SIDEAIRBAG
Replacement,
p a g e2 3 ' 1 ' 1 5
Disposal,
p a g e2 3 ' 1 1 6
FRONTPASSENGER'S
SEATBELT
CABLEREEL TENSIONER
Beplacement, Beplacement,
p a g e2 3 - 1 1 9 page23-4
Disposal,
page23-'116
OPDSUNIT
MEMORYERASE page23-27
Initialization,
(MES}
SIGNAL Replacement, page23-124
CONNECTOR
I2PI
SIOE
PASSENGER'S
IMPACTSENSOR
Replacement,
p a g e2 3 - 1 2 3
DATA LINK
CONNECTOR FRONTPASSENGER'SSEAT
(DLCI16P BELTBUCKLETENSIONER
DRIVER'SSEATBELTTENSIONER
Replacement, page23 4
D i s p o s a pl ,a g e2 3 - 1 1 6

23-13
sRs
Precautionsand Procedures
GeneralPrecautions Steering-related
Plecautions
Pleaseread the following precautionscarefullybefore CableReelAlignment
performingairbagsystem service.Observethe
instructionsdescribedin this manual.or the airbags . M i s a l i g n m e not f t h e c a b l er e e lc o u l dc a u s ea n o p e ni n
could accidentallydeploy and causedamageor injuries. t h e w i r i n g ,m a k i n gt h e S R Ss y s t e ma n d t h e h o r n s
inoperative.Centerthe cable reelwheneverthe
. Exceptwhen performingelectricalinspections. following is performed(seestep 6 on page23-121).
alwaysturn the ignition switch OFF,disconnectthe
negativecablefrom the battery,and wait at least3 - Installationof the steeringwheel
minutesbefore beginningwork. - Installationof the cable reel
NOTE:The memory is not erasedeven if the ignition - I n s t a l l a t i oonf t h e s t e e r i n gc o l u m n
switch is turned OFFor the batterycablesare - Other steering-related adjustmentor installation
disconnectedfrom the battery.
. Use replacementpans which are manufacturedto the . Do not disassemblethe cable reel.
same standardsand quality as the original parts.Do
not installused SRSpartsfrom anothervehicle.Use . Do not apply greaseto the cable reel.
only new pans when making SRS repairs.
. Carefullyinspectany SRS part beforeyou installit. . lf the cable reel shows any signs of damageor
Do not installany part that shows signs of being contamination.replaceit with a new one. For
droppedor improperlyhandled,such as dents,cracks, example,it does not rotatesmoothly.
or deformation.
. Beforeremoving any SRSparts (includingthe

disconnectionof connectors),alwaysdisconnectthe
SRSconnector.
. Use only a digital multimeterto checkthe system.lf it
is not a Honda multimeter,make sure its outout is 10
mA (0.01A)or lesswhen switchedto the lowestvalue
in the ohmmeter range.A testerwith a higheroutput
could causeaccidentaldeploymentand possible
injury.
. Do not put objectson the front passenger'sairbag.
. The original radio has a coded theft protectioncircuit.
Be sure to get the customer'sradio code and write
down the frequenciesfor the radio's presetstations
beforedisconnectingthe batterycable.
. Beforereturningthe vehicleto the customer,enter
the radio code.then enter the customer'sradio
stationpresets,and set the clock.Do the engine
control module (ECM)idle learn procedure(seepage
11-139).
\rc
23-14
AirbagHandlingand Storage . Storethe removedairbagon a secure,
flat surface
awayfrom any highheatsource(exceeding 200'Fi
Do not disassemblean airbag,lt has no serviceable
parts.Oncean airbag has been deployed,it cannot be
repairedor reused.
For temporarystorageof an airbagduring service,

observethe following precautions.
. Storethe removedairbagwith the pad surfaceup.

Never put anythingon the airbag.
Never perform electricalinspectionsto the airbags,

such as measuringresistance.
Do not positionyourselfin front of the airbagduring

removal,inspection,or replacement.
To preventdamageto the airbag,keep it free from

any oil, grease,detergent,or water,
Referto the scrappingproceduresfor disposalof a

d a m a g e da i r b a g .
(cont'd)

23-15
sRs
Precautionsand Procedures{cont'dl .j
SRSUnit, Front lmpact Sensors,and Side . Do not disassemblethe SRS unit,front impactsensors,
lmpact Sensors or side impact sensors.
. Be careful not to bump or impactthe SRS unit, front . Turn the ignition switch OFF,disconnectthe battery
impact sensors,or side impactsensorswheneverthe negativecable,and wait at least3 minules before
ignition switch is ON (ll),or for at least3 minules after beginninginstallationor replacementof the SBS unit,
the ignition switch is turned OFF. or disconnectingthe connectorsfrom the SRSunit.
. During installationorreplacement,be carefulnotto . Be sure the SRSunit,front impactsensors,and side

bump (by impactwrench, hammer,etc.)the area impact sensorsare installedsecurely.with the
aroundthe SRS unit, front impact sensors,and sjde mounting bolts torquedto 9.8 N.m (1.0kgf.m,7.2 lbf.ft)
impact sensor.The airbagscould accidentallydeploy
and causedamageor injury. . Do not spill wateroroil on the SRSunit, front impact
sensors,or the side impact sensors,and keepthem
away from dust.
. Store the SRS unit, front imDactsensorsand side

impactsensorsin a cool (lessthan 104"F/40'C)and
dry (lessthan 80 % relativehumidity,no moisture)
area.
After a collisionin which any airbagsor seat belt

tensionerswere deployed.replacethe SRSunit, front
I
impact sensors,and other relatedcomponents(see
page 23-112).After a collision in which a side airbag
was deployed.replacethe side impact sensoron the
deployedside and the SRS unit. After a collisionin
which the airbagsor the side airbagsdid not deploy,
inspectfor any damageor any deformationon the
SRS unit, front impact sensors,and the side impact
s e n s o r sl.f t h e r ei s a n y d a m a g e r, e p l a c et h e S R Su n i t
and/orthe sensors.
23-16
I
WiringPrecautions for ElectricalInspections
Precautions
Some of the SRSwiring can be identifiedby a special . When using electricaltestequipment,insertthe
yellow outer covering,and the SRSconnectorscan be probe of the tester into the wire side of the connector.
identifiedby their yellow color. Do not insertthe probe of the testerinto the terminal
Observethe instructionsdescribedin this section. side of the connector,and do not tamper with the
connector.
. Neverattemptto modify. splice,or repairSRSwiring.
l f t h e r ei s a n o p e no r d a m a g ei n S R Sw i r i n g ,r e p l a c e
the harness.
Use a U-shapedprobe.Do not insertthe probe

forcibly.
J Be sure to installthe harnesswires so they do not get

Dinchedor interferewith other Darts.
Use specifiedserviceconnectorsin tro u bleshooting.

U s i n gi m p r o p e rt o o l sc o ul d c a u s ea n e r r o ri n
inspectiondue to poor metal-to-metalcontact.
M a k es u r ea l l S R Sg r o u n dl o c a t i o n sa r e c l e a n ,a n d
groundsare securelyfastenedfor optimum metal-to-
metal contact.Poorgroundingcan causeintermittent
problemsthat are difficultto diagnose.
(cont'd)

23-17
sRs
Precautionsand Procedures(cont'dl
Spring-loaded
LockConnector Side Airbag Connector:
Some SRSsystemconnectorshave a spring-loaded Disconnecting

lock. T o r e l e a s et h e l o c k ,p u l l t h es p r i n g - l o a d esdl e e v e( A )
a n dt h e s l i d e r{ B )w h i l e h o l d i n gt h e o p p o s i t eh a l fo f t h e
Front Airbag Connectors: connector.Then pullthe connectorhalvesapart.Be
sure to pull on the sleeveand not on the connectorhalf.
Disconnecting
To releasethe lock.pullthe spring-loadedsleeve(A)
toward the stop (B)while holdingthe oppositehalf of
the connector.Then pullthe connectorhalvesapart,Be
sure to pull on the sleeveand not on lhe connector.
Connecting
Hold both connectorhalves,and pressthem firmly
Connecting togetheruntil the projection(C)of the sleeveside
1. To reconnect,hold the pawl-sideconnector,and
presson the backof the sleeve-sideconnectorin
connectorclicks. J
the directionshown. As the two connectorhalves
are pressedtogether,the sleeve(A) is pushedback
by the pawl (C).Do not touch the sleeve.
When the connectorhalvesare completelV

connected,the pawl is released,and the spring-
loadedsleevelocksthe connector.
\ J
23-18
Backprobing
Spring-loaded
LockConnectors Seatswith SideAirbags
When checkingvoltageor resistanceon this type of "SIDEAIRBAG" label
Seatswith side airbagshave a on
connectorthe first time, you must removethe retainer the seat-back.Becausethe componentpans (seat-back
to insertthe tester orobe from the wire side. cover,cushion,etc.)of seatswith and without airbags
are different,make sure you installonly the correct
NOTE:lt is not necessaryto reinstallthe removed replacementparts.
retainer;theterminalswill stay lockedin the connector
housrno.
A W h e n c l e a n i n gd, o n o t s a t u r a t e t h es e a t w i t hl i q u i d ,
and do not sDravsteam on the seal
To removethe retainer(A),inserta flat-tipscrewdriver Do not reoalra torn or fraved seat-backcover.
(B) betweenthe connectorbody and the retainer,then ReDlacethe seat-backcover.
carefullypry out the retainer.Takecare not to breakthe A f t e ra c o l l i s i o ni n w h i c ht h e s i d ea i r b a gw a s
connector. deployed,replacethe side airbagwith new parts.lf
the seat-backcushion is split, it must be replaced.lf
the seat-backframe is deformed,it must be replaced.
Never put aftermarketaccessorieson the seat{covers,
pads,seat heaters,lights,etc.).
(cont'd)

23-19
sRs
Precautionsand Procedures(cont'dl
DisconnectingSystemConnectors
Beforeremoving a front airbag.side airbag,or other SRS relateddevices{the SRS unit,the cable reel,the front impact
sensors,the side impact sensors,the seat belt buckletensioners,and the seat belt tensionerconnector),disconnecting
connectorsfrom relateddevices,or removingthe dashboardor the steeringcolumn, disconnectthe airbagconnectors
or the side airbagconnectorsto preventaccidentaldeploVment.
Turn the ignition switch OFF,disconnectthe negativecablefrom the battery,and wait at least3 minutesbefore
beginningthe following procedures.
'BeforedisconnectingSRSunitconnectorA(1)fromtheSRSunit,disconnectthedriver'sairbag4Pconnector(3).
the front passenger'sairbag4P connector(4),the driver'sseat belt tensioner2P connector(6),and the front
passenger'sseatbelt tensioner2P connector(7).
. BeforedisconnectingSRS unit connectorB (8)from the SRS unit, disconnectboth side airbag2P connectors(11.'12),
and both seat belt buckletensioner4P connectors(9, 10).
. Beforedisconnectingthe cable reel 4P connector(2),disconnectthe driver'sairbag4P connector(3).
'Beforedisconnectingthefloorwireharness4Pconnector(5),disconnectbothseatbelttensioner2Pconnectors
(6.7).
\ .
23-20
1. Disconnectthe batterynegativecable,and wait at Side Airbag
least3 minutes.
4. Disconnectboth side airbag2P connectors(Alfrom
Driver's Airbag the floor wire harness.
2. Removethe accesspanel (A)from the steering

wheel,then disconneclthe driver'sairbag 4P
connector(B)from the cable reer.
Front Passenger'sAirbag
3. Disconnectthe front passenger'sairbag4P

connector(A)from dashboardwire harnessB.
(cont'd)
23-21
sRs
Precautionsand Procedures(cont'd) 4
SeatBelt Tensioner SRS Unit
bothseatbelttensioner2Pconnectors
5. Disconnect 7. DisconnectSRS unit connectorA, SRS unit
(A)fromthefloorwire harness connectorB, and/or SRS unit connectorC from the
S R Su n i t .
Seat Belt Buckle Tensioner
6. Disconnectboth seat belt buckletensioner4P

connectors(A).
\ J
23-22
Information
DTC(Diagnostic
TroubleCodesl Readingthe DTC
The self-diagnostic function of the SRSsystem allows it When the SRSindicatoris on, read the DTCusing either
to locatethe causesof system problemsand then store of the following methods:
this informationin memory. For easiertroubleshooting,
this data can be retrievedvia a data link circuit. PGM Tester "SRS" Menu Method:
Connectthe Honda PGM Tester{A)to the 16Pdata link
. W h e ny o u t u r n t h e i g n i t i o ns w i t c hO N ( l l ) ,t h e S R S connector{DLC)(B), and follow the Tester'sDromptsin
indicatorwill come on. lf it goes off after 6 seconds, "SRS"
the menu.
the system is normal. lf the Testerindicatesno DTC,no communication.DTC
. lf there is an abnormality,the svstem locatesand 3-6 to 3-'10,DTC4-6 to 4-10,DTC9-1,or DTC9-2,
definesthe problem,storesthis informationin double-checkby usingthe "SCS" menu method.
memory, and turns the SRS indicatoron. The data
w i l l r e m a i ni n t h e m e m o r ye v e nw h e n t h e i g n i t i o n
switch is turned off or if the batteryis disconnected.
. When you connectthe HondaPGlMTesterto the 16P
d a t al i n kc o n n e c t o(rD L C ) t os h o r tt h e S C St e r m i n a l ,
a n d t u r n t h e i g n i t i o ns w i t c hO N ( l l ) .t h e S R Si n d i c a t o r
will indicatethe diagnostictrouble code (DTC)by the
n u m b e ro f b l i n k s .
. When you connectthe HondaPGM Testerto the 16P
data link Connector(DLC),you can retrievethe DTCin
t h e H o n d aS y s t e m s" S R S " m e n u .
. After readingand recordingthe DTC,proceedwith
the troubleshootingprocedurefor th is code.
Precautions
. U s eo n l y a d i g i t a lm u l t i m e t etro c h e c kt h e s y s t e m .l f
it's not a Hondamultimeter,make sure its output is
1 0 m A ( 0 . 0 1 Ao) r l e s sw h e n s w i t c h e dt o t h e s m a l l e s t
v a l u ei n t h e o h m m e t e rr a n g e A , t e s t e rw i t h a h i g h e r
o u t p u tc o u l dd a m a g et h e a i r b a gc i r c u i to r c a u s e
a c c i d e n t aal i r b a gd e p l o y m e nat n d p o s s i b l ei n j u r y .
. Wheneverthe ignition switch is ON (ll),or has been
turned OFFfor lessthan 3 minutes,be careful not to
b u m pt h e S R Su n i Ut h e a i r b a g sc o u l da c c i d e n t a l l y
d e p l o ya n d c a u s ed a m a g eo r i n j u r i e s .
. Beforeyou removethe SRSharness,disconnectthe
driver's airbagconnector.the front passenger's
airbagconnector,both side airbagconnectors,both
seat belt buckletensionerconnectors,and both seat
b e l tt e n s i o n ecr o n n e c t o r s .
. Make sure the batteryis sufficientlycharged.lf the
batteryis dead or low, measuringvalueswon't be
correct.
. Do not touch a tester probe to the terminalsin the
SRSunit or harnessconnectors,and do not connect
t h e t e r m i n a l sw i t h a j u m p e rw i r e . U s eo n l y t h e
backprobeset and the HondaPGM Tester.Backprobe
spring loadedlocktype connectorscorrectly.
(cont'd)
23-23
sRs
GeneralTroubleshootingInformation(cont'd) L 4
PGM Tester "SCS" Menu Method {retrieving the flash Readingthe main code:
codes):
I nc a s eo f 1 - 1 0
Countthe numberof blinks.
The SRSindicator(A) indicatesthe DTCby lhe number
Examplo:
of blinkswhen the Honda PGM Tester(B) is connected 1 . 2S r . 2S 1 . 2S 1 . 2S 1 . 2S
to the DLC(datalink connector)( 16P)(1). *t**t*l*l
""_f]_flfl
'1.
Make sure the ionition switch is OFF.
2. Connectthe HondaPGN4Tester(B)to the DLC(C),

"SCS" menu
and follow the Tester'soromDtsin the Maincodo= 1 + 1 + 1 =3
to ground the SCS line (seethe HondaPGM Tester
In caseot 11..'15
ODerator'sManual). Fourfastblinkscountas 10.
Add anyfunherblinkstogetheras shown.
Example:
0 . 1s
,A
/// t\\\
//lii\\ 1.rs r.2s r.2s 1.2s
_ | *t* - L'- - * l
""ffi
Main code= 10 I =12
l n c a s eo f 2 0 o r m o r e
3 . Make sure the SCS line is grounded,then turn the
T w o s e t s o f f o u r f a s t b l i n k sc o u n t a s 2 0 .
ignitionswitch ON (ll).The SRS indicatorcomes on A d d a n y f u n h e r b l i n k s t o g e t h e ra s s h o w n .
for about 6 seconds,and then goes off. Then it will
Examplo:
blinkto indicatethe DTC(seethe table below).
0 . 1s 0.1s
4. Readthe DTC.
12s12s
,y'fl\,,. /[N *l-
5 . Turn the ignition switch OFF,and wait for 10 *FtftffN*+fH-t-ff
seconds.
6, Disconnectthe Honda PGMTesterfrom the DLC.

Main code= 10 + 10
7. Do the troubleshootingprocedurefor the DTC.
Patteins of DTC Indications: Readingthe subcode:

T h e D T C c o n s i s t so f a m a i n c o d e a n d s u b c o d e . Count
thenumber
of blinks.
Example:
S: Second
0.3s 0.3s 0.3s 0.3s 0.3s 0.3s 0.3s
6S 25 35 l**t**t*t*t*l
o N
oFFl
[ l I t l - l- - - -|- L [l - - - l I S
""ffi
u b c o d e = 1 + 1 + 1 r ' 1 = 4
'3', ' 4 ' , r e c o r da

First emitting Main code Subcode lf the main code is a n d t h e s u b c o d ei s
DTC 3 4.
\ J
23-24
Includingthe most recentproblem,up to three differentDTCScan be indicated(seeexample 1 below).
ln case of a continuousfailure,the DTCwill be indicatedrepeatedly{seeexample 1 below).
In caseof an intermittentfailure,the SRS indicatorwill indicatethe DTCSone time, then it will stay on (seeexample
2 below).
lf both a continuousand an intermittentfailure occur,both DTCSwill be indicatedas continuousfailures.
When the system is normal (no DTCS),the SRS indicatorwill stay on (seeexample3).
lf the SRSindicatorcomes on continuouslywithout a DTC,there mav be a problemwith the svstem.
lf the SRSindicatordoes not come on as indicatedabove,alwayscheckfor an open or a short to ground in the SCS
circuitbeforetroubleshootingthe system.
Example of DTC Indications:
1. Continuousfailure,SRSIndic6torblink$likethis: S: Second
1 . 2S 1 , 2S 0.3s 0.3s
0.3s
ON
OFF
Bulb check Maincode(21 Subcode
l1) Main code l1l Subcode(3) Main code {11 Subcode{'l) Indications
period are lepeated
DTC2-l DTC1-3 DTC1-1 tn cese ot
Most recentp.oblem Sscond-mostrecent Third-mostrocent continuous
2. Intermittent failure, SRS lndicator blinks like this: problem problem failure.
ON
OFF lndicator stays on in

case of i nterm ittent failu re.
Bulb check DTC 5-1
period
3. Normal (no failure|,SRSIndicatorblinks like this:
ON
OFF
Bulb chock No DTC,systom is normal, the indicator
period stays on.
(cont'd)
23-25
sRs
Erasingthe DTGMemory Troubleshootinglntermittent Failures
Specisl Tool Required lf there was a malfunction,but it doesn't recur.it will be
SCSserviceconnector07PAz-0010100 storedin the memory as an intermittentfailure,and the
SRS indicatorwill come on.
To erasethe DTC(S)fromthe SRSunit, use a Honda
PGMTester{seelhe HondaPGfMTesterSRSVehicle After checkingthe DTC,troubleshootas follows:
SystemSupplement)or the following procedure.
1. Readthe DTC(see"Readingthe DTC").
1. Make sure the ignition switch is OFF.
"Erasingthe DTC
2. Erasethe DTCmemory (see
2. Connectthe SCSserviceconnector{A) to the MES Memory").
2P connector(B).Do not use a jumper wire.
3. With the shift lever in neutral,startthe engine,and
letit idle.
4 . The SRSindicatorwill come on for about 6 seconds

and then go off.
Shakethe wire harnessand the connectors.take a

test drive (quickacceleration,quick braking,
cornering),turn the steeringwheel fully left and
'10
right, and hold it there for 5 to seconds.lf the
problem recurs,the SRSindicatorwill come on.
lf you can't duplicatethe intermittentfailure,the

07PAZ-0010100 system is OK at this time.
4. The SRS indicatorwill come on for about 6 seconds,

and then go off. Removethe SCSserviceconnector
from the MES connectorwithin 4 secondsafterthe
indicatorgoes off.
5. The SRS indicatorwill come on again.Reconnect

the SCSserviceconnectorto the MES connector
within 4 secondsafter the indicatorcomes on.
6. When the SRSindicatorgoes off, removethe SCS

serviceconnectorfrom the MES connectorwithin 4
seconds.
r i l l b l l n kt w o t i m e s i n d i c a t i n g
7 . T h e S R Si n d i c a t ow
that the memory has beenerased.
'10
8. Turn the ignition switch OFF,and wait for
seconds.
. h e S R Sj s
9 . T u r nt h e i g n i t i o ns w i t c hO N ( l l )a g a i n T
OK if the SRSindicatorcomes on for 6 secondsand
then goes off.
\ J
23-26
I
Initializingthe OPDS{OccupantPositionDetectionSystem}Unit
Special Tool Required
SCSserviceconnector07PAz-00'1
0100
When a seat-backcover,seat-backcushion,and/or OPDSunit is replaced,initializethe OPDSby following the

procedurebelow.
NOTE:Make sure the front passenger'sseat is dry. Set the seat-backin the normal position,and make sure there is
nothing on the seat.
'1.
l\4akesure the ignition switch is OFF.
2. Connectthe HondaPGM Tester(A)to the DLC(16P)(B),andfollowtheTester's prompts jn the ,,SCS,,menu to
ground the SCSline (seethe Honda PGM TesterOperator'sManuaD.
3. Connectthe SCSserviceconnector(C)to the MES 2P connector(D).Do not use a iumoer wire.
c
07PAZ-00r0100
5. The SRS indicatorcomes on for about 6 secondsand goes off. Removethe SCSserviceconnectorfrom the MES
connectorwithin 4 secondsafterthe SRSindicatorwent off.
6. The SRSindicatorcomes on again.Reconnectthe SCSserviceconnectorto the MES connectorwithin 4 seconds
afterthe SRS indicatorcomes on.
7. The SRSindicatorgoes off. Removethe SCSserviceconnectorfrom the MES connectorwithln 4 seconds.
8. Watch the sRS indicator.
'lftheindicatorblinkstwotimesandthenstayson,theOPDSisinitialized.buttheDTCSneedtobeerased.
step 9, then erasethe DTCS.
.lftheindicatorblinkstwotimesandthengoesoff,theOPDSunitisinitialized.Gotostep9.
' lf the indicatorstayson without first blinking.theOPDSis not initialized.Readthe DTC.lf DTC 15-'lis indicated,
repeatthe initializationprocedure.lf anotherDTCis indicated,go to the appropriatepage in the DTC
TroubleshootingIndex.
9. Turn the ignition switch off, and disconnectthe PGM Tester.
SBS indic.ror
MES
I J DISCONNECTED
23-27
sRs
DTCTroubleshootingIndex t .
DTC Detection ltem Notes
t- | O D e ni n d r i v e r ' sa i r b a qi n f l a t o r (seeDaqe23-36)
Increasedresistancein driver'sairbaq inflator (seeDaoe23-36
t-5 Shon to anotherwire or decreasedresistancein driver's airbag (seepage23-37)
inflator
1-4 Shortto Dowerin driver'sairbao inflator (seepaqe23-39
t-5 Shortto qround in driver'sairbaq inflator {seepaqe23-40
2-1 Open in front Dassenqer's airbaq inflator {seeoaoe23-42
2-2 I n c r e a s e rde s i s t a n cien f r o n tp a s s e n q e r 'asi r b a qi n t l a t o r (seeoaqe 23-42
2-3 Short to anotherwire or decreasedresistancein front passenger's (seepage23-43)
airbao inflator
2-4 Short to oower in front oassenoer'sairbaq inflator (seepaqe23-45
2-5 Short to qround in front passenqer'sairbaq inflator (seepaqe 23-46
3-1 ODenin driver'sseat belttensioner (seepage 23-48
3-2 lncreasedresistancein driver's seat belt tensioner (seepaqe 23-48
3-3 Short to anotherwire or decreasedresistancein driver'sseat belt (seepage 23-49)
tensioner
3-4 Short to oower in driver'sseat belt tensioner (seeDaqe23-51
3-5 Short to oround in driver'sseat belt tensioner (seeoaoe 23-52
21-1 ODenor increasedresistancein driver'sseat belt buckletensioner (seepaqe 23-54
Short to anotherwire or decreasedresistancein driver'sseat belt (seepage23-55)
buckletensioner
2't-4 Short to Dowerin driver'sseat belt buckletensioner (seepaqe 23-56)
2't-5 Shon to oround in driver'sseat belt buckletensioner (seeoaqe23'57
4-'l ODenin front oassenoer'sseat belt tensioner {seepage23-58)
{seepaqe23-58)
4-2
4-3
lncreasedresistancein front oassenqer'sseat belttensioner
Short to anotherwire or decreasedresistancein front passenger's {seepage23-60) t J
seat belt tensioner
4-4 Shon to Dowerin front Dassenqer's seat belt tensioner lsee oaqe23-61
4-5 Short to qround in front oassenoer'sseat belt tensioner (seeDaqe23-63
Open or increasedresislancein front passenger'sseat belt buckle (seepage 23-64)
tensioner
22-3 Short to anotherwire or decreasedresistancein front passenger's (seepage 23-65)
seat belt buckletensioner
22-4 Short to oower in front oassenqer'sseat belt buckletensioner (seepaqe 23-66
22-5 Short to oround in front oassenoer'sseatbelt buckletensioner (seepaqe 23-68
5-1 lnternalfailure of SRSunit (seepage23-69)
5-2 NOTE:
5-4 BeforetroubleshootingDTCS5-1 through 8-6,checkbattery/system
5-8 voltage.lf the voltage is low, repairthe charging system before
6-3 troubleshootinothe SRS.
6-4
6-7
6-8
1-)
7-3
8-1
a-2
8-4
8-5
8-6
\ J
23-28
I J
DTC Detection ltem Notes
9-1 Internalfailure of the SRS unit. lf intermittent,it could mean internal (seepage23-69)
failure of the unit or a faulty indicatorcircuit.Referto
TroubleshootingIntermittentFailures(seepage 23-26).
NOTE:BeforetroubleshootingDTC9-1 or 9-2,checkbattery/system
voltage.lf the voltage is low, repairthe chargingsystem before
t r o u b l e s h o o t i nt gh e S R S .
9-2 Internalfailure of the SRSunit. lf intermittent,it could mean internal
failure of the power supply (VB line).Referto Troubleshooting
IntermittentFailures(seepage 23-26).
NOTE:BeforetroubleshootingDTC9-1 or 9-2,checkbattery/system
voltage.lf the voltage is low, repairthe chargingsystem or replace
the b€tterybeforetroubleshootingthe SRS.
9-3 Faultydriver'sseat belt buckleswitch (seeDaqe23-71)
9-4 FaultLtglt passenger's
seatbeltbuckleswitch lgqgfage 23-74)
9-6 FaultyIeft front imDactsensor {see Daqe23-77)
9-7 Faultyright front impact sensor (seepaqe 23-79)
10-1 Seat belt and seat belt buckletensioners(and airbag(s))deployed (seepage23-69)
10-2 D r i v e r ' ss i d ea i r b a gd e p l o y e d
r0-3 Seat belt and seat belt buckletensioners(and airbag(s))and driver's
s i d ea i r b a gd e p l o y e d
'10-4
Frontpassenqer'sside airbaodeDloved
'10-5
Seat belt and seat belt buckletensioners(and airbag(s))and front
passenqer'sside airbaq deDloved
10-6 Driver'sand front passenqer'sside al
l r 10-7
11-1
Seat belt and seat belt buckletensioners(and airbag(s))and driver's
and front passenger'sside airbagsdeployed
Open or increasedresistancein driver's side airbao inflator ( s e ep a q e2 3 - 8 1 )
Short to anotherwire or decreasedresistancein driver'sside airbao (seepage23-82)
inflator
11-4 Short to power in driver'sside airbaq inflator (seeoaqe 23-83)
I t-5 Short to ground in driver's side airbaq inflator {seepaqe 23-85)
Open or increasedresistancein front passenger'sside airbag (seepage 23-86)
inflator
Short to anotherwire or decreasedresistancein front passenger's (seepage 23-87)
side airbag inflator
12-4 Short to power in front passenqer'sside airbaq inflator {seeDaqezJ-uu}
Iz-5 S h o r tt o g r o u n di n f r o n t p a s s e n g e r 'ssi d ea i r b a qi n f l a t o r (seeoaqe 23-90)
13-1 Internalfailure of the driver's side impactsensor (seepage 23-70)
N o s i g n a lf r o m t h e d r i v e r ' ss i d ei m p a c ts e n s o r ( s e ep a q e2 3 - 9 1 )
13-4 Faultypowersupplyto the df,rglllug t Opacts9I99L (seepage23-92)
- 7 i i
14-1 , Internalfailureofthe frontpassenger's
sideimpactsensor (seepage23-70)
14-3 N o s i g n a lf r o m t h e f r o n t p a s s e n g e r 'ssi d ei m p a c ts e n s o r (seepaqe 23-94)

14-4 Faultypower supply to the front passenqer'sside impact sensor (seepage 23-95)
15-1 F a u l t vO P D Su n i to r O P D Sn o t i n i t i a l i z e d ( s e ep a q e2 3 - 9 6 1
15-2 Faultyside airbagcutoff indicatorcircuit (seeDaqe23-99)
15-3 FaultyOPDSsensor (seeoaoe 23-104)
I J
23-29
SRS
Symptom TroubleshootingIndex \ 4
Symptom Diagnosticprocedure Also check for
SRSindicatordoesn'tcome on S R SI n d i c a t oTr r o u b l e s h o o t i n(gs e e
p a o e2 3 - 1 0 5 )
SRSindicatorstayson when in SRSIndicatorTroubleshooting(see Inabilityto retrieveDTCswith the
"SCS" menu method step 1 on page 23-107) PGM Tester.Retrievethe flash
codes usingthe SCSmenu method
(seepage 23-24).
Slde airbagcutoff indicatorstays . M a k es u r en o t h i n gi s o n t h e f r o n l DTC 15-2troubleshooting
o n a f t e rb u l bc h e c k( l f t h e passenger'sseat.
indicatorstayson, it does not set . lf the side airbagcutoff indicator
a DTC).Side airbagcutoff stayson after the ignition switch
indicatoris flashing i s t u r n e dO N ( l l ) ,i n i t i a l i z teh e
OPDSunit (see page23-271.
- lf the side airbagcutoff
i n d i c a t o or p e r a t e sn o r m a l l Yt,h e
system is OK.
- lf the side airbagcutoff
indicatorstayson, replacethe
u F U 5 S e n S O{ rS e eS e C r O Z nUl.
The sensor is part of the seat-
back Dad.
t r J
\ J
23-30
I SystemDescription
SRSComponents
Airbags
The SRSis a safetydevicewhich, when used with the seat belt, is designedto help protectthe driver and front
passengerin a frontal impact exceedinga certainset limit. The system consistsofthe SRS unit, includingsafing
sensorand impactsensor(A),the cable reel (B),the driver's airbag(C),the front passenger,sairbag (D).seat belt
tensioners(l),seat belt buckletensioners(J), and front impactsensors(K).
Sincethe driver'sand front passenger'sairbagsusethe same sensors,both normally inflateat the same ttme.
However,it is possiblefor only one airbagto inflate.This can occurwhen the severityof a collision is at the margin,or
threshold,that determineswhether or not the airbagswill deploy.In such cases,the seat belt will provide sufficient
protection,and the supplementalprotectionofferedby the airbagwould be mininal.
Side Airbags
The side airbags(E)are in eachfront seat-back.They help protectthe upper torso of the driver or front seat passenger
during a moderateto severeside impact.Side impact sensors(F) in each door sill and in the SRS unit detectsuch an
impactand instantlyinflatethe driver'sor the passenger'sside airbag.Only one side airbagwill deploy during a side
impacl. lf the impact is on the passenger'sside,the passenger'sside airbagwill deploy even if there is no passenger.
Seat Belt and Seat Belt Buckle Tensioners

The seat belt and seat belt buckletensionersare linkedwith the SRSairbagsto further increasethe effectivenessof
the seat belt. ln a front-endcollision,the tensionersinstantlyretractthe belt and bucklefirmly to securethe occupants
in their seats.
OPDS
The side airbagsystemalso includesan occupantpositiondetectionsystem (OpDS).This systemconsistsof sensors
I ( G ) a n da n O P D Su n i t( H )i n t h e f r o n t p a s s e n g e r 'sse a t - b a c kT.h e O P D Su n i t s e n d so c c u p a nht e i g h la n d p o s i t i o nd a t at o

the SRS unit. lf the OPDSunit determinesthat the front passengeris of small stature(for example,a child) and the
front passengeris leaninginto the side airbag deploymentpath,the SRSunit will automaticallydisablethe passenger's
side airbag.The SRSunit will also disablethe airbagwhen the OPDSdetectscertainobiectson the seat.When the
side airbag is disabled,the side airbagcutoff indicatoron the instrumentpanel alertsthe driver that the passenger's
side airbagwill not deploy in a side impact.When the object is removed,or the passengersits upright,the side airbag
cutoff indicatorwill go off after a few seconds,alertingthe driver that the passenger'sside airbagwill deploy in a side
imDact.
(cont'd)
23-31
sRs
SystemDescription(cont'dl !J
SRSOperation
The main circuit in the SRS unit sensesand judgesthe force of impact and, if necessary.ignitesthe inflatorcharges.lf
batteryvoltage is too low or power is disconnecteddue to the impact,the voltage regulatorand the back-uppower
circuit,respectively,will keepvoltageat a constantlevel.
For the SRS to operate:
Seat Belt Tensioners and Seat Belt Buckle Tensioners

(1)A front impact sensormust activateand send electricsignalsto the microprocessor.
(2)The microprocessormust computethe signalsand send them to the tensioners.
(3)The chargesmust ignite and deploy the tensioners.
Driver's and Front Passenger'sAirbagls)

(1)A front impactsensor musl activate.and send electricsignalsto the microprocessor.
(2)The microprocessormust computethe signals.and dependingon the severityof the collisionand whetherthe seat
belt buckleswilch is ON or OFF,it sendsthe appropriatesignalsto the airbag inflator(s).
(3)The inflatorsthat receivedsignalsmust ignite and deploy the airbags.
Side Airbaglsl
( 1)A side impact sensormust activate,and send electricsignalsto the microprocessor.
(2)The microprocessormust computethe signalsand send them to the side airbag inflator(s).However,the
microprocessorcuts off the signalsto the front passenger'sside airbag if the OPDSunit determinesthat the tront
passenger'shead is in the deploymentpath of the side airbag.
(3)The inflatorthat receivedthe signal must ignite and deploythe side airbag.
lw$ad..n sl
T' n0m
P gsfrlctR
S oXrVEr
S I
J
9oEAiA$ SOtlr&G I sEctto
f'**)r !
\ J
23-32
Self-diagnosis System
A self-diagnosiscircuitis built into the SRS uniUwhen the ignition switch is turned ON (ll),the SRS indicatorcomes on
and goes off after about 6 secondsif the SRS is operatingnormally.
lf the indicatordoes not come on, or does not go off after 6 seconds.or if il comes on while driving, it indicatesan
abnormalityin the SRS.The SRSmust be inspectedand repairedas soon as possible.
For betterserviceability,the SRSunit memory storesa DTCthat relatesto the causeof the malfunction,and the unit is
connectedto the data link circuit.This informationcan be read with the Honda PGM Testerwhen it is connectedto the
data link connector(DLc) (seepage 23-23).
23-33
SRS
CircuitDiagram J
rrssf c s
srarsftr
rrl$0[n
r-----Tr-i
i___':--_:"1
\ J
23-34
I J
tr ozr"*
tr ul"ar
1i
NJfl |-(tzl
t l
I J
I J
23-35
sRs
DTCTroubleshooting J
DTC1-1:Openin Driver'sAirbagInflator 6. Reconnectthe batterynegativecable.

Resistance
DTC1-2:Increased in Driver's
AirbagInflator 7. Erasethe DTCmemory.
Special Tools Required 8. Readthe DTC,

. SRS inflatorsimulator07SAZ-TB4011A
. SRSsimulatorlead F 07XAZ-S230100 ls DTC 1-1or DTC 1-2indicated?
1. Erasethe DTCmemory (seepage 23-26). YES-Go to step 9.
2. Turn the ignition switch ON {ll),and checkthat the NO Open or increasedresistancein the driver's
SRSindicatorcomes on for aboul 6 secondsand airbag inflator;replacethe driver'sairbag (seepage
then goes off. 23-113).t
Does the SBS indicator stay on? 9. Turn the ignition switch OFF.Disconnectthe
batterynegativecable,and wait ior 3 minutes.
YES-Go to step 3.
NO Intermittentfailure,system is OK at this time. connectorfrom dashboardwire harnessB (seestep
Go to TroubleshootingIntermittentFailures(see 3 o n p a g e2 3 - 2 1 ) .
page 23-26).
11. Disconnectboth seat belt tensioners2P connectors
3. Turn the ignition switch OFF.Disconnectthe from the floor wire harness(seestep 5 on page23-
batterynegativecable,and wait for 3 minutes. 22t.
4. Disconnectthe driver's airbag4P connector(A)

from the cable reel.
r ( 1 8 P ) f r o mt h e
1 2 . D i s c o n n e cSt R Su n i tc o n n e c t oA
SRSunit (seestep 7 on page 23-22).Do not
a
disconnectthe specialtool from the cable reel.
07sAz-TB4011A
07xaz-s230100
5. Connectthe SRS inflatorsimulator(2 Q

connectors)and the simulatorlead F to the cable
reet.
23-36
'16
13. Checkresistancebetweenthe No. 7 and the No. DTC1-3:Shortto AnotherWire or Decreased
t e r m i n a l sa n d b e t w e e nt h e N o . 6 a n d t h e N o . 1 5 in Driver'sAirbagInflator
Resistance
t e r m i n a l so f S R Su n i tc o n n e c t oAr ( 1 8 P )T. h e r e
s h o u l db e 2 . 0 3 . 0 0 . SpecialToolsRequired
. SRS inflatorsimulator07SAZ-T8401
1A
. SRSsimulatorlead F 07XAZ-S230100
SRSUNITCONNECTOR
A I18P)
1. ErasetheDTCmemory (seepage 23-26).
2. Turn the ignition switch ON (ll),and checkthat the

SRS indicatorcomes on for about 6 secondsand
then goes of{.
Does the SRS indicator stay on?
YES-Go to step 3.
Go to TroubleshootingIntermittentFailures(see
ls the resistance as specilied? page 23-261.
YES-Faulty SRS unit or poor contactat SRSunit Turn the ignition switch OFF.Disconnectthe
connectorA (18P)and the SRSunit, checkthe batterynegativecable,and wait for 3 minutes,
connectionbetweenthe connectorand the SRS
unit. lf the connectionis OK, replacethe SRSunit Disconnectthe driver'sairbag 4P connector(A)
( s e ep a g e2 3 - 1 2 2 ) . 1 from the cable reel.
NO-Open or increasedresistancein dashboard

wire harnessB orthe cable reel;replacethe cable
reel.lf the problemstill present,replacedashboard
w i r e h a r n e s sB .
07sAz-T84011A
07xAz-s230100
ConnecttheSRSinflatorsimulator{2 0
reel.
Reconnectthe batterynegativecable.
1 . Erasethe DTCmemory.
(cont'd)
23-37
sRs
8. Readthe DTC. 14. Checkresistancebetweenthe No. 7 and the No. 16
t e r m i n a l sa n d b e t w e e nt h e N o . 6 a n dt h e N o . 1 5
Is DTC 1-3indicated? t e r m i n a l so f S R Su n i tc o n n e c t o r A( 1 8 P )T. h e r e
should be an open circuit,or at least 1 M Q .
YES Go to step 9.
SRSUNITCONNECTOR
A {18P)
NO Short in the driver'sairbag;replacethe
driver's airbag (seepage 23-'l13).1
GRN/WHT GRN/RED
9. Turn the ignition switch OFF.Disconnectthe
batterynegativecable,and wait for 3 minutes.

connectorfrom dashboardwire harnessB (seestep
3 o n p a g e2 3 - 2 1 ) . GRN/YEL GRN/BLK
1'1. Disconnectboth seat belt tensioner2P connectors Wire side of femaleterminals

from the floor wire harness(seestep 5 on page 23-
22t.
ls the rcsistance as specified?
1 2 . D i s c o n n e cSt R Su n i tc o n n e c t o r A( 1 8 P ) f r o mt h e
SRS unit (seestep 7 on page 23-221. YES FaultySRS unit; replacethe SRS unit (see
page 23-122],.a
13. Disconnectthespecialtool from the cable reel.
NO Go to step 15.
Disconnectthe cable reelfrom dashboardwire

harnessB. Checkresistancebetweenthe No,7 and
the No. 16 terminalsand betweenthe No. 6 and the
No. 15 terminalsof SRS unit connectorA (18P).
Thereshould be an open circuit,or at least 1 M Q .
ls the resistance as specified?
YES Replacethe cable reel.I
N O - R e p l a c ed a s h b o a r dw i r e h a r n e s sB . l
IJ
23-38
DTC1-4:Shortto Powerin Driver'sAirbag Readthe DTC.
Inflator
ls DTC 1-4indicated?
SpecialToolsBequired
. sRS inflatorsimulator07SAZ-T84011A YES-Go to step 9.
NO-Short to power in the driver's airbag;replace
1. Erasethe DTCmemory (seepage 23-26). t h e d r i v e r ' sa i r b a g( s e ep a g e2 3 - 11 3 ) . 1
2 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d c h e c kt h a tt h e 9 . T u r nt h e i g n i t i o ns w i t c hO F F .D i s c o n n e ct h
te
SRS indicatorcomes on for about 6 secondsand batterynegativecable,and wait for 3 minutes.
then goes off.
1 0 .Disconnectthe front passenger'sairbag4P
Does the SRS indicator stay on? connectorfrom dashboardwire harnessB (seestep
3 o n p a g e2 3 ' 2 1 ) .
YES Go to step 3.
1 1 .Disconnectboth seat belt tensioner2P connectors
NO Intermittentfailure,system is OK at this time. from the floor wire harness(seestep 5 on page 23-
Go to TroubleshootingIntermittentFailures(see 221.
page 23-26).
r ( 1 8 P ) f r o mt h e
3. Turn the ignition switch OFF.Disconnectthe SRSunit (see step 7 on page 23-22).
Disconnectthe specialtool from the cable reel.
s 4. Disconnectthe driver'sairbag4P connector(A)

f r o m t h e c a b l er e e l .
't4. Reconnectthe batterynegativecable.
07sAz-T84011A
C o n n e ctth e S R Si n f l a t o rs i m u l a t o r( 2 0
reel.
6 . Reconnectthe batterynegativecable.
(cont'd)
23-39
SRS
DTCTroubleshooting(cont'd) L
Turn the ignition switch ON {ll). DTC1-5:Shortto Groundin Driver's
Airbag
lnflator
1 6 . Checkfor voltage betweenthe No. 7 terminal of
S R Su n i tc o n n e c t oA r ( 1 8 Pa ) n d b o d y g r o u n d ,t h e Special Tools Required
l n d b o d y g r o u n d ,t h e N o . 6
N o . 1 6t e r m i n a a . SRS inflatorsimulator07SM-TB4011A
t e r m i n a la n d b o d y g r o u n d ,a n dt h e N o . 1 5t e r m i n a l . SRSsimulatorlead F 07XM-S230100
and body ground.Thereshould be 0.5 V or less.
1. Erasethe DTCmemory (seepage 23-26).
SRSUNITCONNECTOR
A {18P)
2. Turn the ignition switch ON (ll),and checkthatthe
then goes oIf.
Does the SBS indicator stay on?
YES Go to step 3.

Wiresideol lemaleterminals page 23-26).

Is the voltage as specilied? batterynegativecable,and wait for 3 minutes.
YES-Faulty SRS uniUreplacethe SRS unit (see

page 23-122).a
NO Go to step 17.
4. Disconnectthe driver'sairbag 4P connector(A)
from the cable reel. a
1 8 . Disconnectthe cable reel from dashboardwire

harnessB.
1 9 . Turn the ignition switch ON (ll).

07sAz-T84011A
20. Checkfor voltage betweenthe No. 7 terminal of
S R Su n i tc o n n e c t oA r ( 1 8 Pa ) n d b o d y g r o u n d ,t h e
N o . 1 6t e r m i n a la n d b o d y g r o u n d ,t h e N o . 6 07xaz-s230100
t e r m i n a la n d b o d y g r o u n d ,a n d t h e N o . 1 5t e r m i n a l
C o n n e ctth e S R Si n f l a t o rs i m u l a t o r( 2 0
ls the voltage as specitied? connectors)and the simulatorlead F to the cable
reet.
YES Replace
t h e c a b l er e e l . l
N O - R e p l a c ed a s h b o a r dw i r e h a r n e s sB . l
IJ
23-40
8. Readthe DTC. 14. Checkresistancebetweenthe No.7 terminal of
SRS unit connectorA {18P)and body ground,the
ls DTC 1-5 indicated? N o . 1 6t e r m i n a la n d b o d y g r o u n d ,t h e N o . 6
t e r m i n a la n d b o d y g r o u n d .a n d t h e N o . 1 5t e r m i n a l
YES-Go to step 9. and body ground.There should be an open circuit,
o r a t l e a s t1 M Q .
NO Short to ground in the driver's airbaginflator;
replacethe driver's airbag(seepage 23-113).I A I18PI
SRSUNITCONNECTOR
9. Turn the ignition switch OFF.Disconnectthe GRN/WHT GRN/RED

'10.
Disconnectthefront passenger'sairbag 4P
connectorfrom dashboardwire harnessB (seestep
2 on page 23-21).
11. Disconnectboth seat belt tensioner2P connectors

from the floor wire harness (seestep 5 on page 23-
22t.
12. DisconnectSRSunit connectorA (18P)fromthe
SRS unit (see step 7 on page 23-22],. ls the resistance as specified?
1 3 . D i s c o n n e c t t hsep e c i a l t o o l f r o mt h e c a b l er e e l . YES-Faulty SRS unit; replacethe SRS unit {see

page 23-1221.f
N O - G o t o s t e p1 5 .
Disconnectthe cable reel from dashboardwire

h a r n e s sB .
1 6 . Checkresistancebetweenthe No.7 terminal of

S R Su n i tc o n n e c t oA r ( 1 8 P )a n d b o d y g r o u n d ,t h e
l n d b o d y g r o u n d .t h e N o , 6
N o . 1 6t e r m i n a a
terminaa l n d b o d y g r o u n d ,a n dt h e N o . 1 5t e r m i n a l
a n d b o d y g r o u n d .T h e r es h o u l db e a n o p e nc i r c u i t ,
or at least 1 fvlQ .
ls the resistanceas specified?
t h e c a b l er e e l . I
YES Replace
NO Replacedashboardwire harnessB.l

23-41
sRs
DTCTroubleshooting(cont'dl {
DTC2-1:Openin FrontPassenger's Airbag Readthe DTC.

Inflator
DfC 2-2:Increased
Resistancein Front ls DTC 2-1 or DTC 2-2 indicated?
Passenger'sAirbagInflator
YES Go to step 9.
Special Tools Bequired
. S R Si n f l a t o rs i m u l a t o 0
r 7SAZ-T84011A NO-Open or increasedresistancein the front
. SRSsimulatorlead F 07XAZ-S230100 passenger'sairbag inflator;replacethe front
p a s s e n g e r 'asi r b a g{ s e ep a g e2 3 - 1 1 4 ) . I
'1.
Erasethe DTCmemory {seepage 23-26).
9 . Turn the ignitionswitch OFF.Disconnectthe
2 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d c h e c kt h a t t h e batterynegativecable,and wait for 3 minutes.
then goes off. 1 0 .Disconnectthe driver'sairbag 4Pconnectorfrom
the cable reel (seestep 2 on page 23-21],.
1 1 .Disconnectboth seatbelt tensioner2P connectors
YES Go to step 3. from the floor wire harness(seestep 5 on page 23-
22).
NO Intermittentfailure,system is OK at this time,
Go to TroubleshootingIntermittentFailures(see DisconnectSRS unit connectorA (18P)from the
page 23-261. SRSunit (seestep 7 on page23-22).Do not
disconnectthe specialtool from dashboardwire
3. Turn lhe ignition switch OFF.Disconnectthe h a r n e s sB .
!.
4. Disconnectthe front passenger'sairbag 4P
connector(A) from dashboardwire harnessB.
07sAz-T84011A
07xAz-s230100
5 . Connectthe SRS inflatorsimulator(2 0

connectors)and the simulatorlead F to dashboard
! J
23-42
\
13. Checkresistancebetweenthe No. 4 and No. 13 DTC2-3:Shortto AnotherWire or Decreased

t e r m i n a l sa n d b e t w e e nt h e N o . 5 a n d N o . 1 4 in FrontPassenger's
Resistance Airbag
t e r m i n a l so f S R Su n i tc o n n e c t oAr ( 1 8 P )T. h e r e lnJlator
s h o u l db e 2 . 0 3 . 0 Q .
r 7SAZ-T8401'1A
A {18P)
SRSUNITCONNECTOR
1. Erasethe DTCmemory (seepage 23-261.
2 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) , a n d c h e c k t h a t t h e
then goes off.
Wiresideof femaleterminals YES-Go to step 3.
NO Intermittentfailure, system is OK at this time.

ls the resistance as specified? Go to TroubleshootingIntermittentFailures{see
page23-26).
YES FaultySRSunit or poor contactat SRS unit
connectorA (18P).Checkthe connection;if the 3. Turn the ignition switch OFF.Disconnectthe
connectionis OK, replacethe SRSunit (seepage batterynegativecable,and wait for 3 minutes.
23-1221.a
J NO Open or increasedresistancein dashboard
4. Disconnectthe front passenger'sairbag 4P
connector(A) from dashboardwire harnessB.
wire harnessB; replacedashboardwire
h a r n e s sB . I
07sAz-T84011A
07xAz-s230100
C o n n e ctth e S R Sl n f l a t o rs i m u l a t o r( 2 0
c o n n e c t o r sa)n d t h e s i m u l a t o rl e a dF t o d a s h b o a r d
T J
(cont'd)
23-43
sRs
qJ
DTGTroubleshooting(cont'd)
Readthe DTC. '12.
DisconnectSRS unit connectorA (18P)from the
SRS u nit (see step 7 on page 23-22l..
ls DTC 2-3 indicated?
13. Disconnectthespecialtool from dashboardwire
YES Go to step9. h a r n e s sB .
NO-Short in the front passenger'sairbag inflator; 14. Checkresistancebetweenthe No. 4 and No. 13
replacethe front passenger'sairbag (seepage 23- t e r m i n a l sa n d b e t w e e nt h e N o . 5 a n d N o . 1 4
1 1 4 )t . t e r m i n a l so f S R Su n i tc o n n e c t oA r ( 1 8 P )T. h e r e
s h o u l db e a n o p e nc i r c u i t o, r a t l e a s t1 M Q .
9 . Turn the ignition switch OFF.Disconnectthe
SRSUNIT CONNECTOR
A I18P)
1 0 .Disconnectthe driver'sairbag 4P connectorfrom BLU/RED

the cable reel {seestep 2 on page 23-21).

221.
BLU/BLK
ls the resistance as specitied?
YES FaultySRSunit; replacethe SRS unit (see

page 23-122)'.a
N O - S h o n i n d a s h b o a r dw i r e h a r n e s sB ; r e p l a c e
d a s h b o a r dw i r e h a r n e s sB . l
T J
23-44
DTC2-4:Shortto Powerin FrontPassenger's 8. Readthe DTC.
AirbagInflator
. SRSinflatorsimulator07SAZ-TB4011A YES-Go to step 9.
NO-Short to power in the front passenger'sairbag
1. Erasethe DTCmemory (seepage 23-26). inflator;replacethe front passenger'sairbag (see
p a g e2 3 - 1 1 4 ) . I
SRSindicatorcomes on for about 6 secondsand 9. Turn the ignitionswitch OFF.Disconnectthe
then goes off, batterynegativecable,and wait for 3 minutes.
Does the SRS indicatot stay on? 10. Disconnectthe driver's airbag4P connectorfrom
the cable reel (seestep 2 on page 23-21).
YES-Go to step 3.
11. Disconnectboth seatbelttensioner2P connectors
NO Intermittentfailure,system is OK at this time. from the floor wire harness(seestep 5 on page 23-
Go to TroubleshootinglntermittentFailures(see 22).
page23-26).
3. Turn the ignitionswitch OFF.Disconnectthe

I 4. Disconnectthe front passenger'sairbag 4P

I connector(A) from dashboardwire harnessB.
07sAz-T84011A
07xAz-s230100
Connectthe SRSinflatorsimulator(2 Q
7 . Erasethe DTc memory.
{cont'd)
23-45
sRs
DTCTroubleshooting(cont'd) {
DisconnectSRSunit connectorA (18P)from the DTC2-5:Shortto Groundin FrontPassenger's

SRSunit (seestep 7 on page23-221. AirbagInflator
1 3 .Disconnectthe specialtool from dashboardwire SpecialToolsRequired
harnessB. . SRSinflator simulator07SAZ-T84011A
1 4 . Reconnectthe batterynegativecable.
2. Turn the ignition switchON (ll),and checkthat the
t o . Checkfor voltage betweenthe No. 4 terminal of SRSindicatorcomes on for about 6 secondsand
SRSunit connectorA (18P)and body ground,the then goes off.
l n d b o d y g r o u n d ,t h e N o . 5
N o . 1 3t e r m i n a a
terminal and body ground,and the No. 14 terminal Does the SRS indicator stay on?
YES Go to step 3.
SRS UNIT CONNECTOBA {18PI
Go to TroubleshootingIntermittentFailures{see
page 23-261.

4, Disconnectthe front passenger'sairbag4P

connector(A) from dashboardwire harnessB. 4
Wire side o{ {emaleterminals
ls the voltageas specified?
the SRSunit(see
YES FaultySRSuniureplace
page23-1221
.a
NO-Short to powerin dashboard

wire harnessB;
replacedashboard
wire harnessB.! 07saz-T84011A
07xAz-s230100
5 . Connectthe SRSinflatorsimulator(2 Q
wire harnessB.
\ J
23-46
I
Reconnectthe batterynegativecable. 12. DisconnectSRS unit connectorA (18P)from the
SRS unit (seestep7 on page 23-221.
1 3 .Disconnectthespecialtool from dashboardwire
Readthe DTC. h a r n e s sB .
't4.
ls DTC 2-5 indicated? Checkresistancebetweenthe No. 4 terminal of
SRS unit connectorA (18P)and body ground,the
YES-Go to step 9. No. 13 terminal and body ground.the No. 5
terminaa l n d b o d y g r o u n d ,a n d t h e N o . 1 4t e r m i n a l
NO-Shon to ground in the front passenger's and body ground.Thereshould be an open circuit,
airbaginflator;replacethe front passenger'sairbag o r a t l e a s tl M Q .
( s e ep a g e2 3 - 11 4 ) . 1
A {18P}
SRSUNITCONNECTOR
9 . Turn the ignitionswitch OFF.Disconnectthe
batterynegativecable,and wait for 3 minutes. BLU/RED BLU/YEL
1 0 .Disconnectthe driver's airbag4P connectorfrom


22).
I
I Wire side ol temaleterminals
ls the tesistanceas specitied?
YES FaultySRSuniureplacethe SRSunit(see

page23-122),
.l
NO Shortto groundin dashboard wire harnessB;

r e p l a cdea s h b o a rwdi r eh a r n e sBs . l

23-47
sRs
DTC3-1:Openin Driver'sSeatBeltTensioner 6. Reconnectthe batterynegativecable.
DTC3-2:Increased
Resistancein Driver's
SeatBeltTensioner 7. Erasethe DTCmemory.
Special Tools Required 8. Readthe DTC.

. sRS inflatorsimulator07sAz-TB4011A
. SRSsimulatorlead C 07TM-S25011A ls DTC 3-1ot DTC 3-2 indicated?
YES Go to step 9.
NO-Open or increasedresistancein the driver's
2. Turn the ignition switch ON (ll),and checkthat the seat belt tensioner;replacethe driver'sseat belt
SRSindicatorcomes on for about 6 secondsand (seepage23-4).I
then goes off.
L Turn the ignition switch OFF.Disconnectthe
Does the SRS indicator stay on? batterynegativecable,and wait Ior 3 minutes.
YES Go to step 3. 10. Disconnectthe floor wire harness4P connector

C403{A)from dashboardwire harnessB.
Go to TroubleshootinglntermittentFailures(see
page 23-26).

4. Disconnectthe driver's seat belt tensioner2P

connector{A) trom the floor wire harness. 07sAz-T8401'lA
1 1 .Connectthe SRSinflatorsimulator(2 Q
connectors)and simulatorlead F to dashboardwire
harnessB.
07sAz-T84011A
Erasethe DTCmemory.
07TAZ-52501'lA
1 4 .Readthe DTC.
5. ConnecttheSRSinflatorsimulator(2 0 connector)
and simulatorlead C to the floor wire harness. ls DTC 3-1 or DTC 3-2 indicated?
YES Go to step 15.
NO-Open or increased r e s i s t a n c ien t h e f l o o rw i r e

harness;replacethe floor wire harness.l
t5. Turn the ignition switch OFF.Disconnectthe

batterynegativecable.and wait for 3 minutes.
\ J
23-48
I
to. Oisconnectthe driver's airbagconnector(seestep DTC3-3:Shortto AnotherWire or Decreased
2 on page 23-21),f ront passenger'sairbag in Driver'sSeatBeltTensioner
Resistance
connector(seestep 3 on page 23-21),andfront
passenger'sseat belt tensionerconnector(seestep SpecialToolsRequired
5 on page 23-22). . SRS inflatorsimulator07SAZ-T8401'1A
. SRSsimulatorlead C 07TM-S25011A
1 7 . DisconnectSRSunit connectorA (18P)from the . SRSsimulatorlead F 07XAZ-S230100
SRSunit (seestep 7 on page 23-22).Do not
disconnectthe specialtool from dashboardwire 1. Erasethe DTCmemory (seepage 23-26).
harnessB.
2. Turn the ignition switch ON (ll),and checkthatthe
1 8 . Checkresistancebetweenthe No.8 terminal and SRS indicatorcomes on for about 6 secondsand
t h e N o . 1 7t e r m i n a o r (18P).
l f S R Su n i tc o n n e c t oA then goes off.
T h e r es h o u l db e 2 . 0 - 3 . 0 Q.
A (18P)
SRSUNITCONNECTOR
YES Go to step 3.
RED/WHT
NO-lntermittent failure,system is OK at this time,
Go to TroubleshootingIntermittentFailures{see
i-4
2 3 5 6 1 \lel a; page 23-26).
10 1 l 1Z t 3 t 5 16
E a Turn the ignition switch OFF.Disconnectthe
I RED/BLU
] Disconnectthe driver'sseat belt tensioner2P
Wiresideof femaleterminals connector(A) from the floor wire harness.
YES FaultySRS unit or poor contactat SRSunit

connectorA (18P)and the SRSunit. Checkthe
connection;if the connectionis OK, replacethe
SRSunit (seepage 23-'1221.a
-T84011A
NO Open or increasedresistancein dashboard
w i r e h a r n e s sB ; r e p l a c ed a s h b o a r d
wire harness
B,t
07TAZ-S25011A
5 . C o n n e ctth e S R Si n f l a t o rs i m u l a t o r( 2 0 c o n n e c t o r )
a n d s i m u l a t o rl e a dC t o t h e f l o o rw i r e h a r n e s s .
I
(cont'd)

23-49
sRs
6. Reconnectthebatterynegativecable. 16. Disconnectthe driver'sairbagconnector(seestep
2 on page23-211,lrontpassenger'sairbag
7. Erasethe DTCmemory. connector(seestep 3 on page 23-21),and front
passenger'sseat belt tensionerconnector(seestep
8. Readthe DTC. 5 on page 23-22).
ls DTC 3-3 indicated? r ( 1 8 P f)r o m t h e

1 7 . D i s c o n n e cSt R Su n i t c o n n e c t oA
SRSunit (seestep 7 on page 23-22:,.
YES-Go to step L
18. Disconnectthe specialtool from dashboardwire
NO-Shon in the driver'sseat belt tensioner; harnessB.
replacethe driver's seat belt (seepage 23-4).1
1 9 . C h e c kr e s i s t a n c be e t w e e nt h e N o . 8 t e r m i n a a
l nd
L Turn the ignition switch OFF.Disconnectthe t h e N o . 1 7t e r m i n a o l f S R Su n i tc o n n e c t oA r ('l8P).
batterynegativecable,and wait for 3 minutes. Thereshould be an open circuit,or at least 1 l\4Q .
10. Disconnectfloor wire harness4P connectorC403

SRSUNIT CONNECTOR
A I18P)
(A)from dashboardwire harnessB.
RED/WHT
07sAz-TB4or
1A
RED/BLU
L J
W i r es i d eo f f e m a l e
terminals
YES FaultySRS unit; replacethe SRSunit (see

1 1 .ConnecttheSRSinflatorsimulator(2 Q page 23-1221.a
harnessB. N O - S h o r ti n d a s h b o a r dw i r e h a r n e s sB ; r e p l a c e
d a s h b o a r dw i r e h a r n e s sB . l
1 3 .Erasethe DTCmemory.
1 4 .Readthe DTC.
YES-Go to step 15.
NO Short in the floor wire harness;replacethe

floor wire harness.l
Turn the ignition switch OFF.Disconnectthe

t J
23-50
I J
DTC3-4:Shortto Powerin Driver'sSeatBelt 6. Reconnectthe batterynegativecable.
Tensioner
7. Erasethe DTCmemory.
SpecialToolsBequired
. SRSlnflatorsimulator07SAZ-TB4011A 8. Readthe DTC.
. S R Ss i m u l a t o lre a dC 0 7 T M - S 2 5 0 1 1 A
. SRSsimulatorlead F 07XAZ-S230100 Is DTC 3-4 indicated?
1. Erasethe DTCmemory (seepage 23-261. YES- Go to step 9.
2. Turn the ignition switch ON (ll),and checkthat the NO-Short to power in the driver'sseat belt
SRSindicatorcomes on for about 6 secondsand tensioner;replacethe driver'sseat belt
then goes off. ( s e ep a g e2 3 - 4 ) . 1
Does the SRS indicatot stay on? L Turn the ignition switch OFF.Disconnectthe
YES- Go to step 3.
10. Disconnectfloor wire harness4P connectorC403
NO Intermittentfailure,system is OK at this time. (A) from dashboardwire harnessB.
page 23-261.
Turn the ignitionswitch OFF.Disconnectthe

L
] Disconnectthe driver'sseat belt tensioner2P
connector(A)from the floorwire harness.
TB4O11A
1 1 .C o n n e ctth e S R Si n f l a t o rs i m u l a t o r( 2 0
connectors)and simlator lead F to dashboardwire
07sAz-T84011A h a r n e s sB .
' t 2 .Reconnectthe batterynegativecable.
Erasethe DTCmemory.
5. Connectthe SRSinflatorsimulator(2 !J connector) 1 4 . Readthe DTC.

and simulatorlead C to the floor wire harness.
YES-- Go to step 15.
N O - S h o n t o p o w e ri n t h e f l o o rw i r e h a r n e s s ;
r e p l a c et h e f l o o rw i r e h a r n e s s . I
T u r nt h e i g n i t i o ns w i t c hO F F .D i s c o n n e ct h
te
I batterynegativecable,and wait for 3 minutes.
(cont'd)
23-51
sRs
16. Disconneclthe driver'sairbagconnector(seestep DTC3-5:Shortto Groundin Driver'sSeatBelt
2 on page23-21l,Irontpassenger'sairbag Tensioner
connector(seestep 3 on page 23-2'l),and front
passenger'sseat belt tensionerconnector(seestep Special Tools Required
5 on page 23-221. . sRS inflalor simularor07sAz-TB4011A
. SRSsimulatorlead C 07TAZ-S25011A
17. DisconnectSRSunit connectorA (l8P)from the . SRSsimulatorlead F 07XAZ-S230100
SRS unit (see step 7 on page 23-22).
1. Erasethe DTCmemory {seepage23-26).
18. Disconnectthe specialtoolfrom dashboardwire
h a r n e s sB . 2. Turn the ignition switch ON (ll),and checkthat the
19. Reconnectthe batterynegativecable. then goes off.
20. Turn the ignition switch ON (ll), Does the SRS indicator stay on?
21. Checkfor voltage betweenthe No. 8 terminal of YES Go to step 3.

SRSunit connectorA (18P)and body ground,and
t h e N o . 1 7t e r m i n a la n d b o d yg r o u n d .T h e r es h o u l d NO Intermittentfailure,system is OK at this time.
be 0.5 V or less. Go to TroubleshootingIntermittentFailures(see
page 23-26).
SRS UNIT CONNECTORA {18PI
4, Disconnectthe driver'sseat belt tensioner2P

connector(A) from the floor wire harness,
L

-T84011A
YES-FaultySRSunit;replace
the SRSunit{see
page23-122],
.a
NO Shorttopowerin dashboard wire harnessB; 07TAZ-S25011A

replacedashboard
wire harnessB.l
5. Connectthe SRSinflatorsimulator(2 Q conneclor)
L J
23-52
t
6. Reconnectthe batterynegativecable. 16. Disconnectthedriver'sairbagconnector(seestep
2 on page23-211,lrontpassenger'sairbag
7. Erasethe DTCmemory. connector(seestep 3 on page 23-21),and front
passenger'sseat belt tensionerconnector(seestep
8. Readthe DTC. 5 on page 23-22).
ls DTC 3-5 indicated? 17, DisconnectSRS unit connectorA ('l8P)from the

SRS unit (seestep 7 on page 23-221.
YES-Go to step 9,
18. Disconnectthe specialtoolfrom dashboardwire
NO Shortto ground in the driver'sseat belt harnessB.
tensioner;replacethe driver'sseat belt
(seepage 23-4).I 19. Checkresistancebetweenthe No. 8 terminal of
SRS unit connectorA (18P)and body ground, and
9. Turn the ignition switch OFF.Disconnectthe l n d b o d y g r o u n d .T h e r es h o u l d
t h e N o . 1 7t e r m i n a a
batterynegativecable,and wait for 3 minutes. be an open circuit,or at least 1 M Q .
10. Disconnectfloor wire harness4P connectorC403 A (18P)

SRSUNIT CONNECTOR
(A)from dashboardwire harnessB.
)
07sAz-T84011A
Y E S - F a u l t yS R Su n i u r e p l a c et h e S R Su n i t{ s e e
'11.
C o n n e ctth e S R Si n f l a t o rs i m u l a t o r( 2 Q page 23-122l,.a
h a r n e s sB . NO Short to ground in dashboardwire harnessB;
r e p l a c ed a s h b o a r dw i r e h a r n e s sB . l
Erasethe DTCmemory.
1 4 . Readthe DTC.
YES Go to step 15.
NO-Short to ground in the floor wire harness;

replacethe floor wire harness.l
I batterynegativecable,and wait for 3 minutes.
23-53
sRs
DTC21-1:Openor Increased Resistance
in 8. Readthe DTC.
Driver'sSeatBeltBuckleTensioner
l s D T C 2 1 - 1i n d i c a t e d ?
. SRSinflatorsimulator07SAZ-TB4011A YES Go to step 9.
NO Open or increasedresistancein the driver's
1. ErasetheDTCmemory (seepage 23-261. seat belt buckletensioner;replacethe driver'sseat
b e l tb u c k l e . I
SRS indicatorcomes on for about 6 secondsand 9. Turn the ignition switch OFF.Disconnectthe
then goes off. batterynegativecable.and wait for 3 minutes.
Does the SBS indicatot stay on? 10. Disconnectboth side airbag2P connectors(see
step 4 on page 23-2lland the front passenger's
YES Go to step3. seat belt buckletensioner4P connector(seestep 6
on page 23-22).
Go to TroubleshootingIntermittentFailures(see r ( 1 8 P ) f r o mt h e
1 1 . D i s c o n n e cSt R Su n i tc o n n e c t o B
page 23-261. SRSunit (seestep 7 on page 23'22).Do not
disconnectthe specialtool from the floor wire
3. Turn the ignition switch OFF.Disconnectthe narness.
12. Checkresistancebetweenthe No. 1 and No. 10
4. Disconnectthe driver's seat belt buckletensioner r ( 1 8 P )T. h e r e
t e r m i n a l so f S R Su n i tc o n n e c t oB
4P connector(A) from the floor wire harness. s h o u l db e 2 . 0- 3 . 0 O .
b /
SRSUNITCONNECTOR
B Il8PI
GRN/YEL
l t ' '
A\ I' ? 3 6 1 6 s
Y l r 0t l 1 5 t 6 17 t6
] TI
GRN/BLK
5. ConnecttheSRSin{latorsimulator(2 Q connectors) ls the resistanceas specified?

and simulatorlead F to the Iloor wire harness.
Y E S * F a u l t yS R Su n i to r p o o rc o n t a c a
t t S R Su n i t
6. Reconnectthe batterynegativecable. r ( 1 8 Pa
c o n n e c t oB ) n d t h e S R Su n i t .C h e c kt h e
7. Erasethe DTCmemory. SRS unit (seepage 23-122).a
NO Open or increasedresistancein the floor wire

h a r n e s sr;e p l a c et h e f l o o rw i r e h a r n e s s . l
L J
23-54
I
DTC21-3:Shortto AnotherWireor 8. Readthe DTC.
DecreasedResistance
in Driver'sSeatBelt
EuckleTensioner ls DTC 21-3 indicated?
Special Tools Required YES-Go to step 9.

. SRSinflatorsimulator07SAZ-T840't1A
. SRSsimulatorlead F 07XAZ-S230100 NO- Short in the driver'sseat belt buckle
tensioner;replacethe driver's seat belt buckle.l
1. Erasethe DTCmemory (see page23-26).
2. Turn the ignition switch ON (ll),and checkthat the batterynegativecable,and wait for 3 minutes,
S R Si n d i c a t o cr o m e so n f o r a b o u t6 s e c o n d sa n d
then goes off. 10. Disconnectboth side airbag2P connectors(see
step 4 on page 23-21)and the front passenger's
Does the SRS indicator stay on? seat belt buckletensioner4P
connector(seeslep 6 on page 23-22).
YES Go to step 3.
1 1 . D i s c o n n e c t S RuSn i t c o n n e c t o r B( 1 8 P ) f r o m t h e
NO Intermittentfailure.system is OK at this time. SRS unit {seestep 7 on page 23-22l .
Go to TroubleshootingIntermittentFailureslsee
page 23-26). '12.
Disconnectthe specialtoolf rom the floor wire
harness.
Turn the ignitionswitch OFF.Disconnectthe
batterynegativecable,and wait for 3 minutes. 13. Checkresistancebetweenthe No. 1 and No. 10
I t e r m i n a l so f S R Su n i tc o n n e c t o Br ( 1 8 P )T. h e r e
t e d r i v e r ' ss e a tb e l tb u c k l et e n s i o n e r
f 4P connector(A) from the floor wire harness.
s h o u l db e a n o p e nc i r c u i t o
, r a t l e a s t1 M Q .
SRS UNIT CONNECTORB {18PI
GRN/YEL
GRN/BLK

C o n n e c t t h eS R Si n f l a t o rs i m u l a t o (r 2 i )
c o n n e c t o r sa)n d s i m u l a t o rl e a dF t o t h e f l o o r YES FaultySRS unit; replacethe SRSunit (see
w t r en a r n e s s . page 23-1221.a
6 . Reconnectthe batterynegativecable. NO Short in the floor wire harness;replacethe

f l o o rw i r e h a r n e s s . l
23-55
sRs
(cont'dl
DTCTroubleshootang
DTG21-4:Shortto Powerin Driver'sSeatBelt Readthe DTC.
BuckleTensioner
. SRSinflatorsimulator07SAZ-TB4011A YES Go to step 9.
. SRSsimulatorlead F 07XM-S230100
NO Shon to power in the driver'sseat belt buckle
1. Erasethe DTCmemory (seepage23-26). tensioner;replacethe driver's seatbelt buckle.l
2. Turn the ignition switch ON (ll),and checkthat the L Turn the ignition switch OFF.Disconnectthe
SRSindicatorcomes on for about 6 secondsand batterynegativecable,and wait for 3 minutes.
then goes off.
1 0 .Disconnectboth side airbag2P connectors(see
Does the SRS indicatot stay on? step 4 on page 23-21)and the front passenger's
seat belt buckletensioner4P connector(seestep 6
YES-Go to step 3. on page 23-22).
NO Interminentfailure,system is OK at this time.

page 23'26).
3. Turn lhe ignition switch OFF.Disconnectthe

4. Disconnectthe driver's seatbelt buckletensioner

4P connector(A) from the floor wrre narness.
t, .J
5 . ConnecttheSRSinflatorsimulator{2 0
connectors)and the simulatorlead F to the f loor
wireharness.
\, .J
23-56
1 1 .DisconnectSRS unit connectorB (18P)from the DTC21-5:Shortto Groundin Driver'sSeat
SRSunit (seestep 7 on page 23-22). BeltBuckleTensioner
1 2 . Disconnectthe specialtool from the floor wire Special Tools Required
harness. . SRS inflatorsimulator07SAZ-TB4011A
1. Erasethe DTCmemory {seepage 23-26}.
1 4 . Turn the ignitionswitch ON (ll).
Checkfor voltage betweenthe No. 1 lerminal of SRSindicatorcomes on for about 6 secondsand
SRSunit connectorB {18P)and body ground, and then goes off.
t h e N o . 1 0t e r m i n a la n d b o d y g r o u n d .T h e r es h o u l d
be 0.5 V or less. Does the SBS indicator stay on?
SRSUNITCONNECTOR
B I18PI YES-Go to step 3.

page 23-26).

4 . Disconnectthe driver'sseat belt buckletensioner

I
f J 4P connector{A) from the floor wire harness.
ls the voltageas specitied?
the SRSunit(see
YES FaultySRSunit;replace
page23-1221
.f
NO Shortto powerin thefloorwire harness;

replace
the floorwire harness.l
C o n n e ctth e S R Si n f l a t o rs i m u l a t o r( 2 Q
connectors)and simulatorlead F to the floor wire
n ar n e s s .
(cont'd)
23-57
sRs
Readthe DTC. DTC4-1:Openin FrontPassenger'sSeatBelt
renstoner
ls DTC 21-5 indicated? DTC4-2:lncreasedResistance
in Front
Passenger's
SeatBeltTensioner
YES Go to step 9.
NO Short to ground in the driver's seat belt . SRS inflatorsimulator07SM-T84011A
buckletensioner;replacethe driver's seat belt . SRSsimulatorlead C 07TAZ-S25011A
buckle.l . SRSsimulatorlead F 07XAZ-S230100
'L
9 . Turn the ignitionswitch OFF.Disconnectthe Erasethe DTCmemory (seepage23-26).
Turn the ignition switch ON {ll),and checkthat the
1 0 .Disconnectboth side airbag2P connectors(see SRS indicatorcomes on for about 6 secondsand
step 4 on page 23-21)andthe front passenger's then goes off.
seat belt buckletensioner4P connector(seestep 6
on page 23-221. Does the SBS indicator stay on?
1 1 .DisconnectSRSunit connectorB (18P)from the YES-Go to step 3.

SRS unit (see step 7 on page 23-22)
NO- Intermittentfailure,system is OK at this time.
1 2 .Disconnectthe specialtool from the floor wire Go to TroubleshootingIntermittentFailures{see
harness. page23-26).
'1
1 3 .Checkresistancebetweenthe No. terminal of Turn the ignition switch OFF.Disconnectthe
SRS unit connectorB (18P)and body ground,and batterynegativecable,and wait for 3 minutes.
b e a n o p e nc i r c u i t o Disconnectthe front passenger'sseat belt
tensioner2P connector(A) from the floor wire
SRSUNITCONNECTOR
B {18PI harness.
07TAZ-525011A
ls the tesistanceas specilied?
the SRSunit(see
YES FaultySRSuniureplace 5. Connectthe SRS inflatorsimulator(2 0 connector)
page23-122)
.a a n d s i m u l a t o rl e a dC t o t h e f l o o rw i r e h a r n e s s .
N O - S h o r t o g r o u n di n t h ef l o o rw i r eh a r n e s s ;
replace thefloorwire harness.l
\ J
23-58
)
6. Reconnectthe batterynegativecable. 15. Turn the ignition switch OFF.Disconnectthe

'16.
Disconnectthe driver'sairbagconnector{seestep
8. Readthe DTC. 2 on page23-211, tront passenger'sairbag
connector(seestep 3 on page 23-21),and driver's
ls DTC 4-1 or DTC 4-2 indicated? seat belt tensionerconnector(seestep 5 on page
23-221.
YES Go to step 9.
17. DisconnectSRS unit connectorA (18P)from the
NO-Open or increasedresistancein the front SRS unit (seestep 7 on page 23-22).Do not
passenger'sseat belttensioner;replacethe front disconnectthe specialtool from dashboardwire
passenger'sseat belt (seepage 23-4).t harnessB.
L Turn the ignition switch OFF.Disconnectthe 18. Checkresistancebetweenthe No. 9 terminal and
'18
batterynegativecable,and wait for 3 minutes. the No. terminal of SRS unit connectorA (18P).
T h e r es h o u l db e 2 . 0 - 3 . 0 Q .
10, Disconnectthe floor wire harness4P connector
C403(A)from dashboardwire harnessB.
SRS UNIT CONNECTORA {18P}
RED/YEL
1 2 3 4 5 7 8
{ l
l 6
1 0 11 12 15 1 7 r8l \t
)
07sAz-T840't
1A
r l
RED/BLK
1 1 .Connectthe SRSinflatorsimulator(2 i) YES FaultySRS unit or poor contactat SRS unit

connectors)and simulatorlead F to dashboardwire connectorA (18P)and the SRS unit. Checkthe
harnessB. connection;if the connectionis OK, replacethe
SRS unit (seepage 23-122l,.a
1 2 .Reconnectthe batterynegativecable.
NO-Open or increasedresistancein dashboard
Erasethe DTCmemory. wire harnessB; replacedashboardwire harness
B.T
1 4 . Readthe DTC.
ls DTC 4-l or DTC 4-2 indicated?

'15.
YES-Go to step
NO-Open or increasedresistancein the floor wire

harness;replacethe floor wire harness.I
I
23-59
sRs
DTC4-3:Shortto AnotherWire or Decreased 8. Readthe DTC.
Resistance
in FrontPassenger'sSeatBelt
Tensioner ls DTC 4-3 indicated?
Special Tools Required YES-Go to stepL

. SRSinflatorsimulator07SAZ-TB40l1A
. SRSsimulatorlead C 07TM-S25011A NO-Short in the front passenger'sseatbelt
. SRSsimulatorlead F 07XAZ-S230100 tensioner;replacethe front passenger'sseat belt
( s e ep a g e2 3 - 4 ) . 1
1. ErasetheDTCmemory (seepage 23-26).
2. Turn the ignitionswitch ON (ll),and checkthat the batterynegativecable,and wait for 3 minutes.
SRSindicatorcomes on for about 6 secondsand
'10.
then goes off. Disconnectthe floor wire harness4P connector
C403{A)from dashboardwire harnessB.
YES-Go to step 3.
NO Intermittentfailure.system is OK at this time.

page 23-26).
3. Turn the ignitionswitch OFF.Disconnectthe TB40,I1A

4. Disconnectthe front passenger'sseat belt

tensioner2P connector(A)from the floor wire
L
narness.
1 1 .C onnectthe SRSinflatorsimulator(2 0
harnessB.
1 3 .Erasethe DTCmemory.
1 4 .Readthe DTC.

07TAZ-S25011A
Y E S - G o t o s t e p1 5 .
Connectthe SRS inflatorsimulator(2 Q connector) NO Short jn the floor wire harness;replacethe

and simulatorlead C to the floor wire harness. f l o o rw i r e h a r n e s s . I
6 . Reconnectthe batterynegativecable. 1 5 .Turn the ignition switch OFF.Disconnectthe

\ J
23-60
16. Disconnectthedriver'sairbagconnector(seestep DTC4-4:Shortto Powerin FrontPassenger's
2 on page23-211, front passenger'sairbag SeatBeltTensioner
connector(seestep 3 on page 23-21),and driver,s
seat belt tensionerconnector(seestep 5 on page Special Tools Required
23-221. . SRS inflatorsimulator07SAZ-T84011A
. S R Ss i m u l a t o rl e a dC 0 7 T A Z - S 2 5 0 1 1 A
17. DisconnectSRSunit connectorA (18p)from the . SRSsimulatorlead F 07XAZ-S230100
18. Disconnectthe specialtool from dashboardwire
harnessB. 2. Turn the ignition switch ON {ll),and checkthat the
19. Checkresistancebetweenthe No. 9 terminal and then goes off.
t h e N o . 1 8t e r m i n a o
l f S R Su n i tc o n n e c t oA r (18p).
T h e r es h o u l db e a n o p e nc i r c u i t o
, r a t l e a s t1 M e . Does the SRS indicator stay on?
SRSUNITCONNECTOR
A I18P} YES Go to step 3.
NO- Intermiftentfailure.system is OK at this time.

RED/YEL
2 3 4 5 6 8
It 6] page 23-261.
10 t l 12 t 3 15 16 1 7 r8l \P 3. Turn the ignition switch OFF.Disconnectthe
I
T batterynegativecable,and wait for 3 minutes.
RED/BLK 4. Disconnectthefront passenger'sseat belt

]
Wire side of femaleterminals harness.
YES-FaultySRSunit;replace
the SRSunit(see
page23-1221
.f
NO-Short in dashboard wire harnessB;replace

d a s h b o a rwdi r eh a r n e sB
s .I
07TAZ-S2501'lA
5. Connectthe SRSinflatorsimulator(2 e connector)

{cont'd)
23-61
sRs
6. Reconnectthe batterynegativecable. 1 5 .Turn the ignitionswitch OFF.Disconnectthe
t o . Disconnectthe driver's airbagconnector(seestep
8. Readthe DTC. 2 on page23-211,tront passenger'sairbag
connector(seestep 3 on page 23-21),and drivefs
ls DTC 4-4 indicated? seatbelt tensionerconnector(seestep 5 on page
23-22t.
YES Go to step 9.
1 1 . DisconnectSRS unit connectorA ('l8P)trom the
NO-Short to power in the front passenger'sseat SRS unit (seestep 7 on page 23-22).
belt tensioner;replacethe front passenger'sseat
b e l t( s e ep a g e2 3 - 4 ) . I 1 8 . Disconnectthe specialtool from dashboardwire
h a r n e s sB .
batterynegativecable.and wait for 3 minutes. 1 9 . Reconnectthe batterynegativecable.
'10.Disconnectfloor wire harness4P connector 20. T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .

C403(A)from dashboardwire harnessB.
2 1 .Checkfor voltage betweenthe No. 9 terminal of
S R Su n i tc o n n e c t oA r ( 1 8 Pa) n d b o d y g r o u n d ,a n d
l n d b o d y g r o u n d .T h e r es h o u l d
t h e N o . 1 8t e r m i n a a
be 0.5 V or less.
A (18PI
SRSUNITCONNECTOR
t' J
07sAz-TB4o11A
1 1 .Connectthe SRSinflatorsimulator(2 0
connectors)and simulatorlead F to dashboardwire terminals
WiresideoJJemale
h a r n e s sB .
Reconnectthe batterynegativecable. Is the voltageas specified?
tJ. Erasethe DTCmemory. YES FaultySRSunit; replacethe SRS unit (see

page 23'1221.a
1 4 . Readthe DTC.
N O S h o r t t o p o w e ri n d a s h b o a r dw i r e h a r n e s sB ;
ls DTC 4-4 indicated? w i r e h a r n e s sB . l
r e p l a c ed a s h b o a r d
Y E S - G o t o s t e p1 5 .
NO- Short to power in the floor wire harness;

23-62
I
DTC4-5:Shortto Groundin FrontPassenger's 8. Readthe DTC.
SeatBeltTensioner
. SRSinflatorsimulator07SAZ-TB40'11A YES-Go to step 9.
. SRSsimulatorlead C 07TAZ-S25011A
. SRSsimulatorlead F 07XAZ-S230100 NO Short to ground in the front passenger'sseat
belt tensioner;replacethe front passenger'sseat
1. ErasetheDTCmemory (seepage 23-26]|. b e l t( s e ep a g e2 3 - 4 ) . I
2 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d c h e c k t h a t t h e 9. Turn the ignition switch OFF.Disconnectthe

SRSindicatorcomes on for about 6 secondsand batterynegativecable,and wait for 3 minutes.
then goes off.
10. Disconnectthe floor wire harness4P connector
Does the SRS indicator stay on? C403(Alfrom dashboardwire harnessB.
Y E S - G o t o s r e p3 .

page 23-26l,.

batterynegativecable,and wait for 3 minutes. TB40t 1A
I 4. Disconnectthe front passenger'sseat belt

harness.
1 1 .Connectlhe SRS inflatorsimulator(2 e

h a r n e s sB .
Erasethe DTCmemory.
1 4 . Readthe DTC.

07TAZ-SZ501rA
YES Go to step 15.
Connectthe SRS inflatorsimulator(2 e connector)
a n d s i m u l a t o rl e a dC t o t h e f l o o rw i r e h a r n e s s . NO-Short to ground in the floor wire harness;
r e p l a c et h e f l o o rw i r e h ar n e s s . l
7 . Erasethe DTCmemory. batterynegativecable,and wait for 3 minutes.
(cont'd)
23-63
sRs
16. Disconnectthe driver's airbagconnector(seestep DTC22-1:Openor Increased in
Resistance
2 on page 23-21),front passenger'sairbag SeatBeltBuckleTensioner
FrontPassenger's
connector(seestep 3 on page 23-21).and driver's
seat belt tensionerconnector(seestep 5 on page SpecialTools Required
23-22). . SRSinflatorsimulator07SAZ-T84011A
r ( 1 8 P ) f r o mt h e
SRSunit (seestep 7 on page 23-221. 1. Erasethe DTC memory (see page 23-261.
18. Disconnectthe specialtoolfrom dashboardwire 2. Turn the ignition switch ON (ll),and checkthat the
harnessB. SRSindicatorcomes on for about 6 secondsand
then goes otf.
19. Checkresistancebetweenthe No.9 terminal of
S R Su n i tc o n n e c t oA r ( 1 8 Pa ) n d b o d y g r o u n d ,a n d Does the SRS indicator stay on?
t h e N o . l 8 t e r m i n a la n d b o d y g r o u n d .T h e r es h o u l d
. r a t l e a s t1 M Q .
b e a n o p e nc i r c u i t o YES-Go to step 3.

A {18P)
SRSUNITCONNECTOR
page23-26).
3. Turn the ignition switch oFF. Disconnectthe

4. Disconnectthefront passenger'sseat belt buckle

harness.
\,
w i r e s i d eo f l e m a l et e r m i n a l s
Y E S F a u l t yS R Su n i Ur e p l a c et h e S R Su n i t ( s e e
page 23-1221.1
NO-Short to ground in dashboardwire harnessB;

r e p l a c ed a s h b o a r dw i r e h a r n e s sB . I
5 . C o n n e ctth e S R Si n f l a t o rs i m u l a t o r( 2 Q
connectors)and the simulatorlead F to the floor
w t r eh a r n e s s .
23-64
t
6. Reconnectthe bafterynegativecable. DTC22-3:Shortto AnotherWire or
DecreasedResistance
in FrontPassenger's
7. Erasethe DTCmemory. SeatBeltBuckleTensioner
8. Readthe DTC. SpecialToolsRequired
. SRS inflatorsimulator07SAZ-TB4011A
ls DTC 22-1 indicated? . SRSsimulator lead F 07XAZ,S230100
YES-Go to step 9. '1.

Erasethe DTCmemory (seepage 23-26).
NO Open or increasedresistancein the front 2. Turn the ignition switch ON fll), and checkthat the
passenger'sseat belt buckletensioner;replacethe SRSindicatorcomes on for about 6 secondsand
front passenger'sseat belt buckle.l then goes off.
9. Turn the ignitionswitch OFF.Disconnectthe Does the SRS indicator stay on?
YES Go to step 3.
10. Disconnectboth side airbag2P connectors(see
step 4 on page23-21)and the driver's seat belt NO Intermiftentfailure,system is OK at this time.
buckletensioner4P connector(seestep 6 on page Go to TroubleshootingIntermittentFailures(see
23-22). page 23-26),.
1 1 . D i s c o n n e cSt R Su n i tc o n n e c t oB
r ( 1 8 P ) f r o mt h e 3. Turn the ignition switch OFF.Disconnectthe
SRSunit (seestep 7 on page 23-22).Do not batterynegativecable,and wait for 3 minutes.
disconnectthe specialtool from the floor wire
I harness.
1 2 . C h e c kr e s i s t a n cbee t w e e nt h e N o . 2 a n d N o . 1 1
4. Disconnectthe front passenger'sseat belt buckle
harness.
terminalsof SRS unit connectorB ('l8P).There
s h o u l db e 2 . 0 3 . 0 0 .
SRSUNITCONNECTOR
B I,I8PI
)m 3 6 7 8
r5 r6 1T 1 8
9
5 . C o n n e ctth e S R Si n f l a t o rs i m u l a t o (r 2 Q
connectors)and the simulatorlead F to the floor
ls the resistance as specified? w t r eh a r n e s s .
YES FaultySRS unit or poor contactat SRS unit 6. Reconnectthe batterynegativecable.

r ( 1 8 Pa
c o n n e c t oB ) n d t h e S R Su n i r .C h e c kt h e
connection;if the connectionis OK, replacethe 7 . E r a s et h e D T Cm e m o r y .
SRSunit (seepage 23-122).a

I t harness;replacethe floor wire harness.l
{cont'd)
23-65
sRs
8. Readthe DTC. DTC22-4:Shortto Powerin FrontPassenger's
SeatBeltBuckleTensioner
YES Go to slep 9. . S R Si n f l a t o rs i m u l a t o 0
r 7SAZ-TB4011A
. S R Ss i m u l a t o rl e a dF 0 7 X A z5 2 3 0 1 0 0
NO-Short in the front passenger'sseat belt buckle
tensioner;replacethe front passenger'sseat belt 1. Erasethe DTCmemory (seep age23-26).
buckle.l
2 . T u r nt h e i g n i t i o ns w i t c hO N { l l } ,a n d c h e c kt h a tt h e
9. Turn the ignition switch OFF.Disconnectthe S R Si n d i c a t ocr o m e so n f o r a b o u t6 s e c o n d sa n d
batterynegativecable,and wait for 3 minutes. then goes off.
10. Disconnectboth side airbag2P connectors(see Does the SHS indicator stay on?
s t e p4 o n p a g e2 3 - 2 1 ) a n dt h e d r i v e r ' ss e a tb e l t
buckletensioner4P connector(seestep 6 on page YES Go to step 3.
23-22).
N O I n l e r m i t t e n t f a i l u r e , s y s t ei smO K a t t h i s t i m e .
'11. Go to TroubleshootingIntermittentFailures(see
D i s c o n n e cSt R Su n i tc o n n e c t oB
r { 1 8 P ) f r o mt h e
SRS unit (seestep 7 on page23-221. page 23-261.
12. Disconnectthe specialtool from the floor wire 3. Turn the ignition switch OFF.Disconnectthe
ha r n e s s . batterynegativecable,and wait for 3 minutes.

1 3 . C h e c kr e s i s t a n cbee t w e e nt h e N o . 2 a n d N o . 1 1
terminalsof SRS unit connectorB ( 18P).There
should be an open circuit,or at least M !) .
'l
narness.
u
B {18P}
SRSUNIT CONNECTOR
GRN/RED
GRN
WiresideoI femaleterminals
ls the resistanceas specified? 5 . C o n n e ctth e S R Si n f l a t o rs i m u l a t o r( 2 ! J

connectors)and simulatorlead F to the floor wire
YES FaultySRSunit; replacethe SRS unit (see h ar n e s s .
page 23'1221.a
NO Short in the floor wire harness;replacethe

f l o o rw i r e h a r n e s s . I
\ J
23-66
t
6. Reconnectthe batterynegativecable. 1 0 .Disconnectboth side airbag2P connectors(see
s t e p4 o n p a g e2 3 - 2 1 ) a n dt h e d r i v e r ' ss e a tb e l t
7. Erasethe DTCmemory. buckletensioner4P connector(seestep 6 on page
,1_r'>\
8. Readthe DTC.
1 1 .DisconnectSRS unit connectorB (18P)from the
ls DTC 22-4 indicated? SRS unit (seestep 7 on page 23-221.
YES Go to step g. ' t 2 .Disconnect

the specialtool from the floor wire
harness.
NO-Short to power in the front passenger,sseat
belt buckletensioner;replacethe front passenger,s t5. Reconnectthe batterynegativecable.
seat belt buckle.!
batterynegativecable,and wait for 3 minutes, Checkfor voltage betweenthe No. 2 terminal of
S R Su n i tc o n n e c t oB r { 1 8 P )a n d b o d y g r o u n d ,a n d
b e 0 . 5V o r I e s s .
SRSUNITCONNECTOR
B I18P)
Y E S - F a u l t yS R Su n i t ;r e p l a c et h e S R Su n i t ( s e e
page 23-1221.l
NO Short to power in the floor wire harness;


23-67
sRs
DTC22-5:Shortto Groundin Front 8. Readthe DTC.
SeatBeltBuckleTensioner
Passenger's
. SRSinflatorsimulator07SAZ-T84011A YES-Go to step 9.
NO Short to ground in the front passenger'sseat
1. Erasethe DTCmemory (seepage 23-26). belt buckletensioner;replacethe front passenger's
s e a tb e l tb u c k l e . l
SRSindicatorcomes on for about 6 secondsand 9. Turn the ignition switch OFF.Disconnectthe
then goes off. batterynegativecable,and wait for 3 minutes.
Does the SRS indicator stay on? 10. Disconnectboth side airbag2P connectors(see
step 4 on page 23-21)and the driver'sseat belt
YES-Go to step 3. buckletensioner4P connector(seestep 6 on page
23-22t.
NO - Intermittentfailure,system is OK at this time.
Go to TroubleshootingIntermittentFailures(see r ( 1 8 P l f r o mt h e
page 23-26). SRS unit (see 7
step on page 23-221.
3. Turn the ignition switch OFF.Disconnectthe 12. Disconnectthe specialtool from the floor wire
batterynegativecable,and wait for 3 minutes. harness,
4. Disconnectthefront passenger'sseat belt buckle 13. Checkresistancebetweenthe No. 2 terminal of

harness,
SRSunit connectorB (18P)and body ground, and
the No, 11 terminal and body ground.Thereshould
b U
be an open circuit,or at least 1 M Q.
g {18PI
SRSUNITCONNECTOR
5 . Connectthe SRSinflatorsimulator(2 Q
connectors)and simulatorlead F to the floor wire ls the resistance as specified?
narness.
YES-Faulty SRSunit; replacethe SRS unit (see
6 . Reconnectthe batterynegativecable. page 23-1221.a
1 . Erasethe DTCmemory. NO Short to ground in the floor wire harness;

!U
23-68
I
DTCs-1,5-2,5-4,s-8,6-3,6-4,6-7,6-8,7-1, DTC10-1,10-2,10-3,10-4,10-s,10-6,10-7:
7-2,7-3,A-1,4-2,8-3,8-4,8-5,8-6,9-1,9-2: Airbags,SideAirbags,and/orSeatBeltand
InternalFailureof the SRSUnit SeatBeltBuckleTensionersDeployed
NOTE:Beforetroubleshootingany of these DTCs,check The SRS unit must be replacedafter any airbagsand/or
the battery/systemvoltage.lf the voltage is low, repair tensionershave deployed(seepage 23-122).!
the chargingsystem or replacethe batterybefore
troubleshootingthe SRS.lf the battery/systemvoltage
is now OK, ask the customerif the batteryever went
oeao,
2. Turn the ignitionswitch ON (ll),and checkthat the

then goes off.
Does the SRS indicatot stay on?
t h e S R Su n i t ( s e ep a g e2 3 - 1 2 2 ) . 1
YES Replace

page23-26).

23-69
SRS
DTC13-1,13-2:InternalFailureof the Driver's DTC14-1,14-2:InternalFailureofthe Front
SidelmpactSensor Passenger's
SidelmpactSensor
1. Erasethe DTCmemory (seepage 23-26). 1. Erasethe DTCmemory (seepage23-26).
2. Turn the ignition switch ON (ll),and checkthat the 2. Turn the ignition switch ON (ll),and checkthat the
SRSindicatorcomes on for about 6 secondsand SRSindicatorcomes on for about 6 secondsand
then goes off. then goes off.
Does the SRS indicatot stay on? Does the SRS indicator stay on?
YES Replacethe driver's side impact sensor(see YES-Replace the front passenger'sside impact
page 23-123).a sensor (see page 23-123],.1
NO Intermittentfailure,system is OK at this time. NO-lntermittent failure,system is OK at this time.

Go to TroubleshootingIntermittentFailures(see Go to TroubleshootingIntermittentFailures(see
page 23-261. page 23-26).
I J
23-70
I
DTC9-3:Faulty Driver'sSeatBeltBuckle 6. Bucklethe driver's seat belt.
Switch
Checkresistancebetweenthe No. 1 and No.3
1. Erasethe DTCmemory (seepage 23 26). terminalsofthe driver's seat belt buckleswitch 3P
c o n n e c l o rT. h e r es h o u l db e 0 1 ( J .
2 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,t h e n b u c k l ea n d
u n b u c k l et h e d r i v e r ' ss e a tb e l ts e v e r atl i m e s . Checkresistancebetweenthe No. 1 and No.2
terminalsof the same connector.Thereshould be
3. Readthe DTC. , r a t l e a s t1 M Q .
a n o p e nc i r c u i t o
ls DTC 9-3 indicated? SEATBELTBUCKLE

DRIVER'S SWITCH
3PCONNECTOR
YES Go to step 4.
NO Intermittentfailure,system is OK at this time. BLU/RED

page 23-261.

T e r m i n asl i d eo f m a l et e r m i n a l s
5 . Disconnectthe driver's seat belt buckleswitch 3P

connector(A)from the floor wire harness.
t
Ate the resistancereadings as specified?
YES- Go to step 7.
NO Replacethe driver'sseat belt buckleassembly,

t h e n c l e a rt h e D T C . I
I
(cont'd)
23-71
sRs
(cont'dl
DTCTroubleshooting
7, Unbucklethe driver'sseat belt. 8. Checkresistancebetweenthe No. 1 terminal ofthe
floor wire harness3P connectorand bodv oround.
Checkresistancebetweenthe No. 1 and No.2 '1
T h e r es h o u l db e 0 0.
terminalsofthe driver'sseat belt buckleswitch 3P
c o n n e c t o rT. h e r es h o u l db e 0 1 Q . FLOORWIREHARNESS3P CONNECTOR
Checkresistancebetweenthe No. 1 and No. 3

terminalsof the same connector.There should be
an open circuit,or at least 1 M Q
DRIVER'S
SEATBELT
BUCKLESWITCH3PCONNECTOR
T e r m i n asl i d eo f m a l et e r m i n a l s
BLU/RED YES Go to step 9.
N O O p e ni n t h e f l o o rw i r e h a r n e s so r p o o r g r o u n d
T e r m i n as li d eo I m a l et e r m i n a l s connection a t G 5 5 1 .l f G 5 5 ' 1i s O K , r e p l a c et h e f l o o r
w r r eh a r n e s s . l
9 . Disconnectthe negativecablefrom the battery.
YES Go to step 8.
1 0 . DisconnectSRS unit connectorC (8P)from the SRS
NO-Replace the driver'sseat belt buckleassembly, unit {seestep 7 on page 23-22).
then clearthe DTC.I
\ J
23-72
I
11. Checkresistancebetweenthe No. 2 terminal of the 13. Checkresistancebetweenthe No. 8 terminal of
floor wire harness3P connectorand body ground. SRS unit connectorC (8P)and the No. 3 terminal of
Thereshould be an open circuit.or at least 1 fvlQ , the floor wire harness3P connector.There should
be0 1Q.
FLOORWIRE HARNESS3P CONNECTOR
HARNESS SRSUNITCONNECTORC
FLOORWIRE I8P}
3PCONNECTOB
Wiresideot temaleterminals Wire side of femaleterminals
ls the resistance as specified? ls the resistance as specitied?
Y E S - G o t o s t e p1 2 . YES Go to step 14.
NO Short to ground in the floor wire harnessor NO Open in the floor wire harness;replacethe
multiplexcontrol unit. Replacethe faulty harnessor floor wire harness.l
3 part.I
] g 1 4 . Checkresistancebetweenthe No. 4 terminal of
1 2 .Checkresistancebetweenthe No. 3 terminal of the r ( 8 P )a n d t h e N o . 2 t e r m i n a o
S R Su n i tc o n n e c t oC l f
floor wire harness3P connectorand body ground. the floor wire harness 3P connector.There should
T h e r es h o u l db e a n o p e nc i r c u i to, r a t l e a s t1 M Q . be0-1 0.
FLOORWIREHARNESS3P CONNECTOR FLOORWIREHARNESS SRSUNITCONNECTOR

C IsPI
3P CONNECTOR
LT GRN


t h e S R Su n i t ( s e ep a g e2 3 - 1 2 2 ) . 1
YES Replace
YES Go to step 13.
N O O p e ni n t h e f l o o rw i r e h a r n e s so r m u l t i p l e x
N O - S h o r t t o g r o u n di n t h e f l o o rw i r e harness; control unit, or poor connectionat the floor wire
replacethe floor wire harness.I harness,the under-dashfuse/relaybox, and the
multiplexcontrol unit. Checkthe connectionat the
floor wire harness,the under-dashfuse/relaybox,
and the multiplexcontrol unit. lf the connectionis
OK, replacethe faulty harnessor part.l

23-73
SRS
DTCTroubleshooting(cont'dl J
DTC9-4:FaultyFrontPassenger's
SeatBelt 6. Bucklethe front passenger'sseat belt.
BuckleSwitch
Checkresistancebetweenthe No. 1 and No.3
1. Erasethe DTCmemory {seepage 23-26). terminalsof the front passenger'sseat belt buckle
switch 3P connector.Thereshould be 0- 1 Q.
2 . T u r nt h e i g n i t i o ns w i t c hO N { l l ) ,t h e n b u c k l ea n d
unbucklethe front passenger'sseat belt several Checkresistancebetweenthe No. 1 and No.2
times. terminalsof the same connector.Thereshould be
a n o o e nc i r c u i t o
3. Readthe DTC.
FRONT
PASSENGER'S
SEATBELT
BUCKLE
SWITCH
3PCONNECTOR
YES-Go to step 4. BLU/RED

Go to TroubleshootingIntermiftentFailures{see T e r m i n asl i d eo f m a l et e r m i n a l s
page 23-26)'.

switch 3P connector(A) from the floor wire harness.
Terminalsideof maleterminals
Is the rcsistanceas specified?
YES-Go to step 7.
NO Replacethe front passenger'sseat belt buckle

assembly,then clearthe DTC.I
23-74
7. Unbucklethe front passenger'sseat belt. 8. Checkresistancebetweenthe No. 1 terminal ofthe
floor wire harness3P connectorand body ground.
Checkresistancebetweenthe No. 1 and No. 2 T h e r es h o u l db e 0 1 Q .
terminalsof the front passenger'sseat belt buckle
s w i t c h3 Pc o n n e c t o rT. h e r es h o u l db e 0 1 ! ) . FLOORWIRE HARNESS3P CONNECTOR

terminalsof the same connector.Thereshould be
an oDencircuit,or at least 1 M Q
FRONTPASSENGER'S
SEATBELT
BUCKLESWITCH3PCONNECTOR
Terminalside of maleterminals
ls the tesistance as specified?
YES Go to step 9.
NO-Open in the floor wire harnessor poor ground

Terminalsideof maleterminals connectionat G551.lf G551is OK, replacethe floor
wire harness.I
ls the resistanceas specilied?
9 . Disconnectthe negativecablefrom the battery,
YES Go to step 8.
1 0 . DisconnectSRS unit connectorC (8P)from the SRS
NO-Replace the front passenger'sseat belt buckle unit (see step 7 on page 23-22).
assembly,then clearthe DTC.I
(cont'd)
23-75
sRs
1 1 . C h e c kr e s i s t a n c be e t w e e nt h e N o . 2 t e r m i n a o
l fthe 13. Checkresistancebetweenthe No. 7 terminal of
floor wire harness3P connectorand body ground. S R Su n i tc o n n e c t oC r ( 8 P )a n d t h e N o . 3 t e r m i n a lo f
There should be an open circuit,or at least 1 M 0 . the floor wire harness3P connector.
T h e r es h o u l db e 0 - 1 Q .
FLOORWIREHARNESS
3PCONNECTOR
FLOORWIRE C (8P)
HARNESS SRSUNITCONNECTOR
3PCONNECTOR
ls the resistance as specified? Wiresideof femaleterminals
Y E S - G o t o s t e p1 2 . ls the tesistance as specified?
NO-Short to ground in the floor wire harness; YES-Go to step 14.

replacethe floor wire harness.I
NO Open in the floor wire harness;replacethe
Checkresistancebetweenthe No. 3 terminal of the
floor wire harness3P connectorand body ground.
f l o o rw i r e h a r n e s s . I L J
There should be an open circuit,or at least 1 l\40 . 1 4 . Checkresistancebetweenthe No, 3 terminal of
SRS unit connectorC (8P)and the No. 2 terminal of
FLOOR
WIREHABNESS
3PCONNECTOR t h e f l o o rw i r e h a r n e s s3 Pc o n n e c t o f
T h e r es h o u l db e 0 1 Q .
FLOORWIREHARNESS SRS UNIT CONNECTORC ISPI

3P CONNECTOR
Wiresideof temaleterminals

Y E S - G o t o s t e p1 3 .
NO Short to ground in the floor wire harness; ls the resistance as specified?

replacethe floor wire harness.I
t h e S R Su n i t( s e ep a g e2 3 - 1 2 2 ) . 1
YES Replace
N O O p e nl n t h e f l o o rw l r e h a r n e s sr;e p l a c e t h e
\ J
23-76
DTC9-6:FaultyLeftFrontlmpactSensor 8. Disconnect
the enginecompartment wire harness
2Pconnector{A)fromthe leftfrontimpactsensor.
. SRSinflatorsimulator07SAZ-TB4011A
. SRSsimulatorlead H 07YM-S3AA100

then goes off.
YES-Go to step 3.
NO Intermiftentfailure,system is OK at this time.

page23-26). 9 . DisconnectSRS unit connectorA {18P)from the
SRSunit (seestep7 on page23-22J.
3. Turn the ignitionswitch OFF.Checkthe
connectionsbetweenSRS unit connectorA (18P) 1 0 .Checkresistancebetweenthe No. 10 and No. 11
and the SRSunit. betweenthe engine terminalsof SRSunit connectorA (18P).There
compartmentwire harness2P connectorand the should be an oDencircuit.or at least 1 M 0 .
left front impactsensor{seepage23-13),and at
connectorC401. A (18PI
SRSUNITCONNECTOR
Are the connectionsOK?

2 3 5 6 7 8 9
YES Go to step 4. 10 t l 1Z t 3 15 16 17 1 8
NO-Repair the poor connectionsand retest.lf DTC

9-6 is still present,go to step 4.
RED
I ILK
Turn the ignition switch OFF.Disconnectthe T

Disconnectthe driver'sairbag4P connectorfrom
the cable reel (seestep 2 on page23-21).
Disconnectthe front passenger'sairbag 4P
connectorfrom dashboardwire harnessB {seestep YES Go to step 11.
3 on page23-21).
N O - S h o r t i n t h e e n g i n ec o m p a n m e n w
t ire
7 . Disconnectboth seat belt tensioner2P connectors harnessor dashboardwire harnessB; replacethe
from the floor wire harness(seestep 5 on page 23- f a u l t yh a r n e s s . I
22).
12. Turn the ignition switch ON {ll).
{cont'd}
23-77
sRs
13. Checkvoltagebetweenthe No. 10terminalof SRS 16. Checkresistancebetweenthe No. 10 and No. 11
A (18P)andbodyground.There
unitconnector terminalsof SRS unit connectorA (18P).There
'l
shouidbe V or less. s h o u l db e 1 0 o r l e s s .
SRS UNIT CONNECTORA {,I8P) SRS UNIT CONNECTORA Il8PI
1 2 3 7 8 I
10 11 12 l 3 t 4 15 1 6 1 1 t6
RED
Wire side oI femaleterminals Wire side of femaleterminals
ls the voltage as specitied? ls the rcsistance as specified?
YES-Go to step 14. YES Faultyleft front impactsensoror SRS unit;

replacethe left front impact sensor (seepage 23-125).
NO-Short to power in the engine compartment lf the problem is still present,replacethe SRSunit
wire harnessor dashboardwire harnessB; replace ( s e ep a g e2 3 - 1 2 2 ) . 1
the faulty harness.l
NO-Poor connectionat C401,faulty engine = \y,
1 4 . Turn the ignition switch OFF. compartmentwire harness,or faulty dashboard
wire harnessB. InspectC401.lf it is OK, replacethe
t5. Connectthe SRS inflatorsimulator(jumper faulty harness.l
connector)and simulatorlead H to the engine
compartmentwire harness2P connector(A).
07YAZ-S3AA100
07SAZ-TB,O11A
\."r1
23-78
)
DTC9-7:FaultyRightFrontlmpactSensor Disconnectthe enginecompartmentwire harness

2P connector(A) from the right front impactsensor.
Special Tools Bequired
. SRSinflatorsimulator07SAZ-TB4011A
1. Erasethe DTCmemory {seepage23-26).
2 . T u r nl h e i g n i t i o ns w i t c hO N { l l ) ,a n d c h e c k t h a t t h e
then goes off.
YES-Go to step 3.

page 23-26). DisconnectSRSunit connectorA (18P)from the
SRS unit (see step 7 on page 23-221.
3. Turn the ignitionswitch OFF.Checkthe
connectionsbetweenSRSunit connectorA (18P) '10.Checkresistancebetween
the No. 1 and No. 12
and the SRSunit, betweenthe engine terminalsof SRSunit connectorA (18P).There
compartmentwire harness2P connectorand the should be an open circuit,or at least1 M 0.
t right front impactsensor(seepage 23-13),and at

connectorC401.
SRS UNIT CONNECTORA (18PI
Are the connectionsOK? GRN
YES-Go to step 4. I
F!-
t 1 t 2 ) l 5 6 I 6
NO Repairthe poor connectionsand retest.lf DTC I r o l r l r13 1 6 1 7 18
9-7 is still present,go to step 4. SLK

5 . Disconnectthe driver'sairbag4P connectorfrom
Disconnectthe front passenger'sairbag4P
connectorfrom the dashboardwire harness(see Y E S G o t o s t e p1 1 .
N O - S h o r t i n t h e e n g i n ec o m p a n m e nw
t ire
7 . Disconnectboth seat belt tensioner2P connectors harnessor dashboardwire harnessB; replacethe
from the floor wire harness(seestep 5 on page23- f a u l t yh a r n e s s , I
22).
I
(cont'd)

23-79
sRs
13. Checkvoltagebetweenthe No.1terminalofSRS 16. Checkresistancebetweenthe No. 1 and No. '12
unitconnector A (18P)andbodyground.There terminalsof SRS unit connectorA (18P).There
shouldbe 1 V or less. s h o u l db e 1 O o r l e s s .
SRSUNIT CONNECTOR
A I18P} SRSUNITCONNECTOR
A {18P)
GRN
J_
l r 1 2 l r 5 6 7 8 9
tE.]I t 3 1 1 r5 16 1 1 t6
/A BLK
Wiresideof femaleterminals Wire side of femaleterminals
ls the voltage as specified? ls the resistance as specitied?
YES Go to step 14. YES Faultyright front impactsensoror SRS unit;

replacethe rightfront sensor{seepage 23-125).lfthe
NO-Short to power in the enginecompartment problem is still present,replacethe SRS unit (see
wire harnessor dashboardwire harnessB; replace page 23-1221.a
the faulty harness.l

NO- Poorconnectionat C401,faulty engine
compartmentwire harness,or faulty dashboard
L J
wire harnessB. lnspectC401.lf it is OK, replacethe
Connectthe SRS inflatorsimulator(jumper faulty harness,I
connector)and simulatorlead H to the engine
compartmentwire harness2P connector(A).
07YAZ-S3AA100
23-80
I
DTC11-1:Openor Increased Resistance
in 6. Reconnectthe batterynegativecable.
Driver'sSideAirbagInflator
r 7SM-TB4011A 8. Readthe DTC.
. SRSsimulatorlead E 07XM-S140200
1. Erasethe DTCmemory (seepage 23-26),
YES Go to step 9.
2. Tu rn the ignition switch ON (ll),and checkthat the
SRSindicatorcomes on for about 6 secondsand NO-Open or increasedresistancein the driver's
then goes off. side airbag inflator;replacethe driver's side
a i r b a g( s e ep a g e2 3 - 1 ' 1 5 ) . 1
Does the SBS indicatot stay on?
YES Go to step 3. batterynegativecable,and wait for 3 minutes.
NO Intermittentfailure,system is OK at this time. 10. Disconnectthe front passenger'sside airbag 2P

Go to TroubleshootingIntermittentFailures(see connector(seestep 4 on page 23-21)and both seat
page 23-261. belt buckletensioner4P connectors(seestep 6 on
page 23-221.
4. Disconnectthe floor wire harness2P connector(A)

) J from the driver'sside airbag.
07sAz-T84011A
5. Connectthe SRSinflatorsimulator(2 Q connector)

and simulatorlead E to the floor wire harness.
I
{cont'd)

23-81
sRs
' It . D i s c o n n e c t
r ( 1 8 P ) f r o mt h e
S R Su n i tc o n n e c t oB DTC11-3:Shortto AnotherWireor
SRS unit (seestep 7 on page 23-22).Do not DecreasedResistance
in Driver'sSideAirbag
disconnectthe specialtool from the floor wire lnflator
harness2P connector.
12 Checkresistancebetweenthe No.6 and No. 17 ' S R Si n f l a t o rs i m u l a t o 0
r 7SAZ-T84011A
r ( 1 8 P )T. h e r e
t e r m i n a l so f S R Su n i tc o n n e c t oB . SRSsimulatorlead E o7XAZ-S140200
s h o u l db e 2 . 0- 3 . 0 Q .
1. Erasethe DTCmemory (seepage 23 26).
SRSUNITCONNECTOR
B I18PI
2 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d c h e c kt h a tt h e
WHT/BLU then goes off.
rr--r-{ Does the SRS indicatot stay on?

1 2 0 lTlslsl a
10 t l 15IdFFI \
YES Go to step 3.
WHT/BLK NO Intermittentfailure,system is OK at this time.

Wiresideof femaleterminals page 23-26).

ls the resistance as specified? batterynegativecable,and wait for 3 minutes.
YES-Faulty SRS unit or poor contactat SRS unit Disconnectthe floor wire harness2P connector(A)
r ( 1 8 Pa
c o n n e c t oB ) n d t h e S R Su n i t .C h e c kt h e f r o m t h e d r i v e r ' ss i d ea i r b a g .
SRS unit (seepage 23'1221.a

harness;replacethe floor wire harness.l
07sAz-T84011A
C o n n e ctth e S R Si n f l a t o rs i m u l a t o r( 2 0 c o n n e c t o r )
a n d s i m u l a t o rl e a dE t o t h e f l o o rw i r e h a r n e s s .
23-82
I
8. Readthe DTC. DTG11-4:Shortto Powerin Driver'sSide
AirbagInflator
YES-Go to step9. . SRS inflatorsimulator07SAZ-T84011A
. SRSsimulatorlead E o7XAZ-S140200
NO*Shon to anotherwire in the driver's side
airbag inflator;replacethe driver'sside airbag (see 1. Erasethe DTCmemory {seepage 23-261.
p a g e2 3 - 1 1 5 ) . I
2 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d c h e c kt h a t t h e
9. Turn the ignition switch OFF.Disconnectthe SRS indicatorcomes on for about 6 secondsand
batterynegativecable.and wait for 3 minutes. then goes off.
10. Disconnectthefront passenger'sside airbag2P Does the SBS indicator stay on?
connector(seestep 4 on page 23-21)and both seat
belt buckletensioner4P connectors(seestep 6 on YES Go to step 3.
page 23-22l,.
11. Disconnectthe specialtool from the floor wire Go to TroubleshootingIntermittentFailures(see
harness2P connector. page 23-26l,.
r { 1 8 P ) f r o mt h e 3. Turn the ignition switch OFF.Disconnectthe
SRSunit {seestep 7 on page23-221. batterynegativecable,and wait for 3 minutes.
I 13. Checkresistancebetweenthe No.6 and No. 17

t e r m i n a l so f S R Su n i tc o n n e c t oB r ( 1 8 P )T, h e r e
s h o u l db e a n o p e nc i r c u i to, r a t l e a s t1 M 0 .
from the driver'sside airbag.
SRSUNITCONNECTOR
B {18PI
WHT/BLU
07sAz-TB4011A
WHT/BLK
5 . C o n n e ctth e S R Si n f l a t o rs i m u l a t o (r 2 0 c o n n e c t o r )
ls the resistance as specified? a n d s i m u l a t o rl e a dE t o t h e f l o o rw i r e h a r n e s s .
YES FaultySRSunit; replacethe SRS unit {see

page23-'t221
.a
N O S h o n t o a n o t h e rw i r e i n t h e f l o o rw i r e
(cont'd)

23-83
sRs
(cont'd)
DTCTroubleshooting
6. Reconnect
the batterynegative
cable. 1 1 .DisconnectSRS unit connectorB (18P)from the
SRSunit (seestep 7 on page 23-22l,.
7. Erasethe DTCmemory,
' t 2 .T u r n
t h e i g n l t i o ns w i t c hO N ( l l ) .
8. Readthe DTC.
Is DTC 11-4indicated? SRS unit connectorB (18P)and body ground,and
betweenthe No. 17 terminal and body ground.
YES-Go to step9. Thereshould be 0.5 V or less.
NO Shortto powerin the driver'ssideairbag SRSUNITCONNECTOR

B I18P)
inflator;replacethe driver'ssideairbag(seepage
23-115).t
9 . Turn the ignition swilch OFF.Disconnectthe

WHT/BLK
' 1 0 Disconnect
. the front passenger'sside airbag2P
connector(seestep 4 on page 23-21)and both seat
belt buckletensioner4P connectors(seesteD6 on
page 23-221.
ls the voltage as specitied?
YES- FaultySRSuniUreplacethe SRS unit (see

U J
page 23-1221.a

r e p l a c et h e f l o o rw i r e h a r n e s s . l
\.J
23-84
I
DTC11-5:Shortto Groundin Driver'sSide 8. Readthe DTC.
AirbagInflator
r 7SM-T84011A YES Go to step 9.
' SRSsimulatorlead E o7XAZ-S140200
NO Short to ground in the driver'sside airbag
'1.
Erasethe DTCmemory {seepage 23-26). inflator;replacethe driver'sside airbag (seepage
23-115).t
2. Turn the ignitionswitch ON {ll),and checkthat the
SRSindicatorcomes on for about 6 secondsand 9. Turn the ignition switch OFF.Disconnectthe
then goes off. batterynegativecable,and wait for 3 minutes.
Does the SRS indicator stay on? 10. Disconnectthe front passenger'sside airbag2P
connector(seestep 4 on page 23-21)andboth seat
YES Go to step 3. belt buckletensioner4P connectors(seestep 6 on
page 23-221.
Go to TroubleshootingIntermittentFailures(see 1 1 . D i s c o n n e c t S RuSn i t c o n n e c t o r B( 1 8 P ) f r o m t h e
page 23-261. SRS unit (seestep 7 on page 23-22).
3. Turn the ignitionswitch OFF.Disconnectthe '12.

batterynegativecable,and wait for 3 minutes. r ( 1 8 P )a. n d
t e r m i n a l so f S R Su n i tc o n n e c t oB
'17
b e t w e e nt h e N o . a n d N o . 1 6t e r m i n a l sT. h e n
I
checkresistancebetweenthe No. 17 terminal and
from the driver'sside airbag. body ground.Thereshould be an open circuit,or at
l e a s t1 M 0 .
SRSUNIT CONNECTOR
B I18P)
WHT/BLK
07saz-TB,r011A
Connectthe SRSinflatorsimulator(2 Q connector)
and simulatorlead E to the floor wire harness. ls the resistance as specified?
6 . Reconnectthe batterynegativecable. YES FaultySRSunit; replacethe SRS unit (see

page 23-122).a
NO-Short to ground in the floor wire harness;
r e p l a c et h e f l o o rw i r e h a r n e s s . I
I
23-85
sRs
DTG12-1:Openor Increased
Resistancein Reconnectthe batterynegativecable.
SideAirbagInflator
FrontPassenger's
r 7SAZ-T84011A Readthe DTC.
ls DTC 12-l indicated?
YES Go to step L
SRSindicatorcomes on for about 6 secondsand NO-Open or increasedresistancein the front
then goes off. passenger'sside airbag inflator;replacethe front
p a s s e n g e r 'ssi d ea i r b a g( s e ep a g e2 3 - 11 5 ) . 1
YES Go to step 3. batterynegativecable.and wait for 3 minutes.
'10. Disconnectthe driver'sside airbag2P connector
NO - Intermittentfailure, system is OK at this time.
Go to TroubleshootinglntermittentFailures(see {seestep 4 on page 23-21)andboth seat belt buckle
page23-26). tensioner4P connectors(seestep 6 on page 23-22).


from the front passenger'sside airbag.
07xAz-s1A0200
5. Connectthe SRSinflatorsimulator(2 Q connector)

I J
23-86
I
1't. DisconnectSRS unit connectorB ('l8P)from the DTC12-3:Shortto AnotherWireor
SRSunit (seestep 7 on page 23-22).Do not DecreasedResistancein FrontPassenger's
disconnectthe specialtool from the floor wire SideAirbagInflator
h a r n e s s2 P c o n n e c t o r .
1 2 .Checkresistancebetweenthe No.7 and No. 18 . S R Si n f l a t o rs i m u l a t o 0
r 7SAZ-T84011A
t e r m i n a l so f S R S u n i t c o n n e c t oBr ( 1 8 P )T. h e r e . SRSsimulatorlead E o7XAZ-S140200
s h o u l db e 2 . 0 3 . 0 ( J .
1. Erasethe DTCmemory (seep age 23-261.
SRSUNITCONNECTOR
B {18P)
WHT/RED then goes off.
YES Go to step 3.
WHT/GRN NO - Intermittentfailure,system is OK at this time.

Wiresideof femaleterminals page 23-26).

ls the resistanceas specified? batterynegativecable,and wait for 3 minutes.
I YES FaultySRSunit or poor contactat SRS unit

r ( l 8 P )a n dt h e S R Su n i t .C h e c kt h e
c o n n e c t oB
connection;lf the connectionis OK, replacethe
4 . Disconnectthe floor wire harness2P connector(A)
from the front passenger'sside airbag.
SRSunit (seepage 23-1221.a

h a r n e s sr;e p l a c et h e f l o o rw i r e h a r n e s s . I
07xAz-s1A0200
5. Connectthe SRSinflatorsimulator(2 0 connector)

(cont'd)
23-87
sRs
6. Reconnectthe batterynegativecable. DTC12-4:Shortto Powerin FrontPassenger's
SideAirbagInflator
7, Erasethe DTCmemory.
8. Readthe DTC. . sRS inflatorsimulator07sAz-TB4011A
. SRSsimulatorlead E 07XM-S140200
YES-Go to step I
2 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d c h e c kt h a t t h e
NO Short to anotherwire in the front passenger's SRS indicatorcomes on for about 6 secondsand
side airbag inflator;replacethe front passenger's then goes off.
s i d ea i r b a g( s e ep a g e2 3 - l l 5 ) . 1
batterynegativecable,and wait for 3 minutes. YES-Go to step 3.
10. Disconnectthe driver's side airbag2P connector NO- Intermittentfailure,system is OK at this time.
(seestep 4 on page 23-21)and both seat belt buckle Go to TroubleshootingIntermittentFailures{see
tensioner4P connectors(seestep 6 on page 23-22). page 23-26).
'!1. 3. Turn the ignition switch OFF.Disconnectthe

t e s p e c i a l t o o l f r o mt h e f l o o rw i r e
harness2P connector. banery negativecable,and wait for 3 minutes.
12. DisconnectSRS unit connectorB ('lSPlfromthe 4. Disconnectthe floor wire harness2P connector(A)
SRS unit {see step 7 on page 23-221. from the front passenger'sside airbag.
13. Checkresistancebetweenthe No.7 and No. 18

r ( 1 8 P )T. h e r e
t e r m i n a l so f s R S u n i tc o n n e c t o B
, r a t l e a s t1 M 0 .
s h o u l db e a n o p e nc i r c u i t o
B I18P)
SRSUNITCONNECTOR
WHT/RED
-r-'r-Jl
2 3 ' 8lel
6 n
10 l l 15
-T
i['tl,Bl S
07xAz-s1A0200
WHT/GRN
5. Connectthe SRS inflatorsimulator(2 Q connector)
Wiresideof {emaleterminals a n d s i m ul a t o rl e a dE t o t h e f l o o rw i r e h a r n e s s .
ls the resistance as specilied?
Y E S F a u l t yS R Su n i t ;r e p l a c et h e S R Su n i t{ s e e
page 23-1221.a
N O S h o r tt o a n o l h e rw i r e i n t h e f l o o rw i r e
\.J
23-88
\
6. Reconnectthe batterynegativecable. 1 1 .DisconnectSRS unit connectorB (18P)from the

1? Turn the ignition switch ON (ll).
8. Readthe DTC.
ls DTC 12-4 indicated ? SRS unit connectorB ( l8P) and body ground,and
betweenthe No. 18terminal and body ground.
YES Go to step 9. T h e r es h o u l db e 0 . 5V o r l e s s .
NO-Short to power in the front passenger'sside

SRSUNIT CONNECTOR
B I18P)
airbaginflator;replacethe front passenger'sside
a i r b a g( s e ep a g e2 3 - 1 1 5 t) .
9. Turn the ignitionswilch OFF.Disconnectthe

WHT/GRN
'10.
Disconnectthe driver'sside airbag2P connector
(seestep 4 on page 23-21)and both seat belt buckle
tensioner 4P connectors (see step 6 on page 23-22l,.
ls the voltage as specified?
t YES FaultySRSunil; replacethe SRSunit (see

page 23-1221.a

23-89
sRs
DTCTroubleshooting(cont'dl .t
DTC12-5:Shortto Groundin Front 6. Reconnectthebatterynegativecable.

SideAirbagInflator
Passenger's
. SRSinflatorsimulator07SAZ-T84011A 8. Readthe DTC.
1. Erasethe DTCmemory (seepage23-26).
YES Go to step9.
SRSindicatorcomes on for about 6 secondsand NO-Short to ground in the front passenger'sside
then goes off. airbaginflator;replacethe front passenger'sside
a i r b a g( s e ep a g e2 3 - 11 5 ) . 1
YES-Go to step 3. batterynegativecable,and wait for 3 minutes.
NO Intermittentfailure,system is OK at this time. 10, Disconnectthedriver'sside airbag2P connector

Go to TroubleshootingIntermittentFailures(see (see step 4 on page 23-211and both seat belt buckle
page 23-261. lensioner4P connectors(seestep 6 onpage23-22).
3. Turn the ignition switch OFF.Disconnectthe r ( 1 8 P ) f r o mt h e

batterynegativecable,and wait for 3 minutes. SRS unit (see step 7 on page 23-22).
4. Disconnectthe floor wire harness2P connector(A) 12. Checkresistancebetweenthe No. 15 and No. 18
from the front passenger'sside airbag. r ( 1 8 Pa
t e r m i n a l so f S R Su n i tc o n n e c t oB ) nd
betweenthe No. 16 and No. 18 terminals.Then {
checkresistancebetweenthe No. 18 terminal and
body ground.Thereshould be an open circuit,or at
l e a s t1 M Q .
B {18PI
SRSUNITCONNECTOR
2 3 6 7 8
1 0 11 t6 1 7 1E
LTGRN/REDd WHT/GRN
i 116\l 9 Y 9
07xAz-s1A0200 GRY/RED
o
and simulatorlead E to the floor wire harness. Wire side of femaleterminals
YES FaultySRSunit; replacethe SRS unit (see

page 23-1221.a
N O - S h o r t t o g r o u n di n t h e f l o o rw i r e h a r n e s s ;
23-90
)
DTC13-3:No Signalfrom the Driver'sSide 5. Disconnectthedriver's side airbagand front

lmpactSensor passenger'sside airbag2P connectors(seestep 4
on page 23-21).Also disconnectboth seat belt
Special Tools Required buckletensioner4P connectors(seestep 6 on page
. sRs inflatorsimularor07SAZ-TB4011A 23-22).
6. Disconnectthe floor wire harness2P connector{A}
1. ErasetheDTCmemory (seep age 23-261. from the driver'sside impact sensor.

then goes off.
YES- Go to step 3.

page 23-261.
07sAz-TB4011A

4. Checkthe connectionbetweenthe floor wire and simulatorlead H to the floor wire harness.
harness2P connectorand the driver'sside impact
) sensor.
ls the connectionOK?
YES Go to step 5.
NO-Replace the driver'sside impact sensorand/

or the floor harness,as needed.I
)
(cont'd)
23-91
sRs
8. DisconnectSRSunitconnector B (18P)fromthe DTC13-4:FaultyPowerSupplyto the Driver's
SRSunit (seestep7 on page23-221. SidelmpactSensor
9. Checkresistance betweenthe No.8 andNo.15 1. Erasethe DTCmemory {seepage 23-261.
terminalsof sRSunitconnector B ('l8P).There
s h o u l db e0 1 . 0Q . 2. Turn the ignition switchON (ll),and checkthat the
SRSlndicatorcomes on for about 6 secondsand
B I18P)
SRSUNITCONNECTOR then goes off.

BRN/YEL
3
I
:fr;f;l n
YES Go to step 3.
10 tl \ NO-lntermittent failure,system is OK at this time.

l l r ol r zl r s| Go to TroubleshootingIntermittentFailures(see
page 23-26).
LT GRN/RED
Wire side of temaleterminals batterynegativecable,and wait for 3 minutes.
4. Disconnectthe driver'sside airbagand front

Is the resistance as specitied? passenger'sside airbag2P connectors(seestep 4
on page23-21).Also disconnectboth seat belt
YES Faultydriver'sside impact sensoror SRS buckletensioner4P connectors(seestep 6 on page
unit; replacelhe driver'sside impactsensor(see 23-22).
page 23-123).lf the problem is still present,replace
the SRSunit (seepage 23-122).1
N O O p e ni n t h e f l o o rw i r e h a r n e s sr;e p l a c et h e
floor wire harness.l
23-92
t
5. Disconnect (A)
thefloorwire harness2Pconnector 8. Checkresistancebetweenlhe No.8 and No. l5
fromthedriver'ssideimpactsensor. terminalsof SRSunil connectorB (18P).There
should be an open circuit,or at least 1 M 0 .
SRSUNIT CONNECTOR
B {18P'
BRN/YEL
I
2 3 flliT;l n
10 11 1tr6l1tf;l \
LT GRN/RED
Wire side oI femaleterminals
DisconnectSRSunit connectorB (18P)from the

SRS unit (see step 7 on page 23-22) ls the resistance as specitied?
1 . Checkresistancebetweenthe No. 8 terminal of YES-Faulty driver's side impact sensoror SRS

SRS unit connectorB (18P)and body ground.There unit; replacethe driver'sside impact sensor(see
should be an open circuit,or at least 1 M Q . page 23-1251.lfthe problem is still present,replace
t h e S R Su n i t( s e ep a g e 2 3 - 1 2 2 1 . a
I SRSUNITCONNECTOR
B {18PI
BRN/YEL
NO- Short in the floor wire harness;replacethe
f l o o rw i r e h a r n e s s . I
Wire side of femalete.minals
ls the resistanceas specitied?
YES-Go to step8.
NO-Short to groundin thefloorwire harness;

replace
the floorwire harness.I

23-93
sRs
DTC14-3:No Signalfromthe Front 5 . Disconnectthedriver'sside airbagand front
SidelmpactSensor
Passenger's passenger'sside airbag2P connectors(seestep 4
SpecialToolsRequired buckletensioner4P connectors(seestep 6 on page
. SRSinflatorsimulator07SAZ-TB401'lA 23-22t.
. SRSsimulatorlead H 07YAZ'S3AA100
Disconnectthe floor wire harness2P connector{A)
1. ErasetheDTCmemory (seepage 23-26). from the front passenger'sside impact sensor.

then goes off.
YES Go to step 3.

page 23-26). 07sAz-TB4o11A

7. Connectthe SRS inflatorsimulator(2 0 connector)
4. Checkthe connectionbetweenthe floor wire and the simulatorlead H to the floor wire harness.
harness2P connectorand the front passenger's
side lmpact sensor.
Is the connectionOK?
YES-Go to step 5.
NO- Poorcontactbetweenthe floor wire harness

2P connectorand the front passenger'sside impact
sensor;replacethe front passenger'sside impact
sensorand/orthe floor harness,as needed.
23-94
)
8. DisconnectSRSunit connectorB (18P)fromthe DTC14-4:FaultyPowerSupplyto the Front

SRSunit (seestep 7 on page 23-221. Passenger's
SidelmpactSensor
9. Checkresistancebetweenthe No.9 and No. 16 1. Erasethe DTCmemory (seepage23-26).
terminalsof SRSunit connectorB (18P).There
s h o u l db e 0 - 1 . 0 S 2 . 2. Turn the ignition switch ON (ll),and checkthat the
SRSUNITCONNECTOR
B {18PI then goes off.

PNK/BLU
t- YES-Go to step 3.
2 3 0 l-u5l n
1 0 t1 t5 iFf;l \ NO-lntermittent failure,system is OK at this time.
page 23-261.
GRY/RED
Wiresideol lemaleterminals batterynegativecable,and wait for 3 minutes.
4. Disconnectthedriver's side airbagand front

ls the resistance as specified? passenger'sside airbag2P connectors(seestep 4
YES-Faulty front passenger'sside impact sensor buckletensioner4P connectors(seestep 6 on page
T or SRSunit; replacethe front passenger'sside

impactsensor(seepage 23-125).lf the problem is
still present,replacethe SRS unit (seepage23-122).
23-22t.
5. Disconnectthe floor wire harness2P connector{A}

I from the front passenger'sside impact sensor.
NO-Open in the floor wire harness;replacethe

floor wire harness.!
"-;s.\
\f r l/ \--)
\ l
j
1
- F.,=
DisconneclSRS unit connectorB (18P)from the

SRS unit (seestep 7 on page 23-22i.
I
(cont'd)

23-95
sRs
DTGTroubleshooting(cont'd)
7. Checkresistancebetweenthe No. 9 terminal of DTC15-1:FaultyOPDSUnit
SRS unit connectorB (18P)and body ground.There
should be an ooen circuit,or at least 1 N4Q. NOTE:
. An incorrectOPDSunit can causeDTC 15-1.
. A n e w ( u n i n i t i a l i z eOd )P D Su n i t i n s t a l l e d
witha faulty
B {18PI
SRSUNIT CONNECTOR
O P D Ss e n s o rc a nc a u s eD T C 1 5 - 1 .
. lf you installa new OPDSunit and a new SRSunit at
PNK/BLU t h e s a m et i m e , i n i t i a l i z teh e O P D Sm a n u a l l y( s e e
page 23-27),do not usethe HondaPGM Tester.
1. Make sure nothing is on the front passenger'sseat.
2. Initializethe OPDSunit (seepage23-27).
3. Erasethe DTCmemory (seepage 23-26]'.

4. Readthe DTC.
Is DTC 15-1indicated?
ls the tesistance as specilied?
YES Go to step 5.
YES Go to step 8.
NO-Short to ground in the floor wire harness; Go to TroubleshootingIntermittentFailures(see
replacethe floor wire harness.l page23-26).
Checkresistancebetweenthe No.9 and No. 16 Checkthe No. 9 (10A)fuse in the under-dashfuse/

terminalsof SRSunit connectorB (18P).There relay Dox,
should be an open circuit,or at least 1 M O .
ls the tuse OK?
B (18P)
SRSUNITCONNECTOR
YES Go to step 6.
PNK/BLU
_-r
NO Go to step 9.
2 3 6 '18 sl DisconnectOPDSunit harness8P connector(A)

/i
10 tl tltlis-l \ from the OPDSunit (A) (seepage23-124).
GRY/RED
Wiresideot femaleterminals
YES-Faulty front passenger'sside impactsensor

or SRS unit; replacethe front passenger'sside
impact sensor{seepage 23-125).lf the problem is
s t i l lp r e s e n tr,e p l a c et h e S R Su n i t ( s e ep a g e2 3 - 1 2 2 ) .
I
NO Short in the floor wire harness;replacethe 7 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .

23-96
)
8. Checkfor voltage betweenthe No. 4 terminal of 13. DisconnectOPDSunit harness8P connector(A)

OPDSunit harness8P connectorand body ground. from the OPDSunit.
Thereshould be batteryvoltage.
OPDS UNIT HARNESS8P CONNECTOR
1 4 . Turn the ignition switch ON (ll) for 30 seconds,then

Wiresideof femaleterminals turn it off.
C h e c kt h e N o . 9 ( 1 0 A )f u s e .
ls the f use OK?
YES-Go to step 16.
YES Short to ground in the OPDSunit; replacethe
NO Open in the floor wire harnessor OPDSunit OPDSunit (seepage 23-1241.1
harness;replacethe faulty harness.I
NO-Short to ground in the No. 9 (10A)fuse circuit
9. Replace t h e N o . 9 ( 1 0 A ) f u s ei n t h e u n d e r - d a s h (floor harness,or OPDSharness);replacethe
) fuse/relaybox. affectedharness.I
1 0 .Turn the ignitionswitch ON (ll) for 30 seconds,then to. Turn the ignition switch OFF.
turn it off.
1 1 . Checkresistancebetweenthe No.8 terminal of
1 1 .C h e c kt h e N o . 9 ( 1 0 A ) f u s e . OPDSunit harness8P connectorand body ground.
'1.0
Thereshould be 0 Q.
ls the tuse OK?
OPDSUNIT HARNESSsPCONNECTOR
YES lntermittentfailure,system is OK at this time.
Go to TroubleshootingIntermiftentFailures(see
page 23-26). l4V-'l^l
TVjEl
#
NO Go to step 12. BLK
Replacethe No. 9 ('l0A)fuse. @

I
YES Go to step 18.
NO Open in the floor wire harnessor OPDSunit

h a r n e s so, r p o o rg r o u n d( G 5 5 1 )l.f G 5 5 1i s O K ,
replacethe faulty harness.I
)
(cont'd)
23-97
sRs
1 8 . Turn the ignition switch OFF.Disconnectthe 22. Checkresistancebetweenthe No. 3 terminal of
batterynegativecable.and wait for 3 minutes. SRSunit connectorB (18P)and the No. 7 terminal
of OPDSunit harness8P connector.Thereshould
1 9 . Disconnectboth side airbagconnectors(seestep 4 be0 1.0Q.
o n p a g e2 3 - 2 1 ) a n db o t hs e a tb e l tb u c k l e t e n s i o n e r
4P connectors(seestep 6 on page23-22). B (18PI
SRSUNITCONNECTOR
GRN/ORN
20. DisconnectSRSunit connectorB (18P)from the
Checkresistancebetweenthe No. 3 terminal of Wire side of femaleterminals

SRS unit connectorB (18P)and body ground.There
OPOSUNIT HARNESS8P CONNECTOR
should be an oDencircuit,or at least 1 MQ .
SRSUNITCONNECTOR
B I18PI
BLU
GRN/ORN Wire side of femaleterminals
ls the resistanceas specitied?
YES Go to step23.
NO Openin thefloorwire harnessor in the OPDS

unitharness;
replace
thefaultyharnessl
Wiresideot temaleterminals
Reconnect
the bafterynegative
cable.
ls the resistance as specified? 24. Turnthe ignitionswitchON (ll).
YES- Go to step 22.
NO Short to ground in the floor wire harnessor

OPDSunit harness;replacethe faulty harness.l
23-98
25. Checkfor voltagebetweenthe No. 3 terminal of DTC15-2:FaultySideAirbagCutoffIndicator
SRS unit connectorB (18P)and body ground.There Circuit
s h o u l db e 0 . 5V o r l e s s .
1. Make sure nothing is on the front passenger'sseat.
B (18P)
SRSUNITCONNECTOR
2. Erasethe DTCmemory (seepage 23-26]-.
PNK 3 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) , a n d c h e c k t h a t t h e
then goes off.
YES-Turn the ignition switch OFF,and go to step
Wiresideof temaleterminals
ls the voltageas specilied? page 23-26).
YES Go to step 26. NOTE:ThisDTCmay have been causedby turning

t h e i g n i t i o ns w i t c hO N ( l l ) w i t ht h e g a u g ea s s e m b l y
NO Short to power in the floor wire harnessor in disconnected.
the OPDSunit harness;replacethe faulty
harness.l T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d c h e c k t h a t t h e
J 26. Replacethe OPDSunit (seepage 23-'124),
then
side airbagcutoff indicatorcomes on.
initializethe system (seepage 23-27). Does the side airbag cutoft indicator come on?
2 7 . Erasethe DTCmemory,then checkfor DTC15-1. YES Go to step 5.
ls DTC 15-l indicated? NO Go to step 6.
t h e S R Su n i t( s e ep a g e2 3 - 1 2 2 ) . 1
YES Replace Make sure the side airbagcutoff indicatorgoes off
after 5 seconds.
NO The system is OK.l
Does the side airbag cutoff indicator go otf after 5
seconds?
YES FaultyOPDSunit or SRS uniu replacethe

OPDSunit (see page23-1241. lf the problem is still
present,replacethe SRS unit (seepage 23-122).)
NO Go to step 32.
{cont'd)
23-99
sRs
7. Checkthe No. 10 (7.5A)fusein the under-dash 1 1 .Turn the ignltion switch OFF.
fuse/relaybox.
12. Disconnectthe dashboardwire harness17P
ls the f use OK? connectorK from the under-dashfuse/relaybox,
YES Go to step 8.
NO Replacethe fuse, then turn the ignition switch

ON (ll).lf the fuse blows again,checkfor a short in
the No. 10 {7.5A)fuse circuit(ECMwire harness.
floor harness,or OPDSharness).1
8. Disconnectthe OPDSunit harness8P connector(A)

from the OPDSunit (seepage 23-124).
1 4 . Checkfor voltage betweenthe No. 3 terminal of the

OPDSunit harness8P connectorand body ground.
Thereshould be 0.5 V or less.
OPDSUNITHABNESS
8PCONNECTOR
1 0 .Checkfor voltage betweenthe No. 3 terminal of the

OPDSunit harness8P connectorand body ground.
Thereshould be batteryvoltage.
OPDSUNtT HARNESS8P CONNECTOR
ls the voltageas specitied?
YES-FaultyOPDSunit;replacethe OPDSunit(see
W i r es i d eo f f e m a l et e r m i n a l s page23-124)
.a
NO-Go to step15.
NO Go to step 23.
23-100
)
t5. Turn the ignitionswitch OFF. 1 9 . Turn the ignition switch OFF.
Removethe gauge assembly(seepage 22-64). 20. Disconnectfloor wire harness6P connectorC509

Then disconnectgaugeassemblyconnectorA from (A)from the dashboardwire harness.
the gauge assembly.
22. Checkfor voltage betweenthe No. 3 terminal of the
1 8 . Checkfor voltagebetweenthe No. 3 terminal of the OPDSunit harness8P connectorand body ground.
OPDSunit harness8P connectorand body ground. Thereshould be 0.5 V or less.
Thereshould be 0.5 V or less.
A
) \t OPDSUNITHARNESS
8PCONNECTOB
OPOSUNITHARNESS
8PCONNECTOR
Wire side o{ femaleterminals

ls the voltage as specified?

YES Short to power in dashboardwire harnessA;
YES Short to power in the gaugeassembly; replacedashboardwire harnessA.l
replacethe gaugeassembly.l
NO-Short to power in the floor wire harnessor in
NO Go to step 19. t h e O P D Su n i t h a r n e s si;f t h e O P D Su n i t h a r n e s si s
OK, replacethe floor wire harness.I
I \,
(cont'd)
23-101
sRs
(cont'dl
DTCTroubleshooting
23. Turn the ignitionswitch OFF. 2 9 . T u r nt h e i g n i t i o ns w i t c hO N ( l l i
24. Removethe gaugeassembly(see page22-64l,. 3 0 . ' 0 2 m o d e l :C h e c k f o r v o l t a g e

b e t w e e nt h e N o . 4
With the connectorsstill connectedto the gauge terminal of dashboardwire harnessA 6P connector
'15
assembly,backprobethe No. terminal of gauge C509and body ground.Thereshould be battery
assemblyconnectorA (22P). vorlage.
'03 model: Checkfor voltagebetweenthe No. 5
Turn the ignition switch ON {ll). terminal of dashboardwire harnessA 8P connector
C509and body ground.Thereshould be battery
26. Checkfor voltage betweenthe No. 15 terminal of vollage.
gauge assemblyconnectorA {22P)and body '02 Model:
ground.Thereshould be batteryvoltage.
OASHBOARD
WIREHARNESS
A 6PCONNECTOF
GAUGEASSEMBLY A {22P)
CONNECTOR
Terminalsideof male terminals
Wiresideof femaleterminals '03 Model:
ls thete battery voltage? WIREHARNESS

DASHBOARD A 8PCONNECTOR
YES-Go to step 27.
NO Go to step 31.
28. Dlsconnectfloor wire harness6P connectorC509

{A) from dashboardwire harness.
YES Poorcontactat the dashboardwire harness

A 6 P o r 8 P c o n n e c t oar n df l o o rw i r e h a r n e s sa, n
o p e ni n t h e f l o o rw i r e h a r n e s so, r a n o p e ni n t h e
O P D Su n i t h a r n e s sC. h e c kt h e c o n n e c t i o ni f; t h e
connectionis OK, replacethe faulty harness.l
NO Poor contactat gaugeassemblyconnectorA

{ 2 2 P )o r a n o p e n i n d a s h b o a r d
w i r e h a r n e s sA .
Checkgauge assemblyconnectorA {22P);if the
connectionsare OK, replacedashboardwire
h a r n e s sA . I \ J
23-102
Checkfor voltagebetweenthe No. 2 terminal of 32. Turn the ignitionswitch OFF.
r ( 2 2 Pa
g a u g ea s s e m b l yc o n n e c t o B ) ndbody
ground.Thereshould be batteryvoltage. 33. Disconnectthe OPDSunit harness8P connector(A)
f r o m t h e O P D Su n i t ( s e ep a g e2 3 -1 2 4 ) .
ASSEMBLY
GAUGE CONNECTOR
B {22P)
YEL
1 2 3 4 5 X 6 8 9 10
1t 12 IJ
,/1,/1,/)1 1 21 22
YES Faultyside airbagcutoff indicatorcircuit; 34. Turn the ignitionswitch ON (ll).

r e p l a c et h e g a u g ea s s e m b l y . l
Does the slde airbag cutotf indicator come on?
NO Open in dashboardwire harnessA; replace
dashboard
w i r e h a r n e s sA . I YES Go to step 35.
NO FaultyOPDSunit; replacethe OPDSunit.l
36. Removethe gaugeassembly(seepage 22-64).

Then disconnectgauge assemblyconnectorA from
t h e g a u g ea s s e m b l y .
\,
(cont'd)
23-103
sRs
DTGTroubleshooting(cont'dl J
37. Checkresistancebetweenthe No. 15 terminal of DTC15-3:FaultyOPDSSensor
gauge assemblyconnectorA (22P)and body
ground.Thereshould be an open circuit,or at least 1. Erasethe DTCmemory {seepage 23-261.
1M0.
GAUGEASSEMBLY A I22PI
CONNECTOR SRS indicatorcomes on for about 6 secondsand
then goes off.
YES-Go to step 3.

page 23-26).
NOTE:Aftermarketdevices(fluorescentlights,
laptop computers,etc.)used near the front
passenger'sseat-backcan interferewith the seat-
ls the resistance as specified? backsensorsand causea false DTC15-3.lf one of
these deviceswas used,erasethe DTC,operatethe
YES-Short to ground in the side airbagcutoff devicenearthe seat-back,and recheckfor DTCs.lf
indicatorcircuit;replacethe gaugeassembly.l DTC15-3is reset,eraseit, and do not usethe
devicenearthe seat-back.
NO Short to ground in the dashboardwire
harnessA, floor wire harness,or OPDSunit 3 . Checkthe connectionat the OPDSsensorharness
harness;replacethe faulty harness.l connectorand the OPDSunit connector. {
Are the connectionsOK?
YES-Go to step 4.
NO Reconnectthe OPDSsensorharness
connector,and clearthe DTC.I
foam (seepage
4 . Replacethe OPDSsensor/seat-back
20-141,and initializethe OPDS(seepage 23-27).
Erasethe DTCmemory,then checkfor DTC15-3.
YES Replacethe OPDSunit (seepage 23-1241.a
NO The system is OK.l
23-104
I SRSIndicatorCircuitTroubleshooting
TheSRSIndicatorDoesn'tComeOn 4. Checkfor voltage betweenthe No. l4terminal of
1. Turn the ignition switch ON (ll),and see if the other ground within the first 6 secondsafter turning the
indicatorscome on {brakesystem,etc). ignition switch ON (ll).Thereshould be 8.5 V or less.
Do the other indicatorscome on? GAUGEASSEMBLY

CONNECTOR
A I22PI
YES Go to step 2.
2. Turn the ignition switch OFF,then removethe

gauge assembly{see page22-641. Disconnect
gauge assemblyconnectorA and B from the gauge
assembly.
Wiresideof femaleterminats
Is the voltage as specified?
Y E S - F a u l t yS R Si n d i c a t o cr l r c u i ti n t h e g a u g e
assembly;replacethe gauge assembly.I
I \9
d N O - G o t o s t e p5 .
Checkresistancebetweenthe No. 12 terminal of

gauge assemblyconnectorB (22P)and body
g r o u n d .T h e r es h o u l db e 0 1 . 0 Q .
GAUGE
ASSEMBLY
CONNECTOR
B I22PI
1 2 3 4 5 X 6 8 9 10
11 12 l 3
BLK
/)x 1 1 1B 21 22
o.
Is the resistance as specified?
YES Go to step 4.
N O O p e ni n t h e B L Kw i r e o f d a s h b o a r d wire
l{, h a r n e s sA o r f a u l t yb o d y g r o u n dt e r m i n a l( G 5 0 1 )l.f
t h e b o d y g r o u n dt e r m i n a li s O K ,r e p l a c ed a s h b o a r d
w i r e h a r n e s sA . I
(cont'd)

23-105
sRs
SRSIndicatorCircuitTroubleshooting(cont'dl J
6 . DisconnectSRSunit connectorC (8P)from the SRS 9. Connecta voltmeterbetweenthe No.2 terminal of
unit {see step 7 on page 23-22). gauge assemblyconnectorB (22P)and body
g r o u n d .T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d
7 . DisconnectgaugeassemblyconnectorA (22P). measurethe voltage.There should be battery
Connecta voltmeter betweenthe No, l4terminal of voltaqe.
g r o u n d .T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d GAUGEASSEMBLY B (22P}
CONNECTOR
measurevoltage.There should be 0.5 V or less.
YEL
GAUGEASSEMBLY A {22P)
CONNECTOR
1 2 3 4 5 X 6 8 9 10
ll 12 ,/ ,/ ,/x 11 o 21 22
ls therc battery voltage?

YES FaultySRSindicatorcircuitin the gauge
ls the voltageas specitied? assemblyor poor contactat gaugeassembly
connectorB (22P)and the gaugeassembly;if the
YES-Faulty SRSunit; replacethe SRSunit (see connectionis OK, replacethe gaugeassembly.l
page23-'l22l.a
NO Open in the under-dashfuse/relaybox No. 10
NO-Short to power in the PNKwire of dashboard (7.5A)fuse circuit,or open in the YELwire of
wire harnessA or in the floor wire harness;replace dashboardwire harnessA. lf the under-dashfuse/
t h e f a u l t yh a r n e s s . l relay box is OK, replacelhe faulty harness.l
L Turn the ignition switch OFF.Checkthe No. 10 1 0 . Replacethe No. 10 (7.5A)fuse,then checkto see if
{7.5A)fusein the under-dashfuse/relaybox. the indicatorscomes on.
ls the tuse blown? Do the indicators come on?
YES-Go to step 10. YES The system is OK at thls time.l
NO Go to step 9. N O R e p a i tr h e s h o r tt o g r o u n di n t h e u n d e r - d a s h
f u s e / r e l a yb o x N o . 1 0 ( 7 . 5 A ) f u s ce i r c u i t . l
23-106
I J
TheSRSlndicatorStaysOn Whenln "SCS" t h e N o . 1 3 ( 1 0 A )f u s e .
6. Replace
MenuMethod
NOTE: batterynegativecable,and wait for 3 minutes.
. lf you cannot retrieveDTCSwiththe PGM Tester
usingthe SRSmenu method.retrievethe flash codes 8. Disconnectthe driver'sairbag 4P connector(see
with the Testerin SCS mode {seepage 23-24|,. step 2 on page 23-21).
. A new SRS unit must sensethe entire system is OK
beforecompletingits initialself-test.The most 9. Disconnectthe front passenger'sairbag4P
common causeof an incompleteself-testis the connector(seestep 3 on page 23,21).
failureto replaceall deployedpartsafter a collision,
in particular,seat belt tensionersand seat belt buckle 10. Disconnectboth seatbelt tensioner2P connectors
tenstoners. (seestep 5 on page 23-221.
. An incompleteself-testpreventsthe PGM Testerfrom
retrievingDTCS,althoughflash codesare availablein '11.
D i s c o n n e c t S RuSn i t c o n n e c t o r A { 1 8 P ) f r o m t h e
the Tester'sSCSmode. SRS unit (see step 7 on page 23-22],.
1. Erasethe DTCmemory usingthe MES connector '12.

(seepage 23-26).
1 3 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d w a i t f o r 3 0
Does the SRS indicatorgo off while you are seconds.Then turn the ignition switch OFF.
erasing the DTC memory?
1 4 . C h e c k t h eN o . 1 3 ( ' 1 0 Af)u s e .
YES-Go to step 42.
I NO Go to step 2.
ls the f use OK?
Y E S - S h o r t t o g r o u n di n t h e S R Su n i t ;r e p l a c et h e
Checkthe No. '13{ 10A)fuse in the under-dash SRS unit (seepage 23-122).a
fuse/relaybox.
l s t h e f u s eO K ?
t h e N o . 1 3 ( 1 0 A )f u s e .
15. Replace
YES--Goto step 19.
NO Go to step 3.
3 . R e p l a c e t h eN o . 1 3 ( 1 0 A )f u s e .
T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d w a i t f o r 3 0
seconds.Then turn the ignitionswitch OFF.
C h e c kr h e N o . 1 3 ( 1 0 A )f u s e .
ls the f use OK?
Y E S T h e s y s t e mi s O K a t t h i st i m e . I
NO Go to step 6.
I
{cont'd)

23-107
sRs
SRSIndicatorCircuitTroubleshooting(cont'd)
'16. 24. Beconnectthe batterynegativecable.
Disconnectdashboardwire harnessB connectorS
from the under-dashfuse/relavbor.
Connecta voltmeterbetweenthe No. 3 terminal of
SRS unit connectorA (18P)and body ground.Turn
the ignition switch ON (ll),and measurethe voltage.
Thereshould be bafteryvoltage.
A (18PI
SRSUNITCONNECTOR
PNK
1 1 . Turn the ignition switch ON {ll),and wait for 30

seconds.Then turn the ignition switch OFF, Wiresideof femaleterminals
1 8 . C h e c kt h e N o . 1 3 ( 1 0 A )f u s e .
ls the f use OK?
YES Go to step 29.
YES Short to ground in dashboardwire harness
B; replacedashboardwire harnessB.I NO Go to step 26.
NO-Short to ground in the under-dashfuse/relay 26. Turn the ignition switch OFF.
box; replacethe under-dashfuse/relaybox.l
2 7 . Disconnectdashboardwire harnessB connectorS
1 9 . Turn the ignition switch OFF.Disconnectthe from the under-dashfuse/relavbox.
20. Disconnectthe driver'sairbag 4P connector(see

step 2 on page 23-2'l).
2 1 . Disconnectthe front passenger'sairbag 4P

connector(seestep 3 on page 23-21).
22. Disconnectboth seat belttensioner2P connectors

(see step 5 on page 23-22).
DisconnectSRS unit connectorA (18P)from the

23-108
I
28. Checkresistancebetweenthe No. 3 terminal of 3 1 . C o n n e ctth e N o . 3 t e r m i n a lo f S R S u n i t c o n n e c t o r A
SRSunit connectorA (18P)and the No. 2 terminal (18P)and the No. 5 terminal of SRSunit connector
of dashboardwire harnessB connectorS. There C ( 8 P ) w i t ha j u m p e rw i r e .
s h o u l db e 0 1 . 0 0 .
SRS UNIT CONNECTORC I8P}

DASHBOARD
WIREHARNESS
B CONNECTOR
S
l 2
Wire side of PNK PNK

femaletermr n al s Wire side of femaleterminals
JUMPER
a,SRSuNrr CONNECTOR WIRE
PNKT A I18P) PNK SRSUNITCONNECTOR A I18P)
l 2 3 5 7 8 I
1 0 11 12 l 3 1 4 1 5 16 1 1 l 8

32. Turn the ignition switch ON (llf.

33. Checkthe SRS indicator.
YES-Open in the under-dashfuse/relaybox or
poor contactat dashboardwire harnessB Did the SRS indicator go off?
connectors;checkthe connection.lf the connection
is OK, replacethe under-dashfuse/relaybox.l YES FaultySRS unit; replacethe SRS unit (see
I NO-Open in dashboardwire harnessB; replace

dashboardwire harnessB.I
page 23-122l.a
NO-Go to step 34.
29. Turn the ignitionswitch OFF. 34. Turn the ignition switch OFF.
30. DisconnectSRSunit connectorC {8P)from the SRS 35. Disconnectthe jumper wire betweenthe No. 3
unit (see step 7 on page 23-22],. terminal of SRSunit connectorA (18P)and the
No. 5 terminal of SRSunit connectorC (8P).
3 6 . C h e c kt h e N o . 1 3 ( 1 0 A ) f u s ei n t h e u n d e r , d a s h
fuse/relaybox.
ls the f use OK?
YES Go to step 40.
NO Go to step 37.
37. Replace
t h e N o . 1 3{ 1 0 A ) f u s e .
I (cont'd)
23-109
sRs
SRSlndicatorGircuitTroubleshooting(cont'dl
38. Removethe gauge assembly(seepage 22-64),then 40. Removethe gauge assembly(seepage 22-64),then
disconnectgauge assemblyconnectorA from the disconnectgauge assemblyconnectorA from the
g a u g ea s s e m D l y , g a u g ea s s e m b l y .
3 9 . Checkresistancebetweenthe No. 5 terminal of 4 1 . Checkresistancebetweenthe No. 14 terminal of

SRS unit connectorC (8P)and body ground.There r ( 2 2 Pa
g a u g ea s s e m b l yc o n n e c t oA ) n dt h e N o . 5
should be an ooen circuit,or at least 1 fMQ , terminal of SRS unit connectorC (8P).Thereshould
'l
be 0 or less,
C {8PI
SRSUNITCONNECTOR
SRS UNIT CONNECTORC (8P}
GAUGEASSEMBLYCONNECTOR
A I22P)
ls the resbtance as specitied?

YES-Faulty SRS indicatorcircuit in the gauge
a s s e m b l yr;e p l a c et h e g a u g ea s s e m b l y . I YES FaultySRS indicatorcircuitin the gauge
assemblyor poor contactat gauge assembly
N O S h o r tt o g r o u n di n t h e f l o o rw i r e h a r n e s so r i n connectorA (22P);checkthe connection.lf the
dashboardwire harnessA; replacethe faulty connectionis OK, replacethe gauge assembly,I
harness.l
N O O p e ni n t h e f l o o rw i r e h a r n e s so r i n
dashboardwire harnessA; replacethe faulty
harness.!
23-110
42. Turn the ignition switch OFF. 47. Checkresistance betweenthe No.6 terminalof
SRSunitconnector C (8P)andbodyground.There
43. lf necessary,removethe SCSserviceconnector shoulbd e0 - 1 . 0 Q .
from the l\4ESconnector.
SRS UNIT CONNECTORC I8P)
4 4 . T u r nt h e i g n i t i o ns w i t c hO N { l l } .
Does the SBS indicator come on for about 6

seconds and then go off? I 2
5 0
YES-The system is OK at this time. t BRN
n
NO Go to step 45.
r ( 8 P )f r o m t h e S R S
4 5 . D i s c o n n e cSt R Su n i tc o n n e c t oC
unit (see step 7 on page 23-221. Wiresideof femaleterminals
46. Connectthe HondaPGM Tester{A) to the Data Link

Connector(B),and follow the Tester'sprompts in ls the resistance as specified?
the "SCS" menu (seethe Tester'soperating
m a n ual ) . YES FaultySRSunit or poor contactat SRS unit
connectorC (8P);checkthe connection.lf the
connectionis OK, replacethe SRS unit (seepage
23-1221..
t .r9 NO Open in the SCS line betweenthe No.6

terminal of SRS unit connectorC (8P)and the No. 9
terminal (BRNwire) ofthe data link connector
(DLC),or open betweenthe No. 4 terminal of the
D L Ca n d b o d y g r o u n d .R e p a i rt h e o p e nw i r e ( s ) . 1
,lI
IL,
23-111
sRs
After Deployment
ComponentReplacement/lnspection
NOTE:Beforedoing any SRS repairs.use the PGM
TesterSRSmenu method to checkfor DTCS;referto the
DTCTroubleshootingIndexfor the lessobvious
deployedparts (seatbeit tensioners,front sensors,side
airbagsensors,etc.)
After a collisionwhere the seat belt tensioners

deployed,replacethese items:
' Seat belt tensioners
. Seat belt buckletensioners
. S R Su n i t
. Front impactsensors
After a collisionwhere the front airbag(s)deployed.

replacethese items:
. S R Su n i t
. Deployedairbag(s)
. Seatbelt tensioners
. Seat belt buckletensioners
. Front impactsensors
After a collisionwhere the side airbag{s)deployed,

replacethese items:
. S R Su n i t
. D e p l o y e ds i d ea i r b a g ( s )
. Side impact senso(s)for the side(s)that deployed
Duringthe repair process,inspectthese areas:

. lnspectallthe SRSwire harnesses.Replace,don't
repair,any damagedharnesses.
. I n s p e c t t h e c a b l ree e l f o rh e a t d a m a g el.f t h e r ei s a n y
damage,replacethe cable reel.
Afterthe vehicleis completelyrepaired,turn the

ignitionswitch ON (ll).lf the SRSindicatorcomes on for
about 6 secondsand then goes off, the SRSairbag
system is OK. lf the indicatordoes not function properly,
use the PGM TesterSRS Menu Methodto readthe DTC
(seepage23-23).lf this doesn't retrieveany codes,use
the Tester'sSCSmenu method (seepage23-24).lf you
still cannot retrievea code,go to SRS IndicatorCircuit
Troubleshooting.
\|J
23-112
Driver's Airbag Replacement
Removal Installation
1. Disconnectthebatterynegativecable,and wait at 1. Connectlhe horn switch connector(1P)to the
least3 minutes beforebeginningwork. driver'sairbag.
2. Removethe accesspanel (A)from the steering 2. Placethe new driver'sairbag (A) inthesteering
wheel, then disconnectthe driver's airbag 4p wheel, and secureit with new Torx bohs (B),and
connector(B)from the cable reel. installthe maintenancecover (C).
a
9.8 N.m {1.0kgf.m,7.2 lbt.ft)
Removethe maintenancecover (A),then remove

A the two Torx bolts (B) using a Torx T3Obit. Connectthe cable reelto the driver's airbag4P
\'l9 connector(A),then installthe accesspanel (B)on
the steeringwheel.
Disconnectthe horn switch connector(1P)(D).

4. Connectthe batterynegativecable.
5 . Removethe driver'sairbag (C).
5 . After installingthe airbag,confirm proper system
operation:
. T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ;t h e S R Si n d i c a t o r
should come on for about 6 secondsand then go
off.
. Make sure the horn works.
lfc
23-113
sRs
AirbagReplacement
FrontPassenger's
1. Disconnectthebatterynegativecable,and wait at 1. Placethe new front passenger'sairbag(A) into the
least3 minutes before beginningwork, dashboard.Tightenthe front passenger'sairbag
m o u n t i n gn u t s( B ) .
2. Removethe glove box stops,and lower the glove
box.
thefrontpassenger's
3. Disconnect airbag4P
(A)from dashboard
connector wire harnessB.
9.8N m {1.0kgf.m,7.2lbfft}
Connectthe front passenger'sairbag4P connector

( A ) t o d a s h b o a r dw i r e h a r n e s sB .
4 . Removethe three mounting nuts (A) from the L

bracket.Coverthe lid and dashboardwith a cloth,
and pry carefullywith a screwdriverto lift the front
p a s s e n g e r 'asi r b a g( B )o u t o f t h e d a s h b o a r d .
N O T E : T h ea i r b a gl i d h a sp a w l so n i t s s i d ew h i c h
aftachit to the dashboard.
Raisethe glove box, and reinstallthe stops.
After installingthe airbag,confirm proper system

o p e r a t i o nT; u r nt h e i g n i t i o ns w i t c hO N ( l l ) ;t h e S R S
indicatorshould come on for about 6 secondsand
then go off.
trr
23-114
) SideAirbag Replacement
NOTE:Reviewthe seatreplacementpro6edure in the Installation
Bodysectionbeforepertormingrepairsor service.
NOTE:
Removal . l f t h e s i d ea i r b a gl i d i s s e c u r e db y a t a p e , r e m o v e l h e
rape.
1. Disconnectthebatterynegative
cable,andwait at . Do not open the lid of the side airbagcover.
least3 minutesbeforebeginningwork. . Use new mounting nuts tightenedto the specified
torque.
2. Disconnect
thesideairbagharness2P . Make sure that the seat-backcover is installed
connector
{A). properly,lmproper installationmay preventproper
deployment.
. Be sure to installthe harnesswires so that they are
not pinchedor interferingwith other parts.
1. Placethe new side airbagon the seat-backframe

(A).Tightenthe side airbag mounting nuts (B).
3 . Removethe seatassembly(seepage20-71)and
) seat-backcover (seepage 20-75).
Removethe mounting nut (A) and the side

a i r b a g( B ) .
2. Installtheseat-backcover {seepage 20-75).
3. Installtheseat assembly(seepage 20-71),then

connectthe side airbagharness2P connector.
4. Move the front seat and the seat-backthrough their

full rangesof movement,making sure the harness
wires are not pinchedor interferingwith other parts.
5. Reconnectthe batterynegativecable.
6. After installingthe side airbag,confirm proper

system operation;Turnthe ignition switch ON (ll);
t h e S R Si n d i c a t o sr h o u l dc o m e o n f o r a b o u t6
secondsand then go off.
l,o
23-115
sRs
Airbag Disposal
Special Tool Required Driver's Airbag:
Deploymenttool 07HAz-SG00500
4. Removethe accesspanelf rom the steeringwheel,
Beforescrappingany airbags,side airbags,seat belt then disconnectthe driver'sairbag4P connector
tensioners,or seat belt buckletensioners(including from the cable reel (seestep 2 on page 23-21).
those in a whole vehicleto be scrapped),the airbags,
side airbags,seat belt tensioners,or seat belt buckle Front Passenger'sAirbag:
tensionersmust be deployed.lf the vehicleis still within
the warranty period,the HondaDistrictService 5. Lowerthe glove box,then disconnectthefront
Managermust give approvaland/orspecialinstruction passenger'sairbag 4P connectorfrom dashboard
beforedeployingthe airbags,side airbags,seat belt wire harnessB (seestep 3 on page 23-211.
tensioners,or seatbelt buckletensioners.Only afterthe
airbags,side airbags,seat belt tensioners,or seat belt Side Airbag:
buckletensionershave been deployed(asthe resultof
vehiclecollision,for example),can they be scrapped. 6. Disconnectthe side airbag2P connectorsfrom the
floor wire harness(seestep 4 on page23-211.
lf the airbags,side airbags,seat belt tensioners,and
seat belt buckletensionersappearintact(not deployed), Seat belt tensioner:
treat them with extremecaution.Follow this Drocedure.
7. Disconnectthe seat belt tensioner2P connectors
DeployingAirbagsin the Vehicle from the floor wire harness{seestep 5 on page 23-
22).Pullthe seat belt out all the way, and cut it off.
lf an SRSequippedvehicleis to be entirelyscrapped,its
airbags,side airbags.seat belt tensioners.and seat belt Seat belt buckle tensioner:
buckletensionersshould be deolovedwhile still in the
vehicle.The airbags,side airbags,seat belttensioners, 8, Disconnectthe seat belt buckletensioner4P
and seat belt buckletensionersshould not be connectorsfrom the floor wire harness(seestep 6
consideredas salvageablepartsand should never be on page 23-221.
installedin anothervehicle.
1. Turn the ignition switch OFF,then disconnectthe

batterynegativecable,and wait at least3 minutes.
2. Confirmthat each airbag,side airbag,or seat belt

tensioneris securelymounted.
3. Confirm that the speciaI tool isfunctioning properly

by following the checkprocedureon the tool label.
$ J
23-116
)
9. Cut off each connector,strip the ends of the wires, 10. Connecta 12 volt batteryto the tool.
and connectthe deploymenttool alligatorclips (A)
to the wires. Placethe deploymenttool at least30 . lf the green light on the tool comes on, the igniter
feet (10 meters)away from the vehicle. circuit is defectiveand cannot deDlovthe
component.Go to Disposalof Damaged
NOTE:The driver'sairbagand the front passenger's ComDonents.
airbageach have four wires,two yellow and two . lf the red light on the tool comes on, the
red. Twist each Dairof unlikecoloredwires componentis readyto be deployed.
together,and connectan alligatorclip to each pair.
1 1 . P u s ht h e t o o l ' sd e p l o y m e nst w i t c h T . h e a i r b a g sa n d
tensionersshould deploy (deploymentis both
h i g h l ya u d i b l ea n d v i s i b l e a
: l o u d n o i s ea n d r a p i d
inflationof the bag,followed by slow deflation).
. lf the componentsdeploy and the green light on

the tool comes on, continuewith this procedure.
. lf a componentdoesn'tdeploy,yet the green
light comes on, its igniter is defective.Go to
Disposalof Damagedcomponents.
. During deployment,the airbagscan becomehot
enoughto burn you. Wait 30 minutesafter
deploymentbeforetouchingthe airbags.
12. Disposeofthe completeairbag.No pan of it can be

reused.Placeit in a sturdy plasticbag (A),and seal
I rt securery.
/ :
i'..-':
!
(cont'd)

23-117
sRs
Airbag Disposal(cont'dl J
DeployingComponentsOut of the Vehicle DeploymentTool Check
lf an intactairbagor tensionerhas been removedfrom 1. Connectthe yellowclipsto bothswitchprotector
a scrappedvehicle,or has beenfound defectiveor handleson thetool;connectthetoolto a battery.
damagedduring transit,storage,or service,it should be
deolovedas follows: 2. Pushthe operationswitch:greenmeansthetool is
OK;redmeansthetool is faulty
batteryandthe yellowclips.
3. Disconnectthe
1. Confirmthat the specialtool isfunctioning properly

by following the checkprocedureon this page or
o n t h et o o ll a b e l .
2. Positionthe airbagface up, outdoors,on flat

ground,at least30 feet (10 meters)from any
obstaclesor DeoDle.
3. Follow steps9 through 11 of the in-vehicle

deploymentprocedure. J
Disposalof DamagedComponents
1. lf installedin a vehicle,follow the removal
procedurefor the driver'sairbag (seepage23-113),
front passenger'sairbag (seepage 23-114),side
a i r b a g( s e ep a g e2 3 - 1 1 5 )s.e a tb e l tt e n s i o n e (r s e e
page23-4),and seat belt buckletensioner.
2. In all cases.make a short circuit by cutting,

stripping,and twisting togetherthe two inflator
wires.
NOTE;The driver'sand passenger'sairbageach

have four wires:twist each pair of like-colored
wires together
Packagethe componentin the same packagingthat

the new reolacementDartcame in.
Mark the outsideof the box "DAMAGEDAIRBAG

NOT DEPLOYED'"''DAMAGEDSIDEAIRBAGNOT
DEPLOYED", "DAMAGED
SEATBELTTENSIONER
NOT DEPLOYED"or "DAlvlAGEDSEATBELT
BUCKLETENSIONERNOT DEPLOYED"so it does
not get confusedwith your parts stock.
Contactyour HondaDistrictServiceManagerfor
how and where to return it for disposal.
I|J
23-118
) CableReelReplacement
Removal 6. Removethe dashboardlower cover (Ai.
1 . M a k es u r et h e f r o n tw h e e l sa r e a l i g n e ds t r a i g h t
ahead.
Disconnectthe batterynegativecable,and wait at

least3 minutes.
3 . Removethe driver'sairbag{seepage 23-113).
4 . Disconnectthe connector(Al from the cruise

control sevresumeswitch,then removethe
s t e e r i n gw h e e lb o l t( B ) .
7 . Removethe column cover screws(A),then remove

t h e c o l u m nc o v e r s( 8 , C ) .
5 . Align the front wheels straightahead,then remove

the steeringwheel with a steeringwheel puller (see
'17-6).
step 3 on page
Do not tap on the steeringwheel or steering
c o l u m ns h a f t w h e nr e m o v i n gt h e s t e e r i n gw h e e l .
I,
(cont'd)

23-119
sRs
CableReelReplacement(cont'd) J
Disconnectthe dashboardwire harness4P Installation
connector(A)from the cable reel,then disconnect
the dashboardwire harness5P connector{B}from 1. Beforeinstallingthe steeringwheel. align the front
the cable reel. wheels straightahead.
2. lf not alreadydone, disconnectthe batterynegative

cable,and wait at least3 minutes.
3. Setthe cancelsleeve(A) so the projections(B)are

a l i g n e dv e r t i c a l l y .
9 . R e l e a s teh e t a b ( B ) ,t h e n p u l l o f f t h e c a b l er e e l( A ) .
4 . Carefullyinstallthe cable reel (A) on the steering

column shaft.Then connectlhe 5P connector{B)
I
and the 4P connector(C).
23-120
)
Installthe steeringcolumn covers. 8 . l n s t a l l t h ed r i v e r ' sa i r b a g( s e ep a g e2 3 - 1 1 3 ) .
lf necessary,centerthe cable reel.{New 9. Reconnectthe batterynegativecable.

replacementcable reelscome centered.)Do this by
first rotatingthe cable reel clockwiseuntil it stops, 10. After installingthe cable reel,confirm proper
Then rotateit counterclockwiselabout 2 112lurns) syslem operalton:
untilthe arrow mark on the cable reel label Doints
straightup. . Turn the ignition switch ON (ll);the SRS indicator
should come on for about 6 secondsand then go
off.
. After the SRS indicatorhasturned off, turn the
steeringwheel fully left and right to confirm the
SRSindicatordoes not come on.
. M a k es u r et h e h o r nw o r k s .
. Make sure the cruisecontrolworks,
-
A gn the projectionson the cable reel with the
noleson the steeringwheel, and installthe steering
Ai\eelwith a new steeringwheel bolt (A).
) c
23-121
sRs
SRSUnit Replacement
Removal lnstallation
'1.
Disconnectthe batterynegativecable,and wait at 1 , I n s t a l l t h en e w S R Su n i t ( A ) w i t hT o r x b o l t s( B ) ,t h e n
least3 minutesbefore beginningwork. connectthe connectors{C)to the SRSuniu push
them into positionuntil they clicks.
2. Disconnectthe driver'sand front passenger's
airbagconnectors(seepage 23-21). NOTE:When tighteningthe Torx boltsto the
specifiedtorque, be carefulto turn them in so that
3. Disconnecttheside airbagconnectors(seepage their headsrest squarelyon the brackets.
23-211.
9.8 N.m (1.0kgf m, 7.2 lbf ft)
4 . Disconnectboth seat belt tensionerconnectors(see
page 23-22)and both seat belt buckletensioner
connectors {see page 23-221.
Removethe dashboardcenterlower cover (see

Pull down the consolecarpeton the passenger's

side,then removethe Torx bolt (A)from the SRS
unit.
Reinstallthe dashboardcenterlower cover (see

Reconnectthe driver'sand front passenger'sairbag

connectors (see page 23-21]'.
4. Reconnectthe side airbagconnectors(seepage23-

211.
Reconnectboth seat belt tensionerconnectors(see

page 23-221and both seat belt buckle tensioner
connectors (see page 23-22).
7. Pull down the consolecarpeton the driver'sside,
then disconnectthe connectors.Removethe Torx 6 . Reconnectthe batterynegativecable.
bolts (A),then pull out the SRSunit.
7 . I n i t i a l i zteh e O P D Su n i t ( s e ep a g e2 3 ' 2 7 ) .
8 . After installingthe SRS unit,confirm propersystem

operation:Turn the ignition switch ON (ll);the SRS
i n d i c a t o sr h o u l dc o m eo n f o r a b o u t6 s e c o n d sa n d
then go off.
23-122
)
Side lmpact SensorReplacement
Removal lnstallation
1. Disconnectthe batterynegativecable,and wait at 1 . I n s t a ltlh e n e w s i d ei m p a c ts e n s o rw i t h a n e w T o r x
least3 minutesbefore beginningwork. bolt (A),then connectthe floor wire harness2P
connector{B)to the side impact sensor{C).
2. Disconnectthe appropriateside airbag2P
connector(seestep 4 on page 23-21).
3. Removethe seat assembly(seepage 20-71J.
4 . R e m o v et h e f r o n t d o o r s i l l t r i m a n d t h e B - p i l l a r
lower trim panel (seepage 20-50).
5. Disconnectthe floor wire harness2P connector

from the side impact sensor.
6. Removethe Torx bolt (A) using a Torx T30 bit, then

removethe side impact sensor(B).
2. Reconnectthe negativebatterycable.
3 . After installingthe side impact sensor,confirm

proper system operation:Turnthe ignition switch
O N ( l l ) ;t h e S R Si n d i c a t o sr h o u l dc o m e o n f o r a b o u t
) 6 secondsand then go off.
Installall removed parts.

23-123
sRs
OPDSUnit Replacement
NOTE:Reviewthe seat replacementproceduresin the Installation
body sectionbeforeperformingrepairsor service.
1. Placethe new OPDSunit (A) on the seat-backframe.
Removal Tightenthe two screws(B),and connectthe OPDS
unit harness8P and sensorconnectors(C)to the
1. Disconnectthe batterynegativecable.and wait at OPDSunit. Reinstallthecover (D).
least3 minutesbefore beginningwork.
2. Disconnectthe passenger'sside airbag harness2P

connector(seestep 4 on page23-2'll.
3. Removethe front passenger'sseat assembly(see

page20-71)andseat-backcover (seepage2O-15],.
4. Removethe cover (A),then disconnectthe OPDS

unit harness8P and sensorconnectors(B)from the
OPDSunit.
2 . Installtheseat-backcover (seepage 20-75).
Installthe seat assembly(seepage20-71),then

connectthe side airbag harness2P connector,
4. Reconnectthe batterynegativecable.
Set the seat-backin the normal position,and make

sure there is nothing on the front passenger'sseat.
Initializethe OPDSunit (seepage 23-27).

5. Removethe two screws(C)and the OPDSunit (D).
1 . After installingthe OPDSunit, confirm proper
system operation:Turn the ignitionswitch ON (ll);
the SRSindicatorshould come on for about 6
secondsand then go off.
23-124
)
Front lmpact SensorReplacement
1 . Disconnectthe batterynegativecable.and wait at 1. Installthe new front impact sensorwith new Torx
least3 minutesbefore beginningwork. bolts (A),then connectthe engine compartmentwire
harness2P connector(B)to the front impactsensor
2 . Disconnectthe driver'sairbag4P connectorlsee {c).
step 2 on page23-21),the front passenger'sairbag
4P connector(seestep 3 on page 23-21),both seat A
9.8N.m
belttensioner2P connectors(seestep 5 on page (1.0kgf.m,7.2lbf.ftl
23-221,and both seat belt buckle4P connectors(see
step 6 on page23-22).
Removethe front inner fender (seepage 2O-1O21.
Disconnectthe engine compartmentwire harness

2P connector(A),and removethe two Torx bolts (B)
using a Torx T30 bit, then removethe front impact
sensor{C).
After installingthe front impact sensor,confirm

proper system operation:Turn the ignition switch
) ON (ll);the SRS indicatorshould come on for about
6 secondsand then go off.

23-125
ServiceManuallndex
) s
NOTE:Refertothe lollowing listto look up A/C PressureSwitch Circuit
DTCS, symptoms, fuses,connectors, wire Troubleshooting
.........
...-.-....-...-.-.-....-..21-32
B
harnesses,specifications,
maintenance
schedules,andgeneralservice A/C SignalCircuit
inlormation: Troubleshooting.........................-......
11-'133 Back-upLightSwitch
Test.........................................................
13'3
DTCTroubleshootingIndexes A/F lAir FuelRatiol Sensor
ABS/TCSComponents ........................
19-34 Replacement .......................................
11-113 Back-upLi9ht3
EPSComponents '17-22
................................. CircuitDiagram 22-75
FuelandEmissions 11-i A-Dillar CornerTrim
Heating/Ventilation
................................
21-9 Replacement ...............-.....-..............-....
20,96 BallJoint Boots
s R S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. .3. -. 2
. .8. . . . . . . . . . . . . . . . . . Replacement ...... 1 81 6
ABS IndicatorCircuit
SymptomTroubleshootingIndexes Troubleshooting ... 19-52 BallJoints
ABS/TCSComponents........................ 1935 R e m o v a 1 . . . . . . . . . . . . . - . . ................ . . . 1 8 - 1 0
CruiseControlSystem..........................4 38 ABSModulator-contml Unit
EPSComponents ................................. 17-23 Bemoval/lnstallation ............................
19-57 Betterv
FanControls 10,12 . . . . . . . 2520
Fueland Emissions.............................. 11-10 ABS/TCSComoonents
Heating/Ventilation..............................21 10 Component LocationIndex................. 19-30 Beverage Holder
S R S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. 3. .' .3. 0

. . . . . . .C. .i.r.c. .u.i.t.D i a q r a m . . . . . . . . . . . . . . . . . . . .1. 9. .' .4. 2
.
Blower Motor
Fuse/Relaylndexes AccessoryPoworSocket Front Replacement ..... 2 14 1
Power0istribution...............................22-46
TesVReplacement ..............................
22'149
Under-dash Fuse/Relay Box ...............
22 45 Blowor Pow€rTransistor
Under-hood Fuse/Belay Box ...............22
44 Accessory PowerSockets 21-38
CircuitOiagram..................................
22-149
Connectorand Wire Harnesslndexes Blower Unit
Component Connectors Air Cleaner Removal/lnstallation
............................
21-39
(to harness) ......2214 Rep1acemen1.....................................11-162
Air MixControl Motor

Meintenence
section....................
Section3 Replacement .........................................
21'34 BrakeCelipers
Test ......................21-34Overhaul 19-14,23
Gene.allnlormationsection........Section1
Airbag.Driver's Irake Discs
Replacement ....................................... 23 1'l3 Inspection ....................................... 19-13,22
R e p a i.r. . . . . . . . . . - . . . . . . . . . . . . . . . . . . .2. .3. 1. 1 . .6. . . . . . . . . . . . .
A BrakeFluidLevelSwitch
Airbag.Front Passenger's Test 19.10
Beplacement....................................... 23-114
AIC BrakeLights
Component Locationfndex...................21-3 Altemator CircuitDiagram....................................22-7
D e s c r i p t i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B- e. .p. .l 2
a1 ' 1m' l e. n. .t. . . . . . .............. . . . . . . . . . . 4. .2. .9. . . . . .
ce
CircuitDiagram....................................21-14 Overhaul.................................................4-30 BrakeLinesand Hoses
21.57 Inspection............................................. 19-24
AhernatorFRSignalCircuit R e p | a c e m e n t . . . . . . . . . . . . . . . . . . . . . .1. .9. -. .2. 5.
A/C Compressol T r o u b l e s h o o t i n. .g. . . . . . . . . . . - . . . . . . .1. 3 . .41 1
Replacement .......-...-............................. 21-41 BiekeMeder Cylinder
Antenna Rep1acement......................................... 19-15
A/C Compr€ssorClulch Replacement .........22-103 Inspection............................................. 19-16
Inspecton........ 21-44
Overhaul.......... 2l-49 AudioUnit BrakePads
Removal/lnstallation ..........................22-100 Inspection/Rep1acement................ 19-11,20
A/C CompressorClutchCircuit
Troubleshooting ................................... 21-30 AudioUnitConnector BrakePedal
Replacement 22101 Adjustment.............. 19,6
ArfCComoressorReliefValvc
Replacement ..........-...-.......................... 21-51 Audio/Entertainment Breke Pedal Posilion Switch
Component LocationIndex.................22-9A Test..... ..-.............. 22-84
A/C Compr$sor ThermalProtector CircuitDiagram
R e p l a c e m e n t . . . . . . . . . . . . - . . . . . . . . .2. .1. -. 5 . .1. . . . . . . . . . . . . BrakePedalPositionSwitch SignalClrcuit
Troubleshooting 11-137
) s A/C Condenser
Replacement,.,
A/C CondenserFanCircuit
Troubleshooting
...................
. . . . . .....21-28
.....25 12
(cont'd)

ServiceManualIndex
(cont'dl
BrakeSystemIndicatorCircuit CombinationLight Swilch CylinderHeadAssembly
CircuitDiagram TesVReplacement ..............................22 80 Component LocationIndex..................... 6-3
Conventional
BrakeComponents..... 19-9 Inspection................................................. 66
Troubleshooting ConnectingRod Bearings Removal.......... &23
ABS/TCS ......19-55
Components........... R e p | a c e m e n t . . . . . . . . . . . . . . . . . . . . .-.. . . . 7 - 8 I n s t a 1 1 a l .i .o. n. . . . . . . . . . . . . . . . . . . . . . . . . .6. .3. 9. . . . . . . . . . . . . .
Bulb,Geuge ConnectingRod Bolts CylinderHeadCover

R e p | a c e m e n l . . . . . . . . . . . .......... . . . . . . . 2 2 6 3 7-24
fnspection....................-.-.-.-....................
8emova1 ..............-.-.................................
6-22
Installation..............................................6-41
Bulb,Headlight ConnectingRods
Replacement .........................................
22-A1 Inspection........,,.,.,...,.,.,.,.,,,,.,,,.,.,.,.,.,.,.,..
75 CylinderHead,Bare
Inspecton..,.....,.
Bumper,Front Connectors
Removal/1nsra11ation
............................
20 85 (Seefirstpageof thisIndex)
Bumper,Rear ConventionalBrakeComponent3 D
R e m o v a l / l n s t a l l a t i o.n. . . . . . . . . . 2 0 . 8 6 ComponentLocationIndex................... 19'3
Troub1eshootin9 .....................................
19-4
R e p a i.r. . . . . . . . . . . . . . . . . 19-8 Dampers.Front
R e p l a c e m e n t . . . . . . . . .. .. .. .. .. .. .. .. . . . . . . 1
. .8. 2
. .0. .
c Coolant
Inspectio . .n. . . . . . . . . . . . ........ . . .1 0 6 Oampers,Rear
R e p l a c e m e n t . . . . . . . . . . . . ....... . . . .1 06 R e p 1 a c e m e n t . . . . . . . . . . . . . . . . . . . . .1 . .8. .-.3. .4. . . . . . . . . . . . .
CableReel
Replacement....................................... 23-119 CoolantTemperatureGat|ge DashVents
T r o u b 1 e s h o o t i n 9 . . . . . . . . . . . . . . . . .2. .2. 6. .4. . . . . . . Bemoval/lnstallation
...... .-.......................... 20-64
Camshaft
Inspection.......................-...-................... 6-29 CoolingSyslem Dashboard
Component LocationIndex................... 10-2 Bemoval/1nsta11ation ............................ 20-66
CargoArea Light
TesVRep1acement ................................ 22-97 CountershaftBearings OashboardCenterPanel
R e p l a c e m e n t . . . . . . . .. . . . . . . . . . . . . . 1 . .3. .-.4. .2 Removal/1nstaf 1ation............................ 20 62
Carpet
R e p l a c e m e n t . . . . . - . . ..-. . . . .... . . . . - . 2 0 - 5 5
CeilingLight
Cowl Cover
R e p l a c e m e n t . . . . . . . . . . . ........ . . . . . 2 0 - 9 5
DashboardLower Cover
Removal/lnstallation ...................... 20-59,63 3
-estrReplacement ................................ 22.96 Crankshaft DashboardUnderCover
R e m o v a. l. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7. .- .1. 2. . . . . . .Removal/lnstallation
........ ............................ 20 60
ChargingSystem Inspec(on,,,,, ........14
Component LocationIndex................... 4-20 l n s t a l l a t i o n . . . . . . . . . ... . . . . . . . . . . . . . 1 - 2 4 DifferentialCarrierBearings,M/T
C i r c u iDt i a g r a m. . . . . . . . . . . . . . . . . . . . . . . .4. .-.2. .1. . . . . . . . . Rep1acement,,......,...,...,.,.,,,.,.,,,........,.,. 13-54
Troubleshooting . . . . . . . 4 - 2 2 CrankshaltMain Bearings
R e p l a c e m e n t . . . . . . . . - . - . . . . . . . . . . . . .7. .-.6. . . . . . .Ditferential
. . . . . . . . . . . Oil Seals,M/T
ChildSeatTetherAnchor 8 e p 1 a c e m e n t . . . . . . . . . . . . . . . . . . . . . .1. .3.-. 5 . .5. . . . . . . . . . . . .
R e m o v a l / l n sl at at ;fo n. .. . . . . . . . . . . . . . . .2. .3. .1.1. . . CrankshaftOilSeal,TransmissionEnd
1nstanation .............................................. 7 28 DifferentialPinionGears,M/T
CKP(CrankshaftPosition)Sonsor I n s p e c t i o. n, . . . . - , . , , , . , . . , . - , . , . . . . . .1. .3.5, .3, . , , ,
R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . .1.1. .-.1. .1. 6. . . . . . Crankshafl
..... Pulley
Removal/lnstallation -..................-.......... 6-11 OLCCircuit
Clutch Troubleshooting ................................ 11-109
ComponentLocation 1ndex................... 12-3 CruiseControlActuator
R e p 1 a c e m e n 1 . . . . . . . . . . . . . . . . . . . . . .1. .2. -. 9 . . . . . . .Test
.......... ...................... 4-43 Door Glass
RepIacement.......................4 . .-. 4. .4. . . . . . R
. . e. .p. .1. a. .c e m e n t . , . , , , , , , , , , , , . , , , , , , , 2 , ,0, .-,9. , . , . , . , , , , , , . , ,
ClutchInteYlockSwitch Adjustment. .. .....................20-11
T e s t . . . . . - . . . . . . . . - . . . - .......-.-.-. .. -. . . . . . . . 4 - 6 CruiseControlActuatorCable
Adjustment............................................. 4 45 Door GlassWeathelstrips
ClutchMasterCylinder R e p l a c e m e. n . .t. . . . . . . . . . -. .. .. . . . . . . . . - . . . 1
. .0. 2 0
Replacement.......................1 . .2. .5. . . . . . . Cruise
. . . . . . . .Control
. Main Switch
TesVRep1acement .................................. 4 42 Door Latches
clutch Pedal Replacement ..........-.-.............................. 20-7
Adjustment............................................. 12 4 CruiseControlSet/Resume/Cancel Switch
TesVRep1acement .................................. 4 42 Door LockActuators
ClutchPedalPositionSwitch Test...................................................... 22-154
T e s t . , . , , , , , . , , , . , . , , , , , , . , . ,.,.,.,.,.,.,4, ,4. 5, , , , , . . CruiseControlSystom
Component LocalionInde\................... 4-36 Door LockKnob Switches
Clutch Slave Cylindor C i r c u iDt i a g r a m. . . . - . . . . . . . . . . . . . . . . . . .4. .3. 7 . . . . . . . .Test
. . . -......... . . . - . . . . . . . . ......22-160
Beplacemeit... 12-1
CruiseControl Unit Door LockSwitches
CMP{CamshaftPositionlSenso] I n p u t T e s t . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. ., 4 0 T e s t. . . . . . . ........ . . . . . . . . . . . . . ..................2...2. .-. 1 6 0
R e p l a c e m e n t . . . . - . . . - . . . . . . . . . . . .1.1. .- .1. 2 . .8. . . . . . . . . . .
Door Outer Handles
CMP(TDC)Sensors Rep1acemen1 ........................................... 20-6
R e p l a c e m e n t . . . . . . . . . . . . - . . . . . . . .1.1. .1. 1. .4. . . . . . . . . . . .

)
Door Panels EPSConirol Unit Front Speakers

Removal/lnstallation
-.............................
20-4 Removal/1nsta11ation
..................-.........
17-67 Rep|acement.......................................
22-102
Door SashTrim EPSIndicatorCircuit Front Suspension
Rep1acement.........................................
20 10 Troubleshooting 17-47
................................... ComponentLocationIndex...................
18-3
Door Strikers EPSMotor FuelandEmissions
Adiustment...........................................
20-13 Removal/lnstallation
.-..........................
17-49 Description
...........................................
11-12
Door Weatherst ps EVAPCanister FuelFill Door
Beplacement...........-.............................
20 11 R e p 1 a c e m e n t . . . . . . . . . . . .. . . . . . . . 1
. .1. ., .1 8 9 Adjustment..........-................................
20 93
OriveBeh EVAPControlSyst€m FuelFill Door Openet
Inspecaron ................ 4-26 ComponentLocation
Index ..............'11-170 B e p l a c e m e n t . . . . . . . . . . . ... . . . . . . . .2. .0. . 1 0 9
R e p | a c e m e n t . . . . . . . . . ................ . . . . . .4. .2.6. . . .
EVAPTwo-WeyValve FuelFill Door OpenerCable
DriveBelt Auto-tensionel T e s t. . . . . . . . . . - . . . . . . . . . . . . . - . . . . . . . . 1
. .1. .1. 8. .6. . . . . . .Replacement.......................................
...... 20-lO7
lnspection............................................... 4 21
R e p 1 a c e m e n t . . . . . . . . . . . . . . . . . . . .....4. .-.2. .8. . . . . . .Evaporetor .. Core FuelFilter
R e p 1 a c e m e n t . . . . . . . . . . . . ... . . . . . . . 2 . .1. - 4 2 R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . .1. 1. .-.1. .5. 2 .........
Driver'sPocket
Removal/lnstallation -........................... 20-60 EvaporatorTomperatureSensor FuelGaugeSendingUnit
Replacement......................................... 21-37 T e s t. . . . . . . . . . . . . . . . . . . . . . - . - . . . . . . . . 1 . .1- .' 1. .5. .6. . . . . . . . .
Driver'sTray Test..................................... 2137
Removal/lnstallation .........................-.- 20-65 FuelInjectionSyslem (PGM"FIl
EvaporrtoFHeaterUnit Component Location1ndex................. 11-49
DRL{DaytimeRunningLightsl R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . . .2. .1. 4. .3. . . . . . . . . . . . .
Control Unit FuelIniectors
lnputTest .................... ........ . . . ......22-16 ExhaustManifold R e p 1 a c e m e n 1 . . . . . . . . . . . . . . . . . . . .1.1. .1.1. l. . . . . . . . . . .
Removal/1nsta11ation ................................ I 7
DTCs FuelLinesand Hoses
(Seefirstpageolthis Index) ExhaustPipe I n s p e c t i o. n. . . . . . . . . . . . . . . . . . . . . . . . . .1. 1. .' .1. 4 . .6. . . . . . . .
8 e p | a c e m e n t . . . . . . . . . . . . . . . . . . . . . . . . .9. -. .8. . . . . . .R. .e. .m. .o. .v.a.. l. . . . . . . . . . . . . . ... . . . . . . . . . . .1 1 - 1 4 9
) Dust and PollenFiller I n s t a | 1 a t i.o. .n. . . . . . . . . . . . . . . . . . . . . . . 1 . .1. .1. 5. .0. . . . . . . . .
R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . . .2. .1. -. .3.9. . . . . . . . . . . . .
FuelPipeProtectol
DynamicDamper,Driveshafts R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . .2. .0.-. 1 . .0. .4. . . . . . . .
R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . . . .1 . .6. .-.8. . . . . . . . . . . . . . .
FuelPressureRegulatot
FanControls R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . .1. 1. .-.1. .5. 2 .........
C o m p o n e nL to c a t i oInn d e x . . . . . . . . . .1. .0. .' l.1. .
C i r c u iDt i a g r a m. . . . . . .. . .. . . . . . . . . . . . .1. .0. 1. .3. FuelPulsationDamper
R e p l a c e m e n l . . . . . . . . . . . . . . . . . . . . .1. .1. 1 . .5. .4. . . . . . .
FenderFairing,Front
ECTSensor R e p l a c e m e n t . . . - . . . . . . . . . . . . . . . . .2. 0 . .-.1. .0. .3. . . . . Fuel
. . . . . Pump
R e p l a c e m e n t . , . , , , . , . , , , , , , , , , , , ,1,1, .-.11. .4. . . . . . . . . . . . R e p l a c e m e n t , , , , , . , . , . , , , . , , , , , , ,1, ,1, -, 1 , .5, .3, . , , , . . ,
FinalDrivenGear.M/T
El€ctricalPowerSteeringIEPS) R e p l a c e m e n t.... . . . . . . . . . . . . . . . . . . . . 1 . .3. .-.5. .3. . . . . FuelPumpCircuit
SignalCircuit T r o u b l e s h o o t i-n. g . . . . . . - . . . . . . . . . . .1. 1. .-. 1. .4. .1. . . .
T r o u b l e s h o o t i n. .g. . . . . . . . . . .1 1 - 1 3 5 Frame
R e p a iCr h a n . . . . . . . . . ...... . . . . . . . . . . . .2. .0. 1. .1.4. . FuelSupplySystem
Emblems Component Locationlndex .............. 11 140
R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . .2. -0.-.1. .0. .0. . . . . Frame . . . . . Stiffenel A d j u s t m e n t . . . . . . . . . . . . . . . . . . . . 1. .1. .- .1. 4. .4. . . . . . .
R e p l a c e m e n t . . . . . . - . . . . . . . . . . . . . .2. 0 . .-J. .' .1. 3. . . . . . T
. .e. .s. t . . . . . . . . - . . . - . . . . . ....... . . . . . . . . . . .1. 1. -- 1 4 5
EngineAssembly
R e m o v a. 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. .2. . . . . . . .Front
. . . . . .Console
.... FuelTank
Installation ............._.................................. 5-9 Removal/lnstallation ............................ 20 5l B e p l a c e m e n l . . . . . . . .. . . . . . . . .1 11 5 5
DisassembJy/Reassemb|y ................... 20 58
EngineBlockAssembly FuelTankVapor ControlValve
C o m p o n e nL to c a t i oInn d e r. . . . . . . . . . . . . .7. . 3. . . . . Front Doors T e s t. . . . . . . . . . . . . . . . . . . . . . -. . . . . . . . . 1 1 - 1 8 7
Component LocationIndex................... 20-2 R e p l a c e m e n t , , . , , . . . , . , , , . ,. . , ,.,., .1. .1 1 8 9
EngineBlock,Bare A d i u s t m e n. .t . . . . . . . . . . . . . . . . . . . . . . . . .2. .0. . 1. .2. . . . . . . . . .
Inspect|on ................7-15 Fuses
Repair . . . . . . . . . . . . .1. 1
..1 Front DriveshaftAssembly {Seefirstpageofthis Index)
I n s p e c l i o. .n. . . . . . . . . . . . . . . . . . . . . . 1 6 3
Entry Light ControlSystem R e m o v a 1 . . . . . . . . . . . . . . . ....... - .. .. .. .. .. .1 6 - 3
Component LocationIndex...............-. 22-89 D i s a s s e m b l. y. . . . . . . . . . . . . . . . . . . . . . . . . .1. 6. .5.
CircuitDia9ram.................................... 22 90 Resassemb|y ................................-......... 16-9
I n s t a 1 1 a r.i.o. .n. . . . . . . . . . . . . . . .......... . . . l. 6. . .1 7
) EPSComponents
Component Location1ndex..........-...... 17-!7 Front lmpact Sensors
D e s c r i p t i o. n . . . . . . . . . . . . . . ............. . . . . 1 7 - 2 4 R e p 1 a c e m e n t . . . . . . . . . . . . . . . . . . . .2. 3. . 1 . .2. .5.
C i r c u i tD i a g r a m 1 12 6 (cont'd)

ServiceManualIndex
(cont'dl \
HeaterValveCable lmmobilizerSystem
G A d j u s t m e n. .t . . . . . . . . . . . . . . . . . . . . . . . . .?. .1. -. .4.6. Component LocationIndex .............. 22-162
Description
High Mount BrakeLight C i r c u i t D i a g r a.m
..........................22-164
GaugeA3sembly 8 e p | a c e m e n t . . . . . . . . . . . . . . . . . . . . . .2
. .2. .8. 2. . . . . . . .Troubleshooting
...... ............................ 22,165
R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . . .2. .2. 6. .4. . . . . . . . . . . . . .
Hood InnerFender,Fronl
Gaug€s Adjuslment Repfacemenl....................................... 20-102
Component LocationIndex..........-...... 22 54
H o w - t ol n f o r m a t i o n
. . . . . . . . . . . . . . . . . . . . . . . . 2 2 - 5Hood 6 lnsulator InsideRearviewMirror
CircuitDiagram 22-54 Replacement......................................... 20-89 R e p l a c e m e n t . . . . . . . . . . - . . . . . . . . . . .2. .0. 1. .6. . . . . . . . . . . . . .
GenoralInformation Hood Latch InstrumentPanel
(Seeseclion 1) R e p 1 a c e m e n t . . . . . . . . . . . . . . . . . . . . . . .1
20 8 Removal/1nsta11ation.................
.......20-59
GloveBox HoodOpenerCable IntakeAir BypassControlThermalValve
Removal/1nsta11ation
.......................-....
20-63 ComponentLocation Index ..............20 105 T e s r . . . . . . . . . . . . . . . . . . . ........... . .....1. .1. - 1 6 1
R e p l a c e m e. n
. .t. . . . . . . . . . ...... . . . . . . . . . 2 01 0 6
Grille IntakeAir System
Replacement...........-.............................
20-94 Hood Seal ComponentLocationIndex...-.-........ 11-159
Beplacement.-...........................-...........
20-88
IntakeManitold
Horn Removal/1nsta11ation ................................ I 2
H TesVReplacement . . ................
......22-122
lntermediateShaft Assembly
Horn Switch R e m o v a. 1. . . . . . . . . . . . . . . - . - . . . - . . . . . . .1. 6. .-.1. .9. . . . . . . . . . . .
Test ............-........ 22-122 D i s a s s e m b | y . . . . . . . . . . . . . . . . . . . . . - .1. 6. ., 2 0
Adiustment....... R e s a s s e m b. |. y. . . . . . . . . . . . . . . . . . . . . . .1. .6. 2. .2. . . . . . . . . .
Horns Installation .........-...-.............................. 16-24
HatchHandle Component LocationIndex. . . . . . . . . . . . . . 2 2 - 1 2 0
Replacement 20-110 Circ!itDiagram 22 121
Hatch Latch H02S.Secondary K

Replacement
Hatch Latch Switch

20-'110 Replacement
Hubs
. . . 1. 11 1 3
KeylessEntry Transmitter
$
Test R e p l a c e m e n. .t.. . . . . . . . . . . . . . . . . . . . . . 1. .A.2. .6. . . . . . . Repair............... 22-161
T e s t. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.2. .1. .6.1. . . . . . . . . . . . . .
H.tch Lock Actuator
Test 22-159 KeylessEntry/SecurityAlarm System
ComponenlLocationIndex.............. 22 150
HatchLockCylinder C i r c u iDl i a g r a m. . . . . . . . . . . . . . . . . . . . . 2
. .2. .1. 5 1
R e p | a c e m e n t . . . . . . . . . . . . . . . . . . . . .2. .0. ,. 1. .1. .1. . . . . . . . . .
IAT {lntakeAir Temperature}Sensor KeylessReceiverUnit
HatchSpoiler Replacement.,.........-... '11
115 lnputTest ............................................ 22-153
Replacement
ldle ControlSystem KnockSensor
HatchSupport Struts ComponentLocation Index .............. 11-129 R e p l a c e m e n t . . . . . . - . . . . . . . . . . . . . .1.1. .1. .1. 5
............
Beplacement..... 20-91 I n s p e c t i o n , . , . . . . . . . . . - . . . . . . . , . , . ,1,',l,1, 3, .8, , , . , . , . . . . .
Knuckles
HatchWeatherstrio lgnition Coillsl Replacement
Replacement.... 20-92 Bemoval/lnstallation ...............-.............. 4 18 F r o nS
t u s p e n s r o. .n. . . . . . . . . . . . . . . . .1. 8. .-.1. . . . . .
RearSuspension ........ .................-... 18-28
HazardWarningSwitch lgnition Key Light
test .................... 22_88 T e s t , , . , , , , . , . . . , . . . . . . -.......................
. 22-91
H6adlight lgnition Key Switch

Adjustment ..22-78 Test . . . . . . . . . . . . . . .2. 2
. .-. 9. .1. .
ReQ\ace$ent
lgnition Switch License Plate Light
Hcadlights Test .,,,.,.,.,,,,.,.,. ......22-53 R e p l a c e m e n t . . . . . . .-. . . . .- . . . .....22-83
CircuitDiagram..............................
22-71,72
lgnition System LicenseTrim
Headliner Component LocationIndex................... 4-15 R e p l a c e m e n t . . . . . . . . . . . . . . . . . . - . . .2- 0
. .-. 9. .8. . . . . - . . . . . . .
Removal/lnstallalion
............................
20-54 C i r c u i t D i a 9 r a. m
. . . . . . . . . . . . . . . . . . . . . . .4. .' 1
. .6. . . . . . . .
1nspection ............................................... 4-17 Lights,Exterior
HeaterControlPanel ComponentLocalionIndex.................22 68
Removal/1nsta11ation ............................ 21-38 lmmobilizerControl Unit-Receiver
HeaterControl Powerand GroundCircuits

T r o u b f e s h o o t i n g . ................ . . . . . . . . . . . . . . . 2 1 - 2 7
22-161 Lights,Interior
Component LocationIndex.................
C i r c u i t D i a g r.a. m . . . . . . . . . . . . 2 2 - 9 5
22-94
J

)
Low Fuellndicator MoonroofDrainChannelSlider Oil PressureSwitch

Test............. . . . . . . . . 1 1 - 1 5 8 Replacement......................................... 20'44 T e s t. . . . . . . . . . . . . . . . - . - . . . . . . . . - . . . . . . . . .8. -. .4. . . . . . . . . .
R e p l a c e m e n t . . . . . . . . . - . . . . . . . . . . . . .8. .-.1. .6. . . . . . . . . .
LowerArms Moonroof Frame
18 19
Removal/1nsta11ation............................ R e p 1 a c e m e n t , , , , , , , , , , . , . , . , . , . , . 2, .0, ,4,2, , , . . . . .Oil . . .Pump,
. . . . Engine
Overhau1 .................................................. 8-8
LubricationSystem MoonroolGlass
Component LocationIndex..................... 8-3 Adiustment........................................... 20-37 Oil, Engine
Test....................................8 . .4
. . . . . . . .R
. .e
. .p. .1. a
. .c. .e. m . .7. . . . . . . .R. .e. p. .l.a. c e m e n t . . . - . . . . . . . . . . . . . . . . - . - .8. .-.5. . . . . . . . . .
. . e n t . . . . . . . . . . . . . . . . . . . . . 2. .0. 3
Moonroot Limit Switch OPDSUnit

Adjustment........................................-.- 20 46 R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . .2. .3.-1 . .2. .4. . . . . . . . . .
M T e s t. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.2. .1. .1.3. . . . . . . . . . . . . .
OutsideMirror Holders
Moonrool Motor Beplacement......................................... 20-15
M/TAssembly R e p l a c e m e n t . . . . - . . . . . . . . . . . . . . . . .2. .D. .-.4. .1. . . . . . . . . . . .
Removal .......... 13-4 Test . . . . . . . . . . . . . .2. .2. .- .1. 2.. OutsidePower Mirror Actuators
lnstallation....... . . . . .1. 3 - 8 Test...................................................... 22-117
D i s a s s e m b.l.y. . . . . . . . . . . . . . . . . . . . . . . .1. .3.-. 1 . .4. . . . . .Moonrool
... Sunshade Bepfacement..-.................................... 22-114
R e s a s s e m b .l y. . . . . . . . . . . . . . . . . 1 . .3. .- 4 6 R e p 1 a c e m e n t . . . . . . . . . . . ....................2 ....0.4. 0
OutsidePower Mirror Switch
M/TChangeLever MoonroofSwitch Test..-................................................... 22-111
lnspection............................................. 13-19 TesVRep1acement .............................. 22-l 12
Disassembly 8eassemb1y ................... 13-20 Outsid€Power Mirrors
Mooniool Wind Deflector R e p l a c e m e n t . . . . . . . . . . . . . . . . .. .. . .....2. .0. -. .1.5
M/T CountershaftAssembly R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . . .2. -0. -. 3 . .8. . . . . . Component
....... Locationlndex .............. 22-114
I n s p e c t i o. n . . . . . . . . . . . . . . . . . . . . . . . .1. 3. .3. 1. .,3. .3. . . . . . CircuitDiagram.................................. 22-115
D i s a s s e m b.1. .y. . . . . . . . . . . . . . . . . . . . . . .1. 3 . .-. 3. .2. . . . . .Moonroof/Sunroof
... Test-..................................................... 22-116
Resassemb|y ........................................ 13-34 ComponentLocationIndex ...20-35,22-108
T e s t. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. 0. .-.4. .8. . . . . . . . . . . . . . .
M/T Differential C fr c u i tD i a g r a m. . . . . . . . . . . . . . . . . . . . . .2.2. .-1. .0. 9 ......
ComponentLocation Index................. 13-52 P
l A d i u s l m e n. .t . . . . . . . . . . . . . . . . . . . . . . . . .1. .3. -. 5
M/T Maifthaft Assembly

1nspection ...................................... 13-23, 26
. .6. . . . . .MTF
....
I n s p e c t i o n / R e p 1 a c e.m
MuhiplexControlSystem
. .e. .n. .t....... . . . .1. 3. .- 3
Parking Erake
Inspection A d j u s t m e n t. . . . . . . . . . . . . . . . . . 1
. .9. .- 7
Disassembly ......................................... 1325 ComponentLocation lndex ..............22 168
Resassembly ........................................ 13 28 CircuitDiagram.................................. 22-169 Parking Brake Cable
Adjustment........................................... 13-43 0escription......................................... 22-171 Rep1acement.........................1 . .9. .-.2. .6. . . . . . . . .
Troubleshooting ................................ 22-17 2
M/T ReverseShift Fork ParkingErakeSwitch
I n s p e c t i o. n. . . . . . . . . . . ................ . . . . . . . .l .3. .1. 9 . . . . Muliiplex ControlUnit, Under-dash Test................. . . . .1. 9 - 1 0
InputTest
M/T Shift Level EntryLightControlSysiem............. 22-92 Passenger's TraV
R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . . .1. .3. .- .5. 1. . . . . . . . .Keyless .... Entry/Security Alarm Removal/lnstallation ............................ 20-65
Systern.-....................................... 22-155
MainshaftBearings MultiplexControl System.............22 115 PCVValve
R e p l a c e m e n t . . . . , . . . . . . . . . . . . . . . . .1. .3.4. .1. . . . . . . . . Wiper/Washer.................................
..... 22'141 B e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . .1. 1. .'.1. 6 . .9. . . . . . . . . .
T e s t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l. 1. . 1. .6. .9. . . . . . .
Mairtenance
lSeesection3) PistonRings
N 8 e p 1 a c e m e n t . . . . . . . . . . . . . . . . . . . . . . .7. .- .2. 1. . . . . - . - . .
MIL
How to Informatron ............................. 11.46 Pistons
NoiseReductionCondenser R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . - . . .7. .-.1. .8. . . . . . . . . .
MIL Circuit Test,, . . . . . . . . . . . . .1. 0 21 2 1 n s t a | 1 a t.i .o. n ..........................1 . .-.2. .3. . . .
Troubleshooting .......... .- . . . . ......... 1197
PowerR€lay
Mirrors Test...............-.-...................................... 22-51
ComponentLocation Index................. 20'14 o PowerWindow Motor, Driver's
Mode ControlMotor t e s l . . . . . , ,.,,,. , , , . . . . . . . . . . . .
Replacement . . . . . . . . . 2 1 , 3 5 Oil Filte]
T e s t . . . . . . . . . . . . . . . . . . . . ... . . . . . . . . . . . . . . . 2 1 3 5 R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8. -. 6. . . . . . . . Power . . . . . . Window Motors, Passenger's
MoonroofAuto Stop Switchos Oil Filter Feed Pipe

22'113 R e p l a c e m e n t . . . . . . . . . . . . .....- , . . . , . , , , , , , , , 8 - 7
Test...................................................... PowerWindow Switch, Master
lnputTest ..........-.........-....................... 22-126
l' ,e Moon.oot ControlUnil
MoonroofDreinChannel
22-110
lnputTest ............................................
Oil Pan T e s r. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.2. .1. .2. 4. . . . . . . . . .
R e m o v a l. . . . . . . . . . . . . , . , , , , , , , , , , , , . , . , , , .7. .1. .1. . . . - . . .Replacement.......................................
....
l n s t a l l a t i o .n. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7. .- .2. 7
...........
22-133
B e p l a c e m e n. .t .. . . . . . . . . . . . . . . . . . . . . .2. .0.3. .9. . . . (cont'd)

ServiceManuallndex
(cont'dl
PowerWindow Switch, Passenger's RockerArm Assembly Specifications
lnputTest .............-...... 22-130 Removal 6-26 (Seesection2)
22 132 D;sassembly/Reassembly
.....................
6-27
Replacement...,-.-.-...,.. 22-133 lnstallation 6-38 sRs
Component LocationIndex................. 23-13
RockerArms D e s c r i p t i o n. . . . . . . . . . . . . . . . . . . . . . . . . .2. 3. .-.3. .1. . . . . . .
C o m p o n e n t L o c a t i o nI n d e x . . . . . . . . . . . . . . 2122 4 Test 6-7 C i r c uDi t; a g r a m ... .... ...........2334
CircuiD t i a 9 r a m. . . . . . . . . . . . ............ . . . . .2. 2
. . .1 2 5 Inspecton 6-28 lnspection/Replacemenl ................... 23 112
Roof Moldings SRSlndicatorCircuil

Replacement Troubleshooting 23 105
o
SRSUnit
Replacement..-....................................
23-122
Ouaner Window Glass
8ep1acement.........................................
20-29
s StabilizerBar
Replacement
Seat Belts FrontSuspension 1A-17
Component LocationIndex...................
23-3 RearSuspension 18-30
R
Seat8ehs, Front StabilizerLinks
Replacement Removal/lnstallation
Radiator rnspec!on 23-9 FrontSuspension 1 81 8
Test...... 10-3 RearSuspension 18-31
R e p l a c e m e n t. . . . . . . . . . . 10-10 SeatBehs,Rear
Replacement 23-1 Startel
Radiatorand CondenserFans Test
CommonCircuit SeatCover,Front Replacement
T r o u b l e s h o o l i n g . . . ........... . . . . . . . . . 2 12 9 Replacement 20-75 Overhaul
RadialorCap SeatCushionCover,R6ar StarterSolenoid

Test..-.-... 10-3 Replacement 20-84 Test 4-7
RadiatorFanAssembly Seat,Driver's StartingSystem

Test ........................
r0-4 Removaf/lnstaflation............................
20 11 Component LocationIndex...............-.....
4-3 \' {
Disassembly/Reassemb1y ...................
20-73 CircuitDia9ram........................................
44
RadiatorFanCircuit Troubleshooting
Troubleshooting 10-14 Sedt,FaontPassenger's
Disassembly/Reassemb1y...................
20-74 Steering
RadiatorFanSwhch Component 17-3
LocationIndex................-..
Replacement 10-17 Seat,Rear Inspectaon
................... 11-4
Test 10-17 Removal/lnstallation
............................
20-80
SteeringColumn
RadiatorFanSwitch Circuit Seat-backCover,Reer Removal/lnstallation 17-9
Troubleshooting 1 01 6 Replacement Inspection 1 11 1
RearAir Outlet Seat-back Latch, ReaI SteeringGearbox

Replacement 2Q-104 Replacement Removal 17-51
Overhaul 1 75 5
RearWindow Defogger Seat-backStriker.Rear lnstallation 17 63
Index ..............22
ComponentLocalion 104 Replacement
CircuilDiagram 22-105 SteeringHangerBeam
Test 22 106 Seats Replacement 20 68
Component
LocationIndex....-............
20-70
RearWindow D€roggerWires SteeringLinkage
Repair 22-106 Shift Forks Inspefiron
Inspectton 13,21
RearWindow Glass Disassembly/Reassembly
...................
13-22 Steering Lock
Replacement 20-25 Replacement .....11-12
Shitt Lever Trim
SecirculationControlMotor Removal/lnstallation
............................
20 61 SteeringRackGuide
Replacement 2l-36 Adiustment 17-13
Test..... 21 36 SideAirbag,Drivel's
Replacement 23-115
Recirculation Control Motor Circuit 174
Troubleshooting 21 25 Sidelmpact Sensors Removal 17-6
Replacement 23 123 D i s a s s e m b l y / R e a s s e m b l.y. . . . . . . . . . . . . . . .1. .7. .7
Refrigerant 1 n s t a 1 1 a t i o. .n. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. 7. .-.8. . . . . .
Replacement ..-.-.-......................
21 53,54,55 Side Marker Light
Test........................................................
21-56 R e p 1 a c e m e n t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. .2. .-.A. .3. . . . Sublrames
Replacement 20 112
RetrigerantOil Spark Plugs
R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . . . .2
. .1. .-.6. . . - . . . . . . . . . . . . .._..4_19

Suspension
A d j u s t m e n t . . . . . . . . . . . . . . . . - . . . . . . . . . . . . . . . . . . . .V. . . . . . . . 1 8 4 ComponentLocationIndex.................
20-17
SynchroRing,Triple-cone WindshieldGless
I n s p e c t i o n . . . . . . . . . . . . . . . - . . . . . . . . . . . . . . . . . . . . . .V. .a. l.v1e3G
39uides R e p l a c e m e n t . . . . . . . . . . . . - . . . . . . . . .2. .0. 1. .9- . . . . . . . . . .
Inspection............-.-................................ 6 32
SynchroSleeve Beplacement ..........-................................ 6 33 WiperIntermittentControlUnit,
Inspectaon/Reassemb1y ....................... 1339 RearWindow
ValveSeats InputTest .....22-134
R e p a i .r. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6. 3
. .5. . . . . . . . . . . . . . . . .
WiDerMotor, RearWindow
T Rep1acement....................................... 22-146
Adjustment.-.-....... 6-9
Removal...-...-......................................-... 6-31 WiDerMotor,windshield
Taillight Inspec!on .....6-32 Test.......-..........-.....-.........................
Thermostai Vehicle Speed Signal Circuit Wiper/WasheI

Test ........................ 10 4 Troubleshooting .....-...
..........................22-65
Component LocationIndex ..............22-134
R e p l a c e m e n t . . . . . - . . . .- . . . . . . . . . . . . . 1. .0. I. . . . . CircuitDiagram..........................
22-136, 131
vss
Throttle Body Replacement-..............
............
.............22
61 Wiper/Washor
Switch
Test.................. 11-160 TesVReplacement
..............................
22-140
Removal/lnstallation .. . . . . . .. ... 11-'165 VTCActuator
Disassembly/Feassemb|y................-11-166 Inspection .................68 WireHarnesses
. . .2.4. . . . . . . . .( .S e e f i r s t p a g e o f t h i s l n d e x )
R e p l a c e m e n. t. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ThrottleCable
A d j u s t m e n t. . . . . . . . . - . . . . . . . . . . . .1. .1. 1
. .6. .3. V T CO i lC o n l r o l S o l e n oVi d
alve Wi.ing System
R e m o v a l / 1 n s t a 1 1 a t i o n . . . . . . . . . . . . . . . . . . . . . .R. .e. m
. 1o1v1a6l4. . . . - . . . - .| .1.- 1 2 7 H o w t o I n { o r m a t i o. .n. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2
BelayandControlUnit
Tie-rodBallJoint Boots VTCSystem Locations .-....-..............
-.-.-....- 22-7,4, 11, 12
B e p l a c e m e n t . . . . . . . . . - . . . . . . . . . . . .1. .7. .6.7. . . . . . . C
. . o. .m
. .p
. o n e n t L o c a t i o n l n d e x . . . . 1. .1. .-.1. 1
. .7. .
t s Timing/CamChain
lnstallation ...........6
...612
. . .1. 5
.
VTECSolenoidValve
Femoval/lnspection....-......................11-128
Timing/Cam Chain Auto-tensionel

R e m o v a l / 1 n s t a 1 1 a t i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -W
19
Timing/CamChainCaseOilSeal
Installation......................-......................6,21 WasherFluidLevelSwitch
TesVReplacement .............................. 22 144
TrailingArms
Removal/lnstallation .............. . . . . .....1833 WasherFluidReservoir
Replacement ....................................... 22-146
tnm
Component Locationlndex................- 20 49 WasherMotor,Windshield
R e m o v a l / l n s t a l l a. t. i-o. .n. . . . .5200, 5 1 , 5 2 , 5 3 T e s t- . . . . . . . . . . . . . . - . . . . . . . . . . . . . . . . . . . . .1. .4. 4. . 2 2
Troubleshooting WasherTube,Windshield
{Seefirstpageot thisIndex) Replacement......-...-............................
22 147
Turn SignalLight W.ter Outlet

Replacement .........22
A4 Installation '10-9
..................-...........................
Turn Signal/HazardRelay Weter Passage

InputTest........ 22-87 lnstallation . . . . . . . . . . .1. 0
. .I. .
Turn Signal/HazardWarningLights Water Pump

Component LocationIndex.................22
85 Inspection...........................
.. . . . .......10 5
Circuit Diagram................-...................
22-86 Replacement .-.........................................
10 5
WheelBearings
I n s p e c | i o n. . . . . . . . . . . . . . . . . . . . . . . . . . ............1...8. 8. . . .
U
Wheel Speed Sensors
],s
I n s p e c t i o n . . - . . , . , . , , . , , , , , . , . , , , . . . . . . . . . . . .1. .9.-. 5
. .9. . . .
UndeFdashFuse/R€layBox R e p l a c € m e n. t. . . . . . . - . . . ..... . . . . . - . . . 1 . 9-59
Removal/lnstaf
lation............................
22-49
WheelsandTires
UpperArms Inspect|on
R e m o v a l / | n s t a 1 1 a t i o n . . . . . . . .. .. ..1. .8. -. .3. 2.

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How to Use This Manual -

All informationcontainedin this manualis basedon the latest

FirstEdition8/2002 1,168pages HONDAMOTORCO..LTD.

As seclion3 with *inclode SRS comoonentsi

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S H H E P 33 5 ' 2 U 300001 K2OA3 1700001

a. Manufacturer, Make and Type of Vehicle a. EngineType

V€hicle ldentif ication Numbo.

S H H E P 33 5 * 3 U 400001 K2OA3 2700001

Manufacturer, Make and Type of Vehicle a. EngineType

Vehicle ldentif ication Vehicle ldentificalion

2 HNX V O2.O VBP

rH/ @ 2 HNX R OO99 AAH

THISVEHICLECONFORMSTO U.S. EPATIER2 BIN 5

2. Raisethe hoist a few inches,and rock the vehicle

Safety Stands Lower the vehicleonto the stands.

To supportthe vehicleon safetystands.use the same

It is bestto tow the vehicleno farther than 50 miles (80

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Alternator Output At 13.5V and 80A

Exhaust 34.092mm (1.3422 in.)

4.20 (4.4US qt)for oil change,includingfilter

Standardor New ServiceLimit

TurnsOFF Subtract5 15'F(3 8"C)fromactualON

MBSdistance LD. 28.00 28.01mm(1.102 1.103in.) 2 8 . 0 2m m ( 1 . 1 0i3n . )

Overallheight 1,44m 0 m (56.7 in.)

F!el required UNLEADED gasolinewith 86 pumpoctanenumberor higher

Light bulbs Headlighthigh '12v.' 60w

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-30 -20 -10 0 t0 20

(cold)(seepage6 32):lntake:0.21 0.25mm (0.008 0.010in.)Exhaust:

km/ 10years,thenevery60,000mi/ 96,000km/5 years

Checkparkingbrakeadjustment. Shouldbe fullyappliedwithin7 to 9 clicks.

Serviceatthe indicated ortime,

* : According failureto do the maintenance

Serviceat the indicated

Inspectvalveclearance Inspect miles(176,000

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

3 . With the clutch pedal pressed,turn the ignition

Did the starter crank the enginenormally?

7, Checkthe crankingvoltageand currentdraw.

ls ctanking voltagegreatet than or equal to 8.7 V

NO Replacethe starter.or remove and

9. Removethe starter,and inspectits drive gear and

2. Checkthe hold-incoil for continuitybetweenthe S

. lf there is continuity,goto step 3.

3. Checkthe pull-incoil for continuitybetween the S

. lf there is continuity,the solenoidis OK.

Make a connectionas describedbelow using as

Connectthe batteryas shown. Be sure to

6 . Clampthe starterfirmly in a vise.

7 . Connectthe starterto the batteryas describedin

Disconnectthe batteryfrom the M terminal.lf the

lf the eiectriccurrent and motor speedmeet the

1.1 kw 90 A or less (Electriccurrent),

4. Removethe bolt (A) securingthe harnessbracket,

Removethe two bolts holdingthe starter,then