ACUrj|A
INTEGFIF| Service Manual 1994
INTRODUCTION How to Use This Manual This manualis dividedinto 23 sections.The first pageof each section is markedwith a blacktab that linesup with its corresponding thumb indextab on this page and the back cover. You can quickly tind the tirst pageof each sectionwithout lookingthrougha full table of contents.The svmbolsprintedat the top cornerof each page can also be used as a quick referencesystem. Each section includes: 1. A table of contents.or an explodedview index showing: a Partsdisassemblvsequence. a Bolt toroues and thread sizes. a Pagereferencesto descriptionsin text. proceduresand tools. 2. Disassemblv/assembly 3. InsDection. 4. Testing/troubleshooting. 5. Repair. 6. Adiustments.
Specifications
trtl:{lt'
M a i n te n a n c e
4Pi
Engine
H
I-""
SpecialInformation lnai""tes a strong possibility of sevor€ pelsonal iniury @ 01 loss of life it instructions al€ not tollowed. CAUTION: Indicates a possibility ot personal inlury or oquipmont damage if instructions ale not followed. NOTE: Gives helpful information. CAUTfON: Detaifeddoscriptionsot standad workshop procedures, salety principlosand servicaopelationsare not included Pleasonote that this manual conlains warnings and cautions against somo spocific sgrvice methods which could cause PERSONALINJURY, damage a vehicle or make it unsafe. Pleasounderstandthat those warnings cannot cover all conceivablcwaYs in which service, whetheaor not recommended bv HONDA, might be done, or of the possibla hazardous consequences of svery conceivable way, nor could HONDA investigateall such ways. Anyone using seryice plocedures or toofa, whethor 01 not recomondedby HONDA, ,nust sttisfY himsett thoroughly that neither personal saf€ty nor v€hicle safety will be jaopaldized. All informationcontainedin this manualis basedon the latest product informationavailableat the time of printing.We reservethe right to makechangesat any time without notice.No part of this publication mav be reproduced,storedin retrievalsystem, or transmitted, in any Jorm by any means,electronic,mechanical,photocopying, recording,or otherwise,without the priorwritten permissionof the publisher.This includestest. figures and tables.
Fueland Emissions Za *Transaxle * Ste e ri n g
r-\
* Brakes
o
(lncludins !TEg)
l D l \.t/
HONDA MOTORCO.,LTD, 1448 pages First Edition7/93 Service Publication ottice All Rights Reserved and Canada Apply to U.S.A. Specifications
*Electrical As sections with r includ€ SRS components. special precautions are lequiled when servicing.
(lncludins ISBE)
J--*
, ,
SUPPLEMENTAL RESTRAINT SYSTEM(SRS} The IntegraSRSincludesa driver's airbag,locatedin the steeringwheel hub. ln addition,all mod€lsexcepi tna Rs modelfor canada have a front passenger'sairbsglocatedin the dashboardabovethe glove box, InformaUon necessaryto safely servicethe SRSis includedin this servica Manual.ltems markedwith an sstorisk(r) on thr contents page include,or are locatednear, SRScomponents.Servicing.disassemblingor roplacingthea6 ltems will requirespecialprecautionsand tools, and shouldthoreiore be done by an authorhed Acura dealer. ' To avoid ronderingths sRS inoporativo,which could lard to porronll Injury or darth In thc cvant ot. r.yr. trontal collision, all sRs sorvico work must be pcrformcd by !n ruthorizcd Acu.! daerrr, ' lmpTopor3orvica proceduroa,including inco.roct r.movd r d Installation of tha SRS,could Lld to pc[onc Inlury caussd by unintsntionalactivationot tho airbags. ' All sRs oloctrical wiring harnoa$! aro coverod with yallow In3ulatlon, Rcbtcd componcnts arc bcrtad In tha stoeringGolumn,front console,dsrhboa.d,and darhboardlowor plnol, lnd in thc d$hbolrd abovc tha gaov! bor. Do not uas oloctdcalte$ oquipmonton thaaa citcuhs. NoTE: The originalradiohas a codedthett protectioncircuit. Be sureto get the customer'scode numb6r b€lore * disconnecting the battery. - removingthe No. 32 (7.S A) fuse Jromthe undsr-hood fuse/relaybox. - removingthe radio. After service,reconnectpowerto the radioandturn it on. Whenthe word ,,CODE,,is displayed, enterthe cus_ tomer's 5-digit code to restoreradio oDerauon.
GeneralInformation Chassisand PaintCodes ldentificationNumberLocations Warning/CautionLabelLocations Lift and SupportPoints Lift FloorJack Safety Stands Towing
1-2 1-4 1-5 1-9 1-10 1 - 11 1-12
I
Chassisand PaintCodes U.S.Model
VehicleldentificationNumber
EngineNumber
JH4DB754*RSOOOOO 1
8 l 8 B r ------T----r300@l
Manutactulol, Make and Typ€ of Vshicle J H 4 : H O N D AM O T O RC O . ,L T D . ACURAPsssenger car Line, Body and EnginoType
Engine Typ6
DB7:INTEGRA 4-door/B1 881 DB8:INTEGRA 4-door/81 8Cl DC2:INTEGRA 3-door/B18C 1 DC4:INTEGRA 3-door/B1 8Bj BodyType and Trsnsmission Type 3: 2-doorHatchbackS-speedManual 4: 2-doot Hatchback4-speed Automatic 5; 4-doorSedans-speedManual 6: 4-doorSedan4-speedAutomatic
Se al Numbel
81881: 1.8 f DOHCSequentiat Muhi-pori Fuel-injectedengine B l8Cl : 1.8 | DOHCVTECSequ€nrial Multi-port Fu€l-iniected€ngin€
Transmission Numbsr Y80- 1000@ I
Transmission Type Y80: Manual MPTA:Automatic
Vehicle Glado (Seriesl 4: RS 5: LS 8; GS-R
Serial Numbel
Check Digit Model Yaal R: 1994 Factory Code S: SuzukaFactoryin Japan
Paint Code
COLOR BG.33P
Serial Numb€l
Vehicleld€ntification Numberand FederalMotor VehicleSafety StandardCertification 3DOOR
1-2
4DOOR
PaintCode PaintCode BG.33P G-71P NH-5O3P NH-538 NH-575M R-72P R-81 RP.24P YR.5O3M
Color ParadiseBlue-g.€enPeErl LausanneGr6enPead GrsnadaBlack Pea.l Frost White ThunderGrav Metallic Torino Red Pearl MilanoRed Stealth Gray Pearl RosewoodBrown M€tallic
CanadaModel EngineNumber
VehicleldentificationNumbel
8 1 8 8 1 - 17 0 0 0 0 1
JH4DB753.RS800001
Engin€Type Multi-port 81881: 1.8 I DOHCSequential Fuel-injectedengine B 1 8 C 1 :1 . 8 I D O H CV T E CS e q u e n t i a l engrne Multi-DortFuel-iniected
Manutacturer,Makeand Type of v€hicle JH4: HONDAMOTORCO., LTD. car ACURAPassenger Lino. Body and EngineTYPo 4-doot/Bl881 D87: INTEGRA DC2:INTEGRA3-dootBl 8C1 3-dooriB18B1 DC4:INTEGRA Body Type and TransmissionTYPo 3: 2-doorHatchback5-speedManual 4'. 2-doorHatchback4-speed Automatic 5: 4-doorSedans-speedManual 6: 4-doorSedan4-speedAutomatic VehicleGrade{Sedes} SRSairbag 3: RS without passenger 4: RS with passengetSRSaitbag
SerialNumber
Number Transmission Y80-1000001
Type Transmission Y80: Manual MPTA:Automatic SerialNumbel
8: GS-R Check Digit Model Yeat R: 1994 FactoryCode S: SuzukaFactoryin Japan
Paint Code
COLOR BG.33P
Serial Numbel
Numberand Vehicleldentification CanadianMotor Vehicle Safety Standard Certification 3DOOR
4DOOR
Paint Code PaintCode BG.33P G-71P NH-5O3P NH-538 NH-575M R-72P R-81 RP-24P YR-503M
Color Pearl ParadiseBlue-green LausanneGreenPearl GranadaElackPearl Frost White ThunderGrayMetallic TorinoRedPearl MilanoRed StealthGrayPearl RosewoodBrown Metallic
1-3
II I
ldentificationNumberLocations
Vehicle ldontification NumberlvlNl
v.hiclo ldontificalion Numb€rlVlNl
S
Transmbsion Numbor lAuromatic)
Transmissioh l\lumbor lManuall
1-4
LabelLocations Warning/Caution
A: CABLEREALCAUTIONA MANUALFORDETAII'fDINSTRUCTION SERVICE BEFERTO-
B: CABLEBEALCAUTIONB REFERTOSERVICEMAI{UAL FOROETAILEDINSTRUCTION WHEEL OTICE C: STEERII{G
]{OT|CE ORINSTALLATION WIIEELREMOVAL STEERII{G IMPROPEB DAMAGESRSCOMPONENT. CAREFULLY. MANUALINSTRUCTION FOLLOWSERVICE D: DRIVERINFLATORWAR[{|NGTAG WARNII{G AND POSSIBLE D€PLOYMENT TO PflEVE T ACCIDE]TTAL
INJURY: SHORTCOI{NECTOR ALWAYSII{STALLTHEPNOTECTIVE IS WHENTHEHARNESS COI{I{ECTOR O THEINFLATOR DISCONNECTED.
MODULEDANG€R E: DRIVER A DANGER EXPLOSIVE/FLAMMABLE CONTACTWITHACID,WATERORHEAVYMETALSSUCH HARM. MAY PRODUCE LEADOR MERCURY AS COPPER, FUL AND IRFITATINGGASES OR EXPLOSIVECOM. POUNDS. MUST NOT EXCEED2OOOF STORAGET€MPERATURES (1OOOCI. HANDLING.STORAGEAND DISFORPROPER TO THE SERVICEMANUAL, REFER POSALPROCEDURES SRSSUPPLEMEf{T. POTSON SODIUMAZIDEANDPOTASSIUM POISONOUS CONTAINS I{ITRATE. FIRSTAID IF CONTENTSARESWALLOWED,INDUCEVOMITING. FOR EYE CONTACT, FLUSH EYES WITH U'ATER 15 MINUTES.IF GASESIFROMACIDORWATERCONTACT} ARE INHALED.SEEKFRESHAIR. IN EVERYCASE, GET PROMPTMEDICALATTENTION. KEEPOUT OF REACHOF CHILDREN F: DRIVERMODULEWARNING A, WABNING AND' IF ACCIDENTHEAIRBAGINFLATORIS EXPLOSIVE I{URTOR KILLYOU. TALLYDEPIOYED,CAN SERIOUSLY ORPROBTESTEOUIPMEI'IT . DO NOTUSEELECTRICAL ING DEVICES. OEPLOYMENT. THEYCAN CAUSEACCIOENTAL PARTS INSIOE,DO NOT DISAS. . NO SERVICEABLE SEMALE. . PLACEAIRBAGUPRIGXTWHENREMOVED' . FOLLOW SERVICEMANUAL II{STRUCTIONS CAREFULLY.
(cont'd)
1-5
Warning/CautionLabel Locations (cont'd)
G: DBIVEBTNFORMATTON {SUNV|SORt
G: DBIVEBINFORMATTON {SUNvtSORt. ALWAYS WEARYOUNSCIT EELT C.Ai IS EOUIPPEDWITH A DRIVERAIRBAG ANO A_FRo_NTSEAT pASSENGERnrnslc nNo e raoNi SEATPASSENGER AIRBAGAS A SUPPIEMENTALBES. TRAINT SYSTEM {SBSI
ro suppLEMENr rHEsEArBEt-r. Lr_ll^gls_lglls .: BEFoRE oRrvrNG, ReeoL.qsetmsiDrrxE GLovEBox.
1-6
rThis vo.3ion ot tho lsb€l i! us6d in csrs wtth a,ront soat paas€ngor'sairbag.
J: GLOVEBOX INFORMATIOf{ AIBBAGINFORMANO RESTiAINTSYSTEM(SRS) SUPPLEMENTAL TEN YEARSAFTERIT . THE SRSMUST BE INSPECTED IS SHOWN TI{EDATEOFINSTALLATION IS INSTALLED. PLATE,LOCATEDON THE ON THE CERTTFICATION DOORJAMB. DRIVER'S OF SNS . DIAGNOSTICCHECKSAND REPLACEMENT MUST BE DONEBY AN AUTHORIZED COMPONENTS DEALER . SEEYOUROWNER'SMANUALFORAODITIONALSRS INFORMATION. INFLATORWARNINGTAG K: FRONTSEATPASSENGER A WARNING CAN SERIOUSLY ACCIDENTALAIRBAG DEPLOYMENT HURTOR KILLYOU. WHENTHE INCONNECTOR INSTALLTHE REDSERVICE FLATORHARNESSIS DISCONNECTED MODULEDANGER L: FRONTSEATPASSENGER A DANGER EXPLOSIVE/FLAMMABLE CONTACTWITHACID,WATERORHEAVYMETALSSUCH HARM' MAY PRODUCE LEADOR MERCURY AS COPPER. FUL AND IRRITATINGGASES OR EXPLOSIVECOM. POUNDS. MUST NOT EXCEED2OOOF STORGETEMPERATURES AND DISSTORAG€ HANDLIING, tlOO"CI.FOBPROPER MANUAL, REF€BTO THESERVICE POSALPROCEDURES SBS SUPPLEMENT. POTSON SODIUMAZIOEAND POTASSIUM CONTAI'\'SPOISONOUS NITRATE. FIRSTAID INDUCEVOMITING. IF CONTENTSARESWALLOWED, FOREYECONTACT,FLUSHEYESWITH WATERFOR15 MINUTES. IF GASES(FROMACID OR WATERCONTACT)ARE IN. HALED,SEEKFRESHAIR. IN EVERYCASE.GETPROMPT ATTENTION. MEDICAL KEEPOUT OF REACI.IOF CHILDREN.
M: AIRBAGLABEL AIRBAG HOODI N: SRSWARNINGIENGINE SYSTEM(SBSI RESTRAINT SUPPLEMENTAL WITH DRIVERSIDEAIRBAG. THISVEHICLEIS EOUIPPED ARE WIRINGAND CONNECTORS ALL SRS ELECTRICAL YELLOW. COLORED ORUSINGELECTRIWITH,DISCONNECTING TAMPERING ON TI{E SRSWIRINGCAN MAKE CAL TESTEOUIPMENT FIR' OB CAUSEACCIOENTAL THESYSTEMINOPERATIVE ING OF THE INFLATOR. A. WANING AND, IF ACCIDENTHEAIRBAGINFLATORIS EXPLOSIVE HURTYOU' CAf{ SERIOUSLY TALLY DEPLOYED, CAREFULLY. MANUALINSTRUCTIONS FOLLOWSERVICE HOODIi N: SRSWARNINGIENGINE SYSTEM{SRSI RESTRAINT SUPPLEMENTAL WITH DRIVERANO FRONT THIS VEI{ICLEIS EOUIPPED AIRBAGS. SEATPASSENGER ARE WIRINGAND CONNECTORS ALL SRS ELECTRICAL YELLOW. COLORED ORUSI G ELECTRI' WITI{, DISCONNECTING TAMPENING ON THESRSWIRINGCAN MAKE CAL TESTEOUIPMENT FIB' ORCAUSEACCIDENTAL THESYSTEMINOPERATIVE ING OF THE INFLATOB. A WABNING AI{O, IF ACCIDENTHEAIRBAGINFLATORIS EXPLOSIVE HURTYOU' CAN SEBIOUSLY TALI-YDEPLOYED, CAREFULLY. MANUALINSTRUCTIONS FOLLOWSERVTCE 'This vorsionol tho labolis u36din cs.t with a front soat passonger'sairbag.
A' WARNING AND. IF ACCIDENIS EXPLOSIVE THEAIRBAGINFLATOR HURTOR KILLYOU. CAN SERIOUSLY TALLYDEPLOYEO, ORPROB. TESTEOUIPMENT . DO NOTUSEELECTRICAL INGDEVICES. DEPLOYMENT. THEYCAN CAUSEACCIOENTAL . NO SERVICEAALE PABTS INSIDE.OO NOT OISASSEMBLE. . PLACEAIRBAGUPFIGHTWHENREMOVED. . F O L L O W S E R V I C EM A N U A L I N S T R U C T I O N S CAREFULLY.
{cont'd)
1-7 fi{lHfiFe*%
_
Warning/Caution LabelLocations (cont'd)
SERVICEINFORMATION
C) SPARKPtUG II{FORMATION
BATTERY CAUTION
AIR CLEAI{€R, RECOMMENDEO OILand FILTER SERVICE RADIATORCAP CAUTIOI{
TIREINFORMATION {300()R)
1-8
TIREINFORMATIOII t4DOOR)
Lift and SupportPoints Lift plac6 Wh€n heavy16arcompon€ntssuch aa susponsion,luel tank, spale tile and hatch ale to b€ removod, in the tuggageareabsforehoisting.Whensubstantialwoightis lemovedfrom ths l€ar ol th€ car, ths il]iii6iliieigltt cantor of gravity may chango and can cause the cal to tip folward on the hoist'
can assist NOTE: Sinceeachtire/wheelassemblyweighsapproximately14 kg (30 lbs),placingthe front wheelsin trunk with the weight distribution.
1. Placethe lift blocksas shown and rock the car to be sure it is firmly supported. 2. Raisethe hoista lew inches(centimeters) 3. Raisethe hoistto full heightand inspectlift pointsfor solidsupport.
POINT FRONTSUPPORT
LIFTBLOCKS
POINT BEARSUPPORT
1-9
Lift and Support Points FIoor Jack 1 . Set the parkingbrakeandblockthe wheelsthat are
not beinglifted.
2 . When when lifting tritrngthe rear o off the car, put the gearshift lever in reverse(Automatictransmissionin
sition).
a
@ po-
3 . Raisethe car highenoughto insenthe safetystands. 4 . Adjustandplacethe safetystandsas shownon page 1-11 so the car will be approximately level,then lower the car onto them. Front
Centerthe jsck bracketin the middle ot the jack lift platform.
JACK LIFTPLATFORM
Rear
JACK LIFTPLATFORM
1-10
Centerthe jack bracketin the middle of the jack Iift platform.
Always uss satety standswhen working oo 01under any vehiclethat is supponedby only a jack. Naverattompt to use a bumporiack fo. lifting or supporting tho car,
Safety Stands
ATTACHMENTS RUBBER
t$ \F
FROI{TSUPFORTPOII{T
SAFETYSTANDS
POINT REARSUPPORT
1-11
Towing It the car needsto be towed, call a professionaltowing service.Nevertow the car behindanothercar with just a rope or chain. lt is very dange.ous.
Front:
Emergency Towing There are three popularmethodsof towing a car: Flat-bedEquipmont-The operatorloadsthe car on the back of a truck. This is the best way of transportingthe car. Whsol Lift Equipment-The tow truck uses two oivoting arms that go under the tires (front or rear)and lifts them otf the ground. The other two wheels remainon the ground.
rl
Sling-type Equipmont-The tow truck uses metal cables with hooks on the ends. These hooks go around parts of the frame or suspensionand the cableslift that end of the car off the ground.The car's suspensionand bodv can be seriouslydamagedif this methodof towing is attempted. It the car cannotbe transponedby flat-bed,it shouldbe towed with the tfont wheels oft the ground. lf due to damage.the car must be towed with the front wheels on the ground, do the tollowing: ManualTransmission a Releasethe parkingbrake, a Shift the transmissionto Neutral. Automatic Transmission a Releasethe parkingbrake. a Start the engine. a Shift to @ oosition,then to S position. a Turn off the engine. NOTICE:lmpropertowing preparationwill damagethe transmission. Followthe aboveprocedureexactly.lf you cannot shift the transmissionor stan the engine(automatic transmission), your car must be transDortedon a flat-bed. a lt is best to tow the car no tartherthan SOmileslgo km). and keep the speedbelow 3b mph (bE km/h). NOTICE:Trying to litt or tow your car by the bumpers will causeseriousdamage.The bumpersare not designed to supportthe car's weight.
TOWING HOOKS
Real:
SpecialTools lndividual tool lists are located at the front of each section
Specifications 3-2 Standardsand ServiceLimits .'-.'.'."-'-' 3-17 ....'.'.'...."....."...... DesignSpecifications 3-20 '.....'.'. BodySpecifications
Standardsand ServiceLimits CylinderHead/Valve Train(B188tenginel- Secti Declron 6 Compression
Cylinderh.ad
Camshaft
MEASUREMENT STANDARD {NEWI 250rpmandwideopenth.ottl€ Nominal 1,370(14.0,199) (kgflcm?, psi) kPa Minimum 930(9.5,140) Maximumvariation 200t2.0,2a) W6rpage Height
r 3 1 . 9 5 -1 3 2 . 0(55 . 1 9-5 5 . 1 9 9 )
Endplay Camshaft-to-holder oil clearance Totalrunout Camlobeheight
tN EX lN EX tN EX lN EX
(Cold)* Valveclearance ValvestemO.D. Stem-to-guide clearance
width
tN EX tN EX
Steminstslled height Valvespring
Valv6guide
Freelength{Reference}
NH CH
Lu.
lN
Installed height
EX lN
*: Measuredbetweenthe camshaftand rockerarm. NH:NIHONHATSUJO manufactur€d valvespring CH:CHUOHATSUJO manufacturod valvesDrino
3-2
lN EX
- 0.0061 0.05- 0.15(0.002 - 0.0027) 0.030- 0.06910.0012 0.03(0.001) max. 33.71611.327 1l (1.3200) 33.528 - 0.005) 0.08- 0.12{0.003 0.'r6 - 0.20(0.006- 0.008) - 0.2594) 6.580- 6.590(0.2591 - 0.2583) 6.550- 6.s60(0.2579 0.02- 0.0s(0.001- 0.002) 0.05- 0.08(0.002- 0.003) - 0.061) r.25- 1.55(0.049 - 0.061) 1.25- 1.55{0.049 - 41.235 - 1.6234) (1.6049 40.765 - 1.7022) 12.763- 43.235t1,6a37 42.36(1.668) 47.09{1.854} 47.08(1.854) - 0.261) 6.61- 6.63(0.260 6.61- 6.6s(0.260-0.261) - 14.25 - 0.561} 13.75 {0.541 - 0.640) r5.75- 16.2510.620
'
SERVICE LIMIT
0.05(0.002)
0.5(0.02) 0.1s{0.006) 0.04(0.002)
6.s5(0.258) 6.52(0.257) 0.0810.003) 0.11(0.004) 2.0t0.08) 2.0(0.08) (1.6333) 41.485 (1.7120) 43.485 41.s6{1.636) 46.27tl.A22l 46.21l1.a22l 6.65(0.262) 6.6510.2621
Unitof length:mm {in}
s cti 7 k (81881 EngineBlock {Bl6E1 englnel- sectlon (NEWI STANDARD 0.0710.003)max. - 3.190) 81.00- 81.02{3.189
MEASUNEMENT Cylinderblock
Piston
Warpageot decksLrrface Borediameter BoretaPer Reboringlimit SkirtO.D.at 15 mm (0.6in)Irom bottom of skirt in cylinder Clearance Top Groovewidth (Forring) Second --
Pistonring
clearance Ringto-groove
oil top
Second '....=-
Ringendgap
lop
rod Connecting
Crankshaft
Bearing
o.D.
;
T
Second oit rrstonrln
R T
clearance Pin-to-piston Pin-to-rodinterference Smallendborediameter Nominal Largeendborediameter on crankshatt Endplayinstalled Mainjournaldiameter N o .1 ,2 , 4 a n d5 j o u r n a l s No.3 iournal Rodiournaldiameter Taper Out-ofround Endplay Runout oil clearance Mainbearing-to-iournal No.1,2, 4 and5 journals No.3 journal oil clearance Rodbearingto-iournal
R T
- 3.189) 80.98- 80.99(3.188 - 0.0016) 0.01- 0.04(0.0004 - r.010(0.04060.0409) 1.030 - 0.0488) - 1.210(0.0484 1.230 2 . 8 0 -5 2 . 8 2 (00 . 1 1 0 40 . 1 1 1 0 ) - 0.0028} 0.045- 0.070{0.0018 - 0.0026) 0.040- 0.065(0.0016 - 0.0028) 0.045- 0.070(0.0018 - 0.014) 0.20- 0.35(0.008 - 0.012) 0.20 0.30(0.008 0.40- 0.5s(0.0r6 - 0.022) - 0.020) 0.20- 0.s0(0.008 - 0.0181 0.20- 0.45(0.008 - 0.8268) - 21.000 (0.8265 20.994 - 0.0009) 0.0r0- 0.022(0.0004 - 0.0013) 0.013- 0.032(0.0005 20.968- 20.981(0.825s- 0.8260) 48.0(1.89) - 0.012) 0.1s- 0.30(0.006
LIMIT SERVICE 0.10(0.004) 81.07(3.192) 0.05(0.002) 0.25(0.010)
80.9713.188) 0.05(0.002) 1.0610.042) 1.26(0.050) 2.8410.112\ 0.13{0.00s) 0.13(0.00s) 0.13(0.005) 0.60{0.024) 0.6010.024) 0.70(0.028) 0.70(0.028) 0.70(0.028)
- 2.1654) 54.976- 55.000(2.1644 - 2.1651) 54.970- 54.994(2.1642 - 1.7717} - 45.000{1.7707 44.S76 max. 0.00510.0002) max. 0.005(0.0002) 0.10- 0.35(0.004- 0.014) max. 0.03(0.001)
0.010(0.0004) 0.010(0.0004) 0.45(0.018) 0.04{0.002)
- 0.0017) 0.024 0.042{0.0009 - 0.0019} 0.030 0.048{0.0012 - 0.0015) 0.020 0.038(0.0008
0.05010.0020) 0.060(0.0024) 0.050(0.0020)
Ri RIKENmanutacture Pistonring pistonring RINGmanufacture PISTON T:TEIKOKU
3-3
Standardsand ServiceLimits Cylander Head/Valve Train(B18Clenginel Section6 MEASUBEMENT Compr€6sion
Cylind6rhoad
C.mshsft
250rpm and wideop€nthrottle Nomin6l kPalkgl/cmr,psi) Minimum Maximumvariation Warpage H6ight Endplay Camshaft-to-holdsr oil clearance Totalrunout Camloboheight lN Primery Mid
EX
Socondary Primary Mid Secondary
Valvoclorrancelcoldl*
lN EX lN EX lN EX tN EX lN EX
ValvestemO.D. Stom-to-guid6 clerrsnco Valvoseat
Width Sr6minstalledh€ight
Valv€Bpring
Fre6length(Roferenca)
lN EX
Valveguido
l.D. Instslledhoight
Rock€rerm
Arm-to-shaft clearance
': M€asuredbetwoonthe camshattand rcc(ersrm. NH:NIHONHATSUJOmanufacture v6lvespring CH:CHUOHATSUJO manufscturo v6lvespring
3-4
STA]TDARD INEWI
Outer Inner
NH CH NH CH
tN EX lN EX lN EX
SERV|C€ UM|T
(19.0, 1,860 270) 930(9.s,140)
200t2.o,2a) 'r41.95 - 1C2.05 (5.s89 - 5.593) 0.05- 0.1s(0.002- 0.006) - 0.0035) 0.050- 0.089(0.0020 0.015(0.0006) max. 33.411{1.3154) 36.377tl.13221 (1.3601) 34.547 33.1110.3036) 35.72011.4063) 34.381 {1.3536) 0.15- 0.19{0.006- 0.007} 0.17- 0.21(0.007- 0.008) - 0.21591 5.475- 5.48s(0.2156 - 0.21s0' 5.450- 5.460(0.2146 - 0.0022} 0.025- 0.055{0.00'10 - 0.0031) 0.050- 0.080(0.0020
- 0.06't) 1.25- 't.5s(0.049 '1.25 - 1.s5{0.049 - 0.061)
- 1.4935) 37.465- 37.935('1.4750 - 1.4817) 37.16s- 37.635t1.4632
41.05(r.6161 36.'16 {1.4241 36.19t1.425) 41.96(1.652) 4 1 . 9 {41 . 6 5 1 ) - 0.218) 5.51- 5.53(0.217 5.5r- 5.53{0.2r7- 0.218) - r3.0s(0.494 - 0.514) 12.55 - 13.05(0.494 - 0.s14t 12.55 - 0.0020) 0.025- 0.0s2{0.0010 - 0.0020) 0.025- 0.0s2(0.0010
0.05{0.002) 0.5(0.02) 0.15{0.006) 0.03(0.001)
5.11510.21441 s.420{0.2134) 0.0810.003) 0.11{0.(x)4) 2.0(0.08) 2.0(0.08) (1.5033) 38.185 (1.491s) 37.885 40.26(1.585) 35.30(1.390) 35.30(1.390) 40.95(1.612) 40.95(1.612) 5.55(0.219) 5.5s{0.219} 0.08(0.003) 0.08(0.003)
Unit of length:mm (in)
(818C1englnel- Section7 BI k (ltluur Engrne]'ocK Cyiinderblock
Piston
MEASUREMENT warpageof decksurlace Borediameter BoretaPer limit Reboring SkinO.D.ar 15mm (0.6in) {rom bottomot skirt in cylinder Clearance ToP Groovewidth (Forring) Socond
oil
Pistonring
Ring-to-pistongrooveclearance Top Second I oP Ringendgap Socond
oil rrstonrtn rod Connecting
crankshatt
Eearing
o.D.
clearance Pin-to-piston Pinto-rodint€rference Smallendborediameter Nominal Largeendborediameter Endplay installedon crankshaft Msinjournaldiameter N o .1 , 2 , 4a n d5 i o u r n a l s No.3 journal Rodiournaldiameter Taper Out'olround Endplay Runout oil clearance Mainbsaring-to-journal No.1,2, 4 and5 journals No 3 journal oil clearanc€ Rodbearing-to-journal
(NEWI STANDARD 0.05(0.002)max. - 3.190) 81.00- 81.02{3.189
LIMIT SERVIC€ 0.08(0.003) 81.0713.192) 0.05(0.002) 0.25(0.010)
- 3.189) 80.98- 80.9913.188 - 0.0016} 0.0r- 0.04{0.0004 - 0.0409) 1.030- 1.0,r0{0.0406 - 0.0488) 1.230- 1.240(0.0484 - 0.11101 2.805- 2.820(0.1104 - 0.0028} 0.045- 0.070{0.0018 - 0.0026) 0.010- 0.065(0.0016 0.20- 0.35{0.008- 0.014) - 0.022) 0.40- 0,55(0.016 0.20- 0.s0{0.008- 0.020} - 0.8268) 20.994- 21.000(0.8265 - 0.0009) 0.010- 0.022{0.0004 - 0.0014) 0.017- 0.035(0.0007 20.964- 20.997(0.8254- 0.8267) €.0 (1.89) - 0.012) 0.15- 0.30(0.006
80.97(3.188) 0.05(0.002) 1.060(0.0417) 1.260(0.0496) 2 . 8 4 0( 0 . 1 1 1 8 )
0.13(0.005) 0.13(0.005) 0.60(0.024) 0.70(0.028) 0.7010.0281
- 2.16541 - 55.000 (2.1644 54.976 54.974- 54.998(2.'|643- 2.1553) -' I.7717) - 45.000 44.976 {1.7707 max. 0.005{0.0002} max. 0.004{0.0002) 0.10- 0.35{0.00{- 0.014) max. 0.020(0.0008)
-t-oou lo.ooort
- 0.0017) 0.024- 0.042(0.0009 - 0.0019) 0.030- 0.048(0.0012 - 0.0020) 0.032- 0.050(0.0013
0.050(0.0020) 0.060{0.0024) 0.060(0.0024)
3-5
Standardsand ServiceLimits - Section EngineLubrication eclton g u _ MEASUREMENT Engineoil
Capacity f (USqt, lmp qt)
STANDARD INEW}
etaet engine 4.6{4.9,4.0}torengineoverhaul 818C1 engine
O i lp u m p
Reliefvalve
SERVICELIMTT
3.8(4.0,3.3)for oil change,inctudin g talter 3.513.7, 3.11for oil change,withouttiher 4.8{5.1,4.2)for engineoverhaul 4.0(4.2,3.5)lor oit change,includin g filter
3.7 i3.9 3 3l fdr ^il .hi
Inner-to-outer rotorclearance Pumphorising-to-outer rotorclearance Pumphousing-to,rotor axialclearance rressuresettingat engineoil temp.176.F{gO.Ct kPalkgtcm,,psi) At idte At 3,000rpm
0.04- 0.16(0.002- 0.006) 0.10- 0.19(0.004_ 0.007) 0.02- 0.07(0.001, 0.003)
0.20(0.008) 0.21(0.008) 0.1s(0.006)
70 (0.7,10)min. 3{0 {3.5,50)min.
Cooling- Sectiont0 Radialor
Radiatorcap Thermostst
MEASUBEMENT Coolant capacity I {USqt, lmpq 0 8 1 8 8 1e n g i n e engine,heater,I I Including I coolinglineandreservoir I Reservoircapacity: 0.61(0.63USqt,0.53tmpqt) 818C1engine
Openingpressure kPa(kgf/cm?,psi) start to open oF(.C) Fullyopen .F (.C) Valvelift at fully open Coolingfan lhermoswitch"ON" temperature .F {oC) "OFF" Thermoswitch temporature "F (.C) ng the coolantin the reservoirandthat remainingin the engine.
3-6
STANDARD INEWI M/T:6.4(6.8,5.6)toroverhaul
4.4(4.6.3.9) f6r s66lsn1gh66q.* A,rf:6.7{7.1,5.9)for overhaul 4.7{5.0,4.1)for coolantchanoe* M/T:6.7 {7.1,5.9}for overhaul 4.7{5.0,4.1)for coolantchanoe*
,3 - 113toss- trs, r3=Jt&
-
1 6 9- 1 7 6{76 80} 194(90, 8.0(0.31) 196- 203(91- 95) Subtract5 - 14 (3 - 8) from actuat-ON', temperature
Unit ot length: mm {in)
Section 11
Fuel and Emissions
sTAt{ItAno(Newl
MEASUREMENT
SERVICEUMIT | 12011.1'1'21 I too (:.1, g.st
F aa3urorggulator
81881engine in l2 V, 10seconds Disolacoment 818C1engins m, (fl oz,lmp oz) Pressurewith regulatorvacuum hose disconnected Bl8Bl engine kPa (kgflcm',psi) Bl8Cl engin€
22217.5,7 -81min. 364(12.3,12.8)min.
tualt6nk
Caprcity , {US gal,lmp gal)
11.01 50(13.2,
En9in6
ldle sDeed with headlight and cooling fan ofi rpm
7501 50 (M/T:neut..ll 750I 50 {A/T:E or E position}
Fast idle rpm
1,600i 2(x'lM/T:nsurr6l) l,eooI 200(A/T:E or E po6itioo)
ldl6 CO
0.1 max.
.u.l pump
Clutch
%
Section 12 STAM'Ad' IiEWI
MEASUREMENT clutch padsl
clutch disc Pr6sur6 plat€
275- 32a 12.8 -3.9,39.6 - 46.9) 329 - 378 (3.35- 3.85,47.6- 5.47)
P6d6lheight Siroke Pedalplay Disengagementheight Clutchsudace runout Riv€t h€ad depth Thickness Warpage Oiaphragmspringlingeralignment
to lloor to floor
SERVICEUMIT
164(6.46) 130- 140(5.12- 5.51) 12 - 21 (0.47- 0.83) 83 (3.27)min.
max, 0.0510.002) 1.3(0.05)min. 8.4- 9.1 (0.3 - 0.36)
mrx. 0.03(0.001) 0-6(0.02)ma*
0.'15(0.006t 0.2(0.011 6.0(0.24) 0.15(0.006) 0.8(0.03)
3-7 {n+
ll Standardsand ServiceLimits ManualTransmission Section 13 MEASUREMENT
STANDARD{NEWI
SERVICEUMIT 2.2{2.3,1.9}loroilchange 2.3(2.4,2.0)lor assembly
Transmission oil
Capacityf {US qt, lmp q0
Mainshaft
End play Diameterot ball bearingcontactarea (clutchhousingside) Diameterof 3rd gear contactarea Diameterof ball besring contactarea (transmission housingside) Runo!t
0.11- 0.18{0,004- 0.007) 27.977- 27s90 l.1.101- 1.1021
Adjust 2 7 . 9 3( 1 . 1 0 )
37.984- 38.000{1.495- 1.495} 27.987- 28.000{r.1018- 1.1024}
37.93{1.493) 21.94 /.1.10!'
0.02 (0.0008)max.
0.05 (0.002)
Mainshafi 3rd and 4lh gears
t.D. Endplay Thickness
, 1.6939) 43.009- 43.02511.6933 0.06- 0.21(0.0024 0.0083) - 31.97 - 1.3768) (1.3748 34.92 - 1.23SOl 31.12- 31.1711.2370
Mainshaft 5th gear
t.D. Endplay Thickness
43.08t 1.696) 0.3(0.012) 34.8(1.370) 31.3 (1.2321 43.08{1.696) 0.3 (0.012) 3 1 . 3( 1 . 2 3 2 )
Countershaft
Diameterof needlebearingconlact area Diameterof ball boaringcontactarea Diameterof 1st gear contactarea
3rd 4th
Bunout Countershaft lst gear
t.D. Endplay
Countershaft 2nd gear
LD. Endplay Thickness
Spacercollar (Countershaft 2nd gear)
t.D. o.D.
Spacercollar {l'rainshaft 4th and sth gears)
t.D. o.D.
81881engino 818C16ngine
Length
B
3-8
Length
B
- 1.6939) 43.009- 43.025(1.6933 0.06- 0.21 (0.0024- 0.0083) 31.42- 31.47t1.237-1.2391 33.000- 33.015(1.299- 1.300) 24.980- 24.993{0.9835- 0.9840) - 1.4567) 36.984- 37.000(1.4561 max. 0.02 10.0008) - 1.6545) 42.009- 42.02511.6539 - 0.0047) 0.04- 0.12(0.0016 - 1.85r4) 47.009- {7.02511.8507 - 0.0047) 0.05- 0.12(0.0020 - 1.3650) 34.62- 34.67(1.3630 - 1.1405) 28.92- 28.97(1.1386 - 1.4366) 36.48- 36.49(1.4352 - 1.6535) 41.989- 42.00011.6531 29.02- 29.04(1.r42s- 1.1433) - 1.1453) 29.07- 29.09(1.1444 - '1.2209) (1.2205 31.002 31.012 - 1.4951) 37.989- 38.000(1.4956 - 2.22641 56.45- 56.5512.2224 - 1.0268) 26.03- 26.08(1.0248
32.95\1.297) 24.94(0.982) 36.93{1.454) 0.05 t0.002) 42.08(1.657) Adjust 47.0811.854) Adjust 3{.5 (1.358) 28.8(1.134) 36.5(1.437) 4 1 . 9 4( 1 . 6 5 1 )
31.06('1.223) 37.94(1.494)
ManualTransmission
MEASUREMENI Reverseidler gear'1 Synchroring
LD. gear shaft clearance Gear-to-reverse (ringpushedagainst99ar) Ring-to-gear clearance
O o u b l ec o n e synchro ring *2
Clearance {rin9pushedagainstgear) Outersynchroring-to-gear lnnersynchroring-to-gear Outer synchro ring-to-synchrocone
Shitt fork
Shifttork fingerthickness Fork-tosynchro sleeveclearance Shift fork pawl groove width Fork-to-reverseidler gear clearance "1" groovewidth at sth gearside at reversegear side shift piece pin clearance Fork-to-5th/reverse at 5th gear side at reversegear side piece area contact Groovewidth of change arm clearance Changepiece-to-shift
qeverseshift
Shift arm Shift piece
Selector
Unit of length:mm (in)
Section 13
Groovewidth of shift arm contactarea Shift piece'to-shiftarm clearance LD. Shift piece-to-shaftclearance Diameterof shift Iork cont6ctarea Shift piece-to-shiftfork shaft clearance Diameterof changepiececontactarea Arm-to-changepiececlearance Groovewidlh of interlockcontactarea clearance Arm-to-interlock
STANDARDINEW) - 0.7891) 20.016- 20.043(0.7880 0.036- 0.084(0.0014- 0.0033) 0.85- 1.10(0.033- 0.043)
SERVICELIMIT 20.09(0.7909) 0.16(0.006) 0.4(0.0't6)
0.95r 1.68(0.037- 0.066) 0.5- 1.0(0.02- 0.04) 0.5- 1.0{0.02-0.04) 7.4,7.6 (0.291- 0.299) 0.35- 0.65(0.014- 0.026)
0.6(0.024) 0 . 3( 0 . 0 1 ) 0.3 (0.01)
- 0.524) 13.0- 13.3(0.512 - 0.043) 0.5- 1.110.020 -0.303) 7.40- 7.70(0.291 - 0.28s) 7.05- 7.25(0.278
1.0(0.039)
13907)
- 0.03s) 0.4- 0.9{0.016 - 0.018) 0.05- 0.45(0.0020 11.8- 12.0(0.4646-0.4724) 0.05- 0.35(0.002- 0.014) 7.9- 8.0 (0.311-0.315) 0.10- 0.30(0.004- 0.012) 14.000- 14.068{0.551- 0.554) - 0.0036, 0.011-0.092(0.0004 - 12.00(0.469- 0.472) 1'1.90 0.20- 0.50 (0.008- 0.020i 11.90- ' t2.00(0.469- 0.472) 0.05- 0.35{0.002- 0.014) - 0.3996} 10.05- 10.15{0.3957 0.05- 0.2s(0.002- 0.010)
0.8010.031) 0.60(0.024) 0.150(0.0059)
osoto.oart 0.50(0.020) 0.50(0.020)
' 1 : 8 1 8 8 1e n g i n e '2 818C1engine
- Automatic Transmission- oSection 14 rr Eutrlrrl Transmission lluid Hydraulic pressure I kPalkgflcm', psi)
Capacity
I (USqt, lmp qt)
Line pressureat 2,000rpm (E or E position) 2nd clutch pressureat 2,000rpm (DJ position) 3rd clutch pressureat 2,000rpm (lqr posirion) 4th clutch pressureat 2,000rPm {E position) 2nd clutchpressureat 2,000rPm (Elposition) 1st clutch pressureat 2,000rpm ([O or E position) 'lst'holdclutchpressureat 2,000rpm (Elposition) Throttle pressureB
Stallspeedrpm (Checkwith car on levelground)
Throttle fully closed Throtlle Iully opened
SERVICELIMIT
STANDARD{NEWI
MEASUREMENT
5.916.2,5.2)foroverhaul 2.7 (2.9,2.4)for lluid change 830 - 880 (8.5- 9.0, 120- 130)
780{8.0,110)
460 - 14.7,67) throttleIully closed
4 1 0{ 4 . 2 . 6 0 ) throttle fully closed
II
I
830- 880(8.5- 9.0,120- 130) throttlemorethan3/16opened
780{8.0,110) throttle more than 3/16opened
830- 880{8.s- 9.0.120 130)
780(8.0,110)
830- 880(8.5- 9.0,120- 130)
780(8.0,110)
830- 880{8.5- 9.0,120- 130}
780(8.0,110)
0 - 1 s{ 0 - 0 . 1 5 , 02-1 ) 830- 880(8.5- 9.0,120- 130) 2,200- 2,600
78018.0,110) Below 2,200, above 2,600
(cont'd)
3-9
Standardsand ServiceLimits AutomaticTransmis3ion(cont'dl- Sostion14 MEASUFEME'YT Clutch
Clutch initialcl6aranco Clutch rdtu.n spring troe length Clutchdisc thicknosg Clulch plale thickn$3 Clutchond platothictnoss ('l8t)
Clutch ond plato thickn$s (2nd,3rd,ath)
Clutchond pl.t6 thicknoss (lst-hold)
STANDARD {NEWI lst, 2nd 3rd, 4th lst-hold lst, 3rd, 4th 2nd lst-hold
MARK 1 MARK 2 MARK3 MARK4 MARK5 MARK6 MABK7 MABK8 MARK9 MARK10 MAFK 1,I MARK12 MARK13 MAEK14 MARK 1 MARK2 MARK3 MARK 4 MARK 5 MARK6 MARK7 MARK8 MARK9 MARK10 MARK 1 MARK2 MARK3 MARK 4 NO MARK MARK6 MARK7
0.65- 0.85 (0.026- 0.0331 0.40- 0.60(0.016- 0.024) 0.5- 0.8(0.020- 0.031) 3 1 . 0{ r . 2 2 } 33.2{1.31) 34.6 ('t.36) '1.8- 2.0 {0.071- 0.079) 1.95- 2.05(0.077- 0.08r) 2.05- 2.10 (0.08'1- 0.083) 2.1s- 2.20{0.085- 0.087) 2.25- 2.30(0.089- 0.091) 2.3s- 2.40{0.093- 0.091) 2.45- 2.50 (0.096- 0.098) 2.55- 2.60(0.100- 0.102) 2.65- 2.70(0.104- 0.106) 2.75- 2.80(0.108- 0.110) 2.85- 2.90(0.112- 0.111) 2.95- 3.00(0.116- 0.118) 3.05- 3.'r0{0.120- 0.122} 3.15- 3.20(0.124- 0.126) 3.25- 3.30(0.128- 0.130) 3.35- 3.40(0.132- 0.1341 2.05- 2.10(0.081- 0.083) 2.15- 2.20{0.085- 0.087) 2.25- 2.30(0.089- 0.091) 2.35- 2.40{0.093- 0.094) 2.45- 2.50{0.096- 0.098} 2.55- 2.60{0.100- 0.102} 2.65- 2.70(0.104- 0.106) 2.75- 2.80{0.108- 0.r10) 2.85- 2.90{0.112- 0.1r4) - 0.1r8) 2.95- 3.0010.116
2.052.152.252.352.452.552.65-
- 0.083) 2.10{0.081 2.20(0.085- 0.087) - 0.091} 2.30{0.089 2.40(0.093- 0.0941 2.50(0.096- 0.098) - 0.102) 2.6010.100 2.70(0.101-0.106)
SEBVICE UM]T
29.0(1.14) 31.211.231 32.6(1.28) Untilgroov€6wornout Discoloration Discoloration
Discoloration Oiscoloration
II I
I
Discoloration Discoloration
tI I
Oiscolor6tion
-
Unitol length:mm (in)
r.t a t c u a r r u r r 14 AutomaticTransmission- Section MEASUREMENT
iransmission
Diameterof needlebearingcontactarea On mainshattand stator shaft On mainshaft2nd gear On mainshaft4th gearcollar On mainshaftlst gesrcollar (leftside) On countershaft 3rd gear On countershatt 4th gear On countershaft On countershaftreversegear collar lst gearcollar On countershaft on sub'shaft(leftside) On sub-shaft4th gearcollar On reverseidler gear shaft Insidediameterof needlebearingconlactarea On mainshaftlst gear On mainshaft2nd gear On mainshalt 4th gear On countershaftlst gear On countershaft3rd gear On countershaft4th gear On countershaftreversegear On sub-shatt4th gear On reverseidlergear On statorshaft(rightside) On stator shaft {statorside) Reverseidlergearshaftholderl.D. Endplay Mainshaft1stgear Mainshaft2nd gear Mainshatt4th gear 1stgear Countershaft 3rd gear Countershaft 4th gear Countershaft Sub-shaft4th gear Reverseidler gear Countershaftreversegear Selectorhub O.D. Mainshaft4th gearcollarlength Mainshatt'lstgearcollarlength Ist g€arcollarflangethickness lvlainshaft C o u n t e r s h a f td i s t a n c e c o l l a r l e n g t h
reversegearcollarlength Countershaft reversegearcollarflange Countershaft thickness 1stgearcollarlength Countershaft '1st Countershaft gearcollarflangethickness Sub-shaft4th gearcollarlength Sub-shaft4th gearcollarflangethickness
SIANDARD {NEW} - 0.9052) 22.980- 22.993(0.9047 35.975- 35.9910.4163- 1.4169) - 1.2595) 31.975- 31.99r(1.2589 30.975- 30.991t1.2195- 1.22011 36.004- 36.017{r.4r7s- 1.4' l80) - 1.4172) 35.980- 35.996(1.4165 2 7 . 9 8-0 2 7 . 9 9 {31 . 1 0 1-61 . 1 0 2 1 ) 3 1 . 9 7 5 - 3 1 . 9 9( 1 . 2 5 8-91 . 2 5 9 5 ) - 1.2595) 31.975-31.991(1.2589 25.991- 26.000(1.0233 1.0236) 2 7 . 9 8 -0 2 7 . 9 9 (31 . 1 0 1-61 . 1 0 2 1 ) - 0.5512) 13.990 11.000(0.5508 - 1.3786) 35.000- 35.016(1.3780 4 1 . 0 0-0 4 1 . 0 1 {61 . 6 1 4-2r . 6 1 4 8 } - 1.49671 38.000- 38.016(1.4961 - 1.4967) 38.000- 38.0161' ].4961 4 1 . 0 0 -0 4 1 . 0 1 (61 . 6 1 4-21 . 6 1 4 8 ) - 1.2998) 33.000- 33.016(1.2992 38.000- 38.0160.4961- 1.4967) 32.000- 32.016fl.2598 1.2605) 18.007,18.020{0.7089 0.7094) 2 9 . 0 0-0 2 9 . 0 1 (31 . 1 4 r -7 1 . 1 4 2 2 ) - ' j.1638) 27.000- 21.021(1.0630 - 0.5683) 14.416- 14.43410.5676 0.08- 0.24(0.003- 0.009) 0.05- 0.13(0.002- 0.005) 0.045- 0.140(0.002- 0.006) 0.1- 0.5 (0.004 0.020) 0.04- 0.15(0.002- 0.006) 0.05- 0.13(0.002- 0.005) 0.05- 0.17(0.002- 0.007) 0.05- 0.r8 (0.002- 0.007) - 0.010) 0.10- 0.2510.004 51.87- 51.90(2.042- 2.043) 49.00- 49.05(1.929- 1.931) ' |.069) 27.00- 27.15(1.0632.5 - 2.6 \2.098- 2.102) 38.97- 39.00 1.534 1.535) 39.02- 39.05 'r.536- 1.537) 39.07- 39.10 1.538- 1.539) 39.12- 39.r5 1 . 5 4 -0 1 . 5 4 1 ) 39.17- 39.20 r.542- 1.543) 39.22- 39.25 1.544 1.545) 39.27- 39.30 1.546- 1.547) - 1.53r) 38.87- 38.90 1 . 5 3 0 '1.532 - 1.533) 38.92- 38.95 14.5- 14.610.57r 0.575) 2.4- 2.6(0.094- 0.102) '14.5 - 14.6(0.57'-l 0.575) 2.4- 2.6(0.094 0.102) 24.0, 24.1{0.945- 0.949} 3 . 0 0- 3 . 1 5{ 0 . 1 1 8 0 . r 2 4 )
SERVICELIMIT Wearor damage
Wearor damage
Wearor damage
*rd"-"g" Wearor damage
Wearor damage Wearor damage Wearor damage Wearor damage
(cont'd)
3-11
Standardsand ServiceLimits Automatic Transmission (cont'dl - Section 14 MEASUREMENT Transmission (contdl
STANDARD{NEW}
Mainshaft2nd gear thrust washer thickngss
Thrust washerthickness Mainshaftball bearing left side Mainshaft 1st gear left side Mainshatt1stgearrightside Sub-shaft4th gearthrustwasherthickness One-wayclutch contactarea l.D. Countershaftlst gear Parkinggear Mainshaftfeedpip€A, O.D.{at 15mm trom end} Mainshaftleed piDeB, O.O.{at30 mm from end) Countershaft leed pipeO.D.(at l5 mm from end) Sub-shaftfeed pip€ O.D.(at 15 mm trom end) Mainshaftsealingringthickness {29mm and 35 mm) MainshaftbushingLO. MainshaftbushingLD. Countershaft bushingLD. Sub-shaft bushingl.D. Mainshattsealingring goovewidlh Regulator
Sealing ring contact area LD.
Shiftingdeviceand parking brakecontrol
Reverseshift fork tinger thickness Parkingbrako ratchetpawl Parkinggoar Throftlo cam slopper heighl Shift fork shaft bore Lo. Shift fork shaft v6lve bore LO. Oil pump gearsideclearanc€ Oil pump gear-to-bodycl€6rance
Servo body Oil pump
Oil pump driveng6arI.D. Oil pump shaftO.D.
3-12 L
4.00{0.1564.05(0.1584.10(0.r604.'15(0.1624.20(0.1644.25(0.1664.30{0.1681.35{0.1704.40(0.172-
0.'t57} 0.159) 0.1611 0.163) 0.' t65) 0.167) 0.169) 0.17r) 0.173)
Wear or damage
3.451.453.432.93-
3.55(0.1361.50(0.0573.50(0.1353.00(0.115-
0.140) 0.059) 0.138) 0.1181
Wearlordamase
II I
Wearor damage
Woaror damage
t
-
- 3.2821) 83.339- 83.365(3.2810 66.685- 66.69812.6254- 2.6259) 8.97- 8.98 {0.353- 0.354) 5.97- 5.98(0.23s0- 0.2354f - 0.3142) 7.97- 7.98(0.3138 - 0.3142) 7.97- 7.98{0.3138 1.980- 1.995(0.0780- 0.07851
t Wearor damage
6,0189.0008.0008.0002.025-
6.045(0.2380) 9.03(0.356) 8.03(0.3r6) 8.03(0.3161 2.08(0.0821
- 0.2374) 6.030(0.2359 9.015(0.3s43- 0.3549) - 0.3156) 8.01s(0.31s0 - 0.3156) 8.015(0.3150 - 0.0811) 2.060(0.0797 35.000 35.025{1.3780- 1.3782) 5.90- 6.00 {0.232- 0.236)
Drive Driv€n
SERVICE t_tMtT
3.974.024.074.124.174.224.274.324.37-
27.0- 27.r (1.063-1.067) - 0.5516) 14.000- 14.010(0.5512 37.000- 37.039(1.{567- 1.4582) 0.03- 0.05 (0.001- 0.002) - 0.0104) 0.210- 0.265{0.0083 0.070- 0.125(0.0028- 0.0049) - 0.5525) 14.016- 1{.034(0.5518 13.980- r3.990{0.5504- 0.5508)
8.95{0.352t 5.95(0.2341 7.95(0.313) 7.9s(0.313) 1.80{0.071)
35.050(1.3799) 5 . 4 O{ 0 . 2 1 3 ) lWear or other t_'--'
37.045{1:4585} 0.07 (0.003) W6aror damage Wearor damage
-
tt [t!'tttltttt Automatic Transmission
MEASUREMENT Springs
Unit of length: mm (in)
Section 14
Regulatorvalve spring A Regulatorvalve spring I Stator r€actionspring Modulator valv€ body Torque convortercheckvalve Cooierch€ckvalve sprang Reliefv6lvospring 2-3 orifice control valvo spring Throttle valve B adiustingsPring Throttle valve B spring Throttle valvo B 6pring Throttle valve I spring 1-2 shift valve sprang 2-3 shift valve spring 3-4 shift valve spring 'lst-holdaccumulator spring 1st accumulatorsprang 2nd accumulalorspdng 3rd accumulatorspring 4th accumulatorsPrang Lock-upshift valve spring Lock-uptiming B valve spring Lock-upcontrol valve spring CPCvalve spring Kick-downvalvo spring 3-2 kick-downvalvo spring Servo control valve spring 4th exhaustv6lve spring Servo orifice controlvalve spring
STANDAND INEWI Wir. Di.. 1.8{0.071} 1.8(0.071) 5.5(0.217) 1.3{0.0s1) 1.1{0.043} 1.1{0.043) 1.r (0.043) 0.9(0.035) 0.7(0.0281 1.4(0.055) 1.4(0.055) 1.1(0.055) 0.9(0.0351 0.9(0.0351 0.9{0.035) 4.0{0.157) 2.5(0.098) 3.6(0.142) 2.8(0.1r0) 2.6(0.102) 0.9(0.035t 0.8(0.0311 0.8(0.031) 1.3(0.051) 1.0(0.039t 1.3(0.051) 0.9{0.035) 1.0(0.039) 0.8(0.031)
o.D. 14.7(0.579) 9.6 (0.378) 26.4(1.039) 9.4 {0.370} 8.4 (0.331) 8.4(0.3:]t) 8.6 (0.3l9) 6.6 (0.2601 6.2 (0.244) 8.5 (0.335) 8.5 (0.335) 8.5 (0.335) 8.6 (0.339) 7.6 (0.299) 7.6 (0.2991 21.5(0.846t 16.3(0.642) 22.0 (0.866) 17.5(0.689) 16.3(0.642) 7.6 {0.299) 6.6 {0.260} 6.6 (0.260) 9.4 (0.370) 6.6 (0.260) 8.6 (0.339) 6.4 (0.252) 7.1(0.280) 6.6 (0.260)
Fr.. L.ngth 88.6 (3.488) 11.011.7321 30.3(1.193) 37.3{1.469) 33.8(1.331) 33.8(1.331) 37.1(1.461t 33.0(1.299) 34.0 fi.339) 41.5(1.634) 41.5(1.63i1) 41.6{1.638} 40.4(1.591) 57,0 12.2111 52.0(2.047) 71.1Q.A23l 't05.4(4.150) 108.9(4.287) 105.2(4.'142) 103.3{4.067) 73.7 12.9021 60.8 (2.394) 39.5(1.5s5) 35.3(1.390) 2a.5(.1221 45.6(1.795t 34.1{1.343) 60.3(2.374) 48.2{1.898}
t{o. of Colh 16.5 2.1 12.1 't2,5 12.5 13.4 14.9 10.5 11.2 12.1 14.5 26.8 E.3 16 + 8.6 15.2 19.'l 21.2 32.0 22.1 25.O 12.1 11.7 17.0 11.5 18.5 33.0
3-13
Standardsand ServiceLimits Differential(Manualtransmissionl
Section 15
M€ASUREMENT
STANDARDINEW) - 0.7093) 81881engine 18.000- 18.016(0.7087 - 0.7094) 8 1 8 C 1e n g i n e 18.000 18.018(0.7087 - 0.0018) Carrier'to-pinion clearance 81881engine 0.0r3 0.045(0.0005 - 0.047(0.0005 0.0019) B18Ct engine 0.0'13 Driveshafvintermediate shaft contactarea LD. 8 1 8 8 1e n g i n e 28.000- 28.021\1.1024-1.10321 818C1engine 28.005- 28.025(1.1026 1.'1033) Carrierto driveshaftclearance 81881engine 0.020- 0.062(0.0008 0.0024) - 0.0034) BlSC'lengine 0.045, 0.086{0.0018 Carrier-to-intermediate shatt clearance B188l engine 0.050- 0.087(0.0020 0.0034) - 0.0044) 818C1engine 0.075- 0.111(0.0030 (0.002 Differential Eacklash 0.05 0.15 0.006) '18.042 - 18.066(0.7103 0.7113) prnrongear t .D . PiniongeaFto-pinion shaftclearance 0.055- 0.095(0.0022 0.0037) Sel ring-to-bearing outerraceclearance 81881engin€ 0 - 0.10(0 0.004) Differentialtaper roller bearing preload - 3 r.0,13.0-18.7) StartingtorqueN.m {kgfcm,lbf.in) Bl8Cl engine 2.1r- 3.04{21.5 Differential
Differential (Automatic transmissionl
Differential prnrongear
o.t aron, 0.1{0.006}
Adjust 0.15{0.006) Adjust Adjust
Section 15
MEASUREMENT Difterential carfl€r
SERVICELIMIT
PinionshaftcontactareaLD.
Pinionshatt contactarea l.D. Carrier-to-oinion clearance Driveshafvintermediate shaft contactare l.D. Carrier-to-driveshatt clearance
Backlash t.D. Piniongear-to-pinion shaftclearance
Set ring-to-bearing outerraceclearance
STANDAROINEWI - 0.7094) 18.000- 18.018{0.7087 - 0.0020) 0.016- 0.052{0.0006 - 1.1033) 28.00s 28.025{1.1026 - 0.0026) 0.025- 0.066(0.0010 0.05- 0.15(0.002- 0.006) 18.042- 18.066(0.7r03- 0.7113) - 0.0037) 0.059- 0.095(0.0023
0 - 0.r5(0- 0.006)
SERVICELIM]T
0.1{0.004) 0.12(0.005) Adjust 0.15(0.006) Adjust
Steering - Section 17 Steeringwheel
Gearbox Purnp Powersteering tluid Power steering belt*
MEASUREMENT play at steeringwheelcircumference Rotational Staninglosd at steeringwheelcircumference N {kgf,lbfl Enginerunning Angle of rack-guide-screwloosenedfrom locked position Pumppressurewith shut-offvalveclosed kPa(kgtlcm,,psi) fluid Recommended Fluidcapacity f (USqt, lmp q0
For overhaul Forfluid change Deflection with 98 N (1okgt,22lhfl betweenpulleys BelttensionN lkgf,lbl) Measuredwith belttensiongauge
STANDARDINEWI 0 - 10 {0 - 0.39) 3 4\ 3 . 5 , 7 . 7 1 20" i 5' 6,400 7.400165 75.920- 1.r00) Hondapowersteeringfluid V 1 . 0 6( 1 . 1 2 , 0 . 9 8 ) 0.79(0.83,0.70) 11.5- 13.5(0.45 0.53)withusedbelt 8.0- 10.010.310.39)withnew belt 390 - 540 (40- 55, 88 - 120)with used belt 740 880175 90. 170 200)with new belt
' When usinga new belt,adjustdetlectionor tensionto new values.Runthe enginelor 5 minutesthen turn it off. Readiustdetlectionor tensionto usedbeltvalues.
Suspension
Unitof length:mm {in)
Sestion 18
STANDARD I]{EWI
MEASUFEMENT Camber a gnment Caster Totaltoe Frontwhe€lturningangle Endplay
A1lc€lbearing
Rim runout(Aluminumwheel) Rim runoutisteelwhgel)
Brake
Front Rgar Front Front Rear Inwardwhe€l Outwsrd wh€el Front Roaa Axial Radial Axial Radisl
-0. 10'1 1. -0' 15' l$igl 1. 10' rt" 0i2(010.081
rN3:i(0.121ff) 36'0o'r 2' 30. 30'
0 - 0.05(0- 0.002) 0 - 0.05{0- 0.002} STANDARD INEWI 0 - 0.7{0- 0.03) 0 - 0.7(0- 0.03) 0 - 1.0{0- 0.0{) 0 - 1.0(0- 0.04)
Section 19 STANDARD {NEWI
MEASUREMENT trrling brake ; oot brake ,adal
Play in strok€at 200 N {20 kgf, 44 lbt) lever lorce Pedalheighl lwith floor mat removod)
To b€ lockodwhen pulled 6 -10 nolchsa
M/T
Freeplay Vastercylinder
Piston-to-oushrodclearance
f,,s4brake
Oiscthickness Disc runout Disc parallolism Padlhickness
Air Conditioning Ar conditioning
Compressor
UMIT SEBVICE 2.0(0.08) 1.5(0.06) 2.0(0.081 r.5(0.061
Front Re6r Front R6ar Front and rear Front Roar
160(6.30) 155(6.50) 1-5(0.04-0.20) 0 - 0.4(0- 0.2) STANDARD INEWI 20.9- 21.1t0.82- 0.83t 8.9- 9.1{0.35- 0.36)
9.5- 10.5{0.37- 0.41} 7.0- 8.0{0.27- 0.31)
SERVICELIM]T 19.0(0.75) 8.0 (0.31) 0.10 (0.004)
0.r0(0.00a) 0.015(0.0006t r.6(0.06) 1.6(0.06)
Scction22
MEASUREMENT Lubricantcapacitymf (ll oz)
Cond€nser Evaporator Lineor hose Receiver Lubricanttype: NO-OlL8{P/N38899- PR7- A0l) Lubricantcapacitym{ (ll oz} Lubricanttvge: ND-O|L8(P/N38899- PR7- A01) Stator coil resistanceat 68'F (20'C)0 plate clearance Pulley-to-pressure
STANDABOIT{EWI
25(5/6) 40t1 1/3) 1 0( l B t 10(1/31 140';u(4-23';")
3.4-3.8 0.5r 0.15{0.02r 0.006) 7.5- 9.5 {0.30- 0.37)with used b€lt*' Compressor Detlectionwith 98 N (10 kgf, 22 lbf) 8.5- 10.5{0.33- 0.41}witht/sodbelt'3 b€h'r betlveenpulleys 5.0 - 7.0 {0.20- 0.28)with new belt Belt t€nsion N (kgf, lbl) 390 - 540 {r0 - 55, 88 - 120}with used beh*' Measuredwith beltlensiongauge 340- 490 {35 - 50, 77 - 110}with used belt*3 740 - 880 {75 - 90, 170- 200)with new belt .1: Whenusinga new bek,adjustdellectionor tensionto new values.Runthe enginetor 5 minulesihen turn it ott. Readiustdetlectionor tension to lsed beh values. '2: 81881engine '3: 818C1engine
3-15
Standardsand ServiceLimits Electrical
Section23 MEASUREMENT
lgnilioncoil
lgnition wire
ll
il
Sparkplug
Tvpe Gap
lgnition timing
At idling " BTDC(Red)- rpm Deflecrionwilh 98 N {10 kgf,22lbll betweenpulleys
Alternatorb€lt'2
Alternator
STANDARD {NEWI
Rat€dvoltago V Primarywinding resistanceat 58'F (20'C)O Secondarywinding resistance6t 68'F (20"C)kO Resistancear 68"F(20'C)k0
0.6- 0.8 12.4- 19.2
25 max. STANDARDINEW} See Section23 B18Blengine 1.0- 1.1{0.039- 0.043}
B18Clengine M/T
SEN$CE UM]T
1.3{0.051)rl
16"r 2. -750r 50(Neurra0 16"t 2"-750r 50|!]or L?.lposition)
Eelt t€nsion N (kgf, lbf) Measured with belt tension gsuge
9.0- 11.0(0.35- 0.43)with us6db6li 6.0 - 8.0 {0.24- 0.31}with new b6lt 340 - 490 {35 - 50, 77 - 110)with used bolt 690 - 880 {70 - 90, 154- 198}with now boh
Ourput l3.5 V at hot A Coil resistance(rotor)at 68"F{20"C}0 Slip ring O.D. Brush length Erushspring tonsion N (kgt, lbf)
STANDARD INEWI 90 2.9 14.4t0.57) r0.5(0.41) 3.210.33, 0.73)
Output Mica depth 0.5- 0.8(0.02- 0.03) Commulatot runout 0 - 0.02(0- 0.0008) - 1.r81) CommutatorO.D. 29.9- 30.0(1.177 Brushlength 15.0- 15.5(0.s9- 0.61) - 5.3) Brush spring tension (new) N lkgt, lbf) 17.7- 23.5fi.8- 2.4,4.0 *1: Do not adiust the gap, replacespark plug it it is out of spec. *2r When using a new belt, adjust d€tl€ctionor tension to new valu€s.Run tho enginelor 5 minutesthon turn it off. Readiustde{lection or tensionto usodbeltvalues.
SENUCEUMTT
tnnro.rrr 1.5(0.06t
Staner
0.2(0.0081 0.05t0.@2) 29.0(1.142) 10.0(0.39)
DesignSpecifications ]TEM :' vENSTONS
3 DOOR 4 DOOR
Overalllength Ov€rallWidth OverallHeight
3 DOOR 4 DOOR 3 DOOR 4 DOOR
Wheelbase
,rerght(usA) 'le,ght {CANADA)
:\GINE
TrackF/R GroundClearance SeatingCapacity WeightRating{GVWR) crossV€hicle GrossVehiclsWeightRating{GVWR) 8 1 8 8 1e n g i n e Type 818C1engine
CylinderArrangement BoreandStroke Displacement Ratio Compression
L!bricationSystom OilPumpDisplacement WsterPumpDisplacement FuelRequired
8 1 8 8 1engrne 818C1engane 8 1 8 8 1engrne B18CI engine 8 1 8 8 1engine B18C1engine 8 1 8 8 1engine 8 1 8 C 1engine
8 1 8 8 1engrne B18C1 engrne 8 1 8 8 1engine B18C1engine 9 1 8 8 1engine 818C1engine
CLUTCH
Typo NormalOutput NominalVoltage HourRating Directionof Rotation Weight ClutchType
M/T
TRANSMISSION
Area ClutchFacing Transmission Type
M/T
STARTER
PrimaryReduction '1: At 6,000enginerpm '2: At 7,600enginerpm
ENGLISH METRIC 172.1in 4.380mm 178.1 in 4.525mm '1,710 mm 67.3in 1,335mm 52.6in 1,370mm 101.2 in 2,570mm in 103.1 2,620mm 't,475/1,470 mm 5|8.1/57.9 in 150mm Four(3 DOOR)Five (4 DOOR) 3,680lbs
NOIES
1,670kg
4-strokeDOHC Water-cooled, gasoline engine Watercooled,4-strokeDOHC VTECgasoline engine Inline4-cylinder, transverse 3.19x 3.50in 81.0x 89.0mm 3.19x 3.43in 81.0x 87.2mm 112cu-in 1,834 cm3(mf) 110cu-in 1,797 cm3(m{) 9.2:1 10.0: 1 Eeltdriven,OOHC4 valvepercylinder Beltdriven,DOHCVTEC 4 valvepercylinder Forcedandwet sump,trochoidpump 50, {53USqt, 44lmpqt)/minute'l 71 f {75USqt, 62 lmp qt)/minute" 140f (148USqt, 123lmpqt)/minute*! 140f (148USqt. 123lmpqt)/minute*' gasoline with86 Pump UNLEADED OctaneNumb€ror higher gasoline wilh Premium UNLEADED 91 PumpOctaneNumberor higher Gearreduction 1 . 4k W 12V 30 seconds Clockwiseasviewedlrom g6arend 3.7k9 8.3lbs | spring Singleplatedry,diaphragm Torq!e converter 31 sq-in 203cm' I 5-speedforward,1 reverse Synchronized Electronically controlled 4-speedautomatic.1 rcverse Diract1 : 1
(cont'd)
3-17
DesignSpecifications {cont'd} lTEM TRANSMISSION
M E T R I C I € i I G L I S H I N O T E S
Type Enginetypo 1st 2nd 3rd 4th 5th Rov€rs€
G6arRatio
Fin6l Reduction
Geartype Gear ratio
Type
Manual transmission 81881 818C1 |
3.230 r.9(X) 1.360 1.034 0.'t87 3.000
3.230 1.900 1.269 0.966 o.711 3.000
Singlehelicalge.r 4.266 4.400 Automatictransmission
'l6t
GearRatio
2.722 1.464 0.97s 0.638 1.954
znd 3rd 4th Revelse FinalR€duction AIR CONDITIONING
Cooling Capacity Compr6ssor
Cond6ns€r Evaporator Blower
TemperatureControl CompressorClutch Refrigerant STEERING SYSTEM
SUSPENSION
Goartypo Gear ratio
Type OverallRatio Turns, Lock-to-Lock SreeringWheel Dia. Type
14,166BTU/I swash-plare/NIPPoNDENSO 10 150ml /rcv | 9.15cu-in/r€v 7,600rpm 140mf 1-2Blloz | I l.;3 tmpoz (P/N38899- PR7- A01) ND-O|L8
3,570Kcal/h Type/Make No. ol Cylinder CaPtcity Max. Spsed LubricantC6pacity Lubricrnt Type Type Type Type Motor Input SpeedContro Max. Capachy Type PoworConsumption Type Ou.ntity
Front Roar
ShockAbsorb€r,Front and Rear
3-18
Singlehelic6lgoar 4.357
Corrugatedfin Corrugatodtin Siroccotan
200w12 v 4-speed 450 m3/h 15,900cu lvh | Airmix type Dry, singlo plate, poly-V-b€ltdriv6 40 W max./12V at 68"F{20'C) (R-134a) HFC-134a zoo-Ss 24.7-l.aoe I Power assisted,rackand pinion 16.1 2.98 15.0in 380 mm | Independentdouble wishbono, coil spring with st6bilizer Independontdouble wishbong. coil spring with stabilizer Telescopic,hydraulic nitrogen gas-tilled
ITEM WHEEL ALIGNMENT
M E T R I C I E N G L I S H I M ) T E S
Camber
Front Rear Front Front Rear
Caster TotalToe BRAKESYSTEM
Type PadSurfaceArea ParkingBrake
TIRE
Size
Front Rear Front Rear Type Front and r€ar SpareTire
ELECTRICAL
8attery Starter Alternator Fuses In Under-dashFuse/RelayBox In Under-hoodFuse/RelayBox In Under-hoodABS Fuso/RolayBox Headlights FrontSideMarkerLights FrontTurn SignauParkingLights RearTurn SignalLighls Stop/Taillights High Mount BrakeLight'5 FearSideMarkerLights Back-upLights LiconsePlateLights CeilingLights CargoArea Lights (3 DOOR) TrunkLightsl4 DOOR) Spotlights GloveBox Light GaugeLights IndicatorLights llluminationand PilotLights HeaterllluminationLights
High
omm In 2 mm
-0.10' -0.45' 1'1o' oin | ln 0.08in I
Power-assistedselt-adiusting ventilateddisc PoweFassistedself-adjustingsolid disc io.u cm. x z | /,/5 so tn x z 21.0cm, x2 | 3.26sq in x 2 Mechanicalactuating,reartwo wheel brakes P195/60R14 858*1 P195/55R15 84V*2 T115t0D14*3 T135/70O15.4 I2V-36AH6HR '12V -'1.4 kW 12V-90A 7.5A, 10A, 15A, 20 A, 30 A 7.5 A, 10 A. 15 A, 20 A, 30 A, 40 A 50 A, 100A 1 0 A ,1 5 A , 2 0 A , 4 0 A 12V-6sW{HB3} 12V-55W(HB4) 12V-3CP 12V -32n CP 12V -32 CP 12V -32n CP 12V-21W 12V-3CP 12V -32 CP 12V-8W 12V-5W 12v-3.4W 12V-3.4W 12V-5W 12V-3.4W 12V-3.4W v - 0.84w, 0.91w, 1.12W, 1.r W, 3 W 12 V - 0.84W. 0.91W, 1.4W. LEO 12V-1.4W
sAE 168 sAE1157 sAE 1't55 sAE1157 sAE7440 sAE 168 sA€ 1156
*1: RS,LS *2: GS-R *3: RS *1: LS,GS-R *5: Excepthigh mount brakelight installedin rcar spoiler.
3-19
Il I il
Body Specifications 3 DOOf,:
Unit:mm (in)
. DOOR:
Unit mm {inl
3-21
Maintenance Points Lubrication MaintenanceSchedule
.........4-2 ." 4'4
LubricationPoints For the detailsol lubricationpoints and type of lubricantsto be spplied,reter to the illustratedindex and variouswork procedure(such as Assembly/Reassembly, Replacement,Overhaul,Instatlation,etc.) containedin each section. No. I
LUBRICATIONPOII\ITS
LUBRICAI\IT API ServiceGrade:Use SG or SH "Energy Conserving II" grade oil. The oil containermay also displaythe API Certification s€al shown below. Make sure it says'For Gasoline Engines.' SAE Viscosity;See chan below.
Engine
Transmission
Manual Automatic
API Service Grades: SF or SG SAE Viscosity: 1O W-3O or 1O W-4O Honda Premium Formula or DEXRON@II Automatic transmissionfluid
3
Brakeline (lncludesAnti-lockbrake linel
Brakefluid DOT3 or DOT4
4
Clutch line
Bfake tluid DOT3 or DOT4
Power steeringgearbox
SteoringgreaseP/N 08733-BO7OE
Releasefork (Manualtransmission)
Supe. High Temp Urea Grease(P/N O8798*9OO2)
Throttle wire end {Dashboardlower Danelholel C.uisecont.ol actuatot wire end {Dashboardlower Danelholel
Siliconegrease
8
I Throttle cable end (Throttlelinkl 1 0 Cruisecontrol actuatorcable end lActuator link)
'I 'l
17 18
BrakemastercvlinderDushrod Clutch mastercylinderpushrod Enginehood hingesand enginehood latch Batte.v terminals Fuel fill lid Hatch hingesor trunk hinges Door hinges.upper and lowet Door oDendetent
19
Rear brakecalioers
Rust-p,eventive agant
20
Power steering system
Honda power steering tluid-V
21
Air conditioningcompressor
Retrigerantoit ND-otL8 |PlN 38899-pR7-A01) (For Relrigerant:HFC-134a(R-134a))
12 13 14 15 to
.Multi-purposegrease
-20 -30
API CERTIFICATIONSEAL
0 -20
20 -'to
r}() o
60 10
ao 20
Recolnmendodengine oil Engine oil viscosity tor ambient tgmpelalure rangos
30
loooF 40"c
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Engine E n g i n eR e m o v a l / l n s t a l l a t i o. .n. ' ' . . . . . . . .5 - 1 C y l i n d e rH e a d / V a l v eT r a i n . . ' . . . . . . . . . . . .6 - 1
......7-1 EngineBlock.... .........8-1 EngineLubrication System ...... 9-1 IntakeManifold/Exhaust .......1O-1 Cooling
EngineRemoval/lnstallation .".....5-2 S p e c i aTl o o l s . . . . . . . . ..."........ 5-3 EngineRemoval/lnstallation ..' 5-16 Mount/BracketTorque
SpecialTools
ru il
Rst. No.
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I
Tool Numbor 07MAC-SLOO200
Dascription Ball Joint Remover,28 mm
Oty
Pag€ R€terenco
EngineRemoval/lnstallation 2.
@ a
Removethe strut brace
Make surejacks and safety stands aro placed ploperly and hoisl brackots arg attachod to the correct positions on tho engine (se€ ssction 1). a Mak€ sure tho car willnot roll off stands and tallwhile you are wotking under it'
8 x 1.25mm 24 N.m (2.4 kgf.m, 17 rbt.ft)
CAUTION: a Use fendet covals to avoid damaging painted sudaces. r Unspecified itsms alo common a Unplug tho widng connectots carefully while holding the couplor and tha connector portion to avoid oamage. a Mark all wiring and hoses to avoid misconnection. Also, be sulo that thsy do not contact other wiring or hoses, or interfere with oth€l parts. NOTE: Anti-theft radioshave a coded theft ptotection circuit. Be sure to get the customer'scode numberbeJore - Disconnectingthe batterY. - Removingthe No. 32 (7.5 A) fuse from the underhood tuse/relaybox. - Removingthe radio Atter service,reconnectpower to the radio and turn it "CODE" is displayed,enterthe cuson. Whenthe word tomer's 5-digit code to restoreradio operataon. 1.
Removethe hood (seesection 2O).
STRUTERACE
Disconnectthe batterynegativeterminallirst. then the positiveterminal. Disconnectthe batterycablesfrom the undel-hood fuse/relaybox and under-hoodABS fuse/relaybox.
BATTERYCABLES
6 x l.O mm 9.8 N.m (1 .O kgf'm, 7.2 rbl.ftl
{cont'd)
5-3
EngineRemoval/lnstallation (cont'd) Removethe intakeair duct, air cleanerhousingassemblv and the bracket.
m
7.
Removethe enginewire harnessconnectoEon the right side of enginecompartment.
6 x 1 . Om m 9.4 N.m {l.O ksf.m, 7.2 tbf,ftl
6 x'l.Omm 9.8 N-m ll.0 kgt.m.
8.
Relievefuel pressureby looseningthe servicebolt on the tuel filter about one turn {see section 1 1). oo not amoke whito working on tho @ fuel system. Keepopen flame away trom wo.k arsa. Drain fuel only into an approved container. CAUTION: a Beforedisconnoctingany fu€l line. reliovothe tuol pressule as doscribed above. a Placea shop towel ov61the fu6l filter to prevont prossurizedtuel from spraying ovel tho aogine.
Removethe evaporativeemission(EVAp) control canisterhose and vacuum hose.
VACUUM HOSE
9.
Removethe fuel feed hose.
SERVICE BOLT 15 N.m (1.5 kgt.m,11 tbt.ftl
THROTTI.EBODY
BAITJO EOLT 33 N.m 13.4 kgt.m, 25 tbt.ftt
1O. Removethe brake boostervacuum hose and fuel return hose. 6 x 1 . Om m 11 N.m {1.1kgl'm, 8.O rbt.ltl
BRAKEBOOSTER VACUUMHOSE
' t 2 . Removethe enginewire harnessconnectors,terminal and clamps on the left side ot engine comoartment. 6 x 1.0 mm 9.8 N.m {1 .O kgf.m, 7.2 tbt.ftl
ENGINEWIRE HABNESS
BETURNHOSE
' t1 . Removethe throttlecableby looseningthe locknut. linkage. then slipthe cableendout of the accelerator NOTE: a Take care not to bendthe cablewhen removing it. Always replaceany kinkedcable with a new one, a Adjust the throttle cable when installing(seesect i o n 11 ) .
13. Removethe cruisecontrol actualor.
8 x 1.25mm 24 N.m (2,4 kgl.m, 17 lbf.Irl
CRUISECONTROL ACTUATOR
LOCKNUT
AOJUSTINGNUT
5-5
EngineRemoval/lnstallation (cont'd) 1 4 . Removethe engineground cable at the body end. Removethe adiustingbolt and mountingbolt, then remove the power steering (P/Sl belt and pump. a Do not disconnect the P/S hoses.
17. (Manusl transmission)Remove the clutch slave cylinder and pipe/hose assembly. a Do not disconnectthe pipe/hoseassembly. 6 x 1.Orl|m ll
N.m { 1.1 kgt.m,
SLAVE CYLINDER
8.0
8 r 1 . 2 5m m 24 N.m (2.4 kgf.m. 17 lbl.ftl
8 x 1.25mm
24 N.m {2.4 kgl.m, 17 lbt.ftl
6. Loosenthe idlerpulleybolt and adjustingbolt, then removethe air conditioning(A/C)compresso.belt.
18. Removethe transmissionground cable and hose cramp.
6 x 1 . Om m 1l N.m 11,1 kgt.m, I tbt.ftl
IDLERPULLEYBOLT 10 x 1.25mm 44 N.m 14.5 kgt.m, 33 lbl.ftl
5-6
A/C COMPRESSORBELT
19. Removethe radiatorcap.
25. Removethe upperand lower radiatorhosesand the heater hoses.
u"" care whan removing the ladiatol @@ cap to avoid scaldingby hot enginecoolant ol ateam.
UPPERRADIATOR
20. Raisethe hoist to full height. 21. Removethe front tires/wheelsandthe splashshield.
LOWERRADIATOR HOSE 6 x 1 . Om m 9.8 N.m (1.0 kgf'm' 7.2 tbf.ft)
26. (Automatictransmission)Removethe ATF cooler hoses.
2 2 . Drainthe enginecoolant (see page 1O-5). a Loosenthe drain plug in the radaator. Drainthe transmissionoil or fluid. Reinstallthe dtain plug using a new washer.
2 4 . Drainthe engineoil. Reinstallthe drain plug using a new wasner. CAUTION: Do not overtighten tho drain plug.
HOSE
{cont'd)
5-7
*l
EngineRemoval/lnstallation (cont'dl 27. Removethe radiatorassembly{see page 1O-4),
8188l engine:
28. Removethe A/C compressor. a Do not disconnectA/C hoses. 8 x 1.25mm 24 N.m 12.4 kgf.m, 17 tbt.trl
GASKET Replace.
GASKET Replace. SELF.LOCKINGNUT I x 1.25mm 16 N.m (1.6kgt.m, 12 tbf.ft) Replace.
8 x '1.25mm 24 N.m t2.4 kgf.m,17 lbl.ftl
29. Disconnectthe heatedoxygensensor(HO2Slconnector, then removeexhaust pipe A. B'l8Cl engine:
I x 1.25mm 24 N.m (2.4 kgf.m, 17 rbt.ftt
Replace.
5-8
30. Removethe shift rod and extensionrod {M/T).
Ho2s CONNECTOR
SELF-LOCKING NUT 8 x 1.25mm 1 6 N . m 1 1 . 6k g f . m , 12 tbl.ftl Replace.
10 x 1.25mm 54 N.m (5.5 kgl.m, 40 tbt.ttl Replace.
EXHAUST PIPEA SELF 1 0 x 1 . 2 5m m 54 N.m (5.5 ksf.m.4O lbf'ltl Replace.
I x 1.25mm 22 N-m 12.2 kgf.m, '16 lbf.ftl
SHIFTROD
31. Remove the shift cable ( A / T ) .
I x 1.25mm 22 f.m 12.2 kgl'rn' 16 tbl.ftl
34. Removethe driveshatls.
SHIFT CABLE
CAUTION: a Do not pull on tho ddv$halt, tho CV ioint mav como apan. a Uso caro whsn prying out tho assombly. Pult it slraight to avoid damaging th6 differantial oil soal or intormodiato shaft dust seal. NOTE: Coat all precisiontinished surfaces with cleanengineoil or grease.Tie plasticbags over the driveshaftends.
CONTROL LEVER
SHIFT CAALE
covER
locx usiea Replace.
6 x 1.0 mm 14 N.m t1.4 kgf.m, 10 lbl'ftl
32. Removethe dampertork. 3 3 . Disconnectthe suspensionlower arm balljointsusing the specialtool. Referto section 18 tor the proper procedure. NOTE: Adjust the tool so the iaws are parallelto each other.
12 x 1.25mm
REMOVER28 mm oTMAC-S100200
(cont'd)
5-9
I
EngineRemoval/lnstallation (cont'd) 35. Lower the hoist.
I
I
I I I
36. Attach the chain hoist to the engine.
37, Removethe left and right front mounts and brackets.
39. Removethe side enginemounr. 1 0 r 1 . 2 5m m Replace.
WASHERS Replace. SIDE ENGIITE
MOUNTBOLT LEFT FRONT MOUNT 12 t 1.25nn 59 N.m {6.0 kgt.m, 43 lbf.trl Replace.
40. Removethe transmissionmount TRA SM|SS|OI{ MOUNT
MOUNT/BRACKET 38. Removethe rear mount bracket, 1 2 r 1 . 2 5m m
59 N.m (6.0 Replace.
43 rbf.ftl REARMOUNT
12 r 1.25m|n 59 N.m {6.0 kgt.m, 43 tbt.frl Replace.
41. Checkthat the engineis completelyfree of vacuum hoses, fuel and engine coolant hoses, and electrical wi.ing. 42. Slowly raisethe engineapproximately150 mm (6 in), Check once againthat all hosesand wires are disconnected from the engine 43. Raisethe engineall the w8y and removeit trom the car.
14 x 1.5 mm 118 t{.m (12.O kgt.m,86.8 lbl.ft} R6place.
(cont'dl
5-11
EngineRemoval/lnstallation
SIDE ENGITIE MOUNT
5-12
Install the engine side mount, then tighten the bolt/nutson the engineside. Leavethe mount bolt loose.
Engine Installation Installthe enginein the reverseorder of removal. Reinstall the mountbolts/nutsin the followingsequence. Failureto tollow theseproceduresmay causeexcessive noise and vibration,and reducebushinglife. 1.
10 x 1.25mm 52 N.m {5.3 kgf.m, 38 rbf.Itl Replace.
Install the transmissionmount, then tighten the side.Leavethe mount bolt/nutson the transmission bolt loose.
A/T: 12 x 1.25mm 64 N.m (6.5 kgt.m, 47 rbf.ft)
3.
Tightenthe mount bolt on the transmissionmount.
A/T:
M/T: 1 2 x 1 . 2 5m m 64 N.m 16.5 kgl.m, 47 tbt.frl 1 2 x 1. 2 5 n n 74 N.m (7.5 kgl.m, 54 rbf'ftt
M/T:
1 2 x 1 . 2 5m m 74 N.m (7.5 kgt.m, 54 tbt.ftl
{cont'd)
5-13
EngineRemoval/lnstallation (cont'dl 4.
Tightenthe mount bolt on the side enginemount.
6.
Installthe right front mount/bracket,then tighten the bolts in the numberedsequenceas shown (O-@). ' 1 . 2 5m m @ 10 x 44 N.m (4.5 kgt'm, 33 tbt.fr)
A/T:
m'
.tE
12 x 1.25mm 74 N.m (7.5 kgf.m, 54 lbt.ttl O 12 x 1.25mm 64 N.m 16.5 kgt.m,47 lbf.ftl Replace.
5.
Installthe rearmount bracket,then tightenthe bolts in the numberedsequenceas shown {@ @).
M/T: @
' 1 0x 1 . 2 5 m m 44 N-m (4.5 kgf.m,
@ 12 x 1.25mm 59 N.m {6.0 kgf'm, 43 lbl'It) Replace.
12 r 1.25mm 59 .m 16.0 kgl.m,
O 1 2 x 1 . 2 5m m 83 N'm (8.5 kgf.m,61 lbt.frl
Insrallthe left front mount,then tightenthe bolts in the numberedsequenceas shown (O-@),
a Check that the sp.ing clip on the end of each driveshaftclicks into place. GAUTION: Uso oow spring clips.
O 12 x 1.25 ]n]n 83 N.m 18.5kst.m,61 lbt.ftl Replace.
@ 1 2 r 1 . 2 5m m 59 N.m {6.0 kgl.n, 43 tb{.ftl Replace.
a Bleedair trom the coolingsystem at the bleedbolt with the heatervalve open (see page 10-5). a Adjust the th.ottle cable (see section 1 1). a Check the clutch pedaltree play lsee section 12). a Check that the transmission shifts into gear smoothlv, a Adiust the tension of the following drive belts. Alternatorbelt {s€e section 23). P/S pump belt {see section 17). A/C comoressorbelt (seesection 22). a Inspecttor fuel leakage(see section 1 1). . After assemblingfuel line parts, turn on the ignition switch (do not operate th€ starter) so that the Juelpump operatesfor approximat€lV two secondsand the tuel line pressurizes. Repeatthis operation two or three times and check for fuel leakageat any point in the fuel line.
@ 1 0 r 1 . 2 5m m
44 N.m (4.5 kgf.m, 33 lbt.ftl
(cont'd)
5-15 k-
Mount/BracketTorque Mount and BracketEolts/NutsTorque Valve Specification:
il
TRANSMISSION MOUNT:
I
I I
SIDEENGINE MOUNT:
Torqus Spocifications: A : 1 0 x 1 . 2 5m m 59 N.m (6.O kgf.m, 43 lbf.ft) B: 12 x 1.25 mm 59 N.m {6.0 kgt.m. 43 lbt.ft} Reolace. C: 14 x 1.5mm 1 1 8 N . m { 1 2 . Ok g t . m , 8 6 . 8 l b t . t t } Replace. D: 12 x 1.25 mm 74 N.m {7.5 kgf.m, 54 lbf.tt} E : 1 2 x 1 . 2 5m m 64 N.m (6.5 kgf.m, 47 lbf.ftl F: 10 x 1.25 mm 52 N.m {5.3 kgl.m, 38 lbt.ft} Replace. G : 1 0 x 1 . 2 5m m rt4 N.m (4.5 kgf.m, 33 lbf.ft) H : 1 2 x 1 . 2 5m m 83 N.m (8.5 kgt.m. 61 lbl.ft) l r 1 2 x 1 . 2 5m m 64 N.m (6.5 kgf.m, 38 lbf.tt) Reolace.
LEFTFRONTMOUNT:
/> {cont'd)
5-17
Mount/BracketTorque (cont'd) ALTERNATORBRACKET
REARSTIFFENER
10 x 1.25mm
'1.25mm M/T: 12 x 57 N.m 15.8 kgf'm, 42 rbf.ft) A/T: 10 x 1.25mm /14 N.m {4.5 kgf.m, 32 tbt.ftl
8x1.25mm 24 N.m 12.4 kgf'm, 17 tbt.ftt
SIDEENGINEMOUNT BRACKET
lO r 1.25mm 54 N'm (5.5 kgl.m, 40 tbf.ft)
P/S PUMP BRACKET 1 0 x 1 . 2 5m m 44 N.m (4.5 kgf'm, 33 lbf'ft| FRONTSTIFFENER (B18Cl engin€onlyl
t-*i; f--^,c*;"*".*l q I -4M
5-18
-
Ghinein"onvt
ddv
' 1 1N . m ( 1 . 1 k g l ' m , 8 O l b f ' t t )
'12 x 1 .25 mm 57 N.m 15.8 kgt.m, 42 tbf.fr) 8 x 1.25mm 24 N.m (2.4 kgf.m, 17 tbf.ft)
HEAT INSULATOR (818C1
10 x 1.25mm 44 N.m {4.5 kgf.m, 33 rbr.ftt
10 x 1.25mnl 44 N.m (4.5 kgf.m, 33 rbr.tt)
CylinderHead/ValveTrain 8 1 8 8 1e ngine .............6-2 SpeciafTools Valve Clearance ............6-3 Adiustment ValveSeals Replacement(cylinderhead removalnot required) ..................... 6-5 ......6-27 Reconditioning gelt Timing 6-7 lllustratedIndex ............................... .............. 6-9 Inspection 6-9 TensionAdiustment ........................ .................6-10 Removal .............6-12 Installation CrankshaftPulleyBolt .........6-8 Replacement
SpecialTools -
t Ref.No.
I
Tool Numbrr
o o
07GAD- PH70100 07JAB- 001020A OTMAB_ PY3O1OA
o
07757- PJ10toA 07947- 6570100 07984- 657010C
@ @
Oty
Ocacription ValveGuidelnstaller HolderHandle PulleyHolderAttachment,HEX50 mm, Offset ValveSpringCompressorAttachment ValveGuideDriver,6.6 mm ValveGuideReamer,6,6 mm
I o
@
o
e:=-4-b4altltgt
r-l-:ff:-b
@
I
Prgc R.terencc
1 1
6-8
1 1 1 1
6-8 6-22 6-25,26 6-26
ValveClearance Adjustment Set the No. 1 piston at top dead center(TDC)(see p a g e6 - 1 2 ) ." U P " m a r k o n t h e p u l l e ys h o u l db e a t the top, and the TDC grooveson the pulley should align with the TDC groove on timing belt back cover.TDC mark (paintedwhite) on the crankshaft pulley should align with pointeron the timing belt towercover.
NOTE: . Valves should be adjustedcold; at a cylinder head temperatureof lessthan 100'F(38"C). Adjustmentis the same for both intakeand exhaust valves. . After adjusting,retorquethe crankshaftpulleybolt to 177N.m (18.0kgim, 130lbf.ft).
2.
1.
Number 1 Diston at TDC:
Removecylinderheadcover.
ADJUSTINGSCREWLOCATIONS:
"UP" MARKS
INTAKE
TDCGROOVES
EXHAUST
TDCMARKS lPeintedwhitel
CRANKSHAFT PULLEY
6-3
ValveClearance Adjustmentlcont'dl a
Adjustvalveclearances on No. 1 cylinder.
7.
lntlkc: 0.08- o.l2 mm (o.(Xxl- 0.qr5 in) Exhru3t 0.16- 0.20 mm {0.0,05- 0.008in} 4.
Loosen lhe locknut and turn the adjusting screw until feelergaugeslidesbackand fonh with a slight amountof drag.
R o t a t et h e c r a n k s h a f t1 8 0 ' c o u n t e r c l o c k w i s €t o bring No. 4 piston to TDC.The'UP" mark should be pointing straight down. Adjust valves on No. 4 cylinder.
Numb€r il piston at TDC:
LOCKNUT9x0.?5mm 25 N.m 12,5kgf.m, 18lbt'ft|
"UP'MARKS
Tightenthe locknutand recheckclearanceagain. Repeatadjustment if necessary. 6.
Rotate ths crankshaft 180" counte.clockwise (camshaftpulleyturns 90'). The "UP" mark should be on the exhaustside.Adjustvalveson No. 3 cylinder.
I{umbcr 3 pidon !t TDC:
8.
Rotate the crankshaft 180' cou nie rclockwise to bring No. 2 piston to TDC.The "UP" mark should be on the intakeside.Adjust valveson No. 2 cylinoer.
Numbor 2 pirton !t TDC:
-UP" MARKS
.UP' MANKS
EXHAUST CAITISHAFT PULI,IY
INTAKECAMSHAFT PULLEY
NOTE:Referto page6-31when installingcylindorhEEd cover.
ValveSeals (cylinderheadremovalnot requiredl Replacement NOTE: Cylinder head removal is not required in this procedure. The procodureshown below applieswhen usingthe inc a r v a l v e s p r i n g c o m p r e s s o r( S n a p - o nY A 8 8 4 5w i t h Y AAA$-2A 718"attachment). whcn u3ing this tool, a: with any tool, @@ always u!€ agproved cyr Protcction. Using th. right tool for cach iob hclps incraa3. produstivity whilo 3ltrgu8rding tool!, cquipmcnt lnd the u3c1' 1. Turn the crankshaftso that the No. I and the No' 4 pistons are at top d€ad center (TDC). 2.
Removethe cylinderheadcover.
3.
Removethe distributor.
4.
Loosen and disconnectthe timing belt from the c8mshaft pulleys.
5.
Select the 7E in. diameter long compressor attachment and fasten the attachmentto the No. 4 hole of the leverarm with the speedpin supplied. Positionthe pistonat TDCand insertan air adaptor into th€ spark plug hole. Pump air into the cylinder to keepthe valv€closedwhile cgmpressingsprings and removing the valve keepers. Position the lever arm under the cross shaft so the lever is psrpendicularto the shEft and ths compressor attachment rests on toD of the rstainer for th€ spring being compressed.Use the rear position slot on the leveras shown. NOTE: Put shop towels over the oil passag€sto preventthe valve keepersfrom falling into the cylinder h€ad.
OIL PASSAGE
Removethe camshaft holde, bolts, then r€move the camshaft holder,the camshaftand rocksr arms.
lntakc V!lv6 Sclls 6. Usingthe 6 mm bolts suppliedwith the tool, mount the two up.ights to the cylinder head 8t the end camshaftholde.s.The uprightsfit as shown. 7.
Insortthe cross shaft through the bottom hole ot the two up.ights.
OIL PASSAGES
(cont'd)
6-5
ValveSeals Replacement(cylinderhead removal not required) (cont'dl '11.
-
Using a downward motion on the lever arm. compressthe valvespringand removethe keepersfrom t h e v a l v e s t e m . S l o w l y r e l e a s ep r e s s u r eo n t h e spring.
21. Positionthe lever arm unde. the crossshaft so the lever is perpendicular to the shaftand the compressor attachmentrests on top of the retainerfor the spring beingcompressed.Usethe rear positionslot on the leveras shown.
Repeatstep l1 for the othervalvein that cylinder. Removethe valveseals(seepage6-22). '14. Installthevalve seals(seepage6-23).
N O T E :P u t s h o p t o w e l s o v e r t h e o i l p a s s a g e st o preventthe valvekeepersfrom fallinginto the cylinder head. OIL PASSAGE
Installthe springs,the retainersand the keepersin reverseorder of removal. 16. Repeatsteps9 to l5 for the otherthreecylinders. ExhaGt Valvs Soals 17. Usingthe 6 mm bolts suppliedwith the tool, mount t h e t w o u p r i g h t st o t h e c y l i n d e rh e a d a t t h e e n d camshaftholders.The uprightsfit as shown. 18. Insert the cross shaft through the bottom hole of the two uprights.
Using a downward motion on the lever arm, compressthe valvespringand removethe keepersfrom t h e v a l v e s t e m . S l o w l y r e l e a s ep r e s s u r eo n t h e spring.
1 9 . Selectthe 7/8 in. diameter short compressorattachment and fastenthe attachmentto the No. 4 hole of the leverarm with the speedpin supplied. 20. Positionthe pistonat TDCand insertan air adaptor into the spark plug hole. Pump air into the cylinder to keepthe valveclosedwhile compressingsprings and removingthe valvekeepers.
Repeatstep22 for the othervalvein that cylinder. Removethe valveseals(seepage6-22). Installthe valveseals(seepage6-23). Installthe springs,the retainersand the keepersin reverseorderof removal. 27. Repeatsteps20 to 26 on the otherthreecylinders. NOTE:Relerto page 6-31when installingcylinder neaocover.
Timing Belt lllustratedIndex NOTE: . Referto page6-12for positioningcrankshaftand pulleybeforeinstallingbelt. . Mark the direction of rotation on the belt before removing. . Replacethe rubbersealstor oil leakag€betweenthe cylinderheadand cover. a Do not uss the middle cover and lower cover for storing itsms disassembled. . Cleanthe middlecoverand lowercover beforeinstallation. CAPNUT 6xl.0mm 9.8N'm (1.0kgf.m,7.2lbtft) WASHER
\o
Replacowhen damaged or deteriorated. CYLINDERHEADCOVER Referto pago6-31when installing. RUBBERSEALS Replacewhen damaged or deleriorsled.
8 x 1.25mm 37 N.m 13.8kgl.m,27 lbf'ft) BACK OOVER
AD.'USTINGBOLT 10x t.25mm 5/rN.m15.5kgl.m,,o lbtft) Foradjustrnent only, do not r€move, COVER 6x1.0mm 9.8 N'm (1.0kg{.m.t.2 lbf.tt}
6x1.0mm 9.8 N,m 11.0kg{.m, 7.2 lbl.frl TIMIMi BELT Inspection,page 6-9 Adlustment,pago 6-9 page6"10 Replacement,
ALTERNATOR BELT Adjustm6nt, Soction23
lnstallwithconcave surfacefacing in. Clean.
TIMINGBELT DBIVEPULLEY Removeany oil and clean,
LOWEn COVER lnstall with concave surfacefacing out, Removeany oil ano ctean.
NOTE:When installinga new crankshaftand/ornew bolt: O tightenthe crankshaftpulleybolt to 196N'm (20.0kgf'm,145lbf'ft), O loosenbolt, O retightenit to 177N.m (18.0kgt.m,130lbf'ftl.
CRANKSHAFT PULI"EY Romov6any oil and clgaaon thg timing bolt guide plato side.
BOLT
'14x 1,25mm lt7 t{.m 118.0kgl.m, 130lbtftl Replacsmenl,page 6-8
6-7
CrankshaftPulleyBolt
It
Replacement NOTE: . Crankshaftpulleybolt sizeand torquevalue: 1 4x 1 . 2 5m m 177N.m (18.0kgt.m.130lbf.ft) . When installinga new crankshaftand/or new pulley bolt:
When installingthe bolt, lubricatethe threads and flang€with engin€oil, but don't lubricatethe washe. and pulley.
Q tiglten the pulleybolt to 196 N.m (20.0kgf.m,145 tbnft). O loosenthe bolt, O retightenit to 177N.m (18.0kgf'm.130lbf.ft).
Don't lubricat€washer.
HOI-DERHANDII o'JAB -oo1020A
PULI.TY HOI.I'€R ATTACHi'ENT, HEX50 mm. OFFSET
- PY3010A
19 mm SOCrETWRENCH, AVAILABI.I COMMERCI,ALLY
Timing Belt TensionAdjustment
Inspection Removethe cylinderheadcover. .
CAUTION: Always Ediust timing belt tonsion with tho cngin. cold.
Relerto page6-3'lwhen installing.
Inspectthe timing belt for cracksand oil or coolant soaking. NOTE: . Replacethe belt if oil or coolantsoaked. . Rsmove any oil or solvent that gets on the belt.
NOTE: . The tensionetis spring-loadedto apply proper tension to the belt automaticallvaftermakingthe following adjustment. . Always rotate the crankshaftcounterclockwisewhen viewed trom the pulley side Rotating it clockwise may result in improper adjustmentot the belt tension. R e m o v et h e c y l i n d e rh e a d c o v e r . ( R e f e rt o p a g e 6-31when installing.) Setthe No. 1 pistonat TDC(seepage6-12).
3. Rotatethe c.ankshaft5 - 6 revolutionsto set the bslt. 4.
Setthe No. I pistonat TDC.
ADJUSNNGBOLT 54 N.m (5.5kqf.m, a0 rbr.ftl Foradiustmentonly, do not remove,
Rotatepulley and inspscrbell.
After inspecting,retorque the crankshaftpulley bolt to 177N'm ('18.0kgf'm,130lbt'ft).
ol Direction rolatlon. 5.
Loosenthe adiustingbolt 1/2turn (180')onlv
6.
3-teethon Rotatethe crankshaftcounterclockwise the camshaftpulley.
7.
Tightenthe adjustingbolt to the specifiedtorque.
8.
After adjusting,retorquethe crankshaftpulley bolt to 177N.m (18.0kgl.m.130lbf.ft).
6-9
Timing Belt Removal NOTE: . Turn the crankshaftpulley so the No. 1 piston is at top d6ad center (TDC)before removing the belt (see page&12). a Inspectthe water pump when removed the timing bolt {see page 10-9}. 1.
Removethawhe€lwellsplashshield(seepage6-18).
2.
Loosen ths adjusting bolt and mounting bolts, then remove the power steering {P/S)pump belt.
4,
Loosenthe adjusting nut and mounting nut, then removethe alt€rnatorbelt. ADJUSNNGNUT 8 x 1.25mrr 2a N.m l2.a lef.m, 17 rbl.ftl
AA,USNNG
MOUNTINGNUT 10x 1.25mm a,lN.m{4.5kgl.m,33lbfftl MOUivNNGBOLTS 8 x 1.25mm 2aN.m12.4kgf.m,17 lbtfrl Loosenthe adjustingbolt and idler pulley bracket bolt, then remove the air conditioning(A,/C)comoressorbelt.
I
EELT
Removethe cruisecontrolactuator(seepage6-18). Removethe sid6snginemount. 10x 1.25mm 52N.m{5.3kgr'm,38lbtft} Replace.
ADJUSTING
IDLERPUI.IEYBRACKET BOLT l0 r 1.25mm a/aN.m{1.5kgf.m.33lbf'ft}
12 x 1.25mm 74 N.m 17.5kgt m, s4 tb{.ftl
1. 8.
Removethe cylinderheadcover. . Referto page6-31when installing. Removethe Dulleybolt and crankshaftpulley (see page6-8). Removethe middlecoverand the lower cover. NOTE: . Do not usethe middlecover and lower coverfor storingitemsdisassembled. . Cleanthe middle cover and lower cover before installation.
CAPNUT 6 x 1.0 mm 7.2rbl.ftl 9.8N.m 11.0
WASHER when damaged Replace
or
10. Loosenthe adjustingbolt 180'. 1'1. Pushthe tensionerto removetensionfrom the timing belt,then retightenthe bolt. 12. Removethe timing beltfrom the pulleys.
NOTE:Pushthe tensionerpulleyto loosenthe belt.
CYLINDEFHEAD COVER Reterto page 6-31when installing.
ADJUSTINGBOLT 10 x 1.25mm 54 N.m 15.5kg{.m, /r0 lbf.ftl Foradjustmentonly,
TIMINGBELT Adiustment,Page6I MIDOLECOVER
6x1.0mm 9.8 N.m 11.0kgJm, 7.2 lblftl
KE
6x1.0mm 9.8 N.m ('1.0kgt.m,7.2 lbl fr) RemoveanYoiland clean LOWEB@VER NMING BELT GUIOEPLATE lnstallwithconcave surfacefacingout. and clean. 6x1.0mm 9.8N.m (1.0kgtm,7.2lbt'ftl
PULLEY CRANKSHAFT Removeany oil and cleanon ihe timing beltguide platesido.
6-11
Timing Belt Installation Installthe timing belt in the revorceorderof removal; Only key points are describedhere, NOTE:Cl€anthe middle cover and lower cover before installation. L
Position the crankshaftand th€ camshaft pulleys as shownbeforeinstallingthe timing belt. A. Set the crankshaftso that the No. 1 oiston is at top dead center (TDC).Align the g.oovo on the t€eth side of the timing belt d.ive pulleyto the O pointeron the oil pump. L Align the TDC marks on intakeand exhaustpultevs,
2.
NOTE: To set the camshafts at TDC position for No. 1 piston, align the holes in the camshafts with the holes in No. l camshaft holders and insert5,0 mm pin punchesin the holes. PIN PUNCHES,5.0 mm
TDCmark align6d with the pointer on backcover,
6-12
TDC MARK
lnstall the timing belt tightly in the sequence snown. O t i m i n g b e l t d r i v e p u l l e y { c r a n k s h a f t )+ @ A d j u s t i n gp u l l e y * @ W a t e r p u m p p u l l e y - @ Exhaustcamshaftpulley+ @ Intakecamshaftpullev.
CylinderHead lllustratedlndex CAUTION: To avoid damaging the cylind6r hoad, waii until ongin€ coolant temporature drop3 below lOO"F(38"C)b€fore rsmoving it. NOTE:Use new O ringsand gasketswhen reassembling. CAPNUT 6 x 1.0mtn 9.8 N.m 11.0kgtm,7.2lbtftl
e
et CYLINDERHEAD COVER Referto page6-31when installang.
I x 1.25mm 22 N.m 12.2kgt.m, 16 rbf.ft)
RUBBER SEAL Replace whendamaged or doteriorated. INTAKECAMSHAFTHOI.DER
I x 1.25mm
24 N.m12.4kgf.m,-.\ --_r,_ 17rbt.tr)
Seesection __.|._
O-RING Roplace.
EXHAUSTCAMSHAFT HOI.DER RUBBERCAP Replacefor oil leakage.
EXHAUST CAMSHAFT LOCKNUT 25 N.m {2.5kgf.m, 18 tbtfiJ
6x1.0mm 9.8 N.m {1.0kgl.m,7.2lbf.ft)
INTAKECAMSHAFT Inspection,page5-21
-
6tal
SEAL page6-30 Installation, Replace.
--,
ffi;r KEY /
"
.
/
'@
SEAL Replace.
t
@6
I x 1.25mm 37 N.m (3.8kgt.m, 27 rbtftt
ROCKERARM
CAMSHAFTPULLEYS Removal,page6 19 page6,30 Installation, 8 x 1.25mm 37 N.m 13.8kg{.m,27 lbfftl
CAUTION: In h.ndling r m.t!l gr3kct, trko clrc not to fold it or dlmaga tho contact surfacr ol thr gaskat.
VAIVE XEEPERS SPRING \n \.\...i6 RETAINER
r*#:-3 STEMSEAL
--------ig
CYUNDEBHEAD BOLT &t N.m 18,5kgl'm, 61 tbf.ftl Applyengineoilto the threads.
VALVEKEEPERS I
JI --../
ENDPIVOTBOLT 6:tN.ml6.akst'm, ,16lbl.ftl
VALVE SPRING SEAT
ED..$---S---€.----
SPf,ING RETAINEB
nrAxE vaLvESPRING twtAKEvALvESTEMSEAL sEAT valvE SPRING INTAKE VAI-VE GUIT'E Insp€ction,pago S24 R6placom6nt,pago 6-25 Reaming,pag€6-26
EXHAUSTVALVE GUII'E
CYUNDERHEAD Warpage,page6-28
DOWELPIN
TX)WELPIN CYLINDERHEAD GASKET {3 LAYERSOF METALI Reolac6.
EXHAUSTVALVE
INTAKE VALVE Replacement,Page6_22
OIL CONTROL ORIFICE Clean.
O.RING Replac€.
6-15
GylinderHead Removal Engineremovalis not requiredfor this procedure.
I
t
5,
Removethe intakeair duct.
CAUTION: To avoid damaging tho cylinder head, wait until tho ongino coolant temporature drops bolow 100"F {38"C)beforo loo36ningthe rotainin0 bolts. NOTE: . Inspectthe timing belt before removingthe cylinder neao. . Turn the crankshaftpulleyso that the No. 1 piston is at top deadcenter(TDCI(page6-12). . Markall emissionshosesbeforedisconnecting them. . Anti-theftradioshavea codedtheft protectioncircuit. Be sureto get the customer'scode numberbefore. - Disconnectingthe battery. - Removingthe No. 32 (7.5A) fuse irom the underhood fuse/relaybox. - Removingthe radio. After service,reconnectoowerto the radioand turn it on. When the word "CODE"is displayed,enter the customer's5-digitcodeto restoreradiooperation. 1.
Disconnect the negativeterminalfromthe battery.
2.
Drainthe enginecoolant(seepage 10-5). .
3.
Removethe radiatorcapto speeddraining.
Relievefuel pressure(seeSection11). Do not smoke whils working on tusl @ systom, keep opon flame or spark away trom work area.Drain fuol only inlo an approvod containsr.
4.
Disconnect the fuel feed hose.
SERVIC€ BOLT WASHERS Replace.
Removethe breatherhose,water bypasshose and evaporativeemission(EVAP)controlcanisterhose.
Removethe fuel returnhoseand positivecrankcase ventilation(PCV)hose.
9 . Removethe throttlecable. 1 0 . Removethe throttlecontrolcable (automatictransmissiononly). NOTE: . Takecare not to bend the cablewhen removing it. Always replaceany kinkedcable with a new one. . Adjust the throttlecableand throttlecontrol cablewhen installing(seesection11 and 14). CONTROL THROTTLE CABLE
HOSE
R e m o v et h e b r a k e b o o s t e rv a c u u m h o s e , w a t e r bypasshoseand vacuumhose.
ERAKEBOOSTER VACUUM HOSE
VACUUM HOSE
ATI'USTING
1 1 . R e m o v et h e e n g i n ew i r e h a r n e s sc o n n e c t o r sa n d wire harnessclampstrom the cylinderheadand the intakemanifold. a Fourfuel injectorconnectors a Intakeair temperature(lAT)sensorconnector a Engine coolant temperature(ECT)sensor con-
a a a a a a
necror sensor connector TDC/CKP/CYP lgnitioncoil connector ECTgaugesendingunit connector Throttleposition(TP)sensorconnector Manifold absolute Dressure(MAP) sensor connector ldle air control(lAC)valveconnector EVAPpurgecontrolsolenoidvalveconnector
HOSE
(cont'dl
6-17
I
CylinderHead Removal(cont'dl 12. R€movethe spark plug caps and distributorfrom the cvlinderhead. Removethe upper radiatorhose, heaterhose and water bypass hose.
15. Removethe enginegroundcable. Removethe adjustingbolt and mountingbolts,then remove the power steering (P/S)pump belt 8nd P/S pump. .
Do not disconnectthe P/Shoses. ADJUSTING BOLT
WATER BYPASS
6x1.0mm 9.8 N.m 11.0tgfm, 7.2 tbf.ftl
UPPERRAI'IAYOR
8 x 1.25mm 24 .m (2.akstm, 17lbf.ftl
P/S PUMP
Remov€ the air conditioning (Ay'Clcompressor belt (seepags 6-10).
14. Removeth6 solashshield.
1 7 . R€movethe alternatorbelt (seepage6-10).
t 8 Ramovethe cruisecontrolactuator. 8 x 1.25mm 2a N.m 12.4kgt m,
9.8 N.m {1.0 kgt m. t.2 tbr.frt
sHtEut ACTUATOR
Removethe timing belt (seepage6-10).
19. Removethe sideenginemount. 10 x 1.25mm 52 N.m (5.3 kgt'm, 38 lbf'ft)
WASHERS
Removethe camshaftpulleysand backcover. SIDEENGINE MOUNT
12 x 1.25mm 74 N.m {7.5kgf.m, 5{ rbtftl
BACKCOVER
20. Removethe cylinderheadcover. 23. Removethe exhaustmanifold.
CYLINDEBHEAD NUT SELF.LOOKING 8 x 1.25mm
BRACKET
(cont'd)
6-19
CylinderHead Removal(cont'dl 2,0. Removethe intakemsnifold.
Removethe camshaft holder bolts, then remove the camshaftholde.s.camshaftsand rockerarms.
GASXET
IMTAXEMANIFOLD
25. Loosenthe locknutsand adiusting screws.
27. Removethe cylinder head bolts. then remove the cvlindsrhead. CAUTION: To preyant warpago. unlcr.w thc bolt3 in laquoncc 1/3 turn at I tim6; .apeat the $qurnca until sll boltr arc loosrncd.
ADJUSNNG SCNEWLOCATN)NS:
CYLINOER HEADBOLTSLOOSENINGSEOUENCE
Camshafts Inspection
!
1.
Loosenthe adjustingscrews.
2.
Removethe camshaftholdersand the rockerarms NOTE: Mark the rockerarms before removing them.
1 0 . Removethe camshaftholders.Measurethe widest ponion of plastigageon eachjourna.. Camshaft-toHolder Oil Clearance: Standard lNewl: 0.039- 0.069mm (0.0015- 0.0027in) 0.15 mm {0.006inl SarvicoLimit
R e i n s t a ltl h e c a m s h a f ta n d h o l d e r s .T i g h t e nt h e camshaftholderbolts in a crisscrosspattern,beginningwith the innerbolts. 9.8 N.m (1.0kgf.m,7.2lbf.ft)
PLASTIGAGE
Seatthe camshaftsby pushingthem towardthe distributorend of the headwith a screwdriver. Z e r o t h e d i a l i n d i c a t o ra g a i n s tt h e e n d o f t h e camshaft. push the camshaft back and forth and readthe end play. Camshalt End Play: St.ndard lNow):0.05- 0.15mm (0.002- 0.006inl Seivice Limit: 0.5 mm {0,02in) 11. lf camshaft-to-holderoil clearanceis out of toler ance: . And the camshaft has already been replaced, vou must replacethe cylinderhead. . lf the camshafthas not beenreplaced,first check total runout with the camshaftsupportedon Vblocks. Clmshaft Total Runout: StEndard{New): 0.03 mm (0.001inl max' ServicoLimit: o.Oilmm {0.002inl
Removethe camshaftholderboltsfrom the cylinder head. N O T E : U n s c r e wt h e c a m s h a f th o l d e r b o l t s t w o turns at a time, in a crisscrosspattern. Lift the camshaftsout ot the cylinder head. wipe them clean,then inspectthe lift ramps.Replacethe camshaftif any lobes are pitted, scored,or excessrvelyworm Cleanthe camshaftjournal surfacesin the cylinder head,then set the camshaftback in place.Inserta plastigagestrip acrosseachiournal. Installthe camshaftholdersand torquethe boltsto the valuesand in the sequenceshownon page6-30. NOTE:Do not rotatecamshaftsduring inspection.
-
lf the total runout of the camshaftsis within tolerance,replacethe cylinderhead.
-
lf the total runout is out of tolerance,replacethe camshaftsand recheck.lf the oil clearanceis still out of tolerance.replacethe cylinderhead.
6-21
Valves,Valve Springs and Valve Seals Removal N O T E : l d e n t i f yv a l v e sa n d v a l v e s p r i n g sa s t h e y a r e removedso that eachitem can be reinstalledin its oriqinal Dosition. 1.
Tap eachvalve stem with a plasticmalletto loosen valve keepersbeforeinstallingthe spring compressor.
2. lnstallthe springcompressor.Compressspring and removevatveKeeper. VALVESPRINGCOMPRESSOR xo No.3tB. whh r35 JAW o.
07757- PJ10r0A Installthe special tool as shown. Remove the valve seal.
COMMERCIALLY AVAILABLE VALVEGUIDESEALREMOVER LISLEP/N 5t9d) or KO3350 SEAL REMOVER
lntaks Valvo Dimonsions A Standard(New): 30.90- 31.10mm - 1.221inl |.1.217 (Nowl: I Standard 103.80- 10'1.10mm {4.087- 4.098inl C Standard lNow): 6.580- 6.590mm {0.2591- 0.259/rin} C ServicoLimit 6.55 mm (0.258inl D Standlrd (N€w): 1.35- 1.65mm 10.053- 0.065inl D SsrviceLimit: 1.15mm (0.045in) Exhau3tValve Dim6nsions A Standard {New): 27.90- 28.10mm - 1.106inl 11.098 (Newl: B Standard 104.00- 104.30mm (4.094- 4.106inl C St.ndard (New): 6.550- 6.500mm 10.2579- 0.2583inl C ServicoLimit 6.52 mm (0.257in) D Standard{New): 1.65- 1.95mm - 0.077inl 10.065 D ServiceLimit: 1.,[5mm (0.057in)
InstallationSequence NOTE:Exhaustand intakevalvesealsate NOTinterchangeable.
@/.-uo.**.r..", NOTE: Placeth€ 6nd oI valve springwith closelYwoundcoils towrrd th€ cylinder head.
SPRNG NETAINER
EXHAUSTVALVESEAL {8LACKSPRING} Replace.
@*_-.tt* NOTE:Installth€v6lvosprings€ats beforo instsllingthe valv6 sesls.
PLASTICMALIIT
6-23 .tIF"F-
Valves,ValveSpringsand ValveSeals
ValveGuides ValveMovement
Valvelnstallation W h e n i n s t a l i i n gv a l v e s i n t h e c y l i n d e r h e a d ,c o a t valve stemswith oil beforeinseningthem into valve guides, and make sure valves move up and down smoothlv. When valvesand springsare in place,lightlytap the end of each valve stem two or three times to snsure properseatingof valvesand valve keepsrs(use plastic mallet). NOTE:Tap the valvestem only along its axis so you do not bendthe stem.
Measurethe guide-to-stem clearancewith a dial indicator while rocking the stem in the direction of normal thrust (wobblemethod). lntake Valve Stsm-to-GuideClearance: Strndlrd (Newl:0.0i1-0.10mm (0.002- 0.004in) Ssrvicc Limit: 0.16 mm {0.006in) Exhsust Valye Stom-to-GuideClearance: Standard{N€w):0.10- 0.16mm {0.0O'l- 0.006in) Slrvica Limit: 0.22 mm {0.000in) Valveextended10 mm out from seat
PLASNC MALI.IT
lf measurementexceedsthe service limit, recheck usinga new valve. l f m e a s u r e m e n ti s n o w w i t h i n t h e s e r v i c e l i m i t , reassembleusinga n€w valve. l f m e a s u r e m e n st t i l l e x c e e d sl i m i t , r e c h e c ku s i n g a l t e r n a t em e t h o d b e l o w . t h e n r e p l a c ev a l v e a n d guide, if necessary.
?ur
NOTE:An alternatemethod of checkingguide to stem clearanceis to subtractthe O.D.of the valvestem, meas u r e d w i t h a m i c r o m e t e r .f r o m t h e l . D . o f t h e v a l v e g u i d e , m e a s u r e dw i t h a n i n s i d e m i c r o m e t e ro r b a l l gauge. Takethe measurementsin three placesalong the valve stem and three placesinsidethe valveguide. The diiferencebetweenthe largestguide measurement and the smalleststem measurementshould not exceed the servicelimit lntake Valve Stom-to-GuideClearance: Standard (Newl: 0.02- 0.05 mm (0.001-0.002in) 0.08 mm (0.003in) ServiceLimit ExhaustValve Stom.to.Guid€ Clearanco: Standard (Newl: 0.05- 0.08 mm (0.002- 0.003inl Srrvico Limit 0.ll mm 10.00'tinl
6-24
Replacement 1. As illustrated in the removal steps of this proceair-impactdrivdure, use a commercially-available er attachmentmodified to fit the diameter of the valve guides. In most cases.tho same procedure c a n b e d o n e u s i n g t h e V a l v e G u i d e D r i v e ra n d a conventionalhammer.
-----T_|
sz-12.21i^l
Working from the camshaft side. use the driver and an air hammerto drive the guide about 2 mm {0.1 i n ) t o w a r d s t h e c o m b u s t i o nc h a m b e r .T h i s w i l l knock oft some of the carbon and make removal eaSrer. GAUTIOiI: o Alwrys woar safety goggles or a face shiold wh6n using tho Eir hammer. . Hold ths air hammsr directly in lins with the vrlvr guidc to prsvont damaging tho drivor.
COMMERCIALLYAVAILABI,I VALVEGUIDEDRIVER
f
4.
l r l 11.3mm lo.il,l in)
RGmov.lrnd In3tlllation 6.6mm VALVEGUIDEDRIVER, 0?942- 6570100
Turn the head over and drive the guide out towatd the camshaftside of head. lf a valveguide still won't move,drill it out with a 8 mm (5/16in) bit,then try again. CAUTION: Drill guid$ only in oxtremo cases:You could drmrgo tho cylinder hosd if ths guido br"akr.
S e l e c tt h e p r o p e r r e p l a c e m e n tg u i d e s a n d c h i l l t h e m i n t h e f r e e z e rs e c t i o no f a r e f r i g e r a t o rf o r aboutan hour. Use a hot plate or oven to evenly heat the cylinder headto 300'F(150'Cl.Monitorthe temperaturewith a cookingthermometer.
VALVEGUIDEDRIVER,6.6mm 07942 - 65701q)
CAUTION: . Do not use a torch; it may warP the hgad. . Do not get ths head hottq than 3OO'F1150"C); excessivehgat may loos€n thGvalvs soat3. . To avoid burns, usa hoavy glov93whon handling the heated cylinder hoad.
OO
",
O (V /rl
-1-- ) o
one Removethe new guide{s}from the refrigerator, at a time, as you needthem. {cont'd)
6-25
Valve Guides Reaming
Replacement {cont'd} 7.
SliDa 6.5 mm {0.25in) stselwashorand the correct driver attachmentover the end of the driver {The washer will absorb some of the impact and extend the life of the driver).
.,F-q-re t t T It
DRVEn 8,
t
I
6,5mm t0.25in) WASHER
-
NOTE:For new valveguidesonly. Coatboth reamerand valveguidewith cuttingoil. Rotatethe reamer clockwisethe full length of the valveguide bore. C o n t i n u et o r o t a t e t h e r e a m e t c l o c k w i s ew h i l e removingit from the bore.
l
ATTACHMENT
Installthe new guide(s)from the camshaftside of the head; drive each one in until the attachment bottomson the head.lf you have 8ll sixteenguides to do, vou may have to reheat the head one or two moreI|mes.
Thoroughlywash the guide in detergentand water to removeany cuttingresidue. Checkclearancewith a valve(seepage6-24). .
V e r i f y t h a t t h e v a l v e s l i d e s i n t h e i n t a k e8 n d exhaustvalveguideswithout ex€rtingpressure.
REAMERHANDLE
s
VALVEGUII'E REAMER,6.6 MM 079E4- 667ot0c
Valv6 Guida Instsllod Hcight: 13.75- 14.25mm lntaks: (o.sal - 0.561inl 15.75- 16.25mm Exhru3t: {0.620- 0.640in}
Valve Seats Reconditioning 1.
2.
Renewthe valve seatsin the cylinderhead using a valveseatcutter.
The actualvalve seatingsurface,as shown by the bluecompound,shouldbe centeredon the seat.
NOTE: lf guides are worn (see page 6-24),replace them (seepage6-251beforecuttingthe valveseats,
.
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 smoothand concentricseat.
3.
Bevelthe upper edge of the seatwith the 30ocutter and the lower edgeof the seatwith the 60' cutter. Checkwidth of seatand adjustaccordingly.
4.
Makeone more very light passwith the 45"cutterto removeany possibleburrs causedby the other cutters.
.
7.
lf it is too high (closerto the valve stem), you must make a second cut with the 60" cutter to move it down, then one more cut with the 45' cutterto restoreseatwidth. l f i t i s t o o l o w ( c l o s e rt o t h e v a l v e e d g e l ,y o u must make a second cut with the 30' cutter to move it up, then one more cut with the 45"cutter to restoreseat width. NOTE:The final cut shouldalwaysbe madewith the 45' cutter.
Insert intake and exhaust valves in the head and measurevalvestem installedheight Intako Valve Stem Install€d Height: Standard (New): /$.765 - '11.235mm - 1.6234in} {1.604It inl ServiceLimit: ill.il85 mm (1.6:133 ExhaustValvo Stem lnstalled Height: Standard {Newl: ,12.765- i|:|.235mm 11.6a37- 1.1022in1 /B.il85 mm (1.7120inl ServiceLimit
Valvo Seat Width llntake and Exhaustl: Standard: 1.25- 1.55mm {0.049- 0.061inl Servics Limit:2.0 mm 10.08inl
SEAT WIDTH
After resurfacingthe seat, inspect for even valve seating:Apply PrussianBluecompoundto the valve f a c e , a n d i n s e r t v a l v e i n o r i g i n a l l o c a t i o ni n t h e head,then lift it and snap it closedagainstthe seat severaltimes.
8.
lf valve stem installed height is over the service limit, reDlacevalveand recheck.lf still over the service limit, replacecylinder head;the valve seat in the headis too deeo.
ACTUAL SEATING SUBFACE
VALVE SEAT PRUSSIAN
6-27
GylinderHead Installation
t
oil clearances(seepage 6NOTE:lf camshaft-to-holder 2 1 ) a r e n o t w i t h i n s p e c i t i c a t i o nt,h e h e a d c a n n o t b e resurfaced. lf camshaft'to-holder oil clearancesare within specifications,checkthe headfor warpage. lf warpage is less than 0.05 mm (0.002in) cylinder headresurtacingis not required. lf warpageis between0.05mm (0.002in) and 0.2 mm (0.008in), resurfacecylinderhead. Maximum resurfacelimit is 0.2 mm (0.008in) based on a heightof 132.0mm (5.20in). PRECISION STRAIGHTEOGE
Installthecylinderheadin the reverseorderof removal: NOTE: . Always use a new head gasket. . C y l i n d e rh e a d a n d c y l i n d e rb l o c ks u r f a c em u s t b e ctean. . "UP" markon the timing belt pulleysshouldbe at the top. . Do not usethe middlecoverand lowercoverfor storing itemsdisassembled. . Cleanthe middlecoverand lower coverbeforeinstallation. . Replacethe washerwhen damagedor deteriorated. '1. Cylinderhead dowel pins and the oil control orifice must be aligned, NOTE: . When handling a metal gasket,care should be takennot to told it or damagethe contactsurface of the gasket. . Cleanthe oil controlorificewhen installing. CYLINDERHEADGASKET {3 LAYERSOF METALI Replace.
orl coNtnol
OOWELPINS
ORIFICE Clean. O.RING Replace.
Measurealongedges,and 3 ways acrosscenter. Tightenthe cylinderhead bolts in two steps.In the Jirststep tighten all bolts,in sequence,to about 29 N.m {3.0kgf.m,22 lbl.ltJ;in the final step,tighten in the samesequenceto 83 N.m (8.5kgf.m,61 lbf'ft). NOTE: . Apply engine oil to the cylinder head bolts and the washers. . Usethe longerbolts at positionsNo. 1 and No. 2 as shown. CYLINDERHEADBOLTSTOROUESEOUENCE
@
o
@
@
Cylinder Hoad Height: Standard(New):131.95- 132.05mm in} {5.195- 5.191t
Put longer bolts here.
@
Installthe intakemanifoldand tightenthe nuls in a c.isscrosspatternin 2 or 3 steps,beginningwith the inner nuts. CAUTION: Check to. fold3 or 3cratchc! on ihc aurtaco ol tho ga3kot. Roplscs with a nlw gaeket if damagod. 4.
CAUTION: . Mlka 3uro thrt thc k.ywlyr on tho c.mthlttr lrc facing up .nd No. I pi3ton i3 8t top d.rd clnt.r (TDCt. . Rcphct th! rocksr armr in thsir o.iginal potltlom. 6,
Placethe rocker arms on the oivot bolts and ths valve stems.
7.
lnstallthscamshafts,then installth€camshaftsosls with ths open side (spring)facingin.
8.
A p p l y l i q u i d g a s k e ta r o u n dt h e r u b b e r c a p , t h e n installtherubbercao.
Tightenthe intakemanifoldbracketbolts. GASXET Replace.
E x 1.25mm 2irN.ml2.itkg{.m, 17tbf.ftl 5.
8 x 1,25mm 23 N.m12.3kgf.m. 17tbl.frt
Install the exhaust manifold and tighten the new self-lockingnuts in a crisscrosspattern in 2 or 3 steps,beginningwith the inner nuts. . Use new self-lockiflgnuts.
8 x 1.25mm 24 N.m (2,akgf.m, EXHAUST 11
SELF.LOCKING NUT 8 x 1.25mm 31 N.m (3.2 kgt m,23lbfftl Replace.
GASKEI Replace.
m l0 x 1.25mm 8 x 1.25mm a,t N.m 14.5kgf.m, 2il N.m 12.4kg{.m, 33 tbt.ft) 17 rbtftl
(cont'd)
6-29
CylinderHead Installation(cont'dl 9. Apply liquid gasketto the head mating surtacesof the No. 1 and No. 6 camshaftholders,then install t h e m ,a l o n gw i t h N o .2 , 3 , 4 , a n d5 . NOTE: o "1" or "E" marks are stamoedon the camshaft holders. . Do not apply oil to the holder mating surfaceof camshaftseals. . Apply liquidgasketto the shadedareas. . T h e a r r o w s m a r k e do n t h e c a m s h a t th o l d e r s shouldpoint to the timing belt.
11. Tighten each bolt in two steps to ensure that the rockers do not bind on the valves.
6r1.0mm 9.8 N.m 11.0kgf.m,7.2lbtft)
INTAKECAMSHAFTHOLDERS
Installkeysinto camshaftgrooves. No.6
No.5
No.2
N o .1
NOTE:To set the camshaftsat TDCpositionfor No. 1 piston,align the holes in the camshaftswith the holes in No. 1 camshaftholdersand insert5.0 mm pin punchesin the holes. KEYS
10. Tightenthe camshaftholderstemporarily. .
M a k e s u r e t h a t t h e r o c k e ra r m s a r e p r o p e r l y positionedon the valvestems.
I r 1.25mm 37 N.m {3.8 kgf.m,27 lbf.ttl
6x1.0mm 9.8N.m(1.0kgf.m, 7.2tbtft)
1 3 . Pushcamshaftpulleysonto camshafts,then tighten the retainingboltsto the torquespecified.
1 4 . Installthetiming belt {seepage6-12).
1 7 . Apply liquid gask€t to the rubber seal at the eight corners of the recesses.
Adjustthe valveclea.ance(seepage6-31. 1 6 . Installthe rubberseal in the grooveof the cylinder head cover. Seat the seal in the recessesfor thg camshaftfirst, th€n work it into the groove around the outside edges, NOTE: . B e f o r ei n s t a l l i n gt h e r u b b e r s e a l , t h o r o u g h l y cleanthe sealand the groove. . When installing, make sure the seal is seated securelyin the cornersof the recass€swith no gap.
NOTE: . Use liquidgaskst,PartNo. 08718- 0001. . Checkthat the mating surfacesare cl€an and dry beforeapplyingliquidgasket. . Do not install the parts if 20 minutes or mor6 h a v s e l a p s o ds i n c o a p p l y i n g l i q u i d g a s k e t . Instead,reapply liquid gasket after removing old reaidue. . After assembly, wait at lsast 20 minutes before fillingthe enginewith oil.
RUBAER SEAL
Apply liquid g.sket to the shadedareas.
CYUNDERHEAD COVER
(cont'd)
6-31
GylinderHead lnstallation(cont'dl 18. When installingthe cylinder head cover, hold the rubbersealin the grooveby placingyour fingerson the camshaftcontactingsurfaces(top of the semicircles). O n c e t h e c v l i n d e rh e a d c o v e r i s o n t h e c y l i n d e r head,slidethe cover slightlybackand forth to seat the rubberseal.
Tightenthe nuts in 2 or 3 steps.In the final step, tighten all nuts, in sequence,to 9.8 N'm (1 0 kgf'm, 7.2 tbf.ft).
NOTE: . Beforeinstallingthe cylinder head cover, clean the cylinder head contacting surfacesusing a shoptowel. . Do not touch the pans where liquid gasketwas aDplied.
6x1.0mm 9.8 N.m 11.0kgt'm, 7.2 tbf.trl
20. After installing,checkthat all tubes,hosesand connectorsare installedcorrectlY.
6-32 'lllllllllmlmti'""
CylinderHead/ValveTrain 818C1engine SpecialTools
............. 6-34
Rocker Arms wEc Removal ................. 6-60 Troubleshooting Flowchart Location ................. 6-61 WEC SolenoidValve................... lnspection .............. 6-36 6-62 VTECPressureSwitch ................. Arm-to-ShaftG|earance.................. 6-38 6-63 Installation VTECSolenoidValve Inspection....6-41 ............. 5-64 RockerArms Camshafts ManualInspection.....,................. 6-42 Inspection .............. 6-65 InspectionUsingSpecial Valve Guides Tools ....................................,.....,.. 6-/|i| ValveMovement.............................. 6-70 ValveGlearance Replacement .........6-71 Adiustment ............ 6-44 Reaming ................. 6-72 Timing Belt Valve Seals lllustrated1ndex............................... 6-46 Reconditioning ......6-73 .............. Inspection 6-48 Valves. Valve Springs and Valve Seals TensionAdiustment........................ 6-48 ................. Removal 6-67 ................. Removal 6-4{l lnstallationSequence..........,.......,... 6-69 ............. lnstallation 6-51 Valvelnstallation............................. 6-70 Pulley Bolt Crankshaft Replacement .........6-47 CylinderHead lllustratedIndex ............................... 6-53 .................6-55 Removal Warpage ................6-74 ............. lnstallation 6-75
SpecialTools
o @ @ @ /.\
o o
@
ToolNumbar or 07HAH- PJ7010A _ PJTOIOB OTHAH 07JAB- 001020A 07LAA- PR30100 OTLAJ_ PR3O2OA 07MAB. PY3OlOA OTMAF_ PRgO'IOA 07742- 0010100 07757- PJ1010A
ValveGuideReamer,5.5 mm
6-72
HolderHandle
6-17 &45 6-43
TappetAdiusterWrench Air Stoppet HEX50 mm, PulleyHolderAttachment, Offset Valv€SpringCompressorAttachment Extension ValveGuideDriver,5.5mm ValveSpringCompressorAttachment
o
6-11 6-67 6-71,72 6-67
@
o
@
@
6-34
Plea Rctllanca
Dctcription
@
o
@
VTEC Ref€rto page11-32thru I l-39 beforotroubleshooting.
-g:
-mi
\,__-:-/
\.---l-l
Iel-
(MlL) indicates Disenostic rrouble code(Drc)2r:Aproblem inthewEc !5*3ij'i:,*o:",,XTl.Lamp
-l 2,1l-
MIL h.. b..n Fport d on. Wrth aaavica chack connac,tot iomp.d, Codc 2l i. indic.t.d.
O o t h o o n g i n oc o n t r o lm o d u l e (ECM)Rg3otProcgduro.
w6rrn up engine to normal op€rating tsmporature (the cooling fan comogon).
Do th€ RoadTest.'
ls MIL on and does it indicatocod€21?
' RoadTest: Acceleratein 1st gear to 6n engino spoodovor 6000rpm. Hold thst engine sp€edtor at leasttwo seconds. lflhe MIL do6s not coms on during th€ first road tost, reoeatthis test two more tim95. lmormitt.m t ilur., .yrtom i. OK !t thi.tim.. Chacl tor poor connactiont ot loo.. wircr !l VTEC .ol.noid v.lv. lnd ECM.
Turn tho ignition switch OFF.
O i s c o n n e c tt h o 1 P c o n n s c t o r lrom the VTECsolenoidvalvo.
Chockfor continuity betw66n 1P c o n n 6 c l o rt e r m i n a l a n d b o d y 9rcUnO.
ls there '14- 30 07
YES (To pago G37l
6-36
R.pl.c. th. VTEC rolonoid v.lvr,
{From pag6 636}
ooooooooooo ooooooooooo
ooooooooooooo
ooooooooooooo
'lP Ch6ckfor continuity botw6en and A4 termiconnectort€rminal nal.
B.9.lr op.n in th. GRI{/YELwirc b.tw..n ECM{Aa} .od vTEc aolanoidvalvaconnac'tor.
Ch6ckfor continuity botwoon 1P connectorterminal (harnessside) and body ground.
ContinuityT
Ro.ir .hon i|r th. GRN/VELwirc b.iw..n ECM (A4l .nd VTEC aoldroid valv. Gonnac'tor.
Sub.titut! . krown-good ECM |r|d r.ch!ck. lt .ytnptom/indic!tion gor3 away rrplact tha origin.l Ecttl,
6-37
wEc
TroubleshootingFlowchart- VTECPressureSwitch
Referto page11-32thru11-39beJoretroubleshooting' -.+- l{{?l-
(DTC)22:A problemin the VTEC -r";-rIndicatorLamp (MlL)indicatesOiagnosticTroublesCode zizr: Malfunction pressur€Switchcircuit. ;l
- l r @ l - | 2 21 -
MIL har bagn.oportcd on. With t.rvic. chack connactor iump.d, cod€ 22 it indic.t.d.
D o t h e e n g i n ec o n t r o lm o d u l e (ECM)Reset Procedure.
Warm !p engineto normaloperating temperstur€ (cooling fan comeson).
Do the Boad T€st.'
ls MIL on and doesit indi' cate code 22?
* RoadTest: Accoleratoin lst gear to an engine speedover 6000rpm Hold that engine speedfor at leasttwo seconos' lf the MIL does not come on during the first road test' reoeatthis test two more limes. Intc.mift.nt failu.o, ry3tom ia OK at thi. tim.. Chack for pool connaction3ol loo!. rvirat at VTEC Ptasturo 3whch and ECM.
Turn lhe ignition switch OFF
D i s c o n n e c tt h e 2 P c o n n e c t o r lrom the VTECPressureswitch.
C h e c kI o r c o n t i n u i t y b e t w e e n BLKterminaland body ground. Rcpair opcn in BLKwit. botwcon 2P connectorrnd body ground tG101l.
C h e c kf o r c o n t i n u i t y b e t w e e n 8LU/8LKterminaland D6 termi' nal.
(To page6 39)
6-38
(Frompage6-38) Ropairop€n in BLU/BLK$,iro be tween ECM lD6) and 2P conn.ctor, Checkfor continuity between D6 terminaland body ground.
o oooooo ooo ooo I oooooooo trt!*Hffi o oooo ooooo ooo I oo oooo oo
Oooooo ooooo
o o o o o oo o o o o D6
I
R6pri. short in BLU/BLKwir. bctweon ECM (D6l .nd 2P connectoa,
Remove10 mm sealingbolt and connectorl pressuregauge.
GAUGEJOINT ADAPTER SNAPON MT2&17 10 x 1.0mm . lJse new washerwhen installingthe sealingbolt.
Coitlnuity?
Y AVAILAEII GAUGE OILPRESSURE
Connecta tachometer{soe sect i o n1 1 ) .
\n
Startthe engineand warm it up to normal operatrngtemperature.
C h e c ko i l p r e s s u r ea t e n g i n e speeds of 1,000,3,000 and 5,000 rpm,
ls pressurebolow 50 kPa (0.5kgflcm', 7 psi)?
\-
]L NOTE: Keep mgasuringtime as short as possiblebocaus€engine is runningwith no load(lessthan one minute).
Inrpoct tho VTEC aolanoid v.lv..
vtEc sot-€NotD
Turn off the engine. Checklor continuity betweenthe 2 terminals on the VTECpressure switch.
YES (To page 6-40)
Conlinuity?
(cont'd)
6-39
VTEC Flowchart VTECPressureSwitch (cont'dl Troubleshooting u lFrom pag6 6-39) OOMMERCIALLYAVAILABII OIL PRESSURE GAUGE
D i s c o n n s c tl h e 1 P c o n n e c t o r trom the VTECsol6noidvalve.
Attach the battery positivo tormi nal to the GRN/WHTterminal.
Startthe engineand chgckoil pressureat 5,000rpm (lor VTEC test). oil pr€ssure
NOTE: Keep moasuringtim6 as shon 6s possible becauseenginei5 runningwith no load lless than ono minuto).
ls pressureabove 400 kPa (4kgt/cm,,60 psi)?
Checktor continuity betwe6n the 2 terminsls on th€ VTECprsssure switch !nder above condition.
Sub.titut. . klown-eood ECM and rachack.|f aymplom/indication goaa away rrplaca th. o?igin.l ECM.
In.p.ct th. VIEC .olrnoid v.lv..
GAUGE JOIMf ADAPIOR SNAPON MT2S1' 1 0 x 1 . 0m m . Use new washer when installingth6 soalingbolt.
WEC SolenoidValveInspection Disconnectthe 1P connector trom the VTEC solenoidvalve. M€asurs resistancebetween th€ terminal 8nd body grouno.
4.
lf th6 filter is not clogged, push the VTEC solenoid valv€ with your finger and check its movement. .
l f V T E Cs o l s n o i d v a l v e i s n o r m a l , c h e c k t h e enginsoil pr€ssure.
R.3bt!nc!: 1l - 30 O 6x1.0mm
lf the resistanceis within specificstions,romove the WEC sol€noid valve from the cvlindor hsad, and checkthe VTECsolenoidvalvefilterfor clogging. .
lf there is clogging,replacsthe engin€ oil filter and the engineoil. VTECSOT.CNOTD
12 tTln 11.2kg[.m,8.7 lbttt]
6-41
VTEC Arms Rockerrtrrrri' nlrungf
rYrorrtrcr
rrrDPEUtrl,rl
1.
Set rh6 No. I Distonat TDC.
2.
Removethe ignitionwire coverand the wires.
3.
Removethe ignitionclampswhile pullingup on the lock.
4.
Removethe cylinderheadcover. Pushthe mid rockerarm on the No. 1 cylindermanually. Checkthat the mid rockerarm moves independently of the primaryand secondaryrockerarms.
6 x 1.0.nm 9.8 N.m 11.0lgfm, 7.2 lbf.ftl SECONDARY ROCKERARM
w 7.
Checkthe mid rockerarm of eachcvlinderat TDC. .
.
lf the mid rockerarm does not move,removethe mid, primary and secondaryrockerarms as an assemblyand checkthat the pistonsin the mid and primaryrockerarms move smoothly. lf any rocker arm needs replacing,replacethe primary,mid, and secondaryrockerarms as an assemblv.
NOTE:Referto page6-78when installingcylinderhead cover.
RockerArms - InspectionUsingSpecialTools Apply specified air pressure to the rocker arm pistons after looseningthe regulatorvalveon the valve inspectiontool.
CAUTION: . Boforo using tho valvo inspoctiontool. make 3uro that th6 air prsssure gaugs on th6 air comprossol indicatG over 250 kPa {2.5 kgf/cm', 36 psi} . Inspectthe valvs clearancobefors rockel lrm insPoction. . Covor the timing belt with a shop towsl to pl€vent qotting oil on lhe b6lt. . Checkths mid rocker srm of oach cylindor at TDC. 1.
Removethe cylinderheadcover.
2.
P l u g t h e r e l i e f h o l e w i i h t h e s p e c i a lt o o l ( A i r Stopper).
SpecifiedAir Presrure: 250 kPa (2.5 kgt/cm', 36 psi) - 500 kPa 15.0kgf/cm'. 71 Psi) Make sure that the primary and secondaryrocker a r m s a r e m e c h a n i c a l l cy o n n e c t e db y t h e p i s t o n s and that the mid rocker arms do not move when pushedmanuallv.
RELIEFHOLE
LOST MOTION ASSEMALY
3.
o lf any mid rockerarm moves independentlyof tho primaryand secondaryrockerarms, replace the rocker arms as a set.
Removethe bolt and washer from the inspection holeand connectthe valveinspectiontool AIR STOPPEB OTLA' - PR3O2OA
VALVE REGULATOR . Pullthsleverand turn to adjust.
6.
Removethe tools.
7.
Checkthe oDerationof the lost motion assembly by p u s h i n go n t h e m i d r o c k e ra r m . T h e l o s t m o t i o n a s s e m b l vs h o u l d c o m p r e s sf u l l y a n d o p e r a t e smoothlythrough its full stroke.Replacethe assembly if it does not work smoothlY.
8.
A f t e r i n s o e c t i o n ,c h e c k t h a t t h e M a l f u n c t i o n IndicatorLamD(MlL)does not come on
INSPECTION HOtt
WASHER Replace.
PfiIMARY ROCKERARM
NOTE:Referto page6-78when installingcylinderhead cover.
10 x 1.0mm 20 N.m 12.0kgf.m, 1a tbt'ft|
TOOL AVAILABLE} ICOMMERCIALLY
6-43
ValveClearance Adiustment NOTE: . Valves should be adjustedcold; at a cylinder head temperatureof lessthan 100"F(38'C). . Adjustmsnt is the same for intakeand exhaust vatves. o After adjusting, retorque the crankshaftpulloy bolt to 177 N.m ( 18.0kgf.m, 130 lbf.ft). 1.
FOI{IER Ot{ LOWEFCOVER
TDCMANK lP.int d whit.t
Removecylinderheadcove..
BOLTLOCANONS: ADJUSTING IMTAKE No.3 No. 2
No. 4
No. 1
Diroctionof aotation.
3. Adjust valv6 clearanc6on No. 1 cylinder.
No.4
No.3 No.2 EXHAUST
Intlkc: 0.15- 0.19 mm (0.006- 0.0,07inl Exh.u3t 0.17- 0.21 mm (0.007- 0.m8 inl
N o .1
Set No. 1 piston at TDC. "UP" mark on the pulley should be at top, and TDC grooves on the pulley should align with the pointer on back cover. TDC g r o o v e s ( w h i t e p a i n t ) o n t h e c r a n k s h a t tp u l l e y should align with pointer on the timing belt lower cover.
4.
Looson lh6 locknut and turn the adjusting screw until feeler gaugo slides back and fonh with a slight amountof drag.
FEEENGAUGE TAPPETAI\,USTEN WREI{CI{ O'LAA - PRIOIq'
Numbr. 1 pirton .t TDC:
7 x 0.75 mrn
20 f+|n (2.0kgf'm.14lbtftl
6-44
Tightsn the locknut and recheckclearanceagain. Rep6atsdjustm6nt if necossary.
FEEI.IRGAUGE
Rotsts tha crankshaft 180' counterclockwiss (c8mshaftpulleyturns 90'). The "UP" mark should be on th€ sxhaust 8id6, Adiust vslves on No. 3 cylinoer,
7.
Rotatocrankshaft180' countsrclockwiseto bring "UP" mark shouldbo N o . 4 p i s t o n t o T D C .T h e pointing straight down. Adjust valves on No. 4 cylinder.
Numb.r 4 pidon .t Tt C:
8,
Rotatecrankshaft180" counterclockwis€to bring "UP" marks should be on No. 2 piston to TDC.The the intaks sid6. Adjust valves on No. 2 cylinder.
Nonb.r 2 pirton .l TltC:
Nurrb.r3tittondTDC:
.UP' MANKS
NOTE: Referto page 6-78 when installing cylinder head cover.
6-45
TimingBelt lllustrated lndex NOTE: . . . . .
ReJertopage6-51for positioningcrankshaftand pulleybeforeinstallingbelt. Markthe directionof rotationon the belt beforeremoving. Replacethe rubbersealsfor oil leakagebetweenthe cylinderheadand cover. Do not usethe middlecoverand lower coverfor storingitemsdisassembled. Cleanthe middlecoverand lowercoverbeforeinstallation.
WASHER Replacewhen
CAP NUT x 1,0mm 9.8 N.m 11.0kgf.m,7,2lbttrl
or deteriorated.
CYLINDER HEAOCOVER Reterto page 6'78 when installing.
3-E
RUBBER SEALS Replace whendamaged or deteriorated, TIMINGBELT page 6-48 Insp€ctaon, Adjustment.page 6-48 R€placement.page 6'49
MIDDLECOVER
5xl,0mm 9.8 N.m (1.0kgt m, 7.2 rbtftt
8 x 1.25mm 56 N.m 15.7kgt m, 41 tbtftl 6x1.0mm 9.8 N.m {1.0 kgl.m, 7.2lbf.ftl
6x1.0mm 9.8N.m (1.0kgt.m,7.2lbfftl
10 x 1.25mm 5a N.m 15.5kgl.m. (} tbf.ftl Foradiustmentonly do not remove. TIMINGSEL Installwithconcave DRIVEPULLEY surfacetacing out. COVER R e m o v e a n y o i l a n d c l e a n . Removeany oiland clesn. Installwithconcave surfacelacingin. Clean.
NOTE:When installinga new crankshaftand/ornew bolt: O tightenthe crankshaftpulleybolrto 196N.m (20.0kgf.m.145lbf.ft), @ loosenbolt, @ retightenit to 177N.m fl8.0 kgf.m,130lbnft).
6-46
PULLEY Removeany oil and clean on the timing beltguide plateside.
BOLT 1il x 1.25mm 177N.m 118,0kgtm, 130lbtft) Replacement,page 6-47
GrankshaftPulleyBolt Replacement NOTE: . Crankshaftpull€y bolt size and torqus value: 1,0x 1.25mm 177 N.m (18.0kgt.m, 130 lbf'ft) . When instslling a new crankshaft 8nd/or now pulley bolt:
. When reinstallingthe bolt, lubricatethe thresds8nd flangewith engineoil, but don't lubricatethe washer and pulley. Lubricetowith engine oil hers.
O tight6nthe pulleybolt to 196N'm (20.0kgf'm, 145 tbf.ft). @ loosonthe bolt, @ r6tighten it to 177 N.m (18.0kgf'm, 130 lbf'ft).
ATTACHMEUT, PULITYHOLDEB HEXslt mm, OFFSET - PY3O1OA OTMAB
SOCKETWRENCH,19 mm COi'MEBCI,ALLYAVAILABT.E
6-47
TimingBelt TensionAdjustment
lnspection Removethe cylinderheadcover. .
CAUTION: Always adlust timing bslt tsnsion with th6 engine cold.
Referto page6-78when installing.
Inspectthe timing belt for cracksand oil or coolant soaking. NOTE: . Replacethe belt if oil or coolantsoaked. . Removeany oil or solventthat gets onthe b€lt.
NOTE: . The tensioneris spring-loadedto apply proper tension to the belt automaticallyaftermakingthe following adjustment. a Alwavs rotate the crankshaftcounterclockwisewhen viewed trom the pulley side. Rotating it clockwise may result in improper adjustmentof the belt tension. Removethe cylinderhead cover. (Referto page 678 when installing.) Setthe No. 1 pistonat TDC(seepage6-51). Rotatethe crankshaft5-6 revolutionsto setthe belt. 4.
Set the No. 1 pistonat TDC.
AINUSTINGAOLT 5/aN.m 15.5kg{.m,to lbtftl For adjustmentonly,
A
\v-/
\
.//
Direction rotat|on, Rotatepulley and inspectb6lt.
5.
Loosenthe adjustingbolt 1/2turn (180')only. Rotatethe crankshaftcounterclockwise 3 teeth on the camshaftpulley.
After inspecting.retorquethe crankshaftpulleybolt to 177N.m (18.0kgf.m,130lbf.ft).
6-48
7.
Tightenthe adjustingbolr.
8.
After adjusting,retorquethe crankshaftpulley bolt to 177N.m (18.0kgf.m,130lbf'ft).
Removal NOTE: . Turn the crankshaftpulley so the No. 1 piston is at top dead center {TDC)before removing the belt (see page6-51). . Inspectthe water pump when removed the timing belt {seepage10-9).
4.
Loosenthe adiusting nut and mounting nut, then removethe alternatorbelt. NUT I x 1.25mm 24 N.m {2.algf.rn, 17 tbf.ftl
Removethe wheel well splashshield (see page 657). Loosenthe adiustingbolt and mountingbolts,then remove the power steering (P/S)pump belt. AOJUSTING
MOUNTINGNUT 10 x 1.25mm 4,t N.m lia.5 kgl.m, 33 tbt ftl
Removethe cruisecontrolactuator(seepageG58). I x 1.25mm 2aN.ml2.akgt.m,17lbt ttl
Bemovethe side enginemount.
Loosenthe adjustingbolt and idler pulley bracket combolt, then remove the air conditioning(Ay'C) oresso. belt.
10x 1.25mm 52N.m15.3kgtm, 38lbtftl
ADJUSNNG CNGINC
MOUNT
D1IN BOLT 10 x 1.25mm ira N.m (4.5 kgf.m, 33 lbf'ttl
BELT
12 x 1.25mm 74 N.m (7.5kgt m, s4 lbf.trl
(cont'd)
6-49
Timing Belt Removal lcont'd) 1.
8.
a
Removethe cylinderheadcover.
1 0 . Loosenthe adjustingboh 180'.
.
1 1 . Pushthe tensionerto r€movetensionfrom the timing belt,then retightenthe bolt.
Referto page6-78when installing.
Removethe pulley bolt and crankshaftpulley (see page6-47). Removethe middlecoverand the lowercover. NOTE: . Do not uss the middlecover and lower coverfor storingitemsdisassembled. a Cleanthe middle cover and lower cover before installation. WASHER Replacewhen or deteriorated.
1 2 . Removethe timing beltfrom the pulleys.
6x1.0mm 9.8 N.m 11,0kgf'm, 7.2 lbl'ftl
CYLINDER OOVER Rel€rto pago 6-78 when inslalling.
NMING BELT Adjustment,page 6-48
MIDDLE COVER
@^R
RUABERSEALS
v@
R e p l a c 6w h e n
or deteriorated. 6x1.0mm 9.8 N.m {1.0 kgf.m, 7.2 rbnftl
LOWERCOVER 6r1.0mm 9.8N.m 11.0kgf.m,7.2lbtftl CRANKSHAFT PULl"EY Removeany oil and cleanon the timing belt guideplat6side.
BELT TENSIONER ADJUSNI{G BOLT 10 x 1,25mm 5,t N.m 15.5kgf.m, .(l rbf.ftt For adjustm€ntonly,
TIMINGBELT GUIDEPLATE lnstallwithconcave surfacefacing out. Removeany oil and clean.
PULI.TYBOLT 17?N m {18.0kgf.m,130lbtftl
TimingBelt lnstallation Installthe timing belt in the feverseorderof removal; Only key pointsare describedthere. NOTE:Cleanthe middle cover and lower cover before installation. 1.
Positionthe crankshaftand the camshaftpulleysas shown betoreinstallingthe timing belt. A. Set the crankshaftso that the No. 1 piston is at top dead center {TDC).Align the groove on the teethside of the timing belt drive pulleyto the V pointeron the oil pump. B. Align the TDC marks on intakeand exhaustpulleys. 2.
I n s t a l lt h e t i m i n g b e l t t i g h t l y i n t h e s e q u e n c e shown. O T i m i n g b e l t d r i v e p u l l e y ( c r a n k s h a t t*) @ A d j u s t i n gp u l l e y * @ w a t e r p u m p p u l l e y * @ Exhaustcamshaftpulley* @ Intakecamshaftpullev,
(cont'd)
6-51
Timing Belt Installation(cont'dl 1
Loosen and retighten the adjusting bolt to tsnsion thB belt.
4.
Rotatethe crankshaftabout 4 or 6 turns countsrclockwiseso that the belt positions on the pulleys.
5.
Adjust ths timing bolt tension (see pags &48).
1.
l f a c a m s h a f t p u l l e y i s n o t p o s i t i o n e da t T D C . .emove the timing belt and adiust the positioning following the procedureon page 6-51,th6n r6install rhe riming belt. NOTE: Refsrto page 6,19 for timing b€lt removal.
b.
Ch€ckths crankshaftpullsy and the camshaftpullsys at TDC. CRANKSHAFTPULLEY:
CAMSHAFT PULI..EY: "UP- MANKS
6-52
Aft€r installation,adiust the tension of each b€lt. o See section 23 for alternator belt tension adiustmenr. . See section 22 tot NC compr€ssor b6lt tension adjustm€nt. . See section 17 for P/S pump b6lt t€nsion adiustmenL
Cylinder Head lllustratedIndex CAUTION: To svoid dsmaging the cylindor h.ad, wsit until tho engino coollnt tomper.turo drop3 bolow 100'F (38'C) bofore romoving it. NOTE: r Use new O-ringsand gasketswhen reassembling. . Use liquidgasket,Pan No. 08718- 0001. . Replacethe rubbersealsfor oil leakagebetweenthe cylinderheadandcover.
fterw
to anycontactparts. drythem,andapplylubricant cleanallthe partsin solvent, ,o reassembling,
8 x 1.25mm 27 N.m 12.8kgt m, 20 rbt ft)
6x1.0mm 9.8 N.m (1.0 kgt'm, 7.2tblftl
f,
6xl.0mm 9.8 N.m {1.0 kgl m, 7.2 lbf.ftl
4qi
f
CYLINDERHEAD COVER Referto psge 6-78 when instglling.
s
CAMSHAFT
INTAKE CAMSHAFT
6 x 1.25mm 2it t*m 12.4kg[.m, 17 rbf.ftl
SEAL Replace.
liquidgasket to thos€ points.
Replacewhen damaged or det€riorated,
r 1.25mm 56 N.m 15.7kg{.m, ial lbf.ft)
Replace.
6-53
NOTE:Cleanthe headoil controlorificeand the rockershaftorificeswhen installino.
ROCKEBARM ASSEMBLY
CYLINDERHEAD BOLTS 1 1x 1 . 5m m 81 N m (8.3ks{ m, 60
INTAKEVALVESPRINGINNER
Apply clean engine oil to threads and washer contact surface.
SPRINGRETAINER INTAKEVALVESPRINGOUTER
VALVE
SPRINGSEAT
VALVESEAL Replace. SPRINGSEAT VALVEGUIDE
SPRINGRETAINER
MOTION ASSEMBLY
EXI{AUSTVAL SPRING
INTAKEVALVE
VALVESEAL Replace. INTAKE ROCKER ORIFICE Clean.
VALVE LOSTMOTION ASSEMBLY
ROCKERSHAFT DOWEL PIN -,
EXHAUSTVAL OOWEL PIN
ROCKER SHAFTORIFICE
CYLINDERHEAO GASKET 13LAYEBSOF MET Replace.
SEALINGBOLTS,20 mm 64 N.m 16.5kgf.m,47 lbtftl
Cylinder Head Removal Engineremovalis not requiredor this procedure. CAUTION: To avoid damaging tho cylinder head, wail u[tilths.nginc coolant tsmperaturo drops bolow 100"F (38'Cl bafore loos6ningtho retaining bolts.
5. Removeth€ strut brace,
8 x 1.25mm 24 N.m (2.1kg[.m, 17 lbtftl
NOTE; . Inspectthe timing belt before removingthe cylinder head. Turn the crankshaftpulleyso that the No. 1 piston is at top deadcenter(TDc){page6-51). a Markall emissionshosesbetoredisconnecting them. a Anti-theft radios have a coded theft protection circuit. Be sure to get the customer's code number before - Disconnectingthe battery. - Removingthe No.32 (7.5A) fuse trom the underhood fuse/relaybox. - Removingthe radio. After service,reconnectpower to the radio 8nd turn it on. When the word "CODE"is displaved.enter the customer's5-digitcodeto restoreradiooperation, '1. Disconnect the negativeterminalfrom the battery. Drainthe enginecoolant(seepage10-5). .
Removethe radiatorcapto speeddraining.
6. Removethe intakeair duct.
Relievefuel pressure(seesection111. Do not 3moke whilo working on fuel l@ systgm. ko6p opon tlamo ot Sparkaway trom work aroa. Drain fugl only into an approved containsr, 4.
INTAKE AIR
Disconnectthe fuel feed hose.
SERVIC€BOLT 15 N.m (1.5 kgtm, rl bf.tt)
WASHERS Replace.
BANJOBOLT
(cont'd)
6-55
CylinderHead Removal (cont'd) 7.
Removethe vacuum hose and €vaoorativsemission (EVAP)controlcanisterhose.
9. Removeths brake boostervacuum hose and fu€l return hose, BRAKEBOOSTER VACUUMHOSE
6x1.0mm 12N.m11.2kgf.n,8.t lbf.trl EVAPCONTROL CANISTERHOSE
10. R€mov6tho thronlo cable.
Remove the water bypass hose and positive crankcase ventilation{PCV)hose.
PCV HOSE
NOTE: o Taks care not to bsnd the cabl6 when removing it. Always replaceany kinkedcable with a new on6. o Adiust the th.ottle cable when installing (sees6ction1l).
WATERBYPAss HOS€
AD.'USTING THROTTI,"E NUT CABI.T
l l . Removethe engine wire harnessconnectorsand
14. Removethe sDlashshield.
wi.e ha.nessclampsfrom the cylinderheadand the intakemanitold. a Four fuel injector connectors o Intakeair tempe.ature {lAT) sensor connector a Engine coolant temperature(ECT)sensor connector o TDC/CKP/CYP sensor connector a lgnition coil conn€ctor a ECTgaugesendingunit connector a Throttle position (TP)sensor connector a VTECsolenoidvalveconnector a VTECDressureswitch connector a Manifold absolute pressure(MAP) sensor connector a ldle air control{lAC)sensorconnector a EVAPpurgecontrolsol€noidvalvoconnector a Intake air bypass {lABl control solenoid valve conneclor 12. Removethe spsrk plug caps and distributorfrom the cylinderhead.
6r1.0mm 9.8 N.m (1.0kgt m, 1.2 tbtftl
1 3 . Removethe upper radiatorhose, heat€rhose and water bypass hose. 1 5 . Removethe enginegroundcable. Romovothe adjustingbolt and mountingbolts,then remove the power steering (P/S)pump belt and P/S pump. . Do not disconnectthe P/S hoses.
WATER BYPASS
6x1.0mm 9.8 N.m 11.0kgl.m, 7.2 tbt.ttl
HOSE
(cont'dl
6-57 , l
Cylinder Head Removal(cont'dl 1 6 . Removethe heat shield from the P/S bracket(see p a g e5 - 1 8 ) .
21. Removethe cylinderheadcover. 22. Removethe timing belt (seepage6-49).
1 7 . Removethe air conditioning(Ay'Clcompressorbelt (seepage6-49).
23. Removethe camshaftpulleysand backcover.
'18. Remove the alternatorbelt {s€epage6-49). '19.
Removethe cruise control actuato.. 8 x 1.25mm N.m 12.4kgf.m, 17 lbtftl
ACTUATOR 24. Removethe exhaustmanifold.
20. Removethe sideenginemount. 10x 1.25mm
SELF.LOCKING NUT 8 x 1.25 mm 31 N.m {3.2 kgt m, 23 lbf.ftl Replace.
SIDEENGINE
12 x 1.25mrn 7a N.m 17.5kgl.m, 5a rbtftl
6 -5 8 'ilffi{
21. Remove the camshaft holder plates, camshaft hold-
25. Removethe intakemanifold.
ers, and camshafts. GASKET
CAMSHAFT
28. Removethe cylinder head bolts, then removethe cylinderhead. 26. Loosenthe adjustingscrews. CAUTION: To prsvent warpage, unscrew th€ bolts in sequencel/3 turn at a time; repeat until all bolts aro loosoned. CYLINDERHEADBOLTLOOSENINGSEOUENCE No.4
No. 4
INTAKE No.3 No.2
No.3 N o .2 EXHAUST
No. 1
No. 1
6-59
RockerArms Removal Holdthe rockerarmstogetherwith a rubberbandto oreventthem from seParating.
3.
Screw 12 mm bolts into the rockerarm shafts. Removeeach rocker arm set while slowly pulling out intakeand exhaustrockerarm shafts.
BAND RUBBER
Removethe intake and exhaust rocker shaft orifices, then removethe VTECsolenoidvalve and the sealing bolts. NOTE:The shapesof the rockershaftorificesof the intakeand exhaustare different.ldentify the parts as they are removedto ensurereinstallationin the originallocations.
EXHAUSTROCKER SHAFTORIFICE Clean. O.RING Replace.
INTAKE ROCKER SHAFTOBIFICE Clean. O-RING Replace.
ROCKERSHAFTS
Locations tho orifice ls corrccdY GAUTION: Aftcr in3tlllino th! roCk.r shrft o.ifice, trY to tum ihc tock r .hatt to makr luta thlt in3artcd in the holc of tho lockor shrft. It the oritice b in placc' it should not turn' NOTE: in originallocdtions' o ldentifypartsastheyareremovedto ensurereinstallation . lnsoect rockershafts and rockerarms (see pages 6-62and 63)' o Rocke.arms must be installed in the same position it reused' . Cleanthe rockershaft orifices when installing. I
erio, to ,einstalling,clesn all the parts in solvent, dry them and spply lubricantto any contact surfacos'
ARII,IASSEi/IBUES NTAKEBOCXER
BA D RUBBER INTAKEROCXER
sEALlMi BoLTS,20 m|tr 64 N.m 16.5ksf.]n,4.7lbf.ftl
SHAFT Cl6an.
I
& tu
ry
o-nrM;s R6placo.
ry
-%
HOII TROCIGRSHAFT
t
oRrFrcEsl
EXHAUSTROC(ER BOCXER SHAFT
RUASERBA'{D
EXHAUSTB(rcKERARMASSEMBLIES
6-61
RockerArms lnspection N O T E :W h e n r e a s s e m b l i n gt h e) p r i m a r y r o c k e ra r m , oil passageof the c a r e f u l l ya p p l y a i r p r e s s u r et o the t rockerarm.
ROCKERARM SECONDARY
PISTONS
Inspectthe rockerarm piston. ciston.Pushit manually. - lf it does not move smoothly, replacethe rocker smoot arm assembly.
\ xva
V/\'
Checkpistonmovement
. .
6-62
Apply oilto the pistonswhen whe reassembling. B u n d l et h e r o c k e ra r mss with w i a rubber band to keepthem togetheras a set.
Removethe lost motion assemblyfrom the cylinder head and inspectit. Test it by pushjngthe plunger with your finger. - l f t h e l o s t m o t i o n a s s e m b l yd o e s n o t m o v e smoothlv,reDlaceit.
Push
t
LOSTMOTIONASSEMBLY
Arm-to-Shaft Clearance Measureboth the intake rocker shaft and exhaust rocker shaft.
Measureinside diameterof rockerarm and chgck for out-of-roundcondition.
1.
Rock6rA.m-iq.Shaft Clearance: lntak. and Exhaust Standald (Now): 0.025- 0.052mm (0.0010- 0.0020in) S.rvicc Limit: 0.08 mm {0.003in}
Measurediameterof shaftat first rockerlocation,
Surfacoshouldbe smooth.
2.
Zerogaugeto shaftdiameter.
Inspectrockerarm facetor wear.
Repestfor all rockers. - lf over limit. replace rocker shaft and all over tolerancerockerarms. MICROMETER
N O T E : l f a n y r o c k e ra r m n e e d s r e p l a c e m e n t , replaceall three rocker arms in that set (primary, mid, and secondary).
6,63
RockerArms Installation 1.
I n s t a l l t h e r o c k e r a r m s i n t h e r e v e r s eo r d e r o f removal: . Valveadjustinglocknutsshould be loosenedand adjusting screw backedoff before installation. . The componentparts must be reinstaltedin the originallocations.
2.
Installthelost motionassemblies.
3.
Install the rocker arms while insening the rocker arm shaft into the cvlinderhead
4.
Clean and install the rocker shaft orifices with new O - r i n g s .l f t h e h o l e s i n t h e r o c k e ra r m s h a f t a n d cylinderhead are not in line with each other,screw a 12 mm bolt into the rocker arm shaft and rotate the shaft. NOTE:The shapesof the rockershaft orificesfor the intake and €xhaust are different.The orifices must be installedin the originallocations.
NOTE:Removethe rubber band after installingthe rocKerarms.
EXHAUSTROCKER SHAFTORIFICE
INTAKEROCKER SHAFTORIFICE Clean.
Cl6an.
O.RING Beplace.
'/'/
12 mm EOLT
6-64
Beplace.
Camshafts Inspection NOTE: . Do not rotatethe camshaftduringinspection. . Removethe rockerarms and rockershafts. 1.
P u t t h e c a m s h a f t sa n d c a m s h a f th o l d e r so n t h e c y l i n d e rh e a d ,a n d t h e n t i g h t e n t h e b o l t s t o t h e soecifiedtorque. SpecifiedTorque: O - @: 8 mm bolts 26 N.m {2.7 kgl.m,20 lbt'ftl (D -(D:6 mm bolts 9.8 N.m {1.0kgt.m,7.2 lbf'ftl
4,
o
o
o
o
@
Removethe bolts,then removethe camshaftholders from the cvlinderhead. N O T E : U n s c r e wt h e c a m s h a f th o l d e r b o l t s t w o turns at a time, in a crisscrosspattern.
5.
Lift camshaftout of cylinderhead.wipe clean,then inspectlift ramps.Replacecamshaftif lobesare pitted, scored,or excessivelyworn. Cleanthe camshaftbearingsurfacesin the cylinder head.then set camshaftbackin place.
1.
Placea plastigagestrip acrosseachjournal. Installthe camshaft holders,and then tighten the bolts to the specifiedtorque as shown in the left columnon this page.
Seateachcamshaftby pushingit toward distributor end of the cylinderhead. Z e r o t h e d i a l i n d i c a t o ra g a i n s te n d o f d i s t r i b u t o r drive, then push the camshaftback and forth and readthe end play. Camshaft End Play: Standard (New): 0.05- 0.15 mm 10.002- 0.006inl Sawics Limit: 0.5 mm (0.02inl
NOTE:Do not rotatecamshaftsduring inspection. 9.
Removethe camshaftholders.Measurewidest Dortion of plastigagestrip on eachjournal. Camshaft-to-HolderOil Clearance: Standard {New): 0.050- 0.089mm {0.002- o.Ooilin) Sswice Limit: 0.15mm (0.006in)
(cont'dl
Gamshafts Inspection(cont'd) 10, lf camshaft-to-holderoil clearanceis out of lolerance:
11. Checkcam lobewear. Clm Lobs Hcight Standard (N.w):
-
-
And camshaft has already been replaced,you must replacethe cylinderhead. lf camshaft has not been replaced,first check total runout with the camshaftsupportedon Vblocks.
CamehaftTotal Runout: Sisndard (New): 0.015mm (0.0006inl ServiceLimit: 0.03 mm (0.0012in)
IiITAKE
EXHAUST
PRIMARY
33.i{'l1 mm ( 1 . 3 1 5 4i n l
3 3 . 1 1 1m m (1.3036in)
MID
36.377mm l't.4322inl
35.720mm (1.4063inl
SECONDARY
34.547mm ( 1 . 3 6 0 i1n )
34.381mm (1.3536in)
Rotat€camshsft while measuring
Checkthis are6tor wsar.
Crm Porition
-
lf the total runout of the camshaftis within tolerance,replacethe cylinderhead. lf the total runout is out of tolerance,r€Dlacethe camshaftand recheck.lf the oil clearanceis still out of tolerance.replacethe cylinderhead.
INTAKE Mto
CXHAUST
sEc
SEC MID
PRI
fTt-]--Tt-Tt-l \ l l i l i l | / \
t t t t l
LIL__H___}{-}U
ftB
T/B: nMING BELT PRI: PRIMAFY MID:MID SEC:SECONDARY
6-66
ftB
Valves,Valve Springs and Valve Seals Removal N O T E : l d e n t i f yv a l v e sa n d v a l v e s p r i n g sa s t h e y a r e removedso that eachitem can be reinstalledin its orioinal position. 1.
Using an appropriate-sized socketand plasticmallet. lightlytap the valve retainerto loosenthe valve keepersbeforeinstallingthe valve spring compressor.
I n s t a l ls p r i n g c o m p r e s s o rC . o m p r e s ss p r i n g a n d remove valve keeper.
VALVESpRtNG COMPRESSoR ATTACHMENT
VALVESPRING ATTACHMENT COMPRESSoR EXTENSION
Snap-onCFrll
(cont'd)
6-67
Valves,ValveSpringsand ValveSeals Removal(cont'dl 3.
Installthespecialtoolas shown
Valve Dimensions
COMMERCIALLY AVAILABLE VALVEGUIDESEALREMOVER Lrst"EP/N s79(x'OR KD3350
4.
Removethe valveguide seal.
lntrko ValYo A Standsrd (N.wl: ilil.go - *t.10 mm (1.295- 1.303inl B Standard (Newl: 101.00- 101.30mm (3.976- 3.988inl C Standard (N.w): 5.a75- 5.185mm (0.2156- 0.2159inl C Sorvicc Limit 5.i!15(0.21.lt in) D Standard (Ncw): 1.05- 1.35mm (0.04i - 0.05:tin) D Sorvicc Limh: 0.85 mm (0.033inl Exhau3tValve A Stand.rd (Ncwl 27.90- 28.10mm - 1.106inl 11.098 B Standard (Ncwl: 1qr.6lt- loo.glt mm (3.961- 3.972inl - 5.460mm C St.nd.rd (Now| 5./L51, (0.2146- 0.215|,inl C ServicoLimit: 5.a20(0.2134inl D Standsrd lNewl: 1.65- 1.95mm {0.065- 0.077inl D Sorvicc Limit 1.45mm (0.057inl
6-68
InstallationSequence NOTE:Exhaustand intakevalvesealsare NOT interchangeable.
VAIVE IGEPGNS
v^LvEsP'ittNG
/
*nt
/^no,n
/'=\/
INTAKEVALVESPAING
\y
VALVE SPRING
@--'** 9-** EXHAUSTVALVESEAL (BLACKSPRINGI Replace.
NOE: Placethe end ofv.lv€ spring with closelywound coilg loward the cvlinder h€ad.
SPRINGSEAT NOTE: lnstallthe valvo spring se6t6 bsfore installingthe valv6 so6ls,
VALVE GUIDE SEAL II{STALITR KD-2EgS NOTE:UsosmalllD ond oftool.
VALVE SEAL R€place.
P.% 6-69
Valves,Valve Springsand
ValveSeals Valvelnstallation When installingvalves in cylinder head, coat valve stemswith oil beforeinsertinginto valveguides,and makesurevalvesmove up and down smoothly.
Valve Guides ValveMovement clearancewith a dial indicaMeasurethe guide-to-stem t o r w h i l e r o c k i n gt h e s t e m i n t h e d i r e c t i o no f n o r m a l thrust(wobblemethod).
When valvesand springsare in place,lightlytap the end of each valve stem two or three times to ensure proper seatingof valve and valve keepers(use hamm e rh a n d l e ) .
lntaks Valvr Stom-to-GuideClearance: Standard(Newl: 0.05- 0.11mm {0.002- 0.OO'lin) 0.16 mm (0.006in) Ssrvice Limit:
NOTE:Tap the valve stem only along its axis so you do not bendthe stem.
ExhaugtVdve Stem-to-GuideClsarancg: StandaldlNowl: 0.10- 0.16mm (0.00'l- 0.006in) Sorvics Limit: 0.22 {0.0m in) Valveextended10 mm out from seat.
. . .
l f m e a s u r e m e n te x c e e d st h e s e r v i c e l i m i t . recheckusinga new valve. lf measurementis now within the servicelimit, reassembleusinga new valve. lf measurementstill exceedslimit, recheckusing alternatemethod below,then replacevalve and guide,if necessary.
NOTE: An alternatemethod ot checkingguide to stem clearanceis to subtractthe O.D.of the valve stem. measuredwith a micrometer,from the l.D.ot the valve guide,measuredwith an insidemicrometer or ball gauge. Take the measurementsin three placesalong the valvestem and three placesinsidethe valveguide. The differencebetweenthe largestguide measure' ment and the smalleststem measurementshould not exceedthe servicelimit. lntafte Valvs Stom-to-GuidaClearance: Stardard (Nowl: 0.025- 0.055mm (0.0010- 0.0022inl 0.08 mm (0,003in) ServiceLimit: ExhaustValvo Stem-to-GuideClearance: Standard lNew): 0.050- 0.080mm 10.0020- 0.0031in) S€rvics Limit: 0.11 mm {0.0oilinl
6-70
1 . As illustratedin the removal steps ot this proced u r e . u s e a c o m m e r c i a l l y- a v a i l a b l ea i r - i m p a c t driverattachmentmodifiedto fit the diameterof the valve guides. In most cases,the same procedure c a n b e d o n e u s i n g t h e V a l v eG u i d e D r i v e ra n d a conventionalhammer,
COMMCRCIALLY.AVAILABLE VALVEGUIDEDRIVER
5.3mm (0.21inl
Workingfrom the camshaftside, usethe driverand an air hammerto drive the guide about 2 mm (0.1 i n ) t o w a r d s t h e c o m b u s t i o nc h a m b e r .T h i s w i l l knock off some of the carbon and make removal easier. CAUTION: . Always wear ssfcty gogglos 01 a taca rhiold whcn using thc air hrmmcr, . Hold tho.ir hammer diroctly in line with tho v6lvo goido to prov.nt drmaging tho driv6r.
I
_{l
azmm +-
szmm
{3.43inl
tz.zt in)
I
Turn the head over and drive the guide out toward the camshaftsideof head.
tfr
lf a valve guide still won't move, drill it out with a 8.0 mm (5/16in) bit,then try again.
10.8mm 10.42inl
R.mov.l andIn3trll.tion VALVEGUIDEDRIVER. 5.5mm 07742- q)101tt0
CAUTION; Drill guid6 only in oxtromc cs3os:you could dlmsgo tho cylinder hoad if tho guidc brcakr.
t uidesand chill S e l e c tt h e p r o p e r r e p l a c e m e n g them in the freezer section of a refrigerator for aboutan hour. Use a hot plate or oven to evenly heatthe cylinder headto 300'F(150"c).Monitorthe temperaturewith a cookingthermometer.
VALVEGUIDEDBIVER. 5.5mm 07742- 0010100
-_ -\ lo
CAUTION: . Do not us9 a iorch; it may warp ths hsad. . Do not get ths head hottor than 300"F (150"C); excsssivohgat may loogenthe valvo soaG. . To avoid burns, use hsaw glovo3whon handling the heated cylindor h€ad.
i
6.
oc)
one Removethe new guide(s)from the refrigerator, at a time, as vou needthem. (cont'd)
Valve Guides (cont'dl Replacement 7.
Reaming
Slip a 6 mm {0.2 in) steel washer and the correct driver attachmentover the end of the driver (The washerwill absorbsome of the imDactand extend the life of the driver).
:=:-/--P DRIVER
6 mm 10.2int WASHER
ATTACHMENT
Installthe new guide(s)from the camshaftside of t h e h e a d ;d r i v e e a c h o n e i n u n t i l t h e a t t a c h m e n t bottomson the head.lf you have all sixteenguides to do, Vou may haveto reheatthe head one or two more times.
NOTE:For new valveguidesonly. 1.
Coatboth reamerand valveguidewith cuttingoil.
2,
Rotatethe reamer clockwisethe full length of the valveguide bore.
3.
C o n t i n u et o r o t a t e t h e r e a m e r c l o c k w i s ew h i l e removingit from the bore.
4.
Thoroughlywash the guide in detergentand water to removeany cuttingresidue.
5.
Checkclearancewith a valve(seepage6-70). .
Verifythat the valve slidesin the intakeand exhaustvalveguideswithout exertingpressure.
REAMERHANDLE Turn reamerin clockwisedirection onry.
C'
o
a -'{ )
Valve Guide Installed Height: Intake: 12.55- 13.05mm {0.49it- 0.51itinl Exhaust 12.55- 13.05mm {0.494- 0.514inl
VALVEGUIDE
6-72
ValveSeats Reconditioning After resurfacingthe seat, inspect for even valve s e a t i n g :A p p l y P r u s s i a nB l u e C o m p o u n dt o t h e valve face, and insen valve in original location in thc hea.l.then lift it and snap it closedagainstthe seat severaltimes.
Renewthe valve seats in the cylinder head using valve seat cutters. NOTE: lf guides are worn, replacethem before cutting the valveseats.
ACTUALSEATING SURFACE
VALVE SEAT PRUSSIANBLUE
The actualvalve seatingsurface,as shown by the bluecompound,shouldbe centeredon the seat. . lf it is too high (closerto the valve steml, you must make a second cut with the 60' cutter to move it down, then one more cut with the 45' cutter to restoreseat width. . lf it is too low (closer to the valve edge), you must make a secondcut with the 30'cutter to move it up, then one more cut with the 45" cutter to restoreseat width. NOTE; The final cut should alwavs be made with the 45'cuttef.
C a r e f u l l yc u t a 4 5 os e a t , r e m o v i n go n l y e n o u g h materialtoensurea smoothand concentricseat. 1. Bevelthe upperedge of the seatwith the 30' cutter and the lower edge of the seat with the 60'cutter' Checkwidth of seatand adjustaccordingly.
lnsert intake and exhaust valves in the head and measurevalvestem installedheight. Intake Vllve St€m ln3tslled Hsighl: Stsndard (Now): 37.'155- 37.935mm (1.4750- f .il935in) 38.185mm 11.5033in) SorvicoLimit: ExhaustValvo Stom In3talledHoight: Standard (Now): 37.165- 37.6:15mm - 1.,1817 inr 11.4{X}2 (1.i1915 in) Limit: 37.885 Sewico
Make one more very light pass with the 45ocutter to removeanv possibleburrs causedby the other cutters. Valve Seat Width: 1.25- 1.55mm {0.0,19- 0.061in) Stlndard: Ssrvico Limit 2.0 mm 10.08in)
SEAI wlDTH VALVE STEM INSTALLEDHEIGHT
8.
lJ valve stem installed height is over the service limit, replacevalve and recheck.lf still over the service limit. replacecylinder head;the valve seat in the headis too deeD.
6-73
GylinderHead Warpage NOTE: lf camshaft-to-holderoil clearances(see page 6-65)are not within specification.the head cannot be .esurfaced.
Measurealongedges.and 3 ways acrosscenter.
lf camshaft-to-holder oil clearancesare within sDecifications,checkthe headfor warpage. lf warpage is less than 0.05 mm {0.002in) cylinder headresurfacingis not required. lf warpageis between0.05mm {0,002in) and 0.2 mm {0.008in), resurfacecvlinderhead. Maximum resurfacelimit is 0.2 mm {0.008in) based on a heightof 142mm (5.59in). PRECISION STRAIGHTEDGE
Cylindsr Hssd Height: Standard lNsw): 1i11.95- 1,f2.05mm 15.s89- 5.593inl
6-74
lnstallation Installthecylinderheadin the reverseorderof removal: NOTE: . Alwaysusea new headand manifoldgasket. . The cylinderheadgasketis a metal gasket Takecare not to bend it. . Rotatethe crankshaft,set the No. 1 piston at TDC (page6-51). . D o n o t u s e t h e m i d d l ec o v e r a n d l o w e r c o v e rf o r storingitemsdisassembled. . Cleanthe middlecoverand lowercover beforeinstallation. a Replacethe washerwhen damagedor deteriorated 1.
2.
Tightencylinderhead bolts in two steps.In the first step, tighten all bolts in sequenceto about 29 N'm ( 3 . 0 k g f . m . 2 2 l b f ' f t ) .I n t h e f i n a l s t e p ,t i g h t e n i n samesequenceto 81 N.m (8.3kgnm.60lbf'ft). NOTE: Apply clean engine oil to the bolt threads and underthe bolt head. CYLINDERHEADBOLTTOROUESEOUENCE
1 1x 1 . 5m m 81 N.m{8.3kgf.m,60lbfft)
tnstallthe cylinderhead gasket.dowel pins and the headoil controlorificeon the cylinderhead NOTE:Cleanthe oil controlorificewhen installing.
O.RING Replace.
HEAD OIL CONTROL ORIFICE Cloan.
Installthe intakemanifoldand tightenthe nuts in a crisscrosspatternin two or three steps,beginning with the inner nuts. GASKET RePlace
8 x 1.25mm 23 N.m 12.3kgl.m. 17 tbf.ftt 8 x 1.25mm kgf m, 24 N,m 12.,4 17 tbf.ft) (cont'd)
6-75
CylinderHead Installation{cont'd) 4.
Install the exhaust manifold and tighten the new selJ-lockingnuts in a crisscrosspattern in two or threesteps,beginningwith the inner nuts. .
SELF.LOCKING NUT 8 x 1.25mm 31 N.m 13.2kgf'm, 23 lbtltl Replace.
EXHAUST
6-76
O-RING{ReDlace.)
GASKET Replsco.
&,x a.l N.m 14.5kgt m, 33 tbr.trl
Installthe camshafts,camshaftoil sealsand rubber cap. NOTE: . Installthe camshaftswith keyway facing up. o Installtheoil sealwith the springsidefacingin. . The oil sealhousingsurfaceshouldbe dry, . Set the O-ringand dowel pin in the oil passage of th€ No. 3 camshaftholder
Usenew self-lockingnuts.
8 r 1.25mm 2aN..n12.4lgtm, r 7 tbf.ftl
5.
Kgywayis lacingup. A p p l y l i q u i d g a s k e ta r o u n dt h e r u b b e rc a p , t h e n installthe rubbercap.
8 x 1.25mm 24 N.m (2.4 kgt m, rt tbfft)
7.
Apply liquid gasket to the hesd mating surface of th€ No. 1 and No. 5 camshaft holders on both the intako and exhaust side. Confirm that the camshaft koywEysface up, then place those holders,together with th€ No.2, No. 3 and No.4 camshaftholders, on th€ cylind6r head.
9. Tightenthe bolts in the sequenceshown below.
NOTE: The arrows msrked on the camshaft holders shouldpoint to the timing belt. INTAKE CAIISHAFTHOIDERS lrlo.6
Ho.a
r t
No.3
l t
1to.2
t / l bl
d ffi rfl?x 888 ro I t
o
0
o
o
o o o
\trt
EXHAUST
Applyliquidgaskot to lh6 3had€daroas.
Temporarilytightonthe bolts of tho camshafthold6rs and thE camshaftholderplates,
(D - @: 8 x 1.25mm 27 N.m {2.8 kgf.m,20 lbt ttl (D - (D: 6 x 1.0 mm 9.8 N.m (1.0 kgrl.m,7.2 lbf'ft} 10. Installthe backcoverand camshaftpulleys.
CAMSHAFT CAMSHAFT HOI,I'ER
10x 1.25mm 56 N.ln l5.t kgf.m, 4r lbl.trl 6x1.0mm 9.8 N.m 11.0kgtm, t.2lbf'ft)
(cont'd)
6-77
CylinderHead Installation lcont'd) 1 1 . lnstallthetiming belt lsee page6-51).
12. Adjustthe valveclearance(seepage6-44). 1 3 . Installthe rubberseal in the grooveof the cylinder head cover. Seat the seal in the recessesfor the camshaftfirst, then work it into the groove around the outsideedges. NOTE: . B e f o r e i n s t a l l i n gt h e r u b b e r s e a l .t h o r o u g h l y cleanthe sealand the groove. . W h e n i n s t a l l i n gm , a k es u r e t h e s e a l i s s e a t e d securelyin the cornersof the recesseswith no gap.
14. Apply liquid gasketto the rubbe. seal at the eight corne.s of the recesses. NOTE: . Use liquidgasket,PartNo. 08718- 0001. . Checkthat the matingsurfacesare cleanand dry beforeapplyingliquidgasket. a Do not install the parts if 20 minutes or more h a v e e l a p s e ds i n c e a p p l y i n g l i q u i d g a s k e t . Instead,.eapplyliquid gasketafter removingold residue. r After assembly, wait at least 20 minutes before filling the enginewith oil.
Apply liquidgasketto the shadedareas.
COVER
6-78
When installingthe cylinder head cover. hold the rubbersealin the grooveby placingyour fingerson the camshaftcontactingsurfaces(top of the semicircles). O n c e t h e c y l i n d e rh e a d c o v e r i s o n t h e c y l i n d e r head,slidethe cover slightlybackand forth to seat the rubberseal.
Tighten the nuts in 2 or 3 steps. In the final step' tighten all nuts, in sequence,to 9.8 N'm (1.0kgf'm, 7.2 tbf.ft).
NOTE: Before installingthe cylinder head cover, clean t h e c y l i n d e rh e a d c o n t a c t i n gs u r f a c e su s i n g a shop towel. Do not touch the pans where liquid gasketwas applied.
6x1.0mm 9,8 N.m 11.0kgt'm, 7.2 tffirl
1 7 . After installing,checkthat all tubes,hosesand connectors are installedcorrectly.
6-79
EngineBlock PistonRings .............7'2 SpeciafTools .........7-16 Replacement 7-3 lllustratedIndex ................................... .................7-17 EndGap Flywheel and Drive Plate 7 -17 Ring-To-Groove C|earance,,,,.,,,...... .........7-7 Repfacement ..............7-18 Alignment Main Bearings Piston Pins 7-8 ,.............. Clearance ........,........7-18 7-8 Removal ................ Selection 7-19 Installation(818B1engine) ............. Connecting Rod Bearings (818C1 7-20 enginel ............. fnstaffation ............... 7-9 Clearance ..............7-2O fnspection 7-9 ................ Selection Rods Connecting Crankshaft .................7-21 .................7-10 End Play Removal ..........,,,,,,7-22 .................7-12 Sefeetion EndPlay ........,,,.,,7-12 Oil Seal lnspection .............7-25 fnstaffation .............7'22 fnstallation Installation CylinderBlock (engineremoval not requiredl.........7-26 ..............7-13 Inspeetion .....,.,,.7'14 BoreHoning Pistons ..............7-15 Inspaction .............7-16 Installation
SpecialTools
Raf.No.
o
07GAF- PF60300 07HAF- P120102 _ PR4O1OA OTLAD 07LAF PR30100 07LAB- PV00100 or 07924- PD20003or 01924 - PD20002 07948- S800101 07749- 0010000 07973- PE00310 07973- PE00320 07973- 5570500 07973- 6570600
@ @ @
o
@
o
I
Tool Numbcr
I
@
o
@
o
Dcacription
Oty
Piston Pin Easelnsert Piston BaseHead Seal Oriver PilotCollar RingGearHolder
1 I 1 'I
Driver Attachment Driver Piston Pin Driver Shaft Piston Pin Driver Head Piston Base PistonBaseSpring
1 1 1 1 1 1
I
Pago Rotcrenc. 7-14,19,20 1-18,19,20 7-19,20 7-1
1
7-25,26 7-19,20 1-19.20 1 - 1 8 ,1 9 ,2 0 1-18
Eg o
,a\
@
o
@
0 @
7-2
@
lllustrated Index Lubricateall internalpartswith engineoil during reassemory.
NOTE: Apply liquidgasketto the matingsurfacesof the right s i d e c o v e r a n d o i l p u m p h o u s i n gb e f o r ei n s t a l l i n g them. - 0001. . U s el i q u i dg a s k e tP, a n N o . 0 8 7 1 8 . C l e a nt h e o i l p a n g a s k e t m a t i n g s u r f a c e sb e f o r e installingit. .
Bl8Bl engine:
6x1.0mm 12 N.m (1.2kgf.m,I lbf.ftl OIL PAN
wAsHEF DRAINPLUG 44 N.m {4.5kgf.m, 33 tbtfr)
6x1.0mm 11 N.m (1.1kgf.m,8lbtft)
GASKET Replace. OIL SCREEN
6x1.0mm 1'l N.m {1.1kgt.m, I lbtft) 12 x 1.0mm 103N.m (10.5kgf.m,?6lbf ft)
MANUAL FLYWHEEL '12x 1.0mm 74 N.m {7.5kgt m,54lbf.ftl page7 7 Torquesequence,
GASKET Replace.
WASHER
BEARINGCAP
AUTOMATICTRANSMISSION DRIVE PLATE Checkfor cracks, Apply liquidgasket to blockmatingsurface.
11 x 1.25mm 76 N.m 17.8kgl.m, 56 lbf ftl Applyengineoilto the bolt threadsand the washers. NOTE: After torquing each cap, turn crankshaft to checklor binding. CRANKSHAFT End play,page7-12 Runout,Taper,and pages7 12,13 Out-of-Round, page7 22 Instsllation, MAIN BEARING page7-8 Radialclearance, page7-8 Sel€ction, NOTE:New main bearings must be selectedby matching crankand blockidentification markrngs.
6x1.0mm 11 N.m {1.1kgl.m,
8 tbf.frt
OIL SEAL page7-25, Installation, RIGHT SIDECOVER DOWELPINS THRUSTWASHERS Groovedsidesfaceoutward. NOTE:Thrustwasherthickness is tixedand must not be changed by grindingor shamming.
OIL PUMP Overhaul,page 8-9
8 x 1.25 mm 2,1N.m {2.4kgt m, 17 tbt.ft) O.RING Applyengrne orl. Replace.
OIL SEAL page8-11 Installation,
6x1.0mm Apply liquidgasket '11N.m {1.1kgf'm, 8 lbl ft) to blockmating
(conr'dl
7-3
lllustratedIndex (cont'd) NOTE: . Apply liquidgasketto the matingsurfacesof the right side cover and oil pump housing before installing thsm. . Useliquidgask6t,PartNo. 08718- 0001. . C l e a nt h e o i l p a n g a s k e t m a t i n g s u r t a c € sb e f o r e innallingit. Bl8Cl !ngin.:
Lubricateall internalpartswith engineoil during reassemblv.
DBAINPLUG 4,aN.mla.stgl.m. 33 rbr.ftt 6x1.0mm 11 N.m (1.1kgt m, E |bfitl OIL PAN
12x t.0 mln lo:t N.|n110.510f'm, tG lbffrl page7-7 Torquesoquonce.
6x1.0mm ti l*m 11.lkgf m, I tbf.ftl
GASKET Replace.
BAFFLEPLATE 6xl.0mm ll N.m (1.1kgt m. 8 tbt frl O|L SCAEEN 6 x 1.0 rim 11 N.m (1.1 kgf.m, 8 tbt ft)
FLWYHEEL
7-4
No. a 3, /aCAP BOLTS l l x 1 . 5m m 64 N.m {6.5 kgt m, 49 tbf.ftl Applyengineoilto tho bolt threads and the washers. NOTE:Aftertorquing each cap, turn crankshaft to checkfor binding.
BEARING CAPBRIDGE
No. 1,5 CAP BOI-TS 11x 1.5mm 73 N.m {7.4 kgf.m, 56 tbt'ft| Apply engineoil.
CRANKSHAFT Endplay,page7-12 Runout,Taper,and pages7'12.13 Out-of-Round, page7-22 Installation,
BEARINGCAP
YHRUSTWASHERS Groovedsideslace outward. NOTE: Thrust washerthickness is fixedand must not be chano€d
MAIN BEARING page7 8 Radialclearance. S6l€ction,page7-8 NOTE:New main bearings must be selectedby matching crank and block identification marxrngs.
OIL SEAL Installation, pages7-25,26 Replace.
OIL JEI BOLY 16 N.m 11.6kg{'m,12lbtftl Be caretul not to damage.
OIL JET Inspection, page 8-8
6r1.0mm 11 N.m 11.1kgt m, 8 lbf ftl RIGHTSIDE COVER Applyliquidgasket to block mating surface.
OIL PUMP Overhaul,page8-9 Apply liquidgasket to block mating surface. 6x1.0mm 11 N.m {1.1kSf.ft, 8 rbf.ftl
DOWELPIN
DOWELPIN O.RING. Apply engine orl. Replace.
OIL SEAL Instellelion, page8-11 Replace.
8 x 1.25mm 24 N.m {2.4 kgt m, 17 tbtft)
(cont'd)
7-5
lllustratedIndex
F
(cont'd) NOTE: New rod bearingsmust be selectedby matching connectingrod and crankshaftidentificationm a r K r n g s ( s e ep a g e s7 - 8 , 9 )
r@ -1@
Lubricateall internalpartswith engineoil during reassemorv.
PISTONINSTALLATIONDIRECTION
PISTONRINGS page7'16 Replacement, page7-17 Measurement. Alignment,page7 18
EXHAUST
PISTONPIN Removal,page7-18 pages7 19,20 lnstallation, page7'20 Inspection,
INTAKE
Removal,page7'11 page7 15 Measurement,
CONNECTING ROO Endplay,page7-21 page7-22 Selection, page7-21 Smallend measurement.
Inspecttop of each cylinder bore for carbonbuild-upor ridgo betore removing piston. page7'11 Removeridgeit necessary,
ROD CONNECTING EEARINGS page7-9 Clearance, Selection,page7-9
RODNUT CONNECTING 818B1ongine 8 x 0 . 7 5m m 31 N.m {3.2 kgf.m,23 lbf ftl 818C1engine 9 x 0.75mm a,aN.m (4.5kgt m, 33 lbf.ft| Aftertorquingeachbearang cap, rotate crankshaftto checkfor binding.
r-(,
BLOCX page7 13 Cylinderboreinspection, page7'14 Warpageinspection, Cylinderborehoning,page7-14
CONNECTING RODBEARINGCAP page7'23 Installation, NOTE:Installcapsso the bearingrecessis on the samesideas the recessin the rod.
Flywheel and Drive Plate Replacement ManualTransmission:
AutomaticTransmission:
Removethe eight flywheel bolts,then separatethe llyw h e e l f r o m t h e c r a n k s h a f ft l a n g e .A f t e r i n s t a l l a t i o n , tightenthe boltsin the sequenceshown.
Removeth€ eight drive plate bolts, then separatethe drive plate from the crankshaftflange, After installation, tightenthe bolts in the sequenceshown.
RINGGEARHOLOER o?LAB- PV00100, 07924 - PO2IX)03or 07924 - PD20/m2
\
n
.t=?4 fut!!-+-r
t=tz-21 I lvaz'Z
- +
ENGINE BLOCK
/ AK{:{AAo
rs#*ffi_9 r t.0 mm t,l N.m (7.5 kg{.m,54 lbf.ft}
o
-o.r
\
/ oo^t,
\..?bi r10.5kgi.m,76lbt.ftl
7-7
Main Bearings Clearance T o c h e c k m a i n b e a r i n g - t o - j o u r n aoli l c l e a r a n c e , removethe main capsand bearinghalves. C l e a ne a c h m a i n j o u r n a la n d b e a r i n gh a l f w i t h a cleanshop towel. Placeone strip of plastigageacrosseach main iournal. NOTE:lf the engineis still in the car when you bolt the main caD down to checkclearance,the weight of the crankshaftand flywheelwill flattenthe plastigage further than just the torque on the cap bolt, and give you an incorrectreading.Fot an accurate reading, support the crank with a iack under the counterweightsand check only one bearing at a trme. Reinstallthe bearing caps and cap bridge (818C1 engineonly)then torquethe bolts. 81881engine:77N'm (7.8kgf'm,56lbl'ft) 818C1engine: 73 N'm (7.'lkgt'm,56lbf'ftl No. 1,5 cap bolts 6a N'm (6.5 kgf'm, 49 lbf'ftl 4 cap bolts No. 2, 3, NOTE:Do not rotatethe crankshaftduring inspectron, Removethe cap bridge (818C1engine only), caps and bearingsagain,and measurethe widest part oJ the plastigage. Main Bearing-to-JournalOil Cl€arance: Standard (Newl: No. 1, 2, 4, 5: 0.024- 0.042mm - 0.0017inl 10.0009 ServiceLimit: 0.050mm {0.0020inl 0.030- 0.0,18mm No. 3: - 0.0019inl (0.0012 Ssrvice Limit: 0.060mm {0.0024inl
Selection CAUTION: lf ths codes are indeciphorable becau3o ot an lccumulation ol dirt and dust, do not gcrub thgm with a wirs brush or gcrapsr.Clean them only with 3olvont or doisrggnt.
Crankshaft Bore Code Location Letters have been stamped on the end of the block as a codefor the sizeof eachof the 5 main journalbores U s e t h e m , a n d t h e n u m b e r so r b a r s s t a m p e do n t h e crank(codesfor main journalsize),to choosethe correct bearings.
Mlin Joumal CodGLocttion3 (Numborsor
gaBl
STNIP PLASTIGAGE
lf the plastigagemeasurestoo wide or too narrow, (removethe engineif it's still in the car),removethe crankshaft.and removethe upper half of the bearing. Installa new. completebearingwith the same color code (selectthe color as shown in the right column),and recheckthe clearance. CAUTION: Do not file, shim, or scrapoihe bo.rings or the caps to adiust clearance. lf the plastigageshows the clearanceis still incorrect,try the next largeror smallerbearing(thecolor listedaboveor belowthat one),and checkagain. NOTE: lf the Droperclearancecannot be obtained by usingthe appropriatelargeror smallerbearings, reolacethe crankshaftand startover.
7-8
B..ring ld.ntificrtion Colorcodeis on the edge ot the bearang.
Largercrank Dore
c
I
-------.r>
smaller bearing(thicker)
tr;;lIl
IlE;tl t r -I tt l l H l t
I L o . " " lLiGreen Smaller msin journal
Smaller bearing (thicker)
D
G'een Gre€^
Blacr
Green Elack
Blue
ConnectingRod Bearings Clearance
Selection
1.
Removethe connectingrod cap and bearinghalf.
2.
Cleanthe crankshaftrod journal and bea.ing half with a cleanshootowel.
CAUTION: lf the codss are indeciphsrable bocause of an accumulation of dirt and dust. do not scrub tham with a wiro brush or scraper.Clean them only with solvont or dotetgenl.
3.
Placethe plastigageacrossthe rod journal.
Connecting Rod Code Location
4.
Reinstallthe bearing half and cap, and torque the nuts.
A number has been stampedon the side of each connectingrod as a code for the sizeof the big end. Use it, and the lettersstampedon the crank(codesfor rod journal size),to choosethe correctbearings.
81881 sngino: 31 N'm 13.2kgf.m,23 lbt'ft) 818C1sngine: 4,1N.m 14.5kgf.m. 33 lbf'ft} NOTE:Do not rotatethe crankshaftduring inspection. ConnectingRod B€aring-to-JournalOil Clcalancr: 8l88l ongine: Standard (New): 0.020- 0.038mm {0.0008- 0.0015in) ServicaLimit: 0.050mm (0.0020inl 818C1engin€: Standard (New): 0.032- 0.050mm (0.0013- 0.(XP0inl ServiceLimit: 0.060mm (0.0024in)
Halfof numberis stampedon bearing cap and the other half is stampedon rod.
STRIP PLASTIGAGE
Conn.cting Rod Joumsl Codc LocatioN lLotteE or B.trl
ll the plastigagemeasurestoo wide or too narrow, removethe upper half of the bearing.installa new, completebearingwith the same color code (select t h e c o l o r a s s h o w n i n t h e r i g h t c o l u m n ) ,a n d recheckthe clearance.
Berring ldcntification Colorcodeis on the edgeof the bearing.
Largerbig end bore t
CAUTION: Do not file, shim, or scrape lhe bearing or the capgtq adiust clgaranca. 1.
lf the plastigageshows the clearanceis still incorrect,try the next la.geror smallerbearing{the color listed above or below that one), and check clearanceagain. NOTE: lf the proper clearancecannot be obtained by usingthe appropriatelargeror smallerbearings, reolacethe crankshaftand stan over.
2
3 Smallerbearing{thicker)
tF;l It l - l f
Gr€€n
Red
l i B o r ' r lI l
lEalllt
I 1 o . , , ,L' l l Smaller rod journal
Smaller bearing (thicker|
Elack
Bla€k
Blue
Crankshaft Removal NOTE:End play for th€ connectingrods and crankshaft shouldbe inspectedbetoreremovingthe crankshaft. 1.
Removethe oil Dan,oil screenand the oil pump.
OIL PAN
5,
Removethe bearingcap bolts, CAUTION: To prevent warPag€, unscrew ths bohr in 3equoncg1/3 turn at a tim€; rspeat ihe sgquanco until all bolts are loos€ned.
o
@
@
R e m o v et h e c a p b r i d g e { 8 1 8 C 1e n g i n eo n l y } a n d in order. Keepall caps/bearings main caps/bearings.
Removethe baffleplate. Turn the crankshaftso No.2 and 3 crankpinsar€ at the bottom. Removethe right side cover.
7 -1 0
7 . Removethe rod caps/bearings. Keepall caps/bearings in order. 8 . Lift the crankshaftout of the engine,being careful not to damagejournals.
12. Use the wooden handleof a hammer to drive the prslonsouI. CAUTION: a Take care not to damage the contact surfaco ot the metal gasket. . When removing the piston/connecting rod, taks caronot to hit the oil iot {818C1snginsonlyl. . It tho oil iet nozzlo is damag6d or bont, replaco the oil ist assembly (818C1engine only, page 88).
CRANKSHAFT 9 . Removethe upper bearinghalvesfrom connecting
caDs. rodsand setthem asidewith their resDective 1 0 . Reinstallmain caps and bearingson the engine in oroDerorder. 1 1 .l f y o u c a n f e e l a r i d g e o f m e t a l o r h a r d c a r b o n around the top of each cylinder, remove it with a ndge reamer. instructions. Followthe reamermanufacturer's CAUTION: It the ridge is not removed, it may damage the pistons as they are pushed oul.
1 3 . Reinstallthe rod bearingsand caps after removing eachpiston/connecting rod assembly. 1 4 . Mark each piston/connecting rod assemblywith its
RIDGEREAMER
cylindernumberto avoid mixup on reassembly. NOTE:The existingnumber on the connectingrod does not indicateits positionin the engine,it indicatesthe rod bore size.
7-11
Crankshaft End Play NOTE;End play should be inspectedbefore removing crankshaft. Pushthe crankfirmly awav from the dial indicator,and zerothe dial againstthe end of the crank.Then pull the c r a n k f i r m l y b a c k t o w a r d t h e i n d i c a t o r ;d i a l r e a d i n g shouldnot exceedservicelimit.
lnspection . .
Cleanthe crankshattoil passageswith pipe cleaners or a suitablebrush. Checkthe keywayand threads.
Alignment Measurerunouton all main journalsto makesurethe crankis not bent. The differ€nce between measurementson each journal must not be more than the servicelimit. Crank3haftTotal lndicatod Runout: Bl8Bl engins: Sisndod {Nsw): 0.03 mm {0.001in) max. SorviceLimit: 0.05 mm {0.002inl 818C1engin€: Standard {Nsw): 0.020mm (0.0008in} mar. SGrviceLimits: 0.030mm 10.0012in) OIALINDICATOR Rotatetlvo complete revolutions.
CrankshaftEnd Play: Standard(New):0.10- 0.35mm (0.04- 0.01i|inl S€rvic€Limit 0.i15mm (0.018inl .
lf end play is excessive,inspectthe thrust wash€rs Replacepans as and thrust surfaceon the crankshaft. necessary.
NOTE: Thrust washer thickness is fixed and must not be changedeitherby grindingor shimming. Thrustwashersare installedwith groovedsidesfacing outward.
7-12
Support with lathe-
GylinderBlock Inspection Out-ot-Roundand Taper
1.
.
Measureout-of-roundat the middle of each rod and main journalin two places.
.
The differencebetween msasurementson each journal must not be more than the se.vicelimit.
Measure wear and taDer in dirsction X and Y at three levelsin eachcvlindsras shown.
6mm
Journal Oul-of-Round: Bt8Bi.ngine: Strndrrd (Now): 0.(x15mm Scrvicr Limit 0.010mm Bl8Cl cngins: Strnd.rd {Nowl: 0.004mm 0.qt6 mm Sorvicc Limit
Y
(0.0002inl m!x. (o.fixx inl (0.(XD16inl m!x. {0.qx!2,1 in}
near edggs.
.t +
BOREGAUGE CYUNDER
Cyllndor Borr Siz.: Standard (Ncwl: 81.q!- 81.02mm (3.18, - 3.190inl Scrvicr Limh: 81.07(3.192in) Ovar3izc: O.25t81.25- 81.27mm (3.199- 3.200inl Borc Tlpor: (Ditfcrcncc bctw!.n firtt tnd third Scrvice Limit moasurcm.ntl 0.115 mm (0.002in)
.
Journal Tapor: 8l8Bl angino: Standard (Newl: 0.q)5 mm l0.0(Xl2inl m.x. 0.010mm (0.0004inl SorvicoLimit BlSCl ongino: Standrrd (Now): 0.005mm (0.0002inl m8x. Scrvic€ Limit
Meaauremonl Second Moa6urgmont Thi.d M063uremgnt
G mm {0.24in}
.
Measuretaper at the edges of each rod and main journal. The difference between measurementson each journal must not be more than the servicelimit.
frrgt
l f m o a s u r € m e n t si n a n y c y l i n d s r a r e b e y o n d OversizeBore ServiceLimit, rsglacethe block. lf the block is to be rebored, refer to Piston ClearanceInspection(see page 7-151after reboring.
NOTE: Scored or scratchedcylinder bores must be honed. Rcboring Limil: 0.25 mm (0.01inl
(cont'd)
7-13
CylinderBlock Inspection(cont'dl 2. Checkthe top of the blockfor warpage. Measurealong the edgesand acrossthe centeras snown. SURFACES TO BE MEASURED
Measurecylinderboresas shownon page7-13. lf the block is to be reused,hone the cylindersand remeasurethe bores. Honecylinderboreswith honing oil and a fine (400 pattern. grit) stonein a 60 degreecross-hatch NOTE: . Use only a rigid honewith 400grit or finer stone suchas Sunnen,Ammco,or equivalent. a Do not usestonesthat are worn or broken.
Engine Block Warpsgc: 81881ongine: Standard lNewl: 0.07 mm {0.003inl max. ServiceLimil: 0.10mm {0.00,1inl B18Cl engine: Standard (New): 0.05 mm 10.002inl max. ServiceLimit 0.08 mm {0.003inl
W h e n h o n i n g i s c o m p l e t e ,t h o r o u g h l yc l e a n t h e cylinderblockof all metal panicles.Wash the cylinder bores with hot soapy water, then dry and oil immediatelyto preventrusting. NOTE: Never use solvent, it will only redistribute the grit on the cylinderwalls. lf scoring or scralchesare still presentin cylinder bores after honing to the service limit, reborethe engineblock. NOTErSome light venicalscoringand scratchingis acceptableif it is not deepenoughto catchyour fingernailand does not run the full lengthof the bore.
CYLINDERHONE
. .
7-14
After honing,cleanthe cylinderthoroughlywith soapywater. Only scoredor scratchedcylinderboresmust be noneo.
Pistons Inspection 1.
Checkthe oiston for distortion or cracks. NOTE:lf the cylinderis bored,an oversizedpiston must be used,
2.
M o a s u r €t h e p i s t o n d i a m e t e ra t a p o i n t l 5 m m (0.6in) from the bottomof the skin.
3,
C a l c u l a t et h e d i f f e r e n c eb e t w € o nc v l i n d e r b o r e diameteron (seepage7-13)and pistondiametsr. Pbton-io"Cy'indorClea18nco: Stsndard (Nrwl: 0.010- 0.0/O mm {o.ofira- 0.0016in} S.rvic. Limit: 0.05 mm {0.002in)
Pbion Diamat6r: Standard lNowl: 80.S - 80.99mm (3.188- 3.189inl 80.97mm (3.188in) SorvicaLimit
rKI lf the clearanceis near or €xc€edsthe servicelimit, inspect the piston and cylinder block for excessive wear. Ov.rsizc Pilton Diamcter: O.25t81,23- 81.21|rnm{3.1980- 3.198'lin)
7-1
Piston
PistonRings
lnstallation
Replacement
Beforeinstallingthe piston,applya coat of engineoil to the ring groovesand cylinderbores. '1. lf the crankshaftis alreadyinstalled: . Removethe connectingrod caps and slip short sectionsof rubber hose ove. the threadedends of the connectingrod bolts. a Installthe ring compressor,checkthat the bear' ing is securelyin place,then positionthe piston i n t h e c y l i n d e ra n d t a p i t i n u s i n gt h e w o o d e n handleof a hammer. Stop after the ring compressor pops free and checkthe connectingrod-to-crankjournal alignment beforetappingpistoninto place. . Installthe rod caps with bearings,then torque the nuts, 81881 ongino: 31 N.m {3.2 kgf.m, 23 lbf.ftl 818C1cngino: 44 N'm 1,t.5kgf.m, 33 lbf.ftl lf the crankshaftis not installed: o Removethe rod caps and bearings.install the ring compressor,then positionthe piston in the cylinderand tap it in usingthe woodenhandleof a nammer. . Positionall Distonsat toD deadcenter.
The arrow must face the timing beltside of the engine.The connectingrod oil hole must lace the intak€ manifold{81881€ngine).
ROD CONNECTING OIL HOI-E(Br8Bl onginel
NOTE:Maintaindownwardforce on the ring compressor to prevent rings from expanding before enteringthe cylinderbore,
BINGCOMPRESSOR
Usethe woodenhandle of a hammerto pushor tap the pistonintothe cylinderbore.
1 . Usinga ring expander,removeold pistonrings. Cleanall ring g.oovesthoroughly. NOTE: . Use a squared-oJfbroken ring or ring groove cleanerwith bladeto fit pistongrooves. . Top ring groove is 1.0 mm (0.039in) wide, second groove is 1.2 mm (0.047in) wide. and oil ring grooveis 2.8 mm (0.110in) wide. . Filedown bladeif necessary. CAUTION: Do not use a wire brush to cloan thr ring lands, or cut ring lands dsopo. with cl€aning tool. NOTE: lf the piston is to be separatedfrom the connectingrod, do not installnew ringsyet. Installnew rings in the prope. sequenceand position (seepage7-18). NOTE:Do not useold pistonrings.
I '1.
Using a piston, push a new ring into the cylinder bore 15- 20 mm (0.6 0.8 in) from the boftom.
After installinga new set of rings, measurethe ring-togfoove clearances:
M e a s u r et h e p i s t o n r i n g e n d - g a pw i t h a f e e l e r gauge:
Top Ring Cl€arance: Standard lNewl: 0.045- 0.070mm 10.0018- 0.0028in) ServiceLimit: 0.13mm {0.005inl
lf the gap is too small.checkto see if you have the properringsfor your engine. lf the gap is too large,recheckthe cylinderbore diameteragainstthe wear limits on page7-13. ll the bore is over the servicelimit, the cylinder blockmust be rebored.
SecondRing Clearance: Standard {Newl: 0.040- 0.065mm (0.0015- 0.0026inl'1 0.0i15- 0.070mm - 0.0028in)', (0.0018 ServiceLimit: 0.13 mm (0.005inl
Piston Ring End-cap: Top Ring Standard (New): 0.20- 0.35 mm (0.008- 0.01'linl'1 0.20- 0.30 mm - 0.012inl'' 10.008 ServicaLimit: 0.60 mm (0.024in) Second Ring Standard (Now): 0.40- 0.55 mm - 0.022in) 10.016 ServiceLimit: 0.70 mm (0.028in) Oil Ring Standard (New): 0.20- 0.50 mm (0.008- 0.020in)'1 0.20- 0.,15mm {0.008- 0.018inl', ServicaLimit: 0.70 mm 10.028in)
iliiii
.--r.llli.j---.-
PISTONNING
ioi ---'z
ll
ENDGAP-11-RIKENmanufactured pistonring T E I K O K UP I S T O NR I N Gm a n u f a c t u r e do i s t o n r i n q { 8 1 8 8 1e n g i n eo n l y )
RIKENmanufacturedpistonring T E I K O K UP I S T O NR I N Gm a n u f a c t u r e dD i s t o nr i n o ( B ' 1 8 8e1n g i n eo n l y )
7-17
PistonRings
PistonPins
Alignment
Removal
1.
1.
Installtheringsas shown. ldentifytop and secondrings by the chamferon the edge.Makesurethey are in their propergrooveson the prston.
Assemblethe PistonPin Toolsas shown. PISTON BASE HEAD PISTO]TPIN BASE INSEN|T
--r
otGAF- PH6{t1,0
NOTE: The manufacturingmarks must be facing upwaro. TOPBING
--l PISTON BASE SP '{G 07973 - 65r06{X'
SECONDRING
Rotatethe rings in their grooves to make sure they do not bind. MARK
OIL RING
3.
SPACER
Positionthe ring end gapsas shown: sEcoNo ----'-- R|NG _- GAp - {
position ' ring ' gap DO NOT -.:': :.-"' : -any at prston thrustsurfaces.
App.ox. 90"
OIL RING
ls" GAP TOP BINGGAP DO NOTpositionany ring gap in linewith the pistonpin hole.
7 -1 8 ,
SPACERGAP OIL RINGGAP
Installation(B18Bl engine) 2.
Adjustthe lengthA of the pistonpin driver. A:81881 engine:49.70mm {1.957inl Bl8Cl €ngin€:51.70mm {2.035inl
1.
Usea hvdraulicoressfor installation. When pressingthe pin in or out, be sureto position the recessedflat on the piston againstthe lugs on the baseattachment.
PISTONPIN DRIVERHEAD 07973 - PE00320
PISTONPIN DRIVERSHAFT 07973- PE00310 PILOI COLLAR 07LAF- PR30100 Embossedmarkfacingup.
The arrowmustfacethe timing beltsideo{ the engineand the connecting rod oil hole mustfacethe rearsideof the engine,
otl Hols 2. AdjustthelengthB of the pistonpindriver. B:49.70mm (1.957 inl NOTE:Usea hydraulicpress. When pressingpin in or out, makesurethat the recessed portionof the pistonaligns with the lipson the collar.
PISTONPIN DRIVERHEAD 07973- PEfl)320
Placethe piston on the piston base and pressthe pin out with a hydraulicpress.
PISTONPIN DR|VENSHAFT 079?3- PE|X)310 Embossedmark
ffi*.r,"ror","l PILOTCOLLAN 07LAF- PF301(x)
PISTONPIN BASEINSERT 07GAF- PH603oO PISTONBASEHEAD 07HAF- PL20t02 PISTONBASE 079?3- 6570500
NOTE: lnstall the assembledpiston and rod with the oil holefacingthe intakemanifold.
7-19
PistonPins Installation lB18C1enginel 1.
Inspection Measurethe diameter of the piston pin.
Usea hydraulicpressfor installation. .
When pressingpin in or out, be sure you position the recessedflst on the piston againstthe lugs on the baseattachment,
Pi3ton Pin Dirmltlr: Standard lN.wl: 20.994- 21.dlo mm Ovo.3ize:
Th€ arrow must tace timing beltsid€of rhe engino.
(0.8265- 0.8:168inl 20.907- 21.(xxtmm - 0.&16S (0.8267 in)
NOTE: All replacementpiston pins are oversize.
Tho mork must tace the timing belt side ot the engine.
Adjust the l€ngth B of piston pin driver. Br 51.70mm (2.035inl
PISTONPIN
-T-
;
fl--.l j I ll t \J ---..''
tl i-
- ,rH ,l l
ilil
Embossedm.rk ll ll-l!-lJ facins up. \ t
HEAD DRr\rER - PEm32o 07e73 PlsroNPtN sHAFr DRtvER
- PEoo3lo 07s73
-4 r PISTONPIN PILOTCOLLAR
o?LAF-PR3o1n'
I =)ffi ri _-r -_t, -l l l'll,llltllrl ll ll li l i l l
L-lt|lllltlll _-
PrsroNPINBASEINSERT - PH6O3q) O?GAF PISTONBASEHEAD 07HAF- P120102 PISTONBASE 07973 - 65705U)
7-20
2.
Zerothe dial indicatorto the pistonoin diamater.
ConnectingRods End Play 3.
Measurothe piston pin-to-pistonclearance.
NOTE:End play should bs insp€ctedbefore removing the crankshaft.
NOTE: Checkthe Distonfor distonion or cracks. It the piston pin clearanceis greater than 0.022 mm (0,0009in), remeasureusing an ovorsizepiston pin.
Connrcting Rod End Pl.y: Stlndrrd (Nrwl: 0.15- o.3o mm (0.(xt6- 0.012inl Scrvict Limit o./tomm (0.016inl
Pbton Pin-to-PLton Cloeranco: StlndErd (Ncwl: 0.010- 0.022mm
- o.(Xxlg (0.(xto4 inl
a lf out-of-tolerance,install a new connscting rod. a lf still out-of-to16rance, replacethe crankshaft
pages7-10and 7-22) 4.
Check the difference betwsen piston pin diameter and connectingrod smallend diam€ter. Pbton Pin-to4onnocting Rod Inlcdaranca: Strndlrd {Ncw}: Bl8Bl ongino:0.013- 0.G12mm (0.fiX15- 0.0013inl Bl8Cl cngin.: 0.017- 0.036mm IO.ON1- O.|,o11int
7-21
ConnectingRods Selection Eachrod falls into one of four toleranceranges(from 0 to + 0.024mm (0 to + 0.0009inl, in 0.006mm {0.0002in) increments)dependingon the size ot its big end bore. It's then stampedwith a number(1,2,3, or 4) indicating the range. You may find any combinationol 1, 2, 3, or 4 in any engane.
Crankshaft lnstallation Before installing the crankshaft.apply a coat of engineoil to the main bearingsand rod bearings. 1.
Installthe thrustwashersin the No. 4 iournslof the cvlinderblock.
Normsl Boro Sizoi ,18.0mm 11.89inl NOTE: a Referencenumbersare Jor big end bore sizeand do NOTindicatethe positionof the rod in the engine. . Inspectconnectingrod for cracksand heatdamage.
CONNECNNGRODBORE REFERENCE NUMBER HalfoI numberis stampedon bearingcap.th€ otherhalfon connectingrod.
Groovedsidetacing o!tward Insertbearinghalvesin the engine block and connectingrods. Holdthe crankshaftso rod journalsfor cylindersNo. 2 and No.3 are straightup. Lower the crankshaftinto the block. putting the rod journalsinto connectingrods No.2 and No.3. Installthe rod capsand nuts finger-tight,
CONNECNNGROD
7 -22
Rotatethe crankshaftclockwise,put journals into connecting rods No. 1 and No. 4, and install the rod caps and nuts finge.-tight. NOTE:lnstallcaps so the bearingrecessis on the samgsideas the .ecessin the rod. Check rod bearing clsarancewith plastigage(see page 7-9),then tighten the capnuts in 2 steps. l3t 3t.p: 20 N.m (2.0 kgf.m, rl btfil 2nd 3tep: 81881 cnginc: 31 N.m (3.2 kgf.m, 23 lbf.ft) 818C1.ngin!: ,14N.m (4.5 kgt.m,33 lbf.ft)
8.
Checkclearsncewith plastigsge(see page 7-8).then tighten bearingcap bolts in 2 steps. 13t st.p: 29 N.m (3.0 kgf.m, 22 lbt.ftl 2nd 3tsp: 81881 .ngin.: 76 N.m (7.8 kgt.m,56 lbf,ft) Bl8Ct engine: No. 1, 5 cap bol$: 73 N.m (7./rkgf'm, 56 lbf,ftl No. 2, 3, a clp bolbr 6{ N.m (6.5 kgf'm, /r9 lbf,ftl
BEARINGCAP BOLTSTOROUESEOUENCE Bl88l cngino:
NOTE: Referencenumbers on connectingrod are for big-endbore toloranceand do NOT indicatethe positiooof pistonin the engine. I n s t a l l t h e m a i n b e a r i n g s / c a p sa n d c a p b . i d g e (818C1engineonlyl. NOTE:Coatthe bolt threadswith oil. CAPBRIDGE lBlSCl .noin. onlyl
Bl8Cl ongino: EEARIlTG
CAUTION: Whenever any crsnkehaft or connocting rod b.aring is rlphccd. it i5 ncccrsrry aftor rclssombly to run tho ongino ai idling 3p6ad until it re.chei normrl opcrating tcmporature, thon continuo to run it fol spp.oximltoly f 5 minula3. (cont'd)
7-23
Grankshaft Installation(cont'd) 9.
liquidgasketto the blockmatApply non-hardening ing surfaceof the right side cover,and installit on the cylinderblock,
liquidgasketto the blockmat10. Apply non-hardening ing surface of the oil pump, and install it on the cvlinderblock.
NOTE: . Use liquidgasket,PartNo. 08718- 0001. . Checkthat the matingsurfacesare cleanand dry beforeapplyingliquidgasket. . Apply liquid gasket as an even bead, centered betweenthe edges of the mating surface. . To preventleakageof oil, apply liquid gasketto the innerthreadsof the bolt holes. . Do not install the parts if 20 minutes or more have elapsedsince applying the liquid gasket. Instead,reapplyliquid gasketafter removingthe old residue. . After assembly, wait at least 20 minutes before fillingthe enginewith oil.
OILPUMP:
RIGHTSIDECOVER:
6x1,0mm tl N.m {1.1kgr'm. 8 tbf.ftl
RIGHTSIDE
6x1.0mm 11 N.m {1.1tgl.m,
DOWELPIN O.RING R6plac€.
DOWELPINS
7-24
OIL PUMP
8 x 1.25mm 2il l$m l2.iakg[.m. 1t rbf.ftl
Oil Seal lnstallation The sealsurfaceon the blockshouldbe dry. Apply a light cost of oil to the crankshaftand to the liDof the seal.
1 1 . lnstalltheoil screen. Installtheoil pan.
1' I
NOTE:Cleanthe oil pan gasketmatingsurfaces.
Drivein flywheelend sealagainstright sidecover.
Tightenthe boltsas shown below.
NOTE:Drivethe end sealin squarely.
Torque: 12 N.m {1.2 kgf.m, 9 lbf'ft)
DRIVER 07t,49- (xll(xtoo
NOTE: Tighten the bolts and nuts in two steps and toroue the bolts in a crisscrosspattern
lnstallsealwiththe part numberside tacing out.
2.
Confirmthat clearanceis equal all the way around with a fe€lergauge. Cler.6nce: 0.5 - 0.8 mm (0.02- 0.03 inl RIGHTSIDE COVER
NOTE:Reterto right column and 8-10lor installation of the oil pump side oil seal.
7-25
Oil Seal Installation(engineremovalnot required) The sealsurfaceon the blockshouldb€ dry. Apply a light coat of greaseto the crankshaftand to the lio of seal. Using the specialtool, drive in the timing pullsyend seal until the driver bottoms against the oil pump. When the seal is in place,clean any excessgrease off lhe crankshaftand checkthat the oil seal tiD is not distoned. S€ALDRIVEB 07LAD- PRimroA lnstallse6lwith tho Pan number tacing out.
Usingthe specialtool, drive in the flywheel-endseal until the driverbottomsagainstblock. NOTE:Align the hole in the drivsr attachmentwith the Dinon the crankshaft.
7-26
EngineLubrication ........8-2 S p e c i aTf o o l s . . . . . . . . ."' 8-3 l l l u s t r a t e dI n d e x . . . . . . . . EngineOil . . . . . . . . . . . " ' . . .8' - 5 Inspection R e p l a c e m e n. t. . . . . . . . . . . . .".". . . . . . . . ' . ' .8 - 5 Oil Filter R e p l a c e m e n. t. . . . . . . . . . . . . . . . . ." . . . . . . . 8 - 6 Oil Pressure ....' 8-8 Testing Oil Jet I n s p e c t i o n{ 8 1 8 C 1 e n g i n eo n l y } . . . . . 8 - 8 Oil Pump ... 8-9 Overhaul Removal/lnspection/lnstallation. . ' . . . 8- 1O
SpecialTools
Rel. No.
o
@
I
Tool Numbel OTLAD_ PR4OlOA o 7 9 12 - 6 1 1 0 0 0 1
Descrlption
Oty
8-11 8-7
Seal Driver Oil Filter Wrench
o
8-2
I Pago Roferenco
lllustrated Index CAUTIOIiI: Do not ovortighten the drain plug.
NOTE; o Use new O-ringswhen reassembling. a Apply oil to O-ringsbetore installation, . Use liquid gasket, Part No. O8718-OOO1. a Cleanthe oil pan gasket mating surtacesbefore installingit. 6 x'l.omm 12 N.m {1.2 kgt.m,9 lbt.tt)
81881 sngine:
WASHER Replace. DRATTPIUG 44 .m (4.5 tgf.m, 33 lbf'ftl\ Do not ovgr tightgn.
\ \ \
-@5 \
OILPAI{ GASKET R6placs, 6 r l.O mtn 121{.m11.2kol.m, I lbl.ttl
6 x 1.0 mm '11 N.m 11.1 kgt'm,8lbt.ftl
OIL SCREEN
O|L BNEATHER TAIIK
6 x 1 . Om m ll N.m {1.1kgf'm,
I tbt.ftl GASKET Replace. BAFFLEPTATE
eq
nU2o@ \\
u
#-'
I
OIL FIL Repl.cemont, p6gs 8-6
I x 1.25mm 24 N.m 12.4 kgf..n, 17 rbr.ftl
A ENGINEOIL PRESSURE
,F
swlTcH
18 .m 11.8 kgl.m, 13lbl.ftl 'l/8 in. BSP lgritish Standard Pioo Taporl 28 Threads/inch. Use propgr laquid56alant.
HEAD OIL CONTROLORIFICE CIean.
OIL PUMP Overhaul,page 8-9 lnspectionpage, 8-1O Apply liquid gasket to block mating surlace.
6 x 1 . Om m 11 N-m(1.1kgt.m,8lbf.ft)
(cont'dl
8-3
lllustrated Index (cont'dl CAUTION: Do not overtighten rhe dlain ptug. 818C1 engine: DRAINPLUG 44 N.m (4.5 kgf.m, 33 lbt.ftl Do not overtighten.
NOTE: a Use new O-ringswhen reassembling. a Apply oil to O rings before installation. . U s e l i q u i dg a s k e t .P a r tN o . 0 8 7 1 8 - O O O 1 . a Cleanthe oil pan gasket mating surfacesbefore installingit.
OIL PAN 6 x 1.0mm 12 N.m 11.2 kgl.m, 9 lbf.ftl
6 x 1.0 mm 1 1 N . m 1 1 . 1k g t . m , S lbf.fil OIL JET BOLT 16 N.m {'1.6kgf.m, '13 lbf.ft} Replace. OIL JET Be careful not to damage. Inspection,page 8-8 EAFFLEPLATE
O-RING Replace.
6xl.0mm 11 N.m (1.1 kgt.m, I lbt.ft) OIL SCREEN
GASKET Replace.
Il ,--)e 6V ENGINEOIL COOLER 6 r ' 1 . 0m m l 1 N . m ( 1 . 1 K9-m, 8 rb-trl
ENGINEOIL FILTER page 8-6 Replacement,
O-RING Replace.
OIL COOLER CE TER BOLT 74 N.m (7,5 kgf.m, 54 lbf.ft) ENGINEOIL PR€SSURE
swtTcH 1A N.m {1.8 kgf.m, 13 lbf.ft) 1/8 in. BSP {BritishStandard PipeTaperl 28 threads/inch. Use properliquidgasket.
8-4
HEAD OIL CONTROL ORIFICE Clean.
8 x 1.25mm 24 N.m (2.4 kg-m, 17 lb-ft) OIL PUMP Overhaul,page 8-9 Removal/lnspection/lnstallation, page 8-10 Apply liquidgasketto mating surfaceot the engineblock.
EngineOil lnspection
Replacement
Check engine oil with the engine off and ths cal parked on level ground,
CAUTION: Remova tho drain plug cal€fully whilo the ongine is hot; the hot oil may cause scalding.
Make cenain that the oil levelindicatedon the dipstick is between the upper and lower marks.
1. Warm up the engine. 2,
Drainthe engineoil.
3.
Reinslallthedrainplugwith a new washer,and refill with the recommendedoil.
3 . lf the l€vel has droppedclose to the lower mark, add oil until it reachesthe upper mark. CAUTION: Inssrt lho dipstick carotully to avoid bending it.
CAUTION: Do not ovortighton tho drain plug.
Requirement
Capacity
Change
"Energy API ServiceGrade:Use Conservingll" SG or SH grade oil. SAE 5W-3O Drefered.
B 1 8 B 1e n g i n e : 3.51 (3.7 US qt, 3.1 lmpqtl at oil change. 3.8 t (4.0 US qt, 3.3 lmp qt) at change.includingfilter. 4.6 I 14.9US qt. 4.0 lmp qt) after engineoverhaul. B18Cl engine: 3.7 f (3.9 US qt, 3.3 lmp qt) at oil change. 4.O t 14.2US qt, 3.5 lmp qt) at change,includingfilter. 4.a I (5.1 US qt, 4.2 lmp qt) after engineoverhaul. Every 7,5OOmiles (12,OOokm) or 6 months (cont'd)
8-5
EnglneOil Replacement{cont'd)
Oil Filter Replacement CAUTION: Aftar the ongine has boan run. tho oxhaust pipos will bo hot; b€ caretul when wo.king around tho erhaust manitold, Removethe oil tilter with the specialoil filter wrench. Inspectthe threadsand rubbe.sealonthe new lilter. Wipe off seat on engineblock.then apply a light coat of oil to the tilter rubberseal,
ElrclltEs
NOTE: Useonly filrerswith a built-inbypasssystem.
Inspectthreadsand rubbersealsurface-
APICERTIFICATION SEAL
The numbersin the middleof the API Servicelabeltell you the oil's SAE viscosityor weight. Selectthe oil for your car accordingto this chart: Ambient TomDo?aturo
An oil with a viscosity of 5W-3Ois preferredfor improved fuel economyand year-roundprotectionin the car. You may use a l OW-3Ooil it the climatein your areais limited to the tempe.aturerange shown on the chart. 4.
8-6
Fillthe enginewith oil up to the specifiedlevel,.un the enginefor morethan three minutes.then check lor oil leakageand oil level.
Apply oil to rubber seal betore anstalling.
ENGINEOIL COOLER (8'l8Cl ongino onlyl
Eightnumbers{'l to 8) are printedon the surfaceof rhe filter.
Installthe oil tilter by hand. 4.
After the rubbersesl seats,tighten the oil filter clockwise with the specialtool.
The followingexplainsthe procedurefor tightening filters using these numbers.
Tighten: 7/8 turn clockwise. Tightening torque: 22 N.m (2.2 kgf'm, 16 lbf'ft)
1) Makea markon the cvlinderblockunderthe number that shows al the bottom of the filter when the rubber seal is seated.
CAUTION: Installationother than the abova plocedure could r6suh in serious engine damag€ due to oil leakage.
2) Tightenthe tilter by turning it clockwiseseven numbersfrom the markedpoint. For example,if a markis madeunderthe number2 when the tubber seal is seated.the filter shouldbe tightened 'l until the number comes up to the markedpoint.
OILFILTEBWRENCH 07912-6110001
MARK Number when rubber seal is seated.
Numberafter tightening.
Numberwhen rubber seal is seated
4
Numberafter tightening 8
?
5.
I
6 o
7
After installation,till the enginewith oil up to the specified level, run the engine for more than 3 minutes,then check for oil leakageand oil level.
8-7 _l-
.4
Oil Pressure
Oil Jet
Testing
Inspection(B18C1 engineonly|
lf the oil pressurewarninglight stayson with the engine running, check the engine oil level. lf the oil level is correct:
Removethe oil jet (seepage 8-4) and inspectit as follows. a Make surethat a I .l mm (O.04in) diameterdrill will go throughthe nozzlehole{1.2 mm {O.OSin) diameterl. a Insertthe other end of the same 1.1 mm (O.O4 in) drill into the oil intake {1.2 rnm {0.05 in} diameter). Make surethe check ball movessmoothlv and has a stroke of approximately4.0 mm {O.16 in). a Checkthe oil jet operationwith an air nozzle.lt should take at least 2OOkPa (2.O kgf/cmr,28 Dsi)10 unseatthe check ball.
1. Connecta tachometer. 2.
Removethe oil pressureswitch and installan oil pressure gauge.
3.
Stan the engine.Shut it off immediatelyif the gauge registersno oil pressure.Repairthe problembefore continuing.
4.
Allow the engineto reachoperatingtemperatu,e{fan comes on at least twice). The Dressureshouldbe:
NOTE: Replacethe oiljet assemblyif the nozzle is damagedor bent.
Engine Oil Pressure: 70 kPa (0.7 kgf/cmr, 10 psi) minimum At 3,OOOlpm: 340 kPa {3.5 kgf/cmz, 50 psi} minimum At ldle:
1 . 2 m m 1 0 . 0 5i n )
a lJ oil pressureis within speciJications,replacethe engineoil pressureswitch and recheck. a lf oil pressureis NOT within specifications,inspect the oil pump (see page 8-1O). OILPRESSURE GAUGE COMMERCIALLY AVAILABI.E
'16 N.m (1.6 kgt.m, l2lbt.ftl
2.
Mountingtorqueis critical.Be very precisewhen installing. Torque: 16 N.m (1.6 kgt.m, 12lbf.ftl
8-8
Oil Pump Overhaul NOTE: a Use new O-ringswhen reassembling. a Apply oil to O-ringsbefore installation. . U s e l i q u i dg a s k e t ,P a r tN o . 0 8 7 1 8 - O O 0 1 . a After reassembly,check that the rotors move without binding.
6 x 1.0 mm 6 N.m 10.6 kgl.m, 4 lbt'ttl
O.RING Replace.
OUTERROTOR pagesI 10, 11 Inspection,
DOWEL PIN
6 x 1 . Om m 11 N.m (1.1kgf.m, 8 tbf.frl
0
PUMPCOVER Inspection,page 8-10 8 x 1.25mm 24 N.m (2.4 kgf.m, t7 tbt'ft)
INNERROTOR Inspect|on, page 8-1 1
OIL SEAL Installation,Page8-1 1 Replace.
PUMP HOUSING lnspection,pages8-10, 11 Apply liquidgasket to matingsufaceoI the cylinderblock when installing.
8 x 1.25mm 24 N.m (2.4 kgl.m, 17 lbl.Irl
\
RELIEFVALVE Valve must slide treely in housingbore. Replacewhen scored.
SPRING
*\
SEALINGBOLT 39 N'm 14.0 kgf.m, 29 tbt.ttt
Oil Pump Removal/lnspection/lnstallation Drainthe engineoil. Turn the crankshatt and align the white groove on the crankshaltpulleywith the pointeron the lower cover. 5.
Remove the cylinder head cover and middle cover.
4.
Removethe power steeringpump belt, air conditioner belt and the alternator belt.
1O. Removethe screws trom the pump housing,thsn separate the housing and coveJ. 1 1. Check the inner-toouter roto. radialclearanceon the pumP rotor. Innor Rotol-to-Outor Rotor Radial Cloaranco StandErd(Newl: O.O4-O.16 mm (0.O02-0.006 in) Service Limit: O.2O mm (0.008 inl
Removethe crankshaft pulley and remove the lower cover. 6.
Remov€the timing belt.
7.
R€movethe drive pulley.
8.
Remov€the oil pan and oil screen.
9.
Remove the oil pump.
OILPUMP
1 2 . Check the housing-to-rotor axial clearance on the pump rotor. Housing-to-Botor Axial Claalanc€ Standard(Nowl: O.O2-O.O7 mm -O.OO3 inl (O.OO1 ServiceLimit: O.15 mm (0.006 in)
OIL PAN
8-10
HOUSING
t5.
rotor radialclearance. Check the housing-to-outer Housing-to-Outer Rotol Radial Clearance: Standard{Newl: O.1O-O.19 mm (O.oO4-O.OO7in) Servic€Limit: O.2Omm {O,OO8in)
1'l
the oil pump,applyingthreadlockto the Reassemble pump housingscrews.
1 8 . Check that the oil pump turns freely. 1 9 . Apply a light coat of oil to the seal lip. 20. Installthe two dowel pinsand new O-ringon the oil pump. Apply liquidgasketto the cylinderblockmatingsurface of the oil pump. NOTE: . U s e l i q u i dg a s k e t ,P a r tN o . 0 8 7 1 8 - O O O 1 . a Checkthat the matingsurfacesarecleanand dry betore applyingliquidgasket. a Apply liquidgasketevenly,in a narrowbeadcentered on the mating surface. a To preventleakageof oil, apply liquidgasketto the innerthreadsot the bolt holes.
1 4 . Inspect both rotors and pump housingfor scoring or other damage.Replaceparts il necessary. 1 5 . Removethe old oil seal trom the oil pump. to-
Gently tap in the new oil seal until the specialtool bottoms on the PumP. NOTE: The oil seal alone can be replacedwithout removingthe oil pump.
Do not installthe parts if 20 minutesor more have elapsed since applying liquid gasket. Instead. reapply liquid gasket aftet removing the old restclue. After assembly,wait at least 20 minutesbefore filling the enginewith oil.
OIL PUMP
(cont'd)
8-11
Oil Pump Removal/lnspection/lnstallation (cont'd) 22. Installthe oil pump on the cylinderblock. a Apply greaseto the lip of the oil pump seal. Then, installthe oil pump onto the crankshaft. When the pump is in place, clean any excess greaseoll the crankshaftand checkthat the oil seal lip is not distorted. 23. Installthe oil screen. 24. Installthe oil pan. NOTE: Cleanthe oil pan gasket mating surtaces. 8 x 1 . 2 5m m 24 N.m (2.4 kgl.m, 17 tbt.ftl 6 r 1 . Om m 1'l N.m {1.1kgf.m, 8 rbf.fr) OIL PUMP Apply liquidgasketto cylinderblock mating sudace. O-RING Apply engineoil
DOWEL PINS
GASKET Replace.
OIL SCREEN
6 x 1 . Om m 11 N.m ('l .1 kgf.m, 8 tbf.trl
OIL PAN
6 x 1 . Om m 12 N.m {1.2 kgf.m, 9 lbf.ft}
8-12
System lntake Manifold/Exhaust Intake Manifold .. R e p l a c e m e n. t. . . . . . . . . . . . . . . . . . . . . . . . . .9.-. 2 Exhaust Manifold R e p l a c e m e n. .t . . . . . . . . . . . . . . . . . . . . . . . . .9.-. 4 .. Exhaust Pipe and Muffler . .-. 5. . R e p l a c e m e n. t. . . . . . . . . . . . . . . . . . . . . . . . . 9
Intake Manifold Replacement NOTE: Use new O-ringsand gasketswhen reassembling. CAUTION: Check for tolds or scratches on the aurface ot the gasket. Roplacewith a now gasket it damagod, 81881 engine:
5r0.8mm 6 N'm {0.6 kgl.m. 4 rbr.ftl
INTAKEAIR TEMPERATURE IIATI SENSOR
'*o*ot'u""'""N PURGECONTROL SOLENOIDVALVE
5xO.8mm 6 .m (0.6 kg{.m. 4 tbf.ftl
IiITAKE MANIFOLD ReplaceiI cracked or it mating s!rtaces aro damag€o.
O-RING Replace.
8 x 1.25mm 22 N.r 12.2 kgl.m, '16 tbt.ftt GASKETS Replace.
I x 1 . 2 5m m 20 N.m (2.0 kgt.m. 14 rbf.ftl
IDLE AIR {IACI VALVE Be careful not to damage.
O.RING Replace.
THROTTLE BODY O-RINGS Beplace.
8 x 1.25 mm 23 N.m (2.3 kgl.m, 17 lbf.frl
8 x 1.25mm 24 N.m (2.4 kgf'm, 17 rbf.ft)
BRACKET
"o aY c
g
8 x 1.25mm 24 N.m (2.4 kgl'm. 17 tbr.ftl
/
8 x 1.25mm 24 N.m (2.4 kgl'm, 1 7 rbf'ft1
9-2
THERMO VALVE 8e careful not to damage.
NOTE: Use new O-ringsand gasketswhen reassembling. CAUTION: Chock for folds 01 scratches on th6 surfac6 of tho gaskot. Replace wilh a new gasket if damaged. 818C1 engino:
INTAKE MANIFOLD Replaceil cracked or il mating surfaces are damageo. IAT SENSOR
5 x O.8 rnm 6 N.m 10.6 kgl.m, 4 tbt.ttl
l I
{
VALVE
,
? , /
5xO.8mm 6 N.m 10.6 kgf.m, 4 tbf.ftl
EVAP PURGECONTROL
/ GASKETS Replace.
O.BI G Replace.
INTAKE AIR BYPASSVALVE
BODY
INTAKEMANIFOLD CHAMBER
IAC VALVE Be carelul not lo oamage.
8 x 1.25mm 23 N.rn 12.3 kgt'm, 17 tbf.frl
BRACKET
O.RINGS Replace. I x 1.25 mm 22 N.m 12.2 kgl.ft, t6 tbt.tt) 8 x t.25 mfi 24 N.m (2.4 lgf.m. 17 tbt.ft)
8 r 1.25mm 24 N.m {2.4 kgf.h, t7 rbr.ftl
I r 1.25 lnm 24 N.m 12.4 kgt.m, 17 tbt.ftl
8 x 1.25mm 20 .m (2.0 kgt.m, 14 tbf.ftl
THROTTLE AODY
HEATERBYPASS PIPE
o-Rt Gs Replace.
FAST IDL€ THERMO VALVE Be carelul not to damage.
I x 1.25mm 24 N.m (2.4 kgl.m, 17lbf'ft|
9-3
Exhaust Manifold Replacement NOTE: Use new gasketsand seltiocking nuts when teassembling.
GASKET Replace. €XHAUST MAt{IFOLD
I r 1.25 mm 24 N.ln (2.4 kgf.m, l7 lbt.ft)
Ss Z \ tr l'A |
/
t
I
i...1%\ / \\-i
R A\
1tr. \
\
I
8 x '1.25mm 3l N.m {3.2 kgf.m. 23 lbf.ltl Replace.
8 x 1.25mm 24 N.m {2.4 kgf.m, 1 7 tbf.ftl 10 x 1.25mm 44 .m {4.5 kgl.rh. 33 lbf.ft}
ExhaustPipe and Muffler Replacement NOTE: Use new gasketsand selflocking nuts when reassembling. Bl88l engine: HEAT SHIELDS MUFFLER 6 x 1.0 mm 9.8 N.m l1.O kgf.m, 7.2 lbf.ftl EXHAUSTPIPE TIP
I
,
^1
e
e HEAT SHI€LD
,@\ 8 x 1.25mm 22 N.m 12.2 kgt.m, 16 lbf.ftl Replace. Tightenthe bolts in steps, alternatingside-to-side.
SELF-LOCKIIIGNUT 1 0 x 1 . 2 5m m 33 N.m (3.4 kgt.m, 25 tbf.ftt Replace.
COVER
HEATEOOXYGEN SENSOR(HO2Sl 44 N.m 14.5 kgt.m, 33 rbf.ftl
I x 1.25mm 24 N.m 12.4 kgf.m, 17 tbl.frl
BRACKET
GASKETS Replace.
GASKET Replace. THREEWAY CATALYTIC CONVERTER
COVER
SELF-LOCKINGNUTS 10 x 1,25mm 54 N'm 15.5 kgf'm, 40 tbf.ftl Replace.
NUT SELF-LOCKING 8 x 1.25mm 16 N.m {1.6kgf.m, r2 tbt.frl Replace.
6 x 1.0 mm 9.8 N.m l1.O kgf.m, 7.2 lbl.ttl I x 1.25mm
22 N.m (2.2 kgl.m, r6lbt.ftl
Replace. Tighten the flange nuts in steps, alternating side-to-side.
(cont'd)
ExhaustPipe and Muffler Replacement(cont'dl NOTE: Use new gasketsand selt-lockingnuts when reassembling. 818C1 engine: MUFFLER
HEAT SHIELOS
EXHAUST PIPETIP
I
h€
6 x 1.0 mm 9.8 N'm {1.O kgt.m, 7.2 lbf.ft)
HEAT SHIELD
EXHAUSTPIPEB
GASKET Replace.
8 x 1.25mm 22 N.m 12.2 kgf.m, 16 lbf'ftl Replace. Tighten the bolts in steps, alternating side'to-side.
NUT SELF,LOCKING 10 x 1.25mm 33 N.m {3.4 kgf.m, 25 tbf.frl Replace.
COVER HO25 44 N.m {4.5 kgf.m, 33 tbf.fr) I r 1.25mm 24 N.m 12.4 kgf.m, 17 lbf.ftl BRACKET
GASKET Replace.
GASKETS Replace. EXHAUST PIPEA
COVER
SELF.LOCKINGNUTS 10 x 1.25mm 54 N.m 15.5 kgl.m, 40 lbf.frl Replace.
6 x 1 . Om m 9.8 N.m (1.0 kgf.m, 7.2 lbt'ft| 8 x 1.25mm 22 N.m 12.2 kgf.m, 16 lbl.ftl Repiace. Tighlenrhe flangenuts in sreps, alternatingside-to-side.
SELF-LOCKINGNUT 8 x 1.25mm 1 6 N . m 1 1 . 6k g f . m , 12lbf.ftl Replace.
Cooling 10-2
lllustrated Index Radiator
. .O. .-.4. R e p l a c e m e .n. t. . . . . . . . . . . . . . . . . . . . . . . 1 Engine Goolant Refilling and Bleeding
10-5 . . . . . . . . . . . . .1. .0 - 6 .........10-6
C a pT e s t i n g Testing Pressure Thermostat . .O. .-.7. R e p | a c e m e.n. t. . . . . . . . . . . . . . . . . . . . . . . 1 .....1O'7 Testing Water Pump . 10-8 Index......... lllustrated .10-9 Inspection . .O. .-.9. R e p l a c e m e .n. t. . . . . . . . . . . . . . . . . . . . . . . 1
lllustrated Index sy"t". is under high plessurewhen engine @ is hot. To avoid dsnger of relsssing scalding engine coolant. remove cap only when engine is cool. Total Cooling System Capacity (lncluding heater and r€servoirl Bl8Bl engine: Mfl: 6.4 | {6.8 US qt, 5.6 lmp qt} AlTt 6.7 | {7.1 US qt, 5.9 lmp qt} Bl8Cl engine: Mfi: 6.7 t {7.1 US qt, 5.9 lmp qt}
CAUTION: lf any engine coolant spills on paint€d portions ot the body, rinse it ofl immediately. NOTE: a Checkall coolingsystem hosesfor damage.leaksor deteriorationand replaceif necessary. a Check all hose clamps and retightenif necessary. a Use new O-ringswhen reassembling. RADIATOR Enginecoolant refillingand bleeding, page 10-5 'l0-6 Leaktest, page Inspectsolderedjoints and seamsfor leaks. Elow out dirt from between core fins with compressedair. lf insects,etc., are clogging .adiator,wash them off with low pressurewater,
CONDENSER FAN SHROUD {soe soction 221
\* S!
P
*) ATF COOLER HOSES {81881 6ngine)
6 x 1 . Om m 7 N.m (O.7 kgt.m. 5 lbf.ftl
5x0.8mm 4.4 N.m (O.45kgf.m, 3.3 lbl.fr)
FAN SHROUD
M/T: Manual t.anamiaaion A/T: Automatic t.ansmiasion ATF: Automatic t.ansmission fluid
10-2
R U
COOLANT RESERVOIR
ENGINECOMPARTMENTHOSECONNECTIONS: Bl88l engine:
FAST IDLE THERMOVALVE THERMOSTAT HOUSIITG
IDLEAIR CONTROL IIAC} VALVE
BREATHERPIPE
O'RING Replace.
O-RING Replace.
HEATERHOSES
818C1 engine: ENGINEOIL COOLER
BREATHERPIPE
IAC VALVE
HEATERBYPASS PIPE
FASTIDLE THERMOVALVE
THERMOSTAT HOUSING
HEATEBHOSES
10-3
Radiator Replacement 1.
5.
Removethe upperand lower radiatorhoses,and ATF cooternoses.
lnstallthe radiatorin the reverseorder of removal: NOTE: a Set the upper and lower cushionssecurely. a Fill the radiatorand bleed the air.
Disconnectthe fan motor connectors. 4.
Removethe fan shroudassembliesand other parts from radiato..
Drainthe enginecoolant.
Removethe radiatorupper brackets,then pull up the radiator.
UPPERBRACKET AND CUSHTOl{
RADIATOR CAP 6 x l . O m m 9.8 N.m (1.O kgt.m, 7.2 rbf.ft) 6 x 1.0 mm 9.8 il.m 11.Okgt'm, 7.2 lbr.ftl
t
e
FAN MOTOR
CUSHION
O-RING Replace.
SHROUD 6 x 1.0 mm 9.8 N.m ('l.O kgl.m, 7.2 tbl.ttl
DRAIN PLUG LOWERRADIATOR HOSE
EngineCoolantRefillingand Bleeding ne-oving the radiatorcap while the engine @ is hot can cause the engine coolant to splay out, seriously scalding you. Always let the engine and radiatol cool down betore removing the radiator cap. CAUTION: When poudngenginecoolant,be sure to shut the relay box lid and not to let coolant spill on the electlical pans or the paint. ll any coolant spills, rinse it otf immediately. 1.
Slidethe heatertemperaturecontrol leverto maximum heat. Make sure the engineand radiatorare cool to the touch.
2.
Removethe radiatorcao.
3.
Loosenthe drainplug on the bottom of the radiator, and removethe drainbolt from the enoineblock.Let the coolant drain out.
NOTE: . Use only HONDA-RECOMMENOED antifreeze/ coolant. a For best corrosionprotection,the enginecoolant concentrationsmust be maintainedyear-roundat 50% MINIMUM.Coolantconcentrations lessthan 50% may not provide sufficient protection againstcorrosionor freezing. CAUTION: a Do not mix ditterent blands ot anti-freeze/ coolants. a Do not use additional rust inhibitois or anti-rust products; they may not bs compatibl€ with the recommgndsd engins coolant. Engin€ Coolant Retill Capacity: including reservoir {0.6 t (0.6 US qt, 0.5 lmp qt)). 81881 engine: MlTt 4.4 | (4.6 US qt, 3.9 lmp qr) A f f t 4 . 7 [ ( 5 . OU S q t , 4 . 1 l m p q t ] Bl8Cl engine: Mnt 4.7 | (5.0 US qt.4.1 lmp qt) 8. Pourcoolantinto the radiatorup to the baseof the filler neck. 9. Loosenthe bleedbolt on top of the engine.Tighten it againwhen coolantcomesout in a steadystream with no bubbles.
ENGINEDRAIN BOLT 78 N.m {8,O kgt.m, 58 lbt.ftl Apply liquidgaskerto
BLEEDBOLT
9.8 N.m (1.O kgl.m, 7.2 lbf.ftl
bolt thread when installing.
WASHER Replace.
Removethe reservoirfrom its holder by pullingit straightup. Drainthe coolant,then put the reservoir back in its holder. 5 . Whenthe coolantstopsdraining,applyliquidgasket to the drainbolt threads,then reinstallthebolt with a new washer. Tighten it securely
1O. Refillthe radiatorto the base of the tiller neck. Put the cap on the radiator.and tighten it only to the tirst stop, Stan the engineand let it run until it warms up (theradiatorcoolingfan comeson at leasttwice).
6.
Tightenthe radiatordrain plug securely.
11. Turn oft the engine.Checkthe levelin the radiator, and add coolant it needed.Installthe radiatorcaD, and tighten it fully.
7.
Mix the recommendedantifreeze/coolant with an equal amount of water in a clean container.
'12. Fillthereservoirtothe MAX mark. lnstallthereservoir cap.
10-5
Radiator Cap Testing 1 . Removethe radiatorcap, wet its seal with engine coolant,then installit on the pressuretester.
2 . Apply a pressureol: 9 3 - 1 2 3k P a ( O . 9 5 - 1 . 2 5 k g J / c m ' ,1 3 . 5 - 1 7 . 8 p s i )
3 . Check for a drop in pressure. PRESSURE TESTER
PressureTesting 1 . Wait until the engineis cool, then carefullyremove the radiatorcap and fill the radiator with engine coolant to the top of the filler neck. Attach the pressuretesterto the radiatorand apply a pressureof: 93- 123 kPa ( O . 9 5 - 1 . 2 5 k g f / c m , .1 3 . 5 - 1 7 . 8 p s i ) Inspect for engine coolant leaks and a dfop in pressure, Removethe tester and reinstallthe radiatorcap. NOTE: a Checkfor engineoil in the enginecoolantand/or coolant in the engineoil. a Check for ATF in the engine coolant and/or coolant in the ATF (A/T).
10-6
Thermostat Replacement NOTE:Use new gaskets and O-rings when reassembling,
6 x 1 . Om m 1 1 N . m 1 1 . 1k g t . m , 8 . Ol b t . f t l
THERMOSTAT MOUIITINGRUBBER Replace.
l ECT SWITCH 22-25 N.m 12.2-2.6 ksl.m, 'l6-'19 lbl.ttl
Testing Replacethermostatif it is open at room temperature. To test a closed th€rmostat: SusDendthe thermostatin a containerof water as shown.
THERMOMETER
Heat the water and check the temperaturewith a thermometer.Checkthe temperatureat which the thermostatfirst opens and at full lift. CAUTION: Do not let the thelmometer touch the bottom of the hot container. Measurethe lift heightof the thermostatwhen it's fullv oDen.
THERMOSTAT
STANDARDTHERMOSTAT Lift height: above 8.O mm (O.31 inl Starts opening:169 - 176"F {76-8OoCl Fully open: 194oF (90oCl
10-7
Water Pump lllustratedIndex NOTE: a Usenew O-ringsandnew specialboltswhenreassembling. a Useliquidgasket,PartNo. O8718-0OO1. ENGI E COOLAI{T 3;iil3 TEMPERATURE IECTI SENSOR t8 N.m 11.8kot.m,13lbt'ttl
onsino: B18c1
Bl8Bl cngln : ECT SEI{SOR
ECTGAUGESEDINGU]{IT I N.m (0.9 tgf.n, 7 lbf'tt) Apply liquid gaskot to tho threads.
6 r 1 . 0m m 11 N.m l1.l kgl.m,8.O lbl.ftl
6r1.Omm 1l t{.m ll.1 tgl.m. 8.O tbt.ftl
KNOCK SEI{SOR 3l N.m {3.2 kgf.m. 23 tbf.ftl (8l8Cl .ngin€ onlyl
OUTIET
BLEEDBOLT 9.8 N.m (l.O rg[.m. 7.2 lbt'ft| WATER OUTLET COVER Apply liquid gasket to mating sudace.
ECTSIY]TCH
WATERPUMP Inspectaon, pagelO-9
22-26
.m 12.2-2.C )l{/l'nt.
16-19 tbr.ftl
o-Rtt{G Roplaco.
o-itltc Roplrco.
8r1.Orxtr 12 .|n ll.2 lgt.m, 8.7 n{.ftt
6xt.Omm 12 N'ft (1.2 kgf..n.8.7 lbt.ft)
10-8
Replacement
Inspection
J.
Removethe timing belt (81881 engine:see page 6 - 1 O ,B 1 8 C 1e n g i n e :s e e p a g e6 - 4 9 ) .
Removethe timing belt (818B1 engine:see page 6 - 1 0 , 8 1 8 C 1 e n g i n e :s e e p a g e6 - 4 9 ) .
Check that the water pump pulley turns counterclockwise,
2 . Removethe camshaft pulleysand the back cover ( 8 1 8 8 1e n g i n e s: e ep a g e6 - 1 9 . B 1 8 C 1e n g i n e s: e e page 6-581.
Check for signs ol seal leakage. NOTE: A small amount ot "weeping" from the bleed holo is normal,
J.
Removethe water pump by removingfive bolts, NOTE: Inspect,repairand cleanthe O-ringgroove and mating su.lace with the cylinderblock.
BLEEDHOLE
DOWELPIN
6 r 1.O rnm 12 N.m {1.2 kgf.m, 4.7 bf.ftl
BI-EEDHOI-E
4.
lnstall the water pump in the reverse order removat. NOTE: a Keepthe O-ring in positionwhen installing. a Cleanthe spilledenginecoolant.
10-9
Fueland Emissions . . . . . . . . . . . . . . .1. 1 - 2 Fuel Supply System S p o c i aTl o o l s Systam TloubloshootingGuid. ..................1 1-97 Compon€nt Location . . . . . .1 1 - 3 F u o lL i n o s . . . . . . . . . . . . . . . . . . . .1. '.l- 9 8 l n d e x. . . . . . . . . . . . . . . . . ........ 11-100 System Description System Description F u o lP r a s s u r e . . . . . . . . . . . . . . . .1. 1 - 1 0 0 V a c u u mC o n n e c t i o n.a. . . . . . , . . . . . . . . . . . . . . . . .1.1. .- 8 . . . . . . . . . . . . . . . .1. 1 - 1 0 2 E f e c t r i c aCl o n n e c t i o n.s. . . , . , . , . . . . . . , . . . , , . . . . . , ' 1 1 - 1 2 F u 6 lI n i 6 c t o r s Fuel PressureRagulato. .,. 11-106 S y s t € mC o n n e c t o r s. . . , . . . , . . . . . . . . . . . . . . . . . -1. -1- -. 2 O T.oubloshooting F u e lF i l t e r . . . . . . . . . . . . . . . . . . . .1. 1 . -108 T r o u b l e s h o o t i nGgu i d o . . . . . . . . . . . . . . . . . . . . . . .1. .1.- 3 2 F u a lP u m p . . . . . . . . . . . . . . . . . . .1. .1 - 1 0 9 P G M - FM l a i nF 6 l a y. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . .1. .".11 1 Self-diagnosticProcedures.,..,...............1 1-34 H o w t o R o a dF l o w c h a r t s. . . . . . . . . . . . . . . . . . . , .1.1. - 3 9 F u e lT a n k . . . . . . . . . . . . . . . . . . . .t. 1. - 1 1 4 PGM-Fl System Intake Air System S y s t o mD e s c r i p t i o n. . . . . . . . . . . . . . . . . . . . . . . . . . 1. .l.-.4 O System TroubloshootingGuido ..................1 1-1 1 5 Troubleshooting Flowcharts ........ 11-116 Systom Dascription E n g i n eC o n t r o lM o d u l s. . . . . . . . . . . . ...... . . . . . . . .1 1 - 4 2 . . . . . . . . . . . . . . . . . .1. .1 - 1 1 7 Air Clean€r H e a t e dO x y g o nS e n s o r . . . . . . , . . . . . . . . . . . . . . .1. .1. - 4 6 T h r o t t l sC a b l e ................'11-118 HeatedOxyg€n Sonsol Heatel .....,.........1 1-47 T h r o t t l 8B o d y . . . . . . . . . . . . . . .1. 1 - 1 2 0 F u e lS u p p l yS y s t e m. . . . . . . . . . . . . . - . . . . . . . . . . .1. .1. -. 5 0 lntake Air Bypass Cont.ol Systsm Manitold Absolute Pressure . , . . . . . . . . .1 1 - 1 2 3 [B18Cl enginal .... S s n s o r. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.1. .- .5. 2 Intake ................. 11-128 Manilold onginol [B1881 Top D6ad Cente./Crankshatr Position/Cylindor Positionsonsor ........ 1 1-56 Emission Control System EngineCoolantTempsratureSonsor ....... 11-58 Systsm TroubleshootingGuido ..................1 1-129 T h r o t t l oP o s i t i o nS o n s o r. . . . . . . . , . . , , . . . . . . . . 1. .1. - 6 0 ........ 11-130 Systam Doscription Intake Air TemperatursSensor...............11-62 ........... 11-130 TailpipsEmission B a r o m e tc P r s s s u r o S e n s o r. . . . . . , . . . , . . . , . .1, .1 - 6 4 ThraeWay CatalyticConvortor ...,...,.........,11-131 l g n i t i o nO u t p u tS i g n a l. . . . . . . . . . . . . . . . . . . . . . . .1. 1 . .- 6 6 PositivaCrankcaEoV6ntilationSystcm .,....., 11-134 V e h i c l eS p e € dS e n s o r. . . . . . . . . . . . . . . . . . . . . . . .1. 1 . .- 6 8 EvaporativoEmissionContro|,..,..,.,.,,.,,..,..,1 1-135 7 O E l e c t d c aLl o a dD o t e c t o r. . . . , . . . , . . . . . . . . . . , . 1. .1. K n o c kS e n s o r[ 8 1 8 C 1e n g i n e ]. . . . . . . . . . . . . .1. 1 - 7 4 A / T F l S i g n a lA / B . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. 1. .-.7 6
ldle Contlol System
System TroubleshootingGuide ..................1 1-78 ........ 11-79 Systom Description Troubloshooting Flowchans l d l €A i l C o n t r o V . .- 8 2 l a l v e . . . . . . . . . . . . . . . . . . . . . . . .1. 1 A i l C o n d i t i o n i nS g i g n a l . . . . . . . . . . . . . . . . . . . . . .1. .1.- 8 4 A l t e m a t o rF R S i g n a l . . . . . . . . . . . . . . . . . . . . . . . . . 1 . .1. -. 8 6 Automatic Transaxle (A/T) Gear PositionSignal ......... 11-88 B r a k eS w i t c h S i g n a l . . . . . . . . . . . . . . . . . . . . . . . . . .1.1. -. 9 O S t a r t e lS w i t c hS i g n a l. . . . . . . . . . . . . . . . . . . . . . . . .1. 1. .- 9 2 Power Steering PressureSwitch Signal ... 11-93 . .1. -. 9 4 F a s tl d l e T h e r m oV a l v e . . . . . . . . . . . . . . . . . . . , . . . . . 1 l d l s S p e e dS € t t i n g. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. .1.-. 9 .5
SpecialTools
Ref. No I
Tool Numb€r
Description
I OtV I
o
A973X_041*XXXXX
Vacuum Pump/Gauge
,l
@ @ @ @
oTJAZ-O010008 OTLAJ_PT3O1OA oTPAZ-0010100 o7406-OO40001
Vacuum/Pressure Gauge0-4 in. Hg Test Harness SCS Short Connector Fuel PressureGauge
1 1 'l
\t
o
1 1 -2
1
Page Reference. 1't-'t20, 124, ' 1 3 7 ,
140 1 1 - 1 3 91,4 0 't 1-37 I t -J.+
1 1 - t 0 11 , 06
Component Locations lndex 81881 sngin6:
IOLEAIR CONTROLOACI VALVE page '11-82 T
ABSOLUTE MANIFOLD PRESSURE {MAP}SENSOR Troubleshooting,
EVAP PURGECONTROL VALVE SOLENOID Troubleshooting, 11-137
THROTTLEPOSITIOIII{TP) SENSOR Troubleshooting, page 1 1-60
THROTTLECABLE page 1 1-118 Inspection/Adiustment, Installation,page 11-1 18
TOP DEAD CENTER/CRATIIKSHAFT POSITION POSITIOf{/CYLINDER (TDC/CKP/CYP}SENSOR page 1 1-56 Troubleshooting,
INTAKE AIR TEMP€RATUREIIAT) SEI{SOR Troubl€shooting, page 1 1-62 POWERSTEERINGPRESSURE(PSP)
swtTcH
ELECTRICAL LOAD OETECTOR IELD}
page 11-93 Troubleshooting.
Troubleshooting. page,l l-70
sq
MODULE{ICMI IGNITION Troubleshooting, page 1 1-66
IDLETHERMOVALVE Inspection,page 11-94
ENGINECOOLANT TEMPERA page I 1-58 Troubleshooting,
(ECTISENSOR
HEATEO
SENSORlHO2S} pages 11-46, 47 Troubleshooting.
11-3
Component Locations lndex B18Cl ongino: EVAP PURGECONTROL SOLEiIOIDVALVE Troubleshooting, p a g e1 1 - 1 3 7
AESOLUTE MANIFOLD (MAPISENSOR PRESSURE page 11-52 Troubleshooting, THROTTLE (TP} POSITION SENSOR Troubleshooting, page 1 1-6O TOP DEAD CENTER/CRANKSHAFT POSITION POSITION/CYLINDER {TDC/CKP/CYPISEI{SOR Troubl€shooting. Page 1 1-56
INTAKE AIR TEMPERATURE IIAT) SENSOR p a g e1 1 - 6 2 THROTTLECABLE page 'l 1-119 Inspection/Adiustment, page 1 1-1 19 lnstallation, IOLE AIF CONTROL(IACI VALVE Troubleshooting. page 1 1 -82 POWERSTEERINGPRESSURE(PS'I
swtTcH page 1 1-93 Troubleshooting,
ELECTRICAL LOAD DETECTOR IELD} Troubleshooting, page.11-70
IGNITIONCONTNOLMODULE OCMI Troubleshooting, Psge 1'l-66
sElrlsoRtKsl
ENGIT{E COOLANTTEMPERA {ECT}SEI{SOR Troubleshooting, Pag€11-58 VALVE FAST IDLE 'l Inspection, page 1 -94
11-4
Troubfeshooting, page 1 1-7 4 HEATED OXYGEN SENSOR(HO2S} pages 11-46, 47 Troubleshooting,
AIR CLEAI{ERIACL) Replacoment, 11-117
BODY(T8I THROTTLE page11-120 Inspsction, page11'122 Disassembfy,
THROTTLE CABLE pages1l-'l 18, 119 InsDection/Adjustment, pages1 1-118, 119 Inslallation, INTAKE AIR BYPASS (IABI
co TROL OIAPHRAGM {Bl8C1 ongino onlyl Troubleshooting, page 11-124
INTAKE AIR EYPASS IIABI
I
co TnoL
SOLENOID RESONATOR
POSITIVE CRA KCASE vEt{TtLATtOt{(PcVl VALVE psgo1 l-134 Inspection,
VALVE (B18Cl .ngino onlyl Troubl6shooting, p a g e1 1 - 1 2 4
MODULE{ECM) ENGI]TE CONTROL page11-34 Procedures, Selt-diagnostic page11-42 Troubfeshooting,
SERVICECHECX CONNECTOR(2PI page'l 1-34 56ll.diagnosticProcedures,
MAIN RELAY RelayTesting,page 1 1-111 pag€ 1 1-112 Troubleshooting,
11-5
SystemDescription Index
FUELGAUGESE]IIDINGU]{IT Tgsting,s€ction23 FUELFILTER page 11-l OB Replacement,
FUEL PUMP T€sting.page 11-1 10 Roplscam€nt.page 11-l 10
FUELFEEDPIPE
FUELFIIL CAP
FUEL II{JECTORS page 1 1-102 Troubleshooting, page 1 1-105 Replacemont,
FUELTA K R6placomont, p a g el 1 - 1 1 4 EVAFORATIVE EMISSION IEVAP}TWO WAY VALVE Testing,pag€11-140 EVAPORATIVE EMTSStOt{ {EVAP}PURGE
FU€L PNESSURE REGUIATOR Testing,page11-106 page11-107 Roplac€m€nt,
CONTROLDIAPHNAGM VALVE page'l 1-137 Troubleshooting,
FUEL RAIL EVAFORATIVCEMISSION (EVAPI COI{TROLCANISTER Troubl6shooting. pag6 1 1-'l 37
11-6
FUELVAFONAPE
System Description Vacuum Connections 81881 engin€:
EVAPORATIVEEMISSIOT{ (EVAPI PURGECONTROL SOLENOIDVALVE
EVAPORATIVE EMISSION (EVAP}PURGECONTROL To DIAPHRAGM VALVE EVAPORATIVE EMtSSTON {EVAP} TWO WAY VALVE
EVAPORATIVEEMISSION IEVAP) CONTROI-CANISTER
FRONTOF VEHICLE
11-8
ENGINE COOLANT
|l U]
HEATEDOXYGEI{SEI{SOF(HO2S} (MAP)SEI{SON PRESSURE MANIFOI.D ABSOLUTE ENGINECOOLANTTEMPERATURE IECT}SENSOR INTAKEAIRTEMPERATURE IIAT} SEI'ISOR IDLEAIR CONTROL IIAC)VALVE FASTIDLETHERMOVALVE FUELII{JECTOR FUELFILTER REGULATON FUELPRESSURE FUELPUMPIFP) FUELTAI{K
(EVAP}VALVE EMISSION @ FUELTAI{K EVAPORATIVE DAMPER G) FUELPULSATION @ AIR CLEANER @)RESONATOR (TWC) @ THREEWAY CATALYTICCONVEnTER VEITITILAT|ON IPCV)VALVE CRANKCASE o POS|TIVE CANISIER EMISSION IEVAP)COI{TROL @ EVAPOBATIVE @ EvApoRATrvEEMrssroNIEVAP)PURGEcoNTRoL VALVE SOLENOID (EVAP)PURGE CONTROL EMISSION @ EVAPORATTVE VALVE DIAPHRAGM (iDEVAPORATIVE (EVAPITWOWAY VALVE EMISSION
11-9
System Description Vacuum Connections 818C1 engine:
INTAKEAIR SYPASSIIAB} CONTROLDIAPHRAGMVAI-VE
to EVAPORATIVE EMISStON IEVAPI TWO WAY VALVE
MANIFOLOABSOLUTE PRESSURE {MAP) SENSOR EVAPORATIVEEMISSION {EVAP) PURGECONTROL DIAPHRAGMVALVE
INTAKE AIR BYPASS IIAB}
VACUUM TANK
EVAPORATIVEEMISSION IEVAPI CONTROLCANISTER INTAKEAIR BYPASS IIABI CONTROLSOLENOIDVALVE PURGECONTROL SOLENOIDVALVE
11-10
lHO2Sl c) HEATEDOXYGENSENSOR PRESSURE IMAPISENSOB €) MANIFOLDABSOLUTE {ECT}SENSOR O EI{GINECOOLANTTEMPERATURE {IAT)SENSOR €) INTAKEAIR TEMPERATURE tKSl @ KNOCKSENSOR @ IDLEalR coNTRoL llAcl vALvE O FASTIDLETHERMOVALVE @ FUELINJECTOR @ FUELFILTER REGULATOR @ FUELPRESSURE O) FUELPUMP(FPI @)FUELTANK EMISSIONIEVAPIVALVE @ FUELTANK EVAPORATIVE
DAMPER G) FUELPUI-SATION @ AIR CLEANER (D RESONATOR 6 imrlre arR Bypass (tAB)coNTRoL DIAPHRAGM VALVE VALVE (D)IITITP IIN BYPASS{IAB)COTROLSOLENOID ds)INTIXT AIR EYPASSTIABIVACUUMTANK rio'lrnrarg ltn BYPASS(lABl cHEcK vALvE 6 rsnee wav cATALYTtccoNvERTERlrwc) 6 posrnve cRAf{KcAsEvENTILATIoN{Pcv) vALVE 6 evlponlrtve EMtsstot{ tEvAPlcoNTBoL cANlsrER coNTRoL EMtssloN{EvAP}PURGE 6 evlponltvE VALVE SOLENOID (EVAPIPURGE CONTROL EMISSION 6i EVAPORATIV€ VALVE DIAPHRAGM Eutsstof{ IEVAPIrwo wAY vALvE 6o ivlpoalrtve
11-11
SystemDescription ElectricalConnections PGM.FI MAII{ RELAY
@ fUEL PUMP
- rc2lL
IllL i i \| r--ri l {a/Tl .i
FUELINJ€CTORS
DATA LIIIK
To BAOIATORFAt! RETAY,CONDENSER FAI{ RELAY
co t{EcToR
To A/C SWITCH A/C CLUTCH RELAY
A/T GEAR
FUSES I1OOAI* O BATTERY @ oPTroNt50 alr o rG {50 A). @ sroP. HoBN{2OAl* @ BACKUP(7.5 Al* LIGHT{7.5 A) @ No. 3 INTERIOR O Ecu (EcMt(1s A)' @)No. 24 ACG (ALTI0Gl {15 A: 81881sngin6, 2OA:818C16n9ine) @ No. 15 BAcK-uPLlcHTsllo Al RELAY @ No. 13 REARDEFROSTER HEATERMOTORRELAY FAN MOTORRELAYI7.5 A} COOLING SIGNAL 17.5A) O No. l8 STARTER *: UNDER-HOOD BOX FUSE/RELAY
11-12
ITIAP sEl{SOR TP SEI{SOR
..!L1.99'!.elsrl VTEC SOLE]{O|O
EVAP PURGECOT{TROL SOLEI{OIOVALVE
|AA CO TROL SOLEI{OID VAI.VE ECT SEI{SOR
ALT C 416
IUSA or yl
TERMINALLOCATIONS
ooooooooooooo ooooooooooooo
oooooooo oooooooo
ooooooooooo ooooooooooo (cont'd)
11-13
System Description ElectricalConnections(cont'd) rHriRED, fl--fwl
I Jftfi:]ff*-, HO2S
cl13
181881cngr|.l tBl8cl .nerEt Flll--------------YEURED - YEr/wI{ri | |
- YvHrnEr-l | i|APsEIrsoFI -cn AvHrr ll_l cl11 ECTSEI{SOR
c120
{E
, REDI'EL GRI{/BLU
IAT SET{SOR
cl15
1E
YEL/BLU RED/8U( GR]I/BLU
cl19 wt{T/GRl{ wL?/nEor
WHT/GRT{ WHT/REDr
ALTERI{ATOF
cl to tclrl
c131
".rro*.fl..Fl - ll PnEssunE I - atK' swrcH I 1l
(To psge 1 l -15)
11-14
-'-'--''''-''-' D14 :wHT/nED' TDC/CYP/CKPSENSOR 811 812 813 814 815 816
'- -----
:j:on 2-"''''-' :-WHT--------'-''''-'''' :ji oRNi sLU =::::i-:jjjjjjj :ji WHT/ALU jjji-::-:-:::i:jj
KS
t{o. 1 FUEI II{JECTOR
c122 t{o. 2 FUEL II{JECTOR
c123 No. 3 FUEL NJECTOR
c124 YEL/ALX YELI
YEL/BLK - RED2
t{o. 4 FUEL II{JECTOR
EVAP PURGE
cot{TRoL soLE{otD VAIVE
(cont'd)
11-15
System Description ElectricalConnections (cont'dl
BLI(/YEL
oRI{r
BTKiYEL-JT---l oR 1 ----l I vss BLK'
I
I
{l
c't 16
v:r-,sr-*-J
l-----] 'o"
uo.u.
".*,".u {l
I
lA18a1ongine,
lB18C1 6ngin€)
il tl ll
c423 ! caor
".t t enn__JlF-----l r Brx_LlswrcH -L
I
es-ot
c405
eaurvxrJ r BLK -l
1
G401 :--
-
SERVICECHECK COIIIIECTOR
c40a BRN/BLKf DATA LINK LT BLUI corrttIEcToR WHT/RED {
11-16
lBl lcl
I T
t Il
neonr-x
]
RED/WXT
GAUGE ASSEMALY
c449 -
C553 F-
{!L rNDrcAToR GR[{/OR]{
["' To RADIATORFAt{ RELAY, COI{D€I{SER FAI{ RELAY To A/C COTT|PfiESSOR CLUTCH RELAY
To A/C SWITCH
(cont'd)
11-17
System Description ElectricalConnections(cont'dl
160Al
wnrneo J -l ,*rr"a*
fioo Al
c216
wHr/8ru T I YEL/WHT--L c214
wHvem {
sToP. HORI{t20 Al
auryet{ oR nED-l -alx {
If_ "rti' c218 G20r
I{o. 3 lttTERlOR LIGHT
wxrneo
{
"a*,"ao { c44t)
*utwxr
o. la STARTER stGI{At- t7.5 Al
{ wHriRED--l or-rrv:r{ c551
-{ nft
-
C4.
l|5^.llll.n'i'20r!|.c1q*,
No. 15 8ACK-UP LIGHIS t10 al
Af,:
Ca13 f -l 8rr(/nED
surwxr -{ el3t
F w{T/GRr{_-]
cR ^i|Hrl
{Toptg€ 11-19,
11 - 1 8
1
{Frompago 1 1-'l8l
PGM-FI lrtAtt{ REL,AY
t
I
=
G502
11-19
System Description SystemConnectorsIEngineCompartmentl
ENGINE WIRE HARNESS {818C1 onginol
o t3 c132 c131
UNDER, HOOO FUSE/RELAY
aox
MAllrl WIRE HARI{ESS
11-20
ct 04 c220
c102 c222
c112
c111
cl10
cl1
r'ft]
6
r+
lrl2l
trtr
\:-/
lI-FErwHr l-l l 1olGuNlert
IOTBLF------l la lsLx/YEL
fo lanlr
c 132
tr
/ r \
\^y IETYEL/€Lh---l ----,, lohED'
ldlcRr/vEr
ffi
c221
^Jl
r'fr]
c214
---l
c216
c215
I if,l.) l;TYra-"wrrr. I le llel/nEo I I€ TcRNrwHrtl I ,ITwHr^rJl I
I
o
c 13 t
c117 lB18C1engine)
l]l
E:I
ffi
FFIN
fi'Twtl-rirllrlerrrltlerl-l - lll
fr-Twrr
I@ LWHTTREO I
ohN/BLK
l
|/BL!
ALU/YEL
NOTE: a Different wires with the same color have been given a number suffix to distinguishthem (for example, YEL/BLK1and YEL/BLK,are not the same). O: Relatedto Fuel and EmissionsSystem. a - Connectorof male terminals:View from terminalside (cont'd) - Connectorof temaleterminals:View from wire side
11-21
System Description SystemConnectors[EngineCompartment](cont'd)
c 120 {81881sngino}
(B18Cl onginol
11-22
cl16 FI
c117 lBl88l 6nginol EI /
\2 |@|iaf,-'6trlaltrlaru----1
toltEUB'.f----
c121
fr
/
t
t
\
z
t
|6-I!EUBLK lO lhEo'
c122
ffi
ct 20 l8lSBt.nglnrl ET
c119
A
RP --'l I
l6TciN-6LU----loliEo/YEi----.
c 123
24
ffi
ffi
---------l l6'lau,-r,
ct 34
,8. \^y
f6-IPilK/BLu---l I IO IYEUBL(
(Bl8Cl .ngln l F,-f.
\?
16lwHiffiN----f l@lwHrnco' I | 3 l a L & Y E r --- I frlwHrEru
IO IYEL/8LX
cr20
l6-ltR,iEit---l@ IiEp/YcL
I
cr33
A
.2 --.-.1I
|o lhEo/8llJ
I-T-
I
c3t I
O tsF
NOTE: a Different wires with the same color have been given a numbe. suffix to distinguish them (for example YEL/BLK1and YEL/BLK,are not the same). O: Related to Fuel and EmissionsSystem. a - Connector of male terminals: View from terminal sid6 - Connectorof female terminals:Viow from wire side
11-23
System Description System Connectors [Dash and Floor]
ENGINE COMPARTMENT WIRE PGM-FIMAIN RELAY DASHBOAROWIRE HARNESS
REAR WIRE HARNESS
MAIN WIRE HARI{ESS
C1I44
11-24
UNDEN-OASH FUSE/REALY BOX
c4't9 2 3 4 5
7 8
e nc
t6| -
5
a ALUfYEL
YEL'
c431 lwlth cruit€ coniroll
c431 (wlthout crui!a control)
c423
|' l r l
-t t t I
5 6
----'l l6'TwHr/cnN----l 1ol cRN^vHr
BLU/YEL
a
lslnl
t3
12 13
3
fitr G-Fil-----lo ln/Hr/68n I lo lciN,r/vHr I l-IcRY------l
1a 20
c432
c439
ffi
rfltrrn
c44il
riTLF-I
I'VCT,1 lETWrr;eo---f -frlwHr. l3l8rK I t lBLx,REo t 5 I 6 G R N / B L X-f?-TFEpcFN
ffi
14l51617l YEL/BLK'
Ht/alu
2
I I | I
iEO/YIL 15 16 't7
5
lO lGRt/8LU
ktlBrKr--
I o lYcL/Gnir lao laLx./YEL I "] IYEUBL(
ktlterwirr
a BL&"/EL YEL
I
Titfgruffir-----l
---
I I I
20
c444
ffir
trtr] I6TLK^//Hr L' l!!g!!r
-l l
l o l s L k r F E D l]l I |;TBLU'BLi
NOTE: a Ditterent wires with the same color have been given a number suttix to distinguishthem (fot example YEL/BLKrand YEL/BLK,are not the samel. O: Relatedto Fuel and EmissionsSystem. a - Connectorof male terminals:View from terminalside (cont'd) - Connectorof femaleterminals:View from wire side
11-25
System Description System Connectors [Dash and Floor] {cont'd}
DASHBOARD HARNESS
UNDER-DASH FUSE/RELAY BOX
11-26
MAIN WIRE HARNESS
1 2 3
I
gL&YEL
BLK/YEL
BLK GFN,YEL 5
6
2 GFN YEL
15
LT GRII/SL(
6 7
REO/6LU
12
2
4
r0l1 11121131 114115116
8RN/8LK
3 BLU 9
12 BLUf/€L
GRN/BLII
5
YEL/RED
13
YEL YEL/6LK
16
6
BLU
t6
I
a DiJterentwires with the same color have been given a number sutfix to distinguishthem (for example YEL/BLK1and YEL/BLK'are not the same). O: Relatedto Fuel and EmissionsSystem. a - Connectorot male terminals:View from terminalside - Connectorof female terminals:View from wire side
{cont'd)
11-27
System Description SystemConnectors[Dashand Floorl (cont'd)
c/ro5 SERVICE CHECK CONI{ECTOR
11-28
c405
c406
fr
c410 tEGM-Al
r'tr--Jl -----l I6TBRN/B,L(-__-l l€, lwHr/uED l_l l6TLr BN---
ffi
tt4 YEL'
| (jt
ALK/AED
1a
SLU ALK
t(9
YEL
| 0o)
GRN/oRr
ALK' ALK' YEL/BLK BLK l@
c408 {ECM-Bl 3 2 4
9 1 t3tl5 8 1C l 2 4
BLK 2 YEL I
5
ALU/REO
6
6
ALU/YEL
a Different wires with the same color have been given a number suffix to distinguishthem (for example YEL/BLK1and YEL/BLK,are not the same). O: Relatedto Fuel and EmissionsSystem. a - Connectorof male terminals:View from terminalside Connectorof femaleterminals:View from wire side
11-29
System Description SystemConnectors[FuelPumpl
REARWIRE HAFNESS
11-30
c510
NOTE: a Ditferent wiros with tho samo color hava been given a numb€r sutfix to distinguish them {for example YEL/BLKI and YEL/BLK, are not th€ same). O: R€lated to Fuel and EmissionsSystom. a - Connoctor ol malo tarminals: Vi6w from terminal side - Connector ol f6msl€ tarminals: Vi€w from wire sid€
11-31
Troubleshooting TroubleshootingGuide NOTE: Across each row in the chart. the systems that could be sourcesof a symptom are ranked in the order they should be inspectedstaning with O. Find the symptom in the left column, read acrossto the most likely source.then refer to the pagelistedat the top of that column.lf inspectionshows the systemis OK, try the next mosr likelysystemO, etc, PGM.FI
TOPDEADCINTTR/ ENGINE MANIFOLO INfAKE AIR BARO. ENGINE HEATEO CRANKSHAFT COOLANT THROTTTE IGNITION vEHtct-E AESOLUTE TEMP€RA. METRIC CONTROL OXYGEN POSTT|ON/ TEMPfRA. POStTtON OUTPUT SPfED PRESSURE TURE PRESSURE MOOULE S E N S O R CYLINDER TURT SENSOR sar,rs0RSENSOR SIGNAL SENSOR SENSOR POSITION SENSOR SENSOR SYMPTOM
11.42
MALFUNCTION INOICATOR 1 l o r : t : ] : L A M P( M I U " T U R N S ON
4 6 ,4 7 , 5 0
lrmr:
-D:o.:@. MALFUNCTION INOICATOR :O. or-8. L A M P( M I L ) ' ' B L I N K S o, O'
ENGINEWON'T STAffT
o
DIFFICULT TO START ENGIN€ WHENCOLO
@
WHENCOTD FASTIDLE
-
16l-
i;:i' -tK3t-
l 3 l /__-\
@
(9)
RPMTOO LOW
@
WHILE
@
AFTER
@
FREOUENT STALLING
MISFIREOR ROUGH RUNNING
@
POOn PERFOEM. FAITS EMISSION ANCE TEST
@
Loss0F
-r:+r-
-{"Pr: \ --l-l
-l
r 0I | t - /----\ /__-\ 7
11-64
1t-66
-o_ -16l-. z-\
1r-68
r6t
/_-\
\.--r--l
| 1 3|
z_---\
r5 -t
I t - /-]-\1 7t /.---\
@
o
o @
@
@ @
@
POWER
-16l /-----\
11-62
@
@
RPMTOO HIGH
16l ' - \
1l-60
@
@
ROUGHIDLE
l1-58
.E-o.:O: or tr]- - i-i-\! l /
@
ouT0f sPtc IRREGULAR IDLING
11-56
@
@
@
@
*
lf codes other then those listedabove are indicated,count the numberof blinksagain.It the MIL is in fact blinking ^ these codes, replacethe ECM. qy, lf the MIL is on while the engineis running.connectthe SCS shon connectorto the servicecheck connector.It no code is displayed{MlL stays on steady),the back-upsystem is in operation. Substitutea known-goodECM and recheck.lf the indicationgoes away, replacethe originalECM. USA: MALFUNCTION INDICATOR LAMP {MIL) * * *: 818C1engine
1-32
CANADA: CHECK
\ ----l
-ltGl-
|
-
ENGTNE LTGHT
-
{ -1t-
I O L EC O N T R O L
PGM-FI VARIAEIEVALVEVARIABLEVALVE TIMINC& VALVE TIMING& VATVE ELECTRICALLIFTELECTRONIC I-IFTILECTRONIC KNOCK LOAO coNTRO|cottTR0t stNsoR DETECTOR PffESSURE SOLENOID
s38
| 1"70
E \.-r-l
-t l0 t---i-\
r6t-
- ---
t 2 tI
/ --i-\
--\-!-/
l 2j--\2 l /--
11.74
-16l/-----..
IOLEAIR
OTHER OTHER FUEL FUEL IOLE INJECTOR CONTROLS SUPPTY
FI SIGNAL
FI SIGNAT
c0NTR0r-
r 1-76
t 1-76
11-82
E
fl \.--r-z
FUELSUPPLY
11-78
-o_
| 1-102
r 1-97
INTAKE AIR
t 1 - 11 5
€MtsstoN CONTROLS
l l 129
,.''\
\.---l
30 t 3 rt - /----\ [|t 2 3l - -t ,--T-\ l- /-.--\ /--.i-\
I 1 6t\ -
/ _-i-
@ @
@
o o o
@
a,
@
o
@
@
@
Q)
@ @
o
@
o (JJ
@
@
@
o
@
11-3
Troubleshooting Procedures Self-diagnostic When the MalfunctionIndicatorLamp {MlL) has been reportedon, do the following: '1.
Connect the SCS short connecto. to Service Check Connector as shown. (The 2P Service Check Connector is locatedunder the dash on the passengerside of the car.) Turn the ignitionswitch on.
DATA LII{K (3PI CONNECTOR NOTE: Do not attach jumperwire.
2. Note the DiagnosticTroubleCode (DTC):The MIL indicatesI code by the length8nd numbsrot blinks.The MIL can indicatemultiplecomponentproblemsby blinkingseparatecodes,one after another.Codes 1 through Igre indicatedby individualshon blinks.Codes 1Othrough 43 are indicatedby a seriesof long and shon blinks.Th€ numberof long blinksequalsthe first digit, the numberot short blinks equalsthe seconddigit. Sometimesthe firsr blink is difficult to see; always count the blinks at least twice to verify the code.
MALFUNCTIOI{ INDICATOR LAMP IMIL}
CANADA: CHECK ENGINE LIGHT
Sgprrate Prcbaomr:
shT -n-----n-=n+!+1].TL;I!!=-L '" ,JU Long .hon
"
"
= s.o DTc1 = s.. Drc 3
= Sce DTC 13
Multiplr Probl.ln.: = S€. DTC 1 lnd 3 J-l_tx-TL-n-ffu-r-J.rrU-L-r]tltlr'l- __-tnrua = Sce DTC 3 and 4 Jll-lrl-t-----Tt/'tnj]_ = S.. DTC 3 lnd 14
11-34
Engine Control Modute {ECM) Reset procedure 1. Turn the ignition switch otJ. 2' Removeth€ BACK UP (7.5 A) fuse trom the unde.-hoodfuse/relaybox for lo secondsto reset the EcM.
BACKUP I7.5 AI FUSE
UNDER-HOOO FUSE/RELAY BOX
Final Procedurelthis procedure must be done after any troubleshooting) 1. Removethe SCS Short Connector. NOTE: lf the SCS short connectoris connectedand there are no DTCSsto.ed in the ECM,the MIL will stav on. 2. Do the ECM Reset Procedure.
11-35
Troubleshooting Self-diagnosticProcedures(cont'dl DIAGNOSTIC TROUBLE CODE(DTCI
SYSTEMINDICATED
Psge
o
ENGINE C O N T R O LM O D U L EI E C M )
11-42
,l
H E A T E DO X Y G E NS E N S O RI H O 2 5 )
11 - 4 6
a
MANIFOLDABSOLUTEPRESSURE {MAP SENSOR) CRANKSHAFTPOSITION(CKPSENSOR)
11-52
4 o
(ECTSENSOR) ENGINE TEMPERATURE COOLANT
11-58 11-60
THROTTLEPOSITION(TP SENSOR}
11 - 5 6
11 - 5 6
9
TOP DEADCENTERPOSITION(TDC SENSORI No. 1 CYLINDERPOSITION(CYPSENSOR)
10
(IAT SENSOR) INTAKEAIR TEMPERATURE
11-62
13
(BAROSENSOR} BAROMETRIC PRESSURE
1|-64
14
IDLEAIR CONTROL(IAC VALVE}
11-42
t c
IGNITIONOUTPUTSIGNAL
to
FUELINJECTOR
17
VEHICLESPEEDSENSOR{VSSI
20
ELECTRICAT LOAD DETECTOR(ELD)
21
VARIABLEVALVE TIMING& VALVE LIFT ELECTRONIC CONTROLSOLENOID VALVE{VTECSOLENOID VALVE)'
6-36
22
VARIABLEVALVE TIMING& VALVE LIFT ELECTRONIC CONTROLPRESSURE SWITCH(VTECPRESSURE SWITCHI-
6-38
23
K N O C KS E N S O R{ K S } -
1 1 - 74
30
A/T FI SIGNALA
11-76
3'r
A/T FI SIGNALB
11 - 7 6
4'l
HEATEDOXYGENSENSOR(HO25} HEATER
11-47
43
FUELSUPPLY SYSTEM
I
11 - 5 6
11-66
1't-102 11-68 't 1-70
11 - 5 0 ':818C1 engine
a lf codes other than those listed above are indicated, verifv the code. lf the code indicated is not listed above, replace rhe ECM. a The MIL may come on, indicatinga systemproblemwhen, in fact, there is a poor or intermittentelectricalconnection. First, check the electricalconnections,clean or repairconnectionsit necessary. o The MIL and @ indicatorlight may light simultaneously when the DiagnosticTroubleCode (DTC)6, 7 or 17. Check the PGM-Flsystem according to the PGM-Flsystem troubleshooting, then recheck the l!! indicator light. ll it lights, s e e p a g e 1 4 - 5 O ,5 1 . a The MIL does not come on when there is a malfunctionin the A/T Fl signalor ElectricalLoadDetector(ELDIcircuits. However, it will indicate the codes when the Service Check Connector is shorted.
11-36
It the inspectionfor a particularcode requiresthe test harness.removethe right door sill moldingand kick panel. Pull the carpet back to exposethe ECM, Unbottthe ECM cover. Turn the ignitionswitch off and connectthe test harness Check the system accordingto the proceduredescribedfor the appropriatecode(s)listed on the following pages.
KICK PANEL
TEST HARNESS OTLAJ_PT3OlOA DIGITAL MULTIMETER Commarciallyovribbla or KS-AHM-32-OO3
NOT USED
o oooooooooooo oooooooo ooooooooooooo oooooooo TERMINAL LOCATIONS
ooooooooooo ooooooooooo (cont'd)
11-37
Troubleshooting Self-diagnosticProcedures(cont'dl a Punctudng th6 inruLtion on r wirc cln cruaa poo? or Int!finltttri aLctrlcC connac,tlom. a For tosting at connoctofs othor thsn tho taat hrmara, bdng thc tartar probc Into contact whh tha tarnilnal trom thr connector ride of wilo hamclr conn.ctora In thc cnglnc comprnrnam. Foi t.|nab connactorr,lurt touch llgl ly whh tha tostor probo and do not Inlcrt tho prcbc.
TES'EB PNOBE
TERflt]IAI
11-38
How to ReadFlowcharts A flowchrrt is dasignedto be us€d fiom start to final repair. lt's like a map showing you the shortest distanco. But be"map" anywhere but a "stop" symbol, you can easily get lost ware: if you go off tho l6rffil (bold tyDo)
Desclibas the conditions or situation to start a troubleshooting flowchart.
|TeTiONl
Asks you to do something; pedorm a test, set up a condition etc'
<:6Eei6io-fr\>
Asks you about the result of an action, then sends you in the appropriste troubleshooting direction.
I-SJTFI (bold typel
The snd of a series ot actions and decisions, describes I tinal repair action and aomotimea diracts you to 8n garlier part of the tlowchart to confirm your repair'
NOTE: a Tha tarm ,,lntormittgnt Failure" is used in these chans. lt simply means a system may have had a failur6, but it chocks out OK !t this time. lf th6 Msltunction Indicator Lamp (MlL) on ihe dash does not come on, check for poor connections or loose wires at all connectors rolated to the cilcuit that you are troubleshooting (see illustration b6low). a Most ot tho troublashootingflowchans have you reset the EngineControl Module (ECM)and try to duplicate the Disgnostic Troubls Cod6 (DTC). lf the problem is intermittent and you c8n't duplicat€ the cod6, do not continus through the flowchart, To do so will only rosult in confusion and, possibly, a ne€dlessly replaced ECM a ,,opon,'and ,,short,, are common electricalterms. An open is a break in a wir6 or at a conn€ction.A short is an accidontalconnaction ot a wir€ to ground or to another wire. In simple electronics,this usually means som€thingwon't work at all. In complex electronics (like ECM's), this can sometimes mean something wolks, but not the way it's suppoSadto, a il th6 olectricsl readingsare not as specified when using the test harness, check the test harnessconnoctions bsfore procooding.
LOOSE
11-39
PGM-FISystem System Description ENGINECONTROLMODULE(ECMI TDC/CKP/CYP Sensor MAP Senso. ECT Sensor IAT Sensor TP Sensor HO2S
vss BAROSensor ELD Starter Signal ALT FR Signal Air ConditioningSignal A/T Gear Position Signal BatteryVoltage{lcN. 1) BrakeSwitch Signal PSPSwitch Signal Knock Sensor' VTEC PressureSwitchr
lFuettnjectorTimingandDuration] I Electr..l"ldle Contr;il Fit'e' contr; Funcrfit
OUTPUTS Fuel-lnjectors PGM-FIMain Relay(FuelPump) MIL IAC Valve A/C CompressorClutch Relay Radiator Fan Relav CondenserFan Relav ALT
rcM EVAP PurgeControlSolenoid
l6tio;
Ttntrlg c..trol
tEcM aack-,rpFunctiorlsl
HO2S Heater VTEC SolenoidValve' IAB Control Solenoid Valve*
': 818C 1 €ngine
PGM-Fl System The PGM-Flsystem on this model is a sequentialmultipon fuel injectionsystem, Fuol Iniector Timing and Duration The ECM containsmemoriestor the basic dischargedurationsat variousenginespeedsand manifoldpressures.The basicdischargeduration,after beingreadout from the memory,is turther modiliedby signalssent from vanoussensofs to obtain the final dischargeduration. ldle Air Control ldle Air ControlValve (lAC Vatve) When the engineis cold, the A/C compressoris on, the transmissionis in gear (A/T only) the brakepedalis depressed, the P/Sloadis high,or the alternaloris charging,the ECMcontrolscurrentto the IAC Valveto maintaincorrectidlesoeed. lgnition Timing Control a The ECMcontainsmamoriesfor basicignitiontiming at variousenginespeedsand manifoldpressures.lgnitiontiming is also adjustedfor enginecoolanttemperature. a A KnockControlSystemis alsoused.when detonationis detectedby the knocksensof.the ignitiontiming is retarded (B18Cl engine). Other Control Functions 1. StartingControl When the engineis started.the ECM providesa rich mixture by increasingfuel injectorduration. 2. Fuel Pump Control a When the ignitionswitch is initiallyturned on, the ECM suppliesgroundto the PGM-Flmain relaythat supplies currentto the fuel pump tor two secondsto pressurizethe tuel system. a When the engineis running,the ECMsuppliesgfound to the PGM-Flmain relaythat suppliescurrentto the fuel pump. a When the engineis not runningand the ignitionis on, the ECMcuts groundto the PGM-FImain relavwhich cuts current to the fuel pump.
11-40
3.
Fuel Cut-oft Control a During decelerationwith the throttle valve closed, current to the {uel injectors is cut otJ to improve fuel economy at speeds over tollowing rpm: . 8188l engine:91O tpm (Canadamodel: 1,O50 rpm) . 818C1 engine:95O tpm (Canadamodel: l,O5O rpm) a Fuelcut-olf actionalsotakes placewhen enginespeedexceeds,7,O0Orpm {818B1 engine),8,1O0 rpm (B18Cl engine), regardlessoI the position of the throttle valve, to protect the engine from ovet-revving.
4.
A/C CompressorClutch Relay When the ECM receivesa domand for cooling trom the air conditioning system, it del8ys the compressorfrom being enetgized,and enriches the mixture to assure smooth transition to the A/C mode. EvaporativeEmission(EVAP)PurgeControlSolenoidValve Whenthe enginecoolanttemperstureis below 163oF {73"C), the ECMsuppliesa groundto the EVAPpu.gecontrol solenoid valve which cuts vacuum to the EVAP purge control diaphragm valve.
6 . Intake Air Bypsss (lAB) Control Sol€noid Valve When the enginerpm is below 5,750 rpm, the IAB control solenoidvalve is activatedby a signalfrom the ECM, intske air flows through the long intake path, then high torque is delivered. At spaeds highe. than 5,750 rpm, the solenoid valve is deactivated by the ECM, and intake air flows through the short intake path in order to reduce the resistancein airflow. ECM fail-safe/bEck-upFunctions 1. Fail-sateFunction When an abnormalityoccursin a signalfrom a sensor,the ECM ignoresthat signaland assumesa pre-progtammed value tor that sensorthat allows the engineto continueto run. Back-uDFunction When an abnormalitv occurs in the ECM itself, the fuel iniectors are controlled by a back-up citcuit independentof the system in order to permit minimaldriving. 2
FunctionIMaltunctionIndicatorLamp {MlL)1 Self-diagnosis Wh6n an abnormalityoccurs in a signalfrom a sensor,the ECM suppliesground for the MIL and stores the code in erasablememory.When the ignitionis initiallyturned on, the ECM suppliesgroundtor the MIL tor two seconds to check the MIL bulb condition.
4.
Two Trio Detection Method To prevent tals€ indications, th€ Two Trip Dstection Method is used for the HO2S and fuel metering-relatedselfdiagnostictunctions.When an abnormslityoccurs,the ECM stores it in its memo.y. Wh€n the ssme sbnormality recursalter the ignitionswitch is turned OFF and ON ag8in,the ECM informs the driver by lightingthe MlL. However, to ease troubleshooting, this function is canc€ll€d when you short the service check connector. The MIL will then blink immedistelvwhen an abnormalityoccurs.
11-41
PGM-FISystem EngineControlModule(ECM) The Malfunction Indicator Lamp (MlL) n6v6. com6s on lovon fol lwo socondal aftor ignition is tumed on.
NOTE: lf this svmptom is intermittent.check for a loosefuse No. 15 (BACK UP LIGHT,1OA)in the under-dashJuse/relaybox, a poor connectionat ECM terminalA13, or an intermittentopen in the GRN/ORNwire betweenthe ECM (A13) and the gauge assembly.
lurn the ignitionswitch ON. ls the low oil pressurelight on?
InspectNo. 15 {BACK-UP LIGHT} l1O A) luse in the underdash tuse/relay box.
Turn lhe ignition switch OFF.
ls the fuse OK? Conneclthe test harnessbetween the ECM and connectors (see p a g €1 1 - 3 7 ) .
Repairopon in YEL wiio botw6on No.'15IBACK-UPLIGHTI110 A) luso and gaug6 assombly.
I Turn the ignitionswitch ON.
l s t h e M I Lo n ?
- R€placo No. 'l5 IBACK-UP LIGHT) llo Al fuso. - Ropair short in YEL wiro botwoon No. 15 (BACK-UP LIGHT){10 A) fuso ano gauge 6$omblv.
A13
I| | o o o o o o o o o o o o o I o o o o o o o o I o o o o o o l o o o o o o o o o o o I - RsDlacotho MIL bulb. - Ropairopon in GRN/ORNwi.e betwoen ECM {A13} and gaug€ a$6mbly.
lB18B1 onginoonlyl Measure voltage between body Oroundand the tollowingterminafs individuallv:423, 424.
ls there less than 1.O V?
Substituto a known-good ECM and rochgck, lf symptom/indication go€s away, roplacotho original ECM.
11-42
Ropah op6n in BLK wirolsl botw6en ECM and GlOl llocatod at thormostat housing) that had moro than 1.0 V.
G 10'l
Th. ll.lfunction Indicltor Lamp lMlll at!y3 on o. cornaaon alt6l two aacond!.
Connectthe SCS short connector to th6 sorvice check connector (see page 11-34).
Turn the ignition switch ON.
Doesthe MIL indicateanv Oiagnostic Trouble Code (DTC)?
Romoveth€ SCS shon connector lrom the service ch€ck connector.
NOTE: a Whenthere is no code stored,the MIL willstay on if the servicecheckconnector is shorted. a tf this svmotom is intermittent,check for: - A loose ECM fuse (15A) in the under-hoodtuse/relaybox - A looseNo. 24 fuse (ACG)(ALT)( 1 5A: B18B1 engine,2OA: B18C1 engine) in the under-dashfuse/relaybox - An intermittentshort in the BRN/WHTwire betweenthe ECM (D4) and the servicecheck connector - An intermittentoDenin the BLK wire betweenthe servicecheck connector and G4O1 - An intermittentshon in the GRN/ORNwire betweenthe ECM(A 13) and the gauge assembly. - An intermittentshort in the YELMHT wire betweenthe ECM (D19)and the MAP sensor - An intermittentshort in the YEL/BLUwire betweenthe ECM (D20) and the TP sensor Go to iolfdiagnostic Proceduros (se€ pago 11-34).
o o o o o o o o o o o o o l o o o o o o o o l i i i : $ A $ . P s ,ol o o o o o o o o o o oooooooooo ooooooooooooo I oooooooo D22 t-l D 4( + ) Turn the ignition switch OFF.
Try to start the engine.
l"oo,o'. uu,l
Connectthe test harnessbetween the ECM and connectors (see p a g e1 1 - 3 7 ) . Turn the ignitionswitch ON. Measurevoltage botween D4 (+ ) terminaland D22 { - ) terminal. ls thereapprox.5 V?
Ropair shon to body g.ound in BRN/WHT wire betwoon th6 ECM lD4) end sorvlco chock connocto?.
InsDoctECU{ECM)115A) tuse in th6 undeFhood luse/relav box.
ls the luss OK?
(To page 1 'l -44)
connect the SCS shon connector to servlce check connector.
Measure voltage be_ tween D4 {+} terminal and body ground.
- R6pairopen in BRN/WHTwito botwoon EcM lD4) and s6rvice chock connactor. - Repoir opon in BLK wiro botwoon 36rvi@ chock connectoa and G4Ol.
ls thereapprox.5 V?
- Rsolaco ECU{ECM}(15 Allus€. - R6pairshon in YEL/WHT wilo botw6on ECU lEcMl 115 A) fuso and PGM-FI main rolay.
Removethe scs short Connector from the service check connector.
'NOTE: After repair,disconnectthe SCS Short Connsctor,test drivethe car, and rechecktheMIL lor a code.
(cont'd) lTo page 1 1-44)
11-43
PGM-FISystem EngineControl Module (ECMI (cont'dl (Frompage 11-43)
(Frompage 1 1-43)
Inspectthe No. 24ACG {ALT)(lG) (15 A: 81881 engine, 2OA: 818C1 enginelfuse in the underdash fuse/relav box.
ls the fuse OK?
Disconnect"A" connector from the ECM.
- R.pllr .hon in BLK|rEL wlr6 batr.v€qr undariair luro/Fby box lnd FGM-FI m.in .obv. - noebco lto. 24 ACG {lG) nLT) (15 A: 81881 ongin., 2OA: Bl8Cl onein.l tu!6.
Turn the ignition switch ON.
Disconnect the 3P connector ot each sensor one al a time: . MAP sensor . TP sensor
Doesthe MIL remainON?
Subrtltute r knowngood ECM .nd rochock. ll lymptom/indicstlon g@a rw!y, rephco tho origin.l ECM.
ls the MIL ON?
Ropair short to body giound in GRN/ORN wir6 botwoon tho ECM lA131 6nd MlL. Rcplaoo thg lgnlor that caur6d th. llght to Oo out.
Turn the ignition switch OFF.
Dt9 I
connect the test harness. Disconnect the "D" connector from th€ ECMonly, not the main wire harness(see page 11-37).
I o o o o o o o o o oo o o I o o o o o o o o I o m o o o l o o o o o o o o o o o | I o o o o o o o o o o o o o I o o o o o o o o 1 o ( ' o e ( l oI o o o o o o o o o o o | -
| |
l
D2O
I
\-.J Continuity?
Check tor continuity between body ground and D19, O2Oterminals, - Bapai?rhod ro body g.ound in YEL/WHT wi.e boiwoon ECM (Dl9) .nd MAP ..n3or. - R.p!k shon to body ground in YEL/BLU wire b.lwo6n ECM (O2Ol .nd TP 3on!or. Reconnect all tho sensor connecrors, Reconnectthe "D" connector to rhe ECM.
Turn the ignitionswitch ON.
{ T o p a g e1 1 - 4 5 }
11-44
(Frompage 1l-44)
Measure voltage between 426 {- ) andthe following:B'1(+ } and A25 {+t.
BATTERY VOLTAGET
ls there battery voltage?
- Ropsir opon in YEL/BLK wiro botwoon ECM (425, 81l and PGM-FIm6in relay. - Chock PGM-FImain rclay and wiring connectors at PIGM-FI main.olay(soepsg6 11-1121.
Measurevoltage between body ground and the tollowingtermiA23. A24, A26, nalsindividually: 42.
ls there less then 1.0 V?
- noprir opon in BLK wit. b6twson ECM 1A23, A24l and G'101 {locatod al th6.mostat housingl. Repair opon in BRN/BLKwite botweon ECM (A26, B2l and Gl0r.
Substitut6 r known{ood ECM and r6chock. lf symptom/indication goos away, roplacotho original ECM.
ooooooooooo ooooooooooo
oooooooo ooooooo
ooooooooooo ooooooooooo
L€ssthan 1.0 V?
11-45
PGM-FISystem HeatedOxygenSensorlHO2Sl -fi-l:
-t6l--.:
t
z
\ /?\
/
The Malfunction Indicator Lamp (MlL) indicates Diagnostic Troubls Code (DTC) 1: A problsm in the HeatedOxygen Sonsor(HO2S| circuit.
The Heated Oxygen Sensor IHO2S) det€cts th6 oxygon contont in th6 exhaust gas and signals th6 ECM. In operation, the ECM receiv€s th6 signals trom the sensor and vari€s the duration during which tu6l is iniocted. To stabilize thd senaor's output, tho sensor has 8n intarnal heater and the sensor olemant is coatod with a catslyst. The HO2S is installod in TWC housing(B18Cl engine)or exhaustpipe B (Bl8Bl €ngine). sEl{SOR TERMII{ALS sTotcHtoltETnc ztRcot{lA VOLTAGE(V}
AIR-FUEL BANO
ELEiIE'{T
HEATER - --.'!-
-
-__-
l r P l _ l! l -
HEATEB TEBMIT{ALS
- Th! mll h.. bo.n raportad on. - Wlth thr SCS rhon coon cto. connoctad lr.. p!9. 1t-341, cod. t l. Indlcltrd.
Oo th€ ECM Res€t Procodure {soo pag€ 11-35).
Stan the 6ngine. Hold th6 engine A3,qgq rpm with no load {A/T in Lrylor lll position, M/T in nourrall until the radiator lan com6s on. then lot it idle lor ot least on6 minutg beforo road t€6tin0.
Connoctths SCSshort connoctor to th6 sorvic€ check connector lsoo p.g6 1 1-34).
Rood t€st witlthe automatic transmissionin L?l position (M/T: 4th gear). Stsrting st l,600 rpm, acc6lorate u6ing wide open throttlo for at lesgt 5 seconds.Thsn dgcol€rste for at lorst 5 s€conds with th€ throttlo completoly closed.
Ooes the MIL blink and doos it indic6t6 cod6 1?
Go to plga and partonn tad fot cod. 43 lr.a p.go l1-501.
1 1-4 6
Intarmittd[ t llurc, lyri.m b Of !l thla tlmc. Ch.ck lor poor connacdona o? loota wlrat |l C223 (loc.trd at right $ock towo.l, Cr 13 (HO2S| lnd ECM.
- LEAI{ RICH - AN. FUEL RATIO
mll Y-
-.----r-
Diagnostic TroubleCode(DTCI41: A problemin Lamp(MlL)indicates Indicator TheMalfunction the HeatedOxygenSensor{HO2S)Heatercircuit.
)ffltl -:-
\-
l-l
-t tt(gt- r - - - 7 r tt I - Th6 MIL has boenroponod on. - With the SCS rhort connocto. connociod (aoe pago 11-341. codo 41 is indic.tod.
Do the ECM ResetProcedure{see p a g e1 1 - 3 5 1 .
ls the MIL on and does it indicste code 41?
Turn the ignition switch OFF.
Intoamittont tdl||.g, ryrt m i3 OK at thi! timo (tost driv6 lnay bg nscearatYl. Chock tor poor conn6ctions or looro wires at C223 llocatod at right shod( row..l, C3O5 {located 6t loft ahock lowor), C424, C113 (HO2S) and ECM.
t€rminal side
Measurc tasistance betwgen terminals3 snd 4 on the HO2S.
ls thero 1O-4O 0?
DIGITALMULTIMETEB Commorciallyavailabloor KS-AHM-32-OO3
(cont'd) (To page 1 1-481
PGM-FISystem HeatedOxygenSensorHeater(cont'd) 11-471
Check for continuity to body groundon terminals3 and 4of the HO2S.
YEL/BLK I+I
Checkfor continuity betweenter minal4 and terminals1 and 2 individually.
(-I ORI{/BLK
wire side
Turn the ignitionswitch ON.
At the HO2S harness. measure voltagebetweenYEL/BLK1f lteF minal and ORN/BLK l-) termrnal.
HO2S 44 N.m {4.5 kgt.m, 33 lbf.ft}
YES
Measure voltage between YEL/ BLK l+) terminal and body ground.
Turn the ignitionswitch OFF. Disconnectthe "A" from the ECM.
connector
Turn the ignitionswitch ON.
At HO25 harness,measurevoltage between YEL/8LK(+) terminal and ORN/BLK{-) terminal.
ls there baftery voltage? Ropai.opon in YEL/BLK wire botwoan HO2S .nd PGM-FImain relav. Turn the ignitionswitch OFF.
{ T o p a g e1 1 - 4 9 )
11-48
Turn the ignitionswitch OFF.
{ T o p a g e1 1 - 4 9 }
RoDair short in ORN/ BLK wir6 b6tw6on ECM (A6l and HO2S.
"A" Connect the test harness connector to the main wire har ness only, not the ECM (seepage 11 - 3 7 1 .
Connectan ammetetbetweenterminalsA6 {+ ) and 426 (- )
* Monitor over a 5 minute Deriodunl6ss the current drops below O.1A immediatelv.
Turn the ignitionswitch ON.
ls the current less than 0.1A?.
Subrtitulo s known-good ECM .nd r.ch6ck. lf symptom/indication goes away. roplacotho origin.l ECM.
Connoct the test harn€ss "A" connector to the main wire harn6ss only. not th€ €CM {seopage 't't-37).
BATTERY o o o o o o o o o o o o o I o o o o o o o o VOLTAGE?o o Q o o o o o o o o o o I o o o o o o o o
L-E;
ooooooooooo ooooooooooo
Turn the ignition switch ON.
Measwe vohage bstween A6 {+ } tg.minaland A23 {-)terminal.
Ropsii op6n in ORN/BLKwiro botw..n ECM {A6l and tho HO2S.
Subrtiluto s known{ood ECM lnd Echock. ll .ympiom/indic{tirn god !way, '.pLc! f|e origlh.l ECM.
11-49
PGM-FISystem Fuel Supply System rj-t -
-
t
-
.
T,-n - L:!-i -
The MaltunctionIndicatorLamp (MlL) indicaresDiagnosticTroubleCode (DTC)43: A problemin the HeatedOxygen Sensor(HO2S)circuit. or a probtemin the Fuel Supply System.
-+-
1 3| l- t @"-t - -- t--i-'
- Tho MIL h.s boenreportodon. - With rhe SCS short connoctor connocted (soo paga 1l-34), codo 43 b indlcat.d, ls the code 43 accompanied by the MIL and poor driveability?
From codr I troebl.lhoorlng lprgo 1146).
Go to Fuol Supply .y.t.m pag6 1t-971.
(|ec
Do the ECM Resetftocedure lsee p a g e1 1 - 3 5 ) . Connectthe SCSshort connector to the service check connector 'l1-34). {see page Start the engine. Hold the engine at 3,00O rDm with no load {A/T in @or@ position,M/T in neutral) until the radiator Ian comes on, then let it idle for at least one manute, Raisethe enginespeedto 3,000 rpm and hold that throttle position tor at least one minute. Do not vary the throttle position even if the rpm drops.
Intonnitl.nt t llure, tydom lr OK at thi. tim. lto.t drlv. mly b. nocaararyr. Chock lor poo? connactlona ot loots wiro at C223 lloc.t.d at rlghl lhock towo.]. Cl13lHO2Sl and ECM,
Ooesthe MIL blink and does it indicatecode 43?
Turn the ignitionswilch OFF. Connectthe test harnessbetween the ECM and conneclors {see p a g e1 1 - 3 7 1 .
NOTE: . UseDIGITAL MULTIMETER. . U6e2 Volt rang6. o oooooo oooooo I oo oooooo ooQooooo ooooo I oooo oooo 426
ooooooooooo ooooooooooo
JUMPERWIRE With the ignitionswitch OFF,wait for at least two minutes. lnstalla jumper wire on the test harnessbetween A6 and A26. 1Topage 1 1-5'll
11-50
o ooooo oooo ooo I oo oooooo Isdtcllodsl ooo oooooooo o oooo ooo oo ooo I oooo oooo ooooooooooo 426 t-l |.-
vohrgo rhould rl.n.t 0.4-0.5 V wh.n th. ignirioo .wilch i! fird t|rtrod o.r, Itd docr!6a to b.low O.1 V in L.. th6n two minutaa.
D 1 4{ + l
I
{Frompage I 1-5O)
Turn the ignition switch ON.
Measure voltage between o14 (+ l terminaland A26 (- I terminal as soon as the ignition switch is turned on.
ls there O.1 V or less when the igniiion switch is first tu.ned on?
Msasuro voltage between D14 (+) le.minal snd 426 l-) ter-
ls ther€ more than O.1 V?
Turn the ignition switch OFF.
Disconnect the "D" connoctor from the main wire h6rness.
Turn th€ ignition switch ON.
Measure volt6ge betwesn D14 l+) terminal and A26 (-) terminal. Measure voltage al th€ ongino wire harnsss sid€ ol the HO2S conngctor botween WHT/RED (- ). {+)and GRN/BLU
R.pri. rhort in WHT/ REDwire betwo€n ECM (Dl41 rnd lho HO2S.
ls there more than O.1 V?
Subdlht. . known{ood ECM .nd r..firck. ll rymptom/indic!tion goaa !w!y, .aphca rha otiglnll ECM.
ls thero moro than O.1 V?
Ch.ck for oDcn in WHT/RED wir. brrworn ECM (D141 .nd lh. HO2S. It wl]o l. OK, .oprir op€n iD GRil/8LU rvlr. b.tw..n ECM lD22l lnd thc HO2S.
(+) WHT/RED
(-I GRI{/BLU
wire side
DIGITALMULIIMETER avallabloo. Commarcially KS-AHM-32-OO3
HO25 44 N.m (4.5 kgl.m, 33 lbf.ftl
11 - 5 1
PGM-FISystem ManifoldAbsolutePressure(MAP)Sensor fxai -:-
- lfil1 -?-
The MalfunctionIndicatorLamp (MlL) indicatesDiagnosticTroubleCode (DTC) 3: An electrical problemin the ManifoldAbsolutePressure(MAPI Sensorcircuit.
The MAP sbnsorconvertsmanitoldabsolutepressureinto electricalsignalsand inputs the ECM. SENSOR
OUTPUT VOLTAGE
1.5
600 700
(in. Hsl GAUGE READIIIO {mft Hg)
- Tho MIL has boon roportod on. - Wirh tho SCS rhort connoctor connectod lsoo pags 11-34), codo 3 b indicatsd.
Do the ECM ResetProcedure{soe p a g e1 1 - 3 5 ) .
ls the MIL on and does it indicate code 3?
Intormittont tailuro, lystom ir Ol( at thls timo {tort drivo may bs nocessary). Chack to? Door connocllon oi loosa wiroa 6t C223 {locltod at right shock tow6rl, C'l 14 (MAP sonaorl and ECM.
YEL/REDlBlSBl onginc) YEL^YHTlBlaCl .ngin.l | + I
Turn the ignitionswitch OFF.
{+l Disconnectthe 3P connectortrom the MAP sensor,
Turn the ignitionswitch ON.
{ T o p a g e1 1 - 5 3 )
11 -5 2
11,52)
Measurevoltage between YEL/ WHT {818C1 engine),YEL/RED (B188'1engine){+ ) terminaland bodv ground.
ls there approx. 5 V?
Measure voltage between YEL/ WHT (818C1 engine),YEL/RED {B1881engine)(+ } terminaland GRN/WHT(- ) terminal.
Turn the ionitionswitch OFF. ls there approi. 5 V? Connect the test harness "D" connectorto the ECMonly, notto the main wire harness {see page 11,37).
Repair opon in GRN/ WHT wir6 botweon ECM lD2l l and tho MAP sonsor,
Turn the ignitionswitch ON.
Measurevoltage between D19 {+} terminaland D21 {-} termrnat,
Measurevoltage betweon wHT/ YEL (+ ) terminaland GRN/WHT {- } terminal.
ls there approx. 5 V?
Bepairopen in YEL/WHTwi.e betw€6n ECM lD19) and tho MAP aon30t. ls there approx. 5 V? Substitule s known-good ECM and rechock. ll symptom/indica' tion goes away, replac€tho oiigi' nal ECM.
Turn the ignitionswitch OFF.
Reconnecl the 3P connector to the MAP sensor.
Connectthe test harnessbetween the ECMand connector(seepage 11 - 3 7 1 .
Turn the ignitionswitch ON.
(cont'd) { T o p a g e1 1 - 5 4 }
lTo page I l-54)
PGM-FISystem ManifoldAbsolutePressure{MAPISensor(cont'd) l F r o mp a g e1 1 - 5 3 )
(Frompaqe 1 1-53)
M6asure voltage between D17 {+) terminaland 021 (-} terminal. Turn the ignitionswitch OFF.
Connect the test harness "D" connectorto the ECMonly. not to the main wire harness lsee page 11-37).
Turn the ignitionswitch ON.
ls there approx.3 V?
Substituto 6 known{ood ECM .nd rach.ck. It symptom/indication gooa away, Eplaco tho orlginrl €CM.
approx.3 v? D 1 7t i l D 2 1( - l
Measurevoltage botwson Dl7 ( + ) t e r m i n a la n d D 2 1 { - } terminal.
ooooooooooooo
I oooooooo l
o oooooooooooo ! oooooooo
ls there approx. 5 V?
l 5 o i E € t d lo o o o o o o ooooooooooo
R.p.lr opon or ahort in WHT|rEL wi?obotw.on ECM {O17) and tho MAP senso..
NO Substitute a known{ood ECM and rochsck. It prdcribed voltrgo b now availablo, rophce trie original ECM.
11-54 '
.
-
-
-
.
-
'
PGM-FISystem TDC/CKP/CYP Sensor _f'=l_ t:l'6]-i-flG]l, -
The MalfunctionIndicatorLamp (MlL) indicatesDiagnosticTroubleCode (DTC)4: A problemin the CrankshaftPosition(CKP)Sensorcircuir.
fi_l
ftl
The MalfunctionIndicatorLamp (MlL) indicatesDiagnosticTroubleCode (DTC) 8: A problemin the ToD Dead Center ITDC) Sensorcircuit.
-
The MalfunctionIndicatorLamp (MlL) indicatesDiagnosticTroubleCode (DTC)9: A problemin the CvlinderPositionICYP)Sensorcircuit.
ft-]
The CKP Sensordeterminestiming tor fuel injectionand ignitionof each cylinderand also detects enginespeed.The TDC Sensordeterminesignitiontiming at start-up(cranking)and when crank angleis abnormal.The CYPSensordetects the positionof No. 1 cylindertor sequentialfudl injectionto each cylinder.
-
\.--r-l
-
-__l_-
tPJ:;LlJ:lEl--;? l ,: - Tho MIL hos beonroponod on. - With rho SCS short connoctor conneclod lsso pago I l-341, code 4, 8 and/or 9 ar6 indicated.
Do the ECM Resetprocedure(see p a g e1 1 - 3 5 ) .
ls the MiL on and does it indicate code 4, 8 and/or 9?
Turn the ignitionswitch OFF.
Disconnectthe 8P connectorfrom the TDC/CKP/CYP sensor.
{To page 1 1-57)
11-56
Intohittent failuro, syst€m is OK at thia tima {t6st drivo may be noceaSaayr. Chock for poo. connections or looss wires at C222 (located at right shock towerl, C110 (TOC/CKP/CYP Sonsorland ECM.
{ F r o mp a g e 1 1 - 5 6 )
SEIiSOF
Measureresistancebetween terminalsof the indicatedsensor. 'see table
TDC
ls there 35O-7O0 0?
R.olac6 th. distributor housing (8oo aoction 231.
DTC
SENSOR
ECM TENMINAI
COLOR
2
815
ATU/GFN
6
816
BTUTVEI
813
ORN/BTU
a 9
814 B1t
a
ORN
s12
Check for continuity to body ground on both terminalsot the indicatedsensor, Rgplace tho di.tributor housing llo€ loction 23t.
Connect the test harness to the main wire harnessonly, notto the ECM (see page 1 1-371.
Measureresistancebetween terminalsof the indicatedsensoron test harness. 'see table
o oooooo oo ooo o I oooooooo l6coocl o oo ooo ooooo o oooo ooooo ooo I oooo oooo lo{nofioo't oooooooo ooo
350-7000?
ls there 350
70O 0?
812
Roprir opon in tho indicated senaoawirea. *soo tablo
Check for continuity to body groundon 815. 813 and/orB'l 1 terminals.
ls there continuity? NO
Repair short to body ground in tho indicrl.d t€naor wiroa. i s€e tabla
Substituto a known-good ECM and rechock. lf symptom/indication goes away. roplacotho origin.l ECM.
11-57
PGM-FISystem Engine Coolant Temperature(ECT) Sensor - ,-!-t@l-
\ ---1- -l 6 | - The MalfunctionIndicatorLamp (MlL) indicatesDiagnosticTroubleCode (DTC)6: A problemin the EngineCoolantTemperature(ECT)Sensorcircuit. The ECT Sensoris a temperaturedependantresistor(thermistor).The resistanceoI the thermistordecreasesas th€ engine coolant tempe.atureincreasesas shown below. RESISTANCE {k0l
JrsG-11 \
- -\.--r-l t 5| /--i\
j 3 2 6 8 l O r rl a 0 t 7 6 2 t 2 2 a 8( . F l -2tt 0 20 rto ao D r@ t20 (,cl
ENGII{ECOOLAI{TTCMPERATURE - Th€ MIL has boon roDortodon. - Wlth tho SCS shon connoctor connoctod {s66 pag6 '11-34}, code 6 is indicatod.
Do the ECM ResetProcedu.elsee page 1 1-35).
Turn the ignitionswitch ON.
ls the MIL on and does it indicate code 6?
Intoimittont failur6. ryatom is OK el this lime ltosl d.ive may bo nocassaryl. Chock for poor connsctiona or looso wiros al C223 {locatod at tight shock lowor, C111 (ECT sonsorl,C419 {TCMI and ECM.
Start the engine. Hold the engine at 3,O0Orom with no load {Afi in N or lF]position,M/T in neutral) until the radiatorlan comes on, then lot it idle.
Turn the ignitionswirch OFF.
Disconnectthe 2P conneclorlrom the ECT sensor.
Measure resistancebetween the 2 terminalson the ECT sensor.
ls there 2OO-4OOO?
(To page 1 1-59)
11-58 --
ECT SENSOR
Turn the ignitionswitch ON.
Measure voltage betweon RED/ WHT and body ground.
ls there approx. 5 V?
Measure voltage between RED/ WHT {+}terminal and GRN/8LU (- ) terminal. GRN/BLU {-} ls there approx. 5 V?
Ropai. opon in GRN/ BLU wiro botwoon ECM (D221 and tho ECT 36n3('r.
Turn the ignitionswitch OFF.
A/T only
Sub3tituto a known-good €CM and rochock. lf 3ymptom/indication go6s away, roplacothe odginal ECM.
Oisconnectthe 22P connector trom the Transmission Control Module (TCM).
Turn the ignitionswitch ON.
ls there approx. 5 V7
Turn the ignitionswitch OFFand reconnect the connector to the TCM.
I
_i Connect the test harn€ss "D" connectorto the ECMonly. not to the main wire harness {see page 11-37).
Turn the ignitionswitch ON.
Measurevoltage between D13 (+) terminal and D22 (-l termlnal.
ls the.e approx. 5 V?
Repair opoa or shon in REO/WHTwiro botwoen ECM lDl3l and th6 ECT sonsor. R6pairshon in REO/WHTYYi.. b6tw66n ECM{D131andTCM.
Substiluto a known-good ECM and rochock. ll lymptom/indication goea6wsy, replacotho o.igin6l ECM,
11-59
PGM-FISystem ThrottlePosition(TPl Sensor .:-\.----ll@l--l
The MalfunctionIndicatorLamp(MtL)indicateeDiagnosticTroubleCod€(DTC)7: A problcmin rhe ThronlePosition(TPl Sonsorcircuit. TheTPSensoris a potsntiometer,lt is connectedto the throttlevalveshaft.A8 the throttlopositionchan96, the throttlo positaonsensorvariesthe voltagesignalto the ECM. t l-
BBUSH HOLDER
OUTPUTVOLTAGEIV) BNUSH
I a t
RESISTOF
t I
o.| o
IXNOTTII
;0rr- of€ no
TERMIIIAL
THNOTTIE
)ran1 )ril
-Y-
-?..
- Th. MIL h.. baln rlport d on. - With th. SCS thort conn.ciol conn.c-ted (rco pngc 11-341. codo 7 i. indlc.t d.
Do the ECM Resethocedure (se€ page l 'l-35).
ls the MIL on and do€s it indicats codo 7?
l. ..mrtt nt fClur., lyrt m la OX .t thb dm. ll.at drlv. rn.y br ncoaataryl. Chack lor poo? connactlo|ra ot loora wlr.r !t C223 lloc.t d !t dgtn drod( tow..t, Cl15 ITP ...trorl, C419 (TCMI .nd ECM.
Turn th€ ignition switch OFF.
RED/BLK {-I Disconnecttho 3P connectorlrom th€ TP sensor.
YEL/aLUl+l
cnn/BLuI - l
Turn the ignition switch ON.
Meosu.o voltage betwoon YEL/ BLU (i ) terminaland GRN/BLU I -, torminal.
ls there approx. 5 V?
Measurs voltagG betw66n YEU BLU (+l terminal and body giound.
(To page 1 1-6'l) (To page 1 1-611
11-60 ,,,----
TP SEITSOR
(From
{From page 1 1-60)
1 1-60)
ls there approx. 5 V ?
Turn the ignitionswitch OFF.
Repsir op.n in GRN/ 8LU wii6 botwoon ECM lD22l snd tho TP aenaot.
Turn the ignition switch OFF.
Connectthe test harnessbetween the ECM and connectors (see page 11-37l-.
Connectthe test hamessbetween the ECMand connector{seepage 11-37). Turn the ignitionswitch ON.
Turn the ignilion switch ON. Measure voltage between D2O { + ) t e r m i n sal n d D 2 2 { - } termtnal, ls there approx. 5 V 7
Measure voltagebetweenD11 {+ ) terminaland 022 (- I terminal.
Ropoi. open in YEL/BLU wire bgtween ECM {D20} and rho TP 30naot.
-ReDai. ahort in YEL/BLU wiro borwoonECM (D2Oland tho TP son30t. -Sub3tituto a known-good ECM 6nd rochock. It prcacribodvolt6go is now availablo, roplaco th6 original ECM.
Fr.
o.5 v n tua .b
drdn
?
A/T only Turn the ignitionswitch OFF. ls voltageapprox.O.5 V at lull close throtlle. and approx. 4 v at full open throttle? NOTE:Thereshouldbe a smooth transition as the throttle is depressed.
Disconnect the 22P connector from the Transmission Control Module (TCM).
lurn the ignitionswitch ON. Substitute a known-good ECM and roch6ck. ll symptom/indication 9063 away, roplacoth6 original ECM.
ls voltageapprox.0.5 V ar full close throttle, and approx. 4 V at tull open throttle? NOTE:There shouldbe a smooth transition as the throt' tle is deprossod.
-
Replaco tho TP aonsoa, Repai. opon or ahon in RED/BLKwir. b€twoon ECM lDl1l, TCM 6nd TP sonsor.
11-61
PGM-FISystem IntakeAir Temperature(lAT) Sensor \ ----:--
z
\ ---L
/
-h6lI- t0 l-\ The MalfunctionIndicatorLamp (MlL) indicstesDiagnosticTroubleCod6 (DTC) 1O: A problemin / | \ / the Intake Air TemDerature(lAT) Sensorcircuit, The IAT Sensor is a temperature dependant resistor (the.mistor). The resistanc€ of the thermistor d6creases8s the intake air temDeratura incroases as shown below. RESTSTAXCE tmt
THERMISTOR
-a a2 aa roa .t7a 212 a t |l -20 o 20 rto ao I t6 rro t.cl
I TAKE AIR TEiiIPTFATURE
)1611:till ---l---i-\ /
\
-
z
Th! *llL hs b!!n Egortad on. \|\rrdrdra SCS rhon connrcto. conn.ct.d lt . psg. 1l-341. cod. 10 l. hdlclt.d.
Bl8Bl onglnc:
Do the ECM Resot kocoduro {se€ pago 11-35).
Turn the ignition switch ON.
ls the MIL on and doos it indicate code 10 ?
Turn the ignition swiich OFF.
wi.a sido
Into.n{tlont failuro. rysr.m ir OK .t thi. iim. (toat drlvc m6y b6 arooa!!1ryt. Ched( tor poor clnncclioiE or loote wlrar 6t C223 lloc.tod right lhock toworl, C12O (lAT renrcrl and ECM.
Oisconnoct tho 2P connector from the IAT sensor. 818C1 .nglnc:
Meosu.eresistonc€ betweenthe 2 torminalson the IAT aengor.
ls thero 0.4-4.0 k0?
Rlobco tho IAT aonsor.
(To pago 1'l-63) RED/YELI+ )
11-62
IAT SEI{SOR
{Frompag6 l1-62}
Turn the ignition switch ON.
Messuro voltage b€tw€6n RED/ YEL (+) terminal and body ground.
ls thore approx. 5 V ?
M€asurs voltage between RED/ YEL {+) rerminaland GRN/BLU { - I terminal,
Turn the ignition switch OFF. ls thero a99rox. 5 V ? Connsct lhg t€st hamess "D" connoctorto the ECMonly. not to th6 main wire harness lsse page 11-371.
Rsp.lr op.n in GBt{/ 8LU wir bctwo.r ECM lD22l snd tho IAT aanaor.
ECM Sub.lhul. a tnown{ood lnd rachack. It rymptom/lndlc!don gort arv.y, t pl.c. dr! oilgln.l ECM.
Turn tho ignition switch ON.
Mgasur€ voltag€ bstwgon D15 (+) terminal and D22 l-l tgrminal.
ls th€re spprox. 5 V ?
Rap.lr opon or rhon In REDfYEL wh. b.tw..n ECM lDl5l rnd th. lAf tcrrao.-
ECM S0brlitrrt. . lnown{ood '|d '.
11 - 6 3
PGM-FISystem BarometricPressure(BAROISensor fAl-
f;ff: L--:g
The MaltuncrionIndicatorLamp (MtL) indicatesDiagnosticTroubteCode (DTCI 13: A probtemin the BarometricPressure{BARO)Sensor.
The BARO Sensoris built into the ECM.
/
-.+.-- \--r- / t ( g t - t 1 3t '
\
-
/
_
i
-
\
Tho MIL has booo reponod on. with th6 scs Short COnnOCtO. connoctod (aeo psgo 11-34), cod€ 13 is indicatod.
Do the ECM ResetProcedurc(see p a g e1 ' l - 3 5 ) .
Turn the ignitionswitch ON.
ls the MIL on and doesit indicate c o d e1 3 ?
Substituto . knorvn-good ECM and reck6ck. lt symptom/indicrtion goes away, roplacoth6 original ECM.
11 -6 4
Intormitt€nt trluro, system is OK !l this timo {le!t driv6 msy bo necoSaaiy).
PGM-FISystem lgnition Output Signal i16;11 '--=--
-
:ffi1 . -r-
t
The MalfunctionIndicatorLamp(MlLl indic8tesDiagnosticTroubleCode(DTC)15: A probl€min the lgnitionOutput Signslcircuir.
Th. MIL hsr b..n roport.d od. Widr ths SCS .hon cohnecto. connoct€d {..o plgo 11-341, codg |5 i! indicatrd.
Do the ECM Reset ftocedure (see page 'l'l-351.
NOTE| ll the onoine won't stan. it may take 20 seconds ot cranking to 5€t th€ COde.
ls th€ MIL on and do€s it indicate code 15 ?
I
Intarmltt nt hllur.. ryltam i. OK !t drlr dm. (t |l drlva mly bo naoaaalry). Chack tor Door cmnactiona or loo|. rYlrar !t C223 llocltld !t rlghr .hoct tow.rl, Cl10 (lCMl .nd ECM.
Turn the ignition swirch OFF.
D|STNIBUTOB
Turn the ignitionswitch ON.
wir6 sido
Measure voltage betwoon BLK/ YEL (+) terminal snd body grouno.
ls the.e battory voltage ?
(To page 11-67)
11-66
R.p.ir op.n In BLK/YELwlr. boftvarn th. 2P conn.cior lnd ionition rwitch.
Turn tho ignition 3witch OFF.
TTERYVOLTAGE4 421 (+l Connoct th€ toat hamess bgtwe,sn the ECM and conn€ctors {see pago 11-371.
ooooooooooooo oooooooooooo
Turn th6 ignition switch ON.
Measurc voltags betwe€n A21 {+) te.minaland A26 {-} t6rminal. -
R.pl.c.
th! lC
(trr..ctlo[
23t.
ls th6re bottory vollsge 7
- napllr op.n or .ho?t In YEL/GB'{wlrc b.tw.cn ICM ..d Eciil lA21l. NoTEr lf rhe YEL/GRNwke was shortsd, tho ICM may bo damaged.
Sub.thut. ! known{ood ECM .nd r.ck ck. ]t .ymptom/lndlc.don go.. !w!y, ..pbc. lha odgln.l ECM.
11-67
PGM-FISystem Vehicle Speed Sensor (VSS) - _-_f_-.,
It6l-
\-=1_
-
IndicatorLamp(MtL)indicateE Diagnostic Trouble Code IDTC) 17: A problem in -l tl' l- The Maltuncrion ths VehicloSD6sd(VSS)circuit.
The VSS generates a pulsing signal when the front wheels turn.
*
Tha mll hs b..n ltgortld o.r. Yvlrh th. Sc]S $o.r coi[cto. connast.d l... ploa I l -341, cod! 17 i. Indlc.i.d.
Do the ECM Basot Procodur6 16€€ pag€ I I -351.
Roadrosr whh A/T in13 positaon {M/T: in 2nd O6ar),accol6rat6to 4,OOO rpm, thon d6c6l6,ate to 1,5OO .pm with th.ottlo fully closod tor at loast 5 s6conds.
ls th6 MIL on and doos it indic.t6 'l7 code ?
Block roar whe€19 and 5st th6 parking brsko. Jsck up th€ f.ont of the c6. and support with saf€iy standa.
Int rmltllrt t llur., .yrtam b O|( .t drlr drr. Chcct lor poor conicctlon! oa lootc wl... !t C3O50ocrtad rt Ltt rhod. torr.l, eA24. C112 IVSA).nd ECil.
@4""r
r.r whadr b.lor. l.d.lnC up tront ol cat,
Turn the ignition Bwitch OFF.
Connect tho t€st hamos3 b€tw€€n tho ECM ond connoctora {as€ p a g 61 1 - 3 7 ) .
Tu.n th€ ignitioh switch ON. Block the .ight lront whoel and alowly rctato loft tront wh6ol and m6asur6 voltago b€twoon BlO {+) torminal and A26 l-} terminal.
Doss voltago puleo O V and 10 v?
Sub|tllul. ! knosn{ood ECM lnd r!ch.ck. lt .Vmgiom/lndlc.tlon g@.. .w.y, r.pLca di. orlgln.l ECM.
11-68
a 2 5{ - t
atol+l 0- 10V ?
NOTE:Transmission in llj positionlA/Tl.
Tu.n th€ ignition switch OFF.
lTo p6ge 1 1-691
(Frompage 1 1-68)
Disconnect the "B" connector from the ECM only, not the main wile hatness.
Turn the ignitionswitch ON.
Block tho right front who€l and slowlv rotate l6ft front wheel and m€asure voltage between 8'l O l+) terminaland A26 (-) terminal.
Doos voltage pulso O V and
'tov?
-
-
SubrtituL . known-good ECil lnd Ech.ck. fi lynptom/ndcltbn gp.. rw!y, .rpleco lh. originalECM.
Roo.ir lhort in ORt{ wire belween ECM 18101tnd rhs VSS or cruia6 control unit. ncp.i. op€n in ORI{ wira botwoan ECM (8101and the vSS. It wir. i! OK, tott tho vSS. lsoc aection 231
11 - 6 9
PGM-FISystem ElectricalLoad Detector (ELDI tft;-]/ -Li!-
The Maltunction Indicaror Lamp (MlL) indicatss Diagnostic Trouble Code IDTC) 20: A probtem in tne ElectricalLoad Detecror{ELD}circuit.
With lho SCS lhon connectol connoctod {ree pago 11-34}, cod. 20 is indicatod.
Do the ECM B6setProcedurs{see page 1 'l-35).
Start engine and keep engin€ speed at idle. Turn on headlights.
Ooes the MIL indicato code 20?
lntennlna tlllure, lyrtom lt Ol( !t irl. dm. (lgtt driv. mly bo na@raaryl. Chrck for Door connactlona oa loota wiro. rt C218 IELD, lnd
Ectrt.
View trom wire side
B L K( - ) Romove the undgr-hood fusg/ relay box and remove the tus6/ relav box lowet cover.
GRn/iEDI - |
BLK/YELI + I
Turn lhe ignition switch ON.
Measure voltage betw€on BLK/ YEL (+l terminal and BLK (-) terminal.
ls there bartory voltagel
Msasuro voltag€ b€tweon BLK/ Y€L {+) terminal snd bodv ground. Rcpir oo.n in BLK wir. batwaan lha 3P connrctor lnd G2Ol {loc.t.d troit ot angh|. comprnm.r dghl .ld.l, B.p.lr op.n in BLKrYEL wlrr b.tw..n o.24ACG (ALn flcl115 A: Bl88l .ngln!, 20 A:818C1 cnginol fu!. In thr und.r{..h tu.o/r.lly bor lnd tho 3P conrcclo?.
( T o p a g e1 1 - 7 ' l )
11 -7 0
(Frompog6 1 1-7Ol
Meaauro voltage betweon GBN/ RED ierminal and body ground.
13the.e approx, 5 V?
Boplir opon 01lhort in GR /RED wir. batworn ECM (DlOl and tho 3P connoctor. 1l wir. i! OK, .ubrtituta. knowngood ECM .nd rochock.
wire side
B L K{ _ I GR /NEDI-I Turn tho ignition switch OFF.
BLKIEL { + }
connect tho loat hamasa botweon tho ECM and connectors (soa pag€ 11-37),
(To page 11-72)
11-71
PGM-FISystem ElectricalLoad Detector (ELD) (cont'd)
While measuringvoltagebetween D l O 1 + ) t e r m i n a al n d 4 2 6 l - ) terminal,turn the headlighrswitch to the secondposition(a) {low).
Does the voltage drop when the headlightsare turned on?
Subrtitute . known-good ECM and rochock. lt 3ymptom/indic€tion goos away, ioplaco th6 original ECM.
11-7 2
425t-t ,
D 1 0l + ) DoosVolrago Orop?----------------J
PGM-FISystem Knock Sensor(KS) tB18C1 enginel ml-
nl:
The Malfunction IndicatorLamp(MlL)indicatesDiagnostic TroubteCode(DTC)23: A probtemin the KnockSensor(KS)circuit.
a6l--fzt .i--1/.---r+\
-
The MIL h6s boon r6port6d on. With th6 SCS ahort connector connoctod (soe pago 11-341,codo 23 is indicrtod.
Oo the ECM ResetProceduro(see p a g e1 1 - 3 5 ) .
Startthe engine.Holdthe engine g!-3,Opqrpm with no load {A/T in LrylorlPlposirion,M/T in neurra until the radiatorfan comes on, then let it idle.
Holdthe engineat 3,0O0-4,000 rpm for 10 seconds.
Turn the ignitionswirch OFF.
Intomittor failure, ay5t.m is OK at this tim6 (teat drivo mav bo nec€saary,. Chock tor Door connection3 or loo3o wlaos et C222 {locatod 6r ghr shock tow6r), Cl33 (KSl and ECM.
Connect the test harness to the main wire harnessonly, not to the ECM (seepage 1 1-37). ware sido oooooo ooo ooo o loooooooo o oooo ooo oo ooo I oooo oooo
Check for continuity between D3 terminaland body ground.
Ropdr short in RED/BLU wiro b€tweon ECM {D3l and ths Ks.
( T op a g e1 1 - 7 5 )
11-7 4
(Frompage 1 1-74)
Chock tor continuitv on REO/8LU wirs botween D3 tormin6l8nd 2P conn6ctor.
Rop.ir op.n in RED/BLUwir. b.twcen ECM (D3l and th. KS.
Stsrt the engine. Hold th€ engine st 3,000 rDmwith no load (A/T in @ or@ position,(lvt/t in neutratl until the r6diator l6n comoa on, then l6t it idl€.
Holdthe engin€at 3,000-4,OOo rDmlor 10 seconds.
Subrtitutr r known{ood ECM .nd 6ch.ck. lt tymptoh/indic!liarn goar away. raplaca lha otigind ECM.
KS 32 N.m (3.2
wire side
11-75
PGM-FISystem A/T Fl Signal A/B (A/T only) \[l0l-L=\ tItil-Li!-
\.__r_/
The MaltunctionIndicarorLamp (MlL) indicatesDiagnosticTroubleCode (DTC) 30: A problemIn the A/T Fl SignatA circuit between TransmissionControlModule (TCMI and ECM. The MalfuncrionIndicarorLamp {MlL) indicatesDiagnosticTroubleCode {DTCI 31: A problemIn the A/T Fl SignalB circuit between TransmissionControtModule (TCM) and ECM.
\.__r_/
- l 3 0l - o ' - l 3 t l -----\ /----\ Wlth tho SCS ahon connocrol coni|ocd {!o. p.g. 'l 1-341, codo 3O and/or 31 ars indicltod.
Oo ths ECMResotProceduro{see pag€ 'l 1-35).
Test drive necessary. Drive the car lor severalmiles so that the transmissionuDshiftsand downshilts several times.
Doesthe MIL indicarecode 30 and/or 31?
Intormittant tsilu.o, sy3tem iB OK at thir tima, Chack lor poor connactions ot l.ro!€ wiror at C419 (TCM] and ECM.
Turn the ignition switch OFF.
Connect the test harness to th€ main harnessonly, not to the ECM (see p8go l'l-37).
Disconnect the 22P connector from the TCM. 84'
Check lor continuity between B3 andlor 84' terminal and body grouno.
ulty?
+
Continuity?
r: code 31 1A/TFl signal Bl Ropairlhon in GRN/8LUor GRY' wiro b6twoon ECM (83 or 84'l and tho TCM.
( T op a g e1 1 - 7 7 )
11 -7 6
(Frompage 1 'l-76)
Check for continuity on GRN/BLU or GRY'wire between83 or 84' and 22P connectorof the TCM. Ropairopen in GRN/BLUor GRY' wiro botwoon ECM lB3 or B4'l and the TCM, Substituts a known-good ECM and rochock. ll symptom/indication goos 6way, roplacatho original ECM.
11-77
ldle Gontrol System Guide SystemTroubleshooting NOTE: a Acrosa each row in the chan, the sub-systemsthat could be sourcesof a symptom are ranked in the order they should be inspected, starting with O. Find the symptom in the left column, read across to the most likely source, then reler to the page listsd at ths top ot that column. It inspection showa the system is OK, try the next system @, etc. a lf the idle speed is out of sp€cification and th€ Malfunction Indicator Lamp {MlL) does not blink Diagnostic Trouble Code (DTC) 14, 9o to inspectiondescrib€don pags 1 1-81. POWER AUTOMATIC HOSES AIR STEERII'IGFASTIOLE ALTER. IRAI{SA(LE ERAK€ STARTER IDTI IDLEAIR coN0f ANO THERMO swrTcH swtTcH PffESSURE FN GtAR OJUSTIi c0NTROtCONNEC. TtoNtitc NAION SIGNAL P0sm0 SIGNAL SIGNAT swncH SCREW TIONS SIGNAL SIGNAL stGIAt
PAGE
11-95
SYMPTOM
11-42
11-84
11 - 8 6
11-88
DIFFICULTTO START ENGINEWHEN COLD WHEN COLD FAST IDLE OUT OF SPECl1,0OO- 2,0OO rpm|
11-90
11-92
I 1-93
o
@
o
o
@
o
ROUGH IDLE
ldl6 3p6od b b€low specitisd rpm (no loadl
@
ldla 5p66d doos nol incraas€alter initial
TOOLOW
o
On mod6l3 with automatic transmBsion,ths idlo sp€ed drops in 963r
o
ldl6 sp€eds drops when 8ir condilioner in ON
o
ldls spo6d drops when 6ts6iing wh66l i6 turninC
@
@
o
AFTERWARMING UP
o
@
FAILS EMISSIONTEST
o o o
WHILE WARMING UP FREOUENT STALLING
o
o
ldla spoed lluctust63 with alactrical load
1 1 -7 8
o
o
WHEN WARM RPM TOO HIGH
WHEN
11-94
o
SystemDescription The idle speed ot lhe engineis controlledby the ldle Air Control {lAC) Valve. The valve changes the amount ot air bypassing into the intake manifold in responseto electric current controlled by the ECM. When the IAC Valve is activated,the valve opens to maintainthe proper idle speed.
#l' ----r
To FGM-FI MAIN RELAY
VARIOUS SENSORS
IAC VALVE
FAST IDLE THERMO VALVE
BLK
r
INTAKE MAI{IFOLD
(cont'd)
11-79
ldle Control System System Description (cont'd) 1.
Atter the engineslarts.the IAC valveopensfor a censin time, The amountot air is increasedto raisethe idle soeed about 15O-3OO rom.
2.
When the coolanttemperatureis low, the IAC valve is openedto obtain the properfast idle speed.The amount of bypassedair is thus controlledin relationto the enginecoolanttemperature.
IDI-ESPEED lrpm)
176 80
11-80
ENGINE COOLANTTEMPERATURE t"Fl (oct
1. when the idls speedis out of specificationand the MalfunctionIndicatorLamp(MlLldoesnot blink DiagnosticTrouble Code (DTC) 14, check the tollowing items: . Adiust the idle speed {see page I1-95) . Air conditioningsignal (see page l1-84) . ALT FR signal (seepage '11-86) A/T gea, positionsignal(see page 11-88) Erakeswitch signal (see page 1 1-90) Starter switch signal(see page 1l-921 PSPswitch signal(see page 1 1-93) Fast idl6 thormo valve (see page l1-94) Hoses and connsctions IAC valve and its mountingO-rings 2.
lf the above items are normal,substitutea known-goodIAC vslv€ and readjustthe idle speed (see page 11-95)' . It the idle speed srill cannot be adjusted to speciJication(and the MIL does not blink code 14) after IAC valve roplacement, substitute a known-good ECM and recheck. It symptom goes away, replsce the original ECM.
11 - 8 1
ldle Control System ldle Air Control(lACl Valve -l lf l- The MaltunctionIndicatorLamp (MlL) indicatesDiagnosticTroubleCode {DTC} 14: A problemin lt6l'' the ldle Air Control llAC) Valve circuit. The IAC Valve changes the amount of air bypasEingthe throttle body in respons€ to a current signal from the ECM in order to maintainthe properidle speed.
/
ffi:| \ r;611 /--T-\ -
The MIL h.3 beenreport don, With tho SCS shon connoctol connoctod (soo pago 'l 'l -341, cod6 14 is indicatod.
Do the ECMResetProcedure(see p a g e1 1 - 3 5 ) .
ls the MIL on and does it indicate code 14?
With the engine running snd the accelerator pedal releas€d, disconn€ct th€ 2P connector frort tho IAC valvo.
Disconnectthe 2P connectorfrom the IAC valve.
Sub.iituto . known{ood vdva lnd iotolt.
{ T o p a g e1 1 - 8 3 }
11-82
IAC
htarmitlaot frlu]., ayat.m i. OK !t thir tlft. ll.rl drlv. mly ba nacaaaaryl. Chack tor Doo. conn€ctlonr oi loora wirca at C3O5 (loc.t.d .t |.ft lhock tow.tl, C424, Cl tB (lAC v.lvol .nd ECM.
(From page 'l 1-82)
Measure voltago between the YEL/BLKwire and bodv ground.
ls th€rs battery voltage?
Turn th€ ignition swirch ott and reconnectthg 2P cohnectorto the IAC valve.
R.pair op.n In YEL/8LK who b.twoon IAC vCvc dd PGM-FImdn relay. IAC VALVE
BLK/BLU{ _ }
Conn€ct the test hs.ness "A" connector to the main wirs hrrn6ss only, not the ECM lsee page t 1-37).
Tu.n tho ignition switch ON.
Momentarilyconnect Ag torminal to 423 terminol seveaaltim€s.
Does th6 IAC valve click?
Raplir op.n or rhort in 8LK/BLU wl]. b.tw.cn IAC v!lv..nd ECM (A91, It th. wlro L OK, r.Dhc.lhe IAC v.lv..
Sub.titutr ! known{ood ECM .nd ral..t. lt .ymptom/hdlcatioo goa! awsy. rophca tia origlnal ECM.
JUMPERWIRE A9 l+)
A23{-l
1 1-83
ldle Gontrol System Air ConditioningSignal This signals the ECM when there is a demand for cooling from the air conditioning system.
Connectthe t€st harnessbetween the ECM and connectors.Disconnect "B" connectorfrom the main wire harnessonlv, not the ECM {see page 11-37}.
Turn the ignition switch ON.
.pprox. 5 V? 426 (- )
Measurevoltagebetween851+ ) lerminaland A26 l- I terrninal.
ls there approx. 5 V?
Sub.litut ! known{ood €CM rnd r6
Turn th€ ignition switch OFF.
Reconnect"8" connector to the main wire harness. Cllcklng?
ooooooooooooo oooooooo oooooooooooo oooooooo
ooooooooooo ooooooooooo
Turn the ignilionswitch ON.
MomentarilvconnectA15 terminalto A26 terminsl severaltimes.
ls there a clicking noise from the A/C comDressorclutch?
Momsntarilv connect the 8LK/ REDt€rminal of the 4P connector on the A/C clutch rel6v to body ground sevsral times.
ls there a clicking nois€ lrom th€ A/C comoressor clutch?
lTo page
Rop.ir opon in BLK/BEDwiro betwo.n ECM {A15} and A/C clurch rally.
11-84 -
3o6 rlr condhlohar inrDactlon llaa lac{ion 221.
(Frompage 11-84)
than 1.0 V?-----------.1 r-Less 85{+l I |----------------
I|
| ooooooooooooe loooooooo 1t)6i}66i)l ooooooooooo l-_---_-------l426t_t I
Does A/C operate?
Measurevoltage between 85 {+ ) terminaland A26 (-) terminal.
ls voltagelessthan 1.O V?
Aii coiditiodlng slgnal i! OK.
I
R€pairopoi in BLU/RED wiro b€trYaen ECM lBSl and A/C awilch.
Substituto a known-good ECM and rochock, lf 3ymptom/indication goos 6way, r€placoth6 original ECM.
11-85
ldle Control System Alternator (ALTI FR Signal This signalsthe ECM when the Alternator(ALT) ascharging.
Inspection ot ALT FR Sign.l.
Connectthe tost harnessbetween the ECM and connectors.Disconnect "D" connector from the main wire harnoss only, not the ECM lsee page 11-37).
ooo oo oooooo ooooooooooo
Turn the ignitionswitch ON.
Measurevoltage between D9 (+ ) terminaland A26 {-}terminal.
ls there approx. 5 V?
Sub{inno s known-good ECM and redrack. It pro.ctibod volt go la now availablg, ropllco tha orlginal ECM.
Turn the ignitionswitch OFF.
Reconnect"D" connectorto the main wire harness,
Start tho engino. Hold the engine !L3,099 rpm with no load (A/T in LN]or El position, M/T in neutral) until the radiator tan comes on, rhen let it idle.
Voh.go?
D 9l + )
ooooooooooo
Measurovoltage between Dg (fl terminaland 426 (- I terminal.
Does the voltage decrease when headlightsand .ear delogger are turned on?
ALT FR rignal is OK.
(To page 1 1-87)
11 - 8 6
ooooooooooo
Turn ths ignitionswitch OFF.
(Frompage 1 1-86)
Disconnect "D" connector lrom ECM only, not the main wire harnesa,
Disconnect tho nsgstive baftery cable from the baftery.
Check for continuity betwe€n D9 terminal and body ground. Continuity?
Check for continuity betwoan D9 te.minal and body ground.
soe AIT Inrpactlon (... r.ctlon 231.
Check lor continuity between D9 t€rminsl snd body ground.
Rop.lt C|on in WHT/RED wi.. b.tw.on ECM lDgl rnd ALT.
Ropair op€o in WHT/RED wito b6tween ECM {D9} .nd .ltomrtor. Sao ALT inapaction lres .lctlon 231.
11-87
ldle Control System Automatic Transaxle {A/Tl Gear Position Signal {A/T onlyl This signalsthe ECM when the transmissionis in @ or @ position.
Turn the ignition switch ON.
obsorve the A/T shift indicator a n d se i e c l e a c h p o s i t i o n separately.
Soo A/T goa. position indicator inspoqtion ls6o lection 141.
Turn the ignitionswitch OFF.
Connectthe test hamessbetween the ECM and connectors.Disconnect "B" connoclorlrom the main wire harnessonly, not the ECM (seepage 11-37).
appror. 5 V?
87l+) Turn the ignitionswitch ON.
ooooooooooooo oooooooooooo A26 {-}
Measurevoltage between 87 (+ I terminaland 426 1- ) terminal.
ls there approx. 5 V?
Subslituto . known-good ECM 6nd .ech6ck. lf pr63cribod voltage ia now availablo,rcplacoths o.iginel ECM.
Turn the ignitionswitch OFF.
Reconnect"8" connectorlo lhe maanwire harness.
( T op a g e1 1 - 8 9 )
1 1 -8 8 -.
{Frompage 11-88)
L63r than 1,0 V? 87 l+)
ooooooooooooo oooooooooooo 426 (- ) Measurevoltagebetween87l+) terminal and A26 (-) teJqrinal with the transmission in Lryl posataon.
ls there lessthan 1.0 V?
Measurevoltage between 87 (+ I terminal and A26 (-) reJqrinal with the transmissionin lPl position.
ls there less than 1.0 V?
Ropair open in LT GRN/BLK wir. botwoon ECM lB7) and gaugo as!€mbly. - Rspalr opon in GR wito b.twoon tho gaug6 a$ombly lnd A/T goar position .witch.
Lo.s rhln 1.0 v? --ii
t+t o o o o o o o o o o o o o I o o o o o o o o I O O n P s O lo o o o o o o o o o o ooooo ooooo ooo I oooooooo lQcosito I ooooooooooo A26 (- ) Reprir open in GRNMHT wi.r bgtwoon gaugo ssrombly and A/T goar poritlon 3witch.
BATTERYVOLTAGE? --;; MeasurevoltagebetweenB7l+) terminal and A26 l-) terminal with the transmission in gear.
ls there battery voltage ?
{+ I
A26 t- ) R6oai. short in LT Git{/BLK wire botwo6n ECM (B7l and gaugoaraombly.
A/T goat position signal b OK.
11-89
ldle Control System Brake Switch Signal This signalsthe ECM when the brake pedal is depressed.
Inlp.ction ot Brd(. Switcfi Siignal.
Are the brake lights on without depressinOthe brake pedal?
ltuoacl ths braka .wilch {!.a !acdon 191,
Oo the brake lights come on?
InspectSTOP,HORN(20 Alluse in the undeFhoodfuse/relavbox.
ls the luse OK.?
Connect tho t€st harness to the main wire hamessonly, not to the ECM {seepage 11-37).
( T o p a g e' l 1 - 9 1 )
11-90
- Ropalropon In WHT/GRNwiro batwoan b'lka lwltch and STOP, HORTI{20 Al lu!o. - InlDect tho braka awitch la6a .6cdon 19).
R.pl!c. S T OP , HOR {2O A) tu... R.pdr dbrt In WtlT/ GBI wlrr batu..n b?!ka .wltch a.rd sToP, HOR[{ (20 A} lura.
(Frompage 11-9Ol
426 {-) I-Measurcvohage between D2 (+ l terminal and A25 (-) terminal with the brake oedal deoressed.
BATTERY VOLTAGE?
D 2( + l
Repair opon in GRI{/WHT wiro botwoen th6 b..ko rwitch .nd ECM {D2}. Brako lwitch signal ir OK,
11 - 9 1
ldle Gontrol System Startel Switch Signal This signalsthe ECM when the engineis cranking. BATTERY VOLTAGE?
Connectthe lest harnessbotween the ECMand connector(seepage 11,37).
Measurevoltage between 89 (+) terminal and 426 (-) terminal with the ignition switch in the start position.
ls there batterv voltage?
ooooooooooooo oooooooooooo A 2 6{ - } NOTE: a M/T: Clutch pedal must be oeprgsseo. a A/T: Trsnsmission in lll or LIJ position.
InspectNo. 18 STARTERSIGNAL {7.5 A) fuse in the under-dash fuse/relav box. - Roplac. No. 18 STARTER SIG AL (7.5 A) lurc, - Rrpsir lhort In BLU/ WHT wir. batwccn ECM (89) .nd No. 18 STARTER SIG. t{AL {7.5 Al 1u.., PiGM-Fl fi.ln rol.y. R.palr opon in BLU/WHT wir6 b6tw€.n ECM lB9l and t{o, 18 STARTERSIGNAL 17.5 Al lu.o.
Startor .witch .ign.l is OK.
11-92
Power Steering Pressure(PSP)Switch Signal This signalsthe ECM when the power steeringload i s h i g h .
-;"nection.*."------'.ill] -
-
;;;;;;;l ;:"r"tffa;i'
(see connecrors
w
o ooooo oooo ooo I oo ooo oo o l.Do€d(iltl ooooooooooo o oooo ooo ooooQ I oooQ oo oo $aG$ast.l oooooooo oo A 2 6l - ) B gl + l L6s! thsn l.O V?
Turn the ignitionswitch ON.
Measurevoltagebetween88 {+ ) terminaland A26 {-) terminal.
Turn the ignitionswitch OFF.
Disconnectthe 2P connectortrom the PSPswitch. ls there lessthan 1.0 V? Tu.n the ignitionswitch ON.
Turn steeringwheel slowly.
Measurevoltage between B8 (+) terminal and 426 (-) termanal while steeringwheel is turning.
PSP switch signal is OK.
ls there less than 1.O V?
Ropair opon in GRN wire betwssn ECM {88} and PSPsrYilch ot BLK wi.o botw6cn PSP switch and G301 (locatodat loft ongin6compartm6ntr.
Disconnectthe 2P connectorlrom the PSPswitch.
wire side GRN
PSP SWITCH
Repairshort in GRNwi.e botwoon ECM {881 and PSP switch. ll wiro i3 OK, substitute a knowngood ECM and.ocheck. lI proscribod vollage is now avail able, replaco tho original ECM.
11-93
ldle Control System Fast ldle ThermoValve DEscliptlon To prevent erratic running when the engine is warming up, it is n€cessaryto raise the idle speed. The fast idle thermo valve is controlledby a thermowax plunger,When the engineis cold. the enginecoolant su.roundingthe thermowax contracts the plunger,allowing additionalair to be bypassed into the intake manifold so that the engine idlss taster. When the enginereachesoperatingtemperatur€, the valve closss, reducing the amount of air bypassing into the manifold.
Inspaction NOTE: The tast idle thermo valve is factory adiustsd; it should not be disassombl€d. 1.
Remove the intake air duct from the throttlg body.
2.
Stan the engine.
3.
Put your finger over ths lower port in throttle body and make sure that there is 8ir flow with tho engine cold (engine coolant temperatute below 86oF, 300c).
a lf not, leplace the fast idle thermo valvs and retest. FASTIDLETHERMO VALVE
o-Rr{Gs Replace
AIN EYPASSVALVE
llo kgf.m, 7 lbt.trl 4.
Start the engine. Hold the sngine at 3.0OOrpm with no load (A/T in I or @ position, M/T in neutral] until the radiator fan comes on, then let it idl6. Checkthst valve is completelyclosed. lt not, air suction can be telt at the lower Don in the throttle body, a It any suction is felt, the valve is leaking Check engine coolant level and for air in tho engine coolant system (see section 1O). ll OK, rsplace the fast idle thermo valve and rechock.
11-94
- ldle Speed Setting Inspoction/Adiustment NOTE: a When the idle speedset, checkthe followingitems: - The MIL has not been reported on. - lgnitiontiming - Sparkplugs - Air cleaner - PCV svstem a (Canada)Pulltheparkingbrakeleverup. Stan the engine, then check that the headlightsare off. 1
Start the engine. Hold the engine at 3,000 rpm with no load (A/T in S or @ position, M/T in neutral) until the radiatortan comes on, then let it idle.
2.
Connecta tachometer.
3.
Disconnectthe 2P connectottrom the ldle Air Control {lAC) valve.
Turn the ignitionswitch OFF. Reconnectthe 2P connectoron the IAC valve,then removethe BACKUP (7.5 A) fuse in the under-hood tuse/relavbox for 1O secondsto reset the ECM. e
Restart8nd idlethe enginewith no-loadconditions for one minute, then check the idle speed. NOTE: (Canada)Pull the parking brake lever up. Startthe engine,then checkthat the headlightsate off. ldlo speed should be;
4.
Start the engine with the sccelerator pedal slightly depressed.Stabilizethe rpm at 1,OOO,then slowly release the pedal until the engine idles. Checkidlingin no-loadconditions:headlights,blower fan, reardefogger,radiatorfan, and ai. conditioner are not operatrng.
81881 ongino: MTf
75O !
50 rpm
AIT
75O t 50 rpm (in[]or@positionl
818C1 engine:750 1 50 rpm
ldl€ spood should bo; 81881 ongino: MlT
48O ! 50 rym
An
48O I 50 rpm lin@or@oosition)
818C7 engine:48O ! 50 rym Adjust the idle speed, if necessary, by turnmg the idle adiustingscrew. NOTE: After adiustthe idle speedin this step, check the ignitiontiming (see section 231. lf it is out ot spec. go back to step 4.
(cont'd)
11-95
ldle Control System ldle Speed Setting (cont'd) 9. ldle the enginefor one minute with headlights{Low} ON and check the idle sDeed. ldla sp6od should bo; 81881 engine:
M/T
750 i
An
75O t 50 rpm {in $ or p] positionl
50 rpm
818C1 engine:75O 1 50 rpm
1 0 .Turn the headlightsoff. ldle the enginefor one minute with heatertan switch at Hl and air conditioneron, then check the idle speeo. ldls spood should bo; 81881 ongino:
M/T
82O 1 50 rpm
AN
840 1 50 rpm (in [N] or lll position)
818C1 engino:85O t 50 nm NOTE: lf the idle speedis not within specitication, see SystemTroubleshooting Guideon page 1 1-78.
11-96
Fuel Supply System System TroubleshootingGuide NOTE: Across each row in the chart, the sub-systemsthat could be sources of a symptom ara tanked in tho order they should be inspected starting with O. Find the symptom in the left column, read across to the most liksly source, then refer to the page listed at the top of that column. lf inspection shows the system is OK, try the next most liksly system @, etc. PAGE
FUEL LINES 11-98
SYI\4 PTOM
FUEL FUEL PRESSURE INJECTOR REGULATOR 11-102
11 , 1 0 6
FUEL FILTER
FUEL PUMP
PGM-FI MAIN RELAY
l1-toa
11-109
t'l 'nl
ENGINE WON'TSTART
@
o
DIFFICULT TO START ENGINEWHENCOLDOR HOT
o
\4
o
ROUGHIDLE MISFIRE OR ROUGH RUNNING
LOSS OF POWER
FREOUENT STALLING
@
@
o
@
@
o
FAILS
POORPER. EMtSSION FORMANCE
CONTAM' INATEO FUEI
@
@
@
WHILE WARMING UP
o
AFTER WARMING UP
o
o
11-97
FuelSupplySystem Fuel NOTE:Check all fuel system lines and hoses for damage, leaks or deterioration, and replaco if n€cessery.
11-98
NOTE: Chock 8ll hoso clamps and r€tighton if necossary.
Sot th€ centgr
l2 mm (0.47 inl 12-15 mm to.47-o.59 hl
t2 mm {0.47 in}
11-99
FuelSupplySystem SystemDescription The fusl supply system consists ot a fuel tank, in-tank high presssurefu6l pump, PGM-FImain relay, fuel filter, tuel pressure regulatot, fuel inioctors, fusl pulsation damper and fuol delivery and return linss. This system deliverspressure-regulatored fu6l to the fu6l injectorsand cuts the fuel delivory wh6n the engine is not running.
FuelPressure
a Do not smok6 while working on the fuol syst6m, Keep open flames or spalks away tlom your work aroa. a 8e sure to raliavofuol p.essur6while th6 6n9in6is off. NOTE: Eeforedisconnectingfuel pipes or hoses, release pressure from the system by loosening the 6 mm se.vice bolt on top of the fuel filter. 1.
Disconnectthe batterynegativecablefrom the battery negativeterminal. NOTE: The LS and GS-Rmodel radio may have a coded theft protectioncircuit. Be sure to get the customer's code number betore disconnectingthe batterv, After service, reconnect Dowe. to the radio and turn it on. When the word "CODE" is displayed.enter the customer's s-digit code to restore radio ooeration.
2.
Removethe fuel fill cap.
3.
Use a box end wrench on the 6 mm servicebolt at the fuel tilter, while holdingthe specialbanjo bolt with anotherwrench.
4.
Placea rag or shop towel over the 6 mm servicebolt.
5.
Slowly loosenthe 6 mm servicebolt one complete turn.
SERVICEBOLT 15 N.m (1.5 kgf.m, 11 rbr.ftl
FUELFILTER
NOTE: a A fuel pressu.egaugecan be attachedat the 6 mm seryicebolt hole. a Alwavs replacethe washerbetweenthe service bolt and the specialbanio bolt. wheneverthe service bolt is loosened. a Replace all washers whenever the bolts are removeo.
11 - 1 0 0
a lf the fuel pressureis not as specified, first check the fuel pump (seepage 1 l - 1 1O).lf the fuel pump is oK, check the following:
Insp6ction 1.
Relievefuel pressure(see page 11-1OO)
2.
Removethe servicebolt on the tueltilter while holding the banjobolt with anotherwrench. Attach the specialtool
3.
Siart the engine.* Measurethe {uel pressur€with the engineidlingand vacuumhoseof the fuel pressure regulatordisconnectedfrom the tuel pressure regulatorand pinched. Pressureshould b€; 818B1 engins: 275-324 kPa (2.8-3.3 kgl/cm2,40-47
psil
818C1 ongine: 329-37a kPa (3.35-3.85 kgf/cmz,48-55 4.
- lf the fuel pressurois higherthan specified,inspectfor: . Pinched or clogged tuel return hose or line. . Faultyfuel pressureregulator(see page 11-106) - It the fuel p.essu.eis lower than specitied,inspect fo.: . Clogged fuel tilter. . Faultyfuel pressureregulator(seepage '11-106). . Leakagein the fuel line.
pei)
Reconnect vacuum hose to the tuel plessure regulator. Prossuroshould b€; Bl8Bl ongino: 216-245 kPa (2.2-2.5 kgf/cm' , 31 -36 psil B18Cl on9in6: 27O-319 kPa 12.75-3.25 kgt/cm', 39-46
FUEL PRESSUREGAUGE 07406 - OO4000 1
psi)
CLAMP
lf the enginewill not stan, turn the ignitionswitch on. wait for two seconds,turn it off, then back on again and read the fuel pressure.
11 - 1 0 1
Fuel Supply System Fuel Injectors - --l-
-
\-l-l
tc l1 1 6 l - /- l---i/---r-\ \
The MalfunctionIndicatorLamp (MlL) indicatesDiagnosticTroubleCode (DTC) l6: A problemin the Fuel lniectorcircuit.
The Fuel Injectors a.e a solenoid-actuatedconstant-stroke pintle type consisting of a solenoid, plungel n€edlevalvs and housing. When cur.ent is appliedto the solsnoid coil, the vslve litts up and pressurizedfuel is injected. Becausethe needle valve litt and the luel pressureare constant, the iniection quantity is determined by the length of time that the valv€ is open (i.e.,the durationthe cu.rent is suppliedto the solenoidcoill. The Fu€l Iniectoris sealedby an O-ringand seal ring at the top and bottom. These seals also reduce operating nois6. FILTER
PTUNGER -_--
- ___L-
- I| r.G - -l -- :l t_o- l - Tho MIL has boen roportod on. - Wilh tho SCS .hon connocto. conoctod (soo pago 11-34), code 16 is indicalod.
Do the ECM Besel Procedure(see page l l -351.
NOTE:lf enginewillnot start, it may tak6 lO secondsol cranking to sgt th6 code.
ls the MIL on and does it indicatecode l6?
{To page 1 1-1O31
11-1 0 2
Intermittant tailura, aystam ir OK at thir tim. (t..1 drivo m.y b. nocaar!ry1. Ch.ck lor poor connactiona ot 100!6 wir6!.t C221 (loortod rt right .hock low.rl, C121,C122, Cl23, Cl24 llu6l InFctorrl, lnd ECM.
O.RII{G
FUEL RAIL
lFrompsge11-1021
St6n the enoin€8nd listgnat oach fuol inioctor fo. a clicking sound.
Turn the ignition switch OFF.
Disconnoct tho 2P cohnector from th6 lu€l iniocto. th6l does not click.
Mossur€ rggistancebatwson th€ 2 terminalEol fuol injocto..
FUEL II{JECTOR
ls thoro 1O- 13 07
R.phce tho fuol ini.ctor/lni.ctor! that ar€ not 10- 13 O.
T!.n tho ignition switch ON.
Moaaur€ voltage b€tweon YEL/BLK { + I terminsl in ths 2P connoctor and body ground.
ls thore battory volt6g€7
(To p6ge I l-1O41
B.prh op.n In tho YEL/BLK wlt6 botwaan tha luol inioctor aad lha PGM- Fl main r.lsy.
(cont'd)
11-103
Fuel Supply System Fuel Injectors (cont'd) (Frompage 'l1-103)
Turn lhe ignitionswitch OFF.
Reconnect the 2P connector to the tuel injector.
Connectthe test harnessbetween rhe ECM and connectors {seo page'11-371.
Turn the ignitionswitch ON.
Measure voltage between A23 {-) terminal and following terminal: . No. 1 tuel injector: A1 (+ ) terminal. . No. 2 fuel injector: A3 {+ I terminal. . No. 3 fuel injector: A5 {+ ) terminal. . No. 4 fuel injector: A2 {+ ) terminal.
A3{+)
oooooooooo oooooooooooo
oooooooo oooooooo
A2{+}
Ropairopon in the wi.o betw6on th6 ECM(A1, A3, A5 or A2l and th6 tuel iniector. Sub3titute a known-good ECM and r6chock. lf symptom/indication goes away, .eplsco tho original ECM.
11-1 0 4
ooooooooooo ooooooooooo
Rapl!c!ment
7 . Slide new cushionrings onto the luel iniectors.
oo not smoko during tho work. Keep open @ fllma3 lway from your wolk aloa.
t'.
Retievetuel pressure{see page 1 1-10O).
1. 2.
Disconnect the connectors trom the fuel iniectors.
3.
Disconnect the vacuum hose and fuel return hosa from the fuel pressure regulatol. NOTE: Placea r8g or shop towel over the hoses befor6 disconnecting them. Loosenthe retainer nuts on the Juel rail and harness holder.
4.
Coat new O-ringswith cleanengineoil and put them on the fuel injectors.
9 . Insen the injectors into the tuel rail tirst. 1 0 . Coat new sealringswith cleanengineoil and press them into the intake manifold. 1 1 .Installthe Jueliniectorsand fuel railassemblyin the intake manilold. CAUTION: To plovont damage to th€ O-dngs, instsll tho fuol inioctors in tho fuol r8il first, thon install th€m in the intaks mEnitold.
5 . Disconnectthe tuel 18il. 6.
Removethe fuel injectors from the intake manifold.
cusHloN RING Replace.
12. Alignthe centerlineon the connectorwith the mark on the fuel rail.
FUEI.RAIL
FUEL
MABKI'{GS
1 3 .Install and tighten the retainer nuts 1 4 .Conn€ct the vacuum hose and tuel retuln hose to the fuel pressure regulator. lnstall the connecto.s on the fuel injectors. 1 6 . Turn the ignition switch ON, but do not operate the starte.. After the tuel pump runs for approximately two seconds,the tuel pressurein the fuelline rises. ReDeatthis two or threetimes,then checkwhether there is any fuel leakage
11-105
Fuel Supply System FuelPressureRegulator Description The fuel pressure.egulatormaintainsa constant Juel pressureto the tuel injectors. When the difference between the fuel pressureand manitoldpressur€exceeds 3.O kgf/cm' 1294 kPa, 43 psi) tB18C1 engine: 3.5 kgt/cm, (343 kPa, 50 psi)], the diaphragmis pushed upward, and the excessfuel is fed back into the fuel tank through the retufn line,
Te6ting oo not smoko during the t€st. Ko6p opon @ flames away from your work area, 1. Attach a fuel pressuregaugeto the se.viceport of t h e l u e l f i l t e r{ s e ep a g e 1 1 - 1 0 1 ) . Prossuroshould be; Bl88l ongin€: 275-324 kPa (2.8-3.3 kgf/cm', 40-47 psil B18Cl €ngino: 329-378 kPa (3.35-3.85 kgf/cm' .48-55 pEi) (with tho tuol pressurersgulator vacuum hoso dlsconnoctod and pinched)
CLOSE:
FUELPRESSURE GAUGE 1 07406 - oO/IOOO DIAPHRAGM
\r__l FUELINLET
INTAKE MA'{IFOLD VACUUM
Reconnectthe vacuum hose to the fuel pressure regulator. DIAPHNAGM
Checkthat the tuel pressurerises when the vacuum hosefrom the fuel pressureregulatoris disconnected again. a lf the fuel pressuredid not rise, replacethe fuel pressure regulatot.
/1-
\J
FUEL RETURI{
11-106
FUELINLET
Raplacoment oo not amoko whil6 working on fuel sys@ tam. Koop open flamo away tlom your work atea' 1. Placea shop towel under the fuel pressureregulator, then reliev€tuel pressure(seepage 1l-10O). 2.
Disconnectthe vacuum hose and fuel returnhose.
3.
Remove the two 6 mm retainer bolts. 12 N.m {1.2 kgl.m, 9 rbf.ft)
Rsplace.
NOTE: a Replacothe O-ring. a When assemblingthe fuel pressureregulator,apply clean engineoil to the O-ringand assemble it into its proper position, taking care not to damagethe O-dng.
11-107
Fuel Supply System Fuel Filter
a Do not smoko while wo*ing on tusl system. Keop open tlame away ftom your wotk area. a While replaclng th6 tusl liher, be caletul to koop a safo distanc6 betweon battery torminals and any tool3. The Juelfilter should b€ replacedevery 4 years or 60,0O0 miles(96,OOO km), whichevercomesf irst.or whenever the fuel pressure drops below the specilied value 1275 - 324 kPa, 2.8 - 3. 3 kgJ/cmr,40-47 psi (Bl 8C 1 e n g i n e :3 2 9 - 3 7 8 k P a , 3 . 3 5 - 3 . 8 5 k g f / c m r ,4 8 - 5 5 psi) with the fuel pressure regulator vacuum hose disconnectedl afte. making sure that the tuel pump and the fuel pressureregulatorare OK. 1,
Disconnectthe batterynegativecabletrom the battery negativeterminal. NOTE; The LS and GS-Rmodel radio may have a coded theft protectioncircuit, Be sureto get the customer's code number before disconnectingthe batterv. After service, reconnect power to the tadio and turn it on. When the word "CODE" is displaved,enter the customer's 5-digit code to restore radio operation.
2.
Placea shop towel underand aroundthe fueltilter.
3.
Relievefuel pressure(see page 11-100).
4.
Removethe specialbanio bolt and the fuel feed pipe from the fuel tilter. Removethe fuel filter clamp and tuel Jilter. When assembling,use new washers,as shown, NOTE: Cleanthe llared joint ot high pressurehoses thoroughlybefore reconnectingthem,
11 - 1 0 8
SPECIAL BOLT 33 N.m (3.4 kgt.h, 25 rbf.ft)
SERVICEBOLT 15 N.m ll.5 kgt.m, 1 I rbr.ftl WASHER Replace
1Ottl.m (1.Okgf.m, 7 tbt.ftl
[":::,::-' Eecauseof its compactimpellerdesign,the fuel pump is installedinsidethe fueltank, therebysavingspaceand simplifyng the fuel line system.
FUELPUMP
FUEL FILTER FUEL PUMP BRACKET
N lTop vi6w) FUEL PUMP ASSEMBLY CROSSSECTION
FUEL PUMP CROSSSECTIONlsido vi6rvl
D|SCHARGEFORT ^
PORT . tNLEr P
PUMPCOVER IMPELLERS
CHECK VALVE
GROOVES
PUMP CASING IMPELLER
lir systems, The fuel oumo consistsof a DC motor, a circumferenceflow pump, a reliefvalve for ptotectingthe fuel line emblyconsistsof a check valve for retainingresidualpressure,an inlet port, and a dischargeport. The fuel pump assembly p cover. the impellers(drivenby the motor),the fuel pump casing{whichforms the pumpingchsmber),and the fuel pump OPERATION togeth with the (1) When the engineis started.the PGi/t-Flmain relay actuatesthe fuel pump, and the motor turns together impellers. Differentialpressureis generatedby the numerousgroovesaroundthe impellers. rgh the th discha.ge (2) Fuelenteringthe inlet porr flows insidethe motor from the pumpingchambe.and is forced through port via the check valve. ss the fuel to the lf tuel flow is obstructedat the dischargeside of the tuel line, the relief valve will open to bypass pressure. prevent port fuel excessive inlet and t retainthe avitv to (3) When the enginestops,the tuel pump stops automatically.However,a checkvalve closesby gravity residualpressurein the line, helpingthe engineto aestanmore easily. (cont'd)
11-109
Fuel Supply System FuelPump(cont'dl Tc.ting
Roplacomont
o" not smoko during tho tesr. Koop open @E flrmo away fiom your work area.
oo not smoks whilo worklng on fuel syr@ tem. Kaop opon llamos away from your wolk araa.
lf you susp€ct a problem with the tuel pump, check that the lusl pump actuallyruns;when it is ON, you will hear some noise if you hold your ear to the luel lill oon with the fuel fill cap remov6d. The fuel pumD should run for two seconds, when ignition switch is first turned on. ll the fuel pump does not make noiss, check as tollows;
1.
Removethe rear ssats {soe section 2O).
2.
Removethe accessoanel.
3.
Disconnectthe 2P connectorfrom the fuel pump.
4.
Removethe fuel pump mountingnuts.
5.
Removethe fuel pump trom the luel tank.
6.
Installa new washeron the banio bolt, then install Darts in the revers€ order of removal.
1. -'2. 3.
Removothe rear seat (see section 2O). Removethe accesspanel. Disconnect the 2P connector from the fuel pump. CAUTION: 86 lure to tum th6 ignition switch OFF botor6 disconnoctlng th€ wilos,
4.
Connect the BLK|yEL@ wire 8nd YEL/GRN@ wire with a iumpe. wire 8t the PGM-FI main relav connectot.
l.t,
.\
.--/ .
re
-Fl
6 N.m lO.6 kgl.m,. 4 tbt.ftl
MAll{ RELAY
Jumper
BL& YEL
Check that battery voltage is available at the tuel pump connectorwhen the ignitionswitch is turned ON (positive probe to the YEL/GRNwire, negative probe to ths BLK/WHT wire). ACCESS PANEL
side YEL/ GRN
a lf battery voltage is available, replace the fuel pump. a It there is no voltage, check the tusl pump ground and wire harness{see page I 1-1 l2).
11-110
27 .m (2.4 kgt.m, 21 tbt.ftl
PGM-FlMain Relay Doscription The PGM-Flmain relavactuallvcontainstwo individual rerays. This relay is locatedat the lett side of the cowl. Onerelayis energizedwheneverthe ignitionis on which suppliesthe battery voltageto the ECM, power to the fuel injectors,and power for the secondrelay. The secondrelay is energizedfor 2 secondswhen the ignitionis switchedon, and when the engineis running, to supply power to the fuel pump.
Relay Testing NOTE: lf the car stans and continuesto run, r the PGMFl main relay is OK. 1.
Removethe PGM-Flmain relay.
2.
Attach the batterypositiveterminalto nalto the No. 2 terminal and the battery negativeterminal termir to the No. 1 terminalof the PGM-FImain relay. lay. Then T checkfor continuity between the No. 5 terminal minaland No. 4 terminal of the PGM-FImain relay. a lf there is continuity,go on 10 to step ste 3. a lt thereis no continuity,replace ce the PGM-Flmain relay and retest.
PGM-FI MAIN RELAY
No.2
FUEL PUMP
To lGN. I
To GROUND
8Ar C)
ECM {425, 81)
To ST. SWITCH
To ECM {47}
J To FUELPUMP
inalto the No. 5 terAttach the battery positive terminalto negative terminsl termil to the No. battery minal and the ay. Then Tl checkthat 3 terminalof rhe PGM-Flmain .elav. ; terminaland there is continuitybetweenthe No. 7 re ain relay. No.6 terminalof the PGM-Flmain a lf there is continuity,go on to step st€ 4. th€ PGM-Flmain a lf there is no continuity, replace ce the relay and retest. inalto the No. 6 terAnach the batterypositiveterminalto termil to the No. minal and the battery negativeterminal Tl checkthat ay, Then 1 terminalofthe PGM-Flmainrelay, : terminaland there is continuitybetweenthe No. 5 nainrelay. r No. 4 te.minalof the PGM-Flmain -Flmain a It there is continuitv, the PGM-FI mi relayis OK. a lf there is no continuity, replace ce the th( PGM-Flmain relav and retest. (cont'd)
11-111
Fuel Supply System PGM-FlMain Relay(cont'dl Tloubloshooting - Engino will not sran. - Inspection oI PGM-FImain relay and rolay ha.n6!a.
Checklor continuitvbetweenBLK terminal@ and body ground. Rapairopen in BLK wire botwoon PGM-FImain.el6yand GIO'l llocatod at thormostot housingl. Measure the voltage between YELMHT terminal@ and body ground.
ls there battery voltage?
- Roplacoth. ECUIECMI(15Al lus6 in tho under-hoodfu!o/r6lay box. - Ropair opan or short in the YEL/WHT wil6 botwosn the PGM-FImain rolayand the ECU {EcMl 115 A} luso.
Turn the ignitionswitch ON.
Measure the voltage between BLK/YELterminal @ and body ground.
Turn the ignition switch to the STARTposition.
Measure the voltage between BLUMHT terminsl@ and body ground.
- Reolac. ths No. 24 ACG {ALT} { l c l { 1 5 A : 8 1 8 8 1 6 n g i n o2, 0 A: Bl8Cl engin6)tuse in tho undor-dashfuso/rolaYbox. - Ropaii op6n or rhon in tho BLK/YEL wiro botwoen tho PGM-FImain ielay and th€ No. 24 ACG {ALT) flG} {'15 A: 818Bi ongine,20 A: 818Ci onginol fuso. NOTE: . M/T: Clutch pedal must be depressed. . A/T: Transmission in N or E] position. - Replacothe l\lo. 18 STARTER SIGNAL {7.5 A} fuso in tho undor-dashfuaa/rolay box. - R6pai. open or short in tho BLU/WHT wire botweon ths PGM-FImain relay and tho No. 1A STARTERSIGNALI7.5 AI luse.
{ T o p a g e1 1 1 1 3 }
11-112
BLU
BLU/ wHt Bt-x
BLK/ YEL
YEL/ BLK
( F r o mp a g e ' l ' l - 1 1 2 1
Turn the ignitionswitch off.
Connectthe test harnossb€tween the EcM and conneclors. Oisconnect "A" connector trom the ECMonlv. not the main wire harness(see page 1'1-37).
Check for continuity between GRN/BLUterminal O and A7 lermrnal. Roplir op.n in GRI{/BLUwirc botw..n ECM lATl lnd PGM-FI main rolay.
YES Reconn€ct"4" connector to the ECM.
Bstt.ry vohago? r-----r_-l A 2 3 ( - l A 2 5B l
Turn the ignition switch ON.
Measure the voltag€ between A23l- ) t€rminaland the tollowing t€rminals;A25 (+ ) Bl (+ ). - Ropair opon in rh. YEL/BLK wir. @ b€twoon the ECM 1A25, 8tl .nd PGM-FI mrin raLy. - Roplsc. ttro PGM+I min ru4.y. Turn the ignition switch OFF.
Brttaiy voftago? a7 (+l A23(-) M€asurethe voltage betw€en A7 (+)torminal and A23 { - } t€rminal when the ignition switch is first turned ON for two soconds.
ls there 1.O V or l€ss?
Subrlitutc . known{ood ECM .nd 6chock. lf p..crib.d volt.g. ir now avallablo, rodaco lha otlginsl ECM.
Chod. th6 FGM-FI fioin relay {3o. p 6 g 61 1 - 1 1 1 1 .
11-113
Fuel Supply System Fuel Tank Replacement @
oo not smoke while working on fusl syltem. Koep opon flame rway from your wort ar6a.
Relievethe fuel pressure{see page 11-1OO). Jack up the car and support with jackstands. Removethe drsin bolt and drain the fuel into an approvedcontainer. Removethe rear seat, accessDanelsand disconnectthe 2P and 3P connectors. Remove the EVAP two way valve cover and tuel hose protector. Disconnectthe hoses. CAUTION: a Whan disconnacling tho hosos, slide back tho clampr, th6n twist horos as you pull, to lvold drmlglng thcm. a Clean the tlarod roint ot high plossulo hosos thoroughly brforc roconnccling thsm. 7. Place a jack. or other support, under the tank. 8. Remove the strao nuts and let the straDs tall free. 9. Removethe Jueltank. NOTE: The tank may stick on the undercoat applied to its mount. To remove, caretully pry it off tho mount, 1O. Installa new washer on the dlain bolt, then installpsns in the raverseordgr ot rsmoval. 1. 2. 3. 4. 56.
FUEL PUMP EVAP TWO WAY VALVE
FUEL TANK
38 l{.m (3.9 kgt'm, 28 rbl.ftl
EVAP TWO WAY VALVE COVER
FUELTAI{K STRAPS tO t{.m ll.O kgt'm, 7 lbl.frl
11-114
Intake Air System System TroubleshootingGuide NOTE: Across 6ach row in the chart, the sub-systems that could be sources of a symtom are ranked in the order they should be inspected st8rting with O. Find the symptom in the left column, read across to the most likely source, then ret€r to the page listod at the top of that column. tf inspection shows the system is OK, try the next system @, etc. 181881onglnol
't
11-118
1-117
WHENCOLD FAST IOLEOUT OF SPEC
WHENWARM IDLESPEEDTOO HIGH
lB18Cl cngin.l
PAGE
I sue-svsreu _\.-..\
sYMPToM
\---...-
THROTTLE CABLE
THROTTLE BODY
INTAKEAIR BYPASS(IAB) CONTROL
AIR CLEANER AND INTAKE AIR DUCT
1 11 1 9
1't-120
11-124
1 l 117
@
@
o
WHENCOLDFAST IDLEOUT OF SPEC
WHENWARM IDLESPEEDTOO HIGH
LOSSOF POWER
o
o o
11-115
Intake Air System SystemDescription The system supplies air for allengine needs. lt consists of the intake air pipe, Air Cleaner(ACL), intake air duct, Throttle Body (TB), ldle Air Control {lAC) Valve, tast idle thermo valve, and intake manifold. A resonatorin the intake air pipe providesadditionalsilencingas air is drawn into the system.
na
cot{TRoL
To
ffi -------------+ i'"ii'i''
SOLENOID VALVE
RELAY
VARIOUS SENSORS IAB CONTROL DIAPHRAGM VALVE
-BLK --L EI{GINE
-
cooLnnt
t
U
FAST IDLE THERMO VALVE
INTAKE AIR DUCT
11-116
INTAKE AIR PIPE
Air CleanerIACL) ACL Element Rsplacoment
ACL HOUSING COVER
ACL ELEMENT Clean air cleaner element everv 15,OOOmiles (24,OOOkm) or 'l2 months and reDlaceeverv 3O,OOOmiles (48,00Okm) or 24 months underdusty conditions,rough or muddy roads.
AKE AIR OUCT
11-117
Intake Air System Throttle cable [81881 enginel Inspection/Adiustment
Installation
'I .
Startthe engine.Holdthe engineat 3,000 rpm with no load (A/T in $ or@ oosition,M/T in neutral)until the radiatorfan comes on, then let it idle.
1.
Fullyopen the throttle valve.then installthe throttle cablein the throttle linkageand installthe cable housingin the cable bracket.
2.
Checkthat the throttle cableoperatessmoothly with no bindingor sticking.Repairas necessary.
2.
3.
Checkcablefree play at the throttle linkage.Cable d e f l e c t i o ns h o u l db e 1 O - 1 2 m m ( O . 3 9 - O . 4 7i n . )
Start the engine.Holdthe engineat 3,OOOrpm with no load (A/T in S or @ position,M/T in neutralluntil the radiatortan comes on, then let it idle. CABLE ARACKET
THBOTTLELII{K
-l-r ,)
j
i;
ITINERCABLE
DEFLECTION 1O-12 mm 1O.39-0.47 in.l
5.
LOCKNUT
Hold the cablesheath,removingall slack from the cable. Turn the adjustingnut until it is 3 mm (O.12 in.) away trom the cable bracket.
4.
lf deflectionis not within specs,loosenthe locknut and turn the adjustingnut until the deflectionis as specifled.
Tightenthe locknut. The cabledeflectionshouldnow be 10- 12 mm (O.39-O.47 in.). lf not, see Inspection/Adjustment.
With the cableproperlyadjusted.checkthe throttle valve to be sure it opens fully when you push the acceleratorpedalto the floor. Also checkthe throttle valve to be sure it returnsto the idle oosition wheneveryou releasethe acceleratorpedal.
3 mm {0.12 in)
LOCKNUT 1ON.m {1.O kgl.m, 7 tbt.ft)
1 1 - 11 8
Throttlecable [B18C1enginel Inspection/Adiustment 1. Start the engine. Hold the engine at 3,O0Olpm with no load in neutraluntil the radiatorfan comes on, then let it idle. 2.
Checkthat the throttl€ cableoperatessmoothly with no bindingor sticking.Repairas necessary.
3.
Check csble free play at the throttle linkage, Cable d e f l e c t i o ns h o u l db e 1 0 - 1 2 m m ( O . 3 9 - O . 4 7i n . )
lnstallation 1. Fullv open the throttle valve, then install the throttle cable in the throttle linkage and install th€ cable housingin the cable bracket. 2.
Stan the engine. Hold the engine at 3,OOOrpm with no load in neutraluntil the radiatorfan comes on, then let it idle. THROTTLELI K
CABLEBBACKET
I{UT ADJUSTING 5.
DEFLECTIOI{ 10-12 mm (O.39-O.47in.l 4.
lf deflectionis not within sDecs,loosenthe locknut and turn the adjusting nut until the deflection is as specitied. With the cable properly adjusted, check the throttle valve to be sure it opens fully when you push the acceleratorDedalto the tloor. Also checkthe throttle valve to be sure it retums to the idle position whenever vou release the accel€rator pedal.
With part A of the cabl€ bracket, support the cable sheath so that there is no inner wire free play. Turn the adjusting nut until it touches part A, leaving a gap between the locknut and adiusting nul. Move the cable sheath to psrt B of the cable bracket that so the bracket slides into the gap between the locknut and adiusting nut. Tighten the locknul.
LOCKT{UT lO t{.m (t.O kgl.m, pARTB 7 lbt.ftl {Locked by bracket)
NUT ADJUSTING
PABT A
LOCKNUT
NO GAP
AIUUSTING NUT
5,
The cable deflectionshould now be 10-12 mm {O.39-O.47 in.). lf not, see Inspection/Adiustmsnt
11-119
lntake Air System Throttle Body Description The throttle body is ot the single-barrel side-draft1ype. The lower portionof the throttle valve is heatedby engine coolantfrom the cylinderhead.The idle adjusting screw which increases/dec.eases bvDassair and the EvaporativeEmission(EVAP)ControlCanisterport are locatedon the top of the throttle body.
Insoection CAUTION: Do not adiust the thlottle stop screw. lt is preset at the lactory. 1.
Startthe engine.Holdthe engineat 3,OOOrpm with no load (A/T in S or E position,M/T in neutral)until the radiatorfan comes on, then let it idle.
2.
Disconnectthe vacuum hose (to the EVAPcontrol canister)from the top of the throttle body; connect a vacuum, gaugeto the throttle body.
IOLEAOJUSTING
VACUUM PUMP GAUGE A973X-O41-XXXXX
THROTTLE STOP SCREW (Non-adiustsb16l
3.
Allow the engineto idle and check that the gauge indicatesno vacuum. a li there is vacuum,checkthe throttle cable (see p a g e1 1 - ' l1 8 , 1 1 9 ) . Checkthat vacuumis indicatedon the gaugewhen the throttle is openedslightlyfrom idle. a lf the gaugeindicatesno vacuum,check the throttle body port. lf the throttlebody port is clogged. clean it with carburetorcleaner.
5 . Stop the engineand check that the throttle cable operatessmoothly without bindingor sticking. a lf thereare any abnormalities in the abovesteps, check for: - Excessive wear or Dlavin the throttlevalveshaft. Sticky or bindingthrottle lever at full close posrtron. betweenthrottlestop screwand throtClearance tle lever at tull close Dosition.
11-120
818B1 engino:
There should be no clearance.
THROTTLESTOP SCREW (Non-adiustablel
818Cl engine:
THROTTLELINK
(Non-adjusrablel
Replacethe throttle body if there is excessiveplay in the throttlevalve shalt or if the shaft is bindingor sticking.
11-121
IntakeAir System Throttle Body (cont'dl Dirarssmbly
GAUTION: a Ths throttlo stop scrow is non-adrustablo. a Aftar reassombly, adiust rhr throttlo Gablo(pago 11-118, 1 19). and A/T throttlo contlol cabl6 (section 14) for c!r8 rYith A/T. a Tho TP sonaor ir not lomovablo
MAP SENSOR Troubleshooting p a g e1 1 - 5 2
O.BING
TP SETSOR Troubleshooting poge1l-60
I d^'%
IDLEADJUSTING SCREW
o-RtftG Replace.
FASTIDLE THERMO VALVE page11-94 Inspection, 1ON.m 11.Okgl.m. 7 tbf.ftl
11-122
IntakeAir Bypass(lABl ControlSystem tBl8C1 enginel Osscription t favorabl€ favc for a Two air intakepaths are providedin the intake manifoldto allow the selectionof the intak€ path most given enginespeed. valve! HightorSatisfactorypower peformanc€ is achievedby closingand openingthe intakeair bypass(lAB)controlvslves. que at low RPMis acheivedwhen the valvesare closed,whereashigh power at high RPMis achievedby when the valves 8re oDeneo.
IAB CONTROL VALVES
To PGM-FI MAIN RELAY RELi
IAB CHECK VALVE
(cont'dl
11-123
IntakeAir System
IntakeAir Bypass(lAB) ControlSystemtBl8C1 enginel(cont'dl
Troublcahooting Insp€ction of IAB Conltol Sytt.m
tA8 COI{TROL DIAPHRAGM Start engino and allow to idle.
VACUUIIPUMP/GAUG€ A973X-041-XXXXX R€move# 13 vacuumhosetrom the IAB control diaph.agm and connect vacuum gauge to the hose. R€move # 12 vacuum hose from th€ IAB vacuum tank, then check tor vaccum at the IAB vacuum tank. Rcplir lh. block.g. ot vacuufi laak boiwaao tha IAB vacuum tank m!nilnd th. intlk fold. Disconnect the 2P conn€ctor lrom the IAB control solenoid valve.
Measure voltage between YEL/BLK(+l torminal and PNK/8LUl-) terminsl.
IAB CONTBOL VALVE SOLENOID
from wiro haana sid€
PI{K/ B L UI - I
YEI/ a L Kl + l ls thoro battery voltage?
Measure voltage b€tween BLK^|/EL(+) torminal and body ground.
(Frompage 1 1-124)
Raise engine speed to above 6,000 rpm.
{Frompago 1 1-124}
ls there battery voltage?
Repsirop6n in YEL/BLK wiro botwoon tho 2P connector and FGM-FI main relaY.
Turn the ignitionswirch OFF. Checklor vacuumat #'l3 vacuum hose. Connectlhe test harnessbetween the ECM and connectors lsee p a g e1 1 - 3 7 ) . Turn the ignitionswitch ON and connect a lumper wke between ECM (A17) terminal and ECM {A26) terminal. Ooes the solenoid valve click when the jumper is connected?
RopaiioponinP K/BLU wiao botwoen ECM lAl7l and tho 2P connectot.
Sub3titute a known-good ECM and rechock. lf symptom/indication goos away, r6placetho original ECM.
Disconnectthe 2P connectortrom the IAB control solenoidvalve.
Turn the ignitionswitch OFF.
Checkfor continuity to ground on the PNK/BLUwire. ls there continuity to ground?
IAB control syst6m is OK.
Ropairshort to g.ound at PNK/BLU wiro botwo6n ECM {A17) and tho 2P connector.
Substituto a known-good ECM and racheck. It symptom goos swsy, roplace tho original ECM.
11-125
a Intake Air System IntakeAir Bypass(lABl ControlValve IB18C1 enginel Trlting GAUTIOI{; Do not rdlust lho IAB control valvo tull-close screw. lt is prosot at th. t.ctoty. 1.
Chsck the IAB control valve shsft for binding or sticking.
2.
Check th6 IAB control valve for smooth movement.
3.
With the engine at idle, check that @ot the IAB control valve is in close contact with the stoppsr when vacuum hose is disconnected.
With th€ ongine at idl6, check that @of the IAB control valve is in close contact with the full-closo acrew whsn the vacuum hose is connectad.
a lf 8ny fault is lound, clean the linkage and shatts with carburetor claaner' - lf the oroblam still exists after cleaning, disassemblethe intake manifold and check the IAB valvE body sss8mbly.
11-126
Dls!$.muy:
ITTAKE MANIFOLD 23 N.m 12.3kgt.m. 17 tbt.ftl
6
a a
GASXET Rgplace.
|AA VALVEAODY
I]{TAKE MANIFOLD CHAMBER
24 N.m (2.4 kgf.m, t7 tbf.ftl
11-127
Intake Air System IntakeManifoldIB18B1enginel Disassembly:
{ uuu 24 N.m 12.4 kgf.m, t7 tbt.ftl
11-128
23 N'm (2.3 kgt.m, 17 tbf.ftl
EmissionControl System System TroubleshootingGuide NOTE: Acrosseach row in the chart,the sub-systemsthat could be sourcesof a symptomare lanked in the ord€rthey should be inspected starting with O. Find the symptom in the lett column, read across to the most likely source, then reJerto the page list€d at the top of that column. lf inspection shows the system is OK, try the next most likely system @, etc. PAGE
SUB.SYSTEM
SYMPTOM
THREEWAY CATALYTIC CONVERTER
POSITIVE CRANKCASE VENTILATION SYSTEM
1 1 - 1 3 21, 3 3
1 1 -1 3 4
1 1 tJo
o
ROUGHIDLE
POORPERFORMANCE
EVAPORATIVE EMtSSTON CONTROLS
FAILS EMISStON TEST
o
LOSSOF POWER
o
@
11-129
EmissionControlSystem SystemDescription The emissioncontrol system includesa ThreeWay Catalytic Convener (TWC), Positive Crankcase Ventilation (PCV)system and EvaporstiveEmission{EVAP)Contfol syst€m. The emissioncontrol system is designedto meet federsl and stats emissionstandards.
Tailpipe Emission Inspection
f!fifil
oo nor amoro ou]rngrnr! Foacqurr. ^!op
any open flame away from yout wotk atca.
Start the engine. Hold the engine at 3,OOOrpm with no load (A/T in @ or@ position,M/T in neutral)until the radiatorfan comes on, then let it idle, Connect a tachometer. Check and adiust the idle speed, if necessary (sss p a g e11 - 9 5 ) . Warm up and calibrate the CO meter according to the meter manutacturer'sinst.uctions. Check idle CO with the headlights, hester blower, rearwindow defogger,coolingfan, and air conditioner otf. NOTE: (Canada)Pull the parking br8ke lever up. Stan the engine,then checkthat the headlightsare off. CO meter should indicate0.1
11-130
maximum.
ThreeWay GatalyticConverterITWC) Dr!criplion Th6 Three Way Cstalytic Converter (TWC) is used to convert hydrocarbons (HCl, carbon monoxide (CO), and oxides ot nitrogen{NOx) in the exhaustgas, to carbondioxide (COr},dinitrogen(N2land water vapo.. The illustrationshows the TWC tor the 818C1 engine.
THREEWAY CATALYSTS FBONTOF VEHICLE
11-131
EmissionControl System ThreeWay CatalyticConverter(TWC)(cont'dl Inspection lf sxcessive oxhaust system back-pressureis suspected. remove the TWC trom the car and make a visual check for plugging, meltingor crackingof ths catalyst. Replacethe TWC if any of the visiblearea is damagedor plugged. 81881 ongino:
T SHIELO
TI{REEWAY CATALYTIC CONVERTER{TWCI Removsl/installation,see section 9 Inspecthousingfor cracksor other damage. Inspect element tor clogging by lookingthroughthe inside.
HEAT SHIELD
11-132
818Cl engine:
HEAT SHIELO
THREEWAY CATALYTIC COI{VEBTEB{TWCI R€moval/installation.sso s€ction 9 Inspoct housing tor cracks or othor damage. Inspect elemont for clogging by looking through the inside. HEAT SHIELD
11-133
r
EmissionControlSystem PositiveCrankcaseVentilation(PCVISystem Description
Insp€cdon
The Positive Crankcase Ventilation (PCV) system is designed to prevent blow-by gas {rom escaping to the atmosphsre. The PCV valve contains a spring-loadsd plunger. When the Bnginestarts, the plunger in the PCV valve is lifted in proportion to intake manifold vacuum and the blow-by gas is drawn directly into th€ intak€ manifold.
1.
Check th€ PCV hos6sand connectionstor lsaks and clogging. SREATHER
FCV VALVE
.F: ILOW-BYVAFOR er FRESHAIR
2 . At idle, mak6 sur€ th6fe is a clicking sound from th6 PCV valve when the hose between rcV valve and intake manifold in lightly pinched with your fingors or oli€rs.
Gontly pinch hero.
a lf thera is no clicking sound, ch6ck the PCV valve grommet for cracks or damage. ll the grommet is OK, reolace the PCV valve and recheck.
11-134
EvaporativeEmission(EVAPIControls Da.cdptlon Thg avaporstive omission controls are designed to minimize the smount of fusl vapor escaping to the atmosphero. The system conaists ot the following compon€nts: A . Evlporttly. Emlttbn (EVAPI Control Caniltot An EVAP control canistor is used lor the temporary storage ot fuel vapor until the fuel vapor can be purged lrom th€ EVAP control canister into the engin€ and burned. vlpor hr]gG Cmt]ol Syst m €VAp control canistgr puroing is accomplished by drawing fresh air through tho EVAP control canister and into a pon on th6 throttl€ body. Th€ purging vacuum is controllsd by the EVAP purge control diaphragm valve end the EVAP purge control solenoid valve.
C.
Ft|.l Tmk Vlpor Control Systom When fuel vapor prassurein the fuel tank is higher than the set v8lue of the EVAP two way v8lv6, th€ valve opens and regulates the flow ol fuel vapor to the EVAP control canister.
(cont'd)
11-135
EmissionGontrol System EvaporativeEmission(EVAPIControl(cont'd)
EVAP TWO WAY VALVE FUELTANK
EVAP PURGE CONTROL SOLENOID VALVE
EVAP VALVE
FUEL FILLCAP
VARIOUS
sEt{soRs
5
EVAP CONTROL CANISTEB FRESH AIR
11-136
BLK
#7 VACUUM HOSE Troublclhooting
Disconn€ct #7 vacuum hose trom the EVAP putgo control di' aph.agmvalve lon the EVAPcont.ol canistor) and connoct a vacuum gauge to tho hose.
VACUUM PUMP/ GAUGE A973X-O41-XXXXX
COI{TROL EVAPPTJBGE VALVE DIAPHRAGM
Stsrt the €ngine and allow it to idls. NOTE: Engine coolant temperature must be b€low 163oF (73ocl Oisconnectthe 2P connegtortrom the EVAP purge control solenoid
Bl8Bl .noin.: YEL/ B L KI + I
EVAP PUBGECONTROL VALVE YEL/ B L K( + I
(-t wirg aide
--\
EVAP R'RGECOI{TROL VALVE SOLENOID
M e as u r o v o l t a g o b e t w € e n YEL/BLK{+) terminsl 6nd RED l-) terminal.
ls ther6 battery voltage?
Inapactvacuum hoa€ ror.ring. l| OK, toolrc. EVAP purgo conttol solenoid
Moasule voltage botween YEL/BLK {+) terminal bodY ground.
(To page 1 'l-139) (To pa96 1 1-138)
(cont'd)
11-137
EmissionGontrolSystem EvaporativeEmission(EVAP)Gontrols(cont'd) (Frompage 1 1-137)
Start the engine. Hold the engine at 3,OOOrom with no load lA/T in E orE position,M/T in neutrsl) unlil lhe radiator tan comes on. then let it idle.
{ F r o mp a g e 1 1 - 1 3 7 }
ls there baftery voltage?
Ropair opon in YEL/BLK wirc b.tw..n EVAP purgo control rolanoid vrlvo and th. xiM-Fl mlin r6lay.
Inspoct RED wirc for 6n opon to trody g.ound botween ECM lA20) and th6 conn6ctor. It wir. b OK, substiluto a knowngood ECM and rochock, It symptom 9o6s away, roplaco tho original ECM,
Checklor vacuum at # 7 vacuum hose alter starting the engine.
Oisconnectthe 2P connoctorfrom the EVAP purge control solenoid
ls there manifoldvacuum?
Inrpoct for a short i|t REDwire bolwoen ECM {A2Ol and th6 connoclor. ll wiro la OK, substituto a knowngood ECM 6nd .echock. lf symptom goes away, loplacetho original ECM.
lTo page 1 1-'l39)
11-138
Intpoct vacuum hoaa rcuting. It OK, reolrco tr|c EVAP Purge contlol lolanoid
(F.om pdge 1l-138)
VACUUMPRESSURE GAUGEO-4 In.Hg oTJAZ-OOIOOOB
Connoct a vlcuum gaugo to caniator purg! lir ho!o.
Stsn tho onginc lnd rai!. spo€d to 3,50O rpm.
PURGEAIR HOSE
Do€avocuum opp€aron gougo within 'l minuto?
Saa EVAP tso {ay vdv. t.!t io conrDbta. Evapoardva ambdon coartaoL|.|
ox.
Connect a vacuum gauge to the csnister puag6hos6 and raisethe sngin€ spe€d to 3,500 rpm.
Inapoct tha purga hoso and drronl. body potl for pinch or blocklga.
(cont'd)
11-139
EmissionControl System EvaporativeEmissionControls (cont'dl Evaporativ€ Emission {EVAPI Two Way Valvo Tasting l.
Removethe tuel fill cao.
2.
Removevapor line trom the two way valve on the fuel tank and connect to T-fitting trom vacuum gauge ano vacuum pump as snown. VACUUM/ PRESSURE GAUGE oTJAZ-OOIOOOa
A973X-041-XXXXX
f
T-FITTING
Apply vacuum slowly and continuouslywhile watching the gauge. Vacuum should stabilize momentarilv at 5-15 m m H g ( 0 . 2 - 0 . 6 i n .H g ) . a It vacuumstabilizes(valveopenslbelow5mmHg (O.2in.Hg)or above I 5 mmHg (O.6in.Hg),install a new valve and retest. 4.
Move vacuumpump hosefrom vacuumto pressure titting, and move vacuumgaugehosetrom vacuum to oressureside as shown.
J-.
fF
,T
. -,-/asr^:
4?e
Slowly pressurize the vaporlinewhile watchingthe gauge. Pressure shouldstabilizeat 1O-35 mmHg(0.4- 1.4 i n .H g ) . a lf p.essuremomentarilystabilizes{valveopensl a t 1 O - 3 5 m m H g ( O . 4 - 1 . 4 i n . H g ) t, h e v a l v ei s
oK. a lf pressurestabilizesbelow 10 mmHg {O.4in.Hg) or above35 mmHg(1.4 in.Hgl,installa new valve and retest.
11 -1 4 0
Transaxle 12-1 Clutch M a n u aTl r a n s m i s s i o. .n. . . . . . . . . . . . . . . . 1 . .3. .- 1 A u t o m a t iT c r a n s m i s s i o. .n. . . . . . . . . . . . . 14-1 ... Differential ManualTransmission 15-1 81881 engine 15-9 818C1engine 15-19 AutomaticTransmission ............... 16-1 Driveshafts
Glutch . . . . . . . .1 2 - 2 S p e c i aTf o o l s . . . . . . . . .... 12-3 f f f u s t r a t e Idn d e x . . . . . . . . Clutch Pedal ................12-4 Adjustment Clutch Master Cylinder .... 12-5 Removal/lnstallation Slave Gylinder .... 12-6 Removal/lnstallation PressurePlate ..... 12'7 Removal/lnspection Clutch Disc ..... 12-8 lnspection/Removal Flywheel, Flywheel Bearing . 12-9 fnspection R e p l a c e m e n. .t . . . . . . . . . . . . . . . . . . . . . . . . .1.2. .-.9 Clutch Disc, PressurePlate 12-10 Installation ReleaseBearing 12-11 Removal/lnspection
SpecialTools
Ref. No,
o /^ ri)
@ @
I
12-2
I
Tool Number OTJAF_PM7011A OTLABPVOO1 OOor o7 924-PD20003 07NAF-PR30100 07746-0010100 07749-OO10000 07936-3710100
Description Clutch AlignmentDisc Ring Gear Holder Clutch AlignmentShaft Attachment, 32 x 35 mm Driver Handle
Oty 'I
Page Reference
1
12,7 1 2 - 1 ,8 , 9 , 1 0
I 1 I I
1 2 - 7, 8 , 1 0 12-10 12-10 1 2 - 1, 8 , 1 0
lllustrated Index NOTE: a Wheneverthe transmissionis removed,clean and greasethe releasebearingslidingsudace. a It the pans marked r are removed.the clutch hydraulicsystem must be bled (see page 12-6). a Inspectthe hoseslor damage,leaks,interterence,and twisting.
*RESERVOIR HOSE ASSISI SPRING
COTTER Beplace.
I
N n Il
6 x 1,0 mm 9.8 N.m ll.0 ksf.m, 7 lbf.tt)
9 t
v-_fl
PEDAL PIN
1 5 N . m 1 1 . 5k g l . m , 11 tbt.ftl TCLUTCHMASTER CYLINDER page 12-5 Removal/lnstallation,
.CLUTCH PIPE
CLUTCH PEDAL Adjustment, page 12-4
15 N.m {1.5kgl.m, 1 1 rbf.ft) JOtt{T 8 x 1.25mm 25 N.m (2.6 kgl.m, 19 lbt.ttl
19 N.m ll.9 kgt.m, 14 lbf.ftl
FLYWHEEL Inspection.page 12-9 page 12-9 Replacement,
RELEASEBEARING Romovaf/lnspection, page 1 2-1 1 lnstaffation,page 12- 12
CLUTCH DISC page'12-8 Removal/lnspection. Installation,page 12-10
TRANSMISSION Romoval. see section 13
12 x 1.0 mm 103 N.m llO.5 kgt.m, 76 rbf.ftl
ICLUTCH PIPE
PRESSUREPLATE page 12-7 Removal/lnspection. Installation,page 12,10 8 x 1.25mm 22 N.m (2.2 kgf.m. 16 lbl.rr)
TSLAVE CYLINDER Removaf/lnstallation. page 12-6
32 N.m {3.3 kgf'm, 24 tbf.ftl ICLUTCH
15 N. m {1.5kgf.m, '| I tbf.ftl
12-3
Pedal Pedat Clutch ctutch
I
Adjustment
[-],ll'"-""
| :;i:'":fff*tr#:?iff:".,*::,::". | .#::J::: |
"orr,O", CAUTION: It there there is no clearanco clearancobetween between the master mastel cylinder piston and push lod. the releasoboaringis held diaphragm spring, which can result result in clutch clutch againsl the diaphragm against spring, which problems. slippage 01 othel slippage othel clutch clutch problems. 1 . Loosenlocknut A, and back otf the clutch switch 1. bolt) until it no longertouchesthe clutch adjustingboltl {or adiusting pedal.
f
sb''''"" | |
Turn the clutch switch (or adjustingbolt) in 3/4 to 1 full turn further.
NOTE: a To check the clutch interlock switch and clutch switch, see seclion 23. a The clutch is selt-adjusting to compensatefor wear.
6 . Tighten locknurA.
| | |
7. aoo""n ,. Loosenlocknut B and the clutch intertoct interlockswitch. switcl.
| | I
| I I
I |
I p e d a l15-2O 1 5 - 2 0 mm m m {(O.59-O.79 9. R 9. Release e l e a s the teh e clutch c l u t c hpedal O.59-O.79 I in) trom int from ttre the fully depressedpositionand hold it there. I Adiustthe positionof the clutch interlockswitch so that the enginewill start with the clutchpedalin this oosition.
I I
I
push rod in or Loosenrocknut locknut c, C, and and turn rurn the push the rod in or out out ,2 . ::":"" |
floor boardand 8. Measuretne the clearancebetweenthe tloor depressed. clutch pedalwith the clutch pedaltully deeressed.
iliiiliffi:l1l:J"'1"-:H"l:tJ:i"i#fT:I
I
I
'-"'"'';*1,,0* ::***r**'' .,".,u"**; | II , to get the specifiedstroke(@)and height(O) at the clutch pedal.
10. Turnclutchinterlockswitch 3/4 to 1 tull turn funher.
I tf ,:.;:,nterrockswitch3/4torrurrturnturtner. 1 1 . T i g h t e nl o c k n u tB .
. il*:*j':"'-(@)andheisht(olatthe Tighten locknut C.
Turn the clutch switch (or adjustingbolt) until it contacts the clutch pedal. ASSIST SPRING
|
LOCKNUTB 9.8 N.m (1.0 kgf.m,7 lbf.ftl
-6ll
PUSH ROD
CLUTCH INTERLOCK
swtrcH
CLUTCH MASTER CYLINDER
CLUTCH SWITCH {or AOJUSTING BOLTI
LOCKNUTC l3 N.m l'l.3 kgf.m, 9
LOCKNUTA 9.8 {N.ml (1.0 kgl.m, 7 lbt.ftl
(STROKEat PEDALI:130-140 mm 15.12-5.51 in) {TOTALCLUTCHPEDALFREEPLAY):12-21 mm 10.47-0.83 inl includingtho p.dal play I -lO mm 10.04-0.39 inl {CLUTCHPEDAL HEIGHTI: 164 mm (6.46 in} to tho lloot {CLUTCHPEDAL DISENGAGEMENTHEIGHTI: 83 mm 13.27 inl minimum to tho lloo.
Clutch Master Cylinder Removal/lnstallation CAUTION: a Do not sgill b.ake lluid on the car; it may damags the painl; it biake fluid does contact tha paint. wash it otf immediately with water. a Pluglhe end ot the clutch pips and r€servoilhose with a shop towel to prsvent blake fluid ttom coming out. 1.
Remove the brake fluid from the clutch master cylinde.reservoirwith a syringe.
2.
Disconnectthe clutch oioe and reservoirhosefrom the clutch master cvlinder.
Removethe clutch mastercylinder. NOTE: Do not spillbrakefluid on the clutch master cylinderdamper.
CLUICH PIPE 15 N'm {1.5kgl.m, 1 1 tbf.ftl
OAMPER
CLUTCH CLU MASTER M AI cYL CYLINDER
!l rn in Ine reverseorInstallthe clutch mastercylinder der of removal. (seepage c system s\ NOTE: Bleedthe clutchhydraulic 12-61.
CLUTCH MASTER CYLINDER Pry out the cotter pin. and pull the pedal pin out ot the yoke. Remove the nuts. NUTS 13 N.m {1.3 kgf.m, 9 lbt.frl
12-5
Slave Cylinder Removal/lnstallation Install the slave cylinder in the reverseorder ol removat.
CAUTION: a Do not spill brake tluid on the car. it may damago tho paint; it brake tluid doos conlacl tho paint, wash it off immediately with watei. a Plug tho €nd of the clutch pipe with a shop lowsl to plevcnt b.ake fluid from coming out.
NOTE: Make surethe boot is installedon the slave cylinder.
Super High Temp Urea Grease {P/N
-61,
08798-9002). : BrakeAssemblyLubeor equivalentrubber grease. '1.
CLUTCH PIPE 15 N.m (1.5 kgf.m, 11 lbf'ftl
Disconnectthe clutch pipe from the slavecylinder. SLAVE CYLINOER
Removethe slavecylinderfrom the clutch housing.
-Cl
tP/N08798-90021
8 x 1.25mm 22 N.m 12.2 kgl'm, 16 rbt'ft)
...::
:^. Gil^lt
i
(BrakeA$embry Lubol 4.
BOOT Remove and check for signs ol leaking and deterioration.
12-6
Bleedthe clutch hydraulicsystem. a Attach a hose 1o the bleederscrew, and suspend the hose in a containeroJ brakefluid. a Make surethere is an adequatesupplyof tluid at the clutch mastercylinder.then slowly pumpthe clutch pedaluntil no more bubblesappearat the bleederhose. a Refillthe clutch mastercylinderwith fluid when done. a Use only DOT 3 or 4 braketluid.
PressurePlate Removal/lnspection Check the diaphragmspring fingers for height using the specialtools and a feeler gauge.
4.
StandardlNew): 0.6 mm (0.02 inl Max. ServiceLimit: O.8 mm {O.O3in}
Inspectthe fingers of the diaphragm diaphrag springfor wear nracr area. ar at the releasebearingcontact
FEELER GAUGE
CLUTCHALIGNMENTOISC OTJAF_PM7011A
Inspectthe pressureplateI surfacefor wear, cracks, and burning.
DIAPHRAGM SPRING PRESSUREPLAT€
07936-3710100
07NAF-PR30100
.
lf the heightis morethanthe servicelimit,replace the pressureplate.
2.
Installthe specialtools.
3.
To prevent warping, unscrew the pressureplate mounting bolts in a crisscrosspattern in several steps, then removethe pressureplate.
6.
Inspectfor warpageusinga straight stru edge and feef er gauge. prer plate at three NOTE: Measureacrossthe pressure pornls. Standard(Newl: 0.03 mm (0.0 0.001 in) Max. SorviceLimit:0.15 mm (0.0O6 )O6 inl
STRAIGHTEOGE CLUTCH ALIGNMENTSHAFT 07NAF-PR30100 HANDLE 07936-3710'l OO
FEELERGAUGE RINGGEARHOLDER 07LAB-PVOOlOOor 07924-PD20003
PI PRESSUREPLATE
lf the warpage is more than replace the pressure plate.
12-7
Disc Disc Glutch ctutch
'.#fu;;
I
l
Removal/lnspection
'1.
Removethe clutch disc and specialtools.
Measure the depth trom the lining surface to the rivets, on both sides.
Inspectthe liningof the clutchdiscJorsignsoJ slippingo. oil. lf it is bu.nedblackor oil soaked,replace it.
Standard(Now): 1.3 mm (O.05 inl Min. Se.viceLimit: O.2 mm {O.OO8inl
""-*":'--
''
inr {o'oo8
=-.--']! ; i , n-\ ll Drsc DISC "LUrcH CLUTCH
|
CLUTCHDISC
I
I
W@*-l @
slbir":ix:l# Ii!fr..;*'::l;'"o^" \t'=f | CLUTCHALIGNMEI{T SHAFT 07NAF-PR30100 HAt{DLE 07936-3710t0O
3.
thickness. Measu.ethe clutch disc thic
Standard{Now}: 8.4-9.1 mm (o.33*0.36 inl Sarvica Limit: 6.0 mm (O.24 in)
LINING SURFACE
CLUTCH DISC
It the rivet deDth is less than the service limit, reolacethe clutch disc.
lf the thickness is less than the service limit, reolacethe clutch disc,
II
Flywheel, Flywheel Bearing Replacement
Inspection Inspect the ring gear teeth for wear and damage.
Install the special tool.
Inspect the clutch disc mating surface on the flywheel fo. wear, cracks, and burning.
Remov€the flywhe€l mounting bolts in a criascross pattern in severalsteps 8s shown, then remove the tlywheel.
Measurethe flywheel runout using a dial indicator through at least two full tu.ns. Push against the Ilywheel each time you turn it to take up the crankshaft thrust washe. clearance.
FLYWHEEL
NOTE; The runoutcan be measu.edwith engineinstalled. Standard (ttlervl: O.O5 mm (O.002 inl Max. Service Limit: 0.15 mm 10.006 inl RING GEAB
FLYWHEEL
MOUI{TII{G BOLTS
3.
Remov€ the flywheel bsaring from th€ tlywheel.
DIALII{DICATOR It the runout is more than the servicelimit, leplace the flvwheel. Turn the inner race of the flywheel bearingwith your finger. The bearingshould turn smoothly and quietly, Checkthat the bearingouter race fits tightly in the flvwheel.
FLYWHEEL BEARING It the racedoes not turn smoothly,quietly,or fit tight in the flywheel, replacethe flywheel bearing.
(cont'd)
12-9
Flywheel,FlywheelBearing
Clutch Disc, PressurePlate
Replacement(cont'd) 4.
Drivethe new flywheelbearingintothe flywheelusing rhe specialtools as shown.
Installation l.
Installthe ring gear holder.
t
Apply greaseto the splineof the clutch disc, then install the clutch disc using the specialtools as snown.
DRIVER 07749-O010000
NOTE: Useonly SuperHighTemp UreaGrease(P/N 08798-9OO2).
CLUTCH DISC ATTACHMENT. 32x35mm 07746-OOlO100
FLYWHEEL
FLYWHEELBEARING
5 . Align the hole in the flywheel with the crankshaft dowel pin and installtheflywheel.Installthemounting bolts finger-tight. o.
Installthe specialtool as shown, then torque the flywheel mounting bolts in a crisscrosspattern in severalsteDsas shown. FLYWHEEL
RINGGEARHOLDER OTLAB-PVOOI O0ot 07924-PD20003 3.
CLUTCH ALIGNMENTSHAFT 07NAF-PR30100 HANDLE 07936-3710100
Instalithe pressureplate.
CLUTCH ALIGNMENTSHAFT oTNAF-PR30100 HANDLE
07936-3710100
PRESSUREPLATE
MOUNTINGBOLTS 12 x 1.0mm 1 0 3 N . m 1 1 0 . 5k g f . m , 76 tbf.fr)
12-10 \_
t
ReleaseBearing Removal/lnspection 4.
Torquethe mountingbolts in a crisscrosspatternas shown.Tightenthe boltsin severalstepsto prevent warping the diaphragmspring.
1 . R e m o v et h e release fork boot trom the clutch housing. 2.
Removethe releasetork trom the clutchhousingby squeezingthe releasefork set springwith pliers.Remove the releasebearing.
CLUTCHHOUSING 8 x 1.25mm 25 N.m 12.6 kgt'm, 19 tbt.ftl
RELEASEFORK
Checkthe releasebearingfor play by spinningit by hand. CAUTION: The release boaring i6 packed with grease. Do not wash it in solvent. Removethe specialtools. Recheckthe diaphragmspring fingers tor height (see page 12-7]..
-24/--2,t'.2424?'
IJ ,F=:=
l{ there is excessiveplaY,rep)acethe rdease\Earing with a new one.
ReleaseBearing Installation 1 . With the releasetork slid betweenthe releasebearing pawls, installthe releasebearingon the mainshaft while insertingthe releasefo.k through the hole in the clutch housing.
2 . Alignthe detentot the releasefork with the release tork bolt, then pressthe releasefork over the release fork bolt. NOTE; Use only Super High Temp Urea G.ease(P/N 08798- 9002).
-611 lPlN 08798-
-6 {P/N0879a- 9002)
Move the releasefork right and left to make surethat the fork tits properlyagainstthe releasebearing,and that the releasebearingslidessmoothly.
4.
lnstallthe releasefork boot.
12-12
ManualTransmission ............. 13-2 SpecialToofs Maintenance Transmission Oi1,...,........,........,.,..... 13-3 Back-upLight Switch Replacement .........13-3 TransmissionAssembly Removal ..,.......,...... 13-4 lllustratedIndex ................................... 13-8 TransmissionHousing Removal ...........,..... 13-10 ReverseChangeHolder,Reverseldler Gear lnspestion....................... 13-11 Glearance Removaf ................. 13-12 ChangeHolderAssembly Inspection....................... 13-13 Clearance ................. 13-15 Removal Disassembly/Reassembly ............... 13-16 Mainshaft, Gountershaft,Shift Fork ...,............. 13-17 Removal Shift Rod 13-18 Removal ................. Shift Fork Assembly Index ................ ......13-19 13-20 Clearance Inspection.......................
MainshaftAssembly Index ................ ......13-21 Clearancefnspection ....................... 13-22 Disassembly ..........13-25 Inspection .............. 13-26 Reassembly 13-21 ........... Countershaft Assembly Index ................ ......13-28 13-29 ClearanceInspection ....................... Disassembly ..........13-30 Inspection .............. 13-31 Reassembly ........... 13-32 SynchroSleeve,SynchroHub Inspection .............. 13-34 Installation ............. 13-34 SynchroRing,Gear lnspection .............. 13-35 Clutch HousingBearing Replacement .........13-36 Mainshaft Thrust Clearance Adiustment ............ 13-38 Transmission Reassembly ........... 13-tl1 TransmissionAssembly ............. 13-46 lnstallation Gearshift Mechanism ................ 13-50 Overhaul
SpecialTools
Rsf. No.
o o o o @ @ @ @ @
07GAJ- PG20110 07GAJ- PG20130 .07736 - A010004 07746- 0010300 07746- 0010400 07746- 0030r00 07746- 0030300 07746- 0030400 07745- 0041100 07749- 0010000
Oty
D!3cription
Tool Numbrr
I
MainshaftHolder MainshaftBas€ AdjustableBearingPuller,25 - 40 mm Attachment,42 x 47 mm Attachment,52 x 55 mm Oriver,40 mm l.D. Attachment,30 mm l.D. Attachment,35 mm l.D, Pilot,28 mm Driver
I
1 1 1 1 1 1 1 1 1 1
13-40 13- 36,37 13-36 13- 36,37 1 3- 2 7 , 3 3 1 3- 2 7 , 3 3 1 3- 2 7 , 3 3 13-36 13- 36,37
* Must be usedwith commerciallvavailable3/ 8"- 16 SlideHammer.
ll
o
13-2
o
@
@
@
@
@
@
Prgc R.{.rcnc. '13- 40
Back-upLightSwitch
Maintenance - TransmissionOil
Replacement
NOTE:Checkthe oil with the engineOFF,and the car on levelground. 1.
/itch, see section 23. NOTE:To checkthe back-uplight switch, 1.
rem( the back-up Disconnect the connector,then remove ]onnectorclamp. light switchconnectortrom the conn
2.
Removethe back-uplight switch.
Removethe oil filler plug, then checkthe level and condition of the oil. OIL FILLERPLUG 44 N.m lia.5kgf.m,
33tbtftl
ProperLevel
Replace.
2 . T h e o i l l e v e lm u s t b e u p t o t h e f i l l e r h o l e .l f i t i s below the hole. add oil until it runs out, then reinstallrhe oil filler plug. 3.
l f t h e t r a n s m i s s i o no i l i s d i r t y , r e m o v et h e d r a i n p l u ga n dd r a i nt h e o i l .
4.
R e i n s t a ltlh e d r a i n p l u g w i t h a n e w w a s h e r ,a n d refillthetransmissionoil to the properlevel. NOTE:The drain plug washershouldbe replacedat everyoil change.
5
BACX-UPLIGHTSWITCH 25 N.m 12.5kg[.m, 18 lbf.ftl
Replace.
-up light switch. lnstallthe new washerand the back) page13-3). Checkthe transmissionoil level(see
Reinstallthe oil filler plug with a new washer. OilCapacity 2.2 ( ''2.3US.qt,1.9 lmp.qt) at oil chang€. 2-3I l2.1Us.ql,2.0lmp.qtlat oyerhaul. '10W - 40, API Service Use only SAE 10 w - 30 or grade. or SG SF PLUG OILFILLER a4N.ml{.5 kgf.m,33 lbf.ftl
ORAINPLUG $ N.m 14.0kgf.m. 29 lbf.fr)
13-3
TransmissionAssembly Removal Mskc aurs iack! and safoty Etandsaro placod properly lsl8 saqtion 1|. Apply parking brake tnd block rear whccl! to car will not roll ofl stand3 and f.ll on you while wotking undrr it.
4.
Disconnectthe back-up light switch connoctor and the transmissiongroundwir€.
5,
Remove the lower radiator hose clamp trom ths transmissionhangerB. BACK.UPLGHT suTcH cot{t{EcToR
CAUTION: Use tondcr coyar3.to avoid drmlging plintsd 3qrfaca3, Disconn€ctthe negative {-) cable from the battery, then the positive(+)cable. Drain the transmissionoil, then reinstallthe drain plug with a new washer(seepage 13-3), Removethe intakeair duct and the air cleanerhousing assembly,
AIR CITANER HOUSING
lnaNsMttistoN WIRE GROUND
HANGEBB
o.
R€movethe wire harnessclamPs.
1.
Disconnectthe stsrt€r motor cables and the vahicla soeed sensor (VSS)connector.
VSS OONNECTOR
13-4
tnaNsi ssloN
Removotho clutch pip€ bracketand th€ slave cylinoer.
10. Removethe enginesplashshield.
NOTE: Do not operate the clutch pedal once th€ slavg cvlinder has been r€moved.
R€move the three uppor transmission mounting bolts 8nd lower staner motor mounting bolt.
11. Disconnectthe heatedoxygen sensor(HO2S)connector,lhsn rsmove the exhaust pipe A, and the threeway catalyticconverter(B18ClEngine).
HO2S
IIUT SELF.LOCK Ropl.ce.
STARTEB MOTOB MOUNNNG BOLT
co NEctoR
EXHAUST PIPEA MOUNNNG BOLTS NUT SELF.LOCK THBEEWAY Replace. CATALYTIC CONVEEIER engin6) 1818C1
13-5
21. Placea transmissioniack under the transmission and a jackstandunderthe engine.
19. Removethe clutchcover.
Removethe transmissionmount. TRANSMISSIONMOUNT
23. Removethe rear mount bracketbolts and the transmissionmountingbolts.
MOUNT/BRACKET BRACKET
24. Pull the transmissionaway from the engine until it clearsthe mainshaft,then lower it on the transmission iack.
13-7
lllustratedIndex Referto the drawingbelowfor the transmissiondisassembly/reassembly. Cleanall the partsthoroughlyin solventand dry with compressedair. I
ruurlcateattthe partswith oil beforereassembly.
NOTE: the majorhousings; useliquidgasket(P/N08718-0001) . Thistransmission between usesno gaskets page 13-43). {see a Alwavscleanthe magnet@ wheneverthe transmissionhousingis disassembled. a Inspectall the bearingsfor wear and operation.
*N o @
o @ @ @ @ @ @
@
(3 (, @ @ @
t
n
a
lt
@
(9 @
l
q
^ I
n
q
'
Ej
1
l
u
l
11-4fi
,\|j Uh
@ B t
g
Y
o @ @ @
[@.--oa F5i,--@ :7
13-8
, Bolt Size 6x1.0mm 6x1.0mm I x 1 . 0m m 8 x 1 . 2 5m m 8 x 1 . 2 5m m 8 x 1 . 0m m
B
c D E F i) e 9 A O .d t !) O
1 2 N . m( 1 . 2k g i m , 9 l b n f t ) 15 N.m (1.5kgnm,11 lbf.ft) 15 N.m (1.5kgf.m,11 lbf.ft) 24 N.m (2.4kgf.m,17 lbf'ft) 27 N.m (2.8kgnm,20lbnft) 30 N.m (3.1kgf.m,22 lbf'ft)
BALLBEARING sroPPER R|NG TAPERRING NEEDLEEEARING SPACER SYNCHRORING sYNcHRo SPR|NG sYNcHRo SLEEVE 5TH/REVEFSE SYNCHROHUB 5TH/REVERSE
nlruc [0 sYrucxao
ii i) 5TH GEAR O 38 x 43 x 26 mm NEEDLEBEARING t3 SPACEECOLLAR O 4TH GEAR .iB SYNCHROFING .Ii9SYNCHROSPRING {, 3RD/,ITHSYNCHROHUB @ 3RD/4THSYNCHBOSLEEVE t9 3RDGEAR O MAINSHAFT
O wasHER
@ WASHERBeplace. @ TRANSMISSIONHOUSING
6980 mm SHIM(*1)
79.5mm SHIM{*21
@ THRUSTSHIM{*2I
T. 2.0 mm (0.079in)
@ BEARINGOUTERRACE{*2} @ SHIFTPIECESHAFT @ INTERLOCK @ SHIFTPIECE @ SHIFTARM HOLDER @ SELECTARM @ SELECTRETURNSPRING @ 10 mm SHIM 6D 10 mm WASHER q0 LOCKCOLLAR
3 x 16 mm SPRINGPIN Replace. o €x8 mm SPRINGWASHER
v0 CHANGEPIECE @ SETSCREW
22 N.m {2.2kgf.m, 16 lbf.ft}
@) SPRINGWASHER 40 BALLBEARING O 28 x 41 x ? mm OIL SEALReplace. ad 35 x 56 x 8 mm OIL SEALReplace. a0 14 x 20 mm OOWELPIN @ OIL CHAMBERPLATE 'A BEVERSEIDLENGEARSHAFT
@ SPRINGL.25.6mm {1.01inl 0! STEELBALLD. 5/16 in
IDLERGEAF .A REVERSE CHANGEHOLDER O REVERSE SHIFTPIECE 3A sTH/REVERSE O 1ST/2NDSHIFTFORK 04 3RD/.TH sHlFr FoRK SHIFTFORK @ 5TH/REVERSE O9'OIL GUTTERPLATE 6' SNAPRING @ 72 mm THRUSTSHIM ) OIL GUIOEPLATE i!0 10 mm WASHERReplace. .4i]REVERSE IDLERGEARSHAFTBOLT 54 N.m {5.5kgt m, 40lblftl ) TRANSMISSIONHANGERB (3 BREATHER CAP @ TRANSMISSIONHANGERA 63 BACK.UPLIGHTSWITCH 25 N.m (2.5ksf.m,18lbfftl @r 14 mrn waSHER Replace. 67 16 mm SEALINGBOLT 29 N.m (3.0kgl.m, 22 lbf ft) @ 32 mm SEALINGBOLT 25 N.m (2.5kgf.m.18lbt'ft| @ 40 x 62 x 9 mm OILSEALReplace. D STEELBALLD. 5/16 in Gl SPRINGL. 30 mm {1.2in} @ 12 mm WASHERReplace. 63)SETSCREW 22 N.m 12.2kgl.m, 16 lbt'ft, @ OILORAINPLUG 39 N.m {4.0 kgt.m,29 lbf'ftl €9 WASHERReplace. @ oIL FILLERPLUG 4,1N.m14.5kgJm, 33 lblftl
61 BEARINGOUTERRACEI*2I @ THRUSTSHIMI*2)
t-2) @ wasHER
@ MAGNET
@ CLUTCHHOUSING @ 14 x 25 x 16 mm OILSEALReplace. @ SHIFTROD ASSEMBLY al DIFFERENTIAL Seesection15
T. 2.5mm (0.098in, SHIFTRODBOOT OIL GUID€PLATE 33 x 60 x 20 mm NEEDLEBEARING BEARINGRETAINERPLATE LOCKWASHERReplace. COUNTERSHAFT THRUSTSHIM 37 x 42 x 25 mm NEEDLEBEARING lST GEAR FRICTIONDAMPER SYNCHRORING SYNCHROSPRING lST/2ND SYNCHROHUB REVERSE GEAR DOUBLECONESYNCHRO I*2I BINGI*1) SYNCHRO FRICTIONDAMPER SPACER 42 x 6? x 24 mm NEEDLEBEARING 2NDGEAR 3RDGEAR 4TH GEAS 5TH GEAR NEEDLEBEARING BALLBEARING SPRINGWASHER LOCKNUTReplace. 108- 0- 108N.m ( 1 1 . 0- 0 * 1 1 . 0k g tm , 80- 0- 80lbf.ft) 005 x 22 mm SPRINGPIN Replace.
{
*1:81881engine *2:B18Clengine
13-9
Transmission Housing Removal NOTE: . l f t h e t r a n s m i s s i o nh o u s i n go r c l u t c h h o u s i n ga . e r e p l a c e d ,t h e b e a r i n g p r o l o a d m u s t b e a d j u s t e d (818C1 engine). . Placethe clutchhousingon two piecesof wood thick enough to keep the mainshaftfrom the hitting the workbench. 1.
Removethe back-uplight switch.
2.
Removethe transmissionhangerB,
3.
Removethe set screws,the springs,and the steel balls.
5.
Loosenthe transmissionhousingattachingbolts in a crisscrosspattern in severalsteps.then remove them. TRANSMISSION
Tna sMtsstoN
ATTACHINGBOLT
SPBING L. 30 mm 11.2inl
Removethe 32 mm sealingbolt. 7.
SETSCBEW
Expandthe snap ring on ths countershaftball bearing and removeit from the groove using a pair of snap ring pliers.
WASHER Replace.
4.
Remov€the reverseidlergear shaftbolt,
32 mm SEALINGBOLT
L WASHER Replace.
SNAPRING REVERSE
13-10
ReverseChangeHolder,
ReverseldlerGear ClearanceInspection Separstethe transmissionhousingfrom the clutch housing,and wipe it cleanof the sealant.
re cnange Measurethe clearancebetween the reverse holder and the sth/revsrseshift piece p t n .
R e m o v et h e 7 2 m m t h r u s ts h i m a n d t h e o i l g u i d e platefrom the transmissionhousing.
Standard: BevorseSido: 0.05- O.ilsmm (0.002-. 0( . 0 1 8i n l ),1in) 5th Sido: o.ia- 0.9 mm 10.02- 0.0,1
t2 mm THRUST SHIM
SHIFTPIECEPIN REVERSE CHANGE
€ ,
HOUSING TRANSMISSION 1 0 . Removethe 16 mm sealingbolt and the oil gutter plate.
mealf the clearanceare not within the standard, sti re change surethe width of the groovesin the reverse holder. Standsrd: ( in) RovsreaSide: 7.05- 7.25 mm {0.278- 0.285 I inl 7.1-7.7 mm (0.29- 0.30 sth Sido: REVERSC SIOE REVERSE
OIL GUTTERPLATE
I
'
'--
sTHSIDE
lf the width of the grooves are n o t w i t h i n t h e Ingeholderwith standard,replacethe reversechan€ a new one. wi the stanlf the width of the groovesare within rift piece with a dard, replacethe sth/reverseshift new one, (cont'd)
1 3 - 11
ReverseChangeHolder,Reverseldler Gear ClearanceInspectionlcont'd) Measurethe clearancebetween the reverss idler gear and the reversechange holder.
Removal 1.
Standard: 0.5 - 1.1 mm (0.02- 0.04 inl SorvicoLimit: 1.8 mm (0.07inl
REVERSE CHA'{GEHOLDER
4.
Removothe reversechangeholder.
REVERSECHAMiE HOII'ER
2.
Remove the revorss idler g€ar, th€ rev6rs6 idlsr gearshaft,and the washor{B18Clengine}.
lf the clearanceis more than the service limit, measurethe width ofthe reversechangehold6r. St.ndrrd: 13.0- 13.3mm (0.512- 0.52/tinl
REVERSE CHANGEHOTI'ER
lf the width is not within the standard,replace the reversechangeholderwith a new one. lf the width is within the standard,reolacothe reversaidler gearwith a new one.
13-12
REVERSE IDI.TR GEAFSHAFT
ChangeHolderAssembly
{
ClearanceInspection Measurethe clearancebetween the shift piece and the shift arm holder.
3.
Measure the clearancebetween the select 8rm and the interlock. 0.05- 0'25 (0.002- 0.010in) Standlrd: Scrvica Limit 0.5 mm (0.02in)
0.1 - 0.3 mm (0.004- 0.012inl Silndrd: Scwic. Limit: 0.6 mm (0.02inl SHIFT PIECE
INTERLOCK
SHIFT ARM HOI.I'ER
It the cloaranceis more than the service limit, measureth€ width of the groovein the shift piece. Stlndffd: 8.1 - 8.2 mm (0.319- 0.323inl
4.
lf the clearanceis more than the servicelimit, measurethe width ot the interlock. Stlndrrd: 9.9 - 10.0mm (0.391t- 0.39ain)
SHIFTPIECE
ll the width of the groove is not within the standard,replscethe shift piecswith a new one. lf the width of the grooveis within the standard. roolacethe shift arm holder with a new one.
lf the width is not within the standard.replace the interlockwith a new one. lf the width is within the standard,replacethe selectarm with a new one. (cont'd)
13-13
ChangeHolderAssembly ClearanceInspection{cont'd} 7,
Measurethe clearancebetweenthe selectarm t h e 1 0m m s h i m . Stsndard: 0.01- 0.2 mm (0.0004- 0.008inl
9. Measurethe clearancebetweenthe shift arm holder and the changepiece. Standard: 0.05- 0.35 10.002- 0.01i1in) SorvicoLimit: 0.8 mm (0.03in)
SETICTABM SHIFTARM HOLDER
10 mm SHIM
8.
lf the clearanceis not within the standard.select and installthe appropriate10 mm shim for the correctclearancefrom the chan below.
1 0 . ll the clearanceis more than the servicelimit. measurethe grooveof the changepiece. Standafd: 12.05- 12.15mm {0.47ilil- 0.iU83 in)
10 mm Shim Part Numbsr 24435-689-000 B
24436-689-000
Thickn€ss 0.8 mm (0.03'lin) '1.0mm (0.039 in)
24437-689-000
1 . 2m m ( 0 . 0 4 7i n l
24438-689-000
1 . 4m m { 0 . 0 5 5i n )
24439-689-000
1.6mm (0.063in)
lf the groove is not within the standard,replace the changepiecewith a new one. lf the groove is within the standard,replacethe shift arm holderwith a new one.
13-14
Removal Removs the shift piece shaft, then remove the shift piecaand the interlock.
1 1 . Moasureth€ clsarancebetweenthe s6l6ctarm 8nd
thochangepiece. 0.05- 0.35mm (0'002- 0'014in) Sundrrd: S.rvic. Limit 0.5mm 10.02Inl
SHAFT SHIFTPIECE
SEI.ECTARl,l
2.
Removethe changeholderassembly.
1 2 . lf the clesranceis more than the servicelimit, measurethe width ofthe changePiece. - o.'U&l in) Strndrrd: 12.05- 12.15mm {0./17,11
CHANGEHOLDERASSEMBLY
PIECE CHANGE
lf ths width is not within the standard,replace the changepiec€with a n€w one. lf the width is within the standard,replacoth€ selectarm with a new one.
13-15
ChangeHolderAssembly Disassembly/Reassembly I
eriorto reassembling. cleanall the partsin solvent,dry them and apply lubricantto any contactsurfaces.
10 mm SHIM SELECTRETURNSPRING
3 mm PIN
13-16
Shift Fork Mainshaft,Gountershaft, - Removal 1.
Removethe mainshaftand the countershaftassemblieswith the shift forksfrom the clutchhousing. NOTE:Tape the mainshaftspline belore removing assemblies. the mainshaftand the countershaft
2
4.
Removethe chamberplate.
CLUTCHHOUSING
Removethe springwasherand the washer.
CHAMBCRPLATE
Removethe differentialassemblyfrom the clutch housing. OIFFERENTIAL
CLUTCHHOUSING
13-17
Shift Rod Removal 1.
Removethe shift rod boots.
2.
Romovethe change piece sttaching bolt and the springwasher.
3.
Removethe set screw,then removethe spring and the steolball.
4.
R e m o v €t h o s h i t t r o d , t h e n r e m o v e t h e c h s n g e piece.
5.
Removeth€ oilseal.
SETSCBEW OIL SEAL Roploc€.
CHANGEPIECE
*q
SPRING L 25.6
ll.0r in, STEELAALL (D.5/16
SPRINGWASHER ACHINGBOLT
13-18
Shift ForkAssembly I
erior,o ,"""sembling,cleanall the partsin solvent,dry them and apply lubricantto any contactparts
mm PIN PUNCH
5TH/REVEFSE SHIFTFORK
3RD/{TH SHIFTFORK
13-19
Shift Fork Assembly ClearanceInspection NOTE:The synchrosl€€v€and the synchrohub should be replac€das a set,
Measurethe clearancebetweenthe shift Dieceand the shift fork shafts.
1.
Strndard: 0.2 - 0.5 mm {0.qt8 - 0.02 in] S.rvico Limit: 0.8 mm (0.03inl
Measureth€ clearancebetweeneach shift fork and its matching synchro sleeve. Strndud: 0.35- 0.65 mm (0.014- 0.026in) S€rvicoLimit 1.0 mm (0.0'l in)
IFT FORK
SYNCHROSLEEVE SHIFTPIECE
/
SHIFTFORK
lf the clearanceis more than the servicelimit. measure the thicknessof the shift fork finoers.
lf the clearanceis more than the servicelimit, measurethe width of the shift piece.
Standard:7.4 - 7.6 mm (0.291- 0.299inl
Stsndard: 11.9- 12.0mm (0.469- 0.472in)
lf the thicknessof the shift fork fingers is not within the standard, replacethe shift fork with a now one. lf the thickness of the shift lork fingers is within the standard, replace the synchro sleeve with a new one.
1 3 -2 0
lf the width of the shift piece is not within the standard,rsplacethe shift piecewith a new one. lf the width of the shift pieceis within the standard,replacethe shiftfork with a new one.
MainshaftAssembly NOTE:The 3rd/4thand the 5th svnchrohubsare installedwith a press. cleanall the partsin solvent,dry them and apply lubricantto any contactsurfaces,The Priorto reassembling. 3rdl,lthand the sth synch.ohubs,however,shouldbe installedwith a pressbeforelubricatingthem.
SYNCHROBING page'13_35 Inspection, 818Cl cngino: Inirllstion dstailr, pag. 13-27
STOPPER RING TAPERRING NEEDLEBEARING lnspectfor wear and operation. 3RD/'TH SYNCHROSLEEVE 3RD/'TH SYiICHROHUB
SPACER Insp6clron, page13-35 SPRING
SPRING 3RDGEAR Inspectaon. page 13-22 NCEDE AEARING Inspocltor wear and operalton.
SYNCHROHUB SYNCHROSI..EEVE SYNCHRO SPRING Inspectaon. pag6 13-35 5TH GEAR rnspec!on, page13-24 SPACER COLLAR 4TH GCAR Inspection, page13-23
13-21
MainshaftAssembly ClearanceInspection NOTE: lf replacementis required.always replacethe synchrosleeveand the synchrohub as a set. 1.
Measurethe clearancebetween2nd and 3rd gears. Standard: 0.06- 0.21 mm {0.002- 0.008inl Ssrvica Limit: 0.3 mm (0.01in)
2.
lf the clearanceis more than the servicelimit, measurethe thicknessof 3rd gear.
EngineType Standard
ServiceLimit
818C1 34.92- 34.97mm - 1 . 3 7 7i n ) (1.375
81881 34.42- 34.47mm - 1 . 3 5 7i n ) (1.355
34.8 mm ( 1 . 3 7 0i n )
34.3mm (1.350 in)
3RD GEAR
lf the thicknessof 3rd gear is lessthan the service limit, replace3rd gearwith a new one. lf the thicknessof 3rd gear is within the service limit, replacethe 3rd/4thsynchrohub with a new one.
13-22
, Measurethe clsarancebetw€en,lth gear and the soacercollar. 0.06- 0.21 mm (0.002- 0.(xt8in) St.ndffd: Scwicr Limh: 0.3 mm (0.01in)
5.
lf distanceO is not within the standard,replacethe spacercollarwith a n€w one. lf distance@ is within th€ standard,measurethe thicknessof 4th gear.
EngineType Standard ServiceLimit
1.
818C1 3 1 . 4 2- 3 1 . 4 7m m - 1.239 (1.237 in)
81881 30.92- 30.97mm '1.2'19 inl \1.211-
3 1 . 3m m l'1.232inl
30.8mm ( 1 . 2 1i3n )
lf the clearanc8is more than the servicelimit, measuredistance@ on the spacercollar Stlnd.rd: 26.03- 26.m mm 11.025- 1.027in)
lf the thicknessof 4th gear is less than the service limit, replace4th gearwith a new one. lf the thicknessof 4th gear is within the service limit, replacothe 3rdl4thsynchrohub with a new one.
SPACERGOLLAR
(cont'd)
13-23
MainshaftAssembly GlearanceInspection(cont'd) M e a s u r et h e c l e a r a n c eb e t w e e n5 t h g e a r a n d t h e spacerco ar. Standard: 0.06- 0.21mm (0.002- 0.008in) Servicelimit: 0.3 mm 10.012 inl
8.
lf distance@ is not within the standard,reDlacethe sDacercollarwith a new one. lf distance@ is within the standard,measurethe thicknessof sth gear. Standard: 31.12-31.47mm (1.237- 1.239in) ServiceLimit:31.3mm (1.232inl
sTH GEAR
sTH GEAR
lf the clearance is more than the service limit, mea s u r e d i s t a n c e B o n t h e s p a c e rc o l l a r . Standard: 26.03 - 26.08 mm (1.025- 1.027 in)
SPACERCOLLAR
13-24
lf the thicknessof sth gear is lessthan the service limit,replacesth gearwith a new one. lf the thicknessof 5th gear is within the service l i m i t , r e p l a c et h e 5 t h s y n c h r oh u b w i t h a n e w one,
- Disassembly R e m o v et h e b a l l b e a r i n gu s i n ga b e a r i n gp u l l e ra s
3.
S u p p o r t3 r d g e a r o n s t e e l b l o c k s ,a n d p r e s st h e mainshaftout of the 3rd/4thsynchrohub, as shown.
BEARING PULLER
BALLB€ARING
CAUTION: Removethe synchro hubs using a press and the steel blocks .s shown. Use of a jaw-type puller can cau3edamags to the gear teeth. S u p p o r t5 t h g e a r o n s t e e l b l o c k s ,a n d p r e s st h e mainshaftout of the 5th synchrohub,as shown.
13-25
MainshaftAssembly Inspection 1 . Inspectthe gear surfacesand the bearingsurfacss for wear and damage,then measurethe mainshaft at pointsA, B. and C. Standord: - 1.102'linl A: 27.987- 28.000mm 11.1018 B: 37.98/r- 38.q)0 mm {1.il95il- l.il960 in} Ct 27.977- 27.99Omm {1.1015- 1.1020in}
2.
Inspectfor runout. Stlnd.rd: 0.02 mm (0.(xxl8inl M!I. S.rvic. Limit 0.05 mm (o.qP inl N O T E : S u D p o r tt h e m a i n s h € f ta t b o t h e n d s a s shown.
S€rvicoLimit; A: 27.9{, mm (1.1(XXlin} B:37.930mm 11.4933 inl C: 27.930mm {1.0996in}
Inspectoil passagestor clogging.
l f t h e r u n o u t i s m o r 6 t h a n t h s s e r v i c el i m i t , rsplacethe mainshaftwith a n6w one.
lf any parts of the mainshaftare less thsn the servicelimit. .eolacemainshaftwith a new one.
13-26
ReassemblV 1_ CAUTION: o Pless the 3rd/ilth and the 5th synchro hubs on the msinshafi without lubrication. . When installing the 3rd/4th and the sth synchro hubs, support the mainshaft on the steel blocks, and install synchro hubs using a press, . Install the 3rd/,lth and the sth synchro hubs with a maximum pressureof 19.6kN (2.000kgf, 1+466lbt). ^JOTEiReferto page 13-21for reassemblysequence. Support 2nd gear on steel blocks,then install the 3rd/4thsynchro hub using the specialtools and a press,as shown.
2,
Installthe sth synchro hub using the specialtools ano a pressas snown. OBIVER,,O mm LD. 0t7it6 - 003010O
ATTACHMENT, 35 mm l.D.
PRESS
sTH SYNCHROHUB
077t6- 00304{x)
NOTE:After installing,checkthe operationof the 3rd/4thsynchrosleeveand hub. B18Blsngine: ATTACHMENT, 35 mm LD. 07746- 0o30/rc0
DRIVER.40 mm l.D. 07746- 0030100 3RD/4TH SYNCHROHUB
Installthe ball bearingusingthe specialtools and a prsssas shown. NOTE:Installthe ball bearingwith the taperedend facingdown.
2NO GEAR
8l8Cl engine: Assemble the 3rd/4th synchro hub and sreevetogether before installing them on the mainshaft. PRESS 3RO/4TH SYNCHROHU8 : osed end
DRIVER4o mm l.D. 07746- tD30100
3RD/TTH SYNCHRO SLEEVE 2NDGEAR
13-27
CountershaftAssembly lndex NOTE:The 4th and 5th gears are installedwith a press.
3
Priorto reassembling. cleanall the pans in solvent,dry them and apply lubricantto any contactsurfaces.The 4th and sth gears.however,shouldbe installedwith a pressbeforelubricatingthem.
SYNCHROSPBING LOCKNUTReDlace. l(E*0*10EN.m /r1.0- 0 - 11.0kgtm,I l8o- o-80rbf.ft I WASHER BALLBEARING Inspectfor wear and operat|on, NEEDLEBEARING InspectIor wear and operation. SYNCHRORING
sTH GEAR
4TH GEAR
3RDGEAR
2ND GEAR THRUST BEARING
NEEDLEBEARING Inspectfor wear and operation. SPACER page13-29 Selection. FRICTIONDAMPER DOUB1I @NE SYNCHROl818Cl .ngin.l Inspection,page 13-35 SYNCHRORINGlBl8Bl .ngin ) Inspection,page 13-35
13-24
Inspection Glearance 'L
Measurethe clearancebetweenthe thrust shim and 1stgear,
3.
Measurethe clearancebetween2nd and 3rd g68rs. Stlndlrd: 0.05- 0.12 mm (0.002- o.(x}5inl Scrvice Limlt 0.18 mm (0.007inl
0.0,1- 0.12 mm (0.fi12- 0.005inl StEndard: Servics Limit: 0.18 mm (0.007in)
'HRUST SHIM
2.
lf the cleatanceis more than the servicelimit,select and installthe appropriatethrust shim to. the correctclearancefrom the chan below.
B
23922-PKs-900
1.95mm (0.0768in) 1.96mm (0.0772in)
A
Part Numb"r 2 3 9 1 7 - P 2 1- 0 1 0
B
23918-P2r-010
Thicknces
D
23924-PKs-900
1.97mm (0.0776in) 1.98mm (0.0780in)
E
23925-PKs-900
1.99mm {0.0783in)
F
2 3 9 2 6 - P K s - 9 0 0 2.00mm (0.0787inl
23923-PK5-900
23927-PKs-900 H
23928-PKs-900
lf the closranceis more than the service limit, selsct and install the appropriatespacer for the corr€ct clearancefrom the chartbelow.
Spaccl
Thrust Shim Part Numbar 23921- PKs- 900
4.
Thickncla
29.02- 29.0,{mm ( 1 . 1 4 2-5 1 . 1 4 3i3n ) 29.07- 29.09mm ( 1 . 1 4 4-5 1 . 1 4 5 i3n )
2.01mm (0.0791in) 2.02mm (0.0795in)
2 3 9 2 9 - P K s - 9 0 0 2.03mm (0.0799in) K
2 3 9 3 0 - P K s - 9 0 0 2.04mm {0.0803in) 2.05mm (0.0807inl 23931- PKs- 900
L
23932-PK5-900
M
23933-PKs-900
N
23934-PKs-900
o
23935-PKs-900
P
2 3 9 3 6 - P K s - 9 0 0 2.10mm (0.0827in)
2.06mm (0.0811in) 2.07mm (0.0815in) 2.08mm (0.0819in) 2.09mm (0.0823inl
13-29
CountershaftAssembly Disassembly 't.
2.
S e c u r e l yc l a m p t h e c o u n t e r s h a f ta s s e m b l yi n a benchvisewith wood blocks.
4,
Removethe bearing outer .ace, then remove the needlebearingusinga bearingpulleras shown.
Raisethe locknuttab from the groove in the countershaft,then remove the locknut and the spring washer. BEARINGPULLER
BEARING
CAUTION: Romovethe gclrs using a pross and tho steol blocks rs shown. U3a of a l.w.typo pullor can cau36damaggto tho gsar iocth. Removethe ball bearingusing a bearingpuller as shown.
Support 4th gear on steel blocks. and press the countershaft out of sth and 4th gears,as shown.
PULlTR
13-30 \
-
Y
Inspection 1.
Inspectthe gear surfacesand the bearingsurfaces for w€ar and damage,then measurethe countershaft at points A, B, and C. St.ndard: - 1.1021inl A: 2/t.980- 27.9!13mm (0.91|:15 B: 36.984- 37.q)Omm {1.4551- 1.'156?in} C: 33.qD - 33.015mm (1.2992- 1.2998inl SorvicaLimit: A: 2,a.930mm (0.9815in) B: 35.930mm (1.a539inl C: 32.950mm 11.2972inl
Inspgcttor runout. 0.02 mm {0.(xn8 inl Max. Stlndrrd: Srrvic. Limit 0.05 mm {0.(x)2in) NOTE: Suppon the countershaftat both ends as snown.
Rotate tl/vo compl6t€ rcvolutions.
Inspecttor wear 6nd damage.
lor clogging. Inspectoil passage .
l f t h e r u n o u t i s m o r e t h a n t h e s e r v i c 6l i m i t , rgDlacethe countershaftwith a new one.
lf any parts of the countershaftare less than the service limit, replacecount€rshaftwith a new one.
13-31
CountershaftAssembly Reassembly GAUTION: . Pr93r 4th and 5th goar3 on the qountorshrft without lubricrtion. . Whon in3talling 4th and sth goa6, srpport the shaft on st..l block3,8nd in3tall thc 9.116 uring a prors. . Inst.ll 4th lnd 5th gcar with a maximum pro33ur€of 25.5 kN (2,6@ksr. 18,806lbo.
4.
Installthe reversegear. I n s t a l lt h e s y n c h r os p r i n g , a n d t h e d o u b l e c o n e s y n c h r o( 8 1 8 C ' le n g i n e ) ,o r s y n c h r or i n g ( 8 1 8 8 1 engine), as shown.
NOTE:Referto page 13-28for reassemblysequence. Installthe thrust shim and the needlebearinoson the countershaft.
SYNCHRO SPRING
NEEDLEBEARING
REVERSE GEAfi
THRUSTSHIM
COUNTERSHAFT
Assemblethe friction damper,the needlebearing, and 2nd gear,then installthem by aligningthe fingers on the frictiondamper and the groovesin the 1sv2ndsynchrohub with the fingers of the double c o n e s y n c h r o a n d t h e g r o o v e so n 2 n d g e a r , a s shown.
Installthefrictiondamper.the synchroring,and the synchrospringon lst gear, Installthe lsv2nd synchrohub by aligningthe fingers on the friction damperand the groovesin the 'lsV2ndsynchrohub, as shown.
Installthe spacer.
2ND GEAR
1ST/2ND
NEEDLEBEARING SPACER
FRICTIONDAMPER
8. lST GEAR
13-32
Install the parts assembledin steps 2 - 6 on the countershaft.
9 . S u p p o r t t h e c o u n t e r s h a f to n a s t e e l b l o c k , a n d install4th gear usingthe specialtools and a press, as snown.
1 1 .Installthe needlebearing.then installthe ball bearing usingthe specialtoolsand a pressas shown.
PRESS
DRIVER.,l0 mm l.D. 07746- 0030100
DRIVER,40 mm l.O. 077{6 - 0030100
PRESS
ATTACHMENT,30 mm l.D. 07746 - d)30300 BALLBEARING
NEEDLEBEARING
1 0 . S u D D o r t h e c o u n t e r s h a f to n a s t e e l b l o c k , a n d install5th gear using the specialtools and a press, as shown.
12. S e c u r e l yc l a m p t h e c o u n t e r s h a f ta s s e m b l yi n a benchvisewith wood blocks. 1 3 . Installthe spring washer.tighten the locknut,then stakethe locknuttab into the groove.
DRIVER,40 mm l.O. 07746- 0030100
LOCKNUT 1 0 8 * 0 * 1 0 8N . m ( 1 1 . 0- 0 - 1 1 . 0k g f . m , 80+0*80lbf.ftl
LOCKNUT
30 mm l.O. ATTACHMENT, 0?7a6- (X)303(x)
wooo BLocKs
13-33
SynchroSleeve,SynchroHub Installation
Inspection '1. Inspectgear teeth on all synchrohubs and synchro sleevesfor rounded off corners,which indicates wear. 2.
I n s t a l le a c h s y n c h r o h u b i n i t s m a t i n g s y n c h r o sleeveand checkfor Jrgedomof movement. NOTE: lf replacementis required,always replace the synchrosleeveand synchrohub as a set.
When assemblingthe synchrosleeveand synchrohub, be sure to match the thr€e sets of longer testh (120 degreesapart) on the synchro sleeve with the three sots of deepergroovesin th€ synchrohub. CAUTION: Do not install thc synchro 3l.6yc with itt longor tosth in tha 13t/2nd synchro hub 3lob, b.c!u3a it will d.mago tho spring ring.
TEETH LONGER
sYt{cHRo HUBSLOT
SYNCHRO HUB
SLEEVE
13-34
SynchroRing,Gear r Inspection 1.
SYNCHROSPBING
Inspectthe synchroring and gear. A: lnspectthe insideof the synchroring for wear. B: Inspectthe synchro sleeveteeth and matching teethon the synchroring for wear (roundedoff).
SYNCHRORING
CC
GOODWORN C: Inspectthe synchro sleeveteeth and matching teethon the gearfor wear (roundedoffl.
oo
GOODWORN D: Inspectthe gear hub thrustsurfacefor wear. E: Inspectthe conesurfacefor wear and roughness. F: Inspectthe teeth on all gears for uneven wear. scoring,galling,and cracks. Coatthe cone surfaceof the gearwith oil, and place the synchroring on the matchinggear, Rotatethe ring, makingsurethat it does not slip. Measurethe clearancebetween the synchro ring a n dg e a ra l l t h ew a y a r o u n d . NOTE:Holdthe synchroring againstthe gear evenly while measuringthe clearance. Synchro Ring-to-GgarClgarance Standard: 0.85- 1.10mm (0.033- 0.0/B in) Limit:0.i1 mm 10.02inl Service Double Cone Synchro-to-GearCloaiance Standald: @: {Outer Synchro Ring to Synchro Cone) 0.5- 1.0mm 10.02- 0.0i1in) @: lSynchroConeto Goar) 0.5- 1.0mm (0.02- 0.04in) O: loutsr Synchro Ring to Gsarl 0.95- 1.68mm (0.037- 0.066inl ServiceLimit: 6): 0.3 mm 10.01inl @: 0.3 mm t0.01inl G):0.6 mm (0.02in)
SYNCHROCONE SYNCHRORING
o
lf the clearanceis lessthan the servicelimit, replace the synchroring and synchrocone.
13-35
ClutchHousingBearing Replacement Mainrhaft: 1.
3.
Drivethe new oil seal into the clutch housingusing the specialtoolsas shown.
Removethe ball bearingusing the specialtools as shown.
3/8' - 16SI.IDEHAMMCR (commercially av6ilable)
CTUTCH
ATTACHMEIVT, a2 x 4t rnm 0r7a5- 0010300
()|L SEAI Roplacs.
ADJUSTABIT AEARING PULER,25- a0mrn 07736- A01moA
2.
Removethe oil sealfrom the clutchhousing.
Drive the ball bearing into the clutch housing usin! the sDecialtools as shown.
CLUTCHHOUSING
BATI.BEAMIO
13-36
3.
Countcr'h!ft: '1. Bsnd the tab on the lock washer down, then remove the bolt 8nd bearingretainerplate.
Positionthe oil guide plate and new needlebearing in the bore of the clutch housing,then drive in the needlebearingusingthe specialtoolsas shown. NOTE:Positionthe needlebearingwith the oil hole facingup.
OIL GUIDCPLATE CI-UTCH HOUSING
CLUTCHHOUSING
Remove th€ needle bearing using the specisl lools as shown,then removethe oil guide pl8te.
3rE' - 16SUI'€HAiiMER availabls) {commorcially
Installthe bearingretainerplateand new lockwasher, then bendthe tab againstthebolt head.
8 x 1 0m m 15N.mll.5 kd.m, 11lbf.ttl
LOCK WASHEA Repl6ce.
AD.'USTABIIBEARIITG PULIIR, 25- ao mm 07t36- A0rm0a
13-37
MainshaftThrustGlearance Adjustment 1.
Removethe 72 mm thrust shim and oil guide plate from the transmissionhousing. 72 mm THRUST SHIM
TRANSMISSION HOUSING
OIL GUIDEPLATE
5.
Measure distance @ betlveenthe end of the clutch housingand bearinginnerrace. NOTE: . Usea straightedgeand depthgauge. a Measureat three locationsand averagethe readIngs.
\.u
END of CLUTCHHOUSING
o
B o
fr INNEBRACEot BALLBEARltac
lnstall the 3rd/4th synchro hub, spacer collar, sth synchrohub, spacer,and ball bearingon the mainshaft.then installthe above assemblyin the transmissionhousing.
Selectthe prcpet 72 mm thrust shim from the chart by usingthe formulabelow.
Installthewasheron the mainshaft.
NOTE:Useonly one 72 mm thrustshim.
Measuredistance@ betweenthe end of the transmissionhousingand washer.
Shim Sslsction Formula:
NOTE: . Usea straightedgeand verniefcaliper. . Measureat three locationsand averaoethe readIng.
ENDol TRANSMISSION HOUSING
MAINSHAFT
WASHER
you made in steps4 and 5: Fromthe measurements -1. Add distance@ (step5lto distance@ (step4). -2. From this number.subtract0.93 (which is the midpointof the flex rangeof the clutchhousing bearingspringwasherl. -3. Takethis number and compareit to the avaif ableshim sizesin the chart. (Forexample) B:2.39 + C: O.22
2.61
- 0.93 1.68
. Try the 1.68mm (0.0661in) shim.
AALLAEARING
13-38
7.
72 mm Thrust Shim Part Number 23931- P21-000
2 3 9 3 2 - P 2- 0 100
c D
23933- P21-000 -000 23934-P21
- P21-000 23935 F
-000 23936-P21
2 3 9 3 7 - P 2- 0 100 2 3 9 3 8 - P 2- 0 100 -000 23939-P21 J
23940-P2r-000
K
23941- P21-000 23912-P21-OOO -000 23943-P21 2 3 9 4 4 - P 2 -10 0 0 23915- P21-000 23946- P21,000
L M N
o P
o
23947-P21 -000 23948- P21 000
s
-000 23919-P21 -000 23950-P21 23951- P21-000 23952- P21 000
T
X
2 3 9 5 3 - P 2- 0 100 23954-P2r-000 -000 23955-P21
z
2 3 9 s 6 - P 2, 0 100
AB
2 3 9 5 7 - P 2 -10 0 0 23958- P21-000 23959- P21-000
AC AD AE
AH
AI AK
AN AO
- P21-000 23960 23961-P21 -000 23962 P21,000 -000 23963-P21 23964- P2'1-000 23965- P2'1-000 -000 23966-P21 -000 23967-P21 23968- P21-000 23969- P21 000 -000 23970-P21 23971 P21 000
Thickness 0.60mm (0.0236in) 0.63mm (0.0248in) 0.66mm {0.0260in} 0.69mm (0.0272in) 0.72mm (0.0283in) 0.75mm (0.0295in) 0.78mm (0.0307in) in) 0.81mm (0.0319 in) 0.84mm (0.0331 0.87mm (0.0343 in) in) 0.90mm (0.0354 in) 0.93mm (0.0366 0.96mm (0.0378 in) 0.99 mm (0.0390in) in) 1.02mm (0.0402 in) 1.05mm (0.04'13 1.08mm (0.0425 in) in} 1.11mm {0.0437 1.14mm (0.0449inl 1.17mm (0.0461in) 1.20mm {0.0472in) 1.23mm {0.0484in) 1.26mm (0.0496in) 1.29mm 10.0508 in) in) 1.32mm 10.0520 in) 1.35mm (0.0531 1.38mm (0.0543 inl 1.41mm (0.0555 in) 1.44mm (0.0567 in) 1.47mm (0.0579 in) 1.50mm {0.0591in) 1.53mm {0.0602in) 1.56mm {0.0614in} 1.59mm (0.0626in) 1.62mm (0.0638in) 1.65mm (0.0650in) 1.68mm {0.0661in) 1.71mm 10.0673 in) in) 1.74mm (0.0685 '1.77mm (0.0697 in) 1.80mm (0.0709 in)
Checkthe thrust clearancein the mannerdescribed below. NOTE:Carryout the measurementat normal room remperarure. -1. Install the thrust shim selectedand oil guide platein th€ transmissionhousing.
?2 mm THRUST
otL
PLATE
TRANSMISSION HOUSING
I n s t a l lt h e s p r i n g w a s h e ra n d w a s h e ro n t h e ball bearing. NOTE: . Cleanthe springwasher,washerand thrust shim throughlybeforeinstaliation. . I n s t a l lt h e s p r i n g w a s h e r .w a s h e r a n d t h r u s t shim properly.
a-=s-.r*os".^ .,,-B*^INGWASHER Installthemainshaftin the clutchhousing. - 4 . Placethe transmissionhousingover the main-
shaftand onto the clutchhousing. Tighten the clutch and transmissionhousings with severalSmm bolts. NOTE:lt is not necessaryto use sealingagent betweenthe housings. 8 x 1.25mm 27 N.m {2.8 kgf.m, 20 lbf.ft} Tap the mainshaftwith a plastichammer,
(cont'd)
13-39
MainshaftThrustClearance Adjustment (cont'd) -7. Slidethe mainshaftbaseover the mainshaft. MAINSHAFT
- 11.Zeroa dial gaugeon the end of the mainshaft. 12.Turnthe mainshaftholderbolt clockwise;stop turning when the dial gauge has reachedits maximum m o v e m e n t .T h e r e a d i n go n t h e d i a l g a u g e i s t h e amountof mainshaftend play. CAUTION: Turning the mainshaft holder bolt mor€ than 60 degrees after the needle ol the dial gauge stops movingmay damagethe transmission, DIALGAUGE
- ) , .
"7t/'-
'..' .'i'
i. , MAINSHAFTBASE 07GAJ- PG20130
\
-8. Attachthe mainshaftholderto the mainshaftas fol-
NOTE: . Back-outthe mainshaftholder bolt and loosen the two hex bolts. . F i t t h e h o l d e r o v e r t h e m a i n s h a f ts o i t s l i p i s towardsthe transmission. . A l i g n t h e m a i n s h a f th o l d e r ' sl i p a r o u n dt h e g r o o v ea t t h e i n s i d eo t t h e m a i n s h a f ts p l i n e s , then tightenthe hex bolts.
f- t{-c
l\-_.r' nrTh
l\nex
\ ._/_/lrl Borrs
L ___E_J \
MAINSHAFT HOLDER 07GAJ- PG20110 MAINSHAFTBASE 07cAJ _ PG20130 - 9 . S e a t t h e m a i n s h a f tf u l l y b y t a p p i n g i t s e n d w i t h a plastic hammer. - 1 0 . T h r e a dt h e m a i n s h a f th o l d e r b o l t i n u n t i l i t j u s t c o n tacts the wide surface of the mainshaft base.
13 -4 0
- 13.lf the reading is within the standard, the clearance is correq. lf the reading is not within the standard, recheckthe shim thickness. Standard: 0.11 - 0.18 mm {0.004- 0.007 in)
MAINSHAFT HOLOER BOLT
|
MAINSHAFTHOLDER 07GAJ- PG201r0
Transmission ReassemblV ; 8. Installthe differentialassembly.
1 . l n s t a l l t h en e w o i l s e a l .
DIFFERENTIAL ASSEMBLY
2.
Setthe changePiece.
3.
lnstallthe shift rod.
4
Installthesteelball,the spring,and the set screw.
5.
lnstallthe changepieceattachingbolt.
6.
Installthe shift rod boots.
8x1.0mm 30 N.m 13.1kg{ m. 22 tbl.ltl
SETSCREW 1 2x ' 1 . 0m m 22N.m{2.2kg{.m,16lbl.ft} SPRING L. 25.6mm
9 . Set the spring washer and the washer. 1 0 . Install the mainshaft, the countershaft, and the shift fork assemblies. SHIFTROD
N O T E :A l i g n t h e f i n g e r o t t h e i n t e r l o c kw i t h t h e groovein the shiftfork shaft. MAINSHAFT
I n s t a l l t h eo i l c h a m b e r P i a t e .
6x1.0mm 12 N.m (1.2kgt'm,9lbtft)
COUNTERSHAFT SHIFTFORKS
(cont'd)
13-41
Transmission (cont'd) Reassembly 11. Install the change holder assembly. 6x1.0mm 15 N.m (1.5 kgf.m, 11 tbf.ftl
13. Measurethe distance@ after mounting the shift pieceshaft.lf it's incorrect,checkthe installation. DistanceO: 11.9- 12.3mm 10.47- 0.48in)
CHANGE HOLDER ASSEMBLY
12. Installthe shift piece and the interlock,then install the shift pieceshaft. 1 4 . lnstallthe washer (B18C1engine),the reverseidlo. gear.and the reverseidler gearshaft.
REVERSE IDLERGEAR
13-42
15. Installthereversechangeholder.
Installtheoil gutterplate. '18. Bendthe hook of the oil gutterplate,then installthe 16 mm sealingbolt.
6x1.0mm 15 N.m (1.5kgt'm,11lbfftl
NOTE:Apply liquidgasket{P/N08718- 0001)to the threads,
BOLT 16mm SEAI-ING 29 N.m t3.0kgf m, 22 lbl'ftt
Installtheoil guide plateand the 72 mm thrustshim into the transmissionhousing.
72 mm THRUSTSHIM
1 9 . Apply liquid gasketto the surfaceot the transmission housingas shown. NOTE:
a Use liquidgasket(P/N08718- 0001)
Removethe dirt and oil from the sealingsurface' of the bolt holesto a Sealthe entirecircumference preventoil leakage. lf 20 minutes have passedafter applying liquid gasket,reapply it and assemblethe housings, a n d a l l o w i t t o c u r e a t l e a s t 3 0 m i n u t e sa f t e r assemblybeforefillingthe transmissionwith oil.
Liquid g.!k.t
(cont'd)
13-43
Transmission (cont'd) Reassembly 20. Installthedowel oins.
23, Check that the snap ring is securely seated in the groova of th€ countershaftbearing.
2 1 . I n s t a l lt h e t r a n s m i s s i o nh o u s i n gb y a l i g n i n gt h e groove in the housing with finger on the stopper .ing.
Dimcntion O as inst.lbd: il.6 - 8.3 mm (0.181- 0.327inl
GROOVE
22. Lower the transmissionhousingwith the snap ring pliers and set the snap ring in the groove of tha countershaftbearing. TNANSMISSION HOUSING
13-44
Installth6 transmissionhang€rA and back-uplight switch clamp,thon tighten th6 transmissionhousi n g a t t a c h i n gb o l t s i n t h e n u m b e r € d s e q u o n c o shown below. 6 | i.25 mrn 2t .m l2.8 lgf.m, 20 lbf.ftl
{ 27. I n s t a l l t h e s t e s l b a l l s , t h e s p . i n g s , a n d t h e s e t
24. Installth€32 mm seslingbolt.
screws. NOTE:Apply liquidgasket(P/N08718- 0001)to the threads.
28. lnstallthe back-uplight switchand the transmission hangerB.
32 mm SEALINGBOLT 25 N.m {2.5 kgl'm,
SWITCH LTGHT BAC|(-UP 2s N.m{2.5kg{.m,18lbtft)
,*"""."'" HAiIGER B SPRIMi L. 30 mm {1,2in}
8 x 1.25mm 24 N.m(2.4kgfm, 17lbtftl
/ I
l /
12x 1.0mm 22 N.m(2.2kgi.m. 10tbtft)
26. Tight€n ths teverse idler gear shaft bolt.
REVERSEIDI.^CR SHAFT IOLT l0 r 1.25rnm 5a t$m 15.5kg{.m.(} lbtftl
13-45
TransmissionAssembly lnstallation 1.
Inst€llthedowel pins on the clutchhousing.
2.
Apply greaseto the partsas shown,then installthe releasefork and releasebeaaing.
6,
N O T E :T o r q u et h e m o u n t i n gb o l t a n d n u t s i n t h e sequenceshown.
NOTE:Use only SuperHigh Temp Urea Grease (P/N08798- 9002). 3.
Raisethe transmission, then installthe transmission mounI.
CAUTION: Checkthat the bushings are not twistod or offset,
Installthe releasefork boot.
BELEASEFORKBOLT 29 N.m (3.0kgl.m,
22 tbt-ttl
O 12 x 1.25mm 54 N.m {6.5kgt m, 47 tbtfrl
tPlN 08798- 90021 RELEASE BEARING
@ I
RELEASE REEASE FORK FORK BOOT
{P/N 08798- 90021
@ 12 x 1.25mm 7,1N.m 17.5kg{.m, 5/r lbtftl
7. P l a c et h e t r a n s m i s s i o no n t h e t r a n s m i s s i o ni a c k , and raiseit to the enginelevel.
Installthe three uppertransmissionmountingbolts and lower startermotor mountingbolt.
Installthe transmissionmountingbolts and the rear mount bracketbolts sELF-LocKrNG BoLT 12x 1.25mm 6it N.m 16.5kgl.m, 47 lbf.ftl
Replace. 1 4 x 1 . 5m m
1 2 x 1 . 2 5m m 64 N.m 16.5 kgf.m, 47 lbf.ftl
10 x 1.25mm 44 N.m lil,s kgt m, 33 tbf.ftl
13-4 6
8,
Instsll the right tront mounvbracket.
1 0 . lnstall the tront ( 8 1 8 C 1e n g i n e )a n d r e a r e n g i n e stiff€nsrs.
SELF.LOCKINGBOLT Replac€. 12 x 1.25mm
12 x 1.25mm 5t N.tn {5.8 42 tbt ftt
8 x 1.25mm 24 N.m l2.a kgf.]n, 17 tbtftl RIGHT 10 x 1,25mm il a N.m (i4.5kgf..n, 33 tbtftl
8 x 1.25 FROifTENGINE 2r N'm (2.4kg['m, 12 x 1.25ftm 5? N.rn l5.Ekg[.m, 17lbf.ttl SnFFENERS 42 tbl.ft) lBl8Cl lngin.l
11. Installthechangerod,the springpin, and the clip.
9.
Installtheclutchcover.
NOTE: . Installthe clip and the spring pin on the change joint as shown. . Turn the shift rod boot so the hole is facing down as shown. . Make sure the shift rod boot is installedon the cnangeroo, 12. Installthe changeextension. 1 3 . I n s t a l l t h eh e a ts h i e l d( 8 1 8 C 1e n g i n e ) .
6r1.0mm 12 N.m 11.2kgtm, 9 rbf.ftl
8 x 1.25mm 22 N.rn 12.2kgl-m. 16 tbtftl
CHANGEROD
SPRINGPIN Replace.
. l3-
e-- nrr,l I ll'--PuNcH CHANGE EXTENSION
8 x 1.25mm 12 x 1.25mm 2il N'm 12.4kg{.m, 57 N.m ls.E kgf.m, 17 tbffrt a:I lbl.trl l818Bl .ngin.l
5xl.0mm 9.8 N.m 11.0kgt'm, 7 tbf.ftt HEATSHIELD (B18Cl .nginol
/^
"-*
sHtFTROOaOOt
2M
i@
qlL# --7
C LIP
HOt.C (cont'dl
13-47
Transmission Assembly Installation (cont'd) 1 4 . I n s t a l lt h e i n t e r m e d i a t e s h a f ta n d t h e d r i v e s h a f t s (seesection16)-
17. lnstall the exhaust pipe A, and the three way cata l y t i c c o n v e r t e r( B l 8 C ' 1e n g i n e ) ,a n d c o n n e c tt h e heatedoxygensensor(HO2S)connector.
NOTE:Replacethe set ringswith new ones. DNIVESHAFTS GASKET SELF-LOCKING NUT Replace. 10 x 1.25mm 33 N.m (3.4 kgt.m,
HO2S CONNECTOR
2s tbtftt
-Sl SET RING Replace.
::.t
INTERMEDIATE SHAFT
10x 1.25mm 38 N.m (3.9 kgt m, 28 tbtft)
Replace.
15. Installthe ball joints onto the lower arm (see section18). 16. Installthe right damperfork (seesection18). 10x 1.25mm 43 N.m{4.oksf.m.32lbf.ft)
RIGHT DAMPER FOBK
t
LOWERARM SELF.LOCKING NUT Replace. 12 x 1.25mm 64 N.m {6.5 kgf.m, 47 tbtft)
13-44 L
:\ CASTLENUT 12x 1.25mm 49 - 59 N.m 15.0- 6.0kgf m. 36 - 43 tbf.frl
COTTERPIN Reptace.
GASKET Replace.
SELF.LOCKING NUT Replace. 8 x 1.25mm THREEWAY CATALYTIC 16 N'm 11.6kgt m, CONVERTER l2tbt.ftl 1818C'l enginel
SELF.LOCKING NUT Replace. 10 x 1 25 mm 54 N.m 15.5kgt m, iro lbf.ftl
18. Installthe enginesplashshield.
'19. Installthe slavecylinder,then installthe clutchpipe bracket. N O T E :U s e o n l y S u p e r H i g h T e m p U r e a G r e a s e (P/N08798- 9002).
22, lnstallthe lower radiatorhose clamp on the transmissionhang€rB. 2 3 . C o n n e c tt h e t r a n s m i s s i o ng r o u n d w i r e a n d t h e back-uplight switchconnector. BACK.UPLIGI{T SWITCHCONNECTOR
16 tbf.ftt CLUTCHPIPE
6x1.0mm 9.8N.m {1.0kgf.m,7 lbfft)
GROUNDWIRE 8 x 1.25mm 22 N-m 12.2kgl.tr't, tPlN 08798- 90021 16 rbf.ftl
HANGERB
24. Install the air cleaner housing assembly and the air intake duct. 6x1.0mm AIR CLEANER 9.8 N.m 11.0kgt'm,7 lbtftl HOUSING ASSEMALY
20. Connectthe vehiclespeed sensor(VSS)conneclor and the startermotor cables. 2 1 . Installthe wire harnessclamPs. 6x1.0mm 9.8 N.m (1.0kgt m,7 lbf ftl VSS CONNECTOR
9 \
AIR INTAKE DUCT
\<
8 x 1.25mm 8.8 N.m 10.9kgf.m, 6.s tbf.ft)
Refillthe transmissionwith oil (seepage 13-3). Connectthe positive(+) cablefirst,then connectthe negative( - ) cableto the battery. 27. Checkthe clutchoperation. WIRE HARNESS CLAMPS
STARTER MOTOR CABLES
28. Shift the transmission.and checkfor smooth operatron. 29. Checkthe front wheelalignment(seesection18).
13-49
GearshiftMechanism Overhaul NOTE: .Insp€ctrubberpartsforwearanddamagewhendisassembling;replaceanywornordamagedparts. . lnstallthespringpin and the clip on the changejoint as shown. . Turn the shift rod boot so the hole is facingdown as shown. . Makesurethe shift rod boot is installedon the changerod.
t@)-I -/l
I t/
SHIFTIIVER KNoB 7.8N.m{0.8Isl.m, 6 lbt{tl
\U
8 x 1.25mm 22 N.m {2.2 kgt m, 16 tbtft)
#:
EXTENSION END WASHER A
@-tHrFrLEVERaoor SHIFTLEVER DUSTSEALA
6
(7\ RUBBER EXTENSION WASHER B
8x22mm SPRINGPIN Replace.
I CHANGEROD Replsc€. 5x1.0mm 9.8 N.m 11.0kgf.m, 7 tbf.ftt
,,'/
"t't
9oo-
seu'locrtnc ruur neptace.
8 x 1.25mm 22 N.m 12.2kg{ m, 16 tbtft) SHIFTRODBOOT
=
/
;1tffi =ff NEARJOINT BUSHING
O.RINGS Replece. REARJOINT BUSHING THRUSTWASHER
13-50
CLIP
Automatic Transmission 'l4-2
H v d r a u l i cF l o w L o c k - u pS y s t e m
14-3 't 4-6 14-8 14-14 14-23 . . . - - . . . . . 1. 4 - 2 4 . . . . . . . .1 4 - 3 8
Eloctrical Systom C o m p o n e nLt o c a t i o n. . . . . . . . . . . . , . . . , . . . . . . . . . . . .I.4. .-.4 5 . . . . . . . . . . . .1 . 4-46 C i r c u i tD i a g r a m ' T r o u b l e s h o o t i nPgr o c e d u r e.s. . . . . . . , . . . . . . . . . .l.4, - 4 8 Symptom-to-Component Chart ...... 14-50 ElectricalSystem ElectricalTroubleshooting T r o u b l e s h o o t i nFgl o w c h a r t. . . . . . . . . . . . . . . . . .1. .4 - 5 2 Lock-uoControl SolenoidValve A/8 - - . . . .\ 4 - 8 2 Test .................. , . . . , . . . , . . ,1 . 4-82 ReDlacement Shift Control SolenoidVslve A/B . . . . . .1 4 - 8 3 Test .................. . . . . . . . . . . . . .1. 4 - 8 3 Reolacement TransmissionControl Module (TCM) *ReDlacement . . . . . . . . . . .1 4 - 8 4 SDeedSensors Mainshalt/CountershaJt . . . . . . . . . . . .1. 4 - 8 5 Reolacement Hydraulic Systom Symptom-to-Component Chart HydraulicSystem Road Test Slall Speed
T e s t. . . . . . . . . . . . . . . . . . FluidLevel Checking/Changing Pressu.e Testing
14-86 14-90 't4-92 14-93 14-94
Transmission Transmission . . . . . .1 4 - 9 9 R e m o v a. l. . . . . . . . . . . . lllustratedIndex R i g h tS i d eC o v e r. . . . . . . . . . . . . . . . . . . . . . . . . . .1. 4. .-.1.0. 4 . T r a n s m i s s i oHn o u s i n 9. . . . . . . . . . . . . . . . . . , , . . . .I.4. .- 10 6 Torque Converter HousingNalve . . . 1 4 -1 O 8 B o d y. . . . . . . . . . . . . . . . . . Right Side Cover . . . . . .1 4 - 1 1 0 R e m o v a. l. . . . . . . . . . . . TransmissionHousing . - . . - .1 4 - 1 1 2 R e m o v a. l. . . . . . . . . . . . Torque ConvenerHousingNalveBody . . . . . .1 4 - 1 1 4 R e m o v a. l. . . . . . . . . . . . Valve Caps .............1 . .4. - 1 1 6 Description Valve Body . . . - . .1 4 - 1 1 7 R e p a i .r . . . . . . . . . . . . . . . Valve A s s e m b l y. . . . . . . . . . . Oil Pump Inspection
Main Valve Body Disassembly/lnspection/Reassembly 1 4 - 1 2 0 RegulatorValve Body Disassembly/lnspection/Reassembly 14-122 Lock-up Valve Body ....... 14-123 Disassembly/lnspection/Reassembly Secondary Valve Body ....... 1 4 - 1 2 4 Disassembly/lnspection/Reassembly Servo Body ....... 14-126 Disassembly/lnspection/Reassembly 1st-holdAccumulator/RightSide Covet .,..,.. 14-124 Oisassembly/lnspection/Reassembly Mainshaft -..-... 14- 129 Disassembly/lnspection/Reassembly . . . . . . . . . . . . . . . .1. 4 -1 3 0 lnsDection Countershaft ....... 14-132 Disassembly/lnspection/Reassembly D i s a s s e m b l y / R e a s s e m. .b. l.y. . . . . . . . . . . . . . . . .1.4. - 13 3 . . . . . . . . . . . . . . . .1. 4 - 1 3 4 lnsDection One-way Clutch/ParkingGear D i s a s s e m b l y / l n s p e c t.i .o. n. . . . . . . . . . . . . .-. . .- . 1 4 - 1 3 7 Sub-shaft ....... 14-138 Disassembly/lnspection/Reassembly D i s a s s e m b l v / R e a s s e m. .b. l. v. . . . . . . . . . . . . . . . .1.4. - 13 9 Sub-shaft Bearings . . . . . . . . . . . . l. 4 - 1 4 0 Replacement Clutch f l l u s t r a t el n d d e x. . . . . . . . . . . . . -. . . .- . . . - . . . . . . .1. 4. .- 14 1 , , , . , , . . . . . . .1. 4 - 1 4 4 Disassembly . . . . . . . . . . . . .1. 4 - 1 4 6 Reassembly Torque Converter Housing Bearings MainshaftBearing/OilSeal . . . . . . . . .1 4 - 15 0 Reolacement CountershaftBearingReplacement.......,, 14-15l TransmissionHousingBearings Bearing Mainshsft/Countershaft ...-..-..14-152 Repfacement S u b - s h a fB t e a r i n gR e p l a c e m e n. .t. . . . . . . . . . .1. 4 - 15 3 Reve.seldler Gear . . . . . . . . . . . . . . .1. 4 - 1 5 4 lnstallation ParkingBrakeStopper l n s p e c t i o n / A d j u s t m e.n. .t. . . . . . . . . . . . . . . . . . . . . . . ' 1 4 - ' 1 5 4 Transmission .14_156 .............,. Reassemblv T o r o u eC o n v e r t e r / D r i vPel a t e. . , . . , . . . . . . . . . . . . .1. 4. - 16 3 Transmission 14-164 lnstallation 14-168 CoolerFlushing 'Shitt Cable . .n. . . . . . . . . . . . . . . . . . . . . . . .14-'t . . . 70 R e m o v a l / l n s t a l l a t .i o . . . - . . - . . . . . . -1.4 - ' 1 7 1 Adiustment *GearshiftSelector D i s a s s e m b l y / R e a s s e m. .b. l.y. . . . . . . . . . . . . . . . .1,4. - 1 72 *Shift IndicatorPanel -..........-...14-173 Adjustment Throttle Control Cable . . . . . . . , . . , . . . . .1. 4 - 1 74 fnspection . . . . . . . . . . . . .1. 4 - 1 7 6 Adjustment
SpecialTools
Rol. No.
o
Tool Numbsl
Description
OTGAB PF50lOO oTGAB-PF50101 oTGAE-PG40200 oTHAC-PK4010A oTHAE-PL50lOO oTLAE-PX40100 OTLAJ PT30lOA OTMAJ-PY4O'I 1A oTMAJ-PY40120 -OO10100 oTPAZ 07406-OO20003 o7406 0070000 07736 A01000A o7746-O010100 o7746-O010500 07746-OO10600 07746 0030100 o7749-O010000 07947-6340500
IA\ ,6\
@ €/
o
@ rt) @ @ \9
@ @ @ @ @ @
Oty
Page Reference
MainshattHolder
'I
1 4 - 11 1 . 1 6 0
Clutch SpringCompressorBolt Assembly HousingPuller Clutch SpringCompressorAttachment Clutch SpringCompressorAttachment Test Harness A/T Oil PressureHose, 221O mm A/T Oil PressureAdapter SCS Short Connector A/T Oil PressureGaugeSet w/panel A/T Low PressureGaugew/panel AdjustableBearingPuller,25-40 mm Attachment, 32 x 35 mm Attachment, 62 x 68 mm Attachment, 72 x 75 mm D r i v e r ,4 0 m m l . D . Driver OriverAttachment
I 1 1 ,1
14-144,147 1 4 - 113 1 4 -1 4 4 , 1 4 7 14 144,'t47 14-49,90 14-94 14-94 't 4-44 14-94 14-94 14-150,151 14-139,140 1 4 - 1 4 0 .510 , 15 1 , 15 2 ,15 3 14-150,152 14-134 14 - 13 9 , ' 1 4 01, 5 0 . 15 1 , 15 2 14,150
1 1 1
,| 1 1 1 1 1 I I 'I 1
Edrn$r--€
o
a)
a6l
@
o
@
@
@
@
(
r
)
*@ Must be used with commerciallyavailable 3/8 in. x 16 threads/in.slide hammer.
14-2
@
The Automatic Transmissionis a combination of a 3-e,ement torque convefter and triple-shaft electfonically controlled automatictransmissionwhich provides4 speedsforward and 1 speedreverse.The entireunit is positionedin line with the engine. Torque Converter, Gears and Clutches The torqueconverterconsistsof a pump,turbineand statorassemblyin a singleunit, The torqueconverteris connected to the enginecrankshaftso they turn togetheras a unit as the engineturns. Aroundthe outsideof the torque converter is a ring gearwhich mesheswith the starterpinionwhen the engineis beingstaned. The entiretorqueconverterassembly servesas a flywheel while transmittingpower to the transmissionmainshaft. The transmissionhas three parallelshafts,the mainshaft.countershaftand sub-shaft.The mainshattis in line with the enginecrankshaft. The mainshaftincludesthe clutchesfor 1st, and 2ndl4th, and gearsfor 3rd. 2nd, 4th, reverseand l st (3rd gear is integral with the mainshaft,while reversegear is integralwith the 4th gear). The countershaftincludesthe 3rd clutch and gearsIor 3rd, 2nd,4th, reverse,lst and parking.Reverseand 4th gears can be lockedto the countershaftat its center, providing4th gear or reverse,dependingon which way the selectoris moved. The sub-shaftincludesthe lst-hold clutch and gearsfor 1st and 4th The gearson the mainshaitare in constantmesh with those on the countershaftand sub-shaft.When certaincombinations of gearsin the transmissionare engagedby the clutches,power is transmittedfrom the mainshaftto the countershaft via the sub-shattto provide@, E, tr. tr and @ position. Electronic Control ControlModule{TCM),sensors,and 4 solenoidvalves.ShiftThe electroniccontrolsystemconsistsof the Transmission ing and lock-upare electronicallycontrolledfor comfortabledriving under all conditions. The TCM is locatedbelow the dashboard,behindthe left side kick panelon the driver's side. Hydraulic Control The valvebodiesincludethe mainvalvebody, secondaryvalvebody, regulatorvalvebody. servobody, and lock-upvalve body throuqh the respectiveseparatorplates. They are bolted on the torque converterhousing. The main valve body containsthe manual valve, 1-2 shift valve, 2-3 shift valve, Clutch PressureCont.ol (CPC)valve, 4th exhaustvalve, relief valve, and oil pump gears. The secondaryvalve body containsthe 4-3 kick-down valve,3-2 kick-down valve,2-3 orifice cont.ol valve, 3-4 shitt valve, orifice control valve. modulatorvalve, and servo control valve The regulatorvalve body containsthe pressureregulatorvalve.lock-upcontrolvalve,torqueconvertercheckvalve,and cooler check valve. The servo bodv containsthe servo valve which is integratedwith the reverseshift fork, throttle valve B, and accumulators. The lock-ugvalve bodv containsthe lock-upshift valve and lock-uptiming B valve.and is boltedon the secondaryvalve body. Fluidfrom the regulatorpassesthrough the manualvalve to the variouscontrol valves. Shitt Control Mochanism Input to the TCM i.om varioussensorslocatedthroughoutthe car determineswhich shift controlsolenoidvalve should be activated. Activatinga shift control solenoidvalve changesmodulatorpressure,causinga shift valve to move. This pressurizes a line to one of the clutches.engagingthat clutch and its correspondinggear. Lock-up Mechanism In @ position.in 2nd, 3rd and 4th, and E positionin 3rd, pressurizedtluid can be drainedfrom the back of the torque converterthroughan oil passage,causingthe lock-uppistonto be held againstthe torque convertercover. As this takes Dlace,the mainshaftrotatesat the samespeedas the enginecrankshatt.Togetherwith hydrauliccontrol,the TCM optimizesthe timing ol the lock-upmechanism. The lock-upvalvescontrolthe rangeof lock-upaccordingto lock-upcontrolsolenoidvalvesA and B, and throttlevalveB When lock-upcontrol solenoidvalves A and B activate,modulatorpressurechanges.Lock-upcontrol solenoidvalves A and B are mountedon the torque converterhousing,and are controlledby the TCM. (cont'd)
14-3
Description (cont'd) Gear Selection The selectorlever has sevenposirions;E PARK,E REVERSE, N NEUTRAL,@ , l 2 n d g e a ra n d [ ] 1 s t g e a r . t h r o u g h3 r d p o s i t i o n sQ
Position PARK l3?]]
1st through 4th positions.E
1st
Description Front wheels locked; parkingpawl engagedwith parkinggear on countershatt.All clutches reteaseo,
[R] REVERSE N
NEUTRAL
Reverse;reverseselectorengagedwith countershaltreversegear and 4th clutch locked. A l l c l u r c h e sr e l e a s e d .
'lst, D+l DRIVE shifts automaticallyto 2nd, 3rd, then 4th, dependingon vehicle Generaldriving;starts off in ('lst through 4th) speed and throttle position.Do'vnshiftsthrough 3rd, 2nd and 1st on decelerationto stop. The lock-upmechanismcomes into operationin 2nd, 3rd and 4th when the transmissionin lDt posrtron. Dgi DRIVE For rapid accelerationat highway speedsand generaldriving; starts off in 1st. shifts automatical(1st through 3rd) ly to 2nd then 3rd, dependingon vehiclespeed and throttle position.Downshiftsthrough lower gearson decelerationto stop. The lock-upmechanismcomes into operationin 3rd. El SECOND
Drivingin 2nd geari stays in 2nd gear, does not shift up and down. For enginebrakingor better traction starting off on loose or slipperysurfece.
L]l FIRST
Drivingin 1st gear; stays in lst gear, does not shilt up. For enginebraking.
Starting is possibleonly in @ and I
Oositionthrough use ot a slide-type,neutral-safetyswitch.
Automatic Tlansaxle{A/T) Gear PositionIndicatol A/T gear pos;tionindicatorin the instrumenlpanel shows what gear has been selectedwithout having look down at the console.
14-4
VALVE BODIES TOROUECONVERTER ASSEMBLY 1ST-HOLDCLUTCH
VEHICLESPEEDSENSORIVSSI
3RD CLUTCH
SUB SHAFT
MAINSHAFT SPEEDSENSOR
SPEEDSENSOR 1ST CLUTCH COUNTERSHAFT
14-5
Description Clutches gears. the transmission The four speedautomatictransmission useshydraulically actuatedclutchesto engageor disengage When clutch pressureis introducedinto the clutch drum, the clutch piston is applied.This pressesthe iriction discs and steel platestogether,lockingthem so they don't slip. Power is then transmittedthrough the engagedclutch pack to jts hub-mountedgear. Likewise,when clutch pressureis bled from the clutch pack. the pistonreleasesthe friction discs and steel plates,and they are {ree to slide past each other while disengaged.This allows the gear to spin independentlyon its shaft, transmitting no power. 1st Clutch The l st clutch engages/disengages 1st gear,and is locatedat the end of the mainshaft,just behindthe right sidecover. The 1st clutch is suppliedclutch pressureby its oil feed pipe within the mainshaft. 1st-holdclutch The 1st-holdclutch engages/disengages 1st-holdor I Fosition,and is locatedat the centerol the sub-shaft.The 1sthold clutch is suppliedclulch pressureby its oil feed pipe within the sub-shait. 2nd Clutch The 2nd clutch engages/disengages 2nd gear, and is locatedat the center of the mainshaft.The 2nd clutch is joined back-to-backto the 4th clutch. The 2nd clutch is suppliedclutch pressurethroughthe mainshaftby a circuitconnected to the regulatorvalve body. 3rd Clutch The 3rd clutchengages/disengages 3rd gea..and is locatedat the end oJthe countershaft,oppositethe right sidecover. The 3rd clutch is suppliedclutch pressureby its oil feed pipe within the countershaft, 4th clurch The 4th clutch engages/disengages 4th gear. as well as reversegear, and is locatedat the center of the mainshaft. The 4th clutch is joined back-to-backto the 2nd clutch. The 4th clutch is suppliedclutch pressureby its oil feed pipe within the mainshalt. One-way Clutch The one-wayclutch is posjtionedbetweenthe parkinggear and 1st gear. with the parkinggear splinedto the countershaft. The 1st gear providesthe outer race, and the parkinggear providesthe inner race surface.The one-way clutch locks up when power is transmittedfrom the mainshaft 1st gear to the countershaftlst ggel _ The 1st clutch and gears remainengagedin the 1st. 2nd. 3rd, and 4th gear rangesin the @, E or E position. However,the one-way clutch disengageswhen the 2nd. 3rd, or 4th clutches/gearsare appliedin the E, lD.l o, E oosttton. This is becausethe increasedrotationalspeedof the gearson the countershaftover-ridethe locking"speed range" of the one-way clutch. Thereafter,the one-way clutch free-wheelswith the lst clutch still engaged. 1ST GEAR COUNTERSHAFT LOCKS
aF
FREE
:>
NOTE: Viewtrom rightsidecoverside.
14-6
MAINSHAFT 4TH GEAR SUB.SHAFT4TH GEAR
MAINSHAFT3RD GEAR
lST,HOLD CLUTCH MAINSHAFT 2ND GEAR
TOROUE CONVERTER
SUB-SHAFT1ST GEAR
2ND CLUTCH
SUB.SHAFT
STARTER NINGGEAR 4TH CLUTCH
MAINSHAFT1ST GEAR
LOCK-UP CLUTCH
1ST CLUTCH DRIVE PLATE MAINSHAFT
ONE-WAY CLUTCH PARKINGGEAR ,IST GEAR COUNTERSHAFTREVERSEGEAR REVERSESELECTOR HU8 REVERSE SELECTOR COUNTERSHAFT4TH GEAR COUNTERSHAFT2ND GEAR COUNTERSHAFT 3RD GEAR FINALDRIVENGEAR 3RD CLUTCH DIFFERENTIAL
14-7
Description Power Flow --.-.-___-t.-t*
REVERSE PARKING 4TH t5t1STGEAR2ND GEAR3RDGEAR GEAR GEAR 3RD HOLD 1ST 2ND VERTER CLUTCH CLUTCH CLUTCH CLUTCH GEAR CLUTCH
TOROUE
coN-
E
tr
N
1ST
E
2ND 3RD 4TH 1ST
E
2ND 3RD
tr tr
o o o o o
o o o
o o o o
X
X
X
X
X X
X
X
o
o
o
X
x
X
x
X
X
X
X
X
X
X
X
X
o 'o
x
X
X
X
X
X
o
X X
X X
x X
.o
-o o
-o -o
X
.o
o
o
X
x
X
X
X
X
X
o
X
X
X
X
X
o
o
X
X X
X
X
X
X
X
X
o
X
X
X
X
x
o
X
x
X
X
X
X
X
X
X
X
X
X
X
X
X
o X
': Q: Operates,X: Doesn'toperate, Althoughthe 1st clutch engages,drivingpowe. is not transmittedas the one-way clutch sliDs.
14-8
@ Position pressure to the countershaJt. Hydraulic is not appliedto the clutches,Poweris not transmitted @ Position Hydraulicpressureis not sppliedto the clutches.Poweris not transmittedto the countetshaft. the parkinggear. is lockedby the parkingpawl interlocking The countersha{t
TOROUECONVERTER
REVERSESELECTOR HUB PARKINGGEAR REVERSESELECTOR
REVERSEGEAR
SERVOVALVE/ SHIFTFORKSHAFT
14-9
Description Power Flow lcont'dl Lll Position Acceloration In f
position,hydraulicpressureis appliedto the lst clutch and lst-hold clutch.
The power flow when acceleratingis as tollows: 1.
Hydraulicpressureis appliedto the 1st clutch on the mainshaltand power is transmittedvia the lst clutch to the mainshaft1st gear.
2.
Hydraulicpressureis also appliedto the 1st-holdclutch on the sub-shatt.Powertransmittedto the mainshaft1sl gear is conveyedvia the countershaft1st gearto the one-wayclutch. and via the sub-shaft1st gearto the l st-hold clutch. The one-way clutch is used to drive the countershaft.and the 1st-holdclutch drivesthe countershaftvia the 4th gears.
3.
Power is transmittedto the finai drive gear and drivesthe final d.iven gear, SUB.SHAFT 'IST GEAR SUB-SHAFT4TH GEAR lST-HOLD CLUTCH
SUB-SHAFT
MAINSHAFT1ST GEAR
1ST CLUTCH
COUNTERSHAFT
ONE-WAY CLUTCH
PARKINGGEAR
,IST GEAR
FINAL DRIVENGEAR
14-10
L!_jPosition Deceleration The power tlow when deceleratingis as follows; 1.
Rollingresistancelrom the road surfacegoesthroughthe tront wheelsto the final drive gear,then to the sub-shaft 1st gear via the 4th gear, and lst-hold clutch which is appliedduring deceleration.
2.
The one-way clutch becomesfree at this time becausetorque reverses.
3.
The counterforceconveyedto the countershaft4th gear turns the sub-shaft4th gear via the mainshaft4th gear. At this time, sincehydraulicpressureis also appliedto the 1st clutch, counterfo.ceis alsotransmittedto the mainshaft. As a result, enginebrakingcan be obtainedwith lst gea.-
CLUTCH
TOROUECONVENTER
SUB-SHAFT 4TH GEAR
SUB-SHAFT1ST GEAR
SUB'STIAFT
lST CLUTCH
MAINSHAFT
COUNTERSHAFT
FINAL DRIVE REVEFSESELECTORHUB
REVERSESELECTOR
4TI1 GEAB
(cont'dl
14-11
Description Power Flow (cont'd) Ll Position @ Positionis providedto drive only 2nd speed. 1.
Hydraulicpressureis appliedto the 2nd clutch on the mainshattand power is transmittedvia the 2nd clutch to the mainshaft2nd gear.
2.
Powertransmittedto the mainshalt2nd gearis conveyedvia the countershaft2nd gear,and drivesthe countersha{t.
3.
Power is transmittedto the final drive gear and drives the final driven gear. NOTE: Hydraulicpressureis also appliedto the lst clutch, but since the rotationspeedof the 2nd gear exceedsthat of 1st gear, power from 1st gear is cut off at the one-way clutch. TOROUECONVERTER
2ND CLUTCH
MAINSHAFT
COUNTERSHAFT FINAL DBIVE
2ND GEAR
FINALDRIVENGEAR
14-12
In [Q! or l!31 position.the optimumgear is automaticallyselectedfrom 1st, 2nd, 3rd and 4th speeds,accordingto conditionssuch as the balancebetween throttle opening(engineload) and vehiclespeed. D! or lE.l Position, lst speed 1. Hydraulicpressureis appliedto the lst clutch. which rotatestogether with the mainshaft,and the mainshaftlst gear rorares. 2.
Power is transmittedto the countershaft1st gear, and drivesthe countershaftvia the one-way clutch.
3.
Power is transmittedto the final drive gear and drives the final driven gear. NOTE: In lDil or [Dl]l position,hydraulicpressureis not appliedto the 1st-holdclutch. TOROUECONVERTER
1ST CLUTCH
MAINSHAFT
COUNTERSHAFT
FINALDRIVEGEAR
FINALDRIVENGEAR
(cont'd)
14-13
Description PowerFlow (cont'd) JD.l or lD"l Position, 2nd speed 1.
Hydraulicpressureis appliedto the 2nd clutch, which rotatestogetherwith the mainshaft,and the mainshatt2nd gear rotates.
2.
Power is transmittedto the countershaft2nd gear, and drivesthe countershaft.
3.
Power is transmittedto the tinal drive gear and drives the final driven gear. NOTE: In @ or @ position,2nd speed,hydraulicpressureis also appliedto the lst clutch. but sincethe rotationspeed of 2nd gear exceedsthat of 1st gear. power trom lst gear is cut off at the one-way clutch. 2ND CLUTCH
TOROUECONVERTER
MAINSHAFT
COUNTERSHAFT FINAL DRIVE GEAR
FINAL DRIVEN GEAR
14-14
I o.l or 16ll Position, 31d sp€od 1.
Hydraulicpressureis appliedto the 3rd clutch.Powerfrom the mainshatt3rd gearis transmittedto the countershaft 3rd gear,
2.
Power is transmittedto the tinal drive geat and drives the final driven gear. NOTE: In ]Dil or lDJl position.3rd speed.hydraulicpressureis also appliedto the Ist clutch, but sincethe rotationspeed of 3rd gear exceedsthat of 1st gear, power trom lst gear is cut ofJ at the one-way clutch,
TOROUECONVERTER MAINSHAFT 3RD GEAR
MAINSHAFT
COUNTERSHAFT FINAL DRIVE GEAR
3RD CLUTCH
FINAL DBIVEN GEAR
14-15
Description Power Flow (cont'dl E
Poshion. 4th sp6od
1.
Hydraulic pressure is applied to the 4th clutch, which rotates together with the mainshatt, and th€ mainshaft 4th gear rotates.
2.
Power is transmifted to the countershaft 4th gear, and drives the countershaj-t.
3.
Power is transmittedto the final drive gear and drivesthe final driven gear. NOTE: In @ Oosition,4th speed, hydraulic pressure is also applied to the 1st clutch, but since the rotation spe€d of 4th gear exceedsthat oJ 1st gear, power from 1st gear is cut off at the one-way clutch.
TOROUECONVERTEB
MAINSHAFT 4TH GEAR
4TH CLUTCH
MAII{SHAFT
COUI{TERSHAFT
REVERSE SELECTOR HUB
REVERSESELECTOR
14-16
llj
Po.ltbn
1.
Hydraulic pressure is swilched by the manual valve to the se.vo v8lve, which moves the reverse shilt tork to the r€verseposition. The reverseshiJt fork engageswith the reverseselector, reverseselsctor hub,and the countershaft raverss g€ar.
2.
Hydraulic pr6ssure is also appli€d to the 4th clutch. Power is transmifted from the mainshaft reverse gear via the revetse idler g6ar to the countershaft reverse gear.
3.
Rotation dirsction ol the countershsft reverse gear is changed via the .everse idler gear.
4.
Powef b transmitted to the linal drive gear and drives the final driven gear.
TOROUECONVEBTER 4TH CLUTCH
MAI SHAFTREVERSE GEAR
COUNTERSHAFf
FII{AL DRIVEGEAR
REVERSE SELECTOR HUB REVEFSESELECTOR
COUIITERSHAFT REVERSE GEAR
14-17
Description ElectronicControlSystem Electronic Control System The electroniccontrolsystemconsistsof the TransmissionControlModule(TCM),sensors.and 4 solenoidvalves.Shifting and lock-upare elect.onicallycontrolledfor comfortabledriving under all conditions. The TCM is locatedbelow the dashboard,behindthe left side kick panel on the driver's side.
Lock-up Control Solonoid Valvo A
14-18
Lock-up Control From sensorinput signals,the TCM determineswhether to turn the lock-upON or OFF and activateslock-upcontrol solenoidvalve A and/or B accordingly. The combinationof driving siqnalsto lock-upcontrol solenoidvalves A and B is shown in the table below.
Lock-upcontrol Solenoidvalve \
B Lock-upcondition
\
Lock-upOFF
OFF
OFF
Lock-up,slight
ON
OFF
Lock-up.halt
ON
ON
Lock-up.full
ON
ON
Lock-up during deceleration
ON
Duty operation OFF-ON
Shifl Conrrol The TCM instantaneously determineswhich gear shouldbe selectedby varioussignalssent trom sensors.and actuates the shift controlsolenoidvalvesA and B controlshitting.Also. a GradeLogicControlSystemhas beenadoptedto control shifting in E] positionwhile the vehicleis ascendingor descendinga slope, or reducingspeed.
\
Shift control solenoidvalve ------\ t"*b" ,t"-l
E,E E
a tr l-Rl
B
('lst) (2ndl
OFF
ON
ON
ON
(3rd)
ON
OFF
(4th)
OFF
OFF
(2nd)
ON
ON
(lst)
ON
OFF
{Reverse)
ON
OFF
(cont'd)
14-19
Description ElectronicControl System (cont'd) .
GRADE LOGIC CONTROLSYSTEM
How it works: The TCM comparesactual drivingconditionswith drivingconditionsmemorizedin the TCM. basedon the input trom the vehiclespeed sensor,throttle positionsensor,enginecoolanttemperaturesensor,brake switch signaland select lever positionsignal,to control shifting while a vehicleis ascendingor descendinga slope. or reducingspeed.
SIGNALSDETECTED
Dliving Resistance
Judgement of Controlling Area
Engine Coolant TemDerature Sensor
. Flat road mode . Asconding mode (Fuzzylogic) . Gradual Ascending mode . Steep Ascending
14-20
. Ascending Contlol When the TCM determinesthat the vehicleis climbinga hill in @ position,the system extendsthe engagementarea Irom frequenrlyshittingbetween3rd and 4th gears,so the vehiclecan run smooth of 3rd gearto preventthe transmission and have more power when needed. NOTE: Shift schedulesbetween 3rd and 4th gear are stored in the TCM to enablethe transmissionto automatically selectthe most suitablegear accordingto the magnitudeof a gradientby Fuzzylogic. . Descending Control When the TCM determinesthat the vehicleis going down a hill in @ position.the shift-upspeedfrom 3rd to 4th gear when the throttle is closedbecomestaster than the set speedfor tlat road drivingto widen the 3rd gear drivingarea. This, in combinationwith engine brake from the decelerationlock-up, achievessmooth driving when the vehicle is descending. Thereare two ascendingmodeswith different3rd gear driving areasaccordingto the magnitudeof a gradientstoredin theTCM. When the vehicleis in 4th gear, and you are deceleratingon a gradualhill, or when you are applyingthe brakeson a steephill,the transmissionwill downshittto 3rd gear.When you acceleratethe transmissionwill then returnto 4th gear.
F
0
Vohicle SDood
. DecelerationControl When the vehiclegoes around a corner,and needsto deceleratefirst and then accelerate,the TCM sets the data for decelerationcontrolto reducethe numberof times the transmissionshiftsto obtain smooth driving.When the vehicle is decelerating from speedsabove27 mph (43 km/h).the TCM shiftsthe transmissionfrom 4thto 3rd earlierthan normal to cope with upcomingacceleration to maintainsmooth driving. NOTE: FuzzyLogic:Fuzzylogic is a from at artificialintelligencethat lets computersrespondto changingconditionsmuch like a human mind would.
14-21
Description ElectronicControl System {cont'dl
*t-l
T
777 TH SCI
sHtfTc0mRoL
scs ECM
SHFTCOI{rFOL VALVEB SOLINOIO ACCL AFSB
NEP
LG1 LG2
TOCK-UPCONTROL SOLENOIOVALVE A
SPEEO SENSOF COUNTE8SHAFI SPEEO SENSOR L_______.1 tGcotL
f-r,'__l I Jll6 i
A/T CEANPOSITION INDICATOR
14-22
LOC(- UPCONTROL SOLENOIO VALVEB
Hydraulic Control The valvebodiesincludethe main valvebody, secondaryvalvebody, regulatorvalvebody, servobody and lock-upvalve body. The oil pump is driven by splinesbehindthe torque converterwhich is attachedto the engine.Oil flows th.ough the regulatorvalve to maintainspecifiedpressurethrough the main valve body to the manualvalve, directingpressureto each of the clutches,
SHIFT CONTROLSOLEIIOID VALVE ASSEMBLY
RTGHTSIDECOVER
LOCK.UPVALVEBODY
VALVEBODY
V REGULATOR BODY
4<.__i :
)o.-
OIL PUMP GEARS SOLENOIDVALVE ASSEMBLY
14-23
Description HydraulicControl(cont'dl Ragularol Valve Body The .egulator valve body is located on the main valve body. The regulator valve body consists of th€ regulator valva, toroue converter check valve, cooler check valve, and lock-up contlol valve.
VALVE REGULATOR VALVE REGULATOR BODY
COOLERCHECKVALVE
LOCT.UPCONTROI. VALVE
TONOUECOI{VERTEB CHECKVALVE
Lock-up Valvo Body The lock-up valve body with the lock-up shilt valve and lock-up timing B valve is located on th€ regulator volvs body.
LOCK.UPSHIFT VALVE
TIMITG B VALVE
14-24
Rcgulator Valve The r€gulator valve maintains a constant hydraulic pressure from the oil pump to the hydraulic control system, whil€ alEofurnishingoil to the lubricatingsystem and torque convener. Oil flows through B and B'. The oil which entersthrough B flows thfough the valve orificeto A, pushingthe regulator valve to the right. Acco.dingto the level of hydraulicpressurethrough B, the positionof the valve changes,and the amount of the oil thlough D from B'thus changes.This operationis continued.thus maintainingthe line pressure. IEI{GINE]IIOT RUNNINGI
{ENGINERUNNING)
From OIL PUMP
Siator Reaction Hydtaulic PressureControl Hydraulicpressureincrease,accordingto torque, is performedby the regulatorvslve using stator torque reaction.The stator shaft is splinedto the stator and its a.m end contacts the fegulatorspring cap. When the car is acceleratingor climbing (Torque Convener Range).stator torque reaction acts on the stator shalt and the stator shaft arm pushes the rsgulator spring cap in this - direction in proportionto the reaction.The spring compressesand the regulatorvalve moves to increasethe regulatedcontrol pressureor line pressure.Line pressureis maximum when the stator reactionis maximum.
TOR VALVE
STATOR SHAFT
STATOR SHAFT ARM
(cont'd)
14-25
Description Hydraulic Control (cont'dl Main Valvo Body The manualvalve, 1-2 shift valve, 2-3 shift valve. 4th exhaustvalve. CPC valve, and relief vatve are all assembledin the main valve body, The primaryfunctionof this valve body is switchingoil passageson and off and controllingthe hydraulicpressuregotng to the hydrauliccontrol system. CPC VALVE
4TH EXHAUSTVALVE
RELIEFVALVE
MANUAL VALVE MAIN VALVE BODY 1.2 SHIFT VALVE
S€condary Vslve Body The secondaryvalve body is locatedon the main valve body. The 3-2 kick-downvalve,4-3 kick-downvalve. 2-3 orifice controlvalve.orificecontrolvalve,3-4 shift valve,modulatorvalve,and servocontrolvalveare assembledin the seconda.y valve body. ORIFICECOIITROL VALVE
2-3 ORIFICECONTBOLVALVE 3.4 SHIFT VALVE
VALVE BODY MOOULA
14-26
COITTROLVALVE
S6rvo Body The servo bodv is locatedon the secondaryvalve body. The servovalveis integratedwith the shiit fork shatt, throttlevalve B. and accumulatorpistons,which are all assembled in the servo bodv.
SERVOVALVE/ SHIFTFORKSHAFT
THROTTLEVALVE B
SERVOBODY THROTTLELONG VALVE
Accumulator Pislons piston The accumulatorpistonsare assembledin the servo body and right side cover. The l st-holdclutch accumulator pistons in lhe servo body. assembled are is in the right side cover, and the 1st, 2nd 3rd, and 4th accumulator 1ST-HOLDACCUMULATOR
RIGHTSIDECOVER
4TH ACCUMULATOR
IST ACCUMUI-ATOR 2ND ACCUMULATORPISTON
3RD ACCUMULATORPISTON
14-27
Description HydraulicFlow Genelal Chart ol Hydraulic Pressure
Oil Pump - RegulatorValve -
Line Pressure Torque ConverterPressure LubricationPressure
Distribution ot Hydraulic Pressure . RegulatorValve
- , . Ltne rressure Torque ConverterPressure ] LubricationPressure L
. M a n u a lV a l v e
To Select Line Pressure
. ModulatorValve
ModulatorPressure
. 1-2ShiltValve l . 2-3 Shitt Valve . 3 4 Shift Vlave ] . Throttle Valve B NO.
Clutch Pressure
Throttle B Pressure
D E S C R I P T I OONF P R E S S U R EN O .
I
LINE
6C
2
LINE
6D
3
LINE
9
3'
LINE
10
3"
LINE
4
LINE
D E S C R I P T I OONF P R E S S U R EN O . MODULATOR CONTROL SOLENOID VATVE AI ITOCK-UP MODULATOR (IOCX.UP CONTROT SOTENOID VALVE B)
D E S C R I P T I OONF P R E S S U R E
55
THROTTLEB
56
THROTTLEB
LINE
57
THROTTLEB
l ST CLUTCH
58
THROTTLEB
1ST-HOLD CLUTCH
90
T O R O U EC O N V E R T E R
It)
l ST.HOLDCLUTCH
91
TOROUECONVERTER
LINE
18
LINE
92
T O R O U EC O N V E R T E R
5
LINE
20
2ND CLUTCH
93
O I LC O O L E R
5'
LINE
21
2ND CLUTCH
94
TOROUECONVERTER
5"
LIN E
25
LINE
95
LUBRICATION
6
MODULATOR
30
3RD CLUTCH
96
TOROUECONVERTER
6'
MODULATOR
31
3RD CLUTCH
97
TOROUECONVERTER
6A
MODULATOR (SHIFT CONTROL SOTENOID VALVE A MODULATOR (SHIFT CONTROL VALVE SOLENOID B
40
4TH CLUTCH
99
SUCTION
41
4TH CLUTCH
6B
14-28
BLEED
E Position (99) and disAs the engineturns, the oil pump also startsto operate.Automatictransmissionfluid (ATF)is drawn from ( chargedinto (1). Then,ATF pressureis controlledby the regulatorvalve and becomesline pressure 1). The torqueconverter inlet pressure(92) enters (94) of torque converterthrough the orifice and dischargesinto {90}. The torque convertercheck valve preventsthe torque converterpressurefrom rising' Under this condition,the hydraulicpressureis not appliedto the clutches. NOTE: . When used, "left" or "right" indicatesdirectionon the llowchart . SOL-@: Shift Control SolenoidValve A ' SOL{D:Shift ControlSolenoidValve B . SOL@: Lock-upControl SolenoidValve A . SOL-@: Lock-upControl SolenoidValve B
(cont'd)
14-29
Description HydraulicFlow (cont'd) L1l Position The line pressure{1) becomesline pressure(4) at the manualvalve and passesto the lst clutch and 1st accumulator. Then line pressure(41flows through the 1st-holdclutch and lst-hold accumulator. Fluid flows by way of: - LinePressure{4} - 1-2 Shitt Valve * 2-3 Shitt Valve - 3rd Clutch Pressure{31) - 3-4 Shift Valve - 4th Clutch Pressure(41) - ManualValve - lst-hold Clutch Pressure{15) - 1st-holdClutch The modulatorpressure(6) is suppliedto the 1-2 and 2-3 shift valves. The line pressure(1) also flows to throttle valve B. NOTE: . When used. "left" or "right" indicatesdirectionon the flowchart. . SOL-@: Shift Control SolenoidValve A . SOL@: Shift Control SolenoidValve B . SOL-@: Lock-upControlSolenoidValve A . SOL-@: Lock-upControl SolenoidValve B
14-30
f4 Position ihe line pressure(11becomesline pressure(41as it passesthrough the manualvalve.lt then goes through line l2O) to the 2nd clutch via the 1-2 and 2-3 shift valves.Also, line pressure(1) goes to the modulatorvalve throughthe filter and becomesthe modulatorpressure(6). Modulatorpressure(6) is not suppliedto the 1-2, 2-3 and 3-4 shift valves becausethe shitt control solenoidvalves A and B are turned on by the TCM. NOTE: . When used, "left" or "right" indicatesdirectionon the flowchart . SOL-@: Shift ControlSolenoidValve A . SOL-@: Shilt Control SolenoidValve B . SOL-O: Lock-upControlSolenoidValve A . SOt -@ : Lock-upControl SolenoidValve B
(cont'd)
14-31
Description HydraulicFlow (cont'dl @
or @
Position
1.
lst Spe€d The flow of fluid throuth the torque convener circuit is the same as in S Oosition. The line pressure( 1) becomesline pressure(4) and it becomesthe 1st clutch pressure(1O).The I st ctutchpressure is appliedto the lst clutch and l st accumulator;consequently,the vehiclewill move as the enginepower is transmitted. The line pressure(1) becomesthe modulatorpressure(6) by the modulatorvalve and travelsto 1-2 and 3-4 shift valves. The 1-2 shift valve is movedto the right sidebecausethe shilt controlsolenoidvalveA is turnedoff and B is turned on by the TCM. This valve stops 2nd clutch pressureand power is not transmittedto the 2nd clutcn. Line pressu.e{4) also tlows to the seryo valve and line pressure(1} also flows to throttle valve B. NOTE: . When used, "left" or "right" indicatesdirectionon the flowchart. . SOL-@: Shitt ControlSolenoidValve A . SOL-@:Shift ControlSolenoidValve B . SOL-O: Lock-upControlSolenoidValve A . SOL-@: Lock-upControlSolenoidValve B
14-32
I
2nd Sgeed prescribed The llow of fluid up the 1-2 shift valve is the same as in 1st speed.As the speedof the car reachesthe to the left is moved valve the 1-2 shift value,the solenoidvalve A is tulned on by meansot the TCM. As a result, is engaged' 2nd clutch and uncoversthe port leadingto the 2nd clutch; the Fluidflows by way of: - Line Dressurel4l -
'l-2
Shift Valve - 2-3 Shitt Valve - 2nd Clutch Pressure(2'1) * 2nd Clutch
The hvdraulicpressurealsoflows to the 1st clutch,However,no power is transmittedbecauseof the one-wayclutch. NOTE: . When used, "lett" or "right" indicatesdirectionon the flowchart . SOL-@: Shift Control SolenoidValve A . SOL@: Shift ControlSolenoidValve B . SOL-@: Lock-upControl SolenoidValve A . SOL-@: Lock-upControl SolenoidValve B
{cont'd)
14-33
Description HydraulicFlow (cont'd) 3rd Speed The tlow of fluid up to the 1-2 and 2 3 shift valves is the same as in 2nd speed.As the speedof the car reaches the prescribedvalue,the shift controlsolenoidvalve B is turned off {shilt controlsolenoidvalveA remainson). The 2-3 shift valve is then movedto the left, uncoveringthe oil port leadingto the 3rd clutch. Sincethe 3-4 shitt valve is moved to the right to cover the oil port to the 4th clutch, the 3rd clutch is turned on. Fluid tlows by way of: - Line pressure l4l - 1-2 shift valve - 23 Shift Valve * (not controlled) 3rd Clutch Pressure(3O) - 3rd Clutch
3rd ctutch pressure(31) -
3-4 shift valve
The hydraulicpressurealsoflows to the l st clutch. However,no power is transmittedbecauseof the one-wayclutch as in the 2nd speed. NOTE: . When used, "lett" o( " tight" indicatesdirectionon the flowcharl. . SOL-@: Shift ControlSolenoidValve A . SOL-@:Shift ControlSolenoidValve B . SOL-O: Lock-upControlSolenoidValve A . SOL-@: Lock-upControlSolenoidValve B
14-34
Lq4 Position 4.
4th Spe6d The flow of tluid up to the 1-2, 2-3 and 3-4 shift valvesis the sameas in 3rd speed.As the speedof the car reaches the prescribedvalue, the shift control solenoidvalve A is turned oJt (shift control solenoidvalve B remainsoff). As this takes place,3-4 shift valve is moved to the left and uncoversthe oil port leadingto the 4th clutch. Since the 1-2 and 2-3 shift valvesare kept on the left side,the fluid flows throughthe 4th clutch;the power is transmitted through the 4th clutch. Fluid flows by way of: - Line Pressurel4l - 'l'2 Shift Valve -t 2-3 Shitt Valve - 3rd Clutch Pressure(31) 4th Clutch Pressure{4O) - 4th Clutch 4th Clutch pressure(41) - ManualValve The hvdraulicpressurealsotlows to the as in 2nd and 3rd soeed.
3-4 Shift Valve
'1st clutch.However,no power is transmittedbecauseof the one-wayclutch
NOTE: . When used, "left" or "right" indicatesdirectionon the flowchan. . SOL-@: Shitt Control SolenoidValve A . SOL-@: Shift Control SolenoidValve B . SOL-O: Lock-upControlSolenoidValve A . SOL-@: Lock-upConttol SolenoidValve B
(cont'dl
14-35
Description HydraulicFlow (cont'd) LEI Position The flow ot fluid throughthe torqueconvenercircuitis the same as in S position.The tluid ( 1) trom the oil pump flows through the manualvalve and becomesline pressure(31.lt then flows through the 1-2 shift valve to the servo varve via the servo control valve, causingthe shift tork shatt to be moved in the reversedirection. Underthis condition,the shift control solenoidvalve A is turned on whereasthe valve B is turned ofJ as in 3rd speed in [Dil or lDs]lposition.As a result,the 1-2 shift valve is also moved to the left. The ftuid (3'] will ftow throughthe servo valve and manualvalve to the 4th clutch; power is transmittedthrough the 4th clutch. ReverseInhibitorControl When the @ positionis selectedwhile the vehicleis movingforward at a speedover 6 mph ( 1Okm/h).the TCM outputs 1st signal (A: OFF, B: ON), and the 1-2 shift valve is moved to the right side. The line pressure{3) is interceptedbv the 1-2 shift valve; consequently,power is not transmittedas the 4th clutch and servo valve are not oDerareo. NOTE: . When used, "lefl" ot "tight" indicatesdirectionon the flowchart. . SOL-@: Shift Control SolenoidValve A . SOL€: Shift Control SolenoidValve B . SOL€: Lock-upControlSolenoidVatve A . SOL-@: Lock-upControlSotenoidVatve B
14-36
Lll Position The flow of fluid throughthe torque convertercircuit is the same as in I position.The line pressure( l ) becomesline pressure(3) as it passesthroughthe manualvalve.Then line pressure(3) flows throughthe 1-2 shift valveto the servo valve via the servo control valve. causingthe shift fork shaft to be moved to the reversepositionas in E position. However.the hydraulicpressureis not suppliedto the clutches.Power is not transmitted. NOTE: . When used, "left" or "right" indicatesdirectionon the flowchart. . SOL-@: Shitt ControlSolenoidValve A . SOL-@: Shift Control SolenoidValve B . SOL-O: Lock-upControlSolenoidValve A . SOL-O: Lock-upControl SolenoidValve B
14-37
Description Lock-up System Lock-up Clutch 1. Operation(clutch on) With the lock-upclutch on, the oil in the chamberbetweenthe torque convenercover and lock-uppiston is discharged, and the converteroil exerts pressurethrough the piston againstthe convertercover. As a result,the converterturbine is locked on the convertercover firmly. The etfect is to bypassthe converter,thereby placingthe car in direct drive. tpowefJlo-wl
LOCK-UP TURBINE
The power tlows by way of: Engine I Drive plate I Torque convener cover I Lock-uppiston I Damperspring I Turbine t Mainshaft
TOROUECONVERTER COVER
,
\
To oil cooler
OUTLET
t
2. Operation(clutch off) With the lock-upclutch off, the oil tlows in the reverseof CLUTCHON. As a result,the lock-uppiston is moved away from the convertercover; that is, the torque converterlock-upis released.
Fowtttowl Engine I Drive plate I Torque convertercover Pump I Turbine I Mainshaft
14-38
TURBINE
fluid is drainedfrom the back of the torqueconIn E positionin 2nd, 3rd and 4th, and @ positionin 3rd, pressurized verter through an oil passage,causingthe lock-uppiston to be held againstthe torque convertercover. As this takes place,the mainshaftrotatesat the same speedas the enginecrankshaft.Togetherwith hydrauliccontrol,the TCM optimizedthe timing ot the lock-upsystem. Undercertainconditions,the lock-upclutch is appliedduringdeceleration,in 3rd and 4th sDeed. The lock-upsystemcontrolsthe rangeof lock-upaccordingto lock-upcontrolsolenoidvalvesA and B, and throttlevalveB. When lock-upcontrol solenoidvalves A and B activate.modulatorpressurechanges.Lock-upcontrol solenoidvalves A and B are mountedon the torque converterhousing,and are controlledby the TCM. NOTE: When used, "left" or " tight" indicatesdirectionon the tlowchart.
\ LOCK IJP COIITBOL
Solenoid valve L""f."p
B
"."aiti""\
Lock-upOFF
OFF
OFF
Lock-up,slight
ON
OFF
Lock-up,half
ON
ON
Lock-up.full
ON
ON
ON
Duty operation O F F- O N
Lock-up during deceleration
LOCI( UP TIMII{G B VAIVE
ott coot€R
{cont'd)
14-39
Description Lock-upSystem(cont'dl No Lock-uo The pressurizedfluid regulatedby the modulatorworks on both ends of the lock-upshift valve and on the left side ot the lock-upcontrolvalve.Underthis condition,the pressu.esworking on both ends ol the lock-upshitt valve ate equal. the shift valve is moved to the right side by the tensionof the valve springalone.The tluid from the oil pump will flow through the left side of the lock-upclutch to the torque converter;i,e., the lock-upclutch is in OFF condition. NOTE: When used.
"left" or "right" indicatesdirectionon the flowchart.
LOCK.UPCONTRO!
<-
L O C K . U PT I M I G A V A L V E
14-40
MOOULATOi PBfSSURE
{ Partial Lock-up Lock-upControlSolenoidValve A: ON Lock-upControl SolenoidValve B: OFF The TCM switchesthe solenoidvalve A on to releasethe modulatorpressurein the left cavity ol the lock-upshift vatve. The modulatorpressurein the right cavity of the lock-upshift valve overcomesthe springforce, thus the lockiup shifi valve is moved to the left side. The modulatorpressureis separatedto the two passages: F1: Torque ConverterInner Pressure:enters into right side-toengagelock-upclutch F2: Torque ConvenerBack Pressure:enters into left side-todisenqagelock-upclutch The back pressure(F2) is regulatedby the lock-upcontrol valve whereasthe positionof the lock-uptiming B valve is determined by the throttle B pressure, tension of the valve spring and pressure regulated by the modulator, Also the positionof the lock-upcontrolvalveis determindedby the back pressureof the lock-upcontrolvalveand torqueconvener pressureregulatedby the check valve.With the lock-upcont.ol solenoidvalve B kept oft, the modulatorp.essu.eis maintainedin the left end of the lock-upcontrolvalve;in other words, the lock-upcontrolvalveis moved slightlyto the left side. This slight movementof the lock-upconlrol valve causesthe back pressureto be loweredslightly.resulting in panial lock-up. NOTE: When used. "left" or "right" indicatesdirectionon the flowchart. LOCK.UPCOIIIROL SO!ENO|o VALVE A
LOCK UP COIITROI SOTENOIDVALVE B
<-
MODUI.AIOi
PAESSUFE
LOCK-UPIIMII{G B VATV€
otl coolEn
7
l.ont'al
14-41
Description Lock-upSystem (cont'dl Halt Lock-up Lock up Control SolenoidValve A: ON Lock-upControl SolenoidValve B: ON The modulatorpressureis releasedby the solenoidvalve B, causingthe modulatorpressurein the lett cavity of the lockuD control valve to lower. Also the modulatorpressurein the left cavity of the lock-uptiming B valve is low. Howeverthe throttle B pressureis still low at this time; consequently.the lock-uptiming B valve is kept on the right side by the spring force. With the lock-upcontrolsolenoidvalve B turnedon, the lock-upcont.ol valve is moved somewhatto the Ieft side.caus ing the back pressure(F2)to lower. This allows a greateramount of the fluid (F'1)to work on the lock,up clutch so as to engagethe clutch. The back pressure(F2) which still exists preventsthe clutch from engagingtully NOTE: When used, "left" or "right" indicatesdirectionon the flowcnarr.
LOCX UP CONTROL
r.oct( uP corlTRol sorENoto vatvE a
<-_
LOCK UP IIMiI{G B VAI-VE
orr coorER
14-42
MOOULATORPRESSTJBE
Full Lock-uo Lock-upControlSolenoidValve B: ON Lock-upControl SolenoidValve A: ON When the vehiclespeedfufther increases,the throttle B pressureis increasedin accordancewith the throttle opening. The lock-uptiming B valve overcomesthe spring force and moves to the left side. Also, this valve closesthe oil port leadingto the torque convertercheck valve. Underthis condition,the throttle B pressureworking on the right end of the lock-upcontrolvalve becomesgreaterthan that on the left end (modulatorpressurein the lelt end hasalreadybeenreleasedby the solenoidvalveB); i.e.,the lock-up control valve is moved to the left. As this happens,the torque convener back pressureis releasedfully, causingthe lock-upclutch to be engagedfully. "right" indicatesdirectionon the tlowchart. NOTE: When used, "left" or
LOC( UP COi{TAO!
toc( uP coNtnol SOIENOID VAIVEB
THRO]TIE A PFESSURE
PNESSUFE
FEGUTATOFVAIVE LOCK-UPTIMIIIG B VALVE
orl cootER
(cont'd)
14-43
Description Lock-up System (cont'dl Dacslsration Lock-uD Lock-upcontrol solenoid valve A: oN Lock-upcontrol solenoid valve B: Duty operation {oN - oFFl The TCM switchessolenoidvalveB on and off rapidlyundercertainconditions.The slightlock-upand half lock-upregions are maintainedso as to lock the torque converterproperly. NOTE; When used, "left" or "right" indjcatesdirectionon the flowcnarr.
LOCK-I.PCOt{lFOt
LOCI(,UPTtMt G B VAIVE
14-44i
loc(,uP cot{TRoL SOIENOID VATVEB
Component Location
,/s\ )/
{ 7 v
A0t
AUTOMATIC TRANSAXLE IA/TI GEAR POSITIONSWITCH
COUNTERSHAFT SPEEDSEf{SOR
VEHICLESPEED SENSOR{VSSI MAINSHAFTSPEED THROTTLEPOSITION(TP} SENSOR SENSOR
at
, (ECTI ENGINECOOLANTTEMPERATURE SENSOR
)''
14-45
Circuit Diagram
UNDERHOODFUSE/RELAY 80X
No.411100A)
(7.5A) No.32
tGNtTtoN c0 -
V
II
I
BLU
423 424 Ar0
A20 D2 TRANSMISSION CONTROL MOOUI.E {TCM) A19 A18 A21
A8
AN GEAR POSITION INDICATOR
BLK
T G201
14-46
I
|
A'
*---i.
A17
A15
A13
V
A-"
t2
t,,,:----<)
A/'I GEARPOSIIION
swtrcH
8LK
{ G201
Alt
l1
. VEHICI.E A/C SPEED COMPRESSOR SENSOR . SPEEOOMETER CLUTCH REI.AY
SERVICE CHECK CONNECTOR
/8tK
'HBOTfLE ENE'NE Postto^l coolAlvr SENSOR TEMPERA. TURE SENSOR
D 9 0 1 3 0 1 1D l 6 D 3
D6
D7
D5 A25
A26
TMNSMISSION CONTROL MODULE {TCM}
Dls
019
Dl2
A5
A3
I
I.OCK'UPCONTROL SHIFTCONTROL VATVE SOLENOIO VALVE SOLENOID
COUNTERSHAFT SPEEO SENSOR
A3 A5
A9
A6 A8 A 1 (
A1:
MAINSHAFI SPEED SENSOR
421
,/1,/1,/A 1 t TCMT6rmin6lLocations
14-47
Troubleshooting Procedures when the TcM sensesan abnormalityin the input or output systems.the E]indicator light in the gaugoassemblywill blink. when the service check Connector{locatedunder the dash on the passengerside} is connectedwith the specaat tool as shown, the E] indicatorlight will blink the DiagnosticTroubleiode {DTCI when the ignitionswitch is turned on. When the lDil indicator light has been reported on, connect the service check connector with the special tool. Then turn on the ignition switch and observethe @ indicatorlight. GAUGEASSEMSLY DAI'A LI]TK
(3P) cor{r{EcToR
)
't
NOTE: Do not atlach jumpe.wire.
scs sHoRTCO[{]{ECTOR oTPAZ-OOl0too
codes 1 through I are indicatedby individualshort blinks,codes 1o through 15 are indicatedby a series tong of and shon blinks.one long blinkequals l0 short blinks.Add the long and short blinkstogetherto dete;minsthe cod€. Aft6r determiningthe code, refer to the erectricarsystem symptom-to-componentchart on pages 14-5o and 51. ahon
f"l Sc. DTCI
So. DTC2
S.. DTC14
some PGM-FIproblemswill also make the @ indicatorlight come on. After repairingthe pGM-Frsystem, disconnect the BACK UP tuse (7.5 Al in the under-hoodfuse/relaybox tor more than 1o secondsto reset the TcM memorv. NOTE: a PGM-FIsvstem The PGM-FIsystem on this model is a sequentialmultipon fuel iniectionsvstem. ' Disconnectingthe BACK UP tuse also cancelsthe radio anti-theftcode, presetstationsand the clock setting. G6t the customer's code numbe. and make note of the radio presets befote temoving the fuse so you can reset them.
14-48
CAUTIOI{: a All SRS eloctdcal wiring harna$os are covcred whh yollow lnaulation. a Sofora disconnecting any pan ot tho SRS wirc har' n6ss, connoct the short connoctots (s€6 pago 23-701. a Roplacs tho entiro aff.ct d SRS ham6t. rssombly it ii has an opon circuil or damagcd wlrlng.
a TCM Ro3at Procoduro 1.
Tum the ignition switch off.
2.
Removethe No. 32 BACK UP fuse {7.5 A} from the under-hoodluse/relay box 'or 10 seconds to reset the TCM. NOTE; Disconnoctingthe No. 32 BACK UPtuse also cancelsths radioanti-theft code, presetstations and tho clock sefting. Get the customer's code number and make note ol the radio presets before removing the fuss so you can reset them.
BACKUP(7.5 A} FUSE
lf the inspection to. a particularlailure code requir6sthe use of Test Harness {07LAJ - PT3O1OA): 1,
Removethe left side kick panelon the driver'sside (seepage 1+84).
2.
Connect the wire harness to the Tsst Harness. and/or connect the Test Harnessto the TCM sccording to the troubleshooting flowchart. NOTE: a Onlythe A and D terminalsof the TestHarnsssaro used for Ay'Ttroubleshooting. a Unless otherwise noted, use only the Digital Multimeter, commerciallv available or KS-AHM32{)03, for testing.
a Finll hoc.dulr
c
NOTE: This procedure must be done after any troubleshooting. 1.
Removsths s9ocialtoolfrom the ServiceCheckConnoctor.
2.
Resetthe TCM.
3,
S6t th€ radio preset stations and clock setting.
DIG]TALMULTIMETER Comm€rciallvavailable KS-AHM-32-.003, or gouivalEnt ) o o o o o o o o o o ) olo D o o o o o qoo o o o olo o o o o . o o o . c
To.miml Locrtlonr
14-49
Symptom-to-ComponentChart ElectricalSystem Numberof @ indicatorlight blinks while indicaror Service Check @] light Connectoris connectedwith the specialtool. Blinks
Blinks
Blinksor OFF
4
Blinks
Blinks
OFF
7
8
a
14-50
Blinks
Blinks
Blinks
PossibleCause
Symptom
Referto page
Disconnectedlock-upcontrol solenoid valve A connector Short or open in lock-upcontrol solenoid valve A wire Faulty lock-upcontrol solenoidvalve A Disconnectedlock-upcontrol solenoid valve B connector Short or open in lock-upcontrol solenoid valve B wire Faulty lock-upcont.ol solenoidvalve B
Lock-upclutch does not engage. Lock-upclutch does not disengage. Unstableidle speed.
14-52
. Lock-up clutch does not enga9e. 14-54
Disconnectedthrottle position (Tp) sensorconnector Short or open in TP sensorwire Faully TP sensor
. Lock-upclutch does not engage.
Disconnectedvehiclespeed sensor (VSS)connector Short or open in VSS wire Faulty VSS
. Lock-upclutch does not engage.
. Short in A/T gear positionswitch wire . Faulty A/T gear positionswitch
. Failsto shift other than 2nde4th gears. . Lock-up clutch does not engage.
14-58
DisconnectedA/T gear positionswitch connector Open in A/T gear positionswitch wire Faulty A/T gear positionswitch
Failsto shift other than 2nd-4th gears. Lock-up clutch does not en98ge. Lock-upclutch engages and disengagesalternately.
14-60
Disconnectedshift control solenoid valve A connector Short or open in shitt control solenoid valve A wire Faulty shift control solenoidvalve A Disconnectedshitt control solenoid valve B connector Shon or open in shift control solenoid valve B wi.e Faulty shift control solenoidvalve B
. Failsto shift (between 1st-4th, 2nd-4th or 2nd-3rd gears only). . Failsto shift (stuck in 4th gear).
Disconnectedcountershattspeed sensor connector Short or open in the countershaft speed sensorwire Faultycountershaftspeed sensor
. Lock-upclutch does not engage_
. Failsto shiJt (stuck in lst or 4th gears).
14-56
't
4-57
14-62
't 4-64
Numberof @ indicatorlight blinks while indicator ServiceCheck @ light Connectoris connectedwith the specialtool.
'lo
Blinks
1l
OFF
13
Blinks
14
't5
Blinks
PossibleCause
Symptom
Disconnectedenginecoolant temperarure (ECT)sensorconnector Short or open in ECT sensorwire Faulty ECT sensor
Lock-upclutch does not engage.
Disconnectedignitioncoil connector Short or open in ignition coil wire Faulty ignitioncoil . Shon or open in LT GRN wire between the D3 terminaland ECM . Faulty barometricpressure{BARO) sensor NOTE:The BAROsensor is built into the ECM . Short of open in FAS {YEL}wire between the D16 terminaland ECM . Faulty ECM
OFF
Disconnectedmainshaftspeed sensor connecror Short or open in mainshaftspeedsensor wire Faulty mainshaftspeed sensor
. Lock-upclutch does not engage.
Refer to page
14-68
't4-70
. No specificsymptom appears. 14-71
. Transmissionjerks hard when shitting. . Transmissionjerks hard when shifting. 14-75
It the self-diagnosis LQ4 indicatorlight does not blink, perform an inspectionaccordingto the table below. Symptom
ProbableCause
LQ! indicatorlight is on steady, not blinkingwheneverthe ignitionis on. [Q3]indicatorlight does not come on for 2 secondsafter ignitionis first turned on. Lock-upclutch does not have duty operation(ON-OFFI.
Ret.page 14-77 14-78
Lock-upclutch does not engage.
Check A/C signalwith A/C on.
14-80
Shitt leve. cannot be moved lrom @ positionwith the brake pedal depressed.
Check brakeswitch signal,
14-41
a lf a customerdescribesthe symptoms for codes 3, (yet the LQ! indicatorlight is not blinkingl,6, 1 1 or 15, it will be necessa.yto recreatethe symptom by test driving.and then checkingthe @ indicatorlight with the ignitionstill
oN.
e lt ttre @ indicatorlight displayscodes olher than those listed above or stays lit continuously,the TCM is faulty. . Sometimesthe Lqd indicatorlight and the MalfunctionIndicatorLamp (MlL)/CheckEnginelight may come on simultaneously.lf so, check the PGM-Flsystem accordingto the numbe. of blinks on the MIL/CheckEnginelight. then resetthe memoryby removingthe BACK UP fuse in the unde.-hoodfuse/relaybox for more than 1Oseconds.Drive the vehicle for several minutes at speed over 30 mph (5O km/h), then recheck the MIL/Check Engine light. NOTE: . PGM-FIsystem The PGM-Flsystem on this model is a sequentialmultiportfuel injectionsystem. a Disconnectingthe BACK UP luse also cancelsthe radioanti-theftcode. presetstationsand the clock setting.Get the customer'scode numberand make note ot the radio the fuse so vou can resetthem.
14-51
ElectricalTroubleshooting TroubleshootingFlowchart Possible Cause
Turn the ignition switch ON.
. Disconnected lock-up control s o l e n o a dv a l v e A c o n n e c t o r . Short or open in lock-up control solenoid valve A wire . Faulty lock-up control solenoid
Check whether the Malfunction IndicatorLamp (MlL) blinks (see section I 1).
ls the MIL blinking?
Repair the PGM-FI System (see section 1 l ).
NO Turn the ignitionswitch OFF.
Disconnectthe 26Pand 22Pconnectorsfrom the TCM. Connectthe Test Harness"A" and "D" connectorsto the wire harnessonly, not to the TCM {see page 14-49).
ooooooooooo oooooooo9oo
oooooooooooo oooooooooooo Turn the ignitionswitch ON.
Measure the voltage between the D18 and A25 or 426 terminals.
f s t h e v o f t a g e4 . 7 5 5 . 2 5 V ?
Repair open or shorl in WHT/ BLK wir€ botwe€n th€ D18 terminal and the ECM.
YES
A25
Measurethe voltagebetweenthe 46 and A25 or A26 terminals-
ls there voltage?
NO Turn the ignitionswitch OFF.
To page 14'53
14-52
(-)
" "" o" " oooo" I | | o" q" " ooo oo ooq litigse.*grq$:,1:d:sd:siia:l r z 6 r o ' r + r r-t IL--l l /trtr-Repail short to power sourco in YEL wi.e between the A6 terminal and the lock-up control solenoid valve A.
Me6surethe resistancebetween the 46 andA25 or A26terminals.
ls the resistance14
16 O?
Checkfor loos€ TCM connectors. It necessary,substitute a known_ good solenoid valve assembly or TCM and recheck.
Disconnectthe 2P connectorlrom the lock-upcontrol solenoidvalve
CheckIor continuitv between the 46 and A25 or 426 terminals.
ls there continuity?
Repairshort to groundin YELwiro between tho AG t€rminal and th€ lock-uo control solsnoid valve A. View lrom terminalside
Measurelhe resistanceof the solenoidat the 2P connector.
ls the resistance14- 16 0?
Ch€ck tor open in YEL wire botween the A6 terminal and the lock-uDcontrol solenoidvalve A.
RoDlacath6 lock-up control sol€noid valv6 assembly.
{cont'd}
14-53
ElectricalTroubleshooting Troubleshooting Flowchart(cont'dl PossibleCause
Turn the ignitionswitch ON.
. Disconnectedlock-up conlrol solenoidvalve B connector . Short or open in lock-up control solenoid valve B wire . Faultylock up controlsolenoid valve B
Check whether the Malfunction IndicatorLamp (MlL) blinks (see section 1 1).
ls the MIL blinking?
Ropair tho PGM-FI Sysrom (se€ soction 11).
Turn the ignitionswitch OFF.
Disconnectthe 26P and 22P connectorstrom the TCM. Connect the Test Harness "A" and "D" connecto.slo the wire harnessonly, not to the TCM (see page 14-49).
Turn the ignitionswitch ON.
Measurethe voltage between the D'18and A25 or 426 terminats_
ls the voltage4.75-5.25 V?
Rapair opon or shon in WHT/ BLK wi.e botweon the O18 te.minal rnd the ECM.
lvleasurethe voltage between the 44 and A25 or 426 rerminals. Ropsir shon to power source in GRN/BLK wi.o betwoon the A4 t6.minal and th€ lock-up control solonoid valve B. Turn the ignitionswitch OFF.
14-54
Measurethe resistancebetween the A4 and A25 or A26 terminals.
is the resistance14- 16 0?
Check for loosoTCM connocto.s. lf nocoasary,substitute a knowngood solenoid valvo assombly ot TCM and rochock.
Disconnectthe 2P connectorfrom the lock-upcontrol solenoidvalve assemory,
Checklor continuitv between the A4 and A25 or A26 terminals.
Ropair 3horl to Itound in GRN/ BLK wir6 botwoon tho 44 totminal and th6 lock-up cont.ol solonoid valv6 B.
2P CONNECTOR View trom terminal side.
Measure the resistance ol the solenoid at the 2P connector.
q .UP CONTROL
ls the resistance14- 16 07
Chock lor opon in GRN/BLKwiio botwaen tho A4 torminal and th6 lock-up contrcl solonoid valvo B.
SOLENOID VALVE ASSEMBLY
R6Dlacotho lock-up conttol 3016noid valvs assembly.
(cont'd)
14-55
TroubleshootingFlowchart (cont'd) Sof{irgnolis D! indic€tor tight blinks throo rim6s.
Turn the ignitionswitch ON.
Possible Cause . Disconnocted throttle position {TP) sensoaconnoctor . Short or oDenin TP s€nsorwire . Faulty TP senaor
Check whother the Malfunction IndicatorLamp (MlL) blinks(see section 1 1).
ls the MIL blinking?
Replir thc PGM-FI Syrtom l.s. !.ction 111.
Turn the ignitionswitch OFF.
Oisconnectrho 26P 6nd 22P connectors lrom the TCM. Connect the Test Harness "A" and "D" connectors to the wire harnessonly, not to the TCM lsee page |4-491.
Turn the ignitionswitch ON.
Measurethe voltage between the Dl8 and A25 or A26 teiminats.
ls the voltage4.75-5.25 V?
Rcpalr opon or shon In WHT/ BLK wlr. botw.cn th. D18 t.minsl rnd th. ECM.
Turn the ignirionswirch OFF.
Connect the Test Harness "A" and "D" connectorsto the TCM.
Turn the ignition switch ON.
Measurethe voltage betwe€n the D7 and A25 or 426 rerminals.
ls the voltage0.4-0.6 V?
Chock tor looro TCM connoctora. ll noce$rry, subatitulo r knowngood TCM and rechock.
Roprlr oprn o. lhon in RED/BLK wil. botwaan tha DT ta]minal and tha TP ranaor.
S. d.gno.b lql bllnkr tour tlm...
indic.to. light
PossibleCaus6 . Disconnectsd vehicle speed sensor{VSS}connector . Short or open in VSS wire . Faulty VSS
R.lor to Soctlon 23 for vohicle rpood lonsoi {vSSl to!t.
Shift t.nsmisiion
to A
position.
a Mak€ sure lifts,lacks, and safety stands aro placod ploporly {see Eaclion 1}. a S6t th6 parking brake eecurely and block tho tear wh6ol3' a Jack up tho f.ont ot tho car and rupport whh sstoty standa.
Disconn6ctthe 26Pand 22P conn.ctors trom th€ TCM. "A" Connect ths Tgst Harnoas "O" connectors to tho wire 8nd harnsssonly, not to the TCM (see page 1+49).
Turn the ignilionswitch ON.
Rotat€th€ tront wh6ol and chsck fo. volt6g€ botwean the D9 and A25 o. A26 terminals.Blockthe other whaol 30 it do€s not turn.
Doss lhe voltage O V and app.ox. 10 V appe.r alternately?
Ch6ck to. shoft or opon in OFil wlro b€twoen tho .)9 t6tminsl and rho VSS. lf wiro is OK, ch€ck tho VSS lsoo soction 231.
Ch.d( tor loo.. TCM co.!n.cto.r. ll nacaaalay, lubrtituta ! known_ geod TCM and t chock.
(cont'd)
14-57
ElectricalTroubleshooting TroubleshootingFlowchartlcont'dl Solt-diagno8isl!4 indicato. tight blinks fiv6 timos.
PossibleCause 'Short in A/T gear posilion switch wire . Faulty A/T gear position switch
Turn the ignitionswitch ON.
Observethe A/T gear position indicator,and selecteach position separately.
Do any indicators stay on when the selectorlever is not in that position?
NOTE:Code 5 is causedwhen the TCM receivestwo gear position inputsat the sametime.
The systom is OK ai this timo. Ch.ck tho wiro ha|noss tor oamago.
Turn the ignitionswitch OFF.
Connect the Test Harness be, tween the TCM and connectors {see page 14-49}.
Turn the rgnitionswitch ON.
Or 4 2 5t - | Shilt to other than E position.
Measurethe voltage b€tween the A21 and A25 or 426 terminats. Chock for short in GRN/REDwi.o botwoon tho A2t torminal and th6 A/T goar po6ition swirch or A/T 96ar posirion indicator. lf wire is OK, chock for loo8o TCM connocioF. lf necassary,subatituto a known-good TCM and rochsck.
-l@r A 1 9 l + ) A 2 5( - ) Measurethe voltage between the 419 and A25 or 426 terminals.
ls the battery voltage? YES To page 1 4 , 5 9
14-5 8
Ch6ck for 6hon in LT GRN/BLKwi.e borwoon tho A19 torminal and tho A/T goar position indicato., o. a shon in GRN/WHT or GRN wiros botwson tho A/T goa. position indicato. and tho A/T goa. position swhch. ll wire is OK. chock for looso TCM connactoE. lf nocos$sry, substituto a knowngood TCM and .ech6ck,
14-58
shift ro other than E
posirion.
Measurethe voltage belween lhe A17 and A25 or A26 terminals.
ls there battery voltage?
Shifi to other than E]
Chock to. short in PNK/GRNwire betwoon tho Al7 torminal and th6 A/T gsar position switch. It wire is OK, chsck for looso TCM connoctors. lf nocessary, substitute a known-good TCM and roch€ck.
position.
oooooooooooo oooooooooooo
ooooooooooo oooooooo ooo
Measurethe voltage between the A15 and A25 or 426 terminals.
ls there batteryvoltage?
Chock for short in GRN/BLUwire betweon the A15 terminal and the A/T gosr position switch or A/T g€a. position indicato.. ll wiro is OK, chock for loose TCM connectors. ll nocessary,substituls a known-good TCM and rochock.
Shilt to other than E position.
oooooooooooo oooooooooooo
ooooooooooo ooooooooooo
Measurethe voltage between the A13 and A25 or 426 terminals.
ls there battery voltage?
Shift to other rhan I
oosirion.
Chock for short in GRN/YELwire betweon ths A13 torminal and the A/T gear position switch or A/T gear posilion indicator. l{ wiro is OK, check lor loose TCM connectors. lI necessarv,substituta a known-good TCM and rechsck.
oooooooooooo oooooooooooo
ll
ooooooooooo ooooooooooo
Measurethe voltage between the Al l and 425 ot 426 tetminals.
ls thgre battery voltage?
YES
Chock tor shon in LT GRN/WHT wi.e b€twoan th6 A1'l lerminal and the A/T gear position switch or A/T gear position indicator. lf wira b OK, ch6ck foi loose TCM conneclors. lf noc€ssary,substituto a known-good TCM and rocheck.
Chock for looso TCM conn€ctors. lf noce$ary, substitute a knowngood TCM and recheck.
{cont'd)
14-59
ElectricalTroubleshooting TroubleshootingFlowchart{cont'dl Self-diagnosisE indicator light blinkasix timos.
Connect the Test Harnessbe, tween the TCM and connectors (seepage '14-49).
PossibleCause . DisconnectedA/T gear position swrtcn connector ' Open in A/T gear positionswitch . FaultyA/T gear positionswitch
Turn the ignitionswitch ON.
-
- r9t a 2 1 ( +I A 2 5 { - ) oooooooooooo oooooooooooo
ooooooooooo ooooooooooo
Measurethe voltagebetweenthe A21 and 425 or 426 terminals.
ls there voltage?
Shilt ro N or E position.
Ropairopen in GRN/REDwire be, tweon th6 A21 terminal and the A/T gssr position switch.
A25t-l oooooooooooo oooooooooooo
Measure the voltage between the A19 and A25 or A26 terminals.
ls there voltage?
NO T o p a g el 4 - 6 1
14-60
Ropairopen in LT GRN/BLKwire b€tw6onthe 419 torminaland th€ A/T gear position indicato..
ooooooooooo ooooooooooo
oooooooooooo oooooooooooo
ooooooooooo ooooooooooo
Measurethe voltage betweenthe A 1 7 a n d4 2 5 o r A 2 6 t e r m i n a l s .
voltage?
Roprir opon in PNK/GRNwire botwoon the A17 torminal and rh6 A/T goar position switch.
oooooooooooo oooooooooooo
ooooooooooo ooooooooooo
Measurethevoltagebetweenthe A 1 5 a n dA 2 5 o r A 2 6 t e r m i n a l s . Ropairopen in GRN/BLUwir6 bolwoen the A15 r6.minal and tho A/T goar position switch.
oooooooooooo oooooooooooo
ooooooooooo ooOoooooooo
Measurethe voltage between the A 1 3 a n dA 2 5 o r A 2 6 t e r m i n a l s .
voltage?
ReDairopen in GRN/YELwito botw€on the Al3 torminalandth€ A/T goarposilion switch.
All(+ I
oooooooooooo oooooooooooo
ooooooooooo ooooooooooo
Measure the voltage between the A11 and A25 or A26 terminals.
voltageT
Ropaii opon in LT GRN/WIIT wiro botw€en the A 11 te.minaland tho A/T goar oosition switch.
Checklor loos€ TCM connectors. It necossaty,substituto a known_ good TCM and r6ch6ck.
(cont'dl
14-61
ElectricalTroubleshooting Troubleshooting Flowchart(cont'dl S€ltdiagno3b Lql indicaror lighr blinks sovon timgs.
Turn the ignition switch ON.
PossibleCause . Discohnectedshift control solenoid valve A connector . Short or open in shift control solenoid valve A wire . Faulty shill control solenoid
Check whether the Malfunction IndicatorLamp {MlL) blinks(see section 11). ls the MIL blinking?
Ropai lhe PGM-FI Sysrem (so€ Bection1 11,
Turn th6 ignition switch OFF. Disconnect the 26P and22P connectors from the TCM. Connect the Test Harness "A" and "D" connectors to the wire harnessonly not to the TCM (see page 14-49).
D l 8 (r I Turn the ignitionswitch ON. Measurethe voltage betw€€n the D18 and A25 or A26 lerminals. fs the voftage4.75-5.25 V?
Repairopon o. sho.t in WHT/BLK wire botwoon th€ D18 tarminal and the ECM.
oooooooooooo ooooo oooooooa
ooooooooooo t:tJio*ie*O:lt$!l$4lrulitEijt'lo oo oooooooo
Measurethe voltage between the A5 and A25 or A26 terminals.
Ropair lhon to powor sourc6 in BLU/YEL wiro botwoon the A5 torminal and th6 lhift control solonoid valve A. Turn the ignitionswitch OFF.
{
oooooooooooo oooooooooooo
ooooooooooo ooooooooooo
Measurethe resistancebetween the A5 and 425 or 426 terminals.
ls the resistance14-16 0? NO
Chock lor loora TCM connectoE. lf n6c€53ary,sub3titut6a knowngood solonoid valvo assembly or TCM and r6check.
Disconnectthe 3P connectortrom the shift control solenoidvalveassembly.
Check for continuitv between the A5 and A25 or 426 torminals.
Ropair shon to ground in BLUI'EL wir6 botwoon tho A5 tstminal and tho shift conlrol solonoidvalvo A. 3P CONNECTOR View from terminalside. Measure lhe resistance of the solenoidat lhe 3P connector.
ls the resistance'14-16 0?
Check fo. opon in BLU/YELwiro bolween th6 A5 torminal and tho shift control solenoid valve A.
SHIFT CONTROL SOLENOIDVALVE ASSEMBLY
(cont'd)
14-63
ElectricalTroubleshooting Troubleshooting Flowchart(cont'dl Solfdiagnolir [!4 Indicato. light bllnk! eight tim6r.
Turn the ignition switch ON.
PossibleCau6e . Disconnected shift control solenoid valve B connector . Short or open in shift control solenoid valve B wire . Faulty shilt control solenoid valve B
Check whother the Malfunction Indicator Lamp {MlL) blinks (see section I 11. ls the MIL blinking?
Rcpsir rho FGM-FI Syrtem lso6 scciion l1l.
Turn the ignition swirch OFF. Oisconn€ctthe 26P and 22P connectors trom the TCM. Connectthe Test Harness"A" and "D" connectors to the wiro hamessonly. not to the TCM {ses p6ge 14-49).
A2s(- | o oooooooooo oooooooooooo
Turn the ignition switch ON.
D l A (+ I
Measurethe voltage betwe€n the D18 and A25 or A26 terminals. ls the voltage4.75-5.25 V?
Ropeiropon or short in WHT/BLK wiro trotweon th6 D18 terminel and tho EcM.
Measurethe voltage between th€ A3 and A25 or A26 terminals.
Ropair rhort to powor rourco in GR /WHT wir6 b€twgan tho A3 tormirEl and shift conLol lolonoid valve B. Turn the ignitionswitch OFF.
To page
oooooo ooooo oooo oooo
Measurethe resistance between the A3 and A25 or A26 terminals.
ls the resistanceI +16 07
Chod. lor looro TCM connoctoB. lf nocdaary. 3ubatltute a knowngood rolonold valv6 6ra6|nbly ot TCM snd recheck.
Disconn€ctth6 3P conngctorfrom the shift control solenoid valve assembly.
oooooooooooo Check for continuity between the A3 and A25 or A26 terminals.
oooooooooooo
ooooooooooo ooooooooooo
Ropair short to ground in GRt{/ WHT wiro botwoon th6 A3 torminrl and tho shitt control aolonoid valve B.
Measure the resistance ot the solenoid at the 3P connector.
ls the r€sistance14- 16 O?
Roplace lhe rhift control solenoid valve arr€mblv.
Chock to. open in GRN/WHT wiro b6twe.n th€ A3 lerminal and tho shifl control solonoid valvo B. SHIFT CONTROL SOLENOIDVALVE ASSEMELY
(cont'd)
14-65
ElectricalTroubleshooting TroubleshootingFlowchart{cont'dl Self-diagnosisLq! indicator lighr blinks nino timos.
PossibleCause . Loose or faulty connection berween the TCM and car harness. . Disconnectedcountershaft speed sensor connector . Short or open in the countershatt speed sensor wire . Faulty counlershaft speed sensor
ls the countershaftspeed sensor installed properly
Disconnectthe 2P conneclorlrom the countershaft speed sensor connector,
Measure the resistance ot the co!ntershaft speed sensor.
2P CONNECTOR
COUNTERSHAFT SPEEDSENSOR
ls the resistance 4OO 600 0?
To page 14-67
14 -6 6
Disconnoct the 22P connector trom the TCM. Connecr tho T€st Harness "D" connector to the whe harnessonlv, not to the TCM '14-49). lsee page
Check for continuitv between body ground and 017 terminal and D15 terminslindividually. Rgpllr short in BLU/GRI{ ot BLU|/EL wlro b€twgon Dl7 and Dl5 torminsla and ths countarrhaft apo€d sengor. Reconnect the countershaft sDe00sensor connector.
Msasure the rgsistancebetween D 17 and 015 terminals.
ls the r€sistance4OO-600 07
Rgpairlooa6 ta.minsl or opon in 8LU/GRN o. 8LU/YEL wiro botrvaon D'17 and D15 tormindg and tho count6rlhafl !p6gd !€ntor,
Ch6ck for looaa TCM conn6cto.. ll nocaslrry, aubrlitut6 a knowngood TCM a.d .6ch.ck.
(cont'd)
4-67
ElectricalTroubleshooting Troubleshooting Flowchart(cont'dl Self-diagnosisE indicator light blinks ten times.
Turn the ignitionswitch ON.
Possibl€Caus6 . Disconnoct€dengine coolant t€mp€rature (ECTI sensor connoctor . Short or open in the ECT sensor . Faulty ECT s€nsor
Check whether the Malfunction IndicatorLamp {MlL} blinks(see section 11)-
ls the MIL blinking?
Rop.ir tho PGM-FI Syrt.m (!go !.ction 111.
Turn the ignitionswitch OFF.
Disconnectthe26P and 22P connectorstrom the TCM. Connectthe Test Harness"A" and "D" conneclorsto the wire harnessonly, not to the TCM (see p a g e1 4 4 9 ) .
oooooooooooo oooooooooooo
ooooooooooo oooo oooo Dlal+ I
Measurethe voltage between the D'18and A25 or A26 lorminals.
ls the voltage4.75-5.25 V?
Turn the ignition switch OFF.
Bopairop.n or .hofi In WHT/BLK wiro botwoon tho O18 tanni.|al .nd the ECM.
Conneci the Test Hs.ngs6 "A" and "O" connectorsto thg TCM.
Start the engine and warm it up to normal ope.ating t€mpsratuG (the rsdiator fan comes on).
Measurgthe voltage between the 05 and A25 or A26 terminals.
ls the voltago less th6n lV?
Rlplir opsn or rhort in BED/WHT wira botwaan tra D5 torr nC lnd tha ECT lanaor.
Ch.ct tor loora TCMco.rmcror.. It nocgallry, sublthuta a knowngood TCM .nd rechrck.
14-69
ElectricalTroubleshooting TroubleshootingFlowchart(cont'd) Solt-diagnosislq.l indicstor light blinks elovon tim6s.
Disconnect the 26P connector Irom the TCM.
PossibleCause . Disconnected ignition coil conneclor . Short or open in ignition coil . Faulty ignition coil
Turn the ignitionswitch ON.
Measurethe voltage between the Ag (BLU)and A25 (BRNiBLK) or A26 (BRN/BLK) terminals.
ls there baftery voltage?
Ch6ck lor loos6 TCM connactora. It nacosaary,substituto a knowngood TCM and rochock.
14-70
NOTE: View from wire side.
R6pai?opon or short in BLU wiro lrotwqan lh. A9 torminll 6nd th. ignilion c!il.
Soll-diagnosisLq! indicator light blinks thirtoon tim6.
ls rhe Malfunction lndicator Lamp (MlL) on and does it indicatecode 13?
Possible Cause . Short or open in LT GRNwire betweenthe D3 terminaland the ECM. . Faukythe barometricpressure{8ARO}sensor. NOTE:The BAROsensoris built into lhe ECM.
Do the TCM Rest Procedure(see page 14-49).
Turn the ignitionswitch ON.
ls the MIL on and does it indicarecode 13?
Substituto a knowngood ECM and rechock. ll symptom/lndication goos away, .oplacethe originalECM.
Turn the ignitionswitch OFF.
Disconnectlhe 26Pand 22P connectors trom the TCM Connect the Test Hahess "A" and "D" connectorsto the wire harnessonly, not to th€ TCM {see pare'14-49).
Turn the ignitionswirch ON.
A25t-| o o o o o o o o o o o o o o O O q g o p g I , o i O O O O ool o o o o o o o o o o o o o o o o o o o o o o 0 ooocqooo:Joo.oipggl o oooooo o 9oo
Measurethe voltage between the D18 and A25 or A26 terminals.
ls the voltage4.75-5.25 V?
Ropairopon or short in WHT/BLK wir6 botwoon th€ D18 to.minal and tho EcM.
Turn the ignitionswith OFF.
fo page 14-72
14-71
ElectricalTroubleshootang TroubleshootingFlowchart (cont'd) From page
'14-71 NOTE: View from wire side.
Disconnect the 22P connectors lrom the TCM and ECM. ECM 22P COiINECTOR Check for continuity between the D3 {LTGRN)terminalol the TcM 22P connecrorand the D8 ILT GRN) terminalof the ECM 22P connector.
TCM 22P CONNECTOR Ropai. opon In LT GRN rvi.a b.twoon tho TCM and ECM.
Checklor continuity between the LT GRN wire and body ground.
Ropair short lo body ground in LT GRN wir6.
Ch€ck lor loos6 TCM and ECM connectors, lf necessary,aubaritute a known-good TCM and rccheck.
14-72
S.fdl.enorl! L&l indicdor lighl blinks fourtoon tlmoa.
PossibleCause . Sh"rt ". "e"" i" FAS |YEU ,"rirt . FsultyECM.
ls the Malfunction Indicator Lamp (MlL) onl
Ropair tho PGM-FI Syrtom lloo ..ctlon 111.
Stan the ongine and warm it up to normal operating temperature {th€ radiatorlan com€s on).
Shift to E position,
Turn rhe ignition switch OFF.
Connect the Test Harness between the TCM and connociors {seepage 14-491.
Turn the ignition switch ON and wsit for at least two seconds.
o oooooo ooo ooo l.tto.oodooo l:,gEoo.ottl o ooooo oooo o o oooo oooooooo
o oooooooooo l:OOOOOO60 l.,OO{tO.O6,'l
Measure lhe voltagebetwganths o16l+ ) andA25 or A26(- | tormrnals.
ls thoro approx. 5 V?
Chock for looro TCM connoctora. lf noco$ary, subatituta a knowngood TCM and .ech€ck.
Turn the ignition switch OFF.
Dkconnectthe TestHarnessfrom the TcM. Leaveconnect€dto car harness.
Turn the ignition switch ON.
fo page 14-74
lcont'd)
14-73
ElectricalTroubleshooting TroubleshootingFlowchart(cont'd) From page 14-73
o o o o o o o o O o O o O $:O.COOtt9O$:l:OtO:CtOiOi:l
Oo OO OOo Oo o O
o o o o o o o o o o o o O I:f(O.{iltltO{t{t:I:OFA:F:d:O:l o o o o o o o Oo o o Measurethe voltage between the D 1 6 { + ) a n dA 2 5 o r A 2 6 { - ) t e r mtnals.
ls there approx. 5 V?
Check for loos€ TCM connoctors. ll ngcossary,substituto a knowngood TCM and rechock.
Disconnectthe 26P connector from the ECM.
Check for continuitv between the D16 andA25 or A26 rerminalsof the Test Harness.
oooooooooooo oooooooooooo
Ropairshortin YEL IFAS)wire betw6on TCM and ECM.
Disconnectthe 26P and 22P connectors from the Test Harness. 22P CONNECTOB Check for continuity betweenthe D16 (YEL)terminalot fCM 22P connectorand A19 (YEL)terminal of ECM 26P connector. NOTE:View lrom wire side.
ls there continuity? NO Ropairopon in YEL {FAS}wiro botrve€n TCM and ECM.
Chgck tor loos€ TCM connoctofs. lf nocassary,substitute o knowngood TCM and rech6ck.
ooooooooooo ooooooooooo
solf-diagnosisE indicator light blink tiftoon timos.
PossibleCause . Disconnected mainshaft speed sensor connecror . Short or open in mainshalt speedsensorwrre. . Faulty mainshatt speed sensor.
NOTE: . A code 15 on the TCM doesn't alwsys mean there's an electrical problem in the mainshaftor countershaftspeedsensorcir'15may also indicatea mechanicuit; code cal Droblemin the transmission.
Are the mainshaft and countershalt speed sensors installed properly?
Disconnectthe 3P connectorlrom the mainshaftspeedsensor.
Measurethe resistanceot the mainshaftspeedsensor.
3P CONNECTOR
ls the resistance4OO-600 O?
Disconnectthe 22P connector from the TCM. Connectthe Test Harness"D" conneclor to the wire harness only, not ot the TCM (see page 14-49).
I o o o o o o o oo o o o o I:OtlO$O$g:Sl!:OlXOl*Ofill
o o o o o o o o o Oo |
I|
o oooop oo ooo | 6 I ooooooooooooo l Sciii:ddii:ijii:l:i$idi$;d6#:l " f
1(0) - L
Check the continuity between D19 and D12 terminalsand body ground.
Y -! Rcoair short in ORN/BLU ot WHT/BLU wiros botween Dlg and Dl2 to.minals and tho mainshatt speod ronsor.
Reconnectthe 3P connectorto the mainshattspeedsensor,
To page 14-76
(cont'd)
14-75
ElectricalTroubleshooting TroubleshootingFlowchalt (cont'd) From page 14-75
ooooooooooooo ooooooooooooo
ooooooooooo ooooooooooo
Measurethe resistancebetween D19 and D12terminals.
ls the resistance4O0-600 0?
Disconneclthe 3P connectorfrom the mainshaft speed sensor.
RunElectricalTroubleshootingfol code 9. Check for loos6TCM connectors. It nocessary,substitute a knowngood TCM and r.check.
ooooooooooooo ooooooooooooo
oooooooooo ooooooooooo
Check tor continuitv between D19 terminaland the mainshalt speedsensotconnector.
MAINSHAFTSPEEDSENSOR
Ropairop.n in ORN/BLUwir6 b6tweon D19 terminalsnd th€ main' shaft spa6d sensor. Chock tgr continuity between D12 terminaland the mainshatt speed sensor connector.
ooooooooooooo ooooooooooooo
ooooooooooo ooooooooooo
3P CONNECTOR View from terminalside
MAINSHAFTSPEEDSENSOR
Ropairopen in WHT/BLUwire betwe€n D12 tgrminaland th€ mainshaft sD6ed sonsor. Chsck for loos€TCM connoctors. ll noco$ary, substitute a knowngood TCM and rocheck.
14-76
@ indic"to, light i8 on st6sdy Inot blinkingl whenevor the ionition switch is ON.
Turn the ignitionswitch OFF.
Disconnectthe 26P connector from the TCM. Connectthe Test Harness"A" connector to the wite harness only, not to the TCM (see page 14-49).
Turn the ignitionswitch ON.
o o o o oo o oo o oo o l:qssoo9pc,I:oocto:osil oooQooooooooo
o o o oo o o o o oo o ooooooo ooo
Measurethe voltage between the A8 terminaland body ground.
ls there voltage?
Ropairshon to power in GRN/BLK wiro botwoen A8 terminal and gauge assembly.
Connectthe Test Harness"A" conneclorto the TCM.
Measurethe voltage between the 417 terminal and body ground with the selectorleverin anv oo' sition other than El.
ls there volrage?
Check for a sho.t to ground on the PNK/GRNwi.e. ll th€ wir. is OK, roplac€ the A/T gear poaition indicator.
ReDlace tho TCM.
{cont'd)
14-77
ElectricalTroubleshooting TroubleshootingFlowchaft (cont'dl Lq4 indicatorlight do6s not come on with the ignitionswitch ON. (lt should come on Ior about 2 seconds.l
ls the servicecheck connector connectedwith the special tool ISCS Short Connectod?
Does the @ come on?
Diaconnect tho spocial tool from th6 sgrvice check connoctor and recheck.
Check {or loos6 TCM connoctors. lf necessaw,substitute a knowngood TCM and recheck.
indicatorlighr
Turn the ignitionswitch OFF.
Disconnectthe 26P connector from the TCM. Connectthe Test Harness"A" conneclor to the wile harness only, not to the TCM (see page 14-49).
I
|
A25
ooo oo oooooo I | o ooooo o oo o ooo r:sjc.o.sl'1*st,li*os.s.4tcl
ooooooooooooq lifrif.S..n${5git:li$gg-:aiiigitll ooooooooooo I I| - - . -I T ..I
+
a26
d
+
Check for continuity between the A25 terminal and body ground and A26 and body ground. R€pair open BRN/BLK wires betwe6n A25 or A26 torminals and G1 0 1 . Turn the ignitionswitch ON.
Measurethe voltage between the A23 or A24 and A25 or A26 ter mrnals-
ls there baftery voltage?
YES Turn the ignitionswitch OFF.
To page 14-79
14-78
I + )A23A25l- l
(+ tA24426(- | t \ @ Repaii open or short in BLK/YEL wire between tho A23 and /ot 424 terminals and underhood tuse /relav box.
Connect the Test Harness "A" connectorto the TCM.
Turn the ignitionswitch ON. 8e sure that voltage is available for 2 secondsbetweenthg A8 torminal and A25 or A26 terminal.
a26t- | oooooooooooo oooooooooooo
ooooooooooo ooooooooooo
A8(+)
Chrck for opon or rhort in GR / 8LK wirc bctw.on th. A8 terminal and tha gauOaarrambly. Turn the ignition switch OFF.
Disconnectthe Test Harness"A" connector from the TCM.
Checkfor continuity between the A8 terminal and the GRN/BLK wire at tho gaugo assgmbly (see section23). B.p.ir op.n in GRI{/BLKwi.. bolwaen the A8 terminal and th. gauga 6aaombly. Ch€ck for loor6 TCM conn6ctor3. Check the A/T goa. polition awitch. ll noc€$ary, subrtitutg a known-good TCM .nd rochock.
(cont'd)
14-79
ElectricalTroubleshooting TroubleshootingFlowchart{cont'dl
In3poction ol ths A/C aign6l. . Lock-up clutch does not have duty operation(ON-OFF). . Lock-upclutch does not engage.
TLrrnthe blower switch ON.
Pushthe A/C switch ON.
Soe Air Condilioning inspoction lsee rection 221.
Disconnect the 26P conneclor from the TCM.
BR /ALK
Measurethe voltage between the A22 {BLK/RED)and A25 (8RN/ BLKI or A26 IBRN/BLK)terminals. (A/C compressorOFFI Repairopon in 8LK/REDwiio b6twoon lho A22 torminal and A/C comprossor clulch rel6y. . A/C aignal ls OK. . Chock lor looso TCM connectoB. lf n6co$ary, substitute a known-good TCM and rschock. . Inrpoct tho 6ir condhioning lsoo loction 221.
Symptom Shift lever cannot be moved lrom E position with the brake pedal depressed. Check thar the brake lights come on with the brake pedal depressed.
Aro brake lights ON?
Disconnecllhe 26P and 22P connectors from the TCM. Connoct the Test Harness "A" and "D" coonectors to th€ wire harnessonly, not to the TCM {see page 14-49).
R.prir l.ulty br6ko rwitch cuita 18o6lactlon 231.
cir-
A 2 5t - ) oooooooooooo oooooooooooo
ooooooooooo oooooooooo D 2l + )
Measurethe voltage between the 02 and 425 or A26 terminals with the brake pedal dopressed.
ls there battery voltage?
. Bfako switch signal OK. . Check for 10036TCM connectors. It noco$ary, sub3tiluto a known-good TCM and ioch6ck. . Insp6ct tho brako switch circuii lsoo soction 23).
Ropalrop6n in GRt{/wHT wiro b.tween tho D2 to7minsland brak. !witch.
Lock-up Control SolenoidValve A/B Replacement NOTE: Lock-uDcontrolsolenoidvalvesA and B must be removed/replaced as an assemblv.
Removethe mountingboltsand lock-upcontrolsolenoid valve assembly.
l.
Disconnect2P connectortrom the lock-uocontrol solenoidvalve A/8.
NOTE: Besureto removeor replacethe lock-upcontrol solenoidvalves A and B as an assembly.
2.
Measurethe resistancebetweenthe No. 1 terminal (solenoidvalve A) ot the lock-up cont.ol solenoid valveconnectorand body ground,and betweenthe No. 2 terminal(solenoidvalve B) and body ground.
Checkthe lock-upcontrol solenoidvalve oil passages tor dust or dirt. and replace as an assembly,if neceSsary.
STANDARD:14- 16 O 2P CONI{ECTOR View trom terminal side.
6 x 1.0 mm 12 N.m (1.2 kgf.m,8.7 lbf'ft)
Cleanthe mountingsudace and oil passages.
VAI-VE SoLENOTO ASSEMBLY ?
Reolacethe lock-uocontrol solenoidvalve assembly if the resistanceis out of specitication.
4.
lf the .esistanceis within the standard,connectthe No. 1 terminalot the lock-uocontrolsolenoidvalve connectorto the battery positiveterminal.A clicking sound shouldbe heard.Connectthe No. 2 terminal to the battery positive terminsl. A clicking soundshouldbe heard.Replacethe lock-upcontrol solenoidvalve assemblyif no clickingsound is heard.
14-82
Cleanthe mountingsurtaceand oil passagesof the lock-upcontrolsolenoidvalveassembly.and install a new filter/gasket. Checkthe connectorfor rust, dirt or oil and reconnect rt securely.
Shift Control SolenoidValve A/B Test NOTE: Shift controlsolenoidvalvesA and B must be removed/replaced as an assembly.
1 . Removethe shift control solenoidvaive assembly protector.
1 . Disconnect3P connectorfrom the shitt controlsolenoid valve A/8.
Removethe mountingbolts and shift control solenoid valve assembly.
Measurethe resistancebetweenthe No. 1 terminal (solenoidvalveA) of the shift controlsolenoidvalve connecto.and body ground,and betweenthe No. 2 terminal(solenoidvalve B) and body ground.
NOTE: Be sure to removeor replacethe shitt control solenoidvalves A and B as an assembly.
S T A N D A R D1: 4 - 1 6 O
Checkthe shitt controlsolenoidvalve oil passages for dust or dirt, and replace as an assembly, it necessary.
6 x 1.0 mm 12 N'm (1.2kgl.m,4.7 lbl.ftl
SHIFT CONTROLSOLENOIO VALVE ASSEMBLY
VALVE ASS€MBLY
Clean the mounting surfaceand oil passages. Replace.
3 . Replacethe shift controlsolenoidvalve assemblyif the resistanceis out oI sDecificaiton. lf the resistanceis within the standard,connectthe No. 1 terminalofthe shift controlsolenoid valveconnector to the battery positiveterminal.A clicking soundshouldbe heard.Connectthe No. 2 terminal to the battery positiveterminal.A clicking sound shouldbe heard.Replacethe shift control solenoid valve assemblyif no clickingsound is heard.
Cleanthe mountingsurfaceand oil passagesof the shitt control solenoidvalve assembly,and installa new filter/gasket. Checkthe connectorfor rust, dirt or oil, and reconnect it securely.
14-83
TransmissionControl Module Replacement I The Transmission ControlModule(TCMIis locatedbelow the dashboard,behindthe lelt side kick panelon the driver's side.
1.
Removetwo clips securingthe kick panelthen move it.
CAUTION: a All SRS electrical wiring hahesses are covered with yellow insulation. a Betore disconnecting any pan ot the SRS wile harness. connect the short connectorslsee page 23-7O). a Replacethe entir6 affected SRS harness ass€mbly if it has an open circuit or damaged wiring.
KICK PANEL
2.
Disconnectthe connectorsand removethe TCM.
6 x 1.0 mm 12 N'm {1.2kgf.m, 8.7 tbf.Itl
SRS MAIN HARNESS
WIREHARNESS/ CONNECTORS
14-84
6 x 1.0 mm 12 N.m (1.2 kgf.m, 8.7 lbt.ftl
Mainshaft/Countershaft SpeedSensors Replacement Disconnectthe speed sensorconnectors,then remove the harnessclampon the countershattspeed sensorharnessfrom the harnessstay. Removethe 6 mm boltssecuringthe mainshaftand countershaltspeedsensorsfrom the transmission housrng. Remove the mainshaft and countershaft speed sensors, Installthemainshattand countershaltspeedsensors in the reverseorder of the removal.
I{ARNESSSTAY
6 x'l,Omm l2 N.m {1.2kgf.m, 8.7 tbf.fr)
6 x 1 . Om m 12 N.m (1.2kgf.m, 8.7 tbf.ltl COUNTERSHAFT SPEEDSENSOR
14-85
Chart Symptom-to-Component Hydraulic System Check these items on the NOTESList
Check these items on the PROBABLE CAUSEList
SYMPTOM Engineruns, but car does not move in any gear.
1, 6, 7, 16
K,L,R,S
Carmovesin @ and@, but not in @, @ or I posataon.
a, 29, 44. 4a
c,M,o
9,30,49
C, L
1, 11, 22, 34, 38, 39, 40
c,L,o
1,8, 9, 10,11,46,47
C,D
Excessiveidle vibration.
5, 1'1
B,K,L
Slips in all gears.
6, 7, 16
C,L
No enginebrakingin E position.
12
C,D,L
Slips in 1st gear.
8, 29, 44, 4A
c,N,o
Slips in 2nd gear.
9, 20, 23, 30, 49 1 0 ,2 1, 2 3 , 3 1, 4 9
C,L
Slips in 3rd gear. Slips in 4th gear.
1 1 ,2 3 , 3 2 , 4 4
C,L,N
Slips in reverse gear.
11,32,34,44
C,N
Flareson 1-2 upshilt.
3 , 1 5 ,2 3
E,L,V
Flareson2 3 upshilt.
3, 15, 23, 24, 49
E,L,V
Flareson 3-4 upshift.
3, 15, 23, 25, 49
E,L,N,V
No upshift;transmissionstays in 1st gear.
14,19,
G, L
No downshift to lst gear.
1 2 .1 9
G,L
Carmovesin E, @, [, @, uut not in E position. car movesin p:1, [o-il, [2-],[!, uut not in E position. Car moves in N
position.
C,L
Late upshift.
14
Erraticshitting.
2, 14,26
Harshshift (up and down shiftingl.
2, 4, 15, 23, 24, 25, 26, 27, 47
A , E ,H , I ,L , V
H a r s hs h i t t { 1 - 2 ) .
2 , 9 . 1 5 ,2 3
C,D,E,V
Harshs h i l t ( 2 - 3 ) .
2, 10, 15, 23, 24
C,D,E,H,L,V
Harshshift (3-4).
2 , | 1, 15, 23, 25
C , D , E ,I , L , V
Harshkick'down shifts.
2, 15, 23, 26, 27. 2A
E,L,O,V
Harshkick-downshift 12 1)
48
o
Harshdownshift at closedthrottle.
2 , 1 5 ,2 3
F T
Harshshift when manuallyshiftingto E] position. Axle{s}slips out of transmissionon turns.
33
L
43,50
Axlels) stuck in transmission.
43
L,O
Ratchetingnoise when shiftinginro E position.
6,7,38,39,40
K,L,O
Loud poppingnoise when taking ott in E position. Ratchetingnoise when shiftingfrom E to E positionor from E to N I oosition.
3a,39,40
L,O
38,33,40,45
L,O
Noisefrom transmissionin all selectorlever positions.
6, 11
K,L,O
Noisetrom transmissiononly when wheels are rolling.
39, 42
L,O
Gear whine, rpm related(pitchchangeswith shitts).
a, 13, 41
K,L,O
Gearwhine, speedrel6ted(pitchchangeswith speed).
38, 42
L,O
Transmissionwill not shift into 4th gear in @
1,21,24.32
L
Lock-upclutch does not lock-upsmoothly.
17,36, 37
L
Lock-upclutch does not operateproperlV.
2.3. 14, 15. 18,35, 36, 37
E,L,V
Transmissionhas multitudeof problemsshitting. At disassembly,largeparticlesoI metal are found on magnet.
43
L,O
14 -8 6
position
PROBABLECAUSE 1
o.
7. 8.
9. 10. 11
12. 13. 14. lo.
18. 'I 9.
21 23.
26. 27. 24. 29. 30. 31
35. 36. 37.
38. 39. 40. 41
43. 44. 45. 47. 48. 49. 50.
Shitt cable broken/outof adiustment. Throttle cabletoo short. Throttle cabletoo long. Wrong type ATF. ldle rpm too low/high. Oil pump worn or binding. Pressureregulatorstuck. l st clutch detective. 2nd clutch detective. 3rd clutch defective. 4th clutch defective. 1st'hold clutch defective. Mainshattworn/damaged. Modulatorvalve stuck. Throttle valve B stuck. ATF strainerclogged. Toroue converterdefective. Torque convertercheck valve stuck. 1-2 shift valve stuck. 2-3 shift valve stuck. 3-4 shift valve stuck. Servo control valve stuck. Clutch Dressurecontrol (CPC)valve stuck. 2-3 orifice control valve stuck. Orificecontrol valve stuck. 3-2 kick-downvalve stuck. 4-3 kick-downvalve stuck. 4th exhaustvalve stuck. 1st accumulatordetective. 2nd accumulatordetective. 3rd accumulatordefective. 4th accumulatordefective. 1st-hold accumulatordefective. Servo valve stuck. Lock-uptiming B valve stuck. Lock-upshift valve stuck. Lock-uocontrol valve stuck. Shift fork benr. Reversegears worn/damaged(3 gears). Reverseselectotworn. 3rd gearsworn/damaged(2 gears). Finalqearsworn/damaged(2 gearsl. DifferentialDinionshatt worn. FeedpipeO-ringbroken. 4th qearsworn/damaged(2 gearsl Gearclearanceincorrect. Clutch clearanceincorrect. One-way (sprag)clutch defective. Sealinqrings/quideworn. Axle-inboardjoint clip missing.
Symptom-to-ComponentGhart HydraulicSystem(cont'd) The following symptoms can be caused by improperrepairor assemblv
Checkthese items on the PROBABLECAUSEDUETO IMPROPER REPAIR List
Carcreepsin E position.
R 1 ,R 2
Car does not move in @ or @ position. Transmissionlocks up in @ position.
R4
Excessivedrag in transmission. Excessivevibration,rom related.
R6
R 3 ,R l 2 R7
Noise with wheels moving only Main seal pops out.
R5
Variousshifting problems.
R9, R1O
Harshupshifts.
R11
R8
PROBABLE CAUSEDUE TO IMPROPER REPAIR R1
R2.
lmproperclutch cleatance. lmDroDerqear clearance.
R3.
Parkingbrake lever installedupsidedown.
R4.
One-way (spraglclutch installedupsidedown,
R5.
Reverseselectorhub installedupsidedown.
R6.
Oil oumo bindind
R7. R8.
Torque converternot fully seated in oil pump. Main seal improperlyinstalled.
R9.
Springsimproperlyinstalled,
R10.
Valves improperlyinstalled.
R11
Ball check valves not installed.
R12.
Shitt fork bolt not installed.
14-8 8
Items on the NOTESList
K.R
NOTES A.
B.
E.
H.
K. L.
M.
N.
o. P.
o.
R. q
T,
See flushing procedure,page l4-168 and 169. Set idle rpm in gear to specitiedidle speed.lf still no good, adiust motor mounts as outlinedin engine section of servicemanual. lf the largeclutch piston O-ringis broken,inspect the piston groove for rough machining. lf the clutch pack is seizedor is excessivelyworn, inspectthe other clutchesJor wear, and check the orifice control valves and throttle valves for free movement. It throttle valve B is stuck, inspectthe clutchesfor wear. lf the 1-2 shift valveis stuck closed,the transmissionwill not upshift.lI stuck open,the transmission has no lst gear. lf the 2-3 orifice control valve is stuck, inspectthe 2nd and 3rd clutch packs for wear. ll the orifice cont.ol valve is stuck, inspect the 3rd and 4th clutch packs for wear. lf the clutch Dressurecontrol valve is stuck closed,the transmissionwill not shilt out of 1st gear. improperalignmentor main valve body and torqueconverterhousingmay causeoil pump seizure.The symptoms ale mostly an rpm-relatedticking noise or a high-pitchedsqueak. ll the ATF straineris ctoggedwith paniclesof steelor aluminum,inspectthe oil pump and ditferential pinionshaft. lt both are OK and no causelor the contaminationis found, replacethe torqueconverter. lf the 1st clutch feedpipeguidein the right sidecover is scoredby the mainshaft,inspectthe ball bearing for excessivemovementin the transmissionhousing.lf OK. replacethe rightsidecover as it is dented. The O-ringunderthe guide is probablyworn. ReDlacethe mainshsttif the bushingfor the 4th feedpipeis loose or damaged. It the 4th feedpipeis damagedor out ot tound, replacethe right side cover' Replacethe subjshaft it thtbushing for the 1st-holdJeedpipeis loose or damaged. lf the 1st-holdfeedpipeis damagedor out of round, replaceit. Replacethe mainshaftif the bushinglor the 1st feedpipeis loose or damaged. lf the lst feedpipeis damagedor out ot round, replaceit. A *o- r, da."s"d "p-g clutch is mostly a result of shifting the transmission in El or Lq! position while the wheels rotate in reverse,such as rockingthe car in snow. InsDectthe frame for collisiondamage. Inspectfor damageor wear: 1. Reverseselectorgear teeth chamfers. 2. Engagementteeth chamtersof countershaft4th and reversegear. 3. Shift fork for scutt marks in center. 4. DifferentialDinionshaJtfor wear under pinion gears. 5. Bottom of 3rd clutch for switl marks. Replaceitems 1, 2, 3 and 4 it worn or damaged.lf transmissionmakesclicking,grindingor.whirring noise,atso replacemainshaft4th gear and reverseidler gear and countershaft4th gear in additionto 1,2,3ot4. lf ditiersntialDinionshaft is worn, overhauldifferentialassembly,and replaceATF strainel,and thoroughly clean transmission,tlush torque convertet,cooler and lines. lf bottom of 3rd clutch is swirled and transmissionmakes gear noise, replacethe countershaft and tinal driven gear. Be wry carefulnot to dsmagethe torque converterhousingwhen replacingthe main ballbearing.You may al;o damagethe oil pump when you torque down the main valve body. This will resultin oil pump seizureit not detected.Use propertools. Install the main seal tlush with the torque converter housing, lf you push it into the torque converter housinguntil it bottoms out. it will block the oil return passageand result in damage. coasting to a stop with zero th.ottle may be caused by a bent-in throttle valve Harsh do\/vnshiJt"\./l,'hen cable adjustmentmay clear this problem. Throttle stopper. retainer/cam ifuitle cable adjustment is essentialfor proper operation of the transmission. Not only does it affect the shift points if misad,usted, but also the shift quality and lock-up clutch operation' A cableadjustedtoo long will resultin throttle pressurebeingtoo low for the amountof enginetorque input into ihe trsnsmissionand may causeclutch slippage.A cableadjustedtoo short will resultin too hi;h throttle pressurewhich may cause harsh shitts, erraticshrfts and torque con
14-89
Road Test NOTE: Warm up the engineto operatingtemperature(the coolingfan comes on). 1
Apply parking brake and block th€ wheels. Start the engine, them move the selector lever to E] position while depressingthe brake pedal.Depressthe acceleratorpedal, and releaseit suddenly.The engineshould not stall,
2.
Repeatsame test in @
3.
Shift the selecto.lever to E position,and chock that the shift points occur at approximatespeedsshown. Also check fof abnormalnoise and clutch slippage.
position.
NOTE: Throttle positionsensorvoltage fepresentsthe throttle opening. - 1. Connect the Test Harness between the ECM and connector (see section 1 1). -2. Setthe digitalmultimeterto check voltagebetweenD1 1{+)terminal and D22 - terminalfor the throttle { ) Dosition sensor.
TEST HARI{ESS OTLAJ_PT3OlOA
DIGITAL MULTIMETER Commarciallyavsilablo o. KS-AHM-32-OO3
0 1 1{ + ooooooooooooo oooooooo oooooo ooooooooooo o o o o o o o o o o o o o o o o o o o o o oooooo ooooooooooo
14-9 0
@ or @ Position . Upshitt Throftle Opening
Unit of spe6d
Throttle positionsensor voltage:O.75 V
Km/h
27,30
20-22 3 2 . 5- 3 5 . 5
mph
Throttle positionsensor v o l t a g e :2 . 5 V
3rd-4th
2nd-3rd
l st- 2nd 17,O 19.O
43.5-48.5
mpn
Km/h mph Km/h
3 3 . 5- 3 6 . 5 30- 34
Unit ot speed
Full-openedthrottle
49.O- 55.O
57.O-63.O 62-65 99.O- 105.O
89.O-95.O 98- 101 15 7 . O - 1 6 3 . O
4th- 3rd
3rd - 2nd
2nd- l Et
Downshift Throttle Op€ning
mph
Full-closedthrottle
Km/h
mph
Full-openedthrottle
Km/h
1a-21 29.O-33.O
6-g (3rd- 1st) 1O- 14 (3rd- lst)
23-27 37.0-43.O
54- 58
85-89 13 7 . O - 1 4 3 . 0
87 . 0- 9 3 . 0
LOCK-Up
@ Position Throttle Opening
Unit of speed
Throttle positionsensor voltage: 2,5 V
km/h
throttle Full-opened
mpn
mpn
km/h
Lock-uo control solenoid valve A ON tJ-
Lock-up control solenoid valve B ON
1 7- 2 0 2A.O-32.O 92-96 r48.0,1 54.O
to
21.O- 25.O 92-96 1 4 8 . O- 1 5 4 . 0
i
E Throttlo Opening
Unit of sp6ed
Throttle positionsensor v o l t a g e :1 . OV
mph kmih mph
Full-openedthrottle
km/h
4.
Lock-up control solenoid valve A ON
Position Lock-up control sol€noid valv6 B ON
b|-oJ
98- 102 85 89 137 143
Accelerateto about 35 mph {57 km/h) so the transmissionis in 4th, then shift from @ The car should immediatelybegin slowing down from enginebraking. CAUTION: Do not shift from @ may damage the tlansmission,
or @
61 63 98- 102
85-89 137- 143 Oositionto E position.
positionto @ of E positionat speedsover 1OOmph (160 km/h); you
5. Check lor abnormalnoise and clutch slippagein the following positions. E (1st Gear)Position - 1 . Acceleratefrom a stop at full throttle. Check that there is no abno.malnoise or clutch slippage. -2. Upshiftsshould not occur with the selectorin this position E (2nd cear) Position. - 1 . Acceleratefrom a stop at full throttle. Check that there is no abnormalnoise or clutch slippage. -2. Upshittsand downshitts should not occur with the selectorin this position. E {Reverse)Position Acceleratefrom a stop at full throttle, and check for abnormalnoise and clutch slippage. 6. Test in E {Parking)Position Parkcar on slope(approx.16o ), applythe parkingbrake,and shift into LE position.Releasethe brake;the car should not move.
14-91
Stall Speed CAUTION: a To plevent transmission damage, do not test stall speed fot mote than 1O seconds at a time. a Do not shift the level while raising th€ engine speed. a Be sure to remove the pressure gauge belot€ testing stall speed. 1. 2. 3. 4. 5. 6.
Engagethe parkingbrakeand block all four wheels. Connectthe tachometer,and start the engine. Make sure the A/C switch is OFF. After the enginehas warmedup to normaloperatingtemperature(the coolinglan comeson), shift into ft position. Fully depressthe brake pedal and acceleratorfor 6 to 8 seconds.and note enginespeed. Allow 2 minutesfor cooling,then repeatthe test in [, fDil and @ positions. NOTE: a Stall speedtests should be used lor diagnosticpurposesonly. . Stall speed should be the same in E, tr. tr and @ positions. Stall SpeedRPM: rpm Specification: 2,400 rym Service Limit: 2,2OO-2,600 tpm
TROUBLE
Stallrpm hish in E, posrtron
Stall rpm high in I
PROBABLE CAUSE
and@
E, I
position
Stall rpm high in @ position Stall rpm high in @
position
Low fluid level or oil pump output CloqgedATF strainer Pressureregulatorvalve stuck closed Slippingclutch Slippageof 1st clutch, 1st-holdclutch or 1st gear one-way clutch Slippageof 2nd clutch Slippageof 1st clutch, lst gear one-way clutch
Stall rpm high in @ position
Slippageof 4th clutch
Stallrpm low in E, position
Engineoutput low Torque converterone-way clutch slipping
14-92
E, I
ana@
Fluid Level Checking/Changing Checking
Changing
NOTE: Checkthe fluid levelwith the engineat normal operatingtemperature(the cooling lan comes on).
1.
Bringthe transmissionup to operatingtemperature by drivingthe car. Parkthe car on levelground,turn the engineoft, then removedrain plug.
1. Parkthe car on levelground. Shut otf the engine. 2.
Removethe dipstick (yellow loop) from the transmission,and wipe it with a clean cloth.
3.
Insertthe dipstick into the transmission.
NOTE: lf a cooler flusher is to be used, see page 1 4 - 1 6 8a n d 1 6 9 . 2.
Reinstailthe drain plug with a new sealingwasher, then refillthetransmissionto the uppermark on the dipstick. Automatic Transmission Fluid Capacity: 2.1 | l2.S US qt, 2.4 lmp qt) at change 5.9 ? (6.2 US qt, 5.2 lmp qt) at overhaul
TRANSMISSIONRIGHT SIDE COVER
DIPSTICK(YELLOWLOOPI
4.
Removethe dipstick and check the fluid level. should be betweenthe uoDerand lower marks.
P il \---
T
1 8 x 1 . 5m m 49 N.m (5.0 kgl.m, 36 lbl.ft)
IT {J. t)-i-
U P P EM RARK LowERMARK
5 . lf the level is below the lower mark, add fluid into the tube to bring it to the upper mark. Use Honda PremiumFormulaAutomaticTransmissionFluidor a n e q u i v a l e n t D E X R O Nl l@ AutomaticTransmission Fluid (ATF)only. 6.
lnse.t the diDstickback into the transmission.
14-93
PressureTesting a While testing, be caretul of the rotating flont wheels. a Make aura litts, jacks, and sat€ty stands alo placed plop6rly {see section 1}.
4.
Start the engine,and measurethe respectivepressure as follows. a Line Pressure a Clutch Pfessure a Clutch Low/High Pressure a Throttle B Pressure
5.
Installa new washer and the sealingbolt in the inspectionhole and tighten to the specifiedtorque.
CAUTION: Betoret€sting, be sure the transmissionfluid is tilled to rh6 ploper l€vet. 1.
Raisethe car (seesection i),
2.
Warm up the engine{thecoolingfan comesonl, then stop the engineand connect a tachometer.
3.
Connectthe oil pressuregaugeto each inspection holels). TOROUE:18 N.m (1.8 kgf.m, 13 tbf.fr) CAUTION: Connect ths oil prsssure gauge s€cur€_ ly; be sule not to allow dust and other foleign pani_ cl6s to 6nt€1 th€ inspection holo. A/T OILPRESSURE GAUGE SETWPANEL 07406-002oi+oo
TOROUE:18 N'm {1.8 kgf.m, 13 tbf.ft) NOTE: Do not reuseold aluminumwashers. a Line Pressure M€asurement - 1 . Set the parkingbrakeand block both rear wheels securely. -2.
Run the engineat 2,OOOrpm
-3.
Shift the selecr lever to S
-4.
Measureline pressure.
or @ position.
LINEPRESSURE INSPECTION HOLE A/T LOW PRESSURE GAUGE W/PANEL 07/rO6-0O70300
A/T OIL PRESSUREHOSE, 22'10 mm OTMAJ_PY4OITA {4 Roquirod) A/T OIL PRESSUBEHOSE ADAPTER OTMAJ - PY/+O120 14 Roqui.odl
NOTE: Use the A/T Oil PressureGaugeSet (07406_ O02OOO3)or A/T Low Pressure Gauge (07406OOTO0OO). and the oil pressuregaugehosesand adap_ ters shown above.
PRESSURESELECTOR
POStTTON
Line
No'E
SYMPTOM
PROBABLE CAUSE
FLUIDPRESSURE Standard
No (or low) Torque converter, 83O-88O kPa lrne pressure orl pump, pressure ( 8 . 5 - 9 . O k g f / c m , , regulator,to.que 120- I 30 psi) convener check valve
Service Limit 78O kPa {8.0 kgl/cm,,1lO psi}
NoTE: Higherpressuresmay be indicatedit measurementsare made in selectorpositionsother than @ or @ position.
14-94
a Clutch Pressuro M€asur€ment wtit" testing, be careful ot the rotating front wheols.
@ 1. 2. -3. -4. -5.
Set the parkingbrake and block both rear wheels securely. Raisethe front of the car and supportwith safety stands. Allow the front wheels to rotate freely, Run the engineat 2,OOOrpm. Measureeach clutch Pressure. LOCK.UPCONTNOLSOLENOID VALVE ASSEMBLY
INSPECTIONHOLE
rl|E!!UltE
1st Clutch l st-hold Clutch
SELECTOB POST ON
Eo'E
tr
2nd Clutch
a
2nd Clutch
E
FLUIDPRESSURE SYMPTOM
PROBABLE CAUSE
1st Clutch No or low lst Pressure No or low 1st-hold pressure
1st-holdCIutch
83O-880 kPa (8.5-9.O kgf/cm', 120- 130 psi)
Service Limit 78O kPa { 8 . Ok g f / c m ' ,1 1 O p s i )
2nd Clutch No or low 2nd pressure 2nd Clutch No or low 2nd pressure
3rd Clutch
3rd Clutch No or low 3rd pressure
4th Clutch
4th clutch No or low 4th pressure
E
Standard
Servo Valve or 4th Clutch
4'l o kPa 460 kPa (4.2 kgt/cm' , 60 psi) |'4.7 kgtlcm2, 67 psil throttle control lever throttle control lever fully closed fully closed 78O kPa 830-880 kPa (8.O kgf/cm' , 1 1O psi) (8.5 - 9.0 kgt/cm' , throttle control lever 120- l30 psi) m o r et h a n 3 / 1 6 o p e n e d throttle control lever m o r et h a n 3 / 1 6 o p e n e d 830-880 kPa (8.5 9.0 kqf/cm' , 120- 130 psi)
780 kPa (8.0 kgf/cm' , 1 1O psi) (cont'd)
14-95
PressureTesting (cont'dl a
Clutch Low/High P.essure Measuroment
wtite resring. b€ calefut ot tha loraring @[ flont wh66ls. - 1. Allow the front wheels to rotate freely. -2.
Removethe cableend of the throttlecontrolcable from the throttle control lever. NOTE: Do not loosenthe locknuts.simplvunhook the cable end.
CAALE END
-3.
Start the engineand let it idle.
-4.
Shitt the select leve. to E
-5.
Slowly move the throttle linkageto increaseengine rpm until pressureis indicaiedon the oil oressure gauge. Then releasethe throttlelinkage,allowingthe engrneto returnto an idle,and measurethe Dressure resding.
14-96
position.
-6.
With the engine idling, lift the throttle control lever up approximately1/2 of its possibletravel and increase the engine rpm until pressure is indicated on the gauge,then measurethe highestpressure readingobtained.
- 7. Repeatsteps 5 and 6 for each clutch pressurebeing inspected.
LOCK.UPCONTROL SOLENOIDVALVE
4TI{ CLUTCH PRESSURE INSPECTIONHOLE
SHIFT CONTROL SOLENOIDVALVE ASSEMBLY PROTECTOR 3RD CLUTCH PRESSURE INSPECTIONHOLE
INSPECTIONHOLE
PRESSUNE 2nd Clutch
SELECTOR POStTtON
E
SYMPTOM
PROBABLE CAUSE
FLUIDPRESSURE Standard
No or low 2nd Clutch 2nd pressure
3rd Clutch
No or low 3rd pressure
3rd Clutch
4th Clutch
No or low 4th pressure
4th Clutch
460-88O kPa (4.7 -9.O kgtlcmt, 67- 130 psil varies with throttle openrn9
Service Limit 41OkPa {4.2 kgf/cm,, 60 psi} with throttle control lever released 78O kPa l8.O kgtlcm,, 1'lO psil with throttle control lever more than 3/1 6 opened
(cont'd)
14-97
PressureTesting (cont'dl a Throttle B Ptsssure Measuremcnt wrril" resring, be caretut ot rhe rotaring @@ front wheels. 1. Allow the front wheels to rotate treelv. -2. Removethe cableend of the throttlecontrolcable from the throttle control lever.
3. -4. -5. -6. -7.
Shift the selectorlever to @ or @ position. Run the engineat 1,OOOrpm Measurefull-closedthrottle B pressure. Move the throttle control leverto full-openedthrottle position. Measurefull-openedthrottle B pressure.
NOTE: Do not loosenthe locknuts,simplyunhook the cable end.
PRESSURE
SELECTOR SYMPTOM POSTTTON
PROBABLECAUSE
Throttle B
loil orlDll
Thfottle Valve B
Pressuretoo high
No or low Throttle B pressure
14-98
FLUIDPRESSURE Standard
S€rvica Limit
O-15 kPa { O - O . 15 k g f / c m , , 0-2.1 psi) throttle control lever fully closed 83o 88O kPa (8.5-9.O kgf/cmz, 120 130 psi) thfottle control levet fully closed
78O kPa (8.O kgl/cm,, l lO psi) throttle control lever tully closed
Transmission Removal a Make sur€ lifts. iacks and safety stands are placad properly, and hoist brackots are attachod to tho correct position on ths sngine {seo sectionl }. o Apply parking brake and block rear wheels, so car will not roll off stands and fall on you whil6 working undel it
4.
Bemove the t.ansmissionground cable from the transmissionhanger. Disconnectthe lock-uDcontrol solenoidvalve connectorand the shitt controlsolenoidvalve connector, then removethe harnessclamp on the lock-up control solenoidharnessfrom the harnessstav.
CAUTION: Use tender covers to avoid damsging painted surlaces, 1.
Disconnectthe battery negative{ - } and positive( + ) cables from the battery.
2.
Removethe intakeair duct and air cleanerhousino assembly.
HARNESSCLAMP
LOCK-UPCONTROL SOLENOIDVALVE CONNECTOR
AIR CLEAI{ER HOUSINGASSEMBLY
SHIFT CONTROL SOLENOIDVALVE CONNECTOR
TRANSMISSION GROUNDCABI-E
Disconnectthe vehiclespeed sensor(VSS),mainshaft sDeedsensorand countershaftspeedsensor connectors.
3 . Removethe startermotor cablesand cable holder
VEHICLESPEED SENSORCONNECTOR
from the starter motor.
STARTERMOTOR CABLE CABLE HOLDER
VEHICLESPEED SENSOR COUNTERSHAFT SPEEDSENSOR CONNECTOR STARTERMOTOR
?/\
STARTERMOTOR CABLE
MAINSHAFTSPEED SENSORCONNECTOR(cont,d)
4-99
Transmission Removal{cont'd) 7.
Removethe transmissionhousingmountingbolts.
9. Removethe splashshield.
6 x 10
CLIP S pcs. Removethe drainpluganddrainthe automatictransmissiontluid (ATF).Reinstallthe drain plug with a new sealingwasher lsee page 14-93).
10. Remove the cotter pins and castle nuts, then separatethe balljointsfrom the lower arm {seesection 18). 11. Removethe right dampe. fork bolt. then separate right damperfork and damper.
PINCI{ BOLT
/\
SELF.LOCKING NUT Replace. DRAINPLUG 1 8 x 1 . 5m m 49 N'm 15.0 kgt-m,36 tbt-fr)
14-100
DAMPERFORK
CASTLE NUT
COTTERPIN Replace.
12. Pry the right driveshaftout of the differentialand pry the lett driveshattout of the intermediateshaft. '13.
Pull on the inboardjoint and removethe right and left driveshafts(see section 16).
'14.
Tie plastic bags over the driveshaftends.
17. Removethe intermediateshaft.
NOTE: Coat all precisionfinished surfaces with clean engineoil.
1 8 . Removethe shift cablecover,then removethe shift cable by removingthe control lever. PLASTICBAG Disconnectthe heatedoxygen sensor(HO2S)connecror.
CAUTION: Take care not to bend the shift control cabls whilo removing it.
1 6 . Removethe exhaust pipe A. SHIFT CABLE
LOCKWASHER CONTROLLEVER Replace.
SELF-LOCKING NUT Replace.
Replace.
(cont'dl
14-101
Transmission Removal(cont'dl '1 9. Removethe right tront mount/bracket,then remove the end ol the throttle cont.ol cabletrom the throttle control lever.
23. Placea jack underthe transmission,raisethe lransmission just enough to take weight off ol the mounts. then removethe transmissionmount.
20. Removethe ATF coolerhosesat the joint pipes.Turn the endsof the coolerhosesup to preventATF from flowing out, then plug the joint pipes. NOTE: Check tor any sign ot leakageat the hose joints.
'i
THROTTLE CONTROL
"
z/'l e (-J
t'
RrcHTFRoNTiiouNT/BRAcKET BoLTs
ATF COOLER Replace. HOSES
21. Removethe enginestiftenerand totque converter cover. 22. Removethe eight drive plate bolts one at at time while rotatingthe crankshaftpulley.
24. Removethe t.ansmissionhousingmounting bolts and rear enginemounting bolts. 25. Pullthe transmissionaway from the engineuntil it clearsthe 14 mm dowel Dins,then lower it on the transmissioniack.
WASHERS Replace.
14-102
lllustrated Index Right Side Cover
14-104
O RtcHTslDEcovERpRoTEcToR @ RrcHTstDEcovER spEEDsENsoR O MAtt{sHAFr @ o-RtNGReptace. SPEEO SENSOR @ cour{TERSHAFT STAY @ HARNESS O RoLLCR @ COLLAR O O-RINGReptace. @ FEEDPIPEFLAI{GE @ o-RrNG @ sIrlAPRING @ 3RDCIUTCHFEEDPIPE LOCKNUT(FLAt{cEf{UTl Reptace. @ COUNTERSHAFT @ coultTERsHAFf col{tCAL SpRtt{cWASHERReotace. @ PARKI G GEAR @ oNE-waY cLUTcH @ couNTERsHAFrlsr GEAR BEARING @ NEEDLE @ couNTERsHAFrtsr GEARcoLLAB @ O-RINGReptace. @ l sT-HoLDaccuMuLAToR ptsToN spBfi{c @ isT-HoLD ACCUMULAToR @ o-RtNGReptace. covER @ rsT-HoLDACGUMULAToR @ SNAPRrr{G @ PAFKINGBRAKEPAWL BRAKEPAWLSPRII{G @ PARKING BRAKEPAWLSHAFT @ PARKING aRAKEPAWLSToPPER @ PARKING @ LOCKwasHEn Reptace. @ PARKI G BRAKEs?oPPER BRAI(ELEVER @ PARKING @ PARKI G BRAKELEVERSPBING @ DowEL PrN @ O-RltIGReptace. stoE covER GASKETFeptace. @ RTGHT @ isT ct-uTcH FEEDptpE @ o-RtNGReptace.
@ FEEDPIPEGUIDE @ SNAPRING NUT)ReDIace. @ MAINSHAFTLocKNUT{FLANGE SpRtNGWASHERReotsce. @ MAfISHAFTCONTCAL @ IsT cLUTcHASSEMBLY @ O-RINGReptace. @ THRUSTWASHER BEARIG @ THRUSINEEDLE @ EEDLEBEARING @ MAI'{SHAFTlsT GEAR @ THRUSTWASHER @ MAINSHAFTlsT GEARcoLLAR @ RoLLER @ coLLAR @ O-Rlt{cReptace. @ FEEoPIPEFLANGE @ o-RINGR€ptace. @ SNAPRING @ lsr-HoLD cLUTcH FEEDptpE LoCKNUTIFLAt{c€NUTIReptace. @ SUB-SHAFT @ suB-sHAFr cot{tcAl spRtNGWASHERReptace. lST GEAR @ SU8-SHAFT @ LOCKWASHERf,eptace. @ THRoTILEcor{TRoL LEVER @ THRoTTLEcoNTRoL I.EVERSPRING @ oll sEAt Reptace. coNTRoL CABLESTAY @ THRoTTI"E SOLEI{O|O HARNESS @ sHtFTCONTROL @ Jor T BoLT PIPE @ ATF COOLER Roptace. @ SEAL|NGWASHERS @ ATF cooLER P|PE @ ATF LEVELGAUGE @ JOINTEOLT @ vEHtcLEspEEDsEf{soR @ o-RtNGReptace. @ DRAINPLUG @ SEALINGWASHERReplace.
TOROUESPECIFICATIONS Ret No. B D F
Torque Value '12 N.m (1 .2 kgf.m, 8.7 lbJ.tt) 14 N.m (1.4 kgf.m, 10lbf.ft) 22 N.m 12.2 kgf.m, 16 lbf.ft) 8 N.m (O.8 kgf.m, 6 lbf.ftl 28 N'm (2.9 kgf.m, 21 lbf.ttl 49 N.m (5.O kgf.m, 36 lbf'ft) 93 N.m {9.5 kgf.m, 69 lbt.ft}
Bolt Size 6 x 1 , Om m 6 x 1 . Om m I x 1 . 2 5m m 5x0.8mm 12 x 1-25mm '1.5 18 x mm t Y x t . z 5m m
K
1 0 3 N . m { 1 O . 5k g f . m , 7 5 . 9 l b f . f t l - O 1 O 3N . m ( 1 0 . 5 k g f ' m . 7 5 . 9 l b f . f t )
2 3 x 1 . 2 5m m
L
93 N.m (9.5 kg-m, 69 lb-ft)
'19 x 1 . 2 5m m
Remarks Specialbolt
ATF cooler pipe joint bolt Drainplug Mainshaftlocknut (flangenut): Left-handthreads Countershaftlocknut (tlangenut) Lett-handthreads Sub-shattlocknut (flangenut)
14-105
lllustrated lndex Transmission Housing
@
I ',
TTI]
a''-.2
14-106
O) COUNTERSHAFTREVERSEGEAR COLLAR @ NEEDLEBEARING G) COUNTERSHAFTREVERSEGEAR @ LOcK WASHERReptace. sHIFT FoRK @ REVERSE @ BEVERSESELECToR O REVERSESELECToRHUB @ couNTERSHAFT 4TH GEAR @ NEEDLEBEARING @ DTSTANCECOLLAR, 29 mm Setecrivepart. @ coUNTERSHAFT2ND GEAR @ THRUSTNEEDLEBEARING @ GoUNTERSHAFT3RD GEAR @ NEEDLEBEARING @ THRUSTNEEDLEEEARING G) COUNTERSHAFT3RD GEAR COLI-AR O 3RD cLuTcH ASSEMBLY (!) O-RINGSReplace. @ coUNTERSHAFT @ REVERSEIDLERGEAR @ SNAP RING @ THRUSTWASHER @ THRUSTNEEDLEBEARING @ MAINSHAFT4TH GEAR @) NEEDLEBEARINGS @ THRUSTNEEDLEBEARING @ MAINSHAFT 4TH GEAR coLLAR @ 2ND/4TH cLUTcH ASSEMBLY et O-RINGSReplace. @ THRUSTwaSHER, 36.5 x 55 mm Setectivepan. @ THRUSTNEEDLEEEARING @ MA|NSHAFT2ND GEAR €, NEEDI.EBEARING @ THRUSTNEEDLEEEARING .O MAINSHAFT
@ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @
SEAL|NGRtNGs, 3s mm SEAL|NGR|NG,29 mm NEEDLEBEARING sET RING 1ST-HOLDCLUTCH O-RINGReplace. THRUST WASHER THRUST NEEDLEBEARING NEEDLEBEARING SUB.SHAFT4TH GEAR THRUST NEEDLEBEARING SUB.SHAFT4TH GEAR COLLAR SUB-SHAFT SUB.SHAFTNEEDLEBEARING NEEDLEBEARINGSToPPER otL GUTDEcAP Reptace. REVERSEIDLERG€AR SIIAFT/HOLDER NEEDLEBEARII{G sHIFT GONTROLSOLENOIDvAI.vE ASSEMBLY PROTECTOR VALVE A/B sHrFT CONTROLSOLENOTD SHIFT CONTROLSOLENOIDVALVE A/B FILTER/GASKET Replace. TRANSMISSIONHANG€R TRANSMtsstoN MouI{T BRAGKET oll SEAL Replace. sET RING Replace. TRANSMISSIONHOUSINGGASKET Replace. DOWEL PrN SNAP RI G SUB-SHAFTIRANSMtSStON HOUSNG AEARTNG MAINSHAFT TRANSMISSIONHOUSINGBEARING coUNTERSHAFT TRANSMISSIONHOUSINGBEARING DIFFERENTIALASSEMELY OtL SEAL Replace. CoNNECTORSTAY
TOROUESPECIFICATIONS Rel No. B E H
Torque Value 1 2 N . m ( 1 . 2 k g f . m , 8 . 7l b t . t t ) 1 4 N . m ( 1. 4 k g f. m . 1 0 l b f. f t ) 44 N.m (4.5 kgt.m, 33 lbf.ft) 6 4 N . m ( 6 . 5 k g f. m , 4 7 l b f. f t )
Bolt Size 6 x 1 . Om m 6 x 1 . Om m ' l Ox 1 . 2 5m m
Remarks Specialbolt
1 2 x 1 . 2 5m m
14-107
lllustratedIndex Torque Converter Housing/ValveBody
^\
14-108
OIL FEEDPIPE ACCUMULATORCOVER O-RINGReplace. OIL FEEDPIPE OIL FEEDPIPE SERVOOETENTEASE LOCNWASHERFeplace. ATF STRAINER SUCTIONPIPECOLLAR SERVOBOOY THROTTLECONTROLSHAFT E RING SERVOSEPARATORPLATE 1ST ACCUMULATORCHOKE CHECKBALL STOPPERSHAFT STAY SECONDARYVALVE BODY DOWEL PIN SECONDARYSEPARATORPLATE LUBRICATORPLATE OIL FEEDPIPE LOCK.UPVALVE BODY DOWEL PIN LOCK-UPSEPARATORPLATE TOROUECONVERTERCHECKVALVE SPRING TOROUECONVERTER CHECKVALVE COOLERCHECKVALVE SPRING COOLERCHECKVALVE
@ REGULAToRvALvE BoDY @ STOPPERSHAFT @ O-RINGReptace. @ STATOR SHAFT @ otl FEEDPIPE @ MAIN vALvE BoDY @ CHECK EALL @ DowEL PIN @ oIL PUMP DRIVEGEAR @ OIL PUMPDRIVENGEARSHAFT Q9 OIL PUMPDRIVENGEAR @ MAIN SEPARAToR PLATE @ DowEL PrN @ coNTBoL sHAFT @ DETENTSPRING @ DETENTARM SHAFT @) DETENTARM @ ATF MAGNET TOROUECONVERTER HOUSING @ COUNTEBSHAFT NEEDLEBEANING @ oIL GUIDE PLATE @ TOROUECONVERTERHoUSING HOUSINGBEARING @)MAINSHAFTTOROUECONVERTER @ oll SEAL Reptace.
soLENotD vALvEA/B @ LocK-upcoNTRoL STAY @ coNNECTOR VALVE A/B @ LOCK-UPCONTROLSOLENOTD FILTER/GASKET Replace.
TOROUESPECIFICATIONS ReI No.
Torque Value
Bolt Size
1 2 N . m ( 1. 2 k g f . m , 8 . 7 l b f . f t )
6 x 1 . Om m
Remarks
14-109
Right Side Cover Removal NOTE: a Cleanall pans thoroughlyin solvent or carburetorcleaner,and dry with compressedair, a Blow out all passages. a When removingthe transmissionright side cover, replacethe following: . Right side cover gasket . Lock washers SIDE COVER PROTECTOR . O-rings . Each shaft locknut 1.O mm BOLTS . Conicalspring washers . Sealingwashers RIGHT SIDE COVER
SUB.SHAFT Replace.
CONICAL SPRING WASHER Replace.
WASHER Replace.
MAINSHAFT 1ST GEAR
PARKINGGEAR
ONE.WAYCLUTCH
SUB.SHAFT 1ST GEAN THROTTLECONTBOL LEVER
1STGEAR
THRUST WASHER ,IST GEAB COLLAR
BEABING NEEDLE lST GEARCOLLAR
JOINT AOLT ATF LEVELGAUGE ATF COOLERPIPES SEALINGWASHERS Replace.
14-110
'1.
Removethe 13 bolts securingthe right side cover and right side cover protector,then removethem. Slip the specialtool onto the mainshaftas shown.
5. Pry the lock tab of the mainshaftlocknut. 6. Cut the lock tabs of the countershaftand sub-shaft locknutsusinga chiselas shown. Then removethe locknut from each shatt.
MAINSHAFTHOLOER 07GAB-PF50101
NOTE; a Mainshaftand countershaftlocknuts have letthand threads. a Cleanthe old countershaftlocknut,it is used to installthe parkinggear on the countershaft. a Always wear safety glasses. CAUTION: Keop all of th€ chis€led panicles out of the tlanamigsion.
llrF-"""* LocKNUr
,fl(,-..-
@-.**'o' 7 . Removethe lock pin that was installedto hold the sub-shaft. 3.
Engagethe parkingbrakepawl with the parkinggear.
4.
Align the hole ot the sub-shaft l st gear with the hole of the the transmissionhousing,then inserta pin to lock the sub-shaft while removing the sub-shaft locknut.
8 . Removethe specialtool from the mainshaftafter removingthe locknut. q
Removethe 1st clutch and mainshaft1st gear assembly from the mainshaft.
1 0 .Removethe sub-shaft 1st gear, 1 1 .Removethe parkingbrake pawl. COUNTERSHAFT LOCKNUT Replace.
MAINSHAFT LOCKNUT Replace.
8 mm pin. comm€rcially available SU8-SHAFT LOCKNUT Replace.
1 2 . Usinga universaltwo jaw puller.removethe parking gea..one-wayclutch and counlershatt1st gear assembly.
PARKINGGEAR
1 3 .Removethe parking brake lever from the control shaft. Align the holes. CONICAL SPNING WASHERS Replace.
1 4 . Removethe throttle control lever from the throttle control shaft. 1 5 . Removethe ATF cooler pipes. t o . Removethe ATF level gauge.
14-111
Transmission Housing Removal
TRANSMTSSTOIr HOUSIIG MOUNTING BOLTS
fl TSAt{SMtSStOt{ HANGER TRANSMISSIO HOUSII{G
TRA[{SMrSSrOr{ MOUNTBRACKET 'RAI{SMTSSTOHOUS|IG GASKET Rgolace. REVERSEGCAR COLLAR
]{EEDLEBEARII{G NEVERSE GEAR
MAINSHAFT SUA.ASSEMBLY
LOCTWASHEF Replace. SHIFT FORX
REVERSE SEL€CTON COUI{TERS}IAFT SUB-ASSEMEI.Y DIFFEFEI{IIAL ASSEMBIY
(-t\
14-112
NOTE: a Clean all parts thoroughly in solvent o. carburetor cleanerand d.y with compressedair. a Blow out all passages. a When removingthe transmissionhousing,replacethe following: . Transmissionhousinggasket . Lock washer 1.
Removethe countershaft reversegear with the collar and needlebearing.
6 . Remove the lock bolt securing the shitt fork. then remove the fork with the reverse selector trom the countershatt. Remove the countershaft and mainshaft subassemblytogether.
Removethe transmissionmount b.acket.
2 . Remove the transmission housing mounting bolts and hanger. Align the spring pin of the control shaft with the transmissionhousinggrooveby turningthe control shaft. 4.
Installthe specialtool on the transmissionhousing, then removethe housingas shown. HOUSING PUI-LER 07HAC-PK4010A
8.
Removethe ditferentialassemblv.
14-113
Torque GonverterHousing/ValveBody Removal
Bolts, 7
\ LOCK-UP VALVE
B . D Y \ u ll DOWELPIN LOCK-UPSEPARATOR PI.ATE REGULATORVALVE AODY
otL FEED PIPES
OII- FEEDPIPES
TOR COVER
A
OIL FEEOPIPE
Ll ll|i
8oll3.3
SERVODETENT BASE
|]V
ATF STRAINER
OIL FEED PIPES
SUCTION PIPE COLLAR
8olts, 4 Boll DOWEL PIN
MAIII VALVE BODY
OIL PUMP DRIVENGEAR SHAFT
SECONDARYVALVE BODY
OIL PUMP DRIVEN DOWEL PIN SECONDARYSEPARATOR PLATE
MAIN S€PARATOR PLATE
ft--
rrr urcler
TOROUECONVERTER HOUSING
14-114
NOTE: a Clean all parts thoroughly in solvent or carbuetor cleanerand dry with compressedair. a Blow out all passages. a Whenremovingthe valvebody replacethe following: . O-rings . Lock wsshers
1 5 .Cleanthe inlet opsningof the ATF strainerthoroughly with compressedair, then check that it is in good condition,and the inlet openingis not clogged.
1 . Removethe oil feed pipes from the servo body, s€rvo detent base, accumulatofcover, lock-uDvalve body and main valve body. 2, Removethe three bolts securingthe ATF strainerand servo detent base, then remove them. 3. Removethe three bolts securingthe accumulator cover. then removethe accumulatorcover. 4. Removethe six bolts secu.ing the servo body, then removethe servo body and separatorplate. 5. Removethe bolt securingthe secondaryvalve body, then removethe secondaryvalve body and separator plate. 6. Removethe eight boltssecuringthe lubricatorplate and lock-upvalve body, then removethe lubricator plate, lock-upvalve body and separatorplate.
II{LET OPENING
1 6 . Replacethe ATF strainerit it is cloggedor damaged. NOTE: The ATF strainer can be reused if it is not clo9ged.
7. Femovethe bolt securingthe.egulatorvalvebody, then.emove the regulatorvalve body. 8. Remove the stator shaft and stopper shaft. 9. Removethe detent spring t,om the detent arm. then remove the control shaft from the torque convener housing. 1O. Removethe detent arm and detent afm shaft t.om the main valve bodv. 1 1. Removethe four bolts secu.ingthe main valve body, then removethe main valve body. 12. Removethe oil pumpdrivengearshaft,then remove the oil pump gears. '13.
Removethe main separatorplate with two dowel Dtns.
14, Removeand clean the ATF magnet.
14-115
Valve Caps Description Caps with one projectedtip and one flat end are installedwith the llat end toward the insideot the valve body. Caps with a projectedtip on each end are installed with the smallertip toward the insideof the valve body. The small tip is a spring guide.
Toward outside ot valv6 bodv.
Capswith hollow ends are installedwith the hollow end away from the insideof the valve body. Capswith notchedends are installedwith the notch toward the insideof the valve body. Capswith flat ends and a holethroughthe centerare installedwith the smallerholetowardthe insideof the valve body.
Toward outside oI valv€ bodv.
lrj taj u rq
fq1 @.
Toward inside of valve body.
Towa.d inside of valve body.
Caps with one projected tip and hollow end are installed with the tip toward the inside of the valve body. The tip is a springguide.
Capswith llat ends and a groovearoundthe cap are installedwith the groovedsidetoward the outsideof the valve body.
Towa.d outside ot valve body.
Toward outside of valve bodv.
Sectional view
Toward inside of valve body.
14-11 6
Toward inside of valve body.
Valve Body Repair NOTE: This repairis only necessaryil one or more of the valvesin a valve body do not slidesmoothlyin their bores.You may use this procedureto lree the valvesin the valve bodies. 1. Soak a sheet of #600 abrasivepaper in ATF for about 30 minutes. 2.
5 . Removethe #600 paperand thoroughlywash the entire valve body in solvent, then dry with comperssedair. 6 . Coat the valve with ATF then drop it into its bore. It shoulddrop to the bottom o{ the bore under its own weight. lf not. repeatstep 4 then retest.
Carefullytap the valve body so the stickingvalve drops out of its bore. CAUTION: lt may be necessaryto use a small screwdiiver to pry the the valve lree. Be carelul not to sclatch the bore with ihe sc.ewdliver.
3.
4.
Inspectthe valvetor any scuff marks.Usethe ATFsoaked# 600 pagperto polishoff any burrsthat are on the valve,than wash the valvein solventand dry it with compressedair.
VALVE BODY
Rollup halt a sheetoI ATF-soakedpaperand insert it in the valve bore of the stickingvalve. Twist the paper slightly,so that it unrollsand fits the boretightly,then polishthe boreby twistingthe paper as you push it in and out. CAUTION: The valve body is aluminumand doesn't requiremuch polishingto removeany burs.
W 7 . Remove the valve and thoroughly clean it and the valve body with solvent. Dry all parts with com pressed air, then reassemble using ATF as a lubricant.
14-117
Valve Assembly NOTE: Coat all parts with ATF belore assemblv. a Installthe valve, valve springand cap in the valve body and secure with the 10116r.
-6^<
a Set the springin the valve and installit in the valve body. Pushthe springin with a screwdriver,then installthe spring seat.
ROLLER
5-1
SPBINGSEAT
VALVE BODY
VALVE BODY
Installthe valve, spring and cap in the valve bodv. Pushthe cap, then installthe cliD,
ROLLER VALVE EODY
VALVE
CAP
14-118
Oil Pump lnspection l.
Installthe oil pump gearsand oil pump driven gear shait in the main valve body.
Measurethe sideclearanceot the oil pumpdriveand driven gears. Oil Pump Gsars Sido (Radisl) Clsarance: Stsndard {N€w}: Drive g€ar n) O . 2 1 O - O . 2 6 5m m ( O . O O 8 3 - O . O 1 0i 4 Drivon g6al O . O 7 O - O . 1 2 5m m ( O . O O 2 8 - O . O O 4i n9)
CHAMFER
GROOVE
YI Grooved and chamfered side faces separator plate.
OIL PUMP DRIVENGEAR Inspect teeth tor wear or damago.
DRIVEGEAR Inspectteethlor wearor damaage. Removethe oil pump drivengear shaft, and measure the thrust clearanceof the oil pump drivengearto-main valve body. Oil pump Drive/DrivenGearthrust (Axiall Clearance: Standard(Nawl: 0 . 0 3 - O . O 5 m m { O . O O-lO . O O 2i n ) Sorvice Limit: O.O7mm {O.0O3in}
MAIN VALVE BODY
STRAIGHTEDGE
14-11 9
Main Valve Body Disassembly/lnspection/Reassembly NOTE: a Clean all parts thoroughly in solvent or carburetor cloaner and dry with compressed air. a Blow out all passaoes. a Replacevalve body as an assemblyit 8ny parts are worn or damaged. a Check all valves lor free movement.lf any fail to slide freely, see Valve Body Repairon page 14-117. CAUTION: Do not use a magnot to romovo ths check batb; it may magnotize the balls.
2.3 SHIFTVALVE
CHECK BALLS, 3 DETENTARM SHAFT
DETEfITARM
F
rrl\.
J ST VALVE
'-ir,
i
,^r @
q--RELIEFVALVE
t'-'t @
\\ i f l @
MANUAL VALVE
\
VALVECAP CLIP MAIN VALVE BODY
14-120
Qr DETENTARM SHAFT MANUAL VALVE
sPat G sPEctFtcaTtot{s Unit ot length: mm (in) Standard lNowl o,
o @ o o @
Epfng Relief valve spring 4th oxhaust valve spring 2-3 shift valve spring CPC valve spring 1-2 shift valv6 spring
Wiro Dia.
1. 1 { O . O 4 3 l 1. 0 { 0 . 0 3 9 t 0.9 {0.035t 1 . 3{ O . 0 5 1 ) 0.9 {0.03s)
o.D. 8.6 (0.339) 7.1 (O.2801 7.6 (O.2991 9.4 (0.370) 8.6 (O.339)
F.oo Lsngth
3 7 . 1{1 . 4 6 1 ) 60.3 12.3741 57.O 12.2441 3 5 . 3{ 1 . 3 9 O ) 4 0 . 4{ 1 . s 9 1 t
No. ot Coils 13 . 4 18.5 26.4 12.4 14.5
14-121
RegulatorValve Body Disassembly/lnspection/Reassembly NOTE: a Cleanall pans thoroughlyin solvent or carburetorcleaner,and dry with compressedait. a Blow out all passages. a Replacevalve body as an assemblyit any parts are worn or damaged. a Check all valves for free movement.lf any fail to slide freely, see Valve Body Repairon page 14-117. 1.
Hold the .egulatorspring cap in place while removingthe lock bolt. Once the bolt is removed.releasethe spring cap slowlv. CAUTION: The .egulator spring c8p can pop out whsn the lock bolt is removod. Reassemblyis in the reverseorder of the disassemblyprocedute.
2.
NOTE: . Coat all pans with ATF. a Align the hole in the regulatorspringcap with the hole in the valve body, pressthe springcap into the body and tighten the lock bolt.
t,-V
REGULATORVALVE
,*6t'"
LOCK.BOLT 6 x 1 . 0m m 12 N.m (1.2 kgl.m,8.7 lbf.ftl
REGULATORSPRINGCAP COOLERCHECK
OOWELPINS, 2 ROLLER REGULATORVALVE BODY
.
"%= .
I',.-2"
/
ll
VALVESLEEVE SPRINGSPECIFICATIONS Unit of length: mm (in) Standard (New) No.
o /a @ \9/
Spring Regulatorvalve spring A Regulatorvalve spring B Stator reactionspring Lock-upcontrol valve spring Coolercheck valve spring Torque convertercheck valve spring
Wiro Dia.
o.D.
1 . 8 0 ( O . O 7 1 ) 1 4 . 7 0( O . 5 7 9 18 8 . 6 0( 3 . 4 8 8 t 1 . 8 0 ( 0 . 0 7 1 ) 9 . 6 0 ( 0 . 3 7 8 ) 44.OOt't.7321 5 . 5 0 ( O . 2 1 7 1 ' 2 6 . 4 0 ( 1 . O 3 9 )3 0 . 3 0( 1. 19 3 t
o.80(o.o31) 6.60 (O.260) 3 9 . 5 0( 1 . 5 5 5 ) 1.10(0.043) 8 . 4 0 ( O . 3 3 1 ) 3 3 . 8 0( 1. 3 3 1I 1.10(O.O43t 8 . 4 0 ( 0 . 3 3 1 ) 3 3 . 8 0( 1. 3 3 1) lnside Diameter
14-122
Free Longlh
No. of Coils 16.5 2.1 25.O 'l2.5 12.5
Disassembly/lnspection/Reassembly NOTE: a Cleanall paris thoroughlyin solvent or carburetorcleaner,and dry with compressedair. a Blow out all passages. a Replacevalve body as an assemblyit any parts are worn or damaged. a Check all valves tor free movement.lf any fail to slide fre€ly, see Valve Body Repairon page 14-117. a Coat all parts with ATF before reassembly.
LOCK-UPSHIFT VALVE
TIMING8 VALVE LOCK.UP
,ar
CAP
\,/
SPRINGSPECIFICATIONS Unit ot length; mm (in) Standard {Nsw} No.
Spring Wile Di8.
o
@
Lock-upshift valve spring Lock-uptiming B valve spring
o . 9 0( o . 0 3 5 ) o . 8 0( o . 0 3 1 )
o.D.
Flee Length
7 . 6 0 ( 0 . 2 9 9 ) 73.70 i.2.9021 6 . 6 0 { O . 2 6 0 ) 6 0 . 8 0( 2 . 3 9 4 )
No. of Coils
32.O 22.1
14-123
SecondaryValve Body Disassembly/lnspection/Reassembly NOTE: a Cleanall parts thoroughlyin solvent or carburetorcleaner.and dry with compressedair. a Blow out all passages. a Replacevalve body as an assemblyif any parts are worn or damageo. a check all valves for lree movement.rf any fair to sridetreery,see varve Body Repairon page 14-1r7. a Coat all parts with ATF betore reassembly. CAUTION: Do not use a magnetto removethe check balls; it may magnetizethe balls.
CHECKBALLS.7 1ST ACCUMULATOR CHOKE
@
a/ \.^l "i\
SPRINGSEAT
\ll /
'.'.)
'-
-\)--
o{
v
\ @
n
2.3 ORIFICECONTROL VALVE 3-4 SHIFT VALVE
le
, r / \i\
DOWEL PIN, 2
I
SECONDARYVALVE EODY MODULATORVALVE
o
b
a )
');fi
l"
@
a-/ xii;.
trd \ VALVE
14-124
CHECK BALL
CHECKBALLS FILTER
SPRINGSPECIFICATIONS Unit ot length: mm (in) Standard(N€wl No.
o @ tcl \9
@
Spring 3-2 kick-down valve spring 4-3 kick-downvalve spring Orifice control valve spring 2-3 orifjce control valve spring 3-4 shift valve spring Servo control valve spring Modulatorvalve spring
Wire Dia. 1. 3 { O . 0 5 1 ) 1. O ( O . O 3 9 ) o.8 (o.031)
o.9 (o.03s) 0.9 {0.035) o.9 (o.o35) 1.3(O.O51)
o.D. 8.6 tO.339) 6.6 (O.260) 6.6 (0.260) 6.6 (0.260) 7.6 (O.299) 6.4 lO.252l 9.4 (O.370)
Free Length 45.6 28.5 48.2 33.O 52.O 34.1 37.3
1.795) 1.1221 1.898) 1.299) 2.O47l 1.343) 1. 4 6 9 )
No. of Coils 1 7. O 14.7 33.O 14.9 26.8 12.4
14-125
Servo Body Disassembly/lnspection/Reassernbly NOTE: a Cleanall pSrtsthotoughlyin solvent or carbu.etorcleaner,and dry with compressedair. a Blow out all passages. a Replacevalve body as an assembly it any parts are worn or damageo. a Coat all parts with ATF before resssemblv. a Replacethe O-rings.
@
THROTTLECAM SYOPPER
\P O-RING Replace.
4TH
PISTON
6 r 1 . Om m 12 N.m (1.2 kgf.m, 8.7 rbt.ftl
SERVOBODY THROTTLEADJUSTIIIIGBOLT CAUTION: Do not loo3on or
I
THROTTLE VALVEB
o LONG VALVE
i
'
l
l
r Replace.
l
V8;lilSl O-RING Replace. 3RD ACCUMULATOR PISTON
14-126
SPRINGSPECIFICATIONS Unit of length: mm (in) St8ndard {Newl No.
o rar 6\ ra\
o
@ (!,
@
Spring Throttle valve B adiustingspring Throttle valve B sp.ing Throttle valve B spring Throttle valve I spring 4th accumulatorspring 1st accumulatorspring 3rd accumulatorsp.ing 2nd accumulatorspring
Wire Dia. 0.7 (0.028) 1.4 (O.O55) 1.4 (O.O55) 1.4 (O.O55) 2.6 l0.102l 2.5 (O.O98) 2 . 8 ( O . 11 0 ) 3.6 (O.142)
o.D. 6.2 t0.244l 8.5 (O.33s) 8.5 (O.3351 8.5 {0.33st 1 6 . 3( O . 6 4 2 ) 1 6 . 3( O . 6 4 2 ) 1 7 . 5( O . 6 8 9 ) 2 2 . O( O . 8 6 6 )
Fre6 Longth 3 4 . O( 1 . 3 3 9 ) 4 1 . 5 ( 1. 6 3 4 1 4 1 . 5 ( 1. 6 3 4 ) 41.6(1.638) 103.3(4.067) 'l 05.4 (4. 150) 105.2 14.142]. 108.9(4.287)
No. ot Coils 15.2 10.5 11.2 12.4 16 + 8.6 19.1 15.2
14-127
1st-hold Accumulator/RightSide Cover Disassembly/lnspection/Reassembly NOTE: a Clean all pans thoroughly in solvsnt o, carburetor cleaner, and dry with compressed 8ir. a Blow out all passages. a coat all parts with ATF betors raassembly. SNAP RI]TG
l ST.HOLOACCUMULATORCOVER
1ST-HOLDACCUMULATORSPRING
PISTON IST.HOLDACCUMULATOR
O.BING R6place.
RIGHT SIDE COVER
SPRINGSPECIFICATIONS
Unit of length: mm (in) St8ndard lt{ew)
Spring
No.
o
1st-hold accumulatorspring
14-128
Wlro Dia.
4 . 0 0 ( o . 15 7 )
o.D.
Froo Length
2 1 . 5 0 ( 0 . 8 4 6 ) 7 1 . 7 0l 2 . A 2 3 l
No. of Coils
8.3
Mainshaft Disassembly/lnspection/Reassembly NOTE: a Lubricateall pans with ATF during reassembly. a Installthe thrust needlebearingswith unrollededge of bearingretainerlacing washer. a Inspectthe thrust needlebearingsand the needlebearingsfor gallingand rough movement. a Betoreinstallingthe O-rings,wrap the shaft splineswith tape to preventdamagingthe O-rings. a Locknut has lett-handthreads. CONICAL SPRINGWASI{ER Replace.
LOCKNUT(FLANGENUT) 19 x 1.25mm 93 N.m {9.5 kgf.m, 69 lbf.ftl Replace. Left-hand threads lST CLUTCH ASSEMBLY
SNAP RING
\ MAINSHAFT Check splinestor excessive wear or damage. Check bearing surface for scoring, scralches or excessive wear,
THRUSTWASHER THRUSTNEEDLE BEARING 4TH GEAR
o-ntNGs Replace.
THRUSTWASHER THRUSTNEEDLE BEARING BEANING
NEEOLEBEARIT{GS
lST GEAR
THRUST WASHER 1ST GEAR COLLAR
4TH GEAR COLLAR 2ND/4TH CLUTCH ASSEMBLY
O.RINGS Replace. THRUST WASHER, 36.5 x 55 mm Solective part.
THRUST NEEDLE BEAFING SEALINGRINGS, 35 mm SEALINGRING. 29 mm NEEDLEBEARING SET RII{G
2ND GEAR NEEDLEBEARING THRUST NEEDLE BEARING
TRANSMISSION HOUSINGBEARING
Mainshaft Inspection Torque the mainshaft locknut to 29 N.m (3.0 kgf.m, 22 lbf.ft).
a ClearanceMeasurement NOTE: Lubricateall parts with ATF during assembly.
NOTE: Mainshaftlocknut has lett-handthreads. 1.
Removethe mainshaftbearinglrom the transmission h o u s i n g( s e ep a g e 1 4 - 1 5 2 ) .
2.
Assemblethe parts below on the mainshaft. NOTE: Do not assemble the O-rings while inspecting.
29 N.m (3.0 kgl.m, 22 lbt.ft) LOCKNUT
/
1ST CLUTCHASSEMBLY THRUSTWASHER lST GEARCOLLAR TBANSMISSION HOUSINGBEARING THRUSTWASHER
4.
Hold 2nd gear againstthe 2nd clutch. then measure the clearancebetween 2nd gear and 3rd gear with a feelergauge. in at leastthree Dlaces NOTE: Takemeasurements and take the averageas the actual clea.ance. STANDARD:0.05-0.13 mm {0.002-0.005 inl
4TH GEAR COLLAR 2ND/4TH CLUTCH ASSEMBLY
3RD GEAR
2ND GEAR
THRUSTWASHER Selectivepart. TI{RUSTNEEDLE BEARING 2ND GEAR NEEDLEBEARING THRUSTNEEOLE BEARING
THRUSTWASHER36.5 x 55 ftm
MAINSI.IAFT
3RD GEAR
14-130
2ND GEAR
5.
lf the clearanceis out of tolerance,removethe thrust washer and measurethe thickness
6.
Selectand installa new washer then recheck.
THRUSTWASHER36.5 x 55 mm No,
Thickness
9 0 4 4 1- P G 4 - O 1 0
4 . O Om m ( O . 15 7 i n )
90442 PG4-010 90443-PG4-O10
4 . 0 5 m m { O .15 9 i n ) 4 . 1 Om m ( O . 1 6 1i n )
90444-PG4-O10
4 . 15 m m ( O . 1 6 3i n )
90445-PG4-O10
4 . 2 0 m m ( O . 1 6 5i n )
6
90446-PG4-Ol O
4 . 2 5 m m ( O . 1 6 7i n )
7
90447,PG4 0r0
4 . 3 O m m ( O . 1 6 9i n )
8
90448-PG4-O10
4 . 3 5 m m { O . 17 1 i n )
q
9 0 4 4 9 - P G 4 - O r0
4 . 4 O m m ( O . 17 3 i n )
1
4
7,
Part Number
AIter replacingthe thrust washer, make sure the clearanceis within tolerance.
14-131
Countershaft Disassembly/lnspection/Reassembly NOTE: a Lubricateall parts with ATF belore reassembly. a Installthe thrust needlebearingswith unrollededge of bearingretainerfacing washer. a Inspectthe thrust needlebearingsand the needlebearingstor gallingand rough movement. a Beforeinstallingthe O rings, wrap the shaft splineswith tape to preventdamagingthe O-rings. a Locknut has left-handthreads. CONICAL SPRING WASHER Replace. REVERSE GEARCOLLAR NEEDLEEEARING
LOCKNUT{FLANGENUTI 23 x 1.25mm 1O3-0-lO3N.m {10.5-O-'l0.5ksf.m, 75.9*O-75.9tbf.fr) Replace. Left-hand threads PARKINGGEAR
REVERSE GEAR BEVERSE SELECTOR
ONE.WAY CLUTCH
.IST GEAR
REVERSESELECTOR HUB
NEEDLEEEARING
4TH GEAR
lST GEAR COLLAR
NEEDLEBEARING DISTANCECOLLAR, 28 mm Selectivepart. COUNTERSHAFT Check splinesfor excessive wear or damage. Check bearingsurfacefor scoring, scratchesor excessivewear_
2ND GEAE THRUST NEEDLE BEARING 3RD GEAR
NEEDLEBEARING THRUSTNEEDLEBEARING 3RD GEARCOLLAR
3RD CLUTCH ASSEMBLY
O-RINGS Replace.
TRANSMISSION HOUSINGBEARING
Disassembly/Reassembly 1,
Usinga hydraulicpress,pressout the countershatt while supponing4th gear. NOTE: Placean attachmentbetweenthe pressand the countershattto preventdamageto the shaft. CAUTION: Do not allow the countershaftto lall and hit the ground.
2 . Assemblethe parts on the countershaftas shown oetow. NOTE: a Lubricateall parts with ATF duringassembling. a Before installingthe O-rings, wrap the shalt splines with tape to prevent damaging the O-rings.
4TH GEAR
NEEDLEBEARING DISTANCECOLLAR. 29 mm Selectivepart.
2ND GEAR THRUSTNEEDLEBEARING
3RD GEAR NEEDLEBEARING THRUSTNEEDLEBEARING 3RD GEAR COLLAR
3RD CLUTCHASSEMBLY
O-RINGS Replace.
COUNTERSHAFT
{cont'd)
Countershaft (cont'd) Disassembly/Reassembly a
Installthe reverseselectorhub on the countershaft sub-assemblV, and then pressthe reverseselector hub using the specialtool and a press as shown.
Inspection a ClearanceMeasurement NOTE: Lubricateall parts with ATF during assembly. 1.
Removethe countershaftbearingfrom the transmiss i o n h o u s i n g( s e ep a g e l 4 - 1 5 2 ) .
2.
Installthe pans belowon the counte.shaftusingthe specialtool and a pressas describedon this page. NOTE: Do not assemble the O-rings while inspecting.
REVERSESELECTOR HUB 4TI{ GEAR NEEDLEBEAFING DISTANCECOLLAR, 28 m|n Selective part.
COUNTERSHAFT
14-134
Install the parts below on the countershaftsubassembly,then torque the locknut to 29 N'm (3.O kgf.m, 22 lbf.ft).
Measurethe clearancebetweenthe 2nd gear and the distancecollar, 28 mm wilh a feelergauge. in at leastthreeplaces. NOTE: Takemeasurements and take the averageas the actual clearance. S T A N D A R DO : . O 5 - 0 . 1 3 m m ( 0 . O O 2 - O . O 0 i5n )
2ND GEAR
DISTANCECOLLAR, 28 mm
LOCKNUT Left-hand threads CONICALSPRI G WASHER PARKINGGEAR/ONE-WAY CLUTCH/1STGEAR ASSEMBLY NEEEDLEBEARING lST GEARCOLLAR TRANSMISSIONHOUSING BEARING REVERSEGEAR COLLAR
2ND GEAR
(cont'd)
14-135
Countershaft Inspection(cont'dl 5.
lf the clearanceis out of tolerance,removethe distance collaf, 28 mm and measurethe width,
6.
Select and install a new distance collar, then recheck.
DISTANCECOLLAR,28 mm No.
Part Number
Width
1
90503-PC9-OOO
3 9 . O 0m m ( 1. 5 3 5 i n )
,
90504-PC9-OOO
3 9 . 1 0m m ( 1 . 5 3 9i n ) 3 9 . 2 0 m m ( 1 . 5 4 3i n l
90sos,Pc9-ooo 5
90508-PC9-000
3 9 . 3 0 m m ( 1 . 5 4 7i n ) 3 9 . 0 5 m m ( 1. 5 3 7 i n l
6 7
90509-PC9-000 90510 PCg*000
3 9 . 15 m m { 1 . 5 4 1i n ) 3 9 . 2 5m m ( 1 . 5 4 5i n )
I
9 0 5 1I - P C g - O O O
3 8 . 9 0 m m { 1 . 5 3 1i n )
90512 PCg 000
3 8 . 9 5m m { 1 . 5 3 3i n )
90507-PC9-000
7,
Altet selectinga new distancecollar,recheckthe clearanceand make sure it is within tolerance.
14-136
One-way Clutch/ParkingGear Disassembly/lnspection 1 . Separatecountershaft1st gearfrom the parkinggear by turningthe parkinggear in the directionshown.
Inspoct tha psrta a3 tollows:
PARKII{GGEAR Inspectthg parking tor w€s. or acoring.
COUNTERSHAFT1ST GEAR
O E.WAY 2.
Inspect tho ono-way clutch fo. damageaor faultv movement.
Removethe one-way clutch by prying it up with the end of a screwdrive..
courrERsHAFrlsr.EAR 9IlYlL9iY^t.?I NOTE: lnstall in this direction. l ST GEAR Inspect counior6haft 1 tor wegr or scoaing.
3.
After the Dartsare sssembled,hold counte.shaft lst gear and turn tho parkinggear in the directionshown to be sur6 it turns freelv,
CLUTCH O'TE.WAY COUNTERSHAFTlST GEAR
1STGEAR COU TERSHAFT SCREWDRIVER
14-137
Sub-shaft Disassembly/lnspection/Reassembly NOTE: a Lubricateall parts with ATF during reassembly. a Installthe thrust needlebearingswith unrollededge ot bearingretainertacing washer. a lnspectthe thrust needlebearingsand the needlebearingsfor gallingand rough movement. a Beforeinstallingthe O-rings,wrap the shaft splineswith tape to preventdsmagingthe O-.ings.
TRANSMISSIOI{HOUSING
TRANSMISSION HOUSINGBEARING
lST-HOLD CLUTCH ASSEMELY
O.RINGS Replace.
6 x 1.0 mm 12 N.m (1.2 kgf.m, 8.7 lbf.ft)
THRUST WASHER THRUST NEEDLE BEARING NEEDLEBEARING
SUB.SHAFT Checksplinestor excessive wear or damage. Check bearingsurlacetor sconng.scratchesor excessive
4TH GEAR THRUST I{EEDLE AEARIIIG
OIL GUIDECAP Replace.
NEEDLEBEARIT{G STOPPER
4TH GEAB COLLAR
NEEDLEEEARING
Disassembly/Reassembly Removethe oil guide cap by pushingthe sub-shaft insidethe transmissionhousing. Removethe 1st-holdclutchassemblyby pullingthe sub-shaft,then removethe sub-shatt. Installnew O-ringson the sub-shaft. NOTE: Wrap the shaft splineswith tape to prevent damagingthe O-rings. Placethe sub-shaftin the transmissionhousingand installthe 1st-holdclutch assembly. Installnew oil guide cap usingthe specialtools as snown.
DRIVER 07749-0010000
ATTACHMENT32x35mm 07746-0010100
,IST.HOLD CLUTCH ASSEMBLY
14-139
Sub-shaft Bearings Replacement NOTE: Lubricateall parts with ATF beforereassembly 'l . To removethe sub-shaftballbearingtrom the transmissionhousing.expandthe snapringwith snapring pliers,then push the bearingout using the special tools and a Dressas shown.
Installthe new needlebearingin the transmlsston anda pressas shown. housingusingthe specialtools PRESS
ATTACHMENT, 32 x 35 mm 07746-0010100 ATTACHMENT, 62 x 68 mm 07746-0010500 Removethe needlebearingstopper. Removethe needlebearingfrom the transmisslon housingusing a drilt Punch.
DRIFTPUNCH
5 . Expandthe snap ring with snap ring pliers,then insert the ball bearingpart way into the housingusing the specialtoolsand a pressas describedin step 1. Installthebearingwith the groovefacingoutside the housing. Releasethe pliers,then push the bearingdown into the housinguntilthe snapringsnapsin placearound rt. 7 . After installingthe ballbearing,verifythe following: a The snap ring is seatedin the bearingand housing grooves. a The snap ring ope.atesproperly a The ring end gap is correct. E N DG A P :0 - 7 m m
?A SNAP RING
14-140
Clutch lllustratedIndex 3RD CLUTCH
CLUTCH DRUM
O-RINGS Replace. CLUTCH PISTON DISC SPRING RETURNSPRING SPRINGRETAINER SNAP RING
1ST CLUTCH CLUTCHEND CLUTCH DISCS PLATE Stsndard thickness: 1.94 mm {0.076 in)
SNAP RING SNAP RING
O-RINGS Replace.
SNAP RING
CLUTCH PLATES Standard thicknass: 2.00 mm {0.079 in}
CHECKVALVE
(cont'd)
14-141
Clutch lllustratedIndex (cont'd) 2ND/4TH CLUTCH
SNAP RING CLUTCH END PLATE
CLUTCH DISCS Standard thickno3s: 1.94 mm 10.076in)
CLUTCH PLATES Standard thickness: 2.OOmm 10.079inl
)
SNAP RING
l
SPRINGRETAINER RETURNSPRING
CLUTCH PISTON SPRING RETURNSPRING CHECKVALVE
RETAINER SNAP RING
4TH CLUTCHDRUM CLUTCH PLATES Standa.d thickness: 2.00 mm 10.079 in)
;;i;;; ( / \
Y)
CLUTCH DISCS Stsndard ihickn€ss: 1.94 mm 10.076in) CLUTCH END PLATE SNAP RING
14-142
/
lST.HOLD CLUTCH
SNAP RING CLUTCH END PLATE CLUTCH DISCS Standard thicknoss: 1.94 mm 10.076 inl
DISC SPRING CLUTCH PISTON O-RINGS Roplace.
CLUTCH PLATES Standard thickno3si 2.00 mm (0.o79 in)
14-143
Clutch Disassembly Removethe snap ring. then.emove the clutch end plate, clutch discs and plates.
3.
Installthe sDecialtools as shown. CLUTCHSPRIT{G COMPRESSOR ATTACHMET oTLAE-PX40100
SNAP RII{G
cLuTcHspnrc
2.
COMPNESSOR ATTACHMET oTHAE-Pr60tOO
Removethe disc spring. SPNING
otsc sPfit c
CLUTCH SPRII{C COMPNESSOR ATTACHi'ENT OTLAE-PX,l{,TOO
2ND CLUTCH
DISC SPBING
CLUTCH SPBII{G COMPRESSOR ATTACHMEI{T oTHAE-Pt50100
1ST, 3RD, 4TH .nd l ST.HOLD CLUTCH
14-144.
CAUTION: lf either end ot the comprassol attachm€nt is sel ovsl an araa ol the spdng retaine. which is unsupported by the retum spring.the letainermay be damag6d,
5 . Remove the snap ring. Then remove the special tools, spring retainerand return spring.
S AP RING Do not set horo.
6. 4.
Compressthe return spring.
Wrap a shop towel aroundthe clutch drum and apply air pressureto the oil passageto remove the piston.Placea fingertip on the other end while applying air p.essure.
COMPRESSEDAIR HOSE NOZZLE OSHA-approved30 psi rype onry
CLUTCH
RETURNSPRING
PISTON
14-145
Clutch Reassembly NOTE: a Clean all psrts thoroughly in solvent or carburetor cleaner.and dry them with compressedair. a Blow out all passages. a Lubricateall pans with ATF before .eassembly. 1.
3,
Installthepistonin the clutchdrum. Apply pressure and rotate to ensureproper seating. NOTE: Lubricatethe pistonO-ringwith ATF before installing,
Inspectthe check valve; if it's loose, replacethe prston,
CAUTION: Do not pinch rh6 O-ringby installingth€ piston with too much lorco.
NOTE: Except 1st-holdclutch. CLUTCH DRUM
CHECKVAIVE
4.
Installthereturnspringand springretainer.and position the snap ring on the retainer
SNAP RING SPRINGRETAINER
RETURNSPRING
CLUTCHORUM
PISTON
14-146
r 5,
Installthe specialtools as shown.
CAUTION: lf €ithor end of the comprossor attachment is set over an area of the spring rotainerwhich iE unsupportedby tho retum spring, the latainer may bo damaged.
CLUTCH SPRING COMPRESSOR ATTACHMENT 07LAE-PX40100
CLUTCH SPRING COMPRESSOR ATTACHMENT oTHAE-Pl50100
Do not set here.
CLUTCH SPRING COMPNESSOR BOLT ASSEMBLY oTGAE-FG40200
6,
Compressthe return spring.
CLUTCII SPRING COMPRESSOR ATTACHMENT oTLAE-PX40100
CLUTCH SPRIIIG COMPRESSOR ATTACHMENT oTHAE-Pl50100 CLUTCH SPRING COMPRESSOR AOLT ASSEMBLY 07GAE-PG40200
RETURNSPRING
(cont'd)
14-147
Clutch Reassembly(cont'd) 7.
Installthe snap ring.
1O. Soakthe clutch discsthoroughlyin ATF for a minimum of 30 minutes. 11. Starting with a clutch plate, alrernatelyinstallthe clutch platesand discs. Installthe clutch end plate with flat side toward the disc. NOTE: Beforeinsrallingthe platesand discs,make sure the insideof the clutch drum is free ot dirt or other toreign matter.
CLUTCH END PLAT€ Installin this direction
SNAP RING
Removethe specialtools. Installthe disc spring. NOTE: Installthediscspringin the directionshown.
DISCSPRING
1 2 . I n s t a l tl h e s n a p r i n g .
SCREWDRIVER
SNAP RING
.\
):ll 1ST, 3RD, 4TH and l ST.HOLDCLUTCH
14-148
'13. Measurethe clearancebetweenthe clutchend plate and top disc with a dial indicator.Zerothe dial indicatorwith the clutchend plateloweredand lift it up to the snap ring. The distancethat the clutch end platemovesis the clearancebetweenthe clutchend plate and top disc. N O T E r M e a s u r ea t t h r e el o c a t i o n s . Clutch End Plate-to-Too Disc Clearance: Clulch
lst 2nd 3rd 4th 1st-hold
Service Limit O.65 o.85 mm O . 6 5- O . 8 5 m m O . 4 O - O . 6 0m m 0.4O-0.60 mm 0.50-0.8O mm
( O . 0 2 6 O . O 3 3i n ) { O . 0 2 6 - O . O 3 3i n ) ( 0 . O 1 6 o . O 2 4i n ) (0.016-0.024 in) { O . 0 2 O - 0 . 0 3 1i n }
IAL INDICATOR
lST CLUTCHEND PLATE PlateNo. 1 2 3 4 5 6 7 8 I 10 11 1 ) I J
14
PartNumber
Thickness
2 . 1 m m 1 0 . 0 8 3i n ) 22551-PF4-000 2 . 2 m m ( 0 . 0 8 7i n ) 22552-PF4 000 2 . 3 m m ( 0 . 0 9 1i n ) 22553 PF4 000 2 2 5 5 4 - P F 4 - O O O 2.4 mm (0.094in) 2 . 5 m m ( 0 . 0 9 8i n ) 22555 PF4-000 2 . 6 m m { 0 . 1 0 2i n } 22556 PF4-000 2 . 7 m m i 0 . 1 0 6i n ) 22557-PF4 000 in) 2 . 8m m ( 0 . 1 1 0 22558-PF4 000 2 . 9m m ( 0 . 11 4 i n ) 2 2 5 5 9 -P F 4 -0 0 0 3 . 0 m m ( 0 . 11 8 i n ) 22560-PF4 000 3 . 1 m m ( 0 . 12 2 i n l 22561 PF4-000 3 . 2 m m { 0 . 1 2 6i n } 22562-PF4 000 3 . 3 m m ( 0 . 13 0 i n ) 22563-PF4 000 3 . 4 m m ( 0 . 1 3 4i n ) 22564 PF4-OOO
2ND- 3RD and 4TH CLUTCHEND PLATE PlateNo.
PartNumber
Thickness
1 2. 3 4 5 6 7 8 I 10
22551 P56,N00 22552-P56-N00 22553-P56-N00 2 2 5 5 4 -P 5 6- N 0 0 22555-P56 N00 22556 Ps6-N00 22557- P56 N00 22558 P56-N00 22559-P56 NOO 22560 P56-N00
2 . 1 m m ( 0 . 0 8 3i n ) 2 . 2 m m ( 0 . 0 8 7i n ) 2 . 3 m m ( 0 . 0 9 1i n ) 2.4 mm (0.094in) 2 . 5 m m ( 0 . 0 9 8i n ) 2 . 6 m m { 0 . 1 0 2i n ) 2 . 7 m m { 0 . 1 0 6i n i in) 2 . 8m m ( 0 . 1 1 0 2 . 9 m m ( 0 . 11 4 i n ) 3 . 0 m m ( 0 . 11 8 i n )
lST.HOLD CLUTCHEND PLATE PlareNo.
22551-PS5 003 22552 PS5-003 22553-PS5 003 4 22554-PS5-003 5 (Nomark) 2 2 5 5 5 - P S 5 - 0 0 3 22556 PS5-003 6 7 22557 PS5-003 1
2 3
14. lf the clearanceis not withinthe servicelimits,select a new clutch end plate lrom the following table.
Part Number
ThicknEss
2 . 1 0m m ( 0 . 0 8 3i n ) 2 . 2 0m m ( 0 . 0 8 7i n ) 2.30 mm (0.09'1in) 2 . 4 0m m ( 0 . 0 9 4i n ) 2 . 5 0m m { 0 . 0 9 8i n ) 2 . 6 0m m { 0 . 1 0 2i n } 2 . 7 0m m ( 0 . 1 0 6i n )
NOTE: It the thickest clutch end plate is installed, but the clearanceis still over the standard,replace the clutch discs and clutch Dlates. PLATENUMBER
Thickn€ss
CLUTCHEND PLATE
14-149
Torque Converter Housing Bearings MainshaftBeadng/OilSeal Replacement 1.
Driveout or pull up the mainshaftbearingand oil seal, using the specialtools as shown.
2 . Drivein the new mainshaftbearinguntil it bottoms in the housing,using the specialtools as shown.
DRIVEN 07749 -OOIOOOO
ATTACHMENT, 62x68mm 07746-0010500
3 . Installthenew oil sealflush with the housingusing the sDecialtools as shown.
Slide Hammer CommerciallyAvailable 3/8 in.x 16
ATTACHMENT, 72x75mm 07746-0010600
14-150
CountershaftBearingReplacement l.
Removethe countershattbearingusingthe special tools as shown.
SlideHammer CommerciallyAvailable 3/8 in. x 16
ADJUSTABLE BEARING PULLER, 25-40 mm 07736-AOIOOOA
K-i.
',--CZ_
( ( -)
_-=\._ -) ))\
-:-:-:1.-=41" Installthe oil guide plate.
Drivethe new bearinginto the housingusingthe special tools as shown.
14-151
TransmissionHousingBearings Mainshaft/Countershaft BearingReplacement 1. To removethe mainshaftand counte.shaftbearings trom the transmissionhousing,expandeach snap ring with snap ring pliers,then pushthe bearingout using the specialtools and a press as shown,
Expandeach snap ring with snap ring pliers,insert the new bearingpan-wayinto the housingusingthe specialtoolsand a pressas shown. Installthebearing with the groove tacing outsidethe housing.
NOTE: Do not remove the snap rings unless it,s necessafyto cleanthe groovesin the housing.
NOTE: Coat all parts with ATF. Releasethe pliers.then push the bearingdown into the housinguntil the ring snaps in placearoundit,
PRESS
ATTACHMENT, 62x68mm
o7746-
DRIVER o7749-OOIOOOO
GnoovE
I
Mainshatt Inltallation us6: ATTACHMENT, 72x75mm 07746-0010600 Counto.shalt In3talldtion uso: ATTACHMENT. 62x68mm 07746-O010500
---7i \)
4.
After installingthe bearingverify the lollowing: a The snap ring is seatedin the bearingand housIn9 grooves. a The snap ring operatesproperly a The ring end gap is correct.
MAINSHAFT
END GAP: O-7 mm Mainshaft Removal uaoi ATTACHMENT72 ,, 75 mm o7746-OOlO600 Counterrhaft Removal uao: ATTACHMENT, 62x68mm 07746-O010500
TRANSMISSION
t|oustitc
14-152
SNAP BING
Sub-shaftBearingReplacement I.
To remove the sub-shaft bearinglrom the transmission housing,expandthe snap ring with snap ring pliers, then push th€ bearing out using the special tools and a Dressas shown. NOTE: Do not remove the snap ring unless it's necessary to clean the groove in the housing.
2 . Expandthe snap ring with snap ring pliers,insert the new bearingpart-way into the housingusingthe special tools and a pressas shown. Installthe bearing with the groove facing outside the housing. NOTE: Coat all parts with ATF. a
PNESS
Releasethe pliers,then pushthe bearingdown into the housinguntil the ring snapsin placearoundit, using the specialtools as shown. DRIVER 07749-0010000 ATTACHMEI{T, 62 x 68 mrn 077/+6-OOlO500
GROOVE
4. ATTACHMENT, 62x68m|n 07746-(Xr10500
After installingthe bea.ingverify the following: a The snap ring is seatedin the bearingand housing grooves. a The snap ring operatesProperlv a The ring end gap is correct.
El{DGAP:o-7 mm
HOUS[{G
14-153
Reverseldler Gear Installation 1.
ParkingBrake Stopper Inspection/Adjustment
Installthe reverseidler gear.
1 . Set the parkingbrake lever in the E position. 2.
Measurethe distancebetween the parking brake pawl shaft and the parkingbrakeleverrollerpin as shown. STANDARD:72.9-73-g mm (2.87-2.91 in)
ROLLERPIN PANKING BRAKE LEVER
7A\
Meaauring
\v
Installthereverseidle,gearshaft holderand needle bearinginto the transmissionhousing,then tighten the bolts.
PARKING BBAKE PAWLSHAFT
PARKINGBRAKE STOPPER
lf the measurementis out of tolerance,select and installthe appropriateparkingbrakestopperfrom the table below.
6 x l.O mm 12 N'm 11.2 kgt.m. 4.7 lbf.ft)
PARKINGBRAKESTOPPER Mark 1
2
4.
14-154
PartNumbol
Lz
- PA9-003 11 . 0 0m m 24537 {0.433in}
1 1 . 0 0m m {0.433in)
-003 24538-PA9
10.80mm (0.425in)
1 0 , 6 5m m ( 0 . 4 1 9i n l
24539- P49,003
1 0 . 6 0m m ( 0 . 4 1 7i n )
1 0 . 3 0m m {0.406in)
After replacingthe parkingbrakestopper, make su.e the distanceis within tolerance.
Transmission Reassembly NOTE: a Coat all parts with ATF. a Replacethe parts below: . O-rings . Lock washers . Gaskets . Locknuts . Conicalspring washers . Sealingwashers T O R O U E1: 2 N . m ( 1 . 2 k g t . m , 8 . 7 t b f . f r ) OIL FEEDPIPE LUBRTcAToR orL PLATE FEED PIPES
/
LOCK-UPVALVE
,
f| l n /
EODY
/
OOWELPINS,2
OIL FEEDPIPES ACCUMULATOBCOVER
/""n
v{
e'f
*'
OIL FEEDPIPE
_\
_! 1.-...-]] vaLVE spRtNGS
ToRouE coNvERTE n \-\.-CHECK VALVE
----.-.
\
--'r
LOCKWASHER
"o't
\
\_(<
Bolts,3
e E
SERVODETENT BASE
CONTROL SHAFT
COOLERCHECKVALVE
-. :-,.
REGULATORVALVE BODY OIL FEEDPIPES
Bolts,4 SERVOBODY DOWELPINS.2 MAIN VALVE . EoDY |
SERVOSEPARATOR PLATE "1-
Bolt
OIL PUMPDRIVEN GEARSHAFT SECONDARYVALVE BODY
OIL PUMP DRIVENGEAR
DOWELPINS,2 MAIN S€PARATOR PLATE
OOWELPINS,2
SECONDARYSEPARATOR PLATE ATF MAGNET
14-156
E '.
1 . Installthe ATF magnetand suctionpipecollarin the torque converternousrng.
7. Installthe servo body and separatorplate with six bolts.
2 . Installthe mainseparatorplatewith two dowel pins
8. lnstallthe accumulatorcover with three bolts
on the torqueconverterhousing.Then installthe oil pump drivegear,drivengearand drivengearshalt. NOTE| Install the oil pump driven gear with its groovedand chamteredside facing down. OIL PUMP DRIVEGEAR
Groovedand chamfered side faces separator plate.
CAUTION: Failureto align the oil pump d1iv6ngear shaft corroctly will result in a seized oil pump drivo geal of oil pump drivon gear shatt.
Loosely install the main valve body with Iour bolts. Make sure the oil pump drive gear rotates smoothly in the normal operating direction and the oil pump driven gear shaft moves smoothly in the axial and normal operating directaons. Installthe secondary valve body, separator plate and two dowel pins on the main valve body. Installthe control shaft in the housing, with the control shatt and manual valve togelher.
6.
1 0 . T i g h t e nt h e f o u r b o l t st o 1 2 N . m ( 1 . 2 k g f ' m , 8 . 7 lbf.ft) on the main valve body. Make sure the oil pump drive gear and oil pump driven gear shaft move smoothly same as in the step
11. lf the oil pump drive gear and oil pump driven gear shaft do not move freelY.loosenthe four bolts on the main valve body and disassemblethe valve bodies. Realignthe oil pumpdrivengearshaft and reassemble the valvebodies,then retightenthe bolts to the specifiedtorque,
OIL PUMP ORIVENGEAR
J.
9. lnstallthe servodetent base and ATF strainerwith three bolts and new lock washers.
Installthe detent arm and arm shatt in the main valve body, then hook the detent spring to the detent arm.
36
DETENT SHAFT
SERVOSEPARATORPLATE
--- 8ixli"'
(l . . \. l
=L,1ffi# .. N j-*/: OIL PUMP DRIVEGEAB
OIL PUMP DRIVENGEAR
OIL PUMP DRIVENGEAR SHAFT
12. Installthe stator shaft and stoppershatt. 13. Installthe stoppershatt stay on the secondaryvalve body with the bolt. 14. Installthe regulatorvalve body with the bolt.
DETENI SPRING DETENTARM
MANUAL VALVE
15. Installthe torque convertercheck valve,coolercheck valve and valvespringsin the requlatorvalve body. 16. Installthe lock-upvalvebody, separatorplate,two dowel pins and lubricatorplatewith the eight bolts. 1 7 . I n s t a l tl h e o i l f e e d p i p e s .
(cont'dl
14-157
Transmission (cont'dl Reassembly
TRANSMISSIONHOUSING MOUNTINGBOLTS,18 l0 x 1.25mm 44 N.m (4.5 kgl.m. 33 lbf.trl
fl TRANSMISSION HANGER TRANSMISSIONHOUSING TRANSMISSION MOUNT BBACKET 12 x
'1.25
fifi
64 N.m {6.5 kgt'm,
47 tbt'tr)
CONNECTORSTAY
T=
MAINSHAFT SUB-ASSEMBLY
TRANSMISSION HOUSING GASKET Replace. REVERSEGEAR COLLAR NEEOLEBEARING REVEBSE GEAR LOCKWASHER Replace. SHIFTFORK
DOWELPINS,3
REVERSESELECTOR COUNTERSHAFT SUB.ASSEMBLY
DIFFERENTIAL ASSEMBLY
TOROUECONVERTER HOUSING
14-158
18. Installthe sub-shaftassemblyin the transmission h o u s i n g{ s e ep a g e 1 4 - 1 3 8 ) .
,,1
19- Installthe reverseidler gear and gear shatt holder ( s e ep a g e 1 4 - 1 5 4 ) .
24. Align the spring pin of the control shaft with the
20. Installthe differentialassemblyin the torque converter housing.
lnstall the reversegear with the collar and needle bearingon the countershalt.
transmissionhousinggrooveby turningthe control shalt.
25. Placethe transmissionhousingon the torque converterhousingwith a new gasketandthe dowelpins.
21. Installthe mainshaftand countershaftsub-assembly together in the torque converterhousing.
CONTROL
MAINSHAFT SUB.ASSEMBLY COUNTERSHAFT SUB.ASSEMBLY
/K"\
// 2 " \
TRANSMISSION HOUSING
Installthe transmissionhousingboltsalongwith the t.ansmissionhangerand the connectorstay, then torque the bolts in two or more steps in the sequence shown.
2 2 . Turn the shift fork so the largechamteredhole is facing the fork bolr hole.then installtheshift fork with the reverseselectorand torquethe lock bolt. Bend the lock tab againstthe bolt head.
TOROUE:44 N.m (4.5 kgf.m, 33 lbf'ft) TRANSMISSION HANGER CONNECTOR
SHIFTFORK LOCI( WASHER Replace. 6 x 1.0 mm 4 N.m (1.4 kgl.m, rO lbt.ft)
Largechamferedhole faces this way.
14-159
Transmission (cont'dl Reassembly 27. Slip the specialtool onto the mainshaftas shown.
MAII{SHAFT HOLDER oTGAa - PF5010I
32. Use th6 old locknut and old conicsl spring washot to tighten th€ parking gear to th€ sp€cifi€d torque, then loosen the locknut. TOROUE:103
.m (1O.5 kgf.m, 75.9 lbf'ftl
NOTE: Locknut has left-hand threads.
PARKII{GGEAR
24. Install the parking b.ake lever on the control shaft. 29. Installthe mainshaft 1st g6ar collar and thrust washer on the mainshaft.
30. Installthe countershaft1st gear collarand n6€dls bearing,then installthe count€rshatt1st gear/oneway clutch/parking gea, assembly on the countershalt.
3 1 .Install the parking b.ake pawl in th€ transmission housing,then engageit with the parkinggear.
33. Install the sub-shaft lst gear on thg sub-shaft. 34. Install new O-rings on the mainshaft. lST CLUTCH PARKI''IGGEAR PARTI G ARAKE LEVER
SUB-SHAFT
14-160
MAIt{SHAFT
COU TERSHAFT
NOTE: Wrap the shaft splines with tspa to prevont damago to the O-rings. Assembloth€ thrust wash6r, thrust naedle bearing, needlebearingand msinshsft lst gear on tho lst clutch assombly,then installthem on the mainshaft.
36. Alignthe holeof the sub-shaft1st gearwith the hole of the transmission housing,then inserta pinto lock the sub-shaftwhiletighteningthe sub-shaftlocknut.
3 9 . Stake each locknut using a 3 . 5 m m p u n c h . . MAINSHAFT
37. Installnewconicalspringwashersand new locknuts on each shaft. CAUTION: Installthe conical spdng washers in the dilection shown. 38. Tightenthe locknutsto the specifiedtorque. TOROUE: MAINSHAFT 93 N.m (9.5 kgf'm, 69 lbf.ft) COUNTERSHAFT 103 N.m (1O.5 kgf.m, 75.9 lbf.ft) SUB-SHAFT 93 N.m (9.5 kgf.m. 69 lbf.fi) NOTE: Mainshaltand countershaftlocknutshave left-handthreads.
. COUNTERSHAFT
O,7- 1.2 mm CONICAL DISC SPRINGS lnstallin rhis direcrion.
0.7- 1.2 mm
in) 1O.03-O.05 SUB-SHAFTLOCKNUT
14-161
Transmission Reassembly(cont'dl 40. Set rhe parkingbrakelever in the E position,then verifythat the parkingbrakepawl engagesthe parkIng gear.
44. Installthe throttlecontrolleverwiththe leverspring on the throttle control shaft. TOROUE:7.8 N.m (O.8 kgf.m, 5.8 tbf.ft)
4 1 . l f t h e p a w l d o e sn o t e n g a g e f u l l yc,h e c k t h ep a r k i n g brakepawl stopperclearanceas describedon page 14-154.
45. Installthe tramsmissionmount bracket. TOROUE:64 N.m (6.5 kgf.m, 47 lbf.trl
42. Tightenthe lock bolt and bend the lock tab. 46. Installthe ATF cooler pipes and ATF level gauge. 6 x 1 . 0m m 10 tbf.frl
PARKINGGEAR PARKINGBRAKEPAWL
Installthe right side cover and right side cover pro lecror. TOROUE:12 N.m {1.2 kgf.m, 8.7 lbf.ftl
14-162
Torque Converter/DrivePlate
6 x'l.Omm 12 N.m {1.2 kgf.m, 8.7 lbf'tt)
12 x 1.0mm 74 N.m {7.5 kgf.m, 54 lbl.ftl Torquein a crisscrosspattern.
0
0d
DRIVE PLATE
TOROUECONVERTER ASSEMELY
14-163
Transmission Installation 1 . F l u s ht h e A T Fc o o l e ra s d e s c r i b eodn p a g e sI 4 - 1 6 8 'l thru 69. 2.
5.
12 x 1.25mm 64 N.m 16.5 kgl.m, 47 lbf.ft)
Installthe starter motor on the transmissionhousi n g ,t h e ni n s t a l l t h el 4 m m d o w e lp i n si n t h e t o r q u e converrernousrng.
STARTERMOTOR
Installthe transmissionmount.
45 N.m 14.5 kgf'm,
'14 mm DOWELPIN
I
i.'l,i; TOROUE CONVERTER J.
O-RING Replace.
1 2 x 1 . 2 5m m 74 N.m 17.5kgf'm, 54 rbt'ft)
14 mm OOWELPIN
Placethe transmissionon a transmissionjack, and raiseto the enginelevel.
6.
Installthe transmissionhousingmountingbolts.
Attach the transmissionto the engine,then install the transmissionhousingmounting bolts and two rear enginemounting bolts with new washers. TRANSMISSION HOUSING MOUNTINGBOLTS
REARENGINE MOUNT BOLTS 1 4 x 1 . 5m m
59 N.m 16.0 kgf.m,43 lbl.ftl
TRANSMISSION HOUSING MOUNTING BOLTS 12 x 1.25 rnm 74 N.m (7.5 kgf'm, 54 lbf.ftl
14-164
7 . Removethe transmissionjack.
11. Connectthe ATF cooler hosesto the joint pipes.
L Attach the torque converterto the drive plate with eight bolts and torque: Rotatethe crankshattas necessaryto tighten the boltsto 1/2 of the speciliedtorque,then to the final toaque,rn a cnsscrosspattern. After tighten the last bolts, check that the crankshaft rotatesfreely.
12. Connectthe throttlecontrolcableto the throttlecontrol lever and installthe right front mount/bracket.
THROTTLECONTROLLEVER
THROTTLECONTROL CABLEEND JOINT PIPES
T O R O U E1: 2 N . m { 1 . 2 k g l . m . 8 . 7 l b f . f t }
9 . Install the torque converte. cove. and engine stiffener. 6 r 1 . Om m 12 N.m 11.2 kgt.m, 8.7 lbl.ltl
ATF COOLERHOSES 10 x 1.25mm RIGHT 44 N.m (4.5 kgf'm, FRONT MoUNT/ 33 rbl.ftl BRACK€T t5.
1 2 x 1. 2 5 m m 64 N.m {6.5 kgf.m, 47 tbf.ftl Replace.
Install the control lever with a new lock washer to the control shalt. then install the shift cable cover. CAUTION: Take care not to bend the shift cable.
10 x 1.25mm 44 N'm {4.5 kgf.m. 33 rbt'frl
SHIFTCABLE
8 x '1.25mm 24 N.m (2.4 kgl.m, 17 tbf.trl 1 2 N . m 1 1 . 2k g f . m , 8.7 rbt.ft)
CONTROL SHAFT
l O x ' 1 . 2 5m m 43 N.m 14.4 kgf.m, 32 lbf.ltl
1 0 .Tighten the crankshaft pulley bolt to specified rorque.
6 x 1.0 mm 12 N.m {1.2kgf.m, 8.7 lbl.rr)
TOROUE:177 N.m {18.O kgt.m, 130 lbf'ft} SHIFT CABLE COVER LOCK ASHER Replace.
CONTROLLEVER 6 x 1.0 mm 1 4 N . m 1 1 . 4k g l . m , 10 lbf.fr)
(cont'dl
14-165
Transmission Installation{cont'd) 1 4 . Installnew set ringson the end of the intermediate shaft and the driveshaft.
17. Installthe right and left drivershafts(seesection l6l. NOTE: Turnthe right and left steeringknucklefully outward, and slide the right driveshaft into the differentialuntil you feel its springclip engagesthe side geaf. Slidethe left driveshaftinto the intermediate shaft until you teel the springclip of the intermediateshaft engagethe driveshaft.
1 5 . Installthe intermediateshaft.
18. Installright damperfork, then installthe right and lett balljointsto eachlowerarm with the castlenuts and new cotter Dins. DAMPER PINCH BOLT 10 x 1.25mm 43 N.m 14.4 kgf.m,
32 tbr.ftl
SET RING Beplace. 10 x 1
39 N.m 14.Okgf.m, 29 lbf.ftl SHAFT
1 6 . Installexhaustpipe A. and connectthe heatedoxvgen sensor{HO2S)connector.
\ SELF.LOCKINGNUT 1 2 x 1. 2 5 m m 64 N.m (6.5 kgl.h, 47 lbt.ftl Replace.
COTTER Replace. CASTLE NUT 1 2 x 1 . 2 5m m 49-59 N.m {5.O-6.0 ksf.m, 36-43 rbt'ft1
1 9 . I n s t a l tl h e s p l a s hs h i e l d .
SELF-LOCKINGNUT 10 x 1.25mm 54 N.m (5.5 kgl.m, 40 rbt.trl Replace.
14-166
GASKET Replace. SELF.LOCKINGNUTS I x 1.25mm 22 N.m 12.2 kgl'n, 16 lbt.trl Repl6ce.
6 x 10 mm BOLT
cltPs, 5
20. Connectthe vehiclespeedsensor(VSS),mainshatt speed sensor and counterchalt speed sensor con nectors. VEHICLESPEEDSEiISOR CONNECTOR
23. Connectthe startercableto the startermotor, and install the cable holder. NOTE: When installingthe starter motor cable, makesurethat the crimpedsideof the ringterminal is facing out (see section 23). CABLE HOLDER
6 x 1 . 0m m '12 N.m (1.2 kgf'm,8.7 lbt.tl) N.m
lO.9 ksr.m, 7 tbr-rtt
STARTERCAELE
2 4 . Installthe air cleanerhousingassemblyand intake a r ro u c l . AIR CLEANERHOUSING ASSEMBLY
INTAKEAIR DUCT
21. Connectthe lock-uDcontrolsolenoidvalveconnector and shift controlsolenoidvalveconnector.then clampthe lock-upcontrolsolenoidharnesswith the harnessstay. 22. Connectthe transmissionground cable. LOCK-UPCONTROL SOLENOIDVALVE HARNESSSTAY
25. Retillthe transmissionwith ATF(seepage '14-93). 26. Connectthe battery positive( + ) and negative( - ) cablesto the battery. Startthe engine.Setthe parkingbrake,and shift the transmissionthrough all gearsthree times.
24. Checkshitr cableadjustmentas describedon page 14-171 . 2 9 . C h e c kt h a t f r o n t w h e e la l i g n m e n(ts e es e c t i o n1 8 ) . (thecool30. Letthe enginereachoperatingtemperature ing tan comeson) with the transmissionin S or @ position,then turn it off and check the fluid level. 3 1 . R o a dt e s t a s d e s c r i b e do n p a g e 1 4 - 9 o a n d 9 1 .
14-167
Transmission CoolerFlushing ro prevent iniury to tace and eyes, always S!@ wear safety glas$esor a tace shieldwhen usingthe transmission flusher. NOTE: This procedureshouldbe performedbeforereinstallingthe transmission.
7. With the water and air valvesoff. attach the water and air supplies to the flusher. (Hot water it available.)
OFF
1. Check tool and hoses for wear or cracks before using. lf wear or cracks are found, replacethe hoses before using. 2.
Usingthe measuring cup, tillthe tankwith 21 ounces {approximately213 lulll of biodegradabletlushing fluid (J35944-20).Do not substitutewith any other fluid. Followrhe handlingprocedure on the fluidcontainer. Securethe tlusherfillercap and pressurizethe tank with compressedair to between 550-829 kPa ( 5 . 6 - 8 . 4 5 k g t / c m , ,8 0 - 1 2 0 p s i ) , NOTE: The air lineshouldbe equippedwith a water trap to ensurea dry air system. Hang the tool under the vehicle. Attach the dischargehoseof the tank to the return line of the transmissioncooler using a clamp.
6.
Connectthe drainhoseto the inlet lineof the transmissioncoolerusinga clamp.Securelyclampthe opposite end of the drain hoseto a bucket or floor drain.
8. Turn on the flusherwater valve so water will tlow throughthe oil coolerfor 1Oseconds.lf water does not flow through the oil cooler it is completely plugged,cannot be flushed,and must be replaced. 9. Depressthe triggerto mix the tlushinglluid into the water tlow. Use the wire clip to hold the trigger oown. 10. While flushingwith the water and flushingfluid for 2 minutes.turn the air valveon for 5 secondsevery 15-20 secondsto create a surgingaction. AIR PRESSURE: MAX 829 kPa (8.45 kgt/cm,, 12O psi)
DISCHARGEHOSE
1 1. Turn the water valve off. Releasethe trigger,then reversethe hosesto the coolerso you can flush in the oppositedirection.Repeatsteps 8 through 1O. 12. Releasethe triggerand allow water only to rinsethe cooler with water for one minute. 13. Turn the water valve off and turn off the water supply. 14. Turn the air valve on to dry the systemout with air for two full minutesor until no moistureis visible leavingthe drain hose. CAUTION: Residual moisture in the oil cooler 01 pipes can damage the transmission. DRAIN HOSE TRANSMISSION
BUCKET
14-168
TRANSMISSION COOLERFLUSHEB CommorciallyAvailablo KENT MOORE#J38405_A
15. Removethe flushertrom the coolerline.Attach the drain hose 10 a oil container. 16. lnstallthetransmissionand leavethe drainhose attached to the cooler line.
't 7. Make sure the transmission is in @ position. Then fill the transmission with ATF and run the engins tor 30 sacondsor until spproximatelyons quart iB discharged.
TOOL MAINTENANCE 1.
Empty and rinse aftor each use. Fill the can with water and pressurizethe can. Flush the discharge line to ensurethat the unit is clean.
2.
lf dischargeliquiddoesnot toam, the orificemay be blocked.
3.
To clean,disconnectthe plumbingtrom the tank 8t the large couplingnut.
4.
Remov€the in-linefilter trom the dischargeside and clean it necossarv.
5.
The fluid orilice is located behind the tilter. Cleanit with the Dickstoredin the boftom ot the tank handleor blow it cl6anwith air. Securelvreassemble all Darts.
1 8 .Rsmove the drain hose and reconnect the cooler return hoae to th€ transmission.
1 9 .Refillth€ trsnsmission with ATF to the prop€r levol.
FILLERCAP COUPLII{GI{UT FILTER
---0--L--
I
O.BI G
ORIFICE
14-169
shift cable Removal/lnstallation a All SRS electrical wiring hamosses are covor€d with yellow insulation. a Before disconnecting any pan ot th€ SRS wire harnoss, connect the short connectorc(soepage 23-7O1. a Roplaceth€ entiro attect€d SRS haness assembly it it has an open circuit ot damaged wi.ing.
3.
Removethe shift cable bracket.
6x1.0mm 1 2 N . m 1 1 . 2k g f . m , 4 . 7l b f . f t l
uar" @@[ section 1).
4.
Removethe shitt cable holder.
5.
Removethe shift cable cover.
6.
Removethe control leverfrom the control shaft, then removethe shift cable.Take care not to bend the cable when removing/installing it.
sul€ litts are placed proparty {so6
1.
Removethe center console {seesection 20).
2.
Shift to N position.then removethe lock pin from the cable adjuster.
SHIFT CABLE I{OLDER
@J^ll
AJUI [qJ ]l tl ---l
LOCK NUT 7 N.m (O.7 kgf.m, 5 lbf.ft)
12 N.m 11.2 kgf.rh, 8.7 lbf.ftl 14 N.m 11.4 kgl.m, 10lbt.ft)
7 . Installthe shift cable in the reverseorde. of removal. 8.
14-170
Checkthe cableadjustmenton reassembly, on page 14-171.
Adjustment CAUTION: a All SRS electrical widng harn€ssesare covar€d with yollow insulation. a Before disconnecting any part of ths SRS wire harness, connect the shon connectors(seepage 23-701. a R€placethe entire affected SRS halnass asssmbly it it has an op€n circuit or damaged wiring.
4. Check that the hole in the adiuste. in perfectly alignedwith the hole in the shift cable.Thereare two holes in the end of the shitt cable, They are positioned 9Oo apart to allow cable adiustmentin 1/4 lurn Incremenls.
ADJUSTER
Cable I oo snon
Cable Too Long
Exact Alignment
tu"t" sure lifts a.e placed properly ls66 @ ssction 1).
5. It not perfectlyaligned,loosenthe locknut on the shift cable and adjust as required.
'1.
6. Tightenthe locknut to 7 N.m (O.7kgf.m, 5lbf.ft).
Start the engine.Stritt to @ positionto see if the reversegear engages.lf so, refer to troubleshooting on page 14-86 thru 89. Wilh the engineoff, removethe centerconsole{see section 20). Shilt to N position.then removethe lock pin from the cable adjuster.
]H
@ @ @
/
''fidlfr
7. Installthe lock pin on the adiuster.lf you feel the lock pin bindingas you reinstallit, the cable is still out of adjustmentand must be readjusted. 8. Move the selector to each gear and verify that the automatictransaxlegear positionindicatortollows the automatictransaxlegear positionswitch. 9. Startthe engineand checkthe shift leverin allgea.s. lf any gea. does not work properly, refer to troubleshootingon page 14-86 thru 89. 1O. lnsert the ignitionkey into the key cylinderon the shift indicatorpanel,ve.ify that the shift lock lever is released,
I
t+@ \
\ / CABLE
-.'.-_--l../
ADJUSTER
14-17 1
GearshiftSelector Disassembly/Reassembly CAUTION: a All SRS electrical wiing haln€ssss are covered with y6llow insulation. a 8€fore disconnecting 8ny pan of the SRS wire harneaa.connOctth6 short connectors(sse page 23-701. a Roplacethe entire affected SRS hahess assembly if il has an opon circuit or damaged wiring.
SRS MAIN HARNESS
[E--__
9.8 N.m {1.O kgf.m, 7.2 lbf.frl
SHIFT LOCK SOLENOID
rocK ptN
ADJUSTER
-6{ stLtcoNE GREASE
e-
LEVERCOVER
-#q SILICONEGREASE
CONTROLBRACKET
LOCK PIN ROD
5 N.m (0.5 kgt.m, 4 lbt.ftl
@6 SELECTLEVERBRACKET
9.8 N.m (1.0 7 .2 tbt.ltl
AUTOMATIC TRANSAXLE GEAR POSITIONSWITCH Testing,see Section23
CONTROLSEAL
12 N.m (1.2 kgf.m, 8.7 lbf.ftl 9 . 8 N . m 1 1 . 0k g f ' m , 7 . 2 l b f . f t l
14-172
Shift Indicator Panel Adjustmet CAUTION: a All SRS olectrical wifng harnessesaro covered with yellow insulation. a Bofors disconnecting any pan of the SRS wire harness, connect tho sho.t connectors{sse page 23-7O), a Replacethe entire aflect€d SRS harness assembly if it has an open circuit or damaged wiring,
1 . Check that the index mark on the indicatoraligns with the N]mark on the shift indicatorpanelwhen the transmissionin NEUTRAL. lf not aligned,removethe centerconsole(seesection 2O). Removethe shift indicatorpanelmountinqscrews and adjust by moving the panel. NOTE: Wheneverthe shift indicator panel is removed, reinstallthe panel as describedabove.
INDEXMARK
@ @ @ SRS MAIN HARNESS
MOUNTING SCREW 3 N'm lO.3 kst.m, 2 lbf.ftt
14-173
Throttle Control Cable Inspection NOTE: Betoreinspecting the throttlecontrolcable,make sure: a Throttle cable free play is correct (seesection 1 1). a ldle speed is correct (see section 1l). a To warm up the engineto normaloperatingtemperature {the coolingfan cor'reson) 1.
Verifythat the throttlecontrolcableis clampedcorrectly with three positions.
14-174
Verify that the throttlecontrollevelis synchronized and releaswith the thronlelinkagewhiledepressing ing the acceleratorpedal. lf the throttlecontrolleveris not synchronizedwith the throttle linkage.adjust the throttle control cable.
,r:
\
4.
Check that there is play in the th,ottle control lever while dep.essing the accelerator pedsl to th€ full throttle Dosition.
F.o. play
Remove the cable end of the th.ottle control cable from the throttle control lever. o.
Check that the throttle control lever moves smoothlv,
14-175
Throttle Control Cable Adjustment NOTE: Beforeadjustingths throttle control cable, make sute:
4.
Remove the free play of ths throttl6 control cabl€ with the locknut, whils pushing thg throttlo control leve. to the full-closed Dotision as snown,
5.
Tighten the locknuts.
a Throttle cable free play is correct {see section 11). a ldle speed is correct (seesection 11). a To warm up the engine to normal oporsting temperature {the coolinglan comes on}. I.
Verify that the throttle control c8ble is clamDedcorrsctly with three positions. THROTTLE COI{TROL CABLE
ATF COOLER PIPE
Clamp on blu6
CLAMP Verify that the throttle linkage is in the full-closed position. 5.
Loosen the locknut of the throttle control cable at the throttle linkage. THROTTLELII{KAGE
After tightening the locknuts, inspect the synchronization and throttlg control l6ver movemenr.
LOCKI{UTS
14-176
Differential ManualTransmission 81881 engine
15-1 8 1 8 C 1e n g i n e. . . . . . . 15-9 AutomaticTransmission .................. 15-19
Differential(81881 enginel ........15-2 S p e c i aTf o o l s. . . . . . . . Differential lllustrated Index......... . 15-3 BacklashInspection .... 15-4 FinalDrivenGearReplacement ...... 15-4 15-5 BearingReplacement .................... Oil SealRemoval ........15-5 SideClearance Adiustment...........15-6 Oil Seallnstallation ..... 15-8
SpecialTools
Ref. No.
o ra) @
I
Tool Numbol
oTJAD-PH80101 07746-OO30100 o7749-OO10000 o7947-SO90200
Description
Oty
Seal DriverAttachment D r i v e r ,4 0 m m l . D . Driver Seal DriverAttachment
15-8 15 - 5 . 6 15-8 15-8
€
o
I
(^
s F
A
$-l) o
15-2
I Pag€ Reference
@
Differential(B1881 engine) lllustrated Index
OIL SEAL Replace. Removal,page 15-5 Installation,page 15-8 FINAL DRIVENG€AR Inspectfor wear and damage, page 15-4 Replacement,
DIFFERENTIALCARRIER Inspection.page 15-4
BALL BEARING Inspect lor wear and operation. page 15 5 Replacement, BALL BEARING Inspect for wear and operation. page'15-5 Replacement,
10 x 1.0 mm 101 N.m llO.3 kgt'm,74.5 lbf.ftl Left-handthreads
80 mm SHIM Selection,page 15-6
'l5-5 Removal,page lnstallation,page 15-8
15-3
Differential(818B1 enginel BacklashInspection '1.
Placedifterentialassemblyon V-blocksand install both axles.
FinalDrivenGearReplacement 1 . Remove the bolts in a crisscross Datt€rn in several steps, and remove the final driven gear from the differentialcarrier.
M€asurethe backlashof both pinion gears. Standard(New):0.05-O.15mm (0.OO2-0.006 inl
DIAL II{OICATOR
NOTE: The final driven gear bolts have left-hand threads. 1 0 x 1 . 0m m 101 N.m llO.3 kgl.m,74.5 lbf.ftl Lelt-handthreads
FINAL DRIVEIIIGEAR Chamfer on inside diameter ot linal driven gear taces carrier.
DIFFEREI{TIAL CARBIER
3.
It the bscklsshis not within the standard,reDlace the differential carrier.
15-4
Installthe final driven gear by tighteningthe bolts in a c.isscross pattern in several steps.
Oil Seal Removal
Bearing Replacement NOTE: Checkthe ball bearingsfor wear and rough rotation. It bearingsare OK, removalis not necessary. 1.
1 . Remove the ditterential assembly. Remove the 8O mm shim from the transmission housing.
Removethe ball bearingsusing a standatdbearing puller and bearingseparatoras shown. BEARINGPULLEB
80 mm SHIM
TRA[{SMtSStON HOUSING
3.
Removethe oilseal from the t.ansmissionhousing.
4.
Removethe oil seal from the clutch housing,
BALL BEARING
Installnew ball bearingsusing the specialtool as snown. NOTE: Drivethe bearingssquarelyuntil they bottom againstthe carrier.
DRIVER,40 mm l.D. 07746-0030100
BALL BEARING
OIL SEAL R€plac6.
15-5
Differential(81881 engine) Side ClearanceAdjustment l.
Installthe diflerentialassembly,makingsureit bottoms in the clutch housing.usingthe specialtoolas shown.
?
Installthe transmissionhousing(seesection 13). NOTE: Do not applyliquidgasketto the matingsur,ace ot the clutch housing.
4.
Tighten the transmissionhousing attaching bolts (see section 13). 8 x 1.25 mm 27 N.m 12.8 kgf'm, 20 lbf.ftl Usethe specialtool to bonom the differentialassembly in rhe clutch housing.
tt.
HOUSING
2.
Installthe 80 mm shim. NOTE: Instsllthe 80 mm shim that was removed.
mm SHIM
15-6
Measure clearance between the 80 mm shim and bearing outer race in the transmission housing.
'l
lf the clearanceis not within the standard, select a new 80 mm shim from the following table. Strndard: 0-O.1O mm (O.O04inl
Thicknoss
A
41441-PL3-BO0
B
41442-PL3-BOO
1 . Om m 1 0 . 0 3 9 4i n ) 1 . 1 m m ( O . O 4 3 3i n ) 1 . 2 m m ( O . O 4 7 2i n ) 1 . 3 m m ( 0 . 0 5 1 2i n )
D
41444-PL3-BOO
E
41445-PL3-BO0
f
41446- PL3-BO0
1 . 4 m m { 0 . 0 5 5 1i n l 1 . 5 m m ( O . O 5 9 1i n )
41447-PL3 -BOO
1.6 mm (0.0630in)
41448-PL3- B00 41449-PL3- BO0
1 . 7 m m ( 0 . 0 6 6 9i n )
N
1 . 8 m m ( 0 . 0 7 0 9i n l 41450- PL3-BOO 1 . 0 5m m { o . o 4 1 3i n l 4 1 4 5 1 - P L 3 - B O O 1 . 1 5m m ( 0 . 0 4 5 3i n ) in) 4 1 4 5 2 - P L 3 - B O O 1.25 mm (O.O492 4 1 4 5 3 - P L 3 - B O 0 1. 3 5 m m ( 0 . 0 5 3 2i n )
P
41454-PL3-BOO
o
41455-PL3-BOO
1 . 4 5 m m ( 0 . 0 5 7 1i n ) 1. 5 5 m m ( 0 . 0 6 1 Oi n )
R
1 . 6 5 m m ( 0 . O 6 5 0i n )
s
41456-PL3-800 41457 - PL3-BOO
T
41441-P21-OOO
1 . 8 5 m m ( 0 . 0 7 2 8i n )
U
41442-P21-OOO
1.90 mm (o.o748in)
41443-P21-OOO
1 . 9 5 m m ( 0 . O 7 6 8i n )
J
K L M
recheck the clearance.
missionhousing{see section 13).
Pan Number
H
9 . Replacethe 8O mm shim selected in step 7, thon 1 0 . Reassemblethe transmission and install the trans-
8O mm Shim
41443-PL3- BOO
8 . Remove the bolts and transmission housing.
1 . 7 5m m ( 0 . 0 6 8 9i n )
NOTE: lf tho clearancemeasuledin step 6 is within th€ standard, it is not necessary to go to step 9.
15-7
Differential(8188l enginel Oil Seal Installation 1.
Installthe oil sealinto the t.ansmissionhousingusing the specialtools as shown
DRIVER 07749-0010000
DRIVER 07749-0010000
OIL SEAL Replsce.
OIL SEAL Replace. HOUSING
15-8
Installthe oil seal into the clutch housingusingthe soecialtools as shown.
Dif f er en ti a(8 l 18C1enginel 15 - 1 0 S p e c i aT l ools ........ Differential 1 5 - 11 l l l u s t r a t e dI n d e x . . . . . . . . . 15-12 BacklashInspection F i n a lD r i v e nG e a rR e p l a c e m e n.t. . . . . 15-12 TaperedRollerBearingReplacement.1 5 - 1 3 15-13 Oil Seal Removal BearingOuter Race Replacement... 15-14 TaperedRollerBearingPreload 15-15 Adjustment 15-17 Oil Seal Installation
SpecialTools
Ref. No. I
o
( ,a\ @ r.l @
I
TootNumber oTHAJ-PK40201 oTJAD-PH80101 oTNAD-PX40100 o7746-O030'l OO o7749-OO10000 o7947-SD90200
o
Descriprion
I
PreloadInspectionTool Seal DriverAttachment DriverAttachment Driver,40 mm l.D. Driver Seal Drive. Attachment
rt\
$ s
@
15-10
tl
Oty I I 1 I I 1
aa\
I Page Reference 1 5 - 15 15- 14 1 5- 14 15-131 4 15- 14 1 7 15 - 1 7
Differential(B18C1 engine) lllustrated Index NOTE: lf the ' mark parts were replaced,the tape.ed roller bearingpreloadmust be adiusted(see page 15-15).
OIL SEAL Replace. Removal,page 15-13 Installation,page 15-17 'THRUST SHIM T. 2.5 mm lO.O98inl
ROLLER TAPERED BEARING Inspectfor wear and oporation. page'15-13 Replacement,
*BEARING OUTERRACE Inspect tor wear and damage. page 15-14 Replacement. 10 x 1.0 mm 101 N.m 11O.3kgt.m,74.5 lbt.ft) Left-hand threads FINAL DRIVENGEAR Inspectlor wear and damage. page 15-12 Replacement,
}DIFFERNTIALCARRIER Inspection,page 15-12
.TAPERED ROLLERBEARING Inspect for wear and operation. page 'l5-13 Replacement,
T. 2.0 mm (0.079 inl *79.5 mm SHIM Selection,page 15-16 OIL SEAL Replace. R e m o v a lp, a g e ' l 5 - 1 3 Installation,page 15-17
Differential(818C1 enginel BacklashInspection Placeditterentialassemblyon V-btocksand instatl both axles.
FinalDrivenGearReplacement 1. Romovethe bolts in a crisscrossDatternin several steps, and remove the tinal driven gear f.om the differentialcarrier.
Measurethe backlashof both pinion gears. Standard(Now):0.o5-o.15 mm {0.oo2-0.O06 in)
NOTE: The tinal driven gear bolts have lett-hand threads.
1 0 x 1 . Om m 101 N.m (10.3 kgt.m, 74.5 lbf.ftl Left-hand threads.
FII{AL DN|VENGEAR Chamfer on inside diameter of linal driveng€ar taces carrier.
DIFFERETTTIAL CABRIER
lf the backlashis not within the standard,reDlace the differentialcarrier, Installthe final driven gear by tighteningthe bolts in a crisscrosspattern in severalsteps.
15-12
TaperedRollerBearingReplacement NOTE: a The tapered roller bearingand bearing outer race should be replaced as a set. a Inspectand adjustthe taperedrollerbearingpreload whenevef the taperedrollef bearingis replaced. a Checkthe taperedrollerbearingstor wear and rough rotation.lf taperedrollerbearingsare OK, removalis not necessary. 1.
oil SealRemoval 1 . Removethe differentialassembly. Removethe oil sealfrom the transmissionhousing.
Removethe taperedrolle. bearingsusinga bearing puller and bearingseparatoras shown,
BEARING
BEARII{G SEPANATOR (Commercially available)
3.
Removethe oil seal from the clutch housino.
Installnew taperedrollerbearingsusingthe special tool as shown. NOTE: Drivethe taperedrollerbearingson until they bottom againstthe differentialcarrier.
15-13
Differential(B18c1 eng:nel BearingOuter RaceReplacement CAUTION: Do not rous€ the thrust lhim and tho 79.8 mm shim il tho outer rac6 was ddvon out.
4.
NOTE; a The bearing outer race and taper€d toller bearing should be reDlacedas a set. a Inspect and adjust the tapered roller bearing proload whenever th€ tapered roll€f bearing is roplac€d. 1.
Removethe oil seals from the transmissionhousing and clutch housing(see page 15-13).
2.
Removethe bearingouter raca, the thrust shim, and the 79.5 mm shim from th€ transmissionhousing.
Installthe new thrust shim and 79.5 mm shim,then drive the bearing outer races in the both housings using the specialtools as shown. NOTE: a Install the bearing outsr race squarely. a Check that there is no clearance between tha bearingouter race, thrust shim, and transmission housing. BEARIl{G OUTER
TRANSMtSStOl{ HOUStl{c
Removethe bearingouter racs and thrust shim trom the clutch housing. 07749-OOTOOOO ONNER ATTACHMENT OTttAD-PX/IOlOO
5.
15-14
lnstallthe oil sesl (see page 15-171.
Tapered Roller BearingPreloadAdjustment Instsllthethrustshim and 79.5 mm shim,then drive the bearingouter race in the transmissionhousing { s e ep a g e l 5 - 1 4 ) .
NOTE: lf any of the items listedbelow were replaced, the taperedrollerbearingpreloadmust be adjusted, a a a a a 1.
Transmissionhousing Clutch housing Diffe.entialcarrier Taperedrollerbearingand bea,ingouter race Thrust shim Removethe bearingouterrace,the thrust shim,and the 79.5 mm shim from the transmissionhousing (see page 1 5- 14).
NOTE: a Installthe bearingouter race squarely. a Check that there is no clearancebetween the bearingouter race.thrust shim and transmission housing. 4.
CAUTION: Do not reuss lhe thrust shim it the bearing outer raco was driven out. 2.
With the mainshaftand countershaft.emoved,instsllthe differentialassembly,andlorquethe clutch housingand transmissionhousing, 8 x 1.25 mm 27 N.m 12.8 kgf.m, 20 lbf.ft)
First t.y the same size 79.5 mm shim that was removeo.
NOTE: lt is not necessaryto use sealingagent between the housings.
CAUTION; Do not uso moro than two shims. Rotate the ditterential assembly in both directions to seat the taperedrollerbearings. o.
Measurethe starting torque of the differenlialassembly with the specialtool and a torque wrench.
79.5 rnm SHIM
NOTE: Measurethe taperedrollerbearingpreload in both directions. STANDARD:2.1 1 -3.O4 N.m (21.5-31.0 kgf'cm, 18.7-26.9 lbf.inl
HOUSING
{cont'd}
15-15
Differential(B18C1 enginel TaperedRollerBearingPreloadAdjustment(cont'dl 7.
It the taperedrollerbearingpreloadis not within the standard,selectthe 79.5 mm shimlrom the following table which will give the taperedrollerbea.ing preloadclosestto the standardmeanvalueof 2.50 N . m ( 2 5 . 5 k g J . c m ,2 2 l b f . i n ) . NOTE: Changingthe 79.5 mm shimto the next size will increase or decreasetapered roller bearing p r e l o a da b o u t O . 3 - O . 4 N . m ( 3 - 4 k g f . c m , 2 . 6- 3 . 5 l b t . i n ) . 79.5 mm SHIM
Recheckthe taperedroller bearingpreload. 9 . How to selectthe correct 79.5 mm shim: - 1) Comparethe taperedrollerbearingpreloadyou get with the 79.5 mm shim that was removed with the specifiedmean preloadof 2.50 N.m (25.5 kgf.cm. 22 lbf.inl. -2) lf your measuredtaperedrollerbearingpreload is lessthan specified,subtractyour's from the soecified. lf your's is more than specified,subtractthe specifiedfrom your measurement. Forexamplewith a 1.38 mm (O.O543in) shim:
Part Numbel
Thickness
41460-PY4-000
0 . 6 6 m m ( 0 . 0 2 6 0i n )
AB
41461-PY4-000
1 . 1 7 m m ( O . 0 4 6 1I n ,
AC
2 . 0 N . m { 2 0 k g f . c m ,1 8 l b t . i n }l e s s
AD
41462-PY4-000 1 .2O mm (0.0472 in) 41463-PY4-000 1 . 2 3 m m ( O . O 4 8 4i n )
AE
41464-PY4-000
1 . 2 6 m m ( 0 . 0 4 9 6i n )
AF
41465-PY4-OOO 1 . 2 9 m m ( O . O 5 O i8n )
3.29 N.m {33.5kgl.cm,29 lbl.in) @you measure - specified 2.50 N.m {25.5kgf.cm,22 lbf.in)
AG
41466-PY4-OOO 1 . 3 2 m m ( O . O 5 2 O in)
AH
41 467-PY4-000
AI
1 . 3 5 m m { O . O 5 3 1i n ) 41468-PY4-000 1 . 3 8 m m ( O . O 5 4 3i n )
AJ
41469-PY4-000
AK AL
41470-PY4-OOO 1 . 4 4 m m ( 0 . 0 5 6 7i n ) 41 47 1-PY4-OOO 1 . 4 7 m m ( 0 . 0 5 7 9i n )
AM
41 47 2-PY4-OOO
AN
41473-PY4-000
AO
AR
1 . 5 6 m m ( 0 . 0 6 1 4i n ) 4 1 4 7 5 - P Y 4 - O O O ' l. 5 9 m m ( O . 0 6 2 6i n ) 4'1476-PY4-O00 1 . 6 2 m m ( 0 . 0 6 3 8 i n ) 41 47 7 -PY4-OOO 1. 6 5 m m ( 0 . 0 6 5 0 i n )
AS
41478-PY4-000
AP AO
AU
1. 4 1 m m ( O . 0 5 5 5i n )
1 . 5 0 m m { O . O 5 9 1i n ) 1. 5 3 m m ( 0 . 0 6 0 2i n )
41 47 4-PY4-OOO
1. 6 8 m m { 0 . 0 6 6 1 i n ) 41479-PY4-OOO 1 . 7 1 m m ( O . 0 6 7 3i n ) 41480-PY4-OOO 1 . 7 4 m m ( 0 . 0 6 8 5i n ) 41481-PY4-OOO 1 . 7 7 m m { 0 . 0 6 9 7 i n } 41442-PY4-OOO 1 . 8 0 m m ( O . O 7 O i9n )
AX
41483-PY4-OOO 1 . 8 3m m ( 0 . 0 7 2 0i n l
@ specified2.50 N.m (25.5 kgf.cm, 22 lbf.in) - you measure0.54 N.m (5.5 kgt.cm, 5lbt'in)
0.8 N.m (8 kgf.cm,7lbt.in) more 3) Each shim size uD or down from standard makesabout O.3-O.4 N.m (3-4 kgf.cm, 2.6-3.5 lbf.in) difJerencein tapered roller bearingpreload. a In example@, your measuredtaperedroller bearingpreloadwas 2.O N.m (20 kgf'cm, I 8 lbl.in) less than standard so you need a 79.5 mm shim five sizesthickerthsn standard {trv the 1.53 mm (0.0602 inl shim and recheck). a I n e x a m p l e@ y o u r ' s w a s O . 8 N . m ( 8 kgf.cm, 7 lbJ.in)more than standard, so you needa thrust shim two sizesthinner (try the 1.32 mm (0.0520in) shimand recheck). 1 0 . After adjustingthe tapered.oller bearingpreload,assemblethe transmission, and installthetransmission housing{see section 13). 8 x 1 . 2 5m m 27 N.m 12.8 kgt.m. 20 lbf.ttl 1 1 .Rotatethe diJJerential assemblvin both directions to seat the taperedrollerbearings.
15-16
Oil Seal lnstallation 1 . lnstalltheoil seal into the transmissionhousinqusing the specialtools as shown.
DRIVER 07749-OOIOOOO
Installthe new oil sealinto the clutch housingusing the soecialtools as shown.
DRIVER 07749-OOlOO00
OIL SEAL Replace.
OIL SEAL Replace. HOUStl{G
15-17
Differential(AutomaticTransmissionl . . . . . . . .1 5 - 2 0 S p e c i aTl o o l s . . . . . . . . Differential (Automatic Transmission) .15-21 f l f u s t r a t eIdn d e x . . . . . . . . . .... 15-22 BackfashInspection B e a r i n gR e p l a c e m e n.t. . . . . . . . . . . . . . . . . 1 5 - 2 2 DifferentialCarrierReplacement.... 15-23 ........15-24 O i l S e a fR e m o v a l Oil Seal Installation/ 15-24 S i d eC l e a r a n c .e. . . . . . . . . . . .
SpecialTools
Ref. No.
o r^ aa) @
I
Tool Number
Dascription
oTJAD-PH80200 oTNAD-P200100 07746-0030100 07749-0010000 o7947-SD90200
o
Pilot, 26 x 30 mm Driver, 52 x 55 mm Driver,40 mm l.D. Driver OriverAttachment
I Pago Retelonco
15-26 15-26 15-22,24,25 't 5-26 15-26
1 1 1 I 1
o
@
@
15-20
Oty
@
Differential(AutomaticTransmissionl lllustrated Index
FINAL DRIVENGEAR
BALL BEARING
ENTIAL.ARRIER --ttot"'
'
-
6 ROLLER.5xlOmm
BALL BEARING
15-21
Differential(Automatic Transmission) BacklashInspection 1 . Placethe differentialassemblyon V-blocksand install both axles. Check backlashof both pinion gears.
BearingReplacement NOTE: Checkthe bearingsfor wear and roughrotation. lf the bearingsare OK, removalis not necessary. 1.
Removethe ball bearingsusing a bearingpuller.
Standard(New):0.05-O.15 mm (0.002-0.006 inl BEARINGPULLER SIDE GEARS
BALL BEAING
3.
lf backlashis out of tolerance,replacethe differential carrier.
Installthe new ball bearingsusing the specialtool with a Dressas shown.
DRIVER,40 mm l.D. 07746 0030100
15-22
DifferentialCarrierReplacement 1 . Remove the final driven gear from the differential carrier.
5.
Align the hooked end of the snap ring with the pinion shaft as shown, then installthesnap ring in the diff€rential carrior groove.
NOTE: Tho final driven gear bolts have left-hand threads. Hooksd €nd
SI{APRII{G Installin this direction.
Pry the snsp ring ofl differentialcarrier.then remove the speedometerdrive gear 8nd 5 x 1O mm roller.
DRIVE GEAR o.
5.
lnstall th6 5 x 1Omm roller in the differentisl csrrier'
4.
Installthe speedom€terdrive gear with its chamfered side facing the carrier, Align the cutout on the bore of the speedometerdrive gesr with the 5 x 10 mm roll€r.
Install the final driven gear, then tighten the bolts to th6 spscified torque. TOROUE:101 N.m (10.3 kgf.m, 74.5 lbf.ft) NOTE: The final driven gear bolts have left-hand threads.
BOLTS 10 r 1.0 mm lOi N.m (1O.3 kgf.m, 74.5 tbt'ft) Left-hand thrgads
SPEEDOMETEB DRIVEGEAR Instsllin this diroction.
7.
Installthe ball bearings{see page 15-22).
15-23
Differential(Automatic Transmissionl Oil Seal Removal
Oil Seal Installation/SideClearance-
1 . Removethe differentialassembly.
1.
lnstalla2.50 mm (O.O98in)thrustshim in the rransmissionhousing.
2 . Removethe oil sealfrom the transmissionhousino. NOTE: Do not installthe oil seal yet.
TRAt{SMtSStON HOUSING
OIL SEAL Replace. seal from the rorque convener
TRANSMISSIO HOUSING
Installthe differentialassemblyinto the torquecon_ v€ner housingusing the specialtool as shown.
DRIVER,40 mm l.D. 07746-OO30100
DIFFERENTIAL ASSEMBLY
/-l TOROUECONVERTER HOUSING
15-24
TOROUE CONVERTER HOUSING
Assemblethe transmission(see section 14). Installthe transmissionhousingand tighten the bolts (see section 14).
Measurethe clearancebetween the thrust shim and outer race of the ball bearingin the t.ansmission housing.
Tap on the transmissionhousingsideof the differential assembly with the special tool to seat the dilferentialassemblyin the torque converterhousing.
STANDARD:O-0.15 mm {0-O.OO6 in}
lf out of limits, selecta new thrust shim from the following table: THFUSTSHIM, 80 mm Pan Numb€r 90414-689-OOO 90415-689-OOO 90416-689-000 9041 7- 689-000 904r 8-689-OOO 90419-PH8-OOO
Thickness 2.50 mm (O.O9843in) 2.60 mm {0. I 0236 in) 2 . 7 0 m m ( O . 1 0 6 3 0i n ) 2 . 8 Om m ( O .1 1 O 2 4i n ) 2 . 9 0 m m ( 0 . 11 4 1 6 i n ) 3.OOmm{O.11811in)
NOTE: It the thrust shim-to-ballbearingouter race clearancemeasuredin step 5 is lessthan the specification, it is not necessa.yto pertorm steps 7 and 8. Removethe transmissionhousing. 8.
ReDlacethe 2.50 mm (0.098 in) thrust shim with the one oJ the correct thickness selected in step 6.
9.
Installthe transmissionhousing(see section 14).
(cont'd)
15-25
Differential(Automatic Transmissionl Oil Seal Installation/SideClearance (cont'dl 9. Installtheoil sealin the transmissionhousingusing the specialtools as shown.
DRIVER 07749-0010000
ATTACHMENT 07947 -SD90200 PILOT
26x30mm oTJAD-PH80200
10. Installthe oil seal in the torque converterhousing using the specialtools as shown.
DFIVER 07749-0010000
DRIVER,52 x 55 mm oTNAD-P200100
15-26
SpecialTools
R!t. No.
o @ o @ @ @
o
@
I
Tool Numbcr
07JAF- SH20400 07LAD- PW50601 07MAC- 5100200 07746- 0010300 07746- 0010400 07746- 0030400 07749- 0010000 07965- SD90100
D.lcription
Oty
Suppon BsseAttachment Attachment,40 x 50 mm l.O. BallJoint Remover,28 mm Anachment, 42 x 47 mm Attachment,52 x 55 mm Attachment,35 mm l.D. Driver Support Bas€
1 1 1 1 1 1 1 1
I
Psgo Rctcr.nct 1 6 -1 3 16-14 16-4 16-13 16-14 16-'r4 1 6 - 1 31, 4 16-13
(4,
o
16-2
Driveshafts Inspection
Removal
DriveshaftBoot Checkthe boots on the driveshaftfor cracks,damage, leakinggreaseor looseboot bands. l f a n y d a m a g e i s f o u n d , r e p l a c et h e b o o t a n d b o o t Danos.
Loosenthe wheel nuts slightly. Raise the front of car and support it with safety (seesection1), standsin the properlocataons Removethe wheel nuts and front wheels,
Looso Splines Turn the driveshaftby hand and make sure the splines and joint are not excessivelV loose. lf damageis found, replacethe inboardjoint,
Drainthe transmissionoil or fluid (seesection13 or 14). NOTE:lt is not necessary to drainthe differentialoil when the left driveshaftis removed.
Twistod or Cracked Makesurethe driveshaftis not twistedor cracked. Replaceit if necessarv.
R a i s et h e l o c k i n gt a b o n t h e s p i n d l en u t , t h e n removethe nut.
WHEELNUT DBIVESTIAFT
Replace.
6.
Removethe self-lockingnut and self-locking bolt.
EOOTBANDS
GAUTION: Roplacoth€ s€lt.locking bolts if you can sasily thread a non€elf-locking nut prst thoir nylon locking inserts. (lf should require I N.m (0.1 kgt.m, 0.7 lbf.ft) ol torqus to turn lhs nut on the bolt). Removethe damDerfork. BOLT SELF.LOCKING 10 x 1.25mm
NUT SELF-LOCKING 12 x 1.25mm Replace.
(cont'dl
16-3
Driveshafts Removal(cont'dl 8. Removetha cotter pin from the lower arm ball joint castlenut, and removethe nut.
12. Pull the inboardjoint, and removeth6 right driveshaft from the differentialcase as an assemblv.
9. Installa 12 mm hex nut on the ball ioint. Be sure that the hex nut is flush with the ball joint pin end, or the threaded section of the ball ioint pin might be damag6dby the balljoint remover.
CAUTION: . Do not pull on tha dlivo3haft, a! th! inborrd ioint may comc !p!rt, . U3c carc when prying out tha a$qnbly, lnd pull it rtraight to lvoid drmlging thc diftcrrntial oil soal or thc int.rmcdirto shrft outel saal.
10. Use th€ ball joint remover, 28 mm, as shown on page 18-11.to separatethe ball joint and lower arm. CAUTION: Bo crrolul not to damrgo th. ball ioint boot. NOTE: lf necesssry,apply penetratingtype lubricant to loosenthe ball joint.
SCREIYDRIVER
1 1 . Pry the driveshaft assembly with a screwdriver, as
shown, to force the set ring at the driveshaftend past the groove.
-
Left Driveshaft: Removethe left driveshaftfrom the bearing support by tapping the inboard joint of the driveshaftwith I Dlastichammer.
SCREWDRIVER
BEARINGSUPPOFT
16-4
13. Pullthe knuckleoutward,and removethe driveshaft outboard joint from the front wheel hub using I Dlastichammer.
1 . Removethe set ring from the inboardjoint. To removethe boot band, pry up the lockingtabs with a screwdriverand raisethe end of the band, CAUTION: Taks caro not to damagc thc boot.
KNUCKLE
NOTE:Carefullyclamp the driveshaftin a vise with soft iaws.
DRIVESHAFT
SET RING Replace.
-
lf the boot band is the welded type, cut it off as snown,
16-5
Driveshafts Disassembly(cont'd) 3,
Mark each roller and inboard joint to identify the locationsof rollersand groovesin the inboardjoint. Then removethe inboardjoint on the shop towel.
9. Wrap the splineson the driveshaftwith vinyltape to preventdamageto the bootsand dynamicdamper. 10. Removethe boot bandand inboadboot.
NOTE: Be carefulnot to drop the rollerswhen separatingthem from the inboardjoint. INBOARD JOINT Check splines tor w6aror damage. Ch€ckinsideborefor wear. Inspecttor cracks.
CAUTION: Take car. not to damageth€ boot. 1 1 . R e m o v et h e d y n a m i cd a m p e r b a n d a n d d y n a m i c damoer. CAUTION: Tako cars not to damage the dynamic damper. 12. Removethe boot bands and outboard boot, then removethe vinyltape. CAUTION: Take csre nol to damagetho boot. INBOARD BOOT DYNAMICDAMPER Inspectlor cracking, Checktor damage. splitting andwear.
DYNAMICDAMPER
Marka
Mark the rollersand spiderto identifythe locations of rollerson the spider.Then removethe rollers. Removethe circlip. o.
Mark the spider and driveshaftto identifythe position of the spideron the shaft. Removethe spider using a commerciallyavailable bearingremover.
OUTBOARD BOOT lnspectfor cracking, splining andwear. 13. Inspectthe outboardjoint for faulty movementand wear. lf any roughnessor excessplay is felt, replace the outboardjoint.
Removethe stopperring. BEARING
14. Checkthe outboardring for damage.
,'0
STOPPER RING
CIRCLIP
OUTBOARDJOINT ROLI-€RlFor loft ddvcshrfrl
16-6
Reassembly NOTE: panswith solvent, o Cleanthe disassembled anddrythemthroughly with compressed air.Donotwashthe rubberparts with solvent. o *.'.l|@l
: Thoroughlypackthe inboardjoint and both joint bootswith the joint greaseincludedin the new driveshaft ser.
G.ea3o quontity: 120- 130g |'4.2- 4.6 ozl 90 - 100g {3.2- 3.5oz}
lnboardJoint OutboardJoint
SETRING Replace.
RIGHTINBOARDJOINT
ROLI.TR {For lcft
w
b ,RDJOINT
INAOARDBOOT
---"-G1
Packcavity with gr€ase.
-Gl DYNAMICDAMPER
Pack cavity wrth grease.
EOOTBANDS Replace.
(cont'd)
16-7
Driveshafts Reassembly(cont'dl 1.
Wrap the splineswith vinyl tape to preventdamage to the bootsand dynamicdamper.
2.
I n s t a l lt h e o u t b o a r d b o o t , d y n a m i c d a m p e r a n d i n b o a r db o o t t o t h e d r i v e s h a f tt,h e n r e m o v et h e vinyl tape.
6.
Packthe outboardjoint with the joint greaseincluded in the new driveshaftset, Greasequantity: 90 - 100 g (3.2- 3.5 oz)
CAUTION: Take care not to damage the boots and dynamicdamp€r.
,.% VINYLT
OUTBOARDBOOT
DYNAMICDAMPER
7. INBOARD BOOT
Installthestopperring into the driveshaftgroove. NOTE:Always rotatethe stopperring in its groove to be sure it is fully seated.
Fit the rollersto the spiderwith their high shoulders facingoutward. NOTE: . Reinstallthe rollersin their originalpositionson the spiderby aligningthe marks. . H o l d t h e d r i v e s h a f tp o i n t e du p t o p r e v e n tt h e rollersfrom fallingoff.
Installthe spider on the driveshaftby aligningrhe markson the spiderand end of the driveshaft.
-r
+ {l-
Fit the circlipinto the driveshaftgroove. NOTE:Always rotatethe circlip in its grooveto be sure it is fully seated. CIRCLIP SPIDER
STOPPER RING
16-8
SPIDER ROLLER
ROLLER {For left driv8hattl
8.
Packthe inboardjoint with the ioint greaseincluded in the new driveshaftset. Greasequantity; 120- 130 g 11.2- 4.6 ozl
1 0 .Adjust the length of the driveshaftsto the figure below. then adjust the boots to halfway between full compressionand full extension. NOTE:The ends of boots seat in the groove of the driveshaftand joint.
Left:475- 480mm {18.7- 18.9inl
Right: 475 - 480 mm (18.7- 18.9inl
9.
Fitthe inboardjoint onto the driveshaft. NOTE; . Reinstallthe inboardjoint onto the driveshaftby aligningthe marks on the inboardioint and the rollers. . Holdthe driveshaftso the inboardjoint pointsup to preventit from fallingoff. Left drivoshaft: Align the holder directionof the rollers toward the slot ot inboard joint as
1 1 . lnstallnew boot bandson the boots,and bend both
setsof lockingtabs. Lightlyrap on the doubled-overportionsto reduce their height.
\ /,.-:--\\\ di,ection sotine I INBOARD JOINT
A\ {(@} HOLDER
{cont'd)
16-9
Driveshafts (cont'dl Reassembly t5.
Positionthe dynamicdamperas shown below. . Installa new dynamic damper band. and bend down both sets of locking tabs. Lightly tap on the doubl€d-overponion of the bandto reduceits height,
Installation 1.
Installthe outboardjoint into the knuckle.
KNUCIGE
Loft/Right 29 r 2 mm (1.1r 0.1 inl DAMPER DYNAMIC
DYNAMICDAMPERBANO
OUTBOARD JOINT
Apply 1.0- 1.5s (0.04- 0.05oz) of specifiedgroase to the whole splined surtace of the intermediats shaft. NOTE: After applying grease,remove the grsase f.om the splinedgroovesat intervalsof 2 - 3 sDlines and from the set ring grooveso air can bleedfrom the inboardjoint. Installthe new set ring onto the driveshaftor intermediateshaftgroove. CAUTION: Always uso a now sot ring whcncycr tho driveshaft is boing in3tallod.
RING
b SET RINGGROOVE
16-10
Insertthe inboardend of the driveshaftinto the diff e r e n t i a lo r i n t e r m e d i a t es h a f t u n t i l t h e s e t r i n g locksin the groove.
1 . Installthe knuckleon the lower arm, then tighten the castlenut and installa new cotterpin. NOTE: Wipe off the grease before tightening the nut at the ball joint.
INBOARD JOINT
CAUTION: . B€ careful not to damago tho ball ioint boot. . Torqu€ tho castle nut to ths lower torquo 3paci. fication, then tighlon it only tar snough to slign the slot with th€ pin hole. Do not align tho nut by loossning, INAOARDJOINT
GROOVE
OIFFERENTIAL 5.
Installthe damperfork over the driveshaftand onto t h e l o w e r a r m . I n s t a l lt h e d a m p e r i n t h e d a m p e r fork so the aligning tab is alignedwith the slot in the damperfork.
CASTLENUT 12 x 1.25rnm
a9- 59N.m15.0- 6.0kgt.m,36- a:tlbtftl
8. Installa new spindlenut,then tightenthe nut, 9. Installthe front wheelwith the wheel nuts. NOTE: Beforeinstallingthe wheel,cleanthe mating surfacesof the brakediscand the wheel.
L o o s e l yi n s t a l lt h e s e l f - l o c k i n gb o l t a n d t h e n e w self-lockingnut.
FRONTWHEEL
NOTE:The bolts and nut should be tightenedwith the vehicle'sweight on the damper.
SELF.LOCKING BOLT 10 x 1.25mm a:' N.m lir,4 kgt m, 32 lbf.ftt
COT1ERPIf{ On reassembly, bend the cotter pin as shown.
WHEELNUT 12 x 1.5 mm 108N.m (11.0kgf.m,80lbtft,
ALIGNINGTAB
NUT 22 x 1.5mm
kgl'm,134lbt'ftl 181N m 118.5 NOTE:Altortightening,usea driftto nutshoulder stakethesPindle againstthe driveshaft 1 0 . Tightenrhe self-lockingbolt and the new self-locking nut with the vehicle'sweight on the damper. 1 SELF.LOCKING NUT 12x 1.25mm 64 N.m (6.5 kgt m, 47 lbf.ftl
'I.
Refill the transmissionwith recommendedoil or fluid (seesection13 or 14).
12. Checkthe front wheel alignmentand adjust if necessary{seepage 18-4).
1 6 - 11
Intermediateshaft Removal
2.
Disassembly
Drsinthe transmissionoil or fluid (seesection13 or 14).
NOTE:Be carefulnot to damagethe metal rings on the intermediate shaftduringdisassembly.
Removethe left driveshaft(see page 16-3).
1.
Removethe set ring,
Removethe three dow€l bolts.
2.
Removethe intermediateshaft outer seal from the bearingsupport.
3.
Removethe eldernalcirclip.
Removethe intermediateshaft f.om the differential. CAUTION; Hold the intormediato shaft horizontrl until it b clear of the dittorential to prevent damago to thr dittarontial oil so!|.
16-12
OUTEBSEAL Replsce.
t SETRING Replace.
1.
Pressth6 intermBdiateshaft out of the shaft bearing using the specialtools and a press as shown.
5.
Removethe internalcircliD.
Pmar INTEBNALCIRCLIP
I
Pressthe intermediateshaft bearing out of th€ boaring support using ths spscialtools and a prsss as snown. Praa!
BASE SUPPORT ATTACHMENT 07JAF- SH2oalXt
FLOANNGRUBB€R DA'iIPER Checkfor det€rioration and dama9e.
ATTACHMENT, 1i2xa7fim 07ta6 - 00ro:!00 SUPPORTBASE ATTACHMENT - SHZ!(|O
BEARINGSUPFORTRING Chscktor damagg or distonion.
BASE 07965- Sll9or00 SUPPORTBASE 07965 - SDg,|q'
INIERiIEDIAIE SHAFT Checkfor damage. BEARINGSUPPORT Checkfor damage.
NOTE: . Cleanthe disassembledparts with solvent,and dry them thoroughlywith compressedair. Do not wash the rubber parts with solvent. . Be car€ful not to damagethe metal rings on the intermedists shaft during reass€mbly
DOvvELBOLTS 10r 1.25ftm :tlt N.m {a.Otgt m, 29 lbfftl EXTENTALCIRCUP
ob.
Packthe intorior of the outer saal. 2.0- 3.5 g {0.07- 0.12oz}
SETRING Replace. INTERMEOIATESHAFT BEABING Reolaco. BEARING
v ourER SEAL Rspbce.
{conr'd)
IntermediateShaft (cont'dl Reassembly '1. Press the intermediateshaft bearinginto the bearing support using the specialtools and a press as shown.
Seatthe externalcirclip in the groove of the intermediate shaft. NOTE:Installthecirclipwith the taperedend facing our. Installthe outer seal into the bearingsupportusing the specialtools as shown. NOTE: Installthe seal flush with the bearingsupport.
ATTACHMENT, 52x55mm 07716- 001o/UX)
DRIVER 07749- 00t(xD0 Packthe interior ol the olter seal. 2.0 - 3.5 g 10,07- 0.12 o2l
Seatthe internalcirclipin the grooveof the bearing suoDon.
OUTERSEAL
CAUTION: Install the circlip with the tapersd end facing out. Pressthe intermediateshaft into the shaft bearinq usingthe specialtoolsand a press.
ATTACHMENT, aOx 5{)mm l.D. 07LAD - PW50601
Pross
I
lnstall the new set ring in the intermediateshaft groove.
16 -1 4
lnstallation lnsert tha intermediate shaft assembly into the differential. CAUTION: Hold th€ inlorm.diltc ahrft horizontsl to prryonl dsmrge to thc difflrontill oil taal.
INTERMEDIATESHAFT
2.
Installthe threedowel bolts,then tightenthem.
DOWELBOLTS 10x 1.25mm 39 N.m {a.Orgl.m, 29 lbl.ft}
INIERMEDIATESHAFT
16-15
Steering ............. 17-2 SpecialTools Component Location lndex ................ ......17-3 System Description Ffuid Flow Diagram ......................... 17-1 17-5 SteeringPump ................................. 17-7 SteeringGearbox............................. Troubleshooting 17-10 GeneralTroubleshooting................ 17-14 Noiseand Vibration......................... ............. 17-16 FluidLeaks Inspection and Adiustment 17-14 SteoringOperation .......................... Power Assist Check with CarParked........................... 17-18 SteeringLinkageand Gearbox.......17-19 .............. 17-20 Pump Beh .....17-21 RackGuideAdjustment ............. ...................... .....17-21 Ffuid Replacement .... 17-22 Pump PressureCheck.................. 17-23 FfuidLeakagelnspection ................ +Steering Wheel Removal ..,,,,,,,........ 17-24 ............... 17-25 Disassembly/Reassembly 17-26 fnstallation ,......,,,,,.
* SteeringColumn Removaf .................17-28 Inspection .............. 17-30 ............. 17-31 Installation Power Steering Hoses.Pipes .........17-3tl Replacemont Power SteeringPump Removal ................. 17-35 Disassembly ..........17-35 Reassembly ........... 17-'10 lnstallation ........,..., l7-tltl Steering Gearbox .,.,............. 17-45 Removaf ..........17-/E Disassembly ........... 17-53 Reassembly ............. 17-63 lnstallation Ball Joint Boot Replacement..........17-65
SUPPLEMENTALRESTRAINTSYSTEM{SRSI The IntegraSRS includesa driver's airbag.locatedin the steeringwheel hub, In addition,all modelsexcept the RS modelfor Canadahave a front passenger'sairbaglocatedin the dashboardabovethe glove box. Information necessarvto safelyservicethe SRS is includedin this ServiceManual.ltems markedwith an asterisk{') on the or replacingthese items contents page include,or are locatednear, SRS components.Servicing.disassembling Acura dealer. done by an authorized precautions should therefore be and tools, and will requirespecial a To avoid rsndering ths SRS inoporative, which could load to po.sonal iniury 01 d€ath in th€ event ot a ssvare lrontal collision, all SRS service work muat be performod by an authorizod Acura deal6t. a lmploper service procodules. including incorloct romoval and installation of the SRS,could lead to personaliniury caused by unintontional activation ot the airbags. a All SRS elsctdcal wiring harnessesara covorod with ysllow insulation. Rolalod compon€nts 8re locatsd in tho stse ng column, tront console, dashboard, and dashboard lower panel, and in the dashboard above the glove box. Do not use oloctrical tost equipmoni on thosa cilcuits. NOTE: The originalradiohas a codedthett protectioncircuit. Be sure to get the customer'scode numberbefore - disconnectingthe battery. - removingthe No. 32 (7.5 A) tuse from the under-hoodfuse/relaybox. - removingthe radio. "CODE" is displayed'enter the cusAlter service,reconnectpower to the radioand turn it on. When the word tomer's 5-digit code to restoreradio operation.
Rcf. No.
I
Tool Numb€l
o
07GAF- PH70100 07GAF- SD40700 07GAG- SD40100 07GAG- SD40200 07GAG- SD40400 07JGG- 0010104 07MAC- 5100200 07MAG - 5100100 07NAD- SR30200 07NAG- SR30900 OTNAK- SR3O11A OTNAK- SR3O12A 07406- 0010001 07406- 0010300 07405- 0010400 07725- 0030000 07746- 0010100 07746- 0010200 007i$ - 0010000 07916- SA50001 07947- 6340500 07974- 6890801 0797,1- SA50200
@ @ (t @ @
o
@ @ @ @ @ @ @.r @-2 @ @ @
@ @ @ @ @
I
e
t
F--,'---l
o
@
o
Y
@@
17-2
1 'I 1 1 1 1
17-50 17-5{ 17-22 1 7- 2 2 't1-22 17-22
1 1 'l 1 I 1 1 1 1
17-35,53 17-55,56 17-1'l t7-55 17-2'l 17-11 17-57,58 17-55
@
6 w @,2
v ^dN
@: @
17-20 't7-15
1 1
@
@-r
@
17-EO
I
@
lx:__E
1 1 1 1
a
@ 16)
17-39 17-57 17-57
I
\v
,h z6)
'17-52
1
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@
P!9. Relrrrncc
U
@
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O'ty
PilotCollar Hub DivAssembly Base PistonSealRingGuide PistonSealRingSizingTool Cylinde.End Sealcuide BeltTensionGauge BallJoint Remover,28 mm BallJoint BootClip Guide Cylinder End Seal RemoverAttachment ValveSsalRingSizingTool P/SJoint Adapter(Pump) P/SJoint Adapter (Hos6) P/S PressureGsuge PressureControl Valve PressureGauge UniversalHolder Attachment,32 x 35 mm Attachment,37 x 40 mm Driver LocknutWrench, i[0 mm Driver Anachment CylinderEnd SealSlider SleeveSesl RingSizingTool
q
re
aL2
Dcscription
@
@
@
ComponentLocation lndex Powar Siooring: NOTE: It an intact airbag ass€mbly has been r€moved from a scrappedcar or has been found defective or damaged during transit. storage or service,it should be doploy€d (seesection 23). a Before removing tho gearbox, remove ths ignition key to keep the steering shaft Jrom turning. a After installingthe gearbox,checkths whe€l alignmentand adiustif necessary. CAUTION: . All SRS aloctricll wiring h!m!|$a rrc covcred with yrllow in3uhtion. . 8€for€ disconnocling lny ptrt ol thc SRS wiro h!r' ne*r, connect thc lhort conncctor{3l. . Rcplsce lhc ontira ttfact d SRS harnccc a$embly il it hs3 !n oprn circuh 01 dtm!9.d wiring.
SIEERING COLUiIN Removal,page 17-28 Inspection,pago 17-30 Installation,p6ge 17-31 rcNMON SwlTCH See s6ction23 STEERII{GGEARBOX RackGuide Adjustment,pag.11-21 Removal,pags 17-45 Diossombly,page 17-{8 Bea65€mbly,page 17-53 Installation,page 17-63
POWENSTEERINGPUMP Pump Beft Inspoction.page 17-2O Pump EeftAdjustm6nl, pago 17-2O Pump PressurgCh€ck,page 17-22 Removai,p6go 17-35 Disassembly,p3gs 17-35 Reassombly,psge l7-40 lnstallation,page 17-44
STEERINGWHEEL Removal.page 17-24 page 17-25 Oisassembly/Reassembly, page17-26 Installation,
TIE'RODEND BALLJOINT Ball Joint Eoot Replacement,page 17-63
17-3
System Description FluidFlow Diagram The system is a compact rotary-valvs-typepower stssring, connoctedto the st€oring gearbox. Th6 fluid pressureis provided by a vane-type pump which is driven by the engine crank pulley. The amount of fluid and pressurs is regulsted by the flow control valve built into ths pump, The fluid prssaursfrom th6 pump is dolivsred to tho valve unit sround the pinion of the steering g€arbox. The vslv€ inside the valvs unit controls the hydraulic prossur€End changosthe direction ot the flow. The fluid then flows to the power cylinder, where rack thrust is gen6rat6d.Fluid returning from th6 powsr cylinder flows backto the .eservoir,where the fluid is 'filtered" and supplied to the pump Egain.
17-4
Construetion The pump is a vane-typeincorporatinga flow controlvalve(with an integratedreliefvalve)and is driven by a V-beltfrom the crank pulley. The pump features 10 vanes, Each vane performs two intake/dischsrgeoperations for every rotation of the rotor.This meansthat the hydraulicfluid pressurepulsebecomesextremelysmallduringdischarge.
INLETPORT
CAM RING
VALVE FLOWCONTBOL
I
DRIVESHAF' VANE
Operation The belt-drivenpulley rotatesthe rotor through the drive shaft,As the rotor rotates,the hydraulicpressureis appliedto of the cam .ing. the vanechamberof the rotor and the vaneswitl rotatewhile beingpushedonto the innercircumference so the rollers portion of the shaft. respect to the center with ring has an extonded of cam inner circumference the The move downwardin the axialdirectionas the carrierrotates.As a resultof this rollermovemsnt,the internalvolumeof the vane chamberwill change,resultingin fluid intakeand discharge.
STARTOF FLUIDINTAKE:
FLUIDINTAKE:
FLUIDMOVEMENT:
FLUIDDISCHABGE: DISCHARGE P('BT
The vanes are pushed onto the inner circumferenceof th6 cam ring.
Th6 volumsotth€ van€chamber increasosso that lluid is suckodin.
T h 6 s u c k e d - i nf l u i d m o v e s towsrd the discha196pon.
As the vanes returnto th€ their original positionon the inner side,the volume of the vane chamber decreasesso the fiuid is discharg6dfrom the dischargeport.
(cont'd)
System Description SteeringPump(cont'dl Flow Control The flow controlvalve in the pump performsthe following steps@ throughO to controlthe flow of fluid, i.e.to increasethe dischargevolum€ wh6n engine speed is low and to decreaseit when the enginespeedincreases. The assistance thrust of the steeringgearboxchangesin compliancewith the changein the dischargevolume.
FLOWCURVE
. J5
I
l o
tr o=
PUMPR.P,M.
o
When the engine starts,fluid dischargedfrom the dischargeport starts to run through the metering orificein the pump.The dischargevolume increas€s as the enginespeedincreases,
@ A s t h e f l o w h a s a l r e a d y b e e n r e g u l a t e db y t h e meteringorificewhen the enginespeedis at or near the idle speed,a constantand regulatedamount ot fluid is dischargeduntil the engine speed reaches t h e m i d d l e s p e e d r a n g e .A s t h e e n g i n es p e e d increases, the pressuredifferencebetweenthe ends of the meteringorificeincreases.A pressuredifference is createdbetweenthe top and bottom ends of the flow controlvalve,too, pushingthe flow control valveto open the by-passpassage.This allowsthe excessfluid to return to the inlet pon preventing pressureat the dischargeport trom rising excessively.
@ As the enginespeedcontinuesto increase,the tlow c o n t r o l v a l v e i s p u s h e d b a c k f u r t h e r .W h e n t h e enginespeedreachesa given speed.the returnpassage outside the metering orifice is connectedto t h e i n l e t p o r t , a n d t h e o p e n i n gt o t h e i n l e t p o r t w i d e n s i n p r o p o r t i o nt o t h e i n c r e a s ei n e n g i n e speed.This makespan of the fluid regulatedby the meteringorificereturnto the inlet pon of the pump; t h e r e b y d i s c h a r g e df l u i d f r o m t h e p u m p i s decreasedslowly by this amount.
@ T h e o r i f i c e i n t h e r e t u r n p a s s a g er e g u l a t e sa n d m a i n t a i n st h e f l o w o f f l u i d d i s c h a r g e df r o m t h e pump at a given level until the enginespeedreaches the high speedrange.
17 -6
VALVE
PressureRelief Pressu.6outside of the metering orifice is directedto the bonom ot the flow control valve. When the pressure buildsup, the relietvalvein the flow controlvalveopens to relieve the pressure.As the flow control valve is pushed back by the pressuredifferencethis time, the convolling flow of fluid in the bypasspasssgeincreases, the pressureoutside the metering orifice. The above operationsare repeatedto provide constantdischarge prsssurelrom the pump, VALVE
{Dacrarlai cxco33iva Yibrationin iha valva.l
(cont'dl
17-7
SystemDescription SteeringGearbox The rack-and-pinion type steeringgearboxhas a valve unit incorporatedwith the pinionto controlthe steeringfluid pressure.Steeringfluid from the pump is regulatedby a rotaryvalve in the valve unit and is sentthroughthe cylinderpipe to the power cylinder,where hydraulicpressureis applied.The steeringfluid in the other side of the power cylinderreturns throughthe cylinderpipe and valveunitto the reservoir.
VALVEUNIT CYLINDERPIPE
POWEBCYLINDER
Valve Unit Insidethe valve unit is the valve,which is coaxialwith the pinionshaft,and controlsthe steeringfluid pressure.The valve housingis connectedwith the fluid pipe from the pump, return pipe to the pump, and the two cylinderpipesfrom the respectivepowercylinder. The pinionshaft is double- structuredwith the input shaftconnectedto the piniongear,both of which are interconnected with the torsionbar. The pin insenedin the valve and the pinion shaft grooveengage;this allowsthe pinion shaft to rotatetogetherwith the directionbetweenthe input shaftand the valve Becauseof this construction, the differencein angle in the circumferential becomeslarger accordingto the torsional strength of the pinion or steering resistance.However,maximum torsion betweenthe shaftsis regulatedby the engagedsplinesof the shaftsat the pin engagementsectionto hold the torsion bar within the set value. type steeringif the steeringfluid is not pressurThis allowsthe steeringsystemto lunctionas an ordinaryrack-and-pinion izedbecauseof a faulty pump.
VALVE Difforcnco in .ngl. bo{w€cn tha input shalt rnd pinion !h.tt
ln -1 INPUTSHAFT B lEngag€with the pinion shaft groove)
1 7 -8
PressureControl Low assistat higherspeeds: When steeringresistanceis low. such as when driving at high speeds.or when driving straightahead,the input shaft is near or in the neutralposition,so there is little or no flow to any of the power cylinderorifices,Most of the feed pressure trom the pump is bypassedto the reservoir.Becauseof this, the pressurestaysthe same in both sidesof the power cylinder, resultingin low or no assist.
RESERVOIR
vALVE
az =- S \->/ -\7/
F.om PUMP RETURNPASSAGE (To RESERVOIRI
VALVE UNIT A
INPUTSHAFT
Highassistat lower speeds: When steeringresistanceis high, suchas when drivingat low speed,or when turningthe wheelwith the car stopped,the differencein anglecreatedbetweenthe input shaftand the valveopensthe fluid passageon one side,and closesthe fluid passageon the other side,at each pair of orifices.The fluid pressureincreasesin the side of the powercylinderfed by the largerfluid passage.This increasedpressurepusheson the rackpiston,allowingthe steeringwheelto be turnedwith light effon. On the other side of the power cylinder,the returnpassageopensallowingthe steeringfluid to returnthroughthe input shaftto the reservoir.The fluid passagesto the power cylinderautomaticallychangein size,increasingas the steerIn other words,the passagesbecomelargerand power assistincreaseswhen the steeringeffort ing resistanceincreases. would normallybe high, (for example.when parkingor makinglow speedturns).and the passagesbecomesmallerand power assistdecreaseswhen the steeringeffort would normallybe low, (for example,when driving at high speedsor straightah€ad).
/t-:\ v" =iJ
FLUIOPASSAGETO POWERCYLINDER
From PUMP RETURN PASSAGE FLUIDPASSAGEFROM POWERCYLINDER
17-9
Troubleshooting GeneralTroubleshooting Checkthe followingbetoreyou begin: . Hasthe susp€nsionbeenmodifiedin a way that would affectsteering? . Are tire sizesand air pressurecorrect? . ls the steeringwhe€loriginalsquipmentor equivalent? . ls the power steering pump belt properly adiusted? o ls steering fluid reservoirfilled to proper level? o ls the engineidle speedcorrectand steady?
Checkpump fluid pressurg(soe page 17-221, Measure steady-statefluid pressure while idling with the shut-off valve fully open. I r s h o u t db e 1 , 5 0 0k P a ( 1 5 k g t cm' , 213psi)or bolow.
r Fluid pro$ure is too low: Chockth€ rgturn circuit pipe and hose between tho gearbox and pump tor clogging and dotormation. * Fluid pressureis too hioh: Checkthe pipe and hosg connectedfrom th6 pump to tho georboxtor clogging and delormation.
Normal
Checkpump fluid pr€ssur€{se€ page 17-221. M e a s u r ep u m p r e l i e f p r e s s u r e while idling with the shut-off valvefullyclosod. h should be 6,400- 7,400kPa {65 - 75 kgtcm,, 924- 1,067psi)
Normal reliel pressure
II Gotopatetu.lt
17-10
Checkthe flow control valve. * Checklhe valve for smooth movement in thg hou6Ing. * Chockthg reli€f valve for leaks.
Abnormal
II Faultyflowtontroi valve
Ch6ck force r6quired to turn tho wheel(seepage17-18). S t 6 t h e e n g i n ea n d m 6 a s u r e force required to turn the whgel to the right and left. Dilferenceol t h e l o . c e r e q u i r e dt o t u r n t h e who€l to the right and to the lett should be 5 N (0.5 kgf, 1 lbf) or below.
Normal
Ch6ckpump fluid pressure(see page 17-221. Turn the steeringwheel lully to the right and left whil€ idling with the shut-off valvo fully op6n, and measuretho fluid pressu.e.lt should be 6,400- 7,400kPa (65 75 kg?cm,,924- 1,067psil.
Abnormal -----|.
Faultygearbox
Abnormal
Chsck the other parts than the gearbox-ralatedpsrts for propor rotstion, * lmpropor rotation ofthe steeringcolumn-rolat€dpan(sl 'Faulty st6€ringjoint a Faultyrack end^ie-rodend balljoints 'Intederence in the steeringsystem
Normal
Chockthe gearbox. Removethe goarbox and measurethe piniontorque. The torqueshouldbe; * 0.7- 1.2N.m (7 - 12 kgf.cm,6 '10lbt in) with the steering rack in the straightdrivingposition.
|r
Normal
Adjust the rack guide (see page 11-211. Adiust the rackguide and recheck the pinion torque.
lmproperly adjustedrackguide
(cont'dl
17-11
Troubleshooting GeneralTroubleshooting{cont'd} Assist (excessivelylight steering)at high speed.
Check the rack guido proper ad' justment (seepago 17-21).
Shockor vibration when wheel is turned to tull lock.
Checkthe rack guide tor proper adjustment(ses psge 17-21).
ll the problem is not correctedby adjustingth6 rack g!ide. adjust the front wheel alignment (see section 18).
Rackguide is adjustedprop€rly.
Ch6ckthe belt tor slip and adjust as nocessary(see page 17-20).
lf th€ problem is not correct€dby adiusting the rack guide, roplace the gesrbox.
lf oither one or both of the cylinder pip€ A and B is/aredeformed, rsplace,
Wheelwillnot returnsmoolhly.
lf the cylinderpip6 A and B are normal, remove the gearbox from th€ f.ame and mossure the pinion torqug on the gearbox.
It shouldbe 0.7- 1.2N.m {7 - 12 k g f . c m ,6 - 1 0 l b f . i n )o r b e l o w with the sleering rack in the straight aheaddriving position.
lf lhe measurem€ntsare out of specilications.adjust the rack guid6.
ll ihe problem is not correctedby adjusting the rack guide, replace ihe gearbox.
17 -1 2
Unovonor rcugh 8te6ring.
Adjustrackguide(se€poge 17-21).
ll the probl6m is not correctedbY adjusting lhe rack guide. replaco the gearbox.
Adiud bolt t€nsion.Roplaceb€lt, if n€c€ssary{s€e page 17-20).
ldl6 soosd low or orrrtic.
lf the ongin€ stallswhen wheel is turned whil€ car is stoDPedor moving at low spoed,adjust idle sp€€d (soesection 11).
Air in rssorvoir. or ch€ck pow6a steoringfluid l6v6l.
Chockpower sieeringIluid levol.It lgv6l ie excessivoly low, ch€ck for leaks in the system. Add fluid to tho spocifiod level.
lf fluid lev6l is OK, check o-rings and seals on both €nds of iho pump inlet hose, and th€ oil pump housing mating surfacos for suction leaks. Reolace oarts 65 n€CeSSAry.
Pump b6lt slippingon pull6y (pump stops momontarily).
Adjust belt tonsion (see page 17m) or r€Dlacobeh.
Sel the power itooring p.oasure gaug6. Cl066th€ shut-off v6lv6 f u l l y a n d m € a 5 u r ot h o p u m p pr6ssur6(6s€pagg 17-221,
Checkif pump prossureis within the ranoe6.400- 7,100kPa(65- 75 kgr/cm,, 924 - 1,067psil and th6 gsuge needls travol is 1500 kPa {15 kgflctn2,t71 p6i) or less. Checkthe flow control valve if the needle tr.vel €xcoods 1500 kPa {15 kg?cm,,i71 psi).lf rhe flow control valvo is normal, replaceth€ pump as an assomblv.
7-13
Troubleshooting Noiseand Vibration NOTE:Pump noisein first 2 - 3 minutesafterstartingin cold weather(-20.C,-4"F or colder)is normal.
Humming
Humming due to pulsation ol fluid is no.mal, paniculady when wheel is turned with ca. stopped.
lf equippedwith automatictransmission,the hum could b€ torque conveneror pump notse.
Confirm by temporarily removing pump b€lt.
High pressureline touching the frame,
Reposhiontho line.
Right cylinder end soal squeak
Rattleor chattering
Loose steeringshaft connector. tie-rod,or balljoint.
C h e c ka n d t i g h t e n , o r r e p l a c e pa s as necessary.
Column shaft wobbling.
Replacecolumnassembly.
Checkthe rack guide for proper adjustment(16opage17-21).
Adjust, if n€ca€ssry.
Rattlingsound and feeling when turning the steoringwheel right and lett with tho engine OFFis a sound when th6 valve unit contactstho stopper.This is normal.
Striking sound wh6n turning the ste€ringwhoglfully right o. left is a sound when the r6ckend contactsth6 stopper.This is normal.
Pump noise. though not loud,lrom the vslvo bodv unit can be heard when turning the steeringwheel right or left. This is normsl.
17-14
Checkfluid level. l f l o w . f i l l r e s e r v o i rt o p r o p e r level,and checktor l€aks. Tighten or roplac6as n€cessary.
Gratingnoisefrom pump
Checkfor crushedsuction hose or a loose hose clamp allowing air into the system. Tighten or replaceas noce$ary.
Pumpgearnoise
NOTE: Pump noise up to 2 - 3 m i n u t e sa l t e r s t a r t i n gi n c o l d weather (-20'C, -4'F or colder) is normat, Comparopump noise at operatin9 temperatureto anothercar.
lf pump noiseis abnormallyloud, chgckthe pump ball b€aringand any pans (seepage 17-351.
1 7 -1 5
Troubleshooting Fluid Leaks Checkthe gearboxassemblyfor oil leakscarefully.Oil can leak out of various points.dependingon locationof the faultyoil seals/seal rings.Checkthe followingbeforeremovingthe gearboxfrom the frame.
SteeringGearbox
Leakingfrom the oil seal on the top of the valvehousing.
Roplacethe valve oil seal from the valvehousing.
Leakingfrom cylinder end into left tie'rod boot.
Replacethe valve oil seal lrom the pinion shaft.
R e o l a c et h e c v l i n d e r e n d s e a l .
Leakingfrom cylinder end into right tie rod boot.
17-16
Leaking from the vslve body uniVhousingmounting soction.
Tighten attachingbolts or replace the valvebody unit or gearhousIng.
Leakingfrom cylind6rpipeA or B connection(attlarenut).
Tightenconnector.It still leaking. r e p l a c et h e p i p e , c y l i n d e r o r valvehousingunil.
Leakingcausedby damagedcylinderpipeA or B.
R e p l a c et h e c y l i n d e r p i p e A o r B .
L e a k i n gf r o m f e e d p i p 6 a n d returnpipe of the valvebody unit (atflarenut).
Tightenconnector.lI still leaking, replacethe pipe or valve hous In9,
ReplacehousingO-rings. lI the housingstill leaks,replace the pump.
Reservoiroverfilled. Pullotfthe hoseand drainto pro' per tevet.
Air leakin suctionside of system lreservoitinlet hose,front pump seal),
Pump outlet line (highpressure)
Low pressurehoses
Leaking b€causeol dsmage, de' terioration,or improp€r assem-
Replaceor repairas necessary.
Leakingat g6srboxconnection. {atflarenut}.
Tightenconnector.lf still leaking, replacethe pipe or v€lve hous' Ing,
17-17
Inspectionand Adjustment SteeringOperation Placethe front wheelsin the straightahesdpositionand measurethe distSncethe steeringwheel can be turned without moving the front wheels.
PowerAssist Gheckwith GarParked 1.
Checkthe power steeringfluid level (see page 1721) and pump belttensionlsee page l7-20).
2.
Startthe engine,allow it to idle, and turn the steering wheel from lock-to-locksev€raltimes to warm uo the fluid.
ROTATIONALPLAY:0 - 10 mm l0 - o.:Xlinl lf the plsy excsedsthe service limit, psrform rack guide adjustment (see page 17-211. lf the play is still excessiveafter rackguide adjustment, inspectthe stsering linksgoand gearbox as described on the next page.
Attacha springscaleto the steeringwheel.With the engine idling and the car on a clean,dry floor, pull the scaleas shown and read it as soon 8s the tires beginto turn,
ROTANONAL PLAY
il.
1 7 -18
The scal6should read no more than 33 N (3.4 kgf, 7.5 lbf). lf it reads more or less, ch€ck the gearbox and pump.
SteeringLinkageand Gearbox
STEERINGCOLUMN lnsoecttor loosecolumn mountingboltsand nuts.
BOOT Inspect f6r damage anddeterior6tion.
STEERINGJOINTS Checktor loosejoint bolts.
PINIONSHAFTGROMMET Inspectlor damage and deterioration.
STEERING Inspectlor loose mounting bolts. GEARBOXMOUNTINGCUSHIONS Inspectfor deterioration.
TIE.RODLOCKNUT Checkfor looselocknut.
BALLJOINT BOOT Inspecttor damageand deterioration. Seepsge 17-63for replacement.
17-19
Inspectionand Adjustment PumpBelt NOTE: When using a new b€li, first adiust the deflection or t€naion to the values for the new belt, thsn readiust ths deflection or tension to the values tor the used b€lt after running sngine for five minutss.
Adiu3tmant 1,
Loosenthe power stesring pump mounting bolts.
2.
Turn ths adiusting bolt to gst the propor bolt tension, then rstighten the bolts.
3,
Start ths €ngine and turn the steering wheel trom lock-tolock s€veraltimes, then stop the engino and recheckths deflection of the belt.
lnspoction Attach th€ belt tonsion gauge to th6 belt and measure ths tension of the bslt. Tanaion: U3.d Brft: 391,- 5/O N (lO - 55 kgf, 88 - r20 |bf) Ncw Bch: 7aO- 89, N (75 - 90 kgt, 170 - 20OlbO
AD'USN G BOLT
NOTE: . lf thsre are cracksor any damage evident on the belt, raplacait with a now ono. . Follow the manufacturer'sinsructions for the tonsion g8uge.
PUII"EY 07JGG- 00r0r0a Inspectthe pump belt for cracksor any damage. Replacethe belt with a new one if nec€ssary. Mc!3uramrnl without Bch Tcntion Grugr: Apply a torce of 98 N (10 kgl, 22 lbll and measure ths deflectionbetweentho power ste€rin9 pump and tho crankshaftpulleys. Daffaction: U:ed Bch: 11.5- 13.5mm (0.,t5-0.53 inl Nlw Brh: 8.0 - 10.0mm (0.31- 0.39 inl
here,
17-20
NOTE:Performrack guide adjustmentwith the wheels in the straightaheadposition.
Checkthe reservoirat regularintervals.and add fluid as necessary.
1 . Loosenthe rack guide screw locknutwith the specialtool,then loosenthe rackguidescrew.
GAUTION: Use only Genuine Honda Power Stosring Fluid-V. Using othsr fluids such as ATF or other manufacturer's power stoering fluid will damags ths systcm,
the Tightenthe rackguide screwuntil it compresses springand seatsagainstthe .ackguide,then loosen it. R e t i g h t e nt h e r a c k g u i d e s c r e w t o 3 . 9 N . m { 0 . 4 kgf'm, 2.9 lbf.ft),then back it off to specifiedangle.
SYSTEMCAPACITY: LO6 litor (1.12US. qt, 0.93lmp.qtl
at disasssmbly RESERVOIR CAPACITY: 0.79lit6r (0.8:lUS.qt, 0.70 lmp.qt)
SpecifiedR6turn Angle: 20 t 5" UPPERLEVELUNE
T i g h t e nt h e l o c k n u tw h i l e h o l d i n gt h e r a c k g u i d e screw.
LOWERLEVELLINE Raisethe reservoirand disconnectthe return hose that goesto the oil cooler. Connecta hose of suitablediameterto the disconnectedreturn hose and put the hose end in a suitablecontainer.
RACKGUIDESCREW
CAUTION:Tako caro not to 3pill tho tluid on tho body and parts. Wipe off the spilled tluid at onqe. ,l
25 N.m 12.5kgf.m, 18lbtftl
Startthe engine.let it run at idle.and turn the steering wheel from lock-to-lockseveraltimes. When f l u i d s t o p s r u n n i n go u t o f t h e h o s e ,s h u t o f f t h e engine.Discardthe fluid,
40 mm L(rcKNUTWRENCH, 07916- SAs(xtOl
Checkfor tight or loose steeringthrough the completeturningtravel. 6.
Performfollowinginspections: . Steeringoperation(seepage 17-18). . Power assistwith car parked.
7.
Refitthe returnhoseon the reservor. Fillthe reservoirto the uDoerlevelline. Startthe engineand run it at fast idle,then turn the severaltimes to bleedair steeringfrom lock-to-lock f.om the system. Recheckthe fluid leveland add some if necessary. CAUTION: Do not lill the roservoir beyond tho uppgr lovel line.
lnspectionand Adjustment PumpPressureCheck C h e c kt h e f l u i d p r e s s u r ea s f o l l o w s t o d e t e r m i n e whetherthe troubleis in the pump or gearbox. NOTE: First check the power steering fluid level and pump belttension, CAUnON: Dilconn€st the high pros3uroho3s with cale !o e3 not to spill tho powor stooring fluid on th6 lramo lnd olhor parG. 1.
2,
3.
Disconnect the outlet hosefrom the oumo outletfitt i n g , 8 n d i n s t a l lt h e p u m p j o i n t a d a p t e ro n t h e pump outlet. Connectthe hose joint sdapterto the power steering pressuregauge,then connectthe outlet hoseto the adaotor. Instsll the power steering pressuregauge to the pump joint adaptoras shown. OUTLETHOSEFlTnNG
HOSEATTACHINGBOLT 1l Nm11.1kg{ m 8lbf.ftl
Startthe engineand let it idle. 1 . Turn the stee.ing wheel from lock-to-lockseveral timesto warm the fluid to operatingtemperature. M e a s u r es t e a d y - s t a t fel u i d p r e s s u r ew h i l e i d l i n g with the shut-offvalvefully open. lf the pump is in good condition, the gauge should read less than 1500kpa (15 kgf/cm,,213psi). lf it reads high, checkthe feed line or valve body unit (seeGeneralTroubleshooting l7-10). Close the shut-off valve. then close the pressure c o n t r o l v a l v e g r a d u a l l yu n t i l t h e p r e s s u r eg a u g e needleis stabl6,Readthe pressure. 1 0 . lmmediatelyopenthe shut-offvalvefully. CAUTION: Do not keep the shut-ott valvs closod moro thgn 5 soconds or th9 pump could b6 dam" agod by over-h6ating, lf the pump is in good condition,the gaugeshould read at least 6.400- 7,400 kpa (65 - 75 kgIlcm,,924 - 1,067psi). A low readingmeans pump output is too low for full assist.Repairor replacethe pump.
P/S PRESSURE GAUGE
6 x 1.0 m.n BOLT {P!rt of tooll 11 N.m 11.1kgtm,8lbf.ftl
P/S JOINTADAPTORIPUMPI o?NAK- SmolrA
PUMPOUTI.TT FITIING Openthe shut-offvalvefully. Openthe pressurecontrolvalvefully.
1 7- 2 2
FluidLeakageInspection
BOOT Check lor leaks.
GEARBOXrnd VALVEBODYUNIT Checkfor leaksat the matingsurface and rlare nut connections.
PUMPASSEMBLY Ch€ckfor leaksat the pump seal, inlet and outlet fiftings.
Inspecthosesfor d6mage,leaks, interferenceor tlvisting, Inspectfluid linesfor damage, rustingor leakage. Inspectfor leaksat hose and lineiointsor connections,
17-23
Steering Wheel Removal Airbag Removal CAUTION: . All SRS electrical wiring harnossesare covered with yellow insulation. . Before disconnecting any part oI the SRS wiro harness,connect the 3hort connector{g}. . Replacethe entire sffected SRS harness assembly it it has an opon circuit or damagedwiring.
1 . Disconnect the negativeand positivecablefrom the battery. Removethe accesspanel from the steeringwheel lowercover,then removethe shon connector. Disconnectthe connectorbetweenthe airbag and cablereel. Connectthe shon connectorto the airbag side of the connector. AIRBAG CONNECTOR
CABLEREEL CONNECTOR
R e m o v et h e l i d B a n d c r u i s ec o n t r o l s e t / r e s u m e switch cover. Removethe TORX@ T30 bit bolts then removethe airbagassembly. AIRBAGASSEMBLY
17-24
Removal Disconnect the connectorstrom the horn and cruise controlsevresumeswitches.
8.
Removethe steeringwheel nut. R e m o v et h e s t e e r i n gw h e e l b y r o c k i n gi t s l i g h t l y from side-to-sideas you puil steadily with both STEERING WHEEL hands. NUT STEERINGWHEEL Replace.
HORN
Disassembly/Reassembly store a removed airbag assembly with @ the pad 3urfacs up. lf the airbag is improperly stored face down, accid€ntaldaployment could prop€l tho unit with enough forca to causeserious iniury. NOTE:lf an intact airbag assemblyhas been removed f r o m a s c r a g o e dc a r o r h a s b e e n f o u n d d e f e c t i v eo r damagedduring transit.storageor service,it should be deployed(seesection23). TORX6BOLT 10 N.m {1.0 kgf m, Tlbt.ttl
t
CAUTION: C8r€{ully inspoct ihe sirbag assombly betors install. ing. Do not install an airbag ass6mblythat 5how3 signs ol boing dtopped or improperly handled, such as dents, crack3or deformation. Always k€gp tho short connector on the aitbag connector when ths harneggi9 disconnected. Do not disassembleor tamper with the airbag assombly.
TORX6BOLT 10 N.m {1.0 kgf.m, 7lbf.ft)
HORNCONTACTPI-ATE STEERINGWHEEL
LID
\s
SPACER
/
@ CRUISECONTROLSET/ NESUMESWITCHES CRUISECONTROLSET/ RESUMESWITCHESCOVER
17-25
SteeringWheel Installation Airbag installation CAUTION: . B€fore inrtalling the stooring wheel, align tho front who6l3 etraight ahead. . Bo sure to install the harness wires so that thGy are not pinched or intorfsring with othor car parts. . Do not roplace thc original stsoring wheel with any othor design. since it will maks it impo$ibla to properly install the airbag. {Only use genuine HONDA replscomont parts) . After rols3embly. confirm thai the whoels are still straight ahoad 8nd that steoring wheel spoke anglo is correct. lf minor spoke anglo adiustment is noc€ssrry, do so qnly by adlustment ol th€ tie-rods, not by romoving and repositioning the steering wh€€|.
2.
Installthe steeringwheel. NOTE: Be sure the steeringwheel shaft engages the cablereeland cancelingsleeve.
contirm ihat the airbag assombly is @ socurely attachsd to the stooring wheel; oth€rwise, scvoro porsonal iniury could r€sult during airbag doploym6nt. 1.
B e f o r e i n s t a l l i n gt h e s t e e r i n gw h e e l , c e n t e r t h e cablereel. Do this by tirst rotating the cable reel clockwise until it stoos. Then rotate it counterclockwise(approximatelytwo turnsl until: - The yellow gear tooth linesup with the mark on the cover. - The arrow on the cablereel label pointsstraight UD.
YELI-OWGEAR
a9 N.m (5.0 ksf'm,36 lbf.ftl
Attach the cruise control sevresume switch€s connectorto the steeringwheelclip. Connectihe horn connector. CRUISE CONTROL SET/NESUME SWITCHES CONNECTOR
ALIGNMENTMARK
17-26
5.
Installthe airbagassemblywith new TORXobolts.
Connectthe battery positive terminal and th€n connectthe nsgativeterminal.
1 0 . After installing the sirbag assembly,confirm proper system opera(on: . Turn the ignitionto ll: the instrum€ntpan6l SRS indicatorlight should come on for about 6 seconds and then go off, . Confirm operation of horn buttons. . Confirm oDerationof cruise control sevresume switches. a Turn the steering wheel countetclockwiseand make su.e the yellow gear tooth still lines up with the alignmentmark.
YELLOWGEARTOOTH
BOLTS TORXO 10N.m{1.0kgf'm.7lbfftl
the shortconnectortrom the airbagconDisconnect nector. 7.
Connectthe airbag3-Pconnectorand cablereel3-P connector.
ALIGNMENTMARK
Attachthe short connectoron the accesspanel.and installthe accesspanelon the steeringlowercover. CABLEREEICONNECTOR
17-27
Steering Golumn Removal CAUTION: . All SRS el€ctrical wiring hlrnesses are coversd with yollow insuhtion. . Bctore dieconnocting any part ol tho SRS wiro h!rnesa,connoct the thort connector (s). . Roplacetho ontire aftected SRS harness asr€mbly if it has !n open circuit or d!mlgod wiring.
5.
Removethe connectorholder and disconnectthe SRSmain harnessfrom the cablereel wire ha.ness at the underside ot the column bracket.
Removethe airbag assemblyand steering wheel page 17-25). .(see Removethe lower cover. Removethe driver'skneebolster.
HARNESS
R e m o v et h e c a b l e r e e l a n d t u r n s i g n a lc a n c e l i n g steeve. 7. LOWER COVER R e m o v et h e c o l u m n c o v e r s b y r e m o v i n g t h e screws.
Removethe combinationswitch from the steering columnby disconnecting the connectors, TURNSIGNALCANCELING SlTEVE
COMA|NANON SW]TCH
STEERING COLUMN
scREws
17-2A
CABI..E REEL
8.
Remov€the stesringioint cover.
1 0 . Disconnoctthe ignition switch connectorsfrom th6 undor-dashfuse/relavbox. 'l1.
R e m o v et h o s t e e r i n g c o l u m n b y r e m o v i n g t h e attaching nuts 8nd bolts.
JOIMTOOVER STEERINGCOLUMN
BOITS
Removetho steering joint bolts, and move the ioint towardths column.
17-29
SteeringColumn lnspection Checkthe steeringcolumn ball bearingand steering joint bearingsfor play and propermovement. lf there is noiseor excessiveplay,replacethe joint or columnassembly.
Checkthe tilt mechanismfor proper movementand oamage. -
Checkthe retainingcollarfor damage. lf it is damaged,replacethe retainingcollar. COI-UMNBALL EEARING
STEERINGJOINT BEARINGS
Pr6load:70 - 90 N 17- 9 kgt, 15 - 20 tbf) -
-
RETAININGCOLLAR
Attacha springscaleto the knob of the tilt lever. Measurethe preloadrequiredto move the lever.
lf the preloadmeasuredis not within the sDecification. removethe 6 mm bolt and stoDDer. Adjustthe preloadby retighteningthe rilt tockbolt untilthe correctforcecan be obtained. Reinstallthe stopperand 6 mm bolt and recheck the Dreload.
TILT LOCKBOLT
Checkthe absorbingplates,absorbingplate guides and slidingcapsulesfor distonionor breakage. Replacethem as an assemblyif they are distonedor broken.
ABSONBING
9.8 N'm {1.0kgt.m,7.2lbt'ftl
SLIDINGCAPSULE This part is attached to the columnbracket with the plasticinjections.
17-30
lnstallation
STEERINGCOLUMNASSEMBLY
RETAININGOOLLAR
STEERING JOINTBOLIS 22 N.m{2.2tst m, 16lbf.ftl
FLANGEBOLT 22 N m 12,2kgl.m, 16lbf.ftl
FLAMiE NUT 13 N.rn {1.3kgt m, 9 lbt ftl
17-31
SteeringColumn Installation(cont'dl CAUTION: . All SRS electrical wiring hrrnossos are covgrod wilh yellow insulation, . When disconn€ctingthe SRS wire harness,install the short connector on the airbag. th€n dbconnoct the wire harness. . Replacathe entire alfected SRS harness assembly if there is an open circuit or damage to tho wiring. 1.
I n s t a l lt h e s t e e r i n gc o l u m n w i t h t h e f l a n g e n u t s , then installthecolumnholderand flangebolts. Tighten the upper and lower steering joint bolts looselyinstalledin steD2,
Slip the upperend of the steeringjoint onto the column shaft {line up the bolt hole with the flat on the shaft),and loosely install the upper steeringjoint bolt. Finaltorque: 22 N.m {2.2kgf.m, 16lbt.ftl
UPPERSTEERING JOINT BOLT Bolt must line up with flat on shaft.
FLANGEBOLTS 22 N.m 12.2ksi.m,16tbtftl STEERING JOINT
Installthe steeringjoint cover with the clampsand clip.
Slip the lower end of the steeringjoint onto the pini o n s h a f t .L i n e u p t h e b o l t h o l e w i t h t h e g r o o v e aroundthe shaft)and looselyjnstallthelower bolt. NOTE: . B e s u r e t h a t t h e l o w e r s t e e r i n gj o i n t b o l t . i s securelyin the groove in the steering gearbox pinion. . Beforetighteningthe steeringjoint bolts,pull on the sleeringjoint to make sure that the steering joint is fully seated. LOWERSTEERINGJOINT BOLT Fin6ltoroue: 22 N.m {2.2kgt m. 15 lbf.ftl
CLIP
1 7 -3 2
Connectthe ignition switch wire connectorsto the under-dashfuse/relavbox. 7.
Installthe combinationswitch and turn signalcancelingsleeveonto the steeringcolumn.
9. Installthecolumncovers.
UPPER COLUMNCOVER
NOTE:Be sure the wires are not caughtor pinched by any parts when installingthe combination switch.
coMatNATroN swncH
scREws TURNSIGNALCANCELING SLEEVE
1 0 . lnstallthe driver'skneebolster. 1 1 . lnstallthe lowercover. Installthe cablereel onto the steeringcolumn,then connectthe SRS main harnessand cable reel wiro harnessand installthe connectorholder.
't2. Installthesteeringwheel
'17-26). {seepage
NOTE:Align the slot in the cablereel with the projectionon the cancelingsleeve.
17-33
PowerSteeringHoses,Pipes Replacement NOTE: . Connecteachhosgto the correspondingpipe securgly until it stopsat the stopp€ron the pipe. Installthe clamp or ad,ustableclamp at the specified distancsfrom the hoseend as shown in the drawing. . Add the power steeringfluid to the speciliedlevelon the reservoirand checkfo. leaks(seepage17-23).
CAUTION: Chock all clampsfor doterioration 8nd dstormation, and rsplacGwith new onss if n6co33!ry,
Putoverthe pipe untilthe hose stops at the stopper.
Putov6rthe pipe untilthehosestopsat the $opper.
2.5 - 5.5 mm {0.01- 0.22 inl
2.5 - 5.5 mm 10.01- 0.22 in)
2.0 - 4.0 mm - 0.16inl 10.08
OUYI.fT HOSE 11 N.m {1.1 kgl.m, 8 lbl.ftl
ABLECLAMP
INI."ETHOSE
RETURNHOSE CLAMPS
coot"ER CLAMPS
17 -34
PowerSteeringPump Disassembly
Removal NOTE: Before disconnectingthe hoses from the pump, placea suitablecontainsrunderthe car.
Pulley Removal 1.
Drainthe fluid from the pump.
2, 2.
Removethe belt by looseningthe pump adjusting bolt and mountingbolts.
Holdthe stee.ingpump in a visewith soft iaws, and hold the pulleywith the specialtooland removethe pulleynut and pulley.
3.
D i s c o n n e c t h e i n l e t a n d o u t l e t h o s e sf r o m t h e pump and plug the hoses.
CAUTION: Bo clrstul not to damage the pump ho$ing with thr iaw3 of ths vise.
NOTE;Take care not to spill ths tluid on the body or parts.Wipe off spillodfluid at once.
NOTE:Pullevnut has left-handthreads.
1.
Drain the power steeringfluid from the rsservoir.
4.
Removethe pump mountingbolt, then removeth€ pump N O T E : D o n o t t u r n t h e s t e e r i n gw h e s l w i t h t h e pump removeo
5.
Wrap the opening of th€ pump with a piece of taps to provent any foreign mat€rial. Se6 pags 17-44for oumDinstsllstion,
OUTI.TTHOSE
tNt.€THOSE
PULLEYNUT {Left-handthread)
(cont'dl
17-35
PowerSteeringPump (cont'dl Disassembly Flow GontrolValveRemoval/lnspoction l.
2.
Rsmovethe control valve cov€r by romoving the threeflangebolts.
il.
Inspectthe bore for the flow control valvs for scratches or wear.
5.
Slip the valve back in the pump and chockthat it movesin and out smoothly.
Removethe spring, flow control valve and O-rings.
FLOW CONTROL VALVE
-
lf OK, go on step 6, if not replace th6 valve and rochsckthe valve movsment.
NOTE: The original valve was selectedfor a precise fit in the pump housingbore,so makesureths n€w on6 has the same identificationmark. Outsid€Oiam€ter
Checkthe flow control valvg for wgar, burrs, and other damage to the edges of th€ groovos in tho
Mark
Part Name FLOWCONTROL VALVEA
A
FLOWCONTROL VALVEB
FLOW OONTROLVALVE
-
6.
Outside Diameter mm (in) 17.991- 17.996 (0.7083- 0.7085) 17.996- 18.001 {0.7085- 0.7087}
lf the valve movement still incorr€ct, replacothe pump as an assembly.
Attach a hose to the end of the valve as shown. HOSE
Ch6ckfor damags to €dgos.
FLOW CONTROLVALVE
17-36
7 . Submergethe valve in a containerof power steering fluid or solvent,and blow in the hose.lf air bubb l e s l e a kt h r o u g h t h e v a l v e a t l e s s t h a n 1 0 0 k P a 11.0kgf/cm,,14.2psi),replaceor repairit as follows.
Pump Rotor Removal CAUTION: Tho pump components are made ot aluminum. B€ car6ful not to damagethem when servicing. 1.
Removethe inletjoint and O-rjng.
AIR PRESSURE
i-
POWERSTEEBING FLUIDor SOLVENT
13x 1.9mm O.RING Replac€.
'\)4.
8, Hold the bottom end of th€ valve with a oDenend wrencn.
nlll
9. Unscrewthe seat in the top end of the valve, and removeany shims,the reliefcheckball, reliefvalve and reliefvalvespring, REUEFVALVE
RELIEFCHECKBALL
sHrM(sl lf us€d.
SEAT 13 N.m 11.3ks[.m, I lbf.tt]
2.
Removethe pump coverand O-ring.
PUMPCOVER
Clampthisend in a vise with sott iaws.
FLOWCONTROL VALVE
REUEFvALvE SPBING
58.5x 1.5mm O.RING Feplace.
10. Clean all the parts in solvent, dry them off, then reassembleand retestthe valve.Sge page 17-43for f low controlvalve installation. NOTE: lf necessary,relief pressureis adiustedat the facto.y by adding shims under the check ball seat.lf you found shims in your valve,be sure you reinstallas many as you took out,
(cont'd)
17-37
Power Steering Pump Disassembly{cont'd} 3.
Removethe pump cam ring from the pump housIng.
Removethe two rollersfrom the side plate. Removethe side piateand preloadspring.
N O T E :R e p l a c et h e p u m p a s a n a s s e m b l y i. f t h e cam ring must be replaced.
N O T E : R e p l a c et h e p u m p a s a n a s s e m b l y i, f t h e side platemust be replaced.
PUMPCAM RING Checkfor damageor wear.
ROLI..ER 5 x 26.8 mm
SIDEPLATE Checkfor damageor wear. ROLLER 4,5 x 119.8 mm
Removethe pump rotorand vanes. N O T E :R e p l a c et h e p u m p a s a n a s s e m b l y ,i f t h e pump rotor or vanesmust be replaced.
7.
Remove the O-rings from the side plate.
PUMPROTOR Checklor damageor wear.
16.8x 1.9mm O.RING Replace.
54 x 1.9 mm O-RING Replace.
17 3 4
R e m o v €t h e c i r c l i p ,t h e n r e m o v et h e d r i v e s h a f t assemblyfrom the pump housing using a plastic namm€r.
Removeand discardthe bearingusing the special tool and a gress. Pra3s
+
Removethe sealspacerand oil seal. Inspectthe pump housingfor damageon the sealing surfaces. /-clRcLlP
ra-,"
Q'/ DRIVESHAFT for bend, damageor wear,
I{UB DIS/ASSEMBLYBASE 07GAF- SD40700
1 3 . Installthe new bearingusing the
special tool and a
press.
Press
PUMPHOUSING
+
11. lnspectthe bearingby rotatingthe outar raceslowly. lf any play or roughnessis felt, replacethe bearing. Installwiththe red shieldedside lacingdown.
07GAF- SDis)700 NOTE:Supportthe innerrace with the tool securely.
17-39
PowerSteeringPump Reassembly CAUTION: The power steering componsnts are mado of sluminum. Avoid dsmaging th€ componcnts during assombly, NOTE: . Cleanthe disassembledpans with a solventand dry them with compressedair. Do not dip the rubber parts in a sof vent. . Alwaysreplacethe O-ringsand rubbersealswith new ones beforeassembly. . Apply recommendedpower steeringfluid or steeringgrease(HondaP/N:08733- B070E)to the parts indicatedin the assemblvprocedures. . Do not allow dust,dirt, or otherforeignmaterialsto enterthe powersteeringsystem. . Replacethepump asan assemblyifthe partsindicatedwith asterisk(*) are worn or damaged.
ROLLER 5 x 26.8 mm
PUMPcovEn
\
."'MP cAM RING /
,
/
.",orr*r,
-e^urrae vrues sirx1.smm \ ^ / / / pratesl {ro {ro Platesl o_nrNc o-ntNG \A \Al I / I Replace. d A - h 1 / / E Z i l * l / / / ' ^ e e ' a c e
,h$;@:",n1 i'"otr
16.8x 1.9mm O-RING
.PUMP HOUSING
xf:.i'/pp@6{fr;ry tt.m,1a|t t.fti//
/-V#m /
ROLLER RoLLER / a.5 x 49.8 1.5 ag.amm / 68.5x 1.9 mm o-RING O-R|NG
Reptace. Replace.
DRIVESHAFT
\E
/
PUMPSEAL SPACER
|
| I //
>ei
INLETJO-INT
I 'PUMP ROTOR
iiij:f:,ll-T;-,",,,,ll;il'- g--lblY""."*"; Replace.
:
$+--E 22.r x r.9 mm o-RfNG ------t@-<'t Replace.
srntnc -5.8x1.9mm o^::t:\-G Replace.
FLANGEBOLT '11N.m 11.1kg-m,8lb-ftI CONTROLVALVECOVEN
17-40
Pump Rotor Installation L
6. Install the preload spring in the pump housing.
Coatthe lip of the new oil sealwith steeringgrease (HondaP/N08733- 8070E).
7. Set the 4.5 x 49.8 mm roller in the 4.5 mm hole in t h e p u m ph o u s i n g .
I n s t a l lt h e n e w o i l s e a l i n t h e p u m p h o u s i n gb y hand,then installthe pump sealspacer.
8. Setthe side plateover the rollerand installit on the p u m ph o u s r n g .
NOTE:Insertthe oil seal with its groovedside facingin.
9. Set the 5 x 26.8mm roller in the 5 mm hole in the side plate. 5 x 26.8 mm ROLLER
3. Installthe pump drive shaftassemblywith the specialtool. 4.
Installthe 38 mm circlipwith its taperedsidefacing out, DRIVERATTACHMENT 07947 - 6:1io500
5 mm HOLE
38 mm
SIDEPLATE
crncuP -
PRELOAD SPRING
DRIVE
fu'/'i,Er
t\=zl4
PUMPSEAL
I"J
If /sprcen
x, tY
,1.5mm
-ot seal
-Gll ATTACHMENT, 37 x ,r0 07t,16- dt102d,
1 0 . Assemblepump rotorto the drive shaftwith the "o" markon the rotorfacingupward. 1 1 . Setthe 10 vanesin the groovesin the rotor.
5.
Coatthe side plate grooveswith the recommended p o w e r s t e e r i n gf l u i d , t h e n p o s i t i o nt h e 1 6 . 8x 1.9 mm and 54 x 1,9mm O-ringson the side plate.
NOTE:8e surethat the round ends of the vanesare in contactwith the slidingsurfaceof the cam ring. PUMPROTOR
16.8x 1.9mm O.RING
5a x 1,9 O.RING
l (cont'd) SIDEPLATE
17-41
PowerSteeringPump (cont'dl Reassembly Set the pump cam ring over the two rollerswith the "8" markon the cam ring upward.
1 7 . Setthe 13 x 1.9mm O-ringon the inletjoint. 1 8 . Installthe inletjoint on the pump housing.
1 3 . Apply clean power steeringfluid to the vanes and cam ring. 11.1kgt.m. t lbf.ftl INLETJOINT
PUMPCAM RING
1 3x 1 . 9 O.RING
E
T9 1 4 . Installthe 68.5x 1,9mm O-ringon the pump cover. 1 5 . Align the rollerset holesin the pump coverwith the rollers. '16. Align
the projectionon the pump housingand the projectionon the pump cover,and tighten the four bolts.
20N.m {2.0 kg .m, lil lbf.ftl
PUMPCOVER
PROJECTIONS
17 -42
Flow Gontrol Valve Installation 1.
Apply steeringgrease(HondaP/N08733- B070E)to new O-rings.
2.
Coatthe flow controlvalvewith clean power steeri n gf l u i d .
3.
Install the flow control valve, spring and control valvecoveron the pump housing.
4.
Tightenthe threecontrolcover bolts.
PulleyInstallation 1.
Holdthe steeringpump in a visewith softjaws. CAUTION: Be careful not to damago the pump hou3ing with the laws ol th€ vise.
2.
Installthe pump pulley as shown. Then installthe pulleynut.
PULLEYNUT FLOWCONTROL VALVE
E;W SPRING
11 N.m {1.1kgl.m,8lbtftl
2
Holdthe pulleywith the specialtool and tightenthe pulleynut. PULLEY
PULLEY NUT 6irN.m(6.5kgt.m,47lbt tt) Checkthat the pump turns smoothlyby turningthe pulrey.
17-43
Power Steering Pump lnstallation 1.
Adjustthe pump belt (seepage 17-201.
C o n n e c tt h e i n l e t a n d o u t l e t h o s e s .T i g h t e nt h e pump fiftingssecurely. 5. Looselyinstallthe pump in the pump bracketwith mountingbolts. 11N.m 11.rkgf.m,8lbf.ftl OUTIIT HOUSE
O-RING Replaco.
INI.TTHOSE
Fillthe reservoirto the uoDerlevelline. NOTE;Takecare not to spill the fluid on the body and parts.Wipe off the spilledfluid at once. GAUTION: Uro only Ganuino Honda Powor Stsor. ing Fluid-V. Using othor tlui& 3uch a3 ATF or oiher manutacturor's powor steering tluid will drm89e the rystgm. SYSTEM CAPACITY: 1.06litor(1.12US.qt,0.93lmp.qt) RESERVOIR CAPACIW: 0.79 litor (0.1|:|US.qt, 0.?0 lmp.qtl
ADJUSTING BOLT
UP?ERI.fVEL LINE
IEVEI LINE
-
Start the engine,let it run at idle, then turn the steering wheel lock-to-lockseveraltimes to bleed air from the system.
-
Recheckthe fluid level and add some if necess8ry.
PUMPMOUNTINGBOLTS 2,r N.m {2.4 kgl.m. 17 lbf'ft}
Installthe DumDbelt. CAUTION: . Make surs that thg powor gtooring bslt i! securglyon the grooyos of ths pulloy!. . Do not get powor stggring fluid o. groaso in thg power steering bclt or pulley trc6. Cloanoft 8ny tluid or groa36belore installation. BELT POWER STEERING PULI..EY
17 -44
CAUTIONTDo not fill tha .63ervoir boyond th6 upp€r lcvol lino.
SteeringGearbox Removal NOTE:Usingsolventand a brush,wash any oil and dirt off the valve body unit, its lines, and the end if the gearbox. Blow dry with compressedair. 1.
Drain the power steering fluid as describedon page 1 7- 2 1 .
2.
Rsisethe front of car, and support on safety stands in the propsr locations(seesection 1).
3.
Removethe front wheels.
il.
Removsthe st€eringjoint cove.,
R e m o v et h e c o t t e r p i n t r o m t h e c a s t l e n u t a n d removo the nut. Installthe10 mm hex nut on the balljoint. Be surethat ths 10 mm hex nut is flush with the ball ioint pin end, or the threaded section of the ball i o i n t p i n m i g h t b e d a m a g e db y t h e b a l l i o i n t remover. NOTE: Removethe ball joint using the Ball Joint Remover,28 mm {07MAC- 5100200}.Referto page l8-11 fot how to use the ball joint rcmover,
8. Separat€the tie-rodball joint and knuckleusingthe soscialtool. SIEERINGJOIi{TCOVEB
CAUTION: Avold d.maging th. blllloint boot.
28 mm BALLJOlt{T REMOVER. 07MAC- SLqt2|X) Removethe steering joint lower bolt, and move the joint towardthe column.
Disconnectthe shift linkage {MfI model: see section 13,A/[ model see section 14).
NOTE: Lock the steering shaft with the ignition key to retain the steering shaft position.
1 0 . Disconnectthe heatedoxygen sensor (H02S)conngctor, and separatethe three way catalyticconverter by removing the s€lf-lockingnuts. NOTE: Always replacethe gasketswith new ones. HEATEDOXycEt{S€NSOnOONNECTOR SELF.LOCKINGNUT
{cont'd) Replacs.
IHREE WAY CA?ALYTICCONVERTEN
17-45
SteeringGearbox Removal(cont'dl 1 1 . Removethe return pipe clamp from the left side of the rear beam.and move the returnpiDeabovethe steeringgearbox.
12. Removethe rearbeambrace.
14. Disconnectthe two linesfrom th€ valve bodv unit on the steering gea.box. CAUTION: Aftor dkconnccting tho ho3o and pip., plug or r.d thc ho3. rnd pipc whh I pioco of tapo or .quivll.nt to prcvont torcign m!tori!|3 f.om ritrdng thc vdv. body unit.
RETURNPIPECLAMP
NOTE: . Placethe pipe disconnectedin the previous step at the rear side of the gearboxso that they do not hinderin the gearboxremoval. . Do not loosen the cylinder pipes A and B betweenthe valvebody unit and cylinder, RETUR]T HOSE
1 3 . Removethe left tie-rod end, then slide the rack the way to the right.
I.TFTTIE-ROD END 15. Removethe steeringgearboxmountingbolts.
GEARBOXMOU NNG BOLTS
17-46
Pull the steeringgearboxall the way down to clear the pinion shaftfrom the bulkhead,and removethe pinionshaftgrommet. 1 1 . Move the steeringgearboxto the right so the left rackgnd clearsthe rearbeam. 1 8 . Hold the steeringgearboxand slidethe rackall the way to the left, then placethe left rack end below the rearbeam. 1 9 . Move the steeringgearboxto the left. and tilr the left side down to remove it from the car.
PINIONSHAFTGROMMET
STEEBINGGEARBOX
17-47
Steering Gearbox Disassembly Stssring RackDisassembly
5.
Hold the steeringrack with a wrench and unscrew the rackend with a wrench.
NOTE: . Before disassemblingthe gearbox,wash it off with solventand a brush. . Do not dip sealsand O-ringsin solvent. 1.
Removethe steeringgearbox(seepage 17-45).
2.
Removethe air hoseand clips.
3.
Removethe tie-rodend and locknut.
L o o s e nt h 6 l o c k n u t a n d r e m o v e t h a r a c k g u i d e screw. 7. CLIP
4.
Ramovethe spring and rack guide from the gear housing.
Removethe boot bands and tube clamps.Pull the bootsawayfrom the endsof the gearbox.
TUBECLAMP LOCKNUT
BOOT
17-48,
RACKGUIDE
Removethe cylinder pipe A and B from the gearbox. Drainthe fluid from the cylinderfittings by moving the steeringrackbackand forth,
CYLINDERPIPEB
1 1 . Drill a 3 mm {0.12in) diameterhole approximately 2.5 - 3.5 mm (0.10- 0.14in) in depth in the stakedpoint on the cylinder. NOTE: Do not allow metal shavingsto enter the cylinderhousing. STAKEOPOINT - 0.12inl D.prh:2.5- 3,0mm 10.10
CYUNDER END
12. Installa pulleryoke to the stesringgearbox.Clamp the puller yoke in a vise with soft iaws as shown, then loosenand removethe cvlinderend. Removethe two flangebolts,then removethe valve body unit from the gearbox. {See page 17-51for valvebody unit disassembly.)
PULLER YOKE: Commercirlly Avrilablo Sn.p-OnoT/N qrie'-1 oTcloT/N 7372
VALVEBODYUNIT FLANGEBOLT
(cont'd)
17-49
SteeringGearbox Disassemblylcont'd) 13, Setthe gearboxin a pressso the gearhousingpoints upward. 14. Installtheflangeboltintothe endofthe steeringrack until it bottomsin the hole,then backthe flangebolt out 1/4 turn. Hold the tlange bolt and tighten the flangenut againstthe rackby hand. 15. Pressthe cylinderend sealand steeringrackout of the gearbox, NOTE: Holdthe sreeringrackto keepit from talling when pressedclear. Pre$
VINYL TAPE
I
1 7 . Removethe 12 mm bolt and nut from the steering
rack,then installa 24"long.3/8"driveextension,and the specialtool into the cylinderfrom the gearbox side. CAUTION: Be caretul not to damagc th€ in3idr surfaceot ths housing with tho tool3. 1 8 . Setthe gearboxin a press,then pressout the cylinder end sealand backupring trom the gearbox. CAUTION: Ksepthe tool straight to avoid damagingthacYlind.r wall. Chscktis tool angls, and corr€st if nrcolrary, whsn rsmoving the cylinder end seal. Use ! prors to r6movo tho cylinder end rgal. Do not try to remove the soal by 3triking ths tool. h will break the brckup ring and tho cylind€r end leal will romain in ths gsarbox.
2it" LONG3/8" DRIVEEXTENSION: Comm€rcirllyAvailobl. 12 mm FLANGENUT
STEERING GEARBOX
1 6 . Removethe soecialtool and cylinderend seallrom the steeringrack. ENDSEAL CYLINDER REMOVERATTACHME?ST CYLINDERENO SEAL
19. Carefullypry the pistonseal ring and O-iing off the pistonof the rack. CAUTION: Be careful not to damags th€ insidc ot seal ring groove whgn romoving th€ seal ring.
Replace.
17-50
20. Apply vinyl tape to the pinionshaft. 2 1 . Separatethe valve housingfrom the pinion shafv valveusinga press. VALVEHOUSING
2 3 . C h e c kf o . w e a r . b u r r s a n d o t h e r d a m a g et o t h e edgesof the groovesin the sleeve. NOTE:The pinion shaft and sleeveare a precision matched set. It either the pinion shaft or sleeve must be replaced,replacethe both partsas a set.
SLEEVESEALRINGS Ch6ckfor oeel off or oamag0,
Vinyl t.p.
22. Checkthe innerwall of the valve housingwherethe seal ring slideswith your finger.lf there is a step in t h e w a l l , t h e v a l v e h o u s i n gi s w o r n . R e p l a c et h e valvehousing.
24. Removethe circlipand pinionshaft sleevefrom the oinionshaft.
NOTE: There may be the sliding marks from the seal ring on the wall of the valve housing. Replace the valvehousingonly the wall is stepped. When the valve housingis replaced,installnew 3 2 m m s h i m ( s )o n t h e b e a r i n gs u r f a c eo f t h e housingto adjustthe thickness.
(cont'd)
17-51
SteeringGearbox Disassembly(cont'dl 25. Using a cutter or an equivalenttool, cut and remove the four seal rings from the sl6eve.
Removathe valve oil seal 8nd backup ring from the pinionshaft.
CAUTION: Bc clroful not to drmrg. ths .dgc. ot thc alcava g1oov6 whan rcmoving the 3cd rings lnd O.ring.
NOTE: . Inspectthe ball bearing by rotating the outer race slowly. lf thsre is excessiveplay, replacethe pinionshaftand sleeveas an assembly. . The pinion shaft and sleeve are a precisefiu do not intermix old and new pinion shaftsand steev8s,
SI-EEVE
26. Using a cutter or an gquivalenttool, cut the valve seal ring and O-ring Et the groove the pinion shaft. Removethe valv€ saal ring 8nd O-ring, CAUTION: Br crrltul not to drm.gr thc cdgct of thc plnion rhdt grooya whcn rcmoving the vllvc !.!l ring rnd O-ring.
Cutting slot position.
17.52
28, Pressth6 valve oil s€al and roller besring out ofthe valve housing using a hydraulicpress and special tool shown below.
PILOTCOLLAR O?GAF- PHTO1OO
Reassembly NOTE: . Cleanthe disassembledpartswith a solventand dry them with compressedair. Do not dip the rubberparts in a solvent. . Alwaysreplacethe O-ringsand rubbersealswith new ones beforeassembly. . Apply power steering fluid or steering grease{HONDAP/N: 08733- 8070E)to the parts indicated in the assembly procedures. . Do not allow dust,dirt. or otherforeignmaterialsto enterthe powersteeringsystem. . Usethe appropriatespecialtoolswhere necessary. FLANGCBOLT 20 N.m 12.0kg{.m, lil lbt'ftl
VALVEI{OUSING
CYLINDERPIPEA 26 N'm (2.7 kgf.m, 20 lbf.ftl
BOLI..ERBEARING Replace. VALVE SEAL RING Replace.
+-cncl|P SITEVE
S1IEVE SEAI RINGS Reolace. BACKUPRIM} VALVE SEAL RING Raplacs. RACKGUIDESCREW
O.RING Replac€.
LOCKNUT
PINIONSHAFT CYLINDERHOUSING BACKUPRING
\
\
SHIMS
O-RING Replace.
O-RING Replace.
CYUNDERENDSEAL Reolace.
CYLINDEREND SEAL Replaco.
GEARHOUSING
O.RING Replace.
I
x$ Ynd#
I
PISTONSEALRING Replace.
STEERINGRACK
(cont'd)
17-53
SteeringGearbox Reassembly lcont'd) Vllvc Body Rea3sombly 1.
2. 3. 4.
Apply vinyl tape to the steppedportion of the pinion shaft,and coat the surfaceof the vinyl tape with the power steeringtluid, I n s t a l lt h e b a c k u p r i n g w i t h i t s t a p e r e d s i d e a s shown below. Coat the inside surface of the new valve oil seal with powersteeringfluid. Slide the valve oil seal over the pinion shaft.being carefulnot to damagethe sealinglip. CAUTION: ln3tall the valve oil ssal with hs groovad 3idetacing opposits the besring.
Vinyl trpo lst.ppcd ponion,
7. Apply power steering fluid to the surface of the v a l v e s e a l r i n g t h a t w a s i n s t a l l e do n t h e p i n i o n shaft. 8. Apply power steeringfluid to the insideof the special tool. Set the largerdiameterend of the special tool over the valvesealring. 9. Move the specialtool up and down severaltimes to makethe valvesealring Jit in the pinionshaft. 10. Removethe specialtool. . 1 1 . T u r nt h e s p e c i atlo o l o v e ra n d s e t t h es m a l l e r d i a m eter end of the specialtool over the valveseal ring. Move the sDecialtool uD and down severaitimes to m a k et h e v a l v e s e a l r i n g s n u g l yf i t i n t h e p i n i o n shaft.
Taperedposition.
Groove side.
VALVESEALRING
VALVEOIL SEAL
S€alinglip
E Fit the new O-ringin the grooveof the pinion shaft. Then slide the new valve seal ring over the shaft and groovein on the pinionshaft. Removethe vinyl tapefrom the pinionshaft. NOTE:Do not over - expandthe valvesaalring. PINION SHAFT
VALVESEALRING
17-54
(H(ffi Usethe widerdiameter end ot the special tool first to make the valvesealring fit in the pinion shaft.
Make the valve seal ring snuglyfit in the.pinion shaftusingthe otherend (smallerdiameterend)of the specialtool.
Apply powersteeringfluid to the surfaceof the specialtool. Set the new sealrings overthe specialtool f r o m t h e s m a l l e r d i a m e t e re n d o f t h e t o o l , a n d expandthe seal rings.Do two rings at a time from eachend of the sleeve, NOTE: . Do not over-expand the seal ring.Installthe resin seal rings with care so as not to damagethem. After installation,be sure to contract the seal rings usingthe specialtool{sizingtool}. . There are two types of sleeve seal rings: black a n d b r o w n . D o n o t m i x t h e d i f f e r e n tt y p e s o f sleevesealringsas they are not compatible.
't7. Apply power steeringfluid to the surfaceol the pinion shaft,then assemblethe sleeveover the pinion shaft,aligningthe locatingpin on the insideof the sleevewith the cutoutin the shaft, NOTE:Be carefulnot to damagethe valveseal ring when insertingthe sleeve. 1 8 . Installthe circlipsecurelyin the pinionshaftgroove. NOTE:Installrh€ circlipwith its taperedside facing OUI.
Cutout,
1 3 . Setthe specialtool in the groovesin the sleeve.and set eachring in eachgroovesecurely. NOTE: After installation,compressthe seal rings with your fingerstemporarily. BALLJOINT BOOTCLIPGUIDE o?MAG - SL001d)
19. Apply power steeringfluid to the seal ring lip of the v a l v e o i l s e a l .T h e n i n s t a l lt h e s e a l i n t h e v a l v e housingusinga hydraulicpressand specialtools as shown.
14. Apply power steeringfluid to the seal rings on the sleeveand to the entireinsidesurfaceof the special tool. 15. Insertthe sleeveinto the specialtoolslowly. 1 6 . M o v e t h e s l € e v ee a c h d i r e c t i o ns e v e r a lt i m e s t o makethe sealringssnuglyfit in the sleeve.
ATTACHMENT, 32x35mm 077{6 - 0010100
NOTE:Be surethat the sealringsare not turnedup. SLEEVESEALRING SIZINGTOOL 07974- 5450200
VALVEOIL SEAL
{cont'd)
17-55
ir
SteeringGearbox (cont'd) Reassembly 20. Pressthe new roller bearinginto the valve housing usinga hydraulicpressand specialtool as shown. NOTE:Placeths roller bearingon the valve housing with its letter stamped facing up towards the valveside. Pr.33,
I
2 4 . P r e s st h e p i n i o n s h a f t / s l e e v eu s i n g a h y d r a u l i c Dressas shown. CAUTION: Before irserting the pinion 3haft, bo suro that the backup ring is csntored with the pin. ion shaft bearing,
ATTACHMENT, 32x35mm - (x)1010O 077/aO
BACKUPBING ROLLERBEARING Letterstampedface
2 1 . Apply vinyl tape to the pinion shaft,then coat the vinyl tape with powersteeringfluid. Insertthe pinionshaftinto the valvehousing. CAUTION: Be carotul not to damage tho valvs soal rings. 23. Removethe vinyltapefrom the pinionshaft. Soalinglip frc.. VALVEOIL SEAL
VALVCHOUSING
PINION
E SI,-EEVESEAL RINGS Be surethat the searings are not turnedup,then install.
17-56
25. Coatthe pistonseal ring guide with power steering fluid, and slideit onto the rack,big end first.
3 1 . Coatthe sliding surfaceof the specialtool and new cylinderend sealwith powersteeringfluid.
26. Positionthe new O-ringand new pistonseal ring on the specialtool, then slide them down towards big end of the tool.
32. Placethe seal on the specialtool with its grooved
NOTE: . Do not over expand resin seal rings. Installthe resin seal ring with care so as not to damage them. After installation,be sure to contractthe sealring usingthe specialtool (sizingtool). . Replacepiston'sO-ringand sealring as a set.
sidefacingoppositethe specialtool.
Groovedside.
Pull the O-ringoff into the pistongroove,then pull the pistonsealring off into the pistongrooveon top of the O-ring. PISTON
CYLINDEREND SEAL
PISTONSEALRING GUIDE 07GAG- SD,OI00
CYLINDEREND SEALSLIDER 0797a - 6890801
Apply a thin coat of greaseto the insideof the special tool, and installit on the steeringrack. CAUTION:Make sure the rack teeth do not tace the slot in the specialtool.
O.RING PISTONSEALRING
CYLINOERENDSEAL
28. Coat the piston seal ring and inside of the special toolwith power steeringfluid. Carefullyslide the tool onto the rack and over the pistonsealring. 30. Move the specialtool back and forth severaltimes to makethe pistonsealring fit snuglyin the piston.
PISTON
E SEALSLIDER 0t974 - 6890801
(cont'd)
17-57
SteeringGearbox Reassembly lcont'dl 34. Separatethe cylinderend sealfrom the spscialtool, then remove the tool from the steering .ack.
CYUNDERENDSEAL
3 7 . Setlhe gearboxin a presswith the cylindorhousing facing upward. Installthe flangebolt intothe end of the steeringrack until it bottomsin the hole,then backthe flang€bolt out 1/il turn. Hold the flange bolt and tighten the flangenut againstthe rackby hand. 'to Installthe cylinderend seal into the bottom of the cylinder by pressingon the bolt with a press as shown. CAUTION: Do not push on ihc bolt with excelcivr forcc; 83 it may dEmagothr cylindor ond 3o!1. Pr9!t
I 12 x 170 mm FLANGEBOLT 12 mm FLANGENUT lnstall the backup ring on the steering rack, then placethe cylinderend sealto piston. STEERINGRACK
BACKUPRING
CYUNDERENDSEAL
Removethe flangebolt and centerthe steeringrack. 4 1 . Installthe specialtool or vinyl tape onto the end of CYLINDERENDSCAL
Greasethe steering rack teeth, then insert the steering rackinto the gear housing. CAUTION: Be clrs{ul not to d.mage to inn9r !urftca of thc goar housing with th€ rsck cdg6.
the steering rack, then coat the specialtool or vinyl tapewith powersteeringfluid. Coatthe insidesurfaceof the new cylinderend seal with power steeringfluid. Installthe cylinderend seal onto the ste€ringrack with its grooved side toward the piston. Removethe specialtool. Push in the cylinder end sealwith finger. NOTE: Take care not to damagethe cylinder end seal with the threads and burrs at the stakod oosition of the gearbox. St k d po3ition.
c.oov.d3id...--#
CYUNDERENDSEAL
17-58
Installa puller yoke to the steeringgearbox,then clamp the puller yoke in a vise with soft jaws as shown. YOXE: PULLER CommcrcirllyAvrihblo Sn.p-OnoT/N Cr123-l orco T/N 7372 or aquivrlani
,t8. Selectthe 32 mm shim(s). N O T E :O n l y r e i n s t a ltl h e o r i g i n a l3 2 m m s h i m ( s ) when the steering gearbox is reassembledwithout replacingthe pinion shaft,valve housing,and gearbox housingwith new ones. l f t h e p i n i o n s h a f t , v a l v e h o u s i n g ,a n d g e a r b o x housingare replaced,selectthe new shim{s)as folrows. Shim r€lection: -'1. Set the four 32 mm shimson the b€aringsurfaceof the gearbox housing. Total thicknessof the four shimsshouldeoualno more than 0.70mm. 0.10 mm, Shim set: tour 32 mm shims (Thickness: 0.15mm, 0.20,0.25mm respectivelyl CAUTION: The tour 32 mm shimr do not hlva thlckn$s idcntitication mukt. Mo!3ur. tho thicloa33 of rach 3him using a miclomctrl, and mlrk tho shim lor id6ntific8tion.
Greasethe insidesurfaceof the cylinderend, then installthe cylinderend by screwingit into the cylind e rh o u s i n g . 4 1 . After tighteningthe cylinderend, stakethe point of the cylinderhousingshown below. NOTE:Stakein the cylinderin the positionopposite from where the stake was removed during disassemblv. Strke point, D.pth: 1.0 mm (0.04inl CYLINDERHOUSING
- 2 . I n s t a l lt h e v a l v e b o d y u n i t o n t h e g e a r b o x ,a n d tighten the flange bolts to the specitiedtorque VALVEBODYUNIT
FLANGEBOLT 20 N.m {2.okgtm, 14lbt'ftl SHIM SET {foul thim.)
4.0 mm 10.15inl CYLINDEREND
Measurethe clearancebetween the gearbox and valvebody unit usinga feelergaugeas shown. NOTE:Measurethe clearanceat the point midway betweenthe two mounting bolts.
CYLINOER 69 N.m 17.0kgf.m, 51 lbtft)
(cont'd)
17-59
SteeringGearbox Reassembly lcont'd) - 4 . D e t e r m i n et h e r e q u i f e dt h i c k n e s so f t h e 3 2 m m shims by subtractingthe clearanceobtainedin the step-3 from the total thicknessof the four shims. ( T o t a lt h i c k n e s so f t h e 4 s h i m s ) - ( C l e a r a n c e=) Requiredthicknessof the shims NOTE:Selectthe shims so that th6 total thickness is closeto, but lessthan the requiredthickness. Exampls: Measu.ementis 0.28mm (0.011in): 0.70- 0.28= 0.42mm (0.028- 0.011= 0.0't7in)
54. Installthecylind6rpipesA and B. NOTE: . Cleanthe jointsofthe cylinderpipeA and B tho.oughly. The joints must be free of foreign mat€.iat, o Installthe cylinderpipe A and B by tighting the flare nuts by hand first, then tighten the flare nuts to the specified torque starting with the cylinderside nuts. CYLINDER PIPEB 26 N.m (2.7kg{.m,20lbtft)
The selectedshims should be 0.25 mm (O.O1O in) and 0.15mm (0.005in) in thickness. l f t h e r e q u i r e ds h i m t h i c k n e s si s 0 . l O m m o r l e s s ,n o shims are necessary. i[9. Set the selected32 mm shims on the bearingsurfaceof the g€arboxhousing. 50, Coatthe new O-ringwith gresseand installit in the groovein the gearboxhousing. c t . Apply greaseto the needlebearingin the gearbox housing. Installthe valve body unit on the gearboxhousing by engagingthe gears. NOTE: Note the valve body unit installationposition (directionof pipe connection). Tightenthe flangeboltsto the specifiedtorque. FLANGEBOLT 20 N.m (2.0 kgt m, 14lbf.ft)
Greasethe sliding surface of the rack guide and installit onto the gear housing. Apply a thin coat of greaseto the n€w O-ring and installit on the rackguidescrew. Installthe spring, rack guide screw and locknuton the gear housing. Adjustthe rackguide screw(seepage l7-21). NOTE:After adjusting,checkthat the rack moves smoothlyby slidingto rackright and left.
VALVEBODYUNIT
-6t O-RING
-ffiti LOCKNUT
NEEOLEBEARING
_#{
17-60
BACKGUIDESCREW
Install the new lock washor in the groov€ in the steering rack.
62. Apply steering groass to the circumferenc6 of tho rackend housing.
60. Hold the steering rack with I wrsnch and tighten the rackend.
Coat the rack end groove and inside of the boot with siliconegreas€.
After tightening th€ rack end, stskethe four sections of lock washer with a commerciallyavailableroll Dindrift and a mallet.
64. l n s t s l l t h e b o o t s i n t h s r a c k e n d w i t h t h e t u b e clamos.
o l
ROLL PIN DRIFT Comm.rcl.lly Av|il.bl. lsnrp-On No. PPR8or .rquiv.lenll
NOTE: Installthe boots with the rack in the straight ahsad position (i.6. right and l€ft tis-rods ar€ squal in length).
NOTE: Wipe ths gro.se off the thread s€ction.
NOTE: This drift has a fl8t, to prevent puncturing of motal washer.
TUEE CLAJTIP
(cont'dl
17-61
SteeringGearbox Reassembly(cont'dl 65. Adjust the air hose fitting position of the boots by turning it as shown below.
6 7 . Install new boot bands on the boot and bend both sets of locking tabs. Lightlytap on the doubled-overportionsto reduce their height. GAUTION: Stake tho band locking tabs firmly.
Front
AIR HOSEFITTING
Slide the rack right and left to be certainthat the boots are not detormed or twisted.
70. Install the right and left tie-rod ends on the rack ends. C o n n e c t h e a i r h o s e b e t w e e nt h e r i g h t a n d l e f t boot.then installthe clips on the cylinderpipe B as snown.
Install therightclip in thisposition. CLIP
17-62
lnstallation CAUTION; BGGlrc{ul not io bcnd or drm8go tho piping whcn in3tllling tho gea.box. 1.
Beforeinstallingthe gearbox,slide the rack all the way to right.
2.
Passthe right side of the steeringgearbox above and throughthe right sideof the rearbeam.
3.
Hold the steeringgearboxand slidethe rackall the wav to the left.
4.
Raisethe left side of the steeringgearbox above and throughthe leftside of the rearbeam.
5.
Installthe pinion shaft grommet and insertthe pinion shaft up throughthe bulkhead.
7.
Centerthe steering rackwithin its stroke. Makesurethat the cablereelof the SRSis centered as follows: Turn the steeringwheel left approx.150degrees, to checkthe cablereelpositionwith indicator. . lfthe cablereelis centered.the yellowgeartooth linesup with the alignmentmarkon the cover. . R e t u r n t h e s t e e r i n gw h e e l r i g h t a p p r o x . 1 5 0 degrees to position the steering wheel in the straightaheadposition. .
YELLOWGEARTOOTH
NOTE:Align the tab on the pinion shaft grommet with the slot in the valvebodv. TAA
MARK ALIGNMEi'IT Slip the lower end of the steeringjoint onto the pinion shaft(line up the bolt hole with the groove aroundthe shaft),and tightenthe lower bolt. NOTE: . Connectthe steeringshaft and pinion with the cablereeland steeringrackcentered. . Be sure that the lower steeringioint bolt is securelyin the groove in the steeringgearboxpinion. . lf the steeringwheel and rack are not centeted, r e p o s i t i o nt h e s e r r a l i o n sa t l o w e r e n d o f t h e steeringjoint.
6.
Installand tightenthe gearboxmountingbolts. NOTE: After installingthe gearbox,check the air h o s e c o n n a c t i o n sf o r i n t e r f e r e n c ew i t h a d j a c e n t pans.
58 N.m 15.9kg[.m, $ lbl.ftl
LOWERBOLT 22 N.m 12.2kgi.m, 16lbf.ftl
(cont'dl 38 N m 13.9kgl.m, 28 lbt.ftl
17-63
SteeringGearbox Installation(cont'd) 10. Installthe steeringjoint cover with the clampsand cliDs.
1 2 . I n s t a l lt h e r e a r b e a m b r a c e r o d a n d r e t u r n p i p e clampon the rearbeam. N O T E : I n s t a l lt h e r e a r b e a m b r a c et o w a r d t h e returnpipeclamp.
STEERINGJOINTCOVER
38 N.m 13.9kg{.m,28 lbf.ft)
CLIP
11. Connectthe fluid linesto the valvebodv unit. RETURNHOSE
13. Install the three way catalyticconverter with the new gasketsand new self-lockingnuts,and connect the heatedoxygensensor(H02S)connector, HEATED OXYGEN SENSOR CONNECTOF SELF.LOCKING NUT 33 N.m 13.4
SELF.LOCKING NUT 22 N.m (2.2 kgt m, 16 lbt.ftl
14. Connectthe shift linkage (M/T model: see section 13,A/T model:seesection14).
17-64
BallJoint Boot Replacement 1 5 . Threadthe right and lefi tie-rodends onto the rack an eoualnumberof turns. TIE.RODLOCKNUT
TIE-ROOEND
Removethe boot set ring and the boot. CAUTION:Do not contaminateihe boot in3tallstion section with gr€aso. Packthe interiorof the boot and lip with grease. Wipe the greaseoff the sliding surfaceof the ball pin,then packthe lower areawith freshgrease. CAUTION: . Ke€p g;eass off the boot in3tallation section and tho laperad section of the ball pin. . Do not altow dust, di.t, or other toreign mat6tials to enter tho boot, LIP
BALLPIN TAPERED SECTION Wipe off the grease.
the tie-rodends to the steeringknuckles, R€connect tighten the castle nut to the specifiedtorque, and installnew cotterpins. CAUTION:Iorquo tho castle nut to tho lower torque lpocification, thsn tighton it only far cnough to align thc slot with tho pin hole. Do not align tho nut by loosoning. NE.RODEND
BOOTINSTALLATION SECTION wiDe off the grease.
BOOTINSTALLATION SECTION Wipe off the grease.
Installthe boot in the grooveot the boot installation sectionsecurely,then bleedair. SALLJOINTBOOT CLIPGUIDE 07MAG- SL(x)l00 Adiust the depth by turningthe tool.
CASILE NUT 39 - 47 N.m 14.0- a.8 kgf.m. 29 - 35 lbf ftl
COTTERPIN On reassembly,bend the cotterpin as shown.
17. lnstallthe front wheels.
18. Fill the systemwith pgwer steeringfluid and bleed air from the system(seepage 17-21). performthe followingchecks. 19. After installation. . Checkthe gearboxJor leaks(seepage 17-231 . Adjustthe front toe (seesection18). o Checkthe steeringwheel spokeangle.Adjust by turningthe right and lefttie-rods,if necessary.
SET RING
Insertthe specialtool into the threadsin the ball pin and align the end of the tool with the groovein the boot. Slidethe clip overthe tool and into position CAUTION: After installing the boot, check th. b.ll pin taperod section tor grease contamiration and wipe it if nocossary.
Turn the right and lefttie-rodsequally.
17-65
R6ar Door: '13.
Adjust clearance"H" as follows.
"H"
lsos page 20-421
-3 Loosenthe locknutssecuringthe centerglass guide,and adjustthe glassfore and aft by moving the center glassguide. NOTE: Hold the adjusting bolts with a hex wrench or tlat tip screwdriverwhen loosening the locknuts.
- 1 Loosenthe nut securingthe stopperplates. 2 Loosenthe nut securingthe rollerguide, and move the guide up or down to alignthe glass with the body at the rear and center pillars.
GLASS
I ROLLERGUIDE
-4 Repeatsteps-2 and -3 until clearance"H" is within the specifiedlimits.then fasten the center glass guide and rollerguide. Pressthe stopperplatesagainstthe glassstoppers, then fasten the stopper plates. NOTE: Checkthat the stopperplatescontact the glassstoppersevenly. STOPPERPLAYE lF ontl
204s
Doors GlassAdjustment(cont'dl 14. Adjust clearance"8" as follows.
-3 Loosenthe upper locknut on the center glass guide, and turn the adiustingbolt until cleatance "B" is within the soecifiedvalue. ADJUSTING EOLT
"8" (see page 20-421
-l
Lower the glass 1O mm {0.39 in).
- 2 Pushthe glassoutward 1Omm (O.39inl. then
LOCKNUT 1 2 x 1 . 2 5m m 22 N.m 12.2kgf.m, 16 tbt.ft)
pushthe insidestabilizers againstthe glssslightly. Fastenthe insidestabilizers. NOTE: Checkthat the glassmoves smoothly.
* GLASS
NOTE: Do not adjustthe lower adjustingbolts on the center glass guide. -4 Move the glass up and down to seat it, then measureclearance"8" at the designatedlocattons. - 5 Measureclea.ance"H" againto make sure it is still wilhin the specifiedlimits at the designated locations. NOTE: Repeatthe above steps until the correct clearancesafe obtained.
20-46
15. After the clearanceshave been adjusledproperly. reinstallthe weatherstrip.
1 7 . Check for water leaks. NOTE; Do not use high pressurewater.
16. Check that the glass contacts the weatherstrip evenly. NOTE: Measuringpoints are describedon page 20-42.
WEATHERSTRIP
Conter Pillar soction:
18. Routethe door harnessand connectors,and fasten them to the door (see pages 20-22, 331. 19. Disconnectthe oowef window switchfrom the doo. harness,then installthe power window switch on the door panel (see page 20-41). 2O. Attach the plasticcover,then installthe door panel (see pages 2O-2O, 321.
2047
Doors Striker Adjustment
PositionAdjustment NOTE: Placethe vehicleon a tirm, levelsurfacewhen adjustingthe doors.
Make surethe door latchessecurelywithout slamming. lf it needs adjustment;
After installingthe door, check for a flush fit with the body, then checkfor equalgapsbetweenthe front, rear, and bottom door edges and the body. The door and body edgesshouldalso be parallel.Adiust at the hingesas shown.
1 . Draw a line aroundthe st.iker for reJerence. Loosenthe screws,and move the strikerlN or OUT to make the latch tit tighter or looser.Move the striker UP or DOWN to align it with the latch opening. Then liqhtly tighten the screws and recheck.
CAUTION: Plac€ a shop towsl on tho jack to prevent damage to the door when loosening the dool and hingo mounting bolts for adjustmont. BOLTS DOORMOUNTING 8 x 1.25 mm 29 N.m l3.Okgl m, 22lbftrl Loosen lhe door mo!nting bolts slightlyto move the door lN or OUT until ir's flush waththe body. It necessary,you can installa shim behind one hingeto make the door edgesPAFALLELwith the body.
DOOR
HIIGE xrruceMouNTTNG BoLTs I x 1.25mm 29 N.m l3.O kgt'm,22 lbl'ft) Loosenthe hingemounting bolts, and move the door BACKWARDoI FORWARD, UP or DOWN as necessary to equalizethe gaps.
SHOPTOWEL
The door and body edges should be parallel.
20-48
I x 1.25mm 18 N.m ('1.8kgt.m, 13lbf.ttl
NOTE: Holdrhe outerhandleout, andpushthe door againstthe body to be sure the striker allows a flush fit. lf the door latchesproperly,tightenthe screwsand recheck.
Lower the glass,
NOTE: Check tor water leaks.
scREws
Mirrors PowerDoor Mirror Replacement Hstchback
Sedan
1. Pry out the cover panelwith a flat tip screwdriver, then removeit.
1. Removethe door panel (seepage 20-201and disconnect the connector.
CAUTION: When prying with a flat tip screwdriver. w'ap it whh protoctiva tapo to pravont damage.
2.
Pry the cover panelout with a flat tip screwdriver, then remove the cover panel. CAUTION: Whsn prying with a flat tip scrowd.lv€l, wrap it with protectiv€ taps to p.svont damag6.
HOOKS
2.
Disconnectthe connector.Removethe nuts, then removethe door mirror while holdinoit.
3.
< i Scrow locations
< : Nut locltion3,3
^^
Removethe screws while holdingthe door mirror.
, A< : Scrow, 2
sxo.8mm
I
!
| l m-t uto.+ .+rg r.m, I rst.. l$9| +111 i 3 lbl'lrl
,"",''@
.I s ' 0 . 4(0.4
- ---J'/
\
4 N.m
, B< : Scr6w, I
I 66 |
kst.m, \
\3_!!t.rrr__
sro.'"e-.
+ w.m (0.4 kgt.m,
\!Lbllq
cot{t{EcToB (Doo. mirror ddol
DOOR MIRROR
CONNECTOR lDoor harnoss .ide)
CONNECTOR
3.
Installation is the reverse o{ the removal procedure.
CONNECTOR
4.
Installation is the reverse of the removal procedure,
20-49
Mirrors Mirror Holder Replacement 1.
Carefullypry out the mirror holder with a tlat tip screwdriveras shown. CAUTION: To p.ev€nt damage to tha mirlor, wrap ths end ot a tlat tip screwdriv€r with a shop towel.
Mirror Visor and Mirror Covel Replacement Hatchback 1.
Removethe mirror holder.
2.
Turnthe actuatorforward.then removethe screws.
< : Scrawlocation3,4
MIRRORHOLDER 2.
Installationis the reverseof the removalorocedure. NOTE: Apply greaseto the locationsindicatedby the arrows.
Hatchback
3.
Detachthe hooks, then removethe mirror visor.
JOINT PIN
Sedan
MIRRORVISOR
JOINT PIN
20-50
I
4.
Turn the actuatorto the originalposition. Removethe screws,then removethe mirrorcover.
Sedan 1,
Removethe mirror holder.
2.
Turn the mirror base forward, then remove the screws.
< : Scrowlocttions,3
< : Sciow location! A< : Sc.ew, 4
8<: Screw, I
ACTUATOR
@ _ J
I
4E0 l . _ J
_
MIRRORBASE
5,
Installationis the reverseol the removalDrocedure, 3.
Detach the hook. then removethe mirror visor.
{cont'd)
20-51
Mirrors Mirror Visor and Mirrol Covel Replacement{cont'd) 4.
Removethe actuator,then removethe screws.
RearviewMirror Replacement 1 . Pry the cover off using the end ot a flat tip screwdriver.
<: Scraw locations A < : S c r € w ,3
B { : S c r e w ,2
CAUTION: To provent damage to tho miror and cov€l, wrap tho end of the screwdriver with I shop towol.
C < : S c . e w ,1
Remove the screws, then remove the rearview mtrror.
SCREW 5x0.8mm 4 N.m {0.4 kgf.m, 3 tbf.ftl
ACTUATOR
REARVIEW MIRROR
Turn the mirror base as shown, then removethe mirror cover
SHOP TOWEL
3.
MIRRORCOVER
lnstallationis the reverseof the removalprocedure.
20-52
Installation is the reverse of the removal procedure.
Windshield,RearWindow, OuarterGlass lndex NOTE: The numbersafter the part names show the quantitiesof the parts used. Hatchback UPPERMOLOING
UPPERRUBBERDAM
RIGHTSIDE CLIP E. 2 Whir€ Cl-lP F, 2 Loft. Whito Right. Bluo CLIP A, I Rod
RETAINER,6 Orengo CLIP B, 2 O.an96
CLIPC, 2 Black LEFTSIDEMOLDING Removal,page 20-55 Installation,page 20-56
e.'.
CLIP D. 2 G.6en
RETAINER, 2 Ysllow REARWINDOWMOLOING page 2O-65 Replacement,
UPPERSEAL
UPPERFASTENER,2 (S€lt-adh.sive-type,glass sid6l UPPERFASTENER,2 (Self-6dhosiv6-type,hatch sidel
SIDERUAAER DAM. 2
SIOESPACER.2
REARWINDOW Removal,page 20'6'1 Instaflataon,page 20-62
f ? * ""'^i^r.{"'/\ LOWERFASTENER.2 {Self-adh6siv€-type, glass sidel
LOWERFASTENER,2 {Selt-adhosive-1ype, hatch sid6)
ADHESIVETAPEB, 2
20-53
Windshield,RearWindow lndex NOTE: The numbersafter the part names show the quantitiesof the parts used. Sodan UPPER MOLDII{G
UPPERRUEBEROAM
RIGHT SIDE MOLDING
cLtP E, 2 Whir6 CLIP F, 2 L6ft. Whlto Righl. Bluo CLIP A, I Rod
&...€
e WINDSHIELD Removal,page20-55 Installation,page20-56
*aro,nr*. 6 o'!.gc CLIP B, 2 B?own
bq
,@ A
\ / '
GLASSBRACKET, 2
RET AINER. 2
Yollow
REARWINDOWMOLOING
2 UPPERFASTENER, {S.ll-.dho!lvo-typo,gh$ .ldcl
g .qB.....--
REARWINDOW Removal, page 20-68 Installation, page 20-69
urra" FAslEr{ER,2 (Cllp-typo, body .ld.l
&'.....- r,o, sPAcER, 4
R.-.......-"-.owER
FA'TENER. 2
lsolf-.dhe3ivo-type, sla$ sidol
\
LOWERCOVER
20-54
LOWERFASTENER, 2 (Solt-rdhe.lvo-typo. body sidol
Windshield Removal CAUTION: a Woar glovos to l€mov€ and install the windshiold, a Us€ saat covers to avoid damaging any surfaces.
3.
Removethe right and left glass brackels.
4.
Peeloft the upper molding.
1. To removethe windshield,first removethe: a Front pillartrim (seepage 20-911 . Headliner(seepages 20-98. 1OO) a Front wipers and air scoop (seesection 23) 2.
Detach the clips trom the retainers,then remove both side moldingsas shown. NOTE: lf necessary,replaceany dsmagedclips.
NOTE: Whenthe uppermoldingremovalis ditticult, cut the upper rubber portion O off, then cut the side rubber portion@. UPPER MOLDII{G
ADHESIVE
WINDSHIELD
f-CLIPC, D
5.
>
Removethe other retainerstrom the bodv.
lcont'd)
20-55
Windshield Removal(cont'd) 6.
lnstallation
Apply protective tape to along the edge ot the dashboard and body as shown. Usingan awl, make a hole throughthe rubberd8m and adhesivefrom insidethe car. Pushthe pianowire th.ought the hole, 8nd wrap each end arounda paece of wood.
w|l{osHlELo
1.
ScraDethe old adhesivesmooth with a knife, to a thickness of about 2 mm (O.O8in) on ths bonding surtace aroundthe entite windshieldopeningflange, NOTE: a Do not scrapedown to the paintsd surfaco ot the body; damaged paint will interfere with proper bonding. a Remove the rubber dam from the bodv. a Mask off surrounding surfaces betore painting.
2.
Cleanthe body bondingsurtacewith a spongedampened in alcohol. NOTE: Atter clesning,keep oil, greaseand water from getting on the surface.
3. WII{DSHIELD PIANOWIRE
lf the old windshi€ldis to be reinstalled,use a putty knife to scrape df{ all iraces oJ old adhesive, then cleanthe windshieldsurfacewith alcoholwhere new adhesiveis to bs applied. NOTE: Make su.e the bonding surface is kept {ree of water, oil and grease. CAUTION: Avoid sotllng thE wlndshiold on hs edges; small chips may latct dcvelop into crack3'
ADHESIVE DAM
Wilh a helperon the outside.pullthe pianowire back and forth in a sawing motion. and carefully cut through the rubberdam and adhesivearoundthe entire windshield. CAUTION: Hold tho dano vyi]oas clos6to tho windshield as possible to pr€vsnt damag€ to ths body and dashboard.
a Cleanthe shadowedarea. a Cleanthe area@ as shown. InCd.
+
vn77777ri_ t
wtt{DsHtELo
WINDSHIELD
8.
Carefullyremovethe windshield.
20-56 .--
4.
Center and glue the upper moldingto the upper edge of the windshield.
6.
Installthe glsss bracketsand retainersas shown. NOTE: The numbersatterthe pan namesshow the quantitiesof the psrts used.
ALIGNMENTMARK
BRACKET,2
GIuethe uDDerand lower rubberdamsto the inside face ot the windshield,as shown, to contain the adhesiveduring installation,
7.
NOTE: Be careful not to touch the windshieldwhere adhesivewill be applied.
12 mm {0.47 inl
Set the windshieldon the glassbrackets,then center it in the opening.Make alignmentmarksacrossthe windshieldand body with a greasepencilatthe four points shown. ALIGNMENTMARK
RUBBER UPPERMOLDING UPPER DAM
1O mm 10.39ln)
8.
Removethe windshield.
20-57
Windshield Installation(cont'd) With a sponge.apply a light coal oJ glass primer aroundthe edgeot the windshieldas shown, then lightly wipe it olt with gauzeor cheesecloth. NOTE: a Do not apply body primerto the windshield,and do not get body and glassprimerspongesmlxed up. a Nevertouch the primedsurfaceswith your hands. ll you do, the adhesivemay not bondto the windshieldproperly,causinga leakafterthewindshield is installed. o Keep water, dust, and abrasivematerialsawaY from the primed surface.
10. With a sponge,apply a light coat of body primerto the originaladhesiveremainingaround the windshieldopeningflange. Let the bodY primerdry tor at least 1O minutes. NOTE: a Do not apply glass primerto the body, and be careful not to mix up glass and body primer sponges, a Nevertouch the primedsurfaceswith your hands. a Mask otl the dashboard before painting the flange. //////, I Aeely bodv Primerh6te. 16mm {0.63in)
V//f, : apptv stassptimer hors.
5 mm {0.19 inl
UPPER
UPPERRUBBER WINDSHIELD
6 mm (0.23 in) 16 mm 1O.63inl
5mm ( O . 1 9i n l
RUBBER -
DAM .YJ * o
16 mm 10.63inl
>\ast, /
\
WINDSHIELD \ UPPERMOLOING
1 1 . Thoroughlymix the adhesiveand hardenertogether on a glass or metal plate with a putty knife. NOTE: a Cleanthe platewith a spongeand alcoholbefore mixlng. a Follow the instructions that come with the adhesive. 12. Beforefilling a cartridge,cut the end ol the nozzle, as shown. Cut nozzleend, 10 mm (O.39inl
7 mm 10.27in)
20-58 ,*-
13. Pack adhesiveinto the cartridgewithout air pockets to ensurecontinuousdelivery.Put the canridge in a caulkinggun, and run a beadot adhesivearound the edge ot the windshieldas shown.
15. Installthe clips on both side moldings. >: Clip localione A> : Clip A, I
NOTE: Apply the adhesivewithin 30 minutesafter applying the glass primer. 12 mm (0.47 in, T-/
l_/
UPPER RUBBER
: roxesrve
l
A
B < : C l i pB , 2
i
f f i l "___)
_)
U
C<: Clip C lHatchback,2l lsodan,4l D<: Cllp D {Hatchback,2l
8 m m lO.3'l inl
Make a slightlythicker
2mfi lO.O7 inl
E V : C l i pE , 2
MOLDING
LOWER RUBBEB DAM
I
F)
F llelt. Whitel lRight. Bluel
E lwhite)
I
A lRodl
'14.
Use suction cups to hold the windshieldover the opening,alignit with the alignmentmarks made in step 7, and set it down on the adhesive.Lightly push on the windshielduntil its edgeis fully seatedon the adhesiveall the way around. NOTE: Do not close or open the doors until adhesive is dry.
SIDE MOLDING
A (Rod)
/
It
B lHatchback, Orangel lsedan, B.own)
\
C (Hstchback, Elack) (Sodan, Orangel
SUCTION D lHatchback, Green) C (Sodan, O.ange)
16. Sc.apeor wipe the excessadhesiveoff with a Dutty knife or towel. NOTE: To removeadhesivetrom a paintedsurface or the windshield,wipe with a solt shoptowel dampened with alcohol.
20-59
Windshield lnstallation(cont'd) 18. Let the adhesivedry tor at least one hour. then spray water overthe windshieldand checkfor leaks.Mark leakingareas,and let the windshielddry, then seal with sealant.
17. lnstall both side moldings.
g
NOTE: a Let the car stand tor at leastfour hoursafter windshieldinstallation,lf the car hasto be used within the first four hours,it must be drivenslowly a KeeDthe windshielddry for the first hour after installation. a Check that the ends of the side moldingare set under the air scooP.
CLIPE
19. Reassembleall removedPans.
SIDEMOLOING
RETAINER
CLIP B
CLIP C, D
20-60
RearWindow Removal Hatchback CAUTION; a Use covsrs to avoid damaging tho interior. a Wear gloves to romove and install the glass. a Do not damags the defroster grid linss. a Tako care not scratch th€ raar window molding,
4.
CAUTION: Hold ths piano wire as clos€ to the roat window as possibleto prevont damageto the body and molding.
1. To removethe rear window. first removethe: a Rearshelt (seepage 20-91) a Hatch side trim and hatch trim panel (seepage 20-146) . High mount brake light (see section 23) a Rearwiper and wiper motor (seesection 231 2.
With a helperon the outside,pullthe pianowire back and forth in a sawing motion, and carefully cut through the adhesivethe along the top and the sides oJ the rear window.
Removethe rear window trim and disconnectthe connectors.
PROTECTIVETAPE
PROTECTIVE TAPE CONNECTOR
3.
Apply protectivetape to the innerand outer edges of the hatch. Usingan awl. make a hole th.ough the adhesivetrom the inside.at the top ot the hatch. Pushpiano wire through the hole, and wrap each end a.ound a piece of wood.
Cut the adhesivewith a knife at the bottom of the aearwindow. NOTE: Do not use piano wire in this area. 6.
Carefullyremovethe rear window.
MOLOING
NOTE: Replace the fasteners with new ones wheneverthe rear window has been removed.
20-61
-r
RearWndow lnstallation Scrapethe old adhesivesmooth with a knife to a thicknessof about 2 mm (O.O8in) on the bonding surface around the entire rear window opening flange. NOTE: a Do not scrapedown to the painted surface of the body; damagedpaint will interferewith proper bonding.
4.
Apply the upper sealto the insideface of glassas snown. Gluethe uppertasteners,lower fastenersand side spacers,to the insidetace ot the rear window on each side. UPPERSEAL
a Removethe upperand lower fastenerstrom the hatch. a Mask otf surroundingsurtacesbefore applying primer. Clean the hatch bonding surface with a sponge dampenedin alcohol. NOTE: After cleaning,keepoil, greaseor water trom getting on the surface. lI the old rearwindow is to be reinstalled,usea putty knile to scrapeott all tracesot old adhesive,then cleanthe rear window surfacewith alcoholwhere new adhesiveis to be applied. NOTE: Make sure the bondingsurfaceis kept tree of water, oil and grease. CAUTION: Avoid s€tting ths rear window on its edges; small chips may lator devalop into cracks, NOTE: Cleanthe shadowedarea,
REARWINDOW
20-62
F A S T E N E' R , 2 FASTENER,2 / ALIGNMENT
sroE SPACER,2
G||lethe lower fastenersand upperJastenersto the hatch, as shown.
7 . Set the rear window upright on the hatch, then center it in the opening. Make alignmentmarks acrossthe rearwindow and body with a greasepencil at the tour points shown.
1O. Installthe rear window trim.
ALIGNMENT MARKS
1 1. With a sponge, apply a light coat of glass primer around the edge of the rear window, then lightly wipe it ott with gauzeor cheesecloth.
8 . Removethe rear window. cl
Centerand glue the side rubbe.dams to the inside face of the rearwindow, as shown, to containthe adhesiveduring installation. NOTE: a Gluethe siderubberdams,usingthe printeddots as a guidea Be carefulnot to touch the rear window, where adhesivewill be applied. a Mask off surroundingsurfacesbefore applying pnmeI. REARWINDOW
NOTE: a Do not applybodyprimerto the rearwindow,and do not get body and glassprimerspongesmixed up. a Nevertouch the primedsurfaceswith your hands. lf you do, the adhesivemav not bondto the rear window properly,causinga leak after the rear window is installed. a Keep water, dust. and abrasivematerialsawav from the primed surlace. ////
, appV glass primor hero.
NOTE: Apply the glass primer, UPPER using the printeddots as a (0.0ainl guroe.
15 mm
10.6inl
MOLOING 1 5 m m {0.6 in}
REARWINDOW MOLDING
(cont'd)
20-63
RearWindow Installation(cont'd) 1 2 .With a sponge,apply a light coat ol body primerto the originaladhesiveremainingaroundthe rearwindow openingflange.Let the body primerdry tor at least 10 minutes. NOTE: a Do not apply glass primer to the body, and be careful not to mix up glass and body primer sponges. a Nevertouch the primedsurfaceswith your hands 7//,
15. Pack adhesiveinto the cartridgewilhout air pockets to ensurecontinousdelivery.Put the cartridge in a caulkinggun, and run a beadof adhesivearound the edge of ihe rear window, as shown.
it.E\,",1/: ADHESTVE UPPER 5 m m SEAL
1 0 . 1 9I n l
8mm 10.31inl
I Applv body p.lmor h.]o. MOLDING
10 mm {0.4 in)
40 mm 11.6 Inl 16 mln 10.63Inl 1 mm {0.04 inl
NOTE: Apply the adhesiv€, using the printed dots aa a guide.
fu.:*1",
lO.Oainl 16 mm {0.63 inl t|nm (O.35 Inl
)E--lT-* -\
MOLDING
I J.
Thoroughlymix the adhesiveand hardenertogether on a glassor metal plate with a putty knife' NOTE: a Cleanthe platewith a spongeand alcoholbefole mixing. a Follow the instructions that came with the adhesive.
1 4 . Beforelilling a cartridge,cut the end of the nozzle' as shown.
1O mm {0.39 inl
7 mm (0.27 inl
-C= /
/ GLASS
\
MOLDING
RearWindow Molding Replacement 16. Use suctioncups to hold the rear window over the opening,align it with the alignmentmarks made in step 7, and set it down on the adhesive.Lightlypush on the rear window until its edges are fulty seated on the adhesiveall the way around,
1.
Remove the rear window, then remove the uppGr seal.
2.
Placethe rear window on its surface,as shown, with a helperholdingthe rear window.
NOTE: Do not open or close the doors until the adhesiveis drv.
CAUTION: Avold setting the rea? ryindow on h! odgos: small chips may latol dovolop into cracka.
ALIGNMEI{T MARKS
3.
Cut the innerside rubberportionO olf the molding, then cut the top rubber portion @. REAR wtNDow
REARWINDOW
17. Scrapeor wipe the sxcessadhesiveotf with a Dutty knife or towel,
4.
Turn the rearwindow over, then cut the outer side rubber portion@ of the motding.
NOTE: To remove adhesive lrcm a painted swface or the rear window, use a soft shop towel damDened with alcohol. 18. Let the adhesivsdry tor at least one hour, then spray watgr over the raar window and check tor leaks. Mark leakingareasand let the rear window dry, then seal with sealant. NOTE: Let the car stand for at least tour hours al_ ter rearwindow installation.lf the car has to be used within the first four hours,it must be drivenslowlv.
5.
Scrapeall tracesof old moldingtrom the chamtered edges of the glass. NOTE: Be sure to scrapeall traces of old molding thoroughly.
19. Reinstallall remainingremovedparts.
6.
Cleanthe rear window su.tacewith alcoholwhere new moldingis to be installed. NOTE: Makesurethe su.faceis kept tree of waler, oil and grease. {cont'dl
20-65
RearWindow Molding Replacement(cont'd) 7.
With a brush. apply a light coat of glass primer aroundthe edge of the glass. NOTE: Scrapeotl excessglassprimerwith a putty knife after installingnew molding.
6mm 1O.23Inl
1O. Placethe rearwindow outside-up.then alignthe joint "T" mark at the top ot the ot the moldingwith the glass as shown.
JOINT
MOLOING
SUBFACE INSIDESURFACE 6mm
(0.23inl
8 . Degrease the inner surfaces ol new molding
thoroughly,then apply a light coat ot glass primer to the surtaces. wtNDOW NOTE: a Apply glassprimeraroundthe entiregrooveof the new molding, a Do not apply glass primerto the outer surface.
1 1 .Pressthe molding into position around the entire edge of the rear window. NOTE: Checkthat the moldingis not wrinkledor lifted awav at corners.
L
Run a bead oJ adhesivein the groove of the molding'
MOLDING MOLDING
20-66
12. Scrape o. wipe the excess adhesiveofJ with a Dutty knife or gauge. NOTE: Cleanthe moldingand rearwindow surface with alcoholwhere upper seal is to be apptied.
1 5. Scribe a line on the molding lip with a greas€pencil to show the cutting portion ot the molding lip, as shown.
{Gla*r Surtacel Surfaco to be wiped clean.
{Gla$ Insido Surtacel
1 mm (0.04 In)
16. Cut the moldinglip off, as shown. 13. Apply the uppersealto the insideface of glass(see page 2O-621. 14. After the adhesiveis dry, use suctioncups to hold the rearwindow over the opening,set the rearwindow on the hatch, then center it in the opening. SUCTION CUPS
MOLDING LIP
17. Closethe hatch, then check the gap between the moldinglip and body. 18. lf the moldinglip contactsthe body, cut the molding lip off. keepingthe gap para el wiih the body.
20-67
RearWindow Removal 4.
Sadan
Peel off the molding. NOTE: When moldingremovalis difficult, cut the moldingwith a knife.
CAUTION: a Wear gloves to remove and install the leal window. a Do not damage the delloster grid lines.
MOLOING
1. To removethe rear window, f irst remove: . Trunk lid {see page 20-149) a Rearseat-backside bolsters(seepage 20-11 1) . Rearshelf (see page 2O-95) a Rearpillartrim panel {seepage 20 95) 2.
REARWINOOW
Disconnectthe defrosterleads, and remove their holders. NOTE: Avoid scratchingthe rearwindow with the cutter blade.
3.
S
Removethe clips, then removethe lower cover. NOTE: Use a clip removerto removelhe clips. REAR
wlNDow Pull down the rear of the headliner (see page 20-101). CAUTION: Take care not to bend the headlinerexcessively. o.
Apply protectivetape to the edge of the body, as shown. Usingan awl. makea holethroughthe adhesivefrom insidethe car. Pushthe pianowire throughthe hole and wrap each end around a piece of wood. PROTECTIVETAPE
ADHESIVE
/ - a,o*o*'*a
MOLDING HEADLINER
PIANOWIRE LOWERCOVER
LowERsPAcER/ ;ru/ FASTENER LowER
oore,srvr \3
PRorEcrtvE rlee
20-68 ---
Installation 7 . With a helperon the outside,pullthepianowire back and torth in a sawing motion, and carelully cut through the adhesivearoundthe entire rear window.
Scrapethe old adhesivesmooth with a knite, to a thicknessof about 2 mm (O.08in) on the bonding surface around the entire rear window opening flange.
CAUTION: Hold tho piano wir€ as closo to the real window as possibleto prevent damageto the body. a Do not scrapedown to the painted sudace of the body; damagedpaint will interferewith proper bonding. a Removethe upper and lower fastenerstrom the body. a Mask off surroundingsurfacesbefore applying Dflmer.
REARWINDOW
2.
Cleanthe body bondingsurfacewith a spongedampened in alcohol. NOTE: After cleaning,keep oil, greaseand water from getting on the surface.
3.
PIANO wlRE
ll the old rearwindow is to be reinstalled,usea Dutty knifeto scrapeoft all tracesof old adhesive.then cleanthe rear window surfacewith alcoholwhere new adhesiveis to be aDolied. NOTE: Make sure the bondingsurfaceis kept free of water, oil and grease.
8.
Carefullyremovethe rear window.
CAUTION: Avoid setting the rear window on its edges; small chips may later develop into cracks.
Cleanthe shadowedarea.
/s \\--
t\
{cont'd)
20-69
RearWindow lnstallation (cont'd) 4.
Apply the double-facedadhesivetape to the inside o{ the rear window, as shown
6.
Install the upper fasteners and glue the lower fastenersto the bodY,as shown. NOTE: The numbers atter the parts names show quantity of the Part used.
lnside
0.16 mm (0.006 inl 5 0 0 m m ( 1 9 . 7i n )
5OOmm 119.7in)
ALIGNMENT MARKS
Glue the moldingaroundthe edge oi the rear window, as shown.
7.
Gluethe sideandlower spacersand tastenersto the inside face ot the rear window and molding, as shown. NOTE: The numbersafterthe part namesshow the quantitiesof the Partsused.
5 O Om m 1 1 9 . 7
> : Spac6r,lastonellocations
SIDE S P A C E R , 4^
lo, \./O
MOLDING
'7:^ c
rs s-." \\t--
MOLDING
l\ 4!9!llEN,r_r\,ry!s q la,Loqrcen.t
(4relycv!|I!"
l$;*
\'*'w \ o.f9!T.nl"1"*"
ALIGNMENT MARKS
20-70
8. Set the rearwindow, then centerit in the opening. Make alignmentmarksacrossthe rearwindow and body with a gfease pencilat the tout Dointsshown. ALIGT{MENTMARKS
S
1 1. With a sponge.apptya light coat ot body primerro the originaladhesiveremainingaroundthe rearwindow opening flange. Let the body p.imer d.y tor at least 10 minutes. NOTE: a Do not apply glass primer to the body, and be careful not to mix up glass and body primer sponges. a Nevertouch the primedsurfaceswith vour hands. l//////1,:appv body p'imo' hero.
i"lT ;o:d:';",
16 mm 10.63inl
9. Removethe rear window. O. With a sponge, apply a light coat of glass primer around the edge of the rear window as shown, then lightly wipe it otf with gauze or cheesecloth. 6 mm 10.23inl NOTE: a Do not apply body primerto the rear window, and do not get body and glassprimerspongesmixed up. a Nevertouch the primedsurfac€swith your hands. lf you do, the adhesive may not bond to the rear window prope.ly, causing a leak after the rear window is installed. a Keep water. dust, and abrasive materials awav f,om the D.imedsurtace. 72/:
Appl,t gltst onmrr sctc.
16 mm 10.63inl
12. Thoroughlymix the adhesiveand hardenertogether on a glassor metal plate with a putty knife. Fo ow the instructionsthat came with the adhesive. NOTE: Cleanthe plate with a spongeand alcohol before mixing.
All around. 10 mm lO.4 inl
/.s s
13. Beforefillinga cartridge,cut the end of the nozzle, as shown.
10 mm (0.39 in)
7 mm (0.27 inl
{cont'd)
20-71
RearWndow Installation(cont'dl 14. Pack adhesiveinto the cartridgewithout air pockets to ensurecontinuousdelivery.Put the cartridge in a caulkinggun, and run a beadof adhesivearound the edge oI the rear window, as shown. NOTE: Apply the adhesivewithin 30 minutesafter applyingthe glass Primer.
16. Scrapeor wipe the excessadhesiveoff with a putty knife or towel. NOTE: To removeadhesivefrom a paintedsurtace or the rear window, use a soft shop towel dampened with alcohol. 17. Installthe lower cover.
12 mm (O.47inl
[/
, aoxesrve
t-l
ADHESIVE
^X-"--"-,
s-_T--r-
8 mm (o,31inl REAR WINDOW
\
I MOLOING
cr-rss
1 5 . Use suctioncups to hold the rearwindow over the opening,align it with the alignmentmarks made in step8, andset it down on the adhesiveLightlypush on the rear window until its edgesare fully seated on the adhesiveall the way around. NOTE: Do not close or open the doors until the adhesiveis drv. SUCTION
20-72
ALIGNMENT
'18. Let the adhesivedry for at least one hour, then spray water over the rear window and check Jor leaks' Mark leakingareas,let the rearwindow dry, then seal with sealant. NOTE: Let the car stand Jo. at leastfour hoursafter rear window installation,lf the car has to be used within the tirst tour hours,it must be drivenslowly' 19. Raisethe headlinerback up into position,then install: a Rear pillart.im Panel a Rear shelf a Rearseat-backside bolstels
OuarterGlass Replacement a W€ar glov€s to romove and installthe quartol glass. a Use seat covers to avoid damaging any surfaces.
3.
NOTE: Replacethe quarter glass with new one when removingit. 1.
2.
Pullthe piano wire back and forth in a sawing motion, and carefullycut throughthe adhesivearound the entire quarterglass. CAUTION: Hold th€ tiano wire as closoto the qurter glass as possibleto prevent damage to th6 body and quarter pillar trim panol.
To removethe quarterglass,first removethe quarter trim (seepage 20 93).
NOTE: Wheneachcornercut is difficult.usea knife to cut through the adhesivefrom insidethe car.
Apply protectivetape to the edgeof the quarterpillar trim panel and body as shown. Usingan awl. make a holethrough the adhesivefrom insidethe car. Pushthe pianowire throughtthe hole, and wrap each end around a piece of wood. OUARTERPILI.AR TRIM PANEL AOHESIVE
PROTECTIVE TAPE
OUARTERGLASS
PIAI{O wlRE
PROTECTIVE TAPE
OUARTERGLASS
CLIP PROTECTIVE TAPE
ADHESIVE TAPE
ADHESIVE OUARTERPILLAR TRIM PANEL
ADHESIVE
PROTECTIVE TAPE
4.
Carefullyremovethe quarterglass.
20-73
OuarterGlass Replacement(cont'd) Scrapethe old adhesivesmooth with a knife. to a thicknessof about 2 mm (O.08in) on the bonding surface around the entire quaner glass opening flange. NOTE: a Do not scrape down to the painted surface of the body: damagedpaint will interferewith proper bonding. a Mask oft surroundingsurfacesbefore applying orimer. b-
Cleanthe body bondingsurfacewith a spongedampened in alcohol. NOTE: Atter cleaning,keep oil, greaseand water from getting on the surtace.
8.
adhesivetapesto the moldApply the double-faced ing, as shown, NOTE: o Be careJulnot to touch the quarter glass where adhesivewill be applied. a Do not peel the separatoroff the double-taced adhesivetaPes.
srDE sPAcERI \ nrolonci
\ /
IfR-.s -l
3 mm (0.12 inl
i
ADHESIVE TAPE8
i
MOLDING
I
_c$$l Cleanthe new quarter glass surface with alcohol where adhesiveis to be aDDlied. NOTE: Make surethe bondingsurfaceis kept tree of water, oil and grease. CAUTION: Avoid setting th€ quartsr glass on its edgas; small chips may later d€velop into cracks. 195 mm (?.68 in)
150 mm 15.9 inl
CLIP 4 . 5 m m 1 O . 1 8i n l
ADHESIVE
Clean the shadowed area all the way around.
CLIP MOLDING
MOLDING
9.
With a sponge.applya light coat of glassprimerto the insideface ot the quarterglass,as shown, then lightly wipe it ott with gauze or cheesecloth.
1O. Installthe quartertrim. OUARTER
NOTE: a Do not apply body primerto the quaner glass,and do not get body and glassprimerspongesmixed up. a Nevertouch the primedsurlaceswith your hands. lf you do, the adhesivemay not bond to the quaner glassproperly,causinga leakafter the quarter glass is installed. a Keepwater, dust. and abrasivematerialsawav from the primedsurface. V///
, AooV glass primer h6re1 1. With a sponge.apply a light coat of body primerto the originaladhesiveremainingaroundthe quarte. glass openingflange. Let the body primer dry lor at least 1O minutes. NOTE: a Do not apply glass primerto the body, and be careful no1 to mix up glass and body prime. sponges. a Nevertouchthe primedsurfaceswith your hands. '////7, , aepty body p.imer here.
5 m m lO.2 inl
ffi 10 mm lO.4 inl
16 mm 6mm 10.24in) {0.63 in}
'16
mm (0.63 inl OUARTER TRIM
10 mm lO,4 inl
5 mrr| 10.2inl
(cont'd )
20-75
OuarterGlass (cont'd) Replacement 12. Thoroughlymix the adhesiveand hardenertogether on a glass or metal plate with a putty knife.
t5.
to.
NOTE: a Cleanthe platewith a spongeand alcoholbefore mixing. a Follow the instructions that came with the adhesive. 13. Beforetillinga cartridge,cut the end of the nozzle, as shown. Cut nozzleend, as shown.
Installthe fastenersto the body as shown. Use suctioncups to hold the quarterglassover the opening,alignit with the clip settingpoints,and set it down on the adhesive.Lightlypuch on the quarter glassuntil its edgesare tully seatedon the adhesive all the way around. NOTE: Do not open or close the doors until the adhesiveis dry.
10 mm 10.39in)
7 mm {0.27 inl
14. Pack adhesiveinto the cartridgewithout air pockets to ensurecontinuousdelivery.Put the cartrige in a caulkinggun, and run a beadof adhesivearound the edge of the quarter glass as shown. NOTE: a After applyingthe adhesive,peel the separator off the double-facedadhesivetapes. a Apply the adhesivewithin 30 minutesafter applying the glass Primer.
t1;T,,1\
:ADt'Es'vE
17. Scrapeor wipe the excessadhesiveoff with a putty knile or towel,
I mm 10.3in) 8 mm lO.3 in) AOHESIVETAPES 8
-1r *-{6
2mm{0.08
IL_-_ J,
NOTE: Usea soft shoptowel dampenedwith alcohol to removeadhesivefrom a paintedsurfaceor the quarler glass. 18. Letthe adhesivedry for at leastone hour,then spray water over the quarter glass and check for leaks' Markleakingareasand let the quarterglassdry, then seal with sealant. NOTE: Let the car stand for at least tour hoursatlf the car hasto be used ter quarterglassinstallation. within the f irst four hours,it must be drivenslowly.
SIOE SPACER
'19.
ADHESIVE TAPEA '12 mm (0.47 inl
20-76
2 mm lO.O8in)
Reinstallall remaningremovedparts.
Moonroof Index Hatchback
CABLE ASSEMBLY Replacement,page 2O-81
SUNSHADE page 20-79 Replacement,
MOTOR page 20-80 Replacement,
GLASS BRACKET page 20-81 Replacement,
SUI{SHADE RAIL FRONT DRAII{ CHANNEL
a'# /
DRAIN CHANN€L
-4
FRAMESEAL
GUIDERAIL page 20 8l Replacement, FRONTRAIL HOLDER
,**4
REAR ORAINTUBE
U
\a FRAME
20-77
Moonroof Troubleshooting Probable Cause
Symptom Water leaks
1 Cloggeddrain tube. Gap between glass weatherstripand roof panel. Defectiveor improperlyinstalledglass weatherstrip. 4 GaDbetween drain seal and roof panel.
Wind noise
1. Excessiveclearancebetween glass weatherstripand roof panel.
Motor noise
1. Loosemotor. 2. Worn gear or bearing. 3. Cableassemblydeformed.
Glassdoes not move, but motor turns
1. Clutch out of adjustment. 2. Foreignmatter stuck between guide rail and slider, 3. Inner cable loose. 4. Cableassemblynot attachedproperly.
Glassdoes not move and motor does not turn (glasscan be moved with moonroofwrench)
1 . B l o w nf u s e . 2. Faultyswitch. 3. Battery run down. 4. Defectivemotor. 5. Faulty realy.
GlassHeightAdiustment The roof panelshouldbe even with the glassweathers t r i p ,t o w i t h i n l 8 t O . 5 m m ( O . O 7I 0 . O 2i n ) a l l t h e way around. It not, slidethe sunshadeback, and:
Y : Bolt locstions, 6
1 . Tilt-up the glass.
2 . Loosenthe bolts and adjustthe glass. Repeaton oppositeside it necessary.
1 . 8 1 0 . 5 m m l O . O 7i 0,O2 in)
i
ROOFPANEL
GLASS ERACKET
GLASS WEATI{ERSTRIP
4.
Side-to-side fit ot glass weatherstrip can be adjusted by loosening the frame mounting bolts and moving the frame right or lelt and forward or backward by hand (see page 2O-8O).
20-78
GLASS BRACKET
f )
RearEdgeClosingAdjustment Open the glass about a foot, then close it to check where rear edge beginsto rise. lf it rises too soon and seats too tightly againstthe roof panel,or too late and does not seat tightly enough,adjust it. 1.
Removethe headliner(seepsge 20-98).
2.
Removethe glass.
3.
Removethe motor {see page 2O-8O).
4.
Align the tilt-up positionof the lifter on each side.
Glass and Sunshade Redacernent 1.
Open the sunshade.
2.
Tilt-upthe glass.
3.
Removethe bolts, then removethe glassfrom rhe glass bracket. V : 8oh locations,6
GLASSBRACKET
Checkthat the alignmentleft and right. then install the motor.
4.
Removethe screw and lift the sunshaderailon each side.
5.
Silde the sunshade forwa.d, then remove the sunshade. V : Scrawlocations,2
Installthe glass,then check for water leaks.
II
NOTE: Do not use high pressurewate.. lnstallthe headliner.
SUNSI{ADE
l-t
)
6
Installationis the reverseof the removalprocedure.
7
Check for water leaks. NOTE: Do not use high pressurewater.
20-79
Moonroof Motor, DrainTube and FrameReplacement CAUTION: B€ caretul not to damag€ lhe seats, dashboard and other interior trim.
4.
Removethe bolts,then removethe trame from the car.
1. Removethe glass (see page 2O-79)and headliner (see page 20-98). 2.
Disconnectthe drain tubes.
NOTE: You may requireassistancewhen removing the frame.
Disconnectthe motor connector,and removethe clips securingthe ceilinglight wire harness.
: Eolt locations, I < : CliD locations. 2 6 x 1.0 mm 9.8 N.m (1.0kgt m, 7.2 rbr.ttl )
CEILIINGLIGHT
TUBECI-IP
FRAME
FRAME
3.
DRAIN TUBE To install,slidethe drain tube over the ftame nozzle at least 10 mm {O.4 in}.
Removethe bolts and nuts,then removethe motor, if necessarv, NOTE: Make sureboth slidersare parallelwhen in-
6.
Pull the drain tubes out the front and rear pillars. NOTE; Betorepullingout the draintube, tie a string to the end of it so it can be reinstalled.
stalling the motor. : 8olt, nut locationg A
: Bolt, 2
B : N u t ,3 Ld
6x1.Omm 9.8 N.m
I I
tt.o kgf.-,
,.?-", _,/I
FRONT
7 . Installationis the reverseol the removalprocedure. NOTE: a Cleanthe surtaceof the frame. a Check the trame seal. a Check for water leaks.
20-80
GlassBracket/Slider, Lifter, GuideRailsand CableAssemblyReplacement 1 . Removethe frame from the car {see page 2O-8O).
5.
Removethe motor (seepage 2O-8O).
Removethe front rail holderon each side.
V : Nut, scrow locations AV : f{ut, 2
Removethe drain channel.
BV: Screw,
NOTE: Take care not to damage,twist or lift the seat. SUNSHADE V : Screwlocations,2 DRAIN CHAI{NEL
b.
Removethe anchorspring on each side.
7.
Removethe nuts and screws, then lift and remove both guiderailsand cableassemblyfrom the trame. Removethe sunshadeand both sunshaderails.
V : Nut, rcrow locations AV : Nut. 2
4.
BV : Sciow, 4
Removethe front drain channel on each side.
V : Clip locations,2 NOTE: To instalt,Iill the gtoove rn each grommet with sealant, GUIDERAIL
GUIDE RAIL
20-81
Moonroof GlassBracket/SliderLifter GuideRailsand CableAssemblyReplacement (cont'dl 8.
Slidethe guide rail fofward, then removeit.
1 0 .Slide the anchor rod forward, then remove it from the guide rail.
NOTE: Take care not to bend the inner cable.
CABLE ASSEMBLY
STOPPER
To install. insort the anchor rod by turning the stopper 9Oo.
GUIDERAIL
q
Separatethe glassbracket,lifter, slidestopperlink and slider,
ROD AIT|CHOB
11. lnstallationis the reverseol the removalprocedure. INNERCABLE
GLASS
SLIOER NOTE: To inst€ll,apply multipurposegreaseto the lifter and slide stooDer link.
20-82
NOTE: a Dsmsgedpansshouldbe replaced. . Applygreaseto the slidingportion.
Opening Drag Check (Motor Removedl Betoreinstallingthe motor, measurethe etfort required to open the glass using a spring scale as shown. CAUTION: When using a spring scale, protoct the leading edg6 ot th€ glass with a shop towel. lf load is over 40 N (4 kgt, 9lbf). check side clearance and glass height adjustment(see page 2O-78).
Closing Force Check (Motor Installedl 1. After installingall removedparts,havea hetperhotd the switch to close the glass while you measure torce requiredto stop it. Attach a spring scale as shown. Readthe force as soon as the glasssiops moving, then immediatelyreleasethe switch and spnng scare. CAUTION: When using a spring scale, protoct tho leading odge ol th€ glass with a shop towel.
200-290 N (20- 30 kgf, rt4- 66 lbf)
GLASS
\
lf the force is not within specification,installa new lock washer,adjustthe tensionby turningthe motor clutch adjustingnut, and bend the lock washer againstthe motor clutch adjustingnut. LOCK WASHER Replace.
'r
coul{TERcLocKwrsE To decrease
20-83
Moonroof lndex Ssdan
GLASS BRACKET Replacement,page 20-88
----/_--4 DRAIN CHANNEL SUNSHAOE Replacement,page
SLIDE STOPP€RLINK
SUNSHADERAIL FRONTORAIN
GUIDERAIL Replacement,page 20-88
REARRAIL HOLDER
MOTOR page20-87 Replacement,
SEAL
REAR DRAIN
('
/
20-84
\
V \ FROi{TDRAINTUBE
FRAME Repfacement,page 20-87
e
Symptom
Probable Cause
Water leaks
1. Cloggeddrain tube. 2. Gap between glass weatherstripand roof panel. 3. Defectiveor improperlyinstalledglass weatherstrip. 4. Gap between drain seal and roof panel.
Wind noise
1. Excessiveclearancebetween glass weatherstripand root panel.
Motor noise
1. Loosemotor. 2, Worn gear or bearing, 3. Cableassemblydeformed.
Glassdoes not move, but motor turns
1. 2. 3. 4.
Glassdoes not move and motor does not turn {glasscan be moved with moonroofwrench)
1 . B l o w nf u s e . 2. Faulty switch. 3, Battery run down. 4. Defectivemotor. 5. Faulty relay.
Clutch out of adjustment. Foreignmatter stuck between guide rail and slider. lnner cable loose. Cableassemblynot attachedproperly.
Glass Height Adjustment The roof panelshouldbe even with the glassweathers t r i p t, o w i t h i n1 . 8 t O . 5 m m { O . O 71 O . O 2i n }a l l t h ew a y around. lf not, slidethe sunshadeback, and:
V : Eolt localions, 6
I 6x LOmm "), 9 . 8 N . m 1 1 . Ok g f m 7.2 tbf.ttt
1 . Tilt-upthe glass.
2 . Loosenthe bolts and adjust the glass. GLASS
Repeaton oppositeside if necessary.
4'/ 10.5 mm lO.O7 1O.02 inl
ROOF PANEL GLASS ERACKET
GLASSWEATHERSTRIP 4.
Side-to-side fit of glassweatherstripcan be adjusted by looseningthe frame mountingbolts and moving the frame right or lett and forward or backward by hand (see page 20-87).
GLASS BRACKET
12
Forward
Moonroof Rear Edge Closing Adjustment Open the glassabout a foot, then close it to check where rear edge beginsto rise. It it risestoo soon and seats too tightly againstthe roof panel,or too late and does not seat tightly enough,adjust it.
Glass and SunshadeReplacement 1.
Open the sunshade.
2.
Tilt-up the glass.
3,
Removethe bolts, then removethe glassfrom the glass bracket.
1. Removethe headliner(seepage 20-1OO). 2.
Removethe glass.
3.
Removethe motor (see page 20-87).
4.
Align the tilt-up positionof the lifter on each side.
Using the moonroof
BOLTS 6 x 1 . Om m 9.8 N'm lt O kgf m, 7.2 tbt.ftl
GLASS BRACKET
4.
Removethe screws and lift the sunshaderails.
5.
Silde the sunshade forward. then remove the sunsnaoe.
5 . Checkthat the alignmentlett and right, then install the motor. o.
SUlTSHADE RAIL
Installthe glass.then check for water leaks. NOTE: Do not use high pressurewater.
7.
Installthe headliner.
Installationis the.everseot the removalprocedure. Check for water leaks. NOTE: Do not use high pressurewater.
20-86
Motor, DrainTube and FrameReplacement CAUTION: Be carotul not to damago th€ seats, dashboard and other int6rior trim, 1. Removethe glass (see page 2O-86)and headliner (see page 20-10O). Disconnectthe motor connector,and removethe clips securingthe ceilinglight wire harness. SCREW
NOTE: To removethe motor, removethe screws. Disconnectthe drain tubes. 4.
\/
Loosenthe front bolts. Removethe bolts,then removethe trame from the car. NOTE: a You may requireassistancewhen removingthe trame. a Take care not to bend the sunshaderails. TUBE CLIP
CONNECTOR
Make sure the sliders are parallel when installing the motor,
FRAME
BOLT 6 x 1 . 0m m 9.8 N.m (1.Olg{.rn. 7.2 tbt.ttl DRAINTUBE To install,sladethe drain tube ov6r the frame nozzleat least 10 mm lO.4 in).
Loosen the tront bohs Fo?w!?d
SUNSHADE RAILS
tt.
Pullthe draintubes out of the tront and rearoillars. NOTE: Beforepullingout the draintube, tie a string to the end of it so it can be reinstalled.
Installationis the reverseof the removalgrocedure. FRONT DRAIN VALVES NOTE: a Installthe tube clips with the ends facing the side to ease installation of the headliner. a Cleanthe surtaceof the frame. a Check the frame seal. a Check for water leaks. a Make sure the sunshademoves smoothlv.
20-87
Moonroof
Lifter,GuideRailsand CableAssemblyReplacement GlassBracket/Slider,
1 . Removethe frame (seepage 20-87). 2.
3.
Removethe screws,then removethe sunshaderail by slidingit backward.
Removethe drain channel. SUNSHADERAIL
NOTE: Take care not to damage,twist or litt the seal. SCREW
4.
Removethe motor (seepage 20-87).
5.
Removethe front drain channel.
6.
Removethe nut, then removethe front rail holder.
7.
Removethe screws @ attschingthe guide rail. then litt the guide rail.
8.
Removethe nut. then removethe rear rail holder.
ITUT 6xl.Omm 9.8 t{.m {1.0 kgt.m, 7.2 tbf.ttl
NOTE: Removethe anchorspring. AI{CHOR
REAR RAIL HOLDER
SUB-SEAL
NUT
6 x 'l.O mm 9.8 N.m {1.O kgf.m, 7 .2 tbt-lrl
NOTE: Installthe rear rail holder, then glue the sub-seal to the trame.
9,
Slidethe glass bracket/slider,liJterbackward,then removeit.
20-88
10. Separatethe glass bracket, lifter, slide stopper lank and slider.
INNERCABLE
LIFTER
GLASS BRACKET
1 2 . Slidethe guide rail backward, then removeth€ gude rail from the inner cable. NOTE: To install.apply the caulkingro gurde rarl mount faces of the frame.
GUIDE RAIL
SLIDER
NOTE:To install,applymuttjpurpose grcase to th€ liftsr and slidestopperlink.
Applycaulking before instaing the guiderait.
1 3 .Removethe screws,then removethe cableassem1 1. Slidethe anchorrod forward, then removeit from the guide rail.
bly from the frame. NOTE: Take care not to bend the cable pipes. FRAME
STOPPER
To install, inson tho anchor rod by turning tho stopper 9Oo
NOTE:lo install,fill the groovein eachgrommetwith sealant. 1 4 . Installationis the reverseof the .emovalprocedure. AI{CHOR ROD
NOTE: a Damagedpsrts should be replaced. a Apply greaseto the slidingportion.
20-89
Moonroof OpeningDragCheck (Motor Removed) Beforeinstallingthe motor. measurethe effort required to open the glass using a springscale as shown CAUTION: Whon using a spring scalo. protoct the l€ading odge ol the glass with a shop tow€I. lf load is over 40 N (4 kgl, 9lbt), check side clearance and glass height adiustment(see page 20-85)'
Closing Force Check lMotor Installed) 1. After installingall removedparts,havea helperhold the switch to close the glass while you measure force requiredto stop it. Attach a spring scale as shown. Readthe torce as soon as the glass stops moving, then immediatelyreleasethe switch and spring scale. CAUTION: When using a sp ng scala. protect th€ leading odge ol the glass with a shop towel' ClosingForce:200-290 N 120-30 ksf. 44-66
lbf)
GLASS
\
lf the lorce is not within specification,installa new lock washer.adjustthe tensionby turnangthe motor clutch adjustingnut, and bend the lock washe. againstthe motor clutch adjustingnut.
clocKwlsE/i 1 Toincrease \ l, torce,
20-90 L.
I
coutrenctocKwlsE Io decrease force
InteriorTrim Replacement a W€al glovesto removeand installth€ trim and panols. a When prying with a flat tip screwd.ivor. wrap it with protective tap€ to prevent damaga. NOTE: Take care not to bend or scratchthe trim and Danels.
Hatchback Rear trim panet/Sidetrim panel/Ouarterpillar trim p-l 16moval: 1. Open the hatch. 2.
Kick panel/Front pillar trim removal:
Removethe .ear shelt. REARSHELF
l.
Removethe kick Danel. < : Clip locations A< | Cllp,1
B< : Ctip,1
CV : C[p, 1
U ry-ry J t l , M l *
NOTE: Removethe driver'skick panelwhile pulling the hood releasehandle.
REARSHELF KICK PANEL
Removethe rear seat (seepage 20-'l08). 4.
Removethe trunk mat and sparetire lid.
Pullthe door trim back,then removethe front oillar rflm.
< : Clip locations, 4
SPARETIRELID
FRONTPILLAR
TRUNKMAT
lnstallationis the reverseof the removalprocedure. NOTE: lf necessary,.eplaceany damagedclips.
ao..t dr
20-91
lnteriorTrim (cont'd) Replacement 5.
7.
Removethe rear trim panel.
Removethe side trim Panel.
> : Clip locations
v : Clip locations,7 1 ) P u s ht h e i n n e rc l i p . - 2 ) D e t a c ht h e c l i p b y pulling it. NOTE:Do not push it in too lar.
INNERCLIP
@ M)
BD : Clip, 4
A> : Clip. 4
W-tNj w) !) DV : Clip, 1
CD : Clip, 3
,Ull
|
,,zqzz4 |
> : Boll, screw locations
A> : Bolt,2
B > : S c i o w ,2
@-, PANEL
Removethe speakerlid and left accesspanelfrom the side trim panel. > : Clip locaiions 8V : CliP,2
A> : Clip, 2
,e-,ff)
ffi
i,Gffi'^*^
,Kl^\ fo
B
SPEAKER LID
\ LEFT
accEss PANEL
NOTE: Disconnectthe cargo area light connector trom the left side trim Panel.
CARGO AREA LIG}IT
8. Removethe upper anchorbolts from the front and rear seat belts (seepages 20-1 15, 1 19).
11. Removethe quarterpillartrim panel. > : Clip locations
9. Removethe door trim. A>: Clip7 , NOTE: When installingthe door trim, align it with the door openingflange notch.
Btr: Clip3 .
S;+ )
NOTE: Removethe front seat belt lrom the belt 9UrOe.
BELT 1O. Removethe quartertiim and coat hangerfleft sidel. : Screw locstions, 'l
Pry lhe lid.
'12.
Installationis the reverseof the removalprocedure. NOTE: a lf necessary,.eplaceany damagedclips. a When installingthe side trim panel, make sure there are no twists or kinks in the front and rear seat belts. a Wheninstallingthe reartrim panel,installtheclip as follows. - 1 I Pull the inner clip up as shown.
t Q-.-INNER cLrP (./ilk \c4z )
\/
tl
\#
-2) Installthe clip in the rear trim panel.then push the inner clip until it's flush. INNERCLIP
20-93
lnteriorTrim Replacementlcont'dl Removethe front and rear door trim
3.
Sodan
NOTE: When installingthe ffont and rear door trim, align them with the door openingflange notch.
Center pillar lower trim/Center pillal trim removal: Removethe belt hole cap, then slip the front seat belt through the slit in the belt hole cap.
1.
<: Sc.ew location,1
e)
I
FRONT SEAT BELT
BELTHOLE CAP
v
)
CENTERPILLAR LOWERTRIM
2.
Removethe upperand lower anchorbolts trom the tront seat belt, then removethe center pilla.lower tirm. NOTE: a When removingthe anchorbolts, use a 17 mm socket or box-endwrench. a On reassembly,replacethe upperanchorbolt (* ) and use liquidthread lock.
4.
Removethe center pillartrim.
< : Cllp locations.2
A : Clip localions.2 nfa147zzn
trui L_,)
*UPPER EOLT ANCHOR 7/t6-20 UNF 32 N m (3.3 kgf'm, 24 lbl ft) ANCHOR COVER FRONT
SEAT EELT
CENTERPILLAR TRIM
CENTERPILLAR LOWERTRIM
lnstallationis the reverseoJthe removalprocedure.
ANCHOR CAP
20-94
LOWERANCHOR BOLY 7/16-20 UNF 32 N.m 13.3 kgt.m, 24 lbt.ltl
NOTE: a lf necessary,replaceany damagedclips. a Beloreattachingthe centerpillarlower trim and belt hole cap. make sure there are no twists or kinks in the front seat belt.
Roar pillar tlim panel/Rearshell trim panel/Rsar she removal: 1.
2.
4.
Bemove the rear shelf trim panel.
V : Clip locrtions, 2
Remove both seat-back side bolsters {see page 2 0 - 11 1 ) .
f
r
l
^affi-_--.]-"t't
Removethe upperportionof the reardoor sill molding, then pull the reardoor trim awav on each side.
Y,r\-J/ \t -
'/ -
> : Clip locations, 2
REARsHEr-F TRIMPANEL
REAR PILLARTRIM PANEL
5.
3.
Removeboth rear pillartrim panels.
Slip the rearseat belr throughthe slit in the rearshelf.
REARSHELF
> i Cliplocalionr,12
W.,
REAR PILLAR TRIM PANEL
NOTE: When installing,make sure the rear window defoggerwire harnessis .outed properly.
6.
R e m o v et h e s e a tl o c kc o v e r{ s e ep a g e2 0 1 1 1 ) a n d high mount brake lighr (seesection 23).
(cont'd)
20-95
lnteriorTrim (cont'd) Replacement 7.
q
Removethe rear shelf.
NOTE: a lf necessary,replaceany damagedclips. a When installingthe rear shelf, make sure there are no twists or kinks in the rear seat belt'
V : Clip locations
BV: Cllp,2
AV : Clip, 4
N i ==:
w "ff= t ;
_)
8.
=)
lf necessary,removethe belt hole cap and speaker cover from the rear shelf, : Screwlocatlons,3
AELTHOLE CAP
REARSHELF
20-96
lnstallation is lhe reverseof the removal plocedure.
Trunk Trim Replacement NOTE: Take care not to bend or scratchthe panels. '1. 2.
4.
Fold the rear seat-backforwaro.
Removethe clips,then removethe trunk side panel on each side. NOTE: A clips on the trunk side panel can be removed in the same way as those on the rea. trim paner.
Lift the trunk mat, then removethe sparetire lid. TRUNK MAT
< : Cllp locationt A{ : Cllp,6 8v : Cllp,4 FASTENERS
@q lF --
3.
l
t"
Removethe clips,then removethe reartrim Danel.
V : Clip loc.tlorE AV : Clip, 4 - I l Push the inner clip. NOTE: Do not push it in too Iar.
-2) Detach the clip by pullingit.
II{NEB CLIP
ffi
5 . Installationis the reverseot the removalprocedure.
gV I Cllp, 2 - I I Loosen the inner clip. II{NER
w {*
,/
-21 Detach the clip by pullingit.
(8r-ct-tp hfr
)J"'J eEdf,
..&G\
NOTE: a lf necessary,replaceany damagedclips. a When installingthe reartrim panel,installthe A clip as follows. - 1) Pull the inner clip up as shown.
t 4
Y_)
F
rd[h H
tNt{ER
cLrP
v
-2) Installthe clip in rhe rear trim panel,rhen push the inner clip until it,s flush. INI{ER CLIP
20-97
Headliner Replacement CAUTION: Whon Fyhg with I flat tip sclewdrivsr, wrap it whh protectivs tapo to prevent damaga. NOTE: a Take care not to bend and scratchthe headliner. a Be caretulnot to damagethe dashboardand other interior lrim. a Fold the front seat-backbackward. Halchback
3.
Removethe tront and rear ceilinglights, then disconnect the conneclors. : Sc.ew, nut localions
A
B : Nut, 2
: Scrcw, 2
&) ?)
CONNECTOR
1. Remove; . Door trim (see page 20-93) a Front Dillartirm {see page 20-91) a Ouartertrim (see page 20-93) a Coat hanger(see page 20-93) a Rearviewmirror {seepage 20-52) 2.
Removethe sunvisorand holderfrom each side. : Scrowlocation!,6
a
u)
LOCK WASHER (Outside)
l H
"^/
Aaqr+-
HOLDEB
SUNV|SOR
BRACKET
A
HOOK
ffi) CONNECTOR
LENS
Y
HOOK
NOTE: a lf necessary,remove the sunvisor bracket as shown. a When installingthe sunvisorbracket,apply grease and make sure it's installedproperly.
suNvlsoR BRACKET
suNvrsoR
20-98
I
m) H ,r--T-\
LENS
HOOKS
4.
Removethe grabhandle(frontpassenger.s) and grab hole caps (driver's), : Scrowlocationsl2l
6.
Removethe upperanchorbolts from the front and rear seat belts (seepages 2O-l j 5, I l9).
7.
Removethe upper ponion of the quaner pilla.trim panel,then detach the headlinerclio on each side.
e)
A : Clip locotions,2 HEADLINER
HOOKS
_ t
:
8 . Removethe roof trim (moonrootmodel). Open the hatch, then removethe rear root trim. Removethe headliner.
ROOF TRIM
5.
socxET
Removethe socket plug (moonroofmodel).
FRAME
-@'
//Gr
HEADLII{ER OUARTERPILLAR TRIM PANEL
I
n
{ +=s
, SOCKET PLUG (cont'dl
20-99
Headliner {cont'd) Replacement 9, Lower the headlineras shown. NOTE: Take care not to bend and scratch the headliner. HEADLINER
Sodan '1.
Remove: a Center Dillarlower trim (seepage 20-94) a Front and rear door trim lsee page 20-94) a Front pillartrim (see page 2O-9 . a Center pillartrim (seepage 20-94) a Rear pillartrim panel (seepage 20 95) a Rearview mirror (see Page 20-521
2 . Removethe sunvisorand holderfrom each side : Screw locationS, 6
^
LEFT OUARTERPILLAR TRIM PANEL
RIGHTOURTERPILLAR TRIM PANEL
1O. Bemovethe headlinerthrough the hatch opening'
s,1 HOLDER
NOTE: a When insertingthe headlinerthrough the hatch opening,be carefulnot to fold or bend it. Also, be carefulnot to scratchthe bodY. a Checkthat both sidesof the headlineraresecurely attachedto the trim and Panels. a When installingthe roof trim, install the Joint toward the rear.
LOCKWASHER loutsidel
/
$-.unu,"o" BRACKET /'
HEADLINER
1 1 .Installationis the reverseof the removalprocedure.
l
NOTE: a lf necessary,remove the sunvisor bracket as shown. a Wheninstalling the sunvisorbracket,applygrease and make sure it's installedproperly.
, @
suNvrsoR
20-100
3.
Removethe tront and rear ceilinglights, then disconnect the connectors.
A : Screw,nut locations A A : S c . 6 w 2,
4.
Remove the grab handles (tront and rear pas' senger'sland grab hole caps (driver,s). : Sc.sw locatioh!l2l
orlx -A-i
B : N u r ,2
CONNECTOR
CEILING
.-L----- ----z
CONNECTOR
GRAB HOLE CAPS
REARCEILING LIGHT
HOOKS
20-101
Headliner {cont'd) Replacement 5.
Removethe .ool trim (moonroofmodell.
6.
Detach the clips by slidingthe headlinerforward.
A : Clip locations,3
) HEADLINER
door Removethe headlinerthroughthe passenger's opening. HEADLINER
lnstallationis the reverseot the removalprocedure NOTE: a When insertingthe headlinerthrough the door opening.be carefulnot to fold or bend it. Also, be careful not to scratchthe body a Check that both sidesot the headlinerare securely attachedto the trim and Panels. a When installingthe roof trim, install the joint toward the rear.
20-102
Seats Front Seat Removal NOTE: Take care not to scratch the seat covers and bodY. 1.
3.
Remove the bolts.
V:Boh locatlong
Slidethe lront seat backward,then removeth6 bohs,
A V : Bolt, 1 > i Eolt locltlon..
2
I'
> : 8olt,
@
8 x '1.25mm
I
ii i.:iiil..i'xst.^. I 16:t'ftt -
/)
NOTE: When insralling,use--i liquid thread lock.
Slide the front seat forward, then romove the seat track end covers.
4.
Lift the front seat, then disconnectthe connector (driver's).
CAUTlOltl: When prying wlth E flat tip scr.wddvor, w.ap lt whh protactive tapo to prevont damago,
CONNECTOR
Carefullyremove the front seat through the door opening. Installationis the reverseof the removalprocedure.
20-103
Seats Front Seat RePlacement NOTE: Take care not to scratch the seat covers and body. 1.
2.
(see Removethe front seat through the door opening page 20-1O3).
5,
> : Bolt location., 2
lnnrnt v)*
Removethe screws and reclineknob, then remove the reclinecover.
COVER RECLINE
Foldthe seat-backcover and pad, then removethe bolts.
I |
l O x 1 . 2 5m m i 47 N'm 14.8kgl ln, I
SEAT.gACK COVER PAO
"?"!."t_J
SCREW
Removethe screws,then removethe centercover.
6.
Removethe Pivot nut.
PIVOT WASHER
SEATBELT BUCKLE '1 {seepage2O'1 7)
PLAIN WASHER
PIVOT NUT 8 r 1.25mm 22Nm12.2kgl'm, 16 lbf.ftl
CENTERCOVER
scREws Removethe hook and fastener,then lold the seatback cover back.
20-104
7 . Removethe seat-back. NOTE: Take care not to bend the hinge bracket.
+
sEAr-BAcK
8.
Separatethe seat cushionand seat tracks.
RECLINE AOJUSTER
NOTE: a B e f o r e s e p a r a t i n g ,s l i d e t h e s e a t c u s h i o n backward. a Take care not to bend the joint rod. < : Bolt locations, 4
9. Separatethe seat track and reclineadiuste.. : Bolt, nut locations A
: Bolt, I
BY : Nut,2
j
j @i+ilJ A;iil;iiry-,'_o()_
_/
_
_].'*",
RECLINE ADJUSTER
JOINTBOD Disconnect the rearseataccesscable(hatchback passenger'sl.
REARSEAT ACCESSCABLE
1 0 . Installationis the reverseof the removalprocedure. NOTE: a To preventwrinkleswhen installinga seat-back cover,make sure the materialis stretchedeven, ly over the pad beforesecuringall the hooks. a Apply greaseto the moving surtaces.
20-105
Seats Front Seat CoverRePlacement CAUTION: Wear gloves to removo and install the 36at cov€rs.
4.
\\ ilff-]s)
NOTE: Take care not to tear the seamsor damagethe seat covers. Soat-back covor lomoval: 1. Slidethe Jrontseat forwa.d and told the seat-back forward. 2.
Removethe lumbarsupport knob.
fH".,
Removethe hooks and fasteners.then fold the seatback cover back. FASTE]IIER FASTENER
5.
Removethe seat-backcover by releasingthe inside chps.
Cllp removrl:
Removethe headrestand headrestguide. Scr€w location,
,e,
Y
I
i
c J /
HEAOREST
SEAT.BACK
20-106 -
6.
Pull back the edge of the seat-backcover all the way around,then releasethe clips.
Seat cushion romoval: 1. Removethe seat cushionfrom the seat tracks (see p a g e2 0 - 1 0 5 ) . 2.
Removeall clips from underthe seat cushion,then loosenthe seat cushioncover
Cllp romoval:
Installationis the reverseof the removalptocadtr!. NOTE: a To preventwrinkleswhen installinga seatcover, make sure the materialis stretchedevenlyover the pad before securingall the clips. a Replacethe.eleased clips with new ones.
CLIP UPHOLSTERYRING PLIERS
NEW CLIP
PAD WIRE {Pad sido}
SEAT CUSHIONCOVER 2
Pullback the edgeof the seat cushioncover all the way arounC,then releasethe clips. SEAT CUSHION COVER
20-107
Seats RearSeat Replacement 3.
Hatchback NOTE: Take care not to scratch the seat covers and body.
Removethe cliD pin on each side. Slidethe seat-backsoutward, then removethe seatbacks from the pivot bracket.
1. Fold the seat-backs{orward.
CLIPPIN
(seepage 20-1Og)
SEAT.BACK
SEAT.BACKS
2.
Remove the clips, then fold the trunk mat.
V: Clip locations,14
+
I
|
v / J
TRUNKMAT
SEAT-BACK
20-108
PIVOTBRACKET
4.
Removethe bolt, then removethe seat cushion. : Bolt locations,t
LATCH COLIAR
l--): Xoot locations,2
6 r 1.0 mm 9.8Nm
I
SEAT-BACK COVER
SEAT CUSHION
NOTE: When removingthe striker,removethe side t.im panel (see page 20-91). > : Bolt locations,2
.a\
tDt@
|
STRIKER
l I
6x1.0mm i 9 , 8 N . ml 1 . Ok g l . m , l 1.2lbl..ttl ._ /l CUSHION
5.
lf necessary,removethe seat latch lrom the seatback and removethe striker. CAUTION: Wear gloves to remov€ and install the soat latch and latch collar.
> : Bolt, sc.€w locrtions A > : B o l t ,2
^
8 ) : S c r e w ,1
{
l l ' .,,W Gp" II 9 . 8N . m1 1 . 0k s fm . I 7 2 tP!ft!---/'
./ LATCH COLLAR
.otc" rtroa
6.
Installationis the revelseof the removalprocedure. NOTE: a Make sure the seat,backslock securely. a lf necessary,adjust the strikers. a Betoreattachingthe seat-backsand seat cushion, makesurethere are no twists or kinks in the rear seat belts. a When installingthe seat cushion,stipthe seat belt bucklesthrough the slits in the seat cushion. REARSEATEELT
El LATCH COVER
SEAT LATCH
t'
T-8ACK
( c o n t ' d)
20-109
Seats
(cont'd) RearSeat Replacement 3.
Sedan
Detach the hook, then removethe trunk mat.
NOTE: Take care not to scratch the seal covers and booy. 1.
TRUNK MAT
a-^ Nry Y
Fold the seat-backforward.
SEAT.BACK
I { \ t \
HOOK
TRUNK MAT SEAT-8ACK
2.
4.
Removethe clips.
Removethe bolts. then removethe seat-back.
V : Eolt locations,4
V : Clip locations,I
I
l Il
I E gel?"Til.*,,", iI 7.2 tbt'trl
/-.;-\ ----+tl ---M\r/ / I ,/
"
-----r" TRUNKMAT
REARSEATLAICH/ LOCKCYLINDER {seepage2O-'l11l
REARSEAT PIVOTBRACKET (seepage2O-111)
REARSEAT PIVOT BRACKET SEAT-BACK
20-110
SEAT.BACK
5.
Removethe bolt, then .emove the seat cushion.
Y: Bolt location. 1
i
-r
7.
lf necessary,removethe rearseat latch, lock c!ftiab and rear seat pivot bracket.
i Hool loc.lion3. 2
Roar soat latch/Lock cylinder r€moval: 6r1.0mm i 9.8N.m I
Pry the rear shelj up after removing the rear shelt trim panel (seepage 2O-95)and seat lock cover. NOTE: Take care not to bend the lock rod.
SEAT CUSHION V i Bolt. scrow locations AV i Boll, 2
I
9: l;o--' 9.8 tt.m
EI v_
i .m, kgf.m, l1.O lr.o tgf I 7.2 tbf.ft!____//
BV : Sc?ow, 2 4x0.7mm 4 N.rrt {O.4 kgf'm,
3tbt.ttt
I )
J
SEATLOCK COVER
SEATLOCK covER\-_L/-R\
w -"1/ -
B
LOCK CYLINDER
Pry here.
LOCKROD Removethe bolts, then removethe seat-backside bolstersby lifting them upward. : Bolt locationr, 2
6 r 1 . om m 9.8 N.m ( 1 . 0k g l ' m , 7.2 tbt.fti
REARSEAT LATCH
r'): Hook locetions, 2
I i I )
R6ar seat pivot brackol removal: NOTE: When installingthe pivot bolt, applygrease to it. TOOTHED BUSHTNGLOCKWASHER REARSEAT PIVOT BRAC(ET PIVOT BOLT 8 x 1.25mm 22 N.m (2.2 kgf m, 16 tbf.ftt
WASHER
20-111
Seats (cont'd) RearSeat Replacement 8.
lnstallationis the reverseot the removalprocedure NOTE: a Make sure the seat-backlocks securely. a It necessary,adiust the rear seal latch and seat-back. a BeJoresttaching the seat-back,side bolstersand seat cushion,make sure there are no twlsts or kinks in the rear seat belts and center belt a When installingthe seat cushion,slip the seat belt bucklesthrough the slits in the seat cushion.
RearSeat CoverRePlacement CAUTION: Wear glov€s to l€movo and install tho seat covgls. NOTE: a Take care not to tear the seamsor damagethe seat covels, a Removethe cliDsas shown.
SEAT-BACK Soat-back cover romoval: Hatchback 1 . Removethe seat-back(see page 20-108). 2.
Removethe latch cover and latch collar (seepage 20-109). Removeallthe clipstrom the back of the seat-back, then loosenthe seat-backcover.
E
SEAT.BACK COVER
ilgF] CLIP
4.
Pull back the edge of the seat-backcover all the way around,then releasethe clips. SEAT-BACK
CLIP
20-112
Sodan l. 2.
Seat cushion cover lsmoval:
Removethe seat-back(seepage 2O-11O1. Removeall the clipsfrom the backof the seat-back, then loosenthe seat-backcover.
Harchbacr( 1.
Removethe seat cushion (see page 20-lOg).
2.
Removethe cushioncentertrim panel.
SEAT-BACKCOVER
V : Scrowlocations,2
/+r
Y
I
I
v ,-.,)
CEITTER
J.
CLIP
Removeall :he clips from under the seat cushion. then loosenthe seat cushioncovers. SEAT CUSHION
covERs 3.
Pullback the edge of the seat-backcover all the way around,then releasethe clios. SEAT-8ACK COVER
CLIP 4.
Pullbackthe edgeof the seatcushioncoversallthe way around,then releasethe clips. SEAT CUSHION
covEBs
CLIPS
CLIP
lconl'dl
20-113
Seats Rear Seat Cover Replacement (cont'd) S6dan 1 . Removethe seat cushion (see page 20-1 1 1).
Removeall the clips from under the seat cushion, then loosenthe seat cushioncover SEAT CUSHION COVER
)rir
ry"M CLIP
Pullback the edge of the seat cushioncover all the way around.then releasethe clips. SEAT CUSHION COVER
t) ll
ll
CLIPS
Installationis the reverseof the removalprocedure. NOTE: a To preventwrinkleswhen installinga seat cover. mark sure the materialis stretchedevenlYover the pad before securingall the clips. a Replacethe releasedclips with new ones. UPHOLSTERYRING PLIERS Commerciallyavailable.
{Cover sid6}
20-1 1 4
Seat Belts Front Seat Belt Replacement cAUTloN: chock tho tlont seal belts for damage and lsplace them if necessary. B€ carelul not to damag€ then during romoval and installation. F.ont seat belt romoval: Hatchback 1.
Removethe following parts, and slidethe front seat fo.ward fullv. . Rearshelf (seepage 20-911 . Rear trim panel (see page 20-921
2
a Rearseat (seepage 20-1Og) a Side trim panel (see page 2c,-92}
Removeall the anchorbolts, the retractorbolt and the retractormountrngbott, then removethe front seat belt. NOTE: When removingthe anchor bolts and the retractorbolt, use a l7 mm socket or box-endwrench.
3.
Check that the retractorlockingmechanismfunctions as describedon page 20_122-
Pry the anchorcover.
UPPERANCHOR BOLT 7/16-20 UNF 32 N.m (33 kgl.m, 24 tbt.ttl
Remove the tront seat belt trom the belt ouide-
EELTGUIDE
RETRACTORMOUNTING BOLT 6 x 1 . Om m 9.8 N.m (1.0 kgt.rn. 7.2 tbl.ftl
RETRACTOR
RETRACTORBOLT 7/16-20 UNF 32 ltl.m {3.3 kgl,m, 24 tbt.ftl
LOWERANCHORBOLT 7/'16-20UNF 32 N.m 13.3 kgl.m, 24 rbf.ft)
{cont'd)
20-115
Seat Belts FrontSeat Belt Replacement {cont'dl Sedan
4.
Removethe retractorbolt and retractormounting bolt, then removethe front seat belt.
1. Slide the front seat tully forward. 2.
Removethe belt hole cap. then slip the front seat belt through the slit in the belt hole cap.
NOTE: When removingthe retractorbolt, use a 17 mm socket or box-endwrench.
< : Screwlocation,1 I
FRONTSEATBEI.T FRONTSEAT BELT
II
MOUNTING RETRACTOB BOLT 'l.O mm 6x
BELTHOLE CAP
I
9.8 N.m {1.o kgl.m,
7 .2 tbt.ltl
v
RCTRACTOR
) CENTERPILLAR LOWERTRIM 3.
SLIT
Removethe upperand lower anchorbolts from the front seat belt, then remove the center pillar lower trim. NOTE: When removingthe anchorbolts, use a 17 mm socket or box-endwrench.
RETRACTOFSOLT 7/16-20 UI{F 32 N.m {3.3 kgl.m. 24 tbf.ftl
A : Clip locations, 2 f '"
f -1t'-
i
l
r _Ju i l
*UPPERANCHORBOLT 7/16-20UNF 32 N.m (3.3 ksf'm, 24 lbf.ftl
_.|
Check that the retractorlocking mechanismfunctions as describedon page 2O-122.
6 . Removethe centerpillartrim {seepage20-94}.then removethe shoulderanchoradjuster.
ANCHORCOVER
u-.
FRONT SEAT BELT
8 x 1.25mm 23 N.m 12.3 kgl.m, 17 tbt.ft)
ANCHORCAP
20-116
LOWERANCHOR BOLT 7/16-20 UNF 32 N.m (3.3 kgt.m, 24 tbt.ftl
Seal b6lt buckle romoval: 1. Removethe rear console(see page 20-128). 2.
3.
> : Scrow locations, 2
Slidethe front seat until you can removethe screw. then removethe center cover.
SEATBELT BUCKLE
Oisconnectthe connector (driver's),remove the center anchorbolt, then removethe seat belt buckle.
CONNECTOR
iCENTER ANCHOR BOLT 7/16-20 UNF 32 N.m (3.3 ksf.m,7.2 lbf.ftl CENTEBCOVER
Upper and lower anchor bolt construction: Hatchback
LOCK WASHER
COLLAR
PLAIN WASI{ER
PLAIN WASHER
LOWERA CHOR BOLT
BEARING
lcont'd)
20-117
Seat Belts (cont'd) Front Seat Belt Replacement Sodan
.UPPER ANCHOR BOLT
Canter anchor bolt consttuction:
Rotractor bolt conslruction:
BEARING
WAVE WASHER
Installationis the reverseot the removalprocedure. NOTE: a Make sure you assemblethe washersand collarson the upper and lower anchor bolts as shown. a Beforeattachingthe sidetrim panel(Hatchbacklor centerpillarlower trim (Sedanl. makesurethe.e are no twists or kinks in the front seat belt. a On reassembly,replacethe upper anchor bolt {Sedanland center anchorbolt (*), and use liquid thread lock.
20-118
Rear Seat Belt Replacement CAUTION: Check lhs roar saat bslts tor damago and ioplaca them it necassary. 86 careful not to damago thcm d.rhe romoval and imtallation. Hatchback 1. Remove: o Rearshelf {seepage 20-911 a Reartrim panel (seepage 20-921
. R€arseat (seepage 20-1081 a Side trim panel (see page 20-921
Removeall the anchorbolts, the retractorbolt and the retractormountingbolt, then removethe rearseat belt and center belt. NOTE: When removingthe ancho. bolts and the retractorbolt, use a 17 mm socket or box-endwrench. Check that the retractorlockingmechanismfunctions as describedon page 2O-122.
Pry the anchor cover.
MOUNTING RETRACTOR BOLT 6xl.Omm 9.8 N.m {'l.Okgf.m, 7 .2 tbt.ttl
UPPERANCHORBOLT 7/16-20Ul{F 32 N.m (3.3 kgt.m, 24 tbt.ft)
RETRACTOB REAR SEAT AELT NETRACTORBOLT 7/16-20 UNF 32 N.m (3.3 kgl.m, 24 tbt.fr)
LOWERANCHOR BOLT 7 t16-20 UNF 32 N'm 13.3 kgf.m, 24 tbt.ftl
CENTERANCHOR BOLT 7/16-20 UNF 32 N.m {3.3 kgl m, 24 lbf.ft)
BUCKLE (cont'd)
Seat Belts (cont'd) RearSeat Belt Replacement Sodan 'I .
Remove: a a a .
Rear seat {see page 20-1 10) Rear pillartrim panel (seepage 20-951 Rear shelf trim panel (seepage 20-95) Rear shelf (see pag€ 20-96)
a Trunk mat (see page 20-97} a Reartrim panel {see page 20-971 . Trunk side panel (seepage 20-97)
Remove all the anchor bolts, the retractor bolt and the retractor mounting bolts, then remove the rear s€at belts and center belts. NOTE: When removingthe anchor bolts and the retractorbolt, use a 17 mm socket or box-endwrench. Check thst the retractorlockingm€chanismtunctions as describedon page 2O-122' ANCHORBOLT UPPER 7/16-20UNF 32 N.tn (3.3 kgf'm, 24 lbl ft)
RETRACTOR MOUNTING BOLT 6 x 1 . 0m m 9.8 il.m (1.0 kgt.m, 7.2 tbt.tll
RETRACTOR BOLT 7/16-20UNF 32 .m (3.3 kgl.m, 24 tbt.ft)
RETRACTOR
REAR SEAT BELT
AI{CHORBOLTS CENTER 7/16-20UNF 32 N.m (3.3 ksl'm,
LOWERANCHORBOLT 7/16-20UNF 32 N.m (3.3 kgf.m, 24 tbf.ftl
24 lbl ftl
CENTERBELTS
20-120
Uppo. anchor bolt construction: Hatchback
Sedan LOCK WASHER ANCHOR COVER UPPERAI{CHOR
UPPERANCHOB BEARING
COLLAR
TOOTHED LOCKWASHEN COLLAR
WASHER
Lower and cantol ancho. bolt conatluction:
LOWEBAI{CHORBOLT/ ANCHORBOLT
Rotracto. mounting bolt construclion: RETRACTOR BOLT MOUNTING \ \ /{- tr-
TOOTHED LOCKWASHER {Sedanl / J
l-n( l$t".,-,fu tYlf-\ u tY \
Rotractor bolt construction: RETRACTOR AOLT TOOTHEO LOCK WASHER
TOOTHED LOCKWASHER
b'ryd
Installationis the reverseof the removalprocedure. NOTE: a Make sure you assemblethe washersand collarson the upper anchorbolt as shown. a Beforeattachingthe side trim panel (Hatchbacklor rear shelf (Sedan),make sure there are no twists or kinks in the rear seat belt. a Beforeattachingthe seat-back,side bolsters{Sedan)and seat cushion,make sure there are no twisls or kinks in the rear seat belts. a When instsllingthe seat cushion,slip the seat belt bucklesthrough the slits in the seat cushion.
20-121
Seat Belts lnspection Retractol InsDection 1. Beforeinstallingthe retractor,check that the seat belt can be pulledout freely. 2.
Make surethat the seat belt doesnot lock when the retractoris leanedslowlyup to 150 from the mounted oosition. The seal belt should lock when the retractoris leanedover 4O".
Rear:
RETRACTOR
CAUTION: Do not attempt to disassemble the tgtractol. Hatchback
' : Mounted Position
3.
Replacethe seat belt with a new one if there is any abnormality.
On-the-Cal S€at Belt Inspection 1 . Checkthat the seat belt is not twisted or caughton anythrng.
2 . After installingthe anchors,check lor free movement
RETRACTOB Forwald
removethe anchor on the anchorbolts.lf necessary, boltsandcheckthat the washersand otherpans are not damagedor improperlyinstalled.
-
Rear:
3 . Check the seat belts for damageor discoloration. Cleanwith a shop towel iI necessary. CAUTION: Use only soap and water to clean. NOTE: Dirt build-upin the metalloopsof the upper anchorscan causethe seat beltsto retractslowly. WiDethe insideof the loopswith a cleanclothdampened in isopropylalcohol. 4. Iniid6
Forward
Checkthat the seat belt does not lock when pulled out slowly.The seatbeltis designedto lockonlyduring a suddenstop or impact. Make sure that the seat belt will retract automatacally when released.
Sedan Front:
Replacethe seat belt with a new one it there is any abnormality.
Forward
20-122
lnsido
Child Seat Anchor Plate Attachmentpointsare providedfor a rearseat mounted child restraintsystem which uses a top tether, The attachmentpointsare locatedon the reartrim panel or rear shelf, just behindthe rear seat-back. Whenusinga childseatwith a top tether,installthechild seat anchor platessecurely. Hatchback NOTE: The reartrim panelhas perJorations at each attachmentpoint. Cut the reartrim panelalongthe perforationsto make a hole,
TOOTHEDWASHER
BEAR TRIM PANEL
NOTE: a Do not removethe toothed washer from the child seatanchorplate.Usethe childseatanchorplate with the toothed washer attachedto it. a When installinga childseat on the rearseat, follow the intructionsof the manufacturerof the child seat, a Additionalanchor platesare available.
ATTACHMENT POINTS
Sedan
a Do not use the child seat anchor plate for any other puipos€; it is dosigned exclusively tor installation of a child seat. a Mako sure tho roar seat-back is locked firmlv wh€n installing a child soat.
NOTE: Removethe plug covers from the attachment points of the rear shelf (Canada). Use a razor bladeor sharp knife to carefullycut a 1 inch diametercircleat the locationof the attachment point (USAI. IOO mm 265 mm 13.94inl ( 1 0 . 4i n l
REAR SHELF
20-123
Garpet Replacement SRS wire harnessesare routed near the carpet.
1.
Remove: Hatchback
CAUTION: a All SRS slectrical wiring harn€ssosal€ covorod with yollow insulation. a Belore disconn€cting 8ny patt of th€ SRS wite harness,connoct th€ short connectors {see pago 20-2721. a ReDlacethe €ntire affected SRS haln€sa assambly if it has an opan cilcuit or damaged wiring.
a a a a a a a . a a
Front seat (seepage 2O-103) Rear seat (seepage 20-108) R e a rs h e l l { s e ep a g e 2 O - 9 1 } Rear trim panel {see Page 20-921 Side trim panel (see page 20-92) Front seat belt lower anchor(seepage 20-115) Front and rear consoles(seepage 2o-128) Kick panel (seepage 2O-91) Dashboardlower cover (see page 20-131) Openercover (see page 20-154)
Sedsn
ORIVER'SAIRBAG
a a a a a a a a o 2.
Front seat (seepage 20-103) Rearseat {seepage 2O-110) Rear pillartrim panel (seepage 20-95) Center pillarlower trim (seepage 20-94) Front seat belt lower anchor{seepage 20- 1 16l Front and rear consoles(seepage 20-128) Kick panel (seepage 20-91) Dashboardlower cover (seepage 20-131) Openercover (seePage20-155)
Removethe footrest.
V : Bolt locatios,2
I
v
6 x 1 . Om m 9.8 N.m {'l.o 7 .2 tbt.ftl
FOOTREST
20-124
Removethe door sill moldinglrom each side. NOTE: a Take care not to damagethe door sill moldings. a lf necessary.separatethe door sill moldingand carper.
: Push nul locatlon3, 5
V : Clip locatlons AV : Clip, 2
------l.l\-\\\).\\\1,
B< : Ctip, 'l
| /rryz)'
C < : C l i p ,1
| ru4l
O > : C t 9 .r
rA
l_ w_) MW i -) _)I W I : Push nut locations, 2
DOORSILL MOLDING
Sedan A : Clip location3,
: Push nut locations, 4
''*'N*
w /
CARPET I I I I
{ NUr I ":-/
FRONTDOOR SILL MOLDII{G
|
20-125
Carpet (cont'd) Replacement 4.
Removethe SRS unit covers.
Cut the carpet under the parkingbtake lever'
6.
PARKINGBRAKE
> : Clip locations,2
CARPET
Cut here.
7.
Removethe dashboardcenter bracket and center beam bracket.
V : Bolt locatlona B > : B o l t ,1
AV : Boll, 4
s x 1.2smm I SRS UNIT COVERS
Cut tne @ ana@ areasin the carpet,then pull it back, as shown.
SRS MAIN
20-126
22 N.m 12.2ksf m, 16 tbt.ftl
I I /,/
l:?'o'!"t
C> : goli, 2
6 x 1.0 ftm 9.8Nm 11.0kst'm,
6x1.Omm 9.8 N'm tl.O kgl m,
I I i
'1Y"!_/
-'/
I I
8.
Removethe carpet by slidingit rearward.
a Reattachthe @ cut area of the carpet {seepage 2 0 - 1 2 6 ) .a s t o l l o w s .
V : Cllp loc6tions AV : Clip, 3
- 1) Cleanthe back of the carpetwith a sponge damoenedin alcohol. Attach the fastenersto the edgeof the car, pet with double-facedadhesivetape.
B > : C l i p ,1
:ft
r,,-, FASTENERS
Hatchback
FASTENERS
-2) Attach the other tastener.as shown. FASTENERS
CARPET
CARPET
Ssdan -3) Align the carpet with the fastener, then pressthe carpet down securely.
FASTENERS
FASTENER
REARCONSOLE BRACKET
CARPET
SILL MOLDING SILL MOLDING
Installationis the reverseof the removalprocedure.
Reattachthe cut area under the parking brake leverand(9 cut area(seepage20-126)with wire ties, as shown.
NOTE: a Take care not to damage,wrinkle or twist the carpet. a Make sure the seat harnessis routed correctly. a Slip the slits in the carpetover the rear console bracket. REARCONSOLE BRACKET
Cut otf.
WIRETIE SLIT
a lf necessary,replaceany damagedclips.
20-127
Frontand RearConsoles Replacement SRS wire harnessesare routed near the front console. CAUTION: a All SFS electrical wiring harnessesaro coverod with y6llow insulalion. a Betore disconnecting any part of lho SRS wire harness,connect th€ short connoctorc (so€ pago 20-272t. a Replacotho sntilo aftocted SRS halness assombly it it has an opon circuit or damaged wlring.
NOTE: Take care not to scratch the tront and rear consoles,and dashboard. 1.
Removethe accesscap. CAUTION: liYhenprying with a flat tip scr€wd.lv€r, wrap it with protoctivo tape to provent damag€.
ACCESSCAP
FBONT PASSENGER'SAIRBAG
2.
Remove the sctews.
v : Scraw loc€tlona At : Scr.w, 2
E)
20-128
Bv : Scrow, 2
w)
3 . Removethe rear console,
5.
NOTE: a Lift up the parking brake lever. a Oetach the hooks by lifting the front ot the rear consoleand slidingit rearward.
Remove the trim ring, then remov€ th€ console panel. NOTE: a Take cafe not to scratch the selecter l6ver 8nd A/T gear positionindicatorpanel. a Removethe shiJtlever knob (M/T).
A : Cllp,hook loc.tions AA : Clip,2
BA : Cllp,2
CA : Hook,2
SHIFTI.EVER KNOB CONSOLEPANEL IM/TI TRIM RI'{G
\ r "onroar€
,"Hr"tz{o$
co soLE 4.
SELECTER POStTtON LEVEB INDICATOR PANEL
Removethe sshtrsy and front consolepanel. > : Scrowlocatlon3,2 6.
l Diaconn€ct the connector.
Removethe screws. > : Screwlocationr,4
6bo'' I : . /
20-129
Front and RearConsoles (cont'd) Replacement 7.
Removethe Jront consoleas shown.
8.
NOTE: Wrsp the selecterlever and A/T gear position indicator psnel with a shop towel to prevent damage.
It necessary, disassemble the Jront and rear consoles. : Scrowlocations,5
A i _Y_)
CONSOLEPANEL (MTI
SHIFT LEVER BOOT (M/TI
CONSOLE
: Scraw locations, I
A I Y,/
ARMREST
REAR CONSOLE PARKINGBRAKE COVER
COVERSET PLATE
cof{solE Box 9.
20-130
Installationis the reverseof the removalprocedure.
Dashboard Component Removal/lnstallation SRSwire harnessesare routednear the dashboardand steeringcolumn. CAUTION: a All SRS olectrical wiring harnessesar6 covolod with yallow insulation. a Betoro disconnecting any paft ot th6 SRS wiro harn€ss,connoct th€ shoi connectots (s66page 23-2721. a Replacoth€ entire Itlocted SRS hsrness asaembly il h has an open circuh or damagod wiring.
CAUTION: Whan prying with a flat tip scrowdiv... wrap it with protoctiv€ tape, and apply protectivo tapo a.ound th€ felatsd parts. to provent damag€. Instiumont p8n6l, Dashboad lower covor. Knec bobtcf ramoval: l.
Lower the steeringcolumn.
2.
Remove the screws and detach the cliDs, then remove the instrumentpanel.
3.
Removethe coin oocket.
4.
Removethe screws and detach the clips, then remove the dashboardlower cover. Disconnectthe connector.
: Scraw location3, 5
A
F
A \ g
|
]
I
A i Clip locationg AA: Cllp, 2
_:n ,,4< -ft
)
B> : Clip, 2
I |
,-__-,
l-l
L'l
itrvi ) 4Z)
)
INSTRUMENTPAI{EL
COIN POCKET
(cont'd)
20-131
Dashboard Component Removal/lnstallation(cont'dl 5.
Removethe knee bolster. : Bolt locations, 3
fi
CONNECTOR
6rt.omm
i Bolt locations. 2 6 x 1.0 mm 9.8 N.m {1.0kgl.m,
6 i;i'i#., 7.2 tbr.ftl
?
CASSETTE
KNEE 6.
Installationis the reverseof the removalDrocedure.
Stol€o radio/cassette, Heater control panal removal: 1.
Removethe rearconsole,then removethe front cons o l e ( s e ep a g e 2 0 - 1 2 8 ) . Loosen the bolts, then remove the stereo radio/ cassetteby pullingit out. Disconnectthe connectorand antennalead. NOTE: The originalradiohas a codedtheft protection circuit,Besureto get the customer'scodenumber belore - disconnectingthe battery. removingthe No. 32 17.5A)fuse from the underhood fuse/relaybox. - removingthe radio. After service,reconnectpower to the radioand turn i1 on. When the word "CODE" is displayed.enter the customer's 5-digit code to restore radio operation.
20-132
3,
Carefullypry the hazardwarning switch and rear window defoggerswitch out of the heatercontrol Daner. Disconnectthe connectors.
HAZARD WARNING
swtTcH
REARWINOOW DEFOGGERSWITCH
4.
Removethe screws. Detachthe harnessclip and connectorclip.
Pullthe heatercontrol panelout, then disco.rEt rhG conneclors.
> : Screwlocations,2
NOTE: Take care not to bend the atr mtx control cable. AIR MIX COI{TROL CABLE
HEATER CONTROI PANEL
7,
lnstallationis the reverseo{ the removalprocedure. NOTE: Make sure the connectorand air mix control cable are connected properly.
CONNECTORCLIP
Disconnectthe air mix control cablefrom the heater unrt. AIR MIX CONTROL CABLE
HEATERCONTROL
AIR MIX CONTROL CABLE
(cont'd)
20-133
Dashboard (cont'd ComponentRemoval/lnstallation Side air vent .emoval:
Front passsng€r's
Drivsi's
Careiullypry the side air vent at the lower edge, then pull it out.
1. Remove the dashboard lower cover (see page 2 0 - 13 1 ) . 2.
Caretullypry the moonroofswitch out of the side air vent, then disconnectthe connector.
MOONROOF
swrTcH
CONI{ECTOR
A : Clip,hook locationg AA : Clip, 1
BV : Hook, 2
Hi
1.''
11,/
SIDE AIR VENT
SIDE AIR VENT
PROTECTIVE TAPE 3,
Removethe screw, then removethe side air vent. < : Clip, hook locatlont
> : Sc.6w location,
I o@)
Sido detoggor t m romoval:
A< : Clip, 1 BV : Hook, 3
Carefullypry the side detoggertrim at the rearedge,then remove rt. A : Cllp,hook location! AA : Clip,l
B A: Hook, 1
PROTECTIVE
SIDEAIR VENT
4.
lnstallationis the reverseof the removalprocedure. NOTE: Make sure the connector is connected properly.
20-134
Clock rsmoval:
4.
Caretullypry the clock at the left edge.then pull it out. Disconnectthe connector.
Remove the damper and striker.
>: Nut, icrgw locations A> : l{ut, 1
CLOCK
,
-
.
B \
: Scrow, 2 '
F
l
o \ +t ] ! } l l aE l l CONNECTOR
_
__,/
*'
,/
tl @
Glove box removal: '1.
Open the glove box. DAMPER
2.
Removethe screw, then removethe damperfrom the glove box.
3.
Removethe screw, then removethe glove box.
5.
Installationis the reverseo{ the removalorocedure.
: Bolt, scr6wlocstions A
: Bolt, 2
A
B < : S c r o w 1,
l
^
6)P)
l
20-135
Dashboard Precautions Replacement SRSwife harnessesare routed nearthe dashboardand steeringcolumn. CAUTION: a Alt SRS olectrical wiling harness€sale covorad with Yollow insulation. a Botore disconnecting any part ot the SRS wiro harness,connect ths short connscto6 (seepage 23-2721. a Roplac6ih€ entiro aflectod SRS halnoss assembly il it has an opon cilcuit or damagod wiling'
2 . lnstallthe short connectors(RED) Ddvar's: Removethe accesspanel,then disconnectthe connector betweenthe cable reel and driver's airbag' Connectthe short connector(RED)to the driver's airbag connector lsee page 23-27 2l' DRIVER'SAIRBAG
CABLEREEL CONNECTOR
DRIVER'S AIRBAG CONNECTOB
DRIVER'SAIREAG
SHORT CONNECTOR (RED)
SRS UNIT LEFT DASH SENSOR
ACCESSPAI{EL
Front passongor's: Removethe glove box {seepage20-135},then disconnect the connector between the tront pas' senger'sairbagand SRSmainharness Connectthe short connector(RED)to the front passenger'sairbag connector(seePage 23-273).
Bstora lomoving the dashboaid: To avord accioenlal dsployment and !@@ ""iUU inir.v, always install the plotoctive short ;onnectors on the driver's and tlont pass€ngel'sairbag connectorsbolors working near any SRSwiring' 1.
FROf{T PASSENGER'S AIRBAG FRONT PASSET{GER'S AIRBAG CONNECTON
Disconnectthe batterynegativecable,then disconnecl the positivecable. NOTE: The originalradiohas a codedtheft protec tion circuit.Be sureto get the customer'scodenumber before - disconnectingthe battery. - removingthe No 32 (7.5A) Iuse from the underhood fuse/relaYbox' - removingthe radio. After service,reconnectpower to the radioandturn "CODE" is displayed,enter it on. When the word the customer's 5 digit code to restore radlo ooeration.
20-136
SHORT CONNECTOR (REDI
SBS MAIN HARNESS CONNECTOR
Replacement To removethe dashboard,first removethe: a a a a a . a a
3.
Front seats (seepage 2O-103) Front and rear consoles(seepage 20-128) Dashboardlower cover (seepage 2O-131) Knee bolster (seepage 2O-132) Glove box lsee page 2O-135) Clock (seepage 20-135) Moonrootswitch (seepage 20-1341 Stereo radio/cassette{seepage 20-132)
Removethe nuts, then removethe front passsnger,s airbagbracket, To avoid accidantar daploym.nr ",'d @ possibls iniury, always install th€ protoctiv. 3hqt connoctor on tho ,ront passongor'aairbag conncctor whon tha SRS main ha.na$ is disconncctod llcr pago 20-136). : Nut locatlons,4
Lower the steeringcolumn (seesection 17).
FRONTPASSENGER'S
ro avoid accidentat dedoyment and @@ possiblo in ury, always install the prot€ctive short connector on tho drivsr's airbag connector bgtor€ lowering tho stooring column (so€ page 20-1361. NOTE: To preventdamageto the steeringcolumn, wrap it with a shoDtowel. : 8olt, nul locations A
8
: Bolt, 2
8 x 1 . 2 5m m 22 N-m 12.2ksl.m, 16 lbt.frl
: u t ,2 8 x 1.25mm
gill$"'l
FRONTPASSENGER'S AIRBAG BRACKET SRS MAIN HARNESS
STEERINGCOLUMN
4.
Disconnect the air mix controlcable and connectors. AIR MIX CONTROL CAELE
CONNECTORS
(cont'dl
20-137
Dashboard (cont'd) Replacement 8 . Remove the bolts, then lift and remove the
Disconnectthe antennalead.
5.
dashboard. CAUTION: Use protoctive tspe on the bottom ol tha lront tillar trim; NOTE: a Take care not to scratchthe dashboard. a To prevent damageto the shift lever (M/T) or selecter lever and A/T gear position indicator panel (A/T), wrap them with a shop towel. V : Bolt locations,6
6.
Disconnectthe connectorsfrom the under-dash fuse/relaybox.
6 x 1 . 0m m 9.8 N.m (1.0 kgt'm, I 7.2 tbt.ftt
____/ PROTECTIVE
CONNECTOR (A/T only)
CONNECTORS SHOPTOWEL
Removethe accesspanelson both sides. GAUTION: When prying with 8 tlat tip scrowdrivor' wrap it with protective tapo to pl€vent damaga' DASHBOARD
accEss PANEL
HooK\ lcCesS Plnel /
20-138
___E--
ffiL
RE=-cLrP
9.
lnstallationis the reverseof the removalprocedure NOTE: a Make surethe dashboardfits onto the body correctly. a Beforetighteningthe bolts, make surethe dashboard wire harnessesare not pinched,and thal the dashboardis not interferingwith the air mix control cable.
Bumpers Front Bumper Replacement NOTE: a An assistantis helpfulwhen removingthe front bumper and lront bumper beam. a Take care not to scratchthe front bumper. a Open the hood.
3.
Removethe bolts, then removethe front bumoer.
V : Bolt locations
: Clip locadrn., 2
A A
B V : B o l r ,2
A V : B o h ,I
+Et= -+EP_
1. Removethe tront turn signallight, then disconnect the connectorson each side.
:
< : Sci6w locatlons,2
CONNECTORS
FNONTTURN SIGNAL LIGHT 2.
FRONTBUMPER
Pull the inner fender down. then remove the screws from the front bumper and lower bumper on each 5rcte.
: Scrow, 2
> : Boll, screwlocations A > : 8 o l t ,2
: Scr6w locations A
NOTE: lf necessary,disassemble the tront bumper.
BA: Scrow, 2
_A_, __s_,
8>: Bolr5 ,
C V : B o l r I,
D < : S c r e w8,
q-l -ry-l_9, =g A : Clip locarions
AA : Clip, 2
/H\ -<€L9'a-
BA : Ctip,4
i I /
FRONT BUMPERr
{-r-*=\
__tr:i!uF&,
g
FRONTTURN SIGNALLIGHT HOLOER
nolt
D
Et2" 'l-eo
/
/
D
sroe
stoE
SEAL
CLIPS
fr:**M
INNERFEl{DER
BUMPER
LOWERBUMPER
20-139
Bumpers Front Bumper RePlacement(cont'd) 4.
Removethe absorberand bumperbeamgusset on each side. then removethe front bumperbeam.
NOTE: o Installthe holesin the front bumperbeamover the hookson the bodY.
: Eolt locotions. 4
6
of the removalprocedure. is the reverse Installation
E
rcr
8 r 1.25mm
22 N.m (2.2 kgt'm,I 't6 tbt fti _/
FRONTBUMPERBEAM
FrBo*sidor HOLE
(Frontbumperb€amsidel
Align the front bumperside clips with the tront fender properly,then installthe front bumper. FRONTFEiIDER
FRONT BUMPER ABSORBER
a Make surethe connectoris connectedproperly.
20-140
Rear Bumper Replacement NOTE: a An assjstantis helpfulwhen femovingthe rearbumper and rear bumperbeam. a Take care not to scratch the rear bumper.
4.
Removethe bolts, then removethe rear bumper. : Bolt locations,2
Hatchback 1.
Removethe screw from each side.
: Scrow I A
A\
REARBUMPER REARBUMPER
5. Openthe hatch, then removethe reartrim panel (see page 20-921-
lf necessary,removethe bumperupperbeam from the rear bumper. : Screwlocotions
J.
Removethe nuts, and disconnectthe licenseplate light connectorand grommet.
A
: Scr€w,4
> : Nut locotions, 4
/\
^
--E-
6x1.OmmI
Q) i;L'i$-.l _':'y:) ,/
LEFTS|DE
B <: Sc.ow,4
I
i
@ s l
I V: Cliplocations,
_ ' / BIGHTSIDE TRIM PANEL
.--r-Fl^
|
--lEr_\"., J
LICENSEPI-ATE LIGHT HARNESS
L|CENSEPLATELtcHT
To remove the nuts, remove the rear portionof the side trim panelon each slde {see page 20-921.
REARBUMPER
(cont'd)
20-141
Bumpers (cont'dl RearBumperReplacement 6.
Removethe absorber,bumper beam gusset and rear bumper beam.
Sadan 1. Removethe screw from each side
y: Boltlocalions, 4
: Sciow locations,2
I 1 2x 1 . 2 5m m 64Nm{65kgfm,I
* "r:,
) ACCESSCAP
REARBUMPER
2.
ODenthe trunk lid, then removethe reartrim panel (see page 20-97).
3.
Disconnectthe license plate light connector and grommet from the rear trunk atea. Removethe clips and bolts, then removethe rear bumper'
v: Cllploc.tions,5
\\rLlF/d,rft
€
l
#.,1
2 : 8ok locations,
6 x 1.0mm I 9 . 8N . m l 1 . Ok g l m , 7.2 rbr.ft)
REAREUMPER BEAM
BEAM EUMPER GUSSET lnstallationis the reverseof the removalprcedure. NOTE: Make surethe licenseplate light connector is connected,and the grommetis installedproperly,
GBOMMET
20-142
i I J
4.
5.
lf necessary,removethe licenseplate light harness, bracket and lens from the rear bumper (see page 20-1411. Removethe absorb€r,bumper beam gusset and fear bumper beam.
V i Bolt locatlons,4 12 x 1.25mm 64 .m (6.5 kgf. m , 47 tbt.ftl
6.
Installationis the .everseof the removalprocedure. NOTE: a Make sure the licenseplate light connectoris connected, and the grommet is installedproperly. a Make sure the rear bumper engagesthe side clips securelv.
I j )
REARBUMPER
REAR BUMPER BEAM BUMPERBEAM GUSSET
20-143
Hood Replacement NOTE: a An assistantis helplul when removingthe hood. a Take care not to damagethe hood and body. a When removingthe clips, use a clip remover. a Open the hood. 1. It necessary,removethe hood edge protector.
NOTE: It necessary,removethe hood hinge. V : Boh locationa,4
I3;;,iH"-,,., I .rtor"t
j : Cliploc.tions,16
- ) HOOD HINGE
HOODEDGE PROTECTOR
\ HOOD 2.
Removethe bolts. then removethe hood. : Boltlocalions, 4
NOTE: a lf necessary,replaceany damagedclips. a Make su.e the hood locks securely. a Make sure the hood opens properly. a Adjust the hood alignment(seepage 20-1451.
6x1.0mm 9.8 N'm {l.O kgl m, 7.2 lbl.fr)
n r) HOOD
20-144
lnstallStionis the reverseof the removalprocedure.
Adjustment NOTE: Beforeadjustingthe hood, looseneach bolt slightly. 1. Adjust the hood hingesright and left as well as tore and att by using the elongatedholes. 2.
Turn the hood edge cushions,as necessary,to make the hood lit flush with the body at front and side edges.
3.
Adjust the hood latch to obtain the proper height at the forward edge.
NOTE: Move the hood latch right or left until the striker is centeredin the hood latch, as shown.
HOOD LATCH
HOOD LATCH
6 r 1 . om m
4.
After adiustment,tighten each bolt securely.
20-145
Hatch Replacement NOTE: a An assistantis helpfulwhen removingthe hatch. a Take care not to damagethe hatch and body. a Take care not to scratchthe hatch sidetrims and hatch tnm paner. a Open the hatch. a Removethe high mount brakelight {seesection23). 1.
NOTE: Detachthe clips by slidingthe hatch trim panel forward, then remove it.
Removethe hatch side trim on each side. < : Clip locations, 8
HATCH
3.
Remove the hatch spoiler as describedon page 2 0 - 1 5 9 ( f o r s o m et y p e ) .
4.
Disconnectthe connectors,then removethe wire harnessesfrom the hatch. V : Clip locations Av : Clip, 3
: Speclal bolt locetlons,2
t
A 2.
A : Clip localions
::::/
+
r
L
l
4
l )
NOTE: Before pulling out the wire harness,tre a strinqto the end of it so you can pull it backin when the hatch is reinstalled.
BV : Clip, 3
W',dtri
f
R@t @ ,/l ' L,/
Remove the hatch trim panel.
AA : Clip, 11
t
BA: CliP,6
HATCI{
WIRE I{ARNESSES
_:_/
HATCH TRIM PANEL
CONNECTORS CONNECTOR
WIRE HARNESS
5.
20-146
Removethe rear wiper motor (seesection 23).
o.
Removethe uDDeranchorbolts from the tront and rear seat belts {seepages 20-1 15, 'l 19), then remove the upperportionof the quarterpillartrim panel (see page 20-991.
NOTE: a lf necessary,replacethe supportstrut. a When scrappingthe suppon $rut, dispose ir as describedon page 20-149.
7 . Removethe rearroof trim, then pull the rearof the headlinerdown (see page 2O-99). NOTE: Take care not to bend the headliner,
8 . Removethe supportstfut on each side while holding the hatch. HATCH
I x 1 . 2 5m m 22Nm 12,2kgt'm, 16 tbt.ftl
SUPPORT STRUT
a lf necessary,removethe hatch hinge. V : Solt locdlions,4
9.
Removethe nuts, then removethe hatch. 8 x 1 . 2 5m m 22 N.rn 12.2kgt.m, 16 tbf.ft)
a : Nut locations,4 12.2kgl.m, I
,6'y!:t ,/
HATCH HINGE
HATCH HATCH
1O. Installationis the reverseot the removalprocedure. NOTE: a lf necessary,replaceany damagedclips. a Make surethe connectorsare connectedproperly. a Make sure the hatch locks securely. a Make sure the hatch opens properly. a Adjust the hatch alignment(seepage 20-148).
20-147
Hatch Adjustment NOTE: a Beforead,usting the hatch.looseneachbolt andnut slightly. a Do not installthe suDDort struts. 1 . Adjust the hatch hingesright and left as well as fore and aft by using the elongatedholes.
Turn the hatch edge cushions,as necessary.to make the hatch tit flush with the body at each side. Adjust the hatch fit to the hatch openingby moving the striker, 4.
Use shims, as necessary,to make the hatch tit flush with the body at the rear edge. HATCH
8 x 1.25mm
HATCH EDGECUSHION
HATCH
NOTE: Move the striker right or left until it's centered in the hatch latch, as shown. HATCH LATCH
t
+Q. 6x1.0mm 9.8 N m (1.0 kgl m, 7 .2 tbt.trl
5.
Atter adjustment,tighten each bolt and nut securely,
Trunk Lid SupportStrut Disposal
Replacement
Tha support strut contains nitrog.n gas and @ oil unde. pr€ssul€. The pressuremust be relievedbsfo.e disposalto prevant explosion and possible injury wh€n sc.apping.
NOTE: a An assistantis helpfulwhen removingthe trunk lid. a Take care not to damagethe t.unk lid and body. a Open the trunk lid.
Placethe support strut on a level surface with its rod extended,and drilla hole 2-3 mm (3/32"1diameterin the body to releasethe gas.
1.
Disconnectthe connectorsand trunk lid openercable.Removethe wire harnessandt.unk lid opnercable from the trunk lid. NOTE: Before pullingout the wire harness,tie a stringto the end ot it so you can pull it backin when the trunk lid is reinstalled.
> : Clip locationg AD : Clip, 3
B< : Clip, 1
CA : Clip, 5
e-i
20 mm (O.79inl
_rP
WIRE HARNESS
TRUNKLID OPEN€R CABLE
CONNECTOR SUPPORTSTRUT
always w€ar €ye prot6ction to avoid get@ ting motal shavings in your eyea when roloasingth€ gas fiom the support st.ut.
,/
CONIIECTOR
TRUNKLID LATCH {seepage20-157}
TRUNK LIO OPENER CABLE A A
(cont'd)
20-149
Trunk Lid (cont'dl Replacement 2.
a Remove the bolts, then remove the trunk lid hinge.
Removethe bolts. then removethe trunk lid.
> : Bolt loc.rlons.4
V : Bolt locaitons,4
NOTE: Take care not to hit the rear window when removing the bolts.
TRUNKLID
removethe trunklid hinge lf necessary. NOTE: a Removethe rearshelf{seepage20-95). a Removethe torsionbarswith the torsionbar assembly tool.
TRUNKLID HINGE
4.
lnstallationis the reverseot the removalprocedure. NOTE: a Make surethe connectorsare connectedproperly. a Adjust the torsion bars tore or aft with the torsion bar assemblvtool as shown.
O =NormalPosition O = Highertension
a Make sure the trunk lid locks securely. a Make sure the trunk lid opens properly. O Adjustthe trunk lid alignment(seepage20-151).
TORSION8AB ASSEMBLYTOOL
20-150
Adjustment NOTE: Beto.e adjustingthe trunk lid, looseneach bolt slightly. 1. Adjust the trunk lid hingesright and left as well as fore and aft by using rhe etongatedholes. 2.
Turnthe trunk lid edgecushions,as necessary,to makethe trunk lid fit flush with the body at the rearand sideedges.
3.
Adjust the lit betweenthe trunk lid and the trunk lid openingby moving the striker. TRUNKLID EDGE CUSHION
/21
ft(M Y4Y
TRUNK LID HINGE
TRUNI(LID
6r1.Omm 9.8 N.m 11.0 ksl m, 7.2 lbt'ft|
NOTE: Move the st.iker right or left until it's centered in the trunk lid lalch, as shown,
6 x '1.0mrn 9.8 N m 11.0 lo,f.m, 7.2 tbt.hl
STRIKER
STRIKER
4.
Atter adjuslment,tighten each bolt securelv.
20-151
OpenerCables Replacement NOTE: a Whenremoving the clips,usea clip remover. a Takecarenot to bendthe openercables. HOODOPENER CABLE
Hood Opener Cable: v : Clip location.
> : Scrow locrtions, 6
Av:CllP,5
M) Bv:Clip.6
E \ I :=r ,/
____lEt-
-
HOODRELEASE HAI{DLE (se€page20-154)
Otr" I :_
_) HOOD LATCH (seepage 20"154)
L
-\-
NOTE: Loosen the screw, then remove the clip using a clip remover.
INNER FENDER
Hatch/Fuol Lid Oponer Cabls lHatchback): (seepage2O-91),then pull thecarNOTE: Removethe rearseat (seepage 20-108), reartrim pan€land sidetrim panel Det back. as necessarylsee page 20-124). A : Clip,csblocushionlocation3 AA : Clip, i r
8A : Clip, 2 ,
CA : CliP, 7 ,
DD : Cllp, 1 ,
Etr : Cllp, I ,
FA : Cllp,
GA : Clip,
HA : C.bl6 cushlon, 5
s-,$, g, e&r@)s,l Wt9) Right sids:
HATCH LATCH lsee page 2O-156)
HATCH
Loft 3ido:
FUEL LID LATCH lsse page 2O-155)
HATCH OPENERCABLE
LID HATCH/FUEL OPENER {seepage2O-'l54)
20-152
Trunk Lid/Fuol Lid Opan.. Cablo (Sodanl: NOTE: Removethe rearseat {seepage 2O-110) and centerpillarlowertrim (seepage20-94}, then pullthe carDetback. as necessa.y(see page 2O-1241.Removerhe left trunk side panel (see page 20-97). > : CliD, c.bla cu.hion locstlon! A > : C l l p ,1
BV:Clip,2
C A: Clip,,t
D >: Clip,3
E A r C l l p ,1
ws@:ffi;6,1
F < : C.ble culhlon, 1
7--
TRUITIKLID LAICH (s€ep6ge20-157)
FUEL LID
OPENER {se6page 20-155)
FUEI.LID LATCH (soopago20_'|55) Installationis the reverseof the removalorocedure. NOTE: a Make sure each openercable is routed and connectedproperly. a Make sure the hood, hatch. trunk lid and fuel lid open properlt.
20-153
Openerand Latch Replacement NOTE: Take care not to bend the openercables. Hood Latch:
Hood RelsaseHandle:
< : Bolt locations
< i Bolt locations,2 6 x 1.0 mm 9.8Nm (1.0kgl m, 7.2 tbl.lrl
6 x 'l.O mm 9.8Nm 1 1 . 0k g l m , 7 .2 tbt ftl
HOODOPENER CABLE (seepage20'152)
HANDLE
,/
HOOD LATCH
HOOD RELEASE HANOLE Removethe kick panel (seepage 20-91).
HOOD LATCH I
Removethe bolt while pullingthe handle.
HOOD OPENER CABLE
Hatch/FuelLid OpenerlHatchback): < : Bolt, sclow locations A
HATCHiFUELLID OPENER the
6 x 1.0 mm 9.8 N m 11.0kgl'm, 7.2 tbl.fr)
OPENER COVER
BV:Sc.sw, 1
6'\ I
v l /
FUEL LID OPENERCAELE
HATCH OPENERCABLE (seepage 20-152)
lnstallationis the reverseof the removalprocedure' NOTE: a Make sure each openercable is connectedproperly a Make sure the hood locks securely a Make sure the hood, hatch and fuel lid open properly.
20-154
J't
o @ t-
NOTE: Take care not to bend the openercables. Trunk Lid/Fuel Lid Oponer {Sodan}:
Pry the ljd.
OPENER COVER
< : Bolt, scrowlocatlon!
o
A<:Bolr,2
t
OPENERLOCK CYLINDER
*rr*@
-
o
6 r 1 . 0m m 9 . 8 N m 1 1 . Ok g l m , TRUNKLID/FUEL LID OPENER B V: Scrow, 1
A -}{H.
II I
_:_) ()t FUELLID OP€NERCABLE (seopage 2O-153)
TRUNKLID OPENER CABLE (seepage20-153)
Fuol Lid Lstch: < : Boh,locotions,2 6r1.0mm
9 . 8 N m 1 1 . 0k s l ' m , i 7 '2 tbt'''l ------,//
FUELLIDOP€NER CAALE ( s e ep a g e s2 0 - 1 5 2 1, 5 3 ) FUEL LIO LATCH Removethe fuel lid latch by turning it 90o.
FUEL LID
LIO LATCH Hatchbock: Remove the rear shelf and rear trim oanel. then pull the rear edge ot the lett side trim panelback (soepage 2O-91). Sodan:Removethe rear trim panel, then pull the rear edge of the left trunk side panelback {seepage 2O-971.
lnstallationis the reverseof the removalorocedure. NOTE: a Make sure each openercableis connectedproperly. a Make sure the fuel lid fits flush with the body. a Make sure the tuel lid locks securelv. a Make sure the trunk lid and fuel lid open properly.
20-155
Hatch Latch and Lock CYlindet Replacement NOTE: Takecarenot 10 bendthe cylinderrod and hatch openercable. 1.
Removethe rear trim panel (see page 20-921.
2.
Disconnectthe cylinderrod and connector.
4.
Disconnectthe hatch openercable.
HATCH LATCH
5.
Removethe lock cylinderby turning it 45o
>: Bolt localion,1
CYLINDERROD
3.
Remove the hatch latch.
>: Screw locatiois, 3
^ {-D m
6x1.omm I s . e N m ( 1 . 0k s l m , ,?tb:tn __/ o.
lnstallalionis the reverseof the removalprocedure. NOTE: a Apply greaseto the hatch latch.
HATCH LATCH
a Make sure the hatch locks securely. a Make sure the hatch opens properly. a Make surethe connectoris connectedproperly.
20-156
Trunk Lid Latch and Lock Cylinder Replacement NOTE: Takecarenot to bendthe cylinderrod and trunk lid openercable.
4.
Removethe lock cylindercover. HOOKS
l.
CLIP
Disconnect the connectorand trunk lid openercable. CONNECTOR
LID CABLE
LOCKCYLINDER COVER
CLIPS
5.
Removethe bolt, then pullthe lock cylinderout. Re, move the lock cylindertrom the cylinderrod, then take them out. : Boltlocation,'l
2.
Disconnectthe cylinderrod.
F 6xl.Omm
q;i!!"jy
I
LOCK CYLINDER
CYLINDER ROD
Removethe bolts, then removethe trunk lid latch. CYLINDER ROD
A : Bolt locations,3 6.
Installationis the reverseol the removatproceoure. NOTE: a Apply greaseto the trunk lid latch,
/
./,.,
,/'e4
a Make sure the trunk lid locks securelV. a Make sure the trunk lid opens properly. a Make sure the connectoris connectedproperly.
20-157
Retainersand WeatherstriP Replacement CAUTION: Wear gloves to lemov€ and install tho i€tain€rs' NOTE: Take care not to bend the retarners. < : Screwlocalions,19
< : Clip locations,I
!9
|
REAR CLIP
.€\
!:
RETAINER q
l{
SHOPTOWEL
CENTERPILLAR MOLDING WEATHERSTRIP
Boot side section: RETAINER
Center oillar section: PILLAR FRONT CENTER
I CENTERPILI-AR MOLDING NOTE: The numbers atter the part names show the quantities ot the parts used
WEATHERSTRIP
RETAINER
lnstallationis the reverseof the removalprocedure. NOTE: a Check the weatherstriplor damageor deterioration,and replaceif necessary' a After installingthe weatherstrip,check for water leaks' a lf necessary,adjust the positionof the door glass (see page 20-40) a It necessarv,replaceany damagedclips.
20-158
FenderWell Trim and
Hatch Spoiler
WheelhouseProtector
Replacement
Replacement
a Take care not to scratch the hatch. a Open the hatch. 1.
Removethe hatchsidetrim and hatchtrim panel(see p a g e2 O - 1 4 6 ) .
2.
Removethe nuts and disconnectthe connector.
: Nut locations,4 6 x 1 . 0m m Ch 9.8 N.m (J (1.0 ksl m,
__.
7,4b1!t
a Take care not to bend the tender well trim. a Beforeinstallingthe lender well trim, cleanthe bodv bondingsurfacewith a spongedampenedin alcohol. a After cleaning,keepoil, g.easeor wafer lrom getling on the surface. > i Scr€wlocations.
I ,/
I
coI{t{EcroR
Removethe hatch spoilerby turningthe clip nut on the left side counterclockwise. HATCH SPOILER
ADHESIVE
3.
FENDERWELL TRIM
Installationis the reverseof the removalprocedure.
20-159
Hatch Weatherstdp/TrunkLid Weatherstrip Replacement HatchWeatherstrip: NOTE: a Beforeinstalling applyclearsealantinto its channelat the > locations. the hatchweatherstrip, a After applyingthe sealant,installthe hatchweatherstrip.
ALIGNMENT MARK ff6llowl HATCH WEATHERSTRIP
Trunk Lid W€athorstrip:
MAE( ALIGI{MENT (Whitol TRUNKLID WEATHERSTRIP
HATCH/TRUNKLID WEATHERSTRIP When installingthe hatchor ttunk lid weatherstrip.align it with the alignmentmark on the hatch or trunk lid openrng. NOTE: a Make surethere are no wrinklesin the weatherstrip. a Check tor water leaks. ALIGNMET{' MARK Forward
Roof Molding Replacement CAUTION: When prying with I flat tlp scrowddv€r, wrap it with protoctivo tapo to pravent damag6.
a
Pullthe roof molding up and detach the bracket lrom the pin, then removethe roof molding.
NOTE: Take care not to scratch the bodv and root molding. 1.
Pry the rool molding with a flat tip screwdriver as snown. CAUTlOfil: Use protoctivo rape on tho body. ROOF MOLDING
SIDEMOLOII{G BRACKET
Pull and slide the root molding, then detach the bracket on the end of the roof molding from the pin.
4.
Installation is the reverse of the removalorocedure. NOTE: a Takecare not to damagethe windshieldside
ROOF MOLDING
molding. a Make sure the roof molding is installed securely.
R(X)F MOLDING PIN {Body ddq)
ROOF MOLDING
20-161
Door and Side Moldings Replacement protective tape to pr€vont damag€' CAUTION: When prying with 8 flal tip screwdriver, wrap it with NOTE: pages 2O-4' 2O' 32],' a To remove the doot moldlng, temove the door panel and plastic cover {see (see page 20-91) a To removethe rear side molding,removethe side trim panel a Take care not to bend the door moldings. is bent. Replacethe door molding a The steel core in the door moldingcann-otbe restoredto its originalshapeonce it if the steel core is bent. V : Clip locations av : cllp (Hatchb6ck, 5)
BV: clip (Hatchback' 3)
Dv: Cliplsodan,1)
CV: Cllp (Halchback,1l {Sodan,2l
STEEL
CLIP
V: Plastic nui locatlon (Hatchback, 1) (Sedan,1)
Hatchbsck
l r >
r9
O '
NOTE: a BeJoreinstatlingthe rear door molding, scrapethe adhesivetape from the molding and body. a Cleanthe motdingand door bondingsurJaceswith a spongedampenedin alcohol' a Atter cleaning,keepoil, greaseand water Jrom getting on the surface. a Gluethe new adhesivetape to the molding as shown. 30mm 6mm
ls 2f 61 . t.l.18inl
REAR DOOR MOLDING
30 mm ( 1 . 1 8i n l lnstallationis the reverseoJ the removalProcedure. NOTE: It necessary,replaceany damagedcliP.
20-162
NEW ADHESIVETAPE Thicknoss:1.2 mm lo.o5 inl
Forward
Side Sill Panel Replacement V : Clip locations AV: Ctip {Harchbsck,8) {Sodan. 8 l
> : Screw locations, 4
q,
BA : Clip (Harchback,7) {sodan,7l
/
SIDECLIP Removethe side clips from rhe body by turning them 45o
NOTE: Loosenthe screw, then .emovethe lower clip using a clip remover.
Remove the lower clips, then removethe side sill panel by sliding it forward.
Hatchback
\y':
NOTEj When removing the side sill panel, lhe side clips will
SIDE SILL PANEL
FENDER
To installthe side sill panel,removethe side clips from the body, installthem on the side sallpanel,then instatl the side sill panel on the car. NOTE: a Take care not to twist the side sill panet. a lf necessary,replaceany damagedside and lower clips,
20-163
RearEmblems lnstallation Align the applicaliontape with the rearturn signallight and the gap betweenthe taillightand tape' the emblem into place. Removethe applicataon
body, as shown, then press
NOTE: a Beforeapplying,clean the body surlace with a spongedampenedin alcohol' a After cleaning,keep oil, greaseand water from getting on the surface' a When applying,make sure there are no wrinklesin the emblem' Attachment Point:
REARTURN SIGNALLIGHT
Hatchback
REARTURN SIGNAL LIGHT
!---_-----------,-i-J
TAILLIGHT
20-164
Sub-frame Sub-t.ame Torque Sequence: cAUTloN: After rooseningtho rsar beam mounting borts be sura to repracothom with new onea.
6 x 'l.O mm 9,8 N.m (1.0 kgt.rn, 7.2 tbt-fll
REABBEAM BBACE 1 0 x 1 . 2 5m m 44 N.m {4.5 kgt.m, 33 rbr.ftl
FEAR BEAM COLLAR
REAR BEAM
REARBEAM 14 x 1.5 mm 89 tt.m (9.1 kst.m, 66 lbf.ftl Beplace.
20-165
FrameRepairGhart
1
-! ar"tr*,,,ua \
Model
Dls6ft-\
M/T
@
514.5 120.261
5 0 1. 5 (19.7)
U-)
2.5 (0.10)
25 {o.98)
(J
\---!e!s! Distance
{10.53) 112.03)
Sedan
\
o
2150 2100 (84.6t lE2.71 2642 2632 {103.6) {105.6}
J5
2 6 11 (102.8)
@
2657 2607 (102.6) (104.6)
t22.Ol
(104.8)
674 (26.5)
B A S EL I N E d11.5
d l 1 . 5t O _ 011.5
c r 1 . 5( 0 .
20-166
I cir (o-36;E;\ry+ Poinr ,
Aoad
|
9rl
lv
Front Osmpsr Lowsr Bush
POINT w
d 2 5 l l . o l L o c a r eH o l e g
@
20-167
Heater and Air Conditioning Heater A i r C o n d i t i o n i n .g. . . . . . . . .
. . . . . . . .2 1 - 1 ..22-1
RESTRAINTSYSTEM{SRS} SUPPLEMENTAL The IntegraSRS includesa driver'sairbag,locatedin the steeringwheel hub. In addition.all modelsexcept the RS model for Canadahave a front passenge.'sairbaglocatedin the dashboardabove the glovs box. Information necessaryto safely servicethe SRSis includedin this ServiceManual.ltems msrk€d with an asterisk(') on the conlents page include,or are locatednear, SRS components.Servicing,disassemblingor,eplacing thes€ items will requirespecialprecautionsand tools, and shouldthereforebe done by an authorizedAcura dealer.
a To avoid r6nd6dng tho SRS inoporativo. which could lead to personal injury or dealh in tho svont ot a sevele frontal collision, all SRS servica work musl b€ portormed by an authorized Acura dealer. a lmpropor sorvico procaduro3,including incorrect romoval and installatlon of tho SRS,could load to porsonaliniury causod by uninlonlional activation of tho ailbag8. a All SRS eloctdcal widng harnossosare covored with yollow in3ulation. Relatsd compononts a.o locatod in tha stsering column, flont console, daehboard,and dashboafd low6r pan6l, and in lhe dsshboa.d above lh€ glove box. Do not uao electdcal tost equipmont on theae circuhs. NOTE: The originalradiohas a coded theft protectioncircuit. Be sureto get the customer'scode numberbeto.e - disconnecting the battery. - removingthe No. 32 (7.5 A) luse from the under-hoodfuse/relaybox. - removingthe radio. "CODE" is displayed,enter the cusAfter service,reconnectpower to the radioand turn it on. When the word tomer's 5-digit code to restore radio operation.
Heater l f l u s t r a t eIdn d e x . . . . . . . . . . . . . .........21-2 HeaterDoor Positions .........,..,.21-3 C i r c u i tD i a g r a m . . . . . . . . . . . . . . . . . . . .2. .1.- 6 Troubleshooting S y m p t o mC h a r t . . . . . . . . . . . . . ......21-8 Flowcharts B l o w e rM o t o rS p e e d. . . . . . . . . . . . . . . . . . . . . . . . . . 2. .1. -. .9 B f o w e rM o t o r . . . . . . . . . , . . , , , , ,2. 1 . -11 M o d eC o n t r o M l o t o . . . . . . . . . . ...... . . . . . . . . . . . . . .2. 1. - 1 4 Recircufation ControlMotor ......,...,.,,,.,.... 21 -17 Heater Control PanelInput/ O u t p u tS i g n a l s ..............21-19 Blower Unit Repfacoment . . . . . . . . . . . . . . . . . . . .2. .1.- 2 0 Overhaul .......21-21 +HeaterUnit Repfacement . . . . . . . . . . . . . . . . . . . .2. .1. - 2 2 Overhaul .......21-24 DefrosterDoor Adjustment ...,............. ......,, 21 -25 Heatel Control Panel Repfacoment . . . . . . . . . . . . . . . . . . . .2. .1. - 2 5 Overhaul .......21-26 Heater Valve Cable Adjustment ...21-27 Air Mix Control Cable Adjustment ... 21-27 Mode Control Motol T e s t. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. .1.-. 2 e Repfacement . . , . . . . . . . . . . . . . . , , ,2, .1. - 2 8 Recirculation Control Motor T e s t. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. .1. -. 2 9 Repfacement . . . . . . . . . . . . . . . . . . . .2. .1. - 2 9 Relay T e s t. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. .1. -. 3 0 Heater Fan Switch T e s t. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. .1.-. 3 0 Mode Control Switch T e s t. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. .1. -. 3 1 Recilculation Control Switch T e s t. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. .1.-.3 1 *: Read SRS precautionsbefore working in this area.
lllustratedIndex CAUTION: a All SRS electrical wiling harnessesare covered with y€llow insulation. a Bafore disconnecting any pan of the SRS wile harness. connect the sholt connectorlsl. a Replacethe sntire aflected SRS halness assembly if it has an open circuit or damaged wiring. NOTE: The originalradio has a coded thelt protection circuit. Be sure to get the customer'scode numberbefore - disconnectingthe battery. - removingthe No. 32 (7.5 Al fuse lrom the underhood fuse/relavbox. - removingthe radio. After service,reconnectpower to the radio and turn it "CODE" is displayed,enterthe cuson. when the word 5-digit code to restoreradio operation. tomer's
SRS MAIN HARNESS
BLOWERUNIT Replacement,page 21-2O O v e r h a u lp, a g e2 1 - 2 1
I{EATERVAIVE CABLE Adjustment,page21-27
HEATERUNIT page2l 22 Repfacement, page21-24 Overhaul,
RECIRCULATIONCONTROLMOTOR Test, page 21-29 Replacement,page 21 29
BLOWENRESISTOR Test, page 21-9
W,
AIR MIX CONTROL CABLE Ad,ustment,page 21-27 Replacement.page 21-26
a/c swrTcH
(wirh A/cl Test,page22-20 RECIRCULATION CONTROLSWITCH T e s t ,p a g e2 1 - 3 1 HEATERFAN
swtTcH Test, page 2'l-3O
MODE CONTROLMOTOR Test, page 21-28 Repfacement,page 21'28
I
MODE CONTROLSWITCH T e s t ,p a g e2 1 ' 3 1
HEATERCONTROLPANEL Repfacement, page 21 -25 Overhaul,page 21-26
21-2
TEMPERATURECONTROL LEVER (Adjustmonl: See AIR MIX CONTROLCABLE}
Heater Door Positions
*)
!
xor
fr
coor.
VENTOOOR
-*) (HEAT/VENTI
(cont'd)
21-3
Heater Door Positions (cont'd)
\) IHEATI
El IHEAT/DEF)
N
CircuitDiagram - OASH UiIDEN FUSE/RETAY 8OX
- HOOO FUSE/REI.AY 8OX UNOER
(7.5A1 N0.13
WtlT/BtK.+WtfT
RECIRCUI.ATION
Moron coMTBor-
nrot
G401
21-6
UGHTIG
swtTcH
I
RED/BI.K
I r . l . | | I r t , /
I t v
A . t t A _ l t I I , f r r , /
v
I r v
A- l_t r r A- l. | , / t t f
v
I r v
A - f_ r r A- l. | | , f t t , /
v
I r v
A - l -r l , f I
v
I
HEATER CONTROL PANEI.
OASHIIGTTTS EnrGFr ESS coNTROU.IT
21-7
Troubleshooting Symptom Chart NOTE: Check the enginecoolant level and allow the engineto warm up before troubleshooting.
SYMPTOM Hot air flow is low.
No hot air Jlow
REMEDY
Blower motor runs, but one ol more speeds are inoperative.
Follow the tlowchart (see page 21-9).
Blower runs properly.
Check for the following: . Cloggedheaterduct . Cloggedheater outlet . Incorrect door position
Blowel motor does not run at all.
F o l l o wt h e f l o w c h a r t( s e ep a g e2 l - l 1 l
Blower motor runs.
Check for the following: . clogged heatet duct . Cloggedblower outlet . Cloggedheatervalve . Faultv air mix door . Heatervalve cable sdjustment lsee page 2'l-271 . Air mix control cable adjustment(see page 21-27) . Faultythermostat (seesection lO) . Cloggedevaporator(with air conditioning) . Frozenevaporator(with air conditioning)
Mode control motor does not run, or one or more modes are Follow the flowchart (see page 21-14). inooerative. Recirculationcontrol door does not changebetween FRESH Follow the flowchart (see page 21- 17). and RECIRCULATE.
21-A
Blower Motor Speed Blowor motor run3, bul ono ol mors rpoodt aro inoporotivo.
-l
Turn the ignitionswirch ON lll). and the heater tan switch OFF.
Does the blower motor run?
Turn the ignitionswitch OFF.
|t|
To pago 21-1O
\\ \
lI
iii
I!i
Measurethe rosistancebetwoen the No. 2 and No. 4 terminalsoI the blow€r resistor.
ls there aDorox.2-3 ohms?
Removethe heater conlrol pan€l {seo page 21-25}.
Turn the ignitionswitch ON (li).
At the heater fan switch 6P connector, ground each of these waresindividuallyin ths lollowing order: . BLU wire . BLUMHT wir€ . BLU/YELwire . 8LU/BLK wi.e
T o p a g e2 1 - 1 0
(cont'd)
21-9
Troubleshooting Blower Motor Speed (cont'd) From page 21-9
Does the blower motor run at progressively higher speeds?
Raplacatho hollar fan rwitch.
Ropair opon or cau36 ol oxcoalivt rosbtanco in tho appaopaiato wire(3| b6twoon thg hostct lan switch and tho blower todstor.
View trom whe side
From page 21-9
Turn the ignition switch OFF.
Removethe heater control panel (seepage 21-25).
Iilil -l
View from wire side
BLU/U,HT Checkeach wire for continuitybetween the heater tan switch 6P connector and body ground. . BLU wire . BLUMHT wire . BLU/YELwke . BLU/BLKwire
!\i
Raplaca tha haater lan awltch.
Bopair shon in the wir6{s} b€lwo€n lho heatot lan switch rnd th6 blowor ro3bto?.
21-10 --
BlowerMotor Blowor motor doos noi iun at all.
check the No. 37 (4o A) fuse in tho under-hood fuse/relay box.
View from wire side At th€ blower motor 2P connector, connectthe BLU/8LKwirc terminal to body ground wath a jumpe. wire.
Turn the ignitionswitch ON (ll).
Does the blower motor run?
To page 21-12
Disconnect the blower motor 2P connector, and measurethe voltago between the ELU/wHT wire terminal {+} and body ground
View from wire side
"uf"'\'
{-}.
,)
Turn the ignitionswitch OFF.
Remove the blower motor relav from the under-hood fuse/relav box and test it {seepage21-3O}.
Roplacotho blowor motor rolay.
Measurethe voltage betwgen the No. 1 terminal (+) and body g r o u n d( - ) .
T o p a g e2 l - 1 3
(cont'dl
21-11
Troubleshooting Blower Motor (cont'dl F r o mp a g e2 1 - 1 1
View trom wire side
BLU/BLK{+ } Turn the ignition switch OFF.
Removethe heater control pan6l (seepage 21-25).
Turn the ignitionswitch ON (lll.
Measurethe voltage b€twsen the 8LU/BLKwire terminal l+) and body ground {- ).
ls there battory voltage?
Rgp.lr op.n In lh. BLU/BLK wh. batwoen lh! blowar motor lnd tho hcolar f.n .wltch.
Turn the ignition switch OFF.
Check tor continuity in lhe BLK wire between the heater lan switch and body ground. Ch.ck tor an opan in lhr Bl-K wiro bdtwaan tho hortar tln lwftch .nd body ground. lf tho wlra l. OK, ch.ck for poor ground .t G201 .nd /rO1.
Roplacotho hsator tan lwitch.
21-12
From page 21-11
Tu.n the ignition switch ON (ll).
Measuretho voltage botwoon tho No. 4 torminal (+) 6nd bodv ground (- l.
ls there battery voltage?
Ropair opan in tho BLK/YEL wir. batworn lha undor-hood fuaa/rahy box snd tho undor-dr.h tur./rolay box.
Turn the ignirion switch OFF.
Checkfor continuity between the No. 2 torminal and body ground. Ch.d( to. !n oF|rn in th6 BLK wiro batwagn lho undar-hood luro/ralry box lnd body ground. ll th. wlre it OK. chock tor poo. ground at G2Ol lnd G/lol.
Rop.ir opon in th. BLU/WHT wlr. betweon tho undsr-hood lura/l.lay box and tho blowor motoi.
Troubleshooting Mode ControlMotor Modo control motor dooa not nm, or ono oa moto modo arc In_ oporgtivo.
Disconnectth6 mode control mo_ tor 8P connector.
Turn the ignition switch ON (ll).
Measuroth€voltage b€tween tho BLK/YELwire terminal (+) and bodv ground (- ).
R.p.lr op.n In lho BLrrYEL wl.. bctw.rn lha undard!.h fuaa/rul.y box .nd ih. mod! corttol motor.
Turn the ignition switch OFF.
To page 21-15
21-14
From page 21-14
View lrom wi.e side GRl{/YEL
Check for continuity in the BLK wire betweon the mode control motor and body ground. Chock lor an op6n In tho BLK wt botwo€n tho modo control motot lnd body ground. It thr wlro i! OK, chock for poo. grouhd ot G2O1 8nd G/tOl. Test the modo control motor (see page 21-281.
ls the mode control motor OKI
Removethe heater control oanel {soe page 21-25).
Disconnect the heater control Danel14P connector.
Ch€ckeach wire for continuitybotwoon the mod6 control motor and body ground. . YEL/BLUwire . Y€L wire . 8LU,^/VHTwire . GRNI/EL wire . YEL/REDwire
Romovothe mode control motor (soo pag6 21-281.
Ch€ck the modo control linkago and doo.s tor smooth movoment.
Do tho mode control linkage and doorc movs smoothlv?
Ropairth6 mod6 control linkago or doors.
Raplace thc modo control moto..
Roprir any .hort in th. wlrol!) b.tworn tha moda control anotot and tha holtar control pan6l. Checkthe samewires lor vohage.
ls the.6 any voltage? NO
Roplir rho.t to powar In tha 8LK^'EL wiro b.two.h lh. modo conlrol hotor rnd tha haat* control p!rr.|. (Thi! damrg.. tha hello. control p!nel.)
To psg6 2'l - 16
lconl'dl
21-15
Troubleshooting Mode Control Motor (cont'd) View from wire side From page 21-'l 5
Checkeach wire for conlinuitybetween the mode contiol motor and the heater control panel. . YEL/BLUwire . YEL wire . BLU/WHT wire . GRN/YELwire . YEL/REDwire R.psir any opon in fro wir6{.1 botwocn tho mod€ control motol snd tho holtar contiol prnal. Rsplocotho hoator conlrcl panol.
21-16
yEL
RecirculationControlMotor Rocirculation control doo. dooa not chsng€ botwoon FRESH6nd RECIRCULATE.
ffi
Disconnectthe rgcirculationcontrol motor 4P connector.
Turn the ignilion switch ON l).
Measurethe voltage betweenthe BLK^/ELwire rerminal {+) and body ground (- ).
ls there battery voltage?
Reprir op.n In th. BIK/YEL wir. botwoon thr und.r+rh fu!./r.by box 6nd lha radrculdion co.rtrol motoi.
Turn the ignition switch OFF.
T o p a g e2 1 - 1 8
{cont'd)
21-r7
Troubleshooting RecirculationControl Motor (cont'd) F r o mp a g e2 1 - l 7
Test the recirculationcontrol mo_ tor (see page 21-29).
ls the recirculationcontrol motor OK?
Removethe recirculationcontrol motor (see pag. 21-291.
Check the recirculation control linkage and door for smooth movement. Removethe heater control pan€l {seepage 21-25).
Do the recirculation control linkage and door move smoothly?
Disconnect the heater control panel 14P connector.
Ropalrtho ioclrculatioo conirol linkaga ot dool.
No. 5 GRN/RED
o. 6 GRI{MHT View from wire side Check for continuity in the GRNMHT and GRN/REDwires between the recirculationcontrol motor 6nd body ground.
RoDair shorl in rhs GRNMHT and/or GRN/REDwitols) botwoen the rocirculation conl.ol motot and tho hoster control Panol. Checkthe same wircs for voltage.
ls there any voltage?
Ropair 3hon lo Power in tho BLK/YELwiro botwoon ths rocitculalion control motoi and lhe ho6tor control Panel' {Thir ddmagos tho h€atot cont.ol oanol.)
Check for contin!ity in the GRN/WHTand GRN/REDwires between the recirculationcontrol motor and the heater control panel.
Ropair opsn in the GRi|/WHT and/o. GRN/REDwiro{sl botwoon ths rocirculstion conttol motot and tho hoator control Panol. Reolaceth€ heatsr control Panal.
21-18
View from wire sid6 GRN/RED
ffii
HeaterControlPanelInput/OutputSignals
No. Wire Color I
BLU/WHT
Signsl
N o . Wire Color
HEAT
INPUT
8
YEL
I{EAT/DEF
INPUT
q
YEL/BLU
DEF
BLK
GROUND
5
GRN/RED
RECIRCULATE
o
GRN/WHT YEL/RED
2 4
Si9n8l
GRN/YEL HEATA/ENT INPUT RED/BLK COMBINATION LIGHTSWITCH INPUT
INPUT 1 0 RED BRIGHTNESS CONTROLLER OUTPUT OUTPUT 1 1 BLU/RED A/C THERMOSTAT INPUT INPUT
12
FRESH
INPUT
1?
VENT
INPUT
't4
GRN
HEATERFAN SWITCH
OUTPUT
BLK/YEL
tG2
INPUT
21-19
Blower Unit Replacement NOTE: The blower motor, recirculation control motor and blower resistor can be replaced without lemoving t h e b l o w e ru n i t ( s e ep a g e2 l - 2 1 ) . 1.
Removethe glove box (see section 2O),
2.
Removethe fou. bolts and the glove box frame.
With Air Conditioning 3-b. Removethe evaporator(see page 22-261.
CLIPS
6 x I 9.8 .ft 11.Okgt.m, 7.2 tbt.ftl GLOVE BOX FRAME
Without Ail Conditioning 3-a. Removethe wire harnessclips trom the heat€rduct. Removethe Jour self-tapping screws 8nd the heater duct.
4.
Oisconnectthe connectors from the blower motor, blower resistor and the recirculationcontrol motor. Removethe wire harnessclip from the recirculation control motor, and releasethe wire harnessfrom the clamo on the blower unit. Removethe two mountingbolts, mountingnut and the blower unit, 6 x 1 . 0m m
9.8 .m (1.O kgl'm, 7.2 lbf'ft}
HEATERDUCT
6 x 1 . Om m 9.8 N'm (1.0 kgf'm. 7.2 tbt.ftl
6.
21-20 --
lnstall in the reverse order of removal, and make sure there are no air leaks.
Overhaul NOTE: ' Before reassembly, make sure that the recirculation control door and linkage move smoothly without binding. ' When teattaching the recirculationcontrol motor, make sure its positioning will not allow the recirculationcontrotdoo. to be pulled too fat. Attach the recirculationcontrol motor and 8ll links, then connect power and ground, and watch the movement ol the reci.culation control door.
m BLOWERRESISTOR Test. pags 2l-9
21-21
HeaterUnit Replacement CAUTION: a All SRS electrical witing hame$os are covoed wlth yollow insulation. a Before disconnecting any patt of tho SRS wito harneas, connect tha shott connoctol(s|. a Roplacoth€ enlire sffacted SRS harnosr a$smbly if it has an opon cilcult or dsmaged wiring.
3.
Disconnect the heater hoses from the heater unit' CAUTIOII: Engino coobnt will damago paint. orickly dnse any rpilled engine coolant from paintod surfac63. NOTE: Enginecoolantwill tun out when the hoses are disconnected,drain it into a clean drip pan' CLAMFS
NOTE: The original radio h8s a coded theft protection circuit. Be sureto get the customer'scode numberbetors - disconnecting the bafterY. - removingthe No. 32 (7.5 A) fuse from th€ underhood tuse/relavbox. - removingthe radio After service. teconnect power to the radio and turn it "CODE" is displayed,enterthe cuson, when the word tomer's 5-digit code to restoreradio operation. 1. When the engineis cool, dtain the enginecoolant from the radiator(see section 1O). oo not lomove tho radiator cap whan @@ the ongine is hol; tha ongino coolant is undot pressure and could a€voralYtcald you. 2. Snap open the clamp and disconnect the heater valve cable from the heater valve arm. HEATERVALVECABLE
21-22
HEATERHOSES
4.
Remove the mounting nut from the heater unit. NOTE: When removingthe mounting nut, take care not to damage or bend the fuel pipes, brake pipes, etc. 8 r 1,25rn|n 22 N.m 12.2kgt.m, tO lbf'ftl
5.
Rsmove the dashboard (see section 2O).
6 . Remove the heater duct (see page 21-20) or the evaporator lse€ page 22-26).
7.
Rsmovethe two bolts, nut and the passenger,sSRS (}eam.
8 x 1,26 mln
22 N.m 12.2kgf.m, 18 tbt.ttl
9.
Install in the reverse order of removal, and: a apply sealant to the grommets. a do not int6rchange the inlet and outl€t hoses. Make sure that the hose clamps are secure. a loosen th€ ble6d bolt on th6 engine and r€fillthe tadiator and coolant r€servoirwith the propsr en_ gine coolant mixture (sse section 1O). Tightenthe blsed boh when all the trappedair has 6sc8p6dand engine coolant begins to flow from it (seesection 1O). a connect all csblesand make surethey 8re properly adiusted (see pdge 21-271.
PASSEIVGER'S SRSEEAM
8 . Disconnect the mode control motor conngctor, and remove the wire harness clip from the h€8ter unit. Removethe two mounting nuts and the haater unit.
6 r 1 . 0m m 9.8 .m (l.O kgt.m,7.2 tbt.frl
MODE COI{TROLI,IOTOR
col{t{€cToF
21-23
HeaterUnit Overhaul 1 . Remove the screw and the damper arm cover.
Pull out the heater core.
Disconnect the link from the dampar arm, and remove the screw and the damper arm.
NOTE: Be careful not to bend the inlet and outlet pipes during heater core removal.
?
Removs the two screws and the heater core cover.
Assemble in the rev€rse older of disassembly.
4.
Remove the screw and the pipe clamp. HEATERCORECOVER
DAMPERARM COVER
HEATERCORE
DAMPEFARM
21-24
HeaterControlPanel DefrosterDoor Adjustment
Replacement
Set the mode control switch on HEAT.
Disconned the air mix control cable from the heater unit lsee page 21-271.
Loosen the adiusting screw.
Remove the rear window defogger switch and the hazardwarning switch.
Turn the adjusting arm to the left, as shown, so that there will be no heat leakagefrom the defrosterdoor, 4.
Remove the two self-tapping screws, then pull out the heater control panel and the center air vent. Disconnect the connectots,and removethe heatercontrol panel and the center air vent.
Tighten the sdjusting screw.
AD.'USTII{G ARM
NOTE: The locking tabs of the hazard warning switch and heater control panel connectors are on the bottom. CE]TTER AIR VEI{T
REARWITIDOW DEFOGGER swtTcH
ADJUSTI G SCREW AIR MIX CONTROLCABLE
4.
Removethe four self-tappingscrews and the center air v€nt.
CENTEBAIR VE T
Installin the reverseorder of removal.and adjust the air mix control cable at the heater unit lsee page 21-27). lf necessary,adjustthe heatervalve cable l s e ep a g e 2 1 - 2 7 ) .
21-25
HeaterControlPanel Overhaul HEATERFAN SWITCH Test, page 21-30
AIR MIX CONTROLCABLE Adjustment, page 21-27
Air Mix Control Cable Replacom€ni 1. Removethe ait mix control caDle' 2.
lever, and push the cable housinguntil it Hook the tip of the new air maxcontrol cableto the temperaturecontrol is locked.
AIR MIX CO]IITROLCABLE
NoTE:Alterassemb|y,checkthatthetemperaturecontro||eve's|idessmooth|ythroughthe'u||strokefromright to left.
21-26
Heater Valve Gable
Air Mix ControlCable
Adjustment
Adjustment
Disconnectthe heatervalve cablefrom the heater valve arm and the clamp,and from the heatercontrol arm and the clamp.
'l
.
Disconnectthe air mix control cable from the air max control arm and the clamp.
2.
Set the temperaturecontrol lever to MAX, HEAT.
3,
Turnthe air mix controlarm as shown. and connect the end of the air mix cont.ol cable to the air mix control arm.
4.
Gently slidethe air mix control cable housingback trom the end enoughto take up any slack in the air mix controlcable,but not enoughto makethe tempe.aturecontrol lever move, then snap the air mix control cable housinginto the clamp.
2 . Set the temperaturecontrol leverto MAX. HEAT. Turn the heatercontrolarm as shown. and connect the end of the heatervalvecableto the heatercontrol arm. Gentlyslidethe heatervalve cablehousingback from the end enoughto take up any slack in the heater valve cable,but not enoughto make the temperature controllever move. Holdthe end of the heater valvecablehousingagainstthe stop, then snapthe heatervalve cable housinginto the clamp.
NOTE: The heatervalvecableshouldalwaysbe adjusted wheneverthe air mix controlcablehas been disconnected. AIR MIX CONTROL CABLE
HEATERCOIITBOL ARM
5.
AIB MIX CONTROL ARM
HEATEBVALVE CABLE
Turn the heate.valve arm as shown, and connect the end of the heatervalvecableto the heatervalve arm. Gentlyslidethe heatervalve cablehousingback from the end enoughto take up any slack in the heater valve cable, but not enoughto make the temperature control levermove,then snapthe heatervalve cable housinginto the clamp, NOTE: The air mix controlcableshouldalways be adjustedwheneverthe heatervalvecablehas been disconnected.
CLAMP
21-27
Mode Control Motor Test
Replacement Disconnoct ths mode control motot 8P connector, and remove it from lhe heater unit.
ConnectbatterYpower to the No. 4 terminslof the modecontrol motor and connectgroundto the No' 8 terminal. Using a jumper wire, short the No. 8 terminsl individuallyto the No. 1, 2, 3. 6 and 7 terminals,in that order.
Remove the two sclsws, mode control motot, and flango coll8,. MODECONTROL iioroR
a Eachtime the short circuit is mad€,the mode control motor should run smoothly and stop. NOTE: ll the modecontrolmotordoesnot run when shortingthe tirst terminsl,short that t€rminalagain after shortingthe other terminals. The mode control motor is no.mal it it runs when shortingthe tirst terminalagain.
3.
lf the modecontrolmotor doesnot run in step 2, re' move it, and check ths mode control linkage8nd doors for smooth movement.It the mod€ control linkageand doors move smoothly, replaceth€ mod€ control motor.
21-28
lnst8ll in tho rsvsrse order of removal. After inst8llstion, make sur€ the modo control motor runs smoothlv.
Recirculation ControlMotor Test
Replacement
Connectbafterypower to the No. 1 terminalof the recirculation control motor, and connect ground to the No. 2 and No. 4 terminals;the recirculation control motor should run smoothly.
Disconnectthe 4P connector from the recirculation control motor, and removethe wire harnessclio from it. Removethe two screws, recirculationcont.ol mo, tor and flange collar.
Disconnectthe groundfrom the No. 2 or No. 4 terminals; the recirculation control motor should stoo at FRESHor RECTRCULATE.
4P CONNECTOR
CAUTION: N6v€r conn€ct the batt6ry in ths oppoaite direction. NOTE: Don't cycle the recirculationcontrol motor for a long time.
SCREWS 3.
REC|RCULAT|OII CONTROL MOTOR
Instsllin the reverseorderof removal.After installation, make sure tha tecirculationcontrol motor runs smoothlv.
It the recirculationconttol motot does not run in steD '1, removeit, and check the recirculationcontrol linkage and door for smooth movement.lf the recirculation control linkage and doo. move smoothly, replacethe recirculationcontrol motor.
21-29
Heater Fan Switch
Relay There should be continuity b€tween the A and C terminals when Dower and ground are connectedto the B and D terminals. There should be no continuity when power is disconnected.
Check for continuitv bstween the terminalsaccordingto the table below.
Terminal
A
D
B
E
Position OFF ,l
3 4
rl
r?
21-30
I I
ooo-
-o -o -o -o
RecirculationControl Switch
Mode Control Switch
Test Check for continuity between the terminalsaccordingto the table below.
Terminal Position
4
Heat/Def
o --o --o o-
Def
G
Vent
o-
Heat/Vent
G-
Heat
J
7
8
Check for continuity between the terminalsaccordingto the table below.
Terminal Position Fresh Recirculate
-O
4
oo-
5
6
--o -- -o
--o --o
21-31
Air Conditioning *Evaporator Repfacement Overhauf Compressor
.........22-26 ................ 22-27
Description ............ 22-28 fffustratedfndex ............................... 22-29 Replacement .........22-30 Cfutch lnspection ....................... ......22-32 Cfutch Overhaul............................... 22-33 Refief Vafve Replacement............... 22-34 A/C Compressor Belt Repfacement .........22-35 Adiustment ............22-36 Condenser Replacement .........22-37 A/C System Service Evacuation ....,.......,22-38 Charging ................ 22-39 LeakTest ...............22-40 +: Read SRS precautionsbefore working in this area.
SpecialTools
Ref. No.
I
Tool Numbel OTLAJ- PT3O1OA 07JGG- 001010A
I 22-2
Test Harness BeltTensionGauge
lllustratedIndex CAUTION: . All SRS electrical wiring harnossosare cover€d with yellow insulation. . B€fors disconnacting any part of the SRS wire harness,connsct the 3hort connsctor(s). . Replacethe entirs affscted SRS harness assembly it it has an open circuit or damaged wiring. NOTE;The original radio has a coded theft protection c i r c u i t . B e s u r e t o g e t t h e c u s t o m e r ' sc o d e n u m b e r before - disconnecting the battery. - r e m o v i n gt h e N o . 3 2 ( 7 . 5A ) f u s e f r o m t h e u n d e r hood fuse/relaybox. - removingthe radio. After service,reconnectDowerto the radio and turn it on. When the word "CODE"is displayed,enter the customer's5-digitcodeto restoreradiooperation.
SRSMAIN HARNESS lcover€d with yellow insulationl
EVAPORATOR page22-26 Replacement, Ovethaul.Oase22.27
SERVICEVALVE (LOWPRESSURE SIDEI
SERVICE VALVE IHIGHPRESSURE SIDE)
RECEIVER/DRYER CONDENSER Replacement, page22,37
A/C PRESSURE SWITCH W h e n t h e r e f r i g e r a n tp r e s s u r ei s b e l o w 2 0 0 k p a ( 2 . 0 kqflcm,,28 psi) due to refrigerantleakageor above3]OO kPa (32 kgf/cm,, 460 psi) due to coolant btockage,the A,/C pressureswitch opens the circuit to the A"/Cswitch and stopsthe air conditionang to protectthe compressor.
COMPRESSOR page22-30 Replacement,
22-3
Wiring/ConnectorLocations
A/C DIODE CONNECTOR (Loc.ted .bovo tho.ight kick p.n.ll
RADIA'OR FAN RELAY {Localedin the undel-hoodfu3o/reltY box) A/CTHERMOSTAT CONNECTOR
CONDENSERFAN CONNECTOR
MAIN WIREHARNESS A/C WIREHARNESS CONNECTOR RADIATORFAN CONNECTOR
A/C WIREHARNESS
CLUTCH COMPRESSOR CONNECTOR
22-4
A/C PR€SSURESWTTCH CONNECTOR
Circuit Diagram
N0.41l10oAl No.39{5OAl
No.1317,5A)
MOIATOR REI.AY
22-5
Description Outline refrigerantthroughthe sysThe air conditionersystemdeliverscooledair into the passengercompartmentby circulating tem as shown below.
Hightemperature/ Trapsdebris Hightemperature/ Hightemperature/ gas hilh pressureliquid and removes high pressureliquid high pressure molsture heat of Radiation SuctionandcomPression
RECEIVER/DRYER
-
coMpRESsoR -coNDENSER
Moreliquidified vaPor low Pressure Absorptionof heat VALVE EXPANSION EVAPORATOR <-'----------.-
Less moisturized low pressurevaPor
EVAFORATOR
CONDENSOR
to the following {R-134a)refrigerantwhich does not containchlorofluorocarbonsPay attention This car uses HFC-134a service items: (R-134a)They are not compatible' Do not mix refrigerantsCFC-I2(R-l21and HFC-134a designedfor the Rrefrigerantoil (ND-OIL8: P/N38899-PR7-A01) potyatkytenegtycol {PAG) Use onty the recommended oil will resultin comrefrigerant 134acompressor.Intermixingthe recommended(PAG)refrigerantoil with any other pressortailure. .A||lvcsystemparts(compressor.dischargeIine,suotionIine,evaporator,condenser.receiver/dryer,expansionva|ve. o-ringsforioints}havetobeproperforre'rigerantR-l34a.DonotconfusewithR.l2parts. . Usea halogengas leakdetectordesignedfor refrigerantR-134a' Only use a Recovery/Recyclins/Charging . R-.12and C-l34a refrigerantservicingequipmentare not interchangeable. J2210 to serviceR-134aair conditioningsyssAE of requirements the to meet and is certifLd Systemthat is U.L.-listed rems. any Systembeforedisconnecting . Always recoverthe refrigerantR-134awith an approvedRecover/Recycling/Charging A,/Cfitting.
. .
22-6
Troubleshooting Reference Ghart . .
Any abnormality must be correctsd before continuing the test. Becauseof the precisemeasurgmentsneeded,use a multimeter when testing.
Before performing any troubleshooting procedurescheck: . Fus€s.r No. 35120A), *1 No. 33 (20A), ), No. 13(7.5A) . G r o u n d sN o . G 4 0 1 G , 2 0 1G , ' 1 5 1G, 1 0 1 . Cleanliness and tightnessof all connectors *1:In the under-hoodfuse/relaybox *2:In the under-dashfuse/relaybox SYMPTOM
REMEDY
Radiatorfan does not run 8t all.
Performthe proceduresin the flowchan(seepage22-8).
Condenserfan does not run at all.
Performthe proceduresin the flowchart(seepage22-10).
Both fans (radiatorand condenser)do not run for engine cooling, but they both run with the Ay'Con.
Performthe proceduresin the flowchan(seepage22-12).
Eothfans do not run at all.
Performthe proceduresin the flowchart(seepage22-13).
Compressorclutchdoes not engage.
Performthe proceduresin the flowchart(seepage22-14).
Ay'Csystem does not come on {compressorand both fans}.
Performthe proceduresin the flowchart(seepage22-16).
22-7
Troubleshooting RadiatorFan Redi.to. fan doo3 not run at all. check rhe No. 33 {20 A) fuse in the under-hoodluse/relaybox.
R e m o v et h e r a d i a t o rl a n r € l a y from the under-hoodIuse/relay box and test it (seepage 22-19). Raplacatha radiator tln rahy.
Measurethe voltage betweenthe No. 3 terminal (+) and body ground{-}. ls therg batteryvoltag€?
Connectthe No. 1 and No. 3 terminalswith a jumperwire. Doesthe radiatorIan run?
To p3ge 22-9
Chockfor continuityin the BLK./ REDwire between the No. 1 terminaland the radiatorfan. R.p.ir opdr in th. 8LK/RED wir. batwaon th. unda.-hood fut./ ralay box rnd tha radirtor f.n. Checkfor continuity in th€ BLK w i r e b e t w e e nt h e r a d i a t o r{ a n and body ground. Ch.ck to..n op.n in th. BLK wirc batwaan th. rldirtor hn lnd body ground, lf tha wita i! OK, chack tor poor gtound rt G2ol lnd GiOl. Rephco tho radi.tor frn motor.
22-A
Fromprge 22€
Disconn.ct the iump.r wirc lnd tu.n th6 ignition gwitch ON (fD.
Mo66u,otho voltlgs botwoontho No. 4 torminll (+) 6nd bodv ground {-}. Rap.lr o9.|| ln th. GRN wlr. b+, twaan tha ondar.hood tuaa/ rtLy box .nd thr A/C diod..
B.p.lr olrn h th. BLX.IYEL wlrr batw..n th. undar.hoodtu../ rcl.y bor aDd iha undar.darh fur/r.Ly box.
22-9
Troubleshooting CondenserFan
BLK/WHTl+l Removethe condenserfan relay and test it (seepage22-19).
Replacothe condan3arfrn rclay.
Measurethe voltag€ betwe€nthe WHT wire terminal(+) and body ground(-). Replir opcn in tho WHT wiro botwoen tha undor-hoodfura/Jolay box rnd tha condonr.rlan rclay.
BLU/YEL Viewlrom wireside
Connoctthe WHT and BLU/BLK w i r e t e r m i n a l sw i t h a j u m P e r
Doesthe condenserfan run?
10 page 22-11
View from wire side Checkfor continuityin the BLU/ BLK wire betweenthe condenser fan Ian relayandthe condenser
BLU/BLK Reprir op€n in th. BLU/BLKwiro batwcen the condenrai lan rolay and the condcntor ftn
Checkfor continuity in the BLK wire between the condenser fan and body ground. C h e c kf o t . n o p . n i n t h o B L K wire botween the condental trn and bodv g.ound. It the wiro i3 OK, chock lor Poo. ground rt G151. Raplaco the condon36r fan motor.
22-10
Frompage22-10
Disconnectthe iumper wire and turn the ignitionswitchON (ll).
Measurethe voltage betweenthe BLK/WHTwire terminal (+) and body ground(-). Reptir open in tha BLK/WHT o. BLK/YELwire betwoon tho conden3o. f.n rel.y and tho unde.dash tus6/rel.y box. Remove the iay'Cdiode from the Ay'Cdiode 3P connector.
ls the A,/Cdiode OK?
Reprir op6n in th. BLU/YELwire betwocn tho conden3ertsn reltv .nd tho A/C diod€.
22-11
Troubleshooting Bolh tanr lradiltor and condan.arl do not run fot angina cooling. bul th.y bolh tun whh th. A/C on.
Disconnecttho engino coolanl temporsture(ECT)switch 2P conn6ctor.
Turnrhe ignitionswitchON (ll).
Measureth€ voltago botw€enth6 cRN wire terminal(+) and body ground{-}. R.p.ir op.n in ih. GRN wir. b.tw..n th. ECT .wilch .nd th. undrr.hood ful./t l.y box.
Turn the ignition switch OFFand check lor continuity in the BLK wire beMeen the ECTswitch and body ground. Ch.ck tor.n op.n in th. BLK wir. b.lw.!n th. ECT .witch .nd body ground. It th. wit. i. OK, chacl lor poor Oround tt G10r.
Do€s it road above normal?
22-12
Both Fans Both tans do not run at all.
Remove the A,/Cdiode from the A,/Cdiode 3P connector.
ls the !y'Cdiode OK?
Rep.ir op€n in tho 8LU/REDwirc belwoen tho A/C diod. lnd th. A/C o.$sure lwitch.
22-13
Troubleshooting Gompressor
R6movethe comPressorclutch refayand test it (see Page22-19l..
BLK/YEL{+l
WHTl+l
Measurothe voltage bgtlveenth€ WHT wire terminal{+) and body ground{-}. Rap.ir op.n in ih. WHT wit. batwaan tha undar-hood fuaa/ ralay box and thg comptaalol clutch r.l.y. Connect tho WHT and 8€D wire terminalswith a jumPerwire.
BLK/RED Viewfromwir€side
View lrom wire side
Disconnect the comPressor clutch1Pconnsctor.
To page22-15
Checkfor continuityin the RED w i r o b o t w e e nt h e c o m P r e s s o r clutch relay and the comPressor clutch. Replir op.n in th. REO wi.c batwaan tho comPrdaor clutch rol.y and the compr.33oi clulch.
Inapact tha compter3oa clutch clelranca !nd ihc comPacaaor ctutch fi€ld coil {!.. P.9.22'32}.
22-14
Frcm page22-11
Turn the ignition switch ON (lI).
M€asurethe voltage betweonth6 BLK/YELwire terminsl {+) and body ground (-).
ls there battery voltage?
R.p.i. opcn in th. 3LX/YEL wirr balwarn tha undar.da3h tuaa/ .clay box and iha como.aaao. clutch rahy.
Turn the ignition switch OFFand i n s t a l l t h e c o m p r o s s o rc l u t c h relay.
Bdt ry vohro.? Connectthe test harness"A" and "8" conoectorsto th6 main wire harnessonly, not to the ECM(s6g section11).
_@_____-l
Blttary vohago?
r_--@_
Bs {+)
Turn th6 ignition switch ON (II). TESTHARNESS 07t4, - PT3010a Measurethe voltagGbetweenthe A15 terminal (+) and body ground(-1.
R.prir op.n in th. BLK/REDwirt b.twran the compraa.or clotch ..1.y .nd th. ECM. Make sure the A/C and heate. ten switch6sare OFF.
Measuretho voltage b€tweenthe 85 terminsl(+) and body ground
(-).
R.p.ir op.n in th. BI-U/REDwir. b.tw.rn th. A/C diod. .nd th. CCM. Sub.titute r known-good ECM and rocheck. lt lymptom/indicrtion go€3rwry, rapbca th. originrl ECM.
22-15 "
,
-1llltf,'tfrSfiiwiafi
Troubleshooting A/G System A/C ay3t6m doe3 not como on (compro!3orand both f.ns).
D i s c o n n e c tt h e A / C p r e s s u r e switch 2P connector.
Turnthe ignitionswitchON (II).
Measurethe voltage beoveenthe w i r e t e r m i n a l( + ) a n d BLU/RED bodv ground1-).
View from wire side
Reprir opon in thc 8LU/REDwire batwoan tho A/c prossute rwitch rnd th. A/C diod..
Turnthe ignitionswitchOFF.
Checklor continuity betwoenthe No. 1 and No. 2 terminalsof the A,/Cpressureswitch.
Checkfor NC system Pressure.
R e c on n e c t t h e A / C p r e s s u r e switch2P connector.
10 page22-17
22-16
Rophcetha A/C pre3!u.6 awitch.
YEL/WHT
BLU/RED{+l
Frompage22-15
Turnthe ignitionswitchON (IIl.
YEL/WHTl+l Measuretho voltage betweonthe BLK/YELwire terminal (+) and body ground(-).
R.p.i. op.n ir th. BLX/YEL wiro batwc.n tha unda.-darh fuao/ r.l.y box .rd rh. A/C th.rmo.t!r. Measureth€ voltage betweenthe YEL/WHTwire terminal {+} and body ground (-).
ls there battoryvoltage?
R.prir op.n in th. YEL/WHT wiro bctwaan tha A/C praaau.c rwhch .nd th. A/C th..mo.ht.
T!rn the ignition switch OFF.
R€connectthe Ay'Cthermostat 3P conn€ctorand connectthe BLU/ REDwire terminalto groundwith a l!mper wire,
View from wir€ side
Do the radiator and cond o n s e rf a n s r u n a n d t h e compressorclutchengage?
Turn the ignition switch OFFand disconn6ct the jumperwire.
To page 22-18
(cont'd)
22-17
Troubleshooting A/C System(cont'dl Frcm page22'17
Removethe heatercontrolPanel (seepage21 25)
D i s c o n n e c t h e h e a t e rc o n t r o l panel14Pconnector'
No. 11 BLU/REDl+l
View lrom wire side
Turnthe ignitionswitchON (lI).
Measurethe voltagebetweenthe w i r e t e r m i n a l( + ) a n d BLU/RED body ground{ } Rop.i. opon in tho BLU/BEDwir. b.twoon tha A/C thermort.t lnd the haat.r control Panal
Turnthe ignitionswitchOFF.
ls the A/C switch OK?
Checkfor continuitYin the GRN wire betweenthe heatercontrol paneland the heaterfan switch R.prir op.n in the GRN wiro be' twoen thc hartet contlol Panal and tho h.rtor fln switch.
Checkfor continuity in the BLK wire between the heater{an switchand body ground. Chock fol an opon in the BLK wi.a b.tween th. hotte. hn lwitch tnd bodY ground. ll tho wiro it OK, chock for Poor g.ound .t G4ol .nd G402. Replace the heater lan switch.
22-18
A/C Thermostat
Relays
Test Connectbatterypower to terminalC and ground terminal B, and connecta test light betweenterminalsA and
N O T E :U s ea 1 2V , 3 W - 1 8 W t e s tl i g h t .
Thereshould be continuitybetweenthe A and C term! n a l s w h e n p o w e r a n d g r o u n da r e c o n n e c t e dt o t h e B and D terminals. There should be no continuitywhen power is disconnected.
Dip the A-/Cthermostat into a cup filled with ice water, and checkthe test light.
,r I
The light should go off at 37"F(3"C)or less.and should come on at 39"F(4"C1or more.
.I I
n
lf the light doesn't come on and go off as specified, replacethe Ay'Cthermostat. .
I
b P
I
Radiatorfan relay
12V.3W-18W
A
B
C
a Condenser fan relay a Compressor clutchrelay
22-19
Diode Test NOTE: The diode is designedto pass current in one directionwhile blockingit in the oppositedirection. U s e a n a n a l o g o h m m e t e r ,o r a d i g i t a l o h m m e t e r equippedwith a diodetester. Checkfor currentflow in both directionsbetweenthe A and B. and B and C terminals.There should be current flow in onlv one direction.
A/C Switch Test NOTE:The Ay'Cswitch containsa diode. Use an analog ohmmeter,or a digitalohmmeterequippedwith a diode tester. Checkfor current flow in both directions betweentermi nals 11 and 12.Thereshouldbe currentflow in only one direction. Terminal Position ON OFF
22-20
11
o
A/C ServiceTips and Precautions (R-134a) The air conditionersystemusesHFC-134a (PAG)retrigerantoil (ND-OILg: p/N .efrigerantand polyalkyleneglycol 38899- PR7- A0l ), which are not compatiblewith CFC-12 refrigerantand mineraloil. Do not use R-12refrigerantor \R-'12) mineraloil in this system,and do not attemptto use R-'12servicingequipment;damageto the air conditionersystemor your servicingequipmentwill result. only use serviceequipmentthat is u.L,-listedand is certifiedto meet the requirementsof sAE J2210to removeR-134a from the air conditionersvstem. CAUTION: Exposurelo air conditioner refrigorant and lubricanl vapor or mi3t cln irritato gyos, nose and throat. Avoid breathing lhe air conditioner refrigerant and lubricant vapor or mist. lf accidentalsystemdischargeoccurs,ventilatework areabefor€resumingservice. R-134aserviceequipmentor vehicleair conditionersystemsshouldnot be pressuretestedor leaktestedwith compressed air. some mirtures of air and R-l3ifa have been 3hown to be combu3tible at slsvated prossurosand can relult @ in fire or explosion causing inlury or property damage. Never use complessod ai. to prgssuret€|st R-134aservice equipment or vehicle air conditiongr systems. Additionalhealthand safetyinformationmay be obtainedfrom the refrigerantand lubricantmanufacturers. '1. Alwaysdisconnect the negativecablefrom the batterywheneverreplacingair conditioningpans. 2. Keepmoistureand dust out of the system.When disconnecting any lines,plug or cap the fittingsimmediately;don't removethe capsor plugsuntil just beforeyou reconnecteachline. 3. Beforeconnectingany hoseor line,applya few dropsof refrigerantoil (ND-OIL8: P/N38899- PR7- AO1)to the O-ring. 4. Whentighteningor looseninga fitting,usea secondwrenchto supportthe matchingfitting. 5. When recoveringthe system,use a R-134arefrigerantRecovery/Recycling/Charging System;don't releaserefrigerant into the atmosDhere. 6. Add refrigerantoil (ND-OlL8: P/N38899- PR7- A01)after replacingthe followingparts: NOTE: . To avoidcontamination, do not returnthe oil to the containeroncedispensed,and nevermix it with other refriqerant orls. . lmmediatelyafterusingthe oil, replacethe cap on the containerand sealittoavoid moistureabsorption, . Do not spill the refrigerantoil on the car; it may damagethe paint;if the re{rigerantoil contactsthe paint,wash it off immediately. Condenser..................... 25 m/ (5/6fl.oz,0.9 lmp.oz) ilo mf 17113fl.oz,1.4lmp.oz) Evaporator................. Line or hose 10 ml (1/3 fl.oz. o.il lmp'ozl Receiver/Dryer .....,.,,...., 10 m{ l1l3 tl.oz,0.4 lmp.ozl Leakagerepair .............. 25 mf (5/6fl.oz,0.9 lmp.ozl Compressor For compressor .eplacom€nt, subtract the volumo of oil drained from tho removed compressor trom 140 ml 11 213 ll.oz, 1,9 imp.ozl, and drain the calculalgdvolume of oil from t h o n e w c o m p r e s s o r :1 4 0 m f 1 1 2 1 3 l l . o z , 1 . 9 imp.ozl- Volume ot removod compressor= Volume to drain from n€w compressor. NOTE:Even if no oil is drainedfrom the removed c o m p i e s s o rd, o n ' t d r a i n m o r e t h a n 5 0 m l 1 1 2 1 3 fl.oz,1.8lmp .oz)from the new comDressor.
hoseto the compresso.(6 x 1.0mml O Dischargo (, Dischargehosato ths condenser(6 x 1.0mm) pipeto tho condenser(6 x 1.0mml @ Condenser pipeto the receiver/dryer (6 x 1.0mm) @ Condenser pipeA to tho receiver/dryer @ Receiver 16x 1.0mm)
.............................. 9.8N.m {1.0kgt.m,7.2lbf.ft) . 9.8 N.m {1.0kgf.m,j.Z lbl.ftl 9.8N.m n.O kaf.m,t-2tbl.ftl ......................... 9.8N.m (1.0katm,7.2lbf.ft) ......................... 9.8N.m(1.0kttm. 7.2lbt.ft) @ Receiverpipe A to th6 receiverpipe B ...................................... ........13N.m {1.3kgt.m.9.4lbt'ft) O Receiverpipe B to the receiverpipe C ......................................
@ Receiverpipe C to the evaporator(6 x 1.0mm) @Suaion pip€B to the evaporator{6x 1.0mm) ................ @ SustionpipeA to the suctionpipeB .................. (, Suctionhoselo the suctionpipeA ................ OASuctionhoseto the compressor {5x 1.0mm} ................
13 N.m {1.3 kgf.m.9.4 lbf'ft)
9.8 N.m {1.0kgf.m, j.Zlbl.ftl ................ 9.8N.m tt.Ot!f.-, r.Z tUttt} 3t N.m (3.2klnm,23 lbf.ft) ......31 N.m (3.2kgf.m,23 tbf.ftl ................. 9.8N.m11.0kgt.m,7.2lbf.ft)
22-21
A/C System Service Recovery and is cerOnlv use serviceequipmentthat is U.L.-listed tified to meetthe requirementsof SAEJ2210to remove (R-134a) from the air conditionersystem. HFC-134a CAUTION: Expo3ute to air conditioner rcfrigelant rnd lubricant vapor or mist can irritatc oyo!, no3o and throat. Avoid bresthing the lir condhionot rofrigorlnt and lubricant vapor or misl.
R.cov.rylR.cycling/Ch.rging
lf accidentalsystem dischargeoccuts, ventilate work areabeforeresumingservice. R-134aserviceequipmentor vehicleair conditionersystems should not be pressuretested or leak tested with comoressedair. some mixturos ot Eir and R'134. hsvc !!@ bsen shown to be combu3tible st elavllcd prs33urc3 and can result in fire or oxplosion cau3ing iniurY or property damage,Nsvor u36 comprg3Sodlir to P|'3turl test R-134aservic€ equipmont o. vohiclc rir condhioncr 3ystems. A d d i t i o n a lh e a l t h a n d s a f e t y i n f o r m a t i o nm a y b e obtained from the refrigerantand lubricant manufacrures. '1. Connecta R-134arefrigerantRecovery/Recycling/ ChargingSystem to the car, as shown, following instructions. the equipmentmanufacturer's 2.
M e a s u r et h e a m o u n t o f r e f r i g e r a n to i l r e m o v e d from the A/C system after the recovery process is comoleted. NOTE:Be sure to installthe same amount of new r e f r i g e r a n to i l b a c k i n t o t h e A / C s y s t e m b e f o t e charging.
22-22
Pf,ESSUFE
sy.t m.
PressureTest Chart NOTE: PerformanceTest on page 22-24. TESTRESULTS RELATED SYMPTOMS Dischsrge AftErstoppingcompressor,pressure (high)pressure dropsto about200kPa(2.0kof/cmr.28 psi)quickly,andthenfallsgr;dua y. abnormally nrgn
PROAABLE CAUSE Air in system
No bubbles in sight g16sswhen condenser is cooled bv water. Reducedor no air flow through conoenser.
E-\cessive refrigerantin sys-
Lineto condenseris excessivelvhot.
Restrictedflow of refrigerant In syslem
Cloggedcondenseror radiato. fins Condenser o. radiator fan not working properly
Dischargepres- Excossive bubblesin sightglass; sure abnormal- condenser is not hot. Highand low pressures arebalanced soonafterstoppingcompressor. Low sideis higherthannormal, Outletof expansionvslve is not frosted,low pressure gaugeindicates vacuum, Suction(lowl Excessive bubblesin sightglass; pressure conqenser rsnot hot_ abnormally low
Insufficient refrigerant in syslem
FaultycompressordiscnargevaNs Faultycompressorseal . Faultyexpansionvalve . Moisturein sysiem Insufficientrefrigerant
Expansion valveis nottrostedandlow pressur€line is not cold. Low pressure gaugeInorcates vacuum.
. Restricted lines Checkfor leak Charge system
Replacethe compressor. . Replace . Recover,evacuateand recharoe with specifiedamount. Reoairthe leaks. Reaover,evacuateand recharoe with sDecifisd amount. Charqeas required. Replacethe expansion valve.
Discharge temperaturg is low and the air flow from vents is restricted.
Frorenevaporator
Expansionvalveis frost€d. Receiver/dryer outlet is cool and inlet isrryarm(shouldbe warm duringoper-
Runthe tan with comoressoroft then checkAy'Cthermostat.
Clogged expansion valve
Cloggedr€ceiver/dry€r
Cl€anor replace. Replace
'
Repairor replace.
SuctionpresLow pressurehose and checkjoint are sure abnormal- coolerthan the temDeraturoaround ly high evaDorator. Suctionpressure is loweredwhencondenseris cooledby water, Highandlow pressure areequalized as soon as the compressoris stopped, andbothgaugesfluctuatewhilerunnrng. Suctionand discharg€ pressufes aonormally high
Frozen expansion valve Faulty expansion valve
REMEDY Recover,evacuate and recharqo with sDecifiedamount. Evacuation:see Daqe22-38 Charoino:se6 D;op--2?-?q Recover,evacuate and recharqe with specitiedamount. Clean Checkvoltage and fan rpm unecKlan ofeclton
Reducedair flow through condenser.
No bubblesin sight glasswhen concl€nser is cooled bv water. Suctionsnd Low pressure hose and metal end dischargepres- afeas are cooler than evaDorator. sur€ abnormal- Temperaturearound expansionvalve is too low compared with that around recerver/orver. Refrig€rant Compressorclutchis dirty. leaks
Compressorbolt(s)are dirty. Compressorgasketis wet with oil.
u"lu"oD"ntoo ffin"nsion
. Looseexpansioncapillary Excessive refrigerantin sysrem
Recover,evacuateand recharqe with sDecifi€damount.
Faultv oasket FaultyFigh pressurevalve Foreign particle stuck in high pressure valve . Cloggedcondenseror radiatorfins . Condenseror radiatorfan not working properly.
Replacethe compressor.
Excessive refrigerantin sysrem
Rgcover,€vacuate and recharoe with sp€cified amount. Fepair or replace.
Cloggedor kinkedtow pre€sure nos€ pans Cloggedhigh pressureline
Cleancondenserand radiator Checkvoltageand fan rpm Checkfan direcrion
Repairor replace.
Compressorshaftsealleak-
Replacethe comDressor.
Leaking around bolt(s)
Tightenbolt(slor replace compressor. Replacethe compressor.
Ing
I Gasketleaking
22-23
A/G System Service PerformanceTest The performancetest will help determineif the air conditionersystemis operatingwithin specitications. and is cerOnly use serviceequipmentthat is U.L.-listed tified to meet the requirementsof SAE J2210to remove from the air conditionersystem. HFC-134a {R-134a)
Rocov.rylB.cycling/Ch!lging SFtrm.
CAUTION: Exposure to air conditioner relrig€rant and lubricant vapor ot mist can irritate eyes, nose and throat. Avoid breathing the air conditioner rstrigerant and lubricant vapor or mi3t. It accidentalsystem dischargeoccurs,ventilate work areabeforeresumingservice. R-134aserviceequipmentor vehicleair conditionersystems should not be pressuretested or leak testedwith atr. comPressed some mixtures ot air and R'1344 hrv6 !@ been shown to be combustibls at elovatod prsssurel and can result in firg or explosion causing iniury 01 property damage.Ngvor usg compregsedail to prossuro t€st R-134assrvice equipment or vohicl€ air conditioner syst€ms. A d d i t i o n a lh e a l t h a n d s a f e t y i n f o r m a t i o nm a y b e obtainedfrom the refrigerantand lubricantmanufacturers. 1.
Connecta R-134arefrigerantRecovery/Recycling/ ChargingSystem to the car, as shown, iollowing instructions. the equipmentmanufacturer's
2.
Inserta thermometerin the centervent outlet. Determinethe relativehumidityand air temperature by callingthe localweatherinformationline,
3.
Testconditions: . Avoid directsunlight. . Open hood. . Openfront doors . Set the temperaturecontrol leverto MAX COOL, the mode control switch on VENTand the recirculationcontrolswitchon RECIRCULATE. . Slidethe heaterfan switchon MAX . Runthe engineat 1,500rPm in vehicle. . No driveror passengers
4.
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 gf o r 1 0 m i n u t e s under the above test conditions.read the delivery temperaturefrom the thermometerin the dash vent and the high and low systempressurefrom the A,/C gauges.
22-24
LOWPRESSURE
To completethe chans: . Markthe deliverytemperaiurealongth€ venicalline. o Mark the intaketemperature (ambient air temperature)8long the bottom line. o Drsw a line strsightup from the air temperatureto the humidity. . Mark I point one line above and one line below the humidity l6vel (10 % above and 10 % below the humidity l6vsl). . Fromeachpoint,drawa horizontalline acrossthe deliverytemparaturs. . The deliverytemperatureshouldfall betweenthe two lines, . Completethe low side pressuretest and high side pressur€test in the sameway. o Any measurementsoutside the line may indicatethe need for further inspection.
29q) (301 Ii(t0l
kp. lksf/cm') lpril
at%
2stx' t25) t360l
kpr lkgflclrfl lpril
2qx) t20l t2q)l
500
15{Xt {151 12r0t
,o0
OEUVERY PRESSURE 9BO t10l t1()l
T'EUVERY PRESSUNE
ts)
171!
{4)
tsTl
86 t30)
3q, {3t I€I
71 l25l
ax)
68 120,
l2l t28t
INTAKE PRESSUBE
30%
100 t1l n4l
59 t15l
50 (101
11
ts) DEUVERY TEMPEMTURE 77 {25t
6 t30t
95 (35}
104 laltl
"F fc}
INTAKETEMPERATURE
22-25
Evaporator Replacement CATION: . All SRS eloctrical wiring harnessesare coverod with yollow in3ulation. . B€tore disconnocting 8ny part of tho SRS wire harnsss,conngqtth€ 3hort connestor{sl. . Roplacaths entire aftected SRS harness a$embly if it has an op€n circuit or damaged wiring.
3.
Removethe glove box (seesection20). Removethe four boltsand the glove box frame.
Disconnectthe connector from the Ay'Cthermostat, and removethe wire harnessclips from the evaporator. lcove.edwith yellowinsulation) L
Recoverthe refrigerant with a Recovery/Recycling/ ChargingSystem lsee page 22-22]-.
2.
Femovethe bolts,and disconnectthe receiverline and the suctionline from the evaporator.
Removethe four self-tappingscrews,mountingbolt and the mountingnut. 1.
Disconnectthe drain hose,and removethe evaporator.
NOTE:Plug or cap the lines immediatelyafter disconnectingto avoid moistureand dust contamination into the svstem.
SUCTIONLINE
6x1.0mm 9.8 N.m {1.019f.m, 1.2 tbl.ttl
6x1.0mm 9.8Nm{1.0kg{.m, 7.2 tbtft)
8.
RECEIVEB LINE
22-26
APORATOR
Installin the reverseorderof removal.and: it you're installinga new evaporator,add refrigerant oil (ND-OIL8: P/N 38899- PR7- A01) (see page22-2'll. replacethe O-ringswith new ones at eachfitting. and apply a thin coatof refrigerantoil (ND-OlL8: P/N38899- PR7- A01l beforeinstallingthem. NOTE:Be sure to use the right o-rings for HFC134a{R-134a} to avoid leakage. applysealantto the grommets. a makesurethat there is no air leakage. a chargethe system (see page 22-39)and test its performance(see page 22-241.
Overhaul L
Pull out the Ay'Cthermostat sensor from the evaporatorfins.
2.
Removethe self-tappingscrews and clamps from the housing.
3.
C a r e f u l l ys e p a r a t et h e h o u s i n g sa n d r e m o v et h e evaporator.
5.
Assemblein the reverseorderof disassembly, and: .
4.
.
lf necessary, removethe expansionvalve. . NOTE:When looseningthe expansionvalve nuts. usea secondwrenchto hold the expansionvalveor evaporatorpipe.Otherwise,they can be damaged.
feplacethe O-ringswith new ones at eachfitting, and applya thin coat of refrigerantoil (ND-OIL8: P/N38899- PR7- A01)beforeinstallingthem. NOTE:Be sure to use the right O-ringsfor HFC134a{R-134a) to avoidleakage. i n s t a l lt h e e x p a n s i o nv a l v e c a p i l l a r yt u b e w i t h the capillarytube in contactwith the suctionline di.ectly,and wrap it with tape. reinstallthe Ay'Cthermostatsensorto its original location.
6 th fin trom inlet 3id6
1 2 0 1 5m m 14.72! 0.2 inl
EVAPOAATOR blow dirt out of fins with compressedair. A/C THERMOSTAT Test.page22-19
16 N,m 11.6kgl.m, 12 tbt.ttl
8 N.m (0.8 kgf'm, 6 lbf.ftl
24 N.m (2.i1kg{.m, 17 rbt.ftl
EXPANSIONVALVE
LOWERHOUSING CAPILLARY TUBE TAPE Replace. Make sure there is no foreign matter stuck between the capillarytube and outletline.
22-27
Gompressor Description (R-' |34a). A revolvinginclineddiscdrivesthe surThis compressoris a Nippondensopistontype compressorfor HFC-134a protectedby a ceramicshoe,thus pistons, pushes the it revolves. disc inclined prstons. As the rounding10 reciprocating compressingthe refrigerant
o
?-*:-=3 22-28
/al
lllustrated lndex
CENTER BOLT
CLUTCH SET Inspoc!on, page 22-32
SNAPRINGA Replace.
colL Inspection, pag6 22 32
-t f--
COMPRESSOR COMPLETE lDo nor disassemble)
RELIEFVALVE R e p l a c e m e n t ,p a g e 2 2 - 3 4
22-29 '-f
Compressor GlutchInspection Checkthe platedpartsot the pressureplatetor color changes.peelingor other damage.lf there is dam8ge,replacethe clutchset.
of the tield coil. Checkresistance
Checkthe pulley bearing play and drag by rotating the pulleyby hand.Replacethe clutchset with a new one if it is noisvor hasexcessiveplay/drag
replacethe lf resistanceis not within specifications, field coil.
Measurethe clearancebetlveenthe pulley and the pressureplate all the way around.lf the clearanceis not within specifiedlimits,the pressureplatemust be removedand shims added or removed as required. Jollowingthe procedureon page22-33. Clearrnce:0.50t 0.15mm {0.02i 0.01inl NOTE:The shims are availablein three thicknesses: 0 . 1m m , 0 . 3m m a n d0 . 5m m .
22-32
Fisld Coil Rosistance:3.6 t 0.2 ohm at 68"F {20'C)
GlutchOverhaul l.
Removethe centerbolt while holdingthe pressure ptate.
A/C CLUTCHHOLDER commorciallyavailsble Robinair: P/N 10204 Kont.Moore:P/N J37872
CENTERBOLT 13.2N.m (1.35kgt.m,9.76lbf.ftl
R e m o v et h e s n a p r i n g B w i t h a s n a p r i n g p l i e r s , then removethe pulley. NOTE: . B e c a r e f u ln o t t o d a m a g et h e p u l l e ya n d c o m presso.during removal/installation. a Oncethe snap ring B is removed,replaceit with a new one, SNAPRINGB Replace.
Removethe pressureplateand shim(s),takingcare not to losethe shims.
sHrM{s)
(cont'd)
22-33
Compressor ClutchOverhaul(cont'dl Removethe screwfrom the field coil ground termanal. Removesnap ring A with snap rjng pliers,then removethe field coil.
1.
NOTE: . Do not let the compressoroil run out. . Make sure there is no foreign matter in the system.
NOTE: . Be carefulnot to damagethe field coil a n d c o m pressorduring removal/installation. . Once snap ring A is removed,replaceit with a new one. SNAPRINGA Replace.
FIELD
corL
Removethe reliefvalveand the O-ring.
4t-N r-l\ \
-l/
RELIEFVALVE 13.2N.m {1.35kgtm,9.76lbtftl
2.
5.
lnstallin the reverseorderof removal,and: install the field coil with the wire side facing down (see above). clean the pulley and compressor sliding surfaces with non-petroleum solvent. a check the pulley bearings for excessive play. a make sure the snap rings are in the groove propefly. apply locking agent to the threads of the center bolt, and tighten it securelY make sure that the pulley turns smoothly after it's reassembled.
22-34
lnstall and tighten the relief valve. a Cleanthe matingsurfaces. a Replacethe O-ringwith a new one at the relief
t al v a l v e ,a n d a p p l y a t h i n c o a t o f r e f r i g e r a no (ND-OIL8: P/N38899- PR7- A01) beforeinstalling it. NOTE: . To avoid contamination,do not returnthe oil t o t h e c o n t a i n e ro n c e d i s p e n s e da, n d n e v e r mix it with other refrigerantoils. . l m m e d i a t e l ya f t e r u s i n gt h e o i l , r e p l a c et h e c a p o n t h e c o n t a i n e r ,a n d s e a l i t t o a v o i d moistureabsorption. . D o n o t s p i l l t h e r e f r i g e r a not i l o n t h e c a r ; l t may damage the painu if the refrigerantoil contactsthe paint,wash it off immediately. Checkfor leaks,and insertthe cap in the top of the valve.
A/C CompressorBelt Replacement Automatic TransmissionType 1. Loosenthe adjust pulley bracketpivot bolt and the adjusting bolt, then remove the A/C compressor beltfrom the oullevs.
Manual TransmissionType 1. Loosenthe adjust pulley bracketpivot bolt and the adjusting bolt, then remove the A/C compressor beltfrom the pullevs.
2,
2.
Removethe two mounting bolts from the left front engine mount, then pass the A,/Ccompressorbelt through the gap betweenthe body and left front en9rnemount.
ADJUSTINGBOLT
ADJUSTPULLEYBRACKET PIVOTBOLT
Removethe two mounting bolts from the left front enganemount. Removethe enginemount nut, washer,bolt and the leftfront enginemount. Removethe A,./C comoressorbelt.
ADJUSTINGBOLT
ADJUSTPULLEYBRACKET PIVOTEOLT
l!l',
I
14x 1.25mm 83 N.m 18.5kgl.m. 61 tbf.ft)
LEFTFRONT ENGINEMOUNT
l a ar10 x 1.25mm 54 N.m (5.5 kgf.m, 4(' rbr.ft) WASHER
Installin the reverseorder of removal,and adjust the A,/Ccompressorbelt (seepage22-36).
1 2x ' 1 . 2 5m m 69 N.m {7.0 kgf.m, 51 tbf.ftt 10 x 1.25mm 54 N.m (5.5 kgtm, irc lbf.ft)
Installin the reverseorder of removal,and adjust the Ay'Ccompressorbelt (seepage22-36). N O T E : W h e n t i g h t e n i n gt h e e n g i n e m o u n t n u t , make sure the washer is set properly on the left front enginemount as shown.
22-35 "t.M'
A/C CompressorBelt Adjustment Dstlsqtion Method 1. Apply a force of 98 N (10 kgf, 22 lbf), and measure the deflection between the A,/Ccompressor and the crankshaftDullev.
Tonsion Gauge Method 1. Attach the belt tension gaugeto the Ay'Ccompressor belt as shown below, and measurethe tension of the belt. A/C CompressotBelt Used 8€lt: Bl8Bl engine 390 - 540 N (40 - s5 kgf, 88 - 120 lbfl Bl8Cl ongine 3il0 - il90 N (35 - s0 kgf, 77 - 110 lbfl N€w Belt 7,10- 880 N {75 - 90 kgf, 170-200lbl}
A/C CompressorBelt Us€dEelt:81881engine7.5- 9.5 mm (0.3- 0.4 in) Bl8Cl engine8.5- 10.5mm (0.3-0.11 inl New Belt: 5.0- 7.0 mm (0.2- 0.3 inl Power Stesring Pump Belt 'l1.5- 13.5mm (0.,[5- 0.53inl UsedBeli: New 8€lt: 8.0- 10.0mm (0 3 - 0.39inl
Powor Steoring Pump Belt Used Belt: 390 - 5,{l N (40 - 55 kgf, 88 - 120 lbll N6w Bolt: 74O- 880 N 175- 90 kgf, 170-200lbt)
NOTE: . lf there are cracksor any damageevidenton the belt,replaceit with a new one. . "Used belt" means a belt which has been used for five minutesor more. . "New belt" means a belt which has been used for lessthan five minutes.
NOTE: . lf there are cracksor any damageevidenton the belt,replaceit with a new one. . F o l l o wt h e m a n u f a c t u r e r 'isn s t r u c t i o n sf o r t h e belttensiongauge. . "Used belt" means a belt which has been used for five minutesor more. . "New belt" means a belt which has been used tor lessthan five minutes,
2.
Loosenthe adjust pulley bracketpivot bolt and the adjustingbolt locknut of the Ay'Ccompressorbelt.
3.
Turn the adiustingbolt to get proper belt tension, then retightenthe adjust pulley bracketpivot bolt and the adjustingbolt locknut.
2.
Loosenthe adjust pulley bracketpivot bolt and the adjustingbolt locknut of the AVCcompressorbelt.
Recheck the deflectionof the lvc compressorbelt
3,
Turn the adjustingbolt to get proper belt tension, then retightenthe adjust pulley bracketpivot bolt and the adjustingbolt locknut.
4.
Recheckthe tensionof the A{/Ccompressorbelt.
4.
22-36
Condenser Replacement Recoverthe relrigerantwith a Becovery/Recycling/ ChargingSystem (see page 22-221. Removethe coolantreservoir, NOTE: Do not disconnectthe reservoirhose from the coolantreservoirand the radiator.
Removethe bolts.and disconnectthe dischargeline and the condenserlinefrom the condenser. NOTE:Plug or cap the lines immediatelyafter disconnectingto avoid moistureand dust contamination into the system. DISCHARGE LINE
COOLANT RESERVOIR
6x1.0mm 9.8 N.m (1.0kgl.m,7.2 lbt.ft)
......-..... CONOENSER LINE
Removethe two mounting bolts, then lift out the condenseras shown. NOTE: Do not damagethe radiatorand condenser fins when removingthe condenser. 6x1.0mm 9.8N.m(1.0kgf.m,7.2lbl.tt)
R e m o . v teh e b o l t s a n d t h e r a d i a t o ru p p e r m o u n t brackets,and removethe bolt from thg suctionhose bracket. 9.8 N.m {1.0 kgf.m.7.2 lbtftl
RAOIATORUPPEN MOUNT BRACKETS
Installin the reverseorderof removal.and: . if you'reinstallinga new condenser,add refrigerant oil (ND-OIL8: P/N 38899- PR7- A01) (see page 22-21t,. . replacethe O-ringswith new onesat eachfitting, and apply a thin coat of refrigerantoil {ND-OIL8: P/N38899- PR7- A01)beforeinstallingthem. NOTE:Be sure to use the right O-ringsfor HFC1 3 4 a( R - 1 3 4 at o) a v o i dl e a k a g e . a do not damagethe radiatorand condenserfins when installingthe condenser, . be sure to installthe condensermount cushions securelyinto the holes. . chargethe system (see page 22-39)and test its performance(see page 22 24!.
22-37 '1Iffi
A/G System Service Evacuation and is cerOnly use serviceequipmentthat is U.L.-listed tified to meet the roquirementsof SAE J2210 to remove (R-134a) lrom the 8ir conditionersystem. HFC-134a
R.cov.ry/R.cycling/Chtroing
CAUTION: Exposulo to 6ir conditioner refligorrnt and lubricani vapor or mi3t crn i.ritato 9y33, noaa and thrort. Avoid bratthing ths .ir conditionor rsfrigorrnt snd lubricsnt vtpor or mist. lf accidentalsystem dischargeoccurs,ventilate work area before resuming service. R-134aserviceequipmentor vehicle8ir conditionersystems should not be pressuretested or leak tested with compressedait. somo mixtuto3 ot ril and R'134! hav. !@ been shown to bo combustible at olevltad prossulo3 and can re3ult in fire or explosion crusing inlurY or property damago,Navor us! comprossodair to prgsauro test R-13/aa3orvicr €quipmlnl or vohiclo air conditionol sy3lems. Additional health and safety information may be obtainedfrom the retrigerantand lubricantmanufactures. 1. When an Ay'CSystemhas beenopenedto the atmosDhere,suchas during installationor repair,it must be evacuated using a R-134arefrigerant Recovery/ Recycling/ChargingSystem. {lf the system has been open for several days, the receiver/dryershould be replaced.l 2.
C o n n e c ta R - 1 3 4 ar e f r i g e r a n tR e c o v e r y / R e c y c l ing/ChargingSystemto the car, as shown, followinstructions. ing the equipmentmanufacturer's NOTE; lf tow pressuredoes not reach more than 9 3 . 3 k P a ( 7 0 0m m H g , 2 7 . 6 i n ' H g )i n 1 5 m i n u t e s , t h e r e i s p r o b a b l ya l e a k i n t h e s y s t e m .P a r t i a l l y charge the system and check tor leaks {see Leak Test).
2234
aotnPRESSURE SIDE
Syttom
Charging Only use serviceequipmentthat is U.L.-listed and is certified to meet the requirementsof SAE J2210 to remove (R-134a) HFC-134a from the air conditionersvstsm.
R.cov.rylRccacling/Ch.rging Syrtom
CAUTION: Exporuro to rir conditionor .etrigorant and lubric8nt yapor or misl can irritats cyos, no36 and throlt. Avoid broathing tho lir conditionor rofrig6rant lnd lubricant vlpor or mbt, It accidentalsystem discha.ge occurs, ventilate work a r e a b e f o r e r e s u m i n gs e r v i c e .A d d i t i o n a lh e a l t ha n d safety information may be obtained from the refrigerant and lubricantmanufactures. Rofrigerantcapacity:f00:3n g (24.7:l,oz) CAUTION: Do not ovorchlrgo thc syrtem; tho compr6ssor will be damagad. C o n n e c t a R - 1 3 4 ar e f r i g e r a n t R e c o v e . y / R e c y c l i n g / Charging System to the car, as shown, following the equipmentmanufacturer's instructions.
22-39
A/C System Service LeakTest and is cerOnly useserviceequipmentthat is U.L.-listed tified to meetthe requirementsof SAEJ2210to remove (R-134a) from the air conditionersystem. HFC-134a
Rocov.ry/R.cycling/Ch.tging Sy3tcm
CAUTION: Exposura to air condition ratrigerant and lubaicant vapor or mist can irritato oyes. nose and throat. Avoid br€athing tho sir conditionsr reftigolant and lubricant vapor or mist. lf accidentalsvstem dischargeoccurs,ventilate work areabeforeresumingservice. R-134aserviceequipmentor vehicleair conditionersystems should not be pressuretested or leak tested with comoressedair. some mixturos ot air and R'13'la have @ b.6n shown to b€ combustible at glsvated pressur€s and can result in firo or sxplo3ion causing iniury or proporty damage. Ngvar uso compress€dtir to pro33ure tost R-134a$rvics oquipmont or vohicl€ air Gonditionsr systcms. Additional health and satetYinformation may be obtainedfrom the refrigerantand lubricantmanufactures' 1.
Connecta R-134aretrigerantRecovery/Recycling/ ChargingSystem to the car. as shown, following instructions. the equipmentmanufacturer's NOTE:Be sure to installthe same amount of new r e f r i g e r a n to i l b a c k i n t o t h e A / C s y s t e m b e f o r e chargtng.
2.
Open high pressurevalve to chargethe system to about 98 kPa (1.0 kgf/cm' , 14 psi), then close the supplyvalve.
3.
Checkthe systemfor leaksusing a R-134arefriger'!4 g {0.5 oz) ant leak detectorwith an accuracyof per year or better.
4.
l f y o u f i n d l e a k st h a t r e q u i r e t h e s y s t e m t o b e opened (to repair or replacehouses,fittings,etc.), recoverthe system accordingto the Recover Procedureon page22-22.
5.
Aiter checkingand repairingleaks,the systemmust be evacuated (see System Evacuationgn page 2238).
22-40
LOW PRESSURE SIDE HIGH SIDE
Electrical Special Tools
Troubleshooting T i p s a n d P r e c a u t i o n .s. . . . . . . . . . . . . . . . . . . . . . . . . . .2. .3.-. 3 Five-stop T l o u b l e s h o o t i n.g. . . . . . . . . . . . . , . . . - . . -Z. .3. - s S c h e m a t i cS y m b o l s. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . .3. _- 6. w i r e C o l o rC o d € s. . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. .3. -. 6 .... Relay and Control Unit Locations E n g i n eC o m p a r t m e n .t . . . . . . . . , . . . . . . . . . . . .- - .2 3 - 7 Dsshboard a n d D o o r . . , , . . . . . . . . . . . . . . . . . . . . . 2. .3. .- g D a s h b o a ra d n d F l o o r. . . . . . . . . . . . . . . . . . . . . . . . . 2. .3. .- t O O u a n e rP a n e l .....-.....23-12 Connector ldentification and Wire HarnessRouting ........ 23-i 3
Index to Circuits and Systems Airbag ............... ...-..-..2 . g-26s Air Conditioning ....,.. Section2l Altelnator . . . . . . _ . . . . . . . . . . .2. .3. - 9 9 Anti-lock Brake Systsm (ABS) Section 19 Automatic Transmission Section 14 Battery.............. . . . . . . . . . .2 3 - 6 6 C h a f g i n gS y s t e m ..........2 . 3-98 r C i g a l s t t eL i g h t e r. . . . . . . . . . . . . . . . . . . . . - . . . - . . . . . . - . . - . . Z3-2O4 C f o c k. . . . . . . . . . . . . . . . . ..........23-197 rcruise Controf .......--..-...23-242 Distributor . . . . . . . . . . . . . . . . . .2. .3 - 8 7 F a nC o n t r o l s . . . . . . . . . . . . . . .2 . .3 - 1 o g Fuel and Emissions ... Section 1i *Fuses U n d e r - d a sFhu s e / R e l aByo x . . . . . . . . . . . . . . . . .2. .3 - 4 8 Undor-hoodABS Fuse/Retay Box ............23-51 U n d e r - h o oF d u s e / R e l aByo x , . . . . . . . . . . . . . . . . 2 . .3 - 5 2 rGauges Engine Coolant Temperature {ECT) G a u g e. . . . . . . . . . . . . . . . ..23-126 F u e fc a u g e . . . . . . . . . . . . . .2. g - 1 2 3 ' G a u g eA s s e m b l y ....--.23-113 Speedometer . . . . . - . . . , , 2. 3 - 1 1 4 Tachometer . . . . . , . . . . . - .2. 3 - 1 1 4 GroundDistribution ........ 23-60 H e a t e r, , , . . . . . . . . , . . . . . . . . . S e c t i o n2 l r H o r n. . . . . . . . . . . . . . . . . .........2 . .3 - 1 9 9 * f g n i t i o nS w i t c h . . . . . . . . . . . .2. 3 - 7 0 fgnitionSyst6m .......-..-..23-A7 l g n i t i o nT i m i n g . . . . . . . . . . . . .2. 3 - 8 9 Indicator Lights " A / T G e a rP o s i t i o n. . . . . . . . . . . ...... . . . . . . . . . . . . . . . . 2 3 - 13 2 B 1 a k 6S y s t e m ...,..,..-.23-127 E n g i n eO i l P r e s s u r .a. . . . . . . . . . . . . . . . . . . . . . . . _ . .2. .3. - 15 1 L o w F u e l. . . . . . . . . . . . ......23-125 MalfunctionIndicatorLamp {MlL} ...,,. Section I l
tfnteglated Control Unit ...29-144 * l n t e r l o c kS y s t e m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 3 - 13 g Lights, Exteriol B a c k - u pL i g h t s ..........2 . 3-179 B r a k eL i g h t s . . . . . . . . . . . . .2. 3 - t 8 l tDaytime RunningLights {Csnada}........... 23-156 F r o n tP a l k i n gL i g h t s . . . . . . . . . . . . . . . . . . . . . . . . . 2 . .3. .- 16 5 F l o n t S i d e M a r k e rL i g h t s. . . . . . . . . . . . . . . . . . . . 2 . .3. - 1 6 5 F r o n tT u r n S i g n a lL i g h t s. . . . . . . . . . . . . . . . . . . . .2. .3. - 16 5 * H a z a r dW a r n i n gL i g h t s. . . . . . . . . . . . . . . . . . . . . . . . . 2g-1A4 Headlights . . . . . . . . . . . . . . .2 . .3 - t 6 t L i c e n s eP l a t eL i g h t s. . . . . . . . . . . . . . . . . . . . . . . . . .2. .3. .- 16 9 Taillights (Harchback) . . . . . . . . . .2 3 - 1 6 6 { S e d a n.). . . . . . . . . . . . . .. 23-167 Lights. Inteliol Cargo Area Light {Hatchback)......-..-..-... 23-177 C e i f i n gL i g h t ........-..-.23-175 Dash Lights BlightnessControt ..............23-t70 G l o v eB o x L i g h r. . . . . . . . . . . . . . . . . . . . . . . . . . . .2. 3. .-.1.6. 9. S p o t f i g h r. . . . . . . . . . . . ....-.23-174 T r u n kL i g h t ( S e d a n l. . . . . . . . . . . . ...... . . . . . . . . .-. .2 3 . - 1 7 7 *LightingSysrem .......-.-...23-152 :Moonroof ,,.,.......,..,,,,,.-.23-211 PGM-FISystom ........ S€crion 11 Power Distribution .,.-..--..23-54 P o w e rD o o r L o c k s . . . . . . . . . . . . . , , . . . . . . . . . . . . . . . .2. .3. .- .2 3 3 P o w e rM i r o r s . . , . . , . . . . - . . .2- 3 - 2 1 6 P o w e rR e l a y s . . . . . . . . . . . , . . . 2. .3 - 6 8 Power Windows ............ 29-222 * R e a rW i n d o w D e f o g g e r. . . . . . . . , . . . . . . . . . . . , . . . . . - 23-20,6 Reminder Systems K e y - i nR e m i n d eS l y s t e m . . . . , . . . . . . . . . . . . . , .2 . .3. - 15 0 L i g h t s - o nR e m i n d eS r y s t e m . . . . . . . . . . . . . . . . .2. .3 - l 5 f *MaintenanceRemindersystem ..,,....-..--. 23-.12g S e a t B e l t R e m i n d eS r y s t e m . . . . . . . . . . . . . . . . . 2. -3 - 1 2 5 *Side Markel/Turn Signal/Hazard F f a s h eS r ystem .,..,..-.23.-1A4 S p a r kP f u g s . . . . . . . . . - . . . - . . .2. .3 - 9 7 Starting System ....,,.....-.23-73 * S t e r e oS o u n dS y s t e m . . . , . . . . . . . . . . . . . . . . . . . . . . . , , . . g g 23-l SupplementalRestraintSystem {SRS}......... 23-265 V e h i c f eS p e e dS e n s o r{ V S S ). . . . . . . . . . . . . - - . . - . 2. .3. - 1 2 2 * W i p e r / W a s h eSr y s t o m . . . . . . . . . . . . . . . - - . . . . . . . . . - . . Zg 254 rRead SRSpi€cautions on Page23-271
betore working
in these areas.
-
+
SpecialTools
Rel. No.
Tool Numbol
I
Description
o o
DeploymentTool 07HAZ-SG00400 Antenna Nut Wrench 07JAA-001000c 0 7 J G G - 0 0 1 0 1 0 A Belt TensionGauge @ Test HarnessC 07LAZ-S140300 @.' Test HarnessD oTLAZ-S140400 @' Test HarnessA oTMAZ-S100500 @' Test HarnessB oTMAZ-SP00500 o T N A C - S R 2 0 1 0 0 Fuel Senderwrench @ SCS Short Connecto. oTPAZ-0010100 @ lncludedin SRSToolSet oTHAz-SGoOooA Included in SRSToolSet OTMAZ-SLOo10A
o--
Oty.
I Pago R6toronce
23-300 23-195 23-108 23-201,248,285 23-247 23-241 23-244 23-124 23-89
o
@
@
o @
I
z3-2
Troubleshooting Tips and Precautions Before Troubloshooting a Check applicablefuses in the appropriatefuse/relay DOX.
a Check the batteryfor damage,state of charge,and clean and tight connections. a Check the alternatorbelt tension. CAUTION: a Do not quick-charg€ a battery unless the battery ground cabla has be€n disconnoctsd. oth€rwiso you will damage the alternator diodss. a Do not att6mpt to crank the engine with the battery ground cable looselyconnectsd or you will sevorsly damag€ tho widng. a The original radio has a codod thatt plotection ci.cuit. Be sul€ to got tho customor's code numbet before - disconnecting th€ battery. - lomoving tho No. 32 (7.5 Al tuso f.om the under-hood tuse/lelay box. - removing tho radio. Aflor s€lvic€. reconn€ct powet to tho radio and turn it on. Whon the word "CODE" is displayed, €nt€l the customer'E s-digit codo to .astore ladio operation. Handling Connectors a Makesurethe connectorsarecleanand haveno loose wire terminals. a Make sure multiple cavity connectots are packedwith grease(exceptwatertight connectors). a All connectorshave push-downreleasetype locks.
a Nevertry to disconnectconnectorsby pullingon thei. wires; pull on the connectorhalvesinstead. a Always reinstallplastic covers.
Beloreconnectingconnectors,make sure the lerminals are in Dlaceand not bent.
a Check tor loose retainerand rubber seals.
LOCKII{GTAA RETAINER
LOCKING TAB a Someconnectorshavea clio on their sideusedto attach them to a mount bracket on the body or on anothercomponent.This clip has a pull type lock. a Some mountedconnectorscannot be disconnected unlessyou first releasethe lock and removethe connector from its bracket.
LOCKING PAWL ON OTHER HALF OF Pull to CONNECTOR orsengage
a The backs of some connectors are oacked with grease.Add greaseif needed.It the greaseis contaminated, reDlaceit.
BRACKET (cont'd)
23-3
Troubleshooting Tips and Precautions(cont'dl a lnsert the connector all the way and make sure it is securelylocked. a Positionwires so that the open end of the cover taces down.
V
Faca opon and cown
Handling Wir€s and Hamorao8 a Secure wires and wile harnessesto the frame with their respectivewire ties at the designatedlocations' a Removeclips carefully;don't damagetheir locks'
Stip pliers under the clip base and through the hole at an angle,then squeezethe expansiontabs to releasethe clio.
a Seat grommets in theil grooves properly.
GOOD
]TOTGOOD
n ll
, ,,'
/
i
l
,
r ll
/
,,
s*j -:ut*/ --ry\ -.w-,
Tosting and Ropails a Do not us€ wires or harness€swith broken insulation. Replacethem or repair them by wrapping th€ break with electricaltape. a After installing pans, make sure that no wir€s are Dinchedundsr them. a When using electrical test €quipment, follow the manufacturer's instructiona and those dsscribed in this manual, a It possible,insert the probe of the toster from the wire side {except waterproof connector).
a Use a probe with a tapered tip.
SI'IAP-ANG PLIERS
a After installingharnessclips, make su.€ the hatness doesn't interfe.e with any moving parts. a Keeo wire hatnessesaway from exhaust pipes and other hot parts, ftom sharp edges of brackets and holes, and from exposed screws and bolts.
23-4
Referto the instructionsin the HondaTerminsl Kit for identificationand .eplacemento{ connectortelminals'
Five-stepTroubleshooting 1.
Verify The Complaint Turn on all the componentsin the problemcircuitto verifythe customercomplaint.Notethe symptoms. Do not begindisassemblyor testing until you have narroweddown the Droblemarea.
2.
Analyze The Schomatic Look up the schematicfor the problemcircuit. Determine how the circuit is supposedto work by tracing the current paths from the power leed through the circuitcomponentsto ground.It severalcircuits fail at the same time, the luse or ground is a likely cause.
4.
Fix The Problem Once the specilic problemis identified,make the repair. Be sure to use proper tools and safe proceoures.
5.
Mak6 Suro The Circuit Wolks Turn on all componentsin the repairedcircuit in all modes to make sure you've fixed the entire problem. It the problemwas a blown Juse,be sureto test all of the circuits on thst tuse. Make sure no new problemsturn up and the originalproblemdoes not recuf.
Basedon the symptomsand your understandingof the circuitoperation,identity one or more possible causesof the Droblem. 3.
lsolato The Problom By Testing The Circuit Make circuittests to checkthe diagnosisyou made in step 2. Keepin mind that a logical,simpleprocedure is the key to etticienttroubleshooting. Test for the most likely cause of failure first. T.y to make tests at points that are easilvaccessible.
23-5
Troubleshooting ym Schematic Symbols
le @l l l
I
e-
LIGHTER COIL,SOLENOID CIGANETTE
FUSE
GROI,ltD Componontground Ground terminal
BATTERY
H t+j A
I
+ ilHe e H + + D a 0 Y II VARIABLERESISTOR
RESISTOR
THERMISTOR
tcNtTtol{ swTcH
-1o
MOTOR
PUMP
CIRCUITBREA(ER
BULB
HEATER
DIODE
SPEATER,BUZZER
oF
HORI'
I
T
TRA SISTORlTrl
ANTI INNA
Mast
RELAY {ln no rmal poritionl Normallyopen relay Normally closed relay
*G t-i- |
l l l
l'*^f
SWITCH (ln ngrmal position) ' Normally closod Normally open I switch switch
t
i
@ l
i
CONNECTION Output Inpur
f7 I 23-6
\
I
l
CO'IDENSER
I T LIGHTEMITTING DIODE(LEDI
A[,
@ T T l CONNECTON
--+>-
/
tl' l
BEEDSWITCH
A
lril
Y
Wire GolorCodes
The tollowing abbreviationsare used to identity wire colors in th€ circuit schematics: w H T . . . . . . . . . . .W . hite Y E L . . . . . . . . . . . . .Y. 6 l l o w B L K . . . . . . . . . . . . .B. l a c k B L U . . . . . . . . . . . . .B. l u e . reen G R N . . . . . . . . . . . .G R E D . . . . . . . . . . .R . . e. d . range O R N . . . . . . . . . . . .O P N K . . . . . . . . . . . . .P. i n k B R N. . . . . . . . . . . . .B. r o w n . ray G R Y . . . . . . . . . . . .G P U R. . . . . . . . . . . . .P. u r p l e L T B L U . . . . . . . . .L i g h tB l u e L T G R N . . . . . . . . .L i g h tG r € e n
The wi.e insulation has one color or one color with another color stripe. The s€cond color is the stripe.
WHT/ALK , / t
, / l / l
--
R
Relay and Control Unit Locations EngineCompartment ABS PUMP MOTOR RELAY ELECTRICALLOAD DETECTOR(ELD)
UNDER.HOOD FUSE/RELAY BOX
UNOER-HOOD ABS FUSE/BELAY BOX
. ABS FRONTFAILSAFERELAY I Wirc colors:WHT/GRN,BRN/BLK, I snd BLK IYEL/GRN I . ABS REARFAILSAFERELAY I Wire colors:WHT, BLU/BLK, I and BLK I YEL/GRN I
. CONDENSER FAN RELAY I Wi]o colors: WHT, BLUiBLK, I I BLKMHT and 8LU/YEL I . A/C COMPRESSORCLUTCH RELAY I Wiro colors: WHT, RED,I I BLK/YELand BLK/RED I
23-7
Relay and Control Unit Locations Dashboardand Door CUTRELAYIMIT) STARTER I wir. colo]s:BLKMHT,BLU/BLKI I BLKMHT ANdBLK/RED I REARwlNDOW DEFOGGER FELAY I Wirocolo6: I I BLKA'EL,BLK/GBN, I I BLUffEL8nd BLK^^THT I
MOONROOFRELAY Wirs colors: WHT,GBN/BLK, GRN 6nd BLK
CRUISECONTROLUNIT
PGM-FI MAIN RELAY
POWERWINDOW RELAY
INTEGRATEO CONTROLUNIT TURN SIGI{AL/ HAZARDRELAY
23-8
IIORNRELAY J wi.o color3:WHT/GRN,BLx,l and BLU/RED I I BLU/GBN, UNDEB-OASH FUSE/RELAY8OX
I
I
POWERDOOR LOCK COI{TROLUNIT
ENGINECONTROLMODULE (ECM}
23-9
Relay and Control Unit Locations Dashboardand Floor INT€RLOCKCONTROL UNIT IA/T)
G
23-10
MAINTENANCE REMINOERUNIT
TRANSMISSIONCONTBOL MODULEITCMI
23-11
Relay and Gontrol Unit Locations OuarterPanel
ABS CONTROLUNIT
23-12
Connectorldentificationand Wire HarnessRouting How to ldentity ConnoctolS: ldentification numbers have been assignedto all connectors. The number is preceded by the letter ,,C,, for connecrors, "G" for singleground terminalsot "f" hr singlenon-groundterminals. Location Hamess Starter cables
Engino Compartmont
Darhboard
T1, T2, and (E
Battery ground cable
G1 and O
Engineground cable A
T3
Engineground cable B
T4 G3
Under-hoodABS fuse/relavbox cable
T5 and (D
Enginewire harness
C 1 0 1 t h r o u g hC 1 3 4 Tl Ol andT102 G1 0 1
A/C wire harness
C l 5 ' l t h r o u g hC 1 5 6 G151
ABS modulator unit wir€ harness
C 1 6 1 t h r o u g hC 1 6 8
Engine companment wire ha.ness
C3O'l through C32O G301
Main wire hatness
C2O1 through C223 G2Ol and G2O2
C4O1 through C449 G401
Rear wire harness DashboSrdwire harness
Othors (Floor, Door, Trunk, Rootl
C501 through C536 G 5 0 1 ,G 5 0 2a n dG 5 O 3 C551 through C569 G551
Driver's door wire harness
C 6 0 1 t h r o u g hC 6 1 2
Front passenger's door wire harness
C626 through C634
Left rear door wire harness(Sedan)
C651 through C654
Right rear door wire harness(Sedan)
C656 through C659
Roof wire harness
C661 through C667
Heater sub-harnessA
C671 through C677
Heatersub-hatnessB
C681 through C684
ABS sub-harness
C7O1 through C7O6 G7O1,G702 and G703 (Sedan)
Tailgatewire harness(Hatchback)
C751 through C756
Spoilersub-ha.ness(Hatchback)
C761 through C763
Rearwindow defoggerground wire (Hatchback)
c77'l G771
SRS main harness
C8O1 through C8O7 G801
23-13
Gonnectorldentificationand Wire HarnessRouting Startol cablos Connector or Terminal
Numbsr of Cavities
Location
Connects to
Notos
Right side of enginecompartment Under-hoodfuse/relaybox Right side of enginecompartment Starter motor Battery positive terminal Battery
T1
r2 @ B8ttory Ground Cable Conn€ctor or T€rminal
Numborof Csvities
G1 \l
Location
Connects to
Right front shock tower
Body ground,via battery ground cable
Battery
Battery negative tetminal
Notos
Engine Ground Cable A Connoctor or Tolminal
Number of Cavities
Location
Connocta to
T3
Left side of engine
Valve cover
G2
Left side of engine compartment
Body ground. via engineground wire A
Notes
Engine Ground Cable B Connoctor or Torminal
Number ol Cavitios
Location
Connocts to
Not€s
Right side of enginecompartment Transmissionhousing Body ground, via engineground Right side of front frame wire B
r4 G3
A/C Wiro H81n6ss Connoctor 01 Terminal
Numbor of Cavities
cl51 cl52 c153 c154 c155 c156
I 4 4
1
Location Right side ol enginecomPartment Left side of enginecompartment Left side of engine comPartment Lett side ot enginecompartment Left side of enginecomPanment Left side of enginecompartment
Connects to
Notes
Main wire harness(C2O7) Condenserfan relay A/C compressorclutch relay A/C pressure switch Condenserfan motor A/C compressorclutch
Right side of tront Jrame
G151
Under-hood ABS Fus€/RelavBox Cablo Conngctor or Terminal T5
@
23-14
Numbor ot Caviti€s
Localion
Connects lo
Right side of enginecomPartment Under-hoodABS fuse/relaybox Right side of enginecompartment Battery positive terminal
Notes
UNOER.HOOD A8S FUSE/RELAY BOX CABLE
BATTEBYGROUND CABLE
ENGIT{E GROUND CABLEB
A/C WIRE HAFNESS
EI{GINEGROUND CABLEA
23-15
Gonnectorldentificationand Wire HarnessRouting EngineWire Harness{B1881 engine) Connector 01 Terminal
Numberof Cavities
c10'l c102 c103 c104 c105 c106
10 14 6 1
c107
1
c108 c108 c109 c110
2
c111
2
c113 c114 c115
3
L t t o
t
2 8
c117 c118 c119 c't 20 c121 c122 c123 cl24 c125 c't26 c127 c128 c129 c130 T1 0 1 r102 G1 0 1
23-16
1
2
2 ) 2 8 14 2 2
Location
Connectsio
M a i n w i r e h a r n e s s( C 2 2 1 ) Main wire harness{C222} Main wire harness(C223) Main wire harness{C220) Startersolenoid Enginecoolanttemperature{ECT) sensor Enginecoolant temperature(ECT) Right side ol engine gauge sendingunit Back'up light switch Transmission Lock-upcontrolsolenoidvalveA and B Transmission lgnitioncoil Middle of engine Top dead center/Crankshaft lvliddleof engine position position/Cylinder (TDC/CKP/CYP) sensor Enginecoolanttemperature(ECT) Right side ot engine switch Right side of enginecompartment Vehiclespeedsensor (VSS) ldiddlerearof enginecompartment Heatedoxygen sensor (HO2S) MAP sensor Middle of engine Throttle position (TP)sensor Middle ol engine ldle air control (lAC) valve Middleof engine Evaporativeemission(EVAPIpurge o f e n g i n e Middle control solenoidvalve Engineoil pressureswitch Middle ot engine Alternator Left side of engine Intake air temperature{lAT} sensor engine lvliddleof 'l No. fuel injector M i d d l eo f e n g i n e No. 2 tuel injector Middle of engine No. 3 fuel injector Middle ot engine No. 4 fuel injector ol engine Middle Junction connector Left side of enginecompartment Enginecompartmentwire harness Left side of enginecompartment (c304) Enginecompartmenlwire harness compartment of engine Left side (c305) Shift control solenoidvalve A and B Transmission Countershaitspeed sensor Transmission Mainshaftspeed sensor Transmission
Right side of Right side of Right side of Right side ol Right side of Right side of
Notes
enginecompartment enginecompartment enginecompartment enginecompartment enginecompartment engine
Alternator Lelt side oI engine Right side of enginecompartment Under-hoodtuse/relaybox Right side of engine
Engine ground, via engine wire harness
M/T NT
NT NT
ENGINEWIRE HARNESS (B188i snginel
cl19 c126
clla c121 c122 c123 c124 cl13
23-17
Gonnectorldentificationand Wire HarnessRouting Engine Wire Harnoss (B18Cl enginol Connoctor 01 Totminal
umbor ol Cavitio8
c101 cl 02 c103 c104 c105 c106
4 10 14 ,l 2
Right side of Right side of Right side ot Right side of Right side of Righrside ot
enginecompartment engine compartment engine comPanment engine compartmsnt engine compartment engine
Right side of engine
c107 c108 c109 c110
2 8
Transmission Middle ol engine MiddleoJ engine
c111
2
Right side of engine
cl12 c113 c114 c115 c116 c117
J
4 3
'I
Connecla to
Location
Right side ot engine comPartment Middl€ reat of enginecompartment Middle of engine Middle of engine Middle ol engine Middleo{ engine
Main wire harness(C221) Main wire harness(C222) Main wire harness(C223) Main wire harness(C22O) Starter solenoid Engine coolant temperature (ECT) sensor Enginecoolant temperature{ECTI gauge sendingunit Back-up light switch lgnition coil Top dead center/Crankshaft position/Cylind€r Position (TDC/CKP/CYP) sensor Enginecoolanttemperature{ECT) switch Vehiclespeed sensor (VSS) Hsated oxygen sensor{HO2S} MAP sensor Throttle position {TPl sensor ldle air control (lAC) valve Evaporativeemission{EVAPIpurge control solenoid valve Engineoil pressureswitch Alt€rnatot Intake 8ir temperature(lAT) ssnsor No. 1 fuel injector No. 2 fuel iniector No. 3 fuel injeclor No. 4 fuel injector Junction connector Enginecompartmentwareharness
I 2
Middle of engine Lelt side ot engine Middle of engine Middle of engine Middle ol engine Middle ot engine Middle of engine Left side of engine companment Lelt side ot engine compartment
't4
Left side of engine compartment
EnginecomPanmentwire harness
Right side ot engine Right sid€ of engine Middle ot engine Middle of engine
VTEC solenoid valve VTEC oil pressureswitch Knock sensor (KS) Intaka air bypass (lAB) control solenoid valve
T101 r102
Left side of engine Right sid6 ot engine compartment
Alternator Under-hood fuse/relay box
G1 0 1
Right side of engine
Engineground, via enginewire harness
c1r8 c119 c120 cl2'l c122 c123 c124 c125 c't26 c'127 c131 c132 c133 c134
23-18
4
2
1
{c304)
(c305)
f{orc!
EI{GINEWIRE HARNESS lBl8C'l onginel
c126 c119
'13 crrs
cl17 cl14
23-19
Connector ldentificationand Wire HarnessRouting ABS Modulatol Unit Wile Harness Connoctor or Torminal L t o l
c162 c163 c164 c165 c166 c't 67 c168
Numbor ot CaviiieE
't4
2 2
Location Right side of enginecomPartment ABS modulatorunit ABS modulatorunit ABS modulatorunit ABS modulatorunit ABS modulatorunit ABS modulatorunit ABS modulatorunat
Connocta to
oies
Main wire harness(c21 1) ABS Dressureswitch ABS right Jront solenoid(OUT) ABS right front solenoid(lN) ABS rear solenoid(OUT) ABS rear solenoidllN) ABS le{t front solenoid {OUT) ABS left tront solenoid(lNl
Engine Compartmont Wile Hatnaaa Connector or Tolminal
c301 c302 c303 c304 c305 c306 c307 c308 c309 c310 c311 c312 c313 c314 c315 c316 c317
Numbd of Cavilies
20 20 1 2 14 2 1 1 2 4 2 2 1 2
c318 c319
2
c320
5
G301
23-20
Location Behindleft kick Panel Behindleft kick panel Behindlett kick Panel Left side of engine compartment Left side of enginecomPartment Left side of enginecomPartment Left side o{ engine comPartment Left side of enginecomPartment Left side of engine compartment Lelt side oJ engine comPartment Middle of engine comPartment Left side of engine comPartment Left side oJ enginecomPafiment BehindleJt headlight Behindleft headlight Behindleft headlight Behind left corner ot front bumper Behind lett corner ot front DUmper Behindleft corner of ftont DUmper Behindleft cornet of front DUmper Lett side of enginecomPartment
Connocta to
t{oioE
Main wire harness(C4231 Main wire harness(C424) Option Front fog light sYstem Enginewire harness(C126) Enginewire harness(C127) Test tachometer connector Canada Daytime running lights resistor Windshi€ld wiper motot Brake fluid level sensor ( + | Brakefluid level sensor (- ) Power steering pressure (PSPI switch USA ABS Lett front wheel sensor Cruise control actuator Left headlight(Low beam) LeJ-theadlight(High beam) Option Front fog light system Windshieldwasher motor Rearwindow washer motor Left front side matker light Left front tu.n signal/parking lights Body ground,via enginecomPartment wire harness
ABS MODULATOR UI{IT WIREHARI{ESS
Et{GI1{ECOMPARTMET{T WIRE HARI{ESS
23-21
Connector ldentificationand Wire HarnessRouting {Undor-hood
c201 c202 c203
Behindright side of tront bumper Behindright corner of tront bumper Behindright corner of front bumpet Behindright headlight Behindright headlight Right side of enginecomPartment Right side of enginecomPartment Right side ot enginecomPartment Right side oJ enginecomPartment Right side of enginecomPartment Right side oJ enginecomPartment
Horn Right tront turn signal/Parking light Right Iront side marker light
c213
Right headlight(Low beam) Right headlight(High beam) Radiatorfan motor A / C w i r e h a r n e s s( C 1 5 1 ) ABS front fail saJerelay ABS rear fail sate relay ABS pump motor ABS modulatorunit wire harness (c161) Under-hoodABS fuse/relaYbox comPartment of engine Right side (c901) box Right side of enginecomPartment Under-hoodABS fuse/relaY
c214 c215 c216 c217 c218 c219 c220
Bight side ot enginecomPattment Right side of enginecomPartment Right side of enginecomPartment Right side of enginecomPartment Right side of enginecomPartment Right side of enginecomPartment Right side of enginecomPartment
c204 c205 c206 c207 c208 c209 c210 c211
8 4 14
c212
c220 c221 c222 c223
23-22
(c902)
7 J
2
Under-hoodfuse/relaybox (C907) Under-hoodtuse/relaYbox (C909) Under-hoodfuse/relaybox (C9l Ol Under-hoodfuse/relaYbox (C908) Under-hoodfuse/relaYbox (C911) Right front wheel sensor Enginewire harness{C104)
(C'l04) Righl side ot enginecomPartmenl Enginewire harness (C101) Right side of enginecompartmenl E n g i n ew i r e h a r n e s s (Cl 02) harness wire Engine Right side of enginecomPartmen' harness {C103) wire Engine comPartment Right side of engine wire Right side of enginecompartment Body ground, via main harness wire Right side of enginecomPartment Body ground, via main harness
UNDER.HOOD FUSE/RELAY BOX
MAIN WIRE HARNESSlcont'dl
c222 c221 c223 c220 c212 c213 Continuos on pago 23-25
23-23 itfltfitfi
Connector ldentificationand Wire HarnessRouting Main Wire Ha.ness {Right branch} Connactor or Terminal
Numbsr of Caviti€s
c401
,E
c402 c403 c404 c405 c406 c407 c408 c409 c410
23-24
10 2 22 lo
22 26
Location Front Passenger'sdoor Under right side of dash Under right side ot dash Under right side of dash Under right side of dash Under right side ot dash Behindright kick panel Behindright kick panel Behindright kick panel Behindright kick panel
Connscts to Front passenger'sdoor wire harness(C626) A/C diode Heatersub-harnessA (C672) Heatersub-harnessA {C671} SCS short connectol Data link connector(DLC) ABS sub-harness(C7011 Enginecontrol module (ECM) Enginecontrol module (ECM) Enginecontrol module (ECMI
ttlotor
MAIN WIRE HARNESSlcont'dl
Continuos on pago 23-27
Continuod from pa90
23-25
Connector ldentificationand Wire HarnessRouting Msin Wiie Harness (Left branch) Connector or Terminal
Numbel ot Cavities
c411 c412 c413 c414 c415 c416 c4'17 c418 c419
14 8 4 I 14 20 22
Centerfloor Centerfloor Centerfloor Under left side ot dash Behindleft kick panel Behindleft kick panel Behindleft kick panel Behindleft kick panel Behindleft kick panel
c420
26
Behindleft kick panel
c42'l
10
c423
20
Behindleft kick panel Behindleft kick panel Under left side of dash
c424
20
Under left side of dash
c425 c426 c427 c42A c429 c430 c431 c43l c432 c433 c434 c435 c436 c437 c438 c439 c440 c44'l c442 c443 c444 c445 c446 c447 c448 c449 G401
23-26
't4 4 2 10 4 7 4 o
7 I 7 22 6 4 7 4 15
to
Connects to
Notes
A/T gear positionconsolelight Shift lock solenoid A/T gear positionswitch Interlockcontrol unit Daytimerunninglights control unit Daytimerunninglights control unil Cruisecontrol unit Junction connector Transmissioncontrol module (TCM) Transmissioncontroi module {TCM) Rearwire harness(C501) Rear wire harness{C502) Enginecompartmentwire harness (c301) Enginecompartmentwire harness
Afi AiT Afi Afi Canada Canada
Location
Under lett side of Under left side ot Under lett side of Under lett side of Under lett side of Under lett side of Under lett side ot
dash dash dash dash dash dash dash
Under left side of dash Under left side ol dash Under left side of dash Under left side of dash Under left side of dash Under left side of dash Under left side of dash Behinddashboardlower cover Behinddashboardlower cover Behinddashboardlower cover Under left side of dash Under left side of dash Under left side of dash Under lett side of dash Under left side of dash Behindunder-dashfuse/relaybox Under left side ot dash Behinddashboardlower cover Behinddashboardlower cover Behindleft kick panel
Arf
An
(c302)
Roof wire harness(C663) Securitysystem (Option) SRS main harness(C802) Clutch interlockswitch Clutch switch (Cruisecontrol) Dashboardwire harness(C552) Brakeswitch (Without cruise control) Brakeswitch (With cruisecontrol) lgnitionswitch Securitysystem (Option) Combinationlight switch Combinationlight switch Combinationlight switch Combinationlight switch Under-dashfuse/relaybox {C9131 Under-dashfuse/relaybox {C9161 Underdash tuse/relaybox (C9'l7l Securitysystem (Option) Securitysystem {Option) PGM-FImain relay Starter cut relay Rearwindow defoqgerrelay Integratedcont.ol unit Securitysystem {Option) Horn relay Dashboardwire harness(C553) Body ground,via main wire harness
Canada
M/T M/T Atr
Canada
Canada Canada M/T
Canada
MAIN WIRE HANNESS
Continuod from poge 23-25
c418
C430 9432
c412 c41t
c449
c440
UNDER.DASH FUSE/RELAYBOX
23-27
Connector ldentificationand Wire HarnessRouting Roar wiro Harn$s (Hatchbsckl Connector or Torminal
Numbor of Cavitios
Location
Connecta to
Behindleft kick panel Behindleft kick panel Behind dashboard lower cover Behind dashboard lower cover Behinddashboardlower cover Driver's door Center tloor Center lloor Left qusrter panel Fueltank Fueltsnk Right quarter panel Right quarter panel Left quarter panel Left quarter panel Left quarter panel Left quarter panel Left side corner of cargo area L€ft side corner of cargo area Left side corner of cargo area Left rear corner of cargo area Center ot cargo area bulkhead Right rear cornor oJ cargo area Center of cargo area bulkhsad Right side of cargo area Right side of cargo area
Main wire harness(C4211 Main wire harness(C422) Under-dashfuse/relaybox (C912) Under-dashfuse/relaybox (C915) Dashboardwire harness(C554) Driver'sdoor wire harness{C6011 Driver's seat belt switch Palkingbrakeswitch Driver'sdoor switch Fuel pump Fuel gauge sendingunit Passenger'sdoor switch Right rear speaket Left rear speaker Noise condenser ConnectorC517 ConnectorC516 Power antennamotor Cargo area light Traile.lightingconnector LeJt taillight License plate lights Right taillight Tailgate latch switch Tailgatewire harness(C752) Tailgatewire harness(C751)
G501
Behindleft kick psnel
G502
Left side of Jloor
G503
Center ot cargo area bulkhead
Body ground, via rear wire harness Body ground, via rear wire harness Body ground,via rear wire harness
c501 c502 c503 c504 c505 c506 c507 c508 c509 LStt
c 5 11 c512 c513 c514 c515 c516 c517 c 5 r8 c519 c520 c521 c522 c523 c524 c525 c526
23-28
10 '14 10 12 25 2 1 1 2 I 2 20 20 2 6 b
2 2 2 4
llotos
REARWIRE HARNESS
G503
23-29
Connector ldentificationand Wire HarnessRouting Rear Wire HamsEs (S6danl Connector ol Torminal
Number ot Caviti6s
c501
10
c503 c504 c505 c506 c507 c508 c509 c510
10
Connocts to
Locaiion
4 6
Behindleft kick panel Behindleft kick panel Behinddashboardlower cover Behinddashboardlower cover Behinddashboardlowe, cover Driver'sdoor Centerfloor Centerfloor Left B-pillar Fueltank Fueltank Right B'pillar Above right side of trunk Above left side ot trunk Left quarter panel Left quarter panel Left quarter panel Left side corner of trunk Above center of trunk Left side corner of trunk Left rear corner of trunk Right rear corner of trunk Right rear corner of trunk Left ,ear door
c52A
6
Right rear door
Main wire harness(C421) Main wire harness(C422) Under-dashtuse/relaybox {C912} Under-dashfuse/relaybox (C915) Dashboardwire harness(C554) Driver'sdoor wire harness(C6Ol ) Driver'sseat belt switch Parking brake switch Driver'sdoor switch Fuel pump Fuelgauge sendingunil Front passenger'sdoor switch Right rear speaker Left rear speaker Noisecondenser C o n n e c t oC r 517 C o n n e c t oC r 516 Power antenna motor Trunk light Trailerlightingconneclor Left outer taillighr Licenseplate lights Right outer taillighr Left rear door wire harness (c651) Right rear door wire harness
LCZY
1 ,|
LeJt quarter panel LeJtside oJ rear window Above right side of trunk Right quarter panel Right side of rear window Left side ot trunk lid Centerot trunk lid Right side ot trunk lid
Lett rear door switch Rearwindow delogget (+ ) High mount btake light Right rear door switch Rear window defogger(- ) Left inner taillight T,unk latch switch Right inner taillight
G501
Behindlett kick panel
G502
Left side of floor
G503
Above center of trunk
Body ground,via rear wire narness Body ground,via rear wire narness Body ground,via rear wire narness
aEt t
c512 L9
IJ
c514 c515 c516 c517 c518 c519 c520 c521 c522 c523 c527
c530 c531 c532 c533 c534 c535 c536
23-30
12 25 'I 1 a 1
2 2 20 20 2 6 4
2 1 I 4 4
(c656)
Notos
c528 c532
c533 13
REARWIRE HARNESS
23-31
Connector ldentificationand Wire HarnessRouting Dashboardwile Ha.n6ss Connector ot T€rminal
Number of Caviti6s
20 10 c553 c554 L55b
c556 c557 c558 c560 LCO
12 5 22 10 13 16
I
c563 c564 c565 c566 c567 c568 a 6ACl
23-32
to
10 6 to
2
Location
Connects to
Behinddashboardlower cover Behinddashboardlower cover Behinddashboardlower cover Behinddashboardlower cover Under lett side oJ dash Under left side of dash Behindgauges Behindgauges Behindgauges Behindgauges Behindmiddleof dash Left side of dash Behindmiddleof dash Behindmiddleof dash Right side of dash Under middleof dash Under middleof dash Behinddashboardlower cover Under middleof dash
Under-dashfuse/relaybox (C919) Main wire harness(C43Ol Main wire harness(C4491 Rear wire harness{C505) Cruisemain switch Junction connector Gaugeassembly Gaugeassembly Gaugeassembly Gaugeassembly Clock Dash lights brightnesscontroller Hazardwarning switch Rear window defoggerswitch Glov€ box light Stereo radio/cassette PlaYer Chime Maintenancereminde.unit Cigarettelighter
Under middle of dash
Body ground, via dashboardwire harness
Notes
Afi
c5P3 csor
cl6a cs,aa "ru.,
DASI{BOARD WIRE HARNESS
UNDER-DASH FUSE/RELAY8OX
23-33
Connector ldentificationand Wire HarnessRouting Drlvar's Door Wir6 Hamors Connectot 01 Torminal
Number of Cavitles
c601 c602 c603 c604 c605 c605 c606
25 2 4 14 I I
Location Driver'sdoor Driver's door Driver'sdoor Driver'sdoor Behindmirror panel Driver'sdoor Driver'sdoor
c607 c608 c609 c610
10 10 o
Driver'sdoor Driv€r's door Driver's door Driver's door
c611 c612
2 I
Oriver'sdoor Driver'sdoor
23-34
Connocts to
Notos
Oriver'sdoor wire harness(C506) Driver'sdoor speaker Driver's power window motor Power door lock control unit Left power mirror Hatchback Left power mirror Sedan Lett tweeter 818C1 engrne Driver'sdoor lock switch Power mirror switch Power window masterswitch D.iver's door lock actuatorassembly Driver'skey cylinderswitch Power window master switch Sedan
Hatchback:
Sedan:
23-35
Connectorldentificationand Wire HarnessRouting Flont Pasa€ngol's Door Wire Hamosg Conngctor or Talminal
Numbel of C8viti63
c626 c627 c628
25 2 2
Front passenger's door Front passsngel's door Front pssseng€r's door
c629 c629 c630
8 tt
Behind cover panel Front passenger's door Front passengor's door
c631
2
Front passenger's door
c632
5
Front Passonger'sdool
c633
2
Front passeng€r's door
c634
23-36
Locatlon
Front pass€ngot's door
Connocts to Main wire harness(C4O1) Front passenger's door speaker Front passeng€r's power window motot Right power mirror Right power mirror Right tweeler Front passenger's door lock switch Front passengor's Power window switch Front passenget's door lock actuator Front passengor's door key cylind6r switch
Not6s
Hatchback S6dan 8 1 8 C1 6n9ino
Hatchback:
PASSENGER'SDOOR WIRE HARNESS
Sedan:
FRONT PASSENGEB'SDOOR WIBE HARNESS
23-37
Connectorldentificationand Wire HarnessRouting Left R6ar Door Wil8 Harn6ss (Sedan) Connoctol ol Tarminal
Number ot Caviiies
Lbc I
b
c652 c653 c654
Locstion Lett rear door Left rear door Left rear door Left rear door
Connocta to Resr wira harness(C527) Loft rsar power window motor Left rsar gower window switch L€It roar Powor window sctuator
Right Rear Door Wilo Hatnosr (S6danl
Right rear door Right rear door Right r€ar door Right rear door
23-38.
Rear wira harness {C528) Right 168r power window motor Right 168rpower window switch Right rear Powor window actuator
l{ot.t
LEFTREARDOOR WIRE HARNESS
WIRE HARNESS
23-39
Gonnectorldentificationand Wire HarnessRouting Roof Wire HanesE Connector ol Terminal
Number ot Cavitiss
Connccts to
Location Behindleft kick panel
Under-dashfuse/relay box (C918)
4
Behindleft kick panel
Moonroot relay
c664
4
Behindleft kick panel Left side of dashboa.d
Main wire harnoss(C425) Moonroof switch
LOO5
2
Roof
Moonroof motor
LOOO
I
Roof
Spotlight
Roof
Ceilinglight
c661 c662 LOOJ
c667
23-40
Notct
with moonroof with moonroof with moonroof with moonroot with moonroot
Hdchback:
FUSE/RELAY BOX
Scdrn:
ROOF WIRE HABNESS UNDEB.DASH FUSE/RELAYBOX
23-41
Gonnectorldentificationand Wire HarnessRouting ABS Sub-harn6ss Connactor ol Terminal
Number of Cavities
c701 c702 c703 c704 c705 c705 c706 c706
22
G701 G702
23-42
20
22 2 2
Location
Conn€cts to
Behindright kick panel Right side of Jloor Right quarter panel Bighl quarter panel Right side of cargo area Right side of trunk LeJt side of cargo area Left side ot trunk
Main wire harness(C407) ABS maintenanceconnecto. ABS control unit ABS control unit ABS right wheel sensor ABS right wheel sensor ABS left wheel sensor ABS left wheel sensor
Right quarter panel Right quarter panel
Body ground, via ABS sub-harness Body ground, via ABS sub-harness
Notas
Hatchback Sedan Hatchback Sedan
Hatchback:
Sedan:
23-43
Connector ldentificationand Wire HarnessRouting Hatch Wire Harnsss {Hatchbackl Connector or Torminal
Numbor ol Cavilies
c751 c752
4
L/5J
1
c754 c755
4
G751
Location
Connscts to
Right side oJ cargo area Right side of cargo area Right side of reat window Right side of hatch
Rearwire harness(C526) Rear wire harness(C5251 Rearwindow defogger(+ I Spoilersub-harness(C761)
Middle of hatch Middleof hatch
Rear window wiper motot High mount brake light
Right side oJ hstch
Body ground, via hatch wire naaness
l{otos
8 1 8 C1 engine 8 18 8 1 engine
Spoilor Sub-harn6ss(Hatchback with B18C snginel Connoctor or Terminal
c761 c762 c763
Number ot Cavitios I 1
Localion Right side of hatch Middle of hatch Middle of hatch
Connocls to
Notos
Hatch wire harness(C754) High mount btake light ( + ) High mount brake light ( - )
Roar Window Defoggor Ground Wire (Hatchbackl Connoctol or Tgrminal
Numbor of Caviti6s
c77'l
1
G771
23-4r'i
Location
Connoctg to
Lett side ot rear window
Rearwindow defogger(-)
Left side ot rear window
Body ground, via tear window deJoggerground wi.e
Notes
HATCH
WIRE
BEARWII{DOW DEFOGGER GROUND IVIBE
c763 SPOILERSUB.HAFIIESS
23-45 'r]fi
Connector ldentificationand Wire HarnessRouting Hoator Sub-harneEsA Connoctor or Terminal
Numb€r of Cavities
'lo
c671 c672 c673 c674 c675 c676 c677
2 4 4 14
Location Under right side ot dash Under right side of dash Under right side of dash Behindglove box Behindglove box Behindglove box Behindmiddleof dash
Conn6cts to
Notog
Main wire harness(C404) Main wire harness(C4o3) Blower motor Blower resistor Recirculationcontrol motot A/C thermostat Heatersub-harnessB (C681)
Hoator Sub-hameEsB connoctor 01 T6rminal
Number of CavitioE
c681 c682 c683 c684
14 I 6 14
Location Behindmiddleof dash Middle ol floor Behindmiddleof dash Behindmiddle of dash
Connocts to Heatersub-harnessA (C677) Mode control motor HeaterJan switch Heaterconttol Panel
HEATERSUB-HARI{ESSB
23-46
Notos
Connector ldentificationand Wire HarnessRouting SRS Main Harness Connector or Terminal
Number ol Cavities
c801 c802 c803 c804 c805 c806 c807
2 4
G801
o
18 2
Location I Behinddashboardlowet cover J Under left side of dash Under left side of dash Middle of floor Under left side of dash Under right side of dash Behindglove box Middle of floor
Connocts to
l{otos
Under-dashf use/rclay box (C929) Main wire haness 1C427) Cable reel SRS unit Left dash sensor Right dash sensor Passenger'sairbagassembly Body ground, via SRS main harness
UNDER-DASH FUSE/RELAYBOX
23-47
Fuses Under-dashFuse/RelayBox c919 lTo dashboardwire harness(C55'l)l
c918
lTo root wiro harness (C661ll
c920 .elayl lTo lurn signal/hszard
c928 lTo SRS luso block {C931}l
cg22 lTo powor window rclayl
Auxili.ry fulo holdei
Elnnnr.'trJnnrJn 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 2 0 2 1 22 UUIJUIJULJLILIIJ
n|:]nnnnnn 1
2
3
t4l 5
6
(7) 8
LIIJLIULJUUU
r: Not usod .: Canadd | ): S6dan
23
UIJ
r''lN11 9. 1 0 1 1
U LILI
r . - - - - - - - l
O: C923 loplion lBATll @: C924 toption (BATll O: C925 toption llc2)1 @r C926 loption{No.19 fusoll @: C927 loption {ACC)I
c929 J To SRSmain I {C8011I I harnass c930 I To ignitionl i I switch
c931 I To und€rdash I I fuso/rolaybox {C928)I
SRS FUSE BLOCK
23-48
Fuse Numb€r AmDs 1
30A
Wire Colol
WHT
2 3
Gomponent ls) or Circuit (s) Prot8cted Moonroof motor Not used
7 . 5A
WHT/RED Integratedcontrol unit, Ceilinglight, Power antennamotor. Data link connector (DLC)
4
20A
YEL/BLK
Right rea. power window motor (Sedan)
5
20A
WHT/YEL Driver'spower window motor
o
20A
WHT/GRN
Power door lock control unit
7
20A
GRNiBLK
Lelt rear power window motor (Sedan)
I
20A
I
1 0A
BLU/BLK Passenger'spower window motor RED/BLU Right headlight{High beaml
10
1 0A
R E D / G R N Left headlight(High beam). High beam indicato.tight
11
Not used
12
Not used
13
7.5 A
BLK/YEL
Rearwindow defoggersystem, A/C system, ABS control unit, power mrrror actuator
14 '15
20A
GRN/BLK
Wiper/washersystem, Moonroof relay, Integratedcontrol unii
1 0A
YEL
to
7.5A
YEL/BLK
17
1 0A 7.5A
WHT/YEL Daytimerunninglights control unit (Csnada) BLU^tvHT ECM, PGM-FImain relay
1 0A
RED/BLK
'to
20 21
23
Gauges,Clock, Back-uplights, Maintenancereminderunit Daytimerunninglights control unit (Canadal
Dash lights, Parkinglights, Taillights,Licenseplate tights Not used
1 0A
RED/WHT
Right headlight(Low beam)
1 0A
RED/YEL
Left headlight(Low beam)
1 5A
YEL/RED
Stereo radio/cassette player, Cigarette lighter
24
REO
BLK/YEL 25
1 0A
PNK
26
1 0A
YEL/BLK
SRS unit PGM-FImain relay, TCM, Cruisecontrot unit, VSS, ELOunit IUSA) SRS unit Turn signal/hazard relay
' 1 N o . 24 115 Al: 8 1 8 8 1 e n g i n e N o . 24 t2O At:. B 1 8 C l e n g i n e
23-49
Fuses Under-dashFuse/RelayBox (cont'd) NOTE: View from the backside of the under-dashtuse/relay box
c916 [To m.in wlro h.rnr.t lol39]l
cgt5 tTo ..r wftt hJtr.r (CsOrDl
c9r4
[To Int grrtad control unhl
c917 [To mrin wh.
c913 lTo m.in wlro hlni.rr
23-50
(qt38)l
c91 tTo r..r w|? hrt|.|t
(C6O3ll
Under-hoodABS Fuse/RelayBox T5 [To undo]-hood ABS fuso/rolay box cabl.l
C9O3 ITo ABS pump molor rolayl
C9O1 [To main wiro ham6$ (C212]l C9O2 [To moin wiro hs1n6ss(C213]l
Wire Color ABS 81
20A
WHT/GRN
ABS 82
1 5A
WHT
ABS MOTOR 4 0 A ABS UNIT
1 0A
Componont (s) or Circuit (sl Protectsd Right/left ABS front solenoids ABS control unit, ABS rear solenoid ABS pump motor relay, ABS unit (10 A) fuse
BRN/YEL
ABS control unit
23-51
Fuses Under-hoodFuse/RelayBox
n F n nn 46 45 /t4 35 3l
ALTERI{ATOR fTo .ngino wlto hsrno$ {Tlolll
UU U UU
n 32 U
n
n 42
33
U
r:r
U
n 43
g
U
U
[To rldidor
hn r.l.Yl
Not usod r: l\lot u3.d
umbor Amps
Componon! (sl 01 Clrcuit 13)Protoqtod
Color
31
1 5A
YEL/WHT PGM-Flmain relay
32
7.5 A
WHT/BLU ECM, TCM. Clock, Stereo radio/cassette plsyer, Maintenance reminder unit
a2
204
BLK/RED
Radiator Jan motor Not used
34 50A
Condenserfan motor, A/C compressorclutch WHT/RED N o . I { 3 OA ) , N o . 3 ( 7 . 5 A ) . N o . 4 l 2 O A l , N o 5 ( 2 OA ) , N o . 7 ( 2 OA ) , No. I (20 A) fuses
37 38
40A
BLU/lVHT
Blower motor
30A
BLK/GRN
Rear window defogger,Noisecondenser
?q
50A
WHT/BLK
lgnitionswitch {BAT}
40
50A
WHT
41
1 0 0A
42 43
20A
WHT/GRN
Horn system, Brake system, Key interlock solenoid (Aff)
1 0A
WHT/GRN
Turn signal/hazard.elay
35
204
WHT
Combinationlight switch, No. 17 (1O Al fuse Power distribution
44
Not used
45
Not used
46
Not used
23-52
NOTE; View from the backside of the under-hood fuse/relav box c907 lTo m.ln wiro h.mo$ (C214)l
[To msinwlro hEmosslc215l]
lTo mrin wiro hameq lC217ll
lTo mlln wlr. hlmct.
(C216li
c911 lTo ftain wiro hamers(C218)l:USA
23-53
PowerDistribution Gircuit ldentification 8OX ABSFUSE/FEIAY UNOER-HOOD ABS81 {2OA)
WHT/GRN f
r-
Bight tromsotcooia blt ) nas
A8682II5AI
ABSoumomotor 8n /YEL-
A8Scontol unit
Btx/YEL <
tu!. ib.l3l7.5Al
YER/RED
A&Scontrol unit
BATTERY Stldar motor
r BLKffEL
_o_
- HOODFUSE/RELAY 8OX UNDER
:
No.43ll0Al
wHT/GRt{
Turnsi0nrl/h.z.rd|thY
WHT/GRN
tlom llom mLy Keyintodocklohnokl{A/Tl ECM Cruisocontrolunil controlmodub(TcMl Tran.mksion ABScontiolunh &6k lighl!
I AL]ERNATOR
L"I .r"-
oiot
G401
23-54
No.1l(100A)
{Topsge23- 55)
no.42l20A)
GRi{/REo
ECM
_HOODFUSE/NEUY UNDER 8OX
{Fromp.So23- 541
YELJWHT
PGM-R mlin |rhv TrdEmirConco rolrl|oduL
frcMt
-OASH UI{DEF FUSSRELAY BOX tTop!9c23- 581
n^OIATOR FANREI-AY 8LK/RED
No.l317.5Al FUSE
V
Radi.torfln molor
ENGII{E COOTAMI TEMPEMTURE IECT)
swtTcH
*@"r;1
L swyel
oiot BTOWER MOTOR RETAY
'"---G20t G40t 8bw.r motor
8LU/WHT
8tX/GRtl-f E WHT-----
R!!r windowd,.to![.r Noia€condsn..r
-
Cord.nrorlan motor IJC como.a.lorclutdt
1/-
y ut{DER-oAsH R sE/nEL BoX(Toprs.23- 58I
-IB> wHTnED
*,"r^*__E>
Fl,$SlrrrrTgl,*r,
No,40l50Al COMBIMTON UGHTSWTTCH {Top!!€ 23-59 )
- DASIIFUSAREUY UiIDER BOXfTop{6 23- 58 llc$.d!l
23-55
PowerDistribution Circuit ldentification
- DASHFUSE/REIAY BOX UNDER
IGNITION SWITCH
sRsFusE 81-0cK No.25l10Al
l r c z Ml
t
-'-
\'-
_ ^ACC
+
Chuging sY3l.m light lln tho g6ug€s3€mblyl Cruis€controlunit Cdis6 msin 3whch itdicttor light
p age23- 5 7 1
r 1 No.24115A): 81881 engin€ No.24l20A):Bl8C16ngin.
PGM- Flmlin r6lry lrrmmirdon controlmodulo[ICM) ) Vohag6rcoulator Vehiclosp.€dsomorIVSS) E|.l)unitIUSA) Crubeconttolunit No.14l20A) GRNiEI( GRNAt(
Moonrcofrclay Wind.hicldwipotmotor Wirdlhi€ldwaah6.motor R6arwindowws3hormotot{Hrtchblctl Int.gGtodcontrolunit PowerwirdowtclaY Int6lrat€dcontrclunit
GRN/8I..K
R6afwindow wipor motol (H3tchbtck)
BLKffEt
No.l5{1041 N0.40{504) FUSE (Frompago23- 551
-EiT"h#,H#J:r" YEt..--
* 2 N o . 1{71 0 4 1
bor sockstl
ShittlocksolenoU{Ml -up lights Eack C924 optionconn€ctor: Daytimo runninglightsconttolunit
23-56
IGNITION SWTCHISTI lFromp.!€ 23- 561
f7 I
.---F------l
i
I
STARTFP
-
l
Bffi,!'HT6u?'ili,iY
'| rt-11iPt
I
l-+{
i
r
t
i .'.io-F
l - l
l
l\ \ clurcr I inl-rhicicxswrcr 1,,,,,,
;rui8rrH --.5 BIK/RED
BLX/!\,HT
st.dersotenoid
BLKMHT-
Starlsrsolenoki
I
i
r
BLK/REO
fr r---
uxrivnSr$!gfr*,r., L€-eumo
-------J
-DASHFUSEiRELAY UNDER BOX
No.l817.5A) ELUMHT--?(From pag623-56 ) No.23ll5Al lG2 lFromp.!623- 56 )
PGM_ Ftmsinrctay ECM lnt€gretodcontrol unit
--E YEURED boxsockotl {Fus€/relay
St6r6oradio/c$r€tt6 playot Cig€ronelightor Optionconnoctor: C927
Pow6rminor *tuetols noarwandowdologgorswitch indicrtorlight
+ l,lo,16 {7.5A1
R6dietorfan roby Elowormotor rclay fuC compr$sor clutch rsl6y A/C lhomGtst Cond6ns&tan ml6y Mod6controlmotor Rocicubtion control motor H6at€rcontrolpanol Rearwindow deloggorrelay ABS pompmotor tolay ABSinsp€ctionconnoctor ABScontrcl unit Optionconnoctor:C925 Daytimerunninglights controlunit
23-57
PowerDistribution Circuit ldentification
- OASHFUSE/REI-AY UNOER BOX
WHT/RED -
-
TrunUcergo .rur lght Fbwer.nr.nn! moror
E
Spotlight(Wrt'hmoonmoll C.ilin! light Drl! link conn ctor lDLCl
WHT/REof boxsockstl
Irtogrltad control unit
WHT/GRN
Pow6rdoor locl control unit
optionconnoclor: C923 No,14l20l FUSE
{lntomalconnaclionl
*G20t G40l WHTIYEL *
BLU/4X+l
Powor windowconttolunrt {&ih intoDoworwindowmarloirwhchl p,i""1" *;n6o* no1o,
l_
| l,lssrng6r'swndowmotor
GRN/BLX -
)
YEUE|-K -
)
r: Sedln
23-58
| l-
Leftrerrwindowmoror ftenroar winoowmotor
- DASHFUSE/RELAY UNOER 8OX
DIMMEN
No.9l10A)
neontu
REo/BLU
? o *c--i| No.lolloAl
ftghtl b.rml lHish I hordlishr
--E:::::l-
i |
|
I
No.2lll0A) REDiU,HT+REo^wHT I I No.22ll0Al -TiED,TEL-L.trr |
l"JnJ"",,**".
_
Rgh,I | h.rdliohtlLowb€rml
|
t
l optioncondsclor: C926 RED/BLK *
L
o.sh hhts briohtners co .oll€r Dlshlght!
-
A/T gorr pGition conloh hht Horler control Drnellioht
l_tft
Rishn. Iro
REDALK ..-
REDEL(+
parung rgnr
fff')t.'..,nt tillisht{s€danl f#t) inner Lic.n!€ pbt€ li0hts Truilorliglfi ng connoclor
tGNtTloN swtTcH ltcl) p3€6 23- 56) lFrom
V I l-
FUS€ HOLDER t
BLK,ryEL #
I
tt I
l
m.ze rroo
_
_
_
_
I
-
l
YEUBTK-
Tumdgnd/hazrrdr6i.y
l l
23-59
GroundDistribution Gircuitldentification
Blttory
_d_ : GI
Tnnll|iltirn
houinc
_d_ : G3 Et -
Y€||tr rpo€ollrEor rYSq VrECDlaaaura rwitch 18| 8Cl.r{i|r) Engino coohnttomporlru|!ICCTI !wilch
-
ux_r]---..o eu{l{
"-
*" ", iTl*;,,
E
Dlt linl connctor lDl"Cl I Tranamildrficontroldbduh
t (TcMt
ECM(-G ECMILG2I
Xmct t rmr l(Sl {VTEC} lLatadorvo.n !.ruor lHozsl
Cnnkd|rft Doritiont ICKPI$nlor t
ECM
I
TDC!.No. t
Cylndaroolitirn f ICYPI!.ir.o. 1 L-----------
on[/8LU-r-.
Mdn httt !p6od ..n.or lAlTl
WHT/BI-U+ sLu/GRN-F
Co(||llanhrft !p.€d r.Bor WT)
BLUrYEL -
Irn ry oroundcebh E , Etgi," *ir" ha."o 0oondcrbL A E , Etgir. *rp"nn"nt *ir. han*"s E: Enoina | ground €ngino c.bL 8 E: Mdnwirbhem6r E E:
23-60
I
I I
Tnnln&don codaol moduL
frcMt
l-
Cor|danlor lan motor
-f, :
G15l
h.ldtgh
+
s
lLow be.ml
Rbhttror pr*ino^um .ign.l lehr Righttro li,. m|.t rhht EtounitIUSAI
- HOOO UI{DER FUSE/R€TAY 8OX Elowormotorrolay R6!r*indow dsloegrrrcby
G40t fro p.g. 23- 62)
AB{iF np motor
au#eu
ABSpr..&r! lwltch
E , A/c*ir" tr".osr unitwitchrrn.r E : ABSdbduknor : Min wirr h.moB Ul
23-61
GroundDistribution Circuit ldentification
lHi0hberm)
'LK
H[l[llsf#"ff'"Jfl1"'o"
Homrol.y lgdtionkoylrvitch 8r
-;€[email protected]*'*.,
oq_
BIK -{
t .
|-{N| l-
-
4.X -7 BIK
tr tr E
lub - hamar! A
Engin6comprrtmonl wiro htrnds
@ :llort.|
Main wiro hftn.ss
tlt . H6!t6r lub - harara$B
Frcnt prsongor'! door wim hlmosg
23-62
F L
Cftxchsvynch {M/Twhhcruisccontroll conlrclunit I lArt Intorlocl
r-
Ct rch htodock swhch lM/Tl Ra'r window wioar/washotlwitdl
l-
P!.rsong.r'!dootloct kcycylind€rsYritch doorbck 3witch P!s!6n06r's Windlhiald wio.r/w$h6r rwhch
G,Ol lR!6t p.g! 23-621
I
cod$rionl
Porvlrwidow rlhy Tlm demlftd.id nhy Intaeiltadcontrolunh
*-----ilHHlifr,
JUNCtOI{
coif{EcroR
g..(
SRslidbnor loht/&dit
d{
Daahhhr Mchinalaconto{.. Clocl Grler. .nd hdixor hhtr Mdntandranrnlidarurlt R.r rvlndoud.foglr r*hdr
n"K
Chino Cigrfi.ItDt.r Gbv! boxhhl Crui$ contmlmin .witdr
Starao[do/clalatta pbyal
c56l
) snsu'* G80r
E: MdnYdoh.m..! E, ootrtoct ,lo ttetr".. @: noor*in |trttan
E'sasnr*rtrrtu
23-63
GroundDistribution Circuit ldentification Hstchbsckl Pow6r doorlockcontolunh Driver'B doorlockectrrtor Driv6r'sdoorlockk6ycylind6lswhch Drivor'sdoorlockswitch Powor mirroa swhch ] Pow6rwindowmanorswitch
) 8r-K
Ddver'3seat bah 3whch
----BLK,lVHT
Fuolg&lge s€odiogunil R rl pump
nuo, Poworsntonmmotor Tnibr lighingconn€ctor L
E eLx -i]-
BLK-
I
;l:. I taillisht Lic€nroph6 light3 HishrDunt br.k6tisht
BtK---------
) ABs*nuoruni
AIY_I
I_ BI.KA.VHT
Lrh
I ABScontolunh ABScontrolunh
Rorrwirdowwipcrnotor
cirt Ro window d€foggor
nirt
E E E
Roarwiroharnoss Ddv6r's doorwileham63s ABSsub-hernoss
23-64
@ :Tailgatowirc hamoss @ : R6erwindow d6lo9g€rgro{nd wirc
S€d8n:
,.-*-{.4rr-*
Powgrdoorlockcontrclunit Drivor'sdoor lock actustor D ve/s door lock key cylind€l rwhch Ddv6r'sdoor lock switch ] Powerwindow mrster switch
)
Drivor's soat bolt swhch
--E Brx,4/vHr
*",r *n lfr]ff;nj
G5o2
Irunk latchswhch f l8iler lightingconnector Licoruopl.to lights RiohtI . nnst rrn gnr L€-ft J Riohr) .... . ran||gnr L€-ft J Poweranlonnamotot Highmo0ntbt'k6light Rearwindow dotoggor
otoa
oo "onuo,unn ]
t,*----l =,-"*-
-
,_^
f
ABscontrclunh
.: G702
@: @ :Ddvo/sdoorwir€ hemoss
E ' ABSsub- hafn6s.
23-65
Battery
a Battory tluid (6lectrolyt€l contains sulturic acid. lt may cauaa aevere burns iI it gots on your skin or in youl oyos. Woar protoctivo clothing and I fac€ shield, - ll aloctrolyt6 gots on youl skin or clothos, rimo it off with wator immediately, - lf eloclrolyto g6ts in your oyos, tlush it out by splashingwat6r in youl eyes for at least 15 minutes; call a physiclan immediately, a A battery gives off hydrogon gas, lf ignit6d. tha hydrogsn will orploda and could crack tho baflory cas6 and splattor acid on you. Koep spa*s. flames, and cigarottos away from the baftery. a Overchargingwill raiso ths tempelature ot th€ electrolyte. This may force electrolyte to splay out of the battery venta. Follow lhe chargor manutacturer's instluctions and chargo tho battory at a prop61rate. NOTE: The originalradiohas a codedtheft protectioncircuit. lt serviceto the car requiresany of the lollowing, be sure to get the customer'scode number before - disconnectingthe battery. - removingNo. 32 (7.5 Al fuse from the under-hoodfuse/relaybox - removingthe radio, After service,reconnectpower to the radioand turn it on. When the word "CODE" is displayed,enter the customer's s-digir code to restore radio operation, Use eithera JCI or BearARBSTtester, and follow the manufacturer'sprocedures.It you don'r have one of these computerized testers, follow this conventional test procedure: To get accurateresults,the temperatureot the electrolytemust be between TOoF l21ool and IOOoF{38oCl.
lf the case is cracked or the posts are loose, replace the battery.
lf the indicator shows low electrolvte, add distilledwater it oossible.
Test Load Cspacity (# 1) . . . .
Apply 3OOamp losd fo. 15 secondsto remove surJacecharge. Allow 15 secondsrecoveryperiod. Apply test load (see Test Load Chartl. Recordvoltage at the end of 15 seconds.
Voltagestays above 9.6 volts: The batterv is OK.
23-66
Chargeon High Setting {4O ampsl Chargeuntil EYEshows chargeis OK; plus an additional30 minutesto assuretull charge. NOTE:lf the battery chargeis very low, it may be necessaryto bypassthe charger's polarityprotectioncircuitry. lf the EYEdoes not show chargeis OK within three hours,the battery is no good; replaceit. Write down how long the battery was charged.
Test Load Capacity l#21 Apply 300 amp load for 15 secondsto removesurfacecharge. Allow 15 secondsrecovervDeriod. Apply test load (seeTest Load Chan). Recordvoltaoe at the end of 15 seconds.
Voltagestays abov€ 9.6 volts: The Uatteryis Of. I
Voltagedrops below 9.6 volts: The battery is no good.
For oramplo: AOD26L.MF .-
I
I
BATTERY ERY COOE COOE TEST LOAD CHART Use the test load ot 112the cold crankingamps (CCA)printed on the labelon the top of the battery. lf neithe. is indicated, us€ the informationbelow: BATTERY CODE
COLD CRANKING AMPS (CCA)
80 70
550
55
405
440
TESTLOAD lamps, 270 220 200
23-67
Power Relays RelayTest t{ormally-op€n Type: 1.
Remove the power relay from its sockat.
2.
Check continuity between relay terminals.
a Power window relay a Radiator fan relay a glower motor relav
a There should be continuity between the A and C terminals when power and ground ar€ connected to the B and D t€rminals a There should be no continuitv wh€n power is disconnected.
T6rminal A
(B- D) PowEr Connactod Di!c!nnact6d
IP
tb
I I
a a a a a
Staner cut relay Condenser fan .elay A/C compressor clutch relay ABS t.ont {ail-saferelay ABS lear fail-saterelav
.
A \
B /
tffit t[fT4r \ C
23-68
D ,
8
D
A
c
23-69
lgnition Switch CAUTION: a All SRS electdcal wiring harnessssaro covotod whh yollow insulation. a Botore disconnocting any part ot th6 SRS wiro harn6ss. connoct tha shon connoctor(t). a Replac€tho ontiro affected SRS hames! asllmbly It it has an op6n circuit 01 damagod widng.
J.
Chsck tor continuity b€tween the terminals in each switch position according to the table.
SRS MAIN HARI{ESS (Cov6red with Yollow inrulltiori)
1.
Removethe dashboardlower cover and knee bolster.
Terninal
\
BAT
tG1
ST
P6ition
--o oI KNEE BOLSTER
DASHBOARDLOWERCOVER
Disconnect the 5-P connector flom the undsr-dash fuse/relav box and the 7-P connector from the main wire harness.
23-70
4.
lf continuity checks do not agre€ with the tabl6, reolace the €lectrical part of the switch lsee page 23-72t.
ElectricalSwitch Replacement a All SRS €lectric8l wiring hamossesar€ covorsd with yellow insulation, a Befora disconnecting any pan of tho SRS wilo harneas. connect the short connoctor(sl. a R6placethe entire attect6d SFS harnessassombly if it has an opon circuit 01 damaged wiling.
NOTE: The originalradio has a coded theft protection circuit, Be sure to get the customer'scode numberbefore - disconnectingthe battery. - removingthe No. 32 (7.5 Al fusefrom the under-hood luse/relaybox. - removangthe radio. After service,reconnectpower to the radio and turn it on. Whenthe word "CODE" is displayed,enterthe customer's 5-digit code to restoreradio ope.ation.
4.
Removethe steeringcolumn covers. UPPERCOVER
E
Insertthe key and turn it to ,,O',. Removethe two bolts and replacethe switch.
1. Disconnectthe negativecable from the batery. 2.
Removethe dashboardlower cover and knee bolster {seepage 23-70).
3.
Disconnectthe 5-P connectorfrom the under-dash fuse/relaybox and the 7-Pconnectorfrom the main wire harness (see page 23-70).
7.
Installin the reve.seorde. of removat.
23-71
lgnition Switch Steering Lock Replacement CAUTION: a All SRS electrical wiring harnessesale covsred with yellow insulation. a Belore disconnecting any parl ot the SRS wir€ halness, connecl the short connector{s). a Replacethe entire alfected SRS harness a$6mbly il it has an open circuit or damaged wiring.
NOTE: The originalradio has a coded thett protection circuit. Be sureto get the customer'scode numberbetore - disconnectingthe batterY. - removingthe No. 32 (7.5 A) fusefrom the under-hood fuse/relaybox. - removingthe radio. After service,reconnectpower to the radio and turn it "CODE" is displayed,enterthe cuson. Whenthe word tomer's 5-digit code to restoreradio operation.
6. Lower the steeringcolumn sssembly. each oJ the two shearbolts and drill 7. Center-Dunch their heads off with a 5 mm {3/16 in) drill bit' CAUTION: Do not dama96 tho switch body whon r€movlng the shoar bol$.
8 . Remove the shear bolts from the switch body.
1.
Disconnectthe negativecable from the battery.
2.
Removethe dashboaldlowercoverand kneebolster (see page 23-7'l).
3.
Disconnectthe 5-P connectorfrom the under-dash fuse/relaybox and the 7-Pconnectortrom the main wire harness{see page 23-71).
1 1 .Insert the ignition key and check for proper opera-
4.
Remove the steering column covers (see page 23-711.
1 2 . Tighten the shearbolts untilthe hex headstwist off.
5.
Removethe columnholdermountingboltsand nuts'
NUT 13 N.m (1.3 kgf.m, 9.4 lbl'ftl
BOLT 22 N.m 12.2 kgl'm. 16 tbt.ftl
23-72
q
Installthe new ignitionswitch without the key inserted.
1 0 . Loosely tighten the new shear bolts. tion of the steering wheel lock and that th€ ignition key turns freely.
StartingSystem GomponentLocationIndex
STARTERCUT RELAY {M/T} Test, page 23,68
A/T GEAR POSITIONSWITCH Test, page 23-136 page 23-137 Replacement,
CLUTCHINTERLOCK SWITCH(M/T} Test, page 23-78 Switch Adiustment.section 12
BA Test, page23-66
Test, page 23-76 SolenoidTest, page 23 78 page 23 79 Repfacement, Overhaul,pages23-8O Reassembly, page 23,85
23-73
Starting System GircuitDiagram(M/Tl tGNtTt0t{ SWTCH
UNOERHOOO FUSE/REI.AY BOX
+O
/.^1\tOFr
\_:/
I I
BT.KMHT
STARTER CUTREIAY
I
EUqWHT
II t*u* I
I 8l-K
r H l I STARTER
G 20r G40r
Circuit Diagram(A/T) -HOOD UI{DER FUSE/NEUY BOX N,0.41 {l00Al
Io.39160t
G?{rao swncH
-{€ 6i\ o+
\_v
I
I Bl-torvHT
II
I
,(h\
A/I GEAR
g, ffi.:11?[:#ir11,",,
II
BI.K/BED
Starting System Startel Test NOTE: The air temDeraturemust be between 59 8nd 10OoF(15 and 38oC) beforetesting.
Chock Stan€r Engag6ment: 1.
Recommendsd Procodure:
Disconnectthe 2-P connector(ignitioncoil primary lead) from the distributor.
a Use a staner svstem tester. a Connect and operatethe equipmentin accordance with the manutacturer'sinstructions. a Test and troubleshootas described. Altohato Procedure: a Use the following equipment: - Ammeter. 0-4OO A - Voltmeter, O- 20 V {accuratewithin 0.1 volt) - Tachometer,O- 120O rpm a Hook up voltmeterand ammeteras shown'
2 . Pressthe clutch pedalallthe way in (M/T),and turn
"Start". The starter should the ignition switch to crank the engine. NOTE: On cars equippedwith manualtransmission, the enginewill not crank unlessthe clutch pedalis fully depressed. lf the staner does not crank the enginego to step 3.
J.
Check the baftery, battery positive cable, ground, and the wire connections for looseness and corrosion, Test again.lf the starterstill does not crankthe engine, go to step 4.
4.
Bvpassthe ignitionswitch citcuit as follows {make sure the transmissionis in neutral): Unplug the connector (BLK/WHTwire and solenoid terminsl) trom the starter. Then connect a jumper wire from the battery positive ( + ) terminal to the solenoid terminal. The starter should crank the engrne.
TERMINAL NEGATIVE NOTE: After this test, or any subsequent repair, resetthe ECMto clearany codes (seesection 1 1)
23-76
a lf the starter still does not crank the engine, replace it and diagnose its internal problems. a lf the starter cranks the engine,go to step 5.
5.
Check lor 8n op€n in the BLKMHT wire circuit between the staner and ignition switch, and connectors.
Chack Cranking rpm:
6.
Check the ignitionswitch (see page 23-70).
lf spe6d is too low, ch€ck for:
7,
On cars with automatic transmission,check the A/T gear position switch (neutral position switchl and connector.On cars with manualtransmission,check the staner cut relay, clutch interlock switch, and connectors.
a a a a a
NOTE: Check the No. 39 (5O A) fuse in the under-hood fuse/relay box for the starter cut relay. Check tor Woar and Damago: The starter should crank the engine smoothly and steadily. lf th€ startsr engages, but cranks the engine erratically, remove it. Inspect the starter, drive gear, and flywheel ring gesr for damage. a Check the drive gear overunning clutch for binding or slippingwhen the armatureis rotated with the drive gear held. Replacethe gesrs if damaged.
Enginespsod during cranking should be above 1O0rpm.
Loose battsry or starter teminals Excessively worn starter brushes Open circuit in commutator segments Dirty or damaged helical spline or drive gear Defective drive gear overrunning clutch
Chock StErtor Disongagomoni: Pressthe clutch pedalallth€ way in (M/T),turn the ionition switch to "lll" and roleaseto "11". The starter drive gear shoulddisengagefrom the tlywheel ring gear. When you roleasethe key. lf the drive gear hangsup on th€ flywheel ring gear, check for: a Solenoid plunger and switch malfunction a Dirty drive gear assembly or damaged overrunning clutch
Check Cranking Voltago 8nd Current Draw: Cranking voltage should be no less than 8.O volts. Current draw should be no more than 360 amperes. lf cranking voltag€ is too low, or current draw too high, check for: a Fully charged battery a Open circuit in starter armaturecommutatot segments a Starter armature dragging a Shoned armature winding a Excessivedrag in engine
23-77
Starting System Starter Solenoid Test
Clutch Interlock Switch Test 1.
Removethe dashboardlower cover and knee bolster (seepage 23-70), then disconnectthe 2-P connector from the switch.
2.
Check tor continuity between the terminals according to the table.
1.
Check for continuitv between the tetminals accotding to the table.
Tsrminal
\
M
Coil HOLD-IN
T€rminal A
B
o
o
ClutchPedal
PULL-IN
D
Housing
o- ---c
o- ---.o
RELEASED
PUSHED
Pt LL- tt{ coll
lf necessary.replacethe switch or adjust the switch oosition (seesection 12).
23-78
HOLD- |l{ COIL
Starter Replacement 1 . Disconnectthe negativecable from the batterv. 2.
4.
Removethe intake air duct.
Disconnect the staner csble from the B terminal on the solenoid,then the BLK/WHTwire from the S terminal. Removethe two bolts holdingthe staner, then remove the startef.
UPPER MOUI{TII{GBOLT 44 N..h (4.5 kgl.m, 33 lbt,ftl 8 TERMII{ALMOUIITTI{G NUT 9 .ln (0.9 kgf.m, 6.5 tbf.ttl
AIR CIEANER HOUS|L TERMINAL
Removethe enginewire harnessand startefcables from their brackets. BLI(AA/HTWIRE ENGINEWIRE HARI{ESS
6.
Installin the reverseorder of removal,
CAALES
23-79
StartingSystem Startel Overhaul CAUTION: Disconneclth€ battery n€gativecable befole lomoving the startet.
SOLENOID PLUNGER Inspection,page 23-85
STARTER SOLENOID Test, page 23-78
NOTE: The originalradio has a coded theft protection citcuit. Be sureto get the customer'scode numberbefore - disconnectingthe batterY. - removingthe No.3 2 (7.5 A) fusefrom the under-hood fuse/relaybox. - removingthe tadio. Atter service,reconnectpower to the radio and turn at "CODE" is displayed,enterthe cuson. Whenthe word BRUSHHOLOER tomer's 5-digit code to restoreradio operation.
ARMATURE PINIONGEAR
IDLERGEAR
ENOCOVER
t r . /
.' BRUSH HOLDER Test, page 23-8'l
ERUSH Inspection,page 23-11
COVER
SOLENOIDHOUSING
6
I
IDLERGEAR
I
@*
HARNESSBRACKET
ARMATURE lnspection and Test, page 23-82 ROLLERBEARINGS and CAGE Prevenl rollers trom being scattered and lost. MOLYBDENUMDISULFIDE
STEELBALL installsteel ball from clutch side.
-s@] MOLYBDENUM DISULFIDE CLUTCHASSEMBLY OVERRUNNING Inspection,page 23_84
_R1 MOLYADENUM DISULFIDE GEAR HOUSING
23-80
Starter Brush Holder Test 1.
Checkthat there is no continuity between the O and O brush holders.lf continuity exists. replacethe b,ush holderassembly,
G) BRUSHHOLDER
O BRUSHI{OLDER
E BRUSHHOLOER
Starter Brush Inspection Measurethe brush length. lf it is less than the service limit, replacethe armaturehousingand brushholderassembly. Brush L€ngth Standard{Now): 15.O- 15.5 mm (0.59-0.61 inl Se.viceLimit: 10.0 mm (0.39 inl
O BRUSHHOLDER
Insertthe brushinto the brushholder,and bringthe brush into contact with the commutator,then attach a springscaleto the spring,Measurethe springtension at the moment the spring lifts off the brush. SpringTension:17.7 -23.5 N {1.8-2.4 kgf, 4.O_5.3 tbfl
NOTE: To seatnew brushesafter installingthem in their holders,slip a strip of # 5OOor # 600 sandpaper,with the grit side up. over the commutatorand smoothlyrotate the armature.The contact surfaceof the brushes will be sandedto the same contouras the commutato..
SPRINGSCLAE
23-81
StartingSystem ArmatureInspectionand Test 1.
CommutrtorRunout Standard(Naw):0-O.O2 mm (0-O.OO08inl SowicoLimit: 0.O5 mm (O.O02inl
Inspectthe armaturefor wear or damagedue to contact with the field coil magnets.
Inspect tor damage
COMMUTATOR
A dirtv or burnt commutator surface may be l€sulfaced with emery cloth or a lathe within the following specilications. Commutator Diamet€r S t s n d a l d( N 6 w ) :2 9 . 9 - 3 O . O m m ( 1 . 1 7 - 1 . 1 8 I n l Selvico Limit: 29 mm (1.14 lnl
VERNIEBCALIPER
23-82
3 . lf the commutator runout and diamete. are within limits, check the commutator tor damageor for carbon dust or brass chips between the segments. 4.
lf the surf6c6 is dirty, recondition it with # 50O or # 600 sandpsper.
Checkfor mica depth. It necessary,undercutmica with a hacksaw bladeto achieveproperdepth.
Placethe armatuteon an armaturetester. Hold a hacksawblade on the armaturecore,
ITOTGOOO
ARMATURETESTER
HACKSAW BLADE
MICA DEPTH
Commutator Mica D6pth Stsndard{Nsw):0.5-0.8 mm (O.O2-0.03 in} Sslvice Limit: 0.2 mm (O.OO8inl
ARMATUFE
Check tor continuity between the segments of the commutator.lf an open circuitexists betweenanv segments,replacethe armatute. It the blade is attracted to the core or vibrstes while the core is turned,the armatureis shorted.Reolace the armature. 8.
Check with an ohmmeterthat no continuityexists betweenthe commutatorand armatutecoilcore. and between the commutator and armatureshaft. lf con_ tinuity exists, replacethe armature
M SHAFT
COMMUTATOR
23-83
StartingSystem Starter Field Winding Test
OverrunningClutch InsPection
1.
Check for continuity between the brushes.lf there's no continuity, replace the armature housing.
Slidethe overrunningclutch slong the shatt. Does it move treely? ll not, replace it.
2.
Check for continuity between each brushand the armature housing{ground) lf continuity exists, replace the armatulehousing.
Rotate the overrunning clutch both ways. Does it lock in one direction and rotate smoothly in reverse? lf it does not lock in either direction or it locks in both directions, replace it.
BRUSHES CLUTCH GEAR
DRIVEG€AR
ll the starter drive gear is worn or damaged, replsce the ovsrrunning clutch assembly; the gea. is not available separately. 4.
23-8,4
Check the condition of the flywheel or torque converter ring gear if the starter drive gear teeth ale damaged.
Solenoid PlungerInspection Check the contact points and the face of the staner solenoid plunger for burning, pitting or any other defects. lf surfacas are rough, recondition them with a strio of # 500 or #600 sandpaper.
StarterReassembly R€assemblethe starter in the reverse order of disassembly. 1.
Pry back each brush spring with a screwdriver,thon position the brush about halfway out of its holder, and release the spring to hold it there.
2.
Instsllthe armaturein the housing.Next pry back each brush spring again and push the brush down until it seats against the commutator, then release the spring against the end of the brush.
soLEr{otD PIUNGER
a&T&'
s.. V
3.
BRUSH
Installthe end cover on the brush holder.
23-85
StartingSystem PerformanceTest NOTE: Beforestaning the tollowing checks. disconnect the wire Jrom te.minal M, and make a connectionas describedbelow usingas heavya wire as possible{preferably equivalentto the wire used for the car).
Rotracting Test:
Pull-in Coil Tasl:
NOTE: Do not leavethe battery connectedtor more than 1O seconds.
Disconnectthe battery negative cable. ll the pinion retracts immediately, it is working properly.
Connectthe battervas shown. It the starterpinionpops out, it is working properly. GAUTION: Do not leavothe battery connectodfor mora than 10 seconds.
Startoi Noioad Test: 1, Clamp the starte. firmly in a vise. 2,
Connectthe starterto the battery as shown and contirm that the motor starts 8nd keeps rotating.
Hold-in Coil Tost: Disconnectthe battetv from the M terminal.lf the pinion does not retract,the hold-incoilis working properly. CAUTION: Do not l6avetho battory Gonnectedfor moro than 10 soconds.
It the electric current and motor speed meet the when the batteryvoltageis at 11 V, sDecifications the staner is working properly. Spacifications: 90 A or less {Eleciric curentl. 3OO0 rpm or more (Motor speodl
23-86
lgnition System Gomponent Location Index IGNITIONTIMINGCONTROLSYSTEM a Troubleshooting, section I1 a Inspectionand setting, page 23-89
DISTRIBUTOR Top End Inspection,page 23-91 Removal/lnstallation, pages23-91, 92 Overhaul,page 23-93 Reassemblv, page 23,94 lgnitionCoil Test/Replacement, page 23-95 lgnitionControlModule {lCM} Inpur Test, page 23-96
SPARK PLUGS fnspection, Page 23-97
WIRES Inspection, psge 23-94
23-87
lgnition System Circuit Diagram BOX HOOO FUSE/RELAY UNOERECM
V I YEUGNiI
posilioo sonsor CKP:Cr6nk.halt position s€nsor CYP|Cylindor TOC/CKP/CYP SENSOR
-_r_1=__E -J---L--L--Lr
U'+++ ORN
23-88
tG tTtoNc0NTROl(cMl MoDUr.r / H8sbuilt in \ I OOrsO I
lgnition Timing Inspection and Setting 1 . Startthe engine.Holdthe engineat 3,00Orpm with no load (A/T in S or E position,M/T in neutral)until the radiatorfan comes on, then let it idle. Pullout the servicecheckconnectorlocatedbehind the rightkick panel.Connectthe BRN/WHTand BLK terminalswith the SCS short connector. DATA LINK CONNECTOR{3-P} NOTE: Do not attach the jumper wire.
4.
Adiust ignitiontiming, if necessary,to the following specifications: lgnition Timing: 16 t 2 BTDC (RED)at 75O 1 50 rpm in noutral
NOTE: a Shift lever must be in neutral. a All electricalsystemsshould be turned OFF.
POINTER
SCS SHORT CONNECTOR {0?PAZ-O010't00t
SERVICE CHECKCONNECTOR I2.PI NOTE:Locatedbehindthe right kick oanel
Connecta timing light to the No.1 ignitionwire and point it toward the pointeron the timing belt cover.
REOMARK
TIMINGLIGHT
lcont'd)
23-89
lgnitionSystem lgnition Timing lnspection and
Setting (cont'd) 5.
To adjust ignition timing, loosen the distributor mounting bolts, and turn the distributor housing counterclockwise to advance the timing, or clockwise to retard the timing.
ldle Speed Inspection Shift to neutral or Ll] and start the engine. Hold the engineat 3,OOOrpm with no load until the radiator fan comes on, then let it idle.
2 . Connect a tachometer to the test tachometer connector.
MOUNN G BOLTS 24 N.m (2.4 kgl.m, 17 lbt'ftl
b.
Tighten the adjusting bolts and recheck the timing. Remove the SCS short connector trom the service check connector.
ldle sp6od M/T: 750 t 50 rpm in neuttal A/T: 75O t 50 rpm in @ or @ NOTE: Allelectricalsystemsshouldbe turnedOFF. Adjustthe idlespeedil necessary(seesection 1 1).
23-90
DistributorTop End Inspection
Distributor Removal
1 . Checkfor rough or pitted rotor and cap tefminals.
1.
2 . Scrapeor file oft the carbondeposits. Smooth the rotor terminal with an oil stone or #600 sandpaperi{ rough.
2 . Disconnectthe ignitionwires from the distributor
2
Disconnectthe 2-P and 8-P connectorsfrom the distributor.
cap.
Check the distributorcap Jor cracks, wear, and dSmage,lf necessary,clean or replaceit.
3.
Removethe distributor mounting bolts, then remove the distributorIrom the cvlinderhead.
23-91
lgnitionSystem DistributorInstallation Coat a new O-ring with engine oil, then install it.
5.
Connect the ignition wires as shown.
Slip the distributorinto position. NOTE: The lugs on the end of the distributorand its mating grooves in the camshaft end are both offset to eliminate the possibility ot installing the distributor 18Oo out of time.
DISTRIBUTOR END
CAMSHAFTEND
Set the timing with a timing light (se€page23-89). After setting the timing, tighten the mounting bolts.
24 N.m (2.4 kgf'm' 17 lbt'ft|
Install the mounting bolts and tighten them temporarily. Connect the 2-P and 8-P connectors to the distributor.
23-92
DistributorOverhaul BLKTYEL
DlsTNIBUTOR
ROTORRETAII{IITGSCREW lMust be madeof diamagnsticmateriall
Chock tor cracks, wear, damage, or fouling. Clean or replace.
HOUSING Check for cracks oa damage. IGNITIONCONTROLMODULE {ICM) Troubleshooting,section 1 1 Input tost, page 23-96
23-93
lgnition System Distributor Reassembly 1 . When reassemblingthe dislributor, install the distributor rotor so on the shaft that it faces in the direction shown (toward the No. 1 cylindetl,
lgnition Wire lnspection and Test CAUTION: Caretully removo the ignition wiros by pulling on tho rubbq boots. Do not bend the wilos; you might bl€ak tham inside. 1.
Checkthe conditionof the wire terminals.lf any te.minalis corroded,cleanit. and if it is brokenor distorted. reolacethe wire.
IGNITION WIRE
2 . Alignthe indexmarkon the distributorhousingwith the index mark on the end of the shaft.
2 . Connect ohmmeter probesand measureresistance. lgnition Wile Roaistanco: 25 k0 max. at 68oF (2OoCl
INDEX MARKS IGNITIONWIRE
3.
23-94
lf resistanceexceeds25 kO,replacethe ignitionwire,
lgnitionCoil Test
lgnition Coil Replacement
With the ignition switch OFF, remove the distribulor cap.
1.
With the ignition switch OFF, remove the disrributor cap, rotor, and cap seal, then remove the leak cover.
Removethe two screws to disconnect the BLK^/EL and WHT/BLUwires from terminalsA (+ ) and B ( - ) respectively.
CAP SEAL
Removethe two screws to disconnect the BLK/YEL and WHT/BLUwires from the coil. 3.
Using an ohmmetet, measur€ tesistance betwe€n the terminals,Replacethe coil if the resistanceis not within specifications.
3 . Remove the two screws and slide the ignition coil out of the distributorhousing,
NOTE: Resistancewill vary with th€ coil t€m9erature; sp€cificationsare at 68oF l20oC) Prlmary Winding Rosistanco (8otwo6n tho A and B torminalsl: 0.6-0.g ohms Secondary Winding Rssistanc6 (Botwoon the A and socondary winding tomlnalsl: 1 2 . 8- 1 9 . 2 k O A l+)
I11 t L
B{-}
l WHT/BLUWIRE
23-95
lgnition System lgnition ControlModule(lCMl Input Test NOTE: a SeesectionI 1 if the malfunctionindicatorlamD(MlL) blinks. a Pertorman input test for the ignitioncontrol module (lCM)after finishingthe fundamentaltests for the ignition system and the fuel and emissionssystems. a The tachometershouldoperatenormally. 1.
Removethe distributorcap, the distributorrotor, and the leak cover.
2.
Disconnectthe BLK/YEL,WHT/BLU,YEL/GRN,and BLU wires from the lCM.
4.
Turn the ignitionswitch ON. Checkfor voltagebetween the WHT/BLUwire and body ground. There should be battery voltage. a lf there is no battery voltage,check: - lgnition coil - WHT/BLUwire betweenthe ignitioncoil and the ICM a lf there is battery voltage. go to step 5. Checkthe YEL/GRNwire betweenthe ECMand the tcM.
6 . Checkthe BLUwi.e betweenthe tachometerand the
rcM.
7 . It all tests are normal,replacethe lCM.
YEL/GRN wlRE
3.
Turn the ignitionswitch ON. Checkfor voltagebetween the BLK/YELwire and body ground. There should be battery voltage. a lf there is no batteryvoltage,checkthe BLK^/EL wire betweenthe ignitionswitch and the lCM. a lf there is battery voltage,go to step 4.
23-96
Spark Plug Inspection 1. Inspectthe electrodesand ceramicinsulatorfor:
Replacethe plug if the centerelectrodeis rounded as shown below: ROUNDED ELECTROOE
. . . . Damaged gask6t
rmpropergap Oil-touling Carbondeposits Crackedcenter electrodeinsulator
Bl8Cl engine: a Make surethat the '1.4mm (0.055 in) wire-type pluggaugedoes not go into the gap for the platinum tip plug. lf the gaugegoes into the gap, do not attemptto adjustthe side electrode;replace the plugwith a new one.Useonlythe sparkplugs listed below. ROUNDEOELECTRODE Electrode Gap Standard:1 .2-'l .3 mm {0.047-O.051 in) ServiceLimit: 1.4 mm {0.055 in)
Burned or worn electlodes may be caused by: . Advancedignitiontiming . Loose spark plug . Plug heat rangetoo low . Insufficientcooling Fouledplug may be causedby: . Retardedignitiontiming . Oil in combustionchamber . lncorrectspark plug gap . Plug heat rangetoo high . txcessive idling/lowspeed running . Cloggedair cleanerelement . Deterioratedignitioncoil or ignitionwires Check the electrodegap. Bl88l engine: a Adjust the gap with a suitablegappingtool. ElectrodeGap 1 . 0 - 1 . 1 m m ( O . O 3 9 - 0 . O 4 3i n ) Standard:
CAUTION: Do not use a blade-type plug gaugs, it may damagethe platinumtip of the centerolectrodo. S p a r kp l u g sf o r t h e 8 1 8 8 1 e n g i n e :
Z F R s F -11( N G K ) K J l 6 C R - 111 (Nippondenso)
For all normaldriving
Z F R 6 F -1 ( N G K ) KJ2OCR-11 1 (Nippondenso)
For hot climatesor continuous high speed driving
S p a r kp l u g sf o r t h e B ' l 8 C l e n g i n e :
P F R 6 G _ 1( N 3GK) PK2OPR-113
I I Forall normaldriving
{Nippondenso) 1 . 1m m {0.0,$ in)
3.
Applya smallquantityol anti-seize compoundto the plug threads. Screw the plugs into the cylinderheadiingef-tight, t h e n t o r q u et h e m t o 1 8 N . m ( 1 . 8 k g f . m , 1 3 l b f . f t ) .
23-97
ChargingSystem ComponentLocationlndex
CHARGINGSYSTEM LIGHT lln the gauge sssemblyl T€st. pages23-1OO.101 Bulb Locations, page 23-1 15
BOX UI{DER.HOOD FUSE/BELAY (USA:Hasbuilr-inELECTRICAL LOADDETECTOR {ELD)UNIT) Troubleshooting ot ELD,s€ction11
BATTERY Tost,
ALTERNATORBELT Inspoction and Adiustment, page 23-108 Alt6rnator/Regulator Tosl, pag€s23-102, 1O3 Replacament.page 23-'l 04 Ovsrhaul, pago 23-105
23-98
CircuitDiagram
- HOODFUS€/REI.AY UI,IDER 8OX No.4t11004) /a\
ilo.39l50Al
*1 :USA +2 llo.24ll SAl:81881.min tlo.24{2041: 818C| .niin6
UNDER_OASH FUSE/REIAY 8OX
. NTEGRATED COMTNOL UMT
. aBscoilTRoruNn
I
VI ECM
I
VI
Fr€|'l) wNort'lc
AI.TERNATOR
oiot
G401
23-99
ChargingSystem Troubleshooting Bofore troubleshooting check - tightnessof the alternatorbelt (see page 23-1Og). - that the malfunctionindicatortamp lMlL) of the ECM does not blink. lf it blinks,refer to section 1 1. lf the charging system light is on, or th€ battery is dead or low, p€rtorm the following tests in the order listed below: 1. 2. 3.
Baftery Test (see page 23-66) Charging System Light Test Alternator/RegulatorTest
ChErging Sysrom Light T6tt
Tu]n tho ignhlon srvitch on (lll.
Does th€ charging syslem light come on7
o pago23-1011
Does tho charging system light go ott?
BOX FUSE/RELAY (r..r tid.) Turn the ignition switch otf. I'{TEGRATED CO]TTROLUI{IT Disconnect the 4-P connoctor lromt th€ altornator.
Turn the ignitionswitch on {ll),
Ramova tfto 26-P connactd trom th. ABS control unh snd lh. intggrotad conrol unh ttoln tha tad ol tho und..dlrh tu!a/r.l.y box. It thr .hlrglng .yrtom lighl .l.Y. on, rrpalr tho ahon to ground In rhr WHT/BLU wi...
NOTE: After this test or relaled rep6irs, roconnoct the control units. th6n aosetth€ ECMto cloar any cooos.
Does the charging system light come on? Sad.n:
H.tchb.ck:
UNIT ABS COI{TROL tlo rhon o. opon h ih. WIfT/BLU who. Porfom dtomrtor/rogdttol rost beo pag. 23-l02l.
2A-P CONi{ECTOR
26.P CON ECTOR ABS CONTROL
23-100
lFrom page 23-10O)
' N o . 2 4 ( 1 5 A ) : 8 1 8 B ' l ongrne N o . 2 4 ( 2 0 A ) : 8 1 8 C 1 engine
Turn the ignition switch ott.
Check fuse *No. 24 in the underdash tuse/relay bor.
Disconnect the 4-P connector Irom the alternator.
Turn the ignitionswitch on {ll).
Ch6ckforvoltago between tho lG terminal(BLK/YELwire) of rho il-P connectorand body ground.
ls there battery voltage?
Rgp.i. op.n in th. BLK|'EL wiro.
wirg side
L IWHT/BLUI
Ground the WHT/BLUwire at the L terminal ot the 4-P connector.
Does the charging system light come on?
Chockfor ! blownchrrgingry3rom llghr bulb. It rh. butbi! oK, ropairopenin lho IiYHT/BLUwiro.
(cont'd)
23-101
ChargingSystem Altornator/RegulatorTest NOTE; Mske surethe battery is sufficientlychargod(sa€ page 23-66). LOADADJUSTER ICARBONPILE)
FULLFIELD TESTEB LEAD(BLUI
Connoct tho Sun VAT4O {ot ooulvslont lgrt equipmonl) and tum tho s6l6ctor rwitch ro posi_ tion I |rtarting).
VOLTMETER t{EGATIVE LEAD(8LK} O IOAD
shift to neurralorlPland start the engino. Hold the ;;gine at 3oO0 rpm wiih no load until the radia_ tor lan com€s on. then let it idle.
Raisethe engine speed to 2OOO rom and hold il there.
ls lhe voltageover 15.1V?
VOLT SELECTON
TEST
swlTcH
II{DUCTIVE FICK.I.|P IGR ' VOLTMETER POStTtVE LEADIREDI
Releasethe acceleratorpedaland let the enginoidle.
EGATIVETESTER CABLE(BLKI Make sure all electrical systems are turned otf. Turn the selector swilch to position2 (charging).
INDUCTIVE PICK.UP B TERMI]TAL WIRE
Removethe inductivepick-upand zero the ammeter.
Place the inductive pick-uP over the B terminalwire oI the altgrnator so that the arow Dointsaway trom the alternator.
Raisethe engins speed lo 20OO rpm and hold it there.
ls the voltagelessthan 13.9V? NO tropagezJ-ruJ,
23-102
T..t itr b.ttry (.- 9|e. 8€Al.
(Frompage 23-1021
Apply a load wirh the VA'-4O until the battery voltagedropsto bet w e e n 1 2 - 1 3 . 5V .
ls the amperage 60 A or more?
With the engine spe6d still at 2OOOrpm, full-tieldthe altemalor.
NOTE; Attach a probeto the VAT-4Ofull field test lead and insert the orobe into the full tield sccesshole at the back of the alternator.Switch the field selector to the "A (Ground)" positionmomentarilyand check amperagereading. CAUTION: The voltago will ris6 quickly whon the slternator is full-fiolded. Do not allow th€ voltago to oxc66d 18 V 01 it may damage the elect.ical system REGULATOR {Locatod the end cover) FULL FIELD ACCESSHOLE
Toat rnd rooalr d|e dtomEtor {soo psg.. 23-104 to 23-tO7).
4-P CONNECTOR
Turn the ignition switch off; then turn aton again.
Disconnocl lhe 4-P connector Irom the altornator.
Check lor voltage between the lG terminal (BLK/YEL) and body ground.
ls there battery vokage?
Rop.ii open in tho BLK/YELwiro. IG IBLKATELI
wire side
L IWHT/BLUI
23-103
ChargingSystem Alternator Replacement NOTE: The originalradio has a coded theft protection circuit. Be sure to get the customer'scode numberbefore - disconnectingthe battery. - removingthe No. 32 {7.5 A) fuse from the under-hood fuse/relaybox. - removingthe radio. After service,reconnectpowet to the radioand turn it on. "CODE" is displayed,enler the cusWhen the word tomer's 5-digit code to restoreradio operation. 1.
Disconnectthe groundcablefrom the batterynegative (- ) terminal.
2.
Disconnectthe alternatorconnectorfrom the alrernaror. NUT TERMINAL
7. Removethe lower and upper mounting bracket bolts and the mountingbrackets.
UPPERMOUNTII{G BOLTS BRACKET il4 N.m {4.5 kgl'm, 33 lbl'ft}
,\\\- ( \ \
\(^
\-/ I
B TERMINAL
24 N.m 12.4 kgf'm, 't 7 tbf.ftl ALTERNATOR CONNECTOR
Removethe terminal nut and the WHT wire from the B terminal.
BRACKET
BOLTS BRACKET 44 N.m (4.5 ksl.m, 33 lbt'ft1
Loosenthe adjustingnut. then removethe mountIng nul. ADJUSTING NUT
8. Removethe adiustingnut and uppermountingbolt, then lift out the alternator. 9. lnstall the altetnator in the reverseorder of removal. CAUTION: Adiust tho alternalor belt tension aftor installation (seo Page 23-1O81. NOTE: Reconnectthe battery ground cable and turn "CODE" is displayed, the radioon. When the word 5-digit code. enter the customer's
NUT MOUNTING 44 N.m (4.5 kgt.m, 33 lbf'ftl 5. Removethe alternatorbelt from the alternatorpulley. 6.
Removethe lower mountingbolt, then lift the alternator upward.
23-104 w
AlternatorOverhaul CAUTION: Do not r€move th€ pulley unl€Esthe t.ont bearing needs r6placsm6nt.
PULLEY
To loosenthe pulley locknut, use 10 mm and 22 mm wrenches.It necessary,use an impact wrench.
Test, page 23-107 SPACER RING REAR BEARING
10 mm BOX WRENCH PULLEYLOCKI{UT 1 ' l l N . m 1 1 1 . 3k g t . m , 8 2 t b f . t r l
rl
@n
FRONTBEARING
STATOR/DRIVEEND HOUStt{G
CAUTION: Do not get grease or oil on the slip rings.
BBUSHHOLDER INSULA TOR ARUSH HOLOER
)
(@P "
STATOR THROUGH
BOLT VOLTAGEREGULATOR
%A
re
DIODEIRECTIFIER)ASSEMBLY Test, page 23-106
PULLEYLOCKNUT 111 N.m (11.3 kgt.m,82 lbf.ft)
REAR HOUSING
6
q
Inspection,page 23-
TERMINALINSULATOR
qt
".," fu"- "o*n.r" -
BRACKET
23-105
GhargingSystem Rectifier Test NOTE: The diodesare designedto allow currentto pass in one directionwhile blockingit in the oppositedireclion. Each diode must be tested for continuitvin both directionswith an ohmmeterthat has diode checking capability.Since the alternatorrectifier is made up of '16 checks, eight diodes(four pairs),there are a total of 1. Checkfor continuityin each ditectionbetweenthe B and P terminals,and betweenthe E (ground)and P terminalsof each diode pair. All diodesshouldhave continuity in only one direction,
AlternatorBrushInspection Remove the end cover, then lake oul the brush holder by removing its two screws Measurethe length of the brusheswith a vernier calioer. Aliornatol Brush Longlh: Standard:10.5 mm (O.41 in) Servic. Limit: 1.5 mm (O.06 in)
VERI{IEBCALIPEB
lf the brushesare less than the service limit, replace the b.ush holderassemblv.
lf any of the eight diodestails, replacethe rectifier assembly.(Diodesare not availableseparately.)
23-106
RotorSlip RingTest 1.
Stator Test
Checkthst there is continuity betweenthg slip rings.
1. Chockthat there is continuitybetweeneach pair of l6ads.
ROTORSHAFT
cotl coRE
2
Check th8t there is no continuity betw€en the slip rings and the rotor or rotor shaft.
Ch6ck that there is no continuity between each lead and the coil core.
3
lf the rotor fails either continuity check, rsplace th€ alternator.
lf th€ coil fsils eithercontinuitycheck. replacethe alt6rnator.
23-107
ChargingSystem AlternatorBelt Inspectionand Adjustment Deflection Method: Apply a force of 100 N (1o kgt, 22 lbJ)and measurethe deflection between the alternator and the crankshatt pulley.
Boh Tsnsion Gaug6 Mothod: Foltowingthe gauge manuJacturer'sinstructions,attach the belt tension gauge to the belt and measurethe tension.
Detlsction:9-11 mm (0.35-O.43 inl
Tension:340-49O N (35-50 kgl, 77-110 lbfl
NOTE; On a brand-new belt {one that has be€n run for lessthan five minutes),the deJlectionshouldbe 6-8 mm 1O.23-O.32 in) wh€n first measured.lf the belt is worn or damaged,replaceit.
NOTE: On a brand-new belt (one that has been run for less than tive minutes), tension should be 690-880 N (70-90 kgt, 154- 198 lbJ)when tirst measured.lf the belt is worn or damaged,replaceit.
ALTERI{ATOR ADJUSTING NUT 24 .ln 12.4 kst'm, 17lbl'ft}
NUT ADJUSTIT{G ALTER'{ATOR 24 N.m {2.4 kgl'm, 17 lbl'ft1
MOUt{Tlt{G NUT 44 t{.m (4.5 kgt.m, 33 tbf.ft)
PULLEY ALTEBNA
oTJGG-0O1010A
lf adiustment is nocessarY:
lf adi$tmsnt is nscaasary:
1. Loosenthe alternatoradjustingnut and mounting nur.
1.
Loosen the alternator adiusting nut and mounting nut.
2.
Move the alternatorto obtain the properbelt tension, then retighten the adjusting nut and mounting nut to the specifiedtorques.
2.
Move ths ahernatorto obtain the properbslt tension, then retightenthe adjustingnut and mountingnut to the specified torques.
3.
Recheck the deflection ot the belt.
3.
Recheckthe tension of the belt,
NOTE: lt necessary,adiust the P/S pump belt (see section 17) and A/C compressorbelt lsee section 22t.
23-108
NOTE: lf necessary,adjust the P/S pump belt (see section 17) and A/C compressor belt (see section
22t.
Fan Gontrols ComponentLocationIndex For the A/C system, see section 22.
RADIAIOR FAN REI.AY Test, page 23-68
UNDER-HOOD FUSE/RELAY BOX
CONDCNSER FAI{ BELAY lwir6 color3:ELKnirHT,WHTI IBLUryEL,and BLU/BL( I Test, page 23-68
ENGII{E
cooLA T TEMPERATURE
FAN MOTOR Test, page 23-112
{ECT) SwlTCH Tesr,page23-'l12
BADIATORFAN MOTOR Test,page23-112
23-109
FanControls Circuit Diagram(WithoutA/Cl
- DAstl ul{o€R GIINONSWITCH FUSC/RELAYBOX
- HOODFUS€/REI.AY BOX UI{OER No.4l{lmA,
No.39l50Al
.{
6r\
\-Y
ECM
V
Gtr{
l,*^,
($fffiHil'r"n.''
t?i'r?Tdf.ol I
I ffi,"'l I
Btl(
II :
G10l
23-110 FIIF.-
F'rrr^'l
-l
ots YEt{<\o*r
Gircuit Diagram(With A/Cl
- HOOO UNOER FUSE/REIAY BOX No.41l100Al
G FIONSWIICH
,5
No.39l50At
RAOIATOR FAN REI.AY
GRt{
| ,*n,n,
,z*r CoOtAt{T
qU llffffarunErEcrr
t?i'i."1",i:"ol
I
I
monronI FAN
I MOTOR
I
I
BI-K
II :
G10l
23-111
Fan Controls Fan Motor Test
Engine Coolant Temperature (ECT) Switch Test NOTE: Bleedair from the cooling system atter installing the enginecoolanttemperature(ECT)switch (seesection 1O).
1.
Disconnectthe 2-P connectorfrom the fan motor.
2.
Test the motot by connectingbatterypower to the B terminal,and groundto the A terminal
3.
lf the Jan motor fails to run smoothly, replaceit.
1. Remove the ECT switch from the thermostat housing.
NOTE: The illustrationshows the radiatorfan.
2.
Suspendthe ECT switch in a containerof coolant as shown.
Heatthe coolantand checkenginecoolanltemperature with a thermometer. Checkthe continuitybetweenthe A and B terminals accordingto the table:
Terminal
\
B ;;,".,"---\ Above196 2O3"F {91-95'C) Switch
B e l o w1 8 1 - 1 8 9 o F (83-87'C)
23-112
o_
-o
GaugeAssembly ComponentLocationIndex CAUTION: a All SRS electrical wiring harnossesare cov€rod with yellow insulation. a Bofore disconnecting any prn ot th€ SRS wire harness, connect tho short connector(sl. a R€placeth6 entirs affGctedSRS halne$ assembly if it has an open circuit o? damaged wiring.
(C61'iostho SBS indicator signal)
SRS MAIN HARNESS {Cov.r6d with yollow inrularionl
GAUGE ASSEMBLY GaugeLocationIndex,page 23-114 IndicatorLocationIndex,page 23-114 TerminalLocationIndex,page 23-114 Bulb Location.page 23-'l 15 Disassembly. page 23-119 Removal,page 23-118
FUEL GAUGE SENDINGUNtT Test, page 23'124 Repfacemenr,page 23-124
VEHICLESPEEOSENSOBIVSS} Test, page 23-120 fnput Test. page 23-120 Repfacement,page 23-122
PARKITTG BRAKESWITCH Test, page 23-127 BRAKE FLUID LEVELSWITCH Tesr, page 23-127
EI{GINEOIL PBESSURESWITCH Test, page 23-122 ENGINECOOLANTTEMPERATUREIECTI GAUGE SENOINGUNIT Test, page 23-126
23-113
GaugeAssembly LocationIndex Gauge/lndicator/Terminal CAUTIOI{: a All SRS olectrical wiring harnessosaro covorod with yellow insulation, Belol€ disconnecting any part ot tho SRS wiro hatnesa. connoct the short connoctol(El. Replacoth6 entire aff6cted SRS hamess sssombly lf it has an open circuil or damagod widng.
"8" CoNNECTOR (c5601
Bi ----------+
co r{EcroR"c" (c558}
B16
Cl ----+ClO
A/T GEARPOSIT|O IIDICATOR SYSTEI Seepags23-132
TACHOMETER: Indicatos lOO rpm at 20O puls€s per minul€ of the ignition control modul€llCM).
FUEL GAUGE: GaugeTest, page 23-123 Sending Unit Tost, page 23-124
f',. /i)
)Y
- " b \_./ \J
\-___--
E GI[{E COOLAI{TTEIIPEFATUREIECTI c6uge TEst, p6g6 23-126 Sending Unit Tsst, pago 23-126
a1 -----> A5
Dl-------.>D13 SPEEDOMETER: Indicates (60 mph 6i 1025 rpml or {60 km/h at 637 rem) of th€ v€hicle spe6d sonsor lVSSl.
coNNECfOR
"A" (C557)
col{]{ECTOR"D" (C5591
23,-114 rtrF
--
BulbLocations
HIGH BEAM INDICA
L|GHT{r.4 Wl
LEFT TURI{ SIGNAL INDICATORLIGHT II.4 WI RIGHTTURN SIGNALINDICATORLIGHT(I.4 W} CHARGINGSYSTEMLIGHTII.4 WI BBAKESYSTEMLIGHT(1.4 W) SEAT BELTREMINDER LIGHTI1.4 WI POSITIOIII]{DICATORLIGHT (1.12 W x 7l
OOOR-OPEN INDICATORLIGHT{1.4 WI
LOW EI{GII{EOIL PRESSURE
TOBLIGHT11.4WI MALFUI{CTIONINDICATORLAMP (MrLl fi.4 wt
iSRS INDICATORLIGHT(1.4 W}
LOW FUEL INDICATORLIGHT {3.4 WI
LIGHTS MAINTENANCE REMINOER LIGHTIT.4 WI
{3.4 W x 3}
cRutsE LTGHT tl.4 Wl ABS INDICATORLIGHT(1.4 W} TAILGAT€-OPENINDICATORI-IGHT{1.4 W): Harchback TnUNK-OPENINDICATORLIGHT 11.4 W): Sodan
*: On the SRS printed circuit board
23-115
GaugeAssembly GircuitDiagram
r3 [o.24 ll5 ): 81E81dttr 10,24120 ):B1&1.mir
ulocn-DsH
&X RISC/RELAY
Tw'lcu I
+ 3r,4ts. r t_gstr
sas tNtT
I I A
FUSE
l{l(
T
:
6t0l
[fffi"vv
sns txocAloR UGTIT
.lsffiisl {,MT
VI
- r Gin&no
".lJ r l
I C,afi/ilD
GMVn!O
#n
ir ll
l8flfl*';
i| \()n
I RUNIiITGI I uGfiTs \
ht0/Git{
I
Gn[/Ft0
6mii' I -
23-116
r -" | .
r
l
| snrxt I Rlp
ir |ffi. l Itrr
r l it A :
r6ii G30r
N'ElGAI.EE sExDr6 ulllT
a{G|l|€ c@lat{T Il$EiA'l il tErcTt SAdTG txt
IIFT TURt{ stcll L DtCATOn UGHI
fircll E€AT lotc ToR TIGHT
r |l{rE|Arcc Sfn 0ER ucfir
6tc|l|€ Oh.
mEssunr [oic Toi IIGHT .,tlvt
stAT Et T gIDEN IJGHT
M Ut[CrOrl OG TOi
txtu
nooB-oPEtl fptc^Ton TIGHI
I|
tt,4w)
' B1
.
a2
_
l
HflHh*'F:
€trtc[iE olL FnISSUNE s1vlrcH
I OFVEFS SCAT*LT slvtTcH
6
1:
G501 G502
23-117
GaugeAssembly Removal Tilt the steeringwheel down with the tilt adjustment tevet.
CAUTION: a All SRS electrical wiling harnessesara cover6d with yollow insulation. a Eofore disconnecting any part ol the SRS wiro harn6ss, connoct lhe short connector(sl. a Roplacetho entirs affocted SRS harneasassembly if it has an open circuit 01 damaged wi.ing.
Removethe three mountingscrews, and spreada protectivecloth on the steeringcolumn.
lcarrio. tho SRs indicolor 8ignal)
CLOTH PROTECTIVE Prythe gaugeassemblyout, and disconnectallconnectorsfrom it. SBSMAIN HARI{ESS (Covor6dwith Yollowin.ulationl
1 . Removethe two screwslrom the instrumentpanel. 2 . Removethe instrumentpanel. NOTE: Remove the instrument panel careJully without damagingthe cliPs. CLIPS GAUGE ASSEMBLY o.
23-118
Take out the gauge assembly as shown.
Disassembly NOTE: Handlethe terminalsand printedcircuit boardscaretullyto avoid damagingthem.
TAGHOMETER MOUI{TINGSCREW(x 3l
ENGINE COOLA]TT TEiIPERATURE {ECT} GAUGE MOUNTING SCREW(x 3)
SPEEDOMETER MOUNTTNG SCREWtx 4l
k)T n FUELGAUGE UNIT Test, psge 23-123
. SPEEDOMETER Specilication, pa96 23-1 14 Troubfeshooting. page 23-1 20 . ODOMETER Troubleshooting,page 23-1 20 . TRIP METER Troubfeshooting,page 23-120
23-119
Speedometer/TripMeter/Odometer Troubleshooting NOTE: The numbersin the table show the troubleshootingsequence. Item to be inspected
:
-9
lt) a
o
; 6
+* c.r i . ( D z c *
f
E
;5
9 c d)=
Symptom Odometerand trip meter wotk, but speedometerdoes not.
q)
6
'
E
E
qlv
'i F
-9 (L
a
> g
o o
2
1
works, but odometerand trip meter do SDeedometer nor,
E
o
1
Speedometer.odometer,and trip meter do not work. VSS Input Test (At ham€ss side of 3-P connector) T€st: Desirsdresult Tost condition No. Wir6 1
BLK
Under all conditions lgnition switch ON (ll)
BLK/YEL
ORN
lgnitionswitch ON (ll)
Possiblecause it result is not obtained
Check for continuityto ground: . An open in the wire . P o o rg r o u n d( G 1 O 1 ) There should be continuity. Blown *No. 24 fuse in the unde.Check tor voltageto ground: dash tus€/relay box There should be battery Short to ground voltage. An open in the wire Check for voltageto ground: There should be about 5 V.
. Shon to ground . An open in the wire
NOTE:A shortto groundin the ORN wire can be causedby a short in any componentconnectedto lt. vSS Tost Speedometerdoes not work.
3-P CONNECTOR
Inspect'No. 24luse in the underdash tuse/relay box belore testing.
Turn the ignitionswitch ON lll). Measure voltage between the BLK/YEL wire terminal and the 8LK wire terminalin the harness side of the 3-P connector.
{To next page)
23-120
2 4 ( 1 5 A ) : 8 1 8 8 1 e n g i n e N o . 2 4 { 2 0 A ) : 8 1 8 C 1e n g i n e
{From previous page)
ls there battery voltage?
Check tor continuity between the BLK terminaland body ground.
Measure voltage between the ORNand the BLKwire terminals.
ls there about 5 V?
Raisethe tront of the car and support it with salety stands.
Ropair opon belw€on VSS and groundG101.
Ropairopon in tho BLKrYELwiro botwoen VSS and undor-dssh luse/rolay box.
Ropair op6n in th6 ORN wire or shon to body ground.
Touch a probe to the ORN wire and connect at to body ground through a voltmeter.
Putthecar in neutralwithkevON.
Slowly rotate one wheel with the other wheel blocked.
Does voltage pulse from O to about 1O V?
Roplac. tho VSS {see page 23-1221.
Touch a probe to the ORN wire and connect it to body ground througha voltmeter.
Slowly rotate one wheelwith the other wheel blocked.
Ooes the meter indicate pulsingvoltage?
Ropairopon in th6 OBil wire botween tho VSS and th6 3p.odomolgt.
23-121
VehideSpeedSensor(VSSI Replacement Disconnectthe 3-P connectortrom the vehiclespeed sensor{VSS).
EngineOil Pressure IndicatorSystem EngineOil PressureSwitch Test 1.
Removethe YEL/REDwile from the engineoil pressure switch.
Remove ihe two mounting bolts, then remove the VSS.
ENGI'{EOIL PRESSURESWITCH
TERMII{AL POSITIVE
Check tor continuitv between the positive torminal and the engine{gtound)with the ignhionswhch OFF. a lf there is continuity,go to step 3. a lf there is no continuity, replace the switch.
InstSll in the revsrse order of removal.
Check for continuity again, this time with th€ engine runnrng.
NOTE: The VSS drive link is a very small paru caretul not to lose it.
a lf there is continuity,go to step 4, a lf there is no continuity, the switch is OK. Make sureengineoil levelis OK, then checkengin€ oil pressure (s€e section 8). a lf engineoil pressureis OK, replacethe switch' a lf engineoil pressureis low, checkthe sngineoil pump (seesection 8) and, if necessary,replac€it.
23-122 nlmlliitl
FuelGauge GaugeTest NOTE: Referto page23-1 16 for the luelgaugesystem circuit. '1.
Check the No. 15 {1O A) fuse in the under-dash fuse/relaybox beforetesting.
2.
Removethe rear seat (seesection 2Ol.
3,
Removethe protective cover and access DanelJrom the tloor.
4.
With the ignition switch OFF, disconnectthe 3-p connectotfrom the fuel gauge sendingunit. PROTECTIVE
o.
Turn the ignition switch OFF. Attach 8 jumper wir€ between the BLKA HT and YELMHT terminats. then turn the ignitionswitch ON 0l). Check that the pointer of the fuel gauge starts moving toward the "F" mark. CAUTION: Turn th€ ignition switch OFFboforo the pointer roachas "F" on tho gauge dial. Failuroto do ao may damage tho fuel gauge. NOTE: The fuel gaugeis a bobbin(c.oss-coitltype gauge.hencethe tuel levelis continuouslyindicated even when the ignitionswitch is OFF, and the pornter moves more slowly than that of a bimetal rype gauge. a lf the pointerof the fuel gaugedoes not move at all, replacethe gauge. a lf the gaugeis OK, inspectthe {uel gaugesending unit.
Connect the voltmete. positive paobe to the YELMHT terminal and the negativeprobe to the BLKMHT terminal,then turn the ignitionswitch ON (ll). Thereshould be between 5 and 8 V. a lf the voltage is as specified.go to step 5. a It the voltage is not as specified,check for - an open in the YEL/WHT. BLU/WHT or BLK/WHTwire. - poor ground (G5O2).
23-123
FuelGauge SendingUnit Test/Replacement oo not lmoke while working on tho fuol @ system. Kaop open flamos away from your wotk aroa. 1.
Remove the rear seat (see section 2O).
2.
Removethe protective cover and accesspanel lrom the floor.
3.
With the ignition switch OFF, disconnect the 3-P connector from the fuel gauge sending unit.
4.
Removethe tuel gauge s€ndingunit.
5.
Measurethe resistancebetween the A and B terminalsat E (empty),1/2 (halffull) and F (full)by moving the tloat. Float Position Resistance lO)
6.
E 1 0 5 - 1 1 0 25.5-39.5 2-5
Check the change in resistanceby moving the float uo and down.
(
lf unableto obtain the above readingsor it resistance do€s not change,replacethe fuelgauge sendingunit.
o
23-124
Low FuelIndicator
Seat Belt Reminder System
IndicatorLight Test
Seat Belt Switch Test
NOTE: Reterto page 23- 1 16 tor the wiring description of the low fuel indicatorcircuit.
1 . Slide the driver's seat to the middle position, then disconnect the 2-P connector Jrom the back ot th€ sear.
1. Park car on level ground.
2 . Check for continuity between the A and B terminals oo not rmoko whil6 working on th€ @ fuol system, Keop op€n llamg3 awsy from your work area. Drain fuel only into an approvod container,
in each conditionaccordingto the table. Terminal
\
Drain tuel into an 8pplov€d container. Then install the drain bolt with a new washer.
\
UNEUCKLED J.
B
A C"**
Add lessthan 8.2 t (2.2 U.S.Gal,1.8 lmp.Gal)of fuel and turn the ignitionswitch ON (ll).The low fuel indicator light shouldcom€ on within lour minutes,
o--
o
BUCKLED
a lf the light does not come on, remove the access Daneland disconnect the 3-P connector from the fuel gauge sending unit, Connect the A (BLKMHT) terminal to the C (BLU/WHT)terminal with a iumper wir€. - lf the light comeson, the problemis eitherthe sendingunit or its ground. - lf the light does not come on, the problemis an openin the BLU/WHTwire to the gaugeassembly, no power to the gauge, or a blown bulb. a l f t h e l i g h t c o m e s o n , a d d a p p r o x .4 , { 1 . 1 U.S.Gal,O.9lmp.Gal)ot tuel, the light shouldgo ofJ within four minutes.
ANCHOR
3-P CONI{ECTOB
NOTE: Befer to page 23-146 for the seat reminderinout test. 3.
lf necessary.replacethe seat belt switch.
View lrom wire side
23-125
EngineCoolantTemperature(ECTIGauge GaugeTest
ECT Sending Unit Test
NOTE: Referto page 23-116 fot the wiring description oJ the enginecoolant temperature(ECT)gauge circuit diagram.
Disconnectthe YEL/GRNwire from the ECT sending unit. With the enginecold, use an ohmmeterto measure resistancebetween the positiveterminal and the engine (ground).
1. Check the No. 15 (10 A) fuse in the under-dash tuse/relay box before testing. 2.
Make sure the ignitionswitch is OFF,then disconnect the YEL/GRNwire from the ECT gaugesending unit and g.ound it with a jumper wire.
TERMINAL POSITIVE
Check the temperatureof the coolant. Runthe engineand measurethe changein ,esistance with the engineai operatingtemperatu.e{the radiator tan comes on). J.
Turn the ignitionswitch ON (lll. Check that the pointer of the ECTgaugestarts moving toward the "H" mark, CAUTION: Tuln th6 ignition switch OFF botore th€ point reaches "H" on tho gaugo dial. Failuroto do so may damago tho gaugo. a It the pointerof the gaugedoes not move at all, check Jor an oDenin rhe YEL or YEL/GRNwire. lf the wires are OK, replscethe ECT gauge. a It the ECT gauge works, test the ECT sending untt.
23-126
Temperatu.e Resistance(O) 5.
1330F(560C)
't37
185.F(850C)2 1 2 0 F( 1 0 0 0 c )
46-30
ll the obtainedreadingsare substantiallydifferent Jromthe specificationsabove, replacethe ECTsending unit.
BrakeSystemlndicator ParkingBrakeSwitch Test
Brake Fluid Level Switch Test Removethe reservoircaD.
Removethe tloor console, and disconnect the connector from the switch.
Check that the tloat moves up and down freely, if it does not, replacethe reservoircap sssembly.
Check for continuity b€tween the positive terminal and body ground in each lever position accordinoto the table.
Torminal L6vorposition
POSITIVE
Chsck for continuitv between the terminals in each float positionaccordingto the table.
EODY
Terminal Floatposition
UP
NEGATIVE
POSITIVE
UP
DOWN
-o
DOWN
POStTtVE CAP RESERVOIR
DOWN POSITION
when float drops.
TERMINAL
Canada: lf the parking brake switch is OK, but ths brake system indicator does not function, pertorm the input test for the daytime running lights control unit (see p a g e2 3 - 1 5 6 ) . Switch contacts open at proper fluid level.
4.
lf necessary,replacethe reservoircap assemblv.
23-127
MaintenanceReminderS ystem Gomponent Location Index CAUTION: a All SRS eloctrical wiring haln€sses are coveled with y€llow insulation. a Bsfore disconnocting any part of the SRS wire harne6a, connect tho shon connoctor(s). a Replacethe entire affoctod SRS hsrness ass6mbly if it has an open circuil or damag€d wiring.
MAINTENAf{CEREMINDERLIGHT (ln th6 gaugo 63.smblyl GaugeAssembly.page 23-113
VEHICLESPEEDSENSOR{VSS) {On the t.ansmirsion houaingl Test, page 23-120, 121 Input Test, page 23-120 page 23-122 Repfacement,
MAINT REOD
MAINTENANCEREMINDERUNIT lBohind tho dashboard lowor covor) Input Test, page 23-131
23-128
Description Basedon signalsrecaivedtrom the vehiclespeedsensor (VSS),the microcomputerin the maintenanceremande, unit, which is located behind the dashboardlower cover, computes the distances traveled. When you turn the ignition switch on, the reminder light in the gauge assembly will come on for two seconds (bulb check tunction). Ar 9,650 t 160 km (6,000 t lOo miles)intervals,the reminderlight witl gtow for two secondsand then btankten seconds att€r you turn the ignitionswitch on. This will repeateverytime you turn the ignitionswitch on until the car reaches 12,O7O! 160 km (7,500 1 10O mites). Beyondthe 12,O7O! 160 km (7,500 t IOO mite)interval,the tight will continuero gtow after the butb check until you turn the ignition switch off or reset the unit. To reset the unit, the car must be pa.ked and the ignition switch must be on. Pressthe reset button on the unit for mo.e than three seconds,and the remindertight will go otf. NOTE: a Turn the ignitionswitch OFF b€foreyou r€movethe 5-P connectorfrom the maintenancereminderunit. otherwise you will cancel all data in the memorv. a The data will remainin the memoryeven when the ignitionswitch is turned ofJ, or if the unit is disconnected. When the ignitionswitch is turned on, and the car is driven. additionaldata will be stored.
sEt{son tvss
-----------------l MAINTENANCEREMINDENUN|T
23-129
Maintenance ReminderSystem CircuitDiagram UNDER-HOOD FUSE/REIAY 8OX
MAINIET,IAT,ICE REMINOER UiIIT
23-130
MaintenanceReminderUnit Input Test 1 . With the ignition switch OFF, disconnectthe 5-P connectorfrom the reminderunit, Inspect the connector and socket terminals to be sufe they are all makinggood contact.
View trom wire side
a lJ the terminalsare bent, looseorcorroded, repair them as necessary,and recheckthe svstem. a It the terminalslook OK, make the following inPut tests at the connecto.. - lf a test indicates a problem, tind and correct the cause,then recheckthe system. - It allthe input tests proveOK, the reminderunit must be taulty; replace it.
No.
Wire
I
BLK
Tost condltion Unde. all conditions Under all conditions
WHT/BLU lgnitionON (lll
YEL
4
E
Possibl€cause if result is not obtained
Check for continuityto ground: . P o o rg r o u n d( G 2 0 1 ,G 4 O 1 ) . An open in the wire Thereshould be continuitv. . B l o w nN o . 3 2 ( 7 . 5 A ) f u s e i n t h e Check tor voltageto ground: There should be battery voltage under-hoodtuse/relaybox . An open in the wire . B l o w n N o . 1 5 ( 1 OA ) f u s e i n t h e Check for voltageto ground: There should be batte.y voltage under-dashfuse/relaybox . An open in the wire
lgnitionON (ll)
Connectto body ground; The reminderlight shouldgo on.
B l o w n N o . 1 5 ( 1 OA ) t u s e i n t h e under-dashfuse/relaybox Blown bulb An open in the wire
lgnition ON {ll), car in neutral with lront ol car raised,one wheel rotated with other wheel blocked
Check for voltageto g.ound: Meter should indicatepulsing voltage.
. Faulty vehiclespeed sensor (VSS) . An oDenin the wire
PNK
ORN
Test: DaEiredrasult
23-131
A/T GearPositionIndicator ComponentLocationlndex cAUTtOt{: a All SRSolectdcalwiring harnossos a16covarodwith yellow insulation. Boforo disconnocting any part ot the SRS wlr. harnoaa, conngct the short conn6ctor(sl. Roplacotho entire aff6ct6d SRS harn$s assombly il it has an op6n cilcuit or damagod wiling,
SRS MAIN HARI{ESS (Cov.rod whh ygllow io.ul.tlonl
GAUGE ASSEMBLY Bemoval,page 23-118 Disassombly,pag€ 23'1 19 Bulb Locations,pago 23-115 IiIIERLOCK SYSTEM page 23-139 DGscription.
A/T GEARPOSITION IlTDICATOR InputTest,pago23-134
A/T GEAR P('SITIOI{ SWITCH Test, page 23-136 ReDlacement,6ection 14
23-132
CircuitDiagram
IGNITION
UNOER-OASH FUSSREI-AY 8OX
swrTcH
UNOER_HOOD FUSE / REI.AY 8OX
wHT/BLX +wHT+
/-?t CH-
\ty
ftrt*l
"l
Bl.x/Y€t-+<.\-o+!
No.19ll0A) FUSE
I
TMI{SMrSSr0r,l c0IJTRor i.IODULE ITCMI
YEL lln thogtugo8ls€mbvl
fitMritc-;-
D4
CANCEL
AN GEAR POSITION INDICATOR DIMMING CIRCUIT
t
lgll
l
YELTWHTGRN/8L|(
t
II .
INTERLOCK coMtRot
_
l
TRANSMISSION MODU|.! [TCM}
UNJ]_
o*nn,o_yTT
I
GRT'IMHT
pr{x/cR1 -J No.19 {l FUSE
GR €|-U -l
V
GRiITYEt
I
I
LTGNNiW{T
A/TGEAN POStTt0N
coNsot-E LIGHT
0.4w) M GEAR
PosrTroN swncH
I DASHI-IGHTS BRIGHTNESS CONTROI.IER
I
G201 G40t
G2ol G401
23-133
A/T Gear PositionIndicator Indicator Input Test CAUTION: a All SRS electrical widng harn6ssosara cov6r6d whh yellow insulation. a Before disconnecting any part ot the SRS wiro hErness. connect the shon connoctolls). a Replacethe entire affectod SRS harnosr assombly il it has an op€n circuit or damaged wiring. Removethe gauge assemblyfrom the dashboard(see page 23- l 18), and disconnectconnectors"8", "C" and "D" from it. lnsoectthe connecto.terminalsto be sure they are all makinggood contact. a lf the terminalsare bent. looseor corroded,repairthem as necessary,and recheckthe system. a lf the terminalslook OK, makethe following input tests at the connector. - lf any test indicatesa problem,find and corect the cause,then recheckthe system. - lf all the input tests prove OK, the gaugeassembly must be taulty; replaceit.
"8" CONI{ECTOR
SS
23-134
CONNECTOR"D": Visw from wire side ot femals tetminals
No.
Wila
BLK
Test condition Under all conditions lgnitionswitch ON {ll}
2
YEL
Test: D€sirod rasult Possiblecause if result is not obtainod Check for continuityto ground: . P o o rg r o u n d( G 2 O 1 G , 4O1) . An open in the wire There should be continuitv. . B l o w n N o . 1 5 ( 1 OA ) t u s e i n t h e Check for voltageto ground: There should be battery voltage. under-dashfuse box . An open in the wire
CONNECTOR"8": View from wire sid6 of fem.l6 i6lminals
No.
1
Wile
Tost condition
RED/BLK
Tost: D€sir6d result
Possiblocause if result is not obtained . Faulty dash lights b.ightnesscontrol Combinationlight Check for voltage between RED/BLK switch ON and dash RED/BLK and RED terminals: system ano lights brighlnesscontrol There should be baftery voltage. . An open in the wire RED dial on full bright
CONNECTOR"C": Vi3w lrom wire sido of temale t6rminals
No.
Test condition Shift lever in position@ GRN^^/HT NOTE:Don't pushthe brakepedal. GRN/RED Shift lever in position@ GRN Shift lever in positionS
YELAA'HT
GRNA HT
Tost: Desirod r6sult Check for continuityto ground: Thereshould be continuitv. NOTE:Thereshould be no continuity in any other position.
GRNITEL GRN/BLK
Possiblecause it result is not obtained Faulty A/T gear positionswitch Poor ground An open in the wire
GRN/BLU Shitr leverin position@ GRN/YEL Shitt lever in positionf2 ]
LTShift lever in positionE GRNMHT
GRN/BLK
lgnitionswitch ON (ll) and shift lever in any positionexcept @
. Faultyt,ansmissioncontrol module Check for voltageto ground: (TCM) There should be battery voltage . An open in the wire for two seconds after the ignitionswitch is turned ON, and less than 1 V two seconds later.
3 YEL/vVHT
lgnition switch ON (ll) and shitt lever in any positionexcept @
Check for voltage to ground: There should be less than 'l V tor two seconds after the ignitionswitch is turned ON and more than 5 V two secondslater.
. Faultytransmissioncontrol modute (TCMI . An open in the wire
lgnitionswirch ON {ll}
Check for voltageto ground: Thereshould be mofe than 5 V
. Faulty transmission control module ITCM) or ECM . An open in the wire
2
4
LT. GRN/BLK
23-135
A/T GearPositionIndicator I I gear A/T Fosluon Dwtrcn I esr Gea Position Switch Test 1 . Removethe console.then disconnectthe 14-Pconnector from the switch.
2 . Checkfor continuitvbetweenthe terminalsin each positionaccordingto the table.
tgrminal 90e
a Move the lever back and forth at each position without touchingthe pushbutton,and checktor continuity within the rangeof free play. a lf there is no continuitywithin the.ange of free play, adjustthe installingpositionol the switch as describedon the next page.
14-P CONI{ECTOR
Back-up Ught Swhch
A/T Goar Position Swhch (Without crulso contloll Terminal \ P*ii-_\
B
tr a
ooooooo-
E E N
tr tr
N
F
D
M
Terminal _\
--o -.o -o --o
tr a E E E E E
23-136
o- --o oo-
N
--.o
o- --o
Back-up Llght Swltch
6
P*,i-
K
--o
A/T Goar Position Switch (With cruiss controll \
Noutrrl Polition Swhch
D
M
oo- --o t{outral Potidon Swltch J
K
--o --o
G_
oo-
--o
o- --o
oo- --o
A/T GearPositionSwitch
A/T Gear Position Switch Adjustment
Replacement
Removethe console, then disconnectthe 14-P connectof from the switch.
1.
Shift to the ill position,and loosenthe nuts.
2.
Slide the switch in the direcrionof E position [within2.Omm (O.079in.)lso that thereis continuity betweenthe "A" and "L" terminalsin the ranqeof free plsy oJ the shiJt lever.
3.
Recheckfor continuity between each ot the terminals.
Remove the two console switch mounting nuts.
swtTcH
SHIFTLEVER
NOTE: a lf adiustmentis not possible.check for damage to the shiJt lever detent and/or the bracket. lf there is no damage,replacethe consoleswitch. a The engineshouldstart when the shift leveris in position LN] in the range of free play.
LOCKPIN
Positionthe switch sliderto "Neutral" as shown above. 4.
Move the shift lever to switch into position.
then slip the @ porition
Attach the switch with the two nuts. Test the switch in the @ and E] position ot the shift lever.The engineshouldsta.t when the shift lever is in position p anywhere in the range of free play. Connectthe 14-Pconnector,clampthe harnessand installthe console.
NUTS
23-137
Interlock System ComponentLocationIndex All SRS electrical wiring harnass€sare covered with yallow insulation. Before disconnecting any part of the SRS wire harness, connect the shon connector(sl. Replacethe entire affected SRS halness ass€mbly it it has an open circuit or damagedwiring.
SRS MAI[{ HARNESS lcovorod with yellow insulstionl
INTERLOCK CONTROL UNIT fnput Test, page 23-141
KEY INTERLOCKSOLENOID snd KEY INTERLOCKSWITCH (ln the steeringlock assembly) Test, page 23-142
SHIFT LOCK SOLENOIO Test, page 23- 143 Repfacement,page 23-143
23-138
Descraption The car is squippod with thq following dovlc6. to prevont inadvoft.nt shitting: a A/T selector with shift lock a Key cylinder with interlocked ignition key Shift Lock Syst6m; The shitt lock system prevents the shift lever from moving to @ or lDil from the @ position unless the brake pedal is depressed and the accelerator is in its rest oosition. NOTE: a The shift lever cannot be shifted when the brake pedsl and the accelerator are depressed on at the same time. a In case ot system malfunction, the shift lever can be releasedby pushing a key into the releaseslot near the shift lever.
Koy Ints.lock Systsm: The ignition key cannot be removed from the ignition switch unless the shil-t lever is in the E position When the shift lever is in any position other than @, a sol€noid is activated, making it impossible for the key to be removed until the shift lever is moved to the llj position. Th€ shift lever is in the E position.
SOLEI{OID ON: LOCK OFF:UNLOCK
KEY CYLINDER
The shift lever is in any position except pl .
II{TERLOCKLEVER
swtTcH
23-139
lnterlockSystem CircuitDiagram NOTE: Differentwires with the same color have beengiven a numbersuffix to distinguishthem (tor examplg, GRNMHT 1 and GRNMHT 2 are not the same).
-HOODFUSE/REi.AY BOX UNOER
N0.41(1OCA) No.39l50A) W}IT/BLK+WHT WHT/GRN
THROTTLE POSITION ITPI SENSOR
Y
I
, IN/vt,H]
^'v"' i I I
if,f,trfi
I l......................_GRNA,t/r{rz1
/r\ S'ftiei f lJlT,ll*n""n,
23-140
ControlUnit Input Test Oisconnectthe 8-P connector from the interlock control unit. Check for good contact between the connectorand socketterminals.lf the terminals8re OK, make Iollowing input tests at the connector.lf all inputtests are OK, but the problemremains,replacethe cont.ol unit, NOTE: lf the shilt lock solenoidclickswhen the ignition switch is ON and the brake pedal is pushed (shift tever is in lfl position, acceleratoris in rest position), the shift lock system is electronically normal; test the A/T gear positaonswitch as described on page 23- 134.
Shift Lock Sy.tem: No, Wlr6
'I
wn t/hEu
Tost condition
Tost: Dosiredresult
Possiblocause if rssuh is not obtainod
lgnitionswitch ON (ll) Brakepedal pushed
Check for voltage to ground: There should be bsttery voltage
lgnitionswitch ON I [ ) , brske pedal and accelerator pushed at the same time
Check for voltage to ground: There should be less than battery voltage.
Blown No. 41 (15 A) fuse in the under-hood fuse/relay box Faulty transmission control module (TCM} Faulty ECM Faultv brake switch Faulty throftle position lTP) sensor An oDen in the wire
Shift lever in @
Check lol continuity to ground: There should be continuity.
Faulty A/T gear position switch Poor ground {G201, G401} An oDenin the wire
lgnitionwitch ON (lll
Check for voltageto ground: There should be battery voltage
Blown No. 15 (10 A) luse in the under-dashfuse/relay box Faulty shift lock solenoid An oDenin the wire
GRN^/vHT'
YEL/BLK
Koy Intodock Systam: No. Wire T6st condition
T6st: Desiled reault
Possible caure if rosult is not obtainsd . Poor ground (G2O1,G4O1) . An ooen in the wire
Under all conditions
Check for continuity to ground: There should be continuitv.
Shift lever in position
Check for continuityto ground; Ther€ should be continuity.
Faulty A/T gear position swirch Poor ground (c2O1, G4O1) An oDenin the wire
Check for voltage to ground: There should be battery voltage
3
lgnition switch tu.ned to ACC (ll 8nd the key WHTAYEL pushedin
Bfown No. 42 l2O Al fuse in the under-hood tuse/relay box Faulty steering lock assembly (kev interlock solonoid) An oDenin the wire
Check tor voltage to ground: There should be batery voltage,
4
lgnition switch turned to ACC (ll and the key WHT/BLU pushedin
Bfown No. 42 l2O Al fuse in the under-hood fuse/relav box Faulty steering lock assembly (key interlock solenoid) An oDenin the wire
BLK
2
E
23-141
Interlock System I esr Interlock Dorenoro Solenoid Test Kev IntenocK Key CAUTION: a All SRS electrical wiring harnessesar€ covered rYith yollow insulation. a 8eforc disconnecting any pan of the SRS wire harness. connecl tha short connoclol{s|. a Raplacethe ontire affected SRS harness assembly if it has an opon circuit or damaged wiring,
4.
Checkfor continuitvbetweenthe terminalsin each switch positionaccordingto the table.
\______________rry Position
lonition S hchAcc
Koypush€din r KoyroleEsod
o-
7
--o --o
* : l5-20ohms
5,
{Covorod with yollow inlulrtionl
1 . Removethe dashboardlower cover Removethe knee bolster. Disconnectthe 7-P connectorfrom the main wire narness.
23-142
Checkthat the key cannot be removedwhen the battery is connectedto the No. 6 8nd No. 7 terminals. a It the kev cannot be removed, the key interlock solenoidis OK. a lf the key can be removed, replace the steering lock assembly(key interlock solenoidis not available separately).
Shift Lock Solenoid Test/Replacement Removethe console,then disconnectthe 2-p conneclor oJ the shift lock solenoidfrom the main wire harness. NOTE: Do not connectpowe. to the B { - ) terminat (reversepolarity)or you will damsgethe diode inside the solenoid. Connect battery power to the A terminal,groundthe B terminal momentarily. and check solenoid oDeralron.
Replace.
9,8 N.m {1.0 kgl.m, 7.2 tbl.hl 5.
Check and, if necessary,adjust the solenoid'sposition. a When the shift lock solenoidis ON, check that there is a clearanceol 2.5 1 O.5 mm {O.O98I O.O2Oin) between the toD rear corner ot the shift lock lever 8nd the lock pin groove,then tighten the selflocking nuts. NOTE: Use new self-lockingnuts. 2.5 t O.5 mm {0.098 t 0.020 inl
SHIFT LOCK LEVEB
a lf the solenoiddoes not operate,replaceit as describedin steps 3,4, and 5. a lJ the solenoiddoes operate, check and, if necessary, adiust its two positionsas shown in step 5. a
Removethe shift lock collar and the solenoidpin. Removethe selflocking nuts and shift lock solenoid, then installthenew solenoidin the reverseotderot removat.
LOCKPINGROOVE a When the shift lock solenoidis OFF,make sure that the lock pin is blocked bv the shift lock lever. LOCK PIN
LOCK PIN GROOVE
23-143
IntegratedControl Unit Circuit Diagram D.3c ptlon An integrat€d control unit, located in the left kick panel, integratss the functions of tho keyin/seat beh r6mind€r, sido markar light {lasher, wiper/washer, lights-on r6minder, rear window dsfogger timer, brak€ system light bulb check, and enging oil pressure indicator flasher circuitE, NOTE: Difforent wires with the same color have be6n given a numbor suffix to distinguish them (for Example, and GRN/RED'are not the same). GRN/RED1
HOOD FUSE/RELAY 8OX UNOER-
- DASHFUS€/RETAY BOX UNOER
WIPER/ WNOSHIELD WASHER SWITCH IMT
OFFiINT
Ir l I I I I I I I I I I I I I I
I
t P
r r r
3 8 e
l t
i ;
t I
5
r
t-0w ErGrilE 0|l
PRESSI'RE INDICATOR LIGI{T
B r
COI{TROI UNIT NTEGRATED
WINDSHIELO WIPERAVASHER
YEUEE
swtTcH
tr-/ I BLK/GRNBI
WINDSHIELO WIPER MOTOR {Asl
washef-wip€roporation lr ) : Withcombinod
23-144
VOLTAGE REGULATOR {lnahamator,
Br-u/Brx fr,rTrtl.* r*r., + /\ J L
r--------Y----__tfl I moan swtTcH i PosrIoN t,x*rt
€-
t
v
BLK/RE9 -----J
- OASHFUSE/REI-AY UND€R 8OX
ERAKE SYSTEM I.IGHT ll.4wl
YEISEAT8EI-T REMIi/OER LIGHT t1.4Wl
3
a E t .?
RED/BLU
I
I
I a'u,[!
tsl
I
BI-K
|
*rt
|
(3CP,
QiftHl. I
BI..K
{
{
G20r
G30l
G40l
RIGHT FRONT SIDE MASKER I,IGHT t3cP'
23-145
IntegratedControlUnit Input Test CAUTION: a All SRS elocttical widng hatness€sato covored with yollow insulation. a Botolo disconnocring any pan ot the SRS wile hal' ness, conn€ct tho shon connoctor(3l. a Replaca tho ontlrg affsctod SRS hE noaa assombly if it has an opon circuit or damag6d wifng. Remove the dashboSrd lower cover and knee bolstar. then disconnect the 1 5-P connector Jrom the integratsd control unit. Removethe integrated control unit from the under-dash Juse/relavbox. SRSMAII{ HARI{ESS Inspect the connector and socket tetminals to be sure they are all makinggood cont8ct. a lf the terminalsare bent, looseot corrod€d,repairthem as necessary, and recheck the system a lf the terminalslook OK, makethe tollowing input tssts at the connector and under-dashtuse/relsy box. - lf any test indicatesa problem,find and correct the cause, then recheck the system. - It all the input tests prove OK, the control unit must be faulty; replace it.
NOTE: a Diftorent wires with the sam€ color have been given a number suffix to distinguish th€n {for 6xample, GRN/BLUIand GRN/BLU' arenot the same). a Do not disconnect any connectors on tho under-dash fu8e/relay box except the integratsd contlol unit.
H_____-t{
.BLK/GBI{ LT
15.P CONNECTOR
BLU/WHTI BLU/GR]{I BLU/YELI LT GB /BED YEL/BLU
23-146
GRN/BLUI GRI{/RED
All Systems: No. Tsrminal 1
N
T€st condition
T6st: Desired rosult
Possiblacause it result is not obtained Check for continuityto ground: . Poor ground (G201, G4O1) . An open in the wire There should be continuitv. . Blown No. 3 (7.5 A) fuse in the Check for voltageto ground: There should be battery voltage. under-dashfuse/relaybox . An oDenin the wire . B l o w nN o . 1 5 ( 1 0 A ) t u s e i n t h e Check for voltage to ground: There should be bsttery voltage under-dashfuse/relay box . An open in the wire
Under all conditions Under all conditions
lgnition switch ON {ll) F
R€ar Window Detogger Timer System: No. Wire Tost condition I
YEL
Test: Dosiled result
Defoggerswitch pushed
Check lor continuityto ground: There should be continuityas the switch is Dushed.
Faultydefoggerswitch P o o rg r o u n d{ G 2 0 1 ,G 4 O 1 } An open in the wire
lgnitionswitch ON (ll)
Connectto ground:The rear window defoggershould work and the detoggerswitch indicator light should come on.
Blown No. 13 {7.5 Al fuse in the under-dashfuse/relaybox Faulty defogger relay Blown bulb An open in the wire
BLUiYEL
Intermittent Wip6r Relay System: Wir€/ No. Terminal Test condition
,|
T€Et: Desir6d result
lgnitionswitch ON (ll) and windshieldwipet YEL/BLU switch INT
Check tor voltageto ground: There should be battery voltage
Windshieldwiper BLU/WHT switch OFF or INT ano and wiper bladesin BLUiGRN park position
Check for continuity between the BLUMHT and BLU/GRNterminals:There should be continuity.
.E
Possiblecause il rosult i8 not obtained
lgnitionswitch ON (lll
Possiblocause if rosult is not obtained Bfown No. '14 l2O Al fuse in the under-dashfuse/relay box Faulty windshieldwiper switch An oDenin the wire Faulty windshieldwiper switch Faultv windshieldwiDer motor An open in the wire
. An open in the wire Check for voltageto ground: There should be battery voltage.
lgnitionswitch ON (ll) Check for voltageto ground: . Faulty windshieldwasher switch * B L K / G R N and windshieldwasher There should be battery voltage. . An open in the wire motor switch ON *: With combinedwasher-wiper operation (cont'd)
23-147
IntegratedControl Unit Input Test (cont'd)
M
rWith combined washeFwipot operation
Engine Oil PressureIndicator Flashal System: Wire/ Tsst condition No. Telminal Enginerunning
1
lgnitionswitch oFF
LT BLU
. Faulty charging system Check for voltageto ground: There should be battery voltage . An oDenin the wire Check for continuityto gtound: . Faulty engine oil ptessure switch . An oDenin the wire There should be continuitv. Check indicatorlight. lf the light . Blown bulb . An open in the ware does not come on, Sttach the ground: YEL/REDterminalto The light should come on as the ignitionswitch is turned ON.
Start the engine.
Check for voltage to ground: There should be battery voltage
Key-in/Seat Bolt Reminder Systam: Test condition Wila No.
LT GRN/ RED
Driver'sdoor open Front passenger'sdoor switch open NOTE:Betoretesting, remove No. 3 (7.5 A) tuse from the underdash fuse/relaybox. lgnition key inserted into the ignitionswitch
lgnition switch ON (ll) RED/BLU and driver's seat belt unbuckled
Test: Dosired lesuh
;.rqFft,
Insufficientoil lmproper lubrication Faulty engineoil pressureswitch
Possiblecauso if resuh is not obtainod
Check for continuityto ground; . Faulty driver's door switch . An ooen in the wire There should be continuitv. Check tor continuityto ground: . Faultylront passenger'sdoor switch . An ooen in the wire There should be continuitv.
Check for voltage to ground: There should be 1 V or less.
Faulty ignition key switch Poor ground (G201, G401) An ooen in the wite
Check lor voltageto ground: There should be 1 V or less.
Faulty seat belt switch Poor ground {G551) An open in the wire
NOTE: Referto page 23-125 for the seat belt switch test.
23-148'
Possiblo c€use if r6rult is not obtainod
lgnition switch ON (ll)
YEL/RED
GRN/BLU'
Test: Desired result
Bulb Check System (blake system lightl No. Tsrminal Test condition
I
Tost: Desirod resuh
Possibls caus6 it result is not obtainod
lgnitionswitch at START
Check lor voltageto ground: There should be battery voltage.
Blown No. 18 {7.5 Al fuse in the under-dashfuse/relay box Faulty clutch int€rlock switch or starter cut relay {M/T} Faulty neutral position switch (A/T) An open in the wire
lgnition switch ON (ll), brake fluid reservoir tull, and parkingbrake lever down
Connectto ground: Brake system light should come on.
M
D
Lights-on Romind6rSystom: Wire/ No, Toiminal T6Et condition
GRN/8LU'
H
Driver's door open Combinationlight switch ON.
Connectthe I terminal to the J terminal.
5
Side Markol Light Flashar System: Wiro/ No. Terminal Test condition 1
H
Combinationlight switch ON
lgnition switch ON {ll) G R N / B L U 1and turn signalswitch to "Left" 2
4
Tost: Dositod rosuh
Possibl6caus6 if rosuh is not obtainod Check for continuityto ground: . Faulty driver's door switch . An oDenin the wire There should be continuity. Check for voltage to g.ound: Blown No. l9 (1O A) tuse in the There should be battery voltage under-dashfuse/relav box Faulty combination light switch An oDenin the wire Check chime operation:Chime . Faulty chime . An open in the wire should activate each time the batterv is connected,
Tast: Desired rosult Check for voltageto ground: There should be battery voltage
Po$ible cause if result is not obtained . Blown No. 19 (1O A) tuse in the under-dashfuse/relay box . An open in the wire
Check for voltageto ground: It should changefrom O-12-O V repeatedly.
Blown No. 26 (10 A) luse in the under-dashfuse/relav box Faulty turn signal/hazardrelay An oDenin the wire
Check the front side marker light: Left (or Right) front side markerlight shouldcome on as the batterv is connected.
Blown bulb P o o rg r o u n d( G 2 O 1 c, 3 O 1 , G 4 O 1 l An open in the wire
lgnitionswitch ON {ll) GRN/YEL and turn signalswitch to "Right" lgnitionswitch ON (ll) GRN/WHT and turn signalswitch to "Left (or Rightl": Connectthe H terminal GRN/REDl to the GRNMHT (or GRN/REDl)terminal.
. Blown brake system light . An oDenin the wire
23-149
Key-in ReminderSystem Door Switch Test
lgnition Key Switch Test NOTE: Referto page 23-145fot a diagramof the keyin lemindercircuit,and to page23-148 Jorthe inputtest ol the beepercircuit.
l.
Removethe screw, then pull out the door switch. Disconnectthe 1-P connectorfrom the switch.
When the ignitionkey is not removed,the key-inreminder in the integratedcontrolunit sensesgroundthroughthe closedignitionkey switch. When you open the driver's door, the beepercircuit sensesgroundthrough the closed "LT BLU" and "GRN/ door switch, With groundat the BLU" terminals,the beepersounds. 1.
Removethe dashboardlower cover and knee bolster (see page 23-70).
2.
Disconnectthe 7-P connectorfrom the main wire harness.
Open the door.
BASE PLATE
4.
Check lor continuity between the positive terminal and the baseplate (ground)in each switch position accordingto the table.
Terminal
POSITIVE
BASEPLATE
Position Checkfor continuitybetweenthe No. 2 and No. 4 terminalsin each conditionacco.dingto the table.
PUSHED {doorclosedl RELEASED ldooro!en)
Terminal Condition
KEYINSERTED KEYREMOVED
23-150
4
--o
o
o
EngineOil Pressure Indicator System Description
Lights-onReminder
System Description
NOTE: Reterto page 23-144 tor the circuitdiagramot the engine oil pressureindicatorflasher,snd to page 23-148 lor the input test of the flashercircuit.
NOTE: Referto page23-145 tor a diagramof the lightson remindercircuit, and to page 23-149 for the input tests of the circuit.
The low engine oil pressureindicator tight works in two ways. lt will flash continuouslyfollowinga momentary loss of oil pressure, or it will go on and stay on with a completeloss of oil pressure.
When the ignitionkey is turnedto OFF8nd removed.with the lights on, voltageis apptiedto the remindercircuit in the integrat€dcontrol unit. When you open the driver,s door, the circuit senses ground through the closed door switch. With voltage at the "H" terminal, ground at the "GRN/BLU2" terminaland no voltageat the ,,F,' terminal, the chime sounds to remindthe driver to turn oJf the lights.
When the engine first starts, before oil Dressurerises above 29.4 kP8 10.3 kgf/cmr, 4.3 psi), current flows through the low engineoil pressureindicatorlight and the oil pressureswitch to ground.This tests the circuit. Wilh the enginerunning,voltageis appliedro the ftasher circuit of the integrated control unit. With normal oil pressure,the oil pressureswitch is openandthe low engine oil pressureindicatorlight does not operate.lf the oil pressureswitch closesmomentarily(morethan O.5 secondsl,but then opensagain,terminal"yEL/RED,'will sensegroundthrough the switch. The integratedcontrol unit willthen provide and remove ground for th€ low engine oil pressure indicator light through terminal "YEL/RED". The light will flash on and olf until the ignition switch is turned to "OFF". lf engineoil pressurefalls below 29.4 kPa (O.3kgJ/cmr, 4.3 psi) and does not increase,the oil pressureswitch willstsy closed.The low engineoilpressureindicatorlight will go on and stav on.
ChimeTest Removethe dashboardlower cover and knee bolster {see page 23-70). Disconnect the 2-P connector t.om the dashboard wire hamess. CHIME
NOTE; Referto page23-122lot the engineoil pressure switch test.
Test the chime by connecting battery power to the "A" te.minal and groundto the "B" terminal,and power cycling the on-off repestedly. lf the chime fails to sound every time power is cycled, reDlaceit.
23-151
Lighting System ComponentLocationsIndex All SRS el€ctrical wiring harnessesale covered with yallow insulation. B€fore disconnocting any pan of th€ SBS wire harness, connect the short connactor(sl. Replac€th6 entire affocted SRS harnessassembly it it has an open circuit or damagod wiring.
HIGI{ BEAM INDICATORLIGHT (ln the gaugeassembly) Bulb Locations,page 23-115
COMBINATIONLIGHT SWITCH page 23-160 Replacement, Test, page 23- l58
OAYTIME RESISTORlC.nodal Test, page 23-160
HEAOLIGHTS Adjustment, page 23-162 page 23-164 Replacement, FRONT PARKING/FRONTTURN SIGNAL LIGHT page 23-165 Replacement,
FRONTSIDE MARKERLIGHT page 23-165 Replacement, DAYTIME RUNNIT{GLIGHTS CONTROLUNIT {C6nada) Input Test, page 23-156
23-152 -
Hatchback:
LICENSEPLATE LIGHTS page 23-169 Replacement. TAILLIGHT . Replacement, page 23-166 . Eulb replacement,page 23-166
Sodan:
LICENSEPLATE LIGHTS page 23'169 Roplacement, INI{ER TAILLIGHT . Replacement, page 23-167 . Bulb replacement.page 23-168 TAILLIGHT
. Repfacement,page 23-167 . Bulb replacement,page 23-168
23-153
LightingSystem CircuitDiagram(USAI
- HOOD UNOER RJSE/NELAY 8OX
-r DIMMER
No.lo tloAr
t
'1 No,22 (0oA)
I
lo|
,-.
otF
I'I
t
''t No.g (floAr
No.2l |l0A]
T
iil; )
REO/GNN
HEADLIGHT HIGHEEAM INOICATOR LIGHT fi.4W)
@il,", @f,*, 6il*
8LK
8tK
G 20l G401
G301
I
23-154
RIGHT HEAOUGHT
G20'| G40l
6p*
DASHUGI{TS 88rGr{TESS CONTrcUTR DASHUGHTS . PAR(II{C PAR(II{G UGHI UGHTS . TAItUGt{TS TAILUGI{TS . UCENSE PI.ATE UGHTS
- D SH UtrloER RJSE/RELAY
sox
GircuitDiagram(Canadal UNOER_HOOD FUSEiRETAY 8OX
BATTERY
G"* -il
w
/ d \
coMBrNAtor{ rcHrswnc
BAT
'.=r"
|
tlL-J
I
l l ' L
I
I
"- l-'li' "orr ;-\d " ;j I I *o\." r.r-,9 I L I LI RED/BLU
t'
REO/}VHT
l
RED, GRN
l
UNDEN-DASH FUSEiIEI,AY 8OX
I I
t
I I
l
I
i,"# llrrff li'rrt,I
No.2l fl0A)
\
( Jm.tr
No.l9 |l04]
t
I
I
BLU REOr' TVHT
RED/ GRtI
rGNrTrot{
tG2 swITcH \9-l
NED/B
t10A)t
No.l6 {7.54}
t
WHTTYEL
V
. DASH LGHTS BRIGHTNESS COI{TROLLER . DASH I-IGHTS . PARKING I-GHIS . TAII,LIGHTS . UCENSE N"AT€LIGI{TS I a-r jllA/Vr neonru
oI RED/GRI{ +\{H
I
I r-0
1651,1/) | l55W) HIGHBEAM INOICATOR UGHT fl.4W
l"
wxrinto
I
DAYTIME RUNNING UGI{TS RESISTOR
RED/ GRN
Hr
f#
HI
t85W)
LO t55Wl RIGHT HEADLIGHT
PARKIIIG BRAKE
sw{TcH
I 23-155
Lighting System DaytimeRunningLightsControlUnit Input Test (Canada) CAUTION: a All SRS eloc{dcal wi ng harn€ssesare covelod with yollow insulation. a Boforo dbconnocting any psrt of the SRS wir€ h8rnoss, connoct tho shon connector(s). a Roplacethe entire affected SRS harness assombly it it has an opon Gilcuit or damagod wifng. 1.
Removethe dashboardlower cover and knee bolster.
2.
Disconnectthe connectorsfrom the daytime running lights control unit.
3.
Insoectthe connectofand socket terminalsto be sure they are all making good contact. a ll the terminalsare bent, loose or coroded, repair them as necessary. and recheck the system, a lf the terminalslook OK, make the followinginput tests at the connector, - lf any test indicates a problem, find and cor.ect the cause, then recheck the system. - ll allthe input tests proveOK, the controlunit must be taulty; replaceif
4-P CONI{ECTOR
8-P CONNECTOR
YEL/ALK GRN/RED
WHT/RED
WHTA'EL
RED/GRI{
View from wire side
23-156
Vi6w from ware side
T€st condition
1
Under all conditions
Check Jor voltageto ground: There should be battery voltage.
lgnition switch ON (ll)
Check tor voltageto ground: There should be battery voltage.
Blown No. 16 (7.5 A) tuse in the under-dashfuse/relay box Faulty ignition switch An open in the wire
Combinationlight switch in "O" position
Check for voltageto ground: The.e should be battery voltage.
Blown No. 40 {5O A) fuse in the under-hood fuse/relay box Faultycombinationlight switch An ooen in the wire
Left and right headlight(high beaml should be on but dim, and high beam indicatorlight should come on.
Poor ground (G201. G401. G301) Blown bulbs Faulty daytime runninglights reststor An open in the wire
Connectto ground:The brake system light shouldcome on.
B l o w n N o . 1 5 ( 1 OA ) t u s e i n t h e under-hood fuse/relay box Blown brake system light An open in the wire
RED/WHT
Combinationlight switch is OFF; connect a iumper wire between 5 WHT/REOthe YEL/BLKand WHT/REDterminals, then turn th6 ignition switch ON. lgnition switch ON (ll), brake fluid res€rvoil GRN/RED full, and parking brake lever down RED/GRN
. P o o rg r o u n d{ G 2 0 1 ,G 4 0 1 ) . An open in the wire . Blown No. 17 { 10 A} luse in the under-dashtuse/relay box . An ooen in the wiae
Check for continuityto ground: There should be continuity.
YEL/BLK
tt
Possiblacause if rosult is not obtainad
Under all conditions
BLK WHT/YEL
4
Test: Desirad losult
Parking brake lever up
Check for continuityto ground: The.e should be continuitv.
. Faulty brake lever switch . An open in the wire
23-157
Lighting System Combination Light/Turn Signal Switch Test CAUTION: a Atl SRS Oloctricslwiring harnessesar6 covered with yellow insulation. a Bslor€ disconnecting any pan ot the SRS wire harness, connact the short connsctollsl. a Replacethe sntire aftectad SRS harne$ assembly if it has an opon circuit or damagod wiring. 1. Remove the dashboardlower cover and steering column covers (see page 23-71). 2.
Disconnectthe 4-P and 7-P connectorsfrom the switch.
3.
Checkthe connector and socket tetminalsto be sure they are all making good contact. lf the terminalsare bent, loose, or cotroded, repair them as necessary, and recheck the system.
4.
Checktor continuitvbetweenthe terminalsin each switch positionaccordingto the table.
SRS MAIN HAR ESS
4-P CONI{ECTOR
B D
G H
7.P CONNECTOR
23-158
ComHnrtlon llght Swhch :
TErminsl Position Hsrdfightstvitch
E
t-
J
H
OFF 1J
--o
n
L0w
a
o o
HIGH OFF
Passing switch
ON
G
o
Tum Slgn.l Swhch :
/ t \
RIGHT
Tsrminal A
Position RIGHT
8
D
-o
o
NEIIIMT
uFr
o
(J
23-15,9
Lighting System Combination Light Switch
Replacement
'1.
Removethe steeringcolumn covers.
UPP€RCOVER
Daytime RunningLights Resistor
Test lCanada) CAUTION: The daytime running lights resistor becomas vely hot when the daytime running lights are on; do not touch it or the attaching hardware immediatelyaftel th€ lights h8ve b€en turned otf. 1.
Disconnectthe 3-P connectorfrom the resistor.
DAYTIMERUNNING LIGHTS RESISTOR
Disconnectthe 4-P and 7-P connectorsfrom the combination lighr switch, then remove the two screws and lift out the switch.
?nd
V
-
c
View trom lerminalside
Measurethe resistancebetweenthe resistorterminals (A and B) and the DowerterminalC. R€sistance:1.4 O I O.O7O
Replacethe resistorwith a new one if any ot the resistancesare bevond soecification.
23-160
Headlight Description The low beam lightsare proiector-typelightswhich are more compactwhile maintainingsufficientbrightness.Bundling the light raysreducesstray light and yieldsa spotlight-effect which improvesvisibilityduringnight or foul weatherdriving. For easieraiming,the headlightsare equippedwith vertical and horizontalgauges. NOTE: As the oute. lensesare made oI a resin material,don't cover the headlightswhen they a.e turned on.
OUTER LENS
coNvExLEI{S SUB-REFLECTOR sEcoND FOCUS INTERRUPTER PLATE REFLECTOB FIRST FOCUS BULB
23-161
Headlight Adjustment Belol€ adiusting lha hoadlights:
3.
Turn the low beams on. lJ necessary,align the vertical indicator with its "O" mark by turning the vertical adiuster with a Phillipsscrewdriver, and check aiming with the chart on page 23-163.
4.
lf necessary,alignthe horizontalindicatorwith its "0" mark by turningthe horizontaladjusterwith a
a Parkthe car on level ground. a Make sure the luel tank is full. a The driveror someonewho weighsthe same should sit in the driver's seat. a Loadthe trunk with the items you usuallycarry (if you usuallypull a trailer,attach it to the carl. a Push down on the tront and rear bumDersseveral times to make sure the car is sitting normally. a When installinga new headlightassembly,tighten the four mountingbolts so that.theindicatorin the verti"O" mark. cal gauge comes to the
Phillipsscrewdriver,and check aimingwith the chart o n p a g e2 3 - 1 6 3 .
1. Open the hood. 2.
Check that both the horizontaland verticalgauge read " O" . . lf the gaugesrcad "O", check headlightaiming with the aimingchartson page 23-163. (lf aiming isn't correct,refer to the trame repairchart in section 20.) a lf one o. both gaugesdon't read "O". go to step
5.
Recheckthat the verticalindicatorbubbleis aligned with "o" 1 1. lf necsssary,adjust as describedin step 3. Turn the high beamson and check aimingwith the charts on page 23-163.
23-162
Measurements (Standardl: A: 9 fi 10 in (3000 mm) B: 23 in (585 mm) C: 46.1 in (1170 mml D: 33.5 in (85O mm) E; 1.2 in {31 mm}
FLOOR
Headlight Aiming Low beam:
High besm:
HEADLIGHT LOW BEAM CEt{TER
HEADLIGHT HIGH BEAM
FLOOR
CAUTION: Th6 out6r lonses get very hot when tho hoadlights are on; do not cover them.
23-163
Headlight Headlight Replacement 1. Removethe front bumoer.
Bulb Replacement CAUTION: a Halogon headlights can bocomo voly hot in usa; do not touc$ them or tho attaching hardware imm6diatoly arter they hava been lurnod off, a Do not try to roplaceor cl6an the headlights with the lights on. I.
Oisconnectthe 2-P connector(s)from the headlight.
FRONTBUMP€R
Removethe mountingbolts,then pullout the headlight, and disconnectthe connectorsfrom it.
coNlrtEcToR
2.
HEADLIGHT
Afte. replacement.the horizontaland verticalaiming must be checkedusing conventionalmethods, Use the aimingcharts on page 23-163.
23-164
Turn the bulb(s)counterclockwiseand removethe bulb(s).
Front Parking/Front Turn Signal Lights Replacement l.
Removethe screw, and pull the front parking/front turn signal lights out ot the tront bump6r.
Front Side Marker
Lights
Replacement Remove the screw, and pull the front side marker light assemblyout of the tront bumper. Disconnectthe 2-P connectorfrom the lioht. Turn the bulb socket 45o counterclockwiseto remove it from the housing.
Disconnect the 2-P conn€ctor trom the tight. Turn the bulb sock€t 45o counterclockwise to remove it from the housing.
BULE{3 CPI FRONTSIDE MARKERLIGHT
23-165
Taillights(Hatchbackl Bulb Replacement
Replacement 1 . Open the resr hatch. Removethe rearpanelliningandthe sidelining{see section 20).
R6ei tum slgnal/Rolr parking lights: 1.
Openthe rearhatch,then removethe accesspanel.
2.
Removethe bulb lrom the bulb socket.
Disconnect the 4-P connector from the taillight. 4.
ACCESS PANEL
Removethe six mounting nuts, then pull out the taillight.
4-P CON[{ECTOR
@: REARTURN SIGNALLIGHTBULB(32 CPI @: REARPARKINGLIGHTBULB{3 CP) Brake/T8illight/Back-uplights: NOTE: a Inspect the gasket. Replaceit if it is distorted or stavs compresseo. a After installation. run wate. over ths lights to make sure thev don't leak.
1. ODenthe rear hatch. 2.
Removethe rear panel lining {see section 20).
o: BACK-UPLIGHTBULB{32 CP} BULB(32l3 CP) @: ERAKE/TAILLIGHT
23-166 -
Taillights (Sedan) Replacement Tsillight: 1. Open the trunk lid, then removethe r€ar panel lining and side lining (seesection 20). 2.
Disconnect the 4-P connector from the tsillight.
3.
Removethe four mountingnuts, then pull out the tsillight.
Innol Taillight: 1. Open the trunk lid. 2.
Disconnectthe 4-P connectorfrom the innertaillight.
3.
Remova the four mounting nuts, then pull out the inner taillight. INNERTAILLIGHT
TAILLIGHT
4-P CONi{ECTOR
NOTE: a Inspect the gasket. Replaceit if it is distoned or stsys compresseo. a After installation, run water over the lights to make sure thev don't leak.
23-167
Taillights(Sedanl Bulb Replacement Tsillight: 1. Open the trunk lid. then removethe rear panel lining and side lining {see section 20}.
lnnor T.illlght: 1. Open the trunk lid, then removethe bulb housing. 2.
2.
Remove the bulb from the bulb housing.
Removethe bulb from the bulb socket.
BULBHOUSII{G
BULB(32l3 CP} @: BRAKE/TAILLIGHT
@: T U R NS I G N A LL I G H TB U L B( 3 2 C P }
O:
@: REARPARKINGLIGHTBULB{3 CP)
BULBI3213CP} @: BRAKE/TAILLIGHT
23-168 l'r'qn'F',
LIGHTBULB(32 CP} BACK-UP
LicensePlateLights Replacement
Glove Box Light Test
Remov€ the screws and pull out th6 license plate lights.
Removethe glove box and disconnectthe 2-p conneclor.
Turn the bulb socket 45o counterclockwise to remove it from the housing.
Checkfor continuitybetweenthe A and B terminals in each conditionaccordingto the table.
T€rminal B
Condition PUSHED {lidclosodl REI"EASED {lidoDen)
o-
/:\
\7
---o
BULB (3.4 W)
ql -----11 dl
cior G4{t1
23-169
DashLightsBrightnessGontrol CircuitDiagram
8OX UNDER.HOOD FUSE/REIAY
COMBII{ATION LIGI{TSWTTCH
wnr-@-
UNDERDASH 8OX FUSE/NETAY
neorenn REO/BLK
. GATJGE UGHTS . CruEECOITNOL DIMMING CIRCUTT . A/TGEAR POSMON N(ICATOR DIMMII{G CIRCUIT ' HAZAnD LIG}fr WARi{|NG S:WltCH . REAR SiWTTCH UGHT WINOOW OEFOGGER . CFUISE UGHT COMTROT MAINS,IVITCH . A,ITGEAN UGHT POSITION CONSO|.! . HEATER PANEL UGHTS COMTNOL
T R €D
BI.K
G201 G40t
23-170
Controller Input Test NOTE: 8e carefulnot to damagethe controllerand the instrumentpanal. 1. Removethe instrumentpanel lrom the dsshboard { s e ep a g e 2 3 - 1 1 8 1 . 2.
Remove the dash lights b.ightness controller {rom the dashboard.then disconnect the 3-P connector. Inspect the connector and socket terminals to be sure they are all making good contact.
View from whe side
a lf the terminalsare bent. looseo. corroded,repsir them as necessary, and recheck the system. a It the terminalslook OK, make the tollowing inDut tests at the connector. - lf any test indicates a problem, find and correct the cause, then recheck the system. - lf all the input tests prove OK, the dash lights brightnesscontrollermust be faulty; replaceit. 3-P CON[{ECTOR
OASH LIGHTS COI{TROLIER
Wire 1
BLK
Tost condition
Check for continuity to ground: There should be continuitv.
Headlightswitch ON
Check Jor voltageto ground: There should be battery voltage.
Headlightswitch ON
Connectto ground: Dash lights shouldcome on full bright.
RED/BLK
a
RED
Togt: Dasired resuh
Under all conditions
Possiblecauso it resull is not obtained . Poor ground (G20l , G4O1) . An open in the wire B l o w n N o . 1 9 ( 1 OA ) t u s e i n t h e under-dashfuse/relay box Faulty combinationlight switch An open in the wire . An open in the wire
23-171
Area Lights, Spotlights Ceiling/Trunk/Gargo Component Location Index r 1: Sedan r2: Hatchback
CEIIING LIGHT Test/Replac€mont.page 23-175 SPOTLIGHTS Test/Rsplscement, page 23-1 74
.1 LEFT REAR DOOR SWTCH Test. page 23-150
FRONT PASSEl{GER'S DOOR swtTcH Test, pago23-150
*2 HATCH LATCH
11 RrcHTBEAR DOORSWrCH Tost. page23-150
swtTcH Test/Replacement, page 23-178
23-172 rII-
11 TRUNK LATCH SWITCH Test/Replac€ment, page 23-178
'1 TRUI{K LIGHT Test/Replacemont Page 23-177
CircuitDiagram - HOOD UNOER FUSE/RELAY 8OX
- - - - -Hltcnb&n --1
CARGO ASEA UGHT t3.4Wl
U DEN-DASH FUSE/RELAY 8OX
lS.d.nl
TBUi{K UGHT t3.4Wl
GRI{
I
l**,-0,,n I rNorcAToR I UGHT
IY
i'
GRN
LT II{IEGRATED 1
cotlrnor I I,NIT
I
GRr{/Bt U t-t
d_ f:
Iq*",,., I DOOR
I swncH
II
FROiTT PASSEiIGEB'S DOOf, SWTCH
:
J
23-173
Area Lights, Spotlights Ceiling/Trunk/Cargo Spotlight Test/Replacement 1. Turn the light switch OFF. 2.
Pry off the lens.
3,
Removethe two screws,then pull out the housing.
4.
Disconnectthe connectorfrom the housing.
5.
Checkfor continuitybetweenthe terminalsin each switch positionaccordingto the table.
\
Hatchback:
;r,,-
CONNECTOR
tEFr
Torminal ----l
ON
BorB'
A
/:\ \:/
o-
OFF
ON RIGHT
Sedan:
""li **li
BULB
23-174
--o --o
o-
OFF
B'O
CorC'
B
Ceiling Light Test/Replacement With moonrool:
5.
1. Turn the light switch OFF. 2.
Pry otJ the lens.
3.
Removethe two mountingnuts, then pull out the housing.
\
Checkfor continuitybetweenthe terminalsin €sch swatchpositionaccordingto the table.
re.mrnal Position OFF
DOOR ON
A
c
8or8'
\
oo-
za \7
G-
/1
\7
D
--o --o --o
\:.,/
3-P CONNECTOR
F om o.3l7.5Al FUSE (ln th. snd.. - dr.h fu!./r€by boxl
4.
Disconnectthe 3-P connectorf.om the housing.
23-175
Area Lights' Spotlights Geiling/Trunk/Cargo Geiling Light Test/Replacement 5.
Without moonroot:
Check for continuity between the terminals in each switch position according to the table.
1. Turn the light switch OFF. 2.
Pry ofJ the lens.
3.
Removethe sctew, then pull out the housing'
\
T6ninsl P"riti""
DOOR
ooLF
D
BorB'
\
OFF
ON
A
/:\ \:.,/ A
--o --o
/A
3-P CONNECTOR
4.
Disconnectthe 3-P connectorfrom the housing.
23-176
F om o.3l7.5Al FUSE tln thr uid.r - ddr h|. /,.LY borl A
--o
Trunk/CargoArea Light Test/Replacement Pry the trunk/cargoafea light lens out of its housing. Pry out the light assembly. Disconnectthe 2-P connectortrom the housing. Hatchback:
4.
Make surethat the bulbis in good condition.Check for continuitybetweenthe A (+) and B (-lterminals. There should be continuitv (Hachback:the switch must be Dushed).
Hatchback: 2.P CONNECTOR
Froh o.3 (7.5A1FUSE {ln th. undor- d!.h fur./r.hy box)
BULE13.4Wl
To HATCH LATCH
A {+}
swtTcH
B{-)
Sedan: 2.P CONNECTOR
F om o.3 (7.5A1FUSE {ln th. und.i- da.h tur€/r.hy box)
HOUSING
BULB{3.4 W)
To TRU K LATCH swtTcH
23-177
Area Lights,Spotlight Ceiling/Trunk/Cargo Latch Switch Test/Replacemsnt Sedan:
lhtchb.ck:
1. Openthe trunk lid. and disconnectthe 2-P connector from the trunk latch switch.
1.
Op6n the hatch, and disconnect the 2-P connector trom the hatch latch switch.
2.
There should be continuity between thg A terminal and component ground.
2.
There should be continuity between the A and B terminals.
\j
C C 3 . lf necessary,removethe three mounting bolts to pull out the hatch latch switch trom the latch, then disconnact the lock rod Jrom the hatch latch switch 4. ll necessary,removethe three mounting bolts to pull out the trunk latch switch from the trunk lid, then disconnectthe lock rod from the trunk latch switch. 4.
Disconnect the trunk opener cable from the trunk latch switch. TRU'{KOPG ER
TRUNK LATCH SWITCH
23-178
Disconnect the hatch opener cable trom the hatch latch switch,
Back-upLights CircuitDiagram
UI{DER_ IIOOOFUSEiBEIAY BOX
wHT/Bt(+WHT
A/TGEAR
Posrnotr swrTcH 'l f 8ek- uplioht
--------_J
L---------
23-179
Back-up Lights Manual Transmigsion:
Automatic Transmission:
NOTE: Checkthe No. 1 5 { 1O A) fuse in the under-dash fuse/relaybox befote testing.
NOTE: Checkthe No. l 5 ( 1O A) fuse in the under-dash fuse/relay box belore testing.
'1. Test the back-uplight switch by placingthe shift lever in reverseand turning the ignition switch to ON ( ).
1. Test the back-up light switch by shitting the shift lever to l3l and turningthe ignitionswitch ON (ll).
2.
It the back-uplightsdo not go on, check the backup light bulbs in the taillightassembly.
3.
lf the tuseand bulbsareOK. disconnectthe connector from the back-uplight switch.
2.
lf the back-uplights do not go on, checkthe backup light bulbs in the taillightassembly.
3.
lf the tuse and bulbs are OK, disconnectthe 14-P connector from the A/T gear position switch (backup light switch).
4.
Move the lever back and torth at the LBI position without touching the push button, and check tor continuitv between th€ C and D terminals. There should be continuitY within the range of free plsy of the shift lever.
terminal sade
This washer must always be replaced tor the switch to lunction properlY and to ptevent oll teaKs.
4.
With the shift leverin reverse.checkJor continuity betweenthe A and B terminalswith the switch installed. There should be continuity. a lf there is no continuity,replacethe switch {see s e c t i o n1 3 ) . a lf there is continuity, but the back-uplights do not go on, check for: - Poor ground (G5O3) - An open in the wire
23-180
a lf there is no continuity within the range oJ J.ee play, adjust the position ot the A/T gear position switch lsee section 141. a lt there is continuity, but the back-uplights do not go on,check{or: - Poor ground {G503) - An oDen in the wire
BrakeLights CircuitDiagram
UNDEE-HOOO FUSE/NELAY BOX
. HORi{ . IMTERI.OCK SYSTEM
{u 8tK
{.
*H-i {.
BLK
23-181
Brake Lights HighMount BrakeLightReplacement (LEDtypel
Brake Switch Test lf the brakelights do not go on, check the No. 42 {2O A) fuse in the under-hoodfuse/relaybox, and the brakelight bulbs in the taillighrassemblyand high mount brake light.
1. Removethe four screws and the high mount btake light, then disconnectthe connectors.
lf the fuse and bulbsare OK. disconnectthe 2-P or 4-P connector {rom the brake switch.
'|Frt
A
B
jr'li C
D
HIGHltlOUt{T BRAKELIGHT{LEDTYPEI
3.
Check fo. continuitv between the B and C terminals. There should be continuity with the brake pedal pushed. a lJ there is no continuitv, replscethe switch or adjust pedal height {see section 19). a lf there is continuity,but the brakelightsdo not go on, inspectfor: - Poor ground (G5O3) - An ooen in the wire
23-1A2
High Mount BrakeLight Replacement {Bulbtype) Hatchback:
Sadan:
1. Open the hatch.
1. Openthe trunk lid, and disconnectthe 2-P connector trom the high mount brake light.
2.
Removethe two clips and the cover.
3.
Removethe two nuts and the high mount brakelight, then disconnectthe 2-P connector.
2.
Removethe two nuts, then remove ths high mount brake light from the rear shelt.
2-P CONt{ECTOR
4.
Turn the socket 45o counterclockwiseto removethe bulb.
2
Installthe high mount brakelight in the reverseorder of removal. Cleanthe rear window glass before installingrhe light.
Installthe high mount brakelight in the reverseorder of removal,and cleanthe rearwindow glassbetore installing. CAUTION: Whon installing ih6 high mount brake light. make sur6 the rubber soal fits against the real window ev6nly.
23-183
Side Marker/TurnSignal/HazardFlasherSystem Component Location Index GAUTION: a All SRS electrical wiring harnessosar6 covered with yellow insulation. a Belor€ disconnocting any pan of the SRS wire harngss, connoct the short connector{s). a Rsplacetho 6ntir€ affect€d SRS harnoss sssembly il it has an op€n cilcuit or damaged widng.
TURN SIGNAL INDICATORLIGHTS (ln the gaugeassembly) Bulb Locations, 23-115 COMBINATIONLIGHT SWITCH page 23-160 Replacement, Test, page 23-1
SRS MAIN HARI{ESS (Cov.rod with Ysllow in3ulationl
HAZARD WARI{ING SWITCH page 23-187 Replacement, Test, page 23-187
UNDER-DASH FUSE/RELAY8OX
TURN SIGNAL/HAZARORELAY Input Test, page 23-186
23-184 -
GircuitDiagram UNDEN-HOOD FUSE/RELAY 8OX N0.411100A) No.40(50A)
UNDER-DASH FUSE/RELAY 8OX
COMBINATION LIGHTSWTCH A. ---of-RED/GRN IGNITION SWITCH
WHT/BTK +WHT+
/6i\\
\jv
+-
FUSE HOTJER
BIK/YET
GRN/BtU
TURNSIGiIAL
swtTcH
I | l +
MAFKER SIOE LIGHT FLASHER CIRCUIT controlunitl llnthointogruted
RIGHTTURNSIGNATTIGHTS
DASHTIGHTS BRIGHTNESS CONTROLLER
INOICATOR I FRONTI REAR L|GHT I t32CD I t32CPl
(1.4W1
2 3 - 185
Side Marker/TurnSignal/Hazard FlasherSystem Turn Signal/Hazard RelayInput Test CAUTION: a All SRS electrical wiring harn6ss6sar€ covered with yellow insulation. a B€foro disconn6cting any part of th€ SRS wire harnoss, connoct tho short connector(s). a Replacotho ontiro sftoctod SRS harness ass€mbly it it has an open circuit or damagod wiring, I.
Removethe turn signal/hazardrelay from ths underdash Juse/relaybox.
2.
Inspectthe relayand socketterminalsto be surethey are all makinggood contact. a It the terminalsare bent, looseor coroded, repair them as necessary,and recheckthe system. a lf the terminalslook OK, make the tollowing input tests at the socket. - lf a test indicatesa problem,find and correct the cause, then recheck the system. - lf all the input tests prove OK, the turn signal/hazardrelay must be taulty; replaceit.
SBS MAIN HAR ESS {Covg.ed with yollow inrulltion)
UI{DEB-DASH FUSE/RELAY BOX Telminal ,l
E
2
B
3
23-186 -
TeEt condition
Test: D€sired rosult
Po$iblo causo it fosult is not obtainod
Check for continuityto ground: . Poor ground (G201, G4O1) . An oDenin the wire There should be continuitv. lgnitionswitch ON (ll) Check for voltageto ground: Blown No. 26 (10 A) fuse in ths fuse There should be battery voltage. holder and hazardwarning switch OFF Faulty hazardwarning switch An open in the wire Blown No. 43 (10 Al fuse in the lgnitionswitch OFF and Check for voltageto ground: hazardwarning switch There should be battery voltage. under-hood fuse/relay box ON Faulty hazard warning switch An ooen in the wire Hazardwa.ning switch Hazardlights should come on. Poor ground (G2O1,G3O1, G4O1 is ON; connect the B G503) terminalto the L Faulty hazard warning switch termrnat. An open in the wire . Faultyturn signalswitch lgnition switch ON (lll Right or left turn signallights . An open in the wire and turn signalswitch should come on. in right or left; connect the B terminalto the L terminal. Under all conditions
HazardWarning Switch Test
HazardWarningSwitch Replacement CAUTIOI{: Bo car.ful not to damag8 tho switch and conlolo panol. 1.
Prythe hazardwarning switch out of the centervent,
2.
Disconnectthe 10-P connectortrom the switch.
1 . Removethe hszardwarning switch. 2 . Check fo. continuity between the terminals in each switch positionaccordingto the table.
\
I"j'!ld
A
I
D
F
H
Position OFF
ON
10-PCO
@ r)
o @
ECTOR
A B C D
\ uorr ) to.uwl
23-187
StereoSoundSystem ComponentLocationIndex CAUTION: a All SRS el€ctrical wlring harneaseEare covered with yallow insulation. a Belore dbconnscting any part of the SRS wire harnass, connect tho short connector(sl. a Replacetho entir6 affoctod SRS harn6ss assembly if it has an opan circuit or damag6d widng. NOTE: The original radio has a coded theft protection circuit. Be sureto get the customet's code numberbelore - disconnecting the battery. - removingth€ No. 32 (7.5 A)tuse from the under-hood fuse/relay box. - removingthe radio. After service, reconn€ct power to th€ radio and tutn it "CODE" is displaved,enterthe cuson. Whenthe word tomer's 5-digit code to restore radio opelation.
Hatchback:
SBS MAII{ I{ARI{ESS (Covor€d wirh y6llow in3ulationl
STEBEORADIO/CASSETTE PTAYER paoe23-191 Removal. page23-192 Terminals, RIGHTREAR SPEAKER Replacement. page23-193
DOOR SPEAKER page23-192 Repfacement, LEFTTWEETER page Replacement, 23-192
DRIVER'S DOOR SPEAKER Repfacement,page 23-192
LEFT SPEAKER Replacemenr.page 23-193
23-188 !iltil;s'
ANTENNA MOTOR Test, page 23-194 page 23-196 Replacement,
Soden:
RADIO/CASSETTE STEREO PLAYER paoe23-191 R€moval, FBONT PASSENGER'S T€rminals.page23-192 DOOR
i FIGHT TWEETER page 23-192 Replacement, *: USA
SPEAKER page 23-192 Replacement,
RIGHTREAR SP€AKER page2 3 - 1 9 3 Replacement,
DRIVER'S DOOB SPEAKER Repfacement,p8ge 23-192
POWERANTENNA MOTOR Test, page 23-194 page 23-196 Replacement,
23-189
StereoSoundSystem CircuitDiagram tGNtTOt{ SWTTCH
FUSE BOX UNDER-HOOO i RETAY tlo.4lllo0Al
No.39l50Al
+WHT WHT/BI"K
No.l9ll0Al RJSE
UNDEN-DASH FUSENEIAY
8ox
SIER€OMOO CASSETTE N.AYER AI{TE?{NA MAST
AMTEI{iIA ITAD
-L-fl
4
-fi1 .a'J POWER AIT€NI{AMOTOF ntrrct d fulvl M_nhthoantanna | : Excoot!ad!n of Crnede
23-190
RIGI{T REAR SPEAXER
Unit Removal CAUTION: a All SRS oloctrical wi ng harn.$.s ara covcrrd with yellow insulation. a B€toro disconnocting any part ot tho SRS wirc hrrnosa, connsct tho short conn6ctol(rl. a Raplaco the sntirs sttoctod SRS hamoas asacmbly it it has an opon circuil 01 damagod widng.
3 . Removethe four mounting screws, then removethe front console.
FRONTCONSOLE
SRS MAII{ HABNESS
NOTE: The original radio has a coded theft protection circuit. Be sureto get the customer'scode numberb€lore - disconnecting the battery. - removingthe No. 32 (7.5 A) fuse in the under-hood fuse/relaybox. - removingthe radio. After ssrvice,reconnectpower to the radioand turn it on. When the word "CODE" is displayed,enter the customer's 5-digit code to restore radio operation. 1.
Remove the center console (see section 2O).
2,
Remove the cigarette lighter assembly {see page 23-205t.
4.
Loosen the two mounting screws, then disconnect the 16-P connectorand the antennalead, and oull out the stereo .adio/cassette player.
16-P COi{i{ECTOR
ANTENlTASUB-LEAD
23-191
Stereo Sound System Stereo Radio/CassettePlayer
Terminals
Front Speaker/Tweeter
Replacement Front Spoakor: 1. Carefullypry out the speakercover. 2.
\
Removethe three screws,then disconnectthe 2-P connector Jrom the speaker, and remove the speaker.
*i,.,-terlll A
FO] ANTENNA LEAD
r^lt
T I!NM[IAL
I
\ 2.P CONNECTOR
r
7
SPEAKER COVER
A9---------+A16
Twootor: 1. Removethe door paneland disconnectthe tweeter 2-P connector. Connects to A1
RED/GRN Frontpassenger's door speakerO
A2
BLU/GRN Driver'sdoor speaker@
A3 A4
RED/BLK Lights-onsignal WHT/8LU Constantpower {Tuningmemory)
A5
YEL/RED ACC (Mainstereopowe. supplyl
A6
YEL/GRN Radioswitchedpower (To antenna)
A7
BLU/YEL Left rearspeakerO
A8 A9
RED/YEL Rightrearspeaker@ BRN/BLK Frontpassenger's door speakerO
A10
GRY/BLK Driver'sdoor speakerO
A 412
lnot used) (notused)
A13
(not usedl
A14
BLK
Ground(G551)
Al5
GRY/WHT Left rearspeakerO
A16
BRNAA/HT Rightrearspeakere
23-192
2.
Remove the two screws, then remove the tweeter ano covet.
RearSpeakerReplacement Hatchback: 1.
Remove the sDsakercover.
2.
Removethe three screws, then disconngct the 2-P connocter trom the rear spoakor.
LEFTREAR SPEAKER
1 . Removethe three screwsfrom the trunk side,then remove the soeaker cover. Removethe tour screws, then disconnectthe 2-P connector t.om the s9eaker, and remove the soeake,.
OUARTERTRIM PAI{EL
,r--I
SPEAKERCOVER
LEFT REAR SPEAKEN
2-P CONNECTON
SPEAKERCOVER
REABTRAY
23-193
StereoSound System Power AntennaMotor Test Removethe quartertrim panel(Hatchback)or trunk side trim panel (Sedan).
AI{TE T{A MAST
Disconnect the 3-P connector from the motor, and remove the connector from its clamD.
3 . Check for power to the motor at the connector terminals: a There should be battery voltage between the WHT/RED(+l and BLK{-} terminalsall thetime. a There should be battery voltage between the YEL/GRN {+) and BLK(-} terminalsonlvwith the ignition and radio switched ON. 4.
AI{TEI{I{A LEAD
Test motor oDeration: EXTEND:Connect battery power to the "A" 8no "B" terminals and groundthe "C" terminal. C
RETRACT:Then disconnectpower trom the terminal,
ftYhh lha lnLnn.
r.tr.ci.d
t|Ilyl
"4"
Sticking Ant6nna: The antennasticks in either the up or down position.
*ft'^to
?r*
*r'
TIFIT
1 . Usingthe antennawrench, removethe antennanut, spacer (see page 23-195). Cleanthe antennamast housingthreads,and reinstall the soacer.
YEL/GRN
PLASTICSLEEVE
AIITENNA MAST
Cloan mast housing throads.
lf the motor fails to run or does not run smoothlv, reDtacetr.
23-194 fmft,
Usethe antennanut wrench and tightenthe antenna nut to 2.3 N.m (0.23 kgf-m, 1.7 lbf-tt). lJ you overtightenedthe nut. the antenna may stick. lf stickingoccurs, back the nut off a little, then turn the radioon and off to raiseand lower the antenna again. Repeatuntil the antennamoves treely.
Antenna MastReplacement Ramoval:
Installation:
NOTE: The antennamast alone can be replacedwithout havingto removethe power antennamoror.
1.
1.
Removethe antennanut and spacer.
2.
Carefullywithdraw the antennamast while extending it by turning the radio switch ON.
Holdthe antennaso that the teelh on the drive cable tace in the directionshown. then insen the cable into the antennahousing.
AI{TENNA I{UT
SPACER
ANTENI{A NUT WRENCH
Direction oI the teeth
, ANTENNA NUT 2.3 N.m 10.23kgl-m, 1.7 lbt-ft)
Checkfor engagementof the cableteeth with the drive gear by carefully moving the cable up and oown. Turnthe rsdioswitch "OFF", and let the motor Dull the drive cable into the antennahousing.
4.
Cleanthe antennahousingthreads,then insen the antennainto the housing.Installthe bushingspacer, and installand tighten the antennanut to 2.3 N.m {O.23 kgl-m. 1.7 lbf-Jt). Checkthat the antennamast retaactsand extends fully when the radio switch is tu.ned ON and OFF fepeatedly. It you overtightenedthe nut, the antenna may stick. lf stickingoccurs,back the nut otf a little,then raiseand lowerthe antennaagain.Repeat until the antennamoves treelv.
POWERANTENNA MOTOR UNIT
23-195
StereoSoundSystem PowerAntennaMotor Replacement 1 . Removetho quart€r trim panel (Hatchback)or trunk side trim panel (Sedan). Disconnectthe 3-P connectorand antennaleadtrom the motor, then remove the antenna nut and motor bracket nut. AI{TENNA1{UT 2.3 l{.m
AT{TEI{]{AI{UT WBEI{CH oTJAA-OOlo(xrc
3+CO
ECTOR
DRAI HOSE
MOTOR BRACKET TUT
3 . Remove the motor and antenna as an assemblv. NOTE: Tighten the antenna nut, then tighten tha motor bracket nut.
23-1 9 6
Circuit Diagram
V
STEREO RADIO/ CASS€TIE PI-AYER
23-197
Clock Terminals
Replacement CAUTION: a Pry th6 clock out at th€ left sido, a Be carsful not to damage the clock and the dashboE d whon prying the clock out. 1.
Pry the clock out from the dashboard,then disconnect the 4-P connector. 4-P COI{NECTOR
CLOCK
Torminal A
Connecta to
Wiro
BLK YEL
Ground {Main clock power sup-
plv)
RED/BLK Lights-on signal D
23-198
Constantpower
WHT/BLU (Time memory)
Horn Component Location Index CAUTION: a All SRS €lectricsl wiring harnessesal€ covered with yellow insulation. a B€fore disconnecting any part of the SRS wiro harneaa, connect tho short connectol(sl. a Replacothe entire aftected SRS harnessassembly if it haa an open circuit ot damaged wiring.
HORN Test,page23'2O3
{Covo.ed wiih yollow insulationl
HORNSWITCHES Test, pago23-2Ol
<------\ -\----.....=
UNDER.DASH FUSE/RELAYBOX CABLE REEL Repfacement,page 23-302
HORN RELAY I Wiro coloB: BLU/RED,BLK, I IWHT/GRN, and BLU/GR l Test, page 23-68
23-199
Horn CircuitDiagram MTTERY
------------.,1
r-T-l lll-
l
I
l1'l
SHORT c0ill{EcToR L------------J
Wrthoutcrub6conlrol,
23-200
()
Switch Test CAUTION: a All SRS el6ctrical wiring harnossosare covarod with yellow inaulation. a Beforo disconnecting any pan ot the SRS wire harneaa, connoct ths short connector(s). a Roplacethe entil€ afloctod SRS harne$ a$6mbly if it has an open circuit or dsmagad wlring.
4.
Disconnect the cable reel harness 6-P connector from the SRSmain harness,then connect Test Harness C onlv to the cable reel harness. CABLEREEL HARNESS
NOTE; The originalradio has a coded theft protection circuit. Be sure to get the customer'scode numberbefore - disconnecting the battery. - removingthe No. 32 {7.5 A) fuse lrom the under-hood tuse/relavbox. - removingthe radio. After service, reconnect power to the radio and turn it on. Whenthe word "CODE" is displayed,enterthe customer's 5-digit code to restore radio operation. 1.
Disconnectthe battery negative cable, then disconnect the positivecable.
2.
Connectthe short connector(slto the airbag(sl. DRIVER'S AIRBAG
CABLEREEL 3.P CO NECTOR
TESTHAR ESSC oTLAz- SL/l{,3OO
5 . Check for continuity between the No, 3 terminal ot the 8-P connector of Test Harness C and body ground with the horn switch pressed. a lf there is continuity,the horn switch is OK. a lf there is no continuity, go to step 6. TESTHARNESS C OTLAZ-SI/I()3OO
DRIVER'S AIRBAG
3-PCO'TNECTOR COI{NECTOR {RED}
ACCESS PAI{EL
SHORT CONTIECTOR {REO}
Removethe dashboatdlower cover and kne€ bolster (see page 23-701.
(cont'd)
23-201
Horn Switch Test (cont'd) Check for continuity between the horn positive terminal and the steering column shaft with the horn switch pressed, There should be no continuity.
6 . Removethe two TORX@bolt6 using a TORX@T30 bit, then removethe driver's airbagassembly.
DB|vEN'S
HORNSwlTCH TERMIITAL POSITIVE
AIRBAGASSEMBLY
TORXO BOLT (U!6 s TORxo T3O bitl
a lf there is continuitv: - With cruise control: Test the set/resume switch. lJ the switch is OK, replacethe cable reel. - Without cluise control: Replacethe cable reel. a lJ there is no continuity. remove the steering wheel and the four screws, then remove the steering wheel cover. Replace the faulty horn switch. 8.
23-202
Reinstallthe steeringwheel {see section 17).
Horn Test t . Removethe front bumper (seepage 23-164). 2 . Disconn€ct the 2-P connector from the hofn. 5.
Remove the horn.
2-P COt{t{ECTOB
MOUNTI G AOLT
4.
Test the horn by connecting battery power to one terminsland groundingthe other, The horn should sound.
5.
Reolacethe horn if it fails to sound.
23-203
CigaretteLighter CircuitDiagtam
UNOER-HOOD FUSE/RELAY BOX
No.tgll0Al FUSE
UIIOER-DASH FUSE/N€[AY BOX
BI.K
G20t Gilol
23-204
Replacement CAUTIOI{: a All SRS sloctdcal wiring harnossasare covered whh yollow insulatlon. a B.tore disconnoctlng any part ot the SRS yyi16 h.rnosa, connrct tho short connoctot(al. a Rsplaco th. onti.e !ffoct.d SRS hamoss a$ombly lf It ha! an opon cilcuit or damagod wiring.
Disconnect the thermotuse case from the socket €no.
3 . Remove the thermal protector. and pull out the cigarette lighter socket. CIGARETTELIGHTEN LTGHT(1.4 Wt ASHTRAY LIGHT
( r . 4w l
FROI{TCO|{SOLE
THERMOFUSE CASE RI G NUT THERMALPAOTECTOR
Removethe two ashtray mountingscrews. Then pull out the ashtray from the front console, and disconnect the 4-P conn€ctor, SOCKET
4 . When installing the cigarette lighter, align each lug on the face panel, illuminationring, and cigarefte lighter socket with the groove of the hole, then position the bulb housing on the thermal protector between the stops in the console panel. Make sure that the ground wire, bulb socket, and thermofuse housingare seatedto the cigarette lighter assomblv.
scREws
23-205 .--
Rear Window Defogger Component Location Index CAUTION: a All SRS olectrical wi ng ham€$6s are covoled with y€llow insulation. B6foro disconnocting any part of ths SRS wire harness. connoct tho short connector(s). Roplacsthe ontire affectod SRS harness assombly if it has an open circuit or damagcd wiring.
REABWINDOW RELAY DEFOGGER Test,page23-68
SRS MAII{ HAR'{ESS REARWINDOW DEFOGGERSWITCH Removal, page 23-209 Test, page 23-2Og REARWINDOW DEFOGGER Test, page 23-210
UI{DER.DASHFUSE/RELAYBOX REARWINDOW DEFOGGERTIMER CIRCUIT {ln the integrated control unil) fnput Test, page 23-147
The rear window defoggeris controlledby the integratedcontrol unit, Pushingthe defoggerswitch in the instrument panel it sends a signalto the defoggertime. in the integratedcontrol unit, and the detoggerstays on tor 25 minutes or until the ignitionswitch is turned off. The indicatorlight in the switch comes on when the deJoggerworks.
23-206
UNDERHOOO FUSE,NE[AY 80X
B[K/GRN
I [ql
t=l BLK/GRN
I
trI
;ERI
NOISE CONDENSER
I'
I
8LK
I
I :
H.tchback:G77 Ssdan:G50
23-207
RearWindow Defogger Troubleshooting NOTE: The numbersin the table show the troubleshootingsequence. Item to be inspected
.E
o.-
9\
c g
*o-< f
o 0to
: E g o
@
oP
o
' Symptom Defoggerworks, but indicator light does not go on. Defogger does not work and indicatorlight does not go on.
lD
o!
o5 . E 6 ('r6
z i
z ) ;5
i i 9 c
o
5.
o o o o o
= 3 o ED o
o
o
o o-
g8 o o
o5 BLKTYEL oTBLU/YEL
1 1
2
2
Defogger does not work, but indicstorlight goes on. Defogger-ontime is too long or too short (normaloperationtime is 25 minutes).
!
=
1
4
2
G201 G401 '1i G771
YEL, BLUfYELor BLK/YEL BLU|YELor BLKIYEL
3 ',: G5O3 BLK/GRNoTBLKMHT
1 '1: Hatchback '2: Sedan
23-208 IINIilfi
Switch Removal
Switch Test
CAUTION: Be caroful not to damags the hoator contlol/centel ail vent.
NOTE: Be caretul not to damage the heate. control/centerair vent.
1, Carefully pry the switch out of the heater contfol/centerair vent.
1. Carefully pry the switch out of the heater control/center air vent.
2.
2.
Disconnectthe 6-P connecto,from the switch.
\
Checktor continuitybetweenthe terminalsacco.ding to the table. Torminal I
P*il*__\
PUSHED
ooo-
RETEASED
D \../ -\
-o o-
F
_o -o
/\ \:,,t
o-
/:\ \7
REARWINDOWDEFOGGER SWITCH
Remove the indicator bulb (turn the socket 45o counterclockwise),and removethe illuminationbulb. REARWINDOW DEFOGGERSWITCH
[-4
I ) ll:g'",li'T
to.a4wt
23-209
Rear Window Defogger DefoggerWires Repair
Function Test CAUTION: Be carelul not to scratch 01 damago ths defogger wires with th€ tsster probe. 1.
Check for voltage between the positiveterminal and body groundwith the ignitionswitch andthe delogger switch ON. There should be battery voltage. a lf -
NOTE: To make an eftective repair. the broken section must be no longerthan one inch. 1.
Lightly rub the area around the break with line steel wool, then clean it with alcohol.
2.
Carefullv mask above and below the broken portion of the defoggerwire with cellophanetape.
there is no voltage,check for laulty detoggerrelay. faulty defoggerswitch. faulty integratedcontrol unit. an open in the BLK/GRNwire
OPEN
a lJ there is baftery voltage, go to step 2.
NEGATIVETERMIiIAL
TERMINAL POSITIVE
Using a small brush,apply a heavy coat of silverconductive paint extendingabout 3 mm ( 1/8 inl on both sides of the break. Allow 30 minutesto dry. NOTE: Thoroughly mix the paint before use. Turn the rearwindow detoggerswitch OFF,Check for continuity between the negativeterminal and body ground. a It there is no continuity,checkto. an open in the defoggerground wire. a ll there is continuity,go to step 3. Touch the voltmeter positive lead to the halfway point of each defoggerwire, and the negativelead to the negativeterminal. Thereshouldbe apptoximately6 V with the ignition switch and defoggerswitch ON. a lf the voltageis as specified,the defoggerwire is OK. a lf the voltage is not as specified.repai,the defogger wire: lf it is more than 6 V, look for the damageon the negativehalf on the grid. - lf it is less than 6 V. iook for the damageon the positivehalf of the grid.
23-210
4.
Check for continuity in the repaired wire.
t
Apply a secondcoat of paint in the same way. Let it drv three hours betore removing the tape.
Moonroof GomponentLocationlndex a All SRS oloctrical wiring harnessesaro covared with yellow insulation, a Eoforo disconnocting any part of tho SRS wire harneaa, connoct th6 shon connector(sl. a Roplaceth6 entire 8ff6cted SRS harness assombly if it has an open circuit or damaged widng.
SRS MAIN HARI{ESS {Covered with yellow insulation)
MOO BOOFSWTTCH page23-214 Remov8l, Test, page 23-215
MOO ROOFMOTOR Test,pag€23-215 Replacoment, section20
23-211
Moonroof CircuitDiagram
- --------f"-----------lo
i|OoNRoOFMOf0R H.rchb.ckl
23-212 -
MoOnOoFttoton 6.ddl
ElectricalTroubleshooting NOTE: The numbers in the table show the troubleshooting sequence.
It€m to be insoected
es ( ! O
EE :
FE3
o
o
b 9 . o 6 ; g :
'r3
oiSE
<-c o 9
bE*
F 6
5 : 3
?t;
: - =
iE d
Symptom
-9 - . 9 :t<
o 6 6
z c 3 9
a 9 t c
dl=
3 E
.9
;o-
< €
E-
3tr € t \ f i
3 l .', l
ct
z )
t5 > l
g o
3E
o o
o
o o
o o
o o
o o o o
.:: a-g
o 6
Moonroof does not move, but motor tums. Moonroof does not move and motor does not tum lmoonroot can be moved with moonroof wrenchl.
In all switch positions With OPEN switch
with closE switch
a
1
4
5
G201 G401
WHT, GRN/BLK, GRN,BLK
I
2
GRN/REO
I
2
GRN/YEL
23-213
Moonroof FunctionTest CheckJor continuity between the No. 2 terminal and body ground.
Removethe dashboardlower cover, and if necessarv, removethe knee bolste..
a ll a lf 4.
there is no continuity,check for an ooen in the BLK wire. poor ground (G201, G4Ol). there is continuity,go to step 4.
Check tor voltagebetweenthe No. 4 terminal( + ) and No. 2 terminsl{ - ) with the ignitionswitch ON {ll). There should be battery voltage. a lf there is no baftery voltage, check tot - blown No. 1 (3o Al or No. 14 {20 A) fuse in the under-dashtuse/relay box. - an open in the wires (GRN/BLK,GRN,WHT) or loose terminals. - faulty moonroof relay. a lf there is battery voltage, go to step 5. Connectthe No. 4 terminalto the No. 3 terminal, and the No. 1 terminalto the No, 2 terminalwith jumper wires. The moonrootshouldopen when the ignition switch is turned ON (ll).
KNEEBOLSTER
DASHBOARD LOWER COVER
2.
Carefullypry the switch out of the left side air vent panel,then disconnectthe 4-P connectorto remove the switch.
4-P CONI{ECTOR
SWITCH MOOi{ROOF
. r - - r
l l l 2--t l f--T
l 3 1 4 l View from wire side
23-214
lf the moonroof ooens, check the moonroof switch, ll it doesn't open, removethe headlinetand check the motor.
Switch Test
Motor Test Removethe headliner(see section 20).
1, Removethe dashboardlower cover. 2.
Carefully pry the switch out of the left side air vent Danel, then disconnect the 4-P connector and remove the switch.
3.
Checklor continuitybetweenthe terminalsin each switch positionsccordingto the table,
Disconnect the 2-P connector from the moonroot moror. Checkthe motor by connectingpower and ground accordingto the table. NOTE: Motor clutch test is in section 20.
Torminal ---__\
\ P"ri i-
A
--o
G-
OFF
o- --o
OP€N
D
I
\ Condition
Te.minal -- ---------l
A
o
OPEN
G-
CLOSE
B
@
o- --o
CLOSE
SWITCH MOONROOF
lHatchblckl
(Scd!n)
View from terminalside
4.
I
OPEiI
It the motor fails to run or doesn't run smoothly. replaceit.
,l Ir\./ dcLos€
OFF
Y
23-215
PowerMirrors Component Location Index
POWERMIRRONS Test, page 23'220 Repfacement,page 23'221
POWERMIRRORSWITCH Function Test, page 23'219 Test, page 23-218
23-216
GircuitDiagram - HOOO FUSE/BELAY UNDER 8OX
*,,^.-**Q
!.,$iii.,i
LEFTT
---il;---;--------------;
ln
rI
G501 G502
23-217
Power Mirrors Switch Test Removethe driver's door panel (see section 2O). Checktor continuitvbetweenthe terminalsin each switch positionaccordingto the table.
Mirror Switch rermrnal
\
Position
J
\
OFF
G"
UP
o-
DOWN
UP
-o -o -o
o-
DOWN
G-
tEFT
-(J_
-o -o -o -o
G-
aaaaaaaa A-------+J
oo-
OFF
23-214
-o
o-
RIGHT
RIGHT
-<>-
o- -o
R
LEFT
-o
P -o
FunctionTest NOTE: To test, removethe driver's door panel (seesection 20), then disconnectall of the connectorsfrom the door oanel. View from wire side
Loft mirror inopsrative: Connectthe BLK/YELterminalof the 10-Pconnectorto the YEL/RED1 terminaland the YEL/WHT(or YEL/BLKr) terminalto body ground with jumper wires. The left mirror should tilt down (or swing leftl when you turn on the ignitionswitch. a lf the mirrordoes not tilt down (or does not swing leftl, check Jor an open in the YEL/WHT (or YEL/BLK1) wire betweenthe left miffor and the switch. It the wir€ is OK, check the left mirroractuator. a lf the mirro. neithertilts down nor swings left, repair the YEL/RED1wire between the left mirror and the switch. a lf the mirror operates properly, check the mirror swatch.
Right mirror inoporative: Connect the BLK/YELterminal of the 1O-Pconnector to th€ BLU/WHTterminaland the YEL/WHT{or BLU/BLK) terminalto body ground with iumper wires. The right mirrorshouldtilt down (or swing left) when you turn on the ignitionswitch. a lf the mirrordoes not tilt down (or does not swing left), removethe right door paneland checkfor an open in the YELMHT (or BLU/BLK)wire betweenthe right mirror and the switch. lf the wire is OK. checkthe right mtrroractualor. Miror Tost NOTE; Checkthe No. 13 (7.5 A) tuse in the under-dash fuse/relaybox beforetesting. Ono or both inop€rativa: 1.
Checkfor voltagebetweenthe BLKIrEL terminal8nd body ground with the ignitionswitch ON (ll). There should be battery voltage. a lf there is no voltage,check tor: - Blown No. 13 {7.5 A) fuse in the under-dash fuse/relav box - An ooen in the BLK/YELwire a It there is battery voltage, go to step 2.
2.
Checkfor continuitybetweenthe BLKterminaland body ground. There should be continuity;check Jor: - An ooen in the BLK wire - Poor ground (G501, G5O2)
a ll the mirror neither tilts down nor swings lelt, repair the BLUMHT wire between the right mirror and the switch. a lf the mirror operates properly, check the mirror swatch.
23-219
Power Mirrors Door MirrorTest 1,
Removethe mirror panel and door panel (Sed8n). then disconnect the 8-P (Hatchback)or 3-P (Sedan) connector from the power mirror actuator.
TILT: Terminal Position
Sedan:
'|(H)
2(G)
UP
@
I
DOWN
tJ
o
SWING: MIRNOR
Terminal Position
LEFT RIGHT
Hatchback:
Check actuator operation by connecting power and ground accordingto the table.
23-220
3.
2(G)
3(Ft
o (D
lf the mirror fsils to operate properly, replace it.
PowerMirror Replacement l.
Carefully pry out the miror panel with a llat tip screwdriv€r.
2 . Remove th€ door panel (see section 20). HEtchblck:
hca! hara to rolalaa lha conn9clor
MIRRORPA]IEL
CO
ECTOR
t
Disconnectthe 8-P (Hatchb€ck)or 3-P (Sedan)connector from thg oower mirror actuator.
4.
While holding the mirror with one hand, remove its mounting nuts (Hatchback) or mounting screws (Sedan) with the other.
23-221
PowerWindows ComponentLocationIndex
POWERWINDOWRELAY Test, page23-68
FOWERWINDOW MASTERSWITCH {Has built-in control unitl fnput Test, page 23-226, 228 Tost, page 23-229, 23O Ropfacement,page 23-231
UI{DER-DASH FUSE/RELAYBOX
WII{DOWSWITCH FRONTPASSEI{GER'S Test, page23-230 Repfacement. page 23-231 FRONTPASSENGER'S WII{DOWMOTOR fosr, page 23-232 RIGHTREARWll{DOWSWITCH(Sodrn} Tost, page23-230 page23-231 Replacement, RIGHT REARWII{DOW MOTOR (Sod.nl Test, page 23-232
DBIVER'SWINDOW MOTOR Test, page 23-232
LEFT REARWINDOW MOTOB {S6dan) Test. page 23-232
LEFT REAR Wlt{DOW SWITCH lsodanl Test, page 23-230 Repfacement,page 23-231
23-222
CircuitDiagram(Sedanl DASHFUSE/RELAY BOX UNDER_
UNOER-HOOO FUSE/RELAY 8OX
DRiVER'S WINOOW MOTOR
RIGHT REAN WINOOW MOTOR
LEFTREARWINDOW MOTOR
FROI{T PASSENGER'S
wrNoow i,roToR
G501 G502
G20r
G401
23-223
PowerWindows Circuit Diagram(Hatchback)
- HOODFUS€/REI.AY UNDER BOX
UNOEROASHFUSE]NEI.AY 8OX
tlo.41l100Al ilo.39{50A)
8LXz D PASSENGER'S
wrNDow swITcH
PASSENGEN'S wtN00wM0T0n
23-224
G50t G502
G401
Troubleshooting NOTE: The numbers in the table show the troubleshooting sequence
Item to be insoected o 1 0 x
9 I
3E <.i S H
r!
Symptom
o
(t
o SJ
i
N
@
t
t5
o
; o-
3 I
-g
z ) 9 c
o
.= '
,i
z
z
i
3
6
6
N
E !
F\
o
z
6
; z i
o
t
t o
qt
i o-
E 3 o
E 3
t o
o
o
o
;
; .= ;
E 3
t = ()
o
I a o-
o-
x .9
E 3
i
-
.E
3
: !
g 3 ' . c O E
All windows do not work.
G20r G401 G50l G502
Driver's window does not
I
4
Driver'swindow does not work in AUTO. Passengsr's Right tront windows do *Lett rear not work. r Right rea.
WHT/YEL BLU, BLK/WHT
1 1
5 I
5
BLK/YEL WHT/RED
BLUi BLK
3
4
GRN/BLK
2
4
YEL/BLK
23-225
PowerWindows Master Switch Input Test (Sedan) NOTE; The control unit is built into the Dowerwindow maste. switch, and onlv controlsdriver'sdoor window ooerations. 1. Removethe driver'sdoor paneland disconnectthe 16-P and 1-P connectorsfrom the master switch. 2.
Inspectthe connectorand socket terminalsto be sure they are all makinggood contact. a lf the terminalsare bent, looseor co.roded, reDair them as necessary.and techeckthe system. a It the terminalslook OK, make the following input tests at the connecto.. - It a test indicatesa problem,tind and correct the cause,then recheckthe system. - lf allthe input tests proveOK, the power window masterswitch must be faulty; replaceit.
BEDI'EL
8LU/YEL I
I GRN
YEL/BLK
View from wire side View lrom wire side
23-226
Test condition BLK2 ano BLK3
Under all conditions
WHT/YEL lgnitionswitch ON (lll BLU/BLK
T€st: Desirod rosult
Possibl€cause if result is not obtainad
Check for continuityto ground: . Poorground{c501, G502) . An openin the wire There should be continuitv, Check for voltageto ground: The.e should be battery voltage.
GRN/BLK
YEL/BLK
Blown No. 14 (20 Al fuse in the under-dashfuse/relaybox Bfown No. 5, 8, 7 ot 4 l2O Al fuse in the under-dashfuse/relay box Faulty power window relay An open in the wire
Connect the WHT/YEL and RED/YEL1 terminals, RED/BLU1 and the RED/BLU1 and ano BLK3terminalswith jumREDATELl per wires, then turn the ignitionswitch ON (lll.
Check the driver's window motor: It should run (the window moves down).
. Faulty drivea'swindow motor . An open in the wire
4
Connectthe BLU/BLK and BLU/GRNterminals, BLU/YEL and the BLU/YELand and BLK, terminalswith jumBLU/GRN per wires, then turn the ignitionswitch ON (ll).
Check the tront passenger's window motor: It should run {the window moves down).
. Faultyfront passenger'swindow motOa . An open in the wire
5
Connect the GRN/BLK and GRN terminals,and GRN/YEL the GRN/YELand 8LK, ano terminalswith iumper GRN wires, then turn the ignition switch ON (ll).
Check the left fear window motor: It should run (the window moves down).
Faulty left rear window motof Faulty lett rear window switch An oDenin the wire
6
Connectthe YEL/BLK and YEL/GRNterminals, YEL/GRN and the YEL and BLK, and terminalswith iumper YEL wires, then turn the ignition switch ON (ll).
Check the right rear window motor: It should run (the window moves down).
Faulty .ight rea. window motor Faulty right rear window switch An open in the wire
7
Connectthe WHT/YEL and RED/YEL1 terminals. BLU and the REo/BLU1and ano BLK3terminalswith jumBLK/VVHT per wires. then turn the ignitionswitch ON (ll).
Conned an analogohmmeterto te.minalsBLU and BLK/wHT: The meter needleshould move back and lorth alternatelvas the driver's window motor runs.
Faulty pulser Faultydriver's window motor An open in the wire
23-227
Power Windows MasterSwitch lnput Test (Hatchback) NOTE: The control unit is built into the power window master switch, and onlv controls driver's door window operations, 1. Removethe driver'sdoor panaland disconnectthe 1O-Pconnectol from the masterswitch. 2.
lnsDect the connector and socket terminals to be sure they are all makinggood contact. a lf the terminsls arc bent, loose or corroded,rspair them as necessary, and recheck the system. a lf the terminals look OK, make the following input tests at the connector terminals. - lf a test indicates a problem, find and correct the cause, then recheck the systsm. - lf all the input tests proveOK, the powsr window master switch must be faulty; replace it.
Wiro 1
BLK'
Tost condition
RED/YEL RED/BLU
BLU/GR'{
BLU/BLK
View from wirs sido
Tost: Dashodr€suh
PGslblo cluso if rosuh ir not obtalnad
Underall conditions
Ch€ck for continuity to ground: There should be continuity.
Poor ground (G501, G5O2) An oDen in the wire
lgnitionswitch ON {ll)
Ch6ck for voltags to ground: Th€re should be battery voltage.
Blown No. 14 l2O Al fuse in the under-dashfuso/relay box Blown No. 5, or No. 8 (2O A) tuse in the under-dashluse/relay box Faulty power window relay An oDen in the wire
8LK3 WHT/YEL
BLU/BLK Connectthe WHT/YEL and REDfYELIterminals, RED/BLU1 and the RED/BLU1 and ano BLK3terminalswith jumRED/YELI per wires, then turn the ignitionswitch ON {ll).
Check the driver's window motor: It should run (the window moves down).
. Faulty driver's window motor . An ooen in th€ wire
Check ths passengor's window motor: It should run (the window moves down).
. Faulty pass€nger's window motor . An oD€n in the wire
4
Connectthe BLU/BLK and BLU/GRNterminals, BLU/YEL and the BLUTYEL and and BLK2terminalswith jumBLU/GRN per wires, then turn the ignitionswitch ON {ll).
5
connect the WHTTYEL and BEDrYELIterminals, and the RED/BLU1 and BLK3terminalswith jumpe. wires, then turn the ignitionswitch ON (ll).
BLU anq BLKMHT
23-228
Conn€ct an analog ohmmeter to thE BLU ANd BLKMHT t€Tr minals: The meter needle should move back and torth alternately as th€ driver's window motor runs.
Faulty pulser Faultv driver's window motor An oDenin the wire
MasterSwitch Test (Sedan) 1.
Remove the driver's door pan6l (sse section 2O).
2.
Disconn€ct the 16-P and l-P connectors trom the switch.
3.
Check for continuity b€tw€€n tho terminals in each switch position according to the tables.
Front Paslongrr't Swltch: Terminal \
I Main \ Position I Swirch \ OFF
UP
DRIVER'S SWTCH
ON
o-
OFF
G--
ON OFF
LEFTREAR
MAtit swtTcH DOWN
POWERwl DOW MASTEBSW]TCH
Lcft Rear Swhch: Terminal \
j Main I Position I Switch \
swtTcH
OFF
ON OFF
RIGHT REAN SW|TCH
UP
ON ut'f
A B C D E
DOWN
O-
o-
ON OFF
PASSEI{GER'S
o
H
ON OFF
o- -_o E
r)
--o --o --o o- --o
o
F
o- o --o o- --o --o o--o o--o oo- --o G- --o -o
Rlght Roar Swhch: Teminal \
If I Main Position I Switch \ OFF
N
OFF
UP
OFF
Ddv.r't Swh.tr; Th6 driv€r's switch is combined with the cont.ol unit so you cannot isolatethe switch to t6st it. Instead , run the maater switch input test procedurss No. 1, 2. 3, and 7 on page 23-226. lf the tests are normal, th6 driver,s switch must be fsulty.
DOWN
ON OFF
o
0
o --o o- --o --o --o G_
ON
ot'l
--o
o-
---o
o-
o- --o G-
--o
o- -o
23-229
Power Windows Window Switch Test Passenger's
Master Switch Test (Hatchbackl 1 . Removethe drivef's door panel (seesection 201.
Front: 1 . Removethe passenger'sdoor panel {seesection 20).
Oisconnectthe 1O-Pconnectorfrom the switch. Checktor continuitybetweenthe terminalsin each switch positionaccordingto the table.
2.
Disconnectthe 5-P connectorfrom the switch.
3.
Checkfor continuitybetweenthe terminalsin each switch positionsccordingto the table.
pOWERWTNDOW PASSENGEB'S MASTERSWTTCH SWITCH
\
Torminal
il;_\
i 1 \ i
OFF
A
o-
\4r-I^l,r
)rvti\
--o o- --o
UP
G_
.Fi'ilj
Passengsl'r Switch: Te.minsl \
I Msin \ Position I Switch\ ON OFF OFF
UP
ON OFF
ON DOWN OFF
D
H
Rear (Sedanl: 1. Removethe inn€r handle (seesection 2O)' 2,
Disconnectthe 5-P connectorfrom the switch.
3.
Checkfor continuitybetweenthe terminalsin each switch position according to the table.
J
--o o- -o o-o- --o o- -o -o o--o o-o o-
o-
(J
\
Terminal
OFF
UP
D
I
;;__\
DOWN
23-230
--o
o- --o
DOWr.l
Drive.'s Switch: The driver'sswitch is combinedwith the controlunit so you cannotisolatethe switch to test it. Instead, run the masterswitch input test proceduresNo. 1, 2, 3, and 5 on page 23-228, lf the tests are normal, the d.ivet's switch must be faultv.
D
R
G_ G_
--o --o o-
o-
--o o- --o --o
o-
Master Switch Replacement
Passenger's Window Switch Replacement
Hatchback:
Flont:
1. Removethe driver's door panel (seesection 20).
1.
Removethe passenger'sdoor panel (seesection 201.
2.
Disconnectthe 1O-Pconnectorlrom the switch,
2.
Disconnectthe 5-P connectorfrom the switch.
3,
Removethe threemountingscrewsand the switch.
3.
Removethe two mountingscrews and the switch.
swtTcl{ Roar (S6danl: Sedan:
1.
Removethe inner handle(see section 20).
1. Removethe driver's door panel (seesection 2O).
2.
Disconnectthe 5-P connectorfrom the switch.
2.
Disconnectthe 16-P and 1-P connectorsfrom the switch.
3.
Removethe two mountingscrews and the switch.
3.
Removethe two mountingscrews and the switch.
w|I{Dow .swtTcH
POWERMIRROR
swtTcH
scREws
INNERHANDLE
23-231
Power Windows Window Motor Test Passenger's
Driver'sWindow Motor Test
Removethe passenger'sdoor panel (seesection 20).
Motor Test:
l.
1 . R e m o v et h e driver's door panel (seesection 20).
2 . Disconnectthe 2-P connectorfrom the motor.
2.
NOTE: a Frontpassenger'sdoor is symmetricaltodriver's ooor. a The illustrationshows the right reardoot, left rear door is svmmetrical.
Disconnectthe 4-P connectortrom the motor.
. ,-,.f,/ll/
NZJI I ..Q]qql,fiftl\ I $e /tE \
2.P CONNECTOR
View from lerminal side
4.P CONNECTOR 3.
Test the motor in each directionby connectingbattery power and ground accordingto the table. Terminal
\
(B)
Direction
B {A} View from terminalside
UP DOWN
@
O
3.
Test the motor in each direction by connecting battery power and ground accordingto the table. Terminal
\ O***
B
A
o
o
\
UP DOWN
@
{ }: Sodan CAUTION: When the motor stops running. disconnect one lead immediately. 4.
lf the motor does not run or tails to run smoothly, replaceit.
PulserTest: 5.
6-
Connectthe test leadsof an analogohmmeterto the C and D terminals. Runthe motor by connectingpower and groundto theAandBterminals, The ohmmeterneedleshouldmove back and torth alternately.
23-232 -'
CAUTION: When the motor stops tunning. disconnect on€ lead imm€diately. lf the motor does not run or Jailsto run smoothly, reDlaceit.
Power Door Locks Component Location Index
FRONTPASSENGER'S DOORKEY CYLII{DER SWITCH Test,page23-240 FRONTPASSENGER'SDOOR LOCK ACTUATOR Test. pago 23-239 Reolacement.section 20
RIGHT REAR DOOR LOCK ACTUATOR lsodanl Test, 23-239 LEFT REAR DOOR LOCK ACTUATOR {Sodan} Test, page 23-239
FRONTPASSENGER'S DOOR LOCK SWITCH fest, page 23-241
1 DOOR KEY CYLINDERSWITCH Test. page 23-24O
DBIVER'S LOCK ACTUATOR Test, page 23-238 Roplacement,seclion 20
DOOR LOCK SWITCH 'lest, page 23-241 POWEROOOR LOCK CONTROLUNIT fnput Tost, page 23-236
Description For this model, a new door lock system has been adopted to improve convenienceand safety. lf the kev is insened into the driver'sdoor key cylinder,turned to the unlock position,and pulledout immediatelythereafter,oNLy the driver.s door will unlock. However,if the key is kept in the unlock positiontor one secondor more, ALL doors wi unlock.
23-233
PowerDoorLocks CircuitDiagram FUSE/RELAY BOX UiIDER-HOOD BATTENY
No.41l100Al iJo,36l50A)
@'"t
DRIVER'S OOOB KEYCYI,INDER swITcH DRIVER'S
oooRrocK swtTcH
o00Rtoc( KN08
V
L____ I
FRONT PASSENGEN'S DOOR LOCK
OOOR POWER LOCKCONTROI.
swncH
FROMT PASSENGER'S
oooRt-ocK
ACIUATOR
@r
I uFt REAR 000RLocK ACTUATOR
@"
r RIGHT REAR 000RLocK ACTUATOR
@'
I
G501 G5o2
23-234 I
BLK
8rl(
8LK
.&
A -l
A
G201 G401
GSot G502
G501 G5o2
;
=
Troubleshooting NOTE: The numbersin the table show the troubleshootingsequence. Item io be inspected
;
= 3-
-9 -.9 )x<
.= 3
t
o o
3
: o o
St
c
o o
c
z ) It 9 c
Symptom
Doors don't lock or unlock with the driver's door lock switch.
All doors
Doors don't lock or unlock with the passenger'sdoot lock switch.
All doors
O n eo r more doors
One or more ooors
Doo.s don't lock or unlock with the driver's door lock knob.
All doors
Doo. don't lock o. unlock with the passenger'sdoot key.
All doors
Doors don't unlock wilh the driver's door key.
Oriver's ooor 'All doors
One or more ooors
o)
O E
o'o
dl=
Power door lock system doesn't ooerateat all.
9 E
c
;-s o
TL
o
o
(L
o-
G501 G502
1
G501 1
- c
WHT/GRN GRN/REDor GRN^/lr'HT
WHT/RED or YEL/RED
J
G 2 0 1 BLK/RED or G 4 0 1 BLK/WHT WHT/REDor YEL/RED
1
G501 G502
1
BLU/REDor BLU/WHT WHT/REDor YEL/RED
1
O n eo r more doors
2
5
G 2 0 1 L T G R No r G401 LT BLU WHT/RED or YEL/RED G501 G502
I
BRN,WHT/RED or YEL/RED
Gsol BRN,WHT/RED G502 or YEL/RED
+ It the system is working normally,€lldoorswill unlockwhen you holdthe door key in the unlockposition(kev cvlinder switch and door lock knob switch turned ON) for one secondor more.
23-235
Power Door Locks Control Unit Input Test Removethe driver's door panel {see section 2O). Disconnectthe 1+P connectorJromthe control unit. Inspectthe connectorand socket terminalsto be sure they are all makinggood contact. a It the terminalsare bent. loose or corroded,repair them as necessary.and recheckthe system. a lf the terminalslook OK. make the following input tests at the connector. - lf any test indicatesa problem,find and correct the cause,then recheckthe syslem. lf all the input tests proveOK, the controlunit must be faultv; replace it.
POWERDOORLOCK UNIT CONTROL
t4-P COI{NECTOR
View from wiro side
23-236
Disconnectthe 14-P connectorfrom the power door lock control unit. I{o.
Wire
I
BLK
Tost condltlon Under all conditions
Connectthe YEL/RED tarminal to the WHT/ GRN terminal,and the WHT/REOterminalto WHT/REDthe BLK terminsl momentarily. 2 and YEL/RED Connectthe WHT/RED terminal to the WHT/ GRNterminal,and the YEL/REDterminalto the BLK terminal momentarilv.
Test: Dosirsd rosult Check tor continuity to ground: There should be continuitv. Check door lock oDeration: All doors should unlock.
Possibls cause if rosult is not obtainod . Poor ground (G501, G502) . An open in the wire Faultv actuator An open in the wire Blown No. 6 (2O A) fuse in the under-dashfuse/relav box
Check door lock ooeration: All doors should lock.
Reconnecttho 14-Pconnectorto th6 powor door lock control unit. t{o.
Wlro
e
WHT/GRN
Tost: Dolir6d r6auh
Posslblo caus6 it rosuh is not obtainod . Blown No. 6 {2O A) fuse in the under-dashfuse/relay box . An open in the wire
Under all conditions
Check tor voltage to ground: There should be battsry voltage.
GRN/WHT
Driver's door lock switch in LOCK
Check for voltagg to ground: There should be I V or less.
GRN/RED
Driver's door lock switch in UNLOCK
Faultv driver's door lock switch Poor ground (G501, G5O2) An oDenin the wire
BLK/wHT
Right tront door lock switch in LOCK
Check for voltage to ground; There should bs 1 V or less.
BLK/RED
Right lront door lock switch in UNLOCK
Faulty front passenger's door lock switch Poor ground (G201, G4O1) An ooen in the wire
BLUMHT
Driver'sdoor lock knob Check for voltage to ground: in LOCK There should be 1 V or less.
BLU/RED
Driver'sdoor lock knob in UNLOCK
Faulty driver'sdoor lock actuator Poor ground (G501, G5O2) An ooen in the wire
4
I
6
7
Tost condition
Driver'sdoor key cylinderin UNLOCK
Check for voltage to ground: There should be 1 V or less as the switch is turned.
Faulty d,iver's door key cylinder switch Poor ground {G501, G5O2l An open in the wire
LT BLU
Front passenge.'sdoot key cylinderin LOCK
LT GRN
Front passenger'sdoor key cylinderin UNLOCK
Check for voltageto ground: There should be 1 V or less as the switch is turned.
Faulty tront passenger's door cylinde.switch Poo. ground (G201, G401) An oDen in the wire
BRN
I
CAUTION: To provonl damago to tho molor, rpply battory voltago only momrntadly.
23-237
Power Door Locks Driver'sDoor Lock Actuator Test 1 . Removethe door panel (seesection 20).
5.
Check fo. continuity between the terminals in each switch positionaccordingto the table.
Disconnectthe 6-P connectorfrom the actuator.
\
Terminal
LOCK UNLOCK
DOORLOCKKI{OB
Checkactuatoroperationby connectingpower and ground accordingto lhe table.
Terminal ---\
\
D
;;"
LOCK UNLOCK
@
o
lJ
@
CAUTION: To prevont damagolo tho actualol, apply battery voltage only momentarily. lf the actualor fails to work properly,replaceit.
23-238
I
il;----t o
o o-
-o
Passenger'sDoor Lock Actuator Test 1.
Removethe door panel (seesection s 20).
Rear Passenger's Dool:
2.
Disconnectthe 2-P connector r from the actuator.
NOTE: Left rear actuato, is shown, right rear actuator is similar.
Front Passonger's Door:
terminalside
View from terminalside Checkactuatoroperationby connectingpower and ground accordingto the table.
Terminal
\
B Position
2-P CONNECTOR
\
LOCK UNLOCK
ACTUATOR
@
@ ,-,
CAUTION: To prevent damageto the actuator, apply battery voltage only momentarily.
4.
It the actuatorfails to work properly,replaceit.
23-239
Power Door Locks DoorKeyGylindet FrontPassenger's Switch Test
Driver's Dool Key Cylinder Switch Test 1.
Removethe door panel (see section 20).
1. Removethe door Danel{see section 2O).
2.
Disconnectthe 2-P connectorfrom the switch.
2.
Disconnectthe 3-P connectortrom the switch. FRONT PASSENGER'S DOOB KEY CYLINDER
swtTcH
coN ECIOR
terminalside
3.
Checkfor continuitybetweenthe terminalsin each switch positionaccordingto the table.
Terminal
B
Position
G
UNLOCK
o
3.
\
Check tor continuitv between the terminals in each switch position according to the table.
Terminal
P""ft;---l LOCK
A
B
----o
o
OFF
OFF
o
UNLOCK
UNLOCK
<
UNLOCK -r--O
I
I LOCK
tfil*rr
23-240
c
----o
Door Lock Switch Test 1. Removethe insidehandle.
Disconnectthe 3-P connectorfrom the switch. Checkfor continuitybetweenthe terminalsin each switch positionaccordingto the table.
termtnal
\ Position
LOCK
n
\
o
c
o
OFF
UNLOCK
o
23-241
CruiseControl Component Location Index a All SRS 6l6ctrical wiring harnessosaro covorod with yallow insulation, a Bofo.6 disconnecting any part of th6 SRS wire harness, connoct th€ shon conneclor(s). a Replacothe ontiro affected SRS halness assombly if it has an op€n circuit or damagod widng.
SRS MAIN HARNESS (Cov.rod wilh yollow In.ulation)
MAINSWITCH Test, page23-250 page23-250 Replacement,
CRUISELIGHT (Builtinto gaugeassembly) Bulb Locations,page 23-115
SET/RESUME SWITCH Test. page23-248 page23-248 Repfacemont,
BRAKE SWITCH Test. page 23-251 CLUTCH SWITCH (M/TI Test, page 23-251 CRUISECONTROL fnput Test, page 23-246
23-242
A/T GEAR POSITIOI{
swtTcH
Test, page 23-136, 252
ACTUATORASSEMBLY Test,page23-253 CableAdjustment, page23-253
23-243
CruiseGontrol CircuitDiagram + No.24 onoine ll5Al:81881 No.24 ensine l20Al:818C1 _HOODFUSE/RELAY BOX UNOER
FUSE/RELAY BOX UNDER-DASH
No.4l(100A)No.39l50A)
HORN
Y INDICATOR TIGHT {0,91W}
IP
I D Suur
PNK
BTK
II I
f7 VEHICLE SPEED SENSOR iVSS)
6yffi
M/r : CLUTCH SWITCHI A/T: A/TGEAR I POS|T|oN SWTTCH I
Bi,G#,,'.
InIEI,E)
T
t
G201 G401
G201 G401
BI-K
23-244
I
-
Troubleshooting NOTE: a The numbersin the table show the troubleshootingsequence. a Beforetroubleshooting, - check the No.15 {10 A) and *No. 24 fuses in the under-dashfuse/relaybox, and the No.41 (1OOA), No.39 (50 A). and No.42 (20 Al fuses in the under-hoodfuse/relavbox. - check that the horn sounds. check the tachometerto see if it wo.ks pfoperly. *No.24 {15A): Bl8B1engine N o . 2 4 { 2 OA } : 8 1 8 C 1 e n g i n e Item to be inspected !
F o) 'F c f
E ;
c
I
U)
3
.!o
F
-c. !
Symptom
a a
F
oi
f
E c
3 .9 :
'.E
B
I
_q E
dl
.9
_9
^
E .E o
f
2 '9o1 E
l L
og BLU/GBN,LT GRN/RED.
Cruisecontrol cannot be set.
1
G301, BLU, BLK/YEL,LT GRN, G201, GRY, ORN. BRN/WHT, G401
3
BRN/BLK,BRN/REDor PNK
Cruisecontrol can be set, but indicatorlight does not go on.
2
Cruisespeed is noticeablyhigher or lower than what was set.
I
Excessiveovershootjngor undershootingwhen trying to set speed
2
Steady speed is not held even on a flat road with cruisecontrol set.
LT GRN/BLK LT GRN/RED
,1
Set sDeed is not cancelled when shift lever is moved to fM tnnt.
I
Set speed is not cancelledwhen brake pedal is pushed.
Set speed is not resumedwhen RESUMEbutton is pushed(with main switch on, but set speed temporarilycancelled).
3 2
Set sDeedis not cancelledwhen clutch Dedalis oushed(M/Tl.
Set speed is not cancelledwhen main switch is pushedOFF.
3
I
2
Car does not decelerateor accelerateaccordinglywhen SET or RESUMEbutton is pushed.
G201, YEL or RED/BLU G401
'I
2 2
1
LT GRN/BLK LT GRN/RED
23-245
CruiseControl ControlUnit Input Test CAUTION: a All SRS olectrical wi ng harnessosare covored with yellow insulation. a Botore disconnecting any part of th6 SRS wire harneaa, connect the short connoctor(sl. a Roplacethe €ntir€ affectod SRS hamass assembly il il has an opan circuit or damaged wifng. 1,
Removethe dashboardlower cover and knee bolster (see page 23-70).
2.
Disconnectthe 14-Pconnectortrom the control unit. Insoectthe connectorand socket terminalsto be sure they are all makinggood contact. a lf the terminalsare bent, loose or corroded,repair them as necessary,and recheckthe system. a It the terminalslook OK, make the following inDut tests at the connector. - It any test indicatesa problem,find and correct the cause.then recheckthe svstem. - lf allthe input tesls proveOK, the controlunit must be faulty; replaceit.
SRS MAIN HARNESS
CRUISECONTROLUNIT 14-P COI{NECTOR
Viow from wire side
23-246
tlo.
Wlfe
I
BLK
2
BLKryEL
5
4
Tost condition
lgnitionswitch ON (ll)
Check for voltage to ground: There should be battery voltage.
LT GRN
lgnition switch ON (ll) and main switch ON
Check for voltageto ground: There should be battery volt€ge.
GRY
lgnitionswitch ON lll), main switch ON and brake pedal pushed, then released
Check for voltageto g,ound; There should be O V with the pedal pushedand battery voltage with the pedal released,
Brakepedal push€d, then r€leased
Check tof voltage to ground: There should be battery voltage with the pedal pushed,and O V with the Dedalreleased.
Blown No. 42 l2O Al tuse in the under-hood fuse/relay box Faulty brake switch An open in the wire
lgnitionswitch ON (ll)
Connectto ground; Indicator light in the gauge assembly comes on.
Blown bulb B l o w nN o . 1 5 ( 1 0 A ) f u s e i n t h e under-dashfuse/relaybox Faulty dimmingcircuit in the gauge assembly An open in the wire
Check for voltageto ground: There should be battery voltage.
Faulty SET/RESUME switch Faultycable reel An open in the wire
MT/: Clurch pedal released A/T: Shift l€ver in -[Zl,
Check for continuityto ground: There should be continuity. NOTE:There should be no continuity when the clutch pedal is depressed or when the shift lever is in other positions.
Faulty or misadiustedclutch switch (M/T) Faulty A/T gear position switch (A/T) Poor ground (G201,G4O1) An open in the wire
Start the engine.
Chsck for voltageto ground: There should be battery voltage.
lgnitionswitch ON (ll) and main switch ON; rsise the front of the car, rotat€ one wheel slowly.
Check Jor voltage between the ORN @ and BLK O terminals: There should be O- about 1 0 V - O - a b o u t 1 OV repeatedly.
RED/BLU
7
LT GRN/ RESUME button pushed BLK
6
LT GRN/ RED
11
. P o o rg r o u n d( G 2 0 1 ,G 4 0 1 1 . An open in the wire . Blown rNo. 24 fuse in the underdash fuse/relay box . An open in the wire . Faulty main switch . An open in the wire . Faulty brakeswitch . An open in the wire
Check for continuityto ground: There should be continuitv.
6
10
Possibl6caus€ it losult is not obtained
Under all conditions
GRN/wHT
q
Tost: Desired rosult
PNK
BLU
ORN
SET button pushed
lD:I,orlE.l
. Faulty ignitionsystem or ECM . An open in the wire . Faulty vehiclespeed sensor(VSSI . An oDen in the wire
'12 8RN/WHT Connect battery power
Check the sound of the actuator motor: You should hear the motor runningsmoothly.
. Faulty actuator . An opsn in the wire
Connect battery power 1 4 BRN/RED to the BRN/RED terminal. *No. 24 (15 Al: 81881 engine N o . 2 4 l 2 OA ) : 8 1 8 C 1e n g i n e
Check the operation of the magnetic clutch: Clutch should click and output link should be locked.
Faulty actuator An open in the wire Poor ground (G3O1)
to the BRN/WHT terminaland ground to 1 3 BRN/BLK the BRN/BLKterminal.
23-247
CruiseGontrol Set/ResumeSwitch Test/Replacement CAUTION: a All SRS ol6ct cal widng herne$a3 err covorod with y6llow insulation. a Bototo disconnecting any part ot tho SRS wiro h8rn6sa, connoct tho ghort connector(sl, a Rsplacothe antire aftected SRS harness arsombly if it has an op6n chcuit or damagod wiring.
SRS MAIN HARNESS
NOTE: The original radio has a coded theft protection circuit, Be sureto get the customer'scode numberbefor€ - disconnectingthe battery. - removingthe No. 32 (7.5 A) fuse from the under-hood fuse/relay box. - removingthe radio. Afte, service, reconnect power to the radio and turn it on. Whenthe word "CODE" is displayed,enterthe customer's s-digit code to restore radio op€ration. 1.
Disconnectthe battery negativecable, then disconnect the Dositive cable.
2.
Connectthe short connector(s)to the airbag(s).
DRIVER'S AIRBAG 3-P CONNECTOR
23-248
SHORT CON]TECTON (REDI
ACCESS PANEL
3.
Removethe dashboardlower cover and knee bolster (seepage 23-70).
4.
Oisconnectthe cable reel harness6-P connector from the SRSmain harness,then connectTest HarnessC onlv to the cablereelside of 6-P connector.
CABLE REEL CONNECTOR lHlrnoa! Eidol
5.
Check lor continuity between the terminals of Test HarnessC in each switch positionaccordingto the table.
Terminal Position
SETIONI RESUME {ONI
7.
Remove the two screws and remove the switch.
8.
Check lor continuitv between the terminals in each switch positionaccordingto the table.
2
o- ---o ---o o-
a lf there is continuity, the switch is OK. a lf there is no continuity, go to step 6. 6,
Remove the cover carefully by prying between the cover and the switch in the sequenceshown.
\
Tominal
A
A'
B
Position OFF SFT(ON) RESUME ION)
\_r-
oo-
-o ---o
a lf there is no continuity in any position, rsplace the switch, CRUISE CONTROL SET-RESUME
swtTcHcovEF
a lf thsre is continuity in every position, replacethe cable reel (see psge 23-302).
23-249
CruiseGontrol Main Switch Test/Replacement NOTE: Be carefulnot to damagethe switch and the instrument oanel. 1.
Removethe instrumentpaneltrom the dashboard (see page 23-1 18).
2.
Removethe switch from the dashboard,then disconnect the 5-P connecto,.
3.
\
Ch6ck for continuity betwo€n the terminals in each switch position according to the table.
Tenninrl A
B
D
P".ii";--\
-o o-
OFF A
ON
/a A
\7
-o
a lf thera is no continuity in any position, replace th€ switch.
A
y' ucsr rxorcaToR UCI{T [ ()
to.grwl \ 7 lo.grwl
E
A B C D E
23-250
BrakeSwitch Test '1.
2.
GlutchSwitch Test (M/T)
Disconnectthe 4-P connectorfrom the switch.
I
Checkfor continuitvbetweenthe terminalsaccording to the table. 2.
Terminal
\
Disconnectthe 2-P connectorfrom the switch,
B
il"*on---\ BELEASED PUSHED
Check{or continuitvbetweenthe terminalsaccording to the table.
o-
-o
--o
\
| ormtnal
Clutchpodal
RELEASED
\
o
o
PUSHED 3.
It necessary,replacethe switch or adjust pedal height {see section 19).
3.
lf necessary,replace the switch or adjust pedal height (seesection 12).
23-251
I
CruiseControl A/T GearPositionSwitch Test 1 . Removethe center console,then disconnectthe 14-P connectortrom the switch.
View trom terminal side A
B
H
I
C
D
E
F
G
Checkfor continuitvbetweenthe terminalsin each switch positionaccordingto the table. NOTE: a Move the lever back and forth at each position without touchingthe button, and check for continuity within the rangeof free play ot the shift lever. a ll there is no continuitywithin the rangeof free play, adjustthe installationposition of the switch.
J
K
L
M
A/T Gear Position Swhch (For cruis€ control) \
Terminal
il;---t tr a E lu4l
N
B E
23-252
o o o
3.
---o
lf necessary,replacethe switch (seesection 13).
Actuator AssemblyTest
Actuator CableAdjustment
1 . Disconnect the 4-P connector from the actuator.
Check that the actuator cable operaressmoothtv without bindingor sticking.
2 . Check that the output linkage moves smoothly.
Start the engineand warm it up to normaloperating temperature(radiatorfans come on twicel,
3 . Connect battery power to the D terminaland ground to the A terminal,
Measurehow far the output linkage moves from the fully closedposition.Freeplay shouldbe 1 1 1 1.5 mm (O.43 I 0.06 in). ACTUATOR
FREEPLAY: 1 1 I 1.5 mm (0.43 r 0.06 int
FULLYCLOSED POSITION 4.
Check for I clickingsound trom the magneticclutch, and that the output linkage is locked. lf the outDut linkageis not locked, replacethe actuator asssmblv.
4.
Check the operation oJ the actuator motor in each output linkago position according to the table (you should be able to hear the motor). Battery polarities
o
Output linkage position
lf the free play is not within specs,loosenthe locknut and turn the adjustingnut as required. NOTE: lf necessary,checkthe throttlecontrolsystem {seesection 1 I }, then recheckthe output linkage free play.
5.
Retightenthe locknut and recheckthe free play.
FULLY M I D D L E FULLY CLOSED POStTtON OPEN The
B Terminal Terminal molor runs.
The molor runs.
The molor srops.
The I Terminal Terminal motor stops.
The motor runs.
The motor runs.
FULLY CLOSED
23-253
Wipers/Washers Component Location Index WINDOW WII{DSHIELD/REAR SWITCH WIPERAA'ASHEB Test,page23-258 Replacement, oase23 257_.. wtNosHlELDWIPER ARMS/BLADES ___-=4, Repfacemont, Page23'261 /tt'
2 /
WINOSHIELD IVIPERMOTOR Test, page23-260 paee23-281 Repfacement,
FUSE/RELAY BOX
INTERMITTENTWIPER BELAY CIRCUIT (ln the int€gral.d control onitl Input Test, page 23-146 REARWII{DOW WIPERMOTOR Test, page 23-262 pago 23-263 Replacemont,
23-254
Circuit Diagram UNOERDASH FUSE/RELAY BOX
- HOOO UNOER FUSENEUY 8OX
WHT/ll-X-FWHr
GRX/4X WII{DSHI€ID WIPERAIVASHER S1VITCH
si 4.t,,1/'i;",ry)"'.,
8tK
REAR WINOOW WIPER MOTOR
REARWINOOW WIPER/WASHER
swtTcH
l*_
(ittwA!
Y
Mor
8LK
BLK
REAR wtN00w WASHER MOTOR
|-
8LK
BLK
I
{
G30l
G20r
G101
G503
G20'I G401
G30l
. : whh comtinadwchar-wllbr olrnlirn
23-255 ,r-
Wipers/Washers Troubleshooting NOTE: The numbersin the table show the troubleshootingsequence Item to be insDected
6 i
0, (t
'96 ;5
a.P
>; e b
bE
: 6
rD! otD
t €3
r!
o
z )
3
it
o
;
E
E ID
i 5
o .
i
d
cqt =Y.
E P
3 3
.45
o o
z
.9! O
o
:!
O
ot
E r o c
o o o-
- c o o
;
4
2
ln INT
I
3
YEL/BLU,8LU/GRN
In LO or Hl
1
2
BLU,BLU/YEL
ln MIST
1
BLU/YEL
a
GRN/BLK,GRN LT GRN/BLK
ln all positions
Rear window wiper does not work.
GRN/BLK I
1
Blades do not return to park position when the switch is turned OFF. Intermittent cycle is erratic or wipers do not work intermiftently. Little or no washer fluid is pumped. WiDersnd washer do not work at the same time.
23-256
;E
E
o
=
Symptom
Wipers do not
i=
o
o o-;i
G301, G401
2
G503, G751
BLU/wHT, LT GRN/BLK
I
BLU/GRN YEL/BLU. 2
1
4
?
1
G301
2 1
BLU/BLK BLK/GRN, BLK/GRN
Wipers/WashersSwitch Replacement Disconnectthe 8-P and 6-p connectorsfrom the switch.
a All SRS electrical wiring harnessesale covered with yellow insulation. a Belorodisconnectingthe SRSwif6 harnoss,installthe short connector(sl. a R€placethe entire atlscted SRS hamess assombly il it ha6 an open citcuii ot damaged wiring.
Removethe two sctews and the switch. wIPERS^IITASHEBS SWtTCl.t
A-P CONNECTOR
4.
6-P CONNECTOR
Install in the reverse order of removal.
Removethe steeringcolumn covers.
UPPERCOVER
23-257
Wipers/Washers Switch Test Wipers/Washers CAUTION: a All SRS electrical wiring harn6ss6salo covered with yellow insulation. a Belore dkconnecting any part ot th6 SRS wire harneaa. connect the short connoctor(sl. a Replac6the 6ntire affoctod SRS harnessassembly it it has an open cilcuit 01 damaged wiring. 1.
Removethe steeringcolumn covers.
2.
Disconnectthe 8-P and 6-P connectorsJrom the swatch.
5
It necessary,removethe two screws and the switch.
4
Checkfor continuitvbetweenthe terminalsin each switch positionaccordingto the table. SRS iIAIN HARNESS {Covor.d rvilh yollow inrulation}
I
scREws
23-258
J
K
A
B
C
D
Windshield WiperAi\laEhelSwitch D
'w*+t+*i' 4l ?u Io"/j^o-"-
1
_J
l=f,.
M|ST
M|ST
OFF/INT
E B
\
Terminal
c
il;----__\ o-
OFF
INT
o-
LO
G-
D
Mistswitch"ON' Washer switch"0N"
n
---o
o- *--o
---o *-o --o ---o
o-
HI
E
G--
---o
o-
R6ar Window Wip€r/Washol Switch I
L
I
I
,i1..___.______,x..
fr."ql|.fr tiT rermrnal
\ Position
L \
Washer switch"0N" OFF
ON Washer switch"ON" (withwiDer'0N")
o- ---o o- -*o --o o---o o-
N
o- ---o o- ---o
23-259
Wipers/Washers Windshield Wiper Motor Test Open the hood and remove the cap nuts and the wiper arms (see page 23-261). NOTE: Removethe wiper arms carefullywithout damagingthe hood. Removethe hood seal and air scoop by prying out their trim clips.
A SLUTYEL} D IGB /BLK)
B (BLUI
Disconnectthe 5-P connectorfrom the windshield wiper motor. Test the motor by connectingbattery power and ground accordingto the table. \
Terminal
Pi"i,i""---\
B D {GRN/BLK) {8LU)
LOW SPEED
@
H I G HS P E E D
@
(BLU/YEL}
Reconnectthe 5-P connector to the wiper motor assembly. Connect an analog voltmeter between the E {BLU/wHT)and the C (BLK)terminals.Runthe motor by turning the wipet switch ON (LO or Hl position). The voltmeter should alternately indicate O V and more than 4 V. NOTE: Use an analogtester.
lf the motor does not run or fails to run smoothly, replacerr.
23-260
Windshield Wiper Motor Replacement Openthe hood and removethe cap nuts and wipel atms.
o.
Separatethe wiper linkageand crank arm at thejoint. Removethe three mounting bolts and wipet motor.
NOTE: Removeth€ wiper arms carefullywithout damagingthe hood. MOUNTII{G BOLTS 9.8 N.m (1.0 kgm.l,7.2 lbI.ftl
Remove the hood seal and air scoop by prying out their trim clios.
Disconnect the 5-P connector trom the windshield wiDer motor.
8.
Installin the reverseorder of removal.
Removethe four mounting bolts and wiper linkage assembly. Removethe wiper harn€ssfrom the wipe. linkage.
23-261 Irflnfi]
Wipers/Washers -Keal I esr wlper |Yloror Motor Test wlnqow Wiper Rear Window 1.
Disconnectthe 4-P connectorfrom the wiper motor.
lf the moto. does not run or fails to tun smoothly, replaceit. 4.
Reconnectthe 4-P connectorto the wipet motor assembly. Connect an analog voltmeter between the D (LT GRN/BLKIand B (BLK)terminals.Run the motor by turning the wiper switch ON. The voltmeter shouldslternatelyindicateO V and more than 4 V. NOT€: Use an analogtester.
4-P CONNECTOR
A (GBN/BLK)
C IGRNI
Viewtrom terminal side
2.
Test the motor by connectingbatterypower to the A (GRN/BLK) and groundto the C (GRN)terminals. The motor should run smoothly.
C (GRI{}
23-262
Rear Window Wiper Motor Replacement
Washer Motor Test
1 . Removethe cover, mounting nut, and wiper arm.
l.
Removethe front bumper (see section 20).
Removethe rubberseal, specialnut, and washer.
2.
Disconnectthe 2-P connector lrom the washer motor.
RESERVOIR
MOUNTINGNUT 14 N.m 11.4 kgf.m, 10 tbt.trl WIPERARM RUBBERSEAL SPECIALNUT 8.8 N.m {0.9 kgt'n, 6.5 rbt.fr)
Openthe tailgate and removethe tailgatetrim panels (seesection 20). Disconnectthe 4-P connectorfrom the wiper motor. Removethe threemountingboltsand the wiper motor assembly. MOUNTING BOLTS 9.8 N.m (1.O kgf.m, 7.2 lbf.ttl
6,
-4 )
WINDSHIELD
REAR
wrNDow Test the motor by connectingbatterypower to the A ( + ) terminaland ground to the B (- ) terminal. a ll the motor does not run or fails to run smoothly, replaceit. a lf the motor runssmoothly,but littleor no washer fluid is pumped.check for a disconnectedor blockedwasherhose, or a cloggedpump outlet in the motor.
Installin the reverseorder o{ removal.
23-263
Wipers/Washers Washer Replacement 1 . Bemovethe Jront bumper (seesection 2Ol. Removethe left lront inner fender. Disconnectthe 2-P connectorand hose from the washer motor. Removethe three mountingbohs and the washer reservorr. 5 . Removethe washer motor from the reservoir. 6.
Removethe windshieldwiper arms and air scoop (see page 23-261). Then removethe washer nozzles and hoses.
7 . lnstall in the reverseorder of removal. NOTE: a Take care not to pinch the hosesduring installation. a Installthe clips tirmly. a After installing,adjust the aim of the washer nozztes.
WINDSHIELD WASHER NOZZLE
n V
..,.,,@
lH (
n
MOUNTING BOLTS 9.8 N.m {1.O kgf.m, 7.2 lbf.ftl
23-264
REAR wtt{Dow WASHER t{ozzLE
SupplementalRestraintSystem
(sRst
GomponentLocationIndex.................. 23-266 Description ..23-267 Circuit Diagram 23-268 Wiring Locations 23-270 Precautions/Procedures ..23-271 Troubfeshooting ............. ..23-276 AirbagAssembly Repfacement .................. 23-295 Disposal ....23-299 CableReel Replacement .................. 23-301 DashSensor Replacement .................. 23-305 SRSUnit Replacement .................. 23-307
SupplementalRestraintSystem(SRS) ComponentLocirtionIndex SRSINDICATORLIGHT (ln th6 gaug6 assembly) page23-276 Troubleshooting, Gaugeassembly,page23-113 CABLEREEL Replacement, page23-301
To CRUISECONTROL SET/RESUMESWITCH
AIRBAG page23.295 Beplacement,
UNDER.DASH BOX FUSE/RELAY FRONTPASSENGER'S AIRBAG lExceptCanadsRS model) page23-295 Replacement, page23'299 Disposal,
RIGHTDASHSENSOR page23-305 Replacement,
LEFTDASHSENSOR R e p l a c e m e n t ,p a g e 2 3 - 3 0 5
SRSMAIN HARNESSFRONTPASSENGER'S AIREAG BRANCHlExc€ptCaned. RS modol)
SRSUNIT (lncludingcowl sensorl Replacement,page23-307
23-266
Supplemental RestraintSystem(SRSI CircuitDiagram(WithoutFrontPassenger's Airbagl SRSINOICATOR CIRCUIT {lnth€glug€sssombv}
r---r n r t l
ill SADHUNOER_ HOOD DRIVER'S FUSE/ AIRBAG RELAY INFLATOR 80x
SAOC BUC GNO
o a a @ o a a @ a @ a @
rDc @ MI
23-268
@
a a
GircuitDiagram(With FrontPassenger's Airbagl UNOE8DASH FUSSRELAY BOX
SRSINOICATOF CIRCUIT lln lh6 grugo.$.mblyl
I I I
I n I ll I tl t U I SADH
UNDER HOOD FUSE/ REI.AY
80x
DRIVER'S AIREAG INFI.A]OR
o @ o
FROI.IT PASSENGER'S AIREAG INFLATOR
@ @
a a @ a @ a
@ @ @
a a SRSUNITl8-P COI'INECTOR
23-269
SupplementalRestraintSystem (SRSI Wiring Locations CAUnON:Makesureall SRSgroundlocrtion3lrc clrln rnd ground3tra |.curalv rltachad. NOTE: withysllowinsulation. arecovered o AltSRSelectricsl wiringharnesses . RsDlace the entireaffectedSRSharnessassemblyif it hasan opencircuitor damagedwiring. CABIEREELto DdrrEFS AnaAC 3+ OOI{iECTOR DASHBOARDWIRE HARNEi9 to INDICATOBUGHT in GAUGE ASSEMBLY 5-PCONNECTOB
SRS MAIN HARNESStO MAIN WIREHARNESS +P OONNECTOR
aFs irA[t H^RiEss Ana G to FROiITPASSEMIEFS 3t coftf'Eclon C.
b Ra nod.ll
SRSMAINHARNESS to UNDER-DASH FUSE/RELAY BOX 2"P@NNECTOR
MAIN WIREHARNESS to DASHBOARDWIRE HARNESS lGP CONNECTOR
SBS MAIN HARNESSto LEFTDASHSENSOR 2.P CONNECTOA
23-270
SnS Alt{ ll^ntc8s to
o sHSErson
2+ OOt{tlEcT()R
GeneralPrecautions Carefullyinspectany SRSpart beforeyou installit. D o n o t i n s t a l la n y p a r t t h a t s h o w s s i g n s o f b e i n g droppedor improperlyhandled,suchas dents,cracks or deformation: -
Airbagassembly{driver'sand front passenger's) Dashsensors Cablereel S R Su n i t
Airbag Handlingand Storage Do not try to disassemble the airbagassembly.lt has no serviceableparts. Once an airbag has been operated (deployed), it cannotbe repairedor reuseo. F o r t e m p o r a r ys t o r a g eo f t h e a i r b a ga s s e m b l yd u r i n g service,pleaseobservethe followingprecautions: .
Storethe removedairbagassemblywith the pad surfaceup.
It the airbag is impropsrty stored facs !@ down, accidentaldeployment could propel the unit with enough force to causesetious iniury
Use only a digital multimeterto checkthe system.lf it's not a Hondamultimetermakesure its output is 10 mA (0.01A) or less when switchedto the smallest value in the ohmmeterrange.A testerwith a higher outputcould damagethe airbagcircuitor causeacci dentaldeploymentand possibleinjury. Do not installusedSRSpartsfrom anothercar.When makingSRSrepai.s,useonly new pans. E x c e p tw h e n p e r f o r m i n ge l e c t r i c a il n s p e c t i o n s , alwaysdisconnectboth the negativecable and positive cableat the batterybeforebeginningwork. R e p l a c e m e n to f t h e c o m b i n a t i o n l i g h t a n d wiper/washerswitchesand cruisecontrol switchcan be donewithout removingthe steeringwheell - C o m b i n a t i o nl i g h t a n d w i p e r / w a s h e rs w i t c h (seepage23-160). replacement - Cruisecontrolsevresumeswitch replacement {see page 23-2491.
SHORTCONNECTON {REDI
Store the removedairbagassemblyon a secureflat suffaceaway from any high heat source(exceeding 212"Fl1OO'Cl and free of any oil. grease,detergentor
CAUTION: lmproper handling or storage can internally damagethe airbag assembly,making it inoperativ€. ll you suspect the airbag assembly has been damagod, install a new unit and rgler to the Deployment/Digposal Procedureslor disposing of the dsmaged airbag.
The originalradiohasa codedtheft protectioncircuit. Be sure to get the customer'scode number before disconnecting the battery. When reinstallingthe SRSunit cover,be sure it snaps togetherproperly.
23-271
SupplementalRestraintSystem(SRSI Wiring Precautions o Neverattemptto modify.spliceor repairSRSwiring.
Connecting the Short Connectors
NOTE:All SRS electricalwiring harnessesare covered with yellow insulation.
To avoid accident8l deploymont and pos@ 5ibl6 iniury, slways insiall the protectiva short connector(s) on tho drivgr'3 and passengor'sairbag connec. tor(s) be{oreworking noar any SRSwiring. NOTE:The original radio has I coded theft protection c i r c u i t . B e s u r e t o g e t t h e c u s t o m e r ' sc o d e n u m b e r the batterycables. beforedisconnecting 1.
Disconnectthe batterynegativecable.then disconnectthe Dositivecable.
2.
Connectthe shortconnector(s) {RED):
Driver's Side: . Removethe accesspanel from the steeringwheel. t h e n r e m o v e t h e s h o r t c o n n e c t o r( R E D )f r o m t h e Daner. DRIVER'S AIRBAG
Be sure to installthe harnesswires so that they are not pinchedor interferingwith othercar pans.
CONNECTOR IREDI Disconnectthe 3-P connectorbetweenthe driver's airbagand cablereel,then connectthe shortconnector {RED}to the airbagside oi the connector.
M a k e s u r e a l l S R S g r o u n d l o c a t i o n sa r e c l e a na n d groundsare securelyfastenedfor optimum metal-tometal contact.Poorgroundingcan causeintermittent problemsthat are difficultto diagnose.
23-272
Front Pas3enger'sSide: . Removethe glove box damper (seesection20),and then removethe glove box. .
Disconnectthe 3-P connector between the front oassenger'sairbagand the SRSmain harness,then connect the short connector (RED)to the airbag side of the connector. SHORTCONNECTOR (REDI
Disconnectingthe SRS Connector at the Under-dash Fuse/relay Box: CAUTION: Avoid br.aking the connoctor; it's doubtelocksd. 1.
First lift the connectorlid with a thin screwdriver, then pressthe connectortab down and pull the conneclorout.
CONNECTOR
t_tD
SRSMAIN HARNESS
To reinstallthe connector.push it into positionuntil it clicks,then closeits lid.
23-273
SupplementalRestraintSystem(SRS) Steering-relatedPrecautions SteeringWheel and CableReelAlignment
Steering Column Removal
NOTE:To avoid misalignmentof the steeringwheel or airbagon reassembly,make surethe wheelsare turned straightaheadbeforeremovingthe steeringwheel.
CAUTION: . Bofore romoving tho 3l6oring column, first discon' nect tha connector between ths cablo 16ol snd tho SRSmain harness. . lf th6 stssring column is going to be removed without dbmounting the stesring wh6el, lock the sl6sring by turning th€ ignition k.y to o-LOCKpo3ition or removo tha k€y llom ths ignilion so that th6 3loaring wheel will not turn.
Rotatethe cablereelclockwiseunit it stops. T h e n r o t a t e i t c ou n t e r c l o c k w i s e( a p p r o x i m a t e l yt w o t u r n s lu n t i l : - T h e y e l l o w g e a rt o o t h l i n e s u p w i t h t h e a l i g n m e n t markon the cover. - The arrow mark on the cablereel labelpointsstraight up. ARROWMARK
D o n o t r e p l a c et h e o r i g i n a ls t e e r i n gw h e e i w i t h a n y other design,sinceit will make it impossibleto properly instsllthe airbag(only use genuineHondareplacement oans). After reassemblvconfirmthat the wheelsare still turned straightaheadand that the steeringwheel spokeangle is correct,lf minor spokeangleadjustmentis necessary, do so only by adjustmentof the tie-rods,not by removthe steeringwheel. ing and repositioning
ALIGNMENTMARK
23-274
SensorInspection
InspectionAfter Deployment
CAUTION: Tak€ €xtra care whon painting or doing body work in the ar€a bslow th6 dalhboard. Avoid dirost exposure ot lh6 sonsors or wiring to hest guns, wolding, or spraying equipmont.
Di3connact both the nogativo and po3itivo b!ftery cable3. Connsct tho short conneclor(s) before working bslow the da3hboardor nsar lhe dash sen3o.3.
After any degree of frontal body damage, inspect both dash sensors.Replacea sensor if it is dented, cracked,or deformed.
After a collision in which the airbags were deployed. inspectthe following: 1.
Inspectthe dashsensorsfor physicaldamage. lf the sensorsare damaged,replacethem.
2.
Inspectall the SRS wire harnesses,ReDlace,don't repair,any damagedharnesses.
3.
Inspectthe cable reel for heat damage.lf there is any damage.replacethe cablereel.
4.
After the car is completelyrepaired.turn the ignition switch on. lf the SRS indicatorlight comes on for about six secondsand then goes off, the SRS systemis OK. lf the indicatorlight does not function properly,go to SRSTroubleshooting (nextpage).
DASHSENSOR
a Be surethe sensorsare installedsecurelv,
BOLTS
23-275
SupplementalRestraintSystem(SRSI Troubleshooting Self-diagnosisFunction
Connectingthe Short Connectors
function.lf there The SRS unit includesa self-diagnosis is a failure in the sensors.SRSunit, inflator,or their circ u i t s ,t h e S R S i n d i c a t o rl i g h t i n t h e g a u g e s s s e m b l y comesON.
To avoid.ccidental doploymont and pos. @ siblo iniury. alway3 connect ths protoctive short con. noctor to tha driver's airbag connectot and, on caf! equippod with front passongor'sairbag, conncqt Prolactivs ghort connoctors to the d.ivsr's and tront passsngar's airbag before working nsai any SRSwiring. NOTE:The original radio has a coded theft protection c i r c u i t . B e s u r e t o g e t t h e c u s t o m e r ' sc o d e n u m b e r before disconnectingthe battery cables, 1 . Disconnectthe battery negative cable, then disconnectthe oositivecable.
As a system check,the SRS indicatorlight also comes on when the ignition is first turned ON to the (ll) position. lf the light goes off after approximatelysix seconds,the systemis OK. lf the SRSindicatorlighr remainson (or failsto come on in the systemcheckmode),one of the SRScomponents (or the wiring/connectors inbetween)is laulty TroubleshootingPrecautions a Always use the test harness.Do not use test probes directlyon componentconnectorterminalsor wires; you may damagethem or the SRSunit. a When connectingany of the test harnessesto the system,push the connectorsstraight-in;do not bend the connectorterminals, . Beforedisconnectingany part of the SRSwire harness,connectthe shon connector(RED)on the driver's airbag. On cars equippedwith a front passenger'sairbag,connectshortconnectorson the driver's airbag. airbagand the front passenger's
SRS Indicator Light Troubleshooting Possibloconditions: 1. SRS indicatorlight does not come on at all - see page 23-278. 2.
SRS indicatorlight stays on constantly- see page 23-242.
3.
SRSindicatorlight comeson in combinationwith a failure of another electricalsystem (chargingsyst e m l i g h t ) . C h e c k f o r d a m a g e / c o r r o s i o na t t h e under-dashtuse/relaybox connector.
NOTE: check . Beforestartingthe applicabletroubleshooting. t h e c o n d i t i o no f a l l S R Sc o n n e c t o r sa n d g r o u n d points. . lf the fault is not found after completingthe applicable troubleshooting,substitutea known-goodSRS unit and checkwhetherthe indicatorlight goesoff.
23-276
2.
(RED): Connectthe shortconnector(s)
Drivsr's Sido: . R o m o v e t h e a c c o s sp a n e l t r o m t h e s t e e r i n g wheel, then remove the shon connector(BED) from the panel. CABLER€EL DRIVER'S AIRBAG 3-P
ACCESS PANEL
SHONTCONNESTOR
(REDI . Disconnectthe connectorbetweenthe driver's a i r b a g a n d c a b l e r e e l ,t h e n c o n n e c tt h e s h o r t connector{RED}to the airbagside of the connector. Front Pas€ngo/s Sido: . Removethe glove box damper (seesection20), and then removethe glovebox. . Disconnectthe connectorbetweenthe front passenger'sairbagand SRSmain harness,then connectthe short connector(RED)to the airbagside of the connector, SHORTCONNECTOR
MAIN HARNESS
Test Harnesses and AttachmentPoints TestHsrnessA SRSUNIT
TESTHARNESSA 07MAZ - SL|D500 2
3
TESTHARNESSC 07LA:Z- SL.()3(X'
8
to n 12 l 3
1 6 16
Tast HarnessB
TESTHARNESSB 07MAZ - SP@500 ROWA ISRSUNfT ENDI 2 I
2
13 12
1 5 16 17 | l 1 5 l6
17 1A
ROW B IWIREHARNESSEND)
23-277
SupplementalRestraintSystem(SRS) Troubleshooting The SRSIndicatorDoesNot Light CAUTION: Uss only a digital multimeter to check the system. lf it's not a Honda multimeter, make sure its output is 10 mA {0.01Al or less when switched to the smallest value in the ohmmeter rang€. A tester with a highor ouiput could damagethe airbag circuit or causeaccidentalairbag deployment and possibleiniury NOTE:The originalradio has a codedtheft protectioncircuit.Be sure to get the customer'scode number beforedisconnectingthe batterycables. Dilconn6ct the battory negaiive cable rnd thon tho positive cable. Connest the short connectorlsl to tho airbaglsl (seo p6ge 23272t.
R€connectthe batterY Positive c a b l ea n d t h e n t h e n e g a t i v e cable.
Turnthe ignitionswitchON (ll).
Does the brake system light come on (in the gaugeassembly)?
Turnthe ignitionswitchOFF.
D i s c o n n e ctth e S R S m a i n h a r n e s s l 8 - P c o n n e c t o rf r o m t h e SRSunit.
Turnthe ignitionswitchON (ll).
D o e st h e S R S i n d i c a t o r lightcomeon?
Turn the ignition switch OFF.
Io page 23'2791
23-274
I n s p e c tt h e N o . l 5 1 1 0A ) f u s e (under-dash tuse/relay box).
ls No. 15fuseOK?
Repairopen in dashboardwir6 harnessbetween the No. 15 tus€ and gauge a3sombly. SRSMAIN HARNESS 18.PCONNECTOR
The SRSunit is faully.
SRSUNIT
SRSMAIN HABNESS
(From plgr 23.27E1
Disconnocttho SRS m.in h6,ng88 {-P conn6clorf,om tho mrin wiaoharn6$.
Tum lhq ignition switch ON (lll.
MAIN VNRE HARNESS
D o o 3t h o S R S i n d i c . t o r light com6 on?
Th. SRS rnlin h..n...
i.t
ulty.
Tu.n tho ignition switch OFF.
R o m o v ot h o g ! u 0 c ! s s . m b l y th6n inrpoct ths SBS indicator light bulb. DASHBOARDWIFEHARNESS 5-PCONNECTOR Raplacalh. indlc.toi llOht birlb.
Connoct ! voltmotoa bdwoln thr No. 5 lormin.l (+) of tho 5-P connoctor rnd body ground (-).
Turn the ignition switch ON (ll).
Moaaurotha voltrgo bolwcon tha No. 5 termin.land body g.ound.
(Top.go 2+280) 8tU{+
@
I :
23-279
SupplementalRestraintS ystem(SRSI Troubleshooting(cont'd) (Frompage23-279)
ls therelesslhan8.5V ?
Short in 8LU wire ol the da.hborrd wi.o halno3s. Roplacatha d.3hbosrd wiro ha.no$.
Turnthe ignitionswitchOFF DASHBOARDWIREHARNESS Connecttho voltmeter between the No. 1 terminal(+)and the No. 3 terminal (-) of the dashbo€rd wire harness5-Pconnector. YELI+,BLK{-I Turn the ignitionswitchON (ll). View lrom wire side. Measurethe voltage betweenthe No. 1 terminaland th€ No.3 termrnal,
ls there batteryvohage?
Ch6ckfor continuity betweenth6 No.3 terminaland body ground. R.prir opcn in tho BLK wir. (No. 3 tarmin!l) batwaan th. gluga araambly and body ground ot look tor. poor ground 1G201, cilol I.
Turnthe ignitionswitchOFF.
{To page23-281}
23-280
Rcprir open in th. YEL wi.o lNo. t t6rminall of the d.3hbo.rd wir6 hamer! batwaen tho gtugo r3s6mblv rnd tho No. 15 ll0 Al fu36.
(From page 23-280)
Reconnecteach connectorto the g a u g e a s s e m b l ya n d S R S u n i t then connect Tgst Harness A to the SRSunit.
Turn the ignirion ON 0l) and moasureth€ voltage betwegnthe No. 13 terminal (+) and body ground (-) tor six seconds.
TEST HARNESSA 07MAZ - S!IX)s{X' 4
9
ls th€r6 more than 8.5 V?
10 It l2
8
13 l 4
15 16
SBS indic.tor circqit {in th. e.ug. r.t mblv, i. hulty,
23-2a1 ,;l tflEt$
r'
SupplementalRestraintSystem(SRSI Troubleshooting(cont'dl SRSIndicatorLight Stayson Continuously NOTE: Beforetroubleshooting,make sure that battery voltageis 12 V or mo.e. Otherwiseyou'll obtain wrong test readings. 1.
Make a photocopy of the chart on page 23-283,
2.
ConnectTestHarnessA to the SRSunit as shown.
I
1
2
to
ll
l2 t3
NOTE:The original .adio has a coded theft protection c i r c u i t . B e s u r e t o g e t t h e c u s t o m e r ' sc o d e n u m b e r before disconnectingthe battery cables. Beforedisconnectingany pan of the SRSwire harness,connectthe short connecto(s) {RED)to the airbag(s)(seepage23-2721. Connect Test Harness B between the SRS unit and SRSmain harn€ss18-Pconnector.
I
t l rt
TEST HANNESS
Tu.n the ignitionswitchON (lll. .
.
"battery Voltagesin the chart assumethe car's voltage"is about 12 volts.Lessthan 12 volts will result in different or possiblytalse readings. Do not disconnectthe airbags ftom the circuit when checkingSRSunit voltages.
7.
Checkfor continuitvbetweenthe 85 terminal and b o d y g r o u n d , a n d t h e B l 5 t e r m i n a la n d b o d y ground.
F i r s t , c h e c k f o r v o l t a g e b e t w e e nT e s t H a r n o s s TerminalNo. 12 (+)and ground(-). lf no voltageis indicated,go to stepI and continue checkingall the otherterminals. o lf vottsge is indicated,there is a poor ground at the SRSunit.Readthe followingNOTE,and then go on to step 5. .
TEST HARNESSB 07MAZ - SPqrS{X)
lf there is continuityat eitherterminal,the SRS unit is faulty. Replaceit and checkthe voltages accordingto the chan on page23-283. lf there is no continuity at either terminal, the S R S u n i t g r o u n d ,t h e S R S u n i t c o m p o n e n t g r o u n d s o r t h e S R S m a i n h a r n e s si s f a u l t y Checkthe grounds (checkwire and control unit mounting bolts) and, if necessary,replaceth€ S R S m a i n h a r n e s s .T h e n c h e c kt h e v o l t a g e s accordingto the charton page23-283
23-282
8.
Recordyou. voltagereadings.for eachterminal,in the row of blank boxes near the top of the chart. Compareeach readingwith the voltagerangeslisted in the column below it. lf ths readingis within a range,circlethat range.
o
4.5
o
lf you circledall the FailureMode rangesacrossany row. checkthe car for the ProbableFailureMode listsd at the end of the row. (Referto the letter for that mode on the followingpages),
12,O 1/4.3
I /
".)6r-
4.6
It youcircl€d alltheranges in thisrow,tollowthe procedure troubleshooting underfailuremode,,C"on the followingpages.
4.5 12.O 5.5 - 14.3
at'9\r t.g 5.t
4,5
r2,o -t4.3
2.9
rl.5 -5.5
12.0 - 14.3
2 . 91 8 . 7 | 3 . 7l - r r . 2 l
lf you did not circle all the rangesacrossany row, replacethe SRS unit with 8 known-good unit, and retest. - l f a l l y o u r v o l t a g e r e a d i n g sa r e n o w n o r m a l , replacethe originalSRSunit. - lf your voltage readingsare still not normal but t h e y d o n ' t f i t w i t h i n a c o m p l e t er o w o f F a i l u r e Mode ranges,checkthe conditionof the terminals in esch of the SRS connectorsshown in the svstom diagram on page 23-270,
l..s lr2.ol | - 5 . 8l - r a . 3 l
Circlethe rangeif your readingis within it.
NOTE:Do not disconnectthe airbagwhen checkingSRSunit voltages. Whh tront passongor'ssirbag: 1 SAOH
2
o
a SADC
4,3 4.3 5.4 -5.6
2.5 -3.7
5
2_A
o
4.5
12.0 -14.3
4.5
12.O - 1rt.3
4.5 -5,5
12.0 14_3
8,6 a_6 l1_3-11.3
4,5 12.0 5.5 - 14.3
5_7
4.5
12.0 - 14.3
10 aucl t1,5 - 14.5
GNO
o
t3 tDc 4.4 1 3 . 6 - 10.9
3.1 -4,9
11.5 - r4.5
o
o
11.5 14.5
o
2.O 8.4 4.5 - 1 0 . 9
11.2 -14.6
11.5 - 14.5
o
2.O 4.5
4.4 10.9
-9.7
r1,5 -14,5
o
2.O 4.5
8.4 to.9
2.O -4,5
4.4 10.9
4.6
2.9 -3,7
4.5 1 2 , O -5.5 -14.3
3,7 4.9
I1.5 l4_5
0
2.O 4.5
8.4 10.9
2.9
4.7 - 1 1. 2
4.5 '12.o -5.5 -14.3
3.7 4.9
11.5 - 14.5
o
2.O a_5
4.4 10.9
4,6 a_6 l1_3-t1.3
4.5 12.O 5.5 - 1 4 . 3
I t.5 - r4.5
o
2.O -4,5
4.4 10.9
11.5 - t lt.5
o
2.O -4.5
4.4 - 1o.9
11 . 5 - 14.5
o
4.3 -5,6
4.3 5.6
o
o
4.3 5,6
4_3 5.6
4.5 5.5
12.O r4.3
o
-7.3
o 18.5 4.4 - 13.6 1 0 . 9
23-283
SupplementalRestraintSystem(SRSI Troubleshooting(cont'd) NOTE:Do not disconnectthe airbagwhen checkingSRSunit voltages. Without lront Passongor'ssirbag: l SAOH
saoc
8
10 BUCI
12 Gto
5,6 -7.3
11.5 - 14,5
o
13 t4 toc a _ 5 8.:a - 1 3 . 6 ro.9
11,5 -14.5
o
2 . O 8.4 -8.5 - r 0 . 9
11.5 -14,5
o
2 . O 8./a -8.5 - r 0 . 9
11.2 - 14.6
11.5 14,5
o
2.O
8./t -r0.9
t2.o 14,3
-9.7
tt.5 - 14_5
o
-8.5
8.1 -10.9
4.5 12.0 - 5 . 5 - 14.3
3.7 -4.9
1t.5 14.5
o
a.a 2.O - 8 . 5 -r0.9
vcc
5
12.O 5.5 - 1 4 . 3
4,3 5.6
4.5 5.5
2.4 3.7
't2.o 14.3
o
4 . 5 12.O 5,5 - 1 4 . 3
4.6 -11.3
-5.5 - 14.3
12.O
4.5
5.7 4.6 11.3
3.7 4.9
o
4.3
o
o
5,6 -7.3
11.5 14,5
o
4.3 -5.6
4.5 -5.5
12.O - 14.3
-7.3
t1.5 - 14-5
o
Modo A: Open in one cowl sonsor conlact r The SRSunit is faultY.Substitutea known-goodSRS unit and recheckthe voltagesaccordingto the chart on page23-283. Mods B: . Short to driver's or Passonger'saitbag inflator body (body groundl . Short in dash sonsor . Opsn in both cowl sgnsor contacts NOTE:The original radio has a coded theft protection c i r c u i t . B e s u r e t o g e t t h e c u s t o m e r ' sc o d e n u m b e r before disconnectingthe battery cables. 1. Disconnectthe batterynegativecable and then the positive cable.Then connectthe short connectots(s) (RED)to the airbag(s)(seepage23-272). 2. ConnectTest HarnessB betweenthe SRS unit and SRSmain harness18-Pconnector. SRSUN]T SRSMAIN HARNESS 18.PCONNECTOR
'...
2,O
8.it
,r0.9
H ll{o. 26 lo Al o.
o ta,5 E,4 - 1 3 . 0 t- 1 0 . 9
Reconnectthe driv€r's airbag connector,then check continuity betweenthe B1 terminal and body ground, and b€twesn the 87 terminsl and body grounq,
3.
B TESTHABT{ESS A B
.
lf there is continuity at either terminal, go to step o.
lf there is no continuity at sither terminal' - go to step 5 (without front passonge/sairbag)' - go to step il (with front passenger'sairbag)' Reconnectthe front passonger'ssirbag connector, then checkcontinuitybetwo€nihs 82 t€rminaland body ground, and between the 88 terminal and body ground. .
lf there is continuityat eitherterminal,go to step 10. lf there is no continuityat eitherterminal,go to step 5.
23-284
Checkcontinuity between body ground and each terminalof both dssh sensors.
7.
Checkcontinuity betweenthe No. 4 terminal and body ground, and between the No. 5 terminal and body ground.
TESTHARNESS B o?MAZ- SFmSd) TEST HABI{ESS C 07LAiZ- SLIO:loo
.
lf there iscontinuityat anyof theterminals,go to step 12.
.
lf thsre is no continuity at any terminal, go to steo 13.
Disconnectthe cable reel 6-p connectorfrom the SRS main harn€ss,then connect Test HarnessC only to the cablereel sideof the 6-p connector.
lf there is continuity at either terminal, go to step 8. lf there is no continuity at either terminal, the SRS main harnessis faulty. Replaceit and re_ c h s c k t h e v o l t a g e sa c c o r d i n gt o t h e c h a r t o n page 23-283.
CABLENEEL&P CONNECTOR
(cont'd)
23-285
SupplementalRestraintSystem(SRS) Troubleshooting{cont'd} 8.
Disconnectthe drive/s airbag 3-P connectortrom the cable reel,then connectTest HarnessC to the driver'sairbag3-Pconnector.
airbag3-Pconnecthe front passenger's 10. Disconnect tor from the SRS main harness,then connectTest HarnessC to the airbagside of the connector. FRONTPASSENGER'S ANBAG
DRIVER'SAIRBAG
o7LAiZ- Slao:tq,
Checkcontinuitv betweenthe No. 7 terminal and body ground,and betweenthe No. 8 terminal and body ground.
1 1 . Checkcontinuitv betweenthe No. 7 terminal and body ground,and betweenthe No. 8 te.minal and body ground.
lJ there is continuityat eitherterminal,the drive r ' s a i r b a g i n f l a t o r i s f a u l t y . R e p l a c ei t a n d recheckthe voltagesaccordingto the chart on page z3-z6J.
lf there is continuitvat eitherterminal,the Jront passenger'sairbag inflator is faulty. Replaceit and recheckthe voltagesaccordingto the chart on page 23-283.
lf there is no continuity at either terminal, the cable reel is faulty. Replaceit and recheckthe voltagesaccordingto the charton page23-283.
lf there is no continuitv at either terminal, the S R S m a i n h a r n e s s i s f a u l t y . R e p l a c ei t a n d recheckthe voltagesaccordingto the chart on page 23-283.
23-286
12. Connect Test Harness D between the dash sensor and SRS main harness2-P connector.Checkcontinuity betweenthe No. 1 terminsland body ground, 8nd betweenthe No.2 terminaland body ground,
o lt rssistanceis 3.8 - 4.2 kO for both sensors.the SRSunit is faulty.Substitutea known-goodSRS unit €nd recheckthe voltagesaccordingto th€ chart on page 23-283. o lf resistancsis l6ss thsn 3.8 kO for either sensor. go to step 14.
sRs MA[{ HARNESS 2-POOTTNECTOR
1il. Connect Test Harness D between the dash sensor and SRSinain harness2-P connector.Measurethe resastancebetweenthe No. 1 terminal and No. 2 terminal. SRSMAIN HARNESS 2.PCONNECTOR
TESTHARNESS D o?LAiZ- SL()a(xt
TESTHARNESSD
otlA:z- sl(,(x)
rffi-l
?
?
TEST HAR ESS D 07LAZ - SL.{)a(xl
TESTXARNESS D otlA:z - sl4|)4tx)
t'l
.
lf there is continuityat eitherterminal,the dash sensor is faulty. Replaceit and recheckthe voltagesaccordingto the chan on page23-293.
.
lf there is no continuity at either terminal, the S R S m a i n h a r n e s s i s f a u l t y . R e p l a c ei t a n d recheckthe voltagesaccordingto the chart on page 23-283.
Measure the resistancebetween the l6ft dash sensor terminalsB'12and Bl6, and betweenthe right dashsensorterminalsB4 and 86.
lf resistance is 3.8- 4.2kO,the SRSmain harness is faulty. Replaceit and recheckthe voltages accordingto the chan on pag€23-283. lf resistanceis lessthan 3.8 kO,the dash sensor is faulty. Replaceit and recheckthe vottages accordingto the charton psge 23-283.
IESTHARNESS B 07MAZ- SPqt500
(cont'd)
23-287
SupplementalRestraintSystem(SRS) Troubleshooting(cont'd) Modg C: Shon in one cowl son3ol, or open in both dash sensors Mode D: Open in ono da3h sensol
3.
Measure the resistancebetween the left dash sensor terminals812 and 816, and betweenthe right dashsensorterminals84 and 86.
NOTE:The original radio has a coded theft protection c i r c u i t . B e s u r e t o g e t t h e c u s t o m e r ' sc o d e n u m b e r the batterycables beforedisconnecting 1.
Disconnectthe batterynegativecable and then the positivecable.Then connectthe short connector(s) to the airbag(s)(see page 23'2721.
2.
ConnectTest HarnessB betweenthe SRS unit and SRSmain harness18-Pconnector.
lf resistanceis more than 5 kO for eiiher set of terminals,go to step4. lf resistanceis less than 5 kOtor both sets of term i n a l s , t h e S R S u n i t i s f a u l t y . S u b s t i t u t ea known-goodSRS unit and recheckthe voltages accordingto the charton page23-283.
23-2AA
4.
Connect T6st Harness D between the dash sensor and SRSmain harness2-Pconnector. Measurethe resistancebetween the No. 1 terminal and No. 2 terminal.
Mode E: Op€n in driver's airbag inflator or cable reel NOTE:The original radio has a coded theft protection c i r c u i t . B e s u r e t o g e t t h e c u s t o m e r ' sc o d e n u m b e r beforedisconnecting the bafterycables. 1 . Disconnectthe batterynegativecableand then the positivecable.Then connectthe short connector(s) (RED)tothe airbag(s)(seepage23-272).
SBSMAIN HARNESS 2-PCOI{NECTOR
2.
ConnectTest HarnessI betweenthe SRS unit and SRSmain harnessl8-P connector.
sRsuNtt
TEST HARNESSD
orlA:a- sl{tarx)
TESTHARI{ESSD OTLAZ- sl/to4{lo
Reconnect the driver's airbag connector, then measure the resistance between the 81 and the 87 ter, m rn a l s .
lf resistance is more than 5 kO,the dash sensoris faulty.Replacethe dash sensorand recheckthe voltagesaccordingto the charton page23-283.
TESTHARNESSB o?MAZ - SP00500
lf resistanceis lessthan 5 kO,the SRSmain harnessis faulty.Replacerhe SRSmain harnessand recheckthe voltagesaccordingto the chart on page 23-283.
lf resistance is more than 0.2 kO,go to step4. lf resistanceis lessthan 0.2 kO,the SRS unit is f a u l t y .S u b s t i t u t ea k n o w n - g o o dS R S u n i r a n d recheckthe voltages accordingto the chan on page23-283. (cont'd)
23-289 ; r.il
SupplementalRestraintSystem(SRS) Troubleshooting{cont'd} 4,
Disconnectthe cable reel 6-P connectorfrom the SRS main harness,then connect Test HarnessC onlv to the cable reel side ot the connector.
6.
Disconnectthe driver's airbag 3-P connsctorfrom the cabls reol harness,then connoct Test Harn6ssC to the driver's airbag 3-P conn6ctor.
DRIVER'SAIRBAG
CAB1I REEL&P CONNECTOB
TESTHARNESS C 07LAZ- SLIO300
Measurethe resistancebetween the No. 4 terminal and the No, 5 terminal.
TEST HARI{ESS C OTLAiZ- Sl/t{r3q)
lf resistance.ismore than 0.2 ko, go to step 6. It resistanceis less than 0.2 k0, the SRS main harnessis faulry. Replaceit and recheckthe voltagesaccordingto the charton page23-283.
7.
Measurethe resistancebetween the No. 7 terminsl and the No. 8 terminal.
TESTHARI{ESSC OTLAZ- AL/|{,3OO
lf resistanceis more than 0.2 kO, ths drivsr's a i r b a g i n f l a t o r i s f a u l t y . R e p l a c et h e a i r b s g ass€mbly and recheckthe voltages according to the chart on page 23-283, lf resistanceis lessthan 0.2 kO.the cable reel is f a u l t y . R e p l a c ei t a n d r e c h e c kt h e v o l t a g € s accordingto the chart on page 23-283.
23-290
Modc F: Opon in tront pa3s6ngs/s rirbag inflstor NOTE:The original radio has a coded theft protection c i r c u i t . B e s u r e t o g e t t h e c u s t o m e r ' sc o d e n u m b e r before disconnectingthe battery cables.
Disconnectthe front passenger'sairbag 3-P connector from the SRS main harness,then connectTest HarnessC to the front passenger'sairbag sids of the connector, FAONT
1,
Disconnectthe batterynegativecableand then the positivecable.Then connectthe short connoctor{sl {RED}to the airbag(s)(seepage23-272).
2.
Connect Test Harness B between the SRS unit and SRSmain harness18-Pconnector.
SRSUNIT
TESTHARNESS C - SL/O300 07LA,Z Measurethe resistancebetweenthe No. 7 terminal a n dt h e N o .8 t e r m i n a l . 07MAZ - SP|D500
Reconnectthe front passenger'sairbag connector, then measurethe resistancebetweenthe 82 terminal and the B8 terminal.
TEST HAB ESS C 071-Aiz- sll|{,300
TESTHARNESSB oTMAZ - SP005(x)
lf resistanceis more than 0.2 kO,the front pass e n g e r ' sa i r b a g i n f l a t o ri s f a u l t y . R e p l a c et h e front passenger'sairbag assemblyand r€check the voltagesaccordingto the chart on page 23243. lf resistanceis more than 0.2 k0, go to step 4. lf resistanceis lessthan 0.2 kO,the SRS unit is faulty. Substitutea known-good SRS unit and recheckthe voltages accordingto the chart on page 23-283.
lf resistanceis lessthan 0.2 kO,the cable reel is faultv. Replacethe cable reel and r€checkthe voltages accordingto the chart on page 23-283. (cont'd)
23-291
SupplementalRestraintSystem(SRSI Troubleshooting{cont'dl Modc H: Blown SRSNo. 25 fur., ol opcn in the wire NOTE:The original radio has a coded theft protection circuit. Be sure to get the customer's code number betore disconnectingthe battery cables. 1.
Ch€ckthe SRSNo. 25 (10 A) fuse in the under-dash fuse/relaybox. lf it's OK, go on to step 2. lf it's blown, replace it with a now 10 A fuse, then turn the ignitionswitchON (ll): .
lf the fuse doesn't blow, 90 on to step 2.
.
lf the fuse blows. troublsshoot as necessaryto find th6 short.
2.
Disconnectthe battery negative cable and then the positive cable. Then connect the short connector(sl (RED)to the airbag(s)(see page 23-272).
3.
Conn€ct Teat Harnsss B between the SRS unit and the SRSmain harness18-Pconnector.
Reconnectth6 positiv€ 8nd negativecable to the battery. Measureths voltage betweenthe 813 terminal (+) and body ground{-)with the ignitionswitchON (ll).
TESTHAN ESSB oTMA:Z- SPOOs{X' 2
2
3
a 6
7
a
10 n
1
6
1o
ll
l3
12
1 6 1a 1 7
ra
1 6 1a 1 7 |a
lf there is battery voltage, the SRS unit is faulty. Replaceit and rscheckthe voltages accordingto the chan on page 23-283. lf there is lsss than b8ttery voltage,the SRSmain harnessis faulty. Replaceit and recheckthe voltag6s accordingto the chart on page 23-283.
SRSUNIT
23-292
Modc l: Short 01 opcn in SRS indicrtor whc hrrnaas 1.
Disconnectthe battery negative cable and then the positive cable. Then connect the sho.t connector(s) (REDltothe airbag(s)(seepage23-272).
Disconnecttho SRS main harness 4-p connector from the main wirs harn6ss.
Connect Test Harness B between the SRS unit and SRSmain harness18-Pconnector.
WIREHABNESS
2.
Turn the ignitionswitchON (ll) 8nd wait for six seconds. Measu.s the voltage betweenths No. il terminal (+) in the SFS main harness4-P connectorand body ground,
*-
F4
5.
Reconnectthe battery positivecable and negative caote.
6,
Checkfor continuitybetweenthe 811 terminal body ground.
BLU
d.L Vrowllom wi|! rftro.
.
lf voltage is more thsn 8.5 V, go to step 8.
.
It voltage is lessthan 8.5 V, go to step 3.
NOTE: The original radio has a coded theft protection circuit. Be sure to get the customer's code number before disconnectingthe banery cables.
lf there is continuity,the SRS main harnessis s h o r t e d . R e p l a c et h e S B S m a i n n a r n e s sa n o recheckthe voltagesaccordingto the chart on page23-283. lf there is no continuity,go to step7.
(cont'dl
23-293
SupplementalRestraintS ystem(SRSI Troubleshooting(cont'dl 7.
Checkfor continuity betweenthe 811 terminal of Test HarnessB and the No. 4 terminal of the SRS main harness4-Pconngctor,
o
Turn ths ignitionswitchON {ll} and wait for six seconds. Measurethe voltagebetweenthe No. 5 terminal (+)and body ground (-).
OASHSOAROIVIRE HARNESS s.PCO ECTOR
TESTHARNESSB 07MAZ - SF|D500
Vrawfromsil! rira,
.
.
8.
l f t h e r e i s c o n t i n u i t y ,t h e S R S u n i t i s f a u l t y , Replaceit and recheckthe voltages according to the charton page23-283. lf there is no cootinuity.there is an open in the SRS main harness.Replacethe SRS main h8rness and recheckthe voltagesaccordingto the charton page23-283.
Reconnectthe SRS main harness4-P connecto.to the main wire ha.ness.Disconnectthe dashboard wire ha.ness5-Pconnectorfrom the gaugeassemDtv.
DASHBOARDWIRE HARNESS 5.P OONNECTOR
23-294
lf voltage is mora than 8.5 V, the SRS indicator circuitis faulty (in the gaugeassemblyl.Replace the SRS indicatorcircuit assemblyand recheck the voltsges according to the chart on page 23243. lf voltageis lessthan 8.5 V, the dashboardwire h a r n e s s( o r t h € m a i n w i r e h a r n e s s )i s f a u l t y . Replaceit and recheckthe voltages accordingto the chart on page 23-283.
AirbagAssemblyReplacement storc a r.movcd @E p.d surfaco up, if tho lirbrg down, accidontald.ploymert cnough torcr lo causclariour
lirb.g rslombty with thc is improparly 3iorad frca could plopcl tha unit with iniury.
CAUTION: . Do not inst.ll urld SRS plrts trom lnothar c!1, Whon lepairing, uss only now SRSprrt!. o Carefully inlpcct thc airblg rlrcmbly bltorc you install it. Do not inst.ll an airbag !$.mbly thrt 3how! sign3 of bcing droppcd or improparly hrndlod, such as dont!. crack3or dstormation. . Alwry! koop ths rhort connactor(3l (REDI on tha airbrg{s} whon tho hsrnca3i! dirconnastld. . Do not diras3ombl! or tamp€l with tha lirbrg a$ombly.
Fror{ P$!.ngar/3 Sida: .
Remove th6 glove box damper, then remove the glove box.
.
Disconnoctthe front psssenger'sairbag 3-p connect o r f r o m t h e S R S m a i n h a r n e s s ,a n d c o n n e c tt h e short connoctor (RED)to the front passenger,sairbag 3-Pconnector. FROIVTPASS€NGEF'S AIRBAG 3.PCONNECTOR
SHOBTOONNECTOR (REDI
NOTE:The original radio has a coded th6ft protection c i r c u i t . B e s u r e t o g e t t h e c u s t o m e r ' sc o d e n u m b e r before disconnectingthe battery cables. 1.
Oisconnectthe battery nogative cabl6, then disconnect the positive cable.
2.
Connect the short connecto(s) (R€D)to the aifbag side of the connector(s);
Drivo/s Sido: a Removethe accesspanel from the steeringwhesl, then ramove the short connector (REDI from th6 paner. .
Disconnectthe 3-P connectorbetwesn the driv6r's airbagand cablereel,then connectth6 short connector {RED}to the airbagsideof the connector.
(cont'd)
23-295
SupplementalRestraintSystem(SRSI AirbagAssemblyReplacement(cont'd) 3.
Removethe airbag(s):
Driver's Side: .
Removethe two TORXobolts using a TORX0T30 bit, then removethe driver'sairbagassembly. DRIVER'S AIRBAG ASSEMBLY
23-296
Front Palsugor'r .
Sidc:
Removethe four mounting nuts, then lift the front passenger's airbagout of the dashboard. NOTE:Oo not confusethe lower mountingnutswith the upper mounting nuts. The upper mounting nuts are not selt-locking. FRONTPASSENGER'S AIBBAGASSEMBLY
CAUTION: Bo 3uro to in3tsll tho SRSwiring so that it is not pinchod or intoforing with other car parts.
Front Pa$aogsr's Sid€: .
4.
Installthe new airbag(s): Driver's Sido: Placethe driver's airbag assembly in the steeringwheel, and secureit with new TORX@ bolts. TORXCBOLT 9.8 N'm 11.0kgt m. 7.2lbf.ftl Replace. Uio a TORXOT30 bit
Placethe front passenger'sairbag assemblyin the dashboard. Looselyinstallall four mountingnuts. Tighten the upper two nuts first, then the lowsr two nuts. Adjust the lower mounting bracketif necessarV.
FRONTPASSENGER'S AIRBAG ASSEMALY
UPPER MOUNTINGNUTS
TORXOBOLI 9,8 N'm l'1.0kgf.m, 7.2lbtftl Replaco. Us. . TORX6T30 bit
LOWER MOUNTINGNUTS 9.8 N.m (1.0lgtm, t.2lbtftl Reolace.
CONNECTOR IREDI
{cont'd)
23-297
SupplementalRestraintSystem(SRSI (cont'd) AirbagAssemblyReplacement 5.
Connect the battery positive cable, then the negative cable.
Removeand properlystore the short connector(s), then reconnectthe airbagconnector(s). 7.
Front Pass€ng€r'sSide: . Remove the short connector (RED)from the front p a s s e n g e r ' sa i r b a g c o n n e c t o r ,t h e n c o n n e c tt h e airbag 3-P connectorto the SRS main harness3-P connector.
Turn the ignition ON (ll): The instrumentpanel SRSindicatorlight shouldcome on for aboutsix secondsand then go off. . Make sure both horn buttons work. a Take a test drive and make sure the cruise control sevresum€switch works. .
SHORTCONNECTOR FRONTPASSENGER'S ,,' AIRBAG3.P CONNECTOR
8.
. Then reinstallthe glove box on the dashboard, Driver's Side: Removethe short connector(RED)from the driver's airbag connector,then connectthe airbag 3-P connectorto the cablereel3-Pconnector. CABI-EREEL 3-PCONNECTOR
SHORTCONNECTOR IRED)
DRIVER'S AIRBAG3.P CONNECTOR
Attachthe short connector(RED)to the accesspanel, then reinstallthe panelon the steeringwheel.
23-294
After installingthe airbagassembly,confirm proper systemoperataon:
Enter the code number to restoreradio oDeration (seepage23-191).
Airbag Assembly Disposal Beforescrappingany airbag(s)(includingone in a whole car to be scrappedl,the airbag must be deployed. t{ the car is still within the warranty period, before you deplov the ai.bag,the AcuraDistrictServiceManagermust give approvaland/or specialinstructions.Onlv after the airba9 has beendeployed(asthe resultof vehiclecollision, for example),itcan be scrapped. lf the airbag(s)appear(s)intact (not deptoyed,treat it {them)with extremecaution. Followthis Drocedure:
Front Passonger'sAirbag: 4.
R e m o v et h e g l o v e b o x d a m p e r ( s e es e c t i o n2 O ) . then removethe glove box. then disconnectthe 3-p connectorbotweenthe front passenger,s airbagand SRSmain harness. FRONT PASSENGER'S SHORT CONNECTOR AIRBAG3.PCONNECTOR IRED}
Doployingthe Airbag(sl:In-car N O T E : l f a n S R S c a r i s t o b e e n t i r e l y s c r a p p e d .i t s airbag(s)should be deployedwhile still in the car. The a i r b a g ( s )s h o u l d n o t b e c o n s i d e r e da s s a l v a g e a b l e pan(sland shouldneverbe installedin anothercar. confirm that osch airbsg assemblyis @ s6cursly mounted; oihorwis6. s€voro parsonal iniury could result from doployment. 1.
Disconnectthe banerynegativecable.then discon_ nectthe Dositivecable.
2.
Confirmthat the specialtool is functioningproperly by followingthe checkprocedureon the labelof the tool set box, or on page23-300,
SRSMAIN I{ARNESS
Driver's Airbag: 3.
Removethe accesspanel,then disconnectthe 3_p connecto.betweenthe driver'sairbagand the cable reel. CABLEREEL 3.P CONNECTOR
Cut off the airbag connector,strip the ends of the airbagwires, and connectthe specialtool alligator clips to the sirbag.Placethe specialtool aboutthir_ ty feet (10meters)awayfrom the airbag. DRIVER'S AIRBAG
FRONTPASSENGER'S AIRBAG
ALLIGATOR CLIPS lY.llowl
12 V BATTERV
OPERATION
swrTcH DEPLOYMENT TOOI (cont,dl 07HAZ- SG00400
23-299
SupplementalRestraintSystem(SRSI AirbagAssemblyDisposal(cont'd) Connecta l2 volt battervto the tool:
Doploying the Airbag: Out-ot{!r.
.
NOTE: lf an intsct airbag assembly has been removed from a scrappedcar, or has been found dofectiveor damagsd during transit, storage or service, it should bs dsployed as follows:
.
lf the green light on the tool comes on, th€ a i r b a g i g n i t e r c i r c u i t i s d € f e c t i v ea n d c a n n o t d e p l o y t h e a i r b a g . G o t o D s m a g € dA i r b a g SpecialProcedure. lf the red light on the tool comeson, the airbagis readyto be deployed.
P u s h t h e t o o l ' s d e p l o y m e n ts w i t c h . T h 6 s i r b a g should deploy (deploymentis both highly audible and visibls- a loud noiseand raDidinflationof the bag, followed by slow deflationl.
Porition th6 lirbrg rr:.mbly t.ce up, out@ doo6 on flat ground !t lorrt thirty foot from rny ob3t.. clar or pcoplo.
.
lf audible/visibledeploym€nt happsns and the green light on the tool comes on, continuswith this Drocedure. . lf the airbag doesn't deploy, yet the green light comes ON, its igniter is dofectiv€. Go to DamagedAirbagSpecialProcedure. Duringdeploym€nt,the airbsg assom@ bly can becomehot enoughto burn you. Wait thirty m i n u t e s a f t e r d e p l o y m e n tb e f o r o t o u c h i n g t h e assemblv. Disposeof the completeairbag sssembly.No pan of it can be reused. Place it in I sturdy plastic bag and sealit securelv.
1.
2. 3.
Confirmthat the specialtool is functioningproperly by followingthe checkprocedureon this pageor on the tool box label. Removethe short connectorfrom the airbag connector. Folfowsteps5,6,7, and 8 of the in-cardeployment orocequre.
Dlmlged Airbsg Sp.ci8l Procoduro. CAUTION: Woar a taco shiold lnd glov.s whon hlndling ! doploy.d airbag. Waeh your hands and rin3a tham wall with wslor aftor handling r deploycd !irb!g.
f rn lirbag crnnot be deploy.d, it rhould E!@ not br trcltcd !s normll scrrp; ii 3hould still bc comidercd a potantillly oxplolivr dcvicc thli cln c!u3a 3ariou3 iniury. 1. 2. 3. i[.
5.
lf instslledin a car,follow the removalprocedureon page 23-295. In all cases,make sure a short connector is properly installedon the airbagconn€ctor. Packagethe airbag in sxacily the same packaging part cama in. that the now replacement Mark the outside 0f the box "DAMAGEDAIRBAG NOT OEPLOYED"so it does not get confused with your parts stock. Contact your Acura District Service Manager for how and where to return it for disoosal.
Dcploymont Tool: Chcck Procedure. 1. 2. 3.
23-300
Connectthe yellow clips to both switch protector handleson the tool; connectthe tool to a battery. Pushth€ operationswitch:green meansthe tool is OK; red means the tool is faulty. Disconnectthe battery and the yellow clips.
CableReelReplacement store r rcmov.d !!@ prd ruf.cc up. It th. .irb.g down, sccid.ntd d.ploym.rf rnough torca to caure a.?iour
rirbrg rsldnbty with thr i3 impropcrly 3to.rd f.cc could propcl th. unit with iniury.
5.
Connectthe sho.t connector(s) to the airbag(s). DRIVER'S AIRBAG
GAUTION: o Clrdully in3pcct thc airbrg r$.mbly brtorc instll_ ling it. Do not inttrll !n lirb.g |3..mbly ihst fiow3 rignr of bring droppcd or improp.rly handled. ruch .3 dant!, crrck3 or dafo?mation. . Atw!$ krro th. tkroR connctot(3l on ths rtbrg\t\ connactor whan tha h|rn!|a l! dbconncstad, . Do dis.tlambla or tampar with thc ai.brg !rlo-t t.mbly. NOTE: The original radio has a codod theft Drotoction c i r c u i t . B s s u r e t o g e t t h e c u s t o m e r , sc o d e n u m b e r bsfore disconnectingth6 battery cables. l.
Disconnectth6 banory negstive cable and thsn the positive cable.
2.
Makesurethe whe€lsare alignedstraightahoad.
3.
Removo th€ dashbosrd lowsr covsr and kne6 bol_ $er.
IRED}
SRSMAIN HARNESS
R e m o v et h e d r i v e r ' s a i r b a g a s s e m b l yf r o m t h e steerangwheel (two T30 TORXObolts), then remove the steering wheet nut. TOR)(' BOLTS U.. . TORX. T30 bh
DRIVER'S AIRBAG ASSEMBLY
DASHBOANO LOWEROOVER Removs tho glove box damper (s6e s€ction 2O), then removethe glove box,
(cont'd)
2 3-301 -
SupplementalRestraintSystem(SRSI GableReelReplacement(cont'd) Disconnect the connectorsfrom the horn and cruise controlsevresumeswitches,then removethe cable reel3-Pconnectorfrom its cliD.
10. Disconnectthe 6-P connector between the cable reel and SRS main harness,then remove the connectorholderfrom the steeringcolumn. CABITBEEL
CONNECTOFHOI-DER
8.
Removethe steeringwheelfrom the column.
9.
Removethe upperand lowercolumncovers.
COVER UPPER COLUMN
23-302
'l l. Removethe cablereelfrom the column,
GAUTION: o Eatorainstdlingtho steoringwhosl,lha front whaels
lhould bo alignod straight !ho!d. Bc auro to imtalt tho hrrnass wiros so that th6y !16 not pinchod or intsrt6ring with othor crr parts. . Aftor rsassambly. conlirm that tho whods lre 3till turnad straight ahead and lh.t the steering wheol rpoko angle is corrsct {rosd tesi}. lf mino. spok€ angl6 adiustmont is necols!ry, do 30 only by ldiust_ mgnt ol tho tio-rod9. not by removing and rgpositioning tho rteering whoel. .
1 4 . Installthesteeringcolumnupperano towercovers. t5.
Centerthe cable reel. Do this by first rotatingthe cable reel clockwise until it stops. Then rotate it counterclockwise (approximately two turns)until: .
T h e y e l l o wg e a rt o o t h l i n e su p w i t h t h e a l i g n ment markon the cover. a The arrow mark on the cable reel label Doints straightup. ABROWMARK
12. Align th€ cancelsleevegrooveswith the cable reel projections. CABLEREEL
ALIGNMENTMARK
Carefullyinstallth€ cable reel on the steeringcolumn shaft.Then attachthe connectorholderto the steeringcolumn.
YELLOWGEAR TOOTH
16. Installthe steeringwheel and attach the cable reel 3-Pconnectorto the clip. CRUISE CONTROL SET/RESUME HORNCONNECTOR
CABI.I REEL
CONNECTOR HOLDER
't7.
Connectthe horn connectorand cruisecontrol sev resumeswitchconnector. (cont'd)
23-303
SupplementalRestraintSystem{SRSI (cont'd) CableReelReplacement 2 1 . Removeand properlystore the shon connector(s)
18. Installthesteeringwheel nut.
{RED},then reconnectthe airbagconnector(s}(and reinstallthe glove box).
22. Reconnectthe battery positive cable,then the nega-
TORXOBOLTS 9.8 N.m (1.0kgf.m,7.2lbtftl Replace. Us6 a TORX6T30 bit
tive cable.
23. After installingthe cable reel,confirm proper sysl€m operalron: Turn the ignition ON (ll); the instrument panel SRS indicator light should go on for about six sscondsand then go off. a Make sure both horn buttons work. a M a k e s u r e t h e h e a d l i g h ta n d w i p e r s w i t c h e s work. Go for a test drive and makesurethe cruisecontrol switcheswork. Rotatethe steering wheel counterclockwiseto make sure the yellow gear tooth lines up with
WHEELNUT STEERING ,19N.m 15.0kgt m, 36 lbt ft) Replace.
AIRBAG ASSEMBLY
1 9 . Installthe driver'sairbagassembly. 20. Connectthe cable reel 6-P connactorto the SRS m a i n h a r n e s s ,t h e n i n s t a l lt h e k n e e b o l s t e ra n d dashboardlower cover.
24. Enterthe code number to restore radio operation (seepage23-191).
DASHBOARDLOWEROOVER
23-304
DashSensorReplacement GAUTION: . Oo not drmrgc the sensor wiring. . Do not instrll used SBS part3 from anothor c!t, When repairing an SRS:use only new part3. o Roplaco. 3onsor it it is dented, crackod,or doform. od.
Removethe footrestdriver,sside only and door sill molding,then pull the carpetback,and removethe dash sensor protector.(Left side shownj right side is similar.)
NOTE;The original radio has a coded theft protection c i r c u i t . 8 e s u r e t o g e t t h e c u s t o m e r , sc o d e n u m b e r before disconnectingthe b€ttery cabres, 1.
Oisconnectthe batterynegativecableand then the posative cable.
2.
Remove the glove box damper (see section 201. then remove the glove box. SHOBTCONNECTOR IREDI DASH
PROTECTOR
SRS MAIN HARNESS
3. Connectthe shortconnector(s) to the airbag(s).
5.
Removethe two mounting bolts.then removethe dash ssnsor.
DASH SENSOB
DRIVER'S AIRBAG
DRNEN'S ANAAG 3.P CONNECTOR
SHORT CONNECTOR IREDI
MOUNTIITGBOLTS
(cont'd)
23-305
SupplementalRestraintSystem(SRSI (cont'dl DashSensorReplacement CAUTION: . Be 3ure to install the harnesswires so that theY ars not pinchcd or interfering with othor car parte. o Carefully inspest the dash sensorslor signs of boing dropped or improperlyhandled,3uchas dents, cracksor dsformation. . For the SRS to lunction propotly, ths right and lsft sensorsmust be installsd on the propor sidos. 6.
Installthe sensorsecurely.
Removeand properlystore the short connector{sl, then reconnectthe airbag connector(s)(and rsinstallthe glove box). Reconnectthe battery positive cable,then the negative cable. 1 0 . After installingthe dash sensor,confirm proper system operation:Turn the ignition ON (ll):the instrument panel SRSindicatorlight should come on for aboutsix secondsand then go off. 1 1 . Enter the code number to restoreradio operation (seepage23-191)-
DASH SENSOR
MOUNTINGBOLTS 8 mm x 1.25 22 N.m (2.2kgf.m, 16lbfftl Replace.
7.
Reinstallall other removedparts.
23-306
SRSUnit Replacement CAUTION: . 8€tor6 disconneciing any part of the SRS wire harness, connect the short connectorlsl (RED)to tho sirbagl3). o Do nol drmsgo thc SRS unit terminal! o. connocto.s. . Do not disassemblotho SRS unit; it ha3 no rervico.blo parts. . Storo tho SRS unit in a cleln, dry srea. . Do not us€ lny SRS unit which h.s been subisctod to wator damag€ or shows sign3 ol b€ing droppad or improperly handl6d, such as dents. cracki or d6tormation.
4.
Removethe left side cover from the SRSunit. then disconnectthe SRS main harness lg-p connector from the SRSunit.
SRSUNIT
NOTE:The original radio has a coded theft protection c i r c u i t . B e s u r e t o g e t t h e c u s t o m e r , sc o d e n u m b e r before disconnectingthe baftery cables. 1.
Disconnect the batterynegativecable,then the pos_ itivecable. Connectthe short connector(s) to the airbag(s)(see page 23-2721. Removethe right sidecoverfrom the SRSunit.
Removethe four TORXobolts from the SRS unit, then pull out the SRSunit from the driver,sside.
(cont'd)
23-307
SupplementalRestraintSystem{SRSI (cont'd) SRSUnit Replacement CAUTION: B€ suro to install tho SRS wiring ro thlt it i3 not pinched or interfeling with other car plrts. 6.
Installthe new SRSunit, SRS UNIT
SRSMAIN HARNESS 18.PCONN€CTOR
Remove and properly storo the short connector{s), thgn roconnectthe sirb8g connector(s)(and reinst8ll tho glove box). Roconnoctthe battery positivo cable,th€n the n€98tivo cabls. 1' l. After installing the SRS unit, confirm proper system operation: Turn the ignition ON (ll): th€ instrumont panel SRS indicator light should come on for about six sscondsand then go off.
12. Ent6r tho code number to rostors radio operation (seepage23-191).
TORX' BOLTS 9.8N.m11.0ksl'm. 7.2tbf.ftl Replace. U.. . TORX' T30bit
LEFTSIDECOVER
SRSUNIT
TOD(' BOLTS 9.8N.m(1.0tc[.m, 7.2tbf.ftl Ur. . TORX.T30bit
COVER
Connectthe SRS main harness18-Pconnectorto the SRSunit;push it into positionuntil it clicks. Installthe SRSunit covers(rightand left). NOTE: Make sure the coverssnap tog€ther in the middle.
23-308
